Detect, Measure, Analyse,Compare Data with XLGO and 3D Probe,during the Inspection on Gas Turbine.

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1 Detect, Measure, Analyse,Compare Data with XLGO and 3D Probe,during the Inspection on Gas Turbine. BERGEN NORWAY June 12, 2012 Massimiliano Bandini GE Inspection Technologies Global Account Manager O&G 1

2 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 2

3 Gas Turbine 3

MS5002E Heavy Duty Isometric View Gas generator RPM : 7455 2 stages HP turbine Thick wall cast iron casing (with

4 MS5002E Heavy Duty Isometric View Gas generator RPM : stages HP turbine Thick wall cast iron casing (with horizontal split) Power Turbine RPM : stages LP turbine 11 Stages Axial Compressor 6 DLN Can combustors 4

5 Where Gas Turbines used? LNG Liquefaction LNG Re-gasification Refinery Power plant Co-generation Platform Floating Production Vessels Pipeline 5

6 CROSS SECTIONAL 6

7 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 7

8 POTENTIAL FAILURE AREA 8

9 TYPICAL FAILURE MODES Examples of Foreign Object Damage (FOD): Bent leaf: Missing material on the blade: 9

10 TYPICAL FAILURE MODES Corrosion pitting on leading edge: Liquid erosion on the leading edge: Cross section Point clouds 3D Volume 10

11 TYPICAL FAILURE MODES Corrosion pitting on radius and fillet: 11

12 TYPICAL FAILURE MODES Dirt build up on trailing edge: 12

13 PHOTOS GALLERY 13

14 PHOTOS GALLERY 14

15 PHOTOS GALLERY 15

16 PHOTOS GALLERY 16

17 PHOTOS GALLERY 17

18 CATASTROFIC FAILURE 18

19 CATASTROFIC FAILURE 19

20 DETAIL OF CATASTROFIC FAILURE 20

21 Typical Inspection methods Boroscope Inspection XLGO+ XLG3 21

22 The Rhythm Platform Turning information into intelligence DR EC CR UT Review Visual Inspect DICONDE One standard = One platform Report Share Archive 22

23 Software Solutions Menu Directed Inspections ( MDI )

24 The Inspection Process The Present and Future One - Time Repeat Build Load Inspect Report Build inspection using MDI Builder Load inspection on VideoProbe (XL Go+ or XLG3) Perform inspection using MDI Generate report on VideoProbe, Review on PC Send Characterize Send inspection to Rhythm Report Review Archive 24

25 Plan Inspect Report Rhythm Automatically generated on XL Go+ PC Setup (one time) 25

26 Menu Directed Inspection (MDI) making a routine inspection CFM56-7B 26

27 3D Phase Measurement 3D Surface Scanning and Measurement System Video Borescope Technology Enables Internal 3D Examination of Equipment

28 Phase Shifting What if we had many shadows? Fiber Bundle Slit Aperture Shadows Imager Shadow Tip Z 1 Z 2 And the shadows had structure? 28

29 Phase Shifting Typical Setup Object Image 0 Image 1 Image 2 Image 3 Camera Projector 29

30 Phase Shifting in the XLG3 LED Arrays Shadow Pattern Viewing Optics 30

31 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. 31

32 Phase Images 32

33 Phase Images 33

34 Phase Images 34

35 Image Capture and Analysis

36 Types of 3D Measurement Length Multi-Segment Length Area Point to Line Depth Depth Profile 36

37 Depth Profile Illustrative example: 37

38 Depth Profile Slot Should be in same plane Scale No Data Distance Between Cursors Point furthest from reference plane Cross-Sectional Area (only when no red included) 38

39 Depth Profile Tear in Welded Blade Edge 39

40 Point Cloud 40

41 Point Cloud x,y,z file Compare worn condition to new geometry 41

42 Application Turbine Blade 42

43 Application Weld Inspection 43

44 Application Corrosion Pitting 44

CORROSION PITTING 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.

45 CORROSION PITTING 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. Typical Pits What causes pitting corrosion? For a defectfree "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. 45

46 Study on : GT MS5002 C Blade R0 AREA 0130 PIT IDENTIFICATION 0130_2 0130_5 Material: GTD450 Plant :LNG 46

47 Study on MS5002 C Blade R0 0130_5 47

48 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_ _ 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 48

49 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

50 Typical Failure mode on Turbine Wheel Axial view reveals crack locations in discs with axial-entry fir tree type blade attachment grooves. 50

51 Example of Eddy Current application on R0 Blade R0 Blade Leading Edge P-Cut Feature Benefits Early Detection helps to avoid catastrophic failures Fast and accurate detection Detects cracks as small as

GT Installed fleet (Norway example) 3 48 >50 MW 25-50 MW 140

52 GT Installed fleet (Norway example) 3 48 >50 MW MW MW 191 Gas Turbine installed, the oldest have more then 30yrs 52

53 Q & A 53

54 Thank you! 54

Introducing 3D Phase Measurement

Introducing 3D Phase Measurement New Optical Measurement Technique For the XLG3 Video Borescope Based on phase shifting principles of optical metrology, 3D PM is an Exciting Breakthrough for the RVI industry.