GE Energy
6B & 9E
Extendor & Performance Uprates
Maximize Productivity
2
Copyright 2008 General Electric Company. All Rights Reserved. FOR GE INTERNAL USE ONLY. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
.
Contents
1.
What is Extendor?
2.
Benefits of Extendor
3.
How Extendor Works?
4.
Extendor Features
5.
Applicability
6.
Extendor Experience
What is Extendor?
Advanced design Combustion hardware
that allows you to EXTEND HOURS
Between Combustion Inspections
4
Copyright 2008 General Electric Company. All Rights Reserved. FOR GE INTERNAL USE ONLY. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
.
Sample Inspection Intervals
Year
1
2
3
4
5
6
6B / 9E
Standard
Combustion
System
CI
CI
HGPI
CI
CI
MI
6B Extendor
Combustion
System
HGPI
MI
9E Extendor
Combustion
System
CI
HGPI
CI
MI
9E Advanced
Extendor
Combustion
System
HGPI
MI
Extendor Benefits
Availability- Eliminate 4 CI in 6 years – extra 20 days availability
Generation- Extra MWHr each year. Extra Steam each year.
Penalty Savings- Avoid penalties in Gas Take or Pay Contracts
Repair Cost Savings- Reduce CI repair costs by up to 66%
Services Cost Savings- Reduce CI craft labor & TA costs by 66%
Repair Shipping Savings– Reduce CI repair shipping by 66%
Reliability Improvement- Less restart problems and less time
off site for CI parts. Also less testing such as overspeed.
6
Copyright 2008 General Electric Company. All Rights Reserved. FOR GE INTERNAL USE ONLY. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
.
Focus on combustion system wear
• Reduce vibratory motion in the system
• Reduce wear rate on
– Fuel nozzle tips
– Combustion liner stops
– Combustion liner hula seal/transition piece
– Transition piece forward support and bracket
– Transition piece seal slots
– Transition piece material change
Liner hula seal to
transition forward
sleeve
Fuel nozzle tip
to liner collar
Liner stop
Transition piece
forward support
Transition piece
seal frame
Technical modifications
Transition piece
modifications
Fuel nozzle tips
Extendor fuel nozzle tip to combustion liner collar sub-system
•
Wear-couple material
•
Sacrificial material applied to fuel nozzle tip
•
New liner collar applied to each Collar
8
Copyright 2008 General Electric Company. All Rights Reserved. FOR GE INTERNAL USE ONLY. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
.
•
3-position liner stop modification applied to each liner and flow
sleeve
•
Critical clearance control between liner and flow sleeve stops
•
Wear material with sacrificial slow-sleeve liner stop covers
•
Verification that modified liner achieves design fit with modified
flow sleeve
Liner stop system
Sacrificial material on liner stop
• Hula seals with sacrificial wear-resistant
material
• Transition piece forward sleeve with sacrificial
wear-resistant material
• Wear coatings added by HVOF High Velocity
Oxy Fuel spray
• Tightened critical clearance control between
liner hula seal and transition piece forward
sleeve
Liner hula seal to transition piece
Liner with Extendor hula seals
Hula seals
Transition piece
forward sleeve
10
Copyright 2008 General Electric Company. All Rights Reserved. FOR GE INTERNAL USE ONLY. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
.
•
New sacrificial wear cover applied to each transition
piece forward bracket
•
“Wear couple” material applied to support bracket to
significantly reduce wear
Transition piece forward support
Bull-Horn/Wear
Cover
Bull-Horn
Bracket
H-Block
(Guide)
Transition
Piece
•
Sacrificial “slot-protectors” installed in the transition piece end
frames
•
Redesigned side seals
•
Modified inner and outer floating seals (without slots)
Transition piece seal frame
Transition piece
Transition piece
aft frame
Floating seals
Wear resistant
insert
12
Copyright 2008 General Electric Company. All Rights Reserved. FOR GE INTERNAL USE ONLY. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
.
Nimonic 263* aft “picture frame”
•
Replaces hastelloy-X aft frame
•
Provides greater creep strength
Class C thermal barrier coating
•
Reduces bulk metal temperature
•
Reduces creep deformation
Class C TBC
Nimonic
end frame
Liner
Transition piece modifications
Applicability
Applicable to Frame 5, 6B, 9E Units
Available as new parts or
existing parts can be modified in our GE Service
Shop in Bandung, Indonesia
14
Copyright 2008 General Electric Company. All Rights Reserved. FOR GE INTERNAL USE ONLY. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
.
Extendor experience
Customers like Extendor combustion system
•
More than 60% of new 6B and 9E gas turbine shipped with
CL-Extendor since 2002
•
Numerous retrofits on operating fleet performed
Frame
Applied as retrofit*
6000B Std combustion
122
6000B DLN1 combustion
21
7001E/EA Std combustion
43
7001E/EA MNQC comb.
4
7001E/EA DLN1 combustion
40
9001E Std combustion
37
9001E DLN1 combustion
32
Total
299
Reducing wear and creep
Understanding wear and creep root causes
•
Thermal cycle causing cracks and distortion
•
Dynamic pressure creating mechanical vibration and erosion
•
Heat causing creep
•
Experience shows that wear is a leading contributor to combustion system
repair cost
Advanced Extendor leverages GE’s extensive fleet experience
and technology improvements from DLN1+ and F-class
•
Enhanced thermal barrier coatings (TBC)
•
Material changes
•
Wear coatings
•
Hardening of surface in contact
16
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Copyright 2011 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
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From Extendor to Advanced Extendor
Components
9E Standard combustor
Primary fuel nozzle
Fully machined nozzle tip with wear coating
Liner
Thicker liner body, double leaf hula seal, spring loaded liner stops
Flow sleeve
Spring loaded liner stop
Transition piece
Integral mount, full length class-C TBC, cloth seals
Casing
No change
Crossfire tubes
Material change, wear coating
Spark plugs
No change
Flame detector
No change
®
Nimonic is a trademark of Udimet Corp.
Spring
loaded
stops
Double leaf hula seal
• Double leaf hula seal provides tighter air control and reduced seal
temperatures
• Spring loaded stops for uniform loading, reduced wear and wear
variation, improved installation (from F-class)
• Thicker liner body reduces risks of bulging and crack initiation
18
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Transition piece
• Nimonic 263 has better creep and strength characteristics than
Hastelloy-X
• Class C TBC for reduced metal temperatures
• Integral mount reduces the aft frame deformation and improves its
durability (from DLN1+)
• Cloth seals for tighter air control (from F-class)
Nimonic 263 and full length class-C TBC
Current TP with
tractor mount design
Cross-fire tubes
• Inner male and female cross-fire tube material changed from stainless
steel to alloy to provide better heat resistance
• Wear coating applied on collars
Inner male cross-fire tube
Inner female cross-fire tube
20
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Copyright 2008 General Electric Company. GE Proprietary Information.. All rights reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
*
ISO
with
distillate
fuel,
STD
combustor, no inlet or exhaust
losses
** Available as retrofit only
Current New Unit
Production
40
100
125
150
PG9141E
Tf = 1955°F
17 Units
PG9151E
Tf = 2000°F
46 Units
1978
1983
1988
PG9161E
Tf = 2020°F
57 Units
1993
PG9171E
Tf = 2055°F
264 Units
MS9001E continuous improvement
9E Latest Evolution
PG9171E
Tf = 2055°F
>200 units
2003
111 MW
105 MW
116 MW
123 MW
126 MW
22
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Copyright 2008 General Electric Company. GE Proprietary Information.. All rights reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Advanced Technology
New and Improved
Designs
Materials, Coatings
Improved Cooling,
Sealing
Leveraging Aircraft
Engine Technology
Improved Performance
Increased Reliability &
Availability
Improved Output & Heat
Rate
Reduced Emission Levels
Reduced Maintenance
Costs
CM&U Philosophy – Providing
Customer Value
Contents
1.
Firing temperature uprate
2.
Compressor uprates
3.
Sealing uprates
4.
2008 NPI – Advanced Aero
5.
2011 NPI – 9E Performance
24
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Copyright 2008 General Electric Company. GE Proprietary Information.. All rights reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
6B Value proposition
As a result of increasing the firing temperature of your MS6001B
with the GE firing temperature uprates,
you have the ability to reposition your unit for future growth and
compliance to regulatory changes,
resulting in ...
• gas turbine output increased up to about 5.25%*
• gas turbine heat rate improvement up to about 1.05%*
* Based on PG6541B model and uprate from 2042°F/1116°C
to 2084°F/1140°C with required components only.
9E Value proposition
As a result of increasing the firing temperature of your MS9001
with the GE Firing temperature uprates,
you have the ability to reposition your unit for future growth and
compliance to regulatory changes,
resulting in ...
• Gas turbine output increased up to about 5.6%*
26
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6B Technical modifications
• Improved heat rate and increased output due to increase in firing temperature
and reduction in cooling flows
• Advanced technology combustion and hot gas path parts
GTD-222+*
stage 2 nozzle
HR-120
*
1
st
stage shrouds
Brush Seal
(optional)
TBC coated
combustion liners
Nimonic263*
transition piece
GTD-222+ stage 3
nozzle
GTD-111 DS*
stage 1 buckets
Improved cooling
stage 2 buckets
IN-738* stage 3
buckets
Improved cooling
stage 1 nozzle
* GTD-111 DS, GTD-222+ are trademarks of the General Electric Company.
HR-120 is a trademark of Haynes International, Inc., which is not affiliated with General Electric.
Firing temperature uprates for 6B
Several firing temperature uprates are available to match your specific
configuration and needs
Model
PG6541
PG6551B
PG6561B
Original Tf (°F/°C)
2042 / 1116
2042 / 1116
2042 / 1116
Max Uprate Tf (°F/°C)
2084 / 1140
2084 / 1140
2084 / 1140
Output improvement, minimal configuration
5.25%
4.25%
4.25%
Heat rate improvement, minimal
configuration
-1.05%
-0.65%
-0.65%
Expected performances when combined with other uprate offerings
Output improvement with other uprates
10.70%
8.70%
8.10%
Heat rate improvement with other uprates
-4.12%
-3.32%
-3.25%
28
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Copyright 2008 General Electric Company. GE Proprietary Information.. All rights reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
9E Technical modifications
• Improved heat rate and increased output due to increase in firing temperature
and reduction in cooling flows
• Advanced technology combustion and hot gas path parts
*GTD-111, GTD-222+ are trademarks of the General Electric Company.
** Nimonic-263 and In-738 are a trademarks of the Special Metals Corporate group of companies, which is not affiliated with General Electric.
***HR-120 is a trademark of Haynes International, Inc., which is not affiliated with General Electric.
GTD-222+*
Stage 2 nozzle
HR-120
***
stage 1
shrouds
Brush seal
(optional)
TBC coated
combustion liners
Nimonic-263
**
transition pieces
GTD-222+*
stage3 nozzle
BLE/DS GTS-111*
stage1 buckets
Improved cooling
stage 2 buckets
IN-738** stage 3
buckets
Improved cooling
stage 1 nozzle
Firing temperature uprates for 9B/9E
Several firing temperature uprates are available to match your specific
configuration and needs
Expected output and heat rate improvement
Model
9B
9E
9E
9E
Original Tf (°F/°C)
1840 / 1004
1955 / 1068
2000 / 1093
2020 / 1104
Max Uprate Tf (°F/°C)
2020 / 1104
2020 / 1104
2055 / 1124
2055 / 1124
Output improvement, minimal
configuration
24.78%
8.80%
9.30%
5.60%
Heat rate improvement, minimal
configuration
-5.20%
-1.30%
-2.05%
-1.60%
Expected performances when combined with other uprate offerings
Output improvement with other
uprates
28.38%
13.40%
12.90%
9.20%
Heat rate improvement with
30
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6B Firing temp increase 2084°F
Required Components
•
Nimonic*-263 transition pieces with TBC
coating & aft frame cooling holes
•
Slot-cooled combustion liners with TBC
coating
•
Improved cooling stage 1 nozzle
•
GTD**-111 DS perimeter cooled stage 1
buckets
•
HR-120 stage-1 shroud blocks with
improved spline sealing
•
GTD-222+ stage 2 nozzle
•
Stage 2 buckets with improved cooling
•
GTD-222+ stage 3 nozzle
•
IN-738 Stage 3 buckets
•
Inner barrel counter bore covers
•
GTD-450 reduced camber high flow
IGV’s (pre-1987 units)
Optional Components
•
Stage 1 shroud abradable coating
•
Stage 2 & stage 3 honeycomb
shroud blocks
•
Brush seals (high pressure packing,
stage 2 nozzle interstage)
•
Increase IGV angle to 86 degrees
(for units with GTD-450 IGV’s)
•
Extendor
*
combustion system
•
Shrouded stage 17 and exit guide
vanes
•
5163 RPM speed increase
•
Advanced Aero stage 3 buckets and
nozzles
* Nimonic is a trademark of the Special Metals Corporate group of
companies, which is not affiliated with General Electric.
9E Firing temp increase to 2055
o
F
Required Components
•
Nimonic-263** transition pieces with TBC
coating & aft frame cooling holes
•
Slot-cooled combustion liners with TBC
coating
•
Improved cooling stage 1 nozzle
•
GTD*-111 DS/BLE stage 1 buckets
•
HR-120*** stage 1 shroud blocks with
improved spline sealing
•
GTD-222+ stage 2 nozzle
•
Stage 2 buckets with improved cooling
•
GTD-222+ stage 3 nozzle
•
IN-738* stage 3 buckets
•
Exhaust frame blowers
•
Inner barrel bore plugs
•
Stage 3 shroud cooling air modification
Optional Components
•
Stage 1 shroud abradable coating
•
Stage 2 & stage 3 honeycomb
shroud blocks
•
Brush seals (hpp, #2 bearing,
interstage)
•
Increase IGV angle to 86 degrees
(for units with GTD-450 IGV’s)
•
Extendor* combustion system
•
Shrouded stage 17 and exit guide
vanes
•
1100°F of exhaust isotherm limit
•
Advanced aero stage 3 buckets
32
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Detail A
Compressor Discharge
Casing
S17
EGV-1
EGV-2
Detail A
Stage 17, EGV-1, EGV2
Thicker
Shroud
Increased
Clearance
Inner Barrel
Casing
•
Stage 17 stator and EGVs 1 & 2 have been shrouded to reduce the sensitivity of
the structure and help prevent blade failure
•
Applicable to sites with low ambient conditions, steam or water injection, or
modulating IGVs (i.e. for heat recovery applications)
Variable
thickness
airfoil
Higher
performance
airfoil design
• Airfoil design for higher flow
• Variable airfoil thickness to maintain reliability
• GTD-450 for higher tensile strength and
superior corrosion resistance
• Provides :
• Output up to +4.4% for 9B and 1.5% for 9E
• Efficiency up to –0.7% for 9B and –0.38% in
heat rate for 9E
• Option to open inlet guide vanes to 86 degrees
• 1% increase in airflow, loss in compressor
efficiency
• Output up to +0.4%,
heat rate increased
by +0.2%
• Modification includes IGV stops and
GTD-450 high flow IGV
FT6B
1.8
GTD 450
AISI 403SS
1.6 1.4 1.2 1.0 .8 .6 .4 .2 0 10 20 30 40 50 60 70Mean Stress (KSI)
A
lt
e
rn
a
ti
n
g
S
tr
e
ss
A
m
p
li
tu
d
e
(R
a
ti
o
t
o
A
IS
I4
0
3
)
34
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No. 2 Bearing Brush Seals for 9E
•
Reduces air leakage to bearing cavity
•
Reduces oil mist
•
More durable than labyrinth seals
Compressor
extraction
flow
Air Seal
Cross-Section Bearing Housing
High pressure packing (HPP) with
brush seal
Inner barrel
Aft stub shaft
Reduces air leakage
Tolerant of misalignments
More durable than labyrinth seals
FS2V
Inner barrel
36
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Honeycomb material
Stage 2 honeycomb shroud block
•
Honeycomb material brazed between casing shroud teeth
•
Tighter clearance with buckets improves performance
•
improved output (up to 0.35%)
•
increased efficiency (up to 0.35%)
•
Reduced bucket damage, less potential for rubs
•
Requires buckets with cutter teeth
Stage 2 Interstage brush seal
First aft
wheelspace
Second forward
wheelspace
1-2 Turbine wheelspacer
Brush seal
element
FS2Z
38
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6B Experience
Firing temperature uprates performed as of 2Q ‘08
•
7 conversions to PG6571B (2077°F)
•
16 conversions of PG6581B (2084°F)
All components are integrated in current production of 6B turbine
All components have been applied as part of retrofits
Components
Reference code
Applied as retrofit
Stage 1 buckets GTD-111 DS perimeter cooled
FS4A
59
Improved cooling stage 2 buckets
FS4B
76
Improved cooling Stage 1 nozzles with chordal hinge
FS2J
60
GTD-222 stage 2 nozzles
FS1P
176
GTD-222 stage 3 nozzles
FS1R
67
HR120 stage 1 shrouds with cloth seals
FS2Y
130
Stage 2 honeycomb shroud blocks
FS2T
124
Stage 3 honeycomb shroud blocks
FS2U
96
Slot cooled combustion liners with TBC
FR1G
6
Combustion liner Extendor kit
FR1V/FR1W
201
Brush seals (HPP, Interstage)
FS2V/FS2Z
208
9E Experience
Firing temperature uprates performed as of 1Q ’08 :
•
1 conversions from 9B (1840°F) to 9E (2020°F), and 5 9B uprate 1840°F to 1965°F
•
8 conversions of 9E to 2055°F
Proven components: All components are integrated in current production of 9E
turbine and have been applied as part of retrofits
Components
Reference code
Applied as retrofit
Stage 1 buckets GTD-111 BLE-DS
FT6J
21
Improved cooling stage 2 buckets
FS2F
19
IN-738 stage 3 buckets
FS2K
18
Improved cooling stage 1 nozzles with chordal hinge
FS2J
42
GTD-222 stage 2 nozzles
FS1P
43
GTD-222 stage 3 nozzles
FS1R
26
HR-120 stage 1 shrouds with cloth seals
FS2Y
57
Stage 2 honeycomb shroud blocks
FS2T
37
Stage 3 honeycomb shroud blocks
FS2U
46
40
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Firing temperature uprate
Benefits
•
Increases output, improving revenues
•
Improves efficiency (heat rate), reducing fuel
costs
•
Reduces maintenance costs with extended
maintenance intervals
GE advantage
• Largest installed fleet and experience
• Patented and proven technology
• Extensive testing, validation and monitoring
•
Component design and system integration
•
OEM commitment and longevity
6B Tech requirements & effect on heat rate
Reference
Code
Required
for
2084°F
PG6541 (*)
PG6551 (*)
PG6561 (**)
Original Tf
2042°F / 1116°C
2042°F / 1116°C
2042°F / 1116°C
Uprated Tf
2084°F / 1140°C
2084°F / 1140°C
2084°F / 1140°C
Required hardware and software
%
%
%
Increase in Tf to 2084 & Control Mod
FT4P
X
-0.20
-0.20
-0.20
GTD-111 DS Perimeter cooled Stage 1 bucket
FS4A
X
0.00
0.00
0.00
Improved Cooling Stage 1 nozzle with chordal Hinge
FS2J
X
0.00
0.00
0.00
GTD-222+ Stage 2 Nozzle
FS1P
X
-0.40
0.00
0.00
GTD-222+ Stage 3 Nozzle
FS1R
X
0.00
0.00
0.00
HR-120 Stage 1 Shrouds with Cloth Seals
FS2Y
X
-0.45
-0.45
-0.45
Improved cooling 6 holes Stage 2 bucket
FS4B
X
0.00
0.00
0.00
IN-738 Stage 3 bucket
FS2K
X
0.00
0.00
0.00
Nimonic Transition Pieces w/TBC
FR2B
X
0.00
0.00
0.00
Slot Cooled Combustion Liners w/TBC
FR1G
X
0.00
0.00
0.00
S17 protection (Inner barrel counterbore covers
+ Shrouded EGV)
FS2B
X
0.00
0.00
0.00
-1.05
-0.65
-0.65
Additional 2° IGV (86°)
FT4M
0.20
-
-HPP Brush Seals
FS2V
-0.50
-0.50
-0.50
5163 RPM load gear
FP4E
-0.07
-0.07
-S1S Abradable Coating
FS6A
-0.70
-0.70
-0.70
Stage 2 nozzle Interstage Brush Seal
FS2Z
-0.50
-0.50
-0.50
Stage 2 Shrouds w. Honeycomb Seals
FS2T
-0.35
-
-Stage 3 Shrouds w. Honeycomb Seals
FS2U
-0.25
-
-Advanced Aero Stage 3 bucket/nozzle
FS4L/S4K
-0.90
-0.90
-0.90
-4.12
-3.32
-3.25
Total expected heat rate (%) improvement with further options
42
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6B Tech requirements & effect on output
Reference
Code
Required
for
2084°F
PG6541 (*)
PG6551 (*)
PG6561 (**)
Original Tf
2042°F / 1116°C
2042°F / 1116°C
2042°F / 1116°C
Uprated Tf
2084°F / 1140°C
2084°F / 1140°C
2084°F / 1140°C
Required hardware and software
%
%
%
Increase Tf to 2084°F & controls modifications
FT4P
X
3.20
3.20
3.20
GTD-111 DS perimeter cooled Stage 1 bucket
FS4A
X
0.00
0.00
0.00
Improved Cooling Stage 1 nozzle with chordal Hinge
FS2J
X
0.00
0.00
0.00
GTD-222+ Stage 2 Nozzle
FS1P
X
1.00
0.00
0.00
GTD-222+Stage 3 Nozzle
FS1R
X
0.00
0.00
0.00
HR-120 Stage 1 Shrouds with Cloth Seals
FS2Y
X
1.05
1.05
1.05
Improved cooling 6 holes Stage 2 bucket
FS4B
X
0.00
0.00
0.00
IN-738 Stage 3 bucket
FS2K
X
0.00
0.00
0.00
Nimonic Transition Pieces w/TBC
FR2B
X
0.00
0.00
0.00
Slot Cooled Combustion Liners w/TBC
FR1G
X
0.00
0.00
0.00
S17 protection (Inner barrel
c
ounterbore covers + Shrouded EGV)
FS2B
X
0.00
0.00
0.00
5.25
4.25
4.25
Additional 2° IGV (86°)
FT4M
0.40
-
-HPP Brush Seals
FS2V
0.75
0.75
0.75
5163 RPM load gear
FP4E
1.10
1.10
0.50
S1S Abradable Coating
FS6A
0.70
0.70
0.70
Interstage Brush Seal
FS2Z
1.00
1.00
1.00
Stage 2 Shrouds w. Honeycomb Seals
FS2T
0.35
-
-Stage 3 Shrouds w. Honeycomb Seals
FS2U
0.25
-
-Adavnced aero Stage 3 buckets/Nozzles
FS4L/FS4K
0.90
0.90
0.90
10.70
8.70
8.10
Total expected output(%) improvement with further options
Total expected Tfire output improvement (%)
Total effect are compounding effect of all the performance improvements above.
All performance estimates apply at ISO conditions (59°F/15°C, 14.7psia/1.013 bar)
(*) Assumes current GT speed is 5100 RPM
9E Tech requirements & effect on heat rate
Reference Code Required 9B to 9E 2020°F Required for 2020°F Required for 2055°F Original Tf 1840°F 1004°C 1840°F 1004°C 1840°F 1004°C 1955°F 1068°C 1985°F 1085°C 2000°F 1093°C 1955°F 1068°C 1985°F 1085°C 2000°F 1093°C 2020°F 1104°C Uprated Tf 1905°F 1041°C 1965°F 1074°C 2020°F 1104°C 2020°F 1104°C 2020°F 1104°C 2020°F 1104°C 2055°F 1124°C 2055°F 1124°C 2055°F 1124°C 2055°F 1124°CRequired hardware and software
% % % % % % % % % % Increase Tf to 9E FT6X X -1.10 -2.00 -2.60 - - - -Increase in Tf to 2020 & Control Mod FT6C X - - - -0.60 -0.27 -0.15 - - - -Increase in Tf to 2055 & Control Mod FT6Y X - - - -0.77 -0.54 -0.42 -0.27 GTD-111 BLE-DS Stage 1 bucket FT6J X X X 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Improved Cooling Stage 1 nozzle with chordal Hinge FS2J X O X -1.90 -1.90 -1.90 - - - -0.25 -0.25 -0.25 -0.25 GTD-222+ Stage 2 Nozzle with reduced cooling flow FS1P X O X 0.20 0.20 0.20 - - - -0.40 -0.40 -0.40 -0.40 GTD-222+ Stage 3 Nozzle FS1R X X X 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 HR120 Stage 1 Shrouds with Cloth Seals FS2Y X X X -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 Air-Cooled Stage 2 bucket FS2F X O X - 1.10 1.10 - - - 0.00 0.00 0.00 0.00 GTD-450 camber IGV's (84°) FT6B X X X -0.90 -0.90 -0.90 -0.30 -0.30 -0.30 -0.30 -0.30 -0.30 0.00 IN-738 Stage 3 bucket FS2K X O X -0.60 -0.60 -0.60 - - - -0.28 -0.28 -0.28 -0.28 Nimonic Transition Pieces w/TBC FR1D X X X 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Slot Cooled Combustion Liners w/TBC FR1G X X X 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Exh. Frm. Motor Blowers/ Isotherm temp. Upgrade FS1W X X X 0.00 0.00 -0.10 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Inner barrel bore plug FS2S X X X -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20
-4.70
-4.50 -5.20 -1.30 -0.97 -0.85 -2.40 -2.17 -2.05 -1.60
Additional 2° IGV (86°) FT5H O O O 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 HPP Brush Seals FS2V O O O -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 #2 Bearing Brush Seals FS2X O O O -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 S1S Abradable Coating FS6A O O O -0.40 -0.40 -0.40 -0.40 -0.40 -0.40 -0.40 -0.40 -0.40 -0.40 GTD-222+ Stage 2 Nozzle with reduced cooling flow FS1P X O X - - - -0.40 -0.40 -0.40 - - - -Interstage Brush Seal FS2Z O O O -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 -0.20 Stage 2 Shrouds w. Honeycomb Seals FS2T O O O -0.35 -0.35 -0.35 -0.35 -0.35 -0.35 -0.35 -0.35 -0.35 -0.35 Stage 3 Shrouds w. Honeycomb Seals FS2U O O O -0.15 -0.15 -0.15 -0.15 -0.15 -0.15 -0.15 -0.15 -0.15 -0.15 Advanced Aero Stage 3 bucket/nozzle FS4L/S4K O O O -1.00 -1.00 -1.00 -1.00 -1.00 -1.00 -1.00 -1.00 -1.00 -1.00
-7.00
-6.80
-7.50
-4.00
-3.67
-3.55
-4.70
-4.47
-4.35
-3.90
MS9001E
MS9001E
Maximum expected heat rate(%) improvement with further options
Total expected Tfire heat rate improvement (%)
44
Paul Gilmurray - Indonesia SOA
5/11/2012
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9E Tech requirements & effect on output
Reference Code Required 9B to 9E 2020°F Required for 2020°F Required for 2055°F Original Tf 1840°F 1004°C 1840°F 1004°C 1840°F 1004°C 1955°F 1068°C 1985°F 1085°C 2000°F 1093°C 1955°F 1068°C 1985°F 1085°C 2000°F 1093°C 2020°F 1104°C Uprated Tf 1905°F 1041°C 1965°F 1074°C 2020°F 1104°C 2020°F 1104°C 2020°F 1104°C 2020°F 1104°C 2055°F 1124°C 2055°F 1124°C 2055°F 1124°C 2055°F 1124°C
Required hardware and software
% % % % % % % % % % Increase Tf to 9E FT6X X 6.70 12.80 18.20 - - - -Increase in Tf to 2020 & Control Mod FT6C X - - - 6.50 4.00 2.70 - - - -Increase in Tf to 2055 & Control Mod FT6Y X - - - 9.50 7.00 5.70 3.50 GTD-111 BLE-DS Stage 1 bucket FT6J X X X 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Improved Cooling Stage 1 nozzle with chordal Hinge FS2J X O X 0.00 0.00 0.00 - - - 0.00 0.00 0.00 0.00 GTD-222+ Stage 2 Nozzle w/ reduced cooling flow FS1P X O X -1.00 -1.00 -1.00 - - - 1.00 1.00 1.00 1.00 GTD-222+Stage 3 Nozzle FS1R X X X 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 HR120 Stage 1 Shrouds with Cloth Seals FS2Y X X X 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 Air-Cooled Stage 2 bucket FS2F X O X - 1.65 1.65 - - - 0.00 0.00 0.00 0.00 GTD-450 camber IGV's (84°) FT6B X X X 4.40 4.40 4.40 1.50 1.50 1.50 1.50 1.50 1.50 0.00 IN-738 Stage 3 bucket FS2K X O X - 0.60 0.60 - - - 0.30 0.30 0.30 0.30 Nimonic Transition Pieces w/TBC FR1D X X X 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Slot Cooled Combustion Liners w/TBC FR1G X X X 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Exh. Frm. Motor Blowers/ Isotherm temp. Upgrade FS1W X X X 0.00 0.00 0.20 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Inner barrel bore plug FS2S X X X 0.33 0.33 0.33 0.40 0.40 0.40 0.40 0.40 0.40 0.40
10.83 19.18 24.78 8.80 6.30 5.00 13.10 10.60 9.30 5.60
Additional 2° IGV (86°) FT5H O O O 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 HPP Brush Seals FS2V O O O 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 #2 Bearing Brush Seals FS2X O O O 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 S1S Abradable Coating FS6A O O O 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 GTD-222+ Stage 2 Nozzle w/ reduced cooling flow FS1P X O X - - - 1.00 1.00 1.00 - - - -Interstage Brush Seal FS2Z O O O 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 Stage 2 Shrouds w. Honeycomb Seals FS2T O O O 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 Stage 3 Shrouds w. Honeycomb Seals FS2U O O O 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 Adavnced aero Stage 3 buckets/Nozzles FS4L/FS4K O O O 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
14.43 22.78 28.38 13.40 10.90
9.60
16.70 14.20 12.90
9.20
MS9001E
MS9001E
Maximum expected output(%) improvement with further options
Total expected Tfire output improvement (%)
MS9001B
Total effect are compounding effect of all the performance improvements above.
All performance estimates apply at ISO conditions (59°F/15°C, 14.7psia/1.013 bar)
New S3B consists of a higher-efficiency,
3-D aerodynamic design
Shank Pocket – Reduces stress
concentrations
Platform – Better bucket balance
Tip Shroud – Improved stage
efficiency and durability
Airfoil – Higher efficiency
Bucket Stack – Reduced stresses
46
Copyright 2008 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
.
New S3N design provides significant
efficiency improvement
New aerodynamic nozzle configuration
• Improved output and heat rate
• Optimized airflow distribution
• Improved airflow exit angle
Red-Uprate
Green-Baseline
View Looking Upstream
• Improved mechanical design features
complement this new design
6B - Benefits
Provides Significant Improvement in Output and Heat Rate
Efficiency improvement results in exhaust temperature and exhaust energy decrease.
Combined cycle analysis can be provided to estimate over-all plant impact.
Ambient temperature
Output
S/C
Heat Rate
S/C
New S3B/New S3N,
Hot Day, 100F/38C,
Reference only
+0.6%
-0.6%
New S3B/New S3N,
ISO Day, 59F/15C,
Guarantee pt
+0.9%
-0.9%
New S3B/New S3N,
Cold Day, 0F/-18C,
Reference Only
+1.1%
-1.1%
48
Copyright 2008 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner
.
9E - Benefits
Provides Significant Improvement in Output and Heat Rate
Efficiency improvement results in exhaust temperature and exhaust energy decrease.
Combined cycle analysis can be provided to estimate over-all plant impact.
Ambient temperature
Output
S/C
Heat Rate
S/C
New S3B/New S3N,
Hot Day, 100F/38C,
Reference only
+0.7%
-0.7%
New S3B/New S3N,
ISO Day, 59F/15C,
Guarantee pt
+1.0%
-1.0%
New S3B/New S3N,
Cold Day, 0F/-18C,
Reference Only
+1.2%
-1.2%
Experience
•
More than 30 S3B/S3N installed* as retrofit
ValPak
•
14 7E/7EA
•
12 9E
•
8 6B
•
7EA Fleet leader reached 24,000 hrs in
March 2008
•
Introduced as an option into new units as
part of Performance Improvement Pack
•
7EA in 2007
Copyright 2011 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
50
New advanced features
Reduced leakage and improved cooling
Hot Gas Path (HGP) cooling and clearance closure
S1B cooling
S1S abradable coating thickness
S1N cooling
S2B cooling and sealing
S2S aluminized honeycomb
S2N material and cloth seal
S3B Advanced aero sealing
S3S aluminized honeycomb
S3N Advanced aero sealing
Increased performance
• In combined cycle, approximately:
• In simple cycle, approximately:
• Design retains all current parts life and rotor life estimates
Combined cycle
Output
Heat rate
Exhaust energy
9E PIP – 1x1
+1.95%*
-0.66%*
+0.75%*
9E non PIP
Site specific evaluation
Simple cycle
Rating
Ship
Output
Heat rate
Exhaust energy
9E PIP
128MW
Since 2010
+1.29%
-0.66%
+0.49%
9E PIP
127MW
2008-2009
+1.95%
-0.79%
+0.75%
9E non PIP
126MW
2003-2007
+4.18%
-2.50%
+0.34%
Copyright 2011 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
52
Benefit: Improved cooling & sealing
Scope and design changes
• Stage 1 nozzle
– Reduced leakage on cloth seals
– Film cooling hole improvement
– Re-designed retaining ring with improved cooling
and anti-rotation pin slot
• Stage 1 bucket
– Improved cooling technology (turbulators)
– Enhanced dovetail sealing
• Stage 1 shroud
– Enhanced cloth seal
– Thicker GE proprietary gen3 abradable coating
HGP sub-package #1
Stage 1 shroud
Stage 1 nozzle
HGP sub-package #2
Benefit
• Improved cooling & sealing
• Improved component life
Scope and design changes
• Stage 2 Nozzle
– Material change to GTD*262 alloy with improved
creep improved creep, low cycle fatigue and
oxidation compared to GTD*241
– Enhanced sealing
• Stage 2 Bucket
– Cooling design change reducing creep
– Dovetail sealing
• Stage 2 shroud
– Thicker abradable honeycomb for improved
operating clearance
Improved design
8 holes advanced
Cooling
Stage 2 nozzle
Stage 2 bucket
Copyright 2011 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
54
HGP sub-package #3
Benefit
• Improved cooling & sealing
• Reduced performance degradation
Scope and design changes
• Stage 3 Nozzle
– Advanced Aero with cloth seals instead of solid
seals
• Stage 3 Bucket
– Advanced Aero with improved dovetail sealing
• Stage 3 shroud
– Cloth and solid seals replacing pumpkin teeth
– Abradable honeycomb for improved operating
clearance
Advanced Aero stage 3 nozzle
-dovetail sealing
Advanced Aero stage 3
bucket
Stage 3 shroud
Gas change leads to design changes
• Fuel nozzle
– Sized for nominal gas composition
– Nozzles are capable of handling +/- 5%
Modified Wobbe Index variation from nom
– Wrong sized nozzles lead to combustion
dynamics and hardware damage
• Gas Valves
–
Sized for supply pressure and composition
–
Incorrect valve sizing can limit load
• Gas Piping
– Sized for nominal gas composition
– Increases in inert % such as N2, CO2 may
require piping redesign
– Incorrect piping sizing can limit load
56
Paul Gilmurray - Indonesia SOA
5/11/2012
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A
B
H
Extended Layup Requires Preservation
• Fuel gas skid
– Servos
– Solenoids
– Instrumentation
– Wiring
– Hydraulics
• Gas Valves
–
Corrosion
–
Contamination
• Extensive Protection Systems
•
Many trip sources
• Replace better than Repair
$0 $500 000 $1 000 000 $1 500 000 $2 000 000 $2 500 000 $3 000 000 0 1 2 3 4 5 6 7 8 9 10
First year Fuel price ($MMBtu)
Fuel savings – 5 year NPV
Fuel savings
– Improved heat rate of 0.66%*,
resulting
in significant fuel cost reduction
– $345k* yearly
– $1.4MM NPV* over 5 years
Incremental output
–
1.95%* output increase
generates
gross revenue
– $525k* yearly
– 2.1MM* NPV over 5 years
Same or better maintenance
intervals
* Net Present Value & Conditions
• 9E with PIP
•Combined cycle, Natural gas – ISO conditions
• 109E CC output baseline :
190 MW
• 9E Heat rate baseline :
7,030 kJ/kWh
• Utilization :
6,000 hours/year
Incremental income – 5 year NPV
58
Paul Gilmurray - Indonesia SOA
5/11/2012
Copyright 2008 General Electric Company. GE Proprietary Information.. All rights reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
