PRESENTATION ON

RESIDUAL LIFE ASSESSMENT

STUDY OF
210 MW, UNIT – III TURBINE
THERMAL STATION II
28th OCTOBER To 24th November 2003
 RLA ACTIVITY CHAIN
• Turbine Shut down on : 15/10/2003
@ 16.44 hrs.
• STG was stopped on : 23/10/2003
• Dismantling of turbine started on : 25/10/2003
• RLA tests started on : 28/10/2003.
• RLA of Turbine undertaken by : M/s Alstom
Projects India
Limited.
• RLA Tests completed on : 23/11/2003
 NON-DESTRUCTIVE TESTS
1. Visual Inspection (VO)
2. Dimensional Measurement (DIM)
3. Wet Fluorescent Magnetic Particle Inspection
(FMI)
4. Liquid Penetrant Inspection. (LPI)
5. In-Situ Metallography - Replication. (IM/REP)
6. Boroscopy (BO)
7. Borosonic (BS)
8. Natural Frequency Test. (NFT)
9. Eddy Current Test. (ECT)
10. Hardness Measurements. (HM)
11. Ultra Sound Test. (UT)
12. Thickness Measurements (TM )
PROCEDURES AND METHODS
LIQUID PENETRANT INSPECTION TEST.
 To check for any surface cracks.
 Penetrant liquid is applied to the surface to
be tested. After some time the penetrant is
cleaned and Developer is applied. The
penetrant comes out of the cracks, if
present on the surface and is visible to the
naked eye.
PROCEDURES AND METHODS
WET FLUORESCENT MAGNETIC
PARTICLE INSPECTION TEST.
 To check for any surface cracks and sub surface
cracks up to a depth of 3 mm.
 The surface to be tested is exposed to a magnetic
field using an electromagnetic yoke. Fluorescent
iron oxide powder suspended in kerosene is
poured on the surface. The fluorescent particles
accumulate in the defective area, which can be
seen using an ultra violet lamp.
PROCEDURES AND METHODS
IN-SITU METALLOGRAPHY-REPLICATION. (REP)
• To check for the grain structure of the metal which
would give an idea of the disintegration of the metal
due to creep and thermal stresses.
• Surface cleaning is done locally where the replica has
to be taken. The cleaning involves:
• Grinding the surface with a fine emery paper.
• Cleaning the surface by 2% Nictel solution.
• Etching and polishing the surface by an Electrolytic polisher and
etching unit.
• A film material (cellulose acetate) is pressed against
the metal surface and the impression of the grain
structure is taken. This sample is taken for analysis.
PROCEDURES AND METHODS
ULTRASOUND TEST
• To check sub surface defects and to measure
thickness of material.
• An ultrasound probe connected to a monitor
cum control unit is moved along the surface to
be tested. The ultrasound waves created by
the probe travel through the metal and get
reflected from the defective area. The echo
thus attained is sensed by the same probe and
is displayed in the monitor.
 PROCEDURES AND METHODS
HARDNESS MEASUREMENTS. (HM)

• Tomeasure the surface hardness value of

the material.
• The hardness tester has a ball, which is held
in position by a magnetic field. The tester is
placed on the surface and the ball is released.
The ball hits the surface and rebounds. The
displacement of the ball on the rebound is
calibrated to give the hardness value directly.
PROCEDURES AND METHODS
NATURAL FREQUENCY TEST (NFT)
• To check for any change in the natural
frequency of the LP rotor last stage
freestanding blades.
• The probe, which is connected to a monitor,
having data storing facility is placed on the
blade whose natural frequency is to be
measured. The blade is excited by striking
with a rubber hammer and the acceleration
component of the vibration is monitored on
the display screen.
PROCEDURES AND METHODS
BOROSCOPY

• To have a view of pitting, rusting and surface

cracks on the bore internal surface.
• A videoimageoscope is inserted into the bore
of HP-IP and LP shafts. The camera is
connected to a monitor, which shows the view
of the inner surface.
 PROCEDURES AND METHODS
BOROSONIC TEST

• To check for any surface and subsurface

cracks of the rotor bore.
• A head containing an ultrasound probe is
inserted into the bore of HP-IP and LP shaft
and the echo obtained is monitored. The head
is moved axially and radially to cover all areas
of the bore. The test is conducted with two
probes viz. normal flat probe and 45o angle
probe.
PROCEDURES AND METHODS
BOROSONIC TEST

• To check for any surface and subsurface cracks of the

rotor bore.
• A head containing an ultrasound probe is inserted
into the bore of HP-IP and LP shaft and the echo
obtained is monitored. The head is moved axially and
radially to cover all areas of the bore. The test is
conducted with two probes viz. normal flat probe
and 45o angle probe.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
ACTION
COMPONENTS TEST FINDINGS TAKEN

HP-IP TURBINE
CASINGS MILD SOFT RUST Removed by
BDA COLOR Mechanical
HP INNER DEPOSITS. cleaning
CASING
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
ACTION
COMPONENTS TEST FINDINGS TAKEN

HP BLADE RING
In the 13th stage, black
Deposit
color deposits were samples sent
observed on the fixed for analysis.
HP-IP TURBINE: blades. Deposits
DIAPHRAGMS
BDA removed by
IP BLADE RING – 1
Minor brown color
steam
washing and
deposits were observed
sand blasting.
at the back of the 6
th

stage blades.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
ACTION
COMPONENTS TEST FINDINGS TAKEN

IP BLADE RING – 2
• Oil like brown color
sticky deposits were
observed in the 7th &
Deposit
8th stage blades. samples sent
• Adherent brown color
for analysis.
HP-IP TURBINE: Deposits
DIAPHRAGMS BDA hard deposits were
removed by
observed in the 9th –
11th stage blades. steam
• In the 12th stage washing and
blade, huge amount of sand blasting.
soft deposits were
observed.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE TEST FINDINGS ACTION TAKEN
NTS
LPT inner casing:
• In bottom half, 2 to 3
cracks of 10 to 15 mm • The crack edges
length were observed
near 6th extraction were punched.
tapping (RHS) on the • Deposit samples
parting plane. collected and sent
LP BDA, • In the 3rd and 4th stage
TURBINE: for analysis.
blades Grey color soft
CASINGS FMI deposits were • Deposits were
observed. removed by
• More corrosion was mechanical
observed in the inner cleaning / sand
rim surface between 5 th
blasting.
& 6 stages and 5
th th

stage blades.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE
TEST FINDINGS ACTION TAKEN
NTS
LP rotor 6th stage:
Linear indications
(cracks) were observed
in the lacing wire as
follows: .
• IP side – 24 in the • Cracks were
LP ROTOR LPI inner lacing wire & 29 repaired.
in the outer wire.
Generator side – 7 in
the inner lacing wire
and 13 in the outer
wire.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE
TEST FINDINGS ACTION TAKEN
NTS
•In the 3rd and 4th stage
blades, Grey color soft
deposits were • Deposits samples
observed. sent for analysis.
•In the LPT rotor 5th Deposits
LP ROTOR BDA stage (IPT end & Gen removed by sand
end) heavy erosion – blasting.
corrosion has been
• Shall be attended
observed in all the
blades of the respective
during LEP
stage.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE
TEST FINDINGS ACTION TAKEN
NTS
•In NFT, last stage
blades (generator side),
7 packets (1 packet = 4
blades) showed
deviation. After repair
• Shall be attended
LP ROTOR NFT works in the welding
during LEP
region of the inner &
outer lacing wires, 2
packets alone showed
deviation.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE
TEST FINDINGS ACTION TAKEN
NTS
•In the impulse wheel,
erosion was observed
in the tenon region (in
one quarter area, in the
direction of rotation) • Deposits samples
BDA, •In the HP reaction sent for analysis.
stages, 2-3 mm linear
HP ROTOR FMI, indications were
Deposits removed
LPI observed in the blade by steam washing
rivet region, in some of and sand blasting.
the stages, indicating
slight relaxation of the
rivet flaring.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE ACTION
TEST FINDINGS
NTS TAKEN
•In HP 13th stage, Black color
blade deposits were
observed.
• Deposits
•In the IPT rotor: 6th stage
minor Brown color deposits samples sent
were observed on the for analysis.
blades. In the 7th and 8th Deposits
HP ROTOR BDA stage blades, sticky Brown removed by
color deposits like an oil steam
coating was observed. In the
stages 9–11th Brown color washing and
hard deposits were sand
observed. In the 12th stage blasting.
brown color soft deposits
were observed.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE ACTION
TEST FINDINGS
NTS TAKEN
•In the Dye Penetrant Test
(LPI), star shaped crack was
observed at the front top
end (LHS); another crack
observed at the rear end
BEARINGS (LHS) and the rear side • New bearing
NO – 3 LPI, edges showed disbond has been
symptoms provided for
BOTTOM UT
•In the Ultrasonic testing bearing No.3.
HALF.
(UT), a disbond area of
24.5% of total bearing area
was observed. M/s Alstom
has recommended for
replacement of the bearing.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE ACTION
TEST FINDINGS
NTS TAKEN

• Minor edge disbond

BEARINGS indications and deep

NO – 2 crack at 2 locations
• 2 thrust pads
BOTTOM LPI, was observed.
were
HALF. & UT • Thrust collar: In two
replaced.
THRUST thrust pads, babbit
COLLAR metal plug indications
were observed.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE ACTION
TEST FINDINGS
NTS TAKEN

GOVERNING VALVES( 6
NOS
• In the Dye penetration
test, linear indications
(cracks) of length 100 • Shall be
TURBINE LPI,
to 150 mm were considered
VALVES FMI observed at the during LEP
circumferential weld
joints of valve seats to
the valve body.
observed.
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE ACTION
TEST FINDINGS
NTS TAKEN

STEAM CHEST AND

TRANSFER PIPE LINES:
•In the boroscopy of the
steam chest transfer pipes for
• Shall be
TURBINE a length of 2 Mts of transfer
BO pipes of all control valves - a considered
VALVES
few shallow pits were during LEP
observed in the transfer
pipes R3 & L3, indicating a
comparatively greater
OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE ACTION
TEST FINDINGS
NTS TAKEN

RHSV (left):
• At the flap seat region a

blowhole was observed and • Shall be

TURBINE
BO one crack indication
considered
VALVES
during LEP
originating from this

blowhole of 4 mm length

was also observed.

OBSERVATIONS, FINDINGS AND
REMEDIAL MEASURES
COMPONE ACTION
TEST FINDINGS
NTS TAKEN
CROSS OVER PIPE IP
TO LP:
• Expansion joint stitch
welds were found to have
• Repair works
cracks.
PIPING FMI were carried
• Expansion ring at LPT end
out.
(external and internal
welds) - cracks were
observed at 3 vertical