When Bad Things Happen To Good Turbines

When Bad Things Happen
to Good Turbines
PAL Turbine Services, LLC
ALFRED SHUMAN - Senior Staff Engineer
Engineering Specialties
Gas Turbine Maintenance
CMU Modifications
Product Service
Engineering Technical Training
Experience
41-years gas turbine experience
Senior Consulting Engineer for PAL Turbine Services
since 2000
GE Field Engineer
Lead Technical Training Specialist, FEP
GE Service Supervisor, Baltimore, MD
GE Senior Installation Engineer, Futsu Japan site for
14 MS9001E STAG plants (5-year project)
Performed numerous major overhauls on GE model
series including MS5001, 6001, 7001
Education
E6, Machinist Mate, Class A, US Navy Submarine
Nautilus
AAS Mechanical Design Engineering, Wentworth
Institute of Boston, MA
GE Training Programs:
Field Engineering Program (FEP)
Gas Turbine Maintenance Schools
Six Sigma Training

Office: 518-371-1971
Fax: 518-371-1756

Note That Some of the Examples
Shown are from Not Only MS-6001B Units,
but also MS-5001N and MS-7001EA Units
Bolting Issues
1. Plated Bolting
2. Rusted Bolting
World War II Liberty & Victory Ships
These ships were the first to be built completely welded
with no use of rivets
Components for ships built modularized in many different
locales and then welded together at the assembly shipyard
This process drastically reduced the time to build these
ships at a time when the Allies were desperate for war
materials
Some of the issues of Embrittlement, due to temperature along
with contaminants and also with an excess of Hydrogen in the
welds, led to significant failures of hulls during launching
Launch of Liberty Ship from Dry Dock
Catastrophic Failure of Launched Hull
Due to Embrittlement
Successfully Built Liberty Ship
Helping the Allies War Effort
Case #1 Cadmium & Zinc Plated Bolting
Do not use Cadmium plated bolts in the
combustion, hot section or exhaust.
Above 450
0
F the cadmium melts & attacks
the grain structure of the bolts and the bolt
fails.
The failure mode is called Liquid Metal
Embrittlement and it is similar in nature to
Hydrogen Embrittlement.

Failed Cadmium Plated Bolts
Failed Cadmium Plated Bolts & Nuts
Combustion Can Cover, with Fuel
Nozzle & Pigtails, Blew Off
Collapsed Liner
& Flow Sleeve
Discussion of the
Root Cause of
this Failure
Case #2 Rusted Bolting in Inlet Ducting
Rusted Bolting in Inlet Ducting
Inlet Bellmouth
Bernoulli Effect:

Pressure Drop
Produces Increase
in Flow Velocity

All GE Heavy Duty GTs
produce a Velocity
increase of Mach 0.5

Typical
295 lb/sec
(1,062,00 lb/hr)
Velocity
=
Mach 0.5

Why Does Foreign Object Damage Occur
So Rapidly Within the Flange-to-Flange
Pond And Lucier, LLC
Pressure &
Temperature
Across
Gas Turbine

Typically,
the Delta-P
Across the
Inlet Throat
Results in
a Delta-T
of 23
0
F
T4 = 1000 F
P4 = 14.7 psia

T1 = 59 F
P1 = 14.7 psia
T2 = 450 F
P2 = 196 psia
Flame Temp = >3000 F
T3 = 2035 F
P3 = 196 psia
1
2
3
4
Collateral Damage
From Failed Bolting
Collateral Damage From Failed Bolting
Collateral Damage From Failed Bolting
Discussion of the
Root Cause of
this Failure
During reassembly, ensure that crew
understands to report when something gets
dropped into an open turbine.
No one will be fired or censured for
dropping something into the machine as long
as it is promptly reported.
Two case histories of when bad things
happened because of dropped/missing parts
Cautions with Open Casings
Case #3: MS-7001EA after
a HGP & subsequent restart
Units MW output was significantly less
then before the outage.
Pcd read higher than expected, but
output was still lower than expected.
Significant testing indicated a problem in
the Turbine section.
Decision made to open Combustion
system in order to inspect Stage 1 Nozzle
View of Stage 1 Nozzle from
inside Wrapper
Damage which Choked Nozzle
(Note how TE is pushed upstream)
Note how TE is pushed upstream
Damage as Viewed from Turbine
Bucket Denting & Splatter
1
st
Stage Bucket F.O.D.
2
nd
Stage Bucket Splatter & F.O.D.
Setting Pressure Ratio (P
R
)
Nozzle Throat Dimension
The Tightest Orifice in the Hot Gas
Flow Path
Typical Nozzle Throat Dimension Check Points
Damage which Choked Nozzle
& caused High Pcd
1
st
Stage Nozzle F.O.D. & Buckling
1
st
Stage Nozzle Impact Zone
Discussion of the
Root Cause of
this Failure
Case #4: MS-6001B After
Major Inspection
Complete Major Overhaul, with
replacement of all HGP parts along with
a refurbished CDC Inner Barrel.
Performance was ~9% lower than before
the outage.
Significant testing & a borescope
inspection
Unit reopened

Borescopic View of Stage 1 Bucket Airfoil
Borescope View of Stage 2 Bucket Shroud
Note Gouges on Inside of Inner Barrel
Close up of Gouges in Inner Barrel
Distance Piece Interface with
Stage 1 Wheel
Stage 1 Bucket Pressure Side Deposits
Stage 1 Nozzle Inner Sidewall Deposits
Stage 1 Nozzle LE & PS Deposits
Stage 2 Bucket Shroud Tip deposits
Discussion of the
Root Cause of
this Failure

Case # 5: Effects of Turbine Clearances
Being Too Tight
Rubs & Consequential damage are most
often a low speed event.
Damage usually occurs during very first
start-up after outage.
Make sure that you fully understand the
true costs of trade offs made during
reassembly.
Effects of Turbine Clearances
Being Too Tight
Power Plant Users often believe that, since they are going
to change out Turbine Nozzles and Buckets during an
outage, it is not important to take all of the Internal
Clearances when opening the unit and again, when closing
the unit.
They believe that they can save outage time by not
expending the effort to take accurate readings and compare
them to what they were at the last outage; such a belief
quickly becomes a False Economy.
Being Too Tight
Turbine, Compressor, and Bearing Clearances are indeed
where the rubber meets the road.
The OEMs Design Engineers view the Clearance
Diagrams with their specific tolerances as the Bible for
setting the performance and reliability parameters for any
Heavy Duty Gas Turbine.

Being Too Tight
It is crucial that the person taking the clearances not only
has a good understanding of how and where to take the
clearances accurately, but also understands that this task is
one of the most important of the outage.
Adherence to the designed tolerance range affects optimum
performance. You must review all of the before/after
clearances; the Turbine is speaking to you. If you
understand the inseparable dimensional relationship
between the Rotor and the Stator during various phases of
operation, then you can determine where to make
judgments as to where to go outside of the optimum
clearance envelope.

MS6001 Turbine Clearance Composite
Bucket to Honeycomb Shroud Clearance
Correcting Clearances Below Minimum
Values on Stage 2 and 3 Buckets
MS-6001B Stg 2 Shroud Rub
Stg 2 Bucket Shroud Rail
Rubbed Off
Comparison of Buckets
Discussion of the
Root Cause of
this Failure
Effects of Ignoring Recommendations
Case #6
MS-6001B Stage 2 Bucket Shroud lift
phenomenon
Unit was open for a HGP
Customer chose not to follow OEMs TIL
recommendation to change to new buckets
due to potential cracking on airfoils.
Customer installed a set of buckets from
another unit on site which had shown
marginal shroud lift readings.
What it Looked Like at First Outage
What It Looked Like at 2
nd
Outage
Stg 2 Bucket Stubs
Stg 1 Buckets are only lightly damaged
Collateral Damage
to Exhaust Frame
Outer Barrel
Collateral Damage
to Exhaust Frame
Outer Barrel
Collateral Damage to Exhaust Frame Outer Barrel
2
nd
& 3
rd
Stage Stator Damage
2
nd
& 3
rd
Stage Stator Damage
Discussion of the
Root Cause of
this Failure
Corrosion Case #6
Contaminating reagents can enter the gas
path via:
Ambient air
Fuel (oil/gas)
Diluents/Misting/Evaporative Cooling
Contaminants from all sources are
additive in concentration & impact
Stage 1 Nozzle Exposed to Boiler Carryover in
Steam Injection Attemperation
Stage 1 Nozzle Exposed to Boiler Carryover in
Steam Injection Attemperation
Stage 1 Nozzle
Partitions
Discussion of the
Root Cause of
this Failure
Case #7:

Rush to make-up lost time in MS6001B
Major Inspection Schedule leads to the
Law of Unintended Consequences

Results in an Order of Magnitude more lost
time along with replacement and/or rework
of Critical Components
View of S1 Vane Through
VIGVs & R1 Blades
Damage to Stator Dovetail Slot Along with
Rubs & Dings to Blades & Vanes
Arrows Show Where Retaining Keys
Should Be Locked in Place
Note Rubbing Damage to Dovetail Slot
Caused by Rotation of Blade Rings in Service
Note Damage to
Stator Vanes
& Blade Ring
Discussion of the
Root Cause of
this Failure
Conclusions & Recommendations
Hug your Gas Turbines!
Treat them well, especially during outages!
Confirm that Proper Form, Fit, & Function
parts are being used as replacements!
If schedule is causing an inordinate rush
stop to think, review situation, and act
accordingly!
Work Safely & Work Smart!
Conclusions & Recommendations
Account for every single tool removed &
every part installed properly before
closing up Gas Turbine!
Following Good Engineering Practices
will always trump False Economy!

Centuries of experience
In maintaining gas turbine generators

When Bad Things Happen To Good Turbines

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

When Bad Things Happen To Good Turbines

Загружено:

Авторское право:

Доступные форматы

When Bad Things Happen

Вам также может понравиться