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
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Fig. 1

Typical burner and combustor configuration

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Fig. 2

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

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Fig. 3

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

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Fig. 4

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

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Fig. 5

View down onto the burner substrate and powder bed

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Fig. 6

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

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Fig. 7

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

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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.

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Fig. 9

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

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Fig. 10

Tensile properties as a function of temperature. Normalized data.

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Fig. 11

Creep properties at elevated temperature. Normalized data.

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Fig. 12

Light-optical micrograph of the burner tip interface

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Fig. 13

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

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Fig. 14

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

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Fig. 15

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

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Fig. 16

Burner rig test for verification of flame shape

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Fig. 17

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

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Fig. 18

Burner tip area subject to destructive examination

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Fig. 19

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



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