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The leading technology of the Siemens SGT5-4000F heavy duty gas turbine is demonstrated through recent engine measurements at customer sites. The 4000F fleet comprises more than 240 engines that exceed performance targets because of well established, non-heuristic design processes that are continuously enhanced. On-site measurements of pressure, temperature and flow were performed at various locations in the flow path of the 4-stage turbine to support validation of Siemens’s proprietary 3D Computational Fluid Dynamics (CFD) analysis suite. Despite inherent but well understood modeling deficiencies, these advanced CFD prediction capabilities surpassed other tools and increased the accuracy of the overall turbine design process. The performance of each turbine stage and flow features related to the exhaust diffuser were captured by the calculations. Overall performance characteristic shapes coincided with heat balances based on measurements. Radial traverses at the turbine exit, static pressure along the engine axis, and temperature sensors were matched well. The level of accuracy in delta predictions exceeded industry standards. The design suite was able to predict performance parameters prior to measurement within respective confidence levels. Therefore, this advanced 3D CFD design suite, validated with the test data, will form the basis for future turbine development programs.

The first Siemens SGT5-8000H had extensively been tested in Simple Cycle in Irsching during 2008 and 2009. About 3000 sensors had been installed for monitoring of the engine operation, the results demonstrated that all performance targets have been exceeded. Detailed measurements of pressure, temperature and flow were performed in the turbine flow path at various locations in circumferential and radial direction. The experimental test results in the turbine flow path have been used for additional detailed analysis of the fluid dynamics operation by a High Fidelity 3D CFD whole turbine model. This standardized whole turbine CFD process forms an important element in the Siemens design chain. The model was set up with all geometrical details to resolve all relevant flow features such as shrouds, cavities, coating, fillets etc. This paper summarizes and compares the experimental test results with predicted CFD design values for overall thermodynamic operation and aerodynamics data at turbine outlet. Besides the results from the Simple Cycle prototype test phase, performance test results are presented from recent measurements during customer acceptance testing in Combined Cycle in 2011. These results show a confirmation of the previously measured overall performance values after complete rebuild and re commissioning of the engine for combined cycle operation.