1.

0 Executive Summary
Nowadays, Gas turbines are progressively being utilized as power generators
around the globe for a variability of utilizations. The significant of this study is to
escalate the gas turbine performance in term of the efficiency. The problem occurred in
the gas turbine section where the combustion process occurs from the resultant of
reaction spark with mixture of fuel gas and air (oxygen). To increase the performance in
term of efficiency and also the operation, the gas turbine compartment must be improved
to eliminate the gas turbine trip and jammed occurrences from average 1.5 times to zero.

Besides the gas turbine combustion compartment cooling blower frequent

jammed where the belt driven the cooling blower fan jammed due to high temperature.
From the report, it occurred by average once per month and must be reduce by
eliminating this gas turbine trip and unplanned shutdown from once per month to zero
and prolong gas turbine running hours by reducing low cycle fatigue caused by frequent
start-stop event. In conclusion, the gas turbine combustion compartment cooling blower
frequent jammed due to blower defect where premature repetitive failure (more than
once) before standard overhaul interval and also jammed due to DE bearing damaged
had effected the production of the product. As a recommendation, to further improve the
overall performance of the gas turbine unit, the problem must be resolved, in order to
achieve zero gas turbine tripped and jammed in the future.

3
2.0 Introduction
Gas turbine is heat motor where fuel vitality is utilized to create mechanical yield
power, through a rotating shaft (modern gas turbines) as torque or through a fumes
nozzles (aircrafts motors) as plane force as speed (velocity). A gas turbine is otherwise
called combustions turbine, is a revolving motor where extricating of energy from a
stream of hot gas which created by ignition of gas or fuel oil in a surge of packed air.
The gasses are coordinated over the turbine blades, turning the turbine, and
mechanically driving the compressor. The temperature more than 2000 degrees
Fahrenheit was smoldered the blend. The expanding high temperature, high weight gas
stream that enters through the turbine unit were delivered from the combustions.”

The separated air from the pivotal stream compressor from a few focuses, giving
a spotless air supply to air worked control valves, working in cooling turbine inner parts,
and utilized for fixing the bearing. Throb security of the compressor is utilizing
compressor extraction air amid start-up and shut-down of the turbine. The flow of air
from the gas turbine compressor to different parts of the gas turbine rotor and stator gave
by the cooling and fixing air framework amid typical operation and for fixing of the
turbine bearing to prevent unnecessary temperature accumulation. In cooling the turbine
exhaust frame, the air from two centrifugal blowers is being used. These motor fans
situated on a base are part of a cooling system which is nearby the low part of the gas
turbine exhaust system. Any lubricating fluid contain that cause pressurized air cools
and seals the bearings within the bearing housing which might leak past the mechanical
seals then. Pressure barrier to the lubricating fluid provided by air which is directed to
both ends of each bearing casing.

The simultaneously operation of the blowers in parallel provides air for cooling
the exhaust frame and turbine shell. Each blower sensed blower discharge pressure using
pressure switch. If one of the blowers should fail, the loss of blower discharge pressure
will cause contacts of the specific pressure switch to close and an alarm will be
annunciated. The continuous running of turbine will operate with the automatic change
over preliminary the blower.

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2.1 Objectives

There are three main objectives of the project which are:

 Eliminate blower Trip and jammed occurrences from average of 1.5 times per
month to zero by onwards.
 Eliminate Gas Turbine Trip and Unplanned Shutdown from average of once per
month to zero by onwards.
 Prolong Gas Turbine Running Hours by reducing low cycle fatigue caused by
frequent start-stop event.

2.2 Scope of Study

The study that have been conducted and following the team in the period of
internship of seven months mainly target on the gas turbine combustion compartment
cooling blower. From the previous inspection, there are problems occurred during the
process where it is always jammed due to some trip that happened on the gas turbine.

The gas turbine blower is frequently trip that resultant in blower part change out
and also the power import of the system. Else, the power chances to be exported into the
gas turbine process will be loss and effect the gas turbine running hours to be long. The
blower is being overhaul every 24000 running hours.

The study have been done at Gas Turbine B, C, and E area by the Maintenance
and Operation Team where the drive end bearing of the belt transmission jammed
causing the blower of the gas turbine to be jammed together. This situation will be in
high risk for online rectification to be complete. Online rectification involved online belt
replacement and online blower replacement.

5
2.3 Problem Statement

The burning of the gas turbines being introduced in a large number of today's
normal gas-energized power plants are intricate machines, however they essentially
include three fundamental areas. The compressor, which air is pulls in into the motor,
pressures it, and bolsters it to the combustions chamber at several miles of velocities for
each hour. The burning framework ordinarily made up of a ring of fuel injectors that
infuse a constant flow of fuel into combustions chambers where it blends with the air.
The combustions produces a high temperature, higher force gas stream that enters and
extends through the turbine segment.

Regularly, a blower is a divergent fan that exchanges air or different gasses. The
radiating power produced is utilized by the pivot of the impellers to expand the pressure
of the gasses and constrain them through the blower. Blowers are requiring a lot of
maintenance, yet it is a simple piece of equipment, mainly for bearings. The problem
will become higher when the speed is higher. Harm to the rotor shaft, push orientation,
turbine blading, spout ring, or blower impeller is a piece of the inconveniences that may
keep a blower from playing out its capacity that commonly comes about because of
absence of oil, an unequal rotor, or operation with undue temperature of fumes.

Premature bearing failure as often as possible brought about by the high

temperatures, the nature of the disappointment being predicated on the temperature to
which the bearing is raised and the oil with which it is greased up. The rise of mellow
temperature may make oil channel which cause the effectiveness of the grease lessened.
The oxidation happened causes loss of lubricating elements and the formation of carbon,
under gradually elevated temperature conditions. When the carbon formed, the bearing
may be locked or jammed. Early failure of the belt might occur due to high temperatures
which reduce the hardness of the metal, loss of internal clearance and preloading results.
The significances of improper belt tensioning are expensive. The belt will slip and gaze
or burn when the tension is too low. Thus, the belt destroyed due to failure shut down of
the equipment must be done in order to replace them destroys. Belt failure normally
occurred in the early because of unnecessary pressure over-hassles belt ropes.

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2.4 Relevancy of the Project

The project that has been done is very relevant as it can be seen by judging on
how it can be beneficial to the company if it is implemented. This project comprises of
engineering study in mechanical engineering where at university, we just learn and the
theory part of the mechanism but throughout internship and involvement in the team, it
enable student to get better understanding on the current problem at plant and see with
our own eyes on the real job situation. The project also increased the knowledge not
only to the newbie as an intern student but also to the staffs and contractors

The investigation made earlier revealed that the flame scanners experience loss
of signal due to increased Turbine Compartment Temperature within 3-hours resultant
from insufficient heat removal from Gas Turbine Compartment Cooling Blower. By
implementation of this project, the turbine compartment cooling blower can be more
reliable and efficient in order to avoid the unplanned shutdown and trip. Moreover, the
profit of the company will be stable and the operation becomes efficient thus preventing
the unplanned plant shutdown.

As a conclusion, this project is very relevant to the company and towards the
betterment of the production operation. Besides, throughout the involvement of the
team, the valuable chances in improving and polishing communication and critical
thinking are very profitable.

7
3.0 Background of the Project
3.1 Feasibility of the Project

Student Industrial Project (SIP) is a 14-week course as set by Centre of Student

Internship and Adjunct Lectureship (CSIMAL) UTP. Thus, the completion of the project
and report shall be feasible during the period. The Gas Turbine Compartment cooling
blower can be completed within the scope and time frame as every source and
information were finding at the working place. Studying the information helps to
understand deeper about the data and also the system of the gas turbine. From the
information, the study on the design of the equipment is also applicable during the
project execution. It helped the Bubbles team to completely implement the project
within the time frame since the technical data and theoretical data are obtains from
respective sources.

As the initial purposes of the project were to eliminate blower Trip and jammed
occurrences, to eliminate Gas Turbine Trip and Unplanned Shutdown and prolong Gas
Turbine Running Hours by reducing low cycle fatigue caused by frequent start-stop
event, the installation and reinstated equipment have to be done successfully to fulfill the
goal. At the end of this project, gas turbine is expected to perform the operation
efficiently, thus the production can be continued normally without any trip or delay and
also maintaining the business of the company.

To ensure the execution of this project run smoothly as per schedule, all parties
involved were required to give their fullest commitment and support. Service Provider,
sub-contractors, Maintenance team and project team had to work hand-in-hand to
successfully execute the project. All the team from various backgrounds expected to
provide the idea and support as a whole team so that any inconvenience could be
prevented.

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3.2 Literature Critical Analysis

3.2.1 Description of Gas Turbine Cooling and Sealing Air System

The arrangement of cooling and sealing the air gives key stream of air from
the gas turbine compressor to alternate parts of stator and rotor in counteracting
unnecessary temperature that development in these parts all through ordinary operation
and for fixing direction of the turbine. The two blowers that operate simultaneously in
parallel provide air for cooling the exhaust frame and turbine shell. These motor fans
situated on a base are part of a cooling system which is nearby the low part of the gas
turbine exhaust system. These two motors equipped with heaters to avert the motors
from condensed condensation when they are not operate. The system provides cooling
and sealing functions are as follow:

i. “Sealing of the turbine bearings.”

ii. “Cooling of internal turbine parts exposed to high temperature.”
iii. “Cooling of the turbine outer shell and exhaust frame.”
iv. “Providing an operating air supply for air operated valves.”

The air entry was outline in the turbine case, turbine spouts and turning wheels,
channeling for the compressor extraction air and related segments, particularly to cool
and fixing air framework. Related components used in the system include:

i. Turbine deplete outline cooling blowers

ii. Air filter (with poro-stone element)
iii. Pressure gauge
iv. Dirt separator

The loss of blower discharge pressure will cause contacts of the respective
blower pressure switch to close when one of the blowers fail. The automatically changes
occurred over the blower starting continued the turbine to run normally. If one of the
blowers fails, the turbine will continue to run with the other blower at low flow rates.
The turbine will be shut down if all blowers fail to operate in a normal shut down
sequences.

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 3.2.2 Gas Turbine Basic Operation

Study from Minnesota University in “Engaged in Thermodynamics”, (Gas

Turbine Power Plant, turbine power plants be worked with an open or closed cycle, open
cycle plants are more basic. The working fluid in an open cycle plant is climatic air,
continually attracted to the compressor where it is normally packed up to 18 times
atmospheric pressure and after that sent to a combustor. In the combustor, natural gas is
smoldered to heat the air and extend it before attains the turbine. The exhaust further
grows in the turbine, to roughly air pressure, and moves the turbine blades to do the job.
The fumes are then discharged to the environment.

In a closed cycle, the working fluid is burned through the compressor and after
that warmed by an outside source before it enters the turbine. Rather than being
discharged to the air, the fumes is sent through a warmth exchanger that concentrates
heat from the fumes before it is come back to the compressor. In both cycles the turbine
shaft is associated with a generator that changes over the rotational power into electrical
power.”

A gas turbine cannot be turned on like a fuel or diesel motor. Since the
compressor is driven by the pole of the turbine, an outside source is required to begin the
framework. For instance, the starter framework at "Faribault Energy" Park incorporates
an electrically mechanized generator that curves the turbine shaft to the rate of 500 rpm.
By then the combustors are turned on and the turbine starts to turn all the more quickly.
The generator engine is off when the framework is turning at 3200 rpm. The framework
will keep on speeding up until it achieves the standard working rate of 3600 rpm.

3.2.3 Fuel

Gas power plants can be driven by a few distinct sorts of energizes, however
the most appropriate fuel is natural gas, since it can causes less contamination and
scarcest costly. In the event that regular gas is excessively costly or not promptly
reachable, be that as it may, utilizing most fluid fills can work the gas power plants. For
instance No. 2 fuel oil, otherwise called heating oil, is a typical substitute for
characteristic gas. Heating oil is a petroleum subsidiary alike to diesel fuel. It is utilized

10
to fuel heaters, boilers, and gas turbines. Natural matter disintegrates without oxygen,
made the Biogas, which is likewise used to fuel gas turbine power plants. The gas is
gathered and utilized as a part of the burning chamber set up of regular gas.”

At the point when picking fuels, it is every now and again required to consider
the effect on discharges that that specific fuel will have. While fuel oils, for example,
heating oil are usable in gas turbines for a long haul, it is not an appropriate option as the
expanded outflows from the smoldering itself. A portion of the other real contaminations
that are nearly checked are: Nitrogen oxides (𝑁𝑂2 ), carbon monoxide (CO), and volatile
organic compounds (VOC). A portion of the contaminations are basically only outcomes
of the combustion responses, some are because of deficient combustion, and some are
because of particular fuel attributes. Picking fuel hotspots for every gas turbine
application must consider these things into record. For example, the low 𝐶𝑂2 emissions
are one reason why natural gas is the principle fuel sort in gas turbines.”

3.2.4 Efficiency

Basic cycle common gas power plants are not essentially compelling. The
present effectiveness of the basic cycle gas power plants being used are around 35%
efficiency for two primary reasons. First, a great deal of energy utilized by the
compressor as a part of packing the air to the obliged pressure to run the air through the
turbine. Rotational energy stays just 1/3 for change into electrical energy as the other 2/3
of the turbine outlet is utilized to drive the compressor. Secondly, after the ignition
gasses go through and exit the turbine they are still to a great degree hot (around 900–
1200°F), so a critical measure of thermal energy is lost through the stack. In a basic
cycle, when the exhaust is discharged straightforwardly into the air, it will precipitate
this energy to be abused. Be that as it may, by utilizing the fumes to preheat the
compressed air going into the combustor (which would minimize the fuel prerequisites),
or by warming the air in the building or steam utilizing a warmth recuperation steam
generator, the energy can be recouped.”(Handbook of Heating, Ventilation, Air
Condition, Google Book, last accessed: 7/12/2015).

11
 The level of gas turbine power plant productivity is relying on upon the
temperature of the air going through the framework. The cooler the air is that enters the
combustion chamber, the less productive the burning will be. The hotter the air is that
enters the compressor the less proficient the compressor will be. In drawing nearer this
issue, there is couple of various ways. Cooling the air before it enters the framework is
one of the best approaches to make the compressor more proficient. This procedure is
called as turbine inlet cooling, which builds the air density, along these lines
empowering the compressor to do less work for the same output.

After the air is packed it goes into the combustion chamber, keeping the air as
warm as could be expected under the circumstances diminishes the energy required for
the ignition procedure. Preheating the air can be accomplished without extra energy
contribution by going it through a heat exchanger, called a regenerator. Significant
measures of heat still contained in the fumes leaving the gas turbine to be exchanged
empowered by the regenerator from the exhaust to the air that is going to enter the
combustor. This procedure produces hotter leaving air that thusly creates more power
from the gas turbine when the effectiveness of the combustor increments.

3.2.5 Advantages

There are a few favorable circumstances to utilizing a gas power plant to

create electrical force when contrasted with different frameworks. Gas turbine power
plants can be begun up and keep running at full limit in just 10 to 20 minutes, making
them appropriate as reinforcement plants for utility company that require extra power
quickly. Since they are littler than coal or nuclear plants, gas power plants can be
fabricated speedier and at a lower cost. Gas turbine frameworks likewise require
considerably less water than steam power plants, and they are effortlessly changed over
into consolidated cycle power plants, which are a great deal more effective.

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 3.2.6 Disadvantages

Gas turbine power plants have disadvantage also. The force expected to drive
the compressor diminishes the net output, devouring more fuel to do likewise measure of
work. The working temperature in gas turbines is higher than in other power plant
frameworks and can abbreviate the lifespan of a portion of the framework parts.
Moreover, in light of the fact that the thermal energy is squandered when the fumes is
discharged, the productivity levels of gas turbine plants are lower than those of different
sorts of power plants.

3.2.7 Gas Turbine Cycle

A cycle, called Brayton cycle defines what happens to air as it goes into,
through and out of the gas turbine. The relationship between the spaces involved by the
air in the framework (called volume, V) and the pressure (P) it is under are represented
utilizing the cycle. The properties of a stable amount of air as it pass through a gas
turbine in operation represented by Brayton cycle. (M Aidil B Zaini. March, 2008)

Figure 3.1: Brayton Cycle Pressure-Volume

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 Figure 3.2: P-V Diagram

Figure 3.3: T-S Diagram

The P-v and T-s diagrams of an ideal Brayton cycle are shown in Figure 3.
Notice that each of the four procedures of the Brayton cycle is performed in steady-flow
procedures. They ought to be considered as steady-flow process. At the point when the
kinetic changes and potential energies are dismissed, the vitality adjusted for steady-
flow process can be communicated, on a unit-mass basis as:

14
 ((𝑞1 − 𝑞2 ) + (𝑤𝑖𝑛 − 𝑤𝑜𝑢𝑡 ) = ℎ𝑒𝑥𝑖𝑡 − ℎ𝑖𝑛𝑙𝑒𝑡

Therefore, heat transfers to and from the working fluid are

𝑞𝑖𝑛 = ℎ3 − ℎ2 = 𝐶𝑝 (𝑇3 − 𝑇2 ) And 𝑞𝑜𝑢𝑡 = ℎ4 − ℎ1 = 𝐶𝑝 (𝑇4 − 𝑇1 )

Then the thermal efficiency of the ideal Brayton cycle under the cold-air-standard
assumptions turns into

𝑇
𝑤𝑛𝑒𝑡 𝑞𝑜𝑢𝑡 𝐶𝑝 (𝑇4 − 𝑇1 ) 𝑇1 (𝑇4 − 1)
1
ƞ𝑡ℎ , Brayton = =1− =1− =1−
𝑞𝑖𝑛 𝑞𝑖𝑛 𝐶𝑝 (𝑇3 − 𝑇2 ) 𝑇3
𝑇2 ( − 1)
𝑇2

Process 1-2 and 3-4 are isentropic, and P2 = P3 and P4 = P1. Thus,

𝑇2 𝑃2 (𝑘−1)/𝑘 𝑃3 (𝑘−1)/𝑘 𝑇3
=( ) = ( ) =
𝑇1 𝑃1 𝑃4 𝑇4

Substituting these equations into the thermal efficiency relation and simplifying give

1 𝑇3
ƞ𝑡ℎ , Brayton = 1 − 𝑘−1 =
𝑇4
𝑟𝑝 𝑘

𝑃2
𝑟𝑝 =
𝑃1

𝑟𝑝 = 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑟𝑎𝑡𝑖𝑜

𝑘 = 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 ℎ𝑒𝑎𝑡 𝑟𝑎𝑡𝑖𝑜

Above equation shows that under the cold-air standard assumptions, the thermal
efficiency of an ideal Brayton cycle relies on upon the pressure proportion of the gas
turbine and the particular ratio heat proportion of the fluid working.

15
 3.2.8 Insulation of Bearing Compartment

Gas turbine power plant units contain three primaries bearing used to bolster
the gas turbine rotor. The unit in like manner consolidates push bearing to keep up the
rotor-to-stator crucial position. The area of these three bearing congregations are, one at
the inlet, one in the compressor release packaging, and one in the exhaust outline. All
bearing are weight greased up by the oil that is supplied from the primary lubricating
system.”

Lubrication for these pressure-lubricated turbine bearings is alluded to as

double piping and its premise is that in case of a channel being break, oil would not be
vanished or showered on adjacent gear, along these lines disposing of a potential safety
hazard. Oil on the surface of the turbine shaft is dodged from being spun along the pole
by oil seals in each of the three bearing housing. A smooth surface is machine on the
pole and gathered the seals so that lone a little freedom exits between the oil and the
shaft and seal deflector. Pressurized sealing air is conceded into this space and keeps
lubricant oil from scattering along the shaft. Some of this air comes back with the oil to
the focal lubricating oil tank and is vented through a lube oil outlet.”

Figure 3.4: Brayton Cycle of Gas Turbine

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4.0 Organization
The organization chart of Gas Processing Kerteh, PETRONAS Gas Berhad:

Figure 4.1: PGB Management Committee

17
Figure 4.2: GPU Plant Leadership Team

18
Figure 4.3: POE Organizational Chart

19
5.0 Environmental Impact
PETRONAS Gas Berhad has always paid high commitment to the environment.
Any abnormal operations in downstream of their plants, specifically the engineers,
operators and even leaders would work together to solve the problems. Any off-spec
discharge is non-tolerable. Thus, the establishment of Gas Turbine combustion
Compartment cooling blower Project where the aim is to eliminate the trip is one of the
examples.

Throughout the internship period, it can be perceived that PETRONAS Gas

Berhad really take extra care of the environment anyplace they work by embracing
capable natural administration rehearses in each part of their operations. Past that, they
additionally add to the preservation and biodiversity of the earth for the security and
soundness of the group.

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6.0 Work Breakdown
This chapter comprises an audit of the research method and configuration fittingness,
how the data is being collected, key milestone of the project, Gantt chart to illustrate the
project schedule and the tools that have been used in the process of collecting and
analyzing the data.

6.1 Research Methodology

Keeping in mind to guarantee the accomplishment of this project, legitimate

arranging has been taken with several methods in order to gather all the information and
materials needed for the project. The following steps are used in order to describe and
explain the problem identification, data gathering, planning and progress of this report.

Problem
Identification

Scope of Study

Objectives

Data Collection

Data Analysis and

Findings

Solutions

Final Report
Completion

Evaluation

Figure 6.1: Research methodology

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 6.1.1 Problem Identification

The effect of the blower in the gas turbine can be foreseen in a few year times
resulting higher temperature as the cooling blower made from extraction type that
extract heat from gas turbine combustion compartment and cause the blower to trip and
unplanned shutdown of the gas turbine. These have impact the process and also
production of the product. A proper investigation and study on this problem should be
done with a specific end goal to improve else to prevent from Gas Turbine combustion
compartment cooling blower frequent jammed.

6.1.2 Scope of Study

The scope of study is been contracted down the task study into more particular
and points of interest perspective, in this manner the project can be engaged, constrained
and be identified with the objectives and the problem statement. The project is proposed
to implement some changes on the gas turbine aiming to prevent zero blower tripping
and jammed by onwards and zero gas turbine unplanned shutdown and tripping due to
Blower defects by onwards. Some of the solution that is possible is to change bearing
seal into metal seal, use grease with higher heat resistance, utilize belt tensioning tools
and change to direct drive blower type.

6.1.3 Objective

Objective is been set to give a reasonable motivation behind directing this

anticipate. The project target is set inside a degree to be a sensibly accomplished inside a
normal time allocation with accessible assets.

6.1.4 Data Collection

In order to complete the project, the team study regarding the gas turbine
combustion cooling compartment is being done by referring to the data sheet of the
previous years. Besides that, the methods and list of sources are being list down in order
to complete this project. The lists are as per listed below:

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Table 6.1: Methods and list of sources

Method Sources Data/information

Self-study and research 1. Project team – Bubbles 1. Datasheet and
2. Internet technical exposure
3. Host company 2. Relevant process data
Supervisor 3. Project background

Discussion 1. Bubbles team 1. This method used to

2. Host Company get better
Supervisor understanding,
clarification and
explanation
2. Joining the team
meeting
Observation, interviews and 1. Photo Taking 1. This strategy used to
site visits 2. Engineers/contractors on validate the issues
duty at the site utilizing photographs
and meetings.

6.1.5 Data Analysis and Findings

The data and information were collected and presented in graph form for better
interpretation through the trend lines and also table data. A team discussion session was
held monthly together with my Host Company Supervisor as a facilitator of the team,
Pn. Hanniza Therina bt Jopri in order to analyze the data recorded and discuss on the
way forward of the project gas turbine combustion compartment cooling blower frequent
jammed.

23
 6.1.6 Recommendation and Proposed Solution

After looking into every aspect of this project, there still some recommendation
and proposed solution that can be done in order to improve the effectiveness of this
project and it will be mentioned in the next chapter.

6.1.7 Final Report Completion

All the data and findings will be compiled and documented in a softcopy and
hardcopy. The report will be submitted to UTP supervisor to be reviewed.

6.1.8 Project Presentation and Evaluation

In the end of this internship program, the report will be presented in front of the
Host Company Supervisor and also UTP Supervisor.

24
7.0 Activities Estimate
7.1 Findings

Few findings managed to be generated during the project where three Gas
Turbines have been chosen specifically for the data gathering of this project, which is
Gas Turbine A, B and E.

7.1.1 Damage of the Bearing

There are many factors that contribute to the damage of bearing. One of the
factors is grease which accumulates inside bearing housing. Based on the observation by
the team during the inspection, bearing housing was found filled with old grease.

Figure 7.1: Old grease accumulation

Table 7.1: Inspection on bearing damage

Unit As Found Condition during Overhaul

Gas Turbine B Bearing damaged, Bearing Seal detached

Bearing damaged, Bearing seal detached, traces of grease within

Gas Turbine C
bearing compartment

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 7.1.2 No Insulation within Bearing Compartment

Next factor that caused the bearing to damage is the blower operation. The
blower will jam if there is damage on the bearing. It is because of no insulation within
bearing compartment. Overheating happened on the bearing due to the loss of grease on
the specified compartment.

7.1.3 Belt Premature

The belt premature was snapped when the damage of belt occurred due to high
pressure in the compartment. After the observation being done for the inspection, the
result was recorded as there is no insulation also within the belt housing. Apart from that
situation, the blower happened to jam and in the same time they will lead to unplanned
shutdown of the plant.

7.1.4 Non-standard Belt Tensioning Method

The non-standard belt tensioning consequences are very crucial. If the tension is
too low, the belt slip and coating or smolder. This activity obliterates the belts and
hardware must be shutdown to supplant them. The impacts of low pressure on a
synchronous belt are similarly awful. Low strain permits the belt teeth to ride up on the
sprocket teeth. This development places serious weight on the teeth, in the end tearing
them free from the body of the belt. Under ample burdens, the drive can bounce teeth
(ratchet), which prompts fast belt failure. The observation being done during PM works
showed that the belt tensioning was done manually without using any measuring tool.

7.2 Data Gathering and Analysis

The problems that has found and identified in the project are coming out with
few possible solution analysis for each root causes. After verification using data and
evidence collection, the root causes being summarize where there are four root causes
which are:

1. No Insulation within bearing compartment

26
2. No Insulation within belt housing

3. Grease accumulate inside bearing housing

4. Non-Standard belt tensioning method

Apart from the summary of the root causes, few possible solution analyses have
been surfaced whereby each of the team members need to come out with the idea for
each root causes. Each possible root causes considering the pro’s and con’s before it can
be implemented as an improvement to the equipment of the gas turbine cooling
compartment.

Table 7.2: Pros and Cons

No Solution Pro’s Con’s Cost

 Standardize belt
Utilize belt
tensioning works amongTraining required to
1 tensioning RM 6,000.00
all units handle tool
tools
 Prevent over tensioning

Old grease can flow out of

bearing housing during
greasing activity, leaving
Introduce Bearing grease RM 0.00
fresh grease inside
2 grease outlet accumulate inside (additional
housing without
point bearing compartment task)
 Eliminate bearing seal
defect recurrence due to
over grease

Reinstate  Protect internal

Insulation as bearing parts and belt No standard among RM 3000.00
3
per OEM from combustion all blowers. per Blower
Standards compartment heat

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7.3 Implementation of the Project

One of the solutions to overcome the problem of the blower trip and unplanned
shutdown is to reinstate insulation with improved specification and also increased the
thickness of the insulation. The specification and thickness of the insulation is aim to
avoid the belt of the gas turbine from damage due to high of temperature. The insulation
is being done in the belt housing and conducted during blower overhaul by maintenance
team and appointed service provider which is PETRONAS sub-contractor. The task for
the team is to check on the design specification, material selection and measurement at
the site on the same time make preparation for the installation of insulation as per OEM.

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 8.0 Estimated Cost
Gas Turbine combustion Compartment cooling Blower project was a project
where new equipment was fabricated. This means that this project already spent a large
capital expenditure (CAPEX) at the time of finding. Therefore, it is given that the OPEX
has to be minimized to as low as possible while sustaining the system and production.

Since there is an involvement of new equipment, which needs to be purchased

and used continuously, the usage of the equipment must be maintain and inspected
regularly to prevent any damage of equipment or rusty before being used.

From the table shown below, if the inspection is not conducted regularly, the unwanted
damage and jam will occur, the Company may have to use more money on unnecessary
things. In current situation of oil price crisis where every oil and gas industry and all
other related fields are struggling in not spending CAPEX and minimizing their OPEX,
small efforts like continuing in ensure that the equipment are in a good condition would
contribute a lot to the company.

Table 8.1: Cost incurred to complete project

Unit As Found Condition during Overhaul Cost

Blower Overhaul
1 • 1 unit RM 16,000.00
• Planned Cost (FY2015/FY2016)

2 Modification onto bearing RM 0.00

Reinstate Insulation
3 RM 0.00
(include in overhaul cost)

Optibelt TT Frequency Tension Tester

4 RM 4,500.00
(Once-off Purchase, Fixed Asset)

Total RM 20,500.00

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9.0 Schedule
9.1 Key Milestone

Finalizing EIS Project title

Problem Identification

Gathering &Analyzing
Data

Drafting Report

Assessment and
Correction on Final Report

Submission and
Evaluation on Final Report

Figure 9.1: Key milestones for the completion of the project

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9.2 Gantt chart

Gantt graph is utilized to outline the schedule of the project. This chart shows schedule
of the project from planning part until the end of the project.

Table 9.1: Gantt chart planning

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10.0 Health & Safety Issues
10.1 Safety Training

In the oil and gas industry and even in other industries, safety of the worker and
safety practices in the workplaces has always been the main priority. During the period
of internship in Gas Processing Kerteh, PETRONAS Gas Berhad (GPU/PGB), I learnt
that the host company and even the parent company has their own safety regulations to
be applied and to be obliged by the workers and staffs at their work place. PETRONAS
itself has come out with its own safety practices namely ZeTo Rules which is short-
formed from Zero Tolerance Rules.

It has been made compulsory for everyone to oblige with the rule that have been
set so that risk, danger, incident and accident that would happen during the working
hours can be minimize. ZeTo Rules comprises of 10 basic rules which are:

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11.0 Discussion & Recommendation
11.1 Discussion

According to possible failure discussion by thermal mechanical fatigue and high

cyclic fatigue, which may be exhaust diffuser distortion, flexible seal damage and
deteriorate on third stage buckets. Scheduling provide for additional failure in the next
hot gas path inspection. For the duration of hot gas path inspection, there are several
failures occur on exhaust diffuser part and construction. Discussion, firstly, as air
separately supply to cool the turbine shell and the exhaust frame radial struts for
maintaining tight turbine-section clearance control and to prevent the cracking,
distortion and deform in exhaust frame. The cyclic operation cause thermal mechanical
fatigue and effect to exhaust frame distortion. Moreover the flexible seal misaligned to
end with crack.

GE fundamental of gas turbine training manual describe “Exhaust frame radial

struts cross the exhaust gas stream. These struts position the inner cylinder and third
bearing in relation to the outer casing of gas turbine. The struts must be maintained at a
constant temperature to control the center position of rotor in relation to stator.
Temperature stabilization is accomplished by protecting the struts from exhaust gases
with a metal fairing that forms an air space around each struts. Turbine shell cooling air
flows through the space between the struts and the wrapper to maintain uniform
temperature of the struts”.

Secondly, problem solving, the effect of plant generate in the cyclic duty
operation instead of the continuous duty operation in which was demanded to start/stop
every weekend. The starts-based maintenance criteria were considered for preventing the
thermal mechanical fatigue. The compartment was repaired, refurbished and considered
new material for serving cyclic duty operation. The first question was “Which material
is suitable for high cyclic fatigue?” the flexible seal material was changed from SUS 304
to SUS 310S which is more composition of Ni and Cr. Inner cylinder liner was carefully
replaced.

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 As for the discussion into the contexts of engineering in society courses, it can be
said that the whole project relates to the content of the engineering in society courses.
We can see that how important the engineering principles playing its role into the plant
behavior. Therefore, as engineer, we must responsible for our own jobs and task and
must taking into account the integrity of engineers. Engineers must practice a good code
and ethics for engineers so that there are less and maybe no catastrophic events that lead
to deaths of the people surrounding.

11.2 Recommendation

After the completion of Gas Turbine Cooling Compartment Project, the

BUBBLES team now already has done a great job to ensure the process perform well
and meet the desired standards. However, the new implementation requires constant
supervision of the equipment and a proper site visit must be conducted regularly, it is a
concern that these needs may not be fulfilled.

To ensure a smooth continuation of the production, every party that involved in

this project has to take in-charge and be committed to ensure that the equipment is
available and the inspection are being conducted as per plan. This is necessary to keep
the production always running and preventing from trip and jammed. Higher
temperature of the blower will cause the belt premature and disturb the disruption of the
gas turbine, and this will lead to unwanted loss to the company’s business.

In addition, any improvement or solution that can lead to improvise the process
of the production should be noted and discussed which at the same time want to align
with the PGB 3ZERO100 Transformation. Furthermore, any action that also can be
improvised or deviate from the focal person or manpower from their normal routine
during plant operation also needs to be concerned.

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12.0 Conclusion
Gas Turbine combustion Compartment cooling blower project has left nothing
and give some positive effect on the environment somehow eliminate the need of online
rectification upon blower trip (rectification during Gas Turbine Online condition); thus
eliminates the major risk of exposing to extreme heat. Fuel gas Emission burnt can be
reduced upon venting off to surrounding via elimination of unplanned Start and Stop
Event. From the observation throughout the involvement, it can conclude that
PETRONAS Gas Berhad commitment to the environment is praiseworthy and
healthiness.

This project has given the impact not only for the team, but for the people
surrounding. One of the impacts is in enhancing troubleshooting response among the
Asset Owner and Maintenance Team. Other than that, it can enhance and widen
networking with Subject Matter Expert, Service Provider and Utilities Fraternity. On the
same time, this networking and medium provide Knowledge Sharing platform thus
improves Fraternity’s Capability. In a bigger context, this project also helps
PETRONAS Gas Berhad to maintain their reputation as a client company which is
committed to the contributing back to the service provider and society.

In the public sector of organization and being in the team, knowledge sharing
involve sharing some information related to work in internalizing of mutual trust and
sincere attitude towards work and organization, aligned with one of PETRONAS
Culture Belief (PCB) which is Shared Success, collaborate for the greater good of the
company. This project promotes Knowledge Sharing among fraternity and the
opportunity given in enhancing the Technical Competency aspect that is resultant from
comprehensive and systematic Standards and Procedures. It is very impactful and
effective to the people and the gas processing plant as a whole. The exposure in project
management helps organization in developing competent staff as part of human capital
development.

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 This Gas Turbine combustion Compartment cooling blower project by Bubbles
team is one of the great solution as it influenced the improvement in productivity, safety
and equipment efficiency, and aligned with the PETRONAS Gas Berhad 3ZERO100
Transformation Agenda which is Zero Interruption, Increased Product Reliability and
No HSE Incident during site execution. Besides, improvement that has been applied
upon blower performance and durability, it is applicable to all Gas Turbine Frame Unit
where the same cooling mechanism can be used by all of them. In achieving the vision
as a leading Gas Infrastructure and Utilities Company, this project helped to prevent
uninterrupted production and supply, thus maintaining our nation, Malaysia, the
prosperity in Power, Gas & Petrochemical supply chain.

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13.0 References
[1] University Teknologi PETRONAS, (2015). Industrial Internship Guidelines for
Students, UTP: Center for Student Internship, Mobility and Adjunct Lectureship
(CSIMAL).
[2] PETRONAS Code of Conduct and Business Ethics (CoBE).Retrieved October
24, 2013 from PETRONAS:
http://www.petronas.com.my/aboutus/governance/Pages/governance/code of-
conduct-business-ethics.aspx Petroliam Nasional Berhad. (1999).
[3] HSE Policies and Guidelines. (n.d.). Retrieved October 25, 2013, from:
http://www.petronas.com.vn/PCVL/HSE/Policies_Guidelines.aspx PETRONAS.
(n.d.).
[4] Corporate Sustainablility Framework. Retrieved October 20, 2013 from
PETRONAS: http://www.petronas.com.my/sustainability/Pages/corporate-
sustainability framework.aspx PETRONAS. (n.d.).
[5] El-Wakil. (1984). Power Plant Technology, McGraw-Hill. Retrieved
from,http://faculty.uoh.edu.sa/n.messaoudene/Thermal/powerplants/Lec05GasTu
rbinePowerplants.pdf
[6] Dr. Patrick, T. Minnesota State University, Mankato. Engaged in
Thermodynamics: Gas Turbine Power
Plant.cset.mnsu.edu/engagethermo/systems_gtpp.html
[7] Mohd Aidil, Zaini. The Study on the Performance of the Gas Turbine for Power
Generation. Faculty of Chemical and Natural Resources Engineering University
Malaysia Pahang (UMP). March, 2008.

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