Barinas Power Plant

Gas Generator
Removal/Installation

El FurrialPower
Barinas
PowerPlant
Plant

Learning Objectives
Upon completion of this training, participants will be
able to:

Describe removal and installation procedures for the

gas generator and free turbine.

Identify special handling and lifting fixtures required.

Describe preparation procedures for shipment of gas

generator and free turbine.

El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure
The gas generator and free turbine are removed from the
gas turbine enclosure through the removable roof hatch
provided.
Special lifting and handling fixtures are required for this
procedure.

El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Gas Generator

STEP 1 REMOVE HATCH DOOR
Equipment required:
Storage container
Crane or suitable lifting device
1. Unbolt enclosure roof hatch.
2. Disconnect engine heater supply tube.
3. Disconnect engine heater electrical supply.
4. Attach lifting cables to roof hatch.
5. Remove hatch.
6. Place roof hatch in storage container.
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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Gas Generator

TYPICAL HATCH DOOR REMOVAL

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Barinas
PowerPlant
Plant

Removal Procedure Gas Generator

STEP 2 PREPARE GAS GENERATOR FOR REMOVAL
Equipment required (Typical)*:
Support PWA 11718 1 each
Saddle PWA 20474 1 each
Sling PWA 20472 1 each
Nylon Strap 1 each
Adapter, Lifting PWA 20473 1 each
Transport stand 1 each
1. Disconnect all fuel, oil, air and electrical connections
from gas generator to base assembly and enclosure.
2. Remove two free turbine cooling air tubes.
* See applicable Gas Generator Maintenance Manual for specific model
data.
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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Gas Generator

3. Support free turbine at turbine case front flange with
PWA 11718 Support.
4. Remove the Bellmouth using nylon strap.
5. Remove nose cone.
6. Position sling (PWA 20472) over gas generator.
7. Attach PWA 20473 Lifting Adapter to engine sling
(PWA 20472), and connect to intermediate case.
8. Position PWA 20474 Saddle under turbine nozzle
case (inboard of all external tubes) and attach to
engine sling.

El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Gas Generator

GG REMOVAL PREPARATION
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Barinas
PowerPlant
Plant

Removal Procedure Gas Generator

STEP 3 REMOVAL OF GAS GENERATOR
1. Attach crane hook or suitable device to sling (PWA
20472).
2. Support weight of gas generator with sling.
3. Remove the nuts and bolts from Flange L.
4. Release front mount links.
5. Remove inlet case mount pads.
6. Carefully raise gas generator through roof hatch
opening.

El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Gas Generator

GAS GENERATOR REMOVAL

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Barinas
PowerPlant
Plant

Removal Procedure Gas Generator

STEP 4 PLACE GAS GENERATOR ON TRANSPORT
STAND

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Gas Generator

PLACING GAS GENERATOR ON (TYPICAL)

TRANSPORT STAND
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Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

Typically, the gas generator must be removed from
enclosure or moved forward sufficient to clear roof
hatch door in order to remove the free turbine.

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

STEP 1 REMOVAL OF FLEXIBLE COUPLING AND
EXHAUST INNER DUCT
Equipment required:
Brace IPC 4561
Brace IPC T1013
1. Install IPC 4561 and IPC T1013 Braces to support rear
uprights.
2. Disconnect and remove rear flexible coupling.
3. Remove bolts securing exhaust inner duct and slide
rearward.
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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

TURBINE SHAFT HEATSHIELD

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

STEP 2 REMOVAL OF FREE TURBINE SHAFT AND
INSTALLATION OF LIFT AND TURN MOUNTS
Equipment required:
Adapter PWA 11557 2 each
1. Install a block or trolley to support the turbine
exhaust duct.
2. Remove bolts, nuts and brackets from Flange T,
disconnecting turbine exhaust duct from free turbine.
3. Mount PWA 11790 1 each.

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

4. Mount PWA 11791 1 each
5. Remove bolts which secure front end of free turbine
shaft to rear flexible coupling. Allow shaft and
exhaust inner duct to rest on the turbine exhaust
duct.
6. Install PWA 11790 and PWA 11791 Lift and Turn
Mounts. Attach a PWA 11557 Adapter to each mount.

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

FREE TURBINE SHAFT REMOVAL

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

STEP 3 FREE TURBINE REMOVAL
Equipment required:
Trolley 1 each Hoist
Chain 2 each
Sling, Crane 1 each
1. Attach two chain hoists to trolley and attach lifting
hooks to PWA 11557 Adapters.
NOTE
Free turbine weighs approximately 4300 pounds.
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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

2. Apply enough lifting tension to chain hoists, to
relieve free turbine pressure on mounts; then remove
retaining pins and attaching hardware from side and
lower mounts.
3. Raise free turbine, with chain hoists, to clear side
and lower mounts.
4. Move trolley and free turbine under hatch.
5. Attach crane sling to trolley, and lift trolley and free
turbine.

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

FREE TURBINE REMOVAL

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

STEP 4 REMOVAL
ENCLOSURE

OF FREE TURBINE FROM

1. Turn trolley and free turbine 90 degrees; then

carefully remove from enclosure.

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

REMOVAL OF FREE TURBINE FROM ENCLOSURE

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

STEP 5 PLACING FREE TURBINE ON SHIPPING
STAND
1. Rotate free turbine to vertical position with exhaust
case down, using straps for controlling rotation.
2. Place free turbine on shipping stand.

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El FurrialPower
Barinas
PowerPlant
Plant

Removal Procedure Free Turbine

PLACING FREE TURBINE ON SHIPPING STAND

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure
The gas generator and free turbine are installed in the
gas turbine enclosure through the removable roof hatch
door provided.
Special lifting and handling fixtures are required for this
procedure.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

STEP 1 REMOVAL
SHIPPING STAND
Equipment required:

OF FREE TURBINE FROM

Sling, Crane 1 each

Adapter PWA 11557 2 each
Mount PWA 11790 1 each
Mount PWA 11791 1 each
Hoist, Chain 2 each
Trolley

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

NOTE
The roof hatch must be removed from enclosure, and
gas generator must be removed or far enough forward in
enclosure to allow installation of free turbine.
1. Install PWA 11790 and PWA 11791 Lift and Turn
Mounts to free turbine brackets; then attach PWA
11557 Adapters to lift and turn mounts.
2. Install two chain hoists to enclosure trolley and lift
free turbine from shipping stand.
3. Place free turbine in horizontal position.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

REMOVAL OF FREE TURBINE FROM SHIPPING STAND

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

STEP 2 LOWER FREE TURBINE INTO ENCLOSURE
1. Position over hatch so that trolley is along the main
axis of enclosure.
2. Carefully lower into enclosure.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

INSTALLATION OF FREE TURBINE IN ENCLOSURE

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

STEP 3 INSTALLATION OF FREE TURBINE
Equipment required:
Support PWA 11718 1 each
1. Position and lower trolley over enclosure tracks, with
free turbine in position shown.
2. Raise free turbine to clear mounting pads, and roll
into position.
3. Place PWA 11718 support in position; then lower free
turbine into mounts.
4. Secure free turbine to lower and side mounts.
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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

FREE TURBINE INSTALLATION

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

STEP 4 INSTALLATION OF FREE TURBINE SHAFT
Equipment required:
Heater PWA 20366 1 each
1. Remove chain hoists
2. Remove PWA 11790 and PWA 11791 Lift and Turn
Mounts.
3. Apply antigalling compound to bolts and secure
Flange T, at turbine exhaust deflector and duct, along
with previously removed hardware.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

4. Heat free turbine rear flexible coupling with PWA
20366 Heater.
5. Remove heater and immediately assemble free
turbine shaft to flexible coupling with bolts,
tabwashers, and nuts. Torque nuts.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

INSTALLATION OF FREE TURBINE SHAFT

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

STEP 5 INSTALLATION OF FREE TURBINE SHAFT
HEATSHIELD AND CONNECTION OF SHAFT
1. Install new gaskets in front and rear gasket retainers.
2. Place both halves of free turbine shaft heatshield
together around gaskets with horizontal joints in a
vertical plane.
3. Apply anitgalling compound to bolts and secure
halves together with bolts and nuts. Torque bolts.
4. Connect free turbine shaft to customer equipment.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Free Turbine

INSTALLATION OF EXHAUST INNER DUCT AND

COUPLING
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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

STEP 1 REMOVAL OF GAS GENERATOR FROM
TRANSPORT STAND
Equipment Required (Typical)*:
Saddle PWA 20474 1 each
Sling PWA 20472 1 each
Nylon Strap 1 each
Adapter, Lifting PWA 20473 1 each
Crane or suitable lifting device
*

See applicable Gas Generator Maintenance Manual for specific model

data.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

NOTE
The roof hatch must be removed from enclosure.
1. Attach PWA 20473 Lifting Adapter to PWA 20472
Engine Sling.
2. Hoist sling over engine and connect adapter to
intermediate case.
3. Position PWA 20474 Saddle under turbine nozzle
case (inboard of all external tubes) and attach to
engine sling.
4. Release gas generator from transport stand, and
raise from stand with crane.
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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

5. Attach PWA 20884 Lifting Adapter to PWA 20472
Engine Sling.
6. Attach lifting adapter to lifting eye on engine mount
cross beam.
7. Hoist cross beam over gas generator with crane or
other suitable lifting device and connect cross beam
to intermediate case.
8. Position PWA 20790 Saddle under turbine nozzle
case (inboard of all external tubes) and attach to
engine sling.
9. Release gas generator from transport stand, and
raise from stand with crane.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

REMOVAL OF GAS GENERATOR FROM (TYPICAL)

TRANSPORT STAND
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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

STEP 2 TRANSFER OF GAS GENERATOR FROM
TRANSPORT STAND TO ENCLOSURE
1. Carefully lower gas generator into enclosure.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

GAS GENERATOR TRANSFER TO ENCLOSURE

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

STEP 3 INSTALLATION OF GAS GENERATOR
1. Install front mounts.
2. Clock engine to position machined pad at bottom of
inlet case in a horizontal plane and secure exhaust
case of gas generator to inlet duct of free turbine,
aligning bolt holes, as required.
3. Secure gas generator to free turbine with bolts and
torque.
4. Remove sling,
generator.

adapter

and

saddle

from

gas

5. Remove PWA 11718 Support from free turbine.

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El FurrialPower
Barinas
PowerPlant
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Installation Procedure Gas Generator

6. Install nose cone.
7. Install the bellmouth using nylon strap.
8. Install and secure two free turbine cooling air tubes.
9. Attach all fuel, oil, air and electrical connections from
base assembly and enclosure to gas generator.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

GAS GENERATOR INSTALLATION

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

STEP 4 INSTALLATION OF HATCH DOOR
Equipment required:
Crane or suitable lifting device.
1. Attach lifting cables to roof hatch.
2. Lift roof hatch from storage container and install.
3. Attach engine heater electrical supply.
4. Attach engine heater supply tube.

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El FurrialPower
Barinas
PowerPlant
Plant

Installation Procedure Gas Generator

TYPICAL HATCH DOOR INSTALLATION

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Barinas
PowerPlant
Plant

Are there any questions?

Review the sections learning objectives.

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