Modernization & Upgrades for Utility Steam Turbines

Tailored Service for your Equipment

In a performance-based market structure, when plants are managed as profit centers, it is necessary to strategically improve efficiency, optimize capacity, minimize costs and maintain high reliability in order to be competitive - especially when it comes to aging plants. Therefore, Siemens Energy Service has developed an array of Performance Enhancement solutions that can help you make your generating assets more profitable.

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Description

The Perfect Modernization Solution for your Steam Turbine

Given the relatively low fuel cost of coal- and nuclear-powered steam turbine generators, and the increasing strategic value of existing sites, a modernization of existing equipment can be more cost-effective and faster than installing new generation equipment.
Non-destructive examination measurements

Performance Enhancement solutions can help you improve assets and environmental compatibility, as well as lead to higher reliability and overall performance.

 

Our customers are impressed by the performance enhancements resulting from modernizations. We can prepare your power plant, your plant in the oil & gas sector or your industrial plant for tomorrow and beyond.

 

We inspect your plant, whether it’s a Siemens Energy plant or a plant by another OEM, and give you the options tailored to your needs.

Modernization activities on a Steam Turbine

Focused on the turbine generator and its auxiliaries, Siemens Energy provides the interface across various disciplines to address the boiler (or steam generator), the control system and the balance of plant considerations on any modernization activity.

 

We moreover assist in evaluating the net present value calculation and IRR (Internal rate of return) analyses necessary to justify the project.

 

In addition, uniquely qualified engineers provide complete turnkey installation of modernized equipment in concert with the plant's inspection requirements and scheduled outage duration. They can help plan the outage work in detail with other subcontractors to ensure an on-time completion.

 

Finally, Siemens Energy has the capability to utilize creative financing for the modernization capital, based on sales of the incremental megawatts.

Ensuring a reliable supply of power and water at the Shuaibah Power and Desalination Plant in Saudi Arabia

Saving outage time while enhancing efficiency with an HP barrel replacement
Benefits

Benefits

Your benefits may include:

Power increase

Increased power output after modernization

Reliability Increase

Extension of component lifetime

Availability increase

Enable secure operation range

Sustainability

Emission reduction to meet environmental requirements

Cost Optimization

Reduced maintenance costs by extended maintenance intervals and shorter outages

Portfolio

Performance Enhancement Solutions

Comprehensive performance enhancement solutions for fossil, nuclear and combined cycle plants:

Over the last years, our power plant customer are facing challenges such as an increase of renewable energy, the decrease in energy prices or the increased demand for energy. Siemens Energy anticipated and reacted to the needs of the market by developing technologies and solutions to provide a full range of performance enhancement solutions for the steam turbine.

 

Furthermore, enhanced power plant reliability as well as the reduction of costs can be necessary to further strengthen competitiveness in the rapidly changing energy market. Especially mature steam turbines can additionally experience performance and reliability losses, which may lead to the need to take action for a secure future operation.

 

Siemens Energy has decades of experience in the field of modernization and maintenance of large steam turbines built with Siemens KWU, Westinghouse and Parsons technology. 

 

 

 

 

 

 

 

 

 

Our steam turbine modernization portfolio can, amongst others, include:

  • Plant / turbine operability enhancement
  • Full turbine element replacements
  • Valve repair and replacement
  • New rotors, blade path and casing packages

 

Our experienced team is ready to assist you to find the right solution for your steam turbine. With our experts in engineering, manufacturing and/or field service in close collaboration, we can offer optimum performance enhancement solutions for your power plant.

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Examples

Examples for Upgrades

Examples for the comprehensive performance enhancement programs for large steam turbines include retrofits or upgrades like the following:

HP Barrel Exchange / Upgrade

Potential Benefits:

  • Reduce outage time
  • Increase performance and lifetime
  • Reduce potential for reliability issues and extend lifetime
  • Reduce maintenance costs
  • Increase flexibility

 

By

  • New rotor, inner and outer casing and bladepath
  • Application of Flex-Power solutions
  • Application of 3DS blade and 3DV blading technology and advanced seal designs

IP / LP Turbine Upgrades

Potential Benefits:

  • Increase performance and lifetime
  • Reduce maintenance cost
  • Reduce outage time
  • Reduce potential for reliability issues and extend lifetime

 

By

  • New rotor, inner casing and bladepath
  • Application of 3DS blade and 3DV blading technology and advanced seal design

Condenser Upgrades            

Potential Benefits:

  • Replacing the complete tube bundle(s) can improve condenser performance in various areas.
  • Reduced condenser pressure – increased power output and efficiency of the steam turbine.
  • Increased condenser operating reliability and reduced forced outages

OOEM Upgrades            

  • Siemens Energy has the capability to service, repair and modernize steam turbines including those of other manufacturers.
  • Depending on the application, our global Service network may be able to inspect OOEM (Other Original Equipment Manufacturer) steam turbine components and recommend appropriate measures.
  • Furthermore, Siemens can reverse engineer and manufacture OOEM parts.
References

Examples of Successful Projects

Find out more about some of our reference projects
Drax coal-fired power station
United Kingdom

Steam Plant Modernization

  • Upgrade of the HP turbines with a new inner casing, rotor and blade path

    Upgrade of the LP turbines with new rotors and blade paths retaining the existing cylinder construction

  • Enhanced power output up to 686 MW, increased efficiency and reduced maintenance costs

Ibbenbüren coal-fired power plant
Germany

Modernizing of Steam Turbines and Condensers

  • Modernization of the high pressure turbine, the intermediate pressure turbine, the two low pressure turbines and the two condensers

  • Increased performance of 86 MW, efficiency increase, flexibility improvement

  • Better operating characteristics than prior to the modernization

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Coal fired power plant
China

LMZ Modernization & Thermal Uprate

  • Many existing Steam Power Plants (SPP) designed for base-load operation have to change to flexible mode, requiring optimized startup performance.

  • As many of the plants have already completed the designed lifetime, it is not a feasible option to run these plants in flexible mode.

  • The option left is shifting to flexible mode only after the old turbines are modernized using state-of-the-art materials and technology-enhanced components such as blades, sealings, casings & rotors.

Download PDF

Related Topics

Repowering

Repowering

Existing direct-fired plants can utilize the advanced cycle concept by adding a gas turbine and a HRSG. This so-called repowering scheme makes the existing power generation facility equally efficient as modern combined cycle power plant.
Aspects of Flex-Power Services™

Flex-Power Services™ for Fossil Power Plants

Flex-Power Services™ for Fossil Power Plants

Flex-Power Services can in many cases be provided as a retrofit for the Siemens Energy service fleet and combined with other modernizations. Implementing these state-of-the-art features can help power plants enhance operational flexibiliy and increase the competitiveness of the plant in the changing energy market.

Modernization and Upgrades for Condensers

Modernization and Upgrades for Condensers

The overall efficiency of a fossil or nuclear power plant is strongly influenced by the performance of its condenser. Upgrading the condenser improves utilization of the thermal potential in the water/steam cycle.

Steam turbines

Steam turbines

Find out more about Siemens Energy steam turbines from 10 kW to 1,900 MW.