Russia Power 2012, Moscow SGT5-2000E Gas Turbine - reliable, safe, and flexible power generation Frank Richter,

Siemens AG Dr. Alexander Lebedev, Siemens Gas Turbine Technology Gerhard Bohrenkmper, Siemens AG Dr. Nils Herzog, Siemens AG Frank Schneider, Siemens AG 0. Abstract Customers expectations are characterized by an increasing demand for operational flexibility and the requirement to lower power generation costs. To accommodate these requirements a gas turbine has to be robust, flexible and cost effective. An engine with a proven and reliable design should operate under varying fuel parameters and different specific conditions. Siemens Fossil Power Generation incorporates decades of operating experience with heavy-duty gas turbines based on proven technology. Application of the accumulated know-how is being implemented for reliable, efficient, flexible and save operation. Due do the robust design, the Siemens SGT-2000E Gas Turbine series operates at high levels of reliability and availability even under challenging conditions. This paper is focusing on the broad range of SGT-2000E applications with emphasis on the Oil & Gas industry and the operation under cold ambient conditions. These applications require solutions with respect to safety, reliability availability and serviceability. Conformity to dedicated industry regulations is essential as well. Siemens offers specifically tailored packages that cover demands of a wide range of exploitation fields either by supporting direct mechanical drive or an allelectrical drive solution. Another feature, highlighted in this paper is the capability of the 2000E frame to operate in an ambient temperature range far below minus 15 C.

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Introduction SGT5-2000E ..................................................................................3 1.1. 1.2. 1.3. Maturity...................................................................................................3 Design Features .....................................................................................4 Current Applications..............................................................................6 Market .....................................................................................................7 SGT5-2000E Oil and Gas Specific Capabilities ....................................8 2.2.1. Operational Capability................................................................9 2.2.1.1. 2.2.1.2. Start up time ....................................................................9 Black Start Capability ...................................................10

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Oil and Gas.........................................................................................................7 2.1. 2.2.

2.2.2. Fuel Capability ..........................................................................10 2.2.3. Service Concept .......................................................................11 3. Cold Ambient ...................................................................................................11 3.1. 3.2. 3.3. 3.4. 3.5. 4. 5. Market and requirements.....................................................................11 SGT5-2000E Standard Capabilities ....................................................12 Power Limit Increase of the SGT5-2000E ...........................................12 SGT5-2000E Optimizations for Cold Ambient temperatures down to 40 .......................................................................................................14 C SGT5-2000E Optimizations for Cold Ambient Temperatures below 40 .......................................................................................................16 C

Lookout ............................................................................................................16 Takeaways........................................................................................................16

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1.

Introduction SGT5-2000E

1.1. Maturity The SGT5-2000E is the E class working horse of Siemens. It has been available for more than 30 years. During these years the SGT5-2000E has satisfied demands of different markets as Power Generation, and Industrial- as well as Oil and Gas- applications. Key factors for this success are the continuous design improvements resulting in a unique engine maturity and the ability to respond to a broad range of specific requirements. The SGT5-2000E proved an availability of 95%. The reliability is even higher and achieves 99%. These world class figures are based on a deployment of far more than 300 engines with around 20Mio Total EOH (Equivalent Operating Hours) in the 50Hz and 60Hz market. The SGT5-2000E is appreciated for its light-weight design enabling a broad range of operational modes. The engine serves in continuous duty as well as in cyclic duty covering peak loads, providing an excellent start up capability. The SGT5-2000E proves that it is possible to reconcile ambitious economic and environmental targets. Despite its high flexibility in terms of operation and fuels, the NOx and CO2 emissions of a SGT5-2000E are minimized.

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Figure 1 SGT5-2000E market

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In 2001 Power Machines and Siemens AG have concluded a License Agreement with the right to produce and sell GTE-160 gas turbine with rated power of 157 MW under documentation of V94.2 which was a previous naming for the SGT 2000E . As a result, the first power plant of Kalinigradskaya CHP-2 with CCP-450 was accepted for commercial operation. As for scheme and equipment composition, this plant was identical to North-West CHP plant, only instead of 94.2 there were applied GTE-160 gas turbines, manufactured by LMZ under License from Siemens. Validation tests conducted in May, 2006, have confirmed the GT performances specified. Now the fleet of GTE-160, produced by OJSC Power Machines and assembled by Interturbo, accounts for 35 units (included 5 V94.2): in operation - 13 GTE-160 and 5 V94.2; in stage of erection at power plants - 8 GTE-160; in stage of manufacturing - 7 GTE-160, including 2 GTE-145.

1.2. Design Features Siemens 2000E series gas turbines are single-shaft machines. They are suitable both, as prime movers for industrial machines and for driving generators at constant speed in base load and peak load operation. These machines can be used stand alone for peaking duty or in combined cycles and district heat applications. They are suitable for operation with gaseous or liquid fuels. The main design characteristics of SGTx-2000E Series turbine to ease maintenance are described below. 1) Casing: Horizontally split turbine outer casings with separate vane and turbine carriers, free to expand with temperature 2) Rotor: Single shaft disc-type rotor with radial Hirth-serrations and one central tie rod 3) Compressor: 16 (50Hz) / 17 (60 Hz) stage compressor (with 0th row variablepitch IGV vanes, fast acting for grid frequency stabilization) 4) Combustion system: Two large external silo-type combustors 2 x 8 (2 x 6 for 60 Hz) hybrid burners for 50 / 60 Hz; ceramic and metallic lining of the flame tubes 5) Turbine: Four stage turbine, Si3D (Siemens innovative 3D design) for new apparatus and service modernizations 6) Welded design for hot gas casings 7) Axial exhaust for ease of combined cycle 8) Two bearings only: Combined thrust and journal bearing at compressor end (8a) and Journal bearing at turbine end (8b) 9) Cold end drive

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4 6 7 6 5 6 5 3 2 8 9 1 4 8

Figure 2 SGT5-2000E Design

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1.3. Current Applications The SGT5-2000E is characterized by large volume-combustion with moderate turbine inlet temperatures. The result is a very robust engine with a simple hot gas path design that allows a broad range of application. The standard fuel gas operation for the fossil power generation covers the majority of the operating fleet. Beyond this Fossil Power Generation the SGT5-2000E even supports fast growing non standard applications that require low BTU (British Thermal Unit) fuels. The engine has to cover problems like Lean Blow Out (LBO) and flame stabilization. The SGT 5-2000E proved within an IGCC-application (Integrated Gasification Combined Cycle) in China the ability to handle challenges as e.g. safe ignition and the flashback risk With liquid fuels the engine is faced to different challenges. The less the fuel is refined, the more it is necessary to treat the fuel with respect to viscosity and contamination. Some contaminations as sodium and potassium can be washed out of the fuel. Some other contaminations as vanadium or lead remain within the fuel and have to be treated with inhibitors. This inhibition causes ash. The engine has to be able to deal with the ash. An increasing fleet of engines that are running the Crude Oil application proves that Siemens has the ability to guarantee the habitual high standards with respect to reliability and availability.
Customer Segment

Standard Fossil Power Generation

Standard Power Generation
Simple Cycle Combined Cycle

Oil & Gas Business Applications

Direct Mechanical Drives
LNG, GTL, LPG Pumping of oil, gas and other liquids and gaseous media Refinery applications

IGCC
IGCC Plant

CO / HFO Operators
Simple Cycle (CO / HFO) Combined Cycle (HFO only)

Industrial Applications
Standard Power Generation (SC, CC) and Poly-Generation for Steel and Chemical Plants

All Electric Drive

Power Generation for Oil & Gas Applications

Application

Typical Fuels

Standard Natural Gas, Natural Gas Light Fuel Oil

SynGas LowBTU

Crude Oil, HFO

Standard, LowBTU, SynGas

Standard, LowBTU, SynGas

Standard, LowBTU, SynGas;

Operation Mode

Base, Cycling, Peaking mode Dual fuel operation

Base-, Part- load, Intermed. Cycling with no- or partialair side integration Dual fuel operat.

Base, Cycling mode

Compressor Drive mode.

Base load, Part load, Intermediate Cycling

Base load, Part load, Intermediate Cycling

GT Version

SGTx-2000E

SGT5-2000E (LC)

SGTx-2000E (CO)

SGTx-2000E (CD) - as Compressor Drive

SGTx-2000E (CD) - as Geno-Drive SGT5-2000E (LC)

SGTx-2000E SGTx-2000E (CD) SGT5-2000E (LC) SGTx-2000E (CO)

Figure 3 SGT5-2000E applications

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2. Oil and Gas

2.1. Market The Oil and Gas market is being segmented into exploration and production (Upstream) supply, transport and storage (Midstream) refinery / petrochemical (Downstream) The growing potential especially in the up- and midstream area appears significant due to the fact that O&G companies are expanding their values chain vertically. The change from a deployed mechanical driven compressor infrastructure to an all electrical approach bears for the Oil and Gas companies the potential to decrease operational costs by increasing the availability. In some areas even the availability of an own independent power supply becomes more and more crucial. The larger the exploration fields are, the more an all electrical approach becomes obvious. This development leads to the expectation of a growing Heavy Duty Gas Turbine market within the O&G business. The key success factor for Oil and Gas companies is a proven design that guarantees availability, reliability and safety operation. The gas turbine package shall be optimized to fulfill the following requirements: selected API- (American Petroleum Institute) codes, flexible application of different fuels, application of H2S rich gases increased reliability and starting reliability, extended maintenance concept, pre-packed solution for fast erection and service island operation

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2.2. SGT5-2000E Oil and Gas Specific Capabilities The specific capabilities, described within the following chapter, cover dedicated requirements of the Oil and Gas industry. However one of the most important assets to become successful in this market is the outstanding maturity, availability and reliability and the extensive field experience of the SGT5-2000E fleet. Oil and Gas applications are often faced to challenging climate conditions and difficult EHS- (Environment Health and Safety) requirements as e.g. a toxic ambient atmosphere. Even the transport infrastructure and accessibility of the exploration fields are usually rather limited The gas turbine package is provided as pre-packaged solution, aiming to be installed, commissioned and serviced on the site in very short interval.

Figure 4 Prepackaged SGT5-2000E for the Oil&Gas industry

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2.2.1. Operational Capability Since most of the O&G applications are distant from existing grids or no stable grid is available, it is necessary to optimize the package for island operation. Once there is a demand change on power from local grid, the gas turbine has to provide the corresponding need instantaneously such that the local grid can maintain its frequency. This is, besides the constant and reliable power supply a very typical requirement within the Oil and Gas environment. The standard speed range allows operation between 47.5 Hz and 51.5 Hz. The operation below or above these boundaries is limited to 20s maximum time and 30 min accumulated operation time in the upper frequency range from 51.5 52Hz and in the lower frequency range from 47Hz to 47.5Hz.

2.2.1.1. Start up time A warm start up time in less than 20 minutes to base load can be fulfilled with the standard load gradient of 11MW/min or 15 MW/min. A Starting Frequency Converter is used to assist the start-up and operates the generator in synchronous start-up as a synchronous motor. When selecting the converter, the required generator together with its excitation system is aligned with the applicable Starting Frequency Converter. During start-up with the set point for the static excitation equipment of the generator is defined by the Starting Frequency Converter. During normal operation the generator can be used as helper to drive the compressor as well as supply electricity to the grid, in case of grid sustaining for example. If a start-up time of maximal 10 minutes from turning mode to full load operation is demanded, than this requirement can be fulfilled for temperatures above 15 For very low temperatures a rotor preheating might become necessary and C. can be implemented for cold ambient projects, as an option. The start-up time below 10 minutes can be reached with the higher load gradients of 30MW/min. For this scenario 9:46 min from turning mode (120rpm) to base load operation are feasible within the ambient temperature range from 15 to 40 C C:

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2.2.1.2. Black Start Capability To insure the capability to operate several engines in an island grid it is necessary to insure the black start capability. The main task is to determine the minimum value of the active power rate limit (typically designated as PGF) enabling black start of the gas turbine generators with respect to gradual increase in load. The most demanding scenario is single-generator island mode operation. Due to limited rotating mass in the island, switching of 10MW and 20MW load blocks is easily challenging for system stability and maintaining operational frequency within the normal tolerance band. The black start of the SGT5-2000E in this configuration is possible if active power rate limit is at least 2%, for switching of 10MW loads, and 4%, for switching of 20MW loads. Black start and loading of the SGT5-2000E with 10MW and 20MW load blocks in network configurations involving more than one generator is not as critical with proper controller settings. More generators provide more spinning reserve and in case of switching loads the expected frequency drop is not as severe. Our studies prove that switching of load blocks 20MW in size in two-, three- and fourgenerator configuration is stable, thus possible, if active power rate limit of SGT52000E is 2% or greater, whereas it can be 1% for switching of 10MW loads. Our experience leads to the conclusion that stable system operation under scenarios and network configurations considered is ensured if the active power rate limit is, in all cases, set to 4%. At this value, the frequency is maintained within the frequency tolerance band (typically between -2.5Hz and +1.5Hz) and sufficiently away from the relay trip settings.

2.2.2. Fuel Capability The fuel flexibility of the SGT5-2000E was already mentioned in chapter 1.3 above. As a typical Oil and Gas application requirement an increased H2S content of the fuel gas has to be considered. The SGT5-2000E can handle H2S contents of up to 10.000ppm H2S without a decrease in performance and life time. However some modifications have to be taken into consideration as e.g.the interconnecting piping for fuel gas.

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2.2.3. Service Concept The most probable service concept is based on replacement of key components using the Roll-Out/Roll-In concept to keep outage times as short as possible. Minor inspection must be executed every 16 kEOH (Equivalent Operating Hours). During each minor inspection, the combustion chambers are exchanged completely. Inspection of the turbine/compressor is performed according to a respective checklist. A Major Overhaul after 48 kEOH covers the key components of the gas turbine as, the complete rotor with inner casing, turbine guide vane assembly, compressor and combustion system. These components will be replaced onsite and refurbished later on.

3.

Cold Ambient

3.1. Market and requirements One of the most critical issues for the operation of a gas turbine under cold ambient conditions of course is the behavior of the materials that are in touch with low temperatures. The degree of mechanical strengths referred to the temperature change declines significantly faster in the cold ambient range compared to hot temperatures. As a result the embrittlement increases and the risk of damages, caused by fatigue of the material, is immanent. Improved materials or heating measures are covering these risks. The increased mass flow due to colder ambient conditions has to be considered as well. This effect actually is positive with respect to power output. However the whole configuration has to be able to cover an increased power output as well as occurring effects like vibrations, stresses and axial thrust. A significant part of the gas turbines provided by OJSC Power Machines and assembled by Interturbo has been supplied to regions with extremely subzero ambient air temperatures in winter periods. For example, Novy Urengoi (up to -60 ), Novo-Bogoslovsk (up to -50), Perm (up to -50), Izhevsk (up to -50), Vladimir (up to -45), Kirovo-Chepetsk (up to -45), Chelyabinsk (up to -48) and others. Due to this reason many GTE-160 customers submit increased requirements to ensure gas turbine reliable operation at ambient air temperatures below -15.

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3.2. SGT5-2000E Standard Capabilities The most recent version of the SGT5-2000E provides in simple cycle operation a power output of 170 MW with an efficiency of 35.3. Typical 2x1 Combined Cycle operation is capable for more than 500MW. Main lever of the power and efficiency improvements in comparison to previous versions is the introduction of the Siemens-Innovative-3-Dimensional Turbine Blades & Vanes (Si3D). The Si3D technology supports an optimized airfoil design and a significant reduction of parasitic losses. Various SGT5-2000E gas turbines are in operation after implementing Si3D blades and vanes for turbine stages 1 & 2 (e.g. 2x in Argentina, 4x Belgium,3x United Arab Emirates,2x United Kingdom). The first power plant that became equipped with this technology for even stage 3 and 4 was Townsville (Australia) in 2009. The Hydraulic Clearance Optimization is a further feature that improves the power output by more than 1 MW. It enables the engine to reduce the clearances during the operation by hydraulic rotor shift, using pistons behind the axial compressor bearing. The HCO was introduced in 2009 in Marib (Yemen) and has proven more than 60000 EOH (Equivalent Operating Hours) worldwide. 3.3. Power Limit Increase of the SGT5-2000E The SGT5-2000E is currently limited at a maximum power output of 170 MW. The main goal of the power limit increase (PLI) program is to further extend this limit.

P after PLI

P before PLI

Power Output

Compressor Inlet Temperature

Figure 5 Influence of the power limit increase on the power output

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The benefit in power output for cold ambient temperatures is also shown in the figure above. Assuming the measurements are successful, the extra power due to the PLI is remarkable The additional power results in a higher stage load for each stage in the turbine. Apart from minor validation efforts for other components the most critical components to be regarded if the power limit is increased are the last turbine blade rows. To evaluate these essential components measurements have to be carried out to analyze the frequency behavior under higher loads. For the Power Limit Increase blade vibration measurements of the Turbine blades have to be carried out. As strain gauge measurements pose the disadvantage that the measurements can only be successful in the first weeks after commissioning, non intrusive NSMS (Non Intrusive Stress Measurement) measurements were chosen as the best option for the flexible validation at adequate ambient conditions. Therefore the turbine blades rows have to be prepared for instrumentation. In each stage several probes have to be placed and therefore it was checked, if probe positions under the gas turbine are accessible for the instrumentation and collision has to be avoided. The probes were placed in accessible positions as shown in the figure below.

Figure 6 SGT5-2000E with NSMS probes

The probes can be placed when cold weather conditions occur and therewith high power output is guaranteed. After the measurement the probes can be removed and no further exchange of casing components or rotor disks is necessary. The optical sensors can be easily replaced if a defect is detected. After a successful validation and evaluation of the data a higher load for the affected turbine blade rows can be released and therewith the higher power limit can be confirmed.

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3.4. SGT5-2000E Optimizations for Cold Ambient temperatures down to 40 C The target of the cold ambient program for the SGT5-2000E was to extend the operation limit from -15 to down to -40 Within this program all components C C. were regarded and critical components were identified, such as the cold compressor and casing parts of the engine. Moreover all operation conditions were analyzed and the influence of the very cold ambient conditions on the combustion regulation, rotor clearances and the secondary air system. As an example, a whole core engine thermal analysis was conducted to ensure that the expected temperature differences will cause no material stresses beyond a certain point. The figure below shows the temperature distribution in the compressor vane carrier as a result of the 2 dimensional analyses.

Figure 7 Temperature analysis of compressor vane carrier

As another example the clearance limits especially during the warm up phase of the engine were evaluated and the clearances tolerances were adapted accordingly in order to avoid damages of the rotating equipment. Some key features are the modified compressor inlet casing (CIC) and the compressor blade 3. A material change became necessary for these components, as they are exposed to the cold inlet air. Furthermore the bolt materials for the CIS-supports and the CIC-struts were optimized in order to bear the forces.

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The bolt material of the Compressor Inlet Guide Vans (IGV) was revised and beyond this material change the preset value for the adjusting force was increased by 40% as a more powerful IGV actuator is used. The hardware changes go along with necessary validation efforts. Apart from all calculations that were performed the final release of the SGT5-2000E for -40 is C associated to validation measurements. The measurements described in the following may give an overview of some of the validation procedures which are illustrated in Figure 8. Before the measurements can begin, a tuning of the combustors has to take place during. The combustion process has to be evaluated with respect to ignition behavior, fuel gas mass flow, resulting resonance and humming frequency and last but not least the emission limits that have to be kept.
- Burner tuning during commissioning - Combustion Chamber inspection after commissioning and after 2.000 EOH Pressures and temperatures at Compressor Air Extractions

Clearences at the flame tube ceramic tile column

Non contact blade vibration (BSSM)

Adjustment forces of IGV Cooling air temperatures and pressures

Pressure at shaft seal of turbine bearing

Commissioning/ Inspection Validation Measurement

Figure 8 Cold ambient validation efforts for the SGT5-2000E

The key measurements after or during commissioning are the non contact compressor blade vibration measurements for Compressor Blades and the non intrusive NSMS measurement with the cold temperature resistant blade material. Additionally the temperature and pressure for the air extractions, the cooling air temperatures in Turbine Vanes, the pressure at the shaft sealing of the turbine bearing and the adjustment forces of the IGV have to be measured. After the first 2000 EOH an inspection of the combustion chamber has to be considered. After this validation program of the SG5-2000E is accomplished, its reliable operation can be insured also under very cold conditions down to -40 C.

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3.5. SGT5-2000E Optimizations for Cold Ambient Temperatures below 40 C One possible alternative to operate a gas turbine below -40 based on the C measures mentioned above is the use of an air pre-heater system. These kinds of systems bear the necessity of heating large air masses of cycling air in the air intake system, resulting in additional constant pressure losses on air heater in the filter house. This causes power losses and a decrease in combined cycle plant efficiency. An alternative approach to the use of an air pre heater system is the further development of components, impacted by very cold temperatures. Further material substitutions especially for the compressor stages 1 - 4 and the respective rotor components have to be foreseen. The material for the compressor bearing casing as well as for the inlet duct has to be improved as well. Another measure is the front shaft heating which was already proven by an operation down to an ambient temperature of -60 C.

4.

Lookout

It is the distinct goal of the SGT5-2000 to serve an increasing amount of E-class market. However the SGT5-2000E has a tremendous potential to adapt further requirements. Based on the maturity developed over the years and the world class reliability and availability the design is open for a broad variety of applications beyond the power generation market.

5.

Takeaways

The SGT2000E is a well proven gas turbine that proves its outstanding capabilities with respect to availability, reliability, safety and operational flexibility including start up behavior. These advantages are appreciated not within the power generation market only, but even within the Oil and Gas business. The standard SGT2000E package operates down to -15 ambient C temperature. The operation down to -40 ambient temperature ca n be achieved as well, C considering some dedicated adaptations as variations of materials for parts of the engine that are exposed to or impacted by the very cold intake air. For ambient temperatures below -40 air-pre heati ng or further material C substitutions have to be taken into account. The fleet of Siemens and his partners is able to gain experience from the gas turbine operation even down to -60 C

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