Common Problems & Practical Solutions

Gas turbines are critical assets in power plants, refineries, and industrial facilities. Reliable performance is essential for maintaining operational efficiency and minimizing downtime. However, like any high-speed rotating equipment, gas turbines may experience performance issues due to mechanical, electrical, or control-related faults.

This blog highlights common gas turbine problems and practical troubleshooting approaches used in modern industrial environments.

1. Starting Failure of Gas Turbine:-

One of the most common issues is failure to start.

Possible Causes:

• Low lube oil pressure
• Faulty ignition system
• Fuel supply interruption
• Control logic fault
• Speed sensor malfunction

Troubleshooting Approach:

• Check lube oil pump operation and pressure levels
• Inspect ignition transformers and spark plugs
• Verify fuel gas pressure and valves
• Review alarm history in control system
• Check speed pickup signals

2. High Vibration in Gas Turbine:-

Excessive vibration can lead to serious damage if not addressed immediately.

Common Reasons:

• Rotor imbalance
• Misalignment
• Bearing wear
• Blade damage
• Loose foundation bolts

Corrective Action:

• Perform vibration analysis
• Conduct alignment check
• Inspect bearings and coupling
• Schedule rotor balancing
• Check foundation integrity

3. High Exhaust Temperature:-

High exhaust temperature reduces turbine efficiency and may indicate combustion issues.

Possible Causes:

• Blocked air filters
• Combustion imbalance
• Fuel nozzle clogging
• Turbine blade damage

Solution:

• Clean or replace air filters
• Inspect combustion liners
• Clean fuel nozzles
• Conduct borescope inspection

4. Sudden Trip of Gas Turbine:-

A sudden trip is a protective action triggered by the control system.

Common Trip Signals:

• Overspeed
• High vibration
• High exhaust temperature
• Low lube oil pressure
• Flame failure

Modern control systems such as GE Speedtronic Mark VIe provide advanced diagnostics and trip analysis, helping engineers quickly identify the root cause.

5. Low Power Output:-

If the turbine is running but not producing expected power:

Check for:

• Compressor fouling
• Inlet air temperature
• Fuel quality issues
• Control calibration errors

Regular compressor washing and proper maintenance planning can significantly improve output performance.

Importance of Preventive Maintenance

Routine inspection, vibration monitoring, and proper control system diagnostics are essential for reducing unplanned shutdowns. Implementing predictive maintenance strategies improves turbine reliability and lifecycle performance.

Conclusion:

Gas turbine troubleshooting requires a systematic approach combining mechanical inspection, control system diagnostics, and operational data analysis. Early detection of abnormalities helps prevent costly failures and extends equipment life.

If your organization requires expert support in gas turbine maintenance, spare parts supply, or control system services, working with an experienced turbine solutions provider ensures reliable and efficient plant operations.