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Update on Siemens 8000H CCPP Technology and Operational Experience

Authors:

Dr. Kais Sfar Siemens Energy, Head of Product Line Marketing Plant Solutions

Armin Staedtler Siemens Energy, Head of 8000H R&D Program

PowerGen Asia Bangkok, October 3 – 5, 2012

Abstract

More than one year ago, the start of commercial operation of “Ulrich Hartmann” power plant in Irsching (unit #4, Germany) marked the dawn of a new era in combined cycle power plant construction. For the first time the magic figure of 60% efficiency was topped. However, not only this world-record efficiency level sparked the interest of the power generation community, but also the successful optimization of the plant’s operational flexibility. The high level of plant flexibility is setting benchmarks and enabling an operating regime, which today already meets the rising demand of the future. Rapidly increasing share of renewables-based power generation and high fluctuating load demand – especially in small grids – will require combined cycle power plants able to provide highest performance at base and part load and at the same capacity for fast cycling and grid support. Initial tests already demonstrated that the plant exhibits excellent characteristics in terms of grid stabilization. It was also demonstrated that the FACY ™ package developed by Siemens enables startup times of less than 30 minutes.

This paper describes Siemens answer to the different regional market requirements and focus on both the SGT-8000H gas turbine series and the corresponding combined cycle power plant solutions for the 50Hz and 60Hz regions. The market introduction of the 8000H class technology was based on an extensive validation and test strategy first in Irsching for the 50Hz frame under real field conditions and later for the 60Hz frame, which is a direct scale of the SGT5-8000H, in the Berlin test facility. This paper will further summarize all field validation activities and results, showing how Siemens is bringing the 8000H to the market based on a comprehensive approach to ensure a risk minimized market introduction. Finally this paper will describe the current commercial experience and the first references within the 50Hz and 60Hz markets.

Table of contents

1. The challenge – Fluctuating power demand at raising

fuel costs

4

2. Siemens 8000H combined cycle power plant solutions

8

2.1. SGT-8000H gas turbine: Proven design with highest efficiency & flexibility

8

2.2. SCC-8000H combined cycle power plant solutions

13

3. Operational experience

19

3.1. Test and validation of the SGT5-8000H and SCC5-8000H

19

3.2. Test and validation of the SGT6-8000H

23

4. Market launch and first commercial references

27

5. Conclusion

29

6. References

31

7. Copyright

33

8. Disclaimer

33

1. The challenge – Fluctuating power demand at raising fuel costs

Considering the worldwide trend of increasing demand for eco-friendly power generation, a major concern to power producers aiming to build new plants is to understand the impact of the long-term CO 2 reduction targets on the power generation market of today and the future. Despite all uncertainties related to the potential future changes in regional environmental policies and CO 2 reduction targets, today’s power plant solutions must be capable of running profitably throughout the whole service life, which in the case of combined cycle power plants is typically more than 20 years. Customers expect environmentally-compatible and economical state-of-the-art solutions, which offer a maximum value and long-term investment security, even in a volatile market environment.

Driven by stringent CO 2 reduction targets, the share of renewable energy resources is rapidly growing. The analysis of the predicted residual load, which is the difference between incoming renewables-based power supply and power consumption, shows an extremely fluctuating course over the year. Based on further statistical analysis a clear shift of the fossil power plants' operating regime from base load towards intermediate and peak load is predicted. Also, the remaining conventional power plant fleet has to be able to cope with much higher load ramps and therefore partly serve as backup, e.g. in case renewables feed-in is interrupted, on short notice.

Considering the ASEAN region, which is characterized by strong economic growth, a continuous increase of power demand of approx. 6% per annum is anticipated over the upcoming years. Accordingly, new generating capacities will have to be built to meet this increase in the years ahead. Inversely to Europe, renewable energy power generation in the ASEAN region is still limited and plays a secondarily role within today’s energy mix. Nevertheless, it is clearly expected that in future the renewable power generation share will increase. Therefore new future power plant investments have to consider renewable’s impact at a very early stage of the planning process.

Since natural gas availability in the region is growing, e.g. through the continuous

extension of the LNG terminals network around the South Pacific Rim, gas fired power

generation plays a key role in securing the energy supply of the region.

Thanks to their outstanding dynamic characteristics, combined cycle power plants are

able to offer highly flexible solutions that can accommodate sharp daily fluctuations in

power consumption. Operational flexibility is based mainly on three major aspects:

Operational efficiency comprising highest efficiency throughout the whole load range and optimized start-up and shut-down operation

Power on demand comprising rapid availability by fast starts and load ramps

Grid support, also comprising load ramps, stable operation in case of grid

incidents and backup power

Since gas fired power plants represent a major portion of the energy mix, it is clear that

this type of plant is used to cover a certain portion of the base load needed in the region.

During this load regime highest efficiency is a key requirement to drastically reduce fuel

consumption and, of course, reduce CO 2 emissions.

Siemens combined cycle power plants are addressing the major environmental and economical market drivers Gas
Siemens combined cycle power plants are addressing
the major environmental and economical market drivers
Gas prices
Ecological
awareness
Lowest investment
Highest efficiency
Operational flexibility
+
+
Steep load ramps
and fluctuating
power demand
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector

Figure 1 Major power plant requirements

The evaluation of the different regional requirements (Figure 1) as discussed earlier leads

to the following key drivers:

Investment: lower specific investment (EUR/kW) resulting from economies of scale, while achieving highest reliability and availability.

Performance: increase combined cycle net efficiency to over 60% with a power output over 550 MW in a 1 on 1, while drastically reducing emissions.

Operational flexibility: reduce startup and shutdown times, increase load ramps for fast load-following ability, improve turn down capability, part-load efficiency and startup reliability.

These factors have been considered by Siemens Energy in the development of the new

H-Class gas turbine SGT-8000H series and the combined cycle power plant, the SCC-

8000H series, taking both environmental protection as well as economical focus into

consideration. The 8000H program was started in 2000. It was dedicated to consistently

implementing our engineering know-how not only for the gas turbine but also for the

overall plant solution. Thus, Siemens Energy can provide the right answer to tomorrows’ energy supply needs already today.

2. Siemens 8000H combined cycle power plant solutions

2.1. SGT-8000H gas turbine: Proven design with highest efficiency & flexibility

Following the merger of Westinghouse Power Generation with Siemens in 1998, the decision was made to develop a Next Generation Family of Gas Turbines and therewith widen the existing product portfolio based on the H class frames for 50Hz and 60Hz markets (Figure 2). The SGT-8000H series addresses the major market requirements in terms of efficiency, environmental protection, operational flexibility and economical value.

Siemens Large Scale Gas Turbines: Product Portfolio for 50 Hz and 60 Hz SGT5-8000H 375
Siemens Large Scale Gas Turbines: Product Portfolio for 50 Hz and 60 Hz SGT5-8000H 375
Siemens Large Scale Gas Turbines: Product Portfolio for 50 Hz and 60 Hz SGT5-8000H 375

Siemens Large Scale Gas Turbines:

Product Portfolio for 50 Hz and 60 Hz

Siemens Large Scale Gas Turbines: Product Portfolio for 50 Hz and 60 Hz

SGT5-8000H

375

SGT5-4000F

292

SGT6-8000H

274

SGT6-5000F

200

SGT5-2000E

168

SGT6-2000E

113

SGT6-5000F 200 SGT5-2000E 168 SGT6-2000E 113 Bangkok, Oct. 3 – 5 PowerGen Asia 2012 Output in

Bangkok, Oct. 3 – 5

PowerGen Asia 2012

Output in MW @ ISO conditions

© Siemens AG 2012 Siemens Energy Sector

Figure 2 Siemens Energy large scale gas turbine product portfolio

The SGT-8000H gas turbine series combines the best design features and technologies of the established product lines with some technology innovations and enhancements and is the result of a continuous optimization and harmonization development activities. The functional and mechanical design of the engine was built on the extensive experience

gathered over decades with the predecessor 50Hz and 60Hz engines of both companies Siemens and former Westinghouse. Proven design features were applied wherever possible, and “Design for Six Sigma” tools were used throughout the process, to deliver a robust product which meets all requirements (Figure 3). The results of the 8000H development, testing and validation activities were also used as an enabler for the different F class engines upgrades.

SGT-8000H engine concept based on harmonization and new technology Siemens V Design Siemens W Design
SGT-8000H engine concept
based on harmonization and new technology
Siemens V Design
Siemens W Design
Single tie bolt
Compr. stat. design
Turbine cylinder
Turbine vane carrier
Exit housing
Front hollow shaft
Bearings
Compressor cylinder
Turbine features
Turbine diffuser
ULN can-annular
Secondary Air
Harmonized
combustion system
System
Compressor
The SGT-8000H concept uses proven features from Siemens and (former)
Westinghouse engines and introduces new technology
© Siemens AG 2012
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
Siemens Energy Sector

Figure 3 Concept of the SGT-8000H series

Based on the SGT-8000H frames different packages and plant product configurations for both 50Hz and 60Hz markets were developed (Figure 4). A detailed plant solution view will be discussed in the next chapter.

 
 

Configuration and Performance Overview

 

50 Hz

60 Hz

SGT5/6-8000H
SGT5/6-8000H
SCC5/6-8000H 1S
SCC5/6-8000H 1S

SGT-PAC 8000H

375 MW

274 MW

40

%

40 %

SCC-PAC 8000H 1S

570 MW

410 MW

60

%

60 %

SCC-PAC 8000H 2x1

1.145 MW

824 MW

60

%

60 %

SCC-PAC 8000H 3x1

- -

1.236 MW

SCC5/6-8000H 2x1
SCC5/6-8000H 2x1

- -

60 %

at ISO conditions

Bangkok, Oct. 3 – 5

PowerGen Asia 2012

© Siemens AG 2012 Siemens Energy Sector

Figure 4 Configuration and performance overview

The basic engine design is summarized in Figure 5 and has the following features, which account for the high efficiency and the increased operational flexibility: The SGT-8000H series is an integrated product line with common features and an evolutionary design.

The engine uses the well known SGT5-4000F disc-type hollow-shaft rotor with a single tie bolt. The discs are interlocked and centered using Hirth couplings. This shaft design has smooth and stable running behavior due to the low weight with high stiffness and uniform thermal expansion under all operating conditions. Siemens has over 16 Million EOHs and more than 750 gas turbines operating with this type of rotor.

The 13 stages high efficiency axial compressor is Siemens harmonized design, which is offered on the SGT6-5000F as well as the SGT-8000H engines. This design has four variable guide vanes to maintain high part load efficiency and low emissions. This design continues to offer the ability to replace blades without a

rotor lift. The 50Hz and 60Hz versions are conceptually identical and are geometrically scaled.

– The can annular combustion system design is based on the SGT6-5000F and is purely air-cooled. The existing Siemens fleet with over 400 operating units offers more than 8,500,000 EOHs of extensive experience with this type of combustion system. Both 50Hz and 60Hz SGT-8000H engines have a common combustor assembly.

The turbine part of the engine consists of four high efficiency stages with air- cooled turbine blades. Blade R1 uses directionally solidified material and enhanced TBC system. There is no need for single crystals use and steam cooling. The first stage blade and vane are removable through the combustor without cover lift. Further measure for improved serviceability and shorter outages is the use of a single turbine vane carrier. Similar the SGT5-4000F the turbine has a conical flow path, which allows for hydraulic clearance optimization.

SGT5-8000H Efficient & Flexible Evolutionary 3D blading Advanced Can Annular combustion system 4 stages of
SGT5-8000H
Efficient & Flexible
Evolutionary 3D blading
Advanced Can Annular
combustion system
4 stages of fast acting variable-
pitch guide vanes (VGV) allowing
for improved part load efficiency
and high load transients
> 60% combined
cycle efficiency
Proven rotor design
(Hirth serration,
central tie rod, internal
cooling air passages)
for world class fast
(cold) start and hot
restart capability
3D Four stage turbine with
advanced materials and
thermal barrier coating
High cycling capability due
to fully internally air cooled
turbine section
HCO for reduced
clearance losses
Transient protection of clearances
for reduced degradation with
hydraulic clearance optimization
(HCO) active clearance control
Performance features
Flexibility features
Designed for >60% efficiency in combined cycle
and best in class operational flexibility
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector

Figure 5 Main design features of the SGT-8000H series

A key design feature towards operational flexibility and a major concept decision which

had to be made early in the SGT-8000H program, was the selection of the engine cooling method. Siemens Energy gas turbine portfolio has both types of the major cooling technologies: The SGT5-4000F and the SGT6-5000F are both based on purely air-cooled engine concepts, while the SGT6-6000G had a combined air and steam cooled approach. This experience offered a wide information and experience basis, showing the benefits and disadvantages of both technologies. Due to the heavy impact of the steam cooling on the engine operational flexibility and design complexity, the internally fully air-cooled design was selected for the SGT-8000H. This design feature enables faster starts, since there is no need to wait for steam from the water/steam cycle. The avoidance of steam cooling and external coolers enable easier simple cycle and bypass operation, faster load following and part load operation. Design simplicity especially in terms of sealing designs provides higher engine robustness. SGT-8000H proven design allows achieving outstanding performance and operational flexibility without the higher risk associated to the steam cooling.

A further key aspect which was incorporated in the SGT-8000H was the special focus on

design features to enable easy and quick serviceability:

– Replacement of compressor blades without rotor de-stack or lift

Roll out/in capability of the turbine vane carrier enables exchange of stationary turbine hardware without rotor lift

All turbine blades removable without rotor lift

– Turbine vane 1 and blade 1 removable without cover lift (access through combustion chamber)

Turbine blade 4 removable without cover lift (towards the exhaust end)

2.2.

SCC-8000H combined cycle power plant solutions

As shown in Figure 4 Siemens Energy offers different combined cycle power plant configurations based on single- and multi-shaft arrangements. Additionally Siemens is unique in offering a flexible scope of supply varying between entire power plant (turnkey scope) over power block / power island and up to an extended power train. This enables Siemens to add – depending on the project specific setup– the regional partners and local knowledge (Figure 6). The portfolio flexibility with regards to different arrangements and scope of supply allows a wide range of technical and commercial (risk and cost) optimizations, allowing best fit to customer’ requirements.

Different scope variations for Siemens combined cycle power plants

Extended

Power Train

Power Island

Power Block

Entire Power Plant

Power Train Power Island Power Block Entire Power Plant Bangkok, Oct. 3 – 5 PowerGen Asia

Bangkok, Oct. 3 – 5

PowerGen Asia 2012

© Siemens AG 2012 Siemens Energy Sector

Figure 6 Siemens offers various scopes to customers adding regional partners & local knowledge

A major solution within the product portfolio is the proven single-shaft design that was developed in the early 90s. Since then, it has since been successfully implemented in the F-class (SCC5-4000F 1S) with about 100 units in commercial operation. The power plant SCC-8000H series was developed based on the SGT-8000H as prime mover, the Irsching 4 test plant and the large F class experience as mentioned above. The design principle comprising the gas turbine, the generator, the coupling and the steam turbine on a single- shaft has remained the same, as this continues to offer the customer the greatest economy and at the same time supreme operational and financial flexibility. The SCC- 8000H series is also characterized by its high degree of harmonization, modularization and compact design towards footprint and space requirements. Both solutions for 50Hz and 60Hz markets are based on the same design principles.

The overall plant design was optimized to provide over 570 MW net power output at ISO conditions and a net efficiency greater than 60%, while keeping the emissions extremely low, in this case 25 ppm NO x emissions or less at gas turbine base load (Figure 7). Further performance figures for single and multi-shaft configurations for both 50Hz and 60Hz are shown in Figure 4.

SCC5-8000H 1S designed for η > 60% and highest operational flexibility Published Design Steam Turb.:SST5-5000
SCC5-8000H 1S designed for η > 60% and highest
operational flexibility
Published Design
Steam Turb.:SST5-5000
Targets:
HRSG: Benson TM
Performance (net, ISO)
3Pr/RH 600 °C/170 bar
Power:
>570 MW
Combined HP/IP
Dual flow LP
HP: 170 bar / 600 °C
IP: 35 bar / 600 °C
LP: 5 bar / 300 °C
Efficiency: > 60%
Emissions (Base load)
NOx < 25 ppm
CO < 10 ppm
Generator: SGen5-3000W
Water cooled stator winding
Hydrogen cooled rotor winding
MICALASTIC ® Stator insulation
World class efficiency
Gas Turbine: SGT5-8000H
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector

Figure 7 SCC5-8000H 1S designed for highest efficiency and operational flexibility

Siemens Energy solutions single shaft design is also optimized for CHP applications. Despite the compact design with the floor mounted turbine generator train, it’s possible to provide up to a three stage steam extraction for heating purposes or process steam. Figure 8 shows the possible heat extraction of both SCC-8000H product lines. In chapter 4 of this paper a commercial reference of the SCC5-8000H 1S with CHP will be discussed.

SCC-8000H Possible heat extraction in large CHP combined cycles SCC5-8000H 1S 570MW SCC6-8000H 1S 410MW
SCC-8000H Possible heat extraction in large CHP combined cycles SCC5-8000H 1S 570MW SCC6-8000H 1S 410MW
SCC-8000H Possible heat extraction in large CHP combined cycles SCC5-8000H 1S 570MW SCC6-8000H 1S 410MW

SCC-8000H

Possible heat extraction in large CHP combined cycles

SCC-8000H Possible heat extraction in large CHP combined cycles
SCC5-8000H 1S 570MW SCC6-8000H 1S 410MW 0 50 100 150 200 250 300 350 400
SCC5-8000H 1S
570MW
SCC6-8000H 1S
410MW
0
50
100
150
200
250
300
350
400
Possible heat extraction [MWth]
SGT5-8000H
SGT6-8000H
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector

Figure 8 SCC-8000H with combined heat & power (CHP) application

The selected steam turbine type used for SCC-8000H series comprises one combined HP/IP casing and one double-flow low-pressure casing. The advanced steam turbine design is optimized for combined cycle applications, providing enhanced transient thermal behavior for fast loading and fast cycling. For the single shaft configuration the synchronous self shifting (SSS) clutch allows a self-contained individual turning mode of the gas turbine and the steam turbine increases the operation flexibility and allows also a faster start-up of the power plant.

Depending on the frequency and plant configuration different generators within the H 2 and H 2 O cooled product lines are used. Both types are contributing to the overall plant efficiency increase based on its outstanding performance. Due to the large plant output the 50Hz single-shaft solution is using – as a unique configuration – a generator with direct radial hydrogen cooling for the rotor winding and water cooling for the stator winding. This frame is mainly characterized by its high efficiency and reliability beyond 99%. A start-up frequency converter is used for start-up of the turbine generator unit.

The generator acts as a motor in the converter mode to start the gas turbine set without an additional rotating device.

As the SGT5-8000H provides a high exhaust temperature of approximately 625 °C, a further efficiency increase was achieved based on an advanced three pressure reheat water steam cycle (up to 600°C inlet temperature and 170 bars inlet pressure) with a BENSON type heat recovery steam generator (HRSG) and condensate polishing. Further efficiency improvement measures were based on the use of fuel preheating at 215°C, reduction of pressure losses in the HRSG and piping, feed water pumps with variable speed drives, etc. The combination of all efficiency improvement measures enables the major step over 60% efficiency at base load and an efficiency increase of up to 1,7%-Pt. compared to typical F class over the main operation range.

The Benson-type HRSG for high steam parameters is an essential component in addition to the "rotating equipment". The HRSG is designed and built by Siemens (Figure 9). As this component is of major importance for boosting efficiency and flexibility, the decision was taken to develop and build it in-house on the basis of the available experience with previous Benson boilers, such as in the projects Karstoe, Simmering and Timelkam. Due to the increased thermal cycle parameters, advanced high temperature materials known from the 600 °C steam power plant technology were used for the HRSG design. For both design standards DIN and ASME Siemens Energy provides solutions with proven materials for up to 600°C water / steam cycles. Depending on the plant configuration economics main steam parameters for 50Hz and 60Hz may be decreased to 150bar and 585°C to enable e.g. the use of a drum type HRSG.

HRSG with Siemens Benson T M HP section designed for 600 °C steam temperature Irsching
HRSG with Siemens Benson T M HP section designed for 600 °C steam temperature Irsching
HRSG with Siemens Benson T M HP section designed for 600 °C steam temperature Irsching
HRSG with Siemens Benson T M HP section designed for 600 °C steam temperature Irsching

HRSG with Siemens Benson TM HP section designed for 600 °C steam temperature

HRSG with Siemens Benson T M HP section designed for 600 °C steam temperature

Irsching 4 Benson TM* HRSG is designed and delivered by Siemens

HP pressure/Temp.: 170 bar/600 °C RH pressure/Temp: 35 bar/600 °C Mass flow: 100 kg/s Weight:

HP pressure/Temp.: 170 bar/600 °C

RH pressure/Temp:

35 bar/600 °C

Mass flow:

100 kg/s

Weight:

~ 7000 tons

Heating surface:

> 500.000 m²

(*) Siemens is owner of the Benson TM patent

Bangkok, Oct. 3 – 5

Proven

Benson

Design

Concept

Siemens Benson HRSG design, 19 units built, e.g. Malzenice, Gönyü, Severn Power, Sloe Centrale…

Based on F-class technology as executed in e.g. Karstoe, Simmering, Timelkam

Based on Siemens Benson TM Technology * (Elimination of HP drum)

Utilization of high temperature materials applied for 600 °C Steam Power Plants

Siemens

Design

Principles

Benson

Evaporator

Design

600 °C

Technology

PowerGen Asia 2012

HRSG + Plant Development in one Hand

=

Innovation based

on proven

technology and

materials

© Siemens AG 2012 Siemens Energy Sector

Figure 9 BENSON HRSG designed for 600 °C steam temperature

All flexibility features – well known from our SCC5-4000F series – were implemented in SCC5-8000H. The FACY (FAst CYcling) concept with its key components is summarized in Figure 10.

SCC5-8000H 1S – a proven concept optimized for highest operational flexibility High-capacity Stack damper
SCC5-8000H 1S – a proven concept optimized for
highest operational flexibility
High-capacity
Stack damper
de-superheater
FACY
Benson TM
ST stress
Fast Cycling
technology
controller
Advanced
steam parameter
Up to 600 °C
Optimized GT
load ramp
Low complexity
(No GT external
cooling interface)
Proven cycle
concept
Triple pressure
HRSG stand-
Condensate
reheat cycle
by heating
polishing plant
Specific features included in our advanced 8000H plant cycle design for
most flexible and reliable operation
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector

Figure 10 SCC5-8000H 1S optimized design to allow highest operational flexibility

The implementation of the FACY concept in combination with the hot start on-the-fly allows a hot start-up time reduction down to less than 30 minutes in comparison to “conventional” hot starts. The concept is based on a procedure for parallel start-up of gas and steam turbines, while monitoring and controlling the temperature gradients within limits acceptable for all critical plant components and long term operation experience with different steam conditions in the Siemens turbine design. A new start-up sequence, which avoids gas turbine load hold points, was implemented. The main innovation here is the early steam turbine starting point with earlier acceleration and loading of the turbine. The FACY technology allows for higher number of starts and faster cycling without compromising plant lifetime consumption.

3. Operational experience

3.1. Test and validation of the SGT5-8000H and SCC5-8000H

The 8000H program was started in 2000, and after thorough development and engineering successful component testing paved the way to the first field installation in a simple cycle configuration built by Siemens for E.ON Kraftwerke in the Irsching site (Figure 11).

Irsching Units 1 - 5, as of June 2011 Owned by E.ON Kraftwerke Block #4
Irsching Units 1 - 5, as of June 2011
Owned by E.ON Kraftwerke
Block #4 – SCC5-8000H
Ulrich Hartmann
1S
Block #5 – SCC5-4000F 2x1
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector

Figure 11 Irsching power plants – Unit 4 built based on SCC5-8000H 1S and the first commercial

SGT5-8000H

First firing took place in December 2007. First synchronization to the grid occurred on March 7, gas turbine base load was achieved on April 24, 2008, and the field validation program was successfully completed in August 2009, after over one and a half years in simple cycle operation. The total 18-month validation program consisted of multiple measurement campaigns, covering the full operating range starting from hot

commissioning to a final endurance test in open cycle configuration. This validation phase confirmed its functionality, operational capability, performance, serviceability, integrity and stability limits.

Following completion of GT field validation in August 2009, extension and conversion to a combined cycle power plant started at Irsching and was completed on schedule in December 2010. The conversion to a complete combined cycle power plant went off without hitch within a very tight time frame of only 16 months. With the re-ignition of the gas turbine in its new configuration for the first time in January 2011 and steam admission just few weeks later, the commissioning phase, including the final test and validation of the entire combined cycle power plant, was begun. Only few days after this, in March 2011, it was possible to run the plant at combined cycle base load for the first time. The further commissioning activities up to June 2011 were marked by tests to validate the performance of the components and the overall thermal cycle and to demonstrate the plant's high operational flexibility and capability in meeting the most stringent grid requirements, to optimize the startup times and load rejections, and to verify its output and efficiency.

Once all tests were completed, the plant was adjusted to the guarantee conditions, which were agreed with E.ON in 2005 and increased in 2008 (in terms of output, efficiency, emissions and startup times). During the customer performance test the plant achieved for the first time in the history of power plant engineering a net electrical efficiency of 60.4% while producing at the same time a unit net output of 561 MW complying with all contractually defined emission limits. The achieved efficiency level and the low emissions (NO x below 25 ppm and CO below 10 ppm) make Irsching 4 – SCC5-8000H 1S a milestone in environmentally friendly fossil power generation

In terms of operational flexibility following results were achieved under combined cycle operation conditions:

Fast hot start-up using FACY TM technology and hot start on the fly: the overall plant can be very reliably run up to full load in less than 30 minutes, putting over 500 MW in to the grid at combined cycle load ramps up to 50MW/min. It should

be mentioned that under simple cycle operation conditions, GT full load can be achieved within 10 minutes at GT load ramps of 35MW/min.

Plant fast shut down was achieved in less than 30 minutes. During the combined cycle operation fast plant de-loading was also tested to demonstrate its ability to run under stable conditions at minimum load (combined cycle load of approx. 100MW or less than 20% of rated output with both GT and steam turbine in operation).

Fast cycling dynamic load tests showed excellent capability to effectively contribute to grid stabilization and to run in a fast load following mode. Load gradients up to 35 MW/min. were demonstrated and the plant achieved over 200 MW load increase and decrease in less than 7 minutes, while all systems were running under perfectly stable conditions.

– Grid support capability: The UK grid code is the most stringent in the world. Two major aspects of the UK grid code define the requirements for frequency response and load stabilization in case of island grid formation. In terms of primary and secondary frequency response, the Irsching 4 plant surpassed the UK grid code target as a 12% load increase initiated by a simulated frequency drop was demonstrated in less than 10 seconds. In order to fulfill the island formation requirement a load reduction of 45% within 6 seconds as an instantaneous answer to the detected frequency deviation in the gas turbine controller was achieved. Such capabilities are indispensable to allow effective grid stabilization and avoidance of grid blackouts, especially within small grids.

Prior to customer handover world record performance test runs were done. The plant was operated and tested according to its design conditions. These runs have demonstrated, also under the supervision and verification of the independent certified body TÜV, the potential that this plant harbors in this configuration for further planned commercial projects. The achieved performance at Irsching 4 reference site conditions were:

– Power output of 578 MW

Efficiency of 60.75% (net) with compliance to the emission limits.

Since the customer handover in July 2011, the gas turbine SGT5-8000H has achieved in the Irsching 4 power plant in sum more than 17,000 equivalent operating hours (whereof more than 12,5000 EOH in combined cycle operation) and more than 400 starts (Figure

12).

Operational Record Ulrich Hartmann CCPP Irsching unit #4 as of July 30, 2012   Phase
Operational Record Ulrich Hartmann CCPP Irsching unit #4 as of July 30, 2012   Phase
Operational Record Ulrich Hartmann CCPP Irsching unit #4 as of July 30, 2012   Phase
Operational Record Ulrich Hartmann CCPP Irsching unit #4 as of July 30, 2012   Phase
Operational Record Ulrich Hartmann CCPP Irsching unit #4 as of July 30, 2012   Phase

Operational Record Ulrich Hartmann CCPP Irsching unit #4 as of July 30, 2012

Operational Record Ulrich Hartmann CCPP Irsching unit #4 as of July 30, 2012
  Phase I GT Testing (open cycle) Phase II / Combined cycle plant operation Starts
  Phase I GT Testing (open cycle) Phase II / Combined cycle plant operation Starts
  Phase I GT Testing (open cycle) Phase II / Combined cycle plant operation Starts
  Phase I GT Testing (open cycle) Phase II / Combined cycle plant operation Starts
 

Phase I GT Testing (open cycle)

Phase II / Combined cycle plant operation

Phase II / Combined cycle plant operation

Starts

85

326

Total EOH

4.365

12.689

Grand Total

GT > 17.054 EOH

Combined Cycle > 12.689 EOH

Irsching 4 is running with outstanding availability and startup reliability

Bangkok, Oct. 3 – 5

PowerGen Asia 2012

© Siemens AG 2012 Siemens Energy Sector

Figure 12 Operating experience gained in Irsching 4

Since commercial operation two planned short time outages after 6,000 EOHs and 8,000 EOHs were performed and allowed a visual inspection of the hot gas path and confirmed the anticipated excellent engine conditions. Based on these results the decision was made to potentially defer the combustor inspection to the 12,000 EOHs outage. After a further visual inspection at 10,000 EOH finally the combustor inspection took place during the outage in May 2012. The engine conditions and the hot gas path components were found to be in excellent conditions. Since then the unit was brought back in service successfully.

With start of the commercial operation the combined cycle unit 4 in Irsching impressively showed its ability as a daily start/stop unit. Figure 13 shows the typical dispatch situation of Irsching unit 4. Although the plant was designed and sold as a base load unit, the current dispatch situation can be perfectly matched thanks to the plant’s capacity in terms of operational flexibility. The plant is typically starting up early in the morning with the increasing power demand. Over the day the unit is running in a load following mode with a cycling load profile between full load and 50 – 60% part load at the time same meeting the emission compliance and expected efficiency. Overnight shut downs enable our customer to save fuel cost and unnecessary emissions of NOx, CO and CO 2 . The intensive monitoring of Irsching 4 shows outstanding plant availability and starting reliability, which is necessary for a daily cycling operating regime.

Operation profile of Irsching 4 Jun. 11 – Jun. 25, 2012 Plant output GT speed
Operation profile of Irsching 4
Jun. 11 – Jun. 25, 2012
Plant output
GT speed
Monday
Monday
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector

Figure 13 Typical daily load profiles of Irsching unit #4

3.2. Test and validation of the SGT6-8000H

The SGT6-8000H is a full scaled design (geometry factor 1.2) to the SGT5-8000H. The major difference is the number of burners (12 instead of 16) and the related design

adjustments (e.g. casing; transition from burner to turbine vane 1) in order to be able to use the same combustion system for 50 and 60Hz Version.

Siemens has a vast and long lasting experience in scaling gas turbine design (e.g. SGT5- 2000E/SGT6-2000E or SGT5-4000F/SGT6-4000F). This approach allowed Siemens to achieve a relative short design phase for the 6-8000H; in fact the design of the SGT6- 8000H was initiated during the validation phase of the SGT5-8000H while the first commercial contract was signed only 2 years later. Of course the approach to start design after having already 50Hz validation results available significantly increased the confidence in achieving the desired design targets. There is still some remaining risk in scaling, especially for the non-scaled design parts. Examples are turbine inlet temperature profile; the specific transition-piece from combustor to turbine inlet and even production processes for the individual parts.

Siemens experience in scaling allows for precise prediction of the items in question. However, in order to further limit the implementation risk of such a scaled prototype for both customer and Siemens, it was decided to perform a stringent test- and validation program also for the SGT6-8000H. Even if the risk for such an event is low, any unexpected prototype issue will cost both OEM and customer valuable time and money, if experienced during commissioning in a commercial project. Siemens policy is to avoid this. Therefore the 60Hz 8000H engine was implemented in the Berlin Test Facility within the Berlin gas turbine factory. Connected to a water brake instead of a grid connection via a generator, the engine can be operated at the design frequency of 60Hz as well as any desired under- and over-frequency despite being located in a 50Hz region. After a significant rebuilt of the test center in 2010/2011 the first SGT6-8000H was operated for a ca. 10 months test phase.

Test Bed in Berlin allowing up to 300 MW Testing at various speed conditions thanks
Test Bed in Berlin allowing up to 300 MW Testing at various
speed conditions thanks to a water brake concept
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector

Figure 14 Berlin gas turbine test bed facility

Focus of the validation phase was threefold. One target was to confirm the design of the scaled engine like hardware integrity, thermodynamical behavior, emission profile etc. Second target was to confirm the validation results of the SGT5-8000H. Third target was to add some additional test topics that were not conducted in Irsching like oil operation or sub-25ppm NOx operation. The test program was structured accordingly. The first test phase consisted of a baseline testing while oil operation or sub-25ppm NOx testing was conducted after corresponding outages.

The targets of the SGT6-8000H test program were fully achieved. The data retrieved confirmed both performance prediction of SGT6-8000H and SGT5-8000H; all engine parameters (temperatures, pressures etc.) were as expected; predicted temperature profiles were confirmed via thermal paint testing; under- and over-frequency behavior of the engine was confirmed; operational behavior on both fuel gas and fuel oil did meet the requirements. Lessons learned from the validation phase are implemented in the production engines for the commercial projects; as a result any impact on the commercial projects could be avoided. So it can be concluded that the approach to validate also

the scaled SGT6-8000H did prove to be beneficial for both Siemens and the Siemens customers.

4. Market launch and first commercial references

With the successful conclusion of Irsching 4 and the related validation and testing phases, Siemens Energy is the first OEM to operate a gas turbine engine and a combined cycle plant with efficiency far beyond 60%. Siemens impressively demonstrated that world-record technology is commercially available to the customers and that the 8000H technology has a clear advance of years on the gas turbine and combined cycle market.

Despite the direct scale approach, the full scale 60Hz engine was tested in the Berlin test facility, prior to shipment to first customer’s site. Indeed the next commercial success was achieved in Florida, USA, where 6 units of the SGT6-8000H were placed. Both Florida Power & Light sites in Riviera Beach and Cape Canaveral are equipped with the 8000H gas turbine in a multi-shaft configuration (3 on 1) and provide approximately 1200 MW electrical energy each. At the same time period the next order from South Korea for the supply of a complete combined cycle power plant equipped with the SGT6-8000H in a single shaft configuration was placed by the independent power producer GS Electric Power & Services, Ltd. As a consortium leader, Siemens is installing the 400MW class power plant Bugok 3 as a turnkey project. In 2012 further six units were successfully sold in South Korea, with ANSAN as a multi-shaft configuration and ANDONG, POSCO as a single shaft arrangement. The first 60Hz units will start the commercial operation already in summer 2013. Following the success in Asia Siemens Energy has received an order for turnkey erection of the Lausward combined cycle power plant with district heat extraction in Düsseldorf, Germany. The order was placed by Stadtwerke Düsseldorf AG (SWD). With an electrical unit output of around 595MW and a net efficiency of over 61% as a single shaft arrangement, the Lausward CCPP will set a new world record. In addition, the generated thermal energy will be used for the district heating system in the city of Düsseldorf. Never before has it been possible to extract 300 MWth of district heat from a single power plant unit in combined cycle operation. Thus, the overall efficiency of the natural gas fuel will be around 85 percent. The Lausward CCPP plant will be one of the most efficient and environmentally sustainable plants in the world. An overview of the references of the SGT-8000H and accordingly SCC-8000H is shown in Figure 15 SGT-8000H & SCC-8000H references

 
 
 

SGT-8000H References

Ulrich Hartmann – Irsching 4, Germany 1x SCC5-8000H 1S, >17.000 EOH
Ulrich Hartmann – Irsching 4, Germany
1x SCC5-8000H 1S, >17.000 EOH
Ulrich Hartmann – Irsching 4, Germany 1x SCC5-8000H 1S, >17.000 EOH
Cape Canaveral / Riviera Beach, Florida, USA 2x SCC6-8000H 3x1, COD 05/2013, COD 05/2014
Cape Canaveral / Riviera Beach, Florida, USA
2x SCC6-8000H 3x1, COD 05/2013, COD 05/2014
Cape Canaveral / Riviera Beach, Florida, USA 2x SCC6-8000H 3x1, COD 05/2013, COD 05/2014
Bugok 3, South Korea 1x SCC6-8000H 1S, COD 08/2013 Ansan, South Korea 1x SCC6-8000H 2x1,
Bugok 3, South Korea
1x SCC6-8000H 1S, COD 08/2013
Ansan, South Korea
1x SCC6-8000H 2x1, COD 01/2015
 
Andong, South Korea 1x SCC6-8000H 1S, COD 04/2014
Andong, South Korea
1x SCC6-8000H 1S, COD 04/2014
Andong, South Korea 1x SCC6-8000H 1S, COD 04/2014
Lausward, Germany 1x SCC5-8000H 1S CHP, COD 02/2016
Lausward, Germany
1x SCC5-8000H 1S CHP, COD 02/2016
Düsseldorf, Düsseldorf, ´Center ´Center
Düsseldorf,
Düsseldorf,
´Center ´Center
Düsseldorf, Düsseldorf, ´Center ´Center
Posco Power 2, South Korea 3x SCC6-8000H 1S, COD 11/2014, 02/2015, 05/2015
Posco Power 2, South Korea
3x SCC6-8000H 1S, COD 11/2014, 02/2015, 05/2015
Posco Power 2, South Korea 3x SCC6-8000H 1S, COD 11/2014, 02/2015, 05/2015
 

Status: August 2012

15 SGT-8000H gas turbines sold

 

Bangkok, Oct. 3 – 5

PowerGen Asia 2012

© Siemens AG 2012 Siemens Energy Sector

Figure 15 SGT-8000H & SCC-8000H references

5. Conclusion

This paper provides an overview regarding the Siemens SGT-8000H and the related SCC-8000H series product portfolio. The core engine of Siemens’ H Class is fully air cooled without having any external interfaces to external coolers. This key design feature is decisive for shifting the operational flexibility of the overall solution beyond the existing F Class limits, while providing a net performance far above 60%.

The main elements of the different solutions for 50Hz and 60Hz were presented. Siemens’ H Class product portfolio is based on single shaft and multi shaft arrangements with optimized water / steam cycle and live steam parameters up to 600°C and 170 bars. The product portfolio offers several solutions with a flexible scope of supply, which drastically reduce life cycle costs and specific investment costs.

The SGT-8000H is fully field tested and validated. An overview about all activities prior to market introduction was shown and which demonstrates Siemens’ approach in keeping the overall technology risk and hence customer’s risk at a low level. The Irsching unit #4 has already achieved more than 17,000 EOHs in commercial operation and has impressively demonstrated the high level of gas turbine and plant availability and starting reliability. In addition, the full scale 60Hz engine is tested and validated in the Berlin plant test facility prior to customer’s site shipment in order to limit remaining scaling risks. The operational records of our field validations and commercial operation have confirmed our expectations towards engine design reliability.

Siemens 8000H product lines are the result of a long term development program with significant financial investments, demonstrating Siemens commitment to meet customer’s expectations and to durably improve customer’s value. Since commercial

availability 15 1 units were sold. This great success confirms the achievements in design, test and validation over more than a decade.

1 Status August 2012

6. References

[1]

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POWER2007-22100

[2]

P. Ratliff, P. Garbett, W. Fischer, “SGT5-8000H Größerer Kundennutzen durch die neue Gasturbine von Siemens”, VGB PowerTech, September 2007

[3]

U. Gruschka, B. Janus, J. Meisl, M. Huth, S. Wasif, “ULN System for the new SGT5- 8000H gas turbine: Design and High Pressure Rig Test Results”, ASNME Turbo Expo GT2008-51208

[4]

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[5]

R. Rudolph, R. Sunshine, M Woodhall, M. Haendler, “INNOVATIVE DESIGN FEATURES OF THE SGT5-8000H TURBINE AND SECONDARY AIR SYSTEM” ASME Turbo Expo, June 2009, Orlando, Florida, USA, GT2009-60137

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[7]

W. Fischer, S. Abens, “SGT5-8000H Design and Product Validation at Irsching 4 Test Center”, VGP Power Tec 09/2009

[8]

Dr. M. Huth, U. Gruschka, Dr. B. Janus, J. Meisel, “Design of the Combustion System for the SGT5-8000H and First Experiences in the Irsching Power Plant”, VGP Power Tech 10/2009

[9]

W. Fischer, “SGT5-8000H / IRSCHING 4: On The Way To 60% World Record

Efficiency And Path To 60 Hz SGT6-8000H”, 18 th Conference of the Electric Power Supply Industry (CEPSI), Taipei, Taiwan, Oct. 2010

[10]

Dr. S. Abens, W. Fischer, „SGT5-8000H / IRSCHING 4, On the way to 60 % World Record Efficiency And Path to 60 Hz SGT6-8000H”, PowerGen Asia, Singapore, Nov. 2010

[11]

L. Balling, Dr. U. Tomschi, A. Pickard, G. Meinecke, “Fast Cycling and Grid Support Capability of Combined Cycle Power Plants to optimize the Integration of Renewable Generation into the European Grid: Live examples from projects in NL, F, UK, D”, PowerGen Europe, Amsterdam, June. 2010

[12]

Dr. K. Sfar, T. Hagedorn, “Siemens H Class CCPP Technology: Implementation of the first 50Hz unit and update on latest 60Hz plant design standard”, PowerGen Asia, Kuala Lumpur, Sept. 2011

[13]

W. Fischer, A. Städtler, “SGT5/6-8000H & SCC5/6-8000H Product Line: Advanced Generation of High Performance Gas Turbine and Combined Cycle System”, 6th IDGTE GT Conference, Milton Keynes, November 2011

[14]

A. Städtler, “SGT5-8000H/SCC5-8000H 1S First experience of Commercial Operation at Irsching 4”, Russia Power, Moscow, March 2012

[15]

W. Fischer, “SGT-8000H Product Line: Actual Update”, PowerGen Euorpe, Cologne, Jun. 2012

7.

Copyright

The content of this paper is copyrighted by Siemens AG Energy Sector and is licensed only to PennWell for publication and distribution. Any inquiries regarding permission to use the content of this paper, in whole or in part, for any purpose must be addressed to Siemens AG Energy Sector directly.

8. Disclaimer

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