19th World Conference on No

Non-Destructive Testing 2016

EXAMINA ATION OF SERVICE LIFE

FE OF
GENERATOR ROTOR
RO RETAINING RING
NGS MADE
OF ASTM A2899 CLASS C STEEL USING
G LDC1000
SENSOR

Zbigniew Hilary ŻUREK 1, Gerd DOBMANN 2, Dariusz BAR ARON 3

1
Silesian University
U of Technology, Katowice, Poland
2
Universi
ersität des Saarlandes, Saarbrücken, Germany
3
Ethos
hosEnergy Poland S.A., Lubliniec, Poland
Contact e-mail: zbigniew.zurek@
@polsl.pl, gerd.dobmann@t-online.de, dariusz.baron@e
@ethosenergygroup.pl

Abstract. The paperr ppresents a review of currently used techniques for pred
rediction of
service life of austeni
enitic generator rotor retaining rings. The method iss bbased on
comparison of the test
ested physical properties of generator rotor retaining rings
rin made
of ASTM A289 Class lass C steel with the material initial condition. Compa parison of
changes in materiall iis possible by indirect measurements of relativee magnetic
m
permeability and elect
ectrical conductivity versus frequency. A convenientt method
m is
detection of degradatio
ation changes in electrical resonance, using a new geneneration of
inductive converterss LDC1000.
L

1. Introduction

Austenitic steels used in power

pow engineering are characterized by increa reased resistance to
heating caused by eddy curren
rrents generated by an alternating magnetic field
ield. Austenitic steel
ASTM A289 Class C opera erates under complex operational loads, both oth mechanical and
thermal. It is used e.g. as mat
aterial for generator's rotor retaining ring 1,, which
w protects end
windings 2 of the generatorr rotor
ro - see Fig.1.

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 Fig. 1. Location of generator’s rotor retaining ring

The operational loads of the generators' rotor retaining rings cause three basic types of
defects, that is mechanical, electro erosive and corrosive. Examples of mechanical and
electro erosive defects are shown in Fig.2.

Fig. 2. Mechanical and electro erosive defects

Operational diagnostics of the retaining rings is most important on account of potential
hazards to the safety of people and power plants.

1.1 Steel characteristic

ASTM A289 Class C steel is an alloy. Its chemical composition is shown in Table 1. It is
mechanically resistant and paramagnetically stable (Table 2).

Table 1. Chemical composition of steels used for retaining rings

Chemical
composition C Mn Cr S Si N P
%
0.12 17.5 – 17.5 – 0.015 0.80 0.50 0.050
G18H18
max. 20.0 20.0 max. max. min. max.
0.13 17.5 – 17.5 – 0.015 0.80 0.45 0.060
ASTM A289-C
max. 20.0 20.0 max. max. min. max.
0.45 – 17.0 – 3.0 – 0.035 0.17 – 0.075
G18H3 c. 0.1
0.60 19.0 4.0 max. 0.50 max.

2
 Table 1 - continued
Al B Ni Ti V Fe
0.030 0.001
- - - remainder
max. max.
0.04 2.00 0.10 0.25
- remainder
max. max. max. max.
-
- - - - remainder

Table 2. Catalog values - electrical and magnetic parameters of steels used for retaining rings
Specific conductance γ [S/m]
Material µr [-] ( Resistivity ρ [Ωm] )
- Rp0,2 900 MPa Rp0,2 1000 MPa
1.380⋅106 1.370⋅106 1.400⋅106
G18H18 ≤ 1.004 -6 -6
( 0.725⋅10 ) ( 0.730⋅10 ) ( 0.714⋅10-6 )
6 6
1.330⋅10 1.320⋅10 1.290⋅106
G18H3 ≤ 1.004 -6
( 0.752⋅10 ) -6
( 0.758⋅10 ) ( 0.775⋅10-6 )

Variations in the electrical conductivity of the steels due to temperature changing are
shown in Fig.3. Austenitic steel’s conductivity depends on chemical composition of a given
steel and its final structure; this is shown for temperature equal to 20°C. This relationship
may be observed in the Schaeffler constitution diagram (Fig.4).

2,2
γ, S/m 1,45

2,0
1,40 3

1
2

1,8 1,35

4
5

1,6 1,30
6

0
C
1,25
1,4 31
2
20 40

45
6
1,2 304
316
321
1,0 1 G18H18
2 Rp0,2 900 MPa
0,8 3 Rp0,2, 1000 MPa
4 G18H3
5 Rp0,2 900 MPa
0,6 6 Rp0,2, 1000 MPa
T, 0C
-270 1600

Fig. 3. Electrical conductivity of austenitic steels

Testing of steel with designed high stability is somewhat difficult, since changes of
magnetic permeability and specific conductance allowable in operation are very small.

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 Cr-Mn
G18H18
ASTM A289-C
G18H3
Cr-Ni
AISI 304
AISI 316
AISI 321

Fig. 4. Schaeffler constitution diagram for Cr-Mn and Cr-Ni steels

With the exception of G18H3 steel, all remaining steels are grouped near the boundary
between austenitic and austenitic-ferrite phases.

2. Experiment - identification of technical condition

Acquisition of data in-between routine repair tasks is difficult on account of annual

operational cycle. The initial investigation was composed of several stages; e.g.
measurements of ultrasonic wave attenuation in the material were conducted (Fig.5). The
results of sound wave attenuation for eight retaining rings taken out of operation are set out
in Table 3. Magnetic measurements were run with the 1.069 magnetoscope of the company
Förster shown in Fig.6.

Retaining ring Developed view of retaining ring’s

outer surface

Rotor body side

Fig. 5. Testing points and measurement equipment used

Table 3. Averaged results of measurements – ultrasonic wave attenuation in the retaining ring material; tests
run with retaining rings taken out of service (worn out) and with newly-manufactured retaining rings

Retaining ring (G18H3) Retaining ring (G18H18)

Retaining
RR1.1 RR1.2 RR2.1 RR2.2 RR3.1 RR3.2 RR4.1 RR4.2 new
ring No.
[dB/m] 61 41 73 66 84 80 38 50 ~0
< 3 dB/m (value close to 0 dB/m) – attenuation of newly-manufactured material
≤ 60 dB/m – limit attenuation value, adopted in practice, testifying to complete material wear

4
 (a) (b)
Fig. 6. Förster magnetoscope 1.069 (a) and measurement probe (b)
The probe of the magnetoscope (Fig.6.b) is composed of a magnet and coils for measuring
the magnetic field. The permanent magnet generates the magnetic field for inspection.
When the probe is brought close to material with given magnetic permeability, the
magnetic field becomes distorted. This distortion is measured by the measuring coils of the
probe and used to calculate magnetic permeability of the tested material.
The measurement results for relative magnetic permeability µr and magnetic
susceptibility κ of the tested retaining rings' steel [2,3] are shown in Table 4. The test
results are for G18H18 steel in two cases: for newly-manufactured material and for material
taken out of service, marked in bold-typed numbers; these results may be compared. The
remaining retaining rings were manufactured with G18H3 steel used in the past. Since this
steel is no longer commercially available (it was withdrawn in the eighties), it is not
possible to compare these results with those of newly-manufactured material.

Table 4. Measurement results of relative magnetic permeability µr

and magnetic susceptibility κ for steel of tested retaining rings

Retaining ring (G18H3) Retaining ring (G18H18)

Retaining
RR1.1 RR1.2 RR2.1 RR2.2 RR3.1 RR3.2 RR4.1 RR4.2 new
ring No.
µr [-] 1,00275 1,00270 1,00270 1,00270 1,00265 1,00275 1,00355 1,00375 1,00320
κ [-] 0,00275 0,00270 0,00270 0,00270 0,00265 0,00275 0,00355 0,00375 0,00320
Values required (for comparison purposes):
for newly-manufactured material µr ≤ 1,004 (manufacturer’s catalog), in service µr ≤ 1,05

2.1 Lab tests – identification of state observer’s function

The lab tests started with three different kinds of shaped samples: hourglass, flat and round
ones (Figs. 7a, b and c - respectively). The samples were subjected to different mechanical
load cycles (pendulum cycle, pulsating stress cycle where minimum stress is zero and
constant stress cycle with stress greater than zero). It was assumed that biggest strain took
place in regions marked with 1, and the smallest in regions marked with 3.

5
 (a) (b) (c)
Fig. 7. Mid-parts of G18H18 steel samples subjected to mechanical cyclic fatigue loads; areas dedicated to
microstructural analysis are marked
(a) hourglass sample - mechanical stress, pendulum cycle
(b) flat sample - - mechanical stress, pulsating cycle where minimum stress is zero
(c) round sample - mechanical stress, constant and greater than zero
Differences in degradation of cyclic stress regions of hourglass sample are shown in Fig.8.

Fig. 8. Cross-section of hourglass sample and images of structure degradation

The tested steel loaded under operational conditions is characterized principally by micro
structure degradation and increased glide bands of dislocations. This defect is responsible
mainly for changes in steel's electrical conductivity. The range of further lab tests was
limited to one sample type and test stand accessible within the framework of the project
[15] on account of costs.

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2.2 Choice of method

The samples of G18H18 steel were acquired from the forging of newly-manufactured
retaining ring. Direction of sampling is shown in the cross-section of retaining ring forging
in Fig.9; it is conformable with direction of principal mechanical stresses in the retaining
ring. The photo of cut-out flat samples is shown in Fig.9 as well.

outer diameter of
retaining ring forging

sample outline

inner diameter of
retaining ring forging

Fig. 9. Sector of retaining ring forging’s cross-section, direction of sampling is shown; samples prepared for
tests
Important stage in the research was constituted by initial laboratory assessment how
electrical parameters of G18H18 steel may change due to fatigue processes [2, 3].

2.2.1 Measurements of electrical conductivity

After series of high cycle mechanical fatigue loads, the samples were tested for changes in
their electrical parameters. The results of specific conductance γ and resistivity ρ
measurements of G18H18 steel samples are shown in Fig.10. Three batches of samples
were tested: a) where material was brand-new (i.e. not subjected to fatigue loads), b) where
material was subjected to 1 100 000 cycles, and c) where material was subjected to
10 100 000 cycles. Resistance measurements were conducted with the help of voltmeter-
ammeter method (low resistance variant). The procedure was half automated.

(a) (b)
Fig. 10. The ranges of equivalent changes of specific conductance γ (a) and resistivity ρ (b) of G18H18 steel
samples under three different fatigue load conditions
Measurement results of G18H18 steel samples have demonstrated change in their electrical
parameters as high as 2.5% after 10.1 million load cycles (fatigue load series). In the tested
range of load cycles, the increase in the cycle number has resulted in decrease in specific

7
conductance (i.e. increase in resistivity). The measured changes are significant from the
viewpoint of assessing technical condition of retaining ring steel and they correspond to its
level of fatigue degradation.

3. Theoretical principles

When current I flows through LCR bridge (Fig.11), the voltage drop across empty coil E0
and voltage drop across coil containing sample E (elements C-R3 of the equivalent scheme
are neglected for conducting materials) are related as follows [8]:

E Z
= (1)
E0 Z 0
Z ωL R − R0
= −j (2)
Z0 ω L0 ω L0

Fig. 11. Basic measurement scheme and equivalent model [1]

ω Lp R − R0
The quantities present in ratios and p (normalized impedance components [8])
ω L0 ω L0
are, apart from impedance Zm, main indirect parameters which make it possible to assess
the rate of degradation. They are calculated from the parameters of series connection of Ls
and Rs elements of the tested circuit. The coil may enclose or it may be adjacent to the
sample [8, 11].
When results obtained from material samples are compared, it is important to
maintain sample geometry (sample radius r0) and measurement coil geometry on account of
the significant impact of η coefficient ( η = ( D p / D s ) 2 ) [8]. This is shown in theoretical
formulas for normalized impedance components (calculated with the help of Mathematica
software).
Dp 2
η =( ) , k = Sqrt[−i × ω × γ × µr × µo ] (3)
Ds
2 J ( k × ro )
µ sk = × 1 , (4)
k × ro J 0 ( k × ro )
ωL
[γ _, µ re _, ω _ η ] = 1 − η + ηµ re Re[ µ ef ], (5)
ω L0
R − R0
[γ _, µ r e _, ω _,η ] = −ηµ r e Im[ µ ef ]. (6)
ω L0
The measurement circuits based on electric circuit models [7] do not take into account
material’s electrical conductivity. The proposed solution makes allowance for eddy currents

8
and for material’s electrical parameters [8, 9, 10, 11]. In the case of testing ferromagnetic
materials these parameters are significant in the frequency range of cheap LCR bridges.

4. Experimental tests–HIOKI bridge

Changes in parameters were measured with the help of HIOKI bridge (Fig. 12a);
measurements were applied to samples previously subjected to fatigue tests. In order to
avoid errors due to coil design, the measurements were conducted in selected locations of
the sample (at the narrowing), using one measurement coil (Fig. 12b). These measurements
are the result of the analysis of the theoretical fundamentals of eddy current flaw detection.
The results were compared in the charts of Fig. 13.

(a) (b)
Fig. 12. Test stand (a) and coil enclosing sample (b)

The processed measurement data from three sample groups are shown in Fig.13 (new
samples and samples loaded with 12 and 24 million cycles).

2500 100
Z, Ω fatique phase, deg fatigue
cycles 80 cycles
24 mln 24 mln
2000
12 mln 60 12 mln
0 0
40
1500
20

1000 0

-20
500
-40

3,19483E6 3,33939E6 -60

0
f, Hz -80 f, Hz
0 1000000 2000000 3000000 4000000 5000000
0 1000000 2000000 3000000 4000000 5000000

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2500
100
Rs, Ω Ls, H 0,00007
⊕
⊕∅ phase, deg
fatigue
⊕∅ ∅
⊕ 80
∅ cycles
2000 ⊕ 0 0,00006
∅
⊕ 12 mln 60
∅ ∅
⊕
⊕ 24 mln
⊕⊕∅ ∅ 0 0,00005
fatigue
∅
⊕∅ 40
⊕∅ ∅ ⊕ 12 mln cycles
1500 ⊕∅ ⊕
⊕ ⊕∅ 24 mln 24 mln
∅
⊕
∅
⊕
∅ ⊕∅
⊕
∅
⊕
∅ ⊕∅ ∅ 20
⊕
⊕
∅
∅
⊕ ⊕∅
⊕∅ ⊕ ⊕ 0,00004 12 ml
∅
⊕
∅⊕
∅
⊕ ⊕
∅
⊕∅ ∅∅⊕
∅
⊕
∅⊕
∅
⊕ ⊕∅⊕∅
⊕∅ ∅ ∅
⊕
⊕
∅
∅⊕
⊕
∅
∅
∅⊕
⊕
⊕
⊕⊕ ⊕⊕
⊕⊕⊕
⊕
∅∅⊕∅
⊕∅ ∅ 0
∅
∅
∅⊕
⊕
∅
∅
∅⊕
⊕
⊕
∅
∅
∅⊕
⊕
∅
∅
∅⊕
⊕
⊕
∅
∅⊕
⊕
∅
∅⊕
⊕
∅
∅⊕
∅
∅∅
∅∅
∅ ⊕ ⊕
1000 ⊕ 0
∅ 0,00003
∅
⊕
-20
⊕ ∅
⊕
∅
⊕ 0,00002
500 ∅
-40

∅ 0,00001
-60
⊕
0
f, Hz 0,00000 -80 Z, Ω

0 500 1000 1500 2000 2500

0 1000000 2000000 3000000 4000000 5000000

Fig. 13. Presentation of impedance, phase, Ls and Rs components and Z vs. phase
The changes in resonance frequency may be observed in the charts (at points where phase
direction changes).

4.1 Experimental tests – LDC1000EVM module

The LDC1000 circuit was used in this procedure [14]. The constructional parameters of the
system with a multi-layer coil make it possible to detect changes in the resonance frequency
band when testing the steel. It is possible to identify the change in resonance frequency in
the degraded material.

1 Location of test points

2

Retaining ring’s Area of shrinkage

mid-zone mounting

Fig. 14. Sector of the retaining ring showing location of test points, LDC1000 module and prototype test
probe

Table 5. Results of calculating equivalent parallel resistance component Rp

proximity proximity data R pMAX ⋅ R pMIN

Test Y= RpMIN R pMAX Rp =
data 215 R pMIN ⋅ ( 1 − Y ) + R pMAX ⋅ Y
point [kΩ] [kΩ]
[-] [-] [kΩ]
1 3250 0.09918 0.798 9.235 4.508
2 4025 0.12283 0.798 9.235 4.018

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 Table 6. Results of calculating resonance frequency f sensor and L
Module settings Calculated values
f sensor [MHz] L [µH]
Test f ext response_time C 1
fcount
1 f L=
point [MHz] ( RAW ) [cycle] [pF] f sensor = ⋅ ext ⋅ response _ time C( 2π f sensor )2
3 f count
1 6 3098 6144 100 3.966 16.104
2 6 3070 6144 100 4.003 15.808

The test results conducted on the surface of the retaining ring (Tables 5 and 6) at
analyzed test positions (Fig.14) show differences in the probe’s output quantities (i.e.
proximity data and frequency count), as well as in the calculated resonance parameters (Rp,
fsensor, L). This confirms the possibility of applying this probe for testing operational fatigue
degradation of the retaining ring material, i.e. chromium-manganese steel which is stable in
the austenite phase. If appropriate patterns of operational variability of measured
parameters for a given steel are available, it is possible to assess the rate of fatigue
degradation for this steel and to forecast the future period of a reliable operation. The
measurement probe presented here makes it possible to test all types of steel, both
ferromagnetic and paramagnetic. It is a simple and cheap test device, characterized by high
repeatability of measurements, so versatile that it may be used in industry.

5. Conclusions

The measurement of degradation changes in highly stable austenitic steels used in power
engineering industry is possible even when cheap measurement transducers such as
LDC1100 inductive converters are used. The initial tests which are aimed at precise
characterization of the material are particularly important in diagnostic tests. The conducted
measurements of structure analysis and unconventional research methods have brought-
about results which are comparable to those obtained with professional measuring devices.
The motivation for taking action when finances are limited has been confirmed. Some dis-
satisfaction may be discernable among the manufacturers of NDT and NDE apparatus.

References

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