Gt13e2 m Mxl Upgrades

GT13E2 M/MXL Upgrades Erol Morgan

July 2006

Agenda GT13E2 M/MXL M blading GT13E2 MXL GT13E2 M References New Blade 5 M Compressor Upgrade 2 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.


GT13E2 Turbine Upgrades GT13E2 Upgrades:

GT Power output and efficiency (ISO conditions)

y c n e i n c i i f e f s e a / t e r u c p n t i : u e o d r a e r w g o p p U T M G

GT13E2 M

z

Enhanced GT power output and efficiency versus extended inspection intervals

D i f f f f e er r e e n t n p o s i t t i i o o n i n g n p o s s i ib s l e b e

GT13E2 MXL GT13E2

GT13E2 XL

Baseline, GT13E2 ISO conditions, NG

24,000

32, 000

36,000

XL & MXL Upgrades: extend C-inspection intervals intervals

Hot gas path C insp. interval (EOH) 3

ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.


M Blading

Customized solutions e n c a r m o f r P e

M Blading

L i f e t i m e

GT13E2 M

z

Unchanged firing temperature

z

Clear performance increase

z

Inspection intervals unchanged

GT13E2 MXL

Whatever suits best

z

Lower temperature

z

Extended inspection intervals

z

SC performance slightly increased 5


M Blading Concept

# blades: 63 (all rows) z # vanes: 40/48/48/60/50 z SHS-A,B,C new heat shields z Shroud-less blade 1,2,3,4 z Cooled vane 3 z Blade 4 hollow design z Shrouded blade 5 (w/o damping bolt) z Blade 5 cast solid blade z All blades & vanes in CC-IN738LC z

TBC at Vane 1, 2 & Blade 1 Module 3 New stages 4,5

Module 2 New stages 2,3

Module 1 Modified stage 1 6


M Upgrades Commissioning & Operational Requirements

z

TIT changed – M Æ TIT increased – MXL Æ TIT decreased Re-Commissioning Procedure – Heat Balance – NOx mapping in the upper load range (70 % - 100%) • incl. pulsation measurement add. equipment / measurements: – Tk2, exhaust pressure, ∆p air inlet implementation of new ODC delivering more detailed information regarding operating mode of GT (e.g. frequency response, peak mode) EOH formula modified

z

approx. 4 - 5 days re-commissioning time required

z

z

z

z

12 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Summary

z z

z

Simplified design of M-blading components Thorough validation of new components under real operation conditions Design benefits from 10 years of operating experience with GT13E2 – > 1,300,000 OH

z z

Increased operation flexibility with M-technology M-blading technology is now standard for all new GT13E2 units since mid 2003



GT13E2 MXL

Power output & efficiency (ISO conditions)

Extended Lifetime Improved Availability z Reduced maintenance costs z

GT13E2 M + 6.1 MW / + 0.4 %

+ 1.0 MW / + 0.2 %

GT13E2

GT13E2 XL

GT13E2 MXL

+/- 0 MW / +/- 0 %

24’000

z z

32’000

36’000

Hot gas path insp. interval (EOH)

Extended inspection intervals (36 kEOH) Slightly increased SC performance (power output & efficiency) 15 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

GT13E2 MXL - Scope of Work

Modification of Turbine Vane Carrier on-site

z z

Zone 2 inner and outer shell with TBC

Improved stage 1 version A with TBC and optimized cooling New Vanes, Blades & Heat-Shields at Stage 2-5

Enlarged Axial Thrust Bearing

Operation Concept z Hot gas path C-inspection each 36’000 EOH z Slightly increased SC performance


GT13E2 M / MXL Modifications of Turbine Vane Carrier

GT13E2

New: z Vane row 2 direct cooling air feed from Plenum z 24 add. cool. holes in TVC z Old cooling holes plugged

New: z Cooled vane row 3 z 82 add. cooling holes in expansion bends

GT13E2 M / MXL 17


GT13E2 M / MXL Modifications of Turbine Vane Carrier Stage 1: z

SHSS A: no modification required for Power Plants equipped with 1st stage version A

Stage 2: z

Vane 2: (48 vanes instead of 60) — —

z

new fixation of vanes new cooling feed

SHSS B: new design of stator heat shield require intermediate rings

Stage 3: z

Vane 3: (48 vanes instead of 60) —

z

All rework can be done on site

new fixation of vanes

SHSS C: new design of stator heat shield require intermediate rings 18


GT13E2 MXL - Summary

GT13E2

24’000

GT13E2 MXL Years

C

24’000

36’000 1

2

3

C

C 4

24’000 36’000

5

6

7

C

24’000

C 8

9

C

36’000 10

11

C 12

Save 1 out of 3 C-inspections in a span of 9 years z z

GT13E2 MXL with 36’000 EOH C-inspection intervals Slightly increased SC performance (ISO / Baseload) – + 1.0 MW / + 0.2%

Boost your plant availability with 36’000 EOH C-inspection intervals 19 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Additional advantages of MXL

z

z z

Peak load application up to 16°C increased TIT allowed for continuous operation and counted with only factor 1.5 A-, B-inspection cycle 9,000 EOH (+ 3,000 EOH) Lower TIT compared to GT13E2 and GT13E2 XL – less thermal stress – reduced reconditioning efforts – direct positive impact on lifetime



GT13E2 M

Power output & efficiency (ISO conditions)

Improved performance Increased Power Output z Increased Efficiency z

GT13E2 M + 6.1 MW / + 0.4 %

+ 1.0 MW / + 0.2 %

GT13E2

GT13E2 XL

GT13E2 MXL

+/- 0 MW / +/- 0 %

24’000 z

32’000

36’000


Unchanged inspection intervals compared to GT13E2 22 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

GT13E2 M - Scope of Work

Site specific checks (e.g. Generator & Transformer capacity, etc.) necessary Modification of Turbine Vane Carrier on-site

z z

Zone 2 inner and outer shell with TBC

Improved stage 1 version A with TBC and optimized cooling New Vanes, Blades & Heat-Shields at Stage 2-5

Enlarged Axial Thrust Bearing

Operation Concept z Hot gas path C- inspection each 24’000 EOH z Increased performance 23


Performance compared to GT13E2 Performance [Power & Efficiency] Standard C-inspection

Upgrade

Standard C-inspection

+ 6.1 MW / + 0.4%

Maintenance Interval

24’000 EOH

Performance recovery during a standard C-inspection

24’000 EOH

24’000 EOH

Plant Lifetime

Increase power output and efficiency 24 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

GT13E2 M - Summary

GT13E2

24’000

C

24’000

C

24’000

C

24’000

C

GT13E2 M

24’000

C

24’000

C

24’000

C

24’000

C

1

3

4

6

7

9

10

Years

2

5

8

11

12

Increase performance while keeping insp. intervals unchanged z z

GT13E2 M with 24’000 EOH C-inspection intervals Increased performance (ISO / Baseload) – + 6.1 MW / + 0.4 %

Reduced costs per MWh due to increased power output and efficiency ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

25


GT13E2 M/MXL - Fleet Growths Status: January 2006 45 40

GT13E2 upgrade packages

35 30 25

s t i n 20 U

15

13 units in operation z 43 units sold z

Customized solutions for competitive markets.

y a d o t

Higher power output z Increased efficiency z Increased availability z Extended inspection intervals z

10 5 0 Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

2002

2003

2004

2005

2006

2007

2008

2009

ALSTOM’s implementation success: z 36 MXL configuration sold 5 M configurations sold z

GT13E2 M/MXL – higher performance at increased availability 27 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Status: February 2006

…GT13E2 Upgrade List (2) Plant

Unit

In Op

Zawia Zawia Benghazi Keppel Keppel Braemar Braemar Braemar Aluar Aluar Diemen 33 Lageweide Wagerup Wagerup Sohar Sohar Sohar Sohar

GT12 GT16 GT14 GT11 GT12 GT11 GT12 GT13 GT11 GT12 GT1 GT7 GT11 GT12 GT11 GT12 GT13 GT14

2Q/00 3Q/05 2Q/02 1Q/07 1Q/07 3Q/06 3Q/06 3Q/06 4Q/07 4Q/07 2Q/95 4Q/94 4Q/07 4Q/07 3Q/08 3Q/08 3Q/08 3Q/08

Current Set-up MXL MXL MXL MXL MXL MXL MXL MXL MXL MXL MXL MXL MXL MXL MXL MXL MXL MXL

Since 2006 Aug 2005 2006 Jan 2007 Jan 2007 July 2006 July 2006 July 2006 Nov 2007 Nov 2007 Oct 2008 Mar 2009 Oct 2007 Oct 2007 June 2008 June 2008 June 2008 June 2008

Last Set-up -

Original Set-up V96 MXL VA MXL MXL MXL MXL MXL MXL MXL V96 V96 MXL MXL MXL MXL MXL MXL 29


Status: February 2006

…GT13E2 Upgrade List (3) Plant

Unit

In Op

Afam Afam Afam Dubal Dubal Kwinana Deeside Dunkerque Dunkerque

GT11 GT12 GT13 GT1 GT2 GT1 GT1 GT1 GT2

2008 2008 2008 1Q/07 3Q/07 4Q/08 2Q/94

Current Set-up MXL MXL MXL MXL MXL MXL MXL MXL MXL

Since

Last Set-up

2008 2008 2008 March 2007 Sept 2007 Nov 2008 Oct 2006 -

Original Set-up MXL MXL MXL MXL MXL MXL V96 VA VA


GT13E2 M - Reference Kuala Langat First unit (GT#14) in Kuala Langat completed 1 st C-cycle Operation data Commercial base load operation, primarily on z natural gas 22,103 OH, 45 starts, 26,795 EOH by z March 31, 2005 Operation experience z 100% reliability of M-blading Good conditions allowed stretched C-cycle! z


GT13E2 M/MXL - Fleet Key Data Status: May 2006

43 units sold of which 13 units in commercial operation 5 M and 38 MXL (5 M and 8 MXL in operation) Total Fleet Data z First unit in operation since June 2002 z > 130’000 Equivalent Operating Hours z > 120’000 Operating Hours z > 580 Starts Fleet Leader completed C-cycle z More than 22,103 OH on gas – More than 26,795 EOH



New Blade 5 M for GT13E2 M & MXL New

z

z

z

z

Extensive testing showed potential for improvement Further Improvement of the existing Blade 5 Version M Achieves an even further improved turbine exit profile shape and exhaust diffusor characteristic Improves both power and efficiency of the GT13E2 M & MXL

Original New Tip

Mid

Original

New

Hub

Original 34 ©

ALSTOM (Switzerland)Ltd 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

New Blade 5 M for GT13E2 M & MXL z

New Blade 5 M NOT mixable with old Blade 5 M

z

No influence on duration of C-inspection

z

No other new hardware required Æ Only new Blade 5 M

z

Hardware available within standard delivery time

z

Unchanged Operation Concept

z

Unchanged EOH formula

z

Already implemented and validated in 2 units Status May 2006

– GT#14: S = 38; OH = 7’482; EOH = 9’813 – GT#15: S = 17; OH = 7’628; EOH = 8’190


Benefits of New Blade 5 M

z

Simple Cycle – Power + 1.1 MW compared to GT13E2 M/MXL – Efficiency + 0.2% (additive) compared to GT13E2 M/MXL – At ISO, Base Load, Gas Operation

z

Combined Cycle – Expected Power ~+ 0.5 MW compared to GT13E2 M/MXL – Expected Efficiency ~+ 0.1% (additive) compared to GT13E2 M/MXL – To be determined case per case


Benefits of New Blade 5 M GT13E2 M/MXL performance compared to GT13E2 Performance [Power & Efficiency] Upgrade

Standard C-inspection

M SC + 7.2 MW/ Standard + 0.6%

C-inspection Maintenance Interval

24’000 EOH

MXL (SC +2.1 MW/ +0.4%)

24’000 EOH


M 24’000 EOH (MXL 36’000 EOH)

Plant Lifetime


Benefits of GT13E2 M/MXL & New Blade 5 M Power output & efficiency (ISO/Base Load/ New & Clean) + 7.2 MW / + 0.6 % + 6.1 MW / + 0.4 %

+ 2.1 MW / +0.4 % + 1.0 MW / +0.2 %

GT13E2 M + New Blade 5M (2005) GT13E2 M (2003)

GT13E2 MXL + New Blade 5M (2005)

165.1 MW / 35.7 %

GT13E2 (1993) 24’000

GT13E2 MXL (2003)

36’000


Continuous improvement keeps your plant competitive 38 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Benefits of GT13E2 M

GT13E2

24’000

C

24’000

C

24’000

C

24’000

C

GT13E2 M

24’000

C

24’000

C

24’000

C

24’000

C

1

3

4

6

7

9

10

Years

2

5

8

11

12

z

Increase performance while keeping inspection intervals unchanged

z

GT13E2 M with 24’000 EOH C-inspection intervals and New Blade 5 M

z

Increased SC performance (ISO / Baseload) – + 7.2 MW / + 0.6 %

Reduced Costs of Electricity due to increased power output and efficiency 39 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Benefits of GT13E2 MXL

GT13E2

24’000

GT13E2 MXL Years

C

24’000

36’000 1

2

3

C

C 4

24’000 36’000

5

6

7

C

24’000

C 8

9

C

36’000 10

11

C 12

z

Save 1 out of 3 C-inspections in a span of 9 years

z

GT13E2 MXL with 36’000 EOH C-inspection intervals and New Blade 5 M

z

Slightly increased SC performance (ISO / Baseload) – + 2.1 MW / + 0.4%

Boost your plant availability with 36’000 EOH C-inspection intervals 40 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.


Product Information

GT13E2 MXL Compressor Upgrade VELE

VELA

VIGV

Flow

Restaggered Rows 42 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

GT13E2 Compressor Compressor Upgrade z

Increased mass flow by stagger angle adjustment on leading compressor rows

z

Development with the proven tools and methods already used for earlier compressor upgrades

Stagger angle adjustment Stagger angle change

Compressor row Stages 1 to 5

Open

Between 0.6° and 1.5°

Stagger Angle Engine Axis

Output increase through approx. 4% mass flow increase 43 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Product Information – Degree of re-stagger angle reduced at every row in flow direction – Material & coating unchanged i.e. ST12TNIE + Coating (VIGV, Blades 1-5 & Vanes 1-4) – Upgrade released for GT13E2 MXL (combination with Maximum Continuous Load (MCL) operation to be checked due to possible capacity limitations such as Geno, Transformer, etc.) – Other upgrade applications (e.g. GT13E2, GT13E2 XL and GT13E2 M) are being investigated


Product Information Compressor Upgrade results in:

z

¾ ¾ ¾ ¾ ¾

~3-4 % increased Air Mass flow Increased power output of ~5 MW SC (CC details must be calculated case by case) + 0.2% Efficiency (additive) No extension of C-insp duration All casings & assembly material unchanged, only blades and vanes replaced with re-staggered ones

Compressor Upgrade settings are specific for each unit

z ¾ ¾

Site specific re-commissioning settings are required Adaptation of operation concept (e.g. VIGV)

Already implemented and validated in one unit

z ¾

GT#13 more than S = 18, OH = 5’746, EOH = 6’695 45 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Benefits of Compressor Upgrade Performance compared to GT13E2 MXL SC Performance [Power & Efficiency] Standard C-inspection

Upgrade

Standard C-inspection SC +5 MW /+0.2%

Maintenance Interval

36’000 EOH


36’000 EOH

36’000 EOH

Plant Lifetime

Increase power output 46 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Benefits of GT13E2 MXL Upgrade Power output & efficiency (SC / ISO / Base Load / New & Clean / Gas) + 7,1 MW / +0.6 %

New Blade 5 M + Compressor Upgrade (2005)

+ 6.1 MW / + 0.4 %

+ 6 MW / +0.4 %

GT13E2 M (2003) + 1.0 MW / +0.2 % 165.1 MW / 35.7 %

GT13E2 (1993) 24’000

GT13E2 XL

32’000

GT13E2 MXL (2003)

36’000


Reduced Cost of Electricity due to increased power output 47 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Benefits of GT13E2 MXL Upgrade with Compressor Upgrade

GT13E2

24’000

GT13E2 MXL Years

z z z

C

24’000

36’000 1

2

3

C

C 4

24’000 36’000

5

6

7

C

24’000

C 8

9

C

36’000 10

11

C 12

Save 1 out of 3 C-inspections in a span of 9 years GT13E2 MXL with 36’000 EOH C-inspection intervals and Compressor Upgrade Increased SC performance (ISO / Baseload / Gas / New & Clean) – + 6 – 7.1 MW / + 0.4 – 0.6% compared to GT13E2 (depending on B5 M version)

Boost your plant availability with 36’000 EOH C-inspection intervals Extremely reduced Cost of Electricity due to increased power output 48 ALSTOM (Switzerland)Ltd © 2001Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Gt13e2 m Mxl Upgrades

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