Largest gas turbine: 2,838 sensors, 90 GB data per hour of testing

Largest gas turbine, from Siemens, is expected to deliver 530 MW at more than 60% thermal efficiency. Some 2,838 sensors and associated wiring are deployed to monitor the turbine. Of these, 597 turn with the rotor; total data collection during testing amounts to 90 GB/hour. Other sensors include...

02/13/2009


Irsching (near Ingolstadt), Germany – Much is made of the benefits of modular design and construction but not often associated with the large scale of power plants. Yet, this is the path Siemens Energy has taken to bring online the

world’s largest H-class gas turbine, expected to deliver 60%+ thermal efficiency

in combined-cycle operation. That operating mode will come after adding a steam turbine, with full system completion and handover expected in mid-2011.

Siemens’ H-class SGT5-8000H turbine is 440 metric tons and expected to deliver 530 MW.

Thinking BIG generates excitement:

Installed at the Irsching gas power plant, SGT5-8000H gas turbine is a 440 metric ton, 50-Hz machine that outputs 340 MW—and is designed for 530 MW in eventual combined-cycle operation. Control Engineering was fortunate to be able visit Irsching Unit 4 in late-Nov. 2008 to obtain a first-hand progress update from Willibald Fischer, Siemens program manager for H-turbines. The site is Siemens’ turbine Test Center until turnover of the system to German power company E.ON Kraftwerke.
Siemens’ H-class turbine is now in phase 2 endurance/durability testing until mid-year `09, accumulating operating hours and start-up experience, explains Fischer. “This is a semi-commercial operating stage, with tenders ongoing to other customers,” he says.
Instrumentation engineer’s dream: 597 spinning sensors
The Irsching test site is an exciting place for control/instrumentation engineers. Some 2,838 sensors and associated wiring are deployed to monitor the turbine. Of these, 597 turn with the rotor, with data brought out to telemetry units at each end. Most numerous are temperature and pressure sensors (1,688 and 616, respectively), and strain-gages (357), besides accelerometers and other sensors for clearance, blade vibration, and flow/force measurement. All test information goes to onsite computers for monitoring by a small staff; then, data are transmitted for detailed analysis to Siemens facilities in Orlando and Jupiter, FL, and Mülheim, Germany. “Data flow is near real time. One hour of testing produces 90 gigabytes of data,” Fischer explains.

Wired for data collection


With modular construction, the SGT5-8000H currently produces electric output only by shaft power directly coupled to the generator (simple-cycle operation). Through Nov. `08, approximately 250 hours of operation have been logged. Siemens intends to demonstrate reliable turbine operation under cyclic loads, thus daily shutdowns are part of the testing. H turbine is said to be capable of 150-200 starts per year, if needed, but also can deliver 8,000 hours of baseload operation.
The gas turbine’s second output—exhaust to the heat recovery steam generator (boiler)—will come into play during combined-cycle gas turbine (CCGT) operation. Build-out of the CCGT plant begins in mid-2009. However, foundations for the steam turbine, other civil engineering works, an air-intake filtration system, and myriad auxiliary equipment are in place, thanks to modular construction.

Related reading on efficient power generation

- The hunt for 60%+ thermal efficiency (August 2008).
- New, efficient industrial gas turbines coming .

In a single-shaft CCGT plant layout, the steam turbine will connect to the end of the generator opposite the gas turbine. The boiler will be installed behind the gas turbine’s high-temperature exhaust diffuser and connected to the steam turbine by steam piping systems. The boiler, steam turbine, and condenser, are scheduled to arrive in 2010. Program completion date of July 2011 remains on target, as the “steam side” of the plant represents more predictable, standard technology, notes Fischer.
Kilovolts next to millivolts
Test work at Irsching is one of contrasts. “While kilovolts of electricity flow from the system’s output to the grid, just millivolts monitor banks of sensors at other points of the same system to ensure the turbine’s health,” Fischer adds.
Siemens’ investment in H-class gas turbines is projected to be€500 million through the project’s completion. An undertaking of this size is bound to be costly and needs to be viewed as a lease on the future.
Frank J. Bartos , P.E., Consulting Editor
Control Engineering News Desk
Register here to select your choice of eNewsletters free.





No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Your leaks start here: Take a disciplined approach with your hydraulic system; U.S. presence at Hannover Messe a rousing success
Hannover Messe 2016: Taking hold of the future - Partner Country status spotlights U.S. manufacturing; Honoring manufacturing excellence: The 2015 Product of the Year Winners
Inside IIoT: How technology, strategy can improve your operation; Dry media or web scrubber?; Six steps to design a PM program
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Warehouse winter comfort: The HTHV solution; Cooling with natural gas; Plastics industry booming
Managing automation upgrades, retrofits; Making technical, business sense; Ensuring network cyber security
Designing generator systems; Using online commissioning tools; Selective coordination best practices

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me