SGT5-4000F Trusted Operational Excellence

Transcription

1 Power Gen Europe, Cologne / June 2014 SGT5-4000F Trusted Operational Excellence Dr. Eberhard Deuker, Siemens Energy siemens.com/answers

2 Table of Content SGT5-4000F Trusted Operational Excellence Fleet Experience: Trusted Operational Excellence Latest Upgrade Step: Operational Experience Flexibility Features Summary Page 2

3 SGT5-4000F Trusted Operational Excellence Fleet Experience: Trusted Operational Excellence Operating Status Evolutionary Design Steps Page 3

4 SGT5-4000F Operating Status The SGT5-4000F gas turbine has clocked up approx. 9,000,000 EOH. The fleet leader has accumulated > 130,000 EOH > 220 GT in operation, > 285 GT under contract Robust design was demonstrated multiple times after 100 keoh inspections - no significant deviations from the predictions detected - units returned very quickly into operation. The reliability of the SGT5-4000F fleet is at a high level of > 99% The current availability (depending on major outages) is 95.5% Page 4

5 SGT5-4000F Evolutionary Development Steps Adjusted pressure ratio 298MW / 40,0% 1st compressor upgrade 2nd compressor upgrade (CMF+) combustor cooling air saving HCO, FGP 240 MW / 37.0 % Cooling air reduction 271 MW / 38.9% % 289 MW / 39.8 % 292 MW / 39.8 % Upgrades are retrofitable 440 MW / 59.8% efficiency demonstrated on the first engine 1996 Market introduction st upgrade nd upgrade rd upgrade th upgrade Page 5

6 SGT5-4000F Evolutionary Development Steps Upcoming Improvement steps Adjusted pressure ratio 298MW / 40,0% 2nd compressor upgrade (CMF+) combustor cooling air saving HCO, FGP Cooling air reduction 289 MW / 39.8 % 292 MW / 39.8 % 1st compressor upgrade 271 MW / 38.9% % 240 MW / 37.0 % Upgrades are retrofitable Further upgrades are in development 1996 Market introduction st upgrade nd upgrade rd upgrade th upgrade Siemens continues to invest in retrofitable upgrades of its existing fleet Page 6

7 SGT5-4000F Trusted Operational Excellence Latest Upgrade Step: Operational Experience Fuel Gas Operation Fuel Oil Operation Operation at Cold Ambient Conditions Page 7

8 Latest Upgrade Step: Operational Experience Possible Load and Wobbe Range for Different Optimization Strategies 3 0 Performance Optimized Mode Wobbe range +/- 13% Fuel Flexibility Mode Wobbe range +/- 16% Limitations: High dynamics (cold gas) 25 ppm NOx Limit (hot gas) Environmental Mode (15 ppm) Fuel gas temperature: -3 Latest upgrade step enables large operational flexibility Page 8

10 Latest Upgrade Step: Operational Experience Water addition Dry operation Source: Deuker et al, Power Gen Europe 2013 Fuel oil operation: - Engines can be operated with NOx < 58 ppm in dry operation - NOx < 42 ppm possible with water addition Page 10

11 approx. relative GT Power in % Latest Upgrade Step: Operational Experience SGT5-4000F: Fuel Transfer FG-> FO Fuel transfer Loading to fuel oil BL Premix gas to premix oil Activation of oil premix mode Unloading to fuel Loading to transfer window Reduction of switch over time fuel oil BL Unloading to premix Premix gas to oil transfer window diffusion oil 0 time Source: Meisl et. al, VDI Fachtagung Stationaere Gasturbinen, 2012 Fuel change over: Significant reduction of the switch over time Page 11

13 Latest Upgrade Step: Operational Experience TC1 = 0 C: CC load benefit > 5 MW TC1 = 0 C: CC efficiency benefit 0.2 %pts New CAC (Cold Ambient Curve) improves CC performance significantly Page 13

14 SGT5-4000F Trusted Operational Excellence Flexibility Features Air preheater, air inlet chiller Wet compression (WetC) Multistage burner Operation with flexibility features Page 14

15 Flexibility Features Inlet Air Preheater Decrease of CO emissions in part load Increase of combined cycle part load efficiency Anti icing Inlet Air Chiller Increase of power output at high ambient temperatures Wet Compression (WetC) Water injection with optimized droplet size evaporation within the compressor Increased efficiency (effect of inter-cooling) Increased power output (>25 MW demonstrated) Multi Stage Burner: Fuel supply to the premix and pilot stage is each splitted up into two parts that can be controlled individually allows for an individual adjustment of the fuel/air mixing process Increased Wobbe range More stability margin at baseload NOx reduction possible in a wide range of operational conditions Page 15

16 Flexibility Features Power Flex Operation Line Standard Operation Line Operation without Extra Oil Chiller up to 50ºC Ambient Temperature Fast Start Up (30 min to baseload) Primary Frequency Response Secondary Frequency Response Manual Operation BLOC Peak Power Part Load Fast Shut Down Time 30 MW/min GT Gradient FACY start up concept 3%/s GT Gradient 50 MW/min GT Gradient 50 MW/min GT Gradient Grid Sustaining - Turn Up - temporary TT1 boost - Fast WetC Extra Power - Turn Up - temporary TT1 boost - Evap Cooler - Chiller - WetC Lower Min. Partoad by - TT2 Increase - Air Preheater 30 MW/min GT Gradient Page 16

17 Summary and Outlook The SGT5-4000F is a well established engine with proven technology, high performance, very good reliability and availability. A fleet of more than 220 engines demonstrates operational excellence. The latest upgrade step is well established in the market excellent performance demonstrated quantum jump in fuel flexibility (Wobbe range +/- 16%) Several flexibility features are available for improvement of start up time frequency response operation minimum part load operation performance optimized as well as power optimized operation modes Siemens will continue to develop the 4000F frame Page 17

18 SGT5-4000F - Trusted Operational Excellence Thank you for your attention! Slides provided by: Eberhard Deuker Axel Schaberg Andreas Heilos Holger Streb Page 18

19 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 19

20 Disclaimer Backup Page 20

21 Wobbe index Ambient Humidity Latest Upgrade Step: Operational Experience dynamics Load MEL (Minimum Environmental Load) 100% Ambient Temperature NOx < 15 ppm NOx > 15 ppm possible, depending on ambient conditions NOx > 15 ppm Fuel gas operation with NOx < 15 ppm for a large range of ambient and operational conditions Page 21

22 T [ C] TC1 [ C] CO CO [ppm] Compressor Inlet Air Preheater / Chiller Purposes of compressor inlet air preheating are Anti icing Decrease of CO emissions in part load Increase of CCPP part load efficiency Epoxy coated Al/Cu heat exchanger In front of inlet air filters Glycol/water mixture inside Purposes of compressor inlet air chilling are Increase of power output at high ambient temperatures Page 22 Example: CO reduction by compressor inlet air preheating Compressor inlet air temperature CO emissions without APH CO emissions with APH Load P [%]

23 Evap Cooling / Wet Compression Air Filter Exhaust Evap. Cooling Wet Compression Air Intake Pump skid C T Gasturbine Page 23

24 relative power [%] Fast WetC Operational Flexibility: Measures to fulfill Grid Code Requirements german grid code UK grid code standard 15 C compressor turn-up overfiring Fast Wet Compression rotational speed [%] preferred measure: compressor Turn-Up additional measure at <10 C: Overfiring additional measure at >10 C: Fast WetC SGT5-4000F Engines are capable to fulfill the UK Grid Code Page 24

25 Plant Load Operational Flexibility: Advanced start-up with FACYTM Features Conserve hot/warm starting conditions during plant standstill Automation concept with turbine stress controller Start on the fly: Improved start-up sequence Improved Start-up Curve Improvement Current Start-up Curve Benefits Shortest start-up time Plant life design limit increased Highest starting reliability < 30 min. 1) Page 25 1) Expected Plant Start-up Time Optimized Operating Flexibility at Hot Start-Up. With FACY Start-Up Concept Full Load is reached in 30 Minutes 1) Expected Plant Start-up Time Time

26 Latest Upgrade Step: Operational Experience TC1 = 0 C: CC load benefit > 5 MW TC1 = 0 C: CC efficiency benefit 0.2 %pts TC1 = -20 C: CC efficiency benefit 0.4 %pts New CAC (Cold Ambient Curve) improves CC performance significantly Page 26