GE Frame 5 Service Manual
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37 A .2) Example 2 – Hot Gas Path Factored Starts Calculation A 7E.03 user has accumulated operating data for the past year of operation. This data shows number of trips from part, base, and peak load, as well as peaking-fast starts. The user would like to calculate the total number of factored starts in order to plan the next HGP outage. Figure 43 is used to calculate the total number of factored starts as shown below. Operational history: Normal cycles Peaking starts with normal shutdowns Peaking starts with trips Normal starts with trips Total Part load cycles, N A35 01 541 Base load cycles, N B25 4235 66 Peak load cycles, N P40 0010 50 To t a l Tr i p s 5. 50% load (aT1 = 6.5), T1 = 5 + 1 = 6 6. B ase load (a T2 = 8), T2 = 35 + 2 = 37 7. P eak load (a T3 = 10), T3 = 10 Additional Cycles Peaking-fast starts, F = 7 From the starts-based criteria, the total number of factored starts (FS) and actual starts (AS) is determined from Figure 43 . Maintenance Factor ==FS AS= 3.6558 157 = 0.5 · 41 + 66 + 1.3 · 50 + 3.5 · 7 + (6.5 - 1) 6 + (8 - 1)\ 37 + (10 - 1) 10 = 558 AS = NA + NB + NP = 41 + 66 + 50 = 157 FS = 0.5NA + NB + 1.3NP + PsF + n i=1 (aTi - 1) Ti GE Power & Water | GER-3620M (00015001200140018 )
38 B) Examples – Combustion Maintenance Interval Calculations (reference Figures 40 and 41) DLN 1 Peak Load with Power Augmentation +50F Tfire Increase Factored Hours = Ki * Afi * Api * ti = 34.5 Hours Hours Maintenance Factor = (34.5/6)5 .8 Where Ki =2.34 Max(1.0, exp(0.34(3.50-1.00))) WetAfi =1.00 Natural Gas FuelApi =2.46 exp(0.018(50)) Peak Loadti =6.0 Hours/Start Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 17.4 Starts Starts Maintenance Factor = (17.4/1)17 .4 Where Ki =2.77 Max(1.0, exp(0.34(3.50-0.50))) WetAfi =1.00 Natural Gas FuelAti =1.00 No Trip at LoadApi =1.57 exp(0.009(50)) Peak LoadAsi =4.0 Peaking StartNi = 1.0 Considering Each Start 3.5% Steam Augmentation Peaking Start Natural Gas Fuel 6 Hours/Start Wet Control Curve Normal Shutdown (No Trip) Standard Combustor Base Load on Crude Oil No Tfire Increase Factored Hours = Ki * Afi * Api * ti = 788 .3 Hours Hours Maintenance Factor = (788.3/220)3 .6 Where Ki =1.43 Max(1.0, exp(1.80(1.00-0.80))) DryAfi =2.50 Crude Oil, Std (Non-DLN)Api =1.00 Base Loadti =220.0 Hours/Start Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 5.9 Starts Starts Maintenance Factor = (5.9/1)5 .9 Where Ki =2.94 Max(1.0, exp(1.80(1.00-0.40))) DryAfi =2.00 Crude Oil, Std (Non-DLN)Ati =1.00 No Trip at LoadApi =1.00 Base LoadAsi =1.00 Normal StartNi = 1.0 Considering Each Start 1.0 Water/Fuel Ratio Normal Start Crude Oil Fuel 220 Hours/Start Dry Control Curve Normal Shutdown (No Trip) DLN 2 .6 Base Load on Natural Gas with Trip @ Load No Tfire Increase Factored Hours = Ki * Afi * Api * ti = 168.0 Hours Hours Maintenance Factor = (168.0/168)1 .0 Where Ki =1.00 No InjectionAfi =1.00 Natural Gas FuelApi =1.00 Base Loadti =168.0 Hours/Start Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 2.6 Starts Starts Maintenance Factor = (2.6/1)2 .6 Where Ki =1.00 No InjectionAfi =1.00 Natural Gas FuelAti =2.62 0.5+exp(0.0125*60) for TripApi =1.00 Base LoadAsi =1.00 Normal StartNi = 1.0 Considering Each Start No Steam/Water Injection Normal Start Natural Gas Fuel 168 Hours/Start Dry Control Curve Trip @ 60% Load DLN 2 .6 Base Load on Distillate No Tfire Increase Factored Hours = Ki * Afi * Api * ti = 943.8 Hours Hours Maintenance Factor = (943.8/220)4 .3 Where Ki =1.72 Max(1.0, exp(1.80(1.10-0.80))) DryAfi =2.50 Distillate Fuel, DLNApi =1.00 Base Loadti =220.0 Hours/Start Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 5.3 Starts Starts Maintenance Factor = (5.3/1)5 .3 Where Ki =3.53 Max(1.0, exp(1.80(1.10-0.40))) DryAfi =1.50 Distillate Fuel, DLNAti =1.00 No Trip at LoadApi =1.00 Base LoadAsi =1.00 Normal StartNi = 1.0 Considering Each Start 1.1 Water/Fuel Ratio Normal Start Distillate Fuel 220 Hours/Start Dry Control Curve Normal Shutdown (No Trip) DLN 2 .6 Peak Load on Natural Gas with Peaking Start +35F Tfire Increase Factored Hours = Ki * Afi * Api * ti = 12.5Hours Hours Maintenance Factor = (12.5/4)3 .1 Where Ki =1.67 Max(1.0, exp(0.34(3.50-2.00)))Afi =1.00 Natural Gas FuelApi =1.88 exp(0.018(35)) Peak Loadti =4.0 Hours/Start Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 12.8 Starts Starts Maintenance Factor = (12.8/1)12 .8 Where Ki =2.34 Max(1.0, exp(0.34(3.50-1.00))) DryAfi =1.00 Natural Gas FuelAti =1.00 No Trip at LoadApi =1.37 exp(0.009(35)) Peak LoadAsi =4.0 Peaking StartNi = 1.0 Considering Each Start 3.5% Steam Augmentation Peaking Start Natural Gas Fuel 4 Hours/Start Dry Control Curve Normal Shutdown (No Trip) DLN 1 Combustor Base Load on Distillate No Tfire Increase Factored Hours = Ki * Afi * Api * ti = 1496.5 Hours Hours Maintenance Factor = (1496.5/500)3 .0 Where Ki =1.20 Max(1.0, exp(1.80(0.90-0.80))) DryAfi =2.50 Distillate Fuel, DLN 1Api =1.00 Part Loadti =500.0 Hours/Start Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 3.7 Starts Starts Maintenance Factor = (3.7/1)3 .7 Where Ki =2.46 Max(1.0, exp(1.80(0.90-0.40))) DryAfi =1.50 Distillate Fuel, DLNAti =1.00 No Trip at LoadApi =1.00 Part LoadAsi =1.00 Normal StartNi = 1.0 Considering Each Start 0.9 Water/Fuel Ratio Normal Start Distillate Fuel 500 Hours/Start Dry Control Curve Normal Shutdown (No Trip)
39 Reliability: Probability of not being forced out of service when the unit is needed — includes forced outage hours (FOH) while in service, while on reserve shutdown and while attempting to start normalized by period hours (PH) — units are %.Reliability = (1-FOH/PH) (100) FOH = total forced outage hours PH = period hours Availability: Probability of being available, independent of whether the unit is needed – includes all unavailable hours (UH) – normalized by period hours (PH) – units are %: Availability = (1-UH/PH) (100) UH = total unavailable hours ( forced outage, failure to start, scheduled maintenance hours, unscheduled maintenance hours) PH = period hours Equivalent Reliability: Probability of a multi-shaft combined-cycle power plant not being totally forced out of service when the unit is required includes the effect of the gas and steam cycle MW output contribution to plant output – units are %. Equivalent Reliability = GT FOH = Gas Turbine Forced Outage Hours GT PH = Gas Turbine Period Hours HRSG FOH = HRSG Forced Outage Hours B PH = HRSG Period Hours ST FOH = Steam Turbine Forced Outage Hours ST PH = Steam Turbine Period Hours B = Steam Cycle MW Output Contribution (normally 0.30) Equivalent Availability: Probability of a multi-shaft combined-cycle power plant being available for power generation — independent of whether the unit is needed — includes all unavailable hours — includesthe effect of the gas and steam cycle MW outputcontribution to plant output; units are %. Equivalent Availability = GT UH = Gas Turbine Unavailable Hours GT PH = Gas Turbine Period Hours HRSG UH = HRSG Total Unavailable Hours ST UH = Steam Turbine Unavailable Hours ST PH = Steam Turbine Period Hours B = Steam Cycle MW Output Contribution (normally 0.30) Operating Duty Definition: Duty Service Factor Fired Hours/Start Stand-by < 1% 1 to 4 Peaking 1% – 17% 3 to 10 Cycling 17% – 50% 10 to 50 Continuous > 90% >> 50 MTBF–Mean Time Between Failure: Measure of probability of completing the current run. Failure events are restricted to forced outages (FO) while in service – units are operating hours. MTBF = OH/FO OH = Operating Hours FO = Forced Outage Events from a Running (On-line) Condition Service Factor: Measure of operational use, usually expressed on an annual basis – units are %. SF = OH/PH x 10 0 OH = Operating Hours on an annual basis PH = Period Hours (8760 hours per year) ST FOH HRSG FOH GT FOH ST PH B PH GT PH + B + x 1001 – GT UH ST UH HRSG UH ST PH GT PH GT PH + B + x 100 [[]1 – [ ] C) Definitions GE Power & Water | GER-3620M (00015001200140018 )
40 D) Estimated Repair and Replacement Intervals (Natural Gas Only) Repair/replace intervals reflect current production hardware, unless otherwise noted, and operation in accordance with manufacturer specifications. Consult previous revisions of GER 3620 or other unit- specific documentation for estimated repair/replacement intervals of previous generation gas turbine models and hardware. Consult your GE service representative for further information. MS3002K Parts Repair IntervalReplace Interval (Hours) Replace Interval (Starts) Combustion Liners CI4 (CI) 4 (CI) Transition Pieces CI (1)4 (CI) 4 (CI) Stage 1 Nozzles (HGPI) (2)4 (HGPI) 2 (HGPI) Stage 2 Nozzles (HGPI) (2)4 (HGPI) 4 (HGPI) Stage 1 Shrouds (HGPI) (2)4 (HGPI) 4 (HGPI) Stage 2 Shrouds (HGPI) (2)4 (HGPI) 4 (HGPI) Stage 1 Buckets – (3)2 (HGPI)(3)2 (HGPI) Stage 2 Buckets (HGPI) (2)4 (HGPI) 4 (HGPI) Note: Repair/replace intervals reflect current production hardware, un\ less otherwise noted, and operation in accordance with manufacturer specifications. They represent initial re\ commended intervals in the absence of operating and condition experience. For factored hours and starts of the\ repair intervals, refer to Figure 39. CI = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval (1) Repair interval is every 2 combustion inspection intervals. (2) Repair interval is every 2 hot gas path inspection intervals with the ex\ ception of 1st stage nozzle start-based repair interval where repair interval is one inspection inte\ rval. (3) No repair required. GE approved repair at 24,000 factored hours may exte\ nd replace interval to 72000 factored hours. Figure D-1 . Estimated repair and replacement intervals MS5001PA / MS5002C,D Parts Repair Interval Replace Interval (Hours) Replace Interval (Starts) Combustion Liners CI4 (CI) 3 (CI) Transition Pieces CI (1)4 (CI) 4 (CI)(5) Stage 1 NozzlesHGPI(2)4 (HGPI) 2 (HGPI) Stage 2 Nozzles HGPI (2) 4 (HGPI) 4 (HGPI) Stage 1 Shrouds HGPI (2) 4 (HGPI) 4 (HGPI) Stage 2 Shrouds – (3)4 (HGPI) 4 (HGPI) Stage 1 Buckets – (4)2 (HGPI)(4) 2 (HGPI) Stage 2 Buckets HGPI (2)4 (HGPI) 4 (HGPI) Note: Repair/replace cycles reflect current production hardware, unles\ s otherwise noted, and operation in accordance with manufacturer specifications. They represent initial re\ commended intervals in the absence of operating and condition experience. For factored hours and starts of the\ repair intervals, refer to Figure 39. CI = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval (1) Repair interval is every 2 combustion inspection intervals. (2) Repair interval is every 2 hot gas path inspection intervals with the ex\ ception of 1st stage nozzle start- based repair interval where repair interval is one inspection interval. (3) No repair required (4) No repair required. GE approved repair at 24,000 factored hours may exte\ nd replace interval to 72000 factored hours (5) 6 replace intervals (starts-based) for DLN and lean head end (LHE) u\ nits. Figure D-2 . Estimated repair and replacement intervals 6B .03 Repair Interval Replace Interval (Hours) Replace Interval (Starts) Combustion Liners Cl4 (Cl) 4 (Cl) / 5 (Cl) (1) CapsCl4 (Cl) 5 (Cl) Transition Pieces Cl4 (Cl) 4 (Cl) / 5 (Cl) (1) Fuel NozzlesCl2 (Cl) 2 (Cl) / 3 (Cl)(4) Crossfire TubesCl1 (CI) 1 (CI) Crossfire Tube Retaining Clips CI 1 (CI) 1 (CI) Flow Divider (Distillate) Cl 3 (Cl) 3 (Cl) Fuel Pump (Distillate) Cl 3 (Cl) 3 (Cl) Stage 1 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 2 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 1 Shrouds HGPI 3 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI 3 (HGPI) 4 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 4 (HGPI) Stage 1 Buckets HGPI 3 (HGPI) (2)3 (HGPI) Stage 2 Buckets HGPI 3 (HGPI) (3)4 (HGPI) Stage 3 Buckets HGPI3 (HGPI) 4 (HGPI) Note: Repair/replace cycles reflect current production (6B.03) hardw\ are, unless otherwise noted, and operation in accordance with manufacturer specifications. They represent initial\ recommended intervals in the absence of operating and condition experience. For factored hours and starts of \ the repair intervals, refer to Figure 39. Cl = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval (1) 4 (CI) for non-DLN / 5 (CI) for DLN (2) 3 (HGPI) with strip and recoat at first HGPI (3) 3 (HGPI) for current design only. Consult your GE Energy representativ\ e for replace intervals by part number. (4) 2 (CI) for non-DLN / 3 (CI) for DLN Figure D-3 . Estimated repair and replacement intervals
41 7E .03 (7) Repair IntervalReplace Interval (Hours) Replace Interval (Starts) Combustion Liners Cl 3 (Cl) / 5 (Cl) (1) 5 (Cl) Caps Cl 3 (Cl) 5 (Cl) Transition Pieces Cl 4 (Cl) / 6 (Cl) (5) 6 (Cl) Fuel Nozzles Cl 2 (Cl) / 3 (Cl) (6) 3 (Cl) Crossfire Tubes Cl 1 (Cl) 1 (Cl) Crossfire Tube Retaining Clips CI 1 (CI) 1 (CI) Flow Divider (Distillate) Cl 3 (Cl) 3 (Cl) Fuel Pump (Distillate) Cl 3 (Cl) 3 (Cl) Stage 1 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 2 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI 3 (HGPI) 4 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 4 (HGPI) Stage 1 Buckets HGPI3 (HGPl) (2)(3) 3 (HGPI) Stage 2 Buckets HGPI3 (HGPl) (4) 4 (HGPI) Stage 3 Buckets HGPI3 (HGPl) 4 (HGPI) Note: Repair/replace intervals reflect current production (7121(EA)\ or 7E.03) hardware, unless otherwise noted, and operation in accordance with manufacturer specifications. They rep\ resent initial recommended intervals in the absence of operating and condition experience. For factored hours\ and starts of the repair intervals, refer to Figure 39. Cl = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval (1) 3 (CI) for DLN / 5 (CI) for non-DLN (2) Strip and Recoat is required at first HGPI to achieve 3 HGPI replace i\ nterval. (3) Uprated 7E machines (2055 Tfire) require HIP rejuvenation at first\ HGPI to achieve 3 HGPI replace interval. (4) 3 (HGPI) interval requires meeting tip shroud engagement criteria at p\ rior HGP repair intervals. Consult your GE service representative for details. (5) 4 (CI) for DLN / 6 (CI) for non-DLN (6) 2 (CI) for DLN / 3 (CI) for non-DLN (7) Also applicable to 7121(EA) models. Figure D-4 . Estimated repair and replacement intervals 9E .03 (6) Repair Interval Replace Interval (Hours) Replace Interval (Starts) Combustion Liners Cl 3 (Cl) / 5 (Cl) (1) 5 (Cl) Caps Cl 3 (Cl) 5 (Cl) Transition Pieces Cl 4 (Cl) / 6 (Cl) (4) 6 (Cl) Fuel Nozzles Cl 2 (Cl) / 3 (Cl) (5) 3 (Cl) Crossfire Tubes Cl 1 (Cl) 1 (Cl) Crossfire Tube Retaining Clips CI 1 (CI) 1 (CI) Flow Divider (Distillate) Cl 3 (Cl) 3 (Cl) Fuel Pump (Distillate) Cl 3 (Cl) 3 (Cl) Stage 1 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 2 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 1 Shrouds HGPI 3 (HGPI) 3 (HGPI) Stage 2 Shrouds HGPI 3 (HGPI) 4 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 4 (HGPI) Stage 1 Buckets HGPI3 (HGPl) (2) 3 (HGPI) Stage 2 Buckets HGPI3 (HGPl) (3) 4 (HGPI) Stage 3 Buckets HGPI3 (HGPl) 4 (HGPI) Note: Repair/replace intervals reflect current production (9171(E))\ hardware, unless otherwise noted, and operation in accordance with manufacturer specifications. They represe\ nt initial recommended intervals in the absence of operating and condition experience. For factored hours an\ d starts of the repair intervals, refer to Figure 39. Cl = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval (1) 3 (CI) for DLN / 5 (CI) for non-DLN (2) Strip and Recoat is required at first HGPI to achieve 3 HGPI replace i\ nterval. (3) 3 (HGPI) interval requires meeting tip shroud engagement criteria at p\ rior HGP repair intervals. Consult your GE service representative for details. (4) 4 (CI) for DLN / 6 (CI) for non-DLN (5) 2 (CI) for DLN / 3 (CI) for non-DLN (6) Applicable to non-AGP units only Figure D-5 . Estimated repair and replacement intervals GE Power & Water | GER-3620M (00015001200140018 )
42 6F .03 Repair IntervalReplace Interval (Hours) Replace Interval (Starts) Combustion Liners CI2 (CI) 2 (CI) Caps CI3 (CI) 2 (CI) Transition Pieces CI3 (CI) 2 (CI) Fuel Nozzles CI2 (CI) 2 (CI) Crossfire Tubes CI1 (CI) 1 (CI) Crossfire Tube Retaining Clips CI 1 (CI) 1 (CI) End Covers CI 4 (CI) 2 (CI) Stage 1 Nozzles HGPI2 (HGPI) 2 (HGPI) Stage 2 Nozzles HGPI2 (HGPI) 2 (HGPI) Stage 3 Nozzles HGPI3 (HGPI) 3 (HGPI) Stage 1 Shrouds HGPI2 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI2 (HGPI) 2 (HGPI) Stage 3 Shrouds HGPI3 (HGPI) 3 (HGPI) Stage 1 Buckets HGPI3 (HGPI) 2 (HGPI) Stage 2 Buckets HGPI3 (HGPI) 2 (HGPI) Stage 3 Buckets HGPI2 (HGPI) 3 (HGPI) Note: Repair/replace intervals reflect current production (6F.03 DLN \ 2.6) hardware, unless otherwise noted, and operation in accordance with manufacturer specifications. They rep\ resent initial recommended intervals in the absence of operating and condition experience. For factored hours\ and starts of the repair intervals, refer to Figure 39. CI = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval Figure D-6 . Estimated repair and replacement intervals 7F .03 Repair IntervalReplace Interval (Hours) Replace Interval (Starts) Combustion Liners Cl 2 (Cl) 2 (Cl) Caps Cl 2 (Cl) 2 (Cl) Transition Pieces Cl 2 (Cl) 2 (Cl) Fuel Nozzles Cl 2 (Cl) 2 (Cl) Crossfire Tubes Cl 1 (Cl) 1 (Cl) Crossfire Tube Retaining Clips CI 1 (CI) 1 (CI) End Covers CI 2 (Cl) 2 (Cl) Stage 1 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 2 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGPI) Stage 1 Buckets HGPI 3 (HGPI) (2) 2 (HGPI)(4) Stage 2 Buckets HGPI3 (HGPI) (1) 3 (HGPI)(1) Stage 3 Buckets HGPI 3 (HGPI) (3) 3 (HGPI) Note: Repair/replace intervals reflect current production (7F.03 DLN \ 2.6 24k Super B and non-AGP) hardware, unless otherwise noted, and operation in accordance with manufacturer sp\ ecifications. They represent initial recommended intervals in the absence of operating and condition experien\ ce. For factored hours and starts of the repair intervals, refer to Figure 39. Cl = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval (1) 3 (HGPI) for current design. Consult your GE service representative fo\ r replacement intervals by part number. (2) GE approved repair procedure required at first HGPI for designs withou\ t platform cooling. (3) GE approved repair procedure at 2nd HGPI is required to meet 3 (HGPI) \ replacement life. (4) 2 (HGPI) for current design with GE approved repair at first HGPI. 3\ (HGPI) is possible for redesigned bucket with platform undercut and cooling modifications. Figure D-7 . Estimated repair and replacement intervals 7F .04 Repair Interval Replace Interval (Hours) Replace Interval (Starts) Combustion Liners Cl 2 (Cl) 2 (Cl) Caps Cl 2 (Cl) 2 (Cl) Transition Pieces Cl 2 (Cl) 2 (Cl) Fuel Nozzles Cl 2 (Cl) 2 (Cl) Crossfire Tubes Cl 1 (Cl) 1 (Cl) Crossfire Tube Retaining Clips CI 1 (CI) 1 (CI) End Covers CI 2 (Cl) 2 (Cl) Stage 1 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 2 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 3 Nozzles HGPI 4 (HGPI) 4 (HGPI) Stage 1 Shrouds HGPI 3 (HGPI) 3 (HGPI) Stage 2 Shrouds HGPI 3 (HGPI) 3 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGP) Stage 1 Buckets HGPI3 (HGPI) 3 (HGPI) Stage 2 Buckets HGPI3 (HGPI) 3 (HGPI) Stage 3 Buckets HGPI3 (HGPI) 3 (HGPI) Note: Repair/replacement intervals reflect current production (7F.04 \ DLN 2.6) hardware, unless otherwise noted, and operation in accordance with manufacturer specifications. T\ hey represent initial recommended intervals in the absence of operating and condition experience. For fact\ ored hours and starts of the repair intervals, refer to Figure 39. Cl = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval Figure D-8 . Estimated repair and replacement intervals 7FB .01 Repair IntervalReplace Interval (Hours) Replace Interval (Starts) Combustion Liners Cl 2 (Cl) 3 (Cl) Caps Cl 2 (Cl) 3 (Cl) Transition Pieces Cl 2 (Cl) 3 (Cl) Fuel Nozzles Cl 2 (Cl) (1) 3 (Cl)(1) Crossfire Tubes Cl 1 (Cl) 1 (Cl) Crossfire Tube Retaining Clips CI 1 (CI) 1 (CI) End Covers CI 3 (Cl) 3 (Cl) Stage 1 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 2 Nozzles HGPI 1 (HGPI) 1 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGP) Stage 1 Buckets HGPI1 (HGPI) 1 (HGPI) Stage 2 Buckets HGPI3 (HGPI) 3 (HGPI) Stage 3 Buckets HGPI3 (HGPI) 3 (HGPI) Note: Repair/replace cycles reflect current production (7251(FB) DL\ N 2.0+ extended interval) hardware, unless otherwise noted, and operation in accordance with manufacturer sp\ ecifications. They represent initial recommended intervals in the absence of operating and condition experien\ ce. For factored hours and starts of the repair intervals, refer to Figure 39. Cl = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval (1) Blank and liquid fuel cartridges to be replaced at each CI Figure D-9 . Estimated repair and replacement intervals
43 9F .03 Repair IntervalReplace Interval (Hours) Replace Interval (Starts) Combustion Liners Cl 2 (Cl) 3 (Cl) Caps Cl 2 (Cl) 3 (Cl) Transition Pieces Cl 2 (Cl) 3 (Cl) Fuel Nozzles Cl 2 (Cl) (1) 3 (Cl)(1) Crossfire Tubes Cl 1 (Cl) 1 (Cl) Crossfire Tube Retaining Clips CI 1 (CI) 1 (CI) End Covers CI 2 (Cl) 3 (Cl) Stage 1 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 2 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGPI) Stage 1 Buckets HGPI 2 (HGPI) (2) 2 (HGPI)(4) Stage 2 Buckets HGPI 3 (HGPI)(5) 3 (HGPI)(3) Stage 3 Buckets HGPI3 (HGPI) (5) 3 (HGPI) Note: Repair/replace intervals reflect current production (9F.03 DLN \ 2.6+) hardware, unless otherwise noted, and operation in accordance with manufacturer specifications. They rep\ resent initial recommended intervals in the absence of operating and condition experience. For factored hours\ and starts of the repair intervals, refer to Figure 39. Cl = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval (1) Blank and liquid fuel cartridges to be replaced at each CI (2) 2 (HGPI) for current design with GE approved repair at first HGPI. 3\ (HGPI) is possible for redesigned bucket with platform undercut and cooling modifications. (3) Recoating at 1st HGPI may be required to achieve 3 HGPI replacement life\ . (4) GE approved repair procedure at 1 (HGPI) is required to meet 2 (HGPI)\ replacement life. (5) GE approved repair procedure is required to meet 3 (HGPI) replacement \ life. Figure D-10 . Estimated repair and replacement intervals 9F .05 Repair Interval Replace Interval (Hours) Replace Interval (Starts) Combustion Liners CI4 (CI) 4 (CI) Caps CI4 (CI) 4 (CI) Transition Pieces CI4 (CI) 4 (CI) Fuel Nozzles CI2 (Cl) (1)2 (CI)(1) Crossfire Tubes CI1 (Cl) 1 (Cl) Crossfire Tube Retaining Clips CI 1 (CI) 1 (CI) End Covers CI4 (CI) 4 (CI) Stage 1 Nozzles HGPI1 (HGPI) 1 (HGPI) Stage 2 Nozzles HGPI2 (HGPI) 2 (HGPI) Stage 3 Nozzles HGPI3 (HGPI) 3 (HGPI) Stage 1 Shrouds HGPI2 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI2 (HGPI) 2 (HGPI) Stage 3 Shrouds HGPI3 (HGPI) 3 (HGPI) Stage 1 Buckets HGPI1 (HGPI) (2)1 (HGPI)(2) Stage 2 Buckets HGPI1 (HGPI)(2)1 (HGPI)(2) Stage 3 Buckets HGPI1 (HGPI)(2)1 (HGPI)(2) Note: Repair/replace intervals reflect current production (9F.05) ha\ rdware, unless otherwise noted, and operation in accordance with manufacturer specifications. They represe\ nt initial recommended intervals in the absence of operating and condition experience. For factored hours an\ d starts of the repair intervals, refer to Figure 39. CI = Combustion Inspection Interval HGPI = Hot Gas Path Inspection Interval (1) Blank and liquid fuel cartridges to be replaced at each CI Figure D-11 . Estimated repair and replacement intervals GE Power & Water | GER-3620M (00015001200140018 )
44 Compressor 15th, 16th, 17th Stag e Compressor 0-6th Stage 24.5° 24.5° 24.5° 24.5° 99.5° 204.5° 9.8° 100.5° 170.2° 10.5° 100.5° 160.5° 9.73° 189.73° 12° 102° 155° 24.5° 1st Stg. LE1st Stg. TE2nd Stg. LE2nd Stg. TE3r d Stg. LE- Turbine Primary Inspection Access (Normal Inspection) Secondary Inspection Access (Additional Stators and Nozzles) Figure E-1 . Borescope inspection access locations for 6F machines Compressor 14th, 15th, 16th Stag e Compressor 0-5th Stage 25° 25° 25° 66° 13° 15° 151° 66° 62°130° 64° 39° 25° 1st Stg. LE1st Stg. TE2nd Stg. LE2nd Stg. TE3r d Stg. LE-T urbine Primary Inspection Access (Normal Inspection) Secondary Inspection Access (Additional Stators and Nozzles) Figure E-2 . Borescope inspection access locations for 7F and 9F machines E) Borescope Inspection Ports
45 F) Turning Gear/Ratchet Running Guidelines Scenario Turning Gear (or Ratchet) Duration Following Shutdown: Case A.1 – Normal. Restart anticipated for >48 hours Until wheelspace temperatures
46 G) B/E- and F-class Gas Turbine Naming Class PlatformModel DesignationPrior model seriesPrior model number Prior names F-class 6F - MS6001(FA)6101(FA) 6FA.01 6FA 6F.03 6111(FA) 6FA.03 6FA+e - --6F Syngas- 7F - MS7001(FA)7221(FA) 7FA.01 7FA - 7231(FA) 7FA.02 7FA+ 7F.03 7241(FA) 7FA.03 7FA+e 7F.04 - 7FA.04 - - MS7001(FB) 7251(FB) 7FB.01 - - --7F Syngas- 9F - MS9001(FA)9311(FA) 9FA.01 9FA - 9331(FA) 9FA.02 9FA+ 9F.03 9351(FA) 9FA.03 9FA+e - MS9001(FB)9371(FB) 9FB.01 - - - 9FB.02 - 9F.05 - 9FB.03 - Figure G-1 . F-class gas turbine naming Class Platform Model DesignationPrior model seriesPrior model number Prior names B/E-class 6B - MS6001(B)6521(B) - - 6531(B) - - 6541(B) - - 6551(B) - - 6561(B) - - 6571(B) - 6B.03 6581(B) - - - 6B PIP 7E - MS7001(EA)7111(EA) - - 7121(EA) - 7E.03 - 7EA PIP 9E - MS9001(E)9151(E) - - 9161(E) - 9E.03 9171(E) - 9E.03 - 9E PIP 9E.03 - 9E AGP - -9E Syngas Figure G-2 . B/E-class gas turbine naming