g GE Power Systems

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7F Users Conference
April 4, 2001
Atlanta, Georgia

Click on a title to see the presentation:

Fleet Experience
Red Flag Review Process
Trip Reduction
DLN Combustion System Status
Compressor Update
Generator Update
Repair Solutions
Advanced Technology Offerings
e-Business Review: GE PartsEdge
e-Business Review: Outage Optimizer
M&D-Derived Performance Data
e
GE Energy Services

Advanced Technology
Offerings For the
7F and 9F Fleet
Gas Turbines

Dean Christner
CM&U Application Engineering
April 4, 2001
F Technology

GE “F” Technology: A Winner in Every Category

• Proven Advanced Technology

• Over 3.5 Million F-Class Operating Hours
• Extensive Application Experience
• High Availability
• History of Competitive Uprating Advantage
• Low Life-Cycle Costs
• Best emission control in industry

Most Proven High-Efficiency Turbine in the Market

Benefits
Uprating with Latest F Technology

• Improved Performance (output and Heat Rate)

• Better Maintenance and Inspection Intervals
• GE Guarantee and Support
• Uprate Experience:
– successful uprates of 2 7FA units and 2 9FA+ units to FA+e
configuration
– successful partial uprates including every combination of
HGP parts, combustors, and compressor modifications

GE Has The Only Proven Uprate Program

Design Time Line
1987 GE Presents 7F
7F FSNL Testing
1988
7F Factory Load Testing
1989 Introduction of 9F
1990 First 7F Plant in operation - Operated in Combined Cycle
1991 9F FSNL Testing
1992 9F Testing at Load
1993 First 9F in Commercial Operations
1993
6F Program Begins
1994 Compressor and Turbine Issues occur
1995 First 6F assembled
1997 GE exceeds 1 million hours of “F” operation
2001 GE Exceeds 3.5 million hours of “F” operation

Successful Sustained Program

9F Fleet

• Leveraged 60 Hz Experience
• Introduced in 1989
• Extensive Use of Geometric Scaling
- Components Scaled Up By 1.2x
- 44% Higher Output
- Same Stresses, Aerodynamics, Relative
Frequencies
• 212 MW Original MS9001F Simple-Cycle Rating
• 52.8% Introductory Combined-Cycle Efficiency

Leveraged 60 Hz Development & Design

 7F Fleet
Product-line Evolution
PG7211(F) PG7221(FA) PG7231(FA+) PG7241(FA+e)

Output 150 MW 159 MW 168.8 MW 171.7 MW

HR 9880 Btu/KWh 9500 Btu/KWh 9380 Btu/KWh 9360 Btu/KWh
Press Ratio 13.5 15.1 15.5 16.2
Firing Temp. 2300F 2350F 2400F 2420F
Compressor Stages 18 18 18 18
Turbine Stages 3 3 3 3
Installed Fleet Size 16 44 30 71 and growing
Operational Date 1990 1993 1998 2000

Evolution Consistent with GE’s Philosophy to Leverage Technology

 9F Fleet
Product-line Evolution
PG9281(F) PG9311(FA) PG9331(FA+) PG9351(FA+e)

Output 212.0 MW 226.5 MW 240.0 MW 255.6 MW

HR 9995 Btu/KWh 9570 Btu/KWh 9420 Btu/KWh 9250 Btu/KWh
Press Ratio 13.5 15.0 15.1 15.4
Firing Temp. 2300F 2350F 2400F 2420F
Compressor Stages 18 18 18 18
Turbine Stages 3 3 3 3
Installed Fleet Size 3 38 2 10 and growing

9F Fleet Based on 30 Years Direct Design and Field Experience

 Strategy
Parts and Kits
Past Strategy
• Old Strategy - 9 kits with different variations of nozzles, buckets, and
shrouds and full uprate options (Not very flexible)
• Significant Engineering effort required to ensure full compatibility of
individual FA+e parts with F/FA/FA+ - successful!

New Strategy - February 2001

• Allow individual parts (nozzles, buckets, or shrouds) to be sold with
performance guarantees.
• In most cases, CM&U still required to ensure proper interchangeability
with fleet
• There are no Technical Barriers to Conversion. Some Component
Rules may apply.

GE Modifies Strategy To Be More Customer Centric

 Technology Overview
Turbine Enhancements
Compressor Modifications Combustor Changes

Thrust Bearing Marriage Flange Mod

Technology Overview
Uses Proven GE Aircraft Engine Advancements
Compressor Aero Combustion Turbine Aero

Computer Advanced Cooling w/

Modeling High-Strength Alloys

A Marriage of Two Proven

GE Technologies
 Compressor
Upgrades
• New Blades and Stators 2-5 & 9-17 (applies to 7 & 9 F/FA)
– TIL 1235-2R1 recommends replacement of blades which are sensitive to
vibratory modes. New blades are less sensitive to surface debits (tip rubs,
rough finish)

• Bigger Better Fillet - BBF (applies to 7&9 F/FA, 7FA+, and

early 9FA+e)
– This modification reduces stress concentrations in the compressor tie bolt nut
groove

• Robust Backend (applies to 7&9 F/FA, 7FA+, and early 9FA+e)

– This modification improves overall compressor stability through numerous mods
• Uncambered IGV (applies to 7 & 9 F-fleet)
– Improve contour of IGV blade thus reducing profile losses

Upgrades Improve Overall Reliability

 Compressor
CL
Uncambered IGV
• Available as a one-piece
IGV (replace during Major Gear
Inspection) Set Screw
• Also available as a two- Pin
piece IGV (replace during
Combustion Inspection in
5-7 days with rotor in place)
• New IGV improves 1-Piece IGV (Top Half)
compressor airflow and
efficiency
• Operates in same fashion Jack Shaft

as old IGV Cap Screw

• New IGV set includes IGV
gear - reuse existing IGV
rack and ring
Washer

2-Piece IGV (Bottom Half)

Compressor Stability Modifications
Enhancements:
1. Bigger Better Fillet = Nut groove filet radius
enhancement
2. HPP has new axial position and changed to
honeycomb seal
3. Tie bolt thread change to 12 per inch, refined
undercut and shank undercuts. Using Lessons
Old Design Learned from 3rd turbine subassembly bolt
Centerline redesign.
Stage 13 wheel Stage 17 wheel (aft stub shaft)
4 & 5. Solid wheels on Stages 16 and 17 to
thermally match wheels and control the rabbet
fillet.
7 2
6. Stage 15 bore sized for improved rabbet
8
3 engagement and fillet stress.
1 7. Larger fillet radius to improve load distribution.
6 8. Solid bolt faces Stages 15 and 16 for
increased rotor transient stiffness.
9. Solid Stage 14 for increased load carrying
Robust Back End capability, to support solid inertia belt.
4 5 Centerline
9
Rotor
Reversed Marriage Flange

Legend:
STG 1
CASS DP CASS - Comp. Aft Stub Shaft
DP - Distance Piece
STG 1 - stage 1 turbine wheel

Before After

Reversed Marriage Flange Rabbet

(Moved Radically Outward)

Female Male Male Female

Identified as potential problem Marriage flange reversed rabbet

area based on reanalysis design (rework distance piece).
 Rotor
Thrust Bearing
• New aft thrust bearing
required to handle
increased rotor thrust
• Cooling oil feed orifices
must be resized
Unit Centerline Aft Thrust Bearing
( Active )
• Most significant impact
on thrust is FA+e stage
1 bucket
• 96k # / 170k # thrust brg.
Load Rating for the
7F/FA & 9F/FA
respectively
Airflow • 170k # / 236.6k # thrust
brg. Load Rating for the
7FA+e & 9FA+e
respectively
 Combustor
DLN 2.6e & 2.0+ Combustion System - 9ppm Nox

End Cover With Pre-Mix Cap DLN Liner

Integral Fuel Nozzles

Uprate Changes:
• New liner arrangement • Pulsed Water Wash System
• Cap assembly and aft case • Reuter-Stokes flame detection
• Transition piece arrangement system
• Fuel nozzles • Piping modifications
• Combustion chamber arrangement
• Sparkplugs
• Control valves
 Turbine
FA+e Stage 1 Nozzle

FA+e added
TBC and
Cooling Holes

Inner Side Wall Outer Side Wall

• Redesigned cooling hole configuration FA+e:

improves thermal stress resistance Increased
• Improved sealing using cloth seals and Trailing
FA+e added
TBC
Edge Flow
reverse retaining ring hooks
• FSX-414 nozzle with TBC (porous FA+e:
ceramic) added to Sidewalls Increased
Cooling Flow With
• Requires new nozzle support ring when Shaped Holes
being put into FA & FA+
 Turbine
FA+e Stage 1 Bucket
Ceramic Top Coat
Serpentine Improved Airfoil Tip Cooling
Cooling Revised
Tip Cooling
Showerhead
LE cooling GT33 Bond Coat
Turbulated FA FA+e
Cooling Substrate
Passages
Impingement
LE cooling FA Round
Aluminide EDM/Stem
Coating
FA+e Elliptical
Cast (45 Holes)
Reduced Stress Trailing Edge
• Airfoil rotated closed for better aerodynamics
• Improved cooling using leading edge (LE) impingement and film
cooling, shower head LE cooling, and active tip cooling
• Airfoil has Dense Vertically Cracked (DVC) Thermal Barrier
Coating (TBC)
Advantages of TBC :
- TBC reduces heating in metal substrate by ~ 150F
- The cooling flow reduction is ~ 15% in the 9FA+e
 Turbine
• 2 piece shroud
FA+e Stage 1 Shroud • Eliminated pumpkin tooth
• Inner and Outer shroud design
has cloth seal design for • Cloth seal design for
improved sealing improved sealing compared
• Inner shroud has improved to the older pumpkin tooth
FA design with q-tip, spline, and
cooling through backside
impingement and film
FA+e dogbone seals
cooling on an enhanced heat • Inner shroud has improved
transfer surface cooling through backside
• Inner shroud has thermal impingement and film
barrier coating (TBC - cooling on an enhanced
porous ceramic) for heat transfer surface
improved thermal • Inner shroud has (TBC -
protection porous ceramic) for
improved thermal protection
e
• Special CM&U version of
FA+e shroud used to
accommodate differences in
casings for F/FA/FA+
Inner Shroud retrofits (stepped shroud)
compared to current FA+e
casings
Turbine
FA+e Stage 2 & 3 Shroud

Cloth Seals

Honeycomb
Insert

• Single piece shroud design compared to 2 piece F design

• Added cloth seals for improved intersegment shroud sealing instead of
dogbone seals
• Added honeycomb insert at interface between shroud and bucket for
improved stage efficiency
• Honeycomb shroud requires new cutter tooth bucket. Must be
purchased as a pair if new shroud is desired
Turbine
FA+e Stage 2 & 3 Buckets Scalloping
Cutter Tooth

Cooling Holes
Cutter tooth
Leading Edge

• Improved cooling for stage 2 buckets

Stage 2 Bucket
• Scalloped bucket tip shroud to reduce the tip stress
and improve creep resistance to deformation
• Added cutter tooth design for integration with
honeycomb shroud to improve overall stage
efficiency
• Cutter tooth bucket may be installed without
Internal
installing honeycomb shroud
Cooling Air Flow • Stage 3 bucket remains uncooled
Turbine
FA+e Stage 2 & 3 Nozzles

Stage 2:
• Newly designed core plug for optimized cooling air
distribution for stage 2 nozzle
• Cloth seals used for inter-segment sealing between
nozzle and diaphragm
• Better distribution of trailing edge cooling holes
• GTD-222 nozzle material makes the nozzle resistant
to oxidation

Stage 3:
• Nozzle cooling air extracted from compressor
stage 9 instead of previously used stage 13
• Cloth seals used instead of dogbone seals
between the nozzle and diaphragm segments
• GTD-222 nozzle material makes the nozzle resistant
to oxidation
Other
Off Base Modifications
• New LCI (Load Commutated Inverter) (applies to 7 & 9 F/FA)
• Due to the new compressor characteristics, the starting means
capacity must increase to handle larger starting torque
• New Inlet Bleed Heat System - IBH (applies to 7 & 9 F-fleet)
• Turbine and combustor operability rely on the redesigned High
Pressure system and associated Control system changes
• New Pulsed Water Wash System (applies to 7 & 9 F-fleet)
– 50% reduction of total water volume used for off-line washing
– Increased drainage area keep water out of combustor
– Design does not require disconnection the gas fuel pigtails which
significantly reduces overall time to perform water wash
• Controls Modifications
• Piping Modifications
 7FA+e Performance
The following performance is a result of putting 7FA+e parts into the older fleet

Put into F Put into F Put into FA Put into FA

Ä Output (%) Ä Heat Rate (%) Ä Output (%) Ä Heat Rate (%)
FA+e Stage 1 Nozzle No Engineering Approval No Engineering Approval +0.43 +0.02
FA+e Stage 1 Bucket Insignificant Performance Ä Insignificant Performance Ä +0.54 -0.49
FA+e Stage 1 Shroud +1.16 -0.53 +1.07 -0.46
FA+e Stage 2 Nozzle Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä
FA+e Stage 2 Bucket Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä
FA+e Stage 2 Shroud +0.31 -0.23 +0.45 -0.38
FA+e Stage 3 Nozzle Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä
FA+e Stage 3 Bucket Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä Insignificant Per formance Ä
FA+e Stage 3 Shroud +0.27 -0.23 +0.30 -0.25
Increase IGV Angle (88 to 90) +0.45 +0.05 +0.45 +0.05
UnCambered IGV (88C* to 89U*) +1.84 -0.30 +1.84 -0.30
HPP Inner Barrel Brush Seal** +0.70 -0.35 +0.55 -0.20

* Legend:
C ~ Cambered
U ~ UnCam bered
HPP ~ High Pressure Packing

** Notes:
HPP Brush Seal applies to those compressors which have NOT been modified to the “Robust Back End”
 9FA+e Performance
The following performance is a result of putting 9FA+e parts into the older fleet

Put into F Put into F Put into FA Put into FA

Ä Output (%) Ä Heat Rate (%) Ä Output (%) Ä Heat Rate (%)
FA+e Stage 1 Nozzle No Engineering Approval No Engineering Approval +0.61 -0.07
FA+e Stage 1 Bucket Insignificant Performance Ä Insignificant Performance Ä +0.23 -0.34
FA+e Stage 1 Shroud +0.92 -0.43 +0.87 -0.38
FA+e Hybrid Stage 2 Nozzle +0.21 -0.27 +0.38 -0.43
FA+e Stage 2 Bucket Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä
FA+e Stage 2 Shroud +0.28 -0.23 +0.42 -0.37
FA+e Stage 3 Nozzle Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä
FA+e Stage 3 Bucket Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä Insignificant Performance Ä
FA+e Stage 3 Shroud +0.11 -0.13 +0.13 -0.15
Increase IGV Angle (88 to 90) +0.45 +0.05 +0.45 +0.05
UnCambered IGV (88C* to 89U*) +1.84 -0.30 +1.84 -0.30
HPP Inner Barrel Brush Seal** +0.75 -0.35 +0.60 -0.20

* Legend:
C ~ Ca mbered
U ~ UnCambered
HPP ~ High Pressure Packing

** Notes:
HPP Brush Seal applies to those compressors which have NOT been modified to the “Robust Back End”
Uprate Options - Flexibility
Summary
• Engineering has completed extensive reviews and has approved
interchangeability of FA+e parts being put in F/FA/FA+ vintage units
(except S1N into a F)
• Full Uprate includes all new HGP, combustion system, and latest
compressor modifications
• GE can upgrade every nozzle, bucket, or shroud independently as needed
• Compressor design changes improve reliability and overall stability
• New combustion system offers best emission on the market (9 ppm Nox)
• Strong performance gains (due to increased firing temperature (to 2420F),
improved cooling & sealing technology, and increased compressor airflow
– unit specific performance evaluated in uprate proposal
• FA+e technology is a direct result of CR&D and Aircraft Engine
development

Evolved Technology Proves GE Commitment