O&M and Lifecycle Management for CCGT Power Plants Flex Power Services Enhancing a plant s market capability

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1 International Conference: May, 2016 Birmingham, UK O&M and Lifecycle Management for CCGT Power Plants Flex Power Services Enhancing a plant s market capability siemens.com/energy

2 Flex Power Services Enhancing a plant s market capability Agenda: 1. New market conditions for CCGT`s in different European countries are 3 leading to new developments on OEM-side 2. Overview of Siemens Flex Power Services Grid Services Power on demand Improved part load performance and minimal part load operation Practical example for minimal part load operation & impact on operation Summary & Outlook 31 Page 2

4 Flex Power Services Enhancing a plant s market capability New Market Conditions: UK market development av. CCGT load December March 2016, UK Status of CCGT slightly stabilizing 0 Page 4 Source: bm-reports

5 Flex Power Services Enhancing a plant s market capability Power Plant Operation needs to be adapted Increasing plant flexibility with Flex-Power Services TM Page 5

6 Flex Power Services Enhancing a plant s market capability Upgrade Fleet penetration and customer benefit Upgrade Potential Benefit *site specific results may vary Business Benefit Performance & Maintenance Thermal Performance Upgrade up to +30 MW and +0.6%pts efficiency in combined cycle* ++++ Compressor Mass Flow Increase up to MW in combined cycle* +++ Improved Hot Gas Parts up to 8 keoh major interval extension* +++ Water Injection into Compressor up to 15% temporary power increase* ++ Operation Improved Ramps up to 50 MW/min* +++ Extended mass flow control range up to 200 MW fast accessible load range* ++ Reduced emissions in part load up to 10% pts. CO compliant part load reduction* ++ Extended gas fuel flexibility +/- 13% Wobbe range possible* + Fuel Alternative fuel applications Biodiesel, hydrogen admix, H2S, Naphtha, Condensates + FCO Fuel Change Over Premix-Premix Fuel Change Over + Page 6

8 FlexPower Services Fast Start / Ramp Products SGT5-4000F CCPP Combined Cycle Load Gradient Secondary Frequency Response FLG Turn Up Primary Frequency Response Fast Wet Compression Part Load Upgrade Modified ST Valve Staggering Extended Turn Down CO- Reduction Flex-Power Services Modified Pre- Warming Concept Fast Start Up FSG Hot Start On The Fly Fast Cool Down Maintenance Interval ST Fast Preservation Degassed Conductivity Shut down On The Fly Fast Cooling Purge Credit Fast Release to nominal speed FSG FLG Fast Start Gradient Fast Load Gradient Gas Turbine Combined Cycle Page 8

10 Grid Services (Flex-Power Services ) Fast Load Gradients in IGV range - SGT5-4000F Negative Frequency Response within 5 min* Potential upgrade benefits GT Load 100% 13 MW/min 26 MW/min 50 MW/min CO limit HW Scope site specific 5 min Improvement +56 MW negative reserve capacity Time Faster load changes with up to 50 MW/min in IGV range Faster shut down time Increased reserve capacity Additional reserve capacity in steam cycle No additional cyclic life consumption Experience Upgrade successfully implemented and verified in a number of units across Europe Page 10 Primary frequency response tests with high load gradients and load deltas successfully conducted in 5 engines * Requirements: - Site specific assessment of additional HW scope - Site specific assessment of steam cycle

11 V94.3A / SGT5-4000F Turn Up Opportunity / Objective Turn-up refers to opening the IGV beyond it standard design position Provides reserve power beyond base load for frequency response operation Precondition is installed CMF+ compressor. Features / Scopes: IGV hardware Feature / Scope / Benefit I&C including margin controller Benefit: power output improvement Power on demand Primary and secondary frequency reserve above 100% power output References * New Apparatus: Number of engines in Europe Service: Selected engines in Europe Page 11 ** Subject to specific technical plant evaluation, expected values with test condition

13 Power on Demand (Flex-Power Services ) Fast Start Up (GT) and Hot Start on the Fly (CC) Aspect of Flex-Power Services Fast GT Start Up* Faster Start Up with GT load gradient of up to 30 MW/min Retrofit possible for Service Fleet of SGT5-4000F no. of cold fast starts per interval w/o penalty factor No additional restriction for hot fast starts up to -11 min.* Hot Start on the Fly The Hot Start On The Fly introduces a startup concept for the overall plant by using the first produced 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 has been implemented in 13 combined cycle power plants. 26 min. demonstrated* * Benefits are subject to specific technical plant evaluation, expected values with test ISO condition, actual results may vary Page 13

15 Part Load Upgrade (Flex-Power Services ) Minimum Load Improvement Secondary Air Control Additional Extraction Anti Icing E2 E3-10% GT Load with constant CO emission within IGV range add. Turn Down and Ext. Turn Down Upgrade Scope Part load OTC increase * Optimized secondary air control* Add. air extraction at combustor plenum (optional) Anti Icing activation* or Air Preheater * Experience: Positive effect on CO emissions demonstrated on several units, current New Apparatus Standard Potential benefit Extended Part Load Operation Range with low Emissions (down to 10ppm CO and 25ppm NOx, ~10% deeper GT load possible with constant CO emissions in IGV range**) Optimized part load efficiency OTC increase Savings of fuel if no electric power needed ** Depends on site configuration and ambient conditions Page 15

16 Part Load Upgrade (Flex-Power Services ) Part Load Upgrade w/ or w/o cooling air augmentation Power GT 100% Standard CO limit OTC increase - available for different versions - asmc for stability reasons recommended IGV limit Turn Down limit Part load OTC increase Optimized secondary air control Anti Icing/ Air Preheater activated Extended Turn Down Extended Part Load Operation Range with PLU Extended Part Load with extended Turn Down Ext Turn Down limit Turn Down operation line Ext. Turn Down operation line OTC Page 16

18 CCPP Göny - Minimum load reduction Christian Schäferkordt / Head of Maintenance CCPP Göny Page 18

19 CCPP Göny Main plant data Unit EOH OH Starts as of 01 st April 2016 Basic Plant Data GT Type & Configuration Combustion HRSG ST Generator 1 x SGT5-4000F(6), single shaft Premix pilot, Dual Fuel STF, Triple Pressure (HP Benson) + Reheat Siemens SST5-5000, HP/IP + LP Siemens SGen5-3000W COD May 2011 Capacity, CC 429 MWe Page 19

20 History of efforts to reduce the minimum load Original Pmin = 250 MW Contracted value 2011 Test step1: 230 MW June 1 st 2012 Test step2: 210 MW August 1st 2012 Successful HRSG stability test June 6 th 2013 / Uniper internal project SIEMENS Part Load Upgrade September 2015 Page 20

21 Part Load upgrade scope Implementation of CO Reduction (COR) package Hardware - Additional pressure measurements at compressor extractions of casings 2 / 3 Software - Activation of Air Pre-Heater (APH) during part load (no conventional anti-icing installed) - OTC part load increase - Advanced control concept for the cooling air flaps Page 21

22 Part Load upgrade scope To supervise HRSG behaviour especially within the HP evaporator some 50 additional thermocouples have been installed at various HP evaporator harps. All TC s are permanently connected to DCS Early detection of instabilities Ability to approach real HRSG load limit and to verify effectiveness of counter-measures Page 22

23 Expectations / effects of COR Package Reduction of Minimum Environmental Load (site CO limit: 100mg/Nm3); Siemens expected value was ~196MW CC load Increase of part load efficiency during a certain load range HRSG instabilities expected at low loads. Siemens advised to increase HP system pressure to 95 bar (from 75bar) increase blow-down rate in order to increase the mass flow install additional orifices between HP Evap 1 and 2 Original situation Expected situation with COR Page 23

24 Expectation / effects of COR Package Uniper in-house engineering company Uniper Technologies (UTG) created steady-state and dynamic HRSG models to verify Siemens statements Ledinegg instabilities seen at different plant Siemens predictions verified but at even lower loads plus Confidence given that no HRSG hardware modification is required Page 24

25 Results Commissioned and tested during 2 days end of September 2015 CO compliant minimum load could be reduced within test environment to 165MW (net) for steady state operation, not proven or used during normal operation Final settings in pre-defined load range from 210MW to 190MW (all net) Compressor inlet temperature: 35 C GT exhaust duct temperature: 620 C (was 595 C) Cooling air flaps MBH22/MBH23 a bit more closed than normal Resulting CO emissions at 190MW: 13mg/Nm 3 Page 25

26 Results (continued) OTC Cpr Inlet Temperature CC Load CO Emission Page 26

27 Results (continued) However, dynamic behaviour of APH proved to be insufficient to handle bigger load changes, i.e. Switching off while loading takes too long Switching on while de-loading takes too long that might lead to violation of the CO emission limits It seems the control of the APH was not built for these purposes Efficiency expectations not fully met especially due to increased aux. boiler operation It was decided to set the minimum load to 180MW net in order to utilise the wider load range while offering ancillary services reduce over-night must run costs Page 27

28 Results (continued) HRSG generally stable during tests, only at lowest test load some instabilities could be observed, mitigated by increasing HP system pressure In the past months instabilities within one HP evap 2 tube (row 3) experienced Page 28

29 Results (continued) In the meantime some further modifications have been done by us Further testing of HRSG stability done due the mentioned instabilities within HP Evaporator 2 FEM calculation of HP Evap 2 header initiated to evaluate influences of existing temperature gradients Aux. boiler pressure set point decreased to ~3 bar in order to optimise the supply of the aux. steam system. In order to avoid gland steam system trips, the set point of the aux. steam system had to be changed to 2.5 bar Polygon implemented to define the compressor inlet temperature set point depending on the actual load at 260MW t CPR,inlet,set = 3 C at 180MW t CPR,inlet,set = 35 C Min flow requirement of LP admission valve removed and the influence on LP SH (due to low or no flow) has been checked and found to be uncritical Page 29

30 Conclusion Expectations partially met Turn-down rate better than expected Efficiency expectations not fulfilled HRSG stability can be achieved Evaluation of results are still ongoing regarding future utilisation of COR Package Seen as beneficial product for our plant however General Siemens has an upgrade solution available that can be beneficial to improve a plants situation. However benefits highly depend on site specifics and the market environment. Any evaluation depends on expected benefits that might prove wrong during testing. HRSG and BoP influences are better to be checked as well independently. Page 30

32 Summary & Outlook Products are available for different customer needs, from purging optimization to prestartup optimization to faster gradients to part load packages a close look has to be taken to overall plant conditions to ensure safe operation in all conditions further developments are underway especially for combined cycle plants for lower part load capability, e.g. newly designed combustor for extreme low loads, exhaust gas attemperator (EGA) etc. Follow up of new grid requirements or discussions about (e.g. Ireland) underway Page 32

33 Contact page Christian Schäferkordt Head of Maintenance CCPP Göny Uniper Hungary Kft. Széchenyi István tér 7-8. H-1051 Budapest Office Kossuth Lajos utca 2/a H-9071 Göny Phone: Mobile: Page 33

34 Contact page Andreas Dibbert Dipl. Ing. (TU) GT LTE & Modernization Europe Siemensdamm Berlin Germany Phone: Fax: Mobile: Page 34

35 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, and on the SEC s website, 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. Page 35

36 Backup Page 36

37 Part Load Upgrade (Flex-Power Services ) Extended Turn Down - Concept Ext. Turn Down Upgrade Scope Minimum IGV position setting depends on ambient conditions (VLe1 icing risk) Benefit Extended Part Load Operation Range* Optimized part load efficiency Savings of fuel if no electric power needed * Depends on site configuration and ambient cond. Page 37