SCC5-8000H / Irsching 4 Beyond 60% - Pioneering H-class Efficiency with World Class Flexibility Irsching General Manager for GT Power Plant Solutions Europe, Africa, Asia and Australia Siemens AG 2011. All Siemens rights reserved. AG 2011
SCC5-8000H development based on comprehensive component and field validation Plant efficiency beyond 60% Highest operational flexibility Best economic and ecological solution Program Initiation Design Gate Product Release Series Release Program Closure 2001-03-21 L. Balling Gate 1 2001-11-05 W.D. Krüger Gate 2 2004-08-17 K. Riedle Gate 3 2008-08-28 / 2010-06-21 R. Hauenschild Gate 4a Gate 4b 2011 Gate 5 Strategic Product Planning Design Sales Design Implementation Validation Prep: M00 M20 M30 M40 M50 M60 M70 M80 M90 M100 R0 R1 R2 R3 R4 R7 R8-1 R8-2 R5 R9 R10 10 years of rigorous development process realized the answer to the today s and tomorrow s most challenging Energy requirements Page 2
Agenda Introduction Siemens H-class combined cycle power plant solution Irsching 4 project: world class performance Conclusion Page 3
Siemens Combined Cycle Power Plants addressing the major environmental and economical market drivers Wind Power Solar Power Lowest investment Highest efficiency Operational flexibility + + CO 2 Emission Reduction Gas Prices Page 4
We need flexible plants in the future: Power Generation Scenario 2020 (Germany) High wind day Typical Summer Week (June 2020) residual load [MW] 20.000 15.000 10.000 5.000 0-5.000-10.000 Load ramps: Average: 52 MW/min Max.: 181 MW/min Min.: 0,467 MW/min Overload Peaks 9h 6h 10h 8h 11h 0 1 3 5 7 9 11 13 15 17 19 21 23 25 time [h] Peak 4 GW 2 GW 11h 6h 8h 2 GW 1 GW 2 GW 9h 6 GW 10h 100% daily start-stop Germany 2020: Up to 100% of the non-renewable fleet requires daily start-stop operation, Load ramps of about 200 MW/min to be covered Page 5
Agenda Introduction Siemens H-class combined cycle power plant solution Irsching 4 project: world class performance Conclusion Page 6
SCC5-8000H 1S designed for η > 60% and highest operational flexibility Published Design Targets: Performance (net, ISO) Power: >570 MW Efficiency: > 60% Emissions (Base load) NOx < 25 ppm CO < 10 ppm Steam Turb.:SST5-5000 Combined HP/IP Dual flow LP HP: 170 bar / 600 C IP: 35 bar / 600 C LP: 5 bar / 300 C HRSG: Benson TM 3Pr/RH 600 C/170 bar Generator: SGen5-3000W Water cooled stator winding Hydrogen cooled rotor winding MICALASTIC Stator insulation World class efficiency Gas Turbine: SGT5-8000H Page 7
SCC5-8000H 1S, a proven concept optimized for highest operational flexibility Stack damper BENSON technology High-capacity de-superheater ST stress controller FACY Fast Cycling Advanced steam parameter 600 C cycle Optimized GT load ramp Low complexity (No GT steam cooling system) HRSG standby heating Condensate polishing plant Proven cycle concept triple pressure reheat cycle Specific features included in our advanced 8000H class cycle design for most flexible and reliable operation Page 8
HRSG with Siemens Benson TM HP section designed for 600 C steam temperature Irsching 4 Benson TM* HRSG is designed and delivered by Siemens Proven Benson Design Concept Siemens Benson HRSG design, 19 units built, e.g. Malzenice, Gönyü, Severn Power, Sloe Centrale Siemens Design Principles Based on F-class technology as executed in e.g. Karstoe, Simmering, Timelkam HRSG + Plant Development in one Hand = HP pressure/temp.: 170 bar/600 C RH pressure/temp: 35 bar/600 C Mass flow: 100 kg/s Weight: ~ 7000 tons Heating surface: > 500.000 m² Benson Evaporator Design 600 C Technology Based on Siemens Benson TM Technology * (Elimination of HP drum) Utilization of high temperature materials applied for 600 C Steam Power Plants Innovation based on proven technology and materials (*) Siemens is owner of the Benson TM patent Page 9
Irsching 4 Siemens Benson TM HRSG New technology step beyond F-class F-class HRSG H-class HRSG Rel. increase of H-class HRSG Steam Pressure 130 bar 180 bar + 35% Steam Temperature 565 C 600 C + 35 C Steam Mass Flow 77 kg/s 100 kg/s + 30% Heating Surface 100% 145% + 45% Width 11,5 m 15,1 m + 30% The Siemens Heat Recovery Steam Generator in Irsching 4 sets a new standard in size and performance Page 10
Agenda Introduction Siemens H-class combined cycle power plant solution Irsching 4 project: world class performance Conclusion Page 11
Irsching 4 Combined Cycle extension Highlights of the successful project execution 2009 2010 2011 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Phase 2: Erection CC testing & Validation Customer Acceptance of GT CC Extension GT 1 st Fire 1 st Steam admission Start com. operation First combined cycle base load achieved within 2 days of operation after 1 st steam admission Validation program completed (incl. CC Performance, steam turbine, FACY TM Start-up, min. and part load operation, grid code dynamic tests, Benson TM HRSG) All contractual Phase 2 tests necessary for reliability run completed Achieved operating experience: > 2.500 (> 4000) Operating hours > 215 Starts (~ 250) >> 90% Starting Reliability(/comm.) Irsching 4 project phase 2 fully on track Validation and testing program completed Page 12
Dynamic load tests Plant fast hot start-up (FACY TM, hot start on-the-fly) 600 60 Plant Start-up Time < 30 min. CC Full Load 500 50 Plant Output 400 300 200 GT Speed ST Speed Plant Output Ø Ramp Rate > 25 MW/min 40 30 20 Turbine Speed GT Load up to 35 MW/min 100 10 0 0 GT ignition Time [min] GT @ base load More than half a GW in less than half an hour Page 13
Load tests: Plant fast shut down (FACY TM ) and minimum stable load 600 Plant Shut Down Time < 30 min. 760 60 500 660 GT Speed ST Speed 50 400 Plant Output 300 200 Plant Output 35 MW/min GT Load 28 MW/min 560 ST Speed 460 360 260 GT Speed Turbine Speed 40 30 20 100 0 160 60 GT Load ~ 60 MW 0 15-40 0 30 30 60 90 0 GT @ base load Time Geno. breaker open GT Load ~ 60 MW Time Plant min. load ~100 MW 10 Page 14 Plant ramp down to min. load at 100 MW (~ 20%) or shut down in less than 30 minutes
Dynamic load tests Plant load changes 15 MW/min 35 MW/min 600 500 HP Steam Temp. 600 C 27 MW/min 22 MW/min ± 35 MW/min 600 500 Plant base load Plant Output 400 300 200 14 MW/min 16 MW/min Plant Output GT Load Steam Temperature 400 300 200 100 100 Plant cycling operation with over 200 MW load change in less than 7 minutes Different load gradients successfully tested at stable plant system operation Page 15 0 0 60 120 180 240 300 360 Time 0
Dynamic capability: Frequency response Irsching 4 test results UK Grid Code frequency response requirements: Primary Operating Reserve: 10% CC load within 10 s, for further 20 s Secondary Operating Reserve: 10% CC load within 30 s, for further 30 min Load increase 64 MW (12%) in 10 s CC load Achieved results: Frequency drop induced plant load increase by 12% within 10 s No load reduction followed Frequency simulation -500mHz Page 16 Frequency response target overachieved Potential for more stringent future demand
Dynamic capability: Island operation Irsching 4 test results UK Grid Code island formation requirements: Frequency control and deloading up to 45% Load adjustement within few seconds Load decrease 250 MW (45%) in 6 s Achieved results: Island detection in GT controller based on frequency deviation No plant trip occured Deloading by 45% followed within 6 s Combined response of GT and ST Stable behavior of plant systems and components Page 17 Island operation capability target achieved We are already prepared for the upcoming ENTSO-E network code
Irsching 4 Combined Cycle Power Plant World record test run *1 *1 Irsching 4 reference site conditions Independent body verified and certified our test and operation results Page 18
Siemens high efficient H-class CCPP solution enables significant CO 2 emissions reduction 100% Average coal fired power plant fleet in Europe CO 2 reduction by fuel switch from coal to gas CCPP Efficiency Improvement CO 2 reduction by Siemens H-class CCPP ~ 40% Siemens H-class CCPP CO 2 saving: 4,2 Mill tons/year/ 1000 MW* (*) per 1000 MW unit power output at 36% average efficiency and 8000 operation hours ~ 60% CO 2 emission reduction due to lower carbon content of natural gas and higher efficiency with our SCC5-8000H Page 19
Agenda Introduction Siemens H-class combined cycle power plant solution Irsching 4 project: world class performance Conclusion Page 20
Siemens H-class CCPP sets new standards for efficiency, power and operational flexibility The new technology features experienced intensive testing and validation programs and exceeded all expectations Phase 1 core engine validation in simple cycle operation mode Phase 2 combined cycle extension including plant performance and operational flexibility validation First operation of the new 50 Hz H-class combined cycle power plant achieved at: Page 21 World record net efficiency at 60,75% High net power output at 578 MW Highest operational flexibility with fast start-up time below 30 min Highest starting and operation reliability already in commissioning Commercial operation in project schedule