ConferencePaper PredictionofPollutantsEmissionsina CFM56 ...
Detect, Measure, Analyse ,Compare Data with XLGO and 3D ...ndt.sitegen.no/customers/ndt/files/VT...
Transcript of Detect, Measure, Analyse ,Compare Data with XLGO and 3D ...ndt.sitegen.no/customers/ndt/files/VT...
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BERGEN – NORWAY June 12, 2012
Massimiliano Bandini GE Inspection Technologies Global Account Manager O&G
Detect, Measure, Analyse ,Compare Data with XLGO and 3D Probe,during the Inspection on Gas Turbine.
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Summary :
• Gas Turbine Cross Section • Gas Turbine Failure mode • Software for NDE (Rhythm) • Software MDI • 3D Probe (XLG3) • Corrosion pitting • Study MS5002C – R0 • Eddy Current on Rotor MS5002C • Gas Turbine Fleet in Norway
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Gas Turbine
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Isometric View Gas generator
RPM : 7455
Power Turbine RPM : 5714
Thick wall cast iron casing
(with horizontal split)
11 Stages Axial Compressor
6 DLN Can combustors
2 stages HP turbine
2 stages LP turbine
MS5002E Heavy Duty
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Where Gas Turbines used?
Pipeline Floating Production
Vessels
Platform
LNG Liquefaction LNG Re-gasification
Refinery
Co-generation
Power plant
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CROSS SECTIONAL
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ROTOR FAILURE MODE
Components :Blades & Buckets - FOREIGN OBJECT DAMAGE
- EROSION
- CORROSION
- RUBBING
- CRACKS
-DIRT BUILD-UP
-MISSING MATERIAL
-BENT LEAVES
How we can be prevent failure Inspection
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POTENTIAL FAILURE AREA
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TYPICAL FAILURE MODES
Examples of Foreign Object Damage (FOD):
Bent leaf: Missing material on the blade:
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TYPICAL FAILURE MODES Corrosion pitting on leading edge: Liquid erosion on the leading edge:
Cross section
Point clouds 3D Volume
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TYPICAL FAILURE MODES
Corrosion pitting on radius and fillet:
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TYPICAL FAILURE MODES
Dirt build up on trailing edge:
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PHOTOS GALLERY
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PHOTOS GALLERY
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PHOTOS GALLERY
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PHOTOS GALLERY
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PHOTOS GALLERY
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CATASTROFIC FAILURE
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CATASTROFIC FAILURE
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DETAIL OF CATASTROFIC FAILURE
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Boroscope Inspection
Typical Inspection methods
XLGO+
XLG3
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The Rhythm Platform “Turning information into intelligence”
Inspect
Review
Report
Archive Share
DR
CR
UT
Visual
DICONDE “One standard = One platform”
EC
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Menu Directed Inspections ( MDI )
Software Solutions
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The Inspection Process The Present and Future
Build inspection using MDI Builder
Build
Load inspection on VideoProbe
(XL Go+ or XLG3)
Load
Perform inspection using
MDI
Inspect
Generate report on VideoProbe, Review on PC
Report
Send inspection to Rhythm
Send • Characterize
• Report
• Review
• Archive
One - Time Repeat
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Automatically generated on XL Go+
PC Setup (one time)
RhythmReportInspectPlan
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Menu Directed Inspection (MDI) making a routine inspection CFM56-7B
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3D Phase Measurement
• 3D Surface Scanning and Measurement System • Video Borescope Technology • Enables Internal 3D Examination of Equipment
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Imager Shadow
Tip
Fiber
Bundle
Shadows
Slit
Aperture
Z 1 Z 2
Phase Shifting
What if we had many shadows?
And the shadows had structure?
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Phase Shifting Typical Setup
Camera Projector
Object
Image 0
Image 1
Image 2
Image 3
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Phase Shifting in the XLG3 LED Arrays
Shadow
Pattern Viewing
Optics
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Optics Configuration
• Line patterns are projected using 3 LEDs on each side of viewing optics.
• Object distance at each point is computed using pattern trajectories (triangulation) known from calibration.
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Phase Images
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Phase Images
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Phase Images
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Image Capture and Analysis
1
3
2
4
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Types of 3D Measurement
Length
Multi-Segment Length
Area
Point to Line
Depth
Depth Profile
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Depth Profile Illustrative example:
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Depth Profile 0.180” Slot
Scale No Data
Distance
Between Cursors
Cross-Sectional Area (only when no red included)
Point furthest from reference plane
Should be in same plane
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Depth Profile
Tear in Welded Blade Edge
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Point Cloud
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Point Cloud – x,y,z file
Compare worn condition to new geometry
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Application – Turbine Blade
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Application – Weld Inspection
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Application – Corrosion Pitting
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What is pitting corrosion? Pitting Corrosion is the localized corrosion of a metal surface confined to a point or small area, that takes the form of cavities. Pitting corrosion is one of the most damaging forms of corrosion. Pitting factor is the ratio of the depth of the deepest pit resulting from corrosion divided by the average penetration as calculated from weight loss.
CORROSION PITTING
What causes pitting corrosion? For a defect-free "perfect" material, pitting corrosion is caused by the ENVIRONMENT (chemistry) that may contain aggressive chemical species such as chloride. Chloride is particularly damaging to the passive film (oxide) so pitting can initiate at oxide breaks.
Typical Pits
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Study on : GT MS5002 C –Blade R0
Material: GTD450 – Plant :LNG
0130_2
0130_5
AREA 0130 PIT IDENTIFICATION
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Study on MS5002 C –Blade R0
0130_5
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Methods
Eddy Current (Coil : Absolute)
(Freq:1Mhz)
Microscope (Confocal Microscopes)
RVI 3D PROBE ( 6 mm OD)
PIT ID Depth (µm)
Depth (µm)
Depth (µm)
130_5 262 240 210
130_2 177 163 148
Eddy Current
Microscope
RVI 3D PROBE
Lead time Day Week Hrs
Investment Low time by time High one time Medium
Skilled resource Medium High Low
Result Certificate Report Automatic report + point clouds
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Example of Eddy Current application on Turbine Wheel
Benefits
• Early Detection – helps to avoid catastrophic failures
• Patented multi-channel (96) eddy current array probe fully
conforms to dovetail profile
• Complete coverage in single pass
• Detects cracks as small as .030”
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Typical Failure mode on Turbine Wheel
Axial view reveals crack
locations in discs with
axial-entry fir tree type
blade attachment grooves.
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Example of Eddy Current application on R0 Blade
Benefits
• Early Detection – helps to avoid catastrophic failures
• Fast and accurate detection
•Detects cracks as small as .030”
P-Cut Feature
Leading Edge
R0 Blade
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GT Installed fleet (Norway example)
191 Gas Turbine installed, the oldest have more then 30yrs
0-25 MW
25-50 MW
>50 MW
140
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3
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Q & A
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Thank you !