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Gas Service Solutions

Quality control
and assessment methods

Reconditioning of gas turbine components


At Alstom, quality
control is a mindset
that permeates the
organisation because
the reliability, efficiency
and emissions
performance of a gas
turbine is the sum of the
quality of decisions and
processes involved for
every component at every
lifecycle stage.

Quality management an integral


part of the reconditioning process
A modern quality assurance system is an integral part of Alstoms reconditioning
process. From the inspection of incoming parts, to the final check before it is returned
to the customer, every part is subject to the tightest, fully traceable quality control at
every step of the reconditioning process.
As a gas turbine Original Equipment Manufacturer (OEM) with over 30 years
reconditioning experience we know that reconditioning only makes financial sense if
the original reliability and performance criteria can be fully restored or even upgraded
to latest design standards.
Reliability depends on the ability to fully restore the mechanical integrity and strength
of each part. Performance depends on the ability to precisely restore the original
dimensions and design intent that are so critical for the tight clearances that determine
the efficiency of an engine.
Quality assurance at Alstom represents our commitment to protecting our customers
assets and revenues by supporting the operation of efficient, reliable and emissionscompliant gas turbines.

Customer benefits

Global standards

Alstoms global reconditioning


network is organised and
equipped to ensure the same high
standards worldwide.

Shape and strength restored


Our quality control ensures the
restoration of precise dimensions
for smooth reassembly and
mechanical integrity for reliable
operation.

PWER/LEAF/QLCSTH11/eng/GAS/06.13/CH/7509

Full traceability

Our R-DAS database stores


manufacturing and reconditioning
steps and quality-relevant data
for every component over its full
lifecycle.

Full portfolio of tests

All types of quality control can


be accomplished with our full
portfolio of assessment methods.

Alstoms Reconditioning Process

Quality
Assess

Strip/Clean

Repair

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it
is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is
subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Alstom contributes to the protection of the environment. This leaflet is printed on environmentally-friendly paper.

Coating

An expert system for enhanced quality assurance


Throughout the entire reconditioning procedure a complete record
of all the data relevant to quality is kept in Alstoms R-DAS database
Every part has identification and serial numbers that link
it to detailed original specifications and a record of all the
subsequent processes, design upgrades or quality checks
conducted on that part.
This makes the manufacturing processes and each step in
quality fully traceable for every individual part.

The R-DAS builds on individual, technical component

specifications such as zone drawings, dimensions and


standardised repair criteria.

When a part arrives for reconditioning, an initial assessment


is made and entered into the R-DAS database.

An incoming inspection report is generated.


Then the system documents the findings and automatically
proposes the necessary reconditioning steps.

As the reconditioning proceeds, the steps are recorded in the


R-DAS along with the outcomes of the interim assessments
and tests conducted.

After all reconditioning steps are completed, a final


reconditioning report is produced.

Gas Service Solutions


Quality Control and Assessment Methods

Reconditioning diagnostics and statistics (R-DAS) platform


Reconditioning
specifications
& drawings

Detailed component
assessment

Standard processes,
inspection & test plans
Strip/clean
Repair
Coating

Customer reporting
Standardised
Automated

R-DAS platform

The unique features of R-DAS

R-DAS is a web-based, advanced system that builds


on 30 years of reconditioning experience. It is continuously
being developed and updated to meet the needs of
our customers all over the world.
It facilitates:
Systematic inspections and quality
data storage
Automatic repair proposals
Automatic scrap tracking
Systematic feedback for product improvement
Globally consistent standards throughout
the Reconditioning Network
Cost and delivery schedule estimates

Assessment and non-destructive testing technology


Non-destructive testing (NDT) refers to non-invasive techniques used to determine the structural
integrity of a component without causing any damage or permanently altering the properties
of the component or material being inspected
Alstom uses NDT in the initial assessment and for quality
control during and after the reconditioning process. In
conjunction with our wide range of assessment methods,
we are able to offer customers firm evidence of the success
of a reconditioning process.
Thanks to our assessment and certified NDT technology, we can
provide our customers with the assurance that a reconditioned
part will perform safely and reliably alongside new or original
components.

The following range of tests is employed:


Visual boroscope inspection
Fluorescent penetrant inspection (FPI)
Dimensional checks
Ultrasonic testing (UT)
Eddy-current measurement techniques
Magnetic particle inspection (MPI)
Airflow
Waterflow
X-ray and computer tomography
Weight moment checks and frequency tests for rotating parts

Gas Service Solutions


Quality Control and Assessment Methods

Visual boroscope inspection


The internal structure of air-cooled components can be very
complex. Modern boroscope technology allows detailed visual
inspections of the inside of such components to be made.
Visual boroscope inspections are used to verify:
Whether there are any surface defects, such as corrosion
of the inner surface.
The integrity of the internal structure, e.g. state of the
impingement plates that guide the cooling air within the
component.
That the component is free of internal deposits.

Fluorescent Penetrant Inspection


(FPI)
FPI is the ideal method for detecting all sorts of indications
and surface flaws. After cleaning the part, a fluorescent dye is
applied and then, after the application of a developer, a visual
inspection is performed under UV light.
Alstom has developed an automated application system to
enhance the reproducibility of the results and allow our qualified
inspectors to concentrate on the analysis of the surface.

Boroscope inspection on GT26 Vane 3

FPI on GT24 HPT vane: Linear indications and surface flaws are clearly visible
under UV light

Dimensional checks
Checking dimensions is a fundamental aspect of quality control.
3D Coordinate Measuring Machines (CMM) and other methods
are used to ensure that reconditioned parts meet specifications.
Particular attention is paid to ensuring perfect assembly
clearances.

Ultrasonic Testing (UT)


Ultrasonic Tests (UT) rely on high-frequency sound energy to
conduct examinations and make measurements. Ultrasonic
inspection can be used for flaw detection/evaluation, dimensional
measurements, material characterisation, and more.

Assembly gage or shaft

wheels can also be used


for assembly tests.

3D coordinate measuring machine


(CMM)

Ultrasonic testing on GT24 HPT blades

Gas Service Solutions


Quality Control and Assessment Methods

Airflow
To test the full functionality of the cooling system of
reconditioned air-cooled components, we measure
airflow in the engine-ready condition.

Waterflow
Waterflow tests give clear visual indications of whether cooling holes are either open or clogged.

The consumption of cooling air has an impact on


engine efficiency and emissions. For components with
an advanced cooling system, individual sectors of the
component can be checked in isolation to ensure the optimal
cooling of individual sectors or rows of cooling air holes.

Airflow quantity control on GT24 HPT vane

Waterflow

Computer tomography of a GT24 HPT blade

X-ray and computer tomography

Weight moment check

If necessary, we can apply X-ray or computer tomography tests


to assess the internal structure of parts.

The weight moment measurement for rotating parts, i.e.


blades, provides the basis for specifying the blade distribution
during assembly. This is necessary to meet the rotors dynamic
requirements. Prior to the weight moment measurement, a
frequency test may need to be performed to ensure that parts
are within the designed frequency band after reconditioning.

Computer tomography of a GT24 HPT blade

Weight moment check

Weight moment check


and frequency test

Gas Service Solutions


Quality Control and Assessment Methods

We put quality first


At Alstom, quality control and assesment is an integral part of every
manufacturing and reconditioning process
Our quality assesment methods are based on our extensive OEM knowledge and our
global fleet and lab-based benchmarks. Alstoms global Reconditioning Diagnostics
and Statistics (R-DAS) database supports full traceability of all quality-relevant data
throughout a components lifecycle.
Based on these firm foundations, the results of our comprehensive range of assesment
methods and non-destructive tests provide reliable predictions that improve your
engines reliability, availability and performance.

Key Advantages

Alstoms OEM knowledge of the

original design intent in combination


with vast field experience allows us to
check all quality-relevant topics.

Systematic storage of quality and

manufacturing data in R-DAS for full


traceability of all parts and processes.

State-of-the-art quality testing


methods with a high degree of
automatisation.

Persistent training and further


qualification of employees.

Consistent quality standards across the


Alstom network.

ISO 9001/ 14001 and OHSAS

PWER/LEAF/QLCSTH11/eng/GAS/06.13/CH/7509

18001 certifications to ensure best


management, environmental and
safety practices.

To find out more about reconditioning of


gas turbine components, please contact
your local Alstom representative.
ALSTOM (Switzerland) Ltd.
Brown Boveri Strasse 7
5401 Baden
Switzerland
Visit us online: www.alstom.com

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it
is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is
subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Alstom contributes to the protection of the environment. This leaflet is printed on environmentally-friendly paper.