© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Agenda
Introduction Page 3
Water Jet Cleaning Page 5
Water Jet Cutting Page 10
Automated Phased Array Ultrasonic Testing Page 15
Conclusion Page 21
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Introduction
Outage Optimisation
Time savings
In-situ work
Speed and accuracy
Remote support
Tasks
Dismantling
Surface preparation
Inspection
Repair
Re-assembly
General Solutions
Modern technology
Automation
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Agenda
Introduction Page 3
Water Jet Cleaning Page 5
Water Jet Cutting Page 10
Automated Phased Array Ultrasonic Testing Page 15
Conclusion Page 21
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Reasons for cleaning
− To ensure safe operation− To prepare for inspection− To restore swallowing capacity*− To increase efficiency*
* Valid for blading
• Conventional Sand-Blasting
− Time consuming− Poor quality control− Requires component removal− Limited accessibility− Risk of damage
HP rotor requiring cleaning
Example 1 – Water Jet Cleaning
Background
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Newly patented by Alstom, with the following features:
− Hard abrasive at 3-5% mix− Water and abrasive pre-mixing− Pressure range: 150 - 250 bar− Hose Ø: <12mm− Tungsten carbide fan jet nozzle− Jet velocity: 150m/s (approx)− Water recirculation− Continuous operation
Manual tool
Suspension
system
Water Jet Cleaning
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Air blasting
Garnet 120 mesh
+ Glass beads
Waterjet cleaning
Corundum mesh
220
Water Jet Cleaning
100100µµmm 1010µµmm
100100µµmm 1010µµmm
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Advantages
− Minimal material removal− Surface quality, Ra= 0.8µm
(sandblasting Ra= 3.2µm)− Reduction in cleaning time: 20%
Water Jet Cleaning
0
0.5
1
1.5
2
2.5
3
3.5
Dry blasting Water Jet Cleaning
with Garnet
Water Jet Cleaning
with Corundum
Water Jet Cleaning
with Zirblast 125
Water Jet Cleaning
with Zirblast 63
− High mobility (cleaning in situ)− Short installation time− Improved steam path efficiency
Su
rfa
ce
ro
ug
hn
ess R
a [
µm
]
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Agenda
Introduction Page 3
Water Jet Cleaning Page 5
Water Jet Cutting Page 10
Automated Phased Array Ultrasonic Testing Page 15
Conclusion Page 21
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Reasons for cutting
− Stuck component fixings(10% of blade root pins)
• Conventional Drilling
− Imprecise− Time consuming− Tools not mobile− Risk of damage
Blade root pins
Drilling damage
Example 2 – Water Jet Cutting
Background
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Method
− Push out pins with hydraulic system− Cut into stuck pins to weaken them
Water Jet Cutting
• Parts
− Camera• 5M pixels
• 40mm from abrasive jet
− Cutting head• 10 mins (approx) per pin
• Different sizes available
− Catcher• Placed behind pin
• Detects breakthrough
• Different sizes available
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Water Jet Cutting – Pin cutting procedure
Set up robotics next to the steam turbine
Fix system withclamping mechanism
Set pin position usingcamera tool
Set parameters for piercing and cutting
Pierce a hole in thecentre of the pin, cutting of rivet head
Cut the pattern
1 2 3
4 5 6
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Advantages
− Reduction in process time− Greater process control− Improved reliability− Elimination of EHS risks− High mobility for on-site− Low risk of damage
Water Jet Cutting
60mmMin gap (discs)
14Max pin l/Ø ratio
200mmMax pin length (l)
4.5 – 25mmPin Ø range
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Agenda
Introduction Page 3
Water Jet Cleaning Page 5
Water Jet Cutting Page 10
Automated Phased Array Ultrasonic Testing Page 15
Conclusion Page 21
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Reasons for inspection
− Stress corrosion and HCF− High risk from largerotating parts
Example 3 – Phased Array UT Testing(i) LP blade roots
BackgroundBlade failure caused
by undetected crack
• Manual Inspection
− Inconsistent− Time consuming
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Blade Fixture
− Phased array Ultrasonic Testing (UT)− Designed for blade profile− Automated traversing (some types)− Scan recorded on a laptop− Process validated by tests
Phased Array UT Inspection(i) LP blade roots
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Benefits
− Automated scanning− In-situ capability− Good process control− High quality data− Repeatability− Data transmission for remote review
Phased Array UT Inspection(i) LP blade roots
Example test piece and results
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Features:
− Automated, with motor drive unit− Magnetic wheels− Width 54mm− Parallel scanning− Instant data− Developed for straddle roots− Head calibrated for different geometries
Phased Array UT Inspection(ii) rotor disc heads
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Benefits
− Fast inspection(LP disc in 10 minutes)
− Can be done with rotor in-situ− Validated, consistent process
The unit between discs
Phased Array UT Inspection(ii) rotor disc heads
Data
output
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Agenda
Introduction Page 3
Water Jet Cleaning Page 5
Water Jet Cutting Page 10
Automated Phased Array Ultrasonic Testing Page 15
Conclusion Page 21
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Conclusion
Full Autonomy
Full
Automation
Manual
Guided
MovementFree Movement
on Regular Surfaces
Free Movement
on Complex Surfaces
Degree of Autonom
y
Manual
Scanner
Degree of Mobility
Robotics
From manual inspection tools to robotics
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
1. Bolt Inspection Table
− MPI by moveable coil− Endoscopy and hardness testing− Motorised turntable− Range of sizes− Foldable for transportation
2. Hollow Bolt Scanner
− UT testing− In-situ inspection− Stress corrosion cracks detected
Conclusion - other new technologies
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Conclusion - other new technologies
3. Rotor Bore Scanner
− Ultrasonic Testing (UT)− Magnetic Particle Inspection
(MPI)− Life assessment− >50 references
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Presentation title - 01/01/2007 - P 25
Title (Alstom 28)
• Level 1
− Level 2
• Level 3
Subtitle / Main message (Alstom 26)