GE Innovation Forum 2015 BRANDMAKER | 1

GE Innovation Forum 2015The future of Work in Korea: A new strategy for growth

GE Power & WaterPower Generation Session : Maintenance... And your long term Success

Life after COD…

2

XOperational challenges

Х Higher operating cost due to due to fuel HV variance … $320k per year

Х Missed opportunity due to system inflexibility … $400K per year (200 starts)

As designed• Sold in $/kW• Meet COD MW/HR• Ideal processes• Assumed profile

Configuration challenges

Х Higher maintenance cost due to due DSS operation… $20-40k per hot start

Х Cycle losses (degradation) due to system inflexibility… $2MM per year (2% HR)

X

As running• Competes daily• Different profiles• Higher start costs• Degraded assets

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N&C P-Test condition...EOH ≠ FFH correction condition

Test Condition : ~700 FFH = ~1700EOH

ITB Requirement: 300 fired hour allowance for New & Clean before correction

ITB Response:"If the unit equivalent operating hours exceeds 300 hours from first firing of gas turbine, the unit performance shall be corrected to new and clean condition based on the performance and efficiency degradation curve... "

EOH Calculation:

ITB required Commissioning Schedule:

OperatingHour

Numberof Starts

Numberof Trips

Factored Fired Hours

Equivalent Operating Hours

(= 1 EOH) (=20 EOH) (=150 EOH) FFH Cum EOH CumInitial Firing 4hr 1start 4 4.00 24 24

Steam Blowing 240hr 10start 240 244 440 464Initial Load Test 24hr 1start 24 268 44 508Reliability Run 380hr 1start 380 648 400 908

Full Load Rejection Test 4hr 2starts 2trips 4 652 344 1252

Overspeed Test 6hr 1start 1trip 6 658 176 1428

Misc operation during start-up 24hr 3start 1trip 24 682 234 1662

Performance Test 1st 4hr 1starts 4 686 24 1686Performance Test 2nd 4hr 1starts 4 690 24 1710

(Normal Operating Hour) + XNumberofStart150EOH/trip X NumberofTripsandloadrejection

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N&C P-Test condition...EOH ≠ FFH correction condition

% HR

True Evaluation difference

FFH vs EOH

0.5% HR gap

EOH BasedCondition

FFH-BasedCondition Hours

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Life CycleConsiderations?

How $$$ are lost during Life Cycle...

So what is the value of 1% in terms of dollars?

Availability Operational Flexibility Maintenance duration/interval

Reliability Forced Outage Rate Proper Equipment coverage

Degradation of Performance New & Clean corrections Actual versus Planned

Typical KPI Metrics

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What is 1% worth?

500 MW CCPP w/ Gas @ $12/MMBTU & $100/Mw-Hr

Availability/Reliability Revenue Loss of $4.38MM/Yr

HR degradation Additional fuel cost ~$2.0 MM/Yr

Output degradation Revenue Loss of ~$3.0 MM/Yr

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Multi-YearAgreements

Capital Parts ComponentsCombustion & Hot Gas Path components Fuel Nozzles Cap Assembly Unibody (Liner and TP) Buckets Nozzles Shrouds & NFPS

Periodic Inspection, Repair, and Replace (including In & Out) as required

Inspect Only ComponentsTurbine rotors, Generator & Steam TurbineGT Compressor vanes, blades, IGVs and components requiring removal of GT rotorTurbine & Generator casing and shell

Inspected under Covered Maintenance, Defects corrected as Extra Work

AuxiliariesSkids (Gas Fuel, Compressor Water Wash, Lube Oil,…)Modules (Accessory, Interconnection) Hydraulic Power Units, Excitation System, Packaged electrical Control Cab, Hydrogen Manifold

Periodic Inspection and Replacement Parts as required but not including disassembly, installation, or reassembly of those parts

Long Term Maintenance Coverage

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Long Term Services...

Maintenance Scope Offerings: Parts, services and repairs at CI, HGPI and MI

Field engineering and Craft Labor services to support maintenance events.

Staggered outage schedule of the GT’s to accommodate repair cycle

Variations in scope and intervals throughout contract terms, due to technology development

24/7 remote monitoring and diagnostic service, providing technical support to operators.

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MYA...Not just maintenance...

Asset Performance Mgt:• Beyond M&D Analytics

• Extension of coverage to CCPP

• Operational Flexibility and optimization

• Condition Based Maintenance

MYA Philosophy

Customer & GE:• Goals aligned through KPI

guarantees• Creative financial

payment scheme to suitfinancial models

• Best practice sharing

Partnership

Covered Maintenance:• Parts, repair and services

• Future technology advancement & upgrades

• Continuous M&D support

Coverage Predictability

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Customer Success <=> GE Success

Software Solutions enabled Asset Performance Management

Asset Visibility Maintenance OptimizationReliability Excellence

Collect & analyze data while keeping IT costs low

Reduce downtime & extend asset life

Balance maintenance costs & operational risk

Metrics Drive APM Implementation

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Drive KPI’s through visibility, insights, and actions

14

What is the status? How does it compare? (vs. target, fleet, & potential)

VisibilityPerformance trending & projection

Component- level diagnostics

Recommendations to address issues

Example with product screenshots

What are the underlying drivers?

Insights

What actions to take? Estimated impacts?

Actions

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Trips Analysis:• Trip Stats• Pareto of top trip causes

Availability/Reliability Analysis:• Outage/Failure Stats• Pareto of top outage causes

A DAY IN THE LIFE OF A MYFLEETTM USER

Plant Manager...

Data driven decision supportUse the power of information… to maximize your plant’s capabilities

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MyFleetTM – Operational ExcellenceTarget Audience: VP & Asset Managers

Key Apps:• GT Operating Stats• GT Performance• Plant Performance• GT Efficiency• Op Plots

Benchmarking capabilities

Combined Cycle Stats & Performance

Filters:• Region• Frame Type• Duty Cycle• Customers• Sites

Downloads:• Charts• Tables

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Future of WorkExamples

Enabling Examples...

Continuous Autotune Operation

Performance Degradation Management

Operational Flexibility and Outage Interval

Reliability / Condition-Based Maintenance

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Software Solutions Enabler… Autotune

Fuel Flexibility of HA gas turbines:

Capable to operate on natural gas with MWI variation of ± 10 %

Combustion Inspection interval = Hot Gas Path Intervals

Continuous Autotune on AGC operation

Continuous Tuning increases Combustion Reliability

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Autotune losses w/ load control

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Annual Tunes 4Base Rating 500 MWSMP 120Load Constraint 60%

Tuning Loads Duration AGC payment LC Payment100% 30 min $ 30,000 $ 18,00090% 30 min $ 30,000 $ 16,20080% 30 min $ 30,000 $ 14,40070% 30 min $ 30,000 $ 12,60060% 30 min $ 30,000 $ 10,80050% 30 min $ 30,000 $ 9,00020% 30 min $ 30,000 $ 3,600Total 3.5 hours $ 210,000 $ 84,600

$ 125,400

Annual Lost Revenue $ 501,600

Loss Revenue for Tuning

Degradation Concept

ElectricalEnergy

Energy from Steam/Gas

OutputDegradation

Heat RateDegradation

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Data driven… continuous improvement

Results driven technology investments

Super finishAdvance filtration Compressor wash

(Examples)

Technology flow-down from aircraft engines (GE90, GEnx, LEAP X, CF6 PIP

Kit). Validated via 3 operators

Enhanced maintenance schedules, wash process and scope

Performance degradation model

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Degradation Types...

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Optimal Water-wash Timing...

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Missed Degradation “visibility” causing huge losses

•Heatrate Gap > 1.5%•Output Gap > 4.0%

NPV Gap ~ $15MM /yrs

Continuous monitoring to determine the optimal timing for compressor wash

Maintenance Interval... FS vs ES

GT operating profile

Baseline

Load

Normal Start = 1 FS & 1 ES “0” FS ≠ “X” ES “0” FS ≠ “Y” ES

AGC

Factored Start = Actual Starts + (Trips)

Equivalent Starts = Actual Starts + (Trips) + (runbacks) + (load-swing)

ES Abridging by ~ 120 days in 900 Start HGP interval

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FS vs ES

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Annual Operation 64.6% 36 initial HGP 32,000 FFH 900 FS 900 ESFFH 6,000 Follow on 32,000 FFH 900 FS 900 ES

Starts 250 Runbacks (RB) 0 0.0% with 4.0% Runbacks (RB)Trips 2 0.8%

Year Hours Starts Trips RB Cum FFH FS ES Event RB FS ES Event1 6,000 250 2 0 6,000 266 266 10 266 3262 6,000 250 2 0 12,000 532 532 10 532 6523 6,000 250 2 0 18,000 798 798 10 798 978 HGP4 6,000 250 2 0 24,000 1,064 1,064 HGP 10 1,064 1,3045 6,000 250 2 0 30,000 1,330 1,330 10 1,330 1,6306 6,000 250 2 0 36,000 1,596 1,596 10 1,596 1,956 MI7 6,000 250 2 0 42,000 1,862 1,862 MI 10 1,862 2,2828 6,000 250 2 0 48,000 2,128 2,128 10 2,128 2,6089 6,000 250 2 0 54,000 2,394 2,394 10 2,394 2,934 HGP

10 6,000 250 2 0 60,000 2,660 2,660 10 2,660 3,26011 6,000 250 2 0 66,000 2,926 2,926 HGP 10 2,926 3,58612 6,000 250 2 0 72,000 3,192 3,192 10 3,192 3,912 MI13 6,000 250 2 0 78,000 3,458 3,458 10 3,458 4,23814 6,000 250 2 0 84,000 3,724 3,724 MI 10 3,724 4,564 HGP

With No Runback Assumed with Runbacks assumed

GER 3620… the starting point...

Scope• GT Operating and maintenance

considerations...

• Highest Level Maintenance Reference...

Content• GE maintenance philosophy

• Gas Turbine sub-section considerations

• Operational impacts on maintenance timing

• Standard inspection scopes

• Maintenance factor calculations

Use• Recommendations and reference for scheduled

Gas Turbine maintenance plans...

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Hours-Based HGPI Equation

FFH Equation:

Summation ofFuel and load factors

Hours

Api= Load severity factor for given operating mode• Ap = 1.0 up to base load• Ap > 1.0 for peak load, .

Afi = Fuel severity factor for given operating mode• Af = 1.0 for natural gas• Af = 1.5 for distillate

Si= Water/steam injection severity factor• Si= 0 for DLN combustion system

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Starts-Based HGPI Equation

Factored Starts Equation:

. .

NA = Annual Number of Part Load Start/Stop Cycles (<60% Load)

NB = Annual Number of Base Load Start/Stop Cycles

NP = Annual Number of Peak Load Start/Stop Cycles (>100% Load)

Ps = Peaking-Fast Start Factor

F = Annual Number of Peaking-Fast Starts

T = Annual Number of Trips

aT = Trip Severity Factor = f(Load)

n = Number of Trip Categories (i.e. Full Load, Part Load, etc.)

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Software Solutions

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Visibility... Do you know where your unit is?

Let’s take a look...MyFleetTM Plant Performance Monitor

http://www.ge-myfleet.com

Where are you sarting?

95%

Potential Target

How do you stack up?

Startup TimeISO-Corrected

HeatrateStartup Fuel Use

Startup TimeVariances

Trips Water Wash

ISO-Corrected MW

Startup Reliability

Degradations

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Monitoring & Diagnostics

• Anomaly detection• Initial diagnostics• Operations history tracking

OSMOn-Site Monitor

• Equipment health assessment• On-site testing & repair• Service logistics

Field Service

Engineer

On-LinePower Answer Center • Equipment health assessment

• Diagnosis - root cause justification• Prognosis - parts and service

requirements• Service recommendations• Field service coordination

ServiceSpecialist

Operator

Communication Network

Life-Cycle CustomerEquipment Service

Increased equipment availability Enhanced equipment performance Increased quality and responsiveness of service Lower and more predictable O&M costs

Expert Systems and Data Bases Customer Site Monitored

Data Trending O&M History Problem-Solution

Equipment Configuration Fleet Performance Parts Catalog Service Procedures

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M&D Services

Gas TurbineSystem Monitoring

Combustion System Bearing and Lubrication System

GeneratorSystem Monitoring

Stator Cooling System Bearing and Lubrication System

Steam Turbine System Monitoring

Inlet Steam System Expansion System Bearing and Lubrication System

Risk Mitigation Trending Anomaly Detection Alert Watch…Focusing on Specific Issues Customer Operational Assessment Reports Gas Turbine Performance Monitoring

Diagnostics Trip Assistance Reduces Equivalent Forced Outage Rate Improves Equipment Availability Reduces Repeat Events Customer Recommendations

Solving issues with our Customers to avoid failures... 24 X 7 X 365

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Monitoring & Diagnostics...

Total avoided cost savings over the past year > $100MM Total avoided cost savings since the start of the program > $1.5B

Two-Day Planned Outage vs. 15-Day Forced Outage

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Reliability Excellence architecture Smart Signal Suite

Plant User

Dispatch User

HQ’sUser

GT

ST

Gen

Aux’s

BOP

Operations

Maintenance

Mark VI DCS

OpFlex

BN System 1

CBM

Mark VI DCS

Operations

Maint. CMMS

OSMpowered by Proficy

M&D

SmartSignal Predictive Analytics

Alarm Case management

Data storage &

management

APM

OE

ME

Data + KPI + CBM

visualization

Proficy SmartSignal SuiteMonitoring & Analysis Portal

PersonalsCCPP facility Data & Analytics

Plant

PlantProcesses

Plant

Plant

Plant

PlantProcesses

Currently existing at the plant

Partially new scope New scope GE SW Solutions

Cloud Services

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Mechanical work

Total Outage Duration

Prep for restart

Shutdown & PTW

Mechanical Scope

What are you really getting?

36

Availability...

CoolDown

LOTO UndoLOTO

ElecFinish Tune PT

GT 1-2 1 x 1 1-3 ½ 2 1 ~10+

ST 5-7 1 x 1 2-3 1 2 1 ~15+

Outage Work

Non-AGCoperation

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What counts…– GT F2F

– Steam Turbine

– Generator

– Controls

and…– Sensors

– Switches

– Gauges BOP ?– Redundancy– Reliability of non-OEM supplied items…

37

Reliability...

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Software Solutions Scope... tbd...

Software Solutions... Applied to Combined Cycle power plant can Reduce Life Cycle Cost and Improve Reliability and Availability

Emissions• CEMs• Optimization

Fuel Handling System• Optimization• Pump monitoring• Valve position• Fuel quality• Fuel flow• Piping – Separators, Filters, etc.

HRSG• Efficiency• Water Quality• Duct Burner monitoring

Cooling Towers• Efficiency• Water Quality• Flow measurement• Pump monitoring• Chemical Injection System

Excitation• Digital Generator

Protection (DGP)

Inlet Foggers• Optimization• Flow Measurement• Water quality• Inlet pressure• Ambient Humidity• Pump monitoring

Gas Turbines• Efficiency• Optimization• Temperature• Vibration• Flame Sensors

De-Mineralized Water System• Water Quality• Flow Measurement• Pump Monitoring• Chemical Injection System

Transformers• Cooling Systems• Load Tap Changers• Dissolved Fault Gases• Oil Analysis• Pump Monitoring

Lube Oil System• Pump monitoring• Oil quality• Oil flow• Piping – Filters, etc.

Steam Turbines• Efficiency• Temperature• Case & DE Expansion• Vibration Generators

• Vibration• Temperature• Hydrogen Cooling• Moisture

Instrument Air System• Vibration• Temperature• Moisture

Raw Water Conditioning• Water Quality• Flow Measurement• Pump Monitoring

Inlet Chillers• Optimization• Flow Measurement• Water quality• Inlet pressure• Pump monitoring

Switchgear• Operating Coil Monitoring• Pneumatics & Hydraulics• Gas Temp & Pressure

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Reliability Excellence Portal

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