Recent Developments in Small Gas Turbines Siemens

Recent Developments in Small Industrial Gas turbines
Ian Amos Product Strategy Manager Siemens Industrial Turbomachinery Ltd Lincoln, UK
Copyright Siemens AG 2009. All rights reserved.
Content
Gas Turbine as Prime Movers

Applications History
Technology
thermodynamic trends and drivers core components
Future requirements
Market developments
Page 2
Nov 2010
Copyright Siemens AG 2009. All rights reserved. Energy Sector
Gas Turbine as Prime Mover Prime mover : A machine that transforms energy from thermal, electrical or pressure form to mechanical form; typically an engine or turbine. Gas Turbines vary in power output from just a few kW more than 400,000 kW. The shaft output can be used to generate electricity from an alternator or provide mechanical drive for pumps and compressors.
Page 3 Nov 2010 Copyright Siemens AG 2009. All rights reserved. Energy Sector
Siemens Industrial gas turbine range

Utility Turbines
Figures in net MW
SGT5-8000H SGT5-4000F SGT6-8000H SGT6-5000F SGT5-2000E SGT6-2000E SGT-800 SGT-700 SGT-600 SGT-500 SGT-400 SGT-300 SGT-200 SGT-100 168 113 47 31 25 17 13 8 7 5 198 266 287
375
Industrial Turbines
Page 4
Nov 2010
Industrial Gas Turbine Product Range

Portfolio (MW) SGT-100-1S SGT-100-2S SGT-200-1S
47 SGT-800 30 SGT-700 SGT-600 25 SGT-500 17 SGT-400 13 SGT-300 8 SGT-200 7 SGT-100 5
SGT-200-2S
SGT-300
SGT-400
SGT-500
SGT-600
SGT-700
SGT-800
Page 5
Nov 2010
Industrial Gas Turbine Product applications

Power Generation Pumping Compression CHP Comb. Cycle
An SGT-100 generating set is installed on Norske Shell's Troll Field platform in the North Sea
Thirty SGT-200 driven pump sets on the OZ2 pipeline operated by Sonatrach, Algeria
Two SGT-700 driven Siemens compressors for natural gas liquefaction plant owned by UGDC at Port Said, Egypt.
An SGT-800 CHP plant for InfraServ Bavernwerks chemical plant in Gendork, Germany.
Two SGT-400 generating sets operating in cogeneration/ combined cycle for BIEP at BPs Bulwer Island refinery, Australia
Page 6
Nov 2010
Gas Turbine Refresher

Comparison of Gas Turbine and Reciprocating Engine Cycle
AIR INTAKE FUEL COMBUSTION EXHAUST COMPRESSION
Continuous
Intermittent
AIR/FUEL INTAKE
Page 7 Nov 2010
COMPRESSION
COMBUSTION
EXHAUST
Gas Turbine as Prime Mover
Gas Turbine Characteristics

Size and Weight High power to weight ratio giving a very compact power source Operation and Maintenance No Lubricating oil changes High levels of availability
Fuel flexibility Vibration Rotating parts mean vibration Dual fuel capability free operation requiring simple Burn Lean gases (high N2 or CO2 mixtures) foundations Varying calorific values Emissions Very low emissions of NOx
Brayton Cycle
1-2 2-3 3-4
Air drawn from atmosphere and compressed Fuel added and combustion takes place at constant pressure Hot gases expanded through turbine and work extracted
(in single shaft approx 2/3 of turbine work is used to drive the compressor)
Page 9
Nov 2010
Ideal Engine Cycle: Efficiency
1 Simple cycle efficiency = 1 1 P P2

Ideal thermal efficiency 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 10 20 30 40
( 1) /
Cycle efficiency is therefore only dependant on the cycle pressure ratio. Assumption : Ideal cycle with no component or system losses.
50
Pressure Ratio
Engine Cycle: The Real Engine Deviations from Ideal Cycle Aerodynamic losses in turbine and compressor blading Working fluid property changes with temperature Pressure losses in intakes, combustors, ducts, exhausts, silencers etc. Air used for cooling hot components Parasitic air & hot gas leakages Mechanical losses in bearings, gearboxes, seals, shafts Electrical losses in alternators
Page 11 Nov 2010
Real Efficiencies Practical simple cycle gas turbines achieve 25 to 40 % shaft efficiency Complex gas turbine cycles can achieve shaft efficiencies up to 50% However, heat rejected in the exhaust can be used :Large combined cycle GT can achieve close to 60% shaft efficiency Cogeneration (Heat and Power) can exceed 80% total thermal efficiency
Energy Cost Savings GT cycle parameter study

43.0
25
42.0
22
Shaft Efficiency (%)
41.0
20
40.0 39.0 38.0

14
18
PRESSURE RATIO
16
37.0
1300C 1350C
1400C
1450C
36.0
1200C
1250C FIRING TEMPERATURE
35.0 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 Shaft Specific Output (kJ/kg)
Increase Pressure ratio and firing temperatures for higher simple cycle efficiencies
Design Drivers : Low Specific Fuel Consumption Higher Pressure Ratios Increased Cycle Efficiency Increased number of compressor / turbine stages and therefore cost Complex Cycles Increased Cycle Efficiency and/or Specific Power Can impact operability, cost and reliability Higher Firing Temperature Requires increased sophistication of cooling systems Can impact life and reliability and combustor emissions
Page 13
Nov 2010
Design Drivers : Availabilty, Cost and Emissions High reliability. Moderates the trend to increase firing temperature and cycle complexity. Low Emissions (Driven by environmental legislation) More difficult to achieve with high firing temperatures and combustion pressures Lowest possible cost. Encourages smallest possible frame size, i.e. high specific power high firing temperature. Reduced Pressure ratios (< 20:1) to avoid auxiliary fuel compression costs
Compromise is required in the concept design to get the best balance of parameters
Core Engine Trends: Key Parameter Trends
Centrifugal Compr.
16 15 14 13 12 11 10 9 8 7 6 5 4 3 1950 1960 1970
1300 1200 1100 1000 900 800 700
Pressure Ratio
es Pr
n in g Fiir F
t tu ra era pe mp Tem Te g
re ure
YEAR Year
1980
1990
2000
Page 15
Nov 2010
Engine Trends: Thermal Efficiency

350 40
SGT-400
Specific Power (kJ/kg)
38 36
300
250
SGT-200
34
SGT-100
32
200
Specific Power Output

150 TB5000
30 28 26
Thermal Efficiency
100 1975
1980
1985
1990
1995
2000
24 2005
Year
Dramatic impact of increased TET and pressure ratio over last 25 years:

Page 16
Specific Power increased by almost 100% Specific Fuel Consumption reduced by over 30% reduced airflow for a given power output and has resulted in smaller engine footprints, reduced weight and reduced engine costs
Nov 2010 Copyright Siemens AG 2009. All rights reserved. Energy Sector
Thermal Efficiency (%)
Firing Temperature C
o o attii Ra eR re ur su s
Future Machines
SGT-200
SGT-100
SGT-300
SGT-400
3CT
TG
TA
TD
TE
TB
TF
Product Evolution
SGT-300 Introduced 1995 7,900 kWe 30.5% eff
TA Introduced 1952 750kW 17.6% eff
Developed to 1,860kW
Page 17
Nov 2010
Gas Turbine Layout - single shaft or twin shaft
Single Shaft
Expansion through a single series of turbine stages. Power transmitted through rotor driving the compressor and torque at the output shaft
Twin Shaft
Expansion over 2 series of turbines. Compressor Turbine (CT) provides power for compressor Useful output power provided by free Power Turbine (PT)
SGT-400 Industrial gas turbine

Combustion system
Compressor
Gas Generator Turbine
Power Turbine
Page 19
Nov 2010
Combustion
10
Environmental Aspects Pollutants and Control

Pollutant Carbon Dioxide Carbon Monoxide Sulphur Oxides Nitrogen Oxides Hydrocarbons Smoke Effect Greenhouse gas Poisonous Acid Rain Ozone Depletion Smog Poisonous Greenhouse gas Visible pollution Method of Control Cycle Efficiency DLE System Fuel Treatment DLE System DLE System DLE System
DLE - Dry Low Emissions

Page 21
Nov 2010
Exhaust Emission Compliance Emissions control: Two types of combustion configuration need to be considered:
Diffusion flame Dry Low Emissions (DLE or DLN) using Pre-mix combustion
Diffusion flame
Produces high combustor primary zone temperatures, and as NOx is a function of temperature, results in high thermal NOx formation Use of wet injection directly into the primary zone to lower combustion temperature and hence lower NOx formation
Dry Low Emissions

Lean pre-mixed combustion resulting in low combustion temperature, hence low NOx formation With good design and control <25ppm NOx across a wide load and ambient range possible
11
Combustion NOx Formation

1000 100
NOx Formation Rate [ ppm/ms ]
10 1 0.1 0.01 0.001
Diffusion Flame
Lean Pre-mix
0.0001 0.00001 0.000001 1300
1500
1700
1900
2100
2300
2500
Flame Temperature [ K ]
Flame temperature affects thermal NOx formation

Combustion NOx Formation

Flame Temperature as a function of Air/Fuel ratio Diffusion flame reaction zone temperature
Lean burn
Flame temperature
Diffusion flame
Lean Pre-mixed (DLE/DLN)
Lean
Stoichiometric FAR
Rich
Page 24
Nov 2010
12
Combustor Configuration NOx product is a function of temperature
Diffusion Combustion
- high primary zone temperature
Cooling
Dry Low Emissions Combustion

-low peak temperature achieved with lean pre-mix combustion
DLE Lean Pre-mix Combustor

(SGT-100 to SGT-400 configuration)
Igniter Pilot Burner Liquid Core Main Burner Radial Swirler
Robust design involving no moving parts Fixed swirler vanes Variable fuel metering via pilot and main fuel valves
Main Gas Injection Igniter Pilot Gas Injection Air Pre Chamber
Gas/Air Mix
Gas
Air Double Skin Impingement Cooled Combustor

Page 26
Nov 2010
13
Lean PreMix combustion Simple fuel system Variable fuel metering via pilot and main fuel valves Low NOx across a wide operating range of load and ambient conditions
BLOCK VALVE BLOCK VALVE
MAIN FLOW CONTROL VALVE
MAIN MANIFOLD
BLEED VALVE
PILOT MANIFOLD
PILOT FLOW CONTROL VALVE
Page 27
Nov 2010
Combustion DLE Lean Premix System
Key to success
good mixing of fuel and air
multiple injection ports around swirler
long pre-mix path

fuel injection as far from combustion zone as possible
good air flow distribution

can annular arrangement with top hats
use of pilot burner

CO control & flame stability
use of guide vane modulation/air bleed

air flow management
Page 28
Nov 2010
14
DLE System : Siemens experience
15million operating hours across the range (SGT-100 to SGT-800) Approximately 1000 DLE units About 90% of new orders DLE
Page 29
Nov 2010
Experience Stable load accept/reject

Daily profile for unit running more than 8000hrs DLE operation on liquid fuel.
kW
Daily variations Load Shed and Accept
Page 30
Nov 2010
15
Gas Fuel Flexibility

BIOMASS & COAL GASIFICATION High Hydrogen Refinery Gases Other gas Associated Gas
3.5
Landfill & Sewage Gas
37
49
LPG
65
Siemens Diffusion
Off-shore lean Well head gas IPG Ceramics Off-shore rich gas
Operating Experience
Siemens DLE Units operating DLE Capability Under Development

Pipeline Quality NG Low Calorific Value (LCV) Medium Calorific Value (MCV) Normal High Calorific Value (HCV)
SIT Ltd. Definition
10
20
30 40 50 Wobbe Index (MJ/Nm)
60
70
Page 31
Nov 2010
The change in WI by the addition of inert species to pipeline quaility gas
50 45 40 UK Natural Gas
CO2 N2
Medium CV Fuel
Wobbe MJ/m
35 30 25 20 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 LCV Burner MCV development Range Definition
CO2 or N2 content of UK Natural Gas

16
Examples of Siemens SGT Fuels Experience

NON DLE Combustion Natural Gas Wellhead Gases Landfill Gas Sewage Gas High Hydrogen Gases Diesel Kerosene LPG (liquid and gaseous) Naphtha Wood or Synthetic Gas Gasified Lignite
Sewage gas standard burner Gasified Biomass Special Diffusion burner Landfill gas Special Diffusion burner
High Hydrogen gas standard burner UK Natural Gas Liquified Petroleum gas modified MPI
10
15
20
25
30
35
40
45
50
55
60
65
70
Wobbe Index MJ/m3 standard gases
Gaseous Fuel Range of Operation
DLE experience on Natural Gas, Kerosene and Diesel DLE on fuels with high N2 and CO2 content. DLE Associated or Wellhead Gases
Turbine
17
Aerodynamic optimised design !
Minimised loss optimum pitch/width ratio across whole span. low loading
High speed high stage number
low Mach numbers thin trailing edges low wedge angle zero tip clearance
Page 35
Nov 2010
Aerodynamics High Load Turbine
Computational Fluid Dynamics (CFD) used to complement experimental testing of advanced components.
18
Analytical optimised design !
Reduce blade stresses Minimal shroud

shroud may still be desirable for damping purposes.
High hub/tip area ratio Low rotational speed. Maximise life Low temperatures Low unsteady forces
Page 37
Nov 2010
Mechanical Design Improved analysis software (grid and solver) and improved hardware allow traditional postdesign to be carried out during design iterations. Meshing of complex cooled blade could take many man months in early 90s - now down to minutes. More sophisticated analysis for detailed lifing studies still required after design.
Page 38
Nov 2010
19
Fatigue Life of Rotating Blades Positions of Concern
Blade Vibration response

Predicted by FE and measured in Lab. Identifies critical blade frequencies and modes (Campbell Diagram)
Aerofoil
High Cycle Fatigue

Fillet Radii between aerofoil & platform Top neck of firtree root
Fillets
Low Cycle Fatigue

In areas of highest stress Eg - blade root serrations Root Serration (including skew effects)
Mechanical Design - Vibration analysis

Campbell Diagram for LPT Blade (Blade only)
6000
mode 6
EO20 EO19 EO18 EO17
5000
mode 5
Frequency (Hz)
100%
95%
4000
105%
EO11 EO10
3000
mode 4 mode 3
EO9
2000
EO6
mode 2
1000
mode 1
EO3
0 15000
15500
16000
16500
17000
17500
18000
18500
19000
19500
20000
Iteration 3 version 10
Engine Speed (rpm)
D G Palmer 3-8-01
Page 40
Nov 2010
20
Cooling optimised design !!
Large LE radius minimise stagnation htc thick trailing edge thickness and large wedge angle for cooling thickness distribution to suit cooling passages. Minimise gas washed surface.
Page 41
Nov 2010
Cooled Blading Designs

SGT100 > SGT300 > V2500 Aeroengine
Page 42
Nov 2010
21
SGT400 First Vane Cooling Features
Impingement Cooling
Film Cooling
Turbulators
Cast 2 Vane Segment
Trailing Edge Ejection
Page 43
Nov 2010
SGT-400 13MW Industrial Gas Turbine First Stage Cooled Vane Hot Blades are life limited. -Oxidation - Thermal fatigue - Creep
Life typically 24,000 hrs. Life can be increased or decreased depending on duty and environment.
22
SGT-300 First Stage Cooled Rotor Blade Ceramic Core forming Cooling Passages SGT300 8MW Industrial Gas Turbine Multi-Pass Cooled First Stage Rotor Blade
Page 45
Nov 2010
HP Turbine Blade Coatings

Hot Gas Surface Coatings for Corrosion & Oxidation protection Aluminide, Silicon Aluminide (Sermalloy J) Chromising Chrome Aluminide, Platinum Aluminide MCrAlY Internal Coatings on Cooled Blades operating in poor environments
Ceramic Thermal Barrier Coatings Yttria stabilised Zirconia Plasma Spray Coatings used on Vanes EBPVD Coatings used on rotating blades More uniform structure for improved integrity
Page 46
Nov 2010
23
Turbine Validation Process Design Analysis
Assess
evaluation and calibration of methods
Prototype
Test
Page 47
Nov 2010
New technology incorporated into existing engine platforms

SGT-100 Product Development New ratings have been released Aerodynamic modifications to compressor and turbine.
HP Rotor blade SX4 material Triple fin shroud Step Tip seal
Compressor Blade Stator stages S1& S2 Rotor stages R1 & R2
Power generation, 5.4MWe

(launch rating 3.9MW previously 5.25MWe)
Mechanical Drive,
(previously 4.9MW)
5.7MW
Page 48
Nov 2010
24
Industrial Gas Turbines Advanced Materials & Manufacturing
SGT400 PT 2 Nozzle Ring

Bladed Turbine Disc
Page 50
Nov 2010
25
The Gas Turbine Package In addition to the main package, the following is also required: Combustion air intake system Gas turbine exhaust system Enclosure ventilation system (if enclosure fitted) Control system UPS or battery and charger system
Page 51
Nov 2010
SGT-300 Industrial gas turbine Package design The latest Module Design
Available as a factory assembled packaged power plant for utility and industrial power generation applications Easily transported, installed and maintained at site Package incorporates gas turbine, gearbox, generator and all systems mounted on a single underbase Preferred option to mount controls on package, option for off package. Common modular package design concept Acoustic treatment to reduce noise levels to 85 dB(A) as standard (lower levels available as options)
26
Typical Compressor Set
Page 53
Nov 2010
SGT-400 New Package Design

Minimised customer interfaces reducing contract execution/installation costs 1 1 2 3 4 5 6 7 7 6
Combustion Air Intake Enclosure Air Inlet On-Skid Controls Fire & Gas System Interfaces Lub Oil Cooler Enclosure Air Exit
4 5 3 2
Highly flexible modular construction Customer configurable solutions based upon pre-engineered options Standard module interfaces to allow flexibility and inter-changeability Additional functionality provided dependent upon client needs Base design provides common platform for on-shore and off-shore PG and MD
27
Future direction
Future Trends - guided by market requirements Universal demand for further increases in efficiency and reliability, and reduction in cost. Oil & Gas (Mech drive and Power Gen) Fuel flexibility - associated gases, off-gases, sour gas Remote operation Emissions -inc CO2 Independent Power Generation Fuel flexibility - syngas, biofuels(?), LPG Flexible operation - part load operation Distributed cogeneration (rather than centralised generation) Emissions - inc CO2
Page 56
Nov 2010
28
Oil and Gas remote operations / fuel flexibility

First application of its kind in Russia (Western Siberia) burning wellhead gas which was previously flared Solution: Three SGT-200 gas turbine Output 6.75 MWe each DLE Combustion system Guaranteed NOx and CO emission levels of 25ppm Min. air temp. (-57oC) Max. air temp. (+34oC) Gas composition with Wobbe Index >45MJ/m3 Total DLE hours approximately 22,300 hours for each unit Significant reduction of emissions : 80-90% reduction of NOx level Siemens has supplied 135 gas turbines for Power Generation , Gas compression and pumping duty throughout the Russian oil & gas industry
Power Generation re-emergence of cogeneration

WATER
GRID
FUEL
BOILER OR DRIER
PRODUCT / STEAM
~
29
Thank You
Page 59
Nov 2010
30

Recent Developments in Small Gas Turbines Siemens

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Recent Developments in Small Industrial Gas turbines

Copyright Siemens AG 2009. All rights reserved.

Gas Turbine as Prime Movers

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Siemens Industrial gas turbine range

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Industrial Gas Turbine Product Range

47 SGT-800 30 SGT-700 SGT-600 25 SGT-500 17 SGT-400 13 SGT-300 8 SGT-200 7 SGT-100 5

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Industrial Gas Turbine Product applications

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Gas Turbine Refresher

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Gas Turbine as Prime Mover

Gas Turbine Characteristics

1-2 2-3 3-4

Ideal Engine Cycle: Efficiency

1 Simple cycle efficiency = 1 1 P P2

Energy Cost Savings GT cycle parameter study

Shaft Efficiency (%)

40.0 39.0 38.0

1250C FIRING TEMPERATURE

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Core Engine Trends: Key Parameter Trends

16 15 14 13 12 11 10 9 8 7 6 5 4 3 1950 1960 1970

1300 1200 1100 1000 900 800 700

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Engine Trends: Thermal Efficiency

Specific Power (kJ/kg)

Specific Power Output

Thermal Efficiency (%)

SGT-300 Introduced 1995 7,900 kWe 30.5% eff

TA Introduced 1952 750kW 17.6% eff

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Gas Turbine Layout - single shaft or twin shaft

SGT-400 Industrial gas turbine

Gas Generator Turbine

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Copyright Siemens AG 2009. All rights reserved.

Environmental Aspects Pollutants and Control

DLE - Dry Low Emissions

Dry Low Emissions

Combustion NOx Formation

NOx Formation Rate [ ppm/ms ]

10 1 0.1 0.01 0.001

Flame temperature affects thermal NOx formation

Combustion NOx Formation

Lean Pre-mixed (DLE/DLN)

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Combustor Configuration NOx product is a function of temperature

Dry Low Emissions Combustion

DLE Lean Pre-mix Combustor

Air Double Skin Impingement Cooled Combustor

MAIN FLOW CONTROL VALVE

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Combustion DLE Lean Premix System

long pre-mix path

good air flow distribution

use of pilot burner

use of guide vane modulation/air bleed

DLE System : Siemens experience

Copyright Siemens AG 2009. All rights reserved. Energy Sector

Experience Stable load accept/reject