Gas Turbines

Maintenance Inspections
and Calculations of
Equivalent Operating
Hours
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1. M A I N T E N A N C IEN S P E C T I O N(3
S .5 – 0 0 2 2 )

Maintenance operations must be performed on the gas turbine at

regular intervals. As with any plant operation will lead to wear and
tear. It is the function of maintenance to detect and influence wear
and tear and to generate new wear and tear reserves by way of
repairing (cf. DIN 31 051). Section 3.4-0051, Maintenance Intervals,
deals with all operations that can be performed on the gas turbine
including its auxiliary systems in operation or on stand-by without
impairing availability. Here, as a supplement, time sequences are
given for maintenance measures that cannot be performed unless the
gas turbine is at stand-still. Since stress on the hot items (combustion
chambers and turbine blades) is especially high, it is expedient to
base the intervals on the cumulative operating stress of these items.
All cycle times given in the following are guide values that may be
extended or shortened by up to 20 per cent depending on the site
conditions and findings of previous inspections.

Unit Maint Interval Duration (days)

1-2 Combustion Inspection 4000 10
Major Overhauling 24000 60
3-4 Combustion Inspection 3000 10
Hot Gas Path Inspection 6000 30
Major Overhauling 18000 45
9-10 Minor Overhauling 25000 10
Major Overhauling 50000 60
5-8 Combustion Inspection 7500 10
Hot Gas Path Inspection 22500 45
Major Overhauling 45000 45
11-12 Minor Overhauling 25000 10
Major Overhauling 50000 45
13-14 Combustion Inspection 4000 7
Hot Gas Path Inspection 25000 -
Major Overhauling 50000 60
15 Minor Overhauling 25000 7
Major Overhauling 50000 60

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2. EQ U I V A L E N O
T P E R A T I N GHO U R S (3 .5 – 0 0 2 2 )

Rapid changes in the turbine inlet temperature and operating periods

at gas temperatures exceeding those of base load cause additional
stresses on the hot-gas-path items. The effect of such stresses on the
service life of these items is allowed for by determining the
equivalent operating hours at base load stress. For this purpose,
various process events and operating hours in the various
temperature ranges are assigned individual factors which are then
totalled. Equivalent operating hours t ae are calculated using the
formula given below define the duration of the interval between two
major inspections.
n3
tae = a1n1 + a2n2 a+ Σ + b1t1 + b2t2
3
where
n 1 = number of start-ups a 1 = 10, factor for one start-
up
n 2 = number of rapid loadings a 2 = 10, factor for rapid
loading
n 3 = number of rapid a 3 = factor for rapid
temperature changes temperature change
t 1 = operating hours at base b 1 = 1, for base load exhaust
load temperature
t 2 = operating hours above b 2 = 4, for peak load exhaust
base load up to peak load temperature

Any start-up process at which a pronounced increase in the

measured and recorded gas temperatures indicates ignition of the
main flames is classified as a start-up (n 1 ). With automatic
recording (major inspection clock), one start-up is counted when
the speed switching value of the start-up ramp function generator
is exceeded at about 1/3 rated speed. The associated weighting
factor is a 1 =10 h, identical for all gas turbines. The same speed
switching point starts and stops counting of the operating time.

Rapid loading (n 2 = 30 MW/min) is counted on depression of the

dedicated selector switch during operation. The standard setting of
the rapid loading process in the automatic program is assigned the
weighting factor a 2 = 10 h. If the possibility of a start-up at reduced
start-up power (e.g. black start at synchronous starting) is selected
acceleration will be at an increased hot gas temperature. In terms of
additional stresses, this process is to be assessed the same as one
rapid loading.
Other process events n 3 need not be taken into account unless, due
to special requirements imposed by the load consumer (e.g. electric
smelting furnaces), the turbine is subjected to load changes the
gradients of which exceed the specified standard automatic program

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values for loading and unloading. Weighting factor a 3 for rapid

temperature changes is shown in Fig. 1 ‘Equivalent operating hours
for rapid temperature changes in the turbine’ applicable to a given
type of gas turbine. The hours for trip and load rejection are given in
Fig. 2 ‘Equivalent operating hours for Trip and Load Rejection’.
The decisive factor is the change in the outlet temperature
irrespective of the mathematical sign. Pronounced and rapid heating
and cooling will increase the maximum stress difference on the item.
Changes taking place within 10 seconds are classified as temperature
steps. As a rule, the initial and final values can be seen in the
temperature record. The temperature at trip is taken on trip initiation,
whereas the non-steady-state temperature after flame extinction is
taken as 150 °C.
The creep dependency of the hot-gas-path items, particularly of the
turbine blades, on the operating temperature is allowed for by
weighting factors b. After commissioning of the gas turbine, those
turbine outlet temperatures are determined at which the assured
base and peak loads are reached. Automatic correction of outlet
temperature ϑ AT with simultaneously measured compressor inlet
temperature ϑ VI using the formula

ϑ ATK =ϑ AT – 0.46 • ϑ VI

ensures that the turbine inlet temperature likewise remains constant

at a constant corrected turbine outlet temperature ϑ ATK .
Unless the ϑ ATK value, which is thus assigned to the base load, is
exceeded, the equivalent and actual operating hours increase
uniformly at weighting factor b 1 = 1. At higher ϑ ATK values, a reduced
blading service life can be anticipated. The major and maintenance
inspection intervals will change accordingly, since then the equivalent
operating hours accrue more rapidly than the actual operating hours.
This is calculated with weighting factor b2 = 4, by which the operating
hours t2 between base load and peak load are multiplied.
Due to the fact that the metallic parts of the flame cylinder are
protected by a lining of refractory tiles, the fuel-dependent radiant
heat of the flames has only a low impact on the metal temperatures.
Hence, equivalent operating hours are not dependent on the fuel
used, provided the fuel complies with the SIEMENS/KWU fuel
specifications.
3.1 C a lc u la tio n o f E q u iv a le n t O p e ra tin g H o u rs
Unit FO Gas HSD Trip Start
1-2 1 1 1 100 (750) 10
3-4 - 1 1.5 - 10
9-10 - 1 1 - 25

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5-8 2.5 1 2.5 - 1

11-12 1 1 1 - H=5,
W=25,
C=50
13-14 1 1 1 Max. 140 10
15 1 1 1 - 25

3 .2 E q u iv a le n t O p e r a t in g H o u r s fo r F a s t T e m p e r a tu r e C h a n g e s in
T u rb in e

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Examples a fast change from initial turbine outlet temperature of 540 °C to final turbine
: outlet temperature of 230 °C (or from 230 °C to 540 °C) is equivalent to ∆ ϑ =
310 °C. This yields
71 equivalent operating hours with open (100 %) inlet guide vanes
29 equivalent operating hours with half-closed (50 %) inlet guide vanes
8 equivalent
In case of a trip, operating
the final turbine hours
outlet with closedis(0
temperature %) inlet
about 150guide
°C. vanes
In case of load rejection with open inlet guide vanes, the final turbine outlet temperature is
about 200 °C.
In case of load rejection with closed inlet guide vanes, the final turbine outlet temperature is
about 275 °C.
3 .3 E q u iv a le n t O p e ra tin g H o u rs fo r T rip a n d L o a d R e je c tio n

Examples a trip (sudden temperature decrease) from 540 °C initial turbine outlet
: temperature corrected with inlet guide vanes open yields about 140 equivalent
operating hours.
Prepared
a by:
loadFazal-ur-Rehman Babar
rejection from the same initial temperature yields about 90 equivalent
operating hours.
a trip from about 540 °C initial temperature with closed inlet guide vanes yields
 193

Inspection Cycles at peak load and intermediate load operation

frequently, and particularly during the weekends time periods will
occur, during which the gas turbine is shut down for more than one
day. These standstills allow regular inspections without impairing
scheduled operation. Thanks to the provision of easily removable
access ports, SIEMENS/KWU gas turbines allow easy and fast
performance of inspections of the hot-gas-path items in the
combustion chamber and turbine areas largely without the need for
dismantling of combustion chambers or time-consuming endoscopy
which are otherwise required. On this basis, we recommend an
inspection interval of 4000 equivalent hours.
Special attention in the monitoring operations is given to
quantitative recording of the wear and tear in sliding joints which is
primarily caused by start-stop cycles and at locations subjected to
high temperature gradients. The more frequently such
measurements and inspections are performed, the more precise the
assessment of the maintenance efforts required at the next
extended shutdown will be. If this results in process dependent
extended shutdowns, an inspection interval of 2000 hours may be
expedient and recommendable. With liquid fuels requiring additives
or exceeding the admissible particulates content specified in
Section 3.1-0173, inspection of the fuel nozzles at intervals of 2000
hours is recommended.
If, in addition to electric energy, thermal energy is also supplied to
continuously operating industrial plants, the gas turbine inlet
temperature will ideally be constant over an extended time period.
Load changes will occur very slowly. These plants are not used for
frequency back-up control and are either not operated at peak load
at all or for less than 50 hours annually. The operational mode
described is also applicable to gas turbines that are operated
exclusively for base-load power generation. This operational mode
produces a very low detrimental impact on the gas turbine since
non-steady-state excessive temperature gradients and relative
expansions are minimized. In this case, the inspection interval may
be extended to up to 1 year.
If interruptions of operation of more than 12 hours provide the
opportunity of an intermediate inspection of the hot-gas paths, this
opportunity should be taken, provided the last visual inspection
was performed more than 2000 hours ago.

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Cycles for Hot-Gas-Path Item Servicing and Major

Inspections
Maintenance operations such as renewal of the protective surface
coating of turbine blades require opening the gas turbine casings
and removing the rotor. When work has to be performed on the
compressor and turbine blading, the moving blades can be removed
without having to disassemble the rotor. Hot-gas-path item
maintenance shall be performed at intervals of 25,000 equivalent
hours. For continuously operating plants, this results in a cycle of
three years. For plants which operate only a fraction of the time, a
cycle should not exceed 6 calendar years.

Items not in contact with the hot gas such as the rotor items
(discs, hollow shafts, tie rod) and the compressor blading for
which creep stress is of little or no importance, are subjected to
only minimal stress. Such items will not even be adversely
affected by hot gas temperature step changes and peak load
operation. After the first major inspection, the inspection interval
encompassing all items can thus be twice that of the cycle for
hot-gas-path items. The major inspection interval is therefore
50,000 equivalent hours. For continuously operating plants, this
results in a cycle of 6 years. As a rule, inspection of the above-
mentioned rotor items can additionally be limited to a few areas
which are subjected to higher loadings. If the total of all start-ups
during the following major inspection interval is expected to
exceed 3000 however, all rotor items should be subjected to non-
destructive examination. The major inspection interval of plants
in operation only a fraction of the time, where suitable counter
measures prevent standstill corrosion to a large extent, may be
extended to up to 12 calendar years.

The major inspection after 75,000 equivalent hours should be

accompanied by an investigation of the residual service life of the
item parts, since at the next major inspection interval the design
service life of the turbine blading will be exceeded.

The components in the hot gas path between the burners and the
turbine blading must be inspected at regular intervals. KWU gas
turbines use film cooling within the range of the flame tube plate
and ceramic liners in the cylindrical section of the flame tube,
and operate with relatively low stressing of the combustion
system. A periodic replacement of the hot gas path components
is thus not necessary. Being enclosed by considerably colder
outer casings, the hot inner parts between the flame tube and the
turbine move relative to each other and to the outer casing in the
sliding-motion guides provided for this purpose. A completely
uniform thermal expansion of the inner parts cannot be achieved
by design measures. For this reason, the inner parts are subject
to a certain wear due to frictional forces and low-cycle fatigue.

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The maintenance inspections are intended to keep a check on

this wear phenomenon at regular intervals (see under Intervals
for Maintenance Inspections and Major Inspections) and to
prevent its progress by suitable remedial measures. The
execution of this work is greatly facilitated by the very simple
access through manholes designed for quick opening. Direct
visual examination of all burnes, hot gas duct walls and first
stage turbine rotor and stator blades minimises manpower and
time requirements (as compared to borescope inspection or
flame tube disassembly).

Approximately eight hours after shutdown, the gas turbine on

the turning gear will have cooled down to a temperature at
which the combustion chambers can be entered without special
heat protection. During the cooling-down period, other
maintenance work on the compressor and external to the gas
turbine can be performed. In addition, the waiting period can be
considerably reduced by running up the gas turbine several
times to approximatel, 1/3 of rated speed without ignition using
the starting equipment.

Depending on the number of personnel, two to three 10-hour

shifts are required to perform the work in the hot gas duct.
Turning gear operation is only interrupted for inspection of the
turbine blading, and the gas turbine is ready for restarting
immediately after closure of the manholes.

The work should preferably be performed during an outage and

will take an average number of 50 man-hours. If the unit
operates mainly or exclusively on liquid fuel, an additional
inspection of the oil burners will normally be required. This
work, which involves disassembly of the oil burners, can be
performed in parallel with other work and requires
approximately 20 man-hours. With high wear of the injection
nozzles due to a higher contaminant content of the fuel, it may
become necessary to inspect the oil burners after half the
normal inspection interval.

The periods indicated are based on the employment of

manufacturer's experienced maintenance personnel. Following
suitable training, the maintenance inspection can also be
perforrned by the user. The accuracy required in performing the
visual examination and the correct interpretation of the findings
can however, for the extensive knowledge and experience of a
suitably qualified inspector. It is therefore recommended to
have at least this part of the work performed by the

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manufacturer. Irrespective of this requirement, the inspection

facts and remedial measures should be advised to the
manufacturer in each case and evaluated when planning the
next maintenance inspection or major inspection.

Prepared by: Fazal-ur-Rehman Babar