Recent developments in small gas turbines - Siemens - Near You
Recent developments in small gas turbines - Siemens - Near You
Recent developments in small gas turbines - Siemens - Near You
You also want an ePaper? Increase the reach of your titles
YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.
<strong>Recent</strong> Developments <strong>in</strong> Small<br />
Industrial Gas turb<strong>in</strong>es<br />
Ian Amos<br />
Product Strategy Manager<br />
<strong>Siemens</strong> Industrial Turbomach<strong>in</strong>ery Ltd<br />
L<strong>in</strong>coln, UK<br />
Content<br />
Gas Turb<strong>in</strong>e as Prime Movers<br />
Applications<br />
History<br />
Technology<br />
thermodynamic trends and drivers<br />
core components<br />
Future requirements<br />
Market <strong>developments</strong><br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Page 2 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
1
Gas Turb<strong>in</strong>e as Prime Mover<br />
Prime mover : A mach<strong>in</strong>e that<br />
transforms energy from thermal,<br />
electrical or pressure form to<br />
mechanical form; typically an eng<strong>in</strong>e<br />
or turb<strong>in</strong>e.<br />
Gas Turb<strong>in</strong>es vary <strong>in</strong> power output<br />
from just a few kW more than 400,000<br />
kW.<br />
The shaft output can be used to<br />
generate electricity from an alternator<br />
or provide mechanical drive for<br />
pumps and compressors.<br />
Industrial Turb<strong>in</strong>es<br />
Page 3 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
SGT5-8000H<br />
SGT5-4000F<br />
SGT6-5000F<br />
SGT5-2000E<br />
SGT6-2000E<br />
SGT-800<br />
SGT-700<br />
SGT-600<br />
SGT-500<br />
SGT-400<br />
SGT-300<br />
SGT-200<br />
SGT-100 5<br />
Figures <strong>in</strong> net MW<br />
SGT6-8000H 266<br />
Utility Turb<strong>in</strong>es <strong>Siemens</strong> Industrial <strong>gas</strong> turb<strong>in</strong>e range<br />
47<br />
31<br />
25<br />
17<br />
13<br />
8<br />
7<br />
113<br />
Page 4 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
168<br />
198<br />
287<br />
375<br />
2
Industrial Gas Turb<strong>in</strong>e Product Range<br />
Portfolio<br />
(MW)<br />
SGT-800<br />
SGT-700<br />
SGT-600<br />
SGT-500<br />
SGT-400<br />
SGT-300<br />
SGT-200<br />
SGT-100<br />
30<br />
25<br />
17<br />
13<br />
8<br />
7<br />
5<br />
SGT-500<br />
47<br />
SGT-100-1S<br />
SGT-200-2S<br />
SGT-600<br />
SGT-100-2S SGT-200-1S<br />
SGT-300<br />
SGT-400<br />
SGT-700 SGT-800<br />
Page 5 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Industrial Gas Turb<strong>in</strong>e<br />
Product applications<br />
Power<br />
Generation<br />
An SGT-100<br />
generat<strong>in</strong>g set is<br />
<strong>in</strong>stalled on Norske<br />
Shell's Troll Field<br />
platform <strong>in</strong> the<br />
North Sea<br />
Pump<strong>in</strong>g<br />
Thirty SGT-200<br />
driven pump sets<br />
on the OZ2 pipel<strong>in</strong>e<br />
operated by<br />
Sonatrach, Algeria<br />
Compression CHP Comb. Cycle<br />
Two SGT-700<br />
driven <strong>Siemens</strong><br />
compressors for<br />
natural <strong>gas</strong><br />
liquefaction plant<br />
owned by UGDC<br />
at Port Said,<br />
Egypt.<br />
An SGT-800 CHP<br />
plant for InfraServ<br />
Bavernwerk’s<br />
chemical plant <strong>in</strong><br />
Gendork,<br />
Germany.<br />
Two SGT-400<br />
generat<strong>in</strong>g sets<br />
operat<strong>in</strong>g <strong>in</strong><br />
cogeneration/<br />
comb<strong>in</strong>ed cycle<br />
for BIEP at BP’s<br />
Bulwer Island<br />
ref<strong>in</strong>ery, Australia<br />
Page 6 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
3
Gas Turb<strong>in</strong>e Refresher<br />
Comparison of Gas Turb<strong>in</strong>e and Reciprocat<strong>in</strong>g Eng<strong>in</strong>e Cycle<br />
Cont<strong>in</strong>uous<br />
Intermittent<br />
AIR INTAKE<br />
FUEL<br />
COMPRESSION<br />
COMBUSTION<br />
EXHAUST<br />
AIR/FUEL INTAKE COMPRESSION COMBUSTION EXHAUST<br />
Page 7 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Gas Turb<strong>in</strong>e as Prime Mover<br />
Gas Turb<strong>in</strong>e Characteristics<br />
Size and Weight<br />
High power to weight ratio<br />
giv<strong>in</strong>g a very compact power<br />
source<br />
Vibration<br />
Rotat<strong>in</strong>g parts mean vibration<br />
free operation requir<strong>in</strong>g simple<br />
foundations<br />
Emissions<br />
Very low emissions of NOx<br />
Operation and Ma<strong>in</strong>tenance<br />
No Lubricat<strong>in</strong>g oil changes<br />
High levels of availability<br />
Fuel flexibility<br />
Dual fuel capability<br />
Burn Lean <strong>gas</strong>es (high N2 or<br />
CO2 mixtures)<br />
Vary<strong>in</strong>g calorific values<br />
Page 8 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
4
Brayton Cycle<br />
1-2 Air drawn from atmosphere and compressed<br />
2-3 Fuel added and combustion takes place at constant pressure<br />
3-4 Hot <strong>gas</strong>es expanded through turb<strong>in</strong>e and work extracted<br />
(<strong>in</strong> s<strong>in</strong>gle shaft approx 2/3 of turb<strong>in</strong>e work is used to drive the compressor)<br />
Page 9 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Ideal Eng<strong>in</strong>e Cycle:<br />
Efficiency<br />
Simple cycle efficiency<br />
Ideal thermal efficiency<br />
0.7<br />
0.6<br />
0.5<br />
0.4<br />
0.3<br />
0.2<br />
0.1<br />
⎛ ⎞<br />
⎜ 1 ⎟<br />
= 1−<br />
⎜ ⎟<br />
⎜ P1<br />
⎟<br />
⎝ P2<br />
⎠<br />
( γ −1)<br />
/ γ<br />
0<br />
0 10 20 30 40 50<br />
Pressure Ratio<br />
Cycle efficiency is therefore<br />
only dependant on the<br />
cycle pressure ratio.<br />
Assumption : Ideal cycle<br />
with no component or<br />
system losses.<br />
Page 10 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
5
Shaft Efficiency (%)<br />
Eng<strong>in</strong>e Cycle:<br />
The Real Eng<strong>in</strong>e<br />
Deviations from Ideal Cycle<br />
•Aerodynamic losses <strong>in</strong> turb<strong>in</strong>e and<br />
compressor blad<strong>in</strong>g<br />
• Work<strong>in</strong>g fluid property changes<br />
with temperature<br />
• Pressure losses <strong>in</strong> <strong>in</strong>takes,<br />
combustors, ducts, exhausts,<br />
silencers etc.<br />
• Air used for cool<strong>in</strong>g hot<br />
components<br />
• Parasitic air & hot <strong>gas</strong> leakages<br />
• Mechanical losses <strong>in</strong> bear<strong>in</strong>gs,<br />
gearboxes, seals, shafts<br />
• Electrical losses <strong>in</strong> alternators<br />
‘Real’ Efficiencies<br />
• Practical simple cycle <strong>gas</strong><br />
turb<strong>in</strong>es achieve 25 to 40 % shaft<br />
efficiency<br />
• Complex <strong>gas</strong> turb<strong>in</strong>e cycles can<br />
achieve shaft efficiencies up to<br />
50%<br />
• However, heat rejected <strong>in</strong> the<br />
exhaust can be used :-<br />
•Large comb<strong>in</strong>ed cycle GT can<br />
achieve close to 60% shaft<br />
efficiency<br />
•Cogeneration (Heat and Power)<br />
can exceed 80% total thermal<br />
efficiency<br />
Page 11 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Energy Cost Sav<strong>in</strong>gs<br />
GT cycle parameter study<br />
43.0<br />
42.0<br />
41.0<br />
40.0<br />
39.0<br />
38.0<br />
37.0<br />
36.0<br />
1200ºC<br />
1250ºC<br />
1300ºC<br />
1350ºC<br />
FIRING TEMPERATURE<br />
1400ºC<br />
1450ºC<br />
35.0<br />
280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480<br />
Shaft Specific Output (kJ/kg)<br />
Increase Pressure ratio and fir<strong>in</strong>g temperatures for higher simple cycle efficiencies<br />
Page 12 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
14<br />
25<br />
16<br />
22<br />
20<br />
18<br />
PRESSURE<br />
RATIO<br />
6
Design Drivers :<br />
Low Specific Fuel Consumption<br />
Higher Pressure Ratios<br />
• Increased Cycle Efficiency<br />
• Increased number of compressor / turb<strong>in</strong>e stages and<br />
therefore cost<br />
Complex Cycles<br />
• Increased Cycle Efficiency and/or Specific Power<br />
• Can impact operability, cost and reliability<br />
Higher Fir<strong>in</strong>g Temperature<br />
• Requires <strong>in</strong>creased sophistication of cool<strong>in</strong>g systems<br />
• Can impact life and reliability and combustor emissions<br />
Page 13 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Design Drivers :<br />
Availabilty, Cost and Emissions<br />
High reliability.<br />
Moderates the trend to <strong>in</strong>crease fir<strong>in</strong>g temperature and cycle<br />
complexity.<br />
Low Emissions (Driven by environmental legislation)<br />
More difficult to achieve with high fir<strong>in</strong>g temperatures and<br />
combustion pressures<br />
Lowest possible cost.<br />
Encourages <strong>small</strong>est possible frame size, i.e. high specific<br />
power high fir<strong>in</strong>g temperature.<br />
Reduced Pressure ratios (< 20:1) to avoid auxiliary fuel<br />
compression costs<br />
Compromise is required <strong>in</strong> the concept design to get the best<br />
balance of parameters<br />
Page 14 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
7
Core Eng<strong>in</strong>e Trends:<br />
Key Parameter Trends<br />
16<br />
15<br />
14<br />
13<br />
12<br />
11<br />
10<br />
9<br />
8<br />
7<br />
6<br />
5<br />
4<br />
3<br />
Pressure Ratio 16<br />
3CT<br />
Centrifugal Compr.<br />
TA<br />
TE<br />
TF<br />
Pressure Ratio<br />
Pressure Ratio<br />
Fir<strong>in</strong>g Temperature<br />
Fir<strong>in</strong>g Temperature<br />
700<br />
1950 1960 1970 1980 YEAR<br />
Year<br />
1990 2000<br />
Page 15 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Eng<strong>in</strong>e Trends:<br />
Thermal Efficiency<br />
Specific Power (kJ/kg)<br />
350<br />
300<br />
250<br />
200<br />
150 TB5000<br />
TG<br />
TD<br />
SGT-200<br />
TB<br />
SGT-100<br />
100<br />
24<br />
1975 1980 1985 1990<br />
Year<br />
1995 2000 2005<br />
SGT-200<br />
SGT-100<br />
SGT-300<br />
SGT-400<br />
Specific Power Output<br />
Thermal Efficiency<br />
SGT-400<br />
Future<br />
Mach<strong>in</strong>es<br />
1300<br />
1200<br />
1100<br />
1000<br />
Page 16 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
900<br />
800<br />
Dramatic impact of <strong>in</strong>creased TET and pressure ratio over last 25 years:<br />
• Specific Power <strong>in</strong>creased by almost 100%<br />
• Specific Fuel Consumption reduced by over 30%<br />
• reduced airflow for a given power output and has resulted <strong>in</strong> <strong>small</strong>er<br />
eng<strong>in</strong>e footpr<strong>in</strong>ts, reduced weight and reduced eng<strong>in</strong>e costs<br />
40<br />
38<br />
36<br />
34<br />
32<br />
30<br />
28<br />
26<br />
Thermal Efficiency (%)<br />
Fir<strong>in</strong>g Temperature °C<br />
8
Product Evolution<br />
Page 17 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Gas Turb<strong>in</strong>e Layout<br />
- s<strong>in</strong>gle shaft or tw<strong>in</strong> shaft<br />
Tw<strong>in</strong> Shaft<br />
Expansion over 2 series of<br />
turb<strong>in</strong>es.<br />
Compressor Turb<strong>in</strong>e (CT)<br />
provides power for compressor<br />
Useful output power provided by<br />
free Power Turb<strong>in</strong>e (PT)<br />
SGT-300<br />
Introduced 1995<br />
7,900 kWe 30.5% eff<br />
TA<br />
S<strong>in</strong>gle Shaft<br />
Introduced 1952<br />
750kW 17.6% eff<br />
Developed to 1,860kW<br />
Expansion through a s<strong>in</strong>gle series of<br />
turb<strong>in</strong>e stages.<br />
Power transmitted through rotor<br />
driv<strong>in</strong>g the compressor and torque at<br />
the output shaft<br />
Page 18 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
9
SGT-400 Industrial <strong>gas</strong> turb<strong>in</strong>e<br />
Compressor<br />
Page 19 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Combustion<br />
Combustion<br />
system<br />
Gas Generator<br />
Turb<strong>in</strong>e<br />
Power<br />
Turb<strong>in</strong>e<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
10
Environmental Aspects<br />
Pollutants and Control<br />
Pollutant Effect Method of Control<br />
Carbon Dioxide Greenhouse <strong>gas</strong> Cycle Efficiency<br />
Carbon Monoxide Poisonous DLE System<br />
Sulphur Oxides Acid Ra<strong>in</strong> Fuel Treatment<br />
Nitrogen Oxides Ozone Depletion<br />
Smog<br />
DLE System<br />
Hydrocarbons Poisonous<br />
Greenhouse <strong>gas</strong><br />
DLE System<br />
Smoke Visible pollution DLE System<br />
DLE - Dry Low Emissions<br />
Page 21 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Exhaust Emission Compliance<br />
Emissions control:<br />
Two types of combustion configuration need to be considered:<br />
Diffusion flame<br />
Dry Low Emissions (DLE or DLN) us<strong>in</strong>g Pre-mix combustion<br />
Diffusion flame<br />
Produces high combustor primary zone temperatures, and as NOx is a<br />
function of temperature, results <strong>in</strong> high thermal NOx formation<br />
Use of wet <strong>in</strong>jection directly <strong>in</strong>to the primary zone to lower combustion<br />
temperature and hence lower NOx formation<br />
Dry Low Emissions<br />
Lean pre-mixed combustion result<strong>in</strong>g <strong>in</strong> low combustion temperature, hence<br />
low NOx formation<br />
With good design and control
Combustion<br />
NOx Formation<br />
NOx Formation Rate [ ppm/ms ]<br />
1000<br />
100<br />
10<br />
1<br />
0.1<br />
0.01<br />
0.001<br />
0.0001<br />
0.00001<br />
0.000001<br />
1300 1500 1700 1900 2100 2300 2500<br />
Flame Temperature [ K ]<br />
Page 23 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Combustion<br />
NOx Formation<br />
Lean Pre-mix<br />
Diffusion Flame<br />
Flame temperature affects thermal NOx formation<br />
Flame Temperature as a function of Air/Fuel ratio<br />
Flame<br />
temperature<br />
Lean burn<br />
Lean<br />
Lean Pre-mixed<br />
(DLE/DLN)<br />
Stoichiometric<br />
FAR<br />
Diffusion flame reaction<br />
zone temperature<br />
Rich<br />
Diffusion flame<br />
Page 24 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
12
Combustor Configuration<br />
NOx product is a function of temperature<br />
Cool<strong>in</strong>g<br />
Page 25 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
DLE Lean Pre-mix Combustor<br />
(SGT-100 to SGT-400 configuration)<br />
Pilot<br />
Burner<br />
Ma<strong>in</strong> Gas<br />
Injection<br />
Igniter<br />
Igniter<br />
Gas/Air<br />
Mix<br />
Liquid<br />
Core<br />
Pilot Gas<br />
Injection<br />
Air<br />
Gas<br />
Ma<strong>in</strong> Burner<br />
Radial<br />
Swirler<br />
Air<br />
Diffusion<br />
Combustion<br />
- high primary zone<br />
temperature<br />
Dry Low<br />
Emissions<br />
Combustion<br />
-low peak temperature<br />
achieved with lean<br />
pre-mix combustion<br />
Robust design <strong>in</strong>volv<strong>in</strong>g no mov<strong>in</strong>g<br />
parts<br />
Fixed swirler vanes<br />
Variable fuel meter<strong>in</strong>g via pilot and<br />
ma<strong>in</strong> fuel valves<br />
Pre Chamber<br />
Double Sk<strong>in</strong><br />
Imp<strong>in</strong>gement<br />
Cooled Combustor<br />
Page 26 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
13
Lean Pre–Mix combustion<br />
Simple fuel system<br />
Variable fuel meter<strong>in</strong>g via pilot and ma<strong>in</strong> fuel valves<br />
Low NOx across a wide operat<strong>in</strong>g range of load and ambient conditions<br />
BLEED<br />
VALVE<br />
BLOCK<br />
VALVE<br />
BLOCK<br />
VALVE<br />
PILOT FLOW<br />
CONTROL<br />
VALVE<br />
M<br />
MAIN FLOW<br />
CONTROL<br />
VALVE<br />
MAIN<br />
MANIFOLD<br />
PILOT<br />
MANIFOLD<br />
Page 27 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Combustion<br />
DLE Lean Premix System<br />
Key to success<br />
good mix<strong>in</strong>g of fuel and air<br />
multiple <strong>in</strong>jection ports around swirler<br />
long pre-mix path<br />
fuel <strong>in</strong>jection as far from combustion zone as possible<br />
good air flow distribution<br />
can annular arrangement with top hats<br />
use of pilot burner<br />
CO control & flame stability<br />
use of guide vane modulation/air bleed<br />
air flow management<br />
Page 28 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
14
DLE System : <strong>Siemens</strong> experience<br />
15million operat<strong>in</strong>g hours across the range (SGT-100 to SGT-800)<br />
Approximately 1000 DLE units<br />
About 90% of new orders DLE<br />
Page 29 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Experience<br />
Stable load accept/reject<br />
Daily profile for unit runn<strong>in</strong>g more than 8000hrs DLE operation on liquid fuel.<br />
kW<br />
Daily variations<br />
Load Shed and Accept<br />
Page 30 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
15
Gas Fuel Flexibility<br />
BIOMASS &<br />
COAL GASIFICATION<br />
3.5<br />
Landfill & Sewage<br />
37 49 65<br />
Gas<br />
LPG<br />
Low Calorific<br />
Value (LCV)<br />
Off-shore lean<br />
Well head <strong>gas</strong><br />
High Hydrogen<br />
Ref<strong>in</strong>ery Gases<br />
IPG Ceramics<br />
Pipel<strong>in</strong>e<br />
Quality NG<br />
Other <strong>gas</strong><br />
Associated Gas<br />
Off-shore rich <strong>gas</strong><br />
Medium Calorific Value (MCV) ‘’Normal’’ High Calorific Value<br />
(HCV)<br />
<strong>Siemens</strong> DLE Units operat<strong>in</strong>g<br />
DLE Capability Under<br />
Development<br />
10 20 30 40 50 60 70<br />
Wobbe Index (MJ/Nm³)<br />
<strong>Siemens</strong> Diffusion<br />
Operat<strong>in</strong>g<br />
Experience<br />
SIT Ltd.<br />
Def<strong>in</strong>ition<br />
Page 31 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
The change <strong>in</strong> WI by the addition of <strong>in</strong>ert species to pipel<strong>in</strong>e quaility <strong>gas</strong><br />
Wobbe MJ/m 3<br />
50<br />
45<br />
40<br />
35<br />
30<br />
25<br />
20<br />
15<br />
10<br />
5<br />
UK Natural Gas<br />
Medium CV Fuel<br />
MCV Range development<br />
Def<strong>in</strong>ition<br />
LCV Burner<br />
0<br />
0 10 20 30 40 50 60 70 80 90 100<br />
CO 2 or N 2 content of UK Natural Gas<br />
CO2<br />
N2<br />
Page 32 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
16
Examples of <strong>Siemens</strong> SGT Fuels Experience<br />
NON DLE Combustion<br />
Natural Gas<br />
Wellhead Gases<br />
Landfill Gas<br />
Sewage Gas<br />
High Hydrogen Gases<br />
Diesel<br />
Kerosene<br />
LPG (liquid and <strong>gas</strong>eous)<br />
Naphtha<br />
‘Wood’ or Synthetic Gas<br />
Gasified Lignite<br />
DLE experience on Natural Gas, Kerosene and Diesel<br />
DLE on fuels with high N2 and CO2 content.<br />
DLE Associated or Wellhead Gases<br />
Page 33 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Turb<strong>in</strong>e<br />
Gasified Biomass<br />
Special Diffusion<br />
burner<br />
Sewage <strong>gas</strong><br />
standard burner<br />
Landfill <strong>gas</strong><br />
Special<br />
Diffusion<br />
burner<br />
High Hydrogen <strong>gas</strong><br />
standard burner<br />
UK Natural Gas<br />
Liquified Petroleum <strong>gas</strong><br />
modified MPI<br />
5 1 0 15 2 0 25 30 3 5 40 45 5 0 5 5 6 0 6 5 7 0<br />
Wobbe Index MJ/m3<br />
standard<br />
<strong>gas</strong>es<br />
Gaseous Fuel Range of Operation<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
17
Aerodynamic optimised design !<br />
Page 35 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Aerodynamics<br />
High Load Turb<strong>in</strong>e<br />
M<strong>in</strong>imised loss<br />
optimum pitch/width ratio<br />
across whole span.<br />
low load<strong>in</strong>g<br />
High speed<br />
high stage number<br />
low Mach numbers<br />
th<strong>in</strong> trail<strong>in</strong>g edges<br />
low wedge angle<br />
zero tip clearance<br />
Computational Fluid Dynamics (CFD) used to complement experimental test<strong>in</strong>g of<br />
advanced components.<br />
Page 36 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
18
Analytical optimised design !<br />
Page 37 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Mechanical Design -<br />
Reduce blade stresses<br />
M<strong>in</strong>imal shroud<br />
shroud may still be desirable<br />
for damp<strong>in</strong>g purposes.<br />
High hub/tip area ratio<br />
Low rotational speed.<br />
Maximise life<br />
Low temperatures<br />
Low unsteady forces<br />
Improved analysis software<br />
(grid and solver) and improved<br />
hardware allow traditional ‘postdesign’<br />
to be carried out dur<strong>in</strong>g<br />
design iterations.<br />
Mesh<strong>in</strong>g of complex cooled<br />
blade could take many man<br />
months <strong>in</strong> early 90’s - now<br />
down to m<strong>in</strong>utes.<br />
More sophisticated analysis for<br />
detailed lif<strong>in</strong>g studies still<br />
required after design.<br />
Page 38 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
19
Fatigue Life of Rotat<strong>in</strong>g Blades<br />
Positions of Concern<br />
Aerofoil<br />
Fillets<br />
Blade Vibration response<br />
Predicted by FE and measured <strong>in</strong><br />
Lab.<br />
Identifies critical blade frequencies<br />
and modes (Campbell Diagram)<br />
High Cycle Fatigue<br />
Fillet Radii between aerofoil &<br />
platform<br />
Top neck of firtree root<br />
Low Cycle Fatigue<br />
In areas of highest stress<br />
Eg - blade root serrations<br />
Root Serration (<strong>in</strong>clud<strong>in</strong>g skew effects)<br />
Page 39 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Mechanical Design - Vibration analysis<br />
Frequency (Hz)<br />
6000<br />
5000<br />
4000<br />
3000<br />
2000<br />
1000<br />
mode 6<br />
mode 5<br />
mode 4<br />
mode 3<br />
mode 2<br />
mode 1<br />
Campbell Diagram for LPT Blade (Blade only)<br />
0<br />
15000 15500 16000 16500 17000 17500 18000 18500 19000 19500 20000<br />
Iteration 3 version 10<br />
95%<br />
100%<br />
Eng<strong>in</strong>e Speed (rpm)<br />
D G Palmer 3-8-01<br />
Page 40 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
EO20<br />
105%<br />
EO19<br />
EO18<br />
EO17<br />
EO11<br />
EO10<br />
EO9<br />
EO6<br />
EO3<br />
20
Cool<strong>in</strong>g optimised design !!<br />
Large LE radius<br />
Page 41 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Cooled Blad<strong>in</strong>g Designs<br />
SGT100 > SGT300 > V2500 Aeroeng<strong>in</strong>e<br />
m<strong>in</strong>imise stagnation htc<br />
thick trail<strong>in</strong>g edge thickness<br />
and large wedge angle for<br />
cool<strong>in</strong>g<br />
thickness distribution to suit<br />
cool<strong>in</strong>g passages.<br />
M<strong>in</strong>imise <strong>gas</strong> washed<br />
surface.<br />
Page 42 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
21
SGT400 First Vane Cool<strong>in</strong>g Features<br />
Cast 2 Vane<br />
Segment<br />
Film<br />
Cool<strong>in</strong>g<br />
Trail<strong>in</strong>g Edge<br />
Ejection<br />
Imp<strong>in</strong>gement<br />
Cool<strong>in</strong>g<br />
Turbulators<br />
Page 43 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
SGT-400 13MW Industrial Gas Turb<strong>in</strong>e<br />
First Stage Cooled Vane<br />
Hot Blades are life<br />
limited.<br />
-Oxidation<br />
- Thermal fatigue<br />
- Creep<br />
Life typically 24,000<br />
hrs.<br />
Life can be <strong>in</strong>creased<br />
or decreased<br />
depend<strong>in</strong>g on duty<br />
and environment.<br />
Page 44 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
22
SGT-300 First Stage Cooled Rotor Blade<br />
Ceramic Core form<strong>in</strong>g<br />
Cool<strong>in</strong>g Passages<br />
SGT300 8MW Industrial Gas Turb<strong>in</strong>e<br />
Multi-Pass Cooled First Stage Rotor Blade<br />
Page 45 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
HP Turb<strong>in</strong>e Blade Coat<strong>in</strong>gs<br />
Hot Gas Surface Coat<strong>in</strong>gs for Corrosion & Oxidation protection<br />
Alum<strong>in</strong>ide,<br />
Silicon Alum<strong>in</strong>ide (Sermalloy J)<br />
Chromis<strong>in</strong>g<br />
Chrome Alum<strong>in</strong>ide, Plat<strong>in</strong>um Alum<strong>in</strong>ide<br />
MCrAlY<br />
Internal Coat<strong>in</strong>gs on Cooled Blades operat<strong>in</strong>g <strong>in</strong> poor environments<br />
Ceramic Thermal Barrier Coat<strong>in</strong>gs<br />
Yttria stabilised Zirconia<br />
Plasma Spray Coat<strong>in</strong>gs used on Vanes<br />
EBPVD Coat<strong>in</strong>gs used on rotat<strong>in</strong>g blades<br />
More uniform structure for improved <strong>in</strong>tegrity<br />
Page 46 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
23
Turb<strong>in</strong>e Validation Process<br />
Design<br />
Analysis<br />
Prototype Test<br />
Page 47 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
New technology <strong>in</strong>corporated <strong>in</strong>to exist<strong>in</strong>g<br />
eng<strong>in</strong>e platforms<br />
Compressor Blade<br />
• Stator stages S1& S2<br />
• Rotor stages R1 & R2<br />
T P<br />
HP Rotor blade<br />
• SX4 material<br />
• Triple f<strong>in</strong> shroud<br />
• Step Tip seal<br />
Assess<br />
evaluation<br />
and<br />
calibration<br />
of methods<br />
SGT-100 Product Development<br />
New rat<strong>in</strong>gs have been released<br />
Aerodynamic modifications to<br />
compressor and turb<strong>in</strong>e.<br />
Power generation, 5.4MWe<br />
(launch rat<strong>in</strong>g 3.9MW<br />
previously 5.25MWe)<br />
Mechanical Drive, 5.7MW<br />
(previously 4.9MW)<br />
Page 48 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
24
Industrial Gas Turb<strong>in</strong>es<br />
Advanced Materials & Manufactur<strong>in</strong>g<br />
Page 49 Nov 2010<br />
SGT400 PT 2 Nozzle R<strong>in</strong>g<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Bladed Turb<strong>in</strong>e Disc<br />
Page 50 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
25
The Gas Turb<strong>in</strong>e Package<br />
In addition to the ma<strong>in</strong> package, the follow<strong>in</strong>g is also<br />
required:<br />
Combustion air <strong>in</strong>take system<br />
Gas turb<strong>in</strong>e exhaust system<br />
Enclosure ventilation system (if enclosure fitted)<br />
Control system<br />
UPS or battery and charger system<br />
Page 51 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
SGT-300 Industrial <strong>gas</strong> turb<strong>in</strong>e<br />
Package design – The latest Module Design<br />
Available as a factory assembled<br />
packaged power plant for utility and<br />
<strong>in</strong>dustrial power generation applications<br />
Easily transported, <strong>in</strong>stalled and<br />
ma<strong>in</strong>ta<strong>in</strong>ed at site<br />
Package <strong>in</strong>corporates <strong>gas</strong> turb<strong>in</strong>e,<br />
gearbox, generator and all systems<br />
mounted on a s<strong>in</strong>gle underbase<br />
Preferred option to mount controls on<br />
package, option for off package.<br />
Common modular package design<br />
concept<br />
Acoustic treatment to reduce noise<br />
levels to 85 dB(A) as standard (lower<br />
levels available as options)<br />
Page 52 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
26
Typical Compressor Set<br />
Page 53 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
SGT-400<br />
New Package Design<br />
M<strong>in</strong>imised customer <strong>in</strong>terfaces reduc<strong>in</strong>g contract execution/<strong>in</strong>stallation costs<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
Combustion Air Intake<br />
Enclosure Air Inlet<br />
On-Skid Controls<br />
Fire & Gas System<br />
Interfaces<br />
Lub Oil Cooler<br />
Enclosure Air Exit<br />
Highly flexible modular construction<br />
Customer configurable solutions based upon pre-eng<strong>in</strong>eered options<br />
Standard module <strong>in</strong>terfaces to allow flexibility and <strong>in</strong>ter-changeability<br />
Additional functionality provided dependent upon client needs<br />
Base design provides common platform for on-shore and off-shore PG and MD<br />
2<br />
3<br />
4<br />
Page 54 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
1<br />
7<br />
5<br />
6<br />
27
Future direction<br />
Future Trends<br />
- guided by market requirements<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Universal demand for further <strong>in</strong>creases <strong>in</strong> efficiency and reliability, and<br />
reduction <strong>in</strong> cost.<br />
Oil & Gas (Mech drive and Power Gen)<br />
Fuel flexibility - associated <strong>gas</strong>es, off-<strong>gas</strong>es, sour <strong>gas</strong><br />
Remote operation<br />
Emissions -<strong>in</strong>c CO2<br />
Independent Power Generation<br />
Fuel flexibility - syn<strong>gas</strong>, biofuels(?), LPG<br />
Flexible operation - part load operation<br />
Distributed cogeneration (rather than centralised generation)<br />
Emissions - <strong>in</strong>c CO2<br />
Page 56 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
28
Oil and Gas<br />
remote operations / fuel flexibility<br />
•First application of its k<strong>in</strong>d <strong>in</strong> Russia<br />
(Western Siberia) burn<strong>in</strong>g wellhead <strong>gas</strong><br />
which was previously flared<br />
•Solution:<br />
Three SGT-200 <strong>gas</strong> turb<strong>in</strong>e<br />
•Output 6.75 MWe each<br />
•DLE Combustion system<br />
•Guaranteed NOx and CO<br />
emission levels of 25ppm<br />
•M<strong>in</strong>. air temp. (-57 o C)<br />
•Max. air temp. (+34 o C)<br />
•Gas composition with Wobbe Index<br />
>45MJ/m 3<br />
•Total DLE hours approximately 22,300<br />
hours for each unit<br />
•Significant reduction of emissions : 80-90%<br />
reduction of NOx level<br />
•<strong>Siemens</strong> has supplied 135 <strong>gas</strong> turb<strong>in</strong>es for<br />
Power Generation , Gas compression and<br />
pump<strong>in</strong>g duty throughout the Russian oil &<br />
<strong>gas</strong> <strong>in</strong>dustry<br />
Page 57 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
Power Generation<br />
re-emergence of cogeneration<br />
GRID<br />
FUEL<br />
WATER<br />
BOILER<br />
OR<br />
DRIER<br />
PRODUCT / STEAM<br />
Page 58 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
~<br />
29
Thank <strong>You</strong><br />
Page 59 Nov 2010<br />
Copyright © <strong>Siemens</strong> AG 2009. All rights reserved.<br />
Energy Sector<br />
30
Change language