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Gas Turbine Repair Technology Abstract Unit availability and effective utilization of maintenance funds are two of the most impor- tant concerns of a gas turbine owner/operator. Major gas turbine components have limited lives in comparison to the unit’s useful life. Owners/operators are continually faced with decisions regarding component replacement and/or repair. A component repair program that minimizes maintenance costs and maxi- mizes equipment availability can be instituted within the installed base to meet or improve fi- nancial objectives. This paper summarizes some of the state-of-the-art gas turbine component re- pair processes developed by GE to support the fleet of GE-designed heavy-duty gas turbines. Operation and Maintenance Considerations GE’s recommended operating and mainte- nance practices are discussed in the publica- tion, “Heavy-Duty Gas Turbine Operating and Maintenance Considerations” (GER-3620G). This paper discusses the factors that influence equipment life. These life-limiting factors must be understood and accounted for in the owner’s maintenance plans (Table 1). Each one of these factors has an effect on gas turbine maintenance intervals and component parts’ lives and will vary depending on each unit’s operation. Some of the potential and typ- ical failure modes for hot gas path components in continuous and cyclic-duty machines are list- ed in Table 2. Thermal mechanical fatigue is the predomi- nant life limiting factor for peaking machines, while creep, oxidation and corrosion are the dominant limiters for continuous-duty ma- chines. GER-3620G discusses these limiting fac- tors in detail and provides criteria for establish- ing maintenance inspection intervals. The scope of typical maintenance inspections (com- bustion, hot gas path and major) are outlined there and estimated repair and replacement cy- cles are provided for some major components. Repair vs. Replacement Once a maintenance plan is established, the owner/operator implements it. The mainte- nance cycle starts with the pre-outage planning, continues through the outage, and ends with the post-outage assessment. As one would ex- pect, most gas turbine components have a finite life or expected life in the turbine under the GE performance guidelines. (See Table 3.) During the maintenance or outage cycle, owners and operators decide to use the component “as is,” repair the component, or replace the compo- nent. This post-outage assessment provides the basis for planning the next outage. Throughout this outage process, the owner/ operator will be faced with many difficult deci- sions that will determine unit reliability, mainte- nance costs, and operating benefit. Table 1. Major life limiting factors Since GE is continually improving gas turbine technology and applying it to component de- signs that can be retrofitted in older units, the owner can evaluate the economics associated with upgrading or uprating the unit by replacing one or more components with state-of-the-art components. GE can consult in various manners by contacting a Customer Service or Product Service specialists. One can also perform some GE Power Systems ■ GER-3957B ■ (04/01) 1 • Fuel • Firing Temperature • Steam/Water Injection • Cyclic EffectsPDF Image | Gas Turbine Repair Technology GE
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