POWER SERVICE

7th GT13E2 Users’ Conference, Bahrain

GT13E2 Rotor Information

Stefan Florjancic05/03/2007

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 Information – 05/03/07 - P 2

GT13E2 Rotor Information

Rotor Lifetime Page 3

Testing Methods Page 7

Planning Page 11

Lifetime Extension Page 17

Summary Page 21

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 Information – 05/03/07 - P 3

Rotor Lifetime Considerations

• Design Expected Lifetime of 120 kEOH

• ~40% of the fleet soon to reach 96 kEOHat next C inspection

• 9 units soon to reach 120 kEOH at next C inspection

• Forging‘s lead times increasing

• Early planning essential for optimal plant rotor retirement program

Ageing Monitoring Planning Lifetime Extension

Lifetime of rotor can be extended

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 Information – 05/03/07 - P 4

Rotor Lifetime Risk Assessment

Lifetime ExtensionAgeing Monitoring Planning

Monitoring will optimize lifetime without reducing safety margins

Rotor Lifetime

100 %

Failure Expectancy Curve

Without LifetimeMonitoring

Lifetime Monitoring Using NDT

OptimizedLifetimeFailure

Expectancy

Minimum Predicted Service Lifetime expectancy

Active Monitoring of Remaining Lifetime

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 Information – 05/03/07 - P 5

Rotor LifetimeMechanism of Limitation

Lifetime ExtensionAgeing Monitoring Planning

A: Cyclic C: CorrosionB: Creep

Rotor Lifetime

• Starts• Load

• Driven by n° of starts

• Load• Time

• Driven by operating time

• Load• Time

• Driven by operating time

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 Information – 05/03/07 - P 6

GT13E2 Rotor Information

Rotor Lifetime Page 3

Testing Methods Page 7

Planning Page 11

Lifetime Extension Page 17

Summary Page 21

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 Information – 05/03/07 - P 7

Testing MethodsLocation of Interests

Lifetime ExtensionAgeing Monitoring Planning

A5 Internal Relief Groove Radii: LCF

B Fir tree Blade Row 3: Creep

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

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 Information – 05/03/07 - P 8

Testing MethodsPhased Array Technique

Lifetime ExtensionAgeing Monitoring Planning

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 Information – 05/03/07 - P 9

Testing MethodsEddy Current Techniques

Lifetime ExtensionAgeing Monitoring Planning

Radial bore deviceComputer controlledcentral bore device

Fir tree device Comp. blade groove device

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 Information – 05/03/07 - P 10

Testing MethodsCreep Measurement Device

Lifetime ExtensionAgeing Monitoring Planning

• 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

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 Information – 05/03/07 - P 11

Testing MethodsAlstom NDT Field Experiences

Lifetime ExtensionAgeing Monitoring Planning

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

Fleet wide more than 330 rotors inspected by NDTLCF− 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

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 Information – 05/03/07 - P 12

GT13E2 Rotor Information

Rotor Lifetime Page 3

Testing Methods Page 7

Planning Page 11

Lifetime Extension Page 17

Summary Page 21

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 Information – 05/03/07 - P 13

PlanningBase Load and Peaking Units

Base Load PeakingMain damage mechanism: - Creep - LCFDriven by: - Operating Hours - StartsPlant specific evaluation required: - Yes - YesMethods available: - Visual Inspections - Visual Inspections

- Creep Monitoring - Eddy Current Testing- Magnetic Particle

Inspection (MPI)- Phased Array US

Testing (PAT)Retirement/Reconditioning criteria: - Design Lifetime - Design Lifetime

- Assessment - Assessment- NDT - NDT- Material Data - Material Data

Lifetime Drivers

Ageing Monitoring Lifetime ExtensionPlanning

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 Information – 05/03/07 - P 14

PlanningTesting Schedule

Theoretical End of Life*

C3C2C1

GT13E2 FleetGeneral Recommendation

Time C4 C5 C6

Visual Inspection

Creep Monitoring & Magnetic Particle Inspection

Eddy Current & Phased Array Testing

* Figures may change according to Upgrade type and Operating RegimeCritical Opportunity for Start of Tests

Ageing Monitoring Lifetime ExtensionPlanning

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 Information – 05/03/07 - P 15

PlanningSimulated Retirement Program for a 5 GT Plant

“End of Life“

New

Approx. 15 months* Approx. 15 months* Approx. 15 months* Approx. 15 months* ~ 5 years

Reco. Reco. Reco. Reco.

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.

Ageing Monitoring Lifetime ExtensionPlanning

* Figures may change according to raw material availability

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 Information – 05/03/07 - P 16

GT13E2 Rotor Information

Rotor Lifetime Page 3

Testing Methods Page 7

Planning Page 11

Lifetime Extension Page 17

Summary Page 21

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 Information – 05/03/07 - P 17

Minor Repairs performed

Compressor

Turbine

Replacement

Lifetime ExtensionRotor Reconditioning

Rotor Reconditioning

Cutting Zone

Ageing LifetimeExtensionMonitoring Planning

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 Information – 05/03/07 - P 18

Lifetime ExtensionRotor Reconditioning

− All advanced processes established and available

• Proven technology based on 50 years of experience

− Complete Hot End replaced Material properties reset

• Manufacturing & test procedures according to new rotor manufacturing

including bladed balancing

− More than 20 GT-rotors reconditioned and in operation

− Throughput time approximately 15 months*

Rotor Reconditioning

Ageing LifetimeExtensionMonitoring Planning

* Figures may change according to raw material availability

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 Information – 05/03/07 - P 19

GT13E2 Rotor Information

Rotor Lifetime Page 3

Testing Methods Page 7

Planning Page 11

Lifetime Extension Page 17

Summary Page 21

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 Information – 05/03/07 - P 20

Summary

− Rotor requires dedicated consideration

− ~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

Summary

Ageing Monitoring LifetimeExtensionPlanning

No Alstom welded rotor failure to date

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