Runner Repairing Report

DERBENDIKHANHYDROPOWERSTATION
REHABILITATIONWORKSFORTURBINEUNITNO.
RUNNERCRACKSREPAIRREPORT
Preparedby
Engineer
KhalidSaleemAhmed
SULAIMANIYAH/DERBENDIKHAN
MAY
MAY
DERBENDIKHANHPSRunn
ner&DraftTu
ubeInspection,MAY
DerbendikhanHydroPo
owerStattion
DocumentNo.ReportMA
AYNON
NN.DOC
Page
DERBENDIKHANHPSRunner&DraftTubeInspection,MAY
DOCUMENTRELEASEINFORMATION
Projectname
Documenttitle
Derbendikhanhydropowerstationrehabilitationworks
forturbineunitNo.Runnercracksrepair
Runneranddrafttubeinspectionandwelding
procedureunitNo.runnerrepairreport.
DocumentNo.ReportMAYNONN.DOC
Page
Contents
.INTRODUCTION.............................................................................................................................
.BACKGROUNDINFORMATION..............................................................................................
.CURRENTINFORMATION....................................................................................................
.ComponentMaterials...........................................................................................................
.RunningHoursComparisonChat
.UNIT...........................................................................................................................................
.Runner(Unit)......................................................................................................................
.RUNNERCRACKS(UNIT)..................................................................................................
.bladeandskirt................................................................................................................
.NoseConeAdjacentBlade()........................................
.Blade
()...
.Blade
()...
.Runner
Diagram.
.RepairCavitationDamage....................................................................................................
.UnitNo.Runnerconditionassessment...........................................................................
Repair..........................................................................................................................................
.Cracking...............................................................................................................................
.Cavitationsdamage..............................................................................................................
Drafttubelinner.....................................................................................................................
.Condition.
.Repairrequirement....
AppendixMitsubishiData.
.material.
MaterialsperformanceAndChemicalAnalysis..
WeldingProcedureUnitno.RunnerRepair...
Page
References.
EXECUTIVESUMMARY
Inspection of Unit Derbendikhan Hydropower station was undertaken

during May as part of ongoing general monitoring of condition. This
Unit had no remedial work carried out under the HECEC contract of
September to December ,serious deterioration of the runner in the
form of cracking and significant deterioration of the draft tube liner was
found.
Remedial action for unit runner is given special attention in this report
withaviewtothosepotentiallyinvolvedtoassessrequirements.
Drafttubelinerremedialworkwithrespecttoeffectiveprotectivecoating
application to arrest advanced corrosion and assist with mitigation of
cavitationerosionisapressingrequirementforallthreeunits.
Page
PersonalMotivation
ItiswellknownthattheturbineUnitnumbertwoininDarbandikhan
hydro power s station broke due to cracks and blocking in runner part.
Shortly after that several foreign and local companies visited the site and
they demanded high cost and more time without giving any guarantee.
They asked to buy and change runner part which required more than
()fivemillionUS$onlytopurchaseit.
Because I was working in this field for several years, I planned to fix this
problem and I visited several times the relevant ministry. After several
attempts,myplanwasapprovedandIwasappointedtobethesupervisor
oftheproject.Theturbinewasrepairedwithinashortperiodanditcould
produce megawatt of electricity which was very beneficial for
summertimeinthatperiod.
ThetotalcostwasonlyUS$andtheministerhimselfvisitedthesite
and he was very proud of this achievement and he asked to elevate my
rank. The turbine is now working very well after repairing since till
now.Itisworkingmorethan()hours.Itprovesthatreparationwas
done provisionally scientifically and we could save about () seven
millionUS$.
Thisachievementwashighlyappreciatedbythepeopleandmediaandeven
bytheforeigncompanies.
Enginner
Page
KhalidSaleemAhmed
.INTRODUCTION
.BACKGROUNDINFORMATION
Abriefhistoryofthepowerstationis:
Mitsubishicontractwasletin1979.
Workcommencedin1980.
Contractcompleted1985.
Iraq/Iranwar1980to1988.
1994132kvlinetoSulaymaniahReestablished.
1996Unit2Repaired.
AcontractwasletwithHECECbyUNDPfordrafttubeandRunnerrepairs
toallUnitsandworkwascarriedoutduringtheperiodSeptember
1999.becausetheextentofworkrequiredwasmuchgreaterthanhadbeen
assessedorallowedforinthecontract,workscouldnotcontinuebeyond
thattime.
.CURRENTINFORMATION
As inspection of Unit was conducted late February and it was
noticed that there were cracks evident in the Runner that had developed
significantlyandthattherewerenewcracksaswell.Furthercheckingwith
dyepenetrantwasinstigatedwithoneadditionalcrackbeingfoundandthe
Page
details taken by photograph and measurement. A total of cracks have

beenidentified.
Early inspection details have been circulated for opinion regarding
appropriate repair of the runner to return it to satisfactory condition.
Opinion from persons experienced in this work, includes Malcolm Scott,
Roger Hurt of Alston and Frank McKnight of UNDP (part author of this
report)arefoundinappendix.
Drafttubedefectsintheareaimmediatelybelowtherunnerwereinspected
also,butwithlessattentiontothesethantheconditionoftherunner.
Becauseofthefindingsassociatedwithunit,inspectionsofunitand
were arranged, particularly to inspect for cracking of the runners. No
cracking of the runners of those two units was found. Some liner
deterioration has occurred, but is considered to be progressive without
immediate threat to operation compared to the crack propagation and
associatedapproachofcatastrophicfailureoftheunitRunner.
.ComponentMaterials
Themechanicaldatabookforthepowerstation(byMitsubishi)providesa
descriptionofthematerialoftherunnerasstainlesssteelcasting.(See
appendix).
Page
.Runninghourscomparisonchart
UNIT YEAR RUNNING TOTALS
N.
HOURS
COMMENTS
Putintooperationon//
Inspectioncarriedouton//
.UNITN.
OnFebruaryas inspectionwascarriedoutonunit #drafttube

andrunnerby(UNDP)and(SEA)staffalongwitharepresentativefromthe
SalahadinUniversity.
Severalcrackswereobservedintheturbinerunner.
A second inspection was carried out on February for a more detailed
inspection and photographs were taken of the large cracks in the runner,
plusthecavitationsdamagetothedrafttubelinerandairinletpipework.
Page
UNDP staff carried out a further inspection on March to instruct

the local staff on the use of dye penetrates on the runner to accurately
measurethelengthofthecracks.
.Runner(Unit)
Dyepenetratenondestructivetestingemployedtobetterestablishthefull
extentofcrackingfoundduringtheearlierinspectionsandtoensureasfar
aspossiblethattherewerenofurthercracksinanypartoftherunner.
Cavitationdamagewasalsocarefullyinspectedanddocumented.
.RUNNERCRACKS(UNIT)
IsummariesbelowthecracksasIunderstandfromthereportandphotos:
Significantcrackingasinspectedisreportedbelowbladecrackdata.
BLADE
Noandskirt
(Refplate)
Lowerskirt
STRING
LINE
STRAIGHTLENGTH LENGTH
(crack
followed
with
loosestring).
mm
mm
Adjacentno
(refplate)
Nosecone
mm
LOCATION
mm outside
nosecone.
Page
No
(refplate)
No
(refplate)
No
(refplate)
Noseconeendon mm followed mmtotal

noseconeside. bymm.
(mm
along
mmline).
Noseconeendon
mmtotal
noseconeside.
(mm
along
mmline).
Noseconeendd/s mmwicketgate mmtotal.
edge.
side.
mm nose cone
side.
Table..bladecrackdata
.Bladeandskirt
Thecrackisatthetrailingedgeofthebladeatthebladetothelowerskirt
transition(weldedjointandthenverticallyupintotheskirtwellawayfrom
thejoint,straightlinelengthmm.itmaywellbethatthecrackisfull
depth,butthiswouldneedtobedeterminedbyultrasonicinspection
techniqueorassessedduringgrindingapartofarepairprocedure.
Page
Bladeandskirt(plate)
.Noseconeadjacentblade
Alargecrackwasclearlyvisibleontheoutsideoftheconeverticallybeyond
bladeNointhedirectionofbladeNo,thiscrackwasalsoontheinside
ofthenosecone,indicatingfulldepthcrackingoverthesmallerlength.
Thecrackislongerontheinsideofthenoseconeatmmcomparedto
ontheoutsideatmm.ltisoutsidethetransitionoftheweldedjoint
betweenthebladeandthenoseconeandextendswellaboveandwell
belowthistransition.Itisnotknownwheretheverticalnoseconejointis
(havingbeenmanufacturedfromplate).
Page
Outsidenoseconeadj.blade(plate)
.Blade
Horizontally large crack was clearly visible in blade no between the
trailing edge and a point well towards midway back in to the blade,
horizontallyinazigzagmanner(veepattem)andnearthetopoftheblade,
(seeplateaandplate).
Thiscrackhasatotalactuallengthofmm(followedwithloosestring)on
the nose cone side (see plate ). The sharp change in direction is a
significantphenomenonasiftwoseparatecrackshavebeenpropagatingat
rightanglesandtowardsoneanotherandhavemet.Itisclearlytrailingoff
towards the inlet edge the blade and the indistinct curve appears to be
surficialratherthandeepuntiltheveryendnotseenontheothersideuntil
this point. The camera was able to pick up the end mark but there was
Page
insufficientroomtoexaminethisbydirecteyesightduetothelimitedspace
inthearea.
Bladeonnoseconeside(plate)
Page
BladeNo.crack(plate)
.Blade
Thisisshowninthefollowingphotos(plate).
Thecrackextendsrightaroundthetrailingedgeneartothenoseconejoint.
It continues mm from the trailing edge of the blade on the wicket gate
side and mm from the trailing edge on the nose cone side, with a total
lengthofmm(followedwithloosestring).
Page
Thereisexcessdeveloperawayfromthecrackwhichgivestheimpression
ofdiscontinuitiesinthesurface.Thesedonotexist.
BladeNocrack(plate)
Page
Page
.RunnerCavitationDamage(unit)
Thetrailingedgesoftherunnerbladesthemselvesexhibitheavycavitation
erosioncoveringareasindicatedintable..
BladeNo
LowerRadius
BladeFace
TrailingEdge
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm* cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cmcm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
cm*cm
Table..cavitationserosionunitrunnerbladestrailingedgesthe
entriesindicateareaswhereheavecavitationdamagecoversmostlythe
lowerradiusandcarriesthroughtothebladefaceasawhole.
Page
.UnitRunnerConditionAssessment
The damage and defects that have been described give rise to serious
doubts regarding the success of any repair action that may be
contemplated.
Runninghoursaresignificantlylessthanthoseforanyotheroftheturbine
units, %of the hours of unit and % of the hours of unit , yet the
degreeofcrackingisextremebycomparisonwiththeothertwo.Duringthe
contract for repair of the draft runners and tubes when work was
undertakenonunitand,onlycrackwasevidentintherunnerofeach
andinneedofrepair.
During previous inspections of the No. unit runner no cracks have been
found. Whatever the circumstances it is unlikely that all cracks have been
missed previously. This indicates that at least some of the cracks are
propagatingataratesuchthatfurtheroperationofthisunitwouldputitat
highriskoffailureatanunknowntimeandlikelytobeaccompaniedwith
catastrophicdamagetootherturbinecomponents.
Theapparentrapidonsetofcrackingalsoraisesseriousquestionsaboutthe
metallurgical state of the runner. This has been implied by Malcolm Scott
who,inhisopinionincludedinappendix,recommendsfullradiographicor
ultrasonic examination of the runner to further check the integrity of the
runner. Deep and sizable inclusions in the casting may be weakening it
and/orcausingworkhardeningbyflexureoutsidedesignlimits.Also,itmay
Page
bethattheannealingcarriedoutwasnotsufficientinthiscaseandresidual
stressesarehavingeffectinthemannerobserved.
Whatevertheexactcause,itisnotpossibletodetermineitbyfurthervisual
determination.Ultrasonicorradiographicand/orsampletestingisrequired
to gain further knowledge of the runner condition. as ultrasonic or
radiographic equipment are not readily available, it is considered that
samples testing would be the best first choice. Metallographic testing to
determinethestateoftherunnermaterialandthepresenceofinclusionsor
porosityatfailuresitesshouldthereforebeundertakenforthenextstageof
condition assessment towards estimation of the extent of further service
life.
Atthepresenttime,asummarystatementisthatthereisnoindicationthat
therunnerissafeforanyfurtheruseuntilmeasurearetakentoimproveits
conditionbyameasurabledegree.
Page
Repair
.Cracking
WeldrepairswerecarriedoutinsituonunitNo..including()cracksrepair
thathasnotfailedafterafurtherhours.Thepotentialforsuccessby
weldrepairisthereforeestablished,contingentuponthematerial.A
strategyofstructural(minimal)repair(dealingwithcracksonly)ormore
extensiveinvolvingsomecavitationsdamagecouldthenbedetermined.
Toadepthandwidthsuchasisshowninthesketchof
PreparatoryGrinding. theweldbelowtobevariedaccordingtodepthofcrack
andaccessonthereverseside.Fulldepthcracksin
bladeswouldhavehalfdepthgrindinginitially,withall
remainingdepthofcrackremovedandweldedfromthe
reverseside.
Preheating&
Ctobeachievedandmaintainedinthedrafttube
temperature
LocalheatinginthegroundareatoCandthen
maintenance.
maintainingCbasemetaltemperatureallaround
thecrackareathroughouttheweldingprocedure
weldrunsAll
Welding
Builduprun:runtowithGr,.dia
requirements.
Cappingruns:runtowith,.dia
Dyepenetratechecks,
Beforewelding,duringbuildupandaftercompletion
Peenbetweeneachlayerofweld
Backgrindingasnecessarybeforeproceedingwith
furtherwelding
Maintainingtemperatureinthebasemetalof Cfor
Postweldheating
aspecifiedperiodaccordingtoweldsizeafterthe
Page
completionofwelding.Thenallowingaircoolingwith
drafttubetemperaturestillmaintained
Finishgrindingand
polishing.
GrindingtoprofilewithanyfinishweldingusingTIG
withwire,butagainusingpreheating
temperaturemaintenanceandpostweldheatingas
required
Table..typicalcrackrepairtechnique
(Tobecustommodifiedforeachdefectinunitrunners)
Itshouldbenotedthatthelogisticsofcarryingoutrepairsinthiswayare
verydemandinguponthewelding.Eachcrackrepairmustcontinuewiththe
heating levels maintained .It is therefore necessary to have several (
recommended) certified welders to operate in turn with one another and
welders assistants ( recommended) to operate in the same cycle for the
heating maintenance and testing procedures .Between welding
temperatureinthedrafttubemustbemaintainedandcoolingdownofthe
basemetaltemperatureaccordingtotheaboverequirements.
.CavitationsDamage
Cavitationsdamagerepairisconsideredseparatedasitdoesnotconstitute
animmediatestructuralthreattotherunnerandthedamageinitselfdoes
notpreventtherunnersavailabilityforstandbyuseintheeventofan
emergency.
Atypicalrepairmethodology,asdefinedforthepreviousrepairstotheUnit
Nrunners.
Page
Task
REQUIREMENTS
Initial
Dimensionalcheckandrecordingof
bladeandcriticalrunner
dimensions,(centerdistancesof
blades,gapsbetweenrunnerwear
ringandSStopliner).
Manufacturesheetfrom.mm
steelwithfinishedprofilegauged
fromabladechosentobeleast
damaged.Severaltobemadeto
coverprofilechangesalongthe
damagedarea.
Grindingtoensureasoundbasefor
weldingwithdiskssuitedtothis
requirement(Pferdinox)havebeen
previouslynominated
Allelectrodestobefreeofmoisture
anddriedoutatCforhour
priortouse.
Preheatingofdrafttubetoc.
Preheatbasemetaltoc.
Sequentialweldingtominimizeheat
concentrationinoneareaofrunner.
Preferably,oppositerunnerblades
toberepairedinturntominimize
distortioneffects.Initialruntobe
withAWSERLelectrodes.
Initialruntobecoveredwithcavitec.
(seelistofmaterialsavailableex
UNDPwarehousereboth
consumables)
Manufactureoftemplatesofblade
profiles.
Preparationforwelding
Weldinggeneral
Page
Weldingtechnique
Testing
Finishing
Verticaluptechnique.
Maintainbasemetaltemperatureof
c.
Dyepenetrates testingafterwelding
backgrindingandrepairingas
necessaryaccordingtotestresults.
ProofgrindandthenNDT.
Finishgrindtoprofileandpolishwith
emerywheel.
FinalNDT.
Dimensionalcheckofbladesand
runnercriticaldimensionscompare
tothoseatstartandtakeremedial
actionitnecessary
CavitationsDamageRepairTypicalforRunnerBlades
Aswiththecrackrepairs,itshouldbenotedthatthelogisticsofcarryingout
thisworkareverydemandinguponthewelding.Eachrepairmustcontinue
withtheheatinglevelsmaintained.itisthereforenecessarytohaveseveral
(recommended)certifiedwelderstooperateinturnwithoneanotherand
weldersassistants(recommended)tooperateinthesamecycleforthe
heatingmaintenanceandtestingprocedures.Anybreakswouldstillenquire
drafttubetemperaturemaintenance.
Page
DraftTubeLiner(UnitNo.)
.Condition
Thetopstainlesssteelsectionofthedrafttubelinerappearstobeingood
conditionbutthecarbonsteelbelowitisinpooroverallcondition.
TheworstpartisnearthefirstlegoftheairadmissionpipeNo.(seeplate
),attherightoftheentrancedoor.Theheavycavitationserosionatthe
bottomlefthasholedtheplateandcavitationsarenowerodingthe
concreteinthisareaverydeeply.
Heavy cavitation damageliner holed in the wake of air admission pipe

(plate)
Page
Thetransitionareabetweenthestainlesssteelandcarbonsteelsectionsis
in poor condition (see plate ) and exhibits cavitationerosion by small
holes in areas through to the concrete, right around the draft tube to
approximatelycmbelowtheweldjoin.
In this area, the liner plate appears to be about mm thick which is
consideredinadequatefortherequiredservice.Theimplicationisthatthis
sectionofdrafttubelinerwasnomorethanmmthickwheninstalledas
hasbeensuggestedonpreviousoccasionsforunitduringitsrepairunder
theHECECcontract.
Theothertwolegsoftheairadmissionpipeworks.
Drafttuberepairing(plate)
Page
.RepairRequirements
Allrepairrequirementshavebeennominatedatearlierdates.Significantly
increaseddeteriorationnowshouldbeundertakenassoonaspossible.
Repairbyweldinginnewsectionsofplate,minimum,intheshortterm,
perhaps including stainless steel overlays to better resist the cavitation
proneareas.
Establishadequateanchorageoftheliner.
Rerouting of voids behind the liner and the area (s) that have been
affectedbycavitation/wateringress.
Applicationofaprovenprotectivecoatingtomanufacturersspecification
includingabrasiveblastcleaningandcoatingbuildundercorrectapplication
conditionisalsorequiredassoonaspossible.
Page
APPENDIXMITSUBISHIDATA
.MATERIALS
The Mechanical Data book for the power station (byMitsubishi) gives the
followinginformationunderMaterialList:
Nameof
Component
Runnerand
GuideVane
Facingplate,
WearingRing
Turbineshaft
Sleeve,Runner
Consandupper
Part of Draft Tube
Liner
Material
Material
Specification
Stainless
JISG
steel
Grade
casting
(SCS)Modify
Stainless
JISG-
steelplate (SUS)
DraftTubeLiner, steelplate
Pit Liner and
StorageTank
JISG
SS
Equivalent
ASTM
A-
GradeCA-
A-
Type
Equivalent
BS
GradeA
A
GradeB
Grade
(EnA)
Page
MaterialsPerformanceandChemicalAnalysis
Under Appendix in the Mechanical Data book, the following tabulated
informationisgiven:
MechanicalProperties
Material
SCSC
Tensilestrengthminksi
(kg/mm)
YieldPointminksi(kg/mm)
Elongationininchesmin
Reductionofarea,min
BrineilHardnessNumber
Carbon,Max%
Silicon,Max%
Manganese,max%
Phosphorus,Max%
Sulfur,Max%
Chromium,%
Nickel,Max%
Molybdenum,Max%
.
(.)
.
(.)
%
Min
.
.
.
.
.
. .
. .
A Grade B.S.
CA-
GrA
.
.
.
.
.
.
. (a)
. (a)
. . . .
.
.
. (a)
(a)Chemical analysis is not normally required for the elements

phosphorus ,sulfur and molybdenum, but if they are present in
amounts over those stated they may be cause for rejection
.xaCFCccvca
Page
WeldingProcedureUnitNo.RunnerRepair
Thelargecrackintherunnercouldberepairedbythefollowingstandard
procedures.
CleanandDyepenetratecheckforcrack
Profileshapeofblade(profilecombortemplate)
Drillholeatendsofcracktopreventfurthertravelling
Grindhalfwaythroughareaofcrack
HeatdrafttubetoC
LocalheatgroundareatoC
Weldgroundareawithappropriatestainlesssteelmaterialuntilraised
abovenormalbladearea
Grindbacktoflushwithnormalbladearea(usingprofilecombortemplate
asguide).
Polishareasmoothwithemerywheels.
Alltheactivitiesabovecanbecarriedoutinconjunctionwitheachother;
thefollowingstepswouldberequiredtocompletetherepairs.
Theaboverepairswouldsafeguardtherunnerfromanyfatherdamageto
theseareas.
Page
References
MyworkingexperiencesinDarbandikhanpowerstationespecially
(RunnerandDrafttube)
WorkingexperiencewithHECECanAustraliancompanyinwhich
expertintreatmentofcavitation
TechnicalspecificationdocumentswhichpreparedbyMitsubishifor
Darbandikhanpowerstation
UNDPEngineersReport
AMalcolmScott
BFrankMcKnight
CMurrayShinkfield
Page

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DERBENDIKHANHYDROPOWERSTATION

Inspection of Unit Derbendikhan Hydropower station was undertaken

details taken by photograph and measurement. A total of cracks have

OnFebruaryas inspectionwascarriedoutonunit #drafttube

UNDP staff carried out a further inspection on March to instruct

Noseconeendon mm followed mmtotal

Heavy cavitation damageliner holed in the wake of air admission pipe

(a)Chemical analysis is not normally required for the elements

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