f.i.r.s.t. gas turbine end of life...
TRANSCRIPT
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 = 281-446-0627 Cell = 281-381-0218
FIRST INDEPENDENT ROTOR SERVICES OF TEXAS
6942 FM 1960 EAST # 374 HUMBLE, TX 77346 281-446-0627 ● [email protected]
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.
FIRST INDEPENDENT ROTOR SERVICES OF TEXAS
6942 FM 1960 EAST # 374 HUMBLE, TX 77346 281-446-0627 ● [email protected]
3-D Representation of a Compressor Blade Being Installed Using the In-Situ Method
Components of the In-Situ Process
F.I.R.S.T.
Presentation Outline 1. Who is F.I.R.S.T. 3--5 2. What Does F.I.R.S.T. Do 6–7 3. TILs & TIL #1576 8 4. End of Life Capabilities 9–10 5. End User Inspection 11 6. Critical Flaw Found 12–16 7. 3-D Charts Showing High Stress Areas 17–18 8. Innovating New Inspection Approach 19 9. How to Contact F.I.R.S.T 20
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F.I.R.S.T.
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 = 3rd Party Inspection / Surveillance Number of Consultants = 9
Man Years of Experience = 275
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F.I.R.S.T. 2011 Customer Sampling
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F.I.R.S.T. An Innovative Company
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Consulting Services
Work Scope Development
TIL Rotor
Compliance O&M / Site
Training
Bucket R/R RPM Mod
Zero-Hour Packages
Repair Shop Construction TB Wheels
TRI Seal Pins In-Situ Blade
Mod
End of Life
Testing
F.E.A. Rotor Models
3rd Party Inspection
Shop Surveillance Technology Packages
F.I.R.S.T. 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.
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F.I.R.S.T. End of Life Testing
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.
F.I.R.S.T. End of Life Testing
GE TIL #1576 was issued by GE in 2007. 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.
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F.I.R.S.T. Approach End of Life Testing
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
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F.I.R.S.T. End of Life Testing TIL 1576 & End of Life Testing 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 critical flaw.
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F.I.R.S.T. End of Life Testing TIL 1576 End of Life Testing
Specific Rotor Components Tested
GE 5001P GT 13 - 16 Stage Compressor Wheels
Distance Piece
HP and LP Turbine Disks
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3.80”
4.30”
Approximate Location of Flaw - Indication
F.I.R.S.T. End of Life Testing
14 Flaw Cluster as Determined by Phased-Array Inspection
Flaw No.1
Flaw No.2
Flaw No.3
Flaw No.4
Flaw No.5 FIRST End of Life Testing
F.I.R.S.T. End of Life Testing
15 Close-up of Flaw Cluster as Determined Shown in Previous Slide
Sharp projection off Flaw 1 volume
Sharp projection off Flaw 2 volume
FIRST End of Life Testing
F.I.R.S.T. End of Life Testing
16 Resulting Principle Stresses
Principle Stresses in Bore Region of Concern
-100,000
-75,000
-50,000
-25,000
0
25,000
50,000
75,000
100,000
125,000
150,000
175,000
200,000
2.00 2.50 3.00 3.50 4.00 4.50
Radius (in)
Stre
ss (p
si)
Equivalent (Von Mises) StressesMaximum Principle StressesMiddle Principle StessMinimum Principle Stresses
3.80 “
F.I.R.S.T. End of Life Testing
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TB Rotor Model Temp Results from Applied Steady-State Thermal Inputs
FIRST End of Life Testing
18 Radial Deformation Results for the Turbine Section Model
F.I.R.S.T. End of Life Testing
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F.I.R.S.T. Approach End of Life Testing
Innovative On-Site In-Situ End of Life Testing 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.
