GE Power & Water

Predictive Maintenance
and Interval Extension
Paul Gilmurray
Power Services Engineering

Australian Gas Turbines Conference | Thu 26 Nov 2015

2013, General Electric Company. Proprietary information. All rights reserved.

GE Power & Water

2015 General Electric Company.

GE Proprietary Information - The information contained in this document is
General Electric Company (GE) proprietary information. It is the property of
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creation, manufacture, development, or derivation of any repairs,
modifications, spare parts, or configuration changes or to obtain government
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laws. Unauthorized export or re-export is prohibited.

Comparative or relative statements refer to GE technology unless

otherwise stated.

2013, General Electric Company. Proprietary information. All rights reserved.

Agenda
Interval Extension Technology

Experiences to and beyond 32K

Repair Technology & Predicting Remaining Life

9E Customer Presentation
2013, General Electric Company. Proprietary information. All rights reserved. Slide 3
Extending outage intervals with
Advanced Gas Path
and Extendor Technology

2013, General Electric Company. Proprietary information. All rights reserved.

Offerings to Extend Outage Intervals

Hot Gas Path

Combustion

From experience and lessons learned on 3000+ installed

6B/7E/9E gas turbines with 800+ units under long term service
agreements
9E Customer Presentation
2013, General Electric Company. Proprietary information. All rights reserved. Slide 5
Interval Extension Benefits
Availability- Eliminate inspections increase availability
Generation- Increase MWHr/year
Penalty Savings- Avoid penalties in Gas Take or Pay
Contracts
Repair Cost Savings- Reduce repair costs
Services Cost Savings- Reduce craft labor & engineer
costs
Repair Shipping Savings Reduce repair shipping costs
Repair Duty Savings - Reduce parts import duty
Reliability Improvement- Less restart problems and less
time off site for spare parts. Also less testing such as
overspeed.
9E Customer Presentation
2013, General Electric Company. Proprietary information. All rights reserved. Slide 6
6B Hot Gas Path :
6B Performance Improvement
Package

2013, General Electric Company. Proprietary information. All rights reserved.

6B 3-series Performance
Improvement Package
Stage 1 Shroud Abradable Coating

Advanced Aero
Stage 3 Bucket and
Nozzle

Stage 2 Nozzle
Diaphragm
Brush Seal

2013, General Electric Company. Proprietary information. All rights reserved.

6B 3-Series Gas Turbine
Performance Improvement Package
6B 3-Series Gas
Benefits 2
Turbine
Output (S/C) +2.1%
Heat rate (S/C) -1.8%
Stage 1 shroud abradable
HGP Inspection 32,000 FFH coating surface
Interval
2at
ISO conditions, 100%
methane
Decision to include Performance
Improvement Package (PIP) in all
new 6B 3-series gas turbine units
made in 2010 based on retrofit Advanced aero stage 3
experience bucket and nozzle
9

2013, General Electric Company. Proprietary information. All rights reserved.

 6B Combustion :
Advanced Extendor

2013, General Electric Company. Proprietary information. All rights reserved.

Extendor - How to reduce wear and
creep?
Understanding the 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
Analyzing fleet data and experience
Dry-Low NOx (DLN) performance and combustion testing
F-class monitored fleet
Developing technology improvements
Enhanced thermal barrier coatings (TBC)
Material changes
Wear coatings
Hardening of surface in contact
Clearance reduction

9E Customer Presentation
2013, General Electric Company. Proprietary information. All rights reserved. Slide 11
Technical modifications

Copyright 2008 General Electric Company. All Rights Reserved. FOR GE INTERNAL USE ONLY. This 12
material may not be copied or distributed in whole or in part, without prior written permission of the
copyright owner.
6B Advanced Extendor* changes
compared to Extendor*
Components 6B Standard combustor 6B DLN combustor
Primary fuel nozzle Fully machined nozzle tip with New weld neck flange design
wear coating
Secondary fuel Not Applicable New gas only transferless design, new
nozzle flangeless gas only transfer, tip class B
TBC coating
Liner Double leaf hula seal Double leaf hula seal with 2-cool
design, bulk liner top material, Nimonic
fat boy section with class-C TBC
Flow sleeve No change No change
Transition piece Full length class-C TBC Full length class-C TBC
Casing No change No change
Crossfire tubes Material change, wear coating Material change, wear coating
Spark plugs No change No change
Flame detector No change No change
Nimonic is a registered trademark of Udimet Corp. 13
* Trademark of General Electric Company

2013, General Electric Company. Proprietary information. All rights reserved.

6B - 32K Availability
Inspection Intervals - Replace intervals factored
factored fired hours (FFH) fired hours (FFH)
Standard combustor
Non-Extendor* hardware 12,000 48,000

Extendor* or CL-Extendor 24,000 48,000

Advanced Extendor* 32,000 64,000

DLN combustor

Non-Extendor* hardware 12,000 48,000

Extendor* or CL-Extendor* 24,000 48,000
DLN1 Advanced Extendor* or DLN1+ 32,000 64,000
Hot gas Path/Major inspection without
24,000/48,000 72,000/200,000
Advanced Extendor* or DLN1+
Hot Gas Path/major inspection with PIP
32,000/64,000 96,000/200,000
after Advanced Extendor* or DLN1+

Starts are unchanged compared to Extendor*. Advanced Extendor* is available for all 6B models
with firing temperature equals or below 2084F, except Syngas and heavy fuel oil applications
14
* Trademark of General Electric Company

2013, General Electric Company. Proprietary information. All rights reserved.

9E Hot Gas Path :

9E Advanced Gas Path

2013, General Electric Company. Proprietary information. All rights reserved.

9E 3-series advanced hot gas path
Hot gas path evolution Engineering and operational
Performance

Maintains emissions experience (B/E, FA/B, 6C, H)

3D aero (S3N,S3B)
Balanced work split
Cooling and sealing improvements
Improved clearances

Advanced materials
Durability

GTD*262 Alloy
Improved cycle fatigue
Reduced oxidation
Reduced creep

Output and efficiency

S1N S1B S2N

* Trademark of General Electric Company 9E Customer Presentation

Slide 16 11/26/2015
2013, General Electric Company. Proprietary information. All rights reserved.
Features and benefits
Advanced gas path
Stage Part Improvement Benefit
Improved sealing Clearances
Nozzle
Advanced cooling Durability/perf
1st Turbulators Durability/perf
Bucket
Dovetail sealing Clearances
Shroud Abradable shroud Clearances
Advanced cooling Durability and
Nozzle
GTD*262 Alloy performance
2nd Advanced Cooling Durability/perf
Bucket
Dovetail sealing Clearances
Shroud Abradable honeycomb Clearances
Nozzle 3D aero Performance
Bucket 3D aero Performance
3rd
Shroud Abradable honeycomb Clearances

More performance, higher durability, improved maintenance - retrofittable

* Trademark of General Electric Company 9E Customer Presentation

Slide 17 11/26/2015
2013, General Electric Company. Proprietary information. All rights reserved.
 9E Combustion :
Advanced Extendor

2013, General Electric Company. Proprietary information. All rights reserved.

9E 3-series Advanced Extendor*
combustion system
Extended repair intervals for both DLN and Standard combustors to
32,000 Factor Fired Hours (FFH) Combustion Interval
Reduce wear
Leverage operating experience and most recent technology (DLN1+)
Advanced Extendor* changes compared to Extendor*
Components 9E 3-series 9E 3-series
standard combustor DLN combustor
Primary fuel nozzle Fully machined nozzle tip with wear Bolted, fully machined nozzle tip with wear
coating coating
Secondary fuel nozzle Not Applicable Flangeless architecture, grooved tip
Liner Thicker liner body, double leaf hula Nimonic 263 aft sleeve, double leaf hula
seal, spring loaded liner stops seal with 2-cool architecture, spring loaded
liner stops, class-C TBC
Flow sleeve Spring loaded liner stop Spring loaded liner stop
Transition piece Integral mount, full length class-C TBC, Integral mount, full length class-C TBC, cloth
cloth seals seals
Crossfire tubes Material change, wear coating Material change, wear coating

* Trademark of General Electric Company

9E Customer Presentation
2013, General Electric Company. Proprietary information. All rights reserved. Slide 19
9E - 32K Availability
Inspection Intervals - Replace intervals
factored fired hours (FFH) factored fired hours (FFH)
Standard combustor
Basic hardware 8,000 48,000
Extendor combustion system or 12,000 48,000
CL-Extendor combustion
system
Advanced Extendor combustion 32,000 64,000
system1
DLN1 combustor
Basic hardware 12,000 48,000
Extendor combustion system or 16,000 48,000
CL-Extendor combustion
system
Advanced Extendor combustion 32,000 64,000
system1
HGP2
9E PIP/AGP with redesigned 32,000 96,000
S2B
1 Replacement Intervals may be evaluated for longer replacement interval on a case-by-
case basis, depending on customer operating profile 20
2 Redesigned S2B must be applied. Not valid for HFO or syngas operation.
2012, General Electric Company. Proprietary information. All Rights Reserved. 11/26/2015
Field experience from units that have
completed their first 32,000
hour cycle

2013, General Electric Company. Proprietary information. All rights reserved.

32K Experience DLN1+ Combustion
Baseload
Location Model Cycle Hours Starts Duty NOx
DLN1+ Fleet experience (ppm)
39 Units 6B/7E/9E gas turbines California 6B CoGen 67,700 137 Baseload 7- 8
Introduced 2005 on 7E and 6B Texas 7E CoGen 67,100 226 Baseload 4.5
Texas 7E CoGen 67,100 121 Baseload 4.5
Fleet leader > 67,000 hours Texas 7E Simple 61,900 94 Variable 4.5
>1,000,000 cumulated hours Texas 6B CoGen 57,800 76 Baseload 3.7 - 4.0
California 6B CoGen 55,700 94 Baseload 7- 8
California 7EA CoGen 55,200 169 Baseload 3
Texas 7E Simple 52,600 62 Variable 4.5
Repairs Texas 7EA CoGen 52,600 104 Base/ Peak 4.5 - 6.5
Multiple 32K inspections conducted with California 7EA CoGen 51,600 210 Baseload 3
Texas 7EA CoGen 51,400 126 Base/ Peak 4.5 - 6.5
no major findings on parts Texas 7C CoGen 51,100 72 Baseload 4.5
California 7EA CoGen 48,800 123 Baseload 3
California 7EA CoGen 48,800 290 Baseload 3
California 7EA CoGen 43,400 271 Baseload 3
California 7EA CoGen 42,200 178 Baseload 3
Canada 7E CoGen 36,600 38 Baseload 4.5
California 7EA CoGen 32,700 111 Baseload 3
California 7EA CoGen 29,600 145 Baseload 3
Netherlands 6B Simple 29,500 70 Baseload 4.5
Oman 7EA Mech 26,600 5 Baseload 25
France 6B Simple 26,300 58 Baseload 6
France 6B Simple 24,800 31 Baseload 6
California 7EA Simple 20,000 209 Baseload 4?
Dubai 9E Simple 19,400 4 Baseload 25
Nevada 7EA Simple 12,200 574 Peak 4.5

Slide 22
2015, General Electric Company. Proprietary information. All rights reserved.
32K Experience STD & DLN1
Combustion Frame
7E.03
Country
NIGERIA
Extendor type (DLN/Standard)
DLN Extendor
Combustion
interval (FFH)
23500
Leveraging fleet experience 7E.03
7E.03
NIGERIA
NIGERIA
DLN Extendor
DLN Extendor
23500
23500
>750 6B/7E/9E gas turbines (~25% 9E.03 CHILE DLN Extendor 23800
6B.03 ITALY DLN Extendor 24000
fleet) having GE Contractual Services 6B.03 QATAR DLN Extendor 24000
Agreements 6B.03 QATAR DLN Extendor 24000
Repair experience 6B.03
6B.03
QATAR
QATAR
DLN Extendor
DLN Extendor
24000
24000
6B.03 QATAR DLN Extendor 24000
6B.03 QATAR DLN Extendor 24000
7E.03 AUSTRALIA DLN Extendor 24000
Commonality of parts between 9E.03
9E.03
CHILE
TURKEY
DLN Extendor
DLN Extendor
24000
24000
7E.03 and 9E.03 6B.03
6B.03
QATAR
QATAR
DLN Extendor
DLN Extendor
26000
26000
Same combustion hardware with 7E.03 USA DLN Extendor 27000
9E.03 UK DLN Extendor 32000
exception of the transition pieces 9E.03 GHANA Standard Combustor Extendor 17800
9E.03 GHANA Standard Combustor Extendor 19400
6B.03 QATAR Standard Combustor Extendor 24000
6B.03 QATAR Standard Combustor Extendor 24000
6B.03 TURKEY Standard Combustor Extendor 24000
6B.03 TURKEY Standard Combustor Extendor 24000
7E.03 MEXICO Standard Combustor Extendor 25300
6B.03 BRAZIL Standard Combustor Extendor 27000
6B.03 USA Standard Combustor Extendor 32000
Liner hula seal after 32K Liner with TBC class B, with 6B.03 CHAD Standard Combustor Extendor 32000
hours with minimal no spallation after 32K hours 7E.03 MEXICO Standard Combustor Extendor 32000
wear 6B.03 NIGERIA Standard Combustor Extendor 34000
7E.03 MEXICO Standard Combustor Extendor 35400
7E.03 MEXICO Standard Combustor Extendor 35700
Slide 23
2015, General Electric Company. Proprietary information. All rights reserved.
32K Experience 9E PIP Hot Gas Path
9E.03 HGP hardware after 30,400 hours of operation

S1B in good condition S2N in good condition S1S in good condition

Frame Country HGP config HGP intervals

9E.03 China PIP 30400
9E.03 China PIP 29700
9E.03 Australia PIP 29100
9E.03 South Africa PIP 26700
9E.03 Australia PIP 26600
9E.03 Australia PIP 26000

Slide 24
2015, General Electric Company. Proprietary information. All rights reserved.
32K Experience - 9E.03 AGP
Operating Hours to date
48,000 FFH Total fleet
17,000 FFH Fleet leader
Performance to date
Met or exceeded all performance metrics
32 AGP sets delivered
(includes 15 new units)
13x9E AGP in operation
5x in Middle East
4x South America
2x Africa
1x India
1x Eastern Europe

Just sold first set into APAC to Indonesia

2015, General Electric Company. Proprietary information. All rights reserved.

32K Experience-9E AGP DLN1+ Fleet
Leader
Installed and validated in the field
May 2013
Unit in continuous operation: 4k FFH
Borescope @ 4000 hours Dec 13
Growing Experience

Borescope @ 13000 hours Nov 14

Borescope @ 24000 hours Feb 16
HGP inspection @ 32000 hoursFeb17
13k FFH

13k FFH

Liner & Transition piece Liner center body S1B SS S2B Tip Shroud Cut tooth

Reliable Operations - Exceeding Performance

Slide 26
2015, General Electric Company. Proprietary information. All rights reserved.
Repair technology and predicting the
remaining life of components

2013, General Electric Company. Proprietary information. All rights reserved.

GE Repairs Non GE Parts
Deviation from Features applied per
Component Made by GRS shop
GE layout customer's request
6BS1N GE Full body TBC Abu Dhabi
6BS1B PSM DVC-TBC Singapore
6BS2B PSM Modified shroud Abu Dhabi
6BS1S Ansaldo Gen3 coating China
6BS2S Ansaldo Abu Dhabi
PFN GE Abu Dhabi
SFN GE Abu Dhabi
CL GE with Ansaldo mods Atypical liner stops Abu Dhabi
TP Ansaldo Wider wear inserts new TBC Abu Dhabi
Anti-oxidation/wear
XFT Ansaldo coating inside Abu Dhabi
Female XFT
Bullhorns Ansaldo Atypical wear covers Abu Dhabi

If it is a GE turbine, we want to be your first choice of repairs. Regardless of

whose components are being used, or who repaired them in the past.

28

2015, General Electric Company. Proprietary information. All rights reserved.

Voice Of Customer Fulfilling requests
Gen 3 coating on S1S
Location Date available
Greenville Now
Qinhuangdao Now

Full body TBC on S1N

Location Date available
Greenville Now
Abu Dhabi Now
Dammam Now

Full body TBC on S1B

Location Date available
Greenville Now
Singapore Now

29

2015, General Electric Company. Proprietary information. All rights reserved.

Gen 3+ Stage 1 Abradable Shroud
Benefit :
Better performance through improved clearances
between the stage 1 bucket and shroud
Benefits last through HGPI interval

Stage 1 shroud abradable

Product features : coating with pattern
Stage 1 shroud blocks coated with an abradable 9E Gas turbine Benefits*
coating on inner diameter surface Output (S/C) + 0.4%
Abradable material, chosen due to its resistance to
Heat Rate (S/C) - 0.4%
oxidation, abradability, erosion resistance, thermal
shock resistance and endurance 6B Gas turbine Benefits*
Abradable material will wear before bucket tip
Pattern on the surface, derived from F-class Output (S/C) + 0.7%
Shrouds are stripped and re-coated at each hot gas Heat Rate (S/C) - 0.7%
path outage
Abradable coating can be applied twice on same 7E Gas turbine Benefits*
shroud blocks Output (S/C) + 0.5%
New sets of shrouds or shrouds already with service
hours can be used Heat Rate (S/C) - 0.5%
*at ISO conditions, 100% methane
GE Repair & Refurbished Programs
GE Certified Refurbished Parts
Cost Effective alternative to buying new parts
Ready to ship in days, rather than weeks
4200+ parts shipped in 2014
1500+ orders in 2014
700+ types of parts available in inventory

Zero-Cycle Repair
Eliminate inventory carrying costs
Reduce cycle-time to zero
Covered under GE warranty until your
next operating interval or 1 year

Parts Acquisition
Reduce inventory carrying costs & parts disposal
Acquisition transaction can be completed under the following circumstances
1. Exchange for a New Part
2. Credit towards an upgrade or new spares
3. Cash or Credit for future purchases with GE

2015 General Electric Company - All rights reserved

The Future :
Lifesight

2013, General Electric Company. Proprietary information. All rights reserved.

LifeSight* creep sensors

Wire-free strain/creep sensor

Permanently affixed to part
surface
Indicates strain beneath
sensor
Each sensor is unique
integrated bar code
Material independent
Scalable
Ideal for process equipment
and harsh environments
33
* Trademark of General Electric Company.

2015, General Electric Company. Proprietary information. All rights reserved.

LifeSight* technology approach to blade creep

LifeSight Sensor New condition Creep condition

Server
Sensor data Sensor Data

Benefits may include:

Expand the value of existing gas turbine assets
Maintain assets more effectively through their
entire life cycle
Reduce unscheduled down time
Avoid unnecessary maintenance and repair costs
Extend component life and reduce inventory

34
* Trademark of General Electric Company.

2015, General Electric Company. Proprietary information. All rights reserved.

Conclusions

2013, General Electric Company. Proprietary information. All rights reserved.

Conclusions
GE has deep experience in interval extension

Much experience with CI and HGPI to and beyond 32K

Continuous research & development to bring you great

customer value and amazing breakthrough technology

9E Customer Presentation
2013, General Electric Company. Proprietary information. All rights reserved. Slide 36
 2013, General Electric Company. Proprietary information. All rights reserved.
9E AGP Increased performance
In combined cycle, approximately:
Combined cycle Output Heat rate Exhaust energy
9E 3-series PIP +2.0%2 -0.7%2 +0.8%2
1x1
9E 3-series Site specific evaluation
PIP = Performance Improvement Package
In simple cycle, approximately:
Simple cycle Rating Ship Output Heat rate Exhaust
energy
9E 3-series 128MW Since 2010 +1.3% -0.7% +0.5%
PIP
9E 3-series 127MW 2008-2009 +2.0% -0.8% +0.8%
PIP
9E 3-series 126MW 2003-2007 +4.2% -2.5% +0.3%
Architecture retains all current life estimates on parts and rotor
9E
2
3-series <126MW Before 2003 Unit specific evaluation
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.

9E Customer Presentation
Slide 38 11/26/2015
2013, General Electric Company. Proprietary information. All rights reserved.
Real time maintenance factors
Per GER-3620M
Automate data collection and calculations
Accurate accounting for operation
Factored fired hours and starts
Real-time maintenance factor
Visualization with instant feedback

Maintenance factor Inspection projections

Comb, HGP, Rotor Comb, HGP, Rotor

39

2015, General Electric Company. Proprietary information. All rights reserved.

Thank You

2013, General Electric Company. Proprietary information. All rights reserved.