Beruflich Dokumente
Kultur Dokumente
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
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COMPRESSOR ROTOR REPAIR
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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)
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COMPRESSOR ROTOR REPAIR
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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.
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COMPRESSOR ROTOR REPAIR
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COMPRESSOR ROTOR REPAIR
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FRAME7ROTORCOMPRESSORROTORUNSTACKANDREASSEMBLE
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COMPRESSOR ROTOR REPAIR
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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
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COMPRESSOR ROTOR REPAIR
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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.
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COMPRESSOR ROTOR REPAIR
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COMPRESSOR ROTOR REPAIR
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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.
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COMPRESSOR ROTOR REPAIR
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COMPRESSOR ROTOR REPAIR
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COUPLING HELICOILS
These helicoils should be replaced
during every major rebuild of the
rotor.
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BLADE BLENDING
Examples of compressor blade tip
blending
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Power Plant Services
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COMPRESSOR ROTOR REPAIR
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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.
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COMPRESSOR ROTOR REPAIR
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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
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COMPRESSOR ROTOR REPAIR
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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
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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.
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MS7001 B - EA TURBINE ROTOR REPAIR MODULE
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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
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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.
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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.
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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
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TURBINE ROTOR REPAIR
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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.
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TURBINE ROTOR REPAIR
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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
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TURBINE ROTOR REPAIR
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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.
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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.
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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.
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STUB SHAFTS
Both turbine rotor stub shafts are
set up and checked for
concentricity.
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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.
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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.
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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.
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TURBINE ROTOR REPAIR
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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.
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TURBINE ROTOR REPAIR
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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
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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.
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MS 7001 ROTOR REPAIR MODULE
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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.
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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.
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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
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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
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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
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OTHER ISSUES
TIL-1049-3R1. TURBINE WHEEL DOVETAIL MATERIAL LOSS
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