We developed remote in-situ dye penetrant inspections on the compressor stage R-0 and R-1 rotor blade tips for radial cracks in 2001. Since that time we have inspected over Four Hundred units in the fleet and have identified cracked blades on over Seventy units. Our extensive experience performing this inspection has evolved our examination time into just Twelve Hours per unit. This allows our clients to perform the TIL 1509-1 NDT during weekend non-peak periods. Our staffing level allows us to complete a Four unit site in One day. Our high level of Borescope and NDT expertise makes us one of the leaders in the industry.
NDE/NDT Inspection Methods & Repair/Refurbish Offerings
GE MS7001FA:
Frame-7FA R-1 Eddy Current Inspection to test for platform cracking. (Cracking in this area caused the R-1 failure in 2007 at a site in Mississippi)
Frame-7FA R-1 Phased Array Ultrasonic Inspection on the standard and P-Cut blades. This inspection is designed to identify cracking at the P-Cut and dovetail. ATS has identified cracks on standard and P-Cut blades.
Frame-7FA S-0 and S-1 Eddy Current Inspection is designed to identify cracking in the stator vanes. ATS has continued to identify units with cracked stator vanes. Cracking such as this has been attributed to the catastrophic failue of several units in the Fall of 2007.
Frame-7FA High-Resolution Corrosion Pitting Inspection method was developed for the S-0 through S-3 stator vanes. This inspection is designed to identify corrosion pits that have lead to stator vane failures at over sixteen sites. We at ATS have refiined this inspection method to the extent that we can now inspect the entire leading edge of 90+% of the stator vanes in each row. Other companies offer only a platform inspection on a limited number of vanes without the High Resolution capability. We’ve identified severe corrosion pitting on a unit they designated as pit free only days earlier.
Frame-7FA: TIL 1509-1 Dye Penetrant Inspections
Frame-7FA R-0 Molds with independent lab evaluation.
Frame-7EA and 7FA Remote in-situ Blending and Crack Removal from stages R-1 and R-2 on the 7EA’s and R-0 and R-1 on the 7FA. All blended blades receive a follow-up dye penetrant examination to ensure all traces of the crack or damage are removed.
Frame-7EA and 7FA Remote Shim Removal and Grinding Per TIL 1562 on stages S-0 to S-2 on the 7FA’s and S-1 to S-2 on the 7EA’s. We’ve repeatedly pulled S-2 shims for one utility with minimal unit disassembly.
GE MS7001EA:
Frame-7EA S-1 and S-2 Eddy Current Inspection: This inspection is designed to identify cracking in the stator vanes. Numerous 7EA’s have been destroyed by stator vane failures.
Frame-7EA R-1 and R-2 Remote Dye Penetrant Testing: This inspection is similar to the 1509-1 and is designed to identify radial tip cracks in the rotor blades caused by blade tip to case rubs. We have identified cracks on over 50 7EA’s since we started offering this service.
GE MS5001:
Frame-5 S-1 and S-2 Eddy Current Inspection: This inspection is designed to identify cracking in the stator vanes. Numerous Frame 5’s have been destroyed by stator vane failures.
Frame-5 in-situ Hook Fit Inspections at the Case Breaks without unit disassembly. This is the area where hook fit cracking typically initiates. Performing a frame 5 inspection without inspecting this area is like not checking the oil level in a car during a tune up. We’ve identified at least ten units with cracked hook fits prior to failure.: