PGT25DLE Maintenance

GE Oil & Gas
Aeroderivative Gas Turbine

PGT25 DLE
Maintenance Approach
Imagination at work.
Maintenance planning
Design features and maintenance flexibility
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Power Turbine characteristics
PGT25+ power turbine, notwithstanding

its heavy duty design, features easy
replacement procedures, allowing “on
condition” maintenance as for the gas
generator.

• Running inspections
• Monitoring of main operating parameters:
temperatures, vibrations, pressures, speed etc.
Preventive
Maintenance
• Stand-by inspections
• Checks of equipments when unit is not in
operation
• Corrective maintenance refers to any action taken

as a result of a shutdown for cause, failure or a
Corrective condition noted through “on condition” monitoring
Maintenance that could lead to a failure
• Levels 1, 2, 3, 4 and 5

Preventive Maintenance
Running Inspections
• Gas turbine is in operation

• Operators must check and
record the values every one or
two hours.
• Records help to find the root
causes of gas turbine troubles

HP Recoup pressure check

HP Recoup pressure check

Stand-by Inspections
They are required when the gas turbine is not in operation. During this period of time,
the following items should be checked:
• LUBE OIL SYSTEM COMPONENTS

• FUEL SYSTEM COMPONENTS
• INTAKE SYSTEM AND FILTERS
• INSTRUMENTATION SETTINGS AND REPAIRS/SUBSTITUTIONS
• EMERGENCY BATTERIES STATUS
• FLUIDS LEVELS (OILS, WATER, ETC.)
• OTHER AUXILIARIES IN GENERAL
• BORESCOPE INSPECTION FOR ALL THE INTERNAL PARTS

Borescope Inspection
Borescope inspection allows to check gas turbine internal components without casings removal
Main components
• Miniature camera
• Screen
• Battery
• Joystick
INSPECTION TO BE PERFORMED SEMIANNUALLY

Borescope inspection should be scheduled according to:
• operating conditions and environment of the gas turbine
• recommendation from the O&M manual and TILs

40 access ports
For further information,

refer to the O&M manual
Each stage of the axial

compressor can be
inspected by borescope

LP TURBINE BORESCOPE ACCESS LOCATIONS

PGT25+ HSPT Maintenance
Borescope Inspections
1 Buckets 2
1 Nozzles 2

Corrective Maintenance
Inspection Levels
• Level 1: On-Site
 Engine Removal & Reinstallation
 Borescope Inspections
 External Parts Replacement
• Level 2: On-Site
 Compressor Blade and Vanes Replacement and/or Repair
 High Pressure Compressor Trim Balance
 Power turbine Blade and Vane Blend Repair
 Accessory Gearbox and Component Replacement
 Hot Section Repair/Exchange
• Level 3: In-Shop
 Disassembly Down to Module Level
 Disassembly of Modules Down to Single Piece Part
 Level 4 plus equipment to repair pieces parts and components

Level 1 activities
Gas generator removal

from enclosure
Check of auxiliary systems

and replacement if needed
Check of sensors and

replacement if needed
For further details,


Level 2 activities
Compressor Casings and Blade/Vanes

Replacement and/or Repair.
High Pressure Compressor Balance.
Power turbine Blade and Vane replacement

and/or Repair.
Accessory Gearbox and Component

Replacement.
Hot Section Repair/Exchange.


Level 2 activities
Level 2 Vertical Maintenance
Vertical maintenance-lift and turn Vertical maintenance-turning

Level 2 activities
Vertical maintenance-Turbine mid frame Vertical maintenance-HPTR

Level 2 activities
Vertical maintenance-Stage 1 HPT Vertical maintenance-Combustion liner

Level 2 activities
Compressor stator cases removed Compressor rear frame removed

Level 2 activities
Level 2 Horizontal Maintenance
Removal/installation of high pressure Removal/installation of

turbine rotor & 2nd stage nozzle 1st stage HPT nozzle

Level 2 activities
Removal/installation of combustor Compressor stator cases removed

Level 2 activities
Rear frame/stator cases removal

Level 3, 4 & 5 activities
Level 3, 4 and 5 maintenance activities can only be performed at permanent shops,

where adequate space, special tools and services are available.

Level 3 activities
Complete disassembly of the gas turbine into the

following major sub-assemblies:
• Compressor rotor
• Compressor rear frame
• HP turbine rotor
• LP turbine rotor
Test cell and balance capabilty is recommended.

Level 4 activities
Level 4 includes Level 3 capability plus equipment to

disassemble the major sub-assemblies into piece
parts such as:
• HP and LP turbine stator and rotor blades

• Turbine bearings
• Turbine discs
• Combustor components
Test cell and balance capabilty is required.

Level 5 activities
Level 5 includes Level 4 capability plus equipment to

repair piece parts and components. Repair involves
the following major specialised activities:
• Welding
• Machining
• Flame spray operations
• Testing
Test cell and balance capabilty is required.

PGT25DLE Power Turbine Maintenance
PGT25 Power Turbine Maintenance
Maintenance Action Frequency (*)
Borescope 4,000 hrs (*)

The following intervals (excepted for
borescope inspections) are expected
Hot Gas Path 25,000 hrs
for continuous duty and they are for
reference only.
Major Overhaul 50,000 hrs Specific maintenance planning should
be scheduled based on borescope
observation.
Parts replacement can be carried out on site or in a service shops.


Hot Gas Path Inspection – Gas Generator Translation Fixture

Hot Gas Path Inspection – Gas Generator and Power Turbine coupling flanges

Hot Gas Path Inspection – 1st phase of Gas Generator Translation

Hot Gas Path Inspection – 2nd phase of Gas Generator Translation

Hot Gas Path Inspection – 3rd phase of Gas Generator Translation

Hot Gas Path Inspection – Transition piece outer casing removing 1st phase

Hot Gas Path Inspection – Transition piece outer casing removing 2nd phase

Hot Gas Path Inspection – Transition piece outer casing removing 3rd phase

Hot Gas Path Inspection – 1st stage nozzles removing 1st phase

Hot Gas Path Inspection – 1st stage nozzles removing 2nd phase

Hot Gas Path Inspection – 1st stage nozzles removing 3rd phase

Hot Gas Path Inspection – 1st Stage Turbine Casing Removing

Hot Gas Path Inspection – 2nd stage turbine casing removing 3rd phase

Hot Gas Path Inspection –components inspection

Hot Gas Path Inspection – components inspection
Typical nozzles crack
mode and acceptability
limits





Major Inspection – overview
The parts involved in “Major Inspection” are:
- Gas generator (translation or removal if it is interested to maintenance activities);

- Transition piece;
- 1st stage nozzles;
- 1st stage turbine casing;
- 2nd stage nozzles and diaphragms;
- 2nd stage turbine casing;
- 1st and 2nd stage buckets;
- Rotor;
- Journal and thrust bearings;
- Seals (oil/air seals);
- Exhaust diffuser;
- Exhaust casing.

Major Inspection – Casings and rotor assembly removal 1st phase

Major Inspection – Casings and rotor assembly removal 2nd phase

Major Inspection – Casings and rotor assembly removal 3rd phase

Major Inspection – Casings and rotor assembly removal 3rd phase

Major Inspection – Lifting Collar

Major Inspection – Rotor and casing assembly set over the modified trolley

Major Inspection – Exhaust casing and diffuser inspection
1. Exhaust casing inspection

a) Check for exhaust casing distortion, cracks, overheating, combustion
residuals deposit.
b) Check for exhaust casing internal bag distortion, cracks, overheating,
combustion residuals deposit.
c) Proceed with necessary cleaning and repairs.
2. Exhaust diffuser inspection

a) Check for exhaust diffuser distortion, cracks, overheating, and
combustion residual deposit.
b) Check for exhaust diffuser centring ring. The ring shall not force
the exhaust seals.
3. Exhaust seals clearance

a) Check for exhaust seals wear, erosion, corrosion.

Major Inspection – Bearing inspection
Journal and thrust collar inspection

The inspection of rotor journal and thrust collar shall be performed as follows:
a) The surfaces of the rotor (journal and thrust collar) should be checked in order to detect any
trace of wear and deterioration.
When these surfaces have intolerable defects, the rotor journal can be reduced by means of
machining. In such a case, special journal bearing should be used.
As far as the thrust collar is concerned, it can be re-machined and the value of the axial thrust
of the rotor readjusted using special thrust bearings. For further information consult the
Customer Service at N.P. or a representative of the company.
b) The rotor journal diameter shall be checked as follows:

- Clean the journal surface
With the help of an outside micrometer check the journal diameter checking the dimension in
three axial points (at the centre and at the two extremities), in the bearing operation area,
and performing two dimensional check 90° degrees apart for each axial point.
- Record the values detected

b) Check that the conditions of the anti-friction metal coating of the pads and measure the
average diameter of the journal bearing in order to calculate the clearance between the
bearing and the journal
as follows:
- Check the pad surfaces coated with anti-friction metal.

No cracks or missing anti-friction metal are acceptable.
- Make sure that the anti-friction metal coating is not abnormally or excessively worn.
- Check for scratches, scores or dent on the anti-friction metal coating. If these are not
important, both in number and depths, they can be left there.
c) If the journal or the thrust bearing has experienced excessive temperature, the anti-friction
metal shows evidence of smear and wiring.
d) Accurately eliminate the foreign objects that may have fouled the anti-friction metal without
causing any burr or excessive depression.
For further information about these procedures, consult the N.P. Customer Service or a N.P.
representative.

e) With the bearing disassembled and cleaned, the pads inspected and conformed to be
reused, clean the mating surfaces of the bearing casing. Make sure that they have no
burrs or dents. Put them together and block them with their screws.
- Measure the base diameter of the pads in the casing in five points at zero degrees,
vertical axis, at 45 degrees, at 90 degree, above and below the horizontal joint, at 135
degrees. Calculate the mathematical average of the values detected.
- Measure the maximum value of the pad thickness (at the centre of the arc) with the
help of on outside micrometer gauge with spherical sensors.
Calculate the mathematical average of the thickness values taken on the five pads.
From the average calculated from the base diameter subtract the average calculated
from the pads twice.
The result will correspond to the (average internal diameter of the bearing).
From the average bearing diameter, subtract the average diameter of the
corresponding journal.
The result will correspond to the diametrical clearance between the journal and the
bearing liner. Compare the obtained value with the clearance requested on the
“Clearance Diagram”.

Thank you.
Questions & Answers
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Introduction & General Overview

PGT25DLE Maintenance

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GE Oil & Gas

Aeroderivative Gas Turbine

November 15 GE Proprietary Information | All Rights Reserved Page 2

PGT25+ power turbine, notwithstanding

November 15 GE Proprietary Information | All Rights Reserved Page 3

• Corrective maintenance refers to any action taken

November 15 GE Proprietary Information | All Rights Reserved Page 4

• Gas turbine is in operation

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November 15 GE Proprietary Information | All Rights Reserved Page 8

• LUBE OIL SYSTEM COMPONENTS

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INSPECTION TO BE PERFORMED SEMIANNUALLY

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For further information,

Each stage of the axial

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LP TURBINE BORESCOPE ACCESS LOCATIONS

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Gas generator removal

Check of auxiliary systems

Check of sensors and

For further details,

November 15 GE Proprietary Information | All Rights Reserved Page 16

Compressor Casings and Blade/Vanes

High Pressure Compressor Balance.

Power turbine Blade and Vane replacement

Accessory Gearbox and Component

Hot Section Repair/Exchange.

For further details,

November 15 GE Proprietary Information | All Rights Reserved Page 17

Level 2 Vertical Maintenance

Vertical maintenance-lift and turn Vertical maintenance-turning

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Level 2 Vertical Maintenance

Vertical maintenance-Turbine mid frame Vertical maintenance-HPTR

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Level 2 Vertical Maintenance

Vertical maintenance-Stage 1 HPT Vertical maintenance-Combustion liner

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Level 2 Vertical Maintenance

Compressor stator cases removed Compressor rear frame removed

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Level 2 Horizontal Maintenance

Removal/installation of high pressure Removal/installation of

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Level 2 Horizontal Maintenance

Removal/installation of combustor Compressor stator cases removed

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Level 2 Horizontal Maintenance

Rear frame/stator cases removal

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Level 3, 4 and 5 maintenance activities can only be performed at permanent shops,

November 15 GE Proprietary Information | All Rights Reserved Page 25

Complete disassembly of the gas turbine into the

Test cell and balance capabilty is recommended.

November 15 GE Proprietary Information | All Rights Reserved Page 26

Level 4 includes Level 3 capability plus equipment to

• HP and LP turbine stator and rotor blades

Test cell and balance capabilty is required.