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Page 1
Restricted © Siemens Industrial Turbomachinery AB 2014. All rights reserved.
MGT Products & Maintenance Continuous ImprovementDr. V. Navrotsky, MGT Fleet Director
Page 2
Restricted © Siemens Industrial Turbomachinery AB 2014. All rights reserved.
Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
Page 3
Restricted © Siemens Industrial Turbomachinery AB 2014. All rights reserved.
Home Market
57813172530
4768
121157
187190
253265
SGT-100SGT-200SGT-300SGT-400SGT-500SGT-600SGT-700SGT-800SGT-1000FSGT-3000ESGT-2000ESGT-5000FSGT-3000FSGT-6000GSGT-4000F
Uti
lity
app
licat
ion
Ind
ust
rial
ap
plic
atio
n
SST-9000SST-8000SST-6000SST-5000SST-4000SST-3000SST-1000
19001100
1200700
300250200
180+
130+150
100856550109
Uti
lity
app
licat
ion
Ind
ust
rial
ap
plic
atio
n
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
Page 4
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
Page 5
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Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
Page 6
Restricted © Siemens Industrial Turbomachinery AB 2014. All rights reserved.
SGT- 500 SGT- 600
SGT- 700 SGT- 800
MGT Operating Experience
Page 7
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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
Page 8
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
Page 9
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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
Page 10
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Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
Restricted © Siemens Industrial Turbomachinery AB 2014. All rights reserved.
• 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
Page 12
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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
Page 13
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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
Page 14
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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
Page 15
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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
Page 16
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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
Page 17
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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
Page 18
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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
SCC-800 2x1 135 370 kW 6239 Btu 54,7% 6583 kJ 92 600 kW 44 200 kW
SCC-800 1x1 71 400 kW 6193 Btu 55,1% 6534 kJ 49 100 kW 23 100 kW
SCC-800 2x1 143 600 kW 6159 Btu 55,4% 6498 kJ 98 300 kW 46 800 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”
Page 19
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.
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
Page 20
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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
Page 21
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Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
Page 22
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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
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Current repair status SGT-700Repairs 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
SGT-700 repair as a part of Maintenance Program to reduce maintenance cost
Repairs according to maintenance plan & on condition(for current standard components)
Page 24
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Turb blade #1
Honeycomb seals
Sealing edge replacement
1st Vane 2nd Vane
Combustion ChamberComp, recoat abradable rings
Ready
Under development
Comp, blade & vane recoating
SGT-600 repair as a part of Maintenance Program to reduce maintenance cost
Current repair status SGT-600Repairs according to maintenance plan & on-condition
Page 25
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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
Current repair status SGT-500Repairs according to maintenance plan & on-condition
Page 26
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Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
Page 27
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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
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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
Page 29
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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
Page 30
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Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
Page 31
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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
Page 32
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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
Page 33
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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
Page 34
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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
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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
Page 36
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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
Page 37
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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
Page 38
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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
Page 39
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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
Page 40
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Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
Page 41
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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.
Page 42
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Thank youfor your attention!
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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.
Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners.
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