02 8-8.4 General Scope of Scheduled Services 08-12-2024 D.pdf

8 GENERAL SCOPE OF SCHEDULED SERVICES

The following table lists typical maintenance tasks performed during the Level A (4,000 operating hours) and Level B (8,000 operating hours) maintenance visits.

Based on equipment configuration and operating conditions of the Covered Equipment, the scheduled services may include such items. This provides an opportunity to minimize the downtime required to perform the maintenance.

8.1 CTG-1 Combined Turbine Compressor

8.1.1 Air Systems

Level A (4,000 hours)

Level B (8,000 hours)

Inspect air inlet housing (obstructions, leaks or contamination). Record differential pressure. X X

If self-cleaning air filters used, inspect supply pressure. Manually cycle through cleaning operation as required. X X

Inspect inlet guide vanes and position. Inspect linkage and actuation systems.

Inspect electric / hydraulic actuators for cleanliness or damage. X X

Inspect engine compressor variable vane mechanism for wear. Inspect for bent arms, loose linkage, or loose bushings. X X

Inspect bleed valve actuator mechanism for proper operation.

Electric/hydraulic actuators, inspect shafts for cleanliness or scoring. X X

Inspect intake and exhaust systems (debris, leaks, damage). X X

Inspect enclosure vent fans and filters. X X

8.1.2 Electrical and Control Systems

Level A (4,000 hours)

Level B (8,000 hours)

Visually inspect gages and indicators for proper operation. X X

Inspect control console electrical connections for cleanliness and security. X X

Verify and record speed magnetic pickup sensor output. X X

Inspect condition of thermocouple harnesses and supports. X X

Inspect fire detectors for cleanliness and sensitivity. X X

Test fire eyes and thermal devices. Verify system solenoids for proper operation. X X

For enclosed units, test hazardous package sensors /detector(s). Calibrate as required. X X

Inspect critical gages. Calibrate, fill, or replace as required. X X

Inspect speed and temperature control boxes, if equipped. Calibrate as required. X X

Inspect and verify back-up over-speed protection monitor. Calibrate as required. X X

Check gas detection devices. X X

Visually inspect control console. X X

Inspect and verify safety warning and shutdown devices. Calibrate or adjust as required. X X

Inspect and verify package vibration monitoring and associated vibration devices (transducers). X X

Inspect charger (batteries) for condition and proper operation. X X

Perform a battery run down test. - X

Replace PLC battery. - X

8.1.3 Fuel Systems

Level A (4,000 hours)

Level B (8,000 hours)

Record fuel pressure. Government adjust regulator as required (may be off package). X X

Inspect fuel control system (integrity, leaks, proper operation). May include fuel system (valves, actuators, linkage & connections). X X

Inspect fuel control poppet valve. Replace as required (condition based). X X

Inspect pilot gas filter element. Replace as required (condition based). X X

Disassemble, clean, and/or rebuild gas shutoff pilot control valves as required (condition based). X X

Inspect and lubricate liquid fuel shutoff valves. Re-assemble with new O-rings. X X

Inspect and clean fuel strainers. X X

Inspect fuel injectors for cracks, excessive oxidation, or damage. Remove or replace as required. X X

Inspect, clean, and/or rebuild primary and secondary fuel shutoff valves (condition based). X X

Inspect igniter torch housing for cracks and excessive erosion, inspect discharge tube for chaffing wear. Replace as required. X X

Inspect air purge manifolds (discoloration, cracks, overheating). X X

Liquid/dual fuel units, inspect purge system for proper operation as required. X X

8.1.4 General

Level A (4,000 hours)

Level B (8,000 hours)

Review unit operating data. X X

Inspect package lines and hoses (leaks, wear, chaffing). Correct as required. X X

Inspect mechanical linkages (wear, looseness). Correct as required. X X

Visually inspect entire package for fuel, oil, and air leaks. X X

Check condition and operation of solenoids and shutoff valves. Correct as required (kits as necessary). X X

Inspect package for unusual noise, discoloration, cracks, and chaffing lines.

Correct as required. X X

Visually inspect exhaust bellows for cracks or distortion. X X

Perform cleaning of engine per performance condition or as required (off-line detergent wash). X X

Perform borescope inspection of the compressor, combustion section, and the power turbine. X X

Conduct vibration survey. X X

Lubricate all electric motors that are equipped with grease fittings per recommended schedule or as required. - X

Check all safety valves as required. X X

Inspect, clean/replace all package filters (condition based) (excludes air inlet filters). - X

Witness turbine restart, record acceleration time. Monitor control system for proper sequencing. X X

Conduct engine performance analysis as required (condition based). - X

8.1.5 Generator (Driven Equipment)

Level A (4,000 hours)

Level B (8,000 hours)

Inspect generator for cleanliness. Inspect fan blades, generator rotor and stator for contamination and damage. - X

Inspect coupling shear bolts for wear or damage. X X

Disassemble, clean, inspect gear engagement wear as required. Repack (Contractor coupling grease). Re-assemble (new gaskets). - X

Based on vibration data, check and realign driver/driven equipment as required. - X

Perform resistance check (PI). - X

Inspect, repair, and assemble rectifier. Replace diode. As required

Replace bearings and oil seal. As required

Oversee contractor in cleaning the generator utilizing OEM recommendations or industry standard practices. As required

8.1.6 CTG-1 Lube Oil and Servo Oil Systems

Level A (4,000 hours)

Level B (8,000 hours)

Inspect lube oil tank level. Record oil consumption. X X

Verify proper operation of oil makeup system, if installed. X X

Check oil cooler louver operation, where applicable. X X

Check lube oil tank vent fan and/or mist eliminator for proper operation. X X

Collect oil sample for condition analysis. X X

Inspect and record lube oil filter (Delta P). Rotate to standby filter assembly if equipped (condition based). Inspect /replace filter elements as required. X X

Inspect servo oil filter “pop-out” condition indicator. Replace filter as required (condition based). X X

Inspect lube oil cooler assembly (cleanliness / proper operation).

- X

8.1.7 Start Systems and Auxiliary Motors

Level A (4,000 hours)

Level B (8,000 hours)

Inspect starter reservoir or lubricator oil level. Fill reservoir as required. X X

Replace starter hydraulic filter (if equipped). X X

Inspect and verify pre/post lube oil pump and backup lube oil pump. X X

Inspect starter clutch (if applicable) to ensure proper engagement and operation. X X

Check pneumatic starter assembly (if applicable) for unusual wear and oil consumption. Verify proper operation of starter when unit is in startup cycle. X X

Verify starter gas vent overpressure protection is functional (if applicable). X X

Inspect VFD’s for proper operation and set points. X X

Pneumatic starters: clean, inspect or rebuild shutoff valve (versa valve, etc.)

as required. - X

8.2 Full-Service Agreement - General

Level A (4,000 hours)

Level B (8,000 hours)

Engine overhaul (Exchange Program) as needed. Unlimited for warranted failures.

As required by manufacturer

Planned maintenance visits As required by manufacturer

Unscheduled maintenance and field service call outs.

As required by manufacturer

Designated Site Service Manager As required by manufacturer

HMI Platform services.

As required by manufacturer

Package parts, repair, or replacement.

As required by manufacturer

Equipment inspections, repairs, and maintenance.

As required by manufacturer

Semi-annual and maintenance reports As required by manufacturer

Condition assessment visits and equipment condition reports.

As required by manufacturer

8 GENERAL SCOPE OF SCHEDULED SERVICES