Nicholas Marsh

13th February 2012

Advanced Outage Compression

Methods for Steam Turbines

© 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

www.alstom.com

© 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)