RotoR Life

ManageMentAdvanced, OEM engineering assessment, inspection, and repairs to enable operation beyond original design life

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add yeaRs to youR RotoR’s Life

Rotors are the highest-energy components in a gas turbine, are critical to performance, and are subjected to extreme mechanical stresses and high temperatures over their operating life. Their integrity can be negatively impacted by operating issues such as corrosion and undetected vibration; but even normal operation will gradually diminish their structural integrity over time. So each rotor is designed for a finite lifespan measured in factored fired hours (FFH) and factored fired starts (FFS).

Exceeding the recommended design life, or not adhering to specified inspection intervals and maintenance activities can put your turbine at risk of failure that could cause extensive damage to your turbine and adjacent assets, and serious injury to your personnel.

But every turbine’s operating life is unique—so it is possible for a rotor to safely and effectively operate beyond its original design life, if the proper assessments and preparations are performed.

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Advanced, condition-based solutionThe specialized Rotor Life Management (RLM) service from Baker Hughes, a GE company (BHGE), is the best way to determine if your rotor meets the requirements, or if specific repairs could enable extended operation. RLM combines inspection results with a dedicated design analysis based on the actual condition of the rotor, specific unit configuration, operating history, and prior maintenance history at the inspection interval.

Key benefits

• Possible life extension up to two major inspection cycles

• Reduced operating costs through proven life-extending repairs

• Reduced or postponed CAPEX by avoiding current rotor replacement

Components covered

• Turbine wheels

• Shafts

• Compressor disks

Compressor blades are typically removed to allow a complete analysis of the disks. Turbine buckets, cover plates, and consumable parts (bolts, nuts, twist locks, tie rods, damper pins), will be maintained or replaced as determined by the RLM assessment.

applicability

The RLM service can be performed on a range of gas turbine models. Please contact us (oilandgas.rotorlife@bhge.com) to verify its applicability to your machine.

Engineering assessmentBHGE has robust knowledge of rotating equipment design and specification, and a strong technical heritage for machine maintenance. Connection to our iCenter analytics and other networked digital services feeds operational and condition-based data to continually improve our in-house risk-assessment capabilities, which include:

• Operational history

• Maintenance practices

• Material properties

• Model development

Inspection and repairWe will perform a rotor inspection, including disassembly and complete teardown of the rotor in an authorized BHGE service shop. This enables thorough analysis of all rotor components in both compressor and turbine sections. The analysis is performed by a fully certified and highly experienced OEM inspection team, using advanced algorithms and material data to identify potential subsurface defects that may have developed during operation.

disassembly and non-destructive tests

• Dimensional inspection

• Fluorescent penetrant inspection

• Hardness test of turbine and compressor disks

• Magnetic particle testing

• Ultrasonic testing

• Boresonic testing of disk bores

• Eddy current testing

• Array eddy current testing

• Metallography/replication of turbine and compressor disks

Repair and assembly

• Servicing (coating)

• Manufacturing replacement parts

• Restacking

• Balancing

Rotor Life Management (RLM) process

finite element modelsBase material propertiessubcomponent condition

RLM input

Database

Custom analysis

RLM output

Rotor history data: accumulated fired hours, total startups, accumulated trips/hot restarts, turbine wheel space temperatures, and historical operating data

Base material database (new and serviced): fracture toughness,

strain controlled fatigue (SCF), fatigue crack

growth (FCG), creep crack growth (CCG), etc.

Field data from RM&D

Physics-based predictive models (transient thermal

run, mechanical DOEs—normal and steady-state), for

failure modes.

Recommendations (use, repair or replace for each rotor component) and Rotor life extension limitation, in terms of residual factor fired hours and factored fired starts, and next rotor inspection

Gas turbine machine design analysis(Monte Carlo simulation)

Standard and additional inspection

(dedicated equipment)

Copyright 2018 Baker Hughes, a GE company, LLC (“BHGE”). All rights reserved. The information contained in this document is company confidential and proprietary property of BHGE and its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced, altered, or used for any purpose without the express written consent of BHGE.

Baker Hughes reserves the right to make changes in specifications and features shown herein, or discontinue the product described at any time without notice or obligation. Contact your BHGE representativeforthemostcurrentinformation.TheBakerHugheslogoisatrademarkofBaker Hughes,a GE company, LLC. GE and the GE Monogram are trademarks of the General Electric Company.

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about our company

Baker Hughes, a GE company (BHGE), is the world’s first and only fullstream provider of integrated oilfield products, services, and digital solutions. Drawing on a storied heritage of invention, BHGE harnesses the passion and experience of its people to enhance productivity across the oil and gas value chain.

BHGE helps its customers acquire, transport, and refine hydrocarbons more efficiently, productively, and safely, with a smaller environmental footprint and at lower cost per barrel. Backed by the digital industrial strength of GE, the company deploys minds, machines, and the cloud to break down silos and reduce waste and risk, applying breakthroughs from other industries to advance its own.

With operations in over 120 countries, the company’s global scale, local know-how, and commitment to service infuse over a century of experience with the spirit of a startup—inventing smarter ways to bring energy to the world.

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