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Gas Turbine Performance Deterioration

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Gas Turbine Performance Deterioration GAS TURBINE PERFORMANCE DETERIORATION by Cyrus B. Meher-Homji Chief Engineer Mustapha A. Chaker Chief Research Scientist Mee Industries Inc., Gas Turbine Division Monrovia, California and Hatim M. Motiwala President and CEO Monimax Inc. Levitown, New York Cyrus B. Meher-Homji is Chief Engineer Hatim M. Motiwala is President and of Mee Industries Inc.’s Gas Turbine CEO of Monimax Inc., in Levitown, New Division. He has 21 years of industry York, a company specializing in developing experience including gas turbine and software solutions for plant performance compressor design, troubleshooting, and monitoring. He has developed perform- engine development. Mr. Meher-Homji’s ance monitoring software that has been areas of interest are power augmentation, applied to a wide range of turbomachinery aerothermal analysis, gas turbine deterio- used on offshore platforms, thermal power ration, blade failures, and vibration plants, and large combined cycles. His analysis. Prior to joining Mee Industries, areas of interest include thermodynamic he worked as a Turbomachinery Specialist modeling of gas turbines and compressors, at Bechtel Corporation and as Director of Engineering at Boyce and aerothermal and vibration condition monitoring of Engineering International Inc. turbomachinery. Prior to starting Monimax in 1997, Mr. Motiwala Mr. Meher-Homji has a B.S. degree (Mechanical Engineering) worked as a Senior Systems Design Engineer at Boyce Engineer- from Shivaji University, an M.E. degree from Texas A&M ing International on software development of thermodynamic University, and an M.B.A. degree from the University of Houston. condition monitoring systems and high performance spectral He is a registered Professional Engineer in the State of Texas, and analysis software. He has managed the implementation of several is a Fellow of ASME and Chairman of the Industrial and condition monitoring systems worldwide. Cogeneration Committee of ASME’s International Gas Turbine Mr. Motiwala has built and patented a novel rheometer design used Institute. He has several publications in the turbomachinery for measuring visco-elastic properties of fluids. He has B.S. and M.S. engineering area including award-winning ASME papers on degrees (Mechanical Engineering) from the University of Houston. compressor deterioration and condition monitoring. ABSTRACT Mustapha A. Chaker is Chief Research With privatization and intense competition in the utility and Scientist at Mee Industries Inc., in petrochemical industry, there is a strong incentive for gas turbine Monrovia, California, where he directs a operators to minimize and control performance deterioration, as research program relating to high pressure this directly affects profitability. The area of gas turbine recoverable gas turbine inlet fogging technology. His and nonrecoverable performance deterioration is comprehensively investigations include the kinetic and treated in this paper. Deterioration mechanisms including thermodynamic behavior of droplets and the compressor and turbine fouling, erosion, increased clearances, and fluid dynamics and heat transfer of fog flow seal distress are covered along with their manifestations, rules of in intake ducts. He conducts theoretical and thumb, and mitigation approaches. Permanent deterioration is also experimental studies utilizing a wind tunnel covered. Because of the importance of compressor fouling, gas and state-of-the-art laser measurement turbine inlet filtration, fouling mechanisms, and compressor systems. Dr. Chaker is internationally known for his work in droplet washing are covered in detail. Approaches for the performance physics and atomization. He also works on the thermodynamic monitoring of steady-state and transient behavior are presented modeling of gas turbines and combined cycle plants and the uses of along with simulations of common deterioration modes of gas CFD techniques for fogging system design and optimization. turbine combined cycles. As several gas turbines are used in Dr. Chaker has a B.S. and M.S. degree (Engineering Physics), cogeneration and combined cycles, a brief discussion of heat and a Ph.D. degree from the University of Nice-Sophia Antipolis, recovery steam generator performance monitoring is made. France. He conducted post doctoral research at California State University, Long Beach and is a member of ASME and the INTRODUCTION Material Research Society. With the introduction of high performance gas turbines and increasing fuel costs, maintaining of the highest efficiency in gas 139 140 PROCEEDINGS OF THE 30TH TURBOMACHINERY SYMPOSIUM turbine systems becomes an imperative. A large-scale 934 MW where Am is the axial flow area. The stress levels increase with the combined cycle plant can have an annual fuel bill of 203 million square of the speed and linearly with the mass flow. dollars. Over its life cycle of 20 years, the fuel would cost over four The blade Mach number (also commonly known as the U/C billion dollars even assuming a flat fuel cost of $4/MM BTU. With ratio), is defined by: a moderate fuel cost escalation, this can easily total six or seven u billion dollars. With the deregulation of the electric utility market Ma = (2) fostering competition between power producers and an γ RT0 environment in which fuel costs have dramatically escalated, plant operators have to understand and control all forms of gas turbine The blade Mach number provides a better understanding of the performance deterioration. situation. This blade Mach number does not differ a lot between There are several excellent papers that treat this important subject different engines. In a turbine with a choked nozzle, it is often either in a highly mathematical fashion or focus on a particular around 0.6. The ideal value for an impulse stage with a sonic subset of the deterioration phenomenon. The goal of this paper is to nozzle is about 0.47 to 0.5, and for a reaction stage is around 0.8. provide a nonmathematical treatment of the physics of performance The specific stress then can be expressed in terms of the hub/tip deterioration covering the subject matter so that plant operators and ratio (vht) by the equation: engineers can grasp the underlying causes, effects, and 2 measurement of gas turbine performance deterioration. To this end, σ Ma 1 =− 1 γ RT (3) rules of thumb and checklists are provided. The APPENDIX will ρ 0 bht2 v provide some simple models and equations that can be used for day-to-day performance deterioration monitoring. Details on gas In high-pressure turbines, the hub/tip ratio is limited by the turbine performance are found in Walsh and Fletcher (1998). This clearances and the associated leakage and losses to values less than reference is particularly valuable because of its comprehensive 0.9. The specific stress in the blades will increase with turbine inlet treatment of gas turbine performance and its appendix providing all temperature (TIT). Consequently the materials have to be the required equations. constantly improved. The area of performance retention is also one of considerable • Mass flow—Several of the newer turbines are uprated by interest to commercial airlines. The techniques for measurement increasing the flow rate by “zero staging.” This approach increases and control used for civil aircraft engines are worth studying as the the output with minimal cost and risk. The early stage is often industrial sector can benefit from some of the techniques employed. transonic, which requires special transonic blading that is less tolerant of incidence losses than subsonic blading. The higher Gas Turbine Design Aspects and Performance Deterioration relative velocities increase the possibility of erosion if hard In order to understand gas turbine and deterioration issues, some particles are present in the airflow. basic aerodynamic and mechanical design issues are covered. • Compressor stall and surge are an important issue often linked Three main limiting factors in gas turbine design and to performance deterioration. Part speed operation results in the development are: earlier stages not making the design pressure ratio and • Restriction on the material temperatures. consequently the density in the latter stages drops. This results in a Stress levels and (therefore) the rotor speeds. choke condition in the rear of the compressor that can force the • early stages into stall. As will be shown ahead, compressor • Fluid dynamic behavior—choking, separation, stall, and mixing. deterioration can often result in surge damage. To attain a high thermodynamic efficiency, heat addition (in • Turbine design considerations—Turbines have not been as essence the turbine inlet temperature) should be at as high a difficult to design as compressors because of the fact that diffusing temperature as possible. This means that cooling has to be flow is not present. The turbine is still the component that will employed. There is an inherent tradeoff between increasing the define the gas turbine operating line and any change in nozzle area cycle temperature and the cooling penalties in the cycle. Cooling or turbine fouling will affect the match point of the gas turbine and flows can impact the overall thermal efficiency of the gas turbine therefore its output and efficiency. and, therefore, losses that increase cooling flow can have a cycle penalty. Several forms of deterioration can directly impact the Simplified Physical Understanding of Gas Turbine Matching cooling flow and impact in turn the reliability of the gas turbine. In a gas
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