O&M and Lifecycle Management for CCGT Power Plants Flex Power Services Enhancing a plant s market capability

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O&M and Lifecycle Management for

CCGT Power Plants

Flex Power Services ™– Enhancing a plant’s market capability

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Flex Power Services ™– Enhancing a plant’s market capability

Agenda:

1. New market conditions for CCGT`s in different European countries are 3 leading to new developments on OEM-side

2. Overview of Siemens Flex Power Services ™ 7

2.1. Grid Services 9

2.2. Power on demand 12

2.3. Improved part load performance and minimal part load operation 14 3. Practical example for minimal part load operation & impact on operation 17

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Agenda:

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av. CCGT load December 2015 - March 2016, UK

Status of CCGT slightly stabilizing

Source: bm-reports

Flex Power Services ™– Enhancing a plant’s market capability New Market Conditions: UK market development

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Power Plant Operation needs to be adapted

Increasing plant flexibility with

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Upgrade Fleet penetration and customer benefit

Upgrade Potential Benefit

*site specific results may vary

Business Benefit P e rf o rm a n c e & M a in te n a n c

e _{Thermal Performance Upgrade} up to +30 MW and +0.6%pts efficiency in combined

cycle* ++++

Compressor Mass Flow Increase up to +22.5 MW in combined cycle* +++

Improved Hot Gas Parts up to 8 kEOH major interval extension* +++

O p e ra ti o n

Water Injection into Compressor up to 15% temporary power increase* ++

Improved Ramps up to 50 MW/min* +++

Extended mass flow control range up to 200 MW fast accessible load range* ++

Reduced emissions in part load up to 10% pts. CO compliant part load reduction* ++

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Extended gas fuel flexibility +/- 13% Wobbe range possible* +

Alternative fuel applications Biodiesel, hydrogen admix, H2S, Naphtha,

Condensates +

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Flex Power Services ™– Enhancing a plant’s market capability Agenda:

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Fast Start / Ramp Products SGT5-4000F CCPP

Turn Up Fast Wet Compression Flex-Power Services™ Primary Frequency Response Part Load Upgrade Extended Turn Down Fast Start Up FSG Secondary Frequency Response FLG Combined Cycle Load Gradient

Fast Cool Down

Fast Release to nominal speed Hot Start On The Fly Modified Pre-Warming Concept Degassed Conductivity Combined Cycle Gas Turbine Maintenance Interval

FSG Fast Start Gradient FLG Fast Load Gradient

Fast Cooling Modified ST Valve Staggering CO- Reduction Purge Credit Shut down On The Fly ST Fast Preservation

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Agenda:

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Grid Services (Flex-Power Services™)

Fast Load Gradients in IGV range - SGT5-4000F

G T L o a d Time Improvement 13 MW/min 5 min 100% CO limit 26 MW/min +56 MW negative reserve capacity * Requirements:

- Site specific assessment of additional HW scope - Site specific assessment of steam cycle

50 MW/min

Faster load changes with up to 50 MW/min in IGV range

Faster shut down time

Increased reserve capacity

Additional reserve capacity in steam cycle No additional cyclic life consumption

Negative Frequency Response within 5 min*

HW Scope site specific

Potential upgrade benefits

Experience

Upgrade successfully implemented and verified in a number of units across Europe Primary frequency response tests with high load gradients and load deltas successfully conducted in 5 engines

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Feature / Scope / Benefit

Features / Scopes: • IGV hardware

• I&C including margin controller Benefit:

• power output improvement • Power on demand

• Primary and secondary frequency reserve above 100% power output

Opportunity / Objective

References *

Turn-up refers to opening the IGV beyond it standard design position

Provides reserve power beyond base load for frequency response operation

Precondition is installed CMF+ compressor.

New Apparatus:

Number of engines in Europe

Service:

Selected engines in Europe V94.3A / SGT5-4000F

Turn Up

** Subject to specific technical plant evaluation, expected values with test tolerance @ISO condition

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Agenda:

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Faster Start Up with GT load gradient of up to 30 MW/min

Retrofit possible for Service Fleet of SGT5-4000F

no. of cold fast starts per interval w/o penalty factor

No additional restriction for hot fast starts

Power on Demand (Flex-Power Services™)

Fast Start Up (GT) and Hot Start on the Fly (CC)

The Hot Start On The Fly introduces a start-up concept for the overall plant by using the first produced steam to start-up the steam turbine.

Load holds for the gas turbine not necessary.

Hot Start On The Fly is applicable to Drum Boilers as well as Benson® Boilers and has been implemented in 13 combined cycle power plants.

Fast GT Start Up* Hot Start on the Fly

* Benefits are subject to specific technical plant evaluation, expected values with test tolerances @ ISO condition, actual results may vary

Aspect of Flex-Power Services™

up to

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Agenda:

2.3. Improved part load performance and minimal part load operation 14

3. Practical example for minimal part load operation & impact on operation 17

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Part Load Upgrade (Flex-Power Services™) Minimum Load Improvement

** Depends on site configuration and ambient conditions Upgrade Scope

Part load OTC increase *

Optimized secondary air control*

Add. air extraction at combustor plenum (optional)

Anti Icing activation* or

Potential benefit

Extended Part Load Operation Range with low Emissions (down to 10ppm CO and 25ppm NOx, ~10% deeper GT load possible with constant CO emissions in IGV range**)

Optimized part load efficiency

Savings of fuel if no electric power needed

* Experience: Positive effect on CO emissions demonstrated on several units, current New Apparatus Standard

Anti Icing

Secondary Air Control Additional Extraction

E2 E3

OTC increase

-10% GT Load

with constant CO emission within IGV range

Air Preheater

add. Turn Down and Ext. Turn Down

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Part load OTC increase Optimized secondary air control Anti Icing/ Air Preheater activated

P o w e r G T OTC OTC increase 100% Standard CO limit

Extended Part Load Operation Range with PLU

IGV limit

Turn Down limit _{Extended Turn Down} Extended Part Load with

extended Turn Down

Turn Down operation line

Ext. Turn Down operation line

Ext Turn Down limit

- available for different versions

- aSMC for stability reasons recommended

Part Load Upgrade (Flex-Power Services™)

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Agenda:

2.3. Improved part load performance and minimal part load operation 14

3. Practical example for minimal part load operation & impact on operation 17

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CCPP Göny - Minimum load

reduction

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CCPP Göny – Main plant data

Unit EOH OH Starts

1 26‘468 16‘826 765

Basic Plant Data

GT Type & Configuration

1 x SGT5-4000F(6), single shaft

Combustion Premix pilot, Dual Fuel

HRSG STF, Triple Pressure (HP Benson) + Reheat ST Siemens SST5-5000, HP/IP + LP

Generator Siemens SGen5-3000W COD May 2011

Capacity, CC 429 MWe

as of 01st_{April 2016}

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History of efforts to reduce the minimum load

Original Pmin = 250 MW Contracted value 2011 Test step1: 230 MW June 1 st ₂₀₁₂ Test step2: 210 MW August 1 st₂₀₁₂ Successful HRSG stability test

June 6th_{2013 / Uniper internal project}

SIEMENS Part Load Upgrade

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Part Load upgrade scope

Implementation of CO Reduction (COR) package Hardware

- Additional pressure measurements at compressor extractions of casings 2 / 3

Software

- Activation of Air Pre-Heater (APH) during part load (no “conventional” anti-icing installed)

- OTC part load increase

- Advanced control concept for the cooling air flaps

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Part Load upgrade scope

To supervise HRSG behaviour – especially within the HP evaporator – some 50 additional thermocouples have been installed at various HP evaporator harps. All TC’s are permanently connected to DCS

Early detection of instabilities

Ability to approach real HRSG load limit and to verify effectiveness of counter-measures

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Expectations / effects of COR Package

Reduction of Minimum Environmental Load (site CO limit: 100mg/Nm3); Siemens expected value was ~196MW CC load

Increase of part load efficiency during a certain load range

HRSG instabilities expected at low loads. Siemens advised to increase HP system pressure to 95 bar (from 75bar)

increase blow-down rate in order to increase the mass flow install additional orifices between HP Evap 1 and 2

Original situation Expected situation with COR

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Expectation / effects of COR Package

Uniper in-house engineering company Uniper Technologies (UTG) created steady-state and dynamic HRSG models to verify Siemens statements

Siemens predictions verified but at even lower loads plus

Confidence given that no HRSG hardware modification is required

„Ledinegg“ instabilities seen at different plant

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Results

Commissioned and tested during 2 days end of September 2015

CO compliant minimum load could be reduced within test environment to 165MW (net) for steady state operation, not proven or used during normal operation

Final settings in pre-defined load range from 210MW to 190MW (all net) Compressor inlet temperature: 35°C

GT exhaust duct temperature: 620°C (was 595°C)

Cooling air flaps MBH22/MBH23 a bit more closed than normal Resulting CO emissions at 190MW: 13mg/Nm3

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Results (continued)

CC Load CO Emission

Cpr Inlet Temperature OTC

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Results (continued)

However, dynamic behaviour of APH proved to be insufficient to handle bigger load changes, i.e.

Switching off while loading takes too long

Switching on while de-loading takes too long that might lead to violation of the CO emission limits

It seems the control of the APH was not built for these purposes

Efficiency expectations not fully met especially due to increased aux. boiler operation

It was decided to set the minimum load to 180MW_net

in order to utilise the wider load range while offering ancillary services reduce over-night must run costs

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Results (continued)

HRSG generally stable during tests, only at lowest test load some

instabilities could be observed, mitigated by increasing HP system pressure

In the past months instabilities within one HP evap 2 tube (row 3) experienced

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Results (continued)

In the meantime some further modifications have been done by us

Further testing of HRSG stability done due the mentioned instabilities within HP Evaporator 2

FEM calculation of HP Evap 2 header initiated to evaluate influences of existing temperature gradients

Aux. boiler pressure set point decreased to ~3 bar in order to optimise the supply of the aux. steam system. In order to avoid gland steam system trips, the set point of the aux. steam system had to be changed to 2.5 bar

Polygon implemented to define the compressor inlet temperature set point depending on the actual load

at 260MW t_{CPR,inlet,set} = 3°C at 180MW t_{CPR,inlet,set} = 35°C

Min flow requirement of LP admission valve removed and the influence on LP SH (due to low or no flow) has been checked and found to be uncritical

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Conclusion

Expectations partially met

Turn-down rate better than expected Efficiency expectations not fulfilled HRSG stability can be achieved

Evaluation of results are still ongoing regarding future utilisation of COR Package

Seen as beneficial product for our plant however

General

Siemens has an upgrade solution available that can be beneficial to improve a plants situation. However benefits highly depend on site specifics and the market environment.

Any evaluation depends on „expected benefits“ that might prove wrong during testing.

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Agenda:

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• Products are available for different customer needs, from purging optimization to pre-startup optimization to faster gradients to part load packages

• a close look has to be taken to overall plant conditions to ensure safe operation in all conditions

• further developments are underway especially for combined cycle plants for lower part load capability, e.g. newly designed combustor for extreme low loads, exhaust gas attemperator (EGA) etc.

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Christian Schäferkordt

Head of Maintenance CCPP Göny Uniper Hungary Kft.

Széchenyi István tér 7-8. H-1051 Budapest

Office

Kossuth Lajos utca 2/a H-9071 Göny

Phone: +36 96 802 119 Mobile: +49 170 769 1992 E-mail:

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Andreas Dibbert

Dipl. –Ing. (TU)

GT LTE & Modernization Europe

Siemensdamm 50 13629 Berlin Germany Phone: +49 30 3865 6792 Fax: +49 30 3865 6239 Mobile: +49 174 301 8028 E-mail: [email protected]

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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

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Part Load Upgrade (Flex-Power Services™) Extended Turn Down - Concept

* Depends on site configuration and ambient cond.

Upgrade Scope

Minimum IGV position setting depends on ambient conditions (VLe1 icing risk)

Benefit

Extended Part Load Operation Range* Optimized part load efficiency

Savings of fuel if no electric power needed