7ha Constructability Pitch External

7HA Gas Turbine
Constructability & Maintainability

Seminar
* Trademark of General Electric Company

GE Proprietary and Confidential
GT Accessory Modularization Overview
Upper Enclosure
Upper Enclosure Module, Right
Module, Left
Air Extraction Air Extraction

Module, Left Module, Right
Fuel Control
Module Air Extraction Module, Lower GT Drains
Module
2
7HA Constructability Seminar
Comparative statements refer to GE technology unless otherwise stated. 3/23/2014
© 2013 General Electric Company. All rights reserved.
Modularization Example…Cooling & Sealing Air
7F.03 Cooling and Sealing Air 1 Build Scaffolding
2 Install piping and piping supports
3 Install ship loose valves in piping
4 Build enclosure around piping, mount junction
boxes, cut piping penetrations through walls
5 Route instrument air tubing, electrical wiring
& conduit to wall of enclosure
6 Complete water wash drain piping (EPC scope
of design & supply within enclosure)
7 Commission valves and instrumentation
8 Insulate all piping
9 Install turbine maintenance grating and
7HA.01 Modularized Design handrails
1 Install modules
2 Install piping between GT and modules
3 Insulate field installed piping
7F.03 7HA
3
Air Extraction Module, Lower
Jack stand
Water wash
drain piping
Compartment
Purge air space heaters
cooler
• Purge air cooler complete with water
control valve and piping
• Jack stand integrated as piping support
to prevent from unnecessary piping
removal during maintenance
4
Fuel Control Module
Valve Removal
Trolley
Grating walkways between

valves for maintenance access
Liquid Fuel
Control Valves
Gas Fuel
Control Valves
• Valve removal trolley is capable of lifting

all valves and dropping them in front of
double doors for easy removal
• Module size does not change for gas only
units, remains as open area
5
Quick Disconnect Flanges
Gas Fuel
Liquid Fuel
Manifolds
Manifolds
104 quick release flanges 32 quick release flanges

6 WW drain flanges 24 SAE 4-bolt flanges
6
Air Extraction Module, Left
• Cooling and sealing air piping

• Compressor bleed valve
• Inlet bleed heat valve
• Stage 2 and 3 nozzle cooling valves
• Integrated grating for maintenance
access
• Handrails (not shown) included
7
Air Extraction Module, Right
Over Board
Bleed valve
(FSFL test
hardware only)
Stage 2 Nozzle
cooling valve
8
GT Drains Module
False start
drain valves
Water wash
drain valves
Simplified
interface points
Water wash supply

control valves
Removable grating and
sill for roll-in access
through double doors
9
Combustion Can Maintenance Access
Maintenance area reserved to allow
can removal from below
Width: 5’
Height: 6’
Length: 12’
Double door with removable sill for “roll-in
roll out” access
10
Drains Module Maintainability
Access to
WW supply
Valves
GT DRAIN
MODULE
Access to
Manual
Front
End WW Drain
Valves
2.5’
False Start Manual WW WW supply

Drain Valves Drain Valves Valves
Access to
False Start
• All valves are accessible through access door & platform
Drain Valves
• All manual drain valves are color coded and tagged” to align
with the off-line water wash sequence.
11
Gas Fuel Scrubber and Dewpoint Heater
Start-up Heater
(GE Supplied)
Simplified Customer – GE
Transfer Point at Inlet to
Scrubber
Close-coupled scrubber reduces

EPC supplied SS piping
Dewpoint heater design eliminates
gas pressure drop associated with
startup heating
12
External Modules
Lube Oil Inlet Plenum

Module
Load Coupling
Guard
Liquid Fuel
Filtering
13
Lube Oil Piping
Simplified lube oil

flushing developed
with field engineers
reduce setup time
14
Enclosures and Ventilation
Ventilation
Fans are moved aft over exhaust to
enable simpler roof design and easier
maintenance access
Single extraction &

instrumentation duct
GT Insulated at site by GE or
GE supervision (Union Sites)
Modules ship with

Ventilation inlets and insulation pre-installed
dampers included in
modules
16
GT Enclosure Maintenance Provisions
Deck height set below
turbine centerline to
allow for easy bolt access
Removable grating and

bracing allow valves to
be pulled up to main deck
Maintenance access
points for pneumatic Ladders and Handrails
hoses and power cords incorporated in modules
17
Clean Roof
Exhaust Frame and

#2 Bearing Blowers
GT Compartment
Ventilation Fans
Maj CI HGP
Single Ventilation Extraction

(no removal required)
18
Load Compartment & Load Coupling Guard
Ventilation CFD Current 7F.03 Design
No separate off base load compartment

Load Compartment ventilation fans (2) and silencer
eliminated
Self-Ventilating Load Coupling Guard
Shaft windage used to dissipate heat generated by coupling
Natural ventilation path for hydrogen dissipation when not
running
New 7HA.01 Design
19
Instrument Air
Instrument air tubing to valves pre-installed in

modules and routed to customer connection
20
Inlet Filter House and IBH
2-Pipe IBH
Manifold
All IBH piping is in GE

scope of supply
IBH Control Valve
modularized into GT
enclosure
Simplified
Interconnect Piping
by GE (no bellows)
21
Inlet Bleed Heat Simplification
Trombone Pipes 2 Horizontal
Distribution Pipes
Piccolo Pipes
Previous 7F Design Simplified 7HA Design
All piping field installed Internal piping shipped pre-installed
Extensive welding and x-ray test required 6 field welds and standard 10% x-ray testing
Welding inside duct required for supports No welding inside duct required
Proper
Overmixed
Mixing
22
Interface to turbine hall for indoor installations
Sloped inlet allows for lower

crane and building height
Interface to Indoor
Building
Rotor Removal
Clearance
Top View
Side View
Extension of GT enclosure roof allows for simplified interface to

building and reduced ventilation ducting by EPC
23
Electrical
Electric actuation… no hydraulics
Electric control valves
Gas fuel
Purge
Liquid fuel
Water injection
Factory wired to controllers
220VDC actuation replaces
125VDC for power
24 VDC for signal
Connectorized wire harnesses supplied by

GE between actuator and control cabinet
Compressor vane actuators

IGV: two electric actuators
VSV: two electric actuators control

first three stages of vanes
25
IGV & VSV Maintenance Simplification
Hydraulic tubing and
servos eliminated
Connectorized Digital Valve

Positioner Cabinet for electrically
actuated valves Roxtec cable sealing for
 IGV (2) & VSV (2) enclosure penetrations
 Gas Fuel Control (4)
 Liquid Fuel Control (3)
Plug and Play electrical

design to reduce
installation and
commissioning time
26
Electrical Design Highlights
• Cable tray instead of conduit
• Electrical pre-wired for accessory modules
• Exposed run rated cable to allow for free length at device termination
• 125 VDC power level has been eliminated (replaced by 24 VDC for low power signals and 220
VDC for high power level)
~50% reduction in # of JBs.
~70% reduction in # of field terminations.
BEFORE – Conduit AFTER – Cable Tray
Field installed, cut, and

routed conduit is replaced
by pre-installed cable tray
27
Example FFB Network Topology (Lube Oil)
Connectorized FBSPs - Plug and Play Design
FFB minifast connectors at T/Cs,

transmitters, segment
protectors and linking devices
for Plug and Play wiring design. 28
Haz Gas Detection System Design Highlights
• Aspirated IR design for GT
enclosure, aspirated cat
bead technology for
generator and generator
collector enclosures.
• New technology reduces #
of false trips which was a
nuisance with the older
technology. It is also
immune to poisons which
was a major limitation of
the BN cat bead sensors.
• New design can tolerate
tighter LEL settings and
has a lower calibration
frequency.
29
FFB Constructability and cost
Reference project: 50 Hz Single Shaft CC
Impact to plant construction cost Field control element coverage

Percent reduction (total plant)
>60% >50%
>80% >80%
FOUNDATION fieldbus CANOpen

Source: GE detailed plant configurations & funded study
Profibus Hardwired
30
Fire Protection
Fire Protection System – Water Mist
Zone 1 – Turbine Compartment
Zone 2 – #2 Bearing Tunnel

Zone 3 – Lube Oil Skid
• Meets NFPA 750 standard
• FM Approved system
• Gas pump unit (GPU) is
driven by compressed air
cylinders to drive water to
the nozzles.
• Discharge solenoid valve
open on fire detection or
manual release.
Customer located skid:

Tubing to each zone up to 150ft.
Water mist is standard for fire

protection instead of CO2.
32
Water Mist vs CO2
• SAFETY - Eliminates personnel risks. Mist • EQUIPMENT DAMAGE - Reduces fire

insulates personnel from thermal damage potential by eliminating
radiation. No Risk of Asphyxiation. C02 discharge delay (30 Seconds). Potential
also causes carbonic acid build up in spread of fire reduced.
lungs.
• COST OF OWNERSHIP - Reduces long
• SYSTEM EFFECTIVENESS - Eliminates term cost of ownership, eliminates
suppression failures from loss of periodic full discharge concentration tests
enclosure tightness (37% of CO2 system following major GT maintenance
failures due to C02 system leaks causing (Currently $24,000 per re-test).
inability to reach required concentrations).
Water Mist remains effective with open • ENVIRONMENT – Eliminates hazards to
doors. environment due to C02 Production.
33
Field installation
scope
Water Mist CO2

Skid Customer located
Interconnect 1 line of tubing per zone 3 lines of piping per zone
Piping (3 total) (9 total)
Compartment Thermocouples, manual release stations,
Electrical Devices strobes/horns
Control Panel Installed in PEECC
Commissioning Functional test (full Full discharge
discharge not needed) concentration & enclosure
tightness test
34
Liquid Fuel System Design
Liquid Fuel System: New Design
Legacy Design New Design
Atomization Atomizing Air Pressure Atomized
NOx abatement Water injection Pre-mixed Water & Fuel
Anti-coking Recirculation/N2 Purge Water purge
Purge credit Secondary Design Features Inherent to Design
Purge Cooled Air Purge Water Block
36
Simplified EPC Scope
Fuel forwarding pumps
are no longer required
for new design Piping by GE
Filtration skid
By GE
Interconnect
Piping by EPC
7F.03 Skids
4” if < 1400 ft Liquid fuel forwarding
Water injection (A035)
Fuel heating (E041)
Fuel management spool piece (A245)
Liquid Fuel and Atomizing Air (A162)
7HA Skids
Liquid Fuel and Liquid fuel pumping
Water Injection Water injection pumping
pumps by GE Liquid fuel and Water Injection Filtering
AM10 Fuel Control Module (shared with gas)
37
Simplified field installation & maintenance
LF w/ Atomizing Air Pressure Atomized LF
Labor intensive site installation Modularized manifolds with quick
disconnects at mid-line
38
On-base Piping
• Many potential leak points • Flanges minimized, no tube fittings
• Labor intensive for CIs • Only 2 tubes to remove for CI
39
Simplified field installation
6 endcover connections 2 endcover connections
2 Valves on endcover No valves on endcover
40
Liquid Fuel System: Air Purge vs. Water Purge
Pilot circuit effective area during coking test
Water Flush
Air Purge
• Pilot lost 48% of effective flow area in 50 cycles with air purge at 1.2 pressure ratio.
• Pilot effective area steady after 90 cycles in cartridge with water flush.
• No evidence of main circuit clogging in either case, but air purge test terminated at 50
cycles. Mains circuits are 8 times larger than pilots.
• Coked pilot made a marginal spray, but – no effective area recovered after water flush.
41
Flush Effectiveness Testing - Main
Coupon Testing UV Dye Flush Testing
Filled/Brushed, Covered & Cooked 1 hr @ 425 °F Main Fuel Valve: Test Point #1 Main Fuel Valve: Test Point #7
Flush/Coke Testing
Conclusion
• Final flush test point conservative
compared to actual worst-case main
flush (shutdown)
• Main flush strategy yields very good
results according to dye and coke
tests
42
Main Flushed per Test Point #7, cooked 2 hrs @ 425 °F (3x total) 7HA Constructability Seminar
Liquid Fuel Installation Savings
7HA
7HA
*
*GE installation hour estimates are based on field feedback for various 7F-3 sites
43
Shipping
GT Shipping Configuration
• All combustion cans ship installed on unit

• Inner two fuel manifolds and flex hoses ship installed
• Shipping beam has bolted joint, forward stub used for
fuel gas piping manifold support
45
Summary
Reduction in Field Welds
Reference
MLI 7F.03 7HA.01 Notes
Drawings
0909 74 35 102T0554 Modularized CSA inside GT enclosure.
0972 33 6 146E1221 Simplified exhaust frame cooling path, fewer supports on roof.
969G 31 16 119E6563 Greatly simplified and shortened interconnect piping.
0962 2 2 146E5542 Mostly spool pieces with flex hoses.
969A 39 32 146E3071 Piping will be hung from enclosure, less supports to ground
0905 13 10 143E5962 Welds completed on pipe in pipe and prefit up at supplier
0906 34 30 101T3905 Common supports with main lube oil supply
0907 13 13 146E3514 Similar to 7FA.03
969M 37 0 141E7353 All 969M eliminated with electric IGV implementation.
0965 2 0 102T1571 AA eliminated as part of new pressure atomized LF system.
969D 17 0 102T0837 AA eliminated as part of new pressure atomized LF system.
119E6562 &
0924 52 9 Modularized IBH piping
102T3794
0920 43 20 146E3255 Modularized Drains
0979 6 6 138E5391 Same as 7FA.03
0976 18 16 138E6029 Simplified supports
0918 24 10 146E3136 Purge for Gas Fuel side only, LF purges w/ water through manifold
0961 1 12 137E2503 Mostly tubing before. Now some piping.
969L 33 0 141E7765 Piping eliminated as part of pressure atomized LF system.
969C 30 6 146E6343 Vastly simplified LF interconnect, no tubing, 2 lines now.
0968 5 5 100T7549 Same as 7FA.03
0953 10 10 100T5598 Same as 7FA.03
0915 8 0 102T0095 All 0915 piping eliminated.
525 238 54% Reduction in Field Welds
47
Field Installed Valves
MLI System 7F.03 7HA.01 Notes
0417 Cooling and Sealing Air 13 0 4 eliminated, 9 in modules
0422 Gas Fuel 2 1 SSOV Vent Valve in module
0425 Atomizing Air 1 0 eliminated manifold drain valve
IBH Control Valve Modularized, manual isolation
0432 Inlet Bleed Heat 2 0 valve eliminated
0434 Lift Oil 4 0 Lift Oil flow control valves in interconnect piping
0442 Water Wash & FSD 17 0 FSD Valves and WW Drain Valves modularized
0477 Gas Fuel Purge 6 0 Purge valves modularized into AM40 and AM10
Total 45 1
Only SSOV remains as GE Supplied GT

Accessories Field Installed Valve
48
GE to EPC Piping Interface Points
MLI System 7F.03 7HA.01
0416 Lube and Lift Oil 9 8
0417 Cooling and Sealing Air 13 5
0420 Cooling Water 9 6
0422 Gas Fuel 4 4
0424 Liquid Fuel 4 1
0425 Atomizing Air 1 0
0426 Fire Protection 11 4
0442 Water Wash 13 8
0462 Water Injection 1 1
0471 Inlet and Exhaust 2 1
0477 Gas Fuel Purge 4 4
Total 71 42
49
Constructability Guide
A single document that compiles pertinent
information relevant to a constructor and
erector to estimate the scope of work
necessary to install a GE 7HA gas turbine,
generator, and associated ancillaries
compared to the 7F.03.
50

7ha Constructability Pitch External

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7ha Constructability Pitch External

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7HA Gas Turbine

Constructability & Maintainability

* Trademark of General Electric Company

Air Extraction Air Extraction

Grating walkways between

• Valve removal trolley is capable of lifting

104 quick release flanges 32 quick release flanges

• Cooling and sealing air piping

Water wash supply

False Start Manual WW WW supply

Close-coupled scrubber reduces

Lube Oil Inlet Plenum

Simplified lube oil

Single extraction &

Modules ship with

Removable grating and

Exhaust Frame and

Single Ventilation Extraction

Ventilation CFD Current 7F.03 Design

No separate off base load compartment

New 7HA.01 Design

Instrument air tubing to valves pre-installed in

All IBH piping is in GE

Sloped inlet allows for lower

Extension of GT enclosure roof allows for simplified interface to

Connectorized wire harnesses supplied by

Compressor vane actuators

VSV: two electric actuators control

Connectorized Digital Valve

Plug and Play electrical

BEFORE – Conduit AFTER – Cable Tray

Field installed, cut, and

Connectorized FBSPs - Plug and Play Design

FFB minifast connectors at T/Cs,

Impact to plant construction cost Field control element coverage

FOUNDATION fieldbus CANOpen

Zone 2 – #2 Bearing Tunnel

Customer located skid:

Water mist is standard for fire

Water Mist vs CO2

• SAFETY - Eliminates personnel risks. Mist • EQUIPMENT DAMAGE - Reduces fire

Water Mist CO2

Purge Cooled Air Purge Water Block

• All combustion cans ship installed on unit

Only SSOV remains as GE Supplied GT

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