PROJECT SCOPE
Upon NDE inspection, cracks were found in the original Top Hat welds.The repair consisted of the setting of the strong backs, retaining rings and wedges. WTS supervised the indicating and machining. The damaged Top Hat was machined off. 10°-30° O.D. and 10°- 20° I.D. compound bevels were applied to the F-22 turbine shell and the new Top Hats.

Consumable inserts were installed and the Top Hats were fitted to the turbine shell. The Top Hat area was then preheated to 450°. Root and hot passes were applied via machine welding.

Radiographic testing was done and once approved the I.D. welds were machine welded utilizing the GTAW process. The O.D. was completed using manual SMAW process. Final RT inspection was completed as per ASME B31.1. and found defect free. Stress Relief was performed to ASME B31.1.

THE WTS SOLUTION
WTS completed the replacement of the Top Hats on the Turbine cover within the budget established and at a fraction of the proposed price of the O.E.M. WTS modified standard welding equipment and developed a mounting fixture that greatly reduced weld time, all welding was completed within two 12 hour shifts. Remote optics were employed to inspect the root passes for complete fusion to the consumable inserts. The entire job was completed in 8 days, which was ahead of schedule.

Please feel free to contact Mi Rahimi of Pennsylvania Electric Company (Technical Supervisor for Outage Services) at 1-814-533-8814 for any specific information.

MACHINERY AND MANPOWER REQUIREMENTS
• 1 Project Manager
• 4 Weld Technicians
• 1 Electrical Technician
• 2 Heat Treat Technician
• WTS Modified Welding Equipment