7th GT13E2 Users Conference, Bahrain

GT13E2 Rotor Information

Stefan Florjancic
05/03/2007

POWER SERVICE

GT13E2 Rotor Information

Rotor Lifetime

Page 3

Testing Methods

Page 7

Planning

Page 11

Lifetime Extension

Page 17

Summary

Page 21

Rotor Information 05/03/07 - P 2

ALSTOM 2007. 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.

Rotor Lifetime
Considerations

Ageing

Monitoring

Planning

Lifetime Extension

Design Expected Lifetime of 120 kEOH ~40% of the fleet soon to reach 96 kEOH at next C inspection 9 units soon to reach 120 kEOH at next C inspection Forgings lead times increasing Early planning essential for optimal plant rotor retirement program

Lifetime of rotor can be extended

Rotor Information 05/03/07 - P 3
ALSTOM 2007. 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.

Rotor Lifetime
Risk Assessment

Ageing

Monitoring

Planning

Lifetime Extension

Monitoring will optimize lifetime without reducing safety margins

Failure Expectancy Minimum Predicted Service Lifetime expectancy Optimized Lifetime 100 % Without Lifetime Monitoring Failure Expectancy Curve Lifetime Monitoring Using NDT Rotor Lifetime
Rotor Information 05/03/07 - P 4
ALSTOM 2007. 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.

Active Monitoring of Remaining Lifetime

Rotor Lifetime
Mechanism of Limitation

Ageing

Monitoring

Planning

Lifetime Extension

Rotor Lifetime

A: Cyclic
Starts Load Driven by n of starts

B: Creep
Load Time Driven by operating time

C: Corrosion
Load Time Driven by operating time

Rotor Information 05/03/07 - P 5

ALSTOM 2007. 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.

GT13E2 Rotor Information

Rotor Lifetime

Page 3

Testing Methods

Page 7

Planning

Page 11

Lifetime Extension

Page 17

Summary

Page 21

Rotor Information 05/03/07 - P 6

ALSTOM 2007. 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.

Testing Methods
Location of Interests

Ageing

Monitoring

Planning

Lifetime Extension

A1 Central & Radial Bore: LCF A2 Fir tree Blade Row 1-5: LCF A3 Turbine/Drum Transient Radii: LCF A4 Compressor Groove Rows 20 & 21: LCF A5 Compressor Groove Row 4: HCF

A5 Internal Relief Groove Radii: LCF B Fir tree Blade Row 3: Creep
Rotor Information 05/03/07 - P 7
ALSTOM 2007. 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.

Testing Methods
Phased Array Technique

Ageing

Monitoring

Planning

Lifetime Extension

Rotor Information 05/03/07 - P 8

ALSTOM 2007. 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.

Testing Methods
Eddy Current Techniques

Ageing

Monitoring

Planning

Lifetime Extension

Computer controlled central bore device

Radial bore device

Fir tree device

Rotor Information 05/03/07 - P 9
ALSTOM 2007. 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.

Comp. blade groove device

Testing Methods
Creep Measurement Device

Ageing

Monitoring

Planning

Lifetime Extension

No temperature induced strain deviations by calibration on a special rig

rig made of rotor material rig has comparable dimensions to the real geometry

Higher accuracy than off-the-shelf devices > 10 times higher accuracy Measurement accuracy: +/- 0.005 mm

Rotor Information 05/03/07 - P 10

ALSTOM 2007. 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.

Testing Methods
Alstom NDT Field Experiences

Ageing

Monitoring

Planning

Lifetime Extension

OEM experience on welded gas turbine rotors for over 61 Million OH

Fleet wide more than 330 rotors inspected by NDT
LCF 86 rotors in operation with indications Monitoring 14 rotors reconditioned 8 rotors repaired on-site for one further C interval operation 22 rotors replaced with new ones (commercially driven plant specific decision) Creep 24 rotors reconditioned due to end of creep life, turbine side Continuous development of NDT technologies ongoing Assessment criteria continuously refined

Rotor Information 05/03/07 - P 11

ALSTOM 2007. 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.

GT13E2 Rotor Information

Rotor Lifetime

Page 3

Testing Methods

Page 7

Planning

Page 11

Lifetime Extension

Page 17

Summary

Page 21

Rotor Information 05/03/07 - P 12

ALSTOM 2007. 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.

Planning
Base Load and Peaking Units

Ageing

Monitoring

Planning

Lifetime Extension

Lifetime Drivers
Base Load
Main damage mechanism: Driven by: Plant specific evaluation required: Methods available: - Creep - Operating Hours - Yes - Visual Inspections - Creep Monitoring

Peaking
- LCF - Starts - Yes - Visual Inspections - Eddy Current Testing - Magnetic Particle Inspection (MPI) - Phased Array US Testing (PAT) - Design Lifetime - Assessment - NDT - Material Data

Retirement/Reconditioning criteria:

- Design Lifetime - Assessment - NDT - Material Data

Rotor Information 05/03/07 - P 13

ALSTOM 2007. 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.

Planning
Testing Schedule

Ageing

Monitoring

Planning

Lifetime Extension

GT13E2 Fleet
General Recommendation Eddy Current & Phased Array Testing Creep Monitoring & Magnetic Particle Inspection Visual Inspection
Time C1 C2 C3 C4 C5 C6

Theoretical End of Life* * Figures may change according to Upgrade type and Operating Regime Critical Opportunity for Start of Tests
Rotor Information 05/03/07 - P 14
ALSTOM 2007. 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.

Planning
Simulated Retirement Program for a 5 GT Plant New Reco. Reco. Reco.

Ageing

Monitoring

Planning

Lifetime Extension

Reco.

Approx. 15 months*

Approx. 15 months*

Approx. 15 months*

Approx. 15 months*

~ 5 years

End of Life

Early planning essential for optimal plant rotor retirement program with lowest risk. Early retirement and reconditioning of a rotor may result in the lowest plant maintenance costs.
* Figures may change according to raw material availability
Rotor Information 05/03/07 - P 15
ALSTOM 2007. 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.

GT13E2 Rotor Information

Rotor Lifetime

Page 3

Testing Methods

Page 7

Planning

Page 11

Lifetime Extension

Page 17

Summary

Page 21

Rotor Information 05/03/07 - P 16

ALSTOM 2007. 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.

Lifetime Extension
Rotor Reconditioning

Ageing

Monitoring

Planning

Lifetime Extension

Rotor Reconditioning
Cutting Zone

Compressor Turbine

Minor Repairs performed Replacement

Rotor Information 05/03/07 - P 17
ALSTOM 2007. 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.

Lifetime Extension
Rotor Reconditioning

Ageing

Monitoring

Planning

Lifetime Extension

Rotor Reconditioning
All advanced processes established and available
Proven technology based on 50 years of experience

Complete Hot End replaced

including bladed balancing

Material properties reset

Manufacturing & test procedures according to new rotor manufacturing

More than 20 GT-rotors reconditioned and in operation Throughput time approximately 15 months*

* Figures may change according to raw material availability

Rotor Information 05/03/07 - P 18
ALSTOM 2007. 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.

GT13E2 Rotor Information

Rotor Lifetime

Page 3

Testing Methods

Page 7

Planning

Page 11

Lifetime Extension

Page 17

Summary

Page 21

Rotor Information 05/03/07 - P 19

ALSTOM 2007. 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.

Summary
Summary Rotor requires dedicated consideration

Ageing

Monitoring

Planning

Lifetime Extension

~40% of the fleet soon to reach latest monitoring start opportunity Long forging lead times Alstom offers partnership with the customer for optimal planning Latest calibrated monitoring technologies available at Alstom Detailed design integrity and critical locations known by the OEM Reconditioning processes based on 50 years of new manufacturing

No Alstom welded rotor failure to date

Rotor Information 05/03/07 - P 20
ALSTOM 2007. 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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