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Repair and Rejuvenation of a Severely Damaged 16-Stage Steam Turbine Rotor

[+] Author Affiliations
S. Ingistov

BP/WCC, Carson, CA

R. K. Bhargava

Foster Wheeler USA Corp., Houston, TX

G. Doerksen

Sulzer Turbo Services, Houston, TX

Paper No. GT2009-60006, pp. 677-684; 8 pages
  • ASME Turbo Expo 2009: Power for Land, Sea, and Air
  • Volume 4: Cycle Innovations; Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Marine
  • Orlando, Florida, USA, June 8–12, 2009
  • Conference Sponsors: International Gas Turbine Institute
  • ISBN: 978-0-7918-4885-2 | eISBN: 978-0-7918-3849-5
  • Copyright © 2009 by ASME


This paper describes the recent experience with the extensive overhaul and repairs of a long and flexible 16-stage steam turbine rotor of an integral design. An integral design steam turbine rotor is one where the shaft and disks are machined from a single forging. The steam turbine had sustained a crack at the base of the 11th stage disk as well as moderate to extensive corrosion pitting throughout the center section (stages 5 to 8) of the rotor. The rim of the 6th stage disk also required rebuilding because of the excessive damage due to corrosion and pitting. The steps required to optimize the repair process and minimize repair time as well as precautions taken during the repairs are discussed in this paper. To ensure reliability of the rebuild work, including newly manufactured blades for the 6th stage disk, stress analysis using Finite Element Method (FEM) was used to verify that stress levels are within acceptable limits in the blade’s root-to-dovetail groove, the results of such an analysis are included here. Finally, results of high speed balancing, critical for such a large flexible rotor are presented and discussed. This repair and rejuvenation work allowed salvaging the severely damaged rotor in approximately 5 months (compared to up to 2 years delivery for a new rotor) and at about one-fourth the rotor replacement cost.

Copyright © 2009 by ASME



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