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Part 1 - Development of a Maintenance strategy.

Here is a sample maintenance work division strategy , i am giving a overall top


down view.
External Maintenance personnel
a. Turbine over haul and static testing
b. Generator overhaul and static testing
Internal Maintenance Personnel
a. Field maintenance personnel
i. Plant isolation and blinding
ii. Cleaning and relinquishing of filters , heat exchangers ,
pipelines , insulation etc
iii. control valves , mechanical valves , MOv's servicing
iv. Off line leak arresting , replacment of damaged parts , hot
works like cut and weld jobs in field
b. Rotary Maintenance personnel
i. PM check / refrubrishing / replacement of all axillary pumps
, fans , blowers compressors
ii. co ordination with the Turbine overhaul group
c. Instrument Maintenance personnel
i. Check and calibration of all required field instrumentation
like , pressure transmitters , pressure switches , Temperature transmitters ,
temperature switches , Level transmitters , level switches etc ...
ii. safe removal and isolation of instrument points in Turbine
compartment area
iii. PM check of control system healthiness
iv. work on additional instrumentation points to be provided as
per operational requirement
d. Electrical Maintenance Personnel
i. Safe isolation of axillary drives and electrical points in
the turbine compartment area
ii. PM checks of all axillary drive motors
iv. PM check on Plant HT and LT switch gear
v. PM check on generator and switch gear relays
a. Blind list
d/s of isolation valve after Fire shut off valve
Steam shut off Valve d/s flange(at turbine compartment)
DM water inlet to atomizing cooler valve D/s( acc.comp outside)
DM water outlet from atomizing cooler valve D/s( acc.comp
outside)
4th stage extraction lines ( both side)
10th stage extraction lines to wheel space cooling lines ( both
side)
Atomizing air take off line after the buttervalve
Bearing seal air line
Running GT water wash line
Turbine water wash line
On line water wash line
Both ignitors to be removed & dummy to provided
b. Mechanical Isolation list
Cooling water Inlet ( Pipe rack)
Cooling water Outlet(Pipe rack)
Atomizing air inlet( Acc comp.outside)
Atomizing air outlet(Acc.Comp. Outside)
Warren pump cooler inlet
Warren pump cooler outlet
Discharge at Fuel line ( Quell)
Naptha tank to GT take off valve
Recirculation valve for incoming naptha line
Naptha and HSD Pump 1 suction & discharge
Naptha and HSD Pump 2 suction & discharge
Common discharge header isolation valve
Pump Recirculation line valve

long recirculation line valve


c. Main Job list
GT Fuel change over three-way valve to be serviced/changed.
LO cooler CW inlet & outlet piping modification valve
handlesfixing
Compressor Washing system blinding to be done (separate list
given)
CO2 cylinders house door to be properly fixed in zone-1 &2
Lube oil coolers to be cleaned(2 numbers)
Warren pump lube oil cooler to be cleaned
DM water cooler to be cleaned (Exchanger)
Diesel engine water cooler to be cleaned
Generator air coolers to be cleaned( 5 nos)
Atomizing air cooler to be cleaned
50 microns Naphtha filter elements to be cleaned/replaced.(2
nos)
10 microns Naphtha/25MIC HSD filter elements to be
cleaned/replaced.
6 microns Naphtha/HSD filter elements to be cleaned/replaced.(2
nos)
OFF base
5-micron fuel final filter elements east side to be
replaced
OFF base
5-micron fuel final filter elements west side to be
replaced.
On base
5-micron fuel final filter element to be checked &
/replaced.
Naphtha coalescent filter to be replaced (2 nos)
Off base skid entrance fuel line 'Y' type strainer to be
cleaned.
Both Hi Tec Pump suction strainers to be cleaned.
DM circulation pump Suction strainers to cleaned.(2 nos)
Water wash pump suction strainer to be cleaned
Air intake filter elements to be cleaned/replaced(360 nos)
Self cleaning system pre/after filters to be cleaned/replaced
Comp. air bleed of valve air line filter to be cleaned/replaced
Turbine Hall Air Handling Unit filters to be cleaned.
Forwarding pump #1(nap) short re circulation View glasses
cleaning
Forwarding pump #2(nap) short re circulation View glasses
cleaning
Forwarding pump long re circulation View glasses to be cleaned
Self-cleaning system driers alumna balls to be
checked/replaced.
Boost air comp. D/s NRV to be checked.
Both Hi -Tech Pumps NRV to be checked.
Cooling water inlet and outlet main valves to be serviced
DM water cooler inlet and outlet valves to be serviced
Fuel forwarding area fuel lines valves are to be serviced
Rotary Maintenance work list
a. Main Job List
Accessory compartment vent fan #1 PM checks to be done
Accessory compartment vent fan #2 PM checks to be done
Turbine compartment vent fan #1 PM checks to be done
Turbine compartment vent fan #2 PM checks to be done
Load gear compartment vent fan #1 PM checks to be done
Load gear compartment vent fan #2 PM checks to be done
Off base skid vent fan #1 PM checks to be done
Off base skid vent fan #2 PM checks to be done
Lube oil mist fan#1 PM checks to be done
Lube oil mist fan#2 PM checks to be done
Diverting damper seal air fan#1 PM checks to be done
Diverting damper seal air fan#2 PM checks to be done

Guillotine damper seal air fan#1 PM checks to be done


Naphtha scavenging fan PM checks to be done
Cooling tower fan #1 PM checks to be done
Cooling tower fan #2 PM checks to be done
Off base fuel forwarding pump (IMO) PM checks to be
done.
Warren AOP PM
Warren EOP PM
Main Lube oil
Main Lube oil
Main Lube oil

checks to be done
checks to be done
AOP PM checks to be done
EOP PM checks to be done
pump (main shaft driven) PM checks to be

done
Auxiliary Hydraulic Oil Pump (AHOP) PM checks to be
done
Hydraulic Oil Pump (main shaft driven) PM checks to be
done
Ratcheting pump PM checks to be done
Booster air compressor PM checks to be done
Main air compressor PM checks to be done.
Naphtha forwarding pump #1 PM checks to be done.
Naphtha forwarding pump #2 PM checks to be done.
Hitech (Lubricity additive) Pump #1 PM checks to be
done
Hitech (Lubricity additive) Pump #2 PM checks to be
done
DM Water circulation pump #1 PM checks to be done.
DM Water circulation pump #2 PM checks to be done.
Cooling Water circulation pump #1 PM checks to be done.
Cooling Water circulation pump #2 PM checks to be done.
Cooling Water circulation pump #3 PM checks to be done.
Hydraulic oil filter # 1 elements inspect/change to be
done
Hydraulic oil filter # 2 elements inspect/change to be
done
Trip oil filter #1 elements inspect/change to be done
Trip oil filter #2 elements inspect/change to be done
Main oil filter #1 elements inspect/change to be done
Main oil filter #2 elements inspect/change to be done
Lube oil cooler c/o valve pad to be fixed.
Lube oil filter c/o valve pad to be fixed.
Warren pump LO fileter to be replaced.
Off base Moog valve last chance filter to be changed
ON base Moog valve last chance filter to be changed
IGV last chance filter to be changed
oil mist demister pad to be checked/replaced
Main fuel shut off valve drain line plunger to be
checked/changed
ON base flow divider o/l fuel line ferrule and line to
be changed
OFF base area to be cleaned
ON base floor area to be cleaned.
Main Lube oil changing ( SERVO PRIME 32 T) to be done
Lube oil tank cleaning to be done
Naptha purge drain tank pump-1 PM to be done
Naptha purge drain tank pump-2 PM to be done
HSD false start drain tank pump-1 PM to be done
HSD false start drain tank pump-2 PM to be done
InstrumentionMaintenceWorklist
a. Switches/ control valve/ SOV to be checked/serviced/calibrated
HYD. Supply pressure low
63 HQ-1
3 way valve Sictch (HSD)
33TDD
L20FTX1

3 way valve Sictch (Naphtha)

33TUC

ON Base selection
OFF base selection
Warren pump LO Ac

33 VM-1
33 VM-2
88 QA-2

L20FTX1
Motor

L4QAZ2
Warren pump LO DC motor

88QE-2

Warren pump Lo Pressure switch(SUPPLY)

63 QA-4A, 4B

Warren pump Lo Pressure switch(RETURN)

63 QA-3

Diesel engine lube oil pr. Switch


Diesel engine speed switch

63 QD-1
88 DS-1

Hyd.

88 HR-1

L63QAEOP
63QA-4
63QA-3
63DM1
Ratchet Pump motor start

L20CSX
Seam injection darin valve-1

33BS-1

Seam injection darin valve-2

33 BS-2

Seam injection darin valve-3

33 BS-3

Steam injection control valve


Steam injection Stop valve

33 CJ-1
33 SJ-1

L20BS1X
L20BS2X
L20BS3X
L20SJ1X
steam injection Flow transmitter96 SJ-1
steam injection Flow transmitter96 SJ-2
Main lube oil AOP auto start
63 QA2
63QA-2
Main lube oil EOP auto start

63 QT-2A

63QT-

2A
63QT-2B
63QT-2B
Main lube oil Temp. switches

26 QT1A

26QA-1
26 QT1B
26QT-1A
26 QA1
26QT-1B
warren pump lube oil temp

26 QT-3

comp. Bleed off valve-1


Comp. Bleed off valve-2
Inlet air DP switch

L33 CB1O
L33 CB2O
63 TF-2A
63 TF-2B

26QT-3

2A
63 TF-1
63TF-2B
Exhaust High pressure

63 ET-1

Exhaust High pressure

63 ET-2

OFF line wash -Comp


Off line wash-Turbine
On line water wash
Combustion chamber false start darin
Exhaust Plenum False start darinVA-17-5

20 TW-1 SOV
20 TW-2
20TW-3 SOV
VA-17-1

63 EA-1
63 ET-1,2

b. TRIPS/alarms to be checked
description
Field Switch no
Flame failure Trip
28FD-7, 28FD-8

Mark v Tag no
L28f DT

33CB1O
33CB2O
63TF-1
63TF-

Exhaust spread High trip


L30SPT5
Exhaust Gas temp.High trip
Trip oil Pressure Low trip
63 HL-1,63 HL-2, 63 HL-3
Lube oil Supply Temp.High trip
26 QA-1,26QT-1A, 26QT-1B
Over Speed trip
77NH-1, 77NH-2, 77NH-3
Lube oil. Pressure low
66 QA-2,63 QT-2A,63QT-2B
Exhaust Gas Pressure High trip
63 EA-1, 63 ET-1,63 ET-2
Vibration High trip
39 V-1A,1B,39V-3A,3B,39V-4A,4B,39V-4D,4E,4F, 39 V-5A,5B
Customer Trip
On Base Liquid Fuel Suppy PR. Low
63FL-2A
OFF Base Liquid Fuel Suppy PR. Low
63 FL-2B
Warren pump Lube oil pr. Low
63 QA-3,63 Qa-4
Warren pump Lube oil Temp.High trip
26 QT-3
IGV Control trouble trip
L41 GVT
Turbine Air inlet Filter DP HighL63TFH
1,63 TF-2A,63 TF-2B

L86TXT
L63HLL
L26QT
L12H
L63QTX
L63ETH
L39 VT
L4 CT
L63FL2A Z
L63FL2B Z
L63 QAT
L26QT3
63 TF-

c. Gas monitors to be checked / calibrated


Acc. Comp
45 HA-1,2
Turbine comp
45 HT-1,2
Off base skid
45 HFS-1,2
Off base skid 45 HFS-3
Turbine comp
45 HT-3
Acc. Comp
45 HA-3
d. Fire Protection system sensors/solenoid/switches to be checked /
calibrated
Fire protection -CO2 release solenoid valve
45 CR-1to6
Fire protection Co2 - release Pr. Switch 45 CP-1to6
Fire alarm bell
LS2-1
fire Detector - ACC. Comp
45 FA-1A
45 FA-1B
45 FA-2A
45 FA-2B
fire Detector - Turbine. Comp
45 FT-1A
45 FT-1B
45 FT-2A
45 FT-2B
fire detector - Exhaust Comp
45 FT-8A
45 FT-8B
fire detector - Exhaust Comp
45 FT-9A
45 FT-9B
Fire Detector - OFF base fuel skid
45 FL-1A,2A
Electronic Hooters
EH-1to4
Emergency push buttons
EPB-1to6
e. Additional Job list
Nox steam inlet line first and second valves to be serviced
Nox steam inlet line both flow meters to be checked
Naphtha control valve tuning and stroke check to be done
HSD control valve tuning and stroke check to be done
Atomizing air temperature control valve to be serviced
Self cleaning system SOV 's in south & north bank to be checked
ON-BASE & OFF-BASE MOOG valves to be calibrated.

Electrical Maintenance work List


a. Electrical Maintenance isolation
AOP
AHOP
Warren AOP
ACC. Comp vent fan-1
ACC. Comp vent fan-2
Tur. Com.vent fan-1
Tur. Com.vent fan-2
Load gear comp.vent fan-1
Load gear comp.vent fan-2
Off base comp.vent fan-1
Off base comp.vent fan-2
Mist eliminator fan-1
Mist eliminator fan-2
Naphtha scavenging fan
Lube oil centrifuge
I
MO pump
Naphtha pump-1
Naphtha pump-2
DM water pump-1
DM water pump-2
Hitec pump-1
Hitec pump-2
Space heater ( to be switched on )
DD SAF-1
DD SAF-2
GD SAF
GD/GFD activator gates
Ignitors (110 AC)
Off line water wash SOV TW-1(110V AC)
Tur water wash SOV TW-2(110AC)
ON line water wash SOV TW-3(110VAC)
NAP/HSD fuel C/O valve 230VAC
I/L air filter valve 230V AC
Air processing skid JB 230V AC
FCBC-1 For 125 V Bus & connected load Jobs
FCBC-2 For 125 V Bus & connected load Jobs
EOP
Warren EOP
Ratchet motor
DE starter motor
MARK-5 ( before switching off ensure all oil pumps & fans of GT
are in isolated condition) for all compartments Hot workJobs
HSD false start drain tank pump-1(GT-2)
HSD false start drain tank pump-2(GT-2)
Naptha purge drain tank pump-1(GT-2)
Naptha purge drain tank pump-2(GT-2)
Water wash pump
Water wash detergent pump
Water wash heaters
b. ELectrical PM check and refurbishment
Gen Main breaker
AVR
Gen transformer- PT& CT checking
Transformer Cooling fans
SAT
HRSG MCC
GT MCC
PCC C/o
GT MCC C/o
HRSG MCC C/o
125 V DC FCBC1

125 V DC FCBC2
IMO pump
Aux lube oil pump
Lube oil DC pump
Aux. HYD Oil pump
Warren Lube oil AC Pump
Warren Lube oil DC Pump
Naphtha Pump-1
Naphtha Pump-2
DM pump-1
DM Pump-2
Hi-Tech Pump-1
Hi-Tech Pump-2
Diesel engine staring motor (DC)
Ratchet Motor(DC)
Naptha purge drain tank pump-1
Naptha purge drain tank pump-2
HSD false start drain tank pump-1
HSD false start drain tank pump-2
Aux comp-1
Aux.comp-2
Tur. Comp-1
Tur. Comp-2
Load gear comp.-1
Load gear comp-2
Off base skid-2
Oil mist eliminator-1
Oil mist eliminator-2
Naphtha Scavenging fan
c. Electrical relay checking in Generator , HT and LT switch gear

Turbine overhaul work list


The Turbine overhaul work list during a major shutdown can be
categorised into three main sections. Disassembly, Inspection and
reassembly. Please
read through the Vol 6 of the GE given operation and maintenance manual to
know more. They have given a step wise method for each section. I will give
the
salient points here.
a. Disassembly
i. isolation of turbine from accessory and generator by
removal of coupling guards and load gear.
ii. Removal of gas turbine compartment side walls , roofs
iii. Removal of Gas turbine pipings , combustion parts
iv. Removal of outer casings from IGV to exhaust
v. Removal of Gas turbine rotor
b. Inspection and Refurbishment ( the complete replacement list can
be found in vol 6 manual)
i. Replacement of combustion Compressor and turbine blades
ii. Replacement of turbine shrouds and static blades.
iii.replacement of all combustion parts , liners , cross
flow tubes , burners , new piping for fuel.
iv. General cleaning of rotating parts
v. Inspection and if needed replacement of turbine bearings
vi. Static testing of newly relinquished rotor.
c. Re assembly
i. Rotor placement inside the turbine compartment
ii. alignment checking of the newly installed rotor.
iii. replacement of the outer casings
iv. Replacement of the turbine outer pipings

v. Coupling the turbine to load gear and accessory


compartment coupling
Generator Overhaul work list
The generator overhaul work list can be catrgorised into three main
sections. Disassembly, Inspection and reassembly. Please read through the
OEM maintenance manual to know more about what all needs to be done. I will
give the salient points here.
a. Disassembly
i. Removal of all connecting electrical HT bus bar wiring
and removal of all monitoring instrumentation
ii. Removal of the exciter and PMG (if present) assembly
iii. mechanical isolation of the rotor and removal of the
rotor.
b. Inspection and refurbishment
i. General cleaning (or dry ice cleaning) , varnishing and
testing of Stator coils. (common tests include , DC insulation test , PI
test , AC PF , capacitance testing , Ring flux testing etc.... )
ii. general cleaning (or dry ice cleaning) , varnishing and
testing of rotor. (common tests include insulation test , ring flux testing
, Rotor winding integrity using RSO etc... )
iv. General cleaning , varnishing and testing of main
exciter , PMG
v. Generator AVR testing ( can be done by regular
maintenance or by the OEM)

By arfsm on 26 March, 2011 - 3:16 am


Thankseveryoneforthevaluableinfo..
SpeciallyProcessValue..Excellentinformationprovided..thanksalot..
Hatsofftoyoubrother.
Secondly,imadeamistakebynotgivingfullinformationthatthereisgoingtobeashutdown(MidofMay)notthat
wealreadyshutdowntheplant..
ThanksandKindRegards,
ARFSM

By Process Value
>Wehaveshutdownofthewholeplant
>whichhasfourGasturbineswith
>compressors...(mechanicaldrive)...

on 27 March, 2011 - 1:53 am

Part3Materialsandtoolsmanagement
Nowthatweknowwhatallworksneedstobedone,itisimportanttocomeupwithainventorylistofmaterials
neededduringshutdown.Thisisthepartwherethreeisalotoftugofwarbetweentheexecutionengineersandthe
plantmanagement.Executionengineersalwaysliketohaveabundantsparesbuttheplantmanagementdoesnotshare
theirenthusiasmwiththis.Ihaveseenmostofthemaintenanceworksgetdelayedduetolackofpropermaterial
management.Ideallyyouhavetobuyeverythingintherightquantitysothatnonegetswastedandalsothereisno
shortsupply,butitrarelyhappens.A
sampleinventorylistforafieldjobwilllooklikethis

Job description
50 mic filter replacement

Materials needed
2

50 mic filter elements

inlet air filter replacement


etc.......

320 inlet air filter modules

Aconsolidatedlistforallrotary,electrical,fieldandinstrumentationjobsneedscollectedandsentforprocurement
wellinadvance.Materialsshouldarriveatleastaweekbeforetheplannedmaintenancesothatitcanbeproperly
loggedintotheinventory.
Part4Preparationofaworkschedule
Nowthatweknowwhatworkneedstobedoneandalsothematerielforthejobs,timehascometoallocatethejobs
onatimescaleandtoreleaseittotheexecutionengineers.Astherearetwoseparategroupsworkinghere,onefrom
theinhouseplantmaintenanceandotherfromtheexternalturbineoverhaulgroup,itisimportanttosynchronizethe
workscheduleofthetwo.Theturbineoverhaulpersonnelwillhaveafixedtimetabletochoosefrom.Aturbineover
haulcanbedonein15days(roundtheclock24hoursshift)21days(16hoursshift)and30days(812hourshifts).
Itisimportantwhendecidingwhichtimescaletogoonto.Theimportantcriteriais,whentheexternalpersonnel
finishtheiroverhaul,theplantinhousemaintenancemusthavealsofinishedthejobsallocatedtothemsothatthereis
noexcessivedelay.15dayworkschedulecostsalot,sothereisnopointincommittingtheexternalpersonneltoa15
dayworkschedulewhenyourinhousemaintenanceisgoingtotakeyou1920daystocomplete.Inthiscase(20days
fortheinhouseplantmaintenancetocompletetheirworkschedule),itwillbedecidedtogofora21dayturbine
overhaulschedule.
Nowthatweknowthetimespanfortheshutdownmaintenance.itisnowimportanttocomeupwithawork
schedule.workscheduleisaplanofworktobecompletedeachdayduringtheshutdown.Asampleworkschedule
willlooklikethis

Day
Turbine overhaul group
Generator overhaul group
Plant rotary
Plant electrical
Plant field
Plant
inst
1
arrival at site
begin plant electrical
begin plant mechanical begin plant inst
meeting with the maint group
isolation
isolation
isolation

2
Start of dis assembly
begin job list
PM check of motors

start of cut and weld

jobs etc ........


Part5continuousassessmentandfollowupofshutdown
Thefifthpartiswheretheworkstarts.Plansareplans.itwouldbeniceifitgoesaccordingtoplan,butagainitrarely
does.materialsissues(nonavailabilityofcertainspares,tools,delayindeliveryetc....),unforeseendevelopments
(likewhenyouremovethebolt,theboltheadbreaksleavingthetailpieceinsideit,whichhastobedrilledout.and
believemeitisquitetimeconsumingasyoudonotwantanythingtohappentothecasingthreadschedule),
manpowerproblems(unabletogetrequiredmanpower,supervisorgotsickandcouldnotcomeetc...)willcropup
duringtheshutdown.Itismostimportanttofollowuponthedailyworkscheduleandresolvethisissues.Thetarget
deviationshouldnotbemorethan30%forimportantmilestonesfixedintheworkschedule.somejobswhichare
consideredtimeconsumingandnotnecessarywillhavetobedroppedformoreimportantworks.Abasicand
rudimentarymilestonesduringaturbinemajormaintenancewilllooklikethis
day12Plantelectrical,mechanicalandinstrumentationisolationandblinding.
day28Turbinedisassembly,generatordisassembly,ongoingfield,rotary,electricalandfieldjobs
day914Turbineinspectionandrefurbishment,generatordisassemblyandrefurbishment,ongoingelectrical,field
andinstrumentationjobs
day1519Turbinereassembly,generatorreassembly,closureofelectrical,fieldandrotaryjobs
day1920Plantreconnection,removalofblinding,linecharging,removalofelectricalandinstrumentationisolation,
commencementofprestartupchecks
day2122Plantstartup,troubleshooting,reliabilityrun,readingcomparison,endofshutdown
Part6EndofshutdownPARTY!!!!!!
Thisiswherethewearysoulswhoattimeswork23dayscontinuouslyintheplant,getawelldeserveddrinkatthe
table.Thisiswheretheplanthigherupsbaskinthegloryoftheexecutionengineerswhodidallthework;).Thisis

thetimewhennewfriendshipsarecementedbetweentheplantmaincrewandtheexternalmaintgroupswhothough
atloggerheadsatmosttimescometogetherforajobwelldone.