Overhauling turbine assemblies from industrial power turbines
Overview
This standard identifies the competences you need to carry out a complete overhaul of the turbine assembly from an industrial power turbine, in accordance with approved procedures. The turbine assembly to be overhauled will have been removed from the power turbine, and the overhauling activities will take place in a maintenance environment or manufacturer's workshop.
In carrying out the overhauling operations, you will be required to follow laid-down procedures and use specific dismantling and rebuilding techniques. The overhauling activities will involve removing all ancillary components and subassemblies, removing the low, intermediate and high pressure turbines, turbine shafts, discs, bearings and seals, and stripping the turbine housing of all its components. You will be required to inspect the components for damage and wear, and to make decisions on which components can be reused and which will need replacing.
You will then rebuild the turbine assembly, which will involve fitting replacement or overhauled sub-assembly units and the replacement of all damaged, worn and `lifed' components. The overhauling activities will include making all necessary checks and adjustments to ensure that components are correctly replaced, positioned, aligned, adjusted, torque loaded, locked and fastened, and that the correct sealants are used.
Your responsibilities will require you to comply with organisational policy and procedures for the overhaul of the turbine assembly, and to report any problems with the overhauling activities, or with the tools and equipment used that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment and materials used in the overhauling activities are removed from the work area on completion of the activities, and that all necessary job/task documentation is completed accurately and legibly. You will be expected to work with a minimum of supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying appropriate overhauling techniques and procedures to the turbine assemblies. You will understand the dismantling and reassembly methods and procedures used, and their application. You will know how the turbine assembly functions, the purpose of the individual components and associated defects, in adequate depth to provide a sound basis for carrying out the overhauling activities to the required specification. In addition, you will have sufficient knowledge of these components to ensure that they are fit for purpose and meet the specifications, thus providing a sound basis for carrying out the reassembly.
You will understand the safety precautions required when carrying out the overhauling activities associated with turbine assemblies from industrial power turbines, especially those for lifting, handling and supporting the equipment being removed and replaced. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant overhauling schedules to carry out the required work
- establish the components to be removed and, where appropriate, mark components to aid re-assembly
- ensure that any stored energy or substances are released, safely and correctly
- ensure that all removed components are correctly identified and stored in the correct location
- carry out the overhaul to the agreed level, using the correct tools and techniques
- report any instances where the overhauling activities cannot be fully met or where there are identified defects outside the planned overhauling schedule
- complete the relevant documentation, in accordance with organisational requirements
- dispose of unwanted components, waste materials and substances, in accordance with safe working practices and approved procedures
- deal promptly and effectively with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
- how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- the hazards associated with overhauling power turbine, turbine assemblies and how to minimise them and reduce any risks
- the importance of wearing protective clothing (PPE) and other appropriate safety equipment during the overhaul
- how to obtain and interpret drawings, specifications, manufacturers' manuals, history/maintenance reports, and other documents needed in the overhauling process
- how to carry out currency/issue checks on the specifications you are working with
- the quality control procedures to be followed during the overhauling operations
- the procedure for obtaining replacement parts, materials and other consumables necessary for the overhaul
- company policy on the repair/replacement of components during the overhauling process
- terminology used in power turbine assemblies
- the basic principles of how the turbine assembly functions, its operating sequence, the working purpose of individual units/components and how they interact
- the extent to which the equipment is to be dismantled for overhaul
- the sequence to be adopted for the dismantling/reassembling of the turbine assembly
- the techniques used to dismantle the turbine assembly, without damage to the components or surrounding structure and the need to protect the system integrity by ensuring that exposed components are correctly covered/protected
- how to lift and move large components and assemblies; the methods and equipment used to transport, handle and lift the components during the overhauling activities
- the need to ensure that lifting and handling equipment is within its current certification dates
- methods of checking that components are fit for purpose, how to identify defects and wear characteristics, and the need to replace `lifed' and consumable items
- the uses of measuring equipment
- methods of reassembling the turbine assembly, using new or previously overhauled components
- how to make adjustments to replaced components/assemblies to ensure that they function correctly
- the various mechanical fasteners that are used, and their method of removal and replacement
- the various types of electrical connectors that are used, methods of unlocking, orientation indicators, and locating and locking in of the connections
- the tools and equipment used in the overhauling activities, and how to check that they are in a safe/usable condition
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- the importance of ensuring that all tools, equipment and components are accounted for and returned to their correct location on completion of the overhauling activities
- the procedure for the safe disposal of waste materials
- the need to complete overhaul documentation and/or reports following the overhauling activity
- the problems that can occur during the overhauling activity, and how they can be overcome
- the extent of your own authority and to whom you should report if you have a problem that you cannot resolve
Scope/range
Scope Performance
- Carry out all of the following during the overhaul of the turbine assembly:
- obtain and use the appropriate documentation for the overhaul activities
- adhere to procedures or systems in place for risk assessment, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain safe access and working arrangements for the work area
- ensure that the turbine assembly is suitably supported, and that appropriate lifting and handling equipment is available
- carry out the overhauling activities, following good practice/approved procedures
- ensure that components and surrounding structures are maintained free from damage and foreign objects
- return all tools and equipment to the correct location on completion of the activities
- leave the work area in a clean and safe condition on completion of the activities
- Dismantle the turbine assembly, to include removing all of the following:
- low pressure turbine
- turbine blades
- wire thread inserts
- intermediate pressure turbine
- bearing races
- locking devices
- high pressure turbine
- bearings
- pipes and unions
- turbine shafts
- seals and gaskets
- turbine discs
- shims and packing
- Carry out all of the following activities on the equipment being overhauled:
- cleaning parts prior to dismantling
- pre-disassembly checks and tests
- releasing stored energy (where applicable)
- proof-marking/labelling of components to aid reassembly
- draining/removing any remaining fluids
- applying protection to openings to prevent entry of contaminating debris
- dismantling equipment to unit/sub-assembly level
- dismantling units to component level
- checking components for wear and serviceability (such as visual, measurement, NDT, use of probes/scopes)
- replacing all damaged or defective sub-assemblies and components
- replacing all `lifed' and consumable items (such as seals, bearings, gaskets)
- removing and replacing components having interference fits (such as by expansion, contraction, pressure)
- balancing components (where applicable)
- reassembling the turbine unit
- setting and adjusting replaced components
- `blue bedding' components (where applicable)
- drilling, reaming and riveting (where applicable)
- making mechanical connections
- electrical bonding of components
- applying correct lubrication during assembly
- applying gaskets and sealant/adhesives
- tightening fastenings to the required torque
- securing components using mechanical fasteners and threaded devices (such as nuts, bolts, circlips, pins)
- applying locking and retaining devices (such as circlips, pins, wire locking, lock nuts, stiff nuts, swage nuts)
- Replace/refit a range of turbine assembly components, to include ten of the following:
- low pressure turbine
- dynamic seals
- intermediate pressure turbine
- shims and packing
- high pressure turbine
- locking devices
- turbine shafts
- wire thread inserts
- turbine discs
- pipes and unions
- turbine blades
- mechanical controls (such as plungers, springs, rollers)
- bearing races
- electrical controls (such as solenoids, motors, switches)
- bearings locks and stops
- static seals/gaskets
- other specific components
- Carry out checks and tests on the overhauled equipment, to include all of the following:
- visual inspection for completeness of all operations
- visual inspection for freedom from damage or foreign objects
- applying protection to openings to prevent entry of contaminating debris
- carrying out any `special-to-type' test rig checks
- Overhaul turbine assemblies in compliance with one of the following:
- BS, ISO or BSEN standards and procedures
- customer standards and requirements
- company standards and procedures
- turbine manufacturer's requirements