I N S P E C T I O N A N D M A I N T E N A N C E
INSPECTION AND
Chapter
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MAINTENANCE
1. Introduction
September 1991
1.1. GENERAL
Operation of the combustion gas turbine, as of any rotating
power equipment, must include a planned program of periodic
inspection, with accompanying repair and replacement of parts
as necessary, to ensure the maximum availability and reliability
of the unit.
1.2. OPERATING FACTORS AFFECTING MAINTENANCE:
The factors having the greatest influence on the life of parts for
any given machine are shown in Figure 1-1.
1.3. Fuel
The effect of the type of fuel on parts life is associated with the
radiant energy in the combustion process and the ability to
atomize the various liquid fuels. Therefore, natural gas, which
does not require atomization, has the lowest level of radiant
energy and will produce the longest life of parts.
Natural gas has been the traditional fuel for use with gas
turbines. Due to the need to back up an interruptible gas supply
many gas turbines are dual fuels with a distillate fuel oil used as
the alternate fuel. Contaminants in the fuel also affect
maintenance intervals. This is particularly true for liquid fuels in
which dirt results in accelerated replacement of pumps,
metering elements, and fuel nozzles. Contaminants in fuel gas
can erode or corrode control valves and fuel nozzles.
1.4. Starting Frequency
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Each stop and start of a gas turbine subjects the hot gas path to
significant thermal cycles. Control systems are designed and
adjusted to minimize this effect. However, a gas turbine with
frequent starting and stopping requirements will demonstrate
parts lives that are shorter than those for a similar unit in
continuous-duty service. See Figure 1–3.
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1.5. Load Cycle
The load cycle of the gas turbine, up to its continuous rating, will
have little effect on parts lives, provided it does not require
frequent and rapid load changes.
1.6. Environment
The condition of the inlet air to the gas turbine can have a
significant effect on maintenance costs and intervals if it is either
abrasive or corrosive. If abrasives are in the inlet air (e.g., as
from sand storms), careful attention should be paid to inlet
filtering in order to minimize this effect. If the gas turbine is to
be operated in a corrosive atmosphere (e.g. one with salts),
careful attention should be paid to the location of the inlet air
arrangement and the application of correct materials and
protective coatings. It is essential during the planning stages of
an application to recognize any abrasive or corrosive
contaminants and to take the necessary steps to minimize them.
Contaminants in the fuel and air are additive. Refer to the liquid
fuel specifications.
1.7. MAINTENANCE PRACTICES
Parts condition information is based on estimates only, and will
vary with machines and specific operating conditions. However,
estimates are based on previous experience and can be very
useful in planning a maintenance program. As actual operating
data is accumulated on a specific application, adjustments of
inspection cycles should be the next step in a well-planned
program
Initial inspection planning can be based on the combustion
inspection schedule, hot gas path inspection schedule, and major
inspection schedule tailored to your unit and estimated outage
requirements listed in Figure 1–4.
2. TYPES OF INSPECTIONS:
2.1. Combustion Inspection
A brief shutdown inspection is required to change out fuel
nozzles and to check the combustion liners transition pieces and
crossfire tubes. These parts require the most frequent attention,
as continued operation with a deteriorated combustion system
can result in much shortened life of the downstream parts, such
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as turbine nozzles and buckets. It is also inherent in the gas
turbine design that these parts are the first to require repair or
replacement. Therefore, the importance of this inspection in the
maintenance program must be emphasized.
Figure 1–5 shows these components in relationship to one
another. A visual inspection of the leading edge of the first-stage
turbine nozzle partitions and buckets should be made during the
combustion inspection to note any wear or deterioration of these
parts. This inspection will help to establish the schedule for the
Hot Gas Path inspection. The combustion liners, transition
pieces, crossfire tubes, and fuel nozzles should be removed and
replaced with new or repaired liners, transition pieces, crossfire
tubes and new or cleaned fuel nozzles.
This procedure reduces downtime to a minimum and the
removed liners, transition pieces, crossfire tubes, and fuel
nozzles can be cleaned, inspected and repaired later when it is
more convenient. After the combustion inspection is completed
and the turbine has been returned to service, the removed liners,
and transition pieces can be bench inspected and repaired if
necessary, by competent service personnel, or off-site at a
qualified service facility. Off-site cleaning inspection and repair
of the liners and transition pieces is recommended, since this
activity can best be performed where specialized equipment and
fixtures are available.
The removed fuel nozzles can be cleaned and calibrated on site.
Fuel nozzles should be stored in sets for use at the next
inspection.
2.2. Hot Gas Path Inspection
The Hot Gas Path inspection includes the Combustion Inspection
just described and, in addition, a detailed inspection of the
turbine nozzles and turbine buckets. To perform this inspection,
the top half of the turbine case (shell) and the first-stage nozzle
must be removed. The second-stage nozzle, the third-stage
nozzle, and the turbine buckets will be inspected visually while
still in place in the unit. A complete set of turbine clearances
should also be taken during any inspection of the hot gas path.
Figure 1–5 shows the components involved in the hot gas path
inspection. As with the combustion inspection, it is
recommended that replacement combustion liners, fuel nozzles
and transition pieces be available for installation at the
conclusion of the visual inspection.
The removed parts can then be inspected at a qualified service
facility and returned to stock for use during the next inspection.
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It is also recommended that the Hot Gas Path inspection be
conducted under the technical direction of the GE Company
Field Service Representative for accurate analysis of inspection
data and most effective use of outage time.
2.3. Major Inspection
The Major Inspection involves inspection of all of the major
“flange-to-flange” components of the gas turbine which are
subject to wear during normal turbine operation. This inspection
includes elements of the Combustion and Hot Gas Path
inspections. In addition, casings are inspected for cracks and
erosion, rotor and stator blades are to be checked for tip
clearance, rubs, bowing, cracking, and warpages. Shrouds are
checked for clearance, erosion, rubbing and build-up. Seals and
hook fits of nozzles and diaphragms are inspected for rubs,
erosion, fretting or thermal deterioration. The compressor and
inlet are inspected for fouling, erosion, corrosion, and leakage.
Bearings and seals are inspected for clearance and wear. All
clearances are checked against their original values.
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Figure 5
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Figure 6. Hot-gas-path inspection - key elements
Figure 7. Gas turbine major inspection - key elements
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Figure 8. Hot gas path inspection: hours-based criterion
Figure 9. Hot gas path inspection starts-based condition
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Figure 10. Estimated repair and replacement cycles
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