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FIRST / TBS

Gas Turbine Rotor

Consulting Capabilities

End of Life Inspections

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FIRST Consulting Company

History

FIRST = First Independent Rotor Service of Texas

Company Moto = Think “FIRST” Before You Commit

Incorporated in 2003

Company Description = Consulting Firm

Industry = Industrial Gas & Steam Turbine

Equipment Type = Rotating / Stationary

Services Offered = Multiple Consulting Related Tasks

Number of Consultants = 9

Years of Experience = 300 Man Years

FIRST

Core Offerings

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Consulting Services

Work Scope

Development

TIL Rotor

Compliance

O&M / Site Training

On-Site Bkt Bld R/R

Zero-Hour Packages

RPM Speed Reduction Tb Wheel

Mfg

In-Situ Blade Mod

End of Life

Testing

F.E.A. Rotor Models

End User

Rep

Tech Repair Packages

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TBS

Technical Bolting Solutions

Manufacturing Company

History

T.B.S. = Technical Bolting Solutions

Company Moto = Think “We Talk the Torque”

Incorporated in 2003

Company Description = Manufacturing Firm

Mfg. Locations: Texas, California, South Carolina, Illinois

Industry = Industrial Gas & Steam Turbine

Product Type = Consumable Parts for Rotating / Stationary

We currently provide over 16,000 consumable parts

We are a Certified GE Manufacturing Supplier

TBS

Manufacturing

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Mfg

Services

Outage Bolt

Kits

Filling Outage RFQ’s

Reverse

Eng, Mfg

Steam Turbine

Bkt / Blades

Gaskets Washers

Brg Seals

Oil Deflectors

Fuel Nozzle Capitol Parts

F/7 T/P Bracket Bolts

Hyd Seals

F3 – F/9F Rotor Bolt Kits

W-191- 501F Rotor Bolting

TRI Seal Pins

Bucket Blade Hardware

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FIRST / TBS

2013 Customer Sampling

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FIRST / TBS

Patented Products & Modifications

TRI Seal Pin (Special Bucket Non-Liberating Seal Pin) (*)

RPM Modification (Slowing Down Turning Gear) (*)

In-Situ Compressor Rotor Blade R/R (*)

12 Point Locking Nut (Non-Crimp Style) (*)

Repair Shop Training

In-Place On-Site End of Life Testing

On-Site Rotor Repair (Select Rotors) (Coming in 2015)

( * ) = FIRST Holds USA / International Patents

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FIRST / TBS

Offerings & Products

Without Keys With Keys

“The In Situ Modification”

United States Patent Pending #13 / 091864

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United States Patent Pending #13 / 091864

FIRST / TBS Offerings & Products

“The In Situ Modification”

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FIRST / TBS

Offerings & Products

“The In Situ Modification”

Old Blade is Removed & New Blade & Spacers Installed in +/- 8 Hours

United States Patent Pending #13 / 091864

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FIRST / TBS

Offerings & Products

“The In Situ Modification”

ESTIMATED COSTS FOR FORCED / UNPLANNED ROTOR REPAIR OUTAGE

Rotor Open / Close Rotor Repair Shop Rotor Adders (30%)

Type Turbine Transportation Rotor Repair Bolting Discovery Total *

F/3 $200,000 $6,000 $85,000 $20,000 $24,000 $335,000

F/5 $275,000 $8,000 $175,000 $35,000 $53,000 $546,000

F/6 $315,000 $8,000 $190,000 $35,000 $57,000 $605,000

F/7 $325,000 $10,000 $250,000 $50,000 $75,000 $710,000

F/7F $480,000 $32,000 $450,000 $75,000 $135,000 $1,172,000

* Costs Do Not Include On-Site Crane or Cost to Buy Power

United States Patent Pending #13 / 091864

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FIRST / TBS

End of Life Testing

Technical Information Letter #1576

TIL #1576 was issued in 2007 and it discusses

the maximum allowable starts for rotors in cyclic

operation and has a maximum fired hour limit

for rotors in base load operation.

It limits rotors to +/- 200,000 factored fired hours

with some consideration of extensions and/or

5,000 factored starts for a cycle based turbine

with no extensions.

FIRST / TBS

End of Life Testing

FIRST has developed a protocol whereas, after

the rotors have been disassembled, we

inspect specific rotor components using 3D

volumetric phased array bore-sonics and eddy

current.

We perform hardness testing & replications as

well as mechanical testing to inspect the rotors

components for changes and internal or

detrimental flaws. 14

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FIRST / TBS

EOL Testing & Computer Modeling TIL 1576 places retirement for rotors with +/- 200,000 hours

or 5,000 starts. After the 2007 TIL issuance, we immediately

developed our team of experts to start testing rotor

components. There is a need to review found critical flaw(s)

to make decisions/recommendations to turbine owners. We

mfg rotor component fracture models to perform F.E.A.

analysis for found critical flaw(s).

By using the flaw size & flaw location, we have the ability to

place those flaws into our computer model to see if the

characteristic of the flaw is detrimental to the continued

running of the turbine. We can accurately determine how

many hours or starts remain in the life of the component

containing that critical flaw.

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FIRST / TBS

End of Life

TIL 1576 End of Life Rotor Life Extension

Inspections Performed

F/7B,C,E,EA = 26

F/6A,B = 2

F/5P,LA,L = 21

F3H,J,F = 2

W-501B6 = 2

To Date Total = 53

FIRST / TBS Has Completed the Largest Number of Non-OEM

End of Life Rotor Inspections

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FIRST / TBS Approach

End of Life Testing

Type of Inspections

3-D Bore Sonic Inspection for Internal Flaws

Eddy Current Inspection for Creep

Hardness and Replication for Grain Structure

Critical Diameters Measured for Bore Shrinkage

Finite Element Analysis When Flaws are Found

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FIRST / TBS

End of Life Testing

Rotor Type = GE 5001N

TIL 1576 Specific Rotor Components Tested

Stages 13 - 16 Compressor Wheels

Distance Piece

Stage 1 Turbine Disc

Stage 2 Turbine Disc

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3.80”

4.30”

Approximate Location of Flaw - Indication

FIRST / TBS

End of Life Testing

20 Radial Deformation Results for the Turbine Section Model

FIRST / TBS

End of Life Testing

21 Flaw Cluster as Determined by Phased-Array Inspection

Flaw No.1

Flaw No.2

Flaw No.3

Flaw No.4

Flaw No.5 FIRST

End of Life Testing

FIRST / TBS

End of Life Testing

22 Close-up of Flaw Cluster as Determined Shown in Previous Slide

Sharp projection off Flaw 1 volume

Sharp projection off Flaw 2 volume

FIRST

End of Life Testing

F.I.R.S.T.

End of Life Testing

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FIRST / TBS

End of Life Testing

EOL On-Site Inspections

In 2013, we started performing rotor end of life

inspections on-site.

There are many on-site critical inspection points

that we can perform to assist in determining

where the rotor is along the end of life scale.

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FIRST / TBS

End of Life Testing

EOL On-Site Inspections

As the rotor continues in age, it is critical to

establish early, comparative, base-line data.

There are critical inspections that we can

perform on site to assist us in determining

where the rotor is on the end of life scale.

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FIRST / TBS

End of Life Testing

EOL On-Site Inspections

We can assist end users in setting up an End of

Life inspection protocol with on-site testing so

to provide a clear path on your rotors’ remaining

hours and starts.

This will allow for possible extensions beyond

the current OEM life limitations.

Connect With

FIRST / TBS Consulting

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