Turbine Blade Erosion in Power Plant: A Case Study

9th December 2024

The leading edges of turbine blades in a power generation facility exhibited significant turbine blade erosion, impacting their performance and longevity. Constant exposure to abrasive particles accelerated this wear, making a reliable repair solution essential. The client required a method to restore the damaged areas while providing durable protection to extend the blades’ operational lifespan and maintain turbine efficiency.

Resimac’s Turbine Blade Erosion Solution

Abrasive blast cleaned the blades to ISO 8501/4 SA2.5 standard, achieving a 75-micron profile for optimal adhesion.
Rebuilt pitted and worn sections with 201 Ceramic Repair Paste.
Coated the blades with 203 Superflow in two layers for enhanced protection.

Application Details

To prepare the turbine blades for repair, the surface was abrasive blast cleaned to SA2.5, meeting the ISO 8501/4 and SSPC SP10/NACE 2 standards with a 75-micron angular profile. This preparation ensured a clean and textured surface for the repair products. Damaged areas along the leading edges were filled and reshaped using 201 Ceramic Repair Paste to restore the blade’s original contour. For long term protection, two coats of 203 Superflow were applied by brush, resulting in a nominal total dry film thickness of 500 microns. This final coating created a smooth, wear resistant surface, designed to withstand the operational stresses and corrosive conditions.

Products Used

Results and Benefits

The turbine blade repair not only restored structural integrity but also enhanced the blades’ resistance to operational stresses, including high speed impact from particulate matter. The smooth finish achieved with 203 Superflow improved the aerodynamic performance of the blades, reducing energy losses and enhancing overall turbine efficiency. By creating a robust, erosion resistant barrier, the repair also contributed to greater operational stability, minimising vibration and wear on associated components.

This cost effective solution avoided the need for full blade replacement, reducing downtime and ensuring uninterrupted power generation. The enhanced protection provided by the repair aligns with the client’s goals for long term performance and sustainability in their power generation operations.