Thanaraj Sanmugham - TNB
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Transcript of 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
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
AGENDA
TNB REMACO REPAIR CENTRE AND ITS CAPABILITY
OBJECTIVE OF PROJECT
METHODOLOGY AND ISSUES
REPAIR PROCESS
CONCLUSION
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
MAIN SUBSIDIARY OF TENAGA NASIONAL BERHAD
TNB REMACO REPAIR CENTRE AND ITS CAPABILITY
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
TNB REMACO REPAIR CENTRE – WORLD MAP
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
MAIN SUBSIDAIRIES OF TENAGA NASIONAL BERHAD
TNB REMACO REPAIR CENTRE : 4 MAIN ACTIVITIES
MAINTENANCE SERVICE
REPAIR CENTRE
TEST AND DIAGNOSTICS
PROJECT AND OPERATION MANAGEMENT
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
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
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
OBJECTIVE OF PROJECT
• COST SAVINGS
• OPERATE FOR ANOTHER CYCLE
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
LOCATION OF ROW 4 TULA AND TULE
TULA 4> 110,000EOH
TULE 4> 152,000EOH
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
Scan dataDimension inspection
METHODOLOGY AND REVERSE ENGINEERING
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
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
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
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
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
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
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
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
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
ISSUES DURING INSPECTION
DEFECTS FOUND
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
REPAIR PROCESS – INCOMING INSPECTION
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
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
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
BRAZING FOR TULE PLATFORM
Braze Process was carried out at the defective outer platform at Tule 4 as part of repair process.
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
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
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
REPAIR PROCESS
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
Aug Sep Oct
Refurbishment Process
DURATION OF REPAIR WORKS
Warranty: 1 year / 8000 EOH / 18 months after delivery
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
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.
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
Any Questions?
Hakcipta Azril Dahari
TNB REPAIR AND MAINTENANCE SDN. BHD.
REPAIR CENTRE
Thank You