3angles services overview nov 2013
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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,
p p
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
g g p
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 [email protected]