External Services (Gas Turbine

Heavy-Duty Gas
Turbine Operating
and Maintenance
Considerations

HDGT.PPT/ 1

External Services (Gas Turbine

A Maintenance Program should:

Optimize owners maintenance costs

Maximize equipment availability

HDGT.PPT/ 2

External Services (Gas Turbine

Because not all customers operate their gas turbines the same,
Case 1

Case 2

8,000 Hrs/Yr
160 Starts/Yr
HGP at 3 years

1,000 Hrs/Yr
400 Starts/Yr
HGP at 3 years, not 24 years

not all customer maintenance programs are the same.

BHEL Provides Guidance for Customer Maintenance Planning
HDGT.PPT/ 3

External Services (Gas Turbine

Factors Affecting Maintenance Planning and

Maintenance Program
Manufacturers
Manufacturers
Recommended
Recommended
Maintenance
Maintenance
Program
Program

Design
Design
Features
Features

Duty
Duty
Cycle
Cycle

Diagnostics
Diagnostics

Availability
Availability
Need
Need
On-Site
On-Site
Maintenance
Maintenance
Capability
Capability

Maintenance
Maintenance
Program
Program

Utilization
Utilization
Need
Need

Environment
Environment

Cost
Costof
of
Downtime
Downtime
Type
Typeof
of
Fuel
Fuel
Expert
Expert
Systems
Systems
Reserve
Reserve
Requirements
Requirements
HDGT.PPT/ 4

External Services (Gas Turbine

Potential Failure Modes

Hot-Gas-Path Components
Continuous Duty Application
Creep Deflection
Creep Rupture
Corrosion
Oxidation
Erosion
High-Cycle Fatigue

Cyclic Duty Application

Themal Mechanical
Fatigue
Rubs/Wears

HDGT.PPT/ 5

External Services (Gas Turbine

GE Bases Gas Turbine Maintenance

Requirements on Independent Counts of
Different
Starts & Hours Fatigue Limits Life
Mechanism
Failure Region

Limit Life

Starts
Design
Life
Oxidation
Creep,
Corrosion
& Wear
Limit Life

GE Inspection
Recommendation

Competition
Inspection
Recommendation
(Equivalent Hours Per Start)

Design
Life
GE Inspection
Recommendation
Hours

HDGT.PPT/ 6

External Services (Gas Turbine

GE vs. Equivalent Hours Approach

Case 2
4000 Hrs/Yr
300 Starts/Yr
GE Every 4 Yrs
EOH Every 2.4 Yrs

1200
1000

GE
METHOD

800

EOH
METHOD

Starts 600

Case 1
8,000 Hrs/Yr
160 Starts/Yr
GE Every 3 Yrs
EOH Every 2.1 Yrs

400
200
0
0

12

16

20

24

28

Fired Hours (x1000)

HDGT.PPT/ 7

External Services (Gas Turbine

Maintenance Cost and Equipment Life

Are Influenced by Key Service Factors
Fuel
Firing Temperature
Steam/Water Injection
Cyclic Effects (Start-up rate, number of trips)
Air Quality

Service
ServiceFactors
FactorsDifferent
DifferentFrom
Fromthe
theReference
ReferenceCondition
Condition**
Can
CanIncrease
IncreaseMaintenence
MaintenenceCost
Cost&&Reduce
ReduceMaintenence
MaintenenceIntervals
Intervals
HDGT.PPT/ 8

External Services (Gas Turbine

Maintenance Factors
Hot Gas Path (Buckets & Nozzles)
Typical Max Inspection Intervals (MS6B/Ms7EA)
Hot Gas Inspection 24,000 hrs or 1200 Starts
Major Inspection
48,000 hrs or 2400 Starts
Criterion is Hours or Starts (Whichever Occurs First)

Factors Impacting Maintenance

Hours Factors

Starts Factors

Fuel
Gas
Distillate
Crude
Residual

Trip From Full Load

Fast Load
Emergency Start

1
1.5
2 to 3
3 to 4

8
2
20

Peak Load
6
Water/Steam Injection
Dry Control 1 (GTD-222)
Wet Control 1.9 (5% H20)

HDGT.PPT/ 9

External Services (Gas Turbine

Maintenance Factors Reduce Maintenance

Interval
1400
1200

Starts Factors
Trips, Fast Starts

1000

Starts

800
Hours Factors
Firing Temp
Steam/H2O

600
400
200

Injection
Fuel Type

0
0

12

16

20

24

28

Fired Hours (x1000)

HDGT.PPT/ 10

External Services (Gas Turbine

Estimated Effect of Fuel Type on Maintenance

Residual

Maintenance
Factor
Distillates
Heavy

Light
Natural Gas

7 8 9 10 11 12 13 14 15

20

Fuel Percent Hydrogen by Weight in Fuel

HDGT.PPT/ 11

External Services (Gas Turbine

Hot Corrosion
Oxidation
is
Limiting
Factor

Corrosion becomes
Limiting Factor

Component surface saturated

with condensated corrosive deposits.
Life limited primarily by kinetics of the
corrosion reaction.

Life

Na Concentration in Combustion Products

HDGT.PPT/ 12

External Services (Gas Turbine

Bucket Life Firing Temperature Effect

(MS5001P Uncooled bucket)

100
10
Life
Factor

Peak rating of
Tf + 100 F (65 C)
has life factor of 6

(MS6001B/MS7001EA/MS9001E)

0.1
0.01
-200

-100

100

200

Change in firing temperature - degrees F

HDGT.PPT/ 13

External Services (Gas Turbine

Example 1:
A unit which has operated at Peak Load (+100 F) for
100 hours would have to be operated at - 50 F for 833
hours to maintain a maintenance factor of ONE.
MF =

Factored Hours
Actual Hours
833 hrs (0.4) + 100 hrs (6.0)

=1

(833 + 100) hrs

HDGT.PPT/ 14

External Services (Gas Turbine

Example 2:
Determine the Maintenance Factor for a unit which
operates at Base Load for 6000 hours, Peak Load for
600 hours, and at -50 F Firing Temperature for 15000
hours.
MF =

Factored Hours
Actual Hours

6000 hrs (1.0) + 500 hrs (6.0) + 1500 hrs (0.4)

(6000 + 1500 + 500) hrs

MF = 1.2
HDGT.PPT/ 15

External Services (Gas Turbine

Firing Temperature and Load

Heat Recovery vs Simple Cycle
2500

Close IGVs
84 to 57 deg

Heat Recovery

Tf constant @
2020 F

Simple Cycle

2000

o
57 VIGV

Firing
Temp.
o
F 1500

o
84 VIGV

Close IGVs
84 to 57 deg

1000

Tx constant @ 700 deg F

20

40

60
% Load

80

100

120
HDGT.PPT/ 16

External Services (Gas Turbine

Heavy Fuel Maintenance Factors

(MS6001B/7001EA/9001E)

Maximum Heavy Fuel

Firing Temperature

10

5
Maintenance
Factor

Residual
Crude

2
1
-200

-150

-100

-50

50

Delta Firing Temperature F

HDGT.PPT/ 17

External Services (Gas Turbine

Steam/Water Injection and Nozzle

Creep Deflection
Steam/Water Injection Impacts
Stage 2/3 Nozzle Maintenance
and Life

2nd Stage
Nozzle

3rd Stage
Nozzle

Increases Nozzle Gas Loads

Increases Downstream
Deflection Rate
Decreases Maintenance
Interval

GTD-222 Nozzle Alloy Minimizes

This Effect
HDGT.PPT/ 18

External Services (Gas Turbine

Steam/Water Injection and Bucket/Nozzle Life

Steam/Water Injection Increases Metal Temperature
of
Hot-Gas-Path Components
Water Effects Gas Transport Properties:
- Thermal Conductivity increases
- Specific Heat increases
- Viscosity remains steady

This increases Heat Transfer Coefficients which increases metal

temperature and decreases bucket life
Example (MS7001EA Stage 1 Bucket):
3% Steam increaes bucket metal temperature 15 F and
decreases Life -33%
at constant firing temperature
HDGT.PPT/ 19

External Services (Gas Turbine

Exhaust Temperature Control Curve

Dry Versus Wet Control
Steam Injection for 25 ppm NOX

50

Wet Control
40

Exhaust
Temperature
30
o
F
20
10
0

3% Steam Inj.
o
TF = 2020 F
Load Ratio = 1.10

Dry Control
0% Steam Inj.
TF = 2020 o F
Load Ratio = 1.0

3 % Steam Inj.
o
TF = 1994 F
Load Ratio = 1.08

Compressor Discharge Pressure (psig)

HDGT.PPT/ 20

External Services (Gas Turbine

Maintenance Factors Reduce Maintenance

Interval
1400
1200

Starts Factors
Trips, Fast Starts

1000

Starts

800
Hours Factors
Firing Temp
Steam/H2O

600
400
200

Injection
Fuel Type

0
0

12

16

20

24

28

Fired Hours (x1000)

HDGT.PPT/ 21

External Services (Gas Turbine

Turbine Start/Stop Cycle

Base Load

Light-off

Acceleration

Exh.
Temp.

Unload Ramp

Full Speed
No Load

Load Ramp

Warm-up

Full Speed
No Load

Fired Shutdown
Trip

Start-up

Time

Shutdown
HDGT.PPT/ 22

External Services (Gas Turbine

Maint. Factor

Effect of Start Cycle Max Load Level

1.4
1.2
1
0.8
0.6
0.4
0.2
0
0

20

40

60

80

100

120

% Load
HDGT.PPT/ 23

External Services (Gas Turbine

Low Cycle Fatigue Life
Sensitivities First-Stage Bucket
Leading Edge Temperature/Strain
Normal Start & Trip

Normal Startup/Shutdown

TMAX
Strain
-%

Temperature

Strain
-%

TMAX
Temperature

1 Trip Cycle = 8 Normal Shutdown Cycle

HDGT.PPT/ 24

External Services (Gas Turbine

Trip Severity Factor

Maintenance Factor - Trips from Load

10
9
8
7
6
5
4
3
2
1
0

Base

For trips during Start-up

Acceleration, assume
Trip Severity Factor = 2

FSNL

20

40

60

80

100

120

% Load
HDGT.PPT/ 25

External Services (Gas Turbine

Heavy-Duty Gas Turbine

Shutdown Inspections
Combustion
Hot-Gas-Path
Major

Major inspection
Hot-Gas-Path
Inspection
Combustion
Inspection

HDGT.PPT/ 26

External Services (Gas Turbine

MS7001EA Combustion Inspection Intervals

NOx
Combustor
Emissions
Design
Level (ppm)
Standard
Liner

65
42

Fuel
Diluent

Gas
Hours/Starts

Dry
Steam
Water
Steam
Water

8,000/800
------8,000/400
6,500/300

Distillate
Hours/Starts
8,000/800
8,000/400
6,500/300
3,000/150
1,500/100

Extendor Combustion System Wear Kit Increases

Combustion Inspection to as Much as 24,000 Hours
HDGT.PPT/ 27

External Services (Gas Turbine

Base Line Recommended Inspection Intervals

Base Load - Gas Fuel - Dry
Hours/Starts
Type of
Inspection
Combustion
Hot-Gas Path
Major

MS32/52/51
Upgrade
12000/800
Eliminated/1200
4800/2400

MS6B

MS7E/EA

MS9E/7FA/
9FA

12000/800

8000/800

8000/800

24000/1200

24000/1200

24000/900

48000/2400

48000/2400

48000/2400

Factors That Can Reduce Maintenance Intervals

Trips from Load
Fuel
Start Cycle
Load Setting
Steam/Water Injection
HGP Hardware Design
Peak Load Tf Operation

HDGT.PPT/ 28

External Services (Gas Turbine

Maintenance Factor Definition

IDEAL INTERVAL =
RECOMMENDED
INTERVAL
=

Interval for Continuous Base Load

on Clean Natural Gas

Ideal Interval determined from

application of maintenance factors

HDGT.PPT/ 29

External Services (Gas Turbine

HGPI Hours Based Criterion
MS6001/7001/9001

24000
Maintenance Interval
=
Maintenance Factor
(Hours)

Where:
Maintenance Factor =

Factored Hours
Acutal Hours

Factored Hours = (K + (M x I)) x (G + 1.5 D + Af H + 6 P)

Actual Hours

= (G + D + H + P)

G = Operating Hours on Gas Fuel

D = Operating Hours on Distillate Fuel
H = Operating Hours on Heavy Fuel
Af = Heavy Fuel Severity Factor (Residual Af = 3 to 4, Crude Af = 2 to 3)
P = Peak Load Operating Hours
I = Percent Water/Steam Injection Referenced to Inlet Air Flow
M & K = Water/Steam Injection Constants
K
Control Steam Injection
N2 / N3 Material
M
1
Dry
< 2.2 %
GTD-222 / FSX-414
0
1
Dry
> 2.2 %
GTD-222
0
.6
Dry
> 2.2 %
FSX-414
.18
1
Wet
>0%
GTD-222 / FSX-414
.18

HDGT.PPT/ 30

External Services (Gas Turbine

HGPI Starts Based Criterion

S
Maintenance Interval
=
Maintenance Factor
(Starts)

MS6001/7001/9001
Where:
Maintenance Factor =

Factored Starts
Acutal Starts

Factored Starts = (0.5 NA + NB + 1.3 NP + 20 E + 2 F +

Actual Starts
S
NA
NB
NP
E
F
Tn
aT n
n

aTi Ti )

i=1

= (NA + NB + NP + E + F)

= Maximum Starts-Based Maintenance Interval (Model Size Dependent)

= Number of Part Load Start/Stop Cycles (< 60% Load)
= Number of Normal Base Load Start/Stop Cycles
= Number of Peak Load Start/Stop Cycles
= Number of Emergency Starts
S
Model Series
= Number of Fast Load Starts
1,200
MS6B/MS7EA
= Trips
1,200
MS6FA
= Trip Severity Factor
900
MS9E
900
= Trip number
MS7F/7FA/9F/9FA
HDGT.PPT/ 31

External Services (Gas Turbine

First-Stage Nozzle Wear Preventive Maintenance

Gas-Fired - Continuous Duty - Base Load

New Nozzle Acceptance Standards

1st
Repair

Repaired Nozzle
Nozzle Min. Acceptance
Condition Standard

2nd
Repair

3rd
Repair

Without
Repair

Repair Cost
Exceeds
Replacement
Cost

Severe Deterioration
10,000

20,000

30,000

40,000

50,000

Operating Hours

60,000

70,000

80,000
HDGT.PPT/ 32

External Services (Gas Turbine

Estimated Repair & Replacement
Repair
Interval
Combustion Liners
Transition Pieces
Fuel Nozzles
Cross-Fire Tubes
1st Stage Nozzles
2nd Stage Nozzles
3rd Stage Nozzles
1st Stage Buckets

CI
CI
CI
CI
HGPI
HGPI
HGPI
HGPI*

2nd Stage Buckets

3rd Stage Buckets
1st Stage Shrouds
2nd/3rd Stage Shrouds

HGPI
HGPI
HGPI
HGPI

Replace
Interval
(Hours)
5 (CI)
6 (CI)
3 (CI)
3 (CI)
3 (HGPI)
3 (HGPI)
3 (HGPI)
2 (HGPI)
3 (HGPI)**
3 (HGPI)
3 (HGPI)
2 (HGPI)
3 (HGPI)

Replace
Interval
(Starts)
5 (CI)
6 (CI)
3 (CI)
3 (CI)
3 (HGPI)
3 (HGPI)
3 (HGPI)
3 (HGPI)
4 (HGPI)
4 (HGPI)
2 (HGPI)
4 (HGPI)

CI = Combustion Inspection Interval

HGPI = Hot Gas Path Inspection Interval
* When recoating, perform after one hours-based HGPI
** Two HGPI without recoat, Three HGPI with Recoat
HDGT.PPT/ 33

External Services (Gas Turbine

Maintenance Factors Summary

Maintenance Requirements are Based on an Independent Count of
Hours and Starts
Certain Operating Factors Reduce Maintenance Intervals
Peak Loac
Steam/Water Injection >2.2%
Liquid Fuel
Trips From Load
Fast Starts
Exceeding GE Specification Limits can Significantly Increase
Maintenance Factors and Reduce Component Life
Equations for Establishing Application Specific Hot Gas Path
Maintenance Intervals are Available

HDGT.PPT/ 34

External Services (Gas Turbine

Bucket Life Firing Temperature Effect

MS6001B / MS7001EA / MS9001E
100

Life
10
Factor

1
Change in 0
Firing
0
Temperature

Peak Rating
+100F (56C) T.
Life Factor -6
50
25

100

150

50

75

200
100

250
125

C
HDGT.PPT/ 35

External Services (Gas Turbine

Operating Inspection Data Parameters

Speed
Load
Fired Starts
Fired Hours
Site Barometric Reading
Temperatures
Inlet Ambient
Compressor Discharge
Turbine Exhaust
Turbine Wheelspace
Lube Oil Header
Lube Oil Tank
Bearing Drains
Exhaust Spread

Pressures
Compressor Discharge
Lube Pump(s)
Bearing Header
Cooling Water
Fuel
Filters (Fuel, Lube, Inlet Air)
Vibration Data for Power Train
Generator
Output Voltage Field Voltage
Phase Current Field Current
Stator Temp.
VARS
Vibration
Load
Start-Up Time
Coast-Down Time
HDGT.PPT/ 36

External Services (Gas Turbine

Deterioration of Gas Turbine Performance

Due to Compressor
Blade Fouling
8
6
4

Fouling

2
Heat Rate
Increase
%

5% Loss of
Airflow

-2
-4

Output
Decrease
%

-6
-8
-10

Fouling

-12
-14

-1 -2 -3 -4 -5 -6 -7 -8
Pressure Ratio Decrease - %

HDGT.PPT/ 37

External Services (Gas Turbine

Maintenance Inspections
Hot Gas Path Inspection - Key Elements
Combustion Inspection Work Scope Plus:

Key
KeyHardware
Hardware
Nozzles (1,2,3)
Buckets (1,2,3)
Stator Shrouds
IGVs & Bushings
Compressor Blading
(Borescope)

Inspect
Inspectfor:
for:

Foreign Objects Damage

Repair/Refurbishment
Nozzles
Oxidation/Corrosion/Erosion
Weld Repair
Cracking
Reposition
Cooling Hole Plugging
Recoat
Remaining Coating Life
Buckets
Nozzle Deflection/Distortion
Strip & Recoat
Weld Repair
Abnormal Deflection/Distortion
Blend
Abnormal Wear
Missing Hardware
Clearance Limits

Criteria: Op. & Instr. Manual

TILs
Field Engineers

Potential
PotentialActions:
Actions:

Inspection Visual
Methods: LP
Boroscope

Availability of On Site
Spares Is Key to
Minimizing Downtime
HDGT.PPT/ 38

External Services (Gas Turbine

Maintenance Inspections
Combustion Inspection - Key Elements
Key
KeyHardware
Hardware
Combustion Liners
Combustion Covers
Fuel Nozzles
Transition Pieces
Cross Fire Tubes
Flow Sleeves
Check Valves
Spark Plugs
Flame Detectors
Flex Hoses

Criteria: Op. & Instr. Manual

TILs
Field Engineers

Inspect
Inspectfor:
for:

Potential
PotentialActions:
Actions:
Repair/Refurbishment
Liners
Cracking/Erosion/Wea
r
TBC Repair
Transition Pieces
Wear
TBC Repair
Distortion
Fuel Nozzles
Plugging
Erosion/Wear
Cross Fire Tubes
Wear/Burning
Visual
Availability of On Site
Spares Is Key to
LP
Minimizing Downtime
Boroscope
HDGT.PPT/ 39

Foreign Objects
Abnormal Wear
Cracking
Liner Cooling Hole Plugging
TBC Coating Condition
Oxidation/Corrosion/Erosion
Hot Spots/Burning
Missing Hardware
Clearance Limits
Borescope Compressor and
Turbine

Inspection
Methods:

External Services (Gas Turbine

Maintenance Inspections
GT Major Inspection - Key Elements
Combustion Inspection Work Scope
HotGas Path Inspection Work Scope Plus
Key
KeyHardware
Hardware

Inspect
Inspectfor:
for:

Potential
PotentialActions:
Actions:

Repair/Refurbishment
Foreign Objects Damage
Oxidation/Corrosion/Erosion Stator Shrouds
Turbine Wheels Dovetails
Oxidation/Corrosion/Erosio
Cracking
n
Journal and Seal Surfaces
Buckets
Leaks
Coating Deterioration
Bearing Seals
Abnormal Wear
FOD/Rubs/Cracking
Missing Hardware
Inlet System
Tip Shroud Deflection
Creep Life Limit
Clearance Limits
Exhaust System
Nozzles
Severe Deterioration
IGV Bushings
Criteria: Op. & Instr. Manual Inspection Visual
Wear
Bearings/Seals
Methods: LP
TILs
Booring/Wear
Field Engineers
Borescope
Compressor Blades
Corrosion/Erosion HDGT.PPT/ 40
Compressor Blading