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Exchange Concepts
Welcome to a new era of power plant maintenance!
Our innovative exchange concepts are transforming the way power plants are modernized and maintained, offering unparalleled benefits in terms of efficiency, cost savings, and risk reduction. By providing the option to exchange whole turbines or individual components, we enable power plant operators to adopt cutting-edge technologies and unlock new use cases for their facilities. This streamlined approach not only saves time and reduces on-site work, but also ensures that plants are future-ready, allowing them to maintain peak performance in an ever-evolving energy landscape. Discover how our exchange solutions can revolutionize your power plant maintenance and drive long-term success.
Upgrade existing gas-fired power plants with Brownfield Engine Exchange (BEX)
As the pace of the energy transition accelerates, upgrading or optimizing existing gas-fired power plants has emerged as a more viable option than constructing new ones. Thanks to technological advancements and improvements in energy efficiency, retrofitting older facilities presents a cost-effective means of enhancing output while simultaneously mitigating emissions.
With Siemens Energy's Brownfield Engine Exchange concept, old gas turbines can be seamlessly replaced with new ones within a short outage period.
BEX at a glance
The Brownfield Engine Exchange (BEX) solution is designed based on a plug-and-play concept, providing a streamlined retrofitting process that yields improved performance and efficiency for your gas turbine. By integrating our latest H2-capable gas turbines into your asset, BEX can also help future-proof your operation. BEX operates on three guiding principles:
- Provide the flexibility to maintain the existing steam cycle or update it based on your future requirements
- Develop a tailored solution that fits your unique needs, by involving transparent discussions about layouts, business cases, and Balance of Plant calculations
- Integrating the new gas turbine package while reusing as many existing infrastructure components as possible, i.e. filter house, exhaust channel, foundation, and generator
- Chapters
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- Features and Benefits
- Fleet Applicability
- Improved efficiency and power output
- Significant savings on fuel cost, CO2 tax and maintenance cost
- Fast start and load capability
- Extended outage intervals
- Greater fuel flexibility thanks to the latest DLE technology focusing on renewable fuels (H2 and biofuels)
The BEX concept can be successfully implemented on Siemens Energy gas turbines, but also on a wide variety of other manufacturers' gas turbines, too:
GE: Fr3, Fr5, Fr6, LM1600, LM2500, LM5000, LM6000
Baker Hughes: Fr5, Fr6
Hitachi: H25, PGT25
Solar: MARS, TAURUS
Sulzer: S7
Mitsubishi: MF1-11
MAN Turbo: THM1203, 1304
Westinghouse: W251
Nuovo Pignone/GE: PGT10 & 16
Rolls-Royce: RB211
Customer Ι Story BASF, Germany
Siemens Energy carried out a major outage for BASF in Germany. Thanks to our Brownfield Engine Exchange solution, the power plant could be modernized without interrupting ongoing operations.
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Discover ROTEX – Gas turbine rotor exchange
Service exchange for major components to improve availability, to minimize risks, and to reduce inventory
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.
RotEx at a glance
The RotEx solution is designed based on a plug-and-play concept, providing a streamlined retrofitting process that yields improved performance and efficiency for your gas turbine.
Customers can benefit from improved cash flow, cost reduction and continued modernization when providing us with the flexibility of effectively managing their rotors.
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.
- Availability
- Budget
- Risk Minimization
- Inventory Optimization
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
No surprises, please
Our solution:
- Critical path of outage execution on-site can be minimized with ROTEX
- ROTEX can reduce potential for unexpected findings
- Potential for unplanned costs can be lowered by ROTEX optimized outage planning
Help me with my inventory
Our solution:
- ROTEX can reduce inventory costs by using customer´s spare parts
- ROTEX uses available major components if applicable
- Pool parts are managed by the ROTEX program
- ROTEX pool concept offers economics of scale to customers
Exchange solution for the SGT-4000F series
- Frame Specifics for Rotor Exchange
- Service Pack
- Atep - Advanced Turbine Eddiciency Package
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 the SGT-2000E series
- Frame Specifics For Rotor Exchange
- Upgrade Packages
- SI3D™
- 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+)
Discover ValveEx - Turbine Valve Exchange
Our service product ValveEx increases power plant availability and reliability by transforming valve life decisions into an adaptable asset management strategy.
Swap your power plant equipment for higher avalability and reliability.
ValveEx at a glance
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.
An outage is the best time for implementation of a new service solution. New or refurbished components, according to our latest standards / recommendations, are put into operation during an outage, while your equipment is sent to a Siemens Energy workshop to be overhauled.
This proactive program approach can eliminate Environmental Health & Safety (EHS) risk by reducing on site personnel and increases plant availability by eliminating the risk for unexpected findings during an outage.
- Availability
- Budget
- Minimize Risk
- Inventory
Its all about availability
Our portfolio offers a wide range of options which help optimize your asset
- ValveEx can help reduce outage duration related to a standard valve revision on site
- ValveEx eliminates potential for costly outage delays caused by auxiliary components
- ValveEx increases your dispatch by implementing valuable
Budget is tight
Our portfolio offers a wide range of options which help to optimize your asset
- ValveEx optimized outage planning can reduce outage duration
- ValveEx can reduce potential for additional
- costs resulting from unexpected findings
- ValveEx pool concept offers economics of scale to our customersupgrades during
No surprises, please!
Our portfolio offers a wide range of options which help optimize your asset
- ValveEx can take the standard valve overhaul off the critical path
- ValveEx reduces potential for unexpected findings during outage execution
- ValveEx can lower potential for unplanned costs by optimized outage planning
Environment, Health & Safety
Our portfolio offers a wide range of options which help optimize your asset
- ValveEx can reduce risk of failure of EHS relevant components, e.g. gas supply system
- ValveEx can help reduce EHS risk by having less personnel on site and shorter outage duration
- Gas Turbine Valve Exchange
- Steam Turbine Valve Exchange
Gas turbine valve exchange
The comparison is based on Siemens standard calculations. Site calculations and savings may differ based on site conditions and scope considered.
Steam turbine valve exchange
The comparison is based on Siemens standard calculations. Site calculations and savings may differ based on site conditions and scope considered.
- What - Scope of Supply
- Who - The Field Service Team
Valve overhaul process
Siemens Energy brings its most advanced technologies for auxiliaries and control equipment maintenance under one roof.
Inhouse workshops play a major role by taking this work off the critical time path and preparing them before the on-site works starts.
Our inhouse workshops are ISO 9001 certified and our processes are well developed. We follow a standardized workflow which contains the following steps:
MSR
Scope of work
A significant portion of the operating costs are due to the regular recommended maintenance overhauls of the power plant and all the associated balance of plant equipment. To reduce these costs, it is therefore desirable to limit comprehensive inspections to those components demonstrating marked changes in operational behavior over time or exhibiting a sudden change in quality. Measurements, control, and other diagnostic methods can provide early warning information on equipment conditions and their possible impending damage to components.
Remedial actions can be appropriated ahead of the next scheduled overhaul based on this diagnostic information.
Profit from the expertise and experience of the market leader
- Highly trained Field Service Team
- More than 170 years of manufacturing and
- specialist knowledge
- Products and services from the OEM
- Construction and commissioning of more than
- 20 new power plants annually
Inspections and maintenance annually
- Over 200 gas power plants
- More than150 steam power plants
- Over 50 conventional islands
- What - Scope of Supply
- Who - The Field Service Team
Valve overhaul process
Siemens Energy brings its most advanced technologies for auxiliaries and control equipment maintenance under one roof.
Inhouse workshops play a major role by taking this work off the critical time path and preparing them before the on-site works starts.
Our inhouse workshops are ISO 9001 certified and our processes are well developed. We follow a standardized workflow which contains the following steps:
MSR
Scope of work
A significant portion of the operating costs are due to the regular recommended maintenance overhauls of the power plant and all the associated balance of plant equipment. To reduce these costs, it is therefore desirable to limit comprehensive inspections to those components demonstrating marked changes in operational behavior over time or exhibiting a sudden change in quality. Measurements, control, and other diagnostic methods can provide early warning information on equipment conditions and their possible impending damage to components.
Remedial actions can be appropriated ahead of the next scheduled overhaul based on this diagnostic information.
Profit from the expertise and experience of the market leader
- Highly trained Field Service Team
- More than 170 years of manufacturing and
- specialist knowledge
- Products and services from the OEM
- Construction and commissioning of more than
- 20 new power plants annually
Inspections and maintenance annually
- Over 200 gas power plants
- More than150 steam power plants
- Over 50 conventional islands
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.
- Intended Benefit
- Scope
- Minimizing downtime by up to 80% in comparison to rewinding the current rotor, the Seed Rotor can be effortlessly installed as a plug-and-play solution once the existing rotor is removed.
- Decreased maintenance requirements and related expenses. The Seed Rotor concept provides a cost-effective alternative to a rewound rotor, delivering the advantages of a brand-new one.
- Diminished likelihood of unexpected outages, as the Seed Rotor comes fully tested and includes a standard limited warranty. This reduces the risk of unforeseen issues with the existing rotor compared to a typical rotor rewind.
- Siemens Energy's generator rotor reliability and availability enhancement package is incorporated into the Seed Rotor, potentially reducing forced outages and their associated costs.
- A pre-wound "Seed Rotor" is delivered to the site before the outage, allowing for a seamless swap with the old rotor, as opposed to a traditional rewind that may lead to longer downtime.
- The generator Seed Rotor incorporates enhancements aimed at boosting reliability and availability, including an improved J-Strap, omega pole-crossover, and a retaining ring shrink-fit design.
- All rotor winding braze joints undergo thorough ultrasonic inspection, ensuring 100% testing.
- The upgrade is expertly designed to maintain the same electrical and mechanical interchangeability, proper alignment, regulated cooling flow distribution, and torsional behavior as the current rotor.
The comparison is based on Siemens standard calculations. Site calculations and savings may differ based on site conditions and scope considered.
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