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    Training Session 5: Gas Turbine Repair: by Scott Hastie / Liburdi Turbine Services

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    Training Session 5: Gas Turbine Repair: by Scott Hastie / Liburdi Turbine Services

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    167 views42 pages

    Training Session 5: Gas Turbine Repair: by Scott Hastie / Liburdi Turbine Services

    Uploaded by

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    Training Session 5: Gas Turbine Repair

    By
    Scott Hastie / Liburdi Turbine Services

    Presented at the 2015 Symposium on Industrial Application of Gas Turbines (IAGT)


    Banff, Alberta, Canada - October 2015
    The IAGT Committee shall not be responsible for statements or opinions advanced in technical papers or in symposium or meeting discussions.
    Why do we need to Repair?
    • Maintenance after fuel is the main operating cost over
    the life cycle of a GT
    • Spare part replacement and repairs of hot section
    components represent the major cost portion of all
    maintenance
    • Typically component repairs cost 10% to 30% of the
    replacement new part cost
    • Repairs represent main cost savings opportunity to the
    engine operator
    When do we need to Repair?
    • Meet OEM recommended schedules
    • Based on condition – vibration or borescope inspection
    • Before a part fails
    • Before the part is damaged beyond repair
    • When an engine performance limit is reached
    • At the same time as other parts to match maintenance
    cycles
    What do we need to Repair?
    What do we need to Repair?
    What are the Materials?
    Combustor Compressor
    300SS Casings
    Compressor
    Hastelloy-X, RA-33 Grey Cast Iron
    Some 300SS
    IN-600, IN-617 Carbon Steel
    403, 410, 422,
    Nimonic 75, Nimonic 263 Aluminum
    450 Stainless
    Haynes 230
    IN718 Turbine Shells
    Ti64 titanium Ductile Cast Iron
    Stainless Steel
    Nickel Alloy
    Compressor
    Wheels/Disks
    Ni-Cr-MO-V
    Forging
    Turbine
    Wheels/Discs
    Turbine Rotating Turbine Stationary
    Ni-Cr-MO-V Steel
    N105, N108, N115, Waspalloy, U-500, U520, 300SS, 400SS, C242, C1023
    Cr-Mo-V Forging
    U700,U710, U720, INX750, IN738, N-155, M509, HS-188,L605
    12Cr Stainless
    Rene80, GTD111, Mar-M247, Mar-M002, X-40, X-45, FSX-414, ECY-768
    Discalloy
    PWA1483, CMSX4, ReneN5 IN738, R80, GTD222, GTD444
    A286
    IN718
    What are the Materials?
    Where do we Repair?
    Industrial Frame
    Gas Turbine

    Disassembled in
    Field

    Repair Vendor

    Assembled in
    Field
    Where do we Repair?
    Aero Derivative
    Gas Turbine

    Removed Disassembled at
    from Berth Overhaul Shop

    Repair Vendor

    Returned Assembled at
    to Berth Overhaul Shop
    How do we Repair?
    Repair Process
    Incoming Inspection
    Clean & Strip Coatings
    Post Coating Inspection
    Geometry Repair
    Machine/Finish Geometry
    Heat Treatment
    Pre-Coating Inspection
    Coating
    Final Inspection
    Incoming Inspection
    • Triage
    – Is the component repairable?
    – What is the expected level of the repair
    • For higher technology components Metallurgical Life
    Analysis is required
    Life Analysis
    • Looking beyond what external inspections can see
    • Causes of material loss
    • Internal cracking
    • Internal coating quality
    Life Analysis
    Incoming Inspection
    • Internal Geometry
    Incoming Inspection
    • Cooling System Inspection
    – Qualitative and Quantitative
    Clean and Strip Coatings
    • Internal Cleaning using thermal and chemical processes
    is necessary before stripping
    • Internal deposits and oxides limit the effectiveness of the
    stripping process
    Clean and Strip Coatings
    • Acid mix and temperatures based on materials and
    coatings
    • Internal strip requires careful control of acid
    • External only stripping possible with masking
    Post Strip Inspection
    • Fluorescent Penetrant Inspection
    – Find cracks and porosity
    • Dimensional Inspection Key Features
    – Blades: Tip height, wall and TE thickness, airfoil geometry,
    assembly features, deformation
    – Vanes: Wall and TE thickness, deformation, airfoil geometry,
    assembly features
    Geometry Repair

    Stage 1
    Bucket
    Geometry Repair
    Al
    Geometry Repair

    Blade after First Service Repaired Blades


    Geometry Repair
    • Development of welding alloys with the following
    attributes:
    – Melting temperature below the incipient melting temperature of
    base alloys
    – Wide solidification range
    – Sufficient ductility to accommodate welding stresses by plastic
    deformation within weld beads
    – Strength equal to or greater than conventional repair materials.
    – Cyclic oxidation resistance equal to or greater than that of the
    base alloy.
    Geometry Repair
    • Microstructure of the weld
    – Low porosity
    – Excellent fusion
    – No heat affected zone (HAZ) cracking

    weld deposit
    (silicon modified)

    base alloy
    (GTD 111)
    Geometry Repair
    • The strength and ductility of the modified weld filler
    meets or exceeds that of the standard weld filler at low
    and high temperature
    Material Temperature Yield Stress UTS (ksi) Elongation
    (°F) (ksi) (%)
    Standard 70 120 145 5
    Weld 1800 39 47 13
    Standard 70 137 146 6
    Weld +Silicon 1800 50 55 13
    Geometry Repair
    Geometry Repair
    • Incoming Damage: Burned LE & TE, deteriorated braze
    joint, hot corrosion damage
    • Previously considered scrap
    Geometry Repair
    • LPM high strength alloy as-applied to leading edge, mid
    airfoil, and trailing edges
    • LPM material after high temperature vacuum heat
    treatment to ”cast” material to the airfoils
    Geometry Repair
    • Airfoils machined to original contours, all cooling holes
    re-established by EDM machining, airfoils re-coated ,
    and shrouds coated with TBC coatings.
    • NVGs fully restored for continued service
    Geometry Repair
    • Significant missing material on leading edge due to FOD
    • To maintain cooling design internal geometry must be
    recreated during repair
    Geometry Repair
    • Form casting process allows LPM to be formed to match
    internal geometry
    • LPM applied over form and onto base alloy
    Geometry Repair
    • Part returned for repair after 24,000 hours
    • Inspection revealed no indications or material loss
    Geometry Repair
    • Incoming seal segments distorted (out of round), seal
    slots misaligned, backing plates thin due to oxidation –
    parts were previously declared scrap and replaced with
    new
    Geometry Repair
    • Panel replacement
    Geometry Repair
    • Reconstruction repair
    Geometry Repair
    • Reconstruction repair
    Heat Treatment
    • FSR™ Full Solution Rejuvenation™
    as-manufactured service run: before
    condition Service heat treatment

    Heat Treatment

    rejuvenation heat conventional heat


    treatment treatment
    Heat Treatment
    • Time and temperature parameters unique to alloys
    • Multiple aging cycles used to form a duplex
    microstructure
    Heat Treatment
    Coating
    • Selection of Coating System
    Coating
    Questions?
    • Why?
    • When?
    • What?
    • Where?
    • How?

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