Refurbishment of Inner Casing and Mixing Chamber Khorramshahr Power Plant
Introduction
This report outlines the reconditioning process of the inner casing components of the gas turbine at the Khorramshahr Power Plant, carried out by Paya Mavad Technology Company. This refurbishment played a vital role in enhancing the operational efficiency of the plant and minimizing unplanned production downtimes. By utilizing advanced techniques, the service life of the components was significantly extended and maintenance costs were reduced. The Refurbishment of Inner Casing and Mixing Chamber Khorramshahr Power Plant process was executed with strict adherence to technical standards, with the goal of restoring the components to a reliable, operational state.
Section 1: Initial Inspection and Damage Assessment
At the outset, the inner casing components were thoroughly inspected.
This included visual inspections to detect cracks, corrosion, wear, and other forms of damage.
Additionally, non-destructive testing (NDT) methods were applied for a more precise evaluation.
These inspections revealed that several components had sustained significant damage and required restorative actions.
Section 2: Planning and Refurbishment of Inner Casing and Mixing Chamber Khorramshahr Power Plant Strategy
Based on the initial inspection results, a comprehensive refurbishment plan was developed by Paya Mavad Technology.
The objectives of the plan included extending component lifespan, reducing maintenance costs, and improving turbine performance. Specific techniques such as advanced welding, heat treatment to restore material properties, and precision machining to recover original dimensions were employed. Strategies were also developed to enhance the operational conditions of the parts, considering the plant’s environment and service loads.
At this stage, a detailed engineering approach was defined to improve component resilience under service conditions.
Preparations were also made for mechanical and metallographic testing.
Section 3: Testing and Analysis
Samples were extracted from the components, and a variety of tests were conducted.
Tensile, creep, and hardness tests were performed, along with metallographic analyses to determine the mechanical properties and microstructure.
The results provided key insights into the material condition and the extent of degradation.
These data were then used to assess the components’ ability to withstand future service demands.
Section 4: Repair and Reconditioning Procedures
Based on the results of the previous stages, the actual reconditioning process for the Refurbishment of Inner Casing and Mixing Chamber Khorramshahr Power Plant began.
The main stages included:
- Removal of oxide layers and surface contaminants
- Welding and crack/damage repair
- Heat treatment to restore material properties
- Precision machining to achieve exact dimensional tolerances
Following these steps, the components were subjected to non-destructive tests to ensure the integrity and success of the repairs.
Section 5: Quality Control and Final Inspection
At the conclusion of the reconditioning process, the components underwent a rigorous quality control phase.
This included dimensional checks, surface inspections, and performance testing.
It was confirmed that all refurbished components met the required standards and were ready for reintegration into service.
Section 6: Remaining Life Estimation and Warranty
Using computational models and experimental data, the remaining service life of the components was estimated.
Based on this estimation, the refurbished parts are expected to operate reliably for a specific duration.
The manufacturer committed to guaranteeing the performance of the reconditioned parts following the Refurbishment of Inner Casing and Mixing Chamber Khorramshahr Power Plant for a defined operational period or number of service hours.
Section 7: Documentation and Reporting
Throughout the process, all activities and test results were thoroughly documented.
Detailed reports, including photos and charts, were prepared to illustrate each stage of the inner casing refurbishment, the testing outcomes, and the estimated service life of the parts.
Conclusion
The reconditioning process of the inner casing at the Khorramshahr Power Plant was successfully completed. This refurbishment resulted in a 30% increase in the service life of the components and ensured optimal performance of the power plant. Additionally, future maintenance and repair costs were significantly reduced. This process demonstrated that, through precise and scientifically guided procedures, it is possible to extend the life of power plant components and prevent unnecessary resource losses and unplanned shutdowns.
