Gas Turbine Module Swapping for Shorter Inspection Downtime
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Solution Overview
Problem
The existing methods for inspecting and maintaining gas turbines are time-consuming due to the need to isolate multiple components, which prolongs the inspection period and hampers the goal of maintaining continuous operation.
Innovation Solution
A method for unloading and exchanging gas turbine modules, involving the release of connections, lifting, and moving the modules using specialized equipment, allowing for efficient transfer and replacement without disrupting the entire gas turbine plant operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the gas turbine is inspected by isolating and inspecting each component separately, then the inspection thoroughness is improved, but the inspection period becomes long
Solution Approach 1:
The gas turbine is divided into modular units (compressor module, combustor module, turbine module) that can be independently inspected. Each module can be isolated and inspected separately without requiring complete disassembly of the entire turbine system, thus maintaining inspection thoroughness while reducing overall inspection time.
Solution Approach 2:
Individual modules or components are extracted from the gas turbine system for separate inspection. The compressor, combustor, and turbine can be removed and inspected independently, allowing thorough examination of each component while significantly reducing the time required compared to inspecting the entire system as one unit.
2Duration of action of stationary object
If the gas turbine is exchanged with another gas turbine of the same type, then the operation period is maintained, but the exchange work is complex and time-consuming
Solution Approach 1:
The gas turbine is segmented into standardized modules that can be independently exchanged. When a module requires maintenance, only that specific module needs to be removed and replaced, rather than exchanging the entire gas turbine system. This dramatically reduces the exchange work period while maintaining continuous operation of the plant.
Solution Approach 2:
The modular design creates universal interfaces and standardized connection points that allow any module to be replaced with an identical or equivalent module from another turbine. This universality simplifies the exchange process, making it faster and less complex while ensuring continuous operation capability.
3Adaptability or versatility
If the gas turbine is exchanged by separating the compressor and turbine individually, then the exchange flexibility is improved, but the work period is extended
Solution Approach 1:
The gas turbine is divided into larger functional modules (compressor module, combustor module, turbine module) that can be exchanged as complete units. This provides exchange flexibility for maintaining continuous operation while reducing the work period compared to separating individual components like compressor and turbine separately.
Solution Approach 2:
Related components are merged into integrated modules that are exchanged together. The compressor, combustor, and turbine are grouped into modular units with standardized interfaces, allowing them to be handled and exchanged as single entities. This merging reduces the number of separate exchange operations required, thereby shortening the overall work period while maintaining the flexibility needed for continuous operation.
Data Source
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.