module 18 - gas generator removal-installation.pdf

Barinas Power Plant

Gas Generator Removal/Installation

2El Furrial Power PlantBarinas Power Plant

Learning ObjectivesUpon completion of this training, participants will beable to: Describe removal and installation procedures for the

gas generator and free turbine. Identify special handling and lifting fixtures required. Describe preparation procedures for shipment of gas

generator and free turbine.


Removal ProcedureThe gas generator and free turbine are removed from thegas turbine enclosure through the removable roof hatchprovided.

Special lifting and handling fixtures are required for thisprocedure.


Removal Procedure Gas GeneratorSTEP 1 REMOVE HATCH DOOR

Equipment required:

Storage container Crane or suitable lifting device

1. Unbolt enclosure roof hatch.

2. Disconnect engine heater supply tube.3. Disconnect engine heater electrical supply.

4. Attach lifting cables to roof hatch.

5. Remove hatch.6. Place roof hatch in storage container.


Removal Procedure Gas Generator

TYPICAL HATCH DOOR REMOVAL


Removal Procedure Gas GeneratorSTEP 2 PREPARE GAS GENERATOR FOR REMOVALEquipment required (Typical)*:

Support PWA 11718 1 each Saddle PWA 20474 1 each Sling PWA 20472 1 each Nylon Strap 1 each Adapter, Lifting PWA 20473 1 each Transport stand 1 each

1. Disconnect all fuel, oil, air and electrical connectionsfrom gas generator to base assembly and enclosure.

2. Remove two free turbine cooling air tubes.* See applicable Gas Generator Maintenance Manual for specific model

data.


Removal Procedure Gas Generator3. Support free turbine at turbine case front flange with

PWA 11718 Support.4. Remove the Bellmouth using nylon strap.

5. Remove nose cone.

6. Position sling (PWA 20472) over gas generator.7. Attach PWA 20473 Lifting Adapter to engine sling

(PWA 20472), and connect to intermediate case.

8. Position PWA 20474 Saddle under turbine nozzlecase (inboard of all external tubes) and attach toengine sling.



GG REMOVAL PREPARATION


Removal Procedure Gas GeneratorSTEP 3 REMOVAL OF GAS GENERATOR

1. Attach crane hook or suitable device to sling (PWA20472).

2. Support weight of gas generator with sling.

3. Remove the nuts and bolts from Flange L.4. Release front mount links.

5. Remove inlet case mount pads.

6. Carefully raise gas generator through roof hatchopening.

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El Furrial Power PlantBarinas Power Plant


GAS GENERATOR REMOVAL

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Removal Procedure Gas GeneratorSTEP 4 PLACE GAS GENERATOR ON TRANSPORTSTAND

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PLACING GAS GENERATOR ON (TYPICAL) TRANSPORT STAND

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Removal Procedure Free TurbineTypically, the gas generator must be removed fromenclosure or moved forward sufficient to clear roofhatch door in order to remove the free turbine.

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Removal Procedure Free TurbineSTEP 1 REMOVAL OF FLEXIBLE COUPLING ANDEXHAUST INNER DUCTEquipment required:

Brace IPC 4561

Brace IPC T10131. Install IPC 4561 and IPC T1013 Braces to support rear

uprights.

2. Disconnect and remove rear flexible coupling.3. Remove bolts securing exhaust inner duct and slide

rearward.

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Removal Procedure Free Turbine

TURBINE SHAFT HEATSHIELD

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Removal Procedure Free TurbineSTEP 2 REMOVAL OF FREE TURBINE SHAFT ANDINSTALLATION OF LIFT AND TURN MOUNTSEquipment required:

Adapter PWA 11557 2 each

1. Install a block or trolley to support the turbineexhaust duct.

2. Remove bolts, nuts and brackets from Flange T,disconnecting turbine exhaust duct from free turbine.

3. Mount PWA 11790 1 each.

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Removal Procedure Free Turbine4. Mount PWA 11791 1 each

5. Remove bolts which secure front end of free turbineshaft to rear flexible coupling. Allow shaft andexhaust inner duct to rest on the turbine exhaustduct.

6. Install PWA 11790 and PWA 11791 Lift and TurnMounts. Attach a PWA 11557 Adapter to each mount.

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FREE TURBINE SHAFT REMOVAL

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Removal Procedure Free TurbineSTEP 3 FREE TURBINE REMOVALEquipment required:

Trolley 1 each Hoist Chain 2 each Sling, Crane 1 each

1. Attach two chain hoists to trolley and attach liftinghooks to PWA 11557 Adapters.

NOTEFree turbine weighs approximately 4300 pounds.

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Removal Procedure Free Turbine2. Apply enough lifting tension to chain hoists, to

relieve free turbine pressure on mounts; then removeretaining pins and attaching hardware from side andlower mounts.

3. Raise free turbine, with chain hoists, to clear sideand lower mounts.

4. Move trolley and free turbine under hatch.

5. Attach crane sling to trolley, and lift trolley and freeturbine.

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FREE TURBINE REMOVAL

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Removal Procedure Free TurbineSTEP 4 REMOVAL OF FREE TURBINE FROMENCLOSURE1. Turn trolley and free turbine 90 degrees; then

carefully remove from enclosure.

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REMOVAL OF FREE TURBINE FROM ENCLOSURE

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Removal Procedure Free TurbineSTEP 5 PLACING FREE TURBINE ON SHIPPINGSTAND1. Rotate free turbine to vertical position with exhaust

case down, using straps for controlling rotation.

2. Place free turbine on shipping stand.

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PLACING FREE TURBINE ON SHIPPING STAND

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Installation ProcedureThe gas generator and free turbine are installed in thegas turbine enclosure through the removable roof hatchdoor provided.

Special lifting and handling fixtures are required for thisprocedure.

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Installation Procedure Free TurbineSTEP 1 REMOVAL OF FREE TURBINE FROMSHIPPING STANDEquipment required:

Sling, Crane 1 each Adapter PWA 11557 2 each Mount PWA 11790 1 each Mount PWA 11791 1 each Hoist, Chain 2 each Trolley

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Installation Procedure Free TurbineNOTE

The roof hatch must be removed from enclosure, and gas generator must be removed or far enough forward in

enclosure to allow installation of free turbine.

1. Install PWA 11790 and PWA 11791 Lift and TurnMounts to free turbine brackets; then attach PWA11557 Adapters to lift and turn mounts.

2. Install two chain hoists to enclosure trolley and liftfree turbine from shipping stand.

3. Place free turbine in horizontal position.

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Installation Procedure Free Turbine

REMOVAL OF FREE TURBINE FROM SHIPPING STAND

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Installation Procedure Free TurbineSTEP 2 LOWER FREE TURBINE INTO ENCLOSURE

1. Position over hatch so that trolley is along the mainaxis of enclosure.

2. Carefully lower into enclosure.

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INSTALLATION OF FREE TURBINE IN ENCLOSURE

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Installation Procedure Free TurbineSTEP 3 INSTALLATION OF FREE TURBINE

Equipment required:

Support PWA 11718 1 each1. Position and lower trolley over enclosure tracks, with

free turbine in position shown.2. Raise free turbine to clear mounting pads, and roll

into position.

3. Place PWA 11718 support in position; then lower freeturbine into mounts.

4. Secure free turbine to lower and side mounts.

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FREE TURBINE INSTALLATION

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Installation Procedure Free TurbineSTEP 4 INSTALLATION OF FREE TURBINE SHAFT

Equipment required:

Heater PWA 20366 1 each1. Remove chain hoists

2. Remove PWA 11790 and PWA 11791 Lift and TurnMounts.

3. Apply antigalling compound to bolts and secureFlange T, at turbine exhaust deflector and duct, alongwith previously removed hardware.

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Installation Procedure Free Turbine4. Heat free turbine rear flexible coupling with PWA

20366 Heater.5. Remove heater and immediately assemble free

turbine shaft to flexible coupling with bolts,tabwashers, and nuts. Torque nuts.

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INSTALLATION OF FREE TURBINE SHAFT

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Installation Procedure Free TurbineSTEP 5 INSTALLATION OF FREE TURBINE SHAFTHEATSHIELD AND CONNECTION OF SHAFT1. Install new gaskets in front and rear gasket retainers.

2. Place both halves of free turbine shaft heatshieldtogether around gaskets with horizontal joints in avertical plane.

3. Apply anitgalling compound to bolts and securehalves together with bolts and nuts. Torque bolts.

4. Connect free turbine shaft to customer equipment.

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INSTALLATION OF EXHAUST INNER DUCT AND COUPLING

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Installation Procedure Gas GeneratorSTEP 1 REMOVAL OF GAS GENERATOR FROMTRANSPORT STANDEquipment Required (Typical)*:

Saddle PWA 20474 1 each Sling PWA 20472 1 each Nylon Strap 1 each Adapter, Lifting PWA 20473 1 each Crane or suitable lifting device

* See applicable Gas Generator Maintenance Manual for specific modeldata.

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Installation Procedure Gas GeneratorNOTE

The roof hatch must be removed from enclosure.

1. Attach PWA 20473 Lifting Adapter to PWA 20472Engine Sling.

2. Hoist sling over engine and connect adapter tointermediate case.


4. Release gas generator from transport stand, andraise from stand with crane.

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Installation Procedure Gas Generator5. Attach PWA 20884 Lifting Adapter to PWA 20472

Engine Sling.6. Attach lifting adapter to lifting eye on engine mount

cross beam.7. Hoist cross beam over gas generator with crane or

other suitable lifting device and connect cross beamto intermediate case.


9. Release gas generator from transport stand, andraise from stand with crane.

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Installation Procedure Gas Generator

REMOVAL OF GAS GENERATOR FROM (TYPICAL) TRANSPORT STAND

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Installation Procedure Gas GeneratorSTEP 2 TRANSFER OF GAS GENERATOR FROMTRANSPORT STAND TO ENCLOSURE1. Carefully lower gas generator into enclosure.

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GAS GENERATOR TRANSFER TO ENCLOSURE

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Installation Procedure Gas GeneratorSTEP 3 INSTALLATION OF GAS GENERATOR

1. Install front mounts.

2. Clock engine to position machined pad at bottom ofinlet case in a horizontal plane and secure exhaustcase of gas generator to inlet duct of free turbine,aligning bolt holes, as required.

3. Secure gas generator to free turbine with bolts andtorque.

4. Remove sling, adapter and saddle from gasgenerator.

5. Remove PWA 11718 Support from free turbine.

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Installation Procedure Gas Generator6. Install nose cone.

7. Install the bellmouth using nylon strap.

8. Install and secure two free turbine cooling air tubes.9. Attach all fuel, oil, air and electrical connections from

base assembly and enclosure to gas generator.

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GAS GENERATOR INSTALLATION

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Installation Procedure Gas GeneratorSTEP 4 INSTALLATION OF HATCH DOOR

Equipment required:

Crane or suitable lifting device.1. Attach lifting cables to roof hatch.

2. Lift roof hatch from storage container and install.

3. Attach engine heater electrical supply.4. Attach engine heater supply tube.

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TYPICAL HATCH DOOR INSTALLATION

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Are there any questions?

Review the sections learning objectives.

Gas Generator Removal/InstallationLearning ObjectivesRemoval ProcedureRemoval Procedure Gas GeneratorRemoval Procedure Gas GeneratorRemoval Procedure Gas GeneratorRemoval Procedure Gas GeneratorRemoval Procedure Gas GeneratorRemoval Procedure Gas GeneratorRemoval Procedure Gas GeneratorRemoval Procedure Gas GeneratorRemoval Procedure Gas GeneratorRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineRemoval Procedure Free TurbineInstallation ProcedureInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Free TurbineInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorInstallation Procedure Gas GeneratorSlide Number 50

module 18 - gas generator removal-installation.pdf

Documents

place gas generator

removal of gas generator1

thegas generator

turbine case

support pwa

remove hatch doorequipment

thegas turbine enclosure

enclosure roof hatch