Experience with the Introduction of SAFT Testing in Volume Production of Large Forged Parts

NDT World ◽  
2021 ◽  
pp. 18-24
Author(s):  
Johannes Vrana ◽  
Alexander Zimmer ◽  
Karsten Schörner ◽  
Hubert Mooshofer ◽  
Karsten Kolk
Keyword(s):  
Power Generation ◽  
Detection Limit ◽  
Service Life ◽  
Synthetic Aperture ◽  
Forged Parts ◽  
Volume Production ◽  
Critical Components ◽  
Level 2 ◽  
Sensitive Testing ◽  
Large Rotor

Large rotor forged parts, which are usually one of the most critical components in land-based turbines and generators for power generation, require a complex volumetric test for a sufficient service life. This is usually performed manually or automatically with ultrasound. New requirements, designs and materials require more sensitive testing. This can be achieved by SAFT, also called ultrasound computer tomography. SAFT is based on the Synthetic Aperture Radar (SAR) and has been further developed by several universities. The introduction of SAFT in the volume production of large forged parts was achieved by the introduction of the quantitative SAFT developed by Siemens, also called AVG or DGS-SAFT, which allows an evaluation of each voxel in units of a replacement reflector, and by an acceleration that allows the reconstruction of the complete volume of a large forged component, which could be obtained when the SAFT test was introduced into volume production. The challenges for level 2/3 reviewers are discussed, such as volume-corrected display of results, handling of large amounts of data, focusing of displays, amplitude representation in units of a replacement reflector and handling of the software. Furthermore, it is shown how displays are represented by SAFT, how the detection limit can be determined in the case of quantitative SAFT, and which artifacts can occur during series testing with SAFT.

scholarly journals Research and design of grid connection and waste heat utilization of marine generating units

2020 ◽  
Vol 165 ◽  
pp. 06003
Author(s):  
Anning Yi ◽  
Hongtao Guo
Keyword(s):  
Power Generation ◽  
Service Life ◽  
Temperature Difference ◽  
Electromagnetic Interference ◽  
Frequency Conversion ◽  
Waste Heat ◽  
Economic Benefits ◽  
Energy Output ◽  
Utilization Rate ◽  
Energy Unit

This work is based on the use of waste heat from the temperature difference semiconductor heat exchanger, which can effectively use the waste heat in the exhaust gas, and convert it into electrical energy output through the temperature difference semiconductor material, which can increase engine efficiency and reduce energy consumption; at the same time, it can reduce engine noise and vibration. Extended service life. Due to the strong electromagnetic interference and severe vibration of the generator, there are few remote control devices on the market for the generator. This project uses a 2.4G wireless communication module to control the frequency conversion and speed regulation of the generator. In order to save manpower, start remotely, stop as soon as possible, monitor the operating status of the waste heat temperature difference power generation, reasonably replace the power, start quickly, and reach the electromechanical Integrated product. The realization of intelligent frequency conversion technology can adjust the engine speed according to different electrical appliances, adapt to external loads, realize automatic voltage adjustment, and save fuel consumption. The grid-connected system solves the frequency and phase problems of generators of different models, generations, and manufacturers in parallel, and realizes the re-mixing of old generators, which greatly improves the service life of engines and the best power generation supply, and reduces power generation systems and storage. The configuration cost of the energy unit improves the comprehensive utilization rate of the equipment, has a higher working efficiency, has good economic benefits, and can achieve the purpose of energy saving and emission reduction.

ULTRA 76 TANTALUM

Alloy Digest ◽  
2010 ◽  
Vol 59 (5) ◽  
Keyword(s):  
Corrosion Resistance ◽  
Service Life ◽  
Physical Properties ◽  
Tensile Properties ◽  
Cost Effective ◽  
Heat Treating ◽  
Process Industry ◽  
Industry Applications ◽  
Critical Components ◽  
Corrosive Environments

Abstract ULTRA 76 TANTALUM alloys have been used in various process industry applications requiring resistance to aggressive, hazardous chemicals. These tantalum alloys provide cost-effective, long service-life for critical components in severe (corrosive) environments. This datasheet provides information on composition, physical properties, hardness, and tensile properties. It also includes information on corrosion resistance as well as heat treating. Filing Code: TA-13. Producer or source: H.C. Starck Inc.

Hartwalzen zur Festigkeitssteigerung wälzbelasteter Funktionsflächen

2021 ◽  
Vol 68 (3-4) ◽  
pp. 46-49
Author(s):  
Helmut Hochbein ◽  
Sascha Appelt
Keyword(s):  
Power Generation ◽  
Service Life ◽  
Failure Mechanisms ◽  
Border Zone ◽  
Functional Surfaces

The service life of functional surfaces subjected to rolling loads is limited by fatigue or insuffi cient separation of the rolling partners in the event of inadequate lubrication. These failure mechanisms can be counteracted by hard rolling and thus the introduction of residual compres sive stresses into the border zone, which can, among other things, extend maintenance intervals of production or power generation plants.

On the search for optimal damage precursors

2014 ◽  
Vol 13 (6) ◽  
pp. 601-608 ◽  
Author(s):  
Volker Weiss ◽  
Anindya Ghoshal
Keyword(s):  
Service Life ◽  
Crack Length ◽  
Microstructural Characterization ◽  
Phase Changes ◽  
Material Loss ◽  
Damage Indicator ◽  
Damage Indicators ◽  
Critical Components ◽  
Life Predictions ◽  
Indicator Ratio

A new approach to predict the service life of critical components via study of damage precursors is emerging and is the topic of this article. To date, most service life predictions are based on measurements of damage indicators and their growth toward criticality or failure, for example, fatigue crack length and material loss due to corrosion or wear. This makes lifetime estimates based on measurements of damage, for example, around half-life, or even at 80% life, difficult and inaccurate. To improve the accuracy and reliability of lifetime prediction, efforts are now underway to determine the state awareness of a critical component during service, based on property characterizations, in addition to the measurements of the direct damage indicators, such as crack length, acoustic emission, ultrasound signals, and eddy current measurements. These characterizations will include indirect damage indicators, that is, precursors and allied or affiliated damage indicators. For affiliated damage indicators, residual stress relaxation or development, phase changes, electrical property (resistivity, dielectric constant, permeability), and microstructural characterization must be considered. The selection of the optimal combination of direct and indirect damage indicators will be application specific. It is proposed to assess the efficacy of damage indicators on the basis of their Di/Df versus Ni/Nf, that is, damage ratio versus life fraction curves (referred to as damage indicator ratio curves), searching for indicators with damage indicator ratio curves that best meet the needs of the application.

scholarly journals Penentuan Interval Waktu Perawatan Komponen Kritis pada Mesin Turbin Di PT Pln (Persero) Sektor Pembangkit Ombilin

2016 ◽  
Vol 14 (2) ◽  
pp. 238
Author(s):  
Taufik Taufik ◽  
Selly Septyani
Keyword(s):  
Power Generation ◽  
Production Process ◽  
Continuous Process ◽  
Electrical Energy ◽  
Time Interval ◽  
Critical Component ◽  
Turbine Engine ◽  
Critical Components ◽  
Criticality Analysis

Electrical energy requirements in Indonesia annually increase in line with economic growth and an increase in population. So, PT PLN (Persero) have to be able to fulfill the public demands for electrical energy. One of the power generation existed is Steam PowerGeneration. The condition of power generation depended on the maintenance, so, well maintenance made power plant operated at ease condition. Production process in SteamPower Generation of Ombilin used a closed cycle or continuous process. If a machine or an equipment damaged, it will stop the whole function. In the production process, the company involved several main engines are boiler, turbine, condenser, and generator. But the damage often occurs in turbine engine which caused the generation power in Steam PowerGeneration of Ombilin can not operate. Therefore, it needs a maintenance action of machinery/equipment to be able to prevent the damage. The right strategy to keep the engine operating is determining the optimal maintenance interval of equipment for minimizing downtime.The stages of this research begin by determining the critical engine with Criticality Analysis method. Then, the determination of the critical components using Pareto diagram. Then, the determination of the probability density function (pdf) and the reliability of critical components. After that, the determination of maintenance intervals of the critical components by using the criterion of minimizing the downtime that will be used to make maintenance scheduling.Based on the processing data has been done, it was found that the critical engine is a turbine engine with a total value is 44 and the critical components of a turbine engine are membrane turbine, bearing and turning gear with the examination time interval for each critical component are 960.48 hours (40 days), 908.57 hours (37 days) and 1150.28 hours (48days). While the preventive replacement intervals for components of turbine membrane is after operating for 3410 hours, the replacement for bearing components can be carried out during overhaul after operating for 8000 hours and the replacement intervals for components of turning gear is after operating for 4500 hours. The reliability values for each critical component before and after preventive maintenance remains the same, but the value of downtime on each component decreases. The total values of availability for each critical component exceeds 95%. 

scholarly journals Review on hardfacing as method of improving the service life of critical components subjected to wear in service

2018 ◽  
Vol 36 (4) ◽  
pp. 1095 ◽  
Author(s):  
C Okechukwu ◽  
O.A. Dahunsi ◽  
P.K. Oke ◽  
I.O. Oladele ◽  
M Dauda
Keyword(s):  
Service Life ◽  
Critical Components

scholarly journals Determining the Aging Performance of Vacuum Insulation Panels: Development of a Prediction Model

2021 ◽  
Author(s):  
Melissa Morlidge
Keyword(s):  
Service Life ◽  
Thermal Resistance ◽  
Accelerated Aging ◽  
Extended Period ◽  
Building Envelope ◽  
Core Material ◽  
Vacuum Insulation ◽  
Critical Components ◽  
Quality Material ◽  
Metallic Foils

Vacuum insulation panels (VIPs) are increasingly being explored in building applications. Typically used in industrial processes such as aerospace engineering, cryogenics and refrigerator manufacturing, VIPs have been proven to provide a higher thermal resistance per inch than typical building insulation materials. However, there is speculation on the performance of these panels over an extended period of time due to various factors which gradually cause a reduction in thermal resistance. The purpose of this research project is to identify these variables and how they alter VIP performance over the product’s service life. Based on a thorough literature review, the critical components were interpreted to develop a numerical model which can predict the future performance of VIPs as they age, based on initial material properties. This model is intended to benefit designers and researchers in the construction industry; in understanding the potential for vacuum insulation to contribute to building envelope design. The results of calculation proved to be complementary to experimental results provided by the NRC, (initial calculated conductivities ranged from 4.17x10 The highest calculated conductivity was attributed to the low quality metalized (MF) VIP with a final conductivity after accelerated aging of 5.29 x 10 Some observations included that there is little difference between aluminum and metallic foils in their initial conductivity; however the aluminum foils represented in this report outperformed the chosen metallic foils over time, as they provided smaller gas and water vapour transmission rates. The core material variables with the greatest impact on performance were density and porosity. Some of the simulated panels exceeded the conductivity limit before the end of their service life, while others did not. Therefore the conclusion for VIP performance overall cannot be confirmed, although the development of standards within the industry would ensure high quality material integration within building systems.

scholarly journals Validation of Sentinel-1 offshore winds and average wind power estimation around Ireland

2020 ◽  
Vol 5 (3) ◽  
pp. 1023-1036 ◽  
Author(s):  
Louis de Montera ◽  
Tiny Remmers ◽  
Ross O'Connell ◽  
Cian Desmond
Keyword(s):  
Wind Speed ◽  
Synthetic Aperture Radar ◽  
Wind Power ◽  
Surface Wind ◽  
Synthetic Aperture ◽  
Synthetic Aperture Radar Data ◽  
Average Wind ◽  
Level 2 ◽  
Aperture Radar

Abstract. In this paper, surface wind speed and average wind power derived from Sentinel-1 Synthetic Aperture Radar Level 2 Ocean (OCN) product were validated against four weather buoys and three coastal weather stations around Ireland. A total of 1544 match-up points was obtained over a 2-year period running from May 2017 to May 2019. The match-up comparison showed that the satellite data underestimated the wind speed compared to in situ devices, with an average bias of 0.4 m s−1, which decreased linearly as a function of average wind speed. Long-term statistics using all the available data, while assuming a Weibull law for the wind speed, were also produced and resulted in a significant reduction of the bias. Additionally, the average wind power was found to be consistent with in situ data, resulting in an error of 10 % and 5 % for weather buoys and coastal stations, respectively. These results show that the Sentinel-1 Level 2 OCN product can be used to estimate the wind resource distribution, even in coastal areas. Maps of the average and seasonal wind speed and wind power illustrated that the error was spatially dependent, which should be taken into consideration when working with Sentinel-1 Synthetic Aperture Radar data.

Evaluation of the Power-Generation Capacity of Implantable Thermoelectric Power Generator Driven by Radioisotope Fuel

2011 ◽  
Author(s):  
Yang Yang ◽  
Jing Liu
Keyword(s):  
Power Generation ◽  
Service Life ◽  
Thermoelectric Power ◽  
Thermal Energy ◽  
Temperature Difference ◽  
Radioactive Isotope ◽  
Thermoelectric Generator ◽  
Power Generator ◽  
Thermoelectric Power Generator ◽  
Generation Capacity

The unique merit of the implantable thermoelectric generator lies in its direct utilization of the temperature difference intrinsically existing throughout the whole biological body. Therefore, it can resolve the service life mismatch between the IMD and its battery. In order to promoting the TEG maximum power, a piece of radioisotope fuel was fixed on the TEG hot junction. Recurring to the thermal energy released during disintegration of radioactive isotope, it can guarantee a marked promotion in the temperature difference across the implanted TEG; consequently apply enough power for the IMDs.

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