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Imagination at work
May 15, 2015
Power LifeMax* - Solutions for
B/E Gas Turbine Fleet Ajay Gupta
Product Manager
Atlanta, GA USA
aj1.gupta@ge.com
PowerGen India & Central Asia
© 2015, General Electric Company. Proprietary information. All rights reserved.
GE Power &
Water
© 2015 General Electric Company.
GE Proprietary Information - The information contained in this document
is General Electric Company (GE) proprietary information. It is the
property of GE and shall not be used, disclosed to others or reproduced
without the express written consent of GE, including, but without limitation,
it is not to be used in the creation. manufacture. development, or
derivation of any repairs, modifications, spare parts, or configuration
changes or to obtain government or regulatory approval to do so, if
consent is given for reproduction in whole or in part, this notice and the
notice set forth on each page of this document shall appear in any such
reproduction in whole or in part. The information contained in this
document may also be controlled by the US export control laws.
Unauthorized export or re-export is prohibited.
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 3
ü  40+ years proven performance in
power gen, cogen and mech drive
ü  Largest installed base globally
ü  3000+ units installed. 99 countries
ü  224 GW combined power
ü  143+ million operating fired hours
ü  1.2+ million operating fired starts
ü  98.5+% reliability
B/E Class… mature fleet strategy
Customer Focus… Technology investments… Customized offerings
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 4
91E 40 year history
100
110
120
130
140
150
1975 1980 1985 1990 1995 2000 2005 2010 2015 2020
Output[MW]
132 MW
PG9171E + AGP
8 Units
128 MW
PG9171E
158 Units
PG9151E
46 Units
111 MW
PG9161E
57 Units
116 MW
PG9171E
264 Units
123 MW
PG9171E
145 Units
126 MW
PG9141E
17 Units
105 MW
9E.04
144
MW
9E.03
Custom solutions… for increased performance
9EMax
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 5
Power of customer
collaboration
1Improvements are solution dependent and vary by customer
Improved:1
•  Revenue
•  Availability
•  O&M costs
•  Compliance
21st Century asset revitalization
Delivering customized solutions
Power of hardware
upgrades
Power of data
analytics
Revitalized
assets
* Trademark of General Electric Company
Power LifeMax*… Custom solutions… Exponential results
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 6
GE's Power LifeMax* Suite of
Solutions
Advanced hardware
•  DLN1+ combustion
•  Advanced HGP
•  Fuel flexibility
•  Proven reliability
Advanced software & analytics
•  Enhanced monitoring
•  Controls upgrades
•  OpFlex*
•  Predictive algorithms
Optimal customer outcomes
•  Customized solutions
•  Enhanced performance and reliability
•  Maximized asset value
+ =
Initial
investment
payback
New revenue
line with
upgrades
Power LifeMax* Advantage
Self-managed
upgrades
No upgrades
Upgrade
investments
Assetrevenue
0 30+ Years
Time
GT purchase; Plant start-up
(CapEx)
* Trademark of General Electric Company
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 7
Technology addressing multiple operational
needs
Efficiency
Reliability
Output
Availability
Emissions
Flexibility
•  9E.04
•  Advanced Gas Path
•  OpFlex
VariablePeak
•  DLN1+ Conversion
•  Flange-to-Flange Replacement
•  OpFlex AutoTune / AutoRecover
•  DLN1/1+ Fuel Flex
•  OpFlex Turndown
•  OpFlex Fast Start
•  DLN1+ Combustion
•  OpFlex AutoTune
•  OpFlex AutoRecover
•  9E.04
•  Advanced Gas Path
(AGP)
•  OpFlex* Turndown
•  Flange-to-Flange
•  Monitoring &
Diagnostics
•  OpFlex AutoTune
•  OpFlex AutoRecover
* Trademark of General Electric Company
Customer Focus… Technology investments… Customized offerings
9E Advanced Gas Path
(AGP) Upgrade
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 9
9E Advanced Gas Path (AGP)
* 109E estimate at ISO, NG
Benefits
ü  - 1.5% CC HR (-1.7% SC HR)
ü  +3.8% CC MW (+3.6% SC MW)
ü  Higher exhaust energy
ü  Improved availability.. 32k
ü  Improved life.. 96k
ü  Fuels.. NG, LF, HFO
AGPtechnology
ü  B/E, FA/B, 6C and H experience
ü  Cooling and sealing improvements
ü  Improved clearances
ü  Advanced materials
ü  Balanced work split
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 10
Reliable Operations - Exceeding Performance
9E AGP Fleet Experience
Fleet Leader Inspections
8 units operating
3 x in Middle East
3 x Asia
1 x South America
1 x India
18 sets: Requisition Phase
Experience
29,000 FFH Total fleet
13,000 FFH Fleet leader
Performance
Met or exceeded all performance
metrics
GrowingExperience
S1B SS S2B Tip Shroud Cut tooth
4k FFH
12k FFH
12k FFH
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 11
Features and benefits
Advanced gas path
More performance and higher durability - retrofittable
Stage Part Improvement Benefit
1st
Nozzle
Improved sealing
Advanced cooling
Clearances
Durability/Perf
Bucket
Turbulators
Dovetail sealing
Durability/Perf
Clearances
Shroud Abradable shroud Clearances
2nd
Nozzle
Advanced cooling
GTD*262 Alloy
Durability and
performance
Bucket
Advanced Cooling
Dovetail sealing
Durability/Perf
Clearances
Shroud Abradable honeycomb Clearances
3rd
Nozzle 3D aero Performance
Bucket 3D aero Performance
Shroud Abradable honeycomb Clearances
* Trademark of General Electric Company
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 12
$0
$500 000
$1 000 000
$1 500 000
$2 000 000
$2 500 000
$3 000 000
0 1 2 3 4 5 6 7 8 9 10
First	
  year	
  Fuel	
  price	
  ($MMBtu)
1000	
  h
2000	
  h
4000	
  h
6000	
  h
8000	
  h
Fuel savings – 5 year NPV
2000 hrs/year
1000 hrs/year
Fuel savings
– Improved heat rate of 0.7%4, resulting
in significant fuel cost reduction
§  $345k4 yearly
§  $1.4MM NPV4 over 5 years
Incremental output
–  2.0%4 output increase generates
gross revenue
§  $525k4 yearly
§  $2.1MM4 NPV over 5 years
Same or better maintenance
intervals4 Sample Net Present Value & Conditions
•  9E 3-series with PIP
•  Combined cycle, Natural gas – ISO conditions
•  109E CC output baseline: 190 MW
•  9E 3-series heat rate baseline: 7,030 kJ/kWh
•  Utilization: 6,000 hours/year
•  Electricity price: $70
MWhr
•  Fuel costs: $7/Mbtu
•  Discount rate: 8%
Incremental income – 5 year NPV
2000 hrs/year
1000 hrs/year
Combined cycle - NPV
9E Max
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 14
9E PIP 9EMax
Simple Cycle
Output (MW) 128 144
Efficiency 34.2% 36.9%
Heat Rate (BTU/kWh) 9972 9250
Firing Temp (°F) 2055 +64
Exhaust Flow (pps) 911 911
Exhaust Temp (°F) 1016 1009
Combined Cycle (109E)
Output (MW) 188 210
Efficiency 50.3% 53.6%
Heat Rate (BTU/kWh) 6786 6370
Delta Values
Δ SC Output (MW)
baseline
12.50%
Δ SC Heat Rate -7.24%
Δ CC Output (MW) 11.70%
Δ CC Heat Rate -6.03%
What is 9EMax?
A game-changing leap in
9E gas turbine performance
“Design priorities”
ü Retrofitable … fits current 9E footprint and aux systems
ü Compatible …. similar exhaust energy for Co-gen/CC
ü Reliable ……….. 25 million hours of 9E experience
ü Low-cost ……… utilize proven E-class materials
ü Flexible ………… Fuel flexibility, part load capability
New 4-stage Turbine Module
new casings, HGP, Turbine Rotor, Diffuser
Fully assembled modular retrofit for field coupling
to an existing unit or a new Flange-to-Flange
Re-Engineered
Turbine Shell
High Efficiency
Aerodynamics
New 4-Stage Gas
Turbine Rotor
Advanced
Radial Diffuser
Durable
Exhaust
Frame
Serving installed fleet and new unit needs
9EMax Solutions
Flange to Flange
Turbine Module
New Unit (9E.
04)
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015
Slide 16
Summary
§  40+ years in B/E technology
§  Power LifeMax technology solutions
for mature fleet
§  Advanced Gas Path (3 stage)
§  - 1.5% CC HR (-1.7% SC HR)
§  +3.8% CC MW (+3.6% SC MW)
§  29,000+ FFH on 8 units
§  9E Max (4 stage)..
§  - 6% CC HR (-7.2% SC HR)
§  +11.7% CC MW (+12.5% SC MW)
§  GE proprietary architecture utilizes
OEM knowledge, experience and
tools
GE technology to maximize plant economics
Thank You

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Power LifeMax* - Solutions for B/E Gas Turbine Fleet

  • 1. Imagination at work May 15, 2015 Power LifeMax* - Solutions for B/E Gas Turbine Fleet Ajay Gupta Product Manager Atlanta, GA USA aj1.gupta@ge.com PowerGen India & Central Asia
  • 2. © 2015, General Electric Company. Proprietary information. All rights reserved. GE Power & Water © 2015 General Electric Company. GE Proprietary Information - The information contained in this document is General Electric Company (GE) proprietary information. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation. manufacture. development, or derivation of any repairs, modifications, spare parts, or configuration changes or to obtain government or regulatory approval to do so, if consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the US export control laws. Unauthorized export or re-export is prohibited.
  • 3. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 3 ü  40+ years proven performance in power gen, cogen and mech drive ü  Largest installed base globally ü  3000+ units installed. 99 countries ü  224 GW combined power ü  143+ million operating fired hours ü  1.2+ million operating fired starts ü  98.5+% reliability B/E Class… mature fleet strategy Customer Focus… Technology investments… Customized offerings
  • 4. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 4 91E 40 year history 100 110 120 130 140 150 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 Output[MW] 132 MW PG9171E + AGP 8 Units 128 MW PG9171E 158 Units PG9151E 46 Units 111 MW PG9161E 57 Units 116 MW PG9171E 264 Units 123 MW PG9171E 145 Units 126 MW PG9141E 17 Units 105 MW 9E.04 144 MW 9E.03 Custom solutions… for increased performance 9EMax
  • 5. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 5 Power of customer collaboration 1Improvements are solution dependent and vary by customer Improved:1 •  Revenue •  Availability •  O&M costs •  Compliance 21st Century asset revitalization Delivering customized solutions Power of hardware upgrades Power of data analytics Revitalized assets * Trademark of General Electric Company Power LifeMax*… Custom solutions… Exponential results
  • 6. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 6 GE's Power LifeMax* Suite of Solutions Advanced hardware •  DLN1+ combustion •  Advanced HGP •  Fuel flexibility •  Proven reliability Advanced software & analytics •  Enhanced monitoring •  Controls upgrades •  OpFlex* •  Predictive algorithms Optimal customer outcomes •  Customized solutions •  Enhanced performance and reliability •  Maximized asset value + = Initial investment payback New revenue line with upgrades Power LifeMax* Advantage Self-managed upgrades No upgrades Upgrade investments Assetrevenue 0 30+ Years Time GT purchase; Plant start-up (CapEx) * Trademark of General Electric Company
  • 7. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 7 Technology addressing multiple operational needs Efficiency Reliability Output Availability Emissions Flexibility •  9E.04 •  Advanced Gas Path •  OpFlex VariablePeak •  DLN1+ Conversion •  Flange-to-Flange Replacement •  OpFlex AutoTune / AutoRecover •  DLN1/1+ Fuel Flex •  OpFlex Turndown •  OpFlex Fast Start •  DLN1+ Combustion •  OpFlex AutoTune •  OpFlex AutoRecover •  9E.04 •  Advanced Gas Path (AGP) •  OpFlex* Turndown •  Flange-to-Flange •  Monitoring & Diagnostics •  OpFlex AutoTune •  OpFlex AutoRecover * Trademark of General Electric Company Customer Focus… Technology investments… Customized offerings
  • 8. 9E Advanced Gas Path (AGP) Upgrade
  • 9. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 9 9E Advanced Gas Path (AGP) * 109E estimate at ISO, NG Benefits ü  - 1.5% CC HR (-1.7% SC HR) ü  +3.8% CC MW (+3.6% SC MW) ü  Higher exhaust energy ü  Improved availability.. 32k ü  Improved life.. 96k ü  Fuels.. NG, LF, HFO AGPtechnology ü  B/E, FA/B, 6C and H experience ü  Cooling and sealing improvements ü  Improved clearances ü  Advanced materials ü  Balanced work split
  • 10. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 10 Reliable Operations - Exceeding Performance 9E AGP Fleet Experience Fleet Leader Inspections 8 units operating 3 x in Middle East 3 x Asia 1 x South America 1 x India 18 sets: Requisition Phase Experience 29,000 FFH Total fleet 13,000 FFH Fleet leader Performance Met or exceeded all performance metrics GrowingExperience S1B SS S2B Tip Shroud Cut tooth 4k FFH 12k FFH 12k FFH
  • 11. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 11 Features and benefits Advanced gas path More performance and higher durability - retrofittable Stage Part Improvement Benefit 1st Nozzle Improved sealing Advanced cooling Clearances Durability/Perf Bucket Turbulators Dovetail sealing Durability/Perf Clearances Shroud Abradable shroud Clearances 2nd Nozzle Advanced cooling GTD*262 Alloy Durability and performance Bucket Advanced Cooling Dovetail sealing Durability/Perf Clearances Shroud Abradable honeycomb Clearances 3rd Nozzle 3D aero Performance Bucket 3D aero Performance Shroud Abradable honeycomb Clearances * Trademark of General Electric Company
  • 12. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 12 $0 $500 000 $1 000 000 $1 500 000 $2 000 000 $2 500 000 $3 000 000 0 1 2 3 4 5 6 7 8 9 10 First  year  Fuel  price  ($MMBtu) 1000  h 2000  h 4000  h 6000  h 8000  h Fuel savings – 5 year NPV 2000 hrs/year 1000 hrs/year Fuel savings – Improved heat rate of 0.7%4, resulting in significant fuel cost reduction §  $345k4 yearly §  $1.4MM NPV4 over 5 years Incremental output –  2.0%4 output increase generates gross revenue §  $525k4 yearly §  $2.1MM4 NPV over 5 years Same or better maintenance intervals4 Sample Net Present Value & Conditions •  9E 3-series with PIP •  Combined cycle, Natural gas – ISO conditions •  109E CC output baseline: 190 MW •  9E 3-series heat rate baseline: 7,030 kJ/kWh •  Utilization: 6,000 hours/year •  Electricity price: $70 MWhr •  Fuel costs: $7/Mbtu •  Discount rate: 8% Incremental income – 5 year NPV 2000 hrs/year 1000 hrs/year Combined cycle - NPV
  • 14. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 14 9E PIP 9EMax Simple Cycle Output (MW) 128 144 Efficiency 34.2% 36.9% Heat Rate (BTU/kWh) 9972 9250 Firing Temp (°F) 2055 +64 Exhaust Flow (pps) 911 911 Exhaust Temp (°F) 1016 1009 Combined Cycle (109E) Output (MW) 188 210 Efficiency 50.3% 53.6% Heat Rate (BTU/kWh) 6786 6370 Delta Values Δ SC Output (MW) baseline 12.50% Δ SC Heat Rate -7.24% Δ CC Output (MW) 11.70% Δ CC Heat Rate -6.03% What is 9EMax? A game-changing leap in 9E gas turbine performance “Design priorities” ü Retrofitable … fits current 9E footprint and aux systems ü Compatible …. similar exhaust energy for Co-gen/CC ü Reliable ……….. 25 million hours of 9E experience ü Low-cost ……… utilize proven E-class materials ü Flexible ………… Fuel flexibility, part load capability New 4-stage Turbine Module new casings, HGP, Turbine Rotor, Diffuser Fully assembled modular retrofit for field coupling to an existing unit or a new Flange-to-Flange
  • 15. Re-Engineered Turbine Shell High Efficiency Aerodynamics New 4-Stage Gas Turbine Rotor Advanced Radial Diffuser Durable Exhaust Frame Serving installed fleet and new unit needs 9EMax Solutions Flange to Flange Turbine Module New Unit (9E. 04)
  • 16. © 2015, General Electric Company. Proprietary information. All rights reserved. PowerGen 2015 Slide 16 Summary §  40+ years in B/E technology §  Power LifeMax technology solutions for mature fleet §  Advanced Gas Path (3 stage) §  - 1.5% CC HR (-1.7% SC HR) §  +3.8% CC MW (+3.6% SC MW) §  29,000+ FFH on 8 units §  9E Max (4 stage).. §  - 6% CC HR (-7.2% SC HR) §  +11.7% CC MW (+12.5% SC MW) §  GE proprietary architecture utilizes OEM knowledge, experience and tools GE technology to maximize plant economics