Gas Turbine Components and How They Work
At the core of a gas turbine is the gas generator, which consists of three main sections – the compressor, combustion chamber and turbine. The compressor intake air and compresses it before delivering it to the combustion chamber. Fuel is then injected and ignited in the combustion chamber, generating hot gases which expand through the turbine. This causes the turbine shaft to spin at high speed, driving both the compressor and the external load such as an electrical generator.
Some key components include compressor blades and vanes that compress the intake air, fuel nozzles that atomize and inject fuel into the combustion chamber, combustion liners that contain the combustion process, turbine blades and nozzles that extract energy from the expanding gases to drive the machine. Seals, bearings and gearboxes are also critical components that ensure smooth operation of the Gas Turbine MRO In The Power Sector. Proper functioning of each component is vital for delivering efficient power output.
Gas Turbine Performance Deterioration Over Time
While gas turbines are designed to run for tens of thousands of hours, the high pressure and temperature environment inside the machine causes gradual deterioration of components over time. Blades, vanes and liners erode due to exposure to hot combustion gases. Seals, bearings and gearboxes wear out from continuous operation. Fouling and deposition inside components disrupts airflows. These changes degrade gas turbine performance and reduce efficiency, reliability and output. Unaddressed, they can lead to unexpected outages and failures.
Regular maintenance is thus essential to restore performance, catch developing issues early, maximize asset life and avoid unexpected downtime. This involves on-condition monitoring, routine inspections, component repairs/replacement and overall refurbishment through planned outages (overhauls). Timely MRO helps maintain high availability throughout a gas turbine’s lifespan while still deriving maximum output from the asset.
Typical Scope of Gas Turbine MRO Services
Most power producers outsource Gas Turbine MRO In The Power Sector to expert service providers who can efficiently inspect, assess, repair and restore the plant to like-new conditions. Common activities during maintenance include:
– Compressor blade/vane cleaning, coating restoration and replacement
– Fuel nozzle cleaning/testing and replacement if severely worn
– Combustion inspection and lining repairs/exchange
– Turbine service including stage 1 and 2 blade repair/swap
– Hot gas path inspections using boroscopes to detect issues
– Bearing, seal and gearbox servicing/part replacement
– Fuel control system overhaul and calibration
– Generator rewinds or reinsulations
– Thermal barrier coating restoration on hot section components
– Dynamic balancing of rotating assemblies
– Electrical, piping and auxillary system maintenance
MRO providers use the latest technologies like robotics, laser profiling and on-site coating facilities to accurately service components. Comprehensive testing validates operational parameters are restored before assets are returned to service.
Factors Considered for Planning MRO Outages
Power producers carefully schedule MRO activities consider several factors:
– Operating hours and agreed duty cycles between overhauls
– Trends from vibration, temperature and pressure monitoring data
– Findings from last outage & recommendations of service experts
– Plant’s role in grid (baseload vs peaking and required availability)
– Logistics of spare parts procurement and outage resource planning
– Opportunities for life extensions, retrofits or performance upgrades
– Fuel costs and revenue opportunities during maintenance windows
Ideally outages are synced with periods of low power demand to minimize loss of generation. Service quality and outage duration are also core criteria. With proper planning, MRO improves asset reliability and supports increasing operational flexibility.
Challenges of Executing Maintenance in Tight Outage Windows
Despite careful scheduling, maintenance outages do not always go perfectly as planned. Key challenges include:
– Limited time available between outages increases pressure on service teams. Unforeseen issues can disrupt schedules.
– Finding qualified skills and manpower at short notice to augment existing capabilities.
– Procuring critical parts that may be obsolete or experiencing long lead times.
– Working in hazardous conditions while upholding safety standards.
– Coordinating complex logistical requirements across multi-vendor services.
– Maintaining configuration control and integrating modified components seamlessly.
– Validating performance targets are met before restart to avoid extensions.
– Mitigating outage and generation costs if deadlines are missed.
Service providers leverage technology, standardized processes and experienced multi-crafted teams to work efficiently under such constraints. Banking planning flexibility also helps absorb unanticipated issues. With experience, utilities and contractors get better at aligned expectations and execution.
*Note:
1. Source: Coherent Market Insights, Public sources, Desk research
2. We have leveraged AI tools to mine information and compile it.