Nandipur 425MW CCPP Gas Turbine Maintenance Manual (Volume II Part 1) F

NANDIPUR 425MW CCPP GAS TURBINE MAINTENANCE MANUAL
1
Preface
This manual is edited on the basis of provisions and relevant drawings from
manufacturer and design institute, only for gas turbine generator system maintenance
of Pakistan Nandipur 425MW Gas Turbine Combined Cycle Power Plant. With the
progress of the project, the manual will be supplemented and improved.
2
Content
1General ........................................................................................................ 1
1.1Safety First ....................................................................................................... 1
1.2Risk Assessment............................................................................................... 1
1.3Purge the Engine .............................................................................................. 2
1.4 Keep Complete Records.................................................................................. 2
1.5Maintenance Tasks ........................................................................................... 2
1.6 Maintenance Checks ....................................................................................... 2
1.7Anti-seize Compound....................................................................................... 3
1.8 Sealing Compound .......................................................................................... 4
1.9 Joint Compound .............................................................................................. 4
1.10Piping Flanges ................................................................................................ 4
1.11Bolt and Stud Torquing .................................................................................. 5
1.11.1Before Torquing ...................................................................................... 5
1.11.2Classification of Joints ............................................................................ 5
1.12 Recommend Solvents, Sealants, Cleaners, ETC........................................... 7
1.12.1 Listing..................................................................................................... 7
1.12.2 Note On Anti-seize Compound, High Temperature: ............................. 9
1.13 Ordering Renewal Parts ................................................................................ 9
1.14 Repair and Replacement Parts .................................................................... 10
2 Maintenance Consideration ................................................................... 11
2.1 Introduce........................................................................................................ 11
2.2 Maintenance Planning ................................................................................... 11
3 Gas Turbine Maintenance Devices Inspection..................................... 14
3.1Borescope Inspection ..................................................................................... 14
3.2 Standby Inspections ...................................................................................... 18
3.3 Running Inspections ...................................................................................... 18
3.4Load and Exhaust Temperature ..................................................................... 19
3.5 Vibration Level ............................................................................................. 19
3.6 Fuel Flow and Pressure ................................................................................. 20
3.7 Exhaust Temperature and Spread Variation ................................................. 20
3.8 Startup Time .................................................................................................. 20
1
3.9 Coast-Down Time ......................................................................................... 20

3.10 Rapid Cool-Down ....................................................................................... 20
3.11 Combustion Inspection ............................................................................... 21
3.12 Hot Gas Path Inspection .............................................................................. 23
3.13 Major Inspection ......................................................................................... 26
4 Gas Turbine Auxiliaries Maintenance Schedule Guide ...................... 29
4.1 Introduction ................................................................................................... 29
4.2Safety.............................................................................................................. 29
4.3 Standard Devices ........................................................................................... 32
4.4 Lubricating Oil System ................................................................................. 38
4.4.1Definition ................................................................................................ 38
4.4.2 Maintenance Schedule ........................................................................... 38
4.4.3 Lubricating Oil Recommendations for Gas Turbines ............................ 41
4.5Trip Oil System .............................................................................................. 42
4.6Cooling Water System ................................................................................... 43
4.6.1Definition ................................................................................................ 43
4.7Starting Means System................................................................................... 45
4.7.1Definition ................................................................................................ 45
4.8Liquid Fuel System ........................................................................................ 46
4.8.1Definition ................................................................................................ 46
4.9Atomizing Air System.................................................................................... 49
4.9.1Definition ................................................................................................ 49
4.10Fire Fighting System .................................................................................... 51
4.10.1 Definition ............................................................................................. 51
4.10.2 Maintenance Schedule ......................................................................... 52
4.11Air Inlet Bleed Heating System ................................................................... 53
4.12Hydraulic Supply System............................................................................. 54
4.12.1Definition .............................................................................................. 54
4.12.2Maintenance Schedule .......................................................................... 54
4.13Heatingand Ventilation System ................................................................... 55
4.13.1 Definition ............................................................................................. 55
4.14Compressor Washing System ...................................................................... 58
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4.14.1Definition .............................................................................................. 58
4.15Water Injection System ................................................................................ 59
4.15.1Definition .............................................................................................. 59
4.16Compressor Inlet Guide Vanes System ....................................................... 61
4.16.1Definition .............................................................................................. 61
4.17 Inlet and Exhaust System ............................................................................ 62
4.17.1Definition .............................................................................................. 62
4.18 Fuel Purge System....................................................................................... 65
4.18.1 Definition ............................................................................................. 65
4.18.2Maintenance Schedule .......................................................................... 66
4.19Accessoryand Load Gear and Couplings ..................................................... 66
4.20Acoustical Enclosure .................................................................................... 67
4.21Electrical Auxiliary ...................................................................................... 68
4.22 System ......................................................................................................... 69
4.23Instrument Air System ................................................................................. 70
4.23.1General .................................................................................................. 72
4.23.2Screw compressor RAFALE 37 kW CMP301 ..................................... 72
4.23.3Compressed air tank 500L TK601 ........................................................ 73
4.23.4Air cooler ARO203HT CLR201 ........................................................... 74
4.23.5Water separator filter SEP201 & SEP302 ............................................ 75
4.23.6 Adsorption air dryer SAD255 DRY401 .............................................. 75
4.24Steam Injection System ................................................................................ 80
5 Generator ................................................................................................. 81
5.1Specification of Generator ............................................................................. 81
5.2 An Effective Maintenance Program of Generator ........................................ 82
5.3 Bearing .......................................................................................................... 85
5.4 Generator Coolers ......................................................................................... 86
5.5 Shaft Grounding Brushes .............................................................................. 88
5.6 Brushless exciter ........................................................................................... 89
5.6.1Periodic Maintenance .............................................................................. 89
5.6.2Replacementof Diodes ............................................................................ 89
5.6.3 Insulation Resistance.............................................................................. 90
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5.7The Basic Maintenance of the Series of 88BT .............................................. 90

5.8 Low Voltage Motors88BT-1/2 Maintenance ................................................ 91
5.9 Exhaust Chamber Cooling Air Fan 88EF1/2 ................................................ 94
5.10 Oil Mist Eliminator 88QV-1A .................................................................... 97
5.11Starting Motor 88CR .................................................................................... 98
5.12Turbine Motor 88TG and Auxiliary Hydraulic Oil Pump 88HQ .............. 102
5.12.1 Initial checks ...................................................................................... 102
5.12.2 Frequent monitoring ........................................................................... 102
5.12.3 Bearing Check .................................................................................... 103
5.12.4 Storage conditions .............................................................................. 103
5.12.5 Electrical checks................................................................................. 103
5.12.6 Mechanical checks. ............................................................................ 104
5.12.7 Long still standing periods ................................................................. 104
6 .Acoustic Enclosures Maintenance ...................................................... 104
6.1Gas Turbine Enclosure Maintenance Diagram ............................................ 104
6.2WI Module Enclosure Maintenance Diagram ............................................. 106
6.3Genertor Acoustic Enclosure Maintenance Diagram .................................. 106
6.4 Maintenance of PEECC .............................................................................. 107
6.4.1 System Maintenance ............................................................................ 107
6.4.2 Corrective Maintenance Instructions ................................................... 112
6.4.3 Storage Instructions.............................................................................. 113
Appendix – 1- SPARE PARTS OF APU SYSTEM......................................... 115
Appendix – 2- SPARE PARTS OF MCC......................................................... 122
Appendix – 3- SPARE PARTS OF EX2001 .................................................... 130
Appendix – 4- SPARE PARTS OF GENERATOR PROTECTION ............... 131
Appendix – 5- SPARE PARTS OF GENERATOR ACCESSORY
COMPARTMENT ............................................................................................ 134
Appendix – 6- SPARE PARTS OF FIRE FIGHTING ..................................... 137
Appendix –7- SPARE PARTS OF START MEANS ....................................... 138
Appendix –8- SPARE PARTS OF LUBE OIL SYSTEM ............................... 140
Appendix –9- SPARE PARTS OF ATPMIZING AIR SYSTEM.................... 143
Appendix –10- SPARE PARTS OF WATER WASH SKID ........................... 145
Appendix –11- SPARE PARTS OF SUMP TANK ......................................... 150
Appendix –12- SPARE PARTS OF WATER INJECTION ............................. 152
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5
1General
At all times when performing maintenance work on gas turbines the
following general practices should be observed:
1.1Safety First
Establish a risk assessment, secure access, always follow site safety
procedure, use permit to work and access permit supported by the relevant
lock out/tag out procedure disable unit’s fire protection system and provide an
alternate means of fire protection while the gas turbine’s system is disabled.
Warning
Fire suppressants, in a concentration sufficient to extinguish fire
create an atmosphere that will not support life. It is extremely hazardous
to enter the compartment after the fire protection system has discharged.
Anyone rendered unconscious by fire suppressant should be rescued as
quickly as possible and revived immediately with artificial respiration or
by mouth-to-mouth resuscitation. The extent and type or safeguards and
personnel warnings that may be necessary must be designed to meet the
particular requirements of each situation. It is recommended that
personnel be adequately trained to cope with such an emergency.
1.2Risk Assessment
Risk assessment is an important step in protecting the workers and the
business. It helps to focus on the risks that really matters in the workplace.
Risk assessment is the determination of quantitative or qualitative value of
risk related to a concrete situation and a recognized threat.
Risk assessment includes identifying hazard and risk. Hazard is anything
that may cause harm. Risk is the probability of harmful effect to human or to
ecological systems resulting from exposure to an environmental stressor.
Risk assessment shall be established prior to carry any work on the gas
turbine. It can be driven by specific procedure from the End User or from any
sources of good practice. Hazard and risk can be classified according to ISO
14121.
The main steps for risk assessment are:
Identify the activity, the hazards
Decide who might be harmed and how
Evaluate the risks and decide on precaution
Record your findings and implement them
1
Review your assessment and update if necessary
1.3Purge the Engine

Purge the engine of potentially hazardous fumes before opening casings,
by operating the unit at crank for 5 minutes, with all fuel shut off and purged.
Use extreme care to isolate and vent gas fuel systems
1.4 Keep Complete Records

Prepare and use specific inspection reports and form.
1.5Maintenance Tasks
Use penetrating oil prior to bolt removal. Recommended Solvents, sealers,
cleaners, etc... in this chapter for listing of acceptable penetrating oils).
Clean all removed parts and fasteners and store in separate containers,
tagged to simplify reassembly.
Protect all casing flanges from rust and mechanical damage after removal.
Grease, layout dye or commercial rust inhibitors will retard flange rusting, and
plywood, masonite or equal will prevent mechanical damage.
Debar mating surfaces and eliminate flange face high spots before
assembling any casings. Carborundum stones and flat mill files are effective
for these tasks.
Cover all open pipe and tubing. Do not stuff rags in pipes. Sheet metal or
plywood is effective covers for large pipes, and duct tape will protect tubing.
Never use pipe wrenches or pliers on tube fittings.
Do not reuse gaskets - unless specifically instructed to do so in the
procedures.
Do not reuse lock plates internal to the unit.
Match mark piping, fuel nozzles, couplings and casings to assist in proper
orientation during reassembly.
Don not mark on any combustion system or turbine components with any
compounds containing lead. Nickel base alloys are subject to attack when
heated in the presence of sulfur, lead, copper and other metals. These
materials can cause embritlement and cracking at elevated temperatures. Some
common sources of these compounds are copper hammers, paint, markers and
machining oil. Use of tags wired to the parts (avoid aluminum or other low
melting point alloys), and markers certified free of injurious materials can
eliminate this source of contamination.
1.6 Maintenance Checks

Observe the following general precautions when the unit is undergoing major
2
inspection, maintenance checks and taking clearance readings.
Axial readings must be taken with the rotor positioned downstream (toward
the exhaust end) in contact with the active face of the thrust bearing. Any
pressure applied in moving the rotor aft should be released prior to taking rotor
position or clearance measurements.
Parallel bars and feeler stock, when used with proper attention to detail,
provide good measurements. In order to obtain proper measurement accuracy,
the total thickness of the parallel bar and feeler stock must be measured with a
micrometer.
Snap gages may be used to obtain measurements when proper attention is
applied to the gage orientation. Snap gages used on bevel surfaces will result in
inaccurate readings. taper gages is not recommended because the pointed end of
the gage often “bottoms” on an internal curved surface before an accurate
reading can be obtained. This gage should not be used to take radial clearances.
Never rotate the unit rotor when the unit is undergoing inspection and
maintenance checks without adhering to the following precautions.
Check that the thrust bearing is fully assembled in unit.
Check close clearance areas for potential interference and foreign object
damage.
Warn personnel working on unit to stand clear.
Do not turn the rotor against direction of rotation
To properly tighten new Swagelok stop-collar fittings, snug the nut by hand
after cleaning threads. Then tighten the nut until the stop-collar just stops
turning
1.7Anti-seize Compound
Anti-seize compound shall be applied on all rotor and stator bolting
threads, dowels, rabbets and sliding fits (internal and external), external
bolting threads for mounting associated equipment, pipe flanges, ductwork
etc... Also apply on vertical flange faces of the top halves of outer casings that
may be subject to removal for maintenance.
NOTE
This usage must be restricted to a thin film such that the compound is
not forced into the inner gas path. Should this occur, it must, where
possible, be carefully removed.
Do not apply anti-seize compound to pipe threads or bolting threads internal
to oil or water tanks.
Anti-seize shall not contain sulfur
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1.8 Sealing Compound

Teflon Sealant X9366 (or equivalent) is to be used on all threaded
connections to cast iron castings, after control air filters, and in areas over
260°C (500°F). Apply to the male threads so that the first thread is free of any
compound. When a fitting is removed, the female threads shall be cleaned to
remove all loose particles of compound. Tefloc Sealant X9366 shall be used on
all pipe thread joints. The pipe thread must be clean and free of foreign material
before applying the sealant. Follow instructions on container.
1.9 Joint Compound

For compressor and turbine casings apply Perfect Seal only on the surface of
horizontal joint and only for a distance of one (1) inch (25.4 mm) on both sides
of the four (4) ways joint. The Perfect Seal shall not be applied on the surface of
the vertical joint.
Instant Seal Lock tite Plastic Gasket shall be used on all bolted oil to air
joints (vertical and horizontal) that are not gasketed and on plug openings. This
includes, but is not limited to, bearing housings, continuously lubricated
coupling guards and stationary oil seals. Instant Seal Loctite Plastic Gasket shall
not be used on vertical joints of non-bolted stationary oil seals.
Joint compound shall not be used on sheet metal joints except as follows:
Gasket tape used between exhaust skin, or plenum joints shall be coated on
both sides with Perfect Seal.
RTV-102 Silicone rubber adhesive sealant shall be used between
non-gasketed joints of inlet hoods or plenums. It shall be applied as a
continuous bead of minimum of 0.25 inch wide (6.35 mm) and shall be tangent
to the outboard edges of the flange bolt holes.
1.10Piping Flanges
Use anti-seize compound on the bolts.
Re-install flanges with clean flange surfaces, new gaskets, check gasket
positioning and check flanges concentricity and parallelism. Pipe flanges must
not be forced into alignment. Do not pry on the flanges. If flanges cannot be
brought to within 1/8” (3.18 mm) of parallel by hand, the piping should be
reformed or replaced.
When the flanges are parallel with a new gasket in place, insert the bolts by
hand, proceed to sequence tightening at the relevant tightening torque, secure
bolts with locknut or locking plate for nuts as per drawing.
4
1.11Bolt and Stud Torquing
1.11.1Before Torquing
Remove foreign matter from bolt, nut and bolting surfaces
Apply anti-seize compound to bolt and nut threads and bearing surfaces.
Tighten bolt/or nut to be sure threads are free, then back off until free from
surface. Snug against surface and torque to values shown in Table 1.11.1.
When using impact wrenches, torque to values in Table1.11.1
1.11.2Classification of Joints
All classes of joints (oil tight, air tight and for frame rigidity) with metal to
metal contact shall have their bolt or stud elongation determined by micrometer
measurements, torque wrench or by head rotation. See Tables1.11.1and1.11.2.
All gasket joints shall have their bolt and stud elongation determined by
micrometer measurements or torque wrench. See Tables1.11.1and1.11.2.
To ensure air tight joints there must be a 50 % contact over the critical area.
Burrs and high spots must be removed before assembly.
To ensure an oil tight joint, a line of continuous contact, with 0.25 inch (6.35
mm) minimum width, must be maintained, in addition to 50 % contact over the
critical area. The 50 % contact must be equally distributed over the critical area.
TORQUE VALUES FOR BOLTS AND STUDS – Table 1.11.1

TABLE 1 GENERAL TORQUE REQUIREMENTS
FOR NONSTRUCTURAL FLANGES
Nominal Bolt Head marking 1 Head marking 2 Head marking 3
Diameter& Six radial lines, None L, CR, B7, HB7 A2A, A2B, B8M
Threads Ft.Lbs.(Nm) Ft.Lbs.(Nm) Ft.Lbs.(Nm)
N 8-32 0.8-1(1.1-1.3) 0.8-1(1.1-1.3) 0.2-0.9(0.3-1.2)
N 10-32 2-3(2.7-4) 2-3(2.7-4) 1.5-2(2-2.7)
¼” - 20 5-6(6.8-8.1) 5-6(6.8-8.1) 4-5(5.4-6.8)
5/16” – 18 9-11(12.2-14.9) 9-11(12.2-14.9) 8-10(10.8-13.6)
3/8” - 16 17-21(23-28.5) 14-17(19-23) 11-14(14.9-19)
½” - 13 52-56(71-76) 43-45(58-61) 36-37(49-50)
5/8” - 11 98-105(133-142) 81-85(110-115) 68-69(92-94)
¾” - 10 161-178(218-241) 134-144(182-195) 111-117(151-159)
7/8” - 9 252-277(342-376) 209-224(283-304) 174-182(236-247)
1” – 8 366-407(496-552) 302-329(410-446) 251-267(340-362)
1”1/8 - 8 532-606(721-822) 438-490(594-664) 362-397(491-538)
1”1/4 – 8 699-804(948-1090) 573-650(777-881) 472-527(640-715)
1”3/8 - 8 950-1102(1288-1494) 778-891(1055-1208) 640-722(868-979)
1”1/2 - 8 1201-1400(1629-1898) 982-1132(1332-1535) 807-918(1094-1245)
5
Material: C1A3A,C1A5
Material:B50A125E, B5F5B3, C1A2A, C1A2B, C1A3A, C1A3B, C1A3C,
C1A3D, C1A5C1, C1A5D1
Material: C1F18A1, C1F19A1, C1F19A2, C2F9A, C2F10B
HORIZONTAL AND VERTICAL STRUCTURAL FLANGE
TORQUE– Table 1.11.2
TABLE 2 HORIZONTAL AND VERTICAL STRUCTURAL FLANGE
TORQUE
REQUIREMENTS 60KSI - 400MPa
BOLT DIAMETER & Threads APPLIED TORQUE
per INCH Ft.Lbs (Nm)
¾” - 10 208-229(282-311)
1” – 8 472-520(640-705)
1”1/4 – 8 918-1010(1245-1370)
1”1/2 – 8 1634-1797(2216-2437)
1”3/4 – 8 3370-3708(4570-5028)
2” – 8 6372-7010(8640-9505)
2”1/4 – 8 9205-10125(12482-13728)
2”1/2 - 8 12771-14048(17317-19047)
2”3/4 - 8 17129-18933(23227-25670)
3” - 8 22403-24761(30378-33572)
TABLE 3 HORIZONTAL AND VERTICAL STRUCTURAL FLANGE
TORQUE REQUIREMENTS 40KSI – 276MPa
BOLT DIAMETER & Threads APPLIED TORQUE
per INCH Ft.Lbs (Nm)
¾” - 10 139-153(188-207)
1” – 8 315-346(427-469)
1”1/4 – 8 612-674(830-914)
1”1/2 – 8 1089-1198(1477-1624)
1”3/4 – 8 2247-2472(3047-3352)
2” – 8 4248-4673(5760-6336)
2”1/4 – 8 6136-6750(8320-9152)
2”1/2 - 8 8514-9366(11545-12699)
2”3/4 - 8 11420-12622(15486-17113)
3” - 8 14936-16508(20253-22382)
NOTES:
MATERIALS TYPICALLY USED ON STRUCTURAL FLANGE
APPLICATIONS AREB5F5 AND B5OA125.
APPLICATION OF ANTISEIZE (item1) PER PARAGRAPH 2 IS
REQUIRED DURING EVERY ASSEMBLY CYCLE TO ACHIEVE THE
PROPER PRELOAD WHEN USING THE TORQUES VALUES SPECIFIED
ABOVE.
6
1.12 Recommend Solvents, Sealants, Cleaners, ETC.

GE Energy normally sends out lubricants, solvents and sealants as part of the
loose parts for turbine first installation. The listing below includes special items
recommended for use during maintenance operations. All may be procured
locally or from the manufacturer.
WARNING
Most solvents, sealants and cleaners are flammable at elevated
temperatures. Read and observe manufacturer’s precautions on
substance. Do not substitute gasoline or unknown substances for the
following recommended items.
1.12.1 Listing
DESCRIPTION
NAME REFERENCE
ORAPPLICATION
Non-hardening adhesive
Dux seal plastic 158A2557PT-1
compound.
DGY 1
Used on compartment door
Petrolatum Atlantic Richfield, Gulf Oil.
gaskets to prevent sticking.
Humble oil or equivalent
Silicone rubber sealant white
RTV-102 Adhesive General Electric Co.
paste.
Silicone rubber sealant. Good
RTV-106 Adhesive for high temperature areas red General Electric Co.
paste.
Locktite Pipe
Used on all pipe thread joints. 118D5700
Sealant with Teflon
Locktite Plastic
Oil to air sealing joints. 226A1482P1
Gasket #47
Bolting anti-seize compound,
Fel-Pro C-102 287A1397
high temperature.
Bolting anti-seize compound,
Never Seeze 248A5801
low temperature.
Perfect Seal Gasket sealing compound. K9692676
Contact Cement Exhaust system. 226A2449
Rubber Cement Heat exchanger head gaskets. 248A5557P1
High temperature aluminum
Paint 262A3194P1
silicone.
Rust inhibitive beige primer.
Paint 262A3195P1
Water reducible.
Thinner 1500
High temperature aluminum
Alkyd Resin General Electric Co.
paint.
05B7A
Thinner Carboline Exhaust system paint thinner Carboline Co.
7
33 for Carboline 11 Grey. 32 Hanley Ct.
St. Louis, Mo. 63122
Carboline Co.
Primer Carbo Zinc
Exhaust system paint. 32 Hanley Ct.
Grey
St. Louis, Mo. 63122
Galvanizing paint Unit walkways. 211A8426
Uniroyal Industrial
Apply on heat exchanger head
Adhesive Rubber 248A5557P1
gaskets.
Cement # 6128
Sealing Fiber Sealing fiber for use in
256A1201P4
Adaco electrical conduits.
Adaco # 1 Sealing Sealing compound for use in
256A1200P4
Compound electrical conduits.
Quick setting type suitable for
Adhesives 158A7228P1
outdoor environments.
3M2121 Strip Unit lagging, soft,
156A1563P2 or P1
Caulk non-hardening sealer.
MorelandChemical
Co. Sodiumilicote Heavy grade adhesive paste. 239A5612P19
Adhesive
Vimasco 136 Canvas lagging adhesive. 248A5660P1
Fluorescent penetrant, for From Magnaflux
Zyglo ZL22
crack checks. Corporation (Chicago, Ill.)
Plus Gas Formula From Dockrell Agencies
"A" Penetrating oil. (Scarborough, Ontario,
Dismantling Fluid Canada)
From KANO laboratories,
Kano "Kroil" Penetrating oil.
Inc. (Nashville, Tenn.)
WD-40 Company 1061
WD-40 Penetrating oil. Cudahy Place,
San Diego, Calif. 92116
Cleaning solvent (petroleum Standard Oil of Ohio,
Stoddard Solvent
spirits). Cleveland, Ohio 44115
Cleaning solvent (petroleum Exxon Company Pelham,
Exxon Varsol 1
spirits). N.Y. 10803
Cleaning solvent (petroleum Exxon Company Pelham,
Exxon Varsol 18
spirits). N.Y. 10803
Boron Fast Dry Cleaning solvent (petroleum Standard Oil of Ohio,
3137 spirits). Cleveland, Ohio 44115
Cleaning solvent (petroleum Eastern Chemicals Co.,
Multicleaner N°18
spirits). Albany, N.Y.
Turco Products Co.,
Turco Cold Spray Rust inhibitor.
Patterson, N.J.
Used to lubricate Dresser type Victaulic Co. of America,
Victaulic Lubricant
coupling pipe ends and rubber 3100 Hamilton Blvd., South
(SoapBase)
seal lips inside and outside Plainfield .N.J.07080
8
diameters.
Heat Transfer
Used in VTR temperature
Compound Grade 235A6987
regulating valve wells
Z-80
1.12.2 Note On Anti-seize Compound, High Temperature:

GE Energy has evaluated Fel-Pro C-102, Nickel-Ease, N5000 (Fel Pro
products) and Teutonic Power Tool’s 0505 as acceptable anti-seize
compounds. Although the four compounds listed above are recommended, use
of any other anti-seize compounds is acceptable provided they meet the
guidelines given in table 1.12.1.
A number of other commercially available compounds have been
considered as replacements. However, many have low melting point elements
such as aluminum, copper, or cadmium added in quantities that are detrimental
to the mechanical properties of nickel and cobalt based alloys used in gas
turbine parts (Reference 1). Therefore, the use of anti-seize compounds that
contain any of these added low melting point elements is not recommended.
Anti-seize Chemical Constituent Guidelines-Table 1.12.1
Element Maximum Contents
Lead 25 ppm
Aluminium, Cadmium, Tin, Zinc,

Silver, Tellurium, Selenium,
Antimony, Bismuth, Mercury, 300 ppm total, 100 ppm individual
Copper (present in the metallic state,
not as oxides or other compounds)
1.13 Ordering Renewal Parts

Spare and renewal parts orders should be placed with your local
GESERVICES office. When ordering parts for the gas turbine or associated
equipment, include the following information on the order:
Name of Purchaser.
Complete address of where shipment of the parts is to be made
The delivery requirements, method of shipment desired, and style of
packaging required (domestic, export, or long term storage).
Complete billing instructions and distribution instructions for
correspondence.
Complete information from the turbine nameplate.
9
Description or function of the part being ordered and location of the part
on the unit.
Part number (drawing number) stamped on the part or from a reference
drawing.
If a modification type drawing applies against the assembly from which
replacement parts are being ordered, note both the assembly and modification
drawing numbers and titles Quantity of items needed.
Parts which form one complete working unit must be ordered together; for
example, shafts and bushings, both halves of a bearing, etc...If no drawing,
parts list, or reference publication is available which shows the replacement
part required, a sketch or sample of the item, together with all necessary
dimensions and description of the part’s function, should accompany the order.
Attention to these directions will greatly expedite the shipment of spare and
renewal parts.
1.14 Repair and Replacement Parts

Faulty parts must be returned to GE Energy with joined filled out tags.
This operation will be done in accordance with your GE SERVICES
representative.
The repair of accessories not manufactured by GE Energy should be
handled through your GE SERVICES representative. This office shall
determine the approved location for repairs and assist with the expeditious and
economical return of the repaired component.
The order covering the repair and return of gas turbine components or
accessories to the factory or authorized repair center should contain:
The appropriate information required when ordering renewal parts. It
includes the serial number of the unit of which the returned article is a part,
the description of the article, the total operating hours of the component, the
explicit reason for the return of the part, drawing (part) number, and the
component serial number.
A complete filled out tag, must be attached to the returned article or boxed
with it.
Description of the returned articles.
Quantity of the tags used.
Date and method of returned shipment.
Waybill number and car number (and routing if carload shipment is
made).
Requested date for the return of the repaired components.
On parts for which the tags may become lost or destroyed, it is advisable
10
to paint or stencil (lead and sulfur free) the Purchaser’s name and the turbine
serial number on the part. This is particularly true on parts such as wheels,
diaphragms, nozzles and heavy castings. This practice will facilitate rapid
identification when the part reaches the repair facility.
Gas turbine division should be notified at once of the shipment. Returned
apparatus must be properly packaged and the parts protected to prevent
damage from rust, corrosion and handling. Adherence to the above
suggestions will facilitate checking and inspection of the returned material and
assure more expeditious repair of the material at the factory.
2 Maintenance Consideration
2.1 Introduce
Maintenance costs and availability are two of the most important concerns to
a heavy-duty gas turbine equipment owner. Therefore, a well thought out
maintenance program that optimizes the owner’s costs and maximizes
equipment availability should be instituted. For this maintenance program to be
effective, owners should develop a general understanding of the relationship
between the operating plans and priorities for the plant, the skill level of
operating and maintenance personnel, and all equipment manufacturer’s
recommendations regarding the number and types of inspections, spare parts
planning, and other major factors affecting component life and proper operation
of the equipment.
In this document, operating and maintenance practices for heavy-duty gas
turbines will be reviewed, with emphasis placed on types of inspections plus
operating factors that influence maintenance schedules. A well-planned
maintenance program will result in maximum equipment availability and
optimization of maintenance costs.
Note:
• The operation and maintenance practices outlined in this document are
based on full utilization of GE-approved parts, repairs, and services.
• The operating and maintenance discussions presented are generally
applicable to all GE heavy-duty gas turbines; i.e.,MS3000, 5000, 6000, 7000
and 9000. For purposes of illustration, the MS7001EA was chosen for most
components except exhaust systems, which are illustrated using different gas
turbine models as indicated. Consult the GE Operation and Maintenance
(O&M)Manual for specific questions on a given machine, or contact the local
GE Energy representative.
2.2 Maintenance Planning

Advanced planning for maintenance is a necessity for utility, industrial,
independent power and cogeneration plant operators in order to maximize
11
reliability and availability. The correct implementation of planned
maintenance and inspection provides direct benefits in reduced forced outages
and increased starting reliability, which in turn can reduce unscheduled repairs
and downtime. The primary factors that affect the maintenance planning
process are shown in Figure 1. The owners’ operating mode and practices will
determine how each factor is weighted. Parts unique to a gas turbine requiring
the most careful attention are those associated with the combustion process,
together with those exposed to the hot gases discharged from the combustion
system.
These are called the combustion section and hot gas path parts, and they
include combustion liners, end caps, fuel nozzle assemblies, crossfire tubes,
transition pieces, turbine nozzles, turbine stationary shrouds and turbine
buckets. Additional areas for consideration and planning, though longer-term
concerns, are the lives of the compressor rotor, turbine rotor, casings and
exhaust diffuser. The basic design and recommended maintenance of GE
heavy-duty gas turbines are oriented toward:
• Maximum periods of operation between inspections and overhauls.
• In-place, on-site inspection and maintenance.
• Use of local trade skills to disassemble, inspect and re-assemble gas
turbine components.
In addition to maintenance of the basic gas turbine, the control devices,
fuel-metering equipment, gas turbine auxiliaries, load package, and other
station auxiliaries also require periodic servicing.
The primary maintenance effort involves five basic systems: controls and
accessories, combustion, turbine, generator and balance-of-plant. Controls and
accessories are typically serviced in outages of short duration, whereas the
other four systems are maintained through less frequent outages of longer
duration. Gas turbine maintenance starts with a clear understanding of the
plant operation and the environment in which the plant operates. These two
factors should be the basis for developing a maintenance plan for gas turbines.
The inspection and repair requirements, outlined in the O&M Manual
provided to each owner, lend themselves to establishing a pattern of
inspections. These inspection patterns will vary from site to site and owner
operators should understand how factors such as air and fuel quality will be
used to develop an inspection and maintenance program. In addition,
supplementary information is provided through a system of Technical
Information Letters (TILs) associated with specific gas turbines after shipment.
This updated information, in addition to the O&M Manual, assures optimum
installation, operation and maintenance of the turbine. (See Figure 2.) Many
of the TILs contain advisory technical recommendations to help resolve
issues(as they become known) and to help improve the operation,
maintenance, safety, reliability or availability of the turbine. There
commendations contained in TILs should be reviewed and factored into the
12
overall maintenance planning program. For a maintenance program to be
effective, from both cost and turbine availability standpoints, owners must
develop a general understanding of the relationship between their operating
plans and priorities for the plant and the manufacturer’s recommendations
regarding the number and types of inspections, spare parts planning, and other
major factors affecting the life and proper operation of the equipment. Each of
these issues will be discussed in greater detail in the sections that follow.
Figure-1 Key factors affecting maintenance planning
Figure-2Key technical reference documents to include in maintenance

planning
13
3 Gas Turbine Maintenance Devices Inspection

Maintenance inspection types may be broadly classified as standby,
running and disassembly inspections. The standby inspection is performed
during off-peak periods when the unit is not operating and includes routine
servicing of accessory systems and device calibration. The running inspection
is performed by observing key operating parameters while the turbine is
running.
The disassembly inspection requires opening the turbine for inspection of
internal components and is performed in varying degrees. Disassembly
inspections progress from the combustion inspection to the hot gas path
inspection to the major inspection as shown in Figure 5. Details of each of
these inspections are described below.
3.1Borescope Inspection
An effective borescope inspection (BI) program can monitor the condition
of internal components without the need for casing removal. Borescope
inspections should be scheduled with consideration given to the operation and
environment of the gas turbine and information from the O&M manual and
TILs.
GE heavy-duty gas turbine designs incorporate provisions in both
compressor casings and turbine shells for gas path visual inspection of
intermediate compressor rotor stages, first, second and third-stage turbine
buckets and turbine nozzle partitions by means of the optical borescope. These
provisions, consisting of radially aligned holes through the compressor
casings, turbine shell and internal stationary turbine shrouds, are designed to
allow the penetration of an optical borescope into the compressor or turbine
flow path area, as shown in Figure 3. Borescope inspection access locations
for F Class gas turbines can be found in Appendix E.
Figure 4 provides a recommended interval for a planned borescope
inspection program following initial base line inspections. It should be
recognized that these borescope inspection intervals are based on average unit
operating modes. Adjustment of these borescope intervals may be made based
on operating experience and the individual unit mode of operation, the fuels
used and the results of previous borescope inspections.
In general, an annual or semiannual borescope inspection should use all
the available access points to verify the safe and uncompromised condition of
the static and rotating hard ware. This should include, but is not limited to,
signs of excessive gas path fouling, symptoms of surface degradation (such as
erosion, corrosion, or spalling), displaced components, deformation or impact
damage, material loss, nicks, dents, cracking, indications of contact or rubbing,
or other anomalous conditions.
Figure 3. MS7001E gas turbine borescope inspection access locations
14
Figure 4. Borescope inspection programming
Figure 5. MS7001EA heavy-duty gas turbine – shutdown inspections
15
Standard Parameter of Maintenance Inspection

Table -1 lists the inspection criteria for these areas of inspection.
Table -1 MS 9001 E Inspection Criteria
No. Access Area Inspect for
1 Compressor blades Foreign object damage. Dirt build up. Corrosion. Tip
erosion. Trailing edge thinning. Stator blade root
erosion. Tip clearance.
2 Combustion (Liner Carbon build up. Hot spots. Cracking.
& transition piece) Bulging. Wear. Missing metal.
3 Turbine nozzles Foreign object damage. Corrosion. Blocked cooling

holes.
Cracks. Trailing edge bowing. Erosion. Burning.
4 Turbine buckets Foreign object damage. Corrosion. Blisters. Erosion.
Cracks. Tip clearance. Missing metal.
Table -2 lists the access holes location, casing holes thread size, dimension
from forward or aft face of compressor discharge case and number of holes in
each location.
Table -2 MS-9001E Inspection Access Hole Location
Number
No. Identification Location
of holes
557.35 mm (21.943”) from aft
1 2nd stage compressor stator flange forward compressor 1
casing
2 3rd stage compressor stator 290.45 mm (11.435”) from aft 1
16
flange forward compressor
casing
683.69 mm (26.917”) from aft
3 6th stage compressor stator 1
flange aft compressor casing
518.69 mm (20.421”) from aft
356.57 mm (14.038”) from aft
155.60 mm (6.126”) from
6 11th stage compressor stator forward flange compressor 2
discharge casing
814.48 mm (32.066”) from
7 16th stage compressor stator forward flange compressor 2
discharge casing
1548.66 mm (60.971”) aft of
Aft compressor discharge
8 compressor discharge casing 1
casing
forward flange
1st stage nozzle trailing edge
292.51 mm (11.516”) from
9 and 1st stage bucket leading 8
forward turbine flange
edge
2nd stage nozzle leading edge 391.59 & 405.05 mm (15.417”
10 and 1st stage bucket trailing & 15.947”) from forward 8
edge turbine flange
2nd stage nozzle trailing edge
567.56 mm (22.345”) from aft
11 and 2nd stage bucket leading 5
turbine flange
edge
456.59 mm (17.976”) from aft
3rd stage nozzle leading edge
turbine flange & 832.87 mm
12 and 2nd-stage bucket trailing 5
(32.790”) from forward
edge
turbine flange
456.59 mm (17.976”) from aft
3rd stage nozzle trailing edge
turbine flange & 832.87 mm
13 and 3rd stage bucket leading 5
(32.790”) from forward
edge
turbine flange
3rd stage nozzle trailing edge
130.35 mm (5.132”) from aft
14 and 3rd stage bucket leading 5
turbine flange
edge
1st stage nozzle probes 336.55 mm (13.25”) from
15 4
(position check) forward turbine flange
1st stage turbine clearance 336.55 mm (13.25”) from
16 4
meter forward turbine flange
2st stage turbine clearance 491.74 mm (19.36”) from aft
17 4
meter turbine flange
3st stage turbine clearance 42.93 mm (1.69”) from aft
18 4
meter turbine flange
19 1st stage compressor 396.19 mm (15.598”) from 4
17
(clearance meter) forward flange of forward
compressor casing
384.81 mm (15.150”) from
6st stage compressor
20 forward flange of aft 4
(clearance meter)
compressor casing
457.61 mm (18.016”) aft of
(clearance meter)
forward flange
991.99 mm (39.055”) aft of
(clearance meter)
forward flange
3.2 Standby Inspections

Standby inspections are performed on all gas turbines but pertain
particularly to gas turbines used in peaking and intermittent-duty service
where starting reliability is of primary concern. This inspection includes
routinely servicing the battery system, changing filters, checking oil and water
levels, cleaning relays and checking device calibrations. Servicing can be
performed in off-peak periods without interrupting the availability of the
turbine. A periodic startup test run is an essential part of the standby
inspection.
The O&M Manual, as well as the Service Manual Instruction Books,
contains information and drawings necessary to perform these periodic checks.
Among the most useful drawings in the Service Manual Instruction Books for
standby maintenance are the control specifications, piping schematic and
electrical elementary. These drawings provide the calibrations, operating
limits, operating characteristics and sequencing of all control devices. This
information should be used regularly by operating and maintenance personnel.
Careful adherence to minor standby inspection maintenance can have a
significant effect on reducing overall maintenance costs and maintaining high
turbine reliability. It is essential that a good record be kept of all inspections
made and of the maintenance work performed in order to ensure establishing a
sound maintenance program.
3.3 Running Inspections

Running inspections consist of the general and continued observations
made while a unit is operating. This starts by establishing baseline operating
data during initial startup of a new unit and after any major disassembly work.
This baseline then serves as a reference from which subsequent unit
deterioration can be measured.
Data should be taken to establish normal equipment startup parameters as
well as key steady state operating parameters. Steady state is defined as
conditions at which no more than a5°F/3°C change in wheel space
temperature occurs over a15-minute time period. Data must be taken at
18
regular intervals and should be recorded to permit an evaluation of the turbine
performance and maintenance requirements as a function of operating time.
This operating inspection data, summarized inFigure6, includes: load versus
exhaust temperature, vibration, fuel flow and pressure, bearing metal
temperature, lube oil pressure, exhaust gas temperatures, exhaust temperature
spread variation and startup time. This list is only a minimum and other
parameters should be used as necessary. A graph of these parameters will help
provide a basis for judging the conditions of the system.
Deviations from the norm help pinpoint impending trouble, changes in
calibration or damaged components.
Figure 6. Operating inspection data parameters
3.4Load and Exhaust Temperature

The general relationship between load and exhaust temperature should be
observed and compared to previous data. Ambient temperature and barometric
pressure will have some effect upon the absolute temperature level. High
exhaust temperature can be an indicator of deterioration of internal parts,
excessive leaks or a fouled air compressor. For mechanical drive applications,
it may also be an indication of increased power required by the driven
equipment.
3.5 Vibration Level

The vibration signature of the unit should be observed and recorded.
Minor changes will occur with changes in operating conditions. However,
large changes or a continuously increasing trend give indications of the need
to apply corrective action.
19
3.6 Fuel Flow and Pressure

The fuel system should be observed for the general fuel flow versus load
relationship. Fuel pressures through the system should be observed. Changes
in fuel pressure can indicate the fuel nozzle passages are plugged, or that
fuel-metering elements are damaged or out of calibration.
3.7 Exhaust Temperature and Spread Variation

The most important control function to be observed is the exhaust
temperature fuel override system and the back-up over temperature trip
system. Routine verification of the operation and calibration of these functions
will minimize wear on the hot gas path parts.
3.8 Startup Time

Startup time is an excellent reference against which subsequent operating
parameters can be compared and evaluated. A curve of the starting parameters
of speed, fuel signal, exhaust temperature and critical sequence bench marks
versus time from the initial start signal will provide a good indication of the
condition of the control system. Deviations from normal conditions help
pinpoint impending trouble, changes in calibration or damaged components.
3.9 Coast-Down Time

Coast-down time is an excellent indicator of bearing alignment and
bearing condition. The time period from when the fuel is shut off on a normal
shutdown until the rotor comes to turning gear speed can be compared and
evaluated. Close observation and monitoring of these operating parameters
will serve as the basis for effectively planning maintenance work and material
requirements needed for subsequent shutdown periods.
3.10 Rapid Cool-Down

Prior to an inspection, it may be necessary to force cool the unit to speed
the cool-down process and shorten outage time. Force cooling involves
turning the unit at crank speed for an extended period of time to continue
flowing ambient air through the machine. This is permitted, although a natural
cool-down cycle on turning gear or ratchet is preferred for normal shutdowns
when no outage is pending. Forced cooling should be limited since it imposes
additional thermal stresses on the unit that may result in a reduction of parts
life. Opening the compartment doors during any cool-down operation is
prohibited unless an emergency situation requires immediate compartment
inspection—which requires that the doors be opened. Cool-down times should
not be accelerated by opening the compartment doors or lagging panels, since
uneven cooling of the outer casings may result in excessive case distortion and
blade rubs that could potentially lead to tip distress if the rubs are significant.
20
3.11 Combustion Inspection

The combustion inspection is a relatively short disassembly shutdown
inspection of fuel nozzles, liners, transition pieces, crossfire tubes and
retainers, spark plug assemblies, flame detectors and combustor flow sleeves.
This inspection concentrates on the combustion liners, transition pieces, fuel
nozzles and end caps which are recognized as being the first to require
replacement and repair in a good maintenance program. Proper inspection,
maintenance and repair (Figure 7) of these items will contribute to a longer
life of the downstream parts, such as turbine nozzles and buckets.
Figure 5 illustrates the section of an MS7001EA unit that is disassembled
for a combustion inspection. The combustion liners, transition pieces and fuel
nozzle assemblies should be removed and replaced with new or repaired
components to minimize downtime. The removed liners, transition pieces and
fuel nozzle scan then be cleaned and repaired after the unit is returned to
operation and be available for the next combustion inspection interval.
Typical combustion inspection requirements forMS6001B/7001EA/9001E
machines are:
• Inspect and identify combustion chamber components.
• Inspect and identify each crossfire tube, retainer and combustion liner.
• Inspect combustion liner for TBC spalling, wear and cracks. Inspect
combustion system and discharge casing for debris and foreign objects.
• Inspect flow sleeve welds for cracking.
• Inspect transition piece for wear and cracks.
• Inspect fuel nozzles for plugging at tips, erosion of tip holes and safety
lock of tips.
• Inspect all fluid, air, and gas passages in nozzle assembly for plugging,
erosion, burning, etc.
•Inspect spark plug assembly for freedom from binding; check condition
of electrodes and insulators.
• Replace all consumables and normal wear-and-tear items such as seals,
lockplates, nuts, bolts, gaskets, etc.
• Perform visual inspection of first-stage turbine nozzle partitions and
borescope inspect (Figure 3) turbine buckets to mark the progress of wear and
deterioration of these parts. This inspection will help establish the schedule for
the hot gas path inspection.
• Perform borescope inspection of compressor.
• Enter the combustion wrapper and observe the condition of blading in
the aft end of axial-flow compressor with a borescope.
21
• Visually inspect the compressor inlet, checking the condition of the
IGVs, IGV bushings, and first stage rotating blades.
• Check the condition of IGV actuators and rack-and-pinion gearing.
• Visually inspect compressor discharge case struts for signs of cracking.
• Visually inspect compressor discharge case inner barrel if accessible.
• Visually inspect the last-stage buckets and shrouds.
• Visually inspect the exhaust diffuser for any cracks inflow path surfaces.
Inspect insulated surfaces for loose or missing insulation and/or attachment
hardware in internal and external locations. In E-class machines, inspect the
insulation on the radial diffuser and inside the exhaust plenum as well.
• Inspect exhaust frame flex seals, L-seals, and horizontal joint gaskets for
any signs of wear or damage.
• Verify proper operation of purge and check valves. Confirm proper
setting and calibration of the combustion controls.
After the combustion inspection is complete and the unit is returned to
service, the removed combustion hardware can be inspected by a qualified GE
field service representative and, if necessary, sent to a qualified GE Service
Center for repairs. There moved fuel nozzles can be cleaned on-site and flow
tested on-site, if suitable test facilities are available. For F Class gas turbines it
is recommended that repairs and fuel nozzle flow testing be performed at
qualified GE Service Centers.
Figure 7. Combustion inspection – key elements
22
3.12 Hot Gas Path Inspection

The purpose of a hot gas path inspection is to examine those parts exposed
to high temperatures from the hot gases discharged from the combustion
process. The hot gas path inspection outlined in Figure 8 includes the full
scope of the combustion inspection and, in addition, a detailed inspection of
the turbine nozzles, stator shrouds and turbine buckets. To perform this
inspection, the top half of the turbine shell must be removed. Prior to shell
removal, proper machine centerline support using mechanical jacks is
necessary to assure proper alignment of rotor to stator, obtain accurate
half-shell clearances and prevent twisting of the stator casings. The
MS7001EA jacking procedure is illustrated in Figure 9Special inspection
procedures may apply to specific components in order to ensure that parts
meet their intended life. The special inspections may include, but are not
limited to, dimensional inspections, Fluorescent Penetrant Inspection (FPI),
Eddy Current Inspection (ECI) and other forms of non-destructive testing
(NDT).The type of inspection required for specific hardware is determined on
a part number and operational history basis, and can be obtained from a GE
service representative. Similarly, repair action is taken on the basis of part
number, unit operational history, and part condition. Repairs including (but
not limited to) strip, chemical clean, HIP (Hot Isotactic Processing), heat treat,
and recoat may also be necessary to ensure full parts life. Weld repair will be
recommended when necessary, typically as determined by visual inspection
and NDT. Failure to perform the required repairs may lead to retirement of the
part before its life potential is fulfilled. In contrast, unnecessary repairs are an
unneeded expenditure of time and resources. To verify the types of inspection
and repair required, contact your service representative prior to an outage.
Figure 8. Hot gas path inspection – key elements
Figure 9. Stator tube jacking procedure – MS7001EA
23
For inspection of the hot gas path (Figure 5), all combustion transition
pieces and the first-stage turbine nozzle assemblies must be removed.
Removal of the second- and third-stage turbine nozzle segment assemblies is
optional, depending upon the results of visual observations, clearance
measurements, and other required inspections. The buckets can usually be
inspected in place.
Fluorescent penetrant inspection (FPI) of the bucket vane sections may be
required to detect any cracks. In addition, a complete set of internal turbine
radial and axial clearances(opening and closing) must be taken during any hot
gas path inspection. Re-assembly must meet clearance diagram requirements
to ensure against rubs and to maintain unit performance. Typical hot gas path
inspection requirements for all machines are:
• Inspect and record condition of first, second and third-stage buckets. If it
is determined that the turbine buckets should be removed, follow bucket
removal and condition recording instructions. Buckets with protective coating
should be evaluated for remaining coating life.
• Inspect and record condition of first-, second- and third-stage nozzles.
• Inspect and record condition of later-stage nozzle diaphragm packings.
• Check seals for rubs and deterioration of clearance.
• Record the bucket tip clearances.
• Inspect bucket shank seals for clearance, rubs and deterioration.
• Perform inspections on cutter teeth of tip-shrouded buckets. Consider
refurbishment of buckets with worn cutter teeth, particularly if concurrently
refurbishing the honeycomb of the corresponding stationary shrouds. Consult
your GE Energy representative to confirm that the bucket under consideration
is repairable.
• Check the turbine stationary shrouds for clearance, cracking, erosion,
oxidation, rubbing and build-up.
• Check and replace any faulty wheel space thermocouples.
• Enter compressor inlet plenum and observe the condition of the forward
24
section of the compressor.
• Visually inspect the compressor inlet, checking the condition of the
IGVs, IGV bushings, and first stage rotating blades.
• Enter the combustion wrapper and, with a borescope, observe the
condition of the blading in the aft end of the axial flow compressor.
• Visually inspect the turbine shell shroud hooks for sign of cracking.
• Visually inspect the exhaust diffuser for any cracks in flow path surfaces.
• Inspect exhaust frame flex seals, L-seals, and horizontal joint gaskets for any
signs of wear or damage
The first-stage turbine nozzle assembly is exposed to the direct hot gas
discharge from the combustion process and is subjected to the highest gas
temperatures in the turbine section. Such conditions frequently cause nozzle
cracking and oxidation and, in fact, this is expected. The second- and third-stage
nozzles are exposed to high gas bending loads, which in combination with the
operating temperatures, can lead to downstream deflection and closure of critical
axial clearances. To a degree, nozzle distress can be tolerated and criteria have
been established for determining when repair is required. These limits are
contained in the Operations and Maintenance Manuals previously described.
However, as a general rule, first stage nozzles will require repair at the hot gas
path inspection. The second- and third-stage nozzles may require refurbishment
to re-establish the proper axial clearances. Normally, turbine nozzles can be
repaired several times and it is generally repair cost versus replacement cost that
dictates there placement decision.
Coatings play a critical role in protecting the buckets operating at high metal
temperatures to ensure that the full capability of the high strength super alloy is
maintained and that the bucket rupture life meets design expectations. This is
particularly true of cooled bucket designs that operate above 1985°F (1085°C)
firing temperature. Significant exposure of the base metal to the environment will
accelerate the creep rate and can lead to premature replacement through a
combination of increased temperature and stress and a reduction in material
strength, as described in Figure 10. This degradation process is driven by
oxidation of the unprotected base alloy. In the past, on early generation uncooled
designs, surface degradation due to corrosion or oxidation was considered to be a
performance issue and not factor in bucket life. This is no longer the case at the
higher firing temperatures of current generation designs. Given the importance of
25
coatings, it must be recognized that even the best coatings available will have a
finite life and the condition of the coating will play a major role in determining
bucket life. Refurbishment through stripping and recoating is an option for
achieving bucket’s expected/design life, but if recoating is selected, it should be
done before the coating is breached to expose base metal. Normally, for turbines
in the MS7001EA class, this means that recoating will be required at the hot gas
path inspection. If recoating is not performed at the hot gas path inspection, the
life of the buckets would generally extend to the major inspection, at which point
the buckets would be replaced. For F class gas turbines, recoating of the first
stage buckets is recommended at each hot gas path inspection. Visual and
borescope examination of the hot gas path parts during the combustion
inspections as well as nozzle-deflection measurements will allow the operator to
monitor distress patterns and progression. This makes part-life predictions more
accurate and allows adequate time to plan for replacement or refurbishment at the
time of the hot gas path inspection. It is important to recognize that to avoid
extending the hot gas path inspection, the necessary spare parts should be on site
prior to taking the unit out of service.
Figure 10. Stage 1 bucket oxidation and bucket life
3.13 Major Inspection

The purpose of the major inspection is to examine all of the internal rotating
and stationary components from the inlet of the machine through the exhaust. A
major inspection should be scheduled in accordance with the recommendations
in the owner’s Operations and Maintenance Manual or as modified by the
results of previous borescope and hot gas path inspection. The work scope
shown in Figure 41 involves inspection of all of the major flange-to-flange
components of the gas turbine, which are subject to deterioration during normal
turbine operation. This inspection includes previous elements of the combustion
and hot gas path inspections, in addition to laying open the complete
flange-to-flange gas turbine to the horizontal joints, as shown in Figure 12.
26
Removal of all of the upper casings allows access to the compressor rotor
and stationary compressor blading, as well as to the bearing assemblies. Prior to
removing casings, shells and frames, the unit must be properly supported.
Proper center line support using mechanical jacks and jacking sequence
procedures are necessary to assure proper alignment of rotor to stator, obtain
accurate half shell clearances and to prevent twisting of the casings while on the
half shell. Typical major inspection requirements for all machines are:
• All radial and axial clearances are checked against their original values
(opening and closing).
• Casings, shells and frames/diffusers are inspected for cracks and erosion.
• Compressor inlet and compressor flow-path are inspected for fouling,
erosion, corrosion and leakage.
• Visually inspect the compressor inlet, checking the condition of the IGVs,
IGV bushings, and first stage rotating blades.
• Rotor and stator compressor blades are checked for tip clearance, rubs,
impact damage, corrosion pitting, bowing and cracking.
• Turbine stationary shrouds are checked for clearance, erosion, rubbing,
cracking, and build-up.
• Seals and hook fits of turbine nozzles and diaphragms are inspected for
rubs, erosion, fretting or thermal deterioration.
• Turbine buckets are removed and a nondestructive check of buckets and
wheel dovetails is performed (first stage bucket protective coating should be
evaluated for remaining coating life). Buckets that were not recoated at the hot
gas path inspection should be replaced. Wheel dovetail fillets, pressure faces,
edges, and intersecting features must be closely examined for conditions of
wear, galling, cracking or fretting.
• Rotor inspections recommended in the maintenance and inspection manual
or by Technical Information Letters should be performed.
• Bearing liners and seals are inspected for clearance and wear.
• Inlet systems are inspected for corrosion, cracked silencers and loose parts.
• Visually inspect compressor and compressor discharge case hooks for
signs of wear.
• Visually inspect the turbine shell shroud hooks for sign of cracking.
Figure 11. Gas turbine major inspection – key elements
27
Figure 12. Major inspection work scope
• Visually inspect the exhaust diffuser for any cracks in flow path surfaces.
28
• Inspect exhaust frame flex seals, L-seals, and horizontal joint gaskets for
any signs of wear or damage. Inspect steam gland seals for wear and oxidation.
• Check torque values for steam gland bolts and re-torque to full values.
• Check alignment – gas turbine to generator/gas turbine to accessory gear
4 Gas Turbine Auxiliaries Maintenance Schedule Guide
4.1 Introduction
The present document related to the maintenance of the accessories of gas
turbines is a guide for the End User’s maintenance Engineers.
The aim of this document is to give maintenance interval and
recommendation for the gas turbine accessories systems and their components.
The maintenance activities recommended in this guide are typical and do
not pertain to any particular plant equipment model.
Maintenance activities are mainly driven by periodical checkup and routine
inspections.
● Periodical checkup are jobs to be carried out at predetermined frequencies
like monthly, annually, or during gas turbine inspections as combustion, hot gas
path, major.
● Routine inspections are checkup carried out more often like daily, weekly,
in relation with gas turbine operation. They are related to parameters read out
and analysis, visual inspection, abnormal noise, as explained in the Operation
volume.
● Routine inspections may impact periodical maintenance activities and
may shorten the frequencies defined in the tables here below.
The present document applies for accessories of gas turbines frame 6B, 6C,
6FA, 9E.
4.2Safety
The End User shall take appropriate steps to ensure that only workers who
have received adequate instruction shall have access to equipment. The End
User shall ensure site safe work practices are implemented and enforced (e.g.
proper operator response action to control system alarms, energy isolation
procedures (lockout/tag out), personal protective equipment, permit space entry
procedures, posting of warning signs, training, Material Safety Data Sheets
(MSDS), etc.).
The End User shall ensure that site safe work practices integrate access
permit, work permit and relevant permits and procedures to cover all aspect of
29
safety.
Content of Tables
Maintenance schedule and maintenance activities of each device of a single
system are listed, system by system, in the different tables below. Some devices
like pressure transducers, check valves, orifices, installed in different systems
have identical maintenance schedule and maintenance activities whatever the
system they belong to. These devices are grouped in the first table called
“Standard devices”. The tables are divided into several columns. The two first
are:
Device: designation of the device,
NOTE
Underlined device names are only for a specific gas turbine frame
Check / inspect: list the maintenance activities
The other columns tell how often a device or an equipment should be
inspected and whether or not the turbine can be operating at the time of the
inspection. The meaning of the letters used is:
D: Daily Inspection
W: Weekly Inspection
M: Monthly Inspection
Q: Quarterly Inspection
SA: Semi-annual Inspection
CI: Combustion Inspection
HGPI: Hot Gas Path Inspection
MI: Major Overhaul Inspection
O: Turbine Operating
S: Turbine Shutdown
The recommended maintenance activities, frequencies and turbine status
are representative of an average power plant installation and include both
peaking and continuous operating stations. They are not intended to cover all
variations of equipment supplied and may depend upon station environment. In
some cases, a shutdown may be recommended solely as a precaution against
possible injury to maintenance personnel, because the location of the
component or device is in a hazardous area.
As per GER 3620 maintenance activities are influenced by many factors
like the type and quality of fuel, the starting cycle, the power setting and duty
application, the steam/water injection. Maintenance interval requirement for
below listed devices may also be impacted by those factors. Due to enormous
30
variety of operating conditions from a power plant to another, maintenance
adjustment has to be based on experience and observations made by the End
User.
Lubrication frequency will vary, depending on turbine operating hours and
ambient temperature. It is therefore suggested to keep records of lubrication
intervals to determine variances between periods listed on the chart and those
scheduled for a specific installation.
For all the devices listed here below, always refer to the Original
Equipment Manufacturer (OEM)technical literature / equipment publication
for accurate information regarding maintenance schedule and maintenance
activities for each device.
31
4.3 Standard Devices

Standard Devices
Daily – Weekly- Monthly – Quarterly – Semi-annually – Combustion Inspection – Hot Gas Path Inspection Major
Inspection – X other period O : turbine Operating – S : turbine Shut down
Device Check/inspect D W M Q S CI HGPI MI X
� External visual check for fluid leak, device damage O
Accumulator � Check inert gas pressure, fill up or change the parts
as necessary S
Check valve � Check good operation, erosion, corrosion, sealing on
back pressure, cracking pressure if applicable S
� External visual check device damage O
Dew point
� Check settings and adjust if necessary according to
transducer
device summary S
� Check pressure drop.
Filter S
� Replace cartridges at high level pressure drop O
� Replace cartridges regardless of pressure drop S
� Check during each start up and shut down sequence S
that the flame detector detect presence of flame and
absence of flame
Flame
� Check cleanliness of lens. Check detection of flame
detector
using an ultraviolet source in front of the sensor (at
400-500 mm distance) before starting at the end of
maintenance period S S S
� Visual external and internal inspection per S
Flexible GEK111694. Replace the component by new one if
metal hose any defect appears on visual inspection.
� Pressure test per GEK111694 S
32
Standard Devices
Flowmeter � Check flow signal with test bench and adjust if
possible according to device specification or replace it S
� Check filter (if any) for dirt, clogging O
� Clean device, fan blades (if any), ducts S
Heater (space
� Electrical insulation, electrical consumption, loose S
heater)
connection S
� Check performances
� Tube and shell inspection if loss of
Heat
performance :pressure droop increase or reduction of S
exchanger
thermal efficiency
� Check Wall thickness S
� External visual inspection : no physical damage O
Heat tracing � Electrical part insulation measurement and good
operation test before winter every year S
� External visual check device damage O
Humidity
� Check settings and adjust if necessary according to
transducer
device summary S
Liquid level
� Check device accuracy and adjust if necessary
indicator
according to device specification S
� External visual check for device damage, good O S
operation of actuator mechanism
Limit switch
� Check that the mechanism move freely without
jamming, check mechanism alignment, check if
33
Standard Devices
excessive wear, adjust or replace if necessary, S
according to device specification.
� Check electrical connection and cable gland
� External visual check for device damage, good O
LVDT
operation of actuator mechanism
(Linear
� Check electrical circuits for loose connection or
voltage
corrosion S
differential
� Check that output signal versus valve stroke is
transducer)
according to device summary S
� Check electrical circuits for loose connection or
Magnetic S
corrosion
pick up S
� Check gap is within the specified limits
O
� Check vibration level O
� Cleanliness, abnormal noise
� Brush connection S
� No loose mounting bolts, no loose electrical
Motors
connection, check cable gland S
(Electrical)
� No loose mounting bolt for driven equipment S
� Alignment within tolerances (when applicable) S
� Coupling : bolt tightening and grease
� Grease bearing as necessary S
S
Orifice plate � Check for erosion, plugging, deterioration, sharp
edge or irregular chamfer, original diameter, replace if S
34
Standard Devices
out of tolerances
� External visual check for fluid leak, pipe damage, O
Pipe slip joint loose support, damage insulation
coupling � Coupling in the alignment of the pipe, not in contact
to the stop lateral limit S
� External visual check for fluid leak, pipe damage, O
Piping
loose support, damaged insulation
� External visual check for fluid leak, device damage, O
corrosion
Pressure
� Reading and accuracy : test the pressure gauge using
gauge
a dead weight tester or other equivalent calibrated
means S
leak at stem
Pressure
� Control regulated pressure when measuring means
regulating O
is available
valve(VPR)
� Check settings with test bench and adjust if
necessary according to device summary S
� When test valve is provided, check alarm sequence
Pressure
if applicable O
switch
Pressure
Transducer
necessary according to device summary
35
Standard Devices
S
� Clean the filter housing, clean or replace the filter S
Porous stone
element, check the cleanliness of continuous blow
filter
down line
chattering
Relief valve
Rubber � External visual check for fluid leak, device damage O
bellow � Replace the device every ten years if necessary
Rubber
compensator S
Servovalve � External visual check for fluid leak, device damage, O
chattering
� Check fixing screw, tightening torque, Null Bias S
Solenoid � External visual check for fluid leak, device damage, O
valve chattering, leak at packing or stem
� Check proper operation and seat air tightness with
air pressure if necessary S
Strainer � External visual check for fluid leak, device damage O
� Check cleanliness, dirt characteristics, scale S
Temperature � External visual check for fluid leak, device damage O
regulating � Control regulated temperature when measuring
valves(VTR) means is available O
necessary S
36
Standard Devices
according to device summary
Temperature � External visual check for fluid leak, device damage O
switch � Check settings with test bench and adjust if S
Thermostat necessary according to device summary
Thermometer � External visual check for fluid leak, device damage, O

corrosion
� Reading and accuracy : test the device in an agitated
bath with reference thermometer or other equivalent
calibrated means S
Valve � External visual check for fluid leak, device damage O
� Leakage at stem O
� State of valve plug, seat and seals S
Vibration � External visual check for device damage and O
seismic mounting secure
sensor � Check vibration signal with vibrating table. Adjust if
possible according to device summary or replace the
device S
Vibration � Check routing of cabling for any probe that has
shaft errors at the control panel. Check the electrical
S
displacement connection at each junction for corrosion/humidity.
probe Check for oil leak.
� Proceed to same checks as above for key phasor
S
� Check and recalibrate each probe loop according to
OEM. Refer to TIL1607 S
37
4.4 Lubricating Oil System
4.4.1Definition
• To lubricate the shaft line including the accessory gear box 

• To provide oil for the Hydraulic system
• To provide oil for the torque converter
The lubricating oil system is a close loop where oil flow is built up from the
oil tank located in the lower part of the accessory base by:
• A shaft driven main pump 
• An Alternative Current motor driven auxiliary pump for starting and
shutdown sequences 
• A Direct Current motor driven emergency pump for emergency shutdown
Lubricating oil conditioning includes:
• Oil tank warming up to keep acceptable oil viscosity while the unit is at
standstill.
• Oil flow cooling down to evacuate heat from the bearings.
• Oil flow filtering.
• Oil Header Pressure regulating at constant pressure.
• Oil mist elimination.
Bearings feeding and return lines are concentric lines; feeding line is installed
in return line. The lubricating oil flows back in the tank by gravity.
Part of the gas turbine bearing sealing air provided by the compressor returns
with the oil in the oil tank and is evacuated to the atmosphere through the oil mist
eliminator.
4.4.2 Maintenance Schedule
38
LUBRICATING OIL SYSTEM

Daily – Weekly- Monthly – Quarterly – Semi-annually – Combustion Inspection – Hot Gas Path Inspection Major Inspection
– X other period O : turbine Operating – S : turbine Shut down
� Take a sample for routine control analysis (defined in O
specification 91-438752) and check characteristics according to
GE specification
Lubricating
� Take a sample for complete analysis (defined in specification S
oil
91-438752) and check characteristics according to GE
specification
� Change oil if out of specification S
� External visual check for lube oil level, lube oil leak O
Lube oil
� Check inside the tank : peeling paint, loose S
tank
component, loose fitting, loose clamp
� External visual check for fluid leak, device damage, excessive O
noise
� Gas turbine on continuous operation : check starting sequence
Lubeoil of AC pump using test valve except if included in the software by
weekly test. O S
pumps
� Check outlet pressure, electrical power and vibration are
according to pump and motor characteristics
� Grease motor and pump according to manufacturer literature S
Lube oil � Replace cartridges by a set of new one regardless of the S
filter pressure drop, including standby filter
39
LUBRICATING OIL SYSTEM

Daily – Weekly- Monthly – Quarterly – Semi-annually – Combustion Inspection – Hot Gas Path Inspection Major Inspection
– X other period O : turbine Operating – S : turbine Shut down
O
� External visual check for fluid leak, device damage, excessive

noise S
� Replace coalescent cartridges by a new set. New cartridges
Oil Mist must be manually fully oil imbibed before operation
eliminator � check good operation of internal damper and check valves S
� Clean the vent area
� Adjust oil tank pressure after maintenance after inspection S
O
� Test the valve for smooth open/close movement, lubricate with S
Compressor
high temperature anti-seize compound to all moving parts, as
bleed valve
necessary. Check air tightness
Compressor S
Bleed � Test the valve for smooth open/close movement Apply
Solenoid anti-seize compound to all moving parts
Valve
� External visual check for excessive noise or vibration O
S
Blower � Cleanliness of ducts, housing, screens, blades
S
� Erosion of blades, deposit on blades, rust, corrosion, peeling
40
4.4.3 Lubricating Oil Recommendations for Gas Turbines
These instructions contain information intended to help the purchaser of a

General Electric gas turbine and the lubricant supplier to select the proper grade
and quality of lubricating oil for the turbine application.
The successful operation of the gas turbine and its driven equipment is vitally
dependent upon the lubrication system. Therefore, it is necessary that all factors
contributing to correct lubrication be present and that the entire system be
maintained in good order.
The life of the apparatus depends upon a continuous supply of lubricant of
proper quality, quantity, temperature, and pressure.
When applying a new lubricating oil it is recommended that laboratory test
comparisons be made with a known successful oil.
4.4.3.1 Recommended physical properties
The lubricating oil intended for this service is a rust and oxidation inhibiting
petroleum lubricating oil or synthetic hydrocarbon with greater high temperature
oxidation stability than conventional lubricating oils. Operating experience has
shown the antioxidant of the di-tertiary butyl-para-cresol (DBPC) type is not
adequate for this service. The inhibitors must be of the non-volatile type.
A listing of recommended properties of new oil is shown in Table 1. Included
with this listing is the ASTM test method and the recommended value. The reader
should refer to these methods for details of the tests. The oil is an International
Standards Organization Viscosity Grade 32 (ISO VG 32) oil. The properties
listed are rather typical of turbine lubricating oils except for the oxidation test
requirements. Note that the values in Table 1 are only recommended values. An
oil that has been shown to perform successfully in the field may still be used even
if all values in Table 1 have not been satisfied.
For several years there have been investigations to decide on appropriate
laboratory tests which could distinguish between fluids which gave satisfactory
service in a turbine and those which did not. To date, there has not been complete
correlation between laboratory testing and field experience.
There are three methods recognized by the ASTM for determining carbon
residue. They are D-524,“Ramsbottom Carbon Residue of Petroleum Products”,
D-4530, “Determination of Carbon Residue(Micro Method)” and D-189,
“Conradson Carbon Residue of Petroleum Products”. Although these methods are
similar in concept, they do not provide identical results. Each method contains a
graph that can be used to convert the results for comparison to the other methods.
Although Table 1 only contains acceptance criteria for D-524, either of the other
two methods can be used instead provided the results obtained are equivalent to
the value contained in Table 1 for D-524.
Two oxidation tests are listed in Table 1. The ASTM D-943 (Oxidation
41
Characteristics of Inhibited Steam-Turbine Oils) minimum value must be
satisfied for this service. In addition, both of the Oxidation Stability by Rotating
Bomb tests described below must be satisfied.
ASTM D-2272, Standard Test Method for Oxidation Stability of Steam
Turbine Oils by Rotating Bomb, presently shows the best correlation with service
experience but it is not absolute. It has been found that the volatility of the
inhibitor can have a significant effect on the results of this test. As stated above,
these inhibitors need to be non-volatile.
The ASTM D-2272 test should be run in the normal way and a second test run
on oil which has been treated to remove volatiles. This pretreatment is done by
putting the oil to be tested in a test tube 38 mm ID× 300 mm L. (This is the same
tube used for the International Harvester BT-10 oxidation test.) This tube is
immersed in a bath maintained at 250_F (l21_C). Clean, dry nitrogen is then
bubbled through the heated oil for 48 hours at the rate of 3 liters per hour. The
treated oil is then tested per ASTM D-2272.
4.4.3.2 Corrosion-Preventative Materials
Manufacturing procedures provide for corrosion protection by cleaning and
treating all metal surfaces which will be in contact with the lubricating oil in the
lubrication system.
The inside walls of the lubricating oil tank are processed at the factory using an
oil-resistant paint.
The inner surfaces of all lubricating oil piping, bearings, hydraulic control
devices, and other apparatus whose surfaces will be in contact with the turbine
lubricating oil are coated with a vapor space rust-inhibited(VSI) lubricating oil
which is used as a combination test and shipping oil.
In addition, 50 gallons of this oil is put in the reservoir at shipment and the
system openings are closed. The oil and its vapors provide corrosion protection
during shipment and installation.
At installation this oil should be removed and the reservoir manually cleaned.
The remaining VSI oil should be removed with a displacement flush.
4.5Trip Oil System
Trip Oil System

Daily – Weekly- Monthly – Quarterly – Semi-annually – Combustion Inspection –
Hot Gas Path Inspection Major Inspection – X other period O : turbine Operating –
S : turbine Shut down
� Check good operation S
Tripping of tripping device
device
� Check for sludge S
42
Trip Oil System

and/or varnishing
deposit on spool
and bore of tripping
device
4.6Cooling Water System
4.6.1Definition
The cooling water system is designed for insuring cooling down of:
• The lubricating oil
• The turbine supports
• The flame detectors
• The atomizing air system
The above equipment is part of the installation’s cooling water closed loop.
Cooling water characteristics:
Cooling water characteristics must comply with this manual.
Lubricating oil temperature:
During gas turbine operation the lubricating oil temperature is between 49°C
and 70°C (120°F – 158°F) according to the water flow through the heat exchanger
and the site ambient air temperature.
43

Cooling Water System
� Check cooling water properties, corrosion O
Cooling water
inhibitor and antifreeze, according to GEI 41004
� External visual check for fluid leak, device O
damage, cleanliness, water level
Water tank
� Check inside the tank : peeling paint or corrosion,
deposit, dirt, clean if necessary S
O
� External visual check for fluid leak, device
damage, cleanliness, abnormal noise, O
� Water leak at gland packing or slight drip during
operation, according to manufacturer literature
� Check vibration level, O
� No loose mounting bolts, no loose electrical S
Water pump connection
� Check outlet pressure, electrical power and
vibration
are according to pump and motor characteristics
� Grease motor and pump according to manufacturer S
literature
S
Fin fan � External visual check for fluid leak, device O O S
coolers or damage, excessive noise or vibration, erosion of fins
other coolers � Cleanliness of ducts, housing, screens
44
� Tube and shell inspection if loss of performance :
pressure droop increase or reduction of thermal S
efficiency
� Erosion of blades, deposit on blades, rust,
corrosion, peeling
� External visual check for excessive noise or O
vibration
S
Fan � Cleanliness of ducts, housing, screens, blades
S
� Erosion of blades, deposit on blades, rust,
corrosion, peeling
Air trap � External visual check for fluid leak, device O
automatic damage
vent valve � Cleanliness of internal parts S
4.7Starting Means System
4.7.1Definition
The starting means system is designed for insuring the following functions:
• To break away and crank the shaft line up to nominal speed
• To allow the shaft line cooling down
• To crank the unit for Off line washing
The starting means includes:
• A main electrical cranking motor loaded at 130% of nominal power at maximum torque
• An electrical turning gear motor
• A torque converter including an auxiliary two ways electrical motor to drive the variable inlet guide vanes to adjust the
output torque during starting sequences.
45
Lube oil from auxiliary lube oil pump feeds the torque converter during cranking sequences
Starting Means System

9E : Torque � Replace the input and output side bearings. Refer to S
converter manufacturer literature.
� Visual check for external oil leaks at shaft seals, O
Torque bolted flanges, cover plates
converter O
� Check vibration level,
All units
� Check alignment S
4.8Liquid Fuel System
4.8.1Definition
The liquid fuel system providing liquid fuel for the combustion chambers is designed for insuring the following
functions:
• Fire, warm up and accelerate the unit up to nominal speed
• Power the unit up to base load
• Shut down and trip the unit
The liquid fuel system is an open loop including:
• A safety valve to stop the fuel flow
• A shaft driven main fuel pump
46
• A control valve to adjust the fuel flow by bypassing the main fuel pump
• An electrical clutch to drive the main fuel pump
• Dual high pressure filter
• A flow divider to distribute equal flow in each combustion chamber
• Turbine casing and exhaust casing drain valves to drain the unburned liquid fuel at false starts
Nozzle pressure:
A manual selector is provided to measure individual nozzle pressure. The maximum allowed pressure spread between
the nozzles couldn’t exceed 10 bars. High spread configuration must be analyzed and rectified urgently.
Liquid Fuel System

� Check liquid fuel properties still in accordance with GEI O
Liquid fuel
41047 and Control specification
Liquid fuel � External visual check for fluid leak, pipe damage, loose O
system support, insulation damage
� Check for leaks at the valve sealing system (packing, gland, O
stem). S
Stop valve � Check the good operation of the valve according to
command signal S
� Proceed to valve seat leak test to confirm valve operation
Forwarding � Fuel leak at gland packing or slight drip during operation, O
47
Liquid Fuel System

pump according to manufacturer literature
� Check vibration level, O
� No loose mounting bolts, no loose electrical O
Connection S
� Alignment within tolerances (when applicable)
� Check outlet pressure, electrical power and vibration are S
according to pump and motor characteristics
� Grease motor and pump according to manufacturer literature
S
� Purge at filter top level to vent any air O
Filter
� Replace cartridges S
Main fuel � External visual check for fluid leak O
pump � Pump overall maintenance according to operating hours S S
� Liquid fuel leakage at stem O
By pass
valve � Accurate stroke versus control signal according to control
specification, proper setting of null bias S
Flow � Leakage Outside O
divider � Speed pickups secure and properly set S
False start � Air leak or liquid fuel leak at drain funnel after each start up S O
48
Liquid Fuel System

drain � Free liquid draining and no obstructive matter, no
valves obstructive deposit inside the drain pipe from turbine casing to
sump tank
cleanliness, fluid level
� Good operation of float level device S
Sump tank O
� Check inside the tank : peeling paint or corrosion, deposit,
dirt, clean if necessary S
� Grease motor and pump bearings as necessary
� External visual check for skin damage, loose part or fuel leak S
Spray shield
of Spray shield (called also spray retainer) installed around
(Spray
flanges
retainer)
� Replace spray shield by new one S
4.9Atomizing Air System
4.9.1Definition
Atomization is the process whereby a volume of liquid is converted into a multiplicity of very small droplet by air
stream. The atomizing air system is designed for insuring the following functions:
• To atomize the liquid fuel
• To purge the water injection lines when water is not used
49
The atomizing air system is an open loop where the air from the axial compressor is cooled down and then pressurized
by the shaft driven main compressor. An electrical motor driven booster built up the atomizing air pressure during starting
sequence.
Additional information
Permanent purging:
Permanent atomizing air purging is provided through small orifices and silencers at compressor upstream.
Air ejector:
An air ejector installed on the top of the accessory gear box receives air flow from the atomizing air system to create a
gear box vacuum pressure.
Compressor washing:
Manual valves are provided to isolate atomizing air lines during compressor Off line washing sequence.
Atomizing Air System

Starting �Check lubricating oil level O S
atomizing air �Grease bearing as necessary
booster �Check cleanliness of continuous blow down at S
booster outlet
�Check Belt according to specification 154A3418 S
Atomizing air �External visual check for fluid leak, loose support, O O
compressor hotspot
50
�Check vibration level O

�Absence of oil or vapor at vent
�Check compressor ratio if differential pressure O
transducer is provided
By-pass valve �Apply a coating of lubricant "Never-See z" or S
equivalent anti-seize lubricant to all moving parts
Air separator �Check cleanliness of drain line S
�Check all surfaces and deflector against dirt and wear S
4.10Fire Fighting System
4.10.1 Definition
The fire protection system is designed for insuring the following functions:
• To detect fire automatically
• To trip the unit and extinguish fire quickly
• To keep low concentration of combustive agent after fire
• To inform the operator
• To allow manual firefighting release in the enclosures listed here below :
• Auxiliaries
• Gas turbine
• Load
Firefighting is achieved using carbon dioxide (CO2)
51
Compartments access:
Access inside the compartments at any time must be under strict control using access permit or work permit to
guaranty operator safety regarding potential risk including carbon dioxide emission.
Fire alarm:
Fire alarm appears before fire trip. Any alarm must be investigated and rectified quickly
Carbon dioxide emission:
After carbon dioxide emission and confirmation that fire risk do not exist anymore, the compartment ventilation must
be activated the clear the inside atmosphere. Concentration measurement must be carried out to confirm safe access.
Fire Fighting System

Storage �Check availability of extinguishing agent (from O
cylinders pressure gage, weight indicator, level gauge). Fill
Storage tank up or replace cylinder as necessary.
Piping and �External visual check loose support, loose O

hoses nozzle, hose damage
Fire detectors �Check good operation of fire detectors using an S
adjustable heat source. Replace the device if out of
specification
Break-glass �Check for device damage, and check good S
units operation of the break glass system
Flashing lights, �Check for device damage, and check good S
52
Sirens operation of devices
Nozzles �Check cleanliness of nozzle holes S

CO2 latch and �Check manually good and free mechanical S
damper operation of latch and damper
Sealing of �Visual check of sealing between acoustical panel S
enclosure at walls, at roof, quality of joints, sealing of pipe
wall crossing, sealing of electrical cables wall
crossing. No
day light should be visible from inside through
joints. Initiate corrective action as necessary
System �After major inspection, check for enclosure S
operation sealing and organize carefully with all the
necessary safety precaution a manually real
discharge. Check good
operation of the system, the latches and dampers
and measure the CO2 concentration inside
compartment
4.11Air Inlet Bleed Heating System
Air Inlet Bleed Heating System

Bleed heating � External visual check for leak, abnormal O
system noise, loose support, damage insulation
53
Control valve � Check for leaks at the control valves sealing O

system (packing, gland, stem).
� Check for wear
� Check the valve stroke according to control S
signal S
4.12Hydraulic Supply System
4.12.1Definition
The hydraulic supply system is designed to provide high pressure oil at constant pressure to control:
• The liquid fuel bypass regulating valve and stop valve
• The compressor inlet guide vanes
The hydraulic supply system is a closed loop where the oil pressure is built up from lubricating oil header by:
• A shaft driven main pump
• An electrical motor driven auxiliary pump for starting and shut down sequences
Hydraulic oil supply conditioning includes:
• Automatic purging
• Dual filtering
• Accumulator
Hydraulic oil flows back to the lubricating oil tank by gravity.
4.12.2Maintenance Schedule
Hydraulic Supply System
54

Hydraulic � External visual check leak, abnormal noise, loose O
supply support, damage insulation
system
Refer to "STANDARD DEVICES" table for other components
4.13Heatingand Ventilation System
4.13.1 Definition
The heating and ventilation system is designed for insuring the following functions:
• To evacuate the hot air from inside the compartment to outside
• To dilute gas leak to avoid hazardous area in the enclosures listed here below:
•Auxiliaries
•Gas turbine
•Exhaust
•Load
•Water injection skid
Enclosure purpose is:
• To protect personnel from high temperature and fire risks.
• To provide proper cooling and ventilation for the equipment.
• To provide attenuation of the noise generated by the equipment
55
• To contain fire fighting medium
• To provide weather protection for the equipment.
Redundant electrically driven fans provide airflow. Ventilation airflow direction is according to the need of each
enclosure.
Flap at ventilation air intake are use to restrict airflow while the ventilation is not in operation and to participate to fire
fighting effectiveness.
Electrical heaters are provided in enclosures for heating the ambient air except in exhaust and load compartments.
Compartments access:
Access inside the compartments at any time must be under strict control using access permit or work permit to
guaranty operator safety regarding potential risk including carbon dioxide emission.
Carbon dioxide emission:
After carbon dioxide emission and confirmation that fire risk do not exist any more, the compartment ventilation must
be activated to clear the inside atmosphere. Concentration measurement must be carried out to confirm safe access.
Unit cooling down sequence:
During cooling down period using turning gear, all the turbine compartment doors must remain closed to avoid cool air
excess flow distribution near the gas turbine casing.
Heating And Ventilation System

Inlet duct O
� External visual check for device damage, cleanliness O
filter
56
� Clean or replace the filter element according to

clogging frequency
� External visual check for device damage, excessive O
Damper noise, good operation of damper element
� Cleanliness and lubrication of linkage and bearing S
� External visual check for device damage, excessive S
Ducting
noise, loose bolt
Flow � External visual check for device damage, O S
sensor �Check good operation according to device summary
� External visual check for excessive noise or vibration O
� Cleanliness of ducts, housing, screens, blades S
Fans
� Erosion of blades, deposit on blades, rust, corrosion, S
peeling
� External visual check for device damage, excessive O
noise, good operation S
Space connection, check cable gland
heaters S
� Check cleanliness of heating elements, blades and
louvers
� Check proper thermostat setting S
� Visual check of sealing between acoustical panel at S
Sealing of
enclosure walls, at roof, quality of joints, sealing of pipe wall
crossing, sealing of electrical cables wall crossing
57
4.14Compressor Washing System
4.14.1Definition
The compressor and turbine washing system is designed for insuring the following functions:
• To clean the compressor at stand still (Off line)
• To clean the compressor at nominal speed (On line)
• To clean the gas turbine
A module not included in this chapter provides the clean washing water flow. OFF line washing and ON line washing
use specific spray manifold. Turbine washing uses atomizing air manifold.
Compressor Washing System

Washing O
� Check washing water properties according to GEK
water
107122
Detergent
Water � External visual check for fluid leak at connection O
tank (pipe, heater, level indicator, . .) device damage,
Detergent cleanliness, water level, detergent level
tank � Check inside the tank, clean if necessary S
Water � External visual check for fluid leak, device damage, O
pump cleanliness, abnormal noise,
58
� Check for water leak at gland packing or slight drip X

during operation, according to manufacturer literature
� No loose mounting bolts, no loose electrical connection S
� Check outlet pressure, electrical power and vibration S
are according to pump and motor characteristics
� Grease motor and pump according to manufacturer S
literature
4.15Water Injection System
4.15.1Definition
The water injection system is designed to reduce the NOx level when the gas turbine is burning liquid fuel.
The water injection system is an open loop where water flow is built up by an electrically driven water pump. The
system includes
• Temporary and permanent filters
• An electrically driven water pump
• A water pump re-circulating line to allow pump cooling down
• A water flow regulating valve to adjust the water flow according to the fuel flow
• A flow meter
• Two stop valve to cut off the water flow in each manifold
Injection water flow is injected in the combustion chambers by two manifolds and evacuated in the atmosphere
through the exhaust duct. The regulating valve controls the total injected water flow.
Flow regulating valve and stop valve are piloted using instrument air.
59
Water Injection System


Water � Check water properties according to GEK 101944 O
� External visual check for fluid leak, device O

damage, cleanliness, abnormal noise,
� Check for water leak at gland packing or slight drip O
during operation, according to manufacturer literature
� Check vibration level,
Water pump connection O
S
� Alignment within tolerances (when applicable)
S
� Check outlet pressure, electrical power and
vibration are according to pump and motor S
characteristics S
� Grease motor and pump according to S
manufacturers literature
� Check for leaks at the valve sealing system O

(packing, gland, stem).
Stop valve S
� Check the good operation of the valve according to
S
command signal
60
� Proceed to valve seat leak test to confirm valve

operation
� Check for leaks at the valve sealing system O
Flow control (packing, gland, stem). S
valve � Check for wear S
�Check the valve stroke according to control signal
4.16Compressor Inlet Guide Vanes System
4.16.1Definition
The inlet guide vanes system is designed to adjust the compressor airflow according to compressor and combustion
needs.
The compressor inlet guide vanes system is actuated with hydraulic supply. The oil returns to the lubricating oil tank
by gravity.
Compressor Inlet Guide Vanes System

� Accurate stroke versus control signal according to S
Operation and
control specification, proper setting of null bias
calibration
� Check good operation of tripping system S
Ring, rack, gear � Clean, then Grease with lithium grease S
Actuator � Grease fitting S
61
� Clean if necessary S
� Check for Corrosion, abrasion, pitting, leading/trailing S
Inlet Guide Vanes
edge damage
� Check backlash and bushing clearance S
4.17 Inlet and Exhaust System
4.17.1Definition
The flow inlet & exhaust is designed for insuring the following functions:
• To supply the gas turbine with filtered air flow
• To reduce the compressor air inlet acoustical level
• To protect the air inlet duct against high pressure drop
Inlet And Exhaust System

� External visual check for excess accumulation of O
Inlet screen
birds, insects, debris, screen damage
� Visual check for cleanliness, good operation of O
Inlet air filter
lighting (when applicable)
Self cleaning � Visual check for cleanliness, leak, O X
air � Check good operation of condensate drains trap
62

processing systems, drain manually if necessary O
unit � Check oil level at standstill, check the belts tension
(when applicable) X
� Replace filter element according to pressure droop
� Visual check for scale formation at drift eliminator O
panels
� Replace drift eliminator panel
Evaporative
� Visual check of media pads S
cooler
� Check water quality regarding corrosion, scaling, O
micro biological infestation, refer to GEK 107158 O
� Clean all evaporative cooler S
� Visual check for filter element properly seated and O
secure
Inlet filter
� Check pressure drop. O
element
� Replace cartridges at high level pressure drop and
brush or vacuum clean the area before next start up S
Inlet duct, � Visual check for internal parts properly seated and S
silencer secure
63

� Visual check for state/condition, sealing of
expansion joint S
Inlet structure � External visual check damage, loose mounting bolts S
� Visual check for state/condition, sealing of joint S
� Check good operation of door, of rubber heat tracing S
Bypass door
(when applicable), good operation of electrical control
system : electromagnet, limit switch
� Visual check for hot gas leak O S
� Visual check for internal parts properly seated and
Exhaust duct
secure, quality of insulation material
� Visual check of external support system S
� Visual check of outer cover for any discoloration or O
damage, indicative of excessive heat or movement or
hot gas leak
Expansion � Visual check from inside and outside for adequate
joints on S
ventilation around the expansion joint, loose bolt,
exhaust duct
signs of damage or leakage, cracks, discoloration,
signs of damage on the external insulation
� Replace the expansion joints by a new one every 5 X
64

years
4.18 Fuel Purge System
4.18.1 Definition
The turbine solid compound cleaning system is designed to inject solid compound at the gas turbine inlet to remove
part of the undesirable deposit and ashes due to the use of low grade liquid fuels.
The turbine cleaning system includes a cleaning skid and a set of manual valves with injection nozzles, one for each
combustion chamber. The cleaning skid consist of :
• A low pressure hopper to store the solid compound for one combustion chamber
• A motorized valve to fill up the high pressure hopper
• A high pressure hopper to store the solid compound for one combustion chamber
• An air ejector
• A set of manual valves
Air from the atomizing air system is used to inject the cleaning compound into one combustion chamber at a time
through dilution holes at the end of the liner.
The cleaning cycle is performed at full speed no load.
The cycle of the turbine cleaning system is as follow:
• Fill up manually the low pressure hopper with 25 kg of solid compound for combustion chamber # 1
• Transfer the 25 kg solid compound from low pressure hopper to the high pressure hopper
65
• Inject the solid compound in chamber # 1 during 3 to 5 minutes
• Fill up manually the low pressure hopper with 25 kg of solid compound for combustion chamber # 8
• Transfer the 25 kg solid compound from low pressure hopper to the high pressure hopper
• Inject the solid compound in chamber # 8
• Continue the cleaning sequence for other combustion chambers, one by one in the following
order # 2, # 9, # 3, # 10, # 4, # 11, # 5, # 12, # 6, # 13, # 7, # 14 to balance first nozzle cleaning and to avoid
unbalance in turbine's performance or temperature.
4.18.2Maintenance Schedule
Fuel Purge System

� External visual check for leak, pipe damage,
Purge system loose support, damage insulation, cleanliness of O
funnel
� Check for leakage at stem S
� Check the good operation of the valve according S
to command signal
Purge valves
� Proceed to valve seat leak test to confirm the S
valve operate in the defined leakage class as per
ANSI/FCI70-2-2006
4.19Accessoryand Load Gear and Couplings
Accessory And Load Gear And Couplings
66
9E Accessory � Visual check according to OEM technical S
coupling literature
� Visual check according to OEM technical
Load coupling
literature S
� Visual check for leak, damage, loose bolts, S
Accessory gear anchor bolts, cleanliness, maintenance as per OEM
box literature
S
� Gear box inspection through inspection door
� Visual check for leak, damage, loose bolts, S
anchor bolts, cleanliness, maintenance as per OEM
Load gear box literature
S
� Gear box inspection through inspection door
4.20Acoustical Enclosure
Acoustical Enclosure
� External visual check damage, loose mounting S
Structure
bolts, corrosion
67
� External visual check for cleanliness, painting, O

Panel, Roof panel damage
and gasket � External visual check for air tightness between
panels, water tightness, acoustical insulation S
� External visual check for damage, paint, easy S
Doors opening and closing, good operation of locking
system, quality of gasket
Hoist, traveling � Check good operation of the system, of the brake, S
crane lubricate as necessary
Lighting � Check good operation O
Wall and floor � Visual check of sealing regarding air tightness S
and acoustical insulation at electrical cable and
sealing piping crossing
4.21Electrical Auxiliary
Electrical Auxiliary
� Visual check cleanliness of battery and battery O
Battery rack
� Check battery capacity S
� Check for cleanliness and good operation, no O
Battery charger over heating
� Inspection of battery charger as per OEM S
68
Control panel and � Check for any indication of corrosion or O

components discoloration due to heat
Indicating lamps � Check good operation, replace if necessary O
� Check filter for dirt, clogging O

Space heaters � Clean device, fan blades (if any), ducts S
� Check performances S
� General cleanliness O
Motor Control
� Bus bar loose connection, insulation, cleanliness S
Center
of insulator, good operation of doors and drawers
� Check for cleanliness, damage, good operation O
� Clean filter or replace as necessary, clean water
Air conditioner X
drain, clean dust and dirt from the condenser and
evaporative coils
4.22 System
System

� Check operating parameters according to gas O
turbine operation
Parameters
� Check stroke of fuel control valves according to
control signal S
� Check operation of overspeed trip system
Overspeed
according to GEK 111521 S
69
4.23Instrument Air System
Component function
TK601 Compressed air tank
CAB001 Electrical cubicle
NV201 Air cooler outlet check valve
NV301 Air compressor outlet check valve
NV601 Self cleaning air outlet check valve
NV611 Instrument air outlet check valve
HV201 Air cooler inlet manual isolation valve HT
HV202 Air cooler outlet isolation valve
HV203 Separator air cooler automatic drain valve
HV204 Separator air cooler manual drain valve
HV254 Air cooler regulation pressure switch instrumentation valve
HV301 Compressor air outlet isolation valve
HV303 Separator air cooler automatic drain valve
HV304 Separator air cooler manual drain valve
HV401 Air dryer inlet isolating valve
HV402 Air dryer outlet isolating valve
HV403 Pre filter automatic drain valve
HV404 Pre dryer outlet isolation valve
HV405 Air dryer bypass valve
HV413 Oil filter automatic drain valve
HV414 Oil filter manual drain valve
HV433 Final filter manual drain valve
HV601 Self cleaning air outlet isolating valve
HV603 Air tank automatic drain valve
HV604 Air tank manually drain valve
HV611 Instrument air outlet isolating valve
HV652 Air tank regulation pressure switch instrumentation valve
HV651 Air tank pressure indicator instrumentation valve
HV661 Air tank low pressure switch instrumentation valve
PCV252 Air cooler pneumatic valve air pilot pressure control valve
PCV254 Air cooler outlet pressure control valve
PCV661 Air outlet pneumatic valve air pilot pressure control valve
PCV665 Instrument air outlet pressure control valve
TSV252 Air cooler outlet pneumatic isolation valve
FSV661 Air outlet pneumatic isolation valve
PSV255 Air cooler outlet pressure safety valve
PSV651 Air tank pressure safety valve
PSV666 Instrument air outlet pressure safety valve
PDI451 Pre filter pressure differential manometer
PDI461 Oil filter pressure differential manometer
PDI481 Final filter pressure differential manometer
70
PI651 Air tank pressure indicator
TI251 Air cooler inlet temperature indicator
TI253 Air cooler outlet temperature indicator
TSH252 Air cooler outlet temperature switch high
FY252 Air cooler pneumatic valve pilot air solenoid valve
FY253 Separator air cooler solenoid drain valve
FY351 Separator compressor solenoid drain valve
FY453 Pre filter solenoid drain valve
FY463 Oil filter solenoid drain valve
FY653 Air tank solenoid drain valve
FY661 Air outlet pneumatic valve pilot air solenoid valve
FLT201 Separator air cooler Y filter drain
FLT301 Separator compressor Y filter drain
FLT431 Pre filter Y filter drain
FLT441 Oil filter Y filter drain
FLT601 Air tank Y filter drain
SEP201 Air cooler outlet separator
SEP302 Compressor outlet separator
FLT401 Pre filter
FLT402 Oil filter
FLT403 Final filter
PSLH254 Air cooler regulation pressure switch
PLSH652 Air tank regulation pressure switch
PSL661 Air tank low pressure switch
CLR201 Air cooler
FAN201 Air cooler fan
MO201 Air cooler motor
DRY401 Adsorption air dryer vessel 1
DRY402 Adsorption air dryer vessel 2
FY471 Adsorption air dryer solenoid valve
NV421 Adsorption air dryer check valve
NV422 Adsorption air dryer check valve
MI491 Adsorption air dryer moist indicator
CMP301 Auxiliary screw compressor
MO301 Auxiliary screw compressor motor
SEP301 Auxiliary screw compressor separator
CLR301 Auxiliary screw compressor air/oil exchanger
FAN301 Auxiliary screw compressor exchanger fan
MO302 Auxiliary screw compressor exchanger fan motor
PSH301 Auxiliary screw compressor high pressure switch
PSV301 Auxiliary screw compressor mini pressure switch
71
PSV302 Auxiliary screw compressor pressure safety valve
TSH301 Auxiliary screw compressor temperature switch
TSV351 Auxiliary screw compressor thermostatic valve
PCV301 Auxiliary screw compressor pressure control valve
PI301 Auxiliary screw compressor oil pressure indicator
PI302 Auxiliary screw compressor air pressure indicator
FY301 Auxiliary screw compressor regulation solenoid valve
4.23.1General
The role of the self-cleaning air filter GDX system, designed for GT frame
9Eev, is to remove the contaminants of the ambient air sucked by the G.T.
compressor, in order to protect the mechanical components such as compressor and
turbine blades against erosion, corrosion and fouling.
Self cleaning is accomplished by intermittently injecting compressed through
the blowpipes. Each pulse of air from the blowpipe into the filter cartridge provides
a shock wave inside the filter cartridge and a momentary reverse flow.
The power plant includes 3 Gas Turbine of 9EeV type. Each gas turbine is
supplied by an outdoor
Air processing unit, located close the GT and is designed to supply compressed
air to the GT’s self-cleaning air filter and for instrument air.
The equipment are designed for neutral air compressed free of aggressive
elements.
It’s installed in a tempered container to protect production air compressed skid
components against freezing and sun, direct rain, dust or sand wind.
The Air Processing Unit includes:
- One auxiliary screw compressor CMP301, 37 kW to supply compressed air to
self-cleaning air filter and instrument air for the plant.
- One motorized air cooler CLR201 for the purpose of cooling the compressed
air coming from GT to +5°C above ambient.
- One compressed air tank TK601 500 liters with adsorption air dryer DRY401
for self-cleaning air filter and for instrument air.
- Necessary filters, drain and instrumentation
4.23.2Screw compressor RAFALE 37 kW CMP301
ERVOR screw type rotary compressors, RAFALE Range, have decisive

advantages in terms of performance, reliability, long life and accessibility. That is
why they are particularly recommended for continuous heavy duty applications.
The screw compressor is able to supply 174 Nm3/h required at self cleaning GT
air filter and 5
Nm3/h required for instrument air.
72
The compressor outlet working pressure is from 8 to 10 bar.
- Type ................................................................................ RAF50-3 SP
- Working pressure ........................................................... 8 / 10 bar
- Max. working pressure: .................................................. 12 bar
- Nominal flow ................................................................... 230 Nm3/h
- Compressor revolution speed ......................................... 4000 rpm.
- Coupling ......................................................................... 5 Belts XPA 1180
- Installed power ............................................................... 37 kW
- Revolution speed ............................................................ 2960 rpm.
- Protection class .............................................................. IP55
- Isolation class ................................................................. F
- Temperature class .......................................................... B
- Supply voltage / frequency ............................................. 400 V / 50 Hz
- Heating element ............................................................. yes
- Wiring ............................................................................. Star/Delta start-up
- Working temperature ...................................................... 0°C to +55°C
- Air outlet connection ....................................................... 1”1/2
4.23.3Compressed air tank 500L TK601
The 500 litres air tank will store air coming from the GT for self cleaning air
filter and instrument air.
It's designed following PED CE / ASME VIII, hot dip galvanised.
- Capacity .......................................................... 500 L
- Fluid ................................................................ Compressed air
- Type ................................................................ vertical
- Design pressure ............................................... 10.6 bar
- Maximum allowable temperature .................... +100 °C
- Minimum design metal temperature ................ -15°C
- Hydrostatic test pressure ................................... 15.9 bar
- Joint Efficiency .......................................0.7 (longitudinal) / 0.65 (circular)
- Construction ..................................................... Directive 97/23 CE
- Design .............................................................. ASME VIII div 1
- Protection ........................................................ Int./Ext. galvanized
- Weight of vessel ................................................ 150 kg approx.
73
The air receiver is equipped with:
- One pressure safety valve 10.5 bar PSV651
- One pressure indicator PI651 with instrumentation valve HV651
- One regulation pressure switch PSLH652 with instrumentation valve HV652
- An automatic drain system composed by:
- A solenoid drain valve FY653 with Y filter FLT601
- An isolating valve 1/2" HV603
- A by-passed valve 1/2" HV604
Self cleaning air filter outlet S1:
- One isolating self cleaning outlet valve HV601
- One outlet check valve NV601
- One automatic valve FSV661 controlled by:
- One pressure switch low PSL661 with instrumentation valve HV661
- A solenoid valve FY661
- Pressure regulator PCV661
Instrument and service air outlet S2:
- One instrument air outlet valve HV611
- One instrument air outlet check valve NV611
- One pressure control valve PCV665 to reduce to 7 bar instrument and service
air
- One pressure safety valve PSV666 for instrument and service air 8 bar
In case of compressed air low pressure PSL661 in the tank TK601, the priority
is maintaining instrument and service air pressure to 7 bar and FSV661 is closing
the self cleaning compressed air flow. When the pressure is going up 8 bar,
FSV661 will be opened automatically
4.23.4Air cooler ARO203HT CLR201
An air forced air cooler cool air coming from gas turbine to be used by
compressed air network.
This air cooler is designed to decrease temperature for air coming from gas
turbines compressors
from 390°C to 55°C.
- Air flow capacity .............................................................. 203 Nm3/h
- Air inlet temperature ....................................................... 390 °C
- Air outlet temperature ..................................................... +5°C above
ambient
74
- Maximum working pressure ............................................ 16 bar
- Connections .................................................................... 1” 1/2 G M
- Motor fan power .............................................................. 0.55 kW
- Voltage ........................................................................... 400V/3ph/50Hz
The air cooler is equipped with:
- Manual isolating inlet valve HV201
- Pneumatic isolation valve TSV252 controlled by:
- An solenoid valve FY252
- Pressure regulator PCV252
- Temperature switch high TSH252
- Pressure switch regulation PSLH254 with instrumentation valve HV254
- An inlet temperature indicator TI251
- An outlet temperature indicator TI253
- An outlet pressure control valve PCV254 (setting: 10 bar)
- A pressure safety valve PSV255 (setting: 10.5 bar)
- An outlet isolating valve HV202 with check valve NV201
4.23.5Water separator filter SEP201 & SEP302
Located downstream air cooler and air compressor, the water separator is
designed to separate water due to temperature decrease in the air forced cooler.
- Type ................................................................................ Centrifugal
condensate separator
- Nominal pressure drop ................................................... 0.07 bar
- Connections .................................................................... 1” G F
The water separator filter is equipped with:
- An automatic drain system composed by:
- A solenoid drain valve FY253 &FY351 with Y filter FLT201 &FLT301
- An isolating valve 1/2" HV203 &HV303
- A by-passed valve 1/2" HV204 &HV304
4.23.6 Adsorption air dryer SAD255 DRY401
The adsorption air dryer is located upstream air tank and is able to dry 180
Nm3/h flow rate necessary for self cleaning filter and instrument air. It removes
humidity of the compressed air for abusing with negative ambient temperature.
75
- Air flow capacity at outlet (*) ........................................... 180Nm3/h
(*) working pressure 8 bar - air inlet temperature 50°C
- Type ................................................................................ SAD255
- Working temperature ...................................................... -10°C to 55°C
- Dew point ........................................................................ -25 °C
- Connections .................................................................... 1” G
- Supply voltage ................................................................ 230V – 50/60Hz
- Weight ............................................................................ 196 kg
The air dryer is composed of:
- Two desiccant element receivers DRY401 &DRY402
- Four solenoid valves FY471, FY472, FY473, FY474
- Two check valves NV421, NV422
- One restricted dry air line
- Two isolating valves HV401, HV402
- One bypass by isolating valve HV405
- One moist indicator MI491
- One cyclone pre-filter FLT401 to remove liquid particles. The efficiency is
99.5% for particles above 1Micron.
- Type ................................................................................ G11Z
- Maximum cartridge pressure drop .................................. 0.5 bar
- Working temperature ...................................................... 1.5°C to 55°C
- Connections .................................................................... 1”G
- Filtration .......................................................................... 1 μ
The pre filter is equipped with
- An automatic drain system composed of:
- An isolating valve HV403
- A by-passed valve HV404
- A local clogging indicator PDI451
- One micro oil filter FLT402 to remove oil particles. The efficiency is 99.5%
for particles above0.01Micron.
76
- Type ................................................................................ G11X
- Connections .................................................................... 1”G
- Filtration .......................................................................... 0.01 μ
The micro oil filter is equipped with
- An automatic drain system composed of:
- An isolating valve HV413
- A by-passed valve HV414
- One final filter FLT403 to remove dust particles of the desiccant. The
efficiency is 99.5% for particles above 1Micron.
- Type ................................................................................ G11Z
- Connections .................................................................... 1”G
- Filtration .......................................................................... 1 μ
The final filter is equipped with
- A manual drain valve HV433
PREVENTIVE MAINTENANCE SCHEDULEAIR COMPRESSED SYSTEM
SEQUENC
DESCRIPTIO PERIO
UNIT E ACTION
N D
NUMBER
Carry out a general visual
Air
GT1-GT check and watch out for
SAP compressed D
2-GT3 possible disturbances during
skid
operation
GT1-GT Air Check the ventilation system
SAP D
2-GT3 compressed and the temperature inside the
77
skid container which should be
between +5°C and +45°C
GT1-GT Screw Check and Top up if necessary
CMP301 D
2-GT3 compressor the compressor oil level
Check the loading and off
GT1-GT Screw
CMP301 D loading pressure on the
2-GT3 compressor
compressor pressure gauge
FY253,
Check function by manually
GT1-GT FY351 Solenoid
D operating the bypass
2-GT3 FY453, drain valve
condensate drain
FY463
Do an optical color test on the
blue gel indicator
GT1-GT Adsorption air
DRY401 D (Orange=-25°C / Pink=0°C /
2-GT3 dryer
Transparent
=+15°C)
Check the good ventilation of
GT1-GT Air cooler
CLR201 D the air cooler, reading
2-GT3 ARO203 HT
temperature indicator
GT1-GT Electrical
CAB001 W Check lamp using lamp test
2-GT3 cubicle
Check the differential
GT1-GT
FLT401 Pre filter W pressure of filter; it should not
2-GT3
exceed 0,5 bar.
GT1-GT
FLT402 Oil filter W pressure of filter; it should not
2-GT3
exceed 0.5 bar.
GT1-GT
FLT403 Final filter W pressure of filter; it should not
2-GT3
exceed 0.5 bar.
Check the back pressure at the
silencer placed behind the
4-port directional valve
GT1-GT Adsorption air combination; it should not
DRY401 W
2-GT3 dryer exceed 0.5 bar. Use
manometer of the vessel
which is to be
regenerated.
Check the internal condition
GT1-GT Screw
CMP301 W of compressor for eventual
2-GT3 compressor
leakages
FLT201,
GT1-GT FLT301
Y filter M Clean the screen
2-GT3 FLT431,
FLT441
78
FLT601
GT1-GT Screw
CMP301 M Check belts tension
2-GT3 compressor
GT1-GT Screw Check and clean if necessary
CMP301 M
2-GT3 compressor the intake air filter
GT1-GT Screw
CMP301 M Clean air/oil exchanger
2-GT3 compressor
GT1-GT Screw Change the air/oil separator
CMP301 6M
2-GT3 compressor cartridge
GT1-GT Screw
CMP301 6M Change the intake air filter
2-GT3 compressor
GT1-GT Screw
CMP301 6M Change oil filter cartridge
2-GT3 compressor
GT1-GT Screw
CMP301 6M Drain the compressor oil
2-GT3 compressor
GT1-GT compressed
SAP 6M Clean the unit
2-GT3 skid
GT1-GT Screw Check the flexibility of the
CMP301 Y
2-GT3 compressor hoses.
FY253
Completely disassemble the
FY351 Solenoid
GT1-GT drain and clean all
FY453 drain valve Y
2-GT3 components. Replace if
FY463
necessary
FY653
GT1-GT
FLT401 Pre filter Y Replace filter cartridge
2-GT3
GT1-GT
FLT402 Oil filter Y Replace filter cartridge
2-GT3
GT1-GT
FLT403 Final filter Y Replace filter cartridge
2-GT3
Check the desiccant for
impurities and change it if
necessary. A
brownish/yellowish tone
GT1-GT Adsorption air
DRY401 Y indicates that it has been
2-GT3 dryer
soiled with oil. The desiccant
has a normal lifetime of about
8000
operating hours.
Check the wedge wire screen
GT1-GT Adsorption air and the dust screen installed in
DRY401 Y
2-GT3 dryer the vessel for impurities and if
necessary, clean them.
GT1-GT Adsorption air Check the function of the
DRY401 Y
2-GT3 dryer 4-port directional valve
79
combination by sending
electrical control
signals.
Air
GT1-GT Change the air intake
SAP compressed Y
2-GT3 ventilation filter
skid
Check the correct operation of
GT1-GT Screw various protection device such
CMP301 2Y
2-GT3 compressor as safety valve, temperature
switch and thermal overload.
GT1-GT Screw Inspect the motor and
CMP301 2Y
2-GT3 compressor compressor bearings
GT1-GT Compressed Check the acceptable minimal
TK601 *
2-GT3 air tank residual thickness
GT1-GT Pressure Check the good functioning
PSV255 *
2-GT3 safety valve and test of maneuverability
GT1-GT Pressure Check the good functioning
PSV651 *
2-GT3 safety valve and test of maneuverability
Check the good
GT1-GT Pressure
PSV666 * functioning and test of
2-GT3 safety valve
maneuverability
MAINTENANCE PERIOD
D=Daily 6M=Every 6 months
W=Weekly Y=Yearly
M=Monthly 2Y=Every 2 years
*=as much as required by the regulation current in the country of exploitation
4.24Steam Injection System
Steam Injection System
Check steam properties still in O
accordance with GEK
Steam
101944 and Control
specification
External visual check for steam O
Steam
or water leak, loose support,
system
damage insulation
� Check for leaks at the valve O
Flow sealing system (packing, gland,
control stem).
valve � Check for wear S
� Check the valve stroke S
80
according to control signal
� Check for leaks at the valve O
sealing system (packing, gland,
stem).
Stop � Check the good operation of
valve the valve according to
command signal S
� Proceed to valve seat leak
test to confirm valve operation S
� Check level of condensate
Pressure
pot, fill up with water if
transducer
necessary S
5 Generator
5.1Specification of Generator
ESTIMATED GENERATOR DATA
Generator Type: 9A5
Generator Number: 954X116-118
Station/Project: Nandipur 3x 9E Dongfang Offer
Customer: DONGFANG ELECTRIC CORP
GENERATOR RATING
150000 kVA 3000 RPM 15000 Volts 0.85 PF 0 psig 40 °C Gas 127500 kW 5774
Amps
375 Field Volts 698.817 Ft Alt 0.58 SCR 50 Hz 3 Phase WYE Connection
Exciter Rating
Type : Brushless
360 kW 375 Volts 960 D.CAmps Field Amps @ Generator rated Load 880
Total temperatures are guaranteed
Insulation Class Temperature Rise
not to exceed:
Stator coils: 122 °C by embedded
Armature F B
detector
Field coils 120 °C by Resistance Armature F B
Collector Gas Rise 20 °C by RTD
Cooling water Requirements @ Generator Rating
Generator Output: 150000kVA
Loss to Coolers: 1634KW
Inlet Water Temperature: 36°C
Outlet Cold Gas
40°C
Temperature
Coolant 100%WATER
Maximum Fouling Factor: 0.0005 1/(btu /
81
(hours*footsquared*F) )
700 GPM (total for all
Total Water Flow Required:
coolers)
Coolant temperature Max 60 °C
Head Loss Per Cooler: 14 Feet of Water
Maximum Operating 125 psig
Pressure: 8.6184 bar
Dielectric tests (Between coils and ground, 50/60 hertz AC for 1 min)
Stator 31000V
Rotor 3071V
5.2 An Effective Maintenance Program of Generator
Maintenance Frequency
There are a number of components, which require routine maintenance or
inspections between scheduled outages. The operator will find these
recommendations in various equipment sections, and should also include
additional maintenance tasks as operating experience indicates. Results of this
routine maintenance should be retained in well-organized files readily available
for reference. These routine maintenance records coupled with the information
from the monitored operating data are a good indicator of pending service or
operating problems that should be addressed at the next scheduled outage. The
monitored information alone is usually not sufficient for tracking or highlighting
trends.
During the first several months of operation, the stator winding support
system and some of the other generator components experience a break-in
period with more severe duty/wear than normal. Therefore, the first major
maintenance inspection is recommended for one year after it is placed in service.
For the purposes of the first major inspection, one year is defined as 8760
operating hours; or 300 starts. Regardless of the generator’s duty, the first
inspection should not be deferred beyond two (2) calendar years from COD. If
the unit’s operating experience has been unusual because of mis operation or
very limited in-service hours, etc. You may wish to discuss your particular
circumstances you’re your local GEField Service Office for recommendations
specific to your circumstances.
Subsequent planned outages must also be performed in a timely fashion.
Experience has shown that regularly scheduled maintenance outages are one of
the most important steps in retaining unit reliability and reducing major
repair/failure expenses. A minor maintenance outage is recommended every
30months. During these outages the end shields or end plates are removed to
permit inspection of the end winding area, but the field remains in place. A
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major outage is recommended every 60 months. This includes removing the
field from the stator or using MAGIC (Miniature Air Gap Inspection Crawler) to
permit a thorough inspection of the core section of the stator and field. To
inspect the field and stator using MAGIC requires the removal of a few entrance
gap baffles to allow access to the air gap with the field in place. The inspection
must include a comprehensive series of electrical tests and a thorough visual
inspection. Each has their particular advantage and neither alone is sufficient.
See Section V for a brief description of the capabilities of MAGIC and MAGIC
Jr.
Older generators with asphalt insulated stator windings and core lengths
greater than 150 inches are subject to girth crack failures in the stator bars, and
therefore, these generators should be re inspected twice as often (Minor Outage
- 18 months; Major Outage - 36 months).
These recommended outage intervals have proven themselves over many
years of use. However, high equipment reliability and outage costs, have lead to
increasing interest in extending the time between major inspections. Condition
Based Maintenance (CBM) is one method in development to do this, and is the
focus of considerable attention in the industry. CBM relies on availability of
reliable on-line instrumentation and evaluation techniques. As these evaluation
methods become proven and practical, they will be incorporated into
recommended operation and maintenance packages such that maintenance
outages can be scheduled based on the condition of the unit.
Table 1 Recommended Stator Tests
STATOR
MA
Inspection AI HY LC Mino
Compon GIC/ Major
Test Objectives & R D SW r
ent RAC
Assessment
Checks for
RTD Gas &
calibration &
Element Winding X X X X X
poor
Res. RTD’s
connections.
RTD
Stator Insulation
Ground
Winding condition of X X X X X
Insulatio
RTD’s RTD.
n
Winding Checks for poor
Stator
Copper connections & X X X X X
Winding
Res. breaks.
Insulatio Contamination
n CE and/or
X X X X X
Resistan Bearing deterioration of
ce(aka insulation.
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Megger) Contamination
Hydroge
and/or
n Seal X X X X
deterioration of
Casing
insulation.
Contamination
Polariza
Stator and/or
tion X X X X X
Winding deterioration of
Index
insulation.
Contamination
DC
Stator and/or
Leakage X X X X X
Winding deterioration of
Current
insulation.
Over Ground wall
Stator
Potentia insulation X X X X X
Winding
l/Hipot integrity
Wedge Detect wedge
Stator
Tightnes tightness X X X X X
Wedges
s Map deterioration
Magneti
c Scalar Stator
Weak or
Potentia Core
damaged core X X X X X
l Insulatio
enamel.
(EL n
CID)
Visual Core
Foreign Object
Inspecti Laminati X X X X X
Damage
ons ons
Migration,
Space
cooling passage X X X X X
Blocks
blockage
Gas Gap Cracked welds,
X X X X X
Baffles looseness
Evidence of
Stator
abrasion or X X X X X
Wedges
looseness
Evidence of
Stator
abrasion or X X X X X
Bars
looseness
Evidence of
End
relative motion,
Winding
dusting and/or
s and
greasing, X X X X X X
connecti
loose/broken
on
ties, loose
rings
hardware, corona
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activity
Copper Overheating,
Flux hardware X X X X X
Shield looseness
Overall
Oil or other
cleanline X X X X X
contamination
ss
OPTIONAL TESTS
Partial Stator
Dischar Winding Localized
X X X R R
ge Insulatio deterioration
Analysis n
Water Water
Flow Cooled Restrictions in
X O
Verifica Stator hydraulic circuit
tion Winding
Stator
Core Weak or
Core
Ring damaged core X X X O
Insulatio
Test enamel
n
Dynami
Stator Potentially
c Freq.
End damaging X X X O
Respons
Winding resonance.
e
Slot
Bar Check slot
Support X X X O
Jacking clearance
System
Air – Air Cooled Generator HYD – Hydrogen Cooled Generator LCSW –
Hydrogen Cooled Generator with Liquid Cooled Winding
O - Optional Test X - Pertains only to type of unit selected R - These test are
performed while the unit is running.
Note: Gas cooled bars use the hydrogen column. During high voltage testing the
hollow conductors should be shorted to copper strand
5.3 Bearing
Inspection and Maintenance

A. Replace any shoe if babbited face appears scored or deeply scratched.
B. Replace any shoe if leading or trailing surfaces of shoe show signs of
wear
C. Leading edges of shoes must have a uniform radius of 0.31″ across the
full axial length of the shoe. File radius if necessary to obtain proper size.
D. Light scratches in babbitt faces do not necessarily require replacement. If
no significant wear is detected, scrape lightly with a sharp, straight-edged
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scraper to remove any material upset due to scratching.
E. Check the pivoting surfaces of the shoes and retainer for scratches,
scoring, or other evidence of wear. Polish with fine scotchbrite pad if necessary.
F. Check seal ring bore and faces for nicked edges, deep scratches, or scoring.
Polish with fine scotchbrite pad as necessary. Stone or lap the joint surfaces if
burrs or raised edges exist. Replace seal ring if the diametral clearance between
the journal and the ring bore exceeds 0.020″ at any point.
G. Check flexible hose element of the high pressure lift assembly for signs of
damage. If damage is found, replace entire high pressure lift assembly.
H. Tilting Pad Journal Bearing Clearance Check
Disassemble bearing and prepare parts for clearance check per disassembly
and maintenance instructions. Blue journal shoe pivot surface and check for
contact area and position.
Check for shaft or running clearance on 5 pad bearing as follows:
a. Turn or select a stub mandrel whose diameter is within 0.001 inch of
shaft size. One end of the mandrel must be square with the turned diameter.
Bolt mandrel to a heavy plate with a clean flat, preferable ground surface.
Clamp assembly to table or surface plate.
b. Assemble bearing around mandrel.
c. Tap bearing lightly in back of each shoe to insure that shoes are properly
seated in place.
d. Set dial indicator directly in back of a shoe and move bearing back and
forth in a direct line with the indicator and record reading. Several movements
should be made until the same indicator reading is repeated.
e. Repeat this procedure for each shoe. Set indicator to zero setting for
every new position. Be sure only bearing movement is recorded and not a
possible shift or mandrel or indicator stand.
5.4 Generator Coolers
Except for the rolled joints between the tubes and the tube sheets, all of the joints
on the coolant side of the cooler are outside the circulating hydrogen/air space. This
means that any normal servicing or repairs, such as plugging leaking tubes,
re-rolling tubes, tightening or replacing gaskets, and cleaning tubes can be done
without removing the cooler from the generator.
WARNING
SERVICING OR REPAIRING THE COOLER WHILE THE
GENERATOR IS OPERATING WITH HYDROGEN IN THE CASING IS
EXTREMELY HAZARDOUS AND SHOULD NOT BE ATTEMPTED.
If a hydrogen-cooled generator cooler section fails, the coolant flow to that
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cooler section should be shutoff and the cooler drained. The generator should then
be operated at the levels specified for one section shut down per the original
design data sheet (for example 80% load) until such a time when it is practical to
purge the generator of hydrogen. Only after the generator is purged of hydrogen
should the cooler be repaired.
CAUTION
Eye bolts must be used when lifting the coolers.
A. Repair of Leaky Tube
If it is necessary to repair a leaky tube, the coolant flow to that cooler section
should be shut off and the cooler drained. When the generator has been purged of
hydrogen, if required, the water box covers on each end should be removed. The
faulty tube may be found by pressure testing each tube.
The tube can then be plugged by driving tapered phenolic plugs or equivalent
into both ends of the tube. A few ineffective tubes in each section should not
seriously jeopardize performance. It may be possible to operate satisfactorily with
as many as 10% of the tubes plugged if other conditions such as coolant
temperature and cleanliness of tubes are favorable, and if the plugged tubes are
not concentrated in a small area. The cooler should be replaced if the number of
plugged tubes is suspected to inhibit performance.
B. Cleaning the Tubes
Periodic cleaning improves the heat transfer efficiency of a hydrogen or
air-cooled generator cooler and increases cooler service life by removing deposits
and other obstructions that may cause corrosion. The frequency of cleaning will
depend on local conditions and specific customer maintenance programs.
If it should become necessary to clean the cooler sections while operating, the
coolers may be taken out of service one at a time for cleaning without completely
shutting down the unit. The maximum heat load that may be removed with one
cooler section out of service must be limited to the values given on the Generator
Performance Data drawing C902. For a hydrogen-cooled generator it is not
necessary to remove hydrogen from the machine to clean the cooler sections if the
hydrogen seals around the tube sheets are not broken.
CAUTION
Metal plugs, wire brushes, and similar tools that will disturb or scratch the metal
surface of the tubes are not recommended.
Cleaning cooler tubes with high-pressure water, or water and high-pressure air
is effective in many instances. Specially designed rubber plugs, fiber brushes, or
nylon brushes forced through the tubes with compressed air or high-pressure
water may be required for a more effective cleaning job. Power-driven rotating
brushes, with nylon bristles, have also been shown to be effective.
While the coolers are particularly suited for mechanical cleaning, there may be
a preference for chemical cleaning. There are hazards involved in selecting and
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using the proper cleaning solution as well as ensuring the proper neutralizing and
flushing. Cleaning of this type should be done under the close supervision of
specialists in this type of work. Normally, the outside or plate surface should not
become dirty. If this happens and performance is affected, the cooler should be
removed and cleaned with a stream of water or low-pressure steam followed by
drying with an air blast. If there is an oily deposit, it may be necessary to remove it
by applying an air blast saturated with a solvent suitable for removing the film.
For reasons of safety, reference should be made to the separate instructions listed
in the Table of Contents of the Composite Book for proper choice of a solvent and
its use.
C. Inspection
The best time for the annual inspection and cleaning of the cooler is prior to the
warm season. The need for additional cleaning may be indicated by a gradual
increase in the generator temperatures not attributable to some other cause.
D. Correspondence
For identification purposes, all correspondence should reference the catalog
number, serial number and cooler manufacturer stamped on the cooler nameplate.
The generator and turbine number should also be included.
5.5 Shaft Grounding Brushes
Whenever an unsatisfactory indication is obtained on the shaft-to-ground

voltage check, the following steps should be taken:
——Remove the brushes from their holders, one at a time. Clean brush and
holder so brush may move freely.
——Scrape brush face with a knife to remove glaze.
——Use a soft brush seating stone or a canvas-padded board to remove excess
film from shaft.
——Clean brush clip contacts.
——Check spring force. It should be at least 3 3/4 pounds (1.7 kg); an even
higher force may be advisable in some instances. Machines using a shaft voltage
monitor should use a spring force of 7 ½ pounds(3.4 kg).
——Replace brushes before the pigtail is in contact with top of brush box.
——Check for corrosion or damage on the bracket mounting surface. Clean
the surface if necessary.
——If replacing brush holder, check gap between brush holder and shaft. Gap
typically should be adjusted to 0.12 to 0.25 inch. (3.0 to 6.4mm).
——During turbine inspections, all bearings and hydrogen seal rings should
be carefully checked for any signs of electrical pitting, which will appear to be an
etched or frosted surface, but at a magnification of 25x will show numerous
individual small pits or craters. The thrust bearings deserve particular attention
during inspection. The amount of taper on tapered land thrust bearings should be
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checked with a micrometer or feeler gauge in addition to making a visual
inspection for pitting.
Some idea of the importance of keeping the shaft grounded can be gained by
considering that a failure of one or more bearings might be expected within a year
if the shaft voltage is allowed to rise to approximately50 volts 0-to-peak. As the
shaft-to-ground voltage is reduced, bearing life is increased, and it is expected that
the bearings will suffer no damage from shaft currents as long as the
shaft-to-ground voltage is held to 6 volts 0-to-peak or less.
5.6 Brushless exciter
5.6.1Periodic Maintenance
The exciter rotor, stator, and diode wheel should be cleaned with the same
regularity and in the same manner as the main generator. Make certain that the
rectifier diodes and heat sinks are kept free of dust, grease, and similar material (see
paragraph 3.1.1) because such coatings restrict dissipation of heat and cause low
egger readings. All electrical connections should be in good condition and be
tightly fastened. The corrosion resistant coating on the wheel should not be
damaged. Any connections removed and replaced should be coated with a good
quality, air- drying insulating varnish.
Diode Wheel Cleaning Procedure:
NOTE
Take insulation measurement before and after cleaning (see paragraph 3.3).
WARNING
Adequate diode wheel cleaning requires solvent use. Provide adequate
ventilation and avoid contact with skin. Use extreme caution with petroleum
solvents, as their fumes are highly flammable.
For best results, apply solvents under pressure using an aspirator or similar
device with a clean, dry, compressed air supply. Less efficient, but acceptable
means of applying solvent include self-contained (garden-type)sprayers, vacuum
cleaner with spray attachment, portable sprayers and so forth.
Initial cleaning should be done with a slow drying solvent having good oil and
dirt cutting properties. This should wash out most of the dirt, oil, and soot. Use
“Stoddard” solvent, mineral spirits, or alcohol. This should be followed by a quick
drying solvent such as Freon-TF which finish-cleans and leaves the wheel dry.
5.6.2Replacementof Diodes
Equipment damage may result if diode polarity is reversed. Ensure new

diodes are the same type and rating as those replaced.
Thread lubricants are electrically conductive. Do not get them on
insulating components.
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To properly install diodes and minimize stress on the assembly, follow these
steps:
a. Install the diode modules on diode wheel per
Drawings 1002195 and 1002171.
b. Check to make sure the modules are seated against the wheel rim and that
the diode leads are not under strain.
5.6.3 Insulation Resistance
Periodic measurement of the insulation resistance may prevent a serious

problem caused by a double ground. Megger readings of the combined exciter
rotor, diode wheel, and generator field may be made.
NOTE
If the megger used is over 500 volts, the diodes should be shorted to prevent
possible damage in the event of a ground. Disconnect the field ground transmitter
during Megger testing to prevent damage to transmitter and false megger
readings.
It is difficult to set a minimum value of insulation resistance. This depends
upon such things as age, temperature, humidity, and operating conditions. In
general, the exciter by itself should be over 50 megohms while the combined
exciter rotor, diode wheel, and generator field should be over 10 megohms. The
exciter stator should be over 50 megohms. Typically, the combined resistance is
well over 100 megohms.
A low megger reading can be caused by dirt, moisture, or insulation damage
(usually at some terminal).Cleaning and drying is recommended. If reading does
not improve, separate exciter rotor and generator field to locate the problem.
5.7The Basic Maintenance of the Series of 88BT
Initial checks
All electrical installations, however complex, must be meticulously checked
before being powered up. This check is of particular importance for installations
which may, when they have been powered up, be in an explosion risk zone. To be
totally effective, this check must be performed in the presence of a qualified
representative of the organization which has carried out the work and the user's
service manager or maintenance supervisor, and possibly a representative of the
firm which designed the installation. These checks result in the issuing of an
acceptance report. It is vitally important that this evaluation be carried out in a
rigorous and detailed way, as many important checking operations are possible
without any risk, as long as the installations are not powered up. They will no
longer be able to be carried out without extremely rigorous precautions, once the
plant is working, if the plant operates continuously.
Frequent monitoring
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This monitoring, generally performed by the operation personnel, includes:
- preventive monitoring of the state of the equipment (cables, cable glands, etc.)
taking into account the environment (heat, humidity),
- detecting abnormalities which may be dangerous, as early as possible, such as
damage to a cable sheath caused by abrasion,
- providing regular effective personnel training on the risks involved and how to
minimize them.
Regulatory periodic checks
They can be performed by a technician (who may or may not work for the
company) with an in depth knowledge of the field of prevention of risks caused by
electricity and of the associated regulations. But usually to ensure objectivity and
because of a lack of resources (both personnel and equipment), the company will
use an approved checking body.
5.8 Low Voltage Motors88BT-1/2 Maintenance
General inspection
– Inspect the machine at regular intervals.
– Keep the machine clean and ensure free ventilation airflow.
– Check the condition of shaft seals (e.g. V-ring) and replace if necessary.
– Check the condition of connections and mounting and assembly bolts.
– Check the bearing condition by listening for unusual noise, vibration
measurement, bearing temperature, inspection of spent grease or SPM bearing
monitoring.
* When changes of condition occur, dismantle the machine, check the parts and
replace if necessary.
Machines with permanently greased bearings
Bearings are usually permanently greased bearings of either Z or 2Z types.
Bearing types are specified in the respective product catalogues and on the
rating plate of all our motors except smaller frame sizes.
As a guide, adequate lubrication for sizes up to 200 can be achieved for the
following duration, according to L1
(i.e. that 99 % of the motors are sure to make the interval time) at ambient
temperature of 25°C. For duties with ambient temperatures higher than 25°C,see
the respective product catalogue.
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Depending on application and load conditions, see applicable product catalogue.

Hours of operation for vertical motors are half of the above values.
Motors with roller bearings have considerably shorter grease life. For
continuous operation regressing nipples should be considered.
Motors with regreasing nipples
Lubrication information plate and general lubrication advice
If the machine is fitted with a lubrication information plate, follow the given
values. On the lubrication information plate, regreasing intervals with regard to
mounting, ambient temperature and speed of rotation can be defined. During the fi
rst start or after a bearing lubrication it may appear a temporary temperature rise,
appr. 10-20hours. ABB policy is to have reliability as a vital issue in bearing
lubrication intervals. That is why we follow theL1-principle.
A. Manual lubrication
Regreasing while motor is running
– Remove grease outlet plug or open closing valve if fitted.
– Be sure that the lubrication channel is open
– Press the specified amount of grease into the bearing.
– Let the motor run 1-2 hours to ensure that all excess grease is forced out of
the bearing.
Close the grease outlet plug or closing valve if fitted.
Regreasing while motor is at a standstill
Regrease motors while running. If this is not possible, lubrication can be
carried out while the machine is at a standstill.
– In this case, use only half the quantity of grease, then run the motor for a
few minutes at full speed.
– When the motor has stopped, press the rest of the specified amount of grease
into the bearing.
– After 1-2 running hours close the grease outlet plug or closing valve if fitted.
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B. Automatic lubrication
The grease outlet plug must be removed permanently with automatic
lubrication or open closing valve if fitted. Some motors may be equipped with a
collector for old grease. Follow the special instructions given for the equipment.
We recommend only the use of electro mechanical systems. Contact your
local ABB Sales Office.
The amount of grease per each lubrication interval stated in the tables 4-5
should be doubled if an automatic regreasing system is used.
If 2-pole motors are being automatically regreased, the note (NOTE!)
concerning lubricant recommendations given for 2-pole motors in the chapter
Lubricants shall be followed.
Lubricants
When regreasing, use only special ball bearing grease with the following
properties:
– good quality grease with lithium complex soap and with mineral- or
PAO-oil
– base oil viscosity 100-160 cST at 40°C
– consistency NLGI grade 1.5 - 3 *)
– temperature range -30°C - +120°C, continuously.
*) For vertical mounted motors or in hot conditions a stiffer end of scale is
recommended.
Grease with the correct properties is available from all major lubricant
manufacturers.
Admixtures are recommended, but a written guarantee must be obtained from
the lubricant manufacturer specially concerning EP admixtures, that admixtures
do not damage bearings or the properties of lubricants at the operating
temperature range.
If the ambient temperature is below -25 ° C or above+55 ° C, or bearing
temperature is above 110°C, consult ABB Sales Office regarding suitable grease.
The following high performance grease can be used
– Esso Unirex N2, N3 or S2 (lithium complex base)
– Mobil Mobilith SHC 100 (lithium complex base)
–Shell Albida EMS 2 (lithium complex base)
– SKF LGHQ 3 (lithium complex base)
– Kluber Kluberplex BEM 41-132(special lithium base)
–FAG Arcanol TEMP110 (lithium complex base)Lubrication intervals for
other grease full-filling there quired properties, contact your local ABB Sales
93
Office.
The following grease can be used:
–FAG L69 (polyurea base)
–Kluber Kluber quiet BH 72-102 (polyurea base)
–Lubcon Turmogrease PU703 (polyurea base)
If other lubricants are used, check with the manufacturer that the qualities
correspond to those of the above mentioned lubricants, or if the compatibility of
the lubricant is uncertain, contact your local ABB Sales Office.
5.9 Exhaust Chamber Cooling Air Fan 88EF1/2
Depending on the use the ventilator is put to, maintenance work may be
curative, preventive or conditional.
It is the responsibility of the user, depending on operational requirements and
accessibility, to define maintenance policies.
The recommendations given below are for information only – for standard,
industrial use. The periods between maintenance may be adjusted to cope with the
precise conditions of use of the ventilator. Our Support Department can provide
further assistance in the choice of maintenance policies to be implemented.
Preventive maintenance：
Conditional maintenance
It is possible, by monitoring certain parameters, to delay having to carry out
certain motor bearing lubrication and replacement operations until the condition
of the components themselves actually justify their replacement.
We thus list, for information, certain possible monitoring methods and
thresholds to be applied to a ventilator being used for standard industrial use.
These measures may be modified with regard to the type of use and system
surrounding the ventilator.
Monitoring the temperature of the motor bearings:
The bearings can, on request, be fitted with a temperature sensor to provide
constant monitoring of their internal temperatures.
——If this internal temperature increased by more than 10°C in less than one
hour at a constant ambient temperature, the equipment must be shut down and
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locked-out. Change the bearing in question.
——The internal temperature tends to increase slowly over time. When it rises
to a level of greater than 10°C higher than the temperature recorded for the
machine when new (after running-in), top up the lubricant. If, after restarting, the
temperature does not drop to a level close to that of a new machine, the bearings
should be replaced.
Monitoring motor bearing vibration speed:
The bearings can, on request, be fitted with accelerometers used to provide
continual monitoring of vibration levels.
——If the level of vibration suddenly varies through an amplitude of more
than 15% of the level recorded when new, shutdown the ventilator and check:
——The condition of the transmission belts,
——The condition of the drive shaft and motor bearings,
——The presence of balance weights on the turbine wheel.
Replace any damaged component.
——Due to wear on rotating components, the vibration levels will tend to rise
over time. When the level reaches that defined by ISO 14694 as an alarm
threshold, schedule a SERVICE 2 as soon as possible. The alarm thresholds are:
——7.1 mm/s for a rigid installation
——11.8 mm/s for flexible mountings
All work described below is based upon a securely locked-out ventilator with
its electrical connections disconnected to eliminate any risk to the personnel
involved.
The exhaust and inlet holes are presumed to be accessible.
Cleaning and Inspecting the Turbine Wheel – Access via an inspection
hatch fitted to the casing
——Remove the inspection hatch on the spiral casing.
——Clean the turbine, one blade at a time – turning it by hand. Never use
solvent cleaners this risks damaging the coating. Never spray liquid into the space
this will buildup in the base of the casing.
——Then carry out a visual inspection of each blade checking that there are
no cracks or splits.
——Check the appearance of the turbine disk and cone. Check that the
balance weights are present.
——Refit the inspection hatch.
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Cleaning and inspecting the turbine wheel – access via the inlet casing
This operation concerns narrow ventilators where the width of the casing is
insufficient for an inspection hatch.
——Remove the inlet housing
——Carry out the cleaning and verification operations described in the above
paragraph.
——Refit and adjust the housing (See Para. ‘Adjusting the housing’)
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5.10 Oil Mist Eliminator 88QV-1A
The totally enclosed and fan cooled three phase squirrel cage induction motors
require very little maintenance nevertheless it is recommended to check the
motor regularly in order to prevent a breakdown caused by dust, moisture,
vibrations, too much or too little greasing.
Dust:
The outer parts of the totally enclosed motors, especially the cooling ribs or
cooling channels, have to be kept as clean as possible in order not to obstruct the
cooling air from the fan extracting the heat from the motor frame.
Moisture:
Motors, which are not often run, should be started from time to time to
prevent moisture affecting the windings in the long time.
Wear &vibration
To prevent abnormal wear &vibration, one should:
_take care that the tension of the belt or the chain is not too high
_check whether the mounting of directly coupled machines is correct
_check whether the foundation bolts the bolts to fasten the motor and the
slide rails are tight.
Greasing
Before they leave the factory, the bearings of the DUTCHI Motors are filled
with a high quality Lithium base grease.
The sizes 56 up to and including 250 are provided with shielded/sealed
bearing (ZZ-C3), which have been filled with life-time grease by the
manufacture of the bearings.
Motor with sealed bearing and no re-lubrication system require no
maintenance other than checking for noise &temperature during their lifetime.
Sizes 280 up to and including 400, has been provided with a permanent
lubrication system containing a grease valve.
The lubrication must take place when the machine is running.
The old grease is ejected from the grease valve thus maintaining the correct
level and avoiding overfilling which would be harmful.
Bearing type and bearing inside diameter
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5.11Starting Motor 88CR
Notion of maintenance’s degree

Generally, it is advocated to minimum establish a program based on the
following recommendations, according to the complexity of use of the motor
functioning unit. A 3 degrees classification of maintenance is generally admitted,
concerning asynchronous motors. Those degrees of maintenance have to be
carried out according to the standard intervals of operation, to ensure a predictive
attending of failures. The frequency of maintenance operations will have to be
adapted to the exploitation mode of the motor and to the material and financial
risks, linked to the conditions perturbing the reliability of the motor functioning.
1st degree of maintenance
The first degree consist to realize simple visual action of control and minor
checks necessary for the exploitation, using the integrated equipment of support
and the mechanical and electrical tools adapted to the normal maintenance of the
motor. Those checks have to allow the evaluation and the correction of minor
defaults appearing, by analysing the critical parameters evolution in relation with
predetermined thresholds from the damaging status of the motor components.
Those actions are generally short, around 8 hours. They have to be done every
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4000 hours of exploitation or twice a year.
2nd degree of maintenance
The second degree consists to realize a complementary inspection of the
ignored points from the previous operations and to set the critical points reliable,
as noticed on the components status by repairing or exchanging parts. Objective
of an examination is to realize a complete revision, opening sub-ensembles of the
motor: cooling systems, bearings, junction boxes, stator and rotor status through
trap doors. This degree of maintenance imply the use of measure instruments for
electrical characteristics of the machine.
A spectral analyses of the motor could be realized to detect any anomalies of
the components:
- Wear detection of the rollers,
- Mechanical break,
- Unbalance, alignment
- Default of sealing or resonance
- Electrical defaults,
- Etc.
This allow to anticipate curative or palliative actions of maintenance.
They have to be controlled every 8000 hours of exploitation, means once a
year.
3rd degree of maintenance
The third degree consist to realize a complete inspection of the machine
components and important works of maintenance necessary to repair completely
consequences of defaults and failures reported.
If necessary, those operations can include the complete dismantling of major
parts as the rotor, using adapted tools. Those operations imply a specialized
knowledge, including corrective or preventive maintenance works done by
specialized teams, using general or particular instructions of maintenance. It is
imperative to previously determine spare parts needed for this operations, based
on the previous inspection and to reduce repairing time. Plan to realize this degree
of maintenance every 40 000 hours of exploitation, corresponding to 5 years of
exploitation.
99
100
101
5.12Turbine Motor 88TG and Auxiliary Hydraulic Oil Pump 88HQ
5.12.1 Initial checks
All electrical installations, however complex, must be meticulously checked

before being powered up. This check is of particular importance for installations
which may, when they have been power end, be in an explosion risk zone. To be
totally effective, this check must be performed in the presence of a qualified
represent native of the organization which has carried out the work and the user's
service manager or maintenance supervisor, and possibly a representative of the
firm which designed the installation. These checks result in the issuing of an
acceptance report. It is vitally important that this evaluation be carried out in a
rigorous and detailed way, as many important checking operations are possible
without any risk, as long as the installations are not powered up. They will no
longer be able to be carried out without extremely rigorous precautions, once the
plant is working, if the plant operates continuously.
5.12.2 Frequent monitoring
This monitoring, generally performed by the operation personnel, includes:

- preventive monitoring of the state of the equipment (cables, cable glands,
etc.) taking into account the environment (heat, humidity),
- detecting abnormalities which may be dangerous, as early as possible, such
as damage to able sheath caused by abrasion,
- providing regular effective personnel training on the risks involved and
how to minimize them.
Regulatory periodic checks
They can be performed by a technician (who may or may not work for the
102
company) with an in depth knowledge of the field of prevention of risks caused
by electricity and of the associated regulations. But usually to ensure objectivity
and because of a lack of resources (both personnel and equipment), the company
will use an approved checking body.
5.12.3 Bearing Check
The frequency of these checks depends on the operating conditions.

If a bearing runs hot, even when correctly mounted and lubricated, makes an
abnormal noise or shows considerable radial play:
It is worn and needs to be replaced as quickly as possible to avoid seizing
and all the resulting consequences for the motor and the driven parts.
To dismount a bearing in the best conditions for replacement, the different
parts should be marked to avoid mistakes or inversions.
Bearings are removed with extractors. To put a bearing into place:
- heat it in an oil bath at 80°C
- mount it rapidly by pushing it in to its final position.
After each replacement operation, all labyrinth and seal intervals must be
filled with grease to prevent dust penetration .In some cases, rotating machines
may have been stored in warehouse for long periods of time before being put
into operation. Even though the storage is carried out in good conditions, some
electrical and mechanical checks are necessary before starting up.
5.12.4 Storage conditions
The machine must be stored in a sheltered place well protected from moisture
(i.e. a warehouse).Actually, if the relative humidity degree rises above 90 %,
then the insulation level drops very rapidly to become almost non existent when
reaching 100 %.
5.12.5 Electrical checks
Before starting the machine, it is advisable to check the insulation of stator

winding to the ground and between phases. This checking has to be carried out
with a 500 V D.C. Megger. Insulation resistance must be at a minimum of 10
MΩ when hot (100°C) or 100 MΩ when cold.
In the case when these conditions are not met, or if the machine has been
exposed to water drips, mists, storage in damp place or is covered by
condensates, it is advisable to dry in during 24 hours in a drying oven with a
temperature about 100-110 °C.
If it is not possible to dry the machine in an oven, it is then advisable to
follow one of the procedure listed hereunder.
- Supply it in a three phase A.C. voltage (through an induction regulator or a
step down transformer with adjustable taps) adjusted to about 10 % of the rated
103
voltage during 12 hours with the rotor blocked (rotor short-circuited for slipring
motors),
- or supply it with D.C. voltage, the three phases being series connected (by a
D.C. generator with separate excitation or a storage battery for motors of less
than 30 HP) adjusted to about 1 to 2 %of the rated voltage.
The A.C. or D.C. current should not exceed:
- 40 % of the rated current for drip-proof motors,
- 60 % of the rated current for totally-enclosed motors.
It is advisable to check the current with a clip-on ammeter (A.C.) or with a
shunted ammeter (D.C.)and to put a thermometer on the frame: if the
temperature overcomes 70°C, reduce the above values of voltages or currents by
5 % for a 10°C shift.
5.12.6 Mechanical checks.
Greases used for bearing lubrication tends to oxidize and decompose in

contact with air. Operation with oxidized grease may result in a rapid
deterioration of the bearings.
It is recommendable to carry out lubrication while the machine is running.

5.12.7 Long still standing periods
Obviously similar conditions arise, if the machine has not been running for a
long time, though remaining installed at its operational site.
So as to avoid the difficulties mentioned above, the use of heaters (space
heaters) is recommended, as well as periodical maintenance runs.
6 .Acoustic Enclosures Maintenance
6.1Gas Turbine Enclosure Maintenance Diagram
104
Component
Identification Maintenance
Designation Frequency Action Quantity
Component Sequence
(see note)
Code Number
1xxx 33DT Doors 6M Visual control of seals status 10m
1xxx Doors Hinges 6M Hinges lubrications
1xxx Panic bar M Manual good working checking N.A.
4xxx Frame Assy 6M Visual control of frame N.A.
2xxx Panels and Accessories 6M Visual control of panels N.A.
3xxx Panels and Accessories 6M Visual control of seals status 10m
5xxx Roof panel 6M Visual control seals status 10m
3xxx Lighting (Spot) 3M Control status of lighting 1
3xxx Lighting (Spot) 3M Control status of lighting (bulb) 1
8xxx 88BT Duct blowing Outlet 3M Visual control of flexible sleeve 2
8xxx 88BT Duct blowing Outlet 3M Visual control of flexible sleeve 2
8xxx 88VG Duct blowing Inlet 3M Visual control of flexible sleeve 2
8xxx 88VG Duct blowing Inlet 3M Visual control of flexible sleeve 2
8xxx 88VG Duct blowing Outlet 3M Visual control of flexible sleeve 2
8xxx 88EF Duct blowing Inlet 3M Visual control of flexible sleeve 2
8xxx 88EF Duct blowing Outlet 3M Visual control of flexible sleeve 2
8xxx Duct blowing 3M Visual control of seal status 7m
8xxx 63VL 88VL inlet 3M Visual control of dumper 1
8xxx 88VG Inlet 3M Visual control of seal status 10m
8xxx 88BT Damper 3M Control status of Damper 2
8xxx 88VG Damper 3M Control status of Damper 2
8xxx 88VG Damper 3M Control status of Damper 1
8xxx 88EF Damper 3M Control status of Damper 2
105
Filter 1M Control status and cleanness filter 1
6.2WI Module Enclosure Maintenance Diagram
COMPONENT
maintenance
identification
DESIGNATION frequency ACTION Quantity
Component Sequence
(see note)
Code Number
1xxx Doors 6M Visual control of seals status 10m
Visual control of
8xxx 88JS DAMPER 3M 2
dumper
8xxx 88JS MOTOR 3M Control of motor 1
Control of filter
8xxx FILTER 1M 1
(cleanness)
Control of electrical
8xxx 20JS SOLENOIDE 3M solenoid (cleanness, mechanical 2
adjustment…)
Control status of
8xxx 66JS DPSL 3M 1
pressure switch
6.3Genertor Acoustic Enclosure Maintenance Diagram
Component
Identification Maintenance
Designation Frequency Action Quantity
component Sequence
(see note)
Code Number
1xxx 33DT Doors 6M Visual control of seals status 10m
106
1xxx Doors Hinges 6M Hinges lubrications
1xxx Panic bar M Manual good working checking .A.
4xxx Frame Assy 6M Visual control of frame A.
2xxx Panels and Accessories 6M Visual control of panels A.
5xxx Roof panels 6M Visual control seals status 10m
8xxx 88GV Duct blowing Outlet 3M Visual control of flexible sleeve 2
8xxx 88GV Duct blowing Outlet 3M Visual control of flexible sleeve 2
8xxx Duct blowing 3M Visual control of seal status 7m
8xxx 88VG Inlet 3M Visual control of seal status 10m
8xxx 88GV Damper 3M Control status of Damper 2
6.4 Maintenance of PEECC
6.4.1 System Maintenance
6.4.1.1 List of Equipment
Unit Description Period Action

2 BATTERY
2 A Dedust the chargers
CHARGERS
1 INVERTER Refer to Manual dedicated to inverter
1 125VDC BATTERY Refer to Manual dedicated to battery
These cooling units should be inspected at least once each year by
qualified service person.
2 AIR CONDITIONERS 6M The minimum maintenance requirements for this equipment are as
follows
1. Inspect evaporator coil, drain pan, and condensate drain each cooling
107
season for cleanliness. Clean when necessary.
2. Inspect blower motor and wheel for cleanliness and check lubrication
each cooling season. Clean when necessary.
3. Check that electrical connections are tight and check controls for
proper operation each cooling system
1M Inspect air filters each month. Clean or replace when necessary.
Includes visual and acoustic inspection of different parts of the center as
well as verification of their correct operations:
1. Open doors and rear covers of the equipment.
2. In case of contactors and circuit breaker with pottery blow chamber,
check there is no either verification or metallization.
3. If service operation allows, open the circuit breakers carry out
connection operation, trip relays and verify disconnecting contacts.
MOTOR CONTROL
1 4. Verify mechanism, contacts, micro switches or limit switches, and
CENTRE
check actions every certain no of operations.
5. Verify signaling lamps.
6. Check that terminal blocks and terminals have the suitable clamping
pressure and clamp them stronger if necessary.
7. Introduce with draw able modules.
8. Close doors and covers and restore the equipment to the primitive
connection status.
The whole installation shall be reviewed and cleaned once a year or
twice a year at latest. For that purpose a schedule that allows part of the
main busbar keep working could be followed with the corresponding
MOTOR CONTROL surveillance and safety standards. In this case cleaning intervals for the
1
CENTRE different equipment shall be controlled.
1. Disconnect busbars and ensure they will not be re-connected.
2. Open doors, rear and front covers and verify that is not powered.
Connect phases to the earth.
108
3. Screw-off rear and top covers.
4. Clean supports of the bus bars, etc.
5. Examine and tighten bolted joints.
6. Verify the status of the bus bar supports and flexible bridges.
7. Withdraw with draw able modules and clean them.
8. Control, clean and lubricate plug contacts.
9. Control socket contacts (spring pressure, contact surface) and clean
them.
10. Clean grounding contact of with draw able panel and also the
grounding flat bar of the panel.
11. Clean carefully the panel interior.
12. Verify the rubber or neoprene joints.
13. Clean the warning lamps and auxiliary contacts and verify them
(only when not powered).
14. Put all covers of the connections and re-assemble parts that were
removed.
GENERATOR
PROTECTION
1 Refer to Manual dedicated to this panel
AND EXCITATION
PANEL
GAS TURBINE
CONTROL PANEL
OPERATOR
INTERFACE PANEL
1 AUXILIARY PANEL Refer to Manual dedicated to this panel
FIRE FIGHTING
PANEL
109
6.4.1.2 Health and Safety

Motor Control Centre
High Voltage present.
May cause shock, burns, severe injury or death.
Do not touch exposed wires or terminals.
ANY INTERVENTION SHALL BE CARRIED OUT BY QUALIFIED
STAFF BEING INFORMED
OF THE SPECIFIC ELECTRICITY HAZARDS AND OF THE
PRECAUTIONS TO BE
UNDERTAKEN.
NEVER PRESUME THAT A VOLTAGE IS PRESENT OR ABSENT:
ALWAYS CHECK BY MEANS OF A VOLTMETER.
WARNING:
Indicates a procedure or practice which, if not strictly observed, may result in
injury or death of operator.
CAUTION:
Indicates a procedure or practice which, if not strictly observed, may
seriously damage or destroy the equipment.
WARNING:
The system must only be used in technically perfect conditions in accordance
with its designated use and the instructions set out in the operating manual. The
system must be used only by safety-conscious persons who are fully aware of
the risks involved in operating the system. Any functional disorders, especially
those affecting the safety of the system, should therefore be rectified
immediately.
It is impossible to list all of potential safety hazards, but it is imperative that:
- Personnel involved with the equipment or systems are instructed to conduct
themselves in a safe manner and follow the general safety rules of the plants.
WARNING:
Disconnect electrical power before servicing electrical parts.
Always keep the maintenance floor perfectly clean.
Note:
Special attention shall be given to the monitoring and inspection of the
conditions and materials linked to the safety of the staff, energized components
and cleanliness.
For protective measures, reference shall, as a rule, be made to the
110
country-specific standards.
As regards the required manual dexterity, the maintenance shall be carried
out correctly by qualified staff, using the appropriate equipment and tools.
Battery Chargers
ANY INTERVENTION SHALL BE CARRIED OUT BY QUALIFIED
STAFF HAVING BEEN
INFORMED OF THE SPECIFIC ELECTRICITY HAZARDS AND OF
THE PRECAUTIONS TO
BE TAKEN.
DANGEROUS VOLTAGES ARE AT ALL TIMES PRESENT AT THE
TERMINALS OF THE
BATTERY, THE CHARGER AND THE LOW-VOLTAGE PANEL.
NEVER PRESUME THAT A VOLTAGE IS PRESENT OR ABSENT :
ALWAYS CHECK BY MEANS OF A VOLTMETER.
Note :
The purpose of the maintenance is to prove that the assembly conforms to the
applicable rules and regulations at the time of manufacture or at the time of
modifications. Special attention shall be given to the monitoring and inspection
of the conditions and materials linked to the safety of the staff, energized
components and cleanliness.
For protective measures, reference shall, as a rule, be made to the
country-specific standards.
As regards the required manual dexterity, the maintenance shall be carried
out correctly by qualified staff, using the appropriate equipment and tools.
6.4.1.3 Preventive Maintenance Instructions
The tightening torque of the connection screws varies according to their
respective diameters:
M5 screws: torque of 5.5 Nm to 6.5 Nm max.
M6 screws: torque of 8 Nm to 10 Nm max.
M8 screws: torque of 15 Nm to 17 Nm max.
Battery Chargers
Rectifier maintenance:
Dedust the complete rectifier once per year. Perform, at regular intervals, an
inspection comprising the following operations:
1 - Disconnect the mains input and the battery.
111
2 - Inspect the components and the cabling. Especially look for signs of
overheating and melting of insulating material. Check all connections. Check
that none of the wires is disconnected.
3 - Check that the ventilation is not obstructed.
4 - For rectifiers equipped with air inlet filters (on the door), check that the
filters are clean.
5 - Check the operation of the rectifier and the voltage levels.
Fan maintenance:
The three-phase equipment (TPR) of more than 100 A are equipped with a
fan.
1 - A thermo contact (optional) mounted on the heat sink of the power
converter activates the fan when a temperature of 64°C is exceeded. The fan has
a life cycle of approx. 5 years.
2 - It is recommended to replace the fan every three years. This operation
shall be carried out by specialized staff.
6.4.2 Corrective Maintenance Instructions
6.4.2.1General
Remote alarms in the control room are not sufficient for troubleshooting.
They allow locating the faulty equipment.
Local alarms provide more information about the kind of fault and allow
troubleshooting.
Before starting troubleshooting, it is required to check if the fault is not
caused by external equipment. The wiring and protection circuits must conform
to the original diagrams and setting specifications.
Before replacing a faulty component (in particular electronic one) it is
needed to check if the configuration and the settings of the new component are
correct.
The safety rules must be respected during troubleshooting: the system must
be stopped and the power switched off.
6.4.2.2 Fault processing
General:
Troubleshooting:
The purpose of the procedures is to provide a guide for locating the faulty
component by using the displayed messages as the procedure entry.
The paragraph deals with the faults which are caused by the equipment
discussed in the present document.
6.4.2.3 Troubleshooting procedures
112
Control/monitoring 125 VDC. Fault (30DC-1)
Fault description:
A 125 VDC distribution fault is detected in the low voltage distribution
panel.
Possible fault origin:
Faulty circuit controlled by one of the following circuit breakers.
Fault result:
Generation of a fault in the gas turbine control panel.
Troubleshooting:
When the system is stopped, check the following:
State of the circuit breakers and identify the breaker which detected the fault.
Circuit protected by the opened circuit breaker.
AC power supply faults (30AC-1, 30AC-2 and 30AC-3)
Faults description:
A 400, 230 or 230UPS VAC power supply fault is detected in the low
voltage distribution panel.
Possible faults origin:
Faulty 400, 230 or 230UPS VAC circuit.
Fault result:
Generation of a fault in the gas turbine control panel.
Troubleshooting:
When the system is stopped, check the following:
State of the circuit breakers and identify the breaker which detected the fault.
Circuit protected by the opened circuit breaker.
6.4.3 Storage Instructions

The packing of the equipment shall comply with the general conditions of
industrial packing which are specified by the Industrial Packing Association
(SEI) and to the requirements (storage duration and environmental conditions)
which are specified by the customer.
Storage of the equipment before use.
The packing of the equipment is designed for limited storage duration. It is
also necessary to provide a protection against excessive heat and humidity.
Storage of electronic cards before use
113
The electronic cards are packed separately using a thermo welded pocket and
dehydrating bags. The pocket is provided with hygrometry indicators.
The hygrometry indicators need to be checked regularly in order to guarantee
correct storage conditions.
Storage of spare parts
The spare parts must be stored in a dry location and kept away from heat,
dust and destructive chemical agents.
The spare parts must also be protected against possible mechanical damage.
Battery Chargers
Temperature:
Storage: -25°C to +70°C
Relative humidity:
Storage: 15% to 90% in original package
Low-voltage panel:
If the unpacked unit or a unit in an inappropriate package has remained in a
very humid environment, it is recommended to heat the room or to energize the
heating resistors, if present.
Unless otherwise agreed between the user and the manufacturer, the relevant
transport, storage and on-site assembly conditions shall be met.
Admissible temperatures between -25°C and +55°C and up to +40°C for
short periods not exceeding 24 hours.
114
Appendix – 1- SPARE PARTS OF APU SYSTEM

D09000913-04A Rev.
LIST OF SPARE PARTS DURING START-UP OF THE INSTALLATION AIR COMPRESSED SYSTEM
A Date : 13/10/09
DESIGNATION SPARE PARTS Quantity
SYST ITEM Installed for
UNIT DESCRIPTION DESCRIPTION TYPE start-up
EM No.
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Oil filter cartridge 7 216 101 (1) 1 0
CMP Primary air intake filter
GT1-GT2-GT3 SAP Screw compressor RAFALE 37 kW 7 210 032 (1) 1 0
301 cartridge
CMP Security air intake filter
GT1-GT2-GT3 SAP Screw compressor RAFALE 37 kW 7 210 035 (1) 1 0
301 cartridge
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Separator cartridge 7 211 003 (1) 1 0
Separator cartridge
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW 7 501 030 (1) 1 0
O-ring
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Belts XPA 1180 7 081 056 (1) 5 0
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Oil P46 (can 25l) 7 550 040 (1) 30 l 5
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Regulation valve 7 375 067 (1) 1 0
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Oil return hose 7 355 032 (1) 1 0
Air/oil outlet screw air
end hose
Air outlet separator /
exchanger
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Pressure safety valve 7 720 051 (1) 1 0
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Thermostatic valve 7 230 009 (1) 1 0
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Pressure switch 7 700 019 (1) 1 0
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Pressure gauge 7 741 310 (1) 2 0
Regulation solenoid
valve
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Oil thermostat 7 710 007 (1) 1 0
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Oil drain valve 7 370 009 (1) 1 0
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Oil drain plug + gasket 7 603 032 (1) 1 0
115
D09000913-04A Rev.
LIST OF SPARE PARTS DURING START-UP OF THE INSTALLATION AIR COMPRESSED SYSTEM
A Date : 13/10/09
SYST ITEM Installed for
UNIT DESCRIPTION DESCRIPTION TYPE start-up
EM No.
GT1-GT2-GT3 SAP CMP301 Screw compressor RAFALE 37 kW Screw air end 7 103 004 (1) 1 0
Desiccat : molecular
GT1-GT2-GT3 SAP DRY401 Adsorption air dryer SAD255 7 213 000 (2) 50 kg 0 kg
sieve
port directional valve 63330002530
GT1-GT2-GT3 SAP DRY401 Adsorption air dryer SAD255 1 0
combination V1-V4 0 (2)
Check valve block 63331002530
GT1-GT2-GT3 SAP DRY401 Adsorption air dryer SAD255 1 0
V5-V6 0 (2)
GT1-GT2-GT3 SAP DRY401 Adsorption air dryer SAD255 Dew point indicator gel 7 770 025 (2) 1 0
79903000250
GT1-GT2-GT3 SAP DRY401 Adsorption air dryer SAD255 Silencer 1 0
1 (2)
GT1-GT2-GT3 SAP DRY401 Adsorption air dryer SAD255 Solenoid valve 7 314 011 (2) 4 0
FLT401 Pre fiter / Final filter
GT1-GT2-GT3 SAP Pre filter / Final filter G11Z 7 214 405 (3) 2 0
FLT403 cartridge
GT1-GT2-GT3 SAP FLT402 Oil filter G11X Oil filter cartridge 7 214 205 (4) 1 0
D09000913-04B Rev.
LIST OF SPARE PARTS FOR 2 YEARS OF EXPLOITATION AIR COMPRESSED SYSTEM
A Date 13/10/09
Installed for 2
SYSTE ITEM
UNIT DESCRIPTION DESCRIPTION TYPE years
M No.
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil filter cartridge 7 216 101 (1) 1 1
GT3
GT1-GT2- Primary air intake filter
SAP CMP 301 Screw compressor RAFALE 37 kW 7 210 032 (1) 1 1
GT3 cartridge
GT1-GT2- Security air intake filter
GT3 cartridge
116
D09000913-04B Rev.
A Date 13/10/09
Installed for 2
SYSTE ITEM
M No.
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Separator cartridge 7 211 003 (1) 1 1
GT3
GT1-GT2- Separator cartridge
SAP CMP301 Screw compressor RAFALE 37 kW 7 501 030 (1) 1 1
GT3 O-ring
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Belts XPA 1180 7 081 056 (1) 5 5
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil P46 (can 25l) 7 550 040 (1) 30 l 30 L
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Regulation valve 7 375 067 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil return hose 7 355 032 (1) 1 1
GT3
GT1-GT2- Air/oil outlet screw air
GT3 end hose
GT1-GT2- Air outlet separator /
GT3 exchanger
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Pressure safety valve 7 720 051 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Thermostatic valve 7 230 009 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Pressure switch 7 700 019 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Pressure gauge 7 741 310 (1) 2 0
GT3
GT1-GT2- Regulation solenoid
GT3 valve
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil thermostat 7 710 007 (1) 1 0
GT3
117
D09000913-04B Rev.
A Date 13/10/09
Installed for 2
SYSTE ITEM
M No.
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil drain valve 7 370 009 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil drain plug + gasket 7 603 032 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Screw air end 7 103 004 (1) 1 0
GT3
GT1-GT2- Desicca : molecular
SAP DRY401 Adsorption air dryer SAD255 7 213 000 (2) 50 kg 50 kg
GT3 sieve
GT1-GT2- 4-port directional valve 63330002530
SAP DRY401 Adsorption air dryer SAD255 1 0
GT3 combination V1-V4 0 (2)
GT1-GT2- Check valve block 63331002530
GT3 V5-V6 0 (2)
GT1-GT2-
SAP DRY401 Adsorption air dryer SAD255 Dew point indicator gel 7 770 025 (2) 1 0
GT3
GT1-GT2- 79903000250
SAP DRY401 Adsorption air dryer SAD255 Silencer 1 0
GT3 1 (2)
GT1-GT2-
SAP DRY401 Adsorption air dryer SAD255 Solenoid valve 7 314 011 (2) 4 0
GT3
GT1-GT2- FLT401 / Pre fiter / Final filter
SAP Pre filter / Final filter G11Z 7 214 405 (3) 2 2
GT3 FLT403 cartridge
GT1-GT2-
SAP FLT402 Oil filter G11X Oil filter cartridge 7 214 205 (4) 1 1
GT3
D09000913-04C Rev.
A Date 13/10/09
SYSTE ITEM Installed for 5
M No.
118
D09000913-04C Rev.
A Date 13/10/09
M No.
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil filter cartridge 7 216 101 (1) 1 2
GT3
GT1-GT2- Primary air intake filter
GT3 cartridge
GT1-GT2- Security air intake filter
GT3 cartridge
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Separator cartridge 7 211 003 (1) 1 2
GT3
GT1-GT2- Separator cartridge
GT3 O-ring
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Belts XPA 1180 7 081 056 (1) 5 10
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil P46 (can 25l) 7 550 040 (1) 30 l 60 L
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Regulation valve 7 375 067 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil return hose 7 355 032 (1) 1 2
GT3
GT1-GT2- Air/oil outlet screw air
GT3 end hose
GT1-GT2- Air outlet separator /
GT3 exchanger
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Pressure safety valve 7 720 051 (1) 1 1
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Thermostatic valve 7 230 009 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Pressure switch 7 700 019 (1) 1 0
GT3
GT1-GT2- SAP CMP301 Screw compressor RAFALE 37 kW Pressure gauge 7 741 310 (1) 2 0
119
D09000913-04C Rev.
A Date 13/10/09
M No.
GT3
GT1-GT2- Regulation solenoid
GT3 valve
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil thermostat 7 710 007 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil drain valve 7 370 009 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Oil drain plug + gasket 7 603 032 (1) 1 0
GT3
GT1-GT2-
SAP CMP301 Screw compressor RAFALE 37 kW Screw air end 7 103 004 (1) 1 0
GT3
GT1-GT2- Desiccate: molecular
SAP DRY401 Adsorption air dryer SAD255 7 213 000 (2) 50 kg 80 kg
GT3 sieve
GT1-GT2- 4-port directional valve 63330002530
GT3 combination V1-V4 0 (2)
GT1-GT2- Check valve block 63331002530
GT3 V5-V6 0 (2)
GT1-GT2-
SAP DRY401 Adsorption air dryer SAD255 Dew point indicator gel 7 770 025 (2) 1 0
GT3
GT1-GT2- 79903000250
SAP DRY401 Adsorption air dryer SAD255 Silencer 1 1
GT3 1 (2)
GT1-GT2-
SAP DRY401 Adsorption air dryer SAD255 Solenoid valve 7 314 011 (2) 4 0
GT3
GT1-GT2- FLT401 / Profited / Final filter
SAP Pre filter / Final filter G11Z 7 214 405 (3) 2 4
GT3 FLT403 cartridge
GT1-GT2-
SAP FLT402 Oil filter G11X Oil filter cartridge 7 214 205 (4) 1 2
GT3
120
ADSORPTION AIR DRYER SAD 255--SPARE PARTS LISTS

SAD145-SAD200 SAD255-SAD360 SAD400-SAD620
POS. DESIGNATION SAD750 REF. SAD900 REF.
REF. REF. REF.
Desiccant: molecular sieve 7213000.00 7213000 7213000 7213000 7213000
2 Microfilter 738040008001.00 738040008001.00 738040014001.00 738040014001.00 738040015001.00
5 Manometer 650200031821.00 650200031821.00 650200031821.00 650200031821.00 650200031821.00
6 Drain plug 620160003106.00 620160003108.00 620160003109.00 620160003109.00 620160003109.00
200 Silencer 799030002501.00 799030002501.00 799030004001.00 799030004001.00 799030005001.00
4-port directional valve
100 633300025300.00 633300025300.00 633300040300.00 633300040300.00 633300050300.00
combination V1-V4
Solenoide 230V 7 314 011 7 314 011 7 314 011 7 314 011 7 314 011
Pre-filter cartridge O. OIjj
70.3 7 214 204 7 214 205 7 214 206 7 214 207 7 214 208
(serie X)
70.7 Automatic condensate drain 104100000004.00 104100000004.00 104100000004.00 104100000004.00 104100000013.00
Differential pressure
70.9 7 207 104 7 207 104 7 207 104 7 207 104 7 207 104
manometer
50 Check valve block V5-V6 633310025300.00 633310025300.00 633310040300.00 633310040300.00 633310050300.00
80.3 After-filter cartridge (serie Z) 7 214 404 7 214 405 7 214 406 7 214 407 7 214 408
80.8 Hand drain 632100000001.00 632100000001.00 632100000001.00 632100000001.00 630300001501.00
Differential pressure
80.9 7 207 104 7 207 104 7 207 104 7 207 104 7 207 104
manometer
Dew point indicator gel 7 770 025 7 770 025 7 770 025 7 770 025 7 770 025|
121
Appendix – 2- SPARE PARTS OF MCC
START-UP SPARE PARTS MCC
No. Catalogue Code Manufacturer Description Quantity
1 F5.1A CABUR FUSE 5X20,250V,IF=1A 3
4 F5.6,3A CABUR FUSE 5X20,250V,IF=6,3A 3
5 17419 FERRAZ FUSIBLE 14X51,4A,GI-GG 3
6 17933 FERRAZ FUSIBLE 14X51,12A, AM 3
7 18951 FERRAZ FUSIBLE 22X58,50A,AM 3
11 1591250 ITALWEBER FUSIBLE NH1 250A/AM WITH STRIKER 3
12 DCB CABLE LUG 6mm2 d=10mm 20
21 2009-1040S CUBIC M10x40 screw, class 8,8 150
22 2018-1000 CUBIC Disc washer M10 150
23 0070-0000 CUBIC SPACER 150
24 0062-0000 CUBIC SPECIAL NUT 150
25 31900 DCB HEAT SHRINK TUBING 1" 6m
122
2 YEARS MCC SPARE PARTS LIST
No. Catalogue Code Manufacturer Description Qty
1 1SDA 038291 R1 ABB SHUNT OPENING RELEASE 120-127VAC/DC 0
2 1SDA 038301 R1 ABB SHUNT CLOSING RELEASE 120-127VAC/DC 0
3 1SDA 038323 R1 ABB MOTOR OPERATOR 100-130VAC/DC 0
4 1SDA 038329 R1 ABB INTERLOCK CABLES FOR FIXED PARTS OF 2 CB'S 0
5 1SDA 038351 R1 ABB PADLOCKS FOR EMAX 0
6 1SDA 038361 R1 ABB 5 AUX. CONTACTS SIGNAL RACKED-IN/TEST/RACKED-OUT 0
7 1SDA 038364 R1 ABB INTERLOCK FOR FIXED PART WITHDRAWABLE CB 0
8 1SDA 038366 R1 ABB INTERLOCK FOR MOVING PART OF WITHDRAWABLE CB 0
9 1SDA 055781 R1 ABB 3P BREAKER EMAX W-MP E1N 1600A; 50KA; PR122P-LSIG 0
10 1SDA 058260 R1 ABB ELECTRICAL SIGNALLING OF OVERCURRENT RELEASES TRIP 0
11 1SDA 058267 R1 ABB 10 AUX. CONTACTS SIGNAL CB OPEN/CLOSED 5NO 0
12 1SDA 058278 R1 ABB LOCK IN RACKED-IN/TEST/RACKED-OUT POSITION 0
13 1SDA 059672 R1 ABB 3 POLES FIXED PARTS VR FOR EMAX SIZE E1 0
14 1SFA616921R2141 ABB INTEGRATED LED 130VAC/DC RED 10
15 1SFA616921R2142 ABB INTEGRATED LED 130VAC/DC GREEN 10
16 1SFA616921R2143 ABB INTEGRATED LED 130VAC/DC YELLOW 10
17 1SFA616921R2144 ABB INTEGRATED LED 130VAC/DC BLUE 1
18 FPL7449115R0005 ABB NORE125-01G;1NC;125A;125VDC 1
19 FPL7519115R0005 ABB I〇RE170-10G;1N〇;170A;125VDC 1
20 FPTN410013R0001 ABB AUXILIARY CONTACTS CA12-11 1
21 FPTN410056R0001 ABB SUPPORT 巳 RACKET FOR CA12 1
22 HB0200 ABB AC/DC CURRENT TRANSDUCER 200A,15V DC 1
23 08-50-0013 ABB MOLEX CRIMP TERMINAL - 2759 1
24 22-01-1042 ABB MOLEX CRIMP TERMINAL HOUSING - 5051-N 1
25 ACB.120/BB CABUR Terminal block 120mmp,I=269A 1
27 BTU CABUR End bracket BTU 39
123
28 CB16/PT CABUR End section 2

1 1SDA 038291 R1 ABB SHUNT OPENING RELEASE 120-127VAC/DC 0
2 1SDA 038301 R1 ABB SHUNT CLOSING RELEASE 120-127VAC/DC 0
3 1SDA 038323 R1 ABB MOTOR OPERATOR 100-130VAC/DC 0
4 1SDA 038329 R1 ABB INTERLOCK CABLES FOR FIXED PARTS OF 2 CB'S 0
5 1SDA 038351 R1 ABB PADLOCKS FOR EMAX 0
6 1SDA 038361 R1 ABB 5 AUX. CONTACTS SIGNAL RACKED-IN/TEST/RACKED-OUT 0
7 1SDA 038364 R1 ABB INTERLOCK FOR FIXED PART WITHDRAWABLE CB 0
8 1SDA 038366 R1 ABB INTERLOCK FOR MOVING PART OF WITHDRAWABLE CB 0
9 1SDA 055781 R1 ABB 3P BREAKER EMAX W-MP E1N 1600A; 50KA; PR122P-LSIG 0
10 1SDA 058260 R1 ABB ELECTRICAL SIGNALLING OF OVERCURRENT RELEASES TRIP 0
11 1SDA 058267 R1 ABB 10 AUX. CONTACTS SIGNAL CB OPEN/CLOSED 5NO 0
12 1SDA 058278 R1 ABB LOCK IN RACKED-IN/TEST/RACKED-OUT POSITION 0
13 1SDA 059672 R1 ABB 3 POLES FIXED PARTS VR FOR EMAX SIZE E1 0
14 1SFA616921R2141 ABB INTEGRATED LED 130VAC/DC RED 20
15 1SFA616921R2142 ABB INTEGRATED LED 130VAC/DC GREEN 20
16 1SFA616921R2143 ABB INTEGRATED LED 130VAC/DC YELLOW 20
17 1SFA616921R2144 ABB INTEGRATED LED 130VAC/DC BLUE 2
18 FPL7449115R0005 ABB NORE125-01G;1NC;125A;125VDC 2
19 FPL7519115R0005 ABB I〇RE170-10G;1N〇;170A;125VDC 2
20 FPTN410013R0001 ABB AUXILIARY CONTACTS CA12-11 2
21 FPTN410056R0001 ABB SUPPORT 巳 RACKET FOR CA12 2
22 HB0200 ABB AC/DC CURRENT TRANSDUCER 200A,15V DC 2
23 08-50-0013 ABB MOLEX CRIMP TERMINAL - 2759 2
24 22-01-1042 ABB MOLEX CRIMP TERMINAL HOUSING - 5051-N 2
27 BTU CABUR End bracket BTU 78
124
30 CB4/6/PT CABUR End section 2
31 CBD.16 CABUR Terminal block 16mmp,In=76A 18
32 CBD.2 CABUR Terminal block 2,5mmp,In=24A 210
35 CPM/21 CABUR Screws and sleeve 2
36 CPM/83 CABUR Screws and sleeve 4
37 CSC/00 CABUR Marking tags "0" 4
38 CSC/09 CABUR Marking tags from 0 up to 9 92
48 DFM/600 CABUR Partition for CBD.2 34
52 F5.6,3A CABUR FUSE 5X20,250V,IF=6,3A 2
53 GPM.240/B B CABUR Terminal block 240mmp,I=415A 2
54 PM/20/2 CABUR 2P cross-connections for CBD.2 6
57 PMP/01 CABUR Multiple communing bar 2
58 PMP/13 CABUR Multiple communing bar 4
59 PRT/P CABUR TERMINAL BLOCK COVER 2
60 SFR.4 CABUR TERMINAL BLOCK WITH FUSE 8
125
61 SFR.4/D3A CABUR DIODE-HOLDER BY255/3A, 1300V 2
62 SFR/PT CABUR END SECTION 10
63 SPS/1 CABUR COVER SUPPORT 2
64 SPS/3 CABUR COVER SUPPORT 2
65 TE.4/0 CABUR Earth Terminal block 4mmp 2
66 TIM CABUR TIM MARKING PLATE 14
67 XCSF3 CABUR POWER SUPPLIES CSF3/90-264;24VDC;3A 2
68 FRS2 CARLO GAVAZZI FRONT MOUNTING BEZEL 2
69 MI 100 CARLO GAVAZZI CURRENT METERING TRANSFORMER 10-100AAC 2
70 S 411 CARLO GAVAZZI 11-PINS SOCKET 2
71 SM 115 230 CARLO GAVAZZI 1-PHASE AC CURRENT CONTROL 0,5-500AAC,230VAC 2
72 RMPU3000 ENERDIS 3 PHASE UNDER VOLTAGE RELAY 500V,45-65HZ 2
73 0115168.23 ENTRELEC TERMINAL BLOCK WITH 1N4007 2
74 17419 FERRAZ FUS LE 14X51,4A,GI-GG 6
75 17933 FERRAZ FUS LE 14X51,12A,AM 6
80 D211580 FERRAZ FUSED DISCONNECTOR CMS14/MICR〇“，3P,50A 2
81 Q222470 FERRAZ FUSED DISCONNECTOR CMS22/MICRO,3P,125A 4
82 T215665 FERRAZ FUSED DISCONNECTOR CMS14/MICRO,3P,50A 2
83 1F72-EV-600 FRER VOLTMETER EQ72;0-600V,50HZ;DIRECT 2
84 430088 G.E. FA1BR1 RONIS KEYLOCK 1104B 2
85 430818 G.E. FABAT10 BELL ALARM CONTACT BLOCK NO 2
86 430837 G.E. FAS10R AUX CONTACT NO RIGHT MOUNTED 2
87 430879 G.E. PADLOCKING REMOVABLE FD1PR 2
88 431751 G.E. 3P CIRCUIT BREAKER 80A FEN36TA080JF 2
89 432979 G.E. 3P CIRCUIT BREAKER 200A FEN36TD200KF 2
90 432982 G.E. 3P CIRCUIT BREAKER 250A FEN36TD250KF 2
91 435073 G.E. 3P MAG-BREAKER 7A FEN36MC007JF 2
126
94 435094 G.E. 3P MAG-BREAKER 160A FEN36MC160JF 50KA 2
95 436495 G.E. FENRF/5 ROTARY HANDLE DIRECT ON DEVICE 2
96 607500 G.E. 2P RESIDUAL CURRENT DEVICE 32A/0,03A-D〇CA232/030 2
97 607502 G.E. 2P RESIDUAL CURRENT DEVICE 32A/0,3A-D〇CA232/300 2
98 624929 G.E. PADLOCKING RACKET KS 18
99 672568 G.E. CHANGEABLE AUX./SIGNAL CONTACT CA S/H 18
100 673322 G.E. 2P CIRCUIT BREAKER ;6A/C;10KA-EP102UCC06 2
104 674888 G.E. 2P CIRCUIT BREAKER G100;2A/C;10KA-G102C02 2
111 675029 G.E. 1P CIRCUIT BREAKER G100;40A/D;10KA-G101D40 2
116 730055 G.E. DISCONNECTOR LOADBREAK SWITCH 3P-63A DILOS 1 2
120 730252 G.E. AUXILIARY CONTACTS FOR DILOS 1,2,3 4
121 730255 G.E. HANDLE WITH EXTENSION SHAFT FOR DILOS 4
122 730263 G.E. TERMINAL COVERS FOR DILOS 2 2
123 731024 G.E. SET 2 TERMINAL COVERS FOR DILOS 1 4
124 BCLF01 G.E. INST. AUXILIARY CONTACT BLOCK 6
127
125 BCLF10 G.E. INST. AUXILIARY CONTACT BLOCK 4
126 BELA G.E. MECHANICAL INTERLOCK FOR CL45 2
127 BRLL11 G.E. INST. AUXILIARY CONTACT BLOCK 12
128 BSLDZ G.E. VOLTAGE SUPPRESSOR BLOCK (DIODE) 2
129 BSLR2R G.E. TRANSIENT VOLTAGE SUPPRESSOR BLOCK 130-240VAC 6
130 BSLR3R G.E. TRANSIENT VOLTAGE SUPPRESSOR BLOCK 130-240VAC 2
131 CK08CA311N G.E. 3P CONTACTOR Uc=220/230V;50Hz 2
132 CL00A301TN G.E. 3 POLE CONTACTOR 220/230V50Hz 2
133 CL01AB00TN G.E. 4P CONTACTOR 2NO-2NC;230VAC 2
134 CL02D400TK G.E. 4 POLE CONTACTOR 120-125VDC 2
135 CL06A300MN G.E. 3 POLE CONTACTOR 220/230V50Hz 2
137 CL09A300MN G.E. 3P CONTACTOR Uc=220/230;50Hz 2
138 CL25A300TN G.E. 3 POLE CONTACTOR 220-230V50Hz 2
140 GPAC10FBA G.E. AUXILIARY CONTACT BLOCK 1NO 6
141 GPAL01FRA G.E. ALARM CONTACT BLOCK 1NC 4
142 GPS1BHAD G.E. 3P CIRCUIT BREAKER 0,4-0,63A 2
143 GPS1BHAE G.E. 3P CIRCUIT BREAKER 0,63-1A 2
144 GPS1BHAF G.E. 3P CIRCUIT BREAKER 1-1,6A 2
145 GPS1BHAH G.E. 3P CIRCUIT BREAKER 2,5-4A 2
146 GPS1BHAJ G.E. 3P CIRCUIT BREAKER 4-6,3A 2
147 GPS1BHAK G.E. 3P CIRCUIT BREAKER 6,3-10A 2
148 GPS1BHAM G.E. 3P CIRCUIT BREAKER 11-16A 2
149 GPS1BHAN G.E. 3P CIRCUIT BREAKER 14-20A 2
150 GPS1BHAR G.E. 3P CIRCUIT BREAKER 24-32A 2
151 GPS1MHAM G.E. 3P MAG-BREAKER 16A 2
152 GPS2BHAS G.E. 3P CIRCUIT BREAKER 28-40A 2
153 GPS2BHAT G.E. 3P CIRCUIT BREAKER 35-50A 2
154 MARN440AT G.E. AUXILIARY CONTACTS BLOCK 4NO 2
155 MCRA022ATN. G.E. MINICONTACTOR 220-240V5〇Hz;22 8
156 MCRC022ATL G.E. MINICONTACTOR 2-2;Uc=125VDC 2
128
157 MCRC031ATL G.E. MINICONTACTOR 3-1 ; Uc=125VDC 2
158 MCRC040ATL G.E. MINICONTACTOR 4-0;Uc=125VDC 2
159 MPOAAE2 G.E. VOLTAGE SUPPRESSOR BLOCK 72-250V;50/60HZ 8
160 MPOCAE3 G.E. VOLTAGE SUPPRESSOR BLOCK 250VDC(DI〇DE) 4
161 NMRDV-6 G.E. DELAYED OFF TIMER24-240VAC/DC 2
162 NMTCV G.E. Delayed ON timer 24-240VAC/DC 2
163 P9ARTWS G.E. INSERT HOLDER 28
164 P9B11VN G.E. CONTACT BLOCKS NC 6
165 P9XPNNG G.E. PUSH-BUTTON (LACK) 2
166 P9XSVD0N G.E. 2 WAYS SELECTOR SWITCH 2
167 P9XSVD5N G.E. 2 WAYS SELECTOR SWITCH WITH SPRING RETURN 2
168 P9XSVE1N G.E. 3 WAYS SELECTOR SWITCH STOP-AUTO-MANU 4
169 P9XUGDDO G.E. PILOT LIGHT YELLOW (DIFFUSED LENS) 8
170 P9XULDDO G.E. PILOT LIGHT BLUE (DIFFUSED LENS) 2
171 P9XURDDO G.E. PILOT LIGHT RED (DIFFUSED LENS) 8
172 P9XUVDDO G.E. PILOT LIGHT GREEN (DIFFUSED LENS) 8
173 RT1L G.E. THERMAL OVERLOAD RELAY 4-6,3A 2
174 RT1V G.E. THERMAL OVERLOAD RELAY 25-32A 2
175 RT1W G.E. THERMAL OVERLOAD RELAY 30-40A 2
176 RT22J G.E. THERMAL OVERLOAD RELAY 64-82A CLASS 20 2
177 RT2E G.E. THERMAL OVERLOAD RELAY 30-43A 2
178 RT2H G.E. THERMAL OVERLOAD RELAY 54-65A 2
179 RT2J G.E. THERMAL OVERLOAD RELAY 64-82A 2
180 RT3F G.E. THERMAL OVERLOAD RELAY 140-190A 2
181 RTXP G.E. BASE FOR SEPARATE MOUNTING 2
182 1591250 ITALWEBER FUS 旧 LE NH1 250A/AM WITH STRIKER 6
183 2550110 ITALWEBER 1P FUSE BASE NHU-1 DIN-MS WITH MICROSWITCH 2
184 2590400 ITALWEBER ADAPTERS FOR NHU-1,2 FUSE BASES CONNECTION - T22 2
185 2590710 ITALWEBER SEPARATING PLATES FOR NHU-1,2 FUSE BASES - 1/2-WS 2
186 CA4-A476-600-EV KRAUS& NAIMER 3 POS. CAM SWITCH 10A, BLACK 2
187 DHR 100 C420 LEM FRANCE AC/DC CURRENT TRANSDUCER 100A,24V DC 2
129
188 4793 2003 SOCOMEC TOROID W1-S35 FOR RESYS P40/M20/M40 2
189 4942 2723 SOCOMEC EARTH LEAKAGE RELAYS RESYS P40,230VCA 2
Appendix – 3- SPARE PARTS OF EX2001

SPARE PARTS OF GE EPE REDUNDANT EX 2100R
Quantity Spares Quantity Lead Time
Item Catalog/Part Number Description
Used Recom Wks
1 104X109BE 008 FUSE FNQ-R-1.0 5 5 8
2 104X111AA 034 FUSE HOLDER 1 0 5
3 104X111AA 036 FUSE HOLDER 1 0 6
4 104X122AA 448 CAPACITOR,1MFD 1500VAC 5% 1 9
5 104X122AA 452 CAP1MF2000VAC10%P/PLYPR〇P 1 1 13
6 104X123DE 018 RES 50 5% 40W WW 1 13
7 104X125AA 175 DIO 35A 1000V FULLWAVE 1 1 6
8 151A7823P37 TORROID CORE 1 0 41
9 151X1213BP03PC02 CAP4700MF350V63X155MMSTUD 0 10
10 151X1213BP06PC01 DIODEBRGMOD6PACK,60A1200V 1 1 15
11 228B6661G3 TRANSFORMER3PH. 1 0 9
12 237B6174G1 D. C. REACTOR 0 9
13 323A2354P3 RESISTOR 1 10
14 323A2354P33 RES 5K 5% 40W 1 1 16
15 323A2354P41 RES 70W 20K OHM CENT 1 1 7
16 323A2440P15 SHUNT100MV15A 1 1 5
17 336A3594BA G01 KITEX2100 SERVICECABLES 1 0 6
18 336A5126AGP1 DIO40A1000VBRIDGEFWF/R 1 1 13
19 BMC#CHM2 FUSE HOLDER 2 P〇LE，FNQ，KTK，KLM 1 0 5
20 BMC#KLM-2 FUSE 2A 2 5
21 EBM#4294 FAN, 24VDC W/STAB CO 1 1 10
22 ENT#2423418.00 POWER SUPPLY 24V 1 8
23 IC200EBI001 VERSAMAX ETHERNET 丨 NTRFC 1 1 7
130
SPARE PARTS OF GE EPE REDUNDANT EX 2100R
Quantity Spares Quantity Lead Time
Item Catalog/Part Number Description
Used Recom Wks
24 IC200MDL940 VERSAMAXRELY2AMPFORMA16PT 1 1 7
25 IC200PWR002 VMAX PSPLY，24VDC EXP 33V 1 1 5
26 IC200TBM001 VERSAMAX AUX.I/O TERM.STRIP 1 0 7
27 IC641CFG100 VERSAMAXREMOTEI/OMANAGER 1 1 7
28 IC752SPL013 KEYPAD ASSEMBLY, EXC 0 10
29 IS200DSPXH1D DRIVE DSP CONTROL CARD 1 12
30 IS200ECTBG1A TERMINAL BD- EX2100 1 1 12
31 IS200EISBH1A EXCITER IN-SYNCH-BUS 1 1 12
32 IS200EPCTG1A CARD-EX2100 EPCT EXC 1 1 12
33 IS200EPSMG2A EXCITER POWER SUPPLY *2 2 1 12
34 IS200ERDDH1A DYNAMICS DISCHARGE *2 2 1 12
35 IS200ERGTH1A EX2100 REG GND DETEC 1 1 12
36 IS200ERI0H1A EXCITER MAIN 丨 O 3 1 12
37 IS200ER0CH1A EXCITER REGLTR OPTS CRD 2 1 12
38 IS200ERRBG1A EX2100R M2/C BACKPLA 1 1 12
39 IS200ERRRH1A EX2100R REDUNDANT RE 1 1 12
40 IS200ERSCG2A EX REG CONVERTER *4 1 1 12
41 IS215ACLEH1A ACLE 2 1 8
42 MKE#18-136-16RW/BRKT RES 16 300W 10%W/BRACKET 2 1 8
43 PBI#P40P48D12P1-24 RELAYEX2100 REGULATOR:K4T 1 1 8
44 PDRI7002RP2P125 RES1.2M 5%2WFILM 4 1 6
45 PDSB08A10P3RLCB 8A, 3P, RAIL MTD., M 1 1 4
46 TED124030WL 2 POLE 480VAC 250VDC 30A BREA 2 1 1
47 TED136030WL 3 POLE 600VAC 30A BREA 2 1 1
48 V511BA60 MOV 2 1 11
Appendix – 4- SPARE PARTS OF GENERATOR PROTECTION

SPARE PARTS OF GENERTOR PROTECTION
Line item Device name Description Model Quantity
131
DIGITAL GENERATOR PROTECTION RELAY: 8CT/8VT,
G60-G01-HKH-F8F-H67-
1 G60A 8"A" DO, 16 DI, 8 "C" DO, 125/250V AC/DC power supply, 1
M8F-P6D-U6D-W6C (GE)
RS485+10Base-F and 10Base-T, 19" rack mounted, EGD.
DIGITAL TRANSFORMER PROTECTION RELAY:
12CT/4VT, 8"A" DO, 16 DI, 8 "C" DO, 125/250V AC/DC T60-G01-HKH-F8H-H67-
2 T60A 1
power supply, RS485+10Base-F and 1〇Base-T, 19" rack M8F-P6D-U6D-W6C (GE)
mounted, EGD.
3 96GW-1 EPM ANALOG OUTPUT MODULE PL90002-〇MA〇N-400 1
POWER ANALOG TRANSDUCER: 3-Phase, 4 Wire, 80 to 230
4 96GW-2, 96GW-3 Vca (45 to 65 Hz) and 110 to 325 Vdc powered. 4 configurable M I CA R 2/4A (ENERDIS) 2
Outputs.
EPM POWER SYSTEM MONITOR: 90-276 Volts AC/DC
P L9650-1-A-0-A-1-0000
5 DMM power supply, Ethernet TCP/IP 10Base-T and RS232 1
(GE)
Communication.
EPM MULTIFUNCTION DISPLAY: Multi-Function LED
6 MEASURES P L9000-P40N (GE) 1
Display. For multiple display options.
7 巳 RACKET FOR SURFACE MOUNTING I/O MODULES PL9000-MBI0 (GE) 2
8 KYZ EPM PULSE OUTPUT MODULE: 4 Solid State Pulse Outputs PL9000-4P01 (GE) 1
MINIATURE CIRCUIT BREAKER: 2 Poles, 25A, curve C,

9 98-3 EP62 UC C25 (GE) 1
125V-30kA breaking capacity.
98-1, 98-2, 98-4, MINIATURE CIRCUIT BREAKER: 2 Poles, 4A, curve C,
10 EP62 UC C04 (GE) 5
98-2, 98-6 125V-30kA breaking capacity.
RESIDUAL CURRENT CIRCUIT BREAKER WITH
11 98-7 OVERCURRENT PROTECTION: 1P+N, 16A, diff 30mA, DP60 C16/030 (GE) 1
curve C, Type AC, 240Vac, 6kA breaking capacity.
EMI FILTERS: 30A Low Leakage SK Series with stud termin
12 FL1, FL2, FL3 30ESK6C (CORCOM) 3
and Ground choke option.
132
SYNC. VOLTAGE TRANSFORMER: 110.110/sqr3 (2
13 TO1, TO2 1TTV020 (FRER) 2
primary):110 V (secondary), 15VA, Class 1.
AX1, K100,
K120, K130, AUXILIARY RELAY: 125VDC, 2 Form C contacts, mounted
14 RD-2DI (ARTECHE) 8
K140, K150, on type ‘，D” socket.
32L-OP1, 74-3
AX1, K100,
K120, K130,
15 Type ‘，D” SOCKET: Front connections, DIN rail. DN-DE (ARTECHE) 8
K140, K150,
32L-OP1, 74-3
74/86G-1,
74/86G-2,
74/86L1-1,
74/86L1-2, BISTABLE AUXILIARY RELAY: 125VDC with diode, 8 Form
16 BJ-8BB (ARTECHE) 8
74/86L2-1, C contacts, mounted on type "J，socket.
74/86L2-2,
74/86UAT-1,
74/86UAT-2
74-1, 74-21, AUXILIARY RELAY: 125VDC with diode, 8 Form C contacts,
17 74-22, K10, K20, RJ-8DI (ARTECHE) 7
mounted on type ‘，J，socket.
K30, 41 E_POS
74/86G-1,
74/86G-2,
74/86L1-1,
74/86L1-2,
74/86L2-1,
18 74/86L2-2, Type J，，SOCKET: Front connections, DIN rail. JN-DE (ARTECHE) 15
74/86UAT-1,
74/86UAT-2 74-1,
74-21, 74-22,
K10, K20, K30,
41E POS
133
74/86E-1,
74/86E-2,
74/86T-1, BISTABLE AUXILIARY RELAY: 125VDC with diode, 4 Form
19 BF-4BB (ARTECHE) 6
74/86T-2, C contacts, mounted on type ‘，F，，socket.
74/86N-1,
74/86N-2
94EX-1, 94EX-2,
94EX 86N, AUXILIARY RELAY: 125VDC with diode, 4 Form C contacts,
20 RF-4DI (ARTECHE) 5
EXCIT ALAM, mounted on type ‘，F，，socket.
64F
27 CUBICLE LIGHTING: 18W, 230V, 50Hz PS 4139.180 (RITTAL) 2
28 HR CUBICLE HEATER: 450W AS-B-95 (MALABI) 1
29 TH HEATER THERMOSTAT: 5°-55°, one contact. SK 31 1 0 . 0 00 (RITTAL) 1
CUBICLE SOCKET: 2 PLUGS, 10/16A, 250V, 3.500W ,
30 SOC 5002 (L EGRAND) 1
ground connection
EX2100 SIMPLEX
SIMPLEX EXCITATION CONTROL : (3VBCZ004CD001 :
31 EXCITATION CONTROL 1
ED001)
(GE)
CUBICLE: Two panels of 800mm (wide) X 800mm (deep) X
32 2000+100mm (high) with glass front door, 19" swing rack, 8808.600 (RITTAL) 1
colour RAL 7035
Appendix – 5- SPARE PARTS OF GENERATOR ACCESSORY COMPARTMENT

Spare parts list generator accessory compartment
Component
identification Original
Manufacturer Component
Component component Designation Characteristics
item code Type
sequence code manufacturer
number
134
Component
item code Type
number
F 40 ABB ADDA MWK 17 Surge arrester E Ur: 21kV; Uc: 17kV; 10kA; cl.2
Ratio: 250/1A; Burden: 5VA cl.1; Uins:
Current
T 303 FTM AOC 80 E 0,72/3/10kV; Frq: 50Hz; Ith:
transformer
550A/30sec;丨 dyn: 2,5x 丨 th peak
Cn: 0,25^F; Uins: 17,5/38/95kV; Frq:
C 40 DUCATI 415.62.0037 Capacitor E
50Hz;
FANTIN 丨
E 31 C10A Thermostat E Regulation: 0/+60°C
COSMI
E 311 RITTAL SK 3118.000 Hygrostat E Regulation: 50/100%
Ratio: 8000/1/1A; Burden 1: 60VA
Current cl.5P20; Burden 2: 60VA cl.5P20; Uins:
T 31 FTM AOC 390 MT E
transformer 17,5/38/95kV; Frq: 50Hz; Ith:
80kA/1sec;丨 dyn: 200kA peak
Ratio: 8000/1/1A; Burden 1: 10VA cl.0,2
Current Fs<15; Burden 2: 60VA cl.5P20; Uins:
T 41 FTM AOC 390 MT E
transformer 17,5/38/95kV; Frq: 50Hz; Ith:
80kA/1sec;丨 dyn: 200kA peak
Ratio:
15000:sqr(3)//110:sqr(3)/110:sqr(3)V;
Voltage
T 43 FTM CTY 24/U E Burden 1: 20VA cl.0,2; Burden 2: 5VA
transformer
cl.3P (cl.1 from 0,8 to 1,2Un); Uins:
17,5/38/95kV; Frq: 50Hz
XP N.A. ILME N.A. Plug E 24P+T
XP N.A. ILME N.A. Plug E 2P+T
135
Component
item code Type
number
Ratio: 15000/300V (15x1,3/sqr(3)kV
Neutral with no saturation) 10A/30sec. 1xh
T 302 OCREV MAT/R grounding E (Design 11A) 1,1A continuous (at
transformer 15/sqr(3)kV) Uins: 17,5/38/95kV; Frq:
50Hz
MICROELETTRI Neutral Rn: 0,346ohm; Userv: 300/sqr(3)kV;
R 302 CA NGR grounding E Uins: 17,5/38/95kV; Frq: 50Hz; Ifault:
SCIENTIFICA resistor 500A/30sec 1xh
Minimun count current: 200A 8/20
microsecond wave - Maximum High
DC - TYCO SC12/AC Surge counter E
Current Withstand: 100kA 4/10
microsecond wave
N.A. N.A. SITRE IS-C15 M.V. insulator E Un: 17,5kV
Anticondensate Pn: 100W; Un: 220/240Vac; Frq:
E 30 TORRESAN KT100 E
heaters 50/60Hz
Un: 220…240Vac; Frq: 50Hz; Pn:
E 31 F.LLI FERRARI ES355 Cooling fan E
0,55kW; ~5040m3/h
Anticondensate Pn: 250W; Un: 220/240Vac; Frq:
E 30 TORRESAN KT250 E
heaters 50/60Hz
VENETA M.V. post
N.A. N.A. IPA 15/750 E Un: 17,5kV
ISOLATORI insulator
M.V. bushing
VENETA
N.A. N.A. 80725 insulator with E Un: 17,5kV
ISOLATORI
bars centralizer
136
Appendix – 6- SPARE PARTS OF FIRE FIGHTING
Quant
Component
GE Device Quantity ity *Procur
Part Name Part Location Illustrati Spar Component Supplier
Part Nomenclat used on Rec. ement
/ Description on Item e Supplier (OEM)
Number ure (if Assembl as Cycle
Description on Assembly Number Code -OEM Part
Applicable) y Spare (Days)
Number
s
WISL Weighing on CO2 rack
WISL 101 WISL 101 74 1 M 60 SUNRISE 520070
101 device in container
connection
Flexible between
FH 101 FH 101 NA 74 8 M 60 SUNRISE 504020
hose 10/500 cylinder &
manifold
connection
between
FL 101 Pilot hose FL 101 NA 65 8 M 60 SUNRISE 504030
cylinder &
manifold
Solenoid mounted on
FY 121 FY 101 FY101 4 1 M 60 TYCO SL94004
valve Ass. CO2 cylinder
mounting on
PSV 184 Relief valve PSV 184 PSV 184 4 1 M 60 SUNRISE 503092
CO2 manifold
Pressure mounting on
PSH 183 PSH 183 PSH 183 4 1 M 30 SUNRISE 510040
switch CO2 manifold
Position
mounting at
ZSL 182 Micro ZSL 182 ZSL 182 4 1 M 30 SUNRISE 510013
isolate valve
switch
mounting
LT01 Light inside of LT01 NA 3 1 M 30 SUNRISE SP5017
container roof
137
Appendix –7- SPARE PARTS OF START MEANS
Approximate Replacement (emergency
Group Subgroup Marking Consumable
service life stock)
Air intet silencer Air outlet
115 116
110 silencer Slip rug 10Yeas 1Year
117
compartment fetter unit
120 122 Fitefunit(WPII) 2 Years
Slip rug compartment fetter
130 133 1Year
unit (water coder)
100 (Ventilation) Corestate retinal air
142
ventilation motor fan
140
Compete external air
146
ventilation motor fan
Complete slip hug
150 152 assembly ventilation motor
fan
211 Roller 401XX) hours
212 Compressing ring 400D0 hours
210Antifriction 214 Ejector disk
bearing 215 Ordos 40QD0 hours
216 Vungseal
217 Grease nipple
251 Sleeve
200(DE Bearing) 252 Oil ring
FiM external seaing
253a
assembly
250 254 Roasting internal seal
(Sleeve bearing)
255 Type 12sped3l seal
256a FMer piug
256b Sump plug
256c Oil gauge
138
service life stock)
311 Roller 401XX) hours
312 Compressing ring 400D0 hours
310Antifriction 314 Ejector disk
bearing 315 Ordips 40QD0 hours
316a Vnngseal
317 Grease nipple
351 Sleeve
300 (NDE
352 Oil ring
Bearing)
Full external sealing
35Sa
assembling
350 (Sleeve bearing) 354 Roasting internal seal
355 Type 12sped3l seal
356a FMer piug
356b Sump plug
356c Oil gauge
411 Insulators
410 (main booc)
412 Connection bar
400 (Terminal 421 InsUators
boxes) 420 (ISteutral) 422 Connection bar
423 Connection bar
450 (Auxiliary) 457 Auxiliary toenail box
511 Bearing probe on CS
512 Bearing probe on OSC
515 Internal 3r probe
510 (Temperature sensor)
500 516 External air probe
(Instruments) 517 Water inlet r probe
518 V«'3tef outset T°probe
530 (Heating element) 531 Space heater
139
service life stock)
540 (Water leak sensor) 541 complete leakage detector
550 551 Corestate control box
(Pressurization sensor) 552 Valve
560 561 Baishes 1year
Rotor insulation sensor) 562 Bfush holdef
610
611 Compete slip hng assembly
(Slip ring compartment)
621 Contact
620 622 Pw/of socket
(Sip rings short-circuitng
oevoe) 623 Yoke and bearings
600 (Bush 624 Gear reduction unit + nut
compartment) Set of brushes ipenronent
651 1year
contact)
650 Set of brushes (brushes
651
(Brush holderSer system) lifting device)
653 Set of brush holders
654 solenoid
Appendix –8- SPARE PARTS OF LUBE OIL SYSTEM

Model 2088 Smart Transmitter
Item Spares
Part Description Part Number
No. Category
1,2 Smart Transmitters (Output Code S) Electronics Cover (with 03031-0292-0001 _
O-ring)
6 LCD Meter Cover Assembly 03031-0193-0002 B

2 Cover O-rings 03031-0232-0001 B
140
Model 2088 Smart Transmitter
Item Spares
No. Category
33 Electronics Board Kits S Output (4-20 mA/D|gital HART 02088-0306-0002 A
Protocol) S Output (NAMUR Compliant Operation) 02088-0306-0003 A
4 Optional Mounting Bracket (with 2-inch U-Bolt for Pipe 02088-0071-0001 _

Mounting)
5,6 5 LCD Meter Kit with Cover LCD Meter Kit without Cover 03031-0193-0101 _
03031-0193-0103 A
7 Local Zero and Span Kit 3031-0293-0002 A
88 Standard Terminal Block Transient Protection Block 3031-0332-0003 B
3031-0332-0004 B
Model 2090P
Item Spares
No. Category
1,2 Smart Transmitters (Output Code S) Electronics Cover (with O-ring) 03031-0292-0001 _
2 Cover O-rings 03031-0232-0001 B
Electronics Boards
3 S Output (4-20 mA/Digital HART Protocol) 02088-0306-0002 A
3 S Output (NAMUR Compliant Operation) 02088-0306-0003 A
Optional Mounting Bracket
4 (with 2-inch U-Bolt for Pipe Mounting) 02088-0071-0001 —
9 LCD Meter Kit with Cover 03031-0193-0101 _
9 LCD Meter Kit without Cover 03031-0193-0103 A
8 Calibration Adapter 02088-0197-0001 A
5 Teflon Gaskets (package of 12) 02088-0078-0001 A
6 316 SST Weld Spud with Heat Isolator Groove 02088-0295-0003 _
6 316 SST Weld Spud 02088-0195-0001 _
141
Model 2090P
Item Spares
No. Category
7 316 SSTPIugVHeat Sink 02088-0196-0001 A
11 Standard Terminal Block 03031-0332-0003 B
11 Transient Terminal Block 03031-0332-0004 B
Model 2090F
Item No. Part Description Part Number Spares Category
1 Smart Transmitters (Output Code S) Electronics Cover (with 03031-0292-0001 _
O-ring)
2 O-rings 03031-0232-0001 B
Electronics Boards
3 S Output (4-20 mA/Digital HART Protocol) 02088-0306-0002 A
3 S Output (NAMUR Compliant Operation) 02088-0306-0003 A
Optional Mounting Bracket
7 (with 2-inch U-Bolt for Pipe Mounting) 02088-0071-0001 —
4,5 LCD Meter Kit with Cover 03031-0193-0101 _
4 LCD Meter Kit without Cover 03031-0193-0103 A
6 Calibration Adapter, VA inch 02088-0197-0011 A
6 Calibration Adapter, 2 inch 02088-0197-0012 A
8 Standard Terminal Block 03031-0332-0003 B
8 Transient Terminal Block 03031-0332-0004 B
142
Appendix –9- SPARE PARTS OF ATPMIZING AIR SYSTEM
BILL OF MATERIALS AND SPARE PARTS
series DII
series E
series B series C types series F
types
type B20S types D30SII types
E30S E40S
part name material B30S B40S C30S C40S D40SII F30S F40S
E50S
B50S B60S C50S C60S D50SII F50S F60S
E60SII
D60SII
Quantity Quantity Quantity Quantity Quantity
1 hosing cast iron 1 1 1 —— _
2 driver stainless steel 1 1 1 —— 1
3 driver arm carbon steel 1 1 1 —— 1
4 actuator rod* carbon steel 1 1 1 —— 1
5 cover carbon steel 1 1 2 2 2
6 pivot pin washer* nylon 4 4 4 4 4
7 connector plate carbon steel 2 2 2 2 2
8 pivot pin * stainless steel 2 2 2 2 2
9 pivot pin retainer* stainless steel 4 4 4 4 4
10 Diaphragm plate* cast iron 1 1 1 _ 1
position indicator
11 stainless steel 1 1 _ _ 1
plate
12 lower casing carbon steel N/A N/A _ _ 1
13 diaphragm buna-N 1 1 _ _ 1
14 upper casing carbon steel 1 1 _ 1 1
15 stop screw carbon steel 2 2 2 2 2
16 spacer nylon N/A N/A N/A _ 2
17 cap screw carbon steel 4 4 8 8 8
18 jam nut carbon steel 2 2 2 2 2
19 indicator pointer aluminum 1 1 _ _ 1
20 cap screw carbon steel 1 1 _ 1 1
21 lock washer carbon steel N/A 4 N/A N/A(6) 20(9)
23 driver retainer stainless steel 3 3 3 3 3
143
BILL OF MATERIALS AND SPARE PARTS
series DII
series E
series B series C types series F
types
type B20S types D30SII types
E30S E40S
part name material B30S B40S C30S C40S D40SII F30S F40S
E50S
B50S B60S C50S C60S D50SII F50S F60S
E60SII
D60SII
Quantity Quantity Quantity Quantity Quantity
24 lock nut carbon steel 9 17 29 34(7) 30
25 spring retainer cast iron 1 1 _ 1 1(4)
26 thrust washer nylon 2(8) 2(8) 2 2 2
27 spring housing cast iron 1(1) 1(1) _ 1(2) 1(1)
28 cap screw carbon steel N/A N/A 4 4 4
29 lock washer carbon steel 4 N/A 4 4 4
30 cap screw carbon steel N/A N/A 10 10 20
32 lock washer carbon steel N/A N/A 4 4 4
33 compression spring* carbon steel 1 1 _ _ 1
34 caution plate stainless steel 1 1 _ _ 1
metal-backed acetyl
35 top driver bearing 1 1 — _ 1
resin
metal-backed acetyl
36 bottom driver bearing 1 1 — _ 1
resin
metal-backed acetyl
37 pivot pin bearing 2 4 2 2 2
resin
38 name plate aluminum 1 1 — _ 1
39 stud carbon steel N/A N/A 2 2 N/A
40 hex nut carbon steel N/A N/A 2 2 N/A
41 caution plate stainless steel 1 1 — _ 1
144
Appendix –10- SPARE PARTS OF WATER WASH SKID
SPARE PARTS FOR 2YEARS OF WATER WASH SKID
Installed Suggested Supplier
Description
Quantity quantity reference
CENTRIFUGAL PUMP (P121 & MO121)
1 1
Complete mechanical seal • 004ECCN-43| STALKERWEGWWS-9E-001-001-E
1 1
Cover Gasket/O-Ring General - 2900121720
BALL VALVES 3"
1 1 JMSWWS-9E-019-V
Repair kit consists of seat, gasket, stem packing of PTFE material
PRESSURE SWITCH (PSL173)
1 1 CCSWWS-9E-005-006-1
Complete unit • 604 GZ11
BALL VALVE 1-1/2"
1 1 JMSWWS-9E-019-V
BALL VALVE 2"
1 1 JMSWWS-9E-019-V
PRESSURE GAUGE (PI172)
1 1 WIKA WWS-9E-014-1-A
Complete unit • 233.34
PRESSURE SWITCH (PSH171)
1 1 CCSWWS-9E-005-006-1
Complete unit • 604 VZ1
FLOW SWITCH (FS174)
1 1 MOBREY WWS-9E-008-1
Switch-CCB 311
BALL VALVE 1"
4 1 JMSWWS-9E-019-V
DETERGENT LEVEL GAUGE(LG151)
1 1
Magnetic roller indicator-MRA-M1105 KUBLER WWS-9E-013-1
1 1
Float ZTSS150 with ring on top
WATER TANK LEVEL GAUGE(LG161)
1 1
1 1
WATER TANK LOW LEVEL SWITCH(LSL 162)
1 1 KUBLER WWS-9E-013-1
Magnetic switch AUM80
145
Description
WATER AND DETERGENT FLOAT VALVE HV111&HV101
1 1
Valve seat for 1-1/2'' Ssball float ball
1 1 TECHMATIC CONTROL
Float 1-1/2''
1 1 WWS-9E-018--V
Valve seat for 1'' SS ball float ball
1 1
Float 1''
CHECK VALVE
1 1 JMS
2'' complete unit-A122EN050-V
1 1 WWS-9E-017-V
3''complete unit-A122EN080-V
ELECTRICAL BOX (AR001)
2 Disconnector circuit breaker NS100H 2 LONED ELEC WWS-9E-023-E
2 Auxiliary block 2
1 Circuit breaker 1P+N 2A/C 1
1 Circuit Breaker 1P+N 4A/C 1
1 Thermostat 5-55°C 1
1 Cubicle Heater 20W 1
1 Power Switch 3x100A 1
1 Motor circuit breaker 4-6.3A 1
1 Motor circuit breaker 24-32A 1
1 Auxiliary contact 1NO 1NC 1
1 Auxiliary contact 4NO 1
1 Contactor 32A 230VAC 1
20 Relay 20
20 Base for relay 20
3 Timer relay 1NO/NC 3
146
Description
2 Green light - LED 230VAC 2
2 Orange light - LED 230VAC 2
6 Red light - LED 230VAC 6
5 Black push button 5
1 Auxiliary contact 1 NO 1
3 Auxiliary contact 1NC 3
1 Thermistor protection circuit relay 1
1 Transformer 380-400-415 VAC I 230VAC 630VA 1
1 DC power supply 7.5W 1

Description
CENTRIFUGAL PUMP (P121 & MO121)
1 1
Complete mechanical seal • 004ECCN-43|
1 1
Cover Gasket/O-Ring General - 2900121720 STALKER/WEG
1 1
Impeller SS WWS-9E-001-002-E
1 1
Bearing NDE-BE048
1 1
Bearing NDE-BE082
BALL VALVES 3"
1 1 JMSWWS-9E-019-V
PRESSURE SWITCH (PSL173)
1 1 CCSWWS-9E-005-006-1
Complete unit • 604 GZ11
BALL VALVE 1-1/2"
1 1 JMSWWS-9E-019-V
BALL VALVE 2"
1 1 JMSWWS-9E-019-V
PRESSURE GAUGE (PI172)
1 1 WIKA WWS-9E-014-1-A
Complete unit • 233.34
147
Description
PRESSURE SWITCH (PSH171)
1 1 CCSWWS-9E-005-006-1
Complete unit • 604 VZ1
FLOW SWITCH (FS174)
1 1 MOBREY WWS-9E-008-1
Switch-CCB 311
BALL VALVE 1"
4 4 JMSWWS-9E-019-V
DETERGENT LEVEL GAUGE(LG151)
1 1
1 1
WATER TANK LEVEL GAUGE(LG161)
1 1
1 1
WATER TANK LOW LEVEL SWITCH(LSL 162)
1 1 KUBLER WWS-9E-009-1
Magnetic switch AUM80
WATER AND DETERGENT FLOAT VALVE HV111&HV101
1 1
Valve seat for 1-1/2'' Ssball float ball
1 1 TECHMATIC CONTROL
Float 1-1/2''
1 1 WWS-9E-018--V
Valve seat for 1'' SS ball float ball
1 1
Float 1''
CHECK VALVE
1 1 JMS
2'' complete unit-A122EN050-V
1 1 WWS-9E-017-V
3''complete unit-A122EN080-V
MOTORIZED BALL VALVE
1 1 RCEL WWS-9E-012-V-A
complete unit
FLOW METER
1 1 BURKERT WWS-9E-007-I
complete unit-424012A/423916G(P/N8035)
ELECTRICAL BOX (AR001)
2 Disconnector circuit breaker NS100H 4 LONED ELEC WWS-9E-023-E
2 Auxiliary block 4
148
Description
1 Circuit Breaker 1P+N 4A/C 2
1 Thermostat 5-55°C 2
1 Cubicle Heater 20W 1
1 Power Switch 3x100A 2
1 Motor circuit breaker 4-6.3A 2
1 Motor circuit breaker 24-32A 2
1 Auxiliary contact 4NO 2
20 Relay 40
20 Base for relay 40
2 Green light - LED 230VAC 4
2 Orange light - LED 230VAC 4
6 Red light - LED 230VAC 12
5 Black push button 10
1 Auxiliary contact 1 NO 2
3 Auxiliary contact 1NC 6
1 Thermistor protection circuit relay 1
1 Transformer 380-400-415 VAC I 230VAC 630VA 2
1 DC power supply 7.5W 2
1 Emergency stop push button with key 2
149
Appendix –11- SPARE PARTS OF SUMP TANK
LIST OF SPARE PARTS FOR 2 YEARS OF EXPLOITATION SUMP TANK
INSTALL DESCRIPTION SUGGEST SUPPLIER
QUANTITY QUANTITY REFERENCE
1 ECCENTRIC SCREW PUMPS SERIES SETBP (SETBP 50.1) 1 91-466943
MECHANICAL SEAL
1 STATOR 1
1 GASKET FOR DISCHARGE CASING 1
2 COUPLING ROP PIN 2
2 COUPLING ROP BUSH 2
4 BUSH FOR COUPLING ROP PIN 4
2 RETAINING SLEEVE 2
4 CLAMPING BAND 4
1 COUPLING ROD 1
2 COVER SLEEVE 2
1 MAGNETIC FLOAT SWITCH SERIES ALV2 1 119A6188
NPT-VUUUU-L1515-SV-C30EX COMPLET UNIT
1 VALVE 2”（5050) SLEEVE 1 91-465145
1 POPPET 1
1 SPRING SUPPLIED WITH CUP AND ADJUSTING SCREW 1
1 2 PIECE BALL VALVE 2”（705) GASKETS SET 1 91-465146
1 FLANGE IMMERSION HEATER TYPE TPS 5KW REGULATION 1 91-465998
THERMOSTAT
1 SAFETY THERMOSTAT 1
1 PRECISION DIAL THERMOMETERS COMPLET UNIT 1 91-466949
LIST OF SPARE PARTS FOR 5YEARS OF EXPLOITATION SUMP TANK

1 ECCENTRIC SCREW PUMPS SERIES SETBP (SETBP 50.1) 1 91-466943
MECHANICAL SEAL
1 STATOR 1
150
LIST OF SPARE PARTS FOR 5YEARS OF EXPLOITATION SUMP TANK
1 GASKET FOR DISCHARGE CASING 1
2 COUPLING ROP PIN 2
2 COUPLING ROP BUSH 2
4 BUSH FOR COUPLING ROP PIN 4
2 RETAINING SLEEVE 2
4 CLAMPING BAND 4
1 COUPLING ROD 1
2 COVER SLEEVE 2
1 MAGNETIC FLOAT SWITCH SERIES ALV2 1 119A6188
NPT-VUUUU-L1515-SV-C30EX COMPLET UNIT
1 VALVE 2”（5050) SLEEVE 1 91-465145
1 POPPET 1
1 SPRING SUPPLIED WITH CUP AND ADJUSTING SCREW 1
1 2 PIECE BALL VALVE 2”（705) GASKETS SET 1 91-465146
1 FLANGE IMMERSION HEATER TYPE TPS 5KW REGULATION 1 91-465998
THERMOSTAT
1 SAFETY THERMOSTAT 1
1 PRECISION DIAL THERMOMETERS COMPLET UNIT 1 91-466949
151
Appendix –12- SPARE PARTS OF WATER INJECTION

Common Parts (All Seal Configurations) * Recommended Spare Parts
Item No. Part Name Quantity.
P3-1 Gearbox Housing Flat Washer 7
P3-10 Sight Glass 2
P3-11 Sight Glass Gasket 2
P3-12 Sight Glass Retainer 2
P3-13 Sight glass Self-Tapping Screw 2
P3-14 Oil Drain Plug (Note 1) 1
P3-15 Gearbox Housing 1
P3-17 Gearbox Housing Bolt 7
P3-2 Gearbox Nut 7
P3-3 Drive Gear 1
P3-32 Pump Casing 1
P3-34 Lube Pump Assembly (Note 2) 1
P3-35 Lube Pump Driving Lug Assembly (Note 2) 1
P3-36 Oil Fill Deflector Plate (Note 2) 1
P3-41 Pump Casing Studs 8
P3-42 Pump Casing Nuts 8
P3-43 Flat Washers 16
P3-44 Baffle Plate (Close Coupled Configuration Only) 1
P3-46 Gearbox Housing Lock Washer 7
P3-5 Drive Gear Key 1
P3-71 Gearbox Housing Bolt (Note 3) 1
P3-8 Gearbox Fill/Vent Plug 1
P3-82 Shaft Sleeve O-Ring (Close Coupled configuration ) *1
P3-83 Set Screws (Close Coupled Configuration) 3
P3-84 Shaft Sleeve (Close Coupled Configuration ) 1
P3-85 Baffle Plate Lip Seal (Close Coupled Configuration 1
P3-95 Ball Bearing (Frame Mount) 2
P3-96 Input Shaft (Frame Mount Configuration) 1
P3-99 Coupling Key (Frame Mount) 1
P3-100 Mounting Frame (Frame Mount Configuration) 1
P3-121 Gearbox Housing O-Ring 1
P3-132 Seal Flush Cap 1
P3-139 Splash Guard Washer 2
P3-140 Splash Guard Bolt 1
P3-141 Splash Guard 1
P3-153 Oil Filter Manifold 1
P3-163 Oil Filter *1
P3-175 Heat Exchanger 1
P3-178 Seal Housing Locating Pin 1
P3-190 Baffle Plat© (Frame Mount) 1
P3-192 Baffle Plat© Bolt (Frame Mount) 4
P3-214 Lube Oil Fll Plug 1
152
P3-215 Flow Straightener 1
P3-234 Seal Housing Pipe Nipple (Not© 4) 3
P3-239 Baffle Plat© Lip Seal (Frame Mount) 1
P3-30 Gearbox Vent Nipple 1
153

Nandipur 425MW CCPP Gas Turbine Maintenance Manual (Volume II Part 1) F

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NANDIPUR 425MW CCPP GAS TURBINE MAINTENANCE MANUAL

3.9 Coast-Down Time ......................................................................................... 20

5.7The Basic Maintenance of the Series of 88BT .............................................. 90

1.3Purge the Engine

1.4 Keep Complete Records

1.6 Maintenance Checks

1.8 Sealing Compound

1.9 Joint Compound

1.11Bolt and Stud Torquing

TORQUE VALUES FOR BOLTS AND STUDS – Table 1.11.1

1.12 Recommend Solvents, Sealants, Cleaners, ETC.

1.12.2 Note On Anti-seize Compound, High Temperature:

Element Maximum Contents

Aluminium, Cadmium, Tin, Zinc,

1.13 Ordering Renewal Parts

1.14 Repair and Replacement Parts

2.2 Maintenance Planning

Figure-2Key technical reference documents to include in maintenance

3 Gas Turbine Maintenance Devices Inspection

Figure 4. Borescope inspection programming

Figure 5. MS7001EA heavy-duty gas turbine – shutdown inspections

Standard Parameter of Maintenance Inspection

3 Turbine nozzles Foreign object damage. Corrosion. Blocked cooling

3.2 Standby Inspections

3.3 Running Inspections

3.4Load and Exhaust Temperature

3.5 Vibration Level

3.6 Fuel Flow and Pressure

3.7 Exhaust Temperature and Spread Variation

3.8 Startup Time

3.9 Coast-Down Time

3.10 Rapid Cool-Down

3.11 Combustion Inspection

3.12 Hot Gas Path Inspection

Figure 9. Stator tube jacking procedure – MS7001EA

3.13 Major Inspection

Figure 12. Major inspection work scope

4 Gas Turbine Auxiliaries Maintenance Schedule Guide

4.3 Standard Devices

Thermometer � External visual check for fluid leak, device damage, O

4.4 Lubricating Oil System

• To lubricate the shaft line including the accessory gear box 

LUBRICATING OIL SYSTEM

LUBRICATING OIL SYSTEM

� External visual check for fluid leak, device damage, excessive

4.4.3 Lubricating Oil Recommendations for Gas Turbines

These instructions contain information intended to help the purchaser of a

Trip Oil System

Trip Oil System

4.6.2 Maintenance Schedule

Starting Means System

Liquid Fuel System

Liquid Fuel System

Liquid Fuel System

Atomizing Air System

�Check vibration level O

Fire Fighting System

Piping and �External visual check loose support, loose O

Sirens operation of devices

Nozzles �Check cleanliness of nozzle holes S

Air Inlet Bleed Heating System

Control valve � Check for leaks at the control valves sealing O

Device Check/inspect D W M Q S CI HGPI MI X