Major inspection (MI) along with AGB and LGB overhauling job and Torque converter replacement job of Frame-III Gas turbine and Refurbishment of GT Components like Transition Pieces, Liners, Fuel Nozzles, Cross fire Tubes, Stage-01 nozzle and Satge-01

Amount

Major Insp.(MI), AGB & LGB overhauling

Jobs to be carried out during Major inspection (MI) along with AGB and LGB overhauling job and Torque converter replacement job of Frame-III Gas turbine. A) MAJOR INSPECTION,1. Removal load coupling guard & decouple LGB to turbine. 2. Check initial alignment between LGB & Turbine. 3. Remove Accessory coupling guard & decouple. 4. Check initial alignment between AGB & Turbine. 5. Removal of exhaust, Turbine Compartment Fans, Roof & Side panels. 6. Remove inlet elbow, transition piece & inlet plenum. 7. Removal of exhaust hood. 8. Removal of Flame Detectors and spark plugs. 9. Removal of Gas, water/steam & atomizing air lines. 10. Removal of liquid fuel/Purge tubing's. 11. Removal of Cooling & sealing air lines. 12. Removal of Fuel Nozzles, can covers. 13. Removal of Crossfire tubes, retainers & liners. 14. Removal of false start drains lines. 16. Removal of Fwd flex seals & Fwd. C Wall & aft flex seals. 17. Take initial compressor rotor positioning checks. 18. Establish solid foundation and place mechanical jacks under unit casings. 19. Removal of combustion wrapper. 20. Remove transition pieces from first stage nozzle. 21. Provide support under second stage nozzle control ring. 22. Disconnect nozzle control ring from horizontal joint. 23. Remove 3 upper half diaphragm support pins and install dummy pins. 24. Remove borescope plugs. 25. Remove upper half turbine casing. 26. Remove first stage nozzle. 27. Remove stage # 1 nozzle support ring. 28. Remove inner radiation heat shields. 29. Remove second stage diaphragm. 30. Take turbine clearance checks. 31. Remove discharge casing upper half. 32. Remove compressor casing upper half. 33. Remove inlet casing upper half. 34. Removal of exhaust diffuser. 35. Removal of exhaust casing. 36. Take turbine thrust float and bearing & seal clearance checks. 37. Take compressor clearance checks. 38. Remove no # 1 & 2 bearing housing upper half. 39. Remove compressor rotor. 40. Remove the no # 3 & 4 bearing housing upper half 41. Remove low pressure turbine rotor 42. Remove first stage shroud tip buckets 43. Remove second stage shroud tip buckets 44. Remove stage # 2 nozzle partitions as required 45. Clean/Inspection of Fuel nozzles & Check Valves, Liners, Transition Pieces, Crossfire tubes & Retainers (NDT), Stage # 1 & 2 Nozzles (NDT),Stage # 1 & 2 Buckets (Zyglo, if required), Stage # 1 & 2 Shrouds 46. Clean/Inspection of IGV Inspection (NDT) 47. Inspect 1, 2, 3 & 4 bearings & seals 48. Clean/Inspection of Compressor stator vanes and rotor blades 49. Parts replacement of Stage # 1 & 2 Buckets as required, Stage # 1 & 2 Shrouds as required including positioning, punching and drilling, Stage # 1 nozzle as required 50. Replacement of stage # 2 nozzle partition if required including positioning, marking, drilling, Locking as required. 51. Replacement of Combustion inner elbows as required. 52. Replacement of Turbine casing insulation pads as required. 53. Replacement of Inter stage Diaphragm Insulation pads. 54. Cleaning all tapped holes 55. Removal of broken bolts / tapping can bolt 56. Removal of broken bolts / tapping in casings 57. Stg-1 and 2 shroud drilling 58. HP and LP rotor thrust shim machining as required 59. Reassemble both bearing liners # 1 & 2 bottom half 60. Install HP rotor 61. Reassemble both bearings and check rotor thrust float and correct as necessary 62. Check final compressor & Turbine clearances 63. Reassemble both bearing liners # 3 & 4 bottom half 64. Install LP rotor 65. Reassemble both bearings and check rotor thrust float, correct as necessary 66. Check final LP Turbine clearances 67. Install inner compressor discharge casing 68. Install compressor discharge casing. 69. Install compressor inlet casing 70. Install compressor casing 71. Install stage # 1 nozzle support ring, stage # 1 nozzle top half. 72. Recheck stage # 1 nozzle radial concentricity and adjust 73. Install transition pieces 74. Install exhaust casing 75. Install upper half second stage diaphragm 76. Install outer radiation heat shield 77. Install upper half turbine casing 78. Install 3 upper half diaphragm support pins 79. Install upper half first stage nozzle eccentric pin 80. Install upper half exhaust frame 81. Install exhaust diffuser 82. Remove mechanical support jacks and supports from underneath casings 83. Take final rotor position checks 84. Install inlet plenum 85. Install transition pieces & inlet elbow 86. Install Fwd. Exhaust 'C' wall & Fwd. & aft. flex seals 87. Install wheel space thermocouples & wiring 88. Install Combustion elbows & casings 89. Install Liners, X - fire tubes & retainers 90. Install can covers & fuel nozzles 91. Install flame detectors and spark plugs. 92. Install gas manifold and gas fuel lines 93. Install upper half cooling and sealing air piping 94. Install turbine compartment roof and roof attachments and side panels 95. Install turbine compartment ducts above turbine roof 96. Check alignment between turbines to AGB, AGB- Starting device and correct as required. 97. Install coupling & coupling guard 98. Check alignment between turbine to LGB and correct 99. Install coupling & coupling guard 100.Clean Up, visual inspection & Pre-Start Checks 101.FSNL & Load B) ACCESSORY GEAR BOX Inspection and replacement of Torque converter </> 1. Disassembly of oil deflectors of shaft 1. 2. Disassembly of Aux. coupling flange bolts. 3. Removal of old torque convertor oil inlet/out let lines. 4. Removal of torque converter. 5. Removals of water pump, hydraulic pump, warren pump & atomizing air compressor as available from the aux gear box 6. Removing the aux. gearbox top cover 7. Check backlash & float 8. Taking out of gear train from the gear box 9. Taking out of MOP bearings 10. Taking out of MOP gears 11. Inspection of the MOP gears & bearings, replacement if required 12. Inspection of all the bearing of shaft 1-2,3A,3B & 4 and replace as required 13. Replacing the shafts if gear backlash is found beyond acceptable limits 14. Install new bearings & shafts 15. Check backlash & float 16. Assembly of gear box 17. Re fixing of the accessories like water P/P, main oil P/P , warren P/P, Atom air compressor, Hydraulic pump etc. in position 18. Assembling of torque converter on diesel engine 19. Assembly of jaw clutch hub with bearing on new torque convertor. 20. Re Positioning of diesel engine with jaw clutch and maintain DBSE 21. Drilling and pining on torque converter to support. 22. Drilling and pining on diesel engine. 23. Modification of oil pipelines 24. Assembly of hydraulic cylinders and limit switches 25. Checking of over speed bolt, replacement if required 26. Checking of starting clutch bearing, replacement if required 27. Align the AGB to GT & AGB to starting motor / DE C) Load GEAR BOX Inspection</> 1. Decoupling of load gear shafts from turbine & generator side 2. Removal of LGB compartment roof, vent fan & duct 3. Removal of instruments as required 4. Opening of the top cover of load gearbox 5. Check backlash & float 6. Removal of high speed gears 7. Removal of intermediate housing 8. Removal of low speed gears 9. Inspection of oil seals 10. Inspection of all bearings & seals & clearances are measured 11. Replacement of bearing & seals if required 12. Fixing of intermediate housing 13. Replace of high speed gears 14. Check backlash & float 15. Boxing up of the top cover 16. Check teeth contact 17. Align the LGB to turbine 18. Assembly of the coupling bolts on both turbine & generator side 19. Fix all the instruments.

Job to be carried out during refurbishment of 1st stage Nozzle assembly Fr III</></> 1. Received 1st stage nozzle at BGGTS service center 2. Perform Receiving inspection: Verify identification and condition of the Nozzle assembly with respect to customer paper work 3. Perform incoming condition evaluation of nozzle assembly 4. Perform incoming dimensional checks such as Gas path diameters, segment gaps and drop check 5. Disassemble segments form retaining ring 6. Perform aluminum oxide blast cleaning 7. Remove core plugs, as required 8. Perform Metallurgical and hardness examination of received nozzle 9. Perform visual inspection of segments and Map all defects 10. Check segment cooling holes for blockage 11. Perform visual inspection of nozzle hardware (core plugs, seals etc.) 12. Perform Solution anneal heat treatment in vacuum furnace to restore weld ability, as per GE procedures and processes 13. Perform Metallurgical and hardness examination of the received nozzle 14. Grind out all cracks and defects on segments 15. Weld repair all cracks using nozzle filler wire, as per GE procedures and processes 16. Remove and reform blocked cooling holes 17. Blend weld ments to match contours 18. Correct retaining ring Ovality to with in 0.060 Thou. 19. Perform NDT on segments 20. Assemble segments in retaining ring 21. Correct throat opening as per the drawing requirements 22. Perform AREA and HARMONIC analysis in GE NAH program 23. Perform dimensional inspection of assembled nozzle 24. Disassemble segments and grit blast clean 25. Perform solution annealing heat treatment on nozzle segment in vacuum furnace, as per GE procedures and processes 26. Perform final NDT and repair indications as required 27. Final grit blast clean segments and thoroughly clean segments to remove entrapped grit 28. Re-install core plugs, as required 29. Repair and replace nozzle hardware 30. Reassemble segments in retaining ring 31. Perform final dimensional check 32. Perform final cleaning thoroughly prior to packing and completely removed Aluminum oxide power. 33. Submit report on work performed.

Job to be carried out during Refurbishment of 1st Stage Bucket assembly Fr III 1. Receive and unbox Stage 1 buckets. 2. Label and record Serial Numbers. 3. Perform incoming conditional evaluation. 4. Clean buckets using special non-aggressive coating cleaning process. 5. Perform Non-Destructive Testing (NDT). 6. Perform Dimensional inspection. 7. Engineering review and Repair disposition report Repair 8. ACR Strip coating 9. Grain etches buckets. 10. Perform minor welds and blend repairs. 11. Carry out post repair HT 12. Perform final Non-Destructive Testing (NDT). 13. Prep buckets for coating. 14. Apply recommended coating to buckets. 15. Perform Heat Treat. 16. Shot peen dovetails. 17. Moment weigh and provide charting 18. Pack and prepare for shipment.

Job to be carried out during refurbishment of 1st Stage Shroud assembly Fr III.</></> 1.Receive and un-load firsts stage shrouds at BGGTS Service Center. 2.Perform Receiving inspection: Verify identification and condition of the shrouds with respect to customer paper work 3.Perform incoming condition evaluation of Shrouds 4.Perform dimensional inspection of Shrouds 5.Perform aluminum oxide blast cleaning. 6.Perform visual inspection and map defects found on shrouds 7.Perform penetrate inspection on the shrouds 8.Grind to remove all cracks indications. 9.Weld repair crack indications and worn portions on faces 10.Machine shroud faces to meet drawing dimensions 11.Blend/ machine to match contours 12.Measure dimensions after machining 13.Perform NDT on shrouds 14.Final blast clean shrouds 15.Perform Visual inspection 16.Apply Plasma Spray Hard coating Shroud face as per GE Procedures and processes 17.Perform visual inspection of the coating 18.Perform final Q.C checks 19.Preserve and pack for return shipment. 20.Submit final repair report.

Job to be carried out during Refurbishment of 2nd Stage Shroud assembly Fr III</></> Work scope for repair of Fr-III Stage 2 Shrouds (Standard or Honeycomb Shrouds) 1. Receive and un-load stage 2 shrouds at BGGTS Service Center. 2. Perform Receiving inspection: Verify identification and condition of the shrouds with respect to customer paper work 3. Perform incoming condition evaluation of Shrouds 4. Perform dimensional inspection of Shrouds 5. Perform aluminum oxide blast cleaning. 6. Perform visual inspection and map defects found on shrouds 7. Perform penetrant inspection on the shrouds 8. IF required perform solution annealing of shrouds 9. Grind to remove all cracks indications. 10. Weld repair crack indications and worn portions on seals and faces 11. Machine shroud faces and radial seals to meet drawing dimensions 12. Blend/ machine to match contours 13. Measure dimensions after machining 14. Perform NDT on shrouds 15. Final blast clean shrouds 16. Perform Visual inspection 17. Apply Plasma Spray Hard coating Shroud face as per GE Procedures and processes 18. Perform visual inspection of the coating 19. Perform final Q.C checks20. Preserve and pack for return shipment. 21. Submit final repair report.

Job to be carried out during Refurbishment of Transition Piece assembly Fr III</></> Price is for one set (1 Set = 6nos.) 1.Receive and unload transition pieces at BGGTS service Center 2.Perform Receiving inspection: Verify identification and condition of the Transition Pieces with respect to customer paper work 3.Perform incoming condition evaluation of Transition pieces 4.Dimensional check transition pieces 5.Remove seals from TP body 6.Grit blast clean TP?s 7.Visual inspection and NDT inspection 8.Grind to remove cracks 9.Weld repair on Inner, Outer and side seal slots 10.Weld repair worn areas at aft frame 11.Weld repair cracks on TP body 12.Weld repair support bracket 13.Blend weld-ments to drawing dimensions and contour 14.Perform deflection correction on transition pieces 15.Perform Penetant inspection on TP 16.Grit blast clean transition Pieces 17.Visual and dimensional inspection of all coatings 18.Aluminum Oxide blast clean 19.Weld Repair / Replace floating seals as required 20.Assemble TP with seals 21.Carry out final inspection of transition pieces 22.Pack and prepare for shipment 23.Submit final report.

Job to be carried out during Refurbishment of Combustion Liners Fr III</></> Price is for one set ( 1 Set = 6nos.) 1.Receive and unload combustion liners at BGGTS service Center 2. Perform Receiving inspection: Verify identification and condition of the combustion liners with respect to customer paper work 3.Perform incoming condition evaluation of combustion liners 4.Dimensional check the combustion liners 5.Perform Eddy Current Test on TBC thinness of liners 6.Disassemble combustion liners and caps 7.Grit blast clean combustion liners 8.Perform NDT on combustion liners 9.Grind out weld cracks on liner body 10.Weld repair cracks worn areas on liner body 11.Weld repair worn portions on liner stoppers 12.Blend Stoppers to meeting drawing requirements 13.Weld repair/Replace cross fire tube collars 14.Blend cross fire tube collars to meet required dimensions 15.Repair/Replace spring seals 16.Correct distortion on liner body to meet drawing requirements 17.Weld repair worn Fuel nozzle collars 18.Machine collars to drawing requirements 19.Correct distortion on cowl caps 20.Dimensional check combustion liners 21.NDT check combustion liner bodies & caps 22.Weld repair all indications as required 23.Grit blast clean combustion liners 24.Apply TBC coating to liner body 25.Perform visual and dimensional inspection of all coatings 26.Re-fix Cap with new pins 27.Blast clean combustion liner assembly 28.Final inspection of combustion liners 29.Preserve and pack for shipment . 30.Submit final report.

Job to be carried out during Fuel Nozzle Set Calibration Fr III</> </> Price is for one set (1 Set = 6nos.) Work scope for Repair &Calibration of Fr-III Standard Fuel 1.,,Nozzle Receive and un load fuel nozzle Assembly in BGGTS service centre 2.,,Perform Receiving inspection: Verify Identification and condition of the Fuel nozzles with respect to customer paper work" Perfuming incoming flow testing of the fuel nozzles" Perform Dis-assemble fuel nozzles assembly" 3.,,Perform pressure testing of the fuel nozzle body" Clean fuel nozzle body and internals to remove deposits" Perform visual inspection of the parts and body" 4.,,Perform dimensional inspection of parts" Perform penetrate inspection on parts and body" Report the findings to customer" Weld repair worn areas on gas tip collar and machine to required dimensions" 5.,,Perform assembly fuel nozzles with internals (replace new internals as identified during incoming inspection)" Apply required torque as per the drawing" 6.,,Perform pressure testing of fuel nozzles after assembly" Perform flow testing of the fuel nozzle body" Arrange the fuel nozzles to meet the drawing range" Stack lock plate to body and gas tips" Apply thermal resistant paint" Pack fuel nozzles in wooden box" 7.Submit repair report.

Job to be carried out during Refurbishment of Cross Fire Tubes Frame III</></> Price is for one set (1 Set of 4nos.) 1. Receive and unload cross fire tubes at BGGTS service Center 2. Perform Receiving inspection: Verify identification and condition other cross fire tubes with respect to customer paper work 3. Grit blast clean cross fire tubes 4. Perform visual and dimensional inspection of cross fire Tubes 5. Perform NDT inspection 6. Grind out cracks 7. Weld repair cracks 8. Weld repair worn areas 9. Blend weld-ments to drawing dimensions and contour 10. Perform Penetrate inspection on TP 11. Grit blast clean transition Pieces 12. Perform dimensional inspection 13. Perform final QC check 14. Apply preservatives and pack.

Replacement of FN Tip </> </> Replacement of material.

Replacement of FN Air Cone </> </> Replacement of material.

Replacement of FN Transition Piece </> </> Replacement of material.