Turbine Life Extension For SGT-200 Industrial Gas Turbines Answers for Energy
Component life cycle management is of primary importance when dealing with maintenance activities, particularly with rotating equipment where failures could lead to extensive collateral damage, loss of operation, extended downtime and loss of revenue.
Siemens Experience With nearly 60 years experience in the support of its range of small gas turbines, Siemens Energy Sector Service division, in Lincoln, has been able to use all of that experience to develop a life extension program for the 6.45MW(e) SGT-200-1S product (formerly known as the Tornado Single Shaft). Having sold 430 units since its introduction in 1982, the SGT 200 fleet has now accrued over 25 million running hours.
Life Expectation
Traceability
The life expectation of a gas turbine’s long life components, such as outer casings or compressor rotor parts, may typically be 100,000 running hours or 10,000 starts which equates to a service life of 12 years or possibly longer. Being able to predict the life expectation of parts is essential when scheduling maintenance activities where accurate planning can maximize equipment usage, minimize downtime activities and reduce cost. However, it relies on the turbine history records being maintained and kept updated to ensure product traceability and data integrity.
Siemens can help to benefit those customers who involve the OEM in their maintenance planning and service activities, with the offer of inclusion of the design updates this life extension program provides, which may also help reduce operational risk. However, it must be stressed that this can only be applied where a component’s historical information is maintained, life extension can only be applied to equipment with a traceable history.
The gas turbine OEM is uniquely placed to keep and maintain such detailed history records from original build through the known life of the turbine fleet. Siemens uses this historical data combined with advances in analytical methods to review the expected finite life of components and develop programs to extend the in-service life of the gas turbine fleet.
No matter how long third party service providers have been operating, they do not have the benefit of Siemens’ proprietary design information, nor the long term historical fleet data, to be able to provide the same level of detailed support as an OEM.
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Specific Analysis of the operation and maintenance history by: Obsolescence
Cost Reduction
Health & Safety
Review of the O&M records and the turbine duty cycle Selective component sampling
Benefit by Mods & Ups
Reliability
Fuel analysis & air quality sampling etc.
Environment
IGVs and actuator system Burners
Alternatively Siemens can offer the following solution where there is a lack of traceable history. Solution To be able to offer life extension, the unit will need to be assessed to ensure its integrity; this may typically cover the following scope of supply:
Combustor assemblies Casings Drive train & couplings This will establish the current life capability and what scope of work, including the latest modifications and upgrades, will be recommended to attain the customer’s required turbine life extension. Potential Benefits may include: An opportunity to upgrade previous technology to the latest standard and/or materials Maintain or improve power and/or efficiency Reduced operational risk by Trend Analysis / Condition Health Monitoring Reduced downtime Environmental legislation compliance Reduced Life Cycle Cost
Controls upgrade to the Siemens S7-300TM micro controller.
HEPA intake air filtration upgrade – improved filtration to reduce blade fouling and power loss.
Turbine rotor and stator blading
Continued investment by Siemens into the advanced analysis of component life has demonstrated that many of the long life components can achieve up to 150,000 hours. This can be done without compromising safety allowing a further operational cycle before replacement. However, it is subject to the condition that the parts have been maintained correctly over their operational life and that accumulated operating hours have been recorded accurately.
Associated Modifications & Upgrades:
Fuel System update to incorporate STAR Integrated fuel valve for smoother running.
Detailed Check: Air Intake Filtration and ductwork
Performance
Recommendations
DLE upgrade for low NOx emissions to meet current and future legislation Update by exchange units for reduced downtime and inclusion of latest developments Product Improvement and Product Safety Bulletin inclusion Remote Monitoring System to utilize the technical capability of our 24hr Help desk and, with the appropriate support contract, monthly trend analysis/condition monitoring reports Long Term Service Agreement to provide the benefits of a fully inclusive support contract
For a customer concerned with the safe operation of his plant, the best way to ensure that decisions are based on Siemens’ proprietary information is by agreeing and planning the maintenance program with the OEM.
Published by and copyright © 2013: Siemens AG Energy Sector Freyeslebenstrasse 1 91058 Erlangen, Germany Siemens Energy, Inc. 4400 Alafaya Trail Orlando, FL 32826-2399, USA
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:
[email protected]
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Energy Service Division LCN 2013 - F33.23 LN 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. 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.
