pwr_february-2025 - 21

TURBINE MRO
components, allowing for rapid reverse
engineering and manufacturing of custom
parts, " Eldridge explained.
Other innovative inspection tools are
also adding value. " Advanced imaging
techniques, such as phased-array ultrasonic
testing, X-ray inspection, and thermographic
inspection, provide detailed
insights into component integrity without
the need for further disassembly. These
methods allow MD&A to detect cracks,
wear, and other issues with unparalleled
accuracy, reducing inspection times and
improving repair planning, " he added.
Lastly, MD&A said advances in robotics
have streamlined maintenance tasks
in hard-to-reach areas. The company said
its generator in-situ inspection robot can
perform full generator inspections without
removing the field. " These technological
advances have allowed MD&A
and the broader power industry to offer
faster, more precise, and cost-effective
solutions, " Eldridge reported.
MD&A has used an innovative robotic
generator inspection crawler supplied by
East Hanover, New Jersey-based Nova
Technology Inc. Called the GenEX (generator
explorer), it is reportedly the lightest
generator inspection crawler (Figure
2) and has the highest resolution available
on the market today, according to Nova
Technology. The crawler itself weighs less
than 5 pounds and can enter generators
with gaps as narrow as 0.9 inches (22.86
millimeters). It has dual full-HD
(highdefinition)
color video cameras including
one forward facing camera and one at a
right angle that rotates and has variable
focus. LED (light-emitting diode) lighting
helps provide clear and crisp 5 megapixel
annotatable still images of inspection areas,
which can be displayed on a portable
monitor or laptop computer.
" Until now, in-situ inspection services
have largely been the domain of the
OEMs [original equipment manufacturers], "
Richard Hatley, president of Nova
Technology, told POWER. " We've enabled
service providers to provide an offering
that not only saves time but also
can eliminate the tremendous expense
of an unnecessary field pull. The GenEX
provides accurate assessments in hours
or days, not weeks. "
The GenEX crawler can be used for
stator wedge tightness assessment
(Wedgetap) and electromagnetic core imperfection
detection (El-Cid) inspections,
among others. The GenEX has proven
to be incredibly valuable to users. It has
found faults, shorts, material deterioration,
and more, while cutting downtime
February 2025 | POWER
fective solutions, " Eldridge said. " When
routine
inspections
fail
to
reveal the
2. The GenEX crawler provides rapid assessment
of generators without removing the
rotor, meeting traditional inspection requirements
at a fraction of the cost. Courtesy:
Nova Technology
by avoiding costly field pulls. GenEX has
greater maneuverability than a magnetic
crawler and can get into spaces some
other video inspection crawlers can't.
Hussien Sadek, past president and
current member of The American Society
for Nondestructive Testing (ASNT), and
president and CEO at Technologies Consulting
International, noted that eddy current
array (ECA) examination can be an
important inspection technology in power
generation facilities. ECA rapidly scans
large equipment components by using
custom-designed array coils that generate
C-scan images. These images assist
visual inspection and determine the location,
size, and orientation of defects in
equipment including in turbine blades. Today,
ECA technology employs advanced
data analysis and software to record test
results, minimizing an operator's analysis,
and allowing future analysis by thirdparty
interpretation, characterization, and
generation of final reports.
" When eddy current array technology
is incorporated into the overall predictive
and preventive maintenance program
at a facility, the inspection and the condition
evaluation of major equipment is
conducted rapidly with minimum downtime, "
Sadek told POWER.
Leaning on Experts
Yet, when routine inspections don't lead
to easy answers and more complicated
situations arise, consulting with experienced
engineers who perform turbine
MRO projects for a living can be important.
That's because they often have a
systematic, multi-disciplinary approach
to diagnosing complex issues and/or
may have come across a similar issue at
another facility.
" At MD&A, we excel in tackling these
challenges by leveraging
cutting-edge
technology and a methodical process to
identify root causes and implement efwww.powermag.com
source
of a problem, we begin with a
deep dive into the turbine's operating
history, performance data, and maintenance
records. Next, we deploy advanced
diagnostic techniques tailored to
the suspected issue. "
Eldridge said MD&A's cross-functional
team of engineers and technicians
collaborates closely throughout the
diagnostic process. " Their combined
expertise in materials science, mechanical
engineering, and turbine operations
ensures a thorough evaluation of the
problem from multiple angles, " he said.
" Once the root cause is identified, we
work with the client to develop a targeted
repair or mitigation plan. Whether
it involves component replacement, precision
machining, or an operational adjustment,
we prioritize solutions that not
only resolve the issue but also prevent
recurrence. Comprehensive testing and
validation ensure the turbine is returned
to service with optimal reliability. "
Aging Equipment
The increasing age of installed turbine
fleets has fundamentally reshaped maintenance
strategies, driving a shift from
reactive repairs to proactive and predictive
approaches. Older turbines present
unique challenges, such as material fatigue,
outdated designs, and limited availability
of original equipment manufacturer
(OEM) parts, leading to a requirement for
innovative and tailored solutions.
" At MD&A, we've seen a lot in our 42
years and have become very familiar with
the failure modes of older turbines and
generators, " said Eldridge. " This allows
us to identify and address potential issues
before they result in unplanned outages,
reducing downtime and repair costs. "
Eldridge noted that aging fleets often
suffer from a lack of compatible replacement
parts due to design obsolescence.
" To address this, we utilize reverse engineering
to manufacture custom components
that match or exceed original
specifications. This not only ensures
compatibility, but also extends the operational
life of aging equipment, " he
said. " In addition, we frequently recommend
upgrade solutions, such as control
system retrofits or upgraded valves or
enhanced blades that enhance turbine
efficiency and reliability. "
Extending Component Lifetimes
Elevated temperatures take a big toll on
gas turbine components, risking cracks,
21
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