gt13e2 m mxl upgrades

July 2006

GT13E2 M/MXL Upgrades

Erol Morgan

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.

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GT13E2 MXL

M blading

GT13E2 M/MXL

Agenda

GT13E2 M

References

New Blade 5 M

Compressor Upgrade


3

Different positioning possible

GT13E2 Turbine Upgrades

Hot gas pathC insp. interval

(EOH)

24,000 32,000 36,000

Baseline, GT13E2ISO conditions, NG

GT Power outputand efficiency(ISO conditions)

GT13E2

XL & MXL Upgrades: extend C-inspection intervals

M U

pg

rad

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crea

se in

G

T p

ower

ou

tpu

t / e

ffic

ien

cy

GT13E2 Upgrades:

Enhanced GT power output and efficiency versus extended inspection intervals

GT13E2 XL

GT13E2 MXL

GT13E2 M


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GT13E2 MXL

M blading

GT13E2 M/MXL

Agenda

GT13E2 M

References

New Blade 5 M

Compressor Upgrade


5

M Blading

Customized solutions

GT13E2 MXL

Lower temperature

Extended inspection intervals

SC performance slightly

increased

GT13E2 M

Unchanged firing temperature

Clear performance increase

Inspection intervals unchanged

Perform

ance Lifetime

Whatever suits best

MBlading


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Module 3New stages 4,5

Module 2New stages 2,3

Module 1Modified stage 1

TBC at Vane 1, 2 & Blade 1

M Blading Concept

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


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TIT changed– M TIT increased– MXL TIT decreased

Re-Commissioning Procedure– Heat Balance– NOx mapping in the upper load range (70 % - 100%)

• incl. pulsation measurementadd. 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

approx. 4 - 5 days re-commissioning time required

M Upgrades Commissioning & Operational Requirements


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Summary

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

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


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GT13E2 MXL

M blading

GT13E2 M/MXL

Agenda

GT13E2 M

References

New Blade 5 M

Compressor Upgrade


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GT13E2

GT13E2 MXL

Power output&

efficiency(ISO conditions)

Hot gas path insp. interval(EOH)24’000 32’000

GT13E2 XL

36’000

GT13E2 MXL

Extended inspection intervals (36 kEOH)Slightly increased SC performance (power output & efficiency)

GT13E2 M

+/- 0 MW / +/- 0 %

+ 6.1 MW / + 0.4 %

+ 1.0 MW / + 0.2 %

Extended Lifetime Improved AvailabilityReduced maintenance costs


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GT13E2 MXL - Scope of Work

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

Modification of TurbineVane Carrier on-site

Zone 2 inner and outer shell with TBC

Operation ConceptHot gas path C-inspection each 36’000 EOHSlightly increased SC performance

Enlarged Axial Thrust Bearing


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GT13E2 M / MXL -Modifications of Turbine Vane Carrier

New:Vane row 2 direct cooling air feed from Plenum24 add. cool. holes in TVCOld cooling holes plugged

GT13E2

GT13E2 M / MXL

New:Cooled vane row 382 add. cooling holes in expansion bends


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GT13E2 M / MXL -Modifications of Turbine Vane Carrier

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

Stage 2:Vane 2: (48 vanes instead of 60)

— new fixation of vanes— new cooling feed

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

Stage 3:Vane 3: (48 vanes instead of 60)

— new fixation of vanesSHSS C: new design of stator heat shield require intermediate ringsAll rework can be done on site


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GT13E2 MXL - Summary

GT13E2

GT13E2 MXL

C24’000

36’000 C

4321Years

C24’000 C24’000 C24’000

36’000 C 36’000 C

8765 1211109

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

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

Boost your plant availability with 36’000 EOH C-inspection intervals


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Additional advantages of MXL

Peak load application up to 16°C increased TIT allowed for continuous operation and counted with only factor 1.5A-, 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


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GT13E2 MXL

M blading

GT13E2 M/MXL

Agenda

GT13E2 M

References

New Blade 5 M

Compressor Upgrade


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GT13E2

GT13E2 M

Power output&

efficiency(ISO conditions)

Hot gas path insp. interval(EOH)24’000 32’000

GT13E2 XL

36’000

GT13E2 MXL

Unchanged inspection intervals compared to GT13E2

GT13E2 M

+/- 0 MW / +/- 0 %

+ 6.1 MW / + 0.4 %

+ 1.0 MW / + 0.2 %

Improved performanceIncreased Power OutputIncreased Efficiency


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GT13E2 M - Scope of Work

Modification of TurbineVane Carrier on-site Enlarged Axial

Thrust Bearing

Zone 2 inner and outer shell with TBC

Site specific checks (e.g. Generator & Transformer capacity, etc.) necessary

Operation ConceptHot gas path C- inspection each 24’000 EOHIncreased performance

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


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Performance compared to GT13E2

Increase power output and efficiency

PlantLifetime

Performance[Power & Efficiency]

StandardC-inspection

MaintenanceInterval

24’000 EOH 24’000 EOH24’000 EOH

StandardC-inspectionUpgrade

+ 6.1 MW /+ 0.4%

Performance recoveryduring a standard

C-inspection


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GT13E2 M - Summary

Increase performance while keeping insp. intervals unchanged

GT13E2 M with 24’000 EOH C-inspection intervalsIncreased performance (ISO / Baseload)

– + 6.1 MW / + 0.4 %

Reduced costs per MWh due to increased power output and efficiency

GT13E2 C24’000 C24’000 C24’000 C24’000 C

GT13E2 M C24’000 C24’000 C24’000 C24’000 C

4321Years 8765 1211109


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GT13E2 MXL

M blading

GT13E2 M/MXL

Agenda

GT13E2 M

References

New Blade 5 M

Compressor Upgrade


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0

5

10

15

20

25

30

35

40

45

1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q

2002 2003 2004 2005 2006 2007 2008 2009

GT13E2 M/MXL – higher performance at increased availability

Status: January 2006

GT13E2 upgrade packages

Customized solutions for competitive markets.

Higher power outputIncreased efficiencyIncreased availabilityExtended inspection intervals

ALSTOM’s implementation success:

36 MXL configuration sold5 M configurations sold

GT13E2 M/MXL - Fleet Growths

Un

its tod

ay

13 units in operation43 units sold


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Zawia GT12 2Q/00 MXL 2006 - V96Zawia GT16 3Q/05 MXL Aug 2005 - MXLBenghazi GT14 2Q/02 MXL 2006 - VAKeppel GT11 1Q/07 MXL Jan 2007 - MXLKeppel GT12 1Q/07 MXL Jan 2007 - MXLBraemar GT11 3Q/06 MXL July 2006 - MXLBraemar GT12 3Q/06 MXL July 2006 - MXLBraemar GT13 3Q/06 MXL July 2006 - MXLAluar GT11 4Q/07 MXL Nov 2007 - MXLAluar GT12 4Q/07 MXL Nov 2007 - MXLDiemen 33 GT1 2Q/95 MXL Oct 2008 - V96Lageweide GT7 4Q/94 MXL Mar 2009 - V96Wagerup GT11 4Q/07 MXL Oct 2007 - MXLWagerup GT12 4Q/07 MXL Oct 2007 - MXLSohar GT11 3Q/08 MXL June 2008 - MXLSohar GT12 3Q/08 MXL June 2008 - MXLSohar GT13 3Q/08 MXL June 2008 - MXLSohar GT14 3Q/08 MXL June 2008 - MXL

…GT13E2 Upgrade List (2)

Plant Unit In Op Current Set-up Since Last Set-up Original Set-up

Status: February 2006


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Afam GT11 2008 MXL 2008 - MXL Afam GT12 2008 MXL 2008 - MXL Afam GT13 2008 MXL 2008 - MXLDubal GT1 1Q/07 MXL March 2007 - MXLDubal GT2 3Q/07 MXL Sept 2007 - MXLKwinana GT1 4Q/08 MXL Nov 2008 - MXLDeeside GT1 2Q/94 MXL Oct 2006 - V96Dunkerque GT1 MXL - VADunkerque GT2 MXL - VA

…GT13E2 Upgrade List (3)

Plant Unit In Op Current Set-up Since Last Set-up Original Set-up

Status: February 2006


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GT13E2 M - Reference Kuala Langat

First unit (GT#14) in Kuala Langat completed 1st C-cycle

Operation dataCommercial base load operation, primarily on natural gas22,103 OH, 45 starts, 26,795 EOH by March 31, 2005

Operation experience100% reliability of M-bladingGood conditions allowed stretched C-cycle!


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GT13E2 M/MXL - Fleet Key Data

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

First unit in operation since June 2002> 130’000 Equivalent Operating Hours> 120’000 Operating Hours> 580 Starts

Fleet Leader completed C-cycleMore than 22,103 OH on gas– More than 26,795 EOH

Status: May 2006


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GT13E2 MXL

M blading

GT13E2 M/MXL

Agenda

GT13E2 M

References

New Blade 5 M

Compressor Upgrade


34

New Blade 5 M for GT13E2 M & MXL

New

Tip

Mid

Hub

Original

New

New

Original

Original

Extensive testing showed potential for improvementFurther Improvement of the existing Blade 5 Version MAchieves an even further improved turbine exit profile shape and exhaust diffusor characteristicImproves both power and efficiency of the GT13E2 M & MXL


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New Blade 5 M for GT13E2 M & MXL

New Blade 5 M NOT mixable with old Blade 5 M

No influence on duration of C-inspection

No other new hardware required Only new Blade 5 M

Hardware available within standard delivery time

Unchanged Operation Concept

Unchanged EOH formula

Already implemented and validated in 2 unitsStatus May 2006

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


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Benefits of New Blade 5 M

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

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


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Benefits of New Blade 5 M

PlantLifetime

Performance[Power & Efficiency]


MaintenanceInterval

24’000 EOH M 24’000 EOH(MXL 36’000 EOH)

24’000 EOH


M SC + 7.2 MW/

+ 0.6%MXL

(SC +2.1 MW/ +0.4%) Performance recovery

during a standardC-inspection

GT13E2 M/MXL performance compared to GT13E2


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Benefits of GT13E2 M/MXL & New Blade 5 M

Continuous improvement keeps your plant competitive

Power output&

efficiency (ISO/Base Load/

New & Clean)

Hot gas path insp. interval(EOH)

24’000 36’000

GT13E2 MXL(2003)GT13E2

(1993)

165.1 MW / 35.7 %

+ 6.1 MW / + 0.4 %

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

+ 7.2 MW / + 0.6 %

GT13E2 M+ New Blade 5M

(2005)

GT13E2 MXL+ New Blade 5M

(2005)

GT13E2 M(2003)


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Benefits of GT13E2 M

Increase performance while keeping inspection intervals unchangedGT13E2 M with 24’000 EOH C-inspection intervals and New Blade 5 M

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

Reduced Costs of Electricity due to increased power output and efficiency

GT13E2 C24’000 C24’000 C24’000 C24’000 C

GT13E2 M C24’000 C24’000 C24’000 C24’000 C

4321Years 8765 1211109


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Benefits of GT13E2 MXL

GT13E2

GT13E2 MXL

C24’000

36’000 C

4321Years

C24’000 C24’000 C24’000

36’000 C 36’000 C

8765 1211109

Save 1 out of 3 C-inspections in a span of 9 yearsGT13E2 MXL with 36’000 EOH C-inspection intervals and New Blade 5 M

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



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GT13E2 MXL

M blading

GT13E2 M/MXL

Agenda

GT13E2 M

References

New Blade 5 M

Compressor Upgrade


42

Product Information

Flow

VIGVVELA

VELE

GT13E2 MXL Compressor Upgrade

Restaggered Rows


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Between 0.6° and 1.5°

OpenStages 1 to 5

Stagger angle change

Compressor row

Stagger angle adjustment

GT13E2 CompressorCompressor Upgrade

Increased mass flow by stagger angle

adjustment on leading compressor rows

Development with the proven tools and

methods already used for earlier compressor

upgrades

Output increase through approx. 4% mass flow increase

Engine Axis

StaggerAngle


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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


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Product Information

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

Compressor Upgrade settings are specific for each unitSite specific re-commissioning settings are requiredAdaptation of operation concept (e.g. VIGV)

Already implemented and validated in one unitGT#13 more than S = 18, OH = 5’746, EOH = 6’695


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Benefits of Compressor Upgrade

Increase power output

PlantLifetime

SC Performance[Power & Efficiency]


MaintenanceInterval

36’000 EOH 36’000 EOH36’000 EOH


SC +5 MW /+0.2%

Performance recoveryduring a standard

C-inspection

Performance compared to GT13E2 MXL


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Benefits of GT13E2 MXL Upgrade

Reduced Cost of Electricity due to increased power output

Power output&

efficiency (SC / ISO / Base

Load / New & Clean / Gas)

Hot gas path insp. interval(EOH)

24’000 36’000

GT13E2 MXL(2003)GT13E2

(1993)

165.1 MW / 35.7 %

+ 6.1 MW / + 0.4 %

+ 1.0 MW / +0.2 %

GT13E2 M(2003)

+ 6 MW / +0.4 %

New Blade 5 M+

Compressor Upgrade(2005)

+ 7,1 MW / +0.6 %

32’000

GT13E2 XL


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Benefits of GT13E2 MXL Upgrade withCompressor Upgrade

GT13E2

GT13E2 MXL

C24’000

36’000 C

4321Years

C24’000 C24’000 C24’000

36’000 C 36’000 C

8765 1211109

Save 1 out of 3 C-inspections in a span of 9 yearsGT13E2 MXL with 36’000 EOH C-inspection intervals and Compressor UpgradeIncreased SC performance (ISO / Baseload / Gas / New & Clean)

– + 6 – 7.1 MW / + 0.4 – 0.6% compared to GT13E2 (depending on B5 M version)


Extremely reduced Cost of Electricity due to increased power output


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gt13e2 m mxl upgrades

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