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Maintenance Considerations

1/ GE Title or job number / 5/21/2008

Effects of Air Quality


Air quality affects maintenance and operating costs. Dirt, Dust, salt, and oil cause compressor blade erosion, corrosion, and fouling. Ingestion of oil vapor, smoke, sea salt, and industrial vapors can cause fouling. Corrosion causes pitting in compressor blades leading to cracking. Surface roughness and blade contour changes reduce output and thermal efficiency.

2/ GE Title or job number / 5/21/2008

Effects of Air Quality (continued)

Deterioration of Gas Turbine Performance due to Compressor Blade Fouling


3/ GE Title or job number / 5/21/2008

Effects of Air Quality (continued)


Preventing recoverable losses Recoverable losses account for 70% to 85% of the performance losses. On-line compressor washing can maintain compressor efficiency. Off-line systems can clean heavily fouled compressors. Fouling can be minimized by maintaining inlet filtration system and inlet evaporative coolers. Periodic inspection and prompt repair of compressor blades help control fouling.

4/ GE Title or job number / 5/21/2008

Effects of Air Quality (continued)


Preventing non-recoverable losses Non-recoverable losses are not caused by deposits. Non-recoverable losses occur due to: Blade surface roughness Erosion Blade tip rubs Changes in nozzle throat area Increase in bucket tip clearance Leakages Regular monitoring of performance parameters can help prevent compressor deterioration.

5/ GE Title or job number / 5/21/2008

Maintenance Recommendations
Quality of intake air affects the performance of a gas turbine. Airborne contaminants in a compressor can cause: Erosion Corrosion Fouling The operating environment and filtration level of a compressor determine the type and rate of fouling. To minimize fouling: Reduce oil leaks and ingestion of oily constituents Filter the incoming air

6/ GE Title or job number / 5/21/2008

Maintenance Recommendations (continued)


Use compressor washing to: Slow down corrosion Reduce the formation of fouling deposits Maintain compressor performance

7/ GE Title or job number / 5/21/2008

Maintenance Recommendations (continued)


Methods for detecting a fouled compressor: Visual inspection: Involves inspecting the compressor inlet, bellmouth, IGVs, and early stage blades Performance monitoring: Involves comparing the gas turbine data with the base-line data for monitoring trends

8/ GE Title or job number / 5/21/2008

Maintenance Recommendations (continued)

Turbine Maintenance

9/ GE Title or job number / 5/21/2008

Maintenance Recommendations (continued)

Turbine Maintenance

10 / GE Title or job number / 5/21/2008

Performance Degradation
Compressor Erosion It is caused by the presence of excessive quantities of particulates such as sand or fly ash. Significant blade erosion can occur if 20 micron particles enter a compressor. Orifices and valve seats are more susceptible to compressor erosion.

11 / GE Title or job number / 5/21/2008

Performance Degradation (continued)


Compressor Corrosion Is caused by noxious fumes or ash-forming substances present in the fuel: aluminum calcium iron nickel potassium sodium silicon magnesium

12 / GE Title or job number / 5/21/2008

Performance Degradation (continued)


Increases surface roughness and causes pitting that lead to: decreased compressor airflow and efficiency reduced gas turbine output and overall thermal efficiency

13 / GE Title or job number / 5/21/2008

Performance Degradation (continued)


Compressor Fouling Is caused by liquid or solid particles accumulated on compressor blades Leads to reduced air flow Leads to lower compressor efficiency Leads to lower compressor pressure ratio

14 / GE Title or job number / 5/21/2008

Performance Degradation (continued)


Fouling Deposits Consist of varying amounts of: moisture oil soot water-soluble constituents insoluble dirt corrosion products of the compressor blading material Are held together by moisture and oil

15 / GE Title or job number / 5/21/2008

Performance Degradation (continued)

Compressor Maintenance
16 / GE Title or job number / 5/21/2008

Compressor Washing
Is an effective method for preventing fouling in the compressor of a gas turbine Slows down the progress of corrosion and increases blade life Reduces the formation of fouling deposits by corrosion products Ensures maximum available power output, improved fuel efficiency, and reduced wear and tear on machine components Is done by injecting a solution of water and detergent into the bellmouth and then rinsing the compressor with water and/or water and detergent solution Can be performed while the turbine is operating or after it is shut down

17 / GE Title or job number / 5/21/2008

Compressor Washing (continued)


Methods of compressor washing: On-line compressor washing Off-line compressor washing On-line compressor washing aims at extending the period between off-line washes through frequent washings of short duration. Off-line compressor washing is performed if a compressor is heavily fouled.

18 / GE Title or job number / 5/21/2008

Compressor Washing (continued)


The washing solution used for off-line and on-line compressor washing must meet the quality specifications listed in the following table:
Quality Specification

Off-line washing
Total solids (dissolved and undissolved) Total alkali metal Other metals pH (determined by glass electrode) 100 ppm 25 ppm 1.0 ppm 6.5 to 7.5

On-line washing
Total solids (dissolved and undissolved) Total alkali metal and other metals pH (determined by glass electrode) 5 ppm 0.5 ppm 6.5 to 7.5

19 / GE Title or job number / 5/21/2008

Compressor Washing (continued)


Turbine Performance Degradation Curves

20 / GE Title or job number / 5/21/2008

On-Line Compressor Washing


Is performed to maintain compressor efficiency and is performed before significant fouling has occurred in the compressor Involves injecting water into the compressor while the turbine is operating at full speed Can be performed without shutting down the gas turbine, and therefore, is used to supplement off-line washing

21 / GE Title or job number / 5/21/2008

On-Line Compressor Washing (continued)


In an on-line compressor washing, the addition of water increases the compressor pressure ratio and reduces the surge margin. Recommendations before performing on-line washing: The washing solution must meet the quality specification prescribed by GE. The turbine must be operating at full speed and must not be in process of shutting down. The compressor inlet temperature must be greater than 50 F.

22 / GE Title or job number / 5/21/2008

On-Line Compressor Washing (continued)


Procedure for on-line compressor washing: 1. 2. 3. 4. Select ON-LINE WATER WASH ON from the water wash control display on the turbine control panel. On-line wash water injection valve opens and water flows through the on-line wash water spray manifolds into the compressor. On-line wash cycle begins and continues approximately for 30 minutes. On-line wash water pump automatically shuts down at the end of the on-line wash cycle. On-line wash can be stopped at any time by selecting ON-LINE WATER WASH OFF. Select BASE LOAD or any other desired load target to return the gas turbine unit to normal service.

5.

23 / GE Title or job number / 5/21/2008

Off-Line Compressor Washing


Includes injecting water into the compressor when the turbine is turned at cranking speed and requires the turbine to be shut down Isolates all air extraction points and drains all low points to prevent effluents from entering the piping systems Is performed when the compressor performance degrades by 10% due to fouling or the compressor is heavily fouled

24 / GE Title or job number / 5/21/2008

Off-Line Compressor Washing (continued)


Preparation for off-line compressor washing: Washing solution and the detergent concentrate must meet the prescribed quality specifications. The gas turbine must be shut down and allowed to cool. The differential temperature between the wash water and the interstage wheelspace temperatures must not be greater than 120 F (67 C). The operating compressor should be de-energized during the pulse mode water wash cycle. The inlet plenum and the bellmouth should be cleaned.

25 / GE Title or job number / 5/21/2008

Off-Line Compressor Washing (continued)


Procedure for off-line compressor washing 1. 2. 3. 4. 5. 6. 7. 8. 9. On the Turbine Main control display screen, place the Master Select switch in the CRANK position. Select OFF-LINE WATER WASH ON from the Water Wash control display. From the Main Control display, initiate a turbine START signal. Select CONTINUE WASH to inject the detergent/water solution into the unit. Select RINSE to begin the rinse cycle. Select END RINSE CYCLE to terminate the rinse mode. Select STOP from the Turbine Control Panel interface display. Select WATER WASH OFF from the Turbine Control Panel interface display. Open the Gas Fuel manifold low point drains.

26 / GE Title or job number / 5/21/2008

Off-Line Compressor Washing (continued)


Drying process: After washing, the compressor is drained and the remaining water or the cleaning solution is dried. It involves the following steps: Start the unit backup for the drying cycle. Select Master Reset, and then select START. The gas turbine is allowed to drain and dry for 20 minutes. Check the drain ports visually to ensure that all effluent has drained out of the unit. Initialize the turbine STOP signal and close the drying cycle . Select OFF from the turbine control panel interface to end the drying cycle.

27 / GE Title or job number / 5/21/2008

Off-Line Compressor Washing (continued)


Considerations after washing: Return the drain valves on the gas turbine to their normal positions Shut down the exhaust frame blowers at the motor control center Return the operator selector switch to AUTO and the water temperature setpoint switch to COLD Start the gas turbine within 24 hours after completion of the drying cycle Operate the turbine at full speed for a minimum of five minutes

28 / GE Title or job number / 5/21/2008

Performance Restoration after Washing


After washing: Performance of the compressor increases. An increase of 10% in the BASE load power is quite common. Use the procedure in GEK 28166 for generator drive machines to asses the machine performance and compare the performance data. Implement the concept of regular compressor washing to maintain performance of the turbine.

29 / GE Title or job number / 5/21/2008

Performance Restoration after Washing (continued)

30 / GE Title or job number / 5/21/2008

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