Documente Academic
Documente Profesional
Documente Cultură
On
At
PREPARED BY
TABLE OF CONTENT
INTRODUCTION ................................................................................................................................. 3
OBJECTIVES ......................................................................................................................................... 3
DELIVERABLES: .................................................................................................................................. 3
SITE ASSESSMENT:........................................................................................................................... 3
RESULTS AND OBSERVATIONS: .................................................................................................. 5
GENERAL OBSERVATIONS FOR ALL THE UNITS: ............................................................................................. 5
EXHAUST TEMPERATURE ............................................................................................................................ 6
BOROSCOPY INSPECTION RESULTS TURBINE ................................................................................................ 6
COMPRESSOR INSPECTION ......................................................................................................................... 8
HOT GAS PATH COMPONENTS .................................................................................................................... 8
PICTURES: ............................................................................................................................................ 9
TURBINE SECTION .................................................................................................................................... 9
COMPRESSOR SECTION ........................................................................................................................... 10
HOT GAS PATH COMPONENTS .................................................................................................................. 11
This project assessment was a part of a major repair and overhaul work for four GE Frame 5 and
Five GE Frame 6 power generation units located at Old/New Mullah Abdullah Power Plant, Kirkuk,
Iraq.
Objectives
The objective of this project assessment was to provide information and reconstruction project
information on the present state of the units to the interested parties in order to make the units
as new which included the following:
Deliverables:
• Provide detailed information on the present condition of the units and all the necessary
components needed to make them as new.
• Written assessment report for all work to be performed during the site visit
Site Assessment:
All the nine-operating/standby units have crossed there expected life of operation. From the
available EOD it is clear that there has been no major repairs or overhaul performed on these
engines.
The net result of the combined action of all these damage modes was that many of these high
cost components have finite and often very short lives.
Operations are often performed on the basis of safety by inspection, which is time consuming and
expensive. Relatively crude methods are used to monitor trends and major engine operating
parameters such as temperatures and pressure ratios across different stages and fuel burn, from
which gross changes in component geometry may be inferred. Internal structural damage on the
other hand, due to creep, fatigue or TMF, is difficult to detect, and only empirical models are
available to provide guidance on damage accumulation rates and the critical levels of damage
beyond which remedial action would be essential.
LPTi provides services requiring expert use of computational and analytical methods.
• Predicting the development of faults and residual lives of in-service parts of turbines and
other machinery (maximize capital assets, reduced spare part inventory and increase
plant availability),
• Optimizing overhaul cycles (reduce down time, increased plant availability and reduced
maintenance costs),
• Predicting incipient failures and extending component lives by allowing intervention before
faults become a serious threat. Maximize capital investments in aging turbines while
reducing risk of catastrophic failures resulting in lost revenues and service availability –
the operators maintenance dilemma
LPTi uses its XactLifeTM software, which is an advanced expert system that allows the condition of
critical, and life limited steam and gas turbine components to be assessed in near-real time while
in service in an engine. The operating conditions in an engine are monitored in real time and
analyzed to determine the response of critical components in terms of stresses, strains and
temperature distributions. The damaging loads and other environmental factors are used
together with physics-based damage accumulation models to predict critical damage locations
(also known as fracture critical locations) and the life limiting damage mode(s) including creep,
fatigue, thermal fatigue, oxidation or combinations of these. Calculations are made of life
consumed and residual life remaining using either safe-life concepts or damage tolerance
concepts and employing either deterministic or probabilistic methods.
• All the units were in a real bad state. There was lot of oil in and around the areas where
the units were operating which were caused either due to leakages or because of poor
maintenance on the part of the workers of Mullah Abdullah Power Plant.
• All the Frame 5 and Frame 6 units were operating well below there capacity e.g. the
frame 6 units were operating at 15.5 MW instead of there original capacity of 37 MW
• In case of Frame 5 most of the filters were either missing or they were very dirty leading
foreign material towards the compressor compartment.
• In case of the lube oil system, fuel transfer system and the fuel gas transfer system it
was observed that all the filters need to be replaced. The maintenance people used to put
whatever filter fits wherever without checking kind of filter, size of meshing required,
diameter of filter etc.
• The water used for cooling purposes is used directly without processing it with anti-
corrosive chemical so as to prevent corrosion and ensure longer life of the components
due to this we saw visible areas of oxidation.
Exhaust Temperature
From the above control room readings Exhaust Gas temperature trends show that the
thermocouples are working normally but there are occasional hot spots present in side the hot
gas combustion path 3. The original capacity of the units under normal conditions is 37 MW but
the generation capacity for these two units is limited because the axial discharge compressor is
very dirty internally. The temperature is high because of low cooling and compressed pressure. It
is important to mention that for the energized unit 1 thermocouple WS3FI2 is not working.
MS 6001
MS 5001
Considering that the units have operated for a long period of time without any major repair or
overhaul it will be prudent to apply inspection based life cycle management approach to
maintaining the discs at overhaul. This way, the risk of catastrophic failure due to corrosion-
induced damage etc. can be minimized and the full life potential of these expensive parts can also
be utilized. It will allow the turbine discs to be used well beyond the design life recommended by
the OEM.
Boroscope inspection was performed on the different stages of the compressor and it was found
that there was no abnormal wear on the compressor nozzles and buckets. However, it was
observed that in most of the units the components were very dirty. It is recommended to perform
major cleaning operation with aluminum oxide.
LPTi team observed that in case of all the units the filter house was the most neglected
compartment. In case of the Frame 5 units either the filters were missing or they were really
dirty. Servicing the air filters is one of the most important maintenance operations to be
performed to ensure long compressor life.
The combustion liners, transition pieces, crossfire tubes and fuel nozzles should be removed and
replaced with new or repaired ones. Most of these components show indication of high
temperature working conditions leading to deterioration of Thermal Barrier Coating (TBC) from
the surface or broken components.
In case of cross fire tubes, retainers and transition pieces the most common problems were
• Missing coating
• Broken seals
• Distortion
• Weld cracks
Turbine Section
Body Cracks/Damaged
Deterioration of
Internal coating
Worn out