Thanaraj Sanmugham - TNB

Hakcipta Azril Dahari

TNB REPAIR AND MAINTENANCE SDN. BHD.

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



REPAIR CENTRE

AGENDA

TNB REMACO REPAIR CENTRE AND ITS CAPABILITY

OBJECTIVE OF PROJECT

METHODOLOGY AND ISSUES

REPAIR PROCESS

CONCLUSION



REPAIR CENTRE

MAIN SUBSIDIARY OF TENAGA NASIONAL BERHAD

TNB REMACO REPAIR CENTRE AND ITS CAPABILITY



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



REPAIR CENTRE

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



REPAIR CENTRE

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



REPAIR CENTRE

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



REPAIR CENTRE

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



REPAIR CENTRE

ISSUES DURING INSPECTION

DEFECTS FOUND



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REPAIR PROCESS – INCOMING INSPECTION



REPAIR CENTRE

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



REPAIR CENTRE

BRAZING FOR TULE PLATFORM

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



REPAIR CENTRE

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



REPAIR CENTRE

REPAIR PROCESS



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Aug Sep Oct

Refurbishment Process

DURATION OF REPAIR WORKS

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



REPAIR CENTRE

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.



REPAIR CENTRE

Any Questions?



REPAIR CENTRE

Thank You

Thanaraj Sanmugham - TNB

Engineering

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