Gas Turbine Maintenance

• Classification Gas Turbine Maintenance ;

1. Standby Inspection
2. Running Inspection
3. Dis-assembly Inspection

Dis-assembly Inspection can be classified into :

1. Combustion Inspection
2. Hot Gas Path Inspection
3. Major Inspection
 Maintenance Objectives
Objectives Affecting Factors Measures to be taken
Maximizing availability & Criticality of the turbine Parts reliability improvement
reliability operation Control system upgrade
Cost of down time Standby inspection
Running inspection
Periodic test run
& spare part stock
Minimizing maintenance Inspection interval Shutdown inspection –
cost Hot gas path parts life CI, Borescope, HGPI, MI
extension HGP parts evaluation

Minimizing running cost Fuel cost Fuel system conversion

Performance deterioration Inlet air system & washing
Investment to upgrade GT Uprate HGP parts
Covert to CCP
 Deterioration & Damaged of GT
60
54

50
Fuel Oil System
Thermocouple
40
Lube Oil System
Coooling water system
30
Atomizing Air System
18 Fuel Gas System
20
Others
10 8.5 GT Flange to Flange
6.4 4.7
3.4 2.9 2.1
0
Percentage
 Influence Factors for GT Maintenance

• Hour in Service • Material Deterioration

• Starting Frequency
(start/stop) • Wear
• Load Cycle (Output • Crack
variation) • Oxidation
• Load Duty (Partial or
base) • Corrosion
• Type of fuel (gas or • Erosion
liquid)
• Environment (Particulate
• Plugging
in air)
 Standby Inspection
• Standby inspection pertain particularly to gas turbine used in
intermittent service as peaking or emergency duty.
• Standby inspection is especially important for the units of which
starting reliability is essential.

• - Servicing battery system

• - Changing filters (air, fuel , lube oil & control system)
• - Checking oil & water level
• - Cleaning relays
• - Control device calibration
• - Periodic start test - prevention of rusting & drying up air passage
• - Inspect exhaust duct & plenum
• - General Cleanliness
 Running Inspection
• Running inspection consist of the observation made while an unit is in
service.
• “Gas turbine let you know it is sick, before being effectively ill”.
• Operation data are taken on control panel & turbine instrument panel
at running inspection.
• Operation date are useful for trouble shooting in future and also
indicates the sign of trouble.
• Typical running inspections include :
1. Load vs exhaust temperature TTXM
2. Vibration level
3. Fuel flow & pressure
4. Exhaust temperature variation
5. Turbine output vs ambient temperature
6. Start-up time & coast-down time.
 Dis-Assembly Inspection
• Hot gas path components are subjected to sudden temperature change and
resultant thermal stress during start-up. They are also subjected to hot
combustion gas with combustion oscillation and it is often corrosive. Severe
working conditions of hot gas path parts require periodical inspection and
repair.
 Recommended Inspection Intervals
Inspection Type Fuel Type MS 3002 MS5002 MS6001 MS7001 MS9001

Combustion Gas 16,000 8,000 8,000 8,000 8,000

Inspection
Distillate 16,000 8,000 6,000 8,000 8,000

Hot Gas Path Gas 24,000 24,000 24,000 24,000 24,000

Inspection
Distillate 24,000 24,000 24,000 24,000 24,000

Major Inspection Gas 48,000 48,000 48,000 48,000 48,000

Distillate 32,000 32,000 48,000 48,000 48,000

 Combustion Inspection
• Combustion inspection is provided for the inspection or replacement
of shortest life parts of hot gas path section. The combustion
inspection is relatively short dis-assembly shutdown inspection. (5-7
days)
 Combustion Inspection Work Scope
Parts Action Inspect for
Fuel Nozzle Dis-assembly tip clearance
Unusual wear
Combustion Liners Cleaning. LP Check Hot Spot
Burning
Crossfire tube Cleaning Cracks
Weld condition
Retainer Visual Inspection

Seal Plate Visual Inspection Wear

Spark Plug Tip Clearance

1st & 2nd stage nozzles Borescope inspection Cracks

 Hot Gas Path Inspection
• Hot gas path inspection will be determined by
borescope inspection evaluation made at time of
combustion inspection and fired hours of the
recommended inspection intervals.
• Hot gas path inspection includes a detailed
inspection of turbine nozzles and buckets in
addition to combustion inspection.
• To perform this inspection, the top half of the
turbine casing must be removed.
 Hot Gas Path Inspection Work Scope
Parts Action Inspect for
First Stage Nozzle Cleaning
LP checks Foreign Object
Second Stage Nozzle Damage, Erosion
Corrosion
First Stage Bucket Cracks
Cooling hole plugging
Second Stage Bucket

Turbine Clearance Clearance measurement Excessive wear &

Distortion
Wheel Space Thermocouple Inspection on resistance Faulty thermocouple

Compressor stationary & Borescope inspection Cracks, Foreign object

Rotating blades
 Major Inspection
• Major inspection should be scheduled as per
manufacturer’s recommended inspection interval
or previous inspection results.
• Major inspection includes the overhaul and
inspection of major ‘flange to flange’ components
of gas turbine.
• This inspection also covers combustion and hot
gas path inspection work scope.
 Major Inspection Work Scope
Parts Action Inspect for
Turbine buckets & nozzles Remove from rotor
Foreign Object
Compressor blading Cleaning & LP check Damage, Erosion
Corrosion
Turbine wheel Clean, LP check Cracks
dovetail Cooling hole plugging

Bearing, seals Clean, clearance check Wear, Fouling, Wiping

LP check Deterioration of babbitt
Journals Wear, Scoring

Clearance Clearance measurement Wear Deformation

Others major auxiliary Check bearings. Major inspection

Components – load gear, Clearance measurement
Accessory gear, torque
converter, etc