Advance Gas Turbine Solutions
OTEC Joint Venture Company
PETRONAS CARIGALI SDN BHD
COMPRESSOR INSPECTION
GTC K2400
B11-KA
WORKPACK
VOL 1 OF 1
Prepared and submitted by:
PCSB SK GAS GTS33
Prepared By
AGTS PM
Siemens
Energy PM
Name
Irwansjatria
Ernest Liang
Date
10 Jan 2022
10 Jan 2022
Position
Signature
Reviewed By
Section Head
(GTS/33)
HSE
Executive
(GSE/1)
Endorsed by
Turnaround
Manager
(GTS/24)
Field
Manager
GPD1
Offshore
Installation
Manager
Approved by
TA Head
GTS/24
WORKPACK CONTENTS
/NA
1
INTRODUCTION
i.
Project Summary
√
ii.
Organization Chart
√
iii. Emergency Response Plan
2
3
Tick - √
√
SCOPE OF WORK (SOW)
i.
Thrust bearing inspection and shim adjustment
√
ii.
Thrust balance pipe interface bolts replacement
√
MATERIALS & TOOLS
i.
Table #1 Part list for thrust bearing inspection
√
ii.
Table #2 Part list for thrust balance pipe bolt replacement
√
iii. Table #3 Special tools for thrust bearing inspection
√
1. INTRODUCTION
1.1 Project Summary
Compressor inspection on B11 GTC K2450.
1.2 Project Organization Chart
PCSB
AGTS PM
Irwansjatria
SESB PM
Ernest Liang
1.3 Emergency Response Plan
Scope
To specify the Emergency, Respond Plan throughout the project. The ERP should contain but not
limited to the following content.
Objective
To ensure the site team are aware of the information and action required to be performed on any
case of emergency and able to secure themselves from any danger.
ERP Org Chart
ECC INCIDENT COMMANDER
013-8103568
Email: skgasecc.ic@petronas.com.my
ECC INCIDENT COMMANDER
INCIDENT COMMANDER: 013-8103568
GPD TELEPHONE: 017-8117141
UNIT HEAD
SABTUNI OSMAN
012-2658956
FM GPD/1
BOBBY RANGGAU
013-8788820
EIC GTS/33
STANISAUS LATERAN
010-3724363
ONSHORE
OFFSHORE
B11 OSC
EMERGENCY
RESPONSE TEAM
(ERT)
PS/MS B11
AGTS FSR / ROVING GANG
Legend:
Reporting path
Indirect Reporting
Emergency Contact No
1
Type of emergency & rescue plan
Type of Emergency
Fire Alarm & Evacuation
alarm
Medical treatment
emergency
Rescue Plan
Team Lead to instruct for stop work. Head count to confirm all
team member are available before proceeding to evacuate
the work area towards the mustering station.
Team Lead to instruct stop work quickly assess the severity
of the IP. Team Lead to assign personnel to notify the
OIM/MS/PS /Medic. Medic / Team lead to provide any
temporary medical treatment if required. If not, escort IP back
to LQ/Medic room.
2. SCOPE OF WORK
2.1 Thrust bearing inspection and shim adjustment
2.1.1 Details scope:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
xx.
xxi.
xxii.
xxiii.
xxiv.
xxv.
xxvi.
xxvii.
xxviii.
xxix.
xxx.
Isolation
Inspect spare parts and tools
Remove piping and tubing at non drive end
Remove coupling guard
Remove coupling spool
Temporary tape all open connections (oil lines)
Bump check as found thrust clearance
Remove coupling hub and vibration probes at drive end
Remove thrust bearing housing top half
Remove and inspect inboard and outboard thrust bearing
Remove outboard thrust bearing o-ring
Verify rotor center position
Reinstate inboard and outboard thrust bearing (without o-ring)
Reinstate thrust bearing housing and check thrust float
Remove thrust bearing top half
Adjust shim to inboard and outboard thrust bearing for a reduced axial end float within 0.180.28 mm (target can be 0.23 mm).
Reinstate top halve thrust bearing housing
Verify rotor position and thrust clearance (possibility to use the gas seal insertion tool on
drive-end to be verified by SE to create the appropriate axial force to stack the shims)
Apply sealant to thrust bearing housing (min 24 hours for sealant curing)
Install coupling hub and set axial displacement probe, verify displacement in HMI & Bentley
rack, set as required
Verify shaft alignment and DBFF, verify pre-stretch and shimming
Install coupling spool and shim
Reinstate coupling guard
Remove temporary tape on open connections
Reinstate piping and tubing
Pre-start checks
De-isolation
Pressurization and startup
Monitor compressor operating parameter
Load compressor and monitor axial displacement
2.1.2 Manpower: 1 FSR, 2 millwrights, 1 rigger/helper during mechanical works of 3-4 days.
2.1.3 Duration: 3-4 days mechanical works, 2-3 days for startup, load and monitoring
2.1.4 Spare parts: refer to Table #1
2.1.5 Special tools: refer to Table #3
2.1.6 General tools: Imperial Hand tools (including combination spanner set, allen key set, plier
and screw driver (+) & (-), 2” scrapper, 24” spirit level ruler x 24” steel rule x 1, 12” steel rule,
imperial box socket set up to 1 3/8”, inside micrometer (1”), inside micrometer (1m) , depth gauge
(12”), dial gauges (0.01mm or better) x 4 and magnetic stand x 4, torque wrench with valid
calibration ( below 100Nm), 1 1/2” x 4ft pipe extension.
2.1.7 Consumable: Scotch bright (6pcs), cleaning solvent (3-4 cans WD40), hand glove ( 1 doz),
clean cotton rag 10kg, industrial paper towel 1/2 roll, plastic bags, plastic trays x 4, paint marker
(white and black x2), plywood x 3 pcs (any thickness above 5mm and around 3’ x 4’ or other
readily available matching size), 2” masking tape x 5, stretch film x 1 roll
2.1.8 Overhead crane and tackles (3/8” shackles x 2 and 2m lifting belt x 1 & 1m lifting belt x1) to
lift top bearing housing, coupling spool and guard (below 250kg)
2.2 Thrust balance pipe interface bolts replacement
2.2.1 Details scope:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
Erect scaffold to access compressor case top
Isolation and verify hydrocarbon free
Remove the hex head bolt for thrust balance pipes
Lift and remove thrust pipe, remove gaskets
Temporary tape the connection on case to prevent foreign ingress
Clean and surface rust stain on flanges
Replace the gasket for the thrust balance pipes with new
Lift and reinstate the thrust balance pipe
Lightly lubricate bolt thread, install blue coated thrust balance pipe
Torque hex head bolt for pipe 16 & 17 to 270 and 300Nm respectively
De-isolation
Check any sign of leakage during pressurization.
Remove scaffold
2.2.2 Manpower: 1 FSR, 1 millwrights & 1 rigger/helper during mechanical works of 1-2 days.
2.2.3 Duration: 1-2 days mechanical works.
2.2.4 Spare parts: refer Table #2
2.2.5 Special tools: NONE
2.2.6 General tools: Imperial Hand tools (1/2” drive box socket set including 1 ¾” box socket, 1
¾” slogging wrench, torque wrench with valid calibration (within range of 250 to 350 NM), 2lb
hammer, 2” x 4ft pipe extension, ultrasonic leak detector or LDAR
2.2.7 Consumable: Scotch bright (2pcs), cleaning solvent (1-2 cans WD40), hand glove ( 1 doz),
clean cotton rag 2kg, industrial paper towel 1/10 roll, plastic bags, plastic trays x 1, paint marker
(white and black x1), plywood x 4 pcs (any thickness above 5mm and around 3’ x 4’ or other
readily available matching size), 2” masking tape x 4, stretch film x 1 roll, snoop leak detector
2.2.8 Overhead crane and tackles (1/2” shackles x 3 and 3m lifting belt x 2) to lift top bearing
housing (below 250kg). The bracket to secure pipe for shipment and lifting could be used for
pipe lifting. Double lanyard PPE.
3. MATERIALS AND TOOLS
3.1 Table #1 Part list for thrust bearing inspection
No
Item #
in Dwg
Part #
1
4
002-272-276
O’RING (Thrust Bearing Cover)
2
22
099-010-021
LOCTITE 515
3
27
002-272-126
O’RING (Journal/rework thrust
Bearing Housing)
SPIRAL WOUND GASKET 4,5MM
4'' 150#
SPIRAL WOUND GASKET & RINGS
4.5MM 1.5''
LOCKING CABLE TIE (SEE NOTE #
3) - PANDUIT #PLT.6SM-C
12.00 LEG SHIM PACK IN HALVES
.062 11.0 THK
O-RING, AS 568 - #202 - 234 I.D. X
.139 C/S, VITON
FEED TUBE w/O-RINGS, FT-5
4
1000537236
5
1000537237
6
13.2
7
11
267353-012
8
9.1
052701
9
3.2
10
6
266575-002D1
1000527153
11
6
1000527156
12
6
1000527159
13
6
1000527160
14
6
1000527161
15
059391
1000537235
16
17
18
19
20
31
28
30
29
4
423-749-063
423-749-064
002-272-249
002-272-254
371706-005
21
5
383168-003
22
Part description
Qty
1
6pack
1
1
1
10
2
12
12
FLAT GASKET ITEM 1 DWG 546901-201
FLAT GASKET ITEM 2 DWG 546901-201
FLAT GASKET ITEM 3 DWG 546901-201
FLAT GASKET ITEM 4 DWG 546901-201
FLAT GASKET ITEM 5 DWG 546901-201
SPIRAL WOUND GASKET 4,5MM
2'' 150#
Back-up ring (coupling hub)
Back-up ring (coupling hub)
O-ring (coupling hub)
O-ring (coupling hub)
12.00(6-SHOE)CCW LEG THR
SHOE, CRCU; 65 % OFFSET, LSR,
HST (OUTBOARD)
12.00(6-SHOE)CCW LEG THR
SHOE, CRCU; 65% OFFSET
DR/INSTR,
LSR,HST
Hylomar
2
1
2
1
2
4
2
2
2
2
4
2
Remarks
Thrust bearing assb
1000520766
Thrust bearing assb
1000520766
Thrust bearing assb
1000520766
Thrust bearing oil supply
interface
Thrust bearing oil supply
interface
Thrust bearing 1000520777.
Non SE part #.
Thrust bearing 1000520777.
Non SE part #.
Thrust bearing 1000520777.
Non SE part #.
Thrust bearing 1000520777.
Non SE part #.
Item # 6 (546-905-001) of
Coupling guard 546-900-201
Item # 6 (546-905-001) of
Coupling guard 546-900-201
Item # 6 (546-905-001) of
Coupling guard 546-900-201
Item # 6 (546-905-001) of
Coupling guard 546-900-201
Item # 6 (546-905-001) of
Coupling guard 546-900-201
Coupling guard 546-900-201
pipe connection
Rotor assembly 1000520790
Rotor assembly 1000520790
Rotor assembly 1000520790
Rotor assembly 1000520790
Item # 4 of thrust bearing dwg
1000520777. Non SE part #.
Item # 5 of thrust bearing dwg
1000520777. Non SE part #.
3.2 Table #2 Part list for thrust balance pipe bolt replacement
No
1
Item #
in Dwg
Part #
000-148-903
Part
description
SPIRAL
WOUND
GASKET
Qty Remarks
4
Gasket for thrust pipe 1000532527 (B11-K-PUR-AGTS-000P-DWG-0001 Rev. C) & 1000532528 (B11-K-PUR-AGTS000-P-DWG-0002 Rev. C)
000-201-728
2
HEX HEAD
BOLT
32
Hex head bolt for thrust pipe 1000532527 (B11-K-PURAGTS-000-P-DWG-0001 Rev. C) & 1000532528 (B11-KPUR-AGTS-000-P-DWG-0002 Rev. C)
3.3 Table #3 Special tools for thrust bearing inspection
No
1
2
3
4
5
6
7
Item #
Part #
538-484-205
595-195-204
091-015-005
000-028-952
524-560-208
000-005-319
Part description
Bearing Housing Lifter Assembly
Tools Assembly for Mounting &
Dismounting Gas Seal Assembly
Lubri-Silk Synthetic Grease
Alignment jig/ laser alignment tool
Hydraulic Pump Assembly Kit
Threaded Rod Assembly
Screw
Qty
1
1
1
1
1
1
1
Remarks
General Comments
Others (Additional Workscope)
Activity
Remarks
Inspection Performed By
Field Service Rep
Date
Please list Works not done due to customer or Incomplete Due to Unavailability of Parts
Item
Priority Code
Description
X
B
Part Description
Urgent (Do not use machine until complete)
Within 6 months or 4000 Hours
Part Number
A
C
Qty
Priority
As soon as possible (Next Service)
Plan as appropriate to coincide with other works
ID
Task
Mode
1
Task Name
Duration
Thrust Bearing Inspection Schedule
Start
Finish
Jan 30, '22
M
9 days
Mon 2/14/22 Tue 2/22/22
2
Preparation
2 days
Mon 2/14/22 Tue 2/15/22
3
isolation
2 days
Mon 2/14/22 Tue 2/15/22
4
FSR mob to offshore
1 day
Mon 2/14/22 Mon 2/14/22
5
Inspect spare parts and tools
1 day
Tue 2/15/22 Tue 2/15/22
4 days
Wed 2/16/22Sat 2/19/22
6
Mechanical Work
7
Remove piping/tubing
0.25 days
Wed 2/16/22 Wed 2/16/22
8
Remove coupling guard, spool, hub and DE probes
0.5 days
Wed 2/16/22 Wed 2/16/22
9
Bump check and remove thrust bearing case top
0.25 days
Wed 2/16/22 Wed 2/16/22
10
Remove and inspect inboard and outboard thrust bearing, 0.5 days
verify rotor position
Thu 2/17/22 Thu 2/17/22
11
Reinstate inboard and outboard thrust bearing (without
o-ring) with housing & verify thrust end play
0.5 days
Thu 2/17/22 Thu 2/17/22
12
Adjust shim to inboard and outboard thrust bearing for a
reduced axial end float within 0.18-0.28 mm (target 0.23
mm).
Reinstate bearing assembly and verify thrust end play
0.25 days
Fri 2/18/22
Fri 2/18/22
0.25 days
Fri 2/18/22
Fri 2/18/22
14
Apply sealant to thrust bearing housing (min 24 hours for
sealant curing)
0.13 days
Fri 2/18/22
Fri 2/18/22
15
Install and set axial displacement probe, loop check
0.25 days
Fri 2/18/22
Fri 2/18/22
16
Verify shaft alignment and DBFF, verify pre-stretch and
shimming
0.37 days
Fri 2/18/22
Sat 2/19/22
17
Install coupling hub, spool, shim and guard
0.5 days
Sat 2/19/22 Sat 2/19/22
18
Reinstate piping and tubing
0.25 days
Sat 2/19/22 Sat 2/19/22
4.12 days
Fri 2/18/22 Tue 2/22/22
13
19
Preparation and startup
20
Pre-start check (Seal gas system)
0.5 days
Fri 2/18/22
21
Pre-start check (lube oil & others)
0.5 days
Sun 2/20/22 Sun 2/20/22
22
De-isolation
0.5 days
Sun 2/20/22 Sun 2/20/22
23
Pressurization and startup
1 day
Mon 2/21/22 Mon 2/21/22
24
Loading and monitoring
1 day
Tue 2/22/22 Tue 2/22/22
Project: Thrust Bearing Inspect
Date: Mon 12/27/21
T
W
T
F
S
Feb 6, '22
S
M
T
W
T
F
S
Feb 13, '22
S
M
Sat 2/19/22
Task
Project Summary
Manual Task
Start-only
Deadline
Split
Inactive Task
Duration-only
Finish-only
Progress
Milestone
Inactive Milestone
Manual Summary Rollup
External Tasks
Manual Progress
Summary
Inactive Summary
Manual Summary
External Milestone
Page 1
T
W
T
F
S
Feb 20, '22
S
M
T
W
T
F
S
Feb 27, '22
S