We have 9 GT Frame-VI 30MW each. We are using liquid fuel light cycle oil with mix firing refinery fuel gas. Since last 6 months, one of the BHEL make GT 04 times flowdivider failed (suddenly FQL1 zero). We are additive dosing SR-2008. We have filtration system PALL and Multistage filter, High pressure filter.

Flowdivider make ROPER.

EMAIL: jayeshmehta74 @ yahoo. com

 

Are you saying the same flow divider falied four times, or are you saying the flow divider of GT 04 has failed?

In any case, if the same flow divider on the same unit is experiencing the same failure, and if the failure is that it suddenly stops turning, then it sounds like something is getting past the filter(s) and causing the blockage which is freezing-up the flow divider mechanism.

*OR*

That particular flow divider has internal components which are adversely affected by the oil and/or the additive you are using. Flow divider internal components can be made of differenty materials depending on the fluid(s) which are expected (key word, expected) to be used to run the turbine. Most packagers provide a flow divider which is compatible with the fuel the purchaser is expecting to run at the time the details of the purchase are being discussed and negotiated. It's very common for fuel constituencies to change, and for the owners/operators to not be aware of a need to change components to work properly with the new fuel make-up.

There are also cases of additive manufacturers not being aware of the total package when recommending an additive, or just incorrectly recommending or supplying the wrong additive for the fuel/components at the site.

There have also been cases of equipment not being properly rebuilt time after time after time; or incorrect components; or inattention to proper tolerances; or non-OEM components; or unrecognized problems with components (like a bent shaft or irregularly shaped chambers, or unevenly shaped gears). This is rare, but it has happened before. When the manufacturer's representative is brought in or the component is sent to the manufacturer for analysis these kind of defects or abnormalities, unrecognized by an untrained or unknowing eye, can sometimes be quickly identified and a major problem can be solved with a small change.

Have you tried contacting the manufacturer or a manufacturer's representative with the nameplate data and fuel analysis data and fuel additive data (including the additive flow-rate for various fuel flow-rates)? Try to provide as much information as possible when contacting the manufacturer/representative for the fastest reply.

Have you contacted BHEL for help with the problem? It's not un-heard of for a turbine packager to inadvertently provide the wrong component.

Speaking of non-OEM components (we were, weren't we?) it always amazes me how beancounters, er, uh... people make a "game" of trying to buy "equivalent" or "compatible" parts from vendors/manufacturers other than the OEM. I think their Purchasing/Sourcing departments spend more time (which is !!!HELLO!!! *money*) trying to find parts which are less expensive than the OEM's without ever asking the people who have to use the parts whether they were really worth the savings or whether they actually cost more in the long run. It's been reported elsewhere in this forum about one site pulling several third-party "rebuilt" servo-valves out of stores, none of which worked, before pulling a brand new one from the manufacturer which did work. That probably represented several overtime hours for several people, plus the cost of the servo-valves, *plus* the lost electrical generation and steam production. But, sourcing saved 20% on the cost of each servo-valve buying rebuilt valves from a third-party! There's a company that has more dollars than sense. (Pun intended!)