Gas Turbine Services GE MS9001E COMPONENT TECHNOLOGY ١
Tavanir Presented by Colin Findlay Regional Sales Manager Torraj Mombeini Country Manager Bill Calder Component Repair Product Director ٢
AGENDA 1. Repair objectives. 2. MS9001E Technology Uprates. 3. History Overview. 4. Component Uprate Overview. 5. Incoming Inspection. 6. Typical defects. 7. Building a Repair Programme ( Typical Workscope ) 8. Repair Techniques. 9. Coating Processes. 10. Conversions, Modifications and Upgrades. (CLIP) 11. Differentiators. 12. Questions. ٣
Repair Objectives Life Extension Objectives. Improve on OEM life recommendation, through detailed component analysis. Repair Limits Objectives. Broaden OEM repair limits Repair to 'improved' condition to extend operating life. Ultimate Goal Reduce requirements to fit expensive new replacement components whilst extending operating life. ٤
MS9001E Technology Uprates INCREASED FIRING TEMPERATURES IMPROVE POWER OUTPUT & EFFICIENCY Design Level Firing Temperature E Technology 1100C F Technology 1300C FA Technology 1315C FB Technology 1370C G Technology 1415C H Technology 1427C Advanced Castings, Alloys, Cooling & Coatings Embodied As Firing Temperatures Increase ٥
MS9001E Technology Uprates MODEL SHIP DATES FIRING TEMP F/ C EXHAUST TEMP F/ C PG9111B 1975 81 1840/1004 945/507 PG9141E 1978 81 1955/1068 953/512 PG9157E 1981 83 1985/1085 968/520 PG9151E 1983 87 2000/1093 977/525 PG9161E 1988 91 2020/1104 980/527 PG9171E 1991 -?? 2055/1124 998/537 ٦
MS9001E History Overview History Overview MS9001 development based on MS7001 field experience. Initial 9001 engines had same firing temp (1840F/ 1004C) as 7001 model. MS9001 Uprates have resulted in 42% output increase. Achieved by advances in Materials, Coating, cooling technology advances & modifications to support firing temperature increase of 100F/56F ٧
Component Uprate Overview - Row 1 Blade Major design changes since introduction. Sharp L/E replaced with blunt configuration. Material upgraded from IN738 to GTD 111. Turbulated internal cooling holes introduced. Coating upgrades from PtAl through to MCrAlY plus Internal Aluminide. ٨
Component Uprate Overview - Row 2 Blade Major design changes since introduction. Air cooling introduced on E models. Tip Shroud Scalloped and configuration modified to increase creep life. Material upgraded from U700 to IN738 to current GTD111 Cutter tooth Modification where honeycomb upgrade on shrouds is present. Coating upgrades to MCrAlY plus Internal Aluminide now standard. Dependent on fuel type and operating environment. ٩
Component Uprate Overview - Row 3 Blade Major design changes since introduction. Tip Shroud Scalloped and configuration modified to increase creep life. T/E thickened and chord length increased. Material upgraded from U500 to IN738. Cutter tooth Modification where honeycomb shroud upgrade present. A/F configuration amended. ١٠
Component Uprate Overview - Row 1 Nozzle Major design changes since introduction. X4 generations of design. Cooling design and coverage uprated to minimise cracking. Chordal Hinge modification implemented to aid sealing FSX 414 material across all generations. Support ring Modification required for some nozzle upgrades. ١١
Component Uprate Overview - Row 2 Nozzle Major design changes since introduction. Internal core plug cooling introduced. Chord length increased at L/E. FSX 414 material replaced with GTD 222 to improve downstream resistance. Aluminde coating applied to GTD 222 Nozzles. Brush seal uprate to diaphragm sections. ١٢
Component Uprate Overview - Row 3 Nozzle Major design changes since introduction. Not internally cooled. Chord length increased at L/E. Internal strenthening rib introduced to prevent buckling FSX 414 material replaced with GTD 222 to improve downstream resistance. Coating not required on GTD 222 due to low running temperatures. ١٣
Component Uprate Overview Row 1 Shroud Block Major design changes since introduction. Original Single Piece design life limited in LCF. Uprate design for 2055F/1124C went to 2 piece configuration in 1991 310 S/Steel block with FSX 414 film cooled caps. Reverted to one piece on HR120 design, issue 1998. ١٤
Component Uprate Overview Row 2 & 3 Shroud Blocks Major design changes since introduction. Original design utilised labyrinth sealing only Honeycomb seals implemented to reduce bucket tip leakage. Row 2 & 3 Buckets must have cutter tooth modification. ١٥
Component Uprate Overview Combustion Liners Major design changes since introduction. Original was of louvered configuration. Replaced with slot cooled liners on all 9E types. Hastelloy X base material. Material thickness increased by 0.010 for 2055F/1124C. Thermal Barrier Coating added as standard on all 9E types. Life extension programmes successfully implemented. DLN1 Combustion technology being operated on MS9001E types. ١٦
Component Uprate Overview Combustion Liners Original Louvered designed MS9001B Standard Slot Cooling DLN 1 ١٧
Component Uprate Overview Transition Pieces Major design changes since introduction. Original 9B design was long type transition piece configuration. Redesigned Canted Combustion System resulted in short TP configuration to increase stiffness. Redesigned Canned Combustion System (firing temp up to 2055F/1124C) resulted in lengthening the TP configuration at fwd end. Hastelloy X base material used on Original Thin Walled and Uprated Thick Walled designs. Nimonic 263 material introduced in the Mid 1980 s. Aft bracket design modifications implemented to reduce bracket weld cracking. Thermal Barrier Coating added as standard on all 9E types. Life extension programmes successfully implemented. ١٨
Component Uprate Overview Transition Pieces Original Long Design Standard Design Extended Design ١٩
Building a Repair Programme Intellectual Property Rights For each potential APM /APR product or process we perform a detailed IPR (Intellectual Property Rights) review. This is done before the APM /APR process for an individual product is actually launched. To ensure that Wood Group Heavy Industrial Turbines maintains the integrity of it s own and third party owned IPR. To ensure product integrity and support of customers indemnification obligations. ٢٠
INCOMING INSPECTION Metallurgical Analysis Building the Repair Process Full destructive or material and coating assessment only. ٢١
INCOMING INSPECTION DESTRUCTIVE INVESTIGATION - MICROSTRUCTURE Root Aerofoil mid-height suction face Aerofoil mid-height Leading edge ٢٢
INCOMING INSPECTION Cobalt Alloy mainly HGP static components. New Microstructure discrete carbides Embrittled Microstructure grain boundary carbide precipitation and growth + matrix carbide precipitation and growth Some acicular (needle-like) carbide formation Severely Embrittled Microstructure heavy, continuous grain boundary carbide film formation and acicular carbide formation Some severe cracking ٢٣
INCOMING INSPECTION Creep Degradation Mechanisms High level of stress at elevated temperature Base load operation Fatigue TMF - cyclic thermal loading (low cycle fatigue) High cycle (vibratory) fatigue FOD Upstream failures, Particle erosion Oxidation / Corrosion Temperature, fuel and environment related Microstructural degeneration Overaging, embrittlement ٢٤
INCOMING INSPECTION Cooling passage cracking No general oxidation of cooling passage surface DESTRUCTIVE INVESTIGATION - DEFECTS Tip oxidation and γ agglomeration High temperature oxidation / nitridation ٢٥
INCOMING INSPECTION Metallurgical Assessment Sample/samples taken at receipt of components Life assessment is a key part of the repair process Many techniques available to ensure maximum component life is attained Wood Group offers a comprehensive assessment and repair service for both existing and new technology engines Utilising the skill sets of WGHIT AG, Field Service and Component Repair facilities ٢٦
INCOMING INSPECTION Heat Treatment. High Vacuum based processes. High temperature range in excess of 1200 C Argon pressure quench to achieve correct cooling rates. Base material refinement. Materials heat treated as per manufacturers specifications ٢٧
INCOMING INSPECTION Coating Removal - Chemical Stripping Fully developed Chemical Stripping Proprietary Processes. Acid/Alkali used at elevated temperatures. Fully Controlled Process. All non coated and internal sections masked off. Heat tint used to quantify removal on Nickel based materials. Acid etching used to quantify removal on cobalt alloys. ٢٨
INCOMING INSPECTION Chemical Stripping All uncoated areas masked using high temperature wax to protect base material Tape or Silicone sealant used to mask cooling holes to prevent blockages. Root section not exposed to chemicals. Performed on blade and vane material. ٢٩
INCOMING INSPECTION Heat Tint Inspection Post Coating Strip Example showing gold coloured coated area and blue non coated area. Note the non coated areas are not completely blue and this colour is dependent on the base material. Acid etching can also be used to confirm complete strip ٣٠
INCOMING INSPECTION Fluorescent Penetrant Inspection. Inspection performed to detailed Wood Group Criteria. All Inspectors PCN and/or ASNT approved. Detailed reports specify location, size and type of cracking. ٣١
INCOMING INSPECTION Dimensional Inspection. Co ordinate Measuring Machine ( CMM ) Capability. Full reverse engineered blueprint drawings. On site portable CMM capability. Machine location replication fixtures. To establish critical dimensions. ٣٢
INCOMING INSPECTION Borescope Inspection. To determine IGA, Missing Sections and Internal Cracks In many cases cracks can penetrate the wall on the trailing edge and (less often) the leading edge Hidden trailing edge cracks cannot be found by NDE Uncertainty leads to high scrap rates and reduced warranty conditions ٣٣
INCOMING INSPECTION X Ray Inspection. To locate any INCOMING Internal Cracks. INSPECTION To determine extent and condition of previous repairs. To determine cooling configuration and any blockages. To verify technical integrity post repair. ٣٤
INCOMING INSPECTION Ultrasonic/ Eddy INCOMING Current Inspections INSPECTION To determine base material thickness. Can component be restored? Thin areas on blades can result in scrap To verify technical integrity post repair ie correct thickness has been restored. ٣٥
INCOMING INSPECTION Incoming Inspection INCOMING Report. INSPECTION Comprehensive report detailing all findings. Full extent of required repairs known at this time. Recommendations, Upgrades forwarded to the customer at this point. ٣٦
MS9001E Typical Defects INCOMING INSPECTION Blades Tip Rub & missing material. TMF Cracking. F.O.D Z Notch wear / cracking. Angel Wing Rub. Shroud lift & Twist. Platform cracking. ٣٧
MS9001E Typical Defects Nozzles. Base Material Erosion. Missing Material. F.O.D Multi Aerofoil Cracking. Distortion. Downstream deflection. Coating breakdown. Feather seal wear/cracking. Diaphragm cracking/seal wear Gaps / Clearances outwith specification. ٣٨
MS9001E Typical Defects Combustion Material Fuel Nozzle Bore, x f collar, liner stop wear. F.O.D. Missing Material/cracking. Damaged floating seal slots. Hula skirt breakdown Distortion. Coating breakdown. ٣٩
MS9001E Typical Defects Shroud Blocks Multi Cracking. Seal cracking. Erosion. Honeycomb breakdown. Tenon wear. ٤٠
Building a Repair Programme Typical Repair Workscope Blend to remove oxidation and or defects. Perform NDT to ensure parts are defect free prior to repair. Perform Weld repairs to all prepared areas. Blend to restore component profile. Conventional Machine and or EDM to restore dimensions. Perform NDT to ensure parts are defect free prior to repair. Perform Post Repair Heat Treatment. Perform NDT to ensure parts are defect free prior to repair. Perform Hydrogen Fluoride or Hydrogen Clean in preparation for braze repair. ٤١
Building a Repair Programme Typical Repair Workscope Continued Prepare and apply Transient Phase Restoration repairs. Perform Vacuum heat treatments. Blend to restore component profile. Conventional Machine and or EDM to restore dimensions. Perform NDT to ensure parts are defect free. Perform dimensional inspection. Perform UT/EC tests. Perform Flow checks. Forward for coating. ٤٢
Repair Techniques Repair - Blending To remove defects such as Corrosion, Oxidation. Prepare cracking. Remove defective material. Prepare components to an acceptable condition for weld. ٤٣
Repair Techniques Welding Processes. REPAIR WELDING Pulsed and Micro TIG processes. Laser Powder Fusion ( LPF ) Processes. Welder Approval to ASME IX standard. Highly developed and controlled processes. Sectional Replacement ٤٤
Repair Techniques Tungsten Inert Gas (TIG) Arc created between nonconsumable tungsten electrode and metal. Inert gas is fed through torch to shield electrode and weld pool Electrode - Shielding gas Shielding gas nozzle Filler wire is fed separately into molten weld pool Arc plasma Weld Pool + ٤٥
Repair Techniques TIG welding Good deposition rate control Protective gas shield prevents high temperature oxidation Crack repair Material reclamation Large heat input (HAZ) ٤٦
Repair Techniques Laser Powder Welding Laser achieved by concentration of light waves Light energy converts to thermal energy and weld pool produced Filler powder injected onto substrate over area of beam impingement, into molten pool Rapid melting and solidification of filler metal allows build up of layers Powder & argon Cladding Substrate Concentrated light waves Powder & shield gas ٤٧
Repair Techniques Laser Powder Welding Low heat input Narrow weld runs CNC controlled deposition Weld solidification control ٤٨
Repair Techniques Post Repair - Blending REPAIR Critical process. Reprofiling. Dimensional restoration. Surface finishing. Highly skilled operation. ٤٩
Repair Techniques Hydrogen Fluoride Ion Cleaning ( HFIC ). REPAIR Key step in the process. Essential to ensure high quality repair. Oxidised base material removed by HF Ion clean To remove oxidised species from component surface, and provide a surface amenable to repair by the application of a braze paste. Relies on highly reactive hydrogen-fluoride gas combines with oxides to produce volatile metal fluorides. ٥٠
Repair Techniques Transient Phase Restoration ( TPR ). REPAIR Offers various benefits over more conventional repair techniques: 1. Allows repair in critical areas, where welding not permitted 2. No localised heat input 3. Allows repair of alloys which are difficult to weld 4. No weld cracking of heat sensitive materials. ٥١
Repair Techniques MACHINING CNC Milling Machine CNC Wire Cutting Machine Hydraulic Shear Cutting Machine Horizontal Lathe Vertical Lathe, 4000mm Dia. Radial Arm Drilling Machine Hydraulic Press Machine, 100 Ton Hydraulic Jacking Machine, 150 Ton Electrode Discharge Machine (EDM) EDM Supper Drill Machine Plasma Cutting Machine Water Jet Machining ٥٢
Building a Coating Programme Typical Coating Workscope Blast in preparation for coating.. Mask non coated areas. Apply MCrAlY ( either as bond coat or stand alone ) Apply Internal and/or external diffused aluminide coating. ( If required ) Vacuum Heat treat. ( Solution and Age ) Apply Thermal Barrier Coat. Shot / Ceramic Peen. ( if required ) Assemble internal sections. ( Vanes ) Perform flow checks. Visual Inspect. Dimensional Inspect. ٥٣
Coating Processes MCrAlY Overlay Coatings Comprehensive Protection High Temperature Oxidation Type I Hot Corrosion MCrAlY (M=Co, Ni or Co/Ni) Alumina Formers Additional Elements (Cr,Y & Re Etc) Typically First & Second Stage Components HVOF ٥٤
Coating Processes HVOF APPLIED COATINGS CoNiCrAlY & NiCoCrAlY β(nial) & γ (Ni 3 Al) Microstructure High Density (<1% Porosity) Dispersed Oxide (<0.5%) Interface Contamination (Max 10%) Bond Strength (>10000 PSI) 100 µm ٥٥
Coating Processes Thermal Barrier Coatings. Multilayer Coating System Reduce Metal Substrate Temperatures Zirconia (ZrO 2 ) Top Coat 6-8 wt.% Y 2 O 3 Partially Stabilises Structure MCrAlY Inner Layer (Bond Coat) Air Plasma Deposition ٥٦
Coating Processes DIFFUSED COATINGS Diffused Aluminides. Inward / Outward Diffusion High Activity (760-982 C) Low Activity (982-1093ºC) Oxidation Resistant β-nial Corrosion Resistant Doping Elements Slurry Fusion Deposition Chemical Vapour Deposition Cooling Hole Blade Wall ٥٧
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) THE DEMANDS OF TODAY S POWER GENERATION INDUSTRY INFLUENCES THE NEED FOR INCREASED LIFE EXPECTANCY FOR GAS TURBINE ENGINE COMPONENTS. INCORPORATING THE Combustion Life Improvement Package ( CLIP ) TO THE COMBUSTION SECTION COMPONENTS OF THE GAS TURBINE ENGINE ALLOWS ENGINE USERS TO ACHIEVE THESE REQUIREMENTS. ٥٨
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) WHAT DOES THE COMBUSTION LIFE IMPROVEMENT PACKAGE COMPRISE OF? THE COMBUSTION LIFE IMPROVEMENT PACKAGE COMPRISES OF THE APPLICATION OF WEAR AND HEAT RESISTANT MATERIALS AND COATINGS TO KNOWN HIGH WEAR CONTACT SURFACES ON COMPONENTS THROUGHOUT THE COMBUSTION SECTION OF THE GAS TURBINE ENGINE ٥٩
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) FUEL NOZZLE LOCATION DIAMETER PRE-MACHINED AND CHROME CARBIDE COATING APPLIED TO THE SAME SURFACE TO RESTORE THE COMPONENT TO O.E.M. DIMENSIONS OPTION: THERMAL BARRIER COATING APPLIED TO THIS FACE ٦٠
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) COMBUSTION LINER FUEL NOZZLE LOCATION BORE LINER STOPS CROSS FIRE COLLARS SPRING SEAL THERMAL BARRIER COATING ALSO APPLIED TO INTERNAL SURFACE TO C STANDARD ٦١
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) COMBUSTION LINER STOPS CHROME CARBIDE COATING APPLIED TO THE INNER SURFACE OF THE LINER STOP ٦٢
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) CROSS FIRE COLLARS CHROME CARBIDE COATING APPLIED TO THE INNER SURFACE OF THE CROSS FIRE COLLAR ٦٣
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) SPRING SEAL CHROME CARBIDE COATING APPLIED TO THE OUTER SURFACE OF THE SPRING SEAL ٦٤
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) Cross Fire Tubes FEMALE LOCATION SLOTS PRE- MACHINED AND CHROME CARBIDE COATING APPLIED TO THE SAME SURFACE TO RESTORE THE COMPONENT TO O.E.M. DIMENSIONS LOCATION DIAMETERS PRE- MACHINED AND CHROME CARBIDE COATING APPLIED TO THE SAME SURFACE TO RESTORE THE COMPONENT TO O.E.M. DIMENSIONS MALE ٦٥
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) CROSS FIRE TUBE RETAINER FORK AREA PRE-MACHINED (BOTH SIDES) AND CHROME CARBIDE COATING APPLIED TO THE SAME SURFACES TO RESTORE THE COMPONENT TO O.E.M. DIMENSIONS ٦٦
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) FLOW SLEEVE PRE-MACHINE TO REMOVE 0.080 FROM FLOW SLEEVE LINER STOP LOCATION APPLY STELLITE WELD TO PRE-MACHINED LOCATION TO ALLOW FOR FINAL MACHINE FINAL MACHINE TO O.E.M. DIMENSIONS ٦٧
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) INLET BORE TRANSITION PIECES SEAL SLOTS H BRACKETS THERMAL BARRIER COATING APPLIED TO INTERNAL SURFACE TO C STANDARD ٦٨
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) INLET BORE CHROME CARBIDE HARD FACE COATING APPLIED TO THE INLET BORE AT SPRING SEAL MATING LOCATION THE FIRST 4 OF THE INLET BORE AT THE SPRING SEAL MATING LOCATION IS COATED ٦٩
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) SEAL SLOTS SLOTS ARE PRE-MACHINED TO ALLOW INSERT FITMENT AT THREE POSITIONS ON THE RADIAL SLOTS AND ONE POSITION EACH SIDE SLOT INSERTS WELDED INTO POSITION (L605 MAT L) TO O.E.M. DIMENSIONS ٧٠
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) H BRACKETS REMOVE H BRACKETS FROM MAIN COMPONENT AND PRE- MACHINE TO ALLOW FOR INSERT FITMENT FIT INSERTS (L605 MAT L) AND WELD INTO POSITION TO O.E.M. DIMENSIONS. RE-ASSEMBLE H BRACKETS TO MAIN COMPONENT ٧١
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) INNER RADIAL TRANSITION SEAL CHROME CARBIDE COATING APPLIED TO EACH END OF THE INNER RADIAL TRANSITION SEAL ٧٢
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) OUTER RADIAL TRANSITION SEAL CHROME CARBIDE COATING APPLIED TO EACH END OF THE OUTER RADIAL TRANSITION SEAL ٧٣
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) HARDWARE - SIDE SEAL COMPONENT PRE- MACHINED AND CHROME CARBIDE COATING APPLIED TO THE SAME SURFACES TO RESTORE THE COMPONENT TO O.E.M. DIMENSIONS ٧٤
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) HARDWARE - BULLHORN BRACKET CONTACT SURFACES PRE-MACHINED L605 PLATE MATERIAL WELDED TO PRE-MACHINED CONTACT SURFACES TO RESTORE THE COMPONENT TO O.E.M. DIMENSIONS ٧٥
Conversions, Modifications & Upgrades Combustion Life Improvement Package ( CLIP ) WHAT ARE THE BENEFITS OF IMPLEMENTING THE COMBUSTION LIFE IMPROVEMENT PACKAGE? LONGER ENGINE RUNNING HOURS A REDUCTION IN OUTAGE DOWN COSTS A REDUCTION IN REFURBISHMENT COSTS ٧٦
Differentiators We are not a low tech, low overhead company. We are the best alternative to the OEM. We invest heavily in technical research to offer high integrity solutions. We have already developed and implemented repairs where the OEM and our independent competitors have not. Can demonstrate we have listened to our customers specific issues and developed solutions. Our solutions have achieved lower maintenance costs reduced installation times and have repaired otherwise condemned parts to achieve life Wood Group solutions will ultimately deliver cost savings to the customer but will not always be reflected in the immediate repair costs. ٧٧
Questions ٧٨