3D-printed oil sealing rings installed on SST-300 steam turbine operating in IndiaSiemens has reached yet another industry milestone in the area of Additive Manufacturing (AM) in the power generation industry with the company's first replacement parts 3D-printed from metal for an industrial steam turbine. The company is utilizing state-of-the-art AM technology to pave the way for greater agility in steam turbine component manufacturing and maintenance and to set new benchmarks for industrial power plant services.
Siemens has received an order from Inter Pipeline Ltd ("Inter Pipeline") to provide long-term service for two SGT-800 gas turbine generator sets in Canada. The units are scheduled for operation at the Central Utilities Block (CUB), part of the company's Heartland Petrochemical Complex currently under construction in Alberta's Industrial Heartland near Fort Saskatchewan.
Siemens recently signed an agreement with Shanghai Shenergy Energy Technology Co., Ltd. (Shenergy Technology) to implement a high-temperature subcritical upgrade for a 320MW steam turbine unit at Xuzhou Power Plant, a subsidiary of China Resources Power Holdings Co., Ltd (CR Power) in Jiangsu province. It is estimated that the upgrade will enhance the unit's power output efficiency up to 42.9 percent, reduce its emissions by more than 10 percent and extend its overhaul interval from six to 12 years. This will increase the generation revenue of the plant while reducing maintenance costs significantly. The project is expected to be concluded in mid-2019.
Demonstrating the company's commitment to supporting Iraq's power sector, Siemens has expanded an existing service agreement with KAR Group in Iraq to provide comprehensive operations and maintenance (O&M) for two newly added SSC5-2000E power plant units at the Khormala plant in the Kurdistan region.The 930-megawatt (MW) natural gas-fired power plant meets nearly 30 percent of the power demand targeted by the Kurdistan Regional Government (KRG), supplying more than four million Iraqi people with reliable electricity. The extension of the service agreement is set to improve operational flexibility, availability, and performance of gas turbines for the next 15 years.The agreement between Siemens and KAR Group aligns with Iraqi energy production goals. According to the Mena Power Report 2017, the current power demand in Iraq stands at 21GW and is growing faster than supply. The Kurdistan Regional Government plans to increase capacity by building new power plants and increasing the efficiency of existing facilities."With more than 20 years of experience in O&M of power plants, we currently manage approximately 2,800 MW across the Middle East and North Africa region and over 16,000 MW globally," said Gianluigi Di Giovanni, Senior Executive Vice President of Siemens Power Generation Services in the Middle East. "Our global resources and fleet expertise enable us to provide complete plant services and management. The plant is truly a landmark project, supporting the development goals of the Kurdistan region. That's why we are proud to expand our collaboration with KAR Group to deliver reliable and stable electricity supply to people's homes."The Khormala multi-year agreement with Siemens covers the operation and maintenance of six SGT5-2000E gas turbines, six SGen5-100A generators along with the associated auxiliary and ancillary systems. It also includes the implementation of Siemens Power Diagnostics®, which is part of the company's "Digital Services for Energy" portfolio, to improve asset visibility, reliability and availability.Siemens data-driven services enable valuable data from different assets to be analyzed. From there, data is transformed into actionable insights—such as diagnostics, troubleshooting and condition forecasting—that can help improve plant reliability and reduce downtime. In addition, the data processed by Siemens Power Diagnostics® can help balance maintenance costs, improve inspection intervals and provide invaluable insights into operational risks.Siemens has managed the operation and maintenance of Khormala since 2013 under a multi-year services agreement. Currently, the company has more than 40 personnel on-site managing the power plant on behalf of KAR Group.
Siemens has reached yet another milestone in its journey to realize the many benefits of additive manufacturing (AM) and to lead the development of this innovative technology in the power generation industry. This time the company has successfully 3D-printed and engine tested a dry low emission (DLE) pre-mixer for the SGT-A05 aeroderivative gas turbine, with the impressive results showing a potential for significant reductions in CO emissions. This achievement further solidifies Siemens’ position as one of the world’s leading developers of innovative additive manufacturing techniques and uses in the energy industry."This is another excellent example of how additive manufacturing is revolutionizing our industry, delivering measurable benefits and real value to our customers, particularly as they look to further reduce emissions to meet environmental targets," said Vladimir Navrotsky, Chief Technology Officer for Siemens Power Generation Services, Distributed Generation. "Our achievements using AM are paving the way for greater agility in the design, manufacturing and maintenance of power generation components."The achievements resulting from using AM to manufacture this particular gas turbine component are significant. From concept to engine test, the development took only seven months, which is impressive for a component that requires such tight tolerances and works in high load and temperature. The DLE pre-mixer is highly complex with over 20 parts involved in the casting and assembly using traditional manufacturing methods. By utilizing Siemens qualified nickel super alloys as the AM printing material, the 3D-printed component requires only two parts and lead time is reduced by approximately 70 percent. 3D-printing of the DLE pre-mixer allows Siemens to simplify complexity in the production process, reduce external dependencies in the supply chain, and improves the geometry of the component, thus allowing a better fuel-air mix.First engine testing of the AM-manufactured DLE pre-mixer, which was 3-D printed in Siemens' AM center of competence in Finspang, Sweden, was recently completed and the data received is promising. It showed no start issues, all fuel transitions were accomplished successfully without any controls modifications required, there were no combustion dynamics or noise, measurable CO emissions reductions were realized and full power was achieved. These positive results reaffirm Siemens commitment to continuing to advance toward serial production of highly complex components, such as this one, using AM.Siemens' DLE solution for the SGT-A05 gas turbine reduces emissions through advanced lean burn combustion technology, eliminating the need for water injection. The DLE conversion reduces customers' operating costs associated with water treatment. Application of DLE does not compromise the high dynamic loading response of this aeroderivative engine model. More than 120 engines are successfully utilizing DLE technology to reduce NOx and CO emissions with 3.9 million operating hours accumulated (as of February 2018). ''And now, with AM technology we have an opportunity to go even further with emissions reduction for DLE combustion," said Douglas Willham, Siemens Director of Engineering for the SGT-A05.Last year, Siemens finished its first full-load engine tests for gas turbine blades completely designed and produced using AM technology. Earlier this year, the company 3D-printed and installed into customer's equipment its first replacement part for an industrial steam turbine. In early 2017, Siemens achieved the first successful commercial installation and continuing safe operation of a 3D-printed part in a nuclear power plant – an impeller for a fire protection pump that is in commercial operation. Siemens accumulated more than 30,000 hour of successful commercial operation for SGT-800 burners repaired with AM technology and for SGT-750 burner swirls manufactured by AM. All these combustor components are running in a very high load and temperature environment.
Siemens Financial Services (SFS) has released new research examining how global manufacturers are using innovative finance to seize market opportunities through digitalization and automation. Conducted among manufacturing finance managers in 13 countries, the study found that manufacturers across the world are reporting a need to invest in new-generation technology in order to meet four key sector challenges.These are: to increase production capacity and flexibility to meet changing demand and drive sales; to improve client service quality while reducing production costs; to improve competitive positioning through improved product quality and broader product range and to optimize efficiency, cost control and manufacturing agility through automation and digitalization.
Siemens has introduced a new SGT-800 performance enhancement that is applicable to all existing SGT-800 units with 43-47.5-MW ratings. The new upgrade is designed to provide owners and operators with significant fuel savings and CO2emissions reduction for improved sustainable energy production.
Siemens has won a significant order from Oil and Natural Gas Corporation Limited (ONGC) in India to overhaul 18 units of RT48S & RT56 power turbines of Siemens fleet of aeroderivative gas turbines driven by Industrial AVON & Industrial RB211 gas generators along with installation and commissioning services. The turbines are operating at Mumbai High Asset and Neelam & Heera Asset of ONGC in Mumbai.
Building on its commitment to innovative power plant solutions, Siemens has been awarded a contract from Colbún S.A. to upgrade the Central Termoeléctrica Nehuenco-I plant with Siemens' Power Plant Automation T3000 Cue (SPPA-T3000) system. The 368-megawatt (MW) combined cycle power plant is located in Quillota, Valparaíso Region, in Chile and provides electricity to approximately 350,000 homes in the region.