ATT01 HTCT692232V0001 B Recommended Inspections

1 Recommended Inspections
1.1 Type of inspections

There are three different types of inspections:
• A-Inspection, see "A-Inspection" on page 1-4
• B-Inspection, see "B-Inspection" on page 1-14
• C-Inspection, see “Dismantling & Reassembly-documents”
1.1.1 Inspection methodology

• Maintenance work can be optimized when regular inspections are performed at
appropriate intervals on the right components and operating data are continuously
recorded and analyzed.
• Such scheduled checks of the gas turbine unit are aimed at preventing, wherever
possible, unscheduled outages and assuring a long-term high availability of the
plant.
• Undertaken at regular intervals they allow prediction of the work required at the
next inspection and planning, including just in time delivery of required material and
replacement parts.
• Arrangements for inspections and maintenance should be stated sufficiently far in
advance and in close co-operation between the owner and ALSTOM to enable
proper planning of details for the performance of inspection and eventual corrective
action, and thus a short down-time for the gas turbine set.
1.1.2 Duration of the inspections

Note
For the planning of the inspections please contact your nearest ALSTOM Customer
Service Department for more information.
The duration of a gas turbine inspection depends essentially on the following factors:
• Type of inspection
• Capacity of inspection staff
• Crew qualification
• Inspection planning (inclusive of recommissioning planning)
• Availability and condition of tools, consumables, repair parts and crane
GT13E2 Preventive Maintenance HTCT 692 232 V0001B en 1-1

Recommended Inspections November 2007
© 2007 ALSTOM. All rights reserved. The information in this document is provided for information purposes only. Site-specific deviations are possible. The descriptions do not constitute any
legally binding assurance of certain properties, qualities and/or scope of delivery. Any work described in this manual must be carried out solely under the supervision of personnel expressly
authorized by ALSTOM. Failure to comply with this requirement shall void any warranties, guarantees, representations, or other types of liability which ALSTOM may have given or
undertaken. Subject to change without notice.
1.1 Type of inspections
1.1.3 Preparation for inspections

Safety instructions
All personnel working with or at the machine must have read and understood the
safety instruction manual, which is part of the overall customer documentation set.
A thorough preparation is key to a successful and expedient execution of the A-, B- and
C-Inspections. Focus areas include:
• Issue a detailed timeline/work program for the expected work scope and workflow.
Focusing on a diligent engine disassembly for a C-Inspection will maximize the
time available for inspection and corrective actions. ALSTOM can assist with this
planning. The detailed program should show any additional time required for
implementation of improvements or upgrades, or corrective actions in response to
condition assessment performed during earlier scheduled visual inspections and
from analysis of operating data.
• Determination of the staffing requirements for such work based on the time
schedule and the work program. The staffing plan should establish who supplies
personnel (ALSTOM, Owner, the Operating Company and/or outside contractors),
what professional skills are required at what time and the working hours per day.
Familiarization with the plant should be undertaken and health and safety
instructions are mandatory for all people working on the A-, B- or C-Inspection
programmes.
1.1.4 Test certificates

Test certificates
The test certificates are not part of this manual and are available on request from
ALSTOM.
Inspections and checks, carried out during maintenance tasks, are detailed in the
inspection instructions.
Use copies of the test certificates and Inspection Records to record the results of the
inspection and checks. Forward the completed forms to the ALSTOM Service
Department.
1-2 HTCT 692 232 V0001B en GT13E2 Preventive Maintenance

November 2007 Recommended Inspections
Recommended Inspections 1
Type of inspections 1.1
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1.2 A-Inspection
1.2 A-Inspection
DANGER
Confined Space
Personnel can be killed or seriously injured
Use only low voltage (less than 25V) electrical light
Make sure that the gas turbine has cooled down (TAT at least <50°C)
Wear safety equipment as required by local authorities
Be sure that there is no gas and/or fuel in the gas turbine
DANGER
Turning Rotor
Always make sure that no unwanted turning of the rotor is possible
Do not wear jewelry and any loose fitting clothing that may get caught in the rotor
blades.
Caution
Foreign objects inside thermal block (gas turbine)
Serious damage will be caused to the gas turbine if it is subsequently operated or
turned by hand with foreign objects left inside the combustor
• Empty your pockets before you enter into the gas turbine
• Do not leave tools inside the turbine
• Check the entire area for foreign objects and remove them before exiting
Note
The installation preparing procedure for works (draining, purging, cleaning before and
after works, testing, disconnecting etc.) and safety measures for those works are not
subject of this document and should fulfill standard procedure for performing works
during erection phase or on installation in use.
Note
On site, all regulations of ALSTOM, the local legal regulations and the specific safety
regulations of the sub-contractor must all be considered. In each case, the higher
authority must be taken.
A-Inspections are regularly scheduled checks on the gas turbine set, involving mainly
the hot gas path parts in the gas turbine.
The inspection is used for:
• Early identification of changes in the condition of parts in the hot gas path.
• Initiation of rectification action as may be required.

A-Inspection 1.2
• Checking in operation settings important for availability.

• Obtaining an overall impression of the condition of the gas turbine unit
The unit is not disassembled for this purpose (only the combustion chamber should be
opened). Visual access to the blading is possible by boroscope openings, through the
combustor and the exhaust gas diffuser inspection hatches.
The main objectives are:
• Assessment of the overall condition of gas turbine hot-gas-path parts, compressor
inlet and auxiliaries by means of inspection aid provisions (e.g. boroscope), but
without engine disassembly.
• Determine the actual maintenance work to be performed during the C-Inspection.
• Carry out minor re-calibration, and adjustments as necessary.
• Issue an engine condition report including recommendations for future operation
and maintenance.
During A-Inspections, there is no scheduled replacement of hot-gas-path parts,
including combustor, liners and turbine parts. The ALSTOM EV (EnVironmental)
combustor is, in general, maintenance-free during the operation between C-Inspections.
No separate combustor inspections for maintenance are required. The simple and
robust design without movable parts allows for fast condition assessment during A- and
B-Inspection.
The unit does not need to be disassembled for the A- and B-Inspection. It is possible to
inspect the blading via boroscope inspection holes, through the combustor manhole and
the exhaust gas diffuser inspection hatches. Although the information gained from A-
and B-Inspections and from analysis of operating data is usually sufficient to assess the
potential conditions, unexpected findings during the next visual inspection could lead to
required corrective actions. Adequate spare parts should be made available to cover
such eventualities.

1.2 A-Inspection
1.2.1 Test and checks before shutting down the gas turbine
DANGER
Running gas turbine
• Record all measurements of the last operation mode (EGATROL screen print out).
– Gas turbine baseload run preferred
– Particularly vibrations- and pulsation data
– Exhaust temperature distribution
• Check for air-, oil- hot gas- and fuel leakages (safety checks).
• Check for unusual noise of the turbine and auxiliaries.
• Check the setting of the pressure reducing valves belonging to the bleed valve
system.
Fig. 1-1 Egatrol print out

A-Inspection 1.2
1.2.2 Record operating data

DANGER
Confined Space
• Record all data of the ODC (Operation Data Counter), after the shut down of the
turbine.
1.2.3 Rotor alignment

Read instructions!
For more information read the rotor alignment document HTCT 692 228.
• Check the radial position of the rotor (19, Fig. 1-2) according to the corresponding
test certificate.
1.2.4 Rotor, turbine side

Read instructions!
For more information read the boroscope inspection document HTCT 692 652.
• Check the turbine blade rows 1-5 (20, Fig. 1-2) for impact damage, cracks,
corrosion and coating defects.
• Check the binding bolts for tightness, seizing up and fretting.
1.2.5 Turbine vane carrier

Read instructions!
• Check the turbine vane row 1 (3, Fig. 1-2) for impact damage, cracks, corrosion,
deposits and coating defects.
• Check the heat shield segments rows in 1 and 5 of the stator for impact damage,
cracks, corrosion, deposits and signs of rubbing.
• Check the sealing strips of the vanes.

1.2 A-Inspection
1.2.6 Rotor, compressor side

Read instructions!
• Check the compressor blade rows 1 and 2 (13, Fig. 1-2) for impact damage,
cracks, corrosion and coating defects.
• Check the variable inlet guide vanes for excessive clearance of adjustment
mechanism.

A-Inspection 1.2
Pos. Description Pos. Description
1 Turbine-end bearing assembly, MBD10 12 Compressor housing, MBA80 HA110
2 Exhaust housing, MBA30 HA450 13 Compressor blade rows, MBA80 HB400
3 Turbine vane carrier, MBA30 HA300 14 GT support, compressor
4 Turbine vane rows; MBA30 HA400 15 Fuel distribution system, MBM31
5 EV combustor, MBM30 16 Combustor housing, MBA80 HA200
6 Inner housing 17 Turbine housing, MBA30 HA100

7 Stage 1 and 2 blow-off valves, MBA81 18 GT support, turbine
8 Air intake manifold, MBL30 19 Rotor, MBA01 HB100
9 Air inlet housing, MBA80 HA050 20 Turbine blade rows, MBA30 HB400
10 Compressor-end bearing assembly, MBD20 21 Exhaust diffuser, MBA30 HA500
11 GT support, air inlet
Fig. 1-2 Thermal Block Main Components

1.2 A-Inspection
1.2.7 Combustor
Read instructions!
• Check the cone and burner (3, Fig. 1-3) outlets plane for cracks, deformation and
overheating.
• Check the premix gas holes for erosion, soiling and coking at the burners.
• Check the burner collar for cracks, deformation, excessive clearance or blocking.
• Check the pilot gas openings for coking and erosion at the lances.
• Check the fuel oil nozzles for coking and erosion at the lances.
• Check the NOx water holes for coking and erosion at the lances.
• Check the electrode and nozzles of the ignition torches.
• Check the thermocouples measurement and high voltage coupling.
• Check the sensor at the flame monitor for overheating.
• Clean the glasses of the sight glasses and the flame scanning system.
• Check the burner hood (1, Fig. 1-3) for cracks and if any bolts are broken or loose.
• Check if there is a gap between the hood flange and the segment carrier.
• Check the manhole cover plate for cracks.
• Check the splitline cover plate for cracks.
• Check the front segments (4, Fig. 1-3) and sealings between the segments for
cracks, overheating or deformation.
• Check the welding seam of the Helmholzdampers for cracks.
• Check the restrainer ring at the transition (zone 2) for overheating and scaling.
• Check the inner and outer (zone 1) cooling segments (5 and 7, Fig. 1-3) for cracks,
overheating scaling and deformation.
• Check the zone 2 (6 and 8, Fig. 1-3) for cracks, overheating and deformation.
• Check the transition zone for oxidation and corrosion.
• Check the split line welding seam for cracks.
• Check all fasteners for tightness, cracks or deformation.
• Check the washers for deformation, fretting and cracks.
• Check the sealing segments for wear, rubbing, clearance, scaling and overheating.

A-Inspection 1.2
Pos. Description Pos. Description

1 Hood 5 Outer segment carrier
2 Combustor housing 6 Zone 2 outer shell
3 EV burner 7 Inner segment carrier

4 Front segments 8 Zone 2 inner shell
Fig. 1-3 Combustor assembly, overview

1.2 A-Inspection
1.2.8 Exhaust system (exhaust housing)

• Check the exhaust housing for cracks and deformation.
• Check the exhaust diffuser for cracks and deformation.
• Check all welds on struts in the exhaust diffuser.
• Check the air guide plates between the exhaust housing and the diffuser if they are
in proper position.
• Check the air guide plates for cracks and deformation.
• Check the thermocouples for deformation and damage.
• Check the inner guidance of the exhaust thermocouples for excessive wear.
• Check the thermocouple tips for deposits.
• Check that the probes at the exhaust thermocouples are tight.
• Check the safety plate at the exhaust thermocouples.
• Check the insulation material at the compensator.
• Check the sides of the compensator for deformation and damage.
• Check the NOx-cross.
1.2.9 Air intake manifold

• Check the weather louvres for any damage.
• Check the filter for any damage and for contamination.
• Check the anti-icing system for any damage.
• Check the filter house and silencer for any damage, corrosion and loose parts.
• Check the air intake channel and air intake housing for any damage, corrosion and
loose parts.
• Check the compressor on-line and off-line system for any damage and broken
hoses.
1.2.10 Exhaust end bearing chamber

• Check the exhaust end bearing chamber for any damage and leaks.
1.2.11 Short description of the A-Inspection
Gas turbine
• Air inlet system (8 and 9, Fig. 1-2): check the general condition
• Compressor (12, Fig. 1-2): check the inlet
• Burners (3, Fig. 1-3): check the burner/nozzle condition
• Ignition system: check the function
• Combustion chamber (5, Fig. 1-2): visual check (access through manhole)
• Turbine housing (17, Fig. 1-2): check the hot section
• Exhaust diffuser (21, Fig. 1-2): check the condition
• Bearings (1 and 10, Fig. 1-2): check for leakage

A-Inspection 1.2
Fuel systems
• Fuel oil: leakage and filter check
• Fuel gas: leakage and filter check
• Additive: leakage and filter check
Protection/monitoring
• Check the temperature protection
• Check the overspeed protection
• Check the flame monitor

1.3 B-Inspection
1.3 B-Inspection
DANGER
Confined Space
DANGER
Turning Rotor
Always make sure that no unwanted turning of the rotor is possible
Do not wear jewelry and any loose fitting clothing that may get caught in the rotor
blades.
Caution
Boroscope or metal guide can be damaged
• Turn very carefully the rotor while the boroscope or the metal guide is inserted
into the blade movement area
Note
The installation preparing procedure for works (draining, purging, cleaning before and
after works, testing, disconnecting etc.) and safety measures for those works are not
subject of this document and should fulfill standard procedure for performing works
during erection phase or on installation in use.
Note
On site, all regulations of ALSTOM, the local legal regulations and the specific safety
regulations of the sub-contractor must all be considered. In each case, the higher
authority must be taken.
This inspection is a check of the gas turbine set planned for intervals of an intermediate
length. They include the same type of checks on more components than the A-
Inspection.
It includes checking of:
• The safety equipment of the gas turbine set.
• Hydraulic and electronic closed-loop control systems.
• Open-loop controls and annunciation systems.

B-Inspection 1.3
The B-Inspection includes an A-Inspection plus additional checks on the auxiliaries, the
generator, the controls, and the protection and monitoring system including their
settings. Such tasks may be split into groups for phased inspection.
Similar to the A-Inspection, for the B-Inspection the unit is not disassembled. Visual
access to the blading is again possible via boroscope inspection holes and through the
combustor manhole and the exhaust gas diffuser inspection hatches.
1.3.1 Short description of the B-Inspection
Gas turbine
• Air inlet system (8 and 9 Fig. 1-2): check the general condition
• Valve system: check the function and the settings
• Compressor (12, Fig. 1-2): check the inlet and the filter house
• Burners (3, Fig. 1-3): check the flames and the burner/nozzle
• Ignition system: check the function and the igniters
• Combustion chamber (5, Fig. 1-2): visual check (access through manhole)
• Turbine housing (17, Fig. 1-2): check the hot section
• Exhaust diffuser (21, Fig. 1-2): check the condition
• Bearings (1 and 10, Fig. 1-2): check for leakage
Fuel systems
• Fuel oil: leakage, system and filter check
• Fuel gas: leakage, system and filter check
• Additive: leakage, system and filter check
Protection/monitoring
• Check the temperature protection
• Check the overspeed protection
• Check the fire protection systems
• Check the turbine protection
• Check the measurement instrumentation
• Check the recorder

1.3 B-Inspection
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1 Recommended Inspections

1.1 Type of inspections

1.1.1 Inspection methodology

1.1.2 Duration of the inspections

GT13E2 Preventive Maintenance HTCT 692 232 V0001B en 1-1

1.1.3 Preparation for inspections

1.1.4 Test certificates

1-2 HTCT 692 232 V0001B en GT13E2 Preventive Maintenance

GT13E2 Preventive Maintenance HTCT 692 232 V0001B en 1-3

1-4 HTCT 692 232 V0001B en GT13E2 Preventive Maintenance

• Checking in operation settings important for availability.

GT13E2 Preventive Maintenance HTCT 692 232 V0001B en 1-5

Fig. 1-1 Egatrol print out

1-6 HTCT 692 232 V0001B en GT13E2 Preventive Maintenance

1.2.2 Record operating data

1.2.3 Rotor alignment

1.2.4 Rotor, turbine side

1.2.5 Turbine vane carrier

GT13E2 Preventive Maintenance HTCT 692 232 V0001B en 1-7

1.2.6 Rotor, compressor side

1-8 HTCT 692 232 V0001B en GT13E2 Preventive Maintenance

Pos. Description Pos. Description

1 Turbine-end bearing assembly, MBD10 12 Compressor housing, MBA80 HA110

2 Exhaust housing, MBA30 HA450 13 Compressor blade rows, MBA80 HB400

3 Turbine vane carrier, MBA30 HA300 14 GT support, compressor

4 Turbine vane rows; MBA30 HA400 15 Fuel distribution system, MBM31

5 EV combustor, MBM30 16 Combustor housing, MBA80 HA200

6 Inner housing 17 Turbine housing, MBA30 HA100

8 Air intake manifold, MBL30 19 Rotor, MBA01 HB100

11 GT support, air inlet

Fig. 1-2 Thermal Block Main Components

GT13E2 Preventive Maintenance HTCT 692 232 V0001B en 1-9

1-10 HTCT 692 232 V0001B en GT13E2 Preventive Maintenance

Pos. Description Pos. Description

2 Combustor housing 6 Zone 2 outer shell

3 EV burner 7 Inner segment carrier

Fig. 1-3 Combustor assembly, overview

GT13E2 Preventive Maintenance HTCT 692 232 V0001B en 1-11

1.2.8 Exhaust system (exhaust housing)

1.2.9 Air intake manifold

1.2.10 Exhaust end bearing chamber

1.2.11 Short description of the A-Inspection

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GT13E2 Preventive Maintenance HTCT 692 232 V0001B en 1-13

1-14 HTCT 692 232 V0001B en GT13E2 Preventive Maintenance

1.3.1 Short description of the B-Inspection

GT13E2 Preventive Maintenance HTCT 692 232 V0001B en 1-15

1-16 HTCT 692 232 V0001B en GT13E2 Preventive Maintenance

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