GE Energy
6B & 9E
Extendor & Performance Uprates Maximize Productivity
with Advanced Technology
2Copyright 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
7. 2011 NPI – 9E Advanced Extendor
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may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
What is Extendor?
Advanced design Combustion hardware
that allows you to EXTEND HOURS
Between Combustion Inspections
Starts have different wear mechanisms so
Extendor does not extend starts intervals for CI
4Copyright 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
Eliminate Combustion Inspections !
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may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
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.
6Copyright 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 totransition forwardsleeve
Fuel nozzle tip to liner collar
Liner stopTransition pieceforward support
Transition piece seal frame
Technical modifications
Transition piecemodifications
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may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Fuel nozzle tipsExtendor 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
• Critical clearance control between nozzle tip and liner collar
CL-Extendor: fuel nozzle tip and liner collar pictures from 8000 hour inspection
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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
liner stop
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may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
• 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 from 8000 hour inspection
Hula sealsTransition piece forward sleeve
Combustion liner
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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
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may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
• 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
12Copyright 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
* Trademark of Udimet Corp, which is not affiliated with GE
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may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
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
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may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Extendor experienceCustomers 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
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in whole or in part, without prior written permission of the copyright owner.
Reducing wear and creepUnderstanding 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
• Clearance reduction
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in whole or in part, without prior written permission of the copyright owner.
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.
Existing parts cannot be modified.
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in whole or in part, without prior written permission of the copyright owner.
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
Liner and flow sleeve
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in whole or in part, without prior written permission of the copyright owner.
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
Integral mount TP
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in whole or in part, without prior written permission of the copyright owner.
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
Wear coating on collars
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* ISO with distillate fuel, STDcombustor, no inlet or exhaustlosses
** Available as retrofit only
Current New Unit Production
MS6001B Performance History
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40100
125
150
PG9141ETf = 1955°F17 Units
PG9151E Tf = 2000°F46 Units
1978 1983 1988
PG9161E Tf = 2020°F57 Units
1993
PG9171ETf = 2055°F264 Units
MS9001E continuous improvement
9E Latest Evolution PG9171ETf = 2055°F>200 units
2003
111 MW105 MW
116 MW
123 MW
126 MW
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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 Advantage
23Copyright 2008 General Electric Company. GE Proprietary Information. FOR GE INTERNAL USE
ONLY. 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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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.
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not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
9E Value proposition
As a result of increasing the firing temperature of your MS9001with 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%*
• Gas turbine heat rate improvement up to about 1.6%*
* Based on 9E model and uprate from 2020°F to 2055°F with required components only
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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* 1st
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.Nimonic263 and IN738 are trademarks of the Special Metals Corporate group of companies, which is not affiliated with General Electric.
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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%
Expected output and heat rate improvement (in %)
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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 piecesGTD-222+*stage3 nozzle
BLE/DS GTS-111* stage1 buckets
Improved cooling stage 2 buckets
IN-738** stage 3 buckets
Improved cooling stage 1 nozzle
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not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Firing temperature uprates for 9B/9E
Several firing temperature uprates are available to match your specific configuration and needs
Expected output and heat rate improvementModel 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 other uprates
-7.50% -4.00% -4.35% -3.9°%
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6B Firing temp increase 2084°FRequired 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.
** GTD, Extendor are trademarks of the General Electric Company.
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9E Firing temp increase to 2055oFRequired 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
• GTD-450* reduced camber high flow IGV’s
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 and stage 3 nozzles
*GTD and Extendor 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.
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Detail A
Compressor DischargeCasing
S17 EGV-1 EGV-2
Detail AStage 17, EGV-1, EGV2 Thicker
Shroud
IncreasedClearance
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)
Shrouded stator 17, EGV1, EGV2 FS2B
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Variablethicknessairfoil
Higher performanceairfoil 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 control card
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 70
Mean Stress (KSI)
Alternating Stress Amplitude
(Ratio to AISI403)
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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 extractionflow
Air Seal
Cross-Section Bearing Housing
FS2X
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High pressure packing (HPP) with brush seal
Inner barrel
Aft stub shaft
Reduces air leakage
Tolerant of misalignments
More durable than labyrinth seals
Labyrinth arrangement
FS2V
Inner barrel
Aft stub shaft
Brush seal arrangement
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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
FS2T
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Stage 2 Interstage brush seal
Current stage 2 nozzle design New stage 2 nozzle design
First aftwheelspace
Second forwardwheelspace
1-2 Turbine wheelspacer
Brush sealelement
FS2Z
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6B ExperienceFiring 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 turbineAll 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
Nimonic transition pieces w/TBC FR2B 40
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9E ExperienceFiring 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
Slot cooled combustion liners with TBC FR1G 10
Nimonic transition pieces w/TBC FR1D 17
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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
• Worldwide service and repair network
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6B Tech requirements & effect on heat rateReference
Code
Required
for
2084°FPG6541 (*) 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 -0.65Additional 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 -3.25Total expected heat rate (%) improvement with further options
Total expected Tfire heat rate 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(**) Assumes current GT speed is 5133 RPM
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6B Tech requirements & effect on outputReference
Code
Required
for
2084°FPG6541 (*) 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 counterbore covers + Shrouded EGV) FS2B X 0.00 0.00 0.00
5.25 4.25 4.25Additional 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 8.10Total 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(**) Assumes current GT speed is 5133 RPM
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9E Tech requirements & effect on heat rate
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)
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 -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 -1.60Additional 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 (%)
MS9001B
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9E Tech requirements & effect on outputReference
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 5.60Additional 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)
45
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 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
47
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.
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 temperatureS/C
Output
S/C Heat Rate
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 temperatureS/C
Output
S/C Heat Rate
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%
49
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.
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
• 9E in 2007
• 6B in 2008
*As of April 2008
Copyright 2011 General Electric Company. All Rights Reserved. This material may not be copiedor 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 closureS1B 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
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51
Increased performance
• In combined cycle, approximately:
• In simple cycle, approximately:
• Design retains all current parts life and rotor life estimates
* ISO conditions, 1 GT + 1 steam turbine, 2 pressure reheat cycle, HRSG sized for higher exhaust energy, site specific evaluation required to determine actual performance benefits.
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%
9E non PIP <126MW Before 2003 Unit specific evaluation
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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
Stage 1 bucket
Copyright 2011 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.
53
HGP sub-package #2Benefit• 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
– Cloth and solid seals replacing pumpkin teethStage 2 shroud* Trademark of General Electric Company
Improved design8 holes advanced Cooling
Stage 2 nozzle
Stage 2 bucket
Copyright 2011 General Electric Company. All Rights Reserved. This material may not be copiedor 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
* Trademark of General Electric Company
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not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
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
Fuel Gas Re-Commissioning
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AB
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
Fuel Gas Skid Re-Commissioning
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$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 NPVFuel 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
• Electricity price : $70 MWhr
• Fuel costs : $7/Mbtu
• Discount rate : 8%
Incremental income – 5 year NPV
Combined cycle - value proposition
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Fuel savings – 5 year NPV
Fuel savings– Improved heat rate of 0.61%*, resulting in significant fuel cost reduction
– $125k* yearly
– $500k NPV* over 5 years
Incremental output – 1.29%* output increase generates gross revenue
– $199k* yearly– $796k* NPV over 5 years
Same or better maintenance intervals
* Net Present Value & Conditions•9E PIP output baseline: 128.1MW
•9E PIP Heat rate baseline : 10,570 KJ/kWh
• Utilization : 4,000 hours/year
• Electricity price : $70 MWhr
• Fuel costs : $4/Mbtu
• Discount rate : 8%
Incremental income – 5 year NPV
Simple cycle - value proposition
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