Hot Gas Path Inspection

Operation Department ACWA POWER PLANT ZARQA
Contents`
Table of Figures: ................................................................................................................................................................ 2
Hot Gas Path Inspection.................................................................................................................................................... 4
Introduction: ................................................................................................................................................................. 4
Starts and Hours Criteria ............................................................................................................................................... 4
Hot Path Inspection ...................................................................................................................................................... 5
Parts of Hot Path Inspection : ..................................................................................................................................... 10
Combustion section ................................................................................................................................................ 11
The Turbine section................................................................................................................................................. 18
Operation Section: .......................................................................................................................................................... 24
Introduction ................................................................................................................................................................ 24
Unit shutdown ............................................................................................................................................................ 24
GT/HRSG 13 Cooling Curves .................................................................................................................................... 24
Ambient Conditions .................................................................................................................................................... 25
Unit 13 Start-up (after annual maintenance) ............................................................................................................. 25
Unit 13 Test and Availability ....................................................................................................................................... 26
Unit 13 Start-up (after annual maintenance) ............................................................................................................. 26
DCS TREND DURING START UP ............................................................................................................................... 27
Unit 13 Off-line Washing............................................................................................................................................. 27
Sequence of events is as follows:............................................................................................................................ 27
Water Statistics- Plant Water Consumption during Maintenance ............................................................................. 28
Unit 13 F.F Deluge Test on GSUT, UAT and MV/LV Transformer ............................................................................... 29
Interlock Test .............................................................................................................................................................. 34
Interlock test for GT13 ............................................................................................................................................ 34
Interlock for HRSG 13 .............................................................................................................................................. 36
Maintenance Section .................................................................................................................................................. 48
Main Defects Maintained during Unit 13 Outage ................................................................................................... 48
Other Defects: ......................................................................................................................................................... 49
PTW Issued during unit 13 outage period: ............................................................................................................. 50
Abnormal Findings of maintenance team during annual: ...................................................................................... 53
EYAD N. MASOUD 1
Table of Figures:
FIGURE 1 : GE BASES GAS TURBINE MAINTENANCE REQUIREMENTS ON INDEPENDENT COUNTS OF STARTS AND HOURS ............................................................................4
FIGURE 2 : GE MAINTENANCE INTERVALS .............................................................................................................................................................................5
FIGURE 3 : HOT PATH PART ...............................................................................................................................................................................................5
FIGURE 4 : INSPECTIONS ...................................................................................................................................................................................................6
FIGURE 5 : DURING HOT PATH INSPECTION ............................................................................................................................................................................6
FIGURE 6 : TURBINE START/STOP CYCLE – FIRING TEMPERATURE CHANGES. ..................................................................................................................................7
FIGURE 7 : SECOND STAGE BUCKET TRANSIENT TEMPERATURE DISTRIBUTION .................................................................................................................................8
FIGURE 8 :CRACK IN FIRST STAGE OF NOZZLE ..........................................................................................................................................................................8
FIGURE 9 : REPRESENTATIVE BUCKET LOW CYCLE FATIGUE (LCF)................................................................................................................................................9
FIGURE 10 : HOT GAS PATH INSPECTION – KEY ELEMENTS .......................................................................................................................................................10
FIGURE 11 : COMBUSTION SECTION ...................................................................................................................................................................................11
FIGURE 12 : COMBUSTION WRAPPER AND CAN COVER ...........................................................................................................................................................12
FIGURE 13 : : COMBUSTION COVER AND WRAPPER ...............................................................................................................................................................12
FIGURE 14 : SECONDARY AND PRIMARY DURING MAINTENANCE ...............................................................................................................................................13
FIGURE 15 : SECONDARY AND PRIMARY FUEL NOZZLE ...........................................................................................................................................................13
FIGURE 16 : THE LINER ...................................................................................................................................................................................................14
FIGURE 17 : THE LINER WITH LINER STOP INSIDE SLEEVE .........................................................................................................................................................14
FIGURE 18 : THE LINER AND THE LINER INSIDE FLOW SLEEVE DURING MAINTENANCE .....................................................................................................................15
FIGURE 19 : FLOW SLEEVE ...............................................................................................................................................................................................15
FIGURE 20 : FLOW SLEEVE ..............................................................................................................................................................................................16
FIGURE 21 : CROSS FIRE TUBE ..........................................................................................................................................................................................16
FIGURE 22 : TRANSITION PIECE ........................................................................................................................................................................................17
FIGURE 23 : TRANSITION PIECES END UP WITH 1ST STAGE NOZZLE ............................................................................................................................................17
FIGURE 24 :THE TURBINE'S STAGE ....................................................................................................................................................................................18
FIGURE 25 : THE TURBINE STATOR ...................................................................................................................................................................................18
FIGURE 26 : UPPRER CASE OF TURBINE SHELL ......................................................................................................................................................................19
FIGURE 27 : SHROUDS ...................................................................................................................................................................................................19
FIGURE 28 : HONEYCOMB SEAL ........................................................................................................................................................................................20
FIGURE 29 : SHROUDS ON UPPER CASE DURING THE MAINTENANCE ...........................................................................................................................................20
FIGURE 30 : FIRST STAGE NOZZLE......................................................................................................................................................................................21
FIGURE 31 : NOZZLE BLADES ............................................................................................................................................................................................21
FIGURE 32 :PARTS OF ROTOR TURBINE ..............................................................................................................................................................................22
FIGURE 33 : FIRST BUCKETS .............................................................................................................................................................................................22
FIGURE 34 : STAGES OF ROTOR ..................................................................................................................................................................................23
FIGURE 35 : HP/LP DRUM AND MAIN STEAM COOLING CURVES AND GT SPEED AND EXHAUST TEMPERATURE ....................................................................................24
FIGURE 36 : AVERAGE VALUES FOR AMBIENT CONDITIONS ......................................................................................................................................................25
FIGURE 37 : HP/LP DRUM AND MAIN STEAM COOLING CURVES AND GT SPEED AND EXHAUST TEMPERATURE ....................................................................26
FIGURE 38 : HP/LP DRUM AND MAIN STEAM COOLING CURVES AND GT SPEED AND EXHAUST TEMPERATURE ........................................................27
FIGURE 39 : GSUT F.F DELUGE TEST ................................................................................................................................................................................29
FIGURE 40 : MV/LV PEECC TRANSFORMER F.F DELUGE TEST ...............................................................................................................................................30
FIGURE 41 : UAT F.F DELUGE TEST...................................................................................................................................................................................30
FIGURE 42 :F.F DELUGE VALVE TEST ...........................................................................................................................................................................31
FIGURE 43 : F.F DELUGE VALVE TEST ..........................................................................................................................................................................32
FIGURE 44 : F.F DELUGE VALVE TEST ..........................................................................................................................................................................33
FIGURE 45 : FORCED COOLING STEPS .................................................................................................................................................................................39
FIGURE 46 : CAN NO. 1 PRESSURE .....................................................................................................................................................................................40
FIGURE 47 : CAN NO. 5 PRESSURE .....................................................................................................................................................................................40
FIGURE 48: HRSG-13 LP SH PRESSURE CURVE...................................................................................................................................................................44
FIGURE 49 : LP SUPERHEATER SYSTEM .......................................................................................................................................................................44
FIGURE 50 : LP EVAPORATOR SYSTEM ........................................................................................................................................................................45
FIGURE 51 FIRE PROTECTION ON ZONE 1 ( AUX. & TURBINE COMPARTMENT ) / GT HMI ............................................................................................................47
FIGURE 52 : RCA TRIP DUE TO LOSS OF VENTILATION .................................................................................................................................................48
EYAD N. MASOUD 2
TABLES:
TABLE 1 :CAUSES OF WEAR – HOT GAS PATH COMPONENTS.............................................................................................................................. 7
TABLE 2 : SEQUENCE OF EVENTS (UNIT SHUTDOWN) ................................................................................................................................... 24
TABLE 3 : SEQUENCE OF EVENTS (STARTUP) .......................................................................................................................................... 25
TABLE 4 CONDITIONS BEFORE START ......................................................................................................................................................... 26
TABLE 5 :OFF-LINE WASHING .................................................................................................................................................................. 27
TABLE 6 : WATER STATISTICS ................................................................................................................................................................... 28
TABLE 7 : HYDROSTATIC TEST PRESSURES AND TEMPERATURES ....................................................................................................................... 41
TABLE 8 : REQUIRED ISOLATIONS FOR FILLING PROCESS:................................................................................................................................ 42
TABLE 9 :FIRE AT THE TURBINE COMPARTMENT............................................................................................................................................ 45
TABLE 10 : THE SEQUENCE OF EVENTS ABOUT TRIPPING OUT FAILURE : .......................................................................................................... 46
TABLE 11 : RCA TRIP DUE TO LOSS OF VENTILATION ..................................................................................................................................... 47
TABLE 12 : MAIN DEFECTS MAINTAINED FOR GT13 .................................................................................................................................... 48
TABLE 13 : PTW FOR GT13 DURING INSPECTION........................................................................................................................................... 50
EYAD N. MASOUD 3
Hot Gas Path Inspection
Introduction:
Maintenance costs and machine availability are two of the most important concerns to a heavy-duty gas turbine equipment
Therefore, a well thought out maintenance program that reduces the owner’s costs while increasing equipment availability
should be instituted, there are many factors that can influence equipment life, and these must be understood and accounted for
in the owner’s maintenance planning. Starting cycle (hours per start), power setting, fuel, level of steam or water injection, and
site environmental conditions are some of the key factors in determining maintenance interval requirements, as these factors
directly influence the life of replaceable gas turbine parts. Operators should consider these external factors to prevent the
degradation and shortened life of non-consumable components.
Starts and Hours Criteria

Gas turbines wear differently in continuous duty application and cyclic duty application, as shown in Figure 1. Thermal
mechanical fatigue is the dominant life limiter for peaking machines, while creep, oxidation, and corrosion are the dominant life
limiters for continuous duty machines.
F IGURE 1 : GE BASES GAS TURBINE MAINTENANCE REQUIREMENTS ON INDEPENDENT COUNTS OF STARTS AND HOURS
The inspection interval recommendation is defined by the rectangle established by the starts and hours criteria figure 2 at the
inspection point will have low risk of failure during the subsequent operating interval.
EYAD N. MASOUD 4
F IGURE 2 : GE MAINTENANCE INTERVALS
Hot Path Inspection
The purpose of the hot path inspection is to examine those parts exposed to high temperatures from the hot gases discharged
from the combustion process.
F IGURE 3 : H OT PATH PART
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F IGURE 4 : INSPECTIONS
F IGURE 5 : DURING HOT PATH INSPECTION
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T ABLE 1 :CAUSES OF WEAR – HOT GAS PATH COMPONENTS
Continuous Duty Application Cyclic Duty Application
Rupture Thermal Mechanical Fatigue

Creep Deflection High-Cycle Fatigue
Corrosion Rubs/Wear
Oxidation Foreign Object Damage
Erosion
High-Cycle Fatigue
Rubs/Wear
Foreign Object Damage
Figure 6 illustrates the firing temperature changes occurring over a normal startup and shut down cycle. Light-off, acceleration,
loading, unloading, and shutdown all produce gas and metal temperature changes. For rapid changes in gas temperature, the
edges of the bucket or nozzle respond more quickly than the thicker bulk section, as pictured in Figure 7. These gradients, in
turn, produce thermal stresses that, when cycled, can eventually lead to cracking (Fig 8. crack from the first nozzle during
maintenance).
F IGURE 6 : TURBINE START /STOP CYCLE – FIRING TEMPERATURE CHANGES .
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F IGURE 7 : SECOND STAGE BUCKET TRANSIENT TEMPERATURE

DISTRIBUTION
F IGURE 8 :CRACK IN FIRST STAGE OF NOZZLE
EYAD N. MASOUD 8
Figure 9 describes the temperature/strain history of a representative bucket stage 1 bucket during a normal startup and shut
down cycle. Light-off and acceleration produce transient compressive strains in the bucket as the fast-responding leading-edge
heats up more quickly than the thicker bulk section of the airfoil. At full load conditions, the bucket reaches its maximum metal
temperature, and a compressive strain is produced from the normal steady state temperature gradients that exist in the cooled
part. At shutdown, the conditions reverse, and the faster responding edges cool more quickly than the bulk section, which
results in a tensile strain at the leading edge.
F IGURE 9 : REPRESENTATIVE BUCKET LOW CYCLE FATIGUE (LCF)
Thermal mechanical fatigue testing has found that the number of cycles that a part can withstand before cracking occurs is
strongly influenced by the total strain range and the maximum metal temperature. Any operating condition that significantly
increases the strain range and/or the maximum metal temperature over the normal cycle conditions will reduce the fatigue life
and increase the starts-based maintenance factor .
Trip Full load – Increase in strain reange for a trip cycle results in a life effect that equates to eight normal start/stop cycles .
The hot gas path inspection outlinedin Figure 10 includes the full scope of the combustion inspection and, in addition, a detailed
inspection of the turbine nozzles, stator shrouds, and turbine buckets. To perform this inspection, the top half of the turbine
shell must be removed.
EYAD N. MASOUD 9
F IGURE 10 : HOT GAS PATH INSPECTION – KEY ELEMENTS
For inspection of the hot gas path, all combustion transition pieces and the first-stage turbine nozzle assemblies must be
removed. Removal of the second- and third-stage turbine nozzle segment assemblies is optional, depending upon the results of
visual observations, clearance measurements, and other required inspections. The buckets can usually be inspected in place.
Parts of Hot Path Inspection :

1- Combustion section
2- Turbine section
EYAD N. MASOUD 10
Combustion section
The combustion section for this type of tybine (MS9001E) is reversed flow with 14 Can chamber type DLN-1 system , The
numbring for chambers are counter-clockwise .
F IGURE 11 : COMBUSTION SECTION

The main components of combustion
1- Combustion wrapper
2- Combustion can cover
3- Secondary fuel nozzle
4- Primary fuel nozzle
5- The liner
6- Flow sleeve
7- Transition Pieces
8- Cross Fire tube
9- Spark Plugs
10- Primary flame Detector
11- Secondary flame detector
EYAD N. MASOUD 11
Combustion wrapper and can cover
F IGURE 12 : C OMBUSTION WRAPPER AND CAN COVER
The wrapper is encloses the combustion system and it provides a supporting surfaces for combustion chamber
F IGURE 13 : : C OMBUSTION COVER AND WRAPPER
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Secondary and Primary Fuel nozzle
F IGURE 15 : SECONDARY AND PRIMARY F UEL NOZZLE
F IGURE 14 : SECONDARY AND PRIMARY DURING MAINTENANCE
EYAD N. MASOUD 13
The Liner
It Is the core for combustion system inside the liner air and fuel are mixed and burned it mounted in flow sleeve at the forward
side by three liner stops and insided at end in transiton piece.
F IGURE 16 : THE LINER
F IGURE 17 : THE LINER WITH LINER STOP INSIDE SLEEVE
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F IGURE 18 : THE LINER AND THE LINER INSIDE FLOW SLEEVE DURING MAINTENANCE
The flow sleeve
It mounted on combustion chamber cover and it force the flow of air to enter around the liner and for cooling function among
14 chamber
F IGURE 19 : FLOW SLEEVE
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F IGURE 20 : FLOW SLEEVE
Cross fire Tube
Each chamber connected with other by crossfire tube and its made from male and female parts .
F IGURE 21 : CROSS FIRE TUBE
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Transition
It trans the hot gases from the combustion chamber to turbine 1 st stage nozzle assembly
F IGURE 22 : TRANSITION P IECE
F IGURE 23 : TRANSITION PIECES END UP WITH 1ST STAGE NOZZLE
EYAD N. MASOUD 17
The Turbine section.
There are 3 Stages in turbine each stage has stationary nozzle and rotating buckets the stationary part convert the hot gases into
kinetic and the Rotating blades convert the kinetic to mechanical rotation
F IGURE 24 :T HE TURBINE 'S STAGE
Major components for turbine section
1- The turbine stator
2- The turbine Rotor
The turbine stator:
1- The turbine shell
2-Shrouds
3-Nozzles
F IGURE 25 : THE T URBINE STATOR
EYAD N. MASOUD 18
The turbine shell
F IGURE 26 : UPPRER CASE OF TURBINE SHELL
Shrouds:
The main function of shrouds is minimize the leakage these shrouds attached with shell Honeycomb seal on second and third
shrouds are makes from soft material , the cutter teeth on buckets open a slot on the honeycomb seal
F IGURE 27 : SHROUDS
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F IGURE 28 : HONEYCOMB SEAL
F IGURE 29 : SHROUDS ON UPPER CASE DURING THE MAINTENANCE
EYAD N. MASOUD 20
Nozzles:
The first stage nozzle consists of 18 segments and the second stage nozzle has 16 segments and third stage has 16 segments
also.
F IGURE 30 : FIRST STAGE NOZZLE
F IGURE 31 : NOZZLE BLADES
EYAD N. MASOUD 21
The Turbine Rotor:
It contents three turbine wheel, after and forward shaft and two wheel spacer, The first rotor has 92 buckets, second and third
also .
F IGURE 32 :PARTS OF ROTOR TURBINE
F IGURE 33 : F IRST BUCKETS
EYAD N. MASOUD 22
F IGURE 34 : STAGES OF ROTOR
EYAD N. MASOUD 23
Operation Section:
Introduction
This section describes the main events and works that achieved during inspection of unit 13 including the start-up and
shutdown, interlock tests, main maintenance activates, PTW’s issued during this period, operation activities such as firefighting
tests.
Unit shutdown
Unit 13 stopped at 00:16, 24-Apr-2023 for Hot Gas Path Inspection and still shutdown until maintenance of unit 13 came over on
17-May-2020
*Sequence of Events:
Unit GT/HRSG 13 (Gas, CC) 24-Apr-2023

Stop Time (NCC order) 23:29 (Gross load : 120 MW)
Main Steam Stop Valve Close Time 23:57
Diverter Damper Close Time 00:16
Generator C.B (52-G) Open Time 00:23
Plant Available Load 323.33 MW
Reason NEPCO order (Unit 13 will be N/A, for GT 13 HPGI)
T ABLE 2 : SEQUENCE OF E VENTS (UNIT SHUTDOWN )
GT/HRSG 13 Cooling Curves
F IGURE 35 : HP/LP DRUM AND MAIN STEAM COOLING CURVES AND GT speed and exhaust temperature
EYAD N. MASOUD 24
Ambient Conditions
The average ambient conditions including ambient temperature, relative humidity and barometric pressure during
Hot Gas Path Inspection period demonstrated in the following trend.
• The average ambient temperature is 21 c

• The average atmospheric humidity is 47 %
• The average barometric pressure is 954 mbar
Unit 13 Start-up (after annual maintenance)
F IGURE 36 : AVERAGE VALUES FOR AMBIENT CONDITIONS
T ABLE 3 : SEQUENCE OF EVENTS (STARTUP )
GT/HRSG 13 (Gas, CC) 17-May-

Unit
2023
Start Time (NCC order) 15:25
GT (52-G) C.B Close Time 16:18
Diverter Damper Open Time 16:26
Main Steam Stop Valve Open Time 17:36
Plant Available Load 485 MW
Reason NCC order
EYAD N. MASOUD 25
Unit 13 Test and Availability
At 15:25, 17.MAY.2023 unit declared full available and started to FSNL for dryness and overspeed testing
after hot gas path inspection activities
Event Time (17.05.2023)

GT 13 firing 14:32
GT 13 on FSNL 14:38
Test completed and GT stopped 14:47
F IGURE 37 : HP/LP DRUM AND MAIN STEAM COOLING CURVES AND GT SPEED AND EXHAUST TEMPERATURE
Unit 13 Start-up (after annual maintenance)
Dispatch Order
NCC request to start unit 13-combined cycle on 17-MAY-2023, 15:25
Conditions before Start

T ABLE 4 CONDITIONS BEFORE S TART
Gas Turbine Available Fuel Load (MW) Cool down
11 Yes NG 122 off
12 Yes NG 0 on
13 Yes NG 0 on
Steam turbine Yes 58 MW off
ACC vacuum 9 KPa
Ambient Temp 36 C
Humidity 13.8 %
Atmospheric pressure 949 mbar
EYAD N. MASOUD 26
DCS TREND DURING START UP
F IGURE 38 : HP/LP DRUM AND MAIN STEAM COOLING CURVES AND GT SPEED AND EXHAUST TEMPERATURE
Unit 13 Off-line Washing
GT-13 Offline washing process started at 22:25 (19-04-2023). Water Tank filled with demi water and heater turned on to raise
the temperature of water in order to start water wash process with temperature around 80 c. 30 cm of detergent was used
from the detergent tank in the washing process
Sequence of events is as follows:
T ABLE 5 :O FF -LINE WASHING
Date Time Job Description

19-04-2023 13:00 Water washing tank heater turned on to heat up the
water
19-04-2023 22:00 Temperature of water tank reached 80 c
19-04-2023 22:25 Off-line washing started
19-04-2023 22:25 Rinsing with detergent using 30 cm from detergent tank
19-04-2023 22:35 Soaking on standstill
19-04-2023 23:21 Rinsing with water on crank speed, first sample of water
at drains was 8.1 ms/cm (not accepted)
20-04-2023 08:35 Rinsing with water on crank speed, second sample of
water at drains was 4 ms/cm (not accepted)
20-04-2023 16:15 Rinsing with water on crank speed, third sample of water
at drains was 3.8 ms/cm ( not accepted )
20-04-2023 22:10 Rinsing with water on crank speed, forth sample of water
at drains was 3.5 ms/cm (not accepted)
21-04-2023 05:30 Rinsing with water on crank speed, fifth sample of water
at drains was 2.78 ms/cm (accepted)
21-04-2023 06:00 Off-line water washing process completed
EYAD N. MASOUD 27
Water Statistics- Plant Water Consumption during Maintenance
T ABLE 6 : WATER S TATISTICS

Deep Deep Deep
Deep Deep
well well well Deep well Deep
well well
Pump 1 Pump Pump 2 Pump 3 Well Deep Well
Pump Pump 3 Recycle from pit BD Recycle from pit
Date Flow 2 Flow Flow WAJ Sum(M3)
1 Flow Flow Flow meter(M3) BD Sum(M3)
meter(M Flow meter(M meter(M3 Sum(M digital
meter( meter(M
3) meter 3) ) Digital 3)
M3) 3)
Digital (M3) Digital
25
April 14282 260230 1500 44272 255123 573629 368 360 49122 67
2023
26
April 14282 260230 1640 44272 255490 573986 507 357 49187 65
2023
27
April 14282 260230 1984 49388 255856 574343 710 5473 49217 30
2023
28
April 14282 260230 2354 49688 256222 574699 736 656 49217 0
2023
29
April 14282 260230 2737 49959 256584 575053 745 625 49217 0
2023
30
April 14282 260230 3119 50356 256948 575408 746 752 49217 0
2023
1 May
14282 260230 3495 50749 257308 575759 736 744 49217 0
2023
2 May
14282 260230 3874 51139 257673 576115 744 746 49217 0
2023
3 May
14282 260230 4250 51528 258035 576468 738 742 49217 0
2023
4 May
14282 260230 4442 51728 258402 576826 559 558 49272 55
2023
5 May
14282 260230 4699 51784 258777 577192 632 422 49420 148
2023
6 May
14282 260230 5078 52177 259144 577550 746 751 49533 113
2023
7 May
14282 260230 5323 52343 259423 577823 524 439 49669 136
2023
8 May
14282 260230 5576 52350 259798 578189 628 373 49766 97
2023
9 May
14282 260230 5955 52741 260166 578548 747 750 49883 117
2023
10
May 14282 260230 6346 53136 260532 578903 757 750 49970 87
2023
11
May 14282 260230 6708 53501 260707 579075 537 537 50057 87
2023
12
May 14282 260230 7044 53733 260920 579284 549 441 50148 91
2023
13
May 14282 260230 7413 54110 261047 579406 496 499 50268 120
2023
14
May 14282 260230 7638 54340 261047 579406 225 230 50392 124
2023
15
May 14282 260230 8063 54600 261047 579406 425 260 50542 150
2023
16
May 14282 260230 8421 54966 261047 579406 358 366 50679 137
2023
17
May 14282 260230 8673 55157 261237 579593 442 378 50876 197
2023
EYAD N. MASOUD 28
Unit 13 F.F Deluge Test on GSUT, UAT and MV/LV Transformer
F.F deluge test was done successfully on main GSUT in the presence of civil defense.
F IGURE 39 : GSUT F.F DELUGE TEST
EYAD N. MASOUD 29
F IGURE 41 : UAT F.F DELUGE TEST
F IGURE 40 : MV/LV PEECC TRANSFORMER F.F DELUGE TEST
EYAD N. MASOUD 30
F IGURE 42 :F.F DELUGE VALVE TEST
EYAD N. MASOUD 31
F IGURE 43 : F.F DELUGE VALVE TEST
EYAD N. MASOUD 32
F IGURE 44 : F.F DELUGE VALVE TEST
EYAD N. MASOUD 33
Interlock Test
Interlock test for GT13
EYAD N. MASOUD 34
EYAD N. MASOUD 35
Interlock for HRSG 13
EYAD N. MASOUD 36
EYAD N. MASOUD 37
EYAD N. MASOUD 38
Forced cooling
Forced cooling steps that required after operating the unit with the grid .
It is a recommended form Yury Omelyanyuk to do after HGPI and it for help cut in the 2 and 3 stage shroud block honeycomb
(you can go back to FIG. 28 in this reports ) and mitigate the risk of a low speed rub event.
F IGURE 45 : FORCED COOLING STEPS
Sequence of events were as follows:
T ABLE 7 : EVENTS OF FORCED COOLING STEPS

Event Time (19-05-2023)
First start of crank motor 00:12
Crank motor tripped due to ( 49T) 04:30
Second start of crank motor 05:57
Crank motor stopped after reaching 150 F wheel space
07:44
temperature
GT Cool down on 07:52
EYAD N. MASOUD 39
Diesel Leakage Test
On May 27th 2023, the Unit GT13 Liquid Fuel system integrity test was carried out . Three fire watchers have been assigned: one
for each GT side and the third to Accessory Compartment. Fire Extinguishers are in place. The first attempt of the Unit start
(normal start up sequence simple cycle) on LF was aborted due to observation of two leaks: Can No. 4 and No. 14. The piping
was inspected and reassembled.
The second attempt of the Unit start (normal start up sequence simple cycle) on the LF was aborted due to shut down: Starting
motor overcurrent alarm went off. Unit started and acceleration reached 1200 rpm. one more LF leak was discovered Can No.9
and water Injection hose leak Can No. 11.
The third attempt of the Unit start (normal start up sequence simple cycle) on the LF was aborted due to alarm signal High
exhaust temp: Unit started, and acceleration reached 1200 rpm.
pressure indicator: Can No. 5 and No. 10 have built up the LF pressure 18 bar whereas the rest of Cans had 12 bar of LF
pressure. This may lead uneven flame and high exhaust spread which creates High exhaust temp alarm signal.
F IGURE 47 : CAN NO . 5 PRESSURE F IGURE 46 : CAN NO . 1 PRESSURE
EYAD N. MASOUD 40
Hydrostatic test for the LP SH

On 15-MAY-2023 , HRSG-13 LP Drum side Hydrostatic Test was carried out by increasing pressure from atmospheric to 3 bar and
stay on that pressure for 10 min. then at 6 bar for another 10 min. then raised to 10 bars for 20 min. before test ended
successfully
T ABLE 8 : HYDROSTATIC TEST PRESSURES AND TEMPERATURES
Filling Procedure
1. Assemblies shall be purged in such a way that there are no remaining air pockets, while being filled.
2. The test equipment shall be examined before pressure is applied to ensure that it is tight and that all low-pressure filling lines
and other appurtenances, which shall not be subjected to the test pressures, have been disconnected or isolated by valves or
other suitable means.
3. Make sure that the water quality is acceptable.
4. Fill the system with closed drains and opened vents. Vent valves shall be closed as soon as water escapes during the filling
process.
5. Expelling of air at flange connections will be carried out by temporarily loosening the bolts of the flange connection and
tightening the bolts as soon as water appears.
EYAD N. MASOUD 41
Required Isolations for Filling Process
T ABLE 9 : REQUIRED ISOLATIONS FOR FILLING PROCESS :
Vents
1 LP SUPER VENT 12HAH20AA501 Open to be closed after venting
2 LP DRUM VENT ISO 12HAD20AA511 Open to be closed after venting
Open to be closed after venting” last

3 LP SUPER heater steam drain 12LBA20AA421
vent”
LP EVAP & SUPER Isolations
1 LP EVAP BD DARIN ISO 12HAD20AA423 Closed
2 HP SUPER HEATER Sample ISO 12HAH20AA 601 Closed
3 LP SUPER HEATRE BD DARIN ISO 12LBA20AA411 Closed
4 LP EVAP Sample 12LAC30AA601 Closed
LP Steam Isolation
1 LP Super heater steam second isolation 12LBA20AA002 Closed
Closed after venting from super

2 LP Super heater steam first isolation 12LBA20AA001
heater drain
LP Feed Water Isolation
1 FWP 1 CB 6.6 12LAC10AP001 Open R-out
3 FWP # 1 suction iso valve 12LAB10AA001 Closed
4 FWP # 2 suction iso Valve 12LAB20AA001 Closed
5 FWP #1 Rec to LP iso 12LAB10AA004 Closed
Last
Start filling from condensate system and venting from lower vent to higher Open with a low flow
step
EYAD N. MASOUD 42
Vents & drains

Open when the pressure reaches less
1 LP SUPER VENT 12HAH20AA501
than 1 bar
Open when the pressure reaches less
2 LP DRUM VENT ISO 12HAD20AA511
than 1 bar
3 LP SUPER heater steam drain 12LBA20AA421 Open
LP EVAP & SUPER Isolations
1 LP EVAP BD DARIN ISO 12HAD20AA423 Closed
2 HP SUPER HEATER Sample ISO 12HAH20AA 601 Closed
3 LP SUPER HEATRE BD DARIN ISO 12LBA20AA411 Open
4 LP EVAP Sample 12LAC30AA601 Closed
LP Steam Isolation
1 LP Super heater steam second isolation 12LBA20AA002 Closed
2 LP Super heater steam first isolation 12LBA20AA001 Open
LP Feed Water Isolation
3 FWP # 1 suction iso valve 12LAB10AA001 Closed
4 FWP # 2 suction iso Valve 12LAB20AA001 Closed
LP main steam MOV drain valves under pipe rack No.

7 Open
LBA20AA112,114,116,118,120
8 LP main steam bypass MOV drain valve No. 12LBA18AA10 Open
EYAD N. MASOUD 43
F IGURE 48: HRSG-13 LP SH PRESSURE CURVE
PID of LP SH
F IGURE 49 : LP SUPERHEATER SYSTEM
EYAD N. MASOUD 44
F IGURE 50 : LP EVAPORATOR SYSTEM
Fire at the turbine compartment :

At 04:58 On 23.MAY.2023 , Unit 13 tripped out due to “Fire protection Aux/Tur/Load compartment fire detection” alarm
received at GT screen.
T ABLE 10 :FIRE AT THE TURBINE COMPARTMENT
Unit GT/HRSG 13 (Gas, CC) 23-May-2023
GT (52-G) C.B Open Time 04:58

Main Steam Stop Valve Close Time 05:01
Diverter Damper Close Time 05:01
Plant Available Load 323.34
Tripped out due to “Fire protection Aux/Tur/Load compartment fire

Trip Reason
detection”
EYAD N. MASOUD 45
61 CO2 cylinders was discharged during this event . The plan the put by Eng. Hasan AL Salhi is :
1- Aux. Compartment : loop check for firefighting system sensors, loop check for all instrumentation to ensure
healthiness, visual check for oil system, check no traces of fire.
2- Turbine Compartment : at 09:00 O’clock doors will be opened. Maintenance department will enter inside to visual
check, loop check for firefighting system sensors, loop check for all instrumentation to ensure healthiness .
3- Load Compartment: after completion check Aux. Compartment and turbine compartment visual check, loop check
for firefighting system sensors, loop check for all instrumentation to ensure healthiness
The Sequence of Events About Tripping Out Failure :
T ABLE 11 : THE SEQUENCE OF E VENTS ABOUT TRIPPING OUT FAILURE :
Time Event
GT was running on Natural gas at Load 120 MW in

04:57:00
CC.
Two Thermostatic Fire Sensors detected a High

Temp on turbine compartment leading to
activating the CO2 Firefighting system of Zone # 1
initial and extended discharge.
Alarm Received : [45FP-1] Fire Protection

04:57:44 Aux/Turb/load Compartment Fire Pre-Detect
[PDIO-34Contact 01].
Alarm Received: FIRE PROTECTION – FIRE PRE-

04:57:44
ALARM ZONE 1
04:58:01 Generator Breaker Trip [52GT-1]
05:13 Unit went normally on TG operation

After checking in the local the Zone #1 CO2
Cylinders found Empty, Zone #2 found full,
and Zone #4 found some cylinders empty
also
EYAD N. MASOUD 46
F IGURE 51 F IRE PROTECTION ON Z ONE 1 ( AUX . & TURBINE COMPARTMENT ) / GT HMI
GT13 Trip due to Loss of ventilation at Gas Skid
Unit 13 Tripped caused by Loss of ventilation trip.Failure changeover from 88VL-1 to 88VL-2 and Failure changeover from 88VL-2
to 88VL-1 caused by Electrical Fault on damper of ventilation fan#2 88VL-2
T ABLE 12 : RCA TRIP DUE TO LOSS OF VENTILATION
EYAD N. MASOUD 47
F IGURE 52 : RCA TRIP DUE TO LOSS OF VENTILATION
Maintenance Section
Main Defects Maintained during Unit 13 Outage
T ABLE 13 : MAIN D EFECTS MAINTAINED FOR GT13
Defect
Book
Area Description Open Date
Reference
Number
GT 13 2347M Alarm ''Lube oil tank low level'' on GT HMI 7-May-2023
GT13 1212E Lifting pump on GT 13 88QB-2 CB is stuck 8-May-2023
GT 13 2350M Water leakage from evaporative cooler inlet line 9-May-2023
HRSG 1214E Diverter damper local panel (control supply) circuit breaker tripped out 14-May-2023
13
HRSG13 2358M HRSG13 HPU hydraulic pumps tripped out due to discharge pressure low (check 16-May-2023
Accumulator N2 pressure).
HRSG13 2359M HRSG13 seal air fans tripped due to discharge pressure low 16-May-2023
GT 13 2466C Vibration start inhibit alarm recevied at GT HMI 16-May-2023
HRSG13 1215E Control Feed Off alarm at Diverter damper HMI local panel 16-May-2023
EYAD N. MASOUD 48
Other Defects:
1-Mechanical
1- Defect no. 378M (C.B.D MOV is passing), the defect solved by replace disk, seat and internal parts, lapping was done.
2- Defect no. 292M (HRSG13 IBDs isolation and MOV valves have passing), the defect solved by replace internal parts and
lapping was done.
3- Defect no. 350M (There is passing from HP IBD control valve to blowdown tank), the defect solved by replace internal parts
and lapping was done.
4- Defect no. 2296M (Oil electro-cleaning machine pipes have vacuum pressure (not pumping properly), the defect solved by the
hoses replaced with metal pipes.
5- Defect no. 2350M (Water leakage from evaporative cooler inlet line), Checked and the puncture was welded.
6- Defect no. 2157M (LP Condensate water bypass MOV (13LCA30AA011) make passing), the defect solved by replace internal
parts and lapping was done.
7- Defect no. 2250M (The HP drum level CV "13HAC70AA152" doesn't close to 0 when it’s out of service in local), the defect
solved by replace internal parts and lapping was done.
8- Defect no. 2297M (HP attemperator water MOV (13LAE70AA001) has fault during shutdown unit when closing), the defect
solved by replace internal parts and lappingwas done.
9- Defect no. 2272M (HP attemperator water MOV (13LAE70AA001) has water leakage from packing, the defect solved by
replace internal parts and lapping was done.
10- Defect no. 2338M (GT13 hydraulic filter no.1 differential pressure high), the defect solved by replace filter.
11- Defect no. 2339M (GT13 lube filter no.2 differential pressure high), the defect solved by replace filter
2- I&C
1- BT Fan # 2 on GT 13 give low pressure and made a change – over adjustment and calibration.
2- (VL-2) damper didn’t open fully while unit start up and made change over Cleaned and adjustment flow sensor and
dampers.
3- The exhaust pressure transmitter 96EP-1B has fault reading open and cleaned impulse line.
4- The sample inlet valve 13QUB15AA001 is stuck for HP Superheated steam in sampling skid Replaced HP valve (new
one)
EYAD N. MASOUD 49
PTW Issued during unit 13 outage period:
PTWS FOR GT 13 and HRSG 13

T ABLE 14 : PTW FOR GT13 DURING INSPECTION
PTW No. Department Description of Work

HRSG No.13 HP Main Steam Line Attemperator Spray Water Motorized Shut Off
6631 Mechanical Maintenance Valve (13LAE70AA001), to replace packing.
HRSG#13, CBD isolation valve (13HAD70AA151), to maintain and stop water passi
6632 Mechanical Maintenance ng.
APZ Gas Turbine Unit No.13, Gas Turbine GT, Fuel Gas Coalescing Filters, Duplex C
6710 Mechanical Maintenance oalescing Filter No.1, to replace Filters.
HRSG No.13 HP evaporator syphon breaker Motorized Valve (13HAD70AA501), to
6713 Mechanical Maintenance maintenance.
HRSG No.13 HP Drum Vent (13HAH70AA501,502), to install new isolation valve b
6714 Mechanical Maintenance y welding.
6715 I&C Maintenance GT13 Markvie power ON for M/M welding exhaust.
HRSG No.13 HP continuous blowdown Motorized shut off valve (13HAD70AA410)
6750 Mechanical Maintenance , to maintenance and stop passing.
APZ Gas Turbine Unit No.13, Gas Turbine GT, Lubricating Oil System, Lube Oil Filte
6754 Mechanical Maintenance r No. 1, to replace Cover O-ring.
GT13 Hot Bath Inspection Instrumentation Installed (Flame scanners, spark plugs
6756 I&C Maintenance , space wheel, thermocouples and Tubes for Combustion Tunning.)
Gas Turbine # 13 Hot Gas Path Maintenace
6758 Mechanical Maintenance
6571 Electrical Maintenance GTG#13 GSUT Inspection and Testing
6572 Electrical Maintenance GTG#13 UAT Inspection and Testing
6573 Electrical Maintenance GTG#13 PEECC MV/LV TR Inspection and Testing
6576 Mechanical Maintenance GT 13 APU Annual Inspection
6577 Mechanical Maintenance GT#13, Chrome 6 Containment.
6578 Mechanical Maintenance GT#13, to build scaffolding inside Auxiliary Compartment.
6579 Mechanical Maintenance GT#13, to build scaffolding inside and outside the Turbine Compartment.
6582 Mechanical Maintenance GT-13 ATOMIZING AIR BOOSTER COMPRESSOR Annual Inspection
6583 I&C Maintenance Gas Turbine-13 HOT PATH GAS Inspection Maintenance
6588 Mechanical Maintenance Gas Turbine # 13 Hot Gas Path Maintenace
6589 Mechanical Maintenance Gas Turbine # 13 Hot Gas Path Maintenace / Lifting PTW
6592 Mechanical Maintenance GT 13 Evaporator Cooler Annual Inspection
6593 Mechanical Maintenance GT 13 Oil Mist. Eliminator Annual Inspection
6594 Mechanical Maintenance GT 13 Lube, Hydraulic, Jacking and Diesel Oil Annual Inspection
6595 Electrical Maintenance GT#13 Generator Minor Inspection
6596 Electrical Maintenance GT#13 Generator Minor Inspection / Lifting PTW

GT#13, Torque Converter Replacement, to Lifting the TC and replace it with new
6597 Mechanical Maintenance one.
6598 Mechanical Maintenance GT#13, Torque Converter Replacement, to cut and re-weld the Fixed plate.
GT#13, Torque Converter Replacement and Accessory Gear Box Inspection and Ali
6599 Mechanical Maintenance gnment Process.
6600 Mechanical Maintenance HRSG-13 Maintenance During GT-13 HGPI
EYAD N. MASOUD 50
Mechanical
6601 Maintenance GT 13 Water injection system Annual Inspection
I&C
6602 Maintenance HRSG No.13 Sampling Skid System, To replace HP superheated steam sample valve kks (13QUB15AA001)
I&C
6603 Maintenance Air Processing Unit Peventive Maintenance GT-13
Electrical
6620 Maintenance GT#13 Batteries Discharge Test
Electrical
6623 Maintenance GTG#13 Protection and Metering Panels Inspection
I&C
6627 Maintenance HRSG13 annual inspection
Electrical
6655 Maintenance GTG#13 MCC Annual Inspection
Electrical
6661 Maintenance GTG#13 IPB Major Inspection
Electrical
6662 Maintenance GTG#13 IPB Pressurized Air Control Panel Inspection
Electrical
6663 Maintenance GTG#13 GCB Inspection
Electrical
6664 Maintenance GTG#13 UPS Annual Inspection
Electrical
6665 Maintenance GTG #13 Battery Charger Annual Inspection
Electrical
Electrical
6667 Maintenance GTG#13 BFW Pump #1 MV Motor Inspection
Electrical
6669 Maintenance GTG#13FWP #2 MV Motor Inspection
Electrical
Mechanical HRSG#13, HP Level control valves (13HAC70AA151,152) & HP/LP IBD control valves (13HAN05AA05AA151,152
6681 Maintenance ), to maintenance and readjusting.
Electrical
6690 Maintenance GTG#13 Cranking MV Motor Inspection
Electrical
6692 Maintenance GT#13 LDO Electrical Heater Control Panel Annual Inspection
Electrical
6694 Maintenance GTG#13 GLAC and GNAC Annual Inspection
Mechanical
6702 Maintenance HRSG-13 HPU Annual Maintenance
Mechanical HRSG No.13 LP Condensate Preheater Bypass Motorized Shut Off Valve (13LCA30AA011), to maintenance the
6704 Maintenance valve and stop water passing.
Mechanical
6723 Maintenance HRSG No.13 HP evaporator syphon breaker Motorized Valve, to heat and machinery work.
Mechanical
6724 Maintenance HRSG#13, to build scaffolding beside Blow down Tank.
Mechanical
6729 Maintenance GT#13, Load Tunnel, to inspection and check the internal bolts.
I&C
6732 Maintenance GT-13 exhaust pressure transmitter (96EP-1B) to check and Maintain.
Mechanical
6738 Maintenance GT#13, Evaporator Supply Line, to welding tube puncher.
Mechanical HRSG No.13 HP Drum intermittent blowdown Drain control valve (13HAN05AA152), to maintenance and
6744 Maintenance replace internal parts.
APZMECHPLN
6774 GRUP HRSG#13, HP/LP Drums and Deaerator, to check Manholes Bolts Tightening at hot position.
EYAD N. MASOUD 51
Mechanical Maintenance
1- GT#13 Air Processing Unit Annual Inspection

2- GT#13 Atomizing Air Booster Compressor Annual Inspection
3- GT#13 Evaporator Cooler Annual Inspection
4- GT#13 Closed Cycle Cooling Water Fin Fan H. Exchanger Annual Inspection
5- GT 13 Oil Mist. Eliminator Annual Inspection
6- GT13 Lube oil & Hydraulic Oil System Annual Inspection
7- GT 13 Water injection system Annual Inspection
8- GT#13 HGPI Shutdown Inspection (CEGCO Scope)
9- HRSG 13 HPU Annual Inspection
10- HRSG 13 Maintenance During GT HGPI
11- GT Duplex Coalescing Filter No.1, to replace Filters. 1
Electrical Maintenance
1- GTG #13 UPS annual Inspection
2- GTG #13 MCC Annual Inspection
3- GTG #13 Protection and Metering Panels Major Inspection
4- GTG #13 Oil Filled Transformers Annual Inspection and Testing
5- GTG #13 GLAC and GNAC Annual Inspection
6- GTG #13 GCB Inspection
7- GTG #13 IPB Pressurized Air Control Panel Inspection
8- GTG#13 IPB Major Inspection
9- GTG #13 LDO Electrical Heater Control Panel Annual Inspection
10- GTG #13 MV Motors Major Inspection
11- GTG #13 LV Motors Inspection
12- GTG #13 MV SWGR Inspection
13- Emergency oil pump performance test
14- GTG#13 Batteries discharge test.
I&C Maintenance
1- Air Processing Unit (APU)

2- Jacking Oil Pump
3- Cooling and Sealing Air System
EYAD N. MASOUD 52
4- Cooling and Sealing Air System

5- Gas Fuel System
6- Air Inlet System
7- Fire Protection System
8- Starting Means System
9- Turbine control device
10- Liquid & Gas purge system
11- Hydraulic Oil Supply
12- Inlet Bleed Heating
13- Inlet Gain Valve
14- Cooling Water System
15- Hazardous Gas Detection
16- Auto Calibration Functional Test for (FSR, GCVs & IGV)
17- Heat & ventilation
18- Liquid fuel system
19- Monitoring System
20- Functional Test for HRSG12
21- Miscellaneous
Abnormal Findings of maintenance team during annual:
1- Mechanical Maintenance:
Staring Means Alignment Readings are exceeding the tolerance limit, after installation of new torque converter, alignment have
been carried out under the tolerance.
▪ HRSG LP SH tube defects .
▪ HRSG LP Drum some fixing plate of the Deaerator found fallen. All Plates fixed and inspected carried out to all plate’s defects.
2- Electrical Maintenance:
During insertion of Lube Oil CB, a short circuit happened in CB finger caused PEECC MCC tripping out, inspection was done, BB
was cleaned, and CB figure replaced and MCC re-energized.
3- I&C Maintenance:
No abnormal findings were recorded
EYAD N. MASOUD 53

Hot Gas Path Inspection

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Hot Gas Path Inspection

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Operation Department ACWA POWER PLANT ZARQA

Hot Gas Path Inspection

Starts and Hours Criteria

F IGURE 2 : GE MAINTENANCE INTERVALS

Hot Path Inspection

F IGURE 3 : H OT PATH PART

F IGURE 5 : DURING HOT PATH INSPECTION

T ABLE 1 :CAUSES OF WEAR – HOT GAS PATH COMPONENTS

Continuous Duty Application Cyclic Duty Application

Rupture Thermal Mechanical Fatigue

F IGURE 6 : TURBINE START /STOP CYCLE – FIRING TEMPERATURE CHANGES .

F IGURE 7 : SECOND STAGE BUCKET TRANSIENT TEMPERATURE

F IGURE 8 :CRACK IN FIRST STAGE OF NOZZLE

F IGURE 9 : REPRESENTATIVE BUCKET LOW CYCLE FATIGUE (LCF)

F IGURE 10 : HOT GAS PATH INSPECTION – KEY ELEMENTS

Parts of Hot Path Inspection :

F IGURE 11 : COMBUSTION SECTION

Combustion wrapper and can cover

F IGURE 12 : C OMBUSTION WRAPPER AND CAN COVER

F IGURE 13 : : C OMBUSTION COVER AND WRAPPER

Secondary and Primary Fuel nozzle

F IGURE 15 : SECONDARY AND PRIMARY F UEL NOZZLE

F IGURE 14 : SECONDARY AND PRIMARY DURING MAINTENANCE

F IGURE 16 : THE LINER

F IGURE 17 : THE LINER WITH LINER STOP INSIDE SLEEVE

The flow sleeve

F IGURE 19 : FLOW SLEEVE

F IGURE 20 : FLOW SLEEVE

Cross fire Tube

F IGURE 21 : CROSS FIRE TUBE

F IGURE 22 : TRANSITION P IECE

F IGURE 23 : TRANSITION PIECES END UP WITH 1ST STAGE NOZZLE

The Turbine section.

F IGURE 24 :T HE TURBINE 'S STAGE

Major components for turbine section

1- The turbine stator

2- The turbine Rotor

The turbine stator:

1- The turbine shell

F IGURE 25 : THE T URBINE STATOR

The turbine shell

F IGURE 26 : UPPRER CASE OF TURBINE SHELL

F IGURE 28 : HONEYCOMB SEAL

F IGURE 29 : SHROUDS ON UPPER CASE DURING THE MAINTENANCE

F IGURE 30 : FIRST STAGE NOZZLE

F IGURE 31 : NOZZLE BLADES

The Turbine Rotor:

F IGURE 32 :PARTS OF ROTOR TURBINE

F IGURE 33 : F IRST BUCKETS

F IGURE 34 : STAGES OF ROTOR

Unit GT/HRSG 13 (Gas, CC) 24-Apr-2023

Diverter Damper Close Time 00:16

Generator C.B (52-G) Open Time 00:23

Plant Available Load 323.33 MW

Reason NEPCO order (Unit 13 will be N/A, for GT 13 HPGI)

T ABLE 2 : SEQUENCE OF E VENTS (UNIT SHUTDOWN )

GT/HRSG 13 Cooling Curves

• The average ambient temperature is 21 c

Unit 13 Start-up (after annual maintenance)

F IGURE 36 : AVERAGE VALUES FOR AMBIENT CONDITIONS

T ABLE 3 : SEQUENCE OF EVENTS (STARTUP )

GT/HRSG 13 (Gas, CC) 17-May-

Diverter Damper Open Time 16:26