TB Maintenance ConceptA lifetime of support for your investment.

Energy Service

2

3

Protecting your InvestmentSiemens are committed to helping maintain your operations in the field. The combination of our accurate build information, component history and component lifing data allows us to schedule the correct maintenance, optimizing operation, reducing downtime and reduces the risk of component failure.

What do we provide?

Operational Maintenance 4 - 5 - Typical operational tasks - Parts Kit

Scheduled Maintenance 6 - 11 - Typical maintenance work scopes - Parts Kits

Maintenance Planning 12 - 13 - Maintenance scheduling - General Parts Kits

Remote Diagnostic Services 14 - 15

Typical Operational TasksDaily checks

System pipework and components are checked for signs of leaks.

All gauges and lubricating oil levels in the tank are assessed as a guide to component condition.

Engine and package are checked for oil leaks.

All vents and drain lines are checked to ensure they are clear of obstruction.

A visual assessment of the oil cooler is made and may be cleaned if necessary.

All differential filter indicators (if fitted) are checked and elements replaced as required.

The fuel supply pressure is checked.

The battery charger output is assessed, along with D.C. and A.C. supply levels.

Control panel annunciation lights are checked to ensure that they are fully functional and replaced as required.

The flame-on indication system will be checked to ensure it is functioning.

A general check of the igniter gas bottle should also be done on a daily basis.

Weekly checks

The gas starter motor may be lubricated (if fitted) and the oil fog lubricator will be replenished.

Electrolyte levels of the battery may be checked.

A running check of the operation of the DC Lube oil pump may be performed.

VDU/HMI screens are cleaned to remove dust from the control panel. They might also be examined for any signs of overheating.

All connections on the actuator stepper motor may be assessed for security.

Monthly checks

Oil levels on oil filled type couplings are examined and replenished.

Flame failure head and combustion chamber glass are checked and cleaned.

All solenoids are examined for signs of leakage.

Operation of the fuel changeover system.

Electrical connections on the starter motor are checked and gas/air starter system piping may be assessed for signs of leaks.

In addition, couplings are checked for security, along with an examination of the starter motor hold down bolts.

The control cabinet filter pad is checked (if fitted), and cleaned as required.

Batteries should be boost charged.

Auto drain valves are checked during start up and run down.

Current design philosophy accommodates a six year maintenance cycle before major overhaul, with Gas Generator overhaul at year three.

This information describes the maintenance required for 48,000 running hours, approximately 6 years of operation; however should annual running hours be less than this then the calendar periods between maintenance activities may be extended.

The Gas Turbine requires regular attention in order to replenish / replace consumables, detect trends and to determine abnormalities at an early stage.

Operational MaintenanceOperational maintenance activities are typically performed on a daily, weekly, and monthly basis. Less frequent checks could be “opportunity based” according to operational running regimes.

Quarterly checks

A simulated check of the over speed safety device to be performed.

Generator holding down bolts and visible fixings are checked to be secure in accordance with the manufacturer’s recommendations.

Vibration levels are reviewed.

Lube oil pumps are checked for noisy operation and output pressures are examined.

Six monthly checks

Bearings on all motors will be greased.

An external check of system protective devices to be made.

Door seals, hinges, pivot pins and fasteners are examined and lubricated as required.

A thorough cleaning of the flame trap to be performed.

On condition

Using the installed system, the compressor may be cleaned and its recovery monitored to enable adjustment of the period between cleaning. (The combustion drain to be inspected for particles.)

For Hot wash or cold crank wash on fluid based systems, the correct operation of all automatic drain valves on systems with fluid wash systems may be checked.

An inspection of the under base is made to check for signs of corrosion. If necessary, corrosion will be removed and protective treatment applied.

Parts Kit

All spare parts used during these checks would come from an ‘operational consumables kit’. This kit would contain easily replaceable items such as fuses, bulbs and filter elements etc. These activities would normally be carried out by suitably trained site personnel.

Service exchange Gas Generators and Power Turbine assemblies are recommended as an alternative to the B Type (24,000 hours) inspection on the Gas Generator, and on C Type (48,000 hours) inspection(s) on both the Gas Generator and Power Turbine, where on-site internal inspection of the complete gas generator and power turbine assemblies are normally carried out, based on the expected design life of the hot path components.

It is therefore recommended that any resulting overhaul (strip/rebuild) of the Gas Generator and Power Turbine sections is carried out at a Siemens SGT approved workshop. This ensures that the correct processes and tooling are utilized, including replacement of CT bladed discs and the subsequent balancing of the Gas Generator and Power Turbine rotor assembly is performed to the correct specification.

Typical Maintenance Activity Work Scopes (not exhaustive).

Maintenance activities are classed into A, B or C levels, depending on the scope of work required:

A Service InspectionThis is recommended annually and consists of calibration and system/ operational/ safety checks, filters and consumables are changed and lubricant levels checked and replenished. The condition of the combustion system and first stage stators are checked by removal of the combustor end covers.

The workscope of a typical A service for the TB gas turbine is detailed below. The estimated time to complete the workscope at site using two men (one Siemens personnel and one customer assistant at a total of twenty man hours per day) is approximately 7 days.

Scheduled MaintenanceScheduled maintenance is carried out based on either calendar intervals or running hours, depending on the components under consideration.

Components maintained at calendar intervals are done so on the basis of safety, regulatory or as a consequence of application conditions.

Maintenance based on the running hours of the gas turbine may be related to predictable events such as bearing and blade life.

Pre-shutdown checks

All data from the Turbine Control Module (TCM) may be recorded during the pre-shutdown checks.

The compressor may be cleaned and a post clean data comparison performed.

Other checks include inlet guide vane operation, vibration surveys, leak checks, filter checks, noise levels of the pumps, fans, etc, various engine temperatures and pressures, instrument/gauge checks, liquid fuel piping vibration and a test of fuel changeover, if applicable.

Shutdown procedure

Mechanical or Electronic Over speed checks are made and the annunciation examined.

The operation of the BOVs and slam shut valves are checked.

The operation of the auxiliary lub oil and emergency oil pumps are checked.

The pumps are also checked to ensure that they stop at the correct set point.

The turbine operation is then reviewed in relation to the controls data and customer report information.

Isolation procedure

All components are powered-down to ensure safe working conditions.

Siemens personnel shall be given access to confirm that all isolations have been carried out and a risk assessment will be conducted.

The customer is responsible for the isolation of the turbine and driven unit and to ensure that a permit to work system is in operation.

Mechanical

A boroscope inspection may be made.

A thorough inspection and clearance check of combustion system is done, including; end plates, swirlers and cones, flame tubes and extensions and inspection of CT1 stator blades.

Gas and liquid burners are removed and cleaned. Ignitor bowls are also checked for cleanliness.

UV sight glasses are cleaned; UV bulbs will be replaced and joints renewed where required.

The assembly of the combustion air inlet filter and ducting are examined; filters will be replaced if required.

Operation of the pulse clean system or moving screen filter reservoir are checked. The mechanism greased and checked as applicable.

IGV air relay, bellofram cylinder and P2 supply pipe are removed, cleaned operation fully examined.

P2/Stage 10 air supply pipe is checked for blockages.

Blow off valves are removed, re-greased, diaphragms and valve seats lapped as required.

Further opportunities for maintenance are present during a

scheduled shutdown of your engine.Gas or dual fuel burners can be

inspected for deposits and cleaned.

In addition, there is an opportunity to perform maintenance of the Fire and Gas & Extinguishant systems in

accordance with manufacturer’s recommendations for system

installed.

(Training courses are available through your Siemens

representative.)

On auto drain valves or overhaul ball type assemblies, diaphragms are replaced and drain pipes removed and checked for blockages.

External vent and drain lines are checked to ensure that they are clear with no back pressure present.

Water wash or solid cleaning system components are inspected.

Lubricators are topped up.

Filters are checked, cleaned and replaced on both types.

Lub oil breather system is checked for signs of damage or corrosion, the sand trap vessel is emptied and flame trap is cleaned.

The lub oil level is checked and the customer is assisted in taking oil for analysis as required.

Lub oil sample is checked with the customer and both the tank level and quantity added are recorded.

Fuel, oil, gas/air start systems and ignitor system filters are replaced.

Hale hamilton main and start gas regulator systems are dismantled and cleaned; throttle actuators are checked for excessive backlash.

The demister filter should be replaced. Condensate auto drain valve assembly is removed, inspected and operation checked.

Fuel shut off valves are checked for stiffness and an inspection of the ignitor gas pipe work and non return valves is undertaken.

The driven unit and starter motor hold down bolts are checked for security and alignment; couplings are regreased and rubber couplings are inspected as required.

Electric motor and gas starters bearings are greased.

All pipe work, hoses and flexibles are checked and replaced on condition.

A visual check is made of the vent dampers and their operation.

Electrical

Copies of controls software are taken as required, including package or driven units.

Certified electrical equipment in hazardous areas is inspected, if applicable.

Fuel actuators are calibrated.

Together, we can effectively manage your scheduled maintenance activities to ensure that appropriately skilled people and relevant parts arrive on site at the right time.

Potentiometers are replaced (DC201 star valves only).

UV flame viewing head cable insulation and its operation are checked.

T Max or T Op parameters are recorded including governor settings (Mk 1 Rustronic Control System).

The operation of all package devices are calibrated and operation tested, including solenoids, pressure or temperature monitoring devices, blow in door micro switches, vent systems, emergency stop circuit, thermocouples, indicators, watchdog system and any contract specific devices.

PPM1 battery on Mk 2 systems is replaced.

Allen Bradley control system back up battery is replaced.

TCM monitor or LCD backlight is inspected for signs of degradation and replaced if required.

Checks are made of the battery and charger condition; outputs; electrolyte levels and specific gravities. They are topped up with distilled water if required and boost charged when applicable.

An inspection of the ignitor lead and plug is made, along with insulation/resistance/function checks and is replaced if required.

All motors and A.C. contactors are inspected.

The integrity of vibration monitoring equipment is checked, either vibraswitch or displacement types.

The operation of lub oil warning and shutdown are checked, including auxiliary pump cut out system.

The remote monitoring system (STA-RMS*) is checked to be operational (if installed).

Any driven unit or other third party servicing records are recorded.

Pre-Commissioning

Isolated systems are reinstated and a pre-start integrity check of all systems is made, including static leak checks.

Restart and Running checks

The gas generator is rotated up to spin speed.

The turbine is stopped using the normal stop button and the rundown time is recorded.

The fault protection start/running/functions is checked.

The exhaust volute manual shut-off valve is checked to ensure that it operates on each start-up.

IGV operation is examined.

The turbine system is checked for leaks during running checks and after four hour test run.

Vibration checks are carried out at maximum load.

Planned inspection intervals of 8000 fired hours, or annually, with an intermediate inspection every third year or 24000 fired hours and major inspection every six years or 48000 fired hours, give low cost maintenance and high availability.

*STA-RMS: Siemens Turbomachinery Applications - Remote Monitoring System

B Service InspectionThis is recommended at 24,000 hours and is the A type service plus a total strip of the gas generator to inspect critical components and assess their suitability for a further three year life cycle.

The work scope of a typical B service for the TB gas turbine is detailed below. The B service can be performed at site or as a Workshop Overhaul at a Siemens Service Centre.

The estimated time to complete the work scope at site using 2 men (one Siemens personnel and one customer assistant at a total of 20 twenty man hours per day) is approximately 14 fourteen days.

All ‘A Service’ activities are included, plus the following:

Gearbox

A visual inspection of the internals is made and clearances are recorded on build sheets.

Package

The gas fuel throttle is stripped down, if required.

Core Engine - Gas Generator (GG)

Bearings and labyrinth seals are dismantled and inspected.

The compressor rotor and stator blading is cleaned by hand, as required, with clearances recorded on build sheets.

Operation of the IGV blades is checked and blade stems and bushes are strip cleaned as required.

The compressor turbine (CT) blading is examined for signs of damage/corrosion/erosion. The 1st and 2nd stage CT stator blades undergo dye penetration crack detection. Clearances and all findings are recorded on build sheets.

A sample of the 1st and 2nd stage CT rotor blades is taken, and the blades plus the completed sample sheet are returned to Siemens metallurgical laboratory for analysis.

The swirler cones and flame tube extensions are examined for distortion/cracks/fretting. Clearances and all findings are recorded on build sheets.

The Gas Generator rotor is checked to ensure that it rotates freely, post rebuild.

Power Turbine

The first stage power turbine is visually inspected prior to replacing the Gas Generator.

A dye penetration crack detection is undertaken on the interduct.

The design of the gas turbine provides operators with the facility to carry out on-site blade inspection and servicing of the unit or, at the operator’s choice, at a Siemens approved Service Centre.

C Service InspectionThis is recommended at 48,000 hours and in addition to the B type service, involves a strip of the power turbine.

The work scope of a typical C service for the TB gas turbine is detailed below. The C service can be performed at site or as a Workshop Overhaul at a Siemens Service Centre.

The estimated time to complete the work scope using 2 men (one Siemens personnel and one customer assistant at a total of twenty man hours per day) is approximately twenty one days.

All ‘A and B Service’ activities are included plus the following:

Package

Flow tests are carried out (certain configurations).

Power Turbine (PT)

The PT is dismantled and the blading, bearings and labyrinth seals are inspected. All findings and clearances are recorded on build sheets

Diffuser welds undergo dye penetration crack detection and are repaired as required.

Parts Kit

Spares for these maintenance intervals consist of various kits, an “inspection replacement parts kit” will contain those items that are definitely to be replaced during servicing, and an “inspection contingency kit” will contain critical components that may be replaced during the annual inspection depending on their condition. In support of these it is recommended that an “emergency backup” spares kit should be held on site to cover other items that may be found at fault during servicing such as valves, thermocouples and igniters.

Combustion chambers and fuel burners are easily accessible when

servicing is required.

The TB5000 has been designed for ease of on-site maintenance

thereby maximizing operating availability and minimizing

downtime.

Year 1 Year 2 Year 3 Year 4 Year 5 Year 6

A A B A A C

Fig 1. A typical TB maintenance schedule, with blade sample at 24000 hours

Maintenance PlanningPlanned maintenance reduces the cost and disruption of unscheduled outages

Maintenance planning should cover at least the following areas:

Scope of work: What is required, where it will be carried out and how long it will take.

Spare parts: What parts are required, what is held on site, lead times involved.

Tools and fixtures: What specialist tooling is required and available (lifting beams etc).

Inspection and assembly work: Are the correct personnel and facilities available.

Work plan: What can be performed on site and what needs specialist services.

Capacity planning: Are the facilities, personnel and equipment required?

Logistics: How is equipment supplied – are export licences required?

Site considerations: Permits to work, risk assessments etc.

OEM specialists: Are specialists available (gearbox etc).

Coordination: Who is coordinating all the above activities?

Maintenance Scheduling

The maintenance schedule of the equipment depends on annual running hours and the component life consumed, assuming that the gas turbine is running 8,000 - 8,500 hours per year.

Siemens maintenance planning leaves you to concentrate on your core business.

The customer may want to consider items such as the filtration options available. Highly efficient (HEPA) filtration may lead to increased availability due to reduced requirements for routine maintenance (water washing) and less degradation to core components. This, and other options, can be discussed in detail prior to purchase.

The compressor features variable inlet guide vanes to modulate air flow and assure fast, easy start-up and maximum efficiency under partial loads.

Note: Blade Samples - Turbine section hot path component life

Two diametrically opposed blades are removed from each stage of the Compressor Turbine (CT) rotor and replaced with new pairs of match weighed blades. This is initially conducted at the ‘B’ type inspection (24,000 hours). Removed blades undergo analysis in the Siemens metallurgical laboratory.

The examination will provide a report of blade condition and advise the residual operational life of the blades. The life statement will declare that the blades are either unacceptable for further operation, or expected to be suitable for a further 8,000, 16,000 or 24,000 hour’s operation, with an expected operational life of 48,000 hours.

The expected residual life is based upon the operator utilizing the unit in the same conditions (i.e. fuel quality, engine load, air quality etc).

General Parts Kits

Spares to replace unserviceable items may be held on site. These are generally considered to fall into two types.

‘Emergency backup’ spares may be held on site and used to replace a faulty component, thus maintaining gas turbine availability. This could include items such as electronic modules, thermocouples and igniters. However it is advised that these are only replaced by suitably trained personnel.

‘Capital spares’ may be held on site and are major items or specially engineered parts such as pumps, motors and combustion chambers. These cover items where limited stock is available or carry a long lead time for delivery; these are only changeable by suitably trained personnel.

Remote Diagnostic ServicesRemote data access to provide information and reports, helping to effectively manage your turbine.

STA-RMS* (suitable control systems only)

Siemens remote monitoring solutions are designed to maximize your unit’s performance and are tailored to your specific machine type.

TB gas turbines can be fitted with our latest remote monitoring system, STA-RMS*, which ensures maximum machine availability by monitoring and recording various turbine parameters such as speed, temperature, pressure and vibration and communicates this information via an internet connection to Siemens dedicated servers.

If real time connection is not available due to site location, then data can be stored and downloaded periodically.

Using STA-RMS, Siemens can provide various levels of remote services, from basic reporting and support (office hours), to full 24 hour, 7 day service and either comprehensive thermodynamic and/or rotor dynamic analysis of your asset.

Whichever service level you choose, all can be tailored to suit your specific requirements.

Technical overview

STA-RMS consists of five components:

Data acquisition: this is automatically recorded within the control system of the equipment.

Data transmission: information is transferred via a secure internet, VPN/FTP or phone line connection.

Data storage: all reports are stored centrally within the Siemens intranet for the whole lifetime of the machine. This allows for fleet analysis and product improvement related to the real operation conditions.

Data evaluation: a web-based analysis tool is available to support your TB engine.

Expert diagnostic: we provide rotordynamic and thermodynamic tools such as vibration analysis and diagnostics. Where applicable, this includes polar plots, waterfall diagrams, bode diagrams, frequency charts and performance calculation.

The TB5000 is well suited for cogeneration and combined cycle power applications.

Using exhaust gas to generate steam for process use or supplementary power generation significantly increases the system efficiency

STA-RMS utilizes the experience that we as the OEM have accumulated from our operating fleet of over 330 installed RMS units, coupled with the extensive knowledge of both our field and service engineering teams, to advise you in all aspects of our product range, tailored to the specific requirements of your TB gas turbine.

The key benefits to you are:

Fast, secure online help and advanced troubleshooting.

Proactive recommendations.

Increased production through maximum train performance, availability and reliability.

Outage optimization and reduction of overhaul costs, through trending and root cause analysis.

STA-RMS is tailor made to improve the remote functionality of all Siemens units and is the only OEM approved system commercially available.

STA-RMS can be offered both as part of a Long Term Programme (LTP) or as a stand alone Service Support Agreement, which can be arranged through your Siemens representative.

* Siemens Turbomachinery Applications - Remote Monitoring

System (STA-RMS)

Help Desk

24/7 Hotline Support with duty CSM and technical specialists.

The 24/7 Hotline Support can ensure help is there when you really need it, either by telephone or through secure online connection.

Our help desk is available to assist you with any kind of technical issue, as part of an LTP or Service Support Agreement, whether it is for performance fine tuning or breakdown assistance.

All rights reserved. Trademarks

mentioned in this document are the

property of Siemens AG, its affiliates, or

their respective owners.

Subject to change without prior notice.

The information in this document

contains general descriptions of the

technical options available, which may

not apply in all cases. The required

technical options should therefore be

specified in the contract.

Published by and copyright © 2013:Siemens PlcFaraday HouseFrimley, GU16 6QDUnited Kingdom

Siemens Industrial Turbomachinery Ltd.Ruston House, Waterside SouthLincoln LN5 7FDUnited Kingdom

Siemens Energy, Inc.4400 Alafaya TrailOrlando, FL 32826-2399, USA

For more information, please contactour Customer Support Centre.Phone: +49 180 524 70 00(Charges depending on provider)Email: support.energy@siemens.com

Energy Service DivisionLCN 2013 - F48.1 LN

Printed on elementary chlorine-free bleached paper.

www.siemens.co.uk/energy