Compressor/Rotor Update

Matt Ferslew, Lead Product Service Engineer

Ross Sacharow, Product Service Compressor Technical Leader

7F USERS CONFERENCE | MAY 9-13, 2016 | ORLANDO, FLORIDA

Imagination at work
© 2016, General Electric Company. Proprietary information. All rights reserved.
GE Power

© 2016, General Electric Company.

GE Proprietary Information - The information contained in this document is
General Electric Company (GE) proprietary information. It is the property of GE
and shall not be used, disclosed to others or reproduced without the express
written consent of GE, including, but without limitation, in the creation,
manufacture, development, or derivation of any repairs, modifications, spare
parts, or configuration changes or to obtain government or regulatory approval
to do so, if consent is given for reproduction in whole or in part, this notice and
the notice set forth on each page of this document shall appear in any such
reproduction in whole or in part. The information contained in this document may
also be controlled by the US export control laws. Unauthorized export or
re-export is prohibited.

All relative statements are with respect to GE technology unless otherwise noted. 2

© 2016, General Electric Company. Proprietary information. All rights reserved.

Enhanced Compressor
Fleet Update

© 2016, General Electric Company. Proprietary information. All rights reserved.

F-class enhanced compressor
7FA/7FB fleet 7FA/7FB Flt Ldrs: 54.7K/1.9K
• 667+ units in operation, install, or committed 7FA/B PKG-5 PKG-4 PKG-3 PKG-2

• Building experience … +8.4MM hours/+124K sts. Operation 50 136 162 152

Installation 0 2 1 1
–Hours leader: Pkg-4 54,600+
Committed 2 17 7 3
–Starts leader: Pkg-2 1,920+
New shipped 134
–Pkg-5 leaders: 51,400+ hours
Total 186 1551 170 156
1,635+ starts

9FA/9FB fleet 9FA/9FB Flt Ldrs: 43.3K/1.2K

• 318+ units in operation, install, or committed 9FA/B PKG-5 PKG-4 PKG-3 PKG-2
• Building experience … +1.7MM hours/+25.1k sts. Operation 21 103 7 30

– Hours leader: Pkg-4 43,300+ Installation 0 1 0 0

Committed 5 26 0 1
– Starts leader: Pkg-4 1,150+
New shipped 124
– Pkg-5 leaders: 39,300+ hours
Total 150 1301 7 31
645+ starts

6FA flared 6FA Flt Ldrs: 35.7K/272

• 52+ units in operation, install, or committed 6FA PKG-5 PKG-4 PKG-3 PKG-2
• First unit installed 2Q ‘11 Operation 5 3 3 0

– Hours leader: Pkg-3 35,600+ Installation 0 0 0 0

Committed 0 1 0 0
– Starts leader: Pkg-5 272+
New shipped 40
– Pkg-5 leaders: 14,850+ hours
272+ starts Total 45 4 3 0

As of 23-MAR-2016 4
1Includes aft stator only
© 2016, General Electric Company. Proprietary information. All rights reserved.
Updated Water Wash
Recommendations

© 2016, General Electric Company. Proprietary information. All rights reserved.

Online Water Wash (OnWW) recommendations

GE has studied effects of online 1 3

2
Water Wash on corrosion, erosion,

Degradation/FH
and performance
• Increasing OnWW frequency
(OnWW_hours/FH) …
– Decreases corrosion
– Decreases performance losses
– Increases erosion

• Online Water Wash recommendations

updated per PSIB 20151211A Onww_hours/FH
– For units with Gen I WW (updated per TIL 1323)
1Recommended interval for units with Gen I WW and
and non-enhanced R0 blades:
5 minutes per 48 fired hours non-enhanced R0 blades; less degradation recovery
2Minimum recommended washing for corrosion mitigation
– For all other configurations:
F (site conditions, filtration, Offline WW practices, etc.)
15 minutes per 48 fired hours
3Maximum recommended washing for erosion mitigation

F (inlet humidity, WW generation, etc.)

Recommended frequency of online Water Wash is 15 minutes per 48 fired hours

© 2016, General Electric Company. Proprietary information. All rights reserved.

OnWW study overview

Corrected Power
Performance
• Analyzed degradation for all monitored F-class fleet
• Calculated by comparing performance after
offline Water Wash n to performance before offline
Water Wash n + 1
• Examined unit output, compressor efficiency, Time
OffWW n OffWW
and compressor flow … Normalized by fired hours n+1

Erosion
• Observed erosion levels on 40 F-class units
• Developed regression model based on Water Wash,
humidity, inlet conditioning, age, operation, etc.
• Largest factor for increased erosion levels was
online Water Washing for > 15 minutes/24 FH

Corrosion
• Previous RCAs/studies showing that utilization
of OnWW reduces impact of corrosion
• Best mitigated by following PSIB 20130813A but with
modified OnWW recommendation per PSIB 20151211A
• Units in highly corrosive environments reference
GEK 116269 for recommended filtration systems

© 2016, General Electric Company. Proprietary information. All rights reserved.

S17 Bushing Distress

© 2016, General Electric Company. Proprietary information. All rights reserved.

Mechanically attached bushing experience
‘04 - 2 tack welds
with washer
‘07 - Eliminated washer
and increased bushing
size, 1 tack weld
TIL 1850 published
to address
Tack weld
Welded bolt bushing and shroud
distress examples

‘08 - Eliminated tack

welding; staked bolt
‘11 - Tightened shroud
gap allowance from
0.030” to 0.014”
‘16 - Introducing new
bushing made of
L605 material
Staked bolt bushing and
9
Stake locations shroud distress examples
© 2016, General Electric Company. Proprietary information. All rights reserved.
Root cause of staked bolt S17 wear
• Wear out - relative motion between bushing and shroud caused by flow induced
vibration
• Loose fit of shroud preventing best possible impact damping
• Bushing material is softer, “sacrificial” material
• Shrouds loaded rotationally causing bias to aft of bushing
• Cold ambient, part load, low Cm/U operation accelerates wear

Wear pattern shows that the shroud is Bushing wear can allow enough shroud
loaded rotationally against the LE airfoil movement to make contact and wear
and TE bushing against the inner barrel

Bolt Bushing

Shroud

LE Airfoil
TE

S17 shroud schematics depicting

locations of wear 10

© 2016, General Electric Company. Proprietary information. All rights reserved.

Recommendations
During annual borescope inspections and casings off opportunities, monitor
the shrouded S17s for evidence of recessed or protruding bushings, airfoil tip
or shroud wear, and shroud damage or misalignment
Even with more significant wear, this phenomenon does not usually result in
forced outages and if monitored can be addressed during planned outages
If wear or damage seen, S17 assemblies should be replaced with the latest configuration

Minor wear: More significant wear:

Airfoil tip curl Severe airfoil wear/misalignment
Single bushing minor protrusion Multiple/severe bushing protrusion/wear
Shroud damage/misalignment
Rubs between shroud and CW17

11

© 2016, General Electric Company. Proprietary information. All rights reserved.

Stator Pinning

© 2016, General Electric Company. Proprietary information. All rights reserved.

Non-OEM stator pinning experience
Heavy fretting and sheared pins

Airfoil clashing and liberation

Multiple field events from pinning has resulted in decreased reliability

13

© 2016, General Electric Company. Proprietary information. All rights reserved.

Flat Slot Bottom
Cracking Update

© 2016, General Electric Company. Proprietary information. All rights reserved.

GE experience on TIL-1971r1 unit inspections
TIL-1971 borescope inspection
results (at ~1700 starts)
TIL-1971 service center TIL-1971 service center
inspection at ~1375 starts inspection at ~1700 starts

• Inspection results have shown TIL-1971 units with indications requiring part
replacement within a starts range of approximately 1,400 to ~2,500 actual starts
• Initial inspection recommended at 800-1,200 starts to obtain indication size
and determine operational safety

15

© 2016, General Electric Company. Proprietary information. All rights reserved.

GE experience on TIL-1972r1 unit inspections

TIL-1972 optical TIL-1972 borescope

microscope inspection inspection TIL-1972 borescope
(at ~3,095 actual starts) (at ~1,991 starts) inspection
(at 2,696 starts)

TIL-1972 optical
microscope inspection
(at 3,077 starts)

• Inspection results have shown TIL-1972 units with indications requiring part
replacement within a starts range of approximately 2,400 to ~5,000 actual starts
• Initial inspection recommended at 1,700-2,200 starts to obtain indication size
and determine operational safety

16

© 2016, General Electric Company. Proprietary information. All rights reserved.

Flat slot bottom compressor wheel inspections
3rd party inspection does not allow for follow-up analysis of results

Inspection Data recording Modeling Safer operation

Re-inspection
Methods for Flexibility … capture
Enhanced for interval … Frequency
accuracy and stage-to-stage
configurations of recurring
completeness variation
inspections

Projected analytical
Experienced … Models built off service limit …
>50 inspections inspection history … Allows for
in 2H ‘15 updated regularly adequate time for
rotor planning

Highly recommend use of GE LES resources to get full benefit of inspection

GE’s rotor design and LES teams have developed inspections,
data recording methods, and models that yield the most accurate
inspection results, ensuring safe operation

17

© 2016, General Electric Company. Proprietary information. All rights reserved.

 F-Class Rotor
Service Findings

© 2016, General Electric Company. Proprietary information. All rights reserved.

F-Class rotor service findings
FSS dovetail indications CW bolt face fillet indication TW cooling slot indication

TW balance
CW rabbet and fillet indications/damage TW lockwire tab indication stake crack

Surface corrosion and indications Marriage joint rabbet indication

19

© 2016, General Electric Company. Proprietary information. All rights reserved.

 Appendix

© 2016, General Electric Company. Proprietary information. All rights reserved.

Flared enhanced experience

Flared 6F Flared 7F Flared 9F

Pkg. 4 includes aft stator only

88% of flared 7F have installed or committed to installing

an enhanced compressor package

21

© 2016, General Electric Company. Proprietary information. All rights reserved.

Unflared enhanced experience

Aft
Unflared Pkg-5 Pkg-4 Pkg-3 stators
only

7FA unflared 4 14 9 10

9FA unflared 3 1 1 4

Total 7 15 10 14

• Pkg. 2 tested and removed from field

• Gaining operational experience …
+433K hours/+8300 starts

Unflared 7F

22

© 2016, General Electric Company. Proprietary information. All rights reserved.

7FA flared enhanced compressor
Targeted outage durations R0 biscuit modification is field option in packages 2-5
1 Day 1 Long weekend 1 Hot Gas Path1 Major inspection 1 Major inspection 1

Package 1 Package 2 Package 3 Package 4 Package 5

• 26º IGV start • 24º IGV start • STARSS Sftwr* • STARSS Sftwr* • STARSS Sftwr*
• IGV • IGV • IGV

1 Estimates • R0 with dvtl. coat • R0 w/ dvtl. coat • R0 with dvtl. coat • R0 with dvtl. coat
only;
actual durations may •
vary due to outage
• S0-S5 • S0-S5 • S0-S5
circumstances
• S5 load dams • S5 load dams • S5 load dams
• S6-S8 optional • S6-S8 optional • S6-S8 optional
•
• S14-16 • S14-16
Anticipated implementation R = Rotor blade
S = Stator vane
Package 1: Interim, near-term application • R1-R52
• R6-R8 optional
Package 2: Interim, available short outage
• Enhanced clocking
Package 3: Majority of F-technology fleet … 6, 7, and 9
2 R1-R3 with dvtl. coating
Package 4: Customers with aft stator wear R1-R5 undercut

Package 5: Fleet rotor rebuilds and new unit production since ‘09

23
*Trademark of General Electric Company.
© 2016, General Electric Company. Proprietary information. All rights reserved.
7FA unflared enhanced compressor
Targeted outage durations R0 biscuit modification is field option in packages 3-5
Hot Gas Path1 Major inspection1 Major inspection 1 Major inspection 1 Major inspection 1
Package 3 Package 4 Package 5A Package 5B Package 5C
• R0 with dvtl. coating • R0 with dvtl. coating • R0 with dvtl. coating • R0 with dvtl. coating • R0 with dvtl. coating
• S0-S4 vanes • S0-S4 vanes • S0-S4 vanes • S0-S4 vanes • S0-S4 vanes
• S0-S4 rings • S0-S4 rings • S0-S4 rings • S0-S4 rings • S0-S4 rings
• S5-S8 optional • S5-S8 optional • S5-S8 optional • S5-S8 optional • S5-S8 optional
R=Rotor blade • S14-16
S=Stator vane • S14-16 optional • S14-16 optional • R1-R52
• R6-R8 optional
• R1-R52 • R1-R52
• Upgrade to robust
• R6-R8 optional • R6-R8 optional back-end rotor
Anticipated implementation • Upgrade to robust
back-end rotor
Package 3: Majority of 7F/9F fleet
1Estimates only … Actual
Package 4: FA.02/FA.03 (unflared) durations may vary due
with aft stator wear to outage circumstances

Package 5A: Fleet rotor rebuilds – FA.03 (unflared) only 2R1-R3 with dvtl. coating R1-R5 undercut
• No Package 1 or 2
Package 5B: Fleet rotor rebuilds – FA.02 only • No S5 load dams
• All pkgs. require cambered IGVs
Package 5C: Fleet rotor rebuilds – F.01 and FA.01 only
24

© 2016, General Electric Company. Proprietary information. All rights reserved.

Enhanced compressor overview
Risk Enhancement
R0 LE root crack Retune, large fillet, LSP, full airfoil shot peening
R0 SS dvtl. crack Dovetail undercut, dovetail coating
R0 tip crack Squealer tip, full airfoil shot peening, open clearances
R1 tip crack S0/S1 NUVs, full airfoil shot peening, open clearances
Retune, full airfoil shot peening, stainless steel rings, shorter
FWD stator tip loss
rings (other: squealer tip, S0/S1 NUVs)
Fwd stator clashing Retune, increased axial gap
Full airfoil shot peening, stainless steel rings, shorter rings,
S0 TE cracks
STARSS*
S5 circumferential loading S5 load dams, full airfoil shot peening
Aft stator rocking Big foot mod, enhanced clocking for pkg. 5 (other: squealer tip)
Rotating stall STARSS*
Aft end rubs Open clearances, squealer tip

25
*Trademark of General Electric Company.
© 2016, General Electric Company. Proprietary information. All rights reserved.
Typical F-class CR findings
FSS dovetail slot indications:
• Mechanism - Low cycle fatigue combined
with high cycle fatigue (blade loading)
• Driver: Blade pull load and blade modal
transient response
• Preventive service - install newer F-class R0 dovetail slot indications
style R0 blades
• Repair available – No repair
CW rabbet fillet indications:
• Mechanism - Low cycle fatigue (starts)
and high cycle fatigue Low radius rabbet fillet indications
• Driver: Transient stresses and vibrations
• Repair available – Yes
Surface corrosion and web indications:
• Mechanism – Parent alloy corrosion/thermal
and mechanical stresses
• Driver: Ambient conditions and lower
utilization rates
• Preventive service – Primer/GECC1 coatings
Surface corrosion/web indications
• Repair available – Yes

26

© 2016, General Electric Company. Proprietary information. All rights reserved.

Typical F-class CR findings
CW rabbet interference loss/damage:
• Mechanism – Cyclic start wear
and assembly/disassembly
• Driver: Transient condition relative motion
• Repair available – Yes (patch/coatings) Low Radius and High Radius Rabbets
CW 15 bolt face undercut indications
• Mechanism – Low cycle fatigue combined
with high cycle fatigue
• Driver: Transient initiation with high
cycle fatigue propagation
• Repair available – Yes
MJ Rabbet Indication
• Mechanism – Low cycle fatigue/edge of CW15 Bolt Face Indications
contact combined with high cycle fatigue
• Driver: edge of contact loading and vibrations
• Repair available – Yes

MJ rabbet indications 27

© 2016, General Electric Company. Proprietary information. All rights reserved.

Typical F-class TR findings
Square cooling slot indications
• Mechanism - Low cycle fatigue (starts)
and hold-time fatigue
• Driver: Mechanical stress from bucket loading
+ adverse edge condition + oxidation
• Preventive service – BPP
• Repair available – No repair
(wheel replacement if found)
Lockwire tab indications Cooling Slot Indications
• Mechanism - Low cycle fatigue (starts)
and hold-time fatigue
• Driver: Mechanical stress from bucket
loading + hold-time fatigue propagation
• Repair available – Yes
Lockwire tab Indications
Balance weight groove stakes
indications
• Mechanism – Low cycle fatigue (starts) and
hold-time fatigue
• Driver: stake plus mechanical+thermal stress
• Repair available – Yes
Balance Weight Groove Stake Crack
28

© 2016, General Electric Company. Proprietary information. All rights reserved.

© 2016, General Electric Company. Proprietary information. All rights reserved.