ge adgt services advantages

Imagination at work.

We are at your service for the life of your equipment Alberto Balbo, Asia Regional Manager – TM/CM&U, GE Power & Water’s Distributed Power July 2014

© 2014 General Electric Company – All rights reserved

© 2014 General Electric Company – All rights reserved.

A global delivered fleet... Jenbacher gas engines | Waukesha gas engines | Aeroderivative gas turbines

~37,000 Units 147 GW of Capacity >170 Countries ~5,000 DP employees helping our customers make power in more places

ADGT SOA| July 2014 2


>97%

Services that last a lifetime

Our life cycle management gives you the right service at the right time –

throughout the lifetime of your equipment.



Chapter

GE’s maintenance

philosophy

Value-added services

& case studies

1 2 3 Aeroderivative gas

turbine maintenance

overview

ADGT SOA| July 2014 4 © 2014 General Electric Company – All rights reserved.


• Modular design and engine exchange Exchange major components fast… Reduces services downtime

• Condition based maintenance

Repair only as necessary... Allows balance between planned outages and life extension

• No starts penalty for mid-merit

or base load operation Lightweight design… Maintenance driven by engine condition

• RM&D

Remote troubleshooting and fast response… Reduces unplanned outages and improves performance

GE’s maintenance philosophy: Optional flexibility

1



Modular design

– Major component exchanges

– Easier to handle and transport

– Rotors / stators nominally

– Ground for easy interchange

Split case design

– Compressor cases

– Ease of blade replacement

– Performed in the package

Hot section exchange

- Performed on site in minimum time

- Modules and tooling delivered to site

Engine exchange

- Target of 2 - 3 day outage with spare or lease engines

Modular design and engine exchange



Condition Based Maintenance (CBM): What and how?

“Condition-based” • Inspect and repair as necessary to

restore to desired operational condition

Condition determined by: • Bore scope inspection ports • Vibration data monitoring • Performance data monitoring • Lube oil filter and screen inspection • Lube oil analysis • External engine inspections • Re-start inspections and

operational check



CBM: Aviation heritage Employed to manage and maintain highest levels of aircraft performance

Aviation engine

Aeroderivative turbine

• Common modular configuration as Aviation CF6

• On-condition maintenance • Moving from hours-based

intervals • Remote Monitoring & Diagnostics

(RM&D) + performance monitoring

• Six modules, fully interchangeable

(whole engine CBM) • On-condition maintenance

• No fixed engine time between overhaul

• 9 bore scope ports • In-flight engine condition

monitoring system



Original

targeted outage

Inspection

Inspection Inspection

Check critical components for FOD, other anomalies

Assess deterioration rate to develop unit-specific trend

Inspection

Condition-based outage

reschedule Inspection

Check critical components Assess current condition relative

to CTO limits Reschedule outage based on projection

STOP - Projected condition at next inspection opportunity exceeds CTO limit – execute maintenance event as scheduled

CTO – Continue to Operate

Projected condition incorporates all available information including dynamics and operational profile

Check critical components Assess current condition versus CTO limits

Reschedule outage based on projected condition

CBM: Interval - outage optimization process

Timing of BOP maintenance also considered

Inspection Inspection

Original targeted

outage

Condition-based outage

reschedule Inspection Inspection



RM&D

Faster and more efficient issue resolution

Mitigate event severity and frequency

Improved output, efficiency and capability

Elimination of repeat and systemic issues

ADGT SOA| July 2014

GE Aero RM&D Center, 24x7, Houston, TX

10


RM&D: Infrastructure and engagement map

Remote

Monitoring &

Diagnostics

Customer

Quick Response Center Proactive and reactive customer support from

GE experts

Distributed Power Portal Exchange of on-demand

information and data between customer and GE

Advisory / Reports Push notification based on

issues and subscription

Data



RM&D: Facts

24/7 Monitoring Diagnostics

Helpdesk

200,000 incoming

datasets per hour

400 units connected

75 analytical

outputs per day

25 alerts processed

per day

OEM consultative

services

Top field engineers for

troubleshooting

ADGT SOA| July 2014

Tier 1

12


RM&D: Quick Response Center (QRC)

QRC =

24 x 7 globally dispersed team staffed by field service and

controls experts

• Timely and enhanced technical support

• Immediate operational troubleshooting

• Proactive customer contact for RM&D generated urgent alerts

• GE internal escalation handling

• Remote mapping and emissions tuning

• Analysis of data-logs, trends, and alarm history

• Field technical direction and issue resolution


Industrial Internet

Customer Benefits

- Proactive fault warning

- Outage diagnostic notifications

- Real-time viewing by off-site personnel

- Long-term trend analysis

- Remote troubleshooting

- Global network of GE experts on call

- Remote emissions adjustments

Remote Monitoring & Diagnostics

(RM&D)

- Centralized database

- Trending services

- Data access for remote users

Quick Response Center (QRC)

- Controls diagnostics

- Operability adjustments

- DLE mapping

+ =

“We have ended 2012 and 2013 with the best performance

ever in Songas’ history. We would like to thank GE’s QRC team

in responding to our needs in time,” Songas, Tanzania.

“We love to know that something

is breaking before it trips,”

Mondi, South Africa.



Aeroderivative gas turbine maintenance overview

• Maintenance level • Typical scheduled maintenance • Bore scope inspections

• Engineering consulting • LM maintenance events

• Hot section • MOH • Engine exchange

2



Maintenance level

Level I Preventative and corrective actions performed

on exterior of installed gas turbine (includes gas

turbine change out)

Level II Level I plus interior gas turbine actions performed

onsite

Level IV Complete disassembly and assembly of modules

and major assemblies. Allows replacement of any

individual piece part. Test capability required

Level V* Level IV plus repair of piece parts and control and

accessory items. (*Does not exist as single entity)

Onsite

Depot



Typical maintenance schedule

4,000# Inspection (every 4,000 hours)* ~24 hours

25,000** Onsite hot section replacement ~3-5 days

50,000*** Depot refurbishment ~3 days


100,000*** Depot refurbishment ~3 days


Hours Scheduled Maintenance Action Outage

# For LM6000, interval is 4,000 hours, 450 starts, or once annual, whichever is first

* At 12,500 hours, LM6000 compressor bushings are replaced. ** Assumes gas fuel with water injection to 42ppm NOx. Higher water injection to achieve lower NOx levels may affect combustor life. DLE engines or SAC engines operating dry may see higher life spans. *** Spare or lease engine installed during refurbishment.

Actual time to conduct major maintenance still determined by hardware condition, not the actual hour count. *



Bore scope inspections

Left side

Right side

Bore scope ports permit inspection of the entire gas turbine: All modules Frames Oil system and fuel nozzles

Digital transfer to the factory and engineering allows for real-time analysis

Bore scope inspections are required every six months/4,000 hours, or as directed by troubleshooting

Stage 13 port

Stage 13 port



LPC blades

DLE fuel nozzle

HPC S14 blades

HPT S1 nozzle HPT S1 blades

Samples of bore scope inspections


OEM engineering consulting

Quarterly onsite meetings:

• Site walk by GE engineers

• In-depth discussion of major

RM&D/analytic findings within last

period and derived actions

• Site specific recommendations to

improve asset operation

Value:

• Take advantage of OEM know-how

locally

• Support and train customer

technical staff

ADGT SOA| July 2014 © 2014 General Electric Company – All rights reserved 20


• Exchange your Engine Component for a GE Engine Component

• Hot-Section Exchanges

– Repaired or New Parts Available

– 1 to 2 Day Outage

• Customer Benefits

– On-Site Service... No Shop Visit

– Less Downtime... 1 Shutdown

– Reduced Maintenance Costs

– Firm Price... No Surprises

– Fully Warranted Hardware

– Immediate Availability in most cases

– Light-Weight… easy to Handle & Transport

• Hot-section exchanges

– Repaired or new parts available

– ~ 3 day outage

• Customer benefits

– Onsite service... no shop visit

– Less downtime... 1x shutdown

– Reduced maintenance costs

– Firm price... no surprises

– Fully warranted hardware

– Immediate availability in most cases

– Light-weight… easy to handle and transport

– Includes required tooling, expendables, and onsite labor

LM maintenance: Hot-section exchanges



• Engine is removed from package

• Transferred to container

• Shipped to Service Center

LM maintenance events: Major overhaul



• Engine is removed from package

• Engine is shipped to Service Center for major overhaul

• Major overhaul inspection and repair

- Low/high pressure compressor

- Combustor assembly

- High pressure turbine

- Nozzle assemblies

- Low pressure turbine

- Hydraulic system, gearbox, VIGVs, VBV

LM maintenance events: Major overhaul



LM maintenance events: Engine exchange

Minimized downtime during depot visits

• ~2-3 day outage with spare or lease engines

• Packages are designed for ease of engine removal


D:/Users/almg01t/My Documents/My Videos/2009 LM 6000 x offshore and onshore applications.wmv


GE’s value-added services and case studies

• Multi-year agreement (MYA)

• Aero on Demand

• Customer Cases

3


Value-added services: Multi-year agreement (MYA) Team up to increase performance at lower cost

26

GE collaborates with you to achieve

your business goals

A service agreement is tailored to

complement your capabilities:

maintenance coverage,

performance guarantee,

operation support

GE’s expertise and operations

excellence are at your service

Reducing performance and

maintenance spend; improving

financial and operational planning

ADGT SOA| July 2014 © 2014 General Electric Company – All rights reserved


MYA options: Complete flexibility

Pick up the package that is right for you.

Full CSA MMP Framework

Outage Related Guarantees

Remote Monitoring & Diagnostics

Major Maintenance Scope & Cost Risk

Unplanned Maintenance

Service Bulletin Coverage

Performance Guarantees & Optimization

Major Maintenance Interval Risk

Integrated Lease & Engine Exchange

Pre-negotiated Terms & Conditions

Field Service Engineering & Parts Supply x

x Standard o Optional

x x

x

Level 3

x x

Level 1

x

x

x

x

x

o

o

o

o

o

o

Level 2

• Work scope − Gas turbines − Controls

− Package, gearbox, generators • Guarantees

− Availability, reliability, outage duration

− Output, efficiency • Payment

− Calendar-based fees (annual, quarterly, etc.)

− $/Fired hours − Milestone payments − Bonus/LD as executed

• Unit type and term − Any fleet age − Full range of operational

profiles

− Varying years, term, multi-cycles



MYA: Growing capabilities

The past RM&D today Advanced

Services & MYA

Maintenance

intervals

Hours/starts based

or unplanned Condition based Rolling life prediction

Performance

relative to fleet

Backward look at

quarterly fleet data

Monthly reports

or on demand Available real time

Repeat issues Managed through

service bulletins

Managed by customer

portal access Predictive support

Unplanned events Break fix Basic analytics to predict

issues

Analytics based prevention

and site preparation

Output Fixed and facing asset

degradation issues Enabling ancillary services

Dynamic, cost based

capabilities



RM&D case study: Downtime save

High Power Trip – downtime avoided, faster return to service

RM&D reported a High Power

Trip and multiple alarms

Within 15 minutes, QRC reached

out to the customer to offer

assistance and remotely

connected to site

QRC remotely checked engine

ABC mode, altered bulk

schedule, and brought unit back

into operation

RM&D

detection

RM&D

diagnosis

Action /

outcome


© 2014 General Electric Company – All rights reserved. ADGT SOA| July 2014

Predictivity case study

Customer Metric Goals 2011

Actual 2012

Actual 2013

Actual

Start reliability >97% 97.3% 100% 99%

Availability (peak season) >98% 84.6% 99.7% 99%

Forced outage rate <1% 8% 0.10% 0.69%

Availability (total) >93.8% 80% 83% 94.7%

Preventative maintenance

• Onsite evaluations

• GE led maintenance planning • Service Bulletin prioritization • Outage workscope

Customer involvement

• Onsite O&M training

• Controls training • Monthly GE field service visit • Remote troubleshooting

Ongoing optimization

• My unit vs. Fleet comparison

• Spare parts/inventory • Tech docs and BOM access • Lease pool/asset mgmt.

Focused Implementation

RM

&D

inst

alle

d

30

ge adgt services advantages

Technology

general electric company

condition maintenance

inspection inspection

engine exchange adgt

troubleshooting adgt

projected condition

places adgt soa

operational check adgt