A TECHNICAL APPROACH TO THE

MAINTENANCE AND OVERHAUL OF GAS TURBINES

by
Chester D. Hall
Manager

Plant Technical Services

Dow Chemical, U.S.A.

Freeport, Texas

2. In-house maintenance supervisor and crew, assisted by

Chester D. Hall is a graduate of the an outside consultant.
University of Kansas with a B.S. degree Equipment owners usually have a production or maintenance
in Mechanical Engineering. His industri­ engineer or technician checking on work, but don't really get
al experience is mainly in the petroleum involved in problem solving themselves.
refining, pipeline, and chemical indus­ These approaches are effective, but there are several
tries. He has had many varied respon­ potential problems: Usually, adequate records are not kept on
sibilities in engineering design, mainte­ mechanical condition before repairs; specific repairs made; and
nance, and production. clearances, fits, and finishes when new, before repairs, and
Presently, Mr. Hall is Manager of after repairs. Knowledge gained from failure analysis often
Plant Technical Services, Dow Chemi­ walks out the gate with the consultant and/or repair crew, and
cal, Texas Division, in Freeport, Texas. it never gets back to the people who own the equipment. The
His department is responsible for upgrading technology on personnel actually responsible for day-to-day operation of
process plant equipment and improving equipment perform­ machinery often do not learn the characteristics of their
ance. He is an active member and Past President of the Gulf machines, the things to watch for, and how to improve the
Coast Chapter of the Texas Society of Professional Engineers. machines' performances. Often, engineers or specialists sitting
in remote offices make decisions that affect a machine's per­
formance, though these decision makers have never experi­
ABSTRACT enced living with their decisions.
Conventional approaches to maintenance of large When operating plants get into trouble, where do they get
machines are effective, but they often have problems in the help? M ost industries can no longer afford to shut down
areas of record keeping, access to knowledge gained from equipment while waiting for repair consultants to get free from
previous experience, lack of intimate knowledge of individual other jobs. Extended downtime is too expensive.
machines' operating characteristics, and availability of expert
advice for emergency repairs. AN ALTERNATIVE APPROACH
The author's alternative approach of an in-house, multidis­ The approach to maintenance implemented in the Dow
ciplinary maintenance team is discussed. This approach in­ Texas Division addresses most of these problems. Initially,
cludes the specialty areas of lubrication, dynamic balancing some basic objectives were established:
and vibration, optical alignment, metallurgical engineering,
welding technology, non-destructive testing, mechanical anal­ l. To create in-house technology, so repairs can be made
ysis, and mechanical engineering. intelligently and without delay.
2. To operate machines at the maximum efficiency allow­
able by construction materials, instruments, and oper­
INTRODUCTION ating parameters.
What y ou see is what y ou get! I 3. Not to shut down a machine for overhaul without a
You expect what you inspect! I scientific reason for doing so.
The more y ou know, the more y ou get! 1
All of these statements apply to a well-maintained produc­ Program Structure
tion facility. My theme is this: Get your technical people out of In this approach to maintenance, responsibility is spread
their offices and into the field with their hands on the equip­ among several plant functions. Each of these functions is
ment! described briefly:
It's hard to improve a piece of equipment if you haven't Optical Alignment-The Optical Alignment group works
seen, heard, or felt it. How many of you have had your hands closely with the mechanical analysts at installation and with
on the engine of your favorite automobile? Isn't it great when vibration personnel for initial alignment and vibration analysis.
you can't feel or see the engine move when it's running? How All of our high speed, critical equipment is set on subsole
many of you have had your hands on your gas turbines? Did plates and sole plates. These are optically set flat to within . 002
you get the same thrill? If you didn't, there is something in. In some instances, multiple case trains are bore aligned.
wrong. Tooling balls are installed where possible, and pogo sticks are
I suspect there are at least a few businesses that still use used for trending and hot alignment checks. Shafts can also be
one of the conventional approaches to maintaining large checked for permanent bows. As with the vibration analysts,
machines, including gas turbines: the optical alignment group's plantwide exposure makes their
l. Service contract with original equipment manufac­ expertise invaluable at installation and later in trending and
turer. troubleshooting. Their hands-on experience lets them know

73
74 PROCEEDINGS OF THE TWELFTH TURBOMACHINERY SYMPOSIUM

what a properly running machine feels like. proven itself valuable time and time again, both for trouble­
shooting and for working with vendor technical personnel.
Lubrication-Our Lubrication Department is the comer­
Dynamic Balancing and Vibration-We have our own in­
stone of the preventive maintenance program. Regular
house expertise for dynamic balancing and vibration analysis.
monitoring programs are set up to keep trends of lube oil and
This group is responsible for all phases of vendor and repair
transformer oil condition. Ferrography is used for either trend­
shop and field work. Complete history and documentation are
ing of wear metals or for obtaining precise analytical results.
kept on phase and unbalance effects, resulting in greatly
This technique can determine the types of metal present, as
decreased field balancing times. In-house moment weighing
well as the wear mode (rub, cut, or abrasion). Figure 1 (100 X)
and sequencing of blades also has proven valuable in this area.
and Figure 2 (400 X) show wear typical of abrasion. The lube
The quality and reliability of data are of great concern. Techni-
oil had been contaminated by blasting sand. Silica particles are
visible. Figure 3 (100 X) shows another sample taken 24 hours
later. The wear particles are still large and dense. Figure 4
(100 X) shows a sample taken after extensive flushing while on
line, resulting in a marked decrease both in quantity and size of
wear metal. This allowed the plant to run an additional 18
months until a scheduled shutdown.

Figure 2. Original Oil Sample ( 400 X).

cians are thoroughly trained in the use of spectrum analyzers

and digital vector filters for use in shop inspection, balancing,
and trending. Probe areas are burnished to reduce electrical
runout, and redundant instrumentation is installed on all criti­
Figure 1. Original Oil Sample (100 X). cal equipment. By using specialists, who perform these ser­
vices throughout the plant, we have been able to develop
The Lubrication Department also is knowledgeable in and techniques and become well acquainted with the characteris­
makes recommendations for types of oils. A case in point was a tics of machines plantwide, with the net effect being a quicker,
three bearing gas turbine supplied with a synthetic, fire resis­ more effective balancing and vibration analysis program.
tant lube oil. This lubricant was found to be highly hydrolytic, M etallurgical Engineer-The metallurgical engineer is
resulting in loss of oxidation resistance. The required alumina responsible for ensuring optimum life and performance
treatment was costly and time consuming. The various treat­ through specification of materials, heat-treatments, and
ments proposed to reduce the oxidation caused buildup on the coating.
thrust bearings, leading to shutdown and downtime for Gas turbine blades, transition pieces, nozzles, and cast
cleanup. It was decided to change to a less costly, high vane segments are reheat-treated at the appropriate intervals.
temperature mineral oil and to install a fire protection system. Almost infinite lives are now expected from these pieces.
The first batch of this oil now has over 20, 000 fired hours All row 1 and hotter running row 2 turbine blades are
without degradation. This type of in-house expertise has platinum aluminide coated (see Figure 5). Even with clean fuel
 A TECHNICAL APPROACH TO THE MAINTENANCE AND OVERHAUL OF GAS TURBINES 75

Figure 3. Sample Taken 24 Hours Later (lOOx). Figure 4. Sample Taken After Flushing (100 X ) .

gas, grain boundary corrosion leading to possible fatigue fail­

ures can occur without coating. Weld repairs, especially on
combustor parts and nozzle segments, are made better than
they have to be. Welding every little crack results in more
reliable fixes in the long run.
One example of materials related improvement involves
the failure of a second row blade ring segment (see Figure 6).
This failure resulted in damage to several downstream turbine
blades and vanes. The cause of the failure was determined to
be a small piece of ring segment broken off due to embrittle­
ment caused by formation of sigma phase. Future ring seg­
ments will be cast from HK40 310 SS rather than sigma prone
CH20 309 SS.
We have purchased, or selected vendors for, all compres­
sor and turbine parts with exception of vanes and stationary
blades (see Figure 7). These alternate source parts are available
at 25-50% of OEM price, with equal or better quality and
delivery. Figure 5. Blade on the Left Was Run Uncoated; Blade on the
Dow is using coated compressor blades and vanes in Right Is a New Coated Blade.
almost all of its turbines (see Figures 8 and 9). Both sprayed-on
and pack diffused aluminum coatings are being used, but we strengthened or redesigned. A partial list of successfully re­
prefer the pack diffused coatings because of their longer life. paired stationary parts is presented in Table 1.
Our ongoing study of compressor coatings also includes plasma Non-Destructive Testing-Dow's NDT group is responsi­
sprayed titanium dioxide and teflon coatings. ble for assuring structural integrity of all gas path parts,
Welding Technology-The welding specialist is responsi­ shafts, and fasteners, as well as the determination of coating
ble for working with the metallurgist in determining the cause thicknesses. Dye penetrant or magnetic particle detection tech­
of failure; determining if the part can be put back into "new" niques are used on the fasteners and thinner pieces such as
condition; working with designers to determine how safe the combustors (see Figures 14, 15, 16, and 17). Special eddy
failure mode is, i.e., whether the repaired piece needs to be current probes and techniques are used to test blades for
76 PROCEEDINGS OF THE TWELFTH TURBOMACHINERY SYMPOSIUM

Figure 6. Cracked Blade Ring Segment; Formation of Sigma

Phase in CH20 309 SS Caused Embrittlement.

Table 1. Partial List of Successfully Repaired Stationary

Parts.

Steam turbine diaphragms-410 stainless

Combustor baskets-310 stainless and Hastelloy
Transition pieces-310 stainless and Hastelloy (Figures 10, 11,
12)
Cross flame tubes-Hastelloy X-improved strength and cor-
rosion resistance
Fuel gas nozzles-Incoloy 800
Cast vane segments-X45 cobalt alloy (Figure 13)
Blade ring segment-Cast 309 stainless-Results on vendor
repaired parts were poor. It was discovered later that the
vendors do not repair cracks-they only braze over them.
Figure 7. Combustor Parts and Blades Acquired from Alter­
nate Source Vendors.
subsurface defects (see Figures 18 and 19). In one case, a
complete row of turbine blades was checked by dye penetrant,
revealing no defects. Eddy current probes later detected five
cracked blades (see Figure 20). The NDT group has built and
stocked a shutdown trailer in order to enable the lab facilities
to go to the work, rather than vice versa. This has reduced
NDT turnaround time by approximately 30%.
M echanical Analyst-The mechanical analyst's job is mul­
tifaceted. Typically, an analyst is assigned a specific machine
or group of machines. He learns his machines' particular
characteristics and does routine monitoring. He is responsible
for emergency maintenance, as well as scheduled overhauls
(see Figure 21). Our gas turbines are almost exclusively base
load, and they get a hot end inspection once a year and an
overhaul every two years. Extensive written and photographic
records are kept on each job, to allow later analysis and to
ensure that data are not forgotten. Scrutinizing these records
can lead to improvements in procedures. A case in point is the
Figure 8. Spray Coated Compressor Blades.
removal of the IGV's on a 70MW gas turbine. The manufactur­
er's recommended procedure involved removal of the covers.
Our familiarity and firsthand experience with the machines
enabled us to develop a method of replacement which does not experience "inside the gate" and using it comes into play (see
require removal. This method alone saves 250 man-hours, plus Table 2).
the associated downtime. As a coordinator, the analyst's responsibilities include
One of the analysts' biggest jobs is preplanning and vendor witnessing; all phases of installation, including leveling
critical path development. This is the biggest contributor to of sole plates, setting and aligning of equipment, assuring
reduced turnaround time. We can ensure ourselves that the cleanliness of piping, etc.; and verification of trip points and
proper amount of manpower is available, as well as tools, sequencing. He also helps operating personnel to familiarize
spare parts, and supplies. Here again, the idea of keeping the themselves with the equipment.
 A TECHNICAL APPROACH TO THE MAINTENANCE AND OVERHAUL OF GAS TURBINES 77

Figure 9. IGV Removed from Service Showing Coating Fail­ Figure 11. Transition Pieces and Cast Vane Segment After
ure and Resulting Corrosion of the Parent Material. Repair.

rotor dynamics program, which gives us access to the compu­

ter codes necessary for a complete rotor response analysis. An
analysis is run on each machine to verify critical speed mar­
gins. Torsional critical speed analyses also are made. M ainly
for problem solving, the ZORBA program from Northern
Table 2. Preplanning Activities.

Machinist labor
Electricians
Instrument people
Insulation removal
Ordering and storing supplies
Organizing tools
Rigging
Sandblasting
Figure 10. Transition Piece Showing Broken Spring Clips to
be Weld Repaired. NDT inspection
Metallurgical inspection
Machine shop work on auxiliary equipment
The mechanical analyst contributes through phases of gas
turbine acquisition, installation, and startup. He is a prime Major shop work such as runout checks, balancing, burnishing
example of the hands-on, in-house philosophy working. probe locations, and bore examination of hollow rotors
M echanical Engineer-Mechanical engineers are in­ Locating spare parts and repairing removed parts
volved in all phases of gas turbine specification and in pur­ Transport
chase, testing, installation, commissioning, operation, and Development of critical path and ensuring that nothing is left
troubleshooting. Our gas turbines are bought to conform to to chance
API codes as closely as possible. We participate in the UVA
78 PROCEEDINGS OF THE TWELFTH TURBOMACHINERY SYMPOSIUM

Figure 12. Inside of a Transition Piece Showing Burnt Figure 13. Cracked Strut Was Repaired and Inspected by
Through Hole to be Repaired. NDT.

Research and the FLAG program from NASA Lewis Research

Center are used for detecting stall points and for performance
evaluation.
A critical equipment engineer at the plant follows installa­
tion through setting of the sole plates, setting of the equipment,
alignment, and startup. These engineers also have plantwide
responsibilities giving them maximum exposure and hands-on
experience. This wide experience also helps to minimize redun­
dant effort by making the engineers aware of previous work.
Coordination is also a big part of the engineer's job. He
works with the other disciplines, consultants, owners, and
vendors as needed (see Figure 22).

Results
1. Gas turbine turnaround time has been reduced approx­
imately 50%. Figure 14. Steam Turbine Rotor Undergoing Magnetic Parti­
cle Inspection.
2. M anpower usage has been reduced approximately
50%.
Status
3. Machine failures have been reduced drastically, with
only one gas turbine operating failure in eight years. Though all of the objectives have not yet been met, this
This failure was caused by operator error-the program is in operation today.
operator didn't believe the instrumentation.
4. Component life has been extended by careful inspec­ KEYS TO SUCCESS
tion, metallurgical analysis, rewelding, and heat­ There are three keys to the success of this program:
treating. personnel selection, spreading of technology, and a multidisci-
 A TECHNICAL APPROACH TO THE MAINTENANCE AND OVERHAUL OF GAS TURBINES 79

Figure 15. Large Compressor Shaft Showing Crack with Dye Figure 18. Oscilloscope Trace of Crack Detected by Eddy
Penetrant. Current.

Figure 16. Cracked Fastener Before Inspection. Figure 19. Eddy Current Probe with Test Specimen that Has
Known Crack Sizes and Is Used for Calibration.

Figure 17. Same Fastener as in Figure 16, With a Crack

Detected by Magnetic Particle Inspection. Figure 20. Gas Turbine Blade Showing Cracked Trailing
Edge.
plinary approach to problem solving:
1. Personnel who have the technical talents needed and solvers, in their areas of responsibility. These analysts
who are interested in machinery are selected, and they often initiate design changes on their own, using the
are kept proficient by being involved in hands-on combined talents of other specialists available.
activities. For example, when gas turbine mechanical 2. Having the involvement of several people in solving
analysts are not working on gas turbines, they are problems assures that we are not limited to the abilities
working on steam turbines, process compressors, gear of one individual. If one person is missing, it isn't a
boxes or pumps. They become professionals, problem disaster.
80 PROCEEDINGS OF THE TWELFTH TURBOMACHINERY SYMPOSIUM

3. A multidisciplinary approach minimizes errors in prob­

lem solving. For example, a mechanical problem may
be solved, but material or inspection problems may be
created simultaneously. A multidisciplinary approach
helps to prevent these problems.

SPINOFFS
A multidisciplinary approach to problem solving leads to
maximum use of technical know-how in other process equip­
ment problems. Engineers are allowed to be more creative­
to develop new concepts and approaches. When maximum
development of individuals is allowed,_ there is no end to the
opportunities to improve performance of production equip­
ment. After engineers get used to being "pushed into the
pond," where they have to "produce or perish," most of them
begin to like it; and if they are not kept challenged, they leave.
Figure 21. Middle Bearing from a Three Bearing Gas Turbine;
Parts and Expertise on Hand Greatly Reduced Repair Time. PAYOFF
It would be easy to assume that only large plants can afford
such an operation. However, companies wouldn't be in their
present environments if they were not making profits.
The people evaluating, procuring, and/or repairing parts
for gas turbines contribute enough to convince management
MECHANICAL AND that they are some of the most profitable people on the payroll.
ROTOR DYNAMICS
ACCEPTANCE Technical people should be the biggest profit creators within a
SPECIFICATION ANALYSIS TESTING STARTUP
manufacturing company. If they aren't, someone is doing
something wrong.
APPROVAL INSTALLATION TRAINING Our engineering schools are turning out technical person­
nel with excellent potential. We are getting some of the best
Figure 22. Mechanical Engineering Discipline Functions. engineering raw material that I have seen in 30 years. If these
people are placed in the right atmosphere, trained, and de­
veloped, they can grow to be tremendous profit producers,
regardless of the size of the plant.

CONCLUSION
I believe in America; I believe in its technical develop­
ment. I believe our futures can be fantastic. Our living condi­
tions are limited only by ourselves. We can have the best
running manufacturing equipment in the universe-if we will
only educate, communicate, and motivate ourselves and oth­
ers, and stay intimately involved in problem solving.
Don't wait for someone else to do it for you. Be the master
of your own ship. Put those engineers and technicians to work.
Go home and put your hands on those machines-if a machine
is vibrating, let it tingle your feet. It may make you feel so good
you will go do something about it-yourself!