GAS TURBINE

OPERATION AND
MAINTENANCE
P2M FTUI
September 2008
Operating Factors Affecting
Maintenance
• Type and quality of fuel
– Condensate, contaminants, etc
• Starting Frequency
– Thermal cycles
• Load cycles
– Thermal cycles
• Environment
– Abrasive and corrosive condition
Inspection Interval
 Following table shows the operating hours at
which inspection should be performed for
operation on gas fuel and continuous duty
Recommended Inspection Interval

Note: (1) Hours mean Ëquivalent Operating Hours”reflecting the operation conditions of Gas Turbines
“Roll-in and Roll-out” Procedure
 One (1) complete set of hot parts shall be ready for
Rolling-in. The parts taken out (Roll-out) shall be
reused/repaired/rejuvenated prior to the next inspection
 Summary of GT Inspection
Inspection Procedure
Combustor Inspection Dismantling combustor
basket
Turbine Inspection Lifting the upper housing
of the turbine
Major Overhaul Inspection Lifting the upper housing
of the turbine and
compressor
Lifting the rotor
NDT (1) : Non Destructive Test (Penetrant Test)
NDT (2) : Non Destructive Test (Penetrant Test, Magnetic Particle test and Ultrasonic test
Inspection Items
•Visual inspection & NDT (1) of fuel nozzles,
combustor baskets and transition pieces
•Visual inspection of turbine blade row 4 and
vane row 1 and 4
•Visual inspection of compressor IGV, blade
row 1 and vane row 1
•Visual inspection and NDT (1) of turbine
blades, vanes and seals
•Combustor inspection is carried out at the
same time
•Visual inspection & NDT (2) of all
components from expansion joint of the inlet
air to the first expansion joint of the exhaust
gas
•Inspection of auxiliaries, control systems
and instruments
Combustor Inspection
 No 1. Compressor inlet (1)
 No 2. Turbine blade row 4 (1)
 No 3. Flame detector and igniter (2)
 No 4. Fuel nozzle (2)
 No 5. Combustor basket (2) (1): Visual Inspection
 No 6. Transition piece (2) (2): Roll-in & Roll-out Parts
Combustion Inspection Schedule
(for one (1) Gas Turbine)
 Turbine Inspection
 No 1. Compressor inlet (1)
 No 2. Flame detector and igniter (2)
 No 3. Fuel nozzle (2)
 No 4. Combustor basket (2)
 No 5. Transition piece (2)
 No 6. Turbine blade (2)
 No 7. Turbine vane (2)
 No 8. Compressor last row and
OGV’s blade and diaphragm (1)
(1): Visual Inspection
(2): Roll-in & Roll-out Parts
Turbine Inspection Schedule
(for one (1) Gas Turbine)
 Major Overhaul Inspection

 No 1. Flame detector and igniter (1)  No 8. Exhaust turbine and compressor

 No 2. Fuel nozzle (1) casing
 No 3. Combustor basket (1)  No 9. Compressor blade ring
 No 4. Transition piece (1)  No 10. Turbine blade ring #1, #2, #3
 No 5. Turbine blade (1)
and #4
 Turbine journal brg and thrust brg
 No 6. Turbine vane (1)
 Rotor (2)
 No 7. Compressor blade and diaphragm

(1): Visual Inspection

(2): Roll-in & Roll-out Parts
Major Overhaul Inspection Schedule
(for one (1) Gas Turbine)
Routine Maintenance
Hot Parts Expected Life Time
 The expected life of hot parts has been established based on
design strength and the result of past operating experiences. The
expected hot parts life hours with qualified repairs are as follows:
Definition of “EOH”
Equivalent Operating Hours
 To calculate hours of operation equivalent to base load continuous duty
operation, when operation has been with liquid fuel and/or cyclic duty, it is
necessary to segregate the actual hours of operation by duty (fired hours
per start) and fuel (gas or oil). These segregated values are then used in
the following equation to calculate the hours equivalent to operation at base
load with gas fuel.

where,
H = equivalent continuous duty gas fired hours
BHG = base load operating hours with gas fuel
BHO = base load operating hours with distillate oil fuel
PHG = peak load operating hours with gas fuel
PHO = peak load operating hours with distillate oil fuel
CDF = cyclic duty factor, determined from the following table
Cyclic Duty Factor Table
Hot Parts Life Evaluation
1. Deterioration
a. Creep under High Temperature
b. Low Cycle Fatigue
c. Metal Loss by Surface Oxidation & Corrosion
2. Life diagnosis
a. Load Cycles
b. Start / Stop Frequency
c. Fuel Quality
d. Environment
e. Maintenance Practice

Life diagnosis procedure is decided based on each customer’s

operational conditions
Life Evaluation Method
Evaluation for Maximum Use-up
 Turbine Blade

 Metallurgical Analysis
 phase
γ’
 Creep Rupture Property
 Turbine Vane
 Metallurgical Analysis
 PrecipitatedCarbide
 Tensile Property
Life Evaluation Process for
Turbine Blade
Life Evaluation Process for
Turbine Vane
Life Extension Technology
Reheat Technology
High temp. heating of deteriorated super alloy

Decomposition & re-solution of hypertrophied γ’ phase and

intergranular carbide

Standard heat treatment the material

Recovery of mechanical properties

Terima Kasih