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Power honing is conducted utilizing state-of-the-art equipment, and is exclusive only to KEMA. The HM100 Honing System is an all-electric drive machine that incorporates the use of heavy duty GH-210 Series (General Hone/Sunnen) honing tooling that provides expedited material removal rates for greatly minimized production times. Bore surface finish is on the order of 63 micro inches (Ra) or better, and bores are straightened to produce a uniform diameter across the axial extent of the internal bore cavity. Bottle bores are prepared using the power polishing features of the HM100 and provide automated stroking of the bottle region for improved consistency of material removal that yields a more uniform internal diameter.
After honing measurements
Upon completion of the power honing operation, internal bore diameter measurements are again repeated at 2″ intervals. Both before and after honing bore dimensions are recorded and documented in the formal boresonic inspection report. The bore dimension record form also indicates the delta value of the diameter
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Plug bore preparations and dimensions
When contracted services include preparation of the plug bore and fabrication of a replacement bore plug(s), precise measurements of the plug bores are obtained by the field machining personnel.
Based on plug bore dimensions, specifications for the fabrication of a replacement bore plug(s) are documented and forwarded to the plug vendor. The dimensional information is verified upon receipt of the replacement bore plug(s) and prior to the installation of the plug to assure the proper specified interference fit is maintained.
Conclusions
Given the fact that turbine and generator rotor forgings contain varying numbers of internal defects indigenous to the manufacturing process, periodic NDT examination of rotor forgings are the safest approach to managing the risk of failure due to startup and steady state stresses encountered through continued in-service operation. Boresonic inspection techniques have been proven to be useful in detection and sizing of internal flaws that ultimately reduce the remaining life of the rotor.
The following technological methods will provide turbine owners with the essential tools to manage the reliability of their operational fleet.
- Boresonic inspection to detect and size potential internal flaws
- Rotor condition assessment that includes fracture mechanics and finite element analysis (FEA)
- Material testing to derive case specific material properties
- Corrective machining to remove the presence of harmful flaws
David Yates is an Automated Systems Development Specialist at KEMA with 25 years of experience in the power generation industry providing nondestructive testing services and technical support. Yates holds an AS degree and AAS degree in Nondestructive Evaluation from Moraine Valley Community College. His responsibilities at KEMA include NDT technical support, training, boresonic program oversight and quality assurance/quality control functions. He is a current member of the ASNT, Chicago Section.
Angelo J. Tarantino was the Business Development manager at KEMA TOS prior to his retirement in November 2010. He was the original founder and president of Northeast Inspection Services since 1983 until the acquisition by KEMA in January 2008. He initially served as manager of NDT Services for KEMA TOS prior to becoming Business Development manager, responsible for acquiring new customers, business ventures and sales growth. Tarantino holds a bachelor’s degree in Business Education and a master’s in Business Education, Special Education from SUNY Albany University. He is a current member of the ASNT.
Joop Kraijesteijn is a director at KEMA with 10 years of experience in the energy industry and more than 15 years industry experience in project and account management. Kraijesteijn holds a bachelor’s degree in aeronautical engineering and a master’s in mechanical engineering. His responsibilities at KEMA include managing projects related to power generation, with a focus on technical and operational services, such as condition monitoring of rotating equipment and boilers, quality assurance/quality control, inspections, diagnostics and nondestructive testing. He manages KEMA’s nondestructive testing department in North America and also is responsible for new business development. He is a member of the Operations and Maintenance Committee of the ASME Power Division and has presented several papers at major power industry conferences on issues related to inspections and condition monitoring.
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