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The turbine wheels Axial flow compressor Front bearing.

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1 The turbine wheels Axial flow compressor Front bearing

2 EXHAUST 4 COMBUSTION CHAMBER 2 AIR COMPRESSOR 1 GAS TURBINE 3

3 Maintenance Factor Effect of Fuel 4 3 2 1 RESIDUAL CRUDE DISTILLATE
NATURAL GAS Effect of Fuel

4

5

6 TYPES OF INSPECTION A- INSPECTION OF UNIT “ Running”
B- INSPECTION OF UNIT “ Shutdown” C- SPECIAL INSPECTION

7 A- INSPECTION OF UNIT “ Running”
The running inspection is performed during start up and while the unit is operating. This inspection indicates the general condition of the gas turbine unit and its associated equipment. The registered information can be used to further plan of the unit maintenance

8 I- “Standby” inspections
B- INSPECTION OF UNIT “ Shutdown” Standby inspections are performed with the unit in a stand still position These inspections include: I- “Standby” inspections II- “Combustion” inspections III- “Hot gas path” inspections IV- “Major” inspections

9 I- “Standby” inspections
“Standby” inspections regard particularly the gas turbine used for intermittent duties (peak or emergency). Routine servicing of the battery system, Changing of filters. Checking oil and water levels Cleaning relays Checking device settings and calibrations Lubrication and other general preventive maintenance Periodic test runs are also an essential part of good maintenance program.

10 It is recommended to operate unit at load for one hour bi-monthly.
(to dry out the moisture may accumulate inside the turbine components) If the unit is to be down for long period, weekly turn the rotors to 90 degree, And circulate lubricant to re-coat journal bearings Special inspections such as borescope can be used to further plan periodic maintenance w/o interrupting availability

11 II- “Combustion” inspections
The inspection requires the disassembly of the main parts: Fuel nozzle Spark plug and flame detector Combustion liner

12 III- “Hot gas path” inspections
Hot gas path inspection includes: Combustion inspections Turbine nozzles Turbine buckets To perform this inspection, the upper half of the HP. Turbine and the 1st and 2nd stage must be removed. HP. Turbine buckets will be inspected on site A complete set of turbine clearances should be Taken before removal of parts

13 As with the combustion inspection, It is recommended that the replacement of:
* Combustion liner * Fuel nozzle * Transition piece to be available for installation at the conclusion of visual inspection. The removed parts can inspected at the turbine service facilities and returned back to warehouse. It is recommended that the Hot Gas Path inspection to be conducted under the supervision of the GT. Producer representative.

14 IV- “Major” inspections
Major inspection involves the major flange-to-flange components of the GT. * Casing * Rotors * Bearings * Seals * Bladings * Atomizing air system To carry out this inspection, all the upper casing halves and support bearings must be disassembled.

15 C- SPECIAL INSPECTION “Boroscope” inspection “Boroscope” inspection plan A planned boroscope inspection is usually carried out only when necessary to repair or to replace parts.

16

17 Turbine preparation for boroscope inspection
Turbine must be standstill and the wheel space Temperature not exceed 80 degree centigrade All the access holes for inspection are normally closed through plugs.

18 inspection intervals Combustion inspection
STARTS / FIRED HOURS FUEL INSPECTION INTERVALS HOURS CONINUOUS DUTY GAS/DISTILLATE 6000 TO 8000 < 1/200 4000 TO 5000 GAS/DISTILLATE 1/50 TO 1/200 CYCLIC DUTY --1/50 GAS/DISTILLATE 3000 OR 250 STARTS The first inspection to be after 40% of the table intervals

19 inspection intervals Hot gas inspection 1/1000 1/100 1/50
STARTS / FIRED HOURS FUEL INSPECTION INTERVALS HOURS CONINUOUS DUTY GAS DISTILLATE 16000 to 18000 1/1000 GAS 1/100 DISTILLATE GAS 1/50 DISTILLATE CYCLIC DUTY GAS/DISTILLATE 8000 OR 800 STARTS

20 inspection intervals Major inspection 1/1000 1/100 1/50 16000
STARTS / FIRED HOURS FUEL INSPECTION INTERVALS HOURS CONINUOUS DUTY GAS DISTILLATE 32000 to 36000 1/1000 GAS 1/100 DISTILLATE GAS 1/50 DISTILLATE CYCLIC DUTY GAS/DISTILLATE 16000 OR 1600 STARTS

21 BOROSCOPE INSPECTION INTERVALS FUEL SEMI-ANNUALLY OR AT COMPBUSTION INSPECTION WHICHEVER COMES FIRST GAS OR DISTILLATE

22 Gas Turbine Washing 1- Off Line Wash 2- On Line Wash 3- Solid Wash
a- Gas Turbine Speed crank speed % of full speed b- Liquid used for wash Detergent (wash )+ water (rinse) 2- On Line Wash a- Gas Turbine Speed Operating speed (under load) 100% b- Liquid used for wash water c- Always done after Off Line or Solid wash 3- Solid Wash a- Gas Turbine Speed Operating speed (under load) 100% b- Material used for wash organic or inorganic substance

23 1- Off Line Wash a – Preparation
- Sealing air and atomizing air piping shall be disassembled and plugged to prevent water from entering in. Auxiliary atomizing air compressor connection shall be disconnected. Open the IGV. Make sure all drains are opened. Close the flame detector valves Wheel space temp. shall not exceed 82 c above water temp.

24 b -Wash procedure Wash with Solvent as the quantities shown in table 1 (as a guide) table 1 PGT MS MS 5001/ l/min gpm MS MS EA MS EA Cranking speed push button Apply the detergent for a period from 3-5 minutes, stop the unit Continue to inject during run down The detergent soak the deposits for about 20 minutes. Start cranking speed and wash with water from 5-10 minutes. Check washing efficiency The compressor should be washed until drain water is clean.

25 2- ON Line Wash Wash procedure
ON Line Washing considered as complement of off- line washing and shall never be alone. The turbine shall be under load Water shall be more than 10 C at compressor inlet table 2 PGT MS MS 5001/ l/min gpm MS MS EA MS EA minutes

26 3- Solid wash *When the fouling level is high and washing with liquid is not sufficient to remove deposits. *A large use of solid washing can result a permanent damage of machine components. *Washing with solids shall be carried out at steady speed and reduced load. * Nutshells is better than rice.

27 CHAPTER 7 Miscellaneous

28 Gas Turbine Thrust balance

29 Pd Pd BALANCED ZONE Pd PS UNBALANCED ZONE Pd

30 BALANCING DRUM P4 – P0 + + + + – P0 – P1 + + – P2 – P3 P4 – P0 P4 – P0
Balancing Room BALANCING LINE P4 P0 P1 P2 P3 Balancing Drum P4 – P0 P1 – P0 P2 – P1 + P3 – P2 + P4 – P3 + P1 + – P0 – P1 + P2 + – P2 P3 – P3 P4 P4 – P0 P4 – P0

31 BALANCING DRUM 42 – 2 40 40 + + + + – 2 – 12 + + – 22 – 32 42 2 12 22
Balancing Room BALANCING LINE 42 2 12 22 32 Balancing Drum 42 – 2 12 – 2 22 – 12 + 32– 22 + 42 – 32 + 12 + – 2 – 12 + 22 + – 22 32 – 32 42 40 40

32 P4 Mechanical seal and bearings arrangement P Ps Ps Balancing Pressure
Room P4 P Ps Ps

33 Compressor Surge Phenomenon 33 33

34 But Does not Happen to Reciprocating Compressors
HAPPENS ONLY TO : CENTRIFUGAL COMPRESSORS AND AXIAL FLOW COMPRESSORS But Does not Happen to Reciprocating Compressors 34

35 It is the flow back of gases from the outlet of the
SURGE PHENOMEN It is the flow back of gases from the outlet of the Last stage of the compressor towards the suction and return again to discharge

36 SURGE IN OUT

37 Why SURGE PHENOMEN GAS PROPERTY FLOW-RATE IS NOT ENOUGH
COMPRESSOR PERFORMANCE FLATENESS OF P.C. AT LOW Q

38 FLOW-RATE IS NOT ENOUGH GAS PROPERTY This will happen at
starting and shutdown, also at abnormal conditions. GAS PROPERTY Gas is compressible but liquid is not.

39 FLATENESS OF P.C. AT LOW Q COMPRESSOR PERFORMANCE
Centrifugal and Axial compressors are pumping gas continuously but reciprocating is not. FLATENESS OF P.C. AT LOW Q Gas pressure has the same energy at horizontal portions of the performance curve

40 NO SURGE IF INLET FLOW RATE Q IS ENOUGH IN OUT

41 5 to 20 cycles per second IF INLET FLOW RATE Q IS NOT ENOUGH OUT
COMPRESSOR IS SURGING OUT IN 5 to cycles per second

42 Q M³/ hr Hp A SURGE PHENOMENON B 10000 6000 COMPRESSOR SURGING
SURGE LINE Hp Q M³/ hr 10000 6000 42 42

43 SURGE WILL DAMAGE THE COMPRESSOR THRUST BEARINGS
43

44 CENTRIFGAL COMPRESSOR ROTOR
EFFECT OF SURGE ON CENTRIFGAL COMPRESSOR ROTOR THRUST BEARINGS SURGE WILL DAMAGE THE COMPRESSOR THRUST BEARINGS

45 Hp B1 A B SURGE LINE Q M³/ hr - Q 10000 6000 5 to cycles per second

46 SURGE CYCLE Hp B1 A B SURGE LINE 6000 10000 - Q Q M³/ hr 46 46

47 1- BY PASS WITH ANTI - SURGE VALVE
IN CASE OF COMPRESSOR SURGING P,T FT UIC FY COMRESSOR COOLER ANTI-SURGE VALVE WILL OPEN 47 47

48 1- BY PASS WITH ANTI - SURGE VALVE
COMRESSOR M 3 4000 M 3 6000 M P,T FT UIC FY COOLER ANTI-SURGE VALVE 6000 M 3 4000 M 3 UIC = ANTI- SURGE INTEGRATED CONTROLER 48 FY = TRANSDUCER 48

49 Q M³/ hr GRAPHICALLY Hp BY PASS WITH ANTI - SURGE VALVE B A C
SURGE CONTROL LINE RECYCLE TRIP LINE SURGE LIMIT LINE Q M³/ hr 49 49

50 2 –BLOW OFF VALVE Air UIC = ANTI- SURGE INTEGRATED CONTROLLER
AIR COMRESSOR M 3 3 6000 M BLOW OFF VALVE Air FT P,T FY UIC FY = TRANSDUCER UIC = ANTI- SURGE INTEGRATED CONTROLLER 50 50

51 2 – BLOW OFF VALVE GRAPHICALLY Hp Q M ³/ hr B A B1 SURGE CONTROL LINE
51 51

52 IN CASE OF GAS TURBINE AIR COMPRESSOR SURGE BLEED VALVE WILL OPEN
52 52

53 Mokveld Anti-Surge Valve
Spring Loaded during normal operation Valve Seat Valve Disk moves LHS to open

54 a webs a Section a-a

55 Surge Surge is the point of minimum stable flow and maximum head condition for the centrifugal compressor. The surge region is to the left of the surge line. Operation in this region is highly undesirable and can be very destructive for the machine since a repeated, almost instantaneous flow reversal takes place.

56 Wrong Developing the Surge Cycle on the Compressor Curve Pd Qs, vol Pd
Compressor reaches surge point A Compressor loses its ability to make pressure Suddenly Pd drops and thus Pv > Pd Plane goes to stall - Compressor surges From A to B ms Drop into surge From C to D ms Jump out of surge A-B-C-D-A seconds Surge cycle Pv Compressor starts to build pressure Compressor “rides” curve towards surge Point A is reached The surge cycle is complete Rlosses Pd Pd = Compressor discharge pressure Pv = Vessel pressure Rlosses = Resistance losses over pipe BB AA Driver is started Machine accelerates to nominal speed Compressor reaches performance curve Note: Flow goes up faster because pressure is the integral of flow Because Pv > Pd the flow reverses Compressor operating point goes to point B Pressure builds Resistance goes up Compressor “rides” the curve Pd = Pv + Rlosses System pressure is going down Compressor is again able to overcome Pv Compressor “jumps” back to performance curve and goes to point D Forward flow is re-established D Result of flow reversal is that pressure goes down Pressure goes down => less negative flow Operating point goes to point C C Machine shutdown no flow, no pressure Qs, vol

57 Steam Turbine

58 PRINCIPLE OF OPERATION
The two major components of a steam turbine are Nozzles and Blades ( buckets). Nozzles are stationary; blades rotate. Steam contains energy in the form of pressure and temperature. Nozzles convert this energy into velocity energy. In a nozzle, the pressure drops and the velocity increases . The high-velocity jets from the nozzles strike the blades and cause them to move. In the moving blades, velocity energy is converted to mechanical work, or power. Blades are located in rows on rotating wheels. Nozzles are arranged on stationary wheels, between the rotating wheels

59 Impulse stage FIXED FIXED STATOR STATOR BLADES BLADES MOVING TURBINE

60 Reaction stage FIXED FIXED STATOR STATOR BLADES BLADES MOVING TURBINE

61 A stage contains one row of nozzles, followed by one row of blades.
Turbines may be single-stage or multistage. Curtis Stage A Curtis stage is a special kind of wheel that takes a relatively high pressure drop. It is used for single-stage turbines and as the first stage in most older design multistage turbines. Present day turbine design uses a rateau stage since material and blade attachment methods allow higher blade operating stresses

62 A Curtis stage has one row of nozzles, followed by three rows of buckets. The sequence is as follows: 1. Nozzles 2. Rotating buckets that develop power 3. Fixed buckets that turn the direction of the steam 4. A second row of rotating buckets, that develop more power. All of the pressure drop takes place in the nozzles. Other Types of Stages In a multistage turbine, each stage after the first one has one row of nozzles (stationary) and one row of blades (rotating). These stages may be the "Rateau" type or the "reaction" type.

63 Classification of steam turbines
Turbines are divided into two classes, 1- Power generation 2- Mechanical drive 1- Power generation Generate electric power run at constant speed because the frequency of the generated power must be constant. As the turbine runs at constant speed, features can be designed to give a very high efficiency. Tolerances between the moving and stationary parts are very close.

64 2- Mechanical drive Are used for driving machinery such as compressors and pumps, where variable speed is usually required. Tolerances are larger, and fewer stages are used. Classifications of Mechanical Drive Turbines A- General Purpose General Purpose Turbines are used for low power applications. They are covered by API Standard 611 and are mass produced without regard to specific customer requirements. They are limited to steam supply conditions of less than 600 psig and 750°F. They also operate at speeds less than 6000 rpm.

65 General purpose turbines are usually single-stage turbines that may exhaust to a condensing system or to the atmosphere. Since they are less reliable than other turbines, their applications are limited to noncritical equipment. They are used as drivers for equipment that has a spare, such as pumps and fans. Such equipment is always has a backup. B- Special Purpose. For large power loads and covered by API Standard 612. They are manufactured to specific customer orders. These services are usually not spared; therefore, the turbine must be highly reliable. As these turbines are large machines, efficiency is important, and multistage designs are used. The most common applications are Gas compressors and Large pumps.

66 According to number of pressure stages
Used to drive Electric power generator 2- Multistage Turbines Blowers Pumps Similar equipment I - According to number of pressure stages 1- Single stage Turbines Used to drive Centrifugal compressors Double cylinders Four cylinders Single cylinder Three cylinders II- According to number of cylinders

67 III - According to principle of steam action
Reaction Turbines Impulse Turbines IV- According to Heat drop process 1- Condensing Turbine with generators Extracting steam from stages to heat up feed water 2- Condensing Turbine with extracting steam from stages for industrial process 3- Back pressure Turbines 4- Topping Turbines The exhaust steam is used as a feed to low pressure Turbines .

68 V- According to Steam condition at inlet
        Very high pressure Turbines ( Steam P = 170 to 225 bara ) Super critical pressure Turbines Steam P >     Low pressure Turbines 1 . 2 Medium pressure Turbines 40 High pressure Turbines

69 Principle of steam turbine action

70 Three cases study L = Pu * u ( kg m/ sec) P u = G/g ( C1t – C2)
Steam Mass Flow kg/s G = L = Pu * u ( kg m/ sec) P u = G/g ( C1t – C2) If G = 1 kg P u = 1/g ( C1t – C2) L = work done Pu = force ( kg) u = tangential velocity of blades m/sec C1t = theoretical velocity of steam m/sec C2 = velocity of steam after out m/sec w1=Steam relative velocity in m/sec w2 =Steam relative velocity out m/sec Three cases study P3= 34.7 kg c = 30 Steam u C1t C2 C1t P2= 40 kg b Steam u C2 P1= 20 kg a Steam u C1t

71 a u C1t Steam P1= 20 kg

72 b C1t u C2 Steam P2= 40 kg

73 c = 30 Steam u C1t C2 P3= 34.7 kg

74 Assume C1t = 196.2 m/sec Case (a) Case (b) Case (c)
Steam strikes a flat perpendicular surface P1 = /9.81 ( – 0 ) = Kg Case (b) Steam strikes a 90 deg bend neglecting friction loss Then C2 = – C1t P2 = 1/9.81 ( ) = Kg Case (c) Steam strikes a 30 deg bend ( blade ) neglecting friction loss Then C2 = – C1t P3 = 1/9.81 ( ) Cos = Kg

75 w1= C1t cos 30 – u w2 = - w1= -C1t cos30 + u Case c
Taking into consideration the blade velocity u Relative steam velocity (w) m/sec w1 = C1t – u w2 = C2 = 0 If u = 98.1 m / sec P1= 1/g ( w1- w2 ) = 1/g(C1t - u ) P1= 1/9.81 ( ) = 10 kg Case a w1= C1t- u w2 = - w1= -C1t + u P2= 1/g ( w1- w2 ) = 1/g {(C1t-u )-(-C1t+u)} P2= 2/g {(C1t-u )} P2= 2/9.81 ( ) = 20 kg Case b w1= C1t cos 30 – u w2 = - w1= -C1t cos30 + u P3= 1/g ( w1- w2 ) = 1/g {(C1t cos30 -u )-(-C1t cos30 +u)} P3= 2/g ( C1t cos 30 –u ) P3= 2/9.81 ( 196.2* ) = kg Case c

76 LEGEND C = m/sec C = m/sec C = m/sec C = m/sec w = m/sec w = m/sec w =
= STEAM VELOCITY AT NOZZLE INLET m/sec C 1 = 1t ACTUAL VELOCITY OF STEAM m/sec C 1t = THEORITICAL STEAM VELOCITY AT NOZZLE EXIT m/sec C 2 = STEAM VELOCITY AT MOVING BLADE EXIT m/sec w 1 = RELATIVE VELOCITY STRIKING MOVING BLADES m/sec w 2 = RELATIVE VELOCITY LEAVING MOVING BLADES m/sec w 2t = THEORITICAL RELATIVE VELOCITY LEAVING MOVING BLADES m/sec = f VELOCITY COEFFICIENT = 0.95 TO 0.96 y = VELOCITY COEFFICIENT h o = ADIABATIC HEAT DROP OF STEAM kcal/kg h i = USEFUL ADIABATIC HEAT DROP OF STEAM kcal/kg h n = kcal/kg NOZZLE LOSSES = C21t - C21 / kcal/kg a 1 = NOZZLE ANGLE OF STEAM VELOCITY C a 2 = EXIT ANGLE OF STEAM VELOCITY C b 1 = ENTRY STEAM ANGLE OF RELATIVE VELOCITY w b 2 = EXIT STEAM ANGLE OF RELATIVE VELOCITY w A = 1 / = THERMAL EQUIVALENT OF WORK ( kcal/kg ) u = BLLADE ANGLE m/sec v = STEAM SPECIFIC VOLUME m 3 /kg La = WORK DONE BY 1kg OF STEAM (IDEAL IMPULSE ) = C21t - C22 / 2g = C 2 1t +(w 2t -w 1 ) - C / 2g

77 The following example illustrates the calculation.
EXAMPLE CALCULATION - THEORETICAL STEAM RATE, ACTUAL STEAM RATE, AND OUTLET TEMPERATURE The method used for predicting turbine conditions uses the Mollier Chart for steam. The following example illustrates the calculation. Given: Inlet steam pressure psia Inlet steam temperature °F Outlet steam pressure psia Turbine efficiency % Brake horsepower required hp Calculate: • Theoretical steam rate • Actual steam rate (water rate) • Steam outlet condition + temperature

78 Solution: Use the Mollier chart for steam (Elliot Bulletin H-37B, inside back cover); Locate the Inlet Steam Temperature and Pressure on the Mollier diagram. Read inlet enthalpy, h1 = 1350 Btu/lb 2. Move vertically downward, along a line of constant entropy, to the outlet pressure of 2 psia. Read the outlet enthalpy, h2 = 923 Btu/lb 3. Calculate the isentropic (ideal) Æh Æhis = h1 - h2 = 1350 – 923 = 427 Btu/lb 4. The conversion factor from heat to work is: __Btu_hp-hr

79 = 7.95 lb/hp/hr 5-Therefore, Theoretical Steam Rate, TSR = __ 2545___
Isentropic Æh 2545 427 = 5.96 6. Actual Steam Rate, ASR (Water Rate) ASR = ____TSR_ _____ Turbine Efficiency _5.96 = 0.75 = 7.95 lb/hp/hr

80 = 7950 lb 7. Calculate Steam Flow Rate Steam Flow Rate
= hp x Actual Steam Rate = 1000 hp x 7.95 __lb__ hp- hr = lb hr 8. Outlet Steam Condition: Calculate actual outlet enthalpy Actual Æh = Æhis x Turbine Efficiency = 427 Btu/lb x 0.75 = 320 Btu/lb Actual h2 = h1 - Actual Æh = = 1030 Btu/lb

81 Locate the outlet steam condition on the Mollier chart, at
h = 1030 Btu/lb and 2 psia Read Outlet Temperature = 130 °F NOTE: Since the outlet steam is saturated, and the pressure is known, you can also obtain the temperature from a steam table

82 COMMON OPERATING PROBLEMS
STEAM TURBINES COMMON OPERATING PROBLEMS Problem Possible Cause Insufficient Power Developed • Steam pressure too low. • Backpressure too high. • Supply temperature too low. • Deposits in steam path. • Deposits in steam path. • Erosion of nozzles or blades. Low Efficiency

83 Problem Possible Cause
Erosion of Blades • Too much moisture in turbine; inlet temperature too low or outlet pressure too low. Exhaust Too Hot • Low efficiency • Low steam flow rate Vibration • Deposits • Erosion • Broken blades • Damaged bearings • Misalignment of piping

84 GLOSSARY Actual Steam Rate (ASR)
The actual steam rate required per unit of power. (Pounds per horse power hour.) {Water Rate} Backpressure Turbine A steam turbine that does not exhaust into a condenser. The exhaust pressure will typically be 15 psig or higher. Curtis Stage A type of steam turbine stage with one row of nozzles and one or more rows of buckets. The usual sequence of components is: nozzles, rotating buckets, stationary turning buckets, rotating buckets. Governor A device that regulates the speed of a steam turbine. It may be mechanical or electronic. Hand Valve A valve used to shut off the steam supply to a portion of the inlet nozzles.

85 Impulse Blades Rotating turbine blades in which only velocity decreases; pressure does not decrease. Rateau Stage A steam turbine stage with one row of nozzles and one row of blades. A relatively small pressure drop is taken in the rotating blade of a Rateau stage. Reaction Blade Rotating turbine blades in which pressure drop takes place.

86 Bearings

87 RADIAL BEARING THRUST BEARING ball Bearings roller Bearings Tilting pad Bearings

88 Thrust Ball Bearings DRIVE END NON-DRIVE END HANGED BEAM IMPELLER

89 Non-frictional Bearings
Radial Ball Bearings Thrust Ball Bearings Splash ring

90 MECHANICAL SEAL BEARING HOUSING

91 Thrust Load Radial Load

92 Thrust Pad Bearings DRIVE END NON-DRIVE END IN-BETWEEN TWO
BEARINGS IMPELLER

93 Mechanical seal and bearings arrangement
Equipment

94 THRUST PAD BEARING THRUST SHOES THRUST COLLAR

95 THRUST SHOES LEVEL PLATES BASE RING CASING SHAFT THRUSTCOLLAR

96 White material Tilting pad thrust bearing (carry axial load only)

97 Radial Tilt-Pad Bearing

98 Tilting pad radial bearing (carry radial load only)


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