SGT5-8000H
SCC5-8000H 1S
Experience of Commercial
Operation at Irsching 4
ANIMP-ATI, Sesto San Giovanni
26 June 2012
Massimo Gianfreda
© Siemens AG 2012
Energy Sector
8000H Overview
Validation Status
Summary
Fig. 2
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
©
© Siemens
Siemens AG
AG 2012
2012
EnergySector
Sector
Energy
Siemens Large Scale Gas Turbines:
Product Portfolio for 50 Hz and 60 Hz
SGT5 8000H
375
292
SGT5 4000F
274
SGT6 8000H
SGT6 5000F
200
SGT6 4000F
187
168
SGT5 2000E
SGT6 2000E
113
Output in MW @ ISO conditions
© Siemens AG 2012
Fig. 3
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
Program Launch – Concept Phase
01 Oct 2000
Gate 1: Product Strategy Release
21 Mar 2001
Gate 2: Start GT/CC Basic Design
05 Nov 2001
Gate 3: Product Release
17 Aug 2004
1st 50Hz engine ex Works Berlin
30 Apr 2007
1st Fire
20 Dec 2007
1st Synchronization to grid
07 Mar 2008
1st Base Load
24 Apr 2008
End of 50Hz GT Test & Validation Phase
28 Aug 2009
Gate 4: Series Release
22 Jun 2010
1st 60 Hz engine es works Berlin
1st fire 60Hz engine (Berlin Test Facility - BTF)
End of 60Hz Test & Validation Phase
Jan – Jul 2011
Jan 2011
Sept 2011
Jul 2012
BTF
Combined Cycle Commissioning & Testing
Irsching 4
8000H Program Overview
© Siemens AG 2012
Fig. 4
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT-8000H engine concept
based on harmonization and new technology
Siemens V Design
Single tie bolt
Compr. stat. design
Harmonized
Compressor
Turbine cylinder
Turbine vane carrier
Exit housing
Siemens W Design
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
© Siemens AG 2012
Fig. 5
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT5-8000H
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
HCO for reduced
clearance losses
3D Four stage turbine with
advanced materials and
thermal barrier coating
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
Performance features
Flexibility features
Designed for >60% efficiency in combined cycle
and best in class operational flexibility
© Siemens AG 2012
Fig. 6
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT5-8000H
Designed for serviceability
TVC roll out/roll in capability
Roll out/in capability of the turbine vane carrier
enables exchange of stationary turbine
hardware without rotor lift
Sequence and tooling successfully tested
during final assembly and prototype test
Rollout-Rollin of TVC w/o rotor lift
Blade 1 removal
Removable turbine blades and vanes
All blades removable w/o rotor lift
Vane 1 and blade 1 removable w/o cover lift
(access through combustion chamber)
Blade 4 removable w/o cover lift
(towards the exhaust end)
Removable compressor blades
Combustor Handling Tool for safety and efficiency
All rotating blades replaceable without rotor
de-stack or lift.
Serviceability – a key design factor to assure
optimized outage time and high availability
© Siemens AG 2012
Fig. 7
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
Possible heat extraction per GT Type
in large CHP-CCPPs (Examples)
SCC5-8000H 1S
570MW
SCC5-4000F 1S
430MW
SCC5-2000E (1x1)
230MW
0
SGT5-2000E
50
100
150
200
SGT5-4000F
250
300
350
400
possible heat extraction [MWth]
SGT5-8000H
© Siemens AG 2012
Fig. 8
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT5-8000H / SCC5-8000H
Significant Increase of CC Efficiency
1300
30
26
22 20
Com pressor
Pressure Ratio
■ Increased PR
+ 0,2 %
14
■ Increased TIT combined
with cooling air reduction
+ 0,8 %
■ Improved component
efficiencies
+ 0,2 %
18
16
1250
12
Efficiency, %
Turbine Inlet Tem perature
(acc. to ISO 2314)
10
1200
Placeholder for picture,
size 13 x 14,68 cm
1150
650
600
1100
550
1050
500
Turbine Exhaust Tem perature
■ Fuel Preheating of 215°C + 0,1 %
450
■ Advanced water/steam cycle
(600°C & 171 bar)
+ 0,4 %
1000
Specific Power Output, kW/(kg/s)
Siemens 8000H significantly increases efficiency by up to 1,7%-pts. in
combined cycle.
Without compromising plant flexibility!
© Siemens AG 2012
Fig. 9
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT-8000H
Direct scaling approach
SGT5-8000H
Scaling rules
50Hz
SGT6-8000H
to
60Hz
Speed
x
1.2
Dimensions
÷
1.2
Power, Mass
Flow
÷
1.44
Stresses &
Temperatures
x
1.0
Efficiency
x
~1.0
Harmonized design features allow validation experience
transfer from 50 to 60 Hz
© Siemens AG 2012
Fig. 10
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
Configuration and Performance Overview
SGT-PAC 8000H
SCC-PAC 8000H 1S
SCC-PAC 8000H 2x1
SCC-PAC 8000H 3x1
50 Hz
60 Hz
375 MW
40 %
274 MW
40 %
570 MW
60 %
410 MW
60 %
1.145 MW
60 %
824 MW
60 %
---
1.236 MW
60 %
SCC5/6-8000H 1S
SCC5/6-8000H 2x1
© Siemens AG 2012
at ISO conditions
Fig. 11
SGT5/6-8000H
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
8000H Overview
Validation Status
Summary
Fig. 12
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
©
© Siemens
Siemens AG
AG 2012
2012
EnergySector
Sector
Energy
8000H Program includes
Comprehensive Validation and Testing Concept
Strategic Product Planning
Product Strategy
Sales
Preparation
Design
Techn. Acquisition,
Product,Technology &
Developm. Planning
Conceptual
Design
Basic
Design
Commercialization Planning
Design Implementation
Final Design &
Procurement
Manufacturing &
Assembly
Erection, Installation,
Commissioning and
Trial Operation
Validation
Product
Monitoring
Performance
& Reliability
Validation
Parts tests
•
•
•
•
Casting blades & vanes
Materials, coatings
Manufacturing trials etc.
Stress / Strain verification
Component tests
• Combustion system rig test
• Cover plate rig test
• Mock up
50Hz Prototype
GT field validation
Prototype
CC field operation
Systems tests
• Compressor test &
• Combustion system test
at test bed Berlin
60Hz Prototype
Validation
Siemens carried out the most comprehensive test program in the industry
© Siemens AG 2012
13
Fig. 13
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
Irsching 4, Project Overview
Overall schedule from Contract to Combined Cycle extension and Commercial Operation (PAC)
2005
Q1 Q2
Q3
2006
Q4 Q1 Q2 Q3
Phase 1
SGT5-8000H
open cycle
2007
Q4 Q1 Q2
2008
Q3
Q4 Q1 Q2
Q3
2009
Q4 Q1 Q2
Q3
2010
Q4 Q1 Q2
Q3
2011
Q4 Q1 Q2
Q3
Q4
Open Cycle
Field Validation
SGT5-8000H
18 months
Validation 8000H
PAC
Phase 2
Combined Cycle
extension
Combined Cycle
Reference Plant
SCC5-8000H 1S
Irsching 4
Reference
Power Plant
SCC5-4000F
experiance
© Siemens AG 2012
Fig. 14
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
Irsching 4, Phase II, Combined Cycle Extension
Installation Completed on Schedule
SCC5-8000H 1S
Plant View, June 2011
Single Shaft Power Train
Power Train View, June 2011
Plant in commercial operation since July 2011
© Siemens AG 2012
Fig. 15
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT5-8000H Validation
Example: Simple Cycle Start-up
Increased loading & acceleration rate reduces startup time
Standard Loading: 25 Minutes to 375MW
Fast Loading: 10 Minutes to 350 MW
Normal Startup
Startup w/ fast loading
375 MW
350 MW
in 25 min.
in 10 minutes
80%
Loading
Output (% Load)
100%
60%
40%
20%
0%
6 minutes to
accelerate and sync.
Acceleration
3000
Speed (RPM)
2500
2000
1500
1000
500
0
0
200
400
600
800
1000
1200
1400
1600
1800
Time (seconds)
Proven: GT Fast start-up capability due to internal air cooling concept
© Siemens AG 2012
Fig. 16
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT5-8000H Validation
Example: Performance/Emissions
387,1 MW
Fuel preheat on
Emissions met
© Siemens AG 2012
Fig. 17
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
5-8000H Validation:
Serviceability
Rollout-Rollin of TVC w/o rotor lift
Blade 1 removal
Rotor lift
Blade 1 removal
Rotor destacking
Excellent serviceability proven on customer site boundaries
© Siemens AG 2012
Fig. 18
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
Reality Check:
World Class Flexibility (Plant Hot Start)
30min
GT speed
ST speed
Plant Load
Hot start capability:
540 MW in 30 min.
> ½ GW in ½ hour
Promised and Delivered !
© Siemens AG 2012
Fig. 19
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
Reality Check:
World Class Flexibility (Grid Code Compliance)
Load increase
Load decrease
64 MW (12%) in 10 s
250 MW (45%) in 6 s
CC load
Most stringent
Frequency simulation
-500mHz
frequency
response
target overachieved
Island Operation target
achieved.
We are prepared for
the upcoming ENTSOE network code
Promised and Delivered !
© Siemens AG 2012
Fig. 20
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
Reality Check:
World Class Performance
Promised and Delivered !
© Siemens AG 2012
Fig. 21
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SCC5-8000H 1S Irsching 4
Typical weekly load profile (summer)
© Siemens AG 2012
Fig. 22
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT5-8000H / Irsching 4
Operational Status
Starts
EOH
Phase I
GT Testing
Phase II
CC Extension
85
4365
>295
>11.000
status 2012-05-31
more than 380 starts & 15.500 EOH’s so far
© Siemens AG 2012
Fig. 23
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT-8000H References
status June 2012
1x 5-8000H, Germany
>15.500 EOH
6x 6-8000H, USA
3x PAC 2013, 3x PAC2014
1x 6-8000H, South Korea
PAC 2013
© Siemens AG 2012
Fig. 24
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
SGT-8000H References
status June 2012
1x 6-8000H, South Korea
PAC 2014
2x 6-8000H, South Korea
PAC 2014
1x 5-8000H, Germany
PAC 2015
© Siemens AG 2012
Fig. 25
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector
8000H Overview
Validation Status
Summary
Fig. 26
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
©
© Siemens
Siemens AG
AG 2012
2012
EnergySector
Sector
Energy
8000H
Summary
Siemens has
spent
>10 years with significant
R&D investment to
The
SGT-8000H
/ SCC-8000H
create a robust product and confirmed both integrity & performance
has proven:
to ensure highest customer value at lowest customer risk.
H Class Performance >60%
The SCC-8000H plants promise World Class Power, Efficiency
and Operational Flexibility
beyond
F Class Flexibility
© Siemens AG 2012
Fig. 27
ANIMP-ATI, Sesto San Giovanni, 26 June 2012
Energy Sector