With Rolls-Royce Aero Engine Technology Engineered Solutions siemens.com
2 / Engineered Solutions Major Engineered Solutions Offerings Understanding the rapidly-changing nature of today s industrial and commercial environment At Siemens we understand the rapidly-changing nature of today s industrial and commercial environment, in which market requirements and operating conditions can vary significantly - and often unpredictably. So we design and shape our products and services to help ensure Siemens customers maintain and increase performance and profitability throughout the life of their power generation or oil and gas project. The long-term reliability inherent in Siemens equipment means we have gained unrivalled experience and knowledge when it comes to developing the engineered modifications and upgrades that customers need to sharpen their vital competitive edge by enhancing the efficiency, environmental performance and profitgenerating potential of their equipment. These engineered solutions from Siemens enhance your total package, from the gas generator and its control and ancillary systems through to the final driven equipment. Siemens acquired the Rolls-Royce aero-derivative gas turbine and compressor business effective December 1, 2014. References to Siemens and products are intended to refer to such business as acquired and incorporated into Siemens as from such effective date.
Engineered Solutions / 3 We design and shape our products and services to help ensure Siemens customers maintain and increase performance and profitability throughout the life of their power generation or oil and gas project. The Industrial Avon The focal-point for three influential engineered solutions This long-established aero-derivative gas turbine is the focal-point for three influential engineered solutions from Siemens, each delivering significant enhancements to this robust and extensively used gas generator. Industrial Avon 200 upgrade This modification offering cutting-edge technology focuses Rolls-Royce Aero Engine technology on the turbine section of the Industrial Avon. Results provide increased power, efficiency, component life, reliability and time between overhauls - without increasing the exhaust gas temperature. Advances in materials, sealing, geometry and cooling technologies deliver enhancements within the high-, intermediate- and low-pressure turbine sections, while combustion chamber improvements ensure improved availability, increased reliability, reduced overhaul costs and significant reductions in CO and CO2 emissions. Swirler burner This engineered solution enhances combustion stability by directing compressor delivery air through the burner nozzle exit faces and flame-tube swirler. This system - which is standard equipment on the Industrial Avon 200 - focuses on reducing the possibility of liquid hydrocarbon carry-over from the gas fuel, ensuring smoother combustion, extended discharge nozzle life and reduced burner fouling, all of which improve availability. Increased reliability and reduced overhaul costs also result from the way this engineered solution minimises the effects of high-cycle fatigue on turbine blades and discs. Variable inlet guide vane closed loop control This engineered solution delivers enhanced control of the Industrial Avon variable inlet guide vane (VIGV) system. It provides closed-loop control and electronic switching that exploits latest control technology to replace the current mechanical system. By eliminating VIGV drift it maintains gas generator efficiency while removing the possibility of compressor surge. It also removes the need to check VIGV position and blow-off valve settings during operation, enhancing safety, while eliminating time-consuming regular maintenance and improving reliability and availability.
4 / Engineered Solutions The Industrial RB211 The mainstay of a major global range of industrial applications With more than 650 Industrial RB211 gas turbine systems sold worldwide and some 28 million operating hours logged to date, the Industrial RB211 is the mainstay of a major global range of industrial applications - many of which are in remote or offshore locations where high availability and reliability are crucial. Industrial RB211 engineered solutions from Siemens include upgrades based on comprehensive system history and key performance indicators established in our technical support networks. These upgrades enable a retrofit investment that enhances the customer s operation in key areas such as improved efficiency, increased power, extended reliability, and cleaner environmental performance - one or more of which can give you that vital competitive edge. Industrial RB211-24C to -24G upgrade This engineered solution gives the option of increased power and improved heat rate or increased life when operating at RB211-24C ratings. Replacement turbine components feature directionally-solidified blades with improved cooling, advanced aerodynamics and improved seals allowing higher firing temperatures, which help increase power and improve heat rate. If used at -24C firing temperatures, these materials provide extended component life. Power is increased by up to 13% above -24C base load, while reduced life cycle costs include reduced fuel burn, extended time between overhauls and an improved mechanical design eliminates weaknesses. Significant reductions in CO2 emissions provide another key benefit. Industrial RB211-24C/G to 24G DLE upgrade This engineered solution lowers emissions by replacing the combustor assembly module with nine radial combustors, fuel valves and associated piping. This upgrade exploits latest lean-burn combustion technology and supplies fuel through three manifold systems. Full low-nox and low-co capability is achieved by this conversion. The success of the Industrial RB211-24G in the market is emphasised by the presence of nearly 300 units in service worldwide, with combined operational experience of nearly 10 million hours - and the lead engine with 100,000 hours. Nearly 60-24C rated Industrial RB211 s have received the -24G upgrade, with the lead engine accumulating more than 70,000 hours since conversion.
Engineered Solutions / 5 This engineered solution lowers emissions by replacing the combustor assembly module with nine radial combustors, fuel valves and associated piping. Gzero upgrade Up to 10% more power can be achieved by upgrading to a modified intermediate-pressure compressor equipped with an extra stage of blades at the front (a zero-stage). This engineered solution also matches the flow capacity of the power turbine to the increased gas generator output. Dual fuel conversion Electric start conversion This upgrade replaces existing high-pressure natural gas starter systems with a simpler, more robust electric motor that has worldwide voltage capability. Benefits include a reduced design complexity that delivers a minimum overhaul/service life of 20 years, better reliability, easier maintenance, reductions in emissions and noise and considerable savings in maintenance costs over a 25-year life cycle of an electric starter. This engineered solution increases the flexibility of Industrial RB211 units operating in power generation and oil and gas applications. It gives the option of running the engine on either gas or liquid fuel, while fuels can be switched during steady-state running of the gas generator. The upgrade eliminates the risk of interruption or depletion of the gas generator s fuel supply. It also provides a black start capability. Today more than 80 units are operating with this dual fuel capability, with combined experience of more than three million hours.
6 / Engineered Solutions The Industrial 501 Popular, proven and profitability-enhancing engineered solutions Two popular, proven and profitability-enhancing engineered solutions are available to operators of Siemens Industrial 501 generating sets worldwide, the upgrade from KB5 to KB5S standard and the DLE fuel system upgrade. Industrial 501-KB5 to KB5S This superior Industrial 501-KB5S specification improves the heat rate and increases the output power of the Industrial 501 package. By replacing the KB5 rear turbine bearing support and fourth-stage turbine blades, this engineered solution increases power output by up to 4% without the need to raise firing temperatures, while the heat rate can be improved by up to 6%. The work is undertaken during overhaul of the gas generator. Dry Low Emissions (DLE) conversion Advanced lean-burn combustion technology reduces NOx and CO emissions without the need for water injection. Available for gas-fuelled Industrial 501 installations, the dry low emissions engineered solution ensures ignition and part-power operation is performed by use of the pilot fuel circuit, while full-power operation is achieved solely on the main fuel circuit. Emissions levels of 25 vppm of NOx and 50 vppm of CO are achievable. More than 100 DLE systems have entered service in recent years and customers include Triger Cinergy (with five units), Florida Gas (five units) and Pacific Gas & Electric (four units). This engineered solution is delivered during routine overhaul of the Industrial 501.
Engineered Solutions / 7 With RT48 power turbines, conversion of open-bladed stages to RT48S shrouded blade design enhances efficiency and improves blade vibration damping. Power Turbines The latest in mechanical and aerodynamic improvements Mechanical and aerodynamic improvements, latest component technologies and refurbishments to as new condition are among the Siemens engineered solutions aimed at extending the effectiveness of customers power turbines. For example, RT56 packages can be upgraded to RT62 by changing the power turbine (which shares the same footprint and centre line) to unlock the existing additional power available from the same Industrial RB211 engine. RT56 and RT62 T-PIN to curvic rotor upgrade This engineered solution ensures the second-stage disc rotation is transferred to its shaft by a curvic coupling that replaces the existing T-pin coupling - an enhancement that reduces rotor vibration and enhances availability. RT56 / RT62 hot match conversion RT48 to RT48S and RT56 to RT62 conversions These conversions use latest-technology components to increase power and improve heat rate. They also deliver the benefit of a zero-hour upgrade, in which the unit is returned to as-new condition. With RT48 power turbines, conversion of open-bladed stages to RT48S shrouded blade design enhances efficiency and improves blade vibration damping. Rated speed can be increased to realise full efficiency and an increase in power. RT48S/RT56/RT61 zero hour refurbishment This engineered solution provides the customer with a new set of discs and blades that bring the benefits of running the rotor in as-new condition. The RT56 / RT62 upgrade enables the operator to run another 100,000 hours without major overhaul. This engineered upgrade replaces first-stage vanes with new components, increasing the turbine s throat area and helping to improve performance in hot conditions.
8 / Engineered Solutions Compressors The focal-point for three influential engineered solutions You can match your compressor operation to changes in operating conditions by undertaking a re-aero of Siemens pipeline and barrel centrifugal compressors. At considerably less than the cost of a new compressor, Siemens can rework the aerodynamic bundle to meet new site conditions and restore it to full operational efficiency. Dry Gas Seal (DGS) upgrades bring benefits too by eliminating problems with the high-pressure seal oil system. Better operational performance and higher corrosion resistance add to the value. Low leakage wet seal upgrade This upgrade reduces the potential for oil leaks in compressors by using wet seals. A Kaydon seal (a liquid buffered oil bushing seal with low leakage and high reliability) in a cartridge assembly is fitted to ensure reduced oil leakage. Re-aero / aerodynamic / assembly replacement By upgrading the aerodynamic bundle you can gain greater operational efficiency and extend the head, capacity and operating envelope - for considerably less cost than a new compressor. New components, often steel machinings to replace castings, deliver significant improvements. Efficiency improvements of up to four percentage points can be delivered by better design and manufacturing techniques. Dry gas seal conversion This engineered solution enhances the compressor sealing system and eliminates problems linked to high-pressure oil-based sealing systems. It eliminates oil contamination, saves energy by reducing parasitic losses caused by oil seal pumps and removes the need to dispose of used oil. Maintenance costs and downtime are also reduced.
Engineered Solutions / 9 At considerably less than the cost of a new compressor, Siemens can rework the aerodynamic bundle to meet new site conditions and restore it to full operational efficiency. Controls Engineered controls solutions improve your equipment s reliability Engineered controls solutions improve your equipment s reliability by replacing obsolete controls with new and improved systems. This enhances system diagnostic trending and brings benefits of remote operation and data acquisition. FT125 control system upgrade This influential engineered solution is ideal for Industrial 501, Industrial Avon and Industrial RB211 packages. Based on a programmable logic controller with remote I/O s (Inputs/Outputs), the FT125 is suitable for both new and retrofit applications. It can be used as a stand-alone engine control system, interfaced to a central diagnostic maintenance system or to a central plant control system. The FT125 offers the benefit of availability of extensive information for equipment diagnostics and preventative maintenance, while protecting your equipment to ensure improved availability and reliability. Siemens has developed a variety of control system solutions. It is important to select the most appropriate solution for your needs. Three types of upgrades are available: Full panel upgrade Sub plate replacement Option selection based on operational need, equipment vintage and allowable downtime for replacement. Quickest replacements are achieved via modular upgrade and have been completed within 7-9 days with planning and teamwork between the customer and Siemens field service teams. Complementary upgrades to vibration monitoring, surge control and generator control and protection are also available. FT210 HMI and FT310 upgrades These complementary upgrades along with the FT125 upgrade are also available which bring the software and hardware of the Health Monitoring Instrumentation computer and the engineering work station to the latest standard and configuration. Fuel control system upgrades Siemens engineered solutions can assess your current fuel delivery system and provide you with the most modern and robust system updates. For example, our electricallyactuated metering valves meet demands in gas turbine flow accuracy and are responsive to transient requirements, including those for low-emission gas turbine uses. Bolt-in/plug-in modular replacement
10 / Engineered Solutions North America (NA) Europe Russia & Africa (ERA) Middle East & Central Asia (MECA) Asia-Pacific (AP) South America (SA) The Package Engineered solutions deliver a broad range of package improvements and upgrades Siemens engineered solutions deliver a broad range of package improvements and upgrades, including restoring your power and efficiency in high ambient temperatures, increasing the functionality and reliability of your fire and gas protection systems and improvements to air inlet filtration system to extend operational life and increase air flow. GG Lube Oil System Upgrade The GG Lube Oil system upgrade is applicable to all Industrial RB211 and Industrial Avon gas generators model. This upgrade provides the latest standard lube oil system design for Oil and Gas and Power Generation customers with a free standing state-of-the-art lube oil console. The new Lube Oil System can be an external skid mounted next to the Gas Turbine package or alternatively integrated within the package itself. Various retrofit solutions such as sharing of the same oil reservoir for the Hydraulic Start systems for Industrial RB211 to the new Lube Oil Console is available to maximizes your unit availability and reliability. Hydraulic Start System Upgrades The Hydraulic Start System Upgrade is applicable to all Industrial RB211 gas generators models. This upgrade provides a completely new close loop hydraulic start system that incorporates the latest technology in the market today and also addresses the older obsolete components of the hydraulic starter systems on all older vintage Industrial RB211 engines. The scope of supply involves an on engine hydraulic starter motor plus a completely independent hydraulic starter skid which has an electric motor driven pumps and manifold assembly. Additional pump assemblies rated at 3 x 50% power can be supplied as an option to increase unit hot sparing and redundancy. Inlet fogging system upgrade This system comprises a pump unit with dispensing nozzles placed in the combustion air inlet duct downstream of the air filter. It provides up to 14ºC of cooling effect thus providing a power boost on hot ambient days. Its demineralised water supply is available from an optional water treatment skid. This upgrade is installed at your site. Fuel metering valve and motor controller upgrade The old standard hydraulic fuel valves and motor controllers can be upgraded to the latest standard and are offered as an optional complementary upgrade to the FT125 controls system upgrade. Fire and gas detection/suppression system upgrades This engineered solution uses latest technologies in fire and gas detection. It revises your package s suppression system to conform with local environmental regulations.
Engineered Solutions / 11 The old standard hydraulic fuel valves and motor controllers can be upgraded to the latest standard and are offered as an optional complementary upgrade to the FT125 controls system upgrade. Machinery protection, availability and reliability is improved and systems have on-board diagnostics. Inlet air filtration upgrade Multiple filter options extend operation life and increase air flow. Replacement units for normal unit operation, plus enhanced systems that cope with rapid contamination in harsh environments are the available options. This engineered solution provides high protection from fine particles and extends unit performance by preventing environmental deposits on the inlet housing and compressor rotor. Low-cost turbine protection is gained while compressor fouling and erosion is reduced, increasing your unit s availability and its mean time between overhauls. Regional Sales Offices North & Central America 8303 McHard Road Houston, Texas 77053 USA Telephone: +1 281 436 6700 Fax: +1 281 436 6777 Europe, Russia & Africa The Iceni Centre, Warwick Technology Park Warwick CV34 6DA, United Kingdom Tel: +44 (0) 1926 306000 Tel: +44 (0) 1926 306000 South America Av. Almirante Barroso 52, 9th Floor, 20031-000, Rio de Janeiro, Brazil Telephone: +55 21 2277 0100 Fax: +55 21 2277 0168 Middle East & Central Asia Siemens Energy Ground Floor, Block 6, SAF 2, Masdar City Abu Dhabi United Arab Emirates Tel : +971 2 616 5100 Asia, Far East & Australasia Singapore Siemens Pte Ltd The Siemens Center 60 MacPherson Road Singapore 348615 Tel : +65 6490 6000
Published by and copyright 2014: Siemens AG Power and Gas Freyeslebenstrasse 1 91058 Erlangen, Germany For more information, please contact our Customer Support Center. Phone: +49 180 524 70 00 Fax: +49 180 524 24 71 (Charges depending on provider) E mail: support.energy@siemens.com Order No. E50001-G510-A250-X-4A00 WS 1114 Printed on elementary chlorine-free bleached paper. All rights reserved. Trademarks mentioned in this document are the property of Siemens AG, its affiliates, or their respective owners. Product Mark 501 is a trademark of and used under license from Rolls-Royce plc. Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.