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“Life Extension of Legacy Gas Turbines for Naval Propulsion”
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Grahame Martin Global Business Manager
Company Credit: Liburdi Engineering Limited, Rejuvenation (FSR ®), Safe Life Approach
Introduction
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
• Independent, highly experienced UK based dedicated gas turbine specialist since 2000
• Credible alternative to OEM gas turbine support
• Large stock-holding of Tyne and Olympus spares
• In excess of 450 years combined RR specific experience
• State-of-the-art workshop and test-bed facilities
• All services fully quality-accredited to ISO & OHSAS Standards
Legacy Gas Turbine Support For The Coming Decade
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Alba - LLTS engines / spares
21 Tyne’s - 30 Olympus
Supply chain, spares,
accessory overhaul
Competency of manpower
Life extension – coatings,
repair schemes
Maximum service
flexibility…….
Non Destructive testing
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Rigorous
Inspection criteria
FPI and MPI
Eddy Current
X-Ray
Acoustic
Thermography
Component Repair
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Dog ring, locating dog frettage
Mating receiver for turbine
entry duct
Typical rejection of parts
Components can re-worked
Component Repair
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Weld recovery & heat treatment
Successful rebuild of close tolerance components
Components repaired for service life
Component Repair
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Number 7 bearing housing salvaged
High Temp Labyrinth seal area Silver plated
Pressure tested for proven sealing capability
Component Repair
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
O/H combustion chamber
Hard facing replacement
Sealing ring location recovered
Interconnector frettage recovery
Component Repair
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Component O/H for service life
Installation tolerances restored
Head of combustion chamber ruptured
Replacement head &
securing boss installed
Component Repair
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Worn stator blades and location
Stator contacted spinning rotor
Damage sustained to
compressor rotor and beyond
Component Repair
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Recovered stator location
Replacement O/H stator
Replacement O/H compressor
on dynamic balance
Component Repair
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
There are just some components we can’t recover !!
But we do have replacements in stock !!
Rejuvenation (FSR®)
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Turbine blade life limits – extended by FSR®
Reformation of grain structure
Maintaining optimum grain size
Turbine blades can go through the FSR® up to 3 times
Rejuvenation (FSR®)
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Sets of blades have achieved 3 additional
service intervals and accumulated over
100,000 operating hours
Re-Lifing Of Critical Components
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Assess turbine discs
for: High stresses,
rotating centrifugal,
local stress
concentrations
Creep, grain
boundary wedge
cracks
Corrosion or hot
erosion
Re-Lifing Of Critical Components
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
“Safe Life” Approach
Design component
stresses
Design operating
temperature envelope
Expected material
responses
Safety factors
Calculated minimum
creep / fatigue crack
initiation point (“LIFE”)
Marine Coatings
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
IP Coat Seal Coat
K900 top coat, added protection
IGV’s coated in K900
Air Intake Casing in stove enamel
LP comp cases in stove enamel
Discs and spacers in Sermetel
Marine Coatings
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Turbine Discs and shafts in Sermetel
NGV’s and blades in IP 1041
Discs & Shafts FPI’d and MPI’d
Thermal Barrie Coatings (TBC)
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Can be applied to a number of combustion
and hot gas path components
Component surface temperature reduction
Reduces effects from hot erosion
Extends component life
Technology Innovation
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
Olympus Air start / Inner starter drive Controlled air start in non critical situations
Feature selectable
Providing life extension to internal deep strip components
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
• Gas Turbine Air Starter & Starter gearbox
• Hi Temp / Hi Pressure Air regulator
• Position feedback to controller
MicroLogix controller • Demand control for air regulating
valve • Digital & Analogue inputs /
outputs • Speed referencing • Variable ramp rate application
Ships Bridge Local control panel Switchable selection Normal or fast operation
Air supply
Start air supply
EEinS2015 - International Conference “ENVIRONMENT & ENERGY in SHIPS 2015”
“Life Extension of Legacy Gas Turbines for Naval Propulsion”
Grahame Martin [email protected]
mailto:[email protected]
“Life Extension of Legacy Gas Turbines for Naval Propulsion”IntroductionLegacy Gas Turbine Support For The Coming DecadeNon Destructive testingComponent RepairComponent RepairComponent RepairComponent RepairComponent RepairComponent RepairComponent RepairComponent RepairRejuvenation (FSR®)Rejuvenation (FSR®)Re-Lifing Of Critical ComponentsRe-Lifing Of Critical ComponentsMarine CoatingsMarine CoatingsThermal Barrie Coatings (TBC)Technology InnovationSlide Number 21Slide Number 22