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Gas Turbines' Spare Rotor

The document discusses the history and issues around spare gas turbine rotors for 4 gas turbines (GT-601, GT-602, GT-603, KGT-2501). The original spare rotor believed to work for all was found to only work for KGT-2501 due to inconsistencies. Options are presented to either have GE provide a solution, procure new parts to make rotors common, or uprate GT-601 and seek a non-OEM spare rotor. Maintaining a proper spare rotor for each turbine is needed due to their critical role in operations.

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Ahtsham Ahmad
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201 views

Gas Turbines' Spare Rotor

The document discusses the history and issues around spare gas turbine rotors for 4 gas turbines (GT-601, GT-602, GT-603, KGT-2501). The original spare rotor believed to work for all was found to only work for KGT-2501 due to inconsistencies. Options are presented to either have GE provide a solution, procure new parts to make rotors common, or uprate GT-601 and seek a non-OEM spare rotor. Maintaining a proper spare rotor for each turbine is needed due to their critical role in operations.

Uploaded by

Ahtsham Ahmad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Presented by ZAA / ZS

Intent
GT Rotor Configuration
Background / History of Spare Rotor
Issues in Spare R Rotor
Trade Off
Spare M-Prime Rotor
Current Scenario
Future Action Plan



Keeping in mind 04 GTs Operation and
revised sparing philosophy in that context
demands spare rotor for GT-601, 602 &
603
Alternator
Inductor Rotor
16 Stage
Compressor Rotor
Journal for brg # 1 Journal for brg # 2
2nd Stage Turbine
Wheel
1st Stage Turbine Wheel
GT-603 was relocated from USA and up-rated
from model L to R in 1997/1998.

In 1997, KGT-2501 was up-rated from model L
to M Prime.
Frame-5 M-Prime machine in Baton Rouge was bought.
Rotor of that machine was by refurbished by GE.
Presently this rotor is installed in KGT-2501.

A rotor of Model L from KGT-2501 was,
therefore, a spare one.

Spare Rotor Philosophy:
A spare rotor of KGT (process air compressor driver)
should be available at site with additional benefit of being
spare for the rest of the turbines.

In this context, GE responded that an R rotor can
become spare for all 04 gas turbines.
In 1999, L model rotor was sent to GE Meelsa for
R up-rate as a common spare.
The same rotor was received in 2001 as R rotor.
So it was thought that this rotor is spare for KGT
and GT-603.


In 2003, it was decided to up-rate GT-602
from LA to R using the same rotor received in
2001.
Two glaring issues were revealed during GT-
602 up-rate.
1. No. of holes of the 2
nd
Stage Turbine Wheel end
were 20 instead of 24
2. There was increased clearance between 1
st
stage
bucket and wheel indicating high wiggling or bucket
rock issue which was completely overlooked by GE.
GT-601 GT-602 GT-603 KGT-2501 Spare Rotor
Model L LA R M-Prime R
Spare Rotor Useable
Our Paradigm YES YES YES YES
Reality NO NO NO NO
Why?
2nd Stage Turbine End Flange Bolt Holes 24 24 20 24 20
2nd Stage Wheel Diameter 43.2" 45.8" 43.2"
Wiggling YES
GE Contradicted their earlier stance that spare R rotor is compatible for
KGT-2501 M-Prime.

R rotor was of no use, so spare rotor for
M-Prime was needed the most as per
revised sparing philosophy
So-called spare R rotor was sent to GE in 2005
and was received in April 2007.
Twist lock arrangement in 1
st
stage buckets
instead of lock pin.
GE provided twist lock wheel at that time and
lock pin design wheel could further delay
refurbishment.

This rotor is still lying in safe
custody with W/H.
GT-601 GT-602 GT-603 KGT-2501 Spare Rotor 1
Model LA R R M-Prime M-Prime
1st Stage Bucket Design Lock Pin Lock Pin Lock Pin Lock Pin Twist Lock
1st Stage Wheel Design Lock Pin Lock Pin Lock Pin Lock Pin Twist Lock
Spare Rotor Useable No No No YES
-
2nd Stage Turbine End Flange Bolt Holes 24 24 20 24 24
GT-604 spare rotor is available but it cannot be used on any of the
04 GTs because of difference in type of coupling at both ends and
difference in no. of holes i.e. 32.
The spare rotor available for KGT-2501 can be used in this very
machine only.
As per 04 GTs operation, there is no spare rotor available for GT-
601, 602 & 603.
Each GT demands one separate spare rotor is present conditions.
Option-1
Compilation of complete data of rotors and details sent to GE for
a solution. ( Done )

Option-2
Procure GT-603 Load Gear Coupling with 24 bolt holes
Replace GT-603 2
nd
Stage Turbine Wheel with 24 bolt holes
flange
(This shall make GT-602 & 603 rotor common for both)
Option-3
Uprate GT-601 from LA to R.In addition to Option-2.
(This shall make rotor common for all three GTs
Look for a spare R rotor with scrap vendors or non-OEM
vendors such as MJB, TSL etc. & prepare cost estimates.

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