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Solution: Turbine Blade Inspection

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Many challenges exist with turbine blade inspections -- Cracks and crack initiation in the blade attachment serrations need to be reliably detected. Complex geometry of the component is a very challenging factor for inspection design. In-situ inspection without blade removal is required, thus limiting blade access. This application presentation highlights a recommended solution with techniques to overcome the challenges.

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Solution: Turbine Blade Inspection

  1. 1. © Zetec Inc. All rights reserved Turbine Blade Inspection Application Solution
  2. 2. © Zetec Inc. All rights reserved • Inspection Challenge • Recommended PA UT Solution • Results • Benefits of Zetec Solution Overview 2
  3. 3. © Zetec Inc. All rights reserved • Cracks and crack initiation in the blade attachment serrations (“hooks”) need to be reliably detected • Complex geometry of the component is very challenging factor for inspection design • In-situ inspection without blade removal is required, thus limiting blade access • Inspection speed and reproducibility are key factors for reducing outage time Inspection Challenge 3
  4. 4. © Zetec Inc. All rights reserved Encoded phased array UT improves efficiency and reliability of this challenging inspection, compared to manual UT and PA UT: • 1D linear and/or 2D matrix array probes and wedges • Customized scanner, allowing for in-situ inspection of blades • or PA UT systems, with embedded UltraVision Touch for on-site data recording • UltraVision Classic 3D, complete package for PA UT probe and inspection technique design, and analysis in 3D environment Recommended PA UT Solution 4
  5. 5. © Zetec Inc. All rights reserved Inspection Technique – Legacy 5 • Scanning sequences from: Extrados Intrados Platform • 1D linear array, 5 MHz, with custom wedges to generate acoustic beams 40° to 75°SW, from extrados and intrados • Additionnal scans from platform using LW beams, depending on blade geometry • Data analysis on 2D views with blade overlay
  6. 6. © Zetec Inc. All rights reserved Inspection Technique – Legacy 6 UT coverage maps generated in UltraVision Classic 3D show important limitation, especially for extrados configuration Extrados hooks coverage: from 40 to 70% (depending on blade geometry) Intrados hooks coverage: from 85 to 95% (depending on blade geometry)
  7. 7. © Zetec Inc. All rights reserved • Recording extra data from extrados and intrados, using skewed beams, to increase coverage and detection probability: – From extrados : adding skews -15° and +15° – From intrados : adding skews -15° and +15° • Options : 1. Using same 1D linear array probe, with roof angle wedges, requires 2 extra scanning sequences for both extrados and intrados 2. Using 2D matrix array probe allows to record data from the 3 skews in the same scanning sequence Inspection Technique – Improved Coverage 7
  8. 8. © Zetec Inc. All rights reserved Inspection Technique – Improved Coverage 8 UT coverage maps generated in UltraVision Classic 3D Extrados hooks coverage: from 50 to 80% (depending on blade geometry) Intrados hooks coverage: nearly 100% (depending on blade geometry)
  9. 9. © Zetec Inc. All rights reserved • Custom design based on blade shape (CAD model required) • Easy probe insertion/removal • Easy positioning on the blade • Encoded scanning, motorized or manually driven • Interchangeable probe-head allowing for all required inspection sequences Custom Scanner for Axial Entry Blade Type 9
  10. 10. © Zetec Inc. All rights reserved • Fully integrated, portable, battery operated unit 10 • PA UT 32/128PR for driving 1D linear array probes • Rugged, battery operated • Driven by UltraVision Touch for setup, recording and on-site flaw detection • 2GByte data files on-board
  11. 11. © Zetec Inc. All rights reserved • Fully integrated, portable, battery operated unit 11 • PA UT 64/128PR for driving 2D matrix array probes (more than 32 elements) • 12” Hi-Res touch display • Bipolar pulser, 150 Vpp • Live high-resolution TFM • Driven by UltraVision Touch for setup, recording and on-site flaw detection
  12. 12. © Zetec Inc. All rights reserved 2D & 3D Visualization of Inspection Results 12
  13. 13. © Zetec Inc. All rights reserved • PA UT probes and inspection techniques, using skewed beams for improved coverage and detection probability in all hooks • Feasibility study to optimize inspection technique on specific blade geometry, and for actual coverage evaluation • , , fully integrated portable PA UT systems, with on-board UltraVision Touch include all required tools for data acquisition and on-site flaw detection • Fast and reliable data acquisition in-situ, using custom scanner adapted to blade geometry • UltraVision Classic 3D software, for flaw characterization and sizing in 3D geometry Benefits of Zetec Solution 13

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