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 statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens’ filings with the SEC, which are available on the Siemens website, www.siemens.com and on the SEC’s website, www.sec.gov . Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated. 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