MGT Products & Maintenance Continuous Improvement

Restricted © Siemens Industrial Turbomachinery AB 2014. All rights reserved.

MGT Products & Maintenance Continuous ImprovementDr. V. Navrotsky, MGT Fleet Director


Outline

• Introduction

• Operating experience

• Performance enhancement

• Repair solutions

• Life extension program

• Maintenance improvement

• Summary


Home Market

57813172530

4768

121157

187190

253265

SGT-100SGT-200SGT-300SGT-400SGT-500SGT-600SGT-700SGT-800SGT-1000FSGT-3000ESGT-2000ESGT-5000FSGT-3000FSGT-6000GSGT-4000F

Uti

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app

licat

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Ind

ust

rial

ap

plic

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SST-9000SST-8000SST-6000SST-5000SST-4000SST-3000SST-1000

19001100

1200700

300250200

180+

130+150

100856550109

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app

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SST-900SST-800SST-700SST-600SST-500SST-400SST-300SST-200SST-100SST-050

KK&K

SGT5-8000H 340

30.45-5

Combined ST Products (MW) Combined GT Products (MW)

Single shaft STC-SH STC-SI STC-SO STC-SP

STC-SR STC-STO STC-SV STC-SX

Integrally geared STC-GC STC-GO STC-GT STC-GTO

STC-GV STC-GVT

Compressor for O&G solutions

STC-SPCP STC-ECO

Siemens turbocompressors

Siemens Product rangeSteam Turbines, Gas Turbines & Compressors

Siemens offer a full power range of Steam Turbines, Gas Turbines & Compressors for Industrial and O&G markets

Util

ity T

urbi

nes

Restricted © Siemens Industrial Turbomachinery AB 2014. All rights reserved.Restricted © Siemens Industrial Turbomachinery AB 2014. All rights reserved.

Continued Product and Maintenance Improvement

Rotating Equipment Product & Maintenance Improvement

Product Performance Enhancement

Maintenance Enhancement

Efficiency Enhancement

Power Output Enhancement

Emissions reduction

Repair & Refurbishment

Maintenance Intervals extension

Maintainability Improvements

Life time extension

Focus on Power plant Profitability and Competitiveness Improvement


Outline

• Introduction






• Summary


SGT- 500 SGT- 600

SGT- 700 SGT- 800

MGT Operating Experience


SGT- 500 SGT- 600

SGT- 700 SGT- 800

MGT Operating Experience

SGT-600 first introduced (started) 1986. DLE introduced 1991. Total of units sold today is 309 Total in commercial operation 190 Total fleet operating hours > 7 million hours

- > 5 million of those on DLE Fleet leaders:

- >160 000 hours

SGT-500 first introduced (started) 1955. DLE introduced 1994. Total of units sold today is 178 Total in commercial operation 118 Total fleet operating hours > 9 million hours

- > 220 000 of those on DLE Fleet leaders

- > 230 000 hours

SGT-700 first introduced (started) 2004. DLE standard. Total of units sold today is 65 Total in commercial operation 53 Total fleet operating hours > 900 000 hours Total number of starts > 7 000 Fleet leaders

- PG: > 65 000 hours- MD: > 66 000 hours

SGT-800 first introduced (started) 1999. DLE standard. Total of units sold today is 229

Total in commercial operation 120 Total fleet operating hours > 2 500 000 h

Fleet leaders- PG: > 90 000 hours

SGT- 500

SGT- 700 SGT- 800

SGT- 600

Restricted © Siemens Industrial Turbomachinery AB 2014. All rights reserved.Page 8

SGT- 800 Operating StatisticSystematic follow up, analysis & action

SGT-800 surpassed its Key Performance Indicator goals

Down Time (Forced Outage Rate) Reduction


Modified Components: Compressor blade 1 Turbine blade 1 Turbine vane 1 and 2

Turbine cooling air supply modification: Swirl generator dimension Orifice dimension in extraction from

compressor stage #10

Compressor blade 1

Turbine blade 1 and Turbine vane 1 and 2

Comparison between 47 and 45 MW rating

Gen

erat

or O

utpu

t, M

W

Hea

t Rat

e, M

J/kw

h

Compressor Inlet Air Temperature, C

2 MW

Limited modifications enable + 2 MW and + 0.5 % efficiency to support Customer competitiveness

SGT-800 Upgrade 47MW rating


Outline

• Introduction






• Summary


• SGT-700 first introduced 2001 • DLE standard • Total of units sold today is 65• 53 units are in commercial operation• Total fleet operating hours ≈ 900 000 hours• Total number of starts > 7 000 • Fleet leaders:

- PG: > 65 000 hours- MD: > 66 000 hours25

30

Extended TBO (20 000 h to 30 000 h)Current fleet can be upgraded

SGT- 700 Development history and operating experience


The compressor turbine efficiency has been improved by: Reduced cooling air from areas which has been over cooled Introduction of TBC - reduced required cooling air Improved sealing – reduced leakage

Reduction of cooling air and leakages gives more air to combust and more flow through vane 1 which results in higher power and efficiency.

+ 2,2 MW higher power to support higher Power production + 0,4 % higher efficiency to improve Power Plant profitability

SGT-700 Upgrade31.2 MW rating


SGT-800 Industrial gas turbine Development and Status timeline

1995 20061996 1997 1998 1999 2001 2002 2003 2004

Design, validation, manufacturing

2007 2008 2009

43.0 MW 45.0 MW 47.5 MW

2010

54 units sold114 units sold + 6 upgraded35 units sold25 units sold

2000

Fleet leader: > 60 000 EOHFleet leader: > 100 000 EOH Fleet leader: > 23 000 EOH

Ratings now sold in parallel

50.5 MW

More than 225 units sold and 2.5 million EOH accumulated


SGT-800 Industrial gas turbine Enhanced performance to 50.5 MW

Compressor:Improved blade profiles

Burner tuning and minor combustor design adjustments

Vane #1: Reduced number of airfoils

TBC also on airfoilImproved cooling design

Blade #1:Improved cooling matrix

Reduced number of blades

Vane #2:TBC also on airfoil

New cooling inserts

Blade #3: 9% longer blade and modified

exhaust diffuser heat shield

Stator rings instead of segments

Vane #3:Integrated heat shield

Improved profile

Improved compressor airfoil profile resulting in about 1% higher mass flow and improved aerodynamics

Improved turbine stage #1 aerodynamics and more efficient cooling air layout

Improved turbine stage #3 with increased outlet area (reduced exit losses) and improved aerodynamics

Turbine Inlet Temperature (TIT) is not increased compared to the 47.5 MW rating


Example III: Measured NOx and CO (DLE)

SGT800-Emissions

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

0.0 20.0 40.0 60.0 80.0 100.0 120.0

Load (%)

NO

x (p

pm@

15%

O2)

, PFR

_SP

(%)

0

500

1000

1500

2000

2500

CO

(ppm

@15

%O

2)

PFR-SP %NOx ppmvd@15CO ppmvd@15

Impressive NOx and CO performance demonstrated


SGT-800 Industrial gas turbine Enhanced compressor performance

Enhanced compressor

• Optimized front stage geometry• Enhanced airfoil profiles for all stages• Rotor and casing design unchanged

gives retrofit ability• Improved efficiency and stability• Increased mass flow

• Hot Ambient Match option with optimized stage matching for high ambient temperatures

• 26% more power @ 50°C• 5.8% reduction in Heat Rate @ 50°C

8000

8500

9000

9500

10000

10500

11000

11500

25000

30000

35000

40000

45000

50000

55000

60000

-10 -5 0 5 10 15 20 25 30 35 40 45 50

He

at r

ate,

kJ/

kWh

Gen

era

tor

pow

er o

utpu

t, kW

Ambient temperature, °C

SGT-800 electrical power output and heat rate at ISO conditions

Compressor stator stage #3 to #15 option: Normal or Hot Ambient Matching

Normal Match

Hot Ambient MatchPower

Heat Rate


SGT-800 50.5 MW versionHot Ambient Matching

Optional stagger angles of stator #3 to #15 for Normal and Hot Ambient Matching respectively

All other engine parts are identical

Peak efficiency for the compressor moves 200 rpm in normalized speed (corresponds to 17 degC C)

Nominal VGV closing point moves from +33 degC C to +50 degC C => Higher power output at high ambient

Hot Ambient Match angle Normal Match angle

+ dir -dir

stage# degS3 -1.5S4 -2.5S5 -3.8S6 -3.5S7 -5S8 -4S9 -6S10 -3.8S11 -3.5S12 -3S13 -3S14 -3S15 -4

Hot Match Restagger Angle


Simple Cycle Efficiency Press

Ratio

SGT-800 47 500 kW 9 057 Btu 37,7% 20,2

SGT-800 50 500 kW 8 916 Btu 38,3% 20,8

ISO Base

Rating (kW)

Heat Rate

(Btu/kWh)

Combined Cycle Net Plant

dual pressure, no reheat Efficiency

SCC-800 1x1 66 570 kW 6344 Btu 53,8% 6693 kJ 46 300 kW 21 000 kW




Power (kW)

Heat Rate Steam Turbine

(kJ/kWh) Power (kW)

Gas TurbineNet Plant

Output (kW)

Heat Rate

(Btu/kWh)

SGT-800 Evolution

40

42

44

46

48

50

52

54

1998 2000 2002 2004 2006 2008 2010 2012 2014

Year of first engine start

Pow

er ra

ting

(MW

)

SGT-800 Best in class combined-cycle performance

“Stepwise evolution building on experience and proven design solutions”


.

Focus on further emission reduction, flexible operation & life extension

Flexible operation cyclic operation mode Start reliability Fast start up Flexible maintenance

Part Load operation: Emission improvement Efficiency improvement Accounting lower life consumption

when running on part load

SGT-600 Upgrade to support Customers’ demands & flexible operation


3rd generation DLE (MGT)

MGT DLE technology is effective, simple & reliable(simple principle with no moving parts or staging)

Combustor Bypass system2nd generation DLE (SGT-600)

Combustor technologies2nd and 3rd generation of DLE technology


Outline

• Introduction






• Summary


2nd Vane

Burners

1st Blade Combustion Chamber

1st Vane

Abradable rings

Sealing edge repair

Heat shields

Ready

Under development

Sealing edge repair

SGT-800 repair as a part of Maintenance Program to reduce maintenance cost

Current repair status SGT-800Repairs according to maintenance plan & on-condition



Turb blade #1

Honeycomb seals

1st Vane

2nd Vane

Combustion ChamberReadyUnder development

Burner

Sealing edge replacement

Comp, recoat abradable rings


Repairs according to maintenance plan & on condition(for current standard components)


Turb blade #1

Honeycomb seals

Sealing edge replacement

1st Vane 2nd Vane

Combustion ChamberComp, recoat abradable rings

Ready

Under development

Comp, blade & vane recoating




Gas collector

Ready

Under development

Fuel injectors

LP & HP comp recoating

Combustor

Flame head

Repair as a part of Maintenance Program to reduce maintenance cost



Outline

• Introduction






• Summary


MGT Maintenance Concept

Maintenance plan optimized for cost and availability

Long time between overhauls (up to 30,000 EOH)

Flexible operation & maintenance Components Cyclic life extension Possibility to add 2nd maintenance cycle after

120,000 EOH by applying a RCIE (Rotor & Casing Inspection & Evaluation) program


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

The extension of maintenance intervals can improve the availability by up to ~ 1% & supports customers trends towards flexible operation & maintenance

Maintenance down time reductionExtension 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

Overhaul

Hot Section Inspection

Borescope


MGT RCIE Rotor and Casing Inspection and Evaluation (RCIE)

RCIE - Major Activities Unit specific non-destructive

tests to determine status of major components

Outcome: Tailored scope of repair / replacement

Level-C activities performed at 120,000 EOH, with necessary extended scope + additional Modernizations and Upgrades

Unit specific optimized replacement schedule


Outline

• Introduction






• Summary


SGT-800 Maintenance Plan Maintenance Concept

MAINTENANCEPLAN

CORRECTIVE MAINTENANCE

MAINTENANCE

Daily attendance Routine maintenance

activities

Time or cycle based maintenance Inspection and overhaul Remote diagnostic service

Trouble shooting Repair activities Emergency spares Emergency spare GT 24h service support

OPERATIONMAINTENANCE

PREVENTIVEMAINTENANCE


SGT-800Easy on-site maintenance

Modular build-up for easy maintenance on site

No need for special workshops maintenance

Gas turbine can be removed on rollers through the sliding door

Removable burners for quick and easy inspection

Vertically split compressor casing


Maintenance Design Features On-site Maintenance

• All inspections and overhauls are performed within enclosure

• 8 metric tonnes crane permanently installed inside the gas turbine enclosure

• Minimum space requirements around installation

• No special transport or extra lifting tools necessary

• Modular design and vertical split compressor casing for easy maintenance access


Hot section disassembly

Compressor disassembly GT removalOn “rollers” to external support structure

Remove outer and inner cone 1 2Remove diffuser

casing

3Remove turbine casing 4Remove turbine module and 1st guide vane

5Remove burners, cone and combustion chamber

SGT-800Easy on-site maintenance


Maintenance Design Features Off-site Maintenance – Single lift package

Turbine can easily be exchanged with minimum space requirements

Turbine slides onto support structure outside the enclosure

Support structure is towed out of turbine hall

Turbine lifted from support structure for further transport.

Weight of core 36 tons


SGT-800 Single Lift PackageMaintenance Arrangements

SGT-800 Single lift

48 hours engine quick exchange

Role out of engine on either side of Turbine packages possible


SGT-800 Single Lift PackageMaintenance Options

Exchange of core engine for off-site maintenance with maximized availability Transport of core engine or modules to local workshop for on-site maintenance Weather protection for handling of modules or a mobile workshop solution for core

maintenance that can be provided by customer, according to our specification


Remote ServicesCustomer support through remote monitoring & diagnostics

Remote Service enabling rotating equipment Life Cycle Cost reduction

Customer Plant

STA-RMS* Platform

Server Farm

Data Base

Firewall

Firewall

Countries

Service staff

Firewall

PLC’s

Service staff

New Unit staff

common Remote Service Platform

Data Collector/Win CC

Services that formerly required on-site visits are now available via data transfer.

The complete spectrum of Siemens IP and O&GRemote Operational Services is based on the efficient, comprehensive and secure infrastructure of the SIEMENS common Remote Service Platform.

Today we provide:

Remote Supportconnection is used for checks or to solve problems

Remote Updatestransfer SW to unit to update a control system

Remote Monitoringtransfer operation data to central data base and analyze it, e.g. Vibration, thermodynamics,process data

* STA-RMS =

Siemens Turbo Machinery –Remote Monitoring System

Remote Operational Services at Siemens Industrial Application


SGT-800 Maintainability improvementDevelopment of Maintenance tools

Compressor dummy: reduces down-time improves safety

Turbine module tool: reduces down-time simplifies work

Gear box tools; reduces down-time improves safety

Universal table for stator part inspection: reduces down-time simplifies work improves safety

MGT Maintainability improvement results in Maintenance cost reduction


Outline

• Introduction






• Summary


Summary

Enhancement programs are part of Siemens’ long-term product developmentstrategy and resulted in:

- Positive operation experience- High reliability & availability

Continuous improvements and modifications enabled: - extension of engine life-cycle beyond 120,000 EOH (SGT-500, 600, 700)- extension of maintenance intervals from 20,000 to 30,000 EOH (all MGT)

Extended maintenance intervals from 20,000 to 30,000 EOH enable availability improvement by 1 %.

The life cycle & maintenance interval extension in combination with the

extended scope of component Reconditioning & Remote Services creates additional opportunity for the operator to reduce their rotating equipment Life Cycle Cost.


Thank youfor your attention!


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.

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MGT Products & Maintenance Continuous Improvement

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