Vendor Verification: Step 4-6

Transcription

1 Vendor Verification: Step 4-6 All rights reserved. The following presentation is the intellectual property of Turbine End-User Services Inc. No part may be reproduced or used in any form or by any means without written permission. Vendor Verification: Step 4-6 1

2 Six Steps Presentation is based on: Six steps to successful repair of GT components Hans van Esch Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 How to assess the condition of GT parts onsite Preparing meaningful component repair specs Selecting the appropriate repair vendor Vendor Verification: Incoming inspection Vendor Verification: Work In Progress Vendor Verification: Final Inspection Reference: Combined Cycle Journal 2Q/2005, 3Q/2005, 4Q/2005 and 1Q/2006 Vendor Verification: Step 4-6 2

3 Assessing Degeneration Step 1 Vendor Verification: Step 4-6 3

4 Standard Repair Specifications Receiving Cleaning / Stripping Inspection Heat treatment Welding Brazing Blending / Machining Coating Final inspection Vendor Verification: Step 4-6 4

5 Refined Repair Specs Step 2 Receiving Cleaning / Stripping Evaluation of condition Defining workscope Heat treatment Welding Brazing Blending / Machining Inspection Coating Final inspection Vendor Verification: Step 4-6 5

6 Selecting Vendor Step 3 Different repair facilities New, sold, closed or relocated Technology and experience Changing human resources Internal External Competitive pricing Fast growing company Learning curve and history Vendor Verification: Step 4-6 6

7 Verification / Step 4-6 Stage 1: Initial Inspection Stage 2: Cleaning / Stripping Evaluation of condition Defining workscope Stage 3: Heat treatment Welding Brazing Blending / Machining Inspection Stage 4: Coating Final inspection Vendor Verification: Step 4-6 7

8 Verification / Step 4-6 Stage 1 Stage 2 Stage 3 Stage 4 Reference: Combined Cycle Journal 2Q/2005 Vendor Verification: Step 4-6 8

9 TEServices Audits AUDITS: Technical Audits Knowledge Capability Expertise Quality Audits Environmental Audits Vendor Verification: Step 4-6 9

10 TEServices Vendor Verification VENDOR VERIFICATION: Compressor blades diaphragms Liners and transition pieces Nozzle and Vane Segments Buckets and Turbine Blades Compressor and Turbine Rotors Vendor Verification: Step

11 TEServices Metallurgical METALLURGICAL EVALUATIONS: Incoming Inspection Life Assessment Coating qualifications Failure Analysis Mechanical testing Corrosion testing Vendor Verification: Step

12 Goal of TEServices Training: Participants should be able to: Recognize degeneration of IGT gas turbine components. Select the proper repair and coating technology to reverse this effect. Create an action plan to refurbish (repair and coat) these components, with proper heat treatments and in the right sequence. Vendor Verification: Step

13 TEServices Training First Day General metallurgy, Superalloys and Heat Treatments Second Day Degeneration, Coatings, Vendor Verification [1-3] and Case Studies Third Day Stripping and Cleaning, NDT, Vendor Verifications [4-6] and Case Studies Fourth Day Welding, Brazing and Case Studies Vendor Verification: Step

14 TEServices OTHER: Component assessment Component management Repair specification development Quote development Literature investigation Research and development Vendor Verification: Step

15 Experience Presenter Sulzer Elbar: Metallurgical evaluations Coating development: Diffusion, Air and Thermal Spray Heat treatment development (HIP) Weld procedure development (IN 939) Clean and Stripping development (FCC) Brazing development Vendor Verification: Step

16 Experience Presenter Hickham Elbar / Sulzer Hickham: Engineering and metallurgy Inspection ISO 9001 Production Sales, Marketing and Business development HICoat Development: Brazing, coating Vendor Verification: Step

17 Experience Presenter Chromalloy Holland: Production Coating (Diffusion and thermal spray) Brazing (Honeycomb) Welding (EB welder) Machining (Laser) Heat treatment (training course) Vendor Verification: Step

18 Experience Presenter Turbine End-user Services: Metallurgical evaluations and failure analysis Assessment of components and remaining life Developing repair and coating procedures [EPRI] Vendor Verification and Audits Training Vendor Verification: Step

19 Stage 1: Initial Inspection Vendor Verification: Step

20 Stage 1: Visual Inspect Confirm Degeneration before cleaning Coating performance Oxidation / Corrosion surface Erosion Impact damage Rubs / Wear Cracks [TMF Other] Vendor Verification: Step

21 Stage 1: Metallurgical Evaluation Section plan Visual Microscopy Scanning Electron Microscopy Mechanical Testing Hardness Stress Rupture Tensile Vendor Verification: Step

22 Stage 1: Metallurgical Evaluation Condition Material Condition Coating Condition Surfaces Failure analyses Vendor Verification: Step

23 Stage 1: Dimensional Inspect Check dimensions in assembled stage Area & Harmonics D.S.D. Clearances Z-notch Vendor Verification: Step

24 Stage 1: Dimensional Inspect Critical Dimensions: Fit Clearances Function Contact Vendor Verification: Step

25 Stage 1: Engineering Review Review Dimensional (fixture checking) reports NDT inspection reports Metallurgical evaluation Evaluation Technical impact Compare to initial workscope / quote Commercial and delivery time impact Report to customer Vendor Verification: Step

26 Stage 1: Engineering Review Vendor Verification: Step

27 Stage 2: Clean & Strip and Inspect Vendor Verification: Step

28 Stage 2: Disassemble Critical Dimensions: Fit Clearances Function Contact Vendor Verification: Step

29 Stage 2: Hardware Identify Clean Inspect Repair or replace Vendor Verification: Step

30 Stage 2: Cleaning Degrease Gritting Chemical Thermal Media: Al Contaminations Size Equipment Pressure Operator Vendor Verification: Step

31 Stage 2: Stripping Incoming Ox Clean and blast Chemical strip Etch Presented by Goodrich at ASME TurboExpo, 2005 Vendor Verification: Step

32 Stage 2: Stripping Vendor Verification: Step

33 Stage 2: Pre-weld Solution Heat treat cycle Temperature Time Heat and cooling rates Atmosphere Quality Assurance Calibrations Furnace survey Thermo-couples Vendor Verification: Step

34 Stage 2: NDT Method: Visual, PT, RT, ET, UT or MT Procedures Equipment: Calibration - check Inspectors: Level I, II and III Criteria Vendor Verification: Step

35 Stage 2: Dimensional Inspect Method Procedure Equipment: calibration Inspector Engineer Technician Machinist Repeatability and dimension related to Vendor Verification: Step

36 Stage 2: Engineering Review Vendor Verification: Step

37 Stage 3: Repair Vendor Verification: Step

38 Stage 3: Work In Progress (WIP) Why Vendor Verification of WIP: Ensure proper executing of critical repair processes Ensure proper executing of critical coating processes Ensure proper executing of critical inspections Ensure critical criteria are met To obtain better understanding of the refurbishment To obtain better understanding of your components Vendor Verification: Step

39 Stage 3: Prep for Welding/Brazing Ensure that: Crack are removed in total or Cracks are cleaned - Internal Remove oxides, penetrant, other contaminations - External Vendor Verification: Step

40 Stage 3: Welding Qualified welders (ASM STD 1595) Per qualified and established procedure NDT Criteria - Touch up welding Vendor Verification: Step

41 Stage 3: Brazing First article qualification includes metallurgical evaluation and mechanical testing Brazing per established procedure NDT and destructive testing (metallurgical) Touch up (brazing) Vendor Verification: Step

42 Stage 3: Blending Trained and qualified blenders Inspection: Thickness, profile and smoothness Vendor Verification: Step

43 Stage 3: Machining Trained and qualified machinists Inspection: who Vendor Verification: Step

44 Stage 3: Pre-coat Inspection Dimensions: all that can not be corrected after coating such as: Area & Harmonic - Clearances NDT Vendor Verification: Step

45 Stage 4: Coat and Assemble Vendor Verification: Step

46 Stage 4: Coating First article qualification includes metallurgical evaluation and mechanical testing Coating per established procedure Repeatability Touch up coating Vendor Verification: Step

47 Stage 4: Coating Inspection Qualification booth Weight gain, UT or mechanical thickness Metallurgical Bond strength Bend test Visual PT Vendor Verification: Step

48 Stage 4: Assembly Critical Dimensions: Fit Clearances Function Contact Vendor Verification: Step

49 Stage 4: Fixture Checking Critical Dimensions: Fit Clearances Function Contact Vendor Verification: Step

50 Stage 4: Dimensional Checking Critical Dimensions: Fit Clearances Function Contact Vendor Verification: Step

51 Stage 4: Other Flow and cooling holes Frequency testing Area & Harmonics Moment weight Vendor Verification: Step

52 Stage 4: Assessment of Result For future refurbishments: Are specifications and expectations met Do we have to change repair process Do we have to change coating process Do we have to change vendor After running and assessment components: Are expectations met Did the repair performed well Did the coating protected the component Was the refurbishment successful (vendor) Vendor Verification: Step

53 Pro-active component repair In 6 steps: Onsite assessment Specifications Selection Verification: Incoming WIP Final Repair and coating: Focused on degeneration past and future Defined requirements and expectations By a facility that can meet the requirements and expectations against an attractive compensation Ensure that requirements and expectations are met Vendor Verification: Step

54 Pro-active end-user Checklist per component per engine model. Specifications and criteria per component per engine model. Make use of other end-users, end-users organizations and consultancies. Vendor Verification: Step

55 Combine resources Create a checklist per component per engine model. Create a repair and coat specification per component per engine model. Select and audit repair facility per component per engine model. TEServices Vendor Verification: Step

56 Advantages being pro-active Improving repairs and component: Better understanding degeneration More options for repair and coating Components will last longer Require less expensive refurbishment Better budget maintenance cost Creating more qualified vendors Cost saving Better service Better repairs and coating Result: O.E.M. will become more responsive Cost saving Faster delivery time OEM has to justify their decisions Vendor Verification: Step