Power for Generations Siemens Power Generation

M a ga z i n e o f t h e S i e m e n s Po w e r G e n e r a t i o n G r o u p

Reprint fromPower Journal International

Siemens Gas Turbine Service Helps toBoost Power Producers’ Sucess

Author:Robert L. Misback

“Start Your Engines”With quick and reliable outage work, long-term maintenance and operation support and superior upgradetechnologies, Siemens gas turbine service helps to boost power producers’ success.

10 Siemens Power Journal 2/2000

O P E R ATI N G P L A NT S E RV I C E S

Winners in the

power industry

need the

most responsive,

knowledgeable

service team.

Tony

Sto

ne

Imagine 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

today’s 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 groups—KWU in Ger-

many, Siemens Parsons in Eng-

land, Siemens Power Corp in

Milwaukee, and Siemens West-

inghouse in Orlando—a syner-

gistic, single Global Service Or-

ganization was created.

This combined service com-

pany covers about 500 GW or

33 % of the world’s 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 customer’s

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-

tomer’s 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. MISBACK

Siemens Power Journal 2/2000 11

12 p

j 2/0

0 e

011998 2004

Installed capacity*

Strong Siemens High-TechGas Turbine Fleet Growth ...

1999 2001 2004

Number of outages

... Needs Unprecendented Growthin 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 recruitingand training.

Specialized Outage Teams

Let’s 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

unit’s 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

12 p

j 2/0

0 e

01

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

shorter—and can do it, as shown

in a recent major inspection

with rotor destacks on V94.2

12 p

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0 e

01

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 profitabilityof older operating units by providing more power output and betterefficiencies.

Through improved procedures, and innovative resource solutions,Siemens has been able to consistently reduce outage duration overthe past few years, cutting outage times almost in half while improving service quality.

12 p

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01

Evolution from 1980 to 1989 Evolution since 1990

GT-MORE 51GT-MORE 42GT-MORE 41GT-MORE 33GT-MORE 32GT-MORE 31GT-MORE 23GT-MORE 22GT-MORE 21GT-MORE 12GT-MORE 11

Package no. V94.2 version l V94.2 version ll V94.2 version lll

100 – 110MW class

110 – 120MW class

120 – 130MW class

130 – 150MW class

150 – 155MW class

155 – 160MW class

Amajor 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 forupgrading packages for this

frame.The packages define an up-grading path that offers ampleflexibility for upgrading strategiespursued by plant producers andallows a flexible change from thecurrent rating class of an installedmachine to a higher output ver-sion.The increase in power outputcan be selected so it will be the

best choice depending on thetechnical condition of the overallplant. The system has also beendesigned for future growth. Fu-ture advances in gas turbine tech-nology can be directly convertedinto upgrading packages, whichwill automatically extend the up-grading path.

Model V94.2 Gas Turbine

Systematic Gas Turbine Upgrading

Upgrading Path for Model V94.2 Gas Turbine

12 p

j 2/0

0 e

011992 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-

12 p

j 2/0

0 e

011992 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 furtherincreasing these figures.

W ith almost 100 operat-ing plants equippedwith the Model W501D5

gas turbine, this 60-Hz machineis the backbone of the W501-seriesfleet of Siemens Westinghouse.The two-phase performance up-

grade program for the W501D5engine can reduce heat rate by3 % and enhance output by 6 %.

Phase 1 is an efficiency up-grade that reduces cooling-airleakage, optimizes cooling flow,reduces blade-tip losses, and im-proves the cooling and coatingof row 1 blades.

The Phase 2 upgrade directlyimproves turbine output by in-creasing the firing temperature.It involves upgrade of transi-tions, improvement of coolingand new coatings for row 1vanes, an increase of cooling-airflow through row 1 blade ring,new coatings for row 2 vanes,

Model W501D5 Gas Turbine and improved combustionsystems.

12 p

j 1/9

9 e

07

Increased firing temperatureImproved modulated cooling design

New design and retrofit for turbine vanes and bladesImproved transitions

Cross Section Through the Model W501D5 Gas Turbine and Upgrade Measures

O P E R ATI N G P L A NT S E RV I C E S

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 PowerWhen it Benefits Most

Wet Compression is a method of safely injecting waterinto the compressor inlet duct of gas turbines withsignificant 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

applicationsThe increased power out-

put can be used for examplefor increased earnings dur-ing peak-load demand or forrestoring power loss duringhot days.

Wet Compression Systemupgrades are possible for theW501D, W501D5 andW501D5A gas turbines andsimilar systems for V-seriesmachines are under develop-ment.

Spray rack of the Wet Compression System:Demineralized water is injected directly into thecompressor inlet duct withoptimized droplet size andnozzle flow rates.

W ithin the UnitedStates, Siemens unitsmake up about 35 %

of the installed capacity, yetthese units generate about40 % of the country’s electricity.This means these units aremore economical and competi-

tive than the average. Morecompetitive means more re-liable and more efficient, en-abling these units to oper-ate more and generate morerevenue. That is Siemens’continuous goal.

Siemens Power Journal 2/2000 15

Robert L. Misbackheads Product Line Management for Gas Turbines within the Operating Plant Ser-vices Division. His responsibilities includemodernization projects, product develop-ment, engineering, spare parts supply andmarketing.

• 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. ■

U pgrading with theFast Acting InletGuide Vanes System

for the V-series gas turbinesallows power producers tofully participate in the lucra-tive frequency stabilizationbusiness. With this system a30-percent pow-er change can beachieved in 3 sec-

I n order to minimize com-pressor fouling and theassociated power and effi-

ciency losses of gas turbines,Siemens provides an ad-vanced compressor cleaningsystem (ACCS) for on- and off-line use. The new system isavailable as an upgrade pack-age replacing the standardcompressor cleaning systemin Siemens gas turbines.

It includes new on- andoff-line spray nozzles, opti-

onds to fulfill even the mostdemanding grid codes in theworld. Since the turbine inlettemperature remains con-stant with this system, thereare no efficiency losses andno additional consumptionof equivalent operating hours

during frequencystabilization op-eration.

Keeping the Compressor Clean

mized cleaning agents and asemi-automatic supply kit.Power losses of 3 to 5 % dueto compressor fouling can belimited to a maximum of 1 %by ACCS on-line washing andan almost complete back-forming of compressor foul-ing can be achieved by off-line use. Currently, a cleaningsystem is being developedthat performs safely—i. e., noicing—even at ambient tem-peratures below 4°C.

Left: High compressor fouling after 25,000 equivalentoperating hours and conventional compressor cleaning.Right: Low fouling after 25,000 hours using the Siemens ACCS.

System for fastpitch change ofthe compressor

inlet guide vanes.

Increased Earnings with Better Frequency Stabilization Capability

Siemens Aktiengesellschaft Order No. A96001-S90-A732-X-7600Printed in Germany81D6141 201954 SD 04011.SEK 22318

Subject to change without prior noticePrinted on paper treated with chlorine-free bleach

s

Tw o n a m e s – o n e g l o b a l c o m p a n y

This article appeared in:Power JournalJuly 2000, page 10–15

© copyright 2000 bySiemens AGPower Generation

This reprint is published bySiemens AGPower GenerationFreyeslebenstraße 191058 Erlangen, Germany e-mail: contact@erl11.siemens.dewww.pg.siemens.com

Siemens Westinghouse Power CorporationThe Quadrangle4400 Alafaya TrailOrlando, FL 3 28 26-23 99, USAwww.siemenswestinghouse.com