1510312023, 11:35 TURBINE TIPS for all models of legacy GE gas turbines ~ Combined Cycle Journal EU M le Bae protection STE fans TET 2 TURBINE TIPS for all models of legacy GE gas turbines 1 ame 6 By Team-CCd Shore by Dal tue, founde and GM, PA Trine Sens KC Use correct names of gas-turbine components to avoid confusion Components ané autres for Eg ries hve pete names. is mporantt se conc anes when commuting th he manufacturer of service companies tobe sure you'r understood, For some, i may be ike learning to spesk 9 new language, which can be called “GE- ology 1h 1961, GE intoduced the g2s-tubine Packaged Power Plant. The company’s fist PPP was the MSSOO1—a/k/a Frame 5, When introduced, was designed to produce 12 MW, a rating that prevailed throughout the fst half of the sutes. During the second half of the decade, demand for emergency power was unprecedented, with investor-owned elect gine ies and municialties placing orders for dozens of PPPS Accessory (Comustor Load ‘AuxLO pump CSS” vargbecret Roebes natin fugaoe coun Starting means, yece Aub Exe .0 BERETA To gauo | Aggason | / (paerer | seer aude vanes (f cee Sora tel Ser Tidhster 1AB,\conpRessoR TURBINE EXHAUST Yauae phat Lo oxblos VIGV hydraulic actuator 1. MS50O1 gas turbine (right-side view) identifies auxiliaries and their locations, ‘on the accessory base and turbine base ‘The PPP design had mast ofthe aula fu systems located on the accessory base withthe goal of minimizing installation and startup times. I included the following 1+ Accessory gear with water, cl, and fuel pumps, and atomizing ar compressor. + Lube-ol 10) tank integral to the beam base th oll pumps, coolers, ites pressure regulators, et; inside the base or above it ‘+ Hydraulic supply system using le ol to provide high-pressure ud for epeating Serv valves and the ratchet roterturning deviee, and for enabling dutch engagement. Earlier systems for cuteh operation, ciel actuation, and ratchet engagement relied on high-pressure ai ‘+ Fuclsystem components slo atop the base included the following + guid-uel pump and flow divider + Gos-fuel stop and flow-contol valve, + Cooling water system installed inthe roof with radiators and finan drive hitpstww.cj-onine. comfurbine-tps-for-allmodels-otegacy-ge-gas-turbines! 481510312023, 11:35 TTURSINE TIPS for all models of legacy GE gas turbines ~ Combined Cycle Journal 1+ Stoning device aiesel engine or eanking motor was on-base with aw cle, Fig 1 presents the right-side view ofa gas turbine showing its auxiliaries and their locations on the accessory and turbine base, Fig 2 provides an isometric view, Mast everyting needed to operate the turbine i tagged, Some ofthe components nat visible in Figs 1 and 2 include the fl pump, 12-positon fuel pressure selector valve and gage for exch combustor, snd iquid-el flow divider, Other devices that would be installed on the gos turbine include ‘wo compressor bleed valves, two ignites (a/k/a sparkolugs, and ultraviolet fame detectors. “unin sel and sous assem, Compressor dsenage cashg~. Tus gas pro. Ccomousign ana Pua noeze ‘A compeassr casing Forwardesmpressr casing Accessory oping ‘Hydraulic ratchet gear actastorygoatbox Torque comerer sang engne Age emergency CS'simss int fone grhiy Inlet housing and No. 1 bearing assembly FO stop valve FO titer 2. Isometric view of the engine in Fig 1 showing on-base auxiliaries Given the availabilty of» cuted concrete foundation onsite, PPP instalation typically took less than two months Bear in mind hat this was the fst ine ‘the gas turbine was “introduced to its generator, load gear, contro cab, generator breaker, and protective devices—all manufactured at GE faites in other cies 3. Package Power Plant powered by an MSSOO1L engine at a utility generating Station dates back to 1968 [Atypical PPP (Fig 3) shows the accessory base (eft), 92 prevailed for over SO yeas nthe design of most GE Frame 5 and 6 ga turbines even those installed inside buildings. bine and exhaust (center, and generator (ar igh). Ths configuration of major components A simple way to check gas-turbine performance ce gastwtinesinsate in decre eneting pnts om the mis 19605 te the It 19505 operat nesueny ody--ypily confined oping ans emergency servce—given the avalbilty of more-ffcent machines for mid-range and baseload duty. However, when your legacy engines do rani is {900d to know f they are operating “up to snuff” hitpstww.cj-onine. comfurbine-tps-for-allmodels-otegacy-ge-gas-turbines! 281510312023, 11:35 TTURSINE TIPS for all models of legacy GE gas turbines ~ Combined Cycle Journal Thete's an easy way todo this krowing compressor charge pressure and exhaust temperature, calculating the pressure ratio, and potting this information on the OEM's performance graph proved inthe plant's Control Specifeations Below are the steps involved, using the MSSOO1L gas turbine to ilustate the pracess, These so-called SL tubines were designed with NEMA (National Electrical Manufacturers Assn ratings of approximately 15 MW fora compressor inlet temperature of BF and site elevation of 1000 f (14.17 psi First access the folowing information from the contol system display (Fg 4) a full specie load (SNL ‘+ Turbine exhaust temperature (TAA) + Compressor alscharge pressure (PCD) ‘+ Fuel pump stroke reference (VCO). The data ate repeated inthe caption to fcltate readability. Siven the compressor inlet pressure is 1439 psa from site data if not avalible, use the standard 147 ats impact wil be minimal, especially for legacy turbines), the pressure ratio (CPR) can be calculated a follows: (cba = [76.1 PCO) + 14.38) = 1439 28 4, Data displayed when operating at {ull speedino load (FSNL) are the following: Turbine speed, 181 rpm; turbine exhaust temperature (average ofall working exhaust thermocouples), 487F; compressor discharge pres-_of all working exhaust thermocouples), sure, 76.1 psig; uel-pump stroke, 85 _851F; compressor discharge pressure, psig 90.9 psig; fuel-pump stroke, 168 psig 5. Data displayed after the engine is ‘synchronized fo the grid (so-called base temperature control are the following: Turbine speed, 5181 rpm: turbine exhaust temperature (average Since speed is constant at FSNL in preparation forthe generator to supply power tothe grid, consider that 2 new operating plateau" has been reached synchronous speed. Thereafter, the dats of in st ineeaseincltec elation to fuel lw to the combustors (Fig 8 Again. the data are repeated inthe caption ofactate readabilty. As forthe previous calculation the comoressor inlet pressure is 1439 from and the pressure rato at baseload i the following: CPR = (90 PCD) + 1439] + 1439 = 728, [Next goto Fig 6 and plot the average exhaust temperature at fl ead (851F from Fig 5) against the compressor pres point occurs well below the base temperature contal ine, a the stow indicates. Important to note that GE engines ae designed to ran on the lower contrl lin. When operating below this ne. the units underfring—shatf performing below the design rating. Fig 7 Mustates this with 3 power output ratio of 725 at baseload. That of 12 MW, lower than expected with 3.5 MVAr of reactive power Of cours, you might choose to operate lightly below the engine's sign rating to maintain its eiailty and minimize wear and tea, given the units ge. You can do ths by adjusting the fvel regulator to reduce exhaust temperature Performance analysis. For the Frame SL example power production increases fm 0 MW at FSNL to 12 MW, because fuel low tothe compressor increases during the ramp up in output During this transition, compressor discharge pressure goes from 76.1 t0 90 psig—s rise of only 13.9 psi which considered low and incicative of something being wrong. Here's what to check + Fouled comoressr, typically caused by poot-cualty ambient ait. Examples: Soot deposits are common in gas turbines downstream from a refinery cor chemical processing plant sat deposits in units located within five miles or ofan ocean or ether body of saltwater. Action to consider ‘+ AYFSNL inject Carbo Blast or equivalent for dynamic cleaning of compressor blades. Veterans may recall walnut shells being used fr this purpose bck in the 1960s and 19705, + araly opened compressor bleed valves. During startup, CBVs should be fuly closed at about 75% of rated speed and never leak. Action to consider if your CBV5 leat Disassemble inspect clea, and lap sealing surfaces 3s required Leskage atthe compressor dicharge—such as missing wanstion-pice side seas o at another unwanted opening causing pressure loss, Action te consider: Bring ina qualifed barescope inspection team to look for passages fr leakage ‘+ Cracking or ersion of ane or more first-stage nozzles. the traling edges of nozzle partitions are wor or eraded, the backpressure on turbine buckets wil drop, reducing power output. Acton to consider: Conduct» borescape inspection of fs-stage talng-edge partitions Finally, consider the case where power output increases om FSNL tothe 15 MW designers intended forthe sve SL. For these conditions the expected average turbine exhoust temperature would be approximately SSOF. Also, compressor elscharge pressure shuld increase by neatly 20 psiram 76" ~"g (reer back to Fg 4) to the 95 pig expected based on the NEMA ating fr this machine with a clean compressor. The compressor tatio fr the Fram ¢ NEMA conaltions and using the same calculation presented eater, would be 7.72 hitpstww.cj-onine. comfurbine-tps-for-allmodels-otegacy-ge-gas-turbines! 351510312023, 11:35 TTURSINE TIPS fo all models of legacy GE gat Final step lot the 980F exhaust temperature and 772 pressure ratio on the Fig 6 ‘hare K marks the spot), noting that its above the control ine. Tis means the units cover firing snd the exhaust temperature shouldbe reduced by 20 deg For soto riimize the wear and tear on fist-stage nozzles = Previous Post PSM Uae ear eels -ae) wr o hitpslww.c)-onine.comurbine-tps-for-allmodels-otegacy-ge-gas-turbines! turbines - Combined Cyete Journal g 8 2 2 ‘Turbine exhaust temperature, 8 70 ¥ 75 3.0 8590 Compressor pressure ratio. 6. GE engines are designed to run on the lower control line. The arrow points to the ‘current operating point well below that, as defined by the intersection of the horizontal line for 851F turbine exhaust temperature with the vertical line for a compressor pressure ratio of 7.25 7. Power output (left) and reactive ower output (right) for the Frame SL. described in the article Next Post ~ 451590312023, 11:35 TTURSINE TIPS for all models of legacy GE gas turbines ~ Combined Cycle Journal inetiClean eee to clean a HRSG Recent Posts SOIF and Gu SO1F program for 2023, rs mest together—again SO1F 2022 conference recap: User sessions sotF 2022 501G Users Group program for 2023, onfrence recap: Vendor presentations Except from recent 5016 plant reports Abetracts of recent 5016 u Remembering Steve Bates ‘NOG 2072: Generators continue to be a thorn in side of owner/operator ‘NOG 2022: Steam turbines come nto focus with age and new opportuni NOG 2022: Gas turbine aftermarket robust and ready for challenges facing Alstom fleet AQ 2022: Tsining workshops focus on G failure ana is and generators /AOG 2022: How the Alstom aftermarket has taken shape with trusted solutions provide Categories Select Category v INDEPENDENT VOICE OF THE GAS-TURBINE-BASED GENERATION SECTOR hitpstww.cj-onine. comfurbine-tps-for-allmodels-otegacy-ge-gas-turbines!