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Gas Turbine Technology: Challenges, Achievements, Outlook Session GT Technology Trends
Wolfgang Menapace, Siemens Energy Sector
4. IGT Conference, ETN Brussels, October 15 – 16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved
Gas Turbine Technology: Challenges, Achievements, Outlook
Question 1: Is there a future market for Gas Turbines ? Core requirements Competing plant concepts
Page 1
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Strong steam and combined cycle segments, growth in nuclear power market over next decade World power market [GW/a] 202 13
178 23
147
144 115 ST nuclear
3
68 (China 62)
21
(China 48)
of it ST 126
82 of it ST 101
77 STPP
of it ST 133
96
8
(China 49)
of it ST 85
61 (China 40)
of it ST 101
(China 30)
75 CCPP GTPP
45 38 7 Avg 02-04
STPP: CCPP: GTPP: Page 2
of it GT 30
of it GT 69
of it GT 43
62 of it GT 52
52 of it GT 46
14
19
12
13
Avg 05-07
Avg 08-10
Avg 11-13
Avg 14-18
Steam Turbine Power Plant Combined Cycle Power Plant Gas Turbine Power Plant
ST: GT:
Steam Turbine Gas Turbine
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
Deviations due to figure rounding
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Customers operate Gas Turbines in different scenarios resulting in different requirements Electricity price Fuel cost
Peaker CT
• Start-up Reliability • Power Output
10 • Reliability • Efficiency • Power Output
5
• Efficiency • Reliability, availability • Maintenance costs
Intermediate CC
2 Base load CC
1 peaking
intermediate
Hours per year
base load 8760
Page 3
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud
Copyright (C) Siemens AG - Siemens Management Consulting 2004 All Rights Reserved - Confidential
L:3_01_Power_Gen_2008_IGT_GTT
Business Drivers and Customer Requirements for today's and future Gas Turbine engines Business Drivers
Customer Requirements § Power ↑
Engine Performance
+
§ Efficiency ↑ § Emissions ↓ § First Time Cost ↓ § Operational Flexibility
Reliability / Availability / Maintainability (RAM)
§ Cycling Capability ↑ § Fuel Flexibility ↑ § Upgradeability ↑ § Regulatory Compliance ↑
Market / Competitiveness
§ Product Robustness ↑ § Maintenance Cost ↓
Page 4
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Example for customer evaluation
1% efficiency increase results in Fuel Cost reduction of 1.500.000 €/a* CO2-reduction of
~ 25.000 t/a
per Combined Cycle Power Plant with 400 MW @ 8000 h/a
*based on: 6.5 €/GJ fuel cost
Main driver of economic assessment: Efficiency Page 5
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Competing plant concepts in today's fossil market Comparison of fossil power generation technologies 2010 Gas-fired Combined Cycle Power Plant (CCPP)
Coal-fired Steam Power Plant (STPP)
w/o CO2 – Capture
w/o CO2 – Capture
Integrated Coal Gasification CCPP w/o CO2 – Capture
60%
125% 100%
Plant net efficiency 47%
> 47%
<50% Specific invest
….IGCC may become an alternative if CO2 Capture will be mandatory in future Page 6
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Gas Turbine Technology: Challenges, Achievements, Outlook
Question 2: Evolutionary design approach What are the aims of our GT development ? Achievements
Page 7
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
SGT5-4000F Development Evolutionary Design approach to minimize Risk The development of the engine is mainly driven by two factors: § Evolutionary development to improve performance and flexibility § Implementation of field feedback to maximize reliability and availability Evolutionary Design = § careful changes to a well proven design § based on field experience and analytical methods § high confidence -> lower risk § tested in test rigs, test bed engine or rainbow test in the field § retrofit-ability for field validation and service upgrades
Evolutionary Design leads to Performance and Flexibility Improvements without risking Reliability and Availability
Page 8
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Evolution: Major Upgrades of our SGT5-4000F -
Latest Upgrade
1st Compressor Upgrade 2. Upgrade 292 MW / 39.8% 1. Upgrade
Cooling Air Reduction 287 MW / 39.5%
Market Introduction 266 MW / 38.6%
240 MW / 37.0% 1996
2000
• 2nd Compressor Upgrade • Combustor Cooling Air Saving • Hydraulic Clearance Optimization • Fuel Gas Preheating 2004
2008
Successful history of continuous improvements
Page 9
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Example for Advanced Technology: SGT5-4000F Design Features • Compressor, 15 stage advanced 3-D airfoil design in all stages and with side-wall correction. One variable guide vane row. • Combustion System - annular, low pattern factor - Dry low NOx and dual fuel • 4 stage Turbine. - SX row 1 and SX/DS 2 blades - Film-cooling, TBCs • Rotor with Hirth serration and single tie bolt. Quick thermal response because of rotor internal flow passages. Steel based materials only • Excellent thermal balance due to: - Quick and stiff rotor - Conical turbine flow path • Due to thermal balance: - Quick start up - Hot restart capability
Page 10
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Operating Fleet Experience Summary
Our advanced Gas Turbine Family SGT5-4000F, SGT6-4000F, SGT5-3000E, SGT-1000F (Vx4.xA) has clocked up more than 5,200,000 EOH* (Status March 2008)
> 190 engines in operation. > 65 engines on order
The Reliability of the SGT5-4000F Gas Turbine is at the same high level (> 99%) as our mature fleet
* = Equivalent Operating Hours Page 11
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Gas Turbine Technology: Challenges, Achievements, Outlook
Question 3: What are the next steps and recent experiences of our GT development ?
Page 12
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
60% CCPP efficiency is targeted with advanced gas turbine and steam cycle design CCPP efficiency development
Net Plant Efficiency [%]
Steam cycle development
% 60
from single pressure to triple pressure reheat steam cycle
58
110 bar 540 °C
75 bar 510 °C
52 50 48
50 bar 460 °C
46
960 °C
60 bar 485 °C
1250 °C
100 bar 1190 °C 520 °C
56 54
>130 bar 130 bar 565 °C 565 °C >1250 °C
80 bar 520 °C
1160 °C
1120 °C
1050 °C
1000 °C
Continuous improvement in material & coating, thermodynamic design, e.g.: - Thermal barrier coating - Fuel preheating - 3D blading
Gas turbine development
Fuel: natural gas ISO conditions: 15 °C, 1013 mbar, 60 % humidity
Page 13
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
60% CCPP efficiency will be demonstrated at Irsching 4 Power Plant Combined cycle plant efficiency development
SGT5-2000E (V94.2)
SGT5-4000F (V94.3A)
SGT5-4000F (V94.3A)
CCPP Killingholme, 2 x 450 MW
CCPP Didcot “B” 710 MW + 702 MW
CCPP Mainz-Wiesb. > 400 MW
CCPP Irsching 4, > 530 MW
1996
2001
2008/11
1992
Page 14
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
SGT5-8000H (new platform)
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Siemens advanced air-cooled gas turbines are designed for highest efficiency and reliability Siemens SGT5-8000H gas turbine design features High cycling capability due to advanced blade cooling system
Four stage turbine with advanced materials and thermal barrier coating
Advanced can annular combustion system Evolutionary 3Dcompressor blading
Proven rotor design, Hirth serration and central tie rod
Page 15
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
SGT5-8000H and SCC5-8000H Key Data
Gas turbine
SGT5-8000H
Steam turbine
SST5-5000
Generator
SGen5-3000W
Fuel
nat. gas, #2
GT / CC output
340 / 530 MW
GT / CC efficiency
> 39% / > 60 %
Pressure ratio
19.2 : 1
Exhaust mass flow
820 kg/s
Exhaust temperature
625 °C
Turn down
50%
HRSG / WS-Cycle
Benson 3Pr-RH
SGT5-8000H
SCC5-8000H
600°C / 170 bar
Page 16
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
SGT5-8000H Prototype Test Schedule
2008
2007
2009 Gate 4
First Fire
Test-Phase: Test Program
Page 17
1
Start Up Tests
2
Part Load Tests
3
Full Load Tests
4
Endurance Tests
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
The SGT5-8000H meets Customer Needs for reduced Life Cycle Cost & Flexibility
MW Demand
Customer Needs
Rapid growth
Innovative Solution
Validation and Implementation
Peak Load Intermediate Load
Base Load
§ § § §
High thermal efficiency High availability Operational flexibility Reduced life cycle costs
Page 18
§ § § §
Air cooled 60% combined cycle efficiency Design for serviceability Manufacturing innovations
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
§ Performance validated before series release § Siemens controlled environment § 3,000 measurement points § Knowledge brought to design tools
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Gas Turbine Technology: Challenges, Achievements, Outlook
Question 4: What shows the Outlook ? - Coal-to-Gas Technology: Perspectives for IGCC - Key technologies to advance
Page 19
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
IGCC plants may become in 2020 a third alternative with ~50% efficiency w/o and >43% with CO2 capture IGCC process principle
Siemens core competencies
Page 20
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Siemens was involved in all European coal-based IGCC demonstration plants …… IGCC plant efficiency development
253 MW (net), start -
V94.2
V94.3
Buggenum (Netherlands), 253 MW (net)
1994
Page 21
-
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
Puertollano (Spain), 298 MW (net)
1997 © Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Development of Blades and VanesThe Key of highly sophisticated Gas Turbines 1975
2001 Aerodynamics Cooling technology Materials and casting Coatings (oxidation, corrosion) Thermal barrier coating
APS
Substrate
Uncooled Blade ~ 900° Hot gas temperature
EB PVD
Film cooled Blade >1400° Hot gas temperature
columnar structure
Substrate
Page 22
200 µm
50 µm
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Advanced Material Systems are a key technology to advanced Gas Turbine Technology Closed-loop Cooling
allowable Hot Gas Temperature
Temperature
Temperature /°C
CMC
Film Cooling
Allowable Material temperature
TBC
IN738
2nd Gen. SX
IN939 IN792 DS
1st Gen. SX
U700 1965
1975
1985
1995
2005
2015
Year
Today TBCs are the Material Technology with the highest pay-off Page 23
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Summary Gas Turbines will keep a prime role in the power market Our Evolutionary Design Approach blends Performance Improvements and Reliability Advanced Gas Turbines need intensive R&D and testing / validation Coal-to Gas/ IGCC Technology will be a growing alternative but requires adapted gas turbine technology Advanced Materials are key to develop advanced Gas Turbines
Page 24
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Thank you
© Siemens Power Generation, Inc. 2007. All rights reserved
Wolfgang Menapace, Siemens Energy Sector
4. IGT Conference, ETN Brussels, October 15 – 16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved
Gas Turbine Technology: Challenges, Achievements, Outlook
Question 1: Is there a future market for Gas Turbines ? Core requirements Competing plant concepts
Page 1
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Strong steam and combined cycle segments, growth in nuclear power market over next decade World power market [GW/a] 202 13
178 23
147
144 115 ST nuclear
3
68 (China 62)
21
(China 48)
of it ST 126
82 of it ST 101
77 STPP
of it ST 133
96
8
(China 49)
of it ST 85
61 (China 40)
of it ST 101
(China 30)
75 CCPP GTPP
45 38 7 Avg 02-04
STPP: CCPP: GTPP: Page 2
of it GT 30
of it GT 69
of it GT 43
62 of it GT 52
52 of it GT 46
14
19
12
13
Avg 05-07
Avg 08-10
Avg 11-13
Avg 14-18
Steam Turbine Power Plant Combined Cycle Power Plant Gas Turbine Power Plant
ST: GT:
Steam Turbine Gas Turbine
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
Deviations due to figure rounding
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Customers operate Gas Turbines in different scenarios resulting in different requirements Electricity price Fuel cost
Peaker CT
• Start-up Reliability • Power Output
10 • Reliability • Efficiency • Power Output
5
• Efficiency • Reliability, availability • Maintenance costs
Intermediate CC
2 Base load CC
1 peaking
intermediate
Hours per year
base load 8760
Page 3
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud
Copyright (C) Siemens AG - Siemens Management Consulting 2004 All Rights Reserved - Confidential
L:3_01_Power_Gen_2008_IGT_GTT
Business Drivers and Customer Requirements for today's and future Gas Turbine engines Business Drivers
Customer Requirements § Power ↑
Engine Performance
+
§ Efficiency ↑ § Emissions ↓ § First Time Cost ↓ § Operational Flexibility
Reliability / Availability / Maintainability (RAM)
§ Cycling Capability ↑ § Fuel Flexibility ↑ § Upgradeability ↑ § Regulatory Compliance ↑
Market / Competitiveness
§ Product Robustness ↑ § Maintenance Cost ↓
Page 4
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Example for customer evaluation
1% efficiency increase results in Fuel Cost reduction of 1.500.000 €/a* CO2-reduction of
~ 25.000 t/a
per Combined Cycle Power Plant with 400 MW @ 8000 h/a
*based on: 6.5 €/GJ fuel cost
Main driver of economic assessment: Efficiency Page 5
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Competing plant concepts in today's fossil market Comparison of fossil power generation technologies 2010 Gas-fired Combined Cycle Power Plant (CCPP)
Coal-fired Steam Power Plant (STPP)
w/o CO2 – Capture
w/o CO2 – Capture
Integrated Coal Gasification CCPP w/o CO2 – Capture
60%
125% 100%
Plant net efficiency 47%
> 47%
<50% Specific invest
….IGCC may become an alternative if CO2 Capture will be mandatory in future Page 6
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Gas Turbine Technology: Challenges, Achievements, Outlook
Question 2: Evolutionary design approach What are the aims of our GT development ? Achievements
Page 7
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
SGT5-4000F Development Evolutionary Design approach to minimize Risk The development of the engine is mainly driven by two factors: § Evolutionary development to improve performance and flexibility § Implementation of field feedback to maximize reliability and availability Evolutionary Design = § careful changes to a well proven design § based on field experience and analytical methods § high confidence -> lower risk § tested in test rigs, test bed engine or rainbow test in the field § retrofit-ability for field validation and service upgrades
Evolutionary Design leads to Performance and Flexibility Improvements without risking Reliability and Availability
Page 8
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Evolution: Major Upgrades of our SGT5-4000F -
Latest Upgrade
1st Compressor Upgrade 2. Upgrade 292 MW / 39.8% 1. Upgrade
Cooling Air Reduction 287 MW / 39.5%
Market Introduction 266 MW / 38.6%
240 MW / 37.0% 1996
2000
• 2nd Compressor Upgrade • Combustor Cooling Air Saving • Hydraulic Clearance Optimization • Fuel Gas Preheating 2004
2008
Successful history of continuous improvements
Page 9
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Example for Advanced Technology: SGT5-4000F Design Features • Compressor, 15 stage advanced 3-D airfoil design in all stages and with side-wall correction. One variable guide vane row. • Combustion System - annular, low pattern factor - Dry low NOx and dual fuel • 4 stage Turbine. - SX row 1 and SX/DS 2 blades - Film-cooling, TBCs • Rotor with Hirth serration and single tie bolt. Quick thermal response because of rotor internal flow passages. Steel based materials only • Excellent thermal balance due to: - Quick and stiff rotor - Conical turbine flow path • Due to thermal balance: - Quick start up - Hot restart capability
Page 10
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Operating Fleet Experience Summary
Our advanced Gas Turbine Family SGT5-4000F, SGT6-4000F, SGT5-3000E, SGT-1000F (Vx4.xA) has clocked up more than 5,200,000 EOH* (Status March 2008)
> 190 engines in operation. > 65 engines on order
The Reliability of the SGT5-4000F Gas Turbine is at the same high level (> 99%) as our mature fleet
* = Equivalent Operating Hours Page 11
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Gas Turbine Technology: Challenges, Achievements, Outlook
Question 3: What are the next steps and recent experiences of our GT development ?
Page 12
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
60% CCPP efficiency is targeted with advanced gas turbine and steam cycle design CCPP efficiency development
Net Plant Efficiency [%]
Steam cycle development
% 60
from single pressure to triple pressure reheat steam cycle
58
110 bar 540 °C
75 bar 510 °C
52 50 48
50 bar 460 °C
46
960 °C
60 bar 485 °C
1250 °C
100 bar 1190 °C 520 °C
56 54
>130 bar 130 bar 565 °C 565 °C >1250 °C
80 bar 520 °C
1160 °C
1120 °C
1050 °C
1000 °C
Continuous improvement in material & coating, thermodynamic design, e.g.: - Thermal barrier coating - Fuel preheating - 3D blading
Gas turbine development
Fuel: natural gas ISO conditions: 15 °C, 1013 mbar, 60 % humidity
Page 13
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
60% CCPP efficiency will be demonstrated at Irsching 4 Power Plant Combined cycle plant efficiency development
SGT5-2000E (V94.2)
SGT5-4000F (V94.3A)
SGT5-4000F (V94.3A)
CCPP Killingholme, 2 x 450 MW
CCPP Didcot “B” 710 MW + 702 MW
CCPP Mainz-Wiesb. > 400 MW
CCPP Irsching 4, > 530 MW
1996
2001
2008/11
1992
Page 14
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
SGT5-8000H (new platform)
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Siemens advanced air-cooled gas turbines are designed for highest efficiency and reliability Siemens SGT5-8000H gas turbine design features High cycling capability due to advanced blade cooling system
Four stage turbine with advanced materials and thermal barrier coating
Advanced can annular combustion system Evolutionary 3Dcompressor blading
Proven rotor design, Hirth serration and central tie rod
Page 15
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
SGT5-8000H and SCC5-8000H Key Data
Gas turbine
SGT5-8000H
Steam turbine
SST5-5000
Generator
SGen5-3000W
Fuel
nat. gas, #2
GT / CC output
340 / 530 MW
GT / CC efficiency
> 39% / > 60 %
Pressure ratio
19.2 : 1
Exhaust mass flow
820 kg/s
Exhaust temperature
625 °C
Turn down
50%
HRSG / WS-Cycle
Benson 3Pr-RH
SGT5-8000H
SCC5-8000H
600°C / 170 bar
Page 16
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
SGT5-8000H Prototype Test Schedule
2008
2007
2009 Gate 4
First Fire
Test-Phase: Test Program
Page 17
1
Start Up Tests
2
Part Load Tests
3
Full Load Tests
4
Endurance Tests
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
The SGT5-8000H meets Customer Needs for reduced Life Cycle Cost & Flexibility
MW Demand
Customer Needs
Rapid growth
Innovative Solution
Validation and Implementation
Peak Load Intermediate Load
Base Load
§ § § §
High thermal efficiency High availability Operational flexibility Reduced life cycle costs
Page 18
§ § § §
Air cooled 60% combined cycle efficiency Design for serviceability Manufacturing innovations
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
§ Performance validated before series release § Siemens controlled environment § 3,000 measurement points § Knowledge brought to design tools
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Gas Turbine Technology: Challenges, Achievements, Outlook
Question 4: What shows the Outlook ? - Coal-to-Gas Technology: Perspectives for IGCC - Key technologies to advance
Page 19
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
IGCC plants may become in 2020 a third alternative with ~50% efficiency w/o and >43% with CO2 capture IGCC process principle
Siemens core competencies
Page 20
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Siemens was involved in all European coal-based IGCC demonstration plants …… IGCC plant efficiency development
253 MW (net), start -
V94.2
V94.3
Buggenum (Netherlands), 253 MW (net)
1994
Page 21
-
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
Puertollano (Spain), 298 MW (net)
1997 © Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Development of Blades and VanesThe Key of highly sophisticated Gas Turbines 1975
2001 Aerodynamics Cooling technology Materials and casting Coatings (oxidation, corrosion) Thermal barrier coating
APS
Substrate
Uncooled Blade ~ 900° Hot gas temperature
EB PVD
Film cooled Blade >1400° Hot gas temperature
columnar structure
Substrate
Page 22
200 µm
50 µm
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Advanced Material Systems are a key technology to advanced Gas Turbine Technology Closed-loop Cooling
allowable Hot Gas Temperature
Temperature
Temperature /°C
CMC
Film Cooling
Allowable Material temperature
TBC
IN738
2nd Gen. SX
IN939 IN792 DS
1st Gen. SX
U700 1965
1975
1985
1995
2005
2015
Year
Today TBCs are the Material Technology with the highest pay-off Page 23
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Summary Gas Turbines will keep a prime role in the power market Our Evolutionary Design Approach blends Performance Improvements and Reliability Advanced Gas Turbines need intensive R&D and testing / validation Coal-to Gas/ IGCC Technology will be a growing alternative but requires adapted gas turbine technology Advanced Materials are key to develop advanced Gas Turbines
Page 24
4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008
© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT
Thank you
© Siemens Power Generation, Inc. 2007. All rights reserved
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