Scope of Work For Gas Turbine

Scope of Work (Maintenance Services)
Following to the GE Energy “Operation and Maintenance Manual”
1. Combustion Inspections
1.1. Shutting down of Units
• CO2 Fire Protection System Isolation and CO2 Switch Inhibited
• Turning Gear Motor Isolation
• Fuel Oil Pump A, B, C Isolations
• GT Compartment PKG Ventilation Fan Motor A, B Isolations
• Bearing #2 Cooling Fan Motor A, B Isolations
• Exhaust Frame Cooling Fan A, B Isolations
• Exhaust Compartment Fan A, B Isolations
• Load Gear Compartment Cooling Air Fan A, B Isolations
• Water Injection Pump Isolations
• Hydraulic Pump Isolations
• Atomizing Air Compressor Drive Motor A, B Isolations
• Gas Module Acoustic Enclosure Cooling Air Fan A, B Isolations
• Liquid Fuel Compartment Cooling Air Fan A, B Isolations
• Water Injection Skid Enclosure Cooling Air Fan A, B Isolations
• Gas Fuel Stop Valve Isolation
• Liquid Fuel Stop Valve Isolation
• Cooling Water Supply Isolations
• Spark Plug Isolations
1.2. Disassembly
1. CO2 Fire Protection System Isolation and CO2 Switch Inhibited
• Remove wirings/conduits of flame detectors and spark-plugs
2. Remove the flame detectors

• The flame detector is mounted on the side of the combustion chamber. Prior to
disconnecting and removing the flame detectors mark them with the combustion chamber
number.
• Remove the flame detectors from combustion chambers 1, 2 and 6 (2 flame
detectors in can # 6). Discard all gaskets.
3. Remove the spark plugs

• Prior to disconnecting and removing the spark plugs, mark the combustion
chamber number on each plug.
• Unbolt each spark plug assembly from the casing flanges on combustion
chamber numbers 4 and 5 by removing the four bolts on the spark plug flange.
• Lift spark plugs out. Discard all gaskets.
• Remove old anti-seize compound from all bolts; bag and identify for
reassembly.
• Clean matching flange surfaces.
4. Remove inspection door on inlet plenum and exhaust plenum

• Unbolt the removable exhaust duct access panel.
• Unbolt the right-side removable inlet lagging panel.
• Rig and lift the panels clear of unit and store panels off the ground
5. Remove the turbine compartment roofs and blowers

• Remove roof-mounted electric wiring at nearest pull box and disconnect
conduit.
• Remove ventilation duct from turbine enclosure roof.
• Remove walkways and platform from turbine enclosure roof.
• Unbolt the forward and aft roof sections from the sidewall frames and from each
other. Unbolt only the lower set of bolts at the sidewall frames.
• Attach four eyebolts to a roof section in threaded receptacles provided for
lifting.
• Attach four equal length cables or two equal length cables and come longs to
chain fall connected to crane.
• Check to ensure the roof section is mechanically free to be lifted, and carefully
lift with chain fall until clear.
• Set the roof section on appropriate cribbing.
• Repeat steps 1 through 4 for the remaining roof section.
6. Remove the fuel oil and purge flex hoses

• Prior to disconnecting and removing the fuel oil flex hoses, the hoses must be
match marked with the combustion chamber number.
• CAUTION: The flex hoses must be installed in a low stress state. Avoid
excessive single plane bends, multiple bend planes, kinks, and squirm in the hoses. Avoid
excessive hose tension or compression by reinstalling in the hose in the original bending
plane.
• Starting at cover number 3 and working both clockwise and counterclockwise
up to cover number 6, remove all flex hoses to each combustion cover.
• CAUTION: Do not use the fuel oil flex hoses as climbing aids or footholds.
Proper rigging and scaffolding shall be used.
• Keep fuel oil flex hoses free from dirt, oil, water, or other contaminants. Store
the removed hoses in a weather-protected area with temporary flange covers installed.
• Install temporary flange covers over the exposed gas fuel manifold flanges.
• NOTE: The fuel oil manifolds do not require disassembly for a typical
combustion inspection.
7. Remove the false start drain piping

• Prior to disconnecting the combustion chamber false start drain piping, the pipes
must be match marked with a waterproof marker.
• Match mark the pipe end that connects to the combustion can. Mark the other
end to the drain flex hose. Mark each hose with the chamber number.
• Remove the tubing starting at can 2 and work counter clockwise towards can 4.
• Store the removed tubing in a weather-protected area. Temporarily cover
exposed tubing ends.
8. Remove the other fuel nozzle flex hoses

• Unbolt the nozzle flex hoses from the combustion can end covers.
• Temporarily move the free end of the flex hoses away from the end cover to
gain access to other end cover bolting.
• NOTE: Complete removal of the flex assembly is not usually required to
remove the fuel nozzle assembly.
• Disconnect and remove the steel beam on the top of the steel support column.
• Disconnect and remove the upper portion of the steel support column on both
the left and the right–hand sides.
9. Remove the atomizing air flex hoses and manifolds

• Tag the sections of the atomizing air manifold as upper & lower.
• Disconnect and remove the upper section of the manifold.
• Clean all flange faces and cover all openings. Clean all nuts and bolts, bag and
identify for reassembly.
10. Remove the fuel oil distribution valve drain lines

• Prior to disconnecting the combustion chamber false start drain piping, the
piping must be match marked with a waterproof marker.
11. Remove the fuel nozzle assembly

• Match mark both parts with the chamber number.
• Install a lifting eye to the end cover of #6 chamber. Rig in a manner so that the
assembly can be removed axially from the downstream combustion casing.
• Make sure the three guide pins are in place and that the retaining nuts are tight.
• Raise the crane hook to support the assembly.
• Remove the bolts from the flange between the end cover and the combustion
casing. The assembly is now supported by the guide pins.
• Attempt to slide the cover axially on the guide pins.
• Slide the assembly axially until the guide pins clear the casing flange.
• CAUTION: The cover and casing assembly weigh approximately 800lb
• (360 kg). A crane or other lifting device must be used for removal and
installation.
• The fuel nozzle can be moved away and lifted clear of the turbine.
12. Remove the combustion liners and crossfire tubes

• Remove the combustion liners by first pulling all crossfire tube retainers away
from the crossfire tube collars (two retainers per crossfire tube). Tag all retainer clamps
and identify according to chamber position and side.
• To remove the combustion liner, telescope both crossfire tubes toward the
adjacent chamber until they are clear of the combustion liner. If crossfire tube tends to fall
into the liner being removed, employ a long-bladed screwdriver or one of the retainers to
hold the crossfire tube in the retracted position.
• Pull liner straight out taking care not to snag the spring seals [each liner weighs
approximately 60lb (27 kg)]. Place liners on plywood to prevent damage and cover to
keep dirt out.
• Identify each liner according to chamber position.
• Retrieve both crossfire tube ends previously pushed into adjacent chambers by
pulling each back through the empty chamber. Identify and tag each end with respect to
its combustion chamber location and side.
• Remove the remaining combustion liners and crossfire tubes in the same
manner, identifying and tagging each.
• CAUTION: Be sure that crossfire tubes are disengaged from liner collars
before attempting to move liner or damage will occur.
• Exercise caution when removing liners to ensure that aft spring seal leaves and
crossfire tube collars do not snag over retainer ramp assemblies on the flow sleeve.
13. Remove the outer crossfire tubes

• Remove the bolts from each sealing ring flange on the outer crossfire tube
flanges. Remove the split ring retaining washers, identify them and store for reuse.
• Back off each sealing ring in turn and chisel out a section of each packing ring
to loosen them. Push the outer crossfire tube through the remains of the packing rings into
the adjacent combustion chamber and remove it.
• Identify the tube with the combustion chamber numbers and store for reuse.
• Clean out the remains of the packing rings.
14. Remove the flow sleeves and combustion casings

• Starting with Chamber 6, remove all but four flange bolts. Rig a sling around
the casing and raise the crane hook to pick up the weight of the casing before removing
the last four bolts.
• Pick up the casing and set it down on plywood. Mark location and store until
needed.
15. Remove the upper-half piping

• Unbolt and remove the four 13th stage and 9th stage upper-half piping and two
lower-half flex-piping connections from the turbine casing. Disconnect the other ends of
these flexible pipes near the turbine piping manifold.
• Unbolt and remove the two atomizing air upper-half piping connections from
the turbine casing cone.
• Store pipe sections so as to prevent damage.
• Clean all nuts and bolts of old anti-seize compounds.
• Clean all flange gasket sealing surfaces.
• CAUTION: Cover all flange openings with protective material to prevent
foreign objects from entering the openings. Rags are not adequate.
16. Remove the 1st stage turbine borescope pins

• Remove all 1st stage borescope pins and plugs and tag per removal location.
Clean all plugs and pins and set aside.
17. Place mechanical support jacks under unit casings

• Remove the turbine compartment floor plate covers, provided beneath the
vertical flange joints, so that the concrete pad can be used as a jacking support surface.
Ensure jacks are mounted perpendicular to the gas turbine a Jacking points are provided
at the bottom centerlines of the casing flanges for 2.5 in. (6.35 cm) ball top mechanical
screw jacks.
• Dial indicators should be used at each jacking location. The dial indicators must
be mounted separately from the jacks.
• Install a screw jack at the turbine exhaust flange. Jack to obtain 0.006+0.001”
• (0.0151 + 0.0025 cm) reading on indicator.
• Install a screw jack at the compressor discharge turbine flange Jack to obtain
0.004+ 0.001” (0.016 + 0.0025 cm) indicator reading.
• Record dial indicator readings.
• NOTE: All jacks must be in place at all times when any upper-half casing is
removed and must remain until all upper-half casings have been replaced and bolted up.
18. Remove the turbine casing bolts

• Unbolt the upper-half vertical flange bolting between the turbine casing and
exhaust frame.
• Unbolt the upper-half vertical joint bolting between the turbine casing and the
compressor discharge casing.
• Remove the horizontal joint bolting and body-bound bolting.(Horizontal joint
body-bound bolts are removed by driving them upward).
• Mark body-bound bolts for replacement in same holes.
19. Remove the upper-half turbine casing

• Lubricate and install guide pins and jack-bolts.
• Guide pins are used in the four body-bound bolt hole provisions.
• Rig to lift the turbine casing level. Use a four-point attachment arrangement.
The total weight of the upper-half turbine casing with the second-and third-stage nozzles
and shrouds is approximately 24,450 pounds (11090 kg). The upper-half first-stage
nozzle is not lifted with the casing.
• CAUTION: During removal of turbine casing, some nozzle and shroud
horizontal joint seals may become dislodged. These seals should be removed from the
unit and set aside.
• Using chain falls, carefully lift the upper-half turbine casing clear of the turbine
buckets before using the crane to lift and move clear of the unit.
20. Remove the transition pieces

• Remove the bolts from the side seals of the Number 6 combustion transition
piece. Remove the side seal retainer blocks and the side seals, identify and store.
• Wrap a flat sling around the transition piece body upstream of the aft mount.
Raise the crane hook to pick up some of the transition piece weight.
• Remove the two aft bracket bolts and lock plates. Move the transition piece
upstream until the inner and outer seals disengage [approximately 3/8 inch(0.952 cm)].
Continue to move the transition piece upstream until the forward mount “bat wing”
blocks clear the forward (bullhorn) support clamp and the aft mount guide pin clears the
nozzle retaining ring.
• Transition pieces should be marked and set aside for inspection and re-use. Care
must be taken to avoid damage to the floating seals and the thermal barrier coating during
handling.
NOTE: All CI parts (Fuel Nozzles, Liners, Transition Pieces) to be refurbished for re-use.
1.3. Cleaning and inspection

1. Parts to be inspected
a) Inspect the instrumentation
• Determine if any instrumentation have BDQ (Bad Data Quality) or are out of
range, and if so, troubleshoot and calibrate.
b) Perform calibration of combustion controls

• Perform calibration and function checks of Fuel control valves Gas Fuel Control
Valve: VGC-1 Gas Fuel Stop Ratio Valve: VSR-1
• Liquid Fuel Bypass Valve: VC3-1
• Liquid Fuel Stop Valve: VS1-1
• Perform calibration and function checks of IGV’s
• Perform calibration and function checks of bleed, blow-off, and water-injection
valves
• Bleed Valve: VA20-1
• NOTE: All CI parts (Fuel Nozzles, Liners, Transition Pieces) to be refurbished
by the Contractor for re-use.
• Blow-off Valve: 20CB2
• Water Injection Valve: VC4-1
c) Inspect the piping and flexible hoses

• All piping and flexible hoses should be inspected for visual indication of
damage or need for replacement. Good engineering practices should be observed. Also
note any insulation damage that is observed
d) Pack and ship

• If necessary, using the new part containers when possible, the following
components to shall be cleaned, inspected, repaired and test as required:
Fuel nozzles
Transition pieces
Combustion liners
e) Inspect and test the spark plugs

• Inspect the spark plug assembly for binding, galling, arcing, tip/piston weld
cracks, ceramic insulator cracks and damaged threads on electrical lead connection.
• Check the movement of the spark plug piston by pulling on the lead end ofthe
piston. If any evidence of binding exists, the cylinder assembly must be disassembled and
the binding eliminated. To disassemble the cylinder assembly, remove the four bolts from
the top of the cylinder, then remove the top of the cylinder and the piston
• The igniter needs to be replaced if it has been damaged at the hot end, or fails to
fire properly when tested. To remove the igniter from the piston assembly, unscrew the
igniter’s retaining nut at the cold end. The igniter may then be slid out of the piston
assembly. It should be replaced with a new igniter including a new retaining nut and
ferrule. Slide the igniter assembly into the piston until the retainer nut is against the fitting
and the stop collar is against the retainer nut. Then tighten the retaining nut 1 ¼ turns to
set the ferrule.
• CAUTION: A Hot work permit is specifically required for this step.
• Take care not to lose or damage the nickel sealing ring at the top of the cylinder.
• Remove all foreign material, such as dust, dirt or chips, from the cylinder and
piston assemblies. Remove all oxidation and galling marks and correct the cause of
galling.
• Reconnect the spark plug lead, with the spark plug removed from the turbine.
Rest the body of the spark plug against the turbine shell (or other grounded metal). Make
sure the electrode end of the spark plug is not grounded.
• Energize the ignition circuit and check the spark of the spark plug for
approximately two minutes. If heating occurs at any point along the length of the igniter
or if the spark is weak or erratic replace the igniter.
WARNING: DO NOT TEST IGNITORS IN OR NEAR AN AREA WITH AN
EXPLOSIVE ATMOSPHERE.
BE CAREFUL OF HIGH VOLTAGE.
f) Inspect and test the flame detectors

• The combustion system has four flame detectors. They are mounted on the
combustion casings looking across the upstream end of the reaction zone.
o Clean the scanner lenses. Reconnect flame detector wiring and energize
the control panel. With power on the control panel, check that FL-1 and FL-2indicating
lights are out.
o Using a match or candle, check to assure that each flame detector picks
up and drops out when the light source is placed in front of the sensor and removed. The
unit should be capable of detecting the match or candle at approximately 18 inches (45.7
centimeters).
• CAUTION: The flame detector tube is contained in the flame sensor sub-
assembly. Combined with the body and window subassembly, the two subassemblies
form the ultraviolet flame sensor. Either of these sub-assemblies are field replaceable, but
neither subassembly is field repairable (except for cleaning), and it must be returned to
the manufacturer for repair or replacement.
• Sensor is polarity sensitive and will be damaged if connected with reverse
polarity.
• Black lead of sensor is positive.
g) Inspect the fuel nozzle assemblies

• Inspect and replace.
h) Inspect the combustion liners

i) Inspect the crossfire tubes and retainers

• Inspect crossfire tubes for evidence of distortion, cracks, missing metal, burn-
through and wear.
• Inspect crossfire tube retainers for wear and evidence of bending.
• Record inspection results on appropriate inspection form.
j) Inspect the combustion chamber flow sleeve

k) Inspect the combustion casings

• Inspect inside and outside of combustion casings for cracks, bulging, buckling,
signs of overheating and corrosion.
• Inspect each combustion outer casing for foreign objects.
• Check Heli-Coil inserts in flange at upstream end of casing. Replace if
unserviceable.
l) Inspect the transition pieces

• Clean the transition pieces and record all inspection results on appropriate
inspection form.
• Aft bracket for weld or body cracks on inside surface of transition piece.
• Aft picture frame/body corners for weld or body cracks, or cracks in wear
inserts.
• Forward support ring for weld or body cracks on inside and outside surface.
• Inspect outside of forward support ring for wear from floating ring seal in flow
sleeve.
• Floating seal retainers for weld or retainer cracks.
• Check floating seals for cracks and worn surfaces.
• Check aft side seal spots for cracks, or breached wear coating.
• Check transition piece body for body and weld cracks.
• Inspect inside of transition piece for loss of thermal barrier coating.
• Check forward “bat wing” bracket for cracks.
• Check forward support clamp (bullhorn) for cracks and slot wear.
m) Inspect the IGV

• Visually inspect the inlet guide vanes for erosion, corrosion, cracks, wear, and
missing metal. Measure the clearances to stator, bush wear, and backlash. Verify the
orientation of all blading is within prescribed tolerances.
n) Visually inspect and borescope the inner parts

• A visual inspection will be performed of all accessible internal areas of the gas
turbine using a suitable borescope and camera. Pictures of all areas inspected shall be
taken as evidence of condition. Any evidence of abnormal conditions will be immediately
reported to the customer. Borescope pictures will be included in the final inspection
report.
2. Parts to be replaced
• Worn-out parts including all consumables.
3. Parts to be replaced and then refurbished for re-use

• List of capital parts for replacement -
FUEL NOZZLE ASSEMBLY, DUAL FUEL
TRANSITION PIECE ASSEMBLY
COMBUSTION LINER ASSEMBLY
4. Re-assembly
a) Install the transition pieces
Pre-assembly Inspection and Checks
• Prior to installation, inspect transition pieces for obvious handling or
transportation damage such as deformed floating seals. Trial fit end seals onto transition
piece before installing the transition piece into the machine.
• Trial fit, using hand force only, each support clamp to its respective transition
piece prior to installing the transition piece into the machine.
• Inspect first-stage nozzle segments for axial displacement (steps) between
adjoining segments. Displacement greater than 0.030 inch (0.076 cm) should be reseated
with a 5-pound rawhide mallet -do not use metal hammer.
• Inspect first-stage nozzle seal strips for extension into floating seal slots. Grind
seals back to bottom of the slot if required.
• Inspect all tapped holes for dirt, chips, rust or damaged threads. Re-tap damaged
threads; re-machine for heli-coil insert if threads are elongated or stripped.
• Inspect all heli-coils for cross threading, elongation, stripping or insert backing
out. Remove and replace all damaged heli-coils.
• To minimize handling and adjustments inside the combustion wrapper set the
positions of the inner and outer floating seals. Do not use a metal hammer to position
seals.
• NOTE: If a spare first-stage nozzle is available or if the first-stage nozzle for
the unit is out of the unit, it is recommended that the transition pieces be trial fitted into
the nozzle retaining ring and that the bolt hole alignment and the end seal fit be checked
prior to trying the parts in the unit.
Assembly Procedure
• Lift transition piece into the opening in the compressor discharge casing
(through man way cover opening). Rig a line inside the turbine casing to support the
weight of the transition piece. At the bottom of the turbine a sideline will be needed to
bring the transition piece over to its position.
• It may be easier to align the transition piece seals if it is done without the
presence of the front support.
• Move the transition piece aft until the alignment pin in the aft bracket engages
the hole in the nozzle retaining ring.
• Move the transition piece further aft making sure the inner and outer floating
seals line up with the slots in the first-stage nozzle.
• After the seals have entered the slots in the nozzle, the transition piece should be
moved aft until the aft bracket face contacts the retaining ring.
• Install aft bracket bolt and lock plate. Tighten to first-stage nozzle retaining
ring. Prior to torqueing bolt, check for proper floating seal engagement. Torqueing aft
bracket bolt with floating seal out of its slot will result in damage. Torque bolt to figures
identified in GE specification. Do not bend lock plate tabs at this time.
• To assure proper seating of the transition piece, the aft mounting bolt must be
torqued, loosened and re-torqued to the correct load.
• Slide the front support into place engaging the blocks on the transition piece.
Install the front support bracket bolts and lock plate but do not torque bolts or bend lock
plate
• Adjust support clamp by sliding on block until at least one bearing surface on
each side of support clamp makes contact when transition piece is loaded toward turbine
centerline.
• Torque the support clamp bolts and check the “B” and “C” dimensions between
the nozzle sidewall and the transition piece end frame. These dimensions must agree with
the values given in the Transition Piece Arrangement drawing. Note that the values must
be achieved both for the clearance and the values on adjacent transition pieces so that it is
possible to assemble side seals. a. If the “C” dimension is less than the drawing
requirements, up to two lock plates may be used as shims between the support clamp and
the block.
• When the “C” dimension meets the drawing requirements, bend up the lock
plate tabs on the support clamp and the transition piece aft bracket.
• Install the side seals after the adjacent transition pieces have been installed.
Slide in side seal, the side seal retainer, the lock plate, and the bolt.
• Torque end seal bolt to correct load and bend lock plate tabs.
• Follow the same procedure for each transition piece until the last one is installed
in Position # 6.
b) Install the upper-half turbine casing

• Coat the mating surface of the turbine casing with a light film of anti-seize
compound excluding the four-way joint.
• CAUTION: Only a thin film of anti-seize is to be used or it will interfere with
pulling joints together and act as a gasket. Do not get anti-seize compound into the hot
gas path.
• Check and assure that all items are secure within the casing prior to assembly.
• Rig the casing to lift level.
• Install guide pins in the horizontal joint of the turbine casing. The guide pins are
to be placed in the body-bound stud hole locations. Reinstall nozzle and shroud horizontal
joint spline seals as necessary and orient them perpendicular to turbine case horizontal
flange using wax to hold them upright.
• Position the upper-half turbine casing directly over the lower-half turbine casing
with the crane.
• CAUTION: Do not allow casing to swing and hit the turbine buckets while it is
being lowered into position.
• Lower the casing utilizing the guide pins provided, and ensure that the nozzle
and shroud joint sealing strips at all locations are in position.
• NOTE: Make certain that the upper- and lower-half turbine nozzles are loaded
in the same direction to avoid mismatch at the horizontal joint seals.
• Install all bolts hand tight, including body-bound bolts. Tighten the horizontal
joint bolts, starting at the mid-point and working alternately to the ends.
• Alternate the bolt tightening from the right side of the casing to the left side (or
vice versa).
• Alternately tighten all the vertical bolts, working down each side from the top
vertical centerline.
• NOTE: Work both the aft and forward vertical flanges simultaneously.
c) Install the borescope pins

• Install borescope pins in the same locations they were removed from. Reinstall
borescope plugs and tighten.
d) Install the upper-half piping

• On reassembly of piping, use new gaskets on all gasketed joints.
• Assemble the four 13th stage upper-half and two lower-half flexible pipe
connections at the turbine casing and at existing piping flanges.
• Assemble the two atomizing air piping connections to the turbine casing cone
and the inlet heating piping.
e) Remove the casing jacks
• CAUTION: Jacks are not to be removed until all upper casings have been
installed and bolted up.
• 1. Place two dial indicators (one on each side of the machine) at the horizontal
joint near the area that the jacks are supporting. Attach dial indicators to turbine enclosure
frame and set to indicate on turbine casing. Set dial indicators at zero.
• Release the jacks and observe whether turbine casing has lowered.
• If turbine casing moved downward when the jacks were released, remove the
jacks and jack supports from under the turbine.
f) Install the combustion casing, flow sleeves, and outer crossfire tubes
• Apply a light coating of approved anti-seize compound to all mating parts and
bolts.
• Install a new spiral wound gasket into groove in the downstream flange of the
outer combustion chamber.
• Use a wood or aluminum rod to expand the piston ring at the downstream end
of the flow sleeve to allow the ring to slide over the end of the transition piece.
• Rig a support sling and lift the combustion casing into place.
• Raise casing and engage the locating pins. Slide the combustion can into the
outer casing until the flow sleeve piston ring slides over the transition piece impingement
sleeve. When the piston ring is in place, the rod holding the ring open will be dislodged,
allowing the ring to spring back into contact with the impingement sleeve.
• Tighten the combustion casing flange to compressor discharge casing flange
bolts. Tighten bolts 180~ apart and work around the flange bolting circle in this sequence
until all bolts are tight.
• Continue to install casings until all are in place and properly torqued.
• Inspect sealing surface of outer crossfire tube to be sure it is free of nicks or
burrs.
• Install new packing rings in each end. Slide outer crossfire tube from inside one
aft casing through the crossfire flange and into the adjacent casing. Thread on the packing
rings and the sealing ring flanges to the outer tube in the appropriate order.
• Install the split ring retaining washers and bolts to compress the packing hand
tight.
• Center the outer tube between the two outer casings and use the bolts to
compress the packing to the dimension given in MLI 0701.
• Repeat the process until all outer crossfire tubes are in place and the packing are
compressed.
• CAUTION: Begin by installing the outer casing on Chamber No. 3 and work
up to the top of the turbine.
• The weight of the casing is approximately 400 pounds (181.4 kg).
g) Install the cross fire tubes and combustion liners

• After each combustion casing is installed, insert the two inner crossfire tube
parts before installing the next flow sleeve. Install the two crossfire tube halves so that the
male end is at the clockwise end of the crossfire tube assembly.
• Use the crossfire tube retainers to lock the inner crossfire tube parts away from
the combustor centerline to allow assembly of the liner assemblies.
• Slide the liner assembly into the flow sleeve until the downstream end begins to
enter the transition piece. Then push the liner aft until the spring seal is in the transition
piece.
• Insert the crossfire tube into the collar in the combustion liner and lock it in
position with the crossfire tube retainer.
• Continue to install liner assemblies and crossfire tubes until all are installed
• CAUTION: Secure the rod with a line to allow easy retrieval and to prevent the
rod from falling into the turbine.
h) Install the spark plugs

• Install new gaskets and spark plug assembly in combustion chambers 4 and 5.
Be sure that spark plug tip enters the hole in the flow sleeve and the hole in the can and
liner assembly.
• Coat bolts with anti-seize compound and bolt the spark plug assembly to flange.
• Check to see that spark plug electrode moves freely.
i) Assemble the fuel nozzle assembly to combustion casing

• Check to be sure that the three alignment pins in the aft flange of the fuel nozzle
casing are in place and tight.
• Install an eye bolt in the flange of the fuel nozzle cover and rig so that the
assembly will be in proper alignment for its combustion casing.
• Place a new gasket in the recess of the combustion casing.
• Lift the nozzle assembly and move it to the combustion casing. Move it axially
until the alignment pins engage the flange of the casing.
• Move the assembly axially until the spring seal on the cover enters the
combustion liner. Three or more flange bolts may be used to draw the flanges together.
• Install the rest of the flange bolts, tighten and torque them.
• Continue to assemble until all 6 assemblies are complete.
j) Install the atomizing air flex hoses

• Verify all flange faces are clean and blow out openings. Verify quantity and
cleanliness of all nuts and bolts.
• Install the upper section of the manifold.
k) Install the false start drain piping

• Install new gaskets at all flanges.
• Line up the match marks and numbers on the flanges to the appropriate
combustion cans (2 - 4).
• Tighten bolts in a cross-cross pattern to give uniform gasket compression.
l) Install the liquid fuel lines

• Install the liquid fuel lines to their original combustion can - ensure to hand
thread all Swagelok fittings before tightening with a wrench.
m) Connect the atomizing air lines

• NOTE: All atomizing air, water, liquid fuel, and gas fuel lines must be
absolutely clean when installed. If they have not been previously cleaned and protected,
they must be inspected and cleaned if needed.
• Using new gaskets, connect the flexible atomizing air lines between the fuel
nozzle flange and the manifold flange. Start at cover number 6 and work clockwise and
counterclockwise.
• Tighten bolts in a criss-cross pattern to give uniform gasket compression.
n) Install the water injection manifold and flex hoses

• Install the primary and secondary sections of the water injection manifolds on
the right-hand side.
• Install the two flex hoses on the right-hand side, using new O-rings.
the left-hand side.
• Install the upper section of the water injection manifold.
• Starting at cover number 6 and working clockwise and counterclockwise, install
both the primary and secondary water injection flex hoses to each cover.
• NOTE: The secondary connection is in the center of the cover and has a square
flange. The primary connection is on the outer edge of the cover and is connected to a
distribution valve.
o) Install the flame detectors

• Install new gasket.
• Coat bolts with approved anti-seize compound, being careful not to get any of
the compound into the hot gas path.
• Using new gaskets, install flame detectors on chamber numbers 1, 2, 5 and 6.
• Leave the bolts and connections loose until the manifolds are in place.
• Install the feed and return cooling water manifolds.
• Install the two flex hoses on the right side of the unit.
• Once the manifolds are in place, tighten bolts to each flame detector in a
crisscross pattern to give uniform gasket compression.
• Reconnect wiring to flame detectors.
• Reconnect water cooling feed and drain lines to flame detectors, starting at the
lowest flame detector on each side and working upward.
• Reenergize power supply to flame detectors by reinstalling the flame detector
cards.
p) Install the fuel oil purge tubing

• Install the two lines that were connected to the left-hand panel of the purge
module. These lines run down the left side of the turbine.
• Install, as a bundle, the lines that were connected to the right-hand panel of the
purge module.
q) Install the turbine compartment roof sections

• Reassemble side panel vertical beams if any were previously removed at
disassembly.
• NOTE: If the vertical side beams were cut off with a torch, they can be
reinstalled using doubler plates and nuts and bolts to facilitate future disassembly and
reassembly.
• Apply new gaskets or caulking seal to roof sections where needed.
• Rig a turbine roof to lift it level.
• Position over turbine compartment with crane and lower into place using the
chain falls.
• Repeat steps 3 and 4 for the remaining roof section.
• Apply approved anti-seize compound to bolts and install all bolts.
r) Install the inlet and exhaust duct access panels

• Apply anti-seize compound to all bolting.
• Attach gaskets to duct access panel flanges.
• Lift access panels into place and bolt up.
s) Reassemble the turbine compartment roof components

• CAUTION: Clean all flange openings and inspect for foreign objects.
• Reassemble all piping previously removed.
• Reassemble walkways and platform from the turbine enclosure roof.
• Install the ventilation duct from the turbine enclosure roof.
• Reassemble any tubing conduit and wiring previously removed.
• Apply anti-seize compound to bolts and install all bolts.
t) Clean up, visual inspection, pre-start and startup checks

• Inspect in the MKVIe all transmitters that were disconnected/reconnected
during the CI are reading properly.
• Clean up all alarms in the MKVIe / MKVIeS.
• Clean up all lube oil and water spills.
• Make a visual inspection of the unit and check to ensure that the following has
been completed.
o Check that all removed piping has been replaced.
o Check that all removed conduit has been replaced and electrical
connections made. Confirm function of all devices.
o Inspect inlet and exhaust plenums.
• Reconnect power to all systems disabled at start of job.
• Perform pre-cranking checks as follows:
o Record all panel counter readings.
o Check operation of cool down/emergency lube pumps.
o Check operation of auxiliary hydraulic pump.
o Make visual inspection to see if oil is flowing in bearing drains.
o Block out excitation and generator breaker equipment.
o Place unit on turning gear and observe for leaks, rubs, and control
deficiencies.
• Perform cranking checks as follows:
o Observe pickup RPM of speed sensors versus time.
o Inspect for casing air leaks.
o Observe and record vibration channel outputs.
o Observe and record crank speed.
o Check starting means for proper operation.
o Listen for rubbing noises.
o Check temperature of lube oil in bearing drains or at the bearing header
and tank.
o Observe all panel and hydraulic manifold pressure gauge readings for
abnormalities.
o Trip the unit using the emergency trip and listen for abnormal noises from
gas turbine and associated equipment during coast down.
o Observe proper dropout RPM of speed sensors.
• Initiate a start and perform the zero to full speed, no load firing checks as
follows:
o Observe applicable firing check parameters, relay sequences, exhaust
temperature, vibration and speed.
o Check spark plugs and flame detectors.
o Observe and record acceleration rates.
o Record full set of vibration readings.
o Observe and record temperature suppression set point.
o Note and record pick-up time of all appropriate electrical speed relays.
o Check full-speed-no-load RPM.
o Check digital set point.
o Take a complete set of running data. See Running Inspection section of
this instruction.
o Check for air, oil, gas and water leaks.
o Perform load checks (if applicable) as follows:
o Take a full set of load data, including the staging times from diffusion to
piloted premix and from to piloted premix to premix. This can be done automatically by
the control system.
• Observe normal unloading and shutdown as follows:
o The times and loads for transition from premix through piloted premix
and from piloted premix through diffusion should be recorded during the unloading
period.
o Note and record coast down time.
• Listen for abnormal noises from gas turbine and associated equipment during
coast down.
• Observe unit vibration readings during coast down.
5. Restart operations
• Remove tag out, lock out; reactivate the fire protection system; reactivate
electric power system; reactivate field instrumentation; remove blank-off fuel lines per
local operating instructions.
• Carry out instrumentation functional check per GE O&M manual; check piping
for leaks; auxiliary systems loop check per local operating instructions.
• Offline washing if required per local operating instructions.
• Start up the unit and record and analyze the operating parameters per local
operating instructions and GE O&M manual.
• Submit comments and observations post-startup monitoring and diagnostic
report; submit shutdown inspection report one (1) month after the shutdown.
2. Hot Gas Path Inspections

I. TURBINE INSPECTIONS
2.1. Shutting down of Units
• CO2 Fire Protection System Isolation and CO2 Switch Inhibited
• Turning Gear Motor Isolation
• Fuel Oil Pump A, B, C Isolations
• GT Compartment PKG Ventilation Fan Motor A, B Isolations
• Bearing #2 Cooling Fan Motor A, B Isolations
• Exhaust Frame Cooling Fan A, B Isolations
• Exhaust Compartment Fan A, B Isolations
• Load Gear Compartment Cooling Air Fan A, B Isolations
• Water Injection Pump Isolations
• Hydraulic Pump Isolations
• Atomizing Air Compressor Drive Motor A, B Isolations
• Gas Module Acoustic Enclosure Cooling Air Fan A, B Isolations
• Liquid Fuel Compartment Cooling Air Fan A, B Isolations
• Water Injection Skid Enclosure Cooling Air Fan A, B Isolations
• Gas Fuel Stop Valve Isolation
• Liquid Fuel Stop Valve Isolation
• Cooling Water Supply Isolations
• Spark Plug Isolations
2.2. Disassembly
1. CO2 Fire Protection System Isolation and CO2 Switch Inhibited
• Remove wirings/conduits of flame detectors and spark-plugs
2. Remove the flame detectors

• The flame detector is mounted on the side of the combustion chamber. Prior to
disconnecting and removing the flame detectors mark them with the combustion chamber
number.
• Remove the flame detectors from combustion chambers 1, 2 and 6 (2flame
detectors in can # 6). Discard all gaskets.
3. Remove the spark plugs

• Prior to disconnecting and removing the spark plugs, mark the combustion
chamber number on each plug.
• Unbolt each spark plug assembly from the casing flanges on combustion
chamber numbers 4 and 5 by removing the four bolts on the spark plug flange.
• Lift spark plugs out. Discard all gaskets.
• Remove old anti-seize compound from all bolts; bag and identify for
reassembly.
• Clean matching flange surfaces.
4. Remove inspection door on inlet plenum and exhaust plenum

• Unbolt the removable exhaust duct access panel.
• Unbolt the right side removable inlet lagging panel.
• Rig and lift the panels clear of unit and store panels off the ground
5. Remove the turbine compartment roofs and blowers

• Remove roof-mounted electric wiring at nearest pull box and disconnect
conduit.
• Remove ventilation duct from turbine enclosure roof.
• Remove walkways and platform from turbine enclosure roof.
• Unbolt the forward and aft roof sections from the sidewall frames and from each
other. Unbolt only the lower set of bolts at the sidewall frames.
• Attach four eyebolts to a roof section in threaded receptacles provided for
lifting.
• Attach four equal length cables or two equal length cables and comealongs to
chain fall connected to crane.
• Check to ensure the roof section is mechanically free to be lifted, and carefully
lift with chain fall until clear.
• Set the roof section on appropriate cribbing.
• Repeat steps 1 through 4 for the remaining roof section.
6. Remove the fuel oil and purge flex hoses

• Prior to disconnecting and removing the fuel oil flex hoses, the hoses must be
match marked with the combustion chamber number.
• CAUTION: The flex hoses must be installed in a low stress state. Avoid
excessive single plane bends, multiple bend planes, kinks, and squirm in the hoses. Avoid
excessive hose tension or compression by reinstalling in the hose in the original bending
plane.
• Starting at cover number 3 and working both clockwise and counterclockwise
up to cover number 6, remove all flex hoses to each combustion cover.
• CAUTION: Do not use the fuel oil flex hoses as climbing aids or footholds.
Proper rigging and scaffolding shall be used.
• Keep fuel oil flex hoses free from dirt, oil, water, or other contaminants. Store
the removed hoses in a weather-protected area with temporary flange covers installed.
• Install temporary flange covers over the exposed gas fuel manifold flanges.
• NOTE: The fuel oil manifolds do not require disassembly for a typical
combustion inspection.
7. Remove the false start drain piping

• Prior to disconnecting the combustion chamber false start drain piping, the pipes
must be match marked with a waterproof marker.
• Match mark the pipe end that connects to the combustion can. Mark the other
end to the drain flex hose. Mark each hose with the chamber number.
8. Remove the other fuel nozzle flex hoses

• Unbolt the nozzle flex hoses from the combustion can end covers.
• Temporarily move the free end of the flex hoses away from the end cover to
gain access to other end cover bolting.
• NOTE: Complete removal of the flex assembly is not usually required to
remove the fuel nozzle assembly.
• Disconnect and remove the steel beam on the top of the steel support column.
• Disconnect and remove the upper portion of the steel support column on both
the left and the right–hand sides.
9. Remove the atomizing air flex hoses and manifolds

• Tag the sections of the atomizing air manifold as upper & lower.
• Disconnect and remove the upper section of the manifold.
• Clean all flange faces and cover all openings. Clean all nuts and bolts, bag and
identify for reassembly.
10. Remove the fuel oil distribution valve drain lines

• Prior to disconnecting the combustion chamber false start drain piping, the
piping must be match marked with a waterproof marker.
11. Remove the fuel nozzle assembly

• Match mark both parts with the chamber number.
• Install a lifting eye to the end cover of #6 chamber. Rig in a manner so that the
assembly can be removed axially from the downstream combustion casing.
• Make sure the three guide pins are in place and that the retaining nuts are tight.
• Raise the crane hook to support the assembly.
• Remove the bolts from the flange between the end cover and the combustion
casing. The assembly is now supported by the guide pins.
• Attempt to slide the cover axially on the guide pins.
• Slide the assembly axially until the guide pins clear the casing flange.
• CAUTION: The cover and casing assembly weigh approximately 800lb
• (360 kg). A crane or other lifting device must be used for removal and
installation.
• The fuel nozzle can be moved away and lifted clear of the turbine.
12. Remove the combustion liners and crossfire tubes

• Remove the combustion liners by first pulling all crossfire tube retainers away
from the crossfire tube collars (two retainers per crossfire tube). Tag all retainer clamps
and identify according to chamber position and side.
• To remove the combustion liner, telescope both crossfire tubes toward the
adjacent chamber until they are clear of the combustion liner. If crossfire tube tends to fall
into the liner being removed, employ a long-bladed screwdriver or one of the retainers to
hold the crossfire tube in the retracted position.
• Pull liner straight out taking care not to snag the spring seals [each liner weighs
approximately 60lb (27 kg)]. Place liners on plywood to prevent damage and cover to
keep dirt out.
• Identify each liner according to chamber position.
• Retrieve both crossfire tube ends previously pushed into adjacent chambers by
pulling each back through the empty chamber. Identify and tag each end with respect to
its combustion chamber location and side.
• Remove the remaining combustion liners and crossfire tubes in the same
manner, identifying and tagging each.
• CAUTION: Be sure that crossfire tubes are disengaged from liner collars
before attempting to move liner or damage will occur.
• Exercise caution when removing liners to ensure that aft spring seal leaves and
crossfire tube collars do not snag over retainer ramp assemblies on the flow sleeve.
13. Remove the outer crossfire tubes
• Remove the bolts from each sealing ring flange on the outer crossfire tube
flanges. Remove the split ring retaining washers, identify them and store for reuse.
• Back off each sealing ring in turn and chisel out a section of each packing ring
to loosen them. Push the outer crossfire tube through the remains of the packing rings into
the adjacent combustion chamber and remove it.
• Identify the tube with the combustion chamber numbers and store for reuse.
• Clean out the remains of the packing rings.
14. Remove the flow sleeves and combustion casings

• Starting with Chamber 6, remove all but four flange bolts. Rig a sling around
the casing and raise the crane hook to pick up the weight of the casing before removing
the last four bolts.
• Pick up the casing and set it down on plywood. Mark location and store until
needed.
15. Remove the upper-half piping

• Unbolt and remove the four 13th stage and 9th stage upper-half piping and two
lower-half flex-piping connections from the turbine casing. Disconnect the other ends of
these flexible pipes near the turbine piping manifold.
• Unbolt and remove the two atomizing air upper-half piping connections from
the turbine casing cone.
• Store pipe sections so as to prevent damage.
• Clean all nuts and bolts of old anti-seize compounds.
• Clean all flange gasket sealing surfaces.
• CAUTION: Cover all flange openings with protective material to prevent
foreign objects from entering the openings. Rags are not adequate.
16. Remove the 1st stage turbine borescope pins

• Remove all 1st stage borescope pins and plugs and tag per removal location.
Clean all plugs and pins and set aside.
17. Place mechanical support jacks under unit casings

• Remove the turbine compartment floor plate covers, provided beneath the
vertical flange joints, so that the concrete pad can be used as a jacking support surface.
Ensure jacks are mounted perpendicular to the gas turbine a jacking points are provided at
the bottom centerlines of the casing flanges for 2.5 in. (6.35 cm) ball top mechanical
screw jacks.
• Dial indicators should be used at each jacking location. The dial indicators must
be mounted separately from the jacks.
• Install a screw jack at the turbine exhaust flange. Jack to obtain 0.006+0.001”
• (0.0151 + 0.0025 cm) reading on indicator.
• Install a screw jack at the compressor discharge turbine flange. Jack to obtain
0.004+ 0.001” (0.016 + 0.0025 cm) indicator reading.
• Record dial indicator readings.
• NOTE: All jacks must be in place at all times when any upper-half casing is
removed and must remain until all upper-half casings have been replaced and bolted up.
18. Remove the turbine casing bolts

• Unbolt the upper-half vertical flange bolting between the turbine casing and
exhaust frame.
• Unbolt the upper-half vertical joint bolting between the turbine casing and the
compressor discharge casing.
• Remove the horizontal joint bolting and body-bound bolting. (Horizontal joint
body-bound bolts are removed by driving them upward).
• Mark body-bound bolts for replacement in same holes.
19. Remove the upper-half turbine casing

• Lubricate and install guide pins and jack bolts.
• Guide pins are used in the four body-bound bolt hole provisions.
• Rig to lift the turbine casing level. Use a four-point attachment arrangement.
The total weight of the upper-half turbine casing with the second-and third-stage nozzles
and shrouds is approximately 24,450 pounds(11090 kg). The upper-half first-stage nozzle
is not lifted with the casing.
• CAUTION: During removal of turbine casing, some nozzle and shroud
horizontal joint seals may become dislodged. These seals should be removed from the
unit and set aside.
• Using chain falls, carefully lift the upper-half turbine casing clear of the turbine
buckets before using the crane to lift and move clear of the unit.
20. Remove the transition pieces

• Remove the bolts from the side seals of the Number 6 combustion transition
piece. Remove the side seal retainer blocks and the side seals, identify and store.
• Wrap a flat sling around the transition piece body upstream of the aft mount.
Raise the crane hook to pick up some of the transition piece weight.
• Remove the two aft bracket bolts and lock plates. Move the transition piece
upstream until the inner and outer seals disengage [approximately 3/8 inch(0.952 cm)].
Continue to move the transition piece upstream until the forward mount “bat wing”
blocks clear the forward (bullhorn) support clamp and the aft mount guide pin clears the
nozzle retaining ring.
• Transition pieces should be marked and set aside for inspection and reuse. Care
must be taken to avoid damage to the floating seals and the thermal barrier coating during
handling.
21. Remove the 1st stage nozzle
• Remove the 1st stage nozzle bolts
• Rig and remove the UH 1st stage nozzle
• Rig and remove the LH 1st stage nozzle
22. Remove the 1st, 2nd, 3rd stage shroud blocks

• Remove the shroud block retainers from the UH and LH turbine casing
• Remove the shroud blocks from the UH and LH turbine casing
23. Remove the 2nd, 3rd stage nozzle segments

• Remove the nozzle segment retainers from the UH and LH turbine casing
• Remove the nozzle segments from the UH and LH turbine casing
24. Remove the 1st, 2nd, 3rd stage turbine buckets

• Remove the retainer pins from the buckets
• Remove the lock wire from the buckets
• Remove the buckets
NOTE: All HGP parts (1st, 2nd, 3rd stage of Nozzles, Shroud Blocks, Turbine Buckets) to
be refurbished by the Contractor for re-use.
2.3. Cleaning and inspection

1. Parts to be inspected
a) Inspect the instrumentation
• Determine if any instrumentation have BDQ (Bad Data Quality) or are out of
range, and if so, troubleshoot and calibrate.
b) Perform calibration of combustion controls

• Perform calibration and function checks of Fuel control valves Gas Fuel Control
Valve: VGC-1 Gas Fuel Stop Ratio Valve: VSR-1
• Liquid Fuel Bypass Valve: VC3-1
• Liquid Fuel Stop Valve: VS1-1
• Perform calibration and function checks of IGV’s
• Perform calibration and function checks of bleed, blow-off, and water-injection
valves
• Bleed Valve: VA20-1
• Blow-off Valve: 20CB2
• Water Injection Valve: VC4-1
c) Inspect the piping and flexible hoses

• All piping and flexible hoses should be inspected for visual indication of
damage or need for replacement. Good engineering practices should be observed. Also
note any insulation damage that is observed
d) Pack and ship

• If necessary, using the new part containers when possible, the following
components to shall be cleaned, inspected, repaired and test as required:
Fuel nozzles
Transition pieces
Combustion liners
e) Inspect and test the spark plugs

• Inspect the spark plug assembly for binding, galling, arcing, tip/piston weld
cracks, ceramic insulator cracks and damaged threads on electrical lead connection.
• Check the movement of the spark plug piston by pulling on the lead end of the
piston. If any evidence of binding exists, the cylinder assembly must be disassembled and
the binding eliminated. To disassemble the cylinder assembly, remove the four bolts from
the top of the cylinder, then remove the top of the cylinder and the piston
• The igniter needs to be replaced if it has been damaged at the hot end, or fails to
fire properly when tested. To remove the igniter from the piston assembly, unscrew the
igniter’s retaining nut at the cold end. The igniter may then be slid out of the piston
assembly. It should be replaced with a new igniter including a new retaining nut and
ferrule. Slide the igniter assembly into the piston until the retainer nut is against the fitting
and the stop collar is against the retainer nut. Then tighten the retaining nut 1 ¼ turns to
set the ferrule.
• CAUTION: A Hot work permit is specifically required for this step.
• Take care not to lose or damage the nickel sealing ring at the top of the cylinder.
• Remove all foreign material, such as dust, dirt or chips, from the cylinder and
piston assemblies. Remove all oxidation and galling marks and correct the cause of
galling.
• Reconnect the spark plug lead, with the spark plug removed from the turbine.
Rest the body of the spark plug against the turbine shell (or other grounded metal). Make
sure the electrode end of the spark plug is not grounded.
• Energize the ignition circuit and check the spark of the spark plug for
approximately two minutes. If heating occurs at any point along the length of the igniter
or if the spark is weak or erratic replace the igniter.
WARNING: DO NOT TEST IGNITORS IN OR NEAR AN AREA WITH AN
EXPLOSIVE ATMOSPHERE.
BE CAREFUL OF HIGH VOLTAGE.
f) Inspect and test the flame detectors

• The combustion system has four flame detectors. They are mounted on the
combustion casings looking across the upstream end of the reaction zone.
o Clean the scanner lenses. Reconnect flame detector wiring and energize
the control panel. With power on the control panel, check that FL-1 and FL-2indicating
lights are out.
o Using a match or candle, check to assure that each flame detector picks
up and drops out when the light source is placed in front of the sensor and removed. The
unit should be capable of detecting the match or candle at approximately 18 inches (45.7
centimeters).
• CAUTION: The flame detector tube is contained in the flame sensor sub-
assembly. Combined with the body and window subassembly, the two subassemblies
form the ultraviolet flame sensor. Either of these sub-assemblies are field replaceable, but
neither subassembly is field repairable (except for cleaning), and it must be returned to
the manufacturer for repair or replacement.
• Sensor is polarity sensitive and will be damaged if connected with reverse
polarity.
• Black lead of sensor is positive.
g) Inspect the fuel nozzle assemblies

h) Inspect the combustion liners

i) Inspect the crossfire tubes and retainers

• Inspect crossfire tubes for evidence of distortion, cracks, missing metal, burn-
through and wear.
• Inspect crossfire tube retainers for wear and evidence of bending.
j) Inspect the combustion chamber flow sleeve

k) Inspect the combustion casings

• Inspect inside and outside of combustion casings for cracks, bulging, buckling,
signs of overheating and corrosion.
• Inspect each combustion outer casing for foreign objects.
• Check Heli-Coil inserts in flange at upstream end of casing. Replace if
unserviceable.
l) Inspect the transition pieces
• Clean the transition pieces and record all inspection results on appropriate
inspection form.
• Aft bracket for weld or body cracks on inside surface of transition piece.
• Aft picture frame/body corners for weld or body cracks, or cracks in wear
inserts.
• Forward support ring for weld or body cracks on inside and outside surface.
• Inspect outside of forward support ring for wear from floating ring seal in flow
sleeve.
• Floating seal retainers for weld or retainer cracks.
• Check floating seals for cracks and worn surfaces.
• Check aft side seal spots for cracks, or breached wear coating.
• Check transition piece body for body and weld cracks.
• Inspect inside of transition piece for loss of thermal barrier coating.
• Check forward “bat wing” bracket for cracks.
• Check forward support clamp (bullhorn) for cracks and slot wear.
m) Inspect the IGV

• Visually inspect the inlet guide vanes for erosion, corrosion, cracks, wear, and
missing metal. Measure the clearances to stator, bush wear, and backlash. Verify the
orientation of all blading is within prescribed tolerances.
n) Visually inspect and borescope the inner parts

• A visual inspection will be performed of all accessible internal areas of the gas
turbine using a suitable borescope and camera. Pictures of all areas inspected shall be
taken as evidence of condition. Any evidence of abnormal conditions will be immediately
reported to the customer. Borescope pictures will be included in the final inspection
report.
2. Parts to be replaced
• Worn-out parts including all consumables.
3. Parts to be replaced and then refurbished for re-use

• List of capital parts for replacement -
FUEL NOZZLE ASSEMBLY, DUAL FUEL
TRANSITION PIECE ASSEMBLY
COMBUSTION LINER ASSEMBLY
4. Re-assembly
a) Install the 1st, 2nd, 3rd stage turbine buckets
• Install buckets in accordance with the moment weight
• Install lock wire to lock in the buckets
• Install lock pins and stake within the OEM specs
b) Install the 2nd, 3rd stage nozzle segments

• Install nozzle segments according to location provided on segments
• Install pins and lock plates
• Ensure all pins are fully engaged
c) Install the 1st, 2nd, 3rd stage shroud blocks

• Install shroud blocks according to location provided on shroud blocks
• Install pins and lock plates
• Ensure all pins are fully engaged
d) Install 1st stage nozzle

• Install LH 1st stage nozzle
• Install UH 1st stage nozzle
• Record all necessary measurements and checks to ensure proper alignment of
nozzle
e) Install the transition pieces

Pre-assembly Inspection and Checks
• Prior to installation, inspect transition pieces for obvious handling or
transportation damage such as deformed floating seals. Trial fit end seals onto transition
piece before installing the transition piece into the machine.
• Trial fit, using hand force only, each support clamp to its respective transition
piece prior to installing the transition piece into the machine.
• Inspect first-stage nozzle segments for axial displacement (steps) between
adjoining segments. Displacement greater than 0.030 inch (0.076 cm) should be reseated
with a 5-pound rawhide mallet -do not use metal hammer.
• Inspect first-stage nozzle seal strips for extension into floating seal slots. Grind
seals back to bottom of the slot if required.
• Inspect all tapped holes for dirt, chips, rust or damaged threads. Re-tap damaged
threads; re-machine for heli-coil insert if threads are elongated or stripped.
• Inspect all heli-coils for cross threading, elongation, stripping or insert backing
out. Remove and replace all damaged heli-coils.
• To minimize handling and adjustments inside the combustion wrapper set the
positions of the inner and outer floating seals. Do not use a metal hammer to position
seals.
• NOTE: If a spare first-stage nozzle is available or if the first-stage nozzle for
the unit is out of the unit, it is recommended that the transition pieces be trial fitted into
the nozzle retaining ring and that the bolt hole alignment and the end seal fit be checked
prior to trying the parts in the unit.
Assembly Procedure
• Lift transition piece into the opening in the compressor discharge casing
(through man way cover opening). Rig a line inside the turbine casing to support the
weight of the transition piece. At the bottom of the turbine a sideline will be needed to
bring the transition piece over to its position.
• It may be easier to align the transition piece seals if it is done without the
presence of the front support.
• Move the transition piece aft until the alignment pin in the aft bracket engages
the hole in the nozzle retaining ring.
• Move the transition piece further aft making sure the inner and outer floating
seals line up with the slots in the first-stage nozzle.
• After the seals have entered the slots in the nozzle, the transition piece should be
moved aft until the aft bracket face contacts the retaining ring.
• nstall aft bracket bolt and lock plate. Tighten to first-stage nozzle retaining ring.
Prior to torqueing bolt, check for proper floating seal engagement. Torqueing aft bracket
bolt with floating seal out of its slot will result in damage. Torque bolt to figures
identified in GE specification. Do not bend lock plate tabs at this time.
• To assure proper seating of the transition piece, the aft mounting bolt must be
torqued, loosened and re-torqued to the correct load.
• Slide the front support into place engaging the blocks on the transition piece.
Install the front support bracket bolts and lock plate but do not torque bolts or bend lock
plate
• Adjust support clamp by sliding on block until at least one bearing surface on
each side of support clamp makes contact when transition piece is loaded toward turbine
centerline.
• Torque the support clamp bolts and check the “B” and “C” dimensions between
the nozzle sidewall and the transition piece end frame. These dimensions must agree with
the values given in the Transition Piece Arrangement drawing. Note that the values must
be achieved both for the clearance and the values on adjacent transition pieces so that it is
possible to assemble side seals. a. If the “C” dimension is less than the drawing
requirements, up to two lock plates may be used as shims between the support clamp and
the block.
• When the “C” dimension meets the drawing requirements, bend up the lock
plate tabs on the support clamp and the transition piece aft bracket.
• Install the side seals after the adjacent transition pieces have been installed.
Slide in side seal, the side seal retainer, the lock plate, and the bolt.
• Torque end seal bolt to correct load and bend lock plate tabs.
• Follow the same procedure for each transition piece until the last one is installed
in Position # 6.
f) Install the upper-half turbine casing
• Coat the mating surface of the turbine casing with a light film of anti-seize
compound excluding the four way joint.
• CAUTION: Only a thin film of anti-seize is to be used or it will interfere with
pulling joints together and act as a gasket. Do not get anti-seize compound into the hot
gas path.
• Check and assure that all items are secure within the casing prior to assembly.
• Rig the casing to lift level.
• Install guide pins in the horizontal joint of the turbine casing. The guide pins are
to be placed in the body-bound stud hole locations. Reinstall nozzle and shroud horizontal
joint spline seals as necessary and orient them perpendicular to turbine case horizontal
flange using wax to hold them upright.
• Position the upper-half turbine casing directly over the lower-half turbine casing
with the crane.
• CAUTION: Do not allow casing to swing and hit the turbine buckets while it is
being lowered into position.
• Lower the casing utilizing the guide pins provided, and ensure that the nozzle
and shroud joint sealing strips at all locations are in position.
• NOTE: Make certain that the upper- and lower-half turbine nozzles are loaded
in the same direction to avoid mismatch at the horizontal joint seals.
• Install all bolts hand tight, including body-bound bolts. Tighten the horizontal
joint bolts, starting at the mid-point and working alternately to the ends.
• Alternate the bolt tightening from the right side of the casing to the left side (or
vice versa).
• Alternately tighten all the vertical bolts, working down each side from the top
vertical centerline.
• NOTE: Work both the aft and forward vertical flanges simultaneously.
g) Install the borescope pins

• Install borescope pins in the same locations they were removed from. Reinstall
borescope plugs and tighten.
h) Install the upper-half piping

• On reassembly of piping, use new gaskets on all gasketed joints.
• Assemble the four 13th stage upper-half and two lower-half flexible pipe
connections at the turbine casing and at existing piping flanges.
• Assemble the two atomizing air piping connections to the turbine casing cone
and the inlet heating piping.
i) Remove the casing jacks

• CAUTION: Jacks are not to be removed until all upper casings have been
installed and bolted up.
• 1. Place two dial indicators (one on each side of the machine) at the horizontal
joint near the area that the jacks are supporting. Attach dial indicators to turbine enclosure
frame and set to indicate on turbine casing. Set dial indicators at zero.
• Release the jacks and observe whether turbine casing has lowered.
• If turbine casing moved downward when the jacks were released, remove the
jacks and jack supports from under the turbine.
j) Install the combustion casing, flow sleeves, and outer crossfire tubes
• Apply a light coating of approved anti-seize compound to all mating parts and
bolts.
• Install a new spiral wound gasket into groove in the downstream flange of the
outer combustion chamber.
• Use a wood or aluminum rod to expand the piston ring at the downstream end
of the flow sleeve to allow the ring to slide over the end of the transition piece.
• Rig a support sling and lift the combustion casing into place.
• Raise casing and engage the locating pins. Slide the combustion can into the
outer casing until the flow sleeve piston ring slides over the transition piece impingement
sleeve. When the piston ring is in place, the rod holding the ring open will be dislodged,
allowing the ring to spring back into contact with the impingement sleeve.
• Tighten the combustion casing flange to compressor discharge casing flange
bolts. Tighten bolts 180~ apart and work around the flange bolting circle in this sequence
until all bolts are tight.
• Continue to install casings until all are in place and properly torqued.
• Inspect sealing surface of outer crossfire tube to be sure it is free of nicks or
burrs.
• Install new packing rings in each end. Slide outer crossfire tube from inside one
aft casing through the crossfire flange and into the adjacent casing. Thread on the packing
rings and the sealing ring flanges to the outer tube in the appropriate order.
• Install the split ring retaining washers and bolts to compress the packing hand
tight.
• Center the outer tube between the two outer casings and use the bolts to
compress the packing to the dimension given in MLI 0701.
• Repeat the process until all outer crossfire tubes are in place and the packing are
compressed.
• CAUTION: Begin by installing the outer casing on Chamber No. 3 and work
up to the top of the turbine.
• The weight of the casing is approximately 400 pounds (181.4 kg).
k) Install the cross fire tubes and combustion liners

• After each combustion casing is installed, insert the two inner crossfire tube
parts before installing the next flow sleeve. Install the two crossfire tube halves so that the
male end is at the clockwise end of the crossfire tube assembly.
• Use the crossfire tube retainers to lock the inner crossfire tube parts away from
the combustor centerline to allow assembly of the liner assemblies.
• Slide the liner assembly into the flow sleeve until the downstream end begins to
enter the transition piece. Then push the liner aft until the spring seal is in the transition
piece.
• Insert the crossfire tube into the collar in the combustion liner and lock it in
position with the crossfire tube retainer.
• Continue to install liner assemblies and crossfire tubes until all are installed
• CAUTION: Secure the rod with a line to allow easy retrieval and to prevent the
rod from falling into the turbine.
l) Install the spark plugs

• Install new gaskets and spark plug assembly in combustion chambers 4 and 5.
Be sure that spark plug tip enters the hole in the flow sleeve and the hole in the can and
liner assembly.
• Coat bolts with anti-seize compound and bolt the spark plug assembly to flange.
• Check to see that spark plug electrode moves freely.
m) Assemble the fuel nozzle assembly to combustion casing

• Check to be sure that the three alignment pins in the aft flange of the fuel nozzle
casing are in place and tight.
• Install an eye bolt in the flange of the fuel nozzle cover and rig so that the
assembly will be in proper alignment for its combustion casing.
• Place a new gasket in the recess of the combustion casing.
• Lift the nozzle assembly and move it to the combustion casing. Move it axially
until the alignment pins engage the flange of the casing.
• Move the assembly axially until the spring seal on the cover enters the
combustion liner. Three or more flange bolts may be used to draw the flanges together.
• Install the rest of the flange bolts, tighten and torque them.
• Continue to assemble until all 6 assemblies are complete.
n) Install the atomizing air flex hoses

• Verify all flange faces are clean and blow out openings. Verify quantity and
cleanliness of all nuts and bolts.
o) Install the false start drain piping

• Install new gaskets at all flanges.
• Line up the match marks and numbers on the flanges to the appropriate
combustion cans (2 - 4).
• Tighten bolts in a cross-cross pattern to give uniform gasket compression.
p) Install the liquid fuel lines
• Install the liquid fuel lines to their original combustion can - ensure to hand
thread all Swagelok fittings before tightening with a wrench.
q) Connect the atomizing air lines

• NOTE: All atomizing air, water, liquid fuel, and gas fuel lines must be
absolutely clean when installed. If they have not been previously cleaned and protected,
they must be inspected and cleaned if needed.
• Using new gaskets, connect the flexible atomizing air lines between the fuel
nozzle flange and the manifold flange. Start at cover number 6 and work clockwise and
counterclockwise.
• Tighten bolts in a criss-cross pattern to give uniform gasket compression.
r) Install the water injection manifold and flex hoses

the right-hand side.
• Install the two flex hoses on the right-hand side, using new O-rings.
the left-hand side.
• Install the upper section of the water injection manifold.
• Starting at cover number 6 and working clockwise and counterclockwise, install
both the primary and secondary water injection flex hoses to each cover.
• NOTE: The secondary connection is in the center of the cover and has a square
flange. The primary connection is on the outer edge of the cover and is connected to a
distribution valve.
s) Install the flame detectors

• Install new gasket.
• Coat bolts with approved anti-seize compound, being careful not to get any of
the compound into the hot gas path.
• Using new gaskets, install flame detectors on chamber numbers 1, 2, 5 and 6.
• Leave the bolts and connections loose until the manifolds are in place.
• Install the feed and return cooling water manifolds.
• Install the two flex hoses on the right side of the unit.
• Once the manifolds are in place, tighten bolts to each flame detector in a criss-
cross pattern to give uniform gasket compression.
• Reconnect wiring to flame detectors.
• Reconnect water cooling feed and drain lines to flame detectors, starting at the
lowest flame detector on each side and working upward.
• Reenergize power supply to flame detectors by reinstalling the flame detector
cards.
t) Install the fuel oil purge tubing
• Install the two lines that were connected to the left-hand panel of the purge
module. These lines run down the left side of the turbine.
• Install, as a bundle, the lines that were connected to the right-hand panel of the
purge module.
u) Install the turbine compartment roof sections

• Reassemble side panel vertical beams if any were previously removed at
disassembly.
• NOTE: If the vertical side beams were cut off with a torch, they can be
reinstalled using doubler plates and nuts and bolts to facilitate future disassembly and
reassembly.
• Apply new gaskets or caulking seal to roof sections where needed.
• Rig a turbine roof to lift it level.
• Position over turbine compartment with crane and lower into place using the
chain falls.
• Repeat steps 3 and 4 for the remaining roof section.
• Apply approved anti-seize compound to bolts and install all bolts.
v) Install the inlet and exhaust duct access panels

• Apply anti-seize compound to all bolting.
• Attach gaskets to duct access panel flanges.
• Lift access panels into place and bolt up.
w) Reassemble the turbine compartment roof components

• CAUTION: Clean all flange openings and inspect for foreign objects.
• Reassemble all piping previously removed.
• Reassemble walkways and platform from the turbine enclosure roof.
• Install the ventilation duct from the turbine enclosure roof.
• Reassemble any tubing conduit and wiring previously removed.
• Apply anti-seize compound to bolts and install all bolts.
x) Clean up, visual inspection, pre-start and startup checks

• Inspect in the MKVIe all transmitters that were disconnected/reconnected
during the CI are reading properly.
• Clean up all alarms in the MKVIe / MKVIeS.
• Clean up all lube oil and water spills.
• Make a visual inspection of the unit and check to ensure that the following has
been completed.
o Check that all removed piping has been replaced.
o Check that all removed conduit has been replaced and electrical
connections made. Confirm function of all devices.
o Inspect inlet and exhaust plenums.
• Reconnect power to all systems disabled at start of job.
• Perform pre-cranking checks as follows:
o Record all panel counter readings.
o Check operation of cool down/emergency lube pumps.
o Check operation of auxiliary hydraulic pump.
o Make visual inspection to see if oil is flowing in bearing drains.
o Block out excitation and generator breaker equipment.
o Place unit on turning gear and observe for leaks, rubs, and control
deficiencies.
• Perform cranking checks as follows:
o Observe pickup RPM of speed sensors versus time.
o Inspect for casing air leaks.
o Observe and record vibration channel outputs.
o Observe and record crank speed.
o Check starting means for proper operation.
o Listen for rubbing noises.
o Check temperature of lube oil in bearing drains or at the bearing header
and tank.
o Observe all panel and hydraulic manifold pressure gauge readings for
abnormalities.
o Trip the unit using the emergency trip and listen for abnormal noises from
gas turbine and associated equipment during coast down.
o Observe proper dropout RPM of speed sensors.
• Initiate a start and perform the zero to full speed, no load firing checks as
follows:
o Observe applicable firing check parameters, relay sequences, exhaust
temperature, vibration and speed.
o Check spark plugs and flame detectors.
o Observe and record acceleration rates.
o Record full set of vibration readings.
o Observe and record temperature suppression set point.
o Note and record pick-up time of all appropriate electrical speed relays.
o Check full-speed-no-load RPM.
o Check digital set point.
o Take a complete set of running data. See Running Inspection section of
this instruction.
o Perform load checks (if applicable) as follows:
o Take a full set of load data, including the staging times from diffusion to
piloted premix and from to piloted premix to premix. This can be done automatically by
the control system.
• Observe normal unloading and shutdown as follows:
o The times and loads for transition from premix through piloted premix
and from piloted premix through diffusion should be recorded during the unloading
period.
o Note and record coast down time.
• Listen for abnormal noises from gas turbine and associated equipment during
coast down.
• Observe unit vibration readings during coast down.
5. Restart operations
II. GENERATOR INSPECTIONS

1. Shaft Grounding
• Significant voltage on a turbine or generator shaft is undesirable. Shaft voltages,
uncontrolled, will discharge to ground causing damage to grounded components in close
proximity to the rotating shaft, such as through an oil film. Electrical discharge damage
can appear as frosting, pitting or erosion on the metal surface, which may lead to
untimely replacement or failure.
1.1. Cleanliness
1. Carbon Dust
• Keep the components of the shaft ground brush rigging clean. Normal brush
wear
• produces a fine, conductive dust, which can deposit on insulating surfaces of the
• ground brush instrumentation or shaft-grounding track. Buildup of this
conductive
• dust can result in equipment malfunction by disturbing the grounding path or
• distorting the voltage and current measurements.
2. Freedom from Oil

• It is important to prevent or remove any oil accumulation in the shaft-grounding
area.
• Accumulation of oil and carbon dust impairs the effectiveness of the grounding
track film.
3. How to Properly Clean the Ground Brush Rigging
• The following recommendations should be followed to properly clean the shaft
grounding system while the shaft is at zero speed.
• a) The shaft ground brushes should be removed when cleaning the shaft-
grounding system.
• To clean the ground brush rigging components, start with a vacuum (with a fine
particle filter) and a clean dry rag. Use of compressed air should be kept to a minimum as
this force’s particles into the air, see section II Safety, item 6 on page 7.
• A rag that has been dampened, not saturated, with either contact cleaner, or, if
not available, denatured alcohol, can be used to clean all surfaces. The use of a contact
cleaner or denatured alcohol can result in low insulation resistance readings until the
water content evaporates.
• In addition to rags, scotch bright pads may be used on all surfaces except the
shaft grounding track.
• The shaft-grounding track should be kept clean as described in section VI.A.2.
• If oxidation is found on electrical contact surfaces, it may be removed by a very
light application of sandpaper. If the plating is removed, the part should be replaced.
4. The shaft‐grounding track

A. Shaft-grounding Track
• Shaft-grounding Track Surface Finish. The shaft-grounding track should be free
from markings, rust, dirt and oil. The shaft-grounding track should be polished to a 125
micro-inch (3175 nm) finish.
• Shaft-grounding Track Surface Cleaning. The shaft-grounding track should be
cleaned on a regular schedule. Oil and dirt can be removed with a small amount of
electrical equipment cleaning solvent, after which additional cleaning must be
accomplished by an application of alcohol followed by a dry cloth to remove any
remaining moisture. Never use scotch bright pads on the shaft-grounding track, this will
remove or impede the build-up of the surface film. The cleaning must be done with care
to prevent liquid dripping on insulation parts. Avoid handprints or fingerprints on the
shaft-grounding track, because the body moisture left by such an imprint will cause rust.
• Shaft-grounding Track Film (Carbon Brush Systems). Formation of shaft-
grounding track film is an important factor on which good operation depends. The
formation of a good brush film will depend on freedom from scratches and contaminants
on the shaft-grounding track.
• Shaft-grounding Track Wear. The rate of shaft-grounding track wear may vary
greatly depending mainly on the effectiveness of the protective brush film for carbon
brush systems or contaminants for copper braid systems. Under good conditions the
diametrical shaft-grounding track wear rate is small, typically 0.001” (0.025 mm) per
1,000 hours. Wear rates of the order of 0.005” (0.127 mm) per 1,000 hours indicate poor
environmental conditions. As a rule, wear rates are not constant and vary significantly
with environment conditions. If it becomes necessary to resurface the shaft-grounding
track, the reason for the shaft-grounding track deterioration should be sought out and
corrected. It is recommended resurfacing the shaft grounding track if any of the following
conditions are present:
o Shaft-grounding track pitting (or frosted surface) in brush tracts, which
cannot be removed by normal cleaning.
o Excessive shaft-grounding brush vibration
o Excessive radial runout in the shaft-grounding track. If the shaft-
grounding track contour shows bumps and hollows or flat spots of 0.002” (0.0508 mm) or
over in depth, or radial runout changes more than 0.005” (0.013 mm) per 3 inches
(76mm) indicator travel around the circumference.
o Excessive axial run out or taper. If the shaft-grounding track is grooved
over 0.020” (0.508 mm) deep, or if there is an axially taper greater than 0.010” per inch
(0.010 mm per mm). The shaft-grounding operation is tolerant to minor taper of the shaft-
grounding track. Taper has the greatest effect on the support of brushes, i.e. distance from
the shaft-grounding track surface to the brush holder
B. Inspections and Servicing During Shutdowns
• Replace any broken brushes and brushes that are within 0.125” (3.175 mm) of
their wear limit.
o Look for brushes that have tight / overextended shunts or that are
otherwise hung up.
o Check for overheating.
o Check for dust or oil accumulation.
o Check for chattering of brushes and springs
o Check for loose, frayed, blued, or burned brush pigtails
o Check for broken or loose hardware, replace or tighten as required.
o Check for any noticeable change in the shaft-grounding track film
conditions.
o Look for any significant changes from previous conditions.
o From the control room, if provided, monitor the shaft voltage and current
under similar load conditions for changes. Erratic and generally higher indicated shaft
voltage or current readings could be indication maintenance requirements.
o For systems without automatic shaft voltage monitoring systems, measure
the shaft voltage manually.
o All parts of the ground rigging must be kept tight. At each maintenance
outage, check all nuts, bolts and screws for tightness. This is particularly important, since
the insulating components have a slight tendency to shrink, which relieves the bolting
pressure. If not corrected periodically, excessive vibration of the brush or strap holder
rigging may take place.
o Remove any dirt or carbon dust from the rigging. Clean the shaft-
grounding track.
o Before restarting the machine, inspect for proper clearances.
1.2. Recommended stator tests and inspections:
1.3. Recommended Field tests:
III. RESTART OPERATIONS

3. Major Inspections
Following to the GE Energy “Operation and Maintenance Manual”
Scope of Work (Refurbishment Services)
According to older report
I. Fuel Nozzles
List of work
II. Transition Pieces
1. Turbine Operation Summary
2. Introduction
• One set of (6) Frame 6FA transition pieces with floating seals from Client was
received at the Shop Services (SS). The parts were well packaged and no shipping
damage was present; however, the crates were damaged and new crates were constructed
to return the hardware. The hardware was returned to the customer later. The purpose of
this report is to state the incoming condition of the hardware and describe the repairs
performed.
3. List of Work
The F6FA Transition Pieces were inspected and repaired as described below:
Inspection Workscope
• Receive, identify, and record serial numbers.
• Performing incoming dimensional inspection and fixture check.
• Match mark and disassemble outer wrappers, aft brackets, and cloth seals from
transition pieces.
• Remove all picture frame wear guards from transition pieces.
• Blast clean outer wrappers, aft brackets, and transition pieces to remove coating.
• NDT (VPI) inspect outer wrappers, aft brackets, and transition pieces.
Repair Workscope
• Weld repair indications and wear damage on the outer wrappers and transition pieces.
• Blend welds to match original contours and configurations.
• Weld repair inner and outer cloth seals.
• Restore transition piece inlet and exit end dimensions.
• Perform minor repairs on customer-supplied bullhorn brackets.
• Relocate all transition piece H-blocks.
• Post-weld solution heat treat transition pieces.
• Lightly blast clean transition pieces.
• Final NDT (VPI) inspect outer wrappers and transition pieces.
• Perform pre-coating dimensional inspection and fixture check using customer-
supplied bullhorn brackets.
• Apply Class C TBC to the transition piece IDs.
• Diffusion and age heat treat transition pieces.
• Apply CrC coating to the transition piece inlet IDs and outer inlet band ODs.
• Install new picture frame guards to transition pieces.
• Provide new aft bracket bolts and nuts and new inner stiffener bolts and nuts.
• Assemble outer wrappers and aft brackets to transition pieces using new zipper
hardware.
• Perform final dimensional inspection and fixture check using customer-supplied
bullhorn brackets.
• Install inner and outer cloth seals to transition pieces.
• Hold for customer witness.
• Prepare for shipment.
4. Receiving and Cleaning Procedure

• All parts were received, engraved with the Job Number (SS_1629), and the part,
serial and position numbers (as available) recorded (see Appendix A). The aft brackets,
floating seals and impingement sleeves were removed. All assembly components were
present and no unusual damage or condition was noted. The impingement sleeves were
removed from the TP bodies. The Thermal Barrier Coating (TBC) was removed and all
surfaces cleaned by mechanical grit blasting. The parts were inspected visually,
dimensionally and by Fluorescent Penetrant Inspection (FPI). Results of the inspection
are discussed below and illustrated in photos found in Appendix B.
5. Inspection Observations & Repair Completed

Coatings
• The gas path coating was in service run condition with typical heating patterns
and moderate loss. Coating was removed and replaced with LTS Class III TBC designed
to meet or exceed OEM coating. Class III coating requires heat treatment. Some amount
of discoloration, typically grey streaks or spots, is normal after heat treatment and does
not impact the performance of the coating.
• Chrome Carbide (CrC) wear resistance coating was present on the inlet ID (liner
mating surface) and TP body forward band OD (body/impingement sleeve mating
surface) which was removed and replaced.
Transition Piece Body

• Typical aft frame groove wear was present on all pieces and correctable with
light welding and blending.
• Minor impact damage (FOD) was present in numerous locations. These
indications were corrected as needed or left in place if they did not impact the fit or
function of the part.
• Light wear, distortion, and minor cracking were present on the aft frame wear
strips of all pieces. The inner diameter wear strips were replaced.
• Typical light H-block wear was found and was correctable with blending; no
replacements were necessary.
• Light inlet ID wear was present and corrected with blending to remove stress
concentrations.
• Light wear was present on the forward band OD band which was corrected by
blending.
• Minor distortion (closure) of the aft frame was present. Distortion correction
was performed and the final geometry was reviewed and accepted by SS engineering and
quality assurance. Dimensional inspections are summarized in Appendix C.
Impingement Sleeves
• Deposits were present on all outside surfaces which were removed by cleaning.
• Wear was present on the forward end band ID (TP body mating surface). Worn
wear pads were replaced and additional wear pads were added per customer request.
• Moderate wear and minor cracking were present in the aft end frame area.
Welding and blending were used to correct all indications.
• Light wear and impact damage were noted on the aft bracket.
• Minor impact damage (FOD) was present in numerous locations. These
indications were corrected as needed or left in place if they did not impact the fit or
function of the part.
Floating Seals
• Floating seals had wear which was heavy in some small locations. All were
repairable with welding and blending processes; no replacements were necessary.
• Minor distortion correction was needed.
6. Report Summary
• The repair was medium scope for all 6 pieces. The impingement sleeve, aft
bracket, and floating seals were disassembled and repaired. Gas path coating was
removed and replaced with SS Class III TBC. Floating seals were repairable. Bullhorn
brackets were not received. All hardware was completed using established SS procedures.
New shipping crates were built due to the condition of the incoming crates.
• Following repair, the TP’s are deemed serviceable for 1 operational interval.
Future reparability will likely be possible and should be evaluated after 1 interval.
• The following is a table of the number of spare parts used in the repair of these
components:
III. Combustion Liners
The F6FA Combustion Liners were inspected and repaired as described below:
Inspection Workscope
• Receive, identify, and record serial numbers.
• Performing incoming dimensional inspection.
• Match mark and disassemble cowl caps from liner bodies.
• Blast clean cowl caps and liner bodies to remove coating.
• NDT (VPI) inspect cowl caps and liner bodies.
Repair Workscope
• Weld repair indications and wear damage on the cowl caps and liner bodies.
• Blend welds to match original contours and configurations.
• Restore cowl cap and liner body dimensional distortion.
• Replace 5 cowl cap splash plates.
• Replace 11 cowl cap floating collars and retainers.
• Weld and re-drill to relocate rivet holes on 1 cowl cap (#3).
• Lightly blast clean cowl caps and liner bodies.
• Final NDT (VPI) inspect cowl caps and liner bodies.
• Perform pre-coating dimensional inspection.
• Apply Class B TBC to the cowl caps and liner body IDs.
• Apply CrC coating to the liner body spring seal ODs.
• Install cowl caps to liner bodies using new rivets.
• Perform final dimensional inspection.
• Hold for customer witness.
• Prepare for shipment.

Scope of Work For Gas Turbine

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Scope of Work (Maintenance Services)

Following to the GE Energy “Operation and Maintenance Manual”

2. Remove the flame detectors

3. Remove the spark plugs

4. Remove inspection door on inlet plenum and exhaust plenum

5. Remove the turbine compartment roofs and blowers

6. Remove the fuel oil and purge flex hoses

7. Remove the false start drain piping

8. Remove the other fuel nozzle flex hoses

9. Remove the atomizing air flex hoses and manifolds

10. Remove the fuel oil distribution valve drain lines

11. Remove the fuel nozzle assembly

12. Remove the combustion liners and crossfire tubes

13. Remove the outer crossfire tubes

14. Remove the flow sleeves and combustion casings

15. Remove the upper-half piping

16. Remove the 1st stage turbine borescope pins

17. Place mechanical support jacks under unit casings

18. Remove the turbine casing bolts

19. Remove the upper-half turbine casing

20. Remove the transition pieces

1.3. Cleaning and inspection

b) Perform calibration of combustion controls

c) Inspect the piping and flexible hoses

d) Pack and ship

e) Inspect and test the spark plugs

f) Inspect and test the flame detectors

g) Inspect the fuel nozzle assemblies

h) Inspect the combustion liners

i) Inspect the crossfire tubes and retainers

j) Inspect the combustion chamber flow sleeve

k) Inspect the combustion casings

l) Inspect the transition pieces

m) Inspect the IGV

n) Visually inspect and borescope the inner parts

3. Parts to be replaced and then refurbished for re-use

b) Install the upper-half turbine casing

c) Install the borescope pins

d) Install the upper-half piping

g) Install the cross fire tubes and combustion liners

h) Install the spark plugs

i) Assemble the fuel nozzle assembly to combustion casing

j) Install the atomizing air flex hoses

k) Install the false start drain piping

l) Install the liquid fuel lines

m) Connect the atomizing air lines

n) Install the water injection manifold and flex hoses

o) Install the flame detectors

p) Install the fuel oil purge tubing

q) Install the turbine compartment roof sections

r) Install the inlet and exhaust duct access panels

s) Reassemble the turbine compartment roof components

t) Clean up, visual inspection, pre-start and startup checks

2. Hot Gas Path Inspections

2. Remove the flame detectors

3. Remove the spark plugs

4. Remove inspection door on inlet plenum and exhaust plenum

5. Remove the turbine compartment roofs and blowers

6. Remove the fuel oil and purge flex hoses