Following maintenance, troubleshooting and rectification tasks and activities were carried out during the about mentioned tour:

Day 1 (29-09-2015):

The team arrived at Compressor Station CC-3, Gali Jagir at 3:30 P.M after which Power Turbine (P.T) was unloaded at Unit # 6. The damaged P.T attached with the engine was un-assembled and the overhauled P.T was assembled with the engine.

Day 2 (30-09-2015):

Air intake duct, exhaust collector duct and Stand of the engine were assembled with the engine and put on the skid/ base frame. The covering of exhaust collector duct was also properly set with the wire. Some of the bulbs of on-skid indicators of Unit # 5 & 6 were fused which were replaced.

Day 3 (01-10-2015):

Accessories like lube oil pump, seal oil pump, starter motors, servo oil pump, piping connections and such like are assembled with the drive assembly. Old T-5 thermocouples with harness were replaced with the new one. Boroscopy was performed to check the internal picture of the engine and turbine (GP & PT).

Day 4 (02-10-2015):

Assembling of remaining accessories and piping connections with engine and booster was done along with shaft alignment. Shaft alignment parameters are as below:

0 0 * Axial Distance: 17.36”

FACE BORE * Booster Axial: 0.006” Thrust

+0.002” 0 +0.001” 0 * Booster Radial: 0.005”

Thrust

0 -0.124”

After completing all the mounting and assembling work, a test run was given but could not be successful due to faulty auxiliary lube oil pump. Then the pump was un-assembled and opened. The blades and drum/ cylinder were found damaged. Damaged PT was sent to Compression H.Q. Faisalabad.

Day 5 (03-10-2015):

Gravity filled lubricators (02 No’s) were replaced with manual filled lubricators obtained from CC-1. Starter motors lubricators were modified and converted to manual filled one. Auxiliary Lube-Oil pump RMG-10 was replaced with a new one. An attempt was given to start Unit # 6. Unit operated for 15 mins

on idle speed. Unit ramped up to 80% NGP but failed to exceed further due to improper function of VGV Actuation and insufficient air intake supply. After checking VGV Actuation unit was once again started but it failed again to start due to low seal oil differential pressure.

Then seal oil differential pressure regulator was serviced. Diaphragm replaced with a new one (P/No: 1047167-1). Seal oil filter was also replaced with a new one (P/No: 1024134-1). Afterwards a successful test run was given and readings were noted.

Day 6 (04-10-2015):

Test run was given to Unit # 6 on hot crank @ 94% NGP and readings were noted. Unit tripped off indicating a malfunction i.e. high discharge gas pressure. Speedometer of PT found faulty and need to be replaced. Unit # 6 declared stand-by instead of un-operational after this test run. After that unit # 5 was given a test run on hot crank @ 92% NGP and readings were noted. Total fuel consumption was 120 MCF.

Afterwards Saturn Unit # 1, 2, 3 & 4 were given test runs and readings were noted. Total fuel consumption was 100 MCF. Shell Turbo Oil T-46 was filled in the oil tanks of Unit No # 2, 3 & 4.Readings for test run of Unit # 1, 2, 3, 4, 5 & 6 are in Annexure A.

Day 7 (05-10-2015):

Shell Turbo Oil T-46 was filled in the oil tank of Unit No # 6 and a test run was given by the station team themselves in the presence of Maintenance team and readings were noted.