SKG12 DOMI LEVEL 1

:: Gas Turbine ::

GAS TURBINES
SKG12 DOMI LEVEL 1
:: Gas Turbine ::

Turbines
Gas turbine is an internal combustion engine that operates using the
same cycle of events as reciprocating engine; i.e. Induction,
Compression, Combustion, Expansion, Exhaust.

In 4-stroke reciprocating engine, all parts of the cycle occur in the

cylinder. In a gas turbine, each part of the cycle takes place in a separate
section of the machine.
 Working Cycle
Intake Compression Combustion Exhaust
Gas Turbine Engine Applications

Gas Turbine

Aero Engine Industrial Gas Turbine

Turbo Jet Heavy

Turbo Prop Medium

Turbo Fan Light

Turbo Shaft
 Principle of Divergent Duct

• Velocity - decreasing
• Pressure - increasing
• Temperature - increasing
 Principle of Convergent Duct

• Velocity - Increasing
• Pressure - Decreasing
• Temperature - Decreasing
Sonic Velocity
Spit Roast
 Newton Law of Motion
• Second Law : The acceleration of any body is
proportional to, and in the direction of the force
acting upon it.
• Third Law : Every force acting on a body there
is an equal and opposite force.
Hero’s Engine
Airflow across an Aerofoil
Sir Frank Whittle (1907 - 1996)
Whittle’s Engine Design
 Brayton Cycle
PP
Fuel
Fuel
Combustion
Combustion
Chamber
Chamber 3
22 3
Energy
Energy
Pressure

Extracted
Pressure

Extracted
Turbine
Turbine
Compressor
Compressor

Energy
Energy
Added
Added
11 44

Volume
Volume VV
 Gas Turbine Models

Solar Centaur
Rolls Royce RB211

Solar Mars GE LM2500

 PGB, GDC

PGB, PCSB
 PCSB, MTBE

Rolls Royce Avon

Solar Mars
PGB, PCSB
Rolls Royce Trent
Gas Turbine Major Component
Intake

Compressor
Axial
Centrifugal

Combustor
Can Type
Can Annular
Annular
Silo

Turbine
Gas Producer/Generator Turbine
Power Turbine
Typical Construction
3-Shaft Aircraft Engine
Multiple shafts - Trent 800 LP System
1 Fan stage
IP System 5 Turbine stages
8 Compressor stages >3,000 rpm
1 Turbine stage
>7,500 rpm

HP System
6 Compressor stages
1 Turbine stage
>10,000 rpm
 Intake

Bellmouth Variable
Bellmouth VariableInlet
Inlet
Guide
GuideVane
Vane
Nose
NoseBullet
Bullet

Rolls
RollsRoyce
RoyceRB211-24G
RB211-24G
 Intake

To provide smooth air flow into compressor

 Intake

Variable
VariableInlet
InletGuide
GuideVane
Vane(Closed
(ClosedPosition)
Position)
11ststStage
StageIP
IPCompressor
CompressorBlade
Blade
 Intake

Variable
VariableInlet
InletGuide
GuideVane
Vane(Closed
(ClosedPosition)
Position)
11ststStage
StageIP
IPCompressor
CompressorBlade
Blade
Axial Compressor and Turbine
Operation
 Compressor

To increase pressure and density of the air flow

 Compressor

An axial flow compressor consists

of one or more rotor assemblies
that carry blades of airfoil section.
These assemblies are mounted
between bearings in the casings
which incorporate the stator vanes.
The passageway between each
blade on the rotor and between
each stator vane is made to form a
divergent duct. Moving rotor-blades
draw in air at the front of the
compressor and force it rearwards,
thereby increasing its velocity and
its pressure due to the mechanical
force and the shape of the
passageways.
Rolls
RollsRoyce
RoyceRB211-24G
RB211-24G
IP
IP CompressorRotor
Compressor Rotor
 Compressor

77ththStage
StageIP
IPCompressor
CompressorBlade
Blade

11ststStage
StageIP
IPCompressor
CompressorBlade
Blade

Rolls
RollsRoyce
RoyceRB211-24G
RB211-24G
IP
IPCompressor
CompressorRotor
Rotor
 Compressor

66ththStage
StageHP
HPCompressor
CompressorBlade
Blade

Rolls
RollsRoyce
RoyceRB211-24G
RB211-24G
HP
HPCompressor
CompressorRotor
Rotor

11ststStage
StageIP
IPCompressor
CompressorBlade
Blade
 Compressor

Compressor
CompressorBlade
Blade
 Compressor

Compressor
CompressorImpeller
Impeller

Some
SomeGas
GasTurbine
Turbineuse
usecentrifugal
centrifugal
Compressor
Compressor(eq.
(eq.DresserRand
DresserRandDR990)
DR990)
 Compressor

In the stator vane passages the

velocity is converted into
pressure, again by the divergent
form of the passageway, the air
is lined up for the next row of
moving blades. This process
repeats itself throughout the
compressor, increasing pressure
by 10-20% at each stage.

Rolls
RollsRoyce
RoyceRB211-24G
RB211-24G
IP
IP CompressorStator
Compressor StatorVane
Vane
 Compressor

Rolls
RollsRoyce
RoyceIP
IPCompressor
CompressorSection
Section

From the compressor, the

air that is already hot and
compressed enters the
second stage compressor.
It’s job is to compress the
air even more. When the
air leaves the compressor
it is moving at up to 500
feet per second. Within
the the inner case of the
compressor is the outlet
guide vanes assembly
which directs the hot
expanding gases into the
Rotating blades combustion chamber
where it is mixed with the
Stator vanes
fuel and burnt.

Outlet guide vanes

Compressor Stator Vane
Axial compressor
Axial Compressor
Combustor operation
Diffuser & Combustor
 Combustor

To add heat energy to the flow

 Combustor

Can
CanType
TypeCombustor
Combustor

Can-Annular
Can-AnnularType
TypeCombustor
Combustor Annular
AnnularType
TypeCombustor
Combustor
 Combustor
Front
FrontCombustion
CombustionLiner
Liner

Rear
RearCombustion
CombustionLiner
Liner

Burner
Burner/ /Fuel
FuelInjector
Injector
Dilution Nozzle
NozzleGuide
GuideVane
DilutionTube
Tube Vane

Rolls
RollsRoyce
RoyceRB211-24G
RB211-24G
Combustor
Combustor
Rolls
RollsRoyce
RoyceRB211-24G
RB211-24G
Combustor
Combustor
 Combustor
Combustor

When the air leaves the compressor the air velocity is around 500 feet per
second, at this velocity the air speed is to high for combustion so the first thing
the combustor has to do is to defuse the air. Not all the air is used in the
combustion process about 29-32% of the air is burnt and the rest is used for
cooling of the flame before it reaches the nozzle guide vanes. The nozzle guide
vanes have there own cooling air that is bled of the compressor and fed out the
blades to form a shield over the blades this shield stops the flame from burning
out the blade.
 Combustor

Air flow path in combustor

 Combustor operation
Primary zone Dilution zone
Intermediate
zone

Fuel spray
nozzle
Combustion Process
Apportioning Flow
Flame pattern
 Combustion Theory
Take
TakeMethane
Methane(CH
(CH44))as
asfuel
fuelgas
gas
CH 2O22Æ
CH44++2O Æ2H
2H22O
O++CO
CO22++Energy
Energy

Molecular
MolecularWeight:
Weight: Weight
WeightRatio:
Ratio:
Methane
MethaneCHCH44::16
16 Oxygen
Oxygen == 2(32)
2(32) == 4.0
4.0
Oxygen
OxygenO O22 ::3232 Methane
Methane 16
16

Since
Since23%
23%of
ofair
airis
isO2,
O2,the
theideal
idealstoichiometric
stoichiometriccombustion
combustion
Required
Required::

Fuel
Fuel == 4.0
4.0 == 17.4
17.4
Air
Air 0.23
0.23
Hence,
Hence,for
forevery
every1kg
1kgCH4,
CH4,min
minof
of17.4kg
17.4kgof
ofAir
Airis
isrequired
required
to
toachieve
achievestoichiometric
stoichiometriccombustion
combustion
 Turbine

To convert pressure and thermal

energy into kinetic energy
(rotational)
Turbine Nozzle Guide Vane
 Turbine

Nozzle Guide Vanes

 Turbine

Cooling
Cooling

Air
Airis
isbled
bledfrom
fromthethecompressor
compressor
and
andchannelled
channelledthrough
throughthe
the
engine
engineand
andused
usedto tocool
coolthe
the
guide
guidevanes
vanesandandthe
theturbine
turbine
blades
bladesbybymaking
makingaashield
shieldof
ofair
air
around
aroundthem
themififthis
thiswas
wasnot
notdone
done
the
theblades
blades would
wouldmelt
meltwith
withthe
the
heat from the combustors.
heat from the combustors.
Axial Compressor and Turbine Operation
Compressor Stages Turbine Stages
Rotating Rotating Rotating Rotating
Rotor Row Rotor Row Rotor Row Rotor Row

Airflow Gas flow

Stationary Stationary Stationary Stationary

Vane Row Vane Row Nozzle Row Nozzle Row
How does the gas turbine work?
How Gas Turbine is Used in Plant

Driver Driven
Gas Turbine Compressor
Generator
Pump
SKG16 UPSTREAM OPERATIONS FUNDAMENTAL COURSE
:: Process Equipment – Gas Turbines ::
Turbo-Machinery Package

Main Components

Inlet Filter and Plenum

• Air Compressor
• Combustion Chamber
• Power Turbine
• Exhaust Section

Turbine Auxiliaries
Lubrication System
• Fuel Gas System
• Auxiliary Equipment Section
ƒ Starting Equipment
ƒ Control System
ƒ Safeguarding System
- Pre- and Post-lube
- Single and Dual Fuel
- Drive Gear Box
- Electric, Hydraulic, Pneumatic
- Speed, Temperature, Air Flow
- Over speed, High Temperature,
Vibration, Fire and Gas
General System Operational Sequence
Basic Materials/Design Challenges

• Thermal Oxidation / Hot Corrosion

• Cyclic Life / Fatigue
• Creep Life
• Fuel Gas Compatibility
• Fouling + Corrosion
• Erosion
Improvements in Materials

Random Directional Single Crystal

Crystal Structure Crystal Structure
 Turbine Cooling
Gas Temp: 825ºC Gas Temp: 1425ºC Gas Temp: >1550ºC

Cooling air
Uncooled Multipass Thermal Barrier
Coating
 Definition of Availability
Installed hrs–(Forced outage + Maint outage ) x 100%
Installed hours

Shut-down but Available

• Process shut-down
• Standby
• Power failure, switch gear failure
• Failure to provide fuel
• Manual shut-down
 Maintenance Practices

• 4K PPM
• 8K PPM
• Monthly Gas Turbine Wash + Partial PPM
• Gas Turbine Engine Changeout
- Turbo generator : 50,000 run hours
- Turbo compressor : 40,000 run hours
• Gas compressor, Power Turbine, Gearbox
overhauls – condition based
 Turbine Failures
Compressor collateral damage

Power Turbine broken blade

Loss of post lubrication

Accessory Drive failure

 Reliability Initiatives
1. Root Cause Failure Analysis (RCFA)
2. Project upgrades / Debottleneck - to
improve reliability, availability and
maximize production.
3. Human Development - enhance technical
knowledge via tech talk, in-house training
and witness engine disposition.
4. Monthly gas turbine crank/soak wash.
5. Risk Base Maintenance (RBM) strategies.
6. Pit-crew concept.
4. PM Optimization – Monthly Wash
1 2 3 4 MONTH

PCD MONTHLY

PERFORMANCE
DIFFERENCE
PERFORMANCE
5. Risk Based Equipment Strategies
Decommission
Business Development
Development Process
Process
Objectives •• Structured
Structured Approach
Approach by
by X-Functional
X-Functional Teams
Teams
with Supporting Specialists Run to Failure
with Supporting Specialists
 Recognize
Recognize Equipment
Equipment Criticality
Criticality
Standards Condition
Condition

 Define
Define Unit
Unit and
and Equipment
Equipment Performance
Performance Monitoring
Monitoring and
and
Requirements
Requirements Calendar-based
Calendar-based
 Programs
Programs
Equipment  Identify
Identify Failure
Failure Modes
Modes and
and Degradation
Degradation
Mechanisms
Mechanisms
History
 Recommend
 Assess
Assess Risks
Risks
Redesign

 Establish
Establish Cost-effective
Cost-effective Strategies
Strategies and R&D
Improvements •• Documented
Documented and
and Approved
Approved

Resources
Resources Equipment
EquipmentList
List
Exc Warranting
Warranting
Spr el Best Emergency
EmergencyRepairs
Repairs
ea Practices
d Maintenance
She Maintenance
et Network
Network
6. Adopt F1 Pit Crew Methodology
Shut-down and cool down for……. Production 4 hrs Preferably shut-down at midnight
LOTO Production
Remove air intake transition duct Team 1 4 hours
Remove GP to AD coupling cover Team 1 2 hrs
Remove GP to AD coupling guard and spacer Team 1 1 hr
Remove coupling Team 1 1 hr

Remove tubing and piping

Tubing for VIGV act, pcd, drain vlv, fuel gas, torch gas & bleed v Team 2 1 hr
Cover tubings with poly bags or masking tape
Lube oil #1 supply, return, #2&3 supply, return, Team 2 1 hr
Cover piping with poly bags or masking tape
Install spreader bar Team 2 2 hrs
T5 Thermocouple harness E/I
PT speed probe cable E/I
PT thrust bearing RTD E/I
Bearing # 1,2,3,4 & 5 vibration probe E/I
GP thrust bearing RTD E/I
GP speed probe cable E/I
T1 RTD E/I
Remove exhaust bellows transition duct Team 3 4 hrs
PT lube oil supply Team 3
Lift the old engine out of skid and place it betwe6 hrs
Install insulation blanket onto new engine 1 hr
Install PT hub on new engine using either hot oil bath or open flame
Remove exhaust collector assy
Remove intake plenum from engine
Clean air intake plenum, air inlet expansion joint Rustabout
Move old engine away from Train 2
Transfer new engine between train 2 and 3
Install exhaust collector with new bolts
Install air intake assy with new bolts
Cover inlet and exhaust duct to prevent debris
Install removed wiring conduits from old to new engine
Install engine trunnion support stand. Pin alignment will be a challenge if lifting beam off centre
Install PT oil drain block
Lift new engine into enclosure
Solar Mars Engine Change Out
Thank You
Any Questions?