FIRST / TBS Gas Turbine Rotor Consulting Capabilities End of Life Inspections

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1 Gas Turbine Rotor Consulting Capabilities End of Life Inspections 1

2 FIRST Consulting Company History FIRST = First Independent Rotor Service of Texas Company Moto = Think FIRST Before You Commit Incorporated in 2003 Company Description = Consulting Firm Industry = Industrial Gas & Steam Turbine Equipment Type = Rotating / Stationary Services Offered = Multiple Consulting Related Tasks Number of Consultants = 9 Years of Experience = 300 Man Years 2

3 FIRST Core Offerings Work Scope Development End User Rep Tech Repair Packages End of Life Testing F.E.A. Rotor Models TIL Rotor Compliance Consulting Services Tb Wheel Mfg O&M / Site Training On-Site Bkt Bld R/R Zero-Hour Packages RPM Speed Reduction In-Situ Blade Mod 3

4 TBS Technical Bolting Solutions Manufacturing Company History T.B.S. = Technical Bolting Solutions Company Moto = Think We Talk the Torque Incorporated in 2003 Company Description = Manufacturing Firm Mfg. Locations: Texas, California, South Carolina, Illinois Industry = Industrial Gas & Steam Turbine Product Type = Consumable Parts for Rotating / Stationary We currently provide over 16,000 consumable parts We are a Certified GE Manufacturing Supplier 4

5 TBS Manufacturing Outage Bolt Kits TRI Seal Pins Filling Outage RFQ s Reverse Eng, Mfg Bucket Blade Hardware F3 F/9F Rotor Bolt Kits Mfg Services Steam Turbine Bkt / Blades Gaskets Washers W F Rotor Bolting Fuel Nozzle Capitol Parts Brg Seals Oil Deflectors F/7 T/P Bracket Bolts Hyd Seals 5

6 2013 Customer Sampling 6 3

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8 Patented Products & Modifications TRI Seal Pin (Special Bucket Non-Liberating Seal Pin) (*) RPM Modification (Slowing Down Turning Gear) (*) In-Situ Compressor Rotor Blade R/R (*) 12 Point Locking Nut (Non-Crimp Style) (*) Repair Shop Training In-Place On-Site End of Life Testing On-Site Rotor Repair (Select Rotors) (Coming in 2015) ( * ) = FIRST Holds USA / International Patents 8

9 Offerings & Products The In Situ Modification Without Keys With Keys United States Patent Pending #13 /

10 Offerings & Products The In Situ Modification United States Patent Pending #13 /

11 Offerings & Products The In Situ Modification Old Blade is Removed & New Blade & Spacers Installed in +/- 8 Hours United States Patent Pending #13 /

12 Offerings & Products The In Situ Modification ESTIMATED COSTS FOR FORCED / UNPLANNED ROTOR REPAIR OUTAGE Rotor Open / Close Rotor Repair Shop Rotor Adders (30%) Type Turbine Transportation Rotor Repair Bolting Discovery Total * F/3 $200,000 $6,000 $85,000 $20,000 $24,000 $335,000 F/5 $275,000 $8,000 $175,000 $35,000 $53,000 $546,000 F/6 $315,000 $8,000 $190,000 $35,000 $57,000 $605,000 F/7 $325,000 $10,000 $250,000 $50,000 $75,000 $710,000 F/7F $480,000 $32,000 $450,000 $75,000 $135,000 $1,172,000 * Costs Do Not Include On-Site Crane or Cost to Buy Power United States Patent Pending #13 /

13 End of Life Testing Technical Information Letter #1576 TIL #1576 was issued in 2007 and it discusses the maximum allowable starts for rotors in cyclic operation and has a maximum fired hour limit for rotors in base load operation. It limits rotors to +/- 200,000 factored fired hours with some consideration of extensions and/or 5,000 factored starts for a cycle based turbine with no extensions. 13

14 End of Life Testing FIRST has developed a protocol whereas, after the rotors have been disassembled, we inspect specific rotor components using 3D volumetric phased array bore-sonics and eddy current. We perform hardness testing & replications as well as mechanical testing to inspect the rotors components for changes and internal or detrimental flaws. 14

15 EOL Testing & Computer Modeling TIL 1576 places retirement for rotors with +/- 200,000 hours or 5,000 starts. After the 2007 TIL issuance, we immediately developed our team of experts to start testing rotor components. There is a need to review found critical flaw(s) to make decisions/recommendations to turbine owners. We mfg rotor component fracture models to perform F.E.A. analysis for found critical flaw(s). By using the flaw size & flaw location, we have the ability to place those flaws into our computer model to see if the characteristic of the flaw is detrimental to the continued running of the turbine. We can accurately determine how many hours or starts remain in the life of the component containing that critical flaw. 15

16 End of Life TIL 1576 End of Life Rotor Life Extension Inspections Performed F/7B,C,E,EA = 26 F/6A,B = 2 F/5P,LA,L = 21 F3H,J,F = 2 W-501B6 = 2 To Date Total = 53 FIRST / TBS Has Completed the Largest Number of Non-OEM End of Life Rotor Inspections 16

17 Approach End of Life Testing Type of Inspections 3-D Bore Sonic Inspection for Internal Flaws Eddy Current Inspection for Creep Hardness and Replication for Grain Structure Critical Diameters Measured for Bore Shrinkage Finite Element Analysis When Flaws are Found 17

18 End of Life Testing Rotor Type = GE 5001N TIL 1576 Specific Rotor Components Tested Stages Compressor Wheels Distance Piece Stage 1 Turbine Disc Stage 2 Turbine Disc 18

19 End of Life Testing Approximate Location of Flaw - Indication 19

20 End of Life Testing Radial Deformation Results for the Turbine Section Model 20

21 End of Life Testing FIRST End of Life Testing Flaw No.5 Flaw No.4 Flaw No.3 Flaw No.2 Flaw No.1 Flaw Cluster as Determined by Phased-Array Inspection 21

22 F.I.R.S.T. End of Life Testing Sharp projection off Flaw 2 volume FIRST End of Life Testing Sharp projection off Flaw 1 volume Close-up of Flaw Cluster as Determined Shown in Previous Slide 22

23 End of Life Testing EOL On-Site Inspections In 2013, we started performing rotor end of life inspections on-site. There are many on-site critical inspection points that we can perform to assist in determining where the rotor is along the end of life scale. 23

24 End of Life Testing EOL On-Site Inspections As the rotor continues in age, it is critical to establish early, comparative, base-line data. There are critical inspections that we can perform on site to assist us in determining where the rotor is on the end of life scale. 24

25 End of Life Testing EOL On-Site Inspections We can assist end users in setting up an End of Life inspection protocol with on-site testing so to provide a clear path on your rotors remaining hours and starts. This will allow for possible extensions beyond the current OEM life limitations. 25

26 Connect With FIRST / TBS Consulting 26