Major Inspection
Disassembly of Gas Turbine
AJSS led the disassembly of a GE Frame 6B engine, carefully removing components such as the enclosure roof, upper turbine cases, fuel lines, nozzles, and other critical parts for inspection and refurbishment.
Inspection and Assessment
AJSS conducted a comprehensive inspection of the turbine, including evaluating critical components like the rotor, turbine cases, blades, and associated systems to determine their condition and identify any parts requiring replacement.
Component Replacement and Repair
AJSS provided recommendations and executed the replacement of worn or damaged components, based on OEM specifications and operational requirements.
Reassembly and Testing
After the inspection, AJSS reassembled the turbine, ensuring all components were installed to GE tolerances, followed by performing bump tests to check rotor position and other critical functionality.
Commissioning and Alignment
AJSS assisted with the commissioning process, including correcting alignments, performing hot and cold commissioning checks, and conducting vibration analysis during start-ups.
Flange Management and Quality Assurance
AJSS implemented flange management procedures during reassembly to ensure all connections were secure and met operational standards.
Safety Compliance
Throughout the entire process, AJSS adhered to strict safety protocols, creating lift plans, risk assessments, Safe Work Method Statements (SWMS), and detailed safety documentation to ensure minimal risk to personnel and compliance with safety standards.
Operational Handover
The turbine was restored to operational service, meeting or exceeding the required operational standards, and the site was cleaned and prepared for ongoing use.
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Brief
- 1 GE Frame 6B gas turbine refurbished and returned to service
- 13 AJSS specialists mobilised across inspection phases
- 3 major stages delivered: disassembly, inspection, reassembly
- 2-month outage window successfully executed (Oct–Nov 2023)
- 100% compliance with GE tolerances and site safety requirements
Situation
AJ Stack Solutions undertook a comprehensive Major Inspection project on a GE Frame 6B engine at a prominent power station. The project aimed to refurbish the Gas Turbine engine, allowing it to return to full operational service. The inspection encompassed a detailed examination and replacement of critical components, disassembly and subsequent reassembly within a specified timeline. AJSS also assisted with the commissioning of the unit which included correcting alignments of the unit, performing hot and cold commissioning checks and vibration analysis during start-ups.
Task
The project consisted of three stages; disassembly, inspection and reassembly. The goal was to inspect, repair and replace components within the engine to allow the unit to return to service after being condemned by the OEM. The project required adherence to strict safety protocols and an application of industry best practices to guarantee the successful completion of the inspection and maintenance tasks.
Action
AJSS mobilized a dedicated team, comprising of skilled personnel, including a project supervisor, technical assistant, rigger, mechanical fitters, machinists and boiler makers. The disassembly phase involved the careful removal of numerous components, such as the enclosure roof, walling, all upper turbine cases, flame detectors, fuel lines, nozzles and more. Safety protocols were paramount, with lift plans created for each lift, detailed safety documents such as SWMS, risk assessments and permits produced for each task and detailed accounts of working man hours and safety statistics documented. During the inspection phase, a comprehensive list of replacement parts were provided by the customer to overhaul and rebuild critical components. Adjustments to the original scope were made, and emergent work outside the initial plan was addressed. The reassembly phase involved the installation of new components, bump tests to determine rotor position, and careful reinstallation of various parts. Flange management procedures were implemented to ensure the integrity of connections, with any discrepancies promptly identified and rectified.
Result
The successful completion of the Major Inspection was achieved late November, 2023. The rotor was reinstalled without incidents, and all components were fitted within GE tolerances. The reassembly and testing procedures ensured the turbine unit met or exceeded operational standards. The site was restored to its original state, with thorough cleaning and vacuuming of the package. This project exemplifies AJSS’ commitment to delivering high-quality solutions within specified timelines while prioritizing safety, adherence to contractual obligations, and attention to detail. The successful outcomes demonstrate AJSS expertise in handling complex inspections and maintenance projects within the power generation sector.
