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3angles services overview nov 2013


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Advanced NDT Application …

Advanced NDT Application
Automated boresonic inspections of turbine rotors
Automated inspection of generator retaining rings (in-situ)
Bump testing of generator stator end windings
Generator dovetail slot inspections Generator dovetail slot inspections TIL1292
Wheel side examinations of GE saddle style blade rootsTIL-1277

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  • 1. Services O S i Overview i Albany, NY D Document number Introducing:
  • 2. About 3angles, Inc. g ,  Formerly known as Northeast Inspection Services, Inc. (NISI) and KEMA the company has been around for 30+ years  Our Mission - 3angles Inc. provides innovative and cost 3angles, Inc effective inspection services, engineering and consulting support - 3angles, Inc. supports its clients meeting their quality, safety and operation and maintenance objectives of their capital equipment, products and property  Our values - We care about our clients and each other Safety is always our number one priority We do it right We always look for new and innovative solutions We enjoy what we are doing 2
  • 3. GO BACK Services  NDT methods offered: UT, ET, VT, MT and PT - Inspections of steam turbines, gas turbines, generators and components during power t d t d i generation plant outages - Inspection of wind towers and turbines - Inspection of products from manufacturing shops  Ultrasonic testing capability includes TOFD and Phased Array  Magnetic particle testing, capability with 10,000 Amp Mag Machine  Visual inspections, video endoscopy  Level II and ASNT Level III certified inspectors  ISO 9001-2008 certified  Personnel Qualification and Certification per SNT-TC-1A SNT TC 1A 3
  • 4. Special applications p pp  Automated boresonic inspections of turbine rotors  Automated inspection of generator retaining rings (in-situ)  Bump testing of generator stator end windings  Generator dovetail slot inspections TIL1292  Wheel side examinations of GE saddle style blade rootsTIL-1277 4
  • 5. Boresonic inspections of rotors – over 300 inspected! p p  Macro-inclusions, inclusion arrays, flakes, thermal cracks, forging cracks, porosity, shrink voids and pipe, which concentrate stress that can initiate and g grow cracks on a macro-scale  These flaws are the subject of concern and are the primary target of in-service boresonic inspection  Some ultrasonic techniques may also be employed to detect the p p y presence of segregations and micro-inclusions
  • 6. Typical Boresonic examination program includes  Visual Inspection (VT)  Magnetic Particle Inspection (MT) or Eddy Current (ET)  Ultrasound Inspection ( ) p (UT)
  • 7. Bore plug removal and p p g power honing capability g p y  Bore plugs removed by machining or alternate collapsing techniques  Plug bore cavities are honed and measured for replacement plug  Surface Finish 63 Micro Inches Ra or Micro-Inches better  Tooling Available For Bores From 2.5” To g 10” in Diameter
  • 8. MT Indication Viewed Through Borescope g p  Magnetic particle inspection surface crack indication  Rotor magnetization capability up to 10,000 Amps.
  • 9. Ultrasonic Examination  Boresonic scanners – validated ultrasonic imaging and data acquisition systems:  R/D Tec manufactured μTomscan (TomoView software and host PC) and stepping motor driver MCDU 02 used in MCDU-02 combination with 15” stroke motorized mechanical boresonic scanner.  Z-Tech manufactured Z-Scan UT (UltraVision software and host PC) and DC servo motor driver MCDU-02 used in combination with 30” stroke motorized mechanical boresonic scanner.
  • 10. Rotor Condition Assessments  Rotor bore condition assessment includes: - Reviewing NDE data g - Developing potential flaw sizes - Stress analysis, material data evaluation and fracture mechanics analysis
  • 11. Generator retaining ring inspection g g p  Stress corrosion cracking is the single major cause of retaining ring failure for j g g austenitic materials  It is the combination of stress and corrosive element exposure that cause the conditions for SCC cracking - Ring failures occur by fatigue, corrosion fatigue, fatigue stress corrosion cracking and brittle fracture - Crack initiation, crack propagation and final p rapid fracture. - Moisture, chlorides, nitrates - Subcritical growth of the crack by fatigue, corrosion fatigue or stress corrosion from initial size to critical size - Upon reaching critical crack size, the ring fails rapidly by plastic instability or by brittle fracture
  • 12. Generator Retaining Ring Manipulator g g p  For in-situ testing and inspection of fields removed from stator  Advantages of in-situ inspections: - Reduce cost and outage time by inspecting the rings without removing the field from the stator - No need to disassemble rotor just for ring inspection - UT/ET combination covers 100% of inner and outer surface of a ring and virtually 100% of its volume - Postponement / avoidance of ring f replacement  1.5” Minimum clearance in front part of p ring for manipulator drive unit and 0.75” clearance need for probe travel
  • 13. Engineering Evaluation g g  Finite element stress analysis of retaining ring  Fracture mechanics using NDT flaw data, FEA stresses and ring specific material properties  Condition assessment can predict the remaining life of the retaining ring and/or provide the next required re-inspection id th t i d i ti interval  Metallurgical analysis of ring for identification of alloy composition and microstructure  Hi hl recommended when l Highly d d h large numbers b or a single significant indication is reported by NDT
  • 14. Bump testing of generator stator end windings p g g g  Bump testing analyzes the natural response of stator end-windings upon excitation from a mechanical impulse.  The response is determined by the stator end winding’s properties including winding s properties, mechanical rigidity  Electromagnetic forces cause vibration of stator end-windings  Excessive vibration can cause the following problems: - erosion of coil insulation (causing a ground fault) - breakage of coil strands (leading to overheating) - weakened end-windings and supports (decreasing the rigidity of structure)
  • 15. Types of Measurements yp  Dynamic Flexibility Measurements - Typically on the stator bar ends and supports y y - Phase connection measurements - Terminal connection measurements  Results provide verification of repair
  • 16. GE TIL-1292 Inspection of Winding Coil Slot Dovetails p g  Cracking caused by mechanical fretting and/or negative sequence arcing g q g between wedges  Field Rewinds - Edd current inspection of dovetail l d Eddy ti ti fd t il load surfaces - Magnetic particle testing of the slot after the field winding has been removed  Retaining Ring Off (No Rewind) - Eddy current inspection of dovetail load surfaces after removal of wedges from winding slot  Retaining Rings On and Wedges In g g g - Ultrasonic testing can be performed to detect larger cracks, but is significantly less sensitive than eddy current
  • 17. Wheel Side Examinations of GE Saddle Style Blade Roots y  Phased Array UT is applied for performing wheel side examinations per TIL-1277  The phased array technology has added advances in flaw detection as it applies to TIL 1277 TIL-1277 blade root examinations examinations. - ability to provide a spatial orientation for the dovetail geometry. This is accomplished g g g process aids in through S-scan imaging. Our p the ability to identity internal geometric reflectors and to visually relate non-geometric reflectors in relation to those now imaged reference points points. - The other advance comes from the ability to sweep the ultrasonic energy through a series of angles. This increases the probability of angles detection for defects with variable reflection geometries or reflection geometries other than optimal for single angle (conventional) examinations. i i 17
  • 18. Inspection of components during outages of Power Plants p p g g 18
  • 19. Shop Capabilities p p  NDT inspections on products/components in our workshop in Albany, NY or at clients’ manufacturing facilities 19
  • 20. For more information: Please contact us: For more information, please contact: 3angles, Inc. g , 2 Access Road Albany, NY 12205 Tel. 518 640 0446 Fax. 518 356 0448 e-mail