Protection notice / Copyright notice Siemens AG 2009. All rights reserved.
VGB ConferenceGas Turbines and
Operation of Gas Turbines 2013
11-12 of June 2013, Friedrichshafen, Germany
Gas Turbine Performance and Maintenance Continuous Improvement
Dr. V. Navrotsky,
Siemens Industrial Turbomachinery ABFinspong, Sweden
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 2
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
Outline
Page 3 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
SGT5-4000F
SGT6-5000F
SGT5-2000E
SGT6-2000E
SGT-800
SGT-700
SGT-600
SGT-500
SGT-400
SGT-200
SGT5-8000H
SGT-100 5
287
198
168
47/50
31/33
25
19
13
7
113
375
8SGT-300Industr
ial T
urb
ines
Utilit
y T
urb
ines
Siemens Industrial gas turbine range
SGT6-8000H 266
SGT-750 36
(MWe)
Siemens offer a wide power range of Gas Turbines for Industrial and O&G markets
Page 4 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Two shaft Gas Turbine10 stage compressor (PR=14)
Two stage compressor turbine
Two stage power turbine
SGT-600 Latest Design FeaturesGeneral Design
Welded compressor rotor,
Two variable guide vanes,
Two bleeds after stage 2 and 5,
All blades are coated (titanium blade 1)
Abradable coating on all stator rings
2:nd generation Dry Low Emission Comb.
Integrated by-pass systemThe design for PG is the sameas for a MD
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 5
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
Page 6 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
DLE introduced 1991Total of units sold today is 300+
66% in Mechanical Drive (MD) application34% in Power Generation (PG)
Total fleet operating hours > 7+ million hours5+ million of those on DLE
Fleet leaders:> 160 000 hours> 3 600 starts
Fleet details
The SGT-600 evolution
SGT- 600Key Core Engine Features and Experience, Data - March 2013
Mechanical Drive 34,100 bhp
Electrical Output 24.8 MW
Efficiency (PG/MD) 34.2%/ 35.1%
Exhaust Mass flow 80.4 kg/s
Exhaust Temperature 543 C
2rd generations DLE emission:
NOx on gas: < 25 ppmV @15% O2
NOx on liquid: < 42 ppmV @15% O2
Technical details
SGT-600 first introduced 1986
1975 1980 1985 1990 1995 2000 2005
Prototype testing 300+ units by SiemensTransfer4 units by
Sulzer
#1 Package
DLE
Uprating
#2 Package FloaterPackage
Sulzer Escher Wyss (CH)
Transfer SEW to ABB STAL AB* (SE)
Siemens
SGT-600 Specification
Reliability: 99.5% Availability: 96.5%
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 7
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
Page 8 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
MGT Combustor technologies2nd and 3rd generation of DLE technology
2nd generation DLE (SGT-600)
3rd generation DLE (MGT)
Combustor Bypass system
MGT DLE technology is effective, simple & reliable(simple principle with no moving parts or staging)
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 9
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
Page 10 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Life Cycle Extension ProgramLife Cycle extension LTA / LTE
Level E + LTA
Operation
Maintenance
Level A
Level B
Level C
Level D
LTE
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
EOH x 1000
SGT-600 Maintenance Schedule with LTA & LTE
Life Time Extension
120,000 EOH level C inspection +:Recommended replacements as
agreed with customer
Upgrade packages as agreed with
customer
Life Time Assessment
Performed at 80,000 EOH
Level E inspection, with analysis and evaluation
Status determination of major components:
Non-destructive
Destructive tests
Cost optimization of operationBeyond 120,000 EOH
Tailored scope of repair & replacement parts for LTE
Page 11 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Compressor turbinevanes # 1 & 2
Compressorturbineblades # 1
Combustionchamber
Power turbineblades # 3
Life Cycle Extension Life Cycle extension = LTA + LTE
Tailored scope of repair & replacement parts for LTE
Page 12 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Blade grooves
Centre holes Blade grooves
Balancing holes
Balancing holes
Centre and bolt holes
Stop holes
Internal radius transitions
Replica tests
Weld examination
Life Cycle Extension Rotor condition examination
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 13
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
Page 14 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Extension of inspection intervals from
20 000 EOH extended to 30 000 EOH by
means of improvements in the lifetime of major components
Advantage of Remote diagnostic service
Improvements of maintenance tools
Maintenance Down Time reduction
Extension of Maintenance Intervals -> 3 overhauls instead of 5
10 20 30 40 50 60 70 80 90 100 110 120
Level C
Level B
Level A
OperationMaintenance
Eq. Op. Hrs x 1000
Major Overhaul
Hot Section Inspection
Borescope
5
2 =
3in
sp
ectio
ns
The Extension of Maintenance Intervals can improve the availability by up to ~ 1 %
Page 15 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
.
SGT-600 Maintenance Down time reductionDevelopment of Maintenance tools
SGT-600 Maintainability improvement results in reduction of Maintenance duration and cost
Compressor blade
dismantling tool Gearbox tool Gas Generator
extraction tool
reduces down time
improves safety
reduces down time
simplifies work
improves safety
25% inspection time
reduction
80% blades saving
improves safety
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 16
Outline
1. Introduction
2. Development History & Operating experience
3. Emission reduction
4. Extension of Engine life cycle
5. Maintenance Down Time reduction
6. Maintenance cost reduction
7. Operation Improvement
8. Ongoing SGT-600 Upgrades and Improvements
9. Summary
Page 17 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Repair is primary done to support the maintenance plan. Current repair scope included into Maintenance Plan:
Combustor repair DLE & Conventional
Turbine GV #1 repair
Turbine GV #2 repair
Current scope of repair on condition:Compressor abradable ring recoating
Turbine blade #1 repair
Rotor seal edge repair
Honeycomb seals #1,
