Aero Energy Package Session

LM6000TM and LM2500

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Please turn off or put your mobile phones on vibrate/silence Please withhold from having side conversations Technical discussions only Please feel free to ask questions of GE and other Customers during the presentation dialog is encouraged

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Agenda
LM2500 Technical Programs LM6000 New Product Introduction LM6000 Technical Programs

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LM2500 Package Programs

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LM2500/+ Package Reliability

Units reporting - 2008: 87, 2009: 88
GG

SCP

Pkg

BOP

LM2500 Pkg Reliability 12 months rolling

100 98
99.8

Reliability (%)

96 94 P75 Pkg Reliability 92 90

Au g

P50 Pkg Reliability P25 Pkg Reliability

Source: ORAP; All rights reserved: SPS

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-06 Oc t-0 De 6 c-0 Fe 6 b-0 7 Ap r-0 7 Jun -0 Au 7 g-0 7 Oc t-0 De 7 c-0 Feb 7 -08 Ap r-0 8 Jun -0 Au 8 g-0 8 Oc t-0 De 8 c-0 Feb 8 -09 Ap r-0 9 Jun -09

LM2500/+ Package Availability

Units reporting - 2008: 87, 2009: 88
GG

SCP

Pkg

BOP

LM2500 Pkg Availability 12 months rolling

100 98

97.7

Availability (%)

96 94 P75 Pkg Availability 92 90

Au g

P50 Pkg Availability P25 Pkg Availability

Source: ORAP; All rights reserved: SPS

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-06 Oc t-0 De 6 c-0 Fe 6 b-0 7 Ap r-0 7 Jun -0 Au 7 g-0 7 Oc t-0 De 7 c-0 Feb 7 -08 Ap r-0 8 Jun -0 Au 8 g-0 8 Oc t-0 De 8 c-0 Feb 8 -09 Ap r-0 9 Jun -09

Product Bulletins Issued since September 2008

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Product Bulletins Issued since September 2008, Continued

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Product Letters Issued

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BRUSH Automatic Voltage Regulator

Background
LM2500/LM2500+ Units with Brush AVR has a potential issue relating to the contactor in the Brush AVRs (Automatic Voltage Regulator).

Applicable to: SAC Base Plus +G4

DLE

Investigation/Results

A fault in the field suppression contactor (FSC) may result to overheating of the internal field suppression resistor (FSR) that could lead to a fire

Improvement
Alert PB 194 informs customers of BRUSH Service Bulletin SB0000004B which offers two fault detector kits depending on the AVR configuration. These kits are designed to monitor temperature of the FSR and will trigger at a temperature below that which would cause damage.

Field Action
Incorporate Alert PB 194 (LM2500) to update the existing BRUSH AVR with a fault detector kit. - Timing Code 2
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LM2500+/+ G4 Package Vent Fan Inlet Obstruction by Side Exit Exhaust Collector Background

Applicable to: SAC Base Plus +G4

DLE

Ventilation fans for negative pressure systems pull the insulation on the exhaust collector into the vent fan cavity and blocks the airflow path. This results in poor airflow across the package and may increase enclosure temperature.

Investigation/Results
Straps were not supplied by the vendor.

Exhaust collector insulation straps

Improvement
Campaign PB 190 introduce exhaust collector insulation straps (straps) to hold in place the insulation blankets on the exhaust collector assembly.

Field Action
Incorporate PB 190, Timing Code 3
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LM2500+/HSPT Fire Event Background

LM2500+/HSPT package reported fire event in the main enclosure and the Reduction Gear Box (RGB) enclosure.

Applicable to: SAC Base Plus +G4

DLE

Investigation/Results
Cause of fire was a rupture of the flex joint at mineral lube oil pump outlet. The rupture appeared due to the mis-alignment of the joint.
Flex Joint Cracks

Improvement/Field Action

Alert PB 169 revised to check condition of flex joint and replace if mis-aligned. Properly reinstall new flex joint with correct alignment. Timing Code 1, 2
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735077-ELBOW

735061-PIPE

Exhaust Access Panel Gap Leakage Repair

Background
The package fan cooling air and engine discharge air escapes through a gap between the exhaust access panel and package wall.

Applicable to: SAC Base Plus +G4

DLE

Investigation/Results
Missing gasket from exhaust access panel

Improvement
Campaign PB 188 provides instruction to repair the gap with Sikaflex sealant, which will prevent the air from exiting the package wall
Allow sufficient down time for cooling of the package external wall and curing of the Sikaflex 221 sealant

Field Action
Incorporate PB 188 - Timing Code: 3
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Generator Ladder Safety Gate

Background
On some units with Brush Air-cooled generator, the generator ladder did not include a safety gate
Safety gate is required by OSHA.

Applicable to: SAC Base Plus +G4

DLE

Investigation/Results
Safety gate was not supplied by Brush

Improvement
Alert PB 200 - installation of a gate (supplied by Brush) across the opening of the generator ladder.

Field Action
Incorporate PB 200 Timing Code: 1

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Fire Protection Panel Release Module Replacement

Background
The Release Module on the Fire Protection Panel (FPP) does not provide an alarm/trip functions for CO2 block valve closure.

Applicable to: SAC Base Plus +G4

DLE

Investigation/Results
Fire Protection panels were received from the vendor with an incorrect release module installed.

Action
Campaign PB 186 provides instructions to replace the old Release Module with the new Release Module (Manufacture P/N AL8001443-D) on the FPP.

Field Action
Incorporate PB 186 - Timing Code: 2
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Gas Generator Removal - PL2500-09-01

Background
The GG interferes with the front wall of the package if removed with PT remaining in the package.

Applicable to: SAC Base Plus +G4

DLE

Improvement Plan
Package/lift fixture design change in progress to allow GG removal.
> Design completion ~3Q10

Field Action
For maintenance such as HS replacement, GT removal is required from the affected packages - PL2500-09-01 GT alignment may be required during reinstallation in the package

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Synthetic Lube Oil Pressure Transmitter Range

Background

Applicable to: SAC Base Plus +G4

DLE

With the sealed damper bearing, the oil supply pressure occasionally exceeds the turbine lube pressure transducer limit of 100 psig (689 kPa) during start up. The control system assumes this condition as turbine lube pressure transducer failure and shuts down the engine.

Investigation/Results
Pressure transmitters PT1021A and PT1021B was set to lower range of 0 to 100 PSIG.

Action
Campaign PB 191 & PB 184 introduces software update to increase the range to 0 150 PSIG Timing Code: 2

Field Action
Incorporate PB 191 &PB 184
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Pressure Transmitter

LM6000 New Products

New Product Offerings Summary - 2009

Power & Efficiency LM6000 STIG Upgrade Active VIGV Software Upgrade Post Overhaul Site Performance Guarantee Shipping Container Air Ride Adapter S6 Software Upgrade PC/PD LM6000 Mechanical drive Ammonia Absorption Chiller LM6000PG Product launch Functionality RAM

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Upcoming Products Summary - 2010

Power & Efficiency Dual Fuel DLE LM6000PF Package Low Noise / 80 dBa LM6000PH Product Launch LM6000PC to PG Product Launch LM6000PC/PD/PF Hot End Drive Package for Repower Pro Boost Functionality RAM

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LM6000 STIG Upgrade

Efficiency
- Inject up to 50,000 lbs/hr steam into compressor discharge - 5% maximum heat rate improvement - Maintain current 30,000 lbs/hr steam for NOx control
GT Shaft Efficiency

46% 45% 44% 43% 42% 41% 40% 39% 38% LM6PC STIG LM5 STIG 120 LM6 PC Sprint LM6 PC Sprint Steam NOx Water NOx

Power Scope

- 2 MW improvement in power output, dependent on site conditions

- Initial applicable models LM6000 PC, SPRINT, gas fuel only - In package and on engine steam delivery hardware & controls - Core engine modifications

Availability
- Launch customer identified, site validation test scheduled for 2Q 2010
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- Available to quote today

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LM6000 ARCTICTM Ammonia Absorption Chiller

Performance
Up to 2 MW additional power 200-250 Btu/kWh heat rate improvement

Scope
- 2000 ton chilling capacity - Heating capability performance heating, anti-icing

Additional benefits
Reduced equipment needs anti-icing, switchgear, mech. compressor Supports flexible generation quick start, low load operation

Availability
- First fire in 4Q 2009 - New units and retrofits

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LM6000 Pro Boost

Performance
Smoothes grid instability issues Short-term increase/decrease of power in response to grid frequency change

Scope
- Control schedule - Controls hardware added to turbine control panel

Benefits
Improved LM6000 capability Improves system response better than competing technologies
TCP

Availability
- 2010
Air Fuel

~
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Shipping Container - Air Ride Adapter

Adapter will replicate dampening effect of air ride tractor/trailer Rigorous testing and evaluation has been completed Adapter is currently being service evaluated on the GE lease fleet After service evolution, adapter will be available for customers who are interested
Change Weight Length Width
+3,000 lbs +1,361 kg +4 ft +1.23 m 0

Total
13,619 lbs 6,178 kg 22.4 ft 6.84 m No Change

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Summary
GE continues to develop innovative products to enhance the value of the LM6000 Evaluating programs to leverage technology improvements from the LM6000 PG/PH into the PC/PD fleet Targeting programs that drive customer value, improve heat rate and power Customer feedback is a valuable source for future product development

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LM6000 Package Programs

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LM6000 Technical Programs

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LM6000 Package Reliability

Units reporting - 2008: 282, 2009: 266
LM6000 Pkg Reliability 12 months rolling
100 98
99.9
GT

SCP

Pkg

BOP

Percent

96 94 P75 Pkg Reliability 92 90

Au g

P50 Pkg Reliability P25 Pkg Reliability

Source: ORAP; All rights reserved: SPS

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-06 Oc t-0 De 6 c-0 Fe 6 b-0 7 Ap r-0 7 Jun -0 Au 7 g-0 7 Oc t-0 De 7 c-0 Feb 7 -08 Ap r-0 8 Jun -0 Au 8 g-0 8 Oc t-0 De 8 c-0 Feb 8 -09 Ap r-0 9 Jun -09

LM6000 Package Availability

Units reporting - 2008: 282, 2009: 266
LM6000 Pkg Availability 12 months rolling
100 98
97.9
GT

SCP

Pkg

BOP

Percent

96 94 92 90
Au g

P75 Pkg Availability P50 Pkg Availability P25 Pkg Availability

Source: ORAP; All rights reserved: SPS

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-06 Oc t-0 De 6 c-0 Fe 6 b-0 7 Ap r-0 7 Jun -0 Au 7 g-0 7 Oc t-0 De 7 c-0 Feb 7 -08 Ap r-0 8 Jun -0 Au 8 g-0 8 Oc t-0 De 8 c-0 Feb 8 -09 Ap r-0 9 Jun -09

Bringing a face to the package

In celebrating 25 years of packaging the LM series of gas turbines, GE Energy has developed a series of package labels to establish better curb appeal. All three product lines (LM2500, LM6000 and LMS100) have had decals designed which have a 20 year design life and constructed from the latest materials to withstand fading.
LM2 options
Imagination at work

LM2500

LM2500

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LM6000 Field Events 2009 Pareto

Operation error RGB Safeset Coupling Distress RGB Gearbox Tooth Distress VBV Silencer Baffle Distress Starter Clutch Failures DLE Fuel Gas Contamination Generator Vent Fan Events DC Generator Lube Pump Failure to Start 50 Hz Gearbox Grouting Incorrect Hoist Load Drop

Last 12 Months Prior 12 Months

PB 238
0 1 2 3 4 5 6

Topic Addressed Later

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SPRINT Water in Oil

Background Investigation of water in oil issues

Applicable to: PA PB PC PD PF

Water noted in lube oil during / after SPRINT operation Frequent lube oil filter element replacement required Affected sites typically low elevation / high humidity Water is from LP SPRINT water entering sump pressurization circuit

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SPRINT Water in Oil

Investigation

Applicable to: PA PB PC PD PF

SPRINT water enters B-sump pressurization port Water evaporates before sump entry Water condenses in air/oil separator Water enters lube oil tank via 1/2 oil return line Water in oil may cause filter clogging, high oil tank water content (>1000 ppm limit) and high filter delta-p alarms

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SPRINT Water in Oil

Investigation

Applicable to: PA PB PC PD PF

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SPRINT Water in Oil

Field Action

Applicable to: PA PB PC PD PF

If water in oil experienced, drain second stage air/oil separator to waste tank or other appropriate receptacle
Drain should be less than 20 ounces per hour

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SPRINT Water in Oil

Improvement Plan

Applicable to: PA PB PC PD PF

Install supplementary filter unit at oil tank to continuously circulate and remove water
Filter element holds 5 quarts of water Isolation valves allow filter replacement during unit operation

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SPRINT Water in Oil

Applicable to: PA PB PC PD PF

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MGTB High Temperatures

Background Main Generator Terminal Box (MGTB)

Applicable to NXGN: PA PB PC PD PF

Nexgen package design Located inside generator enclosure Contains generator and supporting systems electronic control input/output (I/O) modules Cooled by enclosure fans

I/O modules reached temperature >170 F and ceased function

I/O packs normally resume operation when MGTB temperature reduced
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MGTB High Temperatures

Investigation

Applicable to NXGN: PA PB PC PD PF

High temperature alarms occur when unit is in standby mode on hot days (~110 F)
Higher heat dissipation of Mark VIe hardware modules Current design of cabinet has no ventilation
No path for heat to escape

No cooling from generator enclosure fans during standby

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MGTB High Temperatures Improvement Plans

Applicable to NXGN: PA PB PC PD PF

Add ventilation fan to the enclosure

Fans energize at >68 F (20 C) 122 CFM (3.45 CMM) fan will provide ~300 air changes of the cabinet per hour

Service evaluation planned 4Q 2009

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50Hz Reduction Gearbox Tooth Distress

Background

Applicable to: PA PB PC PD PF

16 reduction gearbox (RGB) related events since 2002

Both suppliers impacted

Eight events of tooth distress

Required gear set replacement

Six events of Safeset coupling distress

Safeset is torque limiting device internal to gearbox High vibrations detected after coupling disengagement Required coupling replacement

Two events of Safeset retaining bolt distress

Both events occurred on same unit Under investigation
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50Hz Reduction Gearbox Tooth Distress

Investigation Root cause established on 3 events
Event #1, #2, #3

Applicable to: PA PB PC PD PF

Manufacturing issues (Vendor #1) High grind feed/speed caused temper of tooth Position of manufacturing test coupon during carburizing partially masked tooth Alumina inclusion in forging

Events #4, #5 (Vendor #1)

Similar in appearance to #3 No material anomalies found

Event 6, 7 and 8 (Vendor #2)

Investigation continues
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50Hz Reduction Gearbox Tooth Distress

Field Plan Monitor for high gearbox vibration
Inspect gears if vibration exceeds trip level

Applicable to: PA PB PC PD PF

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50Hz Gearbox Coupling Distress

Investigation

Applicable to: PA PB PC PD PF

Safeset coupling mounted on RGB low-speed shaft

Couples low-speed gear shaft to output quill shaft Provides torque-limiting function decouples if torque limit exceeded Torque set by oil pressurization of internal sleeve oil released if torque exceeded
Two models in fleet (F and CB) Different nominal pressures Pressures serial number unique

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50Hz Gearbox Coupling Distress

Investigation

Applicable to: PA PB PC PD PF

All events occurred after initial decouple event

Reason for decouple unknown
Investigating pressurization procedures, potential for incorrect pressure

Most cases had multiple start/synchronization attempts after decouple

Control system does not detect decouple
Symptoms include low generator voltage alarm and LPT overspeed trip but no control action taken

Device is not designed for continued running after decouple Extended running generates excess heat resulting in bearing damage
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50Hz Gearbox Coupling Distress

Field Action

Applicable to: PA PB PC PD PF

Operator to investigate possibility of Safeset release before attempting to restart if symptoms indicate possible decouple
XNSD overspeed trip Low generator voltage

GE plan to issue Product Letter with more detailed information

Pressurization and lubrication

Improvement Plan Investigate automatic detection of decouple

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VBV Expansion Joint Material Distress

Background VBV expansion joint distress reported

Applicable to: PA PB PC PD PF

Typical damage consists of tears at creases of expansion joint

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VBV Expansion Joint Material Distress

Investigation/Results Root cause is material deterioration

Applicable to: PA PB PC PD PF

Typical VBV Joint Distress

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VBV Expansion Joint Material Distress

Field Action

Applicable to: PA PB PC PD PF

Monitor total tear length replace joint if greater than 3 inches

Excessive leakage at VBV joint may compromise fire protection system effectiveness Reference Product Letter 6000-07-02

Improvement Plans
Replace existing expansion joint material with Silicone Aramid Service evaluation underway at 2 sites (3 units)
Maximum hours 200+ Initial reports of distress at 70 hours one unit Distress determined to be pre-existing at installation two units
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Shipping/handling processes being investigated

50 Hz Base Frame Grouting

Background

Applicable to: PA PB PC PD PF

Some 50 Hz sites have insufficient grouting below supporting beams of generator and gearbox
Absence of grouting creates soft foot situation May contribute to:
Difficulty in maintaining alignment Increased vibration levels

Undesirable gap

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50 Hz Base Frame Grouting

Investigation Grouting procedure complex

Applicable to: PA PB PC PD PF

Design of grouting pockets makes grout flow to far corners of pads difficult Insufficient inspection points exist to visually verify grout is fully penetrated below all cross members

Improvement plans Grouting pad design revised to allow improved grout flow Additional inspection ports and inspections added
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50 Hz Pump Motor Space Heater

Background

Applicable to: PA PB PC PD PF

Some 230 Volt mineral lube oil (MLO) and SPRINT pump motors in 50 Hz Packages were supplied with internal space heaters rated for 110 volts
Heating element damaged may result in motor condensation

Motors affected can be identified by attached label

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50 Hz Pump Motor Space Heater

Field Action

Applicable to: PA PB PC PD PF

Step down transformers added to packages in installation prior to operation

Reduce supply voltage to heater

Improvement Plans Design change in process to specify 230 V heater elements on future packages Product Bulletin to issue in 2010 to address fielded units with damaged heaters
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VBV Silencer Distress

Background VBV silencer distress reported on some units
2 types of distress, varies by manufacturer (AAF and VAW)
VAW: distress of sheet metal to acoustic panel welds May allow release of acoustic material AAF: distress of baffle mounting system within duct Allows dislocation of baffles May allow release of acoustic material GE Proprietary - Subject to Restrictions on Cover Page

Applicable to: PA PB PC PD PF

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VBV Silencer Distress

Investigation Root cause on AAF distress is high stress on baffle mounts
Baffle system designed using incorrect flow assumptions Vendor design change rotated baffles 90 degrees creating adverse flow conditions

Applicable to: PA PB PC PD PF

Original

Current

Root cause of VAW distress is insufficient weld attachment of acoustic panel to sheet metal
1.Air
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Flow

VBV Silencer Distress

Field Action

Applicable to: PA PB PC PD PF

Vendors have provided repair procedure

VAW adds reinforcing welded strip at acoustic panel and sheet metal interface AAF adds more robust mounts top and bottom Product bulletin 1Q 2010

Improvement Plans
AAF to revert to 5-baffle design with increased air flow capability Product Bulletin 1Q 2010

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SSS Clutch DC Lube Oil Pump/Motor

Background

Applicable to: PA PB PC PD PF

Direct current (DC) pump/motor is backup to alternating current (AC) system

Affects classic package only DC system tested at startup
If DC system lube pressure too low, start aborted

Pressure permissive lowered to allow start

Lack of lubrication may result in lack of proper clutch lubrication in event of loss of AC power

Investigation DC lube oil motor/pump undersized

Low pressure aggravated by pump/motor deterioration
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SSS Clutch DC Lube Oil Pump/Motor

Field Action

Applicable to: PA PB PC PD PF

Permissive reduced to 7 PSI to allow start

Abates failure to start but does not abate risk of clutch failure.

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SSS Clutch DC Lube Oil Pump/Motor

Improvement

Applicable to: PA PB PC PD PF

High capacity pump added external to tank

Allows permissive to be restored to level that ensures adequate lubrication in the event of AC system disruption Original pump and motor remains (unused)

Replacement pump and motor

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Operations & Maintenance

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Product Bulletins
Purpose
Ensure safe operation Improve reliability Reduce life-cycle maintenance costs Improve performance Customer responsibility

Customer Responsibility
Review Service Bulletins
Planning Information and Accomplishment Instructions

Assess and manage compliance benefits vs. costs Develop maintenance plans for compliance Schedule, document and report compliance

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Product Bulletins Issued Since September 2008

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Product Letters Issued Since September 2008

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LM1600, LM2500, LMS100 and SPRINT are registered trademarks of the General Electric Company (USA) LM6000TM is a pending trademark of the General Electric Company (USA) Strategic Power Systems, Inc. (SPS) and the ORAP family of products & services, including ORAP Parts TrackingTM and ORAP Cycles TrackingTM, are registered trademarks comprising the intellectual property of SPS, with patents pending. All rights reserved. Safeset is a registered trademark of Voith Turbo Safeset AB

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