sssueo| ! REPAIR BLENDING _G.T. ROTATING AND STATIONARY BLADES PART IIL ~ BLENDING LIMITS OF ACCEPTANCE FOR COMPRESSOR ROTATING BLADES 0 _-- GLADE TIP (GOTH EDGES) BLEND OUT 27 CRACKS , DENTS To LIMITS SHOWN 50y. OF ORIGINAL TIP MUST REMAIN, GLADE SURFACE - OUTER SECTION: BLEND QUT SMALL CRACKS, WICKS TO A DEPTH NOT EXCEEDING 0,010" _-— OUTER SECTION C-C: BLEND OUT CRACKS, DEFECTS, DENTS FROM EDG AND PROFILE TIP TO ADEPTH NOT EXCEEDING 1/8", SEE BLENDING PART I-A u- TREAT CRITICAL SECTION 8-8 — —~ RagIUS, FILLET, LEADING AND TRAILING EDGE BLADE SURFACE WITH CAUTION - BLEND TO 0.005" MAX, DEPTH (SMALL CRACKS , DENTS), 4 37327.05 NO DEFECTS CRACKS, DENTS PERMITTED 1 OR AT EDGE OF SLOT ~ NO SLENDING PERMITTED MOTE: 00 NOT BLEND TO A DEPTH EXCEEDING 25% BLADE THICKNESS BASE & ENDS ~ BLE! oul CRACKS, DEFECTS 10 1/32" MAX, DEPTH - SMALE NICKS & OENTS WHICH ARE LESS Tuan 1/32" DEPTH ARE ACCEPTABLE Lester Divisions Westinghouse Electric Corporation, Lester, Pa., U.S.A. ‘Standards Engineering 37327.05'ssueo | sare SREPAIR BLENDING GT. ROTATING AND STATIONARY i 37327.05 BLADES a 4 WK 1/32" DEPTH ARE ACCEPTABLE 7 NOTE: 00 NOT SEXO TO ADEPTH EXCEEDING 25%. BLADE THICKNESS wy 74 953 003 PART Ill ~ BLENDING LIMITS OF ACCEPTANCE FOR COMPRESSOR ROTATING BLADES GLADE TIP (BOTH EDGES ) BLEND OUT CRACKS , DENTS TO LIMITS SHOWN 507. OF ORIGINAL TIP MUST REMAIN BLADE SURFACE - OUTER SECTION: BLEND OUT SMALL CRACKS, NicKS TO A DEPTH NOT EXCEEDING 0.010 QUTER SECTION ¢-C: BLEND OUT AND PROFILE TIP To A DEPTH NOT EXCEEDING 1/8". SEE BLENDING PART 1-A \/ / A | | | | TREAT CRITICAL SECTION 8-8 RADIUS, FILLET, LEADING AND. ae YaalLinic EDGE SLADE SURFACE WITH CAUTION - BLEND 70 a} 0,003" nak, DEPTH SMALL — CRACKS» ENTS) SS oS es \ \ No DEFECTS CRACKS, ENTS ——_GaSE & Ew5 -aLEND OUT —_ Vy PERMITTED FLOR AT EOGE OF CRACKS, DEFECTS 10 1/32) SCOT NO ELENDING PERMNTTED. MAX. DEPTH ~ SMALL NICKS & DENTS WHICH ARE LESS Thad Westinghouse Electric Corporation, Lester, Pa., U.S.A. Lester Divisions 1 37327.05 == Standards Engineering‘ssuto REPAIR BLENDING GT. ROTATING AND STATIONARY BLADES 1 37327.05 NOTE: ag iA ws PART It] ~ BLENDING LIMITS OF ACCEPTANCE FOR COMPRESSOR ROTATING BLADES GLADE TIP (GOTH EDGES) BLEND OUT CRACKS . DENTS To LIMITS SHOWN 500%, OF ORIGINAL TP MUST REMAIN BLADE SURFACE - OUTER SECTION BLEND OUT SMALL CRACKS, NICKS 10 A DEPTH NOT EXCEEDING 0.010" OUTER SECTION C-c: BLEND OUT ——— CRACKS, DEFECTS, DENTS FROM EDGES AND PROFILE TIP To A DEPTH NOT EXCEEDING 1/3", SEE BLENDING TREAT CRITICAL SECTION B-8 RADIUS, FILLET, LEADING AND TRAILING EDGE BLADE SURFACE WITH CAUTION ~ BLEND TO 0.005" WAX. DEPTH (SMALL, CRACKS , DENTS). NO DEFECTS CRACKS, DEWTS PERMITTED #1 OR AT EDGE OF SLOT ~ RO SLENDING PERMITTED. BASE & ENDS - BLEND OUT CRACKS, DEFECTS 10 1/32 WAX. DEPTH ~ SMALL RICKS & DENTS WHICH ARE LESS THaN 1/32" DEPTH ARE ACCEPTABLE DO NOT ELEXD TO A DEPTH EXCEEDING 25%. BLADE THICKNESS Westinghouse Electric Corporation, Lester, Pa., U.S.A. Lester Divisions Standards Engineering £ 37327.05JOVINVG dil 4O ONINLHOIVYLS G109 83ND! A Ko ™ | De VEY NATO. aamoriv Suivase GVM ‘310N ‘SUM 0¢ > STW ot > SUW oF > ld Notsoussoo ®’a04 'SHOWYO NOS SLIATT "3OVWWVa 40 Svauy ‘ONIMOHS avs NOSSINANOD “AL. 4b 3unOId He 208 oH oe sulin doTivos Thorn aNvA suanyoo 347014 730 486 ONsTa i mt { axe | AHOISH aNYA ji A He i stv=.a. ~~ . aa ¥anss coowners Suva] Sa wvHO NOG ‘AS OSAOUAAY| Zo0eT S1va Tsa0n 2 AB “TINA WAWOISNO| vera NAO! 35. W30 #801] waZ1ns NOILvolsIoadS IVETE davi1a YyoOssaudWoo'ssueo za 4 BLADES REPAIR BLENDING -&7, ROTATING AND STATIONARY yi 37327.05 f iS into PART IN| ~ BLENDING LIMITS OF ACCEPTANCE FOR COMPRESSOR ROTATING BLADES BLAQE TIP (GOTH EDGES) BLEND OUT CRACKS , DENTS To LiniTS SHOWN 50% OF ORIGINAL TIP MUST REMAIN BLADE SURFACE - OUTER SECTION BLEND OUT SMALL CRACKS, NICKS OA DEPTH NOT EXCEEDING 0.010" OUTER SECTION C-c: BLEND OUT ——— CRACKS, DEFECTS, DENTS FROM EDGES AND PROFILE TIP To DEPTH NOT EXCEEDING 1/8", SEE BLENDING PART 1-8 TREAT CRITICAL SECTION 8-8 RADIUS, FILLET, LEADING AND TRAILING EDGE BLADE SURFAC: WITH CAUTION - BLEND TO 0.005" MAX, DEPTH (SMALL CRACKS , DENTS) NO DEFECTS CRACKS, DENTS GASE & ENDS - BLEND OUT ~S_. PERMITTED 108 AT EDGE OF CRACKS, DEF ECTS 10 1/32 SLOT ~ nO SENDING PERMITTED, MAX. DEPTH - SMALL NICKS & DENTS wuicH ARE LESS THAN 1/32" DEPTH ARE ACCEPTABLE NOTE: 00 NOT BLE TO A DEPTH EXCEEDING 25% BLADE THICKNESS Westinghouse Electric Corporation, Lester, Pa., U.S.A. Lester Divisions Standards Engineering * 37327.05eove skaven anes A DIMENSION. SecTion a-a a Ae o x spoucaace ase a Baek v0 scene AURFOIL ROOT Cao raeevolae ntl as Figure MI-25 Dent in Leading Edge of Blade. << ——_, Figure MI-24 Typical Compressor Blade Showing stern bs Areas of Damage. Figure MI26 Dent in Trailing Edge of Blade. inne a ae Fisure ML27 Cold Straightening of Tip Damage.1 1 ‘TABLE MI-2 COMPRESSOR BLADING INSPECTION AND REPAIR CRITERIA BLADE CONDITION Bends Blades bent ‘Tips bent Bent airfoil Cracks Blade fatigue crack in any area of blade Blade cracks due to foreign object damage any area of blade EROSION AND CORROSION Corrosion Evidenced by general wasting and pitting. Knife edges at leading and trailing edges. Erosion Evidenced by loss of blade contour. Knife edge conditions. ALLOWABLE LIMITS Up to 10% of the airfoil height from the tip and less than 25% of the chord length. Up to 15% of vane length along tip and a maximum of 60 degress deflection. See Figure MI-27. Not acceptable, No allowable limits. No allowable limits, Loss of 10% of cross sectional area or pit marks 0.015 inch deep or greater. Loss of 10% of eross- sectional area or an unacceptable loss of performance. 4c-4d CORRECTIVE ACTION Cold straighten above pitch line and dye penetrant inspect. Replace if bent below pitch line. Hot straightening is NOT allowed. See Figure MI-24. Cold straighten and aye penetrant inspect. Replace. Replace cracked blade, Replace eracked blade. Replace blade. Replace blade.COMPRESSOR BLADING INSPECTION AND REPAIR CRITERIA (CONT'D) BLADE CONDITION NICKS AND DENTS Foreign Object Damage ‘Small nicks or dents around leading edge or blade. Dents 1. Dents in area around leading edge of blade above and be- low piteh line 2. Dents in area of trailing edge above and below piteh line 3. Dents in both leading and trailing edges. 4, Dents in vane section other than leading and trailing edge Airfoil Damage 1. Dents and nicks on the leading and trailing edge ALLOWABLE LIMITS 0.050 inch diameter or less ‘by 0.020 inch deep. Stages 1 Through 4* One dent D in depth and diameter of 5 times D. Maximum allowable D equal to 0.160 inch. See Figure MI-24 and MI-25. One dent D in depth and diameter of 5 times D. Maximum allowable D equal to 0.160 inch. See Figures MI-25 and MI-26. ‘Combination of condition not to exceed D equal to 0.160 inch above and 0-080 inch below the piteh line. Two 0.040 inch deep above the pitch line. One 0.040 inch deep below the piteh line. *For Stages 5 through 7 use 15% of dimension eriterie, ie., 0.160 inch becomes 0.120 inch. For Stages 8 through final stage use 50% of dimensional criteria. Dents and nieks located above the pitch line and having @ surface area of less than 0.020 inch per inch of blade chord and less than 0,050 inch deep. CORRECTIVE ACTION Should be left alone, no action necessary. Blend out to original contour and polish to a 32 finish or better. Dye penetrant inspect. Radius the edge and polish to @ 32 finish or better. Dye Penetrant inspect. See Figure MI-26. Blend out and radius the edge. Dye penetrant inspect. See Figures MI-25 and MI-26. Polish smooth to remove Toughness, remove as little metal as possible. Dye penetrant inspect. Acceptable, however to ensure smooth air flow, the high metal should be blended and dye pene- trant inspeeted.COMPRESSOR BLADING INSPECTION AND REPAIR CRITERIA (CONT'D) BLADE CONDITION ALLOWABLE LIMITS CORRECTIVE ACTION NICKS AND DENTS (Cont'd) Airfoil Root Damage ‘Dents, nicks or tears in Not acceptable. Replace. the airfoil root section including the fillet radius. See Figure MI-24, 40-46GENERAL @@ ELECTRIC Turbine Marketing and . Projects Operation Customer Service Department Tredneal aformation Letter He, 1004-3 3. Pope. h -75h oa {3 eee LiL Dyer arr STATOR/ROTOR BLADE INLET GUIDE VANE 125" T MAXIMUS CORROSION PIT WIDTH - MILS (MM) 1 a ZONE | Rotor | Rotor | Stator | Stator 1-5 6-17 1-5 17 & TGV ! | ‘ | 1 1 60(1.52) | 40(1.02) | 90(2.29) | 60(1.52) | 90(2.28) | 70(1.78) | 120(3.05) | 90(2.29) | 1 1 {| 120(3.05) | 100(2.54) | 150(3.81) | 130(3.30) 1 90(2.29) | 150(3.81) Figure 1 - Corrosion Limits csp 1018L 2 3. 2 1 CSE Tai 1065 7 TABLE MI-2 COMPRESSOR BLADING INSPECTION AND REPAIR CRITERIA BLADE CONDITION Bends Blades bent Tips bent Bent airfoil Cracks Blade fatigue crack in any area of blade Blade cracks due to foreign object dsmage any area of blade EROSION AND CORROSION Corrosion Evidenced by general Wasting and pitting. Knife edges at leading and trailing edges. Erosion Evideneed by loss of blade contour. Knife edge conditions. ALLOWABLE LIMITS Up to 10% of the airfoil height from the tip and less than 25% of the chord length. Up to 15% of vane length along tip and a maximum of 60 degress deflection. See Figure MI-27. Not acceptable. No allowable limits. No allowable limits. Loss of 10% of eross~ sectional area or pit marks 0.015 inch deep or greater. Loss of 10% of eross~ sectional area or en unacceptable loss of performence. 4C-44 CORRECTIVE ACTION Cold straighten above pitch line and dye penetrant inspect. Replace if bent below pitch line. Hot straightening is NOT allowed, See Figure MI-24, Cold straighten and dye penetrant inspect. Replace. Replace cracked blade. Replace cracked blade. Replace blade. Replace blade.COMPRESSOR BLADING INSPECTION AND REPAIR CRITERIA (CONT'D) BLADE CONDITION NICKS AND DENTS Foreign Object Damage 1. Small nicks or dents around leading edge or blade. Dents 1. Dents in area around leading edge of blade above and be- ow piteh line 2. Dents in area of trailing edge above and below pitch line 3. Dents in both leading and trailing edges. 4, Dents in vane section other than leading and trailing edge . Airfoil Damage 1. Dents and nicks on the leading and trailing edge ALLOWABLE LIMITS CORRECTIVE ACTION 0.050 inch diameter or less Should be left alone, no by 0,020 inch deep. action necessary. Stages 1 Through 4* One dent D in depth and Blend out to original contour diameter of 5 times D. and polish to a 32 finish or Maximum allowable D better. Dye penetrant inspect. equal to 0.160 inch. See . Figure MI-24 and MI-25. One dent D in depth and Radius the edge and polish diameter of § times D. ,to a 32 finish or better. Dye Maximum allowable D ‘penetrant inspect. See equal to 0.160 inch. See Figure MI-26. Figures MI-25 and MI-26. Combination of condition Blend out and radius the edge. not to exceed D equal to Dye penetrant inspect. See 0.160 inch above and 0.080 Figures MI-25 and \ inch below the piteh tine. -26. ‘Two 0.040 inch deep above Polish smooth to remove the pitch line. roughness, remove as little metal as possible. Dye ‘One 0.040 inch deep below _penetrant inspect. the pitch line. *For Stages 5 through 7 use 75% of dimension criteria, i.e., 0.160 ineh becomes 0.120 inch. For Stages @ through final stage use 50% of dimensional criteria, Dents and nicks located Acceptable, however to ensure above the pitch line and smooth air flow, the high metal having a surface area of should be blended and dye pene~ tess than 0.020 inch per trant inspected. inch of blade chord and less than 0.050 inch deep. 40-45 | | |COMPRESSOR BLADING INSPECTION AND REPAIR CRITERIA (CONTD) BLADE CONDITION ALLOWABLE LIMITS CORRECTIVE ACTION NICKS AND DENTS (Cont'd) Airfoil Root Damage 1. Dents, nicks or tears in Not acceptable. Replace. the airfoil root section including the fillet radius. See Figure MI-24, 4C-46160" Bewove swaoeo aneA~ sLegD Sean eoRnens APPLICABLE. DIMENSION SECTION AA a feo AppuicasLe ater | Smee INCLUDING FILLET RADIUS Figure ML25 Dent in Leading Edge of Blade. ‘Typical Compressor Blade Showing secriow a0 Areas of Damage. tot OF vane Figure MI27 AIRFOIL ROOT Kv LEN CORNERS Figure MI26 Dent in Trailing Edge of Blade. Tennis Cold Straightening of Tip Damage. 40-47TIL 1004-2R1 GE POWER GENERATION GLOBAL PRODUCT & TECHNOLOGY SUPPORT June 11, 1998 N LETTER COMPRESSOR BLADE CORROSION LIMITS APPLICABLE TO: MSSO01N/PIR, MS5002, MS6001A/B, MS7001B/C/E/EA, MS9001E PURPOSE This TIL revises the allowable corrosion pit sizes on the compressor blades and stator vanes. The limits are dependenton the operating environment and apply equally to stator vanes or rotor blades. For machines with earlier version AISI 403 blades/vanes, in severe operating environments, a replacement with present production components is recommended during or prior to the first major inspection, BACKGROUND / DISCUSSION Under certain environmental conditions corrosion ‘occurs on compressor blades (stationary and rotating). The primary cause is corrosive chemical elements in aqueous environments including condensate on the blade surface. On earlier machines, Nickel-Cadmium (NiCd) plating was used on AISI 403 blades to minimize the corrosion attack. In recent production, to further counter the effects of corrosive environment, the blade material was changed to GTD-4E0 or 403CB, depending on the stage design GTD-450 material is much better suited to corrosive environments and eliminates the need ‘or coating. Also, in some cases, the old NiCd coating has been superceded by GECC-1 which isa ceramic type coating. Both GTD-450 and GECC-1 are in current production. Recent testing has yielded a further understanding of corrosive environments and new corrosion pit limits which differentiate between operating environments. Tests on AIS! 403 with NiCd show that the environmental qe «© printed on recycled paper. factors are crucial in determining the allowable corrosion pit sizes, In recent experience, field observations have detected cracks on first stage stator vanes on five MS7001E’s with AIS! 403 blades with NiCd coating. One of these five units sustained a stator vane failure with consequential damage to the compressor. In addition, a MS001E stage 1 stator blade of this type has also exhibited these cracks. In all cases, these blades had over 50,000 hours of operation in very corrosive environment. To date, the cracks have been observed on stationary blades only. Another important field observation is that these cracks are difficult to detect and can propagate during normal operation RECOMMENDATIONS 1) New Corrosion Pit Limits for AIS! 403 with NiCd coating. Itis recommended that the inlet guide vanes (IGV's) and first stage rotor blades be inspected for corrosion pitting on an annual basis or when the unit is down for a scheduled inspection. All blading should be inspected during a major inspection when the compressor casings are removed. If corrosion pitting is found that exceeds the limits in table 1, all blades of that stage should be replaced with GTD-450 blades or AISI 403 blades coated with GECC-1 coating TIL Category: FG, HI. J COPYRIGHT 1998, GE “The information published inthis Technical Informal Lete is ofered to you by GE in consideration of is ongoing sales and service relationship with your organizaton, However, ance the opeaton of your plant involves many factors nat witha our Knowledge, ard sce ‘operation of the plant isin your corre and ult sponseity Tors conbruing successul operation vests wi you. Ge specicaly ‘sciame ary responsibilty for labiy based on cams for damage of any type. 1. dec, consequential cr special that may be alleged have been inured as resut of applying this lnvermaton regariass of whether I is claimed that GE Issel table, in reach of conract. breach of waranty, negligent, of gin other respects responsible fr any alleged injury or damage sustained by your organvaton es 2 resut (of appving this informationTIL 1004-23 Page 2 ‘Stator Rotor Blade MAXIMUM CORROSION PIT WIDTH - MILS (MM) ENVIRONMENT Zone Dry Humid Corrosive Environ. | <60% Relative | pH= 851070 | pH< ss rmentote: | Huraly a 300.76) | 15 (0.38) [70(0.25) Band C | 80 (2.03) 80 (2.03) 30 (0.76) Table 1 NOTE: Field observation shows most piting in zone B and C and in the root fillet of zone A. Corrosive environment is defined as operation where the deposits on the blades show a presence of sulfides andlor chlorides or when pH is lower than 5.5 (acidic environment). 2) Itis recommended that AISI 403 stationary and rotating blades, including the IGV's with NiCd coating, operating in a corrosive environment or blades which have evidence of pits or deposits with sulfides and/or chlorides be replaced during or prior to the first major inspection. The recommended replacements are GTD-450 blades, or blades that have GECC-1 coating (the current design is specific to the individual stage)