Gas Turbines & Power Plants Economic Evaluation of Cycling Plants – An Approach to Show the Value of Operational Flexibilitypresented at Power-Gen Europe 2006, CologneThe changed market conditions have an influence on the operating profile of every power plant in order to be dispatched. Combined cycle power plants often do not strictly operate in a base loadlike regime running 8000 hours per year. Many units are operating in a daily start-stop regime with units starting up to two times a day. In this market environment, an economic model that incorporates only a certain amount of base load hours with fix power revenues will not describe the full picture, additional earnings from the above mentioned market opportunities would not be considered.
To be more accurate, an extended approach for evaluating a cycling plant with high flexibility is necessary. Key parameters for operational flexibility are for example start-up time, standby operation and shut-down time. This paper describes an approach for evaluating flexibility for combined cycle cycling power plants.
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SGT6-5000F (W501F) 3 Million Hours Fleet Operational Experience presented at PowerGen 2006 - Orlando, FloridaThis paper describes more than 3 million hours of fleet operational experience by the successful SGT6-5000F gas turbine. This 200 MW class gas turbine has been applied in peaking, intermediate and base load operational modes since its introduction in 1991. The 192 engines in operation have accumulated an impressive operational record. The continuous development efforts to improve its performance, operational flexibility and RAM, and to reduce emissions, operation and maintenance costs and capital costs have enhanced the SGT6-5000F and its value to current and future users. In addition to providing an overview of operational case histories with details on operating hours and starts, this paper describes developments in service interval extension, trip factor reduction, fast start capability, 9 ppm NOx combustion system development and low load turndown improvements. Recent developments of SGT6-5000F adaptation to Integrated Gasification Combined Cycle plant application and combustion system validation for liquefied.
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Experience of 29MW SGT-700 Gas Turbine in Power Generation Applicationspresented at PowerGen 2006 - Orlando, FloridaIn 1997 the market requirement for a 30 MW industrial gas turbine was identified and an intensive development was started, targeting an uprate of the twin shaft SGT-600 (formerly GT10B) at 25 MW to create a gas turbine in the 30 MW range. The concept was based on the well-proven SGT-600 but with third-generation DLE (Dry Low Emissions) combustion technology from the SGT-800. The commercial launch of the 30 MW unit took place in 1999 and the validation of the 30 MW unit started in 2001. Until today (September 2006) a total of 15 units have been sold. This paper describes the testing and verification of Siemens gas turbine SGT-700 (formerly GT10C) and the first phase of operation experience from this frame. Erection, commissioning and the first 10 000 hours in commercial operation will be summarized.
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Report on the first operational experience of the newly commercialized 29MW SGT-700 (GT10C) gas turbinepresented at Power Gen Middle East 2006, Dubai, UAEThis paper reports on the experience from the first 28,000 operating hours of the first seven 29MW SGT-700 gas turbines to be delivered for power generation and mechanical drive applications. High reliability and availability are reported together with other data from the extended first level inspections with the fleet leaders.
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Lifetime extension through advanced non-destructive examination methods presented at POWER-GEN Europe 2006, Cologne, GermanyThe blades and blade attachments in a steam turbine belong to the most-highly stressedcomponents in a turbine/generator. The high turbine speed (3000 rpm) and the dead weight ofthe blades means that the last-stage blades in a steam turbine are subjected to enormouscentrifugal forces during plant operation. The roots on such blades are designed and calculatedusing the most up-to-date methods to allow them to accommodate these high loads. Particularlyduring transient loading conditions (startup and shutdown processes) certain areas of the bladeroots and blade attachment grooves are subjected to high stressing.
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Field experience from 2nd generation of low emission combustion chamberpresented at Power Gen Europe 2006, Cologne, GermanyThis paper describes the experience with the unique DLE (Dry Low Emission) combustion system which was introduced in 1991 into the SGT-600 25MW gas turbine (then called GT10B). Recently this fleet passed the milestone of 3.5 million accumulated operating hours. Measures include an optional combustion by-pass system and the development of a specific calibration procedure as part of pre-delivery quality control.
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Lifetime Extension for SIEMENS Gas Turbines presented at POWER-GEN Europe 2006, Cologne, GermanyThe worldwide demand for power grows faster than the world population. SIEMENS Power Generation develops and builds combined cycle (gas and steam) power plants and power plant components for all energy resources. SIEMENS gas turbines are renowned for their high availability and reliability as well as high power output at low emissions.
With a lifetime expectancy of a combined cycle power station of 30 to 40 years, the gas tur-bine by far exceeds the design lifetime. Essential components of the SIEMENS VX4.2, VX4.3 and VX4.3A gas turbines - especially the components of the hot gas path and rotor – are designed for an operating time of 100,000 equivalent operating hours (EOH, for short) or 3,000 starts. Well founded and realistic lifetime concepts are required to keep the costs over the entire lifetime to a minimum.
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Development & operating experience with the 45MW SGT-800presented at ICCI 2006, Istanbul, TurkeyThis paper describes the development steps of the advanced industrial gas turbine SGT-800 (former GTX100) - including initial driving factors, selection of design principles, performance & emission data, features &benefits, validation testing and commercial introduction.
It also highlights the experience and status of the current fleet of plants in commercial operation as well as results from the latest inspections, carried out during year 2004/2005.
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Emissions management strategies and emission tradingand potential barrier: The faster way to satisfy EU ETScompliance requirements presented at POWER-GEN Europe 2006, Cologne, GermanyEmissions management for single plant is dependent on the complexity of the CO2calculations and the emissions caps imposed by the governmental or the local stateregulator. Different European countries have imposed contrasting data quality constraints.E.g. In the Netherlands spreadsheet cannot be used for data processing but for most othercountries verifiers and regulations have been less stringent.
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New technologies in cogeneration applications: Siemens SGT-300 evolution meets market requirementspresented at ICCI 2006, Istanbul, TurkeyBy introducing new technologies to the established SGT-300, introduced in 1990 as the Tempest, Siemens have delivered a product which meets both today’s legislative requirements associated with emissions and the key business needs of reliability and high plant thermal efficiency. This paper explains the impact of newly developed technology in improving market fit in terms of emission control, reliability and overall plant efficiency and demonstrates the impact of these three critical advances in technology on European cogeneration applications.
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Taking Advantage of Market Opportunities through Siemens Reference Power Plants2006In a market where requirements and the operational environment for plant are changing ratherrapidly compared to former years, flexibility is one key driver for business success. Besides therequirement for high performance and high availability to achieve low life cycle cost, flexibility inthe plant operations and maintenance are strong drivers.
This paper presents two Siemens PG developments for increased flexibility to support ourcustomers in successful competition in the power market.
Starting with a short description of the market requirements driving flexibility demand and a roughsketch of the Siemens Reference Power Plant philosophy two exemplary Siemens solutions forflexibility needs are presented.
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Thermal barrier coating fatigue life assessmentpresented at ASME 2006, Barcelona, SpainIn land-based gas turbines, thermal barrier coatings are used for thermal insulation of hot components (combustor, turbine vanes and to some extent blades). The thermal barrier maintains the metal temperature of a coated component at moderate temperature levels during turbine operation. Coating integrity must be maintained, putting forward demands on a reliable assessment of coating life. This paper studies plasma-sprayed NiCoCrAlY and NiCrAlY bond coats with an yttria partially stabilised zirconia top coat. A fatigue life prediction model has been used based on a Paris law-approach.
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Blading aerodynamics design optimization with mechanical and aeromechanical constraintspresented at ASME 2006, Barcelona, SpainA blading design optimization system has been developed using an aeromechanical approach and harmonic perturbation method. The developed system has the capability to optimize aero-thermal performance with constraints of mechanical and aeromechanical integrity at the same time. ‘Aerodynamic mode shape’ is introduced to describe geometry deformation which can effectively reduce the number of design parameters while preserving surface smoothness. Compared to the existing design optimization practices, the present system is simpler, more accurate and effective.
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ON-LINE MONITORING OF POWER PLANTS presented at Electric Power 2006In recent years significant changes in the business relationships between customers and original equipment manufacturers (OEMs) could be observed in the power industry, which led to new forms of cooperation between those partners. Remote online monitoring is one important outcome of this development.
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A novel approach to predicting NOx emissions from dry low emissions gas turbines presented at ASME 2006, Barcelona, SpainThis paper analyses the fundamental processes are in order to identify the key processes. The representation of these processes is then simplified, based on a clear set of assumptions. The result is a tractable model, which requires empiricism to deliver quantitative predictions. The model described here focuses on natural gas operation.
The approach however can be applied to other gaseous fuels and can be extended to DLE liquid fuelled operation.The paper addresses the NOx formation process and describes key parameters such as the NOx formation kinetics and the impact of unmixedness. The NOx model is then derived and evaluated using high pressure rig data.
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A new test facility for evaluation of parameters defining nozzle guide vane endwall heat transfer presented at 17th International Symposium on Airbreathing Engines 2005, Munich, GermanyA new test facility has been built at Siemens in Finspong for aero- and thermodynamic investigation of the parameters defining nozzle guide vane endwall heat transfer.The overall objective of the work is to evaluate the heat transfer pattern on a master configuration end wall of a nozzle guide vane, which is used to validate a 3D Navier-Stokes CFD flow field and heat transfer calculation.
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Development & Operating Experience with SGT-800, a SIEMENS 45 MW Industrial Gas Turbine for various Applications presented at the 6th Annual Australian Gas Turbines Conference, 2005, Brisbane, AustraliaThis paper describes the development steps of the advanced industrial gas turbine SGT-800 (former GTX100) - including initial driving factors, selection of design principles, performance & emission data, features/benefits, validation testing and commercial introduction.
It also highlights the experience and status of the current fleet of plants in commercial operation as well as results from the latest inspections, carried out during year 2004/2005.
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The Nature of NOx Formation Within an Industrial Gas Turbine Dry Low Emission Combustorpresented at Asme Turbo Expo 2005, Reno, Nevada, USAThe dual fuel dry low emissions combustor is applied across the range of small industrial gas turbines. In gas operation, the newest machines, the Tempest and the Cyclone, can operate at <10ppm NOx. Stringent targets - to reduce emissions still further whilst still meeting all other specifications, such as required life, availability, robustness and cost - necessitate a greater understanding of the fundamental processes of turbulent fluid dynamics, chemistry, thermoacoustics and their complex interactions, as well as their impact on combustor and related components. This paper presents findings from the low NOx development program. Focus is confined to the analysis of NOx formation, in particular the identification of the NOx formation kinetics and the impact of turbulence/chemistry interactions.
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Development of new high AN2 last LP stage turbine - cost-effective solution for the 21st century presented at Asme Turbo Expo 2005, Reno, Nevada, USAA new high AN2 last LP stage turbine has been developed to provide leading performance for turbomachines in the 21st Century. It required a multi-disciplinary design approach involving aerodynamics, new materials (forged 3rd generation gamma-TiAl alloy), mechanics (stress and vibration) and new manufacturing technologies. This paper presents details of the novel approaches used for the design, including preliminary optimization, blading design and results from multistage 3D viscous predictions.
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Novel unsteady temperature/heat transfer instrumentation and measurements in the presence of combustor instabilitiespresented at Asme Turbo Expo 2005, Reno, Nevada, USALower NOx emission from gas turbine combustion systems can be achieved through reducing the equivalence ratio of the main reaction zone and/or increasing the burner pressure drop. This strategy however takes pressure drop and/or air away from the combustor cooling, thereby compromising the combustor life. In order to achieve an optimum design that is a good compromise between low emissions and long component life, accurate heat transfer prediction is essential. This paper reports on combustion tests conducted at gas turbine operating conditions, where pressure dynamics have been controlled by altering combustor operating conditions and through the use of a siren placed in the upstream air flow.
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Impact of Heat Rate, Emissions and Reliability from the Application of Wet Compression on Combustion Turbines presented at POWER-GEN International 2005Wet compression technology has been successfully installed on over 40 combustion turbines around the world. Wet compression systems have been justified due to the significant power gains achieved. What has not been discussed is the impact this technology has on the efficiency (heat rate), emissions and reliability of the combustion turbine.
This paper presents computational and field data that illustrates that there is more to gain than merely addition power output. Experience will be drawn from all types of combustion turbines: aeroderivitive, mature and advanced. The information will be presented in a format that will accurately depict all the benefits of wet compression technology allowing users to fully understand these benefits.
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Online Monitoring of Gas Turbine Power Plants presented at POWER-GEN International 2005In recent years significant changes in the business relationships between customers and original equipment manufacturers (OEMs) could be observed in the power industry, which led to new forms of cooperation between those partners. Remote online monitoring is one important outcome of this development.
After a basic research phase to select the best technologies available, Siemens Power Generation (PG) decided to establish a pilot remote monitoring center in Orlando, Florida, in late 1999. Since that time, the remote monitoring of Siemens’ advanced gas turbine / combined cycle fleet has been largely extended, primarily focusing on long term maintenance contracts (Long Term Programs - LTPs). Continuous remote online monitoring was officially introduced in February 2002 as “Power Diagnostics® Services” (PDS) to enable both customers and OEM to mitigate risk on a 24/7 basis. In the following chapters the Power Diagnostics® concept, infrastructure, and applied tools will be presented, along with some typical findings which actually prove the concept of risk mitigation, creating a win-win situation for both customers and OEM.
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Adaptation of the SGT6-6000G to a Dynamic Power Generation Market presented at POWER-GEN International 2005This paper describes the U.S. market conditions in which the SGT6-6000G was designed and its evolution to accommodate the current and future market requirements. The U.S. market drivers during the SGT6-6000G design were deregulation and replacing the old base load generation, such as old coal plants, with high efficiency/output power and low emissions combined cycle plants. The SGT6-6000G was originally designed primarily for base load operation, but also with sufficient cyclic life margin on its critical components to make it inherently suitable for cyclic operation.
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50-Hz Heavy Duty Gas Turbines – Experience and Evolutionpresented at Power Gen Asia 2005Incremental improvements of the combustion aerodynamics reflect the potential towards lower emissions, higher operational flexibility and even further enhanced performance. The paper will conclude with a review of the latest SGT5-4000F operating experience, including demonstrated customer benefits from the further refinement of the combustion system.
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Proven Upgrade of Siemens SGT5-4000F at Mainz-Wiesbadenpresented at Power Gen Europe 2005This paper describes the latest evolutionary step of the largest Siemens gas turbine – the SGT5-4000F, formerly known as V94.3A – along with the associated commercial operating experience. Adhering to its proven and mature design, the performance characteristics of the SGT5-4000F have been enhanced, resulting in higher component efficiencies due to better compressor and turbine aerodynamics and in greater gas turbine output.
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Generator Performance Plus TM Hydrogen Seal System presented at Electric Power 2004, BaltimoreThe authors’ companies have collaborated to develop an advanced oil seal assembly for hydrogen-cooled generators. This new technology addresses our industry’s needs to reduce oil and hydrogen consumption, improve seal life, and upgrade existing seal technology.
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Extending the Range of Single-Shaft Combined Cycle Power Plants presented at Power-Gen Europe 2004The demand for highly-efficient combined cycle power generation using natural gas has not changed which allows to use well-proven concepts like the Siemens Single-Shaft combined cycle concept.
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Gas Fuel Flexibility in a Dry Low Emissions Combustion System presented at Power-Gen Europe 2004Stricter emissions legislation over the past 15 years has led to the development of Dry Low Emissions (DLE) combustion systems on gas turbines to minimise the emissions to atmosphere of nitrogen oxides (NOx), carbon monoxide (CO) and unburned hydrocarbons (UHC). These DLE combustion systems have gained considerable experience on premium fuels such as pipeline quality natural gas and No. 2 diesel. However, concern over Greenhouse Gas emissions and rising prices of premium quality gas fuels has led to renewed interest in the use of poorer quality gases for power generation.
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Use and Experience of Gas Turbine On-line Diagnostics presented at Power-Gen Europe 2004Ten years ago Gas Turbine (GT) Diagnostic Systems were ordered in less then 10 % of new units. Today this has changed dramatically; almost all newly ordered gas turbines are equipped with at least a basic Diagnostic System. A main reason is the constantly progressing gas turbine technology.
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Fulfillment of Grid Code Requirements in the area served by UCTE by Combined Cycle Power Plants presented at Power-Gen Europe 2004The continental European power system is the result of synchronous interconnection of the electricity networks of the separate transmission system operators (TSOs) involved. To ensure smooth operation of the system and to enable grid disturbances to be controlled, a number of technical rules and recommendations need to be followed in operation of this system. The rules and recommendations of the “Union for the Coordination of Transmission of Electricity (UCTE)” form a common basis for this, providing minimum requirements to be met for grid operation on this system, which is operated in overall synchronism. These rules and recommendations leverage the exchange of electric power beyond the boundaries of the separate countries that form this synchronously interconnected system, and also promote nondiscriminatory exchange of data for this task.
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Technology Evolution of the Proven Gas Turbine Models V94.2 and V84.2 for New UNITS and Service Retrofits + Appendix Figures presented at Power-Gen Europe 2004A continuous development process driven by both the new units market and the service modernization market has resulted in two gas turbine models that have demonstrated their outstanding capabilities in worldwide applications over the past 23 years. These applications include single- and multi-shaft combined cycle, simple cycle, cogeneration and integrated coal gasification combined cycle. In the case of the V94.2 gas turbine, incremental design improvements have increased output and efficiency from initially 112 MW/31% to 163 MW/34.5%. The performance evolution of the V84.2 is similar. During the last five years service modernization products have also contributed to design advancements for the new units market.
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GTX 100 Turbine Section Measurement u sing a Temperature Sensitive Crystal Technique. A Comparison With 3D Thermal and Aerodynamic Analyses presented at Power-Gen Europe 2004In modern gas turbine engines, higher and higher turbine inlet temperature is used in order to increase the efficiency. To achieve a high benefit from increased temperature level it is necessary to minimise the amount of cooling air, which reduces the thermal cycle efficiency. The difficulty in turbine design is to find the optimal path to increase the efficiency without sacrificing the component lifetimes.
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