Power Generation Services – Solutions for … Generation Services – Solutions for challenging Markets – Philipp Leifeld, GT Service Engineering / Dirk Kampe Marketing GT Modernizations

Unrestricted © Siemens AG Österreich 2016. All rights reserved. siemens.at/future-of-energy

Power Generation Services– Solutions for challenging Markets –Philipp Leifeld, GT Service Engineering / Dirk Kampe Marketing GT Modernizations & Upgrades

Matthias Migl, Principal Key Expert Overall Plant

Unrestricted © Siemens AG Österreich 2016. All rights reserved.

June 16, 2016Page 2 Kampe, Leifeld, Migl / Siemens AG

Clean Spark Spread Spectrum 2011 GermanyTypical F-class Combined Cycle Power Plant (CCPP)

Year 2011à 6.054 hours (69,1 %) with apositive Spread

Clean spark spread (CSS)represents the net revenue a generatormakes from selling power, having boughtgas and the required number of carbonallowances.

CSS < -3 €/MWh

CCS > 0 €/MWh

The plant may be able tocompensate the loss only byparticipating successfully inAuxiliary Services à no garantueebecause very competitive

-3 €/MWh < CSS < 0€/MWh

No chance to compensate theaccumulated losses.

Positive CSS à positive income

Legend:



Decline of clean Spark Spreads in GermanyTypical F-class Combined Cycle Power Plant (CCPP)

2010 2011 2012 2013

2014 Year Share ofpositivehours

Positivehours

2010 84,9 % 7.437 h

2011 69,1 % 6.053 h

2012 36,3 % 3.180 h

2013 19,7 % 1.726 h

2014 27,3 % 2.392 h

2015 25,7 % 2.260 h

2016 till May 19th 1.313 h

2015 2016

§ Market stabilization on low level§ CCPP benefit from low gas

prices



Flex-Power ServicesTM

Products available for SCC5-4000F

Flex-PowerServices™

Fast WetCompression

Part LoadUpgrade

ExtendedTurn Down

Start GradientOptimization

Reduced CoolingDown

GridServices

MinimumPart Load

Fast Releaseto nominal speed

Hot StartOn The Fly

Modified Pre-Warming Concept

DegassedConductivity

Combined CycleLoad Gradient

MaintenanceFlexibility

Combined Cycle

Gas Turbine

MaintenanceInterval

Fast Cooling

Modified STValve Staggering

Turn Up

Load GradientOptimization

PrimaryFrequencyResponse

Power onDemand

Adv. Fast LoadingPurge Credit

Exhaust GasAttemperation





SGT5-4000F Flex-Power ServicesTM

Targets all aspects of plant operation

For illustration only; not to scale; results may vary

In this presentation: Optimization of Part LoadPart Load and StartStart GradientsGradients

DynamicPart Load

Stand byMin Load






Part Load Optimizations


Dynamic, emission compliant part load operation is optimized byPart Load Upgrade (PLU)Part Load Upgrade (PLU), Extended Turn DownExtended Turn Down and CombustorCombustor BypassBypass

DynamicPart Load

Stand byMin Load




Part Load Upgrade (PLU)

** Depends on site configuration and ambient conditions

Upgrade Scope

Optimized secondary air control*

Add. air extraction at combustor plenum (optional)

Anti Icing / Air Preheater activation*

Part load OTC increase *

Benefit (Site specific assessment necessary)

Extended Part Load Operation Range with low Emissions(~10% deeper GT load possible with constant CO emissions in IGVrange**)

Optimized part load efficiency

Savings of fuel if no electric power needed* Experience: Positive effect on CO emissions demonstrated

on several units, current New Apparatus Standard

Anti Icing / Air Preheater

Secondary Air Control Additional Extraction

E2 E3

OTC increase

-10% rel. GT Loadw/ constant CO emission within IGV range

Heat Extraction fromBoiler for Air Preheater




extended Turn Down

Upgrade Scope

Extended Turn Down(reduced GT load with constant part load OTC)

Anti Icing / Air Preheater (decreased IGV minimumposition due to higher compressor inlet temperature)


Extended fast accessible Part Load Operation Range


Savings of fuel if no electric power needed

Anti Icing / Air PreheaterExt. Turn Down

Positive results from firstvalidation run (05/2016) inevaluation!





Combustor Bypass Upgrade - Design

Upgrade ScopeCombustor Bypass system (reduced CO by increasedcombustion temp.)Extended Turn Down (reduced GT load with constantpart load OTC)Anti Icing / Air Preheater (decreased IGV minimumposition due to higher compressor inlet temperature)


Extended Part Load Operation Range with low COEmissions**


Savings of fuel if no electric power needed

Anti Icing / Air PreheaterExt. Turn Down

Bypass up to -30% rel. GT loadwith 10ppmv CO


** Depends on site configuration and ambient conditions




Potential for Part Load reduction – summary

Part load OTC increase

Pow

erG

T

OTC

100%

StandardCO limit

PLUPLU

further closed IGV Ext.Ext. TurnTurnDownDown

standard operation line

Ext. Turn Down operation line

Comb. BypassComb. Bypass

Optimized secondary air control

Anti Icing / Air Preheater activated





Start Up Optimization




GT Start Gradient Optimization reduces start up times for hot and cold engines- Site specific total plant capabilities to be considered -



§ Faster Start Up with GT load gradient of up to30 MW/min

§ Retrofit possible for Service Fleet of SGT5-4000F


Fast Start and Hot Start on the Fly (CC)

§ The Hot Start On The Fly introduces a start-upconcept for the overall plant by using the firstproduced steam to start-up the steam turbine.

§ Load holds for the gas turbine not necessary.§ Hot Start On The Fly is applicable to Drum

Boilers as well as Benson® Boilers and hasbeen implemented in 13 combined cycle powerplants.

Fast GT Start Up* Hot Start on the Fly

* Benefits are subject to specific technical plant evaluation, expected values with test tolerances @ ISO condition, actual results may vary

26 min. demonstrated*up to -11 min.*




Standard vs. Optimized combined cycle power plant

Standard power plant

Source: 2014 site data from a European Siemens CCPP

Start-up processStandard PPHot Start-up time: 67 minGas consumption: ~40.000 Nm³

Optimized PP with Flex-Power ServicesTM

Hot start on the fly time: 27 minGas consumption: ~17.500 Nm³

Shut-down processStandard PPShut-down time: 26 minGas consumption: ~17.500 Nm³

Optimized PP with Flex-Power ServicesTM

Shut down on the fly time: 20 minGas consumption: ~13.750 Nm³

Optimized power plant

Benefit

-60%




Products available for SCC5-4000F

Flex-PowerServices™

Fast WetCompression

Part LoadUpgrade

ExtendedTurn Down


Reduced CoolingDown

GridServices

MinimumPart Load

Fast Releaseto nominal speed

Hot StartOn The Fly

Modified Pre-Warming Concept

DegassedConductivity

Combined CycleLoad Gradient

MaintenanceFlexibility

Combined Cycle

Gas Turbine

MaintenanceInterval

Fast Cooling

Modified STValve Staggering

Turn Up

Load GradientOptimization

PrimaryFrequencyResponse

Power onDemand

Adv. Fast LoadingPurge Credit






GT GeneratorHRSG ST

Water injection


Example: Exhaust Gas Attemperator

- Additional hardware for exhaust duct incl. pumps- Revised logics and I&C Implementation- Commissioning & operator training

Scope

- Faster warm and cold starts- Lower minimum part load- Power in hot ambient conditions- Smoother HRSG operation

Benefit

- Various plant configurations

Applicability

Multiple Improvements ______



1996

1997

2007

• Thermal Performance Upgrade• Improved Hot Gas Parts• Burner Upgrade (Low-NOxà Premix-Pilot)• Cooling Air Reduced Combustion Chamber

• HR3 Burner• Firing Temperature Increase• 15 Stage Compressor

Ongoing Development• Further Firing Temperature Increase• Grid and Peak Load Products

Additional Modernization & Upgrades• Advanced Compressor Coating• EVAP Cooler• Advanced Stability Margin Controller• Fast Wet Compression

• Advanced Compressor Cleaning System• Foreign Object Detection System• Flex-Power ServicesTM

• Wet Compression• Fuel Conversion• Fast Load Gradients

20042003

2005• Burner Upgrade (Reduced Swirl)• Fuel Gas Preheating

• Compressor Mass Flow Increase• Turndown• Hydraulic Clearance Optimization

SP6/7

SP4

• Compressor Mass Flow Increase

SGT5-4000F – Frame development to meet market requirements

2015 300 MW

283 MW

226 MW

Mod

erni

zatio

n&

Upg

rade

s

Engine Evolutionary Development: Todaysame engine basis since 1996

315 MW

288 MW2012

MW Values at limiting performance, ISO Cond. pressure losses 10/35 mbar

SGT5-4000F Modernizations & UpgradesFrame Evolution and Gas Turbine Upgrade Packages



SGT5-4000F Modernizations & UpgradesExceeding Guarantees with SP7 Upgrade – 2015, UK

+ I&C Modifications intended to improve operation

Turbine Vanes 2, 3, 4 Upgrade Style Turbine Blades 1, 2Upgrade Style

Upgrade Scope Upgrade BenefitPower & Efficiency*

Additional Scope:Bearing Shell and IGV Improvements, increased CVC1 radii,wear segment at combustor-TVC interface, new Casing Sealings

Burner HR3 Reduced swirl + modified mixingCAR Combustor improvement (Ceramic Mockups only)MHS and Turbine Vane 1 Upgrade StyleTorque discs 1+3 (only for hot ambient)Check of Turbine blade 3+4

Rework of Combustor and Turbine Vane Carrier due to UpgradeCooling Air Concept only

for leackage prevention

* Subject to specific technical plant evaluation, ISO conditions, Dpin=10mbar,Dpout=35mbar

Gain

GT1Power [MW] 19.7Efficiency [%pts] 0.81

GT2Power [MW] 22Efficiency [%pts] 0.7

Upgrade benefit exceeds guaranteed values of efficiency and power



SGT5-4000F Modernizations & UpgradesFirst Time Application of SP7 & CMF++ – 2015, Russia

Successful 50 Hz first time application in Russia showed > 30 MW CC power output

Potential Upgrade Benefit

§ GT power increase: up to 20 MW*§ Efficiency increase: up to 0.3% pts.*§ Power limit increase to 308 MW

Upgrade References

§ Successful first time application in Russia09-2015§ Upgrade operational experience > 6,000 EOH§ Two additional implementations planned for

2016 / 2017

* Expected values based on SP4 configuration, ISO conditions,site specific assessment required

Compressor stages 1-6

Site specific rotor mid section

Additional blow-offline

Burner with modified mixing

Latest combustor design

Casing improvements

New casingsealing concept Latest turbine design

New instrumentation

Compressor disc 1

§ Increased compressor mass flow§ Thermal performance increase

Utilized Effects



Dirk Kampe

Siemens AG Power Generation Services Division Power and GasStand-alone M&U/LTE Key Expert Group for 2000E/[email protected]

Thomas Brandl

Siemens AG Österreich Power Generation ServicesBusiness Unit Power and Gas [email protected]

Thank you for your attention!

è Please contact us to find the best approach for your planthttp://www.energy.siemens.com/hq/en/services/fossil-power-generation/flex-power-services.htm



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Power Generation Services – Solutions for … Generation Services – Solutions for challenging Markets – Philipp Leifeld, GT Service Engineering / Dirk Kampe Marketing GT Modernizations

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