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Dr. Michael F. Opheys, Hans Rauschenbach, Michael Siegel;
Siemens AG Power Generation, D-45466 Mülheim (Germany)
Graham Goode;
Siemens Power Generation, Newcastle (UK)
Detlev Heinrich;
Cegelec AT GmbH & Co KG, Nürnberg (Germany)
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6th international Charles Parsons Turbine Conference, 16 ± 18 September 2003, Trinity College, Dublin

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anternational competition in the field of power generation is increasing and customers


are demanding economic and efficient power plants. an the long term, continuous power
plant availability can only be guaranteed through an effective mode of operation in
conjunction with a systematic maintenance and inspection concept.

Apart from boiler, steam piping and valves, the rotating components of the
turbine/generator (turbine and generator rotor) also belong to the most highly stressed
components in a power plant. Loads result for example from operating parameters, the
mode of operation of the machinery, startup processes, thermal stresses, prestressing,
residual stresses from the manufacturing process, as well as loading from the centrifugal
forces acting on the rotating components. During scheduled outages, highly -stressed
components are subjected to non-destructive testing designed to reliably detect any
possible service-induced damage (e.g. cracking) before this can lead to failure of a
component and severe consequential damage. For example, damage to a blade in the
low-pressure turbine of a South African power plant (600 MW) in January 2003 resulted
in the entire turbine generator unit being destroyed. Quite apart from the risk to
personal health, such damage can lead to unscheduled outages and plant downtime, as
well as unplanned costs for expensive repair and maintenance work on the
turbine/generator. an comparison to these risks, the cost of inspecting such highly -
stressed components is easily justified, as is the need for reliable and qualified
techniques in the field of non -destructive testing.

The following describes two examples for non -destructive techniques used on turbine
blade roots and blade attachment grooves.

   

 
    

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The blades in a steam turbine belong to the most -highly stressed components in a
turbine/generator. The high turbine speed (3000 rpm) and the dead weight of the blades
means that the last-stage blades in a steam turbine are subjected to enormous
centrifugal forces during plant operation. The roots on such blades are designed and
calculated using the most up-to-date methods to allow them to accommodate these high
loads. Particularly during transient loading conditions (startup and shutdown processes)
certain areas of the blade roots and blade attachment grooves are subjected to high
stressing. Under unfavourable conditions unusual events occurring during operation of a
turbine (e.g. loss of vacuum, overspeed) can result in damage to blading, with possible
crack initiation in the highly-stressed areas of the blade root and subsequent service-
induced crack propagation. an addition steam purity is also an important criterion
regarding the susceptibility of a turbine blade to corrosion. af the steam is polluted with
chlorides this is one of the basic prerequisites for the occurrence of corrosion fatigue in
turbine blades, blade roots and blade attachment areas.
an the light of such influences on s afe turbine blade operation, the necessity for non -
destructive testing becomes particularly apparent. Turbine blades and their roots should
be examined non-destructively at predetermined intervals to allow timely detection of
any damage and the replacement of affected blades.
The task faced here was to develop an ultrasonic testing technique for a special type of
blade root to allow inspection of the roots of the last -stage blades in the rotor of a low-
pressure steam turbine. When installed in the rotor the most highly-stressed areas of
the blade root are not accessible for standard crack testing techniques. The objective
was therefore to develop a technique which allowed these highly -stressed areas of the
blade root to be inspected in situ, i.e. without rem oving the blade. The examination
system had to provide reliable and reproducible results while remaining cost effective.

  
   

Extensive theoretical investigations had to be performed before any decisions could be


made regarding selection of the ultrasonic examination technique. The blade under
investigation was a last-stage blade from an LP turbine rotor. Figure 1 and Figure 2 show
the root for such a blade. Performance of the inspection on the blade roots of the dual -
flow turbine rotor required that a calibration block be fabricated for the right and left
side.

Fig 1: Blade root for LP rotor with reference reflectors, Fig 2: Blade root for LP rotor with reference
pressure side reflectors, suction side

Reference reflectors (grooves, 6 mm long, 2 mm deep) were introduced into these


calibration blocks at the most-highly-stressed areas. These areas can be found on the
pressure side in the vicinity of the leading/trailing edge of the blade root in the first
serration of the fir-tree root as well as in the middle of the first serration on the suction
side of the blade root.

The theoretical investigations showed that it is indeed practicable to select scanning


positions at the blade root which allow reliable d etection of the reference reflectors.
Along the complex geometry of this blade root these scanning positions were also
situated in radii and on other curved surfaces which required a customized inspection
solution for the component in question. For this re ason, it was decided to fabricate
specially-fitted pieces for each area to be scanned, which would allow exact positioning
of the ultrasonic search units. This inspection technique seemed to be the right solution
for the inspection problem, providing a sui table tool for power plant inspection services.
Fig 3: graphic for determining possible scanning Fig 4: graphic for determining possible scanning
positions positions

 

     
   


Once various suitable scanning parameters had been determined, practical tests were
able to begin on the calibration blocks. The results of investigations with phased -array
search units at various frequencies (3, 7, and 11 MHz) indicated only limited relia bility.
For the customized solution (using contoured probe holders with integrated search units)
it was decided to use 5 MHz longitudinal wave search units with a transducer diameter of
6.3 mm as well as 60° shear wave search units. These search units were equipped with
Plexiglas wedges. at was then possible to contour the Plexiglas wedges so that they could
be coupled to the surface at the determined scanning positions. Figure 5 is an example
showing the scanning position for a search unit at the transitio n between the blade root
platform and the airfoil.

Fig 5: Scanning positions at transition between root


platform and airfoil for inspecting zone #2.

On the basis of the theoretical investigations, at least two scanning positions were
determined for each reference reflector which seemed suitable for detecting the
reflector. All the scanning positions calculated during the theoretical investigations were
checked during the practical tests on the calibration block. This confirmed that all
reference reflectors could be reliably detected, in all cases. Owing to the fact that the
different reference reflectors were able to be found using various scanning posi tions and
beam angles, it was decided to make use of this during the actual performance of
inspections.

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Once the investigations on the calibration block had confirmed the suitability of the
selected inspection technique for the problem in hand, the contoured probe holders
mentioned above were fabricated. The probe holders are matched to the blade root
contour to guarantee exact positioning of the ultrasonic search units. Three contoured
probe holders were fabricated, each containing several ultrasonic search units. Their use
in conjunction with a 4 -channel ultrasonic instrument (.Tomoscan) guarantees an
effective inspection. Once the corresponding probe holder has been brought into
position, this instrument allows the results from all the integrated search units to be
evaluated at a glance. Three contoured probe holders were made for the blade root
under investigation. When testing the page 4 of 10.inspection system, investigations
were performed using several different blades of the same type, to verify that existing
manufacturing tolerances for these large LP blades do not have any influence on the
results of the examination. at was shown that the dimensional differences existing
between the blades inspected were able to be compensated for using a gel-type couplant
and can therefore be neglected. The couplant bridges the gap between the contoured
probe holder and the blade root. Manufacturing tolerances were not found to have any
effect on test sensitivity/defect detectability.

Fig 6: Probe holder # 1 for inspecting zone # 1 in the Fig 7: Probe holder #1 on blade rootscanning
blade root. scanning positions positions

   

The manual ultrasonic inspection system described above was developed to provide a
reliable and cost-effective method of inspecting turbine blade roots. The main
considerations during development work were:

O| blades must be able to be inspected in situ


O| simple handling and operation (no complex manipulators, etc.)
O| reliable and meaningful test results
O| possibility of verifying indications by using 2 scanning positions
O| fast test method

All these requirements are met by the inspection system. The configuration with the
contoured probe holder and a systematic inspection procedure means that only a short
introduction to the equipment is required before testing can begin.
With respect to the reliability of testing, it proved to be a considerable advantage that
each zone for examination was able to scanned from at least 2 scanning positions, thus
providing the possibility of verifying the presence of any indications detected, by
scanning from a second position.
Fig 8: Test results when inspecting Zone #1 using probe holder #1 on a blade with reference
reflectors.

Fig 9: Test results when inspecting Zone #1 using probe holder #1 on a blade without reflectors.

   
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Due to the world wide SCC issue there is an increasing demand for a non destructive
examination of blade attachments of steam turbine rotors.
an December 2001, Siemens Power Generation¶s NDE laboratory received a request to
perform a non-destructive examination on blade attachment grooves of a non -OEM
turbine (European nuclear power plant). The problem is discussed in greater detail
below.

 
   

There are several designs of blade attachment grooves of LP turbine shafts. The grooves
can run either circumferentially (in which case the blades are inserted in sequence and
secured with a locking blade) or axially.
an the case in question, the blade attachment grooves ran circumferentially. at was
known from experience of turbines of identical design at other operators¶ plants that the
grooves of blade row 6, 7, and 8 were particularly susceptible to crack formation. An
advanced ultrasonic examination technique had to be developed to provide r eliable data
on the condition of blade attachment grooves without deblading the rotor.

Fig 6: blade attachment grooves of an LP turbine shaft

      


 
 


Following analysis of the problem, it was decided to solve it by means of the ultrasonic
phased-array technique. Given the different dimensions of the blade grooves to be
inspected, different scanning positions and angles of incidence are required to exami ne
the highly stressed areas for cracks. This meant that the advantages of the phased -array
ultrasonic examination technique could be fully leveraged.

Following analysis of the problem, it was decided to solve it by means of the ultrasonic
phased-array technique. Given the different dimensions of the blade grooves to be
inspected, different scanning positions and angles of incidence are required to examine
the highly stressed areas for cracks. This meant that the advantages of the phased -array
ultrasonic examination technique could be fully leveraged.

The requirement to ensure that all relevant areas of the blade grooves are scanned, and
that small cracks are also reliably detected, necessitated qualification of the inspection
technique using an identical test piece. Figure 6 shows, by way of example, the profile of
the blade attachment grooves. A separate test piece was fabricated for each blade row
(row 6, 7, and 8). Each test piece reproduces the geometry of the blade groove together
with the outside profile of the turbine shaft. To ensure that incipient cracks exhibiting
different orientations were also detected, test flaws in the form of grooves with a semi-
elliptical profile were introduced at different angles in the most highly stressed areas
(inspection zones 1 and 2 in Figure 10). To ensure detection of even the smallest
incipient cracks, the dimensions of the semi-elliptical grooves used were as follows
(length in mm x depth in mm): 2 x 1, 4 x 1, 4 x 2, 8 x 2. The grooves were positioned in
inspection zones 1 and 2.

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Following fabrication of the test pieces, qualification of the


technique was carried out using a 45 EL3 phased -array search
unit (natural angle of incidence: 45°, search unit frequency 3
MHz, 16 array elements). The tests were carried out using a
triple-axis manipulator in conjunction with the SAPHaR+ phased -
array system.

Due to the complex geometry of the blade grooves and the


associated geometric indications, a vertical scan was
programmed in a range from 30° to 85° in steps of 1°. Figure 12
shows the result of the vertical scanning using a sector scan Fig 11: Qualification of the
presentation. To identify the form echoes more easily the CAD inspection technique on a
drawing of the inspected blade attachment is overlaid. test block.

Assessment of the TD images of all scans enabled the optimum angle of incidence to be
rapidly determined. Figure 13 shows, by way of example, the TD image of a scan in
inspection zone 1 (row 8).

Fig 12: overlay of the sector scan representation with Fig 13: scan results in form of a TD image showing all
the CAD drawing of the blade attachment (row 8). test flaws. (inspection zone1, row 8)

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By scanning the test pieces it was possible to demonstrate that the deployed phased-
array ultrasonic inspection technique is suitable for use in field service to examine blade
grooves of LP turbine shafts for incipient cracking in highly stressed areas in the
assembled condition (in other words without removing the blades).
All of the test flaws in inspection zone 1 and 2 of all three test pieces were detected (the
smallest test flaw was a semi-elliptical groove 2mm x 1mm).
These two examples of advanced inspection techniques demonstrate that direct
customer benefits can be delivered through the use of problem-focused techniques. Key
examples include time savings on component disassembly and reassembly, required with
conventional crack inspection techniques, but elimin ated when advanced techniques are
used. Given the requirement for virtually non-stop power plant availability and the
associated reduction in plant downtimes, these kinds of in -situ service techniques are
playing an increasingly important role in the plann ing and performance of plant outages.




1.| mis miswanathan (EPRa), David Gandy (EPRa), ³Rim Attachment Cracking Promts
Developement of Life Assessment Tools´, 4. anternational EPRa Conference on
Welding & Repair Technology for Power Plants / July 20 00, page 50.[journal]
2.| Darryl A. Rosario, Peter C. Riccardella, S.S. Tang (Structural antegrity Associates
San Jose, CA, USA) ³Developement of an LP Rotor Rim ± Attachment Cracking
Life Assessment Code (LPRimLife)´, Power Engineering / June 2000 Marco asland,
Florida USA
3.| Carlos Arrietta, Francisco Godinez, Marta Alvaro, Andres Garcia (Technatom SA),
³Blade Attachment UT anspection using Array ´, 7 th EPRa Steam/Turbine
Generator Workshop, Baltimore, MD, August 20 -24 2001 [conference]
4.| Richard Fredenberg (Wes Dyne anternational), ³Dovetail Blade Attachment
Experience using Phased Array Ultrasonic Test Techniques´, 7 th EPRa
Steam/Turbine Generator Workshop, Baltimore, MD, August 20 -24 2001
[conference
5.| Petru Ciorau et.al. (Ontario Power Generation anc.) an situ examination of ABB L-
0 blade roots and rotor steeple of low -pressure steam turbine, using phased array
technology, 15 th WCNDT, Rome, 2000
6.| A. Lamarre, N. Dube`, RDTech, Canada; P.Ciorau, P. Bevins, Notario Power
Generation anc.: Feasibility study of ultrasonic inspection us ing paced array of
turbine blade root ± Part 1, EPRa workshop July 29 ± August 01, 1997
7.| Hans Rauschenbach, Dr. Michael Opheys, Uwe Mann : Siemens Power Generation
Jürgen Achtzehn, antelligeNDT Framatom: Advanced NDE anspection Methods for
Field Service at Power Plants, 8 th European Conference on Non -Destructive
Testing, Barcelona June 17 ± 21, 2002 [conference]

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