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Gas Turbine Repair Technology Component Enhancement ExtendorTM GE has established a protective package, the Extendor Wear Kit, that addresses the most common areas of wear on liners, transition pieces and fuel nozzles (See GEA 12276). Kits are available for Frame 6B, 7E/EA and 9E com- bustion systems, whose units typically run in baseload applications. Wear points throughout the combustion system are modified, including transition piece “H” blocks and bullhorn brack- ets, floating and end seal slots, and liner inter- face. The liner modifications include the fuel nozzle and crossfire collars, liner stops and spring seal. Flow sleeves, fuel nozzles and some crossfire tubes are also modified. The major GE service centers have been qualified to make all of the wear enhancing modifications to the combustion components. Special fixtures are used to position the modification and replace- ment parts for optimal fit in the turbine. Coatings Compressor Corrosion Protection Protective coatings used on heavy-duty gas tur- bine compressors are divided into two classes: barrier coatings and sacrificial coatings. Barrier coatings isolate the corrosive environment from the steel substrate, while the sacrificial coatings provide a reservoir of reactive metal in a gal- vanic couple. To avoid potential failure scenar- ios from single layer coatings, GE’s preferred repair for corrosion protection utilizes both a non-conductive barrier coating over a sacrificial coating. The barrier coating prevents the sacri- ficial coating from continually reacting with the environment, while the sacrificial coating pro- tects the base metal from attack in the event of barrier coating breach. If a breach occurs, the barrier coating limits the corrosion cell to the breach area. The dual layer coating consists of a sprayed-on aluminum-based layer that is burnished to make it conductive, followed by a ceramic-based top layer that forms the barrier. (See Figure 25.) These coatings have been applied to individual blades and wheels or to fully bladed and stacked rotors. Turbine Corrosion/Oxidation If a turbine bucket’s external coating is breached or compromised, the bucket requires a repair coating to protect the nickel-base alloy from oxidation and corrosion attack. The met- allurgical evaluation discussed previously deter- mines the extent of distress and whether the bucket is repairable. A chemical stripping proc- ess is employed to remove all of the serviced coatings on repairable buckets. Any welding, dimensional restoration and sub- sequent processing is performed on buckets in this stripped condition. GE reapplies its pat- ented Extendcoat GT-29TM or Extendcoat GT- 33TM chemistries using a proprietary thermal spray process. These coatings provide a surface reservoir of elements that form protective and adherent oxide layers, thus protecting the un- derlying base metal from oxidation and corro- sion attack and degradation. The primary coat- ing applications are listed in Table 5. By virtue of its higher aluminum and nickel contents rela- Figure 25. Compressor airfoil coated with GECC-1 GE Power Systems ■ GER-3957B ■ (04/01) 15PDF Image | Gas Turbine Repair Technology GE
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