Gas Turbine Technology Update n Presentation to EEI Loss Prevention / Risk Mgt Committee Gas Turbine Issues Fall 2006 n EEI Task Force Committee Bob Edel, Jim Mintel EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 1
Gas Turbine Technology Update Outline: n Gas Turbines * GE Frame 7 F Compressors * R-0 Blades * P Cut Blades n Summary EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 2
Gas Turbine Technology Update INTRODUCTION n Technical issues are not uncommon in the world of Gas Turbines. n All units of all manufacturers have undergone improvements to their original design. n The push for higher efficiencies and advances in technologies and metallurgy keep this industry on the cutting edge. n Proper “Management of Change” is generally the key to successful, reliable, loss free operation. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 3
Gas Turbine Technology Update n Goal: To raise awareness of Utility Loss Prevention professionals to Machinery Breakdown perils. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 4
Gas Turbine Technology Update * It should be duly noted that the insurance community recognizes OEM’s as the technical subject matter experts for their units and that they are diligent in developing any necessary improvements as units evolve. n Furthermore, the insurance community does not claim to, and is not attempting to, supersede any recommendations made by the OEM’s. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 5
Gas Turbine Technology Update n The Purpose of this presentation is to raise the awareness of non- operating personnel involved in managing risk By working and communicating together with owners, insurance companies, and OEM’s, Utility Owners can greatly assist in obtaining the most favorable insurance programs. Owner/Insured OEM Insurance Carrier EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 6
Gas Turbine Technology Update What seems to be the issue? GE Siemens Alstom Mitsubishi The following concerns do not necessarily apply to all units manufactured by this OEM Compressor R-0 Blades Segmented Vane pack - Hook Fit B 2 Compressor Mid Compressor Power Turbine Peened vs. Un. Peened V. xx – Tiles Power Turbine Trans Pieces Row 3 Turbine Blade IGV Control Power Turbine SEV Lance EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis Power Turbine 1 st stage turbine blade lock-up 7
Gas Turbine Technology Update What type of exposure are we looking at ? What’s it worth? Issue R-0 Blades Number of losses (10 yrs) At least 10 losses Mid compr Hook fit 11 losses 10 + losses Actual Loss 17 million Potential Loss 23 million 10 million 21 million 6. 5 million 17 million Trans Pieces 20+ losses $7 M $16 M Tiles $2 M $7 M 3 million 25+ million 10+ Compressor IGV Control 3 losses EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 8
EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 9
Gas Turbine Technology Update n During this meeting, we will discuss some of the carrier concerns regarding the GE (7) FA, particularly the R 0 P-Cut Blade. n According to GE, there approximately 1, 000 operating units (including 6 F and 9 F). 416 have P-Cut blades. n Of these 416: 314 are 7 F, 10 are 6 F and 92 are 9 F n What is an R 0 blade ? Why the concern? EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis Why now ? 10
Gas Turbine Technology Update What is an R 0 Blade ? n As described by GE in GER 3434 D EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 11
Gas Turbine Technology Update Why the concern? P-Cut Failure occurred in June 06 n The event occurred June 6, 2006 to a 7 FA+e flared compressor unit. n The unit underwent a base-load trip for high vibration and experienced significant compressor damage. n The unit’s P-Cut blades experienced 17. 5 K fired hours and 45 fired starts. n This unit had one R-0 P-Cut blade liberate and an additional 7 R-0 blades were found distressed (with cracks). n The blade failure was an “original” (Mark I) design. (No enhancements such as the larger fillet radius, dovetail relief cut for fretting, etc) EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 12
Gas Turbine Technology Update Just One ? ? n Only one loss occurred due to failure of this P-Cut blade. This is considered to be a major event in the insurance industry. n Working with GE, the owner and GE have concluded a Root Cause Analysis. n The analysis has revealed that the current blade is susceptible to failure due to point of contact stresses. Additional stress modeling tools, taken from the aero division, have indicated unacceptable levels of stress exist in the P-Cut design. n At this time there is no long term fix; a new design is currently in the works. n Instruction has been published by GE as to what owners need to do. n GE has indicated all current R-0 designs are acceptable for near-term operation EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 13
Gas Turbine Technology Update Compressor Damage EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 14
Gas Turbine Technology Update Cooling Passage debris EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 15
Gas Turbine Technology Update GE 7 FA R-0 History EEI Loss Prevention Task Force : Bob Edel LIU, Jim Mintel - Aegis 16
Gas Turbine Technology Update MS 7001 F Gas Turbine Evolution (up to 7 FA +e) 7 F PG 7191 7 FA PG 7221 Compressor Stages 15. 5: 1 2400 2420 18 Turbine Stages 15: 1 2350 Firing Temp. Class (F) 2300 7 FA+e PG 7241 15: 1 Press. Ratio 13. 5: 1 7 FA+ PG 7231 3 Combustion System Can-Annular (14 chambers) EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 17
Gas Turbine Technology Update From GER 3950 C EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 18
Gas Turbine Technology Update 7 FA+e R-0 evolution • 7191 “ 7 F” Standard R-0 Blade introduced in 1988 with un-flared compressor • 7241 “ 7 FA+e” introduced in 1996 • Standard R-0 Blade introduced into the flared or “Snowflake” Compressor introduced in 2000 • R-0 P-Cut Blade Introduced in 2003 (both flared and un-flared compressors) • R-0 Enhanced P-Cut Blade Introduced in 2005 (both flared and un-flared compressors) EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 19
Gas Turbine Technology Update Snowflake Compressor EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 20
Gas Turbine Technology Update “Standard” design R-0 blades started experiencing problems which began to mount n R-0 blade liberation in several units n Blade liberation to R-0 on flared compressors only. (Failures attributed to Corrosion, Erosion & Impact Damage initiating a defect which propagates to a crack and ultimately failure due to HCF) n R-0 and R-1 rubs led to blade tip liberation EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 21
Gas Turbine Technology Update GE Frame 7 FA/9 FA – Compressor problems (list not current) Site/Customer Frame Date Comments Not known Far East UK Confidential UK Confidential Israel Spain 9 FA 9 FA+e 9 FA+e 9 FA+e April 2001 June 2002 Feb, 2 2005 Feb, 6 2005 Feb, 19 2005 Feb/March 2005 March 19, 2005 March 2005 Feb/Mar 2005 April 29, 2005 Compressor failure/R 0 Cracks Compressor failure/R 0 – 4. 261 FH R 0 cracks and rubbing – 1. 384 FH Compressor failure/R 0 – 12. 000 FH Compressor failure/R 0 Rubbing – 7. 858 FH Compressor failure/Ops Compressor failure/FOD R 1 rubbing R 1 Rubbing – 20% blades damaged Japan USA USA Mexico 7 FA+e 7 FA+e 7 FA HF 7 FA+e 2001 Aug 2002 Jan 2003 Feb 2003 Oct 2004 Feb 1, 2005 March 2005 April 19, 2005 Compressor failure Cracks Compressor failure/R 0 HF Compressor failure/R 0 FOD R 1 Rubbing Compressor failure/R 0 EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 22
Gas Turbine Technology Update GE High Flow R-0 blades n GE introduced Inconnel (IN 718) R-0 blades as a High Flow R-0 model in 2004 n This design was short lived and has been subsequently pulled from all machines EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 23
Gas Turbine Technology Update Inconel High Flow R 0 Distress RCA Issue • Unit with Inconel High Flow R 0 blades discovered with R 0 liberation and collateral damage: • Base load trip on 10/27/04 • High Exhaust Temperature, High Vibration Trip • Inlet inspection shows extensive IGV/R 0/S 0 damage • R 0 blades had approx. 3400 hours and 50 starts • Outage initiated to begin RCA investigation & Repair Work Status • RCA Teams on site (GE CTS, Engineering) • 1 R 0 blade discovered liberated at root • Inlet inspection of Sister Unit shows R 0 indication at root • Engineering/MPE reviewing high flow R 0 NPI • Recommendations for units with blades installed: • Remove R 0 blades and install Undercut GTD 450 R 0 blade set at BOP outage • Remove upper half NUV S 0/S 1’s and install original design • Recommend units planning High Flow R 0 installation to delay outage until RCA complete or install Undercut GTD 450 R 0 blade set R 0 Fracture Surface EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 24
Gas Turbine Technology Update P-Cut introduced EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 25
Gas Turbine Technology Update P-Cut R-0 Overview n The P-Cut R-0 compressor blade was introduced in 2003 and was installed on 416 units worldwide. * Approx 285 units remain since inspections began in JUN 06. n The P-Cut fleet leader had approximately 25, 700 fired hours and 700 fired starts as of July 06 n The P-Cut R-0 blade was introduced to afford an additional margin regarding erosion, corrosion and impact damage as well as removing the need for erosion inspections IAW TIL 1389. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 26
Gas Turbine Technology Update R 0 Blade Erosion Upgrade Options Hardware Description 1. P-cut Blade • Inlet case removal for R 0 blade change out • Erosion tolerant Baseline P-Cut Blade Root P-cut Root Stress Profiles P-cut was touted as a blade that reduces root stress from the LE enabling the blade to tolerate erosion EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 27
Gas Turbine Technology Update Enhanced R-0 Blade design EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 28
Gas Turbine Technology Update Enhanced R-0 Blade design EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 29
Gas Turbine Technology Update P-Cut Failure occurred in June 06 The event occurred June 6, 2006 to a 7 FA+e flared compressor unit. The unit underwent a base-load trip for high vibration and experienced significant compressor damage. The unit’s P-Cut blades experienced 17. 5 K fired hours and 45 fired starts. This unit had one R-0 P-Cut blade liberate and an additional 7 R-0 blades were found distressed (with cracks). The blade failure was an “original” (Mark I) design. (No enhancements such as the larger fillet radius, dovetail relief cut for fretting, etc) EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 30
Gas Turbine Technology Update R-0 Design History Summary n The R(0) Compressor Row continues to pose reliability problems for 7 FA/9 FA operators. n n n TIL 1303 R 1 in 2001 regarding impact of erosion on leading edge first alerted industry. Change in materials from Custom 450 to IN 718 did not work. Addition of P-Cut to blade root to relieve stress in airfoil lead edge did not work. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 31
Gas Turbine Technology Update What has been done ? GE has been very proactive in their communication to owners and carriers. • RCA, evolution of findings • Web. Ex’s with clients and carriers • Carrier Meetings • Unit inspections, etc EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 32
Gas Turbine Technology Update What is the status of the 7 F fleet? n The following is a summary of information provided by GE: EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 33
Gas Turbine Technology Update P-Cut R 0 Inspection Findings Frame Size 6 FA 7 FA 9 FA P-Cut fleet # Inspected Cracked 10 2 0 0% 314 185 74 40% 92 15 0 0% Unflared Cambered Flared Uncambered 67 56 12 21% 17 12 4 33% 230 117 58 50% Compressor Configuration Comp-IGV Config 7 FA P-Cut Fleet # Inspected Cracked EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 34
Gas Turbine Technology Update P-Cut R 0 UT Re-Inspections n 128 units passed the initial P-Cut R 0 UT Inspection 35 of these units have been re-inspected in accordance with GE reinspection intervals n Of these 35 units, 9 units were found with crack indications (27%) n EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 35
Gas Turbine Technology Update What is GE recommending ? EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 36
Gas Turbine Technology Update P-Cut R-0 blade Care (Original & Enhanced Designs) Require Ongoing UT inspections n Continue p-cut inspections and re-inspections… TIL forthcoming n Fleet inspection experience and RCA supports distinguishing inspection intervals between flared and unflared configurations for initial inspection n Until further notice, 9 FA p-cuts should follow inspection intervals previously communicated EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 37
Gas Turbine Technology Update Standard R-0 blade Care (Non-P-Cut) n Require existing inspections and care for root leading edge damage n TIL 1509 F-Class Front End Compressor Inspections n TIL 1389 F Class Erosion Inspections (non-p-cut units) TIL 1509 Inspection n TIL 1518 Maintenance & Inspection Requirements for GT Air Inlet Systems EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 38
Gas Turbine Technology Update What are the implications ? n Operations n Testing n Maintenance n Inspection n Procedures n Training This is what Insurance companies will want to verify to maintain their comfort level. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 39
Gas Turbine Technology Update P-Cut R 0 Summary n Continued inspections of P-Cuts at initial inspection intervals for new or un-inspected blades, and reinspection intervals for previously cleared blades n GE R 0 production returned to original, standard non. P-Cut. Plans include eliminating the P-Cut R 0 from the 7 FA fleet n On-going testing to characterize vibratory stress level drivers to develop options for increasing R 0 robustness n Accompanying testing, GE is evaluating options to enhance the non-p-cut design. Once developed and validated, GE will provide further information EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 40
Gas Turbine Technology Update Summary OEM Guidelines should be followed n GE is making the recommendations, it’s their technology. Insurance companies are attempting to understand the relative risk and how well the process is being implemented/managed. n The more insurance companies understand about what you are doing, the more comfortable we are in assuming risk EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 41
Gas Turbine Technology Update Summary n Avoiding loss is all of our common goals. n Recognizing the risk and mitigating the contributing factors should minimize the probability of failure. n GE has provided interim recommendations to avoid reoccurrence. n GE is now recommending their standard R-0 blade be installed for the short term if R-0 s require replacement. n Awareness and compliance will minimize the probability of similar failure n Ultimately, GE will provide a long term solution. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis 42
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