Swirl Angle: The combustion gases do not exactly flow parallel to the machine axis while the turbine

is in operation because of various reasons like IGVs, deviation from ISO conditions, speed changes etc. These changes cause the exhaust gases to leave the last stage turbine at a different angle than where they entered the first stage. This is commonly called the swirl angle. The most common cause for high spread is restricted fuel nozzles. Dirt, carbon, and other deposits plug the fuel nozzle orifices reducing the fuel flow and hence the low temperature corresponding to that combustion chamber, called cold spot. On a liquid fuel fired unit, this condition is easier to confirm or disprove by reviewing the fuel nozzle pressures. A plugged fuel nozzle will have a higher pressure than the remaining nozzles due to restriction in volumetric flow and would cause a cold spot. Vice versa is also true meaning that an eroded fuel nozzle tip or loose gas tip or a burned oil pilot would result in hot spots. The source of problem could also include the flow divider, gas pig tail pipings, check valves (fuel & purge), transition piece end seals or a major component contributing like combustion liner, transition pieces or broken compressor blades. Following steps can be of guidance in understanding the behavior while it is a fact that the accurate trouble shooting expertise needs experience. Record TTXs Vs Load at steps say FSNL, 25%, 50%, 75% & Base load Fuel line pressure readings (liquid fuel) Look for Cold Spot or Hot Spot. Does the hot spot or cold spot rotate with load? If it rotates with the load, fuel nozzle is the problem, else the spread is being caused else where in the turbine. Use this information (hot/cold spots) to back trace the corresponding combustor causing this hot/cold spot using the swirl angle Cold Spots are normally due to Coking in fuel passages Purge valve leaking (fuel bypassing) TP end seal disengagement Coked check valves/fuel nozzles Burnt cross fire tubes etc. Hot Spots are due to Loosened gas tip Eroded atomizing air cone Burned fuel oil pilot holes etc. There is a ready made application available for GE make machines which can give a fair idea of the combustor number from the spread details. GUIDELINES FOR EXHAUST TEMPERATURE SPREAD IN GAS TURBINES Number of thermocouples is provided in the exhaust plenum aft wall to measure the exhaust temperatures 360 around all the combustors in gas turbines. The number depends upon the size and configuration of the frame size (TT-XD-1 thru 13 or 18 or 24). These thermocouples are wired to the three <RST> controllers in the Speedtronic control panel to provide inputs to the combustion monitor and exhaust temperature control, alarm and trip functions. It is very important that the exhaust temperatures of the gas turbine accurately monitored and correctly interpreted. Preferably, the difference between the highest and the lowest temperatures typically called the exhaust temperature spread is kept as minimum as possible. While it is ideal to run the unit with minimum exhaust spreads, it is acceptable to run the unit with less than 51 C for Frame 6001B & 9001E. It may be noted that high Tx differentials are detrimental to hot gas path parts life and should be addressed immediately to ensure future unit reliability and parts life. An important point regarding the exhaust temperature spread is that the change in spread over a period of time/sudden jump in spread is more valuable than the overall magnitude of the spread. Combustion problems generally do not occur instantaneously but develop over a period of time depending on the nature of the problem. This deterioration can be picked up through monitoring of the exhaust temperature spread. It is also of value to note how the exhaust

temperature spread changes after: 1. an initial startup 2. a shutdown 3. a maintenance outage

'Spread' refers to differential between highest and lowest exhaust gas temperatures (i.e. exhaust gas temperature spread) There are limits on this value as a high spread is indicative of combustor problems; the turbine will trip if the allowable limit is exceeded for a period of time. On GE frame 9 the allowable spread limit (TTXSPL) is calculated value based on average exhaust gas temperature, compressor discharge temp and some constants; value must be within upper and lower limits. It can change quite a bit during transient operations (e.g. start up, fuel change over etc) but when turbine is steady state it should remain fairly constant (max allowable is normally about 60C) The measured spreads are TTXSP1 (difference between highest and lowest exhaust temperature), TTXSP2 (difference between highest and second lowest exhaust temperature) and TTXSP3 is difference between highest and third lowest exhaust temperature. These measured values are used in combustion monitor function along with the spread limit to determine if issues are present. The swirl angle is not exhaust spread but an angle which is used to indicate which combustion can is causing the high or low temperature, and hence increased temperature spread. The angle is needed as the gas flow through the machine is not straight, but rotates as it passes through; the angle generally changes with load and is unit specific. Swirl angle and its relationship to which combustion can could be causing the problem on GE industrial, gas fueled, machines is a bit of an urban myth. Yes the swirl angle will change with load and is a good indication that you have a combustion problem rather than an exhaust thermocouple problem. To try and actually pinpoint which fuel nozzle is causing the problem by looking at the swirl angle and trying to work this back to a fuel nozzle or even a sector of nozzles I have never found to be conclusive. Even if it was, a single nozzle changeout on a GE industrial is not recommended as the nozzles are a flow matched set. Best fix in a high spread situation is to replace the complete set and retest and repair the removed set. Although the cost is high, a spare set of flow tested nozzles is a must andwill pay you back in lost down time in the long run. There have actually been swirl angle calculation circular slide rule type devices produced by various people and I have conclusively proved them to be useless. Please do remember we are looking at can annular combustion system on GE industrials, aero-derivates are a totally different animal and, yes, I agree that swirl angle can be much more predictable. An interesting discussion The thermocouples are mounted in the exhaust where only the tip of the couples will be exposed to the hot gasses. the tip is surrounded by a pipe which guards the tip and decreases the interferences of possible radiation of hot or cold elements near the tip. First the thermocouples are put in an array (TTXD1_n) on position in the exhaust, i.e. thermocouple number.

Second, they are shorted on temeperature and put in array (TTXD2_n), and their location is stored in JXD_n. Example :TT-XD-9=1000F and has the highest temperature results in TTXD2_1 = 1000F and JXD_1 = 9. Location information is used in the combustion spread monitor. Third the faulty thermocouple values are removed before averaging. this is done by comparing of the thermocouple values to the one but highest temperature (TTXD2_2) minus TTKXCO (500F). If a thermocouple is below that value it is rejected from averaging. broken thermocouples will have a negative value, and thermocouple values of a switched off computer are set to zero. GUIDELINES FOR EXHAUST TEMPERATURE SPREAD IN GAS TURBINES Number of thermocouples is provided in the exhaust plenum aft wall to measure the exhaust temperatures 360 around all the combustors in gas turbines. The number depends upon the size and configuration of the frame size (TT-XD-1 thru 13 or 18 or 24). These thermocouples are wired to the three <RST> controllers in the Speedtronic control panel to provide inputs to the combustion monitor and exhaust temperature control, alarm and trip functions. It is very important that the exhaust temperatures of the gas turbine accurately monitored and correctly interpreted. Preferably, the difference between the highest and the lowest temperatures typically called the exhaust temperature spread is kept as minimum as possible. While it is ideal to run the unit with minimum exhaust spreads, it is acceptable to run the unit with less than 51 C for Frame 6001B & 9001E. It may be noted that high Tx differentials are detrimental to hot gas path parts life and should be addressed immediately to ensure future unit reliability and parts life. An important point regarding the exhaust temperature spread is that the change in spread over a period of time/sudden jump in spread is more valuable than the overall magnitude of the spread. Combustion problems generally do not occur instantaneously but develop over a period of time depending on the nature of the problem. This deterioration can be picked up through monitoring of the exhaust temperature spread. It is also of value to note how the exhaust temperature spread changes after: 1. an initial startup 2. a shutdown 3. a maintenance outage