Einsatzmöglichkeit. for the Inspection von and Kunststoffen. Casings of Steam. and Gas Turbine. Generator Sets VGB-M 621. Erste Ausgabe 2000

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1 Merkblatt Guideline Einsatzmöglichkeit for the Inspection von and Kunststoffen Evaluation Inin Service Kühltürmen Rotors and Casings of Steam VGB-M 621 and Gas Turbine Erste Ausgabe 2000 Generator Sets VGB-R 512 M 2 nd Edition 2003 Published by: VGB PowerTech e.v. Obtainable from: VGB PowerTech Service GmbH Verlag technisch-wissenschaftlicher Schriften Postfach , D Essen Tel Fax mark@vgb.org Translated by: Diplom-Übersetzer H.-P. Schmitz FDBR Fachverband Dampfkessel-, Behälter- und Rohrleitungsbau e.v. Düsseldorf Reproduction in whole or in part only with prior permission of the Publishers.

2 3 Preface to 1 st edition The necessity of uniformly representing the inspection and evaluation of inservice components in due consideration of damage reported as well as the improvement of manufacturing technology and examination techniques led to the establishment of this guideline. Inspections and evaluations of large as-delivered forgings and castings were reported in [1]. The development steps in manufacturing technology and non-destructive examination techniques require differential test and inspection plans for the performance of in-service inspections and evaluations of components. This guideline covers the inspection of major castings and forgings of turbogenerator sets, which govern the safety and availability of the plant. The first sections describe the basic principles of design, inspection and evaluation. Then component-specific sections follow which deal with the calculations, test and inspections as well as remedial measures applying to the respective components. This guideline serves as a general guideline for contracting partners (purchaser and supplier). The application of this guideline, whether in whole or by way of extracts, shall be agreed between purchaser and supplier. No liability will be taken by VGB for the technical correctness of the contents. In addition, users of this guideline are responsible for clearing up whether patent rights or other protective rights are infringed upon. Experience gained with the application of this guideline as well as proposals for changing or supplementing this guideline will be collected and evaluated by the VGB office. The following committees were engaged in establishing this guideline: VGB technical committee "Materials and Welding Technology", "Steam Turbines and Steam Turbine Operation" as well as representatives of the VDEW working group "Generators and Motors".

3 4 The following gentlemen took part in the establishment of this guideline: W. Berke, F. W. Bloch, K. Blomeier, Dr. L. Busse, Dr. V. Detampel, Dr. J. Ewald, W. Gayk, Dr. H. W. Grünling, K. Haring, E. Höxtermann, R. Hoffmann, K. Jäger, M. Jägerhuber, Dr. H. Jesper, H.-A. Jestrich, Dr. H. R. Kautz, K.H. Mayer, Dr. H. Müsch, W. Paul, G. Röttger, A. W. Schmitz, H. D. Teichmann, Dr. E. Tolksdorf, and D. Überhorst Our thanks are due to these gentlemen for their co-operation. Essen, November 1991 VGB TECHNISCHE VEREINIGUNG DER GOSSKRAFTWERKSBETREIBER E.V.

4 5 Preface to 2 nd edition With respect to the 1 st edition, several changes and supplements were made especially regarding fracture mechanics safety analysis. By doing so, the results of fracture-mechanics research work which was mainly supported by utilities and VGB in the last years have gone into the making of this guideline. The new edition of this guideline was published in co-operation between VGB and the turbo-generator set manufacturers. The following gentlemen took part in the establishment of this guideline: Dr. H. Bartsch, K. Blomeier, W. Daum, W. Eixelsberger, Dr. C. P. Gerdes, Dr. P. Hilllenbrand, Dr. T. U. Kern, Dr. K. Klemp, H. Luft, H. Mandel, Dr. F. Müller, P. Richter, St. Rodewald-Deckert, Prof. E. Roos, and W. Schwarz Our thanks are due to these gentlemen for their co-operation. Essen, June 2003 VGB PowerTech e.v.

5 6 Contents 1 Preliminary remarks Objective Principles of service life assessment Types of damage and possible consequences Safety analysis, technical evaluation Strength calculation Fracture mechanics strength calculation Examinations and tests during in-service or maintenance... inspections Non-destructive examinations Mechanical testing Remarks on the performance of tests and examinations Re-inspection of turbine rotors Re-inspection criteria, recommendations Non-destructive examinations (NDE) Mechanical tests Evaluation and measures to be taken Fracture-mechanics safety analysis Safeguarding against brittle fracture Safeguarding against ductile fracture Evaluation of the flaw size determined by NDE Safeguarding with respect to operational lifetime extension Measures to be taken Documentation Re-inspection of generator rotors Re-inspection criteria, recommendations Non-destructive examinations Evaluation and measures to be taken Safeguarding against brittle fracture Measures to be taken Rotor retaining rings Documentation...37

6 Re-inspection of turbine casings and valve bodies made of cast-steel Re-inspection criteria, recommendations Non-destructive examinations Mechanical tests Evaluation and measures to be taken Component stresses - Allowable defect sizes Fracture mechanics analysis Safeguarding with respect to operational lifetime extension Measures to be taken Documentation Literature Annexes...46