Endoscopic Fluorescent Penetrant Inspection (FPI)

Transcription

1 Endoscopic Fluorescent Penetrant Inspection (FPI) Center of Industrial Competences in NDT (CCI CND Safran Snecma) ECNDT October th European Conference on Non-Destructive Testing (ECNDT 2014), October 6-10, 2014, Prague, Czech Republic

2 OUTLINE 01/ Definition 02/ Endoscopic FPI Benefits 03/ Endoscopic FPI Implementation 04/ Technology 05/ Endoscopic FPI Training 06/ Operational Experience 1 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

3 /01/ DEFINITION 2 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

4 DEFINITION Technique arising from two different NDT methods: FPI and Endoscopy FPI : applying a range of chemicals allowing detection and localization of surface or open discontinuities Endoscopy: inspection method allowing to view and examine surfaces which are not directly visually accessible Endoscopic FPI : high-sensitivity FPI process carried out in-situ, using available endoscopic engine ports 3 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

5 /02/ ENDO FPI BENEFITS 4 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

6 ENDO FPI BENEFITS Traditional endoscopy does not always allow to determine the actual nature or threat of an indication Suspicious indications: Black marks Scratches Impacts Residual cracks after blending Leading edge of HPC blade (stage 7) after blending, white light illumination To resolve these doubts Endoscopic FPI 5 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

7 ENDO FPI BENEFITS Example 1 : Residual crack after blending? Before blending : After blending : Visual Visual Endo FPI Endo FPI Crack length estimated at 4mm max No crack 6 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

8 ENDO FPI BENEFITS Example 2 : Residual crack after blending? Before blending : After blending : Visual 1st blend : Visual Endo FPI Endo FPI 2 nd blend: Visual Crack length estimated at 0.5mm max Endo FPI Crack length estimated at 5mm max No crack 7 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

9 ENDO FPI BENEFITS Example 3 : Residual crack after blending? Before blending : After blending : Endo FPI Endo FPI Crack Traversing crack 2 nd blend necessary 8 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

10 ENDO FPI BENEFITS The innovation allows to: Resolve such doubts by determining in-situ threats posed by indications Guarantee material health after blending Limit engine disassemblies Contribute to flight safety Lower engine operation costs 9 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

11 ENDO FPI BENEFITS Cost comparison of Endo FPI / Engine disassembly : CFM56-3B TPB Engine Disassembly Cost Blending + Endo FPI cost Engine removal 1.4% Engine rental 0.6% per day (varies with overall rental time) LPT removal and installation 4.7% Engine repair (LPT module servicing) 93.3% Total 100% 6.2 to 7.8% FPI is relatively easy to carry out, however its implementation inside a nondisassembled engine is a delicate task 10 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

12 /03/ ENDOSCOPIC FPI IMPLEMENTATION 11 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

13 ENDO FPI IMPLEMENTATION Spraying of the various FPI chemicals on inspected zone: Cleaning using acetone Application of S4 sensitivity penetrant Excess pre-cleaning using water Application of emulsifier Cleaning using water followed by drying Application of developer Visualize using UV light DECISION Video presentation of complete Endo FPI process available herehttp:// 12 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

14 /04/ TECHNOLOGIES 13 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

15 TECHNOLOGIES Technologies developed by CCI CND (Safran) and EFER Endoscopy : Rigid UV endoscope Flexible articulating UV endoscope Rigid articulating UV endoscope 14 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

16 TECHNOLOGIES Development with EFER Endoscopy of a portable spraying and inspection system: UV and white light source for endoscope FPI chemicals stowage and spraying case Endoscope according to application 15 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

17 /05/ ENDOSCOPIC FPI TRAINING 16 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

18 ENDO FPI TRAINING Objective : Training operators in using Endoscopic FPI Operator prerequisites: COSAC N2 certification in FPI or equivalent Length : 5 days Description : Day 1 Day 2 Day 3 Day 4 Day 5 Theorycourse «The keysto endoscopy» Practicalcourse «The keysto endoscopy» Pratical endoscopic exerciseson test boxes using the different kits Trials on engine using the different kits Trials on engine using the different kits Endoscopy Test Pratical course «The keys to endoscopy» Film projection Instructions manual& qualification file review Equipment presentation(rigidand flexible kits) Practical endoscopic FPI exerciseson test boxes usingthe different kits Trials on engine using the differentkits Trials on engine using the different kits Endo FPI Test Documents delivered: Training certificate 17 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

19 /06/ OPERATIONAL EXPERIENCE 18 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

20 OPERATIONAL EXPERIENCE Applied to all engine types in service or under development : Commercial High power Military Spatial Interventions by engine type 68 engine removals avoided out of 75 inspections, since / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

21 OPERATIONAL EXPERIENCE Applied to modules or airframes having difficult access: TIG welds on reheater brackets (DMS Vernon) APU turbine impeller (Microturbo) Connecting rods welds (Aircelle) 20 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

22 21 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

23 CONTACTS Technical inquiries : M. LEMOAL Jean-Claude : +33 (0) : jean-claude.lemoal@snecma.fr Sales inquiries M. NEGRE Pierre : +33 (0) : negre@efer.com M. TRUJAS Didier : +33 (0) : trujas@efer.com M. COSATTI Dominique : +33 (0) : cosatti@efer.com 22 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER

24 CONTACTS Training inquiries: M. KIMMEL Philippe : +33 (0) : philippe.kimmel@snecma.fr Mme BERNARDI Dominique : +33 (0) : dominique.bernardi@snecma.fr M. PUJOL Marc : +33 (0) : marc.pujol@snecma.fr 23 / European Conference on Non-Destructive Testing (ECNDT 2014) / October 6-10 / SAFRAN Snecma & EFER