Recent Developments in Small
Industrial Gas turbines
Ian Amos
Product Strategy Manager
Siemens Industrial Turbomachinery Ltd
Lincoln, UK
Copyright © Siemens AG 2009. All rights reserved.
Content
Gas Turbine as Prime Movers
Applications
History
Technology
thermodynamic trends and drivers
core components
Future requirements
Market developments
Page 2
Nov 2010
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Energy Sector
1
Gas Turbine as Prime Mover
Prime mover : A machine that
transforms energy from thermal,
electrical or pressure form to
mechanical form; typically an engine
or turbine.
Gas Turbines vary in power output
from just a few kW more than 400,000
kW.
The shaft output can be used to
generate electricity from an alternator
or provide mechanical drive for
pumps and compressors.
Page 3
Copyright © Siemens AG 2009. All rights reserved.
Energy Sector
Nov 2010
Siemens Industrial gas turbine range
Utility Turbines
Figures in net MW
SGT5-8000H
375
SGT5-4000F
287
SGT6-8000H
266
Industrial Turbines
SGT6-5000F
SGT5-2000E
SGT6-2000E
SGT-800
SGT-700
SGT-600
SGT-500
SGT-400
SGT-300
SGT-200
SGT-100
Page 4
198
168
113
47
31
25
17
13
8
7
5
Nov 2010
Copyright © Siemens AG 2009. All rights reserved.
Energy Sector
2
Industrial Gas Turbine Product Range
Portfolio
(MW)
SGT-100-1S
47
SGT-800
30
SGT-700
SGT-600
25
SGT-500
17
SGT-400
13
SGT-300
8
SGT-200 7
SGT-100 5
SGT-100-2S
SGT-200-2S
SGT-200-1S
SGT-300
SGT-400
SGT-500
Page 5
SGT-600
Nov 2010
SGT-700
SGT-800
Copyright © Siemens AG 2009. All rights reserved.
Energy Sector
Industrial Gas Turbine
Product applications
Power
Generation
Pumping
An SGT-100
generating set is
installed on Norske
Shell's Troll Field
platform in the
North Sea
Thirty SGT-200
driven pump sets
on the OZ2 pipeline
operated by
Sonatrach, Algeria
Page 6
Nov 2010
Compression
Two SGT-700
driven Siemens
compressors for
natural gas
liquefaction plant
owned by UGDC
at Port Said,
Egypt.
CHP
Comb. Cycle
An SGT-800 CHP
plant for InfraServ
Bavernwerk’s
chemical plant in
Gendork,
Germany.
Two SGT-400
generating sets
operating in
cogeneration/
combined cycle
for BIEP at BP’s
Bulwer Island
refinery, Australia
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3
Gas Turbine Refresher
Comparison of Gas Turbine and Reciprocating Engine Cycle
AIR INTAKE
FUEL
COMBUSTION
EXHAUST
COMPRESSION
Continuous
Intermittent
AIR/FUEL INTAKE
Page 7
COMPRESSION
Nov 2010
COMBUSTION
EXHAUST
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Energy Sector
Gas Turbine as Prime Mover
Gas Turbine Characteristics
Size and Weight
High power to weight ratio
giving a very compact power
source
Operation and Maintenance
No Lubricating oil changes
High levels of availability
Vibration
Rotating parts mean vibration
free operation requiring simple
foundations
Fuel flexibility
Dual fuel capability
Burn Lean gases (high N2 or
CO2 mixtures)
Varying calorific values
Emissions
Very low emissions of NOx
Page 8
Nov 2010
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Energy Sector
4
Brayton Cycle
1-2
2-3
3-4
Air drawn from atmosphere and compressed
Fuel added and combustion takes place at constant pressure
Hot gases expanded through turbine and work extracted
(in single shaft approx 2/3 of turbine work is used to drive the compressor)
Copyright © Siemens AG 2009. All rights reserved.
Energy Sector
Nov 2010
Page 9
Ideal Engine Cycle:
Efficiency
Ideal thermal efficiency


 1 
Simple cycle efficiency = 1 − 

 P1 
 P2 
( γ −1) / γ
Cycle efficiency is therefore
only dependant on the
cycle pressure ratio.
Assumption : Ideal cycle
with no component or
system losses.
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0
10
20
30
40
50
Pressure Ratio
Page 10
Nov 2010
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5
Engine Cycle:
The Real Engine
Deviations from Ideal Cycle
‘Real’ Efficiencies
•Aerodynamic losses in turbine and
compressor blading
• Practical simple cycle gas
turbines achieve 25 to 40 % shaft
efficiency
• Working fluid property changes
with temperature
• Pressure losses in intakes,
combustors, ducts, exhausts,
silencers etc.
• However, heat rejected in the
exhaust can be used :-
• Air used for cooling hot
components
• Parasitic air & hot gas leakages
• Mechanical losses in bearings,
gearboxes, seals, shafts
• Electrical losses in alternators
Page 11
• Complex gas turbine cycles can
achieve shaft efficiencies up to
50%
•Large combined cycle GT can
achieve close to 60% shaft
efficiency
•Cogeneration (Heat and Power)
can exceed 80% total thermal
efficiency
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Energy Sector
Nov 2010
Energy Cost Savings
GT cycle parameter study
43.0
25
42.0
Shaft Efficiency (%)
22
41.0
20
40.0
18
39.0
PRESSURE
RATIO
16
38.0
14
37.0
1300ºC
1350ºC
1400ºC
1450ºC
1250ºC
36.0
1200ºC
FIRING TEMPERATURE
35.0
280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480
Shaft Specific Output (kJ/kg)
Increase Pressure ratio and firing temperatures for higher simple cycle efficiencies
Page 12
Nov 2010
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6
Design Drivers :
Low Specific Fuel Consumption
Higher Pressure Ratios
• Increased Cycle Efficiency
• Increased number of compressor / turbine stages and
therefore cost
Complex Cycles
• Increased Cycle Efficiency and/or Specific Power
• Can impact operability, cost and reliability
Higher Firing Temperature
• Requires increased sophistication of cooling systems
• Can impact life and reliability and combustor emissions
Page 13
Nov 2010
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Energy Sector
Design Drivers :
Availabilty, Cost and Emissions
High reliability.
Moderates the trend to increase firing temperature and cycle
complexity.
Low Emissions (Driven by environmental legislation)
More difficult to achieve with high firing temperatures and
combustion pressures
Lowest possible cost.
Encourages smallest possible frame size, i.e. high specific
power high firing temperature.
Reduced Pressure ratios (< 20:1) to avoid auxiliary fuel
compression costs
Compromise is required in the concept design to get the best
balance of parameters
Page 14
Nov 2010
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Energy Sector
7
Future
Machines
SGT-400
SGT-300
TB
TD
TG
TF
TE
TA
16
15
14
13
12
11
10
9
8
7
6
5
4
3
1300
ttiioo
RRaa
rree
u
u
s
s
es
Pr
1200
urree
t
aatu
eerr
mpp
eem
T
T
g
1100
inng
FFiir
1000
900
800
Firing Temperature °C
Pressure Ratio
3CT
Centrifugal Compr.
SGT-100
SGT-200
Core Engine Trends:
Key Parameter Trends
700
1950
1960
1970
1980
YEAR
Year
2000
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Energy Sector
Nov 2010
Page 15
1990
Engine Trends:
Thermal Efficiency
40
SGT-400
38
300
36
34
250
SGT-100
32
SGT-200
200
Specific Power Output
Thermal Efficiency
150 TB5000
30
Thermal Efficiency (%)
Specific Power (kJ/kg)
350
28
26
100
1975
1980
1985
1990
1995
2000
24
2005
Year
Dramatic impact of increased TET and pressure ratio over last 25 years:
•
•
•
Page 16
Specific Power increased by almost 100%
Specific Fuel Consumption reduced by over 30%
reduced airflow for a given power output and has resulted in smaller
engine footprints, reduced weight and reduced engine costs
Nov 2010
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8
Product Evolution
SGT-300
Introduced 1995
7,900 kWe 30.5% eff
TA
Introduced 1952
750kW
17.6% eff
Developed to 1,860kW
Page 17
Nov 2010
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Energy Sector
Gas Turbine Layout
- single shaft or twin shaft
Single Shaft
Expansion through a single series of
turbine stages.
Power transmitted through rotor
driving the compressor and torque at
the output shaft
Twin Shaft
Expansion over 2 series of
turbines.
Compressor Turbine (CT)
provides power for compressor
Useful output power provided by
free Power Turbine (PT)
Page 18
Nov 2010
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9
SGT-400 Industrial gas turbine
Compressor
Page 19
Combustion
system
Nov 2010
Gas Generator
Turbine
Power
Turbine
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Energy Sector
Combustion
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10
Environmental Aspects
Pollutants and Control
Pollutant
Effect
Method of Control
Carbon Dioxide
Greenhouse gas
Cycle Efficiency
Carbon Monoxide
Poisonous
DLE System
Sulphur Oxides
Acid Rain
Fuel Treatment
Nitrogen Oxides
Ozone Depletion
Smog
Poisonous
Greenhouse gas
Visible pollution
DLE System
Hydrocarbons
Smoke
DLE System
DLE System
DLE - Dry Low Emissions
Page 21
Nov 2010
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Energy Sector
Exhaust Emission Compliance
Emissions control:
Two types of combustion configuration need to be considered:
Diffusion flame
Dry Low Emissions (DLE or DLN) using Pre-mix combustion
Diffusion flame
Produces high combustor primary zone temperatures, and as NOx is a
function of temperature, results in high thermal NOx formation
Use of wet injection directly into the primary zone to lower combustion
temperature and hence lower NOx formation
Dry Low Emissions
Lean pre-mixed combustion resulting in low combustion temperature, hence
low NOx formation
With good design and control <25ppm NOx across a wide load and ambient
range possible
Page 22
Nov 2010
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11
Combustion
NOx Formation
1000
NOx Formation Rate [ ppm/ms ]
100
10
1
0.1
Diffusion Flame
0.01
0.001
Lean Pre-mix
0.0001
0.00001
0.000001
1300
1500
1700
1900
2100
2300
2500
Flame Temperature [ K ]
Flame temperature affects thermal NOx formation
Page 23
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Energy Sector
Nov 2010
Combustion
NOx Formation
Flame Temperature as a function of Air/Fuel ratio
Diffusion flame reaction
zone temperature
Lean burn
Flame
temperature
Diffusion flame
Lean Pre-mixed
(DLE/DLN)
Lean
Page 24
Nov 2010
Stoichiometric
FAR
Rich
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12
Combustor Configuration
NOx product is a function of temperature
Diffusion
Combustion
- high primary zone
temperature
Cooling
Dry Low
Emissions
Combustion
-low peak temperature
achieved with lean
pre-mix combustion
Page 25
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Energy Sector
Nov 2010
DLE Lean Pre-mix Combustor
(SGT-100 to SGT-400 configuration)
Igniter
Liquid
Core
Pilot
Burner
Main Burner
Radial
Swirler
Robust design involving no moving
parts
Fixed swirler vanes
Variable fuel metering via pilot and
main fuel valves
Main Gas
Injection
Igniter
Pilot Gas
Injection
Pre Chamber
Air
Gas/Air
Mix
Gas
Air
Double Skin
Impingement
Cooled Combustor
Page 26
Nov 2010
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13
Lean Pre–Mix combustion
Simple fuel system
Variable fuel metering via pilot and main fuel valves
Low NOx across a wide operating range of load and ambient conditions
BLOCK
VALVE
BLOCK
VALVE
M
MAIN FLOW
CONTROL
VALVE
MAIN
MANIFOLD
BLEED
VALVE
PILOT
MANIFOLD
PILOT FLOW
CONTROL
VALVE
Page 27
Nov 2010
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Energy Sector
Combustion
DLE Lean Premix System
Key to success
good mixing of fuel and air
multiple injection ports around swirler
long pre-mix path
fuel injection as far from combustion zone as possible
good air flow distribution
can annular arrangement with top hats
use of pilot burner
CO control & flame stability
use of guide vane modulation/air bleed
air flow management
Page 28
Nov 2010
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14
DLE System : Siemens experience
15million operating hours across the range (SGT-100 to SGT-800)
Approximately 1000 DLE units
About 90% of new orders DLE
Page 29
Nov 2010
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Energy Sector
Experience
Stable load accept/reject
Daily profile for unit running more than 8000hrs DLE operation on liquid fuel.
kW
Daily variations
Load Shed and Accept
Page 30
Nov 2010
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15
Gas Fuel Flexibility
BIOMASS &
COAL GASIFICATION
3.5
Other gas
High Hydrogen
Refinery Gases
Associated Gas
37
Landfill & Sewage
Gas
49
65
LPG
Siemens Diffusion
IPG Ceramics
Off-shore lean
Well head gas
Operating
Experience
Off-shore rich gas
Siemens DLE Units operating
DLE Capability Under
Development
Pipeline
Quality NG
Low Calorific
Value (LCV)
Medium Calorific Value (MCV)
10
20
‘’Normal’’
30
40
50
Wobbe Index (MJ/Nm³)
60
SIT Ltd.
Definition
70
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Energy Sector
Nov 2010
Page 31
High Calorific Value
(HCV)
The change in WI by the addition of inert species to pipeline quaility gas
50
UK Natural Gas
45
CO2
N2
Wobbe MJ/m
3
40
35
Medium CV Fuel
30
MCV
Rangedevelopment
Definition
25
20
15
10
5
LCV Burner
0
0
10
20
30
40
50
60
70
80
90
100
CO2 or N2 content of UK Natural Gas
Page 32
Nov 2010
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Energy Sector
16
Examples of Siemens SGT Fuels Experience
NON DLE Combustion
Natural Gas
Wellhead Gases
Landfill Gas
Sewage Gas
High Hydrogen Gases
Diesel
Kerosene
LPG (liquid and gaseous)
Naphtha
‘Wood’ or Synthetic Gas
Gasified Lignite
Sewage gas
standard burner
Gasified Biomass
Special Diffusion
burner
5
10
Landfill gas
Special
Diffusion
burner
15
20
25
High Hydrogen gas
standard burner
UK Natural Gas
30
35
40
45
50
Liquified Petroleum gas
modified MPI
55
60
65
70
Wobbe Index MJ/m3
standard
gases
Gaseous Fuel Range of Operation
DLE experience on Natural Gas, Kerosene and Diesel
DLE on fuels with high N2 and CO2 content.
DLE Associated or Wellhead Gases
Page 33
Nov 2010
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Energy Sector
Turbine
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17
Aerodynamic optimised design !
Minimised loss
optimum pitch/width ratio
across whole span.
low loading
High speed
high stage number
low Mach numbers
thin trailing edges
low wedge angle
zero tip clearance
Page 35
Nov 2010
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Energy Sector
Aerodynamics
High Load Turbine
Computational Fluid Dynamics (CFD) used to complement experimental testing of
advanced components.
Page 36
Nov 2010
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18
Analytical optimised design !
Reduce blade stresses
Minimal shroud
shroud may still be desirable
for damping purposes.
High hub/tip area ratio
Low rotational speed.
Maximise life
Low temperatures
Low unsteady forces
Page 37
Nov 2010
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Energy Sector
Mechanical Design Improved analysis software
(grid and solver) and improved
hardware allow traditional ‘postdesign’ to be carried out during
design iterations.
Meshing of complex cooled
blade could take many man
months in early 90’s - now
down to minutes.
More sophisticated analysis for
detailed lifing studies still
required after design.
Page 38
Nov 2010
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Energy Sector
19
Fatigue Life of Rotating Blades
Positions of Concern
Blade Vibration response
Predicted by FE and measured in
Lab.
Identifies critical blade frequencies
and modes (Campbell Diagram)
Aerofoil
High Cycle Fatigue
Fillet Radii between aerofoil &
platform
Top neck of firtree root
Fillets
Low Cycle Fatigue
In areas of highest stress
Eg - blade root serrations
Root Serration (including skew effects)
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Energy Sector
Nov 2010
Page 39
Mechanical Design - Vibration analysis
Campbell Diagram for LPT Blade (Blade only)
EO20
6000
EO18
EO19
EO17
mode 6
EO11
EO10
3000
mode 4
EO9
mode 3
EO6
2000
mode 2
1000
mode 1
0
15000
15500
Iteration 3 version 10
Page 40
100%
4000
105%
mode 5
95%
Frequency (Hz)
5000
Nov 2010
EO3
16000
16500
17000
17500
18000
Engine Speed (rpm)
18500
19000
19500
20000
D G Palmer 3-8-01
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Energy Sector
20
Cooling optimised design !!
Large LE radius
minimise stagnation htc
thick trailing edge thickness
and large wedge angle for
cooling
thickness distribution to suit
cooling passages.
Minimise gas washed
surface.
Page 41
Nov 2010
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Energy Sector
Cooled Blading Designs
SGT100 > SGT300 > V2500 Aeroengine
Page 42
Nov 2010
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Energy Sector
21
SGT400 First Vane Cooling Features
Impingement
Cooling
Film
Cooling
Turbulators
Cast 2 Vane
Segment
Page 43
Nov 2010
Trailing Edge
Ejection
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Energy Sector
SGT-400 13MW Industrial Gas Turbine
First Stage Cooled Vane
Hot Blades are life
limited.
-Oxidation
- Thermal fatigue
- Creep
Life typically 24,000
hrs.
Life can be increased
or decreased
depending on duty
and environment.
Page 44
Nov 2010
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22
SGT-300 First Stage Cooled Rotor Blade
Ceramic Core forming
Cooling Passages
Page 45
SGT300 8MW Industrial Gas Turbine
Multi-Pass Cooled First Stage Rotor Blade
Nov 2010
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Energy Sector
HP Turbine Blade Coatings
Hot Gas Surface Coatings for Corrosion & Oxidation protection
Aluminide,
Silicon Aluminide (Sermalloy J)
Chromising
Chrome Aluminide, Platinum Aluminide
MCrAlY
Internal Coatings on Cooled Blades operating in poor environments
Ceramic Thermal Barrier Coatings
Yttria stabilised Zirconia
Plasma Spray Coatings used on Vanes
EBPVD Coatings used on rotating blades
More uniform structure for improved integrity
Page 46
Nov 2010
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Energy Sector
23
Turbine Validation Process
Analysis
Design
Assess
evaluation
and
calibration
of methods
Prototype
Test
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Energy Sector
Nov 2010
Page 47
New technology incorporated into existing
engine platforms
SGT-100 Product Development
New ratings have been released
Compressor Blade
• Stator stages S1& S2
• Rotor stages R1 & R2
Aerodynamic modifications to
compressor and turbine.
HP Rotor blade
• SX4 material
• Triple fin shroud
• Step Tip seal
Power generation, 5.4MWe
(launch rating 3.9MW
previously 5.25MWe)
Mechanical Drive,
5.7MW
(previously 4.9MW)
T
Page 48
P
Nov 2010
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Energy Sector
24
Industrial Gas Turbines
Advanced Materials & Manufacturing
SGT400 PT 2 Nozzle Ring
Page 49
Nov 2010
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Energy Sector
Bladed Turbine Disc
Page 50
Nov 2010
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25
The Gas Turbine Package
In addition to the main package, the following is also
required:
Combustion air intake system
Gas turbine exhaust system
Enclosure ventilation system (if enclosure fitted)
Control system
UPS or battery and charger system
Page 51
Nov 2010
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Energy Sector
SGT-300 Industrial gas turbine
Package design – The latest Module Design
Available as a factory assembled
packaged power plant for utility and
industrial power generation applications
Easily transported, installed and
maintained at site
Package incorporates gas turbine,
gearbox, generator and all systems
mounted on a single underbase
Preferred option to mount controls on
package, option for off package.
Common modular package design
concept
Acoustic treatment to reduce noise
levels to 85 dB(A) as standard (lower
levels available as options)
Page 52
Nov 2010
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Energy Sector
26
Typical Compressor Set
Page 53
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Energy Sector
Nov 2010
SGT-400
New Package Design
Minimised customer interfaces reducing contract execution/installation costs
1
1
Combustion Air Intake
2
Enclosure Air Inlet
3
On-Skid Controls
4
Fire & Gas System
5
Interfaces
6
Lub Oil Cooler
7
Enclosure Air Exit
7
6
2
3
4
5
Highly flexible modular construction
Customer configurable solutions based upon pre-engineered options
Standard module interfaces to allow flexibility and inter-changeability
Additional functionality provided dependent upon client needs
Base design provides common platform for on-shore and off-shore PG and MD
Page 54
Nov 2010
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27
Future direction
Copyright © Siemens AG 2009. All rights reserved.
Future Trends
- guided by market requirements
Universal demand for further increases in efficiency and reliability, and
reduction in cost.
Oil & Gas (Mech drive and Power Gen)
Fuel flexibility
- associated gases, off-gases, sour gas
Remote operation
Emissions
-inc CO2
Independent Power Generation
Fuel flexibility
- syngas, biofuels(?), LPG
Flexible operation
- part load operation
Distributed cogeneration (rather than centralised generation)
Emissions
- inc CO2
Page 56
Nov 2010
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Energy Sector
28
Oil and Gas
remote operations / fuel flexibility
•First application of its kind in Russia
(Western Siberia) burning wellhead gas
which was previously flared
•Solution:
Three SGT-200 gas turbine
•Output 6.75 MWe each
•DLE Combustion system
•Guaranteed NOx and CO
emission levels of 25ppm
•Min. air temp. (-57oC)
•Max. air temp. (+34oC)
•Gas composition with Wobbe Index
>45MJ/m3
•Total DLE hours approximately 22,300
hours for each unit
•Significant reduction of emissions : 80-90%
reduction of NOx level
•Siemens has supplied 135 gas turbines for
Power Generation , Gas compression and
pumping duty throughout the Russian oil &
gas industry
Page 57
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Energy Sector
Nov 2010
Power Generation
re-emergence of cogeneration
WATER
GRID
FUEL
BOILER
OR
DRIER
PRODUCT / STEAM
~
Page 58
Nov 2010
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Energy Sector
29
Thank You
Page 59
Nov 2010
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Energy Sector
30