18TH SYMPOSIUM OF THE INDUSTRIAL APPLICATION OF GAS TURBINES COMMITTEE

BANFF, ALBERTA, CANADA

OCTOBER 19-21, 2009

09-IAGT-202

ADVANCED SGT6-5000F DEVELOPMENT

†
Scott Nordlund* , Josh Kovac**
†
*Siemens Energy, Inc. ( Scott.Nordlund@siemens.com)
**Siemens Energy, Inc. (Josh.Kovac@siemens.com)

Keywords: SGT6-5000F, Operational Flexibility

Abstract

The SGT6-5000F engine has demonstrated an exceptional operational record over a 15-
year, 4.7+ million fleet hour history. Since its introduction in 1993, this F-Class gas turbine
has undergone continuous development to improve performance, reliability and opera-
tional flexibility and to reduce emissions and life cycle costs. The result is a gas turbine
with an excellent operational record and customer value. In 2008, Siemens Energy
started production of the latest upgraded version of the SGT6-5000F. The capabilities of
this newest offering include a dual-fuel gas turbine which can deliver 150MW of power to
the grid within 10 minutes and reach baseload in another 2 minutes, an Ultra Low NOx
combustion system (9ppm), and hot gas path components designed for extended mainte-
nance intervals. The first field unit of this latest version was commissioned in June 2009.
This paper describes the technological advances now available and demonstrated in the
SGT6-5000F gas turbine that further improve performance, reliability, operational flexibil-
ity and customer value.

The IAGT Committee is sponsored by the Canadian Gas Association and supported by the National Research Council Can-
ada. The IAGT Committee is not responsible for statements or opinions advanced in the technical papers or at the Sympo-
sium or meeting discussions.
 NORDLUND, KOVAC

1 Introduction

The hallmark of the SGT6-5000F gas turbine, first introduced in 1993, has been
its’ steadily increasing capabilities as market requirements have evolved over
time. The SGT6-5000F kept pace with the need for rapid expansion in the 1990's
with increasing power output and improved thermal efficiency as deregulation and
low natural gas prices opened new market opportunities for base loaded gas tur-
bines. Then with the dramatic downturn in the market in the early 2000's, the
industry saw changing operating modes. The new challenge required transition-
ing plants from expected base load operations to nightly and weekend shut downs
to remain economically viable. Now, the recent upturn in requirements for gas
turbines and expected robust market in the future comes along with the need for a
fully flexible gas turbine solution.

The latest evolution of the Siemens SGT6-5000F version, or simply the F(4), will
excel within these market requirements with increased power output, improved
thermal efficiency, extended maintenance intervals and greatly enhanced operat-
ing flexibility. The SGT6-5000F gas turbines leaving the Siemens factory in North
America includes options for improved economic viability and success of our cus-
tomers. These capabilities include fast start (10 minutes to 150 MW), improved
starting reliability, single-digit NOx capability, low turndown ratios for reduced CO
emissions at part loads and extended operating hours and starts between main-
tenance intervals.

Figure 1. SGT6-5000F(4)

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 ADVANCED SGT6-5000F DEVELOPMENT

2 SGT6-5000F Engine Development Background

The SGT6-5000F introduction represented a technology step change made possible

by advancements in manufacturing, materials, analytical techniques and airfoil cool-
ing. The improvement in thermal performance was achieved simultaneously with
emissions reduction through dry low NOx technology. This gas turbine, which was
designed for both simple cycle and combined cycle (CC) power generation in utility
and industrial applications, represented the evolutionary improvement in the suc-
cessful W501 family. Its design was based on fundamental, time-proven design
concepts used in previous models, as well as new concepts and technologies incor-
porated to increase efficiency, reduce emissions and enhance reliability. It was de-
signed to operate on all conventional fuels, as well as coal-derived low BTU gas for
particular variants. New technologies were validated for engine application by ex-
tensive rig and two full load engine shop tests, as well as field tests in the initial in-
stallation. Figure 1 shows a cross-section of the SGT6-5000F layout. The 13-stage
compressor is connected to the 4-stage turbine by a single tie bolt, and the ultra low
NOx combustion system employs 16 can annular baskets.

3 SGT6-5000F Operating Fleet Overview

The 213 SGT6-5000F engines currently in service are employed in peaking, inter-
mediate and continuous duty operation. The fleet has amassed more than 4.7 million
operating hours and has demonstrated excellent reliability, availability and starting
reliability. These units, plus an additional 27 committed, represent the highest num-
ber of any one model of 60 Hz Siemens gas turbines sold. Due to design enhance-
ments, development efforts, and technology cross flow from other Siemens’ ad-
vanced gas turbines, the simple cycle output has increased from 150 MW to 208 MW
and its LHV efficiency from 35% to 38+%. In 1x1 Combined Cycle applications, the
net plant output and efficiency are now more than 300 MW and 57.5%, respectively.

2009

Figure 2. SGT6-5000F Performance Evolution

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 NORDLUND, KOVAC

The criterion by which a gas turbine is judged to be successful is its’ operating ex-
perience. The specific criteria for success include performance, emissions, mechani-
cal integrity (as defined by RAM and starting reliability), life cycle costs and opera-
tional flexibility. All of the above are important, but in the current competitive and
changing market environment, operational flexibility and adaptability to this environ-
ment have assumed a much greater significance. To be economically viable, the
electricity generating plant must respond quickly, efficiently and reliably to any re-
quired changes in operating conditions such as load demand, start-stop operation,
different fuels, etc., while operating within emissions regulations. The SGT6-5000F
has demonstrated over the last 15 years its success in this environment, providing its
operators with exceptional service.

The demonstrated median measured fleet values for Availability and Reliability (as of
April ’09) are 95.6% and 99.7% respectively as shown in Figure 3. The values pre-
sented represent a statistical view of the service fleet as opposed to simple averages
of these parameters. This provides a more accurate view of the fleet performance.
The lead SGT6-5000F engine has accumulated more than 120,000 operating hours.
The SGT6-5000F engine has demonstrated its mechanical integrity, operational
flexibility and excellent performance through a continuous improvement and dedi-
cated product development effort carried out since its introduction. This includes not
only the gas turbine, but also the generator, mechanical auxiliaries (lube oil, fuel,
etc.), electrical components and control system.

Figure 3. SGT6-5000F Fleet Availability & Reliability

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4 Engine Overview

4.1 Siemens Common Platform

With the merger of Siemens-KWU and Westinghouse Power Generation in 1998,

the process of integrating two design philosophies, frame architectures, and com-
ponent configurations began. A “Common Platform” approach has resulted to be
applied to all future Siemens gas turbine research and development. The integra-
tion of the technical capabilities of the two companies was undertaken via a major
R&D integration effort aimed at selecting the best technologies, design philoso-
phies and practices, analytical tools and engine architecture for future develop-
ment. The elements which make up the common platform have been extensively
verified and tested in the lab, in full load and with the analysis of fleet statistics.
The result was a cutting edge toolbox available for the development of not only
new frames, but also the evolution of the SGT6-5000F.

Over the last 14 years, the evolutionary enhancements of the SGT6-5000F have
improved its performance, reliability and emissions. The F(4) represents the Sie-
mens response to the market requirement for not only ever increasing power and
improving efficiency, but also operational flexibility This significant improvement
was achieved through a concerted development effort. Advancements include:

• compressor technology development,

• combustion system development,
• cooling and leakage air reduction,
• cooling and disc cavity air modulation,
• improved thermal barrier coating (TBC) application on some turbine airfoils,
• selected turbine vane and blade improvements,
• blade tip clearance reduction, and
• exhaust system enhancements.

The F(4)’s demonstrated high performance level attests to the success of these
efforts.

4.2 Component Design

The Siemens “Common Platform” approach has yielded significant improvements

in terms of engine component capabilities, robustness and reduced life cycle
costs. In the paragraphs to follow, some detail is provided about the integration of
the common platform into the SGT6-5000F and the benefits realized from this ef-
fort in terms of the engine value to the customer. Figure 4 below provides a longi-
tudinal view of the F(4) with several “platform” items clearly visible: 13 stage
compressor with 3 rows of variable stator vanes in addition to the variable inlet
guide vanes, single tie bolt rotor and single piece exhaust casing.

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3 VGV
Actuators

Center Tie-Bolt

Figure 4. SGT6-5000F(4) Longitudinal Section

4.2.1 Compressor

Efficiency, superior durability, and expanded operational flexibility were the targets of
the compressor enhancements in the F(4). While maintaining the same design point
pressure ratio and inlet mass flow as the previous variant, and incorporating the best
features and experience from the operating fleet and technology innovation, the aug-
mented design allows a stage count reduction from 16 to 13. State-of-the- art design
tools were employed to incorporate detailed research, analysis, lab testing, and ex-
tensive expertise in aerodynamic and mechanical analysis, leading to revised com-
pressor design that provides optimized compressor performance at both on- and off-
design levels.

Siemens design tools represent the culmination of proven, best practices merged
from Siemens and Westinghouse, and allow for routine front-to-back compressor 3D
CFD multistage analysis, unsteady blade row interaction, forced response analyses
and aero-elastic analysis. New sealing design was incorporated to provide better
leakage control over the complete operating range. Six Sigma methodologies were
utilized throughout the development to implement the technologies into a robust de-
sign. The result was targeted off-design performance, improved surge margin and
turndown ratio capability, wider allowable under/over frequency range and a more
robust mechanical design. The high efficiency airfoils were made more robust with
increased thickness to chord ratios for better FOD resistance and greater tolerance
to ice ingestion. In addition to the variable inlet guide vanes (IGV), three front stage
stator rows were made variable for improved part load performance and operational
flexibility through ambient temperature insensitivity. The stators on the downstream
stages were cantilevered (without inner shrouds), with tight clearances between the
stator ends and the disc rims.

4.2.2 Compressor Operational Experience

In demonstrating the full capability of the design efforts, Siemens employed the Ber-
lin Test Facility, BTF, to validate the improved compressor design. The tests were
conducted over a wider operating range than would be possible in a power plant
connected to the electrical grid. The compressor was instrumented with 800 sen-
sors. These included temperatures, static pressures, radial Kiel head probes, radial
traverses with 5-hole probes at various stages inside the compressor, strain gages
on stators and rotating blades, Kulites to measure dynamic pressure, non-contact

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stress measurement probes for monitoring blade vibration and tip clearance probes.
The test program incorporated starting sequence optimization, overall efficiency and
inlet mass flow measurement, compressor characteristics definition, surge margin
definition, vibratory stress measurement, tip clearance measurement and under/over
speed tests. To date, the compressor which is still in operation in the Berlin Test
Facility has accumulated approximately 500 operating hours, 1100 equivalent starts
and 13 surge tests from full speed no load all the way to base load. Surge test re-
sults confirmed that surge margins were in line with analytical predictions and the
mechanical robustness of the compressor was demonstrated, with no damage in-
curred from the multiple surge events. Test data analysis confirmed that the platform
compressor’s key parameters, such as mass flow, efficiency, operating range and
aero mechanical behavior met or exceeded expectations. Also, taking advantage of
common platform, this compressor has undergone additional validation on the first
SGT5-8000H engine.

During first F(4) unit commissioning in June 2009 the improved compressor de-
sign matched all performance expectations including efficiency and mass flow.

4.2.3 Rotor

As part of the common platform integration into the F(4), the rotor is constructed with
a single center tie bolt. The single tie bolt rotor has been in operation for many dec-
ades in the existing Siemens fleet with an excellent operational and maintenance
track record. To date, greater that 500 units operating with single tie bolt rotors have
amassed over 12 million hours and 149,000 starts. The center tie bolt with its sig-
nificantly reduced parts count and simplified tie bolt tensioning sequence, allows
ease of rotor assembly. The rotor is balanced in the shop using low speed balance
only, with no requirement for a high speed balance or rotor over speed operation in a
sub-atmospheric balance facility. No nickel-based alloys are used in the rotor con-
struction; rather the rotor uses upgraded steel discs in the turbine section, allowing
for greater flexibility in turbine blade cooling air temperature.

4.2.4 Combustion System and Turbine

The upgrade of the combustor system and turbine sections where undertaken with
two major requirements. First, the new components had to meet extended mainte-
nance interval requirements while improving thermal capabilities. Second, the com-
bustion and turbine design were undertaken with a product requirement specification
for complete retrofit-ability into the SGT6-5000F fleet. To achieve these goals, de-
sign changes included aerodynamic, materials, coating systems and cooling tech-
nologies upgrades within the Siemens common platform toolbox.

The combustion system was equipped with state of the art low emission technology
as well as an equipment protection package, that, together cultivate a system capa-
ble of extended operation intervals between required inspections. Combustion sys-
tem options which incorporate the increased maintenance intervals include both
Ultra Low NOx (ULN) systems as well as Dry Low NOx (DLN) systems. Installation
of these advanced combustion systems also include the Combustor Dynamics Pro-

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tection System (SPPA-D3000). Combustion dynamics sensors, which use transis-

tors to measure dynamic pressure, were installed in the combustors to detect low
and high frequencies. When dynamic fluctuations exceed a preset value, the control
system tunes the combustor away from the instability.

As noted in Section 4.6.1, the combustion system mechanical design and manufac-
turing processes were improved and the transition aerodynamic shape and cooling
design were enhanced, allowing for an increase in the combustor inspection interval
by over 50% on hours and 100% on starts.

The enhanced turbine section resulted in increased efficiency, power output, service
life, and lower repair costs. Turbine stage 1 design has new aerodynamic, cooling,
coatings and materials design, Stage 2 includes improved cooling, materials and
coatings technology and stages 3 and 4 utilize new coatings technology. The fourth
stage vane and blade designs contribute to improved efficiency and increased maxi-
mum shaft power limit. Additionally, rotor cooling air optimization supports enhanced
efficiency by way of targeted hot running blade tip clearances.

4.2.5 Combustion System and Turbine Operational Experience

The design improvements to the combustion and turbine noted above were made
using not only the latest Siemens analytical tools but also using empirical data from
the field. Taking into account current hardware performance and identifying the dis-
tress modes, improvements to the life cycle costs have been realized with these new
designs. As with all other new components, the combustion system and turbine sys-
tems designs have been fully verified using both rig testing and full scale, instru-
mented engine testing in the Berlin Test Facility. Following engine testing in late
2006, validation sets have been installed in multiple engines in the fleet to ensure
both the combustion and turbine hardware meet expectations on performance, me-
chanical robustness, maintenance interval, repair cost and overall part life. As of this
writing the validation lead sets both in customer units and the Berlin Test Facility
continue to operate, having accumulated over 3,000 equivalent starts and 70,000
operating hours. Lead sets have accumulated over 400 starts and 15,000 hours.

During first F(4) unit commissioning in June 2009 the improved turbine design
hardware matched all performance expectations including efficiency and swallow-
ing capacity.

4.2.6 Exhaust System

Starting in 2007, SGT6-5000Fs began shipping with an upgraded exhaust system

which is also integrated into the F(4). The development of the improved exhaust
system focused on increased pressure recovery (i.e. thermal efficiency), improved
mechanical robustness and greater operational flexibility. As all Siemens gas turbine
design efforts are now undertaken with the common platform approach, the redes-
igned exhaust is no different. The design leverages the excellent experience with a
“single piece” exhaust system from the Siemens fleet of gas turbines. There are

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 ADVANCED SGT6-5000F DEVELOPMENT

several major changes included in the redesign involving the exhaust casing, diffuser
flow path, main bearing support struts, and other components.

The upgraded exhaust system is currently in operation at the Siemens Berlin Test Facility
where the expected improvements have been verified against analytical predictions. Tem-
peratures, pressures and dynamic aero-mechanical parameters measured as predicted.
The test facility affords the opportunity to put a very high number of thermal cycles on the
exhaust system. The single piece exhaust system installed in Berlin, will for the foreseeable
future be the fleet leader in terms of cycles and will prove out its’ expected long term durabil-
ity. In summary, these aerodynamic, material and mechanical design changes work to-
gether to allow higher exhaust temperature capability, increased aerodynamic efficiency and
improved operational flexibility enabling fast start times and low turndown ratios.

4.3 Future Upgrades

SGT6-5000F gas turbine performance, reliability and operational flexibility have im-
proved, while emissions and life cycle costs have decreased steadily since its intro-
duction. This was accomplished by planned development programs, which facilitated
the introduction of new technologies and concepts, as well as a structured process
for field technical issue resolution. The result was a more competitive product and
added value to our customers.

The SGT6-5000F gas turbine will undergo continued enhancement for both new and
in-service plants. Future product enhancement process will concentrate not only on
performance and emissions, but also on operational flexibility, reliability, availability,
maintainability, lower life cycle costs, longer component lives, improved service fac-
tors and increased repair intervals. Near-term planned enhancements are additional
NOx emissions reduction, improved CO turndown performance, automated engine
control settings optimization, and extensions to maintenance inspection intervals with
reduced fallout rate for service run components.

5 Operational Flexibility

5.1 Emissions

The original SGT6-5000F gas turbine incorporated diffusion flame DF-42 combustors
with 42 ppm NOx (@ 15% O2) emissions on natural gas. Through continuous com-
bustion system development, NOx emission was reduced to 15 ppm with the pre-
mixed dry low NOx (DLN) combustors and now to <9 ppm with the ultra low NOx
(ULN) combustors. In addition to reducing NOx, the ULN combustion system controls
CO, volatile organic compounds (VOC) and particulate emissions. This development
also addressed potential fuel flexibility issues, as more LNG enters the U.S. market,
and expanded operating range (turndown), where low CO emissions are required.

The starting point for latest development was the premixed DLN combustor. NOx
reduction was achieved through temperature and heat release strategy modification
by staging the combustion process. The current DLN combustor design uses 4 fuel
stages to mix the natural gas with combustion air. These stages come on line inde-

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pendently, as the engine is ramped up in power. At all loads the fuel is injected con-
tinuously through the pilot nozzle and is not premixed, thus limiting the achievable
minimum NOx emissions. The modifications required to achieve sub 9 ppm NOx in
the ULN, 5-stage system concentrated on a premixed pilot design and support hous-
ing design changes. The pilot and the main pre-mixers on the combustor support
housing now employ swirler fuel injection, where the fuel is injected off the swirler
vanes, thus providing more injection points and better mixing. The ULN combustion
system validation included CFD modeling, high pressure single basket rig testing
and a full-scale engine test in the Berlin Test Facility (BTF), which allowed testing
over a wide load range. Refer to Figure 5 for photograph of the BTF. The value of
the BTF was demonstrated in field engine validation where the ULN system operated
within the design emissions and dynamics parameters on the first day of testing. The
new combustor design demonstrates emissions and combustion dynamics virtually
not affected by fuel temperature variations, such as when the engine loses the fuel
heater and the fuel temperature drops, or with variations in fuel composition. The
thermal loading on the hot parts, such as the combustor liner, transition and the first
stage turbine vane, is very similar to the existing 25 ppm NOx system.

Figure 5. Berlin Test Facility

During first F(4) unit commissioning in June 2009 sub-9ppm NOx emissions were
obtained from baseload operation down to 38% load.

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5.2 10 Minute Start-Up Time to 150MW

In response to meeting the need to provide reliable, responsive output for spikes in
power demand, Siemens has reduced the time to baseload by over 50%. A start
enabled by a mechanical starting motor from initiation to full power was approxi-
mately 30 minutes. The improved start time capability provides 5 minutes from start
initiation to minimum load, followed by a 30 MW/minute loading rate, such that 150
MW load is reached within 10 minutes (see Figure 6), and full load is achieved in 12-
13 minutes.

To achieve the improved start capability the following steps were taken:

1. Static frequency converter (SFC) (static start, where generator operates as a

motor) replaced the mechanical starter motor. SFC allows more efficient and
faster rotor acceleration than the equivalently sized mechanical starting motor.

2. Turning gear (TG) speed was increased from 3 rpm to 120 rpm.

The higher TG speed enables the generator rotor wedges to lock up, prevents com-
pressor blade locking mechanism wear, and locks turbine blades into running posi-
tion. Higher TG speed also helps the engine cool down faster, because the turbine
parts are cooled faster and tip clearances are similar to the cold tip clearance.

Faster
Start

Normal
Start

Figure 6. Fast Start / Fast Load Rate Reduces Startup Time by Over 60%

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During first F(4) commissioning in June 2009 sub-10 minute start-up time to 150
MW was demonstrated. A time of 5 minutes was required to achieve synchroniza-
tion followed by a loading rate of 30MW/min.

5.3 Part Load CO Emission Reduction

Reduced low load CO emissions were achieved by operational modifications and

bypassing supplemental cooling air around the combustor. The result of bypassing
air around the combustor is increased combustor flame temperature, which leads to
reduced CO production. With the required equipment and operational changes, CO
emission is kept <10ppm down to at least 40% load, without alteration to the internal
architecture of the combustion system. The result is greater flexibility in cyclic opera-
tional mode and better use of equipment in a highly volatile market.

During first F(4) unit commissioning in June 2009 sub-10ppm CO emissions were
achieved down to 38% load when functioning with the air bypass system. This
was achieved simultaneously with sub-9ppm NOx.

5.4 Outlet Temperature Control

Engine control parameter settings were previously based on a function of exhaust

temperature versus combustor shell pressure. This relationship defined the base
load firing temperature to which the engine was ultimately controlled. Engine control
parameter settings are now based on a relationship of exhaust temperature, com-
pressor inlet temperature, and load. The Siemens system employing this relationship
is called Outlet Temperature Corrected (OTC) control. OTC optimizes part load per-
formance reduces NOx drift and reduces the need for seasonal tuning. A standard
control method for V-engines for over 20 years, OTC represents another demonstra-
tion of the common platform approach. A comparison of OTC with legacy control
methodology is shown in Figure 7. Note the improvement in part load turbine inlet
and exhaust temperature maintenance.
Turbine Inlet Temperature

Exhaust Temperature
or

Prior to OTC Control

Figure 7. OTC Control Effect on Turbine Inlet and Exhaust Temperatures

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 ADVANCED SGT6-5000F DEVELOPMENT

5.5 Increased Combustion System Inspection Interval

Combustor basket and fuel nozzle mechanical design and manufacturing processes
were improved to address low-life areas and the transition aerodynamic shape and
cooling design were enhanced. These improvements allowed an increase in the
combustor inspection interval by over 50% on an hours based maintenance cycle
from 8,000 equivalent base load (EBH) operating hours to 12,500 hours and by over
100% on a starts based maintenance cycle from 450 equivalent starts (ES) to 900
equivalent starts. This increase in starts capability will eliminate the need for com-
bustor inspections altogether for a starts based engine since it aligns with a Hot Gas
Path Inspection. This lengthens the interval between maintenance inspections while
improving operational flexibility for units that operate the required hardware.

5.6 Trip Factor Reduction

Maintenance intervals are calculated using operational data in a mathematical for-

mula. One component of this equation that accounts for rapid temperature changes
experienced by the turbine hardware is the number and type of trips experienced in
operation. A “Trip Factor” is assigned a value depending on the severity of the trip
across the load range. The maximum full load Trip Factor was reduced from 20 to 8
equivalent starts due to thermal and structural design improvements to turbine and
combustor components, with corresponding reductions in Trip Factors from part load
conditions. This change allows the operator to run the engine for longer periods be-
tween maintenance inspections thereby reducing life cycle costs and enhancing op-
erational flexibility. See Figure 8 below for a summary of the inspection interval in-
crease and trip factor reduction.

Figure 8. Extended Maintenance Intervals & Reduced Trip Factors

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5.7 LNG Capability

Due to natural gas supply market volatility, increasing prices and declining do-
mestic production, liquefied natural gas (LNG) is becoming an attractive alterna-
tive fuel choice for gas turbines. LNG imports are expected to increase in the fu-
ture with imminent operation of several terminals and many others announced for
construction. LNG consists of methane, which is the main constituent in natural
gas, along with heavier components, such as ethane, propane and butane. De-
pending on the level of heavier constituents, LNG could result in a higher or lower
flame temperature than traditional natural gas and potentially impact the safe and
environmentally sound operation of gas turbine plants.

Safe gas turbine operation on LNG with acceptable emissions, combustion dy-
namics, reliability and parts life was successfully demonstrated at a customer site
for the SGT6-5000F combustion system.

6 Integration into Flexible Combined Cycle Power Plants

To capitalize on the operating flexibility of the SGT6-5000F gas turbine, the bottom-
ing cycle must be skillfully designed to address and alleviate component and system
limitations. Siemens has leveraged it’s knowledge and expertise with the BENSON®
once through HRSG technology and performed extensive transient analysis with key
HRSG suppliers to design the 275 MW SCC6-5000F 1x1 Flex-PlantTM 10 (or simply
Flex-PlantTM 10). Integrated at the core of the Flex-PlantTM 10 is the highly flexible
SGT6-5000F. This combined cycle plant incorporates a simplified single-pressure
bottoming cycle with modified drum and reduced steam temperatures and pressures.
Figure 9 below depicts a graphic from the fully developed 3-D model of a two-unit
Flex-PlantTM 10. Other attributes include pipe pre-warming, high-capacity attempora-
tors, and turbine stress controllers.

The Flex-PlantTM 10 has a net power output of 275 MW at greater than 48% effi-
ciency. Starting from turning gear, it can generate 150 MW within 10 minutes with
NOx emissions of 9ppm. With the installation of SCR and CO catalysts, stack emis-
sions compliance is reached in about 20 minutes. Utilizing the fast start gas turbine
has the additional advantage of greatly reducing start up emissions from a traditional
combined cycle plant. Expected start-up emissions are 152 lb/start for CO, 12.4
lb/start for NOx and 13 lb/start for VOC.

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 ADVANCED SGT6-5000F DEVELOPMENT

Figure 9. Flex-Plant 10 Depiction

With a 10-minute start capability to 150MW, the 1x1 Flex-PlantTM 10 is designed for
peaking to intermediate duty. With net efficiency that is 6-7% points higher than
aero-derivative and ICAD products, 275 MW combined cycle plant offers considera-
bly higher efficiencies without compromising operational flexibility.

The SCC6-5000F 2x1 Flex-PlantTM 30, rated at 618MW, is more of a conventional

combined cycle with some fast start capability and world class efficiency of greater
than 57%. Intended for intermediate to continuous duty, start times (30 min to
baseload) are faster than traditional CC units due to higher loading rate in part en-
abled by use of a once-through Benson HP HRSG and a Turbine Stress Controller.
Combined with high startup efficiency, startup emissions are extremely low. Addi-
tional features enhancing operational flexibility for both Flex-PlantTM offerings include
high-capacity attemperator, condensate polishing plant faster steam purity, auxiliary
boiler, drain and vent automation, mechanical vacuum pumps for the condenser, fast
warm-up of main steam piping, and Low Load CO technologies.

7 Summary

The 213 SGT6-5000F gas turbines in peaking, intermediate and base load opera-
tion have achieved more than 4.7 million operating hours and have established an
impressive service record. The lead unit has been in operation for more than
120,000 hours. The fleet median Reliability and Availability are 99.7% and
95.6%, respectively. The SGT6-5000F is capable of producing 208 MW at 38.4%
efficiency in simple cycle operation and >300 MW at 57.5% in CC applications,
with a maximum shaft power capability over 250 MW. On natural gas fuel, NOx
emissions capability is <9 ppm and <42 ppm on distillate oil fuel with water injec-
tion. A concerted development effort over many years has provided performance
improvements and emissions reductions. In response to current market demands
for cyclic and start/stop operational modes, design enhancements were incorpo-

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rated to further enhance operational flexibility. The starting reliability was im-
proved and starting time to 150MW reduced to 10 minutes. The turndown capa-
bility was reduced to 40% load. The outlet temperature correction control system
was implemented to enhance part load performance and emissions. The Trip
Factor was reduced from 20 to 8 and the combustor/transition inspection interval
was increased to 12,500 hours and 900 starts. Compressor redesign efforts con-
tributed to more advantageous part load performance and increased operational
flexibility. Selected turbine vane and blade aerodynamic enhancements and cool-
ing optimization improved performance and durability, as did the exhaust system
improvements. All of the above enhancements resulted in a product with superior
performance, low emissions, excellent durability and wide operational flexibility.
To further enhance its value, the engine is available for operation in IGCC appli-
cations and on LNG.

The SGT6-5000F gas turbine has demonstrated its capability in the current mar-
ket conditions by its performance, reliability, availability, low emissions and opera-
tional flexibility. It is now, and will continue to be, a very efficient and reliable low
cost electricity generator, which is critical in changing market conditions.

8 Permission for Use / Copyright Statement

The content of this paper is copyrighted by Siemens Energy, Inc. and is licensed
only to IAGT for publication and distribution. Any inquiries regarding permission
to use the content of this paper, in whole or in part, for any purpose must be ad-
dressed to Siemens Energy, Inc. directly.

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References

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