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May, 2007
TurboCare Sp. z o.o.
NDT TESTS
Privileged & Confidential – Page 2
scope of tests
On usual basis we perform:
► Material tests
► Strength tests
► Visual examination
► PT, HD, MT and UT tests
► RT tests – in cooperation
► We use highest quality materials from companies such as : MR Chemie Gmbh and TIEDE
► We use highest quality machines made by companies such as: TIEDE, Krautkramer, Equotip and DEUTSCH
Privileged & Confidential – Page 3
material tests
► Material tests;
► All material tests are done on basis of proper EN standards;
► In preparation of samples process we use abrasive papers and diamond pastes or aluminum oxide suspensions;
► We use only materials from known companies (e.g. STRUERS);
► Preparation of replicas consist in vacuum evaporating and grading of tested materials – we use aluminum, gold or coal;
► Microstructure observation showed in replicas is done by ZEISS NEOPHOT 32`microscope. Photographic recording is done by CCD-Insight Spot digital camera interfaced with photo processing computer system;
► If necessary, for microstructure (samples or replicas) observation we use – in cooperation with Wroclaw Technical University – scanning or emission electron microscopes.
Privileged & Confidential – Page 4
non destructive material tests
► Negative of triafol replicas are made on live object, removed and fixed by adhesive tape on sample glass;
► Sample replicas are prepare by gold, aluminum or coal for further tests;
Privileged & Confidential – Page 5
destructive material tests
► Example samples after impact resistance tests;
► Special system for strength tests in 700°C;
Privileged & Confidential – Page 6
endoscopy and visual examinations
► Whole scope of endoscope and visual examinations are done with careful photographic and descriptive documentation;
► Welch Allyn Videoprobe 2000 videoscope test – Ø9mm 3m probe;
► Olympus endoscope – Ø9mm 1,5m probe;
► Pipelines endoscopy with industrial television from pipes with Ø40mm diameter to 15m length;
Privileged & Confidential – Page 7
ultrasonic tests
► Tests are done according to EN standards and SIEMENS specific instructions of elements (parts) and specific materials tests;
► For tests we use Krautkramer and Starmans equipment;
Privileged & Confidential – Page 8
ultrasonic tests
► Bearings tests;
► Bolts tests;
► Casings tests;
► Journal and shaft tests;
► Rivets and blades tests;
► Welds tests;
Privileged & Confidential – Page 9
wall thickness measurements
► We perform thickness measurements using modern ultrasonic equipment;
► Wall thickness:
► Casings;
► Pipelines;
► Heat exchangers surfaces;
► Hard to reach elements and elements available only from one side;
Privileged & Confidential – Page 10
magnetic powder tests
► Tests are performed according to EN standards and SIEMENS specific instructions of elements (parts) and specific materials tests;
► For tests we use TIEDE and DEUTSCH equipment;
Privileged & Confidential – Page 11
magnetic powder tests
► All found defects are carefully documented and finally shown in protocol, with exact localization and photography;
Privileged & Confidential – Page 12
magnetic powder tests
► During testing of high importance elements we use high sensitivity agents and we perform observation in UV light;
Privileged & Confidential – Page 13
long blades tests
► Magnetic powder test in white and UV light;
► Blade root dye penetrant test;
► Blade root and rivets ultrasonic test;
► Blade hardness test;
Privileged & Confidential – Page 14
dye penetrant tests
► All elements made from non ferromagnetic materials are tested with dye penetrant method – observation is performed as well in white light as in UV light;
Privileged & Confidential – Page 15
hardness tests
► We perform all kinds of hardness tests of materials and machine elements;
► Vicers method hardness test with ultrasonic hardness tester (in Vickers, Brinell or Rockwell scale);
► Energy method hardness test with EQUOTIP-2 hardness tester (in Vickers, Brinell or Rockwell scale);
Privileged & Confidential – Page 16
defect analysis
► Using our knowledge acquired during many years of experience we could indicate probable causes of defects, formed during production as well as during operation;
Privileged & Confidential – Page 17
certificates
► Tests leading personnel has all required certificates;
► Training scope meets requirements of EN473 standard
Privileged & Confidential – Page 18
Privileged & Confidential – Page 19
NDT inspection reports
TurboCare Use Standard Inspection Record Sheets to record and report inspection results and where required dual language reports are provided:
Example 1: Bearing Babbit Bond UT Report
Privileged & Confidential – Page 20
NDT inspection reports
Example 2: Cylinder Blade Shroud Inspection
TurboCare Use Standard Inspection Record Sheets to record and report inspection results and where required dual language reports are provided:
Privileged & Confidential – Page 21
NDT inspection reports
TurboCare Use Standard Inspection Record Sheets to record and report inspection results and where required dual language reports are provided:
Example 3: LP Overhead Pipework Magnetic Particle Inspection
Privileged & Confidential – Page 22
qualified NDT engineers
TurboCare NDT Personnel are experienced Turbine Service Engineers with technical qualifications up to MSc In an Engineering discipline. Every engineer has appropriate NDT certification:
Privileged & Confidential – Page 23
references
► NDT test are performed during all works performed by TurboCare Sp. z o.o. in Poland as well as in most of works abroad;
AUSTRIA GERMANY HUNGARY
SERBIA BULGARIA BOSNIA/HERZEGOWINA
NDT EXPORT TO:
Privileged & Confidential – Page 24
recent service contracts (≥200MW)
Year Customer OEM Output (MW)
DescriptionLocation
2003 DSD LMZ 200 Major OverhaulMaritza, Bulgaria2003 PS Patvov Zamech 200 NDE of PipeworkPatvov, Poland2003 KEK LMZ 200 OverhaulPristina, Kosova2003 TUROW SA Zamech 215 NDE of PipeworkTurow, Poland2003 Energo Opole Zamech 360 OverhaulOpole, Poland
2005 Alstom (ABB) 300 STG Major OverhaulNikola Tesla, Serbia
2003 DSD Alstom 215 Diffuser ExchangeDolna Odra, Poland2004 ZRE LMZ 500 DescriptionKozience, Poland2004 SAG LMZ 300 DescriptionObrenovac, Serbia2004 Polnard SA Alstom 360 TG OverhaulPP Opole, Bulgaria2004 Vantaa LMZ 240 DescriptionTahkoluoto, Finland2004 ZRE LMZ 500 Valve Diffuser ExchangeKozienice, Poland
2003 KEK LMZ 200 OverhaulPristina, Kosova2003 TUROW SA Zamech 215 Rotor/Casing InspectionTurow, Poland2003 PS Patvov Zamech 200 Unit 5 TG OverhaulPatvov, Poland
2005 Polnard SA Zamech 360 TG OverhaulPolnard, Poland
2005 PAK LMZ 200 Turbine ServiceKonin, Poland
2006 ESB BBC 350 Turbine V/v OverhaulMoneypoint, Eire
2005 PS Patvov Zamech 200 OverhaulPatvov, Poland
2006 KEK LMZ 200 OverhaulPristina, Kosova
EPS
Privileged & Confidential – Page 25
THANK YOU FOR YOUR THANK YOU FOR YOUR ATTENATTENTTIONION
WROCLAW – CITY OF TurboCare Sp. z o.o. LOCATION