0
Research Papers: Gas Turbines: Combustion, Fuels, and Emissions

Developing Additive Manufacturing Technology for Burner Repair

[+] Author and Article Information
Olov Andersson

Siemens Industrial Turbo Machinery AB,
Finspong 612 31, Sweden
e-mail: olov.andersson@siemens.com

Andreas Graichen

Siemens Industrial Turbo Machinery AB, Finspong 612 31, Sweden
e-mail: andreas.a.graichen@siemens.com

Håkan Brodin

Siemens Industrial Turbo Machinery AB,
Finspong 612 31, Sweden
e-mail: hakan.brodin@siemens.com

Vladimir Navrotsky

Siemens Industrial Turbo Machinery AB,
Finspong 612 31, Sweden
e-mail: vladimir.navrotsky@siemens.com

Contributed by the Combustion and Fuels Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received June 20, 2016; final manuscript received June 29, 2016; published online October 4, 2016. Editor: David Wisler.

J. Eng. Gas Turbines Power 139(3), 031506 (Oct 04, 2016) (9 pages) Paper No: GTP-16-1244; doi: 10.1115/1.4034235 History: Received June 20, 2016; Revised June 29, 2016

Low emission combustion is one of the most important requirements for industrial gas turbines. Siemens industrial gas turbines SGT-800 and SGT-700 use dry low emission (DLE) technology and are equipped with third generation of DLE burners. These burners demonstrate high-performance and reliable operation for the duration of their design lifetime. The design and shape of the burner tip is of great importance in order to achieve a good fuel/ air mixture and at the same time a resistance to the fatigue created by heat radiation input. This gives a requirement for a tip structure with delicate internal channels combined with thicker structure for load carrying and production reasons. It was found that the extension of the burner lifetime beyond the original design life could be accomplished by means of repair of the burner tip. Initially, the tip repair has been done by conventional methods— i.e., cutting off the tip and replacing it with a premanufactured one. Due to the sophisticated internal structure of the burner, the cuts have to be made fairly high upstream to avoid having the weld in the delicate channel area. Through the use of additive manufacturing (AM) technology, it has been possible to simplify the repair and only replace the damaged part of the tip. Special processes have been developed for AM repair procedure, including the following: machining off of the damaged and oxidized tip, positioning the sintered model on the burner face, sintering a new tip in place, quality assurance and inspection methods, powder handling, material qualification including bonding zone, development of methods for mechanical integrity calculation, and qualification of the whole repair process. This paper describes how we have developed and qualified SGT-800 and SGT-700 DLE burners repair with the help of additive manufacturing technology and our research work performed. In addition, this paper highlights the challenges we faced during design, materials qualification, and repair work shop set up.

Copyright © 2017 by ASME
Your Session has timed out. Please sign back in to continue.

References

Figures

Grahic Jump Location
Fig. 1

Typical burner and combustor configuration

Grahic Jump Location
Fig. 2

Typical tip damages: top, carbon deposits; left, crack in pilot hole; right, oxidized hole

Grahic Jump Location
Fig. 3

Gas turbine burner repairs in the traditional fashion (right line) and the described novel repair process (left line)

Grahic Jump Location
Fig. 4

Layer-wise additive manufacturing of burner tip on top of an existing burner body

Grahic Jump Location
Fig. 5

View down onto the burner substrate and powder bed

Grahic Jump Location
Fig. 6

New machine design with novel z-axis configuration and process chamber design (courtesy EOS)

Grahic Jump Location
Fig. 7

MES architecture and hardware components especially adopted for the AM repair process

Grahic Jump Location
Fig. 8

As-manufactured microstructure of Hastelloy X manufactured by the laser powder-bed process. In the figure, (a) is the material viewed along the build platform and (b) is the view aligned parallel to the build direction.

Grahic Jump Location
Fig. 9

Etched microstructure, Hastelloy X manufactured by AM (laser powder-bed process)

Grahic Jump Location
Fig. 10

Tensile properties as a function of temperature. Normalized data.

Grahic Jump Location
Fig. 11

Creep properties at elevated temperature. Normalized data.

Grahic Jump Location
Fig. 12

Light-optical micrograph of the burner tip interface

Grahic Jump Location
Fig. 13

Defects in base material adjacent to the material interface as a result of remelted manganese-sulfide

Grahic Jump Location
Fig. 14

Testing of the SLM/base metal interface, fractured test bars

Grahic Jump Location
Fig. 15

The flow area is almost identical between sintered holes (light) and machined holes (dark)

Grahic Jump Location
Fig. 16

Burner rig test for verification of flame shape

Grahic Jump Location
Fig. 17

Results from heat transfer test of burner tip, sintered tip (upper line), and machined tip (lower line)

Grahic Jump Location
Fig. 18

Burner tip area subject to destructive examination

Grahic Jump Location
Fig. 19

Sectioning of burner tip, arrows indicates the surface to be examined

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In