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Program Overview
Program Description
The asset value of natural-gas-fired gas turbines, especially in combined-cycle plants, is on the rise, driven by
their inherent efficiency, emissions, operational characteristics, broader market fit with a forecasted affordable
fuel supply, and complementary role covering load swings such as those from intermittent renewables. Cycling
and high-temperature operations adversely affect combustion turbine component life, as well as plant reliability
and availability. The risks associated with hot section durability, compressor failures, rotor cracks, and
combustor dynamics must be cost-effectively managed. Improved operational flexibility, in areas such as dry
low-NOx (DLN) combustor turndown and plant startup, would help plants address load demands. Beyond the
gas turbine, combined cycles have a broader range of concerns, including selective catalytic reduction (SCR)
catalyst deactivation, steam turbine-generator reliability, plant performance degradation, faster startups, and
load response to better accommodate intermittent power sources from wind and solar.
The Electric Power Research Institutes (EPRIs) Combustion Turbine (CT) and Combined-Cycle (CC) O&M
program (Program 79) provides comprehensive resources to address the operation and maintenance (O&M)
needs of conventional and advanced CTs, related emissions control equipment, and combined-cycle rotating
equipment.
Research Value
Members of this program can use the R&D to manage equipment risks through root cause analyses and
engineered solutions; reduce life-cycle costs through repair technology and improved component design; and
enhance overall plant operational flexibility by reducing combustor issues, mitigating cycling damage, and
increasing performance. Specifically, members can:
Manage major O&M risks not typically covered by OEM and third-party service agreements
Improve O&M costs through in-depth understanding of O&M issues at the model/sub-model-specific level,
and significantly reduce overall life-cycle costs without increasing failure risks
Gain expert assessments of original equipment manufacturer (OEM) and independent offerings in
addition to O&M recommendations
Benefit from O&M experience and resources through collaborative interactions
Approach
Program activities address monitoring and inspection, repair technique improvement, component life prediction,
and plant O&M management tools. Model-specific design features are directly addressed in product
development. Members use the R&D for:
Risk management (early detection, root cause, and solutions) R&D uses in-depth studies of high-risk
component issues to identify root cause failure mechanisms and to develop and demonstrate
corrective/damage mitigation solutions.
Research into O&M improvements (life prediction, component design, and repair) research provides
model-specific repair, procurement, and damage-tracking guidelines for hot-section, combustor, and
compressor components.
Operational flexibility (capacity, performance, combustion dynamics, and emissions) R&D produces
techniques for improving interrelated machine operational characteristics, such as tuning and turndown of
DLN systems and mitigating cycling damage.
Plant productivity support tools and training provide O&M cost analysis software, maintenance guidance,
and overhaul planning tools for different CT models and select combined-cycle equipment, as well as
training courses for applying EPRI products.
p. 1
Accomplishments
EPRIs Combustion Turbine and Combined-Cycle O&M program has provided high-quality technical evaluations
and products to support better operations and maintenance for more than 30 years, including:
Summary of Projects
Project Number
Project Title
Description
P79.001
P79.002
P79.003
Operational Flexibility:
Capacity, Performance,
Combustion Dynamics and
Emissions
P79.004
p. 2
P79.001 Risk Management: Early Detection, Root Cause and Solutions (067357)
Key Research Question
The effective operation of complex, tightly integrated combustion turbines (CTs) requires astute monitoring,
regular inspection, understanding of the critical damage mechanisms and root causes, and engineered solutions
to maintain high availability and reliability. This requirement is particularly true for advanced machines, in which
cascading failures can cause more than $10 million in equipment damage. Similar concerns exist for highbackpressure steam turbines (STs) and electric generators used in combined cycles. These types of major
equipment risks usually are not addressed by service agreements and only are partially covered by insurance.
Approach
This project helps members with early detection of incipient damage, as well as in-depth understanding of
damage mechanisms and the underlying root causes driving accelerated deterioration and increased risk of
outright failure.
Cost-effective risk management needs to be tailored to the specific machine model and issue in the
compressor, combustion system, or hot section. This project develops and validates inspection and
monitoring techniques, collects field experience, characterizes component design features, develops
detailed engineering models, and evaluates damage mitigation and corrective design measures.
In the compressor, work is aimed at understanding and mitigating the impacts of extensive rubbing,
erosion/corrosion, deposit buildup, foreign object damage (FOD), stall/flutter flow excitations, and
clashing contributing to blade and stator failures.
In the combustion system, techniques are being developed to detect dry low-NOx burner instabilities,
leading to fuel nozzle failure and downstream hardware damage.
In the turbine hot section and rotor, material testing and design analyses are used to assess risks from
high-temperature creep/oxidation, thermo-mechanical fatigue cracking, and reduced fracture
toughness/embrittlement of costly superalloy and CrMoV components. Detailed component failure and
stress analysis is often covered in supplemental projects.
In the electric generator and bottoming steam cycle, risks from end winding failures or fatigue cracking of
the long-last steam turbine blades are addressed at the root cause analysis level, and corrective
measures are proven by plant testing and experience.
Impact
Mitigate damage by using improved monitoring and inspection techniques to provide advance notice to
CT owners of abnormal conditions and the opportunity to take countermeasures.
Cost-effectively reduce the risk of high-impact failures by understanding damage mechanisms and their
root causes, and adjusting maintenance accordingly.
Develop, evaluate, and demonstrate engineered solutions, including design modifications that effectively
address the root causes.
Determine the useful economic life of high-valued components on a sound, independent engineering
basis.
p. 3
2012 Products
Planned
Completion Date
Product Type
01/31/12
Technical
Update
01/31/12
Technical
Update
12/31/12
Technical
Update
Planned
Completion Date
Product Type
12/31/13
Technical
Update
12/31/13
Technical
Update
12/31/13
Technical
Update
P79.002 O&M Improvements: Life Prediction, Component Design and Repair (067358)
Key Research Question
Combustion turbines require extensive repair and refurbishment at predetermined intervals due to very hightemperature operation. Superalloy blades, vanes, and combustion hardware depend on effective repairs to
achieve their stated economic life. Due to the high cost of repairs (for example, an F-class first-stage blade
replacement can cost $2 to 4 million per row), the need for in-depth guidance is critical. Fallout rates (i.e., for
parts deemed not repairable at the prescribed strip/recoat interval) have exceeded 50% for certain hightemperature combustion turbine models. For mature designs, extending run intervals may be possible with
design and material testing qualification. A new generation of low-conductivity thermal barrier coatings (low-k
TBC) potentially offers extended operating life or enhanced performance benefits. Compressor O&M issues
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include rubbing, tip cracking, foreign object damage, erosion, corrosion, aerodynamic stall/flutter, and surge.
Repair service providers and aftermarket parts suppliers may offer competitive alternatives to the original
equipment supplier for innovative design/repair solutions.
Approach
Effective management of compressor, combustion, and hot-section life-cycle costs focuses on three elements:
optimizing the maintenance interval, extending service life by repair, and obtaining lower-cost/longer-life
replacement hardware. EPRI offers R&D supporting all three areas:
Damage tracking guidance is based on extensive durability analyses that provide objective estimations of
creep, oxidation, and thermal mechanical fatigue damage to specific components locations as a function
of operation. EPRI maintains and continues to expand a series of CT component repair guidelines
covering combustion/hot-section hardware for 50/60-Hz conventional and advanced models. Currently
available model-specific volumes cover: GE 7B, 6B, 7FA, 9FA, 7E/EA, 9E; Siemens-Westinghouse
W501A-D, W501D/D5A, W501F, V84.2, V94.2, V84.3A, V94.3A; Alstom 11N2, GT24, GT26; and
Mitsubishi M501F, M701F.
A series of procurement guidelines for replacement of superalloy components provide technical criteria
for nondestructive examination, acceptable coatings, qualification/approval of master heats, dimensional
conformity, manufacturing and heat treatment, metallurgical requirements, and quality assurance. Also
included is repair technology development using novel welding, brazing, and geometry modifications.
For the compressor, EPRI develops and translates into plant-oriented guidance the following areas:
understanding the influence of inlet guide vane scheduling and aerodynamic conditions on blade
dynamics, surface treatments for erosion/corrosion resistance, and methods to address attachment
fretting and airfoil impact damage. To facilitate the application of guidelines, EPRI routinely issues reports
surveying the capabilities of repair shops and aftermarket parts suppliers.
Impact
Reduce fallout from repair cycles and possibly extend overall economic life using the damage-tracking
guidance to optimize maintenance intervals.
Achieve cost savings from competent, cost-effective refurbishment services made possible by the repair
guidelines.
Reduce replacement hardware costs by procuring more durable designs and competitive bidding.
For those machines covered by extended service agreements, EPRI products play a role in overseeing
quality repairs, establishing objective run/scrap criteria, and factoring in technology improvements into the
overall lifecycle management.
p. 5
2012 Products
Planned
Completion Date
Product Type
12/31/12
Technical
Update
12/31/12
Technical
Update
12/31/12
Technical
Update
Advanced Repair Development and Qualification: A new generation of lowconductivity thermal barrier coatings (TBC) enable the components to operate
at lower metal temperatures or increased turbine inlet temperature. Coupon
testing to establish data critical to quality parameters and performance
characteristics will be performed, leading to field testing. Additional repair
development also is planned for qualifying new high-strength brazing
compositions and for evaluating the effectiveness of alternative heat treatments
used for reconditioning superalloy components.
12/31/12
Technical
Update
12/31/12
Technical
Update
Planned
Completion Date
Product Type
12/31/13
Technical
Update
12/31/13
Technical
Update
12/31/13
Technical
Update
p. 6
Planned
Completion Date
Product Type
12/31/13
Technical
Update
Improve O&M of conventional and dry low-NOx combustors by using model-specific guidance.
Understand the limitations of fuel interchangeability and possible issues with broader fuel supply
sourcing.
Boost electricity production through extensive background information on capacity and storage
enhancement techniques.
Improve overall operational flexibility by introducing field-validated plant modifications.
p. 7
2012 Products
Planned
Completion Date
Product Type
12/31/12
Technical
Update
12/31/12
Technical
Update
12/31/12
Technical
Update
Planned
Completion Date
Product Type
12/31/12
Technical
Update
12/31/13
Technical
Update
12/31/13
Technical
Update
p. 8
A series of O&M guidelines addressing gas turbine island and select combined-cycle equipment that
includes axial compressor performance, predictive maintenance implementation, selective catalytic
reduction (SCR) systems, and segmented feed pumps.
The INTURB CT owners directory, which facilitates contacting peers to share information about modelspecific reliability. The database contains information on more than 5,400 sites.
A series of software packages, called the Gas Turbine Overhaul Plan (GTOP), that provide model-specific
detailed disassembly, inspection, and re-assembly task breakdowns. Current GTOP models include the
GE Frame 7B, 6B, 5, 7FA, 9FA; Siemens-Westinghouse W501AA-D, V84.2; and Alstom GT11N/N1, N2,
11D, with others planned.
The CTCC O&M Cost Analyzer, which enables overall cost assessment of maintenance strategies,
including service agreements, operational cost impacts, and self-maintenance options.
Training courses and workshops that help members apply the program products.
Impact
Manage outages more effectively by using a detailed, model-specific overhaul plan with task-by-task
breakdown structure.
Benchmark and develop best practices by applying equipment O&M guidelines.
Develop detailed modeling and costs for examining operational impacts and changes in maintenance
strategies using the CTCC O&M Analyzer.
Identify and troubleshoot a range of equipment problems by employing the plant equipment guidelines.
Product Type
12/31/12
Software
12/31/12
Technical
Update
p. 9
Planned
Completion Date
Product Type
Tech Transfer: Training Courses: Training courses and webcasts support the
technology transfer of program products. A Hot Section Life Management
course supports the implementation of repair guidelines, damage tracking
module, and procurement guidelines for the replacement of superalloy parts.
Other courses and webcasts support the maintenance of dry, low-emissions
combustors, including tuning procedures, rotor life evaluation, and software
orientation for the use of the CTCC O&M Cost Analyzer and GTOP products
12/31/12
Technical
Resource
type are included in each task. The software platform is Microsoft Project , and
the task database is transferrable to other planning software. Maintenance
procedures and inspection forms can be linked to create a complete overhaul
record.
12/31/12
Software
Planned
Completion Date
Product Type
CTCC O&M Cost Analyzer: Update Version: Software to estimate O&M costs
for simple-cycle and combined cycle plants.
12/31/13
Software
12/31/13
Technical
Update
12/31/13
Technical
Resource
12/31/13
Software
p. 10
Supplemental Projects
Gas Turbine Rotor Life (066745)
Background, Objectives, and New Learnings
Gas turbines (GTs) are used in simple-cycle configuration to supply peaking power generation service. These
machines acquire many cycles but relatively few hours of service. They also are idled for extended periods and
thus are subject to corrosion from condensation. GTs in combined-cycle configuration can be deployed in either
daily cycling or more baseloaded service. As such, combined-cycle rotor life may be governed by hours of
operation or a combination of hours and starts.
GT rotors typically are inspected during hot gas path and major maintenance intervals when casing covers are
removed. The original equipment manufacturer (OEM) typically will assist in these inspections and will judge
whether the rotor is suitable for continued service. Sections of the rotor may be deemed nonserviceable after
100,000 to 250,000 hours or 2500 to 5000 starts. The impacts of an extended outage for a rotor rebuild may be
mitigated by using a pooled spare rotorif one is available.
OEMs have been notifying GT owners that rotors used on high-hours machines should be shipped off-site and
disassembled for extensive inspection. Pending inspection results, a limited operation extension may be
granted. For high-starts machines, the recommendation often is to retire them without inspection. The
engineering basis for rotor operational extension or retirement is unclear, with little field experiential data to
establish a quantifiable risk.
Project Approach and Summary
The overall work scope is structured around two major tasks: Rotor Life Inspection and Evaluation Guidelines,
and Model-Specific Component Evaluation. Life prediction procedures are developed for the particular rotor
design and material, with particular emphasis on rim-blade interface, bolt holes, and center bores or alternatively
welded rotors. The component focus can be adjusted to suit a specific machine operating mode, anticipated
issues, or inspection results. Where available, destructive mechanical testing of retired components may be
included to further quantify material degradation.
Benefits
`Results from this project will provide GT owners with procedures and technical information to objectively
evaluate the condition of their GT rotors. Rotor rebuild/replacement, along with the associated outage, is
estimated to exceed $6 million per machine.
p. 11
Reducing Life Cycle Costs for Gas Turbine Hot Section Components (064708)
Background, Objectives, and New Learnings
Gas turbine (GT) combustion parts and the downstream hot section vanes and blades routinely are inspected,
refurbished, and replaced. The cost of extensive maintenance associated with the gas turbine life-cycle can
exceed the initial equipment cost by as much as a factor of three. Each model type has design-specific features
that require specialized knowledge to effectively manage machine O&M. For instance, each turbine model has
unique blade designs made of superalloy thin-walled castings requiring complex internal cooling, oxidation, and
thermal barrier coatings to survive in a high-temperature environment.
Faced with such specialized hardware, gas turbine owners seek to reduce O&M expenses without increasing
risk by optimizing all the activities and costs related to the inspect/repair/replace life cycle. To effectively support
this goal requires model-specific, objective knowledge of component design, repair, and degradation
mechanisms experienced in their own units.
To meet this basic need, EPRI has developed core competencies in hot-section design analysis and repair
procedures and applied them to different CT models. EPRI collaborative projects supported by the
owner/operators of 50- and 60Hz models have created an extensive knowledge base addressing widely used
conventional and advanced engines.
Project Approach and Summary
The general approach for each model-specific project is optimize the hot-section economic life cycle at either
the plant or fleet level according to how the parts inventory is managed. Tools are developed to manage critical
aspects of the life cycle: repair procedures, accumulated damage tracking, and replacement/upgrade
procurement guidelines. Component testing may be included if suitable specimens are available.
Benefits
The technical knowledge base provided by this project enables participants to more effectively manage gas
turbine hot-section life-cycle costs and the maintenance-related technical issues. The technical issues are
equally relevant to both OEM and independent O&M providers. If the knowledge base is used as part of an
overall maintenance strategy, participants can realize cost savings of 25% or more. These savings can range
from $500,000 for conventional D/E-Class machines to as much as $3.2 million for advanced F-Class machines
per hot gas path, depending on model and operating duty cycle.
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