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Gas Turbine Technology Update

This presentation provides an update on gas turbine technology, specifically focusing on GE Frame 7F compressors, R-0 blades, and P-Cut blades. It discusses the potential risks and losses associated with these components and highlights the importance of effective risk management.

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Gas Turbine Technology Update

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  1. Gas Turbine Technology Update • Presentation to EEI Loss Prevention / Risk Mgt Committee Gas Turbine Issues Fall 2006 • EEI Task Force Committee Bob Edel, Jim Mintel EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  2. Gas Turbine Technology UpdateOutline: • Gas Turbines * GE Frame 7F Compressors * R-0 Blades * P Cut Blades • Summary EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  3. Gas Turbine Technology Update INTRODUCTION • Technical issues are not uncommon in the world of Gas Turbines. • All units of all manufacturers have undergone improvements to their original design. • The push for higher efficiencies and advances in technologies and metallurgy keep this industry on the cutting edge. • 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

  4. Gas Turbine Technology Update • Goal: To raise awareness of Utility Loss Prevention professionals to Machinery Breakdown perils. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  5. 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. • 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

  6. Gas Turbine Technology Update • 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. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  7. Gas Turbine Technology UpdateWhat seems to be the issue? EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  8. Gas Turbine Technology Update What type of exposure are we looking at ? What’s it worth? Issue Number of losses (10yrs) Actual Loss Potential Loss R-0 Blades At least 10 losses 17 million 23 million Mid compr 11 losses 10 million 21 million Hook fit 10 + losses 6.5 million 17 million Trans Pieces 20+ losses $7M $16M Tiles 10+ $2M $7M Compressor IGV Control 3 losses 3 million 25+ million EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  9. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  10. Gas Turbine Technology Update • During this meeting, we will discuss some of the carrier concerns regarding the GE (7) FA, particularly the R0 P-Cut Blade. • According to GE, there are approximately 1,000 operating units (including 6F and 9F). 416 have P-Cut blades. • Of these 416: 314 are 7F, 10 are 6F and 92 are 9F • What is an R0 blade ? Why the concern? Why now ? EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  11. Gas Turbine Technology UpdateWhat is an R0 Blade ? • As described by GE in GER3434D EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  12. Gas Turbine Technology UpdateWhy the concern? P-Cut Failure occurred in June 06 • The event occurred June 6, 2006 to a 7FA+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

  13. Gas Turbine Technology UpdateJust One ?? • Only one loss occurred due to failure of this P-Cut blade. This is considered to be a major event in the insurance industry. • Working with GE, the owner and GE have concluded a Root Cause Analysis. • 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. • At this time there is no long term fix; a new design is currently in the works. • Instruction has been published by GE as to what owners need to do. • 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

  14. Gas Turbine Technology UpdateCompressor Damage EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  15. Gas Turbine Technology UpdateCooling Passage debris EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  16. Gas Turbine Technology UpdateGE 7FA R-0 History EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  17. Press. Ratio13.5:1 15:1 15:1 15.5:1 Firing Temp. Class (F)2300 2350 2400 2420 Compressor Stages18 Turbine Stages3 Combustion SystemCan-Annular (14 chambers) Gas Turbine Technology UpdateMS7001F Gas Turbine Evolution(up to 7FA +e) 7F PG7191 7FA PG7221 7FA+ PG7231 7FA+e PG7241 EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  18. Gas Turbine Technology UpdateFrom GER3950C EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  19. Gas Turbine Technology Update7FA+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

  20. Gas Turbine Technology UpdateSnowflake Compressor EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  21. Gas Turbine Technology Update“Standard” design R-0 blades started experiencing problems which began to mount • R-0 blade liberation in several units • 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) • R-0 and R-1 rubs led to blade tip liberation EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  22. Gas Turbine Technology UpdateGE Frame 7FA/9FA – Compressor problems (list not current) Site/Customer Frame Date Comments Not known 9FA April 2001 Compressor failure/R0 Far East 9FA June 2001 Cracks UK 9FA June 2002 Cracks Confidential 9FA+e Feb, 2 2005 Compressor failure/R0 – 4.261 FH Confidential 9FA+e Feb, 6 2005 R0 cracks and rubbing – 1.384 FH Confidential 9FA+e Feb, 19 2005 Compressor failure/R0 – 12.000FH UK 9FA+e Feb/March 2005 Compressor failure/R0 Confidential 9FA+e March 19, 2005 Rubbing – 7.858 FH UK 9FA+e March 2005 Compressor failure/Ops Confidential 9FA+e March 2005 Compressor failure/FOD Israel 9FA+e Feb/Mar 2005 R1 rubbing Spain 9FA+e April 29, 2005 R1 Rubbing – 20% blades damaged Japan 7FA+e 2001 Compressor failure USA 7FA+e Aug 2002 Cracks USA 7FA+e Jan 2003 Compressor failure/R0 USA 7FA+e Feb 2003 Cracks USA 7FA+e Feb 2003 Cracks USA 7FA HF Oct 2004 Compressor failure/R0 HF USA 7FA+e Feb 1, 2005 Compressor failure/R0 FOD USA 7FA+e March 2005 R1 Rubbing USA 7FA+e March 2005 R1 Rubbing Mexico 7FA+e April 19, 2005 Compressor failure/R0 EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  23. Gas Turbine Technology UpdateGE High Flow R-0 blades • GE introduced Inconnel (IN 718) R-0 blades as a High Flow R-0 model in 2004 • This design was short lived and has been subsequently pulled from all machines EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  24. Gas Turbine Technology Update Inconel High Flow R0 Distress RCA • Issue • Unit with Inconel High Flow R0 blades discovered with • R0 liberation and collateral damage: • Base load trip on 10/27/04 • High Exhaust Temperature, High Vibration Trip • Inlet inspection shows extensive IGV/R0/S0 damage • R0 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 R0 blade discovered liberated at root • Inlet inspection of Sister Unit shows R0 indication at root • Engineering/MPE reviewing high flow R0 NPI • Recommendations for units with blades installed: • Remove R0 blades and install Undercut GTD 450 R0 blade set at BOP outage • Remove upper half NUV S0/S1’s and install original design • Recommend units planning High Flow R0 installation to delay outage until RCA complete or install Undercut GTD 450 R0 blade set R0 Fracture Surface EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  25. Gas Turbine Technology UpdateP-Cut introduced EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  26. Gas Turbine Technology UpdateP-Cut R-0 Overview • 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 JUN06. • The P-Cut fleet leader had approximately 25,700 fired hours and 700 fired starts as of July 06 • 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

  27. Gas Turbine Technology UpdateR0 Blade Erosion Upgrade Options P-Cut Blade Root • Hardware Description • P-cut Blade • Inlet case removal for R0 blade change out • Erosion tolerant Baseline P-cut P-cut was touted as a blade that reduces root stress from the LE enabling the blade to tolerate erosion Root Stress Profiles EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  28. Gas Turbine Technology UpdateEnhanced R-0 Blade design EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  29. Gas Turbine Technology UpdateEnhanced R-0 Blade design EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  30. Gas Turbine Technology UpdateP-Cut Failure occurred in June 06 The event occurred June 6, 2006 to a 7FA+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

  31. Gas Turbine Technology UpdateR-0 Design History Summary • The R(0) Compressor Row continues to pose reliability problems for 7FA/9FA operators. • TIL 1303R1 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

  32. Gas Turbine Technology UpdateWhat has been done ? GE has been very proactive in their communication to owners and carriers. • RCA, evolution of findings • WebEx’s with clients and carriers • Carrier Meetings • Unit inspections, etc EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  33. Gas Turbine Technology UpdateWhat is the status of the 7F fleet? • The following is a summary of information provided by GE: EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  34. Gas Turbine Technology UpdateP-Cut R0 Inspection Findings Frame Size 6FA 7FA 9FA P-Cut fleet 10 314 92 # Inspected 2 185 15 Cracked 0 74 0 0% 40% 0% Compressor Configuration Unflared Flared Flared Comp-IGV Config Cambered Cambered Uncambered 7FA P-Cut Fleet 67 17 230 # Inspected 56 12 117 Cracked 12 4 58 21% 33% 50% EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  35. Gas Turbine Technology UpdateP-Cut R0 UT Re-Inspections • 128 units passed the initial P-Cut R0 UT Inspection • 35 of these units have been re-inspected in accordance with GE reinspection intervals • Of these 35 units, 9 units were found with crack indications (27%) EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  36. Gas Turbine Technology UpdateWhat is GE recommending ? EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  37. Gas Turbine Technology UpdateP-Cut R-0 blade Care(Original & Enhanced Designs) Require Ongoing UT inspections • Continue p-cut inspections and re-inspections… TIL forthcoming • Fleet inspection experience and RCA supports distinguishing inspection intervals between flared and unflared configurations for initial inspection • Until further notice, 9FA p-cuts should follow inspection intervals previously communicated EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  38. Gas Turbine Technology UpdateStandard R-0 blade Care(Non-P-Cut) • Require existing inspections and care for root leading edge damage • TIL 1509 F-Class Front End Compressor Inspections • TIL 1389 F Class Erosion Inspections (non-p-cut units) • TIL 1518 Maintenance & Inspection Requirements for GT Air Inlet Systems TIL 1509 Inspection EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  39. Gas Turbine Technology UpdateWhat are the implications ? • Operations • Testing • Maintenance • Inspection • Procedures • TrainingThis is what Insurance companies will want to verify to maintain their comfort level. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

  40. Gas Turbine Technology UpdateP-Cut R0 Summary • Continued inspections of P-Cuts at initial inspection intervals for new or un-inspected blades, and re-inspection intervals for previously cleared blades • GE R0 production returned to original, standard non-P-Cut. Plans include eliminating the P-Cut R0 from the 7FA fleet • On-going testing to characterize vibratory stress level drivers to develop options for increasing R0 robustness • 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

  41. Gas Turbine Technology UpdateSummaryOEM Guidelines should be followed • 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. • 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

  42. Gas Turbine Technology UpdateSummary • Avoiding loss is all of our common goals. • Recognizing the risk and mitigating the contributing factors should minimize the probability of failure. • GE has provided interim recommendations to avoid reoccurrence. • GE is now recommending their standard R-0 blade be installed for the short term if R-0s require replacement. • Awareness and compliance will minimize the probability of similar failure • Ultimately, GE will provide a long term solution. EEI Loss Prevention Task Force : Bob Edel - LIU, Jim Mintel - Aegis

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