Gas Turbine Maintenance

Classification Gas Turbine Maintenance ; 1. Standby Inspection 2. Running Inspection 3. Dis-assembly Inspection Dis-assembly Inspection can be classified into : 1. Combustion Inspection 2. Hot Gas Path Inspection 3. Major Inspection

Maintenance Objectives
Objectives
Maximizing availability & reliability

Affecting Factors
Criticality of the turbine operation Cost of down time

Measures to be taken
Parts reliability improvement Control system upgrade Standby inspection Running inspection Periodic test run & spare part stock Shutdown inspection CI, Borescope, HGPI, MI HGP parts evaluation Fuel system conversion Inlet air system & washing Uprate HGP parts Covert to CCP

Minimizing maintenance cost

Inspection interval Hot gas path parts life extension Fuel cost Performance deterioration Investment to upgrade GT

Minimizing running cost

Deterioration & Damaged of GT

60 50 40 30 20 10 0 Percentage 18 6.4 4.7 3.4 2.9 2.1 8.5 54 Fuel Oil System Thermocouple Lube Oil System Coooling water system Atomizing Air System Fuel Gas System Others GT Flange to Flange

Influence Factors for GT Maintenance

Hour in Service Starting Frequency (start/stop) Load Cycle (Output variation) Load Duty (Partial or base) Type of fuel (gas or liquid) Environment (Particulate in air)

Material Deterioration Wear Crack Oxidation Corrosion Erosion Plugging

Standby Inspection
Standby inspection pertain particularly to gas turbine used in intermittent service as peaking or emergency duty. Standby inspection is especially important for the units of which starting reliability is essential. - Servicing battery system - Changing filters (air, fuel , lube oil & control system) - Checking oil & water level - Cleaning relays - Control device calibration - Periodic start test - prevention of rusting & drying up air passage - Inspect exhaust duct & plenum - General Cleanliness

Running Inspection
Running inspection consist of the observation made while an unit is in service. Gas turbine let you know it is sick, before being effectively ill. Operation data are taken on control panel & turbine instrument panel at running inspection. Operation date are useful for trouble shooting in future and also indicates the sign of trouble. Typical running inspections include : 1. Load vs exhaust temperature TTXM 2. Vibration level 3. Fuel flow & pressure 4. Exhaust temperature variation 5. Turbine output vs ambient temperature 6. Start-up time & coast-down time.

Dis-Assembly Inspection
Hot gas path components are subjected to sudden temperature change and resultant thermal stress during start-up. They are also subjected to hot combustion gas with combustion oscillation and it is often corrosive. Severe working conditions of hot gas path parts require periodical inspection and repair.

Recommended Inspection Intervals

Ins ec i n Type Combustion Inspection el Type Gas Distillate Hot Gas Path Inspection Gas Distillate Major Inspection Gas Distillate M 3002 16,000 16,000 24,000 24,000 48,000 32,000 M 002 M 001 M 001 M 001 8,000 8,000 24,000 24,000 48,000 32,000 8,000 6,000 24,000 24,000 48,000 48,000 8,000 8,000 24,000 24,000 48,000 48,000 8,000 8,000 24,000 24,000 48,000 48,000

Combustion Inspection
Combustion inspection is provided for the inspection or replacement of shortest life parts of hot gas path section. The combustion inspection is relatively short dis-assembly shutdown inspection. (5-7 days)

Combustion Inspection Work Scope

Parts
Fuel Nozzle Combustion Liners Crossfire tube Retainer Seal Plate Spark Plug 1st & 2nd stage nozzles

Action
Dis-assembly tip clearance Cleaning. LP Check Cleaning Visual Inspection Visual Inspection Tip Clearance Borescope inspection Wear

Inspect for
Unusual wear Hot Spot Burning Cracks Weld condition

Cracks

Hot Gas Path Inspection

Hot gas path inspection will be determined by borescope inspection evaluation made at time of combustion inspection and fired hours of the recommended inspection intervals. Hot gas path inspection includes a detailed inspection of turbine nozzles and buckets in addition to combustion inspection. To perform this inspection, the top half of the turbine casing must be removed.

Hot Gas Path Inspection Work Scope

Parts
First Stage Nozzle Second Stage Nozzle First Stage Bucket Second Stage Bucket Turbine Clearance Wheel Space Thermocouple Compressor stationary & Rotating blades Clearance measurement Inspection on resistance Borescope inspection Excessive wear & Distortion Faulty thermocouple Cracks, Foreign object Cleaning LP checks

Action

Inspect for
Foreign Object Damage, Erosion Corrosion Cracks Cooling hole plugging

Major Inspection
Major inspection should be scheduled as per manufacturers recommended inspection interval or previous inspection results. Major inspection includes the overhaul and inspection of major flange to flange components of gas turbine. This inspection also covers combustion and hot gas path inspection work scope.

Major Inspection Work Scope

Parts
Turbine buckets & nozzles Compressor blading Turbine wheel

Action
Remove from rotor Cleaning & LP check Clean, LP check dovetail Clean, clearance check LP check

Inspect for
Foreign Object Damage, Erosion Corrosion Cracks Cooling hole plugging Wear, Fouling, Wiping Deterioration of babbitt Wear, Scoring Wear Deformation Major inspection

Bearing, seals Journals Clearance Others major auxiliary Components load gear, Accessory gear, torque converter, etc

Clearance measurement Check bearings. Clearance measurement