sgt5-8000h, product validation and operational experience

Copyright © Siemens AG 2010. All rights reserved. 1

PowerGen Europe June 08-10, 2010

Copyright © Siemens AG 2010. All rights reserved.

SGT5-8000H, Product Validation and

Operational Experience at Irsching 4

Willibald J Fischer

Siemens AG

List of Content Abstract ...................................................................................................................................... 3

Introduction ................................................................................................................................ 4

Primary Targets of the 8000H Program ..................................................................................... 4

Major Milestones of the 8000H Program................................................................................... 5

SGT5-8000H Design Features ................................................................................................... 5

SGT5-8000H Validation ............................................................................................................ 6

Thermal Paint Test ..................................................................................................................... 8

Summary .................................................................................................................................... 9

References ................................................................................................................................ 10


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,

originally rated at 340 MW@ISO. 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 Muelheim 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 finally under a field validation in a real power plant

environment at Irsching 4 Power Station, Bavaria/Germany, in a hosting agreement with

E.ON.

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.

The paper will cover:

• Overview 8000H program

• Key features of new gas turbine and cc-plant

• Field validation approach

• Prototype project Irsching 4

• Status of validation phase and key test results


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 Muelheim in Germany, as well as in Orlando and Jupiter 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

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), • 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 being elaborated 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 a 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. Two 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.

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 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.

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.

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 terabytes of very

valuable data were recorded and can be used for further evaluations 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: (Figure 7)

• 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.

When this test phase is completed in the summer of 2009, the engine will have logged

operating experience equivalent to 200 starts and 3000 operating hours. This clearly

completes a success story of gas turbine validation.

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 (Figure 8). 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.

After completion of test phase 4, during which the gas turbine was in simple-cycle operation,

the Irsching 4 plant is now being converted into a single-shaft combined-cycle power plant.

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

scheduled for 2011.

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 SCC5-8000H 1S

Introductory Rating

Output 340 MW 530 MW

Efficiency > 39 % > 60 %

New Rating Output 375 MW 570 MW

Efficiency 40 % > 60 %

(Figure 9)


Based on the positive experience resulting from the 1½-year test phase at Irsching 4, Siemens

Energy is now in a position to offer the 8000H system to the power generation market for

commercial applications.

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.


Fig. 1 IDGTE 2009, Milton Keynes 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



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



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)



Endurance Test Phase

Main Purpose:• Collect further mid-long term operating experience, starts and hours, under

semi-commercial conditions• Test sensor data will still be recorded, however test requirements are no

longer prime focus• Confirmation of „readyness for commercial service“, based on load regime

required by grid operator• Operate by staff w/o special qualification (other than standard GT O&M

experience)

In total, operating experience corresponding to the equivalent of 200 Starts and 3.000 Hours have been accumulated during the Validation & Test Phase.


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 reliabilityalready achieved very early

Overall integrity, Performance,Emissions confirmed

Endurance Testing conducteduntil End of August 2009

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



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