CPM_AP_LM6000-IND-024[1] 2009

Aero Energy Package SessionLM6000TM and LM2500 ®

GE Proprietary Information

The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE

2 GE Proprietary - Subject to Restrictions on Cover Page

Ground Rules

• Please turn off or put your mobile phones on vibrate/silence

• Please withhold from having side conversations

• Technical discussions only

Please feel free to ask questions of GE and other Customers during the presentation…

dialog is encouraged


Agenda

• LM2500 Technical Programs

• LM6000 New Product Introduction

• LM6000 Technical Programs


LM2500 PackagePrograms


LM2500 Pkg Reliability 12 months rolling

99.8

90

92

94

96

98

100

Aug-

06Oc

t-06

Dec-

06Fe

b-07

Apr-0

7Ju

n-07

Aug-

07Oc

t-07

Dec-

07Fe

b-08

Apr-0

8Ju

n-08

Aug-

08Oc

t-08

Dec-

08Fe

b-09

Apr-0

9Ju

n-09

Relia

bilit

y (%

)

P75 Pkg ReliabilityP50 Pkg ReliabilityP25 Pkg Reliability

Source: ORAP®; All rights reserved: SPS®

LM2500/+ Package ReliabilityUnits reporting - 2008: 87, 2009: 88 GG Pkg BOP

SCP


LM2500 Pkg Availability 12 months rolling

97.7

90

92

94

96

98

100

Aug-

06Oc

t-06

Dec-

06Fe

b-07

Apr-0

7Ju

n-07

Aug-

07Oc

t-07

Dec-

07Fe

b-08

Apr-0

8Ju

n-08

Aug-

08Oc

t-08

Dec-

08Fe

b-09

Apr-0

9Ju

n-09

Avai

labi

lity

(%)

P75 Pkg AvailabilityP50 Pkg AvailabilityP25 Pkg Availability


LM2500/+ Package AvailabilityUnits reporting - 2008: 87, 2009: 88 GG Pkg BOP

SCP


Product Bulletins Issued since September 2008


Product Bulletins Issued since September 2008, Continued


Product Letters Issued


BRUSH Automatic Voltage Regulator

Improvement • Alert PB 194 informs customers of BRUSH Service Bulletin SB0000004B

which offers two fault detector kits depending on the AVR configuration. These kits are designed to monitor temperature of the FSR and will trigger at a temperature below that which would cause damage.

Field Action• Incorporate Alert PB 194 (LM2500) to update the existing BRUSH AVR with a

fault detector kit. - Timing Code 2

Background• LM2500/LM2500+ Units with Brush AVR has a potential

issue relating to the contactor in the Brush AVRs (Automatic Voltage Regulator).

Investigation/Results• A fault in the field suppression contactor (FSC) may result to

overheating of the internal field suppression resistor (FSR) that could lead to a fire

Applicable to: SAC DLEBase Plus +G4


LM2500+/+ G4 Package Vent Fan Inlet Obstruction by Side Exit Exhaust Collector

Improvement• Campaign PB 190 introduce exhaust collector insulation straps (straps) to

hold in place the insulation blankets on the exhaust collector assembly.

Field Action• Incorporate PB 190, Timing Code 3

Background• Ventilation fans for negative pressure systems pull the insulation on the

exhaust collector into the vent fan cavity and blocks the airflow path. This results in poor airflow across the package and may increase enclosure temperature.

Investigation/Results• Straps were not supplied by the vendor.

Applicable to: SAC DLEBasePlus +G4

Exhaust collector insulation straps


Improvement/Field Action• Alert PB 169 revised to check condition of

flex joint and replace if mis-aligned. Properly reinstall new flex joint with correct alignment.

• Timing Code 1, 2

LM2500+/HSPT Fire Event

Background• LM2500+/HSPT package reported fire event

in the main enclosure and the Reduction Gear Box (RGB) enclosure.

Investigation/Results• Cause of fire was a rupture of the flex joint

at mineral lube oil pump outlet. The rupture appeared due to the mis-alignment of the joint.


735077-ELBOW 735061-PIPE

Flex Joint Cracks


Exhaust Access Panel Gap Leakage Repair

Improvement• Campaign PB 188 provides instruction to repair the gap with Sikaflex sealant,

which will prevent the air from exiting the package wall› Allow sufficient down time for cooling of the package external wall and curing of

the Sikaflex® 221 sealant

Field Action• Incorporate PB 188 - Timing Code: 3


Background• The package fan cooling air and engine discharge air

escapes through a gap between the exhaust access panel and package wall.

Investigation/Results• Missing gasket from exhaust access panel


Generator Ladder Safety Gate

Improvement• Alert PB 200 - installation of a gate (supplied by Brush) across the opening of

the generator ladder.

Field Action• Incorporate PB 200 – Timing Code: 1


Background• On some units with Brush Air-cooled generator, the

generator ladder did not include a safety gate

› Safety gate is required by OSHA.

Investigation/Results• Safety gate was not supplied by Brush


Fire Protection Panel Release ModuleReplacement

Action• Campaign PB 186 provides instructions to replace the old Release Module

with the new Release Module (Manufacture P/N AL8001443-D) on the FPP.

Field Action• Incorporate PB 186 - Timing Code: 2


Background• The Release Module on the Fire Protection Panel (FPP)

does not provide an alarm/trip functions for CO2 block valve closure.

Investigation/Results• Fire Protection panels were received from the vendor

with an incorrect release module installed.


Gas Generator Removal - PL2500-09-01

Field Action• For maintenance such as HS replacement, GT removal is required from the

affected packages - PL2500-09-01

• GT alignment may be required during reinstallation in the package


Background• The GG interferes with the front wall of the package if

removed with PT remaining in the package.

Improvement Plan• Package/lift fixture design change in progress to allow

GG removal.

> Design completion ~3Q10


Synthetic Lube Oil Pressure Transmitter Range

Action • Campaign PB 191 & PB 184 introduces software

update to increase the range to 0 –150 PSIG

• Timing Code: 2

Field Action• Incorporate PB 191 &PB 184


Background• With the sealed damper bearing, the oil supply pressure occasionally exceeds

the turbine lube pressure transducer limit of 100 psig (689 kPa) during start up.

• The control system assumes this condition as turbine lube pressure transducer failure and shuts down the engine.

Investigation/Results• Pressure transmitters PT1021A and PT1021B was set to lower range of 0 to 100

PSIG.

Pressure Transmitter

LM6000 New Products


New Product Offerings Summary - 2009Power &

EfficiencyFunctionality RAM

LM6000 STIG™ UpgradeActive VIGV Software UpgradePost Overhaul Site Performance GuaranteeShipping Container Air Ride AdapterS6 Software Upgrade PC/PDLM6000 Mechanical driveAmmonia Absorption ChillerLM6000PG Product launch


Upcoming Products Summary - 2010

Power & Efficiency

Functionality RAM

Dual Fuel DLE LM6000PF PackageLow Noise / 80 dBaLM6000PH Product LaunchLM6000PC to PG Product LaunchLM6000PC/PD/PF Hot End Drive Package for RepowerPro Boost


38%

39%

40%

41%

42%

43%

44%

45%

46%

LM6PC STIG LM5 STIG 120 LM6 PC SprintSteam NOx

LM6 PC SprintWater NOx

GT

Shaf

t Effi

cien

cy

LM6000 STIG™ Upgrade •Efficiency

- Inject up to 50,000 lbs/hr steam into compressor discharge

- 5% maximum heat rate improvement

- Maintain current 30,000 lbs/hr steam for NOx control

•Power- 2 MW improvement in power output, dependent on site conditions

•Scope- Initial applicable models… LM6000 PC, SPRINT®, gas fuel only

- In package and on engine steam delivery hardware & controls

- Core engine modifications

•Availability- Launch customer identified, site validation test scheduled for 2Q 2010

- Available to quote today


LM6000 ARCTICTM – Ammonia Absorption Chiller

•Performance– Up to 2 MW additional power– 200-250 Btu/kWh heat rate improvement

•Scope- 2000 ton chilling capacity- Heating capability – performance heating, anti-icing

•Additional benefits– Reduced equipment needs… anti-icing, switchgear, mech. compressor– Supports flexible generation… quick start, low load operation

•Availability- First fire in 4Q 2009- New units and retrofits


•Performance– Smoothes “grid instability” issues – Short-term increase/decrease of power in response to grid frequency change

•Scope- Control schedule - Controls hardware added to turbine control panel

•Benefits– Improved LM6000 capability– Improves system response better than competing technologies

•Availability- 2010

LM6000 Pro Boost

AirFuel

~

TCP


No Change

22.4 ft

6.84 m

13,619 lbs

6,178 kg

Total

0Width

+4 ft

+1.23 mLength

+3,000 lbs

+1,361 kgWeight

Change

Shipping Container - Air Ride Adapter• Adapter will replicate dampening

effect of air ride tractor/trailer

• Rigorous testing and evaluation has been completed

• Adapter is currently being service evaluated on the GE lease fleet

• After service evolution, adapter will be available for customers who are interested


Summary

•GE continues to develop innovative products to enhance the value of the LM6000

•Evaluating programs to leverage technology improvements from the LM6000 PG/PH into the PC/PD fleet

•Targeting programs that drive customer value, improve heat rate and power

•Customer feedback is a valuable source for future product development


LM6000 PackagePrograms


LM6000 Technical Programs


LM6000 Pkg Reliability 12 months rolling

99.9

90

92

94

96

98

100

Aug-

06Oc

t-06

Dec-

06Fe

b-07

Apr-0

7Ju

n-07

Aug-

07Oc

t-07

Dec-

07Fe

b-08

Apr-0

8Ju

n-08

Aug-

08Oc

t-08

Dec-

08Fe

b-09

Apr-0

9Ju

n-09

Perc

ent

P75 Pkg ReliabilityP50 Pkg ReliabilityP25 Pkg Reliability


LM6000 Package ReliabilityUnits reporting - 2008: 282, 2009: 266 GT Pkg BOP

SCP


LM6000 Pkg Availability 12 months rolling

97.9

90

92

94

96

98

100

Aug-

06Oc

t-06

Dec-

06Fe

b-07

Apr-0

7Ju

n-07

Aug-

07Oc

t-07

Dec-

07Fe

b-08

Apr-0

8Ju

n-08

Aug-

08Oc

t-08

Dec-

08Fe

b-09

Apr-0

9Ju

n-09

Perc

ent

P75 Pkg AvailabilityP50 Pkg AvailabilityP25 Pkg Availability


LM6000 Package AvailabilityUnits reporting - 2008: 282, 2009: 266 GT Pkg BOP

SCP


Bringing a face to the package

LM2 options

LM2500

Imagination at work

LM2500

In celebrating 25 years of packaging the LM series of gas turbines, GE Energy has developed a series of package labels to establish better curb appeal. All three product lines (LM2500, LM6000 and LMS100) have had decals designed which have a 20 year design life and constructed from the latest materials to withstand fading.


0 1 2 3 4 5 6

Hoist Load Drop

50 Hz Gearbox Grouting Incorrect

DC Generator Lube Pump Failure toStart

Generator Vent Fan Events

DLE Fuel Gas Contamination

Starter Clutch Failures

VBV Silencer Baffle Distress

RGB Gearbox Tooth Distress

RGB Safeset Coupling Distress

Operation error

Last 12 MonthsPrior 12 Months

LM6000 Field Events – 2009 Pareto

PB 238

Topic Addressed Later


SPRINT® Water in Oil

Background

• Investigation of water in oil issues› Water noted in lube oil during / after SPRINT® operation› Frequent lube oil filter element replacement required› Affected sites typically low elevation / high humidity› Water is from LP SPRINT® water entering sump

pressurization circuit

Applicable to: PA PB PC PD PF



Investigation

• SPRINT® water enters B-sump pressurization port

• Water evaporates before sump entry

• Water condenses in air/oil separator

• Water enters lube oil tank via 1/2’’ oil return line

• Water in oil may cause filter clogging, high oil tank water content (>1000 ppm limit) and high filter delta-p alarms



SPRINT® Water in OilInvestigation




Field Action

• If water in oil experienced, drain second stage air/oil separator to waste tank or other appropriate receptacle

› Drain should be less than 20 ounces per hour



SPRINT® Water in OilImprovement Plan

• Install supplementary filter unit at oil tank to continuously circulate and remove water

› Filter element holds 5 quarts of water› Isolation valves allow filter replacement during unit

operation



SPRINT® Water in OilApplicable to: PA PB PC PD PF


MGTB High Temperatures

Background

• Main Generator Terminal Box (MGTB)› Nexgen package design› Located inside generator enclosure› Contains generator and supporting system’s electronic

control input/output (I/O) modules› Cooled by enclosure fans

• I/O modules reached temperature >170 °F and ceased function

› I/O packs normally resume operation when MGTB temperature reduced

Applicable to NXGN: PA PB PC PD PF



Investigation

• High temperature alarms occur when unit is in standby mode on hot days (~110 °F)

› Higher heat dissipation of Mark VIe hardware modules › Current design of cabinet has no ventilation

– No path for heat to escape

› No cooling from generator enclosure fans during standby




Improvement Plans

•Add ventilation fan to the enclosure › Fans energize at >68 °F (20 °C)› 122 CFM (3.45 CMM) fan will provide ~300 air

changes of the cabinet per hour

•Service evaluation planned 4Q 2009



50Hz Reduction Gearbox Tooth Distress

Background

•16 reduction gearbox (RGB) related events since 2002› Both suppliers impacted

•Eight events of tooth distress› Required gear set replacement

•Six events of Safeset® coupling distress› Safeset® is torque limiting device internal to gearbox› High vibrations detected after coupling disengagement› Required coupling replacement

•Two events of Safeset® retaining bolt distress› Both events occurred on same unit› Under investigation




Investigation

• Root cause established on 3 events› Event #1, #2, #3

– Manufacturing issues (Vendor #1)• High grind feed/speed caused temper of tooth• Position of manufacturing test coupon during carburizing

partially masked tooth• Alumina inclusion in forging

• Events #4, #5 (Vendor #1)› Similar in appearance to #3› No material anomalies found

• Event 6, 7 and 8 (Vendor #2)– Investigation continues




Field Plan

• Monitor for high gearbox vibration› Inspect gears if vibration exceeds trip level



50Hz Gearbox Coupling Distress

Investigation

• Safeset® coupling mounted on RGB low-speed shaft› Couples low-speed gear shaft to output quill shaft› Provides torque-limiting function… decouples if torque limit

exceeded› Torque set by oil pressurization

of internal sleeve… oil released if torque exceeded

– Two models in fleet (F and CB)• Different nominal pressures• Pressures serial number unique



50Hz Gearbox Coupling DistressInvestigation

• All events occurred after initial decouple event› Reason for decouple unknown

– Investigating pressurization procedures, potential for incorrectpressure

• Most cases had multiple start/synchronization attempts after decouple

› Control system does not detect decouple– Symptoms include “low generator voltage” alarm and LPT

overspeed trip but no control action taken

› Device is not designed for continued running after decouple› Extended running generates excess heat resulting in bearing

damage



50Hz Gearbox Coupling Distress

Field Action

• Operator to investigate possibility of Safeset® release before attempting to restart if symptoms indicate possible decouple

› XNSD overspeed trip› Low generator voltage

• GE plan to issue Product Letter with more detailed information

› Pressurization and lubrication

Improvement Plan

• Investigate automatic detection of decouple



VBV Expansion Joint Material Distress

Background

• VBV expansion joint distress reported› Typical damage consists of tears at “creases” of expansion

joint



VBV Expansion Joint Material Distress

Investigation/Results

• Root cause is material deterioration


Typical VBV Joint Distress


VBV Expansion Joint Material DistressField Action

• Monitor total tear length – replace joint if greater than 3 inches

› Excessive leakage at VBV joint may compromise fire protection system effectiveness

› Reference Product Letter 6000-07-02

Improvement Plans› Replace existing expansion joint material with Silicone

Aramid › Service evaluation underway at 2 sites (3 units)

– Maximum hours 200+– Initial reports of distress at 70 hours… one unit– Distress determined to be pre-existing at installation… two units

• Shipping/handling processes being investigated



50 Hz Base Frame GroutingBackground

• Some 50 Hz sites have insufficient grouting below supporting beams of generator and gearbox

› Absence of grouting creates “soft foot” situation› May contribute to:

– Difficulty in maintaining alignment– Increased vibration levels


Undesirable gap


50 Hz Base Frame Grouting

Investigation

• Grouting procedure complex› Design of grouting pockets makes grout flow to far corners

of pads difficult› Insufficient inspection points exist to visually verify grout is

fully penetrated below all cross members

Improvement plans

• Grouting pad design revised to allow improved grout flow

• Additional inspection ports and inspections added



Background

• Some 230 Volt mineral lube oil (MLO) and SPRINT®

pump motors in 50 Hz Packages were supplied with internal space heaters rated for 110 volts

› Heating element damaged… may result in motor condensation

• Motors affected can be identified by attached label


50 Hz Pump Motor Space Heater


50 Hz Pump Motor Space Heater

Field Action

• Step down transformers added to packages in installation prior to operation

› Reduce supply voltage to heater

Improvement Plans

• Design change in process to specify 230 V heater elements on future packages

• Product Bulletin to issue in 2010 to address fielded units with damaged heaters



VBV Silencer Distress

Background

• VBV silencer distress reported on some units

› 2 types of distress, varies by manufacturer (AAF and VAW)

– VAW: distress of sheet metal to acoustic panel welds

• May allow release of acoustic material

– AAF: distress of baffle mounting system within duct

• Allows dislocation of baffles

• May allow release of acoustic material




Investigation

• Root cause on AAF distress is high stress on baffle mounts

› Baffle system designed using incorrect flow assumptions

› Vendor design change rotated baffles 90 degrees creating adverse flow conditions

• Root cause of VAW distress is insufficient weld attachment of acoustic panel to sheet metal


1.Air Flow

Original Current



Field Action

• Vendors have provided repair procedure› VAW adds reinforcing welded strip at acoustic panel and

sheet metal interface› AAF adds more robust mounts top and bottom› Product bulletin 1Q 2010

Improvement Plans› AAF to revert to 5-baffle design with increased air flow

capability› Product Bulletin 1Q 2010




SSS Clutch DC Lube Oil Pump/Motor

Background

• Direct current (DC) pump/motor is backup to alternating current (AC) system

› Affects “classic” package only› DC system tested at startup

– If DC system lube pressure too low, start aborted

› Pressure permissive lowered to allow start– Lack of lubrication may result in lack of proper clutch lubrication in

event of loss of AC power

Investigation

• DC lube oil motor/pump undersized› Low pressure aggravated by pump/motor deterioration




Field Action

• Permissive reduced to 7 PSI to allow start› Abates failure to start but does not abate risk of clutch

failure.




Improvement

• High capacity pump added external to tank› Allows permissive to be restored to level that ensures

adequate lubrication in the event of AC system disruption› Original pump and motor remains (unused)

Replacement pumpand motor


Operations & Maintenance


Product Bulletins• Purpose

› Ensure safe operation› Improve reliability› Reduce life-cycle maintenance costs› Improve performance › Customer responsibility

• Customer Responsibility› Review Service Bulletins

– Planning Information and Accomplishment Instructions › Assess and manage compliance benefits vs. costs › Develop maintenance plans for compliance › Schedule, document and report compliance


Product Bulletins Issued Since September 2008


Product Letters Issued Since September 2008


LM1600®, LM2500®, LMS100® and SPRINT® are registered trademarks of the General Electric Company (USA)

LM6000TM is a pending trademark of the General Electric Company (USA)

Strategic Power Systems, Inc. (SPS®) and the ORAP® family of products & services, including ORAP Parts TrackingTM and ORAP Cycles TrackingTM, are registered trademarks comprising the intellectual property of SPS, with patents pending. All rights reserved.

Safeset® is a registered trademark of Voith Turbo Safeset AB

Documents

CPM_AP_LM6000-IND-024[1] 2009