Ger 3571 H

g
GER-3571H
GE Power Systems
Performance
and Reliability
Improvements for
Heavy-Duty Gas
Turbines
J.R. Johnston
GE Power Systems
Schenectady, NY
Performance and Reliability Improvements for Heavy-Duty Gas Turbines
Contents
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
New Uprate Development Programs Designed for New Units . . . . . . . . . . . . . . . . . . . . . . . . 3
High-Pressure Packing Brush Seals (FS2V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
#2 Bearing Brush Seals (FS2X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stage 2 Nozzle Inner Diaphragm Brush Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stage 2 and 3 Shroud Honeycomb Seal (FS2T/FS2U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stage 1 Shroud Cloth Seals (FS2Y). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Stage 1 Shroud Abraidable Coating (ES20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MS9171E Single-Piece Stage 1 Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reduced Camber, High Flow Inlet Guide Vanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GTD222 Stage 2 Nozzle Material (FS1P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lean Head End (LHE) Combustion Liners (FR1B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MS5432D Advanced Technology Uprate (FT2T). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MS3162K Advanced Technology Uprate (FT1W) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MS7001F/FA and MS9001F/FA Uprate Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Massive Steam Injection for MS7001E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Conventional Uprates Applying New Unit Advanced Technology . . . . . . . . . . . . . . . . . . . . 12
MS3002 Advanced Technology Uprate Package – Models A through G (FT1A) . . . . . . . . . . . . 12
MS3002 Uprate to 3/2F Configuration (FT1U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MS3002 H and J Advanced Technology Uprate Package (FT1D) . . . . . . . . . . . . . . . . . . . . . . . 16
MS3162K Advanced Technology Uprate (FT1W) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MS5001 Advanced Technnology Uprate Package – Models A through P (FT3L and FT3M) . . . 19
Compressor Upgrades – MS5001 Models A through M and R (FT3F) and MS5002A (FT2E) . . 20
MS5001 Speed Increase to 5,355 RPM (FP4E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Exhaust Frame and Diffuser Upgrade (FS1W) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MS5001P Uprate Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MS5002 Advanced Technology Package – Models A and B (FT2C) . . . . . . . . . . . . . . . . . . . . . 22
MS5002 “D” Advanced Technology Uprate (FT2R and FT2S). . . . . . . . . . . . . . . . . . . . . . . . . . 24
MS6001B Uprates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MS6571B Uprate to (FT4L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
MS7001B Turbine Uprate (FT5X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MS7001C, E and EA Uprates to 2035 F/1112 C Tf (FT5Y) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MS7001C, E and EA Uprates to 2055 F/1123 C Tf (FT5Q) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1100 F/593 C Maximum Exhaust Isotherm Limit (FT7G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Uprates with “Tilted” Control Curves (FT7I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
GE Power Systems GER-3571H (10/00)

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MS7001F and FA Uprate to the “MS7001FA Uprate” Configuration (FT5L) . . . . . . . . . . . . . . . 32

MS9001B Turbine Uprate (FT6X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
MS9001 Uprate to 2020 F/1104 C (FT6C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
MS9001 Uprate to 2055 F/1124 C (FT6Y) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
MS9001F Uprate to the MS9001FA Configuration (FT6Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Model Letter Uprates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Absolute Performance Guarantees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Non-Recoverable Performance Degradation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Augmentation Uprates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Combustion System Upgrades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Extendor™ Program for Increased Combustion Inspection Intervals (FR1V) . . . . . . . . . . . . . . . 39
Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Low NOx Louvered Combustion Liners – MS5/1, 3/2, 5/2 (FR1B) . . . . . . . . . . . . . . . . . . . . . . 41
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Abstract levels are included for reference. Advanced

technology uprate packages are available to
Many significant advances in technology have
upgrade almost all of the 6,000 GE-design
been applied to new unit production. These
heavy-duty gas turbines.
advanced technology improvements can be
applied to field units to achieve increased per-
formance, useful life and reliability. Introduction
Additionally, many development programs have Turbine uprate packages have been introduced
been specifically developed for application to because of continued strong user interest in
existing operating units. extending intervals between maintenance,
Several types of improvements are now available improving efficiency and increasing output.
for compressors, combustion systems and hot- Figure 1 lists the main items the customer and
gas-path turbine parts. This paper provides a GE must consider when evaluating a unit for
summary of uprate programs available for all one of the advanced technology uprate options.
models of GE heavy-duty gas turbines with spe- This paper covers new uprates that have been
cial emphasis on new programs for MS6001, successfully developed specifically for field unit
MS7001 and MS9001 (both E and F class mod- application and new uprates that are available
els). Complete tabulations of performance as a result of using engineered components that
improvement, material changes and mainte- were developed for current new-unit produc-
nance interval extensions are included. All tion. Figure 2 lists uprates covered in this paper.
uprates that involve changes in firing tempera- Figure 3 shows the growth in scope and numbers
ture and/or airflow will have some impact on of advanced technology uprates supplied per
emissions. Tabulations of original gas turbine year. To date there are over 400 firing tempera-
emission levels and uprated turbine emission ture uprates for field units involving every
• Performance Improvements (Output/Heat Rate)

• Maintenance/Inspection Interval Extensions
• Availability/Reliability Improvements
• Emissions Impact/Regulatory Agencies
• Life Extension
• Thorough Review of Gas Turbine Components and Accessories
Systems for Compatibility
• Thorough Review of Load Equipment and Accessories for
Compatibility
New Unit Technology/Components

GT2526O
Figure 1. Uprate considerations

■ ■ 1
Sourcebook
Code Frame Size Model Type Uprate
FT1A MS3002 A thru G Advanced Technology Uprate
FT1U MS3002 A thru G MS3002 “A” to “F” Uprate
FT1D MS3002 H&J MS3002J Advanced Technology Uprate
FT1W MS3002 H&J Uprate to Model “K”
FT2C MS5002 A&B MS5002C Advanced Technology Uprate
FT2R/FT2S MS5002 A, B & C Uprate to MS5002D
FT3L/FT3M MS5001 A thru P Advanced Technology Uprate
FT3F MS5001 A thru M and R 16 to 17 Stage Compressor Uprate
FT4L MS6001 A&B Uprate to MS6571B
FT5X MS7001 A&B Uprate With 7001EA Turbine Parts
FT5Y MS7001E C, E & EA Uprate to 2035F /1112C
FT5Q MS7001E C, E & EA Uprate to 2055F / 1123C
FT5L MS7001F F, FA Uprate to MS7241FA
Numerous MS7001F F, FA Uprate with MS7241 Component Kits
-- All Models All High Flow Inlet Guide Vanes
FT6X MS9001 B Uprate With MS9001E Turbine Parts
FT6C MS9001E E (MS9141 & 9151) Uprate to 2020F/1104C
FT6Y MS9001E E Uprate to 2055 F/1124C
FT6Z MS9001F F, FA Uprate to MS9531FA
Numerous MS9001F F, FA Uprate with MS9351 Components
-- All models All Firing Temperature Increase to Full Rating
GT18447 “I”
Figure 2. Gas turbine uprates
6/1B 7/1E 7/1E 7/1E 9/1E

3/2 (A thru G) 3/2J 5/1R 5/1P 5/2 2055F/ 7/1 2020F/ 2035F/ 2055F/ 9/1 2055F/ Total #
Adv Tech Adv Tech Adv Tech Adv Tech Adv Tech 1123C B to E 1104C 1112C 1123C B to E 1124C Uprates
Year (FT1A) (FT1D) (FT3L) (FT3M) (FT2C) (FT4L) (FT5X) (FT5C) (FT5Y) (FT5Q) (FT6X) (FT6Y) Shipped
1984 - - 4 2 - - - - - - - - 6
85 - - 5 5 - - - - - - - - 10
86 6 - - 4 - - - 2 - - - - 12
87 3 - 3 12 1 - - - - - - - 19
88 5 - 4 9 4 - 1 - - - - - 23
89 3 - 2 5 2 - - - - - - - 12
90 4 - 5 24 27 - 1 - - - - - 61
91 2 - 6 12 12 - 1 3 - - 1 - 37
92 3 8 1 19 1 - 2 - - - 1 - 35
93 2 - - 13 4 - 2 4 - - 1 1 27
94 1 1 - 7 - - 3 4 5 - 1 - 22
95 - 2 - 4 - - 4 2 8 - - 1 21
96 4 - 1 8 2 1 - - 15 - 1 - 28
97 4 3 1 2 10 4 1 - 11 1 - 1 37
98 - 2 - 2 2 - 1 1 5 1 - - 21
99 1 2 1 11 2 2 5 - 15 2 - 1 40
__ __ __ ___ ___ ___ ___ ___ ___ __ __ __ ___
Total 38 18 33 139 67 7 21 16 59 4 5 4 411
GT19815L
Figure 3. Gas turbine advanced technology uprate shipments through 1999

frame size. The most common time to consider various uprate programs. In most cases, the eco-
an uprate is during the first or second major nomic evaluation will justify one of the available
overhaul when the unit has been in operation uprate packages at the next major overhaul.
10 years or more. Information on specific uprate packages or
Every owner of GE heavy-duty gas turbines components is available in the Gas Turbine
should evaluate the overall economics of the Sourcebook. Reference codes (such as FT2C for

■ ■ 2
an MS5002 Advanced Technology Uprate) have GE design heavy duty gas turbines. Figure 5
been added to this text and to many of the fig- summarizes these development programs with a
ures and tables. The Sourcebook is an automat- matrix that shows which program applies to
ed system available to all GE offices for quick each frame size. We leverage each new pro-
reference on all uprate options listed in the gram across the entire product line to make
GER and for all other package options available each of these programs available to all cus-
for heavy-duty gas turbines. Soon all of the tomers.
uprate options as well as those for emissions, Approximately 20% of the inlet air to the axial
fuels, reliability improvement and controls flow compressor gets lost to the thermal cycle
upgrades will be accessible directly by cus- due to losses associated with cooling hot gas
tomers on the GE/WEB Optimizer program. path parts or losses due to large clearances.
GE engineers and/or customers have written Most uprates on gas turbines typically are
many papers that document the evaluation and achieved by higher airflow or higher firing tem-
implementation process for the more signifi- peratures. Recently a significant effort has been
cant uprates. Figure 4 lists the most recent ASME applied to reducing airflow losses from cooling
papers that document results of these successful air and improved seals. The majority of devel-
uprate projects. opment in the past few years has been directed
• 86-GT-40 New Technology Uprating of Process Compressor and Generator Drive Gas Turbines
(MS5001LA)
• 87-GT-24 Performance and Reliability Improvements for Heavy Duty Gas Turbines
• 87-GT-123 5001N Gas Turbine Advanced Technology Uprate
• 88-GT-143 The Modernization of a 1965 MS5001 Gas Turbine: New Life for an Old Unit (MS5001K)
• 89-GT-8 Life Extension and Performance Enhancement of an Industrial Gas Turbine Through Upgrading
(MS3002F)
• 90-GT-284 Modification of a GE 7001B Gas Turbine for Increased Reliability by Using 7001E Parts
• 90-GT-350 MS3002 Advanced Technology Uprate Application and Operating Experience (MS3002C)
• 91-GT-48 Field Performance Testing of an Uprated Gas Reinjection Compressor-Turbine Train
(MS5001R)
• 91-GT-49 Turbine-Compressor Train Uprated for 30% Increase in Gas Flow (MS5001R)
• 91-GT-318 Conversion of Two MS5001 Gas Turbines to Meet Emission Requirements in the Netherlands
• 92-GT-335 MS5002B Gas Turbine Advanced Technology Uprate for LNG Application
• 90-GT-13 GE MS7001E Gas Turbine Advanced Technology Uprate
• 97-GT-450 Results of the GT Prime Program Improvements at the T. H. Wharton HL&P Site
• 98-GT-359 Combustion Aspects of Application of Hydrogen and Natural Gas Fuel Mixtures to MS9001E
DLN Gas Turbines at the ELSTA Plant in Terneuzen, Netherlands
Figure 4. Reference ASME papers on heavy-duty gas turbine uprates
New Uprate Development Programs

to reducing these airflow losses. Most of the
Designed for New Units recent development programs are focused in
Most existing uprate programs were based on this area.
leveraging new unit technology. Over the past
High-Pressure Packing Brush Seals (FS2V)
three years we have invested heavily in addi-
tional uprate programs specifically designed to Figure 6 shows the original labyrinth seal design
serve the needs of the existing installed fleet of between the compressor discharge casing

■ ■ 3
3/2H & J 5/1N & P 5/2 B & C 6/1B 7/1 B&E 9/1 B & E
HPP Brush Seal (FS2V) X X X X X X

#2 Bearing Brush Seal (FS2X) - - X - X X
Stage 2&3 Honeycomb Shroud
Seals (FS2T/FS2V) X X X X X X
Stage 1 Shroud Cloth Seals (FS2Y) X X X X X X
Stage 1 Shroud Abraidable Seals (FS2O) X X X X X X
Inner Stage Brush Seal (FS2Z) - X - X X X
One Piece Stage 1 Shroud (FS2Y) - - - - - X
86º IGV with GTD 450 - X X X X X
GTD 222 Stage 2 Nozzles (FS1P) - - - X X X
Lean Head End Liners (FR1B) X X X X - -
Load Gear Speed Increase (FT3X/FP4D) - X - X - -
MS5002D Uprate (FT2S) - - X - - -
MS5002D S1N in MS5002C (FT2T) - - X - - -
Tilted Control Curves with Adv Tech
Uprate (FT7I) X X X X X X
2055F Uprate (FT4L/FT5Q/FT6Y) - - - X X X
Extender Combustion Upgrade (FR1V) - X X X X X
9% Steam Augmentation - - - - X X
MS 3162K Uprate (FT1W) X - - - - -
X = Available Now GER3751-5
Figure 5. Development programs for each frame size
“inner barrel” and compressor aft stub shaft. ance results in considerable unit performance
This seal restricts compressor discharge air loss. For a MS7001E unit, a rub of 20 mils on the
from leaking into the forward wheel space area. labyrinth seal teeth equates to at least 1.0% loss
This seal is designed with a nominal clearance in unit performance.
of 40 mils to allow for thermal growth differen- To increase unit performance and to reduce
tials and rotor movement during high vibration the rate of performance degradation due to
events. wear on labyrinth seal teeth, a new wire brush
In practice, most operating units have clear- seal design has been developed. Figure 6 details
ances significantly higher (20 to 60 mils) than the wire brush seal. Since the wire brush seal is
nominal. This increased labyrinth seal clear- flexible and will bend (not wear) on contact
Brush Seals
• Minimize Air Leakage
• Tolerant of Misalignments
• More Durable than Labyrinth
Seals
Inner Barrel
Current Production
Labyrinth Seal
Brush Seal
Aft Stub Shaft
GER 3751-6
Figure 6. Typical brush seal element

■ ■ 4
with the compressor aft shaft, a closer clearance example of a #2 bearing brush seal arrange-
can be allowed for the initial installation. This ment is shown in Figure 7.
provides an increase in output.
Stage 2 Nozzle Inner Diaphragm Brush
Also, since the wire brush seal will “bounce
Seal
back” to its original configuration after a “rub,”
there will be substantially less performance There is a large gap between the stage 2 nozzle
degradation over time than for the original inner diaphragm and the stage 1-2 wheel spacer
labyrinth seal. Performance improvement is to prevent any contact due to rotor vibration,
typically about 1% output and 0.5% heat rate. thermal transients or nozzle deflection.
Figure 6 shows a typical HPP brush seal. Unfortunately this gap is a substantial leak path.
As a continuation of the successful HPP and #2
#2 Bearing Brush Seals (FS2X) bearing brush seal programs, a brush seal has
The airflow that passes through the High also been designed to improve the inner stage
Pressure Packing (HPP) pressurizes the inner packing seal. This seal is now available for all
wheel space of the turbine. For units with a single shaft designs and provides a performance
• Minimize Air Leakage to Bearing Cavity

Air Seal
• Reduce Oil Mist
Cross-Section Bearing Housing
Brush Seal
GER 3751-7
Figure 7. #2 bearing brush seal
middle bearing, a significant amount of this air improvement of approximately 1% output and
will leak through the #2 bearing outer seals and 0.5% heat rate. A cross-section of a stage 2 noz-
vent to atmosphere. This represents a signifi- zle with a brush seal is shown in Figure 8.
cant performance loss. As a follow-on to the suc-
cessful HPP brush seal program, a brush seal Stage 2 and 3 Shroud Honeycomb Seal
was designed for both the forward and aft outer (FS2T/FS2U)
bearing casing seals. This seal has been success- To avoid bucket tip rub, the clearances between
fully applied for MS7001E, MS9001E and the bucket tip and the stationary shroud blocks
MS5002 units. Performance improvement is have always been about 100 mils. This large
typically 0.3% output and 0.2% heat rate. An clearance allows a significant amount of hot gas

■ ■ 5
First Aft
First Aft Second Wheelspace Second Forward
Wheelspace Forward Wheelspace
Wheelspace
Brush Seal
Element
1-2 Turbine 1-2 Turbine

Wheel Spacer Wheel Spacer
Current Stage 2 Nozzle Design Proposed Stage 2 Nozzle Design

GER 3751-8
Figure 8. Stage 2 nozzle with a brush seal
to flow over the bucket tip, resulting in signifi- a groove into the honeycomb material. The
cant performance loss. To address this issue, a tight clearance between the bucket tip and the
honeycomb seal insert (see Figure 9) was honeycomb shroud seals provide a perform-
designed to be inserted between the labyrinth ance improvement up to 0.6% in both output
seal teeth in the stage 2 and 3 shroud blocks. and heat rate. To make sure we effectively cut a
The honeycomb material is softer than the groove into the honeycomb material we also
shroud and bucket material, which makes it sac- design a “cutter tooth” on the leading edge of
rificial in nature for this application. The buck- the bucket shroud tip labyrinth seals (see Figure
et tip shroud labyrinth seals are designed to cut 10).
Honeycomb Shroud Blocks

• Honeycomb Shrouds
- Reduces Leakage
- Greater Rub Tolerance
• Requires Buckets with
Cutter Teeth
Honeycomb Material
GER 3751-9
Figure 9. Honeycomb seal insert

■ ■ 6
Cutter Teeth
Stage 2 Stage 3
Rotation
GER 3751-10
Figure 10. Bucket shroud cutter teeth
Stage #1 Shroud Cloth Seals (FS2Y) bar type spline seal versus the upgraded cloth
seal.
Leakage of compressor discharge air past the
shroud block segments is one of the most criti- The cloth-seal design seals both radial and axial
cal areas for performance loss. The original flow and provides a flexible seal to allow for
pumpkin-tooth style design with an interlocking individual shroud block misalignment. This
spline seal is a good seal, but is fairly inefficient. improved seal design restricts the higher pres-
The new design has a flat-face shroud block sure, compressor discharge air from leaking
with a cloth seal that inserts into grooves in both into the hot gas path. As a result, it provides a
adjacent shroud blocks. Figure 11 compares the performance improvement of up to 0.7% in
improved design versus the original pumpkin- output and 0.5% in heat rate.
tooth design. Figure 12 compares the original
First Stage Shroud Cloth Seals

• New Material and Improved Sealing
• Improved Performance (Pending Audit)
Cloth Spline Seals
W-Seal
“Bus Bar”
Seal
Side View Pumpkin

Teeth
Bottom View Bottom View

Current Shroud Uprate Shroud
GER 3751-11
Figure 11. “Pumpkin-tooth” design vs. new shroud seal design

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New Intersegment Seal Design

Filter Cloth
Current Spline Seal Cloth Spline Seal

GER 3751-12
Figure 12. Bar type spline vs. cloth-seal design
Stage 1 Shroud Abraidable Coating (ES20) This combination of cloth-seal replacement

shroud blocks and abraidable coating should
Clearance between the stage 1 bucket and the
provide impressive performance improvements
stage 1 shroud block is a critical factor because
in excess of 1.1% output and 0.8% in heat rate.
it allows combustion air to leak over the tip of
the stage 1 bucket, which causes significant per- MS9171E Single-Piece Stage 1 Shroud
formance loss.
The initial design for the MS9171E (2055F)
A large clearance typically is required to design incorporated a two-piece, Stage 1
account for conditions that can result in signifi- shroud. This was necessary to achieve accept-
cant bucket rub: able parts life with the original A&SI 310 stain-
■ Casing out-of-roundness less steel material. The more recent HR120
material is a more crack resistant alloy and is
■ Misalignment of the rotor
better able to withstand the higher firing tem-
■ Shroud block misalignment
perature. Thus we can now provide a single-
The abraidable coating is intended to account piece stage 1 shroud block. The cooling and
for all of these items and to provide an absolute sealing air changes associated with the 2-piece
reduction in hot running clearances. The shroud design resulted in a performance loss of
abraidable seal is a 40-mil thick coating in the 0.9% to output and 0.4% heat rate. Thus for all
inner diameter of the stage 1 shroud blocks. MS9171E (2055F) units we can provide the new
The intention is to have the bucket tips rub into HR120 single-piece shroud to recover this per-
the abraidable coating during the first few start- formance loss (see Figure 14).
ups to mold a round gas path, regardless of cas-
ing roundness, shroud misalignment, rotor mis-
Reduced Camber, High Flow Inlet Guide
alignment or bucket tip rubs (on used buckets). Vanes
The expectation on an installed turbine is a Improvements in Inlet Guide Vane (IGV) mate-
minimum performance improvement of 0.4.0% rial and airfoil design have also increased air-
output and 0.3% heat rate. Figure 13 depicts a flow. Figure 15 details performance increases
typical abraidable coating on a Stage 1 shroud. available by applying the latest IGV designs to

■ ■ 8
Cloth Spline Seals
W-Seal
“Bus Bar”
Seal
Abraidable Coating
Side View
Pumpkin
Teeth
Bottom View Bottom View

Current Shroud Uprate Shroud
Figure 13. Abraidable sealing coating on a stage 1 shroud
• Replace Two-Piece Design

• Haynes HR-120
• Reduced Cooling Required
- Increase in Output
- Decrease in Heat Rate
Cloth Spline Seals
W-Seal
GER 3751-14
Figure 14. MS9171E one-piece stage one shroud block
older units. The new IGVs are directly inter- IGV bushings are also supplied.
changeable with the original IGVs in complete
sets. However, in many cases new control curves GTD222 Stage 2 Nozzle Material (FS1P)
and/or inlet guide vane settings are required to The new GTD222 high-nickel based alloy was
achieve optimal performance. Additionally, the developed in response to the need for an
new reduced camber IGVs are made from GTD improved creep-resistant alloy for stages 2 and 3
450, a stronger and more corrosion-resistant for the MS6/7/9 higher firing temperature
stainless steel. designs. The improvement in creep resistance
As part of the modification kit for GTD 450 was so great that we were able to reduce the
IGVs, a set of tight clearance, self-lubricating cooling air for the stage 2 nozzle. Figure 16

■ ■ 9
Variable IGV-Design Turbines
Reduced Camber High Flow GTD-450 IGV
Temperature
Sourcebook Incremental Changes Change
Codes Output Heat Rate TEX (F/C)
FT3C MS5001N/P Pre-1978 3.9% -0.2% -11/-6

FT3C MS5001P 1978 Thru 1987 1.9% -0.5% -4/-2
FT2B MS5002B Pre-1978 3.8% -0.1% -10/-6
FT2B MS5002B 1978 Thru 1987 1.8% -0.3% -4/-2
FT4C MS6001B Pre-1988 1.9% -0.2% -2/-1
FT5B MS7001B 4.8% -0.7% -12/-7
FT5B MS7001C 4.5% +0.1% -11/-6
FT5B MS7001E Pre-1988 1.9% -0.1% -3/-2
FT5B MS7001EA Pre-1988 1.4% -0.3% -2/-1
FT6B MS9001B 4.8% -0.7% -12/-7
FT6B MS9001E Pre-1988 1.9% -0.2% -2/-1
Fixed IGV-Design Turbines (316-SS IGV)

FT1F MS3002 A Thru J Pre-1978 2.2% -0.5% -6/-3
FT3I MS5001 A Thru M and R 1.0% -0.3% -2/-1
FT2M MS5002A 1.1% -0.4% -2/-1
GER 3751-15
Figure 15. GTD 450 IGV performance increase
• Improved Creep Resistance

• Improved Nozzle Vane
Cooling
- Redesigned Core Plug
• Improved Performance
- Reduced Cooling Air Flow Downstream
Deflection
GER 3751-16
Figure 16. GTD 222 stage 2 nozzle creep
shows typical creep deflection between Hot Gas els. More recent developments in combustion
Path inspections. Figure 17 shows a comparison liner technology enable the use of leaner head
of creep deflection between the original end/lower NOx designs. NOx reductions of up
FSX414 material and the new GTD222 material. to 30% can be achieved by applying the newer
Figure 18 shows the performance improvements LHE technology. Figure 19 shows a comparison
for MS 6/7/9 units. of the original liner versus the LHE liner. In
areas where emission regulations allow it, all
Lean Head End (LHE) Combustion Liners uprates to an advance technology uprate pack-
(FR1B) age can be done when applying the LHE liner
The original design of louvered combustion lin- to actually get an uprate with lower emissions.
ers for MS3/5 units had relatively high NOx lev- Figure 20 shows an overall 20% reduction in

■ ■ 10
• Creep Resistant GTD-222 Material

• Aluminide Coating on Stage 2
- Increased High Temperature Oxidation
Resistance
GTD-222 vs. FSX-414
Nozzle Creep Deflection Comparison
1.2
Relative Deflection
1.0
FSX-414
0.8
0.6
0.4
0.2
GTD-222
0
10 20 30 40 50 60
Time - KHR
GER 3751-17
Figure 17. Stage 2 and 3 nozzle creep deflection
Reduced Cooling Flow

Controlled by Tuning Pin
Performance Improvement
Output Heat Rate
MS6001B +1.0% -0.4%
MS7001E/EA +0.8% -0.3%
MS9001E +1.0% -0.4%
GER 3751-18
Figure 18. GTD stage 2 nozzle performance improvement
NOx emissions when applying an advance tech- applied for both uprates of field units as well as
nology uprate for a MS5001P unit. for new unit production to provide approxi-
mately a 13% power increase.
MS5432D Advance Technology Uprate
(FT2T) MS3162K Advance Technology Uprate
Due to the strong customer interest in uprates (FT1W)
for the MS5382C, the MS5432D was introduced. Due to strong customer interest in uprates for
For the MS5002D we combined the highly suc- the MS3152J, MS3216K is being introduced.
cessful MS5002C hot gas path with the This design improvement applies modern
MS6001B axial flow compressor as shown in advanced airfoil design technology to the
Figure 21. This new design has been successfully MS3002 axial flow compressor. This uprate

■ ■ 11
several years. In most cases the latest upgraded

buckets, nozzles and shrouds can be applied to
all of the older production F/FA units.
Additionally, if these design improvements are
applied in selected packages. significant per-
formance improvements will result. Figure 23
shows specific performance improvements that
can be achieved by applying selected compo-
nent kits to the older production 7/9 F/FA
models.
Massive Steam Injection for MS 7001E

GE has offered steam injection for power aug-
mentation for 40 years on all of our production
GER 3751-19
machines. Figure 71 shows the relative out-
Figure 19. Louvered low NOx lean head end com-
put/efficiency improvements with up to 5.0%
bustion liners
steam injection (as a percentage of airflow).
Considerable design effort was applied in 1999
150 to develop a 9% steam injection option for the
140 MS7001E &EA models. It was determined that
by applying the current production advance
NOx PPMVD - @ 15% O2
130
technology hot gas path parts we can achieve
120
29.0% in output without any loss in parts life.
110
Figure 24 lists various parameters involved in
2
1. Original 51P Turbine
100
2. Estimated Uprate to 51P/NT Advanced
applying the 9.0% steam injection option.
1
90 Technology Uprate
3. Estimated Uprate with “Low NOx”
Combustion Liners
80
0 20 40 60 80 100
3
F Conventional Uprates Applying New
Ambient Air Temperature
-18 -7 4 16 27 38
C Unit Advance Technology
GER 3751-20
MS3002 Advanced Technology Uprate

Figure 20. Lean head end – low NOx louvered
liners Package - Models A through G (FT1A)
requires new compressor wheels and blades but The MS3002 gas turbine was introduced in
retains the original compressor casings. The 1950. Various design changes in combustion
increase in output is 8.0% and the improve- and turbine hot-gas-path design were developed
ment in heat rate is 7.0%. Figure 22 shows a cross over the years, as the unit was uprated from the
section of a MS3002 unit to highlight the parts MS3002A through the MS3002F and G models.
that are affected by this advanced technology Figure 25 lists the performance characteristics
uprate. for the various models. This unit has been used
for many pipeline, process and generator-drive
MS7001F/FA PG 9001F/FA Uprate Packages applications. An advanced technology uprate
There have been numerous uprates/upgrades package was developed because of continued
involved in the 7F/9F product line over the past strong customer interest in reduced mainte-
GE Power Systems GER-3571H (10/00) ■ ■ 12

MS6001B MS5002B
Combine
Two Proven
Technologies
MS5002D
GER 3751-21
Figure 21. MS5002D advanced technology uprate
Sectional drawing of the new MS3162K GT

GER 3751-22
Figure 22. MS3162K advanced technology uprate
nance cycles, improved efficiency and increased units can be uprated to over 10,620 HP at ISO
output. Figure 26 details the MS3002 advanced conditions with greater than 33.0% thermal
technology package. Figure 27 details predicted efficiency, regardless of original unit configura-
improvements in thermal efficiency and output tion. Most simple-cycle units can be uprated to
for the advanced technology parts package for 11,590 HP at ISO conditions. Figure 28 details
regenerative cycle units. expected reductions in maintenance intervals.
Considerable fuel savings are realized with As maintenance inspections for hot-gas path are
improvements in thermal efficiency to 33.0% extended to 48,000 hours, considerable reduc-
for the regenerative cycle. Regenerative cycle tions in planned outages and associated main-

■ ■ 13
HG P UP RAT E P ACKAG ES F O R P G 7001 AND P G 9001 UNIT ( 1 ) , ( 2 )
P G 7211F P G 7221F A P G 7231F A+ P G 9281F P G 9311F A

No . S B CO DE P ACKAG E DES CRIP T IO N % KW % HR % KW % HR % KW % HR S B CO DE % KW % HR % KW % HR
1 FV1N S1N, S1B, S1S ( 4 )
2.08 -0.95 0.64 -0.51 FV4N ( 4 )
1.69 -0.78
2 FV1O S1N, S1B ( 4 )
0.97 -0.48 0.13 -0.37 FV4O ( 4 )
0.79 -0.38
3 FV1P S1B, S1S 1.18 -0.66 1.64 -0.97 0.31 0.00 FV4P 0.72 -0.46 1.10 -0.72
4 FV1Q S1N, S1S ( 4 )
1.50 -0.43 0.70 -0.55 FV4Q ( 4 )
1.40 -0.45
S2N, S2B, S2S, S3N, S3B,
S3S, HPP Brush Seal, CDC
5 FV1T Bore Plugs, and 88 IGV 2.83 -1.05 1.86 -0.89 0.60 ( 3 )
-0.20 ( 3 )
FV4T 1.96 -0.66 0.99 -0.52
S2B, S2S, S3B, S3S, HPP
Brush Seal, CDC Bore Plugs,
6 FV1U and 88 IGV 2.77 -0.98 1.79 -0.80 0.09 ( 3 )
0.00 ( 3 )
FV4U 2.77 -0.98 1.51 -0.61
S2B, S2S, HPP Brush Seal,
7 FV1V CDC Bore Plugs, and 88 IGV 2.49 -0.75 1.49 -0.55 0.08 ( 3 )
0.00 ( 3 )
FV4V 2.49 -0.71 1.37 -0.48
S3B, S3S, HPP Brush Seal,
8 FV1W CDC Bore Plugs, and 88 IGV 2.68 -0.83 1.55 -0.51 0.00 ( 3 )
0.00 ( 3 )
FV4W 2.64 -0.72 1.41 -0.37
Firing Temperature 5.94 -0.45 2.10 -0.02 0.00 0.00 5.89 -0.41 2.08 0.00
9 T O T AL AV AIL ABL E 9.95 -2.16 6.04 -1.86 1.24 -0.71 8.57 -1.53 4.76 -1.30
Note
(1) All KITS consist of FA+E components, and assume no firing temperature increase (except KIT 9).
(2) Control modifications are required
(3) Brush seal, CDC bore plugs and 88 IGV are NOT included for 7FA+
(4) Under review
Figure 23. PG7001F and PG9001F uprate packages
• Standard and MNQC Combustor Only

• 9% of Compressor Air Flow is 55.45 pps Steam
Flow in Wrapper
• Expected Output Improvement of 29.6%
(77.8 MW to 100.8 MW)
• Expected Heat Rate Improvement of 8.1%
(10664 to 9800 Btu/kw-hr)
• Parts Life Impact on Maintenance Schedules
Has Been Established
• Total Plant Solution/Package
GER 3751-24
Figure 24. MS7001EA 9% steam injection
tenance costs are realized. Figure 29 is a cross- gas-path parts for significant improvements in
section detailing existing components that are output, heat rate and expected parts life.
replaced with advanced technology compo-
nents. Performance tests on all units completed Uprating with 3/2F combustion and hot-gas-
to date show actual performance improvements path parts will provide 9,400 HP NEMA rating
in excess of those shown in Figure 27. in regenerative cycle and 9,700 HP NEMA rat-
ing in simple-cycle operation. For example, an
MS3002 Uprate to 3/2F Configuration MS3002A unit rated at 5,000 HP could be uprat-
(FT1U) ed to 9,400 HP in regenerative cycle configura-
Earlier MS3002 Models A through E and G can tion by upgrading with MS3002F hot gas path
be uprated with MS3002F combustion and hot- components. For performance changes for

■ ■ 14
Heat Rate** Firing Temp. (F/C) Air Flow*
Ship hp (kW) (Btu/hp-hr/ (103 lbs/hr/
Model Dates Range* kJ/kWh RC SC 103 kg/hr)
3502A,B 1951-56 5,000-6,700 10,100/14,289 1,450/788 1,450/788 355/161
(3,729-4,996)
3762C 1955-59 To 7,600 9,280/13,129 1,500/816 1,500/816 355/161

(5,667)
3802D 1961-63 To 8,000 9,070/12,832 1,550/843 - 360/163

(5,966)
3852E,G 1963-66 To 8,500 8,900/12,592 1,575/857 1,525/829 371/168

(6,338)
3932F 1966-73 To 9,300 8,490/12/012 1,625/885 1,575/857 371/168

(6,935)
3142H, J 1969-1992 To 14,600 7,410/10,484 1,750/954 1,730/943 415/188

(10,887)
3152J 1992-1999 15,140 9,500 (S.C.)/13,441 - 1,770/966 415/188

(11,290)
3162K 2000- 16,600 8,690 (S.C.)/12,245 - 1,779/970 415/188

(12,450)
*Ratings for models A thru G are based on NEMA (1000 ft/300m altitude and 80 F/27 C) conditions and models H & J are based on ISO (sea level and 50
F/16 C) conditions. To convert from NEMA to ISO ratings for approximate comparison, multiply NEMA rating by 1.12. Includes 0/0 inches H2O inlet/exhaust
pressure drops. Ratings are based on gas fuel.
**Heat rates given are for regenerative cycle and are lower heating value. To convert to % thermal efficiency, divide 2547 Btu/hp-hr by heat rate (Btu/hp-hr)
and multiply by 100.
GER 3751-25
Figure 25. MS3002 performance history
3002A/B 3002C THRU G

• 2 Vane Stage 1 Nozzle X X
• GTD 111 Stage 1 Bucket X X
• High-Pressure Turbine Rotor Assembly X X
• Stage 2 Nozzle X X
• GTD 111 Stage 2 Bucket X X
• Low-Pressure Turbine Rotor Assembly X X
• Floating Seal Transition Piece X X
• Turbine Shell X X
• Combustion Liners X X
• Splash Plate Crossfire Tube Collars X X
• Exhaust Diffuser X X
• Round-The-Corner Combustion X -
GT18449
Figure 26. MS3002 A through G uprate parts
other models, refer to Figure 25. Both ratings The MS3002J combustion system has the added
also include the high flow 81° IGVs. The advantage of being easily converted to a Dry
MS3002F components are much more readily Low NOx (DLN) combustion system if also
available than earlier production parts, which required.
makes it possible to achieve considerable bene- This uprate requires converting to the MS3002F
fits in parts availability and parts standardiza- Stage 1 and 2 shrouds, nozzles, wheels and
tion. In upgrading the combustion system for buckets, and either the MS3002F or MS3002J
older vintage MS3002 units, the MS3002F or combustion system. All MS3002F hot-gas-path
MS3002J combustion systems could be used. components can be retrofitted into the existing

■ ■ 15
Regenerative Cycle
HP Speed = 6520 rpm
LP Speed = 600 rpm
75 º IGV
NEMA Conditions
No Inlet or Exhaust Duct
Pressure Drops
Regenerator
86% Effectiveness
1.5% Air Side DP/P
1.5% Gas Side DP/P
GER 3751-27
Figure 27. MS3002 regenerative cycle thermal efficiency improvements
Figure 28. MS3002/MS5001/MS5002 advanced technoloy packages maintenance interval extensions
turbine shell with some modifications. Figure 30 the turbine to 1,700 F/966 C from the present
details individual component upgrades for use 1,730 F/943 C firing temperature. Figure 25 lists
in applications where a complete “A” to “F” the original performance for these units. Figure
uprate may not be required. 31 details the design improvements for the
MS3002 H and J advanced technology uprate
MS3002 H and J Advanced Technology program. The key ingredient required for the
Uprate Package (FTID) MS3002J advanced technology uprate is the
A modernization and uprate program devel- directionally solidified GTF 111 Stage 1 bucket.
oped for the MS3002 H and J units based on All of the components in this package are nec-
similar design improvements has been intro- essary to enable the uprate and will provide
duced on other units in the GE heavy-duty improvements in output of 3.7% and heat rate
product line. This program involves uprating of 0.3%.

■ ■ 16
Figure 29. MS3002 modernization and uprate program
Sourcebook
Code Component Design Improvements
FS2L Stage 1 Nozzle - FSX414 Investment Casting vs Previous Fabricated Design
FS1J Stage 1 Wheel/Bucket - Solid One Piece 3/2F Forged A286 Wheel Replaces Composite Wheel.
Stage 1 3/2F Bucket Is Made from U500 Material And Has an Integrated
Coverplate
FT1T Stage 2 Wheel/Bucket - Solid One Piece 3/2F Forged A286 Wheel Replaces Composite Wheel.
3/2F Wheel Can Run at 6000 RPM vs. 5000 RPM for Composite Wheels.
Stage 2 Bucket Will Be 3/2F Bucket Made of U500 Material.
FT1V Combustion System - MS3002 J Liner, Casing, Header Elbow and Transition Pieces to Replace
Original MS3002A Design
FS2M Exhaust Diffuser - Longer More Efficient Advanced Technology Design Provides 1% Increase
in Output and Efficiency
GT23767
Figure 30. MS3002F component design improvements
Sourcebook
Code
FT1S - 2 Vane FSX414 Stage 1 Nozzle
FT1R - GTD111 Directionally Solidified Stage 1 Buckets
FR1G - Thermal Barrier Coated Combustion Liner with Splash Plate Cooled Cross Fire Tube Collars
FR1J - Swirl Cooled Cross Fire Tubes
FR1N - Hard Facing on Cross Fire Tube Ends
FR1C - Thick Wall Transition Pieces with Floating Seals
- Performance Improvements
• 3.7% Increase in Output

• 0.3% Decrease in Heat Rate
- HP & LP Turbine Rotor Bolting Tightening (Low Ambient Temp. Applications Only)
- LP Thrust Bearing Pad
FS1U - Stainless Steel Exhaust Diffuser (High Ambient Temp. Applications Only)
GT18454F
Figure 31. MS3002H and J advanced technology uprate
In addition to the performance improvement, complete uprate packages. The significant dif-
considerable extension of recommended ferences are an extension of combustion
inspection intervals can be realized. Figure 28 inspection intervals from 8,000 hours to 12,000
compares recommended maintenance intervals hours and elimination of the recommended
for the original design components and the hot-gas-path inspection, which was at 24,000
advanced technology components when used in hours.
■ ■ 17
As maintenance intervals for hot-gas-path parts perature limit to 1050 F/566 C. Similar per-
are extended to 48,000 hours, considerable formance improvements will be achieved for
reductions of planned outages and associated MS3002J units by using the higher temperature
maintenance costs are realized. Nine sets of stainless steel exhaust diffuser material (see fig-
MS3002J advanced technology uprate parts ure 39).
have been installed. MS3002J units shipped
prior to 1978 would get an additional 2.2% out- MS3162K Advance Technology Uprate
put increase by using the latest design inlet (FT1W)
guide vanes (see Figure 15). High ambient tem- To address strong customer interest in
perature MS3002J units will also need to change improved thermal efficiency and increased out-
the exhaust diffuser material to a high temper- put, the new MS3162K was recently introduced.
ature stainless steel design. Figure 43 shows the The primary design change is in the axial flow
relative performance improvement for an compressor with an improved aerodynamic
MS5002A unit by increasing the exhaust tem- blading design. The overall increase in per-
- Complete Aerodynamic Redesign of Compressor Blades

- Parallel Combustion System
- Combustion Liner and Transition Piece Redesign
- Reduced Area Stage One Nozzle
- Stage One Shroud Seals
- Increased Capacity Thrust Bearing
- High Pressure Packing Brush Seal
- #2 Bearing Brush Seal
- Combustion Wrapper Redesign
- Compressor Anti-Surge Valve
GER 3751-32
Figure 32. MS3162K advanced technology uprate definition
Output Heat Rate

High Flow IGV’s (Pre 1978) (FT1F) +2.20% -0.50%
MS3152J Adv Tech Uprate (FT1D) +3.70% -0.30%
Stage 2 Shroud Honeycomb Seal (FS2T) +0.40% -0.40%
HPP Brush Seal (FS2V) +0.70% -0.50%
Stage 1 Shroud Cloth Seal (FS2Y) +0.50% -0.50%
MS3162K Adv Tech Uprate (FT1W) +8.20% -7.15%
Total +15.7% -9.35%

GER 3751-33
Figure 33. MS3002J uprate summary

■ ■ 18
formance is +8.2% output and –7.15% heat maintenance intervals. Figure 35 details the
rate. The complete redesigned compressor MS5001 parts package for models A through P.
blading will still fit within the existing 3/2 J Figure 28 details expected extensions in mainte-
compressor casings. Figure 22 is a cross-section nance intervals. As maintenance inspections for
of the new MS3162K. A detailed listing of all hot-gas-path are extended to 48,000 hours, con-
design changes is shown in Figure 32. A signifi- siderable reductions of planned outages and
cant visual difference is the change to a parallel associated maintenance costs are realized.
reverse flow combustion system. Estimated output and heat rate improvements
for MS5001 advanced technology uprates are
Figure 33 is a summary of all performance
shown in Figure 36 for models MS5001 L
improvements for MS3142J units
through P.
MS5001 Advanced Technology Uprate Incremental output and heat rate improve-
Package - Models A through P (FT3L and ments can be as high as 31.1% and 9.1%,
FT3M) respectively. Load equipment capability must be
The MS5001 unit was first introduced in 1957. carefully reviewed for each application to deter-
Various design changes in combustion and tur- mine if it is adequate for the uprate or if a simi-
bine hot-gas-path design have been made over lar uprate is required. Several units with
the years, as the unit was uprated from the advanced technology parts have had more than
MS5001A to the current MS5001P model. Figure 50,000 operating hours since the uprate. To
34 lists the original performance characteristics determine the best possible uprate program for
of the various models. This unit has been used each customer, it is usually necessary to do a
for both mechanical- and generator-drive appli- thorough review of all available uprates and to
cations. review the capabilities of all associated load
equipment.
The initial advanced technology uprate pack-
age was designed to apply to models L through Further review of the advanced technology
P only. This uprate package is intended to uprate package resulted in a design to apply the
improve efficiency and output and to extend uprate to older vintage MS5001A through
Air Flow Heat Rate
Firing (103 lbs/hr/ Exhaust (LHV) Btu/ Efficiency %
(1)
Model Ship Dates kW (NEMA) Temp (F/C) 103 kg/hr) Temp (F/C) kW-hr Btu/hr (LHV)
A 1957-61 10,750 1500/816 662/300 840/449 15,810 21.6

C 1961-64 10,750 1500/816 662/300 835/446 15,810 21.6
D 1961-63 10,750 1500/816 662/300 835/446 15,810 21.6
E 1963 11,500 1500/816 695/315 830/443 15,780 21.6
G 1963-64 12,000 1500/816 695/315 830/443 15,120 22.5
H,J 1964 12,500 1500/816 695/315 820/438 14,430 23.6
K 1965 12,500 1500/816 695/315 820/438 14,430 23.6
L 1966-67 14,000 1600/871 702/318 895/479 14,440 23.6
LA 1968-70 15,250 1650/899 709/322 930/499 14,190 24.1
M 1969-70 16,100 1700/927 716/325 965/518 14,050 24.3
kW (IS0) (1)
R 1970-87 19,400 1720/938 767/348 955/513 13,260 25.8
R-N/T 1987- 20,500 1755/957 767/348 970/521 12,780 26.8
N 1970-72 24,600 1730/943 928/421 898/481 12,190 28.0
P 1972-78 24,600 1730/943 938/425 904/484 12,140 28.1
P 1978-86 23,350 1730/943 968/439 901/483 12,020 28.4
P-N/T 1987- 26,820 1765/963 981/445 905/485 11,860 28.7
(1) In early 1970s, Rating Standards Were Changed From NEMA (1000 ft/300m Altitude and 80F/27C) to ISO (Sea Level and 59F/16C) Conditions.
To Convert From NEMA to ISO Rating for Approximate Comparison, Multiply NEMA Rating by 1.12. Includes 0/0 Inches H2O Inlet/Exhaust
Pressure Drops. All Ratings Based on Natural Gas Fuel.
GT18455F

■ ■ 19
Sourcebook
Code 5001 A-K 5001L/LA/M 5001N/P/R
FR1L - Floating Seal Transition Pieces X X X

FR1G - TBC Coated Combustion Liners with Splash Plate
Crossfire Tube Collars X X X
FT3O - 2 Vane Stage 1 Nozzle X X X
FT3R - GTD111 Stage 1 Bucket X X X
FT3T - 4 Vane Cast Segment Stage 2 Nozzle X X X
FT3E - Shrouded Tip Stage 2 Bucket and New Stage 2 Turbine Wheel X X -
- Turbine Shell X - -
- Distance Piece X - -
- Stage 1 Turbine Wheel X - -
- Outer Combustion Casings X - -
- Exhaust Frame X - -
FS1U - Stainless Steel Exhaust Diffuser X X -
(High Ambient Temperature Only)
GT18456C
Figure 35. MS5001 models A through P advanced technology uprate package hardware changes
Incremental % Gains Exhaust Temp.

Drive Output Heat Rate Increase ºF/ ºC
5001L Generator 31.1 9.1 86/48
5001L Mechanical 25.9 7.2 77/43
5001LA Generator 20.3 7.5 51/28
5001LA Mechanical 17.7 7.2 52/29
5001M Generator 14.0 6.5 16/9
5001M Mechanical 12.3 7.1 19/11
5001R Generator 6.0 2.9 16/9
5001R Mechanical 5.7 2.7 15/8
5001N Generator 6.0 3.3 10/6
5001P Generator 6.0 3.3 10/6
GT18457D
Figure 36. MS5001 models L through P advanced technology uprate package
MS5001 K models. This basically involved a new Compressor Upgrades - MS5001 Models A
turbine casing in addition to the advanced tech- through M and R (FT3F) and MS5002A
nology package. Figure 34 shows original per-
(FT2E)
formance for models A through K. The maxi-
mum uprating by applying the advanced tech- In 1970, the basic MS5001 compressor was
nology package is the MS5001 R advanced tech- uprated by adding a zero stage to increase air-
nology rating, also shown in Figure 34. Actual flow by approximately 28% and output by 36%.
percentage improvement for this performance Previous 5001 models A through M and the
uprate can vary depending on original unit con- more recent 5001R models can all be uprated
figurations. to the 5001 N/P compressor design by adding a

■ ■ 20
zero stage. This can be accomplished by chang- turbine uprate. Figure 37 shows an MS5001 16-
ing the compressor bellmouth forward and aft stage compressor and an MS5001 17-stage com-
compressor casings and stages 1, 2, 3 and 10 pressor to demonstrate the differences in
compressor wheels and blades, adding a zero length and configuration between 16- and 17-
stage and adding variable inlet guide vanes. stage compressor MS5001 units. Similarly, the
It is also recommended to change the remain- MS5002A compressor can be uprated to the
ing stages of compressor blading because of the MS5002B configuration by adding a zero com-
age of blades and the increased loading on pressor stage to provide full MS5002B perform-
them, resulting from increased airflow and ance, as is shown in Figure 41.
pressure ratio. For 5001 models A through M, MS5001 Speed Increase to 5,355 RPM
this modification would have to be done in con-
(FP4E)
junction with a hot-gas-path uprate to a 5001R
model configuration to accommodate the Most mechanical-drive MS5001 units were rated
increased airflow. MS5001R units can be uprat- at 4,860 rpm at the 100% speed point. This
ed without combustion or flange-to-flange allowed for the 5% over-speed requirement
changes. most mechanical-drive customers require for
operational process variations.
Sixteen compressor uprates have been shipped
to date. The typical MS5001 shaft speed range To take advantage of the various advanced tech-
for mechanical-drive application is 80% to nology uprate programs available for these
105% of 4,860 rpm for the lower airflow 16- units, it is frequently necessary to drive the load
stage compressor MS5001 A through M and R compressor at a higher speed. Considerable
units. The higher airflow 17-stage MS5001N/P mechanical and dynamic analysis was done on
compressor has a more limited speed range of the MS5001 rotor design (both 16-stage
90% to 105% of 5,100 rpm. Thus, with this mod- MS5001R and 17-stage MS5001P) that resulted
ification, some speed range flexibility loss in a decision to operate MS5001 units as high as
comes with the airflow/output increase. Figure 5,355 rpm (105% of 5,100 rpm). To date, 16
34 shows airflows for all 5001 models. MS5001 mechanical-drive units have been
uprated to operate as high as 5,355 rpm.
An uprate of 36% is possible at site rating con-
ditions of 40 F/4 C at 5,100 rpm with only a There is a fairly minor rotor bending critical
compressor uprate. An uprate of 42% is possi- speed at about 5,400 rpm, so operation at 5,355
ble with compressor and advanced technology rpm does not conform to the API requirement
Figure 37. Comparing MS5001R and P

■ ■ 21
for a 5% speed margin from all critical speeds. with higher temperature material, we can go to a
However, no vibrational problems have resulted much higher limit at 1050 F. This is necessary in
on the units that have the speed increase. many cases to realize the Advance Technology
This successful experience led to allowing gen- Uprate that is shown later in Figure 43.
erator-drive units to operate at 5,355 rpm. As all
MS5001 generator-drive units have load gears,
this uprate would require changing out the load
gear or replacing all the rotating internal parts.
As the turbine will operate at the same torque at
the higher speed, the output will increase up to
3% at higher ambient temperature conditions.
Figure 38 plots output versus ambient tempera-
ture for an MS5001P unit comparing 5,100 rpm
versus 5,355 rpm speed.
The airflow is already so high at lower ambients
that the compressor/turbine efficiency is near GER3751-39
optimum. The higher airflow associated with

the speed increase results in efficiency that off- Figure 39. MS3000 and MS5000 exhaust diffuser
sets the output increase due to speed. Thus, upgrade
there is no performance advantage at lower
ambients, as shown in Figure 38. Figure 39 is an outline of the areas that need to
be upgraded. It is necessary to remove the
Exhaust Frame and Diffuser Upgrade exhaust frame and diffuser assembly to get
(FS1W) access for the rebuild operation.
Many older upgrade MS5001 and MS5002 units MS5001P Uprate Summary
are already near their exhaust temperature con-
Figure 40 is a summary of all applicable uprates
trol limit due to materials in the exhaust diffuser.
for the MS5001 model for reference.
By re-skinning the exhaust frame and diffuser
MS5002 Advanced Technology Package -
Models A and B (FT2C)
The MS5002B gas turbine was introduced in
1970. Various minor design changes have been
made to reach the 35,000 HP ISO rating.
Because of the interest expressed by many cus-
tomers, a development program was undertak-
en to increase the MS5002B rating to 38,000 HP
(ISO). This rating has been applied to current
production units as an MS5002C. This
advanced technology package can be applied to
GT2563 ”I” all existing MS5002 A and B units. Figure 41
shows a comparison of MS5002 ratings for both
Figure 38. MS5001P performance at 5,355 rpm

■ ■ 22
Output Heat Rate

Advanced Tech Update (FT3M) +6.0% -1.0%
GTD 450 IGV’s (Pre 1978/post 1978) +3.9%/1.9% -0.2/0.5%
(FT3B/FT3C)
86º IGV’s +0.2% +0.1%
High Pressure Pkg Brush Seals (FS2V) +0.6% -0.4%
Stage 2 Shroud Honeycomb Seals (FS2T) +0.4% -0.4%
5355 RPM Turbine Speed (FT3X) +3.0% (at High Ambients)
Stage 1 Shroud Cloth Seals (FS2Y) +0.5% -0.5%
Inner Stage Brush Seal (FS2Z) +1.0% -0.5%
S1S Abraidable Coating Seals (FS2O) +0.4% -0.3%
Total +16.0/14.0% -3.2/-3.5%

GER3751-40
Figure 40. MS5001P uprate summary
ISO Rating
Heat Rate** Air Flow
Ship Output Btu/hp-hr Firing (103lbs/hr) Exhaust
Dates hp (kW) (kJ/kWh) Temp F/C (103 kg/hr) Temp (F/C)
RC SC RC SC RC SC RC SC RC* SC
MS5262A 1970 Present 25,200/ 26,250/ 7,390/ 9,780/ 1,705/ 1,690/ 773/ 773/ 987/638/ 975/
18,792 19,575 10,455 13,837 929 921 351 351 531/337 524
MS5322B 1970-1975 31,050/ 32,550/ 7,480/ 9,240/ 1,710/ 1,700/ 923/ 923/ 940/660/ 932/
23,154 24,273 10,583 13,073 932 927 419 419 504/349 500
MS5332B 1975-1978 32,000 33,550/ 7,180/ 8,910 1,710/ 1,700/ 899/ 925/ 942/679/ 930/
23,862 24,981 10,158 12,606 932 927 408 420 506/359 499
MS53352B 1978-Present 32,000/ 35,000/ 7,070/ 8,830/ 1,710/ 1,700/ 899/ 966/ 936/667/ 915/
23,862 26,100 10,003 12,493 932 927 408 438 502/353 491
MS53382C Present 35,600/ 38,000/ 6,990/ 8,700/ 1,770/ 1,770/ 957/ 982/ 970/693/ 961/
26,547 28,337 9,889 12,309 966 966 434 445 521/367 516
MS5432D July 1997 - 42,600/ - 8,700/ - 1,807/ - 1,113/ - 950/

31,770 12,309 986 504 510
Includes 0/0 Inches H20 Inlet/Exhaust Pressure Drops Base Load Operation on Natural Gas Fuel
* First Number is Turbine Exhaust; Second is Regenerator Stack
**Heat Rates are Lower Heating Value. To Convert to % Thermal Efficiency, Divide 2547 Btu/hp-hr by Heat Rate (Btu/hp-hr) and Multiply 100
RC = Regenerative Cycle
SC = Simple Cycle GT18463G
original and uprated configurations. Figure 42 is can also be applied to earlier MS5002A units.
a listing of the MS5002 advanced technology Due to the increase in firing temperature, it is
package. This uprating package has been sold also necessary to change the MS5002A stage 2
for over 70 MS5002B units, uprating their out- buckets to the MS5002B standard design, as
put to meet changing operational conditions. shown in Figure 42. To maximize output at
This advanced technology package also results higher ambients, it will usually also be desirable
in considerable maintenance savings due to to change to a higher temperature stainless
fewer inspections, as shown in Figure 28. The steel for the exhaust diffuser. Figure 43 shows
MS5002 Advanced Technology Uprate Program the difference in output for an MS5002A

■ ■ 23
Sourcebook
Code MS5002A MS5002B
FT2J 2 Vane Stage 1 Nozzle X X

FT2K GTD111 Directionally Solidified Stage 1 Bucket X X
FR1G TBC Coated Combustion Liners With Splash Plate Cooled
Crossfire Tube Collars X X
FR1G Swirl Cooled Crossfire Tubes With Hardfacing X X

- LP Thrust Bearing Pad X X
FS1Y Up-Drain #2 Bearing Liner X X
- Turbine Shell Insulation Packs X X
- HP & LP Turbine Rotor Bolt Tightening X X
(Low Ambient Temp. Applications Only)
- Stage 2 Bucket X -
FS1U Stainless Steel Exhaust Diffuser X -
(High Ambient Temperature Applications Only)
GT18464E
Figure 42. MS5002A and B advanced technology uprate package hardware changes
was developed. This involves replacing the 17-

stage MS5002 axial compressor with a 17-stage
MS6001 axial flow compressor. Figure 21 depicts
the combination of MS6001 and MS5002 tech-
nology to produce the MS5002D.
The MS5002D field retrofit program can be
offered in two phases: MS6001 compressor
upgrade only for about 10% uprate (FS2R) or
MS6001 compressor with optimized hot gas
path for about 12% uprate (FS2S). The primary
design change for the optimized hot gas path is
a new Stage 1 nozzle with reduced throat area to
provide a higher compressor pressure ratio.
Figure 43. MS5002A exhaust temperature limit
impact on advanced technology uprate Figure 44 is a tabulation of all of the available
uprate programs for a typical MS5002B unit.
advance technology uprate with the standard
Figure 45 is an uprate study for a typical
1000 F/538 C exhaust temperature limit versus
MS5002B unit with options to uprate to an
the additional output possible at higher ambi-
MS5002C or an MS5002D configuration. Also
ent temperatures with a 1050 F/566 C exhaust
shown is a comparison of standard uprate per-
temperature limit. The latter exhaust tempera-
formance vs. performance with a control curve
ture limit is possible due to the new high-tem-
“tilted” to optimize high ambient temperature
perature stainless steel material.
output.
MS5002 “D” Advanced Technology Uprate
(FT2R and FT2S) MS6001B Uprates
Due to continued strong customer interest in Figure 46 provides a history of ratings for all vin-
additional uprate capability for the MS5002 tages of MS6001 models. Several uprate options
unit, an MS5002 uprate to the MS5002D model are available (see Figure 47) by applying the lat-
■ ■ 24
Output Heat Rate

GTD 450 IGV’s (Pre 1978/post 1978) +3.8/+1.690% -0.1/-0.3%
(FT2A/FT2B)
86º IGV Setting +0.20% --
MS5002 “B” to “C” Adv Tech Uprate (FT2C) +7.0% --
MS5002 “C” to “D” Adv Tech Uprate (FT2S) +13.0% -1.0%
Stage 2 Shroud Honeycomb Seal (FS2T) +0.40% -0.40%
HPP Brush Seal (FS2V) +0.50% -0.40%
#2 Bearing Brush Seal (FS2X) +0.20% -0.10%
5/2D S1N in 5/2C (FT2T)
(Included in “C” to “D” Uprate) +2.40% -1.0%
Total “B” to “C” +12.6% -2.5%
Total “C” to “D” +16.4% -2.5%
Total “B” to “D” +28.6% -2.5%
GER3751-44
Figure 44. MS5002B uprate summary
bine speed will provide approximately 1% high-

er output. The GTD stage 2 nozzle and inlet
guide vane improvements are shown in Figure
18. The sum of these improvements will yield a
9.45% output increase for units built prior to
1987.
MS6571B Uprate to (FT4L)

All vintages of MS6001 units can be uprated by
35 F/19 C in firing temperature by applying the
MS6001 advanced technology uprate package
(see Figure 47). This uprate program began in
late 1994 with field testing on a fully instru-
mented MS6001 unit to provide a detailed aero-
dynamic and performance map of the existing
Figure 45. MS5002B uprate with “tilted” control design. Based on this test data, an uprate pro-
curve gram was developed to increase firing tempera-
ture by 35 F/19 C. Figure 49 is a summary of all
est new unit technology. The improved honey- the uprate programs for a MS6001B unit.
comb shroud seals (FS2T and FS2U) provide
improved sealing over the shroud tips on stage Due to concern over bucket life for stages 1 and
2 and 3 buckets, thus improving output by 0.6% 2, the metallurgical, mechanical design and
(see Figure 9). The load gear can be replaced to cooling circuits were extensively redesigned to
allow the turbine speed to increase to 5,133 rpm provide considerable additional expected parts
(FP4D), as shown in Figure 48. The higher tur- life and to be suitable for the firing temperature

■ ■ 25
Turbine Ship Firing Temp Output* Heat Rate* Exh Flow Exhaust
Model Dates (F/C) (kW ) (Btu/kW hr/kJ/kW hr) (10 3 lbs/hr) Temp (F/C)
MS6431A 1978 1850/1010 31,050 11,220/11,835 1,077 891/477
MS6441A 1979 1850/1010 31,800 11,250/11,867 1,112 901/483
MS6521B 1981 2020/1104 36,730 11,120/11,729 1,117 1017/547
PG6531B 1983 2020/1104 37,300 10,870/11,466 1,115 1005/541
PG6541B 1987 2020/1104 38,140 10,900/11,497 1,117 999/537
PG6551B 1995 2020/1104 39,120 10,740/11,329 1,137 1003/539
PG6581B 2000 2077/1136 41,090 10,740/11,329 1,161 1010/543
PG6101FA 1998 2350/1288 69,270 10,095/10,648 1,658 1095/591
*ISO conditions, unit operating at Base Load on Fuel and no inlet or exhaust losses. GT25632A
Figure 46. MS6001B performance history
• Stage 1 Bucket - GTD111 With Perimeter Cooling

• Stage 2 Bucket - Turbulated Cooling
• Stage 3 Bucket - IN738 With Advanced Aero
• Stage 1 Nozzles - Chordal Hinge for Improved Sealing &
Side Wall Cooling
• Stage 2, 3 Nozzles - GTD222
• Stage 1 Shroud - Improved Intersegment Cloth Seals
• Nimonic Transition Piece
• TBC Coated Combustion Liners
• Extendor™ Combustion Upgrade GT24956D
Figure 47. MS6571B advanced technology uprate materials
• Increase Turbine Speed

• Performance Improvements
60 Hz 50Hz
Output +0.82% +0.60%
Heat Rate - 0.11% -0.07%
Model 674 GER3751-48
Figure 48. MS6001B 5,133 rpm load gear
increase. The remaining hot gas path parts have perature increase is approximately 3.0%.
been upgraded with the same design changes
MS7001B Turbine Uprate (FT5X)
incorporated in the MS9001E when its firing
temperature was increased to 2055 F/1124 C. The MS7001B model was introduced in 1970.
The performance increase for the firing tem- Design changes in compressor, combustion and

■ ■ 26
Output Heat Rate
Stage 2 Nozzle/GTD-222 (FS1P) +1.00% -0.40%
Stage 2 Shroud Honeycomb Seals (FS2T) +0.35% -0.35%
Stage 3 Shroud Honeycomb Seals (FS2U) +0.25% -0.25%
GTD-450 IGVs (Pre-1987) (FT4C) +1.50% -0.30%
86º IGV Setting (FT4M) +0.40% +0.20%
Turbine Speed Increase (FP4D)* +0.82% -0.11%
Improved Cool Stg 1 Nozzle (FS2J) -- --
Inner Stage Packing Brush Seal (FS2Z) +1.0% -0.50%
HP Packing Brush Seals (FS2V) +0.75% -0.50%
Firing Temp Uprate Package (FT4L) +3.0% -0.20%
S1S Abraidable Coating Seal (FS20) +0.4% -0.30%
Total +9.45% -3.10%
* 60 Hz GE-Supplied Load Gears
GER3751-49
Figure 49. MS6001B uprate summary
Air Flow Heat Rate

Performance* Firing (103 lbs/hr/ (Btu/kW-hr/ Exhaust
Model Ship Dates kW (NEMA) (1) Temp (F/C) 103 kg/hr) kJ/kWh) Temp (F/C)
PG7651A 1970-71 47,260 1650/899 1.851/0.840 11,910/12.563 844/451

PG7711B 1971-72 51,800 1800/982 1.851/0.840 12,090/12,753 944/507
kW (ISO)(1)
PG7821B 1972-1978 60,000 1840/1004 1.905/0.864 10,960/11,560 947/508
PG7851B 1978-1979 61,750 1850/1010 1.967/0.892 10,920/11,518 944/507
PG7931C 1974-1977 68,500 1950/1065 2.129/0.966 10,970/11,571 986/530
PG7971E 1974-75 71,700 1985/1085 2.040/0.925 10,600/11,181 992/533
PG7981E 1976-78 73,200 1985/1085 2.125/0.964 10,530/11,107 974/523
PG7101E 1978-81 75,000 1985/1085 2.176/0.987 10,590/11,170 977/525
PG7111E 1981-84 76,900 2020/1104 2.210/1.002 10,590/11,170 1000/538
PG7111EA 1984-87 80,080 2020/1104 2.303/1.045 10,650/11,234 989/532
PG7111EA 1987-88 81,760 2020/1104 2.366/1.073 10,600/11,181 987/531
PG7111EA 1988-95 83,310 2020/1104 2.332/1.058 10,470/11,044 982/528
PG7121EA 1995-97 85,080 2020/1105 2.332/1.058 10,420/10,991 995/535
PG7121EA 1998- 86,580 2035/1113 2.382/1.079 10,340/10,907 994/534
PG7211F 1988-91 147,210 2300/1260 3.241/1.470 9,960/10,506 1,100/593
PG7221FA 1992-95 159,100 2350/1288 3.347/1.518 9,440/9,957 1,087/586
PG7231FA 1995-99 167,000 2400/1316 3.428/1.555 9,420/9,936 1,101/594
PG7241FA 1999- 171,700 2420/1327 3.581/1.622 9400/9915 1,131/601
PG7251FB 2001 181,400 2555/1402 3.600/1.631 9310/9820 1,149/621
*Base load distillate fuel, includes 0/0 inches H2O iInlet/exhaust pressure drops
(1)
In early 1970s, rating standards were changed from NEMA (1000 ft/300m altitude and 80F/27C) to ISO (sea level and 59F/15C) conditions. To
convert from NEMA to ISO rating for approximate comparison, multiply NEMA rating by 1.12. Includes 0/0 inches H2O inlet/exhaust pressure drops.
GT18468J
hot-gas-path components were introduced over nozzle. As shown in Figure 50, the E unit has a
the years to achieve the present MS7001 EA higher airflow than the B unit, but it has a
model. Figure 50 lists a performance uprate his- smaller “throat area” for the stage 1 nozzle. This
tory for the MS7001 model. By applying stan- design provides a significant increase in com-
dard current production MS7001EA parts to pressor pressure ratio. When the MS7001EA
older MS7001B units, GE can increase output as Stage 1 nozzle is applied to MS7001B units,
detailed in the four possible uprate options list- there is a 6% increase in compressor pressure
ed in Figure 51. Figure 52 details individual ratio. Extensive evaluation indicated the
design improvements for each MS7001EA com- increase in pressure ratio was acceptable on
ponent involved in the B to E uprate. MS7001B units. The first application of this
uprate was to a utility unit in Alaska. Extensive
The most significant design improvement for field testing (completed in August 1988)
each MS7001B and E unit is the stage 1 turbine proved this uprate was a success.

■ ■ 27
Exhaust
Stage 1 Stage 1 Stage 2 Stage 2 Stage 3 Stage 3 Stage 17 Stator *** Frame &
Option IGV Bucket Nozzle Bucket Nozzle Bucket Nozzle Blades and EGVs Combustion Diffuser
(1) GTD-450 X X - - - - X - -
(2)* GTD-450 X X X** X - - X X -
(3)* GTD-450 X X X X X X X X -****
(4)* GTD-450 X X X X X X X X X
* Generator and station electrical equipment uprate may be required.

** Non air-cooled bucket for MS9001B applications
***Blades must be replaced in the 17th EGV1 and EGV2 stator rows for low ambient applications, water or steam injection applications,
or modulating inlet guide vane applications. A new stage 17 wheel is also recommended if replacement with a curved impeller has
not been made for MS7001B applications.
***Exhaust diffuser may be required for option 3 for high ambient temperature applications.
GT25261A
Figure 51. MS7001B and MS9001B material changes with current production E/EA hardware
Sourcebook
FS2J Stage 1 Nozzle - 2 Vane/Segment, 6% Higher Pressure Ratio, Chordal Hinge With Improved
Sidewall Sealing, Improved Sidewall Cooling
FS2G Stage 1 Bucket - DS GTD111, GT33 +, Blunt Leading Edge Airfoil and Coating on Cooling
Holes
FS1P Stage 2 Nozzle - Air Cooled, Long Chord, GTD222 for Increased Creep Resistance,
Aluminide Coating, Reduced Cooling
FS1L Stage 2 Bucket - Air Cooled, IN738, Scalloped Tip Shroud (ten cooling holes)
FS1R Stage 3 Nozzle - Long Chord, GTD222 for Increased Creep Resistance
FS1M Stage 3 Bucket - Increased Firing Temperature Design, IN738 Scalloped Tip Shroud
- Combustion - Slot Cooled Liners (FR1H), Nimonic Thick Wall Transition Pieces (FR1D)
and Thermal Barrier Coated Liners (FR1G)
FS2Y Stage 1 Shrouds - HR120 Material With Cloth Seals
FS2X #2 Bearing - Brush Seals in Outer Bearing Seals
FS2T, FS2U Stage 2/3 Shrouds - Honeycomb Seal Shroud Design
FS2V HPP Brush Seal - Brush Seal on Compressor Inner Barrel Replaces Labyrinth Seal Design
GT18466 “I”
Figure 52. MS7001EA component design improvements
Option 1 involves new reduced camber IGVs diffuser assembly. This option would increase
and MS7001EA Stage 1 buckets and nozzle. Due the MS7001B rating at ISO conditions to
to increased efficiency, the actual exhaust tem- approximately 70 MW.
perature decreases for this option. Option 4 involves increasing the firing temper-
Option 2 is intended to increase firing temperature for an MS7001B unit to the full 2020
ature as much as possible to keep exhaust tem- F/1104 C MS7001E/EA firing temperature by
perature at pre-uprate levels. This option would also changing to the MS7001EA exhaust frame
be applicable to heat recovery unit application, and diffuser assembly. See Figures 57 and 58 for
where exhaust temperature decreases would be these uprate options.
detrimental to combined-cycle efficiency and In addition to the output increases, a significant
exhaust temperature increases might not be improvement in maintenance/inspection inter-
compatible with the HRSG. vals is achieved by using the higher firing tem-
Option 3 is the maximum exhaust temperature perature MS7001E parts. Figure 53 details
with the existing MS7001B exhaust frame and expected extensions in maintenance intervals

■ ■ 28
Inspection Intervals - Hours
7B/9B 7EA/9E Extendor™

Combustion Liners 3,000 8,000 16,000
Transition Pieces - Thin Wall 3,000 - -
- Thick Wall 8,000 8,000 -
- Nimonic - 12,000 16,000
Hot Gas Path 24,000 24,000
Major 48,000 48,000
Significant Savings in Maintenance Cost

GT24891D
Figure 53. Typical MS7001B vs. MS7001E maintenance
using 7EA hot-gas-path parts. Due to the cost of MS7001C, E and EA Uprate to 2035 F/1112C
this uprate, it may be desirable to uprate Tf (FT5Y)
MS7001B units a few components at a time to
All vintages of MS7001C, E and EA units can be
take advantage of the individual component
uprated to the latest 7EA firing temperature of
design improvements. Each MS7001EA compo-
2035 F/1112 C. Figure 54 details all required
nent in Figure 52 can be applied to MS7001B
material changes for each model to uprate to
units with only minor modification. A tur-
2035 F/1112 C. Figures 57 and 58 list output and
bine/generator performance comparison will
heat rate improvements for increasing firing
be required in each case to determine load
temperature to 2035 F/1112 C, and for all other
equipment capability to accept the uprating.
performance improvements applicable to
This may also result in generator and electrical
MS7001 C, E and EA models.
auxiliary modifications.
• Improved Stage 1 Nozzle With Chordal Hinge and Improved

Sidewall Cooling and Sealing Design
• Directionally Solidified (DS) Stage 1 GTD111 Buckets
• New HR120 Stage 1 Shroud Blocks With Cloth Seals
• GTD222 Stage 2 Nozzle - Reduced Cooling Air Design
• 7EA Stage 2 Scalloped Shroud Bucket - IN738
• GTD222 Stage 3 Nozzle
• 7EA Stage 3 Scalloped Shroud Bucket - U500
• Extendor™ Combustion Wear System
• Thermal Barrier Coated Combustion Liners - Hastelloy-X
• Nimonic Thick Wall Transition Pieces
Recommended
• GTD450 Reduced Camber IGVs Set at 86º
• Stage 2/3 Honeycomb Shroud Blocks
• HPP & #2 Bearing Brush Seal
• 1100 F/593 C Exhaust Isotherm Conversion (100 HP Blowers)
GT24916B
Figure 54. MS7001E/EA uprate requirements for 2035 F/1112 C firing temperature

■ ■ 29
MS7001 C, E and EA uprates to 2055F/ detailed in Figure 52. Figure 55 is a diagram of all
1123C Tf (FT5Q) of the MS7001E 2055F uprate sections.
Depending on the turbine vintage, the unit’s
All vintages of MS7001C, E and EA units also can existing firing temperature and other product
be uprated to the latest MS7001EA 7EA firing improvements that may have already been incor-
temperature of 2055 F/1123 C. This involves porated, output may be improved from 5% to
changing the stage 2 and 3 buckets, stage 1 noz- 19% (see Figure 57). Heat rate can also be
zle and stage 1 shroud to the latest designs improved by over 3% as shown in Figure 58.
• Features & Benefits

- Increased Output (+4.9 to 18.0%)
- Decreased Heat Rate (-1.5 to -3.8%)
- Improved Cooling Features
- Improved Materials
TM
Extendor
Extendor TM HR-120
HR-120Stage
Stage11 Honeycomb
Honeycomb Seal
Seal
Combustion
Combustion System
System Improved
Improved Cooling
Cooling Shrouds
Shroudswith
with Stage-2/3
Stage-2/3Shrouds
Shrouds
(optional)
(optional) Stage-1
Stage-1Nozzle
Nozzle Improved
Improved Seals
Seals (optional)
(optional)
TBC
TBCCoated
Coated
Combustion
Combustion
Liners GTD222
GTD222
Liners
Stage-2
Stage-2Nozzle
Nozzle
GTD222
GTD222
Stage-3
Stage-3Nozzle
Nozzle
Brush
Brush Seals
Seals
(optional)
(optional)
BLE/DS
BLE/DSGTD111
GTD111
Stage-1
Stage-1Bucket
Bucket
Nimonic
Nimonic263
263Transition
Transition Stage
Stage22Buckets
Buckets Stage
Stage33Buckets
Buckets
Pieces
Pieces(TBC
(TBCCoated)
Coated) with
with Improved
Improved with
with Improved
Improved
Cooling
Cooling Scalloped
Scalloped Shrouds
Shrouds
GER3751-55
Figure 55. MS7001E 2055 F uprate
Exhaust Frame Cooling Circuit Modification
GER3751-56
Figure 56. MS7E and MS9E exhaust frame diagram

■ ■ 30
MS 7001B-E Uprate Options
I II III IV MS 7001C MS 7001E MS 7001E MS 7001EA MS 7001EA
Original Tf (°F/°C) 1840/ 1840/ 1840/ 1840/ 1950/ 1985/ 2020/ 2020/ 2035/
1004 1004 1004 1004 1066 1085 1104 1104 1113
Maxim um Uprated Tf (°F/°C) 1840/ 1905/ 1965/ 2020/ 2055/ 2055/ 2055/ 2055/ 2055/
1004 1041 1074 1104 1124 1124 1124 1124 1124
Increase in Output
% % % % % % % % %
Increas e in Tf & Control Mods (FT5X) - 6.7 12.8 18.2 - - - - -
2020F & Controls Mods (FT5C) - - - - 7.4 4.0 - - -
2035F & Control Mods (FT5Y) - - - - 8.7 5.4 2.3 1.8 -
2055F & Control Mods (FT5Q) - - - - 10.3 7.0 3.9 3.4 1.6
GTD450 IGVs (84°) (FT5B) 4.3 4.3 4.3 4.3 4.1 1.5 1.5 1.5 -
Additional 2° IGV (86°) 0.4 0.4 0.4 0.4 0.4 0.4 0.4 - -
GTD222 S2N (FS1P) - -1.0 -1.0 -1.0 0.8 0.8 0.8 0.8 -
Exh. Frm . Motor Blowers (FS2D) - - - 0.2 - - - - -
Air-Cooled S2B - -1.65 -1.65 -1.65 - - - - -
HR120 S1S/Cloth Seals (FS2Y) - 0.70 0.70 0.70 0.70 0.70 0.70 0.70 0.70
Stage 2 Bucket Shrouds
with Honeycom b Seals (FS2T) - 0.35 0.35 0.35 0.35 0.35 0.35 0.35 -
with Honeycom b Seals (FS2U) - - 0.15 0.15 0.15 0.15 0.15 0.15 -
HPP Brus h Seals (FS2V) 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
Num ber 2 Bearing Brus h Seals (FS2X) - - - - 0.30 0.30 0.30 0.30 0.30
Stage 2 Nozzle Diaphram Brus h Seals (FS2Z) 0.50 0.50 0.50 0.50 1.00 1.00 1.00 1.00 1.00
S1S Abraidable Coating Seal (FS2O) 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40
Maxim um Output Increase* 6.6 11.7 18.0 23.6 19.5 13.6 10.5 9.6 5.0
*Total effects are a com pounding effect of all the perform ance im provem ents from above.
Sourcebook codes are provided in parenthes es .
NOTE: All perform ance es tim ates apply at ISO conditions (59° F/15°C, 14.7 ps ia/1.013 bar)
GT25155D
Figure 57. MS7001 uprate options: effect on output
MS 7001B-E Uprate Options

I II III IV MS 7001C MS 7001E MS 7001E MS 7001EA MS 7001EA
Original Tf (°F/°C) 1840/ 1840/ 1840/ 1840/ 1950/ 1985/ 2020/ 2020/ 2035/
1004 1004 1004 1004 1066 1085 1104 1104 1113
Maximum Uprated Tf (°F/°C) 1840/ 1905/ 1965/ 2020/ 2055/ 2055/ 2055/ 2055/ 2055/
1004 1041 1074 1104 1124 1124 1124 1124 1124
Decrease in Heat Rate
% % % % % % % % %
Increase in Tf & Control Mods (FT5X) - -1.1 -2.0 -2.6 - - - - -
2020F & Controls Mods (FT5C) - - - - 0.6 -0.3 - - -
2035F & Control Mods (FT5Y) - - - - -0.7 -0.4 -0.1 -0.1 -
2055F & Control Mods (FT5Q) - - - - -0.7 -0.4 -0.1 -0.1
S1N Chordal Hinge (FS2J) -1.9 -1.9 -1.9 -1.9 -0.25 -0.25 -0.25 -0.25 -0.25
GTD450 IGV's (84°) (FT5B) -0.7 -0.7 -0.7 -0.7 -0.1 -0.3 -0.3 -0.3 -0.3
Additional 2° IGV (86°) 0.2 0.2 0.2 0.2 0.2 0.2 0.2 - -
GTD222 S2N (FS1P) - 0.4 0.4 0.4 -0.3 -0.3 -0.3 -0.3 -0.3
Exh. Frm. Motor Blowers (FS2D) - - - -0.1 - - - - -
Air-Cooled S2B - 1.1 1.1 1.1 - - - - -
HR120 S1S/Cloth Seals (FS2Y) - -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5
with Honeycomb Seals (FS2T) - -0.35 -0.35 -0.35 -0.35 -0.35 -0.35 -0.35 -0.35
with Honeycomb Seals (FS2U) - - -0.15 -0.15 -0.15 -0.15 -0.15 -0.15 -0.15
HPP Brush Seals (FS2V) -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5
Number 2 Bearing Brush Seals (FS2X) - - - - -0.2 -0.2 -0.2 -0.2 -0.20
Stage 2 Nozzle Diaphram Brush Seals (FS2Z) -0.3 -0.3 -0.3 -0.3 -0.5 -0.5 -0.5 -0.5 -0.5
S1S Abraidable Coating Seal (FS2O) -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3
Maximum Heat Rate Improvement -3.5 -3.95 -5.0 -5.7 -3.65 -3.55 -3.25 -3.45 -3.35
*Total effects are a compounding effect of all the performance improvements frozm
above.
Sourcebook codes are provided in parentheses. GT25156C
NOTE: All performance estimates apply at ISO conditions (59° F/15°C, 14.7 psia/1.013 bar)
Figure 58. MS7001 uprate options: effect on heat rate
1100 F/593 C Maximum Exhaust Isotherm Many older units were shipped with a 1020 F/
Limit (FT7G) 549 C or 1040 F/560 C maximum exhaust tem-
perature limit (isotherm). In many cases, the
The higher firing temperatures currently used
following resulted:
on MS6001/7001/9001 units frequently result
in reduced operating flexibility and, sometimes, ■ Reduction in output on hot days as
output on higher ambient days. Figure 59 plots firing temperature had to be reduced
exhaust temperature versus ambient tempera- when maximum exhaust temperature
ture for a typical MS7001E unit for different was reached
IGV angles. ■ Inability to operate at lower IGV angles

■ ■ 31
Figure 59. Improved operational flexibility and increased exhaust heat recovery when modulating IGVs with
exhaust isotherm increase to 1100 F/593 C
on hot days to maximize part load on existing units must be reviewed thoroughly
heat rate at part load on heat recovery due to possible impact on other exhaust system
units components.
■ Reduced turn down ratio on DLN
Uprates with “Tilted” Control Curves (FT7I)
units at all ambients
Normally turbine control curves are designed
The increase in maximum exhaust temperature
to keep a constant firing temperature across the
setting to 1100 F/593 C resolves these prob-
ambient temperature range of each site. This
lems, as shown in Figure 59. Figure 56 shows a
results in a significant decrease in unit output at
cross section of the material changes required
higher ambient temperatures. To attempt to
to go to 1100 F exhaust temperature limit. The
partially compensate for this performance loss,
change in maximum exhaust temperature set-
we can “tilt” the control curve to “overfire” on
ting generally will require changing the exhaust
hot days and “underfire” on cold days. The for-
frame blower to 100 HP blowers. The ability to
mula provides 1.55 additional output on hot
raise the maximum exhaust temperature setting
days and loses about 20% on cold days. The
parts life savings on cold days compensates for
the slight parts life decrease on hot days by over-
firing. This option is restricted to base load
units and to units with the latest advance tech-
nology uprate components. See Figure 60 for a
typical example of a tilted control curve.
MS7001F and FA Uprate to the “MS7001FA

Uprate” Configuration (FT5L)
The MS7001F was introduced in 1988 and has
been uprated for new unit production to the
current “MS7001FA uprate” configuration.
Figure 60. MS7001E uprate with “tilted” control Ratings for all vintages of MS7001F units are
curve

■ ■ 32
listed in Figure 50. Numerous design changes in tomers have already purchased several
metallurgy, cooling and coatings have been MS9001E components to uprate their MS9001B
incorporated into the latest 7FA uprate designs. units.
In each case, the original 7F/FA parts can be It is also possible to uprate MS9001B combus-
upgraded individually, on a spare part basis, to tion systems to use MS9001E components by
realize the parts reliability advantages of the lat- changing to the MS9001E type combustion sys-
est PG7241FA uprate parts. Due to variations in tem. This would provide significant improve-
7F units, it is essential that an individual unit ments in recommended combustion inspection
review be made to determine the scope of the intervals (see Figure 53).
uprate kit for each unit. Figure 23 shows the per-
ISO Air Flow Heat Rate

Performance* Firing (106 lbs/hr (Btu/kW-hr Exhaust
Model Ship Dates kW Temp (F/C) 106 kg/hr) kJ/kWh) Temp. (F/C)
PG9111B 1975-81 85,200 1840/1004 2.736/1.241 10,990/11.592 945/507

PG9141E 1978-81 105,600 1955/1068 3.155/1.431 10,700/11,286 953/512
PG9157E 1981-83 109,300 1985/1085 3.183/1.444 10,700/11,286 968/520
PG9151E 1983-87 112,040 2000/1093 3.214/1.458 10,570/11,149 977/525
PG9167E 1988-92 116,930 2020/1104 3.222/1.461 10,290/10,854 980/527
PG9171E 1993 127,300 2055/1124 3.355/1.520 10,620/11,202 1003/539
PG9301F 1993-94 209,740 2300/1260 4.804/2.179 10,080/10,632 1,082/583
PG9311FA 1994 223,760 2350/1288 4.819/2.186 9,630/10,158 1,097/592
PG9351FA 1999 251,800 2420/1327 5.174/2.344 9,295/9,804 1123/623
*Base load distillate fuel, includes 0/0 inches H2O inlet/exhaust pressure drops. GT18469H
Figure 51 details four options for increased per-

formance gains for earlier 7F vintage units by
formance for MS9001B units when using
applying selected kits of PG7241FA parts.
MS9001E hot-gas-path components similar to
MS9001B Turbine Uprate (FT6X) the MS7001B to E uprate.
Many design changes have been incorporated Option 1 involves new reduced camber IGVs
into the MS9001 since its mid-1970s introduc- and MS9001E stage 1 buckets and nozzles. Due
tion. Figure 61 lists a performance uprate histo- to increased efficiency, the actual exhaust tem-
ry for the MS9001 model. Current production perature decreases for this option.
MS9001E buckets and nozzles (all three stages) Option 2 is intended to increase firing temper-
can be retrofitted into all earlier production ature as much as possible to keep exhaust tem-
MS9001B units with minor modifications and perature at pre-uprate levels. This option would
into existing MS9001E units as direct replace- be applicable to heat recovery unit applications,
ment parts. Substantial improvements in where exhaust temperature decreases would be
expected parts life will be realized when uprat- detrimental to combined-cycle efficiency and
ing older MS9001B units with current produc- exhaust temperature increases might not be
tion MS9001E hot-gas-path parts. Two cus- compatible with the HRSG.

■ ■ 33
Option 3 is the maximum exhaust temperature 66 lists heat rate improvements for this uprate
with the existing MS9001B exhaust frame and as well as for all other performance improve-
diffuser assembly. This option would increase ments applicable to earlier MS9001E models.
the MS9001B rating at ISO conditions to • Improved Stage 1 Nozzle With Chordal Hinge and Improved
Sidewall Cooling and Sealing Design
approximately 93 MW.
• Turbulated Cooled GTD111 Stage 1 Buckets
• Two-Piece Stage 1 Shroud Blocks
Option 4 involves increasing the firing temper- • Reduced Cooling GTD222 Stage 2 Nozzle
ature for the MS9001B units to the full 2020 • GTD111 Stage 2 Buckets
• GTD222 Stage 3 Nozzle
F/1104 C MS9001E firing temperature by also • IN738 Stage 3 Buckets
changing to the MS9001E exhaust frame and • Extendor™ Combustion Upgrade
• TBC Coated Slot-Cooled Liners
diffuser assembly. See Figures 65 and 66 for per- • Nimonic Transition Pieces
• 9E Exhaust Frame and Blowers
formance improvements for these four uprate Recommended
• GTD450 Reduced Camber Inlet Guide Vanes
options. • Stage 2 & 3 Honeycomb Shroud Blocks
• High Pressure Packing Brush Seals
• 1100 F/593 C Exhaust Temperature GT24886C
• Turbulated Cooled GTD111 Stage 1 Buckets*
• GTD222 Stage 3 Nozzle**
• Extendor™ Combustion Upgrade
Figure 63. MS9001E uprate requirements for
• TBC Coated Slot-Cooled Liners 2055 F/ 1124 C firing temperature
• Nimonic Transition Pieces
• 9E Exhaust Frame and Blowers
Recommended
• GTD450 Reduced Camber Inlet Guide Vanes All components involved in the MS9001 uprate
• Stage 2 & 3 Honeycomb Shroud Seals programs are identical to the components used
• High Pressure Packing Brush Seals
• 1000 F/538 C Maximum Exhaust Temperature in new unit production. Due to the extensive
* Any vintage GTD111 Stage 1 Buckets Shipped After 1987 Can Be Used scope of these uprate programs, it may be desir-
**A Long Chord FSX414 Stage 3 Nozzle Can Be Used
GT24887C able to incorporate individual components on a
Figure 62. MS9001E uprate requirements for spare/replacement part basis. Figure 64 details
2020 F/ 1104 C firing temperature all the design improvements on the flange-to-
flange components. Performance improve-
MS9001 Uprate to 2020 F/1104 C (FT6C) ments associated with individual components
Earlier models of MS9001E turbines with firing are included in Figures 65 and 66. GER-3928 has
temperatures of 1955 F/1068 C, 1985 F/1085 C complete details on the MS9001 uprate pro-
or 2000 F/1093 C can be uprated to the grams.
MS9161E rating at 2020 F/1104 C. Figure 62 MS9001F Uprate to the MS9001FA
details all required changes and Figure 65 lists Configuration (FT6Z)
improvements in output. Figure 66 lists improve-
The MS9001F began production in 1993.
ments in heat rate for this uprate as well as for
Ratings for all vintages of MS9001F units are list-
all other performance improvements applica-
ed in Figure 61. Numerous design changes in
ble to earlier MS9001E models.
metallurgy, cooling and coatings have been
incorporated into the latest 9FA designs. In
MS9001 Uprate to 2055 F/1124 C (FT6Y)
each case the original 9F parts can be upgraded
All models of MS9001E turbines can be upgrad- individually, on a spare parts basis, to realize the
ed to the MS9171E rating at 2055 F /1124 C. parts reliability advantages of the latest 9FA
Figure 63 details all required material changes parts. Due to variations in 9F units, it is essential
and Figure 65 lists output improvements. Figure that an individual unit review be made to deter-
GE Power Systems GER-3571H (10/00)■ ■ 34

Sourcebook
FS2J Stage 1 Nozzle - 2 Vane/Segment, Improved Sidewall Cooling
FS2H Stage 1 Bucket - GTD111, GT29 +, Blunt Leading Edge Airfoil and Turbulated Cooling Holes
FS2C Stage 1 Shroud - 2 Piece Shroud for 9E
FS1P Stage 2 Nozzle - Air Cooled, Long Chord, GTD222 for Increased Creep Resistance
FS2F Stage 2 Bucket - Air Cooled, GTD111, Scalloped Tip Shroud
FS1R Stage 3 Nozzle - Long Chord, GTD222 for Increased Creep Resistance
FS2K Stage 3 Bucket - Increased Firing Temperature IN738 Material
- Combustion - Slot Cooled Liners (FR1H), Nimonic Thick Wall Transition Pieces (FR1D)
and Thermal Barrier Coated Liners (FR1G)
FS2T, FS2U Stage 2 & 3 Shroud Blocks - Honeycomb Seal Shroud Design
FS2V Inner Barrel - Brush Seal on Compressor Inner Barrel Replaces Labyrinth Seal Design
GT24257B
Figure 64. MS9001E component design improvements

MS 9001B-E U prates
I II III IV 9E-2020 F/1104C (FT6C ) 9E-2055/F1124C (FT6Y)
Original Tf (°F/°C ) 1840/ 1840/ 1840/ 1840/ 1955/ 1985/ 2000/ 1955/ 1985/ 2000/ 2020/ 2055/
1004 1004 1004 1004 1068 1085 1093 1104 1104 1093 1104 1124
Maxim um U prated Tf (°F/°C ) 1840/ 1905/ 1965/ 2020/ 2020/ 2020/ 2020/ 2055 2055/ 2055/ 2055/ 2055/
1004 1041 1074 1104 1104 1104 1104 1124 1124 1124 1124 1124
Increase in Output
% % % % % % % % % % % %
Increas e in Firing Tem p. & C ontrol Mods (FT5X) - 6.7 12.8 18.2 6.5 4.0 2.7 9.5 7.0 5.7 3.5 -
Bore Plugs 0.33 0.33 0.33 0.33 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
C 450 1GV (84°) 4.3 4.3 4.3 4.3 1.5 1.5 1.5 1.5 1.5 1.5 - -
Additional 2° IGV (86°) 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
R otated S3B - - 0.6 0.6 - - - 0.3 0.3 0.3 0.3 -
GTD 222 S2N - -1.0 -1.0 -1.0 - - - 1.0 1.0 1.0 1.0 1.0
Exhaus t Fram e Blow ers - - - 0.2
Air-C ooled S2B - - -1.65 -1.65 - - - - - - -
w ith H oneycom b Seals (FS2T) - 0.35 0.35 0.35 - - - 0.35 0.35 0.35 0.35 0.35
w ith H oneycom b Seals (FS2U ) - - 0.15 0.15 - - - 0.15 0.15 0.15 0.15 0.15
H PP Brus h Seals (FS2V) 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
N um ber 2 Big Brus h Seals (FS2Y) - - - - 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Stage 2 N ozzle D iaphram Brus h Seals (FS2Z) 0.5 0.5 0.5 0.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
H R 120 One Piece S1S W C loth Seals (FS2Y) 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 1.3
S1S Abraidable C oating Seal (FS20) 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
Total Effect on Output * 7.3 13.4 18.6 24.20 11.9 9.4 8.1 16.7 14.2 12.9 9.2 6.3
*Total effects are a com pounding effect of all the perform ance im provem ents above.
N OTE: All perform ance es tim ates apply at ISO conditions (59° F/15°C , 14.7 ps ia/1.013 bar)
GT24910D
Figure 65. Frame 9 uprate options: effect on output
mine the scope of the uprate kit for each unit. show the significant differences in firing tem-
Figure 23 shows the performance gains for earli- perature, airflow and rating among the various
er 9F and 9FA vintage units by applying selected models.
kits of PG9351FA parts.
■ MS3002 (see Figure 25)
Model Letter Uprates ■ MS5001 (see Figure 34)
In addition to the advanced technology uprates ■ MS5002 (see Figure 41)
for a given model gas turbine, it is possible to
uprate from one model letter to another (i.e.,
MS5001L to MS5001R). A quick review of the
performance history charts in this paper will ■ MS9001 (see Figure 61)

■ ■ 35
MS 9001B-E Uprates
I II III IV 9E-2020 F/1104C (FT6C) 9E-2055/F1124C (FT6Y)
Original Tf (°F/°C) 1840/ 1840/ 1840/ 1840/ 1955/ 1985/ 2000/ 1955/ 1985/ 2000/ 2020/ 2055/
1004 1004 1004 1004 1068 1085 1093 1068 1085 1093 1104 1124
Maxim um Uprated Tf (°F/°C) 1840/ 1905/ 1965/ 2020/ 2020/ 2020/ 2020/ 2055/ 2055/ 2055/ 2055/ 2055/
1004 1041 1074 1104 1104 1104 1104 1124 1124 1124 1124 1124
Decrease in Heat Rate
% % % % % % % % % % % %
Increas e in Firing Tem p. & Control Modifications - -1.1 -2.0 -2.6 -0.5 -0.27 -0.15 -0.77 -0.54 -0.42 -0.27 -
S1N Chordal Hinge -1.9 -1.9 -1.9 -1.9 - - - -0.25 -0.25 -0.25 -0.25 -0.25
Bore Plugs -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2
C450 1GV (84°) -0.7 -0.7 -0.7 -0.7 -0.38 -0.38 -0.38 -0.38 -0.38 -0.38 - -
Additional 2° IGV (86°) - 0.4 0.4 0.4 - - - 0.4 0.4 0.4 0.4 0.4
Rotated S3B - - 0.6 0.6 - - - -0.28 -0.28 -0.28 -0.28 -
GTD222 S2N 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
2-Piece Shroud - - - - - - - 0.4 0.4 0.4 0.4
Exhaus t Fram e Blowers - - - -0.1
Air-Cooled S2B - - 1.1 1.1 - - - - - - -
with Honeycom b Seals (FS2T) - 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
with Honeycom b Seals (FS2U) - - -0.15 -0.15 -0.15 -0.15 -0.15 0.15 0.15 0.15 0.15 0.15
HPP Brus h Seals (FS2V) -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5
Num ber 2 Big Brus h Seals (FS2Y) -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3
Stage 2 Nozzle Diaphram Brus h Seals (FS2Z) -0.3 -0.3 -0.3 -0.3 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5
HR120 One Piece S1S W Cloth Seals (FS2Y) -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.2 -0.6
S1S Abraidable Coating Seal (FS20) -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 -0.3
Total Effect on Heat Rate * -4.2 -5.2 -5.8 -6.5 -3.2 -3.0 -2.8 -4.0 -3.8 -3.6 -3.1 -3.3
*Total effects are a com pounding effect of all the perform ance im provem ents above.
NOTE: All perform ance es tim ates apply at ISO conditions (59° F/15°C, 14.7 ps ia/1.013 bar)
GT24911E
Figure 66. Frame 9 uprate options: effect on heat rate
In general, model letter uprates can be accom- es that are directly correlated to performance
plished with relative ease where firing tempera- increases, usually expressed as “percentage
ture changes are involved, and less easily accom- increases” or “delta increases.” The absolute
plished where airflow changes are involved. performance achievable after an uprate can
However, every older unit can be uprated to a vary due to many variables usually present on
higher model letter. older units, such as casing out-of-round, surface
finish of non-uprated parts, and clearances.
Absolute Performance Guarantees
Recognizing that many customers prefer
All performance uprates listed in this paper are absolute performance guarantees, Figures 67
based on airflow or firing temperature increas-
Generator Drive**
Exhaust
Heat Rate Flow
Advanced Technology Firing Output Btu/kW-hr*/ 103 #/hr/ Exhaust
Uprate Model Temp ºF/ ºC kW* kJ/kWh 103 kg/hr Temp ºF/ ºC Comments
MS5001R - N/T 1755/957 19,800 13,250/13,976 774.6/351 975/524 -

MS5001P - N/T 1765/963 25,240 12,430/13,111 952.1/432 924/496 Axial Strut
(Pre 1978)
MS5001P - N/T 1765/963 25,720 12,110/12,774 949.1/431 919/493 Rotated Strut
(Post 1978)
MS7001B/E (#1) 1840/1004 60,910 11,020/11,624 2040/925 911/488 Option #1
MS7001B/E (#2) 1905/1041 63,500 11,100/11,708 2041/926 954/512 Option #2
MS7001B/E (#3) 1965/1074 67,140 11,010/11,613 2042/926 990/532 Option #3
MS7001B/E (#4) 2020/1104 70,540 10,940/11,540 2043/927 1024/551 Option #4
MS7001E 2020/1104 77,840 10,830/11,423 2299/1043 1000/538 -
MS7001E 2035/1113 78,810 10,820/15,308 2299/1043 1010/543 -
MS7001EA 2035/1113 81,950 10,690/15,124 2365/1073 997/536 -
MS9001B/E (#1) 1840/1004 87,960 11,000/11,600 2938/1332 911/488 Option #1
MS9001B/E (#2) 1905/1041 93,270 10,940/11,540 2939/1333 954/512 Option #2
MS9001B/E (#3) 1965/1074 97,600 10,900/11,500 2940/1333 990/532 Option #3
MS9001B/E (#4) 2020/1104 102,580 10,830/11,420 2942/1334 1024/551 Option #4
MS9001E 2020/1104 114,610 10,520/11,100 3316/1504 982/528 -
MS9001E 2055/1124 119,380 10,400/11,000 3317/1504 1004/540 -
* All Uprates Are Based on Using Reduced Camber High Flow IGVs.
** All Uprate Performance is Based on ISO (59 º F/16ºC, Sea Level, 0”/0” Inlet/Exhaust Pressure Drops, 60% Relative Humidity) Natural Gas Fuel, Base Load and Assumes Axial Flow
Compressor is Not Rebladed.
GT23564D
Figure 67. Absolute performance guarantees for advanced technology generator drive

■ ■ 36
Mechanical Drive**
Exhaust
Advanced Heat Rate Flow
Technology Firing Output Btu/kW-hr/ 103 #/hr/ Exhaust
Uprate Model Temp ºF/ ºC HP/kW kJ/kWh 103 kg/hr Temp ºF/ ºC Comments
MS3002F - N/T 1643/895 11,590/8,643 11,140/15,761 410.5/186 980/527 Simple Cycle
MS3002F - N/T 1628/887 10,620/7,919 8,160/11,545 410.5/186 605/318 Regen Cycle
MS3002 A-F 1575/857 9,700*/7,233 - 379*/172 - Simple Cycle
MS3002 A-F 1625/885 9,400*/7,010 8,450*/11,955 379*/172 - Regen Cycle
MS3002J - N/T 1770/966 15,140/11,290 9,500/13,441 415/188 1008/542 Simple Cycle
MS5002A - N/T 1745/952 27,130/20,231 9,940/14,063 776.1/352 1016/547 Simple Cycle
MS5002B - N/T 1770/966 36,000/26,845 9,150/12,945 974.4/442 967/519 Simple Cycle
MS5001R - N/T 1755/957 26,080/19,448 9,700/13,724 735.2/333 987/531 Simple Cycle
* MS3002A-F Uprates Are Based On NEMA Conditions, All Other Numbers Are At ISO Conditions.
** All Uprates Are Based On Using Reduced Camber High Flow IGVs.
GT23566C
Figure 68. Absolute performance guarantees for advanced technology mechanical drive
and 68 were prepared to show common per- Non-Recoverable Performance

formance guarantee points for typical advanced Degradation
technology uprates. All performances listed are
Since uprate performance increases are based
based on ISO conditions (59 F/15 C, sea level,
on real airflow and/or firing temperature
0"/0" inlet/exhaust pressure drops, 60% rela-
increases, the performance increases provide
tive humidity), natural gas fuel and base load,
real and lasting performance improvements.
and assume the axial flow compressor is not
Figure 69 is plotted to show the approximate
rebladed. Similar performance can be easily
performance increase for a typical MS7001B
provided for variations on these conditions.
uprate option III at approximately 48,000 fired
hours.
Figure 69. Estimated non-recoverable performance degradation effects

■ ■ 37
The expected typical non-recoverable perform- Power Augmentation Uprates
ance degradation is plotted for the original con-
For certain applications where power augmen-
figuration as well as for uprate option III. This
tation or supplemental power is needed for cer-
shows that the performance increase of 15.05%
tain operating conditions, a variety of power
at 48,000 fired hours still returns an expected
augmentation options are available:
incremental performance increase of 10.9% at
100,000 fired hours. By comparison, uprates ■ Evaporative coolers for inlet air (FJ3F)
that are based on component refurbishment ■ Steam injection into compressor
and/or blade coatings will usually disappear discharge (F3JB)
completely in 10,000 to 15,000 fired hours. ■ Water or steam injection into
combustor head end (FGIA/FGIB)
Several sealing design improvements listed in
this publication are intended to reduce per- ■ Helper/starter expansion turbines
formance degradation between major over- (FJ3E)
hauls:
Evaporative coolers can result in power increas-
■ Cloth seals for stage 1 shroud blocks es of up to 14% in hot dry ambients. Figure 70
■ High-pressure packing brush seals shows typical power augmentation for adding
an evaporative cooler.
■ No. 2 bearing brush seals
■ No. 2 and No. 3 bucket/shroud honey- Steam injection for power augmentation can
comb seals result in power increases of 15% to 18% by
injection of up to 5% mass flow (of compressor
■ Abraidable coating for stage 1 shroud
inlet air) of steam into the compression dis-
blocks
charge. Figure 71 shows typical power augmen-
Considerable research and development effort tation for adding steam injection. A develop-
continues in order to develop improved gas ment program is in progress to evaluate increas-
path leakage sealing systems that improve out- ing the maximum allowable steam injection
put and reduce performance degradation rate rate with a goal of 9% by mass flow of air (refer
on existing units. to Application Engineering for details).
Figure 70. Effect on output and heat rate of evaporative cooling over the ambient range

■ ■ 38
Steam Increase in Decrease in

Injection Output Power Heat Rate
Model (%) (%) (%)
MS3002J 5 19.0 -9.0
MS5001R 5 15.2 -6.5
MS5001P 5 13.2 -4.6
MS5002B 5 16.0 -7.5
MS6001 5 15.0 -5.0
MS7001B 5 17.0 -6.0
MS7001E 5 15.0 -5.0
MS7001E 9 29.6 -8.1
MS9001B 5 17.0 -6.0
MS9001E 5 15.0 -5.0
GT23563C
Figure 71. Turbine performance improvement with steam injection
Water or steam can be injected into the com- improvements incorporated into new unit pro-
bustor head end using the standard NOx duction during the past several years. All these
water/steam injection systems. Approximately design improvements are available individually
2% mass flow is possible, which results in or as a package. The Sourcebook codes listed
approximately 5% to 6% performance increase. for each option provide an easy reference num-
Helper/starting turbines would have to be sized ber for GE field offices to quickly provide
for specific applications. detailed information on each option. Figures 28
Considerable application engineering support and 53 provide details on maintenance interval
is required to maximize performance improve- extensions.
ment for any of these power augmentation Extendor™ Program for Increased
options. In addition, a thorough review of all
Combustion Inspection Intervals (FR1V)
gas turbine auxiliaries and all load equipment
must be made to ensure that they are compati- All heavy-duty gas turbines undergo periodic
ble with the supplemental power output. combustion inspections to check for material
creep, thermal barrier coating erosion and
Combustion System Upgrades wear. See Figures 28 and 53 for standard
Each of the advanced technology upgrades recommended inspection intervals with
detailed in this paper includes significant conventional and advanced technology parts.
improvements to combustion system compo- Figure 73 details the new combustion wear-
nents. These combustion system upgrades can
resistant components now known as the
also be supplied as individual options for sub-
Extendor™ system. With the Extendor system,
stantial improvements in component life
and/or for extension in recommended com- combustion inspection intervals can be
bustion inspection intervals. Figure 72 details extended up to 24,000 hours for base load
the more significant combustion system design continuous dry units operating dry on natural

■ ■ 39
Sourcebook G.T.
Codes Models 3/2A-G 3/2H-J 5/1A-M 5/1R&P 5/2A&B 6/1A&B 7/1A&B 7/1E&EA 9/1B 9/1E
Combustion Features
FR1L Floating Seal Transition Piece - X X X X - - - - -

FR1C Heavy Wall Transition Piece - X - - - - X X X X
FR1D Nimonic Tranisition Piece - - - - - - X - X -
FR1G TBC Coated Liners X X X X X X X X X X
FT1V 3/2J Combustion for 3/2A-G X - - - - - - - - -
FR1H 7E Combustion for B Units - - - - - X X - - -
FR1V 9E Combustion for B Units - - - - - - - - X -
FR1J Swirl Cooled Cross-Fire Tube - X X X X X - - - -
FR1N Hard Facing - X X X X X X X X X
FR1P New Tech Liners X X X X X - - - - -
FR1Q New Tech T/P X - X X - - - - - -
FR1R Hast X-inner Elbow X X X X X - - - - -
FR1B Low NOx Liners X X X X X X - - - -
FR1E Multi-Nozzle Quiet Combustor - - - - - - X X - -
FR1T Breech Load Fuel Nozzle - - X X - X X X X X
FR1V Extendor™ Wear Kit - - - X X X X X - -
GT23768B
Figure 72. Combustion upgrade features
gas fuel (12,000 hours with water injection tion hardware during routine maintenance or
using breach load fuel nozzles). to new components using the same conversion
package. The system is currently available for
The Extendor system is a combination of:
standard Frame 5, 6, 7 and 9 gas turbine mod-
■ Wear-resistant coatings and materials els with slot-cooled combustion liners and
■ Enhanced clearances Nimonic transition pieces. See Figure 73 for
■ Mechanical design improvements additional details.
The Extendor combustion system improve- Emission Levels

ments can be retrofitted into existing combus- In considering an uprate to an existing gas tur-
Hula
Hula Seal/Transition
Seal/Transition Piece-
Piece- Transition
Transition Piece
Piece Floating
Floating
Fuel
Fuel Nozzle
Nozzle to
to High
Liner-Base High Velocity
Velocity Oxide
Oxide Fuel
Fuel Seal/Transition
Seal/Transition Piece-
Piece-
Liner-Base Metals
Metals Coating
Coating on
on Both
Both GE Improved
GE Improved GE
GE Base
Base Metals,
Metals,
Materials
Materials Replaceable
Replaceable Elements
Elements
Liner/Flow
Liner/Flow Sleeve
Sleeve
Bolted
Bolted Stops,
Stops,
Reduced
Reduced Clearance,
Clearance,
Reduced
Reduced Forces,
Forces,
Replaceable
Replaceable Element
Element
Cross
Cross Fire
Fire Tube/Collar-
Tube/Collar-
Cross “H”
“H” Block-Bull
Block-Bull Horn-GE MS7000EA
MS7000EA Transition
Transition
Cross Fire
Fire Tube,
Tube, GE
GE Base
Base Horn-GE
Metal Base
Base Metal
Metal Interface, Piece
Piece Seal
Seal and
and Tabs-GE
Tabs-GE
Metal Interface
Interface Interface,
Replacement Replaceable
Replaceable Elements Base Metal Interface
Base Metal Interface
Replacement Element
Element Elements
RDC27237
Figure 73. Extendor™ system design improvements

■ ■ 40
H2O/Steam Inj Dry Low NOx
Single Shaft Units Dry
Firing Temp. Gas Dist Gas Dist*
Model F/C Gas Dist. (FG1A/FG1B) (FG1C/FG1F) (FG2F) (FG2F)
MS5001R 1720/938 126 193 42 65 33 42
MS5001P 1730/943 128 195 25 42 20 42
MS5001P-N/T 1765/963 142 211 25 42 20 42
MS6001B 2055/1124 148 267 42 65 9 42
MS7001B 1840/1004 109 165 25 42 - -

MS7001B Option 3 1965/1074 124 191 25 42 15 42
MS7001B Option 4 2020/1104 132 205 25 42 15 42
MS7001EA 2020/1104 154 228 25 42 9 42
MS9001B 1940/1060 109 165 42 65 - -

MS9001B Option 3 1965/1074 124 191 42 65 25 -
MS9001B Option 4 2020/1104 132 205 42 65 25 -
MS9001E 2020/1104 157 235 42 65 25 42
MS9001E 2055/1124 132 241 42 65 25 42
Two Shaft Units*** Dry H2O/Steam Inj Dry Low Nox

Firing Temp.
Model F/C S.C. R.C.** S.C. R.C. S.C. R.C.
MS3002F 1575/1625/857/885 115 201 42 50 - 42
MS3002J 1730/943 128 217 42 50 25 33
MS3002J-N/T 1770/966 140 236 42 50 25 33
MS5002B 1700/927 125 220 42 50 42 65

MS5002C&D 1770/966 137 255 42 50 42 65
* With Water Injection for Distillate Fuel
** S.C. = Simple Cycle and R. C. = Regenerative Cycle
***Two-Shaft NOx Levels Are All On Gas Fuel GT23289F
Figure 74. NOx emission levels at 15% O2 (ppmvd)
bine, the impact on emission levels must be When the advanced technology uprate is
considered. Figure 74 lists typical NOx emission applied in conjunction with the lean head end
levels before and after uprates for many of the louvered P liner, the result is an uprate that
uprate programs. Also listed are reduced emis- results in significantly lower NOx levels (i.e., a
sion levels with various options available for 12% increase due to uprate minus 30% for lean
emission control (water injection, steam injec- head end liner). Figure 20 plots NOx emissions
tion and Dry Low NOx). Detailed review of site for an advanced technology uprate with and
and specific emission levels are provided with without the P lean head end liner. Dozens of
each uprate study. advanced technology uprates have been sold
with the lean head end liner without the need
Low NOx louvered combustion liners – to add emissions control equipment. Lean head
MS5/1, 3/2, 5/2 (FR1B) end liner designs are available for almost all vin-
A lean “head end” louvered combustion liner is tages of MS3002, MS5001 and MS5002 units for
available for MS3002, MS5001 and MS5002 both regenerative and simple cycle applications
units. The louvered slot pattern and dilution for gas fuel only, or for distillate fuel units with
hole pattern have been changed to provide a atomizing air.
much “leaner” combustion system than the
standard louvered liner. This results in an Summary
approximately 30% reduction in NOx as com- GE has an advanced technology uprate package
pared to the standard louvered liner. Figure 20 available to uprate almost all of the 7,200 GE
compares the original louvered liner design design heavy-duty gas turbines, as shown in
("N" liner) to the lean head end liner (“P” Figure 71. These advanced technology uprate
liner). As shown in Figure 74, the NOx emissions packages provide significant savings to our cus-
level for a standard MS5001P unit increases tomers due to reduced maintenance, improved
about 12% when uprating with advanced tech- efficiency and increased output. Changes in
nology parts. emission levels associated with a gas turbine

■ ■ 41
uprate may also make it necessary to replacement in conjunction with a turbine
add/change emission controls due to regulato- uprate to achieve the best overall improvement
ry requirements. It is frequently desirable to in reliability.
also consider a control system upgrade or
GE Has an Advanced Technology Uprate

Package Available to Uprate Most of the
7,200 GE Design Heavy-Duty Gas Turbines
to Improve Performance and Reliability
GT23184C
Figure 75. Uprate summary
Figure 76. Cross-sections of heavy-duty gas turbine product line

■ ■ 42
List of Figures
Figure 1 Uprate considerations
Figure 2 Gas turbine uprates
Figure 3 Gas turbine advance technology uprate shipments through 1999
Figure 4 Reference ASME papers on heavy duty gas turbine uprates
Figure 5. Development programs for each frame size
Figure 6. Typical brush seal elements
Figure 7. # 2 bearing brush seal
Figure 8. Stage 2 nozzle with a brush seal
Figure 9. Honeycomb shroud blocks
Figure 10 Bucket shroud cutter teeth
Figure 11 “Pumpkin tooth” design vs. new shroud seal design
Figure 12 Bar type spline vs. cloth seal design
Figure 13 Abraidable sealing coating on a stage 1 shroud
Figure 14 MS9171E one-piece stage one shroud
Figure 15 GTD 450 inlet performance increase
Figure 16 GTD 222 stage 2 nozzle creep
Figure 17 Stage 2 and 3 nozzle creep deflection
Figure 18 GTD stage 2 nozzle performance improvement
Figure 19 Louvered low NOx lean head end combustion liners
Figure 20 Lean head end-low Nox louvered liners
Figure 21 MS5002D advance technology uprate
Figure 22 MS3162K advance technology uprate
Figure 23 PG7001F and PG9001F uprate packages
Figure 24 MS7001E 9% steam injection
Figure 25 MS3002 performance history
Figure 26 MS3002 A Through G uprate parts
Figure 27 MS3002 regenerative cycle thermal efficiency improvements
Figure 28 MS3002/MS5001/MS5002 advanced technology packages maintenance interval
extensions
Figure 29 MS3002 modernization and uprate program
Figure 30 MS3002F component design improvements
Figure 31 MS3002H and J advanced technology uprate
Figure 32 MS3162K advanced technology uprate definition

■ ■ 43
Figure 33 MS3002J uprate summary

Figure 34 MS5001 performance summary
Figure 35 MS5001 models A through P advanced technology uprate package hardware changes
Figure 36 MS5001 models L through P advanced technology uprate package
Figure 37 Comparing MS5001 R and P
Figure 38 MS5001 P performance at 5355 RPM
Figure 39 MS3000 and MS5000 exhaust diffuser upgrade
Figure 40 MS5001P uprate summary
Figure 41 MS5002 perfomance history
Figure 42 MS5002 A and B advanced technology uprate package hardware changes
Figure 43 MS5002A exhaust temperature limit impact on advanced technology uprate
Figure 44 MS5002B uprate summary
Figure 45 MS5002B uprate with “tilted” control curve
Figure 46 MS6001B performance history
Figure 47 MS6001 advanced technology uprate materials
Figure 48 MS6001 5,133 RPM load gear
Figure 49 MS6001B uprate summary
Figure 51 MS700B and MS9001B material changes with current production EA/E hardware
Figure 52 MS7001EA component design improvements
Figure 53 Typical MS7001 vs. MS7001E maintenance
Figure 54 MS7001E/EA uprate requirements for 2035 F/112 C firing temperature
Figure 55 MS7001E 2055 F uprate
Figure 56 MS7E and MS9E exhaust frame diagram
Figure 57 MS7001 uprate options: effect on output
Figure 58 MS7001 uprate options: effect on heat rate
Figure 59 Improved operational flexibility and increased exhaust heat recovery when
modulating IGVs with exhaust isotherm increase to 1100 F/593 C
Figure 60 MS 7001E uprate with “tilted” control curve
Figure 62 MS9001E uprate requirements for 2020 F/1104 C firing temperature
Figure 63 MS9001E uprate requirements for 2055 F/1124 C firing temperature
Figure 64 MS9001E component design improvements
Figure 65 Frame 9 uprate options: effect on output

■ ■ 44
Figure 66 Frame 9 uprate options: effect on heat rate

Figure 67 Absolute performance guarantees for advanced technology generator drive
Figure 68 Absolute performance guarantees for advanced technology mechanical drive
Figure 69 Estimated non-recoverable performance degradation effects
Figure 70 Effect on output and heat rate of evaporative cooling over the ambient range
Figure 71 Turbine performance improvement with steam injection
Figure 72 Combustion upgrade features
Figure 73 Extendor™ system design improvements
Figure 74 NOx emission levels at 15% 02 (Ppmvd)
Figure 75 Uprate summary
Figure 76 Cross-sections of heavy duty gas turbine product line

■ ■ 45

■ ■ 46

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GE Power Systems GER-3571H (10/00)

MS7001F and FA Uprate to the “MS7001FA Uprate” Configuration (FT5L) . . . . . . . . . . . . . . . 32

GE Power Systems GER-3571H (10/00)

Abstract levels are included for reference. Advanced

• Performance Improvements (Output/Heat Rate)

New Unit Technology/Components

Figure 1. Uprate considerations

GE Power Systems GER-3571H (10/00)

Figure 2. Gas turbine uprates

6/1B 7/1E 7/1E 7/1E 9/1E

Figure 3. Gas turbine advanced technology uprate shipments through 1999

GE Power Systems GER-3571H (10/00)

Figure 4. Reference ASME papers on heavy-duty gas turbine uprates

New Uprate Development Programs

GE Power Systems GER-3571H (10/00)

HPP Brush Seal (FS2V) X X X X X X

Figure 5. Development programs for each frame size

Figure 6. Typical brush seal element

GE Power Systems GER-3571H (10/00)

• Minimize Air Leakage to Bearing Cavity

Cross-Section Bearing Housing

Figure 7. #2 bearing brush seal

GE Power Systems GER-3571H (10/00)

1-2 Turbine 1-2 Turbine

Current Stage 2 Nozzle Design Proposed Stage 2 Nozzle Design

Figure 8. Stage 2 nozzle with a brush seal

Honeycomb Shroud Blocks

Figure 9. Honeycomb seal insert

GE Power Systems GER-3571H (10/00)

Figure 10. Bucket shroud cutter teeth

First Stage Shroud Cloth Seals

Side View Pumpkin

Bottom View Bottom View

Figure 11. “Pumpkin-tooth” design vs. new shroud seal design

GE Power Systems GER-3571H (10/00)

New Intersegment Seal Design

Current Spline Seal Cloth Spline Seal

Figure 12. Bar type spline vs. cloth-seal design

Stage 1 Shroud Abraidable Coating (ES20) This combination of cloth-seal replacement

GE Power Systems GER-3571H (10/00)

Cloth Spline Seals

Bottom View Bottom View

Figure 13. Abraidable sealing coating on a stage 1 shroud

• Replace Two-Piece Design

Figure 14. MS9171E one-piece stage one shroud block

GE Power Systems GER-3571H (10/00)

FT3C MS5001N/P Pre-1978 3.9% -0.2% -11/-6

Fixed IGV-Design Turbines (316-SS IGV)

Figure 15. GTD 450 IGV performance increase

• Improved Creep Resistance

Figure 16. GTD 222 stage 2 nozzle creep

GE Power Systems GER-3571H (10/00)

• Creep Resistant GTD-222 Material

Figure 17. Stage 2 and 3 nozzle creep deflection

Reduced Cooling Flow

Figure 18. GTD stage 2 nozzle performance improvement

GE Power Systems GER-35671H (10/00)

several years. In most cases the latest upgraded