Appendix ICES-APL-003(d)

Main Maintenance Tasks for Alliance Compressor Fleet

(as taken from service agreement with original equipment manufacturer)
Main Maintenance Tasks

PGT25 DLE/LM2500+ DLE HSPT Maintenance Activities Frequency

Gas Turbine driven PGT25/PGT25+ Gas Turbine and
PCL type Centrifugal Compressor
PCL Compressor

GAS GENERATOR (GG)

LEVEL 1 4000 hrs or SA
Borescope Inspection
LEVEL 2 25000 hrs
Hot Gas Path Inspection
LEVEL 4 50000 hrs
Major Inspection

POWER TURBINE
LEVEL 1 4000 hrs or SA
Borescope Inspection
LEVEL 2 25000 hrs
Hot Gas Path Inspection
LEVEL 3 50000 hrs
Major Inspection

PCL COMPRESSOR
MINOR INSPECTION HGPI-S
MAJOR INSPECTION MAJ-S

GEARBOX
MINOR INSPECTION HGPI-S
MAJOR INSPECTION MAJ-S

AUXILIARY SYSTEMS

Dry gas seals system (PCL compressor)

Process gas seal filters

check Dp D-O

Primary vent orifice

check Dp D-O
check process gas flow through D-O
vent

Secondary vent orifice

check % process gas leakage D-O

Synthetic lubrification oil system

Tank
Internal painting control A-S
Dirt cleaning control MAJ-S
Piping flanges torque control MAJ-S
Thermostatic valve
Set-point control MAJ-S
Heat exchanger
Dirt cleaning control MAJ-S
Low pressure filters
Dp pressure differential control D-O
Instrumentation
Set-point control A-S

Synthetic hydraulic oil system

High pressure filters

Dp pressure differential control D-O
Instrumentation
Set-point control A-S

Mineral oil lubrication system (common for P.T. and PCL Compressor)

Tank
Internal painting control A-S
Dirt cleaning control MAJ-S
Flange piping torque control MAJ-S
Pumps
Excessive noise control M-O
Seal wear control MAJ-S
Bearing wear control MAJ-S
Electric motors
Excessive vibration control M-O
check brush wear A-S
check bearing wear A-S
Termostatic valve
check setting MAJ-S
Heat exchanger
cleaning MAJ-S
Low Pressure filters
check Dp D-O
Instrumentation
check settings A-S

Fuel gas system

Y - filter
controllo sporcamento A-S
Pressure control valve
check for leakage D-O
check wear MAJ-S
Flow control valve
check for leakage D-O
check wear MAJ-S

Stop valve
check for leakage D-O
check wear MAJ-S
Instrumentation
check settings A-S

Hydraulic starting system

Tank
check internal painting A-S
cleaning MAJ-S
check piping locking MAJ-S
Pumps
check vibrations M-O
check seals wear MAJ-S
check bearings wear MAJ-S
Electric motors
check vibrations M-O
check brushes wear A-S
check bearings wear A-S
Hydraulic consolle
check correct functioning A-S
Filters
check Dp D-O
Heat exchanger
cleaning MAJ-S
Instrumentation
check settings A-S

Intake, ventilating & anti-firing systems

Filters
check Dp D-O
Fans
check vibrations A-O
check impellers wear A-S
check bearing wear A-S
Electric motors
check vibrations M-O
check brushes wear A-S
check bearings wear MAJ-S
Automatic dumpers
check correct operation A-S
Instrumentation
check settings A-S

Oil vapours ejection system

Fan
check vibrations A-O
check impellers wear A-S
check bearing wear A-S
Electric motors
check vibrations M-O
check brushes wear A-S
check bearings wear A-S
Instrumentation
check settings A-S

Off-line washing system

Tanks
check internal painting A-S
 cleaning MAJ-S
check piping locking MAJ-S
Pump
check vibrations A-O
check seals and impellers wear A-S
check bearings wear A-S
Electric motor
check vibrations M-O
check brushes wear A-S
check bearings wear A-S
Heater
check deposits A-S
Instrumentation
check settings A-S

Control system

check settings A-S

check logics A-S

MECHANICAL INSTRUMENTATION

Pressure gauges check for damages D

Termometers check for reading errors D
Level indicators setting A

ELECTRIC INSTRUMENTATION

Pressure switches check for damages D

Temperature switches check for reading errors D
Level switches setting A
Pressure transmitters check A
Temperature transmitters check A
Level transmitters check A

HYDRAULIC & MECHANICAL

DEVICES

Safety valves check for loss D

Pressure regulating valves check correct functioning D
Non return valves settings A
Orifices check for dirt A
Filters check Dp D

Competencies
Frequency On-site activities Workshop Activities
D = daily APL
SA = Semi-Annually APL
A = annually NP/APL
HGPI = at Hot Gas Path Inspection NP/APL NP
MAJ = at Major Overhaul NP NP

O = equipment in Operation
S = equipment Shutdown
Main Operation Tasks
Competencies
Materials Task
Mineral lube oil refilling Alliance Alliance
Synthetic lube oil refilling Alliance Alliance
Off-line axial compressor washing Alliance Alliance
Cleaning & Preservation Alliance Alliance
PGT25DLE - PCL603 Trains
The following activities are envisaged :
1. Scheduled maintenance
1.1. PGT25 GAS TURBINE
1.1.1. PGT25 Gas generator (LM 2500)
The following levels of maintenance operations and checks are
envisaged :
Level 1 - every 4.000 hours of operation or every six (6) months
a) Motor housing inspection
b) Air inlet inspection
c) Filter housing inspection
d) External Turbine
inspection
e) Starting turbine
f) T 5.4 Thermocouple
g) Pressure pipes PT 5.4
h) Ignition plugs
i) Burners
j) Lube oil pump filters
k) Borescope inspection
l) Calibration of V.S.V.
m) Air pressurization system
- Oil, gas, leakage, exhaust
fumes
- Lighting
- Cleanliness
- Cleanliness
- Structural integrity check
- Cleanliness
- Structural integrity check
- Piping erosion and corrosion
- Brackets integrity
- V.S.V. lever mechanism
integrity and clearances
- Auxiliary gear box (piping racks,
oil leakage)
- Diffuser check
- Impeller check
- Check as required by operation
sheet
- Integrity check
- Integrity and erosion check
- Scheduled inspection including
rotation as reported by
operation sheet
- Cleanliness check
- Gas generator and Power
Turbine inspection as reported
by service note B11
- Relevant curve calibration
check including recalibration if
required
- Pressure values check in
accordance with operation
manual values
 Level 2 - 25.000 hours of operation

Gas generator hot section exchange - (“on condition” operation

to be performed upon evaluation of borescopic inspection
results)

Operations to be performed on site :

• Disassembling of gas generator from power turbine

• Combustion liner, 1st and 2nd stage nozzles, 1st and
2nd stage buckets replacement
• Parts reassembling
• Test run on site

Level 3 - 50.000 hours of operation

Gas generator Overhaul

Operations to be performed on site :

• Removal of the gas generator from package

• Installation of backup gas generator
• Shipment of removed gas generator to authorized
Service Shop for overhaul revision activities

Operations to be performed at the Service Shop :

• Gas generator borescoping and visual inspection. Gas

generator condition videotape recording for future
reference purposes.
• Gas generator disassembling into Gas generator
Maintenance Units (MU) such as :

∗ Compressor front frame

∗ Compressor rotor
∗ Compressor stator
∗ Compressor rear frame
∗ Combustor
∗ HPT Stage 1 & 2 nozzle
∗ HPT Rotor
∗ Turbine midframe
∗ Inlet gear box
∗ Accessory gear box
• MU disassembling into piece parts
• Piece part cleaning
• IRM (GEK 50357) part inspection
• Repair or replacement of out of specification parts
 • Replacement of all bolts, washers and nuts
• Inspection, cleaning and repair of all external hardware
in accordance with IRM prescriptions
• Reassembling of all MU’S in accordance with IRM
prescriptions, including recording of all dimensional
data.
• Final reassembling.
• LM2500 test cell facility gas generator testing.
• Emission of final report and certification.

Successive operations :

• Shipment of overhauled Gas Generator to COMPANY

site
• Reinstallation of Gas Generator on COMPANY
EQUIPMENT.

1.1.2. PGT25 Power Turbine

25.000 hours of operation - Hot section exchange

Operations to be performed on site :

• Transition piece replacement or repair

• 1st stage nozzle and 1st stage blades erosion and
corrosion check and eventual replacement, if
necessary

50.000 hours of operation - Overhaul

Operations to be performed on site :

• Power Turbine removal from package

• Installation of backup power turbine
• Shipment of the removed power turbine to authorized
Service Shop for overhaul revision activities

Operations to be performed at the Service Shop :

• Removal of internal components (assembled module)

• Reassembling and inspection of first and second stage
nozzle
• Inspection of first and second stage buckets
• Bearing inspection
• Replacement of worn parts
• Final reassembling
Successive operations :
• Shipment of overhauled Power Turbine to COMPANY
site
• Reinstallation of Power Turbine on COMPANY
EQUIPMENT
1.2. PCL602 CENTRIFUGAL COMPRESSORS

1.2.1 Minor inspection (on condition only)

Activity description

The following Minor inspection activities are envisaged for

performance in accordance with diagnostic inspection
results :

• Dry gas seal inspection

• Centrifugal compressor alignment check

Timing and manpower requirements

The following timing and manpower requirements are

required for performance of this activity on each train
composed by one compressor and one gearbox :

Timing

• Three (3) twelve hour day shifts

Shift manpower requirements

• One NP supervisor
• One NP technician

1.2.2. Major Inspection (scheduled maintenance)

Centrifugal Compressor Major inspection is scheduled for

performance in the 40,000-50,000 running hour interval.
Activity description

The following activities are envisaged for Centrifugal

Compressor Major Overhaul :

• Installation of spare bundle/rotor assembly

• Installation of spare dry gas seal cartridges
• Replacement of minor compressor components
• Gear box inspection and alignment

Timing and manpower requirements

The following timing and manpower requirements are

required for performance of this activity on each train
 composed by one compressor and one gearbox with
spare rotor/bundle set available at site :

Timing

• Six (6) twelve hour day shifts

Shift manpower requirements

• One NP supervisor
• One NP technician
• Two APL technicians

Component repair activities

• Shipment and repair of overhauled compressors rotors and

diaphragms at NP facilities.
LM2500+DLE - PCL802 Trains
The following activities are envisaged :
1. Scheduled maintenance
1.1. LM2500+DLE GAS TURBINE
1.1.1. LM2500+DLE Gas generator
The following levels of maintenance operations and checks are
envisaged :
Level 1 - every 4.000 hours of operation or every six (6) months
a) Motor housing inspection
b) Air inlet inspection
c) Filter housing inspection
d) External Turbine
inspection
e) Starting turbine
f) T 5.4 Thermocouple
g) Pressure pipes PT 5.4
h) Ignition plugs
i) Burners
j) Lube oil pump filters
k) Borescope inspection
l) Calibration of V.S.V.
m) Air pressurization system
- Oil, gas, leakage, exhaust
fumes
- Lighting
- Cleanliness
- Cleanliness
- Structural integrity check
- Cleanliness
- Structural integrity check
- Piping erosion and corrosion
- Brackets integrity
- V.S.V. lever mechanism
integrity and clearances
- Auxiliary gear box (piping racks,
oil leakage)
- Diffuser check
- Impeller check
- Check as required by operation
sheet
- Integrity check
- Integrity and erosion check
- Scheduled inspection including
rotation as reported by
operation sheet
- Cleanliness check
- Gas generator and Power
Turbine inspection as reported
by service note B11
- Relevant curve calibration
check including recalibration if
required
- Pressure values check in
accordance with operation
manual values
 Level 2 - 25.000 hours of operation

Gas generator hot section exchange - (“on condition” operation

to be performed upon evaluation of borescopic inspection
results)

Operations to be performed on site :

• Disassembling of gas generator from power turbine

• Combustion liner, 1st and 2nd stage nozzles, 1st and
2nd stage buckets replacement
• Parts reassembling
• Test run on site

Level 3 - 50.000 hours of operation

Gas generator Overhaul

Operations to be performed on site :

• Removal of the gas generator from package

• Installation of backup gas generator
• Shipment of removed gas generator to authorized
Service Shop for overhaul revision activities

Operations to be performed at the Service Shop :

• Gas generator borescoping and visual inspection. Gas

generator condition videotape recording for future
reference purposes.
• Gas generator disassembling into Gas generator
Maintenance Units (MU) such as :

∗ Compressor front frame

∗ Compressor rotor
∗ Compressor stator
∗ Compressor rear frame
∗ Combustor
∗ HPT Stage 1 & 2 nozzle
∗ HPT Rotor
∗ Turbine midframe
∗ Inlet gear box
∗ Accessory gear box
• MU disassembling into piece parts
• Piece part cleaning
• IRM (GEK 50357) part inspection
• Repair or replacement of out of specification parts
 • Replacement of all bolts, washers and nuts
• Inspection, cleaning and repair of all external hardware
in accordance with IRM prescriptions
• Reassembling of all MU’S in accordance with IRM
prescriptions, including recording of all dimensional
data.
• Final reassembling.
• LM2500 test cell facility gas generator testing.
• Emission of final report and certification.

Successive operations :

• Shipment of overhauled Gas Generator to APL site

• Reinstallation of Gas Generator.

1.1.2. PGT25+ Power Turbine

25.000 hours of operation - Inspection of inner casing

Operations to be performed on site :

• Inner casing disassembling

• Transition piece, nozzles and buckets inspection
• Inner casing reassembling

50.000 hours of operation - Hot Section Exchange

Operations to be performed on site :

• Inner casing disassembling

• Transition piece replacement or repair
• Nozzle and buckets erosion and corrosion inspection
check
• 1st stage nozzle, 1st stage and 2nd stage buckets
• Inner casing reassembling
1.2. PCL802 CENTRIFUGAL COMPRESSORS

1.2.1 Minor inspection (on condition only)

Activity description

The following Minor inspection activities are envisaged for

performance in accordance with diagnostic inspection
results :

• Dry gas seal inspection

• Centrifugal compressor alignment check

Timing and manpower requirements

The following timing and manpower requirements are

required for performance of this activity on each train
composed by one compressor and one gearbox :

Timing

• Three (3) twelve hour day shifts

Shift manpower requirements

• One NP supervisor
• One NP technician

1.2.2. Major Inspection (scheduled maintenance)

Centrifugal Compressor Major inspection is scheduled for

performance in the 32.000 to 40.000 running hour
interval.

Activity description

The following activities are envisaged for Centrifugal

Compressor Major Overhaul :

• Installation of spare bundle/rotor assembly

• Installation of spare dry gas seal cartridges
• Replacement of minor compressor components
• Gear box inspection and alignment

Timing and manpower requirements

 The following timing and manpower requirements are
required for performance of this activity on each train
composed by one compressor and one gearbox with
spare rotor/bundle set available at site :
Timing

• Six (6) twelve hour day shifts

Shift manpower requirements

• One NP supervisor
• One NP technician
• Two APL technicians

Component repair activities

• Shipment and repair of overhauled compressors rotors and

diaphragms at NP facilities.
Tornado DLE - PCL504 Trains

The following activities are envisaged :

1. Scheduled maintenance

1.1. TORNADO DLE GAS TURBINE

’A’ Class Inspection one year or 8000 hours service

Parameters Operation

1.0 - Pre-shutdown:

*Record operating parameters Record

*Carry out vibration survey Record
*Check for fuel/oil/air leaks Check
*Check air to drain valves Check
*Check VSB’s Check
*Check filters (red or green) Check
*Check pumps and motors for noisy Check
operation
*Check fuel operating pressures Check
*Check fuel changeover Check

2.0 - Shut turbine down

*Check shutdown sequence Check

*AC Pump Check Operation
*DC Pump Check Operation
*Hot/Cold crank wash Check operation
and monitoring
3.0 - Isolate
3.1 Mechanical Checks:
*Check/change filters Mandatory
change
*Borescope turbine Video record
*VSB Check operation
and movement of
unison ring
*Gas slam shut valve Check operation
*Gas demister On-condition
check
*Ignition retraction unit Check operation,
*Gas/liquid fuel valves Function check
*Manual shut-off valves Function check
*Flame traps Check pressures
*Offskid block/vent valves Function check
*BOV On condition
check
*Auto drain valves Function check
*Grease Bearings Supervise
customer’s staff

3.2 Electrical Checks

*Check batteries/charger Check charging
rate, electrolyte
levels
*Check Igniters Function check
*Check solenoids Function check
*Check TCM Function check
*Check thermocouples Function check
*Check RTD’s Function check
*Thermocouple calibration check Check
*Tmax setpoints Record, compare
to data plate
*VIGV Function check
*Vibration equipment Check operation
*Pressure switches Function check
*Temperature switches Function check
*Check Emergency stop buttons Check
*DC Pump circuit Function check
’B’ Class Inspection (work carried out in addition to ’A’
Class work)
every 24,000 hours or three years

*Gas Generator inspection Change bearings,

replace fasteners
- fixings, take
blade samples

*Hot gas path components Inspect

*Calibration of Electrical devices Record on

instrument sheet

Torque Converter/Hydrostart/Gearbox

*Torque converter Overhaul

*Hydrostart Overhaul
*Gearbox (auxiliary) Replace roller
bearings

’C’ Class inspection (work carried out in addition to ’B’

Class work)
every 48,000 hours or six years

*Service Exchange Core Engine Remove

customers core,
replace with S.E
Core,
recommission

*Gearbox (main) Overhaul

*Calibration of Electrical Devices Record on
Instrument Sheet

____________

Note 1: The above workscope could be amended as a result of

field/operating experience and the mechanical integrity
of the equipment.
Note 2: The Boroscope and Hot/Cold Crank Wash will be
completed approximately 1,000 hours prior to each
inspection wherever possible.
1.2. PCL504 CENTRIFUGAL COMPRESSORS

1.2.1 Minor inspection (on condition only)

Activity description

The following Minor inspection activities are envisaged for

performance in accordance with diagnostic inspection
results :

• Dry gas seal inspection

• Centrifugal compressor alignment check

Timing and manpower requirements

The following timing and manpower requirements are

required for performance of this activity on each train
composed by one compressor and one gearbox :

Timing

• Three (3) twelve hour day shifts

Shift manpower requirements

• One NP supervisor
• One NP technician

1.2.2. Major Inspection (scheduled maintenance)

Centrifugal Compressor Major inspection is scheduled for

performance in the 32.000 to 40.000 running hour
interval.

Activity description

The following activities are envisaged for Centrifugal

Compressor Major Overhaul :

• Installation of spare bundle/rotor assembly

• Installation of spare dry gas seal cartridges
• Replacement of minor compressor components
• Gear box inspection and alignment
Timing and manpower requirements

The following timing and manpower requirements are

required for performance of this activity on each train
 composed by one compressor and one gearbox with
spare rotor/bundle set available at site :
Timing

• Six (6) twelve hour day shifts

Shift manpower requirements

• One NP supervisor
• One NP technician
• Two APL technicians

Component repair activities

• Shipment and repair of overhauled compressors rotors and

diaphragms at NP facilities.