Proceedings of

ASME IGTI
ASME TURBOEXPO 2000
ASME Turbo Expo 2000: Land, Sea and Air
May
May8-11,
8-11,2000,
2000Munich
Munich,Germany
Germany

2000-GT-178
Put Paper Number Here

HOT-GAS-PATH LIFE EXTENSION OPTIONS FOR THE V94.2 GAS TURBINE

Gerhard Bohrenkämper, Herbert Bals, Ursel Wrede René Umlauft

Siemens AG, Power Generation KWU Siemens AG, Power Generation KWU
Mülheim a.d.Ruhr, Germany Berlin, Germany

ABSTRACT output of approximately 90 MW and a turbine inlet temperature

Gas turbine and combined cycle power plants are typically
designed for a service life of over 30 years. If operated at base
load in continuous duty, the gas turbine hot-gas-path
components for example in a combined-cycle power plant need
repair and replacement according to the maintenance program
several times during plant life. Most of the hot components
would reach the end of their service life, e.g. 100,000
equivalent operating hours (EOH), after 10 to 12 years. As this
is well before the end of the overall plant service life defined in
the power plant concept, such plant applications therefore
necessitate life extension measures enabling to continuing
operation beyond 100,000 EOH. This paper presents strategic
options for hot-gas-path component life entension.
INTRODUCTION
While repair techniques are considered only briefly, the
focus of this paper is on the strategic aspects for upgraded
operation and maintenance. Salient items are:
of 850°C according to ISO definition (Fig. 2). In various
development steps, the current design has achieved an output of
close to 160 MW at a turbine inlet temperature of 1060°C (ISO
definition). During this evolution the gas turbine efficiency was
raised from 30.3 to 34.6%. To date, 112 turbines are in service,
and an additional 22 are currently being manufactured or
commissioned. Collectively, the V94.2 fleet has up to now
logged 3.8 million hours of operation at base load, 5.5 million
equivalent operating hours and 77,000 starts. The majority of
these gas turbines is operated in the base and intermediate load
ranges in combined cycle application.
Piping Inner casing Exhaust liner
Rotor
Turbine blading

• the use of upgraded hot-gas-path components with higher

durability to reduce maintenance outage time by extented
inspection intervals and reduced scope of overhaul and repair; Mixing casing
• the implications of residual life assessment after one hot-
gas-path-inspection interval or after 100,000 EOH of operation;
• the driving role of upgraded hot components to achieve
higher gas turbine performance during plant life extension after Pressure-tight
casings
100,000 EOH.
Because of the operating experience involved, the
considerations are based on the hot-gas-path components of the
V94.2 gas turbine (Fig. 1) of the authors company. This model
operates on 50 Hz. To a large extend the statements are also Fig. 1: Gas Turbine Main Components, V94.2
valid for the V84.2 gas turbine, which is the 60 Hz derivative of
the V94.2.
The first V94 gas turbine (including the earlier V94.0 and
V94.1 variants) was connected to the grid in 1974 with an

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 Component Repair / Refurbishing Replacement
interval (EOH)1) interval (EOH)
Flame tube ceramic according to findings NOMENCLATURE
tiles -- during MI EOH: Equivalent operating hours are determined from
Mixing casing 33,000 100,000
Inner casing 33,000 100,000
base load operating hours, the start/stop cycles and
Rotor blades stage 1 -- 33,000 to 66,000 2) also operations such as turbine trips, with
Rotor blades stage 2 -- 33,000 to 66,000 2) corresponding weighting factors. For example,
Rotor blades stage 3 33,000 100,000
Rotor blades stage 4 -- 100,000 1 hour of operation at base load is defined as 1 EOH
Stator blades stage 1 33,000 100,000 and 1 start with normal loading gradient is weighted
Stator blades stage 2 33,000 100,000
Stator blades stage 3 Depending on version 100,000
10 EOH.
Stator blades stage 4 -- 100,000 LCF: low-cycle fatigue
HCF: high-cycle fatigue
x 1000
8 16 25 33 66 100 133 166 200 EO H TIT: turbine inlet temperature acording to ISO defintion
HGP: hot-gas-path
HGPI: hot-gas-path inspection
MI MO MO
H G PI MO incl.H G P H G PI MO incl.H G P 1. MAINTENANCE PROGRAM AND UPGRADED
Life Extension Life Extension SPARE PARTS
Not only the turbine inlet temperature has been increased
1)
according to findings a replacement of single parts is expected but also the hot-gas-path (HGP) inspection interval has been
2)
depending on version
MI = Minor inspection; HGPI = Hot-Gas-Path Inspection;
extended from initially 16,000 equivalent operating hours
MO = Major Overhaul; EOH = Equivalent Operating Hours (EOH) to 25,000 EOH and then to 33,000 EOH in 1994 (Fig.2).
Minor inspection interval = 4000-8000 EOH depending on The application of the last step eliminates two hot-gas-path
operating mode inspections within a plant's life of for example 200,000 EOH.
The table in Figure 2 shows the predicted service life data of
Fig. 2: Maintenance Program for Hot-Gas-Path hot components according to the design life under certain basic
Components, V94.2 assumptions (natural gas firing, continuous duty etc.). Apart
from the 33,000 to 66,000 EOH replacement interval for
turbine rotor blades stage 1 and 2 the other hot components are
scheduled for 100,000 EOH of operation. To allow this, the
Component Original Upgrade Latest Upgrade
Mixing casings, austenitic Incoloy 800H with Inconel 617 with higher refurbishment intervals, also shown in this table, have to be met
Inner Casing steel higher strength, strength, improved cooling for these components.
improved cooling
Service life extension involves the following cases:
Rotor blade
stage 1
IN738LC,
serpentine
improved cooling by separate cooling channel at
additional leading edge,
• Components which are in good condition during
cooling, turbolators VPS coating SICOAT 2231 overhauls and which have remaining useful life require no
chromized action to be taken and these components can remain in service.
Rotor blade
stage 2
IN738LC,
uncooled,
cooling with 6 radial improved cooling with 12
bores radial bores,
• The physical condition of the component requires life
chromized VPS coating SICOAT 2231 extending repair measures, such as refurbishing of turbine
Rotor blade Nimonic 90 U520 or U720 with IN738LC, new design, blades, to enable further use of the component.
stage 3 higher strength, aerodynamic improved • The component is replaced with one of equal value.
chromized
• The component is replaced with one of higher value with
Rotor blade Nimonic Nimonic 90 with U520 with higher strength,
stage 4 80A, higher strength, free new design, aerodynamic
focus on higher robustness, increased output and efficiency.
damping standing blade improved As replacement options, hot component upgrades that have
pins without damping been developed during the design evolution of the V94.2 over
pins is more
efficient the last two decades are available (Fig. 3). The decision
Stator blade IN738LC, improved cooling improved cooling, depends on the condition of the component and on the
No.1 chromized VPS coating SICOAT 2231 assessment of possible remaining useable life. Evaluation of the
Stator blade U500, IN738LC with higher VPS coating SICOAT 2231 cost and benefits of these possibilities have a significant
stage 2 chromized strength
influence on the choice.
Stator blade U500, IN738LC, IN939 uncoated
stage 3 chromized chromized
A life assessment of all V94.2 hot-gas-path components is
Stator blade austenitic N155 with higher IN939 with higher strength reported below. By detailed material investigations on turbine
stage 4 steel, strength, single blading of the front stages after 33,000 EOH of operation,
segments airfoils
valuable experience has been gained. Several hot components
Fig. 3: Upgrading V94.2 Hot Gas Path Components that we have monitored and investigated, have proven potential
for further extension of the HGP inspection interval to longer
than 33,000 EOH. Also, our experience with the residual life

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 assessment of the other hot components after 100,000 EOH of
operation is reported.
2. HOT COMPONENT LIFE ASSESSMENT
PROCEDURE
The hot component life assessment procedure has to be
based on the design criteria for these parts.
2.1 DESIGN CRITERIA
Turbine blading is designed, based on creep strength for a
period of 100,000 equivalent operating hours and, in the V94.2
turbine, is made of nickel-base alloys.
Surface coatings are applied to the front stages to protect
the base material from high-temperature corrosion and
oxidation. These coatings are consumed and are then renewed
e.g. after one hot-gas-path inspection interval of 33,000 EOH.
Depending on the blade row, thousands of starts with
normal loading gradients or hundreds of turbine trips are taken
into account. The resulting loads are caused by changes in
mechanical forces such as centrifugal force as well as restrained
thermal expansion and are partially in the plastic range. This
type of loading is characterized by low-cycle fatigue (LCF)
strength. The number of load cycles, which can be achieved, is
mainly dependent on the extent of plastic strain and component
temperature. Furthermore the rotor blades are designed for
withstanding high-cycle fatigue (HCF). This means, the effects
of vibration caused by rotor dynamics, aerodynamic and
combustion effects are below a certain stress value so that the
component can be exposed to essentially unlimited numbers of
stress cycles occurring at high frequency.
The mixing casings and the inner casing are designed
similarly to the turbine blading based on creep strength and
low-cycle fatigue strength. As casings in the hot-gas-path are
exposed to significant low-cycle fatigue loading, these
components require regenerative heat treatment and weld repair
during hot-gas-path inspections.
Design criteria are established according to the different
loads in the operated gas turbine and calibrated on
measurements with gas turbines in test beds and in operation.
The sophisticated and validated philosophy and criteria for
design, manufacturing, repair and quality assurance is fully
available only at the original manufacturer.
2.2 LIFE ASSESSMENT
Based on the design philosophy described above, the
residual life assessment encompasses stress analysis, operation
and repair history, quality control as well as material
investigations of the service exposed parts.
A preliminary step for plant life extension involves the
compilation of all operating data such as the number of starts,
hours of operation and rapid temperature changes (e.g. due to
load rejection or turbine trip, Fig. 4).
The history of maintenance measures and the trends of
findings of the most recent fact-finding on minor and major
inspections must also be accounted for.
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Following selection of the components to be considered,
the corresponding original design criteria and corresponding
Data collection for operating mode and service history
Evaluation of inspection findings
Application of original design data (from
material testing, engine tests,stress analysis...)
- Non-destructive examination
- Material testing
(e.g. sampling of individual blades)
Assessment (Reserves usable? Repair
methods available?)
Decision on extended service life
analysis are used and updated if necessary.
Fig. 4: Hot Component Life Assessment Procedure
Material investigation corresponding to the design criteria
includes both non-destructive evaluation and destructive testing
of components:
• Visual examination is first required to determine whether a
blade has sustained oxidation/corrosion. This is followed by
surface crack examination. Selected areas are then subjected to
metallographic examination to evaluate the surfaces with regard
to consumption of the protective coating, the depth of attack in
the base material and for assessment of the microstructure.
Investigations with the scanning electron microscope of the γ´-
phase may be included if useful.
• Creep tests are performed on selected components, the
samples being taken from the blade airfoil out of areas of the
highest loading. Test time is reduced by performance at test
temperatures which exceed the metal temperature in operation
and by increased test stress levels above the operating stress.
The same tests are performed for comparison purposes on
samples from the blade root, which is not subjected to creep.
• Corresponding low-cycle fatigue tests are required to enable
conclusions regarding low-cycle fatigue strength, the material
property used for evaluation of service life expenditure caused
by starts/stops and rapid temperature changes. These tests are
performed at room temperature. Samples from both the blade
airfoil and root are also tested here. Results can then be directly
compared with the low-cycle fatigue strength design curve, the
lower bounding curve.
• Crack examination yields preliminary indications of
exceeding high-cycle fatigue strength. In the event, that cracks
occur due to cyclic loading, these can be assigned to loading
based on the crack initiation site and crack propagation. If the
blade is free of cracks, the design strength and the high-cyclic
3 Copyright © 2000 by ASME
 loading limits are used for further evaluation. An example for
such investigations is described below .
Based on these material investigations, the original design
and mode of operation of the gas turbine, reusability of the
component(s) in question is evaluated from a technical
standpoint. Following consideration of the costs and benefits of
measures such as requisite repairs, the final decision is made
regarding continued use or replacement.
outlet at the blade tip. Additionally this feature made the airfoil
more resistant against potential foreign object damage.
Additionally this blade was protected with the MCrAlY
type vacuum plasma spray coating SICOAT 2231 on the outer
surface.

3. HOT COMPONENT LIFE EXTENSION

The rotor blades and stator blades of stage 1 and 2 are
highly temperature loaded, internally-cooled blades, and rotor
blades stage 1 and 2 are designed with low wall thicknesses.
Stage 1 and stage 2 are coated with a highly efficient coating on
the outer surface. Compared to stage 1 and 2 the stages 3 and 4
are moderately temperature loaded. Apart from the moderately
cooled stator blade stage 3 the other rows are uncooled solid
airfoils so that life limiters suchs as internal oxidation or low
wall thickness do not play a role here.
All turbine blade stages showed excellent creep strength
during operation. No failures, neglegible creep deflection and Original design: ECM Upgraded design:
excellent microstructures of investigated blades have been manufactured cooling holes • cast-in slots at trailing edge
found. at trailing edge • separate cooling channel at
leading edge
3.1 STAGE 1 AND 2 OF THE TURBINE BLADING Fig. 5: Design Evolution of Rotor Blade Row No. 1
3.1.1 ROTOR BLADE STAGE 1 (TLA1) (TLa1), V94.2
The original design of the Tla1 (Fig. 5) was developed in
the late seventies. This blade already uses - compared to the
state of the art in those years – an advanced serpentine type
Upgraded Design, Outer
convective cooling channel. Turbolators have been added to the surface coating SICOAT 2231
cooling configuration over the years. The cooling holes at the
trailing edge had to be electro-chemically manufactured (ECM) Continous duty, Operating data:
at that time. Since then, several steps of increasing turbine inlet 198 starts
temperature have been carried out. The original design revealed 26398 base load hours
31712 EOH
several findings during the refurbishment after 33000 EOH of
operation. This led to the decision to limit the service lifetime
to one hot gas path inspection interval of 33000 EOH. The
findings were mainly: Suction side 40 µm

• considerable loss of wall thickness due to oxidation at the

outer surface for the chromized type of this blade;
• significant internal oxidation especially at the trailing
edge that caused certain cracking at the cooling holes in
combination with cyclic operation due to LCF;
• occasional LCF cracking of the leading edge due to
cyclic operation.
Therefore, about 6 years ago this blade was redesigned
with several features. Due to the progress in casting technology
it was feasible to cast-in cooling outlet slots instead of the ECM
manufactured holes. This measure resulted in a reduced Leading edge 40 µm
concentration factor, thus significantly improving the low cycle
fatigue strength. The outlet slots were provided with 6 rows of Fig. 6: Upgraded Design TLa 1, V94.2; Coating
cylindrical pins to connect the suction side and the pressure Condition after ~33,000EOH of Operation (I)
side. These pins increased turbolance effects and enlarged the
A systematic life assessment program was carried out on
cooling surface for a more effective heat transfer.
service exposed rotor blades stage 1 after 33000 EOH of
The cooling of the leading edge was improved by a
operation to verify these improvements.
separate cooling channel with turbulators and a cooling air

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 Samples from base load units revealed excellent coating
behaviour even at the leading edge, which is the position of the
highest material temperature (Fig. 6). It shows still useable
coating and therefore potential for longer refurbishment
intervals.
Upgraded Design, Outer surface coating SICOAT 2231
Intermediate Duty, Operation data:
1256 starts,
17228 base load hours,
32606 EOH
The picture for a unit being operated at intermediate duty
with numerous start-stop cycles over one HGP inspection
interval shows comparable excellent coating behaviour. Only at
the leading edge the coating is nearly consumed while other
regions look as good as new (Fig. 7).
The leading edge of the upgraded design, opposite to the
original design, showed no crack indications after comparable
operating conditions. Also no notable internal oxidation was
found with the upgraded design. This is of special interest for
the life of the trailing edge. The trailing edge of the upgraded
design was found crack free in all cases.
In addition a microstructural temperature evaluation by
investigating the coarsening of γ´-phase was performed for the
leading edge. In accordance with the computational analysis
this investigation showed, that the material temperature is about
50°C lower compared to the original design (Fig. 8).
With the upgraded design the useable life of the Tla1 has
been extended by 100% from one to two HGP inspection
intervals including the refurbishment after 33000 EOH.

3.1.2 ROTOR BLADE STAGE 2 (TLA2)

Leading edge 40 µm
Fig. 7: Upgraded Design TLa1, V94.2, Coating
Condition after ≈33,000 EOH of Operation (II)
The MCrAlY type SICOAT 2231 protective coating was
implemented to the outer surface of rotor blade stage 2 as well.
Suction side On samples, taken from such blades after service, excellent
coating and base material conditions have been investigated
after one HGP inspection interval of 33,000 EOH in every case.
One example in Fig. 9 shows a still useable coating thickness of
>150µm and no base material attack, as was the case with the

original
design
1

2
3
at pos. 1, original design at pos. 1, upgraded design

upgraded
design

at pos. 3, original design at pos. 3, upgraded design

2
3
positions for shape shape changes of the γ‘-phase depend on material temperature and operating
investigation of γ‘-phase time, upgraded design shows ~ 50°C lower material temperature at pos. 3

Fig. 8: TLa1, V94.2, Material Temperature Evaluation

after ≈33,000 EOH of Operation

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 chromized type. Therefore, with this enhanced coating,
comparable to the Tla1 the useable life of the Tla2 has been
extended by 100% from one to two HGP inspection intervals
including the refurbishment after 33,000 EOH. The enhanced
coating is not only applied on new blades but also available for
the blades of the original design.
Outer surface coating: SICOAT 2231 Operating data:
198 starts, 26398 base load hours, 31752 EOH
Suction side 40 µm
Design with 12
Leading edge 40 µm
radial cooling bores
Fig. 9: Upgraded Rotor Blade Row No. 2, V94.2,
Coating Condition after ≈33,000 EOH
3.1.3 STATOR BLADES STAGE 1 AND 2
These rows are also supplied with the above mentioned
SICOAT 2231 coating to meet the refurbishment intervals of
33,000 EOH. The refurbishment includes cleaning of the
oxidized outer surface by the SICLEAN® method, recoating of
the outer surface and potential repair of thermally caused cracks
at the trailing edge. During refurbishment the internal cooling
passages also require non destructive surface testing. With
increasing operating time, degradation of the internal cooling
channels accumulates and also repair measures might not be
allowed several times on the same blade. Therefore the scrap
rate increases with the number of refurbishment cycles and
refurbishment after reaching the 100,000 EOH milestone is
considered to be not realistic for these blades.
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3.2 STAGE 3 AND 4 OF THE TURBINE BLADING
AND HOT-GAS-PATH CASINGS
Stator blades in stages 3 and 4 undergo residual life
assessment when reaching the 100,000 EOH milestone, as they
have potential for continued service. Highly influenced by the
operating and repair history and also depending on the material
and design variant, the inner casing and the mixing casings are
assessed for their residual life after 100,000 EOH.
3.2.1 ROTOR BLADE STAGE 3
For this blade a case study is described to illustrate the
comprehensive investigation and the required assessment
program.
The blades of this now described example are forged from
the nickel-base alloy Nimonic 90 and are uncoated. They have
completed 106,973 equivalent operating hours. Most of these
accumulated equivalent operating hours, approx. 90%, are from
operation at base load with a turbine inlet temperature of 930°C
(ISO conditions).
The area of significant findings at the leading edge was
also selected for the microsection from the blade (after blast
cleaning). Surface attack can be seen here, but local grinding
can eliminate this (Fig. 10). Any severe surface attack on such a
blade needs to be avoided, because grinding would affect the
geometry as well as blade frequencies and frequency tolerances
might not be met after refurbishment. The microstructural
investigations performed on these blades show no significant
differences in comparison between the blade root and airfoil
(Fig. 11).
Nimonic 90
Leading edge 50 µm
Fig. 10: Life Assessment of V94.2-TLa3 after
100,000 EOH, Design Criterion Oxidation
The results of creep testing of the Nimonic 90 samples are
shown in the creep scatter band (Fig. 12). Samples were taken
from the most heavily loaded area on the blade airfoil and from
the blade root for comparison.
The creep samples investigated at increased temperature
and stress levels above the operating stress of 115 MPa exhibit
creep which is in line with creep values of "virgin" material. As
6 Copyright © 2000 by ASME
 the blade design is performed using minimum values, this result
already supports further use of this blade set. The creep data
(creep rupture as a function of testing time and stress) of the
airfoil and root samples were approximately the same, about
2,500 hours for the samples at a stress of 370 MPa. These
values lie on the upper limit curve of the scatter band of
„virgin“ material. The samples at a stress of 250 MPa have
reached more than 8,000 hours and have been stopped. Thus no
creep damage to the airfoil area due to operation could be
detected. The test temperature was selected 65°C higher than
the material service temperature of 635°C.
Nimonic 90
Root section 20 µm Airfoil section
Fig. 11: Life Assessment of V94.2-TLa3 after
100,000 EOH, Design Criteria Creep and
Low-Cycle Fatigue (LCF)
The LCF tests for this Nimonic 90 turbine blade showed
that the stress cycles which led to cracking are above the design
curve (Fig. 13). Data for the samples taken from the airfoil and
root are comparable.
With regard to high temperature high-cycle fatigue strength
that includes creep effects, the good material condition ensures
safe operation even after 100,000 equivalent operating hours.
The high-cycle fatigue stress amplitudes applied in the design
have been measured in corresponding prototype test facility
runs.
Based on the life assessment described, this set of blades
can be used for 33,000 EOH of further operation.
3.2.2 ROTOR BLADE STAGE 4
Apart from regular surface crack examination during hot-
gas-path inspection this uncoated blade required no
refurbishment for the upgraded free standing blade type.
However, the original design with damping pins required
monitoring of potential wear during minor inspections at the
damping pins or at the blade itself. Sometimes during hot-gas-
path inspection, a few blades and damping pins had to be
replaced.
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Because of the relatively low blade material temperature
no reportable oxidation was observed even after long operating
hours of 100,000 EOH. For a life assessment after 100,000
EOH of operation, the program described above is necessary
for an extended use in service. The verification of sufficient
high temperature high-cycle fatigue strength has to be included
as described. Therefore blades of the original design from gas
turbines having operated at lower turbine inlet temperatures
-due to an early date of installation or due to life saving
operation below base load temperature – are candidates for life
extension. This has been evaluated in a recent life extension
project, where a set of rotor blades stage 4 has been qualified
for 33,000 EOH of further operation.
In one recent life extension project after 100,000 EOH the
customer has decided to replace the original design with
damping pins by the upgraded free standing version. This
version provides the Nimonic 90 material with enhanced
strength and additionally an increased turbine efficiency
because of reduced aerodynamic loss.
3.2.3 STATOR BLADE STAGE 3
Several materials for the stator blades stage 3 have been
used during the design evolution of the V94.2. The older
versions are chromized while the latest version uses Inconel
939 material without protective coating because of its higher
chromium contents. The latest modification saves
refurbishment costs. The chromized blades of the older
machines show low corrosion/oxidation attack, therefore a
recoating interval of 66,000 to 100,000 EOH is adequate.
During hot-gas-path inspections, the stator blade stage 3, in
addition to the low coating wear, shows only few findings: only
a few blades show wear at the fixations and at the sealing areas.
Therefore the refurbishment scope during the service time span
of 100,000 EOH is low. In some cases the recoating and the
refurbishment heat treatment, that is part of the process, can be
performed just coincident with the major overhaul at 100,000
EOH. Therefore a life assessment after 100,000 EOH of
operation is recommended also for this blade to assure reliable
operation.
3.2.4 STATOR BLADE STAGE 4
Up to now in the life extension projects after 100,000
EOH, the original stator blades stage 4 have been considered.
This version uses forged airfoils that are welded into segments.
Medium wear at fixations and sealing areas and also cracking at
the weld joint of the outer platform are found during major
overhauls. These findings are mainly due to low-cycle fatigue
and fretting. Plastic deformation to a certain extend due to
restricted thermal expansion of the segments leads to increased
fitting work during disassembly and reassembly. Provided that
the required repair work during several maintenance actions has
been performed adequately and the component repair amount at
the 100,000 EOH overhaul is reasonable, a regenerative heat
treatment might be applied at this occasion for continued
service after 100,000 EOH.
7 Copyright © 2000 by ASME
 1,000
Airfoil Root
sample sample

Limit curves of creep

strength scatter band,
Stress
(MPa)

Nimonic 90, 700°C

Airfoil sample
Root sample

Test stopped without rupture

100
100 1,000 10,000 Time (h) 100,000

Fig. 12: Life Assessment V94.2-TLa3 after

100,000 EOH, Design Criterion Creep

10

∆ε Design values Nimonic 90 for 20°C

(%)
Airfoil sample, 6 mm dia. for 20°C
1 Root sample, 6 mm dia. for 20°C
Root sample, 10 mm dia. for 20°C

0,1
100 1,000 10,000 Number of cycles 100,000

Fig. 13: Life Assessment V94.2-TLa3 after 100,000

EOH, Design Criterion Low Cycle Fatigue
(LCF)

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 On the other hand in recent projects several customers used
this milestone life extension to replace the old design by the
modern precision-cast single airfoil design. The benefits of this
upgrade are: a new service life higher than 100,000 EOH
because of the enhanced material strength, easy disassembly
and reassembly work due to neglegible distortion in operation
and improved areodynamic efficiency.
The single airfoil design has already operated more than
100,000 EOH in the fleet leading gas turbine. Only in a few
units some blades showed wear at the fixation of the sealing
ring (Fig. 14), which is weld repaired. Apart from that, only
non-destructive examination is required for this stator blade.
Wear at the fixation of the sealing ring,
findings during hot-gas-path
inspection after 85,836 EOH
Fig. 14: Stator Blade Stage No. 4, V94.2
3.2.5 HOT-GAS-PATH CASINGS
The original design of inner casing and mixing casings
used austenitic steel or Incoloy 800H material, later an
improved design with Inconel 617 material was supplied. The
service history and also the assessment of the further service
potential is very much dependent on the variant being
considered. Up to now in the life extension projects after
100,000 EOH the original design has been considered.
Service history of this original variant austenitic steel or
Incoloy 800H material showed significant oxidation/corrosion,
cracks and deformation after long operating periods, and
subsequent repair. So up to now in the recent projects, it was
stated that the end of life was reached and replacement by a
modern component according to the latest design and with the
enhanced Inconel 617 material was decided.
The modern variants of inner casing and mixing casing
have exhibited much higher robustness, the fleet leading
casings have now reached about 70,000EOH in service and are
prepared for further use until the overhaul at 100,000 EOH.
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4. PLANT LIFE EXTENSION
The plant life extension after 100,000 EOH apart from the
hot-gas-path already described, includes the compressor
blading, rotor parts, pressure-tight casings, pipings and
auxiliaries, and balance of plant. A brief outlook is given in this
context.
The compressor blading of these gas turbines is operated in
a temperature range of up to 350°C and is therefore
dimensioned based on yield strength or hot yield strength. It is
also designed to withstand low-cycle fatigue for at least 10,000
start/stop cycles, especially in the area of the blade root, as well
as to withstand high-cycle fatigue. The wet corrosion affecting
the front compressor region during operation is counteracted
with suitable protective coatings. Compressor blades are thus
designed for practically unlimited use within the useable life of
the overall power plant. However, the compressor blading is
particularly depending on site conditions and maintenance
measures (including compressor washing and dehumidification
during standstills to prevent standstill corrosion).
In contrast to steam turbines, in which the uncooled rotor
and pressure-tight casings withstand the full temperature of the
operating medium, pressure-tight casings in the V94.2 gas
turbine are not swept by the hot gas flow, and the rotor is
cooled. These components in the V94.2 are thus operated at
moderate temperatures, at which creep damage and hence time-
dependent life expenditure do not yet play a role. Areas with
increased stresses such as turbine casing nozzles or rotor disk
blade slots are designed for several thousand LCF stress cycles.
In addition, the rotor parts are designed with a fracture
mechanics concept to prevent spontaneous crack propagation.
A repetitive non-destructive examination is recommended for
the forged rotor parts after 3,000 starts.
Pipings are considered depending on inspection results, for
GT auxiliaries an assessment at least two years before the
100,000 EOH overhaul is recommended. For the GT auxiliaries
including the instrumentation and also for older analogue type
I&C systems, upgrade programs are offered by the
manufacturer. This is also the case for the balance of plant with
regards to the generator, exhaust stack and combined cycle
modules if applicable.
Because of the strategic plant life extension decision for a
further operation for more than one decade, uprating options for
the gas turbine are demanded by the market and offered by the
manufacturer. Therefore uprating options are available for the
units that undergo a plant life extension. As an example, for one
group of V94.2 machines, the use of upgraded turbine blades
Tla1,Tla2 and Tla3 as well as stator blade stage no. 4 allows a
higher turbine inlet temperature. Subsequently up to 11 MW
additional electric output is gained while the fuel consumption
is reduced by 1.1 % in simple cycle operation. For combined
cycle applications this benefit is even higher. The options and
the implications for such uprating projects are described
elsewhere.
9 Copyright © 2000 by ASME
 5. SUMMARY AND CONCLUSION
Life extension options for hot components during regular
HGP inspections and after long operating periods 100,000 EOH
have been presented.
Repair methods and protective coatings have been
continuously improved for those hot components, that need
regular life extension measures during hot-gas-path inspections.
The investigations for life extension of hot-gas-path
components after the long operating period of 100,000 EOH
have revealed, that several hot-gas-path components have
definitely reached the end of their useable life, while others,
e.g. rear rows of the turbine blades, may be useable for one
more 33,000 EOH period or even longer.
Plant life extension including hot-gas-path life extension of
V94.2 gas turbines has been applied on 11 gas turbines V94.2.
Also a large number of additional plant life extensions are due
to take place in comming years. While the basic statements for
life assessment and life extension are valid for the whole V94.2
fleet, it must be emphasized, that each gas turbine needs to be
evaluated individually because of its individual operating
conditions. Up to now, life extension projects involved the early
versions of V94.2 with relatively low turbine inlet temperature
(TITISO) • 1000 °C and with the original hot component
design, while many of the future projects will involve a higher
TITISO > 1000 °C for base load operation with different hot
component design.
The most profitable plant life extension projects:
• include not only residual life assessment of the hot-gas-
path components,
• but also focus on strategic maintenance aspects to use
upgraded hot components for higher durability, longer
inspection intervals, lower scope of inspection and overhaul
work and subsequently higher plant availability,
• and also care for modernization opportunities to improve
the performance and competiveness of the operating plant.
The best way is to evaluate these items in a joint project
involving the electric power producer and the gas turbine
manufacturer.
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REFERENCES
Deblon, Bruno
A Decade of Experience with Model V94 Gas Turbines
ASME-Paper 86-GT-63.
B. Deblon, K.H. Keienburg
Refurbishing Gas Turbine Blades – Technical and Economic
Aspects
ASME-Paper 85-GT-187.
Umlauft, René; Wrede, Ursel; Bohrenkämper ,Gerhard
Life Extension Strategy for Heavy-Duty Gas Turbines after
Long Operating Periods
Power-Gen Asia '99, Singapore, September 22-24, 1999.
Bohrenkämper, Gerhard
Modernization and Uprating of Heavy Duty Gas Turbines in
Service
12th Conference on the Electric Power Supply Industry
(CEPSI), Pattaya, Thailand; November 1998
Deblon, Bruno; Bohrenkämper, Gerhard
Rehabilitation and Retrofitting of Heavy Duty Gas Turbine
Power-Gen Europe '97, Madrid, June 17-19, 1997
Bals, Herbert; Wrede, Ursel; Bohrenkämper, Gerhard;
Umlauft, René
Korrosionsvermeidung an Gasturbinenschaufeln durch
verändertes Design, 11. VDI- Jahrestagung Schadensanalyse,
Korrosion in Kraftwerken, Würzburg , 29-30. Sept. 1999
10 Copyright © 2000 by ASME