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S i O iServices OverviewAlbany, NY

About 3angles, Inc.g , Formerly known as Northeast Inspection

Services, Inc. (NISI) and KEMA the company has been around for 30+ years

Our Mission3angles Inc provides innovative and cost- 3angles, Inc. provides innovative and cost effective inspection services, engineering and consulting support

- 3angles, Inc. supports its clients meeting their3angles, Inc. supports its clients meeting their quality, safety and operation and maintenance objectives of their capital equipment, products and property

Our values- We care about our clients and each other- Safety is always our number one priority- Safety is always our number one priority- We do it right- We always look for new and innovative solutions

We enjoy what we are doing- We enjoy what we are doing

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Services GO BACK

NDT methods offered: UT, ET, VT, MT and PT- Inspections of steam turbines, gas turbines,

t d t d igenerators and components during power generation plant outages

- Inspection of wind towers and turbinesInspection of products from manufacturing shops- Inspection of products from manufacturing shops

Ultrasonic testing capability includes TOFD and Phased Array

Magnetic particle testing, capability with 10,000 Amp Mag Machine

Visual inspections, video endoscopy

Level II and ASNT Level III certified inspectors

ISO 9001-2008 certified

Personnel Qualification and Certification per SNT TC 1ASNT-TC-1A

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Special applicationsp pp Automated boresonic inspections of

turbine rotors

Automated inspection of generator retaining rings (in-situ)

Bump testing of generator stator end windings

Generator dovetail slot inspectionsGenerator dovetail slot inspections TIL1292

Wheel side examinations of GE saddle style blade rootsTIL-1277

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Boresonic inspections of rotors – over 300 inspected!

Macro-inclusions, inclusion arrays, flakes, thermal cracks, forging cracks,

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flakes, thermal cracks, forging cracks, porosity, shrink voids and pipe, which concentrate stress that can initiate and grow cracks on a macro-scaleg

These flaws are the subject of concern and are the primary target of in-service boresonic inspectionboresonic inspection

Some ultrasonic techniques may also be employed to detect the presence of p y psegregations and micro-inclusions

Typical Boresonic examination program includes

Visual Inspection (VT)

Magnetic Particle Inspection (MT) or Eddy Magnetic Particle Inspection (MT) or Eddy Current (ET)

Ultrasound Inspection (UT)p ( )

Bore plug removal and power honing capabilityp g p g p y Bore plugs removed by machining or

alternate collapsing techniques

Plug bore cavities are honed and measured for replacement plug

Surface Finish 63 Micro Inches Ra or Surface Finish 63 Micro-Inches Ra or better

Tooling Available For Bores From 2.5” To g10” in Diameter

MT Indication Viewed Through Borescopeg p Magnetic particle inspection surface crack

indication

Rotor magnetization capability up to 10,000 Amps.

Ultrasonic Examination Boresonic scanners – validated ultrasonic

imaging and data acquisition systems:

R/D Tec manufactured μTomscan(TomoView software and host PC) and stepping motor driver MCDU 02 used instepping motor driver MCDU-02 used in combination with 15” stroke motorized mechanical boresonic scanner.

Z-Tech manufactured Z-Scan UT (UltraVision software and host PC) and DC servo motor driver MCDU-02 used in combination with 30” stroke motorized mechanical boresonic scanner.

Rotor Condition Assessments Rotor bore condition assessment includes:

- Reviewing NDE datag- Developing potential flaw sizes- Stress analysis, material data evaluation and

fracture mechanics analysis

Generator retaining ring inspectiong g p Stress corrosion cracking is the single

major cause of retaining ring failure for j g gaustenitic materials

It is the combination of stress and corrosive element exposure that cause the conditionselement exposure that cause the conditions for SCC cracking- Ring failures occur by fatigue, corrosion

fatigue stress corrosion cracking and brittlefatigue, stress corrosion cracking and brittle fracture

- Crack initiation, crack propagation and final rapid fracture.p

- Moisture, chlorides, nitrates- Subcritical growth of the crack by fatigue,

corrosion fatigue or stress corrosion from initial size to critical size

- Upon reaching critical crack size, the ring fails rapidly by plastic instability or by brittle fracture

Generator Retaining Ring Manipulator For in-situ testing and inspection of

fields removed from stator

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Advantages of in-situ inspections:- Reduce cost and outage time by

inspecting the rings without removing theinspecting the rings without removing the field from the stator

- No need to disassemble rotor just for ring inspection

- UT/ET combination covers 100% of inner and outer surface of a ring and virtually 100% of its volume

/ f- Postponement / avoidance of ring replacement

1.5” Minimum clearance in front part of pring for manipulator drive unit and 0.75” clearance need for probe travel

Engineering Evaluationg g Finite element stress analysis of retaining

ring

Fracture mechanics using NDT flaw data, FEA stresses and ring specific material propertiesproperties

Condition assessment can predict the remaining life of the retaining ring and/or

id th t i d i tiprovide the next required re-inspection interval

Metallurgical analysis of ring forMetallurgical analysis of ring for identification of alloy composition and microstructure

Hi hl d d h l b Highly recommended when large numbers or a single significant indication is reported by NDT

Bump testing of generator stator end windings Bump testing analyzes the natural response

of stator end-windings upon excitation from

p g g g

a mechanical impulse.

The response is determined by the stator end winding’s properties includingend winding s properties, including mechanical rigidity

Electromagnetic forces cause vibration of stator end-windings

Excessive vibration can cause the following problems:problems:- erosion of coil insulation (causing a ground

fault)- breakage of coil strands (leading tobreakage of coil strands (leading to

overheating)- weakened end-windings and supports

(decreasing the rigidity of structure)

Types of Measurementsyp Dynamic Flexibility Measurements

- Typically on the stator bar ends and supportsy y- Phase connection measurements- Terminal connection measurements

Results provide verification of repair Results provide verification of repair

GE TIL-1292 Inspection of Winding Coil Slot Dovetailsp g

Cracking caused by mechanical fretting and/or negative sequence arcing g q gbetween wedges

Field RewindsEdd t i ti f d t il l d- Eddy current inspection of dovetail load surfaces

- Magnetic particle testing of the slot after the field winding has been removedthe field winding has been removed

Retaining Ring Off (No Rewind)- Eddy current inspection of dovetail load

surfaces after removal of wedges from winding slot

Retaining Rings On and Wedges Ing g g- Ultrasonic testing can be performed to

detect larger cracks, but is significantly less sensitive than eddy current

Wheel Side Examinations of GE Saddle Style Blade Rootsy Phased Array UT is applied for performing

wheel side examinations per TIL-1277

The phased array technology has added advances in flaw detection as it applies to TIL-1277 blade root examinationsTIL 1277 blade root examinations. - ability to provide a spatial orientation for the

dovetail geometry. This is accomplished through S-scan imaging. Our process aids in g g g pthe ability to identity internal geometric reflectors and to visually relate non-geometric reflectors in relation to those now imaged reference pointsreference points.

- The other advance comes from the ability to sweep the ultrasonic energy through a series of angles This increases the probability ofof angles. This increases the probability of detection for defects with variable reflection geometries or reflection geometries other than optimal for single angle (conventional)

i iexaminations.

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Inspection of components during outages of Power Plantsp p g g

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Shop Capabilitiesp p NDT inspections on products/components

in our workshop in Albany, NY or at clients’ manufacturing facilities

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Please contact us:

3angles, Inc.g ,2 Access RoadAlbany, NY 12205Tel. 518 640 0446Fax. 518 356 0448e-mail info@3anglesndt.comwww.3anglesndt.com