19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
by
Andrew Tieu (VLN)
on behalf of Marcel van Wonderen
KLM Royal Dutch Airlines
engineering & maintenance
Schiphol Airport
The Netherlandshttp://www.klm.com/engineeringmaintenance/site/en/index.html
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Contents: History of UHPW project at KLM
System of 1994
Which thermal spray coatings ?
Stripping Results
Data
Conclusion
Developments
Other waterjet developments
Awards
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
History of UHPW project at KLM
Start investigation ‘91
Coating and part related tests ‘91/’92
Justification/Specification ‘92/’93
Choice of supplier ‘93
Jan ‘94, system built up and start
Full process approval of GE in March ‘94
2004: 2nd UHPW system in production
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
System of 1994:
Cabin with 4 axes Gantry robot and indexing turntable
CNC and Operator module controlled by PC with ‘PRIMS’
20X ‘FLOW’ Intensifier (100 HP, max. 6.5 l/min., 350 MPa)
Closed Loop filtration with UV-radiation + particle-counter
6, 4 and 3 jet rotating nozzles
Straight and 90° non-rotating ‘FANJET’
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Which thermal spray coatings ? (plasma, flame, electric wire):
Metallic: Al, NiAl, NiCrAl, Inc718, CuNi, CrNiCo, NiAlMo, etc.
Ceramics: Al2O3, ZrO2/Y2O3, TiO2
Carbides: WC, CrC
Combinations: Ni/graphite, Polyester/Al
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
Velocity profile:
red: 800 m/sec yellow: 500 m/sec green: 350 m/sec light blue: 200 m/sec
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
STRIPPING RESULTS (TAT)
Booster shrouds 1 week ½ day
HPC-disk 2 weeks ½ day
Spool 1 week ½ day
HPC-stator case 1 week ½ day
CRF 1 week 1 day
Thermal Shield 3 days ½ day
LPT casing 1 week 1 day
Combustor liner 3 days 1 day
Fourteen years of experiencewith UHPW stripping
PARTS: ‘old methods’ UHPW
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
DATA 1: Parts
Approx. 84.200 parts stripped since Jan. 1994
225 different kind of parts
3 operational faults: wrong nozzle wrong program no rotating table start up in program
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
DATA 2: MaintenanceHigh pressure seal change approx. every 1.3 months
Orifice life of approx. 150 - 300 hours (water quality)
High pressure cylinders (once in 9 years)
Initial Filtration problems (due to Polyester / Al ) with Filtration bags Cartridge filtersSolved with extra: Centrifuge (+ flogging liquid)
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
DATA 3: Production
Average process times decreased 100 times
Average turnaround times decreased 5 times
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
DATA 4: ENVIRONMENT AND OCCUPATIONAL HEALTH
No injuries or illnesses related to UHPW
Sound level < 75 dBa
Continuously recycling of water
Approx. 4300 liters less use of nitric acid per year
Approx. 520 kg less Nickel in sludge-waste per year
Approx. 1400 kg less Nitrates into sewer per year
Approx. 70 kg less use of Sodium Hydroxide per year
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
CONCLUSION:The UHPW-stripping process is a superior alternative for traditional stripping:
Very short stripping times
Only one strip station therefore reduction of turn around times
Virtually none or no attack of the base-material
Little waste
Only water as the active medium (recycled)
Compact system and no special building requirements
Hardly or no dangers for the environment and occupational health
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
Developments at KLM:
Using the UHPW system for cleaning parts, as alternative for Chemical cleaning
Investigating possibilities of stripping HVOF coatings
Investigating possibilities of stripping EB-PVD coatings
2nd UHPW-system
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
“Jet Edge” intensifier (150 HP, 11.4 liter/min., 350 MPa)
New features: Thermostatically controlled cooling systemAutomatic high pressure bleed down valveIntegrated power distribution and power correction capacitorsPLC based control system with built-in network interface.
System of 2004:
Robotic UHPW system (also for 3200 mm shafts)
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Fourteen years of experiencewith UHPW stripping
19th International Conference on Water Jetting, Nottingham, UK from 15-17th October 2008.
Awards: 1994 “LIFE”-award from the European Commission, Directorate General XI of Environment, Nuclear Safety and Civil Protection for Clean Strip Technology nr. 93/NL/A121/NL/3505
1996 Dutch Industrial Environmental Award for Clean Technology
2005 Best research paper award on abrasive waterjet stripping
Fourteen years of experiencewith UHPW stripping