Energy Service

TB Maintenance Concept
A lifetime of support for your investment.

Protecting your
Investment
Siemens are committed to helping maintain
your operations in the field.
The combination of our accurate build
information, component history and
component lifing data allows us to schedule
the correct maintenance, optimizing
operation, reducing downtime and reduces
the risk of component failure.

What do we provide?

Operational Maintenance
- Typical operational tasks
- Parts Kit

Scheduled Maintenance
- Typical maintenance work scopes
- Parts Kits

Maintenance Planning
- Maintenance scheduling
- General Parts Kits

12 - 13

Remote Diagnostic Services

14 - 15

4-5

6 - 11

Current design philosophy

accommodates a six year
maintenance cycle before major
overhaul, with Gas Generator
overhaul at year three.
This information describes the
maintenance required for 48,000
running hours, approximately 6
years of operation; however should
annual running hours be less than
this then the calendar periods
between maintenance activities
may be extended.

Typical Operational Tasks

Electrolyte levels of the battery may be checked.

Daily checks

A running check of the operation of the DC Lube oil

pump may be performed.

System pipework and components are checked for

signs of leaks.
All gauges and lubricating oil levels in the tank are
assessed as a guide to component condition.
Engine and package are checked for oil leaks.
All vents and drain lines are checked to ensure they
are clear of obstruction.

VDU/HMI screens are cleaned to remove dust from the

control panel. They might also be examined for any
signs of overheating.
All connections on the actuator stepper motor may be
assessed for security.
Monthly checks

A visual assessment of the oil cooler is made and may

be cleaned if necessary.

Oil levels on oil filled type couplings are examined and

replenished.

All differential filter indicators (if fitted) are checked

and elements replaced as required.

Flame failure head and combustion chamber glass are

checked and cleaned.

The fuel supply pressure is checked.

All solenoids are examined for signs of leakage.

The battery charger output is assessed, along with D.C.

and A.C. supply levels.

Operation of the fuel changeover system.

Control panel annunciation lights are checked to

ensure that they are fully functional and replaced as
required.

Electrical connections on the starter motor are

checked and gas/air starter system piping may be
assessed for signs of leaks.

The flame-on indication system will be checked to

ensure it is functioning.

In addition, couplings are checked for security, along

with an examination of the starter motor hold down
bolts.

A general check of the igniter gas bottle should also be

done on a daily basis.

The control cabinet filter pad is checked (if fitted), and

cleaned as required.

Weekly checks
The gas starter motor may be lubricated (if fitted) and
the oil fog lubricator will be replenished.

Batteries should be boost charged.

Auto drain valves are checked during start up and run
down.

The Gas Turbine

requires regular
attention in order to
replenish / replace
consumables, detect
trends and to determine
abnormalities at an
early stage.

Operational Maintenance
Operational maintenance activities are typically performed on a daily, weekly,
and monthly basis. Less frequent checks could be opportunity based
according to operational running regimes.
Quarterly checks
A simulated check of the over speed safety device to
be performed.
Generator holding down bolts and visible fixings are
checked to be secure in accordance with the
manufacturers recommendations.
Vibration levels are reviewed.
Lube oil pumps are checked for noisy operation and
output pressures are examined.
Six monthly checks
Bearings on all motors will be greased.
An external check of system protective devices to be
made.
Door seals, hinges, pivot pins and fasteners are
examined and lubricated as required.
A thorough cleaning of the flame trap to be performed.

On condition
Using the installed system, the compressor may be
cleaned and its recovery monitored to enable
adjustment of the period between cleaning. (The
combustion drain to be inspected for particles.)
For Hot wash or cold crank wash on fluid based
systems, the correct operation of all automatic drain
valves on systems with fluid wash systems may be
checked.
An inspection of the under base is made to check for
signs of corrosion. If necessary, corrosion will be
removed and protective treatment applied.

Parts Kit
All spare parts used during these checks would come from
an operational consumables kit. This kit would contain
easily replaceable items such as fuses, bulbs and filter
elements etc. These activities would normally be carried
out by suitably trained site personnel.

Components maintained
at calendar intervals are
done so on the basis of
safety, regulatory or as a
consequence of
application conditions.

Scheduled Maintenance
Scheduled maintenance is carried out based on either calendar intervals
or running hours, depending on the components under consideration.
Service exchange Gas Generators and Power Turbine
assemblies are recommended as an alternative to the B
Type (24,000 hours) inspection on the Gas Generator, and
on C Type (48,000 hours) inspection(s) on both the Gas
Generator and Power Turbine, where on-site internal
inspection of the complete gas generator and power
turbine assemblies are normally carried out, based on the
expected design life of the hot path components.
It is therefore recommended that any resulting overhaul
(strip/rebuild) of the Gas Generator and Power Turbine
sections is carried out at a Siemens SGT approved
workshop. This ensures that the correct processes and
tooling are utilized, including replacement of CT bladed
discs and the subsequent balancing of the Gas Generator
and Power Turbine rotor assembly is performed to the
correct specification.
Maintenance based on the running hours of the gas turbine may be
related to predictable events such as bearing and blade life.

Typical Maintenance Activity Work Scopes

(not exhaustive).
Maintenance activities are classed into A, B or C levels,
depending on the scope of work required:

A Service Inspection
This is recommended annually and consists of calibration
and system/ operational/ safety checks, filters and
consumables are changed and lubricant levels checked
and replenished. The condition of the combustion system
and first stage stators are checked by removal of the
combustor end covers.
The workscope of a typical A service for the TB gas turbine
is detailed below. The estimated time to complete the
workscope at site using two men (one Siemens personnel
and one customer assistant at a total of twenty man hours
per day) is approximately 7 days.

Further opportunities for

maintenance are present during a
scheduled shutdown of your engine.
Gas or dual fuel burners can be
inspected for deposits and cleaned.
In addition, there is an opportunity
to perform maintenance of the Fire
and Gas & Extinguishant systems in
accordance with manufacturers
recommendations for system
installed.
(Training courses are available
through your Siemens
representative.)

Pre-shutdown checks
All data from the Turbine Control Module (TCM) may
be recorded during the pre-shutdown checks.
The compressor may be cleaned and a post clean data
comparison performed.
Other checks include inlet guide vane operation,
vibration surveys, leak checks, filter checks, noise
levels of the pumps, fans, etc, various engine
temperatures and pressures, instrument/gauge checks,
liquid fuel piping vibration and a test of fuel
changeover, if applicable.
Shutdown procedure

Siemens personnel shall be given access to confirm

that all isolations have been carried out and a risk
assessment will be conducted.
The customer is responsible for the isolation of the
turbine and driven unit and to ensure that a permit to
work system is in operation.
Mechanical
A boroscope inspection may be made.
A thorough inspection and clearance check of
combustion system is done, including; end plates,
swirlers and cones, flame tubes and extensions and
inspection of CT1 stator blades.

Mechanical or Electronic Over speed checks are made

and the annunciation examined.

Gas and liquid burners are removed and cleaned.

Ignitor bowls are also checked for cleanliness.

The operation of the BOVs and slam shut valves are

checked.

UV sight glasses are cleaned; UV bulbs will be replaced

and joints renewed where required.

The operation of the auxiliary lub oil and emergency oil

pumps are checked.

The assembly of the combustion air inlet filter and

ducting are examined; filters will be replaced if
required.

The pumps are also checked to ensure that they stop

at the correct set point.
The turbine operation is then reviewed in relation to
the controls data and customer report information.
Isolation procedure
All components are powered-down to ensure safe
working conditions.

Operation of the pulse clean system or moving screen

filter reservoir are checked. The mechanism greased
and checked as applicable.
IGV air relay, bellofram cylinder and P2 supply pipe are
removed, cleaned operation fully examined.
P2/Stage 10 air supply pipe is checked for blockages.
Blow off valves are removed, re-greased, diaphragms
and valve seats lapped as required.

Together, we can effectively

manage your scheduled
maintenance activities to
ensure that appropriately
skilled people and relevant
parts arrive on site at the
right time.
On auto drain valves or overhaul ball type assemblies,
diaphragms are replaced and drain pipes removed and
checked for blockages.

The demister filter should be replaced. Condensate

auto drain valve assembly is removed, inspected and
operation checked.

External vent and drain lines are checked to ensure

that they are clear with no back pressure present.

Fuel shut off valves are checked for stiffness and an

inspection of the ignitor gas pipe work and non return
valves is undertaken.

Water wash or solid cleaning system components are

inspected.
Lubricators are topped up.
Filters are checked, cleaned and replaced on both
types.
Lub oil breather system is checked for signs of damage
or corrosion, the sand trap vessel is emptied and flame
trap is cleaned.
The lub oil level is checked and the customer is
assisted in taking oil for analysis as required.
Lub oil sample is checked with the customer and both
the tank level and quantity added are recorded.
Fuel, oil, gas/air start systems and ignitor system filters
are replaced.
Hale hamilton main and start gas regulator systems
are dismantled and cleaned; throttle actuators are
checked for excessive backlash.

The driven unit and starter motor hold down bolts are
checked for security and alignment; couplings are
regreased and rubber couplings are inspected as
required.
Electric motor and gas starters bearings are greased.
All pipe work, hoses and flexibles are checked and
replaced on condition.
A visual check is made of the vent dampers and their
operation.
Electrical
Copies of controls software are taken as required,
including package or driven units.
Certified electrical equipment in hazardous areas is
inspected, if applicable.
Fuel actuators are calibrated.

 Potentiometers are replaced (DC201 star valves only).

UV flame viewing head cable insulation and its
operation are checked.
T Max or T Op parameters are recorded including
governor settings (Mk 1 Rustronic Control System).
The operation of all package devices are calibrated and
operation tested, including solenoids, pressure or
temperature monitoring devices, blow in door micro
switches, vent systems, emergency stop circuit,
thermocouples, indicators, watchdog system and any
contract specific devices.
PPM1 battery on Mk 2 systems is replaced.
Allen Bradley control system back up battery is
replaced.
TCM monitor or LCD backlight is inspected for signs of
degradation and replaced if required.
Checks are made of the battery and charger condition;
outputs; electrolyte levels and specific gravities. They
are topped up with distilled water if required and
boost charged when applicable.
An inspection of the ignitor lead and plug is made,
along with insulation/resistance/function checks and is
replaced if required.

The remote monitoring system (STA-RMS*) is checked

to be operational (if installed).
Any driven unit or other third party servicing records
are recorded.
Pre-Commissioning
Isolated systems are reinstated and a pre-start
integrity check of all systems is made, including static
leak checks.
Restart and Running checks
The gas generator is rotated up to spin speed.
The turbine is stopped using the normal stop button
and the rundown time is recorded.
The fault protection start/running/functions is
checked.
The exhaust volute manual shut-off valve is checked to
ensure that it operates on each start-up.
IGV operation is examined.
The turbine system is checked for leaks during running
checks and after four hour test run.
Vibration checks are carried out at maximum load.

All motors and A.C. contactors are inspected.

The integrity of vibration monitoring equipment is
checked, either vibraswitch or displacement types.
The operation of lub oil warning and shutdown are
checked, including auxiliary pump cut out system.

Planned inspection
intervals of 8000 fired
hours, or annually, with
an intermediate
inspection every third
year or 24000 fired hours
and major inspection
every six years or 48000
fired hours, give low cost
maintenance and high
availability.

*STA-RMS: Siemens Turbomachinery Applications - Remote

Monitoring System

The design of the gas

turbine provides
operators with the facility
to carry out on-site blade
inspection and servicing
of the unit or, at the
operators choice, at a
Siemens approved
Service Centre.

B Service Inspection
This is recommended at 24,000 hours and is the A type
service plus a total strip of the gas generator to inspect
critical components and assess their suitability for a
further three year life cycle.
The work scope of a typical B service for the TB gas
turbine is detailed below. The B service can be
performed at site or as a Workshop Overhaul at a Siemens
Service Centre.
The estimated time to complete the work scope at site
using 2 men (one Siemens personnel and one customer
assistant at a total of 20 twenty man hours per day) is
approximately 14 fourteen days.
All A Service activities are included, plus the following:
Gearbox
A visual inspection of the internals is made and
clearances are recorded on build sheets.
Package
The gas fuel throttle is stripped down, if required.
Core Engine - Gas Generator (GG)
Bearings and labyrinth seals are dismantled and
inspected.
The compressor rotor and stator blading is cleaned by
hand, as required, with clearances recorded on build sheets.

Operation of the IGV blades is checked and blade

stems and bushes are strip cleaned as required.
The compressor turbine (CT) blading is examined for
signs of damage/corrosion/erosion. The 1st and 2nd
stage CT stator blades undergo dye penetration crack
detection. Clearances and all findings are recorded on
build sheets.
A sample of the 1st and 2nd stage CT rotor blades is
taken, and the blades plus the completed sample
sheet are returned to Siemens metallurgical laboratory
for analysis.
The swirler cones and flame tube extensions are
examined for distortion/cracks/fretting. Clearances
and all findings are recorded on build sheets.
The Gas Generator rotor is checked to ensure that it
rotates freely, post rebuild.
Power Turbine
The first stage power turbine is visually inspected prior
to replacing the Gas Generator.
A dye penetration crack detection is undertaken on
the interduct.

The TB5000 has been designed for

ease of on-site maintenance
thereby maximizing operating
availability and minimizing
downtime.

Combustion chambers and fuel

burners are easily accessible when
servicing is required.

C Service Inspection
This is recommended at 48,000 hours and in addition to
the B type service, involves a strip of the power turbine.
The work scope of a typical C service for the TB gas
turbine is detailed below. The C service can be
performed at site or as a Workshop Overhaul at a Siemens
Service Centre.
The estimated time to complete the work scope using 2
men (one Siemens personnel and one customer assistant
at a total of twenty man hours per day) is approximately
twenty one days.
All A and B Service activities are included plus the following:
Package
Flow tests are carried out (certain configurations).
Power Turbine (PT)
The PT is dismantled and the blading, bearings and
labyrinth seals are inspected. All findings and
clearances are recorded on build sheets
Diffuser welds undergo dye penetration crack
detection and are repaired as required.

Parts Kit
Spares for these maintenance intervals consist of various
kits, an inspection replacement parts kit will contain
those items that are definitely to be replaced during
servicing, and an inspection contingency kit will
contain critical components that may be replaced during
the annual inspection depending on their condition. In
support of these it is recommended that an emergency
backup spares kit should be held on site to cover other
items that may be found at fault during servicing such as
valves, thermocouples and igniters.

Siemens maintenance planning

leaves you to concentrate on your
core business.
The customer may want to consider
items such as the filtration options
available. Highly efficient (HEPA)
filtration may lead to increased
availability due to reduced
requirements for routine
maintenance (water washing) and
less degradation to core
components. This, and other
options, can be discussed in detail
prior to purchase.

Maintenance Planning
Planned maintenance reduces the cost and disruption of unscheduled outages
Maintenance planning should cover at least the following
areas:

Logistics: How is equipment supplied are export

licences required?

Scope of work: What is required, where it will be

carried out and how long it will take.

Site considerations: Permits to work,

risk assessments etc.

Spare parts: What parts are required, what is held on

site, lead times involved.

OEM specialists: Are specialists available

(gearbox etc).

Tools and fixtures: What specialist tooling is required

and available (lifting beams etc).

Coordination: Who is coordinating all the above

activities?

Inspection and assembly work: Are the correct

personnel and facilities available.
Work plan: What can be performed on site and what
needs specialist services.
Capacity planning: Are the facilities, personnel and
equipment required?

Maintenance Scheduling
The maintenance schedule of the equipment depends on
annual running hours and the component life consumed,
assuming that the gas turbine is running 8,000 - 8,500
hours per year.

Year 1

Year 2

Year 3

Year 4

Year 5

Year 6

Fig 1. A typical TB maintenance schedule, with blade sample at 24000 hours

The compressor features

variable inlet guide vanes to
modulate air flow and assure
fast, easy start-up and
maximum efficiency under
partial loads.

Note: Blade Samples - Turbine section hot path

component life

General Parts Kits

Two diametrically opposed blades are removed from each

stage of the Compressor Turbine (CT) rotor and replaced
with new pairs of match weighed blades. This is initially
conducted at the B type inspection (24,000 hours).
Removed blades undergo analysis in the Siemens
metallurgical laboratory.

Spares to replace unserviceable items may be held on site.

These are generally considered to fall into two types.

The examination will provide a report of blade condition

and advise the residual operational life of the blades. The
life statement will declare that the blades are either
unacceptable for further operation, or expected to be
suitable for a further 8,000, 16,000 or 24,000 hours
operation, with an expected operational life of 48,000 hours.
The expected residual life is based upon the operator utilizing
the unit in the same conditions (i.e. fuel quality, engine load,
air quality etc).

Emergency backup spares may be held on site and used

to replace a faulty component, thus maintaining gas
turbine availability. This could include items such as
electronic modules, thermocouples and igniters. However
it is advised that these are only replaced by suitably
trained personnel.
Capital spares may be held on site and are major items or
specially engineered parts such as pumps, motors and
combustion chambers. These cover items where limited
stock is available or carry a long lead time for delivery;
these are only changeable by suitably trained personnel.

The TB5000 is well suited

for cogeneration and
combined cycle power
applications.
Using exhaust gas to
generate steam for
process use or
supplementary power
generation significantly
increases the system
efficiency

Remote Diagnostic Services

Remote data access to provide information and reports, helping to effectively
manage your turbine.
STA-RMS* (suitable control systems only)
Siemens remote monitoring solutions are designed to
maximize your units performance and are tailored to your
specific machine type.

Technical overview
STA-RMS consists of five components:
Data acquisition: this is automatically recorded within
the control system of the equipment.

TB gas turbines can be fitted with our latest remote

monitoring system, STA-RMS*, which ensures maximum
machine availability by monitoring and recording various
turbine parameters such as speed, temperature, pressure
and vibration and communicates this information via an
internet connection to Siemens dedicated servers.

Data transmission: information is transferred via a

secure internet, VPN/FTP or phone line connection.

If real time connection is not available due to site location,

then data can be stored and downloaded periodically.

Data evaluation: a web-based analysis tool is

available to support your TB engine.

Using STA-RMS, Siemens can provide various levels of

remote services, from basic reporting and support (office
hours), to full 24 hour, 7 day service and either
comprehensive thermodynamic and/or rotor dynamic
analysis of your asset.

Expert diagnostic: we provide rotordynamic and

thermodynamic tools such as vibration analysis and
diagnostics. Where applicable, this includes polar
plots, waterfall diagrams, bode diagrams, frequency
charts and performance calculation.

Whichever service level you choose, all can be tailored to

suit your specific requirements.

Data storage: all reports are stored centrally within

the Siemens intranet for the whole lifetime of the
machine. This allows for fleet analysis and product
improvement related to the real operation conditions.

* Siemens Turbomachinery
Applications - Remote Monitoring
System (STA-RMS)

STA-RMS utilizes the experience that we as the OEM have

accumulated from our operating fleet of over 330
installed RMS units, coupled with the extensive knowledge of
both our field and service engineering teams, to advise
you in all aspects of our product range, tailored to the
specific requirements of your TB gas turbine.
The key benefits to you are:
Fast, secure online help and advanced
troubleshooting.
Proactive recommendations.
Increased production through maximum train
performance, availability and reliability.
Outage optimization and reduction of overhaul costs,
through trending and root cause analysis.
STA-RMS is tailor made to improve the remote
functionality of all Siemens units and is the only OEM
approved system commercially available.
STA-RMS can be offered both as part of a Long Term
Programme (LTP) or as a stand alone Service Support
Agreement, which can be arranged through your Siemens
representative.

Help Desk
24/7 Hotline Support with duty CSM and technical
specialists.
The 24/7 Hotline Support can ensure help is there when
you really need it, either by telephone or through secure
online connection.
Our help desk is available to assist you with any kind
of technical issue, as part of an LTP or Service Support
Agreement, whether it is for performance fine tuning or
breakdown assistance.

Energy Service Division

LCN 2013 - F48.1 LN
Printed on elementary chlorine-free
bleached paper.

Published by and copyright 2013:

Siemens Plc
Faraday House
Frimley, GU16 6QD
United Kingdom
Siemens Industrial Turbomachinery Ltd.
Ruston House, Waterside South
Lincoln LN5 7FD
United Kingdom
Siemens Energy, Inc.
4400 Alafaya Trail
Orlando, FL 32826-2399, USA

www.siemens.co.uk/energy

For more information, please contact

our Customer Support Centre.
Phone: +49 180 524 70 00
(Charges depending on provider)
Email: support.energy@siemens.com

All rights reserved. Trademarks

mentioned in this document are the
property of Siemens AG, its affiliates, or
their respective owners.
Subject to change without prior notice.
The information in this document
contains general descriptions of the
technical options available, which may
not apply in all cases. The required
technical options should therefore be
specified in the contract.