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° •__•/•___•
30 / \ o Use of Existing Instrumentation
v
•
w 25 • Instrumentation provided by the manufacturer was used for
0 / recording the data, although this instrumentation was pri-
marily concerned with safe operation rather than performance
20
monitoring. The basic aims were to provide the watchkeeper
15
with a historical picture of the engine operating conditions,
d without any increase or upgrading of the existing instrumen-
E-
/ •
tation. The instruments were re-calibrated.
•
10 0 Maximum
Minimum
The gauges used were about 10 cm in diameter. The minor
scale division of the gauges for gas generator speed, engine
exhaust temperature and the compressor discharge pressure
were 2%, 10°C and 5 KPa respectively. A spared pressure tap
I
0 '
I
of compressor discharge was also utilized via a quick connector
0 1 2 3 4 5 6 7 8 9 10 11 12 to measure the pressure by a master gauge, with 1 KPa as a
Month minor scale division, in order to counter check the pressure as
recorded by the panel gauge.
Fig. 1 Ambient Temperature Variation. Due to the high ambient temperature condition and the pro-
cess load demand, all the engines were running at the maximum
At the very high ambient temperatures experienced the re- possible gas generator speed. Data was recorded by keeping
sulting loss of power may result in the re-cycle valve on the load the gas generator speed as a fixed reference over the increasing
compressor opening, with a consequent loss in production. A ambient temperature. The selection of the gas generator speed
simple and reliable system for detecting power loss was needed, was based on the factors of maximum available speed and the
so that compressor washing can be scheduled to restore power. inlet temperature at which the specific engine reached the lim-
iting EGT. When the engine reached the limiting EGT, this
resulted in a loss of maximum available speed; as a result, the
Compressor Fouling Detection and Cleaning gas generator speed of the engine was selected at 1% less than
Procedures the maximum available. The main purpose of selecting the
speed with this criterion was to record the operational data
Fouling Detection over the wider range of inlet temperatures before the engine
reaches the limiting EGT at this gas generator speed.
The normal practice of detecting a dirty compressor was based Referring to Figure 1, the considerable temperature vari-
on the manufacturer's recommended methods described as fol- ations during the day were quite predictable with respect to
lows. time, making it feasible to analyze data at a specified ambi-
ent temperature; it was felt that the use of non-dimensional
1. Whenever any one of the following symptoms becomes parameters was too complicated for on site use, especially by
apparent; engine fails to accelerate to full speed, general semi-skilled operators.
lowered acceleration, engine compressor surge, high engine
exhaust temperature, inability of the engine to pull full
load. Test Program
2. After certain fired hours, or as often as possible, inspect
air inlet screen, walls of air inlet duct and the inlet guide Preliminary investigation included all ten engines. Initial anal-
vanes for any build-up of oily, dusty or salty deposits. ysis was aimed at establishing the effect of compressor washing
on CDP and EGT after fired hours of around 1250. Figures 2
3. While engine is operating, frequently observe the compres- & 3 show the variation of these parameters as a function of am-
sor discharge pressure (CDP) gauge. Plot actual CDP on bient temperature, with gas generator speed fixed. It should
appropriate speed coordinate over constant air inlet tem- be noted in Figure 2 that Engine K-612 was capable of oper-
perature. If plotted pressure falls more than 5% from the ating at 101% gas generator speed before reaching the limiting
new engine baseline pressure, which is established when temperature of 625°C at an inlet temperature of about 32°C,
the unit is first started up on site, the compressor should therefore, its gas generator speed was selected at 100%.
be cleaned. A clean engine dropped CDP(KPa) as much as 7% and in-
creased EGT(°C) by about 1% as the ambient temperature
Cleaning Procedures increased from 28 °C to 42 °C. Performance comparison of the
engines before and after cleaning is given in Table 1, which
The compressor was cleaned by the manufacturer's approved indicates that CDP behaviour is consistent on all engines.
methods. These are kerosene-water-detergent washing and abra- To further investigate the parameters of the engines a test
sive cleaning. The compressor blades were normally contami- sequence was planned with the aim of increasing the fired hours
nated with oily deposits, therefore the kerosene-water-detergent on the engines before washing. Two pairs of engines were se-
washing method was frequently used. Abrasive cleaning method lected and their deterioration in performance was compared.
was occasionally used when it was noticed that the perfor- One pair of engines, K-516 and K-522, both relatively old, were
mance was not recovered by washing the compressor two or run to the normal planned fired hours of 1250. The other pair
three times with kerosene-water-detergent. of engines, K-517 and K-523, both relatively new, were planned
No base line data was available for any of the engines. It was to run about 2000 fired hours. The performance of these en-
also necessary to identify parameters suitable for detection of gines was monitored twice per week. The engines K-516/517
engine performance deterioration, which should be capable of had a single stage air filtration system and were located at
LS
810 590
25 30 35 40
T (inlet) : 32 Deg.0
Ngg 99 7.
319
A K - 517
• K - 523
3600
L? 318
4A
i1.
c 3500
317 d
0
a.
316
3400
315
0 300 600 900 1200 1500
3300 ' ' ' ' ' ' '
Fired Hours 0 300 600 900 1200 1500 1800 2100 2400
U T (inlet) : 32 Deg. C
4 Ngg 99
o CDP
3 e EGT -
80.5 ■ Ill,
m
ti 2
80.0 '
0
1500 cd
0 300 600 900 1200
Fired Hours —1
Saravanamuttoo and Lakshminarasimha (1985). Taking into 0 300 600 900 1200 1500
account the difficulty of obtaining compressor discharge tem-
perature readings, the calculation required for compressor ef- Fired Hours
ficiency and the small change experienced, both parameters Fig. 8 Parameter Trending (K-516).
were thought unsuitable for monitoring compressor condition.
-4
O CDP
e ECT
a
• lip U
-5 760
0 300 600 900 1200 1600 1800 2100 2400
Fired Hours
750
Fig. 9 Parameter Trending (K-517).
6
0 3
Fired Hours
m
s. 2 Fig. 12 Effect of Fouling on CDP.
800
T (inlet) : 32 Deg.0
CC
Ngg 99 %
co'
C 0 • K - 517
0 790
O K - 523
-1
go -2
e 780
r.CO
0
-3 a
770
-4
0.
5 1 I U
0 300 600 900 1200 1500 760
Fired Hours
Fig. 10 Parameter Trending (K-522). 750
5
T (inlet) : 32 Deg.0
4
Ngg 99 % 740
o CDP 0 300 600 900 1200 1500 1800 2100 2400
0 3
A ECT
m 2 • lip Fired Hours
d
Fig. 13 Effect of Fouling on CDP.
5)
It can be seen that there is always a downward trend as
cs
I.. the fouling progressed. A maximum drop of 3.5% from the
0
a original starting point was noticed (Figure 11). Readings were
easily taken and local gauges were found to be surprisingly
-1
accurate and remained in calibration, when counter checked
with the readings as taken by the master gauge, during the
oA - 2
major service interval , hence they are considered reliable.
Cs Because of the inherent accuracy and ease of reading the
,13 -3
U gauge, CDP was thought to be the most suitable parameter
for a monitoring application.
775 700
15 20 25 30 35 40 45
820 Ngg 99
a • Wash 1
765 • Wash 2
810
. Wash 3
• Wash 4
800
760
790
0.
780
a
755'
0 300 600 900 1200 1500 770
of later stages.
800 ngg 99 %
• • Wash 1
Irregularity of Effectiveness of Compressor 790 • ■ Wash 2
• Wash 3
Washing 780
790
■ Ngg 99 Unit K-517 was run for a period of 1972 fired hours without
• Wash 1 washing (Figure 19). Initial CDP deterioration was as ex-
780
• • Wash 2 pected, with a `self-clean' recovery at approximately 270 hours
■ • Wash 3 and another at approximately 880 hours. The minimum CDP
■ ♦ Wash 4
level was reached at about 1500 hours run, this was still op-
• 770 ■ . O Wash 5
• ❑ Wash 6
erationally acceptable and the unit ran with no known faults.
Past 1500 hours, deterioration appeared to have halted, CDP
760
a remaining fairly constant at 766 KPa as an average. No fur-
ther deterioration was noted until the unit was shutdown after
750
1972 hours.
a
740 800
700
1 ' co Wash 4
15 20 25 30 35 40 45 0.
780
Air Inlet Temp. (Deg.C)
Fig. 18 Bleed Valve Failure (K-516). Wash 3
0 730
720
7.6 15 20 25 30 35 40 45
Fired Hours
1. 1600 fired hours was the maximum allowable running pe-
riod.
Fig. 20 Trending of Compressor Pressure Ratio (K-522).
2. Effect on process parameters e.g. loss of throughput, re-
cycle time.
Comparison of these plots to CDP plots shows little change
of shape. Barometric pressure varies little in that region, more 3. Machine health restrictions e.g. length of time spent at
important is air inlet depression caused by filter condition. topping temperature , number of starts etc.
This can cause a fairly large drop of compressor suction pres-
Fouling had to be restricted to avoid causing excessive re-
sure and hence CDP, thus giving false indications of compressor cycling (due to power loss) of the process gas through the
condition. During the survey a negligible change was observed centrifugal compressor during the peak summer season. A rela-
in OP across the air filters. The usual level of OP was between tionship can be established between CDP and flow transmitter
2.5 — 3.0 inches of water on all the units. output at fixed air inlet temperature and process suction con-
Because of the slight barometric variation found both di- ditions. This relationship has virtual linear characteristics so,
urnally and annually, barometric pressure can safely be elimi- if the recycle point (the flow at which the recycle valve opens )
nated. is known, then 'CDP at recycle' can be established for those
prevailing conditions. At nearly all ambient and process condi-
2) Ambient Temperature tions this 'CDP at recycle' was found to be below the expected
CDP after 1600 fired hours, so, increasing the wash interval
All time-based curves discussed so far have been curves relating would not increase summer recycle time.
to data taken at either constant or increasing air inlet tempera- The condition of fouled compressors immediately prior to
ture. This is inconvenient and requires a lot of non-productive present wash (1250 hours) varies considerably; for each ma-
waiting time to collect the data. Obviously any acceptable chine an average base line (CDP vs air inlet temperature)
monitoring effort must eliminate this to be cost-effective. needed to be established to ascertain fouling limits. This was
To assess compressor condition on an ad-hoc basis we must done by repetitive monitoring prior to washing. Curves es-
know both air inlet temperature and CDP, and the unit must tablished by this method represent the mean level of fouling
be running at constant gas generator speed. Looking again at achieved after 1250 hours. The increased level of fouling ex-
Figure 18, the deteriorating condition of K-516 can be seen. pected by 1600 hours could be calculated from data previously
Clearly, air inlet temperature, CDP and gas generator speed collected (extended runs to 1750 and 1972 hours) and existing
were known and an estimation of compressor condition had curves extrapolated to these new limits. The baselines thus
been easily established. Several curves of CDP vs air inlet established are shown in Figure 21.
temperature at constant gas generator speed were made for Interpolation between 'clean' and `fouled' curves would give
the units in cleaned and fouled conditions, as shown in Figure a number of curves representing degrees of fouling (percent ) .
21. These curves can be transposed into a numerical matrix. This
matrix is applicable only to a specific engine running at specific
gas generator speed (Figure 22). It should be noted that when
an engine is initially installed at a site, the IGV setting is
optimized for the particular installation and then fixed; the
variable stators are fully open by about 82% speed, so are
always fully open when performance measurements are made.
Potential Savings
Increasing the interval between the washes from 1250 to 1600
hours offers significant benefits in terms of decreased down time
and man hours. Applying the increased interval to all 10 units,
for example, decreases the down time from 455 to 358 hours,
the man hours required from 2310 to 1815 and eliminates 15
washes. This can be achieved for a total of 6 man hours per
week and no capital or equipment costs.
Conclusions
1. The effect of high ambient temperature and compressor
fouling on the performance of a fleet of gas turbine engines
is examined. A maximum washing interval of 1600 fired
hours was determined, however, to achieve this interval
without increased risk would require continuous monitor-
ing of the compressor condition. This could be done for
about 300 man hours per annum.
2. The `matrix — method' of predictive monitoring is quick
and simple to use, however, each matrix is unique to each
machine and may require updating every year or so.
3. Predictive monitoring would certainly preclude ineffective
washing, readings being taken the following day.
4. The old interval of 1250 hours was a satisfactory compro-
mise. In the winter season the units may be run even
more than 1600 hours (depending upon the compressor
condition) because of low ambient temperature.
Acknowledgements
The authors wish to thank the Natural Sciences and Engineer-
ing Research Council of Canada (NSERC) for financial sup-
port. They would also like to thank Shell (Petroleum Develop-
ment Oman), Sultanate of Oman, Persian Gulf for permission
to publish these results.