6b9e uprates

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



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



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 !



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.



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



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



• 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



• 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



• 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



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



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



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

155/11/2012Copyright 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.

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



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.



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



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



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

20Paul Gilmurray - Indonesia SOA

5/11/2012Copyright 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, STDcombustor, no inlet or exhaustlosses

** Available as retrofit only

Current New Unit Production

MS6001B Performance History




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




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.




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 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




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.




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 %)




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




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°%




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


• 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.




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


• Stage 2 buckets with improved cooling


• 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.




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




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)




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




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




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




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




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




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




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




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




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




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




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


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



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



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



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



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


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


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


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


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




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




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




$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




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

6b9e uprates

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