maintenance recommendations

7/30/2019 Maintenance Recommendations

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TechComm Simulation Pty Ltd

TechComm Simulation Inspection and Maintenance Guide Shuaiba North CCGT Page 1 of15

Maintenance Considerations for Shuaiba North CCGT

** Noted that this information has been extracted from the various Vendor OEM manuals,and should only be used as a Guide, specific maintenance requirements should be sourced by

the owner using the specific Vendor manuals for detailed maintenance activities.

Fuel Gas Compressors

Functional test of safety devices Yearly

Check function of control mechanism (IGV/DGV) Monthly

Check oil level (oil tanks) Daily

Check oil supply motor Daily

Check oil filter for fouling Daily

Check condensate trap, drain condensate (unless done

automatically) Daily

Check centrifugal compressor for irregular noise/Irregularities, etc. Daily

Check plant for gas, water and oil leakage DailyOil inspection, Lab test Yearly

Compare thermodynamic data Yearly

Minor Inspection plant (includes all of the above) Yearly

Major Inspection plant 2 years

Includes all of the above tests

Gear teeth - Teeth and contact pattern

Axial bearings - Contact pattern and clearance

Pinion shaft bearings - Contact pattern and clearance. Replace if necessary.

Bull wheel shaft bearings - Contact pattern and clearance. Replace if necessary.

Shaft bearing fits - Contact pattern; check diameter

Oil seal - Clearance. Replace if necessary

Shaft seal - Contact pattern, surface, clearances

Axial shaft position pick-up - Mounting, measuring clearance

Shaft vibration pick-up - Mounting, measuring clearance

Adjustable guide vanes - Vanes, ease of adjustment and position, surface

Suction nozzle - Surface

Impeller - Inlet edges, surface cleanliness, concentricity with rotor shaft, crack-test

Coupling - Dismantle spacer, check alignment. Coupling hubs equipped with one shaft key

must be balanced with half of the shaft key installed. Otherwise it must be verified that the

required balancing quality is obtained also with un-grooved hub despite the existing

difference in weight. Vibration and rotor position monitoring calibration check

Probe, cable and proximitor - calibration check

Monitor gain adjustment- calibration check


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GTTwo types of Maintenance

Running - online

Shutdown offline (these include Combustion, Hot Gas path, Major)

Maintenance BasicsIf the GT is offline or will be shutdown for 3 weeks or more with no maintenance activity

happening, then the GT should be placed on turning gear for at least 1 hour per day to reduce build

up of corrosive deposits in the blading (specifically the turbine blades) or Run GT at FSNL for 1

hour to dry out the GT internally.

Time frame assumptions is if the next items are available. all tooling, parts, labour, planning, no

repair time just replacement, mechanical side only. (Flange to Flange.)

Combustion Inspection (Yearly) (Duration 10 x 8 hr shifts)This type of inspection is required to remove and inspect the combustion area components and or

replace as required, Fuel nozzles, Combustion Liners, Transition pieces and Cross fire tubes. It

should be noted that if you need to change any 1 of the individual components then the full set

should done, and kept together. All components can then be cleaned or recalibrated at a later date,to minimise down time.

It should be noted that a visual should also be done on the Leading edge of the First stage Turbine

Nozzle partitions at this time.

Fuel Nozzles

Combustion Liners

Transition Pieces

Cross fire tubes

At the same time these can be done

VIGV checks and calibration as required (linkages, hydraulics, Individual pinion movement)

Hot Gas path Inspection (2.5 Years) (Duration 22 x 8 hr shifts)The Hot Gas Path Inspection requires that the combustion Inspection is also done as well as the

following; The Turbine Nozzles and Turbine Buckets.

Removal of the turbine casing shell

Visual inspection of all nozzle stages

First stage nozzles are removed

Complete set of Turbine blade clearances are taken

Major Inspection (5 yearly)(duration 46 x 8 hr shifts)

The major Inspection includes both the Combustion and Hot gas path Inspections as well as thefollowing;

Casings are inspected for cracks and erosion,

Rotor and stator blades are to be checked for tip clearance, rubs, bowing, cracking, and

warpage.

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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Auxiliary and Control systemsIt should noted that the below information is as a general guide and maybe not specific to the

individual supplier, for specific complete information please refer to the specific vendor manuals.

A Guide of durations

D - Daily InspectionW - Weekly InspectionM - Monthly InspectionQ - Quarterly Inspection

SA - Semi-annual InspectionCI - Combustion InspectionA - Annual InspectionHGP - Hot Gas Path InspectionMaj - Major Overhaul InspectionYrs. - Years


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PERIODIC INSPECTION

SCHEDULE

Inspection Frequency

INSTRUMENTATION

Pressure Switches and Gauge D

Calibration A

Thermometers (Dial Type) A

Calibration A

Flow-meters A

Leaking Seams and Joints A

Calibration A

Vibration Detectors D A

Liquid level indicators A

Panel Meters D M A

CONTROL DEVICES

Temperature Switches D

Calibration A

Dropout Setting A

Thermostats

Calibration Setting A

Pressure Regulating Valves

(VPRs) Packing Leakage M

Temperature Regulating

Valves (VTR s) Packing Leakage M

HYDRAULIC/MECHANICAL EQUIPMENT

Relief Valves

Chattering and Leakage M

Settings A

Full Test A HGP

Solenoid Valves

Leakage M

Proper Operation A

Servo-valves

Verify proper torque (17-19 inch pounds) A

OrificesErosion or Corrosion A


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Plugging, Orifice Deterioration A

Sharp Edges or Irregular Chamfer A

Check Valves

Leakage SA

Corrosion Maj

STRAINERS

Gas/Liquid SA

Filters, Lube D M

Leaking Seams and Joints Dirty Elements SA

Hydraulic Supply Filter D

Leaking Seams and Joints Dirty Elements M SA

Air Filters

(Air Extraction Valve) Moisture Accumulation M

Dirty Filter S A

HEATING COOLING AND VENTILATION

Air Conditioners

Dirty Filter W

Improper Thermostat Setting W

Dirty Condenser Coil

Space Heaters

Improper Operation A

Dirty Heating Elements, Blades and A

Louvers A

Improper Thermostat Setting A

Accessory and Turbine

Compartment Vent Fans Excessive Fan Wheel Wear A

Vibration A

Cleanliness A

MOTORS AND PUMP COUPLINGs

Motors

Excessive Vibration A

Dirty Louvers and Screens A

Loose Mounting Bolts and Electrical Connections A

Dirty Windings, Collector Rings, A

Commutator, Brush Rigging, Brush Condition A

Loose Bolts and Grease Plugs AEvidence of Wear A


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LUBE SYSTEM

Lube Oil Pumps

Excessive Noise Wear D M

Ring Clearance Maj

Thrust Bearing Wear Maj

Bearing Seal Wear Maj

Lube Oil Tank

Oil Levels D

Peeling Paint A

Loose Hardware, Fittings on Internal Piping and Tubing Maj

Presence of Sludge and Unusual Foreign Matter in Bottom of Tank Maj

Lube Oil Properties

Irregular Physical Properties of Lubricant Sample Taken from Tanks

and Presence of Contaminants M

Heat Exchangers

Improper Operation D M

Leakage D M

Contaminated Water M

Plugging of Leaking Tubes 3 Yrs

Lube Oil Immersion Heaters

Improper Operation M

Mist Eliminator

Excessive Pressure Drop across Unit M

Oil Vapour Leakage D M

Dirty Filter Element M

Condition of Filter Element Fibre Bed M

Mist Eliminator Fan

Dirty Fan Housing M

Loose Mounting Bolts M

Excessive Vibration Noise D M

Pipe CouplingsOil Leakage/Hardware Security D

Seal Brittleness A


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WATER SYSTEM

Cooling System Checks

System Fouled with Contaminants Maj

Improper Water Flow Maj

Incorrect Flow Versus Pressure Drop Maj

Water Tank

Evidence of Tank Leakage A

Improper Pressure Cap Setting HGP

Poor Condition of Cap Gasket and Gasket Surface M

Damaged Filler Neck A

Dirt Inside Tank A

Corrosion Inhibition Q

(Or Every Water Addition)

Radiator Header Assemblies

Leaking Seams and Joints M

Corrosion and Erosion of Fins and Tubes M

Damaged Parts M

Cleanliness A

Anti-Freeze Protection Improper Concentration A

Cooling Water Radiator Fan Dirty Wheel Housing, Ducts and Module

Screens A

Excessive Vibration Noise A

Damaged Blades A

Loose Mounting Bolts A

Air Flow Obstructed A

Rust, Corrosion and Peeling A

Cooling Water Pump

Leakage Shaft Seal M

Dirty Shaft Seal Cooling Water Line and Filter Element A

Excessive Wear Ring Clearance Maj

Excessive Mechanical Seal Wear Maj

FUEL GAS SYSTEM

Gas Control Valve

Gas Leakage at Stem, Packing Leak Off or Vent M

Hydraulic Cylinder Rod Seal Leakage M

Rough Operation SA

Improper Operation of Trip Relay S A

Damage Control Surfaces of Valve Plug and Seat M a j

Trip Action with Loss of Hydraulic Trip Oil S A


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HIGH PRESSURE CONTROL OIL, SYSTEM HYDRAULIC SUPPLY

Main Hydraulic Supply

Pump

Excessive Vibration or Unusual Noise,

Improper Discharge Pressure M

Relief Valve Leaking D

Leakage at Shaft and Mounting A

Flanges M

Auxiliary Hydraulic Supply

Pump

Low Discharge Pressure A

Leakage around Shaft and Mounting Flanges M

Excessive Vibration or Unusual Noise M

Hydraulic Supply Manifold

Connections Loose or Leaking A

Air Bleed Valves

Air Bleed Valve Operation A

Accumulator

Check charge Pressure A

Accumulator Safety Disc A

Hydraulic System Piping

Leaking Pipe Connections (All Units) HGP

INLET GUIDE VANE CONTROL SYSTEM

Operation and Calibration Control

Inlet Guide Vanes Proper Operation Specification, Calibration D

20TV Trip Servo Valve for Proper Operation A

Check Trip Action of Inlet Guide Vanes with Loss of Hydraulic Trip Oil SA

Check Operation and Sequencing of -

- Specification Compressor Bleed Valves SALeakage in the System M


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COOLING AND SEALING AIR SYSTEM

PipingOrifice Plates A

Orifice Unions A

Leakage D

Loose Hardware, Hangers and Clamps M

Vibration M

Compressor Bleed Valve

Sluggish Movement Open/Close SA

Leakage M

Compressor DischargePressure Transmitter Calibration A

STARTING SYSTEM

Starting

See Vendors Preventive Maintenance

A or 90 Starts

Starting Motor

See Vendors Preventive Maintenance Procedure in

Starting System Tab A

Starting Clutch

Improper Clearance of Clutch Jaws at Engaged and

Disengaged Positions SA

Improper Operation of Limit Switch SA

Worn Clutch Jaws A

Torque Converter

External Oil Leaks at Shaft Seals,

Bolted Flanges, Cover Plates D

Tubing Connections andHydraulic Hoses

Leakage, Wear, Chafing and Abrasions Q

Ratchet System

Oil Leakage D

Dirt in Commutator A

Faulty Pump A


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FIRE PROTECTION SYSTEM

System Package LaggingLeakage at Lagging A

Open Joints Between Bases, Roof Joints and Door Fits A

Pilot Operated Cylinders Show Improper Pressure at Gauges A

High pressure system

Ventilation dampers operate freely and no obstructions A

High Pressure Storage

Loss of cylinder weight SA

Fire Detectors operation A

High Pressure System Solenoid Pilot Valve Puff test

Confirm operation of the system A

Ventilation dampers operate freely A

Low pressure CO2 System Electric release and Puff Tests

Confirm operation of the system A

Ventilation dampers operate freely A

WATER INJECTION SYSTEM

Control Systems Maintenance

Calibration Electronic Circuits A

Calibration of Control Valve Circuits A

Calibration of Flow-meter Circuits A

Check Flow-meter Accuracy 3 Yrs

Check Control Valve for Leakage A

Check Stop Valve Operation A

Check Stop Valve for Leakage A

Check Forwarding Pump Oil Level M

Check that Water Flow is per Control Specifications DCheck Accumulator charge A

Check Water Spray Nozzles for Plugging and Spray Pattern A


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STATION AUXILIARIES AND SERVICE

BatteryImproper Specific Gravity at Pilot Cell M

Low Electrolyte Level at Pilot Cell M

Loose and Dirty Connections M

Damaged Containers and Cell Covers M

Faulty Sealing or Missing Vent Plugs M

Improper Specific Gravity and Low Electrolyte at any One Cell A

Battery Charger

Check Cleanliness of Charger A

Voltmeter Calibration SA

Check Capacitors and Diodes (if Faulty) A

MOTOR CONTROL CENTRE

Indicating Lamps

Burned Out Lamps (or as necessary)

M

Improper Operating Lighting Sequence M

Main Bus Insulators Dirty Bus Insulators and Barriers A

Main Vertical Bus Joints and Main Bus Supports Loose Connections A

Magnetic Contactors and StartersDirty Contactors and Starters A

Loose Connections A

Contacts Welded Together, Worn and Arcing A

Magnetic Relays

Dirt, Dust, Oil, Grease A

General Purpose Contactors

Damaged Arc Chute A

Improper Arcing Horn Clearances A

Improper Armature Spring Adjustment AWeak Contact Pressure A

Loose Screws, Nuts and Bolts A

General

Improper Closing and Latching of Control Panel Doors A

Nameplates Missing A

Cleanliness of Panel A


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Starting Motor Limit amp Contactor

Loose Screws, Nuts and Bolts Loose,

Electrical Interlocks Contacts, General Condition A

DC Magnet Assembly Alignment per Specification A

Collars on Each Side of Movable Power Tips for Proper Fit and

Alignment A

Accumulation of Dust, Dirt and Foreign Material on

Contactor and Arc Chutes A

COLLECTOR COMPARTMENTS

Fibreglass Expansion Joints

Loose joints M

Cleanliness MCooling Air discharge vents

M

Generator Ends and Compartment interfaces

Seals Damaged/Watertightness M

Collector compartment Air filters

Filter Cleanliness A

INLETAIR SYSTEMS

Inlet Screens

Obstructions D

By-Pass Door System

Correct Seal M

L im it S wi tc h O pe ra ti on ( Mo nt h- Ch ec k, A nn ua l- O pe ra te ) M A

Inlet Ductwork/Silencers

Sealing A

Cleanliness AF i l te r C a rt r i dg e s( M on t h- c o nf i r m D P , A n nu a l- P hy s ic a l c h ec k ) M A

(replace as necessary in between)

IGVs

Corrosion/Pitting A

Moisture Separators

Cleanliness of Media Section M

Build Up on Blades A


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Evaporative Cooler

Lubricate Motor A

Tanks for Debris A

Media Build-up A

Nozzles blocking M

Spray Pattern A

Clean Tank A

Water Flow Adjustment

Proper Water Flow to confirm Media Wetness D

Lubrication SchedulesLubrication is required on most turbine external moving parts, Lubrication requirements are

difficult to establish they depend on Air temperature and operating hours, the owner should

set a basic monthly schedule and monitor the lubrication and adjust the schedule to suit.


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GT Generator

Minor Every 30 Months (2.5 years)

Major - Every 60 months (5 years)After 1 year of duty operation (8760 hours or 300 starts)

Generator end plates/shields are removed to inspect the stator ends wear inspection.

Hydrogen cooling system drained and pressure test if required, all Hydrogen fillingstations checked, Hydrogen seals checked or replaced as required.

After 60 months (5 years) of duty the Stator is removed for full inspection

Complete inspection of the field and rotor coatings, insulation, wear and tear.

Listing of assigned checks and durations

RTD Element Res. - Gas & Winding RTDs

Checks for calibration & poor connections. Minor/Major

RTD Ground Insulation - Stator Winding RTDsInsulation condition of RTD. Minor/Major

Winding Copper Res.- Stator Winding

Checks for poor connections & breaks. Minor/Major

Insulation Resistance (aka CE Bearing Contamination

and/or deterioration of insulation. Minor/Major

Hydrogen Seal Casing

Contamination and/or deterioration of insulation. Minor/Major

Polarization Index - Stator WindingContamination and/or deterioration of insulation. Minor/Major

DC Leakage Current - Stator Winding

Contamination and/or deterioration of insulation. Minor/Major

Over Potential/Hipot - Stator Winding

Ground wall insulation integrity Minor/Major

Wedge Tightness Map - Stator WedgesDetect wedge tightness deterioration Minor/Major

Magnetic Scalar Potential (EL CID) -

Stator Core Insulation Weak or damaged core enamel. Minor/Major

Vacuum Decay - Water Cooled Stator Cher Winding Checks the hydraulic integrity of the entire winding. Minor/Major

Pressure Decay - Water Cooled Stator Winding

Checks the hydraulic integrity of the entire winding. Minor/Major

Capacitance Mapping - Water Cooled Stator Winding

Wet ground wall bar insulation Major

Helium Tracer Gas - Water Cooled Stator Winding

Detects minute leaks in the hydraulic circuit. Major

Visual Inspections

o Core Laminations Foreign Object Damage Minor/Major

o Space Blocks Migration, - cooling passage blockage Minor/Major

o Gas Gap Baffles Cracked welds, looseness Minor/Majoro Stator Wedges Evidence of abrasion or looseness Minor/Major


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TechComm Simulation Inspection and Maintenance Guide Shuaiba North CCGT Page 15 of 15

o Stator Bars Evidence of abrasion or looseness Minor/Major

o End Windings and connection rings

o Evidence of relative motion, loose/broken ties, hardware,

Corona activity Minor/Major

o Copper Flux Shield Overheating, hardware looseness Minor/Major

o Overall cleanliness Oil or other contamination

maintenance recommendations

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