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MAINTENANCE WORKING HOURS FLOW FOR GAS TURBINE

MAJOR
INSPECTION
(MI)

COMBUSTION
12 000 HOURS
INSPECTION
(CI)

HOT GAS PATH


24 000 HOURS INSPECTION
(HGPI)

12 000 HOURS

COMBUSTION
36 000 HOURS INSPECTION
(CI)

MAJOR
INSPECTION
48 000 HOURS
(MI)
ANOTHER WORKING HOURS MAINTENANCE

Compressor Wash
Depends on performance (equivalent drop 2 MW)
Schedule performance for each 3 months
Duration for maintenance is 2 days (cooling down, wheel space
temperature for 49 C)

Steam Turbine
Schedule performance for each 5 years by Major Inspection (MI)
maintenance

Heat Recovery Boiler


Regular Inspection for each 15 months checked from Department of
Safety Healthy (DOSH)
COMBUSTION INSPECTION
Disassembly Procedures
Inspection Procedures
Reassembly Procedure

DISASSEMBLY PROCEDURES

Operation 1: Prepare Turbine Compartment Roof for Removal


Operation 2: Remove Turbine Compartment Roof and Side Panels
Operation 3: Remove Liquid Fuel Lines
Operation 4: Remove Atomizing Air Lines
Operation 5: Remove Gas Fuel Lines (If Applicable)
Operation 6: Remove Steam Injection Lines (If Applicable)
Operation 7: Remove Water Injection Lines (If Applicable)
Operation 8: Remove Liquid Fuel Check Valves
Operation 9: Remove False Start Drain Tubing
Operation 10: Remove Fuel Nozzles
Operation 11: Remove Flame Detectors and Spark Plugs
Operation 12: Remove Eleventh Stage Cooling and Sealing Air Lines
Operation 13: Unbolt and Open Up Combustion Outer Casing Covers
Operation 14: Remove Crossfire Tube Retainers, Combustion Liners, Crossfire Tubes and
Forward Flow Sleeves
Operation 15: Remove Access Port Blank Flange from Upper Half Turbine Casing or the
Upper Section of the Atomizing Air Extraction Manifold
Operation 16: Remove Outer Combustion Casings and Aft Flow Sleeves
Operation 17: Remove Transition Pieces
INSPECTION PROCEDURES

Operation 1: Prepare Test Fuel Oil and Purge Check Valves

Figure 1: Fuel Oil Check Valve Assembly

WARNING
Pressure testing of the fuel oil check valves requires the use
of high pressure oil or air. Use hoses, fittings and
associated equipment suitable for high pressure. Do not
use faulty equipment since its failure could cause injury.
Observe safety precautions applicable to working with
high pressure gases.

1. Using distillate fuel oil, apply 75 psi (5.2 barg) in the flow direction and check for
leakage. There should be zero leakage.
2. Apply 1000 psig (69 barg) oil pressure against the flow direction, to each check
valves to ensure against backflow leakage, or use 80 to 100 psi (5.5 to 7 barg) air
pressure while submerging the valves under water. There should be zero leakage.
3. If leakage is observed in either direction during the leak tests, the check valve should
be replaced or repaired in the following manner.
Valve Disassembly, Inspection and Reassembly
1. Place the inlet body hex in a vice. Using an open-ended spanner, loosen and remove
outlet body.
2. Remove poppet, spring, O-ring and gasket. Do not probe the interior of valve with
metal objects.
3. Before reassembly, inspect all components to be re-used. Ensure all components are
clean and free of contaminants and nicks.
CAUTION
It is important that all valve components are installed in
the proper orientation within the valve. Failure to ensure
this could affect valve operation.
4. Place the spring guide into the outlet body so that the flat side of the spring guide rests
on the outlet body.
5. Place the spring into the outlet body, ensuring that the spring rests inside the spring
guide.
6. Place the poppet over the spring.
7. Lubricate O-ring with a thin film of system lubricant. Place O-ring into inlet body.
Ensure that it is uniformly seated.
8. Place the gasket on the O-ring so that the step in the gasket is facing the O-ring.
9. Thread outlet body into inlet body. It is recommended that the poppet be in the OPEN
position while the body halves are threaded together. Do not use a metal punch or
sharp object for this step as it may scratch the poppet face.
10. Tighten the body halves to 700 ± 35 lbf in torque.

CAUTION

There will be an intentional gap of approximately 𝟏⁄𝟔 ˮ


between valve body halves. Do not overtighten. These
parts seat internally.

11. Test valve for proper operation. When installing valve into the system always hold the
body hex closest to the end being installed.

Operation 2: Inspect Fuel Nozzle

CAUTION
It is imperative that any fuel nozzle disassembly, cleaning,
inspection, reassembly, testing and reinstalling in unit be
performed in accordance with the following procedures.

General
This procedure details the tooling, fixtures, disassembly, inspection, reassembly and the
requirements for testing the reassembled fuel nozzles prior to returning to services.
Pressure Test Procedure
1. Install the fuel nozzle assembly in the test fixture as shown in Figure 2.

WARNING
Use only lines that have been proof tested to 3000 psig (210 barg)
and fittings, valves and gauges certified for use with high
pressure gases. Observe safety precautions applicable to working
with high pressure gases.

2. Pressurize the fuel nozzle oil fuel passage to a leak test pressure of 300 psig (21 barg).
a) Close the shutoff valve and submerge the fuel nozzle assembly in a tank of
water.
b) Check for leakage at areas shown in Figure 2.
c) Record findings on inspection form PBDFN6.
Fuel Nozzle Disassembly (After Pressure Test)
1. Identify, tag and/or mark the outer swirl tip, inner cap and each fuel nozzle body, to
prevent mixing similar parts at reassembly. See Figure 3.

CAUTION
The removal of parts from the fuel nozzle body should be done with extreme care.
Small nicks, scratches or other damage to the flow surfaces and orifices can alter the
nozzle flow pattern and result in undesirable combustion characteristics. The parts
should be placed in clean containers and not placed on steel work benches or
surfaces where the parts may be damaged. Wire baskets are acceptable containers.
See Figure 4.

2. Using an open-ended hex wrench and/or crowfoot hex tool, remove the outer swirl
tip, inner cap and lock plate form the fuel nozzle body. Discard the lock plate. See
Figure 5.

Note: A torque of approximately 275-300 ft. lbs. will be required to release the
lock plate stake when removing the outer tip from the fuel nozzle body.

3. Using an open-ended hex wrench and/or crowfoot hex tool, remove the transition
piece from the fuel nozzle body. Identify the transition piece assembly to the nozzle
body from which it was removed. See Figure 6.
4. Remove and discard the gasket which seals between the nozzle body and the
transition piece assembly. Use care in removing the gasket so as not to nick or scrape
the gasket sealing surface.
5. Record any abnormalities or defects found during disassembly on PBDFN6.

Note: If the transition piece assemblies are to be returned to a JBE/GE facility


for cleaning, inspection, reconditioning and calibration, make sure that each
assembly is wrapped separately in suitable packaging material to ensure
protection against damage during shipping, and identification for turbine
number and customer location is marked on each package (use PBDFN6 forms).

6. Remove the retainer from the transition piece using a 0.500 in. (13mm) straight hex
wrench. Use caution in handling the transition piece because the exit orifice can be
easily damaged.
7. Using a 0.156 in. (4.0mm) dia. wooden dowel and a lightweight mallet, gently tap the
fuel nozzle pilot out of the back of the transition piece, exercising caution to prevent
damaging the swirl slots of the pilot.
8. Record any abnormalities or defects found during disassembly of the transition piece
on form PBDFN6.
Operation 3: Inspect Combustion Liners