maintenance and troubleshooting of gas turbine

Gas turbine maintenance and troubleshooting involve ensuring optimal performance, reliability, and longevity of the equipment while addressing any operational issues promptly. Here's an overview:

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Types of Maintenance:

1). Routine/Preventive Maintenance:

• Daily/Weekly Checks:

Inspect filters, sensors, and seals.

Monitor lubrication levels.

Check for abnormal vibrations, noise, or temperatures.

• Monthly Checks:

Clean or replace air intake filters.

Examine fuel lines for leaks.

Inspect bearings and couplings for wear.

2). Predictive Maintenance:

• Use condition-monitoring tools:

Vibration analysis.

Thermal imaging.

Oil analysis.

Performance trend monitoring.

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3). Scheduled Maintenance (Major Overhauls):

• Occurs after a specific number of operating hours or starts (based on OEM guidelines).

Includes:

Inspection/replacement of hot gas path components (turbine blades, nozzles).

Cleaning or replacing combustion liners.

Overhaul or replacement of the compressor and turbine stages.

Controls and instrumentation testing.

4). Corrective Maintenance:

• Conducted to address specific issues such as part failures or operational anomalies.

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Common Troubleshooting Scenarios

1. Decreased Efficiency or Power Output

• Causes: Compressor fouling. Air or fuel filter clogging. Poor fuel quality. Deterioration of turbine blades.
• Actions: Clean the compressor. Replace filters. Analyze and improve fuel quality. Inspect and repair/replace damaged turbine blades.

2. Abnormal Vibrations

• Causes: Imbalance in the rotor. Loose or misaligned components. Bearing failure.
• Actions: Perform rotor balancing. Tighten or align components. Replace damaged bearings.

3. High Exhaust Gas Temperature (EGT)

• Causes: Fuel nozzle blockages or malfunction. Hot gas path degradation. Improper airflow distribution.
• Actions: Clean or replace fuel nozzles. Inspect and repair hot gas path components. Check for obstructions in the air intake system.

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4. Start-Up or Shutdown Failures

• Causes: Ignition system issues. Faulty sensors or controls. Inadequate fuel supply.
• Actions: Test and replace ignition components. Calibrate or replace sensors. Ensure proper fuel flow and pressure.

5. Frequent Tripping or Alarms

• Causes: Overheating or over-speed conditions. Sensor faults. Electrical/control system glitches.
• Actions: Address overheating by inspecting cooling and ventilation systems. Replace faulty sensors. Troubleshoot and test the control system.

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Best Practices:

1). Follow OEM Recommendations:

• Adhere to the operation and maintenance manuals for your specific turbine model.

2). Maintain a Logbook:

• Record all maintenance, inspections, and operational anomalies to identify patterns and trends.

3). Train Personnel:

• Ensure operators and maintenance teams are well-trained in gas turbine operation and troubleshooting.

4). Use Advanced Diagnostic Tools:

• Employ SCADA systems, performance monitors, and digital twins for real-time diagnostics.

5). Stock Spare Parts:

• Maintain an inventory of critical spare parts to minimize downtime during repairs.

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