About Gas Turbines and how they can be monitored

•• The
TheGas
Gasturbine
turbine
•• Compressor
Compressordesign
design
•• Combustion
Combustiondesign
design
•• Common
Commonmachine
machinefaults
faults
•• Instrumentation
Instrumentation
Gas Turbine Fundamentals

•• ++The
Thegas
gasturbine
turbineisisaathermal
thermalmachine,
machine,ititcoverts
covertsfuel
fuelenergy
energy
into
intoshaft
shaftwork
workto todrive
driveaaload
loade.g
e.gaagenerator.
generator.
•• ++The
Thegas
gasturbine
turbineisisaacompact
compactengine.
engine.
•• ++The
Thegas
gasturbine
turbineisismechanically
mechanicallysimple.-
simple.-High
Highreliability.
reliability.
•• ++The
Thegas
gasturbine
turbinecycle
cycleisiscomplete
completewithin
withinthe
theflange
flangetotoflange.
flange.
•• ++Rapid
Rapidstart
startcapability
capability
•• --Materials
Materialsare
aresensitive
sensitivetotosalt,
salt,chlorine
chlorineand
andsulphor
sulphor
•• --Small
Smallpower
poweroutput
outputgives
giveshigh
highspeed.
speed.
Flow Path in a Gas turbine

Conversions:

Station 0 - The atmosphere

Station 1 - The compressor inlet
Flow Station 2 - The compressor discharge
Path Station 3 - The turbine inlet
Station 4 - The turbine discharge.
Efficiency of a Gas turbine

The efficiency of a gas turbine is improved by:

•• Inter-cooling
Inter-coolingof
ofthe
thecompressor
compressor
•• Pre-cooling
Pre-coolingbefore
beforethe
thecompressor
compressor
•• Exhaust
Exhaustheat
heatrecuperation
recuperationbybyregenerators
regenerators
•• Re-heating
Re-heatingthe
theturbine
turbine(multistage
(multistageburning).
burning).
Gas turbine Cycles

C T L C T T L

Simple open cycle Separated power turbine

C T L C T T L

Simple open cycle Separated power turbine

with regenerator with regenerator
Gas turbine Cycles

C T
C T

C T L
C T L
Compound set
Compound set
with regenerator
C T L

C T

Compound set
HP drive
Types of Gas turbines

Single shaft, heavy duty gasturbine

Types of Gas turbines

Turbine driven

Compressor driven
Heavy Duty Gas turbines

•• Wide
Widepower
powerrange
range1010-100MW
-100MW
•• Not
Notnecessary
necessarycombustion
combustionchambers
chambersall allaround
aroundthe
theturbine
turbine
cylinder.
cylinder.
•• Can
Canhave
haveone
oneorortwo
twocombustion
combustionchambers
chambers
•• Small
Smallunits
units(10-30MW)
(10-30MW)always
alwaysroller
rollerbearing.
bearing.
•• Larger
Largerunits
unitsalways
alwaysjournal
journalbearings.
bearings.
Multi shaft Jet-derived Gas turbine

High Pressure

Load

Low Pressure
Power
Turbine
Multi shaft Jet-derived Gas turbine

Aero-thermodynamical
performance optimized
Generator

Constant speed
Multi shaft Jet-derived Gas turbine

Compressor

Independently
Varied load speed
Jet-derived Gas turbines

•• Light
Lightconstruction
construction
•• High
Highspeed
speed
•• No
Noeasy
easyaccesable
accesableroller
rollerbearings
bearings
•• Several
Severalshafts
shaftsat
atdifferent
differentspeed
speed
Axial and Centrifugal Compressors

Two
Twokind
kindof
ofcompressors
compressorsare
areused,
used,centrifugal
centrifugaland
andaxial
axialflow.
flow.
•• The
TheAxial
Axialcompressor
compressorisissmall
smallinindiameter
diameterand
andlonger
longer
•• The
Thecentrifugal
centrifugalcompressor
compressorisisrugged
rugged
•• The
Theaxial
axialcompressor
compressorhas
hashigher
higherperformance.
performance.
Combustor Design

Combuster
CombusterDesign
Designcriteria:
criteria:

•• Small.
Small.

•• Temperature
Temperaturedistribution
distributionuniform
uniform

•• Combustion
Combustioncontinuos
continuosand
andstable.
stable.
Gas turbine blade types

Impulse turbine

Reaction
turbine
 Gas turbine Failure Statistics

Main location of damage to turbines %.

45
40 Blades
35
Combustion
30 chambers
25 Hot Casing
20 Parts
15 Rotor and
wheel discs
10
Other
5
0

Munich reinsurance company

Gas turbine Failures

•• 20%
20%of of the
the42%
42%rotating
rotatingblade
bladefailures
failurescome
comefrom
from
foreign
foreignbodies
bodies(i.e
(i.eby
bycombustion
combustionchamber
chamberparts)
parts)

•• 30%
30%of of all
allcases
caseswere
werecaused
causedby bythermal
thermal
overloading
overloading
•• 25%
25%of of all
allcases
caseswere
werecaused
causedby bymechanical
mechanical
overloading
overloading
•• 6%
6%were
werecaused
causedby
bylack
lackof
of lubricant
lubricant
Munich reinsurance company
 Gas turbine Failure Statistics

Distribution of 147 cases of damage versus operating hours.

0-10.000
0-10.000
10.000-20000
10.000-20000
20.000-30.000
20.000-30.000
30.000-40.000
30.000-40.000
40.000
40.000- -......

Munich reinsurance company

 Gas turbine PFM’s
Component Element Failure modes Loading source

Compressor Rotor Blades Fatigue,Erosion Vibration

Foreign Object Airborne particles
Rotor (disk) Fatigue, Creep Centrifugal, Thermal
Combustion Liner Fatigue, Creep, Temperature Gradients
Buckling
Casing Fatigue Pressure cycles
Turbine Rotor blades Creep, Fatigue Centrifugal, vibration
Corrosion, Erosion Exhaust products,
Thermal environments
Rotor (disk) Creep,rupture Centrifugal, thermal
Fatigue
Stators Corrosion,erosion, Thermal environments
fatigue, creep, pressure,
buckling exhaust products
Gas turbine Failures

•• The
Thelife
lifeof
ofgas-turbine
gas-turbineblading
bladingand
andofofcombustion
combustionair airor
orfuel-
fuel-
gas
gascompressor
compressorblades,
blades,properly
properlydesigned
designedfrom fromthethestart,
start,isis
determined
determinednamely
namelyby byerosion-corrosions.
erosion-corrosions.
•• In
Incompressors
compressorsthe thereason
reasonforforerosion
erosionisisnormally
normallydust dustfrom
from
the
theblast-furnace
blast-furnacegas gasand
andcombustion's
combustion'sair. air.
•• Increasing
Increasingpollution
pollutionhas
hasmade
madecorrosion
corrosionproblems
problemsininthe the
combustion
combustionair aircompressors
compressorsan anincreasing
increasingproblem.
problem.
•• Emergency
Emergencypowerpowerstations
stationscan
canhave
haveproblems
problemswith withsulfur
sulfur
compounds
compoundsfrom fromcontaminants
contaminantsininthethefuel
fuelgas
gas--due duetotoout
outof of
service
serviceperiods.
periods.
•• Turbine
Turbinehashashigh
hightemperature
temperaturecorrosion
corrosionat atthe
thefirst
firststage(s).
stage(s).
•• Corrosion
Corrosionandanderosion
erosionisisthe
themain
maincause
causeforforblade
bladecracks.
cracks.
 Gas turbine Failures

Particular responsible is the effect of alkalis in conjunction with sulfur and

vanadium.
If over 600º C and heavy fuel oil is used measure must be used for each stop
.
When blast-furnace gas is used, the alkali-chloride can lower the melting point
of the surface on the blades to less than operational temperature.

The efficiency of the turbine is highly invoked by deposits.

The turbine blades exhibit bladeprofile in the first stage - followed by profile
thickening at the last stages.
 Compressor Blade Erosion
The effect of compressor erosion is twofold.

1. It causes blunting of leading edge.

2. It causes thinning of the blade trailing edge.

The result is fatigue and

degeneration of overall
performance.

Modulations of air flow

increased
 Compressor Fouling
The cause of fouling is adhesive materials such as
Oil vapor, smoke, sea salt, industrial vapors.

The result is
Less compressor efficiency
Lower compressor discharge pressure
EGT
Reduced exhaust temperature,
Reduction in fuel efficiency.
DP/P
Higher High Frq. broad band vibrations
Vib %
Tip Clang
The stall can be detected by a sudden
change in ‘Low ‘BP and diagnosed by
autospectrum.

The tip clang raises the ‘High’ BP

dramatically as well.
Internal Cooling Blockage

5um finings
Blade Faults
In general:

Blade
Bladecorrosion-erosion
corrosion-erosiongives
givesaapoor
poorefficiency.
efficiency.

Many
Manyblade
bladefaults
faultsgive
giveaaraise
raiseininthe
theamplitude
amplitudeof
ofthe
theblade
blade
passing
passingfrequency
frequencyandandhigh
highBP.
BP.

Most
Mostblade
bladefaults
faultsgive
giveaarise
riseininenvelope
envelopespectrum.
spectrum.

But the vibrations are highly with the Gas Turbine Control!
 Blade Corrosion
Typical
Typicalsymptoms
symptomson onblade
bladecorrosions
corrosionsdue
duesulfur
sulfuradhesive
adhesive
at
atthe
theturbine
turbineend.
end.
•• Steady
SteadyLProtor
LProtor(N1)
(N1)speeds
speeds
•• Gas
Gastemperature
temperature(EGT)(EGT)rise
riseover
oversome
somedays
daysbut
butnot
not
more
morethan
than20-25C
20-25C
•• Decreasing
DecreasingGas Gasgenerator
generatorspeed
speed(N2)
(N2)(1-2%)
(1-2%)
•• Increasing
Increasingfuel
fuelflow
flow(EF)
(EF)
•• Front
Frontvibrations
vibrationssudden
suddenincrease,
increase, Vib5
but
butno
nomuch
much N1
•• Rear
Rearvibrations
vibrationssteady
steady EGT
N2
All this could be normal operational EF
variations, but together they indicate Vib1
a fault ! And the performance goes down!
The Gas turbine
 Performance Monitoring

The vibration pattern is varying highly with the basic process parameters
at station 0, 1, 2, 3, 4

Vibrations,
Vibrations,ininthe
thebest
bestcombination
combinationwith
withperformance
performancemonitoring,
monitoring,can
canwith
with
aaproper
properinstrumentation
instrumentationpredict
predictblade
bladefaults
faultsbefore
beforeititisisto
tolate.
late.

Vibrations, as the second best combined with process parameters, can

with a proper instrumentation predict blade faults before it is to late.
Instrumentation of Small Heavy Duty Gas turbines

Small heavy duty, go for:

•• Accelerometer
Accelerometernear
nearturbine
turbineinlet
inletand/or
and/orintake
intake
•• Accelerometer
Accelerometerononroll.
roll.bearings
bearingsororintegrated
integratedgears
gears
•• Phase
Phasereference
referenceon
oneach
eachrotor
rotorshaft
shaft
•• EGT,
EGT,Intake
IntakeTemp,
Temp,Fuel
FuelFlow,
Flow,P2
P2
Monitoring Small Heavy Duty Gas turbines
Small heavy duty, setup:

Safety monitoring,running:
BP tracking velocity RMS 1s avg. time 10Hz .. 10X
bp (or BP) acceleration RMS 10s 1KHz .. 20 kHz

Safety monitoring,run up, coast down:

BP/P absolute velocity RMS 1s avg. time 10Hz .. 10 times max speed,
bp (or BP) acceleration RMS 1s 1KHz .. 20 kHz

Predictive monitoring, running:

as, velocity RMS. 10X, 30 avg.

as’s, acceleration RMS 30 avg. center freq. b.p.f , freq.Span 10X
cpb6 acceleration % 0-20KHz
es’s, cep ..
Instrumentation of Large Heavy Duty Gas turbines

Larger heavy duty, go for:


 Accelerometer
AccelerometerPower
Powerturbine,
turbine,intake
intakecombustion(s).
combustion(s).

 Phase
Phasereference
referenceon
oneach
eachrotor
rotorshaft
shaft

 X,Y
X,Yproximity
proximityprobes
probeson
onall
allbearings
bearings

 Bearing
Bearingtemperature
temperature

 EGT,
EGT,Intake
IntakeTemp,
Temp,Fuel
FuelFlow,
Flow,P2,
P2,P5
P5
Monitoring Large Heavy Duty Gas Turbines
Larger duty, setups:
Accelerometers
Safety monitoring,running:
BP tracking velocity RMS 1s avg. time 10Hz .. 10X
bp (or BP) acceleration RMS 10s 1KHz .. 20 kHz

Safety monitoring,run up, coast down:

BP/P absolute velocity RMS 1s avg. time 10Hz .. 10 times max speed,
bp (or BP) acceleration RMS 1s 1KHz .. 20 kHz

Predictive monitoring, running:

as, velocity RMS. 10X, 30 avg.

as, acceleration RMS 30 avg. center freq. b.p.f , freq.Span 10X
cpb6% acceleration 0-20KHz
es, cep ..
Monitoring Large Heavy Duty Gas Turbine
Larger duty, setups:
Proximity probes
Safety monitoring,running:
BP Peak-Peak 1s avg. time 10Hz .. 10*shaft speed and
DC
or Smax 2X and DC
Safety monitoring,run up, coast down:
DC/P 1s avg. time 10Hz .. 10*shaft speed
BP/P Peak-Peak 1s avg 10Hz - 10*shaft speed or SMAX 2X

Predictive monitoring, running:

as peak-peak. 10X, 10 avg.

Orbit 2X+key phaser
Smax 2X
Instrumentation of Jet Derived Gas turbines

Jet derived, go for:


 Accelerometer
Accelerometernear
nearturbine
turbineinlet
inletand/or
and/orintake
intake

 Accelerometer
Accelerometeron
onrol.
rol.el.
el.bearings
bearings

 Phase
Phasereference
referenceon
oneach
eachrotor
rotorshaft
shaft

 EGT,
EGT,Intake
IntakeTemp,
Temp,Fuel
FuelFlow,
Flow,P2
P2
Monitoring Jet Derived Gas turbine
Jet derived , setup:

Safety monitoring,running:
BP tracking velocity RMS 1s avg. time 10Hz .. 10X
bp (or BP) acceleration RMS 10s 1KHz .. 20 KHz

Safety monitoring,run up, coast down:

BP/P absolute velocity RMS 1s avg. time 10Hz .. 10 times max speed,
bp (or BP) acceleration RMS 10s 1KHz .. 20 KHz

Predictive monitoring, running:

as, velocity RMS. 10X, 30 avg.

as, acceleration RMS 30 avg. center freq. b.p.f , freq.Span 10X
cpb6% acceleration 0-20KHz
es, cep ..
Example of Configurations

Example:

Hispano-suiza THM
Acc Acc 350C

TA

TA
Example of Configurations

Example:

Solar Centaur

Acc Acc Acc

TA
G
e
a
r
Example of Configurations

Example:

IHE/GE IM5000
Acc Acc 350C
Acc Acc

TA

TA
Example of Configurations

Example:
ALSTROHM MS 50001 LA

Acc
Acc,T Acc
Acc,T

TA

x,y Ax1,Ax2 x,y

T1, T2
Example of Configurations

Example:

NUOVO PIGNONE (GE)

Acc
Acc

TA
TA
An example of a Gas turbine