Turbomachinery Maintenance

Selection

Exploitation

and

2.1 Selection of hydraulic turbomachines

For a given geometry turbomachine, maximum efficiency is achieved at a given value of flow coefficient, say , energy transfer coefficient
and power coefficient P . 1 1

Usually, the operating conditions, H, P, N for a turbine are specified without reference to the size of the machine. As a result, it is useful to have a dimensionless parameter that does not include the dimension D in it. Such a dimensionless parameter represented as Ns is given by N s
1

= 1 / 1

4 1

NQ 2

( gH )

(2.1)

at the point of max . Ns is the specific speed. It is dimensionless. For hydraulic machines, there is power specific speed given by Ns,p

1 5

NP 2

( gH )

(2.2)
4

Ns and Ns,p are very important in turbomachines selection. In effect, the maximum efficiency condition replaces that of geometric similarity, such that any change in specific speed results in changes in design. The following points are worthy of note - Centrifugal pumps have low specific speeds - Mixed flow pumps have medium specific speeds - Axial flow pumps have high specific speeds - Impulse turbines have low specific speeds - Francis turbines have medium specific speeds

- Propeller turbines have high specific speeds. Normally high specific speed means a smaller machine which is usually cheaper. Consequently, it is desirable to select the highest possible specific speed consistent with good efficiency in hydraulic turbomachines 2.2 Selection of Compressors

Turbo-compressors are those compressors that deliver a continuous flow of gas and comprise of radial flow (centrifugal), mixed flow and axial flow compressors. Mixed flow compressors are rare and will not be considered. For a given task, parameters considered are the pressure ratio, mass flow rate, power, fluid temperature at exit of the compressor and high efficiency. Centrifugal compressors produce highly compressed air and therefore is employed where low power, low mass flow rate, low pressure ratio (about 4:1) at lower efficiency (70-80%) is the requirement. On the other hand, axial- flow compressors are used where higher power, mass flow rate, pressure ratio at good efficiency (86-90%) is required. 2.3 Selection of gas turbines

There are two basic type of gas turbines- the axial flow and radial flow (centrifugal) types. For small mass flow rate, the radial machine is more efficient than the axial flow machine. The radial turbine can also develop high pressure ratio per stage than the axial one, but multistaging is easier to arrange with the axial turbine and as a result large overall pressure ratios can be obtained from them. Radial flow turbines are used in turbochargers for commercial (diesel) engines and fire pumps. High power is usually required for base load and all categories

of steam, gas and hydraulic turbine can meet this requirement but the cost of fuel and long time to build a dam makes the steam turbine preferable for base load whereas the gas turbine is preferable for peak load. However because of low efficiency of the steam turbine, a combined plant (combination of gas and steam turbine) may be a better option. 2.4 Selection of pumps For low to moderate power requirements, centrifugal pumps should be used. Axial flow pumps should be utilized for high power requirement, when large quantity of water at comparatively low heads are to be moved e.g for irrigation purposes.

2.5 Turbomachinery exploitation

The usage to which turbomachines are applied include 2.5.1 Uses of pumps; pumps are used To lift fluids (water) to various heights (to lift water to overhead tank) To transport fluids over long distances, e.g crude oil transport along pipelines from flowstations to refineries. Pumps are used as sub-units in larger machines to transport fluid e.g the automobile fuel pump etc. 2.5.2 Use of turbines; All turbines are used primarily to generate power Both steam and gas turbines are used in cogeneration plants for process heat generation. Gas turbines are employed in ships, jet engines and air craft engines. 2.5.3 Use of compressor

Compressors are used as integral part of all gas turbines Compressors are used in the process and gas transport and distribution industries e.g. refineries, utilities, petrochemicals etc. Compressors are used for sandblasting of corroded surfaces in preparation for painting/coating.

2.5.4 Uses of fans and blowers Fans and blowers provide air for ventilation and air that is needed in some machine operation fans are blowers are equally used in industrial processes.

2.6 Turbomachinery Maintenance

Maintenance defined as the upkeep of property is a very important part of plant operations. The latitude of maintenance activities ranges from strict planning and execution, inspection and overhaul, accompanied by complete reports and accounting of costs, to the operation of machinery until some failure occurs and repairs are undertaken. There must be economic justification for embarking on any maintenance program since the essence of production of any kind is profit making. A new concept of maintenance suggested by Seiichi Nakajima is Total Productive Maintenance (TPM) which is a combination of preventive maintenance, total quality control and total employee involvement to optimize equipment effectiveness eliminate breakdowns and promote autonomous operator maintenance. (Boyce, 2002). The maintenance system can be generally classified into following in increasing order of effectiveness Panic maintenance based on breakdown

Prevention maintenance Performance based maintenance Performance productive maintenance Performance based total productive maintenance

Table 2.1: Benefits of various maintenance systems

Performanc Performanc e based e TPM Productive mtce Economic Yes Yes Yes Yes No Performanc Preventiv e based e mtce mtce Yes Yes No No No No No No No No No Panic mtce

1. efficiency 2. Economic and Yes time efficiency 3.Total system Yes efficiency 4. Autonomous Yes maintenance by operators

Table 2.1 shows the benefits of performance based total productive maintenance. Following this philosophy, overhauls are carried out after a proper data evaluation of the machinery rather than on fixed intervals. The following steps should be followed.

2.6.1. Turbomachinery inspection;

This helps to reduce unscheduled maintenance. Inspection should include daily checks such as Lubrication oil level Oil leakage around the engine Loose fasteners, pipe and tube fittings and electrical connections Inlet filters Exhaust system checks

 Control and monitoring system indicator lights. While the unit is operating and major inspections that require almost total disassembly of the unit. For a gas turbine, the manufacturer generally provides guidelines for determining inspection intervals based on exhaust gas temperatures, type and quality of fuel utilized and number of starts. Table 2.2 below shows the downtime interval for a gas turbines from a number of users and various fuels. The table shows that natural gas is by far the best fuel and operating at a temperature below 927oC gives longer time before maintenance. Table 2.2: Operation and Maintenance life of an industrial turbine Type application and fuel
BASE LOAD Nat. gas Nat. gas Distillate oil Distillate oil Residual SYSTEM PEAKING Nat. gas Nat. gas Distillate oil Distillate oil Turbine peaking Nat. gas Nat. gas Distillate oil Distillate oil

of Firing temperature Firing temperature o o below 1700 F (927 C) above 1700oF (927oC)
Comb. Liners
Starts/hr 1/1000 1/10 1/1000 1/10 1/1000 + 30000 7500 22000 6000 3500

1st stage Nozzle

+ 60000 42000 45000 35000 20000

1st Stage blades

+ 100000 72000 72000 48000 28000

Comb. Liners
15000 3750 11250 3000 2500

1st stage Nozzle

25000 20000 22000 13500 10000

1st stage Blades

35000 25000 30000 18000 15000

1/10 1/5 1/10 1/5 1/5 1/1 1/5 1/1

7500 3800 6000 3000 2000 400 1600 400

34000 28000 27200 22400 12000 9000 10000 7300

60000 40000 53500 32000 20000 15000 16000 12000

5000 3000 4000 2500 2000 400 1700 400

15000 12500 12500 10000 12500 10000 11000 8500

24000 18000 19000 16000 18000 15000 15000 12000

System peaking Normal max. load of short duration and daily starts
Turbine peaking- operating above 50oF-100oF (28-56oC) firing temperature.

2.6.2. Turbomachinery cleaning

Cleaning restores system capability, increases machine efficiency and also prevent failures due to abnormal operating modes. For instance for a dynamic compressor, fouling reduces its head and therefore the maximum glass flow rate but cleaning will restore its capacity. Axial compressors blades should also be cleaned and checked for cracks with a penetrant test during major inspections.

2.6.3. Bearing maintenance

During inspection all journal bearings should be closely inspected. If the machine has not suffered from excessive vibration or lubrication problems, the bearings can be reinstalled. Bearing clearances should also be checked. 2.6.4. Coupling maintenance Disc couplings should be inspected for cracks on the disc or connecting shaft. Gear couplings should be disassembled and the teeth inspected.

2.6.5. Turbine blades

Blades with severe surface damages or cracks should be scrapped, others with no serious damages can be electroplated with substances that can withstand the high temperature it is subjected to.

Example 2.1 Water is to be pumped from a well 30m below a given platform to a tank 5m above the platform. The water flows at a rate of 0.5m3/s. Select a suitable pump for this purpose. Solution Since this involves pumping water to a higher elevation a centrifugal pump (the open impeller type) should be used. Given; height h = 30+5 = 35m Volume flow rate specific gravity
Q = 0 .5 m 3 / s

density for water = 1000Kg/m3

w = =9.81 K / m 3 g N

Let Hm be taken as 40m to account for losses then pump power,

P= H m wQ

4 .8 0.5 0 9 1 = [K w

Assuming o = 80 % = 0.8

then

P = 96 .2[ K 1 W

Thus a centrifugal pump of 196.2[KW] power and 80% efficiency should be used for this job.

References Boyce, M.P. (2002); Gas turbine engineering handbook, 2nd edition, Gulf professional publishing, USA. Dornberger, R., Buche, D. and Stoll, P. (2000); Multidisciplinary optimization in turbomachinery design. ECCOMAS, Barcelona. Dixon, S.L. (2005); Fluid Mechanics and Thermodynamics of Turbomachinery, fifth edution, Elsevier Butterworth-Heinemann, USA. Gorla, R.S.R. and Khan, A.A. (2003); Turbomachinery design and theory, Marcel Dekker Inc., USA. Rajput, R.K. (2007); A textbook of fluid mechanics and hydraulic machines, 3rd edition, S. Chand and Company Ltd., New Delhi. Stoecker, W.F. (1989); Design of thermal system, 3rd edition, McGrawHill.