Chapter 1

Introduction

1.1About Company

GSEG is operating a 156 MW Combined Cycle Power Plant based on Natural Gas at Mora,
District Surat, Gujarat. During the financial year 2015-16, GSEG declared availability 68.12
% due to non-availability of gas at cheaper rate. The Profit after tax was approx. Rs 104.5
Cores for the same financial year [1]. GSEG also undertook expansion by installing another
Combined Cycle Gas Based Project of capacity 351 MW at its existing Site at cost of Rs 1160
Crores. Commercial operation of the Expansion Project was declared on March 22, 2012.This
plant will be operationalized after allocation of domestic natural gas.

Operation and Maintenance

They have been operating facilities ranging from small cogeneration plants to power plants
sites with several 1,000 MW of installed capacity for decades now. Planning, constructing and
operating our own and third-party power plants result in extensive knowledge based on fossil
fuels and renewable energies.Their Service portfolio includes everything from consulting
support through to the complete assumption of responsibility for technical and commercial
operation management [1].

Type: Gas Power Plant

Area: Gujarat
Kind of Fuel: Natural Gas, Naphta
Power Capacity: 156 MW (3 x 52 MW)
Owner: Gujarat State Energy Generation Limited (GSEG)
Shareholders: Gujarat State Petroleum Corporation (GSPC)
Activity since: 2001
Customer GUVNL: (Gujarat Urja Vidhyut Nigam Limited)[1]

1
1.2 Scope and Purpose of Plant
GSEG (Gujarat State Energy Generation Ltd.) is a Special Purpose Vehicle (SPV) formed by
GSPC (Gujarat State Petroleum Corporation) to generate power in Gujarat by harnessing the
eco-friendly and economical natural gas. GSEG is part of the GSPC Group's overall strategy
of establishing a presence in both the upstream and downstream segments of the energy value
chain. The company is committed to using innovative, advanced and reliable technology for
producing gas-based power [2].

GSEG was set up in 1998 as a power generation company. GSEG owns and operates a gas
based power plant in Hazira that was commissioned in 2002. The plant was set up to provide
electricity for the Gujarat state grid, with all electricity currently produced at the plant sold to
Gujarat Urja Vikas Nigam Limited (GUVNL), a Government of Gujarat owned electricity
company.

GSEG is in the process of extending the capacity of its Hazira plant. It has entered into a gas
purchase contract with us to provide the gas required for the expanded plant, effective for 20
years from commissioning, with the gas to be bought at mutually agreed prices. The
additional power to be generated will be bought by GUVNL pursuant to a 20 year
procurement contract effective from commissioning.

1.3 Actualization
 Association with other state sector companies and central sector PSUs like
KRIBHKO and GAIL.
 Alstrom Power India awarded with EPC for the plant.
 The plant available both as modularized, pre-engineered packages
 Development for a156.1 MW, two 52 MW gas turbine (GT8C2), one 52.1 MW
steam turbine and two heat recovery steam generator-combined cycle
 Power generation project begins at Surat.
 30th September,2001 successful initial test firing and synchronizing of the first gas
turbine
 1st Dec, 2001. Plant operational in open cycle mode.
 The plant in combined cycle mode (156.1) MW is commercially operational since
1st June 2002.

2
Plant Layout

A Figure 1.1 shown below gives over all idea of plant layout and flow of all the process in
power plant [3]

Figure 1.1 Plant Layout [3]

3
 1.4 Concept of CCPP
Working principle of combined cycle power plant is explained in Figure 1.2 [4]

Figure 1.2 Concept of CCPP [4]

Gas turbine burns fuel.

The gaszturbinezcompresses air and mixeszitzwith fuel that iszheated toza very high
temperature. zThezhotzair-fuel mixturezmoves throughzthe gas turbine blades, making them
spin.The fast-spinning turbine drives azgenerator thatzconverts a portion ofzthe spinning
energy into electricity

Heat recovery system captures exhaust.

A Heat Recovery Steam Generator (HRSG) zcaptureszexhaust heat from the gas turbine that
would otherwise escape through the exhaust stack [4].The HRSGzcreates steam from the
gaszturbine exhaust heat and delivers it to the steam turbine.

Steam turbine delivers additional electricity.

The steam turbinezsendszits energyztozthe generatorzdrive shaft, wherezitziszconverted into

additionalzelectricity [4].

4
 1.5 Turbine specification [3]
Specifications of turbine ALSTOM GT8C2 are given in Table 1.1

Table 1.1 Technical Specification of Turbine

Technical Specifications
• Gross electric power output 52.7MW
• Gross efficiency 34.7%
• Turbine rotational speed 6210/min
• Compressor pressure ratio 17.2:1
• Exhaust gas mass flow 195kg/sec
• Exhaust gas temperature 510
• Frequency 50/60Hz

5
 Chapter 2

Literature Review

2.1 Literature Review

Process of combined cycle power plant is explained in Figure 2.1.

As shown in Figure 2.1 the fuel is supplied by GSPC in the form of natural gas naphtha.
Compressors suck the air from the atmosphere and compress it up to 45bar which is further
supplied for combustion in combustion chamber. In combustion chamber with the help of
spark the mixture gets ignite and high temperature gas is produce of around 2000 c and
further runs gas turbine. After work done in GT temperature of gas is around 570 degree. This
high temperature exhaust gas is further utilized in HRSG to produce steam. Steam produced
by HRSG is used to run steam turbine and at the end final temperature of gas is around 110
degree [3].

Figure 2.1 Process of Plant [3]

6
Nurbanasari and Abdurrachim has mention following study details of compressor in their
research paper [5]. Azcompressor is one of the main parts ofzevery turbine. Its function is
tampingzof incoming air to thezwedge shape combustion .Thezaxial flow turbines arezthe
most used type of turbines ,that are located inzazcompressor and a turbine on onezshaft .The
highzspeed of rotation, sometimes 11000zrotation/minute ,thezhigh air pressure and the high
temperature in the compressorz, zcause many damages. Thezfracture of the bladeszof a rotor
is one of the most damageszwhichzhappen. Manyzfactorszare the causezofz fracture of
thezcompressor blade, such as: impurityzofzmaterial, creep, anyzdefectzof machining,
zforeignzobject damage (FOD), intensive vibrations, fatigue, etc. zThezfracture of the
frontzcompressorzblades causeszserious damageszof the compressor. Aboutzthezfracture of
the blades of different compressors [5].

Dimensional Specifications - The fractured blade: length: 20cm; average width: 5 cm;
thickness: 5mm. Figure 2.2 shows the damaged blade.

Figure 2.2 Fractured blade

7
Chemical Specifications - The Chemical composition show the type of alloy is Stainless Steel
450 Alloy UNS S45000. Below Table 2.1 shows the weight per cent of the elements of this
alloy.

Table 2.1 Chemical Specification of Blade

Fe Cr Ni Si Mn Mo Nb C P S

74.3 14 6 1.45 1 1 0.75 0.40 0.040 0.05

Table 2.2 Mechanical, and Physical Specifications

Tensile strength 986 MPa

Yield strength (@ strain 0.200%) 814 MPa
Bulk modulus 166 GPa
Shear modulus 83.9 GPa
Charpy impact 125 - 141 J
Hardness, Vickers 287
Thermal expansion co-efficient 10.1 μm/m°C
Density 7.80 cm

Macro Hardness test - The test is done at the root of the blade by Vikers standard. Figure 3
shows places of the hardness test. We observe the thickness of the upper part of the root (the
place of the fracture) is more.

Figure 2.3 Macro hardness testing on the blade [5]

Fractography- The study of the level of the fracture gives the states, the cause and the
condition of the fracture .In Fractography, the most important point is taking proper
microscopic and macroscopic photos which have proper marks of the determination of the

8
type of the fracture. The fraction of azbladezresults in the damage of thezother blades. One
overhaul was done. The done PT testzon thezsecond rowzblades of thiszturbine showedzsome
ofzthese zhavezcrack onztheirzair foilzcorner of thezroot.

Figure 2.4 Damaged compressor Figure 2.5 Crack Existed on Root

blade [5] of the Blade [5]

Figure 2.6 Beach marks and the Figure 2.7 Fatigue cracks in
section of the fracture of the fracture surface [5]
fatigue [5]

9
 Finite Element Model- In order to simulatezthe model, solidworks softwarezis used, and thenzit
is analysiszthe finite element by Ansys software. The usedzelementszin this model are solid
186- type, which have well precision forzanalysis of suchzproblems. Figure 2.8 shows this
model is made of by solid works.

Figure 2.8 Solidworks Model of Blade [5]

Figure 2.9 Von-misses stress on pressure Figure 2.10 Von-misses stress on suction
side [5] side [5]
10
 Figure 2.11 Stress concentration point at the leading edge near the
platform of the blade under the third natural mode shape [5]

Results
The result of observation of thezFractography and finitezelement analysis, zmeanszthat the
fatiguezcrack iszgrown from twozcornerszof the air foil, and because of thezcontact with an
outside objectzwhich might be azfragment of anotherzfractured blade, zthe edges of thezblade
arezbroken andzthe bladezhas changed.

11
 Chapter 3

Problem Specification

3.1 Problem 1- Maintenance of Centrifugal Pump

3.1.1 Identification of Problem

During plant visit with mentors in DM plant abnormal noise and high vibration is
observed. Apart from noise leakage from impeller eye is noticed.

Figure 3.1Centrifugal Pump (DM plant)

3.1.2 Range and Specification

Technical specifications and range of centrifugal pump of DM plant are given in Table 3.1

Table 3.1 Range and Specification of Pump

Range And Technical Specification
Head range up to 76 meters
Discharge range up to 49 LPS
Power rating 0.37 KW
Voltage range 330 V (3 phase)

12
3.2 Problem 2- Blade Failure of Compressor of Gas Turbine (GT-12)
During Operation

3.2.1 Incident detail

GT-12 was running on Base load @ 35.5 MW with TK2 control mode, at 19:34 hrs on 5th
Oct 2018, GT-12 Manually tripped by Pressing the Emergency Push Button (EPB) by the
operator because the vertical pedestal. Vibrations of GT #12 Bearing No.01 (Turbine side) &
Bearing No.2 (Compressor Pedestal side) were in increasing. Trend and reached to
10.8mm/sec and 6.2mm/sec respectively. It has been also observed that the Relative Shaft
Vibrations reached to their limits.

3.2.2 Problem Assessment

Findings and observation in various component are given in following Figure (3.2 to 3.14)
which includes overview of filter house, silencer, air intake manifold, and silencer housing.

(a)

(b)
Figure 3.2 Filter House
13
 Figure 3.3 Air Intake Manifold

Figure 3.4 Air Inlet Casing

Filter Housing

• Corrosion spots seen on the filter house flooring before the pulse filters
• All the screws and bolting in the filter house structure found intact
• Filter house flooring found with dust deposits

Filters Condition
• No maintenance was carried out by customer on the filtered during this shutdown.
• Installed filters are from Dallinger- S65R-U18A9-SPX

14
Silencer Housing

• Area after pulse filters seen with old water puddle marks Filter house flooring found
with dust deposits

• Minor corrosion spots seen after silencers near the retaining plates.

• Stream of dust seen after the silencer housing

Silencers
• All the silencers retaining plates found intact.

Air Inlet Duct

• Nothing unusual found.
• The expansion bellow between air inlet duct elbow joint and the manifold has to be
inspected in detail by erecting scaffoldings, to check the condition of the expansion
bellow

Air Inlet Casing and Manifold

• Air inlet manifold seen with dust particles mostly due to the maintenance on-going on
the gearbox.
• Air inlet casing seen with paint peel off and corrosion around some areas of the casing

Compressor Vanes Assessment

Circumferential Plot of Damage Type Seen on Compressor Vanes 1 To 9

This circumferential plot of axial flow compressor shows various defects and its severity on
circumference of the compressor. It gives idea about the location of various defects and no of
blade which id defected or gets worn out. This plot is prepared using F-chart.

Figure 3.5 Circumferential Plot of Damage Type Seen on Compressor Vanes 1 To 9

15
Vane row 4 impact damage overview

Impact of damage and intensity of defect on vane 4 is shown in Figure 3.7

Figure 3.6 Vane Row 4 Impact Damage Overview

Vane row 5 impact damage overview

Impact of damage and parameter of defect on vane 5 is shown in Figure 3.7 and 3.8

Figure 3.7 Sheared off Vane row 5 - Figure 3.8 Vane row 5 impact damage overview
#4 16
Vane row 6 impact damage overview

Impact of damage and parameter of defect on vane 6 is shown in Figure 3.9

Figure 3.9 Vane row 6 impact damage overview

Vane row 7 impact damage overview

Impact of damage and parameter of defect on vane 7 is shown in Figure 3.10

rthgnfnfnm

Figure 3.10 Vane row 7 impact damage overview

17
Vane row 8 impact damage overview

Impact of damage and parameter of defect on vane 7 is shown in Figure 3.11

(a) (b)

Figure 3.11 Vane Row 8 Impact Damage Overview

Vane row 9 impact damage overview

Figure 3.12 Vane row 9 impact damage overview

18
Vane row OGV impact damage overview

Impact of damage and parameter of defect on OGV is shown in Figure 3.14

Figure 3.13 Vane row OGV impact damage overview

Figure 3.14 Compressor Blade Impact Damage Overview

19
3.3 Problem 3- Performance and Maintenance of Cooling Tower
3.3.1 Identification of Problem

During visit of power plant in working condition it is observed that at the edges of every
cooling tower water gets accumulated due to fill defect, and at various places in CT fill gets
damaged, due to this maintenance issue performance of CT gets affected and its effectiveness
reduces[6]

3.3.2 Defects in CT

System Concerns

Cooling towers are dynamic systems because of the nature of their operation and the
environment they function within. Tower systems sit outside, open to the elements, which
makes them susceptible to dirt and debris carried by the wind. Their structure is also popular
for birds and bugs to live in or around [7]

Figure 3.15 System Concerns in CT

Corrosion

Corrosion is an electro-chemical or chemical process that leads to the destruction of the system
metallurgy. There are different types of corrosion encountered in cooling tower systems
including pitting, galvanic, microbiologically influenced and erosion corrosion, among others
Loss of system metallurgy, if pervasive enough, can result in failed heat exchangers, piping, or
portions of the cooling tower itself

Figure 3.16 Example of a Figure 3.17 Microbiologically Influenced

Corrosion Cell [8] Corrosion (Source: Taprogge GmbH) [8]

20
Fouling

Foulingzoccurszwhenzsuspendedzparticles fall out of solution forming deposits. Common

foulants includezorganic matter, zprocess oils, and siltz (fine dirt particles that blow into
theztower system, orzenter in thezmake-upzwater supply).Factors that lead to fouling are
lowzwater velocities, corrosion, and process leaks. Foulingzdeposits, zsimilar to
scalezdeposits, impede the heatzexchange capabilities of the system by providing an
insulating barrierzto the systemzmetallurgy. Fouling inzthe towerzfill canzplug film
fillzreducing the evaporative surface.

Scaling

Scaling iszthe precipitationzof dissolved minerals components that have become saturated
inzsolution.Figure 3.18z illustrates calcium carbonatezscalezcollecting on a faucet head.
Factors that contribute tozscalingztendencies include water quality, pH, and temperature.
Scale formation reduceszthe heat exchangezability of thezsystem becausezof the
insulatingzproperties ofzscale, zmaking thezentirezsystemzwork harder tozmeetzthe
coolingzdemand.

Figure 3.18 Calcium Carbonate Scale (Source: Hustvedt) [7]

21
Microbiological Activity

Microbiological activity is micro-organisms that live and grow in the cooling tower and
cooling system. Coolingztowers present thezperfect environmentzfor biologicalzactivity due
to the warm, moist environment. They havezstrong insulating properties, they contribute
tozfouling andzcorrosion, and the bi-products they create that contribute to further micro-
biological activity.

Figure 3.19 Bio fouled Heat Exchanger (Source: Taprogge GmbH) [7]

22
3.3.3 Fill Defects in CT

Defects of fill in cooling tower of power plant are shown in below Figures from (3.20 to3.24)
[8].

Figure 3.20 Fill Stack end Defect (Uneven Wrap)

Figure 3.21 Unwanted Extra Gap between Fill

As shown in figure above it shows defect in CT, due to uneven wrap at equal distance at the
end of fill stack reduces cooling capacity and effectiveness of CT.

23
As this plant is located in industrial area various dust and foreign particles are available in the
atmosphere, and this particle gets into the gap between fills and clog fills, due to which proper
cooling and contact of air and water does not take properly hence effectiveness reduces.

Figure 3.22 Clogging Of Fill Due To Foreign Particle and Dust

Figure 3.23 Hole (tear of fill)

24
This defect as shown in figure above is due to uneven flow of water into the fill stacks due to
this some of the fill gets displaced and come down

Figure 3.24 Slip of Fill Stack

25
 Chapter 4

Solution and Recommendations

4.1 Solution 1- Maintenance of Pump

4.1.1 Procedure For Maintenance of DM pump

This is the procedure by which maintenance of DM pump will be carried out step by step in
power plant by Figure 4.1

Figure 4.1 Procedure for Maintenance of DM

pump

Identification of problem
By leakage and abnormal sound during observation. During plant visit with mentors in DM
plant abnormal noise and high vibration is observed. Apart from noise leakage from impeller
eye is noticed.

26
Causes of Problem

Figure 4.2 Causes of Problem of DM Pump

All of the above are predicted causes for problem out of which some of the causes are critical
which are shown in red outline, due to which leakage and abnormal sound are observed
during visit. This fish bone diagram gives us idea about all the possible available causes to the
problem and made easy to identify main and critical cause to problem

Checking of Inventory

 In this stage availability of every parts of pump is to be checked in inventory by

maintenance engineer
 If there is absence of any parts then order will be placed as per requirement by higher
authority

27
Overhauling

Step by step overhauling procedure of DM plant centrifugal pump.

Figure 4.3 Overhauling Process

As discuss in previous section after findings of critical causes of the problem abnormal noise
and vibrations of pump it is concluded that mechanical seal is damaged and two bearings was
worn out , so to replace those parts overhauling is carried out in the sequence as shown in
figure above. First of all bearing housing is to be removed as shown in Figure 4.1 then
bearing seal and oil seal is to be removed and their condition is observed after that closed
impeller is removed and then at last mechanical seal and movable casing is dissembled as
shown in figure.

28
Maintenance Activity

Maintenance activity includes replacement and cleaning of various worn parts of the pump,
which are as follows [9]

Figure 4.4 Parts to Be Changed During Maintenance

Assembly and Testing

After cleaning and changing of parts assembly of pump was carried out and during testing of
pump it was observed that the problem regarding vibration and leakage is no more.

Figure 4.5 DM pump after maintenance

29
4.2 Solution 2 - Damage Assessment of Compressor Failure
4.2.1 Causes Of Problem

Debris below Combustor casing

Figure 4.6 Debris below Combustor Casing

Pieces of blades found inside the compressor casing

Figure 4.7 Pieces of Blades Found Inside the Compressor Casing

30
4.2.2 Assessment Findings in GT Modules

Table 4.1 Assessment Findings & Recommendations

Findings Recommendations / Remarks
Filter Housing
Clean the filter house
Corrosion spots seen on the filter house area.
flooring before the pulse filters Remove corrosion and repaint the affected
All the screws and bolting in the filter house areas
structure found intact
Filter house flooring found with dust deposits

Filters Condition
Carry out replacement of the pulse filters as
No maintenance was carried out by customer per OEM maintenance manual as well as
on the filtered during this regularly monitor the dp across the filters.
shutdown.
Installed filters are from Dallinger- S65R-
U18A9-SPX

Silencer Housing
Clean the filter house
Area after pulse filters seen with old water area.
puddle marks Filter house flooring found Remove corrosion and repaint the affected
with dust deposits areas
Minor corrosion spots seen after silencers
near the retaining plates.
Stream of dust seen after the silencer housing

Silencers

All the silencers retaining plates found intact. None

Air Inlet Duct

Nothing unusual found.

The expansion bellow between air inlet duct None
elbow joint and the manifold has
to be inspected in detail by erecting
scaffholding, to check the condition of the
expansion bellow

31
4.2.3 Solution / Recommendation

Summary of parts to be exchanged based on damage assessment:

Table 4.2 Solution / Summary

PART RECOMMENDATION

Compressor Blade Row 1 REPLACE complete set of compressor blade

row 1 along with
new assembly material

Compressor Blade Row 5 to 12 REPLACE complete set of compressor blade

row 5 to 12 along
with new assembly material

Compressor Vane Row 4 to 12 + REPLACE complete set of compressor vane

OGV row 4 to 12 +OGV
along with new assembly material

GT Blade row 1: # 15 and 73 REPLACE Blade Nr # 15, 73 along with

complete blade row new
assembly material [10]

Consumables Consumables required for re-assembly of the

machine

32
 Table 4.3 Compressor Vanes Findings Related to Damage Assessment &
Recommendations
Compressor Vanes Findings Related To Recommendation
Damage Assessment
Compressor Vane Row 4
Medium tip rubbing seen. Replace complete set of compressor
All the vanes TE found with impact damage vane row 4 along with new assembly
near platform. Material.
Medium Impact (19 vanes): 8,9,10,12, Ensure proper preservation techniques
18,19,20, 26, 27, 28, 30, 34, 40 as per OEM specification document
Significant Impact (30 vanes) 1,2,3,5,6, 7, HTCT690086, when the customer is not
13,14,15,16, 22,23,24, 29, 31, 32, 33, 35, intending to run the machine over a
36, 37, 38, 39, 41, 42, 43, 44, 45, 46, 47, 48 Period of long time.
No dislocation of intermediate pieces seen
Compressor Vane Row 5
Medium tip rubbing seen. Replace complete set of compressor
All the vanes TE found with significant vane row 5 along with new assembly
impact damage approx. 25mm near platform material
Vane #4 completely sheared off. Remaining Ensure new vane tip clearances are
foot piece intact is 10mm checked during installation and if
No dislocation of intermediate pieces seen required vane tip grinding to be carried
Out as per OEM specifications.
Compressor Vane Row 6
Medium tip rubbing seen. Replace complete set of compressor
All the vanes LE found with impact damage vane row 6 along with new assembly
approx. 10-25mm near platform. Material.
LE Medium Impact seen on (18 vanes) : 36, Ensure new vane tip clearances are
36, 40, 41, 42, 43, 44, 45, 47, 50, 52, 53, checked during installation and if
55, 56, 57, 59, 62, 63 required vane tip grinding to be carried
Significant impact damage seen on (31 vanes) out as per OEM specifications
:1,2,3,4,5,7,8,9,10,11,12,15,16,17,22,28,32,
33, 34, 37, 38, 39, 46, 48, 49, 51, 54, 58,
60, 61, 64
No dislocation of intermediate pieces seen or
tip burring found
Compressor Vane Row 7
Vane row 7 found loose Replace complete set of compressor
Medium tip rubbing seen. No burring seen vane row 7 along with new assembly
LE found with light impact on (11 vanes) # 1, Material.
16, 36, 43, 45, 53, 54, 56, 58, 59, 60, Ensure new vane tip clearances are
LE found with medium impact damage on (3 checked during installation and if
vanes) – 8, 31, 47, required vane tip grinding to be carried
LE Significant impact on ( 4 vanes) out as per OEM specifications
# 4: impact -20x3mm at LE near mid-section
# 22 LE impact – 20mm in length near foot
# 26: TE impact- 20mm in length near foot
# 29: TE impact- 15mm in length near foot

33
 Table 4.3 Compressor Vanes Findings Related to Damage Assessment &
Recommendations

Compressor Vane Row 8

Vane row 8 found loose Replace complete set of compressor
Medium tip rubbing seen. No burring seen. vane row 8 along with new assembly
LE found with light impact on (5 vanes) # 8, Material.
30, 35, 44, 48, Ensure new vane tip clearances are
LE found with medium impact damage on (4 checked during installation and if
pieces) # 6, 16, 21, 47 required vane tip grinding to be carried
LE found with significant impact damage on out as per OEM specs
(3 vanes) #
# 20: bent LE 40mm in length
# 26: impact -15x3mm at LE near foot
# 27: impact -5x5mm at LE near foot
Compressor Vane Row 9
Vane row 9 found loose Replace complete set of compressor
Medium tip rubbing seen. No burring seen vane row 9 along with new assembly
LE found with light impact on (13 vanes) # 1, Material.
3, 4, 9, 10, 11, 16, 20, 24, 28, 30, 40, 47 Ensure new vane tip clearances are
LE found with medium impact damage on (5 checked during installation and if
vanes) # 18,23, 36, 39, 41 required vane tip grinding to be carried
LE found with significant impact damage on out as per OEM specifications.
(2 vanes)
# 22: bent LE tip at midsection 30mm in
length
# 17 : impact -10x5mm at LE near tip
Compressor Vane Row 10
Medium tip rubbing seen. No burring seen Replace complete set of compressor
LE found with light impact on (8 vanes) # 7, vane row 10 along with new assembly
12, 24, 26, 34, 35, 39, 40, Material.
LE found with medium impact damage on (8 Ensure new vane tip clearances are
vanes) # 10, 13, 22, 31, 42, 47,55,
LE found with significant impact damage on
(6 vanes)
Compressor Vane Row 11
Medium tip rubbing seen. No burring seen Replace complete set of compressor
LE found with light impact on # (3 vanes) 11, vane OGV along with new assembly
13, 37, Material.
LE found with medium impact damage on (5 Ensure new vane tip clearances are
vanes) # 2, 8, 9, 15, 42 checked during installation and if
LE found with significant impact damage on required vane tip grinding to be carried
(4 vanes) Out as per OEM specifications.
# 16 - Impact- 10X10 mm at LE tip
# 20 -Impact- 5X2 mm at LE Mid-section
# 22 - LE tip bent upto 30mm in length
# 40- Impact- 5X5 mm at LE Mid-section
TE found bent # 3

34
 Table 4.3 Compressor Vanes Findings Related to Damage Assessment &
Recommendations
OGV(Outer Guide Vanes)
Medium tip rubbing seen. No burring seen Replace complete set of compressor
LE found with light impact on (2 vanes) # 2, vane OGV along with new assembly
14 Material.
LE seen with medium impact damage on (8 Ensure new vane tip clearances are
vanes) # 12, 13, 20, 25, 26, 27, 45, 57 checked during installation and if
LE found with significant impact damage on required vane tip grinding to be carried
( 3 vanes): out as per OEM specifications.
# 11 Location- 12mm from foot. Impact- 5X3
mm),
# 28 – Impact – 5 X3 near foot and 25mm air
foil bent at TE
# 56- Impact 5X5mm at LE mid-section
TE mid-section found with light impact
damage on : # 6,
TE mid-section found with medium impact
damage on (6 vanes) # 14, 22, 28, 29, 50,
64
Compressor Casing
Lower and UH Smoothen the sharp edges.
Impact marks seen on compressor casing
between row 5 and 6
No fresh rubbing seen on LH and UH

35
4.3 Performance and Maintenance of Cooling Tower
4.3.1 Performance of CT

Calculating the Capacity [11].

Three factors need to be known:

• The mass flow rate of the water flowing through the tower (kg/sec)
• The specify heat capacity of the water (kJ/kg.K)
• The change in temperature of the water (RANGE of the Tower).

• Where:

• Q = Quantity of energy in kJ/sec ( or kW)

• M = Mass Flow Rate kg/sec (or L/s)

• c = Specific heat in kJ/kg.K (c of water = 4.19 kJ/kg.K)

• Δť = Change in Temperature (K)

• THUS: Q = M c Δť

Cooling Tower capacity.

Table 4.3 cooling tower description

Description values

water passing 6.7 litres (6.7

through it per second kg/sec)

Water inlet temperature(T1) 34°C

Water outlet temperature(T3) 28°C

Temp of air entering(T2) 24°C

Number of CT Cells 8

Total Measured Cooling Water Flow 14166m3/hr

36
THUS,

Q = M Cp Δť

6.7kg/sx4.19kJ/kg Kx6K

6.7x4.19x6

Q=168.438 kJ/s or (kW)

For 8 CT

Cooling capacity =168.43 X

=1347.44KW

Approach

The approach is the difference of the water leaving the tower and the temperature of the air
entering the tower.

With a temp of AIR 24'C,

Approach = Water temp leaving - temp of air entering

= 28°C - 24°C

= 4K

Range

The range is the difference between the temperature of the water entering the tower and the
water leaving the tower.

Range = 34°C - 28°C

=6K

Effectiveness
𝑟𝑎𝑛𝑔𝑒
𝐶𝑇 𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒𝑛𝑒𝑠𝑠 =
𝑟𝑎𝑛𝑔𝑒 + 𝑎𝑝𝑝𝑜𝑎𝑐ℎ

= 60%

37
Evaporation Loss

Evaporation losses in m3/hr. = 0.0085 × 1.8× circulation rate(m3/hr) ×(T1-T2)

= 0.0085 × 1.8 × 14166 ×10

= 216.7398 m3/hrs

Cycles of Concentrations (COC)

Dissolved solid in circulating water

COC =
Dissolved solids in makeup water

COC = 8.25

ASSUMING COC =8.25 from Study of Research Paper

Blow Down Losses:

evoporation loss
𝑩𝒍𝒐𝒘 𝒅𝒐𝒘𝒏 =
(coc − 1)

=29.89 m3/hr

38
4.3.2 Preventive Maintenance of CT [9]

Followings are the procedure of maintenance for cooling tower and its inspection frequency
derived after FMECA analysis and experience of operators and engineers.

Table 4.4 Preventive Maintenance of CT

Sr No. Procedures Inspection Frequency

1. Check condenser water pumps Weekly

2. Check cooling water quality Monthly
3. Check internal surfaces of cooling tower / evaporative Monthly
condenser for scale, rust, sludge and biofilm
accumulation
4. Check cooling water for clarity, odour, surface debris Weekly
and temperature.
5. Check strainers Weekly

6. Check drains Weekly

7. Check condition / cleanliness of fill pack / tubes Weekly

8. Check condition / cleanliness of drift eliminators Monthly

9. Check condition / cleanliness of distribution troughs / Monthly
spray headers and nozzles
10. Check fans, drives and gearbox Weekly
11. Check water level of basin Weekly
12. Check for system leakage and overflow from cooling Regularly
tower
13. Check air inlets and fan screens Regularly

39
 Chapter 5

Conclusions

Conclusions
In the present study of various critical and non-critical equipment’s of power plant such as
centrifugal pump, Cooling tower, Gas turbine and Compressor, problems were identified
during visit by observation and possible efforts were made to solve those problems with
recommendations and suggestions. The major conclusions made from the study are as under:

 By maintenance of centrifugal pump of demineralized plant approximately 2 litre of

feed water per hour was saved. Cost of DM water = 20rs/litre, so, overall saving of
108 X 20 = 2,160 rs/day, (Assuming plant runs 24 X 7).

 After study of various causes of problem it was found that the main cause of problem
was in mechanical seal and all the bearings were worn out due to which vibration and
noise arises

 After damage assessment of various modules of gas turbine (GT) various observations
were made and based on observations changes were recommended. Apart from this
with the help of p-chart software circumferential defect chart for vanes of compressor
were made and based on its decisions of replacement or rework of vanes and blades
was taken.

 It was concluded that the main cause of failure was presence of pieces of blades found
inside the compressor casing and debris below combustor casing.

 The cooling capacity, range, approach, effectiveness of cooling tower were found as
1347.44KW, 6K, 4K, and 60 %

 Preventive maintenance schedule of cooling tower was made with the appropriate
inspection frequency based on FMECA analysis and experience of operators.

40
 References

[1] http://globalenergyobservatory.org/geoid/3509, and

https://en.m.wikipedia.org/wiki/Gujarat_State_Energy_Generation

[2] https://www.steag.in/en/

[3] ALSTOM GT8C2 manual (GSEG)

[4] https://www.ge.com/power/resources/knowledge-base/combined-cycle-power-plant-how-
it-works

[5] Crack of a first stage blade in a steam turbine M. Nurbanasari a,*, Abdurrachim

[6] Code of Practice for Water-cooled Air Conditioning Systems ,2006 Edition

[7] Fisenko, S. P., Brin, A. A., Petruchik, A. I. "Evaporative cooling of water in a

mechanical draft cooling tower". International Journal of Heat and Mass Transfer, 47(1),
165-177 (2004).
[8] Cooling Technology Institute www.cti.org

[9] Machinery Condition Monitoring by Amiya R. Mohanty.

[10] Mukhopadhay N, Chowdhury S, Das G, Chattoraj I, Das S, Bhattacharya D. An

investigation of the failure of low pressure steam turbine blades. J Eng Fail Anal

1998;5:181–93.

[11] https://www.researchgate.net/publication/327830964 A Review Study on Cooling

Towers; Types, Performance and Application

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