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