Repair Engineering Instruction RD-51-B1-1001 Rev.

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REPAIR DOCUMENT RD-51-B1-1001 REV: B

Title: Stage 1 Bucket (Full Repair)

Model Applicability: MS5001

Component or Unit Serial To be performed by Qualified Service Center Personnel?

Numbers (or “All”): All Yes No

TECHNICAL CONTENT OF THIS DOCUMENT IS APPROVED BY GE REPAIR TECHNOLOGY CoE

GE P&RS Gas Service Center Authorized Distribution

Service Center Type Authorized (Y/N) Service Center Type Authorized (Y/N)
ACSC GEA N Houston GE Y
Basildon GE Y KPS TTA N
BGGTS JV Y McAllen GEA N
CAPCO TTA N MEELSA (GEMTEC) JV Y
GE-HPEC (QHD) JV N Nigeria GE N
GE-Hungary GE Y PT Gents JV Y
GE Keppel JV Y TGE JV N
GEPTEC - Kaluga GE N TGTS JV N
Greenville GE Y TNB TENAGA TTA N
GTS JV Y

GE Oil & Gas Service Center Authorized Distribution

Service Center Type Authorized (Y/N) Service Center Type Authorized (Y/N)
Algesco JV Y Houston O&G GE Y
Barcelona (PEGS) GE Y Qatar JV N
Florence GE Y Sapura Crest JV N
Trinidad GE Y Turbimeca GE Y
Edmonton GE Y ZKMK TTA N
Australia SC GE Y

GEA = GE Aviation | JV = Joint Venture | TTA = Technology Transfer Agreement

NOTE: These tables do NOT imply Service Center Certification or Qualification.

© COPYRIGHT 2010 GENERAL ELECTRIC COMPANY

The information contained in this document is GE proprietary information and is disclosed in confidence. The technical data herein is the property of GE and shall not
be used or disclosed to others without the express written consent of GE. If consent is given, this notice or - as necessary, the supplementary notice set forth on each
page of this document, shall appear on any such communication. In addition, the technical data herein, and the direct product of the data, may not be diverted,
transferred, re-exported or disclosed in any manner without prior written approval.

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

REI Approvals

Refer to Repair Engineering procedure GTRE 102 for approval requirements by document type.

Revision History

Rev Description Signature Date

C. Giolli Approved by Email

Internal Aluminizing Avoidance on GTD 111 CC S. Pisegna Approved by Email

A 27/06/2014
Stage 1 Buckets after stripping N. Pieroni Approved by Email
P. Kraleti Approved by Email
C. Giolli Approved by Email
Internal Aluminizing Avoidance on GTD 111 CC S. Pisegna Approved by Email
B Stage 1 Buckets after stripping (Only for Solid 18/07/2014
Version) N. Pieroni Approved by Email
P. Kraleti Approved by Email

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

INDEX
1. Purpose

2. Parts Applicability

3. Description

4. Decision Flow Chart

5. Tools, Equipment, and Materials

5.1. Tools and Equipment

5.2. Consumable Materials

6. Procedure

6.1. Coating Removal

6.2. Blending
6.3. Bucket Tip Preparation for Weld Repair
6.4. Bucket Tip Weld Repair
6.5. Fluorescent Penetrant Inspection
6.6. Dimensional Inspection
6.7. Coating
6.8. Final Heat Treatment
6.9. Dovetail Shot Peen
6.10. Part Marking
6.11. Moment Weigh
6.12. Final Inspection
6.13. Package
6.14. Final Report
7. Appendices

7.1. Appendix A - Reference Documents

7.2. Appendix B - Component Repair Engineering Instructions

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

1. Purpose

1.1. This document provides instructions to perform repair on the MS5001 Stage 1 Turbine Bucket.
The repairs covered include blend repair, tip weld repair, re-coating, shot peening, final
inspection, part marking, and moment weigh.

1.2. Repair Sources that perform procedures listed in this REI must fulfill the requirements listed in
RSS-51-B1-1001, MS5001 Stage 1 Bucket Repair Source Substantiation, and
SP-16-1002, Repair Source Substantiation, Qualification, and Quality System Requirements,
and be qualified by Sourcing or GE Repair Engineering.

2. Parts Applicability

2.1. Refer to IC-51-B1-1001, MS5001 Stage 1 Bucket Inspection, for the most common parts and
configurations to which this document applies. Always consult the Bill of Material (BOM) to
confirm configuration, hardware, and material used.

3. Description

3.1. A detailed description of applicable parts can be found in IC-51-B1-1001.

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

4. Decision Flow Chart

NOTE: This flow chart is for general reference only. Refer to your manufacturing process flow chart
for more operational detail.

Inspection Check Complete

IC -51 -B1-1001

Perform Blend Repairs

Is Tip Weld Manually or

Repair Yes Machine Prep Tip
Required for Weld

Solution Heat Treat

No

Visual Manual or Laser

Inspection Weld Tip
Visual
Inspection

Thermal or Re-Machine Tip

Chemical Etch Height and Blend Diffusion
Contour Heat Treat

Fluorescent Age Heat Treat

Penetrant
Post Weld Solution
Inspection
Heat Treat
Shot Peen
the Dovetail

Fluorescent Part Marking

Penetrant
Inspection
Moment Weigh
the Bucket

Dimensional Inspection Final

Inspection
Is Coating
Application Apply Internal Apply External Package for
Yes
Required? Coating (if required) Coating Shipment to
Customer

Prepare
No Final Report

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

5. Tools, Equipment, and Materials

NOTE: Use of equivalent or alternate tooling, equipment, and/or consumable materials is permissible
with engineering approval and qualification if required.

5.1. Tools and Equipment

5.1.1. Gauge pins, 0.21875 in. (5.556 mm) diameter

5.1.2. Standard shop measuring tools (calipers, surface plate, height gage, etc.)

5.1.3. Fluorescent penetrant inspection equipment per P3A-AG4, Fluorescent Penetrant

Testing

5.1.4. Ultrasonic inspection equipment for wall thickness measurement

5.2. Consumable Materials

5.2.1. Lead Free Permanent Marker as detailed in P23A-AG2, Identification -

Turbine/Generator Parts and Materials

5.2.2. Inconel 625 laser cladding powder (-125+325 mesh size)

5.2.3. GT-33 HVOF Coating Powder per B50-AG12, Cobalt Nickel Coating Powder for HVOF
Process

5.2.4. Inconel 625 weld wire per B50A970, Nickel Base Alloy Welding Wire (High Purity
IN625)

6. Procedure
NOTE: Alternate repair processes may be used with prior approval from GE Repair Engineering.

NOTE: Thermal etching should be combined where possible and shall be done immediately prior to
Fluorescent Penetrant Inspection (FPI) with no intervening surface finish operations used
(such as blasting).
NOTE: During various repair operations, temporary markings may be needed on the part to mark
such things as defect locations, the nature of defects, and size of defects. Make all temporary
markings per P23A-AG2. No lead or graphite marking medium should be used. Markings
should be cleaned off prior to FPI inspection.

NOTE: A complete list of terms and definitions can be found in SP-32-1012, Inspection Terms and
Definitions.

Definitions

• Serviceable Limit is the least or maximum acceptable condition, of specific areas on the
component. These limits allow the component to be used without repair.

• Not Serviceable is any condition that does not meet the Serviceable Limit. This condition does
not allow the component to be used as is. The component will either require repair or must be
retired from service.

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

• Repairable Limit is the amount of the existing condition/distress that can be repaired.

• Not Repairable is a condition for which the component cannot be repaired and must be
replaced.

• Linear Indication is classified as an indication having a length equal to or greater than 3

times width.

6.1. Coating Removal

CAUTION: STRIP ONLY THE COATED AREAS OF THE BUCKET. PROTECT THE
DOVETAIL AND SHANK AREA FROM DAMAGE DURING COATING REMOVAL.

NOTE: Buckets requiring only minor repairs may not require coating removal. If coating was
not removed during inspection process per IC-51-B1-1001, MS5001 Stage 1 Bucket
Inspection Check, consult with local Engineering prior to proceeding with coating
removal per this procedure.

NOTE: Do not strip internal aluminide coatings unless required by engineering or customer.

6.3.1. Suitably mask all non-coated surfaces and coated internal cavities to protect from
stripping process.

6.3.2. Remove coating per SP-23-1002, Advanced Coating Removal (ACR) Repair, or SP-23-
1001, General Stripping Process for Coatings.

6.3.3. Coating removal process shall be qualified per RSS-M-SP-1002, Coating Removal
Repair Requirements.

6.2. Blending

CAUTION: ALL GRINDING MUST BE DONE IN A SLOW AND CAUTIOUS MANNER TO

LIMIT HEAT BUILD-UP AND SUBSEQUENT SUBSTRATE CRACKING. KEEP
PART AT AMBIENT TEMPERATURE DURING BLENDING AND MACHINING

CAUTION: IF COATING HAS NOT BEEN REMOVED FROM BUCKET, DO NOT BLEND ON
COATED SURFACES.

NOTE: After all blending is complete, fluorescent penetrant inspection is required. In-process
fluorescent penetrant inspections are optional.

6.2.1. Airfoil Blending

6.2.1.1. Locally blend indications in the airfoil per SP-42-1001, Blending Procedure
(for Hot Gas Path Components). Indications must be within repairable limits
described in IC-51-B1-1001, MS5001 Stage 1 Bucket Inspection Check.
Remove the minimum amount of material necessary to restore the airfoil
within serviceable limits listed in IC-51-B1-1001. Do not exceed the
maximum blending depth specified in IC-51-B1-1001.

6.2.1.2. For hollow design buckets, after blending in Area A and Area Z, measure wall
thickness per SP-32-1001, Ultrasonic Inspection - Thickness. Verify wall
thickness satisfies serviceable limits specified in IC-51-B1-1001 after
blending.

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

6.2.2. Platform Blending

6.2.2.1. Locally blend top of platform per SP-42-1001, Blending Procedure (for Hot
Gas Path Components), to remove non-serviceable indications. Indications
must be within repairable limits described in IC-51-B1-1001, MS5001 Stage 1
Bucket Inspection Check. Remove the minimum amount of material
necessary to restore the platform region to within serviceable limits listed in
IC-51-B1-1001. Do not exceed the maximum blending depth specified in IC-
51-B1-1001.

6.2.3. Shank Blending

6.2.3.1. Locally blend indications in shank region per SP-42-1001, Blending

Procedure (for Hot Gas Path Components). Indications must be within
repairable limits described in IC-51-B1-1001, MS5001 Stage 1 Bucket
Inspection Check. Remove the minimum amount of material necessary to
restore the shank region to within serviceable limits listed in IC-51-B1-1001.
Do not exceed the maximum blending depth specified in IC-51-B1-1001.

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

6.3. Bucket Tip Preparation for Weld Repair

NOTE: Minor defects on the bucket tip may be repaired by local manual welding. Full tip repair
is also permitted by removing material from the full perimeter of bucket tip and re-
building by welding.

6.3.1. Prepare bucket tip for local repair by hand blending to remove defects.

6.3.2. If damage to bucket tip is beyond repair by local manual welding, machine or hand-
blend entire tip to completely remove damaged material.

6.3.2.1. For hollow bucket design, maximum material removal is 0.100” (2.54 mm)
measured from point P at the tip as described in IC-51-B1-1001, MS 5001
Stage 1 Bucket Inspection Check.

6.3.2.2. For solid bucket design, maximum material removal is 0.080” (2.00 mm)
measured from point P at the tip as described in IC-51-B1-1001, MS 5001
Stage 1 Bucket Inspection Check.

NOTE: The Pre-Weld Solution Heat Treatment is mandatory only if solution HT has not been
done during the inspections (as for Thermal / Chemical Etching).

6.3.3. Perform pre-weld solution heat treat per SP-44-1001, Furnace Heat Treatment.

NOTE: All heat treat cycles must meet the heat up and cool down rates as specified in
SP-44-1001.

6.3.3.1. Solution heat treat GTD111, IN738, or U500 buckets per SP-44-1001.

6.3.3.2. Solution heat treat U700 buckets per B50A524B, Nickel Alloy Precision
Castings.

6.3.4. Performing In-process Fluorescent Penetrant Inspection per P3A-AG4, Fluorescent

Penetrant Testing, to verify complete removal of defects prior to weld repair is optional.

6.4. Bucket Tip Weld Repair

NOTE: Welders must be qualified per SP-41-1001, Global Welder Qualification.

6.4.1. Prior to weld, verify repair area is clean and free from oxidation or corrosion, remnant
coating, and foreign material.

6.4.2. If bucket tip was prepared for repair of local defects only, locally manual weld repair per
P8A-AG1, using Inconel 625 weld wire per B50A970.

6.4.3. If height of full bucket tip was reduced in preparation for repair, weld buildup entire
bucket tip.

6.4.3.1. Weld repair per P8A-AG1, using Inconel 625 weld wire per B50A970 or laser
weld using Inconel 625 laser cladding powder (-125+325 mesh size).

6.4.3.2. Other welding methods to restore tip height are acceptable with GE Repair
Engineering approval.

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

6.4.4. Restore tip height and contour

6.4.4.1. Restore tip height and radius by re-machining to serviceable dimensions per
IC-51-B1-1001, MS5001 Stage 1 Bucket Inspection Check. If only local weld
repair was performed, it is permissible to locally hand blend to restore tip
height at repaired locations.

6.4.4.2. Hand blend per SP-42-1001, Blending Procedure (for Hot Gas Path
Components) or machine to restore tip contour. Wall thickness of tip must
satisfy serviceable limits included in IC-51-B1-1001. The weld repaired area
must blend smoothly with original airfoil contour.

6.4.5. Perform post-weld solution heat treat per SP-44-1001, Furnace Heat Treatment.

NOTE: All heat treat cycles must meet the heat up and cool down rates as specified in
SP-44-1001.

NOTE: There are to be NO surface treatments performed between heat treatment

(thermal etching) and fluorescent penetrant inspection (for example, deburring,
sanding, blasting etc.)

NOTE: Any defects found will need to be corrected to meet the requirements of IC-51-
B1-1001. Hardware having re-work performed will need to be etched prior to
repeating final FPI.

6.4.5.1. Solution heat treat GTD111, IN738, or U500 buckets per SP-44-1001.

6.4.5.2. Solution heat treat U700 buckets per B50A524B, Nickel Alloy Precision
Castings.

6.5. Fluorescent Penetrant Inspection

NOTE: Fluorescent penetrant inspection must be completed on entire bucket after all blending
and weld repairs are completed.

6.5.1. In preparation for fluorescent penetrant inspection, chemical etch repaired areas per
SP-24-1001, Pre-FPI and Post Strip Grain Etch, or thermal etch at 2050°F (1120°C) for
1 hour per SP-44-1001, Furnace Heat Treat. Grain etch or thermal etch is not required
if bucket is post-weld solution heat treated immediately prior to fluorescent penetrant
inspection.

6.5.2. Fluorescent penetrant inspect per P3A-AG4, Fluorescent Penetrant Testing and inspect
per IC-51-B1-1001, MS5001 Stage 1 Bucket Inspection Check.

6.6. Dimensional Inspection

6.6.1. Dimensionally inspect tip height to verify serviceable limits specified in IC-51-B1-1001,
MS5001 Stage 1 Bucket Inspection Check, are satisfied.

6.6.2. Dimensionally inspect dovetail to verify serviceable limits specified in IC-51-B1-1001,

MS5001 Stage 1 Bucket Inspection Check, are satisfied.

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

6.7. Coating

NOTE: All buckets shall be recoated with GT33 (B50AG12) regardless of the original
coating applied at manufacture, unless otherwise specified by Repair
Engineering or the customer.

NOTE: Do not re-apply over-aluminide coating if specified on original bucket drawing,

unless required by Engineering or customer.

6.7.1. If required, Apply aluminide coating per P16C-AG4 to internal cavity of hollow design
buckets and tip pocket of solid buckets (approved alternatives may be used).

6.7.2. Apply GT33 coating to airfoil per P16B-AG14, Application of Extendcoat GT29 and
Extendcoat GT33 to Serviced Gas Turbine Airfoils, using HVOF powder per B50AG12,
Cobalt Nickel Coating Powder for HVOF Process.

6.7.3. Solid Configuration: In case of serviced Stage 1 Buckets in GTD 111 CC Base
Material, the internal aluminizing re-application can be avoided after stripping process.
In case of scrapped Stage 1 Buckets in GTD 111 CC Base Material, they shall be
replaced with new parts in GTD 111 CC Base Material (Casting Part Number
SMH48241) with GT33 coating according to the standard part number (SMU48343 &
SMU48344). In case of a different configuration of bucket is available as spare part,
please contact Repair Eng. Team for compatibility.

6.8. Final Heat Treatment

NOTE: If bucket was solution heat treated (meeting required cool down rate) prior to final
fluorescent penetrant inspection or during the coating diffusion cycle, re-solution heat
treat is not required prior to age heat treatment.

NOTE: The Age heat treat is not required if the Solution heat treatment has not been
performed previously on buckets.

NOTE: All heat treat cycles must meet the heat up and cool down rates as specified in SP-44-
1001.

6.8.1. Perform solution heat treat per SP-44-1001, Furnace Heat Treatment.

6.8.1.1. Solution heat treat GTD111, IN738, or U500 buckets per SP-44-1001.

6.8.1.2. Solution heat treat U700 buckets per B50A524B, Nickel Alloy Precision
Castings.

6.8.2. Perform final age heat treat per SP-44-1001, Furnace Heat Treatment

6.8.2.1. Final age heat treat GTD111, IN738, or U500 buckets per SP-44-1001.

6.8.2.2. Final age heat treat U700 buckets per B50A524B, Nickel Alloy Precision
Castings.

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

6.9. Dovetail Shot Peen

NOTE: Shot peen to be performed only after all heat treatments are complete.

NOTE: Shot peen is not required if Heat Treatments on Buckets have not been performed.

6.9.1. Shot peen the dovetail per P11C-AG5, Shot Peening – Buckets and Blades.

6.10. Part Marking

6.10.1. If not already visible on bucket, Apply ‘H3’ identification code for GT33 to bucket
identification panel per SP-16-1001, Repair Part Marking Standardization.

6.10.2. If original bucket drawing specifies coating other than GT33, line through existing
coating code and apply GT33 code. Assure original coating code remains legible.

6.11. Moment Weigh

NOTE: Perform moment weigh after all other processing is complete.

6.11.1. Moment weigh buckets per 392A5421, Turbine Bucket Moment Weigh Specification.

6.12. Final Inspection

NOTE: Final inspection should be conducted after all repair operations are completed.

6.12.1. Perform visual inspection for any foreign material remaining on the bucket. Foreign
material includes, but js not limited to, tape, masking material, dirt, oil.

6.12.2. If non-serviceable conditions exist as per IC-51-B1-1001, MS5001 Stage 1 Bucket

Inspection Check, repeat repair steps as required.

6.13. Package

6.13.1. Package the buckets for shipment to customer.

6.14. Final Report

6.14.1. Prepare all final reports per local shop method requirements.

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Repair Engineering Instruction RD-51-B1-1001 Rev. B

7. Appendices

NOTE: Use the latest revision of the referenced documents.

7.1 Appendix A – Reference Documents

Document Title
1. B50A970 Nickel Base Alloy Welding Wire (High Purity IN625)
2. B50-AG12 Cobalt Nickel Coating Powder for HVOF Process
3. P3A-AG4 Fluorescent Penetrant Testing
4. P8A-AG1 Welding – General Specification
5. P10A-AG2 Heat Treat Process Control
6. P11C-AG5 Shot Peening – Buckets and Blades
Application of Extendcoat GT29 and Extendcoat GT33 to Serviced Gas
7. P16B-AG14
Turbine Airfoils
8. P23A-AG2 Identification-Turbine/Generator Parts and Materials
9. SP-16-1001 Repair Part Marking Standardization
Repair Source Substantiation, Qualification, and Quality System
10. SP-16-1002
Requirements
11. SP-32-1001 Ultrasonic Inspection - Thickness
12. SP-32-1012 Inspection Terms and Definitions
13. SP-41-1001 Global Welder Qualification
14. SP-42-1001 Blending Procedure (for Hot Gas Path Components)
15. SP-44-1001 Furnace Heat Treatment
16. 392A5421 Turbine Bucket Moment Weigh Specification

7.2 Appendix B – Component Repair Engineering Instructions

Document Title
1. IC-51-B1-1001 MS5001 Stage 1 Bucket Inspection Check
2. RSS-51-B1-1001 MS5001 Stage 1 Bucket Repair Source Substantiation

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