The Rotor Exchange Program (ROTEX) is an integrated service solution so that we can jointly manage the challenges (staying in budget, saving time, improving availability) of our customers’ complete value chain everywhere.Vinod Philip, Chief Technology Officer
At each outage, a just-in-time Siemens-qualified rotor according to Siemens‘ latest standards / recommendations is put into operation, while your existing rotor is sent to a Siemens facility to be updated and included in the rotor pool.
This proactive program can eliminate the rotor as a life-limiting component and enhance your possibility to optimize your assets with latest technology.
Its all about availability
Our solution:
- ROTEX can help to increase availability due to outstanding shortened scheduled outage durations
- ROTEX can help to increase your revenue by being faster back to grid
- ROTEX can minimize the potential for costly outage delays
- Increase your dispatch by implementing valuable upgrades during the swap
Budget is tight
Our solution:
- ROTEX optimized outage planning can reduce outage costs and duration
- Additional investments for upgrades with ROTEX
- ROTEX can reduce potential for additional costs resulting from unexpected findings
- ROTEX can also offer flexible financial & payment solutions
As near as we can, we want to return to the efficiency levels the plant achieved when it was built. The rotor exchange concept was very attractive to our customer.Tony Thomas, Project Manager Peterhead
Regular service is required for smooth and reliable operation of power plants. An outage is also the best time for implementation of Modernizations or Upgrades to increase the power plants performance. With ROTEX it is possible to reduce the time and financial impact of scheduled service. Rethink your service to enhance your performance.
Exchange solution for the SGT-4000F series
Rotor Exchange beneficial if
- Rotor destack is required
- Upgrades and Modifications (SP7, SP8) apply
- Remote Outage or other on-site repairs apply, specifically
- Compressor recoating
- Hub (shaft cover) heavy repair
- Replacement of Start/EOH limited components (eg. Torque disk)
- Projects specifics (high risk, comp. or turbine damage, etc.) - limited / no crane- and laydown area available
Configuration levels
- “Plug and Play” rotor (incl. new set of compressor blades, high-speed balancing and blade grinding)
- Hub (shaft cover) incl. tiles
- Outer Shell (Combustion Chamber)
- Turbine Vane Carrier (if required)
- Compressor Vane Carrier 2 (Outlet Guide Vane OGV)
Blade tip grinding
- Yes
- Ansaldo Frames has to be clarified project specific (impact on outage duration, no significant cost impact
Frame specifics
- clarified specific to project
Customer benefits:
- Simple Cycle power increase up to 21.9 MW with up to 0.15%-pts. higher efficiency
- Combined Cycle power increase up to 33.6MW with up to 0.3%-pts. higher efficiency
Scope:
- New compressor Blades & Vanes stages 1-6
- New Compressor Discs 1-4 ; 13-15 & Torque Discs 1-3
- Ring Segments, Blades & Vanes 1-4
- Ceramic mock-ups, Combustion Chamber Modification of metallic heat shields (step2 design), new ceramic heat shields
- Burner Upgrade (HR3-RST),
- Exchange of Turbine Vane Carrier, Compressor Vane Carrier, Multiple casing sealings, compressor bearing shell and Inlet Guide Vane (IGV) Support optimization
Customer benefits:
- Simple cycle efficiency increase up to 1.8%pts
- GT power output increase up to 27 MW
- Combined cycle efficiency increase up to 1.5%pts
- Combined cycle efficiency increase up to 39 MW
- Reduced OPEX
- Reduced CO₂ per MW
Scope:
- Compressor Mass Flow Increase (CMF+)
- New turbine Blades & Vanes 1-4
- Rework of turbine vane carrier
- Torque Disks & Rear compressor disk (Precondition: Material Cost E)
- Turbine Exit Liner Strut Optimization (optional)
- New compressor bearing with increased axial thrust (optional)
Exchange solution for SGT-2000E series
Rotor Exchange beneficial if
- Rotor destack is required
- Upgrades and Modifications apply
- Remote Outage or other on-site repairs apply, specifically
- Compressor recoating
- Turbine rings (repair)
- Replacement of damping cones
Configuration levels
- Limited / no crane and laydown area available
- “Plug and Play” rotor (incl. new set of compressor blades, high-speed balancing and blade grinding)
- Inner casing (new or refurbished)
- Mixing chambers (if required)
- Turbine vane carrier (if required)
Blade tip grinding
- Yes
- Ansaldo Frames have to be clarified project-specific (impact on outage duration, no significant cost impact expected)
Frame specifics
- Fitting of inner casing with rotor
Customer benefit:
- Simple cycle efficiency increase up to 2.6%pts
- GT power output increase up to 20 MW
- Combined cycle efficiency increase up to 1.6%pts
- Combined cycle power output increase up to 38 MW
Example scope M&U upgrades:
- Compressor Upgrades (CMF+/CMF++)
- Turbine section Upgrade
- Burner Upgrade
- Improved axial trust compressor bearing
- Further Upgrades available
Customer benefits:
- Simple cycle efficiency increase up to 1.8%pts
- GT power output increase up to 27 MW
- Combined cycle efficiency increase up to 1.3%pts
- Combined cycle efficiency increase up to 31 MW
Scope:
- New turbine blades and vanes Si3D+™
- New seal rings 2,3 and 4
- Minor mechanical work on turbine vane carrier to implement cooling air savings
- Improved compressor bearing, optional Hydraulic Clearance Optimization (HCO)
- Improved turbine outlet temperature measurement (OTC+)
Lifetime extension (RCIE) for the SGT-2000E and SGT-4000F series
We provide everything from a single source – from an initial ROI estimate to the feasibility study to project execution; and from providing all components to installation, assembly, and commissioning, including documentation and service by our Field Service Experts. Replan your service to maximize availability and reliability.
ROTEX Rotor Pool Concept
New-built or refurbished rotor delivered to customer site prior to event start. After the outage, service-run rotor returned to Siemens for pooling and systematically establishing parts pool with major components to support customers worldwide.
You can rely on us
We will provide everything from a single source – that is, from an initial ROI estimate through the feasibility study to project execution; and providing all components for installation, assembly, and commissioning, including documentation and service by our Field Service experts.
- ROI estimate
- Data capturing
- Feasibility study
- Project management
- Delivery of equipment
- Installation and commissioning
- Documentation
- Services
Customers will benefit even more from improved cash flow, cost avoidance and continued modernization when entrusting us with the management of their major components, e.g. valves, combustion chamber, turbine vane carrier.
Apart from the turbine rotor, further components can be offered. For SGT-4000F series, complete combustion chambers and associated burner combinations as well as the guide vane carriers can be exchanged.
The provision of SGT-2000E series inner and mixing casings can further reduce the outage lead time.
ValveEx started as an exchange concept for fuel gas valves during an outage on Siemens Energy gas turbine and turned into an integrated service solution for gas turbine and steam turbine valves.
Customers can benefit from the potential for improved cash flow, cost reduction and the potential of availability increase.
- The installed HP barrel is replaced by a new or refurbished HP barrel in accordance with Siemens' latest state-of-the-art
- Refurbishment of old HP barrel takes place ‘offline’ while unit is in operation (in a Siemens or local workshop
- The power plant can be restarted and connected to the grid up to 30 days earlier compared to a regular major overhaul
- Additionally, tailor made solutions like efficiency increase (Green MW’s), performance increase and power plant flexibilizations can be integrated
- The HP barrel replacement is intended to optimize the steam turbine asset with regard to future operation reliability, as well as reduced costs
- Main steam valve refurbishment package designed in accordance with Siemens' latest state-of-the-art can be supplied prior to the outage
- Can apply to 50k EOH, 100k EOH, or emergent outages
- Reduced outage duration and minimized technical risk
- Reduced need for inventory and spare parts planning for valve internals
- Emergent repairs done off critical path
Generator Exchange
Replacing your rotor with a rewound seed rotor with design upgrades can greatly increase the unit availability and reliability.
The generator rotor exchange makes a significant contribution to the economic value as a conventional rotor rewind usually does not fit into regular outage durations from a timeline perspective – a seed rotor replacement usually does.
A Tailored Solution for your Plant
BEX “Brownfield Engine Exchange“ stands for the replacement of existing OEM & oOEM gas turbines with latest technology Siemens Energy units.
BEX is a custom-tailored solution with the target to maximize the performance and in parallel to keep the overall capital spending at an optimized level.
We have 3 different base solutions in our portfolio:
- BEX EcoLow - Investment, increased Performance, keep Output
- BEX Performance - Medium Investment, increased Performance, increased Output
- BEX Max - High investment, increased Performance, maximum Output
Benefits
- Efficiency: Efficiency improvement of up to 3%-pts. in combined cycle enables significant cost reduction and competitively priced energy.
- Flexibility: Part load capability and fast ramp rates improve power system flexibiliy and increase responsiveness to electricity demand and market condition.
- Emissions: Latest technology and high efficiency combustion system enable significant reduction in NOx, CO, and CO2 emissions.
- Pricing: Reduced scope limited to gas turbine exchange enables fast return of invest compared to a new built.
- Integration: BEX can be integrated and combined with various solutions such as Power-to-X or battery storage to provide holistic solutions for future power system requirements.
- Hydrogen: Future-proof technology, capable to burn large amounts of hydrogen.
