siemens ag - non-destructive evaluation techniques...
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Page 1 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Non-Destructive Evaluation Techniques Combined – The Global Inspection System
Siemens AG -
Corporate Technology
Page 2 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Corporate Technology Present in all leading markets and technology hot spots
MunichErlangen Berlin
St. Petersburg MoscowRomsey
(RMR)Princeton
Shanghai
BeijingBerkeley
Tokyo
SingaporeBangaloreVienna
Page 3 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
GTF Nondestructive Evaluation Facts and Figures
Competencies2D/3D Machine Vision Sensors & AlgorithmsActive Thermography2D X-ray and X-ray computed tomographyUltrasound TechnologyOptical TechnologiesPlatforms & Process IntegrationMultimodal Sensor SystemsCondition Monitoring
Mission: Development and industrial application of efficient nondestructive evaluation technologies
Page 4 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Gas turbineRow 1 closest to the center
Row 1 gas turbine bladeTypes of damage
Requirements for Inspection Types of Damage
Cracks
Foreign object damage
Blocked cooling holes
Loss of coating
Delaminations (not visible)
Page 5 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Modular Design
GIS core system
Front end modules Supplementary modules Back end modules
Page 6 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Modular Design Example Configuration
Front end modules Supplementary modules Back end modules
GIS core system
Page 7 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
System Drawings
Further Components:•
2 motors for rotation and tilt (max. 54cm high, 57 cm diameter, 25 kg weight)
•
Safety circuit•
Roof with loading hatch•
2 computers (32/64 bit)
Page 8 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Non-Destructive Evaluation Techniques 2D/3D Measurement
•
11 MPixel CCD camera + custom Full-HD projector•
Active stereoscopy with phase shift approach•
Depth resolution 0.075 mm, lateral resolution 0.2 mm•
Color calibration allows conclusions about the thermal stress a blade had during operation.
Page 9 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
3D model with mapped color texture
top view
side view
2D/3D Measurement Results
Page 10 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Non-Destructive Evaluation Techniques SIEMAT Thermography
•
SIEMAT technology based on infrared camera and piezo actuator
•
Harmonic excitation causes friction at crack faces resulting in localized heating, which can be detected by the infrared camera.
•
Cracks can be found even below the coating.•
Movable infrared camera
Page 11 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
SIEMAT Thermography Results
Color image mapped on 3D model SIEMAT image mapped on 3D model
Crack indications,hardly visible in regular image
Page 12 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
•
Air is heated to 100°C in a hot air hose and lead though the blade from the bottom, alternating with room temperature air.
•
Blocked cooling holes can be detected in the infrared image.
Non-Destructive Evaluation Techniques Hot-Air Thermography
Page 13 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Hot-Air Thermography Results (extract)
Color image mapped on 3D model Hot-air image mapped on 3D model
No blocked channels
Page 14 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
•
The blade surface is heated for a short period of time by 2 flash lamps.
•
Analyzing the way the surface cools down conclusions about delaminations can be drawn.
Non-Destructive Evaluation Techniques Flash Thermography
Page 15 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Flash Thermography Results
Color image in 2D Processed flash image in 2D
Coating delaminations,invisible in regular image
Page 16 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Dye Penetrant Inspection Images with UV Illumination
reflections
penetrant artifacts
cracks
Only fluorescent signals remain in the filtered and post processed image
No filter With UV / IR cut filter
Page 17 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Section of an input image Section of result image enhanced by superresolution (3 images overlaid)
Improved 2D Images Using Superresolution
Page 18 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Inspection-, Marking-
and Analysis-Software
•
Markup in the 2D images will be mapped to the 3D model
•
All measurements appear as layers
•
Comparison to CAD model possible
Page 19 © Siemens AG, Corporate TechnologyH. Euler ([email protected]), CT T DE HW 2
Global Inspection System Conclusion
Modular design for different nondestructive inspection technologies:•
2D and 3D measurement•
SIEMAT acoustic thermography•
Hot-air thermography•
Flash thermography
Standardized inspection and reporting process for all kinds of gas turbine blade defects
Easy evaluation of flaws due to:•
Overlay of visual and infrared images on a 3D model•
Possibility of statistical data analysis •
Comparability of scan to CAD model
Fully integrated, robust mechanical design
Adaptable to new objects and applications Contact:[email protected]/VISION
Features/Versions GIS
Classic1
GISBasic
GISProfessional
GIS-A(Acoustic)
GIS-H(Hot Air)
Classic Inspection2D Images (Object texture) ✔ ✔ ✔ ✔ ✔High Resolution 2D Images (Object texture) 〇 〇 〇 〇 〇UV Light for Penetrant Inspection ✔ 〇 〇 〇 〇Color Fidelity/Highlight Removal color correction intrinsic intrinsic intrinsic intrinsic
Geometrical Inspection3D Surface Scans (Object Model) ✔ ✔ ✔ ✔ ✔High Resolution 3D Surface Scans 〇 〇 〇 〇 〇
Thermography InspectionSmart SIEMAT™ (Acoustic) Excitation — — 〇 ✔ —Flash Excitation — 〇 〇 〇 〇Hot Air Excitation — — 〇 — ✔Movable Infrared Camera — — 〇 〇 ✔
Loading/UnloadingDoor for loading/unloading hinged side side side sideRoof with Loading Hatch — — 〇 〇 ✔Front Door for Markup — 〇 〇 〇 〇
WorkspaceCylindrical 35 cm height/25 cm diameter2 ✔ ✔ ✔ ✔ ✔Cylindrical 54cm height/57cm diameter3 — — ✔ ✔ ✔Turntable with Calibration Marks required required not necessary not necessary not necessary
Processing32 Bit Processing (Windows OS) ✔ ✔ 〇 〇 〇64 Bit Processing (Windows OS) — 〇 ✔ ✔ ✔Scan Time for 12 Views [min] 15 ~10 ~10 ~10 ~10
Device PropertiesDimensions [W cm x L cm x H cm] 70 x 150 x 90 120 x 205 x 195 120 x 205 x 195 120 x 205 x 195 120 x 205 x 195Weight 80 kg ≈ 600 kg ≈ 600 kg ≈ 600 kg ≈ 600 kgModular Base Construction — ✔ ✔ ✔ ✔Maximum Turntable Payload 8 kg 8 kg 25 kg 25 kg 25 kgMotor Controller PC based PC based SIMATIC/SIMOTION SIMATIC/SIMOTION SIMATIC/SIMOTIONInternal Air Conditioning — 〇 〇 〇 〇Certification — 〇 〇 〇 〇
Safety FeaturesDoor loking during operation manual manual automatic automatic automaticOperation Status Display — 〇 ✔ ✔ ✔Emergency STOP — 〇 ✔ ✔ ✔
User InterfaceDisplay fixed LCD LCD on swivel arm LCD on swivel arm LCD on swivel arm LCD on swivel armKeyborad plastic foil industry standard industry standard industry standard industry standard
Application Specific FeaturesBlade Root Scans ✔ ✔ ✔ ✔ —
✔ Included, 〇 optional, — not available 1 Discontinued model included for comparison reason2 Fits to SGT6-5000F/6000G row 1/2 blades3 Fits to SGT5-4000F row 3 blade/vane
Base Modules Bundles