One year of commercial operation in Irsching - Siemens Energy

SGT-8000H series and SCC-8000H power plants 

One year of commercial 

operation in Irsching 

PowerGen Asia 

Bangkok, October 3-5, 2012 

Lothar Balling 

Executive VP Gas Turbine Power Plant Solutions 

Europe / Africa / Asia / Australia 

Dr. Kais Sfar 

Head of Product Line Marketing Plant Solutions 

Armin Staedtler 

Head of 8000H R&D Program 

Siemens AG, Energy, Fossil Power Generation 

Protection notice / Copyright notice

Agenda 

The challenge – 

Portfolio overview 

Fluctuating power demand at raising fuel costs 

SGT-8000 series and SCC-8000H power plant solutions 

Validation of the 50Hz and 60Hz frames 

Operational experience and references 

Page 2 Bangkok, October 3-5, 2012 Balling, Sfar, Staedtler © Siemens AG 2012. All rights reserved

Evolution of Siemens Combined Cycle Technology 

1991 1996 

2008 

2011 

SGT5-2000E SGT5-4000F SGT5-4000F SGT5-8000H SGT5-8000H: 

(Intro) 

(latest upgrade) (Intro) 

(next steps) 

> 50% > 56% > 58,5% > 60% > 61,5% 

CC efficiency* 



CC efficiency* CC efficiency* 

CCPP 

Killingholme (2x1) 

2 x 450 MW 

525 °C / 80 bar 

2PR-non RH 

CCPP 

Didcot B (2x1) 

2 x 705 MW 

CCPP 

Mainz (1x1) 

405 MW 

CCPP 

Irsching 4 (1S) 

578 MW 

�10 % points increase in efficiency over approx. 20 years 

* at ISO conditions 

540 °C / 110 bar 

3PR-RH 

565 °C / 125 bar 

3PR-RH 

600°C / 170 bar 

3PR-RH, Benson 

CCPP 

SCC5-8000H (1S) 

> 600 MW 

Future 

Page 3 Bangkok, October 3-5, 2012 Balling, Sfar, Staedtler © Siemens AG 2012. All rights reserved 

t.b.d 

~ 2015

Siemens Large Scale Gas Turbines: 

Product Portfolio for 50 Hz and 60 Hz 

SGT5-8000H 

SGT5-4000F 

SGT6-8000H 274 

SGT6-5000F 

SGT6-4000F 

SGT5-2000E 

SGT6-2000E 

SGT5-8000H 

04/2007 

113 

Output in MW @ ISO conditions 


168 

187 

208 

SGT6-8000H 

01/2011 

Direct scale 

1 / 1,2 

(50 / 60 Hz) 

292 

375

Agenda 








Overview of Key Data 

SGT5-8000H SGT6-8000H 

SCC5-8000H 1S SCC6-8000H 1S 

Fuel Nat. gas, #2 Nat. gas, #2 

GT, Power 375 MW 274 MW 

GT, Efficiency 40 % 40 % 

CC, Power 570 MW 410 MW 

CC, Efficiency 60 % 60 % 

Pressure ratio 19.2 : 1 19.5 : 1 

Exhaust mass flow 820 kg/s 610 kg/s 

Exhaust temperature 625 °C 625 °C 

Emissions, NOx 25 ppm 25 ppm 

Emissions, CO 10 ppm 10 ppm 

HRSG/WS-Cycle 600°C/170 bar 585°C/150 bar 

Benson Benson/Drum 

Optional 585°C/150bar 600°C/170bar 

Benson/drum Benson 

at ISO conditions 

SGT5-8000H 

SCC5-8000H 1S 


SGT-8000H 

Efficient & Flexible 

Evolutionary 3D blading 

4 stages of fast acting variablepitch 

guide vanes (VGV) allowing 

for improved part load efficiency 

and high load transients 

Proven rotor design 

(Hirth serration, 

central tie rod, internal 

cooling air passages) 

for world class fast 

(cold) start and hot 

restart capability 

HCO for reduced 

clearance losses 

Transient protection of clearances 

for reduced degradation with 

hydraulic clearance optimization 

(HCO) active clearance control 

Designed for >60% efficiency in combined cycle 

and best in class operational flexibility 

Advanced Can 

Annular combustion 

system 

> 60% combined 

cycle efficiency 

3D 4 stage turbine with 

adv. materials and TBC 

High cycling capability due 

to fully internally air cooled 

turbine section 

Performance features 

Flexibility features 


Hydraulic Clearance Optimization (HCO) 

Increased performance and power output 

~5 MW 

The Siemens HCO system: Simple. Fail-safe. Proven for >10 years. 

HCO on 

HCO off 


SGT-8000H engine concept 

based on harmonization and new technology 

� Single tie bolt 

� Compr. stat. design 

Harmonized 

Compressor 

Siemens V Design Siemens W Design 

� Turbine cylinder 

� Turbine vane carrier 

� Exit housing 

ULN can-annular 

combustion system 

� Front hollow shaft 

� Bearings 

� Compressor cylinder 

� Turbine features 

� Turbine diffuser 

Secondary Air 

System 

The SGT-8000H concept uses proven features from Siemens and (former) 

Westinghouse engines and introduces new technology 


Innovative design features and proven technologies 

enable SCC5-8000H 1S to reach η > 60% 

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 

■ Increased pressure ratio 

■ Increased turbine inlet temperature 

combined with cooling air optimization 

■ Improved component efficiencies 

Gas Turbine: SGT5-8000H 

Two main levers to reach highest efficiency 

Water Steam Cycle 

■ Fuel preheating of 215 °C 

■ Advanced water/steam cycle (up to 

600 °C) with BensonTM HRSG 

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 


SCC5-8000H 1S – a proven concept optimized for 

highest operational flexibility 

HRSG standby 

heating 

Stack damper 

Benson TM 

technology 

High-capacity 

de-superheater 

Optimized GT 

load ramp 

ST stress 

controller 

Condensate 

polishing plant 

FACY 

Fast Cycling 

Advanced 

steam parameter 

Up to 600 °C 

Low complexity 

(No GT external 

cooling interface) 

Proven cycle 

concept 

Triple pressure 

reheat cycle 

Specific features included in our advanced 8000H plant cycle design for 

most flexible and reliable operation 


HRSG with Siemens Benson TM HP section 

designed for 600 °C steam temperature 

Irsching 4 Benson TM* HRSG is designed and delivered by Siemens 

� 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 

(*) Siemens is owner of the Benson TM patent 

Proven 

Benson 

Design 

Concept 

Siemens 

Design 

Principles 

Benson 

Evaporator 

Design 

600 °C 

Technology 

Siemens Benson HRSG 

design, 19 units built, e.g. 

Malzenice, Gönyü, Severn 

Power, Sloe Centrale… 

Based on F-class 

technology as executed 

in e.g. Karstoe, 

Simmering, Timelkam 

Based on Siemens 

Benson TM Technology * 

(Elimination of HP drum) 

Utilization of high 

temperature materials 

applied for 600 °C 

Steam Power Plants 

HRSG + Plant 

Development 

in one Hand 


= 

Innovation based 

on proven 

technology and 

materials

FACY improves the start up efficiency 

by 14%-points during a hot start 

load 

Start up times hot start 

< 30 min. 

Improved 

start up 

* Reference SCC5-8000H 1S 

Improvement 

Conventional 

start up 

t conv. 

time 

Efficiency 

advantage* 

Fuel consumption 

(start up only) 

Average efficiency 

(according t conv. ) 

Improvements 

� No hold phase for Steam Turbine, 

simultaneous Gas- and Steam Turbine startup 

� Avoid dumping energy to the condenser during 

start-up 

� Allows optimized Fleet Management 

conventional 

hot start 

~514 MWh 

~36% 

Hot start 

with FACY 

~326 MWh 

~50% 

FACY technology enables optimized start-up operation, saves fuel 

consumption and increases profit 


Dynamic load tests 

Plant fast hot start-up (FACY TM ) 

Plant Output 

600 

500 

400 

300 

200 

100 

0 

GT ignition 

GT speed 

Plant start-up time < 30 min. 

ST speed 

Time [min] 

Plant output 

GT load 

GT @ base load 

CC full load 

“More than half a GW in less than half an hour” 


60 

50 

40 

30 

20 

10 

0 

Plant load ramps of up to 

> 55 MW/min at � of > 25 

MW/min during start-up 

Turbine Speed 

GT load ramps of 

up to 35 MW/min

Dynamic load tests 

Plant load cycling 

600 

500 

Plant Output 

400 

300 

200 

100 

HP Steam Temp. 600 °C 

0 

0 60 120 180 240 300 360 

Time 

Plant Output 

GT Load 

Frequent load changes between 15 MW/min – 35 

MW/min at stable live steam temperature 


600 

500 

400 

300 

200 

100 

0 

Plant base load 

Different load gradients successfully tested at stable plant system operation 

and load changes over 200MW in less than 7 minutes 

Steam Temperature 

200MW in less 

than 7 minutes

Agenda 








Scaling and Validation Approach 

SGT5-8000H SGT5-8000H & SCC5-8000H 

50Hz 

60Hz 

Validation in Irsching 

Testing in simple & combined cycle 

operation … 

… with commercial grid boundaries 

… GT and BoP thoroughly validated 

… beyond req. as for the UK grid code 

16 combustor cans 

2007 2008 2009 2010 2011 2012 2013 2014 2015 

First Fire 

* # of GTs going into commercial operation 

Scaling rules 

50Hz 60Hz 

Speed 

Dimensions 

Power, Mass Flow 

Stresses & 

Temperatures 

Efficiency 

Testing Simple Cycle CC extension CC Validation 

COD Commercial Operation Combined Cycle 

Testing in Test Bed 


� 

1.2 

3* 

SGT6-8000H 

Validation in in Berlin Test Test Bed Facility Berlin 

Testing in controlled environment … 

... Grid independent (e.g. frequency) 

… with fuel gas and fuel oil 

1 

12 combustor cans 

8000H has passed a comprehensive testing before shipping to a customer site … 

… even the 60Hz version as a true scale 

X 

� 

x 

x 

1.2 

1.44 

1.0 

~1.0 

1 

3 

2 

1 

1 

1

SGT5-8000H and SCC5-8000H 1S 

Summary of the main Irsching validation results 

Ulrich Hartmann (“Irsching 4”) 

Bavaria, Germany 

SCC5-8000H 1S 

Customer E.ON 

Total el. Power Output >545 MW 

Plant efficiency >60,3 % 

Simple cycle operation: 

Functionality, operational capability, 

performance and serviceability validated 

and proven after ~1500 hours of operation 

Combined cycle operation 

- World record efficiency of 60,75% 

- Startup time < 30 min 

- Shutdown time < 30min 

- Stable operation down to 20% CC load 

- High cycling capability w/ up to 35MW/min 

GT load ramp 

- Fulfillment of most stringent grid codes 

Special features 

� world record efficiency 

� FACY startup within 30min 

� Siemens BENSON Boiler, 600°C w/s-cycle 


Irsching 4, as of September 2012 

* Opportunistic without availability impact 

22.07.2011 PAC/Commercial operation 

01.-03.10.2011 ~ 6.000 EOH borescope inspection* 



05.-16.05.2012 12.000 EOH combustor inspection 

Operational Summary: 

• Daily start / stop and load following per load dispatch 

requirements 

• more than 440 starts and 17.800 EOH 

• High operational reliability >97% confirmed in 

commercial operation already with the first engine 

> 1 year successful commercial operation; engine in excellent condition 


Typical operation profile of Ulrich Hartmann (Irsching 4) 

CCPP in 2012 

GT speed 

Plant output 

Mon Tue Wed Thu Fri Sat Sun 

Daily start / stop cycle and load following throughout the whole operation period 


Ulrich Hartmann CCPP 

12.000 EOH - Combustor Inspection (May 2012) 

Turbine Vane 1 Turbine Blade 1 

Compressor outlet Combustor Basket 

Turbine Hot Gas Path in excellent condition after 

12.000 EOH / 1 Year Commercial Operation 


SGT6-8000H – Test Bed in Berlin: up to 300 MW Testing 

at various speed conditions due to water brake 

07.09.2011 

26.10.2011 

05.12.2011 

15.12.2011 

10.01.2012 

29.02.2012 

20.04.2012 

24.05.2012 

04.07.2012 

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 

Gas, 

unheated 

Gas, heated 

LLCO 

Fuel Oil 

up to 75% 

load 

Gas, heated 

Fuel Oil 

100% load 

Technical features: 

• 9 stage water brake up 

to 300MW equivalent 

• Off frequency operation 

over a wide range 

• Fuel supply through 

pipe gas and distillate #2 

• Approx. 2000 sensors 

sub 25ppm 

NOx 

03.08.2012 

17.08.2012 

thermal 

paint 

run 

inspection, 

rebuild and 

shipment 

for 

commercial 

use 

Full Speed, Full Load Operation in Test Bed is integral part of the engine validation 


SGT6-8000H Validation at BTF 

Main Results 

� Thermodynamic behavior (temperatures, 

pressures, massflows) as expected 

� Performance expectation met 

� Hardware integrity confirmed 

� off-frequency (eigenfrequency/vibration) behavior confirmed 

� Emission / combustion behavior confirmed 

- FSFL and part load Operation 

- cold & hot fuel gas 

� Fuel oil operation successful: 

- FSFL and part load operation 

- Online fuel transfer 

� Operational flexibility (ramp rates, load rejection,…) as expected 

� LLCO (Low Load CO) operation as expected 

� Confirmation of the base line 5-8000H 

� Confirmation of control & protection logic 

The SGT6-8000H has met all targets � SGT5/6-8000H confirmed. 


Agenda 








SGT-8000H 

Operational Status 

Status September ‘12 

starts 

Operating hrs 

Dynamic hrs 

EOH 

* Thereof 1200 hours non-stop full load 

SGT5-8000H SGT6-8000H 

GT Validation Operation 

85 

1525* 

1990 

4365 

355 

7347 

2519 

13497 

GT Validation 

137 (115 gas, 22 oil) 

302 (236 gas, 65 oil) 

2150 (1640 gas, 510 oil) 

3822 


Sum 

577 

9174 

6659 

21684 

The SGT-8000H has achieved more than 570 starts & 21.500 EOH

Siemens Combined Cycle Power Plants 

EURA H-class 50Hz 

Lausward 

Düsseldorf 

SCC5-8000H 1S 

Customer Stadtwerke 

Düsseldorf 

Total el. Power Output 596 MW 

Plant efficiency >61 % 

ST Type SST5-5000 

Generator Type SGen5-3000W 

Date of order 05 / 2012 

1 st comm. operation mid 2015 

Special features 

� District heating 300MW th 

�� 85 % fuel efficiency 


SGT-8000H References 

Ulrich Hartmann – Irsching 4, Germany 

1x SCC5-8000H 1S, >17.800 EOH 

Cape Canaveral / Riviera Beach, Florida, USA 

2x SCC6-8000H 3x1, COD 05/2013, COD 05/2014 

Bugok 3, South Korea 

1x SCC6-8000H 1S, COD 08/2013 

Ansan, South Korea 

1x SCC6-8000H 2x1, COD 10/2014 

Andong, South Korea 

1x SCC6-8000H 1S, COD 03/2014 

Lausward, Germany 

1x SCC5-8000H 1S CHP, COD 02/2016 

Posco Power 2, South Korea 

3x SCC6-8000H 1S, COD 05/2014, 08/2014, 11/2014 

Daegu City, South Korea 

1x SCC6-8000H 1S, COD 11/2014 

16 SGT-8000H gas turbines sold 

Status: September 2012 


Düsseldorf, 

Düsseldorf, 

´Center 

´Center

Exemplary IRR-based economical comparison of 

profitability F-class vs. SCC5-8000H 

IRR [%] 

Additional Internal Rate of Return of the SCC5-8000H @ 6000 OH/a and 7,50 €/GJ 

Proven F-class 

additional 

Power Output 

Effect of 

higher gas 

prices 

additional 

Efficiency 

additional 

LTP costs 

additional 

EPC costs 

SCC5-8000H 

~ 6,8 %-Pt 

The SCC5-8000H generates higher profits, shorter payback period and lower 

Levelized Electricity Costs 


SGT-8000H series and SCC-8000H power plants… 

� World class net efficiency of 60,75% 

� Fully air-cooled engine design w/o external coolers allows for outstanding 

operational flexibility 

� High reliability >97% achieved in commercial operation already with the 1. 

engine in Ulrich Hartmann plant (Irsching 4) 

� Scaled 60Hz engine tested at full load and successfully validated in Berlin 

Test Field 

� Both engines are thoroughly tested and validated prior to first commercial 

application 

� Extensive field experience with more than 570 starts and 21500 EOH 

� Excellent engine conditions during first combustor inspection 

� Insurability confirmed (LEG 2) 

� Reduced investment and improved life cycle cost 

16 sold engines of Siemens H-class technology for IPPs and utilities 

worldwide demonstrates customer’s trust and commercial viability 


Thank you for your kind 

attention! 

© Siemens Protection AG 2011. notice All / Copyright rights reserved. notice

Disclaimer 

This document contains forward-looking statements and information – that is, statements related to future, not past, 

events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”, 

“plans”, “believes”, “seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on our current 

expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of 

factors, many of which are beyond Siemens’ control, affect its operations, performance, business strategy and results 

and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from 

any future results, performance or achievements that may be expressed or implied by such forward-looking 

statements. For us, particular uncertainties arise, among others, from changes in general economic and business 

conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies 

by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, 

changes in business strategy and various other factors. More detailed information about certain of these factors is 

contained in Siemens’ filings with the SEC, which are available on the Siemens website, www.siemens.com 

and on the SEC’s website, www.sec.gov . Should one or more of these risks or uncertainties materialize, or should 

underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant 

forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens 

does not intend or assume 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, it's affiliates or their respective owners.

One year of commercial operation in Irsching - Siemens Energy

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?