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JAN

28

SAFELY CHECK FOR GAS TURBINE FUEL/AIR LEAKS

CATEGORIES // Combustion Turbine Tips

Combustion Turbine Tips


Generator Tips
Controls Tips

Traditionally operations and maintenance personnel have used gas detectors to


check the fuel pig tail flanges for leaks during the startup process. This is to
ensure that no fuel is present that could cause a fire in the compartment. An
less risky alternative to this process is to perform a soapy water check while the
unit is on crank. A pressurized garden sprayer is filled with soapy water and
while the unit is being cranked and sufficient air pressure is present the entire
unit is sprayed down with the soapy water mixture. Not only will this produce
evidence of leakage at the fuel flanges but will reveal any air leaks on the can
bases, the wrapper four way joints, the primary fuel covers or anywhere else air
can escape.
Since this a relatively simple and safe procedure TGM recommends performing this check prior to any
maintenance being performed (after the unit is shut down and just before the LOTO is initiated). Any and all air
leaks can be identified and they can be addressed during the scheduled maintenance cycle if feasible.
There have been several TIL's released on the care and quality of the flexible metal hoses for CT's. The end user has
gotten into the practice of having the flexible metal hose pressure checked during the hot gas path cycle. If the
soapy water checks are performed prior to any work being performed and any of the flexible metal hoses are
leaking then why bother to have them pressure checked. This approach can save expensive labor cost by eliminating
a test on a hose that will fall out. Plus wouldn't it be better to know you have a leak at the wrapper four way joint
before it is removed to perform a hot gas path than finding out during the inspection at start up?
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NOV

06

COMPRESSOR FAILURES - STATOR VANE LOCK-UP

CATEGORIES // Combustion Turbine Tips

Some compressor failures have been attributed to "lockup" of the stator vanes. The vane roots are designed to rock
slightly at their roots when moved with your hand. Rust and debris can inhibit this movement. An immobile vane
changes the stress profile on the vane which can cause cracking and potential failure. Mechanics should check for
proper movement at each inspection.
Removing lockedup stator vanes has been a challenge for service providers.The OEM has come up with material
upgrades to address the corrosion problems in these areas. The compressor upgrades are designed to reduce the
potential for compressor failures and lockup of the stator vanes.Some providers use destructive methods to cut
out the vanes, potentially damaging the compressor casing. The OEM recommends the use of their (expensive)
special tooling to reduce and hopefully prevent casing damage. An alternate method that TGM has used very
successfully is a process of heating and quenching. Heating the lockedup stator vane segments with a torch and
quickly quenching the vane with cold water will typically free the vane segment for removal without damaging the
casing. The process of heating and quenching (applied by an experienced team) can save time and money while
reducing and hopefully eliminating damage to the compressor casing. TGM can provide its expertise in removing
stubborn stator vane segments and, if needed, quickly replace damaged stator vanes to get the customer back on
line as soon as possible.
TGM's experienced combustion turbine Technical Directors and crews often delight customers by providing
innovative methods that can efficiently and permanently solve issues and get the customer back on line to make
power. Early detection of shim migration and stator vane problems can be performed by TGM through borescope
inspections and eddy current NDE.

TGM's comprehensive borescope diagnostics can provide recommendations and solutions to address many other
compressor issues. Contact Us to find out how we can help.
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SEP

30

PROTECT YOUR TURBINE WITH A GOOD COAT

CATEGORIES // Combustion Turbine Tips

Thermal Barrier Coatings (TBCs) protect the first several rows of hot gas path parts from
the high combustion temperatures in many advanced large frame turbines. Not all coating
applications are equal, and some can even reduce the efficiency of your unit.
TBCs are designed to reduce the temperature of the buckets and stators while providing
resistance to corrosion and reducing oxidation of the component. TBCs form aluminum
oxide and chromiumoxide scales and act as a physical barrier to reduce component
temperatures, extending the life of the parts. These TBCs are subjected to mechanical
stresses, and spallation (coating separation) can occur. If a significant amount of TBC has
separated from the metal, the parent metal will be exposed to the hot combustion gases
and component degradation will be accelerated.
Hot gas path components should be inspected for TBC spallation at every Hot Gas Path or
Major outage. Streaks of brown lines that appear to be coming from the cooling holes are
a good sign that the component is receiving adequate cooling air, and spallation is at a
minimum. When receiving components from the repair shop it is important to carefully inspect the components for
an even coat of TBC. Also inspect the cooling air passages for debris and proper sizing to ensure that proper air flow
can pass through the tiny passages for designed cooling.
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AUG

24

WHEN A WATER WASH FAILS TO RECOVER EFFICIENCY...

CATEGORIES // Combustion Turbine Tips

If a combustion turbine experiences reduced power output and


heat rate, the usual suspect is compressor fouling. But what if
cleaning the compressor through online and offline wash is not
enough to recover lost compressor efficiency?
Some users experience no gain in gas turbine output or
improvement in heat rate even after a Major outage. A likely
suspect is the first row nozzles; refurbished or degraded nozzles
may be contributing to the problem. In many large combustion
turbine frames such as the GE 7FA, the amount of compressed air
used for cooling has a significant impact on gas turbine efficiency.
The first row nozzles in a 7FA can use up to 20% of the air
developed by the compressor for cooling. Turbine efficiency can
be greatly reduced if these cooling holes are enlarged and use too
much air for cooling. First stage nozzle cooling holes may not have
been checked for hole dimensions during the refurbishment
process. This can also affect your ability to tune low NOx
combustion systems. The amount of air being used by first row
nozzles affects the fuel/air ratio, making it more difficult to tune
the unit.
The only solution is to remove the first row nozzles and replace with new or refurbished first row nozzles with
correct cooling hole dimensions. It is also worthwhile to check the first row nozzles when they come back from the
repair shop to ensure the cooling holes are not blocked and are the correct dimension before installing them into
the unit.
Your fuel bill (and possibly your EPA permit) will thank you for it.
Continue Reading

SEP

12

SET IGVS FOR MAXIMUM EFFICIENCY

CATEGORIES // Combustion Turbine Tips

Have your combustion turbines been losing power after overhauls? There are many
factors which can affect power production, but the IGV settings are one area that even
the OEM can overlook.
We recently helped a plant with three GE Frame 6B gas turbines that had lost power
over successive overhauls. Units 1 and 2 had been overhauled by the OEM in the last
few years and Unit 3 had been overhauled in 2006 by a competitor. All three units had
been experiencing an unexplained loss of power.

A gas turbine needs to breathe air and a lot of it to make horsepower. The inlet
guide vanes (IGVs) on a heavy duty gas turbine are designed to modulate (open and
close) in response to commands from the control system to regulate this air flow. These
commands control turbine exhaust temperature, protect against a compressor "stall" or
"surge" (extremely damaging to the compressor blading), and other controlling
functions. The IGVs look like little airplane wings that rotate or pivot to allow more or
less air into the compressor. They are calibrated to the turbine control system by measuring the actual vane angles
with a machinist's protractor and inputting the readings into the control system. This lets the electronic controls
know physically where they are so that the system can properly control the unit.
On checking Unit 1 and 2, the IGV calibration was significantly out of calibration. Unit 3 wasn't as bad but it was
also slightly out of calibration., We accurately calibrated the IGV's to the OEM control specifications on all three
units.
The results of this work were impressive. The heat rate (fuel efficiency) improved on Unit 1 by about 2%, gained 2.5
mw on Unit 2 and 0.5 mw on Unit 3. This made a significant contribution to the customer's bottom line at the
expense of just a few days of work.
The IGV calibrations are just one of the critical instruments or calibrations that could affect power production.
Contact TGM for a full analysis of any reductions to the heat rate or power output of your turbine
Continue Reading

JUL

17

GAS TURBINE COMPRESSOR DEGRADATION

CATEGORIES // Combustion Turbine Tips

Contamination and Erosion


All gas turbines experience losses in performance with time and the compressor has a
significant impact. In a typical heavy duty axial compressor a 1.0% loss in
compressor efficiency will create a 1.1% loss in output.
Compressor fouling is a serious concern and can be mitigated or recovered
through proper operational practices. Dirt, oil and debris in the front stages of
the compressor can result in a loss of mass airflow, and contamination in the
last stages can result in powerrobbing drops in the pressure ratio. These foreign
objects can also erode or damage surface finishes and airfoil geometry,
resulting in reductions in airflow and pressure ratios. Waterwashing can partially clean contaminated blades, but
recapturing full efficiency can only be achieved by opening the unit and mechanically cleaning the surfaces and
replacing damaged components.
While the unit is open, the compressor can be coated to make the airfoils less susceptible to dirt and debris and
increase the ability of the water wash to thoroughly clean the airfoils. Adding filtration to the inlet also helps
maintain a clean compressor.

Leakage
In a typical heavy duty gas turbine compressor section, air is compressed to many atmospheres pressure by the
means of a multiplestage axial flow compressor. The compressor design requires highly sophisticated aerodynamics
so that the work required to compress the air is held to an absolute minimum in order to maximize work generated
in the turbine. Any changes to this precise geometry can materially affect performance.
Air leakage through and around components significantly rob performance. One example is a bleed valve which
remains open during operation. Another would be a leak at the 4 way joint. While sealing the horizontal and
vertical joints are necessary as the machine ages and the casing warps, sometimes all that can be done without
purchasing new casings is to manage the leakage. Leaks are more costly to the aerodynamic cycle at stages further
down the axial compressor. A leak at an early stage might not be worth the cost of repair.

At the tail end of the compressor rotor is the inner barrel, which provides the inner diameter flow path and the
internal support for the exit guide vane (EGV's). On the internal surface of the inner barrel there is a labyrinth seal
called the highpressure packing seal. On field inspections we often find significant rubbing of the rotor to the
labyrinth seals of up to 90 mils. This excess clearance and thus increased airflow results in a loss in performance.
This leakage can be minimized by retrofitting the highpressure packing seal area with a wire brush seal. The wire
brush seal is flexible and will deflect (not wear) if it does contact the rotor. The bristles of the brush deflect in the
direction of rotation so that a closer effective clearance can be maintained. The seal even remains intact during
transient events where some vibration occurs. Also, there will be less performance degradation over time since the
wire brush will bounce back to the original configuration after contact. These losses can only be repaired during an
overhaul.

Calibration
Air temperature and pressure can seriously affect performance. Since the gas turbine is an airbreathing engine, its
performance is changed by anything that affects the density and/or mass flow of the air intake to the compressor.
When measuring performance degradation over time, remember to correct for changes to the reference conditions
of 59 F/15 C and 14.7 psia/1.013 bar. Differing ambient air temperatures affect the heat rate. Correction for
barometric pressure is more straightforward. A reduction in air density reduces the resulting airflow and output
proportionately, but the heat rate and other cycle parameters are not affected.
Humidity is an often overlooked factor affecting performance. Humid air, which is less dense than dry air, also
affects output and heat rate. In the past, this effect was thought to be too small to be considered. However, with
the increasing size of gas turbines and the utilization of humidity to bias water and steam injection for NOx control,
this effect has greater significance.
TGM can help you assess your unit's existing performance versus its original design and establish a performance
measurement process to accurately capture decreases which could indicate the onset of serious problems.
Turbine Generator Maintenance can help you achieve your goals in restoring your machine to its new and clean
condition or upgrading its performance to achieve higher output, lower emissions or both.
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Turbine Generator Maintenance, Inc


125 SW 3rd Place, Suite 300 | Cape Coral, FL 33991
Main Office: 800.226.7557 | Hotline: 888.MrTurbine (678.8724)
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