Theoretical training

Maintenance course
T60 Gatropower

Theoretical training
Maintenance course

Use of plant documentation Maintenance procedures Maintenance plan introduction

Use of plant documentation

Plant documentation

Sytem design manual (files no.1-5) Electrical equipment part 1, 2, 3 (files no.6-8) Mechanical equipment (file no.9) Fire detection and extinguishing system (file no.10) Betobar busducts (file no.11) TAC start diesel (800 kVA) (file no.12)
3

Use of plant documentation

System design manual
Gas turbine manual, lists and data sheets (file 1) Piping and instrumentation diagram (P&I),I&C and operator interface, alarm list and step list, profibus signal list (file 2) Turbine documentation (file 3) Generator documentation (file 4) Wiring and connection diagram (file 5)
General diagrams Electrical schematics

Use of plant documentation

P & I
Purpose
Circuits description Each part/instrument of the turbogenerator is defined with a functional code (composed from letters) and a four-figure number (P&I CODE). The letter code defines the part function, the number mainly is referred to the the circuit the part/instrument belong to

P&I CODE
TT Functional code 3035 Four-figure number
5

Use of plant documentation

P & I T60

Use of plant documentation

P & I T60
P & I CODE Functional code instruments
Letter
A C D F G I L P R S T W Z

1st letter

2nd letter
Alarm Control Differential

3/4th letter

Examples PDI 2122 Pressure Differential Indicator

Smoke Flow Position Level Pressure Fire Speed Temperature Weight

Indicator

Indicator

PZ+ Switch Transducer Shutdown PS 5201 Pressure Shutdown High Pressure Switch 7

Use of plant documentation

P & I T60
P & I CODE Functional code components
AV B C EJ EP EV F FO G Automatic Valve Tank/reservoir Coupling Expansion joint Electro Pump Electro Ventilator Filter Flow Orifice Generator HC HV M PC RV S SA SV TCV Hand Control valve Hand Valve Motor Pressure regulator Check Valve Sound dumper Electrical switch Safety Valve Temp. Control Valve

H
HAL

Light
Horn/light Alarm

V
W

Ventilator
Heater/Heat exchanger

Use of plant documentation

P & I T60
P & I CODE Four-figure number explaination
HV 2 1 22 -1/2 Extension, for multiple positions Part number Subsystem Principal system Functional code

Use of plant documentation

P & I T60
P & I CODE Numeration of systems - principal systems
Number
0 XXX 1 XXX 2 XXX 3 XXX 4 XXX 5 XXX 6 XXX

SYSTEM
General Turbine system Liquid fuel system Lube oil system Generator system Combustion/ventilation air system and exhaust duct External systems

10

Theoretical training
Maintenance course

Use of plant documentation Maintenance procedures Maintenance plan introduction

11

Maintenance procedures

Compressor washing Combustion air filter system Lube oil system Liquid fuel system Air system

12

Maintenance procedures
Compressor washing
Why?
Clean deposits of contaminants (oil, dust,..) on the surface of the compressor blades Maintain the compressors efficiency high

When?
Power drop between 3-5 % in comparison to a performance reference (ex. during commissioning) The air intake area is visible dirt There are particular problems : lack of acceleration, compressor surging, PCD too low,

How?
Off-line compressor washing method
13

Maintenance procedures
Compressor washing
Off-line compressor washing
Washing compressor in crank mode Before washing, the turbine has to be cooled for 8 hours (check that T5 is less than 65C) Minimum interval between two washing cycles : 96 hours When ambient temperature is lower than 7 C, antifreeze products (ethylene glycol) are required to be mixed with washing solution Cleaning solution = 1 part cleaning product(TUMA cleaner) + 4 or 6 parts demineralized water Follow carefully the washing procedure (See details in the operator manual)
14

Maintenance procedures
Compressor washing
Off-line compressor washing
Procedure 1) Preparation of turbine for washing 2) Washing with solvent (cleaning solution) 3) Rinsing solvent with demineralized water 4) Dry sequence 5) Preparation of turbine for start-up after washing 6) Start turbine and check the effects of compressor washing (power gain, other problems solved,..)

15

Maintenance procedures
Procedure

Off-line compressor washing

Preparation of turbine for washing (for details see the operator

manual)
Stop turbine and allow cooling Disconnect and put away the 2 seventh stage bleed lines and install blanking plates Remove PCD measure line Open a drain on the liquid fuel manifold Open drain of the air intake duct Remove spark plug Disconnect drain lines from the torch and the turbine Remove the air intake covers
16

Maintenance procedures
Procedure

Off-line compressor washing

Washing with solvent (for details see the operator manual)

Fill water tank with appropriate solution of water and solvent Prepare the washing line

Crank

Water wash on

Water wash off

Stop

Crank sequence
Water wash allowed
Air.temp low Add antifreeze agent to water

Crank sequence
Water wash in progress

Let drain water for 5 minutes 17

If T1<7C

Maintenance procedures
Procedure

Off-line compressor washing

Rinsing solvent (for details see the operator manual)

Fill water tank with demineralized water (100 liter) Prepare the washing line
Dry 5 minutes

Crank

Water wash on

Water wash off

Stop

Crank sequence
Water wash allowed
Air.temp low Add antifreeze agent to water

Crank sequence
Water wash in progress

Let drain water for 20 minutes

If T1<7C

18

Maintenance procedures
Procedure

Off-line compressor washing

Preparation of turbine for start - up (for details see the operator

manual)
Check all the turbine parts has been drained Check that air intake duct is proper before closing it Connect all the drain lines and other parts disconnected during turbine preparation Check that the turbine is ready to start Start the turbine After stabilization at full power, check the effects of washing compressor
19

Maintenance procedures
Combustion air filters
Cleaning of combustion air filter
Sequences :
Manual air filter cleaning Air filter cleaning Sequence of 12 pulses x 120s each

Auto air filter cleaning

If p air filter >

80 mmH20

Sequence of 12 pulses x 120s each

20

Maintenance procedures
Combustion air filters
Changing of combustion air filter
The pressure drop across the filter system is always displayed on the video When after 3 - 4 cleaning cycles the pressure drop in the filter system is not reduced, the change of filters is required Turbine has to be stopped during the change of filters Control alarm limits :
Warning : Alarm : 100 mmH2O (hyst. = 90 mmH2O) 120 mmH2O (hyst. = 110 mmH2O)

21

Maintenance procedures
Cleaning filters

Container ventilation air filters

The frequency of cleaning filters depend a lot from site conditions (quality of the air) When container exit temperature is too high, check ventilators, shutters and filter bags If it is case, filter bags can be disassembled and cleaned with compressed air (when turbine is not running)

Changing filters
The frequency of changing filters depend a lot from site conditions (quality of the air)

When filter is too dirty or the filter mesh is demaged, filter element should be replaced
22

Maintenance procedures
Lube oil system
Refilling lube oil tank
The turbine consumes a small amount of oil : internal labyrinth seals, evaporation, external spillage Tank is initially filled with 1000 liters oil Warning : 700 liters. Check periodically the level indicator

Refilling tank can be done with turbine running

Remember, when turbine is running approximately 150 liter oil are filling the lube oil piping system Tank should be filled to 150 liter below the maximum indicated level
23

Maintenance procedures
Lube oil system
Switching lube oil filter (duplex filter)
When pressure drop alarm (warning) is activated switch on the second filter cartridge When pressure drop alarm (warning) is active for more than 48 hours, a forced cooldown (alarm) is executed by the control sxstem

Change lube oil filter (duplex filter)

Proceed to change the cartridge after switching on the filter second

Oil filter cartridge can be changed with turbine in normal operation, but it is recomended to change filter only with turbine stopped
24

Maintenance procedures
Liquid fuel system
Changing of liquid fuel filter
LP liquid fuel filter (duplex filter)
Pressure drop control : warning Switch on the second cartridge The frequency of changing filters depends on the quality

liquid fuel

HP liquid fuel filter

Pressure drop control : warning When there is a pressure drop alarm, we must transfer to other fuel mode or stop the turbine LP fuel supply line should be shut off Check that the line is no more in pressure Investigate the cause of the dirt (problem on the HP pump)
25

Theoretical training
Maintenance course

Use of plant documentation Maintenance procedures Maintenance plan introduction

26

Maintenance plan introduction

General maintenance plan (turbine on continous operation)
LEVEL TYPE OF MAINTENANCE FREQUENCY WORKING TIME STANDSTILL DAYS EXECUTION BY I service weekly 3h 0 days Client II intermediate 6 months 24 h 2 days TBM/Client main 12 months 48 h 3 days TBM/Client III IV General overhaul 30000 hours of operation 7 days 8 days TBM/Client

The Maintenance plan of this project can differ from the one above. See Maintenance contract between Turbomach and the Client for details.

27

Maintenance plan introduction

Level I
Service maintenance (turbine running)
General
Turbine operating data recording (data sheets) Inspect adjustment of instrument air pressure reducers Check for leaks (liquid circuit, oil circuit)

External checks

Internal package
Check lube oil tank level Check for leaks (liquid circuit, oil circuit) Check combustion/ventilation air systems Check for strange noises and unusual operating conditions Check bearing lube oil level of generator
28

Maintenance plan introduction

Level II
Intermediate maintenance (turbine at standstill)
General
Maintenance operations of level I Change filters (lube and liquid fuel circuits) Check electrical components (fans, pumps,..) Visual inspection of exhaust gas diffuser Check speed turbine transducers Take a sample of lubricant for laboratory analysis Check operation of fire extinguishing system Check turbine in different operation modes
29

Package

Electrical system

Test run

Maintenance plan introduction

Level III
Main maintenance (turbine at standstill)
General
Maintenance operations of level II Boroscope inspection of the turbine Check fuel nozzles and combustion chamber Check measuring transmitters and sensors Check shut-off and control fuel valves Check generator components (exciter, casing,..) Check MV main circuit breaker Inspect generator lectrical protection devices
30

Package

Electrical system

Maintenance plan introduction

Level IV
General overhaul (turbine at standstill)
Main task
Turbine replacement Inspect generator bearings Inspect generator rotor Change or repair of auxiliary AC motors Change of brushes on DC motors change of batteries

General tasks

31

Maintenance plan introduction

General maintenance plan (turbine on standby)
LEVEL MAINTENANCE I Operational maintenance Once a week B Preventive maintenance Once a year

MAINTENANCE INTERVENCTIONS TECHNICIANS STANDSTILL DAYS

2 0

3 5

EXECUTION BY

Client

TURBOMACH

The Maintenance plan of this project can differ from the one above. See Maintenance contract between Turbomach and the Client for details.

32

Maintenance plan introduction

Level I
Operational maintenance
General
All checks executed by the CLIENT at least once a week Check air systems and lube oil level Leakage check on circuits

Turbine + package

Control cubicles

Check the state of batteries

Check bearing lubrication oil level

Generator Test run

Start turbine and operational tests If possible, test sysnchro at least one time per month
33

Maintenance plan introduction

Level II
Preventive maintenance
General
All checks of level I The maintenance is executed by the TBM once a year Boroscope analysis Function checks (BV, pumps,..) Operational check of fire extinguishing system General electrical checks Tests up to full load
34

Turbine + package

Control cubicles

Generator Test run