SGT5-8000H - Product Validation at Irsching 4 Test Center. Dr. Roland Fischer Phil Ratliff Willibald Fischer. Siemens AG, Energy Sector Germany / USA

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1 SGT5-8000H Product Validation at Irsching 4 Test Center SGT5-8000H - Product Validation at Irsching 4 Test Center Dr. Roland Fischer Phil Ratliff Willibald Fischer Siemens AG, Energy Sector Germany / USA POWER-GEN Asia 2008 Kuala Lumpur, Malaysia October 21-23, 2008

2 Abstract The new SGT5-8000H gas turbine is the result of years of research and development within Siemens Energy to evolve an efficient and flexible engine with low life-cycle costs. Built on the collective development and technology expertise of Siemens and Westinghouse, the SGT5-8000H is the first gas turbine design developed by Siemens after the Westinghouse acquisition. It combines the best features of the existing product lines and advanced technology. The new turbine was developed in strict compliance with the Product Development Process (PDP). The design effort incorporated previous lessons learned, applied proven design features wherever possible and utilized Design for Six Sigma (DfSS) tools to deliver a competitive product focused on life-cycle-costs, performance, serviceability, flexibility, reliability and emissions. Customer needs and benefits are the main drivers for the development of the new SGT5-8000H engine. The air-cooled SGT5-8000H concept offers added value through higher operational flexibility required in deregulated market environment. The SGT5-8000H turbine development team involved more than 250 engineers, working in Erlangen, Berlin and Mülheim in Germany, as well as in Orlando and Jupiter in Florida, USA. An additional 500 employees were involved in the manufacturing, assembly and test preparation of the prototype engine. Single gas turbine components are already tested and verified with success. The complete SGT5-8000H gas turbine is now under comprehensive validation in a real power plant environment at Irsching 4 in a hosting agreement with E.ON. In 2005, Siemens announced the development of the world s largest, most powerful gas turbine. Two-years later, on-schedule, the prototype of the SGT5-8000H was installed at the Irsching 4 gas turbine power plant. Therefore, December 20, 2007, marked a major milestone in the development of the world s most powerful gas turbine its first firing. This was the start of an 18-month trial operation at the Irsching 4 power plant, near Ingolstadt. After successful testing of the turbine, the gas turbine power plant will be rebuilt to a full combined cycle power plant. The high-efficiency combined cycle power plant (CCPP) will have a total output of 530 megawatts and an efficiency of over 60%. The gas turbine supplies enough energy to serve the electricity demands of a city of the size of Hamburg or Barcelona; the combined cycle power plant with the SGT5-8000H will meet electricity demands for a city the size of Madrid or Berlin. The increase of efficiency by 2-percentage points, compared to a state-of-the-art combined cycle power plant, will result in approximately 40,000 tons less CO2 per year. Handover of the CCPP to E.ON Kraftwerke, a subsidiary of E.ON Energy, is expected in The paper will cover: Overview next generation development program Key features of new gas turbine and cc-plant Field validation approach Prototype project Irsching 4 Test and Validation Status

3 Introduction The development of gas turbines is sensitive to market, technical innovation and environmental requirements. The customer expects an economic, competitive product with a high efficiency, great reliability, high flexibility and service kindness at low life time costs. He judges this more and more with the present value (NPV, net present value) determined over the life time of a power station. With a steady technical innovation in development, technologies, materials, and manufacturing, we as manufacturers take these requirements into account. During the development of a new gas turbine, attention must be paid to meet or even exceed the high environmental standards with regard to emissions. Considering all of these influences, a gas turbine can be produced, which increases the customer benefit optimally with regard to efficiency, reliability, flexibility in load ranges and use of fuel as well as in service costs. The new SGT5-8000H gas turbine is the result of years of research and development within Siemens Power Generation. An extremely efficient and flexible, purely air-cooled engine was produced which will be highly competitive against the steam cooled products of the competitors with its low life cycle costs. This is the first new frame developed after the merger of Siemens and Westinghouse and combines the best features of the existing product lines and advanced technology. Interpretation and design of the new engine was built on the experiences of the predecessor 50Hz and 60Hz engines. Proven design features were applied wherever possible, and "Design for-six Sigma" tools were used consistently, to deliver a competitive product which fulfils the features described at the beginning. 8000H Program Overview Overall Duration Development & Validation Testing Schedule Program Launch Concept Phase 01. Oct Gate 1: Product Strategy 21. Mar Gate 2: Start Basic Design (GT) 05. Nov Gate 3: Product Release (GT) 17. Aug P-Type GT ex Works 30. April 2007 P-Type 1st Fire 18. Dec Gate 4: Series Release later in 2008 Page 4 VDI Tagung 2008, Leverkusen, November 2008 Energy Sector Figure 1: 8000H program overview

4 The customer requirements, and with that their advantages were the essential drivers for the development of the new SGT5-8000H. The following key requirements have to be met: Combined cycle net efficiency over 60% Fast start capability and high operational flexibility Lowest life cycle costs High reliability and availability Low Emissions Turn down capability with high efficiency and low emissions With these boundary conditions we started in the year 2000 with the strategic product planning. The engine development was conducted according to a strict milestone plan. In addition to approx. 500 design reviews for individual components, several Gate Releases on Management level were conducted (Figure 1). Engine design and features The engine concept has been selected out of a variety of air cooled engine designs and out of several gas turbine cycle models after a comprehensive feasibility analysis during the conceptual design phase. The selected air-cooled concept offers best added value through higher operational flexibility required in deregulated market environment (Figure 2). Advanced gas turbines in combined cycle are running in both intermediate and base load requiring operational flexibility Market Requirement MW Demand Peak Load Intermediate Load Base Load This range of operation requires flexibility Faster starts Increased turndown High part load performance Our Solution Air Cooled engine with Less Complexity No external engine dependencies for cooling No ties to water-steam cycle for cooling IF THE ENGINE IS TURNING, THERE IS COOLING Page 4 VDI Tagung 2008, Leverkusen, November 2008 Energy Sector Figure 2: Reason for selection of air cooled design The new SGT5-8000H gas turbine is rated at 340 MW in open cycle and 530 MW in combined-cycle with 60% efficiency.

5 The Siemens H-class system is the result of an intensive R&D program to evolve a competitive, efficient and flexible engine. Increased operational flexibility was a major driver in the final choice of technology. The most important gas turbine features are (Figure 3): Single tie-bolt rotor with individual compressor and turbine disks with hirth serration and hydraulic clearance optimization (HCO) Axial 13 stage compressor with high mass flow, high component efficiency, controlled diffusion airfoils (CDA) on front stages & high performance airfoils (HPA) on rear stages, variable guide vanes, cantilevered stator vanes High temperature can annular combustion system, air cooled Four stage, exclusively air cooled turbine Advanced, variable secondary air system (SAS) Direct scaling for further frames e.g. for a 60 Hz gas turbine is possible Advanced highly efficient, high pressure and high temperature combined cycle process with Benson boiler, based on the high mass flow and exhaust gas temperature of the new engine SGT5-8000H World s largest gas turbine High cycling capability due to advanced blade cooling system Advanced ULN* combustion system Evolutionary 3Dcompressor blading Proven rotor design, Hirth serration and central tie rod Four stage turbine with advanced materials and thermal barrier coating 60% Combined Cycle efficiency *Ultra Low Nox Integrated combined cycle process for economy and low emissions Harmonization of V and W frames uses best features from both and introduces new technologies on low risk Page 6 VDI Tagung 2008, Leverkusen, November 2008 Energy Sector Figure 3: Cross section and main features SCC5-8000H combined cycle (CC) plant design Over the past years output and efficiency of combined cycle technology increased significantly from approx. 50 % in the early 90 s towards 60 %. In addition to improvements of the gas turbine, advancements in the water-steam cycle and the heat recovery steam generator were developed.

6 Introduction of the heat recovery steam generator with the once through Benson type offers significant advantages in terms of start-up times and load change flexibility. The following main features are key of the SCC5-8000H plant (Figure 4): Advanced power plant design in a single-shaft combined cycle arrangement Benson boiler for steam generation (HRSG) Water-cooled generator Two-casing steam turbine with double flow low pressure section SGT5-8000H / SCC5-8000H, Key Data Fuel Nat. gas, #2 GT output 340 MW CC outputnet 530 MW SGT5-8000H CC efficiencynet 60% Pressure ratio 19.2 : 1 Exhaust mass flow 820 kg/s Exhaust temperature 625 C SCC5-8000H HRSG/WS-Cycle 600 C/170 bar Benson Page 9 VDI Tagung 2008, Leverkusen, November 2008 Energy Sector Figure 4: Key Data of the SGT5-8000H and the SCC5-8000H Combined Cycle system Gas turbine test and field validation approach For minimization of customer risk during the introduction of a new product, a comprehensive test and validation program was set up. This included tests on prototypical parts already along with the design phase, followed by sub-system validation like atmospheric and high pressure combustion testing, as well as full scale 60 Hz compressor validation. The individual components, sub-systems and engine tests were carried out in the Siemens Berlin test center and at several rig facility sites (Figure 5).

7 Pre-validation on component level Combustion HP Test Rig Full Scale 60 Hz Compressor Berlin Test Center Combustion system and compressor validation in test rigs and under real engine conditions at the Berlin Test Center. Page 13 VDI Tagung 2008, Leverkusen, November 2008 Energy Sector Figure 5: Pre-Validation of combustion system and compressor Prototype test In a final and major step the prototype gas turbine however will be tested under real power plant conditions with connection to the electrical power grid in a hosting agreement with E.ON Kraftwerke. Through this hosting arrangement the gas turbine will be extensively tested in simple cycle operation at the customer site Irsching 4 - under Siemens Energy ownership. This ensures that subsequent commercial units will be brought to market with an adequate testing history. Main elements of this prototype test phase: Test plant operation and engine testing at customer site Irsching 4 by Siemens Energy field test management Extensive testing and validation plan Prototype engine equipped with approx sensors Commercial release of the new SGT5-8000H only after successful completion of the prototype gas turbine testing Prototype plant Irsching 4 The power plant will be erected in two phases (Figure 6). Phase 1 is for the prototype testing of the new developed gas turbine in open cycle configuration.

8 In Phase 1, the plant was erected in the following configuration: Single shaft arrangement, prepared already for the further installation of the steam turbine, connected to the single generator New Siemens gas turbine SGT5-8000H A Siemens water cooled generator SGEN5-300W Temporary exhaust stack Fuel gas supply system connected to the E.ON Ruhrgas gas pipeline grid Auxiliary systems for gas turbine and generator A unit transformer connected to the E.ON high voltage grid Electrical auxiliary power supply, MV & LV switchgear and I&C systems Test and Control center for plant operation Turbine building with heavy load cranes The CCPP Irsching 4, two phase concept Phase 1: Erection and testing GT Phase 2: Extension to CCPP Gas Turbine Set Exhaust Stack Heat Recovery Steam Generator Steam Turbine / Condenser The SGT5-8000H will be validated prior to market introduction to assure product quality and reliability to the customer Page 11 VDI Tagung, Leverkusen, Energy Sector Figure 6: Irsching 4 plant, phased construction concept Upon successful completion of the test phase the plan is to extend this simple cycle prototype test plant to a high efficiency combined cycle plant in phase 2.

9 In its combined cycle configuration the SCC5-8000H power plant will be extended in phase 2 with the following proven technologies and components: A Siemens SST steam turbine A boiler with once through Benson technology Water steam cycle systems, components and piping Cooling water systems, components and piping Extension for electrical power supply, I&C, and control room for combined cycle operation Removal of the exhaust stack, test equipments, and test instrumentations With the successful completion of phase 2 the ownership for the plant will be handed over to the customer E.ON Kraftwerke. Current status of testing (as of Sept. 1st, 2008, submittal of paper): After installation and commissioning in the plant, the unit was 1 st fired on Dec. 20, 2007 and the field validation phase commenced on schedule. In early March 2008, Irsching 4 was 1 st time synchronized to the electrical high voltage grid. Extensive tests have been conducted in the meantime and will continue until mid As of submittal of this paper, approx. 70 starts and 150 operating hours have been accumulated. Key parameters like compressor pressure ratio and aerodynamic efficiency, temperatures in hot gas parts, combustion dynamic behaviour, as well as engine performance, vibrations and emissions have been validated and proven. Further tests to optimize part load behaviour and endurance test phase are scheduled for the coming months. In closing, customer needs for reduced life cycle cost are met by the innovative solutions of the SGT (Figure 7).

10 Figure 7: SGT5-8000H, innovative solutions for reduced life cycle costs The gas turbine will initially target the 50Hz markets in Asia and Europe. At the outset the engine is being developed for use with natural gas and fuel oil, but operation will be expanded to also include special fuel needed for applications such as IGCC. A geometrically scaled 60Hz SGT6-8000H gas turbine will be released after the 50Hz engine verification. REFERENCES [1] Building the world s largest gas turbine, Modern Power Systems, Germany Supplement [2] Neue Gasturbinen für mehr Kundennutzen, VGB-Kongress, Kraftwerke 2006, Dr. Wolf-Dietrich Krüger, Siemens AG Power Generation [3] Kleinfeld, K., Annual Shareholders' Meeting of Siemens AG on January 25, Report by President and CEO of Siemens AG Dr. Klaus Kleinfeld [4] Ratliff, P.,Garbett, P., Fischer, W., SGT5-8000H Größerer Kundennutzen durch die neue Gasturbine von Siemens, VGB PowerTech, September 2007 [5] U. Gruschka, B. Janus, J. Meisl, M. Huth, S. Wasif, ULN system for the new SGT5-8000H gas turbine