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GER-4217A

GE Power Systems

Uprate Options for the MS6001 Heavy Duty Gas Turbine

David J. Taylor Olivier Crabos GE Energy Services, Europe GE Power Systems, Schenectady, NY, USA

20022003 General Electric Company. All rights reserved.

Uprate Options for the MS6001 Heavy Duty Gas Turbine

Contents
Abstract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MS6001 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CM&U Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Simple Cycle Performance Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Impact of the Gas Turbine CM&U on Combined-Cycle Performance . . . . . . . . . . . . . . . . . . . . . . 4 Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Liners (FR1G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transition Pieces (FR2B). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross Fire Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CL-Extendor (FR1V / FR1W). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dry Low NOx (FG2B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Steam Injection (SI) for NOx Control (FG1B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Water Injection (FG1A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inlet Guide Vanes (FT4C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Increase in IGV angle (FT4M). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Compressor Blading and Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Stage 17 and EGV Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Turbine Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Stage 1 Buckets (FS4A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Stage 2 Buckets (FS4B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Stage 3 Buckets (FS3K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Stage 1 Nozzle (FS2J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Stage 2 Nozzle (FS1P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Stage 3 Nozzle (FS1R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Contents (contd)
Turbine Section (contd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Shrouds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Stage 1 Shrouds (FS2Y). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2nd and 3rd Stage Shrouds (FS2T and FS2U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Additional Sealing Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Brush Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 High Pressure Packing Seal (FS2V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Stage 2 Nozzle Interstage Brush Seal (FS2Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Abradable Coatings 1st Stage Shroud (FS6A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PG6571B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Gas Turbine Firing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Speed Increase (FP4D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 PG6581B New Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Life Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installing Individual Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Controls Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 MS6001 Uprate Experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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ABSTRACT
Since the GE MS6001 heavy-duty gas turbine was introduced to the market in 1978, GE has developed many uprates in performance and improvements in availability and reliability for this model size. Based on new material applications and information accumulated from millions of hours of operational experience, GE has been able to develop a series of new heavy-duty gas turbine models. This development work resulted in products and improvements for all the earlier models of heavy-duty gas turbines. This paper will discuss how this development work has been applied to each of the critical components for the MS6001 series of turbines. It also discusses where the latest technology advances can be applied to enhance the performance, extend the life, and provide economic benefits from increased reliability and maintainability of all earlier MS6001 turbines. All these uprates can be applied as a single project or individually phased in over time. If the gas turbine is installed in a combined-cycle plant, the uprates applied to the turbine can be chosen to optimize complete plant performance. Uprates are made possible as a result of GEs underlying design philosophyto maintain interchangeability of components for a given frame size so they can be installed in earlier vintage units with little or no modifications. Installing the latest technology hardware and taking advantage of the highest firing temperatures allows owners/operators to remain competitive in the marketplace. Virtually every key component in the MS6001 series has gone through significant design improvements since the first MS6001A was shipped. Buckets, nozzles, shrouds and combustion components have undergone multiple evolutions based on new designs, manufacturing techniques, materials, and field experience.

MS6001 History
Originally introduced in 1978, the MS6001A gas turbine was scaled from the successful MS7001E gas turbine and had a modest firing temperature of 1850F. It was upgraded almost immediately (in 1981) to the MS6001B machine with a firing temperature of 2020F. The MS6001 is a single-shaft, two-bearing gas turbine designed for either 50 or 60 Hz power generation. Since its introduction more than 900 of these units have been shipped by GE and its manufacturing/business associates. Operating worldwide in both simple-cycle and combined-cycle modes, these gas turbines have proven to be very robust and reliable machines. Many design improvements have been made to the MS6001B to bring it to the current AO (Advanced Order) model list definition of the PG6581B. (See Table 1.)

INTRODUCTION
In todays deregulated market, owners/operators of all gas turbines need to maximize the performance of their assets. In many cases it may prove economically attractive to modernize and uprate their installed fleet of turbines. The MS6001 Gas Turbine can achieve uprate improvements in the following areas: s Performance output and heat rate s Extension of intervals between inspections s Availability and reliability improvements s Emission reductions s Life extension

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Exhaust Flow 103 lb/hr 1,077 1,112 1,117 1,115 1,117 1,137 1,145 1,160 1,166

Turbine Model MS6431A MS6441A MS6521B PG6531B PG6541B PG6551B PG6561B PG6571B** PG6581B

Ship Dates 1978 1979 1981 1983 1987 1995 1997 1997 2000

Firing Temp. F/C 1850/1010 1850/1010 2020/1104 2020/1104 2020/1104 2020/1104 2020/1104 2077/1136 2084/1140

Output* kW 31,050 31,800 36,730 37,300 38,140 39,120 39,620 40,590 41,460

Heat Rate* BTU/kWhr 11,220 11,250 11,120 10,870 10,900 10,740 10,740 10,600 10,724

Exhaust Temp. F/C 891/477 901/483 1017/547 1005/541 999/537 1003/539 989/532 1005/541 1016/546

* ISO with distillate fuel, STD combustor, no inlet or exhaust losses ** Available as retrofit only

Table 1. MS6001 performance history The PG6541B rating was introduced in 1987 with several improvements that increased airflow through the gas turbine and reduced cooling and sealing losses. These included: s Blunt leading edge 1st stage buckets s GTD-450 - high flow IGV (angle 84) s Inboard (Universal) 1st stage nozzle In 1995 GE announced an Advanced Technology Uprate Program for the MS6001 to ensure that it remained a competitive option for owners/operators. (See Figure 1.) The Uprate Programs main features were: s Improved cooling and sealing features s Improved materials s Increased speed s Improved turbine aerodynamics s Increased firing temperature The Advanced Technology Program brought the MS6001 in 1997 up to the PG6571B rating. This rating was only available as a retrofit package. In 1999, engineering teams in the U.S. and France pooled ideas and developed the PG6581B rating. Details of this development work and changes made to the MS6001B are covered later in this paper.

CM&U Program
The Conversions, Modifications and Uprate Program offers a wide range of improvements for the installed fleet of GE turbines (all frame sizes and models). These CM&U packages are offered as individual packages or can be applied in groups. Each package is defined by a fourdigit Source Book code. These codes are referenced in this paper and in all contract proposal documents generated by GE.

Simple Cycle Performance Improvements

Many of the following CM&U packages help to improve the overall performance of the simplecycle gas turbine. Table 2 and Table 3 list the

Figure 1. Cross section of MS6001 gas turbine

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Source Book Required for +42F

Gas Turbine Output Improvements

PG6541

PG6551

PG6561

Table 2. Delta changes in gas turbine output as a result of each CM&U package

Gas Turbine Heat Rate Improvements

Source Book

Required for +42F

PG6541

PG6551

PG6561

Table 3. Delta changes in gas turbine heat rate as a result of each CM&U package

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expected delta changes in performance, for each of these individual modifications. These modifications can be applied one at a time or all together. The gains indicated in these tables are additive. output and reduce heat rate for the simple-cycle gas turbine, but also result in a reduction in exhaust energy available for steam production. However, the net effect on the overall plant in most cases is a small increase in output and a slight reduction in overall heat rate. GE can provide detailed performance calculations for the gas turbine as well as the estimated overall plant performance. (See Table 4.)

Impact of the Gas Turbine CM&U on Combined-Cycle Performance

Where the gas turbine is installed in combinedcycle applications, modifying the unit to improve output and heat rate will change its exhaust characteristics, resulting in changes to the steam production and hence combinedcycle performance. As a rule, any modification that reduces compressor losses and/or cooling airflow will result in more gas turbine output at a reduced heat rate, with more energy available in the exhaust. This leads to an improvement in steam production and hence gains in combined-cycle output and overall efficiency. Modifications that lead to the turbine section becoming more efficient, again result in more

COMBUSTION SYSTEM
The combustion systemcontaining fuel nozzles, liners, transition pieces, X-fire tubes, flame detectors and spark plugsconsists of 10 reverse-flow combustion chambers arranged concentrically around the periphery of the compressor discharge casing. (See Figure 2.)

Liners (FR1G)
Combustion liners are slot-cooled, which provides a uniform distribution of cooling airflow on the inside of the liner body. The liner mate-

Gas Turbine Output Improvements GTD-222 Stage 2 Nozzle Stage 2 Honeycomb Shroud Stage 3 Honeycomb Shroud 86 IGV Setting 5163 RPM Load Gear* High Pressure Packing Brush Seal Stage 2 Nozzle Interstage Brush Seal Stage 1 Shroud with Cloth Seals Improved Cooling Stage 1 Nozzle Increase Tfire to 2084F GTD-111 DS Perimeter Cooled Stage 1 Bucket Improved Cooling 6 Hole Stage 2 Bucket IN-738 Stage 3 Bucket GTD-222 Stage 3 Nozzle Uprate Transition Piece with Cloth Seals TBC Liners Total Change in Exhaust Energy

Source Book FS1P FS2T FS2U FT4M FP4E FS2V FS2Z FS2Y FS2J FT4P FS4A FS4B FS2K FS1R FR2B FR1G

Required for +42F X

Approx % Change in Exhaust Energy 0.50 0.20 0.20 0.70 1.00 0.20 0.40 0.60 0.30 2.90 _ _ _ 5.60

X X X X X X X X X

Table 4. Change to exhaust energy for each CM&U GE Power Systems GER-4217A (12/03)
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Figure 2. Cross section through combustion system

Figure 3a. Slot-cooled liner with TBC applied

Top Coat Bond Coat

Liner

Coating Microstructure

Figure 3b. Thermal barrier coating rial is Hastelloy-X, a nickel-based alloy that was introduced for combustion liners in the 1960s. Liners are now Thermal Barrier Coated (TBC) to insulate the base metal from the combustion gases. (See Figure 3a and Figure 3b.) TBC consists of two materials applied to the inside surface of the linera bond coat applied to the surface, and then an insulating oxide applied over the bond coat. Application of TBC reduces base metal temperature, which leads to a reduction GE Power Systems GER-4217A (12/03)
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in component cracking and an overall reduction in thermal stress.

Transition Pieces (FR2B)

Transition Piece (TP) creep can be a significant problem for many MS6001B units fitted with original Hastelloy-X TPs. TP creep is the deformation of the transition piece body near the end frame caused by gradual relaxation of material due to high temperatures and associat5

Uprate Options for the MS6001 Heavy Duty Gas Turbine

ed stresses over time. To overcome this problem Nimonic-263a precipitation strengthened, nickel-based alloy with higher strength capability than Hastelloy-Xend frames were fitted to the Hastelloy-X body. This became standard for production in late 1995. The Nimonic-263 end frame provides a substantial reduction in TP creep. With the higher firing temperatures associated with Advanced Technology Uprates, the body of the transition piece as well as the aft frame are altogether. Cloth seals are designed to reduce the leakage between the transition piece and the first stage nozzle that occurs with the original floating seal design. The end of the seal that interfaces with the first stage nozzle is similar to the original floating seal. The end of the seal that is inserted into the transition piece aft frame is constructed by wrapping three layers of metallic cloth around a flexible metal shim. This flexibility allows the seal to maintain contact with the aft frame as unit operation causes relative motion between the two components.

Cross Fire Tubes

The ten combustion chambers are interconnected by means of cross fire tubes. These tubes enable flame from the fired chambers contain spark plugs to propagate to the unfired chambers during startup.

CL-Extendor (FR1V / FR1W)

All gas turbines require periodic combustion inspections. For any given machine, the duty cycle, the type(s) of fuel used, and the amount of water and steam injected are the key factors in determining the recommended combustion inspection intervals. These factors directly influence the amount of material creep, thermal stress, wear of combustion components and TBC coating erosion. The CL-Extendor Combustion System can increase combustion inspection intervals by significantly reducing combustion component wear. The CL-Extendor extended inspection interval system is a unification of the successful "ExtendorTM" offered by GE for many years and "CLE" a product offered by GEs French manufacturing associate, which has now become part

Figure 4. Full Nimonic-263 transition piece with cloth seals changed to Nimonic-263. In addition to an allNimonic construction (both body and aft frame), the design includes a redesigned aft support bracket, cloth seals, and Extendor features, discussed later. (See Figure 4.) The redesigned aft bracket is mounted to the aft frame instead of the transition piece body. With the previous design, which mounted the aft bracket on the transition piece body, an area of relatively high stress was created. This stress could eventually lead to body creep on the Hastelloy-X design. The Nimonic-263 material resists this creep, but the reconfiguration of the aft bracket eliminates the source of the stress

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of GE Energy Products Europe (GEEPE). 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. CL-Extendor extends time between inspection intervals by: s Reducing the relative movement between combustion components s Reducing forces and vibrations at wear interfaces s Providing for critical clearance control at wear interfaces s Using proven wear-resistant material couples developed by GE CL-Extendor can be applied to combustion components by modifying existing hardware at an authorized GE Service Center or by having CL-Extendor features built into (or "preapplied" to) new combustion components during the manufacturing process. (See Figures 5a, 5b, and 5c.) The CL-Extendor reduces the effects of wear at the following key interfaces: s Liner stops s Fuel nozzle tip to combustion liner fuel nozzle collar s Combustion liner hula seal to transition piece forward sleeve s Transition piece forward supports and bracket s Transition piece aft picture frame seal There are many ExtendorTM and CLE combustion systems in service throughout the world. Individual components for each of these life extension combustion systems cannot be interchanged with each other. Thus, it is important to provide GE with definitions of all the components in the combustion system when requesting repair or replacement of these components. This ensures that a correct fit will be made during installation and that the expected service life of the components will be achieved.

Figure 5a. Cross section through CL-Extendor

Figure 5b. New aft bracket arrangement GE Power Systems GER-4217A (12/03)
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Figure 5c. Cloth seals for transition pieces 7

Uprate Options for the MS6001 Heavy Duty Gas Turbine

Emissions
Emission levels are affected when a gas turbine is uprated. There are three main emissions abatement options available for the MS6001a Dry Low NOx combustion system, and steam or water injection. These options are available for new build units and for retrofitting to the installed fleet. (See Figure 6.) to allow operation from startup to base load at minimum NOx emission levels over the full operating range of the gas turbine. Details of the DLN combustion system are given in GER 3568G (Dry Low NOx Combustion Systems Heavy Duty Gas Turbines).

Steam Injection (SI) for NOx Control (FG1B)

Steam is injected into the compressor discharge air stream around each of the fuel nozzles to reduce flame temperaturewhich leads to a reduction in NOx emissions. (See Figure 8.) The quality of steam for injection must comply with GEK101944 (Requirements for Water/ Steam Purity in Gas Turbines); typical supply conditions of the steam would be 325 psig with a minimum of 50F superheat. Retrofitting SI will increase the gas turbine output and reduce heat rate. (See Figure 9.) The quantity of steam required will

Dry Low NOx (FG2B)

Dry Low NOx (DLN) is a two-stage premixed combustor designed for operation on natural gas, but capable of operation on liquid fuel. (See Figure 7.) The DLN system achieves low NOx levels by thoroughly mixing the air and fuel in the primary stage and delivers a uniform, lean, unburned fuel air mixture to the second stage. The system must operate in four distinct modes

Single Shaft Units Firing Temp. F/C 2077/1136

Dry Gas Dist. 148 267

Water/Steam Inj. Gas (FG1A/FG1F) 42 Dist. (FG1C/FG1F) 65

Dry Low Nox Gas Dist.* (FG2B) (FG2B) 9 42

Model MS6001B

*With water injection for distillate oil Figure 6. NOx emission levels at 15% O2 (ppmvd)

Figure 7. Cross section of DLN-1 combustion system

Figure 8. Combustion cover with steam injection nozzles

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43,000 42,000 41,000 11,600 11,500 11,400

41,000 40,500 40,000

11,900 11,850 11,800

Heat rate/kJ/kWhr

Output/kW

Output/kW

11,300 40,000 11,200 39,000 11,100 38,000 37,000 36,000 158 0 120 0.53
Output Heat rate

39,500 39,000 38,500 38,000 37,500 37,000 158 0

Output Heat rate

11,700 11,650 11,600 11,550 11,500

11,000 10,900 10,800 90 60 1.88 25 3.67

11,450 11,400 120 0.35 90 60 1.42 42 2.13

NOx/ppmvd @ 15% O2 1.08 SI Flow/kg/sec

NOx/ppmvd @ 15% O2
0.76

WI/kg/sec

Figure 9. Effects of steam injection on output and heat rate depend on the desired NOx level required, the fuel used and the ambient conditions.

Figure 11. Effects of water injection on output and heat rate down the center of the fuel nozzlewhich reduces the risk of water impingement. (See Figure 10.) Retrofitting WI will increase the output and the heat rate of the gas turbine. (See Figure 11.)

Water Injection (FG1A)

Water injection (WI) works in the same way as steam injectionreducing the flame temperature, which results in low NOx emissions. The initial design injected water into the fuel nozzle swirler. This led to water impingement on the combustion liner cap and body, which resulted in thermal shock and increased combustion maintenance. The latest design is a breechloaded fuel nozzlewhere water is injected

COMPRESSOR
The compressor is a seventeen-stage, axial flow type. The compressor rotor is made up of an assembly of compressor wheels and stub shafts connected by through bolts. The 1st stage wheel also includes the rotor stub shaft for the #1 bearing, the thrust bearing and the accessory gear coupling.

Inlet Guide Vanes (FT4C)

IGVs are used to control air inlet flow to the compressor during start-up and part load operation. In 1987 low camber, high-flow IGVs were introduced to all GE frame size gas turbines. The new IGVs have higher reliability due to the use of a special stainless steel alloyGTD-450, a precipitation-hardened, martensitic stainless

Figure 10. Breech-loaded fuel nozzle

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Heat rate/kJ/kWhr

11,750

Uprate Options for the MS6001 Heavy Duty Gas Turbine

Improved Airfoil Design for Higher Flow Variable Airfoil Thickness to Maintain Reliability GTD-450 for Higher Tensile Strength and Superior Corrosion Resistance Increased Output (+1.5%) Decreased Heat Rate (0.3%)
1.8

Higher Performance Airfoil Design

Compressor Blading and Coatings

Originally Rows 18 were 403+Cb with a NiCd coating and Rows 917 were 403+Cb without coating. Since 1994, Rows 12 are GTD-450, Rows 37 are 403 with a GECC1 coating and Rows 817 are 403+Cb. GECC1 (a GE proprietary corrosion resistant coating) is an aluminium slurry coating, which has a protective ceramic top layer that provides improve corrosion resistance. This new GECC1 coating can be applied at a GE service shop to existing compressor blading for all stages of the compressor. However, GECC1 cannot be applied to blades made from GTD450 stainless steel alloy.

Alternating Sresss Amplitude

1.6 1.4 (Ratio to AISI 403) 1.2 1.0 .8 .6 .4 .2 0 0 10 20 30 40 50 60 70

Variable Thickness Airfoil

GTD 450 AISI 403SS

Mean Stress (KSI)

Figure 12. High-flow IGV design improvements with GTD-450 material steelinstead of the original AISI 403SS. (See Figure 12.) These improvements include: s Increased tensile strength s High cycle fatigue resistance s Corrosion fatigue strength s Superior corrosion resistance (due to higher concentrations of chromium and molybdenum) The low camber design increases the airflow across the IGVs giving an improvement in gas turbine output and reduction in heat rate.

Stage 17 and EGV Vanes

A limited number of 6B compressor Stator 17 and EGV1 vanes have experienced high cycle fatigue or cracking. (Refer to TIL 1170-2R1.) Metallurgical analysis of distressed and cracked vanes concluded high cycle fatigue as the cause of distress. Aerodynamic excitation of stage 17 and EGV stator vanes due to flow separation results when the aft end of the compressor is heavily loaded. Aft end compressor loading increases with higher pressure ratios. A number of operational modes have been identified that further increase the loading on the vanes, which may lead to the distress experienced: s Operation during periods of cold ambient temperatures s Operation at reduced load (with closed IGV) s Operation with water/steam injection for NOx reduction or power augmentation s Low BTU gas fuel s Flow path disturbances from inner barrel counter bores 10

Increase in IGV angle (FT4M)

In 1995 the IGV angle was increased from 84 to 86 degrees, allowing slightly higher airflow through the gas turbine and giving increased gas turbine output but with a slight heat rate penalty. Increasing IGV angle will require the application of an inlet plenum scroll on single base Frame 6 gas turbines. (There is an increase in bushing wear associated with the increase in IGV angle and hence regular inspection is required. (Refer to TIL 1068-2R1.) GE Power Systems GER-4217A (12/03)
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Uprate Options for the MS6001 Heavy Duty Gas Turbine

Counter bores, located at the inner barrel splitline, have shown to be significant contributors to the high aerodynamic loading. To minimize the probability of a Stator 17 or EGV vane distress, the following configuration modifications may need to be installed with any of the CM&U uprates detailed in this GER: s New inner barrel counter bore plugs. s Control system modification to change turbine operating curves. This will limit gas turbine minimum IGV angle operation under certain low ambient and extreme operating conditions. Analysis of the unit configuration and operating parameters will allow GE to determine if the above modifications are required. GE is designing new-shrouded Stator 17 and EGV vanes to remove the risk of blade failure. These will be available in mid-2003.

Buckets
Stage 1 Buckets (FS4A)
The original stage 1 buckets (S1B) were made of IN738, a precipitation-hardened, nickelbased super alloy with a LDC coating and 13 cooling holes. IN738 was the standard material for S1B on all frame sizes in the early 1980s. The S1B was upgraded in 1987 with the introduction of Equiaxed GTD-111 material, GT-29 coating, 11 cooling holes, and a Blunt Leading Edge (BLE) airfoil section. Equiaxed GTD-111 was introduced because it had 20C improved rupture strength and was more resistant to low cycle fatigue than IN738. For a period of three years from late 1989, GE experienced several failures of first stage buckets. Many TILs were issued to customers advising them of the potential for failure together with information advising on the restricted service life of each group of buckets. GE identified all Frame 6 gas turbines shipped by both GE and its MA/BAs and which S1Bs were fitted to each gas turbine. GE embarked on an exercise to have all suspect S1Bs withdrawn from service. The failures were caused by a reduction in creep rupture strength exacerbated by accelerated oxidation attack and high bucket metal temperatures. This oxidation resulted from deterioration of the external coating and also by internal oxidation attack of the uncoated cooling holes. This oxidation contributed to local over-temperature by partial plugging of cooling holes and subsequent reduction in creep life. Several design changes to the buckets were made to eliminate risk of failure. An additional cooling hole was added to reduce bulk metal temperature (12 cooling holes) and GT-29 INPLUS coating was applied. This coating is a vacuum plasma spray, with an Aluminide coat-

TURBINE SECTION
The MS6001 Gas Turbine has a three-stage turbine; the first two stages are air-cooled with the 3rd stage uncooled. (See Figure 13.) It is an assembly of three turbine wheels, wheel spacers and the aft stub shaft, all connected with trough bolts.

Figure 13. Cross section through turbine shell

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Uprate Options for the MS6001 Heavy Duty Gas Turbine

ing on the bucket exterior and on the internal cooling-hole passages. This coating provided hot corrosion protection and high temperature oxidation resistance. The directionally solidified (DS) GTD-111 buckets were introduced in the mid-1990s. DS GTD-111 possesses an oriented grain structure that runs parallel to its major axis and contains no transverse grain boundaries. The elimination of the transverse grain boundaries results in additional creep and rupture strength. Current Frame 6 buckets are DS GTD-111 with GT-33 INPLUS coating and 16 cooling holes. The perimeter-cooled stage 1 bucket incorporates several design improvements to allow for operation at the higher firing temperature associated with the 6B Advanced Technology Uprate. (See Figure 14.) The new bucket-cooling scheme includes a series of 16 radial cooling holes located around the "perimeter" of the bucket. Thirteen of the cooling holes include "turbulators" on the internal surfaces of the cooling holes (from 0 to 80% of the bucket span) to increase the efficiency of heat transfer from the bucket metal to the cooling air. The turbulators are STEM drilled (Shaped Tube Electrochemical Machining).
6B Advanced Technology Stage 1 Bucket
BLUNT LEADING EDGE PERIMETER COOLED

The buckets also incorporate a cored or hollow shank that more effectively provides air to the 16 cooling holes. This feature allows for more consistent control of the quantity of cooling air and reduces the risk of cooling holes becoming plugged during operation. In addition to the improvements in cooling, the new bucket has a new airfoil profile. This profile has been designed with heat transfer characteristics appropriate for operation at the higher firing temperature of the 6B Advanced Technology Uprate. This included thinning of the leading edge and rotating the airfoil hub sections. With all of these improvements, the bulk metal temperature of the new first stage buckets operating at the higher firing temperature will be lower than the bulk metal temperature of the current buckets operating at the lower firing temperature. GT-33 INPLUS is now the standard S1B coating for B and E class turbines. Like GT-29 INPLUS, it is also a vacuum plasma spray coating, but offers increased resistance to through cracking. GT-29 INPLUS coating is still available for units that burn corrosive fuels.

Stage 2 Buckets (FS4B)

The stage 2 bucket (S2B) has undergone several design changes since first introduction; it was originally made from IN738 with 4 radial smooth cooling holes and no coating. In 1997 with the announcement of the Advanced Technology Uprate for the 6B, a new 7-cooling -hole design was introduced. Five out of seven holes were turbulated from 40% to 70% of their span to improve cooling of the bucketleading to reduced bulk metal temperatures, even at the higher firing temperature. At the same time, three failures of the 4-hole S2B were experienced. These failures were due

Tf Material Coating Cooling Shank

Base DS GTD-111 GT291N+ 12 Smooth Holes Meanline Radial ECM

Base +35F DS GTD-111 GT331N+ 3 Smooth/13 Turb Holes Perimeter Hollow Core

Figure 14. Stage 1 bucket GTD-111 perimeter-cooled

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to airfoil creep. TIL 1203-1R1 details failure mode and advises inspection requirements of these buckets. All 4-hole buckets are to be replaced at or before 48,000 hours of operation. The current S2B design incorporates several design improvements to allow for operation at the higher firing temperature associated with the 6B Advanced Technology Uprate and the PG6581. The material for the new stage 2 buckets continues to be IN738, however the bucket now has six radial cooling holesfour of which are turbulated from 40% to 70% of their span. (See Figure 15.) New airfoil geometry has been utilized which allows improved cooling to the trailing edge of the bucket. Both the 7-hole and 6-hole S2B include "cutter teeth" on the bucket tip shroud rails. These are designed to cut a slot in the honeycomb seal material on the stage 2 shroud block with no metal transfer to the bucket. Cutter teeth have been included on all stage 2 Frame 6 buckets manufactured since late 1995. (S3B), instead of the original U500. IN738 offers superior hot corrosion resistance than U500. Buckets now include cutter teeth similar to S2B, so that honeycomb stage 3 shrouds can be installed.

Nozzles
Stage 1 Nozzle (FS2J)
The original material used for the first stage nozzle and still used today is FSX-414. It is a cobalt-based super alloy, which has excellent oxidation, hot corrosion and thermal fatigue resistance. It requires inspection during the hot gas path inspection (HGPI @ 24,000 hrs), and is weld-repairable, which allows the nozzle to be refurbished and returned to service during future HGPIs. There have been several generations of the stage 1 nozzle (S1N). A Universal S1N was installed in the MS6001 in 1987, which allowed operation on residual fuels (ash bearing fuels) as well as fuel gas and distillate oil. The Universal S1N has now been modified. It is capable of replacing nozzles based on the older universal nozzle design as well as pre-universal nozzles operating on either conventional or heavy fuel. First time application of the universal nozzle will require a new nozzle support ring. The key modifications include these changes: s Nozzle sidewall cooling s Airfoil trailing edge film cooling holes s New impingement hole pattern on the core plug s New pressure side cooling hole pattern, s Improved inner segment spline seals s Improved sidewall seal s Addition of a nozzle inner sidewall improved hinge rail 13

Stage 3 Buckets (FS3K)

Higher firing temperature associated with the Frame 6B uprate has led to the introduction of IN738 as the material for the stage 3 bucket

Nickel base Alloy material Enhanced cooling of airfoil Contoured tip shroud for creep life improvement

Figure 15. Stage 2 bucket improved cooling (6 cooling holes) GE Power Systems GER-4217A (12/03)
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The major design change incorporated into the improved cooling, stage 1 nozzle is the addition of a more efficient film-cooling pattern. This new design incorporates a sidewall cooling hole pattern that has been relocated to promote better coverage of the most commonly distressed area on the nozzle sidewall, as determined by computer modelling and operational histories. The improved coverage pattern is achieved on current production nozzles by replacing the pressure side film holes with film cooling slots, as shown in Figure 16. The new slots are spaced more closely together and are combined with new cooling holes to the inter-vane space on the nozzle outer sidewall. The resulting improvement in exit conditions significantly increases the cooling efficiency of the airflow to the sidewall areaswithout increasing the overall airflow requirement. The hinge design originates from proven aircraft engine technology applied to today's heavy-duty gas turbines. The improved seal is created on the support lug with a new straight improved seal ridge. This results in an improved seal at the S1N/support ring interface. This seal eliminates the potential leak path due to warping and distortion sometimes associated with the older curved support lug disengaging during operation. The straight improved seal requires a redesigned shorter tangential slot on the inner sidewall support
GTD-222 vs. FSX-414 Nozzle Creep Deflection Comparison
1.2 1.0 0.8 0.6 0.4 0.2 0
Shaped Pressure Side Cooling Holes
Uprate

Spline Seal Improvement

Current

Increased Trailing Edge Hole Size

Additional Cooling Core Plug Modification

Improved Hinge

Figure 16. Stage 1 nozzle showing cooling and sealing modifications lug. This new sealcoupled with the offset of the support lugcombines to create a 'hinging' action downstream from the retaining ring along the radial plane of the nozzle. Improved inner segment sidewall spline seals reduce leakage between nozzle segments.

Stage 2 Nozzle (FS1P)

The second stage nozzle (S2N) design, originally fabricated from FSX-414 material, has been replaced by a newer nozzle design that is fabricated from creep resistant GTD-222 material. This newer, nickel-based alloy significantly reduces the downstream deflection characteristic of the older material. (See Figure 17.) The overall dimensions of the GTD-222 nozzle

FSX-414

GTD-222
10 20 30 40 50 60

Time - KHR

Figure 17. Stage 2 nozzle creep deflection comparison GE Power Systems GER-4217A (12/03)
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Uprate Options for the MS6001 Heavy Duty Gas Turbine

remain unchanged from the previous design and are applicable as either an uprate or a replacement part for units with the older nozzle. FSX-414 nozzles are subject to downstream creep deflection due to: s The cantilevered design of the nozzle s Exposure to high temperatures s Downstream loading caused by axial pressure differentials across the nozzle s Gas reaction forces. Analysis over time has shown that units experiencing downstream creep deflection require additional monitoring leading to increased maintenance and repair costs. The new GTD-222 second stage nozzle is coated with an aluminide coating to provide improved high temperature oxidation resistance. Other modifications include changes to the second stage nozzle's internal core plug. Core plug modifications allow more efficient distribution of cooling air and reduced nozzle-cooling requirements. (See Figure 18.) New tuning pins associated with this uprate and modifications to the first stage shroud blocks that include smaller cooling air orificesin combination with core plug modificationsfurther reduce cooling air requirements and result in gas turbine performance improvements. There are two configurations of S2N diaphragms (referred to as "pressurized" and "non pressurized" designs). Some customers have experienced high 1AO wheelspace temperature problems with the pressurized design, as referred to in TIL 1243-2. The pressurized design nozzle was shipped between 1997 and 2002. All future S2N diaphragms will be the non-pressurized design.

Stage 3 Nozzle (FS1R)

The third stage nozzle (S3N) was redesigned to eliminate the downstream nozzle deflection. Similar to the S2N, GTD-222 material has replaced the FSX-414 due to the superior creep resistance property. The chord length on the S3N was increased to improve the airfoils section modulus so that the bending stress level could be reduced.

Shrouds
Stage 1 Shrouds (FS2Y)
There are several design improvements available for the stage 1 shrouds (S1S). (See Figure 19.) The original material has been changed from 310SS to HR-120. The new material has both higher inherent material strength and more favourable time at temperature characteristics. New spline seals replace the original pumpkin teeth design. This dramatically reduces the leakage of compressor discharge air into the hot gas path, resulting in improved turbine performance. Figure 18. Stage 2 nozzle cooling airflow A new flexible "w" seal is also fitted between the S1S and S1N retaining ring. After a period of

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Cloth Spline Seals

W-Seal "Bus Bar" Seal

SIDE VIEW

SIDE VIEW

BOTTOM VIEW Current Shroud

Pumpkin Teeth

BOTTOM VIEW Uprate Shroud

ances between the bucket shroud tips and the casing shrouds were set based upon expected transients that tend to close the clearances. The clearance had to be large enough to allow these transients to occur without permitting contact between the bucket tip and the shroud. As a result, the steady state running clearance is typically larger than it needs to be from an efficiency standpoint. To provide relatively tight clearances during steady state operation, honeycomb seals will allow contact between the bucket tip and the casing shrouds. Strips of honeycomb material made of a hightemperature, oxidation-resistant alloy are brazed between the teeth on the casing shrouds. "Cutter teeth" on the leading edge of the shrouded 2nd and 3rd stage bucket tip rails will "cut" the honeycomb material away when contact occurs during transients. This produces steady-state running clearances that are on an absolute basisno larger than the difference between the steady state and the transient clearances. The effective clearance is actually tighter than the absolute clearance since the resulting groove in the honeycomb provides a tighter labyrinth seal than could be obtained with solid materials. Honeycomb shrouds also reduce performance degradation by maintaining tighter clearances throughout the life of the shroud. (See Figure 20.)

Figure 19. Improved stage 1 shrouds service or after overhaul/repair, the S1N may be slightly distorted. The flexible "W" seal accommodates for this distortion and again prevents leakage of CD air into the HGP.

2nd and 3rd Stage Shrouds (FS2T and FS2U)

Honeycomb seals are designed to reduce leakage associated with hot gases that flow around the tips of the bucketsthereby improving both heat rate and output. In the past, clear-

Figure 20. Stage 2 shroud with honeycomb sealing GE Power Systems GER-4217A (12/03)
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Additional Sealing Modifications
To improve overall performance of the gas turbine in both output and heat rate, GE has developed a series of sealing technologies available for retrofit in all the heavy-duty gas turbine frame sizes. Some of these seals are installed on the current production models. labyrinth seal. The brush seals also maintain a pressure gradient across the bristle path while minimizing leakage through the bristle pack. A brush seal can easily accommodate misalignment normally not tolerated by labyrinth designs.

High Pressure Packing Seal (FS2V)

The HPP is designed to regulate the flow of compressor discharge air between the stationary inner barrel and the compressor rotor aft stub shaft into the turbine first-forward wheelspace. The clearance between the seals on the compressor discharge casing/inner barrel and the compressor rotor aft stub shaft controls the flow through this area. Some of this bypass airflow is required for cooling the turbine first-forward wheelspace; however, the current flow is excessive. Controlling this bypass airflow to the minimum levels required for cooling will increase the amount of air available to perform work in the cycle. The original design was for a labyrinth seal, which can experience severe rubs during transient operating conditions. Replacing this labyrinth seal with a rub-tolerant brush seal controls this bypass airflow, leading to improved gas turbine performance (output and heat rate). (See Figure 21.) Long-term performance degra-

Brush Seals
Brush seals are available in two locations on the MS6001. Each brush seal option uses brush seals that have been specially designed for the application to take into account the locations operating conditions. Brush seals are comprised of a pack of fine metallic wires (or bristles) held in a frame. Simple designs have been used for basic sealing applications for a number of years. Recently, advanced designs have become prevalent in aircraft engine and industrial gas turbines. In these applications, brush seals are typically used as replacements or additions to labyrinth seals that are not maintaining their desired sealing levels, especially after a number of transient radial excursions. The bristles are simply displaced during the excursion and, then, return to their position once the transient condition has passed. Labyrinth seals would rub under similar excursions introducing higher leakages beneath the

Figure 21. High pressure packing brush seal GE Power Systems GER-4217A (12/03)
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dation is also reduced as the brush seal maintains HPP seal clearances after many starts/stops and operating hours. Clearances between static and rotating components allow the combustion gas to leak past the airfoil section of the buckets. These clearances are influenced by transient thermal growth, rotor alignment, rotor sag, and turbine shell out-of-roundness. The abradable coating compensates for these factors to minimize the required clearance. This reduces bucket tip leakage, which leads to an improvement in turbine section efficiency. Prior to application of the abradable coating, the shroud block is grit-blasted to remove the 6-mil of hard coating typically applied by the shroud block manufacturer. The abradable coating is a 40-mil layer of GT-50. The chemical composition of this coating is CoNiCrAlY with polyester and is suitable for use with a nontipped blade (i.e., a blade that does not require any type of hard/abrasive coating). This material has proven to have the required properties for both abradability and service life at the "E" class firing temperature.

Stage 2 Nozzle Interstage Brush Seal (FS2Z)

The 2nd stage nozzle/diaphragm assembly contains a radial high-low labyrinth seal that reduces flow leakage across the diaphragm and the turbine rotor from stage 1 aft into the stage 2 forward wheelspace. The interstage brush seal further reduces this leakage and hence reduces the cooling air (purge air) flow requirements into the stage 1 aft wheelspace. (See Figure 22.) Reduction of cooling airflow (reduction in losses) allows more air to flow through the combustion system, therefore improving overall gas turbine performance. Cooling airflow to the 2nd stage forward wheelspace will be reduced, but this flow is currently larger than required.

Abradable Coatings 1st Stage Shroud (FS6A)

The stage 1 shroud blocks can be coated with an abradable coating on the inner circumference. The abradable coating is designed to wear away in the event of a bucket tip rub. It allows tighter clearances between the bucket and shroud leading to performance improvements.

PG6571B
This model was only available as a retrofit package. All MS6001 gas turbines shipped before 1999 can be uprated to this rating. It includes many of the sealing modifications discussed

Figure 22. Stage 2 nozzle interstage brush seal GE Power Systems GER-4217A (12/03)
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above, a speed increase and new HGP components, which allows the unit to operate at 2077F firing temperature. available for all earlier models providing that the components listed in Table 5 are installed. An additional 0.2% output increase is achieved over the 2077F firing temperature.

Gas Turbine Firing Temperature

With the introduction of the Type B MS6001 in 1981, the firing temperature reference for the MS6001 was set at 2020F. After performance data collection and analysis by GE performance engineers of a wide selection of PG6541 gas turbines and remodelling of GEs "Cycledeck" program, it was determined that the true firing temperature reference should be 2042F. In 1996 the MS6001B firing temperature reference was changed from 2020F to 2042F, to reflect these findings. When GE offers the +35F firing temperature uprate, this refers to +35F above the true firing temperature reference of 2042Fwhich provides Advanced Technology Uprate gas turbines with a firing temperature of 2077F. There has been some confusion in sales literature which quotes +35F above the original reference temperature of 2020F for an uprate to 2055F. This should be 2077F as advised above. Current production models (PG6581) have a slightly higher firing temperature reference of 2084F. This higher firing temperature is now

Speed Increase (FP4D/E)

GE introduced a speed increase for the MS6001 in 1995, to increase the mass airflow through the turbine and hence increase output. This increased the speed from 5104 rpm to 5133 rpm. More recently a further speed increase to 5163 rpm was introduced. All earlier Frame 6 gas turbines are suitable for this increase in speed, giving 0.5% increased output (5133 to 5163), providing that the new perimeter-cooled S1Bs and the 6- or 7-hole S2Bs are fitted. To achieve this uprate the complete load gearbox is normally replaced.

PG6581B - New Unit Configuration

In 1997, GEs French manufacturing associate, which is now part of GEEPE, decided to uprate their current production MS6001 (the PG6551B model with 5114 rpm turbine speed). Output and efficiency improvements were achieved by: s Increasing firing temperature to 2084F/1140C
Source Book

Components Required for Increase in Firing Temperature to 2084F (FT4P)

Table 5. All components required to operate at a higher firing temperature

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s Reducing leakages in the hot gas path s Reducing inlet and exhaust pressure losses These improvements were introduced in three steps to achieve the PG6BEV2 model rating. See Table 6 for each of the improved features. After the acquisition of GEs French manufacturing associate in June 1999, engineering teams in the U.S. and France pooled ideas and developed the current PG6581B rating. The final configuration of the PG6581B is a harmonization of the PG6BEV2 developed in France and the PG6571B (developed as part of GEs CM&U uprate program in the U.S.). See Figure 23 and Figure 24 for the final PG6581B configuration. The major differences to the PG6571B model are s 13th compressor stage extraction for stage 2 nozzle cooling. (See Figure 25.) s High performance exhaust diffuser. (See Figure 26.) Redesigning the MS6001 achieved an increase of 6% in output and a decrease of 0.6% in heat rateresulting in improved competitiveness for the MS6001 in todays deregulated market. See Figure 27 for a performance comparison between the PG6561B and the PG6581B models. First shipment of the new unit PG6581B was in September 2000. See Table 7 for the current installed fleet of 61BEV2 and 6581B units.

LIFE EXTENSION
Maintenance
The maintenance schedule for the MS6001 is based on publication GER-3620 (Heavy-Duty Gas Turbine Operating and Maintenance Considerations). This advises on the types of maintenance required, the time between main-

OPTION Speed Increase Increase in speed to 5163 rpm Pressure losses reduction Vertical inlet High performances exhaust diffuser Leakages reduction Outer sealing strips on S1 nozzle Chordal hinge on S1 nozzle Braided seal on stage 1 shroud HPP Seal improvement (brush seals) Increase in firing temperature Increase in firing temperature (1140C) S1 Bucket GTD-111 DS, turbulators S2 Bucket GTD-111, turbulators S1 Nozzle improved cooling S2 Nozzle new engine 13th stage bleed and improved shroud cooling Combustion Dry low NOx using natural gas Dry low NOx using distillate Combustion Life Extendor

6561B X X

6BEV X X X

6BEV2 X X X X X X X X X X X X X X X

Table 6. AGT PG656B/6BEV/6BEV2 improved features GE Power Systems GER-4217A (12/03)

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Figure 23. PG6581B configuration (PG6BEv2 and PG6571B harmonization)

6581 Upgraded Components

Firing Temp. Increase Stage 1 Shroud Stage 1 & 2 Buckets Exhaust System

Vertical Inlet

Combustion System 13th Stage Extraction

Improved Sealing HPPS with Brush Seal

Stage 1 Nozzle

Figure 24. PG6581B upgraded components

Stage 13 Extraction
Compressor Discharge Casing
Bleed Belt Incorporated into Casing

Extraction System Pipework

Turbine Casing
Bosses for Pipe Flange Attachment

Second Stage Nozzle Cooling with Radiation Shield

Figure 25. 13th compressor stage extraction for stage 2 nozzle cooling

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Exhaust Diffuser

nents and can be integrated into the gas turbines current configuration. As new technology parts are installed, completion of the uprate can be scheduled and controls modified to achieve the required performance and/or maintenance objectives.

Controls Upgrades
Frame 6 gas turbines have been shipped with SPEEDTRONICTM Mark II, Mark IV and Mark V control systems. All these systems can be upgraded to the latest Mark V or Mark VI control system. Control system upgrades offer much improved gas turbine reliability with: s Digital control s Triple Modular Redundancy (TMR) s Protection against loss of availability of spares Full details of Mark V and Mark VI control systems can be found in GER 3658D (SPEEDTRONIC Mark V Gas Turbine Control System) and GER 4193 (SPEEDTRONIC Mark VI Turbine Control System).

Improved performances in reducing exhaust pressure losses Minimized design change:

same shaft line level and length same generator interface same exhaust casing and struts

Two configurations available

lateral and vertical exhaust

Figure 26. High performance exhaust diffuser tenance and all the factors that affect maintenance scheduling. Table 8 shows the maintenance intervals for Frame 6 for the different firing temperatures and combustion systems. These intervals are based on a reference condition of gas fuel, No SI or WI, and base load operation.

Installing Individual Parts

Customers may order components as individual partsand not the complete uprateto suit their own turbine component service life, and scheduled overhaul requirements. All uprate parts are interchangeable with existing compo-

MS6001 Uprate Experience

GE has successfully uprated seven MS6001s to the PG6571B model rating to date. The MS6001B uprate experience is listed in Table 9.

PG6561B* Output Heat Rate (LHV) Pressure Ratio Exhaust Flow Exhaust Temperature 39,640 kW 11295 kJ/kWh 12.03 : 1 525 t/h 531C

PG6581B** 42,100 kW 11227 kJ/kWh 12.2 : 1 530 t/h 548C

* ISO conditions, Methane, STD combustor, 4/2.5 inlet/exhaust pressure drop ** ISO conditions, Methane, STD combustor, 2.55/2.52 inlet/exhaust pressure drop

Figure 27. Performance data comparison between PG6561B and PG6581B model

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Country France Spain Spain France France Spain Wisconsin/USA Wisconsin/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Philadelphia/USA Ex Works 5/28/99 10/14/99 11/18/99 1/19/00 1/31/00 5/29/00 8/29/00 9/14/00 11/30/00 11/30/00 11/30/00 10/11/00 10/11/00 10/20/00 6/13/01 6/26/01 7/16/01 7/25/01 8/21/01 9/12/01 Model 6BEV2 6BEV2 6BEV2 6BEV2 6BEV2 6BEV2 6BEV2 6BEV2 6581B 6581B 6581B 6581B 6581B 6581B 6581B 6581B 6581B 6581B 6581B 6581B Comments DLN 1 (gas only) STD (dual fuel) STD (dual fuel) DLN 1 (gas only) DLN 1 (gas only) STD (dual fuel) DLN 1 (dual fuel) DLN 1 (dual fuel) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only) DLN 1 (gas only)

Over 70 PG6581B units sold to date

Table 7. PG6BEV2 and PG6581B Fleet

Many other customers have chosen to install current MS6001 new technology components as single spare part replacements, when existing components reach the end of their service life. This is done with a view to increasing firing temperature when all components in Table 5 have been installed. The first MS6001B uprate to 2077F/1136C was successfully completed in spring 1997 at the Midset, Cogen site. Because this was the first uprate of its kind, extensive testing was completed to monitor compressor and turbine performances. Successful testing of five units occurred between 19971998, resulting in average performance improvements better than expected. Uprates on differently rated MS6001s also have

been completed, including several on the more recent PG6551B and PG6561B models.

SUMMARY
GE has an uprate package available for all Frame 6 turbines in the field. These uprates can be done during scheduled outages on a piece-meal basis or all at the same time, depending on when existing hardware is life expire. GE would be happy to provide detailed technical proposal for owners of GE Frame 6 gas turbines and establish performance improvements for those specific turbines. If the gas turbine is installed in Combined Cycle (CC), Cogen, or Combined Heat and Power (CHP), GE can also advise on the impact to the steam cycle, from performing these uprates.

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Summary of Recommended Combustion Inspection Intervals With and Without CL Extendor
Frame Size for Combustion Type 6541/51/61B (2042F) Standard DLN
800 12,000 12,000 NA 12,000 12,000 6,000 8,000 8,000 8,000 4,000 800 24,000 NA 24,000 NA 24,000 24,000 12,000 16,000 16,000 16,000 8,000
Service Factor

6571/81B (20722084F) Standard DLN

800 NA NA NA NA NA NA NA NA NA NA 800 NA 24,000 24,000 NA 24,000 24,000 12,000 16,000 16,000 16,000 8,000 ref 1.0 NA 1.0 1.0 2.0 1.5 1.5 1.5 3.0
Service Factor Service Factor

Non CL-Extendor
Fired Starts Factored Hours with standard T/P Gas, no inj. (dry) GAS, Ext. L-L (dry) Gas, w/ stm inj. Gas, w/stm aug. Gas, w/water inj. Dist, no inj. (dry) Dist, w/stm inj. Dist, w/stm aug. Dist, w/water inj. 400 12,000 12,000 4,000 NA 3,000 2,000 2,667 NA NA 1,333 400 24,000 NA 24,000 8,000 NA 6,000 4,000 5,333 NA NA 2,667
Service Factor

400 NA NA NA NA NA NA NA NA NA NA 400 NA 24,000 24,000 8,000 NA 6,000 4,000 5,333 NA NA 2,667

Service Factor

ref 1.0 NA 1.0 1.0 2.0 1.5 1.5 1.5 3.0

Service Factor

ref 1.0 3.0 NA 4.0 6.0 4.5 NA NA 9.0

Service Factor

CL-Extendor
Fired Starts Factored Hours with standard T/P* Factored Hours* with advanced T/P (Gas/Dry) Gas, no inj. (dry) GAS, Ext. L-L (dry) Gas, w/stm inj. Gas, w/stm aug. Gas, w/water inj. Dist, no inj. (dry) Dist, w/stm inj. Dist, w/stm aug. Dist, w/water inj.
Service Factor

ref

ref

1.0 NA 1.0 1.0 2.0 1.5 1.5 1.5 3.0

1.0 3.0 NA 4.0 6.0 4.5 NA NA 9.0

ref 1.0 3.0 NA 4.0 6.0 4.5 NA NA 9.0

NOTES: 1. 24,000 is the goal for CL-Extendor which is expected to be validated from field experience.

Table 8. Maintenance intervals

Country USA USA USA USA USA USA USA USA AIM UK UK UK Mexico Spain Description PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B PG6001 +35 Degree Uprate MS6001B CM&U Date 1997 1997 1997 2001 2001 2002 2002 2003 2003 2003 2003 2003 2003 2003/2004

Table 9. MS6001B full uprate experience list (firing temperature +35F)

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Uprate Options for the MS6001 Heavy Duty Gas Turbine

List of Figures
Figure 1 Figure 2 Figure 3a Figure 3b. Figure 4 Figure 5a Figure 5b Figure 5c Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Cross section of MS6001 Gas Turbine Cross section through combustion system Slot-cooled liner with TBC applied Thermal barrier coating Full Nimonic-263 transition piece uprate with cloth seals Cross section through CL-Extendor New aft bracket arrangement Cloth seals for transition pieces NOx emission levels at 15% O2 (ppmvd) Cross section of DLN-1 combustion system Combustion cover with steam injection nozzles Effects of steam injection on output and heat rate Breech loaded fuel nozzle Effects of water injection on output and heat rate High-flow IGV design improvements with GTD-450 material Cross section through turbine section Stage 1 bucket GTD-111 perimeter-cooled Stage 2 bucket improved cooling (6 cooling holes) Stage 1 nozzle showing cooling and sealing modifications Stage 2 nozzle creep deflection comparison Stage 2 nozzle cooling airflow Improved Stage 1 shrouds Stage 2 shroud with honeycomb sealing High pressure packing brush seal Stage 2 nozzle interstage brush seal PG6581B configuration (PG6BEV2 and PG6571B harmonization) PG6581B upgraded components 13th compressor stage extraction for stage 2 nozzle cooling High performance exhaust diffuser Performance comparison between PG6561B and PG6581B model

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Uprate Options for the MS6001 Heavy Duty Gas Turbine

List of Tables
Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 MS6001 performance history Delta changes in gas turbine output as a result of each CM&U package Delta changes in gas turbine heat rate as a result of each CM&U package Changes to exhaust energy for each CM&U All components required to operate at a higher firing temperature (+35F) AGT PG6561B/6BEV/6BEV2 improved features PG6BEV2 and PG6581B fleet Maintenance intervals MS6001B full uprate experience list (firing temperature: +35F)

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