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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
www.alstom.com