Professional Documents
Culture Documents
GasTurbineRotorInspection/OverhaulandRepair
EthosEnergyTurboCare Facility,November2014
Safety Moment
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Wood Group
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As the leading independent service provider Our depth and multi-OEM experience provide added insights
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Component
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ManHours/Year
Parts
EthosDesignedParts
AlliancePartners
UsedServiceableParts
Upgrades&
LifeExtensions
GasTurbines
HIT/LIT/Aero
SteamTurbines
Generators
Compressors
EthosOverhaulFacilities
MultiOEMUpgrades
AlliancePartners
Generators
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Rotor winding
Stator coils manufacturing
Modernization / re-design
Refurbishment / replacement
Repairs
Op Speed balancing
Testing / inspection
FIAT
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+ TG16
+ TG20
+ TG50
+ TG 701
WESTINGHOUSE
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W 72
W 81
W 82
W 101
W 111
W 121
W 151
OEM Equivalency
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W 171
W 191
W 191G/M
W 251A,AA
W 251B, B18
W 251B27
W 301
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W 501 AA
W 501 B2-5A
W 501B6
W 501C
W 501D1
W 501D24
W 501D4
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MHI
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RR
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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
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TA 1750
TB 5000
SGT-200 (Tornado)
SGT-100 (Typhoon)
SGT 600 (GT 10B)
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Saturn 10
Centaur 40 / 50
Taurus 60
Mars 90 / 100
SoLoNox
SOLAR
ABB / ALSTOM
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GT11D5
GT13E2
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Field Services
Houston Operations
Description:
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Blast Booth.
Product Lines:
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Balance Machines
Operating Speed Balance (OSB) facility capable of high speed
balancing and overspeed testing of rotors in a vacuum.
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FR5
FR6
FR7E
W101
W191
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W251
W501D5A
W501F
The lift points should be the seal areas of the stub shafts
unless lifting plates attached to the couplings are available
INCOMING INSPECTIONS
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Placing the rotor in the lathe for rotating facilitates the inspection
process.
Rotor run out data is collected including three(3) body run outs to
determine journal /body/journal centerline axis relationship. (rotor
bow)
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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.
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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.
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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
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RESPECTIVE STAGE.
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The process of taking the rotor from horizontal to vertical for destack requires the use of specialized, purpose built tooling and
fixtures.
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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.
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BALANCE VERIFICATION
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requirements.
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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.
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INCOMING INSPECTION
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BALANCE WEIGHTS
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SEAL COATING
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DISCOURAGER SEAL
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COMPONENT INSPECTIONS
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STUB SHAFTS
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ROTOR BALANCE
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FINAL PACKING
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All of the inspections described herein are basic to and in conjunction with the Life Extension
inspections.
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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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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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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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 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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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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