Interval Extension – Combustion System Upgrades

0 k EBH

  • (1200 ES)

  • Enhanced operation reliability

  • Reduced life cycle costs

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General Product Information

Recommended Interval Extension Products: Combustor

Interval Extension for Combustion Systems

Gas turbine customers continue to look for products to increase availability while reducing maintenance costs. GT Interval extension products have been specifically developed to address both these needs. Interval extension products were developed to extend the duration between planned maintenance inspection intervals, which can increase availability and in some cases, eliminate certain type of inspections (e.g. combustor inspections) and reduce maintenance costs.

Operational Flexibility Increase

Availability and Reliability Increase

Emission Reduction

In the example below a unit operating at 8.3k EBH turbine inspection intervals now operates at 25k EBH or 33k EBH turbine inspection intervals. This change in operation provides the following benefits:

  1. In a 100,000 hour duration, only 4 recommended scheduled outages compared to 12 outages, which can result in significant cost savings
  2. Extended duration of 25k EBH between outages which can result in improved availability
  3. Typically, interval extension products also come with advanced Siemens technologies that can help improve performance when coupled with TPU (Thermal Performance Upgrades) products

Note: EBH = Equivalent Base Load Hours, ES = Equivalent Starts, HGP = Hot Gas Inspection, MI = Major Inspection, CI = Combustor Inspection

Key recommended interval extension products: Compressor, Combustor and Turbine

The table below the key recommended interval extension products on the 3 main core focus areas: Compressor, Combustor and Turbine.

The following section highlights some of the available recommended interval extension options for the combustor section. These upgrades can be implemented during a CI or HGP or MI.

For turbine and compressor interval extension products, please refer to the following:

Advanced ULN Combustion System (33k EBH/ 1200 ES / 9 ppm NOₓ)

Applicable Frames: SGT6-5000F (FC, FD, FD2, FD3, F4, F5, F5EE) 

Fuel Type: Gas only, dual fuel     

Your benefits can include

  • Reduced NOₓ emissions (as low as ~9 ppm)
  • Enhanced operation reliability
  • Increase in hours / starts between planned inspections (up to 33k EBH / 1200 ES)
  • Reduced life cycle costs
  • Increased firing temperature capability (+90oF from FD2 level)
  • No Combustor inspection outages

Scope of Supply and Product Features

Core hardware is highlighted below; additional auxiliaries and controls modifications may be required

Baskets

  • Two rows of resonators
  • Resonator ring durability
  • Improved spring clip coating
  • Modified swirlers

Pilot Nozzle

  • Ni Alloy
  • Large diameter outer body
  • Swirler injection

Support Housing

  • New design Ni Alloy
  • Internal coil tube fuel oil lines (eliminates bellows)
  • Cast manifold
  • Swirler injection

Transitions

  • New mechanical & aerodynamic design
  • Interfaces with VGP vane 1

Transition Seals

  • Improved inner and outer floating seals and bolted L-seals
  • Ni-alloy floating seals

Vane 1

  • Ni alloy
  • Designed for higher firing temperatures

Advanced DLN Combustion System (33k EBH/ 1200 ES / 25 ppm NOₓ)

Applicable Frames: SGT6-5000F (FC, FD, FD2, FD3, F4, F5) 

Fuel Type: Gas only, dual fuel     

Your benefits can include

  • Maintained emissions (~25 ppm) at higher firing temperatures
  • Enhanced operation reliability
  • Increase in hours / starts between planned inspections (up to 33k EBH / 1200 ES)
  • Reduced life cycle costs
  • Increased firing temperature capability (+70oF from FD2 level)
  • No combustor inspection outages

Scope of Supply and Product features

Core hardware is highlighted below; additional auxiliaries and controls modifications may be required

Baskets

  • Resonator ring durability
  • Modified swirlers
  • Machined resonator ring
  • Improved spring clip coating

Pilot Nozzle

  • Ni Alloy
  • Large diameter outer body (derived from ULN)

Support Housing

  • New design Ni Alloy
  • Internal coil tube fuel oil lines (eliminates bellows)
  • Cast manifold

Transitions

  • New mechanical & aerodynamic design
  • Interfaces with VGP vane 1

Transition Seals

  • Improved inner and outer floating seals, and bolted L-seals
  • Ni-alloy floating seals

Vane 1

  • Ni alloy
  • Designed for higher firing temperatures

DLN 1.1 Combustion System (33k EBH/ 1200 ES / 25 ppm NOₓ)

Applicable Frames: SGT6-5000F (FC, FD, FD2, FD3) 

Fuel Type: Gas only    

Your benefits can include

  • Maintained emissions (~25 ppm) at higher firing temperatures
  • Enhanced operation reliability
  • Increase in hours / starts between planned inspections (up to 33k EBH / 1200 ES)
  • Reduced life cycle costs
  • Increased firing temperature capability (+20oF from FD2 level)
  • No combustor inspection outages

Scope of Supply and Product features

Core hardware is highlighted below; additional auxiliaries and controls modifications may be required

Baskets

  • Improved spring clip wear coating
  • Improved resonator
  • TBC coating for improved resonator durability

Pilot Nozzle

  • Ni Alloy
  • Heat shield modification

Support Housing

  • New SS forged design
  • Improved manufacturing processes and materials
  • Improved welds

Transitions

  • New mechanical & aerodynamic design
  • Interfaces with VGP vane 1

Transition Seals

  • Improved inner and outer floating seals, and bolted L-seals
  • Ni-alloy floating seals

Vane 1

  • Ni alloy
  • Designed for higher firing temperatures

Non-VGP Combustion System (16k EBH/ 600 ES / 25 ppm NOₓ) – New or Upgrade through Repair

Applicable Frames: SGT6-5000F (FC, FD, FD2, FD3) 

Fuel Type: Gas only, dual fuel    

Your benefits can include

  • Reduced ES factors for fast starts
  • Enhanced operation reliability
  • Increase in hours between planned inspections (up to 16k EBH)
  • Reduced life cycle costs
  • Increased firing temperature capability (+20oF from FD2 level)

Scope of Supply and Product features

Core hardware is highlighted below

Baskets

  • Improved coating on basket OD
  • ID coating for durability
  • VGP spring clip coating to reduce wear and leakage

Pilot Nozzle

  • Robust pilot nozzles have design enhancements to improve durability

Support Housing

  • Coating to provide enhanced resistance against stress corrosion cracking

Transitions

  • Increased TBC length
  • Advanced coating on the exit mouth to reduce wear
  • Inlet ring effusion cooling holes and inlet ring wear coating to improve durability

Transition Seals

  • Thicker wear strips to address wear
  • Improved interface

Vane 1– two options

  • Improved ECY – repair upgrade
  • Ni-alloy vane 1.1 (new design)

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