Welcome to:

Frame 6
Outage Planning
&
Outage Issues
By: Charlie Pond

Pond And Lucier Engineering

 Todays Topics
Job scope Analyze Upgrades
Start Date Common problems
Parts list Pre-outage Borescope
Order parts early Pre-outage Data
How to perform
outage Perform tasks early
Planning, use CPM, Collect special tools
then Brainstorm IGV Inspection & Upgrades
Shorten critical tasks Writing the RFQ
Analyze TILs

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 Step 1
Decide on job scope & date

Combustion inspection
Hot Gas Path Inspection
Major Inspection
Generator Inspection
System Maintenance
Plan well in advance for your budget

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 Make a spare parts list
Fuel nozzles
Cross fire tubes & retaining clips
Combustion liners
Gaskets
New Fasterners
Etc. etc. etc

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 Typical parts list
ALL QT UN NAME DWG MCPC DWG
HOT GAS 10 EA 600lB TRANS PIECE DWG: 101E2572G001 MCPC DWG: ML0702
COMBUSTION
10 EA 600lB TRANS PIECE DWG: 101E2572G001 MCPC DWG: ML 0702
MAJOR 10 EA 600lB TRANS PIECE DWG: 101E2572G001 MCPC DWG: ML 0702
MAJOR 1 EA SEAL AIR DWG: 114A3576G001 MCPC DWG: ML 0801 0007
MAJOR 2 EA STUD BB DWG: 114A3644P002 MCPC DWG: ML 0812 0011
Operational 24 EA FILT CART DWG: 114A3786P003 MCPC DWG: ML 1053
Operational 2 EA VLV SOLEN DWG: 114A8218P034 MCPC DWG:ML 1019
COMBUSTION
10 EA TPBULLHORN MS6001 DWG: 149D2914G002 MCPC DWG: ML 0717 0003
CAPITAL 64 EA BLD STA IGV 6001 450 DWG: 151D8781P001
MAJOR 1 EA BRG DEFL#1 DWG: 154D7145G001 MCPC DWG: ML 0801 0002
Operational 1 EA RELAYHYTRP DWG: 155C1645G003 MCPC DWG ML 0544 0001 0054
MAJOR 2 EA STUD-BB DWG: 156A1591P014 MCPC DWG: ML 0805 0014 0010
MAJOR 2 EA STUD BB DWG: 156A1591P020 MCPC DWG: ML 0802 0005
HOT GAS 2 EA SPKPG TERM DWG: 158A3479P023 MCPC DWG: 1214 0006
COMBUSTION
2 EA SPKPG TERM DWG: 158A3479P023 MCPC DWG: ML 1214 0006
MAJOR 2 EA SPKPG TERM DWG: 158A3479P023 MCPC DWG: ML 1214 0006
MAJOR 4 EA STUD DWG: 158A4647P001 MCPC DWG: ML 0706 0001 0024
MAJOR 1 EA STUD-BB DWG: 158A4647P002 MCPC DWG: ML 0705 001 061 008
MAJOR 1 EA STUD DWG: 158A4647P008 MCPC DWG: ML 0705 001 061 003
MAJOR 56 EA GASKET DWG: 158A7685P004 MCPC DWG: ML 1614 0054
MAJOR 1 EA GASKET DWG: 158A7685P038 MCPC DWG: ML 1614 0052
MAJOR 1 EA GASKET DWG: 158A7685P039 MCPC DWG: ML 1614 0053
MAJOR 128 EA BUSHING DWG: 158A7888P002 MCPC DWG: ML 0811 0011
MAJOR 1 EA BRG SEAL#1 DWG: 164C2807G003 MCPC DWG: ML 0801 0004
MAJOR 1 EA BRG THRUST MS6001 DWG: 164C2817G002 MCPC DWG: ML 1507 0003
MAJOR 1 EA BRG DEFL#2 DWG: 164C2819P001 MCPC DWG: ML 1502 0003
MAJOR 2 EA BRG SEAL#2 DWG: 164C2822G003 MCPC DWG: ML 1502 0004
HOT GAS 10 EA NOZZLE TIP DWG: 169D3414G004 MCPC DWG: ML 0512 0002

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 To order parts, you must
understand the GE system.

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ML = Model List number

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 Make list of expendables
Rags Prussian blue
Duct tape Parts cleaner
Plywood
Tarps
Rope
Anti-seize compound
Permatex
Silicone

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Compare parts lists to inventory
and order parts as early as
possible to save money!

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How do you know how much to
spend?
Where do I draw the line?

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 It all depends on your situation
Some parts have life limits and are scrapped
Refinery running 24-7 (Have all spares)
Petrochemical compressor drive, 24-7 (Have all spares)
Peaking plant 100hrs/yr. (Minimize spares)
Peaking plant 1000hrs/yr. (Balance spares vs. profits or value)
Black start (Testing is the acid test! Not spare parts)
Does the turbine make loads of money? (Have all spares)
Special lucrative contract
Lucrative Steam host

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How should you perform the outage?
LTSA (Most expensive)
Turn Key
(Less expensive, but beware of short cuts)
Hire TA & Labor separately.
TA ensures quality & monitors extra work
In House Overhaul Process (IHOP) NEW !
Train in house staff just before the outage
Man job with TA and MA
Huge savings are realized ($250K-$500K)
Workers take pride in their turbine
You know the unit is 100% perfect

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 Planning the job
Use the Critical Path Method CPM

Microsoft Project 2000

Primavera

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CPM for combustion Inspection

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 Analyze your CPM and
brainstorm on ways to shorten
the total length of the job
More manpower
More tools or special tools (high-torque)
Perform tasks in advance
Study complicated tasks in advance
Label parts in advance
Identify bolt sizes & wrenches in advance
Make shipping crates in advance
Organize all key drawings in advance
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TASK TIME HOW CAN WE MAKE IT SHORTER?
JOB START 1 min
Mobilize 4 days Mobilize as much as possible before JOB START
Install winch and 220 a/c 10 hrs Install before JOB START
Take shutdown data 4 hrs Take data before JOB START
Shutdown 4 hrs Plan the routine in advance. Try NOT to run this just prior to outage.
Tag out unit 2 hrs Have tags prepared in advance. Get photos of Robin & Skip for tags
Label all tubing,piping,nozzles, cans 4 hrs Label before JOB START tags must be heat resistant in case you run
Disable Co2 1 hr Study how you will do this before JOB START to avoid wasting time
Blank off fuel 1 hr Study how you will do this before JOB START to avoid wasting time
Cool down 6 hrs Crank unit for force cool.
Safety meeting 1 hr Hold meeting in advance so that this can be a review and not a full meeting
Rem nozzle piping & tube 20 hrs Have everything labeled in advance, have multiple air tools and wrenches, have gofer to lay down piping
Remove Spark Plugs 1 hr Label bolt size in advance and mark
Remove Flame Detectors 1 hr Label bolt size in advance and mark
Rem fuel nozzles & fwd can 30 hrs Label bolt size in advance and mark
Separate nozzles from fwd can 10 hrs Label bolt size in advance and mark. Make jacking bolts in advance.
Rem liners & x-fire tubes 10 hrs Make the special liner pulling tool or purchase or borrow.
Rem flow sleeves 5 hrs Have multiple sets of wrenches and do 2 or more at once
Rem Outer x-fire tubes 20 hrs Have multiple sets of wrenches and do 2 or more at once
Rem aft cans 20 hrs Label bolt size in advance and mark
Rem access covers 4 hrs Have multiple sets of wrenches and do 2 or more at once
Rem Transition pieces 30 hrs Have multiple sets of wrenches and do 2 or more at once
Pack & Ship Nozzles 10 hrs Have boxes made in advance
Ship Liners & x-fire tubes 5 hrs Have boxes made in advance
Pack & Ship Transition Pieces 10 hrs Have boxes made in advance
Service spark plugs 10 hrs Have a spare set ready to go
Service flame detectors 10 hrs Have a spare set ready to go
Inspect first stage nozzle 1 hr
Drill out broken bolts 20 hrs Have multiple drills and taps, try to avoid breaking by using torch
Clean bolts 20 hrs Have new bolts ready & have multiple wire wheels & apply anti-seize in advance. Use spray nickel-eze
Clean flanges 10 hrs Have multiple sets of wire wheels and do 2 or more at once
WAIT FOR PARTS TO BE REPAIRED 5 wks Plan in advance. Get a reservation at service shop. Pick vendor on delivery date NOT price.
Receive Transition pieces 1 hr Use cordless drill to unscrew boxes, do 2 or more boxes at once.
Receive Liners & x-fire tubes 1 hr Use cordless drill to unscrew boxes, do 2 or more boxes at once.
Receive Fuel nozzles 1 hr Use cordless drill to unscrew boxes, do 2 or more boxes at once.
Install Transition pieces 30 hrs Make sure service shop uses a fixture to avoid fit up problems, have guide pin ready, do 2 at once
Install access covers 4 hrs Label bolt size in advance and mark, bolts pre-prepped, multiple impact wrenches & sockets
Install aft comb can 20 hrs Label bolt size in advance and mark, bolts pre-preped, multiple impact wrenches & sockets
Install flow sleeves 10 hrs Install 2 or more at once
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 Analyze

Technical Information Letters

(TILs) and decide which TILs

to do, skip or postpone.

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MS-6001 TILs
(Partial list)

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Analyze upgrades and decide
which to do or skip.

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Reference GER-4217A GE 12/2003

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OUTPUT Improvements

Reference GER-4217A GE 12/2003

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HEAT RATE Improvements

Reference GER-4217A GE 12/2003

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 Be careful.

If you have a Heat Recovery

Steam Generator you might
shoot yourself in the foot.

Some upgrades reduce exhaust

heat and others increase exhaust
heat mass flow.
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Upgrades vs. Exhaust Energy

Reference GER-4217A GE 12/2003

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Steam Injection (Better heat rate & NOx)
vs.
Water Injection (Higher output)

Reference GER-4217A GE 12/2003

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 IGV Upgrades
Material
Angle
Upgrade to High flow GTD-450 vs. 403ss (FT4C)
1.5% Output increase
.3% Heat rate decrease
Can be changed with rotor in place!
Increase vane angle from 84 to 86(or 87)
Increases MW output
Can increase bushing wear

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 2084 Upgrade

Reference GER-4217A GE 12/2003

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 Common Frame 6 issues
Bucket failures ~40,000 hours
Transition Piece failure ~40,000 hours
Nozzle cooling air tuning plugs
Nozzle creep

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 Bucket Life Extension
Buckets can be stripped & recoated IF
they meet some very stringent
requirements.
Review applicable TILs
Bucket suitability cannot be determined by
external NDT inspection
Must conduct cut-up of at least one bucket and
conduct metallurgical evaluation
Must use qualified lab who understands alloy,
buckets, and creep evaluation

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Pond And Lucier Engineering
Nozzle Tuning Pins

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Borescope BEFORE the outage
This will help you budget (healthy or sick Turbine)
This will help you schedule (healthy or sick Turbine)
You can save thousands on repairs
Know in advance the problems to correct
You may decide to perform the outage sooner
You might even be able to postpone the outage

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 Analyze data in advance !
Tx vs. Pcd (is calibration correct?)
1030

1020

1010

1000
Exhaust Temp (F.)

990

980

970

960

950

940
0 20 40 60 80 100 120 140
Compressor Inlet Temperature (F.)

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 Analyze data in advance !
MW vs. Pcd (is the turbine healthy?)
MW vs Ambient

50

48

46

44

42
Mega Watts

40

38

36

34

32

30
0 20 40 60 80 100 120 140
Ambient Temperature

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 Analyze data in advance !
This will be a great benchmark to compare
the unit AFTER the outage.

Contract should state no loss in

performance

Upgrades should have a guarantee

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 Do all you can in advance
Have parts, expendables, cribbing on site
Special tools
Load gear Centering ring
Nozzle pulleys
X-mas tree
Precision measuring instruments
Coupling jacking bolts
Turbine support jacks and stands
Special rigging
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 Variable Inlet Guide Vanes
They have become a big maintenance item
Numerous TILs

High flow IGVs can be a good upgrade

Increase Output 1.5%

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CHECK TILS FOR DETAILS
421 COVER DRAINAGE MOD
511 CRACK INSPECTION
515 CRACK INSPECTION
517 IGV SEIZING
522 CRACK INSPECTION
532 CRACK INSPECTION
1013 CRACK & BUSHING INSPECTION
1041 SUMMARY OF TILS
1068 BUSHING WEAR INSPECTION
1132 THRUST WASHER INSPECTION

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 WORN BUSHINGS
New style CHEMLOY bushings are extremely
soft.
They never bind, but wear out much faster than
old style.

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 Bushing Wear
TIL 1068

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 TIL 532
Failures occurred at 25-30,000 hrs.
Inspect now and re-inspect @ 4000 hrs

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EXCESSIVE GEAR BACKLASH
After many years Rack &
Pinion gears can get
worn which causes
backlash.

Shim rack gear for 5-10

mils clearance

40 mils maximum
backlash

You can rotate gear for

new teeth

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 40 mils max backlash

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 UPGRADING TO THE HIGH
FLOW IGV
New style IGVs are
made of a stronger
material, C-450.
This allows the cross
section to be smaller
Reduced cross
section increases
airflow and thus,
power output
Old vanes 403-ss or
316-ss

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CHANGING THE LOWER HALF
IGVs
Changing lower half
IGVs requires
removing rotor due to
limited access (2)

Rotor removal
requires a Major
Overhaul costing
$250,000 or more

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 A MAJOR Breakthrough !
Using special tools &
processes, it is now
possible to change
the lower half IGVs
with the rotor IN
PLACE !

This avoids the major

overhaul and thus
saves several
hundred thousand
dollars!
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We have covered all of the following
What is the last step?

Job scope
Start Date Common problems
Parts list
Pre-outage Borescope
Order parts early
Pre-outage Data
How to perform
outage Perform tasks in early
Planning, use CPM, Collect special tools
then Brainstorm IGV Inspection & Upgrades
TILs
Upgrades
Pond And Lucier Engineering
 The Final Step
Writing the Request For Quote
Include all of the normal stuff
Spell out what IS included
Spell out what IS NOT included
Demand quality
Torque bolts
Stone joints
Instrumentation must function (ws, bentley)
Avoid extra work charges
Alignment, Broken bolts, Helicoils, Cleaning
parts, Stoning Joints, Is Not an extra!
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 Summary
Job scope Analyze Upgrades
Start Date Common problems
Parts & expendables Pre-outage Borescope
list Pre-outage Data
Order parts early Perform tasks early
How to perform
Collect special tools
outage
Planning, use CPM, IGV Inspection & Upgrades
then Brainstorm Writing the RFQ
Shorten critical tasks
Analyze TILs
Pond And Lucier Engineering
 Questions ???
OR
Do you have More Input for your
esteemed colleagues?

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 Thank You !
For further questions contact
Charlie Pond at:

913-220-5316

www.pondlucier.com
Pond And Lucier Engineering