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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

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

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

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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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Q & A

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Thank you !