External Services (Gas Turbines)

Heavy-Duty Gas
Turbine Operating
and Maintenance
Considerations

HDGT.PPT/ 1

External Services (Gas Turbines)

A Maintenance Program should:

Optimize owners maintenance costs
Maximize equipment availability

HDGT.PPT/ 2

External Services (Gas Turbines)

Because not all customers operate their gas turbines the same,

Case 1

Case 2

8,000 Hrs/Yr
160 Starts/Yr
HGP at 3 years

1,000 Hrs/Yr
400 Starts/Yr
HGP at 3 years, not 24 years

not all customer maintenance programs are the same.

BHEL Provides Guidance for Customer Maintenance Planning
HDGT.PPT/ 3

External Services (Gas Turbines)

Factors Affecting Maintenance Planning and

Maintenance Program
Manufacturers
Recommended
Maintenance
Program

Design
Features

Duty
Cycle

Cost of
Downtime

Type of
Fuel

Diagnostics

Maintenance
Program
Availability
Need
On-Site
Maintenance
Capability

Expert
Systems

Utilization
Need

Environment

Reserve
Requirements

HDGT.PPT/ 4

External Services (Gas Turbines)

Potential Failure Modes

Hot-Gas-Path Components
Continuous Duty Application
Creep Deflection
Creep Rupture
Corrosion
Oxidation
Erosion
High-Cycle Fatigue

Cyclic Duty Application

Themal Mechanical
Fatigue
Rubs/Wears

HDGT.PPT/ 5

External Services (Gas Turbines)

GE Bases Gas Turbine Maintenance

Requirements on Independent Counts of
Starts & Hours Fatigue Limits Life
Different

Mechanism
Limit Life

Failure Region
Starts

Design
Life
Oxidation
Creep,
Corrosion
& Wear
Limit Life

GE Inspection
Recommendation

Competition
Inspection
Recommendation
(Equivalent Hours Per Start)

Design
Life
GE Inspection
Recommendation
Hours
HDGT.PPT/ 6

External Services (Gas Turbines)

GE vs. Equivalent Hours Approach

Case 2
4000 Hrs/Yr
300 Starts/Yr
GE Every 4 Yrs
EOH Every 2.4 Yrs

1200
1000

GE
METHOD

800

EOH
METHOD

Starts 600

Case 1
8,000 Hrs/Yr
160 Starts/Yr
GE Every 3 Yrs
EOH Every 2.1 Yrs

400
200
0
0

12

16

20

24

28

Fired Hours (x1000)

HDGT.PPT/ 7

External Services (Gas Turbines)

Maintenance Cost and Equipment Life

Are Influenced by Key Service Factors
Fuel
Firing Temperature
Steam/Water Injection
Cyclic Effects (Start-up rate, number of trips)
Air Quality

Service Factors Different From the Reference Condition*

Can Increase Maintenence Cost & Reduce Maintenence Intervals

HDGT.PPT/ 8

External Services (Gas Turbines)

Maintenance Factors
Hot Gas Path (Buckets & Nozzles)
Typical Max Inspection Intervals (MS6B/Ms7EA)
Hot Gas Inspection 24,000 hrs or 1200 Starts
Major Inspection
48,000 hrs or 2400 Starts
Criterion is Hours or Starts (Whichever Occurs First)

Factors Impacting Maintenance

Hours Factors
Fuel
Gas
Distillate
Crude
Residual

Starts Factors

1
1.5
2 to 3
3 to 4

Trip From Full Load

Fast Load
Emergency Start

8
2
20

Peak Load
6
Water/Steam Injection
Dry Control 1 (GTD-222)
Wet Control 1.9 (5% H20)

HDGT.PPT/ 9

External Services (Gas Turbines)

Maintenance Factors Reduce Maintenance

Interval
1400
1200

Starts Factors
Trips, Fast Starts

1000

Starts

800
Hours Factors
Firing Temp
Steam/H2O
Injection
Fuel Type

600
400
200
0
0

12

16

20

24

28

Fired Hours (x1000)

HDGT.PPT/ 10

External Services (Gas Turbines)

Estimated Effect of Fuel Type on Maintenance

Residual

Maintenance
Factor
Distillates
Heavy

Light
Natural Gas

7 8 9 10 11 12 13 14 15

20

Fuel Percent Hydrogen by Weight in Fuel

HDGT.PPT/ 11

External Services (Gas Turbines)

Hot Corrosion
Oxidation
is
Limiting
Factor

Corrosion becomes
Limiting Factor

Component surface saturated

with condensated corrosive deposits.
Life limited primarily by kinetics of the
corrosion reaction.

Life

Na Concentration in Combustion Products

HDGT.PPT/ 12

External Services (Gas Turbines)

Bucket Life Firing Temperature Effect

(MS5001P Uncooled bucket)

100
10
Life
Factor

Peak rating of
Tf + 100 F (65 C)
has life factor of 6

(MS6001B/MS7001EA/MS9001E)

0.1
0.01
-200

-100

100

200

Change in firing temperature - degrees F

HDGT.PPT/ 13

External Services (Gas Turbines)

Example 1:
A unit which has operated at Peak Load (+100 F) for
100 hours would have to be operated at - 50 F for 833
hours to maintain a maintenance factor of ONE.

MF =

Factored Hours
Actual Hours
833 hrs (0.4) + 100 hrs (6.0)

=1

(833 + 100) hrs

HDGT.PPT/ 14

External Services (Gas Turbines)

Example 2:
Determine the Maintenance Factor for a unit which
operates at Base Load for 6000 hours, Peak Load for
600 hours, and at -50 F Firing Temperature for
15000 hours.
MF =

Factored Hours
Actual Hours
6000 hrs (1.0) + 500 hrs (6.0) + 1500 hrs (0.4)
(6000 + 1500 + 500) hrs

MF = 1.2
HDGT.PPT/ 15

External Services (Gas Turbines)

Firing Temperature and Load

Heat Recovery vs Simple Cycle
2500

Close IGVs
84 to 57 deg
Tf constant @
2020 F

Heat Recovery
Simple Cycle
o
57 VIGV

2000
Firing
Temp.
o
F 1500

o
84 VIGV

Close IGVs
84 to 57 deg
Tx constant @ 700 deg F

1000
20

40

60
% Load

80

100

120
HDGT.PPT/ 16

External Services (Gas Turbines)

Heavy Fuel Maintenance Factors

(MS6001B/7001EA/9001E)

Maximum Heavy Fuel

Firing Temperature

10

5
Maintenance
Factor

Residual
Crude

1
-200

-150

-100

-50

50

Delta Firing Temperature F

HDGT.PPT/ 17

External Services (Gas Turbines)

Steam/Water Injection and Nozzle

Creep Deflection
Steam/Water Injection Impacts
Stage 2/3 Nozzle Maintenance
and Life

2nd Stage
Nozzle

3rd Stage
Nozzle

Increases Nozzle Gas Loads

Increases Downstream
Deflection Rate
Decreases Maintenance
Interval

GTD-222 Nozzle Alloy Minimizes

This Effect
HDGT.PPT/ 18

External Services (Gas Turbines)

Steam/Water Injection and Bucket/Nozzle Life

Steam/Water Injection Increases Metal Temperature
of
Hot-Gas-Path Components
Water Effects Gas Transport Properties:
- Thermal Conductivity increases
- Specific Heat increases
- Viscosity remains steady

This increases Heat Transfer Coefficients which increases metal

temperature and decreases bucket life
Example (MS7001EA Stage 1 Bucket):
3% Steam increaes bucket metal temperature 15 F and
decreases Life -33%
at constant firing temperature
HDGT.PPT/ 19

External Services (Gas Turbines)

Exhaust Temperature Control Curve

Dry Versus Wet Control
Steam Injection for 25 ppm NOX

50

Wet Control
40

Exhaust
Temperature
30
o
F
20
10
0

3% Steam Inj.
o
TF = 2020 F
Load Ratio = 1.10

Dry Control
0% Steam Inj.
TF = 2020 o F
Load Ratio = 1.0

3 % Steam Inj.
o
TF = 1994 F
Load Ratio = 1.08

Compressor Discharge Pressure (psig)

HDGT.PPT/ 20

External Services (Gas Turbines)

Maintenance Factors Reduce Maintenance

Interval
1400
1200

Starts Factors
Trips, Fast Starts

1000

Starts

800
Hours Factors
Firing Temp
Steam/H2O
Injection
Fuel Type

600
400
200
0
0

12

16

20

24

28

Fired Hours (x1000)

HDGT.PPT/ 21

External Services (Gas Turbines)

Turbine Start/Stop Cycle

Base Load

Acceleration

Unload Ramp

Light-off

Exh.
Temp.

Full Speed
No Load

Load Ramp

Warm-up

Full Speed
No Load

Fired Shutdown
Trip

Start-up

Time

Shutdown
HDGT.PPT/ 22

External Services (Gas Turbines)

Maint. Factor

Effect of Start Cycle Max Load Level

1.4
1.2
1
0.8
0.6
0.4
0.2
0
0

20

40

60

80

100

120

% Load
HDGT.PPT/ 23

External Services (Gas Turbines)

Low Cycle Fatigue Life
Sensitivities First-Stage Bucket
Leading Edge Temperature/Strain
Normal Start & Trip

Normal Startup/Shutdown

TMAX
Strain
-%

Temperature

Strain
-%

TMAX
Temperature

1 Trip Cycle = 8 Normal Shutdown Cycle

HDGT.PPT/ 24

External Services (Gas Turbines)

Trip Severity Factor

Maintenance Factor - Trips from Load

10
9
8
7
6
5
4
3
2
1
0

Base

For trips during Start-up

Acceleration, assume
Trip Severity Factor = 2

FSNL

20

40

60

80

100

120

% Load
HDGT.PPT/ 25

External Services (Gas Turbines)

Heavy-Duty Gas Turbine

Shutdown Inspections
Combustion
Hot-Gas-Path
Major

Major inspection
Hot-Gas-Path
Inspection
Combustion
Inspection

HDGT.PPT/ 26

External Services (Gas Turbines)

MS7001EA Combustion Inspection Intervals

NOx
Combustor Emissions
Design
Level (ppm)

Standard
Liner

65

42

Fuel
Diluent

Gas
Hours/Starts

Dry

8,000/800

Steam
Water
Steam
Water

------8,000/400
6,500/300

Distillate
Hours/Starts
8,000/800
8,000/400
6,500/300

3,000/150
1,500/100

Extendor Combustion System Wear Kit Increases

Combustion Inspection to as Much as 24,000 Hours
HDGT.PPT/ 27

External Services (Gas Turbines)

Base Line Recommended Inspection Intervals

Base Load - Gas Fuel - Dry
Hours/Starts
Type of
Inspection
Combustion
Hot-Gas Path
Major

MS32/52/51
Upgrade

12000/800
Eliminated/1200
4800/2400

MS6B

MS7E/EA

MS9E/7FA/
9FA

12000/800

8000/800

8000/800

24000/1200

24000/1200

24000/900

48000/2400

48000/2400

48000/2400

Factors That Can Reduce Maintenance Intervals

Trips from Load
Fuel
Start Cycle
Load Setting
HGP Hardware Design
Steam/Water Injection
Peak Load Tf Operation

HDGT.PPT/ 28

External Services (Gas Turbines)

Maintenance Factor Definition

IDEAL INTERVAL =
RECOMMENDED
INTERVAL
=

Interval for Continuous Base Load

on Clean Natural Gas

Ideal Interval determined from

application of maintenance factors

HDGT.PPT/ 29

External Services (Gas Turbines)

HGPI Hours Based Criterion
MS6001/7001/9001

24000
Maintenance Interval
=
(Hours)
Maintenance Factor

Where:
Factored Hours
Acutal Hours
Factored Hours = (K + (M x I)) x (G + 1.5 D + Af H + 6 P)
Actual Hours
= (G + D + H + P)

Maintenance Factor =

G = Operating Hours on Gas Fuel

D = Operating Hours on Distillate Fuel
H = Operating Hours on Heavy Fuel
Af = Heavy Fuel Severity Factor (Residual Af = 3 to 4, Crude Af = 2 to 3)
P = Peak Load Operating Hours
I = Percent Water/Steam Injection Referenced to Inlet Air Flow
M & K = Water/Steam Injection Constants
M

Control

Steam Injection

N2 / N3 Material

0
0
.18
.18

1
1
.6
1

Dry
Dry
Dry
Wet

< 2.2 %
> 2.2 %
> 2.2 %
>0%

GTD-222 / FSX-414
GTD-222
FSX-414
GTD-222 / FSX-414

HDGT.PPT/ 30

External Services (Gas Turbines)

HGPI Starts Based Criterion
MS6001/7001/9001

S
Maintenance Interval
=
(Starts)
Maintenance Factor

Where:
Maintenance Factor =

Factored Starts
Acutal Starts

Factored Starts = (0.5 NA + NB + 1.3 NP + 20 E + 2 F +

Actual Starts

aTi Ti )

i=1

= (NA + NB + NP + E + F)

S = Maximum Starts-Based Maintenance Interval (Model Size Dependent)

NA = Number of Part Load Start/Stop Cycles (< 60% Load)
NB = Number of Normal Base Load Start/Stop Cycles
NP = Number of Peak Load Start/Stop Cycles
E
= Number of Emergency Starts
S
Model Series
F
= Number of Fast Load Starts
1,200
Tn = Trips
MS6B/MS7EA
aT n = Trip Severity Factor
1,200
MS6FA
n
= Trip number
900
MS9E
900
MS7F/7FA/9F/9FA
HDGT.PPT/ 31

External Services (Gas Turbines)

First-Stage Nozzle Wear Preventive Maintenance

Gas-Fired - Continuous Duty - Base Load
New Nozzle Acceptance Standards

Repaired Nozzle
Nozzle Min. Acceptance
Condition Standard

1st
Repair

2nd
Repair

3rd
Repair

Without
Repair

Repair Cost
Exceeds
Replacement
Cost

Severe Deterioration
10,000

20,000

30,000

40,000

50,000

Operating Hours

60,000

70,000

80,000
HDGT.PPT/ 32

External Services (Gas Turbines)

Estimated Repair & Replacement
Repair
Interval
Combustion Liners
Transition Pieces
Fuel Nozzles
Cross-Fire Tubes
1st Stage Nozzles
2nd Stage Nozzles
3rd Stage Nozzles
1st Stage Buckets

CI
CI
CI
CI
HGPI
HGPI
HGPI
HGPI*

2nd Stage Buckets

3rd Stage Buckets
1st Stage Shrouds
2nd/3rd Stage Shrouds

HGPI
HGPI
HGPI
HGPI

Replace
Interval
(Hours)
5 (CI)
6 (CI)
3 (CI)
3 (CI)
3 (HGPI)
3 (HGPI)
3 (HGPI)
2 (HGPI)
3 (HGPI)**
3 (HGPI)
3 (HGPI)
2 (HGPI)
3 (HGPI)

Replace
Interval
(Starts)
5 (CI)
6 (CI)
3 (CI)
3 (CI)
3 (HGPI)
3 (HGPI)
3 (HGPI)
3 (HGPI)

4 (HGPI)
4 (HGPI)
2 (HGPI)
4 (HGPI)

CI = Combustion Inspection Interval

HGPI = Hot Gas Path Inspection Interval
* When recoating, perform after one hours-based HGPI
** Two HGPI without recoat, Three HGPI with Recoat
HDGT.PPT/ 33

External Services (Gas Turbines)

Maintenance Factors Summary

Maintenance Requirements are Based on an Independent
Count of Hours and Starts
Certain Operating Factors Reduce Maintenance Intervals
Peak Loac
Steam/Water Injection >2.2%
Liquid Fuel
Trips From Load
Fast Starts
Exceeding GE Specification Limits can Significantly
Increase Maintenance Factors and Reduce Component Life
Equations for Establishing Application Specific Hot Gas
Path Maintenance Intervals are Available
HDGT.PPT/ 34

External Services (Gas Turbines)

Bucket Life Firing Temperature Effect

MS6001B / MS7001EA / MS9001E
100

Life
10
Factor

Peak Rating
+100F (56C) T.
Life Factor -6

1
Change in 0
Firing
0
Temperature

50
25

100

150

50

75

200
100

250
125

C
HDGT.PPT/ 35

External Services (Gas Turbines)

Operating Inspection Data Parameters

Speed
Load
Fired Starts
Fired Hours
Site Barometric Reading
Temperatures
Inlet Ambient
Compressor Discharge
Turbine Exhaust
Turbine Wheelspace
Lube Oil Header
Lube Oil Tank
Bearing Drains
Exhaust Spread

Pressures
Compressor Discharge
Lube Pump(s)
Bearing Header
Cooling Water
Fuel
Filters (Fuel, Lube, Inlet Air)
Vibration Data for Power Train
Generator
Output Voltage Field Voltage
Phase Current Field Current
VARS
Stator Temp.
Load
Vibration
Start-Up Time
Coast-Down Time
HDGT.PPT/ 36

External Services (Gas Turbines)

Deterioration of Gas Turbine Performance

Due to Compressor Blade Fouling
8
6
4

Fouling

2
Heat Rate
Increase
%

5% Loss of
Airflow

-2
-4

Output
Decrease
%

-6
-8
-10

Fouling

-12

-14

-1 -2 -3 -4 -5 -6 -7 -8
Pressure Ratio Decrease - %

HDGT.PPT/ 37

External Services (Gas Turbines)

Maintenance Inspections
Hot Gas Path Inspection - Key Elements
Combustion Inspection Work Scope Plus:
Key Hardware
Nozzles (1,2,3)

Buckets (1,2,3)
Stator Shrouds
IGVs & Bushings

Compressor Blading
(Borescope)

Criteria:

Inspect for:

Potential Actions:

Foreign Objects Damage

Repair/Refurbishment
Nozzles
Oxidation/Corrosion/Erosion
Weld Repair
Cracking
Reposition
Cooling Hole Plugging
Recoat
Remaining Coating Life
Buckets
Nozzle Deflection/Distortion
Strip & Recoat
Weld Repair
Abnormal Deflection/Distortion
Blend
Abnormal Wear
Missing Hardware
Clearance Limits

Op. & Instr. Manual

TILs
Field Engineers

Inspection
Methods:

Visual
LP
Boroscope

Availability of On Site
Spares Is Key to
Minimizing Downtime
HDGT.PPT/ 38

External Services (Gas Turbines)

Maintenance Inspections
Combustion Inspection - Key Elements
Key Hardware
Combustion Liners
Combustion Covers
Fuel Nozzles
Transition Pieces
Cross Fire Tubes
Flow Sleeves
Check Valves
Spark Plugs
Flame Detectors
Flex Hoses

Criteria:

Op. & Instr. Manual

TILs
Field Engineers

Inspect for:

Potential Actions:

Foreign Objects
Abnormal Wear
Cracking
Liner Cooling Hole Plugging
TBC Coating Condition
Oxidation/Corrosion/Erosion
Hot Spots/Burning
Missing Hardware
Clearance Limits
Borescope Compressor and
Turbine

Inspection
Methods:

Repair/Refurbishment
Liners
Cracking/Erosion/Wea
r
TBC Repair
Transition Pieces
Wear
TBC Repair
Distortion
Fuel Nozzles
Plugging
Erosion/Wear
Cross Fire Tubes
Wear/Burning
Visual
Availability of On Site
Spares Is Key to
LP
Minimizing Downtime
Boroscope
HDGT.PPT/ 39

External Services (Gas Turbines)

Maintenance Inspections
GT Major Inspection - Key Elements
Combustion Inspection Work Scope
HotGas Path Inspection Work Scope Plus
Key Hardware

Inspect for:

Potential Actions:

Repair/Refurbishment
Foreign Objects Damage
Stator Shrouds
Oxidation/Corrosion/Erosion
Turbine Wheels Dovetails
Oxidation/Corrosion/Erosio
Cracking
n
Journal and Seal Surfaces
Buckets
Leaks
Coating Deterioration
Bearing Seals
Abnormal Wear
FOD/Rubs/Cracking
Missing Hardware
Inlet System
Tip Shroud Deflection
Creep Life Limit
Clearance Limits
Exhaust System
Nozzles
Severe Deterioration
IGV Bushings
Criteria: Op. & Instr. Manual Inspection Visual
Wear
Bearings/Seals
Methods: LP
TILs
Booring/Wear
Field Engineers
Borescope
Compressor Blades
Corrosion/Erosion HDGT.PPT/ 40
Compressor Blading