MAINTENANCE OF GAS TURBINE

“ THE SUM OF ALL MEASURES

INTENDED TO DETERMINE THE
ACTUAL CONDITION OF THE GAS
TURBINE, TOGETHER WITH THE
MEASURES REQUIRED TO PRESERVE /
RESTORE THE SPECIFIED CONDITION”
 IMPACT ON QUALITY OF MAINTENANCE

• ADOPTING MANUFACTURER’S RECOMMENDATION

• PROPER PLANNING OF INSPECTIONS
• AVAILABILITY OF DOCUMENTS AND INSTRUCTIONS
• AVAILABILTY OF TOOLS
• STOCKING AND PROCUREMENT OF SPARES
• REPLACEMENT OF WORNOUT SPARES INSTEAD OF
REPAIR
• WORKING CONDITIONS AND SKILLED WORK CREW
• ACCESSIBILITY OF OEM’S TECHNICAL SUPPORT
HOT GAS PATH INSPECTION

•GT #11 06-12-2002 to 15-02-2003

•GT #12 02-05-2003 to 27-05-2003

 ROTOR
UPENDING
TIE ROD
COLLAR
 CONSTRUCTION
• Gas Turbine: SIEMENS make V94.2
• Rating: 137.7 MW at ISO
Conditions
• Turbine: 4 Stages
• Compressor: 16 Stages
• Combustion Chamber: 2 SILO type with
eight Burners in each
HOT GAS PATH INSPECTION
ORIGINAL INTERVAL : 25,000 EOH TO ENSURE
BASE MATERIAL WAS NOT DAMAGED AND
SUBSEQUENT REFURBISHMENT ALLOWED

REVISED INTERVAL: 33,000 EOH . MOVING ROW

1 AND 2 NO LONGER REFURBISHED
 HGPI
INVOLVES
DISASSEMBLY COMBUSTION
CHAMBERS
DISASSEMBLY OUTER CASING
REMOVAL OF TURBINE
STATIONARYBLADE CARRIERS
REMOVAL OF TURBINE ROTATING
BLADES STAGE 1 AND 2
Activities to be carried out HGPI
Components Measure HGPI Major
inspection
1. Turbine blades
Moving blade row 1 & 2 Replacement Yes Yes
Moving blade row 3, stationary Refurbishment Yes Yes
blade rows 1 & 2

Moving blade row 4, stationary NDE Yes Yes

rows 3 & 4
Activities to be carried out HGPI
Components Measure HGPI Major
inspection
2. Compressor blades
Coated rows Refurbishment No Yes

Uncoated rows NDE, Visual No Yes

inspection
Components Measure HGPI Major
inspection
3. Stationary blade
carriers
Turbine NDE, Visual Yes Yes
inspection
Compressor NDE, Visual No Yes
inspection
 Activities to be carried out HGPI
Components Measure HGPI Major inspection
4. Casing hot gas
path boundary
items
Inner casing Regenerative heat treatment No yes
Mixing casing Regenerative heat treatment No yes
Combustion chamber tiles Replace in the event of negative Yes Yes
(flame tube) findings

Components Measure HGPI Major inspection

5. Rotor (highly NDE, Visual inspection No Yes
stressed locations)
6. Burners NDE, Visual inspection, boroscopic Yes Yes
inspection, pressure/ leak test

7. Control Function test, pressure/ leak test, Yes Yes

condition based repair or
equipment, piping
replacement
 Magnetic Particle Inspection
 Hirth Coupling of Turbine as well as
compressor disc
 Compressor vanes and blades
 Tie Rod
 Matching grooves of Damping rings
 Transition of aerofoil to bearing of IGV
 Ultrasonic Testing
Gas Distribution Pipings and Spider
Arms
Transition of aerofoil to hook of
compressor vanes
 Inner casing & Mixing Chamber walls
 Dye Penetrant Test
 Bearings / Thrust Pads
 K-Ring
 All weld seams
 Tile Holders in combustion chambers
 Stationary & Rotating blades of Turbine
 Stage #3 & #4
 Grooves of Turbine Rotor Disc Stage #1 & #2
 Major Observations
Cracks in turbine stationary vanes stage 3
and stage 4 lower half
Coating abrasion in compressor blades
Cracks in right side of inner casing
Dent marks in inner casing seal ring
Wear in cooling ring of mixing chamber
Gap in compressor stationary vane
transition hook has increased.
 Observations contd…
 Maximum replacement was required in A row tiles of
combustion chamber.
VIEW OF
DAMAGED
TILES AND TILE
HOLDERS
BOROSCOPIC
INSPECTION OF
FUEL OIL BURNER