SGT5-8000H / IRSCHING 4 ON THE WAY TO 60% WORLD RECORD ...

POWER-GEN Asia 2010

1 of 16 W. Fischer, Dr. S. Abens, 2010-09-03 Copyright © Siemens AG 2009. All right

SGT5-8000H / IRSCHING 4 ON THE WAY TO 60%

WORLD RECORD EFFICIENCY AND PATH TO 60 Hz

SGT6-8000H

Willibald J Fischer Dr. Steven Abens

SIEMENS AG Germany

POWER-GEN Asia 2010 – Singapore

POWER-GEN Asia 2010

2 of 16 W. Fischer, Dr. S. Abens, 2010-09-03

Abstract The new SGT5-8000H gas turbine, which is the result of years of research and

development within Siemens Energy, is the first new frame developed after the merger

of Siemens and Westinghouse. It is based on well proven features of the existing

product lines combined with advanced technology. Customer needs and benefits were

the main drivers for the development of the new engine, rated at 375 MW@ISO and 570

MW / 60 % in combined cycle. The air-cooled concept offers added value through higher

operational flexibility required in deregulated market environment. The SGT5-8000H

turbine development team involved more than 250 engineers, working in Erlangen,

Berlin and Mülheim in Germany, as well as in Orlando and Jupiter in Florida, USA. An

additional 500 employees were involved in the manufacturing, assembly and test

preparation of the prototype engine. Single gas turbine components were already pre-

tested and verified with success. The complete SGT5-8000H gas turbine was fully tested

and validated under field conditions in a real power plant environment at Irsching 4

Power Station, Bavaria/Germany, in a hosting agreement with E.ON Kraftwerke. This

comprehensive and consequent approach will ensure, that subsequent “commercial”

engines will be brought to market in a risk controlled manner, fully validated based on

extensive operating history. In the meantime, the prototype plant is in Phase II,

extension to combined cycle, where the world record of 60 % combined cycle efficiency

will be demonstrated in a real power plant in 2011.

The paper will cover:

• Overview 8000H program

• Key features of new gas turbine and combined-cycle power plant

• Test results of field validation phase

• Status 60 Hz SGT6-8000H

POWER-GEN Asia 2010


Introduction The worldwide need for energy is constantly rising while at the same time the demand

for reliable, affordable, efficient as well as environmentally-compatible power generation

is increasing. In today’s highly-competitive business environment, customers and power

plant operators expect an economical, state-of-the-art product. Their purchasing

decisions place more and more emphasis on life-cycle cost analyses that span the entire

lifetime of a power plant.

Siemens Energy developed its new generation H-class Siemens gas turbine (SGT™),

the SGT-8000H series, taking both environmental protection as well as economical

focus into consideration. Technical innovations in design and development, process

engineering, materials and manufacturing as well as assembly processes collectively

support Siemens Energy in continually transforming these new requirements into

realities.

The H-Class gas turbine is the first new frame developed since the merger of Siemens

and Westinghouse. It combines the best features of the two established product lines

with advanced technology, the functional and mechanical design of the new engine were

built on the experience gathered with the predecessor 50Hz and 60Hz engines. Proven

design features were applied wherever possible, and "Design for Six Sigma" tools were

used resolutely, to deliver a competitive product which meets the requirements

described in the foregoing.

Primary Targets of the 8000H Program Customer requirements resulting especially from today’s liberalized energy markets and

current trends in today’s generation portfolio requirements for complementing the

substantial market penetration of renewable power, were the essential drivers for

developing the new SGT5-8000H: (Figure 1)

Increase of combined-cycle net efficiency to over 60%, Reduced emissions per kWh produced, Achievement of high efficiency and low emissions in part-load operation also, Fast start-up capability and operational flexibility, Reduced investment costs per kW, High reliability and availability, and ultimately Minimum life cycle costs.

The SGT5-8000H gas turbine development team involved more than 250 engineers,

working in Erlangen, Berlin and Mülheim in Germany, as well as in Orlando and Jupiter

POWER-GEN Asia 2010


in Florida. An additional 500 employees were involved in the manufacturing, assembly

and preparations for testing the prototype engine.

This new turbine was developed in strict compliance with the company’s Product

Development Process. The design effort incorporated previous lessons learned, applied

proven design features wherever possible and systematically utilized Design for Six

Sigma tools to deliver a competitive product focused on life-cycle costs, performance,

serviceability, flexibility, reliability, and low emissions.

Major Milestones of the 8000H Program Consequent program management is essential for successful introduction of a new gas

turbine. As already achieved during the design phase, all major milestones during the

testing period were achieved on time:

Program Launch – Concept Phase Oct. 2000 Gate 1: Product Strategy Mar. 2001 Gate 2: Start Basic Design (GT) Nov. 2001 Gate 3: Product Release (GT) Aug. 2004 1st engine shipment ex Works Berlin Apr. 2007 1st Fire at Irsching 4 Test Center Dec. 2007 1st Synchronization to power grid Mar. 2008 1st Base Load Apr. 2008 End of Test & Validation Phase Aug. 2009 Gate 4: Series Release of the SGT5-8000H Jun. 2010 SGT5-8000H Design Features The engine concept was selected from a number of air-cooled engine design options

and several gas turbine cycle variants after completion of a comprehensive feasibility

analysis during the conceptual design phase. The air-cooled concept selected offers

maximum added value by virtue of its higher operational flexibility – an essential

prerequisite in the deregulated power generation market environment.

The most important gas turbine design features are: (Figure 2) • Single tie-bolt rotor comprising individual compressor and turbine disks with Hirth

facial serrations, • Hydraulic clearance optimization (HCO),

POWER-GEN Asia 2010


• Axial 13 stage compressor with high mass flow, high component efficiency, controlled diffusion airfoils (CDA) in the front stages and high performance airfoils (HPA) in the rear stages, variable guide vanes and cantilevered vanes,

• High temperature, air-cooled, can annular combustion system, • Four-stage, exclusively air-cooled turbine section, • Advanced, on-board variable dilution air system, with no external cooling system, • Advanced, highly-efficient, high-pressure and high-temperature combined-cycle

process with a Benson boiler design based on the high mass flow and exhaust temperature of the new engine. (Figure 3)

A 60 Hz version is now in manufacturing based on the achievements of the 50 Hz project, thereby minimizing operational risks for customers. SGT5-8000H Validation For minimization of customer risk during the introduction of the new product, a

comprehensive test and validation program was set up. This already included tests on

prototype parts during the design phase, followed by sub-system validation such as

atmospheric and high pressure combustion testing, as well as full-scale, 60 Hz

compressor validation. The individual components, sub-systems and then engine tests

were performed in the Siemens Berlin test center and at several other suitable test

facilities. (Figure 4)

The crucial phase of validation is engine operation under real power plant conditions.

Preparation for this phase was already commenced in 2005 with the installation of about

3000 sensors in and on the engine during manufacture of the prototype. In addition to

the standard I&C system, these sensors measure temperatures, pressures, strains,

flows, acceleration, and vibrations encountered during part load and base load operation

and enable engineering to compare the design models with the real engine response.

Three telemetry systems located at the turbine bearing as well as the compressor end of

the intermediate shaft delivered some 600 additional signals from the rotor.

The partner found for this extensive validation project is E.ON Kraftwerke, a major

German electricity provider. A very unique contract was entered to give Siemens

maximum flexibility in testing the new gas turbine and add the world’s first combined-

cycle power plant with 60% efficiency to the E.ON power plant fleet.

POWER-GEN Asia 2010


The contract defines two phases. During the first phase, Siemens built a gas turbine

power plant in a simple-cycle configuration and operated this plant for 18 months for

testing purposes under the terms of a hosting agreement. The existing Irsching power

plant site was selected for this common project. Site preparation started in 2006. The

second phase of the contract, which started after completion of the 18-month test phase

and demonstration of the contractually-defined performance of the gas turbine, covers

the extension of the simple cycle configuration to a single-shaft, combined-cycle power

plant, that will be commissioned and handed over to the customer as under the terms of

a turnkey EPC arrangement.

To operate the gas turbine during the 18-month test phase, additional contracts with a

gas provider and for the sale of electricity have been implemented. The gas contract

does not stipulate any minimum gas consumption. The electricity sales contract covers

any power which is produced by operation of the gas turbine. Both contractual

arrangements allow maximum testing flexibility for validation of the gas turbine.

The engine was shipped from the Siemens gas turbine manufacturing plant in Berlin

plant at the end of April 2007 and was placed on the foundation at the Irsching 4 site at

the end of May 2007. During engine installation, a considerable scope of additional

instrumentation such as externally-mounted blade vibration sensors, pyrometers, tip

clearance and flow field probes as well as two infrared turbine blade monitoring cameras

was installed.

Concurrent with erection of the power plant, test facilities including the extensive data

acquisition system (DAS) were added. The DAS set-up was not limited to the Irsching

site. A dedicated encrypted data network between the Irsching Test Center and the

engineering headquarters in Muelheim, Germany and Orlando, Florida was established.

This network enabled 100 additional engineers to have a live view of engine operation

without the need for on-site presence and contributed to both testing operations as well

as engine safety. (Figure 5)

Cold commissioning of the gas turbine was successfully completed in December 2007.

The 4-phase structured testing operation was commenced with the successful first fire

on December 20, 2007 (Figure 6). The first test phase was mainly driven by auxiliary

and start-up commissioning steps. The start-up and protection settings were optimized.

Also mandatory full speed no load (FSNL) tests such as speed sweeps for compressor

POWER-GEN Asia 2010


and turbine validation and generator protection testing were also conducted. Test phase

1 ended with the first synchronization with the grid on March 7, 2008.

Test phase 2 included the first loading to full speed full load (FSFL) and all related tests

for optimizing the loading schedule for the four stages of variable guide vanes as well as

the five fuel gas stages of the combustion system. Test phase 2 culminated in achieving

base load for the first time on April 24, 2008.

The primary focus of test phase 3 was mapping of aerodynamic and thermodynamic

performance at part load and base load as well as final combustion tuning to meet

emissions requirements. Test phase 3 also included tests with preheated fuel at various

loading rates and also load rejection tests. Pyrometers were utilized to gain a more

comprehensive picture of surface temperatures of the rotating turbine parts. Flow probes

were installed in the diffuser and in the turbine flow path to determine the flow fields

(Figure 7).

Thermal Paint Test Thermal paints, also known as temperature indicating paints, are a simple and effective

means to obtain a permanent visual record of the temperature variations over the

surface of components. Thermal paints do not modify the thermal behavior of a

component during testing and can be applied to surfaces with small-diameter cooling

holes without affecting the cooling effectiveness. Thermal paint tests entail a significant

investment in terms of testing time and financial expenditure.

A comprehensive thermal paint test was conducted at Irsching 4. For this test, two

extensive outages involving cover lifts were required. During the first 8-week outage,

several parts with thermal paint were installed in the combustion and turbine sections.

On January 30, 2009, the engine was restarted and loaded directly to base load for 10

minutes of operation. Precise timing of the operating sequence was mandatory to

produce representative results. Overall, the test run itself only took one hour.

Subsequently, the unit was shut down to remove the painted parts during the second

outage which lasted another six weeks. In the following months, the color changes were

evaluated and very valuable temperature profiles over the entire surface of the hot gas

path parts determined. The evaluation of the thermal paint parts confirms and supports

the GT models used for designing this new Gas Turbine. (Figure 8).

At the end of test phase 3 in April 2009, the engine had accumulated operating 300

hours. The mortality rate of the prototype sensors was comparatively low and thus

POWER-GEN Asia 2010


terabytes of very valuable data were recorded and is still used for further evaluations

now and in the future. Having completed test phases 1-3, all specific operational tests

were successfully concluded. During these 15 months of testing, frequent inspections

were conducted and valuable service and outage experience was also gained. For

example, the overall effort of the thermal paint test described above is comparable to the

effort required for an extended hot gas path inspection.

Test phase 4 is the so-called Endurance Test and has the main purposes:

• Collection of further mid-to-long-term operating experience, starts and hours under

semi-commercial conditions,

• Confirmation of “readiness for commercial service”, based on the load regime

required by grid operator,

• Operation by staff without special qualification (other than standard GT O&M

experience), and

• Recording of test sensor data will be continued, however the prime focus is no longer

on testing.

The operating parameters are set and the engine was operated 24 hours for extended

continuous periods as well as on a daily start-and-stop basis in line with load dispatch

requirements.

This test phase was also successfully completed in August 2009. At the end the engine

has logged operating experience equivalent to 200 starts and 3000 operating hours.

An extraordinary success story of a gas turbine validation came to its end, initiating a

success story for a new highly reliable and innovative Siemens Gas Turbine Product

(Figure 9).

The Irsching 4 plant is currently being converted into a single-shaft combined-cycle

power plant. Takeover by E.ON Kraftwerke and subsequent commercial operation of the

plant is scheduled for July 2011 (Figure 10). Hence the more than 60% combined cycle

efficiency will be demonstrated in reality and the new world record efficiency will shift

existing borderlines.

POWER-GEN Asia 2010


Next Steps towards SGT6-8000H The 60 Hz SGT6-8000H, rate at 274 MW, is a direct scale of the 50 Hz SGT5-8000H.

The design of the SGT6-8000H is strictly based on Siemens’ proven aerodynamic

scaling rules. A scaling factor of 1 : 1.2 is being applied consistently over the entire cross

section of the turbine. The only exception is the combustion system, where exactly the

same components, such as burners and baskets, are used as in the 50 Hz model. In

order to reflect the reduced mass flow of approx. 1 : 1.44, 12 rather than 16 can-

combustors are used on the 60 Hz model. (Figure 11). Based on this approach with

multiple other well proven examples in our company as reference, validation efforts for

the SGT6-8000H can be based on the comprehensive information gained during the

SGT5-8000H test program and will require only limited additional efforts to fully prove

entire integrity of the 60 Hz model. Therefore, the first unit will be installed in the Test

Center of our Berlin factory in 2011 and be subject of a 6 months test program.

As of submission of this paper, detail design of the SGT6-8000H was already finalized

and production of the first engines is in progress.

In parallel, the first commercial order was secured recently with Florida Power & Light

(FPL). Due to its superior world class performance and operational flexibility, FPL has

selected the SGT6-8000H for modernization of its Cape Canaveral and Riviera Beach

power plants. Each of the new CCPP units will comprise of a 3 – 1 configuration, with

three GTG’s, three HRSG’s and one STG. The Cape Canaveral plant will commence

commercial operation 2013 and Riviera Beach will follow in 2014. (Figure 12)

Summary Key parameters such as the compressor pressure ratio and aerodynamic efficiency,

temperatures of hot gas path parts, combustion dynamics behavior, as well as engine

output, vibration and emissions have been validated and demonstrated. The key

performance parameters of the SGT5-8000H met or even exceeded expectations and

the engine has convincingly proven its capability as a 400 MW class gas turbine under

test conditions.

POWER-GEN Asia 2010


Based on careful evaluation of test data and comparison with design predictions,

Siemens Energy is now able to offer uprated performance of the 8000H system as

follows:

SGT5-8000H SGT6-8000H Gas Turbine Rating Output 375 MW 274 MW

Efficiency 40 % 40 %

Combined Cycle Rating Output 570 MW 410 MW

Efficiency > 60 % > 60 %

REFERENCES

[1] “Building the world’s largest gas turbine”, Modern Power Systems, Germany

Supplement 2006.

[2] „Neue Gasturbinen für mehr Kundennutzen“, VGB-Kongress, Kraftwerke 2006, Dr.

Wolf-Dietrich Krüger, Siemens AG Power Generation.

[3] Kleinfeld, K., Annual Shareholders' Meeting of Siemens AG on January 25, 2007.

Report by President and CEO of Siemens AG Dr. Klaus Kleinfeld.

[4] Ratliff, P.,Garbett, P., Fischer, W., „SGT5-8000H Größerer Kundennutzen durch

die neue Gasturbine von Siemens“, VGB PowerTech, September 2007.

[5] U. Gruschka, B. Janus, J. Meisl, M. Huth, S. Wasif, ULN system for the new

SGT5-8000H Gas Turbine, ASME Turbo Expo 2008

[6] W. Fischer, S. Abens, SGT5-8000H Design and Product Validation at Irsching 4

Test Center, VGP Power Tech 9/2009

POWER-GEN Asia 2010


Fig. 1 Energy SectorCopyright © Siemens AG 2008. All rights reserved.

Increase of combined cycle net efficiency to over 60%

Reduced emissions per produced kWh

High efficiency and low emissions also in part-load operation

Fast start-up capability and operational flexibility

Reduced investment costs per kW

High reliability and availability

Resulting in Lowest life cycle costs

SGT5-8000H / SCC5-8000HThe answer to market and customer requirements


Harmonization of ‘V’ and ‘W’ frames uses best featuresfrom both and introduces new technologies on low risk

≥ 60% Combined Cycle efficiency

Integrated combined cycle processfor economy and low emissions

High cycling capability due to advanced blade cooling system

Evolutionary 3D-compressor bladingProven rotor design, Hirth serration and

central tie rod

Four stage turbine with advanced materials and thermal barrier coatingAdvanced ULN*

combustion system

*Ultra Low Nox

SGT5-8000H – World’s largest gas turbine

POWER-GEN Asia 2010



SGT5-8000H / SCC5-8000H, Key Data

Fuel Nat. gas, #2

GT output 375 MW

CC outputnet 570 MW

CC efficiencynet 60%

Pressure ratio 19.2 : 1

Exhaust mass flow 820 kg/s

Exhaust temperature 625 °C

Turn down 50%

HRSG/WS-Cycle 600°C/170 barBenson

SGT5-8000H

SCC5-8000H

at ISO conditions


Sales PreparationStrategic Product Planning Design Design Implementation Validation

Product StrategyTechn. Acquisition,

Product,Technology & Developm. Planning

Conceptual Design

Basic Design

Commerciali-zation Planning

Manufacturing & Assembly

Erection, Installation,Commissioning and

Trial OperationProduct

MonitoringPerformance &

Reliability Validation

Final Design & Procurement

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

Systems tests• Compressor test &• Combustion system test

at test bed Berlin

Prototype GT field validation

Prototype CC field operation

Siemens invested over 500’ EUR to develop an advanced but robust product andconfirmed its integrity to ensure lowest customer risk.

Validation of advanced technologies in test rigs before prototype engine testing

8000H Program includes a Comprehensive Validation and Testing Concept

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SGT5-8000H Field ValidationSensor, Data Acquisition & Data Transfer Concept

2838 Sensors

1688 Temperatures616 Pressures357 Strain Gages59 Accelerometer48 Clearances56 Blade Vibration14 Flows & Forces

597 rotating2241 stationary

458 dynamic2380 quasi-static


Test & Validation Phase, Overview

Build 1 Testing (January – July 2008)

2nd Build Outage (August – October 2008)

Build 2 Testing, Phase 1 (November – December 2008)

Thermal Paint Outage & Test (December 08 – March 2009)

Build 2 Testing, Phase 2 (March – April 2009)

Final Build Outage (May 2009)

Endurance Test Phase (May – August 2009)

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SGT5-8000H Combustion –balanced fuel staging

0%

10%

20%

30%

40%

50%

60%

70%

80%

0% 20% 40% 60% 80% 100%

rel. Power Output

Fuel

Fra

ctio

n

PilotStage DStage AStage BStage C

Pilot & D-Stage

A A+B A+B+C

0%

10%

20%

30%

40%

50%

60%

70%

80%

0% 20% 40% 60% 80% 100%

rel. Power Output

Fuel

Fra

ctio

n

PilotStage DStage AStage BStage C

Pilot & D-Stage

A A+B A+B+C

Pilot & D- Stage

A- & B- Stage

C - Stage


...successfully performed,providing detailed temperature pictures.

397 MW

Straight loading to base load required,otherwise results not representative

TB 4

BasketVane 1 ID

POWER-GEN Asia 2010



SGT5-8000H Successful validation as basis for market introduction

1st fire achieved onschedule

Stable and reliableignition from 1st start

Base load within 9days of operation from 1st synchronisation

High starting reliability already achieved very early

Overall integrity, Performance,Emissions confirmed

Endurance Testing conducted until End of August 2009

Validation program completed on track: overall stability, vibrations, performance, emissions and operational flexibility fully confirmed.


Irsching, Status as of May 2010

Unit 5SCC5-4000F 2x1

840 MW, > 59 % el. netCommercial Operation

Unit 4SCC5-8000H 1S

545 MW, > 60 % el. netPhase II Construction

POWER-GEN Asia 2010



SGT5/6-8000H – direct scaling approach

SGT5-8000H

SGT6-8000H

1.2÷Dimensions

~1.0xEfficiency

1.0xStresses & Temperatures

1.44÷Power, Mass Flow

1.2xSpeed

50Hz 60Hz

Scaling rules 50Hz to 60Hz version


SGT6-PAC 8000H Layout

Inlet Air Filter

Exhaust Diffuserand

Expansion JointGas Turbine

Lube Oil Package

Electrical PackageGenerator

Inlet Air Duct

2013Cape CanaveralEnergy Center

Riviera BeachEnergy Center

2014

SGT5-8000H / IRSCHING 4 ON THE WAY TO 60% WORLD RECORD ...

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