Inspection Procedure 501 Frame Combustion Turbines

Functional Function
Number: Title:

4.7.1 Remove Combustor Cylinder Transitions (Clamshells)

4.7.2 Remove Cross Fire Flame Tubes
4.7.3 Remove Combustor Baskets
4.7.4 Remove Transitions
4.7.5 Inspect Combustor Cylinder Transitions (Clamshells)
4.7.6 Inspection of Cross Fire Flame Tubes
4.7.7 Inspect Combustor Baskets
4.7.8 Inspect Transitions
4.7.9 Install Transitions
4.7.10 Install Combustor Baskets
4.7.11 Install Combustor Cylinder Transitions (Clamshells)
4.7.12 Install Cross Flame Tubes
Function No. 4.7.1

Task Title: Remove Combustor Cylinder Transitions (Clamshells)

Task Dwg Ref/Serial Instructions

1. Remove the self-locking nuts and bolts from Sec.#6 Dwg. 6.3
cylinder. Compressor/Combustor Sect.

2. Install .500” –13 UNC jackscrews (2) and

jack cylinder halves apart. Remove all 14
clamshell sets.

3. Mark mating halves of cylinder and keep as

sets.

4. Inspect self-locking nuts and bolts for dam-

age. The nut may be reused until the fol-
lowing prevailing torque values* cannot be
attained:
Prevailing torque values:
Min-52 in-lbs
Max-300 in-lbs
*Prevailing torque is the torque measured
while the nut is in motion, rotating on the bolt.
Function No. 4.7.2

Task Title: Remove Cross Flame Tubes

Task Dwg Ref/Serial Instructions

1. Remove the Martman coupling from the Sec.#6 Dwg. 6.3

cross flame tube to the combustor basket Compressor and Comp. Combustor Sect.
coupling.

2. Remove the Martman coupling from the

cross flame sleeve.

3. Remove the cross flame tube.

4. Repeat steps 1, 2, and 3 for the remaining 13

cross flame tubes marking each part as it is
removed to allow it to be reinstalled in it’s
original location, position and orientation.
Function No. 4.7.3

Task Title: Remove Combustor Baskets

Task Dwg Ref/Serial Instructions

The combustor cylinder transitions Sect. #6 Dwg. 6.3 Compressor/Combustor

(clamshells) must be removed prior to the Sect.
combustor baskets.

1. Remove the 4 screws from the outside face

of the fuel nozzle port on the compressor/
combustor cylinder that hold each
combustor basket to the inside of the
compressor/combustor cylinder.

2. Slide combustor basket aft (towards

turbine exhaust) and lift free of unit.

3. Remove remaining 13 baskets identifying

each to return to original position.
Function No. 4.7.4

Task Title: Remove Transitions

Task Dwg Ref/Serial Instructions

Combustor baskets must be removed prior Sect. #6 Dwg. 6.3.18

to transitions per Function 4.7.3. Combustor and Transition Assembly

1. Inspect the forward transition support prior Sect. #10 Charts #10-4-11, #10-4-12
to disassembly. Measure clearances and
record on charts #10-4-11 and #10-4-12
in Section #10.
a) Clearance between transition support and
support lock should be 0.010” min. –
0.050” max. (see Fig 4.7.4.A)
b) Axial clearance between support and ear
should be 0.200” min. (see Fig 4.7.4.B)
c) Measure the gap at support finger using a
0.0015” feeler gauge. If it enters gap,
replace screws in the holding supports
(see Fig. 4.7.4.C)

2. Cut lockwire between screws holding

transition to blade ring.

3. Remove screws holding the mounting plate

of transition to blade ring.

4. Loosen screws on the adjacent transitions.

5. Slide the transition forward and lift it free

of unit. If necessary, move the adjacent
transitions aside in order to disengage the
side seals.

6. Remove remaining 13 transitions. Mark

each transition as it is removed with it’s
location number as shown on section F-F
of the Combustor and Transition
Assembly.

7. When required, remove center plane

balance tube. Remove clamps holding
guide tube and remove guide tube.
Function No. 4.7.4 (Continued)

Task Title: Remove Transitions

Function No. 4.7.5

Task Title: Inspect Combustor Cylinder Transitions (Clamshells)

Task Dwg Ref/Serial Instructions

Keep the top and bottom halves together in Sect. #6 Dwg. 6.3 Compressor/Combustor
the same pairs as they were when removed.

Clean and inspect per Service Bulletin Sect. #10 Charts #10-4-7 & 10-4-8
#37616

Record any distress on charts #10-4-7 and SB #37616

#10-4-8 in Section 10, along with all other
information required by the chart and Service
Bulletin #37616.
Function No. 4.7.6

Task Title: Inspection of Cross Flame Tubes

Task Dwg Ref/Serial Instructions

1. Inspect the flexible cross flame tubes: Sect. #6 Dwg. 6.3 Compressor/Combustor
Sect.

A. Visually inspect cross fire tube flanges; if Sect. #10 Charts #10-4-18
the flanges appear to be worn, replace the
tube assembly.
B. Visually inspect tube walls:

1) If the wall thickness is reduced to

60% of the original specified thick-
ness, replace tube.
2) If any holes or cracks are found, replace
the tube assembly.
3) If the cross flame tube cannot be
flexed by hand, replace the tube
assembly.

2. Inspect Marman Clamp:

A. If any cracks are found, replace the clamp.

B. If the clamp will not prevent movement
between mating flanges and cross flame
tube, replace the clamp.
Function No. 4.7.7

Task Title: Inspect Combustor Baskets

Task Dwg Ref/Serial Instructions

1. Inspect all combustor baskets per Service Sect. #6 Dwg. 6.3 Compressor/Combustor
Bulletin #36923.

2. Dust blast clean (Clemtex #5 or Sect. #10 Charts #10-4-5 & 10-4-6
equivalent).

3. Zyglo inspect all spot welds and the SB #36923 & #36916
surrounding metal for 0.75 inch past the
outer circumference of the spot weld per
Service Bulletin #36923.

4. Inspect cross flame tube basket flanges.

A. Inspect flanges for wear.

B. Mate the cross flame tube and Marman

clamp. If there is movement at the flange
after tightening, replace flange, clamp, or
cross flame tube as required.

5. Record any damage for future reference on

chart #10-9.
Function No. 4.7.8

Task Title: Inspect Transitions

Task Dwg Ref/Serial Instructions

Dust blast clean. Sect. #6 Dwg. 6.3 Compressor/Combustor

Zyglo inspect per Service Bulletin #36916.

Inspect transitions and related parts. Sect. #10 Charts #10-4-9 & 10-4-11, #10-4-
12

Chart any damage for future reference on

charts #10-12A, -12B and #10-13.

If any transitions required replacement, SB #36916

remove the transition inner and outer floating
seals for use on the replacement transitions.
Mark each seal with the location number of
the transition from which it was removed.

NOTE: Order new shear pins.

Inspect the transition floating seals for

cracked, worn, or missing metal around the
(shear pin) slotted holes as shown in Figure
4.7.8.A.
Function No. 4.7.9

Task Title: Install Transitions

Task Dwg Ref/Serial Instructions

1. If any of the inner or outer floating seals Sect. #6 Dwg. 6.3.18 Combustor & Transition
have been removed from the transitions, Assy.
install odd numbered seals (as marked per
Function 4.7.8 task 5) on odd numbered
transitions (as marked per Function 4.7.4
task 6) and even numbered transitions.
Use new shear pins. Securely stake the
shear pins in the transitions.

1. To install the transition, specific transitions SB #37706

are to be mounted on their supports, but
not completely aligned until after their
adjacent transitions have been mounted
and aligned. This is done to ensure that
the last transition to be installed will not
be out of alignment tolerance due to the
accumulated tolerances of the preceding
transition installations.

1. Transitions must be installed according to

the following sequence and procedure.
Mounting should be accomplished
according to task 4 and alignments
according to task 5.

NOTE: The locations for the transitions

specified in the following procedures
correspond to the positions shown on Section
F-F, of the Combustor & Transition Assembly
Dwg. In Section #6 of this manual.
A. Mount and completely align the #7 posi-
tion transition.
B. Mount but leave loose the #8 position tran-
sitions.
C. Mount and completely align the #9 posi-
tion transition.
D. Completely align the #8 position transi-
tion.
A. Mount but leave loose the #6 position
transition.
Function No. 4.7.9 (continued)

Task Title: Install Transitions

Task Dwg Ref/Serial Instructions

A. Mount and completely align the #5 position

transition.
B. Completely align the #6 position transition.

C. Mount but leave loose the #4 position transi-

tion.
D. Mount and completely align the #3 position
transition.
E. Completely align the #4 position transition.

F. Mount but leave loose the #10 position transi-

tion.
G. Mount and completely align the #11 position
transition.
H. Completely align the #10 position transition.

I. Mount but leave loose the #14 position transi-

tion.
J. Mount and completely align the #13 position
transition.
K. Mount and completely align the #12 position
transition.
L. Mount and completely align the #1 position
transition.
M. Completely align the #14 position transition.

N. Mount and completely align the #2 position

transition. Install the torque tube cooling air
pipes (if they have been removed) after these
transitions have been installed.
 4. Transition mounting procedure:
A. Ensure that the inner and outer floating seals are
securely attached to the transition and that the
transition will be installed in the correct location
(ref. Task #1).
B. Position both transition U-shaped supports in the
combustor transition supports and slide the tran-
sition toward the #1 turbine blade ring assembly
until the inner and outer floating seals engage the
mating surfaces on the #1 row turbine blade ring
and vane segments.

Function No. 4.7.9 (continued)

Task Title: Install Transitions

Task Dwg Ref/Serial Instructions

A. Install screws throughout the mounting plate to

the #1 row blade ring segment. If the holes
will not align to allow installation of the
screws or if force is required to align the holes,
contact your local Westinghouse office.

NOTES 1: Screws should be sufficiently loose to

allow the transition to be shifted for alignment
purposes.

NOTES 2: For best results, all combustor and

transition alignments are to be done with all covers
bolted in place. If this is not possible, ensure that
the compressor combustor cover vertical joint
surface and the exhaust cylinder cover vertical
joint surface are parallel.
5. Transition Alignment Procedure:
A. Check the side seal gap between transitions as
shown on Fig.4.7.9.C. If the gap is irregular
from space to space, the transition can be
adjusted by loosening the transition mounting
plate screws and moving the transition. If nec-
essary the holes in the transition mounting
plate could be elongated circumferentially to
permit a greater transition adjustment range.
(See view AA of Fig. 4.7.9.B)
B. Check as shown on fig 4.7.9.A that the side
seals are not overlapping each other (and will
not interfere when the circumferential clear-
ance decreases with the heating of the transi-
tions). If they are overlapping, the side seal
strips can be slightly ground on the opposite
side from their weld.
C. Check the gap between the outer periphery of
the transition outlet mouth and the blade ring.
Minimum clearance is 0.121”. (See C in Fig.
4.7.9.B) If gap is too small, grind the transi-
tion to obtain a clearance of 0.140”.
D. Check that for each assembled transition the
inner and outer floating seal can move radially
and axially by hand.
Function No. 4.7.9 (continued)

Task Title: Install Transitions

Task Dwg Ref/Serial Instructions

A. Ensure that the inner and outer floating seals are

correctly meshed with the #1 row blade ring and
vane segments with a clearance of 0.15” to 0.38”
between adjacent seal segments.
B. Measure the gap between the transition support and
transition forward mounting bracket as shown in
Fig. 4.7.9.C. Gap must be 0.20” minimum. Grind
“U” bracket to obtain 0.20” minimum. Check that
there is clearance between the support and the
curved position of the transition forward mounting
bracket. Check the radial clearance between transi-
tion “U” and support as shown in Fig. 4.7.9D. If
greater than 0.050” or less than 0.010”, contact
your local Westinghouse office.
C. Check that the inside surface of the transition inlet
mouth is concentric (within 0.060”) to the inside
surface of the fuel nozzle mounting port in the
compressor/combustor cylinder.
NOTE: The concentricity may be checked either by
measurement or by using a transition alignment tool.
Transitions are to be resting freely on the transition
inlet support or its support plate during alignment.
D. If adjustments are necessary to obtain the specified
concentricity, recheck the aft (exhaust) end align-
ment per tasks #5.A through #5.F. After this is
completed, recheck the concentricity per task
#5.G.
E. Repeat tasks #5.A through #5.H until all dimen-
sional and alignment criteria have been met.
F. As additional transitions are installed, it is possible
that the last transition will not meet the alignment
dimensions. This is due to the combining of the
alignment tolerances during installation of the
initial transitions. This situation can be alleviated
by aligning each transition to the middle of the
specified tolerance range as it is installed. It is also
possible to readjust previously installed transitions
to the limit of the specified tolerance to allow later
transitions to be installed. However, if this
procedure is used it is necessary to recheck all
alignment dimensions per Task #5.A through #5.1
for all transitions that are moved.

G. After all transitions are aligned, tighten the screws

that hold the transition mounting plate to the row
#1 turbine segments and lockwire the screws to
each other. See section #5 for bolting information.
Function No. 4.7.9 (continued)

Task Title: Install Transitions

Function No. 4.7.10

Task Title: Install Combustor Baskets

Task Dwg Ref/Serial Instructions

1. Install combustor basket and slide it forward Sect. #6 Dwg. 6.3.18 Combustor & Transition
(toward the compressor inlet) until the neck Assy.
flange mates with compressor-combustor
cylinder.
NOTE: Start with basket location #7 as shown
on Combustor & Transition assembly Dwg.
Section F-F Assembly and work up around each
side of the combustor cylinder.

2. Rotate basket until cross flame tubes are

properly oriented and mating cylinder holes
align.

3. Install four (4) screws through the compressor

combustor cylinder into the neck flange of
the combustor basket and tighter. See section
#5 for bolting information.
 4. Measure the concentricity alignment of the
combustor basket to transition at eight
equally spaced locations around the inside
circumference of the transition inlet mouth at
points that are past (downstream of) the
tapered section of the transition mouth.
Ensure that the inside of the combustor bas-
ket outlet mouth is concentric to between
0.190” (min.) and 0.310” (max.) with the
I.D. of the transition inlet mouth when mea-
sured at the eight points.
A. Check that the basket does not enter the inlet
mouth of the transition.
B. When the combustor baskets with igniter
holes are installed, the gap between the
igniter guide and the igniter flange on the
basket should be checked:
a) Check that the igniter guide is aligned with
the basket extension for the igniter. If the
basket extension is visible through the
igniter guide tube, the basket extension is
misaligned. Align the basket extension to
the guide tube.

Function No. 4.7.10 (continued)

Task Title: Install Combustor Baskets

Task Dwg Ref/Serial Instructions

a) Check the gap between the igniter guide tube

and the basket extension. This gap
should be between 0.062” and 0.125”.
If the gap is too small, grind the basket
extension to obtain proper gap. If the
gap is too large, replace the basket
extension. (See Fig. 4.7.11)

5. Install the combustor cylinder transition

(clamshell) per function 4.7.11.
 6. Install the next basket using steps 1 through 6.

7. Install the cross flame tube between the two

combustor baskets per Function 4.7.12.

8. On combustor baskets with flame detectors check

the alignment of the flame detector tube to
combustor basket scoop for clear view of flame.

Figure 4.7.10.A
Function No. 4.7.11

Task Title: Install Combustor Cylinder Transitions (Clamshells)

Task Dwg Ref/Serial Instructions

Install the two mating halves of the combustor Sect. #6 Dwg. 6.3 Compressor/Combustor Sect.
cylinder transitions (clamshells) around the
spring fingers of the combustor basket ensuring
that the internal groove in the outlet mouth of the
clamshell is seated around the flange on the O.D.
of the transition inlet.

Position the flange of the clamshells to match the Sect. #6 Dwg. 6.3.18 Combustor & Transition Assy.
orientation of the clamshells shown on Section F-
F of the Combustor & Transition assembly.

Bolt the transition cylinder halves together with

the (self-locking) nuts on the side of the clamshell
flanges that are nearest to the access openings in
the compressor-combustor cylinder.
NOTE: When bolting the transition locking cylin-
der halves together, check the self-locking nuts to
ensure that the nuts are still self locking. The self-
locking feature of the nuts can be checked by try-
ing to turn the nuts by hand (without using any
wrenches) on an unworn length of bolt. The nut
may be reused until the following prevailing
torque values cannot be attained:
Prevailing torque value
Min - 52 in-lbs
Max – 300 in-lbs
Ensure that the clamshells are centered around the
O.D. of the combustor basket fingers and that no
binding will occur between the basket and the
clamshell that will hinder axial movement between
these two parts during thermal expansion.
Final tightening torque values:
Min – 100 ft-lbs
Max – 110 ft-lbs (149 N.M.)
*Prevailing torque is the torque measured while the
nut is in motion, rotating on the bolt.
Function No. 4.7.12

Task Title: Install Cross Flame Tubes

Task Dwg Ref/Serial Instructions

If the cross flame (tube) sleeve has been removes Sect. #6 Dwg. 6.3 Compressor/Combustor Sect.
from the cross flame tube, slip the sleeve over the
smooth end of the cross flame tube until the
flanged end of the sleeve is even with the end of
the cross flame tube.

Install the cross flame tube and sleeve between

two combustor baskets ensuring that the tube is
positioned and oriented as it was when it was
removed by using the markings applied per
function 4.7.2 as a reference.

Cross flame tube should be installed between

adjacent baskets before the next basket in
sequence is installed.

Install a Marman coupling over the flanges of the

cross flame tube sleeve and the combustor basket
cross flame tube “tub”.

Install a Marman coupling over the flanges of the

cross flame tube and the combustor basket cross
flame tube.

Tighten the Marman coupling nuts with 80+ 10

in-lb of torque.
NOTE: the ends of the segments in the Marman
coupling should not butt together at any place
when the nut is tightened to the above torque. If
the ends of the segments do not have a gap at all
junctures, replace the Marman coupling.