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TITLE LP DIAPHRAGM NOZZLE DOCUMENT MOS-03-003

REPAIR
APPLICATION WELDING REVISION -
AUTHOR MOHAMAD FAIZUL DATE 22 FEBRUARY 2019

A. INTRODUCTION

The objective of this method of statement is to describe detail work instructions


on the repair of U2 LMZ Steam Turbine LP diaphragm nozzle repair at Pha Lai
Power Plant.

B. SCOPE

The scope covers the procedure to repair LP diaphragms’ nozzle and outer ring
defects at site.

C. REFERENCE

D. RESOURCES

NO RESOURCE REQUIREMENT REMARK

1 Manpower Technical Advisor (1 no)


Welder (1 no) - NPS
Fitter (3 nos) - NPS
2 Equipment Welding machine - NPS
Electrical grinder - NPS
Pneumatic air tool - NPS
Measuring tool - NPS
3 Jig & fixture Flat table – NPS (1.5 x 1.2 m)
4 Consumable Fillerwire – What type?
Grinding disc - NPS
PT consumables - NPS
5 Estimated Time 14 days – To be confirmed after
TA coming at site

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TITLE LP DIAPHRAGM NOZZLE DOCUMENT MOS-03-003
REPAIR
APPLICATION WELDING REVISION -
AUTHOR MOHAMAD FAIZUL DATE 22 FEBRUARY 2019

E. NOMENCLATURE

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TITLE LP DIAPHRAGM NOZZLE DOCUMENT MOS-03-003
REPAIR
APPLICATION WELDING REVISION -
AUTHOR MOHAMAD FAIZUL DATE 22 FEBRUARY 2019

F. METHOD

Figure 1: Diaphragm nozzle 21 Figure 2: Nozzle partition defect

Figure 3: Nozzle outer ring damage Figure 4: Nozzle leading edge damage

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TITLE LP DIAPHRAGM NOZZLE DOCUMENT MOS-03-003
REPAIR
APPLICATION WELDING REVISION -
AUTHOR MOHAMAD FAIZUL DATE 22 FEBRUARY 2019

Incoming Inspection

1. Perform blast cleaning of the diaphragm nozzle using sandblast.

2. Verify the material using XRF Method.

3. Carry out red dye PT and map all defects.

4. Take measurement of diaphragm nozzle before repair work like Fig 5.

5. Measure the deformation of the nozzle using flat table. The flatness should be within 5
micron.

Contact Contact surface


surface

Figure 5: Points of measurement

Repair of Diaphragm Vane Airfoil

1. Inspect the good airfoil and make template.

2. Measure the thickness of trailing edge of all airfoils. Compare the damaged / thin
trailing edge with good reading. Mark the trailing edge that need to be repair.

3. Blend the vane airfoil as per blending process specified in Table 1

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TITLE LP DIAPHRAGM NOZZLE DOCUMENT MOS-03-003
REPAIR
APPLICATION WELDING REVISION -
AUTHOR MOHAMAD FAIZUL DATE 22 FEBRUARY 2019

Type of defects Method of blending


Dent, Nicks, scratches, sharped-  Operator to select appropriate size of polishing
edged damage disk.
 Gradually remove material until defect is no
longer visible.
 The finish on the blended area must be as close to
the original finish as possible.
 Visual Inspect the blended area. Hand test touch
over the blended area.
 Avoid discoloration due to high input during
blending
 FPI Inspection is not required.
Erosion / Corrosion  Operator to select appropriate size of polishing
disk
 Gradually remove material until erosion /
corrosion is no longer visible.
 Base metal must be preserved.
 The finish on the blended area must be as close to
the original finish as possible.
 Visual Inspect the blended area. Hand test touch
over the blended area.
 Avoid discoloration due to high input during
blending
 NDT Inspection is not required.
Indication / Deformation / Craze  Operator to select appropriate size of burr.
Cracking.  Gradually remove material until indication is no
longer visible.
 Perform NDT Inspection.

Table 1: Blending Process

4. Once the sharped area is removed, mark all the airfoil vanes that need to be weld.
Welding is only permitted 30% from the total length of the airfoil. Contact
Engineering Department for details.
5. Perform the welding as per Table 2.

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TITLE LP DIAPHRAGM NOZZLE DOCUMENT MOS-03-003
REPAIR
APPLICATION WELDING REVISION -
AUTHOR MOHAMAD FAIZUL DATE 22 FEBRUARY 2019

Type of defects Method of welding


Dimensional build up  Ensure the dimensional restoration values that need
 Outer Ring Restoration to be weld up drawing
 Hook Restoration  Weld along the location for restoration as per WPS.
 Seal Slot Restoration  Ensure the ampere is within 50Amp-75Amp and
interpass temperature is below 120°C.
 Grind the weld seam (the weld string) between
different passages to avoid contamination between
weld using suitable burr.
 Clean the surface between different passages using
acetone and steel wire brush.
 Put layer 0.5mm at most till the final height reach
value. Add another additional layer once the
maximum tip height reached.
 Perform spot NDT at the root and final capping.
Acceptance is 0.4mm for linear indication
Linear Indication / Erosion and  Visually check the weld prep to ensure no
corrosion / cracks / wear / porosity contamination.
/ foreign particle impact.  Clean the surface before welding using acetone.
 Weld repairs the indication.
 Grind the weld seam (the weld string) between
different passages to avoid contamination between
weld using suitable burr as per Figure 6

Figure 6: Weld Seam after welding


 Clean the surface between different passages using
acetone and steel wire brush.
 Perform spot NDT at the root and final capping.

Table 2: Welding Process

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TITLE LP DIAPHRAGM NOZZLE DOCUMENT MOS-03-003
REPAIR
APPLICATION WELDING REVISION -
AUTHOR MOHAMAD FAIZUL DATE 22 FEBRUARY 2019

Repair of Diaphragm Outer Ring Airfoil

1. Install bracing device to hold the diaphragm nozzle.

2. Weld build-up at nozzle partition using Fillerwire 309L as per Table 2.

3. Grind to contour after welding.

4. Fabricate the ring if required.

5. Carry out red dye PT on nozzle outer ring.

6. Take measurement of diaphragm nozzle after repair work like Fig 5.

G. APPENDICES

H. DOCUMENT APPROVAL
NAME & POSITION SIGNATURE DATE

Prepared By

Reviewed By

Approved By

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