TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

REFURBISHMENT OF SIEMENS
V94.2 STAGE 4 BLADE AND
VANE COMPONENTS AFTER
Hakcipta Azril Dahari
100,000 EOH
THANARAJ SANMUGHAM
TNB REMACO
23TH NOVEMBER 2016
17TH AUSTRALIAN GAS TURBINE CONFERANCE

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

AGENDA
TNB REMACO REPAIR CENTRE AND ITS CAPABILITY
Hakcipta Azril Dahari

OBJECTIVE OF PROJECT
METHODOLOGY AND ISSUES
REPAIR PROCESS
CONCLUSION

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

TNB REMACO REPAIR CENTRE AND ITS CAPABILITY

Hakcipta Azril Dahari

MAIN SUBSIDIARY
OF
TENAGA NASIONAL
BERHAD

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

TNB REMACO REPAIR CENTRE : 4 MAIN ACTIVITIES

MAINTENANCE
SERVICE

Hakcipta Azril Dahari

REPAIR CENTRE

MAIN SUBSIDAIRIES
TEST AND
DIAGNOSTICS
OF
TENAGA NASIONAL
PROJECT AND
BERHAD
OPERATION
MANAGEMENT

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
Hakcipta Azril Dahari
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: 115
Workshop Total Floor Space: 95293 SQF
Quality: Siemens and GE Certified Shop

ONE STOP CENTRE

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

OBJECTIVE OF PROJECT

COST SAVINGS
Hakcipta Azril Dahari

OPERATE FOR
ANOTHER
CYCLE

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

LOCATION OF ROW 4 TULA AND TULE

Hakcipta Azril Dahari

TULA 4
> 110,000EOH

TULE 4
> 152,000EOH

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

METHODOLOGY AND REVERSE ENGINEERING

Hakcipta Azril Dahari

Scan data

Dimension
inspection

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

DESIGN REPAIR FLOW

Visual and
Metallurgical
Hakcipta
Azril Dahari
Inspection

Final Delivery

Blasting, Heat
Treatment
and FPI

Dimensional
Inspection /
Drop Check

Blend and
Welding

Shot Peen
and Bucket
Moment
Weight

Brazing,
Frequency
Test and
Drop Check

Post Weld,
Dimensional
Inspection
and FPI

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

METHODOLOGY / PREPARATION/ INSPECTION TEST

PLAN

Process /
HakciptaMilestone
Azril Dahari
Welding

Quality Inspection
WPS, WQT, VI,100%PT

Fitting /
Dimension inspection and Drop check
Assembly
Heat Treatment HT Chart, Recorder calibration
cert.,100%PT
Final Inspection Dimensional inspection, VI

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

METALLURGICAL INSPECTION FOR TULA 4

Hakcipta Azril Dahari

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

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

METALLURGICAL INSPECTION FOR TULE 4

Hakcipta Azril Dahari

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

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

ISSUES DURING INSPECTION

Hakcipta Azril Dahari

DEFECTS
FOUND

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

Hakcipta Azril Dahari

Drop check for Tule 4 was replicated using Siemens GT Casing to

verify the hi-low and mismatch between inner shroud

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

BRAZING FOR TULE PLATFORM

Hakcipta Azril Dahari

Braze Process was carried out at the defective outer platform at Tule
4 as part of repair process.

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

STATIONARY FREQUENCY TEST

Hakcipta Azril Dahari

Free-free boundary

Fixed boundary

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

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

REPAIR PROCESS

Hakcipta Azril Dahari

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

DURATION OF REPAIR WORKS

Aug
Hakcipta Azril Dahari

Sep

Oct

Refurbishment Process

Warranty: 1 year / 8000 EOH / 18 months after delivery

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

CONCLUSION

The refurbished Stage 4 Tula Tule was

successfully installed in our Siemens fleet in
Hakcipta Azril Dahari
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.

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

Hakcipta Azril Dahari

Any Questions?

TNB REPAIR AND MAINTENANCE SDN. BHD.

REPAIR CENTRE

Hakcipta Azril Dahari

Thank You