Gas Turbine Module Exchange for Faster Maintenance Turnaround
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Solution Overview
Problem
The existing methods for inspecting gas turbines are time-consuming due to the need to isolate multiple components, leading to prolonged inspection periods and a desire to minimize downtime during maintenance and repair.
Innovation Solution
A method and system for unloading and exchanging gas turbine modules, which involves releasing connections, lifting, and moving the modules using specialized equipment, allowing for efficient removal and replacement without isolating individual components, thereby facilitating faster maintenance and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If gas turbine components are isolated and inspected individually, then inspection thoroughness is improved, but inspection period becomes long
Solution Approach 1:
The gas turbine system is divided into modular units (compressor module, combustor module, turbine module) that can be independently inspected. Each module contains specific components grouped by function, allowing inspectors to focus on one module at a time while maintaining thoroughness. The segmentation enables parallel inspection of multiple modules, reducing total inspection time while preserving inspection quality.
Solution Approach 2:
Before actual inspection, the patent implements preliminary actions including preparing inspection checklists, organizing toolkits, and pre-positioning inspection equipment near each module. This preliminary preparation ensures that when inspection begins, all necessary resources are ready, eliminating delays during the inspection process and maintaining thorough coverage without extending the inspection period.
2Reliability
If gas turbine exchange work is performed, then continuous operation is improved, but work period becomes long
Solution Approach 1:
The gas turbine is segmented into interchangeable modular units that can be pre-assembled and tested separately. When exchange is needed, only the specific faulty module needs to be replaced rather than the entire turbine assembly. This segmentation enables faster exchange operations while maintaining system reliability through hot-swappable modules.
Solution Approach 2:
Replacement modules are prepared in advance with all necessary components pre-installed and tested. Connection interfaces are pre-aligned and connection procedures are pre-planned. This preliminary preparation of replacement units and exchange procedures significantly reduces the actual exchange work period while ensuring continuous operation capability.
3Adaptability or versatility
If multiple connections are released for module removal, then module exchange flexibility is improved, but operation complexity becomes high
Solution Approach 1:
The connection system is segmented into standardized interface types for different modules (compressor, combustor, turbine connections). Each interface type has a consistent connection and release mechanism, reducing the cognitive load on operators. While multiple connections are released for complete module removal, the segmentation into standardized types makes the process more manageable and less complex than dealing with unique connections for each component.
Solution Approach 2:
Universal connection interfaces and tools are designed to work across different module types. The same release mechanism and tooling can be used for compressor, combustor, and turbine module connections. This universality reduces operational complexity by eliminating the need for specialized procedures for each module type, while maintaining the flexibility to exchange any module in the system.
Data Source
Figure 1
Figure 2(A)~2(C)
Figure 3
AI summary
A gas turbine module includes a gas turbine that has a gas turbine rotor and a turbine shell; an inlet plenum that is connected to an inlet of the gas turbine; an exhaust plenum that is connected to an exhaust of the gas turbine; an enclosure that covers the gas turbine; and a common base on which the gas turbine, the inlet plenum, the exhaust plenum, and the enclosure are mounted. When moving the gas turbine, the gas turbine module is moved together.