Rework and Repair Options for Steam Turbine Components Subject to Flexible Operation

Abstract The increase in renewable energy penetration on the grid has accelerated the need to transition conventional fossil-based energy sources from their traditional base load operation to more flexible operational regimes. The mode of operation changed dramatically in terms of number of starts, operating hours per annum and variation in load level. This results in greater thermal transients on operational equipment leading to an increase in Low Cycle Fatigue damage. To ensure the continued integrity of the steam turbine components, it is essential to assess the lifetime status by applying Residual Lifetime Analysis methods. Depending on the amount of lifetime consumption and the extend of potential crack findings, different component repair options are possible. The rework or repair options can be divided into two main groups, namely cold- and hot-rework. These two options can also be carried out consecutively. All rework or repair options provide the opportunity to improve the application of a component by applying profiling with improved stress fields and even superior materials, in the case of hot rework. The aim of the rework / re-conditioning is to ensure that the steam turbine component is suitable for future operation. This ensures that plants are well placed to deliver more flexible operation in the energy industry through carefully tailored refurbishments and reworks.