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
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GT13E2 Turbine Upgrades

GT Power output and efficiency
(ISO conditions)

GT13E2 Upgrades:
GT13E2 M

M Upgrade: increase in GT power output / efficiency

Enhanced GT power output and efficiency versus extended inspection intervals

Diff ere nt p osi tion ing

pos sib le

GT13E2 MXL GT13E2

Baseline, GT13E2 ISO conditions, NG

GT13E2 XL

24,000

32,000

36,000

XL & MXL Upgrades: extend C-inspection intervals

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Hot gas path C insp. interval (EOH) 3

Agenda GT13E2 M/MXL M blading GT13E2 MXL GT13E2 M References New Blade 5 M Compressor Upgrade
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M Blading

Customized solutions
c an m fo r r Pe
GT13E2 M

M Blading

Li f eti

me

GT13E2 MXL Lower temperature Extended inspection intervals SC performance slightly increased
5

Unchanged firing temperature Clear performance increase Inspection intervals unchanged

Whatever suits best

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M Blading Concept

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

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
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M Upgrades Commissioning & Operational Requirements

TIT changed M TIT increased MXL 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 approx. 4 - 5 days re-commissioning time required

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Summary

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

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

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Agenda GT13E2 M/MXL M blading GT13E2 MXL GT13E2 M References New Blade 5 M Compressor Upgrade
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GT13E2 MXL

Power output & efficiency (ISO conditions)

GT13E2 M
+ 6.1 MW / + 0.4 %

Extended Lifetime Improved Availability Reduced maintenance costs

GT13E2 MXL GT13E2 XL

+ 1.0 MW / + 0.2 %
+/- 0 MW / +/- 0 %

GT13E2

24000

32000

36000

Hot gas path insp. interval (EOH)

Extended inspection intervals (36 kEOH) Slightly increased SC performance (power output & efficiency)
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GT13E2 MXL - Scope of Work

Modification of Turbine Vane Carrier on-site

Zone 2 inner and outer shell with TBC Enlarged Axial Thrust Bearing

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

Operation Concept Hot gas path C-inspection each 36000 EOH Slightly increased SC performance

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GT13E2 M / MXL Modifications of Turbine Vane Carrier

GT13E2

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

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

GT13E2 M / MXL
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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 vanes

All rework can be done on site

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

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GT13E2 MXL - Summary

GT13E2 GT13E2 MXL Years

24000

24000 C 4 5

24000 36000

C C

24000 36000 10 11

C C 12

36000 1 2 3

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

GT13E2 MXL with 36000 EOH C-inspection intervals Slightly increased SC performance (ISO / Baseload)
+ 1.0 MW / + 0.2%

Boost your plant availability with 36000 EOH C-inspection intervals

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Additional advantages of MXL

Peak load application up to 16C 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

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Agenda GT13E2 M/MXL M blading GT13E2 MXL GT13E2 M References New Blade 5 M Compressor Upgrade
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GT13E2 M

Power output & efficiency (ISO conditions)

Improved performance Increased Power Output Increased Efficiency

GT13E2 M
+ 6.1 MW / + 0.4 %

GT13E2
+ 1.0 MW / + 0.2 % +/- 0 MW / +/- 0 %

GT13E2 MXL GT13E2 XL

24000

32000

36000

Hot gas path insp. interval (EOH)

Unchanged inspection intervals compared to GT13E2

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GT13E2 M - Scope of Work

Site specific checks (e.g. Generator & Transformer capacity, etc.) necessary Modification of Turbine Vane Carrier on-site Zone 2 inner and outer shell with TBC Enlarged Axial Thrust Bearing

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

Operation Concept Hot gas path C- inspection each 24000 EOH Increased performance
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Performance compared to GT13E2

Performance [Power & Efficiency] Upgrade Standard C-inspection Standard C-inspection

+ 6.1 MW / + 0.4%

Maintenance Interval

Performance recovery during a standard C-inspection

24000 EOH

24000 EOH

24000 EOH

Plant Lifetime

Increase power output and efficiency

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GT13E2 M - Summary

GT13E2 GT13E2 M Years

24000 24000 1 2

C C 3

24000 24000 4 5

C C 6

24000 24000 7 8

C C 9

24000 24000 10 11

C C 12

Increase performance while keeping insp. intervals unchanged

GT13E2 M with 24000 EOH C-inspection intervals Increased performance (ISO / Baseload)
+ 6.1 MW / + 0.4 %

Reduced costs per MWh due to increased power output and efficiency
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Agenda GT13E2 M/MXL M blading GT13E2 MXL GT13E2 M References New Blade 5 M Compressor Upgrade
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GT13E2 M/MXL - Fleet Growths

Status: January 2006
45 40 35 30
Units

GT13E2 upgrade packages Customized solutions for competitive markets. Higher power output Increased efficiency Increased availability Extended inspection intervals ALSTOMs implementation success: 36 MXL configuration sold 5 M configurations sold

25 20 15 10 5 0

13 units in operation 43 units sold

GT13E2 M/MXL higher performance at increased availability

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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

today

Status: February 2006

GT13E2 Upgrade List (2)

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

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

In Op
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
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Status: February 2006

GT13E2 Upgrade List (3)

Plant
Afam Afam Afam Dubal Dubal Kwinana Deeside Dunkerque Dunkerque

Unit
GT11 GT12 GT13 GT1 GT2 GT1 GT1 GT1 GT2

In Op
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

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

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

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

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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 First unit in operation since June 2002 > 130000 Equivalent Operating Hours > 120000 Operating Hours > 580 Starts Fleet Leader completed C-cycle More than 22,103 OH on gas More than 26,795 EOH

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Agenda GT13E2 M/MXL M blading GT13E2 MXL GT13E2 M References New Blade 5 M Compressor Upgrade
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New Blade 5 M for GT13E2 M & MXL

New

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
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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 units
Status May 2006

GT#14: S = 38; OH = 7482; EOH = 9813 GT#15: S = 17; OH = 7628; EOH = 8190
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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 GT13E2 M/MXL performance compared to GT13E2

Performance [Power & Efficiency] Upgrade M SC + 7.2 MW/ Standard + 0.6% C-inspection MXL (SC +2.1 MW/ +0.4%) Maintenance Interval Standard C-inspection

Performance recovery during a standard C-inspection

24000 EOH

24000 EOH

M 24000 EOH (MXL 36000 EOH)

Plant Lifetime

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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 %

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

+ 2.1 MW / +0.4 % + 1.0 MW / +0.2 % 165.1 MW / 35.7 %

GT13E2 (1993)
24000

36000

Hot gas path insp. interval (EOH)

Continuous improvement keeps your plant competitive

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Benefits of GT13E2 M

GT13E2 GT13E2 M Years

24000 24000 1 2

C C 3

24000 24000 4 5

C C 6

24000 24000 7 8

C C 9

24000 24000 10 11

C C 12

Increase performance while keeping inspection intervals unchanged

GT13E2 M with 24000 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

39
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Benefits of GT13E2 MXL

GT13E2 GT13E2 MXL Years

24000

24000 C 4 5

24000 36000

C C

24000 36000 10 11

C C 12

36000 1 2 3

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

GT13E2 MXL with 36000 EOH C-inspection intervals and New Blade 5 M Slightly increased SC performance (ISO / Baseload)
+ 2.1 MW / + 0.4%

Boost your plant availability with 36000 EOH C-inspection intervals

40
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Agenda GT13E2 M/MXL M blading GT13E2 MXL GT13E2 M References New Blade 5 M Compressor Upgrade
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Product Information

GT13E2 MXL Compressor Upgrade

VELE VELA VIGV

Flow

Restaggered Rows
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GT13E2 Compressor
Compressor 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 Stagger angle adjustment
Compressor row Stages 1 to 5 Open Stagger angle change Between 0.6 and 1.5
Stagger Angle Engine Axis

Output increase through approx. 4% mass flow increase

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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 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

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

Already implemented and validated in one unit

GT#13 more than S = 18, OH = 5746, EOH = 6695
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Benefits of Compressor Upgrade Performance compared to GT13E2 MXL

SC Performance [Power & Efficiency] Upgrade Standard C-inspection SC +5 MW /+0.2% Maintenance Interval Performance recovery during a standard C-inspection Standard C-inspection

36000 EOH

36000 EOH

36000 EOH

Plant Lifetime

Increase power output

46
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Benefits of GT13E2 MXL Upgrade

Power output & efficiency (SC / ISO / Base Load / New & Clean / Gas) + 7,1 MW / +0.6 %
+ 6.1 MW / + 0.4 %

+ 6 MW / +0.4 %

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

+ 1.0 MW / +0.2 % 165.1 MW / 35.7 %

GT13E2 (1993)
24000

GT13E2 XL

GT13E2 MXL (2003)

32000

36000

Hot gas path insp. interval (EOH)

Reduced Cost of Electricity due to increased power output

47
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Benefits of GT13E2 MXL Upgrade with Compressor Upgrade

GT13E2 GT13E2 MXL Years 1 24000 C 24000 C 4 5 6 C 24000 36000 7 8 C C 9 10 24000 36000 11 12 C C

36000 2 3

Save 1 out of 3 C-inspections in a span of 9 years GT13E2 MXL with 36000 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 36000 EOH C-inspection intervals Extremely reduced Cost of Electricity due to increased power output
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www.service.power.alstom.com
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