THERMAL ENGINEERING

PRODUCT SERVICE

TIL 1108-R1
19 MARCH 2012
Compliance Category M
Timing Code - 4

TECHNICAL INFORMATION LETTER

CAST SEGMENTED TURBINE NOZZLE ACCEPTANCE GUIDELINES
APPLICATION
All gas turbines with cast segmented turbine nozzles.

PURPOSE
Provide additional guidelines to supplement GE Operation and Maintenance (O&M) manual relative to continued use of
cast segmented turbine nozzles based on field experience.

REASON FOR REVISION

To update TIL with lessons learned from field experience to-date.
Compliance Category
O - Optional

Identifies changes that may be beneficial to some, but not necessarily all,
operators. Accomplishment is at customer's discretion.

M - Maintenance

Identifies maintenance guidelines or best practices for reliable equipment

operation.

C - Compliance Required

Identifies the need for action to correct a condition that, if left uncorrected,
may result in reduced equipment reliability or efficiency. Compliance may be
required within a specific operating time.

A - Alert

Failure to comply with the TIL could result in equipment damage or facility
damage. Compliance is mandated within a specific operating time.

S Safety

Failure to comply with this TIL could result in personal injury. Compliance is
mandated within a specific operating time.

Timing Code
1

Prior to Unit Startup / Prior to Continued Operation (forced outage condition)

At First Opportunity (next shutdown)

Prior to Operation of Affected System

At First Exposure of Component

At Scheduled Component Part Repair or Replacement

Next Scheduled Outage

Optional

2012 General Electric Company

The proprietary information published in this Technical Information Letter is offered to you by GE in consideration of its ongoing sales and service
relationship with your organization. However, since the operation of your plant involves many factors not within our knowledge, and since operation
of the plant is in your control and ultimate responsibility for its continuing successful operation rests with you, GE specifically disclaims any
responsibility for liability based on claims for damage of any type, i.e. direct, consequential or special that may be alleged to have been incurred as
result of applying this information regardless of whether it is claimed that GE is strictly liable, in breach of contract, in breach of warranty, negligent, or
is in other respects responsible for any alleged injury or damage sustained by your organization as a result of applying this information.
This Technical Information Letter contains proprietary information of the General Electric Company, USA and is furnished to its customer solely to
assist that customer in the installation, testing, operation and/or maintenance of the equipment described. This document shall not be reproduced or
distributed in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy Services Engineering. All
rights reserved.

TIL 1108-R1

BACKGROUND DISCUSSION
Cast segmented nozzles are used in a wide variety of GE gas turbine applications. The nozzle segments are stationary
components that help guide and accelerate hot gas through the turbine to produce thrust. The stage one nozzle
additionally serves the purpose of setting the amount of mass flow through the engine.
Extensive field experience has shown that these cast segmented turbine nozzles can withstand some deterioration and
cracking without causing a large impact on overall unit performance or damage to downstream components. The
same experience has also shown that damage to nozzle segments observed prior to HGP intervals is expected and in
most cases does not require immediate repair. Nozzle segments exhibiting damage are typically able to complete the
intended hot gas path interval without any major issues and are still repairable at the time of planned removal.
Some factors that influence nozzle condition and rate of deterioration include but are not limited to load duty, fuel,
operational and repair history.
The information below is intended to inform users of common nozzle conditions observed during routine borescope
inspections.
NOZZLE CRACKING
Cracking can occur on any gas turbine cast nozzle. This is particularly true for stage one nozzles as these operate at
higher temperatures than the downstream stages.
The cracking observed in cast stage one nozzle segments is typically a result of thermal cycling typically during unit
start-up. However, crack damage observed after the first stage is generally driven by creep. This is due to the fact that
these segments are retained axially by hooks at the outer diameter on just one side of the airfoil. That combined with
the load generated by the diaphragm hanging at the bottom of the segment and other operational forces causes any
potential cracks to initiate primarily at the outer leading edge of the airfoil (See Table I). Nozzles operating in units of
cyclic duty tend to be more prone to cracking due to the number of increased starts
It is important to note that nozzle cracks are considered to be a result of normal part operation. Nozzle cracks occur
and propagate early in operation but tend to slow down and stop or arrest themselves over time. Incidents of nozzle
material liberating and causing damage to downstream components are very rare. Cracks are generally monitored by
the standard annual borescope inspections.
Table I below shows some examples of cracks occasionally observed on segmented nozzles.
NOTE: Converging cracks are of particular importance as they could potentially lead to loss of nozzle material

2012 General Electric Company

This Technical Information Letter contains proprietary information of the General Electric Company, USA and is furnished to its customer solely to
assist that customer in the installation, testing, operation and/or maintenance of the equipment described. This document shall not be reproduced or
distributed in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy Services Engineering. All
rights reserved.
Page 2 of 7

TIL 1108-R1
Inner Sidewall Cracks

Outer Sidewall Cracks

Airfoil Chordal Cracks

Leading Edge Cracks

Trailing Edge Cracks

Craze Cracks

Converging Airfoil Cracks

Limit:
A must be greater than D.
D must be less than chordal
length of the airfoil.
Table 1:

Typical nozzle crack conditions

2012 General Electric Company

This Technical Information Letter contains proprietary information of the General Electric Company, USA and is furnished to its customer solely to
assist that customer in the installation, testing, operation and/or maintenance of the equipment described. This document shall not be reproduced or
distributed in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy Services Engineering. All
rights reserved.
Page 3 of 7

TIL 1108-R1
OXIDATION/EROSION
Oxidation damage will generally produce metal loss in specific areas of the nozzles and can vary widely from segment
to segment. In general, this oxidation damage will occur on first stage nozzles as these operate in a higher temperature
environment as compared to the downstream nozzles. It is not uncommon to see most oxidation damage on the inner
and outer sidewalls of the nozzle segments.

Figure 1:

Oxidationdamage

In some rare instances, nozzle airfoil oxidation has been observed as a result of contamination of the internal cooling
cavities (see Figure 4C).
THERMAL BARRIER COATING SPALLATION
Thermal Barrier Coating (TBC) spallation has been observed in the fleet. TBC spallation has a low rate of occurrence and
can be the result of foreign object damage, base metal cracks, normal operating stresses, high operating temperatures,
or some other special cause.
The main function of the TBC is to serve as a protective barrier for the base metal against hot gases. This in turn helps to
ensure the reparability of the part. TBC loss will not affect the functionality or operability of the nozzle. However,
exposure of base metal to hot gases for extended periods of time could result in increased part fallout during repair.

Figure 2:

TBCspallation

FOREIGN OBJECT DAMAGE

Nozzle damage can also occur as a result of foreign object damage (FOD). This can affect the nozzle airfoil and sidewalls
in the form of dents and other damages resulting from impact. FOD generally does not affect part operability and
functionality and is a low risk for continued part operation.

2012 General Electric Company

This Technical Information Letter contains proprietary information of the General Electric Company, USA and is furnished to its customer solely to
assist that customer in the installation, testing, operation and/or maintenance of the equipment described. This document shall not be reproduced or
distributed in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy Services Engineering. All
rights reserved.
Page 4 of 7

TIL 1108-R1

Figure 3:

Foreignobjectdamage

ABNORMAL NOZZLE CONDITIONS

Figure 4 below shows some examples of what is considered to be abnormal nozzle damage that could warrant part
replacement depending on the duration of the remaining tour.

Figure 4:

Abnormalnozzleconditions

Three critical factors in determining the continued use of a nozzle are:

a.

The probability of a portion of the nozzle segment coming loose and going downstream

b. Loss of significant nozzle material such that it interferes with the flow, leading to problems with proper
functionality of the combustion system
c. Loss of material, potentially resulting in substantial ingestion or back-flow of hot gases into the nozzle (airfoil or
sidewall), and rapidly accelerated degradation
Contact your local GE Service Manager or Contract Performance Manager for assistance in determining the disposition
of a nozzle.

RECOMMENDATIONS
NOTE: Perform all the recommended inspections in accordance with your GE Operation and Maintenance (O&M) manual

and other specific OEM recommendations.

During borescope inspections, refer to the guidelines in the Background section of this TIL, and use this information as a
supplement to what is available in the GE O&M Manual and other specific OEM recommendations. Typical nozzle
conditions, as shown in the examples above, require no immediate action if observed prior to HGP intervals. However, if
an abnormal condition is detected or there is any uncertainty about the parts ability to remain in service or the need for
immediate repairs, contact your local GE Service Manager or Contract Performance Manager for assistance or for
additional information.
2012 General Electric Company
This Technical Information Letter contains proprietary information of the General Electric Company, USA and is furnished to its customer solely to
assist that customer in the installation, testing, operation and/or maintenance of the equipment described. This document shall not be reproduced or
distributed in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy Services Engineering. All
rights reserved.
Page 5 of 7

TIL 1108-R1
This TIL may be considered complete when the nozzle inspections, including borescope inspection, have been
completed in accordance with the O&M Manual and the supplementary information in this TIL.

PLANNING INFORMATION
Compliance

Compliance Category: M
Timing Code: 4

Manpower Skills
Normal plant outage personnel
Parts
N/A
Special Tooling
N/A
Reference Documents
GER 3620
Previous Modifications
N/A
Scope of Work
One borescope inspector for one eight-hour shift.
Contact your local GE Service Manager or Contract Performance Manager for assistance or for additional
information.
Contact your local GE Service Manager or Contract Performance Manager in order to update GE unit record sheets
or to submit as-built drawings for changes incurred by this TIL.
NOTE: If you would like to receive future TILs by email, contact your local GE Service Manager or Contract Performance

Manager for assistance.

2012 General Electric Company

This Technical Information Letter contains proprietary information of the General Electric Company, USA and is furnished to its customer solely to
assist that customer in the installation, testing, operation and/or maintenance of the equipment described. This document shall not be reproduced or
distributed in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy Services Engineering. All
rights reserved.
Page 6 of 7

TIL 1108-R1

TIL COMPLIANCE RECORD

Compliance with this TIL must be entered in local records. GE requests that the customer notify GE upon compliance of
this TIL.
Complete the following TIL Compliance Record and FAX it to:
TIL Compliance
FAX: (678) 844-3451
Toll free FAX: 1-888-896-TILS (1-888-896-8457)

TIL COMPLIANCE RECORD

For Internal Records Only #

Site Name:
Customer Contact Information

Customer Name:
GE Contact Information

Contact Name:

Contact Name:

Address:

Address:

Email:

Email:

Phone:

Phone:

FAX:
Turbine Serial Number(s):

FAX:

INSTALLED EQUIPMENT

TIL Completed Date:

100% TIL Completed:

Description:

Unit Numbers:

Part Description:

Part Number

MLI Number

Comments:

If there are any redlined drawings that pertain to this TIL implementation, please FAX the drawings along with
this TIL Compliance Record.

NOTE:

FAX this form to:

TIL Compliance
FAX: (678) 844-3451
Toll free FAX: 1-888-896-TILS (1-888-896-8457)

2012 General Electric Company

This Technical Information Letter contains proprietary information of the General Electric Company, USA and is furnished to its customer solely to
assist that customer in the installation, testing, operation and/or maintenance of the equipment described. This document shall not be reproduced or
distributed in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy Services Engineering. All
rights reserved.
Page 7 of 7