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REPAIR CENTRE

REFURBISHMENT OF SIEMENS V94.2 STAGE 4 BLADE AND VANE COMPONENTS AFTER

100,000 EOH

THANARAJ SANMUGHAMTNB REMACO

23TH NOVEMBER 201617TH AUSTRALIAN GAS TURBINE CONFERANCE

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AGENDA

TNB REMACO REPAIR CENTRE AND ITS CAPABILITY

OBJECTIVE OF PROJECT

METHODOLOGY AND ISSUES

REPAIR PROCESS

CONCLUSION

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MAIN SUBSIDIARY OF TENAGA NASIONAL BERHAD

TNB REMACO REPAIR CENTRE AND ITS CAPABILITY

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REPAIR CENTRE

TNB REMACO REPAIR CENTRE – WORLD MAP

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MAIN SUBSIDAIRIES OF TENAGA NASIONAL BERHAD

TNB REMACO REPAIR CENTRE : 4 MAIN ACTIVITIES

MAINTENANCE SERVICE

REPAIR CENTRE

TEST AND DIAGNOSTICS

PROJECT AND OPERATION MANAGEMENT

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HOT GAS PATH REFURBISHMENT – MAIN DATA

Product Range: • GE/Siemens/ABB Turbine Blade,

Stationary and Combustor Parts, Bearing and Rotor On-Site Machining

Equipment: • Coating Room, Acid Stripping, Rotor

Lathe Machine, White Light Scanner, Laser Welding, EDM Die Sinker, Brazing, Vacuum Furnace, Metallurgical Lab, CMM, NC

Number of Employee: 115Workshop Total Floor Space: 95293 SQFQuality: Siemens and GE Certified Shop

ONE STOP CENTRE

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OBJECTIVE OF PROJECT

• COST SAVINGS

• OPERATE FOR ANOTHER CYCLE

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LOCATION OF ROW 4 TULA AND TULE

TULA 4> 110,000EOH

TULE 4> 152,000EOH

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Scan dataDimension inspection

METHODOLOGY AND REVERSE ENGINEERING

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DESIGN REPAIR FLOW

Visual and Metallurgical Inspection

Blasting, Heat Treatment and FPI

Dimensional Inspection / Drop Check

Blend and Welding

Post Weld, Dimensional Inspection and FPI

Brazing, Frequency Test and

Drop Check

Shot Peen and Bucket

Moment Weight

Final Delivery

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Process / Milestone

Quality Inspection

Welding WPS, WQT, VI,100%PT

Fitting / Assembly

Dimension inspection and Drop check

Heat Treatment HT Chart, Recorder calibration cert.,100%PT

Final Inspection Dimensional inspection, VI

METHODOLOGY / PREPARATION/ INSPECTION TEST PLAN

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METALLURGICAL INSPECTION FOR TULA 4

• Material: IN 939• The grain size was generally fine. • The tensile test properties were

above the expected minimum levels.

• There was no evidence of sigma phase formation.

• Able to run for another cycle

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METALLURGICAL INSPECTION FOR TULE 4

• Material: Nimonic 90• The grain size was generally fine• The stress rupture properties

were above the expected minimum levels.

• The root and 50% span microstructures appeared similar – NO CHANGES IN GAMMA PRIME

• Able to run for another cycle

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ISSUES DURING INSPECTION

DEFECTS FOUND

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REPAIR PROCESS – INCOMING INSPECTION

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DROP CHECK– FOR TULE

Drop check for Tule 4 was replicated using Siemens GT Casing – to verify the hi-low and mismatch between inner shroud

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BRAZING FOR TULE PLATFORM

Braze Process was carried out at the defective outer platform at Tule 4 as part of repair process.

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STATIONARY FREQUENCY TEST

This test was performed to ensure the repaired Tula 4 will be not in resonance mode during operation. The test results was compared with new blades

Free-free boundary Fixed boundary

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REPAIR PROCESS

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Aug Sep Oct

Refurbishment Process

DURATION OF REPAIR WORKS

Warranty: 1 year / 8000 EOH / 18 months after delivery

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CONCLUSION

• The refurbished Stage 4 Tula Tule was successfully installed in our Siemens fleet in February 2016.

• The Gas Turbine has run more than 7000 EOH without any issues.

• Similar methodology has been utilized by TNB REMACO for other parts fabrication.

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Any Questions?

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REPAIR CENTRE

Thank You