Franco Tosi Steam Turbine Blades

Short lead time, High Quality

Challenge

For a major overhaul of a steam turbine, the customer required technical assistance. Stork was contracted to supervise the inspection and to deliver and assemble one stage of LP steam turbine rotor blades. All activities were to be executed on site as the rotor was not allowed to leave the premises. The lead time had to be kept to a minimum in order to limit production downtime as much as possible.

Solution

Initial inspection showed that the last stage of the HP rotor also required new blades due to corrosion, wear and several root cracks. Stork Reverse Engineered, Manufactured and Assembled the new HP blades within three weeks. Once the new rotor blades were fitted, one of stork's turbo machinery specialists balanced the rotor in-situ, resulting in minimal downtime and optimal performance.

Scope

  • Removal of existing blades
  • Cleaning of the grooves
  • NDT on root groove by means of dye penetrant
  • On-site 3D optical scanning for reverse engineering
  • Manufacturing of new HP rotor blades
  • Assembly of new blades
  • In-situ balancing by specialist
  • Supervision of the major overhaul

Facts

  • Unexpected repairs executed in a very short timeframe, resulting in minimal impact on downtime
  • Reverse engineering, manufacturing and assembly of blades all intercompany, resulting in high quality and fast delivery
  • No transport of the rotor
  • Highly skilled field service supervisors

The Ras Laffan Power Company project is an excellent example of the benefits Stork can deliver to its customers by having the complete Turbo Machinery portfolio in-house including services and parts delivery.

Blade manufacturing details

OEM / Machine TypeFranco Tosi High Pressure Steam Turbine
Output (MW) 200 (total HP/IP/LP)
Project TypeReverse Engineering & Manufacturing
Project Lead Time3 Weeks (including in-situ 3D scanning, manufacturing & assembly)
ProductHP Rotor Blade L-0 including rolled & pocketed shroud segments
Material(s)17-4PH Cond. H1150 (W-no. 1.4542)

   

Customer Profile

Ras Laffan Power Company (RLPC) is the very first IWPP in Qatar, which was founded in 2001. The plant is situated in Ras Laffan Industrial City, a real strategic location in the center of the Arabian Gulf. Ras Laffan Industrial City, fully managed and operated by Qatar Petroleum, is approximately 80km north of Doha, the capital of the State of Qatar.

The facility attained its full production capacity in May 2004 and has net. production capacity of 756MW power and 40 MIGD of water.

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