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© 2016, General Electric Company. Proprietary information. All rights reserved.
GE Power
All relative statements are with respect to GE technology unless otherwise noted. 2
As of 23-MAR-2016 4
1Includes aft stator only
© 2016, General Electric Company. Proprietary information. All rights reserved.
Updated Water Wash
Recommendations
Degradation/FH
and performance
• Increasing OnWW frequency
(OnWW_hours/FH) …
– Decreases corrosion
– Decreases performance losses
– Increases erosion
Corrected Power
Performance
• Analyzed degradation for all monitored F-class fleet
• Calculated by comparing performance after
offline Water Wash n to performance before offline
Water Wash n + 1
• Examined unit output, compressor efficiency, Time
OffWW n OffWW
and compressor flow … Normalized by fired hours n+1
Erosion
• Observed erosion levels on 40 F-class units
• Developed regression model based on Water Wash,
humidity, inlet conditioning, age, operation, etc.
• Largest factor for increased erosion levels was
online Water Washing for > 15 minutes/24 FH
Corrosion
• Previous RCAs/studies showing that utilization
of OnWW reduces impact of corrosion
• Best mitigated by following PSIB 20130813A but with
modified OnWW recommendation per PSIB 20151211A
• Units in highly corrosive environments reference
GEK 116269 for recommended filtration systems
Wear pattern shows that the shroud is Bushing wear can allow enough shroud
loaded rotationally against the LE airfoil movement to make contact and wear
and TE bushing against the inner barrel
Bolt Bushing
Shroud
LE Airfoil
TE
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• Inspection results have shown TIL-1971 units with indications requiring part
replacement within a starts range of approximately 1,400 to ~2,500 actual starts
• Initial inspection recommended at 800-1,200 starts to obtain indication size
and determine operational safety
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TIL-1972 optical
microscope inspection
(at 3,077 starts)
• Inspection results have shown TIL-1972 units with indications requiring part
replacement within a starts range of approximately 2,400 to ~5,000 actual starts
• Initial inspection recommended at 1,700-2,200 starts to obtain indication size
and determine operational safety
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Re-inspection
Methods for Flexibility … capture
Enhanced for interval … Frequency
accuracy and stage-to-stage
configurations of recurring
completeness variation
inspections
Projected analytical
Experienced … Models built off service limit …
>50 inspections inspection history … Allows for
in 2H ‘15 updated regularly adequate time for
rotor planning
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TW balance
CW rabbet and fillet indications/damage TW lockwire tab indication stake crack
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Aft
Unflared Pkg-5 Pkg-4 Pkg-3 stators
only
7FA unflared 4 14 9 10
9FA unflared 3 1 1 4
Total 7 15 10 14
Unflared 7F
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1 Estimates • R0 with dvtl. coat • R0 w/ dvtl. coat • R0 with dvtl. coat • R0 with dvtl. coat
only;
actual durations may •
vary due to outage
• S0-S5 • S0-S5 • S0-S5
circumstances
• S5 load dams • S5 load dams • S5 load dams
• S6-S8 optional • S6-S8 optional • S6-S8 optional
•
• S14-16 • S14-16
Anticipated implementation R = Rotor blade
S = Stator vane
Package 1: Interim, near-term application • R1-R52
• R6-R8 optional
Package 2: Interim, available short outage
• Enhanced clocking
Package 3: Majority of F-technology fleet … 6, 7, and 9
2 R1-R3 with dvtl. coating
Package 4: Customers with aft stator wear R1-R5 undercut
Package 5: Fleet rotor rebuilds and new unit production since ‘09
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*Trademark of General Electric Company.
© 2016, General Electric Company. Proprietary information. All rights reserved.
7FA unflared enhanced compressor
Targeted outage durations R0 biscuit modification is field option in packages 3-5
Hot Gas Path1 Major inspection1 Major inspection 1 Major inspection 1 Major inspection 1
Package 3 Package 4 Package 5A Package 5B Package 5C
• R0 with dvtl. coating • R0 with dvtl. coating • R0 with dvtl. coating • R0 with dvtl. coating • R0 with dvtl. coating
• S0-S4 vanes • S0-S4 vanes • S0-S4 vanes • S0-S4 vanes • S0-S4 vanes
• S0-S4 rings • S0-S4 rings • S0-S4 rings • S0-S4 rings • S0-S4 rings
• S5-S8 optional • S5-S8 optional • S5-S8 optional • S5-S8 optional • S5-S8 optional
R=Rotor blade • S14-16
S=Stator vane • S14-16 optional • S14-16 optional • R1-R52
• R6-R8 optional
• R1-R52 • R1-R52
• Upgrade to robust
• R6-R8 optional • R6-R8 optional back-end rotor
Anticipated implementation • Upgrade to robust
back-end rotor
Package 3: Majority of 7F/9F fleet
1Estimates only … Actual
Package 4: FA.02/FA.03 (unflared) durations may vary due
with aft stator wear to outage circumstances
Package 5A: Fleet rotor rebuilds – FA.03 (unflared) only 2R1-R3 with dvtl. coating R1-R5 undercut
• No Package 1 or 2
Package 5B: Fleet rotor rebuilds – FA.02 only • No S5 load dams
• All pkgs. require cambered IGVs
Package 5C: Fleet rotor rebuilds – F.01 and FA.01 only
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*Trademark of General Electric Company.
© 2016, General Electric Company. Proprietary information. All rights reserved.
Typical F-class CR findings
FSS dovetail slot indications:
• Mechanism - Low cycle fatigue combined
with high cycle fatigue (blade loading)
• Driver: Blade pull load and blade modal
transient response
• Preventive service - install newer F-class R0 dovetail slot indications
style R0 blades
• Repair available – No repair
CW rabbet fillet indications:
• Mechanism - Low cycle fatigue (starts)
and high cycle fatigue Low radius rabbet fillet indications
• Driver: Transient stresses and vibrations
• Repair available – Yes
Surface corrosion and web indications:
• Mechanism – Parent alloy corrosion/thermal
and mechanical stresses
• Driver: Ambient conditions and lower
utilization rates
• Preventive service – Primer/GECC1 coatings
Surface corrosion/web indications
• Repair available – Yes
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MJ rabbet indications 27