Operating Experience of GE’s LM6000 and LMS100 Gas · PDF fileAll PC PD PF Total Engines Produced 957 658 216 83 Total Operating Hours 17,510,380 11,512,377 5,538,122 459,881 High

July, 2013

Operating Experience of GE’s LM6000 and LMS100 Gas Turbines

© 2011 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior

permission of the copyright owner.

2 NP Proprietary

LM6000 Gas Turbine

3 NP Proprietary

LM6000 evolution continues Proven, advanced technologies deliver greater value

PA PB

PD

PC

PC

PC

PD

PF

PF

SAC

DLE

w/Sprint

w/o Sprint

HP & LP Sprint

HP Sprint

CF6-80C2 CF6-80E1

1st Generation 2nd Generation

PH

PH

PG

PG LP Sprint

3rd Generation

40% higher output

© 2012 General Electric Company. Proprietary. All Rights Reserved.

4 NP Proprietary

LM6000 Experience

** >40 units have been converted to –PC, -PD or –PF configurations Engine count & operating hours have not been added to -PC/-PD

numbers

Estimated data as of July 16, 2013

All SAC DLE

Total Engines Produced 1128 806 322

Total Operating Hours 26,100,097 19,309,923 6,785,700

High Time Engine 140,250 140,250 132,592

All PA PB


Total Operating Hours 9,040,650 7,793,072 1,247,578

High Time Engine 140,250 140,250 132,592

All PC PD PF

Total Engines Produced 957 658 216 83

Total Operating Hours 17,510,380 11,512,377 5,538,122 459,881

High Time Engine 115,543 115,543 100,544 60,204

All PG PH


Total Operating Hours 4,474 4,474

High Time Engine 1,856 1,856

Equipped with Sprint All PC PD PF PG

Total Engines 572 453 86 33 3

Total Operating Hours 8,626,508 7,314,618 969,364 342,526 4,474

High Time Engine 90,208 90,208 55,682 60,204 1,856

LM6000 Products

LM6000 PC/PD/PF

LM6000 PA/PB

LM6000 PG/PH

5 NP Proprietary

LM6000 Combustion System Experience**

Single Annular Dry Low Emissions

*Includes hours from 2 Dual Fuel –PD (25ppm) prior to conversion to –PF (15ppm)

**Does not include Spare/Lease/Exchange stats

Water Injection

- 25 PPM NOx (gas)

- 42 PPM (liquid)

Steam Injection

- 25 PPM NOx

PD - 25 PPM Nox (gas)

PF – 15 PPM NOx (gas)

– 65 PPM NOx (liquid)

Estimated data as of July 16, 2013

Dry 15 738,799

Steam Injection 49 2,210,328

Water Injection 414 8,604,014

Dry 8 303,963

Water Injection 20 628,235

Dry 10 614,499

Water Injection 279 6,093,607

Gas

Liquid

Dual

Gas 25 ppm 226 6,325,819

Gas 15 ppm 70 258,905

Dual* 25 ppm 4 126,313

Dual 15 ppm 15 106,926

6 NP Proprietary

LM6000 Availability and Reliability Consistent World-Class Results

Aircraft engine & LM family experience

Extensive development testing

Every engine is factory full-load tested

Lease engine and rotable component availability

Aircraft engine maintenance philosophy

Source: ORAP®; All rights to Underlying Data Reserved: SPS®

Gas Turbine Generator Set 50th percentile unit 328 units reporting

Jan-10 Jan-11 Jan-12 Jan-13

Source: ORAP®; All rights to Underlying Data Reserved: SPS®

7 NP Proprietary

LMS100

8 NP Proprietary

Unique LMS100 advantage & value for LNG compression:

• Best GT simple cycle efficiency @ 44% & hot day performance • 3 Shaft design, free PT, no gearbox & high starting torque

• No helper motor required saves $5MM capital and simplifies train • Greater than 10 point efficiency advantage over other simple cycle

machines at base or part power conditions • Higher efficiencies yield over 55,000 tonnes less CO2 than competing gas

turbines. • Less than 1% power loss at off speed conditions

• Common driver for both generator and compressor • On-condition maintenance, modularity and engine exchange capabilities

yield an additional 10 days of production per year over alternative gas turbines

• Over 20% more power on hot day operation versus non-intercooled gas turbines.

LMS100 Mechanical Drive (LNG/F-LNG)

Designs to meet ever evolving LNG industry

9 NP Proprietary

49 Units

LMS100 operations growth

July 31st, 2013

Total Operating Hours 210,599

Total Starts 28,220

High-time Unit Hours 31,314

Fleet Hours Growth

In Commercial Operation

• South Dakota 1 & 2

• Texas 1 & 2

• Argentina

• N. California 1 - 4

• New Jersey

• Connecticut

• Chile

• Canada 1 & 2

• Italy 1, 2 & 3

• Kentucky 1 & 2

• Turkey 1 & 2

• Montana

• New Zealand 1 & 2

• Colorado 1 & 2

• Australia 1 & 2

• S. California – 19 units

• New Mexico

• Venezuela

10 NP Proprietary

Hours Starts

1 South Dakota #1 Jun 2006 4,313 805 5.4

2 South Dakota #2 Jun 2008 2,387 495 4.8

3-4 Texas Units #1-2 Aug 2008 16,769 4,431 3.8

5 Argentina Sep 2008 31,314 505 62.0

6-9 PEC, Firebaugh, Units 1-4 May 2009 16,254 4,114 4.0

10 New Jersey Jun 2009 1,805 847 2.1

11 Connecticut Jun 2009 2,972 1,158 2.6

12 Italy #1 Oct 2009 6,408 1,173 5.5

13 Chile Oct 2009 10,569 787 13.4

14-15 Canada Units #1-2 Oct 2009 18,561 2,416 7.7

16-17 Kentucky Units #1-2 Dec 2009 16,335 1,832 8.9

18 Montana Jul 2011 2,555 362 7.1

19-20 Turkey Units #1-2 Aug 2010 31,413 3,116 10.1

21 Italy #2 Oct 2010 5,337 1,052 5.1

22-23 New Zealand Units #1-2 Mar 2011 16,119 1,588 10.2

24 Italy #3 Jun 2011 4,467 743 6.0

25-26 Colorado Units #1-2 Dec 2011 4,999 694 7.2

27-28 Australia Units #GT2-GT3 Sep 2012 10,650 462 23.1

29-33 S. California 5-unit site Jan-Mar '13 1,873 510 3.7

34-41 S. California 8-unit site Mar-Apr '13 2,016 527 3.8

44-47 S. California 6-unit site Feb-Jun '13 1,431 443 3.2

48 New Mexico (estimated) May-13 684 114 6.0

49 Venezuela (interpolated) Jul-13 1,368 46 29.7

210,599 28,220 7.5 Summary of Total Operations

Avg.

Hrs/Run

Reported Through

July 31st, 2013Unit Location CODUnit Count

LMS100 Fleet Operating Experience

All Operation (commissioning and post-COD)

49 units in operation

Fleet >210,000 hours

High time unit

>31,000 hours

High starts unit

>2,300 starts

[ As of 31 July 2013]

GE Oil & Gas Global Services – Solutions Asset Development

Modular Replacement

12 NP Proprietary

• Speeds-up major overhaul activities

… down to 11 days for Major Overhaul

• Removed modules may be overhauled in service shop

… highest quality standards & best tools available

• Quick recovery from catastrophic failure / emergency shutdown

… maximize uptime

Modular Exchange NEW CONCEPT FOR MAJOR OVERHAUL …

Exchange Gas Turbine Engine instead of opening GT at site

• Best benefits with sites with high costs from loss of production

• Spare MS5002 engine to be purchased

13 NP Proprietary

MS5002C lifting sketch

Single lift ... ~ 73 ton

~ 49.5 ton ~ 23.5 ton

LP only lift HP only lift

~2.2 m ~3.4 m

~1

.8 m

~2

.4 m

~2.2 m ~0.8 m

~4.4 m

~3.0 m

~2

.4 m

~5.0 m

~2

.9 m

~8.0 m

~2

.9 m

~2

.9 m

~3.1 m

14 NP Proprietary

Modular Replacement Replacing GT Tube … restore efficiency and reliability

• Replacing existing GT tube with same model

• Rejuvenate avoiding re-permitting

• Restore original efficiency and reliability

• GT tube Rejuvenation to new life (30+ years)

• Zero plant impact … Short downtime

• Introduce latest design change / CM&U

•MS3002A thru G

• Re-industrialize MS3002F to fit all

• Regen or Simple cycle

• DLN Could be investigated

- New life to aged equipment… parts commonality and availability - Available for MS3002H & J, MS5001 and MS5002 all models - Can be developed for MS3002A…G

15 NP Proprietary

Modular Replacements Contacts

Roberto Mantini GE O&G Global Services

Upgrade Leader

T +39 348 8760964

E [email protected]

Fabio Sventurati GE Oil & Gas

Product Manager

Gas Turbine Upgrade

T +39 055 4586010

E [email protected]

via Felice Matteucci, 2

50127 Florence, Italy Nuovo Pignone S.p.A.

mailto:[email protected]

GE Oil & Gas

Compression technology for LNG applications

16 © 2013 GE Oil & Gas. All Rights Reserved

Unauthorized Reproduction Prohibited



25 years of compression evolution for LNG 1988 2013

Single Compressor Train (size 1000) FR5 Driver

<80% efficiency ~30MW

Increased 2x train capacity with higher efficiency, reliability and flexibility

3 Compressor Train (Size 1400) FR7 Driver

~85% efficiency ~80MW



LNG drivers … technology enablers

Enablers Drivers

Design and manufacturability

Aerodynamic Test capabilities

Rotordynamic Predictability

Size • Large casings

• NEMA

• Large impellers,

flow capabilities

• Large impellers

• CFD

Efficiency • Large impellers

performance

• Side streams

• Model test

• Thermodynamic

test

• Pre-referenced

impeller

Reliability • Aeromechanics

• Large impellers

robust design

• String test

Availability • Robust design

• Stability test

• Torsional analysis test

35

0

2.5

5

7.5

10

12.5

15

17.5

20

22.5

25

27.5

30

32.5

Frequency [Hz]

DEGLOG: 0.1113

Res. Freq :52.7Hz - Res. Speed :3159.3rpm - AF:28.2178 - Zeta:0.0177

Start: 38.7Hz (2323.2rpm) - Stop: 64.6Hz (3877.0rpm)

(04/03/2013 14:03:30) - (04/03/2013 14:05:13)

65.357631.7714 35 40 45 50 55 60

Selected

Original

Laurentian

MID_plane_BW (xrev1)



Propane Centrifugal Compressor Efficiency

0

10

20

30

40

50

60

70

80

90

75

76

77

78

79

80

81

82

83

84

85

86

87

88

19

9…

19

98

19

98

19

99

20

00

20

02

20

13

20

03

20

03

20

04

20

04

20

04

20

05

20

06

20

06

20

08

20

08

20

09

20

10

20

10

20

11

20

12

20

12

20

12

20

13

Po

we

r (M

W)

Po

l. E

ffic

ien

cy

(%)

Test Year

-Radial Side stream arrangement

-Optimized Discharge volute -Optimized Mach Stages

-Optimized casing to increase DR

- Single Casing Propane

- 3 side streams arrangement

- 100 MW reached in single casing

Focus on

Capacity/Power

Focus on

Performance

Full path CFD analysis Optimization of stators

Continuous Casing Optimization

Continuous Stator Optimization Return Channel Optimization

Abradable seals

Full Multistage CFD analysis Optimization of stators

Focus on

Predictability

Validation Model Test Validation Model Test Validation Model Test Validation Model Test



MR Compressor Efficiency

- Optimized Discharge volute - 3d, 2d Stage introduction

- Larger casing to increase DR

Focus on

Performance

Full path CFD analysis Optimization of stators

Continuous Stator Optimization Return Channel Optimization

Continuous Casing Optimization Abradable Seals

Full Multistage CFD analysis Optimization of stators Focus on

Predictability Validation Model Test Validation Model Test Validation Model Test Validation Model Test

10

20

30

40

50

60

70

80

90

100

78.0

79.0

80.0

81.0

82.0

83.0

84.0

85.0

86.0

87.0

88.0

89.0

90.0

19

94

19

98

19

99

20

00

20

03

20

03

20

04

20

05

20

05

20

05

20

05

20

05

20

05

20

06

20

06

20

07

20

08

20

09

20

09

20

09

20

10

20

11

20

11

20

11

20

11

20

13

Po

we

r (M

W)

Po

l. E

ffic

ien

cy

(%)

Test Year



Aerodynamic - Impellers

0.55

0.60

0.65

0.70

0.75

0.80

0.85

0.90

0.95

0.04 0.06 0.08 0.1 0.12 0.14 0.16

Flow coefficient

Inle

t V

s P

eri

ph

era

l Ma

ch N

um

be

r

High Volumetric Flow Capability

High Inlet Tip Diameter (High Mach)

D2 Q Mu

D1s Q M1rs

M1rs

Mu

0.000

0.500

1.000

1.500

2.000

2.500

3.000

3.500

0 0.05 0.1 0.15 0.2 0.25

Flow coefficient

h /

Rc,s

avg

T50H

N

New t41

t13 & t31

c

AC

Good

Performance

Poor Performance

Flow coefficient

No

rma

lize

d c

urv

atu

re

Impeller geometry

Impeller geometry



Aerodynamic - Impellers Head coefficient per stage in LNG application

0.400

0.420

0.440

0.460

0.480

0.500

0.520

0.540

0.560

0.580

0.600

0.0000 0.0200 0.0400 0.0600 0.0800 0.1000 0.1200 0.1400 0.1600 0.1800

Flow Coefficient

Head

co

eff

icie

nt

PR services

Other Services

Polytropic Efficiency per stage in LNG application

0.700

0.720

0.740

0.760

0.780

0.800

0.820

0.840

0.860

0.880

0.0000 0.0200 0.0400 0.0600 0.0800 0.1000 0.1200 0.1400 0.1600 0.1800

Flow Coefficient

Po

lytr

op

ic E

ffic

ien

cy

PR services

Other Services

• Head coeff limits pushed beyond

• Increased head per impeller (4,500m / 44,145 J/Kg / 14,770 ft)

• Need of high head stages to increase

flow and reduce machine lenght

• Mixed flow impellers introduced

• Constant performance in whole range

PR - LP PROCESS STAGE

3000

4000

5000

6000

7000

8000

9000

10000

140000 150000 160000 170000 180000 190000 200000

Volumetric Flow

Po

lytr

op

ic H

ea

d [

m]

8800m @ Surge

8510m @ DP - 3.3% HTRS

8700m @ SCL – 1.4% HRTS

84%

0.54



Aerodynamic – Side Streams

\

radial tangential

• Tangential still valid to reduce bearing span or for revamps

• Optimization to reduce losses: from 3 to 0.5 pressure loss coefficient

Mixing Ratio Side Loads

0

0.5

1

1.5

2

2.5

3

0 100 200 300 400 500 600 700 800

G s

s /

G m

ain

G tot (kg/s)

Bonny train 3

MLNG DUA

TRINIDAD 1-2-3

OMAN train1

MLNG TIGA

Woodside 4-5

NLNG Bonny 4-5-6

Qatargas

Union Fenosa

Hammerfest

Trinidad 4

ELNG

Darwin

Alba

Tangguh

QGII

Perù

Pluto

Angola

Skikda

Arzew

Skikda Aux

Arzew Aux

Gorgon

PNG

GLNG

Ruwais

Ichthys LNG



Aerodynamic

• Max Machine Mach No : 1.20 1.24 in Model Test

• Max Inlet Mach N : 0.98 1.05 in Model Test

• Flow Coefficient : 0.1800 flow coeff=Q/(u2 A)

• Head Coefficient : >0.54 per stage

• Polytropic head : > 4,500m / 44,145 J/Kg / 14,770 ft

• Power per Impeller: >25 MW

• Head rise to surge : < 5

• Inlet Volume Flow: 350,000 m3/h single flange

• SideLoad losses: <1

•Discharge Volute : <0.5

Propane compressor 1st stage impeller

Density distribution at shroud

Flow coefficient=0.1400 - MU=1.120 D2=1.535 m – N=2930 RPM

Inlet Mach No

Technology Milestones



Optimization analysis to increase production Analysis

New impeller design for 10% reduced power

0.50

0.55

0.60

0.65

0.70

0.75

0.80

0.85

0.90

100000 110000 120000 130000 140000 150000 160000 170000 180000 190000

Po

lytr

op

ic E

ffic

ien

cy

Inlet Flow (m^3/h)

c3-3MCL1405 3rd section

Current

Rebundle

0.50

0.55

0.60

0.65

0.70

0.75

0.80

0.85

120000 130000 140000 150000 160000 170000 180000

Po

lytr

op

ic E

ffic

ien

cy

Inlet Flow (m^3/h)

c3-3MCL1405 4th stage

Current

Rebundle



OEM experience enables reduced plant margins

PJ#2 impeller design

Project#3 cross section

• 50+ propane compressors & 160+ propane impellers in operation

• New propane PJ… all impeller already fully tested

• Proven experience for a step up innovation with low risk

12 Full “blue print” PR design

11 Full “blue print” MR train

AN200 + 2BCL806

9 ‘derived’ PR design

Configuration approach

Low tolerances to optimize plant design and boost profitability

2 3 4 1 4

PJ#1 impeller design



Thank you!



Documents

Operating Experience of GE’s LM6000 and LMS100 Gas · PDF fileAll PC PD PF Total Engines Produced 957 658 216 83 Total Operating Hours 17,510,380 11,512,377 5,538,122 459,881 High