SL 2 ECT -

Training text for M701JAC GT

disassembly scope of Planned
Maintenance

Global Field Service Group WGFE20-0047(R0)

Takasago Service Engineering
Department
Takasago Service Division
Power Systems Service Headquarters

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prior written consent of Mitsubishi Hitachi Power Systems,Ltd.
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 SL 2 ECT -

Contents

Preface

Maintenance Philosophy

Disassembly scope of Planned Maintenance

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transmitted, or disclosed without prior written consent of Mitsubishi Hitachi Power Systems, Ltd
 SL 2 ECT -

Contents

Preface

Maintenance Philosophy

Disassembly scope of Planned Maintenance

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 SL 2 ECT -

Preface

This document explains maintenance philosophy,

disassembly scope of Planned Maintenance.

Please refer to work procedure described in

OMM(Operation & Maintenance Manual) for details.

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transmitted, or disclosed without prior written consent of Mitsubishi Hitachi Power Systems, Ltd
 SL 2 ECT -

Contents

Preface

Maintenance Philosophy

Disassembly scope of Planned Maintenance

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transmitted, or disclosed without prior written consent of Mitsubishi Hitachi Power Systems, Ltd
 SL 2 ECT -

Maintenance Philosophy (M701JAC)

1. Planned Maintenance shall be carried out each
12,500 EFH or 20,000AOH or 450ES interval
whichever comes earlier.

Scheduled Outage Hours shall commence when the Covered

Equipment is off-synchronized on shutdown and shall end when the
Covered Equipment reaches base load following conclusion of the
combustion tuning.
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 SL 2 ECT -

Maintenance Philosophy (M701JAC)

2. The items listed below are defined as Hot Gas Path

Parts.
They are subject to Roll-in/Roll-out during planned
maintenance.

Hot Gas Path Parts

・Combustor swirler
・Combustion liner
・Fuel nozzle
・Turbine Vane Row 1 to 4
・Turbine Blade Row 1 to 4
・Turbine Ring Segment Row 1 to 4

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 SL 2 ECT -

Maintenance Philosophy (M701JAC)

3. Each inspection is performed with Roll-in/Roll-out
system:
1) One set of hot gas path parts should be prepared and
replaced at each inspection.
(depending on parts repairing interval)
2) Replaced parts should be repaired by next inspection.
INSPECTION INSPECTION INSPECTION
FIELD

Roll-Out Roll-Out Roll-Out

Roll-In Roll-In Roll-In

SPARE
PARTS NEW PARTS CLEANING Ditto Ditto
OR INSPECTION
REPAIRED PARTS REPAIRMENT
Advantage of Roll-in/Roll-out system:
 Shorten Inspection duration = reduce total plant outage duration.
 Optimize hot gas path parts management.
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 SL 2 ECT -

Cross-section Drawing of M701JAC Gas Turbine

INLET
MANIFOLD COMPRESSOR
INLET COMPRESSOR -COMBUSTOR TURBINE EXHAUST EXHAUST
CYLINDER CYLINDER CYLINDER CYLINDER MANIFOLD
CYLINDER

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 SL 2 ECT -

Contents

Preface

Maintenance Philosophy

Disassembly scope of Planned Maintenance

Proprietary and Confidential Information. This document or information cannot be reproduced, 9

© 2018 Mitsubishi Hitachi Power Systems, Ltd. All Rights Reserved.
transmitted, or disclosed without prior written consent of Mitsubishi Hitachi Power Systems, Ltd
 SL 2 ECT -

Disassembly scope of Combustor Inspection (CI)

No. 1 COMPRESSOR INLET 8 COMPRESSOR DIAPHRAGM
② IGNITERS LAST ROW & OGV
③ FUEL NOZZLES ⑨ ENCLOSURE ROOFS
④ COMBUSTOR SWIRLERS ⑩ PIPINGS
⑤ COMBUSTION LINERS ◯: Disassembled parts
6 TURBINE VANES ROW 1 *Items without ◯ will be only
AND RING SEGMENT ROW 1 visual inspection.
7 TURBINE BLADES ROW 1
AND ROW 4

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 SL 2 ECT -

Schedule of Combustor Inspection (CI)

Conditions of CI
・Scheduled Outage Hours:15 days ・Shift in work :2 shifts 12 hours a day
<Single Shaft, Dual-Ref> [M701JAC] Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day
Combustor Inspection (BtoO:15days) -3 -2 -1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
[2shift-12hour-7days] D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N
Main Key Date Scheduled Outage Hours
GT Operation GT Shutdow n Test OP Reporting
GT Cooling & Turning GT Turning Off Turning On
Work Permit Take Work Permit Return Work Permit

1. Enclosure Package & Insulation SAMPLE

Preparation Preparation
Enclosure Remov al Reassembly
Insulation Remov al Repair Reassembly
2. Instrumentation
Electrical & Instrument Disconnection Re-connection
Igniter Cable Disconnection Spark Test Re-connection
CPFM & Accelerator Sensor Disconnection Re-connection
3. Piping
Fuel Branch Pipe Remov al Reassembly
4. Inlet & Compressor Section
Inlet Manifold & IGV Linkage Mech. Open M/H Cleaning & Inspection Final Check & Close
5. Combustor Section The follow ing program parts are
Combustor Manway Cover Open M/H Final Check & Close required for replacem ent:

Igniter Remov al Reassembly *Fuel Nozzle Ass'y

CPFM Pressure Sensor Remov al Reassembly *Com bustor Sw irlers
Cross Flame Tube Remov al Reassembly *Com bustion Liners
Top-hat Assembly Remov al Reassembly *Outlet seal
Nozzle & Combustor Swirler Disassemble & NDE
Combustion Liner Reassembly
6. Turbine Section
Inspection of T1S, T1C, #1RS Inspection
7. Exhaust Section
Exhaust Duct Manway Cover Open M/H Final Check & Close
8. Inspection & Other
Bolt & Parts Cleaning
NDT
Servo Valve/Actuator Function Check Function Check (if required)
9. Extra Work
GT Auxiliary Equipment

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 SL 2 ECT -

Outline of Combustor Inspection

1. Visual Inspection of the Combustor Swirlers,
Combustion Liners, Fuel Nozzles and Tophat Nozzles

2. Non Destructive Test (Penetrant Test) of the

Combustion Liner’s support and accessary

3. Visual Inspection and Spark Test of Igniters

4. Visual Inspection of Turbine Blade Row 1 & Row 4,

Turbine Vane Row 1 and Ring Segment Row 1 & Row 4

5. Visual Inspection of IGV, Compressor Blade Row 1 and

Diaphragm Last Row & OGV

6. Valve adjustment of IGV, VV and Fuel Control Valve

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 SL 2 ECT -

Disassembly scope of ENCLOSURE ROOF PANEL (CI)

At the beginning of the combustor inspection, the enclosure roof panel in the
yellow shaded area shown below must be removed.

ROOF PANEL

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 SL 2 ECT -

Disassembly scope of FUEL and DRAIN PIPING (CI)

Fuel nozzle has 3 types of oil piping, 5 types of gas piping, and 1 type
of water piping.
Fuel nozzle cannot be removed without removing all of them.
Also, the lower half of the combustor outer shell has drain piping that
must be removed if it interferes with combustor(nozzle, swirler and
liner) removal.

(WATER INJECTION MANIFOLD PIPING) (COMBUSTOR OUTER SHELL DRAIN PIPING)

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 SL 2 ECT -

Outline of FUEL BRANCH and MANIFOLD PIPING

(MAIN OIL A) (MAIN OIL B) (OIL PILOT) (GAS TOPHAT)

(MAIN GAS A) (MAIN GAS B) (GAS PILOT A) (GAS PILOT B)

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 SL 2 ECT -

Disassembly scope of FILTER BLEED AIR PIPING (CI)

Filter bleed air piping must be removed before removing the

combustor swirler and combustion liner.

COMP-COMB CYL. TURBINE CYL.

FILTER BLEED
PIPE

FILTER BLEED AIR PIPING TORQUE TUBE

COVER

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 SL 2 ECT -

Disassembly scope of Turbine inspection (TI)

No. 1 COMPRESSOR INLET 9 COMPRESSOR DIAPHRAGM
② IGNITERS LAST ROW & OGV
③ FUEL NOZZLES ⑩ ENCLOSURE ROOFS
④ COMBUSTOR SWIRLERS & SIDE PANELS
⑤ COMBUSTION LINERS ⑪ PIPINGS
⑥ TURBINE CYLINDER ◯: Disassembled parts
⑦ TURBINE BLADE RINGS *Items without ◯ will be only
⑧ TURBINE BLADES, VANES Visual inspection.
AND RING SEGMENTS

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 SL 2 ECT -

Schedule of Turbine inspection (TI)

Conditions of TI
・Scheduled Outage Hours:24 days ・Shift in work :2 shifts 12 hours a day
<Single Shaft, Dual-Ref> [M701JAC] Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day
Combustor Inspection (BtoO:24days) -3 -2 -1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
[2shift-12hour-7days] D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N
Main Key Date Scheduled Outage Hours
GT Operation GT Shutdown Test OP Reporting
GT Cooling & Turning GT Turning Off Turning On
Work Permit Take Work Permit Return Work Permit
1. Enclosure Package & Insulation
Preaparation Preaparation

SAMPLE
Enclosure Removal Reassembly
Insulation Removal Repair Reassembly
2. Instrumentation
Electrical & Instrument Disconnection Electrical & Instrument
Igniter & Flame Detector Cable Disconnection Spark Test & Lighter Check Reconnection
CPFM & Accelerator Sensor Disconnection Reconnection
Disc Cavity T/C & BPT T/C Removal Reassembly & Reconnection
3. Pipings
Fuel Branch Pipe Removal Reassembly
Bleed Air Pipe Removal Reassembly
Turbine Cooling Pipe Removal Reassembly

4. Inlet & Compressor Section

Inlet Manifold & IGV Linkage Mech. Open M/H Cleaning & Inspection Final Check & Close
5. Combustor Section The following program parts are required
Combustor Manway Cover Open M/H Final Check & Close for replacement:

Igniter & Flame Detector Removal Reassembly *Fuel Nozzle Ass'y

CPFM Pressure Sensor Removal Reassembly *Com bustor Sw irlers
Cross Flame Tube Removal Reassembly *Com bustion Liners
Top-hat Assembly Removal Reassembly *Outlet seal
Nozzle & Combutor Swirler Disassemble & NDE
Combustion Liner Removal Reassembly
Support ring Removal Reinstall
6. Turbine Section The following program parts are required
Turbine Cylinder Removal Reassembly for replacement:

Turbine Blade Ring Removal Reassembly *Turbine Row 1,2,3 Vanes

Seal Housing Removal Reassembly *Row 1,2,3,4 Ring Segm ent
Vane, Ring Segment Removal T1C Reassembly T1C **Turbine Row 4 Vanes
Replacement 1RS,T2C,2RS, T3C, 3RS, (T4C), 4RS **Included in 2nd TI
7. Exhaust Section
Exhaust Duct Manway Cover Open M/H Final Check & Close
8. GT Rotor Section The following program parts are required
Turbine Blade (T1S,T2S,T3S) T1S T1S for replacement:
Removal T2S Reinstall T2S *Turbine Row 1~3 Blades
T3S T3S
9. Inspection & Other
Bolt & Parts Cleaning
NDT Inspection
Servo Valve/Actuator Function Test Function Test
10. Extra Work
GT Auxilliary Equipment

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 SL 2 ECT -

Outline of Turbine Inspection

1. Combustor inspection is carried out at the same time

2. Visual inspection of the Turbine Blades, Vanes, Ring

Segments and Seal housings

3. Non Destructive Test (Penetrant Test) of the Turbine

Blade’s accessary, Vane’s accessary, Ring Segment’s
accessary and Seal housings

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 SL 2 ECT -

Disassembly scope of ENCLOSURE ROOF PANELS (TI)

At the beginning of the turbine inspection, the enclosure roof panels and side panels
in the yellow shaded area shown below must be removed.

SIDE PANELS
ROOF PANELS
TURBINE CYLINDER

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 SL 2 ECT -
Disassembly scope of
TURBINE COOLING AIR, RCA & BLEED AIR, PURGE AIR, FG SWEEP AIR PIPING (TI)

In the turbine inspection, the upper half piping connected to turbine cylinder
must be removed in addition to the piping removed at CI since the turbine
cylinder is removed. Remove only
turbine side
piping

Remove only
turbine side
piping

COOLING AIR PIPING LOW PRESS. BLEED AIR PIPING MIDDLE PRESS. BLEED AIR PIPING

HIGH PRESS. BLEED AIR PIPING GT CASING COOLING AIR PIPING FUEL GAS SWEEP AIR PIPING
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 SL 2 ECT -

Disassembly scope of ENHANCED COOLING AIR PIPING (TI)

Enhanced cooling air piping includes exterior piping and short piping must be removed.
Turbine cylinder and turbine blade ring row 1&2 cannot be removed without removing short
piping.
B
A

TURB CYL EXTERIOR

PIPING

SHORT PIPING

PISTON RING

TURB BLADE
RING ROW 1&2
A
B
COOLING AIR PIPING TURB CYL RIGHT SIDE SECTION AA-AA

BB EXTERIOR
TURB CYL PIPING
AA
BB

SHORT PIPING
AA
PISTON RING

TURB BLADE
RING ROW 1&2

SECTION A-A SECTION B-B SECTION BB-BB

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 SL 2 ECT -

Disassembly scope of Major overhaul inspection (MI)

No.① IGNITERS ⑨ COMPRESSOR BLADE RINGS
② FUEL NOZZLES ⑩ TURBINE BLADE RINGS
③ COMBUSTOR SWIRLERS ⑪ JOURNAL BEARINGS AND THRUST BEARING
④ COMBUSTION LINERS ⑫ ROTOR AND JACK SHAFT
⑤ TURBINE BLADES ⑬ INLET CYLINDER
⑥ TURBINE VANES AND RING SEGMENTS ⑭ INLET MANIFOLD
⑦ COMPRESSOR BLADES AND DIAPHRAGMS ⑮ ENCLOSURE ROOFS & SIDE PANELS
⑧ EXHAUST, TURBINE, COMP-COMB. ⑯ PIPINGS
AND COMPRESSOR CYLINDER ◯: Disassembled parts

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 SL 2 ECT -

Schedule of Major overhaul inspection (MI)

Conditions of MI
・Scheduled Outage Hours:37 days ・Shift in work :2 shifts 12 hours a day
<Single Shaft, Dual-Ref> [M701JAC1] Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day
Major Inspection (BtoO:37days) -3 -2 -1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
[2shift-12hour-7days] D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N D N
Main Key Date Scheduled Outage Hours
GT Operation GT Shutdown Test OP Reporting
GT Cooling & Turning Turning Off Turning On
Work Permit Issue Work Permit CO Flushing LO Flushing Return Work Permit
1. Enclosure Package & Insulation

SAMPLE
Preaparation
Enclosure Removal Reinstallation
Insulation Removal Repair Reinstallation
2. Instrumentation
Electrical & Instrument Disconnection Electrical & Instrument
Igniter Cable Disconnection Spark Test Reconnection Reconnection
CPFM & Accelerator Sensor Disconnection Reconnection
Disc Cavity T/C & BPT T/C Disconnection Reassembly & Reconnection
Vibration Sensor & Journal Bearing T/C Disconnection Reconnection
3. Pipings
Fuel Branch Pipe Removal Transfer Reinstallation
Fuel Manifold Pipe Removal Transfer Reinstallation
Bleed Air Pipe Removal Transfer Reinstallation
Turbine Cooling Pipe Removal Transfer Reinstallation
Vapor & Seal Air Pipe Removal Transfer Reinstallation
4. Inlet & Compressor Section
Inlet Manifold & IGV Linkage Mech. Open M/H Final Check & Close
Inlet Manifold Removal Reinstallation
Coupling Cover Removal Reinstallation
Jack Shaft & Coupling Bolt Disconnect Alignment & Coupling connection
Inlet Casing Removal Reinstallation
CompressorCasing Reinstallation
Comp 1st ~ 3rd Blade Ring Removal Reinstallation
Thrust Bearing Cover & Thrust Bearing Removal Reinstallation
#2 Journal Bearing Removal U/H L/H B/H U/H
Compressor Diaphragms Removal Reinstall Bottom
5. Combustor Section The following program parts
Comp. Comb. Cylinder are required for replacement:

Igniter Removal Reinstallation *Fuel Nozzle Ass'y

CPFM Pressure Sensor Removal Reinstallation *Combustor Swirlers

Cross Flame Tube Removal Reinstallation *Combustion Liners

Top-hat Assembly Removal Reinstallation *Outlet seal

Nozzle & Combutor Swirler Disassemble & NDE
Combustion Liner Removal Reinstallation
Torque Tube Cover & Seal Housing Removal
6. Turbine Section The following program parts
Turbine Cylinder Open M/H Removal Reinstallation Final Check & Close are required for replacement:

Turbine Blade Ring Removal U/H Reinstallation *Turbine Row1~4 Vanes

Seal Housing Removal Reinstallation *Row1~4 Ring Segment
Vane, Ring Segment Removal T1C Reassembly T1C

7. Exhaust Section
Exhaust Duct Manway Cover Open M/H Final Check & Close
Cooling Air Pipe for Turbine Row4 Blade Removal Reinstallation
Exhaust Cylinder Removal Reinstallation
#1 Journal Bearing Removal U/H L/H B/H U/H
8. GT Rotor Section The following program parts
GT Rotor Lift out Reinstallation are required for replacement:

Turbine Blade (T1S,T2S,T3S,T4S) T1S T1S *Turbine Row1~4 Blades

T2S T2S
T3S
Removal T4S
9. Inspection & Other
Bolt & Parts Cleaning
NDT Inspection
Servo Valve/Actuator Function Test Function Test
10. Extra Work
GT Auxilliary Equipment

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 SL 2 ECT -

Outline of Major Overhaul Inspection

1. Turbine inspection is carried out at the same time

2. Visual inspection and/or Non Destructive Test of all

Components(Rotor, compressor blades and
diaphragms,bearings, etc.)

Non Destructiive Test:

Penetrant Test, Magnet Particle Test and Ultrasonic Test

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 SL 2 ECT -

Disassembly scope of ENCLOSURE ROOF PANELS (MI)

At the beginning of the major inspection, the enclosure roof panels and side panels
in the yellow shaded area shown below must be removed.

ROOF PANELS INLET MANIFOLD

SIDE PANELS CYLINDERS

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 SL 2 ECT -

Disassembly scope of SEAL AIR PIPING AROUND GT (MI)

In the major inspection, the piping connected to inlet manifold and all
cylinder must be removed in addition to the piping removed at TI since GT
rotor is lifted up.
The piping around the bearing is mainly added.

SEAL AIR PIPING AROUND GT

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 SL 2 ECT -

Disassembly scope of WATER WASHING PIPING (MI)

The lower half of the water washing

piping does not need to be removed. INLET MANIFOLD

Disconnect at the horizontal part of

the piping, and remove it together
with the inlet manifold.
If only piping is removed, disconnect FLEXIBLE
the flexible hose connection. HOSE
SECTION A-A

BLADE WASHING WATER PIPING

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 SL 2 ECT -

Disassembly scope of LUBE OIL VAPOR PIPING (MI)

This is a Vapor piping that is directly connected to the
bearing. Be careful as oil may drip when removing.
Flexible hoses shall be removed and
stored carefully not to apply FLEXIBLE
excessive load because the flexible HOSE

hoses are easily damaged.

COMP. BRG. PEDESTAL

VAPOR PIPE THRUST BRG. SEAL HSG.
VAPOR PIPE

LUBE OIL VAPOR PIPING

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 SL 2 ECT -

Disassembly scope of COMPRESSOR BLEED AIR PIPING (MI)

Compressor bleed air piping connected to the compressor cylinder

must be removed.

LOW PRESS. BLEED AIR PIPING

MIDDLE PRESS. BLEED AIR PIPING

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 SL 2 ECT -

Disassembly scope of EXHAUST CYLINDER SEAL AIR PIPING (MI)

Disconnect the top of the cylinder from the horizontal and remove the
piping.

for EXHAUST
CYLINDER (AFT.)

for EXHAUST
CYLINDER(FWD.)

EXHAUST CYLINDER SEAL AIR PIPING

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 SL 2 ECT -

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 SL 2 ECT -

Supplementary explanation

①TA & Work Resource Arrangement

・Work organization for TA dispatching
・MHPS TA job description

②Necessary tools for maintenance

・General Tools
・Heavy Equipment
・Special Tools

The details will be explained in the next section, but if these

cannot be prepared, it will cause delay in the process and
deterioration in quality.

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 SL 2 ECT -

①TA & Work Resource Arrangement (1/2)

Work organization for TA dispatching

Owner
TA SCOPE (MHPS scope)
MHPS
Coordinator

Inspection Mechanical Blade I&C DDC Start Up Tuning

Project
Manager
Forman WORKER SCOPE (MHPS scope)

Insulation NDE I&C Crane Core Worker

Welder Operator
Fitter Inspector DDC
Rigger Skilled
Labor shall be provided and also Worker
handled by MHPS under this contract.
Helper

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 SL 2 ECT -

①TA & Work Resource Arrangement (2/2)

MHPS TA job description

Qualification Function
1. To plan and advise on the work (the schedule, necessary manpower, parts and materials).
1. Coodinator 2. To direct/control Technical Advisors.
3. To prepare the post outage report.
1. To advice the allocation and arrangement of the labors.
2. To instruct the labors in the key points of assembly/disassembly as TA deems to be necessary.
3. To ensure the strict requirement for the safety of manpower.
2. Mechanical TA
4. To demonstrate the essential work in assembly/disassembly as the TA judges to be necessary.
Auxiliary TA
5. To observe and assure the assembly/disassembly to be carried out as per correct manner/procedure.
6. To measure the necessary clearances/dimensions, records and compare the data against the criteria.
7. To assure the work to be carried out as per the schedule.
1. To plan the arrangement of the blades.
3. Blade TA 2. To demonstrate the remove/installation of blades with the assistance of labors as the TA judges to be necessary.
3. To measure the blade height to adjust it as required.
1. To advice for dismantle/install work.
4. I&C TA 2. To check/calibrate the instruments.
3. To plan and carry out the interlock test before commissioning.
5. DDC(Direct Digital Control) TA 1. To check and tune DDC(Direct Digital Control).
1. To plan and carry out NDE(Non Destructive Examination) inspection of the parts/components.
6. Inspection TA 2. To judge the result of inspection based on the criteria.
3. To make the inspection report.
1. To plan and carry out start up procedure.
7. Start up TA
2. To plan and instruct to apply the balance weight according to CABS(Computer Aided Balancing System) data, if required.
8. Combustor tuning TA 1. To carry out combustor tuning for starting up GT.

© 2018 Mitsubishi Hitachi Power Systems, Ltd. All Rights Reserved. 35

 SL 2 ECT -

②Necessary tools for maintenance

 General Tools
General tools required for GT inspection.
This will be arranged by MHPS.
 Heavy Equipment
It is necessary for the transportation of hot gas parts, consumable
parts, and removed parts (Cylinder, roof, piping, etc.).
Prepare a suitable heavy equipment for the inspection item.
This will be arranged by MHPS.

Forklift Mobile Crane Truck Crane Truck

 Special Tools
Provided to owner by EPC contract during construction.
Please lend it to MHPS at the time of planned maintenance.
© 2018 Mitsubishi Hitachi Power Systems, Ltd. All Rights Reserved. 36