F.I.R.S.T. Gas Turbine End of Life Presentation

Transcription

1 Gas Turbine End of Life Presentation 1

2 Paul Tucker has been successfully running two Power Generation businesses in Houston, Texas that specializes in (FIRST) consulting on users rotating & stationary repairs and manufacturing (TBS) rotor bolting & consumables from 2002 to present. Contact Office = Cell = [email protected] / [email protected]

3 FIRST INDEPENDENT ROTOR SERVICES OF TEXAS Another Innovation from the Creative Team of Consultants and Engineers at FIRST FIRST is a team of gas turbine rotor and component repair consultants. For nearly a decade the dedicated experts at FIRST have assisted end users with in-shop repair surveillance, provided on-site assistance and offered specific technical training. What s New at FIRST? FIRST is proud to present its brand new In-Situ Compressor Blade Replacement System. With this procedure, repair teams are now able to remove damaged GE-type compressor blades from inside the first and last row without un-stacking the rotor. This is a revolution within the industry, as previous rotor repairs were expensive, involved tedious hours and weeks of labor and days of travel from site to site. The Details GE compressor rotor blades are axially installed and are individually locked in place by spacers and staking on the forward and aft sides of the wheels. Using our patented process, US Patent # 13/091864, we remove the damaged blade(s) and adjacent positioning spacers. A new blade and spacers are then positioned and locked in place using our patented locking feature. Non-OEM or OEM blades can be used to facilitate the process. See page 2 for 3-D pictures showing our patented modification in detail. The End User Whether it s one or a few blades that need to be replaced, the compressor rotor has to be completely un-stacked. Comparing the weeks of time to remove the rotor from its case, ship the rotor to a repair shop, un-stack do the repairs, re-stacking, and ship the rotor back to the site, our In-Situ Blade Replacement System takes approximately eight hours per blade and can be done in the case, in a rotor stand or in a repair shop. Our system reduces what would otherwise be several weeks, perhaps months, down to a single day thus eliminating substantial on-site man power and in-shop rotor repair costs as well as loss of generation FM 1960 EAST # 374 HUMBLE, TX [email protected]

4 FIRST INDEPENDENT ROTOR SERVICES OF TEXAS 3-D Representation of a Compressor Blade Being Installed Using the In-Situ Method Components of the In-Situ Process 6942 FM 1960 EAST # 374 HUMBLE, TX [email protected]

5 Presentation Outline 1. Who is F.I.R.S.T What Does F.I.R.S.T. Do TILs & TIL # End of Life Capabilities End User Inspection Critical Flaw Found D Charts Showing High Stress Areas Innovating New Inspection Approach How to Contact F.I.R.S.T 20 2

6 Company History F.I.R.S.T. = First Independent Rotor Service of Texas Company Moto = Think FIRST Before You Commit Incorporated in 2003 Company Description = Consulting Firm Industry = Industrial Gas & Steam Turbine Equipment Type = Rotating / Stationary Service Offered = 3 rd Party Inspection / Surveillance Number of Consultants = 9 Man Years of Experience = 275 3

7 2011 Customer Sampling 4 3

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9 An Innovative Company Work Scope Development 3 rd Party Inspection Shop Surveillance Technology Packages End of Life Testing F.E.A. Rotor Models TIL Rotor Compliance Consulting Services TB Wheels TRI Seal Pins In-Situ Blade Mod O&M / Site Training Bucket R/R RPM Mod Zero-Hour Packages Repair Shop Construction 6

10 Innovative Company FIRST has developed several modifications and customized products over the past 10 years. We look at problem areas in the industry and go to work to develop creative ideas and methodologies that lessen or remove the impact of those problems. 7

11 Technical Information Letter A TIL is a method that GE issues to notify end users of the various changes, modifications or errors for the turbine equipment that align to the turbines that they have manufactured. We are familiar with the TIL s that have been identified with the F/6 rotors. TIL #1576 was issued in 2007 and it discusses the maximum allowable starts for cyclic turbines and maximum fired hours for base load turbines. It limits usage to 200,000 hours with some consideration of extensions and/or 5,000 starts for a cycle based turbine with no extensions. 8

12 GE TIL #1576 was issued by GE in This TIL dictates that gas turbine users rotors after they have reached 5,000 starts or 200,000 hours that the rotor be retired. There are some deviations or extensions offered but per the OEM, there are established limits on life. FIRST & Veracity Technology have teamed to developed a protocol whereas, after the rotors have been disassembled, we inspect specific rotor components using 3D volumetric phased array bore-sonics and eddy current. We perform hardness testing & replications as well as mechanical testing to inspect the rotors components for changes and internal or detrimental flaws. 9

13 Approach Inspections Includes 100% 3-D Bore Sonic Inspection for Internal Flaws Eddy Current Inspection for Creep Hardness and Replication for Grain Structure Critical Diameters Measured for Bore Shrinkage Finite Element Analysis When Flaws are Found 10

14 TIL 1576 & Computer Modeling & F.E.A. We have manufactured rotor component fracture models to perform F.E.A. analysis when critical flaws are found. Through our critical flaw size and fatigue life estimations, we have the ability to place those flaws into our computer model to see if the characteristic of the flaw is detrimental to the running of the turbine. Our models will determine when/if specific flaws will fail and we can accurately determine how many hours or starts remain in the life of the component containing that 11 critical flaw.

15 TIL 1576 Specific Rotor Components Tested GE 5001P GT Stage Compressor Wheels Distance Piece HP and LP Turbine Disks 12

16 Approximate Location of Flaw - Indication 13

17 FIRST Flaw No.5 Flaw No.4 Flaw No.3 Flaw No.2 Flaw No.1 Flaw Cluster as Determined by Phased-Array Inspection 14

18 Sharp projection off Flaw 2 volume FIRST Sharp projection off Flaw 1 volume Close-up of Flaw Cluster as Determined Shown in Previous Slide 15

19 Principle Stresses in Bore Region of Concern 200, , ,000 Equivalent (Von Mises) Stresses Maximum Principle Stresses Middle Principle Stess Minimum Principle Stresses 125, ,000 75,000 Stress (psi) 50,000 25, ,000-50,000-75, , Radius (in) 3.80 Resulting Principle Stresses 16

20 FIRST TB Rotor Model Temp Results from Applied Steady-State Thermal Inputs 17

21 Radial Deformation Results for the Turbine Section Model 18

22 Approach Innovative On-Site In-Situ Protocol FIRST is developing protocol to be able to perform specific in place tests on your rotors on site without the need of taking the rotors to a facility for un-stacking. These on-site protocols could revolutionize how E.O.L. inspections are performed. This new protocol would eliminate thousands of repair shop man hours. 19

23 Connect With F.I.R.S.T Consulting 20