6B Users Conference Field Design...
Transcript of 6B Users Conference Field Design...
June 23 – 26, 2014 | Fort Myers, FloridaJune 23 – 26, 2014 | Fort Myers, Florida
Imagination at work.
6B Users Conference
Field Design ModificationsPaul Daiber, 6B/7EA/9E/5/3 Application Engineer
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2014 6B Users Conference
Repurposing your E-class units
Effectively three markets• Cogeneration… 6000+ hours• Peakers… 2500 hours• Capacity… <500 hours
Finding answers• Waiting for outages?• New technology?• Steam vs MegaWatts?
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2014 6B Users Conference
Recent 6B Field Design Modifications by GE
Since 2006 GE has provided parts for about 1000 6B field design modifications
Add Low BTU fuel capability
DLN1, DLN1+, IBH
Add Propane Fuel Capability
Remove Liquid Fuel
Extendor CLEX Combustion Mod
Extendor all-Nimonic Transition Pieces
Replacement special fuel nozzles
High Load Premix Transfer,
Sliding P2 for Low Fuel Pressure
False Start Drain Valve replacement
Flame Detector Upgrade, Sight Tube Mod
Flex Hose Pigtails for Gas Fuel and AA
Liquid Fuel Check Valve Upgrade
Add Steam Injection for NOx Control
Add Water Injection for NOx Control
Remove Steam NOx
Anti-Condensation Mod to Flame Detectors
Gas Chromatograph for Low BTU DLN
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2014 6B Users Conference
Recent 6B Field Design Modifications by GE
2042 F to 2084 F Tfire Uprate
HR120 shroud blocks, cloth seals, abraidable coating
Perimeter Cooled S1 Buckets
S2 Nozzle Brush Seal, S2N airbox mod
Advance Aero S3 Bucket, Nozzle
S2 Buckets to new design
Special Coatings on Buckets
6581B PIP kit (hot gas path parts)
Flange-to-Flange Turbine Replacement
Accessory Gearbox Replacement
Compressor Discharge Casing
Cast Nodular Iron Turbine Shell
Loadgear, 5163 rpm (two teeth different from 5100)
Rotor Replacement, Rotor Spare, Rotor Inspection and Life Extension
Reduced Camber IGV's, Rack and Ring
IGV Actuator Relocation, 86 degree IGV's
Shrouded S17/EGV's
Stator Shim Pins per the TIL 1562
Stator Vane kits, Compressor Blade kits
R1 Blades per TIL 1382
Dry Diaphragm Load Coupling, TIL 1709
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2014 6B Users Conference
Recent 6B Field Design Modifications by GEExhaust Frame
Replacement Exhaust Plenum
Inlet Silencer
HPP Brush Seal / Counterbore Covers
Dry Diaphragm Accessory Coupling
Special Instrumentation
Battery Charger Upgrade and Batteries
Torque Converter
Lube Oil Conditioner per TIL 1528-3
ATEX (Europe) AC Lube Oil Pump
Fire Protection System Upgrade
Dead Bus Closure Controls Mod
Mag Pickups for Over Speed (Remove Bolt)
SSS Starting Clutch to replace Jaw Clutch and not stop to restart
SSS Loadgear Clutch for Synchronous Condenser Operation
Combined Cycle Mod
Aero Style Exhaust Thermocouples / Shield
Updated Humidity Sensor
TIL-1566 Fuel Leak Detection / Shut Down
Replacement of Hydraulic Ratchet Pump
Replacement of Hydraulic Accumulator
Compressor Drive Auto Peak Control
Maintenance and Operation Manuals
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2014 6B Users Conference
Recent Inquiries for 6B Design Changes
6B Design Change Requests During the Last 6 Months – North America
Replacement Loadgear – S644 (mounted on generator I-beams) due to oil leaks
Replacement to S664 Loadgear due to problems identified during outage
Occasional Steam-Aug by modifying Steam-NOx system
Compressor Rotor due to Corrosion from no filters and very frequent WW
Extended CI Intervals on a Gas-Only BLFN without AA
DLN High Load Premix Transfer
Rotor Life Extension Evaluation
DLN1+
32k for steam-NOx 6B's
IGV Actuator Relocation
Exhaust Plenum
Maintenance and Operation Manuals (Digital)
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2014 6B Users Conference
Recent Inquiries for 6B Design Changes
6B Design Change Requests During the Last 6 Months - International
Lower Grade Ash-bearing fuel
Add liquid fuel to a DLN turbine
Stainless Steel Purge Piping
DLN for a very low fuel pressure site
6581B PIP
2042 to 2084 F Tfire Uprate
Conversion to Ethanol Fuel
Remove Refinery Gas Capability
DLN for compressor drive 6B
32k CI and HGPI
Exhaust Stack Extension for CEMS
Compressor Casings
Exhaust Plenum
Inlet Bleed Heat for DLN turndown
New Rotor due to End of Life
DLN/Tfire/32k
2114 F Tfire and Fogger
Ratchet Mod for Faster Start
Remove Liquid Fuel Capability
Add propane capability to liquid fuel only 6B
Adv Aero S3B
Shroud Blocks and Other Capital Parts
Replace the Diesel Engine with a Motor
Add Gas Fuel Capability
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2014 6B Users Conference
6B DLN 1+ (Thailand)
Guarantee: 4.85ppm
Actual: 2.5ppm
Scope: 32k, Fuel skid, IBH, FN/Liners, remove Steam-NOx
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2014 6B Users Conference
India
6541B to 2084F
Hot Day Guarantee: 10%MW/-4%HR
Actual: -10%HR
Australia
6531B to 2084F
Guarantee: 9%MW/-4%HR
Actual: -6%HR
6B Tfire Uprate (India & Australia)
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2014 6B Users Conference
Planning For a 6B Uprate or Upgrade .
Ask GE Salesperson for Latest Design Parts
Piece-by-Piece, build to a Tfire Uprate and 32k Inspection Intervals
Parts with New Designs:
• S1*, S2, S3 Shroud Blocks
• Transition Pieces*
• S1, S2, S3 Buckets
• S1, S2, S3 Nozzle
Not all parts supersede to the Advanced Seals or Higher Firing Temperature design
• because some engineering is needed
• * S1 Shroud Blocks and Transition Pieces do not supersede to the 2084 F firing temperature design
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2014 6B Users Conference
False outage barriers
Massachusetts
• 2500 hours/year… 7EA peaker…Tfire=2035• 2055 barrier: S1S, S2N, Mark IV• Solution: 2055… 1.4MW… no hardware• Polar vortex… $1800/kwh
Ohio
• 500 hours/year… 7B/7EA capacity… Tfire=2035• 2055 barrier: S1S, emissions• Solution: 2052… 1.3MW… no hardware• Polar vortex… $1080/kwh
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2014 6B Users Conference
Feedback on GE 6B Field Design Modifications
Hi Paul, The new exhaust plenums have been well worth the money spent. There are no more leaks like we had with the old ones and our load compartment now runs a lot cooler. The removable section on top of the exhaust frame also makes for easier removal of the turbine shell during HGPI .
For the insulation behind the flex seals we ourselves made fitted insulation blankets (bags) by stitching the provided insulation into ceramic wrapping. This is to prevent this blowing out over time between the HGPI/Major inspections every 3 years which was our experience with the older plenums. This improves the durability of the insulation which tends otherwise to gradually blow out even with small air leaks.
Best regards, Richard
6x6B Exhaust Plenums, Customer Email, Indonesia
Voice of Customer Improvement: Ceramic Wrapping of Insulation is now Included
Successful Reduction in Compartment Temperature
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2014 6B Users Conference
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2014 6B Users Conference
Feedback on GE 6B Field Design Modifications
OpFlex / CPC / Autotune / Turndown / Cold Load Path / Variable peak / Smart IBH / Mk-6e migration
Opflex Package 1x6B Germany
So far we have just the verbal commitment from customer that he was more than happy and satisfied with the entire project execution starting from the proposal phase up to final commissioning. This was also communicated by customers upper management to GE’s upper management here in Germany
Best Regards Willi
“Dramatically improved turndown, ability to peak at different NOx levels, set NOx and CO where they want during peak, base and partload, running more efficient in partload … all were improvements they were happy with. ”
Successful Improvement in a DLN Turbine’s Flexibility
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2014 6B Users Conference
OpFlex* solutions suite
Gas turbine
• Start-up NOx / Low Visible Emissions (LVE)
• Fast start
• Purge credit
• Start-up Reliability Pkg.
Steam turbine
• Agility package
HRSG
• Adv. Attemperation
• Adv. SCR Control
• AutoBlend
Grid stability
• Enhanced Transient Stability
Automated tuning
• AutoTune DX
• AutoTune LT
• Ambient Select
Output
• Variable Peak Fire
• Variable Airflow
• Cold-Day Performance
Responsiveness
• Fast Ramp
• Grid code package
• Closed Loop Optimal Control (CLOC)
Turndown
• Extended Turndown
Efficiency
• Variable Inlet Bleed Heat
Fuels reliability
• Heavy Fuel Oil package
• Liquid fuel operability
System Reliability
• AutoRecover
• Trip prevention package
Diagnostics/Productivity
• System Diagnostics Pkg.
* Trademark of General Electric Company.
Advanced controls technology for all modes of power plant operation
Start-up AgilityFast, reliable, repeatable starts with low emissions
Combustion ControlRobust operation during weather, fuel, and grid
variations
Load ControlLoad range expansion,
efficiency, responsiveness and customization
System ReliabilityEnhancements for
reliable, cost effective operations
* Under development
4 Sep 2013
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2014 6B Users Conference
Feedback on GE 6B Field Design Modifications
Paul, I received the following feedback from site regarding the 7B SSS clutch … .
They are working perfect -no fail to crank or starts since we installed, Also we have inspected each one and they look good. One comment is that you need a more skilled mechanic to install and maintain.
Regards, Adam
(A 7B was our last SSS Starting Clutch Turbine Model)
Successful Improvement in Start-Up Flexibility
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2014 6B Users Conference
Feedback on GE 6B/7EA Field Design Modifications
Ten 7EA’s have the Fast Start field modification
• Applies Equally well to 6B’s
• Applies to both Gas and Liquid Fuel
Fast Start – North America
Kentucky (From GE Salesperson after asking the customer about it):
“Yes. Experience has been great. Something unique about xxxxx is they have a single button to fast start 4 units!!
I.e you push one button and get 280+ MW on grid in 10 minutes. ”
Colorado (From Customer’s Pitch to a Conference):
Installed in Dec 2010, Software modification only
Gives the ability to quickly start and load Units A and B
117 MW in ~10 min.
Not used as spinning reserve due to severe penalties
Use increases maintenance cost due to start maintenance factor
Successful and Reliable Fast Starts
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2014 6B Users Conference
Feedback on GE 6B/7EA Field Design Modifications
Tom,
…the updated OpFlex Fast Start offering (“cold load path” for expanded cold weather operability) allows for year-round ASM revenue,…
…OpFlex Fast start allows the unit to synchronize to the grid within 7 minutes and 45 seconds of a start signal …
…I would like to extend my sincerest gratitude to the GE team for your efforts to address our cold weather operability concerns; your help in resolving this matter is truly appreciated! …
Best regards, Mark
Fast Start – Midwest (MISO) 7EA – Customer CommentsSuccessful and Reliable Fast Starts
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2014 6B Users Conference
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Flame TrackerTM DryTIL 1579-R1, 2008. To heighten the awareness of potential risks associated with improper maintenance of the cooling water, water injection and water wash systems…
• Hot end assembly operates up to 200°C to remove water cooling
• Moves electronics to cooler area of turbine compartment
• Built on the proven SiC technology
Enhanced EPIC I can’t see what is happening in the software when you lock
up the EPIC software
Critical Safety Functions
Non-CriticalEng. Control
Customer Specific
Locked
Open
EPIC
313 - SW modules locked down
16 - SW modules locked down*
Enhanced EPIC
*Typical 7F.05 configuration
So what is still locked down …Proprietary information• ARES engine model• Combustor transfer functions … emissions and
dynamics• Compressor maps
Safety critical functions … trip and alarm functionality, not control logic*• Compressor protection• Exhaust over temperature protection• Fire protection• Flame detector protection• Overspeed protection• Failure to ignite protection• Excessive fuel flow (gas or liquid) protection• Vibration protection• P1, P2 protection• False start drain protection• Compartment (Load, tunnel) protection• Hazardous gas protection