GT26 – BLADE3


Perform EC-scanc on blade3 without removing the rotor

In the GT26-BLADE3 projrect we developed the world’s first scanner for Eddy-current (EC) Blade-Inspection with a deployment mechanism that allows accessing inner blades from the exhaust without removing the rotor.

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Background

Due to quality problems with specific blades in row 3, unplanned inspections of these components had to be performed. For significantly saving cost, a new tool was developed- to perform this task without removing the rotor

  • Access Blade-row 3 from the exhaust area, by passing through Blade-row 4 and Vane-row 3
  • Perform EC-scans to search for cracks on these bladesè Avoid removing the rotor (time-consuming, expensive, and risky)

-> Avoid removing the rotor (time-consuming, expensive, and risky)

GT26-BLADE3 was financed by ALSTOM-Power. The time between project start and first commercial inspection was only one year. Until now, more than 30 inspections have been performed.

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KEY INNOVATIONS

  • Segmented arm for scanner-deployment, operated with Bowden-wires
  • Miniature x/y-scanner with remotely retractable probe-arm
  • Camera-system to assist the deployment and monitor the scan

 

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ACHIEVEMENTS

  • Deployment: Simple and user-friendly deployment-system for a scanner – in an area that is very difficult to access
  • Scanner: Very compact (25 x 80 x 200) and reliable XY-scanner for Eddy-current-inspections in narrow areas
  • NDT: Reliable crack-detection on blades, with eddy-current
  • Camera: Compact camera-system for operation between blades

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ALSTOM Inspection Robotics and other partners in the ALSTOM R&D network

This project was done in collaboration with ALSTOM R&D (camera-system),
Sensima (NDT) and EPFL (scanner prototype). Alstom Inspection Robotics
was responsible for the technical project lead, the deployment arm and the
industrialization of the scanner and its probe holder.


 

TANK WALL

Depending on the code, country and asset owner storage tank walls have to be inspected at a certain interval. Usually a visual inspection is the first type of inspection to be performed. Depending on ithe results further NDT methods have to be applied fully assess the condition of the tank.

 


 

POWER PLANT

In power plants the FAST RVI is used to inspect the condition of filter houses, stacks and silencers.


 

VISUAL INSPECTION IN GENERAL

The FAST RVI can be used for all visual inspections on ferromagnetic steel structures.

  • oil rigs
  • pipelines
  • ship hulls
  • steel factories
  • steel bridges

 

FAST WELD FOLLOWING

This innovative technology is using an industrial camera to recognize a weld seam. Image processing algorithms constantly extract the weld features from the image stream and determine its center position. The information is sent to the on-board motor controllers which maneuver the robot precisely along the weld.

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FAST 3D LASER SCANNING

Using a 3D laser scanner on the FAST platform enables the operator to precisely control and steer the robot in hidden environments. First a 3D point cloud is creted which is meshed to a full 3D model of the envirnoment.

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FAST RVI
Dimensions Length 250 mm (9.9") x Width 490 mm (19.3") x Height 160 mm (6.3")"
Weight (without cables) 9.3 kg (20.5lb) without camera
Payload 15 kg (33lb)
Speed fully adjustable, max. 60 mm/s (2.4"/s)"
Drive units 2 integrated drives with 48V brushless DC motors
Power Supply 48V via umbilical cable from external supply station
Protection class IP65
Motor controller inspection robotics motor controller
Communication Gigabit Ethernet
Min outer pipe diameter 600 mm (23.6")"
Max inner pipe diameter 1200 mm (57.2")"
FAST vessel, min inner diameter 1800mm (70.9")"
SUPPLY STATION
Control Built-in touchscreen and industrial Joystick
Power Supply 100-240 V AC 50/60Hz or 48V DC, max 200W
Dimensions Length 340 mm (13.4") x Width 350 mm (13.8") x Height 130 mm (5.1")"
Weight 14kg (31lb) without cabeling
CONTENT BASIC SET
FAST RVI robot in a rugged transport box
Supply Station - built in a rugged hard shell box
40m cable from supply station to robot
OPTIONAL
PTZ camera
Deployment tool for vessel inspection
Top view navigation camera, manway camera

 

WHAT OUR PARTNERS SAY

98% of the cost of Visual Inspections are attributed to EHS & preparation, only 2% is the inspection itself. All our production sites will benefit from that tool.

Chevron_Corporation

The FAST platform fully supports our strategy: no human entry in confined space by 2020.