SGT-8000H series and SCC-8000H power plants
One year of commercial
operation in Irsching
PowerGen Asia
Bangkok, October 3-5, 2012
Lothar Balling
Executive VP Gas Turbine Power Plant Solutions
Europe / Africa / Asia / Australia
Dr. Kais Sfar
Head of Product Line Marketing Plant Solutions
Armin Staedtler
Head of 8000H R&D Program
Siemens AG, Energy, FossilProtection
Power Generation
notice / Copyright notice
Agenda
The challenge
Portfolio
overview–
Fluctuating power demand at raising fuel costs
SGT-8000 series and SCC-8000H power plant solutions
Validation of the 50Hz and 60Hz frames
Operational experience and references
Page 2
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Evolution of Siemens Combined Cycle Technology
1991
1996
SGT5-2000E
2011
2008
~ 2015
SGT5-4000F
SGT5-4000F
SGT5-8000H
SGT5-8000H:
(Intro)
(latest upgrade)
(Intro)
(next steps)
> 50%
> 56%
> 58,5%
> 60%
> 61,5%
CC efficiency*
CC efficiency*
CC efficiency*
CC efficiency*
CC efficiency*
CCPP
Killingholme (2x1)
2 x 450 MW
CCPP
Didcot B (2x1)
2 x 705 MW
CCPP
Mainz (1x1)
405 MW
CCPP
Irsching 4 (1S)
578 MW
CCPP
SCC5-8000H (1S)
> 600 MW
525 °C / 80 bar
2PR-non RH
540 °C / 110 bar
3PR-RH
565 °C / 125 bar
3PR-RH
600°C / 170 bar
3PR-RH, Benson
t.b.d
10 % points increase in efficiency over approx. 20 years
Future
* at ISO conditions
Page 3
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Siemens Large Scale Gas Turbines:
Product Portfolio for 50 Hz and 60 Hz
SGT5-8000H
375
292
SGT5-4000F
274
SGT6-8000H
SGT6-5000F
208
SGT6-4000F
187
168
SGT5-2000E
113
SGT6-2000E
SGT5-8000H
04/2007
SGT6-8000H
01/2011
Direct scale
1 / 1,2
(50 / 60 Hz)
Output in MW @ ISO conditions
Page 4
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Agenda
The challenge
Portfolio
overview–
Fluctuating power demand at raising fuel costs
SGT-8000 series and SCC-8000H power plant solutions
Validation of the 50Hz and 60Hz frames
Operational experience and references
Page 5
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Overview of Key Data
SGT5-8000H
SCC5-8000H 1S
Fuel
SGT6-8000H
SCC6-8000H 1S
Nat. gas, #2
Nat. gas, #2
375 MW
274 MW
40 %
40 %
570 MW
410 MW
CC, Efficiency
60 %
60 %
Pressure ratio
19.2 : 1
19.5 : 1
820 kg/s
610 kg/s
Exhaust temperature
625 °C
625 °C
Emissions, NOx
25 ppm
25 ppm
Emissions, CO
10 ppm
10 ppm
GT, Power
GT, Efficiency
CC, Power
Exhaust mass flow
HRSG/WS-Cycle 600°C/170 bar
Benson
585°C/150 bar
Benson/Drum
Optional
600°C/170bar
585°C/150bar
Benson/drum
SGT5-8000H
SCC5-8000H 1S
Benson
at ISO conditions
Page 6
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
SGT-8000H
Efficient & Flexible
Advanced Can
Annular combustion
system
Evolutionary 3D blading
4 stages of fast acting variablepitch guide vanes (VGV) allowing
for improved part load efficiency
and high load transients
> 60% combined
cycle efficiency
Proven rotor design
(Hirth serration,
central tie rod, internal
cooling air passages)
for world class fast
(cold) start and hot
restart capability
3D 4 stage turbine with
adv. materials and TBC
High cycling capability due
to fully internally air cooled
turbine section
Transient protection of clearances
for reduced degradation with
hydraulic clearance optimization
(HCO) active clearance control
HCO for reduced
clearance losses
Performance features
Flexibility features
Designed for >60% efficiency in combined cycle
and best in class operational flexibility
Page 7
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Hydraulic Clearance Optimization (HCO)
Increased performance and power output
HCO on
~5 MW
HCO off
The Siemens HCO system: Simple. Fail-safe. Proven for >10 years.
Page 8
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
SGT-8000H engine concept
based on harmonization and new technology
Siemens V Design
 Single tie bolt
 Compr. stat. design
Harmonized
Compressor
Siemens W Design
 Turbine cylinder
 Turbine vane carrier
 Exit housing
 Front hollow shaft
 Bearings
 Compressor cylinder
ULN can-annular
combustion system
 Turbine features
 Turbine diffuser
Secondary Air
System
The SGT-8000H concept uses proven features from Siemens and (former)
Westinghouse engines and introduces new technology
Page 9
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Innovative design features and proven technologies
enable SCC5-8000H 1S to reach η > 60%
HRSG: BensonTM
3Pr/RH 600 °C/170 bar
Steam Turb.:SST5-5000
Gas Turbine: SGT5-8000H
Combined HP/IP
Dual flow LP
HP: 170 bar / 600 °C
IP: 35 bar / 600 °C
LP: 5 bar / 300 °C
Generator: SGen5-3000W
Water cooled stator winding
Hydrogen cooled rotor winding
MICALASTIC® Stator insulation
World class efficiency
Two main levers to reach highest efficiency
Gas Turbine
Water Steam Cycle
■ Increased pressure ratio
■ Fuel preheating of 215 °C
■ Increased turbine inlet temperature
combined with cooling air optimization
■ Advanced water/steam cycle (up to
600 °C) with BensonTM HRSG
■ Improved component efficiencies
Page 10
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
SCC5-8000H 1S – a proven concept optimized for
highest operational flexibility
High-capacity
de-superheater
Stack damper
BensonTM
technology
ST stress
controller
FACY
Fast Cycling
Advanced
steam parameter
Up to 600 °C
Optimized GT
load ramp
HRSG standby heating
Low complexity
(No GT external
cooling interface)
Condensate
polishing plant
Proven cycle
concept
Triple pressure
reheat cycle
Specific features included in our advanced 8000H plant cycle design for
most flexible and reliable operation
Page 11
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
HRSG with Siemens BensonTM HP section
designed for 600 °C steam temperature
Irsching 4 BensonTM* HRSG is designed and delivered by Siemens
Proven
Benson
Design
Concept
Siemens Benson HRSG
design, 19 units built, e.g.
Malzenice, Gönyü, Severn
Power, Sloe Centrale…
Siemens
Design
Principles
Based on F-class
technology as executed
in e.g. Karstoe,
Simmering, Timelkam
HRSG + Plant
Development
in one Hand
=
 HP pressure/Temp.: 170 bar/600 °C
Benson
Evaporator
Design
Based on Siemens
BensonTM Technology*
(Elimination of HP drum)
600 °C
Technology
Utilization of high
temperature materials
applied for 600 °C
Steam Power Plants
 RH pressure/Temp: 35 bar/600 °C
 Mass flow:
100 kg/s
 Weight:
~ 7000 tons
 Heating surface:
> 500.000 m²
Innovation based
on proven
technology and
materials
(*) Siemens is owner of the BensonTM patent
Page 12
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
FACY™ improves the start up efficiency
by 14%-points during a hot start
Start up times hot start
load
Improvements
Improvement
 No hold phase for Steam Turbine,
simultaneous Gas- and Steam Turbine startup
 Avoid dumping energy to the condenser during
start-up
 Allows optimized Fleet Management
< 30 min.
Improved
start up
Efficiency
advantage*
Conventional
start up
tconv.
time
conventional
hot start
Hot start
with FACY™
Fuel consumption
(start up only)
~514 MWh
~326 MWh
Average efficiency
(according tconv.)
~36%
~50%
* Reference SCC5-8000H 1S
FACY™ technology enables optimized start-up operation, saves fuel
consumption and increases profit
Page 13
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Dynamic load tests
Plant fast hot start-up (FACYTM)
600
60
Plant start-up time < 30 min.
CC full load
500
50
Plant output
Plant Output
400
40
GT speed
300
30
ST speed
200
20
Turbine Speed
Plant load ramps of up to
> 55 MW/min at  of > 25
MW/min during start-up
GT load
100
10
0
GT load ramps of
up to 35 MW/min
0
GT ignition
Time [min]
GT @ base load
“More than half a GW in less than half an hour”
Page 14
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Dynamic load tests
Plant load cycling
600
600
HP Steam Temp. 600 °C
500
Plant base load
500
Steam Temperature
Plant Output
Plant Output
400
400
300
300
200MW in less
than 7 minutes
200
200
GT Load
Frequent load changes between 15 MW/min – 35
MW/min at stable live steam temperature
100
0
100
0
0
60
120
180
240
300
360
Time
Different load gradients successfully tested at stable plant system operation
and load changes over 200MW in less than 7 minutes
Page 15
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Agenda
The challenge
Portfolio
overview–
Fluctuating power demand at raising fuel costs
SGT-8000 series and SCC-8000H power plant solutions
Validation of the 50Hz and 60Hz frames
Operational experience and references
Page 16
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Scaling and Validation Approach
SGT5-8000H
SGT5-8000H
& SCC5-8000H
Validation in Irsching
Testing in simple & combined cycle
operation …
… with commercial grid boundaries
… GT and BoP thoroughly validated
… beyond req. as for the UK grid code
Scaling rules
50Hz
SGT6-8000H
SGT6-8000H
60Hz
Speed
X
1.2
Dimensions

1.2
Power, Mass Flow

1.44
Stresses &
Temperatures
x
1.0
Efficiency
x
~1.0
Validation ininBerlin
Validation
TestTest
BedFacility
Berlin
Testing in controlled environment …
... Grid independent (e.g. frequency)
… with fuel gas and fuel oil
16 combustor cans
2007
2008
12 combustor cans
2009
2010
2011
2012
2013
2014
2015
50Hz
First Fire Testing Simple Cycle CC extension CC Validation COD Commercial Operation Combined Cycle
60Hz
Testing in Test Bed
3*
1
1 3
2 1 1 1
* # of GTs going into commercial operation
8000H has passed a comprehensive testing before shipping to a customer site …
… even the 60Hz version as a true scale
Page 17
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
SGT5-8000H and SCC5-8000H 1S
Summary of the main Irsching validation results
Ulrich Hartmann (“Irsching 4”)
Bavaria, Germany
SCC5-8000H 1S
Customer
E.ON
Total el. Power Output >545 MW
Plant efficiency
>60,3 %
Simple cycle operation:
Functionality, operational capability,
performance and serviceability validated
and proven after ~1500 hours of operation
Combined cycle operation
- World record efficiency of 60,75%
Special features
- Startup time < 30 min
- Shutdown time < 30min
 world record efficiency
- Stable operation down to 20% CC load
- High cycling capability w/ up to 35MW/min
 FACY™ startup within 30min
GT load ramp
 Siemens BENSON Boiler, 600°C w/s-cycle
- Fulfillment of most stringent grid codes
Page 18
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Irsching 4, as of September 2012
22.07.2011
PAC/Commercial operation
01.-03.10.2011
~ 6.000 EOH borescope inspection*
06.-08.01.2012
~ 8.000 EOH borescope inspection*
17.-21.03.2012
~ 10.000 EOH borescope inspection*
05.-16.05.2012
12.000 EOH combustor inspection
Operational Summary:
• Daily start / stop and load following per load dispatch
requirements
• more than 440 starts and 17.800 EOH
• High operational reliability >97% confirmed in
commercial operation already with the first engine
* Opportunistic without availability impact
> 1 year successful commercial operation; engine in excellent condition
Page 19
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Typical operation profile of Ulrich Hartmann (Irsching 4)
CCPP in 2012
Plant output
GT speed
Mon
Tue
Wed
Thu
Fri
Sat
Sun
Daily start / stop cycle and load following throughout the whole operation period
Page 20
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Ulrich Hartmann CCPP
12.000 EOH - Combustor Inspection (May 2012)
Turbine Vane 1
Turbine Blade 1
Compressor outlet
Combustor Basket
Turbine Hot Gas Path in excellent condition after
12.000 EOH / 1 Year Commercial Operation
Page 21
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
SGT6-8000H – Test Bed in Berlin: up to 300 MW Testing
at various speed conditions due to water brake
Technical features:
• 9 stage water brake up
to 300MW equivalent
• Off frequency operation
over a wide range
• Fuel supply through
pipe gas and distillate #2
• Approx. 2000 sensors
07.09.2011
05.12.2011
10.01.2012
20.04.2012
04.07.2012
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Gas,
unheated
Gas, heated
LLCO
Fuel Oil
up to 75%
load
Gas, heated
Fuel Oil
100% load
sub 25ppm
NOx
26.10.2011
15.12.2011
29.02.2012
24.05.2012
17.08.2012
inspection,
rebuild and
thermal shipment
for
paint
commercial
run
use
03.08.2012
Full Speed, Full Load Operation in Test Bed is integral part of the engine validation
Page 22
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
SGT6-8000H Validation at BTF
Main Results
 Thermodynamic behavior (temperatures,



pressures, massflows) as expected
Performance expectation met
Hardware integrity confirmed
off-frequency (eigenfrequency/vibration) behavior confirmed
 Emission / combustion behavior confirmed



- FSFL and part load Operation
- cold & hot fuel gas
Fuel oil operation successful:
- FSFL and part load operation
- Online fuel transfer
Operational flexibility (ramp rates, load rejection,…) as expected
LLCO (Low Load CO) operation as expected
 Confirmation of the base line 5-8000H
 Confirmation of control & protection logic
The SGT6-8000H has met all targets  SGT5/6-8000H confirmed.
Page 23
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Agenda
The challenge
Portfolio
overview–
Fluctuating power demand at raising fuel costs
SGT-8000 series and SCC-8000H power plant solutions
Validation of the 50Hz and 60Hz frames
Operational experience and references
Page 24
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
SGT-8000H
Operational Status
Status September ‘12
SGT5-8000H
SGT6-8000H
GT Validation
Operation
GT Validation
Sum
starts
85
355
137 (115 gas, 22 oil)
577
Operating hrs
Dynamic hrs
1525*
1990
7347
2519
4365
13497
302 (236 gas, 65 oil)
2150 (1640 gas, 510 oil)
9174
6659
3822
21684
EOH
* Thereof 1200 hours non-stop full load
The SGT-8000H has achieved more than 570 starts & 21.500 EOH
Page 25
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Siemens Combined Cycle Power Plants
EURA H-class 50Hz
Lausward
Düsseldorf
SCC5-8000H 1S
Customer
Stadtwerke
Düsseldorf
Total el. Power Output 596 MW
Plant efficiency
>61 %
ST Type
SST5-5000
Generator Type
SGen5-3000W
Date of order
05 / 2012
1st comm. operation
mid 2015
Page 26
Bangkok, October 3-5, 2012
Special features
 District heating 300MWth
 85 % fuel efficiency
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
SGT-8000H References
Ulrich Hartmann – Irsching 4, Germany
1x SCC5-8000H 1S, >17.800 EOH
Cape Canaveral / Riviera Beach, Florida, USA
2x SCC6-8000H 3x1, COD 05/2013, COD 05/2014
Bugok 3, South Korea
1x SCC6-8000H 1S, COD 08/2013
Ansan, South Korea
1x SCC6-8000H 2x1, COD 10/2014
Andong, South Korea
1x SCC6-8000H 1S, COD 03/2014
Lausward, Germany
1x SCC5-8000H 1S CHP, COD 02/2016
Düsseldorf,
Düsseldorf,
´Center
´Center
Posco Power 2, South Korea
3x SCC6-8000H 1S, COD 05/2014, 08/2014, 11/2014
Daegu City, South Korea
1x SCC6-8000H 1S, COD 11/2014
Status: September 2012
16 SGT-8000H gas turbines sold
Page 27
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Exemplary IRR-based economical comparison of
profitability F-class vs. SCC5-8000H
Additional Internal Rate of Return of the SCC5-8000H @ 6000 OH/a and 7,50 €/GJ
Effect of
higher gas
prices
IRR [%]
~ 6,8 %-Pt
Proven F-class
additional
Power Output
additional
Efficiency
additional
LTP costs
additional
EPC costs
SCC5-8000H
The SCC5-8000H generates higher profits, shorter payback period and lower
Levelized Electricity Costs
Page 28
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
SGT-8000H series and SCC-8000H power plants…

World class net efficiency of 60,75%

Fully air-cooled engine design w/o external coolers allows for outstanding
operational flexibility

High reliability >97% achieved in commercial operation already with the 1.
engine in Ulrich Hartmann plant (Irsching 4)

Scaled 60Hz engine tested at full load and successfully validated in Berlin
Test Field

Both engines are thoroughly tested and validated prior to first commercial
application

Extensive field experience with more than 570 starts and 21500 EOH

Excellent engine conditions during first combustor inspection

Insurability confirmed (LEG 2)

Reduced investment and improved life cycle cost
16 sold engines of Siemens H-class technology for IPPs and utilities
worldwide demonstrates customer’s trust and commercial viability
Page 29
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved
Thank you for your kind
attention!
© Siemens
Protection
AG 2011.
noticeAll
/ Copyright
rights reserved.
notice
Disclaimer
This document contains forward-looking statements and information – that is, statements related to future, not past,
events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”,
“plans”, “believes”, “seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on our current
expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of
factors, many of which are beyond Siemens’ control, affect its operations, performance, business strategy and results
and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from
any future results, performance or achievements that may be expressed or implied by such forward-looking
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Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners.
Page 31
Bangkok, October 3-5, 2012
Balling, Sfar, Staedtler
© Siemens AG 2012. All rights reserved