04 - Mods & Upgrades

SGT5-4000F (V94.
3A)
User Group Meeting Europe 2010
October 13th – 15th in Valencia, Spain
© Siemens AG 2010. All rights reserved.

Service Product
Development Update
Marc Tertilt
Senior Service Product Development Engineer
Advanced Frames
Maximilian Meimerstorf
Advanced Frames
Peter Trauner
Head of Performance Increase
Advanced 50Hz Frames
©© Siemens
Siemens AG
AG 2010. All rights reserved.
Page 2 V94.3A User Group Meeting Europe 2010 AL:N;ECCN:N
User Group Meeting
SGT5-4000F (V94.3A) Europe 2010
Service Product Contents

Development Update
Mods & Upgrade Products 4
Hour Update on Upgrades 8

Senior Service Product Development Operational Flexibility Upgrade 14
Engineer
Advanced Frames Wet Compression 24
Peter Trauner Summary & Conclusion

E S SF Product Line Marketing
User Group Meeting
SGT5-4000F (V94.3A) Europe 2010
Contents
Hour update on Upgrades 8
Operational Flexibility Upgrade 14

Peter Trauner
Head of Performance Increase Wet Compression 24
E S SF Product Line Marketing Summary & Conclusion

SGT5-4000F (V94.3A) UGM Europe 2010
Selective Portfolio of Modernization & Upgrade Products
Benefit Power Efficiency Emission Reliability Operational Lead

Product Reduction Availability Flexibility Time*
Operational Flexibility
Upgrade OFU ++ new
+ product
+ ++ +++ 24
Compressor Mass
Flow Increase CMF+ ++ o n.a. o n.a. 15 - 18
Hydraulic Clearance
Optimisation + + n.a. o n.a. 12
Thermal Performance Upgrade ++ + n.a. o n.a. 12 - 14

Power Turn Down n.a. + + + ++ 6–8
Advanced
Compressor Coating + + n.a. o n.a. 6
Foreign Objects
o o n.a. ++ + 7-9
Detection System
Fuel Conversion o o + + n.a. 18
EVAP-COOLER ++ o o o + 8 - 12
Wet Compression +++First test
+ results+ available
n.a. ++ 10 - 12
Combustion System Upgrade + + ++ + + 12 - 14
Siemens Compressor
Cleaning System + + n.a. + n.a. 9 - 12
* Expected lead times in month - subject to specific plant evaluation/scope

Customer Driven Product Development & Service Packages
• Thermal Performance Upgrade TPU

• Improved Hot Gas Parts SP6 2009
[292 MW; 39,8 % 4)]
• Burner Upgrade (Low-NOx Æ Premix-Pilot)
• Cooling Air Reduced Combustion Chamber
• Burner Upgrade (Reduced Swirl)
• Fuel Gas Preheating SP4
Efficiency
2005
• Compressor Mass Flow Increase
• Torque Disks 2004
• Turndown 2003
• Hydraulic Clearance Optimization
1997 3)
• 15-stage Compressor
• HR3 Burner
• Firing Temperature Increase
183 Units in Commercial Operation 1)
Total EOH > 6.022.000 Ongoing Development
Lead Unit EOH > 107.500 1996 2) • Further Thermal Performance Increase
[240 MW; 37,0 %] • Grid and Peak Load Products
Power Output
Additional Modernization & Upgrades
• Advanced Compressor Coating • Advanced Compressor Cleaning System • Wet Compression
• EVAP Cooler • Foreign Object Detection System • Fuel Conversion
1) 2)
Status as of September 2010 17-stage compressor
3) Since 1998: 15-stage compressor 4) Expected values only, site specific values may vary

Exemplary Upgrade Cycle
Order Long-Lead Contract

Components Negotiation
(Upgrade) 18-24 month
(min 1,5 years Firm Offer
before) (up to 6 month duration)
Detailed Upgrade
Preparation
5-10 month 24 month
(min 0,5 year (min 18 month
before) before)
ÎEarly planningRevision
ensures
Preparation of site / to best meet customer
Interval
Planning of Budgetary
requirements and guarantees availability of parts & personnel
commissioning available
Overhaul
Upgrade At any
1-2 month kEOH Meeting after
Overhaul = first
Detailed selection of upgrades
30-36 months
documentation based on customer
before
and commissioning needs
overhaul
plan available

User Group Meeting
SGT5-4000F (V94.3A) Europe 2010
Contents
Wet Compression 24
Senior Service Product Development Summary & Conclusion
Engineer
Advanced Frames

History of Major Upgrades
Upgrade Projects:
Compressor Mass Flow Increase CMF+
10 units
Accumulated operating
Hydraulic Clearance Optimization HCO hours:
206.000 EOH
Cooling Air Reduced Combustion Accumulated starts:
Chamber*
1.400 Starts
Fleet Lead:
HR3 RS Burner Upgrade*
58.000 EOH
* Note. Features are a prerequisite for Thermal Performance
Upgrade and Fuel Gas Preheating

Upgrade Projects:
8 units
144.000 EOH
• Cooling Air Reduced Combustion
Accumulated starts:
Chamber*
1000 Starts
Fleet Lead:
50.800 EOH
* Note: Features are a prerequisite for Thermal Performance

Success Story – CMF+ & HCO Upgrade
Upgrade Objective: 2 x SGT5-4000F with CMF+ and HCO

Upgrade Scope: Compressor Mass Flow Increase CMF+
Hydraulic Clearance Optimization HCO
Torque Discs
Upgrade Benefit: Power Output and Efficiency Increase
Installation: Last year, incl. Delta Performance Test
Achievements: Delta Performance Guarantees overachieved:
GT Power output increase of +26.2 MW*
CC Power output increase of +39.5 MW*
ÎCMF+, HCO proven power upgrades within M&U product portfolio.

Îs
* Estimated values based on operational data, w/o fuel gas flow measurement and analysis
Upgrade Projects:
5 units
112.000 EOH
Accumulated starts:
Chamber*
323 Starts
HR3 RS Burner Upgrade* Fleet Lead:

43.000 EOH

Upgrade Projects:
17 units
332.000 EOH
Accumulated starts:
Chamber*
2.800 Starts
Fleet Lead:
33.000 EOH

User Group Meeting
SGT5-4000F (V94.3A) Europe 2010
Contents
Operational Flexibility Upgrade14
Wet Compression 24
Maximilian Meimerstorf Summary & Conclusion

Senior Service Product Development
Engineer
Advanced Frames
Operational Flexibility Upgrade = OFU
„Your entry card into a flexible operation regime “

OFU - Benefit
Thermal SC Power Increase: 7,9 MW

Performance SC Efficiency Increase: 0,25 %-pts
CC Power Increase: 12 MW
With
increased
CC Efficiency Increase: 0,35 %-pts
expected values, site specific evaluation necessary, not binding for guarantees
stability
LTP extension SP6 with

Interval Extension
including
Service
Operational Flexibility Upgrade OFU
Pack 6
Upgrade
Siemens specialists will develop withExtension
Interval you best
Baseline package for your specific plant andPerformance)
demands –
(const.
depending on operating regime and service
factor
Max. power output or extended interval can be limited site specific:
- Generator & Transformer limits - Combustion instabilities/limitations
OFU - Optimizing- Existing
your hardware
Plant* regarding
limitations operational
flexibility to serve Energy markets demand
25 kEOH Interval Extended Interval * Contracted equipment

OFU - Thermal Performance Upgrade TPU
OFU - TPU possible with and without Compressor Upgrade
PMP Burner
HR3RS Burner
Additional Scope:
CAR Combustor with Impingement Cooled Tile Holder
• I&C Modifications to improve operation
MHS and Turbine Vane 1 Upgrade Style
• Rework of Combustor Shell and
Turbine Blade 1 and 2 Upgrade Style
Turbine Vane Carrier
Turbine Vanes 1, 2 and 3 Upgrade Style
• Upgrade Cooling Air Concept
Check of old Turbine Blade 3 and Blade 4 for usability

OFU - Improved Turbine Inlet Flowpath
Standard style
Hot gas
Vane 1
Cooling air platform
Upgrade style with optimized transition flowpath
Hot gas
Re-designed heat Cooling

shield and combustor air
hub and shell contour
Vane 1
platform
TPU - Impact of cooling air savings
Standard Step 1: Upgrade Step 2:
Combustion System Combustion System Upgrade Settings
Flame Temperature Flame Temperature Flame Temperature

Air mass flow Air mass flow Air mass flow
Fuel gas mass flow Fuel gas mass flow Fuel gas mass flow
Turbine Inlet Temperature Turbine Inlet Temperature Turbine Inlet Temperature
(ISO) (ISO) (ISO)
Flame temperature decrease Constant Flame temperature
Î Increased Stability Î Increased Performance
Î Decreased NOx Î Constant NOx
References - Experiences
Siemens Gas Turbines in Operation with

Combustor Transition and Turbine (Upgrade style):
Status:
SGT5-4000F 19 engines September 2010
Accumulated experience: Fleet leader experience:

> 2.100 starts and > 300 starts or
> 102.000 EOH > 20.000 EOH
Latest SGT5 - 4000F engines are equipped

with Upgrade turbine and new transition.
OFU – Maximum Performance and Flexibility of your Plant
Optimization of upgrade combinations to provide the best unit specific

balance of plant solution with the maximum possible performance increase
and enhanced maintenance interval as part of LTP contract:
Pending on status of unit and referring to equipped hardware

Pending on balance of plant limitations
Ö Customized solution with LTP extension

What is “OFU” for SGT5-4000F – In a Nutshell
OFU = Operational Flexibility Upgrade...

more operational flexibility in
intermediate and cyclic operation
@ any outage during LTP/O&M
contract typically @ 100 kEOH
extends OEM coverage beyond 100
kEOH
latest 4000F technology
improves GT performance within plant
limits
only for customers with LTP/O&M
contract

OFU Conclusion
First integrated product

incorporating:
- Upgrades,
- Life Time Extension and
- LTP Extension
to provide operational
flexibility for your
gas turbine !

User Group Meeting
SGT5-4000F (V94.3A) Europe 2010
Contents
Hour Update of 8
Wet Compression 24
Engineer
Advanced Frames

Wet Compression - History
History of the Wet Compression system :
2 more units SGT5 - 4000F (in preparation) 2011
1st SGT5 - 4000F – Validation Tests ongoing 2010

New operation mode for peak load units 2008
1st SGT5-2000E 2004
1st SGT6-2000E 2003
1st SGT6-4000F (Test-bed) 2000
1st Installation (W501A) 1995
Î Success Story Continues. So far more

then 40 units are in commercial operation.

Wet Compression – Short Introduction
Wet Compression – Intercooling for the compressor :
Wet Compression is an effective system for power increase on the gas turbine.
c Intercooling Effect:
- Reduced power consumption
of the compressor
- Increased compressor efficiency
Air inlet flow - Not effected by the ambient
humidity
d Evaporation:
- Cooling of the air inlet temperature
- Depends on the ambient conditions
Water injection e Mass Flow Increase:
- Morepower from the turbine due to
increased mass flows (air, water, fuel)
Combustion Chamber
2 1 3
Compressor Turbine
Wet Compression System Generic Scope
The Wet Compression hardware scope generally entitles:
Wet Compression pump skid incl. water lock
Water injection rack with spray nozzles
Interconnecting Piping from pump skid to

spray rack Spray nozzles
and water injection rack
Entire GT compressor coating (ACC)
Argus system upgrade (if not existing)
Integration into existing I&C
Field Service (assembly and commissioning)

ACC = Advanced Compressor Coating
Wet Compression pump skid
Results First Time Application SGT5-4000F
15
35 to
MW35additional
MW additional
powerpower
outputoutput and up to
and 0.7%-pts
efficiency
0,8 %-ptsmeasured at the
GT efficiency prototype at
measured testing withtime
the first a
Wet Compression mass flow of 10.2 kg/s.
application
Efficiency
Power Output
Max. power output or water mass

flow can be limited site specific:
- Generator, Transformer, HRSG limits
With ACC installed - Combustion instabilities/limitations
Minimum WetC Flow
no pitting corrosion
has been found on - Existing hardware limitations
first time
application 2000E Power increase nearly independent of
or 4000F ambient conditions*
.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.0
* Wet Compression operation only permitted
for ambient temperatures > 10°C m-WetC (% of mVI)
Wet Compression – In a Nutshell
GT Power increase: 15 - 35 MW
(expected values, depending on site, ambient and limiting conditions)
GT Efficiency increase: 0,5 ~ 3 %

Exhaust heat increase: ~ 3%

Water consumption (Max): up to 13 kg/s

(depending on site and ambient conditions)
Power benefit remains high for humid air

Æ almost independent from ambient humidity
Power benefit could be gained even

Æ with an already installed evaporative cooler
Power increase could easily be tuned

Æ by adjusting the water mass flow

User Group Meeting
SGT5-4000F (V94.3A) Europe 2010
Contents
Service hour update on Upgrades 7
Wet Compression 24
Engineer
Advanced Frames

Summary
OFU – An integration of proven

products optimizes individual power
plant performance and increases
operational flexibility within LTP.
First results for Wet Compression on
4000F are highly encouraging.
Validation testing is ongoing. Interest
for peaking power applications is high.
Increasing service hours of our
packages provide further validation of
safe and high reliable Mods &
Upgrade products.

Conclusion
Siemens Energy provides you

the power to improve the
performance and the flexibility
of your gas turbine and your
competitiveness!
&
We look forward to updating
you more on our exciting
products which are presently in
development in 2011.

Thank you for your attention
Dipl.- Ing. Marc Tertilt

Advanced Frames
Dipl.- Ing. Maximilian Meimerstorf

Advanced Frames
Peter Trauner
©© Siemens
Siemens AG
AG 2010. All rights reserved.
Disclaimer
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SGT5-4000F (V94.

© Siemens AG 2010. All rights reserved.

Service Product Contents

 Hour Update on Upgrades 8

Peter Trauner  Summary & Conclusion

 Mods & Upgrade Products 4

 Hour update on Upgrades 8

 Operational Flexibility Upgrade 14

© Siemens AG 2010. All rights reserved.

Benefit Power Efficiency Emission Reliability Operational Lead

Thermal Performance Upgrade ++ + n.a. o n.a. 12 - 14

* Expected lead times in month - subject to specific plant evaluation/scope

• Thermal Performance Upgrade TPU

© Siemens AG 2010. All rights reserved.

Order Long-Lead Contract

© Siemens AG 2010. All rights reserved.

 Mods & Upgrade Products 4

 Hour update on Upgrades 8

 Operational Flexibility Upgrade 14

© Siemens AG 2010. All rights reserved.

© Siemens AG 2010. All rights reserved.

© Siemens AG 2010. All rights reserved.

 Upgrade Objective: 2 x SGT5-4000F with CMF+ and HCO

ÎCMF+, HCO proven power upgrades within M&U product portfolio.

 HR3 RS Burner Upgrade* Fleet Lead:

© Siemens AG 2010. All rights reserved.

© Siemens AG 2010. All rights reserved.

 Mods & Upgrade Products 4

 Hour update on Upgrades 8

 Operational Flexibility Upgrade14

Maximilian Meimerstorf  Summary & Conclusion

„Your entry card into a flexible operation regime “

© Siemens AG 2010. All rights reserved.

Thermal SC Power Increase: 7,9 MW

LTP extension SP6 with

© Siemens AG 2010. All rights reserved.

OFU - TPU possible with and without Compressor Upgrade

© Siemens AG 2010. All rights reserved.

Upgrade style with optimized transition flowpath

Re-designed heat Cooling

Flame Temperature Flame Temperature Flame Temperature

Siemens Gas Turbines in Operation with

Accumulated experience: Fleet leader experience:

Latest SGT5 - 4000F engines are equipped

Optimization of upgrade combinations to provide the best unit specific

 Pending on status of unit and referring to equipped hardware

Ö Customized solution with LTP extension

© Siemens AG 2010. All rights reserved.

OFU = Operational Flexibility Upgrade...

© Siemens AG 2010. All rights reserved.

First integrated product

© Siemens AG 2010. All rights reserved.

 Mods & Upgrade Products 4

 Operational Flexibility Upgrade 14

© Siemens AG 2010. All rights reserved.

History of the Wet Compression system :

 2 more units SGT5 - 4000F (in preparation) 2011

 1st SGT5 - 4000F – Validation Tests ongoing 2010

 1st Installation (W501A) 1995

Hour Update on Upgrades 8

Peter Trauner Summary & Conclusion

Mods & Upgrade Products 4

Hour update on Upgrades 8

Operational Flexibility Upgrade 14

Mods & Upgrade Products 4

Hour update on Upgrades 8

Operational Flexibility Upgrade 14

Upgrade Objective: 2 x SGT5-4000F with CMF+ and HCO

HR3 RS Burner Upgrade* Fleet Lead:

Mods & Upgrade Products 4

Hour update on Upgrades 8

Operational Flexibility Upgrade14

Maximilian Meimerstorf Summary & Conclusion

Pending on status of unit and referring to equipped hardware

Mods & Upgrade Products 4

Operational Flexibility Upgrade 14

2 more units SGT5 - 4000F (in preparation) 2011

1st SGT5 - 4000F – Validation Tests ongoing 2010

1st Installation (W501A) 1995

Wet Compression pump skid incl. water lock

Water injection rack with spray nozzles

Interconnecting Piping from pump skid to

Entire GT compressor coating (ACC)

Argus system upgrade (if not existing)

Integration into existing I&C

Field Service (assembly and commissioning)

Mods & Upgrade Products 4

Service hour update on Upgrades 7

Operational Flexibility Upgrade 10

OFU – An integration of proven