SlideShare a Scribd company logo
1 of 25
Turbo Services

Reducing Costs with Condition Based Maintenance
Dr Shaun West and Nathan Self, Sulzer Turbo Services

| slide 1
Sulzer Turbo Services’ experience
- over 15 years of know how developed

Turbo Services

Frame 9E/9FA 7E/7FA

Total V-series

+100 sets of parts

+75 sets of parts

+ 1500 sets of parts

+1400 sets of parts

+ 100 inspections

+25 inspections

Rotor services
(de-stacking, inspection, restacking,
balancing, NDT, life assessment)

+50

+50 projects

New and replacement parts
(consumables, combustion section,
turbine section)

+100 sets

+90 sets of parts

20units

11 units

Combustion component repairs
Blade and vane repairs
Field services
(mechanical, controls, fact finding,
minor and major inspections)

Long-term service agreements

| slide 2
Gas turbine segment trends
- what is ‘mature’ technology today?

Turbo Services

G and H technologies are still maturing
F-tech was first introduced 15 years ago
Improvements keep being introduced to the F-tech units

Most gas turbines can now be considered ‘mature’
Frame 5
Frame 7B

Year of
introduction

Frame 9E
Frame 7E
Frame 6B
Frame 9B

V93

and

Frame 7FA
Frame 9FA

GE

V94.3a

V94.2

Capacity
installed in
calendar year

Siemens

13E2
GT13D

13E

GT24

Alstom

GT26
WH501D
WH251B
1970
Platts, 2007

1975

1980

WH501F

WH701D

WH/MHI

WH701F
1985

1990

1995

2000

2005

2010
| slide 3
How can risks and costs be controlled?
- an LTSA is not for everyone

Turbo Services

Costs can be ‘high’

LTSAs with the manufacturer

Management of technology risk for
introductory technologies
Can be ridged in structure
Extra works normally at ‘list price’
Service delivery is more flexible
Suitable for mature technologies

LTSAs with a non-OEM

Good tool to limit price risks
Extra works normally at agreed rates
Life management possibilities
Management and logistics can be an issue

Transactional services

Costs can be lower – all technical risk
remaines with the buyer
Life management possibilities

| slide 4
Sweating the asset
- where can the most value be created?

Turbo Services

Where can additional value safely be
extracted?
Parts costs
Repair costs

Cost saving creates value

Field service TA costs
Field service craft labour

Parts’ life extension
Extension of inspection intervals

Engineering judgment adds value

Upgrading of capability

| slide 5
Driving cost savings to create value

Turbo Services

Good procurement driving costs out
Cost saving of 10% on repairs
Cost saving of 10% on CI field services
CI/CI/HGP/CI/CI/MI cycle

What is the cost saving?

Six day outage
Repair costs

Cost per CI
100,000USD
200,000USD

2 MI cycle (12 years)
40,000
80,000
120,000

The unit is not put at risk directly…
… risk of poor outage performance
… risk of poor repair life

| slide 6
Value creation from engineering judgment

Turbo Services

Using engineering know how to create value
Removal of combustion inspection
CI/CI/HGP/CI/CI/MI cycle

What is the value created?

Six day outage
Repair costs
Generation gains

Cost per CI
2 MI cycle (12 years)
100,000USD
800,000
200,000USD
1,600,000
100MWx24hx6dx25USD/MWh
360,000USD
2,880,000
5,280,000

This example is based on no additional repair costs!
A little unrealistic as repairs on the combustion capitals may be more extensive

The key is how to do this without putting the unit at risk…
| slide 7
Turbo Services

Key know how…
… how do parts degrade

| slide 8
Corrosion and oxidation
- three different damage mechanisms

Cr2O3

Turbo Services

TBC

Al2O3

Protective layer
Inter-diffusion
Thermo mechanical fatigue

Attack

Type II
Hot Corrosion

500

600

Type I
Type I
Hot Corrosion

700
800
Temperature (°C)

900

Oxidation

1000

1100
| slide 9
Material degradation
- material strength reduces over time
Gamma prime strengthens super
alloys

Turbo Services

Heat treatments can restore the
structure

Time at high temperature causes
rounding of the crystals
LE

CC

CV

TE

TIP

MIDDLE

ROOT

γ’ precipitate size changes with time & temperature
| slide 10
Creep
- Creep damage cannot be recovered

Turbo Services

Material properties are important, like
grain size and volume of γ’precipitates

Strain [-]

Slow deformation at constant stress
level at high temperatures ( T >
0.4Tm )

Creep is a thermally activated process
Strain rate increase with stress and
temperature
Life time reduces with increase in
stress and temperature

| slide 11
Fretting
- damage minimization is key

Turbo Services

What: material removal as a result of
sliding wear
Contact between two surfaces
Vibration

Where: transition pieces
Seals
Mounting brackets

Fix: wear resistant coatings or linings are
usually efficient (W-Cr carbides, Stellites)

| slide 12
Cyclic fatigue
- regular visual inspections are important
High cycle fatigue

Turbo Services

Low cycle fatigue

Large number of cycles until failure (>100,000
cycles)

Low number of cycles until failure
(<100,000 cycles)

Crack initiation can take a long time

Crack initiation period relatively short

Required stress amplitude is relatively low

Stress amplitude is high

Vibration can be caused by:
Tip rubbing
Resonance
Aerodynamic instabilities

Δσ [MPa]

LCF
Fatigue limit
HCF

100

1000

10000

100000

1000000 10000000

Number of cycles [#]
| slide 13
High cycle fatigue
- catastrophic compressor failure

Turbo Services

Excitation caused by: single VIGV closing, blade rub etc

Mode 1

Mode 2

Mode 3

Mode 4

Mode 5

Mode 6

| slide 14
Low cycle fatigue
- start/stop related

Turbo Services

IN939 vanes suffering LCF following imbrittlement of the base material

| slide 15
Repair of blades
- metallurgical understanding key to repairs
Known operational issues

Turbo Services

Repair processes

IN 738/Sicoat 2231

Striping of coating

Cracking leading edges (row 1)

Heat treatment

Inter-granular attack

NDT

Sulzer inspection techniques

Welding

X-ray

Overlay repair by slurry-brazing

Boroscope inspections

Blending

Thermographic analyses

Heat treatment
Coating (where applicable)

Sections used for creep testing
#14844

#14843

#14847

#14845

#14837

#14846
#14842

| slide 16
Repair of vanes
- metallurgical understanding key to repairs
Known operational issues

Turbo Services

Repair processes

Nitration of IN 939

Striping of coating

Fatigue cracking

Heat treatment

Distortion

NDT

Sulzer inspection techniques

Welding

X-ray inspection

Overlay repair by slurry-brazing

Visual inspection of internals

Blending

Dimensional inspection: tooling

Heat treatment
Coating (where applicable)

| slide 17
Turbo Services

Case Studies

| slide 18
Blade re-design to meet a customer’s needs
A customer found that their blades were
failing early in life due to a deformation on the
shroud of the turbine blades

Turbo Services

Original with shroud

Working with the customer and their
insurance company, a tailor-made solution
was developed
The new design has proven itself in operation
The new design provides lower operational
risk because the deformation no longer
plagues the machine

Modified without shroud

Major cost saving:
24kEOH parts now lasting 24k+24kEOH

| slide 19
Rotor life management
- extending operation safely

Turbo Services

Rotor material can become brittle
Replica and phased array NDT are two
assessment tools
Rotor operational history important

Rotors can suffer low cycle fatigue
Finite element modeling provides stress data

Some damage can be repaired/replaced

Major cost saving:
A new rotor can cost 5M USD
An unplanned failure will cost the owner and insurer +10M USD each

Example of FEA on rotor disk
| slide 20
Damaged turbine stub shaft
- repaired and fit for service

Turbo Services

Emergency shut down damaged turbine
stub shaft
Stub shaft was machined, welded and then
machined to original dimensions
Rotor rebuilt and put back into operation
Speed was key for the owner

Major cost saving:
Rotor returned to service within 30 days

| slide 21
Extending outages
- removing an unplanned 8000EOH inspection

Turbo Services

Review of the weak parts of the turbine
Upgrades on the weakest areas
Flow down of advanced technologies
Transfer of technologies used on other units

Understanding of the full hot gas path
FE analysis
Temperature mapping
CFD
Modes of degradation

Own (S West) experience
Burner segment plates – early failure
Weaknesses from fretting and overheating
Solution – low risk, based on coatings

| slide 22
Frame 9FA compressor
- strip, replace, rebuild of the compressor

Turbo Services

Reverse engineering
Determination of natural frequencies
3D scanning
Physical component

Finite element measurement
Computational fluid dynamics

3D solid model

Over 20 F-tech rotors
| slide 23
Making run/no-run decisions
- I am stuck in the middle…

Turbo Services

Engineering judgment helps you to make better decisions
Helps to create value and save cost
‘We need to have a decision
- NOW!’

‘What’s the risk of running
on?’

‘There are high prices
available - we’re losing
opportunity’

‘I don’t want to know the
technical details..’

‘How long can we
run safely for?’

‘How long will it take to fix
and how much will it cost’
| slide 24
Turbo Services

| slide 25

More Related Content

What's hot

Independent service for kkk turbines
Independent service for kkk turbinesIndependent service for kkk turbines
Independent service for kkk turbinesLieve Van Hoey
 
C&K Overview Presentation - 6
C&K Overview Presentation - 6C&K Overview Presentation - 6
C&K Overview Presentation - 6Tad Jenkins
 
06 procedure of start up boiler ok
06 procedure of start up boiler ok06 procedure of start up boiler ok
06 procedure of start up boiler okBunk Bonk
 
Kriebel Anchor linecard 2012
Kriebel Anchor linecard 2012Kriebel Anchor linecard 2012
Kriebel Anchor linecard 2012lmwslide
 
Innovation of LNG Carrier-Propulsion and BOG handling technology (LNG Warring...
Innovation of LNG Carrier-Propulsion and BOG handling technology (LNG Warring...Innovation of LNG Carrier-Propulsion and BOG handling technology (LNG Warring...
Innovation of LNG Carrier-Propulsion and BOG handling technology (LNG Warring...BenedictSong1
 
VMT Company Introduction
VMT Company IntroductionVMT Company Introduction
VMT Company IntroductionBenedictSong1
 
Basic cpp presentation(1)
Basic cpp presentation(1)Basic cpp presentation(1)
Basic cpp presentation(1)nguyen_uptorcem
 
Glass Block Handling for Machine Processing
Glass Block Handling for Machine ProcessingGlass Block Handling for Machine Processing
Glass Block Handling for Machine ProcessingPaul Geer
 
IRZ artificial lift solutions [version 1.2 july 2016]
IRZ artificial lift solutions [version 1.2 july 2016]IRZ artificial lift solutions [version 1.2 july 2016]
IRZ artificial lift solutions [version 1.2 july 2016]Ivan Isaev
 
Thermo-Economic Optimization of Subcritical and Transcritical ORC Systems
Thermo-Economic Optimization of Subcritical and Transcritical ORC SystemsThermo-Economic Optimization of Subcritical and Transcritical ORC Systems
Thermo-Economic Optimization of Subcritical and Transcritical ORC SystemsThomas Tartière
 
Commissioning &amp; Interface With Engineering
Commissioning &amp; Interface With EngineeringCommissioning &amp; Interface With Engineering
Commissioning &amp; Interface With Engineeringasim569
 

What's hot (20)

Bfwp
BfwpBfwp
Bfwp
 
job des
job desjob des
job des
 
Independent service for kkk turbines
Independent service for kkk turbinesIndependent service for kkk turbines
Independent service for kkk turbines
 
C&K Overview Presentation - 6
C&K Overview Presentation - 6C&K Overview Presentation - 6
C&K Overview Presentation - 6
 
06 procedure of start up boiler ok
06 procedure of start up boiler ok06 procedure of start up boiler ok
06 procedure of start up boiler ok
 
Kriebel Anchor linecard 2012
Kriebel Anchor linecard 2012Kriebel Anchor linecard 2012
Kriebel Anchor linecard 2012
 
Innovation of LNG Carrier-Propulsion and BOG handling technology (LNG Warring...
Innovation of LNG Carrier-Propulsion and BOG handling technology (LNG Warring...Innovation of LNG Carrier-Propulsion and BOG handling technology (LNG Warring...
Innovation of LNG Carrier-Propulsion and BOG handling technology (LNG Warring...
 
9 e
9 e9 e
9 e
 
VMT Company Introduction
VMT Company IntroductionVMT Company Introduction
VMT Company Introduction
 
Basic cpp presentation(1)
Basic cpp presentation(1)Basic cpp presentation(1)
Basic cpp presentation(1)
 
Glass Block Handling for Machine Processing
Glass Block Handling for Machine ProcessingGlass Block Handling for Machine Processing
Glass Block Handling for Machine Processing
 
GNwafor WellBond Cement System Design
GNwafor WellBond Cement System DesignGNwafor WellBond Cement System Design
GNwafor WellBond Cement System Design
 
Pre-Insulated Pipe Supports Webinar
Pre-Insulated Pipe Supports WebinarPre-Insulated Pipe Supports Webinar
Pre-Insulated Pipe Supports Webinar
 
Engineered Spring Support Webinar - January
Engineered Spring Support Webinar - JanuaryEngineered Spring Support Webinar - January
Engineered Spring Support Webinar - January
 
IRZ artificial lift solutions [version 1.2 july 2016]
IRZ artificial lift solutions [version 1.2 july 2016]IRZ artificial lift solutions [version 1.2 july 2016]
IRZ artificial lift solutions [version 1.2 july 2016]
 
Thermo-Economic Optimization of Subcritical and Transcritical ORC Systems
Thermo-Economic Optimization of Subcritical and Transcritical ORC SystemsThermo-Economic Optimization of Subcritical and Transcritical ORC Systems
Thermo-Economic Optimization of Subcritical and Transcritical ORC Systems
 
Episode 7 : iCON Basic Training
Episode 7 :  iCON Basic Training Episode 7 :  iCON Basic Training
Episode 7 : iCON Basic Training
 
Episode 22 : PROJECT EXECUTION
Episode 22 : PROJECT EXECUTION Episode 22 : PROJECT EXECUTION
Episode 22 : PROJECT EXECUTION
 
Commissioning &amp; Interface With Engineering
Commissioning &amp; Interface With EngineeringCommissioning &amp; Interface With Engineering
Commissioning &amp; Interface With Engineering
 
Components for Pipe Support Deflection & Restraint
Components for Pipe Support Deflection & RestraintComponents for Pipe Support Deflection & Restraint
Components for Pipe Support Deflection & Restraint
 

Viewers also liked

An Introduction to Condition Based Maintenance (CBM)
An Introduction to  Condition Based Maintenance (CBM)An Introduction to  Condition Based Maintenance (CBM)
An Introduction to Condition Based Maintenance (CBM)abasathab
 
FLAACOs 2014 Conference - Improving Outcomes and Reducing Costs Through Activ...
FLAACOs 2014 Conference - Improving Outcomes and Reducing Costs Through Activ...FLAACOs 2014 Conference - Improving Outcomes and Reducing Costs Through Activ...
FLAACOs 2014 Conference - Improving Outcomes and Reducing Costs Through Activ...MARCYINC
 
PDL World your Engineering, Procurement and Maintenance service provider from...
PDL World your Engineering, Procurement and Maintenance service provider from...PDL World your Engineering, Procurement and Maintenance service provider from...
PDL World your Engineering, Procurement and Maintenance service provider from...PDL World
 
Bearing Information.
Bearing Information.Bearing Information.
Bearing Information.CasterDepot
 
236407565 gas-turbine-notes
236407565 gas-turbine-notes236407565 gas-turbine-notes
236407565 gas-turbine-notesmanojg1990
 
Wind turbine lubricant sampling, flushing, and analysis
Wind turbine lubricant sampling, flushing, and analysisWind turbine lubricant sampling, flushing, and analysis
Wind turbine lubricant sampling, flushing, and analysisRich Wurzbach
 
Practical control valve sizing, selection and maintenance
Practical control valve sizing, selection and maintenancePractical control valve sizing, selection and maintenance
Practical control valve sizing, selection and maintenanceSalih Abker Adam Musa
 
Pr 1047 well integrity maintenance
Pr 1047 well integrity maintenancePr 1047 well integrity maintenance
Pr 1047 well integrity maintenanceLawrence Kwende
 
Boiler feed pump recirculation valve problem
Boiler feed pump recirculation valve problemBoiler feed pump recirculation valve problem
Boiler feed pump recirculation valve problemVudugundla Kodandapani
 
valve maintenance-packing-replacement
valve maintenance-packing-replacementvalve maintenance-packing-replacement
valve maintenance-packing-replacementIzzuwan Yusoff
 
Day-to-day condition monitoring for a large fleet of wind turbines
Day-to-day condition monitoring for a large fleet of wind turbinesDay-to-day condition monitoring for a large fleet of wind turbines
Day-to-day condition monitoring for a large fleet of wind turbinesWindpower Engineering & Development
 
Handbook on maintenance of air brake system in lhb coaches (ftil type)
Handbook on maintenance of air brake system in lhb coaches (ftil type)Handbook on maintenance of air brake system in lhb coaches (ftil type)
Handbook on maintenance of air brake system in lhb coaches (ftil type)SrinivasaRao Guduru
 
six week industrial training report on BHEL ,haridwar
six week industrial training report on BHEL ,haridwarsix week industrial training report on BHEL ,haridwar
six week industrial training report on BHEL ,haridwarRaj Kumar Gupta
 
SINGLE STAGE CENTRIFUGAL PUMP Assembly and Maintenance Exercise Presentation
SINGLE STAGE CENTRIFUGAL PUMP Assembly and Maintenance Exercise PresentationSINGLE STAGE CENTRIFUGAL PUMP Assembly and Maintenance Exercise Presentation
SINGLE STAGE CENTRIFUGAL PUMP Assembly and Maintenance Exercise PresentationSahdev Kaushik
 
Servo valve animation
Servo valve animationServo valve animation
Servo valve animationypatil
 
Magnetic bearings
Magnetic bearingsMagnetic bearings
Magnetic bearingshome!
 
Electro hydraulic system Components and their operation
Electro hydraulic system Components and their operationElectro hydraulic system Components and their operation
Electro hydraulic system Components and their operationSrichandan Subudhi
 

Viewers also liked (20)

An Introduction to Condition Based Maintenance (CBM)
An Introduction to  Condition Based Maintenance (CBM)An Introduction to  Condition Based Maintenance (CBM)
An Introduction to Condition Based Maintenance (CBM)
 
FLAACOs 2014 Conference - Improving Outcomes and Reducing Costs Through Activ...
FLAACOs 2014 Conference - Improving Outcomes and Reducing Costs Through Activ...FLAACOs 2014 Conference - Improving Outcomes and Reducing Costs Through Activ...
FLAACOs 2014 Conference - Improving Outcomes and Reducing Costs Through Activ...
 
PDL World your Engineering, Procurement and Maintenance service provider from...
PDL World your Engineering, Procurement and Maintenance service provider from...PDL World your Engineering, Procurement and Maintenance service provider from...
PDL World your Engineering, Procurement and Maintenance service provider from...
 
Oil & Gas Maintenance Guide
Oil & Gas Maintenance GuideOil & Gas Maintenance Guide
Oil & Gas Maintenance Guide
 
Bearing Information.
Bearing Information.Bearing Information.
Bearing Information.
 
236407565 gas-turbine-notes
236407565 gas-turbine-notes236407565 gas-turbine-notes
236407565 gas-turbine-notes
 
Servo(n)
Servo(n)Servo(n)
Servo(n)
 
Wind turbine lubricant sampling, flushing, and analysis
Wind turbine lubricant sampling, flushing, and analysisWind turbine lubricant sampling, flushing, and analysis
Wind turbine lubricant sampling, flushing, and analysis
 
Practical control valve sizing, selection and maintenance
Practical control valve sizing, selection and maintenancePractical control valve sizing, selection and maintenance
Practical control valve sizing, selection and maintenance
 
Pr 1047 well integrity maintenance
Pr 1047 well integrity maintenancePr 1047 well integrity maintenance
Pr 1047 well integrity maintenance
 
Prop basics(n)
Prop basics(n)Prop basics(n)
Prop basics(n)
 
Boiler feed pump recirculation valve problem
Boiler feed pump recirculation valve problemBoiler feed pump recirculation valve problem
Boiler feed pump recirculation valve problem
 
valve maintenance-packing-replacement
valve maintenance-packing-replacementvalve maintenance-packing-replacement
valve maintenance-packing-replacement
 
Day-to-day condition monitoring for a large fleet of wind turbines
Day-to-day condition monitoring for a large fleet of wind turbinesDay-to-day condition monitoring for a large fleet of wind turbines
Day-to-day condition monitoring for a large fleet of wind turbines
 
Handbook on maintenance of air brake system in lhb coaches (ftil type)
Handbook on maintenance of air brake system in lhb coaches (ftil type)Handbook on maintenance of air brake system in lhb coaches (ftil type)
Handbook on maintenance of air brake system in lhb coaches (ftil type)
 
six week industrial training report on BHEL ,haridwar
six week industrial training report on BHEL ,haridwarsix week industrial training report on BHEL ,haridwar
six week industrial training report on BHEL ,haridwar
 
SINGLE STAGE CENTRIFUGAL PUMP Assembly and Maintenance Exercise Presentation
SINGLE STAGE CENTRIFUGAL PUMP Assembly and Maintenance Exercise PresentationSINGLE STAGE CENTRIFUGAL PUMP Assembly and Maintenance Exercise Presentation
SINGLE STAGE CENTRIFUGAL PUMP Assembly and Maintenance Exercise Presentation
 
Servo valve animation
Servo valve animationServo valve animation
Servo valve animation
 
Magnetic bearings
Magnetic bearingsMagnetic bearings
Magnetic bearings
 
Electro hydraulic system Components and their operation
Electro hydraulic system Components and their operationElectro hydraulic system Components and their operation
Electro hydraulic system Components and their operation
 

Similar to Reducing costs with condition based maintenance, IBC conference Singapore, 2010

ZBC in commodities.ppt
ZBC in commodities.pptZBC in commodities.ppt
ZBC in commodities.pptSoulmananIndia
 
Pro per energy services/ Gas Turbine Operation and Maintenance
Pro per energy services/ Gas Turbine Operation and MaintenancePro per energy services/ Gas Turbine Operation and Maintenance
Pro per energy services/ Gas Turbine Operation and MaintenancePro-Per Energy Services
 
Optimising Efficiency & Capacity Sep 04 Rev 0
Optimising Efficiency & Capacity Sep 04 Rev 0Optimising Efficiency & Capacity Sep 04 Rev 0
Optimising Efficiency & Capacity Sep 04 Rev 0Raja Ratnam
 
AC Power For Forklifts
AC Power For ForkliftsAC Power For Forklifts
AC Power For ForkliftsBrianRhoads
 
OEE - One Metric to Rule them All
OEE - One Metric to Rule them AllOEE - One Metric to Rule them All
OEE - One Metric to Rule them AllVibra
 
"How Gas Engines can help with the Challenges of a Changing Energy System"
"How Gas Engines can help with the Challenges of a Changing Energy System""How Gas Engines can help with the Challenges of a Changing Energy System"
"How Gas Engines can help with the Challenges of a Changing Energy System"Adam Wray-Summerson
 
Andrew Chant\'s CanWEA O &amp; M Presentation
Andrew Chant\'s CanWEA  O  &amp; M  PresentationAndrew Chant\'s CanWEA  O  &amp; M  Presentation
Andrew Chant\'s CanWEA O &amp; M Presentationmtingle
 
Servo Motors Adjust
Servo Motors Adjust Servo Motors Adjust
Servo Motors Adjust Marc Vendrell
 
Servo Motors Adjust-English
Servo Motors Adjust-EnglishServo Motors Adjust-English
Servo Motors Adjust-EnglishMarc Vendrell
 
GE LM2500 bearing damage case study.pdf
GE LM2500 bearing damage case study.pdfGE LM2500 bearing damage case study.pdf
GE LM2500 bearing damage case study.pdfssuser5599ce
 
Gas Turbines technology and the importance of air filtration
Gas Turbines technology and the importance of air filtrationGas Turbines technology and the importance of air filtration
Gas Turbines technology and the importance of air filtrationCamfil UK
 
Energy Efficiency in Diesel Generator Operation
Energy Efficiency in Diesel Generator OperationEnergy Efficiency in Diesel Generator Operation
Energy Efficiency in Diesel Generator Operationeecfncci
 
PDM IMPLIMENTATION
PDM IMPLIMENTATIONPDM IMPLIMENTATION
PDM IMPLIMENTATIONUttam Misra
 
Brent Goliath NCPC-SA
Brent Goliath NCPC-SABrent Goliath NCPC-SA
Brent Goliath NCPC-SA7391456
 

Similar to Reducing costs with condition based maintenance, IBC conference Singapore, 2010 (20)

116805771-Gas-Turbine.ppt
116805771-Gas-Turbine.ppt116805771-Gas-Turbine.ppt
116805771-Gas-Turbine.ppt
 
ZBC in commodities.ppt
ZBC in commodities.pptZBC in commodities.ppt
ZBC in commodities.ppt
 
Pro per energy services/ Gas Turbine Operation and Maintenance
Pro per energy services/ Gas Turbine Operation and MaintenancePro per energy services/ Gas Turbine Operation and Maintenance
Pro per energy services/ Gas Turbine Operation and Maintenance
 
Optimising Efficiency & Capacity Sep 04 Rev 0
Optimising Efficiency & Capacity Sep 04 Rev 0Optimising Efficiency & Capacity Sep 04 Rev 0
Optimising Efficiency & Capacity Sep 04 Rev 0
 
AC Power For Forklifts
AC Power For ForkliftsAC Power For Forklifts
AC Power For Forklifts
 
OEE - One Metric to Rule them All
OEE - One Metric to Rule them AllOEE - One Metric to Rule them All
OEE - One Metric to Rule them All
 
Ex des workshops Julian Wilson
Ex des workshops Julian WilsonEx des workshops Julian Wilson
Ex des workshops Julian Wilson
 
"How Gas Engines can help with the Challenges of a Changing Energy System"
"How Gas Engines can help with the Challenges of a Changing Energy System""How Gas Engines can help with the Challenges of a Changing Energy System"
"How Gas Engines can help with the Challenges of a Changing Energy System"
 
Andrew Chant\'s CanWEA O &amp; M Presentation
Andrew Chant\'s CanWEA  O  &amp; M  PresentationAndrew Chant\'s CanWEA  O  &amp; M  Presentation
Andrew Chant\'s CanWEA O &amp; M Presentation
 
GDP Viva Slides
GDP Viva SlidesGDP Viva Slides
GDP Viva Slides
 
Servo Motors Adjust
Servo Motors Adjust Servo Motors Adjust
Servo Motors Adjust
 
Servo Motors Adjust-English
Servo Motors Adjust-EnglishServo Motors Adjust-English
Servo Motors Adjust-English
 
GE LM2500 bearing damage case study.pdf
GE LM2500 bearing damage case study.pdfGE LM2500 bearing damage case study.pdf
GE LM2500 bearing damage case study.pdf
 
Wgp4205 turbine
Wgp4205 turbineWgp4205 turbine
Wgp4205 turbine
 
Turbina vapor
Turbina vaporTurbina vapor
Turbina vapor
 
Gas Turbines technology and the importance of air filtration
Gas Turbines technology and the importance of air filtrationGas Turbines technology and the importance of air filtration
Gas Turbines technology and the importance of air filtration
 
Energy Efficiency in Diesel Generator Operation
Energy Efficiency in Diesel Generator OperationEnergy Efficiency in Diesel Generator Operation
Energy Efficiency in Diesel Generator Operation
 
PDM IMPLIMENTATION
PDM IMPLIMENTATIONPDM IMPLIMENTATION
PDM IMPLIMENTATION
 
Brent Goliath NCPC-SA
Brent Goliath NCPC-SABrent Goliath NCPC-SA
Brent Goliath NCPC-SA
 
New Ideas for Repairing Gearboxes and Generators
New Ideas for Repairing Gearboxes and GeneratorsNew Ideas for Repairing Gearboxes and Generators
New Ideas for Repairing Gearboxes and Generators
 

More from Shaun West

Smart Service Design The design of smart services in the world of people, pro...
Smart Service DesignThe design of smart services in the world of people, pro...Smart Service DesignThe design of smart services in the world of people, pro...
Smart Service Design The design of smart services in the world of people, pro...Shaun West
 
Study case about the elements of crisis resilience in DACH manufacturing firm...
Study case about the elements of crisis resilience in DACH manufacturing firm...Study case about the elements of crisis resilience in DACH manufacturing firm...
Study case about the elements of crisis resilience in DACH manufacturing firm...Shaun West
 
Successfully integrating new digital to your existing portfolio of products a...
Successfully integrating new digital to your existing portfolio of products a...Successfully integrating new digital to your existing portfolio of products a...
Successfully integrating new digital to your existing portfolio of products a...Shaun West
 
Value-Scope-Price: design and pricing of offerings based on customer value
Value-Scope-Price: design and pricing of offerings based on customer value Value-Scope-Price: design and pricing of offerings based on customer value
Value-Scope-Price: design and pricing of offerings based on customer value Shaun West
 
SDS2021 workshop The design of Smart Services
SDS2021 workshop The design of Smart ServicesSDS2021 workshop The design of Smart Services
SDS2021 workshop The design of Smart ServicesShaun West
 
Digital twin enabled services – digital twins and future trends
Digital twin enabled services – digital twins and future trendsDigital twin enabled services – digital twins and future trends
Digital twin enabled services – digital twins and future trendsShaun West
 
SE training customer journey mapping
SE training customer journey mappingSE training customer journey mapping
SE training customer journey mappingShaun West
 
This is service innovation
This is service innovationThis is service innovation
This is service innovationShaun West
 
Foresighting the Future to Create Actionable Innovation
Foresighting the Future to Create Actionable InnovationForesighting the Future to Create Actionable Innovation
Foresighting the Future to Create Actionable InnovationShaun West
 
Value propositions enabled by digital twins in the context of servitization v002
Value propositions enabled by digital twins in the context of servitization v002Value propositions enabled by digital twins in the context of servitization v002
Value propositions enabled by digital twins in the context of servitization v002Shaun West
 
Call for participation smart services summit 2020
Call for participation smart services summit 2020Call for participation smart services summit 2020
Call for participation smart services summit 2020Shaun West
 
DARE2HACK: Crowdsourcing ideas through hackathons
DARE2HACK: Crowdsourcing ideas through hackathonsDARE2HACK: Crowdsourcing ideas through hackathons
DARE2HACK: Crowdsourcing ideas through hackathonsShaun West
 
Avatars and journey mapping for application in industrial product service sy...
Avatars and  journey mapping for application in industrial product service sy...Avatars and  journey mapping for application in industrial product service sy...
Avatars and journey mapping for application in industrial product service sy...Shaun West
 
Using the perspective of asset management to create value for Smart Operation...
Using the perspective of asset management to create value for Smart Operation...Using the perspective of asset management to create value for Smart Operation...
Using the perspective of asset management to create value for Smart Operation...Shaun West
 
Understanding the barriers that are slowing the digital transformation?
Understanding the barriers that are slowing the digital transformation?Understanding the barriers that are slowing the digital transformation?
Understanding the barriers that are slowing the digital transformation?Shaun West
 
Digital twin based services for decision support over the product lifecycle
Digital twin based services for decision support over the product lifecycleDigital twin based services for decision support over the product lifecycle
Digital twin based services for decision support over the product lifecycleShaun West
 
Hidden services in the lighting industry - from free to fee
Hidden services in the lighting industry - from free to feeHidden services in the lighting industry - from free to fee
Hidden services in the lighting industry - from free to feeShaun West
 
Ecosystem Innovation for Pharma Supply Chains
Ecosystem Innovation for Pharma Supply ChainsEcosystem Innovation for Pharma Supply Chains
Ecosystem Innovation for Pharma Supply ChainsShaun West
 
Digital twins as an enabler for services
Digital twins as an enabler for servicesDigital twins as an enabler for services
Digital twins as an enabler for servicesShaun West
 
Service Operations Management Challenges
Service Operations Management ChallengesService Operations Management Challenges
Service Operations Management ChallengesShaun West
 

More from Shaun West (20)

Smart Service Design The design of smart services in the world of people, pro...
Smart Service DesignThe design of smart services in the world of people, pro...Smart Service DesignThe design of smart services in the world of people, pro...
Smart Service Design The design of smart services in the world of people, pro...
 
Study case about the elements of crisis resilience in DACH manufacturing firm...
Study case about the elements of crisis resilience in DACH manufacturing firm...Study case about the elements of crisis resilience in DACH manufacturing firm...
Study case about the elements of crisis resilience in DACH manufacturing firm...
 
Successfully integrating new digital to your existing portfolio of products a...
Successfully integrating new digital to your existing portfolio of products a...Successfully integrating new digital to your existing portfolio of products a...
Successfully integrating new digital to your existing portfolio of products a...
 
Value-Scope-Price: design and pricing of offerings based on customer value
Value-Scope-Price: design and pricing of offerings based on customer value Value-Scope-Price: design and pricing of offerings based on customer value
Value-Scope-Price: design and pricing of offerings based on customer value
 
SDS2021 workshop The design of Smart Services
SDS2021 workshop The design of Smart ServicesSDS2021 workshop The design of Smart Services
SDS2021 workshop The design of Smart Services
 
Digital twin enabled services – digital twins and future trends
Digital twin enabled services – digital twins and future trendsDigital twin enabled services – digital twins and future trends
Digital twin enabled services – digital twins and future trends
 
SE training customer journey mapping
SE training customer journey mappingSE training customer journey mapping
SE training customer journey mapping
 
This is service innovation
This is service innovationThis is service innovation
This is service innovation
 
Foresighting the Future to Create Actionable Innovation
Foresighting the Future to Create Actionable InnovationForesighting the Future to Create Actionable Innovation
Foresighting the Future to Create Actionable Innovation
 
Value propositions enabled by digital twins in the context of servitization v002
Value propositions enabled by digital twins in the context of servitization v002Value propositions enabled by digital twins in the context of servitization v002
Value propositions enabled by digital twins in the context of servitization v002
 
Call for participation smart services summit 2020
Call for participation smart services summit 2020Call for participation smart services summit 2020
Call for participation smart services summit 2020
 
DARE2HACK: Crowdsourcing ideas through hackathons
DARE2HACK: Crowdsourcing ideas through hackathonsDARE2HACK: Crowdsourcing ideas through hackathons
DARE2HACK: Crowdsourcing ideas through hackathons
 
Avatars and journey mapping for application in industrial product service sy...
Avatars and  journey mapping for application in industrial product service sy...Avatars and  journey mapping for application in industrial product service sy...
Avatars and journey mapping for application in industrial product service sy...
 
Using the perspective of asset management to create value for Smart Operation...
Using the perspective of asset management to create value for Smart Operation...Using the perspective of asset management to create value for Smart Operation...
Using the perspective of asset management to create value for Smart Operation...
 
Understanding the barriers that are slowing the digital transformation?
Understanding the barriers that are slowing the digital transformation?Understanding the barriers that are slowing the digital transformation?
Understanding the barriers that are slowing the digital transformation?
 
Digital twin based services for decision support over the product lifecycle
Digital twin based services for decision support over the product lifecycleDigital twin based services for decision support over the product lifecycle
Digital twin based services for decision support over the product lifecycle
 
Hidden services in the lighting industry - from free to fee
Hidden services in the lighting industry - from free to feeHidden services in the lighting industry - from free to fee
Hidden services in the lighting industry - from free to fee
 
Ecosystem Innovation for Pharma Supply Chains
Ecosystem Innovation for Pharma Supply ChainsEcosystem Innovation for Pharma Supply Chains
Ecosystem Innovation for Pharma Supply Chains
 
Digital twins as an enabler for services
Digital twins as an enabler for servicesDigital twins as an enabler for services
Digital twins as an enabler for services
 
Service Operations Management Challenges
Service Operations Management ChallengesService Operations Management Challenges
Service Operations Management Challenges
 

Recently uploaded

Moradia Isolada com Logradouro; Detached house with patio in Penacova
Moradia Isolada com Logradouro; Detached house with patio in PenacovaMoradia Isolada com Logradouro; Detached house with patio in Penacova
Moradia Isolada com Logradouro; Detached house with patio in Penacovaimostorept
 
stock price prediction using machine learning
stock price prediction using machine learningstock price prediction using machine learning
stock price prediction using machine learninggauravwankar27
 
MichaelStarkes_UncutGemsProjectSummary.pdf
MichaelStarkes_UncutGemsProjectSummary.pdfMichaelStarkes_UncutGemsProjectSummary.pdf
MichaelStarkes_UncutGemsProjectSummary.pdfmstarkes24
 
Presentation4 (2) survey responses clearly labelled
Presentation4 (2) survey responses clearly labelledPresentation4 (2) survey responses clearly labelled
Presentation4 (2) survey responses clearly labelledCaitlinCummins3
 
Toyota Kata Coaching for Agile Teams & Transformations
Toyota Kata Coaching for Agile Teams & TransformationsToyota Kata Coaching for Agile Teams & Transformations
Toyota Kata Coaching for Agile Teams & TransformationsStefan Wolpers
 
Blinkit: Revolutionizing the On-Demand Grocery Delivery Service.pptx
Blinkit: Revolutionizing the On-Demand Grocery Delivery Service.pptxBlinkit: Revolutionizing the On-Demand Grocery Delivery Service.pptx
Blinkit: Revolutionizing the On-Demand Grocery Delivery Service.pptxSaksham Gupta
 
Unlocking Growth The Power of Outsourcing for CPA Firms
Unlocking Growth The Power of Outsourcing for CPA FirmsUnlocking Growth The Power of Outsourcing for CPA Firms
Unlocking Growth The Power of Outsourcing for CPA FirmsYourLegal Accounting
 
Innomantra Viewpoint - Building Moonshots : May-Jun 2024.pdf
Innomantra Viewpoint - Building Moonshots : May-Jun 2024.pdfInnomantra Viewpoint - Building Moonshots : May-Jun 2024.pdf
Innomantra Viewpoint - Building Moonshots : May-Jun 2024.pdfInnomantra
 
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdfThe Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdfbelieveminhh
 
Beyond Numbers A Holistic Approach to Forensic Accounting
Beyond Numbers A Holistic Approach to Forensic AccountingBeyond Numbers A Holistic Approach to Forensic Accounting
Beyond Numbers A Holistic Approach to Forensic AccountingYourLegal Accounting
 
South Africa's 10 Most Influential CIOs to Watch.pdf
South Africa's 10 Most Influential CIOs to Watch.pdfSouth Africa's 10 Most Influential CIOs to Watch.pdf
South Africa's 10 Most Influential CIOs to Watch.pdfTHECIOWORLD
 
High Profile Bangalore Just VIP Brigade Road 100% Genuine at your Door Step
High Profile Bangalore Just VIP Brigade Road 100% Genuine at your Door StepHigh Profile Bangalore Just VIP Brigade Road 100% Genuine at your Door Step
High Profile Bangalore Just VIP Brigade Road 100% Genuine at your Door Stepdarmandersingh4580
 
Top^Clinic ^%[+27785538335__Safe*Women's clinic//Abortion Pills In Harare
Top^Clinic ^%[+27785538335__Safe*Women's clinic//Abortion Pills In HarareTop^Clinic ^%[+27785538335__Safe*Women's clinic//Abortion Pills In Harare
Top^Clinic ^%[+27785538335__Safe*Women's clinic//Abortion Pills In Hararedoctorjoe1984
 
Future of Trade 2024 - Decoupled and Reconfigured - Snapshot Report
Future of Trade 2024 - Decoupled and Reconfigured - Snapshot ReportFuture of Trade 2024 - Decoupled and Reconfigured - Snapshot Report
Future of Trade 2024 - Decoupled and Reconfigured - Snapshot ReportDubai Multi Commodity Centre
 
The Art of Decision-Making: Navigating Complexity and Uncertainty
The Art of Decision-Making: Navigating Complexity and UncertaintyThe Art of Decision-Making: Navigating Complexity and Uncertainty
The Art of Decision-Making: Navigating Complexity and Uncertaintycapivisgroup
 
Jual Obat Aborsi Di Sibolga wa 0851/7541/5434 Cytotec Misoprostol 200mcg Pfizer
Jual Obat Aborsi Di Sibolga wa 0851/7541/5434 Cytotec Misoprostol 200mcg PfizerJual Obat Aborsi Di Sibolga wa 0851/7541/5434 Cytotec Misoprostol 200mcg Pfizer
Jual Obat Aborsi Di Sibolga wa 0851/7541/5434 Cytotec Misoprostol 200mcg PfizerPusat Herbal Resmi BPOM
 
wagamamaLab presentation @MIT 20240509 IRODORI
wagamamaLab presentation @MIT 20240509 IRODORIwagamamaLab presentation @MIT 20240509 IRODORI
wagamamaLab presentation @MIT 20240509 IRODORIIRODORI inc.
 
HAL Financial Performance Analysis and Future Prospects
HAL Financial Performance Analysis and Future ProspectsHAL Financial Performance Analysis and Future Prospects
HAL Financial Performance Analysis and Future ProspectsRajesh Gupta
 
Abortion pills in Muscut<Oman(+27737758557) Cytotec available.inn Kuwait City.
Abortion pills in Muscut<Oman(+27737758557) Cytotec available.inn Kuwait City.Abortion pills in Muscut<Oman(+27737758557) Cytotec available.inn Kuwait City.
Abortion pills in Muscut<Oman(+27737758557) Cytotec available.inn Kuwait City.daisycvs
 
Creating an Income Statement with Forecasts: A Simple Guide and Free Excel Te...
Creating an Income Statement with Forecasts: A Simple Guide and Free Excel Te...Creating an Income Statement with Forecasts: A Simple Guide and Free Excel Te...
Creating an Income Statement with Forecasts: A Simple Guide and Free Excel Te...Aurelien Domont, MBA
 

Recently uploaded (20)

Moradia Isolada com Logradouro; Detached house with patio in Penacova
Moradia Isolada com Logradouro; Detached house with patio in PenacovaMoradia Isolada com Logradouro; Detached house with patio in Penacova
Moradia Isolada com Logradouro; Detached house with patio in Penacova
 
stock price prediction using machine learning
stock price prediction using machine learningstock price prediction using machine learning
stock price prediction using machine learning
 
MichaelStarkes_UncutGemsProjectSummary.pdf
MichaelStarkes_UncutGemsProjectSummary.pdfMichaelStarkes_UncutGemsProjectSummary.pdf
MichaelStarkes_UncutGemsProjectSummary.pdf
 
Presentation4 (2) survey responses clearly labelled
Presentation4 (2) survey responses clearly labelledPresentation4 (2) survey responses clearly labelled
Presentation4 (2) survey responses clearly labelled
 
Toyota Kata Coaching for Agile Teams & Transformations
Toyota Kata Coaching for Agile Teams & TransformationsToyota Kata Coaching for Agile Teams & Transformations
Toyota Kata Coaching for Agile Teams & Transformations
 
Blinkit: Revolutionizing the On-Demand Grocery Delivery Service.pptx
Blinkit: Revolutionizing the On-Demand Grocery Delivery Service.pptxBlinkit: Revolutionizing the On-Demand Grocery Delivery Service.pptx
Blinkit: Revolutionizing the On-Demand Grocery Delivery Service.pptx
 
Unlocking Growth The Power of Outsourcing for CPA Firms
Unlocking Growth The Power of Outsourcing for CPA FirmsUnlocking Growth The Power of Outsourcing for CPA Firms
Unlocking Growth The Power of Outsourcing for CPA Firms
 
Innomantra Viewpoint - Building Moonshots : May-Jun 2024.pdf
Innomantra Viewpoint - Building Moonshots : May-Jun 2024.pdfInnomantra Viewpoint - Building Moonshots : May-Jun 2024.pdf
Innomantra Viewpoint - Building Moonshots : May-Jun 2024.pdf
 
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdfThe Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
 
Beyond Numbers A Holistic Approach to Forensic Accounting
Beyond Numbers A Holistic Approach to Forensic AccountingBeyond Numbers A Holistic Approach to Forensic Accounting
Beyond Numbers A Holistic Approach to Forensic Accounting
 
South Africa's 10 Most Influential CIOs to Watch.pdf
South Africa's 10 Most Influential CIOs to Watch.pdfSouth Africa's 10 Most Influential CIOs to Watch.pdf
South Africa's 10 Most Influential CIOs to Watch.pdf
 
High Profile Bangalore Just VIP Brigade Road 100% Genuine at your Door Step
High Profile Bangalore Just VIP Brigade Road 100% Genuine at your Door StepHigh Profile Bangalore Just VIP Brigade Road 100% Genuine at your Door Step
High Profile Bangalore Just VIP Brigade Road 100% Genuine at your Door Step
 
Top^Clinic ^%[+27785538335__Safe*Women's clinic//Abortion Pills In Harare
Top^Clinic ^%[+27785538335__Safe*Women's clinic//Abortion Pills In HarareTop^Clinic ^%[+27785538335__Safe*Women's clinic//Abortion Pills In Harare
Top^Clinic ^%[+27785538335__Safe*Women's clinic//Abortion Pills In Harare
 
Future of Trade 2024 - Decoupled and Reconfigured - Snapshot Report
Future of Trade 2024 - Decoupled and Reconfigured - Snapshot ReportFuture of Trade 2024 - Decoupled and Reconfigured - Snapshot Report
Future of Trade 2024 - Decoupled and Reconfigured - Snapshot Report
 
The Art of Decision-Making: Navigating Complexity and Uncertainty
The Art of Decision-Making: Navigating Complexity and UncertaintyThe Art of Decision-Making: Navigating Complexity and Uncertainty
The Art of Decision-Making: Navigating Complexity and Uncertainty
 
Jual Obat Aborsi Di Sibolga wa 0851/7541/5434 Cytotec Misoprostol 200mcg Pfizer
Jual Obat Aborsi Di Sibolga wa 0851/7541/5434 Cytotec Misoprostol 200mcg PfizerJual Obat Aborsi Di Sibolga wa 0851/7541/5434 Cytotec Misoprostol 200mcg Pfizer
Jual Obat Aborsi Di Sibolga wa 0851/7541/5434 Cytotec Misoprostol 200mcg Pfizer
 
wagamamaLab presentation @MIT 20240509 IRODORI
wagamamaLab presentation @MIT 20240509 IRODORIwagamamaLab presentation @MIT 20240509 IRODORI
wagamamaLab presentation @MIT 20240509 IRODORI
 
HAL Financial Performance Analysis and Future Prospects
HAL Financial Performance Analysis and Future ProspectsHAL Financial Performance Analysis and Future Prospects
HAL Financial Performance Analysis and Future Prospects
 
Abortion pills in Muscut<Oman(+27737758557) Cytotec available.inn Kuwait City.
Abortion pills in Muscut<Oman(+27737758557) Cytotec available.inn Kuwait City.Abortion pills in Muscut<Oman(+27737758557) Cytotec available.inn Kuwait City.
Abortion pills in Muscut<Oman(+27737758557) Cytotec available.inn Kuwait City.
 
Creating an Income Statement with Forecasts: A Simple Guide and Free Excel Te...
Creating an Income Statement with Forecasts: A Simple Guide and Free Excel Te...Creating an Income Statement with Forecasts: A Simple Guide and Free Excel Te...
Creating an Income Statement with Forecasts: A Simple Guide and Free Excel Te...
 

Reducing costs with condition based maintenance, IBC conference Singapore, 2010

  • 1. Turbo Services Reducing Costs with Condition Based Maintenance Dr Shaun West and Nathan Self, Sulzer Turbo Services | slide 1
  • 2. Sulzer Turbo Services’ experience - over 15 years of know how developed Turbo Services Frame 9E/9FA 7E/7FA Total V-series +100 sets of parts +75 sets of parts + 1500 sets of parts +1400 sets of parts + 100 inspections +25 inspections Rotor services (de-stacking, inspection, restacking, balancing, NDT, life assessment) +50 +50 projects New and replacement parts (consumables, combustion section, turbine section) +100 sets +90 sets of parts 20units 11 units Combustion component repairs Blade and vane repairs Field services (mechanical, controls, fact finding, minor and major inspections) Long-term service agreements | slide 2
  • 3. Gas turbine segment trends - what is ‘mature’ technology today? Turbo Services G and H technologies are still maturing F-tech was first introduced 15 years ago Improvements keep being introduced to the F-tech units Most gas turbines can now be considered ‘mature’ Frame 5 Frame 7B Year of introduction Frame 9E Frame 7E Frame 6B Frame 9B V93 and Frame 7FA Frame 9FA GE V94.3a V94.2 Capacity installed in calendar year Siemens 13E2 GT13D 13E GT24 Alstom GT26 WH501D WH251B 1970 Platts, 2007 1975 1980 WH501F WH701D WH/MHI WH701F 1985 1990 1995 2000 2005 2010 | slide 3
  • 4. How can risks and costs be controlled? - an LTSA is not for everyone Turbo Services Costs can be ‘high’ LTSAs with the manufacturer Management of technology risk for introductory technologies Can be ridged in structure Extra works normally at ‘list price’ Service delivery is more flexible Suitable for mature technologies LTSAs with a non-OEM Good tool to limit price risks Extra works normally at agreed rates Life management possibilities Management and logistics can be an issue Transactional services Costs can be lower – all technical risk remaines with the buyer Life management possibilities | slide 4
  • 5. Sweating the asset - where can the most value be created? Turbo Services Where can additional value safely be extracted? Parts costs Repair costs Cost saving creates value Field service TA costs Field service craft labour Parts’ life extension Extension of inspection intervals Engineering judgment adds value Upgrading of capability | slide 5
  • 6. Driving cost savings to create value Turbo Services Good procurement driving costs out Cost saving of 10% on repairs Cost saving of 10% on CI field services CI/CI/HGP/CI/CI/MI cycle What is the cost saving? Six day outage Repair costs Cost per CI 100,000USD 200,000USD 2 MI cycle (12 years) 40,000 80,000 120,000 The unit is not put at risk directly… … risk of poor outage performance … risk of poor repair life | slide 6
  • 7. Value creation from engineering judgment Turbo Services Using engineering know how to create value Removal of combustion inspection CI/CI/HGP/CI/CI/MI cycle What is the value created? Six day outage Repair costs Generation gains Cost per CI 2 MI cycle (12 years) 100,000USD 800,000 200,000USD 1,600,000 100MWx24hx6dx25USD/MWh 360,000USD 2,880,000 5,280,000 This example is based on no additional repair costs! A little unrealistic as repairs on the combustion capitals may be more extensive The key is how to do this without putting the unit at risk… | slide 7
  • 8. Turbo Services Key know how… … how do parts degrade | slide 8
  • 9. Corrosion and oxidation - three different damage mechanisms Cr2O3 Turbo Services TBC Al2O3 Protective layer Inter-diffusion Thermo mechanical fatigue Attack Type II Hot Corrosion 500 600 Type I Type I Hot Corrosion 700 800 Temperature (°C) 900 Oxidation 1000 1100 | slide 9
  • 10. Material degradation - material strength reduces over time Gamma prime strengthens super alloys Turbo Services Heat treatments can restore the structure Time at high temperature causes rounding of the crystals LE CC CV TE TIP MIDDLE ROOT γ’ precipitate size changes with time & temperature | slide 10
  • 11. Creep - Creep damage cannot be recovered Turbo Services Material properties are important, like grain size and volume of γ’precipitates Strain [-] Slow deformation at constant stress level at high temperatures ( T > 0.4Tm ) Creep is a thermally activated process Strain rate increase with stress and temperature Life time reduces with increase in stress and temperature | slide 11
  • 12. Fretting - damage minimization is key Turbo Services What: material removal as a result of sliding wear Contact between two surfaces Vibration Where: transition pieces Seals Mounting brackets Fix: wear resistant coatings or linings are usually efficient (W-Cr carbides, Stellites) | slide 12
  • 13. Cyclic fatigue - regular visual inspections are important High cycle fatigue Turbo Services Low cycle fatigue Large number of cycles until failure (>100,000 cycles) Low number of cycles until failure (<100,000 cycles) Crack initiation can take a long time Crack initiation period relatively short Required stress amplitude is relatively low Stress amplitude is high Vibration can be caused by: Tip rubbing Resonance Aerodynamic instabilities Δσ [MPa] LCF Fatigue limit HCF 100 1000 10000 100000 1000000 10000000 Number of cycles [#] | slide 13
  • 14. High cycle fatigue - catastrophic compressor failure Turbo Services Excitation caused by: single VIGV closing, blade rub etc Mode 1 Mode 2 Mode 3 Mode 4 Mode 5 Mode 6 | slide 14
  • 15. Low cycle fatigue - start/stop related Turbo Services IN939 vanes suffering LCF following imbrittlement of the base material | slide 15
  • 16. Repair of blades - metallurgical understanding key to repairs Known operational issues Turbo Services Repair processes IN 738/Sicoat 2231 Striping of coating Cracking leading edges (row 1) Heat treatment Inter-granular attack NDT Sulzer inspection techniques Welding X-ray Overlay repair by slurry-brazing Boroscope inspections Blending Thermographic analyses Heat treatment Coating (where applicable) Sections used for creep testing #14844 #14843 #14847 #14845 #14837 #14846 #14842 | slide 16
  • 17. Repair of vanes - metallurgical understanding key to repairs Known operational issues Turbo Services Repair processes Nitration of IN 939 Striping of coating Fatigue cracking Heat treatment Distortion NDT Sulzer inspection techniques Welding X-ray inspection Overlay repair by slurry-brazing Visual inspection of internals Blending Dimensional inspection: tooling Heat treatment Coating (where applicable) | slide 17
  • 19. Blade re-design to meet a customer’s needs A customer found that their blades were failing early in life due to a deformation on the shroud of the turbine blades Turbo Services Original with shroud Working with the customer and their insurance company, a tailor-made solution was developed The new design has proven itself in operation The new design provides lower operational risk because the deformation no longer plagues the machine Modified without shroud Major cost saving: 24kEOH parts now lasting 24k+24kEOH | slide 19
  • 20. Rotor life management - extending operation safely Turbo Services Rotor material can become brittle Replica and phased array NDT are two assessment tools Rotor operational history important Rotors can suffer low cycle fatigue Finite element modeling provides stress data Some damage can be repaired/replaced Major cost saving: A new rotor can cost 5M USD An unplanned failure will cost the owner and insurer +10M USD each Example of FEA on rotor disk | slide 20
  • 21. Damaged turbine stub shaft - repaired and fit for service Turbo Services Emergency shut down damaged turbine stub shaft Stub shaft was machined, welded and then machined to original dimensions Rotor rebuilt and put back into operation Speed was key for the owner Major cost saving: Rotor returned to service within 30 days | slide 21
  • 22. Extending outages - removing an unplanned 8000EOH inspection Turbo Services Review of the weak parts of the turbine Upgrades on the weakest areas Flow down of advanced technologies Transfer of technologies used on other units Understanding of the full hot gas path FE analysis Temperature mapping CFD Modes of degradation Own (S West) experience Burner segment plates – early failure Weaknesses from fretting and overheating Solution – low risk, based on coatings | slide 22
  • 23. Frame 9FA compressor - strip, replace, rebuild of the compressor Turbo Services Reverse engineering Determination of natural frequencies 3D scanning Physical component Finite element measurement Computational fluid dynamics 3D solid model Over 20 F-tech rotors | slide 23
  • 24. Making run/no-run decisions - I am stuck in the middle… Turbo Services Engineering judgment helps you to make better decisions Helps to create value and save cost ‘We need to have a decision - NOW!’ ‘What’s the risk of running on?’ ‘There are high prices available - we’re losing opportunity’ ‘I don’t want to know the technical details..’ ‘How long can we run safely for?’ ‘How long will it take to fix and how much will it cost’ | slide 24