The MS9001E gas turbine generator set operates in a simple cycle, with a base load of 180 tons of heavy fuel oil when producing 13.8 MW of power and a pressure ratio of 12.3. The overall structural layout features the No. 2 bearing located between the compressor and turbine, while the No. 3 bearing is positioned in the turbine exhaust diffuser. The compressor inlet guide vanes are adjustable via the 9OTV-1 control system. Fuel is supplied by the main Fuel Pump, and the fuel bypass valve, controlled by 65FP-1, regulates the fuel flow to manage load variations. However, since the second half of 2002, the 65FP-1 has experienced repeated failures, leading to starting delays or fluctuating fuel levels.
The 65FP-1 is an electro-hydraulic converter (or servo valve). When the input current signal changes, the torque motor actuates the armature and flexible tube, causing flow changes in the first stage of the injection tube. This alters the pressure on the second stage spool valve, allowing fuel to enter or exit the system, thereby affecting the fuel bypass valve’s operation. Common failure symptoms include excessive fuel flow during startup, which can trigger protection trips, or no flow at all, resulting in failed starts. During normal operation, sudden deviations in fuel flow (FQL) from the input signal (FSR) may cause temporary drops or spikes in flow, which usually recover quickly. However, if the flow increases significantly, it can lead to high exhaust temperatures and potential trips.
Upon disassembling the 65FP-1, significant sludge buildup was observed on the oil filter, along with paint-like deposits on metal surfaces and a hard, brown, translucent coating. These contaminants were identified as the primary cause of the servo valve failure. Although conventional lubricant tests (viscosity, cleanliness, acid value) met specifications, further analysis revealed elevated sludge levels—4.21 mg/100mL and 6.12 mg/100mL for the Millipore sludge test. In early 2003, TURBO GT32 Lubricant No. 8 was introduced as a replacement, which resolved the issue on one unit but not on another, where the problem worsened over time. By March 2003, sludge levels on the unaffected unit reached 9.16 mg/100mL, prompting a full oil change in April, after which the 65FP-1 issues ceased.
Gas turbine lubricating oils operate under extreme conditions, especially in high-temperature oxidation environments. Babbitt bearings can withstand up to 120°C, but the surrounding sealing air can reach 130–150°C, exceeding the thermal limits of mineral oils and additives. Oxidation is the most critical challenge for these oils, making high-temperature oxidation resistance a key performance indicator. The Federal Oxidation Test, which simulates aging at 175°C with five metal catalysts, effectively measures sludge formation, viscosity changes, and acid value increases. Conventional tests often overlook the impact of oxidation on hydraulic systems, which is crucial for maintaining reliable control.
After evaluating various lubricants, Shell’s TURBO GT32 was selected due to its XHVI base oil and high-temperature additives. This synthetic hydrocarbon oil exhibits excellent oxidation resistance and low sludge generation. In comparison, mineral-based gas turbine oils produced 750–1000 mg/100mL of sludge in the same test, while TURBO GT32 only generated 35 mg/100mL.
For oil change procedures, it is essential to thoroughly remove residual oil and contaminants. The process includes draining old oil, cleaning the tank and piping, rinsing with flush oil, and finally adding new working oil. Key steps include: draining at 60–70°C, flushing with turbulent flow at 30–80°C, heating oil below 88°C, bypassing sensitive components, and controlling working oil temperature at 60–70°C. Post-change sampling and comparison with new oil ensure quality maintenance.
In conclusion, regular lubricant analysis—especially for oils used in hydraulic systems—is vital. Monitoring sludge content (reaching 5 mg/100mL indicates the need for an oil change) helps prevent rapid sludge accumulation that can damage control systems. Given the unavoidable exposure to high-temperature components, it is recommended to separate turbine and hydraulic oils to reduce contamination risks and simplify maintenance.
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