Reconditioning Gas Turbine Components Quality Control Assessment Method

8/10/2019 Reconditioning Gas Turbine Components Quality Control Assessment Method

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ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that itis 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 issubject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.Alstom contributes to the protection of the environment. This leaet is printed on environmentally-friendly paper.

Quality management an integralpart of the reconditioning processA modern quality assurance system is an integral part of Alstoms reconditioningproce. From he peco of com par, o he a check before reuredo he cuomer, every par ubjec o he he, fuy raceabe quay coro aevery step of the reconditioning process.

A a a urbe Ora Equpme Maufacurer (OEM) wh over 30 yearrecodo experece we kow ha recodo oy make aca ee f

he ora reaby ad performace crera ca be fuy reored or eve upradedto latest design standards.

Reaby deped o he aby o fuy reore he mechaca ery ad rehof each par. Performace deped o he aby o precey reore he oradimensions and design intent that are so critical for the tight clearances that determinehe efcecy of a ee.

Quality assurance at Alstom represents our commitment to protecting our customersae ad reveue by uppor he operao of efce, reabe ad emo-compa a urbe.

At Alstom, quality

control is a mindset

that permeates the

organisation because

the reliability, efciency

and emissions

performance of a gas

turbine is the sum of thequality of decisions and

processes involved for

every component at every

lifecycle stage.

Quality controland assessment methodsReconditioning of gas turbine components

GASSERVICESOLUTIONS

CUSTOMER BENEFITS

Global standardsAlstoms global reconditioningnetwork is organised andequipped to ensure the same highstandards worldwide.

Shape and strength restoredOur quality control ensures therestoration of precise dimensionsfor smooth reassembly andmechanical integrity for reliableoperation.

Full traceabilityOur R-DAS database storesmanufacturing and reconditioningsteps and quality-relevant datafor every component over its fulllifecycle.

Full portfolio of testsAll types of quality control canbe accomplished with our fullportfolio of assessment methods.

Quality

AlstOMs REOnitiOning PROEss

Assess Strip/Clean Repair Coating


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An expert system for enhanced quality assuranceTHROUGHOUT THE ENTIRE RECONDITIONING PROCEDURE A COMPLETE RECORD

OF ALL THE DATA RELEVANT TO QUALITY IS KEPT IN ALSTOMS R-DAS DATABASE

Every par ha decao ad era umber ha k o deaed ora peccao ad a record of a heubeque procee, de uprade or quay checkconducted on that part.

th make he maufacur procee ad each ep quay fuy raceabe for every dvdua par.

the R-As bud o dvdua, echca compoepeccao uch a zoe draw, dmeo adstandardised repair criteria.

When a part arrives for reconditioning, an initial assessment made ad eered o he R-As daabae.

An incoming inspection report is generated.

the he yem docume he d ad auomacayproposes the necessary reconditioning steps.

As the reconditioning proceeds, the steps are recorded in theR-As ao wh he oucome of he erm aemeand tests conducted.

Afer a recodo ep are compeed, a areconditioning report is produced.

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THE UNIQUE FEATURES OF R-DAS

R-DAS is a web-based, advanced system that buildson 30 years of reconditioning experience. It is continuouslybeing developed and updated to meet the needs ofour customers all over the world.

It facilitates: Systematic inspections and quality

data storage Automatic repair proposals Automatic scrap tracking Systematic feedback for product improvement Globally consistent standards throughout

the Reconditioning Network Cost and delivery schedule estimates

GASSERVICESOLUTIONSQUALITY CONTROL AND ASSESSMENT METHODS

Reconditioning

specifcations& drawings

Detailed component

assessment

Standard processes,

inspection & test plansStrip/cleanRepairoa

Customer reporting

StandardisedAutomated

REOnitiOning iAgnOstis An stAtistis (R-As) PlAtFORM

R-DAS PLATFORM

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Aeme ad o-derucve e echooyNON-DESTRUCTIVE TESTING (NDT) REFERS TO NON-INVASIVE TECHNIQUES USED TO DETERMINE THE STRUCTURAL

INTEGRITY OF A COMPONENT WITHOUT CAUSING ANY DAMAGE OR PERMANENTLY ALTERING THE PROPERTIESOF THE COMPONENT OR MATERIAL BEING INSPECTED

Aom ue nt he a aeme ad for quaycoro dur ad afer he recodo proce. icojuco wh our wde rae of aeme mehod,we are abe o offer cuomer rm evdece of he ucceof a reconditioning process.

thak o our aeme ad cered nt echooy, we caprovde our cuomer wh he aurace ha a recodoedpar w perform afey ad reaby aode ew or oracomponents.

the foow rae of e empoyed:

Vua borocope pecoFuorece peera peco (FPi)meoa checkUraoc e (Ut)Eddy-curre meaureme echqueMaec parce peco (MPi)ArowWaerowX-ray ad compuer omoraphyWeh mome check ad frequecy e for roa par

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Boroscope inspection on GT26 Vane 3 FPI on GT24 HPT vane: Linear indications and surface aws are clearly visibleunder UV light

Visual boroscope inspectionFluorescent Penetrant Inspection

(FPI)


the era rucure of ar-cooed compoe ca be verycompex. Moder borocope echooy aow deaed vuapeco of he de of uch compoe o be made.

Vua borocope peco are ued o verfy:

Whether there are any surface defects, such as corrosionof the inner surface.

The integrity of the internal structure, e.g. state of thempeme pae ha ude he coo ar wh hecomponent.

That the component is free of internal deposits.

FPi he dea mehod for deec a or of dcaoad urface aw. Afer cea he par, a uorece dye applied and then, after the application of a developer, a visualinspection is performed under UV light.

Alstom has developed an automated application system toehace he reproducby of he reu ad aow our quaedinspectors to concentrate on the analysis of the surface.

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Dimensional checks Ultrasonic Testing (UT)

3D coordinate measuring machine(CMM)

Ultrasonic testing on GT24 HPT blades

heck dmeo a fudamea apec of quay coro.3 oordae Meaur Mache (MM) ad oher mehodare ued o eure ha recodoed par mee peccao.Parcuar aeo pad o eur perfec aembyclearances.

Aemby ae or hafwhee ca ao be uedfor aemby e.

Uraoc te (Ut) rey o hh-frequecy oud eery ocoduc examao ad make meaureme. Uraocpeco ca be ued for aw deeco/evauao, dmeoameasurements, material characterisation, and more.

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Airow Waterow

Computer tomography of a GT24 HPT blade

Airow quantity control on GT24 HPT vane

Computer tomography of a GT24 HPT blade

Weight moment check

Waterow

Weight moment check

X-ray and computer tomographyWeight moment check

and frequency test


if eceary, we ca appy X-ray or compuer omoraphy eto assess the internal structure of parts.

the weh mome meaureme for roa par, .e.bade, provde he ba for pecfy he bade drbuodur aemby. th eceary o mee he roor dyamcrequreme. Pror o he weh mome meaureme, afrequecy e may eed o be performed o eure ha parare wh he deed frequecy bad afer recodo.

To test the full functionality of the cooling system ofrecodoed ar-cooed compoe, we meaurearow he ee-ready codo.

The consumption of cooling air has an impact onee efcecy ad emo. For compoe whan advanced cooling system, individual sectors of thecompoe ca be checked oao o eure he opmacoo of dvdua ecor or row of coo ar hoe.

Waerow e ve cear vua dcao of wheher coo-ing holes are either open or clogged.

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ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that itis 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 issubject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.Alstom contributes to the protection of the environment. This leaet is printed on environmentally-friendly paper.


We pu quay rAT ALSTOM, QUALITY CONTROL AND ASSESMENT IS AN INTEGRAL PART OF EVERY

MANUFACTURING AND RECONDITIONING PROCESSOur quay aeme mehod are baed o our exeve OEM kowede ad ouroba ee ad ab-baed bechmark. Aom oba Recodo aocad sac (R-As) daabae uppor fu raceaby of a quay-reeva daathroughout a components lifecycle.

Baed o hee rm foudao, he reu of our compreheve rae of aememehod ad o-derucve e provde reabe predco ha mprove youree reaby, avaaby ad performace.

KEY ADVANTAGES

Aom OEM kowede of heora de e combaowh va ed experece aow u ocheck a quay-reeva opc.

Systematic storage of quality andmaufacur daa R-As for furaceaby of a par ad procee.

sae-of-he-ar quay emehod wh a hh deree ofautomatisation.

Persistent training and furtherquacao of empoyee.

oe quay adard acro heAom ework.

isO 9001/ 14001 ad OHsAs18001 cercao o eure bemanagement, environmental andsafety practices.

To nd out more about reconditioning ofgas turbine components, please contact

your local Alstom representative.

ALSTOM (Switzerland) Ltd.Brown Boveri Strasse 7

5401 BadenSwitzerland

Visit us online: www.alstom.com

Reconditioning Gas Turbine Components Quality Control Assessment Method

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