Troubleshooting

Our team of site engineers are available to mobilise at short notice to any plant in the world to diagnose and rectify faults. We have a vast range of experience in the team who have knowledge of many makes of gas turbine and associated control system. Our approach to troubleshooting situations is based around:

  • Analyse as much data as possible before travelling to site, in order to reduce the site time.
  • Travel to site with the appropriate test equipment.
  • Install test equipment in order to identify and isolate potential fault areas.
  • Reduce test runs to a minimum.
  • Leave site with a healthy running machine.

On-Site Maintenance

The key requirements of on-site maintenance are to:

  • Ensure the planned tasks are completed in the allotted time.
  • Reduce the outage time to a minimum.
  • Ensure the equipment is returned to service with the minimum of fuss.
  • Perform the planned tasks safely.

In order to achieve these requirements TCL have a well-developed maintenance procedures which include:

  • Identifying the required maintenance tasks and produce detailed method statements.
  • Producing detailed risk assessments for each task to identify and mitigate all hazards.
  • Ensuring all personnel are suitably trained.
  • Ensuring that all spare parts and tooling are available before the site activities commence.

Engine Inspection

An external inspection and internal borescope inspection are carried out to identify the current condition, this will enable the owner to:

  • Identify parts that may fail in the future
  • Plan future scheduled and non-scheduled maintenance activities
  • Pre-order parts for future replacement
  • Reduce the spare parts holding

The engine borescope service includes:

  • Attendance on site by TCL engineers, with the latest boroscoping equipment.
  • Detailed report highlighting all areas of concern.
  • Video of the engine internals.
  • Recommendations for future maintenance.

On-Site Repair

Traditionally repairs too many of the aero-derivative engines have been carried out off-site at the overhaul company’s workshop. This has resulted in costly repair bills and extended machine outages. The reality is that many repairs can be carried out on site without the need for transporting the engine to a remote facility.

Typical examples include:

  • Combustor can change out
  • Hot end section repair, including turbine replacement
  • Nozzle guide vane (NGV) overhaul
  • Rotor blade overhaul
  • In country balancing services
  • Rear bearing/front bearing changes

Parts are assessed for further operation by carrying out comprehensive NDT inspection on site. Depending upon operational requirements faulty parts are replaced or sent for overhaul.
Following repair, the rotor is re-balanced if required and the engine is tested up to full load to confirm performance figures.

The repairs are carried out using strictly controlled conditions in line with pre-developed procedures. These involve:

  1. Setting up a clean conditions area on site
  2. Full risk assessment survey
  3. Ensuring all parts are on site before the repair commences
  4. Working to agreed procedures and method statements

Fuel Valve Calibration

Calibration of the fuel valve may be possible on site, which may reduce the engine downtime as the valve will not have to be removed and dispatched to an off-site workshop.
Gas valve calibration involves exhausting fuel gas to atmosphere; this may not be possible depending upon the location and environmental constraints.

Liquid fuel valve calibration involves running the HP fuel pumps and circulating fuel through the valve to the LP inlet. Again this may not be practical if the turbine is fitted with engine driven HP fuel pumps.
Contact TCL Customer Support department to discuss your requirements.

Performance Monitoring

Performance monitoring can be carried out by our engineers on site. The turbine will be fitted with the necessary instrumentation to check the efficiency and output of each element of the plant, including:

  • Compressor efficiency.
  • Charging turbine efficiency
  • Power Turbine output and efficiency