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Gas Turbine Repair Technology Figure 1. Stress cracked bucket internal defects can hide, destructive sample analysis can provide valuable information about the set component condition and the repair workscope. For example, it enables the charac- terization of internal cooling passage micro- structure, which may differ from the behavior of the external material. In addition, crack depths can be accurately determined. Furthermore, the information gathered during destructive analyses can be studied together with the gas turbine running conditions to help identify critical operating parameters. The cus- tomer is thereby able to optimize future operat- ing conditions for enhanced performance, as well as improve the prediction of future repair process schedules on the hardware. A complete repair scope is determined only after rigorous analysis of all inspection data. It is interesting to note that not all serviced or dam- aged components are candidates for repair. Some components are damaged beyond GE- prescribed repair limits. Since all gas turbine components have a finite life, the cost of repair or replacement and the component’s future life expectancy are integrated into the engineering repair recommendations. Component Repairs With new technologies being implemented in the gas turbine world, component repair is an ever-changing challenge. The effort toward increased operating efficien- cy and decreased heat rate requires that re- paired components conform closely with origi- nal equipment manufacturer’s (OEM) drawing requirements and specifications. With that in mind, the need for consistent repair practices throughout the service organization has be- come a top company priority. The sharing of piece-part qualifications, best practices, process- es and procedures, fixtures and tooling has be- come more critical than ever. Each repair is engineered to provide the cus- tomer with maximum benefit while balancing cost and cycle times. A multi-organizational en- gineering review and approval process is re- quired by the GE Service Centers before a new repair is implemented. This ensures that critical design and life-enhancing features are checked and re-checked. Each service center documents a new repair in a Manufacturing Process Plan (MPP). This outlines the repair procedures and “freezes” the process so that the repairs are ro- bust and reproducible. GE’s internal audit team reviews each package and requires rigorous test- ing before approval and release is issued. These procedures are in keeping with the ISO 9000 standards embraced by GE and its repair organ- izations. Nozzles Stage One Nozzle There are several nozzle failure modes associat- ed with the high temperature environment of GE Power Systems ■ GER-3957B ■ (04/01) 3PDF Image | Gas Turbine Repair Technology GE
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