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