Gas Turbine Maintenance

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GE Power Systems
Gas Turbine Maintenance Part 1
Revision Date: 09/07/2000
Property of Power Systems University- Proprietary Information for Training Purposes Only!
GE Power Systems
OPERATING FACTORS AFFECTING MAINTENANCE The effect of maintenance factors for fuel, starts, environment and load duty cycles are cumulative. As the maintenance factor increases, the time between inspections and component repairs decreases and it is possible that component replacement frequency will increase.
GE Power Systems
Key Factors Affecting Maintenance Planning
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Plant Level Top 5 System Contributions to Downtime
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MAINTENANCE FACTORS Cyclic Effects
Effects of Startups and Shutdowns / Trips
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Firing Temperature Fuel

Gas, Distillate, Crude, Quality, etc...
Water or Steam Injection Environment

Air Quality
Maintenance Practices
Revision Date: 09/07/2000 Property of Power Systems University- Proprietary Information for Training Purposes Only!
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MAINTENANCE FACTORS Cyclic Effects
Fired Starts
Normal Fast Load Emergency
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Stops
Normal shutdown Trips
>80% Load
Load Changes
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MAINTENANCE FACTORS Causes of Wear - HGP Continuous Duty Application
Creep Deflection Oxidation Corrosion High-Cycle Fatigue Rupture Erosion Rubs/Wear Foreign Object Damage (FOD)
GE Power Systems
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MAINTENANCE FACTORS Causes of Wear - HGP Cyclic Duty Application
Thermal Mechanical Fatigue High-Cycle Fatigue Rubs/Wear Foreign Object Damage (FOD)
GE Power Systems
GE Power Systems
GE Power Systems
GE Power Systems
Fig 41 - Page 28
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MAINTENANCE FACTORS
GE Power Systems
Typical Max Inspection Intervals (MS6B/MS7EA)

Hot Gas Path Inspection Major Inspection 24,000 hrs or 1200 starts 48,000 hrs or 2400 starts
Criterion is Hours or Starts (Whichever Occurs First)
Fig 41 - Page 28
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MAINTENANCE FACTORS Hot Gas Path Buckets/Nozzles Hours Factors
Fuel
Gas Distillate Crude Residual 1 1.5 2 to 3 3 to 4
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Peak Load 1 hr at peak = 6 hrs at base load Water/Steam Injection

Dry Control Wet Control 1 (GTD-222) 1.9 (5% H2O GTD-222)
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MAINTENANCE FACTORS Hot Gas Path Buckets/Nozzles Starts Factors
Trip from Full Load Fast Load Emergency Start 8 2 20
GE Power Systems
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GE Maintenance Interval for Hot Gas Path Inspection
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MAINTENANCE FACTOR VS FUEL TYPE
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Bucket Life Firing Temperature Effect
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Exhaust Temperature Control Curve Dry vs. Wet Control
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Turbine Start / Stop Cycle Firing Temperature Changes
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First - Stage Bucket Transient Temperature Distribution
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Low Cycle Fatigue Life Sensitivities 1st Stage Bucket
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Maintenance Factor Trips From Load
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MAINTENANCE FACTORS Hours Based Hot Gas Path
Maintenance Interval = 24000 (Hours) Maintenance Factor Where: Maintenance Factor = Factored Hours / Actual Hours MF = Factored Hours = (K + M * I) * (G + 1.5D + AfH + 6P) Actual Hours = (G + D + H + P)
GE Power Systems
G = Annual Base Load Operating Hours on Gas Fuel D = Annual Base Load Operating Hours on Distillate Fuel H = Annual Operating Hours on Heavy Fuel Af = Heavy Fuel Severity Factor (Residual Af = 3 to 4, Crude Af = 2 to 3) P = Annual Peak Load Operating Hours I = Percent Water/Steam Injection Referenced to Inlet Air Flow M & K = Water/Steam Injection Constants
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MAINTENANCE FACTORS
Starts Based Hot Gas Path
Maintenance Interval = 1200 (Starts) Maintenance Factor Where: Maintenance Factor = Factored Starts / Actual Starts
GE Power Systems
MF =
Factored Starts = (0.5NA + NB + 1.3NP + 20E + 2F + aT1 T1) i=1 Actual Starts = (NA + NB + NP + E + F + T)
NA = Annual Number of Part Load/Stop Cycles (<60% Load) NB = Annual Number of Normal Base Load Start/Stop Cycles NP = Annual Number of Peak Load Start/Stop Cycles E = Annual Number of Emergency Starts F = Annual Number of Fast Load Starts T = Annual Number of Trips aT = Trip Severity Factor = f (Load) n = Number of Trip Categories (I.e., Full Load, Part Load, etc.)
GE Power Systems
GAS TURBINE MAINTENANCE
Operation of the combustion gas turbine, as any rotating power equipment, must include a planned program of periodic inspection. With accompanying repair and replacement of parts as required, will ensure the maximum availability and reliability of the turbine.
GE Power Systems
OBJECTIVE OF THE GAS TURBINE MAINTENANCE SECTION Describe the inspections and the action to be taken. Identify the components and parts that should be examined. Discuss the Inspection and Maintenance Manual Pre-Inspection Items Standard Practice Review
GE Power Systems
OPERATING FACTORS AFFECTING MAINTENANCE The effect of maintenance factors for fuel, starts, environment and load duty cycles are cumulative. As the maintenance factor increases, the time between inspections and component repairs decreases.
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MAINTENANCE FACTORS Type of Fuel Starting Frequency Load Cycle and Firing Temperature Water or Steam Injection Environment Maintenance Practices
GE Power Systems
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TYPES OF INSPECTIONS Running Inspections
Startup Operating
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Shutdown Inspections
Combustion Hot Gas Path Major
Standby Inspections
Checking of Batteries, Filters, Oil and Water Levels, etc
Special Inspections
Borescope
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GE Power Systems
Keep a record of the inspections made, and the maintenance work performed. It is expected that a maintenance program will start with minor work, and increase in magnitude over a period of time to a major overhaul. Optimized inspections will reduce unit outage time and maintenance cost.
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MAINTENANCE PRACTICES
GE Power Systems
Parts condition information data Initial inspection planning Good maintenance planning for minimum down time requires the availability of replacement parts. Minimum stock of repair parts in a predetermined location. Anticipate needs during outages.
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PRIOR TO GAS TURBINE MAINTENANCE
GE Power Systems
Clean the compressor per the gas turbine Water Wash. A complete set of operating data including vibration readings should be taken and recorded for reference. Inventory and Inspection of tooling. General walk around inspection prior to tear down. Lock Out / Tag Out (LOTO)
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GAS TURBINE COMPRESSOR CLEANING
GE Power Systems
The Gas Turbine Water Wash System will be covered in a separate lecture. Gas Turbines operating with Dry Low Nox Combustion Systems should not use solid compounds for compressor cleaning.
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INSPECTION AND MAINTENANCE MANUALS
Notes:
Highlights an essential element of a procedure to assure correctness.
Caution:
Indicates a procedure or practice, which if not strictly observed, could result in damage or destruction of equipment.
Warning:
Indicates a procedure or practice, which could result in injury to personnel of loss of life if not followed correctly.
GE Power Systems
Introduction Standard Practices Auxiliary and Controls Systems Maintenance Scheduled Turbine Maintenance Combustion Inspection Hot Gas Path Inspection Major Inspection Maintenance Inspection Forms
GE Power Systems
Introduction
General Operating Factors Affecting Maintenance Maintenance Practices Types of Inspection Inspection Intervals Special Inspection
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INSPECTION AND MAINTENANCE MANUALS Standard Practices

General Recommended Solvents, Sealers and Cleaners Lubrication Guidance Gas Turbine Compressor Cleaning Tools and Equipment Special Tools Ordering Renewal Parts, Repair and Replacement parts Returning Turbine Parts for Repair / Replacement Maintenance Parts Recommendations
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LUBRICATION GUIDANCE
GE Power Systems
Lubrication frequency will vary, depending on turbine hours and ambient temperature. It is suggested that records on lubrication intervals be kept to determine variances between periods listed on the chart and those scheduled for a specific installation. Lubricants listed do not exclude comparable products from other oil companies. Use of alternate lubricants must be approved by component manufacture.
GE Power Systems
GE Power Systems
ORDERING RENEWAL, REPAIR AND REPLACEMENT PARTS Spare and renewal part orders for General Electric turbines should be placed with your General Electric Company Representative Operations Office. Parts which form one complete working unit must be ordered together. Any new safety features and design improvements are usually incorporated in replacement parts.
GE Power Systems
ORDERING RENEWAL, REPAIR AND REPLACEMENT PARTS If no drawing, parts list or reference publication is available for a part, a sketch or sample of the item, together with all necessary dimensions and description of the parts function, should accompany the order. Store parts in a suitable place to prevent loss or damage. Coat all finished iron or steel surfaces with oil or other suitable compound to protect them for corrosion.
GE Power Systems
RETURNING PARTS FOR REPAIR OR REPLACEMENT Contact your General Electric Company Representative Operations Office for assistance when returning turbine parts to GE. They will supply you with proper procedures as well as supply the required packing instructions, packing lists and shipping labels. A GE representative can be directed to confirm receipt of your parts and explain factory corrective action recommendations.
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MAINTENANCE PARTS RECOMMENDATIONS
GE Power Systems
Spare parts recommendations are provided to support scheduled combustion, hot gas path and major inspections. Spare parts listings must be used in conjunction with the Parts List and Drawings Volume of the Service Manual. Use the typical spare parts list as a guide, your spare parts stock should be reviewed at a pre-inspection planning meeting.
GE Power Systems
Auxiliary and Controls Systems Maintenance

Periodic Inspection Schedule Inspection and Maintenance Procedures
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GE Power Systems
GE Power Systems
GE Power Systems
Scheduled Turbine Maintenance

Running Inspections Housekeeping Data Recording Special Inspections
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Combustion Inspection Hot Gas Path Inspection Major Inspection

Disassembly Inspection Re-assembly Startup Checks
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GAS TURBINE BORESCOPE
GE Power Systems
Incorporates the use of the optical borescope. Allows rapid inspection of the following areas:
Turbine Section Axial Flow Compressor Combustion System
Removal of spark plugs and flame detectors from combustion system allows access to these areas.
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GAS TURBINE BORESCOPE INSPECTION CRITERIA Compressor Blades:
FOD and DOD Dirt Build Up Corrosion Tip Erosion Trailing Edge Thinning Stator Blade Root Erosion Tip Clearance
GE Power Systems
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GAS TURBINE BORESCOPE INSPECTION CRITERIA Combustion, (Liner and Transition Piece):
Carbon Build-Up Hot Spots Cracking Bulging Wear Missing Metal
GE Power Systems
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GAS TURBINE BORESCOPE INSPECTION CRITERIA Turbine Nozzles:
FOD and DOD Corrosion Blocked Cooling Holes Cracks Trailing Edge Bowing Erosion Burning
GE Power Systems
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GAS TURBINE BORESCOPE INSPECTION CRITERIA Turbine Buckets:
FOD and DOD Corrosion Blisters Cracks Tip Clearance Erosion Missing Metal
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GE Power Systems
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VIGV BUSHING INSPECTION
GE Power Systems
VIGV in fully open position 1. Set vanes to the full open position. 2. Set up dial indicator to measure motion normal to the vane cord. Position the indicator to read as close to the vane inner button as possible. VIGV 3 3. Deflect vane in a tangential direction (perpendicular to the air flow direction) to both sides of the bushing clearance and record full dial indicator reading.
1 Airflow Direction
2 Bushing Dial Indicator
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VIGV BUSHING INSPECTION SCHEDULE
Frame Size MS5001, MS5002, MS6001* VIGV Type
1
GE Power Systems
Bushing
Clearance Limits for Bushing Changeout (>= inches) 0.050 0.050 0.075 0.075 0.070 0.070 0.100 0.100 0.100
Inspection Interval (Hours) 5,000 8,000 8,000 8,000
*Pre Model FA
MS6001FA MS7001*, MS9001*
403 Stainless 403 Stainless GTD 450 GTD 450 403 Stainless 403 Stainless GTD 450 GTD 450 GTD 450
158A7888P004/5/6 315A9681 or 339A9913 315A9681 or 339A9913 339A9913 158A7888 315A9681 or 339A9913 315A9681 or 339A9913 339A9913 328A7020
16,000 16,000
3 3
4 4
*Pre Model F
MS7001F/FA/FA+ MS9001F/FA
16,000 16,000 16,000
3 3 3
8,000 8,000 8,000 8,000 8,000
4 4 4
Note 1: For unit specific drawing number identification, refer to Model List Item 1301 Note 2: For unit specific drawing number identification, refer to Model List Item 0811 Note 3: Nominal Base Load IGV angle of 84 or Lower Note 4: Nominal Base Load IGV angle greater than 84 (i.e. 86 or 88)
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GE Power Systems
END

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Gas Turbine Maintenance Part 1

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Key Factors Affecting Maintenance Planning

Revision Date: 09/07/2000

Plant Level Top 5 System Contributions to Downtime

Revision Date: 09/07/2000

Firing Temperature Fuel

Water or Steam Injection Environment

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Typical Max Inspection Intervals (MS6B/MS7EA)

Criterion is Hours or Starts (Whichever Occurs First)

Revision Date: 09/07/2000

Peak Load 1 hr at peak = 6 hrs at base load Water/Steam Injection

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Bucket Life Firing Temperature Effect

Revision Date: 09/07/2000

Exhaust Temperature Control Curve Dry vs. Wet Control

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

GAS TURBINE MAINTENANCE

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

INSPECTION AND MAINTENANCE MANUALS

INSPECTION AND MAINTENANCE MANUALS

Revision Date: 09/07/2000

INSPECTION AND MAINTENANCE MANUALS

Revision Date: 09/07/2000

INSPECTION AND MAINTENANCE MANUALS Standard Practices

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

INSPECTION AND MAINTENANCE MANUALS

Auxiliary and Controls Systems Maintenance

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

Revision Date: 09/07/2000

INSPECTION AND MAINTENANCE MANUALS

Scheduled Turbine Maintenance