Energy Service, Oil & Gas and Industrial Applications Services

Boost your profitability

with sustainable solutions
Modernizations and upgrades for industrial steam turbines

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 Competitive solutions
to meet new requirements
Industrial steam turbines can have service lives of 30 or more years

and are important components in many industrial processes, the

oil and gas industry, and power generation. It is very likely that

the operating parameters of turbines will change along with market

conditions over such long periods, as well as when new processes

and laws, such as environmental standards, come along.

2
Modernization programs by Siemens help
operators conserve precious resources while
always keeping their systems at peak levels
of efficiency, reliability, and availability
with OEM-quality services.
Operational and economic benefits
Thoroughly planned modernizations and
upgrades help you to keep downtime and
production losses to a minimum. At the
same time, your turbine can be optimized
in terms of efficiency or steam consumption
by implementing state-of-the-art technology
and innovative solutions. Apart from this,
modernizations and upgrades are cost-
effective, since:
Existing parts, systems, and components
can be reused, reducing investment costs
Retrofitting or upgrading a machine
requires less downtime than installing
a new turbine
You continue to work with familiar
equipment and may even have relevant
spare parts in store
What is more, Siemens stringent analysis
ofyour plants operation allows to
implement tailored solutions for specific
operational conditions.
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 OEM service provider for:

ABB/Alstom Industrial Steam Turbines

ABB Prvn brnnsk strojrna
AEG Kanis
AEG/KWU
ASEA STAL
Austrian Energy
BBC Industrial Steam Turbines
Delaval
GMB Grlitzer Maschinenbau
Hamburger Turbinenfabrik
Kanis Turbinenbau
Khnle, Kopp & Kausch (KK&K)
MAN Industrial
STAL LAVAL
Westinghouse

Staying competitive Siemens acquired many other manufacturers

No operator can allow its competitive position and integrated their equipment into its port-
to be weakened in an era of global competi- folio. As a result, Siemens can now offer
tion. Thats the reason for constant invest- OEM services for turbines manufactured
ments in new technology and optimization under another brand name. You can directly
of processes and conditions on the market profit from Siemens knowledge of multiple
keep changing, too. Industrial steam turbines manufacturers and industries, as well as
offer a great opportunity to reduce costs itsall-round experience in developing and
andboost the performance of your plants. implementing innovative solutions.
Ifthe original requirements change due to
A reliable partner, anywhere in the world
differences in operating parameters or other
Siemens globally integrated service orga
constraints, it will be worthwhile to modern-
nization is available 24/7 around the clock.
ize steam turbines and adapt them to new
With corresponding Centers of Competence,
conditions. Especially since upgrades can
Siemens is fully capable of reviewing all
domore than simply optimize processes
inquiries related to steam turbine modifica-
andcan also extend the life of the turbines
tions on very short notice, and then develop-
themselves. Moreover, it usually takes less
ing the most suitable recommendations for
time to modernize than to manufacture a
the application.
newsteam turbine.
A partner with a thorough
knowledge of turbines
Siemens has been developing, building,
and servicing steam turbines for extremely
diverse applications for over a century now.
As it developed into one of the worlds lead-
ing suppliers of industrial steam turbines,

4
 Custom steam
turbine service
No two plants are alike their components
are just as individualized so Siemens
offers tailor-made services of the highest
quality.

From a thorough analysis to a tailored solution

Analysis comes first
When a plant is to be re-engineered, S iemens
starts with a comprehensive analysis of the
condition of both the turbine and the entire
system. A look at current and future require-
ments will quickly show which systems, com-
ponents, and parts can still be used and which
will have to be adapted and replaced. Siemens
proposes solutions to fulfill your requirements
based on that analysis. The last step is a feasi-
bility analysis that lets you evaluate the costs
of retrofits or upgrades for your existing tur-
bines and the system. Whenever possible,
modernization is scheduled so that all work
can be done during planned downtime with-
out additional shutdowns of production.
More power pays off
Modernizations and upgrades by Siemens will
quickly pay off. Your specific requirements are
taken into account, so you get a steam turbine
that is precisely customized for maximum effi-
ciency.
Footprint solutions
A footprint turbine is a replacement turbine
that may have slight changes to the base
frame or foundation. At the same time, the
existing oil system, the driven machine, and/or
the gear unit can be adapted according to new
operating parameters or be used without any
changes.
A footprint turbine is especially appropriate
when modifications must be made for
new operating data or when the service
life of highly stressed components has
been exhausted.
One argument for using a footprint turbine
isthe increase in plant availability resulting
from minimized production downtimes. The
components in the new turbine are designed
and manufactured according to the latest
state-of-the-art technology.
As existing components can still be used,
theinvestment expense is lower than for the
purchase of a completely new turbine system.

5
 A comprehensive
portfolio of services
Siemens modernizations and upgrades
for steam turbines have been specially
developed to meet the requirements for
all different types of steam turbines and
their applications.

Decisive improvements for more

efficient and cost-effective operation
State-of-the-art blade design and Adaptation to more flexible operating
seal technologies parameters/optimization of the turbine
Siemens offers ultramodern blade technology low pressure (LP parts)
that combines robustness and the highest For operators of condensing steam turbines
efficiency. it may become uneconomical to produce
electricity due to changes in the market. A
Brush seals on the balance piston labyrinth
reduction in power output or an increase in
and improved thermodynamic configuration
process steam are ways to restore profitabil-
of the blades improve efficiency, reduce fuel
ity. Options range from cutting back/optimiz-
consumption, and lower emissions.
ing the quantity of low pressure steam to a
Improved turbine operation under complete conversion of a condensing turbine
high exhaust wetness conditions into a back-pressure turbine.
Waste incineration and biomass plants
It may be necessary to make t urbosets flexible
mayoperate with relatively low live-steam
enough to be able to respond to changes
parameters to protect the boiler against
inloads on the power grid. Siemens offers
high-temperature corrosion. That results
solutions for improving fast start capability,
inhigh exhaust wetness conditions for the
reducing temperature-related voltage peaks
turbine, which increases erosion of the low
in turbine components, and optimizing the
pressure portion, including the end-stage
steam channel.
blades. This can be addressed by resistant
materials and changes in geometry of the
end-stage blades to reduce erosion protec-
tion. Hollow guide vanes to suction away
excess moisture from the exhaust steam are
also available for certain types of blades.

6
Retrofitting control systems to enable System-related view of steam
remote monitoring and diagnostic turbine auxiliary systems
services (RDS) Thanks to decades of experience with turbine
Many steam turbines are still operated using production and plant construction, Siemens
mechanical-hydraulic or older electronic isalso an expert at optimizing steam turbine
controls. Wear and tear on components and auxiliary systems. That includes optimum
an uncertain supply of spare parts for older adjustment and integration of turbine-related
electronic systems can impair smooth opera- systems, reducing the use of fuels and oper-
tion. And it isnt always possible to integrate ating materials, lower consumption of on-
into a higher-ranking modern process control site power, and enhanced plant efficiency
system. and availability.
Siemens offers a modular approach to Some practical examples of Siemens
modernizing turbine controls from simple, comprehensive portfolio of modernization
cost-effective retrofitting to comprehensive solutions are shown on the next few pages.
full-scope turbine control systems. Disre
garding low-cost or high-end solutions
APIconformity can be realized. In addition,
remote diagnostic services (RDS) can be
offered provided that corresponding com
ponents are installed.
The positive effects of modernizing t urbine
controls include greater availability, a longer
service life, shorter startup and shutdown
times, and lower maintenance costs.

7
 BBC steam turbine after retrofitting. The following components

Case studies were modernized:

n High-pressure nozzles n Guide blade carrier n Shaft labyrinth bushing

for increased
n Rotor n Balance piston bushing

efficiency

Higher efficiency in a very short time

The challenge The benefits
A customer in the paper industry had to This modernization project offered numerous
modernize the rotor of a BBC steam turbine advantages to the customer. Using an experi-
and turned to Siemens. The aim of the enced partner for overhauling the turbine
modernization was to restore the technical helped reduce the length of the project. At
performance of the turbine during an the same time, the customer was able to
upcoming complete overhaul while strictly choose the best solution based on specific
limiting down time. cost and process parameters. Finally, within
the shortest possible time the customer had
The solution
a turbine with new internals that was well
A complete damage and error analysis was
equipped for the challenges of the future.
done after taking stock. The analysis showed
That includes the fact that today it is again
that over the years the rotor blades and
operating at its original very high level of
guide vanes had eroded and sheet metal
efficiency, an improvement of 7 to 10 per-
seals had been destroyed with corresponding
cent compared with the old rotor that was
losses in efficiency. In addition to conven-
damaged by erosion.
tional repair, the alternative of a completely
new rotor was suggested. After evaluating
allof the options, the customer chose the
new rotor. Siemens supplied a new rotor
with three guide blade carriers and gland
bushings. The overhaul was completed
within theagreed time frame of no more
than threeweeks, and the system was
onlineagain as scheduled.

8
 Dominant consequences of pitting corrosion

Pitting
corrosion
Peaks of stresses
at pitting areas

Micro cracks
based on notch
effects Bending
stress

Design

Existing

Regaining state-of-the-art efficiency

The challenge The costs for repair, the improved reliability,
A BBC steam turbine in a waste incineration better efficiency, shorter delivery time, and
plant had been in use for almost 40 years the expected return on investment led the
when a fatal defect occurred at start-up. customer to select the state-of-the-art blading
Although the unit was tripped immediately, (option 2).
a root cause analysis revealed severe damage
The benefits
that called for an overhaul of the turbine.
After the modernization project was com-
The biggest demand was for short-term
pleted, turbine performance increased by
repairs, preferably with state-of-the-art
880 kW (or 6.3 percent), leading to addi-
design and improved efficiency. The unit
tional profit for the customer. At the same
inquestion is a back-pressure industrial
time, the customer benefited from improved
steam turbine with low live steam parame
availability and reliability of the plant, thanks
ters,driving a generator with maximum
to the application of highly reliable, advanced
performance of 14 MW.
turbine components. In addition, the outage
The solution period for the modernization was much
Dismantling the turbine revealed that the shorter than it would have been for the
entire turbine was severely corroded and installation of a new turbine, and existing
asuspected rotating blade failure in one components could be reused.
rowhad damaged all subsequent stationary
and rotating blades. To repair the turbine,
Siemens developed a modernization concept
with two options for the exchange of turbine
blading:
Option 1: using the original free-standing
blading design
Option 2: using state-of-the-art
shrouded blading

Heavy corrosion of rotor

9
 Case studies Inlet
nozzle
plate
for process
optimization
Retrofitting for higher earnings
The challenge
Siemens installed an SST-900 steam turbine
at a paper mill. Its main purpose is to provide
steam for the pulp and paper process, and
electricity through a generator. After a pro-
cess update, the flow through the turbine
changed because less steam was required
bythe process. As a consequence, the tur-
bine operated off its original design point
resulting in lower efficiency and a loss of
power. Siemens focused on redesigning the
steam path to the new process/boiler condi-
tions in order to increase turbine efficiency
and the total number of MWh produced
annually.
The solution
An assessment of the actual process parame-
ters showed that the inlet flow had decreased
by about 20 percent compared to the design
data, whereas inlet pressure and tempera-
Before overhaul: Broken sealing After overhaul: Remake sealing strips
strip due to wear and tear
10
Diaphragm
#29
Extraction
nozzle
plate
Rotating
blades
#29
ture remained more or less constant. As a
result, Siemens optimized the steam path
forthe new site conditions and upgraded
thesealing design along with adopting
othernew features that have been devel-
oped since the turbine was built. For
stages#2 to #9 this meant using new
state-of-the-art diaphragms and blading
inorder to give the customer the best
possible output for the new steam condi-
tions.
The benefits
The pulp and paper plant profits from a
number of benefits realized in their retrofit
project. First of all, the power output for
thenew steam conditions was increased by
six percent compared with the original steam
path. Secondly, the retrofit was cost-efficient
because the existing rotor could be used for
theoptimized blading. And most importantly,
Siemens knew the turbine inside and out
because they were the o riginal manufac-
turer and this significantly speeded up
theentire process.
 Control Guide The retrofit in detail
valve blade The condensing turbine
carrier Turbine
wasextensively modified
rotor
andsuccessfully adapted to
thenew steam parameters.

The split view shows the

turbine before and after
Before
modification.
modifica-
tion

After
modifica-
tion

Guide
blade
carrier

Engineering for lasting improvements

The challenge densing turbine to a back-pressure turbine

A chemical company uses a Siemens steam and adapted the gears, turbine control, and
turbine to generate electricity. Following a monitoring system to the new speeds and
change in process steam parameters, the performance data in order to optimize effi-
turbine had to be operated under partial ciency. Both machines were successfully
load, which markedly worsened its efficiency started up in October 2010.
and was also unprofitable. The customer
The benefits
asked Siemens to modernize its plant with a
The customer benefits from significantly
footprint turbine. At the same time, exhaust
higher power output, because the footprint
steam from the turbine of a waste incinera-
turbine is optimally adapted to the new
tion plant located four kilometers away
process steam parameters. With the double-
would be used to supply additional steam
extraction system precisely modified for the
forthe customers process. That required
new process, the machine works much more
converting the condensing turbine at the
efficiently. Thanks to the injection of back-
incineration plant into a back-pressure t urbine.
pressure steam from the incineration plant,
The solution the customer was also able to stop purchas-
Siemens developed a footprint turbine with ing primary fuel, greatly reducing its CO2
modern shrouded rotors that was an excel- emissions.
lent fit with the new process steam parame-
ters. The turbine control uses the Turloop
system, while brush seals increase the effi-
ciency. The only work that had to be done
onsite was to adapt the internal steam and
oil p
ipelines to the new turbine. The use of
adouble-extraction system in place of the
previous bleed extraction system means
theturbine can handle the customers steam
requirements at all times throughout the
entire operating range. At the incineration
plant, Siemens converted the existing con-

11
 Case studies
for lifetime
extensions

More decades of profitable operation

The challenge andto re-inspect the most critical parts in
The high investment cost and long delivery the hot areas more frequently in a systematic
time of new equipment make it worth con- way.
sidering the alternative of lifetime extension
By the time of the next major overhaul, the
for existing turbine parts. For that reason, a
turbine had been running with no operational
utility company in Sweden asked Siemens to
disturbances. The detailed knowledge of the
conduct a Life Time Extension (LTE) analysis
condition of specific components from the LTE
on a district-heating turbine. By that time,
study made it easy to establish the scope of
the turbine had accumulated about 70,000
the overhaul in advance. All recommendations
operating hours. The challenge was to ensure
presented in the first LTE analysis were imple-
the turbines ongoing operation beyond the
mented. The NDT activities were repeated at
end of its normal design lifetime.
the same locations and using the same meth-
The solution ods, and then compared with the previous
Before the planned overhaul, Siemens results in order to keep track on the turbine
performed a theoretical study with the aging process.
goal of identifying critical components
The benefits
forwhich a reduced operating lifetime
After the second overhaul the turbine had
couldbe projected. The turbines history,
fewer critical components than before the
original design calculations, and Siemens
start of this LTE program, as well as detail
unique experience with similar units were
knowledge of the components condition.
allpart of the evaluation. For some compo-
Acustomized maintenance plan based on
nents, further analysis was recommended
allavailable information was also delivered
toreduce uncertainty and limit the number
bySiemens. The client is now able to plan
of replacements. Finite element (FE) calcu
future inspections and replacements in
lations were made and an extended non-
themost economical way. In addition,
destructive testing process (NDT) based on
thecustomer can expect to benefit from
the theoretical study was performed during
reduced operating costs for a substantial
the overhaul. The LTE study resulted in a
period of time, thanks to the measures
recommendation to replace some compo-
takenby Siemens.
nents during the next planned overhaul

12
Tailored efficiency increase
The challenge reduced by removing the center pilot valve
An ammonia plant operator had to upgrade his inthe valve gear. Siemens also implemented
topping steam turbine. Because the ammonia a set of mechanical improvements, such as a
market is particularly driven by gas prices, larger exhaust end journal bearing, a heavier
increasing the turbines efficiency had top shaft, a larger exhaust end oil drain, and a
priority. After 25 years of service and count- double-acting Kingsbury thrust bearing in
less operating hours, many improvements place of the existing single-acting one.
and upgrades had already been implemented.
The benefits
To achieve the best result possible, Siemens
Thanks to Siemens upgrades, the turbines
designers started the upgrade process with
steam rate improved by approximately
anempty casing, incorporated the latest
six percent. As a result of design improve-
technical expertise, and came up with a
ments and aging loss recovery, considerable
stepfunction improvement package.
energy savings were achieved. The upgrade
The solution also offers the possibility to reinstall the
Due to the focus on cost savings, this retrofit original internals as spares, using special
involved wholesale changes to an already adapters. In addition, the overall plant
mature design steam turbine. To improve capacity was increased. Combined with
themachines efficiency and augment the equipment improvements, this provides
reheat effect, Siemens added one stage an overall attractive payback.
raising the number of stages to three
andalso slightly raised reaction and velocity
ratio. Also, further radial seals were added
tocontrol leakage losses in the steam path.
Additionally, Siemens used a full arc of blad-
ing and axial entry blading to eliminate the
losses for missing blades now found in the
steam turbine. Valve pressure losses were

13
 Case studies
on controls
upgrades & RDS*
* Remote Diagnostic Services
Fast, inexpensive remote support
The challenge
Following a fire, a textile finisher had to repair
its industrial steam turbine andreplace its
control technology, including switchgear
cabinets. All work had to be done in the
shortest possible time to recommission the
turbine as soon as possible. The customer
also wanted to get quick, precise support
inthe future whenever questions arose
about operation or fault management.
The solution
In addition to the mechanical repair work,
components for remote support and a
remote monitoring system (RMS) were
installed during replacement of the control
technology with the modular TURLOOP S7
control system. Some of the user stations
were designed as engineering stations and
linked to the OEM service using a highly-
Twofold monitoring: The turboset
at a textile processor
14
secure connection via the common Remote
Service Platform (cRSP) from Siemens. The
system records all accessible process and
operating data and transmits itdaily for
monitoring and diagnostics.
The benefit
Thanks to the cRSP connection, Siemens
wasable to provide support to the people
working on the startup the first time the
newcontrol technology went online.
Thisincluded simultaneous (online) work
bytheTURLOOP development engineer
(atSiemens) during adjustment or expansion
ofthe control technology to fulfill additional
customer requirements. It offered superior
support for the customer and avoided
needless coordination costs. In the future,
Siemens will be able to advise the customer
more quickly and less expensively on all
issues and requested changes related to
control technology, visualization, and opera-
tion. The online availability of all relevant
operating data is vital for keeping response
times as short as possible, since this allows
remote error detection and increases the
availability of the system.
 Control system topology
Serial connecton to existing DCS Operator station 1

control Ethernet WIN CC

room
Main

Junction box with emergency stop push button

Redundant 230-V AC power supply 50 Hz/60 Hz

DSL/LAN connection Redundant 110-V AC/DC power supply 50 Hz/60 Hz
Turbine control cubicle (H/W/D) 2,200 mm x 1,200 mm x 600 mm

Power supply Power supply

RMS router for remote SITOP SITOP Signal exchange
monitoring services from/to MCCs
S7-400 PLC for S7-400 PLC for
turbine governor turbine protection
equipment

All 24-V DC consumer in cubicle

Electrical

Profibus and
ET200 or S7 400 IO modules ET200 or S7 400 IO modules hard-wired signal
room

exchange with
generator
protection and
Profibus Profibus AVR System

3-channel speed measurement for 3-channel axial position

governor and overspeed protection measurement for Emergency stop push button
(incl. display) protection (incl. display) (mounted in cubicle door)
Turbine

Hard-wired signal exchange from/to TCC/field

hall

Better performance through optimized controls

The challenge The benefits Modernization measures:
An Indonesian pulp mill customer relied Apart from the improved control functions, Replacement of control
onSiemens expertise for implementing a the customer also enjoys the peace of technology with components
turbine controls upgrade during a major mindbrought about by the availability of for remote support and
overhaul of the entire plant. The controls allrelevant spares through the international monitoring
Some user stations were
upgrade was urgent due to availability Siemens service organization. In addition,
designed as engineering
issues, for example: easy implementation of new operating
stations and connected to
parameters and functions as well as easy
the old programmable logic controllers OEM service over a highly-
adaptation to new processes was feasible. secure cRSP connection
(PLCs) have been phased out
And, most importantly, the remote connec- Recording of all accessible
no spares and support available for
tion to the Siemens experts results in quick process and operating
the installed visualization system data, daily monitoring
service support and the feasibility to plan
the old speed and axial displacement and diagnostics
proactive and preventive maintenance
measuring system is no longer available
measures.
The solution
Siemens installed the modular TURLOOP S7
turbine control system and Siemens S7 PLC
hardware. Turbine and process control
aswell as protection functions were adapted
to the existing plant process. A new process
visualization allows the operators to analyze,
control, and record all operating parameters.
In addition, new hardware for speed/axial
displacement and vibration and relative
extension monitoring was installed for high
operational safety and simplified trouble-
shooting. The connection to higher-level
control systems is established via serial
interfaces with Modbus and Ethernet
protocol and for optimum online support,
anew Remote Monitoring System (RMS)
wasimplemented.
(TURLOOP) Turbine Touchscreen PC for operation
control cubicle and visualization

15
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Energy Sector
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