Gas Turbine Performance and Maintenance … · Page 4 VGB 2013, Friedrichshafen, Germany Dr. V....
Transcript of Gas Turbine Performance and Maintenance … · Page 4 VGB 2013, Friedrichshafen, Germany Dr. V....
-
Protection notice / Copyright notice Siemens AG 2009. All rights reserved.
VGB ConferenceGas Turbines and
Operation of Gas Turbines 2013
11-12 of June 2013, Friedrichshafen, Germany
Gas Turbine Performance and Maintenance Continuous Improvement
Dr. V. Navrotsky,
Siemens Industrial Turbomachinery ABFinspong, Sweden
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 2
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
Outline
-
Page 3 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
SGT5-4000F
SGT6-5000F
SGT5-2000E
SGT6-2000E
SGT-800
SGT-700
SGT-600
SGT-500
SGT-400
SGT-200
SGT5-8000H
SGT-100 5
287
198
168
47/50
31/33
25
19
13
7
113
375
8SGT-300Industr
ial T
urb
ines
Utilit
y T
urb
ines
Siemens Industrial gas turbine range
SGT6-8000H 266
SGT-750 36
(MWe)
Siemens offer a wide power range of Gas Turbines for Industrial and O&G markets
-
Page 4 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Two shaft Gas Turbine10 stage compressor (PR=14)
Two stage compressor turbine
Two stage power turbine
SGT-600 Latest Design FeaturesGeneral Design
Welded compressor rotor,
Two variable guide vanes,
Two bleeds after stage 2 and 5,
All blades are coated (titanium blade 1)
Abradable coating on all stator rings
2:nd generation Dry Low Emission Comb.
Integrated by-pass systemThe design for PG is the sameas for a MD
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 5
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
-
Page 6 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
DLE introduced 1991Total of units sold today is 300+
66% in Mechanical Drive (MD) application34% in Power Generation (PG)
Total fleet operating hours > 7+ million hours5+ million of those on DLE
Fleet leaders:> 160 000 hours> 3 600 starts
Fleet details
The SGT-600 evolution
SGT- 600Key Core Engine Features and Experience, Data - March 2013
Mechanical Drive 34,100 bhp
Electrical Output 24.8 MW
Efficiency (PG/MD) 34.2%/ 35.1%
Exhaust Mass flow 80.4 kg/s
Exhaust Temperature 543 C
2rd generations DLE emission:
NOx on gas: < 25 ppmV @15% O2
NOx on liquid: < 42 ppmV @15% O2
Technical details
SGT-600 first introduced 1986
1975 1980 1985 1990 1995 2000 2005
Prototype testing 300+ units by SiemensTransfer4 units by
Sulzer
#1 Package
DLE
Uprating
#2 Package FloaterPackage
Sulzer Escher Wyss (CH)
Transfer SEW to ABB STAL AB* (SE)
Siemens
SGT-600 Specification
Reliability: 99.5% Availability: 96.5%
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 7
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
-
Page 8 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
MGT Combustor technologies2nd and 3rd generation of DLE technology
2nd generation DLE (SGT-600)
3rd generation DLE (MGT)
Combustor Bypass system
MGT DLE technology is effective, simple & reliable(simple principle with no moving parts or staging)
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 9
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
-
Page 10 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Life Cycle Extension ProgramLife Cycle extension LTA / LTE
Level E + LTA
Operation
Maintenance
Level A
Level B
Level C
Level D
LTE
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
EOH x 1000
SGT-600 Maintenance Schedule with LTA & LTE
Life Time Extension
120,000 EOH level C inspection +:Recommended replacements as
agreed with customer
Upgrade packages as agreed with
customer
Life Time Assessment
Performed at 80,000 EOH
Level E inspection, with analysis and evaluation
Status determination of major components:
Non-destructive
Destructive tests
Cost optimization of operationBeyond 120,000 EOH
Tailored scope of repair & replacement parts for LTE
-
Page 11 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Compressor turbinevanes # 1 & 2
Compressorturbineblades # 1
Combustionchamber
Power turbineblades # 3
Life Cycle Extension Life Cycle extension = LTA + LTE
Tailored scope of repair & replacement parts for LTE
-
Page 12 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Blade grooves
Centre holes Blade grooves
Balancing holes
Balancing holes
Centre and bolt holes
Stop holes
Internal radius transitions
Replica tests
Weld examination
Life Cycle Extension Rotor condition examination
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 13
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
-
Page 14 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Extension of inspection intervals from
20 000 EOH extended to 30 000 EOH by
means of improvements in the lifetime of major components
Advantage of Remote diagnostic service
Improvements of maintenance tools
Maintenance Down Time reduction
Extension of Maintenance Intervals -> 3 overhauls instead of 5
10 20 30 40 50 60 70 80 90 100 110 120
Level C
Level B
Level A
OperationMaintenance
Eq. Op. Hrs x 1000
Major Overhaul
Hot Section Inspection
Borescope
5
2 =
3in
sp
ectio
ns
The Extension of Maintenance Intervals can improve the availability by up to ~ 1 %
-
Page 15 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
.
SGT-600 Maintenance Down time reductionDevelopment of Maintenance tools
SGT-600 Maintainability improvement results in reduction of Maintenance duration and cost
Compressor blade
dismantling tool Gearbox tool Gas Generator
extraction tool
reduces down time
improves safety
reduces down time
simplifies work
improves safety
25% inspection time
reduction
80% blades saving
improves safety
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 16
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
-
Page 17 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Repair is primary done to support the maintenance plan. Current repair scope included into Maintenance Plan:
Combustor repair DLE & Conventional
Turbine GV #1 repair
Turbine GV #2 repair
Current scope of repair on condition:Compressor abradable ring recoating
Turbine blade #1 repair
Rotor seal edge repair
Honeycomb seals #1, #2 & #3 repair
Compressor blade & vane recoating
Siemens invest significantly into R&D development to support further increase
of repair yield and reduce repair cost
Current repair status SGT-600Repairs according to maintenance plan & on condition
-
Page 18 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Turb blade #1
Honeycomb seals
Sealing edge replacement
1st Vane 2nd Vane
Combustion Chamber
Comp, recoat abradable rings
Comp, blade &
vane recoating
Current repair status SGT-600Repairs according to maintenance plan & on condition
SGT-600 repair as a part of Maintenance Program to reduce maintenance cost
-
Page 19 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Hot gas path components
Closer look at combustor and turbine parts going for repair
Combustor
Blade #1
Vane #1
Vane #2
Honeycomb 1
Honeycomb 2
Honeycomb 3
-
Page 20 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
DLE Combustor repair
Typical repair actions:
1. Incoming inspection & assessment
2. Cut combustor according to dwg.
3. Strip coating by grit blasting
4. Inspect heat shield and liner condition
5. Adjust, weld repair and replace parts
6. Recoat heat shield, inner & outer liner
7. Assemble by welding
Typical repair options:
A. Replacement of Heat Shield
B. Replacement of inner and outer
liner
C. Weld repair of burner cone
D. Replacement of by pass sleeves
E. Cleaning of carbonized oil in
burners
Only part of available repair
options are required
-
Page 21 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Turbine GV #1
Oxidation of
parent material
Crack in trailing edge
Typical repair actions:
Incoming inspection & registration
Strip coating, chemical
Inspect & assessment
Blend to remove oxidation
Solution heat treatment
Weld repair as required
Floride Ion Cleaning (FIC)
Braze repair as required
Restore dimensions and gas path
shape
Recoat according to spec
Final insp. incl flow properties
-
Page 22 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Turbine GV #2
Crack in key slot
Oxidation of sealing fins
Typical repair actions:
Incoming inspection and registration
Strip coating, chemical
Inspect and assessment
Blend to remove oxidation
Solution heat treatment
Weld repair as required
Floride Ion Cleaning (FIC)
Braze repair as required
Restore dimensions and shape
Recoat according to spec
Final insp. Incl. flow properties
-
Page 23 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Honeycomb repair
Typical repair actions:
1. Incoming inspection and registration
2. Clean part by light grit blast
3. Remove old HC
4. Inspect and assessment
5. Braze new HC in place
6. Machine HC to final height
7. Final inspection
-
Page 24 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Compressor abradable ring repair
Typical repair actions:
1. Incoming inspection and registration
2. Clean part by light grit blast
3. Remove old coating by machining
4. Inspect
5. Apply Nickel plating
6. Apply abradable coating
7. Machine to final dimension
8. Final inspection
-
Page 25 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Repair technology development
To offer different repairs at reasonable prices Siemens is continuously developing and updating different repair technologies and methods.
Laser Cladding Technology
Laser Sintering
Non-destructive InspectionsInfrared Thermography
3D X-ray Tomography
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 26
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
-
Page 27 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden 27
Expert
Network
Team
Offline Diagnostics
DiagnosticsCenters
Power Plant
Advanced diagnostic
tools & techniques for:
Monitoring of engine conditions
Data collection / processing
Analysis of limit values
& deviation from
normal behaviourWo
rld
wid
e S
iem
en
s
Ne
two
rk f
or
Da
ta E
xch
an
ge
Reports
Info
Access
Monitoring
Analysis
Engineering Know-how:
Interpretation & Diagnostics
Data assessment
Development of
recommendations for future
operations, repairs and / or
modernizations
Online DiagnosticsOnline Diagnostics
Operating Data +
Specialty Monitor
Customer Relationship Management
Operation Improvement & optimization From Data collection & analysis to Customer Value Generation
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 28
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
-
Page 29 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
.
Ongoing SGT-600 Upgrades and Modificationsupports continuous product and services improvement
1200
34 EOH
15 ppm
32.4 %MD
19.8 MWMD
TargetBaselineDescription
600Increased cycle based TBO, without reduced T7-limit at hot ambient conditions.
30 EOHIncreased time based TBO, without reduced T7-limit at hot ambient conditions.
24,4-30 ppm
AEV: Reduced NOx Emissions at 100%-50% load (gas fuel)
31.9 %MDIncreased efficiency at hot ambient temperatures, 45OC
18.3 MWMDIncreased power at hot ambient temperatures, 45OC
Focus on further Emission & Downtime reduction, Flexible operation & life extension (including cyclic life)
36 60 52 6027 60 52 60
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 30
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
-
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 31
Summary
Continuous Improvement of SGT-600 is part of Siemens long-term product development strategy
SGT-600 fleet demonstrates high reliability & availability
Latest modifications of SGT-600 enable: extension of engine life-cycle beyond 120,000 EOHextension of maintenance intervals from 20,000 to 30,000 EOH
Extended maintenance intervals from 20,000 to 30,000 EOH enable availability increase by about 1% p.p.
Currently ongoing SGT-600 upgrades will support flexible operation and opportunity for further Life Cycle Cost reduction
-
Page 32 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden 32
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 SECs 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 33 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden 33
Thank you for your attention!
Copyright Siemens AG 2008.
-
Page 34 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Operation with varying Wobbe-index (WI)
78
Medium Calorific Value (MCV)
10 20 40 50 60 7030
Normal Pipeline NG High Calorific Value (HCV)
Wobbe Index (MJ/Nm)
Low Calorific Value (LCV)
40 55
Fully released; DLE
Sales approved case by case
25
Fully released; Conventional
35
Increased request for operation on gas with varying energy content
Previously handled by adding WI-meter to the governing system
Special configuration of the control system gives the possibility to use the GT
itself as WI-meter using only standard instrumentation and results in:
Faster and more accurate monitoring of the WI
Improved reliability
Reduced cost of installations operating with varying WI
-
Page 35 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Repair as part of maintenance concept
120 EOHNew & Clean0 EOH
Level B20 EOH
Level C40 EOH
Level D60 EOH
Level E80 EOH
Level B100 EOH
CT Blade 1, Set #1 NEW
CT Blade 1, Set #2
CT Blade 1, Set #3
NEW
CT Blade 2, Set #1 NEW
CT Blade 2, Set #2
PT Blade 3, Set #1 NEW
PT Blade 3, Set #2 NEW
Comb. Ch., Set #1 NEW RECONDITIONED
Comb. Ch., Set #2 NEW
RECONDITIONED
RECONDITIONED RECONDITIONED
CT Vane 1, Set #1 NEW
NEWCT Vane 1, Set #2
RECONDITIONED
NEWCT Vane 1, Set #3
RECONDITIONED
RECONDITIONED
CT Vane 2, Set #1 NEW
CT Vane 2, Set #2 NEW
NEW
NEW
RECONDITIONED
RECONDITIOND
NEWPT Blade 3, Set #3
-
Page 36 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Current repair status SGT-600- Repairs technology details and Repair Suppliers
SGT-800 repair as a part of Maintenance Program to reduce maintenance cost
Repair not qualifiedHeat shield
Repair not qualifiedTurbine blade 2
PAS, IrelandN/APtAlYesYesYesTurbine Vane 2
Turbocoating, ItalyAPSPtAlYesN/AYesTurbine Blade 1
PAS, IrelandN/APtAlYesYesYesTurbine Vane 1
Only applicable for conv.
burners, Unison, UKN/AN/AN/AN/AYes, replace tipBurners
In house / Volvo AeroAPSAPS bond coatYesN/AYesCombustor
Recotech, SWN/AMetco 307YesN/ANoAbradable rings
Seals replaced by
caulkingN/AN/AN/AN/AN/ARotor seals
Repair in qualification
CCRS, UKN/AV900YesNoNoComp. vanes
Repair in qualification
CCRS, UKN/AV900YesN/ANoComp. blades
SuppliersTBC typeCoating typeStripingBraze repWeld repairComponent