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ASMEGasTurbineTechnical Chapter

GasTurbineRotorInspection/OverhaulandRepair
EthosEnergyTurboCare Facility,November2014

Safety Moment

Can you spot the safety violation?

Low Speed Balance Columbia.avi

What is EthosEnergy ?
Wood Group

Gas Turbine Services


Heavy Industrial, Light, Aero

Steam Turbine Services

EPC and Fast Track Projects

Construction Site Services

Facility O&M

Auxiliary and Pump Overhaul

Wood Group P&W JV

Siemens

Gas Turbine OEM (Fiat / Westinghouse)

Gas Turbine Services Heavy Industrial

Steam Turbine Services

Generator Services

Compressor Services

Transformer Services
+OEMIntellectualPropertySupport

Where is EthosEnergy ?

+
+
+
+

> $1B in revenues


Over 5,000 Customers
4,500 employees in 100+ countries
ISO-9001, 14001, 18000

As the leading independent service provider Our depth and multi-OEM experience provide added insights
and customized solutions - on a global scale.

Engineered to Deliver Value


CustomerGoalsAcrossAssetLifeCycle

Project,Commercial&TechnicalManagement
AlignmentofNeeds,Capabilities,andSolutions
(>100ProjectMgrsGlobally)
CoreCapability

CoreFunctionalStrengths

(InternalandExternal)

Inventory&
Inventory
Management
+$150Million

Engineering
+200

MultipleOEMExperience
DirectCustomerAccess
7x24M&DCenters
FullAssetLifeCycleView

SupplyChain
>100Qualified
Vendors

Component
Repair

EthosAdvRepairFacilities
AlliancePartners
ShortCycleSolutions

FieldServices
+2.0M
ManHours/Year

Parts

EthosDesignedParts
AlliancePartners
UsedServiceableParts

Upgrades&
LifeExtensions

GasTurbines
HIT/LIT/Aero
SteamTurbines
Generators
Compressors

EthosOverhaulFacilities
MultiOEMUpgrades
AlliancePartners

Full Maintenance Capability


Gas, Steam, Generator, Compressor

+ One-Stop Shop Single Point Accountability


+ Proven Parts, Field Services, Shop Overhaul Track Record
+ OEM Design, Quality, Project Mgt, Supply Chain Mgt
+ Flexible Commercial Structures
Gas Turbines
+
+
+
+
+
+
+
+
+

Shop repair & overhaul


Parts / components
Component repair
Rotor repair / overhaul
Field services
Reverse engineering
Exchange programs
Refurbished equipment
Op Speed balancing

Generators
+
+
+
+
+
+
+

Rotor winding
Stator coils manufacturing
Modernization / re-design
Refurbishment / replacement
Repairs
Op Speed balancing
Testing / inspection

Steam & Compressors


+
+
+
+
+
+
+

Unit assessment & rerates


Rapid reverse engineering
Replacement parts
SMART seals
Geothermal
Rotor welding
Op Speed balancing
5

Gas Turbine: Multiple Platform

EthosEnergy is the OEM


GE

FIAT
+ TG7
+ TG16
+ TG20

+ TG50
+ TG 701

WESTINGHOUSE
+
+
+
+
+
+
+

W 72
W 81
W 82
W 101
W 111
W 121
W 151

OEM Equivalency

+
+
+
+
+
+
+

W 171
W 191
W 191G/M
W 251A,AA
W 251B, B18
W 251B27
W 301

PRATT & WHITNEY


+ GG4 / FT4 **
** - WGPW Joint Venture

+
+
+
+
+
+
+

W 501 AA
W 501 B2-5A
W 501B6
W 501C
W 501D1
W 501D24
W 501D4

+
+
+
+
+
+
+

MHI
+
+
+
+
+
+

RR
+
+

Frame 3 / 5
Frame 6B
Frame 7B-EA
Frame 7FA
Frame 9E
Frame 9FA
LM Series *
MW101
MW171
MW191
MW251
MW701
M701F
RB211 **
AVON **

SIEMENS
+
+
+
+
+

TA 1750
TB 5000
SGT-200 (Tornado)
SGT-100 (Typhoon)
SGT 600 (GT 10B)

+
+
+
+
+

Saturn 10
Centaur 40 / 50
Taurus 60
Mars 90 / 100
SoLoNox

SOLAR

ABB / ALSTOM
+
+

GT11D5
GT13E2

* - Overhauls Through WG TCT JV


** - Overhauls Through RWG JV

Gas Turbine Parts


EthosEnergy combines an OEM level design team,
state of the art materials and design modeling tools,
and supply chain process oversight to deliver the
highest value, lowest risk aftermarket parts in the
industry.

+ OEM provider for Westinghouse and Fiat gas turbines


+ Over 25 Years of Gas Turbine Component Design
+ Capabilities on GE, Siemens, MHI, ABB, Solar Turbines.
+ Over 1,000 Sets of B/E HGP Parts
+ Over 37M Operating Hours on installed parts
+ OEM Level Processes / ISO Qualified
+ Re-Engineered vs Reverse Engineered designs
7

Gas Turbine Component Repair

+ Over 5,000 Sets of Repaired HGP Components in Operation


+ Over 64M Operating Hours on Repaired Components
+ Over 4,000 Fuel Nozzles Repaired

+ To restore your critical turbine components, we offer a broad portfolio of


cost effective component repair services that extend component life.
+ Our customers benefit from leveraging technical expertise, a robust quality
program & our overall Service Excellence philosophy.
+ We mitigate operational risks with a dedicated Project Manager, offer
extended warranties & drive down your cost of ownership with the
objective of improving life cycle value.
8

Gas Turbine Rotors

+ Gas Turbine Rotor Overhauls, Life Evaluation & Extension


+ Compressor & Turbine Disc Manufacturing Capability
+ Rotor & Disc Balancing Capabilities

Complete capability (thru F Class)

Rotor modernizations & upgrades

Rotor mechanical & NDT inspection

Compressor blade & wheel coatings

Advanced balancing capability

Quality programs - ISO-9001, 14001, 18001 certified

OEM level process controls

Full rotor capability in Houston, Texas & Turin, Italy

Rotor storage & environmentally controlled containers

icon Control System Upgrades

Icon control system upgrades provide a


low-risk, long-term open-architecture
solution that eliminates restrictive
operational/support barriers of OEM
purpose built systems
+

OEM turbine controls replacement for GE, Siemens, Solar, Alstom,


Rolls Royce, ABB with expansion capability into BOP level control
solutions

Our experienced icon control upgrade solutions provide increased


flexibility, availability, & risk reduction to owners & operators of gas
and steam turbines

We maximize our customers success by providing a customized


solution based upon our standard design, using non-proprietary &
proven open-architecture solution that allows for the ability to be
self-sufficient.

Longer useful life due to larger, multi-industry installed base of


standard technology versus limited OEM base. applications

10

ECOMAX - Combustion Tuner

+ ~1.5 2.0% Increase in Combined Cycle Power Block


+ Maintains Firing Temperatures within OEM Limits
+ Up to 0.25% Decrease in Gas Turbine Heat Rate

+ Combustion optimization solutions are advantageous to


actively manage the complex dynamics of thermal
performance, emissions, & fuel efficiency.
+ Our cost-effective automated tuning technology
optimizes performance, maintains emissions compliance,
& minimizes potential parts damage.
+ This improved management of your gas turbine
operation can add significant value aligned to customerspecific operations strategies.
11

Field Services

+ Over 5,000 Outages Performed in Last 5 Years


+ Over 3,000 GE Frame Outages
+ Over 250 GE F-Class Outages
+ Over 700 Steam Turbine Outages

With a focus on the overall outage schedule, performance &


cost management to complete a maintenance event, we apply a
core value of safety, our extensive years of experience & a full
tooling & equipment package

A proven team is led by a dedicated project manager who


operates as a single point of contact between the maintenance
crew & plant personnel

Solutions tailored to meet local/regional requirements.


12

Houston Operations
Description:
+

140,000 Sq. Ft Facility

Production area consists of six (6) bays.

One (1) 60 ft. high bay, has a 100 Ton bridge


crane.

Truck thruway for easy loading and offloading


inside the high bay.

The remaining bays each have bridge cranes


ranging from 10 to 50 Ton.

Vertical hanging or horizontal storage.

Operation Speed Bunker

Blast Booth.

Product Lines:
+

Steam Turbines (Units and Internal Components).

Steam Turbine Rotor manufacturing.

Compressors (Units and Internals Components)

Gas Turbine Rotors (OOEM and OEM)

Gas Turbine Compressor Diaphragms (W101, W191, W251,


W501F)

13

Balance Machines
Operating Speed Balance (OSB) facility capable of high speed
balancing and overspeed testing of rotors in a vacuum.
+

Maximum rotor weight: 50,000 lbs.

Maximum rotor swing diameter: 99 in.

Maximum rotor overall length: 316 in.

Maximum rotor journal diameter: 17 in.

Maximum rotor balancing/overspeed: 34,000 rpm

Horizontal Balance Machines:


+

Maximum rotor weight: 100,000 lbs.

Maximum rotor swing diameter: 125 in.

Maximum rotor length: 310 in.

Maximum rotor journal diameter: 22 in.

Vertical Balance Machines:


+

Maximum component weight: 6500 lbs.

Maximum component swing diameter: 81 in.

Impeller Overspeed Test Machine:

Maximum component weight: 500 lbs.

Maximum component swing diameter: 36 in.

Maximum component height: 24 in.

Maximum component overspeed: 30,000 rpm

14

GT Units Assembly & Disassembly

15

Gas Turbines Rotors Overhauls

FR5

FR6
FR7E

W101

W191

16

W251

W501D5A

W501F

Compressor Rotor Repair


RECEIVING ROTOR
+

Standard rigging practices should be followed. Confirmation


of load ratings and safety inspections should be performed
prior to any lifts being performed.

Use of a spreader beam is highly recommended.

The lift points should be the seal areas of the stub shafts
unless lifting plates attached to the couplings are available

INCOMING INSPECTIONS
+

Placing the rotor in the lathe for rotating facilitates the inspection
process.

The general condition of the rotor is photo documented including all


serial numbers, part numbers, blade damage, balance weight
locations etc.

Rotor run out data is collected including three(3) body run outs to
determine journal /body/journal centerline axis relationship. (rotor
bow)
17

Compressor Rotor Repair


INCOMING BALANCE
+

The rotor is placed in the balance machine to determine the incoming balance condition. The
previous overhaul balance weight corrections are removed during this process.

This information should align with the previously recorded run out condition.

The incoming inspections are evaluated to determine the need to dis-assemble the unit for
repairs.

18

Compressor Rotor Repair


BLADE WEDGE MIGRATION
+

Blade wedge migration is a common issue encountered. The wedge used to hold the
compressor blade in its axial position overcomes the staking during start up and shut down,
abnormal operating events inducing vibration, and events causing blade tip contact.

A wedge migration map is completed during this process. This map is generally evaluated in
two ways, total rotor and rotor quadrants.

As a guideline, if more than 50% of the wedges of the total rotor are migrated, dis-assembly is
required

As a guideline, if more than 40% of the wedges in any quadrant are migrated, dis-assembly is
required.

19

Compressor Rotor Repair

Major Compressor FOD

20

Compressor Rotor Repair

STUB SHAFT DIMENSIONAL


+

The forward stub shaft dimensional


information and general condition is
documented carefully. This information is
compared to the field dimensions of the
bearing and seal clearances.

Any deviations from standard should be


determined in the beginning of the repair
process to ensure time to correct the seals
or bearings as required

21

Compressor Rotor Repair


THROUGH BOLT POSITION
+

This finding reflects a lack of quality inspection during the last


assembly of the unit.

There is a strict tolerance for the end of this bolt to be fully


engaged into the pie nut as this is the anchor position for the
bolt tensioning.

BALANCE WEIGHT LOCATION


+

All of the balance weights are mapped for location and type.
The stamp designations on the weights describe the step of the
balance process when the weight was installed.
Example: T = Turbine
C = Compressor
P = Piece

22

Compressor Rotor Repair


Work Scope Creation
+

Based upon the findings of the


inspections, a work scope
document is created. This scope
will include the standard
instruction for dis-assembly,
repair and reassembly and also
contain any special instructions
to address any of the items
special to this unit.
Example: Perform TIL-1342 Row
17 compressor blade change

1.

FRAME 7 ROTOR COMPRESSOR ROTOR UNSTACK AND


REASSEMBLE

2.

RECEIVE AND INSPECT FOR ANY SHIPPING DAMAGE. TAKE


PHOTO OF SHIPPING CONTAINER AND STORE

3.

CONTAINER FOR RETURNING THE ROTOR TO THE


CUSTOMER.

4.

PERFORM AN AS RECEIVED INSPECTION. USE METHOD


#2004.

5.

UT THE BOLTS FROM THE AFT END AND REPORT. ISSUE A


REPORT ON WGPM0007

6.

SET UP THE ROTOR IN THE BALANCE MACHINE AND


PERFORM AN INCOMING BALANCE CHECK/RUNOUTS.

7.

(NO PEENING REQUIRED). USE METHOD #2005.

8.

REMOVE THE INDUCTOR ALTERNATOR SHAFT FROM THE


COMPRESSOR ROTOR. VISUALLY INSPECT THE

9.

HELICOILS AND REPORT ANY DAMAGE TO ENGR.

10. REMOVE FROM THE BALANCE MACHINE.


11. STAND UP THE ROTOR IN THE STACKING PIT (AFT END UP)

AND IDENTIFY EACH WHEEL IN RELATION TO THE

12. # 1 BOLT HOLE. STAMP THE STAGE NUMBER ON THE

RESPECTIVE STAGE.

23

Compressor Rotor Repair


STAND ROTOR VERTICAL
+

The process of taking the rotor from horizontal to vertical for destack requires the use of specialized, purpose built tooling and
fixtures.

These fixtures require periodic inspections to ensure mechanical


integrity.

Highly skilled and experienced crane operator is a necessity.


HYDRAULIC BOLT DE-STRETCH
+

Hydraulic tensioning devices are


used for the manipulation of the
compressor through bolts.

It is critical to physically monitor


the amount of tension or
stretch applied to the bolt.

During disassembly of the unit,


measurement of the amount of
stretch on the bolts is critical
information to determine if the
unit has been biased stretched.

24

Compressor Rotor Repair


THRU BOLT NUT REMOVAL
+

It is not uncommon to have the threads on the bolts or nut


seize during the de-tensioning process.

There are many reasons this occurs including damaged threads


above the nut, dirt and grit in the threads, threads pulling
because of overstretch or improper installation of the
tensioning equipment
NUT REMOVAL
+

The process for nut removal after seizing


is to split the nut in half. This is
accomplished by using and end mill and
plunging down each side of the nut, 180
degrees apart.

The nuts are removed from the


countersunk hole and the OD of the bolt
is ground smooth to allow for the
passing of the individual wheels
25

Compressor Rotor Repair


ROTOR DE-STACK
+

Once the nuts have been removed, dry ice is applied to the aft
stub. This freezing allows for shrinkage of the male rabbet fit
allowing it to release form the 16th stage female rabbet fit.

Care should be taken to not damage the threads on the bolts


during the removal process.

BOLT WHEEL CORROSION


+

Many units operate in less than ideal conditions.


Environmental factors coupled with operating characteristics
often creates erosion and corrosion issues on these parts.

The design clearances are often small and can become


contaminated causing extreme difficulty during the disassembly process.

26

Compressor Rotor Repair


SEIZED THROUGH BOLTS
+

It is not uncommon to encounter through


bolts that are seized to the bolt holes of the
compressor wheels.

Whenever possible the bolts are cut and set


aside while remaining locked in the wheel.

This expedites the de-stack and allows for


the wheel to be set up properly in a drill
press for accurate drilling of the bolt material

THROUGH BOLT DRILLING


+

The process of bolt drilling can be


accomplished using magnetic base drills
while in the de-stack process.

Care must be taken to step up the drill


diameter gradually to ensure there is no
contact with the wheel.

It is often necessary to drill enough to leave


a thin wall of material and then use a burring
tool to grind away that wall
27

Compressor Rotor Repair


BOLT HOLE SLEEVES
+

The wheel through bolt holes


are sometimes sleeved due to
incorrect location from the
factory or severe galling during
the removal process.

RABBET FIT GALLING


+

This galling of fits must be


repaired to perform the critical
run out data.

Typically fits that have more


than 50% of the surface area
affected will receive a patch
ring.

28

Compressor Rotor Repair


WHEEL RUN OUT TABLE
+

All compressor wheels are placed on this table


and run out data is gathered.

The rabbet fits are measured for concentricity


and the relationship to the OD of the wheel.

The bolt circle faces are measured for flatness


and parallelism

WHEEL RUN OUT DATA


+

The face, bore and OD of the wheel are


measured to establish BH 1 and all data is
referenced to that location.

This provides the data required to determine


the orientation of the wheels during the restack process

29

Compressor Rotor Repair


DEFLECTOR CONE
+

The fit area of this cone and


retaining plate can see extreme
wear. If this becomes loose
during operation, severe
imbalance forces can be
imparted into the unit.

THROUGH BOLT INSPECTIONS


+

All bolts are measured for


straightness.

NDT is performed including MPI


and Ultrasonic.

The threads should be carefully


inspected especially on the aft
end of the bolts where the
stretching devices are attached.
30

Compressor Rotor Repair


COUPLING HELICOILS
+

These helicoils should be replaced during every


major rebuild of the rotor.

BLADE F.O.D. / D.O.D.


+

Impact damage below the pitch line of the


blade should not be repaired.

Dents and dings should be left alone while any


damage that includes tears or cuts into the
material should prompt blade replacement

31

Compressor Rotor Repair


BLADE BLENDING
+

Examples of compressor blade tip


blending

FWD AND AFT STUB BALANCE


+

When these pieces are balance


individually, the weights placed into
the grooves are labeled and stamped
P for part or piece weight.

The weights cannot be staked until


the assembled rotor is balanced as
these weights may need weights to
slide past their location
32

Compressor Rotor Repair


COMPRESSOR RESTACK
+

Each compressor wheel is individually


protected during the stacking
process. The number 1

bolt hole location is clearly identified


to ensure correct orientation.

AFT STUB ASSEMBLY


+

The aft stub shaft must be frozen


using dry ice to facilitate reassembly
to the stage 16 wheel

Once the wheel fits are engaged, four


bolts are snug tightened by hand
until all temperatures normalize

The stack orientation is verified and


wheel rim gaps are measured and
approved prior to bolt stretch
33

Compressor Rotor Repair


BOLT STRETCH
+

The bolts are positioned to be flush in the pie


nut. A at rest drop is measured from bolt end
to the face of the stub.

The bolt stretch procedure is implemented and


following a three step process, an overstretch is
performed.

The final bolt stretch is established and verified


with a tensioned drop measurement taken at
the same location as the original at rest

BALANCE VERIFICATION
+

The rotor is placed into the balance machine and


the total vectored correction is determined. The
maximum allowable is 9500 inch grams total or
4750 inch gram per plane.

Three rotor body run out measurements are


taken and compared to the balance weight

requirements.

If acceptable, final balance is performed and the


rotor is ready for machining
34

Compressor Rotor Repair


FINAL MACHINE PROCESSES
+

A complete set of rotor run out data is


gathered. Any probe area machining is
accomplished. Thrust collar polishing is
performed.

The coupling rabbet fit and face is measured


and machined if necessary.

The rotor is turned end for end in the lathe


and the same processes are performed on
the opposite end

The set up process for the rotor requires pins


in the coupling chuck to allow the rotor to
pivot when the steady rest is positioned.

This is a loose grip set up and requires a


safety stop to be in place to prevent the
rotor from walking out of the chuck when
rotated.

This is the pipe and ball seen on the right


side of the picture.

Note the probe area is clearly marked and


protected

35

Compressor Rotor Repair


FINAL PACKING
+

Uncoated rotors are completely coated with preservative. A light oil such as WD-40 is used for short
term and a more viscous product such as LPS-3 is used for intermediate (less than 1 year). Long term
storage should be performed using controlled atmosphere. The rotor is completely wrapped in heavy
corrugated cardboard and wrapped in plastic stretch wrap. The journal is wrapped separately.

36

Turbine Rotor Repair


RECEIVING THE ROTOR
+

Standard rigging practices should be


followed. Confirmation of load
ratings and safety inspections
should be performed prior to any
lifts being performed.

Use of a spreader beam is highly


recommended.

The lift points should be the seal


areas of the stub shafts unless lifting
plates attached to the couplings are
available

INCOMING INSPECTION
+

The rotor is set up in a lathe or


precision roller stand to measure
and record the run out.

The buckets are measured and


visually inspected.

The coupling rabbet fits are


measured and recorded

37

Turbine Rotor Repair


JOURNAL INSPECTION
+

The journals and seal areas are inspected for size


and roundness

The probe areas are located and protected.

The coupling bolt holes are inspected.

COUPLING BOLT HOLE FACE


+

This face will require


machining to prevent
additional damage during
the bolt stretch process.

Another common repair is


damage to the actual bolt
hole.

38

Turbine Rotor Repair


INCOMING BALANCE
+

The incoming balance is measured and


recorded

The buckets can be intermittently removed


and measured if desired.

The buckets can also be removed all rows


and weights to determine the bare rotor
condition.

The bare rotor balance condition along with


the run out data are key to determining the
need to de-stack the rotor.

BALANCE WEIGHTS
+

The staking and securing of the turbine balance


weights is complicated by the interrupted weight
groove

The weight locations are recorded and used to


evaluate incoming balance condition

39

Turbine Rotor Repair


BUCKET LOCKING PIN
+

The first stage buckets are secured with D-keys


and a radial and axial locking pin

Over time the area around the pin becomes


damaged by the staking process. This requires
the turbine wheel be modified to install the pins
180 degrees from the original position

SEAL COATING
+

The stage one and stage two buckets receive


coating on the fir tree areas to provide a seal
boundary for the cooling air.

This boundary forces the cooling air up through


the airfoil cooling holes preventing damage to
the buckets from excessive heat.

40

Turbine Rotor Repair


FIR TREE COATING
+

The buckets can also be applied with coating to


replace the eroded parts of the wheel and/or
bucket.

This is one of the earliest recommendations to


resolve excessive bucket rock more commonly
found in peaking service units.

DISCOURAGER SEAL
+

The Model EA units are equipped with an axially


inserted discourager seal. This seal is located on
the aft face of the 1-2 spacer.

This works along with the fir tree coating to


provide a sealing boundary for the bucket
cooling air.

Clearance/ Crush checks must be performed on


this seal with each bucket change

41

Turbine Rotor Repair


TURBINE DE-STACK
+

The turbine rotor is turned vertically and placed


into a stack pit or mounted to an dis-assembly
plate.

Heat is used on the nuts and all are removed


mechanically, (no bolt stretch)

Dry ice is used to freeze the stub shaft allowing


separation from the turbine wheel.

FWD. STUB REMOVAL


+

Care must be taken to not damage the sealing air


bore tube.

The tube must be removed and independently


inspected. Erosion of the inner wall is a common
problem.

42

Turbine Rotor Repair


DE-STACK PROCESS
+

The turbine wheels have female rabbets on


both sides. Heating up to 350 degrees F is
permitted for removal and installation

The wheel spacers and stub shafts have male


rabbets and require dry ice for removal and
installation.

Stack temperature normalization is required


before proceeding to the next piece in the
process.

COMPONENT INSPECTIONS
+

All of the individual rotor components are blast


cleaned using 220 grit AlOx. Extreme care must
be taken to not dwell on the fir tree areas.

All components are then MPI inspected. Areas


of concern are the fir trees and the turbine
wheel rabbet fit areas.

43

Turbine Rotor Repair


COMPONENT RUN OUT
+

All wheels and spacers are set up individually


and the run outs are collected.

Once the true centerline is established, a


witness skim cut is made to be used after
assembly

COMPONENT FIT REPAIR


+

Skim cutting of the female radius is often


required due to small stress cracks.

HVOF coating application is required to


repair the female fit diameters

44

Turbine Rotor Repair


WHEEL GEOMETRY RESTORATION
+

The geometry of the fir trees is


measured and recorded. This is done
first with a simple shank gap check
using replacement buckets

If not acceptable, additional data is


taken using the pin checks described
in TIL 1049.

Fir tree restoration is accomplished


using Nickel based coating. This is
often top coated with an anticorrosion coating such as 2-F1

STUB SHAFTS
+

Both turbine rotor stub shafts are set


up and checked for concentricity.

45

Turbine Rotor Repair


Re-assembly
+

The aft stub shaft is placed in the stacking


area. The bolts are placed into the stub and
held up in place with temporary supports.

Using alternating heat and dry ice, the


turbine rotor is re-assembled. After each
component is added to the stack, the
temperature is allowed to normalize and the
bolts are checked to insure they can be
turned.

46

Turbine Rotor Repair


Re-assembly
+

The photo is an assembled rotor prior


to re-stretch of the bolts. This is
actually a 7B rotor. The large gap
shown between the 1-2 spacer and
the second stage wheel is far less
wide on the EA unit. The edge of that
spacer holds the discourager seal for
the second stage buckets.

47

Turbine Rotor Repair


RUN OUT VERIFICATION
+

Following the turbine bolt stretch, the


rotor is turned horizontal and placed in
the lathe. A complete set of run out
data is measured and recorded.

DISCOURAGER SEAL MACHINING


+

This is the discourager seal located in


the aft face of the 1-2 spacer. The
second stage bucket to be installed
into the unit is used as a measuring
template. The seal is formed and
machined axially to allow for a small
amount of crush against the face of the
bucket, thus ensuring a good seal area.

48

Turbine Rotor Repair


COUPLING MACHINING
+

The rotor coupling rabbet fits and face


perpendicularity are measured and
recorded.

Patch rings are utilized for rabbet fit


corrections

Tool post grinding is used to reclaim the


tolerances of the coupling faces.

ROTOR BALANCE
+

The turbine rotor is placed into the


balance machine and the bare rotor
balance is measured and recorded.

The total vectored allowable unbalance is


7500 inch-grams. Either correction plane
cannot exceed 3750 inch-grams.

The second stage buckets are normally


installed first to facilitate twist lock staking
49

Turbine Rotor Repair


FINAL ROTOR BALANCE
+

The buckets are installed one stage at a


time. The rotor balance is trimmed back to
acceptable level following each stage. The
final balance is achieved using a weight
consolidation process for each plane. If a
row of buckets exceeds allowable limits, it
is removed and re-moment weighed.

FINAL PACKING
+

Each stage of buckets is wrapped with


Styrofoam packing. The complete rotor
body is then covered with heavy
corrugated cardboard.

This is then seal wrapped completely with


plastic stretch wrap.

Preservation is the same process as the


compressor rotor.

50

MS 7001 Rotor Repair Module


TIL 1576 OVERVIEW
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The intent of this presentation is to provide an understanding of the requirements to


accomplish a typical rotor major overhaul including Life Extension Inspections

This level of disassembly is required to accomplish the Life Extension Inspections.

All of the inspections described herein are basic to and in conjunction with the Life Extension
inspections.

ORIGINAL TIL ISSUED IN 2007


+

For hour based operation, GE defines end of life as 200,000 factored hours, although a one
time hours-based life extension of 50,000 factored hours for/E/EA class units may be permitted
under certain circumstances.

For starts based operation, end of life is defined as 5,000 factored starts with no extensions
permitted by the OEM.

It is important to note the GE has classified this at the highest level: SAFETY Failure to comply
with this TIL, could result in personal injury. Compliance is mandated within a specific
operating time.

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MS 7001 Rotor Repair Module


BACKGROUND (2007)
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A gas turbines risk of failure increases the longer it is in service as a result of normal wear and
tear of components in the system. It is believed the exceeding of the service life of the rotor
system can lead to wheel failure severe enough to cause extensive damage to the gas turbine
as well as the potential for substantial damage to adjacent equipment and serious injury to
nearby personnel.

GER 3620 (Heavy Duty Gas Turbine Operating and Maintenance Considerations) requires that a
rotor inspection be performed at specific intervals recommended by GE. These intervals are set
forth in GER 3620 or through Technical Information Letters. Where specific intervals have not
been defined, rotor inspection should be performed at 5,000 factored starts or 200,000
factored hours.

The inspections as defined in 3620 require a complete disassembly of the compressor and
turbine rotors. Some components may require replacement, and the extent of refurbishments
performed may redefine intervals of subsequent inspections. Failure to perform these
inspections leaves the gas turbine at greater risk for failure.

Numerous techniques are required to perform full inspections on a gas turbine rotor for both
surface connected and sub-surface defects. Along with magnetic particle, eddy current and
ultrasonic techniques, detailed mechanical inspections must be performed.

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MS 7001 Rotor Repair Module


RECOMMENDATIONS (2007)
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GE has defined inspection programs for rotors reaching the tear down inspection intervals.
Numerous techniques are required to fully inspect a gas turbine rotor for both surface
connected and subsurface defects. These inspections. which include magnetic particle. eddy
current and ultrasonic techniques. should be performed in a GE service center where the GE
inspection team uses proprietary algorithms to identify potential sub-surface defects that may
have grown during operation. The inspection results can be combined with design analysis and
specific turbine operating histories to provide recommendations for rotor refurbishment,
replacement and continued service.

Depending upon the condition of the rotor at the inspection. one hours based life extension
may be possible for up to 100,000 hours for frame 3 and 5 units and up to 50,000 hours for Eclass units that have not passed their starts based interval limits as defined in GER 3620, after
which the rotor must be retired. Extensions are under evaluation for FA class units. Currently.
There are no life extensions available for units that reach their starts based interval limit.

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MS 7001 Rotor Repair Module


RECOMMENDATION MODIFICATION
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In 2011 GE issued revision 1 to the TIL. There were only three changes from the original, two of
those minor in nature and the third quite significant.

The units affected was changed from FA class to F class

The inspection process of penetrant was added to the list of types of NDT

The limiting language of 2007 was modified to not specifically eliminate starts based
extensions and the implied easing of the hours based limitation

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MS 7001 Rotor Repair Module


RECOMMENDATION (2011)
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Depending upon the condition of the rotor, specific unit configuration, operating history, and
prior maintenance history at the inspection interval, a rotor life extension may be viable.

OTHER ISSUES
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TIL-1049-3R1. TURBINE WHEEL DOVETAIL MATERIAL LOSS

TIL-1854 COMPRESSOR ROW 2 AND 3 BLADE TIP LOSS

TIL-1342 ROW 17 COMPRESSOR BLADES

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