Virtual Product Development for Power Plant Inspections

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1 Virtual Product Development for Power Plant Inspections Roland Moser Rapperswil,

2 Agenda P 2 1. Introduction 2. Fundamentals of Non Destructive Testing 3. Application of NDT in Inspection Technologies 4. Need for virtual design 5. The CIVA software and its recent developments 6. Conclusion

3 Agenda P 3 1. Introduction 2. Fundamentals of Non Destructive Testing 3. Application of NDT in Inspection Technologies 4. Need for virtual design 5. The CIVA software and its recent developments 6. Conclusion

1.Introduction ALSTOM P 4 Present in 70 countries Sales : 14.2 billion Around 95 000 employees Power N 1.

.. in air quality control systems Transport N 1... in very high-speed trains, high speed trains and tilting trains N 2.

4 1.Introduction ALSTOM P 4 Present in 70 countries Sales : 14.2 billion Around employees Power N 1... in turnkey power plants N 1... in hydro turbines and generators N 1... in service for utility power generation N 1... in air quality control systems Transport N 1... in very high-speed trains, high speed trains and tilting trains N 2... in urban light rail and tram systems, commuter and regional trains, services, signalling and systems One in four of the world s light bulbs is powered by Alstom technologies

5 P5 1.Introduction A typical Gas Combined Cycle Plant Stack Grid Air intake Boiler Gas Turbine Generator Steam Turbine Gas Pipeline

6 1.Introduction Power Plant Components P 6 Gas Turbine Rotor Generator Stator Steam Turbine Rotor Boiler

7 Agenda P 7 1. Introduction 2. Fundamentals of Non Destructive Testing 3. Application of NDT in Inspection Technologies 4. Need for virtual design 5. The CIVA software and its recent developments 6. Conclusion

8 2. Fundamentals of NDT Classification P 8 NDT Methods Dye - Dye Penetrant - Magnetic Particles Electromagnetic - Eddy Current - ACFM - ACPD - Barkhausen testing - DCPD - Flux Leakage - Remote Field Testing - Holographic Inferometry - Shearography Thermal - Flash thermograpy - Thermosonics - Eddy Current ind. - Laser induced Ultrasonic - Pulse-Echo - Time of Flight - Phased Array - EMAT - Acoustic emmision - Laser ultrasonics - Surface waves - Guided waves Radiographic - X-Ray - Isotopes - Neutron radiography - X-Ray fluorescence Used within Alstom Power A big variety of physical processes can be used for NDT

9 2. Fundamentals of NDT Classification P 9 NDT Methods Dye Electromagnetic Thermal Ultrasonic Radiographic - Dye Penetrant - Eddy Current * - Flash thermography - Pulse-Echo * - X-Ray - Magnetic Particles - ACFM * - Thermosonics - Time of Flight * - Isotopes - ACPD * - Phased Array * Detect Surface Flaws Detect Volume Flaws Volume Flaws Probe Surface Flaws Many solutions to a particular NDT problem * Can be automized

10 2. Fundamentals of NDT Dye Methods Dye Penetrant Testing P 10 1.) Pre-Cleaning 2.) Application of Penetrant Dye Detects surface cracks: 3.) Excess Penetrant Removal 4.) Application of Developer Flurescent 5.) Inspection, photographic recording 6.) Post Cleaning Ambient light

11 2. Fundamentals of NDT Dye Methods Magnetic Particle Testing P 11 1.) Pre-Cleaning Detects surface cracks: 2.) Application of Magnetic Dye 3.) Apply Magnetic Yoke Flux lines leave the test piece, concentrate the magnetic particles 50Hz Flurescent 4.) Inspection, photographic recording 5.) Post Cleaning

2. Fundamentals of NDT Electromagnetic Methods Eddy Current Testing 1.

) Screening using Coil Sensor, detecting flaws i @ 200kHz V 0 V crack V 0

) Sizing flaws High ability to detect flaws down to a size of 50µm, but

12 2. Fundamentals of NDT Electromagnetic Methods Eddy Current Testing 1.) Pre-Cleaning Detects surface cracks: Flexible Coil Array P 12 2.) Screening using Coil Sensor, detecting flaws 200kHz V 0 V crack V 0 < V crack 3.) Sizing flaws High ability to detect flaws down to a size of 50µm, but limited sizing capabilities. Eddy Current testing is a volumetric method: A deep narrow crack can have the same signal response like a shallow wide crack.

13 2. Fundamentals of NDT Thermal Methods Flash Thermography 1.) Pre-Cleaning Detects surface and near surface flaws and delaminations: P 13 2.) Optional: Apply black paint 3.) Inject heat using a flash lamp 6000 Watt for 10 ms 4.) Observe the cool-down of the object IR Camera Flaws influence the cool-down rate 5.) Optional: Clean-off the black paint

) Place X-ray source and detector Cathode

14 2. Fundamentals of NDT Radiographic Methods Digital X-Ray 1.) No pre-cleaning Detect and size all flaws P 14 2.) Place X-ray source and detector Cathode Anode (W, Mo or Cu) Vacuum tube Cut X-ray Digital receptor pixels 3.) Detect flaws based on transmission differences - + 5mm Electrons X-rays Flaw shadow Digital X-ray with 50 µm resolution

15 2. Fundamentals of NDT Ultrasonic Methods Pulse Echo 1.) Pre-Cleaning Detects volumetric flaws: P 15 2.) Apply acoustic couplant Oil, water or gel 3.) Place ultrasonic sensor, send one burst of sound Backing material Electrodes Crystal S t 4.) Detect echoes from sound bursts Crack depth = t v v = velocity of sound S Crack echo t Backwall Echo t

$16 TOFD (Time Of Flight Diffraction) 1.$ ) Pre-Cleaning Size volumetric flaws: Modern

) Apply acoustic couplant Oil, water or gel

16 2.Fundamentals of NDT Ultrasonic Methods P 16 TOFD (Time Of Flight Diffraction) 1.) Pre-Cleaning Size volumetric flaws: Modern TOFD equipment 2.) Apply acoustic couplant Oil, water or gel 3.) Place two ultrasonic sensors, Emitter and Receiver Crystal Fixed distance E R Housing and wedge 4.) Detect echoes from crack corners d h Surface wave: t 1 Crack of height h at depth d Fixed distance Typical Screen output Compare t 1, t 2, t 3 and t 4 to find depth d and height h Upper corner wave: t 2 Backwall echo: t 4 Lower corner wave: t 3

Excite the small crystals at different times: The crated macro-wave is a programmable combination of the micro-waves Wedge Disc 1

17 2. Fundamentals of NDT Ultrasonic Methods Phased Array P 17 Concept: Why move the sensor when you can move the ultrasonic beam? Solution: Superposition of small waves (Christian Huygens, 1678) Use of many small crystals instead on one big one. Excite the small crystals at different times: The crated macro-wave is a programmable combination of the micro-waves Wedge Disc 1 Weld Disc 2 Distance to flaw Finite element simulation Excitation 10 small crystal stripes Voltage Wedge 10 small crystal stripes Sound beam Flaws Beam steering

18 2.Fundamentals of NDT Ultrasonic Methods Phased Array P 18 Another illustrations of its capabilities: Beam focusing Voltage Excitation Finite element simulation 15 small crystal stripes Metal Sound beam

19 Agenda P Introduction 2. Fundamentals of Non Destructive Testing 3. Application of NDT in Inspection Technologies 4. Need for virtual design 5. The CIVA software and its recent developments 6. Conclusion

20 3. Application of NDT in Inspection Technologies Generator Inspection P 20

21 3. Application of NDT in Inspection Technologies Generator Inspection P 21

22 3. Application of NDT in Inspection Technologies Generator Inspection P 22

23 3. Application of NDT in Inspection Technologies Steam Turbine Inspection P 23 4h / Disc Manual Method 30min / Disc Automated Method

24 3. Application of NDT in Inspection Technologies Steam Turbine Inspection P 24

25 Agenda P Introduction 2. Fundamentals of Non Destructive Testing 3. Application of NDT in Inspection Technologies 4. Need for virtual design 5. The CIVA software and its recent developments 6. Conclusion

26 4. Need for virtual design Inspection Demand P 26 Steam Turbines Generators ABB, ALSTOM, Asea, BBC, AEG, AEI, AKZ, AP, ATM, ATP, BTH, CEM, DGI, Escher Wyss, GEC, GT, IT, Jugoturbina, KT, Lang, LMZ, MAN, MFO, MV, Rateau, SEW, Towax, Zamech ALSTOM, ABB, Asea, BBC, ACEC, AEI, BTH, Cenemesa, CEA, Dolmel, EE, Electrosila, Ganz, GEC, Marelli, MV, Rateau Boilers Gas Turbines ABL, CE, CEC, EVT, ICAL, Mague, NEI-ICL, PBS, Stein, Sulzer BBC, ABB, ALSTOM A diversified fleet requires various customized NDT solutions

27 4. Need for virtual design Inspection Demand P Average age: 24 years Average age: 22 years Units Units Steam turbines Generators Age [years] Average age: 36 years Average age: 28 years Units Boilers Age [years] An aging installed base requires NDT to increase lifetime Units Age [years] Gas turbines

28 4. Need for virtual design Missions for NDT Example: Steam Turbines Pin Roots P 28 Central Bore Four missions: Prevent damages Predict remaining lifetime Check the quality of repairs Ensure quality of reconditioning Girth Welds NDT is a key technology for aging installed base

$Sudden fracture Half circle$ ) Stress Corrosion Crack Slow

29 4. Need for virtual design Calibration P 29 Real Cracks: 1.) Casting defects, inclusions, porosities Crack initiation from inclusion 2.) Fatigue Crack (HCF, LCF) Sudden fracture Half circle shaped crack front 3.) Stress Corrosion Crack Slow crack propagation Crack age lines Small crack at the surface Many branches It is difficult to produce as real artificial cracks

4. Need for virtual design Missed Defects and False Calls The two main errors in NDT Missed defects: The inspector does not see a real crack because its signal is buried in the instrument s noise (in

30 4. Need for virtual design Missed Defects and False Calls The two main errors in NDT Missed defects: The inspector does not see a real crack because its signal is buried in the instrument s noise (in the Grass ) P 30 False calls: The inspector sees a signal that he interprets as being a crack and initiates an action (e.g. scrap or repair of the part) Example: Choosing the right instrument amplification. Gain Knob 100% Missed Defects False Calls min NDT instrument amplification [db] max A proper calibration and experience is key for NDT

31 4. Need for virtual design Sizing Flaw sizing capabilities: P 31 Surface breaking crack: Measured depth [mm] Ideal Sensor d 2 1 Eddy Current ACFM / ACPD Ultrasonic Time-of-Flight (TOFD) 1 2 Actual flaw depth d [mm] Method selection and proper simulation is critical

32 Agenda P Introduction 2. Fundamentals of Non Destructive Testing 3. Application of NDT in Inspection Technologies 4. Need for virtual design 5. The CIVA software and its recent developments 6. Conclusion

33 5. CIVA Software and case study Principle P 33 CIVA is an analytical simulation software for NDT probe or system development. CIVA was initially developed for the nuclear industry, but is now the industry standard software for power plant and aerospace NDT, as well. CIVA has 3 physics solutions available with ultrasonic testing [UT], eddy current testing [ET] or radiographic testing [RT]. Special feature: Semi-analytical methods rather than fully numerical methods (finite elements, finite differences, etc.), and the development of models integrated into software modules usable by operators who are not simulation specialists.

34 5. CIVA Software and case study Development Project P 34 1 Post-Doc senior software developer, 2 years Post-Doc works at French Nuclear Energy Agency (CEA) near Paris Experimental verification by Alstom Field Inspectors Results to be implemented in future versions of CIVA Simulation of various Phased Array sensors Simulation of various defects

35 5. CIVA Software and case study Problem P 35 In-situ ultrasonic inspection of curvilinear fir-tree blade roots Real blade Test Mock-Up Standard blade configuration of large nuclear steam turbines Note the curved blade root and the shape of the blades

36 5. CIVA Software and case study Limitations of CIVA P 36 CIVA could not calculate «real» 3D Approximation : pièce CAO «2.5D» Rotation Extrusion CIVA was initially designed to simulate weld inspections 3D Represen

even in 2D (Indirect echoes) Ultrasonic sensor 3. Defect 1.

37 5. CIVA Software and case study Limitations of CIVA P 37 CIVA could not calculate rebounds from flancs to defects, even in 2D (Indirect echoes) Ultrasonic sensor 3. Defect CIVA was initially designed to simulate weld inspections

Without multiple rebounds New development: with

38 5. CIVA Software and case study Limitations of CIVA P 38 CIVA could not calculate multiple rebounds Without multiple rebounds New development: with multiple rebounds Échos supplémentaires dus au défaut Rebounds

39 5. CIVA Software and case study Development work P 39 Implementation of indirect echoes Crack Multiple rebounds Diffraction Corner

40 5. CIVA Software and case study Development work P 40 Implementation of indirect echoes Typical output Model calibration and verification using automated NDT Ultrasonic sensor

41 5. CIVA Software and case study Development work P 41 Implementation of real 3D

42 Conclusion P 42 Virtual development saves time and money: 1. No need for dedicated testblocks in real steel 2. Quick adaptation to new geometries 3. Fast feasibility check 4. Design aid to develop new sensors

43 P 43 Questions

We are providing Level I, II Training and Certification as per Recommended practice SNT TC 1A 2006 in the following NDT Methods.

We are providing Level I, II Training and Certification as per Recommended practice SNT TC 1A 2006 in the following NDT Methods. INTRODUCTION: Metal lab is built on strong Material Testing & Non - Destructive Testing, NDT Training & certification Courses expertise, founded in 2004 by group of professionals to serve the industry.