GAS TURBINE FLAME FAILURE

Prepared By: Qurban Ali

CONTENTS
1. Problem /History
2. Liquid Fuel System
3. Possible Causes and Counter Plan
4. Liquid Fuel Check Valve
5. Steps To Be Taken During Startup
6. Recommendation
 1.1 Problem/History
 On 26th Aug 2014, “fail to ignite” alarm appeared several times during
Gas turbine startup.
 EM verified the functioning of spark plugs and found normal.
 IM verified the functioning of Flame scanner and found normal.
 MM verified the functioning of liquid fuel nozzle check valves VCK1-
1~14 found it had been MALFUNCTIONING
 After replacement of all liquid fuel check valves VCK1-1~14 and on
second attempt GT fired successfully.
 Shutdown
Date Fail to ignite Action Taken
Reason

Replaced all liquid

WAPDA Yes fuel nozzle check
26-Aug-2014
system failure (6 times) valves
VCK1-1~14

Schedule
Yes
31-Aug-2014 outage 29~31 No
(1 time)
Sep, 2014
The liquid fuel system providing liquid fuel for the combustion chambers
is designed for insuring the following functions:

• Fire, warm up and accelerate the unit up to nominal speed

• Power the unit up to base load
• Shut down and trip the unit
 3. Possible Causes
3.1 Liquid fuel check valve VCK1-1 To 14 associated failures
due to fuel carbonization(coking) when the turbine is
operating on gas fuel. –
----
3.2 Trips due to excessive fuel flow faults
3.3 Trip due to 3 flame scanner not functioning out of
4 scanners.
3.4 Trip due to spark plug not sparking
3.5 Flow divider, fuel pump, fuel filter and other
--component failures
MM dismantled liquid fuel nozzle check valves and found
stuck due to coking.

INLET OUTLET
Possible Cause:
Atomizing air pressure low due to VA18-1 not fully closed or Passing

Counter Plan:
Verify that atomizing air pressure is 5.2 psi at cranking speed (750 rpm) and -
--4.2 psi at firing speed (480 rpm).

Remarks:
Atomizing air pressure was 4.2 psi at cranking speed (750 rpm) and 3.7 psi --
-at firing speed (480 rpm).
4. Water Cooled Liquid Fuel Check Valve
4.1 Purge System Schematic Drawing
4.2 Liquid fuel & CCW Flow Schematic Drawing

Flow Fuel
Glass Nozzle
 4.3 Check Valves
 Check (non-return) #14 valves are installed in pipelines
to allow flow in one direction only; helping to protect
equipment and processes.
Drawing
 Valve Case
Water Swirl
Jacket

Poppet
Seat
Spring Ass
Nozzle
jammed due
to Coking
 4.4 Specifications Check LFC Valve VCK1
 Inlet Pressure: 0-1225 PSIG
 Inlet Temperature: 15 °C to 120 °C
 Flow Range: 0.5-15.0 GPM
 Check Pressure: 300 PSIG
 Maximum Ambient Temperature: 200 °C
 Operating Flow: 11.00 GPM
 Crack Pressure: 114-126 Psi /8 Bars
 Stainless Steel
 4.5 Cooling System
 The water-cooled jacket that helps maintain check valve internal
temperatures below the coking threshold and The ability to
prevent coke formation
Cooling Water Circuit (L.F Check Valve).

Water Cooling Jacket

 4.6 Coking
 Coking occurs due to high temperatures at valve body.
 An example of coking is hard black deposits on the surfaces
 4.7 High Temperatures cause coking!
 When operating a dual fuel turbine on gaseous fuel the liquid fuel
system is idle.
 Stationary fuel in close proximity to the combustor is exposed to
high temperatures, above 120 degrees C, which oxidize the fuel
and turn it into a hard substance which scale or fouls the internal
surfaces of the check valve components, restricting their
movement.
 Once this (Coking) occurs the check valve will not open and close
properly.
 5.Steps To Be Taken During GT Startup
Following steps will be taken during GT startup:

5.1 MM
 Ensure differential pressure of HP fuel filter

 Ensure pressure of flow divider motor (app: 10 bar)

 Ensure liquid fuel check valves VCK1-1~14

 Ensure liquid fuel purge air check valves VCK2-1 to 14

 Ensure atomizing air booster compressor (CA2) and its NRV is working properly

 Ensure AA by pass valve VA18-1 is fully open & close position by applying air pressure

5.2 EM
 Ensure spark plugs sparking
 Ensure ignition transformer if spark plug is not working
5.3 IM
 Check exhaust temperature trend during firing time, If increased
then check flame detector

 Check liquid fuel purge valve VA19-1 is closed

 Check atomizing air manifold pressure should be more then 4.2

Psi during firing time (480 RPM)
5.4 OPERATION
 Check liquid fuel consumption at liquid fuel filtering skid
flow meter(app: between 14 ~ 16 liters)

 Check oil quantity at False start drain line after flame failure
6. Recommendation
6.1 MM
 Replace liquid fuel check valve during the event of GT water washing
to avoid tripping risk Twice / Thrice A year.
 Replace all purge air check valve during the event of GT combustion
inspection to reduce tripping risk once A year.
6.2 IM
 Perform functional test of flame detector before installation.
6.3 EM
 Perform sparking test/Replace spark plug if not functioning properly
during the every event of GT water washing
6.4 Operation
 Check liquid fuel oil filters, pumps, flow divider & atomizing air
,purge air system parameters are normal.