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Gas Turbine Repair Technology Figure8. MetallurgicalevalutionofADHrepairon FSX-414 with base metal properties indicates that ADH- repaired nozzle trailing edges perform favor- ably. ADH is applied either in a preformed shape or as a slurry. In Figure 9, a GE I&RS re- pair technician uses a slurry-filled syringe to apply ADH to specific areas of a nozzle’s side- wall. Nozzle Modifications An additional advanced repair offering in- cludes a redesign and modification of nozzle cooling holes. Cooling hole upgrades directly improve the service life of investment cast noz- zle segments by enhancing film cooling effec- tiveness and reducing thermal-mechanical fa- tigue. These changes are implemented on the nozzle’s leading edge, pressure side, trailing edge and outer sidewall. Modification of cooling holes on pressure side airfoils and trailing edges is also accomplished with “wishbone coupon” replacements. Wish- bone coupons provide improved cooling effec- tiveness and replace distressed airfoil material with new cast material. Foreign object damage of a nozzle’s aft chord is also easily remedied with wishbone coupon replacements. Another opportunity to improve a nozzle’s effi- ciency during repair and refurbishment is to modify the inner support ring and outer retain- ing ring sealing surfaces. This is known as a chordal hinge modification and it results in a reduction in compressor discharge air leakage around the stage one nozzle. To accomplish this modification, a weld build-up is applied to the inner contact area on each segment and a new sealing surface rib is machined into the nozzle segments. A modification is also made to the flat seals which bear on the retaining ring against the stage one shroud blocks. Stages Two and Three Nozzle Repair Stage two and three nozzles are of a cantile- vered design. They are supported from the outer wall by a series of hook fits to the shroud blocks to the turbine shell. Creep damage re- sults in progressive distortion of the vane sur- faces and the outer sidewalls. Excessive down- stream deflection may result in rubs with the following rotor stage. Detection of excessive creep and resulting deflection is assessed utiliz- ing three primary measurement techniques. Diameter measurements are taken on the inner and outer wall, diaphragm and labyrinth seals. Deviations indicate downstream deflection and/or ovality. Nozzles are inserted into a fix- ture that simulates the turbine casing to check their fit-up in a turbine shell. Critical dimen- sions are taken to determine the amount of dis- tortion that nozzle has experienced and correc- tions are made. (See Figure 10.) Figure 9. Applying ADH with syringe GE Power Systems ■ GER-3957B ■ (04/01) 6PDF Image | Gas Turbine Repair Technology GE
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