POWER PLANT

REPAIR TECHNIQUES
AT CENTRAL GAS
TURBINE
MAINTENANCE
WORKSHOP
FAISALABAD
CENTRAL GAS TURBINE MAINTENANCE
WORKSHOP WAPDA FAISALABAD
CONTENTS

1. INTRODUCTION OF WORKSHOP
2. OBJECTIVES.
3. ORGANIZATION CHART.
4. FIELD OF SERVICES.
5. SERVICES TO PRIVATE &
GOVERNMENT ORGANIZATIONS.
6. FLOW DIAGRAM OF REPAIR PARTS.
7. INTRODUCTION OF REPAIR SHOPS.
8. PARTS RECEIVED/DESPATCHED
9. OVERALL VIEW OF REPAIRED PARTS
10. SOME MAJOR WORKS DONE
After the commissioning of 200 MW GTPS
Faisalabad in order to keep the Power Plant ready for
operation necessity to have sufficient quantity of spare
parts was un-avoidable. This was only possible by
importing new parts or by sending the used ones abroad
for repair.

All the turbine hot gas path components are made of
high temperature (Nickel & Cobalt) alloys.It was not
possible to manufacture or repair of turbine parts in our
country so necessity to repair used parts within our
country was strongly felt.
INTRODUCTION OF CENTRAL GAS
TURBINE MAINTENANCE WORKSHOP
FAISALABAD
This idea was brought in the physical state by
Late Shakoor Ahmad, working as Chief Engineer
(Th) Faisalabad at that time. Which not only helped to
introduce repair of super alloys in Pakistan but on the
other hand helped a lot in decreasing the import of new
parts which resulted in saving precious foreign exchange
& reducing the down time of Power Plant as well as
availability at the earliest.

To establish a repair Workshop funds to import the
equipment from abroad in foreign currency and to
construct a building in pak currency were needed. For
this purpose left over amount after the completion of 200
MW GTPS Faisalabad was utilized local components of
cost of project was provided by Wapda.




CONSULTANCY OF TECHNICAL WORKS.

M/S FICHTNER Suttgart West Germany were appointed
as consultants where as their local counter part was M/S
MIDEAST Consultants Lahore.

SUPPLY OF EQUIPMENT.

Workshop equipment was supplied by M/S SIEMENS
and Co Hamburg West Germany and their local counter
part was M/S MIDEAST Lahore.
CIVIL WORK CONTRACT.

M/S Syed Imdad Hussain Shah and Company were
awarded the contract of civil works to complete the
building. Total cost of the project was Rs.20.2 million.
The bifurcation of which is as under:-
1. Local = Rs.11.10 Million
2. Foreign = Rs. 9.10 Million
Total:- Rs.20.20 Million

After the arrival of equipment it was installed in the
presence of Mr.W. Boll representative of M/S SIEMENS.
Same gentleman later on trained the locally appointed
staff. In this way the repair of turbine hot gas path
components was initiated first time by Wapda itself. So
the old Workshop started functioning during 1983.
MAIN HALL OF OLD WORKSHOP BUILDING
EXTENSION OF WORKSHOP FACILITIES

With the passage of time Gas Turbines ranging from 90
to 140 MW & Steam Turbines from 210 to 320 MW
started operating in Wapda Generation System. So the
necessity to have another Workshop to handle and
repair large parts of above said Gas & Steam Turbines in
future was strongly felt.


For this purpose M/S EU-BANK PRIECE UK were
appointed as consultants by Wapda who were
responsible for the supply of equipment. M/S ICL were
awarded to design and construct Workshop building.
Total cost of the extension project was 219.245 Million.
Bifurcation of which is as under:-

1. Cost of Civil Works = Rs. 59.400 Million
2. Cost of Equipment = Rs.159.845 Million

Total:- Rs.219.245 Million

The installation of most of the equipment was done by
Workshop staff, whereas installation of Heavy Duty
Lathe Machine, Over Head Crane and Vacuum Furnace
was completed by their respective representatives. This
new Workshop started rendering services during 1994.
MAIN HALL OF NEW WORKSHOP BUILDING


OBJECTIVES
TO PROVIDE INSPECTION AND REPAIR FACILITIES TO
ALL THERMAL POWER STATIONS OF WAPDA POWER
GENERATION SYSTEM.

PREVIOUSLY TURBINE DAMAGED PARTS WERE BEING
SENT TO FOREIGN COUNTRIES FOR WANT OF
REPAIRS.

THE FOREIGN REPAIR COST WAS ABOUT 40% OF THE
NEW PARTS PRICE AND ALSO IT REQUIRED LONGER
DOWN TIME OF UNITS.

TO IMPROVE THE TECHNICAL KNOW HOW OF LOCAL
WAPDA STAFF
Workshop is equipped to provide following services:-

1. Repair of hot gas path components of GE Fiat,
Mitsubishi, Westinghouse & KWU Gas Turbines. 2.
Re-balding of Gas, Steam Turbine Axial and
Compressor Rotors.
3. Re-insulation of Generator Rotors.
4. Re-winding of Electric Motors.
5. Re-babiting & machining of all type Bearings.
6. Dynamic balancing of Rotors ranging from 50 to
60,000 Kgs.
7. Non destructive testing of turbines parts.
8. Moment weighing of GE F-9 turbine blades.
9. NDT facilities at site to all customers.
10. On Site Dynamic balancing Rotating Equipments.
FIELD OF SERVICES
In addition to all Thermal Power Station of Wapda Power
Generation System this Workshop is also extending the
repair facilities to more than 100 organisations of Private
and Government Sector, some important are as
following:-
1. Kot Addu Power Company Kot Addu.
2. Karachi Electric Supply Corporation.
3. Pakistan Aeronautical Complex Kamra.
4. Sui Northern Gas Pipe Lines.
5. Attock Oil Refinery.
6. Pakistan Ordinance Factories Wah Cantt.
7. Rousch Power Plant Abdul Hakeem.
8. Pak Arab Fertilisers Multan.
9. Pak-American Fertilizer Daud Khail.
SERVICES TO PRIVATE &
GOVERNMENT ORGANIZATIONS
10. Pakistan Petroleum Limited.
11. Dawood Herculees Sheikhupura.
12. Packages Limited, Lahore.
13. Chenab Industries, Faisalabad.
14. Kohinoor Power Company, Faisalabad.
15. CPC Rafhan Maize Products, Faisalabad.
16. Kohinoor Sugar Mill, Joaharabad.
17. Army Welfare Sugar Mill, Badin.
18. Shakargang Sugar Mill, Jhang.
19. Baba Farid Sugar Mill, Okara
20. Sheikhoo Sugar Mill, Kabirwala.
21. Fauji Power Complex, Kabirwala.
22. Saba Power Plant, Sheikhupura.
23. Oil and Gas Development Limited.
24. Engro Chemicals.
25. Pakistan ordinance Factory Wah.
FLOW DIAGRAM OF REPAIR OF PARTS
Preliminary Inspection
Chemical Cleaning
Dis-Assembling
N.D.T
Annealing
Grinding Welding
Grinding
N.D.T
Assembling
Despatch Point
Mech. Cleaning
Inspect. Dept.
A. MACHINE SHOP.

MACHINES AVAILABLE.
1. CNC heavy duty horizontal lathe machine up to
4 Meter swing dia.
2. Vertical turning lathe machine ranging up to
3.3 Meter swing dia.
3. Vertical lathe machine up to 1.4 Meter swing dia.
4. Horizontal boring & facing machine.
5. Valve lapping machine for globe & gate valve.
INTRODUCTION OF REPAIR SHOPS

7 Radial arm drilling machine.
8. Precision lathe machine.
9. Milling machine.
10. Metal cutting handsaw.
11. Valve grinding machine.
12. Metal plate roller.
13. Manual hydraulic mounting press.
14. 80 tons overhead crane.
15. Metal sheet cutter up to 12 mm S.S Sheets.
B. N.D.T SHOP.


1. Magnetic Particle Inspection
2. Universal AC hand yokes.
3. Penetrant Flouricent Inspection under UVL
4. Penetrant Inspection in day light
5. Ultrasonic flaw detector.
6. Radiography and X-ray equipment.
7. Crack depth meter.
8. Eddy current testing equipment
C. GRINDING SHOP.

1. Burr grinding & re-sharpening machine.
2. Electric discharge machine.
3. Grinding and cutting discs and carbide burrs.
4. Pneumatic and electrical grinders.
5. Carbide burrs of different shapes and sizes.
6. Portable electric / pneumatic grinders.
D. HEAT TREATMENT SHOP.



1. Vacuum Heat Treatment Furnace.
2. Induction Heating Equipment.
3. Electric Heaters Heat Treatment Furnace

E. CLEANING SHOP.

1. Vapour Blasting Machine.
2. Sand Blasting Machine.
3. Steam Jet Cleaner.
4. Turco Cleaning Cycle, Turco 4181, 4338C.
F. ROTOR BALANCING SHOP.

1. Heavy Duty Balancing Machine 60 Ton.
2. End Driven & Belt Driven Balancing Machine from
50 To 3000 Kgs.
3. Moment Weighing Machine For GE F-5 Blades.
4. Universal Vibration Measuring Instrument.
5. Portable Vibration Analyzer.
6. Onsite Balancing Equipment.
G. WELDING SHOP.

1. TIG Welding Equipment.
2. Stationary Spot Welding Machine.
3. Weld Heat Treatment Equipment.
4. Electric Welding.
5. Oxy-Acetylene Welding.

H- ELECTRICAL AND INSTRUMENT SHOPS.


1. Maggers
2. Relay Test Set.
3. Inductance Measuring Equipment
4. LRC Data Bridge.
5. Digital Multi Meters.
6. Motor Winding Equipment.
7. Cable Testing Set
REWINDING OF GENERATOR ROTOR TPS KOTRI
REWINDING OF 6.6 KV MOTOR STATOR
MOTORS OF DIFFERENT POWER STATIONS UNDER REPAIR
1. Carbon.
It is a foremost alloy element of steel and has for
reaching influence in it. In addition to carbon
every unalloyed steel contains silicon
manganese, phosphorus and sulphur. As the
carbon contents rises the mechanical strength
and hardening properties of the steel improves
but the elasticity, forging welding and cutting
properties suffer.
MATALURGY OF SUPER ALLOYS
2. Coblat.
Melting point of this material is 1500 C. It improves the
resistance to tempering and the hot tensile strength..

3. Chromium.
Melting point 1920 C. It increases the hardness and
strength and only reduces the elasticity. It improves the
resistance to heat and non acting properties. With higher
chromium contents the steel becomes corrosion
resistance and with carbon forms high wear
resistance carbide. The welding properties deteriorate in
pure chromium steel and with increasing chromium
contents.
4. Manganese.
The melting point of this material is 1250 C. it
improves the strengthen property of steel but only
slightly improves its elasticity it has favourable
influence on welding properties.

5. Molybdenum.
The melting point of this metal is 2610 C. it improves
the tensile strength and elasticity and heat
resistance and has favourable influence on the
welding properties..
6. Nickel.
The melting point of this metal is 1453 C. it raises the
strength of steel but drops the elasticity. It ensures
hardness when the steel contains chromium.

7. Silicon.
The melting of this metal is 1410 C. It is present in all
steel since the iron ores used in their manufacturing
contain varying amount of it. Silicon increase
mechanical strength, the resistance to scaling.
8. Vanadium.
The melting of this metal is 1730 C. A small addition improves the
hot hardness. It is strong carbide former increases tensile
strength and yield point.
9. Tungsten.
The melting of this metal is 3380 C. It improves the strength
properties and also responsible for high heat resistance values.
10. Zirconium.
The melting of this metal is 1860 C. It increases the life of heat
conducting steels.
Gas Tungsten Arc Welding (GTAW).

This is a process in which joining of metals is
produced by heating them with an arc between a
tungsten (non consumable) electrodes and the
work. It is generally done by using single
electrode. Shielding of the electrode and weld
zone is done by a gas or as gas mixture. It is
some times called TIG. Following of the main
equipment required for TIG welding:-
1. Power force.
2. Welding holder & tungsten electrodes.
3. Shielding by argon & control.
Principal of Operation.
The heat from TIG welding is obtained by an arc
between the tungsten electrode and work piece. High
frequency equipment installed in the welding
machine helps the arc to jump from tungsten to work
piece when the holder is brought at certain distance
from the work piece once arc is established the
welding can be done as per job requirements. During
welding inert gas shield is provided.

Advantages.

It is an excellent welding method due to excellent
control of heat in put and gives high quality welding
free of welding defects.
Limitations.

1. Slower than consumable electrode arc
welding process.
2. Transfer of molten tungsten from the
electrode to the weld causes
contamination. The resulting tungsten
inclusion is hard and brittle.
3. Repair cost is much higher than
ordinarily welding equipment.
4. Use of argon or helium increases the
repair cost.
GAS TUNGSTEN ARC WELDING

RE-BABBITING OF
BEARINGS
This is one of the major / continuous work which is
being done in this Workshop. Variety of the Bearings are
being used in Power Plants. Some of those are:-

i) Journal Bearings.
ii) Journal /Thrust bearings.
iii) Thrust Bearings.
iv) Tilting Pads Bearings.
v) Elliptical Bearing.

For re-babbiting of Bearings white metal is commonly
used. White metal named as R-11 is being used in this
Workshop for re-babbiting of high speed Bearings.
RE-BABBITING OF BEARINGS
COMPOSITION AND TEMPERATURES

Major portion of R-11 is Tin which is about 87% of
whole alloy. Remaining 13% are Cu, lead, Antimony &
Bismith etc.

Melting point of R-11 is about 384 C.

Another metal which provides a bond material between
base metal of Bearings and Babbitt material is pure tin.

Fore re-babbiting of Bearing Oxy Acetylene Method
methods is commonly used.
REPAIR PROCEDURE

In order to re-Babbitt a Bearing following steps are
necessary:-

i) Removal Of Used White Metal Of Bearings.
Ii) Cleaning Of The Bearing Surface With Zinc
and Amonium Chlorides .
Iii) Tinning Of Bearing Surface.
Iv) Finally Re-babbiting With White Metal.

During repair process close watch on the
temperature of Bearing surface is necessary to
avoid the over heating of tin.
NDT OF JOURNAL BEARING BEFORE REMETALLING
RE-METALLING OF JOURNAL BEARING
RE-METALLING OF JOURNAL BEARING

In Workshop extra white metal is removed by
grinding

NDT is carried out to check the Bonding of white
metal with the bearing shell .

After machining ultrasonic testing is carried out
to check the bonding of the white metal with the
shell.

Strict quality control is maintained by inspection
department. Porosity, pin holes & lack of
bonding is not allowed. If a Bearing pass
satisfactorily through all these process.


MACHINING OF JOURNAL BEARING
ULTRASONIC INSPECTION OF JOURNAL BEARINGS
JOURNAL BEARING AFTER FINAL MACHINING
OVERALL VIEW OF PARTS REPAIRED
FROM 1982 TO 06/2009
S/N DESCRIPTION QTY.
1 Turbine Moving Buckets. 12756
2 Combustion Liners. 2993
3 Transition Pieces. 2352
4 Cross Fire Tubes. 2515
5 Shrouds Blocks. 1915
6 Bearings. 1606
7 Compressor Blades. 1513
8 Retainer Plates. 1645
9 Floating Seals. 1191
10 Bearing Pads. 1072
11 Swirl Tips. 918
12 End Seals. 907
13 Vane Segments. 682
14 Scrapper Chain Links. 517
15 Bull Horns. 664
16 Light / Heavy Motors. 370
17 Turbine Nozzle Support Rings 339
18 Turbine Nozzle. 325
19 Pressure Gauges. 300
20 Turbine Diaphragms. 257
21 Electronic Cards. 203
22 Track Block. 181
23 Labyrinth Seals. 134
24 Turbine Rotors. 138
26 Stuffing Box Seals. 83
27 Bushes. 64
28 Contactors. 75
29 Generator Rotors. 63
30 Pumps. 62
31 Slip Rings. 55
32
Steam Turbine Diaphragm Support
Ring.
49
33 Heavy Duty Shafts. 44
34 Hydrogen Seals. 60
35 Impellers. 34
36 Pressure Switches 28
37 Gears. 21
38 Diffusers. 21
39 Control Valves. 19
40
Solenoid Valves. 18
41
Multiple Disc Jaw Clutches. 15
42
Shaft Sleeves. 28
43
Combustor Wrapper. 13
44
Turbine Nozzle Discs. 14
45
Spring Seals. 13
46
Shaft Sleeves. 14
47
Wiper Seal. 2
48
Casing. 4
SOME MAJOR WORKS DONE

RE-BLADING OF 210 MW LP STEAM TURBINE ROTOR

REPAIR OF 35 MW GENERATOR TOROR TPS QUETTA

REBLADING OF 100MW GAS TURBINE COMPRESSOR

RE-BLADING
OF 210 MW
L.P TURBINE ROTOR
OF TPS GUDDU

CASE STUDY


During major overhauling of 210 MW Steam Turbine Power
Plant at TPS Guddu, it was observed outer four stages
(2+2) of LP Turbine Rotor have damaged and need
replacement with new ones.

They sent the Rotor to Central Gas Turbine Maintenance
Workshop Faisalabad.

TECHNICAL DIMENSIONS OF ROTOR

STATION: THERMAL POWER STATION
GUDDU
RATING: 210 MW (UNIT NO.3)
TYPE: LOW PRESSURE
WEIGHT: 25000 KG.
DIA METER: 3050 MM
LENGTH: 7320 MM
MANUFACTURED BY: LENIN GRAD METAL WORKS USSR
SUPPLIED BY: M/S TECHNO PROME EXPORTS
USSR
JOBS: REPLACEMENT OF L.P ROTOR
TURBINE BLADES OF STAGE
NOS.26, 27, 30 & 31 WITH NEW
ONES.
CUTTING OF DAMAGED BLADES WITH WELDING PROCESS
PROCEDURE ADOPTED FOR RE-BLADING
OF LP ROTOR

Cutting of damaged blades with welding process.

Loading of Rotor on CNC Heavy Duty Lathe Machine.

Machining of roots of blades.

Removal of pin portions left in turbine discs.

Fixing of blades in turbine wheels.
FIXING OF ROTOR ON CNC HEAVY DUTY LATHE MACHINE
MACHINING OF ROTORS OF BLADE STAGE NO.26 & 30
FIXING OF BLADES IN TURBINE WHEELS
STAGE NO.26, 27, 30 & 31

Drilling of holes in blades.

Machining of 372 pins to be fixed in.

Fixing of pins in blades.

Fixing of lacing wire in blades.

Machining of turbine blades.

Sand blasting.

Non Destructive Testing.

Dynamic Balancing (final balancing results attached).
DRILLING OF HOLES IN BLADES STAGE NO.26, 27 30, & 31
MACHINING OF PINS TO BE FIXED IN BLADES
FIXING OF LACING WIRE IN BLADES
MACHINING OF TURBINE BLADE OF STAGE No.26 & 30
TO PROVIDE HOSING FOR SEALS OF STATOR
SAND BLASTING OF ROTOR
NDT OF THE ROTOR
DYNAMIC BALANCING OF THE ROTOR
REPAIR OF 35 MW
GENERATOR ROTOR
TPS QUETTA
DAMAGED WINDING IS BEING REMOVED
PROCEDURE ADOPTED FOR REPAIR OF
GENERATOR ROTOR
Run out was checked

Ultrasonic inspection was carried out

Special fixtures were fabricated to remove coupling

Both cooling fans & Generator Rotor Retaining Rings
(GRRR) were removed

Special fixture was fabricated to hold the winding coils
during their removal from Rotor slots.
Wedges were removed from the Rotor body slots.

Winding links of three coils were de-brazed.

Damaged turns of all winding coil were removed

Damaged insulation was removed from each turn of coils

Broken turns were brazed and checked by NDT

New lining of Rotor slots was done with fibber glass.

Nomax paper of proper size was cut and pasted

All coils were inserted back into their respective slots

Special jacks were fabricated to press each coil and were
fitted on the slots in order to press the coil turns.
Two special circular fixtures were fabricated to press the
hanging portion of the windings

NDT of new Generator Rotor Retaining Rings (GRRR) was
carried out (report attached).

The winding of the Rotor was heated up to 180oC by electric
current method and were pressed with special jack method.

Both GRRR and coiling fans were fitted on the both side of the
Generator Rotor.

Insulation strength of the generator was checked and was
found satisfactory.

Dynamic balancing of the Rotor was performed.

After the completion of repair work complete electrical testing
was carried out according to standard and it was found OK.

After installation of rotor in machine some sort of vibration
was observed which was rectified on site.
A FIELD WINDING COILS TURN ARE HELD ON FIXTURE AFTER
PASTING NEW INSULATION PAPER
BRAZING OF DAMAGED ROTOR WINDING
CONNECTION LEAD IS UNDER REPAIR AFTER BRAZING
FIELD COIL INSULATION STRENGTH IS BEING CHECKED
DYNAMIC BALANCING OF GENERATOR ROTOR ON
BALANCING MACHINE
100 MW GAS TURBINE
AXIAL COMPRESSOR
TPS GUDDU
TECHNICAL DIMENSIONS OF ROTOR

STATION: THERMAL POWER STATION
GUDDU
RATING: 100 MW (UNIT NO.4)
TYPE: AXIAL COMPRESSOR ROTOR
WEIGHT: 28600 KG.
DIA METER: 1917 MM
LENGTH: 5030 MM
MANUFACTURED: GENERAL ELECTRIC
JOBS: REPLACEMENT OF BLADES OF
ALL SEVENTEEN STAGES WITH
NEW ONES
RE BLADING OF 100 MW GAS TURBINE
AXIAL COMPRESSOR ROTOR


DEFECT

One blade of 2nd stage was found broken from the root
and it has damaged all the blades of successive stages.

Cleaning of compressor Rotor blades was carried out
with CTC and its inspection was carried out.

Condition of all damaged blades revealed that all these
blades have damaged due to direct hitting and rubbing
with the broken blade.
PROCEDURE ADOPTED FOR
REBLADING OF COMPRESSOR

Sand blasting of Rotor.

NDT of the complete Rotor.

Complete run out check was performed.

Different reference marks were punched on the parts of
the Rotor.

Record of different dimensions & measurements was
prepared for re-assembling of the Rotor.

Hydraulic bolt tensioning system for unbolting of tie
bolts was arranged through tenders.

The compressor Rotor was held vertically in the under
ground pit.

All seventeen-compressor Rotor discs were dismantled one
by one by self made fixture.

Damaged blades and spacers were removed from all
compressor discs.

The compressor wheels were cleaned and NDT of all the
disc & tie rod bolts was performed.

Balancing charts were prepared for the new moving blades.

New blades of all the stages were fitted in these wheels.

All compressor discs were re-assembled in vertical position

All tie rod bolts were tightened

The compressor rotor was brought in horizontal position.

The complete assembly was loaded on the turbine lath
machine and run out check was performed.

Stub shaft of the turbine was attached to the compressor
with the help of coupling bolts.

Dynamic balancing of the Rotor was carried out.

Stub shaft was disassembled from the compressor

The repair work was successfully completed with our
own Technical skill and saved foreign exchange of
millions of Dollars.


THANKS