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.
On March 2nd, 2017, German Chancellor Angela Merkel, Egyptian President Abdel Fattah El-Sisi, Siemens CEO Joe Kaeser and further high-ranking representatives witnessed the symbolic inauguration of the first phase of Siemens' megaproject in Egypt. The event marked an important milestone towards the completion of the project.
In collaboration with the Egyptian Ministry of Electricity and Renewable Energy, Siemens and its consortium partners, Orascom Construction and Elsewedy Electric, announced on July 24, 2018 the completion of the Egypt Megaproject in record time. The parties celebrated the combined cycle commissioning and the start of operations at the Beni Suef, Burullus and New Capital power plants. The stations will add a total of 14.4 gigawatts (GW) of power generation capacity to Egypt's national grid, enough power to supply up to 40 million people with reliable electricity. With this milestone, Egypt and Siemens have set a new world record for execution of modern, fast-track power projects, delivering 14.4 GW of power in only 27.5 months. A single combined cycle power plant block with a capacity of 1,200 megawatts typically takes approximately 30 months for construction. For the Egypt Megaproject Siemens in parallel built twelve of these blocks in record time and connected them to the grid.
Following the delivery of several Siemens SGT5-8000H gas turbines, the first steam turbine for the Egypt Megaproject began its journey in December 2016 from the Siemens factory in Muelheim to the power plant Beni Suef in Egypt. The main components of the 670-ton cargo were lifted with a heavy-duty crane from the production hall onto a transport vessel standing by at the plant's inland harbor facilities. The vessel transported the SST-5000 steam turbine from Muelheim to the deep-water port of Antwerp where it was loaded onto a heavy cargo ship and transported to Egypt.
After the steam turbines installation, the waste heat from the gas turbines will be used to produce steam that will then drive the steam turbine, thus increasing the overall power output and efficiency of the power plant. In total, Siemens will deliver twelve SST-5000 steam turbines for the Egyptian power plants Beni Suef, Burullus and New Capital. All of these steam turbines will be manufactured at the Siemens factory in Muelheim.
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 CO2 emissions reduction for improved sustainable energy production.
Siemens has completed extensive service operations on the gas turbines at Jebel Ali K-station in a record time of only 29 working days, a notable accomplishment for a project of this scale. The power plant is located in Dubai and owned by Dubai Electricity and Water Authority (DEWA) and in operation since 2002. The outage featured the application of the "rotor-swap"; a pioneering concept that has been developed by DEWA to utilize a spare rotor and other critical parts, stored at the plant's site, to maximize each unit's availability and reduce idle time while waiting for the completion of rotor assembly work.Under terms of the agreement, Siemens provided supervisory services for three of Jebel Ali K-station's gas turbines to enable further efficient and reliable operation for approximately 100,000 hours – equivalent to about 15 years. The upgrades also increased power output by 62.6 megawatts (MW) and improved power plant efficiency by about 0.5 percent."The new project is built on over 30 years of trust and partnership with Siemens. We are very pleased to work with the company again and successfully complete services of Jebel Ali K-station's power assets so quickly, which allowed the plant to reduce the length of maintenance outage and return the turbines to service as early as possible," said Nasser Lootah, Executive Vice President of DEWA. "With this project, we will enhance the power output and the long-term availability of our power generation assets."After a certain number of operating hours, all gas turbines need to be dismantled for maintenance services. Typically, an outage of this kind would take up to 45 working days to complete, involving over 100 personnel with different areas of technical expertise. By implementing a newer outage concept, Siemens was able to perform the services within just 29 working days, setting a new benchmark in the global power service industry."DEWA puts a great importance on the availability and sustainability of power for Dubai's population, which results in their continuous commitment to innovative ideas and proactive approach for accomplishing the best results," said Gianluigi Di Giovanni, Senior Executive Vice President of Siemens Power Generation Services in the Middle East. "This project reflects our commitment to bringing the company's latest and most-advanced technologies to the UAE to help boost the efficiency and sustainability of its energy sector."Recently, Siemens and Dubai Electricity and Water Authority (DEWA) have signed an agreement to collaborate on an advanced data-driven project. Siemens and DEWA are working together to identify ways to improve thermal efficiency, provide cost-effective solutions for performance optimization, manage costs and reduce fuel consumption and emissions.
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.
3D-printed oil sealing rings installed on SST-300 steam turbine operating in India
Siemens 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 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.
Highlighting its commitment to supporting Pakistan in meeting its growing power needs, Siemens has announced the signing of a long-term service agreement with Punjab Thermal Power (Private) Limited to provide comprehensive maintenance, parts and repair services for Punjab Power Plant Jhang for the next 12 years. The agreement includes Siemens' Power Diagnostics, part of the company's "Digital Services for Energy" portfolio of data-driven solutions.With the fifth-largest population in the world, Pakistan is working to spur socio-economic development by delivering reliable and efficient power supply to industries and homes. Located in Haveli Bahadur Shah, Punjab Power Plant Jhang, is expected to add 1.3 gigawatts (GW) to Pakistan's grid, making it one of the largest gas-fired, combined cycle power plants in the country. It will also see the first deployment of Siemens' SGT5-8000H gas turbines in the country, selected for their high power output and record-breaking efficiency. Anticipated benefits of the agreement include increasing the availability of the power plant and reducing the maintenance costs. The agreement covers all the scheduled and un-scheduled outage services for two SGT5-8000H gas turbines, generators, related auxiliaries as well as the supply of spare parts and field services."Pakistan's energy sector is undergoing a transformational period to meet the increasing demand of electricity. We are very proud to contribute to this significant project," said Gianluigi Di Giovanni, Senior Executive Vice President of Siemens Power Generation Services in the Middle East. "With our services, cross-fleet experience and digital capabilities, we look forward to bringing value and on-ground support to Punjab Thermal Power, helping maximize the potential of the plant's overall operations."Siemens' Power Diagnostics use advanced data analytics to help predict and eliminate unplanned downtime, and improve power plant productivity by identifying operational challenges in advance. It will also allow the power plant's team to manage outages more efficiently.The current agreement builds on Siemens' contributions towards strengthening Pakistan's power sector. It comes three months after the company signed the largest ever power generation contract in the country to provide a complete power island solution for Punjab Power Plant Jhang.
Building on its commitment to supporting the energy infrastructure in Sudan, Siemens has signed a long-term agreement with the Sudanese Thermal Power Generating Company (STPGC) to provide service and maintenance for the power generating assets and related components operating at the 337 megawatt (MW) Port Sudan and 502 MW Garri power plants.
On January 24, 2018, the most powerful high-voltage direct-current (HVDC) transformer began its journey from the transformer factory in Nuremberg, Germany, to China. The transformer will first be transported to the harbor in Nuremberg by special heavy load transporter, where it will be loaded onto a ship. Its journey will take it to Rotterdam via the Main-Danube Canal, and from there it will be shipped to China, where it will arrive after several weeks on the high seas. In July 2016, Siemens received an order to manufacture four transformers of this type. About a year later, the world’s first 1,100 kV transformer was completed and successfully passed the tests in the testing facility. The enormous dimensions of the transformer – 37.5 meters long, 14.4 meters tall, and 12 meters wide – posed a logistical challenge for the team. In operation, the transformer weighs just under 900 tons and its efficiency is well above 99% of the rated power. For the first time, the transformer will enable a high-voltage direct-current (HVDC) transmission with low losses over a record distance of 3,284 kilometers with a transmission capacity of 12 gigawatts. HVDC transformers are part of the converter station that convert alternating current into direct current at the beginning of the transmission line and convert it back again at the end of the line. The conversion from alternating current to direct current helps to transmit energy over long distances with low losses. Transformers are key components of an HVDC line: Thanks to the transformer, the Changji-Guquan project will be able to transmit direct current with a huge 1,110 kilovolts for the first time in the world. The new transformer not only makes the transmission of this record voltage level possible, but it is also the world’s most powerful tested transformer with a capacity of 587 megavoltamperes. Siemens has thus achieved a new dimension in high-voltage direct-current transmission. The HVDC line between Changji and Guquan will be operated by State Grid Corporation (SGCC), a Chinese grid operator. The connection is expected to begin operation in 2019.