Major inspection MI along with AGB and LGB overhauling job and Torque converter replacement job of Frame-III Gas turbine on stand alone basis at Digboi Refinery

Amount

MI along with AGB/LGB overhauling job

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 <H>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 as required 6.,,Removal of exhaust silencer and Transition duct. 7.,,Removal of flame Detectors and Spark Plugs 8.,,Removal of wheel Space thermo couples as required 9.,,Removal of CO2 piping and compartment lighting as required 10.,,Removal of gas fuel piping as required 11.,,Removal of cooling & sealing air piping as required 12.,,Removal of fuel Nozzles, can covers 13.,,Removal of Crossfire Tubes, retainers & lines 14.,,Removal of false start drain lines 15.,,Removal of combustion cans 16.,,Removal of forward & Aft flex seals 17.,,Take initial compressor rotor positioning checks 18.,,Provide support jacks under GT 19.,,Removal inlet elbow, transition piece & inlet plenum 20.,,Removal of turbine casing bolts & upper Half turbine casing. 21.,,Removal of 1st stage Nozzle & Support ring (top half) 22.,, Removal of compressor casing bolts and upper Half compressor casing 23.,, Removal of exhaust diffuser and slide towards LGB end to facilitate easy removal of exhaust casing. 24.,, Removal of exhaust casing bolts and U/H of exhaust casing 25.,, Removal of inlet casing bolt and U/H of inlet casing 26.,,Removal of compressor discharge casing (CDC) bolts and casing 27.,,Removal of inner CDC 28.,,Take rotor thrust float 29.,,Measure and record initial turbine clearances & compressor clearances 30.,,Dissemble Bearing 1 & 2 and take initial clearances 31.,,Remove 1st Stage Bucket in position 32.,,Rig and remove rotor 33.,,Removal of 2 nd Stage Nozzles 34.,,Removal of stage # 2 buckets 35.,,Removal of stage # 1&2 shrouds 36.,,Replace Fuel nozzles 37.,,Replace Liners, Transition Pieces, Crossfire tubes &Retainers as required 38.,,Replace 1st & 2nd Stage Nozzles 39.,,Replace 1st & 2nd stage Buckets 40.,,Replace 1st & 2nd stage Shrouds 41.,,Inspect IGV (NDT) and replace including hardware, if required 42.,,Clean and inspect 1&2 Bearing & Seals 43.,,Clean inspect compressor Stator Vanes and Rotor Blades(NDT)) 44.,,Check and match new bearings and seals 45.,, Position and mark new shrouds for drilling 46.,,Install stage # 2 Nozzles segments, radial pins in bottom half 47.,,Check wheel space thermocouples entry into stage # 2 nozzles segments 48.,,Reassemble both bearing bottom half 49.,,Rig and position the rotor 50.,,Reassemble both bearing and check rotor thrust float 51.,,Correct rotor thrust float as required (Machining of thrust shim as required) 52.,,Check final compressor &Turbine clearances 53.,,Install inner compressor discharge casing 54.,,Install compressor discharge casing. 55.,,Install compressor inlet casing 56.,,Install compressor casing 57.,,Install exhaust casing 58.,,Install exhaust diffuser 59.,,Install stage # 1 Nozzles support ring top half, followed by stage # 1 nozzle 60.,,Install transition pieces 61.,,Install turbine casing 62,,Removal of support jacks underneath casings 63,,Take final compressor rotor positioning checks 64,,Install inlet plenum 65,,Install transition pieces & inlet elbow 66,,Install Forward & Aft flex seals 67,,Install wheel space thermocouples & wiring 68,,Re-assemble combustion cans 69,,Install false start drain lines 70,,Install liners, X-fire tubes & retainers 71,,Install combustion can covers & fuel nozzles 72,,Install spark plugs & flame detectors 73,,Install cooling & sealing air lines 74,,Install gas, water/steam lines, atomizing air lines as available 75,,Install exhaust transition duct and silencer 76,,Install turbine compartment roofs and panels. 77,,Install CO2 piping and compartment lighting. 78,,Install compartment vent fan and duct 79,,Check alignment between turbine to AGB and correct 80,,Install accessory coupling & coupling guard 81,,Check alignment between turbine to LGB and correct including soft foot if any. 82,,Install coupling & coupling guard 83,,Clean up, visual inspection & pre-start checks 84,,FSNL & Load ,, <H>B) ACCESRY GEAR BOX Inspection and replacement of Torque converter,, </>,,,,,,,,,,,,,, ,, 1,,Disassembly of oil deflectors of shaft 1. 4,,2. Disassembly of Aux. coupling flange bolts. 3. Removal of old torque convertor oil inlet/out let lines. 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 ,, <H>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.

<H>Scope of work for replacement of Torque Convertor without removing diesel engine</> 1. Removal of associated piping for diesel engine. 2. Removal of old torque convertor oil inlet/out let lines. 3. Remove AGB to GT coupling guard 4. Remove the AGB to GT Coupling 5. Remove the AGB upper half casing 6. Removal of AGB gear box shaft no #1 7. Removal of torque converter. 8. Removal of Jaw clutch hub from AGB shaft no#1. 9. Check run out & Measure Dimensions of jaw clutch and AGB shaft no#1. 10. Assembly of jaw clutch on AGB shaftno#1. 11. Assembling of torque converter on diesel engine. 12. Assembly of jaw clutch hub with bearing on new torque convertor. 13. Re Positioning of diesel engine with jaw clutch and maintain DBSE. 14. Assemble AGB shaft no#1 15. Assemble AGB upper casing 16. Carry out alignment between AGB to GT,,,,,,,, 17. Alignment between AGB to torque convertor/diesel engine. 18 Alignment check and correction between GT and LGB if required 19 Drilling and pining on torque converter to support. 20 Drilling and pining on diesel engine. 21 Modification of oil pipelines. 22 Assemble the AGB to GT coupling 23 Assembly of hydraulic cylinders and limit switches. 24 Adjust the gap for clutch engage and disengage. 25 Keep the machine on ratchet if applicable 26 Crank the machine.