"Basic Gas Turbine Metallurgy and Repair Technology Workshop"

Monday, October 4, 2010
George R. Brown Convention Center
Houston, Texas

Pre-Conference IGTI Workshop being held in conjunction with the 2010 Gas Turbine Users Symposium (IGTI) and the Turbomachinery Laboratory’s 39th Turbomachinery Symposium (TAMU)

Overview and Objective
This workshop will explain super-alloy materials, component damage experienced from service exposure, techniques used to analyze the remaining life of components removed from service, protective coatings, component repair technologies, and quality assurance of repairs. The workshop includes many case study examples and the last section is devoted to a workshop where attendees develop component repair solutions. Participants may submit questions in advance regarding repair issues faced in their jobs. Earn 7 Professional Development Hours (PDH’s) and receive a certificate of completion!

After completing the course the participants should be able to explain:

1. What makes superalloys especially suited for gas turbine components
2. How different damage mechanisms (oxidation, corrosion, erosion) affect the component
3. How high cycle fatigue & low cycle fatigue damage is caused, prevented, and repaired
4. Various heat treatments used in repairs, and why they are important
5. Advantages & disadvantages of the many types of protective coatings
6. Critical quality control steps in component repair
7. How to reliably extend the service life of valuable components

Instructors
Lloyd Cooke, Director, Operations, Liburdi Turbine Services; Warren Miglietti, Power Systems Mfg., LLC (an Alstom owned company); Doug Nagy, Industrial Component Repair Manager, Liburdi Turbine Services.

Who Should Attend
A “must” for gas turbine maintenance engineers, managers, repair shop personnel, designers, and technical staff to optimize their repair planning and performance. Useful for business and plant managers, investors and insurers to understand the technology and support sound decision-making.

Course Schedule

Monday, October 4, 2010 8:30 a.m. to 5:00 p.m.
Section I:	Introduction: Why repair and refurbish parts? The Future for Industrial Frame GT Repairs Repair Market Trends Cost Benefit of Repairs Industry Trends The Future for Industrial Frame GT Repairs
Section II:	Gas Turbine Nomenclature, Operations and Maintenance Planning Industrial Gas Turbine Nomenclature Industrial and Aero-derivative Typical Gas Turbine Component Materials Design Differences Advanced Design Turbine Blade Data Operating Modes – Industrial Engines – Industrial Frame Engines Inspection and Maintenance Intervals
Section III:	Materials and Metallurgy: Gas Turbine Materials and their Properties Overview of Why Superalloys are Used in a Gas Turbine Overview of Superalloy Production Routes Investment (Lost Wax) Casting Processing and manufacture of materials Superalloys Compositions and Properties Solid Solution Strengthening Precipitation Strengthening Grain boundary Strengthening
10:00 a.m. – 10:15 a.m.	Coffee Break
Section IV:	Gas Turbine Coatings The Role of Engineering Coatings Applications Selection of Coatings Coating Microstructure and Performance Coating Methods Slurries and Paints Pack Process Chemical Vapor Deposition Thermal Spraying Physical Vapor Deposition
Section V:	Degradation Characteristics in Gas Turbine Components Mechanical and Metallurgical Effects of Service Creep –High Cycle Fatigue –Low Cycle Fatigue Environmental Attack –Oxidation –Corrosion Coating Degradation, Depletion, Cracking, TBC's Thermal Mechanical Fatigue (TMF) Damage Microstructural Aging and Evolution
12:00 p.m. – 1:00 p.m.	Group Lunch
Section VI:	Component Evaluation Component evaluation, where how and why Component Management Program Timing and selection of components for analysis Micro structural analysis Mechanical testing Coating Evaluation Failure Analysis Root Cause of Damage, and Corrective/Preventive Action
Section VII:	Refurbishment & Repair Processes: Procedures and techniques used to restore components to industry standards Typical Damage Coating Stripping Dimensional Checks Re-Coating Selection and Processes HIP and Rejuvenation Heat Treatments Superalloy Weld Processes Diffusion Brazing
3:15 p.m. – 3:30 p.m.	Coffee Break
Section VIII:	Quality Assurance and Inspection Methods QA Certification, Inspections and Quality Plan NDE Defect Criteria Dimensional Specification NDE Inspections techniques Repair Shop Selection and Qualifications
Section IX:	Case Studies & Problem Solving: Case Studies of Turbine component damage and repair strategies.
Section X:	Round Table Discussion: Discussion of the latest repair trends Student questions
5:00 p.m.	Wrap-up and Evaluation