Trainee Name: Trainee Engineer Mechanical Maintenance Dept

TRAINEE NAME
TRAINEE ENGINEER
MECHANICAL MAINTENANCE DEPT
CONTENTS
 Mechanical maintenance strategies and

considerations
 Important learning's during the training period.
 Solutions and improvement suggestions to improve

overall plant efficiency.
 Current standing and future goals.

GAS TURBINE MAINTENANCE
CONSIDERATIONS
A well planned maintenance advantages
 Minimizes system downtime
 Cost effectiveness
 Plant availability
 More reliability
RELATION B/W AVAILABILITY AND
COST
6
3 Availability (Hours)
Cost ($)
0
INGREDIENTS OF A GOOD
MAINTENANCE PROGRAM
 Continuous monitoring of operating conditions
 Routine equipment inspection
 Troubleshooting and diagnostic procedures
 Preventive maintenance of plant equipment
 Proper trainings
 Well documented procedures

 Efficient response to unplanned or unscheduled
maintenance
 Adequate spare parts inventory
 Work is carried out safely with no environmental

impact.
FACTORS AFFECTING MAINTENANCE
INTERVALS
OPERATING CONDITIONS
 Relation between baseline operating conditions

and maintenance intervals recommended by the
manufacturer.
 Calculation of maintenance factor

STARTS AND HOURS CRITERIA
Components wear out differently depending on how

combustion turbine is operated!
 For example: Thermal- mechanical fatigue is the

main cause of mechanical degradation of peaking
machines.
 Creep, oxidation and corrosion are most common

causes of wear for continuous duty machines.
 GE bases gas turbine maintenance requirements on independent
counts of starts and hours.
Number of Starts • Number of Hours
Whichever limit reaches first

GE GAS TURBINE REQUIREMENTS ON INDEPENDENT COUNTS
OF STARTS AND HOURS
SERVICE FACTORS
Typical baseline inspection intervals (6B.03/7E.03):

Hot gas path inspection: 24,000 hrs or 1200 starts
Major inspection: 48,000 hrs or 2400 starts
Criterion is hours or starts (whichever occurs first)
Factors affecting maintenance:
Hours-Based Factors
 Fuel type
 Peak load
 Diluent (water or steam injection)
Starts-Based Factors
 Start type (conventional or peaking-fast)
 Start load (max. load achieved during start cycle, e.g.
 part, base, or peak load)
 Trips
COMBUSTION INSPECTION
HOT GAS PATH INSPECTION
MAJOR INSPECTION
IMPORTANT LEARNING'S DURING
TRAINING
 Rectification of passing of HRSG HP and IP bypass
valves HP MOV 013 and HP MOV 014.
 Dry Ice blasting of HRSG economizer tubes.
 Condenser tube leakage testing using Eddy

Current Testing.
 Major Inspection of STG rotor
 CW pump ARD removal

RECTIFICATION OF HRSG B HP MOV 013
VALVE
 This is a major valve which is used to stop main HP
steam. This valve is a wedge type gate valve which
is motor operated. The technical service
department, after doing thermography on this
valve declared it as passing.
 Thermal images, or thermograms, are actually

visual displays of the amount of infrared energy
emitted, transmitted, and reflected by an object.
GATE VALVE
 Open and close

pipes by lowering
metal gates across
them.
 Designed to be
either fully open or
fully closed.
 The pressure loss

through the valve is
minimal.
DISMANTLING OF THE VALVE
SAFETY RELATING RIGGING
 Synthetic fiber slings must be inspected prior to

each use.
 The entire surface of the sling must be checked

thoroughly for cuts, as even a small cut can
significantly weaken the sling.
 Inspect the sling for any signs of exposure to

excessive heat such as melted spots or burnt
webbing.
 Rigger is certified.
DIAGNOSIS OF THE PROBLEM
Deep cut on the face of the Deep unreparable cuts on the

seat. face of the gate.
SOLUTION
 This valve was overall serviced with new parts installed.
 The new parts included new gates, new stem and new
gland seals.
 The seat of the valve was lapped for two days to

remove the cut.
 Finally DPT was done on the seat and it was found to be

clear .
 Contact check was performed to ensure metal to metal

sealing.
Lapping process Seals being installed
HRSG ICE BLASTING
 Sulfur deposits on the

fins which decrease the
heat exchanging
tendency of the tubes.
 Due to the low

temperature of the flue
gases at the very end
of the HRSG.
 The economizer tubes

are subjected to this
phenomena because
of their relative position
in the HRSG.
SAFETY HAZARDS
 Carbon dioxide is increasingly toxic starting at

concentrations above 1%, and can also displace
oxygen resulting in asphyxia if equipment is not used
in a ventilated area.
 Exhaust vents are required to be at or near ground

level to efficiently remove the gas.
 At normal pressure dry ice is −78 °C (−108 °F) and

must be handled with insulated gloves. Eye and ear
protection are required to safely use dry ice
cleaning equipment.
PROCEDURE
 Dry-ice blasting involves propelling pellets at

extremely high speeds.
Dry-ice pellets are quite soft, and much less dense

than other media used in blast-cleaning (i.e. sand
or plastic pellets).
 Upon impact, the pellet sublimates almost

immediately, producing sheer stresses due to
thermal shock, resulting the contaminant to flake
off.
PROCEDURE
RESULTS
 HRSG A : 820 kgs

 HRSG B : 460 kgs
 HRSG C : 480 kgs
IMPROVEMENT SUGGESTIONS
 Current method performed at the site is not efficient

enough. Only the front surface of the first row is cleaned.
 Tube spreading method:

 Custom spreader bars are fabricated specifically for that HRSG.
 These spreader bars are placed in every fourth tube on each face.
 This process allows us to open up lanes and have direct access to
the face of tubes that are four to five rows deep.
typically a 0.5” decrease in DP will result in a quick

payback of $50,000 to $60,000.
STEAM TURBINE ROTOR PULL OUT AND
INSPECTION
SAFETY HAZARDS
 Proper risk assessment should be attached with

permit.
 Hard copies of crane inspection, crane load test

certificate, third party certificates of man riding
baskets and lifting gears especially for “Special
Tools”.
 Since Rotor removal requires multiple steps like

pulling, lifting etc., therefore Point of Work Lifting
assessments shall be carried out for each single
rigging activity according to the method statement.
PULL OUT PROCEDURE
1. Installation of the Generator Pulling assembly
2. Installation of the ST Generator rotor Sliding platform
3. Opening of the ST generator Drive end bearing
4. Installing the shoes at the Generator drive end bearing
5. Installing the two 20 Ton Chain blocks with the pulling assembly
6. Inserting the Eye bolts in the Non drive end pedestal half
7. Pulling of the Non drive end pedestal with equal pulling from both sides
8. Constantly checking of the air gap between rotor and stator winding. Halt the
work if air gap is not proper
9. Take out half rotor by pulling with the fixture
10. Installing Special tool (Wire rope slings) on the rotor
11. By Up & Down movement for the Crane hook, rest of the rotor needs to be
pulled out. Make sure that the air gap allowance is 15 mm and the crane
movement is not exceeded beyond 15 mm
12. Lift the rotor with crane once the rotor is free from generator casing
13. Slow movement for the rotor is to be done
14. Rotor needs to be placed on the set of wooden planks secured with Scaffolds
15. Proper covering of the rotor to be done
Shoe resting on the rotor sliding platform
IMPROVEMENT SUGGESTION
 Rotor could be easily extracted and if the ST

platform is extended.
 This would not only save time but save crucial man
hours. It would also enormously reduce the safety
hazards as the rotor wouldn’t have to be lifted up
using a crane.
 The rotor could be pulled out while resting on a

trolley. After the work has been finished it could be
easily pushed back into the casing.
 Monitoring the air gap would also be easier and

the risk of the rotor touching the stator winding
would be minimal.
STG ROTOR BEARING INSPECTION
 Bearing clearance was checked.
 Journal bearing babbitt was visually checked.
 Non destructive testing was performed to check for

any cracks, pinholes, pitting etc.
 Dye penetrant testing was performed.
 DPT is based upon capillary action, where low surface tension
fluid penetrates into clean and dry surface-breaking
discontinuities.
 A developer is applied after removal of excess penetrant. The
developer helps to draw penetrant out of the flaw so that an
invisible indication becomes visible to the inspector.
COOLING WATER PUMPS ANTI
REVOLVE DEVICE
 Three 50% capacity pumps
 Each pump operating speed is 495rpm and each develops 58ft head.
 rated output of 76,337 US gallons per minute.

FUNCTION OF THE ARD
 The ARD function comes into use when the pump is

taken out of service.
 When the pump is shut down, the discharge valve is

closed afterwards.
 The ARD is a form of a ratchet attached with the shaft

which ensures that the shaft doesn’t rotates anti
clockwise, due to the deluge of reverse flow.
 That would cause the flow to change direction and start

flowing in the other direction.
PROBLEMS
 ARD has been a major pump downtime contributor

in the previous year 2015.
 Being a part of the pump, it always had to be

replaced.
 Not only damaged itself but damaged the shaft as

well as it has a locking mechanism with the shaft.
SOLUTION AND IMPROVEMENT
PROPOSED
 ARD not used in modern pumps. It could be removed.
 Install a check valve at every pump discharge before

the discharge valve.
 Change the logic of the discharge valve to pump

shutdown.
 This would ensure longer life of the pump and minimum

downtime, hence saving money and man power.
IMPROVEMENT SUGGESTIONS IN
TRAINING PROGRAM
 Trainees should be given more responsibility during
planning and involved in maintenance decisions
under the supervision of managers.
 It should be included in the managers monthly

goals to give trainings and tasks to prepare them for
future posts.
 Trainees should be specifically attached with a

specific manager of their field, who act as a mentor
to them to guide them for a future position.
“ Sometimes when you innovate, you make mistakes.
It is best to admit them quickly, and get on with
improving your other innovations.”
Steve Jobs
Thank you!

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TRAINEE NAME

 Mechanical maintenance strategies and

 Important learning's during the training period.

 Solutions and improvement suggestions to improve

 Current standing and future goals.

 Minimizes system downtime

 Routine equipment inspection

 Troubleshooting and diagnostic procedures

 Preventive maintenance of plant equipment

 Well documented procedures

 Adequate spare parts inventory

 Work is carried out safely with no environmental

 Relation between baseline operating conditions

 Calculation of maintenance factor

Components wear out differently depending on how

 For example: Thermal- mechanical fatigue is the

 Creep, oxidation and corrosion are most common

Number of Starts • Number of Hours

Whichever limit reaches first

Typical baseline inspection intervals (6B.03/7E.03):

 Dry Ice blasting of HRSG economizer tubes.

 Condenser tube leakage testing using Eddy

 Major Inspection of STG rotor

 CW pump ARD removal

 Thermal images, or thermograms, are actually

 Open and close

 The pressure loss

 Synthetic fiber slings must be inspected prior to

 The entire surface of the sling must be checked

 Inspect the sling for any signs of exposure to

Deep cut on the face of the Deep unreparable cuts on the

 This valve was overall serviced with new parts installed.

 The seat of the valve was lapped for two days to

 Finally DPT was done on the seat and it was found to be

 Contact check was performed to ensure metal to metal

 Sulfur deposits on the

 Due to the low

 The economizer tubes

 Carbon dioxide is increasingly toxic starting at

 Exhaust vents are required to be at or near ground

 At normal pressure dry ice is −78 °C (−108 °F) and

 Dry-ice blasting involves propelling pellets at

Dry-ice pellets are quite soft, and much less dense

 Upon impact, the pellet sublimates almost

 HRSG A : 820 kgs

 Current method performed at the site is not efficient

 Tube spreading method:

typically a 0.5” decrease in DP will result in a quick

 Proper risk assessment should be attached with

 Hard copies of crane inspection, crane load test

 Since Rotor removal requires multiple steps like

 Rotor could be easily extracted and if the ST

 The rotor could be pulled out while resting on a

 Monitoring the air gap would also be easier and

 Bearing clearance was checked.

 Journal bearing babbitt was visually checked.

 Non destructive testing was performed to check for

 rated output of 76,337 US gallons per minute.