Fundamentals of Gas Turbine Operation Maintenance

GAS TURBINE OPERATION AND MAINTENANCE
P2M FTUI September 2008
Operating Factors Affecting Maintenance

Type and quality of fuel Condensate, contaminants, etc Starting Frequency Thermal cycles Load cycles Thermal cycles Environment Abrasive and corrosive condition
Inspection Interval
Following table shows the operating hours at which inspection should be performed for operation on gas fuel and continuous duty
Recommended Inspection Interval
Note: (1) Hours mean quivalent Operating Hoursreflecting the operation conditions of Gas Turbines
Roll-in and Roll-out Procedure
One (1) complete set of hot parts shall be ready for Rolling-in. The parts taken out (Roll-out) shall be reused/repaired/rejuvenated prior to the next inspection
Summary of GT Inspection
Inspection Combustor Inspection Procedure Dismantling combustor basket Inspection Items Visual inspection & NDT (1) of fuel nozzles, combustor baskets and transition pieces Visual inspection of turbine blade row 4 and vane row 1 and 4 Visual inspection of compressor IGV, blade row 1 and vane row 1 Visual inspection and NDT (1) of turbine blades, vanes and seals Combustor inspection is carried out at the same time Visual inspection & NDT (2) of all components from expansion joint of the inlet air to the first expansion joint of the exhaust gas Inspection of auxiliaries, control systems and instruments
Turbine Inspection
Lifting the upper housing of the turbine
Major Overhaul Inspection
Lifting the upper housing of the turbine and compressor Lifting the rotor
NDT (1) : Non Destructive Test (Penetrant Test) NDT (2) : Non Destructive Test (Penetrant Test, Magnetic Particle test and Ultrasonic test
Combustor Inspection

No 1. Compressor inlet (1) No 2. Turbine blade row 4 (1) No 3. Flame detector and igniter (2) No 4. Fuel nozzle (2) No 5. Combustor basket (2) No 6. Transition piece (2)
(1): Visual Inspection (2): Roll-in & Roll-out Parts
Combustion Inspection Schedule (for one (1) Gas Turbine)
Turbine Inspection

No 1. Compressor inlet (1) No 2. Flame detector and igniter

(2)
No 6. Turbine blade (2) No 7. Turbine vane (2) No 8. Compressor last row and
No 3. Fuel nozzle (2) No 4. Combustor basket (2) No 5. Transition piece (2)
OGVs blade and diaphragm (1)

Turbine Inspection Schedule (for one (1) Gas Turbine)
Major Overhaul Inspection

No 1. Flame detector and igniter (1) No 2. Fuel nozzle (1) No 3. Combustor basket (1) No 4. Transition piece (1) No 5. Turbine blade (1) No 6. Turbine vane (1) No 8. Exhaust turbine and compressor casing
No 9. Compressor blade ring

No 10. Turbine blade ring #1, #2, #3 and #4 Turbine journal brg and thrust brg Rotor (2)
No 7. Compressor blade and diaphragm
Major Overhaul Inspection Schedule (for one (1) Gas Turbine)
Routine Maintenance
Hot Parts Expected Life Time
The expected life of hot parts has been established based on design strength and the result of past operating experiences. The expected hot parts life hours with qualified repairs are as follows:
Definition of EOH Equivalent Operating Hours
To calculate hours of operation equivalent to base load continuous duty operation, when operation has been with liquid fuel and/or cyclic duty, it is necessary to segregate the actual hours of operation by duty (fired hours per start) and fuel (gas or oil). These segregated values are then used in the following equation to calculate the hours equivalent to operation at base load with gas fuel.
where, H = equivalent continuous duty gas fired hours BHG = base load operating hours with gas fuel BHO = base load operating hours with distillate oil fuel PHG = peak load operating hours with gas fuel PHO = peak load operating hours with distillate oil fuel CDF = cyclic duty factor, determined from the following table
Cyclic Duty Factor Table
Hot Parts Life Evaluation

1.
a. b. c.
Deterioration
Creep under High Temperature Low Cycle Fatigue Metal Loss by Surface Oxidation & Corrosion
2.
a. b. c. d. e.
Life diagnosis
Load Cycles Start / Stop Frequency Fuel Quality Environment Maintenance Practice
Life diagnosis procedure is decided based on each customers operational conditions
Life Evaluation Method

Evaluation for Maximum Use-up Turbine Blade
Metallurgical Analysis
phase Creep Rupture Property
Turbine Vane
Metallurgical Analysis
Precipitated
Carbide Tensile Property
Life Evaluation Process for Turbine Blade
Life Evaluation Process for Turbine Vane
Life Extension Technology

Reheat Technology High temp. heating of deteriorated super alloy Decomposition & re-solution of hypertrophied phase and intergranular carbide Standard heat treatment the material Recovery of mechanical properties
Terima Kasih

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GAS TURBINE OPERATION AND MAINTENANCE

P2M FTUI September 2008

Operating Factors Affecting Maintenance

Roll-in and Roll-out Procedure

Lifting the upper housing of the turbine

Major Overhaul Inspection

Combustion Inspection Schedule (for one (1) Gas Turbine)

No 1. Compressor inlet (1) No 2. Flame detector and igniter

No 3. Fuel nozzle (2) No 4. Combustor basket (2) No 5. Transition piece (2)

OGVs blade and diaphragm (1)

Turbine Inspection Schedule (for one (1) Gas Turbine)

Major Overhaul Inspection

No 9. Compressor blade ring

No 7. Compressor blade and diaphragm

(1): Visual Inspection (2): Roll-in & Roll-out Parts

Major Overhaul Inspection Schedule (for one (1) Gas Turbine)

Hot Parts Expected Life Time

Definition of EOH Equivalent Operating Hours

Cyclic Duty Factor Table

Hot Parts Life Evaluation

Life diagnosis procedure is decided based on each customers operational conditions

Life Evaluation Method

phase Creep Rupture Property

Carbide Tensile Property

Life Evaluation Process for Turbine Blade

Life Evaluation Process for Turbine Vane

Life Extension Technology

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