e GE Energy Services

Gas Turbine Performance

Enhancement
Update

Juan E Kessra
October, 2000
Gas Turbine Uprates

Sourcebook
Code Frame Size Model Type Uprate
FT1A MS3002 A thru G Advanced Technology Uprate
FT1U MS3002 A thru G MS3002 “A” to “F” Uprate
FT1D MS3002 H&J MS3002J Advanced Technology
Uprate
FT2C MS5002 A&B MS5002C Advanced Technology
Uprate
FT2R/FT2S MS5002 A, B & C Uprate to MS5002D
FT3L/FT3M MS5001 A thru P Advanced Technology Uprate
FT3F MS5001 A thru M and R 16 to 17 Stage Compressor Uprate
FT4L MS6001 A&B Uprate to MS6001B
FT5X MS7001 A&B Uprate With 7001EA Turbine Parts
FT5Y MS7001E C, E & EA Uprate to 2035F
FT5L MS7001F F, FA Uprate to MS7001FA+
-- All Models All High Flow Inlet Guide Vanes
FT6X MS9001 B Uprate With MS9001E Turbine Parts
FT6C MS9001E E (MS9141 & 9151) Uprate to 2020F/1104C
FT6Z MS9001F F Uprate to MS9001FA
 Gas Turbine Advanced Technology Uprate
Shipments Through 1997
7/1E 7/1E 9/1E
3/2 (A thru G) 3/2J 5/1R 5/1P 5/2 7/1 202F/ 2035F/ 9/1 2055F/ Total
Adv Tech Adv Tech Adv Tech Adv Tech Adv Tech B to E 1104C 1112C B to E 1124C # Uprates
Year (FT1A) (FT1D) (FT3L) (FT3M) (FT2C) (FT5X) (FT5C) (FT5Y) (FT6X) (FT6Y) Shipped

1984 - - 4 2 - - - - - - 6
85 - - 5 5 - - - - - - 10
86 6 - - 4 - - 2 - - - 12
87 3 - 3 12 1 - - - - - 19
88 5 - 4 9 4 1 - - - - 23
89 3 - 2 5 2 - - - - - 12
90 4 - 5 24 27 1 - - 1 - 61
91 2 - 6 12 12 1 3 - 1 - 37
92 3 8 1 19 1 2 - - 1 - 35
93 2 - - 13 4 2 4 - 1 1 27
94 1 1 - 7 - 3 4 5 1 - 22
95 - 2 - 4 - 3 2 8 - 1 20
96 4 - - 6 1 - - 7 - - 18
97 4 5 1 4 7 - - 10 - 1 21

Total 37 16 31 126 59 13 15 30 4 3 334

CM&U Performance Enhancement
Update 1999 GTUA
3/2H & J 5/1N & P 5/2 B & C 6/1B 7/1 B&E 9/1 B & E
HPP Brush Seal X X X X X X
#2 Bearing Brush Seal - - X - X X
Stage 2&3 Honeycomb X X X X X X
Shroud Seals
Stage 1 Shroud Seals X X X X X X
Inner Stage Brush Seal - X - X X X
One Piece Stage 1 Shroud - - - - - X
86º IGV with GTD 450 - X X X X X
GTD 222 Stage 2&3 Nozzles - - - X X X
Lean Head End Liners X X X X - -
Load Gear Speed Increase - X - X - -
MS5002D Uprate - - X - - -
MS5002D S1N in MS5002C - - X - - -
Tilted Control Curves with X X X X X X
Adv Tech Uprate
2055F Uprate - - - X X X
Extender Combustion - X X X X X
Upgrade
9% Steam Augmentation - - - - X X

X = Available Now
High-Pressure Packing/Inner Barrel

• Brush Seals
- Minimize Air Leakage
- Tolerant of Misalignments
- More Durable than Labyrinth
Seals
Inner Barrel

Current Production

Labyrinth Seal

Brush Seal
Aft Stub Shaft
Brush Seal Trend Data
7EA and 9E Brush Seal Trend Data

6B, 7E/EA and 9E HPP Brush Seal Trend Data

200

150 7E Trend
Across Seal (°F)

9E Trend
Delta Temp

100 7EA Trend

6B Trend

50

0
0 200 400 600
Number of Days Since Brush Seal
Installation
 Gas Turbine Advanced Seals

• Rub Tolerant Rotating Seals Provide Sustained

Performance Gains That Increase Over Time

Brush Seal
X Break-In

Advanced Seals
Performance

Increasing Differential
X+
X

Traditional Seals
No. 2 Bearing Brush Seals

• Minimize Air Leakage to Bearing Cavity

Air Seal
• Reduce Oil Mist

Cross-Section Bearing Housing

Brush Seal
 Frame 7 Advanced Technology Uprate
Interstage Brush Seals

First Aft
First Aft Second Forward Wheelspace Second Forward
Wheelspace Wheelspace Wheelspace

Brush Seal
Element

1-2 Turbine 1-2 Turbine

Wheel Spacer Wheel Spacer

Current Stage 2 Nozzle Design Proposed Stage 2 Nozzle Design

 MS6001B Uprate Field Test Results

Stage 1 Bucket
• Bulk Temperature Substantially
Cooler than Current Bucket

• Temperature Gradients Less

Severe Than Expected

• Coating Oxidation, LCF and Material DS GTD111

Creep Life Exceed Requirements Coating
Cooling
GT33IN+
3 Smooth
13 Turbulated
Perimeter/Meanline
Shank Hollow Core

Bucket Exceeds 3 HGPI Life Requirement

GE Proprietary - 1999
Honeycomb Shroud Blocks

• Honeycomb Shrouds
- Reduces Leakage
- Greater Rub Tolerance
• Requires Buckets with
Cutter Teeth

Honeycomb Material
Bucket Shroud Cutter Teeth - Frame 6

Cutter Teeth

Stage 2 Stage 3

Rotation
 Frame 7 Advanced Technology Uprate
MS7001EA First Stage Shroud
• New Material and Improved Sealing
• Improved Performance (Pending Audit)
Cloth Spline Seals

W-Seal

“Bus Bar”
Seal

Side View Pumpkin

Teeth

Bottom View Bottom

View
Current Shroud Uprate Shroud
Frame 7 Advanced Technology Uprate
MS7001EA First Stage Shroud
• New Intersegment Seal Design
Filter Cloth

Current Spline Seal Cloth Spline Seal

 Frame 5 Advanced Technology Uprate
• Improved Sealing and Coatings for Performance

Cloth Spline Seals

W-Seal

“Bus Bar”
Seal

Abradable Coating
Side View
Pumpkin
Teeth

Bottom View Bottom

View
Current Shroud Uprate Shroud
Turbine Section
One-Piece Stage 1 Shroud
• Replace Two-Piece Design
• Haynes HR-120
• Reduced Cooling Required
- Increase in Output
- Decrease in Heat Rate
Cloth Spline Seals

W-Seal

w
High-Flow Inlet Guide Vane Uprate
Performance Comparison
Design Improvements With GTD-450
High-Flow IGV Designs

• Improved Airfoil Geometry for Higher 1.8

Power
• New Material for High Corrosion 1.6
Resistance Without Coating

Alternating Stress Amplitude

1.4
• Variable Airfoil % Thickness to
Maintain Reliability With New GTD 450

(Ratio to AISI 403)

1.2
Geometry
• Greater Fatigue Resistance Properties 1.0
AISI 403
0.8
Higher
Performance 0.6
Airfoil

0.4
11% T/C
0.2
6% T/C
0
0 10 20 30 40 50 60 70
Variable
Thickness Mean Stress (ksi)
Airfoil
MS6001B GTD-222 Stage 2 Nozzle

• Improved Creep Resistance

• Improved Nozzle Vane
Cooling
- Redesigned Core Plug
• Improved Performance
- Reduced Cooling Air Flow Downstream
Deflection
MS6001B Stage 2 & 3 Nozzles

• Creep Resistant GTD-222 Material

• Aluminide Coating on Stage 2
- Increased High Temperature Oxidation
Resistance
GTD-222 vs. FSX-414
Nozzle Creep Deflection Comparison
1.2

1.0
Relative Deflection

FSX-414
0.8

0.6

0.4

0.2
GTD-222
0
10 20 30 40 50 60
Time - KHR
 MS6001B GTD-222 Stage 2 Nozzle

Reduced Cooling Flow

Controlled by Tuning Pin

Performance Improvement
• Output +1.0%
• Heat Rate - 0.4%
Louvered Low NOx Lean Head End
Combustion Liners
PG 5341 Gas Turbine
Lean Head End - Low NOx Louvered Liners

150

140
NOx PPMVD - @ 15% O2

130

120

110

2
1001. Original 51P Turbine
2. Estimated Uprate to 51P/NT Advanced 1
90 Technology Uprate
3. Estimated Uprate with “Low NOx”
Combustion Liners 3
80
0 20 40 60 80 100 F
Ambient Air Temperature
C
-18 -7 4 16 27 38
MS3 & MS5 Lean Head End (LHE)
Combustion Liners

32J Simple Cycle

32F Simple Cycle 10%
10% No
Noxx Reduction
Reduction
32G Simple Cycle No
No CO
CO Guarantee
Guarantee for
for Same
Same Rating
Rating
52B Simple Cycle*
52C Simple Cycle*
52D Simple Cycle
51P Simple Cycle OR
32C Ryan Cycle
32J Regen Cycle
52B Regen Cycle No
No No
Noxx Increase
Increase
No
No CO
CO Guarantee
Guarantee forfor A/T
A/T Uprate
Uprate
Until
Until Field
Field Verification
Verification Tests
Tests Run
Run

* Field Verification Tests Complete and

Nox Reduction Guarantee 30%
MS6001B 5133 RPM Load Gear

• Increase Turbine Speed

• Performance Improvements
60 Hz 50Hz
Output +0.82% +0.60%
Heat Rate - 0.11% -0.07%

Model 674
MS5001P Performance at 5,355 RPM
MS6001B MS5002B

Combine
Two Proven
Technologies

MS5002D
MS5002B Uprates With Tilted Control Curves

High Ambient
5/2D Titled Curve
Percent Design Output

5/2C

5/2B

Compressor Inlet Temperature (Deg. F)

MS6001B Uprate Requirements for 2055ºF Tf

• Stage 1 Bucket -- DS GTD-111 With Perimeter Cooling and

New Airfoil
• Stage 2 Bucket -- Advanced 7-hole Cooling IN-738
• Stage 3 Bucket -- Material Change From U-500 to IN-738
• Stage 1 Nozzle -- Improved Cooling, Chordal Hinge and
Spline Seals
• Stage 2, 3 Nozzle -- GTD-222 With Reduced Cooling on Stage 2
• Stage 1 Shroud -- Material Change to HR-120 and Improved
Cloth Seals
• All Nimonic-263 Transition Piece
• Class “B” TBC Coated Combustion Liners
• Extendor™ Combustion Upgrade
Frame 7 Advanced Technology Uprate
Firing Temperature Increase to 2055ºF
• Features & Benefits
- Increased Output (+4.9 to 18.0%)
- Decreased Heat Rate (-1.5 to -3.8%)
- Improved Cooling Features
- Improved Materials
Extendor TM
Extendor TM HR-120
HR-120 Stage
Stage11 Honeycomb
Honeycomb Seal
Seal
Combustion
CombustionSystem
System Improved
ImprovedCooling
Cooling Shrouds
Shrouds with
with Stage-2/3 Shrouds
Stage-2/3 Shrouds
(optional
(optional Stage-1
Stage-1Nozzle
Nozzle Improved
Improved Seals
Seals (optional)
(optional)

TBC
TBCCoated
Coated
Combustion
Combustion
Liners GTD-222
GTD-222
Liners
Stage-2
Stage-2 Nozzle
Nozzle

GTD-222
GTD-222
Stage-3
Stage-3 Nozzle
Nozzle
Brush
Brush Seals
Seals
(optional)
(optional)
BLE/DS
BLE/DS GTD-111
GTD-111
Stage-1 Bucket
Stage-1 Bucket
Nimonic
Nimonic 263
263 Transition
Transition Stage
Stage22 Buckets
Buckets Stage
Stage33 Buckets
Buckets
Pieces
Pieces (TBC
(TBCCoated)
Coated) with
with Improved
Improved with
withImproved
Improved
Cooling
Cooling Scalloped
ScallopedShrouds
Shrouds
 MS3/2, 5/1, and 5/2 Exhaust Diffuser
Modifications to Go to 1050F Exhaust Limit
MS7E and MS9E Exhaust Frame
Cooling Circuit Uprate
Proposed Exhaust Frame Cooling Circuit Modification
Use 100Hp Blower Inlet On
blowers Exhaust Frame
(2 parallel)
Orifice
Turbine
Shell
Possibly
Remove
Load
Add Tunnel Cover
Insulation

Plug Some
Holes In
Inner Barrel
MS7001EA 9% Steam Injection

• Standard and MNQC Combustor Only

• 9% of Compressor Air Flow is 55.45 pps Steam
Flow in Wrapper
• Expected Output Improvement of 29.6%
• (77.8 MW to 100.8 MW)
• Expected Heat Rate Improvement of 8.1%
• (10664 to 9800 Btu/kw-hr)
• Parts Life Impact on Maintenance Schedules
Has Been Established
• Total Plant Solition/package
Gas Turbine Advanced Seals/Uprates
MS3002J Uprate Program Performance Increases
OutPut Heat Rate
High Flow IGV’s (Pre 1978) (FT1F) +2.20% -0.50%
MS3002J Adv Tech Uprate (FT1D) +3.70% -0.30%
Stage 2 Shroud Honeycomb Seal (FS2T) +0.40% -0.40%
HPP Brush Seal (FS2V) +0.70% -0.50%
Stage 1 Shroud Cloth Seal (FS2Y) +0.50% -0.50%

Total +7.50% -2.20%

Gas Turbine Advanced Seals/Uprates
MS5002B Uprate Program Performance Increases
OutPut Heat Rate
GTD 450 IGV’s (Pre 1978/post 1978) +3.8/+1.690% -0.1/-0.3%
(FT2A/FT2B)
86º IGV Setting +0.20% --
MS5002 “B” to “C” Adv Tech Uprate (FT2C) +7.0% --
MS5002 “C” to “D” Adv Tech Uprate (FT2S) +13.0% -1.0%
Stage 2 Shroud Honeycomb Seal (FS2T) +0.40% -0.40%
HPP Brush Seal (FS2V) +0.50% -0.40%
#2 Bearing Brush Seal (FS2X) +0.20% -0.10%
Stage 1 Shroud Cloth Seals (FS2Y) +0.50% -0.50%
5/2D S1N in 5/2C (FT2T)
(Included in “C” to “D” Uprate) +2.40% -1.0%
Total “B” to “C” +12.6% -2.5%
Total “C” to “D” +16.4% -2.5%
Total “B” to “D” +28.6% -2.5%
Gas Turbine Advanced Seals/Uprates
MS5001P Uprate Program Performance Increases
OutPut Heat Rate
Advanced Tech Update (FT3M) +6.0% -1.0%
GTD 450 IGV’s (Pre 1978/post 1978) +3.9%/1.9% -0.2/0.5%
(FT3B/FT3C)
86º IGV’s +0.2% +0.1%
High Pressure Pkg Brush Seals (FS2V) +0.6% -0.4%
Stage 2 Shroud Honeycomb Seals (FS2T) +0.4% -0.4%
5355 RPM Turbine Speed (FT3X) +3.0% at High Ambients)
Stage 1 Shroud Cloth Seals (FS2Y) +0.5% -0.5%
Inner Stage Brush Seal (FS2Z) +1.0% -0.5%

Total +15.6/13.6% -5.5%

-2.9/3.2%
Generic Uprate Study for the MS5001N, P Turbines
Source Applicable
Description Book Turbines % Output % Heat Rate

Turbine Modifications
5001P New-Tech (P N/T) Uprate FT3M MS5001N, P 6.0 -3.3

Advanced Seals ALL NUMBERS ARE

HPP Brush Seal FS2V MS5001L-R 0.6 -0.4
S2 Shroud (S2S) Honeycomb FS2T cutter teeth bkts 0.4 -0.4
S1 Shroud (S1S) Block Seals FS2Y MS5001L-R 0.5 -0.5
S2 Interstage (S2D) Brush Seal FS2Z New-Tech S2N Only 1.0 -0.5
Abraidable coating on S1S FS6A MS5001L-R not rated not rated

IGVs ESTIMATES ONLY

Reduce Camber (RC), 85 degrees FT3C MS5001N, P, pre 1978 3.7 -0.3
Reduce Camber (RC), 86 degrees FT3C MS5001N, P, pre 1978 3.9 -0.2
Reduce Camber (RC), 85 degrees FT3C MS5001P, post 1978 1.7 -0.6
Reduce Camber (RC), 86 degrees FT3C MS5001P, post 1978 1.9 -0.5

NOx Reduction, Perf #'s for 59 F day

Low NOx Liner FR1B MS5001LA-R 0.0 0.0
Water Injection, 3 pps, 100 F FG1A, FR1T MS5001N, P 3.9 1.9
Steam Injection, 4.3 pps, 600 F FG1B MS5001N, P 5.4 -3.2
Less Diluent on More Humid Days, Low NOx Liner reduces the amount of diluent needed.

Power Augmentation, Perf #'s for a 59 F day, 60% humidity

5% steam Injection, 13.2 pps, 600 F FJ3B MS5001N, P 16.5 -8.8
Evaporative Cooler, .37 pps FD5A MS5001A-R 2.6 -1.0

Sample Uprate Packages New and Clean Performance Estimate kW btu/kW*hr

MS5001P post 1978 (Original Rating) 0.0 0.0 25350 12020
MS5001P, 85 degree RC IGV's and HPP brush seal 2.3 -1.0 25936 11900
MS5001P N/T Uprate with 86 deg RC IGV's, HPP BS, and S1S Adv Seals 9.2 -4.6 27684 11461
above with S2D brush seal 10.3 -5.1 27960 11404
P N/T with All Adv Seals and 86 IGV's and with 3 pps of Water Injection 15.1 -3.7 29167 11574
P N/T with All Adv Seals and 86 IGV's and with 4.3 pps of Steam Injection 16.7 -8.5 29588 10995
P N/T with All Adv Seals and 86 IGV's and with 13.2 pps of Steam Injection 29.0 -13.8 32704 10359

GE Proprietary - 1999
Gas Turbine Advanced Seals/Uprates
MS6001B Uprate Program Performance Increases
OutPut Heat Rate
Stage 2 Nozzle/GTD-222 (FS1P) +1.00% -0.40%
Stage 2 Shroud Honeycomb Seals (FS2T) +0.35% -0.35%
Stage 3 Shroud Honeycomb Seals (FS2U) +0.25% -0.25%
GTD-450 IGV’s (Pre 1987) (FT4C) +1.50% -0.30%
86º IGV Setting (FT4M) +0.40% +0.20%
Turbine Speed Increase (FP4D)* +0.82% -0.11%
Improved Cool Stg 1 Nozzle (FS2J) -- --
Stage 1 Shroud Cloth Seals (FS2Y) +1.0% -0.4%
Inner Stage Packing Brush Seal (FS2Z) +1.0% -0.50%
HP Packing Brush Seals (FS2V) +0.75% -0.50%
Firing Temp Uprate Package (FT4L) +2.50% -0.20%

Total +8.55% -2.80%

* 60 Hz GE-Supplied Load Gears
Gas Turbine Advanced Seals/Uprates
MS7001 Uprate Program Performance Increases
OutPut Heat Rate
Increase From 2020F to 2055F Firing Temp 4.1% -0.10%
& Control Modifications (FT5Q)
GTD-450 IGV’s (84º Setting) 1.5% -0.30%
(Pre 1987 Units) (FT5B)
Additional 2º IGV (84º) (B&E Units Only) 0.4% +0.20%
(FS5H)
GTD-222 S2N (FS1P) 0.8% -0.30%
Stage 1 Shroud Cloth Seal (FS2Y) 0.5% -0.50%
S2B Shrouds With Honeycomb Seals (FS2T) 0.35% -0.35%
S3B Shrouds With Honeycomb Seals (FS2V) 0.15% -0.15%
HPP Brush Seals (FS2V) 1.0% -0.50%
#2 Bearing Brush Seals (FS2X) 0.30% -0.20%
Inner Stage Packing Brush Seal (FS2Z) +1.00% -0.50%

Total +10.0% -3.0%

Note: All performance estimates apply at ISO conditions
 Gas Turbine Advanced Seals/Uprates
MS9001E Uprate Program Performance Increases
OutPut Heat Rate
Increase in Firing Temperature & 3.5% -0.27%
Control Modifications (FT6Y)
Bore Plugs (FS2S) 0.4%-0.20%
C450 IGV (84°) (pre 1987 production) (FT6B) 1.5% -0.20%
Additional 2° IGV (86°) (FT6F) 0.4% +0.20%
Rotated S3B (FS4D) 0.3%-0.28%
GTD-222 S2N (FS1P) 1.0%-0.40%
Stage 1 Shroud Cloth Seals (FS2Y) 0.4% -0.2%
S2B Shrouds with Honeycomb Seals (FS2T) 0.35% -0.35%
S3 Shrouds with Honeycomb Seals (FS2V) 0.15% -0.15%
Innerstage Packing Brush Seals (FS2Z) +1.0% -0.50%
HPP Brush Seal (FS2V) 1.0%-0.50%
#2 Bearing Brush Seals (FS2Y) 0.3% -0.50%
Stage 1 Single Piece Shroud 0.9% -0.40%
(for units already at 2055°F) (FS2Y)
Total 11.2%-3.45%
Nox Emission Levels at 15% O2 (ppmvd)
 Nox Emission Levels at 15% O2 (ppmvd)
H2O/Steam Inj Dry Low Nox
Single Shaft Units Dry
Firing Temp. Gas Dist Gas Dist*
Model F/C Gas Dist. (FG1A/FG1B) (FG1C/FG1F) (FG2F) (FG2F)
MS5001P 1730/943 128 195 25 42 20 65
MS5001P-N/T 1765/963 142 211 25 42 20 65

MS6001B 2020/1104 148 267 25 42 25**** 42

MS7001B 1840/1004 109 165 25 42 - -

MS7001B Option 3 1965/1074 124 191 25 42 25 42
MS7001B Option 4 2020/1104 132 205 25 42 25 42
MS7001EA 2020/1104 154 228 25 42 25**** 42

MS9001B 1940/1060 109 165 42 65 - -

MS9001B Option 3 1965/1074 124 191 42 65 25 -
MS9001B Option 4 2020/1104 132 205 42 65 25 -
MS9001E 2020/1104 157 235 42 65 25 42
MS9001E 2055/1124 132 241 42 65 25 42

Two Shaft Units*** Dry H2O/Steam Inj. Dry Low Nox

Firing Temp.
Model F/C S.C.** R.C.** S.C. R.C. S.C. R.C.
MS3002F 1575/1625/857/885 115 201 42 50 - 42
MS3002J 1730/943 128 217 42 50 25 33
MS3002J-N/T 1770/966 140 236 42 50 25 33

MS5002 1700/927 125 220 42 50 25 65

MS5002B-N/T 1770/966 137 255 42 50 25 65
Extendor Combustion Systems

Designs in Place:
• 5/1 and 5/2 STD
• 6B STD and 6B DLN-1
• 7EA STD, 7EA DLN-1, and 7E MNQC
• 7EA Robust*
• 7EA MNQC Cyclic
• 9E STD and 9E DLN-1

*Hardware in Inventory - Need Prototype Site

 Extendor Experience

Interval (HRS)
System No. Units Current Extendor Fleet Leader Fired Hrs

MS6001B Standard 30 16000 24000 Hoescht Celanese 20,000+

MS6001B DLN 3 12000 24000 GE Plastics 16,000+
MS7001E/EA Standard 24 8000 24000 Anchorage 12,000+
MS7001E/EA MNQC 1 8000 24000 Exxon Baton 13,000+
MS7001 DLN-1 0 8000 24000 -- --
MS9001E Standard 9 8000 24000 ESB 24,000
MS9001E DN-1 8 8000 24000 Thames Power 14,000+
Complete Systems 75
Transition Piece Only 14
Total Extendor Systems 89
Extendor Summary

• All 6B Designs Progressing to 24,000 Hour Goal.

Side Seal Marginal and Will Require Design
Improvement.

• 7E Extendor I Failed to Meet Program Objective.

• 7E Extendor II Attained 12,000 Hours and
Progressing but Liner to Crossfire Tube Interface,
Inner Floating Seals and Fuel Nozzle to Liner
Interface May Preclude Reaching 24,000 Hours.
• Extendor IIR Will Address These Areas.

• All 9E Designs Progressing to 24,000 Hour Total.