GE

Energy

Uprate Options for the MS9001

Heavy Duty Gas Turbine

Timothy Ginter
GE Energy
Atlanta, GA
May 2008
Contents

Abstract ....................................................................................................................................................................................................................................1
Introduction ..............................................................................................................................................................................................................................1
Packaged Turbine Uprates .......................................................................................................................................................................................................................................1
Individual Upgraded Parts ........................................................................................................................................................................................................................................2
Life Extension ..................................................................................................................................................................................................................................................................2
Emission Levels...............................................................................................................................................................................................................................................................2
Absolute Performance Guarantees and Turbine Degradation ...............................................................................................................................................................2
Control System Upgrades .........................................................................................................................................................................................................................................3
MS9001 E-Class History..........................................................................................................................................................................................................3
MS9001E Current Production Component Technology ....................................................................................................................................................3
Compressor Improvements...........................................................................................................................................................................................5
GTD-450 Reduced Camber High Flow IGV Uprate (FT6B) ..........................................................................................................................................................................5
GTD-450 Compressor Stages 1 to 8 Uprate (FS1F) .......................................................................................................................................................................................6
High Pressure Packing Brush Seal Uprate (FS2V) ..........................................................................................................................................................................................6
No. 2 Bearing Brush Seal Uprate (FS2X) .............................................................................................................................................................................................................7
Shrouded S17 + EGV 1&2 and Counter Bore Covers Uprates (FS2B)....................................................................................................................................................8
Combustion System Improvements.............................................................................................................................................................................8
Uprate Combustion System from 9B to 9E (FR1H) ........................................................................................................................................................................................8
Add Water Injection to Gas or Dual Fuel Units (FG1A)..............................................................................................................................................................................10
Breech Loaded Fuel Nozzle Uprate (FR1T)......................................................................................................................................................................................................11
Add Water Injection for Liquid Fuel Units (FG1C).........................................................................................................................................................................................11
Add Steam Injection for Power Augmentation (FJ3A/B) (A=manual, B=automatic)....................................................................................................................12
Add Steam Injection for NOx Control in Gas or Dual Fuel Units (FG1B/D) (B=manual, D=automatic)................................................................................12
TBC Coated Combustion Liner Uprate (FR1G)...............................................................................................................................................................................................13
Uprated Nimonic 263™ Transition Piece with Improved Aft Bracket (FR1D) .................................................................................................................................13
Extendor* Combustion System Uprate (FR1V and FR1W).......................................................................................................................................................................15
Dry Low NOx Combustion System Uprate (FG2B) .......................................................................................................................................................................................18
Convert to Gas Fuel Only (FA1A) ..........................................................................................................................................................................................................................19
Convert from Liquid to Dual Fuel (FA3D)..........................................................................................................................................................................................................20
Hot Gas Path Improvements.......................................................................................................................................................................................20
Uprated Stage 1 Bucket (FT6J) .............................................................................................................................................................................................................................20
Uprated TBC Coated Stage 1 Buckets (FS4G)................................................................................................................................................................................................22
Uprated GTD-111* Stage 2 Bucket (FS2F).......................................................................................................................................................................................................23
Non Air-Cooled GTD-111 Stage 2 Bucket Uprate (FS2I) ...........................................................................................................................................................................24
Uprated Stage 3 Bucket IN-738™ (FS2K).........................................................................................................................................................................................................24
Uprated Stage 1 Nozzle with Chordal Hinge (FS2J) ...................................................................................................................................................................................25
Enhanced TBC Coating for Stage 1 Nozzle (FS6E).......................................................................................................................................................................................31
GTD-222+* Stage 2 Nozzle Uprate (FS1P).......................................................................................................................................................................................................31
GTD-222+ Stage 3 Nozzle Uprate (FS1R) .........................................................................................................................................................................................................32
Advanced Aero Stage 3 Nozzle (FS4K) and Advanced Aero Stage 3 Bucket Uprates (FS4L)..................................................................................................33
Uprated HR-120™ Improved Stage 1 Shroud with Cloth Spline Seals (FS2Y)................................................................................................................................35
Stage 1 Shroud Abradable Coating Uprate (FS6A) .....................................................................................................................................................................................37

GE Energy | GER-3928C (05/08) i

Contents

Stage 2 and 3 Shroud Blocks Uprates (FS2T and FS2U) ..........................................................................................................................................................................37

Interstage Brush Seal Uprate (FS2Z)..................................................................................................................................................................................................................38
Discourager Seal Replacement (FW3E)............................................................................................................................................................................................................39
Add Compressor and Turbine Water Wash (FC4A and FC4C)...............................................................................................................................................................40
Turbine Uprate Packages ............................................................................................................................................................................................40
Uprate 9B Hot Gas Path and Combustion to 9E (FT6X)............................................................................................................................................................................40
Increase MS9001E to 2020°F Firing Temperature (FT6C) ........................................................................................................................................................................44
Increase MS9001E to 2055°F Firing Temperature (FT6Y).........................................................................................................................................................................46
Compartment and Exhaust Improvements..............................................................................................................................................................47
Turbine Compartment Dual 100 HP Fan Uprate (FF1E) ...........................................................................................................................................................................47
Upgrade to 100 HP Exhaust Frame Motor Bowers (FS2D)......................................................................................................................................................................47
Replaceable Wheel Space Thermocouples Uprate (FK5C) .....................................................................................................................................................................48
Replaceable Exhaust Thermocouples Uprate (FK5K) ................................................................................................................................................................................48
Exhaust Frame Uprate (FS1W) .............................................................................................................................................................................................................................48
Advanced Exhaust Plenum Uprate (FD4K)......................................................................................................................................................................................................49
Summary.................................................................................................................................................................................................................................49
References ..............................................................................................................................................................................................................................50
List of Figures .........................................................................................................................................................................................................................50

ii
Uprate Options for the MS9001 Heavy Duty Gas Turbine

Abstract Introduction
Advanced design technology is usually introduced for new unit
production and subsequently applied to customer-operated gas
turbines by an uprate program. Many new uprate programs have
been introduced for installed GE-designed heavy-duty gas turbines,
including the MS9001E model illustrated in Figure 1. Each uprate
program provides one or more of the following: increased output,
improved heat rate and efficiency, improved reliability, reduced
maintenance costs, longer inspection intervals, or longer parts
lives. Uprates are based on current production components, parts
that are not always specifically unique to older machines, and thus
Advances in materials, cooling technology, and better design are readily available.
techniques have allowed E-class GE MS9001 turbines to be operated
with higher firing temperatures and greater airflows, which result in
higher turbine output and improved efficiency. Improvements in
combustion technology have also made significantly lower emission
levels a reality for operators.

The MS9001 heavy-duty gas turbine has undergone a series of uprates Figure 1. MS9001E Simple-cycle single-shaft heavy duty gas turbine.
since its original introduction to the market in 1975. These uprates are
made possible by the technology advances in the design of new Packaged Turbine Uprates
machines based on information accumulated through millions of fired Component improvements can be applied individually or as a
hours, new materials, and GE’s on-going development programs. complete uprate package, depending on schedule, budget, and

This document discusses design advances in critical components, machine condition. The design improvements and rationale are

and how the latest E-Class technology can be applied to enhance described for each possibility, including their effect on performance

performance, extend life, and provide economic benefits through and maintenance.

the increased reliability and maintainability of operating MS9001B GE Energy’s turbine uprate packages have been introduced because of
and MS9001E turbines. strong customer interest in extending the intervals between maintenance,

The MS9001B is a scaled version of the MS7001B, and MS9001E is improving efficiency, and increasing output. The E-Class technology

a scaled version of the MS7001E; therefore, the confidence level of uprate packages described in this paper include:

MS9001B/E uprates is very high based on a successful history in • MS9001 uprate from “B” to “E”
MS7001B/E uprate experience.
• MS9001E firing temperature increase to 2020°F, and to 2055°F
The first 2055°F uprate for MS9001E was successfully completed in
• MS9001 B and E emissions reduction
1990. Because this was the first uprate of its kind, extensive testing
was completed to monitor compressor performance and start-up • Numerous performance and efficiency improvement uprates
characteristics. Upon testing, the 2055°F uprate program was through airflow, material, and cooling technology advances
determined to be a success and since then many customers have This publication covers uprates that have been successfully
increased their firing temperature—thereby significantly increasing developed using components engineered for new unit production,
wattage output. Numerous customers have purchased the or developed for units in operation. Figure 2 lists the main benefits
individual uprate options described in this paper to realize that should be evaluated for a unit under consideration for each
performance and heat rate benefits. advanced technology uprate option.

GE Energy | GER-3928C (05/08) 1

 according to the outage schedule, or installed in a single outage,
• Performance Improvements (Output/Heat Rate)
with appropriate advance planning.
• Maintenance/Inspection Interval Extensions
• Availability/Reliability Improvements Each owner of a GE heavy-duty gas turbine should evaluate the
economics of the various uprates for a specific application. In many
• Emissions Reduction/Regulatory Agencies
cases, the economic evaluation justifies one of the available uprates at
• Life Extension
the next major overhaul and, in some cases, earlier. When more power
Figure 2. Benefits of uprates offered. generating capacity is required, uprating can provide a cost-effective
alternative to purchasing and installing new units. At the same time,
These uprates are possible due to GE’s underlying design philosophy
the improved parts provide extended life of the existing turbine.
of maintaining the interchangeability of components for a given frame
size—allowing these components to be installed in earlier vintage units Life Extension
with little or no modification. Installing the latest technology hardware Operators can take advantage of technology improvements by using
and taking advantage of the highest, latest available firing temperatures state-of-the-art components to replace older component designs
allows operators to remain competitive in the power generation during major and/or hot gas path inspections instead of replacing
marketplace. in-kind. These advanced technology components yield an increased

Gas turbine reference codes, such as FT6X for an MS9001 B to E service life when used in machines that fire at temperatures lower

advanced technology uprate, have been added to the text and to than that for which the advanced components are designed.

many of the figures for easier correlation to published documents Emission Levels
by GE on specific uprate packages or components. Emission levels can sometimes be affected when the gas turbine is

Individual Upgraded Parts uprated, and these levels must be accounted for during planning.

Since the first MS9001B was shipped in 1975, virtually every key Emission control options reduce the emission levels, and Figure 3

component in the MS9001 series has gone through design compares typical nitrogen oxides (NOx) emission levels before and

improvements. Buckets, nozzles, shrouds, and combustion after uprates. Individual site requirements and specific emission

components have undergone multiple evolutions based on new levels can be provided in an uprate study supplied to GE customers

designs, improved manufacturing techniques, new materials, and through a GE Sales representative.

acquired field experience. Absolute Performance Guarantees and Turbine Degradation

Uprates can make good investments, with many exhibiting prompt Performance uprates discussed in this paper are based on airflow or
payback for a specific operator. Each turbine application must be firing temperature increases that are directly related to performance
evaluated on its own merits, but in many cases, paybacks under increases, expressed as a percentage (Delta) of increase. Quantifying
two years have been registered. Uprates can be phased-in turbine performance degradation can be difficult due to lack of

NOx Emissions Levels at 15% O2 (ppmvd)

Single Shaft Units Firing Temp. Dry H2O/Steam Inj. Dry Low NOx
F/C
Model Gas Dist Gas Dist Gas Dist*
(FG1A/FG1B) (FG1C/FG1F) (FG2F) (FG25)
MS9001B 1840/1004 109 165 42 65 - -
MS9001B Option 3 1965/1074 124 191 42 65 25 -
MS9001B Option 4 2020/1104 132 205 42 65 25 -
MS9001E 2020/1104 157 235 42 65 25 42
MS9001E 2055/1124 162 241 42 65 25 42
MS9001E 2055/1124 162 241 42 65 15 42

Figure 3. NOx emissions levels at 15% O2.

2
consistent and valid field data. In addition, several variables exist, Introduced in 1978, the MS9001E incorporated the experience gained
including site conditions and maintenance characteristics, operation from MS7001E production and operation, as well as the design
modes, etc., that affect turbine performance and degradation trends. improvements that had evolved since the MS9001B was introduced.
Delta upgrades, providing a performance change, are consistent Introductory firing temperature for the MS9001E was 1955°F.
with or without turbine degradation factors. Absolute guarantees
The MS9001E has seen many design improvements since it was
must factor in degradation losses to calculate the final expected
initially introduced, with one obvious change being the increased firing
performance level. Therefore, the absolute performance guarantees
temperature. Advances in materials, coatings, and cooling technology
offered usually appear slightly different than Delta percentage
have supported a series of firing temperature increases. The current
changes in order to account for turbine degradation.
firing temperature for the latest MS9001E is 2055°F. All MS9001E gas
Control System Upgrades turbines can be uprated to the 2055°F firing temperature.
The MS9001B and E turbines are controlled by the GE Mark I* through
Mark VI* generation of controls. Several control system enhancements
MS9001E Current Production
and upgrades are available, providing more reliable operation with Component Technology
today’s superior control technology. Enhanced operating control can Product technology derived from ongoing new product development,
be realized in units that have older control systems. field service reports, and new materials and processes has resulted in
improvements to compressor hardware, combustion liners, transition
MS9001 E-Class History pieces, high flow inlet guide vanes, and all stages of buckets, nozzles,
The first MS9001 E-Class unit shipped in 1975 as a model MS9001B and shrouds.
for the 50 Hz market, incorporating excellent design experience
Many of the design improvements for components involve a
from the successful MS7001B. Operating with a design firing
change in the materials used. Figure 5 lists the composition of many
temperature of 1840°F (base load), the same firing temperature as
of the gas turbine alloys discussed herein. For buckets, nozzles, and
the MS7001B, the MS9001B design represented an increase of 42%
compressor blades, the most advanced materials of choice begin
in output over the MS7001B. This introductory design incorporated
with the designation GTD which signifies a General Electric patented
the air-cooled stage 1 buckets, nozzles, and stage 2 bucket material
or proprietary alloy. Some of the materials listed for these parts are
improvements based on MS7001B design experience gained prior
not used for current production, but are in the table for reference
to 1975. As illustrated in Figure 4, the output of the MS9001 has
concerning machines operating vintage parts made of these older
increased by 45% based on technology improvements through
alloy compositions, such as X40. Many of the materials shown in the
1994 (not including EC or F/FA product lines).

Model Ship Dates ISO Firing Temp Air Flow Heat Rate Exhaust Temp
Performance* °F/°C 106 lbs/hr BTU/kWhr °F/°C
kW 106 kg/hr kJ/kWh)
PG9113B 1975-81 86,200 1840/1004 2.736/1.241 10,990/11,592 945/507
PG9141E 1978-81 105,600 1955/1068 3.155/1.431 10,700/11,286 953/512
PG9157E 1981-83 109,300 1985/1085 3.183/1.444 10,700/11,286 968/520
PG9151E 1983-87 112,040 2000/1093 3.214/1.458 10,570/11,149 877/525
PG9161E 1988-91 116,930 2020/1104 3.222/1.461 10,290/10,854 980/527
PG9171E 1991 123,450 2055/1124 3.231/1.466 10,080/10,632 998/537
2003 – Current 126,100 2055/1124 3.231/1.466 10,100/10,650 1009/543
PG9231EC 1996 165,700 2200/1204 4.044/1.834 9,870/10,411 1,037/558
PG9301F 1993-94 209,740 2300/1260 4.804/2179 10,080/10,632 1,082/583
PG9311FA 1994 223,760 2350/1288 4.819/2.186 9,630/10,158 1,097/582

*Base load distillate fuel, includes 3/10 inches H2O inlet/exhaust pressure drops

Figure 4. MS9001 E-Class performance history.

GE Energy | GER-3928C (05/08) 3

Component Nominal Composition (%)
Cr Ni Co Fe W Mo Ti Al Cb V C B Ta
Buckets
U500™ 18.5 BAL 18.5 – – 4 3 3 – – 0.07 0.006 –
Rene 77™ (U700™) 15 BAL 17 – – 5.3 3.35 4.25 – – 0.07 0.02 –
IN-738™ 16 BAL 8.3 0.2 2.6 1.75 3.4 3.4 0.9 – 0.1 0.001 1.75
GTD-111* 14 BAL 9.5 – 3.8 4.5 4.9 3 – – 0.1 0.01 2.8
Nozzles
X40™ 25 10 BAL 1 8 – – – – – 0.5 0.01 –
X45™ 25 10 BAL 1 8 – – – – – 0.25 0.01 –
FSX-414 29 10 BAL 1 7 3 – – – – 0.25 0.01 –
N-155™ 21 20 20 BAL 2.5 – – – – – 0.2 – –
GTD-222* 22.5 BAL 19 – 2 – 2.3 1.2 0.8 – 0.1 0.008 1
Combustors
SS309 23 13 – BAL – – – – – – 0.1 – –
Hastelloy-X™ 22 BAL 1.5 1.9 0.7 9 – – – – 0.07 0.005 –
Nimonic 263™ 20 BAL 20 0.4 – 6 0.4 0.4 – – 0.06 – –
HA-188™ 22 22 BAL 1.5 14 – – – – – 0.05 0.01 –
Turbine Wheels
IN-706™ 16 BAL – 37 – – – – 2.9 – 0.06 0.006 –
Cr-Mo-V 1 0.5 – BAL – 1.25 – – – 0.25 0.3 – –
A286™ 15 25 – BAL – 1.2 0.3 0.3 – 0.25 0.08 0.006 –
M152™ 12 2.5 – BAL – 1.7 – – – 0.3 0.12 – –
Compressor Blades
AISI 403 12 – – BAL – – – – – – 0.11 – –
AISI 403+Cb 12 – – BAL – – – – 0.2 – 0.15 – –
GTD-450 15.5 6.3 – BAL – 0.8 – – – – 0.03 – –

Figure 5. Gas turbine alloys.

60
4 table for combustors and turbine wheels are still used today. The
FSX-414
40 3
IN-738™
most used alloys for current production of combustors and wheels
Kg/cm2 x 10-3

GTD-222*
are Nimonic 263™, HA-188™, Hastelloy-X™, and IN706™, Cr-Mo-V,
Stress KSI

2
N-155™ U500™ respectively. Figure 6 compares the rupture stress for the bucket
GTD-111*

Buckets and nozzle materials, Illustrating the improvements associated with

1 Nozzles
the new materials developed and offered in uprates.
10
Temp.
500 600 700 800 900
100,000 Hrs °C Figure 7 lists the performance and/or heat rate uprate codes
Life
1000 1200 1400 1600 currently applicable for E-Class turbines.
°F

Figure 6. Creep stress rupture comparison of bucket and nozzle materials.

4
 Uprate Description Compressor Improvements
FA1A Convert To Gas Fuel Only
FA3D Convert From Liquid To Dual Fuel The first four stages of the MS9001B compressor were re-designed
FA3L Uprated Three-Way Valves to Replace Check Valves for DLN-1 for the MS9001E model. Because new compressor casings and all
FC4A Add Compressor Water Wash Off Line new compressor rotor and stator blades would be required to
FC4C Add Turbine Water Wash
upgrade the MS9001B compressor to later design compressors,
FD4K Advanced Exhaust Plenum Uprate
FF1E Turbine Compartment Dual 100HP Fan Uprate this is usually not economically feasible and not typically quoted
FG1A Add Water Injection For Gas Or Dual Fuel Units as part of a unit uprate.
FG1B Add Manual Steam Injection for NOx Control in Gas or Dual Fuel Units
FG1D Add Automatic Steam Injection For NOx Control in Gas or Dual Fuel Units Instead, the existing MS9001B compressor can be re-bladed with
FG1C Add Water Injection For Liquid Fuel Units the original design/length blades, with special blade coatings for
FG2B Dry Low NOx 1.0 Combustion System Uprate materials available for certain applications. Originally, a NiCad
FJ3A Add Manual Steam Injection For Power Augmentation
coating was applied to the first eight stages of the compressor
FJ3B Add Automatic Steam Injection For Power Augmentation
FK5C Replaceable Wheel Space Thermocouple Uprate blades that were AISI 403. (See Figure 5.) NiCad coating helps
FK5K Replaceable Short Lead Design Exhaust Thermocouple Uprate prevent corrosion pitting on the blades by combining a tough
FK5P Replaceable Connector Design Exhaust Thermocouple Uprate barrier of nickel with a sacrificial cadmium layer. NiCad coating was
FR1D Uprated Nimonic Transition Pieces With Improved Aft Bracket
replaced by GECC-1*, which provides the same protection as NiCad
FR1G TBC Coated Combustion Liners Uprate
FR1H Uprate Combustion System From 9B To 9E without the use of cadmium, which is considered an environmental
FR1T Breech Loaded Fuel Nozzle Uprate hazard. Both GECC-1 and NiCad possess outstanding corrosion
FR1V Extendor* Combustion System Retrofit Uprate resistance in neutral and sea salt environments.
FR1W Extendor Combustion System New Uprate
FS1F GTD-450 Compressor Stages 1 To 8 Uprate GTD-450 Reduced Camber High Flow IGV Uprate (FT6B)
FS1L Air-Cooled Stage 2 Bucket Uprate
A widely used uprate product is the GTD-450 reduced camber,
FS1P GTD-222+* Stage 2 Nozzle Uprate
FS1R GTD-222+ Stage 3 Nozzle Uprate high-flow inlet guide vane illustrated in Figure 8. The new design,
FS1W Exhaust Frame Uprate introduced in 1986, was quickly applied across the entire GE
FS2B Shrouded S17 + EGV1&2 And Counter Bore Covers Uprates heavy-duty product line to enhance field unit performance,
FS2C Uprated Stage 1 Shroud Blocks
including MS9001E and B units. Note that previous design IGVs
FS2D 100HP Exhaust Frame Motor Blower Uprate
FS2F Uprated GTD-111* Stage 2 Bucket made of 403L stainless steel (SS) cannot be opened to 86 degrees,
FS2I Non Air-Cooled GTD-111 Stage 2 Buckets Uprate due to insufficient strength of the lower rated, 403L material with
FS2J Uprated Stage 1 Nozzle With Chordal Hinge low carbon (L).
FS2K Uprated Stage 3 Bucket IN738
FS2T Stage 2 Shroud Honeycomb Seal Uprate
FS2U Stage 3 Shroud Honeycomb Seal Uprate
FS2V High Pressure Packing Brush Seal Uprate
FS2X Number 2 Bearing Brush Seal Uprate
FS2Y Uprated HR-120™ Improved Stage 1 Shroud with Cloth Spline Seals
FS2Z Interstage Brush Seal Uprate
FS4G Uprated TBC Coated Stage 1 Buckets
FS4K Advanced Aero Stage 3 Nozzle Uprate
FS4L Advanced Aero Stage 3 Bucket Uprate
FS6A Stage 1 Shroud Abradable Coating Uprate
FS6E Enhanced TBC Coating for Stage 1 Nozzle
FT6B GTD-450 Reduced Camber High Flow IGV Uprate
FT6C Increase 9E To 2020°F Tf
FT6J Stage 1 Bucket Uprate
FT6X Uprate 9B Hot Gas Path And Combustion To 9E
FT6Y Increase 9E To 2055°F Tf
FW3E Discourager Seal Replacement
Figure 7. Uprates available for 9B and 9E units. Figure 8. GTD-450 reduced camber high-flow variable IGV arrangement.

GE Energy | GER-3928C (05/08) 5

The benefits of this uprate are: GTD-450 Compressor Stages 1 to 8 Uprate (FS1F)
This modification for MS9001E units involves replacing the stage
• Model 9B change in output: +4.4%, change in heat rate: -0.9%
1-8 compressor blades and stator vanes with GTD-450 material,
• Model 9E (pre-1988) change in output: +1.5%, change in heat
uncoated. The GTD-450 stainless steel material provides high
rate: -0.3%
corrosion resistance even when uncoated, and significantly
• GTD-450 material provides excellent corrosion protection increases the strength of the blades and stator vanes.

The reduced camber, high-flow inlet guide vane is a flatter, thinner inlet The benefits of this uprate are:
guide vane designed to increase airflow while remaining dimensionally
• High tensile strength
interchangeable with the original inlet guide vane. The reduced camber
• Corrosion resistance and crack resistance
IGV, when open to 84 degrees, can increase power up to 4.4% and
decrease heat rate by up to -0.9% while improving corrosion, crack, • Significantly increased reliability and cycle life of the part
and fatigue resistances. Opening the IGVs to 86 degrees increases
Replacing the existing stage 1 through 8 compressor blades and
output an additional 0.4% at the expense of +0.2% heat rate.
stator vanes with uncoated GTD-450 gives the blades and vanes a
The enhanced IGVs have higher reliability due to the use of a special distinct material advantage. GTD-450 is a precipitation-hardened,
precipitation hardened, martensitic stainless steel GTD-450, which is martensitic stainless steel that provides increased tensile strength
improved over the AISI 403 alloy previously used. (See Figure 9.) and superior corrosion resistance because of its higher concentration
Material developments include increased tensile strength, higher of chromium and molybdenum. GTD-450 uncoated blading with high
high cycle fatigue strength, improved corrosion-fatigue strength, corrosion resistance is supplied for the first 8 stages because during
and superior corrosion resistance due to higher concentrations of standard operation this region could be subjected to liquid water,
chromium and molybdenum. therefore incurring an elevated risk of corrosion.

As illustrated in Figure 9, GTD-450 stainless steel compressor

• Improved Airfoil Geometry for Higher Power Higher
• New Material for High Corrosion Resistance Performance blades and stator vanes offer high tensile strength, high corrosion
without Coating Airfoil resistance, and high resistance to cracking that significantly
• Variable Airfoil % Thickness to Maintain
Reliability with New Geometry increase the reliability and life cycle of these parts.
• Greater Fatigue Resistance Properties
High Pressure Packing Brush Seal Uprate (FS2V)
1.8
Alternating Sresss Amplitude

1.6 This uprate for MS9001B and E units provides +1.0% increase in
1.4
output and improves heat rate by -0.5%. This option consists of
(Ratio to AISI 403)

1.2
11% T/C 1.0 GTD-450 modifying the existing labyrinth tooth and seal arrangement to add
6% T/C .8
AISI 403SS
an effective brush seal element. With this option a new inner barrel
.6
.4 with a new brush seal are installed. Note that FS2V is now a
Variable .2
Thickness 0
standard configuration on all new units since 2003 production year.
Airfoil 0 10 20 30 40 50 60 70
Mean Stress (KSI) The benefits of this uprate are:
Figure 9. Design improvements with GTD-450 high flow IGVs. • Model 9B change in output: +1.0%, change in heat rate: -0.5%

• Model 9E change in output: +1.0%, change in heat rate: -0.5%

The modification kit includes self-lubricating IGV bushings with tight
clearance. A new rack and ring assembly, which controls guide Notes: To obtain the above performance benefits on MS9001B units,
vane positioning, can also be provided for improved reliability. operators should install HPP together with #2 bearing brush seals
(FS2X).

A brush seal for 9E units with a honeycomb inner barrel

configuration is now available.

6
The seal between the compressor discharge casing inner barrel and Two different designs have been used to reduce leakage through
the compressor aft stub shaft is called the high-pressure packing the HPP. New units built since April 1994 shipped with a honeycomb
(HPP) seal. (See Figure 10.) The HPP seal is designed to regulate the seal on the inner barrel (similar to the design used for stage 2 and 3
flow of the compressor discharge air into the first forward wheel shrouds). To retrofit a brush seal onto an operating unit having a
space. The HPP clearance determines the amount of flow to the honeycomb seal, the existing inner barrel must be removed and
wheel space. Ideally, this flow is limited to the amount required for replaced with an inner barrel containing a brush seal. The inner
first forward wheelspace cooling. barrel with brush seal is designed for use with the existing
compressor aft stub shaft with high/low lands.

High-pressure packing brush seals, which are available for both

the 9B and the 9E, provide 1% increase in output and -0.5%
improved heat rate when replacing the labyrinth design. The high
pressure packing brush seal provides 0.2% improvement in both
output and heat rate relative to the honeycomb design.

No. 2 Bearing Brush Seal Uprate (FS2X)

The MS9001B and E units are three-bearing machines that include
two air seals in the No. 2 bearing housing, one on either side of the
bearing. The brushes provide a tighter seal than the original
Typical Brush Seal Element
labyrinth seal. Since any air that leaks past these seals into the
Brush Seals
Reduce air leakage bearing housing does not perform any additional work, any
Tolerant of misalignments
More durable than labyrinth seals reduction in this wasted flow results in an increase in performance.
Inner Barrel Brush seals for No. 2 bearing are illustrated in Figure 11. Note that
Current Production
FS2X is now a standard configuration on all new units
manufactured in 2003 and shipped in 2003 or 2004.

Labyrinth Seal

Brush Seal Air Seal

Aft Stub Shaft • Reduce Air Leakage to Bearing Cavity
Figure 10. HPP brush seal.
• Reduce Oil Mist

With the conventional labyrinth tooth/land seal packing on the inner

barrel, the allowable clearance that can be tolerated is controlled by
the expected rotor displacement during transient conditions, and by
cooling wheelspace requirements. If a rub does occur, the labyrinth
teeth can be seriously damaged and cause excessive leakage through
Cross-Section Bearing Housing
the packing. A 20-mil rub is equivalent to a loss of approximately 1%
Brush Seal
in output. Rub-tolerant brush seals are designed to bend, thereby
withstanding rotor excursions and maintaining clearances in this Figure 11. Brush seals for #2 bearing.

critical area with no increase in cooling airflow leakage. Metallic brush

material is used in place of one of the labyrinth teeth on the inner The benefits of this uprate are:
barrel. With brush seals at the high-pressure packing, the unit is able • Model 9B change in output: +1.0%, change in heat rate: -0.5%
to sustain initial performance levels over an extended time because
• Model 9E change in output: +0.3%, change in heat rate: -0.2%
the inevitable excursion does not increase the clearance.

GE Energy | GER-3928C (05/08) 7

Note: To obtain the above performance benefits on MS9001B units, A CM/U analysis is conducted to determine if shrouded compressor
operators should install HPP together with #2 bearing brush seals exit hardware is required for any specific unit. The stator 17
(FS2X). modifications will be reviewed for low ambient temperature sites,
or where frequent operation with modulating inlet guide vanes
The FS2X bearing brush seals combined with high pressure packing
occurs. Note that higher percentages of performance uprate and
brush seals installed together on the same unit have been tested in
colder ambient conditions both result in a greater need for
the field to yield 0.3% increase in output and -0.2% improvement in
installing shrouded design for a specific unit.
heat rate for MS9001E units, but yield a much better +1.0% increase
in output and -0.5% improvement in heat rate for MS9001B units. Figure 13 illustrates an example of a CM/U analysis for a unit
configuration in ambient temperatures from 41°F to 85°F and
Shrouded S17 + EGV 1&2 and Counter Bore Covers
maximum IGV angle of 84 degrees. The figure illustrates that
Uprates (FS2B)
shrouded hardware is needed for most ambient temperatures at
For MS9001E units, the need to implement the stage 17 stator
the IGV angles used. Counter bore cover plugs in the horizontal
correction is evaluated on an individual basis. Exit guide vane issues
split line bolt holes are recommended on most units operating at
on some MS9001E units have been attributed to aerodynamic vane
colder ambient temperatures.
stall when running under certain operating conditions. To prevent this
failure, the stage 17 stator vanes, and the two stages of exit guide Operators should note that shrouded stator S17 and EGV 1&2 are
vanes (EGVs) that follow the 17th stage, have been re-designed, (See now part of standard new unit design.
Figure 12.) The vanes have all been shrouded and each stage of vanes
goes into a broached ring that slides into a corresponding groove in
Combustion System Improvements
the compressor casing. Setting the vanes in rings and shrouding them Advances in the combustion system are driven by customer desires
reduces the sensitivity of the structure and prevents blade failure. for performance increases and for compliance with regulatory
requirements to reduce exhaust emissions. Relatively simple parts in
Shrouded Stator 17 and EGV 1 & 2 early gas turbines are now complex hardware pieces with advanced
• Stage 17 Stator and EGVs 1 & 2 have been shrouded to reduce materials and processing requirements. Combustion system
the sensitivity of the structure and prevents blade failure
• Applicable to sites with low ambient conditions, steam or water upgrades can be supplied as a package, or as individual options.
injection, or modulating IGVs (i.e., for heat recovery applications) Depending on the option chosen and other machine conditions,
upgraded combustion system components produce substantial
Compressor Discharge
Casing
S17 EGV-1 EGV-2 improvements in component life and/or for extensions in
recommended combustion inspection intervals.

Uprate Combustion System From 9B to 9E (FR1H)

Detail A
Stage 17, EGV-1, EGV-2
Thicker
The combustion system for the MS9001B can be upgraded to the
Shroud
MS9001E. The new combustion system provides increased reliability
and longer maintenance intervals and supports firing temperature
Inner Barrel
Casing
Increased increase.
Clearance Detail A

The benefits of this uprate are:

Figure 12. Side view of the three stages of shrouded compressor blades.

• Increased reliability and longer maintenance intervals

The benefits of this uprate are:
• Supports a firing temperature increase
• Enables stator blades to withstand the stall conditions
TBC coated slot-cooled liners and Nimonic 263™ transition pieces
• Shrouded compressor stator blade assemblies, counter bore are available for the MS9001B. Retrofitting B-combustion systems
covers, or IGV angle re-scheduling reduces the sensitivity of the with E-combustion systems increases inspection intervals and
structure and prevent blade failure allows for higher firing temperatures. On the MS9001B, if the

8
 Plot of Relative CM&U vs. IGV at Different Ambient Temperature

CM&U Limit Without BorePlugs – 0.906

CM&U Limit With BorePlugs – 0.893

Below 0.8929 CM&U value – Shrouded Design Recommended

The Min CM&U for this unit is well below the 0.8929 CM&U S17 restriction Limit
Ambient Temperatures

Figure 13. CM/U analysis for a specific unit showing need for shrouded design.

customer chooses to stay with the louvered liners, a new, an insulating oxide applied over the bond coat. This 0.015-inch thick
advanced designed louvered liner has been designed. coating provides an insulating layer that reduces the underlying
base material temperature and mitigates the effects of hot streaking
The original MS9001B combustion system had parallel combustors.
(uneven gas temperature distribution). The liners also use splash
With the introduction of the MS9001E, the design evolved into a
plate cooling around the crossfire tube collar. Impingement cooling
canted arrangement. Up until recently, in order to retrofit a 9B turbine
on the splash plate increases the cooling effectiveness at the collar
with a 9E combustion system, a new compressor discharge casing
location. This configuration reduces the stress concentrations
was required to accommodate the canted arrangement. A new 9B/E
thereby increasing life of the liner.
combustion system has been developed which incorporates the
design improvements seen in the MS9001E combustion system into
a parallel arrangement. This design significantly reduces the cost and
the installation time of this conversion, making it more attractive to
the customer.

Combustion Liner. The original combustion liners were louvered. To

improve the cooling effectiveness of the liner, a slot-cooled design
was introduced. (See Figure 14.) The slot-cooled liner is significantly
shorter than the louvered design, which further improves cooling.
The inspection intervals for the slot-cooled liners increase to 6,500
hours for water diluent (or 8,000 hours for steam diluent) from the
3,000 hours for the louvered liner. The material is still Hastelloy-X™,
but the liners are now given a thermal barrier coating (TBC). The TBC
consists of two different materials applied to the hot side of the
Figure 14. Improved slot-cooled liner versus original louvered liner.
component, a bond coat applied to the inner surface of the liner, and

GE Energy | GER-3928C (05/08) 9

The E-style slot-cooled liner is shorter than the old louvered liner flow uniformity. (Reference FR1T.) For the 9B, the breech loaded fuel
(39 in. vs. 56 in.). This necessitates new combustor outer casings nozzle design (current new unit configuration) can be an approved
and crossfire tubes. On the MS9001B, a new, advanced design option. (Please contact GE for information on applicability.)
louvered liner is available as an option. This option applies if the
Combustion Casing. The B-style combustion casings must be
customer wants to upgrade the current liners only, and keep the
replaced with a shorter version in order to accommodate the
current combustion arrangement. Current louvered liners have a
shorter E-style slot-cooled liner. The casings should not be cut
louver design that covers 270 degrees of liner circumference. In
down in order to modify them to a shortened version. Shorter
operation, especially when fired at peak firing temperature, this
casings require that the gas fuel and atomizing air manifolds be
can cause buckling along the 90 degree arc where the louvers
moved. The liquid fuel lines are re-laid with longer tubing. The new
are absent. New liners, with full circumferential louvers, have not
combustion casing covers are equipped with hinges to allow for
exhibited this buckling. Combustion inspection intervals with the
ease of maintenance. The new casing arrangement contains
advanced louvered liners can be increased to 6,000 hours.
flanges for a quantity of 4 flame detectors. GE recommends taking
Transition Piece. The new transition pieces are made of Nimonic this opportunity to upgrade to GE’s Reuter-Stokes flame detection
263™, which is a precipitation-strengthened, nickel-based alloy system. (Reference FK5J).
with a higher strength capability than Hastelloy-X™. This material
Spark Plug Leads. Units with spark plug leads 311A5802 or
has been used for over 30 years in aircraft engines, and has shown
354A1513 (all part numbers) and all pre-1995 units should inspect
to have less creep deflection than Hastelloy-X™ transition pieces.
them to ensure conformance to the minimum bend radius
The aft bracket has also been re-designed. The new design helps
requirements identified in TIL-1234-2. Exceeding this limit results in
reduce the cracking at the bracket weld area by being able to pivot
noncompliance with requirements for Factory Mutual certification
about the pin when a force is applied. Like the combustion liners,
for use in hazardous areas (Class 1, Division 1, Groups B, C and D).
the transition pieces are coated with a TBC. The transition piece for
the MS9001B uprate differs from the new production 9E transition Spark Plugs. The E-Class combustion system requires longer spark

piece in that its geometry accommodates the parallel combustion plugs to ensure reliable ignition. The extended reach spark plugs

chamber arrangement. were introduced for this purpose. Extended reach spark plugs
manufactured prior to 178C6648G001 (with serial number 2122)
On the MS9001B, the customer may choose to apply the new Nimonic
should be replaced in accordance with TIL-487C.
263™ transition piece only (Option A), or the new advanced louvered
liner with the Nimonic 263™ transition piece (Option A + Option B), or Manifolds. The gas fuel and atomizing air manifolds are replaced.

go full conversion to an E-type combustion system. (Note: The bracket Liquid Fuel Piping. The liquid fuel piping are re-run due to the
for the Nimonic 263™ transition piece has a different bolt hole pattern shorter casings. New check valves are provided for improved
than the previous designs, and as a result the stage 1 nozzle retaining reliability.
ring needs to be modified with the new bolt hole pattern.)
Purge System (FW1U). The purge system is modified to
Fuel Nozzles. The newer designed fuel nozzle bodies include the lock accommodate the shorter casings. New check valves are provided
plate feature and the weld-neck flanges on the gas and/or atomizing for improved reliability. This opportunity should be taken to ensure
air flanges. The lock plate replaces the lock wire to give increased that TIL-551-B has been addressed, since it addresses gas fuel
reliability and reduced risk of fuel gas leaks. The weld-neck flanges purge system safety concerns.
also reduce fuel nozzles leaks as well as cracking. Dual fuel or gas
only systems are upgraded with hard faced, flow matched gas swirl Add Water Injection to Gas or Dual Fuel Units (FG1A)
tips that reduce wear against the combustion liner fuel nozzle collar. This kit for MS9001B and E units includes the material necessary to add

Dual fuel and oil-only systems are improved with stainless steel and water injection to a unit. The modification kit includes replacement fuel

Stellite™ internal body parts to reduce erosion rates and improve nozzles containing water injection passages and connections, water

10
injection skid, instrumentation, manifolding, on-base piping, fuel flow extends combustion system inspection intervals, reduces downtime
measurement system, and control changes to operate the NOx system. as well as decreases repair costs.

The benefits of this uprate are: The primary benefit of breech-loaded fuel nozzles is to put the injected
water at the same relative position as the fuel entry to the combustion
• Reduced NOx emissions level to meet locally required levels
system. This in turn allows for proper mixing and, based on this,
• Significant increase in power and heat rate reduced hot gas path wear and increased inspection intervals.
This modification is not applicable to dual fuel units without
Water injection has a detrimental effect on the lives of the
atomized air. (Reference FA6B.)
combustion system components. The combustion inspection
The water injection system provides water to the combustion intervals are shorter with water injection and are unit and fuel
system of the gas turbine to limit the amount of nitrogen oxides specific. In order to reduce thermal cracking of the fuel nozzles and
(NOx) emitted in the turbine exhaust. This limit is site-specific and liner cap/cowl assembly, a special breech loaded fuel nozzle was
is dictated by the local regulating governmental agency. Applicable designed. (Reference FR1T.) In this design, the water is injected
local regulations dictate not only the allowable emission levels, but through an annulus in the center of the nozzle directly into the
may also require recording of the minute and hour averages of flame zone. This prevents water from impinging on the fuel nozzle
water flow, fuel flow, actual ratio of water-to-fuel, required water-to- or liner cap/cowl assembly. This typically eliminates the cracking of
fuel ratio, humidity, and megawatt load. Typically the required these components observed in the older designs and has allowed
water-to-fuel ratio is established through field compliance testing of increased combustion inspection intervals. The breech-loaded
the individual unit per a specific standard. Based on these tests, a nozzle also allows easy maintenance of the oil side of the nozzle.
final control schedule is programmed into the control system that On units with oil operation, the application of the breech-loaded
regulates the water injection system. fuel nozzle requires increasing the pressure ratio of the boost
atomizing-air compressor (by increasing speed) and/or controls
Breech-Loaded Fuel Nozzle Uprate (FR1T)
changes for proper ignition.
This modification for MS9001B and E units provides the turbine and
on-base components for converting a water injection system from Add Water Injection for Liquid Fuel Units (FG1C)
a standard, combustion casing end cover located water injection This uprate includes the components needed to add water injection
system to a breech-loaded system in which the water is injected to MS9001B units operating on liquid fuel only. The modification kit
through the fuel nozzle (current new unit configuration). This includes replacement fuel nozzles containing water injection
modification applies to either gas/liquid or liquid only. If the unit passages and connections, a water injection skid instrumentation,
is not currently equipped with water injection, see Uprate FG1A. manifold, on-base piping, fuel flow measurement system, and

The benefits of this uprate are: control changes to operate the NOx system. The water injection
system provides water to the combustion system of the gas turbine
• Reduced or eliminated combustion-liner cap cracking
to limit the amount of NOx in the turbine exhaust. In addition to this
• Extended inspection intervals benefit, an increase in power is experienced.

• Reduced outage time The benefits of this uprate are:

With the latest design breech-loaded fuel nozzles, the water is • Reduced NOx emissions level to meet locally required levels
injected through the center of the fuel nozzle, directing the water
• Significant increase in power and heat rate
at the combustor flame. As a result, the water injection spray does
not impinge on the fuel nozzle swirler or combustion cowl assembly. The water injection system consists of on-base components, controls,

Thus, the breech loaded fuel nozzles reduce or eliminate any and an off-base water forwarding skid. This skid is an enclosed

associated combustion liner cap cracking. This new design nozzle package, which receives water from a treatment facility and delivers

GE Energy | GER-3928C (05/08) 11

filtered water at the proper pressure and variable flow rates for Add Steam Injection for NOx Control in Gas or Dual Fuel
operation of the gas turbine. (The water must be extremely clean.) The Units (FG1B/D) [B=manual, D=automatic]
filtered water is introduced to the turbine combustion system through Provided a New Products Development program is completed and
manifolding on the gas turbine, feeding the water injection nozzles. approved, uprate FJ3A/B might be offered after an in-depth initial
The water is injected as a water mist through water spray orifices that study is concluded. Contact Applications Engineering for further
are installed in each of the turbine fuel nozzle assemblies. The water is information.
injected into the combustion zones of each combustion chamber.
When utilizing for NOx control in MS9001 B and E units, steam is
Typical NOx with water injection is about 42 ppmvd at 15% O2 injected through a set of injectors located in the end cover. The
with natural gas fuel, or 65 ppmvd with liquid fuel. Output power steam injection provides NOx emission control by modulating the
increases and heat rate decreases. steam injection rate proportional to fuel consumption. The steam
injection system consists of steam flow control and regulating
Add Steam Injection for Power Augmentation (FJ3A/B)
valves and control plus monitoring devices located off base in the
(A=manual, B=automatic)
operator’s steam piping. The steam from this off-base source is
Steam injection for power augmentation in MS9001E units includes a
supplied in a controlled flow to the turbine’s steam injection
signal that activates or shuts off the steam injection system due to
manifold. The steam is then injected directly into the combustion
gas turbine and/or load limitations. The maximum steam injection
can through the combustion cover, serving to lower combustion
for power augmentation typically is 5% of compressor airflow for E-
temperatures and thereby reducing NOx production.
Class gas turbines. The power augmentation steam is injected into
the compressor discharge airflow. As an additional benefit, a portion The benefits of this uprate are:
of the steam reacts in the combustion zone of the combustor • Model 9B NOx (gas): typically 42 ppmvd; NOx (distillate oil):
thereby reducing NOx levels. The modification kit includes on-base typically 65 ppmvd
steam injection manifold and piping, off-base steam injection
• Model 9E NOx (gas): typically 42 ppmvd; NOx (distillate oil):
equipment containing the control valve, stop valve, drain valves,
typically 65 ppmvd
steam flow measurement equipment, and control panel changes.
Note that steam injection for power augmentation is not yet Note: Standard combustor with nozzle turbulated design
available for DLN combustion systems. The quantified benefits are: combustion system.

• Model 9E change in output: +13%, change in heat rate: -5% For 9B and 9E units, standard combustion NOx is reduced to 42
ppmvd for natural gas and 65 ppmvd for oil. The modification kit
Note: Estimated simple cycle turbine performance improvement at
includes combustion can covers, on-base steam injection manifold
ISO conditions and 5.0% increase in mass flow.
and piping, off-base steam injection components containing the
Superheated steam is injected into the compressor discharge control and stop valves, steam flow measurement equipment, gas
stream upstream of combustion chambers increasing the mass fuel flow meter, inlet humidity sensor, and control modifications.
flow through the turbine section, resulting in increased output This modification is not applicable for liquid fuel units without
power. The added mass flow is obtained without an appreciable atomized air. (Reference FA6B.)
change in compressor power. Since turbine output decreases with
The addition of steam injection for the NOx control system should be
increasing ambient temperature, output can be maintained
accompanied by increased protective functions. To allow for these
constant at higher temperatures, or be elevated above the non-
additional control functions, a Mark V or later generation of GE control
steam injection cycle unit performance if power augmentation is
system is required. The standard control system changes provide for
desired. In addition, a beneficial reduction in heat rate is
improved data logging functions that meet most regulatory agency
experienced.
requirements. The data to be logged is outlined above.

12
TBC Coated Combustion Liner Uprate (FR1G)
This uprate applies a thermal barrier coating (TBC) to combustion
liners for the MS9001E. (See Figure 15.) TBC-coated liners are
equipped with an insulating layer that reduces the underlying base
metal temperature, allows higher firing temperatures, reduces
thermal stress, and reduces liner cracking.

The louvered liner was replaced with a slot-cooled liner during the
introduction of the first MS9001E. The slot-cooled liner provides a
more uniform distribution of cooling air for better overall cooling.
Air enters the cooling holes, impinges on the brazed ring and
discharges from the internal slot as a continuous film of cooling Figure 16. Slot-cooled combustion liner; cutaway view.
air. A cutaway view of a slot-cooler liner section is illustrated in
Figure 16. The slot construction provides a much more uniform Uprated Nimonic 263™ Transition Piece with Improved
circumferential distribution of cooling airflow. Air enters the cooling Aft Bracket (FR1D)
holes, impinges on the brazed ring and discharges from the For MS9001B units, this modification allows for an increase in firing
internal slot as a continuous cooling film. temperature when purchased as part of a combustion uprate. It
also contributes to increased reliability and lengthening of
The liner body is Hastelloy-X™, a nickel base alloy that has not changed
maintenance intervals.
since the introduction of the MS9001B in 1975. Today, however, a TBC
is applied to the liners. The TBC consists of two materials applied to the The original 9B combustion system was a parallel system with the
hot side of a component: a bond coat applied to the surface of the part combustion liner parallel to the centerline of the rotor. When the
and an insulating oxide applied over the bond coat. (See Figure 15.) This first 9E was developed, the combustion system was re-designed.
TBC provides about a 0.015-inch insulating layer that reduces the The re-designed system was a canted system consisting of a
temperature of the underlying base material by approximately 100°F. shorter transition piece and the slot-cooled liner. Shortening the
The addition of TBC also mitigates the effects of uneven temperature length of the transition section of the transition piece increased its
distribution across the metal. stiffness. The canted design reduced the angle through which the
combustion gases had to flow, thus providing a more direct flow
With the MS9001E firing temperature increase to 2055°F, the
path. The canted design made it possible to shorten the overall
thickness of the liner was also increased by approximately 10 mils
length of the transition piece.
to accommodate the higher temperatures.
When the firing temperature was increased to 2055°F, the canted
arrangement was upgraded to the canned arrangement. The canned
arrangement consists of a longer transition piece with a thicker slot-
cooled liner, as previously mentioned. The longer transition piece
essentially pushes the liner out of the wrapper. Outer combustion
casings are illustrated in Figure 17. The transition piece was
lengthened by adding a 15-inch long cylinder to the forward end.
While the transition piece length was increased, the curved section
remained the same, thereby retaining its stiffness. The transition
piece was lengthened to relocate the transition piece to liner
Figure 15. Thermal barrier coating.
interface, to provide a mount that would minimize wear induced by
the compressor discharge flow. Figure 17 illustrates the differences
between the current 9E production canned arrangement, the canted
arrangement, and the 9B parallel combustor designs.

GE Energy | GER-3928C (05/08) 13

Early 9B units utilized a thin-walled transition piece constructed be uprated beyond their current rated firing temperature. Additionally,
of Hastelloy-X™ material. The original 9E transition piece was a this improved transition piece is required for these units to realize the
thick-walled Hastelloy-X™. In the mid 1980s, the transition piece full benefits of the Extendor* combustion system.
material was changed to Nimonic 263™, which is a nickel base
The new cylinder mount bracket has dual bolting to provide
superalloy with better creep and strength characteristics than
torsional restraint to the body, which reduces wear. A comparison
Hastelloy-X™, increasing the creep life to 12,000-hours. The
of the older and the re-designed bracket is illustrated in Figure 19
Nimonic 263™ transition pieces are coated with TBC material,
and Figure 20. The aft bracket is now a forged cylindrical mount
thereby reducing metal temperatures and increasing component
welded to the body, which eliminates cracking the body-to-mount
life. It has a positive curvature body and the aft bracket allows
weld region. Cooling air is admitted to the cylinder mount via
the transition piece to pivot about a pin during thermal excursion
cooling holes and an impingement plate to film cool the mount
cycles. A comparison of the original and the re-designed aft
area. This film cooling, in conjunction with the thermal barrier
bracket design is shown in Figure 18.
coating illustrated in Figure 20, significantly reduces the transition
The uprate potential of MS9001B machines is affected by the inability piece metal temperatures. The Nimonic 263™ transition piece
of the transition piece to withstand higher firing temperature. The maintains the benefits of inner and outer floating seal
improved Nimonic 263™ transition piece enables MS9001B units to arrangements used with the stage 1 nozzle interface.

Figure 17. MS9001E combustion system comparison.

14
 Extendor Combustion System Uprate (FR1V & FR1W)
The applicable frame to retrofit Extendor onto existing components
(FR1V), and purchase new Extendor components (FR1W), is the
MS9001E. Refer to Figure 21 for illustration of the areas of the
combustion system that receive Extendor treatments.

For new 9E units built since the year 2000, Extendor is an option
re-named as CL-Extendor. CL-Extendor is a unification of two
products offered by GE in the past – Extendor and CLE. GE has
taken the best parts of each product to produce CL-Extendor. It is
available for units with standard diffusion combustion systems and
DLN combustion systems. For units operating in the field, GE offers
Figure 18. Comparison of old and new transition piece aft brackets. either Extendor or CL-Extendor based on the customer’s request.
Please contact Applications Engineering for more information.

The Extendor combustion system was developed to reduce the

effects of wear at the following interfaces:

• Liner and flow sleeve stops

• Fuel nozzle tip to combustion liner fuel nozzle collar

• Crossfire tube to combustion liner tube collar

• Combustion liner hula seal to transition piece forward sleeve

• Transition piece forward supports and bracket

• Transition piece aft picture frame seal

GE heavy-duty gas turbines require periodic combustion inspections

due to wear, creep, and TBC coating erosion. GE has developed the
Extendor product to increase combustion inspection intervals. The
Extendor combustion system shown in Figures 21 and 23 decreases
Figure 19. Nimonic 263™ transition piece for Frame 9E.
combustion component wear, and increases combustion intervals by
reducing the relative movement and associated wear of parts in the
combustion system. Application of the Extendor wear system to 9E
units extends combustion strength and inspection intervals by up to
24,000 hours. Figure 22 and Figure 23 detail the improved
combustion wear inspection intervals.

The benefits of this uprate are:

• Extended combustion inspection intervals (by reducing wear on

combustion system components)

• Eliminating labor costs associated with combustion inspections

• Reduced component repair costs and increased unit availability

Figure 20. Nimonic 263™ transition piece for Frame 9B showing downstream aft
end coated inside only with TBC.

GE Energy | GER-3928C (05/08) 15

Extendor Sub-Systems for MS9171 Model

Figure 21. Areas of combustion system that are Extendorized.

• Providing for critical clearance control at wear interfaces

• Using proven wear-resistant material couples developed by GE

The actual extension of combustion inspection intervals that

Extendor provides depends on the type of combustion system
installed and unit operation. Continuous duty units operating dry
or with steam injection can double or triple combustion inspection
intervals from 8,000 hours or 12,000 hours up to as many as
24,000 hours. Continuous duty units with breech-loaded style
water injection fuel nozzles operating with water injection can
extend combustion intervals from 6,500 or 8,000 hours to 12,000
hours. Figure 22 and Figure 24 provide overviews of possible
maintenance intervals when Extendor is applied.
Figure 22. Extendor technology lengthens maintenance intervals. MS9001E Standard Extendor. The system design is similar to the
MS9001E standard Extendor. There are two minor differences in 9E
The Extendor system is a combination of wear-resistant coatings, transition pieces: (a) the MS9001E does not utilize “rat ears” on the
wear-resistant materials, enhanced clearances, and several end frame to position the floating seals; and (b) for PG9161 and
mechanical design improvements that reduce combustion earlier units, the transition piece forward support uses a “lug”
component wear by: arrangement rather than the “bullhorn” arrangement used on

• Reducing the relative movement between combustion components current production 9E units.

• Reducing forces and vibrations at wear interfaces MS9001E DLN Extendor. The MS9001E DLN Extendor System has
accumulated over 300,000 hours with great success, reliability,

16
and life extension. This system is now available commercially for inspection Intervals section later in this document.) This results in
extended life of combustion components. shorter outages and lower repair costs by eliminating the need to
remove and repair transition pieces.
MS9001E Transition Piece Extendor. This Extendor package is a
subset of the MS9001E standard Extendor combustion system Since 9E dry low NOx (DLN) systems use the same transition piece
described above. Application of this Extendor system allows users to as standard systems, this MS9001E transition piece Extendor can
conduct “mini-combustion inspections” by removing the liners and be applied on DLN system transition pieces.
leaving the transition pieces in the unit. (Refer to the combustion
MS9001E Extendor Component Modifications Standard Comb DLN Trans Piece

Combustion Liners
Three (3) “Lug” Type Liner Stops X X
Increased Clearance – Fuel Nozzle/Liner Collar X
Hardened Fuel Nozzle Collar & Anti-Rotation Stop X
Wear Coating on Hula Seal X X X

Flow Sleeves
Boss for Wire-Type Crossfire Tube Retainer X X
Three (3) Flow-Sleeve Stops X X
Crossfire Tubes & Retainers
Two-piece Crossfire Tubes & Wire-Type Retainers X X

Fuel Nozzles
Reduced Gas Tip Diameter X
Wear Coating on Gas Tip X
Transition Piece Forward Supports (“Bullhorns”)
Sacrificial Wear Covers X X X

Transition Pieces
Wear Coating on Forward Sleeve (Interior) X X X
Hardened Guide Blocks (“H-Blocks”) (9171) X X X
Sacrificial Cover on TP Forward Support Lug (9161)
Sacrificial Wear Strips in End-Frame Slots X X X
New Side and Inner & Outer Floating Seals X X X

Figure 23. Modifications for 9E Extendor.

Combustion Inspection Intervals Dry Steam Water1

Fired Hours Limit — Gas Fuel (42 NOx ppm) (42 NOx ppm)
9001E Standard without Extendor System (see GER3620K) 8,000 8,000 6,500
9001E Standard with Extendor System 12,000 12,000 12,000
9001E DLN System without Extendor System (see GER3620K) 12,000 – –
9001E DLN with Extendor System 16,0002 – –
9001E Transition Piece with Extendor System 24,0002 24,0002 12,0002

Notes
1. Assumes breech loaded fuel nozzle (BLFN). Many water-injected machines with standard fuel nozzles have experienced cracking of the combustion liner cap
due to thermal fatigue because of water splashing on the cap. The BLFN eliminates this problem and is required for the full benefits of Extendor to be realized.

2. Mini-combustion inspections are recommended at the original inspection intervals. Remove and repair (as required) combustion liners, crossfire tubes, fuel
nozzles, etc. Transition pieces may be left in the unit but should be inspected visually and/or with borescope. It is recommended that one or more transition
pieces be removed for detailed inspection (until experience indicates that this is not necessary).

Figure 24. Increased inspection intervals for 9E Extendor.

GE Energy | GER-3928C (05/08) 17

Note: The MS9001E transition piece Extendor package cannot provide caused by water or steam injection. For DLN dual fuel units, emission
the same extension of combustion inspection intervals that the full levels of about 42 ppmvd at 15% O2 on liquid fuel with water injection
Extendor package can. Although transition pieces may be left in the are achieved.
machines, borescope and/or visual inspection of the transition pieces
The DLN combustor has six individual fuel nozzles in the primary
and removal of some of the transition pieces for a more detailed
combustion zone, and a single fuel nozzle in the secondary combustion
inspection are recommended.
zone. (See Figure 26 and Figure 27.) The DLN combustion system offers
MS9001E Extendor Combustion System Modifications. Figure 23 lower NOx emissions levels on gas fuel fired units without parts life
provides a summary of the combustion component modifications reduction associated with water or steam injection NOx reduction
included in the MS9001E Extendor combustion systems described. systems. Emission levels of 15 ppmvd at 15% O2 or less can be reached
Figure 24 shows the increased inspection intervals after installing by using the DLN system on a 9E unit. The DLN-1 combustion system
an Extendor DLN combustion system. lowers the NOx emission levels on gas fuel fired units without the
significant parts life reductions associated with steam or water injection.
Notes:
The dry low NOx two-staged premixed combustor is designed for
1. Assumes breech-loaded fuel nozzle (BLFN). Many water-injected
operation on natural gas and distillate liquid. The combustor
machines with standard fuel nozzles have experienced cracking of
operates by premixing the gas fuel with the air in the first stage,
the combustion liner cap due to thermal fatigue because of water
splashing on the cap. The BLFN eliminates this problem and is
required for the full benefits of Extendor to be realized.

2. Mini-combustion inspections are recommended at the original

inspection intervals. Remove and repair (as required) combustion
liners, crossfire tubes, fuel nozzles, etc. Transition pieces may be
left in the unit but should be inspected visually and/or with
borescope. It is recommended that one or more transition pieces
be removed for detailed inspection (until experience indicates that
this is not necessary).

Dry Low NOx Combustion System Uprate (FG2B)

Customers operating MS9001E units that burn gas fuel without
diluent supplies for injection purposes can achieve NOx emission Figure 25. MS9001 E-Class dry low NOx combustion system.

requirements using dry low NOx combustors. The DLN combustion

system for the MS9001E is illustrated in Figure 25. DLN combustion
reduces NOx emissions without steam or water injection on gas
fuel units. This is done by fuel staging, with lean fuel-to-air ratios
dependant upon premixing fuel with hot compressor discharge air
to yield lower temperature rises across the combustor. NOx control
for gas fuel is via the dry low NOx system, while NOx control for
distillate fuel oil is by lean combustion augmented with a water
injection system.

The benefits of DLN are provided in Figure 3.

DLN combustors without diluent offer emission levels of about 15

ppmvd at 15% O2 on natural gas fuel without impacting parts lives
Figure 26. Dry Low NOx combustor.

18
 Primary operation Lean-lean operation
• Ignition to 20% load • 20 to 50% load
Fuel Fuel
100% 70%
30%

Fuel Fuel
100% 83%
17%

Second-stage burning Premixed operation

• Transient during • 50 to 100% load
transfer to premixed

Figure 27. DLN operating modes.

and then combusting the mixture in the second stage. The fuel/air
mixture flame has more mass than a standard diffusion fuel flame,
and so burns colder with less NOx produced. The DLN combustor
also operates on #2 distillate liquid fuel, but not with premixing the
fuel with air. While operating on liquid fuel, water injection is used
for NOx control. DLN operates at a constant flame temperature,
and so has limited turndown in the premix operation mode. A
product called “inlet bleed heat” mixes compressor discharge air
with inlet air to extend turndown with DLN premix combustion.
Figure 28. MS9001EA Dry Low NOx combustion system.
A typical DLN combustor for the MS9001E is illustrated in Figure 28
and fuel delivery in Figure 29.

Convert to Gas Fuel Only (FA1A)

For MS9001E units that are equipped with dual fuel DLN-1, the
conversion to a gas only fuel system from a dual fuel liquid/gas
system is designed to take advantage of the availability of gas fuel
and to simplify the operation and maintenance of the gas turbine.
This upgrade addresses the conversion of MS9001E DLN-1 units to
gas-only from a gas and distillate dual fuel configuration.

Figure 29. DLN fuel system.

GE Energy | GER-3928C (05/08) 19

The benefits of this conversion are: Depending on site-specific conditions, NOx levels of 42 ppm can be
achieved while operating on gas fuel and using water or steam for
• Ease of maintenance; and some units may utilize an available,
diluent injection.
possibly less costly fuel

• More easily handled fuel with simplified emission controls Hot Gas Path Improvements
This modification is for units that are equipped with a dual fuel, Uprated Stage 1 Bucket (FT6J)
liquid and gas, DLN-1 system that are to be operated in the future The MS9001B and E stage 1 bucket was re-designed with two
on gas only. The conversion calls for a replacement of the primary changes: turbulated cooling and a blunt leading edge (BLE) design
and secondary fuel nozzle assemblies, elimination of the liquid fuel airfoil. The new design is directly interchangeable in complete sets
and atomizing air system, and a controls modification to disable with all existing buckets including the sharp leading edge (SLE)
liquid fuel operation. The primary benefits from converting to a gas design found on 9B units. The modification kit includes the BLE
only system is that it eases maintenance (removes atomizing air buckets and associated installation hardware.
compressor), and could utilize available less costly fuel. Gas fuel is The benefits of this uprate are:
a more easily handled fuel and has simplified emission controls.
• Increased bucket cooling, allowing more cooling air to reach the
The conversion that is outlined here calls for: leading edge
• Modification (not replacement) of the primary and secondary fuel — Significantly reduces thermal gradients and cracks along the
nozzle assemblies leading edge
• Elimination of all distillate fuel and water injection devices, • Improved materials extend the life of the buckets
manifolding and plumbing
• 9B units will experience a slight output increase; however, output
• Removal of the atomizing air compressor is not affected in 9E units
• Modification of the controls to disable the liquid fuel function The advantages of the latest stage 1 bucket come from both the
The advantages of this conversion are: re-design and the use of different materials. The turbulated cooled
stage 1 buckets have air-cooling holes that are ribbed to create
• Modification of the fuel nozzle assemblies is far less costly than
turbulent cooling, thereby increasing heat transfer capabilities.
full replacement
In addition, compared to 9B units, the first stage bucket has been
• Simplified operation and maintenance inherent in a gas-fuel-only improved with the blunt leading edge airfoil. The blunt leading
configuration are achieved edge improves low cycle fatigue (LCF) resistance, and the airfoil re-
design increases the efficiency and performance of the airfoil.
Convert from Liquid to Dual Fuel (FA3D)
Many existing gas turbines in the MS9001B & E family only have The improvement of materials includes the use of the equiaxed
liquid fuel capabilities since (in the past) liquid fuel was felt to be a GTD-111* material for the stage 1 bucket. GTD-111 provides
more viable fuel than gas fuel. However, gas fuel has become more improved rupture strength and is more resistant to low cycle
available with liquid being primarily used as a backup. fatigue. (See Figure 30.)

The benefits of this conversion are: These buckets are coated with GT-33 IN Plus* coating, which is an
advanced MCrAlY vacuum-plasma spray coating applied to the
• Significant operational flexibility
bucket exterior, and a diffused aluminide coating applied to the
• Potential fuel cost savings from some units with the added fuel
internal cooling passages. This coating provides hot corrosion
gas capability
protection and high temperature oxidation resistance. Figure 31
There is no performance difference expected by adding gas fuel; shows a comparison of the older PtAl and GT-29* coatings with
however, natural gas emissions are lower than liquid fuel emissions. the current GT-33 IN Plus coating. For further information on

20
Figure 30. New stage 1 buckets have material and design improvements.

Figure 31. Types of bucket coatings.

bucket materials and coatings, see GER-3569, “Advanced Gas is a slight output performance increase in 9B units; however,
Turbine Materials and Coatings”. output is not affected in 9E units.

The BLE stage 1 bucket design allows more cooling air to reach There have been four major improvements now available to GE
the leading edge of the bucket. This increased cooling significantly customers interested in stage 1 buckets:
reduces thermal gradients and associated cracks along the leading
Design Improvements. The original design sharp leading edge has
edge. The improved materials extend the life of the buckets. There
been blunted to allow more cooling air to flow over the leading

GE Energy | GER-3928C (05/08) 21

edge, which reduces thermal gradients and therefore reduces Cooling Improvements. The latest MS9001 E-Class stage 1 bucket
cracking. The blunt leading edge (BLE) design was initially used as is referred to as “turbulated” cooled. This design change was
the first MS9001E stage 1 bucket. (See Figure 32.) brought about by the latest firing temperature increase to 2055°F.
This increase in firing temperature required an increase in cooling
for the stage 1 bucket to maintain an acceptable temperature
level. By creating air-holes that are “ribbed,” the cooling airflow
Original Design and
becomes turbulent, resulting in improved cooling effectiveness
Thermal Gradients
without the need for additional cooling air.

Uprated TBC Coated Stage 1 Buckets (FS4G)

For MS9001E units, thermal barrier coating can be applied to new

Blunt Nose Bucket and in-service stage 1 turbine buckets to extend bucket life and

with Improved increase maintenance intervals.

Thermal Gradients The benefits of this uprate are:

• Potential of increased bucket life from from 72,000 hours to

96,000 hours for any particular operator, according to design
predictions and field experience
Figure 32. Sharp and blunt leading edge bucket designs. • There is no emissions impact from this upgrade

Dense vertically cracked (DVC) TBC patented by GE provides a

Materials Improvements. The original MS9001 E-Class stage 1
superior coating application due to the following:
bucket was IN-738™, a precipitation-hardened, nickel base
superalloy. In 1987, the material was changed to an equiaxed (E/A) • GE’s bonding coat, GT-33, which is superior to thinner, smoother,
material developed by GE as GTD-111, also a precipitation- and less adhesive third-party coatings
hardened, nickel base superalloy that has a 35°F higher creep • GE’s DVC TBC is more than twice the thickness of third-party TBC,
rupture strength and a greater low cycle fatigue strength than IN- and resists spallation to provide a more robust thermal gradient
738™. GTD-111 also has improved corrosion resistance compared barrier
to other superalloys.
• Extensive GE lab data, GE Global Research studies, and design
Coating Improvements. The original MS9001 E-Class stage 1 bucket engineering modeling have been used to insure the optimum
coating, platinum-aluminide (PtAl), was applied to stage 1 buckets to application, thickness, composition, and product performance
prevent oxidation and corrosion. In 1991, with the addition of of DVC TBC applied by GE
turbulated cooling holes, the bucket coating was changed to GT-29
Coating first stage buckets with TBC increases hot gas path parts life
IN Plus*. The GT-29* coating is vacuum plasma spray applied, and
and maintenance intervals at a very small debit to performance.
then an aluminide coating is applied on the bucket exterior and on
Based on fleet leader data and extensive testing, it has been
the internal cooling hole passages. In 1997, the coating was
determined that 32,000 hour inspection intervals may be obtained.
changed to GT-33 IN*. GT-33 is a vacuum plasma applied coating
However, gains in inspection intervals are impacted by other factors
that offers an increased resistance to cracking. “IN” again refers to
such as firing temperature, base load vs. peaker duty, fuel and fuel
an aluminide coating on the cooling hole passages (no exterior
quality, ambient temperatures, and number of hard starts and this will
aluminide coating). GT-33 IN is GE’s new standard coating for stage
need to be considered on a unit-by-unit basis. (See GER-3620, “Heavy
1 buckets, however GT-29 IN Plus is still available and sometimes
Duty Gas Turbine Operating and Maintenance Considerations.”)
recommended when combusting very highly corrosive fuels.

22
Uprated GTD-111 Stage 2 Bucket (FS2F)
The latest stage 2 bucket for MS9001B and E units is the same design as
the stage 2 E-Type Bucket (FS1L) but is made out of GTD-111 material with
GT-33 coating instead of uncoated IN-738™. GTD-111 material possesses
a 35°F improvement in rupture strength in the equiaxed form compared
to IN-738™. It has a corrosion resistance comparable to IN-738™, the
acknowledged corrosion standard for the energy industry, and is superior
to IN-738™ in low cycle fatigue strength.

The benefits of this uprate are:

• Higher firing temperatures can be achieved with the air-cooling

• Improved elevated temperature strength and hot corrosion

Figure 33. MS9001E stage 2 air-cooled bucket.
resistance with new GTD-111 bucket material

• Creep life increased by 80% over the original design due to the non air-cooled version of this bucket would not be able to

reduced stress with new tip shroud design withstand an increase in firing temperature above 1905°F.

Since these buckets are air-cooled, 9B units require replacing the Tip Shroud Improvements. The shroud tip was scalloped and

spacers between the first and second stage wheel to allow air to thickened between the seal teeth, and the underside of the shroud

flow to the second stage bucket. 9E units have air-cooled buckets was tapered. (See Figure 34 and 35.) Scalloping the leading edge

and therefore have the proper spacers. The spacers have to be decreased the tip shroud stress. The final design resulted in a 25%

ordered well enough in advance to get proper hole size. A GE reduction in stress levels and an 80% increase in creep life over the

Service Shop is required to unstack and restack the rotor as well original design. The latest design change added cutter teeth to the

as rebalance it. bucket tip rails. These cutter teeth were designed for use with the
new honeycomb stage 2 shrouds. During transients when the
The new stage 2 bucket design also includes cutter teeth on the
bucket tip clearance is the smallest, the cutter teeth cut a path
bucket tip shroud rails. These are designed to cut a slot in the
through the honeycomb material in the shroud, thus minimizing
honeycomb seal material on the stage 2 shroud block with no
the steady state clearance. Stage 2 buckets with cutter teeth are
metal transfer to the bucket. This allows new shroud blocks with
required for use with honeycomb shrouds, but can also be used
honeycomb seals to be installed. (Reference FS2T.) Cutter teeth
with the traditional design shrouds.
have been included on all stage 2 MS9001B and E buckets
produced since 1996.

Cooling Improvements. The original MS9001B stage 2 bucket did

not have internal air-cooling. The MS9001E design contains air-
cooled stage 2 buckets, as illustrated in Figure 33. The addition of
air-cooling allows for higher firing temperatures. To replace non
air-cooled stage 2 buckets with the new air-cooled buckets, the Figure 34. Scalloping of bucket shroud.

1-to-2 wheel spacer must be replaced with the new design that
allows air to flow to the stage 2 bucket. The new stage 2 bucket
can be supplied without internal cooling air passages as a direct
part replacement for the MS9001B. With this option, the 1-to-2
wheel spacer would not have to be replaced. While lower in cost,

Figure 35. Final configuration of bucket shroud.

GE Energy | GER-3928C (05/08) 23

Materials Improvements. For early MS9001E production, the Non Air-Cooled GTD-111 Stage 2 Bucket Uprate (FS2I)
material was changed to IN 738™ (a precipitation-hardened, This modification replaces the existing non air-cooled stage 2 buckets
nickel-based superalloy), which provided an increase in elevated on MS9001B units with GTD-111 material, non air-cooled stage 2
temperature strength and hot corrosion resistance. In 1992, the buckets (S2B). This non air-cooled S2B cannot withstand an increase
material was changed to GTD-111, also a precipitation-hardened, of firing temperature above 1905°F. Above this firing temperature,
nickel based superalloy, to improve creep rupture strength. In an air-cooled S2B is required. Performance is not affected, as cooling
addition to higher creep rupture strength, GTD-111 has higher holes are plugged before the buckets are installed.
strength in low cycle fatigue. Originally, 9B turbines had stage 2
The benefits of this uprate are:
buckets made of U-500™, a precipitation-hardened, nickel based
alloy. IN-738™ is a better choice as it is specifically designed for • A non air-cooled stage 2 bucket with overall increased strength

land-based gas turbines. Combining elevated temperature strength • Performance will not be affected, as cooling holes will be plugged
and hot corrosion resistance, IN-738™ has lasted longer and, in
The latest stage 2 bucket is made out of GTD-111 material (equiaxed)
tests comparing it to U-500™, is in better condition even after four
with GT-33 IN coating instead of uncoated IN-738™ material. (See
times testing duration. (See Figure 36.)
Figure 37.) GTD-111 material possesses about a 35°F improvement in
Previous Improved rupture strength in the equiaxed form, compared to IN-738™. (See
Stage 2 Bucket Stage 2 Bucket Figure 37.) It has a corrosion resistance comparable to IN-738™, the
Material U500™ IN-738™ acknowledged corrosion standard for the industry, and is superior to
Shrouded Design Not Scalloped Scalloped IN-738™ in low cycle fatigue strength.
Cutter Teeth* Not Present Present
For 9B applications where no S2B cooling is needed, the air-cooled
Firing Temp Up to 1840°F Up to 1840°F
E-type GTD-111 material stage 2 buckets are sent to a GE service
*Refer to GER3571 for information about cutter teeth applications.
shop to have the six holes plugged on the bucket tip shroud, making

Benefits them directly interchangeable with existing buckets on 9B units, and

• Elevated temperature strength and hot corrosion a new wheel spacer is not needed.
resistance compared to U500™ bucket material
• Improved tip shroud design increases creep life by 80%
Uprated Stage 3 Bucket IN-738™ (FS2K)
over original design The MS9001 E-Class stage 3 bucket has undergone improvements in
• Designed life expectancy of three hot gas path inspections design, manufacturing, materials, and processes. These advanced
(72,000 hours for gas only, dry, base loaded operation)
buckets can be installed on MS9001B and E units. Figure 38 outlines
• Permits operation at higher firing temperatures –
the improvements.
up to 1840°F

Figure 36. Improved stage 2 bucket. The benefits of this uprate are:

• Improved third stage buckets parts lives for higher-firing uprated

Coating Improvements. With the change in material to GTD-111,
temperatures
GT-29 IN Plus coating was added. IN Plus coating refers to an
aluminide coating on the internal cooling passages (IN) and an • Efficiency will improve slightly on 91E units
over-aluminide coating on the exterior of the bucket (Plus). Like the Design Improvements. With the introduction of the 9E, the airfoil
stage 1 bucket, the standard coating was changed to GT-33 IN was redesigned to take advantage of the additional airflow. The
during early 1997. GT-33 IN consists of GT-33, a vacuum plasma airfoil was again re-designed in 1991 as part of the uprate program.
spray coating, on the exterior of the bucket and an aluminide The trailing edge was thickened, and the chord length increased.
coating on the interior of the cooling hole passages. GT-33 IN Like the stage 2 buckets previously described, the shroud leading
provides superior crack resistance relative to GT-29 IN Plus. GT-29 edge was scalloped, the shroud tip was thickened between the seal
IN Plus is still available and is recommended for use in very highly teeth, and the underside for the shroud was tapered. These design
corrosive fuel applications.

24
changes resulted in an increase in creep life of the bucket. Like the Materials Improvements. The bucket material has been improved.
stage two buckets, cutter teeth were added to the bucket tip rails. The stage 3 bucket was originally made of U-500™, a precipitation-
These cutter teeth are required to use with the stage 3 honeycomb hardened nickel based alloy. To improve elevated temperature
shrouds. Current production stage 3 buckets include cutter teeth. To strength and hot corrosion resistance, the bucket material was
use the 9E bucket on a 9B machine, the stage 3 shrouds must be changed in 1992 to IN-738™, a precipitation-hardened nickel
replaced or modified. Figure 39 illustrates the machining points on based superalloy having improved creep properties.
the shroud that are required for the modification. Additionally, due
Uprated Stage 1 Nozzle With Chordal Hinge (FS2J)
to interference with the angel wing, owners/operators may elect to
The MS9001B and E stage 1 nozzle has evolved through four
machine the exhaust frame to facilitate rotor removal, however it is
generations, each improving on its predecessor, starting with
not required.
the MS9001B 4-vane per segment nozzle. The second generation,
Process Improvements. The original MS9001B stage 1, 2, and 3 designed for the MS9001E, was used primarily for cleaner fuel
buckets were cold-straightened after being cast, thereby inducing applications. The third generation—the universal nozzle—was
plastic strain in the material. The combination of the induced and significant because it is applicable for gas, distillate, and ash
creep strains resulted in potential creep-rupture cracks initiating bearing fuels. The fourth generation, known as the chordal hinge
and propagating by high cycle fatigue. GE developed a new nozzle, incorporated GE aircraft engine technology as well as
manufacturing process for the MS9001E bucket, which eliminated improved cooling and sealing technology. A comparison of each
the need for the cold straightening step; thus, eliminating the generation is shown in Figure 40.
process-induced strain and potential creep rupture cracking.

Figure 37. Non air-cooled GTD-111 buckets have better creep properties.

GE Energy | GER-3928C (05/08) 25

Figure 38. Improved stage 3 buckets.

The benefits of this uprate are:

• Model 9B change in output: 0.0%, change in heat rate: -1.90%

• Model 9E change in output: 0.0%, change in heat rate: -0.25%

Note: For 9E firing at 2055°F, no benefit at 2020°F.

Several design modifications were made to the original MS9001B

stage 1 nozzle to develop the MS9001E cleaner fuel stage 1 nozzle.
One of the most dramatic changes was made in response to the
vane fillet cracking problem—caused by high thermal stress induced
by the high thermal gradient across the sidewall/vane interface.
(See Figure 41.) By decreasing the number of vanes per segment,
structural redundancy and thermal stresses were reduced, thus
minimizing the vane fillet cracking. The original 9B stage 1 nozzle
Figure 39. Machining required on stage 3 shroud.
had four vanes per segment and required 12 segments. The cleaner

The benefits of the new stage 1 nozzle include a long operating life fuel nozzle has only two vanes per segment, for a total of 18

up to 72,000 hours, reduced heat rate of operating units, and segments. As illustrated in Figure 40, the interface between the

operation at higher firing temperatures to 2084°F. support ring and nozzle was moved downstream.

At the same time that the number of vanes per segment was reduced,
the shape of the airfoil was optimized and the vanes were rotated to

26
 9B 9E 9B 9B
First Gen. Clean Fuel Universal Third Chordal Hinge
Second Gen. Fourth Gen.

Figure 40. Comparison of 9B and 9E stage 1 nozzles. reduce the throat area. The new airfoil shape and reduction in throat
area increased the pressure ratio. Installing this design into an
MS9001B can increase the pressure ratio by as much as 6%.

The suction sidewall thickness of the nozzle airfoil at the pitch

section was increased by 13%, which effectively reduced the
aerodynamically-induced stress and thereby increased the creep
life of the part. The stress level was further reduced by the addition
of an internal center rib seen in Figure 42.

The universal fuel nozzle was developed from the cleaner fuel
nozzle in response to the need to burn residual fuels, as well as
cleaner fuels. The airfoil shape was rounded (making it more blunt)
and the entire cooling system was re-designed. The pressure side
cooling holes were replaced with slots and placed closer together to
provide more uniform cooling. (See Figure 43.) Trailing edge cooling
was also added as illustrated in Figure 43. This improved cooling
design decreased surface metal temperature by as much as 5%,
thus reducing cracking, airfoil ballooning, and trailing edge bowing.

Figure 41. Cracked stage 1 nozzle.

In the Generation 2 (GEN 2) arrangement the nozzle support ring
interface was moved further downstream, in line axially with the

GE Energy | GER-3928C (05/08) 27

 The fourth and current generation of stage 1 nozzle is the chordal
hinge nozzle introduced in 1994. This nozzle is the result of two
major design changes maintaining the philosophy of burning both
cleaner and heavy fuels. The first design change was made to
reduce the leakage between nozzle segments and between the
nozzle and support ring. The chordal hinge, which incorporates the
latest in GE Aircraft Engine sealing technology, was added. The
chordal hinge refers to a straight-line seal on the aft face of the
inner sidewall rail, which ensures that the seal is maintained even if
the nozzle rocks slightly. The chordal hinge and the new sidewall
seal design are illustrated in Figure 44. The chordal hinge reduces

Figure 42. Stage 1 nozzle airfoil pressure-side-film cooling modification. leakage between the nozzle and the support ring. The leakage
between the nozzle segments was decreased by improving the
nozzle retaining-ring interface. This change was implemented to sidewall spline seals.
minimize torsional forces exerted on the sidewall near the nozzle
The second major change was to improve the sidewall cooling. As the
retaining-ring interface.
firing temperatures increased over the development of the MS9001E,
In 1992, the GEN 3 nozzle added a tangential support lug the nozzle metal temperatures increased, causing oxidation and
consisting of an integrally cast and milled radial slot side-support erosion to occur on the sidewalls. To reduce oxidation and erosion,
lug onto the stage 1 nozzle inner sidewall. A support pin and the cooling effectiveness was increased. The overall cooling
bushing were also added to secure the nozzle segment. A lock effectiveness was improved by relocating some of the sidewall
plate and a single retainer bolt were used to keep the support pin cooling holes and re-shaping some of the vane cooling holes into
in place. This arrangement was intended to provide additional slots, as illustrated in Figure 45.
tangential support for the nozzle.

Figure 43. Stage 1 nozzle airfoil pressure-side film cooling.

28
Figure 44. Stage 1 nozzle improved sidewall sealing with chordal hinge.

Figure 45. Stage 1 nozzle improved cooling outer sidewall film cooling.
Figure 46. First stage nozzle improved inner sidewall tangential support.
When the chordal hinge nozzle was first introduced, the tangential
pin hardware was replaced with a single piece bushing/tangential
hardware, the forward flange on the support ring has been
pin to secure the nozzle. A flat lock plate with two retainer bolts was
eliminated. (See Figure 47.) These design modifications make the
used to keep the bushing /tangential pin in place. (See Figure 46.)
universal nozzle and the chordal hinge nozzle interchangeable with
More recently, the tangential pin hardware has been eliminated
no support ring modifications required.
because field inspections have indicated that the hardware does not
provide additional tangential support. In addition to eliminating the

GE Energy | GER-3928C (05/08) 29

As illustrated in Figure 40, the 9B stage 1 nozzle and the 9E cleaner
fuel nozzle support ring interface are located further upstream than
either the universal or chordal hinge nozzle. Therefore, to install the
chordal hinge nozzle in a unit that currently has the 9B nozzle or the
cleaner fuel nozzle, a new support ring must also be provided to
site. As previously mentioned—when installing the chordal hinge
stage 1 nozzle in a machine that currently has the universal stage 1
nozzle—a new support ring is not required (assuming the installed
ring is not damaged) because the location of the support ring
interface is the same for both designs.

During development of the MS9001 E-Class stage 1 nozzle, the

nozzle material FSX-414, was not changed. FSX-414 is a cobalt
base superalloy that provides excellent oxidation, hot corrosion, Figure 47. First stage nozzle and support ring with no tangential hardware.
thermal fatigue resistance, weldabilty, and castability. Figure 48
illustrates the improvements existing on the upgraded stage 1
nozzle offered. These benefits result in -1.90% and -0.25%
improvements in heat rates for 9B and 9E units, respectively.

GE Energy’s newly designed improved cooling stage 1 nozzle in

Figure 48 offers advanced sidewall cooling and a new sidewall
sealing design that allows operation at higher firing temperatures—
while maintaining component reliability and life cycle. The new
design incorporates the following GE-proprietary features:

• Spline seal improvements

• FSX-414 alloy

• Enhanced thermal barrier coating (ETBC*)

Figure 48. Improvements in upgraded stage 1 nozzle for 9B and 9E units.
The improved cooling stage 1 nozzle is a universal nozzle that can
Coating Options. Based on operating needs, this nozzle is
be used to replace nozzles based on the older universal nozzle
available with three coating options:
design, as well as pre-universal nozzles operating on either
conventional or heavy fuel. • No thermal barrier coating (No TBC): Unless requested otherwise,
no coating is applied to the nozzle. The nozzle should be
Improved Sidewall Sealing and Cooling. A GE-proprietary design
uncoated for heavy fuel applications.
on improvements to the spline seal, along with diffused cooling
holes, provides improved cooling performance, allowing increased • Thermal barrier coating (TBC): This coating offers increased
firing temperatures up to 2084°F. resistance to thermal fatigue that can result in life extension and
improved maintenance intervals.
Increased High Temperature Capability. The GE-proprietary FSX-414
cobalt-based superalloy possesses superior properties (compared to • Enhanced thermal barrier coating (ETBC): With a slick, highly
other nickel-based superalloys) at very high temperatures—allowing erosion-resistant coating, this TBC provides a smooth surface finish
increased firing temperatures up to 2084°F. FSX-414 offers enhanced to the stage 1 nozzle. With GE’s proprietary smooth finish, ETBC
weldability and excellent oxidation/corrosion resistance with high improves the benefits of thermal barrier coatings, and can result
strength at highest firing temperatures. in higher sustained performance over time. (See uprate FS6E.)

30
Enhanced TBC Coating for Stage 1 Nozzle (FS6E) build-up of combustion products on the ETBC, which could negate
For MS9001E units, the stage 1 nozzles can be coated with an its benefits if such build-up might occur.
enhanced thermal barrier coating (ETBC) that can be applied to the
GTD-222+* Stage 2 Nozzle Uprate (FS1P)
leading edge, pressure side, and outer wall of the stage 1 nozzle.
To minimize the tangential deflection due to creep, a series of
(See Figure 49.) ETBC provides a smoother surface finish to the
design changes were implemented for the stage 2 nozzle in
stage 1 nozzle, which incorporates a slick, highly erosion-resistant
MS9001E, as illustrated in Figure 50.
coating over the TBC. The ETBC coating on E-Class stage 1 nozzles
helps protect the TBC from erosion and provides a smooth surface, • Improved Creep Resistance
• Improved Nozzle Vane Cooling
which contaminants cannot adhere upon. – Redesigned Core Plug
• Improved Performance
– Reduced Cooling Air Flow

Reduced Cooling Flow

Controlled by Tuning Pin

Figure 50. Design changes and reduced airflow in non-pressurized stage 2 nozzle.

The benefits of this uprate are:

• Model 9B (non air-cooled) change in output: -1.0%), change in

heat rate: +0.2%

Figure 49. Stage 1 nozzle with enhanced TBC. • Model 9E (air-cooled) change in output: +1.0%), change in heat
rate: -0.4%
The benefits of this uprate are:
Note: The GTD-222+ second stage nozzle significantly reduces
• Enhanced erosion resistance 3X greater than porous, standard TBC nozzle downstream stream creep deflection.

• 5X smoother surface finish compared to standard TBC For the MS9001E only, the first major change was to increase the

• Reduced susceptibility to surface fouling chordal length, which reduced stress levels in the vanes and
improved creep resistance. Note that the MS9001E always had
• Sustained smooth surface finish and unit operating performance
long chord length and short sidewall. (See Figure 51.) In late 1991,
• Predicted heat rate improvement over TBC alone the original nozzle material FSX-414 was replaced with GTD-222+,

• Reduced metal temperatures provide prolonged component life, a nickel based alloy, because of its superior creep strength and

increased durability, and increased maintenance intervals therefore reduced deflection downstream. Figure 52 shows a
comparison of the nozzle creep deflection of GTD-222+ and FSX-
The performance improvements are possible due to the sustained
414. GTD-222+ has a 200°F creep strength and 40% tensile
surface finish of the smooth coat over time. Improved surface
strength advantage over FSX-414 at operating temperatures. An
finish reduces heat transfer, thus increasing part durability,
aluminide coating was then added to protect against high
improving erosion resistance (3X greater in laboratory testing), and
temperature oxidation.
reducing surface fouling. ETBC should not be used by customers
operating with heavy fuel, or an IGCC application due to possible

GE Energy | GER-3928C (05/08) 31

 Reducing the nozzle cooling flow yields an increase in output
power. (See Figure 53.) The MS9001E will see an increase in output
of approximately +1.0% with either the one- or two-piece stage 1
shroud with new tuning pins in conjunction with the GTD-222+
stage 2 nozzle. (The original one-piece shroud must have the aft
cooling hole size reduced to realize the full performance benefit.)
Because the existing MS9001B stage 2 nozzle is not air cooled,
installing this air-cooled stage 2 nozzle results in an output loss of
approximately -1.0% due to the air extracted from the system for
cooling airflow.

GE has developed a brush seal for the stage 2 nozzle diaphragm

based on the successes of the high-pressure packing and No. 2
Figure 51. Long and short chord nozzle design comparison.
bearing brush seal. (Reference FS2Z.) The brush seal design uses
a brush seal in place of the middle long tooth on the diaphragm.
This brush seal provides a performance improvement due to the
GTD-222 vs. FSX-414
reduction in cooling flow.
Nozzle Creep Deflection Comparison
1.2 The seal between the diaphragm and the 1-to-2 spacer regulates
the amount of cooling airflow between the first aft and second
1.0
Relative Deflaction

forward wheel spaces. The current seal is a labyrinth seal with a

FSX-414
0.8 series of short and long teeth on the diaphragm and high and low
0.6 lands with teeth on the spacer. The stage 2 nozzle cooling air
comes in through the stage 1 shroud and enters the stage 2 nozzle
0.4
core plug via the plenum formed between the outer sidewall of the
0.2 nozzle and turbine shell. The air flows through the nozzle core plug;
GTD-222
0 some of the air exits the nozzle via the trailing edge cooling holes
10 20 30 40 50 60
and the remainder of the cooling air flows into the cavity between
Time - khr
the diaphragm and the nozzle. The air flows to the first aft wheel
Figure 52. Nozzle creep deflection comparison. space and through the diaphragm/spacer seal (inner stage
packing) to the second forward wheel space.
With the material change to GTD-222+, less cooling flow for the
nozzle could be reduced, due to the material’s superior high This GTD-222+ nozzle includes an aluminide coating for increased

temperature creep properties. The cooling was deceased by high temperature oxidation resistance.

inserting a longer tuning pin in the stage 1 shroud and decreasing The benefits of the GTD-222+ nozzle are illustrated in Figure 54.
the size of the cooling hole in the aft face of the shroud. For better
GTD-222+ Stage 3 Nozzle Uprate (FS1R)
distribution of cooling air, the nozzle core plug was re-designed and
The original stage 3 nozzle, like the stage 2 nozzle, experienced
the size of the pressure side cooling holes was decreased. GE
tangential deflection. To minimize creep and so decrease
experience with MS9001E gas turbines has found that wheel space
tangential deflection, three design changes were made. (See Figure
temperatures run significantly cooler than the design limit. Based on
55.) First, on the MS9001B only, the chord length was increased to
this experience, the stage 2 nozzle cooling flow that also surges and
reduce overall airfoil stress levels. The MS9001E always had the
cools the wheelspaces can be reduced, providing additional output
longer length. Secondly, an internal airfoil rib, similar to the one for
without affecting parts life.
stage 1 nozzle, was added to provide additional stability and

32
Figure 53. Reduced cooling flow gives increased output.

installed in both MS9001B and E units, is not air-cooled there is no

Blue: GTD-222+
Red: FSX-414 performance benefit like the stage 2 nozzle (and no performance
detriment). Dimensionally, the GTD-222+ nozzle is interchangeable
with the existing FSX-414 nozzle.

The benefits of this uprate are:

• Nozzle downstream creep deflection, a key life-limiting factor,

is eliminated
Note: Unpressurized air box
details not shown • Re-design and change of material for the third stage nozzle
reduces stress levels and increases creep life

GE field experience demonstrates that the GTD-222+ nozzle—after

thousands of operating hours in GE’s high firing turbines—has
achieved a remarkable reliability record and customer satisfaction.
Red: GTD-222+
Advanced Aero Stage 3 Nozzle (FS4K) and Advanced Aero
Stage 3 Bucket Uprates (FS4L)
FS4K Advanced Nozzle. In order to improve output and decrease
heat rate in MS9001B and E units, the advanced aero third stage
nozzle is re-designed with improved airfoil aerodynamics. (See
Figure 54. Benefits of GTD-222+ nozzles as compared to FSX-414 nozzles.
Figure 56.) This improved design gives additional performance
increase the component’s buckling strength. Finally, in 1992, the benefits when used in combination with the advanced aero stage
material was changed from FSX-414 to GTD-222+. Unlike the stage 3 bucket, FS4L, as illustrated in Figure 57. The uprate includes the
2 nozzle, an aluminide coating is not necessary due to lower metal third stage nozzle and diaphragm, plus required hardware.
temperatures seen in stage 3. Since this nozzle, which can be

GE Energy | GER-3928C (05/08) 33

Figure 55. Improved stage 3 nozzle.

Figure 56. Advanced Aero Stage 3 Nozzle. Figure 57. New stage 3 bucket design.

The third stage nozzle was re-designed to improve aerodynamic existing GTD-222+ nozzle. The latest stage 3 nozzle design is also
performance. On the new airfoil, the inner and outer sidewalls are made of GTD-222+.
modified but the airfoil profile and wall thickness are the same. The
On those 9B units that are not already equipped with the GTD-
flow path definition remains the same and the new nozzle design
222+ or the advanced aero nozzle, the installation of the new
allows the use of the old machining fixtures in the hot gas path.
design third stage nozzles provides an opportunity to install
There is no reduction in repair/replace intervals. Dimensionally, the
replaceable wheel space thermocouples, more information can be
advanced aero re-designed nozzle is interchangeable with the
found in FK5C.

34
Installation of Both Parts Provides the Greatest Benefit cut a slot in the honeycomb seal material on the stage 3 shroud
Significant Improvement in Output and Heat Rate block, with no metal transfer to the bucket. This allows new shroud
Part S/C S/C Heat Exhaust Exhaust Temp, blocks with honeycomb seals to be installed. (Reference FS2U).
Output Rate Energy delta

New S3B/New S3N, +0.7% -0.7% -0.8% -6°F Uprated HR-120™ Improved Stage 1 Shroud with
Hot Day, 100°F/38°C, Cloth Spline Seals (FS2Y)
Guarantee Pt
The new shroud design for MS9001E includes several improved sealing
New S3B/New S3N, +1.0% -1.0%- 1.0% -8°F
ISO Day, 59F°/15°C,
features that increase performance (output and efficiency) by reducing
Reference Only leakage between shroud segments and between the stage 1 shrouds
New S3B/New S3N, +1.2% -1.2% -1.1% -9°F and stage 1 nozzles. The improved stage 1 shrouds are made of a one-
Cold Day, 0°F/-18°C,
piece design from Haynes HR-120™ (see Figure 60 and Figure 61), a
Reference Only
solid solution-strengthened iron-nickel-chromium alloy that improves
Efficiency improvement results in exhaust temperature and exhaust energy
decrease. Combined-cycle analysis can be provided to estimate over-all low cycle fatigue life, allows operation at higher 2055°F firing
plant impact. temperatures, increases performance and lowers heat rate.
Figure 58. Performance benefit when Advanced Aero Stage 3 Bucket and Nozzle
are combined on same unit. The benefits of this uprate are:

• Model 9E (PG9171E) change in output: +1.3%), change in heat

rate: -0.6%

• Model 9E change in output: +0.4%), change in heat rate: -0.2%

Note: The performance improvements listed above for PG9171E-rated

9/1E units include: a) conversion to one-piece shroud (+0.9% in output
and -0.4% in heat rate); and b) upgrade to HR-120 design with cloth
seals (+0.4% in output and -0.2% in heat rate). For units that currently
have the older 310-SS, pumpkin tooth, one-piece stage 1 shroud, the
performance improvement would only reflect the upgrade to HR-120™
one-piece design with cloth seals (+0.4% in output and -0.2% in heat
rate). In the third quarter of 2003, the production 91E PG9171 new
Figure 59. Advanced Aero Stage 3 Bucket.
units started shipping with the one-piece HR-120™ improved stage 1
FS4L Advanced Bucket. This modification for MS9001B and E units shrouds with inter-segment cloth seals.
replaces the existing stage 3 buckets with an advanced aerodynamic,
Spline Seal Arrangement (GE Exclusive Design). A new cloth seal
re-designed stage 3 bucket with an improved airfoil. (See Figure 56 and
arrangement, illustrated in Figure 61 incorporates a flat side face
Figure 57.) This improved design allows for additional performance
and multiple cloth seals. This new design significantly reduces
benefits when used in combination with the advanced aero stage 3
leakage between shroud segments, resulting in increased output
nozzle in FS4K. (See Figure 58.)
and lowered heat rate.
For 9E, the advanced aero bucket is dimensionally interchangeable
Haynes HR-120™. This solid solution-strengthened iron-nickel-chromium
with the existing bucket. The advanced aero stage 3 bucket is made
alloy offers improved low cycle fatigue life and allows operation at
of IN-738, offering excellent hot corrosion resistance and outstanding
higher firing temperatures up to 2055°F. The new stage 1 shroud
strength at highest firing temperatures.
material provides a 3X improvement in LCF life, in comparison to the
The advanced aero stage 3 bucket new design includes “cutter teeth” current 310 stainless steel, and permits the use of a one-piece shroud
on the bucket tip shroud rails. (See Figure 59.) The tip shrouds are re- at higher temperatures. The new material has both a higher inherent
scalloped for the new airfoil profile. The cutter teeth are designed to material strength, and more favorable time-at-temperature
characteristics compared to 310 stainless steel.

GE Energy | GER-3928C (05/08) 35

Figure 60. First stage shroud with cloth seals FS2Y.

Figure 61. HR-120™ Improved Stage 1 Shroud.

In order to regain the lost performance associated with the two-
For 9E units, the PG9171 two-piece stage 1 shroud was developed piece design, GE has developed a new one-piece design made of
for the 2055°F uprate program. This is a costly design in terms of Haynes HR-120™. The new stage 1 shroud material provides a 3X
both dollars and performance. The two-piece design was film improvement in LCF life in comparison to the previous 310-SS, and
cooled using airflow from the compressor discharge. The body of permits the use of a one-piece shroud at higher temperatures.
the outer shroud was made of 310 stainless steel (310-SS) and the The new material has both a higher inherent material strength
inner shroud was made of FSX-414. The increase in cooling flow and more favorable time-at-temperature creep characteristics.
required to cool this shroud resulted in a 0.9% decrease in output The new shrouds provide an additional +0.4% performance
and an increase in heat rate of 0.4%. increase and a –0.2% heat rate benefit.

36
Stage 1 Shroud Abradable Coating Uprate (FS6A) coating is designed to preferentially wear away in the event of
The stage 1 shroud blocks on MS9001E units can be coated with a bucket tip rub, greatly avoiding wear of the bucket tips. It also
an abradable coating on the inner diameter surface. (See Figure allows tighter clearances between the bucket and shroud leading
62.) The abradable coating on the stage 1 shroud allows for to performance improvements.
improved airflow control, and it allows tighter clearances between
The benefits of this uprate are:
the bucket and shroud leading to performance improvements.
• Model 9E change in output: +0.4%, change in heat rate: -0.4%
The improved clearance and associated reduction in tip leakage
of cooling airflow create a performance benefit. The abradable The abradable coating on the Stage 1 shroud blocks gives +0.5%
increased output power and an improved heat rate of –0.5%.
Abradable coating addresses performance benefits by clearance
reduction even under conditions of rotor misalignment and casing
out of roundness. (See Figure 63.)

Stage 2 and 3 Shroud Blocks Uprates (FS2T and FS2U)

Stage 2 and 3 honeycomb shroud blocks provide bucket tip sealing
for MS9001B and E units. The original seals on these units were
labyrinth. In an effort to provide better sealing in this area,
honeycomb material was applied to both the stage 2 and 3
shrouds. (See Figure 64 and Figure 65.)

Honeycomb seals are designed to reduce bucket tip leakage,

resulting in an improved heat rate and output. It is estimated that
about 50% of the buckets in a given row will need cutter teeth to
Figure 62. Stage 1 shrouds coated with abradable coating.
ensure proper performance of the honeycomb material and

Figure 63. Abradable coating increases performance when rotor is not 100% aligned or casing is out of round.

GE Energy | GER-3928C (05/08) 37

 clearances during steady state operation. (See Figure 66.) The cold
clearances for the labyrinth seal are set based on avoiding contact
between the bucket tips and shrouds that occur during transients,
thus providing relatively more open clearances during steady state
base load operation (compared to honeycomb shrouds).

Figure 64. Stage 2 shroud blocks with honeycomb and stage 2 buckets with
cutter teeth.

Figure 66. 7EA stage 2 honeycomb inner shroud design.

Honeycomb seals are made of a high temperature, oxidation-resistant

alloy with 1/8-inch cell size and 5-mil foil thickness brazed between the
teeth on the shrouds. “Cutter teeth” on the leading edge of the shrouded
stage 2 and 3 bucket tip rails cut a groove in the honeycomb when
contact occurs during transients. This produces a tighter seal and less
lost airflow as compared to non-honeycomb shrouds.

Installation of honeycomb shrouds requires buckets with cutter

teeth. As previously mentioned, current production stage 2 and 3
buckets have cutter teeth.
Figure 65. Shroud block with honeycomb sealing.
Interstage Brush Seal Uprate (FS2Z)
achieve a +0.35% increase in output with a –0.35% decrease in For the MS9001E, this uprate delivers a +1.0% increase in output
heat rate for stage 2; and 0.15% increase in output, with a –0.15% and a –0.5% heat rate benefit, and a +0.5% increase in output with
decrease in heat rate for stage 3. a –0.3% heat rate benefit for the MS9001B.

The benefits of this uprate are: The benefits of this uprate are:

• Model 9B and E Stage 2 change in output: +0.35, change in heat • Model 9B change in output: +0.5%, change in heat rate: -0.3%
rate: -0.35% • Model 9E change in output: +1.0%, change in heat rate: -0.5%
• Model 9B and E Stage 3 change in output: +0.15%, change in The 2nd stage nozzle/diaphragm assembly contains a radial
heat rate: -0.15% high-low labyrinth seal that reduces flow leakage between the
Honeycomb allows contact between the bucket tip and casing diaphragm and the turbine rotor into the stage 2 forward wheel
shrouds during transient operation and provides relatively tight space area. (See Figure 67.) When added to a unit, the interstage

38
Figure 67. 7EA stage 2 brush seal inner diaphragm design.

main advantage of the second stage brush seal is the reduction of

flow leakage between the diaphragm and the turbine rotor into the
stage 2 forward wheel space area.

For all vintage 9E units that install the stage 2 nozzle brush seal, counter
bore covers are required to be installed on the inner barrels. Based on
aerodynamic analysis, in some cases, compressor pressure ratio (CPR)
control, IGV angle re-scheduling or stage 17 and EGV 1&2 shrouded
vanes with slotted inner barrels may be required. (Reference FS2B).

Discourager Seal Replacement (FW3E)

For MS9001E units, inspection and possible replacement of the
deteriorating Al-Bronze seal material reduces the risk of excessive
leakage from the seal.

Figure 68. Installed interstage brush seal. The benefits of this uprate are:

brush seal further reduces this leakage. (See Figure 68.) Since the • Increasing proper stage 2 bucket cooling with the installation of
hot gas in this leakage performs no useful work, any reduction in the new 410 stainless steel seal tooth material
this leakage results in an increase in performance. Cooling airflow The Al-Bronze material is known to be the cause of premature
to the 2nd stage forward wheel space is reduced, but this flow is discourager seal failures in the field. It is advised that the discourager
currently greater than required when the brush seal is not installed. seal between the stage 1-to-2 spacer be inspected on all units
In testing, the sealing efficiency of a single brush is found to be up shipped prior to 1996 for brittleness of the B50A422A Al-Bronze seal
to 10 times that of a labyrinth seal under similar conditions. The teeth material. (New units shipped in 1997 and after should have the

GE Energy | GER-3928C (05/08) 39

410-SS replacement material.) New seal material 410-SS stainless
Root Cause of Cracking at Third Stage Hook
steel with much longer life is used as the replacement to reduce the
• Compressive yield and elevated temperatures at third stage
risk of excessive leakage from the seal. This leakage has the potential
hook fit cause fatigue cracking
of contributing to issues such as reduced cooling flow to the stage 2
– Compressive yield exceeded on inner surface
buckets, which increases creep. This in turn can contribute to stage 2
– Tensile residual stress on casing inner surface at shut
bucket tip shroud creep deflection that results in loss of engagement
down
of tip shroud interlock. Loss of engagement can result in bucket
– Start and shut down cycles are low cycle fatigue LCF
liberation and forced outage.
– LCF causes cracks
Add Compressor and Turbine Water Wash (FC4A and FC4C) • Stress is below compressive yield for deep cracks
For MS9001B and E units, turbine water wash (FC4C) is used to – No tensile residual stress for deeper cracks
remove ash deposits from turbine sections left by the burning of – Cracks enter region of all compression, no tensile residual
low-grade liquid fuels. These deposits gradually reduce the thermal – No LCF, so cracks self arrest
efficiency and output of the turbine. Water washing must take place
1st stage hook circumferential cracks might be of
while the turbine is off-line, while the wheel space temperatures are concern if deep.
cool, and with the unit at crank speed. For machines burning high-
Figure 69. RCA of cracking at third stage hook fit.
grade liquid fuels or gas, turbine water wash is not needed.
Compressor water wash should be used in conjunction with turbine
Figure 74. The performance improvements associated with each of
wash. The compressor water wash removes dirt and deposits from
these options are given in Figure 75 and Figure 76. The major design
the compressor blading to increase unit performance.
uprates included in this package are given in Figure 71. In addition to
The turbine and compressor water wash systems allow the customer improving performance, the maintenance/inspection intervals can be
to remove deposits from the compressor and turbine sections increased.
thereby recovering lost output and efficiency in machines.
Option I contains the advanced technology stage 1 buckets and
nozzles and GTD-450 reduced camber inlet guide vanes. This
Turbine Uprate Packages
option maintains the firing temperature at 1840°F while increasing
Each of the advanced technology uprates can be installed in
the thermal efficiency, which decreases the exhaust temperature.
MS9001B and E units with minor or no modifications.
This uprate option provides an increase in output of 6.4% at ISO
Examples of design improvements are outlined in Figure 70. conditions with the IGVs open to 86 degrees.
While some of these components provide performance benefits
Option II raises the firing temperature to 1905°F, which is the
individually, the most dramatic performance benefits are obtained
maximum firing temperature that can be achieved while maintaining
by increases in firing temperature, Tf. Generally, Tf increases require
the original exhaust temperature. In addition to the components for
a series of component changes based on the original configuration
Option I, this option includes new stage 2 buckets and nozzles, new
of the unit and the desired firing temperature. Therefore, several
stage 1 shroud, TBC coated slot-cooled liners, Nimonic 263™ transition
different packages have been designed for the MS9001B and E units
pieces, and the Extendor combustion upgrade. The stage 2 buckets are
to provide the maximum benefit for the customer. (See Figure 71.)
GTD-111 buckets without air-cooling. Option 2 is feasible for combined
There are four packages for the MS9001B and two packages for the
cycle applications where a decrease in exhaust temperature would
MS9001E. Below, each of these packages is discussed.
reduce the overall combined cycle efficiency and an increase in
Uprate 9B Hot Gas Path and Combustion to 9E (FT6X) exhaust temperature might be limited by the Heat Recovery Steam
The MS9001B turbine uprate is based on installing current production Generator (HRSG). It should be emphasized that the performance
MS9001E components into the MS9001B. (See Figure 72.) This uprate benefits given in Figure 75 and Figure 76 are based on the IGVs opened
package consists of four different options outlined in Figure 73 and to 86 degrees, and assume that all of the options have been installed.

40
Sourcebook Codes Component Design Improvements

FS2J Stage 1 Nozzle 2 Vane/Segment, 6% higher pressure ratio, chordal hinge

with improved sidewall sealing, improved sidewall cooling
FS2H Stage 1 Bucket GTD-111, T33 INCOAT, blunt leading edge airfoil and
coating on cooling holes, turbulated cooling
FS1PJ Stage 2 Nozzle Air cooled, long chord, GTD-222 for increased creep
resistance, aluminide coating, reduced cooling
FS2F Stage 2 Bucket Air cooled, GTD-111, GT33 INCOAT, scalloped tip shroud,
cutter teeth
FS1R Stage 3 Nozzle Long chord, GTD-222 for increased creep resistance

FS2K Stage 3 Bucket Rotated airfoil, IN738, scalloped tip shroud, cutter teeth

– Combustion Slot cooled liners (FR1H), Nimonic™ thick wall transition

pieces (FR1D) and thermal barrier coated liners (FR1G)

Figure 70. MS9001E component design improvement examples.

MS9001 B/E Uprate Options MS9001E to MS9001E to

2020°F 2055°F
Component Option 1 Option 2 Option 3 Option 4
Firing Temperature 1840°F 1905°F 1965°F 2020°F 2020°F 2055°F
Increase in Output 6.4% 12.6° 18.2% 24.1% 6.4%-10.4% 5.1%-15.5%
S1B 9E GTD111 E/A BLE X X X X X X
S1N 9E 2 Vane Chordal Hinge X X X X X
GTD450 Reduced Camber IGV (86 degrees) X X X X X X
S2N 9E GTD222 Reduced Cooling X X X X
S2B 9E GTD111 Air Cooled X** X X X
S3N IN738 X X X
Stg. 1 Shroud 1 Piece X X X X
Stg. 1 Shroud 2 Piece X
Stg. 3 Shroud (for 9E Bucket Shroud) X X
GE Exhaust Frame and Blowers X X X
Slot-cooled Liners w/TBC X X X X
Extendor Combustion Upgrade X X X X X
Stage 1/2 Wheel Spacer X X X
Nimonic™ Transition Pieces X X X X X
Inner Barrel Bore Plugs X X X X X X
Stage 2 Honeycomb Shrouds*** X X X X
Stage 3 Honeycomb Shrouds*** X X X
High Pressure Packing Brush Seal*** X X X X X X
#2 Bearing Brush Seal*** X X X X X X

* Need to have existing liners coated with TBC. This cost is not included in the package price.
** Non air-cooled buckets
*** Optional – not required for Uprate

Figure 71. MS 9001 E-Class uprate options.

GE Energy | GER-3928C (05/08) 41

 MS9001B to E Advanced Tech Uprate
MS9001B to E Advanced Tech Uprate
MS9001B Turbine Urate (FT6X)
MS9001B Turbine Uprate (FT6X)
Option I
• Current production 91E buckets and nozzles can be
• Includes new GTD-450 High Flow Inlet Guide Vanes,
retrofitted into earlier 91B units w/ minor modifications
first stage buckets and nozzles and inner barrel bore plugs.
• When uprating 91B units with 91E HGP parts, expect
This option maintains the firing temperature at 1840°F/1004°C
substantial improvements in parts life
while increasing the thermal efficiency, thereby decreasing the
• 91B combustion hardware can also be replaced with 91E
exhaust temperature.
components and significantly improve combustion
Option II
inspection intervals
• Provides the material supplied in Option 1 as well as second

Figure 72. Uprating a 9B to a 9E.

stage non-Air-Cooled buckets and second stage nozzles, stage 1
shrouds, TBC coated slot cooled liner, Nimonic™ transition pieces
Option III is designed to raise the exhaust temperature to the limit and Extendor. The addition of these components supports a firing
by increasing the firing temperature to 1965°F. In addition to the temperature increase to 1905°F/1040°C. This is the maximum
material provided for Options 1 and 2, stage 3 buckets, nozzles firing temperature that can be achieved while maintaining the
shrouds, and the turbine rotor 1-to-2 wheel spacer are also original exhaust temperature. This option is applicable to heat
provided. Unlike Option 2, the stage 2 bucket is air-cooled. This recovery unit applications, where exhaust temperature decreases
uprate provides an 18.2% increase in output at an 86 degree IGV can be detrimental to combined cycle efficiency and exhaust
angle and ISO conditions. temperature increases might not be compatible with the Heat
Recovery Steam Generator (HRSG).
Option IV raises the firing temperature to 2020°F. This option
includes all of the components in Option 3, as well as a new exhaust Figure 73. Uprating a 9B to a 9E.

frame and two 100 hp exhaust frame blowers to accommodate the

increase in exhaust temperature. Increasing the firing temperature MS9001B to E Advanced Tech Uprate
to this level can increase the output by 24.1% at an 86 degree IGV MS9001B Turbine Urate (FT6X)
angle and ISO conditions. Option III
• Includes all three stages of buckets and nozzles (including Air
Prior to the sale of any of these options, an engineering review of
Cooled second stage buckets), inner barrel bore plugs, stage 1
the turbine/generator performance is required to ensure that the
two-piece shrouds, stage 3 shrouds, TBC-coated slot-cooled liners,
load equipment can accommodate the increase in output. This
Nimonic™ transition pieces and Extendor. This option allows for an
review may indicate that the load equipment needs to be uprated.
increase in firing temperature to 1965°F/1074°C. This option is
In many cases, the generator can operate at a higher power factor
designed to raise the exhaust temperature to the limit.
to produce more megawatts. A typical MS9001B performance
Option IV
study towards these ends is illustrated in Figure 77.
• Includes the same material as Option 3 as well as an exhaust
Each of these components in these package options can be purchased frame and exhaust frame blowers, which are required to
individually; however, all of the required components in a given option support the firing temperature increase to 2020°F/1104°C.
must be purchased and installed to receive the corresponding increase
in firing temperature for that option. Each of the design improvements Each of these components in these package options can be
associated with the MS9001E components are outlined below. purchased individually; however, all of the components in a
given option must be purchased and installed to receive the
• Stage 1 Buckets. This bucket is now made of GTD-111 with the
corresponding increase in firing temperature.
IN Plus coating, has the blunt leading edge design, and is
turbulated cooled. (Reference FT6J.) Figure 74. Uprating a 9B to a 9E.

42
 MS9001B-E Uprates MS9001E – 2020°F MS9001E – 2055°F
I II III IV
Original TI, (°F) 1840 1840 1840 1840 1955 1985 2000 1955 1985 2000 2020 2055
Original TI, (°F) 1840 1905 1965 2020 2020 2020 2020 2055 2055 2055 2055 2055
Increase in Output
% % % % % % % % % % % %
Increase in Firing Temperature – 6.7 12.8 18.2 6.5 4.0 2.7 9.5 7.0 5.7 3.5 0.5
and Controls Modification
Bore Plugs 0.33 0.33 0.33 0.33 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
C450 IGVs (84 degrees) 4.3 4.3 4.3 4.3 1.5 1.5 1.5 1.5 1.5 1.5 – –
Additional 2° – IGV 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
Rotated S3B – – 0.6 0.6 – – – 0.3 0.3 0.3 0.3 –
GTD-222 S2N – -1.0 -1.0 -1.0 – – – 1.0 1.0 1.0 1.0 1.0
Haynes HR-120 One Piece – – – – – - – 0.0 0.0 0.0 0.0 0.9
Stage 1 Shroud
Exhaust Frame Blowers – – – 0.2 – – – – – – – –
Air Cooled S2B – – 1.65 1.65 – – – – – – – –
S2B Shrouds with Honeycomb Seals – 0.35 0.35 0.35 – – – 0.35 0.35 0.35 0.35 0.35
S3 Shrouds with Honeycomb Seals – – 0.15 0.15 – – – 0.15 0.15 0.15 0.15 0.15
HPP Brush Seals 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
No. 2 Bearing Brush Seals 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Total Effect on Output 6.4 12.8 18.2 24.1 10.4 7.8 6.4 15.5 12.9 11.5 7.6 5.1

Figure 75. Frame 9 uprate options output increases.

MS9001B-E Uprates MS9001E – 2020°F MS9001E – 2055°F

I II III IV
Original TF (°F) 1840 1840 1840 1840 1955 1985 2000 1955 1985 2000 2020 2055
Original TIF (°F) 1840 1905 1965 2020 2020 2020 2020 2055 2055 2055 2055 2055
Decrease in Heat Rate
% % % % % % % % % % % %
Increase in Firing Temperature – -1.1 -2.0 -2.6 -0.6 -0.27 -0.15 -0.77 -0.54 -0.42 -0.27 –
and Controls Modification
S1N Chordal Hinge -1.9 -1.9 -1.9 -1.9 – – – -0.25 -0.25 -0.25 -0.25 -0.25
Bore Plugs 0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2
G450 IGVs (84 degrees) -0.7 -0.7 -0.7 -0.7 -0.38 -0.38 -0.38 -0.38 -0.38 -0.38 – –
Additional 2° - IGV 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Rotated S3B– – – 0.6 0.6 – – – 0.28 0.28 0.28 0.28 –
GTD-222 S2N – -0.4 -0.4 -0.4 – – – -0.4 -0.4 -0.4 -0.4 -0.4
Haynes HR-120 One Piece – – – – – – – 0.0 0.0 0.0 0.0 -0.4
Stage 1 Shroud
Exhaust Frame Blowers – – – -0.1 – – – – – – – –
Air Cooled S2B – – 1.1 1.1 – – – – – – – –
S2B Shrouds with Honeycomb Seals – -0.35 -0.35 -0.35 – – – -0.35 -0.35 -0.35 -0.35 -0.35
S3 Shrouds with Honeycomb Seals – – -0.15 -0.15 – – – -0.15 -0.15 -0.15 -0.15 -0.15
HPP Brush Seals -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 v -0.5 -0.5 -0.5 -0.5
No. 2 Bearing Brush Seals -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2
Total Effect on Heat Rate -3.3 -4.3 -4.8 -5.5 -1.6 -1.3 -1.2 -3.2 -3.0 -2..9 -2.4 -2.2

Figure 76. Frame 9 uprate options heat rate decreases.

GE Energy | GER-3928C (05/08) 43

 slot-cooled liners and Nimonic 263™ transition pieces, new
combustion cans, flow sleeves, and crossfire tubes are required.
The new combustion system provides more effective cooling
allowing for higher firing temperatures. The 9B was introduced
with the “parallel” combustion system meaning that the liners
were parallel to the turbine rotor. When the 9E was introduced,
the combustion system was modified to the “canted” system
where the liners are installed at an angle to the turbine rotor.
The latest design 9E has a canted arrangement that utilizes a
longer transition piece than in the canned arrangement. Both
the canned and the canted arrangements use the same liner.
When uprating the 9B combustion hardware, the 9E slot-cooled
liner is used, however the 9E transition piece is incompatible.
A new Nimonic 263™ transition piece was designed for this
specific application. The 9B and the 9E Nimonic 263™ transition
pieces are not interchangeable.
Figure 77. Typical MS9001B to E uprate performance study.
• Extendor Wear Kit. The Extendor wear kit decreases combustion
• Stage 1 Nozzles. This nozzle has only 2 vanes per segment, component wear and increases combustion inspection intervals
which decrease the thermal stresses, making it less vulnerable to by reducing the relative movement and associated wear of the
fillet cracking. This nozzle also has the improved hinge, improved parts in the combustion system. (Reference FR1W.)
sidewall sealing, and improved sidewall cooling. (Reference FS2J.)
• Exhaust Frame Modification and Exhaust Frame Blowers.
• Stage 1 Shrouds. New stage 1 shrouds are required to Exhaust frame cooling is accomplished by two 100 hp motor
accommodate the new stage 2 nozzle. driven centrifugal blowers. (Reference FS2D.)
• Stage 2 Buckets. The stage 2 bucket is now air-cooled, made • Inner Barrel Bore Plugs. The unplugged cooling circuit tuning
of GTD-111 and coated with IN Plus, and has a scalloped tip holes can be plugged to decrease the cooling airflow across the
shroud. In option 2, the cooling holes in this bucket are plugged. inner barrel high-pressure packing. (See Figure 78.)
(Reference FS2F.)
Increase MS9001E to 2020°F Firing Temperature (FT6C)
• Stage 2 Nozzles. This nozzle is now air-cooled and made of GTD-
This uprate package is designed for MS9001E units with firing
222+ with an over aluminide coating. (Reference FS1P.)
temperatures below 2020°F. This package is based on installing
• Stage 3 Buckets. The material and design of this bucket have the latest technology components into older machines. The
been improved. (FS2K) uprates required for the firing temperature increase are listed in
Figure 71. An engineering review of the current turbine
• Stage 3 Nozzles. This nozzle has an increased chord length and
configuration should be provided to determine the uprates
is now made from GTD-222+. (Reference FS1R.)
required for Tf increase. The performance improvement is derived
• Stage 3 Shrouds. New stage 3 shrouds are required to
from the increase in firing temperature as well as improved
accommodate the new stage 3 buckets.
component designs. Depending on the original configuration of
• GTD-450 Inlet Guide Vanes. The high flow inlet guide vane has a the unit, the increase in output ranges from +6.4% to +10.4%,
reduced camber design to increase airflow. (Reference FT6B.) while the heat rate decreases from -1.2% to -1.6%, (including
optional items for advanced technology uprate).
• Combustion System. In order to utilize the TBC-coated

44
Figure 78. Bore plugs are used to fine-tune cooling air to the first wheel space.

The benefits of this Model 9E uprate are: • TBC Coated Slot-Cooled Liners. TBC coated slot-cooled liners
Original Tf 1955°F 1985°F 2000°F are required as a part of this uprate. The latest design liners are
thick-walled liners that are TBC Coated. The customer has the
Output 10.4% 7.8% 6.4%
option of having the existing thin-walled liners coated with TBC
Heat Rate -1.6% -1.3% -1.2%
or purchasing the new thick-walled TBC coated liners. The thick-
Figure 75 and Figure 76 provide the performance gains associated walled liners can withstand a firing temperature of 2055°F.
with each of the components as well as the entire uprate package.
• Nimonic Transition Pieces. Nimonic 263™ transition pieces are
Again, it is important that the turbine/generator be evaluated to
required for this uprate. These transition pieces increase
determine if the current load equipment can withstand the increase
maintenance intervals and increase hot gas path life.
in output associated with this uprate.
• Extendor Wear Kit. The Extendor wear kit decreases combustion
The design improvements associated with the MS9001E
component wear and increases combustion inspection intervals
components include:
by reducing the relative movement and associated wear of the
• Stage 1 Buckets. This bucket is now made of GTD-111 with the parts in the combustion system. (Reference FR1W.)
IN Plus coating, has the blunt leading edge design, and is
• Inner Barrel Bore Plugs. The unplugged cooling circuit tuning
turbulated cooled. (Reference FT6J.)
holes can be plugged to decrease the cooling airflow across the
• Stage 3 Nozzles. This nozzle has long chord length and is now inner barrel high pressure packing, this increases output.
made from GTD-222+. (Reference FS1R).
• Exhaust Frame Blowers. Exhaust frame cooling is accomplished
• GTD-450 Inlet Guide Vanes. The high flow inlet guide vane has by two 100 HP motor driven centrifugal blowers. (Reference FS2D.)
a reduced camber design to increase airflow. (Reference FT6B.)

GE Energy | GER-3928C (05/08) 45

Increase MS9001E to 2055°F Firing Temperature (FT6Y)
MS9001E 2055°F Uprate Requirements
This uprate package is designed for MS9001E units with firing
• GTD-111 Equiaxed BLE Stage 1 Bucket FT6J
temperatures below 2055°F. This package provides the advanced
• 2 Vane Chordal Hinge Stage 1 Nozzle FS2J
technology components to increase the firing temperature of an
• GTD-111 Air-Cooled Stage 2 Buckets FS2F
earlier vintage MS9001E to 2055°F, the highest firing temperature
• GTD-222 Reduced Cooling Stage 2 Nozzle FS1P
available on an MS9001E.
• IN-738 Stage 3 Bucket FS2K
The benefits of this uprate are: • GTD-222 Stage 3 Nozzle FS1R

• Increase in output ranging from 5.1% to 15.5%, depending on the • HR-120™ Improved Stage 1 Shroud Blocks FS2Y

original configuration of the unit, while the heat rate decrease • GTD-450 Reduced Camber IGVs FT6B

ranges from –2.2% to –3.0%, (including optional items for • Nimonic-263™ Transition Pieces, TBC Coating FR1U

advanced technology uprate) • Thick Slot-Cooled Liners with TBC FR1U

• Exhaust Isotherm Temp Limit Upgrade,
The hardware required for a given unit varies depending on its current
Exhaust Frame Upgrade/100 HP Blowers FS1W/FS2D
turbine configuration. An Applications Engineering review is conducted
• Inner Barrel Bore Plugs FS2S
to define the balance of components required for the uprate of any
specific unit. Most requirements are part of normal maintenance plans.
Improve performance with uprate parts in place of normal spares.
The increase in output associated with the uprate is dependent
Figure 79. Requirements for uprate to 2055°F.
upon the original configuration of the unit. Figure 75 and Figure 76
provide the performance gains associated with each of the • Stage 3 Shroud Cooling Air Modification. Addition of 5th
individual components as well as the entire uprate package. Again, compressor stage extraction piping for supplying cooling air
it is important that the turbine/generator be evaluated to determine between the turbine case and stage 3 shrouds.
if the current load equipment can withstand the increase in output
• Combustion System. The latest design combustion system is
associated with this uprate.
referred to as a “canned” arrangement and replaces the
The items listed in Figure 79 need to be configured on the unit for a “canted” arrangement. The “canted” arrangement is easily
firing temperature increase to 2055°F: identified because the combustion covers bolt directly to the
• Stage 1 Buckets. GTD-111 material, directionally solidified, wrapper without the external combustion casing “cans.” For
equiaxed, 11-hole turbulated cooled GT-33 IN Plus coating. units with a firing temperature less than 2055°F, the combustion
system remains as the “canted” arrangement, which features full
• Stage 2 Buckets. GTD-111 material with advanced cooling
Nimonic 263™ “long” transition pieces and “thick-walled” slot-
(6 cooling holes), scalloped shroud tips, and cutter teeth.
cooled liners, both of which are TBC coated. The longer transition
• Stage 3 Buckets. IN-738™ material with scalloped and piece moves the liner out thus requiring the outer cans. This
interlocking shroud tips with cutter teeth. requires modifications to fuel gas piping (for single gas units), or
• Stage 1 Nozzles. FSX-414 material, improved cooling with requires fuel oil, fuel purge and atomizing air piping (for dual fuel
chordal hinge, and spline seals on inner segment. units). Units equipped with false start drain piping require drains
for the new, lower half combustion cans.
• Stage 2 Nozzles. GTD-222+ material with reduced cooling flow,
non-pressurized. • Exhaust Frame Blowers. Exhaust frame cooling is accomplished
with two 100 hp motor-driven centrifugal blowers.
• Stage 3 Nozzles. GTD-222+ material. This nozzle has an
increased chord length and is now made from GTD-222+. • Inner Barrel Bore Plugs. The unplugged cooling circuit tuning
holes can be plugged to decrease the cooling airflow across the
• Stage 1 Shrouds. One-piece design, HR-120 material with
inner barrel high pressure packing.
improved spline sealing.

46
• Inlet Guide Vanes. GTD-450 material (PG9151E units and earlier the fire-extinguishing agent. When the fire protection system is
do not have GTD-450 high flow inlet guide vanes) with reduced activated, the latch releases and the damper blades close by
camber design to increase airflow. gravity. The damper housing and CO2 latch are bolted to the fan
outlet and shipped as a unit. It should be noted that the CO2 latch
• Inner Barrel Counter Bore Covers. IGV angle restrictions might
could be mounted on either side of the vent fan damper.
also be necessary. (Reference FS2B.)
New motor starters and circuitry changes to the motor control
• Temperature Control Curve. Modification for firing temperature
center are included in this uprate. These changes allow the fans to
increase.
be operated from the existing control unit. Other options that can
Compartment and Exhaust Improvements be incorporated into this uprate include limit and differential
pressure switches, as well as back draft dampers.
Turbine Compartment Dual 100 HP Fan Uprate (FF1E)
This modification for MS9001B and E units involves adding two Upgrade to 100 HP Exhaust Frame Motor Bowers (FS2D)
centrifugal ventilation fans, enclosed in box-type casings and For MS9001E units, cooling of the turbine exhaust casing and frame
driven by AC motors, to the top of the turbine compartment. is accomplished by motor-driven blowers. These fans are mounted
The fans provide ventilation by drawing air up through several externally to the turbine. The replacement kit includes 100 HP
ducts in the turbine and accessory compartments and exhausting exhaust frame blowers, interconnection piping arrangement
it to atmosphere through a horizontal discharge. A dual vent fan modifications, motor control center modifications, and exhaust
arrangement is used to supply symmetrical airflow throughout the frame cooling circuit tuning. The current design exhaust frame is
turbine compartment. cooled with two motor-driven centrifugal blowers. The 100 HP
The benefits of this uprate are: exhaust frame blowers reduce the temperature of the frame
thereby reducing cracking to provide a durable exhaust frame.
• Additional cooling to the turbine compartment
The benefits of this uprate are:
• Dual vent fan configuration symmetrically extracts hot air away
from the turbine, reducing part degradation caused by thermal • Exhaust frame blowers help to reduce temperature of the frame
fatigue — Helping to reduce cracking and general repair costs
This modification provides additional cooling to the turbine — Providing a durable exhaust frame
compartment. The dual vent fan configuration symmetrically
Upgrading the exhaust frame blowers is applicable to units with
extracts hot air away from the turbine, thereby reducing part
the modern design exhaust frame that can use but do not yet have
degradation caused by thermal fatigue. Two holes need to be cut
100 HP blowers. All 9E units have the modern design.
in the existing turbine compartment roof to accommodate the new
vent fans. Appropriate lagging or struts must also be added to the The recommended design for combined cycle machines is 100 HP
existing turbine compartment roof to support the weight of the exhaust frame blowers for 9E units. For simple cycle, the recommended
new equipment. design is 30 HP blowers for 9E units. Simple cycle units generally have
lower horsepower blowers because the gas path pressure is relatively
The ventilation fan assemblies supplied with this uprate have
low for simple cycle. However, for simple cycle units, an upgrade to
externally-mounted motors. Each motor is mounted atop the fan
exhaust frame blowers with 100 HP rating may be required to obtain
enclosure in the ambient environment. This design helps maintain
the elevated exhaust temperature capability needed to get the full
the expected fan motor life by removing the fan motors from the
benefit of a 2055°F firing temperature increase.
hot air discharge path.
Reference FS1W for a modification kit for 9E units that contain the
Each vent fan assembly employs a damper housing. The damper
latest enhancements and recommended plenum upgrades. For 9B
blades are held in a normally open position with a CO2/Halon
units, reference FS1W for the exhaust frame blower addition/upgrade
pressure actuated spring release latch. This latch is operated by
and exhaust frame upgrade.

GE Energy | GER-3928C (05/08) 47

Replaceable Wheel Space Thermocouples Uprate (FK5C) thermocouple device are two separate parts. For a thermocouple
Intended for MS9001B units, the removable wheel space thermocouples failure, the thermocouple is disconnected and removed at the
modification provides thermocouples that can be replaced upon failure radiation shield, the cable is left in place, and then the new
without removing the turbine shell. The new thermocouples are also thermocouple is inserted and reconnected. This significantly
extended which provides greater reliability by moving the termination reduces the labor hours to replace an exhaust thermocouple.
junction from the turbine compartment to outside of the compartment.
Exhaust Frame Uprate (FS1W)
The modification includes all wheel space thermocouples, necessary
For MS9001B and E units, the exhaust frame diffuses high
hardware, and on-base junction boxes.
temperature exhaust gas through the exhaust plenum. The frame
The extended externally replaceable wheel space thermocouples consists of an inner forward diffuser, an outer forward diffuser, an aft
increase turbine availability through a reduction in down time. The exhaust diffuser, and a turning vane sub-assembly. (See Figure 80.)
reliability of the thermocouple increases with the increased shielding
and removal of the termination point from the turbine compartment.

Replaceable Exhaust Thermocouples Uprate (FK5K)

Two options are now available for replacement exhaust
thermocouple kits:

• Option FK5P Connector Design

• Option FK5K Short-Lead Design

The connector design exhaust thermocouples have head design

that reduces the likelihood of damage from improper applied torque
or wiring; and special torque wrenches are no longer required for
installation. This design also eliminates the need to replace the
thermocouple from radiation shield to junction box, and eliminates Figure 80. Improved exhaust frame.

mechanical destruction of TC due to over-tightening of Swagelok

fitting. It also provides for more positive bottoming of TC in the This modification package includes the following as appropriate:

radiation shield, thereby reducing breaking of the TC tip. It has improved cooling air circuit; increased exhaust frame blower

reduced installation time and reduced wear/tear due to its quick capacity; upgraded covers and gaskets for horizontal joints;

disconnect arrangement. upgraded forward flex seals; stress relief scallops; turning vane
enhancements; improved aft diffuser supports; and improved after
The short-lead thermocouple splits the thermocouple device and the
diffuser stress relief. These modifications improve exhaust frame
thermocouple wiring that goes to the outside junction box into two
cooling, reduce general repair costs, and address load tunnel over-
parts. This makes the first connection point at the thermocouple head
temperature issues by reducing exhaust gas leakage.
instead of at the junction box. The modification kits for either the long
lead or the short lead include the frame size specific number of The benefits of this uprate are:

thermocouples, special tools, and all the necessary hardware to • Enhanced exhaust frame for MS9001B and E units (FT6X, FT6Y)
install the modification. firing temperature uprates

The short-lead exhaust thermocouple provides a more positive • Enhanced exhaust frame cooling
bottoming of the thermocouple in the radiation shield. The flex
• Reduced repair costs
leads are not as susceptible to damage from shipping, handling,
and installation. However, the biggest advantage is eliminating the • Reduced exhaust gas leakage (addressing load tunnel over-
need to replace the thermocouple from the radiation shield to the temperature issues)
junction box because the lead (thermocouple cable) and the

48
Advanced Exhaust Plenum Uprate (FD4K) Summary
To ensure that customers have access to high quality gas turbine
GE has advanced technology uprate packages available to uprate
exhaust plenums, GE Energy makes retrofit, re-designed exhaust
MS9001B and E gas turbines. These advanced uprate technology
plenums part of its product offerings. (See Figure 81.) Over time,
packages provide significant savings derived from reduced
exhaust plenums experience hot flanges and outer skin problems.
maintenance, improved efficiency, higher output, better reliability, and
Excessive thermal movement contributes to destruction of control
life extension. Regulatory requirements may necessitate the need for
cables and severe turbulence that can cause liner damage.
emission controls due to changes in emission levels when uprating the
gas turbine, and modifications are available to significantly reduce
emissions. Today’s technology and enhanced production components
allow customers to bring their aging turbines back to better-than-new
condition based upon these offerings.

• GE Energy has advanced technology uprate packages

available to uprate all MS9001 Heavy-Duty Gas Turbines
to improve their performance, efficiency, and reliability

• Uprates are available to increase maintenance intervals

and reduce repairs

Figure 81. Improved exhaust plenum.

The re-designed plenums include: drainable liner floor with optional

jacking port; double sealed wing door; cool shell and cool flange;
designed to be installed with the turbine rotor and aft diffuser in
place (not removed); and an internal floating liner design.

* Mark V, Mark I, Mark VI, Extendor, GT-29, GT-29 IN, GT-29 IN Plus, GT-29 Plus,
GTD-111, GTD-222, GTD-222+, GTD-241, GT-33, GT-33 IN, GTD-741,
Plasmaguard, and ETBC are trademarks of General Electric Company.
Hastelloy-X™ is a trademark of Cabot Corp.
IN-738™ and IN-706™ are trademarks of Inco Alloys International.
H-188™, N-155™, A286™, HR-120™, and HA-188™ are trademarks of
Haynes Corp.
Nimonic 263™, U500™, RENE 77™, and U700™ are trademarks of Udimet Corp.
X40™, X45™, and M152™ are trademarks of Carpenter Corp.
Stellite™ is a trademark of Deloro Stellite.

GE Energy | GER-3928C (05/08) 49

References List Of Figures
1. A. M. Beltran, J. J. Pepe, and P. W. Schilke, “Advanced Gas Turbine Figure 1. MS9001E Simple-cycle single-shaft heavy duty gas
Materials and Coatings,” GER-3569, General Electric, August 1994. turbine.

2. D. E. Brandt and R. R. Wesorick, “GE Gas Turbine Design Philosophy,” Figure 2. Benefits of uprates offered.
GER-3434, General Electric, August 1994. Figure 3. NOx emissions levels at 15% O2.

3. F. J. Brooks, “GE Gas Turbine Performance Characteristics.” GER-3567, Figure 4. MS9001 E-Class performance history.
General Electric, August 1994. Figure 5. Gas turbine alloys.
4. L. B. Davis, “Dry Low NOx Combustion Systems for Heavy Duty Figure 6. Creep stress rupture comparison of bucket and nozzle
Gas Turbines,” GER-3568, General Electric, August 1994. materials.

5. D. Balevic, R, Burger, and D. Forry, “Heavy Duty Gas Turbine Figure 7. Uprates available for 9B and 9E units.
Operating and Maintenance Considerations,” GER-3620K, Figure 8. GTD-450 reduced camber high-flow variable IGV
General Electric, December 2004. arrangement.
6. P. R. Dunne, “Uprate Options for the MS7001 Heavy Duty Gas Figure 9. Design improvements with GTD-450 high flow IGVs.
Turbine,” GER3808, General Electric, 1995.
Figure 10. HPP brush seal.
7. J. R. Johnston, “Performance and Reliability Improvements for Figure 11. Brush seals for #2 bearing.
Heavy duty Gas Turbines,” General Electric, August 1994.
Figure 12. Side view of the three stages of shrouded compressor
8. GEA-12526 (8/95), 12220.1 (1/94) MS9001E Gas Turbines: blades.
Conversions, Modifications, and Uprates.
Figure 13. CM/U analysis for a specific unit showing need for
shrouded design.

Figure 14. Improved slot-cooled liner versus original louvered liner.

Figure 15. Thermal barrier coating.

Figure 16. Slot-cooled combustion liner; cutaway view.

Figure 17. MS9001E combustion system comparison.

Figure 18. Comparison of old and new transition piece aft brackets.

Figure 19. Nimonic 263™ transition piece.

Figure 20. Nimonic 263™ transition piece illustrating downstream

aft end coated inside only with TBC.

Figure 21. Areas of combustion system that are Extendorized.

Figure 22. Extendor technology lengthens maintenance intervals.

Figure 23. Modifications for 9E Extendor.

Figure 24. Increased inspection intervals for 9E Extendor.

Figure 25. MS9001 E-Class dry low NOx combustion system.

Figure 26. Dry low NOx combustor.

Figure 27. Fuel-staged DLN operating modes.

50
Figure 28. MS9001EA Dry Low NOx combustion system. Figure 54. Benefits of GTD-222+ nozzles as compared to FSX-414

Figure 29. DLN fuel system. nozzles.

Figure 30. New stage 1 buckets have material and design Figure 55. Improved stage 3 nozzle.

improvements. Figure 56. Advanced Aero Stage 3 Nozzle.

Figure 31. Types of bucket coatings. Figure 57. New stage 3 bucket design.

Figure 32. Sharp and blunt leading edge bucket designs. Figure 58. Performance benefit when Advanced Aero Stage 3

Figure 33. MS9001E stage 2 air-cooled bucket. Bucket and Nozzle are combined on same unit.

Figure 34. Scalloping of bucket shroud. Figure 59. Advanced Aero Stage 3 Bucket.

Figure 35. Final configuration of bucket shroud. Figure 60. First stage shroud with cloth seals FS2Y.

Figure 36. Improved stage 2 bucket. Figure 61. HR-120™ Improved Stage 1 Shroud.

Figure 37. Non air-cooled GTD-111 buckets have better creep Figure 62. Stage 1 shrouds coated with abradable coating.

properties. Figure 63. Abradable coating increases performance when rotor

Figure 38. Improved stage 3 buckets. is not 100% aligned or casing is out of round.

Figure 39. Machining required on stage 3 shroud. Figure 64. Stage 2 shroud blocks with honeycomb and stage 2
buckets with cutter teeth.
Figure 40. Comparison of 9B and 9E stage 1 nozzles.
Figure 65. Shroud block with honeycomb sealing.
Figure 41. Cracked stage 1 nozzle.
Figure 66. 7EA stage 2 honeycomb inner shroud design.
Figure 42. Stage 1 nozzle airfoil pressure-side-film cooling
modification. Figure 67. 7EA stage 2 brush seal inner diaphragm design.

Figure 43. Stage 1 nozzle airfoil pressure-side-film cooling. Figure 68. Installed interstage brush seal.

Figure 44. Stage 1 nozzle improved sidewall sealing with chordal Figure 69. RCA of cracking at third stage hook fit.

hinge. Figure 70. MS9001E component design improvement examples.

Figure 45. Stage 1 nozzle improved cooling outer sidewall film Figure 71. MS 9001 E-Class uprate options.
cooling Figure 72. Uprating a 9B to a 9E.
Figure 46. First stage nozzle improved inner sidewall tangential Figure 73. Uprating a 9B to a 9E.
support.
Figure 74. Uprating a 9B to a 9E.
Figure 47. First stage nozzle and support ring with no tangential
Figure 75. Frame 9 uprate options output increases.
hardware.
Figure 76. Frame 9 uprate options heat rate decreases.
Figure 48. Improvements in upgraded stage 1 nozzle for 9B and
9E units. Figure 77. Typical MS9001B to E uprate performance study.

Figure 49. Stage 1 nozzle with enhanced TBC. Figure 78. Bore plugs are used to fine-tune cooling air to the first
wheel space.
Figure 50. Design changes and reduced airflow in non-pressurized
stage 2 nozzle. Figure 79. Requirements for uprate to 2055°F.

Figure 51. Long and short chord nozzle design comparison. Figure 80. Improved exhaust frame.

Figure 52. Nozzle creep deflection comparison. Figure 81. Improved exhaust plenum.

Figure 53. Reduced cooling flow gives increased output.

GE Energy | GER-3928C (05/08) 51

©2008, General Electric Company. All rights reserved.
GER3928C (05/08)