Heavy-Duty Gas Turbine Operating and Maintenance Considerations

GT INSPECTIONS
Running Inspections Standby Inspections Shutdown Inspections

HDGT.PPT/ 2

RUNNING INSPECTIONS

PRE START UP CHECKS

AC Lube Oil Pumps ONon Auto Ratcheting / Barring is OK. EOP is tested All MCC modules are switched ON and are kept on AUTO Cooling Water level is OK Lube Oil Level is OK & Oil temp. normal Visual Inspection of Machine is OK
HDGT.PPT/ 3

RUNNING INSPECTIONS

CHECKS DURING STARTUP

Flame is sensed in all Flame Scanners Exhaust Temperatures are uniform and Spread is normal Acceleration is Smooth and Time taken is in line with earlier values

Rise in Exhaust Temperature is Uniform Exhaust Temperature profile is OK and Spread Values are within Limits
HDGT.PPT/ 4

RUNNING INSPECTIONS

CHECKS DURING STARTUP CONTD.

Rise in Wheelspace Temperature is Uniform Vibrations are within Limits and as per earlier values Bearing Oil Drain Temperatures are Normal Opening of Jaw Clutch (Not applicable for Fr9E & Fr6FA) is at approx. at the same Speed as earlier

HDGT.PPT/ 5

RUNNING INSPECTIONS

PARAMETERS TO MONITOR
Temperatures Lube Oil Header Brg. Drains Comp. Inlet Comp. Discharge Exhaust Wheelspace Cooling Water Outlet

Pressure Lube Oil Hydraulic Oil Trip Oil Comp. Discharge Inlet Air Filter DP Cooling water

HDGT.PPT/ 6

RUNNING INSPECTIONS

PARAMETERS TO MONITOR
-CONTD

OTHERS Vibrations Noise, Rubs Startup Time Coast Down Time Fired Starts Fired Hours

GENERATOR Voltage Current Load Stator Temperatures

HDGT.PPT/ 7

Operating Inspection Data Parameters -Summary

Speed Load Fired Starts Fired Hours Site Barometric Reading Temperatures Inlet Ambient Compressor Discharge Turbine Exhaust Turbine Wheelspace Lube Oil Header Lube Oil Tank Bearing Drains Exhaust Spread Pressures Compressor Discharge Lube Pump(s) Bearing Header Cooling Water Fuel Filters (Fuel, Lube, Inlet Air) Vibration Data for Power Train Generator Output Voltage Field Voltage Phase Current Field Current VARS Stator Temp. Load Vibration Start-Up Time Coast-Down Time

RUNNING INSPECTIONS

OPERATIONAL DIAGNOSTICS

Start up Load Hunting Combustion Trouble / exhaust spread Lower Loads Higher Temperatures

HDGT.PPT/ 9

STANDBY INSPECTION
Inspections carried out during Off-peak periods when Unit is not running
Check Battery system, Oil levels, instrument calibrations, replacement of various filters & servicing of accessory systems etc. Crank the Turbine once in a Fortnight to drive away Moisture

HDGT.PPT/ 10

PERIODIC SHUTDOWN INSPECTIONS A Maintenance Program should:

Optimize owners maintenance costs Maximize equipment availability

Factors Affecting Maintenance Planning and Maintenance Program

Manufacturers Manufacturers Recommended Recommended Maintenance Maintenance Program Program

Design Design Features Features

Duty Duty Cycle Cycle

Cost Costof of Downtime Downtime Type Typeof of Fuel Fuel Expert Expert Systems Systems Reserve Reserve Requirements Requirements

Diagnostics Diagnostics

Availability Availability Need Need On-Site On-Site Maintenance Maintenance Capability Capability

Maintenance Maintenance Program Program

Utilization Utilization Need Need

Environment Environment

Because not all customers operate their gas turbines the similarly not all customer maintenance programs are the same.
Case 1 8,000 Hrs/Yr 160 Starts/Yr HGP at 3 years Case 2 1,000 Hrs/Yr 400 Starts/Yr HGP at 3 years, not 24 years

BHEL Provides Guidance for Customer Maintenance Planning

Maintenance Cost and Equipment Life Are Influenced by Key Service Factors
Fuel Firing Temperature Steam/Water Injection Cyclic Effects (Start-up rate, number of trips) Air Quality

Service * ServiceFactors FactorsDifferent DifferentFrom Fromthe theReference ReferenceCondition Condition* Can CanIncrease IncreaseMaintenance MaintenanceCost Cost& &Reduce ReduceMaintenance MaintenanceIntervals Intervals

Potential Failure Modes

Hot-Gas-Path Components Continuous Duty Application Cyclic Duty Application Creep Deflection Thermal Mechanical Fatigue Creep Rupture Rubs/Wears. Corrosion Oxidation Erosion. High-Cycle Fatigue.

Maintenance Factors
Hot Gas Path (Buckets & Nozzles)
Typical Max Inspection Intervals (MS6B/Ms7EA) Hot Gas Inspection 24,000 hrs or 1200 Starts Major Inspection 48,000 hrs or 2400 Starts Criterion is Hours or Starts (Whichever Occurs First)

Factors Impacting Maintenance

Hours Factors Fuel Gas Distillate Crude Residual Starts Factors Trip From Full Load Fast Load Emergency Start 8 2 20

1 1.5 2 to 3 3 to 4

Peak Load 6 Water/Steam Injection Dry Control 1 (GTD-222) Wet Control 1.9 (5% H20)

Operation of Gas Turbine in Extended lean-lean base mode in DLN-1 units has a maintenance factor of 10

HDGT.PPT/ 17

Maintenance Factor Definition

IDEAL INTERVAL = RECOMMENDED INTERVAL =
Interval for Continuous Base Load on Clean Natural Gas

Ideal Interval determined from application of maintenance factors

Maintenance Factors Summary

Maintenance Requirements are Based on an Independent Count of Hours and Starts Certain Operating Factors Reduce Maintenance Intervals y Peak Load y Steam/Water Injection >2.2% y Liquid Fuel y Trips From Load y Fast Starts Exceeding BHEL Specification Limits can Significantly Increase Maintenance Factors and Reduce Component Life Equations for Establishing Application Specific Hot Gas Path Maintenance Intervals are Available

Estimated Effect of Fuel Type on Maintenance

Residual

Maintenance Factor
Distillates Heavy

Light Natural Gas

7 8 9 10 11 12 13 14 15

20

Fuel Percent Hydrogen by Weight in Fuel

Turbine Start/Stop Cycle

540 Deg C

Base Load

Light-off

Acceleration

Unload Ramp

Exh. Temp.

Load Ramp Full Speed No Load Trip

Full Speed No Load

Warm-up

Fired Shutdown

Start-up

Time

Shutdown

Maintenance Factor - Trips from Load

10 9 8 7 6 5 4 3 2 1 0 0 Trip Severity Factor

Base

FSNL

For trips during Start-up Acceleration, assume Trip Severity Factor = 2

40 60 % Load 80 100 120

20

Heavy-Duty Gas Turbine

Shutdown Inspections
Combustion Hot-Gas-Path Major
Major inspection
Hot-Gas-Path Inspection Combustion Inspection

Special Inspections
Borescope IGV Bushing insp.

Base Line Recommended Inspection Intervals Base Load - Gas Fuel - Dry
Type of Inspection Combustion Hot-Gas Path Major MS32/52/51 Upgrade (Standard) 12000/800 Eliminated/1200 48000/2400 Hours/Starts MS6B MS6FA & 9FA Standard DLN2 & DLN1 12000/1200 24000/1200 48000/2400 8000/450 24000/900 48000/2400 MS9E Standard & DLN1 8000/900 24000/900 48000/2400

Factors That Can Reduce Maintenance Intervals Trips from Load Fuel Start Cycle Load Cycle HGP Hardware Design Steam/Water Injection Peak Load Operation

Maintenance Inspections Combustion Inspection - Key Elements

WORK SCOPE:
Key KeyHardware Hardware Combustion Liners Combustion Covers Fuel Nozzles Transition Pieces Cross Fire Tubes Flow Sleeves Check Valves Spark Plugs Flame Detectors Flex Hoses Inspect Inspectfor: for: Foreign Objects Abnormal Wear Cracking Liner Cooling Hole Plugging TBC Coating Condition Oxidation/Corrosion/Erosion Hot Spots/Burning Missing Hardware Clearance Limits Borescope Compressor and Turbine Potential PotentialActions: Actions: Repair/Refurbishment Liners Cracking/Erosion/Wear TBC Repair Transition Pieces Wear TBC Repair Distortion Fuel Nozzles Plugging Erosion/Wear Cross Fire Tubes Wear/Burning Availability of On Site Spares Is Key to Minimizing Downtime

Criteria: Op. & Instr. Manual

TILs Service Engineers

Inspection Visual Methods: LP

Borescope

Maintenance Inspections Hot Gas Path Inspection - Key Elements

WORK SCOPE: Combustion Inspection work scope +
Key KeyHardware Hardware Nozzles (1,2,3) Buckets (1,2,3) Stator Shrouds IGVs & Bushings Compressor Blading (Borescope) Inspect Inspectfor: for: Potential PotentialActions: Actions:

Foreign Objects Damage Repair/Refurbishment Nozzles Oxidation/Corrosion/Erosion Weld Repair Cracking Reposition Cooling Hole Plugging Recoat Remaining Coating Life Buckets Nozzle Deflection/Distortion Strip & Recoat Weld Repair Abnormal Deflection/Distortion Blend Abnormal Wear Missing Hardware Clearance Limits

Criteria: Op. & Instr. Manual

TILs Service Engineers

Inspection Visual Methods: LP

Borescope

Availability of On Site Spares Is Key to Minimizing Downtime

Maintenance Inspections GT Major Inspection - Key Elements

WORK SCOPE: Combustion Inspection Work Scope + HotGas Path Inspection Work Scope +
Key KeyHardware Hardware Turbine Wheels Dovetails Journal and Seal Surfaces Bearing Seals Inlet System Exhaust System Compressor Blading Inspect Inspectfor: for: Foreign Objects Damage Oxidation/Corrosion/Erosion Cracking Leaks Abnormal Wear Missing Hardware Clearance Limits Potential PotentialActions: Actions: Repair/Refurbishment Stator Shrouds Oxidation/Corrosion/Erosion Buckets Coating Deterioration FOD/Rubs/Cracking Tip Shroud Deflection Creep Life Limit Nozzles Deterioration IGV Bushings Wear Bearings/Seals Boring/Wear Compressor Blades Corrosion/Erosion Rubs/FOD
Availability of On Site Spares Is Key to Minimizing Downtime

Criteria: Op. & Instr. Manual Inspection Visual Methods: LP TILs

Service Engineers Borescope

Estimated Repair/ Replacement Cycles

Repair Starts Liners TPs Fuel Nozzles N#1,2,3 B#1 B#2,3 Shroud#1 Shroud#2,3 CI CI CI HGPI HGPI HGPI HGPI HGPI 5CI 6CI 3CI 3HGPI 3HGPI 4HGPI 2HGPI 4HGPI Replacement Hours 3CI 4CI 2CI 3HGPI 2HGPI 3HGPI 2HGPI 3HPGI

Typical and informative only. Depends upon GT type and size

HDGT.PPT/ 28

Repair/ Replacement Cycles Life Extension

FIRST STAGE NOZZLE WEAR - PREVENTIVE MAINTENANCE LIFE EXTENSION

HDGT.PPT/ 29

SPARE PARTS PLANNING - CONSIDERATIONS

Repair / replacement intervals

Cost Procurement cycle time Repair cycle time Vs. Inspection down time Shelf life Storage facilities Environment Transport facilities
HDGT.PPT/ 30

Borescope Inspection

HDGT.PPT/ 31

Borescope Inspection

HDGT.PPT/ 32

Borescope Inspection

RIGID BORESCOPE

BORESCOPE
FLEXIBLE BORESCOPE
HDGT.PPT/ 33

VIGV Bushing Inspection

HDGT.PPT/ 34

VIGV Bushing Inspection

HDGT.PPT/ 35

DOWN TIME REDUCTION

SPECIAL DESIGN FEATURES FOR EASY MAINTENANCE

Casings are horizontally split With upper half of casings removed, it is possible to remove nozzles and inspect buckets without removing rotor All bearing housings are horizontally split and bearings can be replaced without removing the rotor. Large blades are moment weighed and sequenced to avoid rebalancing of rotor after site replacement. Components like governing components, fuel nozzles, combustion components are mounted type for easy maintenance. All major accessories are separate assemblies and are accessible for inspection and maintenance.
HDGT.PPT/ 36