Power for Generations Siemens Power Generation

Magaz i ne of t he Si emens Power Gener at i on Gr oup

Reprint from
Power Journal International
Si emens Gas Turbi ne Servi ce Hel ps t o
Boost Power Producers Sucess
Author:
Robert L. Misback
Start Your Engines
With quick and reliable outage work, long-term maintenance and operation support and superior upgrade
technologies, Siemens gas turbine service helps to boost power producers success.
10 Siemens Power Journal 2/2000
OPERATI NG PLANT SERVI CES
Winners in the
power industry
need the
most responsive,
knowledgeable
service team.
T
o
n
y

S
t
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e
I
magine a field of Formula
One race cars, engines
revving in anticipation of
the green light; the drivers
are ready; the skilled pit
crew is standing by, prepared to
respond quickly and efficiently
to every need. A quick start is
important in any race; yet in the
end, the checkered flag goes to
the racing team with the best
driver and engine, and the most
responsive, knowledgeable ser-
vice team. The same is true of
todays power generators and
their gas turbine power plants.
Like the Formula One racing
crew, Siemens skilled service
teams are prepared to respond
to all customer requirements
with speed and quality.
Gas turbine technology con-
tinues to push the envelope
with more complex compo-
nents, higher firing tempera-
tures and advanced materials.
The increased megawatt out-
put and thermodynamic per-
formance offered by Siemens
advanced gas turbines are two
key factors in operating plant
market success; equally impor-
tant are operating plant relia-
bility and availability. The
power plant operators skill,
combined with the strength of
Siemens field service teams
and upgrade technologies,
drive plant performance and
help ensure customer success.
Global Service from One
Strong Source
By integrating the four ser-
vice groupsKWU in Ger-
many, Siemens Parsons in Eng-
land, Siemens Power Corp in
Milwaukee, and Siemens West-
inghouse in Orlandoa syner-
gistic, single Global Service Or-
ganization was created.
This combined service com-
pany covers about 500 GW or
33% of the worlds installed
generating capacity, including
about 500 large gas turbines.
The organization comprises
more than 3000 field engi-
neers, technicians and support
personnel who are available to
service power producers
equipment anywhere in the
world. Whether the need is for
hardware, repairs, technical
field assistance, or full turnkey
outage support, Siemens has
the personnel and the exper-
tise to meet all plant service re-
quirements.
Close To The Customer
Siemens strategy for service
excellence begins with under-
standing each customers
needs, through close, personal
contact and open dialog. To en-
sure power producers receive
personal attention, the compa-
ny has shifted away from its
previous headquarters-driven
service philosophy: Today, a
network of regional service of-
fices and service centers is
strategically located around the
globe to ensure 24-hour-a-day
customer service. Regionally
based personnel are the cus-
tomers first point of contact for
service. They help plan outages
and assemble the appropriate
resources for service work on
all Siemens equipment and
will provide resources for non-
OEM units as well.
ROBERT L. MI SBACK
Siemens Power Journal 2/2000 11
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1998 2004
Installed capacity*
Strong Siemens High-Tech
Gas Turbine Fleet Growth ...
1999 2001 2004
Number of outages
... Needs Unprecendented Growth
in Siemens Field Service
600
310
90
0
700
600
500
400
300
200
100
43.8 GW
8.4 GW
* W501F, W501G, V64.3A, V84.3A and V94.3A gas turbines
Expected growth in demand for gas turbines over the next four
years will result in an equal need to increase service resources.
Siemens is already addressing this need with increased recruiting
and training.
Specialized Outage Teams
Lets return for a moment to
the Grand Prix race. Several
high-performance race cars,
running nose-to-nose, may pull
into pit row for service at the
same time. But the one with
the quickest, most efficient
crew will be able to get back on
the track first and move into
the lead. Siemens service out-
age teams are similar to a For-
mula One racing team pit crew.
Each team specializes in work-
ing on a single gas turbine
frame such as the 501F or
V94.3A. Dedicated specialized
field-based service resources
are thus the second component
of Siemens strategy.
Before an outage, the service
office works with the operating
units owner and Siemens engi-
neers to determine the expect-
ed condition of the unit and the
optimum work scope. Each out-
age crew is trained in detailed
outage procedures, and devel-
ops specialized tooling pack-
ages for the outage. After the
outage, the inspection results
are documented, performance
is evaluated and ways to im-
prove procedures for future
outages are assessed. The goal
is to continuously reduce out-
age length, improve quality,
and increase unit availability.
The results of this approach
have been outstanding.
Siemens has been able to dra-
matically reduce outage dura-
tion over the past few years.
12 Siemens Power Journal 2/2000
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Siemens is Setting Industry Standards in Outage Performance
Combustor 10 days 7 days 4 days
W501F engine (186 MW)
Minor 5 days 3 days 3 days
Major (incl. rotor destack) 35 days 24 days 21 days
Major 35 days 21 days 18 days
Hot-gas path 21 days 14 days 8 days
Hot-gas path 18 days 12 days 8 days
V84.2 engine (108 MW)
Past Today Target
Outage times have been cut
nearly in half. And the quality
of service has improved even as
advances in gas turbine tech-
nology have made field service
more complex. Siemens targets
outage times that are even
shorterand can do it, as shown
in a recent major inspection
with rotor destacks on V94.2
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Upgrades for W251- and W501-Series Gas Turbine Frames
MW
Power output
(Efficiency increase)
20
200
180
160
140
120
100
80
60
40
W501F
+20 MW
+5%
W251B
+13 MW
+13%
W501B
+10 MW
+6%
W501D
+27 MW
+6%
Gas turbine upgrades increase the competitiveness and profitability
of older operating units by providing more power output and better
efficiencies.
Through improved procedures, and innovative resource solutions,
Siemens has been able to consistently reduce outage duration over
the past few years, cutting outage times almost in half while
improving service quality.
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Evolution from 1980 to 1989 Evolution since 1990
GT-MORE 51
GT-MORE 42
GT-MORE 41
GT-MORE 33
GT-MORE 32
GT-MORE 31
GT-MORE 23
GT-MORE 22
GT-MORE 21
GT-MORE 12
GT-MORE 11
Package no. V94.2 version l V94.2 version ll V94.2 version lll
100 110
MW class
110 120
MW class
120 130
MW class
130 150
MW class
150 155
MW class
155 160
MW class
A
major part of the Sie-
mens V-series gas tur-
bine fleet for 50-Hz
grids is of the V94.2 type. Con-
tinuous advances for this ma-
chine have been the basis for
upgrading packages for this
frame. The packages define an up-
grading path that offers ample
flexibility for upgrading strategies
pursued by plant producers and
allows a flexible change from the
current rating class of an installed
machine to a higher output ver-
sion. The increase in power output
can be selected so it will be the
best choice depending on the
technical condition of the overall
plant. The system has also been
designed for future growth. Fu-
ture advances in gas turbine tech-
nology can be directly converted
into upgrading packages, which
will automatically extend the up-
grading path.
Model V94.2 Gas Turbine
Systematic Gas Turbine Upgrading
Upgrading Path for Model V94.2 Gas Turbine
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1992 1994 1996 1998 2000
Reliability
Year
94.0
92.0
96.0
98.0
100.0
Higher Reliability with Long-Term Maintenance (LTM) Program Support
LTM supported units
Non-LTM supported units
Cumulative
Cumulative
%
engines completed in 21 days at
the Paka plant in Malaysia.
The size of the Siemens gas
turbine fleet is projected to grow
significantly with a correspond-
ing increase in the total field ser-
vice man-hour requirements. It
is anticipated that the required
man-days per month will double
every three years. To meet this
challenge, the company has al-
ready begun to recruit and train
more engineers and technicians
to assure qualified outage teams
are available to meet demand.
Global Repair Strength
Global repair/service centers
are the next key place where
Siemens is dedicating special-
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1992 1994 1996 1998 2000
Availability
Year
85.0
80.0
90.0
95.0
100.0
Higher Availability with Long-Term Maintenance (LTM) Program Support
LTM supported units
Non-LTM supported units
Cumulative
Cumulative
Average for O&M supported units %
Those units that received gas turbine support through Siemens long-term programs
exhibit significantly higher plant reliabilities and availabilities. O&M support is even further
increasing these figures.
W
ith almost 100 operat-
ing plants equipped
with the Model W501D5
gas turbine, this 60-Hz machine
is the backbone of the W501-series
fleet of Siemens Westinghouse.
The two-phase performance up-
grade program for the W501D5
engine can reduce heat rate by
3% and enhance output by 6%.
Phase 1 is an efficiency up-
grade that reduces cooling-air
leakage, optimizes cooling flow,
reduces blade-tip losses, and im-
proves the cooling and coating
of row 1 blades.
The Phase 2 upgrade directly
improves turbine output by in-
creasing the firing temperature.
It involves upgrade of transi-
tions, improvement of cooling
and new coatings for row 1
vanes, an increase of cooling-air
flow through row 1 blade ring,
new coatings for row 2 vanes,
Model W501D5 Gas Turbine and improved combustion
systems.
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Increased firing temperature
Improved modulated cooling design
New design and retrofit for turbine vanes and blades
Improved transitions
Cross Section Through the Model W501D5 Gas Turbine and Upgrade Measures
OPERATI NG PLANT SERVI CES
14 Siemens Power Journal 2/2000
Convincing Statistics
for World-Class Operating Units
ized resources and continues to
invest to upgrade these facili-
ties to foster its state-of-the-art
capabilities for refurbishing
and repairing gas turbine com-
ponents. The company is also
partnering with specialized
suppliers and recently entered a
joint venture with Chromalloy
to enhance the ability to quick-
ly and cost-effectively provide
refurbishment and coating of
gas turbine vanes and blades.
This joint venture provides
the link to the latest
in aero engine repair and
coating technology, as well as
the production capacity neces-
sary to support customers
growing needs for years to
come.
Global Technology Strength
In addition to providing
best pit stop services, Siemens
also offers numerous upgrade
technologies to enhance en-
gine performance as a further
means to gain an even greater
advantage for winning the
power generation race.
Technical innovation is,
therefore, the third element of
Siemens service strategy. R&D
spending for service has dou-
bled each year for the past
three years. Dedicated engi-
neering resources are develop-
ing modernization products to
retrofit advanced gas turbine
technology into older machines
that will extend the life of these
machines and improve perfor-
mance. These upgrades can
produce output improvements
from 10 to 25% and efficiency
improvements of 4 to 14%, in-
creasing the competitiveness
and profitability of older oper-
ating units.
Siemens is also using ad-
vancements in monitoring and
diagnostics technology to in-
crease facility reliability and
lower maintenance costs. Infor-
mation technology hardware
and software developed by the
company now make entire
plant performance monitoring
possible anywhere in the
world. These systems allow de-
tailed analysis of engine perfor-
mance while the unit is on-line,
enabling potential problems to
be detected before they can
cause outages. Equally impor-
tant, performance monitoring
allows power producers to
stretch inspection intervals us-
ing condition-based mainte-
nance. Siemens is building di-
agnostics monitoring centers
in the U.S. and Germany to as-
sure 7-day/24-hour coverage.
Long-Term Maintenance
Programs and O&M
the Consequent Evolution of
Outage Service and Repair
Commercial innovation is
the final element to complete
the strategy. Today, more cus-
tomers are seeking a compre-
hensive service solution to
maximize unit performance
while keeping costs low and
predictable. Deregulation and
shrinking reserve margins have
led to a dramatic increase of
plant reliabilities as many
deregulated plants earn as
much as 90% of their annual
profit in less than 20% of the
year, and are not allowed to fail
during this time. Many power
producers are moving from
owning plants concentrated in
one geographic area to manag-
ing a worldwide fleet. The geo-
graphic distribution of this fleet
together with the pace of tech-
nological change makes an in-
house maintenance organiza-
tion less cost-effective.
These factors have created
the need for a full spectrum of
service arrangements, from
multi-outage packages, long-
term gas turbine maintenance
programs and fleet mainte-
nance, to total plant operation
and maintenance. The goal of
all these programs is to maxi-
mize the revenue producing ca-
pability of operating plants
while reducing the total cost of
ownership by complementing
the customers core competen-
cies.
Long-Term Maintenance (LTM)
Programs include parts supply
and repair along with outage
services, consolidated into a
single contract covering all
scheduled and unscheduled
plant outages. Siemens cus-
tomers obtain a known main-
tenance model for extended pe-
riods, and we share the opera-
tional risks. A typical gas tur-
bine LTM contract includes:
Outage planning services,
Wet Compression: More Power
When it Benefits Most
W
et Compression is a method of safely injecting water
into the compressor inlet duct of gas turbines with
significant performance gain:
Increased power output by up to 20% and more
Decreased heat rate by more than 1.5%
Reduced nitrogen oxide emissions by 20 to 40% (for engines
equipped with conventional combustion systems)
Increased steam production by 2 to 3% in combined-cycle
applications
The increased power out-
put can be used for example
for increased earnings dur-
ing peak-load demand or for
restoring power loss during
hot days.
Wet Compression System
upgrades are possible for the
W501D, W501D5 and
W501D5A gas turbines and
similar systems for V-series
machines are under develop-
ment.
Spray rack of the
Wet Compression System:
Demineralized water is
injected directly into the
compressor inlet duct with
optimized droplet size and
nozzle flow rates.
W
ithin the United
States, Siemens units
make up about 35%
of the installed capacity, yet
these units generate about
40% of the countrys electricity.
This means these units are
more economical and competi-
tive than the average. More
competitive means more re-
liable and more efficient, en-
abling these units to oper-
ate more and generate more
revenue. That is Siemens
continuous goal.
Siemens Power Journal 2/2000 15
Robert L. Misback
heads Product Line Management for Gas
Turbines within the Operating Plant Ser-
vices Division. His responsibilities include
modernization projects, product develop-
ment, engineering, spare parts supply and
marketing.
Replacement of the combus-
tor components with inspec-
tion and refurbishment of the
original parts (which can then
be used in a future outage)
each year,
Replacement of hot-path
components with inspection
and refurbishment of the origi-
nal parts every three years,
Major turbine outage every
six years,
Expedited unscheduled out-
ages service,
Diagnostics to track perfor-
mance, catch failures before
they occur, and perform predic-
tive and condition-based main-
tenance, and
Modernization to keep plants
competitive.
With a Siemens LTM Pro-
gram, customers are assured
pricing certainty for parts and
service during the contract pe-
riod, plus the added value of an
experienced outage team
whose goal is to return the unit
to service quickly and reliably.
Siemens is also participating in
contracts that make the main-
tenance cost a direct function
of the electricity the plant pro-
duces: In these Performance
Partnership Contracts, the com-
pany supplies all turbine main-
tenance and receives payment
for the hours the unit is in oper-
ation, directly aligning our suc-
cess with that of power produc-
ers. Siemens experience in
long-term gas turbine mainte-
nance programs covers more
than 50 contracts worldwide,
and totals more than 14 GW.
Operation and Maintenance
(O&M) contracts take LTM Pro-
grams to the next level. Over
the last several years, Siemens
has entered O&M contracts for
26 customers worldwide. The
company hires and trains the
plant staff and operators, per-
forms all maintenance and
shares in the risks and rewards.
O&M services allow plant own-
ers to focus on the business of
power, while Siemens runs the
power plant.
The payoff for power pro-
ducers in LTM Programs and
O&M contracts is plant perfor-
mance. On average, plants
with Siemens LTM contracts
achieved 94% availability com-
pared to 88% for non-LTM
plants. Those plants under
O&M contract achieved avail-
ability levels over 95%. This
best-in-class performance gen-
erates more revenue for power
producers.
With Siemens on Your Team
You Have a Strong Partner
Like the Formula One pit
crew whose success is tied to
the race car driver, Siemens
knows that its success is tied to
that of its customers. The finish
line and the checkered flag go
to the power producer with the
most competitive and available
generating units. Siemens goal
is to bring home the checkered
flag for customers time and
time again. I
U
pgrading with the
Fast Acting Inlet
Guide Vanes System
for the V-series gas turbines
allows power producers to
fully participate in the lucra-
tive frequency stabilization
business. With this system a
30-percent pow-
er change can be
achieved in 3 sec-
I
n order to minimize com-
pressor fouling and the
associated power and effi-
ciency losses of gas turbines,
Siemens provides an ad-
vanced compressor cleaning
system (ACCS) for on- and off-
line use. The new system is
available as an upgrade pack-
age replacing the standard
compressor cleaning system
in Siemens gas turbines.
It includes new on- and
off-line spray nozzles, opti-
onds to fulfill even the most
demanding grid codes in the
world. Since the turbine inlet
temperature remains con-
stant with this system, there
are no efficiency losses and
no additional consumption
of equivalent operating hours
during frequency
stabilization op-
eration.
Keeping the
Compressor Clean
mized cleaning agents and a
semi-automatic supply kit.
Power losses of 3 to 5% due
to compressor fouling can be
limited to a maximum of 1 %
by ACCS on-line washing and
an almost complete back-
forming of compressor foul-
ing can be achieved by off-
line use. Currently, a cleaning
system is being developed
that performs safelyi. e., no
icingeven at ambient tem-
peratures below 4C.
Left: High compressor fouling after 25,000 equivalent
operating hours and conventional compressor cleaning.
Right: Low fouling after 25,000 hours using the Siemens ACCS.
System for fast
pitch change of
the compressor
inlet guide
vanes.
Increased Earnings with Better
Frequency Stabilization Capability
Siemens Aktiengesellschaft
Order No. A96001-S90-A732-X-7600
Printed in Germany
81D6141 201954 SD 04011.
SEK 22318
Subject to change without prior notice
Printed on paper treated with chlorine-free bleach
s
Two n a me s o n e g l o b a l c o mp a ny
This article appeared in:
Power Journal
July 2000, page 1015
copyright 2000 by
Siemens AG
Power Generation
This reprint is published by
Siemens AG
Power Generation
Freyeslebenstrae 1
91058 Erlangen, Germany
e-mail: contact@erl11.siemens.de
www.pg.siemens.com
Siemens Westinghouse Power Corporation
The Quadrangle
4400 Alafaya Trail
Orlando, FL 32826-2399, USA
www.siemenswestinghouse.com