WELD RESTORATION OF TURBINE DISK

AN EXAMPLE OF ELLIOTTS REPAIR TECHNOLOGY Kevin Barnett Repair Operations Manager

ELLIOTT COMPANY

ROTOR:

A ENGINEERED COMPONENT WHICH ROTATES AT SPEEDS EXCEEDING 1000 RPM ROTOR CAN BE DRIVEN BY MECHANICAL DRIVE COUPLED TO IT. ROTOR CAN ALSO BE DRIVEN BY ELECTROMAGNETIC, LIQUID OR GAS / STEAM FORCES ACTING ON IT SUCH TURBINE ROTOR EXPERIENCES BOTH STATIC AND DYNAMIC LOADING.

STEAM TURBINE ROTOR

COMPRESSOR ROTOR

ARMATURE ROTOR Motor or Generator

RESTORATION:

ACTIONS TAKEN TO MAKE A COMPONENT USEFUL AGAIN FOR ITS INTENDED PURPOSE
REQUIRES A CLEAR UNDERSTANDING OF THE ORIGINAL DESIGN. OR REQUIRES A REVISED DESIGN TO ACCOMPLISH A NEW PURPOSE

RESTORATION CAN INCLUDE:

WELDING MECHANICAL REMOVAL/ /MACHINING/ASSEMBLY PLATING AND COATINGS

FAILED DISK RIM AND SEAL RUB

FAILURE AT DISK RIM 5th STAGE

CLOSEUP VIEW OF FAILED DISK RIM

DRILLING OUT LOCKING PIN

REMOVAL OF LOCKING BUCKET

REMOVAL OF OTHER BUCKETS

SHEAR WAVE ULTRASONIC EXAMINATION

PHASED ARRAY ULTRASONIC EXAMINATION

PARTING OFF DAMAGED DISK RIM

CUTTING THE PARTED OFF RING

TEST RING SEGMENT

CRACK BRANCHING

SCC CRACK PROPAGATION

TEST REPORT OF DISK MATERIAL

MECHANICAL PROPERTIES

TOUGHNESS @ RT and FATT

WELD DESIGN

Weld buildup deposited at least inch outside the steam balance holes.

Heat affected zone located in a low stress area. Weld deposit accessible for ultrasonic examination

PREPARATION FOR WELDING

RUN ON/OFF RINGS & FLUX DAMS

PREHEATING

SUB-ARC WELDING BUILDUP

ROUGH MACHINE COMPLETED WELD

ULTRASONIC TESTING

PREPARE FOR LOCAL HEAT TREAT

POSTWELD HEAT TREATMENT

Electric Resistance Ceramic Heaters Controllable Power Supply Controlling and Monitoring Thermocouples Chart Recorder Capacitor Discharge TC Attachment Welder AWS D10.10 Specification

ROUGH MACHINING AFTER PWHT

MAGNETIC PARTICLE EXAMINATION

MACHINING THE BLADE ROOT FORM

INSTALLING NEW BLADES

PREPARATION OF SHROUD PIECES

CHECK THE QUALITY OF PEENING

PEENING THE ACTUAL BLADING

MACHINING THE PEENED SHROUDS

DYE PENETRANT EXAMINATION

FINISHED BLADE ASSEMBLY

INSTALL NEW SEAL STRIPS

SETTTING THE MECHANICAL TRIP

LOW SPEED BALANCE

AT SPEED BALANCING

APPLY PROTECTIVE COATING

PACKAGE FOR SHIPMENT

SUMMARY
SUBMERGED ARC WELDING
COST-EFFECTIVE MEANS OF WELD RESTORATION OF DAMAGED TURBINE DISK RIM

BASE METAL ANALYSIS

MEANS OF ENSURING A SUCCESSFUL REPAIR

ULTRASONIC EXAMINATION
MEANS OF CHECKING REMAINING BLADED DISKS FOR ONSET OF SCC BY UTILIZING EITHER SHEAR WAVE OR PHASED ARRAY MODE OF EXAMINATION DEPENDING ON BLADE ATTACHMENT DESIGN.

THE END