SEC 2014 Rotor Training Module PDF

MS7001 B - EA COMPRESSOR ROTOR REPAIR MODULE
COMPRESSOR ROTOR REPAIR

Power Plant Services
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
1
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)
2
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.
3
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.
4
BLADE WEDGE MIGRATION

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.
5
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
6
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.
7
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
8
FRAME7ROTORCOMPRESSORROTORUNSTACKANDREASSEMBLE
WORK SCOPE CREATION RECEIVEANDINSPECTFORANYSHIPPINGDAMAGE.TAKEPHOTOOFSHIPPINGCONTAINERANDSTORE

CONTAINERFORRETURNINGTHEROTORTOTHECUSTOMER.
Based upon the findings of the

inspections, a work scope PERFORMANASRECEIVEDINSPECTION.USEMETHOD#2004.
document is created. This scope

UTTHEBOLTSFROMTHEAFTENDANDREPORT.ISSUEAREPORTONWGPM0007
will include the standard instruction
for dis-assembly, repair and re- SETUPTHEROTORINTHEBALANCEMACHINEANDPERFORMANINCOMINGBALANCECHECK/RUNOUTS.
(NOPEENINGREQUIRED).USEMETHOD#2005.
assembly and also contain any

special instructions to address any REMOVETHEINDUCTORALTERNATORSHAFTFROMTHECOMPRESSORROTOR.VISUALLYINSPECTTHE
HELICOILSANDREPORTANYDAMAGETOENGR.
of the items special to this unit.
Example: Perform TIL-1342 Row REMOVEFROMTHEBALANCEMACHINE.
17 compressor blade change

STANDUPTHEROTORINTHESTACKINGPIT(AFTENDUP)ANDIDENTIFYEACHWHEELINRELATIONTOTHE
#1BOLTHOLE.STAMPTHESTAGENUMBERONTHERESPECTIVESTAGE.
9
STAND ROTOR VERTICAL

The process of taking the rotor from
horizontal to vertical for de-stack
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.
10
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.
11
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
12
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
13
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.
14
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 dis-assembly
process
15
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
16
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
17
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.
18
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.
19
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.
20
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
21
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 re-stack process
22
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.
23
COUPLING HELICOILS
These helicoils should be replaced
during every major rebuild of the
rotor.
24
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
25
BLADE BLENDING
Examples of compressor blade tip
blending
26
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 to be removed to allow U
weights to slide past their
location
27
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.
28
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
29
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
30
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
31
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
32
FINAL MACHINE PROCESSES

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
33
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 seperately.
34
END OF COMPRESSOR MODULE
35
MS7001 B - EA TURBINE ROTOR REPAIR MODULE
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
37
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
38
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.
39
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.
40
TURBINE ROTOR REPORT
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.
41
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
42
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
43
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.
44
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.
45
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
46
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.
47
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.
48
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.
49
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.
50
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
51
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
52
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 anti-corrosion
coating such as 2-F1
53
STUB SHAFTS
Both turbine rotor stub shafts are
set up and checked for
concentricity.
54
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.
55
RE-ASSEMBLY
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.
56
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.
57
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.
58
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.
59
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.
60
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
61
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.
62
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.
63
END OF TURBINE REPAIR MODULE
64
MS 7001 ROTOR REPAIR MODULE
TIL 1576 OVERVIEW

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.
65
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.
66
MS 7001 REPAIR MODULE
BACKGROUND (2007)
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.
67
MS 7001 REPAIR MODULE
BACKGROUND (2007) (cont)

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 re-
define 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.
68
MS7001 ROTOR REPAIR MODULE
RECOMMENDATIONS (2007)
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.
69
RECOMMENDATIONS (2007)
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 E- class 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.
Contact GE
70
RECOMMENDATION MODIFICATION
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
71
RECOMMENDATION (2011)
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.
Contact GE
END OF TIL-1576 OVERVIEW
72
OTHER ISSUES
TIL-1049-3R1. TURBINE WHEEL DOVETAIL MATERIAL LOSS
TIL-1854 COMPRESSOR ROW 2 AND 3 BLADE TIP LOSS
TIL-1342 ROW 17 COMPRESSOR BLADES
73

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MS7001 B - EA COMPRESSOR ROTOR REPAIR MODULE

COMPRESSOR ROTOR REPAIR

BLADE WEDGE MIGRATION

BLADE WEDGE MIGRATION

STUB SHAFT DIMENSIONAL

THROUGH BOLT POSITION

BALANCE WEIGHT LOCATION

WORK SCOPE CREATION RECEIVEANDINSPECTFORANYSHIPPINGDAMAGE.TAKEPHOTOOFSHIPPINGCONTAINERANDSTORE

Based upon the findings of the

document is created. This scope

assembly and also contain any

of the items special to this unit.

Example: Perform TIL-1342 Row REMOVEFROMTHEBALANCEMACHINE.

17 compressor blade change

STAND ROTOR VERTICAL

HYDRAULIC BOLT DE-STRETCH

THRU BOLT NUT REMOVAL

BOLT WHEEL CORROSION

SEIZED THROUGH BOLTS

THROUGH BOLT DRILLING

BOLT HOLE SLEEVES

RABBET FIT GALLING

WHEEL RUN OUT TABLE

WHEEL RUN OUT DATA

THROUGH BOLT INSPECTIONS

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

FWD AND AFT STUB BALANCE

AFT STUB ASSEMBLY

FINAL MACHINE PROCESSES

FINAL MACHINE PROCESSES

END OF COMPRESSOR MODULE

RECEIVING THE ROTOR

COUPLING BOLT HOLE FACE

BUCKET LOCKING PIN

FIR TREE COATING

FWD. STUB REMOVAL

COMPONENT RUN OUT

COMPONENT FIT REPAIR

WHEEL GEOMETRY RESTORATION

RUN OUT VERIFICATION

DISCOURAGER SEAL MACHINING

FINAL ROTOR BALANCE

END OF TURBINE REPAIR MODULE

TIL 1576 OVERVIEW

ORIGINAL TIL ISSUED IN 2007

BACKGROUND (2007) (cont)

END OF TIL-1576 OVERVIEW

TIL-1854 COMPRESSOR ROW 2 AND 3 BLADE TIP LOSS

TIL-1342 ROW 17 COMPRESSOR BLADES

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