Additive manufacturing has the potential to become a new key technology. For example it opens up new attractive prospects in the manufacture of gas turbines. This is why Siemens has been investing in this innovative technology right from its inception, and is now driving the industrialization and commercialization of these processes. Additive Manufacturing is a process that builds parts layer-by-layer from sliced CAD models to form solid objects. This enables highly precise solutions to be formed from powdered high-performance materials. Siemens is a pioneer in Additive Manufacturing and already uses the technology for rapid prototyping. Furthermore the company is now developing solutions ready for series-production for manufacturing gas turbine burner nozzles and repairing burner heads. Just recently Siemens achieved yet another breakthrough: the first gas turbine blades ever to be produced using Additive Manufacturing have successfully finished performance testing under full-load conditions.
- Siemens to supply 19 net-gas, off-gas and recycle gas compressors for crude flexibility project
- The project will enable the refinery to process up to 420,000 barrels per day of offshore crude oil
Siemens was recently selected to provide 19 process reciprocating compressors for ADNOC Refining’s crude flexibility project at Ruwais Refinery-West. The project is intended to increase the refinery’s crude processing flexibility, enabling the site to process up to 420,000 barrels of oil per day of the local crude grade known as Upper Zakum, which is found offshore. The upgrade will improve the value of each barrel of oil and allow ADNOC to export more of its main onshore, lighter-grade Murban crude.
Agility is the ability to adjust rapidly to changing market conditions, capitalize on emergent business opportunities, and reduce costs or increase revenue streams in the process. In the wake of decarbonization, decentralization, and digitalization, it is the basis for grid operators' and utilities' future business success.
The Siemens booth at EUW 2018 presented combined solutions for electrification, automation, and digitalization that pave the way for multilayered, distributed, and connected grids, this way enabling the required degree of agility.
- Fulcrum's municipal solid waste-to-fuels plant will contribute to a sustainable future
Abengoa, a Spanish engineering, procurement and construction (EPC) contractor, recently selected Siemens to supply a compressor train for Fulcrum BioEnergy's Sierra BioFuels Plant that will use gasification technology to produce low-carbon fuels from municipal solid waste. The plant will be located in Storey County outside of Reno Nevada and is expected to produce approximately 11 million gallons of biofuel per year that will be used by the aviation industry.
• Agreement is Siemens' largest O&M deal in terms of power generated • Sites to serve as model for other utilities in reliability and efficiency• Digital services and data analytics to optimize plants and ensure reliabilityIn a new milestone agreement, Siemens announced today that it has been selected by the Egyptian Electricity Holding Company (EEHC) to provide comprehensive operation and maintenance services (O&M) for the Beni Suef, New Capital and Burullus power plants, for the next eight years. The agreement, which is the largest ever for the Siemens Power Generation Services in terms of power generated, includes the implementation of the company's Omnivise digital service solutions.Each of the three 4.8GW power plants is considered to be the largest gas-fired combined-cycle plant ever built and operated. Together the plants represent approximately 40 percent of Egypt's power capacity, at the time of signing contracts, generating 14.4GW – enough to supply 40 million Egyptians with electricity."The new agreement aligns with our energy production goals to ensure sustainable growth and maximum reliability and efficiency of new and existing combined-cycle generating facilities," said Eng. Gaber El Desouki, Chairman of the EEHC. "Strategically, it makes sense for us to enlist a single trusted and credible service provider to help operate and manage our large-scale power assets."The multi-year agreement covers all on-site equipment including 24 gas turbines, twelve steam turbines, 36 generators, 24 heat recovery steam generators and three 500 kV gas-insulated switchgear systems. "The new agreement reconfirms our focus to work with Egypt on developing the right mix of solutions to support the country's dynamic needs. It also underscores the tangible cost benefits that digital technologies can bring to the power industry," said Gianluigi Di Giovanni, Senior Executive Vice President of Siemens Power Generation Services in the Middle East and North Africa. "As a key development partner to the country we are committed to contributing to the sustainable growth, diversification and efficiency of the Egyptian energy industry." Siemens will also implement its services portfolio to improve asset visibility, reliability and availability of the three power plants. Data from the plant operation will be collected, analyzed and transformed into actionable insights such as accurate diagnostics, troubleshooting and condition forecasting, improving plant reliability and reducing downtime. Additionally, the data processed can help to balance maintenance costs, optimize inspection intervals and provide valuable insights into operational risks.Building on more than 30 years of experience in power plant operation and maintenance, Siemens currently manages more than 35 GW in 17 countries. The company's global resources and fleet expertise enable it to provide complement plant services and management, along with sharing best practices and technical knowledge with power plant owners.
During the conference, Siemens introduced the new SGT-400 PL Compressor Package, a highly integrated, turnkey gas turbine and centrifugal compressor solution. With field-proven, efficient, and reliable components, this new package offers a single-lift, one baseplate configuration for fast deployment, DLE combustion technology for emissions compliance even at low loads, and expert, 24x7 support for responsive service.
Siemens showcased its comprehensive oil and gas solutions at the Turbomachinery & Pump Symposium (TPS), September 18 – 20, 2018 at the George R. Brown Convention Center in Houston, TX. Oil and gas companies have some of the most complex physical and technical operational challenges of any business on the planet. To manage risks, control costs and optimize asset performance, oil and gas operators increasingly rely on digital technologies and analytics to improve efficiencies and safety for all aspects of oil and gas production, distribution and use. Leveraging 170 years of technological and engineering expertise, with extensive experience in operational technology (OT) and information technology (IT), Siemens' suite of innovative technologies deliver cutting-edge hard and software capabilities for equipment and solutions that enhance efficiency, predictability, reliability and safety for its customers.
Siemens joined Gastech 2018, which took place in Barcelona, Sept. 17 – 20. In its 45th year, the world renowned event was a highly regarded gathering for upstream, midstream and downstream gas and LNG professionals. Siemens used the occasion to highlight its integrated Gas-to-Power (G2P) solutions, through which the company is playing an integral role in increasing utilization of natural gas—a highly abundant, cost-effective fuel—as a feed stock for power plants. Sessions featured Siemens speakers which are outlined below.
Siemens showcased its comprehensive offshore oil and gas solutions at the Offshore Northern Seas (ONS) August 27 – 30 in Stavanger, Norway. From offshore drilling, to subsea, to floating productions platforms, Siemens real world deployments of scalable, software solutions help upstream customers optimize decision-making, increase productivity, maximize capital efficiency, and improve safety and security. Visitors learned how more than 35 years of operational offshore experience – combined with our digital expertise – turned data into value throughout the entire value chain.
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.