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Answers for energy.
POWER-GEN Europe 2012, Cologne, Germany June 12–14, 2012
Authors: Petra Michalke Siemens AG Energy Sector – Service
Division
Thomas Schmuck Siemens AG Energy Sector – Service Division
Powerful Products for the Enhanced Flexibility of Gas
Turbines
www.siemens.com/energy
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2
ContentAbstract 3
Introduction 4
Enhanced flexibility for E-class gas turbines 5
Power Limit Increase 6
Wet Compression 7
Enhanced flexibility for F-class gas turbines 8
Advanced Stability Margin Controller 9
Advanced Compressor Mass Flow Increase 9
Turn Down 10
Turn Up 11
Wet Compression 12
Operational Flexibility Upgrade 12
Conclusion 13
References 13
Permission for use 13
Disclaimer 13
Copyright © Siemens AG 2012. All rights reserved.
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Abstract
With a steadily growing share of renewable sources of power
generation and the ongoing development of com-petitive electricity
and gas markets, the need is emerging for additional flexibility in
our advanced gas turbines. The Advanced Compressor Mass Flow
Increase and Advanced Stability Margin Controller upgrades provide
our customers with the opportunity of additional flexible power and
an economical alternative to additional genera-tion equipment.
The Advanced Compressor Mass Flow Increase upgrade is part of
the SGT5-4000F (V94.3A) new apparatus design based on the proven
SGT5-8000H design. The new 3D compressor blade and vane profile is
highly efficient, resulting in a compressor mass flow increase and
conse-quently in a power increase of up to 10 MW for the gas
turbine and 14 MW in combined cycle (1x1) operation. The Advanced
Compressor Mass Flow Increase upgrade is retrofittable in the
SGT5-4000F (V94.3A) service fleet.
The Advanced Stability Margin Controller continuously monitors
combustor behavior. The resulting feedback enables automatic engine
tuning and automatic engine protection. In addition, the operator
is informed about potential issues with the combustion process. For
natural gas operation, the pilot gas volume and the turbine outlet
temperature are modulated by an automated control logic to prevent
the engine from high combustion chamber ac-celeration events. This
supports engine operation with an optimal power output at the
lowest combustion dynamics.
Fast de-loading, gas turbine trips, and subsequent
com-bustion-chamber inspections can be avoided by increased
combustion stability during part and base load operation.
By implementing the Advanced Compressor Mass Flow increase
and/or the Advanced Stability Margin Controller upgrades, gas
turbines can remain highly reliable and competitive in the
continuously growing F-class market.
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Introduction
Gas turbine design and manufacturing technologies have advanced
significantly in the years since the first gas tur-bine VM1 was
designed in 1956. More than 14 different gas turbine types have
been developed by Siemens since then, reflecting the evolution of
the electricity market, changing environmental requirements
including steward-ship of available fuel resources, and the
globalization of the energy market.
The need for peak load and reserve capacity has been
continuously increasing in recent years. With a growing quantity of
regenerative energy generation (wind, solar) being added to power
systems worldwide, the require-ment for reserve capacity that can
be provided on demand is also increasing. In Germany, for example,
installed wind generation capacity accounts for more than 26 GW
installed capacity, and significant additional generation is being
added through new offshore wind parks. The proportion of the actual
energy contribution from wind generation in Germany is typically
between five and ten percent of annual energy generation, with
generation duration of approximately 18 percent on an annual hourly
basis. Clearly, reserve peaking capacity needs to be avail-able on
short notice when needed by the power system to support renewable
generation. As new projects usually require protracted development
periods due to long lead times for site permitting and
construction, an appropriate alternative is to increase the
capacity of power plants already in existence. [1]
Fig. 1: Development path of V-frame gas turbines
New design and manufacturing technologies – including advances
in design and modeling technologies and the refinement of design
criteria as well as advances in material, cooling, and coating
technologies – have also been used to develop upgrades and
component enhance-ments for the existing fleet. As the original
equipment manufacturer (OEM), Siemens has a huge advantage, and
continuously introduces technical enhancements within its new unit
and service business. The main market drivers for gas turbine
modernization within the service business are the following:■■
Power output increase■■ Efficiency improvement■■ Operational
flexibility■■ Reduction of maintenance efforts■■ Emission
reduction■■ Improvement of reliability and availability
Selected products and technical solutions that enhance the
operational flexibility of V-frame gas turbines will be explained
in the following sections. These products will improve grid or peak
load capacity and part load operation capacity and will expand
existing maintenance concepts.
Years
1960
VM1 1956
VM5 1960
VM80 1961
VM43 V93.0 1972
V94.0 1974
V94.1 1980
V64.3 1990
V84.3 1994
V82.0SGT5-2000E (V94.2) 1981
SGT5-1000F (V64.3A) 1997
SGT6-2000E (V84.2) 1989
SGTx-4000F (Vx4.3A) 1996
SGT5-3000E (V94.2A) 2000
SGT6-8000H 2011
SGT5-8000H 2007
V94.3 1995
1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
Technology
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5
The SGT5-2000E (V94.2) is an extremely well-proven, robust
engine for the 50 Hz market and is used for simple or combined
cycle processes with or without combined heat and power production
in all load ranges, especially in peak-load operation. The
SGT5-2000E (V94.2) was introduced in the early 1980s and was
installed almost 300 times with its 60 Hz equivalent, the
SGT6-2000E (V84.2). Together this fleet has accumulated more than
20,000,000 equivalent operating hours (EOH). Several modernization
and upgrade solutions have been devel-oped over the past 30 years
reflecting various market needs, for example, the changing
requirements for reserve capacity and flexibility.
Fig. 2: Customer-driven service product development SGT5-2000E
(V94.2)
Siemens’ most powerful modernization products for enhancing the
E-class gas turbine’s flexibility are the Wet Compression upgrade
and the Siemens innovative 3D-optimized (Si3D) turbine efficiency
upgrade. With the introduction of the Power Limit Increase to the
SGT5-2000E (V94.2), the remarkable advantages of the optimized
tur-bine blades and vanes are used to achieve an even greater
increase in capacity.
Enhanced flexibility for E-class gas turbines
Siemens innovative 3Doptimized blades and vanes 1+2
Wet Compression
Siemens innovative 3D optimized blades and vanes 3+4
Ongoing DevelopmentPower Limit Increase (PLI)
Compressor Mass Flow Increase
41MACFiring Temperature IncreaseHR3 Burner
33MACTurbine Section Upgrade
203 Units in Commercial Operation*
Total EOH > 14,800,000Lead Unit EOH > 266,000
1981
1986
19892003
2001
2008
2013
2006
[118 MW; 32,4 %]
Power Output
Eff
icie
ncy
[178+ MW; 36+ %**]
[173 MW; 35,8 %**]
Additional Modernization & Upgrades
■■ Advanced Compressor Coating
■■ EVAP Cooler
■■ Fuel Gas Preheating
■■ Fuel Conversion* As of March 2012** Expected values only,
site specific values may vary
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6
Fig. 3: Customer-driven service product development SGT5-2000E
(V94.2)
Power Limit Increase
Our latest development, specially designed for combined heat
plants (CHP) as well as for high power applications like Wet
Compression, is the Power Limit Increase (PLI), which is based on
the Siemens innovative 3D-optimized (Si3D) turbine efficiency
upgrade.
With the latest Siemens innovative 3D-optimized turbine blade
and vane technology for the mature SGT5-2000E (V94.2) frame, and
based on the successful validation test results in the winter of
2012, Siemens is currently preparing the fleet release to expand
the current power limit from 173 MW to 185 MW for all SGT5-2000E
(V94.2) units equipped with Siemens innovative 3D-optimized turbine
stages one to four. However, the unit-specific scope may differ and
is subject to a site-specific evaluation. This not only means more
power over the entire temperature range, it also means additional
output in the temperature range below the current power limit,
which was not acces-sible with gas turbine units of older design
phases.
In addition, CHPs are operated primarily in northern coun-tries
where the demand for electricity meets an effective way of
producing district heating for households or industry. District
heating output at low ambient temperatures is limited by the
current power limit of the rear stages gas turbine blades. With
falling ambient temperatures, power plants with service-exposed
SGT5-2000E (V94.2) units are affected in such a way that the
closing inlet guide vanes that limit the gas turbine’s power also
throttle the district heating output. This forces the power plant
operator to provide the extra heat energy required from other
resources, which usually operate less efficiently than the CHP.
[2]
Compared with the reference case of a SGT5-2000E (V94.2) from an
older design stage, an increase of up to four percent of exhaust
gas energy can be utilized over a wider ambient temperature range.
This huge performance increase helps strengthen power plant
operators’ market position.
Compressor inlet temperature [°C] *TT1iso
Reference V94.2 at 1060°C*
V94.2 with Siemens innovative threedimen-sional optimized stages
1-4 and PLI at 1065°C*
V94.2 with Siemens innovative three-dimensional optimized stages
1-4 and PLI at 1080°C*
V94.2 with CMF+, Siemens innovative three-dimensional optimized
stages 1-4 and PLI at 1080°C*
Gas
tu
rbin
e p
ow
er
ou
tpu
t [M
W]
185 MW Additional benefit of power limit increase 173 MW
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7
Wet Compression
The Wet Compression upgrade is a reliable and proven method of
injecting water into the gas turbine inlet. Wet Compression is
perfectly suited for upgrading peak load gas turbines. Providing
peak power enables electricity producers to react to increased grid
power demand, for example, dur-ing summer peaks or grid
fluctuations driven by renewable energy sources, and increases
customer revenues at high peak load electricity prices. Wet
Compression is designed to increase power output up to 18 MW by
injecting water into the compressor inlet, which inter-cools the
compressor, reduces the compressor inlet temperature, and increases
mass flow throughout the gas turbine.
Wet Compression can be used for various purposes: the most
common and commercially attractive ones are:■■ Seasonal operation
(summer peak operation) ■■ Reserve power and occasional peaking■■
Grid support■■ Base load increase for simple cycle gas turbines
The seasonal operation of Wet Compression to compensate for
capacity losses during high ambient temperature con-ditions is
possible in both dry and humid areas. Moreover, a combination with
an evaporative cooler or chiller is possible as long as the
compressor inlet temperature stays above 10° Celsius. Implementing
the Wet Compression upgrade to increase the marketable power
reserve and for occasional peaking is ideal, because the impact on
the normal operation of the gas turbine is very minimal.
Wet Compression was developed in 1995 and redesigned for the
SGT5/6-2000E (V84.2 / V94.2) in 2003. More than 45 Wet Compression
systems have been installed and operated on Siemens E-class gas
turbines since that year.
20
18
16
14
12
10
8
6
4
2
010 20 30 40 50 60 70 80 90 100
Base load power, dry
Power output with Evaporative cooler (85 % Eff.)
Power output with Wet Compression (2 %-MVI)
Power output at 30 °C ambient temperature related to the
relative humidity
De
lta
po
we
r o
utp
ut
(to
Bas
e L
oad
, R.H
. 10
%)
[%]
Relative humidity [%]
Fig. 4: Comparison of Wet Compression power output with an
Evaporative Cooler at a variation of relative humidity
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8
Fig. 5: Customer-driven service product development SGT5-4000F
(V94.3A)
The proven SGT5-4000F (V94.3A) is characterized by high
performance, low power generating costs, and long inter-vals
between major inspections as well as an easy-to-service design.
Since 1996 more than 200 units have been installed worldwide. Its
60 Hz equivalent SGT6-4000F (V84.3A) was introduced in 1997 and has
been sold more than 50 times since then. Together this fleet has
accumu-lated more than 10,000,000 EOH. The SGT5-4000F (V94.3A) is
based on the SGT5-2000E (V94.2) and on proven standard design
concepts. With optimized flow, combustion, and cooling systems as
well as new materials, a gas turbine efficiency of nearly 40
percent ensures a strong position in a competitive market.
Market requirements have been trending toward fast start-up
times, higher load gradients, and peak load capacity. Research
predicts the development of market demand in the direction of even
higher flexibility required of gas tur-bine operation modes. Our
most powerful modernization and upgrade products that meet the
challenges of the changing power generation market and enhance the
F-class gas turbine flexibility are the following:■■ Advanced
Stability Margin Controller (aSMC)■■ Advanced Compressor Mass Flow
Increase (CMF++)■■ Turn Down ■■ Turn Up■■ Wet Compression ■■
Operational Flexibility Upgrade (OFU)
Enhanced flexibility for F-class gas turbines
1) As of March 20122) 17-stage Compressor
3) Since 1998: 15-stage compressor4) Expected values only, site
specific values may vary
Additional Modernization & Upgrades
■■ Advanced Compressor Coating
■■ EVAP Cooler
■■ Advanced Stability Margin Controler
■■ Advanced Compressor
Cleaning System
■■ Foreign Object Detection System
■■ Wet Compression
■■ Fuel Conversion
Power Output
Eff
icie
ncy
19973)
208 Units in Commercial Operation 1)
Total EOH > 7,734,000Lead Unit EHO > 119,000
1996 2)
[240 MW; 37.0 %]
Ongoing Development
■■ Further Firing Temperature Increase
■■ Grid and Peak Load Products
2003
SP6
SP42004
2005
2008
2010
2011
[292 MW; 39.8 % 4)]■■ Advanced Compressor Mass Flow Increase
■■ Operational Flexibility Upgrade OFU
■■ Thermal Performance Upgrade■■ Improved Hot Gas Parts
■■ Burner Upgrade (Low-NOx -> Premix-Pilot)■■ Cooling Air
Reduced Combustion Chamber
■■ Burner Upgrade (Reduced Swirl)■■ Fuel Gas Preheating
■■ Compressor Mass Flow Increase■■ Turndown■■ Hydraulic
Clearance Optimization
■■ HR3 Burner■■ Firing Temperature Increase■■ 15 Stage
Compressor
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9
Advanced Compressor Mass Flow Increase
Advanced Stability Margin Controller
The Advanced Stability Margin Controller increases combustion
stability during part and base load operation, allowing more
flexible operating conditions in part load and a fast reaction to
grid code fluctuations. The combustion dynamic monitoring system
continuously monitors com-bustor dynamic pressure fluctuations to
provide feedback for automatic engine tuning, automatic engine
protection, and to alert the operator to potential issues with the
com-bustion process.
The combustion tuning potential by pilot-gas variation at low
load is limited due to upcoming combustion insta-bilities and cold
or hot spot problematic. An increased pilot gas mass flow reduces
the cold spot problem but increases combustion instability.
A decreased pilot gas mass flow reduces combustion instability
but increases the cold spot problem. Therefore there is only a
small range available for pilot gas tuning. Depending on combustion
stability, the pilot gas mass flow or the turbine outlet
temperature are modulated to achieve a stable combustion. The
Advanced Stability Margin Controller provides closed-loop control
of the combustion acoustic and the simultaneous evaluation of
control parameters, resulting in a real-time adjustment to changing
gas quality, ambient conditions, and power output. The Advanced
Stability Margin Controller is based on extensive knowledge and
experience in gas turbine combustion acoustics. Siemens Energy has
extensive experiences with more than three million accumulated EOH
worldwide.
Fig. 7: Gas turbine rotor with advanced compressor blades
100
80
60
40
20
200
150
100
50
014:10:00
Hu
Flg_
EnvS
PEC
[mbar] [Hz]
14:15:00 14:20:00 14:25:00
Fig. 6: Combustion acoustics under active Advanced Stability
Margin Controller during operation
This evolutionary component upgrade is based on the well-proven
Compressor Mass Flow Increase (CMF+) introduced in 2003. The
Advanced Compressor Mass Flow Increase (CMF++) enhances the gas
turbine’s power out-put up to 10 MW, and even up to 14 MW in
combined cycle operation (1x1). The established Compressor Mass
Flow Increase upgrade is the state-of-the-art in the new appara-tus
business for the F-class gas turbines and has accumu-lated more
than 1,800,000 EOH since its first introduction in 2003. The
Advanced Compressor Mass Flow Increase is its subsequent
development and includes an aerodynamic redesign of the first six
compressor stages.
It realizes the latest advances: for example, a scoop design of
compressor row one. The improvements are based on the SGT5-8000H
compressor hardware design. The huge performance increase is
realized with no material changes, no changes in flow paths, and
with no impact on the EOH accumulation.
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10
Fig. 8: A higher turbine outlet temperature at part load can
lead to increased combined cycle efficiency
OTCBase Load OTCPart Load OTC
(˜constant)
OTC = correct turbine outlet temperatureCO = carbon
monoxideConceptual illustration only – actual results and
experience may vary
Power
CO = constant
Inlet guide
vane fully
closed wit
h Turn Do
wn
Change
OTC
Use Turn Down
CO Limit
Potential Benefit through increased power range
without Turn Down
with Turn Down
Inlet guid
e vane fu
lly open
Inlet guide
vane fully
closed wit
hout Turn
Down
Turn Down
A growing number of operators are requesting wider ranges for
part load operation, with the gas turbines still achieving their
emission requirements. With respect to combined cycle power plants,
this is constrained by the need to keep the turbine outlet
temperature at the high base load level, allowing the steam turbine
to be operated at a high efficiency level as possible. The
implementation of the Turn Down upgrade is designed to answer the
oper-ator’s demand for lower gas turbine part load operation at
high combined cycle power plant efficiency levels. After
implementing a new linearization unit for the inlet guide vane and
a new positioning sensor, the closed position for the inlet guide
vane is adjusted to a new set point, which results in an increased
power range with low emissions and constant turbine outlet
temperatures. The actual minimum part load depends on site-specific
conditions and the desired carbon-monoxide emission level. The set
point for the minimum part load is usually lower than 40 percent
base load.
The Turn Down upgrade is the state-of-the-art for new Siemens
gas turbines for the F-class market and may be combined with other
modernizations. Since its first application in 2003, more than 100
gas turbines have been in commercial operation worldwide with more
than 2,000,000 EOH.
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11
Turn Up
The frequency response capability of combined cycle power plants
is generally activated by modulating the gas turbine output. The
steam turbine follows the gas turbine’s changes with a physical
delay in steam generation. The Turn Up upgrade can be implemented
in order to combine the full availability of both the minimum
primary and secondary frequency reserve for a high continuous plant
output above 100 percent.
Turn Up refers to opening the compressor inlet guide vane beyond
its standard design position, with an increase of six degrees
toward the open position. This leads to an increased compressor
mass flow resulting in an increased gas turbine power output of up
to six MW, while the compressor efficiency remains nearly
constant.
Fig. 9: Upgrade benefit: gas turbine operation closer to base
load
Due to the fact that Turn Up provides power above base load,
operation closer to the maximum efficiency point can be realized
while still preserving the entire primary frequency response
reserve. Consequently, the gas tur-bine operates at higher part
load. Because the Turn Up upgrade is designed for the optimization
of primary frequency response, fast load gradients are applied. The
average power output of the plant will increase; a minor increase
in average combined cycle efficiency can also be expected.
GT load
96 %
4 MW 4 MW
Turn Up
ηGT
97.5 % 100 % ~101.5 %
Starting point with standard configuration
Starting point with Turn Up
Base Load
Maximal Load with Turn Up
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12
Wet Compression
As already described, the Wet Compression upgrade was
successfully introduced in the E-class gas turbines and was
redesigned for the F-class market to meet their changing
requirements regarding plant flexibility and capability. The
commissioning of the first application on the advanced frame
SGT5-4000F (V94.3A) was success-fully accomplished in 2010. The
system shows a similar potential as on the SGT5-2000E (V94.2). The
highest delta gas turbine power output of about 16 percent has been
measured at a Wet Compression mass flow of about 10.2 kg/s. In
addition, the gas turbine’s efficiency has been increased by about
two percent. The achievable maximum power output of up to 30 MW
with Wet Compression is limited by a maximum water mass flow (two
percent of the compressor inlet mass flow). However, not all sites
can reach the full potential of Wet Compres-sion due to
site-specific limitations that include generator/transformer
limits, shaft limits, combustion instabilities, and special
limiting hardware configurations. [1]
Operational Flexibility Upgrade
The Operational Flexibility Upgrade (OFU) is an integra-tion of
proven products that optimize the individual pow-er plant
performance and increasing operational flexibili-ty within a
long-term service agreement. The Operational Flexibility Upgrade
combines proven technologies that include improved blade and vane
design and enhanced combustion technology.
The Operational Flexibility Upgrade includes a turbine
performance upgrade that modifies key turbine compo-nents and hot
gas parts, allowing for a significant firing temperature increase.
This modernization has been designed to generate a power increase,
an improvement in heat rate, and additional exhaust energy. These
results are achieved through the application of new coat-ings on
the turbine blades and vanes and a reduction in cooling air in the
hot gas path. In addition to the perfor-mance increase, the
Operational Flexibility Upgrade al-lows for a maintenance interval
extension to 33MAC. This results in increased availability of the
entire plant, because the major outage is only performed every
33,000 EOH.
The following benefits can be achieved:■■ Up to 13 MW gas
turbine power output increase
in simple cycle operation■■ Up to 21 MW combined cycle power
output
improvement (1x1)■■ Up to 0.4 percentage points combined
cycle
efficiency improvement■■ Potential reduction of NOX emission
down to 15 ppm The Operational Flexibility Upgrade optimizes
upgrade combinations and provides the best unit-specific balance of
plant solutions, with the maximum possible perfor-mance increase
and enhanced maintenance intervals as part of a long-term program
contract extension. The Operational Flexibility Upgrade is the
ticket to a flexible operating domain that extends the original
equipment manufacturer coverage beyond 100,000 EOH and can be
implemented at any outage during the long-term service agreement
program. The Operational Flexibility Upgrade will typically be
implemented at the 100,000 EOH outage.
Fig. 10: Wet Compression spider nozzle Fig. 11: Schematic
illustration of the Operational Flexibility Upgrade
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13
Conclusion
Recent improvements in turbine technology have pro-duced major
benefits, including increased flexibility and improved reliability
and availability. All of these benefits make a gas turbine
modernization project attractive and highly beneficial for aging
power plants. In addition, short lead times for the realization of
these moderniza-tions and upgrades – when compared with new
installa-tion projects – enable a response to near-term capacity
needs.
The upgrade solutions described above – the Power Limit
Increase, Wet Compression, and Operation Flexibility Upgrade
packages, among others – represent only a small part of the
solutions provided for the Siemens gas turbine fleet today, and
reflect the market’s demand for enhanced capability and
flexibility. Many more solutions are available, and they can be
combined to address the customer’s need for not only improved
flexibility but also high reliability and availability with
reasonable mainte-nance costs and reduced emissions.
Each upgrade step is verified with various test methods to
ensure reliable engine operation. The proven product development
process and the integrated validation con-cepts demonstrate an
extensive quality assurance model for our customers. As part of
this continuous research and development process, Siemens is
committed to delivering excellent solutions that are highly
beneficial for the power generation industry.
References[1] Beiler, J. D. “High Efficient Peak Power on
Demand.” Publication, Siemens AG, 2011.
[2] Sorgenfrey, Chr. “Beneficial lifetime extension of
SGT5-2000E gas turbines through modernization.” Publication,
Siemens AG, 2011.
Permission for useThe content of this paper is copyrighted by
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distribution only. Any inquiries regarding permission to use the
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-
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