Search results for: steam turbine blade

Authors: Avadhesh Yadav, Anunaya Saraswat

Abstract:

An evacuated tube solar collector is experimentally studied for steam generation. When the solar radiation falls on evacuated tubes, this energy is absorbed by the tubes and transferred to water with natural conduction and convection. A natural circulation of water occurs due to the inclination in tubes and header. In this experimental study, the efficiency of collector has been calculated. The result shows that the collector attains the maximum efficiency of 46.26% during 14:00 to 15:00h. Steam has been generated for two hours from 13:30 to 15:30 h on a winter day. Maximum solar intensity and maximum ambient temperatures are 795W/m² and 19^oC respectively on this day.

Keywords: Evacuated tube, solar collector, hot water, steam generation.

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Authors: R. Kazemzadeh, J. M. Kauffmann

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This research deals with investigations on the “Active Generator" under rotor speed variations and output frequency control. It runs at turbine speed and it is connected to a three phase electrical power grid which has its own frequency different from turbine frequency. In this regard the set composed of a four phase synchronous generator and a natural commutated matrix converter (NCMC) made with thyristors, is called active generator. It replaces a classical mechanical gearbox which introduces many drawbacks. The main idea in this article is the presentation of frequency control at grid side when turbine runs at variable speed. Frequency control has been done by linear and step variations of the turbine speed. Relation between turbine speed (frequency) and main grid zero sequence voltage frequency is presented.

Keywords: Power Generation, Energy Conversion, FrequencyControl, Matrix Converter.

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Authors: Aref Maalej, Marwa Fakhfakh, Wael Ben Amira

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We present in this work a numerical investigation of fluid-structure interaction to study the elastic behavior of flexible rotors. The principal aim is to provide the effect of the aero/hydrodynamic parameters on the bending deformation of flexible rotors. This study is accomplished using the strong two-way fluid-structure interaction (FSI) developed by the ANSYS Workbench software. This method is used for coupling the fluid solver to the transient structural solver to study the elastic behavior of flexible rotors in water. In this study, we use a moderately flexible rotor modeled by a single blade with simplified rectangular geometry. In this work, we focus on the effect of the rotational frequency on the flapwise bending deformation. It is demonstrated that the blade deforms in the downstream direction and the amplitude of these deformations increases with the rotational frequencies. Also, from a critical frequency, the blade begins to deform in the upstream direction.

Keywords: Numerical simulation, flexible blade, fluid-structure interaction, ANSYS Workbench, flapwise deformation.

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Authors: Nabil M. Muhaisen, Rajab Abdullah Hokoma

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This paper is concerned with calculating boiler efficiency as one of the most important types of performance measurements in any steam power plant. That has a key role in determining the overall effectiveness of the whole system within the power station. For this calculation, a Visual-Basic program was developed, and a steam power plant known as El-Khmus power plant, Libya was selected as a case study. The calculation of the boiler efficiency was applied by using heating balance method. The findings showed how the maximum heat energy which produced from the boiler increases the boiler efficiency through increasing the temperature of the feed water, and decreasing the exhaust temperature along with humidity levels of the of fuel used within the boiler.

Keywords: Boiler, Calculation, Efficiency, Performance. Steam

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Authors: Yusuf Yasa, Erkan Mese

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This paper investigates the thermal issue of permanent magnet synchronous generator which is frequently used in direct drive gearless small-scale wind turbine applications. Permanent Magnet Synchronous Generator (PMSG) is designed with 2.5 kW continuous and 6 kW peak power. Then considering generator geometry, mechanical design of wind turbine is performed. Thermal analysis and optimization is carried out considering all wind turbine components to reach realistic results. This issue is extremely important in research and development (R&D) process for wind turbine applications.

Keywords: Direct drive, gearless wind turbine, permanent magnet synchronous generator (PMSG), small-scale wind turbine, thermal management.

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Authors: Pilanee Vaithanomsat, Waraporn Apiwatanapiwat

Abstract:

Jatropha curcas stem was analyzed for chemical compositions: 19.11% pentosan, 42.99% alphacellulose and 24.11% lignin based on dry weight of 100-g raw material. The condition to fractionate cellulose, hemicellulose and lignin in J. curcas stem using steam explosion was optimized. The procedure started from cutting J. curcas stem into small pieces and soaked in water for overnight. After that, they were steam exploded at 214 °C and 21 kg/cm2 for 5 min. The obtained hydrolysate contained 1.55 g/L ferulic acid which after that was used as substrate for vanillin production by Aspergillus niger and Pycnoporus cinnabarinus in one-step process. The maximum 0.65 g/L of vanillin were obtained with the conversion rate of 45.2% based on the initial ferulic acid.

Keywords: Vanillin, production, Jatropha curcas stem, steam explosion.

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Authors: Omid A. Zargar

Abstract:

Vibration analysis is the most important factor in preventive maintenance. Gas turbine vibration analysis is also one of the most challenging categories in most critical equipment monitoring systems. Utilities are heart of the process in big industrial plants like petrochemical zones. Vibration analysis methods and condition monitoring systems of this kind of equipment developed too much in recent years. On the other hand, too much operation condition consideration in this kind of equipment should be adjusted properly like inlet and outlet pressure and temperature for both turbine and compressor. In this paper the most important tools and hypothesis used for analyzing of gas turbine power plants discussed in details through a real case history related to an Alstom Typhoon gas turbine power plant in Iran oil industries. In addition, the basic principal of vibration behavior caused by mechanical unbalance in gas turbine rotor discussed in details.

Keywords: Vibration analysis, gas turbine, time wave form (TWF), fast Fourier transform (FFT), phase angle.

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Authors: Seok Min Choi, Minho Bang, Seuong Yun Kim, Hyungmin Lee, Won-Gu Joo, Hyung Hee Cho

Abstract:

The matrix cooling channel was used for gas turbine blade cooling passage. The matrix cooling structure is useful for the structure stability however the cooling performance of internal cooling channel was not enough for cooling. Therefore, we designed the rib configurations in the matrix cooling channel to enhance the cooling performance. The numerical simulation was conducted to analyze cooling performance of rib configured matrix cooling channel. Three different rib configurations were used which are vertical rib, angled rib and c-type rib. Three configurations were adopted in two positions of matrix cooling channel which is one fourth and three fourth of channel. The result shows that downstream rib has much higher cooling performance than upstream rib. Furthermore, the angled rib in the channel has much higher cooling performance than vertical rib. This is because; the angled rib improves the swirl effect of matrix cooling channel more effectively. The friction factor was increased with the installation of rib. However, the thermal performance was increased with the installation of rib in the matrix cooling channel.

Keywords: Matrix cooling, rib, heat transfer, gas turbine.

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Authors: Selvakuma Kumaresh, Man Young Kim

Abstract:

Combustion phenomenon will be accomplished effectively by the development of low emission combustor. One of the significant factors influencing the entire Combustion process is the mixing between a swirling angular jet (Primary Air) and the non-swirling inner jet (fuel). To study this fundamental flow, the chamber had to be designed in such a manner that the combustion process to sustain itself in a continuous manner and the temperature of the products is sufficiently below the maximum working temperature in the turbine. This study is used to develop the effective combustion with low unburned combustion products by adopting the concept of high swirl flow and motility of holes in the secondary chamber. The proper selection of a swirler is needed to reduce emission which can be concluded from the emission of Nox and CO2. The capture of CO2 is necessary to mitigate CO2 emissions from natural gas. Thus the suppression of unburned gases is a meaningful objective for the development of high performance combustor without affecting turbine blade temperature.

Keywords: Combustion, Emission, Can-type Combustion Chamber, CFD, Motility of Holes, Swirl Flow.

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Authors: M. Gomaa Abdoelatef, Robert M. Field, Lee, Yong-Kwan

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Growing human population has placed increased demands on water supplies and spurred a heightened interest in desalination infrastructure. Key elements of the economics of desalination projects are thermal and electrical inputs. With growing concerns over use of fossil fuels to (indirectly) supply these inputs, coupling of desalination with nuclear power production represents a significant opportunity. Individually, nuclear and desalination technologies have a long history and are relatively mature. For desalination, Reverse Osmosis (RO) has the lowest energy inputs. However, the economically driven output quality of the water produced using RO, which uses only electrical inputs, is lower than the output water quality from thermal desalination plants. Therefore, modern desalination projects consider that RO should be coupled with thermal desalination technologies (MSF, MED, or MED-TVC) with attendant steam inputs to permit blending to produce various qualities of water. A large nuclear facility is well positioned to dispatch large quantities of both electrical and thermal power. This paper considers the supply of thermal energy to a large desalination facility to examine heat balance impact on the nuclear steam cycle. The APR1400 nuclear plant is selected as prototypical from both a capacity and turbine cycle heat balance perspective to examine steam supply and the impact on electrical output. Extraction points and quantities of steam are considered parametrically along with various types of thermal desalination technologies to form the basis for further evaluations of economically optimal approaches to the interface of nuclear power production with desalination projects. In our study, the thermodynamic evaluation will be executed by DE-TOP, an IAEA sponsored program. DE-TOP has capabilities to analyze power generation systems coupled to desalination plants through various steam extraction positions, taking into consideration the isolation loop between the nuclear and the thermal desalination facilities (i.e., for radiological isolation).

Keywords: APR1400, Cogeneration, Desalination, DE-TOP, IAEA, MED, MED-TVC, MSF, RO.

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Authors: K. Vakhshouri, M.M. Y. Motamed Hashemi

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A rigorous two-dimensional model is developed for simulating the operation of a less-investigated type steam reformer having a considerably lower operating Reynolds number, higher tube diameter, and non-availability of extra steam in the feed compared with conventional steam reformers. Simulation results show that reasonable predictions can only be achieved when certain correlations for wall to fluid heat transfer equations are applied. Due to severe operating conditions, in all cases, strong radial temperature gradients inside the reformer tubes have been found. Furthermore, the results show how a certain catalyst loading profile will affect the operation of the reformer.

Keywords: Steam reforming, direct reduction, heat transfer, two-dimensional model, simulation.

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Authors: Phoevos K. Koukouvinis, John S. Anagnostopoulos, Dimitris E. Papantonis

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This work is an attempt to use the standard Smoothed Particle Hydrodynamics methodology for the simulation of the complex unsteady, free-surface flow in a rotating Turgo impulse water turbine. A comparison of two different geometries was conducted. The SPH method due to its mesh-less nature is capable of capturing the flow features appearing in the turbine, without diffusion at the water/air interface. Furthermore results are compared with a commercial CFD package (Fluent®) and the SPH algorithm proves to be capable of providing similar results, in much less time than the mesh based CFD program. A parametric study was also performed regarding the turbine inlet angle.

Keywords: Smoothed Particle Hydrodynamics, Mesh-lessmethods, Impulse turbines, Turgo turbine.

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Authors: Pavlo Selyshchev

Abstract:

The theoretical approach is developed to describe the change of drops in the atmosphere of own steam and buffer gas under irradiation. It is shown that the irradiation influences on size of stable droplet and on the conditions under which the droplet exists. Under irradiation the change of drop becomes more complex: the not monotone and periodical change of size of drop becomes possible. All possible solutions are represented by means of phase portrait. It is found all qualitatively different phase portraits as function of critical parameters: rate generation of clusters and substance density.

Keywords: Irradiation, steam, plasma, cluster formation, liquid droplets, evolution.

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Authors: Amil Daraz, Suheel Abdullah Malik, Tahir Saleem, Sajid Ali Bhati

Abstract:

In this paper, Integral Proportional (I-P) controller is employed for superheated steam temperature control system. The Ziegler-Nichols (Z-N) method is used for the tuning of I-P controller. The performance analysis of Z-N based I-P controller is assessed on superheated steam system of 500-MW boiler. The comparison of transient response parameters such as rise time, settling time, and overshoot is made with Z-N based Proportional Integral (PI) controller. It is observed from the results that Z-N based I-P controller completely eliminates the overshoot in the output response.

Keywords: Superheated steam, process reaction curve, PI and I-P controller, Ziegler-Nichols tuning.

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Authors: H. Ghanbari, H. Nikbakht, A. Zahedi, M. Ghanbari

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This paper is focusing on designing a control system for wind turbine which can control the speed and output power according to arbitrary algorithm. Reference Tracking Method is used to control the turbine spinning speed in order to increase its output energy.

Keywords: Wind Turbine, Simulink, Reference Tracking Method.

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Authors: L. Benaaouinate, M. Khafallah, A. Martinez, A. Mesbahi, T. Bouragba

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This paper concerns with the modeling, simulation, and emulation of a wind turbine emulator for standalone wind energy conversion systems. By using emulation system, we aim to reproduce the dynamic behavior of the wind turbine torque on the generator shaft: it provides the testing facilities to optimize generator control strategies in a controlled environment, without reliance on natural resources. The aerodynamic, mechanical, electrical models have been detailed as well as the control of pitch angle using Fuzzy Logic for horizontal axis wind turbines. The wind turbine emulator consists mainly of an induction motor with AC power drive with torque control. The control of the induction motor and the mathematical models of the wind turbine are designed with MATLAB/Simulink environment. The simulation results confirm the effectiveness of the induction motor control system and the functionality of the wind turbine emulator for providing all necessary parameters of the wind turbine system such as wind speed, output torque, power coefficient and tip speed ratio. The findings are of direct practical relevance.

Keywords: Wind turbine, modeling, emulator, electrical generator, renewable energy, induction motor drive, field oriented control, real time control, wind turbine emulator, pitch angle control.

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Authors: Mohsen Nikaein

Abstract:

Because of importance of energy, optimization of power generation systems is necessary. Gas turbine cycles are suitable manner for fast power generation, but their efficiency is partly low. In order to achieving higher efficiencies, some propositions are preferred such as recovery of heat from exhaust gases in a regenerator, utilization of intercooler in a multistage compressor, steam injection to combustion chamber and etc. However thermodynamic optimization of gas turbine cycle, even with above components, is necessary. In this article multi-objective genetic algorithms are employed for Pareto approach optimization of Regenerative-Intercooling-Gas Turbine (RIGT) cycle. In the multiobjective optimization a number of conflicting objective functions are to be optimized simultaneously. The important objective functions that have been considered for optimization are entropy generation of RIGT cycle (Ns) derives using Exergy Analysis and Gouy-Stodola theorem, thermal efficiency and the net output power of RIGT Cycle. These objectives are usually conflicting with each other. The design variables consist of thermodynamic parameters such as compressor pressure ratio (Rp), excess air in combustion (EA), turbine inlet temperature (TIT) and inlet air temperature (T0). At the first stage single objective optimization has been investigated and the method of Non-dominated Sorting Genetic Algorithm (NSGA-II) has been used for multi-objective optimization. Optimization procedures are performed for two and three objective functions and the results are compared for RIGT Cycle. In order to investigate the optimal thermodynamic behavior of two objectives, different set, each including two objectives of output parameters, are considered individually. For each set Pareto front are depicted. The sets of selected decision variables based on this Pareto front, will cause the best possible combination of corresponding objective functions. There is no superiority for the points on the Pareto front figure, but they are superior to any other point. In the case of three objective optimization the results are given in tables.

Keywords: Exergy, Entropy Generation, Brayton Cycle, DesignParameters, Optimization, Genetic Algorithm, Multi-Objective.

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Authors: S. Sabzchi Asl, N. Tahouni, M. H. Panjeshahi

Abstract:

Benchmarking of a process with respect to energy consumption, without accomplishing a full retrofit study, can save both engineering time and money. In order to achieve this goal, the first step is to develop a conceptual-mathematical model that can easily be applied to a group of similar processes. In this research, we have aimed to identify a set of key parameters for the model which is supposed to be used for benchmarking of combined cycle power plants. For this purpose, three similar combined cycle power plants were studied. The results showed that ambient temperature, pressure and relative humidity, number of HRSG evaporator pressure levels and relative power in part load operation are the main key parameters. Also, the relationships between these parameters and produced power (by gas/ steam turbine), gas turbine and plant efficiency, temperature and mass flow rate of the stack flue gas were investigated.

Keywords: Combined cycle power plant, energy benchmarking, modelling, Retrofit.

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Authors: Pasayev, A., C. Askerov, R. Sadiqov, C. Ardil

Abstract:

In contrast to existing of calculation of temperature field of a profile part a blade with convective cooling which are not taking into account multi connective in a broad sense of this term, we develop mathematical models and highly effective combination (BIEM AND FDM) numerical methods from the point of view of a realization on the PC. The theoretical substantiation of these methods is proved by the appropriate theorems.

Keywords: multi coherent systems, method of the boundary integrated equations, singular operators, gas turbines

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Authors: Daniel Pereiro, Felix Martinez, Iker Urresti, Ana Gomez Gonzalez

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Today modern simulations solutions in the wind turbine industry have achieved a high degree of complexity and detail in result. Limitations exist when it is time to validate model results against measurements. Regarding Model validation it is of special interest to identify mode frequencies and to differentiate them from the different excitations. A wind turbine is a complex device and measurements regarding any part of the assembly show a lot of noise. Input excitations are difficult or even impossible to measure due to the stochastic nature of the environment. Traditional techniques for frequency analysis or features extraction are widely used to analyze wind turbine sensor signals, but have several limitations specially attending to non stationary signals (Events). A new technique based on autoregresive analysis techniques is introduced here for a specific application, a comparison and examples related to different events in the wind turbine operations are presented.

Keywords: Wind turbine, signal processing, mode extraction.

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Authors: Jasna Dragosavac, Žarko Janda, J.V. Milanović, Dušan Arnautović

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This paper discusses coordinated reactive power - voltage (Q-V) control in a multi machine steam power plant. The drawbacks of manual Q-V control are briefly listed, and the design requirements for coordinated Q-V controller are specified. Theoretical background and mathematical model of the new controller are presented next followed by validation of developed Matlab/Simulink model through comparison with recorded responses in real steam power plant and description of practical realisation of the controller. Finally, the performance of commissioned controller is illustrated on several examples of coordinated Q-V control in real steam power plant and compared with manual control.

Keywords: Coordinated Voltage Control, Power Plant Control, Reactive Power Control, Sensitivity Matrix

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Authors: Thochi Seb Rengma, Mahendra Kumar Gupta, P. M. V. Subbarao

Abstract:

Hydrokinetic turbines can be used to produce power in inaccessible villages located near rivers. The hydrokinetic turbine uses the kinetic energy of the water and maybe put it directly into the natural flow of water without dams. For off-grid power production, the Savonius-type vertical axis turbine is the easiest to design and manufacture. This proposal uses three-dimensional Computational Fluid Dynamics (CFD) simulations to measure the considerable interaction and complexity of turbine blades. Savonius hydrokinetic turbine (SHKT) performance is affected by a blockage in the river, canals, and waterways. Putting a large object in a water channel causes water obstruction and raises local free stream velocity. The blockage correction factor or velocity increment measures the impact of velocity on the performance. SHKT performance is evaluated by comparing power coefficient (Cp) with tip-speed ratio (TSR) at various blockage ratios. The maximum Cp was obtained at a TSR of 1.1 with a blockage ratio of 45%, whereas TSR of 0.8 yielded the highest Cp without blockage. The greatest Cp of 0.29 was obtained with a 45% blockage ratio compared to a Cp max of 0.18 without a blockage.

Keywords: Savonius hydrokinetic turbine, blockage ratio, vertical axis turbine, power coefficient.

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Authors: T. Unchim, A. Oonsivilai

Abstract:

The Wind Turbine Modeling in Wind Energy Conversion System (WECS) using Doubly-Fed Induction Generator (DFIG) PI Controller based design is presented. To study about the variable wind speed. The PI controller performs responding to the dynamic performance. The objective is to study the characteristic of wind turbine and finding the optimum wind speed suitable for wind turbine performance. This system will allow the specification setting (2.5MW). The output active power also corresponding same the input is given. And the reactive power produced by the wind turbine is regulated at 0 Mvar. Variable wind speed is optimum for drive train performance at 12.5 m/s (at maximum power coefficient point) from the simulation of DFIG by Simulink is described.

Keywords: DFIG, wind speed, PI controller, the output power.

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Authors: M. H. Pour, V. M. Nansa, M. Saberi, A. M. Ghanadi, A. Aghayari, M. Mirzajanzadeh

Abstract:

Stirred tanks have applications in many chemical processes where mixing is important for the overall performance of the system. In present work 5%v of the tank is filled by solid particles with diameter of 700 m that Rushton Turbine and Propeller impeller is used for stirring. An Eulerian-Eulerian Multi Fluid Model coupled and for modeling rotating of impeller, moving reference frame (MRF) technique was used and standard-k-
model was selected for turbulency. Flow field, radial velocity and axial distribution of solid for both of impellers was investigation and comparison. Comparisons of simulation results between Rushton Turbine and propeller impeller shows that final quality of solid-liquid slurry in different rotating speed for propeller impeller is better than the Rushton Turbine.

Keywords: CFD, Particle Velocity, Propeller Impeller, Rushton Turbine.

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Authors: A. Shahsavari, M. Nili-Ahmadabadi

Abstract:

This paper presents an innovative one-dimensional optimization of a transonic compressor based on the radial equilibrium theory by means of increasing blade loading. Firstly, the rotor blade of the transonic compressor is redesigned based on the constant span-wise deHaller number and diffusion. The code is applied to extract compressor meridional plane and blade to blade geometry containing rotor and stator in order to design blade three-dimensional view. A structured grid is generated for the numerical domain of fluid. Finer grids are used for regions near walls to capture boundary layer effects and behavior. RANS equations are solved by finite volume method for rotating zones (rotor) and stationary zones (stator). The experimental data, available for the performance map of NASA Rotor67, is used to validate the results of simulations. Then, the capability of the design method is validated by CFD that is capable of predicting the performance map. The numerical results of new geometry show about 19% increase in pressure ratio and 11% improvement in overall efficiency of the transonic stage; however, the design point mass flow rate of the new compressor is 5.7% less than that of the original compressor.

Keywords: One dimensional design, deHaller number, radial equilibrium, transonic compressor.

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Authors: T. Brahimi, F. Saeed, I. Paraschivoiu

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This paper details the progress made in the development of the different state-of-the-art aerodynamic tools for the analysis of vertical axis wind turbines including the flow simulation around the blade, viscous flow, stochastic wind, and dynamic stall effects. The paper highlights the capabilities of the developed wind turbine aerodynamic codes over the last thirty years which are currently being used in North America and Europe by Sandia Laboratories, FloWind, IMST Marseilles, and Hydro-Quebec among others. The aerodynamic codes developed at Ecole Polytechnique de Montreal, Canada, represent valuable tools for simulating the flow around wind turbines including secondary effects. Comparison of theoretical results with experimental data have shown good agreement. The strength of the aerodynamic codes based on Double-Multiple Stream tube model (DMS) lies in its simplicity, accuracy, and ability to analyze secondary effects that interfere with wind turbine aerodynamic calculations.

Keywords: Aerodynamics, wind turbines, VAWT, CARDAAV, Darrieus, dynamic stall.

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Authors: M. M. Rahman, Thamir K. Ibrahim, M. Y. Taib, M. M. Noor, Rosli A. Bakar

Abstract:

Regenerative gas turbine engine cycle is presented that yields higher cycle efficiencies than simple cycle operating under the same conditions. The power output, efficiency and specific fuel consumption are simulated with respect to operating conditions. The analytical formulae about the relation to determine the thermal efficiency are derived taking into account the effected operation conditions (ambient temperature, compression ratio, regenerator effectiveness, compressor efficiency, turbine efficiency and turbine inlet temperature). Model calculations for a wide range of parameters are presented, as are comparisons with simple gas turbine cycle. The power output and thermal efficiency are found to be increasing with the regenerative effectiveness, and the compressor and turbine efficiencies. The efficiency increased with increase the compression ratio to 5, then efficiency decreased with increased compression ratio, but in simple cycle the thermal efficiency always increase with increased in compression ratio. The increased in ambient temperature caused decreased thermal efficiency, but the increased in turbine inlet temperature increase thermal efficiency.

Keywords: Gas turbine, power plant, thermal analysis, regeneration

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Authors: D. Almazo, M. Toledo, C. Rodríguez

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This work presents a methodology for the design and manufacture of propellers oriented to the experimental verification of theoretical results based on the combined model. The design process begins by using algorithms in Matlab which output data contain the coordinates of the points that define the blade airfoils, in this case the NACA 6512 airfoil was used. The modeling for the propeller blade was made in NX7, through the imported files in Matlab and with the help of surfaces. Later, the hub and the clamps were also modeled. Finally, NX 7 also made possible to create post-processed files to the required machine. It is possible to find the block of numbers with G & M codes about the type of driver on the machine. The file extension is .ptp. These files made possible to manufacture the blade, and the hub of the propeller.

Keywords: Airfoil, CAM, manufacturing, mathematical algorithm, numeric control, propeller design, simulation.

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Authors: Abubakar Rashid, Muhammad Saad, Faheem Ahmed

Abstract:

This paper provides a comprehensive study pertaining to diagnosis of intermittent high vibrations on an industrial gas turbine using detailed vibrations analysis, followed by its rectification. Engro Polymer & Chemicals Limited, a Chlor-Vinyl complex located in Pakistan has a captive combined cycle power plant having two 28 MW gas turbines (make Hitachi) & one 15 MW steam turbine. In 2018, the organization faced an issue of high vibrations on one of the gas turbines. These high vibration peaks appeared intermittently on both compressor’s drive end (DE) & turbine’s non-drive end (NDE) bearing. The amplitude of high vibration peaks was between 150-170% on the DE bearing & 200-300% on the NDE bearing from baseline values. In one of these episodes, the gas turbine got tripped on “High Vibrations Trip” logic actuated at 155µm. Limited instrumentation is available on the machine, which is monitored with GE Bently Nevada 3300 system having two proximity probes installed at Turbine NDE, Compressor DE &at Generator DE & NDE bearings. Machine’s transient ramp-up & steady state data was collected using ADRE SXP & DSPI 408. Since only 01 key phasor is installed at Turbine high speed shaft, a derived drive key phasor was configured in ADRE to obtain low speed shaft rpm required for data analysis. By analyzing the Bode plots, Shaft center line plot, Polar plot & orbit plots; rubbing was evident on Turbine’s NDE along with increased bearing clearance of Turbine’s NDE radial bearing. The subject bearing was then inspected & heavy deposition of carbonized coke was found on the labyrinth seals of bearing housing with clear rubbing marks on shaft & housing covering at 20-25 degrees on the inner radius of labyrinth seals. The collected coke sample was tested in laboratory & found to be the residue of lube oil in the bearing housing. After detailed inspection & cleaning of shaft journal area & bearing housing, new radial bearing was installed. Before assembling the bearing housing, cleaning of bearing cooling & sealing air lines was also carried out as inadequate flow of cooling & sealing air can accelerate coke formation in bearing housing. The machine was then taken back online & data was collected again using ADRE SXP & DSPI 408 for health analysis. The vibrations were found in acceptable zone as per ISO standard 7919-3 while all other parameters were also within vendor defined range. As a learning from subject case, revised operating & maintenance regime has also been proposed to enhance machine’s reliability.

Keywords: ADRE, bearing, gas turbine, GE Bently Nevada, Hitachi, vibration.

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Authors: M. Azadi, N. Tahouni, M. H. Panjeshahi

Abstract:

A techno-economic evaluation for efficient use of energy in a large scale industrial plant of methanol is carried out. This assessment is based on integration of a gas turbine with an existing plant of methanol in which the outlet gas products of exothermic reactor is expanded to power generation. Also, it is decided that methanol production rate is constant through addition of power generation system to the existing methanol plant. Having incorporated a gas turbine with the existing plant, the economic results showed total investment of MUSD 16.9, energy saving of 3.6 MUSD/yr with payback period of approximately 4.7 years.

Keywords: Energy saving, Gas turbine, Methanol, Power generation.

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