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Abstract
Utilizing Dry-Low-Emissions (DLE) combustors that regulate the emission of oxides of nitrogen
(NOX), unburned hydrocarbons (HC), and carbon monoxide (CO) have led to one main drawback
that they are susceptible to produce an alternating or dynamic pressure. This paper is introducing
two ambient related on-line methods we applied on refrigeration unit Siemens Gas
Turbines(SGT400), located on Phases 6,7&8,South Pars Gas Complex experiencing combustor
dynamic pressure oscillation. In our first control, after finding increased 1st stage suction pressure
of refrigerant compressor as the root of perturbation, we requested operation group to keep the
pressure constant by increasing the power-turbine speed as a way to conquer this very harmful and
trip causing phenomena. As the temperature rose during July, oscillations started once more.
However, the control was as we previously recommended. In our next control step we discovered
that the turbine was very sensitive to speeds more than 8500 rpm. Therefore we asked operation
side to do their process controls based on no letting the power-turbine gaining speed more than
mentioned. And we found ourselves again successful in controlling of fluctuations. Without
performing especial maintenance, our methods provided us with production continuity of about
1,516 hours as well as a saving of 12,000,000 USDs.
Article Highlights
Different methods of controlling the phenomena that this paper is about to discuss,utilise at
least one device or software to compensate changes. Regardless of those we controlled the
turbine trip causing malfunction.
Due to the site process investigations,we discovered the driven unit first stage over normal
pressure condition, to be the suspect of stablishing the instability. Controlling that we were
successful in running in safe margins.
When the ambient temperature rises, the method for winning had changed in which by
reducing the drive unit speed we conqured the problem.
The Second Symposium on Sustainable Gas Production
Article Code: 2-44-127
1. Introduction
Air pollution worldwide concerns have led to stricter emissions standards both
domestically and internationally. Pollutant emissions from industrial gas turbines are subject
to Environmental Protection Agency (EPA) standards that regulate the emission of oxides of
nitrogen (NOX), unburned hydrocarbons (HC), and carbon monoxide (CO). In general,
engine emissions fall into two classes: those formed because of high flame temperatures
(NOX), and those formed because of low flame temperatures, which do not allow completion
of the fuel-air reaction (HC & CO). At least some known gas turbines use Dry-Low-
Emissions (DLE) combustors that create fuel-lean mixtures that facilitate reducing NOx
emissions from the engines while maintaining CO and HC emissions at low levels.
and HH is set on 1410 mPSI. If either of the bands reaches HH, turbine will reduce its speed
down to the IDLE (trip to idle), however if two or more bands reach the HH point, the turbine
will trip completely.
3. CASE IN POINT
Follow the procedure if a sub category is needed in a part of the manuscript:
3.1. Phases 6,7&8 (SPGC), SGT400 problem with Dynamic Pressure
On 1 MARCH 2012, instrument team was called for a first time ever happening turbine
alarm and then trip due to malfunctions in combustors of its Twin shaft turbo-compressor
SGT400, with the complete name of:Combustor Dynamic Band1 Hh. Under the supervision
of instrument, production group tried to start the turbine which in all tries, shoot-down
because of the same mentioned trouble. Investigating the root cause, instrument group
requested the mechanical team to join. Surfing the internet and reading related essays, we
decided to start from the easiest ways to conquer the bad situation.
3.1.1. Instrument group duties
- Check and calibrate all fuel gas valves
- Check and calibrate the Inlet Guide Vane(IGV) & Variable Guide Vanes(VGVs)
3.1.2. Mechanical group duties
- Check all fuel gas path for any probable damage or leakage
- Bolt tightening of all flanges and burners
3.1.3. Production group duty
- Perform cold wash(off-line washing) to remove probable coke.
Finalizing all above mentioned activities, we started the engine once more. Observations from
graphs depicted the engine condition was well and in an acceptable range dynamic pressure,
however after a week, due to some unknown reasons, the dynamic pressure started increasing
again to its alarm area. At this moment operation side was kindly requested to stop the
machine for further essential surveys. Pulsation spectra changes when the quality of the fuel
and air is varied. However, the changes in the pulsation bands may also be caused by: 1) A
crack in the combustion chamber, 2) A leaking gasket, 3) A malfunction in the burners or fuel
supply. For all these 3 items, mechanical team was forced to open the combustion chamber to
Perform some PT test and at least cleaning burners and inside the cans as well. Even though
we all knew the situation, we had to consider notes featured below:
According to OEM letter, our phases Siemens Gas Turbines (model SGT400), were
recognized suspicious to fail if we continue running them more than 8000 hours. This
shocking advice had risen due to the improper material applied to 1st Blade Of Compressor
Turbine (CT1 Rotor), And Inner-Interduct. CT1 rotor was firstly believed to have 24000
hours of life span while that was 48000 hours for Inner-Interduct. However, for our case, it
was discovered that both items life span were 8000 hours. Combustion chamber is the hottest
section in the turbine, and if we tried dismantling it, we would have to replace at least the
burners special gasket (Metal Gasket). Maintenance contract for SGT400 is to remove GG
(Gas Generator) and send it back to UK(OEM country), while installing the spare. Obviously
it means that we had no further spares than just a complete G.G.(also called : Core Engine).
The Second Symposium on Sustainable Gas Production
Article Code: 2-44-127
At that time, on the one hand, the engine EOH (Equivalent Operating Hours), was 6641 hours.
That means we had to keep the engine running for another 1359 hours to reach its vendor
recommended maintenance level. On the other hand, since our next train turbine was out in
the queue of being changed with new GG, and process side everyday forces to bring back
their normal condition, I started to study as much as possible to find other actions which not
lead us to remove the combustors. A view of our sites process within refrigeration unit is
illustrated in Image
The found item was: PI004: Refrigerant compressor 1st stage suction pressure. The normal
and the best operating pressure for 1st stage suction pressure of the driven refrigerant
MITSUBISHI COMPRESSOR (MODEL: 7V-6S) -contains a side stream known as its 2nd
suction-, is 0.8 barg. At the time of pressure increase for example to PI004=0.94 barg, and
considering in mind that there was no order from the operators to increase the turbine speed,
which is one of the controlling items in the direction of lowering pi004 back to its normal
rate, the refrigerant compressor tended to decrease its speed. This eagerness affected the
reducing gearbox located between power turbine and load (refrigerant) compressor, hence the
power turbine. All in the way of losing speed. However, there was no command to reduce
speed. Therefore to maintain the situation, power turbine demanded more and more air and
fuel to stabilize itself with the condition. And here is the start point of PI523A:COMBUSTOR
DYNAMIC PRESSURE to fluctuate. As shown in Image 2.
Image 3 and Image 4 show the exact relation and priority of PI004 to PI523A.
The Second Symposium on Sustainable Gas Production
Article Code: 2-44-127
On 27 may 2012, at 10:45 am, operation requested mechanical team to investigate and rectify
the alarm due to fluctuating pi523a, where the instrument group was claiming that the alarm
was completely real, as they had already tested and even changed the probable damaged
indirect sensor. Preparing all previous graphs in a common trend, I saw the exact phenomena
which I was expecting. Again increased PI004(0.95 barg that was 0.15 barg more than
normal), was the starting reason for other items to increase. At that moment the power turbine
speed was 8600 rpm. I requested the operating team to increase the pt speed to 8700 rpm
(where it is permitted to be increased up to 9500 rpm) in order to keep following one of the
ways into decreasing the driven compressor 1st stage suction pressure. 5 minutes after
The Second Symposium on Sustainable Gas Production
Article Code: 2-44-127
stabilized power turbine speed on 8700 rpm, PI523A headed down and after 2 hours the
differential reached to more than 1000( from 1140 mPSI at the time of alarm to about 100
mPSI at our controlled period). Image 5 illustrates the under mechanical team supervision
control of the PI523A.
Finalizing the activities operation team was officially requested not to permit refrigerant
compressors 1st suction to increase more than 0.8 barg. Note It has to be mentioned that this
kind of behavior was found unique to this engine comparing accurately all above mentioned
items with another running SGT400s.
Due to the operation emergencies, they performed before-start cold-wash and at 14:45,
4 AUG 2012, started the engine to be controlled up on second procedure. Starting the turbine
under very tense supervision, we gained more than what we were expecting. We had some
very short-period fluctuations every now and then but the engine continued running up to
finalizing its 8000 hours which was the time for the overhaul and replacement of low-quality
in material CT1 ROTOR & INNER-INTERDUCT.
Engine was kept running till 8157 hours.
5.Calculations
5.1. Control duration
EOH(Equivalent Operation Hours) = running hours + (10 x number of starts) (1)
5.1.1. Starting: 1 may 2012
E.O.H.= 5091+10*155=6,641 hrs
5.1.2. Finalized date due to overhaul: 1 SEP 2012
E.O.H.= 6497+10*1660=8,157 hrs
Control duration=8157- 6641=1,516 hrs
5.2. Propane cost =750 $/ton
Input data
- Feed gas composition based on summer rich
- Feed Gas Into Each Phase =34 mmSCMD, it will be 17 mmSCMD for Each Train
(Two Trains In One Phase)
The Second Symposium on Sustainable Gas Production
Article Code: 2-44-127
6. Conclusions
Reading essays and papers published related to our paper case, their final results were for
example:
- Introduction to combustor dynamic pressure and its harms
- Ambient condition influence on dynamic pressure of combustor
Different methods of controlling the phenomena by putting at least one device or software to
compensate changes (fuel composition, temperature rise, etc.)
What we did as discussed in the paper, was controlling the matter in spite of every other
possible changes that brought us the featured advantages below:
1) Production continuity
Neither fuel composition nor ambient condition change could stop us running the
engine.
2) Maintenance free activities(just initial check-ups)
3) Saving more than 12,000,000 USDs
7. References
[1],[3] G. James ,Chris rankel., Dynamic Pressure Monitoring In Gas Turbines, Skf Reliability
Systems @Ptitudexchange, 2002
The Second Symposium on Sustainable Gas Production
Article Code: 2-44-127
[2] F.Martelli, "Operating Conditions Effect On A Gas Turbine Dln Burner Stability", Proceedings Of
The 8th International Symposium On Experimental And Computational Aerothermodynamics Of
Internal Flows,Lyon, 2007