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 quivalent Operating Hoursreflecting 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

Inspection Items

Combustor Inspection

Dismantling combustor
basket

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

Turbine Inspection

Lifting the upper housing

of the turbine

Visual inspection and NDT (1) of turbine

blades, vanes and seals
Combustor inspection is carried out at the
same time

Major Overhaul
Inspection

Lifting the upper housing

of the turbine and
compressor
Lifting the rotor

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

NDT (1) : Non Destructive Test (Penetrant Test)

NDT (2) : Non Destructive Test (Penetrant Test, Magnetic Particle test and Ultrasonic test

Combustor Inspection

No 1. Compressor inlet

No 2. Turbine blade row 4

No 3. Flame detector and igniter

No 4. Fuel nozzle

No 5. Combustor basket

No 6. Transition piece

(1)
(1)
(2)

(2)

(2)

(2)

(1): Visual Inspection

(2): Roll-in & Roll-out Parts

Combustion Inspection Schedule

(for one (1) Gas Turbine)

Turbine Inspection

No 1. Compressor inlet

No 2. Flame detector and

igniter (2)

No 3. Fuel nozzle

No 4. Combustor basket

No 5. Transition piece

(1)

(2)

(2)

(2)

No 6. Turbine blade (2)

No 7. Turbine vane (2)
No 8. Compressor last row

and OGVs blade and

(1)
diaphragm
(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 No 8. Exhaust turbine and

(1)
No 2. Fuel nozzle (1)
No 3. Combustor basket (1)
No 4. Transition piece (1)
No 5. Turbine blade (1)
No 6. Turbine vane (1)
No 7. Compressor blade and
diaphragm

(1): Visual Inspection

(2): Roll-in & Roll-out Parts

compressor casing
No 9. Compressor blade ring
No 10. Turbine blade ring #1,
#2, #3 and #4
Turbine journal brg and thrust
brg
Rotor (2)

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

Deterioration

1.
a.
b.
c.

Creep under High Temperature

Low Cycle Fatigue
Metal Loss by Surface Oxidation & Corrosion

Life diagnosis

2.
a.
b.
c.
d.
e.

Load Cycles
Start / Stop Frequency
Fuel Quality
Environment
Maintenance Practice

Life diagnosis procedure is decided based on each customers

operational conditions

Life Evaluation Method

Evaluation for Maximum Use-up
Turbine Blade

Metallurgical Analysis

phase
Creep Rupture Property

Turbine Vane

Metallurgical Analysis

Precipitated Carbide
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 phase and
intergranular carbide
Standard heat treatment the material
Recovery of mechanical properties

Terima Kasih