6b users conference field design...

June 23 – 26, 2014 | Fort Myers, FloridaJune 23 – 26, 2014 | Fort Myers, Florida

Imagination at work.

6B Users Conference

Field Design ModificationsPaul Daiber, 6B/7EA/9E/5/3 Application Engineer

GE 6B Field Modification Activity

3© 2014 General Electric Company.Proprietary Information. All Rights Reserved.

2014 6B Users Conference

Repurposing your E-class units

Effectively three markets• Cogeneration… 6000+ hours• Peakers… 2500 hours• Capacity… <500 hours

Finding answers• Waiting for outages?• New technology?• Steam vs MegaWatts?



Recent 6B Field Design Modifications by GE

Since 2006 GE has provided parts for about 1000 6B field design modifications

Add Low BTU fuel capability

DLN1, DLN1+, IBH

Add Propane Fuel Capability

Remove Liquid Fuel

Extendor CLEX Combustion Mod

Extendor all-Nimonic Transition Pieces

Replacement special fuel nozzles

High Load Premix Transfer,

Sliding P2 for Low Fuel Pressure

False Start Drain Valve replacement

Flame Detector Upgrade, Sight Tube Mod

Flex Hose Pigtails for Gas Fuel and AA

Liquid Fuel Check Valve Upgrade

Add Steam Injection for NOx Control

Add Water Injection for NOx Control

Remove Steam NOx

Anti-Condensation Mod to Flame Detectors

Gas Chromatograph for Low BTU DLN



Recent 6B Field Design Modifications by GE

2042 F to 2084 F Tfire Uprate

HR120 shroud blocks, cloth seals, abraidable coating

Perimeter Cooled S1 Buckets

S2 Nozzle Brush Seal, S2N airbox mod

Advance Aero S3 Bucket, Nozzle

S2 Buckets to new design

Special Coatings on Buckets

6581B PIP kit (hot gas path parts)

Flange-to-Flange Turbine Replacement

Accessory Gearbox Replacement

Compressor Discharge Casing

Cast Nodular Iron Turbine Shell

Loadgear, 5163 rpm (two teeth different from 5100)

Rotor Replacement, Rotor Spare, Rotor Inspection and Life Extension

Reduced Camber IGV's, Rack and Ring

IGV Actuator Relocation, 86 degree IGV's

Shrouded S17/EGV's

Stator Shim Pins per the TIL 1562

Stator Vane kits, Compressor Blade kits

R1 Blades per TIL 1382

Dry Diaphragm Load Coupling, TIL 1709



Recent 6B Field Design Modifications by GEExhaust Frame

Replacement Exhaust Plenum

Inlet Silencer

HPP Brush Seal / Counterbore Covers

Dry Diaphragm Accessory Coupling

Special Instrumentation

Battery Charger Upgrade and Batteries

Torque Converter

Lube Oil Conditioner per TIL 1528-3

ATEX (Europe) AC Lube Oil Pump

Fire Protection System Upgrade

Dead Bus Closure Controls Mod

Mag Pickups for Over Speed (Remove Bolt)

SSS Starting Clutch to replace Jaw Clutch and not stop to restart

SSS Loadgear Clutch for Synchronous Condenser Operation

Combined Cycle Mod

Aero Style Exhaust Thermocouples / Shield

Updated Humidity Sensor

TIL-1566 Fuel Leak Detection / Shut Down

Replacement of Hydraulic Ratchet Pump

Replacement of Hydraulic Accumulator

Compressor Drive Auto Peak Control

Maintenance and Operation Manuals



Recent Inquiries for 6B Design Changes

6B Design Change Requests During the Last 6 Months – North America

Replacement Loadgear – S644 (mounted on generator I-beams) due to oil leaks

Replacement to S664 Loadgear due to problems identified during outage

Occasional Steam-Aug by modifying Steam-NOx system

Compressor Rotor due to Corrosion from no filters and very frequent WW

Extended CI Intervals on a Gas-Only BLFN without AA

DLN High Load Premix Transfer

Rotor Life Extension Evaluation

DLN1+

32k for steam-NOx 6B's

IGV Actuator Relocation

Exhaust Plenum

Maintenance and Operation Manuals (Digital)



Recent Inquiries for 6B Design Changes

6B Design Change Requests During the Last 6 Months - International

Lower Grade Ash-bearing fuel

Add liquid fuel to a DLN turbine

Stainless Steel Purge Piping

DLN for a very low fuel pressure site

6581B PIP

2042 to 2084 F Tfire Uprate

Conversion to Ethanol Fuel

Remove Refinery Gas Capability

DLN for compressor drive 6B

32k CI and HGPI

Exhaust Stack Extension for CEMS

Compressor Casings

Exhaust Plenum

Inlet Bleed Heat for DLN turndown

New Rotor due to End of Life

DLN/Tfire/32k

2114 F Tfire and Fogger

Ratchet Mod for Faster Start

Remove Liquid Fuel Capability

Add propane capability to liquid fuel only 6B

Adv Aero S3B

Shroud Blocks and Other Capital Parts

Replace the Diesel Engine with a Motor

Add Gas Fuel Capability

GE CM&U Feedback



6B DLN 1+ (Thailand)

Guarantee: 4.85ppm

Actual: 2.5ppm

Scope: 32k, Fuel skid, IBH, FN/Liners, remove Steam-NOx



India

6541B to 2084F

Hot Day Guarantee: 10%MW/-4%HR

Actual: -10%HR

Australia

6531B to 2084F

Guarantee: 9%MW/-4%HR

Actual: -6%HR

6B Tfire Uprate (India & Australia)



Planning For a 6B Uprate or Upgrade .

Ask GE Salesperson for Latest Design Parts

Piece-by-Piece, build to a Tfire Uprate and 32k Inspection Intervals

Parts with New Designs:

• S1*, S2, S3 Shroud Blocks

• Transition Pieces*

• S1, S2, S3 Buckets

• S1, S2, S3 Nozzle

Not all parts supersede to the Advanced Seals or Higher Firing Temperature design

• because some engineering is needed

• * S1 Shroud Blocks and Transition Pieces do not supersede to the 2084 F firing temperature design



False outage barriers

Massachusetts

• 2500 hours/year… 7EA peaker…Tfire=2035• 2055 barrier: S1S, S2N, Mark IV• Solution: 2055… 1.4MW… no hardware• Polar vortex… $1800/kwh

Ohio

• 500 hours/year… 7B/7EA capacity… Tfire=2035• 2055 barrier: S1S, emissions• Solution: 2052… 1.3MW… no hardware• Polar vortex… $1080/kwh



Feedback on GE 6B Field Design Modifications

Hi Paul, The new exhaust plenums have been well worth the money spent. There are no more leaks like we had with the old ones and our load compartment now runs a lot cooler. The removable section on top of the exhaust frame also makes for easier removal of the turbine shell during HGPI .

For the insulation behind the flex seals we ourselves made fitted insulation blankets (bags) by stitching the provided insulation into ceramic wrapping. This is to prevent this blowing out over time between the HGPI/Major inspections every 3 years which was our experience with the older plenums. This improves the durability of the insulation which tends otherwise to gradually blow out even with small air leaks.

Best regards, Richard

6x6B Exhaust Plenums, Customer Email, Indonesia

Voice of Customer Improvement: Ceramic Wrapping of Insulation is now Included

Successful Reduction in Compartment Temperature




OpFlex / CPC / Autotune / Turndown / Cold Load Path / Variable peak / Smart IBH / Mk-6e migration

Opflex Package 1x6B Germany

So far we have just the verbal commitment from customer that he was more than happy and satisfied with the entire project execution starting from the proposal phase up to final commissioning. This was also communicated by customers upper management to GE’s upper management here in Germany

Best Regards Willi

“Dramatically improved turndown, ability to peak at different NOx levels, set NOx and CO where they want during peak, base and partload, running more efficient in partload … all were improvements they were happy with. ”

Successful Improvement in a DLN Turbine’s Flexibility



OpFlex* solutions suite

Gas turbine

• Start-up NOx / Low Visible Emissions (LVE)

• Fast start

• Purge credit

• Start-up Reliability Pkg.

Steam turbine

• Agility package

HRSG

• Adv. Attemperation

• Adv. SCR Control

• AutoBlend

Grid stability

• Enhanced Transient Stability

Automated tuning

• AutoTune DX

• AutoTune LT

• Ambient Select

Output

• Variable Peak Fire

• Variable Airflow

• Cold-Day Performance

Responsiveness

• Fast Ramp

• Grid code package

• Closed Loop Optimal Control (CLOC)

Turndown

• Extended Turndown

Efficiency

• Variable Inlet Bleed Heat

Fuels reliability

• Heavy Fuel Oil package

• Liquid fuel operability

System Reliability

• AutoRecover

• Trip prevention package

Diagnostics/Productivity

• System Diagnostics Pkg.

* Trademark of General Electric Company.

Advanced controls technology for all modes of power plant operation

Start-up AgilityFast, reliable, repeatable starts with low emissions

Combustion ControlRobust operation during weather, fuel, and grid

variations

Load ControlLoad range expansion,

efficiency, responsiveness and customization

System ReliabilityEnhancements for

reliable, cost effective operations

* Under development

4 Sep 2013




Paul, I received the following feedback from site regarding the 7B SSS clutch … .

They are working perfect -no fail to crank or starts since we installed, Also we have inspected each one and they look good. One comment is that you need a more skilled mechanic to install and maintain.

Regards, Adam

(A 7B was our last SSS Starting Clutch Turbine Model)

Successful Improvement in Start-Up Flexibility



Feedback on GE 6B/7EA Field Design Modifications

Ten 7EA’s have the Fast Start field modification

• Applies Equally well to 6B’s

• Applies to both Gas and Liquid Fuel

Fast Start – North America

Kentucky (From GE Salesperson after asking the customer about it):

“Yes. Experience has been great. Something unique about xxxxx is they have a single button to fast start 4 units!!

I.e you push one button and get 280+ MW on grid in 10 minutes. ”

Colorado (From Customer’s Pitch to a Conference):

Installed in Dec 2010, Software modification only

Gives the ability to quickly start and load Units A and B

117 MW in ~10 min.

Not used as spinning reserve due to severe penalties

Use increases maintenance cost due to start maintenance factor

Successful and Reliable Fast Starts



Feedback on GE 6B/7EA Field Design Modifications

Tom,

…the updated OpFlex Fast Start offering (“cold load path” for expanded cold weather operability) allows for year-round ASM revenue,…

…OpFlex Fast start allows the unit to synchronize to the grid within 7 minutes and 45 seconds of a start signal …

…I would like to extend my sincerest gratitude to the GE team for your efforts to address our cold weather operability concerns; your help in resolving this matter is truly appreciated! …

Best regards, Mark

Fast Start – Midwest (MISO) 7EA – Customer CommentsSuccessful and Reliable Fast Starts

Preparing for Your 6B Field Modification



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

Flame TrackerTM DryTIL 1579-R1, 2008. To heighten the awareness of potential risks associated with improper maintenance of the cooling water, water injection and water wash systems…

• Hot end assembly operates up to 200°C to remove water cooling

• Moves electronics to cooler area of turbine compartment

• Built on the proven SiC technology

Enhanced EPIC I can’t see what is happening in the software when you lock

up the EPIC software

Critical Safety Functions

Non-CriticalEng. Control

Customer Specific

Locked

Open

EPIC

313 - SW modules locked down

16 - SW modules locked down*

Enhanced EPIC

*Typical 7F.05 configuration

So what is still locked down …Proprietary information• ARES engine model• Combustor transfer functions … emissions and

dynamics• Compressor maps

Safety critical functions … trip and alarm functionality, not control logic*• Compressor protection• Exhaust over temperature protection• Fire protection• Flame detector protection• Overspeed protection• Failure to ignite protection• Excessive fuel flow (gas or liquid) protection• Vibration protection• P1, P2 protection• False start drain protection• Compartment (Load, tunnel) protection• Hazardous gas protection

6b users conference field design...

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