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GE Power Systems

Gas Turbine Maintenance Part 1

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GE Power Systems

OPERATING FACTORS AFFECTING MAINTENANCE The effect of maintenance factors for fuel, starts, environment and load duty cycles are cumulative. As the maintenance factor increases, the time between inspections and component repairs decreases and it is possible that component replacement frequency will increase.

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Key Factors Affecting Maintenance Planning

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Plant Level Top 5 System Contributions to Downtime

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MAINTENANCE FACTORS Cyclic Effects
Effects of Startups and Shutdowns / Trips

GE Power Systems

Firing Temperature Fuel


Gas, Distillate, Crude, Quality, etc...

Water or Steam Injection Environment


Air Quality

Maintenance Practices
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MAINTENANCE FACTORS Cyclic Effects
Fired Starts
Normal Fast Load Emergency

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Stops
Normal shutdown Trips
>80% Load

Load Changes

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MAINTENANCE FACTORS Causes of Wear - HGP Continuous Duty Application
Creep Deflection Oxidation Corrosion High-Cycle Fatigue Rupture Erosion Rubs/Wear Foreign Object Damage (FOD)

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MAINTENANCE FACTORS Causes of Wear - HGP Cyclic Duty Application
Thermal Mechanical Fatigue High-Cycle Fatigue Rubs/Wear Foreign Object Damage (FOD)

GE Power Systems

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Fig 41 - Page 28

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MAINTENANCE FACTORS

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Typical Max Inspection Intervals (MS6B/MS7EA)


Hot Gas Path Inspection Major Inspection 24,000 hrs or 1200 starts 48,000 hrs or 2400 starts

Criterion is Hours or Starts (Whichever Occurs First)

Fig 41 - Page 28

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MAINTENANCE FACTORS Hot Gas Path Buckets/Nozzles Hours Factors
Fuel
Gas Distillate Crude Residual 1 1.5 2 to 3 3 to 4

GE Power Systems

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


Dry Control Wet Control 1 (GTD-222) 1.9 (5% H2O GTD-222)

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MAINTENANCE FACTORS Hot Gas Path Buckets/Nozzles Starts Factors
Trip from Full Load Fast Load Emergency Start 8 2 20

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GE Maintenance Interval for Hot Gas Path Inspection

GE Power Systems

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MAINTENANCE FACTOR VS FUEL TYPE

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Bucket Life Firing Temperature Effect

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Exhaust Temperature Control Curve Dry vs. Wet Control

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Turbine Start / Stop Cycle Firing Temperature Changes

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First - Stage Bucket Transient Temperature Distribution

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Low Cycle Fatigue Life Sensitivities 1st Stage Bucket

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Maintenance Factor Trips From Load

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MAINTENANCE FACTORS Hours Based Hot Gas Path
Maintenance Interval = 24000 (Hours) Maintenance Factor Where: Maintenance Factor = Factored Hours / Actual Hours MF = Factored Hours = (K + M * I) * (G + 1.5D + AfH + 6P) Actual Hours = (G + D + H + P)

GE Power Systems

G = Annual Base Load Operating Hours on Gas Fuel D = Annual Base Load Operating Hours on Distillate Fuel H = Annual Operating Hours on Heavy Fuel Af = Heavy Fuel Severity Factor (Residual Af = 3 to 4, Crude Af = 2 to 3) P = Annual Peak Load Operating Hours I = Percent Water/Steam Injection Referenced to Inlet Air Flow M & K = Water/Steam Injection Constants

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MAINTENANCE FACTORS
Starts Based Hot Gas Path
Maintenance Interval = 1200 (Starts) Maintenance Factor Where: Maintenance Factor = Factored Starts / Actual Starts

GE Power Systems

MF =

Factored Starts = (0.5NA + NB + 1.3NP + 20E + 2F + aT1 T1) i=1 Actual Starts = (NA + NB + NP + E + F + T)

NA = Annual Number of Part Load/Stop Cycles (<60% Load) NB = Annual Number of Normal Base Load Start/Stop Cycles NP = Annual Number of Peak Load Start/Stop Cycles E = Annual Number of Emergency Starts F = Annual Number of Fast Load Starts T = Annual Number of Trips aT = Trip Severity Factor = f (Load) n = Number of Trip Categories (I.e., Full Load, Part Load, etc.)
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GAS TURBINE MAINTENANCE

Operation of the combustion gas turbine, as any rotating power equipment, must include a planned program of periodic inspection. With accompanying repair and replacement of parts as required, will ensure the maximum availability and reliability of the turbine.

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OBJECTIVE OF THE GAS TURBINE MAINTENANCE SECTION Describe the inspections and the action to be taken. Identify the components and parts that should be examined. Discuss the Inspection and Maintenance Manual Pre-Inspection Items Standard Practice Review

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OPERATING FACTORS AFFECTING MAINTENANCE The effect of maintenance factors for fuel, starts, environment and load duty cycles are cumulative. As the maintenance factor increases, the time between inspections and component repairs decreases.

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MAINTENANCE FACTORS Type of Fuel Starting Frequency Load Cycle and Firing Temperature Water or Steam Injection Environment Maintenance Practices

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TYPES OF INSPECTIONS Running Inspections
Startup Operating

GE Power Systems

Shutdown Inspections
Combustion Hot Gas Path Major

Standby Inspections
Checking of Batteries, Filters, Oil and Water Levels, etc

Special Inspections
Borescope
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GAS TURBINE MAINTENANCE

GE Power Systems

Keep a record of the inspections made, and the maintenance work performed. It is expected that a maintenance program will start with minor work, and increase in magnitude over a period of time to a major overhaul. Optimized inspections will reduce unit outage time and maintenance cost.

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MAINTENANCE PRACTICES

GE Power Systems

Parts condition information data Initial inspection planning Good maintenance planning for minimum down time requires the availability of replacement parts. Minimum stock of repair parts in a predetermined location. Anticipate needs during outages.

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PRIOR TO GAS TURBINE MAINTENANCE

GE Power Systems

Clean the compressor per the gas turbine Water Wash. A complete set of operating data including vibration readings should be taken and recorded for reference. Inventory and Inspection of tooling. General walk around inspection prior to tear down. Lock Out / Tag Out (LOTO)

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GAS TURBINE COMPRESSOR CLEANING

GE Power Systems

The Gas Turbine Water Wash System will be covered in a separate lecture. Gas Turbines operating with Dry Low Nox Combustion Systems should not use solid compounds for compressor cleaning.

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INSPECTION AND MAINTENANCE MANUALS

Notes:
Highlights an essential element of a procedure to assure correctness.

Caution:
Indicates a procedure or practice, which if not strictly observed, could result in damage or destruction of equipment.

Warning:
Indicates a procedure or practice, which could result in injury to personnel of loss of life if not followed correctly.
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GE Power Systems

INSPECTION AND MAINTENANCE MANUALS

Introduction Standard Practices Auxiliary and Controls Systems Maintenance Scheduled Turbine Maintenance Combustion Inspection Hot Gas Path Inspection Major Inspection Maintenance Inspection Forms
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GE Power Systems

INSPECTION AND MAINTENANCE MANUALS

Introduction
General Operating Factors Affecting Maintenance Maintenance Practices Types of Inspection Inspection Intervals Special Inspection

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INSPECTION AND MAINTENANCE MANUALS Standard Practices


General Recommended Solvents, Sealers and Cleaners Lubrication Guidance Gas Turbine Compressor Cleaning Tools and Equipment Special Tools Ordering Renewal Parts, Repair and Replacement parts Returning Turbine Parts for Repair / Replacement Maintenance Parts Recommendations
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LUBRICATION GUIDANCE

GE Power Systems

Lubrication frequency will vary, depending on turbine hours and ambient temperature. It is suggested that records on lubrication intervals be kept to determine variances between periods listed on the chart and those scheduled for a specific installation. Lubricants listed do not exclude comparable products from other oil companies. Use of alternate lubricants must be approved by component manufacture.
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GE Power Systems

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ORDERING RENEWAL, REPAIR AND REPLACEMENT PARTS Spare and renewal part orders for General Electric turbines should be placed with your General Electric Company Representative Operations Office. Parts which form one complete working unit must be ordered together. Any new safety features and design improvements are usually incorporated in replacement parts.

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ORDERING RENEWAL, REPAIR AND REPLACEMENT PARTS If no drawing, parts list or reference publication is available for a part, a sketch or sample of the item, together with all necessary dimensions and description of the parts function, should accompany the order. Store parts in a suitable place to prevent loss or damage. Coat all finished iron or steel surfaces with oil or other suitable compound to protect them for corrosion.

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RETURNING PARTS FOR REPAIR OR REPLACEMENT Contact your General Electric Company Representative Operations Office for assistance when returning turbine parts to GE. They will supply you with proper procedures as well as supply the required packing instructions, packing lists and shipping labels. A GE representative can be directed to confirm receipt of your parts and explain factory corrective action recommendations.
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MAINTENANCE PARTS RECOMMENDATIONS

GE Power Systems

Spare parts recommendations are provided to support scheduled combustion, hot gas path and major inspections. Spare parts listings must be used in conjunction with the Parts List and Drawings Volume of the Service Manual. Use the typical spare parts list as a guide, your spare parts stock should be reviewed at a pre-inspection planning meeting.
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GE Power Systems

INSPECTION AND MAINTENANCE MANUALS

Auxiliary and Controls Systems Maintenance


Periodic Inspection Schedule Inspection and Maintenance Procedures

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INSPECTION AND MAINTENANCE MANUALS

Scheduled Turbine Maintenance


Running Inspections Housekeeping Data Recording Special Inspections

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INSPECTION AND MAINTENANCE MANUALS

Combustion Inspection Hot Gas Path Inspection Major Inspection


Disassembly Inspection Re-assembly Startup Checks

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GAS TURBINE BORESCOPE

GE Power Systems

Incorporates the use of the optical borescope. Allows rapid inspection of the following areas:
Turbine Section Axial Flow Compressor Combustion System

Removal of spark plugs and flame detectors from combustion system allows access to these areas.

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GAS TURBINE BORESCOPE INSPECTION CRITERIA Compressor Blades:
FOD and DOD Dirt Build Up Corrosion Tip Erosion Trailing Edge Thinning Stator Blade Root Erosion Tip Clearance

GE Power Systems

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GAS TURBINE BORESCOPE INSPECTION CRITERIA Combustion, (Liner and Transition Piece):
Carbon Build-Up Hot Spots Cracking Bulging Wear Missing Metal

GE Power Systems

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GAS TURBINE BORESCOPE INSPECTION CRITERIA Turbine Nozzles:
FOD and DOD Corrosion Blocked Cooling Holes Cracks Trailing Edge Bowing Erosion Burning

GE Power Systems

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GAS TURBINE BORESCOPE INSPECTION CRITERIA Turbine Buckets:
FOD and DOD Corrosion Blisters Cracks Tip Clearance Erosion Missing Metal

GE Power Systems

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VIGV BUSHING INSPECTION

GE Power Systems

VIGV in fully open position 1. Set vanes to the full open position. 2. Set up dial indicator to measure motion normal to the vane cord. Position the indicator to read as close to the vane inner button as possible. VIGV 3 3. Deflect vane in a tangential direction (perpendicular to the air flow direction) to both sides of the bushing clearance and record full dial indicator reading.

1 Airflow Direction

2 Bushing Dial Indicator

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VIGV BUSHING INSPECTION SCHEDULE
Frame Size MS5001, MS5002, MS6001* VIGV Type
1

GE Power Systems

Bushing

Clearance Limits for Bushing Changeout (>= inches) 0.050 0.050 0.075 0.075 0.070 0.070 0.100 0.100 0.100

Inspection Interval (Hours) 5,000 8,000 8,000 8,000

*Pre Model FA
MS6001FA MS7001*, MS9001*

403 Stainless 403 Stainless GTD 450 GTD 450 403 Stainless 403 Stainless GTD 450 GTD 450 GTD 450

158A7888P004/5/6 315A9681 or 339A9913 315A9681 or 339A9913 339A9913 158A7888 315A9681 or 339A9913 315A9681 or 339A9913 339A9913 328A7020

16,000 16,000

3 3

4 4

*Pre Model F
MS7001F/FA/FA+ MS9001F/FA

16,000 16,000 16,000

3 3 3

8,000 8,000 8,000 8,000 8,000

4 4 4

Note 1: For unit specific drawing number identification, refer to Model List Item 1301 Note 2: For unit specific drawing number identification, refer to Model List Item 0811 Note 3: Nominal Base Load IGV angle of 84 or Lower Note 4: Nominal Base Load IGV angle greater than 84 (i.e. 86 or 88)

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GAS TURBINE MAINTENANCE

GE Power Systems

END

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