ROTEX Plug-in Exchange – A solution for gas turbines

Are you ready for the next service level?
Introduction

Discover ROTEX – Gas turbine rotor exchange

Our Rotor Exchange Program ROTEX increases power plant availability and reliability by transforming rotor life decisions into an adaptable asset management strategy.
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, CEO of Siemens Power Generation
Why ROTEX?

Swap your power plant equipment for higher availability and reliability

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.

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

 

 

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

 

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

 

 
 
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 
Plug-in Exchange Solution

Rethink!

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. 

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
 

Example for Upgrade:

  • 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

 

Scope:

  • Replacement of B&V Stage 1-2, 3-4 or 1-4 by Si3D+™ design (Blades and Vanes buy-back program available)
  • New seal rings 2, 3 and 4
  • Improved axial thrust compressor bearing
  • Minor mechanical changes on turbine vane carrier to implement cooling air savings

 
 

Example for Upgrade:

  • 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 HCO
  • Improved turbine outlet temperature measurement (OTC+)
 
 
 

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
 
 

Example for Upgrade:

  • 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
 
 
 

Example for Upgrade:

  • 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:

  • 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)
 
 
 
 
Scheduled outage time savings

Recalculate!

Nothing is more persuasive than figures. ROTEX can pay off in every respect – from emissions, energy consumption, availability and reliability to reduced costs and maintenance-related downtime. Recalculate your service to maximize your availability.

Lifetime extension for the SGT-2000E and SGT-4000F series

 

 

Scope of supply

Replan!

Would you like to save outage time and reduce potential outage extensions during your next outage? You can rely on ROTEX – our Plug-in Exchange Solution.

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
 
Further exchange solutions

Combining swap solutions

Combined ROTEX and other swap solutions deliver higher increased power plant availability and reliability.

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.

 
 
 
 

Gas turbine exchange

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.

 
Valves for SST-3000 & SST-6000 (HE/KN) units:
  • 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
Intended Benefits
  • Reduced outage duration and minimized technical risk
  • Reduced need for inventory and spare parts planning for valve internals
  • Emergent repairs done off critical path
Solution
  • 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
Intended Benefits
  • 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
 

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.

 
Reference Projects

Reconsider!

ROTEX is already being used successfully in plants all over the world with many satisfied customers. Rethink your service to secure your competitiveness.

Contact

Do you need more information?

If you have any questions or would like to find out how we can help you to get your replacement parts, please let us know.