Dedication to efficient service

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1 Published by and copyright 2008: Siemens AG Energy Sector Freyeslebenstrasse Erlangen, Germany Siemens Energy, Inc Alafaya Trail Orlando, FL , USA For more information, contact our Customer Support Center. Phone: / Fax: / (Charges depending on provider) support.energy@siemens.com Energy Service Division Order No. E50001-G5100-A100-V1-4A00 Printed in Germany Dispo 05400, c4bs No P WS All rights reserved. Subject to change without prior notice. Printed on paper treated with chlorine-free bleach. Trademarks mentioned in this document are the property of Siemens AG, its affiliates, or their respective owners. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract. Dedication to efficient service Sustainable planning, consulting and service solutions for industrial applications Answers for energy.

2 Services to support your plant performance and profit Training & Consulting Our range of training programs support your plant s full life cycle. They include on-the-job training, classsroom-based training and in-plant training on our stimulators or at our training facilities under realistic conditions. Implementing Project management is our specialty. Our experience gained in hundreds of successful projects enables us to plan each implementation step exactly. And we never leave the customer until everything is up and running properly. Operating You can either run your plant yourself - or let us run it for you. We offer operating services to match your strategic business needs. You define the level of everyday support. We even provide the plant staff and fully operate the plant. We run many plants around the world. Maintaining Regular inspections help recognize conditions which require maintenance or repairs at an early stage. Our services, such as non-destructive examination techniques, are developed for quick analysis and enable intelligent decision making that can help to cut your costs significantly. Our performance helps to improve yours The driving force behind Siemens Energy Service division is a dedication to speed of response and customer intimacy. This is because the goal is to deliver sophisticated energy services fast. Services that are designed to fit your plant s performance needs and your business goals perfectly. Our global network plays a central role in helping us meet this commitment. We are present in 161 countries worldwide and our six Product Lead Centers and 18 Service Shops offer the world-class logistics to deliver fast and effective results. We do not just offer rapid response and proximity, we also offer our customers personal closeness. We want to really get to know our customers and their personal and technical needs. This makes it easier for us to understand problems, find solutions and, above all, deliver help and support more efficiently. Repairing Changing and repairing components is a routine job. Our goal is to help you stop operating issues from becoming outages. We are helped by incidents diagnostic systems - and our experience. All our efforts focus on keeping your plant online or putting it back on the grid as quickly as possible. Modernizing There are various ways of maximizing plant efficiency. For instance, you can increase output without using more fuel and you can turn an oldertype plant into a modern one. Our modernization solutions are known for their effectiveness in terms of business success and environmental impact. Extending Lifetime When plants reach their designed lives, safety and availability decrease. Our metallurgical, integrity and fracture mechanics analyses reveal the real state of your plant and enable adequate lifetime extension measures - important assets in the deregulated electricity market. Choose the service that is right for your business from our comprehensive portfolio. 2 3

3 Our goal is to overcome market challenges every day Engineering excellence with unique market insight The energy market is becoming increasingly complex and challenging. Costs are rising and governments are tightening legislation, creating economic and political obstacles to achieving and maintaining plant profitability. At the same time, demand for energy is at its highest level ever, increasing the pressure for maximum output. We at Siemens understand that you need to get the most out of your plant every day. We are dedicated to removing unscheduled downtime and keeping scheduled downtime to a minimum. Our certified processes are designed to ensure that each plant component, from the smallest valve to a complete turbine, functions at maximum capacity. In addition, our world class logistics help you react to and deal with today s challenges faster. Helping you plan for tomorrow s market is another of our core service commitments. We focus on long-term operational flexibility, putting you and your plant in the perfect position to adapt to future industry developments, take advantage of new energy opportunities and respond to potential challenges. Service for Compressors Service for Generators Service for Steam Turbines Service for Medium Gas Turbines (MGT) Service for Small Gas Turbines (SGT) 4 5

4 Nothing is faster than already being there Fast service for safer planning In today s fast-moving world, it is even more important to have a partner you can rely on to deliver support and assistance immediately. Whether a valve has to be replaced or a turbine has broken down, our global network has the resources to respond fast and effectively, anywhere in the world. We are present in 161 countries worldwide and have 18 Service Shops around the globe, all manned by local experts who are dedicated to getting your plant back on the grid as quickly as possible and preventing such incidents from happening again. It is not just geographical proximity that enables us to respond quickly. Our dedication to establishing close customer relationships helps us understand and anticipate your plant s operational and equipment needs inside out. Which, in turn, enables us to effectively implement certified processes designed to improve quality and streamline functionality, thus saving you valuable time. Siemens assistance is only a phone call away. Around-the-clock emergency telephone service is manned by a team of operational support specialists. They are ready to provide assistance in the running of your plant. 6 7

5 To know is to understand Closer to your business No two plants are the same. Each has specific technical, operational, financial and environmental needs. Which is why we at Siemens Energy Service encourage you to share your values, aims and individual requirements with us, enabling us to understand what makes your plant different. This gives us access to unique insights, enabling us to spot weaknesses, identify hidden potential and enhance both short and long-term performance. An added benefit of building close working relationships is that you are assigned a dedicated service team to work directly with you. This gives you a single point of contact, be it a replacement parts professional to advise you on delivery and installation or the project manager responsible for running your entire plant. Modernizing Repairing Extending Lifetime Maintaining Training & Consulting Operating Implementing Siemens Energy Service offers you a wide range of opportunities. Whether you need an immediate part replacement or are planning a long-term operation such as the performance enhancement of a turbine. We can also offer you several maintenance contract options. You decide when and how often to take advantage of our support. This is possible throughout a product s entire lifecycle or for certain phases. We can offer you the exact service to fit your requirements perfectly. Service program for client A. Service program for client B. 8 9

6 Turning good into better Performance Enhancement Programs Improving your plant s performance does not have to be costly or time consuming. Just a small change can make a huge difference: it is all about choosing the right one. We at Siemens are committed to finding cost-effective and efficient ways to improve your processes, maximize your output and lower your environmental impact. In a performance-based market structure, where plants are managed as profit centers, it is necessary to strategically improve efficiency, optimize capacity, minimize costs and maintain high reliability in order to be competitive. We plan and undertake extensive plant inspections and operational analysis to identify enhancement potential. Our performance enhancement programs include introducing low maintenance components, upgrading hardware, optimizing workflows or modernizing computer interfaces. In addition, finding ways to reduce emissions and improve performance is one of our main service priorities. Effective and accurate maintenance planning is also crucial to getting the most out of a plant. Our in-depth knowledge of your equipment allows us to anticipate repair works and plan timely intervention, reducing unnecessary downtime. We also closely monitor equipment and machinery, enabling us to identify the best time to upgrade them to meet changing market developments. By simply planning ahead, we can help make an aging plant match the competitive performance of a new one for years to come

7 Identifying faults before they become failures Corrective & Performance Maintenance One of our major service goals is to keep your downtime and subsequent loss of productivity to a minimum. Rather than wait for complications to occur from the tiniest defects to potential worstcase shut down scenarios we act preemptively to prevent them happening. Once our advanced remote monitoring and diagnostic services have identified the issue, our team of specialists are then able to plan and advise on necessary action in advance. Some repairs and service work are unavoidable. But we have the processes and expertise to ensure that necessary repairs do not slow you down. Working closely with you, we anticipate potential maintenance requirement and plan time and cost effective ways to implement them. Whether it is replacing a defective valve, unblocking a pipe or overhauling a turbine, we are the partner you can rely on for fast, effective and comprehensive maintenance that will not affect your productivity. Siemens Energy Service assembles a regional team of experts that works directly with you to determine your needs. By utilizing advanced project management, supervisory and scheduling techniques to coordinate all required activities, we are able to oversee the successful completion of turbine-generator maintenance projects. Waiting for replacement parts can also cause unnecessary delays. Our comprehensive replacement parts service keeps up the levels of your stocks, guaranteeing fast delivery and removing the need to tie up capital in in-house storage. We will even assign you a parts professional to help track your parts and oversee the process. It is all about having a service provider who can get the right part to the right place at the right time

8 Finding the right options for you from a world of choices Service Programs By opting for a Siemens service program, you are choosing the reassurance of a set timeframe and budget. You also have the peace of mind of assigned personal points of contact as well as agreed planning procedures and maintenance routines. Regardless of whether your service requirements are big or small, Siemens can proactively boost your plant s longterm performance with a variety of customizable options to fit your individual needs, both technical and financial. For example, our long-term gas turbine program has proven particularly effective in helping plants around the world effectively manage and reduce downtime. We are able to respond rapidly with replacement parts. This is because we stock 23,000 styles and over 4 million parts in the central parts warehouse, ready for same-day shipment 24 hours a day, 7 days a week

9 Giving you the power of knowledge Training & Consulting We at Siemens understand that knowledge is one of the most important tools in the industry and that it can give you a clear competitive advantange. Welltrained staff who can face any challenge are vital to operating your plant efficiently and productively. That is why the Siemens Power Academy offers a wide range of customized training programs for plant management, operation and maintenance. Training is available on site, online or at our state-of-the-art training facilities including real-life simulators for worst case scenarios. Our wide range of training courses caters for every stage in a plant s lifecycle, covering in-depth and essential equipment and systems knowledge, preventing or carrying out repairs, as well as health and safety. 16 No amount of theory can replace learning by doing. Which is why we focus on both, classroom and handson-training to provide more learning opportunities. We also offer a comprehensive range of tailor-made consulting services, such as advice on building new plants, extending your plant s lifecycle, cost-effective operation, safety and environmental issues and much more. Siemens is the partner to consult if you want to take your plant forward. 17

10 References Creating success stories by working together Customer Morgan Stanley Customer LyondellBasell Industries (former BP Plant), Münchsmünster, Germany Customer INEOS Köln (also known as EC ErdölChemie or BP Köln and Innovene) At Siemens, we have a long tradition of building successful client relationships. Based on mutual understanding and respect, these relationships play a key role in helping us meet our clients specific needs and individual requirements. The three reference projects are perfect examples of our operational flexibility and goal-oriented processes. Background When Morgen Stanley took over the Berkelcentrale cogenerating station in Holland, they were looking for a reliable and flexible partner with the engineering solutions to meet their requirements. Background LyondellBasell Industries needed to upgrade an aging steam turbine to extend its operating life and improve efficiency. Background INEOS Köln ordered a large-scale shutdown of the Kracker 5 plant. This required meticulous planning to keep downtime to a minimum while extensive work took place such as replacing parts and carrying out large and small-scale overhauls. This in-depth knowledge, combined with our unparalleled expertise, facilitates solutions to even the most complex tasks such as regenerating aging turbines. We also make it a priority to deliver these solutions with minimum downtime. Product Gas Turbine SGT-600 a brand new gas generator (GG) combined with the existing power turbine (PT). Scope Product Steam Turbine 3 trains: a footprint turbine with 2 footprint compressors behind it, an ethylene train and a propylene train. Scope Product Compressor and Steam Turbine. Scope Refurbishment/upgrade of an older unit with a high number of start-stop cycles to meet the new operating profile. Upgrade of the combined heat and power plant for maximum operating flexibility to maximize revenues from power sales in an unpredictable wholesale market. Siemens had stored all original data and was able to produce a footprint for the machines. With this footprint the downtime could be kept to the bare minimum. In this case, footprints were created for two new Steam Turbines and one raw gas compressor train. There were two years of preparation work with a team of ten for the preparation phase. The cooperation of different Product Lead Centers and 45 people in two shifts working together at INEOS Köln in the overhaul phase was needed to replace a gas turbine with a body turbine and to do small-scale and long-scale overhauls for ten different machines. Result Result Result The operating life of the two gas turbines was dramatically extended. The expertise to create footprints for the existing machines facilitated the successful completion of the project. Completed with a minimum downtime of only 6 weeks according to schedule