Gas Turbine Technology:

Challenges, Achievements,
Outlook
Session GT Technology Trends

Wolfgang Menapace,

Siemens Energy Sector

4. IGT Conference, ETN

Brussels, October 15 – 16, 2008 © Siemens Power Generation, Inc. 2007. All rights reserved
Gas Turbine Technology:
Challenges, Achievements, Outlook

Question 1:

Is there a future market for Gas Turbines ?

Core requirements
Competing plant concepts

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Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 1 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
 Strong steam and combined cycle segments,
growth in nuclear power market over next decade

World power market [GW/a]

202
13
178
23
144 147
8 96 of it ST 21
115 133
(China 48) of it ST
ST nuclear 3 82 126
of it ST of it ST
77 61
101 101
(China 49) (China 40)
STPP 68 of it ST
85 (China 30)
(China 62)
75
of it GT 62 52
45 69 of it GT
CCPP 38 of it GT of it GT
of it GT 52 46
43
GTPP 30
14 19
7 12 13
Avg 02-04 Avg 05-07 Avg 08-10 Avg 11-13 Avg 14-18
STPP: Steam Turbine Power Plant ST: Steam Turbine Deviations due to figure rounding
CCPP: Combined Cycle Power Plant GT: Gas Turbine
GTPP: Gas Turbine Power Plant
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Page 2 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Customers operate Gas Turbines in different
scenarios resulting in different requirements

Electricity price
Fuel cost

• Start-up Reliability
Peaker CT
• Power Output
10
• Reliability
• Efficiency
• Power Output
5
• Efficiency
Intermediate CC
• Reliability, availability
• Maintenance costs
2
Base load CC

1
peaking Hours per year
intermediate base load
8760

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Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 3 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Copyright (C) Siemens AG - Siemens Management Consulting 2004 All Rights Reserved - Confidential
Business Drivers and Customer Requirements for
today's and future Gas Turbine engines

Business Drivers Customer Requirements

§ Power ↑
Engine Performance
§ Efficiency ↑
§ Emissions ↓
+ § First Time Cost ↓
§ Operational Flexibility
Reliability / Availability /
Maintainability (RAM) § Cycling Capability ↑
§ Fuel Flexibility ↑
§ Upgradeability ↑
§ Regulatory Compliance ↑
Market / Competitiveness § Product Robustness ↑
§ Maintenance Cost ↓

© Siemens Power Generation, Inc. 2007. All rights reserved.

Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 4 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Example for customer evaluation

1% efficiency increase results in

Fuel Cost reduction of 1.500.000 €/a*

CO2-reduction of ~ 25.000 t/a

per Combined Cycle Power Plant with 400 MW @ 8000 h/a

*based on: 6.5 €/GJ fuel cost

Main driver of economic assessment: Efficiency

© Siemens Power Generation, Inc. 2007. All rights reserved.
Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 5 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
 Competing plant concepts
in today's fossil market

Comparison of fossil power generation technologies 2010

Gas-fired Coal-fired
Integrated Coal
Combined Cycle Steam Power Plant
Gasification CCPP
Power Plant (CCPP) (STPP) w/o CO2 – Capture
w/o CO2 – Capture w/o CO2 – Capture

60% 125%
Plant net efficiency 100%
47% > 47%

<50%

Specific invest

….IGCC may become an alternative if CO2 Capture will be mandatory in future

© Siemens Power Generation, Inc. 2007. All rights reserved.
Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 6 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Gas Turbine Technology:
Challenges, Achievements, Outlook

Question 2:

Evolutionary design approach

What are the aims of our GT development ?
Achievements

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Page 7 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
 SGT5-4000F Development
Evolutionary Design approach to minimize Risk

The development of the engine is mainly driven by two factors:

§ Evolutionary development to improve performance and flexibility
§ Implementation of field feedback to maximize reliability and availability

Evolutionary Design =
§ careful changes to a well proven design
§ based on field experience and analytical methods
§ high confidence -> lower risk
§ tested in test rigs, test bed engine or rainbow test in the field
§ retrofit-ability for field validation and service upgrades

Evolutionary Design leads to Performance and Flexibility Improvements

without risking Reliability and Availability

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Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 8 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Evolution: Major Upgrades of our SGT5-4000F
- Latest
Upgrade
1st Compressor
Upgrade
2. Upgrade
292 MW / 39.8%

1. Upgrade Cooling Air Reduction

287 MW / 39.5%
Market
Introduction
266 MW / 38.6% • 2nd Compressor Upgrade
• Combustor Cooling Air Saving
• Hydraulic Clearance Optimization
240 MW / 37.0% • Fuel Gas Preheating

1996 2000 2004 2008

Successful history of continuous improvements

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Page 9 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Example for Advanced Technology: SGT5-4000F
Design Features

• Compressor, 15 stage advanced 3-D airfoil

design in all stages and with side-wall
correction. One variable guide vane row.

• Combustion System
- annular, low pattern factor
- Dry low NOx and dual fuel

• 4 stage Turbine.
- SX row 1 and SX/DS 2 blades
- Film-cooling, TBCs

• Rotor with Hirth serration and single tie bolt.

Quick thermal response because of rotor
internal flow passages. Steel based materials
only

• Excellent thermal balance due to:

- Quick and stiff rotor
- Conical turbine flow path

• Due to thermal balance:

- Quick start up
- Hot restart capability

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Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 10 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Operating Fleet Experience
Summary

Our advanced Gas Turbine Family

SGT5-4000F, SGT6-4000F, SGT5-3000E, SGT-1000F (Vx4.xA)
has clocked up more than 5,200,000 EOH*
(Status March 2008)
> 190 engines in operation.
> 65 engines on order

The Reliability of the SGT5-4000F Gas Turbine is

at the same high level (> 99%) as our mature fleet

* = Equivalent Operating Hours

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Page 11 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Gas Turbine Technology:
Challenges, Achievements, Outlook

Question 3:

What are the next steps and recent experiences of

our GT development ?

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Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 12 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
60% CCPP efficiency is targeted
with advanced gas turbine and steam cycle design

Net Plant CCPP efficiency development

Efficiency
[%]
Steam cycle development
% >130 bar
from single 130 bar 565 °C
60
pressure 110 bar 565 °C >1250 °C
58 to triple pressure 540 °C
1250 °C
reheat steam cycle 100 bar 1190 °C
56 520 °C
80 bar
54 75 bar 520 °C 1160 °C
510 °C Continuous improvement in material &
52 1120 °C
coating, thermodynamic design, e.g.:
60 bar 1050 °C
50 - Thermal barrier coating
485 °C - Fuel preheating
50 bar
48 1000 °C - 3D blading
460 °C
46 960 °C Gas turbine development
Fuel: natural gas
ISO conditions: 15 °C, 1013 mbar, 60 % humidity

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Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 13 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
 60% CCPP efficiency will be
demonstrated at Irsching 4 Power Plant
Combined cycle plant efficiency development

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

(V94.2) (V94.3A) (V94.3A) (new platform)
CCPP Killingholme, CCPP Didcot “B” CCPP Mainz-Wiesb. CCPP Irsching 4,
2 x 450 MW 710 MW + 702 MW > 400 MW > 530 MW

1992 1996 2001 2008/11

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Page 14 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Siemens advanced air-cooled gas turbines
are designed for highest efficiency and reliability

Siemens SGT5-8000H gas turbine design features

High cycling capability due to Four stage turbine with

advanced blade cooling system advanced materials and
thermal barrier coating
Advanced can annular
combustion system

Evolutionary 3D-
compressor blading

Proven rotor design, Hirth

serration and central tie rod

© Siemens Power Generation, Inc. 2007. All rights reserved.

Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 15 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
 SGT5-8000H and SCC5-8000H
Key Data

Gas turbine SGT5-8000H

SGT5-8000H
Steam turbine SST5-5000
Generator SGen5-3000W
Fuel nat. gas, #2
GT / CC output 340 / 530 MW
GT / CC efficiency > 39% / > 60 %
SCC5-8000H
Pressure ratio 19.2 : 1
Exhaust mass flow 820 kg/s
Exhaust temperature 625 °C
Turn down 50%
HRSG / WS-Cycle Benson 3Pr-RH
600°C / 170 bar

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Page 16 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
SGT5-8000H Prototype Test Schedule

2007 2008 2009

Gate 4
Test-Phase: First Fire
Test Program

1 Start Up Tests

2 Part Load Tests

3 Full Load Tests

4 Endurance Tests

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Page 17 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
 The SGT5-8000H meets Customer Needs for
reduced Life Cycle Cost & Flexibility

Validation and
Customer Needs Innovative Solution Implementation

Peak
Load
MW Demand

Rapid
growth
Intermediate
Load

Base Load

§ High thermal efficiency § Air cooled § Performance validated before series

§ High availability § 60% combined cycle efficiency release
§ Operational flexibility § Design for serviceability § Siemens controlled environment
§ Reduced life cycle costs § Manufacturing innovations § 3,000 measurement points
§ Knowledge brought to design tools

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Page 18 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Gas Turbine Technology:
Challenges, Achievements, Outlook

Question 4:

What shows the Outlook ?

- Coal-to-Gas Technology: Perspectives for IGCC
- Key technologies to advance

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Page 19 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
IGCC plants may become in 2020 a third alternative
with ~50% efficiency w/o and >43% with CO2 capture

IGCC process principle

Siemens core competencies

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Siemens Energy Sector PR MK /Menapace/Dr.Taud
Page 20 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Siemens was involved in all European
coal-based IGCC demonstration plants ……

IGCC plant efficiency development

253 MW (net), start

-

V94.2 V94.3

Buggenum (Netherlands), 253 MW (net) Puertollano (Spain), 298 MW (net)

-
1994 1997

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Page 21 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Development of Blades and Vanes-
The Key of highly sophisticated Gas Turbines

1975 2001
Aerodynamics
Cooling technology
Materials and casting
Coatings (oxidation, corrosion)
Thermal barrier coating

APS

Substrate 200 µm

EB PVD
Uncooled Blade Film cooled Blade
columnar structure
~ 900° Hot gas temperature >1400° Hot gas temperature

Substrate 50 µm

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Page 22 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Advanced Material Systems are a key technology
to advanced Gas Turbine Technology

Closed-loop
Cooling
allowable Hot Gas
Temperature
Temperature /°C CMC
Temperature

Film Cooling
Allowable
Material
TBC temperature

IN939 2nd Gen. SX

IN738
1st Gen. SX
IN792 DS
U700

1965 1975 1985 1995 2005 2015

Year

Today TBCs are the Material Technology with the highest pay-off
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Page 23 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Summary

Gas Turbines will keep a prime role in the power market

Our Evolutionary Design Approach blends Performance

Improvements and Reliability

Advanced Gas Turbines need intensive R&D and testing / validation

Coal-to Gas/ IGCC Technology will be a growing alternative but

requires adapted gas turbine technology

Advanced Materials are key to develop advanced Gas Turbines

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Page 24 4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008 L:3_01_Power_Gen_2008_IGT_GTT
Thank you

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