Eighty Years of Damage Detection from the Allianz Center for Technology
Posted: 2012-11-23
A rotating compressor blade in a multi-ton gas turbine is broken; the power
plant has to go offline. Millions of Euros lost with no clear answer as to the
cause. Defective design, material failure or human error after all? This is a case
that calls for the loss assessment experts from the Allianz Center for
Technology (Allianz Zentrum fur Technik or AZT). Their diagnosis: In a routine
replacement of parts, compressor blades with a slightly different material
composition were used, which could not sufficiently absorb the vibrations - and
without failure the inevitable consequence.
The center has investigated many similar major industrial losses during its 80
years of existence - from the Hindenburg airship disaster (1937) to the turbine
shaft accident at the Irsching power plant in 1987 to material problems in
modern power plant boilers. Aside from loss assessments, the center, which is
now part of Allianz’s industrial insurance carrier Allianz Global Corporate &
Specialty (AGCS), also provides expertise in loss prevention. To mark AZT’s 80th
anniversary, a comprehensive report has been published, which provides an in-
depth look at how the center operates and showcases many of its ongoing
research projects.
Experts for industrial technology
AZT specializes in industrial technologies such as energy, power plant
technologies and engineering. The center’s 15 engineers – among them
electrical, mechanical or process engineers as well as chemists and material
experts – investigate damages to core industrial equipment such as boilers,
turbines, drives, generators and transformers. "The insights we gain from our
assessments benefit not only us as an industrial insurer but our clients as well,"
explains Dr. Johannes Stoiber, who jointly heads AZT with Stefan Thumm.
The specialist reports compiled from these investigations are used not only to
analyze claims incidents but also to improve risk assessment by AGCS’s
underwriters when insuring technical risks. The lessons learned are
communicated to the affected companies as well, giving them the tools they
need to develop practical responses and prevent future losses. "This way, we
help each other to learn from damages," says Dr. Stoiber.
Detective work on a microscopic level
Each AZT engineer investigates about 20 cases a year. In many instances, the
AZT engineers trace the causes to the microscopic level. During laboratory
analyses, they discover such root causes of claims as mechanical and thermal
overstress, corrosion and material flaws. "Diagnosis is much easier today. Non-
destructive testing has made enormous strides over the past 10 years," co-head
Thumm explains. Ultrasonic testing, internal stress measurements and scanning
electron microscopes uncover even the tiniest source of a loss.
Nonetheless, on-site inspections remain indispensable. "A loss inspection
resembles detective work," Thumm says. At the site of the loss AZT engineers
will closely scrutinize the damaged part, take photos of details, speak to
involved employees and analyze operational data. Often there are several
intertwined causes that can be attributed to the damage. "That’s why we have to
investigate all aspects of a loss – including design, manufacturing and
operations," adds Thumm.
Expanding global activities
Established in 1932 in Berlin, AZT has its roots in Germany. Since its integration
into the globally active AGCS, the center has increasingly also been assigned to
international claims – for example, when a power plant in Brazil was damaged
or a high-speed train in Shanghai caught fire. The international activities will be
expanded further in coming years – particularly in the emerging markets of Asia
and South America. "We have to know the ins and outs of different claims
handling environments," Dr. Stoiber explains. "But we have a universal strength
– our independent judgment that draws from in-depth technical expertise."
Claims investigation, however, is just one of AZT’s core businesses. The other is
loss prevention. The center advises companies on technical loss prevention
measures and conducts research for AGCS and third parties which is presented
at conferences or published in white papers. "The best loss is the one that
doesn’t happen," says Dr. Stoiber.
Research in renewable energies
In its prevention work, AZT focuses on the fast-growing world of renewable
energies such as geothermal energy, wind power and photovoltaics. For
example, AZT has developed standards for automatic condition monitoring
systems for wind generator units that have contributed decisively to their
industry-wide application. The monitoring systems detect initial signs of
overstress or material fatigue in the gear box or bearings of wind turbines. As a
result, the affected parts can be replaced in time to prevent an actual loss.
The example of wind farms applies to other technologies as well. "We’re
frequently faced with prototypical technologies where we lack any case history,"
Dr. Stoiber explains. "Just as an industry continues to advance, so do we."
Historical milestones of the Allianz Center for Technology
1932 The origins of AZT
Allianz Center for Technology was founded in Berlin as a materials testing
center.
1937 A new location
With more than 17 employees and 470 cases a year, the center moved to new
facilities on the outskirts of Berlin. The reputation of the institute led to the
consultation of AZT in spectacular damages, including the analysis of the
breakage of the propeller of a steam-driven ocean liner and the investigation
into the causes for the accident of the airship Hindenburg in 1937.
1945 Recovery after war
The facility survived World War II largely intact. Work centered around power
plant technology and corrosion problems.
1960s Settling and expanding in Munich
The testing institute in Ismaning, just north of Munich, opened in 1962. In
addition to material analysis the center also began to work on precautionary
analysis and monitoring of machinery. In 1968, AZT purchased one of the first
scanning electron microscopes in Germany, whereby the institute became a
benchmark authority in the analysis of material breakages.
1969 Allianz Center for Technology is created
Allianz transferred the materials analysis division to the "Allianz Zentrum für
Technik GmbH." The new center was responsible for coordinating all Allianz
activities in damage research and loss prevention, concentrating technical
services under one roof. The damage experts continued to develop and expand
their methods and skills, as technical innovations and newly developed
industrial branches, such as nuclear power plant engineering or medical
technology, become more and more important.
Among the biggest damages the AZT investigated in the following years is the
accident in the power plant Irsching, Bavaria, in 1987. Back then, the middle
course of a turbine exploded into 30 pieces. One piece with a weight of more
than one ton skidded up in the air and landed in a distance of about 1 kilometer
to the power plant. Nobody was injured, but the property damage was
enormous. After the accident, the AZT experts perfected the testing technology
for turbines.
2000 up to today
As part of AGCS's subsidiary, Allianz Risk Consulting GmbH, AZT serves as a
carrier for all technical pre- and post-loss services that are not part of any
AGCS insurance policy. Beyond that, AZT’s priority is to offer technical services
to clients globally via the AGCS global network of companies. Worldwide
assignments of AZT include, for example, the fire damage inspection of the
Transrapid in Shanghai, the failure inspection of a technical defect at the hydro
power plant Itaipu in Brazil, as well as the analysis of a gear failure incident with
the conveyor system at a copper mine in Chile.
plant has to go offline. Millions of Euros lost with no clear answer as to the
cause. Defective design, material failure or human error after all? This is a case
that calls for the loss assessment experts from the Allianz Center for
Technology (Allianz Zentrum fur Technik or AZT). Their diagnosis: In a routine
replacement of parts, compressor blades with a slightly different material
composition were used, which could not sufficiently absorb the vibrations - and
without failure the inevitable consequence.
The center has investigated many similar major industrial losses during its 80
years of existence - from the Hindenburg airship disaster (1937) to the turbine
shaft accident at the Irsching power plant in 1987 to material problems in
modern power plant boilers. Aside from loss assessments, the center, which is
now part of Allianz’s industrial insurance carrier Allianz Global Corporate &
Specialty (AGCS), also provides expertise in loss prevention. To mark AZT’s 80th
anniversary, a comprehensive report has been published, which provides an in-
depth look at how the center operates and showcases many of its ongoing
research projects.
Experts for industrial technology
AZT specializes in industrial technologies such as energy, power plant
technologies and engineering. The center’s 15 engineers – among them
electrical, mechanical or process engineers as well as chemists and material
experts – investigate damages to core industrial equipment such as boilers,
turbines, drives, generators and transformers. "The insights we gain from our
assessments benefit not only us as an industrial insurer but our clients as well,"
explains Dr. Johannes Stoiber, who jointly heads AZT with Stefan Thumm.
The specialist reports compiled from these investigations are used not only to
analyze claims incidents but also to improve risk assessment by AGCS’s
underwriters when insuring technical risks. The lessons learned are
communicated to the affected companies as well, giving them the tools they
need to develop practical responses and prevent future losses. "This way, we
help each other to learn from damages," says Dr. Stoiber.
Detective work on a microscopic level
Each AZT engineer investigates about 20 cases a year. In many instances, the
AZT engineers trace the causes to the microscopic level. During laboratory
analyses, they discover such root causes of claims as mechanical and thermal
overstress, corrosion and material flaws. "Diagnosis is much easier today. Non-
destructive testing has made enormous strides over the past 10 years," co-head
Thumm explains. Ultrasonic testing, internal stress measurements and scanning
electron microscopes uncover even the tiniest source of a loss.
Nonetheless, on-site inspections remain indispensable. "A loss inspection
resembles detective work," Thumm says. At the site of the loss AZT engineers
will closely scrutinize the damaged part, take photos of details, speak to
involved employees and analyze operational data. Often there are several
intertwined causes that can be attributed to the damage. "That’s why we have to
investigate all aspects of a loss – including design, manufacturing and
operations," adds Thumm.
Expanding global activities
Established in 1932 in Berlin, AZT has its roots in Germany. Since its integration
into the globally active AGCS, the center has increasingly also been assigned to
international claims – for example, when a power plant in Brazil was damaged
or a high-speed train in Shanghai caught fire. The international activities will be
expanded further in coming years – particularly in the emerging markets of Asia
and South America. "We have to know the ins and outs of different claims
handling environments," Dr. Stoiber explains. "But we have a universal strength
– our independent judgment that draws from in-depth technical expertise."
Claims investigation, however, is just one of AZT’s core businesses. The other is
loss prevention. The center advises companies on technical loss prevention
measures and conducts research for AGCS and third parties which is presented
at conferences or published in white papers. "The best loss is the one that
doesn’t happen," says Dr. Stoiber.
Research in renewable energies
In its prevention work, AZT focuses on the fast-growing world of renewable
energies such as geothermal energy, wind power and photovoltaics. For
example, AZT has developed standards for automatic condition monitoring
systems for wind generator units that have contributed decisively to their
industry-wide application. The monitoring systems detect initial signs of
overstress or material fatigue in the gear box or bearings of wind turbines. As a
result, the affected parts can be replaced in time to prevent an actual loss.
The example of wind farms applies to other technologies as well. "We’re
frequently faced with prototypical technologies where we lack any case history,"
Dr. Stoiber explains. "Just as an industry continues to advance, so do we."
Historical milestones of the Allianz Center for Technology
1932 The origins of AZT
Allianz Center for Technology was founded in Berlin as a materials testing
center.
1937 A new location
With more than 17 employees and 470 cases a year, the center moved to new
facilities on the outskirts of Berlin. The reputation of the institute led to the
consultation of AZT in spectacular damages, including the analysis of the
breakage of the propeller of a steam-driven ocean liner and the investigation
into the causes for the accident of the airship Hindenburg in 1937.
1945 Recovery after war
The facility survived World War II largely intact. Work centered around power
plant technology and corrosion problems.
1960s Settling and expanding in Munich
The testing institute in Ismaning, just north of Munich, opened in 1962. In
addition to material analysis the center also began to work on precautionary
analysis and monitoring of machinery. In 1968, AZT purchased one of the first
scanning electron microscopes in Germany, whereby the institute became a
benchmark authority in the analysis of material breakages.
1969 Allianz Center for Technology is created
Allianz transferred the materials analysis division to the "Allianz Zentrum für
Technik GmbH." The new center was responsible for coordinating all Allianz
activities in damage research and loss prevention, concentrating technical
services under one roof. The damage experts continued to develop and expand
their methods and skills, as technical innovations and newly developed
industrial branches, such as nuclear power plant engineering or medical
technology, become more and more important.
Among the biggest damages the AZT investigated in the following years is the
accident in the power plant Irsching, Bavaria, in 1987. Back then, the middle
course of a turbine exploded into 30 pieces. One piece with a weight of more
than one ton skidded up in the air and landed in a distance of about 1 kilometer
to the power plant. Nobody was injured, but the property damage was
enormous. After the accident, the AZT experts perfected the testing technology
for turbines.
2000 up to today
As part of AGCS's subsidiary, Allianz Risk Consulting GmbH, AZT serves as a
carrier for all technical pre- and post-loss services that are not part of any
AGCS insurance policy. Beyond that, AZT’s priority is to offer technical services
to clients globally via the AGCS global network of companies. Worldwide
assignments of AZT include, for example, the fire damage inspection of the
Transrapid in Shanghai, the failure inspection of a technical defect at the hydro
power plant Itaipu in Brazil, as well as the analysis of a gear failure incident with
the conveyor system at a copper mine in Chile.
