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Gas Turbine

Wolskis

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What am I looking at? Wow.
It's a gas turbine engine used as the prime mover for a generator. Next month we tear it down for replacement of the combustion parts. I have plans of posting more at that time.
 

Wolskis

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This is the upper half. The first 5 seconds is that of the turbine cover which comes off in several days. We are entering the 28,000 operating hour overhaul or HGP, Hot Gas Path. This consists of removing all parts subjected to the high temperatures. The combustion can cover, fuel nozzles, combustion cans, transition pieces, shrouds, seals and buckets (blades). I will post as things progress.
 

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Prep in progress. Toll boxes, hooch build, scaffold.
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Wolskis

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Gas turbine inlet pre & final filter change out. Pre's are 24x24x4 & the finals are 24x24x12". 330 of each. Crew of 9 will have this done tomorrow by 1700. Typically get 15k operating hours between changes.
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Wolskis

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The lift has been pushed to Saturday noon'ish.
 

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Fuel lines coming off. Night shift is a new crew so not much progress expected. We'll see.
 

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Correcting insulation and heat trace issues too. This pic shows a burnt heat trace cable. The fix is another layer as the second pic shows. These are the type of failures that can shutdown a power plant. This is not one of those
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Wolskis

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This flange needs attention for the last 2 outages. It leaks steam then stops. It's in the hot position as the pipes grow down. We torque it to 740 ft/lbs in 5 steps. I need to check this guide plate as the pipe now sits in the cold position. If it's getting caught in the I beam I'll have found the issue and correct in November. The cable you see is high temp heat trace.
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Now in the cold position. This isn't the problem.
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Wolskis

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And we found 3 air leaks. You can't hear this when the plant is running. We'll just replace the hoses and move on.
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Wolskis

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Should have about 42 scaffold structures this time. Our contractor Matt is top notch, he can build anything. Tell him your skeptical and it just fuels him. Typically it's Matt and 1 other starting builds 1 week prior to the outage. I brought him in 3 weeks early this time but ran out of time. Told Matt we need 4 more and it killed him to bring those extras in. Good thing we did, the extras are gone after Sunday and still have 2 large builds to go.
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Wolskis

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Roof came off in 2 picks.
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Wolskis

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More hoses removed
 

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Wolskis

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Boroscope guy
 

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sonicss31

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Instead of filters why not use electrostatic precipitators? Interesting stuff. I just retired from 30years in waste to energy power plant.
 

Wolskis

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Instead of filters why not use electrostatic precipitators? Interesting stuff. I just retired from 30years in waste to energy power plant.
Good for you on the retirement. I hope to be done in 2 years.
The filters are on the inlet side. I have not heard of precipitators on gas turbines. Aren't those on the stack side? That's about 2.5 years of accumulated dirt. I have seen the conical style go out 8 years but they have more surface area. The DP across the filter is linear until it isn't. I've seen pictures where the filters are so dirty they get sucked into the turbine.
The dirt will plate out on the first 3 to 4 stages of the compressor causing air instability which causes a lose of efficiency and if dirty enough a stall.
 

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Last night's crew continued pipe removal
 

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Wolskis

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This morning we finished walking down a 120 tag LOTO for work inside the boilers. Up 100ft to the first, back down and up the second, under the boiler for verification of drain valve positions etc. I'm getting too old for this.
 

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This beam fell last October from 80 feet up. Put a hurting into the deck. Now time to replace.
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HP (high pressure 2200psi) SH (superheat) tube bundle
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Wolskis

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You are looking at the 3rd stage buckets or rotating blades. These grow out when hot and what you see in the second pic is the honey comb seal. These are soft so as the bucket grows it will set its own seal.
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Wolskis

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Combustion liner, the bottom connects to fwd cap and the top connects to the TP or transition pieces which will be coming next. The slotted end is called the hula hoop seal
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Wolskis

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Condenser rupture disc's set to blow out at 5.25 psig. Condenser is under a vacuum to change the steam to liquid. If vacuum gets closer to 0 the stress on the last stage steam turbine blading (L-0) escalates to the point of failure. This is very bad. My last plant suffered this and took 6 months to repair.

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Wolskis

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The yellow is the TPC. Thermal protective coating. This is what has propelled the firing temperature along with the metallurgy of the combustion parts. Back in 1989 the GE Frame 7EA put out 110mw, these 7FA's put out 230mw. The next version put out in excess of 300mw.
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Wolskis

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The section should be on the ground by 0600 est Tuesday.
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Wolskis

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It will get rolled over to remove the buckets and nozzles. Bucket specialists will check the moment weights. Each bucket has a serial number that follows the part from birth to death. Typically can be refurbished 3 times which can put a part at 90k operating hours. Moment weights, when inserting a bucket you want the bucket 180 degrees opposite to be extremely close to same weight. These shafts rotate at 3600rpm's. These specialists will open the crates, grab the weight sheet and do their thing. I should be able to get a pic of the sheet.
So the next time your out with an owner of a gas turbine boat ask if the blades are moment weighted.
 
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Wolskis

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Fuel nozzles fit into the forward can.
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Wolskis

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Pressure testing the flexible fuel gas hoses. The last thing we need is 500psi gas leaking and going boom. Each hose gets 400psi for 15 minutes twice, with nitrogen in a water bath.
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