MAIN PORTION OF THE OVERHAUL AND UPGRADE

1. Major Inspection of Gas Turbine - F2F (Compressor, combustion system & turbine)
Major inspection of the gas turbine consist of the compressor, combustion system and the turbine.
The compressor
the compressor consist of 17 stages of rotating blades (rotor ) and stationary blades called the stator.
Compressed air is used for combustion and turbine cooling, bearing sealing, and actuation of some air
operated valves.
The Combustion system
The combustion system consist of the combustion chambers and transition pieces, the spark plugs, the
ultraviolet flame detectors, cross fire tubes, and fuel nozzles
The combustion system is of the reverse-flow type and consists of canted combustion chambers
arranged around the periphery of the compressor discharge casing. This system also includes the fuel
nozzles, spark plug ignition system, flame detectors, and crossfire tubes. Hot gases, generated from
burning fuel in the combustion chambers, are used to drive the turbine. High-pressure air from the
compressor discharge is directed around the transition pieces and into the annular spaces that
surround each of the 10 combustion chamber liners. This air enters the combustion liners through
small holes and slots that cool the liner, and through other holes that control the combustion process.
Fuel is supplied to each combustion chamber through a nozzle designed to disperse and mix the fuel
with the proper amount of combustion air within the liner

TURBINE SECTION
the three-stage turbine section is the area in which the energy contained in the hot pressurized gas
produced by the compressor and combustion section is converted to mechanical energy.
The MS 6001 B major turbine section components include:
The turbine rotor, turbine shell, exhaust frame, exhaust diffuser, nozzles and diaphragms, and
stationary shrouds.
TURBINE ROTOR
The turbine rotor assembly consists of a distance piece, the first, second and third stage turbine
wheels and buckets, two turbine spacers, and the aft stub shaft. Concentricity control is achieved with
mating rabbets on the distance piece, turbine wheels, spacers and stub shaft. The turbine rotor is held
together by through bolts.

Buckets
 The turbine buckets increase in length from the first to the third stage. The three stages of turbine
buckets are attached to their wheels by straight, axial-entry, multiple tang dovetails that fit into
matching cut-outs in the rims of the turbine wheels. The bucket vanes are connected to their dovetails
by means of shanks. These shanks locate the bucket-to-wheel attachment at a significant distance
from the hot gases, which reduces the temperature at the dovetail. The turbine rotor assembly is
arranged so that the buckets can be replaced without unstacking the wheels, spacers, and stub shaft
assemblies.

TURBINE STATOR
The turbine shell and the exhaust frame complete the major portion of the MS 6001 B gas turbine
stator structure. The turbine nozzles, shrouds and turbine exhaust diffuser are internally supported
from these components. The turbine shell controls the axial and radial positions of the shrouds and
nozzles, and thus controls turbine clearances and the location of the nozzles relative to the turbine
buckets. This positioning is critical to gas turbine performance.
In the turbine section, there are three stages of stationary nozzles. Because of the high pressure drop
across these nozzles, there are seals at both the inside and outside diameters to prevent loss of system
energy by leakage.
Shrouds
The turbine bucket tips run directly under stationary annular curved segments called turbine shrouds.
The shroud's primary function is to provide a cylindrical surface for minimizing bucket tip clearance
leakage. The turbine shroud's secondary function is to provide a high thermal resistance between the
hot gases and the comparatively cool shell.

2. Major Inspection of GT-Generator.

3. Major Inspection of GTG-Load Gear Box.

4. Upgrade of the Air Inlet Filter House.

The turbine air inlet system is the means of receiving, filtering, and directing the ambient air flow into the
inlet of the compressor. The system consists of an inlet filter house, ducting, silencing, elbows and inlet
plenum. The ducting and silencing that come out from the filter house pass over the control and accessory
compartments and down into the inlet plenum. The inlet arrangement includes the inlet air filter,
silencing, ducting and trash screen to protect the compressor from debris. The inlet arrangement generally
comes out from the elevated inlet air house, over the accessory compartment, and down to the inlet
plenum. This arrangement requires minimum plot area and provides easy access to the accessory and
turbine compartments. Maintenance requirements are minimal and consist of annual inspection of the
inlet equipment. Any entrapped foreign material should be removed. Rust and oxidation spots should be
scraped and repainted.
Currently the air inlet filter house is left with no filters. There are a few corrosion spots that need to be
fixed which will get worse with time. On the other hand, putting new filters into the isolated clean area
from the outside air is like exposing the filter to moisture without utilizing them. The filters will get spoilt
before even utilizing them. There are few jobs that need to be carried out in that air inlet filter house, like
repairing the implosion doors or condemning them and to use triple redundancy DP pressure switches that
will protect the machine. In order to have a perfect efficiency of the filtration, it is mandatory to have the
filter house sealed and completely isolated to stop any water from infiltrating.
If this machine will continue to be on standstill for a long time, the air inlet filter will even degrade more.
Due to the proximity of the sea and process activity, risk of compressor fouling and erosion is high, due to
salt contained in sea water and acid concentration in the environment.
In order to guarantee a reliable operation and reduce the frequency of filter replacement as well as
reducing maintenance cost, we propose adding another filtering plane with washable prefilters and
modify the existing filtering plane to a matrix with high performance filters. We will also fix all corrosion
and inlet filter house sealing.

5. Upgrade of the Exhaust System.

In a power plant with gas turbines (combustion turbines), exhaust is a very powerful noise source
potentially causing sound nuisance for personnel of the operator operating in the vicinity as well as for the
neighbourhood (including long distance, a fortiori in the case of tall stacks). It is often necessary to use in
such cases a soundproofing equipment of high technology to ensure compliance of the installation on the
one hand with respect to the legislation on noise at work and on the other hand with respect to the
regulation in terms of environmental protection. In fact gas turbines exhaust silencers must often have
outsized acoustic performance (the overall sound power level to consider is often of the order of 135 dBA
and noise emissions are with a very wide frequency spectrum) in a context where very high temperatures
(around 550 °C or sometimes more) and very high gas flow rates (which are sometimes counted in
hundreds of kg/s) must be considered: great care must be taken on the occasion of the study and of the
sizing to limit the total pressure loss directly impacting the productivity of the plant.
The flow inlet & exhaust is designed for insuring the following functions:
• To supply the gas turbine with filtered air flow
• To provide anti-icing
• To distribute the bleed heating air flow in homogeneous spray
• To reduce the compressor air inlet acoustical level
• To protect the air inlet duct against high pressure drop

The new Upgraded Aft Diffuser consist of:

• Improved sealing and new gasket design for the horizontal joint flanges.
• New flex-seal design and turning vane enhancement.
BENEFITS OF AN UPGRADED OF AN EXHAUSTED PLENUM
• Low Total Cost of Ownership
• Reduce the compressor air inlet acoustical level
• To protect the air inlet duct against high pressure drop
• High quality construction for reliable long-life through
The Gas Turbine Diffusers and Plenums are designed to increase safety and efficiency, accurately
measure your emissions, and reduce environmental impact. The emission systems meet the most stringent
compliance requirements, no matter the scale or power required.

6. Overhaul of the Cooling Water System.

The cooling water system is an auxiliary equipment contained in the accessory compartment which is in
front of the inlet plenum necessary for gas turbine unit operation.
An entire off-base closed-loop pressurized cooling water system is put in place to dissipate heat from the
lube oil and consists of the following major components:
• Banks of finned-tube water-to-air (radiator-type) heat exchangers. Each bank is mounted horizontally.
The system will dissipate the unit heat load up to the maximum site ambient temperature.
• Automatic temperature controller which regulates water flow to control lube oil temperature during
operation. Temperature will vary from 54°C set point to 74 °C at high ambients.
• Main shaft driven centrifugal water pump, with 2300 RPM capacity.
• Fans, driven by AC motors.
• Make up and expansion tanks.
• Instruments for control, indication, and protection of the cooling water system.
By means of a three ways valve, part of the cooling water flow is diverted to control lube oil temperature.
Two air-to-water heat exchangers located in the roof of the generator package are connected to the off-
base cooling water system, with each exchanger equipped with isolation valves for use in the event that
an exchanger develops a leak.
The cooling water system is essential to cool down the oil and the diesel starting the engine. The only
pump to recirculate the water in the system is an accessory gearbox driven pump which works only when
the machine is running.
When backwater is recirculated, the water quality is improved and in turn, the risk of corrosion is greatly
reduced; but when the water is stagnated, it becomes more corrosive and attacks the components of the
circuit. Below are the resulting adverse effects:
I. High risk of ceased pump or damaged seals.
II. Punctured heat exchangers: This damage is already present, and water is currently dropping inside the
accessory compartment and particularly on the top of the accessory lube oil pump electrical motor.
III. The roof of the accessory compartment on top of which are mounted the water to air heat exchangers
started to corrode badly and letting water through. It will get worse if no actions are taken immediately.
IV. The water to oil heat exchanger will also puncture and we will have no option but to plug the affected
tubes and reduce its performance or change it totally.
V. The diesel engine cooling water circuit will also degrade.
VI. The VTR (thermostatic temperature regulating valve) is located at the exterior and it will get stuck if
it stands in only one position with a bad water quality.
In summary, it is important that the machine is running in order to recirculate the water and keep the
cooling water circuit alive.

7. Corrosion Correction and Prevention.

Advanced gas turbine engines essentially need novel materials to exhibit forever greater efficiency by
increasing their operation temperatures. Higher operating temperatures lead to high temperature corrosion
of the components and thereby reduce their life significantly. Oxidation and hot corrosion are two
important factors (under high temperature corrosion), which determine the life of gas turbine engine
components. The rate of degradation is slow under oxidation conditions, while it is significantly fast
under hot corrosion conditions and catastrophic failures are imminent if proper materials association with
appropriate coatings are not used. Two different corrosion processes can be distinguished.

TYPES OF CORROSION EXPERIENCED BY THE GAS TURBINE:

1. Oxidati on:

Oxidation rate increases with increasing temperature. Oxidation of the turbine section components has
led to rust of some parts of te turbine most especially the turbine compartment. Metal loss due to
oxidation will be reduced by the formation of protective oxide scales. Chromium, aluminum, and silicon
are the only chemical elements known to form protective oxide scales at the temperatures encountered in
gas turbine engine hot sections. Painting of the turbine compartment after fixing leakages will help to
reduce corrosion by oxidation.

2. Hot corrosion:

This occurs as a result of an accelerated form of oxidation due to the presence of molten alkali metal
sulphates on the surface of the component. This type of corrosion only occurs in a certain temperature
region. Two different forms of attack have been identified, type II hot corrosion and type I, which occur
over different temperature ranges: 600-750°C and 800-950°C respectively.

Basically, the hot corrosion process proceeds in three stages

I. An incubation stage during which the reaction proceeds at a rate essentially similar to that of
normal oxidation.
II. An initiation step during which the corrosion is accelerated.
III. A propagation stage during which rapid corrosion takes place and ultimate failure of the
turbine component.
Turbine compartment:

Corrosion of the turbine compartment is through oxidation as a result of oxygen reacting to the water
falling on it. GT3 is facing all weather aggressively and already the packaging is degrading. The roof
of the turbine is leaking, the base and support of the turbine are rusted as a result of oxidation. This is
a bad issue and needs to be fixed. The load compartment also has open doors that let water pass
through it and it needs to be repaired.
Combustion chamber:

The combustion chamber is corroded through hot corrosion process. During combustion in the gas
turbine, Sulphur from the fuel reacts with sodium chloride from ingested air at elevated temperatures
to form sodium sulphate. The sodium sulphate then deposits on the hot section components, resulting
in accelerated oxidation (sulfidation) attack.
Exhaust system:

The exhaust system of the machine is severely corroded. Both the exhaust plenum as well as the
diffuser are badly affected. If prompt actions are not taken, the system will be completely damaged.
Air Inlet filter House
The air inlet filter house is degraded. There are corrosion spots that needs to be fixed and that will get
worse overtime, and this can cause damage to the system. The air inlet filter needs to be worked on to
seal up all corroded spots properly. If this machine continues to be on standstill, the air inlet filter will
degrade the more. Prior to surface preparation and coating applications, we shall remove, mask, or
otherwise protect other such items not to be coated that are in contact with surfaces to be coated.
Following completion of painting, we shall restore surfaces contaminated by coating materials.
Removing dirt, splinters, loose particles, grease, oil, [disintegrated coatings,] and other foreign matter
and substances deleterious to coating performance as specified for each substrate before application
of paint or surface treatments. We shall remove oil and grease prior to mechanical cleaning.
Scheduling cleaning so that dust and other contaminants will not fall on wet, newly painted surfaces.
Spot-priming exposed ferrous metals such as nail heads on or in contact with surfaces to be painted.
Before application of coatings, we shall perform the following preparations on surfaces covered by
existing coatings:
• Testing existing finishes for lead before sanding, scraping, or removing.
 • Wiping previously painted surfaces to receive solvent-based coatings. Allowing surface to dry.
Wiping immediately preceding the application of the first coat of any coating, unless specified
otherwise.
• Sanding existing glossy surfaces to be painted to reduce gloss.
• Thoroughly cleaning previously painted surfaces [specified to be repainted] of all grease, dirt, dust
or other foreign matter.
• Removal of blistered, cracked, flaked or otherwise deteriorated coatings.
• Roughening of slick surfaces. Repairing damaged areas such as, but not limited to, nail holes,
cracks, chips, and spalls with suitable material to match adjacent undamaged areas.
• Feathering and sand smoothening edges of chipped paint.
• Cleaning rusty metal surfaces as per SSPC requirements. Using solvent, mechanical, or chemical
cleaning methods to provide surfaces suitable for painting.
• Providing new, proposed coatings that are compatible with existing coatings.

Note:
• Adherence of the paint layers is highly dependent on the surface preparation before, and between,
each coat.
• All operations of applying anti-corrosion protection coating stated before are carried out according
to the standard general specification.

8. Training.
TRAINING ON MKVIe AND GAS TURBINE MAINTENANCE.
Training on site
This training will be provided on site in WRPC’s offices. One daily class (five days/week) will be limited
to four and a half hours. The actual class time, a.m. or p.m. hours, will be dictated by the availability of
the equipment and the staff of WRPC per the normal work schedule. If the trainees cannot be present all
together (too many trainees or shift work necessity) the courses will be done in two groups, one in the
morning, one in the afternoon. In that case, daily class will be limited to five hours (2 hours 30 plus 2
hours 30 or 3 hours plus 2 hours).
ELECTRICAL EQUIPMENT TRAINING (Refresher Course)
GAS TURBINE TRAINING (Refresher course)
SPECIALIZED COURSES "MECHANIC"
SPECIALIZED COURSES "CONTROL” For electrical and instruments specialists
GENERATOR TRAINING

FOREIGN TRAINING
All expenses of travelling, boarding and lodging etc. of WPRC’s staff deputed for training shall be paid
for by WPRC. Our prices allow for training offshore Nigeria in Fortafric’s partner’s premises in US or
Dubai for 11 trainees (5 management staff, two mechanicals, two electricals, two I&C trainees) during a
period of 5 days
WORLD CLASS OVERHAUL, UPGRADE AND OUTAGE MANAGEMENT FOR GAS TURBINE
RAMS- RELIABILITY, AVAILABILITY, MAINTAINABILITY AND SAFETY FOR GAS TURBINE