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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 [email protected]
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
Out
put [
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
Ass
et re
venu
e
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
© 2015, General Electric Company. Proprietary information. All rights reserved.
PowerGen 2015 Slide 9
9E Advanced Gas Path (AGP)
* 109E estimate at ISO, NG
Ben
efits
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
AG
P te
chno
logy
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
Gro
win
g Ex
perie
nce
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
$3 000 000
0 1 2 3 4 5 6 7 8 9 10First year Fuel price ($MMBtu)
1000 hrs/year
2000 hrs/year
4000 hrs/year
6000 hrs/year
8000 hrs/year
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 intervals 4 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
© 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