Siemens Power and Gas

Transcription

1 Siemens Power and Gas Additive Manufacturing of gas turbine components a challenge for industrial application LMP Industry Workshop Jan Münzer Restricted Siemens AG 20XX siemens.com/power-gas

2 Siemens Power and Gas Products LGT lead plant Gas turbine facility Berlin Huttenstraße 130,000 m² plant area 68,700 m² built-up About 65% under crane coverage Berlin plant (Manufacturing, Service, Engineering) Employees 3,700 Women Proportion 19% Number of Nationalities 46 Apprentices 250 Page 2 October 2017

3 A typical product from Berlin: Siemens SGT5-8000H Reliable, flexible, proven and fully on board air-cooled Simple cycle power generation Power output (gross) Fuel (examples, other fuels on request) Exhaust mass flow 450 MW Natural gas, LNG, sour gases, distillate oil, biodiesel, ASL, kerosene, jet fuel, condensate 935 kg/s (2,061 lb/s) Exhaust temperature 630 C (1,166 F) Combined cycle power generation Siemens combined cycle power plant 1x1 2x1 Power output (net) 665 MW 1,335 MW Physical dimensions Approx. weight 445,000 kg (981,000 lb) 61% efficiency in combined cycle Page 3 October 2017

4 AM Network within Siemens PG, PS and CT Substantial equipment for powder-bed based AM DG, Montreal, CA PS, Winston Salem, USA GT Worcester, UK DG, Lincoln, UK DG, PS, Finspang, SE SAG AM Center of Competence (CoC) GT Berlin GT Worcester CT Berlin DG/PS Finspång SAG PG and PS locations using AM Strategic partners and external vendors CT, Charlotte, USA PS, Houston, USA GT, Orlando, USA GT, Mülheim a.r., GER CT, Munich, GER GT & CT, Berlin, GER EOS M270 EOS M280 EOS M290 EOS M400 (-1/-4) Aligned implementation strategy, development roadmaps and equipment base Page 4 October 2017

5 Use Cases for Additive Manufacturing over the life cycle Lead time and performance are major drivers Drivers Technology & Product Development Rapid Development & Validation Production Rapid Manufacturing Rapid Repair After Market & Service Spare Parts on Demand Lead time & Availability Costs Performance & Innovation Examples Product: SGT5-4000F Product: SGT-700/800 Product: SGT-700/800 Product: SGT-1000F Component: Turbine vane Component: Burner frontend Component: Burner tip Component: Burner head AM is a powerful enabler for next level development, manufacturing and repair of advanced gas turbine components. Parts with complex geometry and high impact on customer value(efficiency, durability) are favorites. Page 5 October 2017

6 Key challenges and technologies in the development of future gas turbines for highest efficiency Compressor Increase of mass flow Increase of pressure ratio 3D aerodynamics Reduction of aerodynamic losses Combustion Higher combustion temperatures Optimized burner (fuel flexibility) Reduced emission Increased efficiency Turbine Higher turbine inlet temperatures New materials and coatings Improved cooling and sealing 3D aerodynamics, reduction of losses These goals cannot be reached with conventional development methods, conventional designs and conventional manufacturing technologies! Page 6 October 2017

7 Fast Technology Validation AM enables paradigm shift in design, testing & validation Integrated development: Accelerated iteration cycles in few months 3D (Re-)Design SLM processing Post processing Instrumentation Testing Full Engine Test Bed Clean Energy Center Conventional process Testing is final validation at the end of development process Sequential development processes Conservative development approach Moderate development targets Long development cycles Page 7 October 2017 Novel paradigm Testing is integrated part of development process Parallel and integrated development processes Radical development approaches Ambitious development goals Accelerated development, short iteration cycles

8 Assembly Engine Test Fast Technology Validation SGT-400 Turbine Blade 1 SLM turbine rotating blades tested in real engine full speed, full load! Lincoln SGT-400 test bed engine Stage 1 SLM process Model Breakthrough in fast technology validation of hot gas path components Development cycle time reduction (75 %) Development cost reduction (> 50 %) Page 8 October 2017 SLM blade After test Test conditions: Turbine inlet temperature: 1258 C Turbine speed: 13,600 rpm (blade speed ~ 1,600 km/h) Load on blade tip: ~11 tons

9 Redesign Rapid Manufacturing Part/Assembly: SGT-700/800 burner frontend Testing at customer sites Assembly situation New SLM design burner Burner front ends produced by SLM Source: Tildy Bayar, 2016, The 3D printing future has arrived, Power Engineering International Radical redesign of existing burners for SGT-700/800 to utilize the extended design space offered by AM Significant reduction of components/functional integration elimination of assembly steps(from 13 pcs. and 18 welds to a single part) Optimized cooling in burner tip elimination of thermal barrier coating Significant lead time reduction down to 15% Optimized combustion performance lower emissions Page 9 October 2017

10 Advantages Rapid Repair Part: SGT-700/800 burner tip Step 1: Mechanical preparation of damaged burner tip Step 2: Assembly of burner and fixture for SLM Step 3: SLM repair of burner tip Benefits Efficiency Improvement Faster repair process / reduced lead time Easy upgrade to the latest design Fully established serial repair chain Vision: Spare Parts on Demand close to the customer location Source: O. Andersson, A. Graichen, H. Brodin, V. Navrotsky, 2016, Developing Additive Manufacturing Technology for Burner Repair, Journal of Engineering for Gas Turbnies and Power Additive manufacturing bringing gas turbine burner repair to the next level In commercial operation since 2013 Page 10 October 2017

11 From Fast Technology Validation to Rapid Manufacturing Design evolution of pilot burner cone during testing of SLM prototypes Pre-Mature Prototype Design BTF Engine Test Design Improved Prototype Design Weld Assembly Monolithic design SLM-built Reduced lead time Design for SLM Internal cooling channels Improved lifetime Page 11 October 2017

12 From Fast Technology Validation to Rapid Manufacturing Design for Additive Manufacturing: Pilot Burner Cone Source: Stefan Reich, Siemens AG Meandering cooling channels cannot be realized by investment casting Elimination of weld assembly Improved Performance by function-oriented design Application of Design For Additive Manufacturing (DFAM) Successful example for DFAM and integrated testing within product development Page 12 October 2017

13 Conclusions: AM has already changed development and production of gas turbine components but technology needs to be developed further SLM offers unique potential for future gas turbines: Extended design space allows advanced designs for better performance Efficient repair and refurbishment applications Development and validation paradigm change enables radical approaches Cost & lead time reduction Further industrialization of SLM requires additional development and is substantial for success in the gas turbine industry: - Capacitity (build chamber sizes) & costs (materials, machines) - Productivity accelerated SLM processes (multiple lasers, laser arrays, innovative optics, diode arrays, splitter) - Robustness and repeatability process control and robust machines - EHS industry standards - Line integration standardized interfaces for hard and software - Seamless and streamlined data flow - Process technology for hard-to-weld alloys - New design rules, design tools and a major change in how engineers design parts a change in mindset and an educational concept Page 13 October 2017

14 Additive manufacturing of gast turbine components - a challenge for industrial application Jan Münzer Principal Key Expert Siemens Power and Gas Additive Manufacturing Product Integration Huttenstrasse Berlin Phone: Mobile: jan.muenzer@siemens.com siemens.com Page 14 October 2017

15 Disclaimer This document contains statements related to our future business and financial performance and future events or developments involving Siemens that may constitute forward-looking statements. These statements may be identified by words such as expect, look forward to, anticipate intend, plan, believe, seek, estimate, will, project or words of similar meaning. We may also make forward-looking statements in other reports, in presentations, in material delivered to shareholders and in press releases. In addition, our representatives may from time to time make oral forward-looking statements. Such statements are based on the current expectations and certain assumptions of Siemens management, of which many are beyond Siemens control. These are subject to a number of risks, uncertainties and factors, including, but not limited to those described in disclosures, in particular in the chapter Risks in Siemens Annual Report. Should one or more of these risks or uncertainties materialize, or should underlying expectations not occur or assumptions prove incorrect, actual results, performance or achievements of Siemens may (negatively or positively) vary materially from those described explicitly or implicitly in the relevant forward-looking statement. Siemens neither intends, nor assumes any obligation, to update or revise these forward-looking statements in light of developments which differ from those anticipated. Trademarks mentioned in this document are the property of Siemens AG, its affiliates or their respective owners. TRENT and RB211 are registered trade marks of and used under license from Rolls-Royce plc. Trent, RB211, 501 and Avon are trade marks of and used under license of Rolls-Royce plc. Page 15 October 2017