turbine & generator rotor welding to solve reliability and ......turbine & generator rotor...
TRANSCRIPT
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Turbine & Generator Rotor Welding to Solve
Reliability and Performance Issues
Tom Smith
President
T and A Consultants
April 16-17, 2013
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Rotor Welding History
• Rotor welding was developed in the U.S. in the late 1970’s
• Turbomachinery OEM’s will try and sell new rotors to customers versus repair by welding
• Thousands of rotors have been salvaged by welding damaged shaft areas and turbine wheels
• Many millions of dollars have been saved by customers & insurance companies using weld repair over the cost of new equipment and the long lead times they require
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Scored Bearing
Scored Bearing Journal
Erosion, Rubbing
Bond Failure of Coating
Interstage Packing Rubs
Typical Shaft Damage
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Submerged Arc Shaft Welding (SAW)
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Welded GT Rotor Bearing Journal & Seal Areas
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Welding With Dual Heads for Greater Deposition
Generator Shaft Weld Repair
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Generator Shaft Weld Repair
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Cracked or Broken Shafts
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Attachment of Stub Shaft Forging
The stub shaft & rotor are first joined by TIG welding and then the ”V” area is filled with SAW
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Yes, this one was repair welded with
a new stub shaft!!
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Rotor Prep
Partial Rotor Replacement
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Stub Shaft Includes the L-0 Stage Wheel
Stub Shaft Prep
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Stub Shaft Fit Up
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Narrow Groove Welding – TIG Process
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This rotor was not repaired, but could
have been
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Thrust Bearing Failure - Wheel Contacts Diaphragm
Turbine Wheel Problems
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Intergranular Cracking
Stress Corrosion Cracking (SCC)
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Circumferentially
Loaded Blades Axial Entry Blades
Boiler Compound Buildup - SCC Coming !
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SCC Starts Inside of Blade Slots
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This rotor was less than 5 years old !
SCC In Steam Balance Holes & Shaft
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Wheel failure in the sister rotor to the one in the previous slide
SCC Wheel Failure
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Scan showing multiple
cracks in the wheel
Calibration
Blocks
Phased Array UT Wheel Inspection
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Removal of Damaged Wheels
5 Complete wheels & 1 rim
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More than 2,000 lbs of Weld Wire on 14th wheel
Wheel Rim & Full Wheel Welding
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Full Wheel Weld Initial Weld Buildup
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Intermediate & Final Weld Buildup
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Rotors hung vertically
to prevent distortion
Stress Relieving Using Resistance Heaters
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Stress Relieving with Induction Heating
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Increased wheel thickness & radii
Finish Machined & Upgraded Wheels
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Upgrade Options by Welding
• Use 12Cr wire to eliminate future SCC
• Modify blade root design to lower operating stresses
• Manufacture new blades from lighter material (titanium = 30% lighter)
• Shot peen the blade roots and the blade slots in the wheel to induce compressive stresses to offset operating tensile stresses
• Any combination of the above
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Finish Welded L-0 Wheel
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Upgraded root design
lowered peak operating
stresses by 45%
Upgraded Blade Root Form
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Case Study – Geothermal Unit
• Original rating of 54 MW
• Steam field depleted
• Unit operating at 29 MW
• Removed 1st stage wheels
• Welded six wheels to modify root design
• Supplied new design blades and diaphragms
• Unit tested at 55 MW
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Both 1st stage wheels removed, welded 2nd, 3rd,
4th wheels in order to modify the blade roots
Converted from 6-Stage to 5-Stage
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Converted from 6-Stage to 5-Stage
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Wheel Welding Video
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Twisted
Airfoil
Reliability Upgrade L-0 to Integral Snubbers
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Case Study, L-0 & L-1 Blade Failures
• Repeated blade failures
• OEM changed blades from stainless to titanium with additional failures
• Removed L-0 & L-1 wheels
• Welded wheels considerably wider
• Supplied new design titanium Z-Shrouded blades
• Harmonic tuning of diaphragms to reduce blade stimulus
• Also gained 8% in unit output & improved LP end efficiency by 37%
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L-0 Blade Failures
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Welded & Machined Wheels
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Bladed Rotor
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Bent Rotor in Straightening Stand
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Stress Relief in Process Using Induction Coils
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Yoke Over Rotor During Straightening
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Thank You !!
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Weld wire? Probably not…..