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First Quality Solutions Turbine Inspection Reports

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FIRST QUALITY SOLUTIONS

VISUAL EXAMINATION REPORT

Customer: Sample Turbine Outage PO: 104568912 Report No: S1

Component: Turbine Components WO: 100591641 Code: N/A

Material: Varied – See below Preparation: Blasted Temperature: 70°F

Weld Types: N/A Acceptance Standards: Cust. FQS Procedure: 002-Rev. 5

Visual Aids: Flashlight, mirror, ruler Technique: Direct Visual

Component Acc. Rej. Remarks/Indications

A LP Rotor X See below

B LP Rotor X See below

Diaphragm Assemblies 22 - 25 X See below

Shells & Casings* X See below

Main Steam Stop Valve Assemblies X See below

Windage Covers X See below

Bolting & Studs X See below

Generator Fan Blades X See below

Summary of Inspection Performed:

Examiner: Gordon Austin Level: II Date: 12/20/2010

Examiner: Michael Schantz Level: II Date: 12/20/2010

The components listed above were visually inspected for wear and general condition. In addition to

the preliminary visual inspection each component received additional NDE inspections as indicated

below, as directed by plant engineering. Technique sheets for each inspection performed can be

found within.

A LP Rotor – WFMT Inspection, PT Inspection, UT Inspection

B LP Rotor – WFMT Inspection, PT Inspection, UT Inspection

Diaphragm Assemblies 22 – 25 – WFMT Inspection

Shells & Casings* – WFMT Inspection on selected items

Windage Covers – Visible dye PT Inspection

Bolting & Studs – UT Inspection

Generator Fan Blades – Visible dye PT Inspection

* The shells and casing inspected are as follows:

“A” lower & upper shell

“B” lower & upper shell

LPA upper casing

LPB upper casing

Packing heads

Packing Extension Cones

“A” LP Rotor Visual Inspection

The “A” LP Rotor was removed, blasted, and inspected at selected locations for damage and general

condition. Technique sheets can be found within for the magnetic particle, liquid penetrant, and

ultrasonic inspections. Listed below are the findings of the visual inspection.

Wheels/Bolt holes – Acceptable, no findings to report

Dove Tails & Pins – Acceptable, no findings to report

Buckets

o Generator End

L-0 – Minor impact damage noted at outer 18” on buckets 16, 18, 27, 49, 53, 54,

55, 56, 88, 89, 104, 105, & 106.

L-1 – Light erosion on the trailing edge of buckets 12 – 40 & 56 – 88; minor

mechanical gouging noted on buckets 38 & 77.

L-2 – Minor mechanical gouges noted on buckets 11, 16, 47, & 62.

L-3 – Acceptable, no findings to report.


L-5 – Minor mechanical gouging on the outside 2” typical of all buckets.

o Turbine End

L-0 – Minor impact damage noted at out 18” on buckets 3, 4, 7, 8, 9, 26, 44, 49,

68, 69, 70, 106, 107, 108, 109, & 110; Damage noted on bucket 66, 6” from

outside of bucket (sliver solder chipped and erosion shield pulling away from

bucket).

L-1 – Light erosion on the trailing edge typical of each bucket.

L-2 – Light erosion on the trailing edge typical of each bucket.

L-3 – Minor mechanical gouging noted at buckets 10, 14, 22, & 35.


L-5 – Minor to moderate mechanical gouging on the outside 2” typical of all

buckets.

Tie Wires

o Generator End L-0 – Acceptable, no findings to report

o Turbine End L-0 – Silver solder damaged at buckets 19, 33 & 47.

Stellite Erosion Shields

o Generator End L-0 – Minor porosity noted in silver solder on buckets 15 & 34.

o Turbine End L-0 – Silver solder chipped and erosion shield pulling away from bucket

66.

“B” LP Rotor Visual Inspection

The “A” LP Rotor was removed, blasted, and inspected at selected locations for damage and general

condition. Technique sheets can be found within for the magnetic particle, liquid penetrant, and

ultrasonic inspections. Listed below are the findings of the visual inspection.

Wheels/Bolt holes – Acceptable, no findings to report.

Dove Tails & Pins – Acceptable, no findings to report.

Buckets

o Generator End

L-0 – Minor impact damage noted at outer 12” on buckets 44, 47, 56, 57, 58, 59,

69, 70, 71, & 72.






o Turbine End

L-0 – Minor impact damage noted at outer 18” on buckets 4, 7, 8, 9, 22, 27, 38,

49, 56, 60, 70, 71, 72, 94, 97, 104, 107, & 108.






Tie Wires

o Generator End L-0 – Acceptable, no findings to report.

o Turbine End L-0 – Acceptable, no findings to report.

Stellite Erosion Shields

o Generator End L-0 – Acceptable, no findings to report.

o Turbine End L-0 – Acceptable, no findings to report.

Diaphragm Assemblies 22 – 25

The diaphragm assemblies 22 through 25 stages in both the A&B low-pressure sections were removed,

cleaned, visually inspected, and inspected utilizing the wet fluorescent magnetic particle method. All

deficiencies noted on the diaphragm assemblies were marked and recorded. The list below will provide

the identifications of each diaphragm inspected. Please refer to the technique sheets for the results of

the visual inspection and magnetic particle inspection.

General view of diaphragm staging area

Shells & Casings “A” Shell – Lower

o Minor multiple cracking was noted on the horizontal joint between the14th

and 16th

stage areas on both the left and right sides.

o Separation was noted, at the bolted connection of the hood extension and casing shell

on turbine end left side.

o Cracking was noted in the spacer blocks welds at the 18th

stage turbine end left side.

o Erosion noted on the N3 packing case on the turbine end.

General view of “A” Shell - Lower

“A” Shell – Upper

o #3 door on the left side has 360º cracking on the interior weld.

o #3 door on the right side has 360º cracking on the interior weld and (3) 1” cracks in the

exterior weld. The door insert also has a 1” crack on the exterior.

General view of “A” Shell - Upper

“B” Shell – Lower

o Minor multiple cracking noted at the horizontal joint between the14th

and 16th

stage

areas on both the left and right sides.

o LP Condenser piping cracked on the generator end, right side.

General view of “B” Shell - Lower

“B” Shell – Upper

o #3 door on the left side has 360º cracking on the interior weld.

o #3 door on the right side has 360º cracking on the interior weld and 3” crack in the

exterior weld.

o #2 door on the left side has a 1” void in the exterior weld.

General view of “B” Shell - Upper

LPA Upper Casing

o 1” indication noted on the generator end, left side.

LPB Upper Casing

o Acceptable, no findings to report

General view of LPA & LPB Upper Casings

Packing Heads

o N4 – Acceptable, no findings to report




Packing Cone Extensions

o The N4, N5, N6, & N7 packing cone extensions were inspected at the bolting end

utilizing the magnetic particle method and were found to acceptable, however the

bolting ends were damaged during disassembly and have extremely rough and sharp

edges, a recommendation for repair was made.

Windage Covers A, B, & C Windage covers were inspected utilizing dye penetrant and visual inspection

techniques, with no findings to report

Windage covers A & B

Windage covers C

Bolting & Studs

The following bolting and studs were inspected visually and utilizing ultrasonic inspection techniques:

A & B Coupling studs – Acceptable, no findings to note

Crossover vertical joint studs – Acceptable, no findings to note

HP turbine end crossover studs – Acceptable, no findings to note

Inner shell outside bolts – Acceptable, no findings to note

Steam chest studs – Acceptable, no findings to note

Stop valve bonnet studs – Acceptable, no findings to note

Upper control valve studs – Acceptable, no findings to note

Generator Fan Blades

Fan blades (24) for the collector and turbine ends were examined utilizing dye penetrant and visual

inspection techniques.

Generator fan blades


LIQUID PENETRANT EXAMINATION REPORT


Component: A LP Rotor WO: 100591641 Code: N/A

Material: Silver Solder Preparation: Blasted Temperature: 65°F

Visible: Yes Fluorescent: N/A Black Light Int: N/A

Solvent Removable: Yes Cleaner Type: SKC-S Batch No: 06K02K

Water Washable: N/A Penetrant Type: SKL-SP1 Batch No: 05L01K

FQS Procedure: 003 Developer Type: SKD-S2 Batch No: 04G11K


Generator End – L-0 – Tie Wires X No indications noted

Turbine End – L-0 – Tie Wires X 3 indications (Buckets 19, 33, & 47)

G.E. - Selected Stellite Erosion Shields X 5 indications (B. 14, 15, 22, 34, 56)

T.E. – Selected Stellite Erosion Shields X 2 indications (Buckets 49 & 66)


Examiner: Mike Schantz Level: II Date: 12/20/2010

Examiner: Josh Porter Level: II Date: 12/20/2010

Visible red dye liquid penetrant inspection was performed on the outer tie wires and the stellite

erosion shields of the L-0 buckets at both the generator and turbine ends of the “A” LP Rotor.

Results of each inspection can be found below.

View of typical tie wire


ULTRASONIC EXAMINATION REPORT – PAGE 1

Customer: Sample Turbine Outage PO No: 104568912 Report No: S1

Component: A LP Rotor – Dove Tail Pins WO No: 100591641 Drawing: N/A

Material: C/S Prep: Blasted Temp @ Test: 73° Procedure: 005 Code: N/A

Instrument: Manufacturer: Model: Serial Number: Material Velocity:

Panametrics Epoch III N/A 0.2332

Range: Gain: Reject: Scan Sensitivity: Sweep Delay:

Varied 48 dB N/A + 2 dB N/A

Transducer:

Manufacturer: Frequency: Wave Mode: Size & Shape: Angle:

KBA 2.25 Long. 1/4” Round Normal

Couplant: Type: Ultragel Batch Number:

Calibration: Cal Block No.: Part Thickness: CRT Cal Inches: Major Scrn. Div.:

N/A Varied Varied Varied

Cal. Times: Initial: 07:30 Final: 13:00

Scanning: 100% Weld: 100% Base Mat.: Parallel to Weld: Trans. To Weld:

N/A N/A N/A N/A


A UT inspection was performed on the dove tail pins on the generator and turbine ends of the

double flow rotor. Three (3) rows of 114 pins were examined on both sides of the rotor; all pins

were found acceptable, with no cracking noted.



Item/Weld No. A R Remarks/Indications

Dove tail pins (Generator End) X Three (3) rows of 114 pins examined

(Acceptable - No cracking noted)

Dove tail pins (Turbine End) X Three (3) rows of 114 pins examined


Sketch/Comments:


Examiner: Level: Date:


MAGNETIC PARTICLE EXAMINATION REPORT


Component: B LP Rotor WO: 100591641 Code: N/A

Material: C/S Preparation: Blasted Temperature: 65°F

Visible: N/A Fluorescent: Yes Magnetism: Long.

Particles: Wet – 20B Black Light Int: >1000uw/cm2 Batch No: 05A013

Equipment: Magnaflux Model No: M-500/Y-6 Serial No: FQS-001/FQS-009

Current: A/C Ampere Turns: 800 Prod Spacing: N/A


Generator End – L-0 X See below

L-1 X No indications noted





Turbine End – L-0 X See below








Examiner: Michael Schantz Level: II Date: 12/28/2010

The unit 5 “B” LP Rotor was removed, blasted, and magnetic particle inspected for cracking. The

“B” LP Rotor was replaced during the 2006 maintenance outage, and remains in good general

condition, however, several indications were noted on the turbine and generator end L-0 buckets.

Multiple coil setups and Y-6 magnetism were utilized to complete the inspection. The results of the

MT inspection can be seen below.

“B” LP Rotor




Component: B LP Rotor WO: 100591641 Code: N/A

Material: Silver Solder Preparation: Blasted Temperature: 65°F






Generator End – L-0 – Tie Wires X No indications noted

Turbine End – L-0 – Tie Wires X No indications noted

G.E. - Selected Stellite Erosion Shields X 2 indications (Buckets 27 & 40)

T.E. – Selected Stellite Erosion Shields X No indications noted

Generator End L-0 Weld Repairs

Bucket 69 X No indications noted

Bucket 72 X No indications noted




Visible red dye liquid penetrant inspection was performed on the outer tie wires and the stellite

erosion shields of the L-0 buckets at both the generator and turbine ends of the “B” LP Rotor, as

well as two (2) weld repairs requested by plant engineering. Any findings from each inspection

can be found below.

View of typical tie wire



Customer: Sample Turbine Outage PO No: 104568912 Report No: S1

Component: B LP Rotor – Dove Tail Pins WO No: 100591641 Drawing: N/A






Transducer:








N/A N/A N/A N/A


A UT inspection was performed on the dove tail pins on the generator and turbine ends of the

double flow rotor. Three (3) rows of 114 pins were examined on both sides of the rotor; all pins

were found acceptable, with no cracking noted.




Dove tail pins (Generator End) X Three (3) rows of 114 pins examined


Dove tail pins (Turbine End) X Three (3) rows of 114 pins examined


Sketch/Comments:





Customer: Sample Turbine Outage PO: 104568912 Report No: N/A

Component: GE LPA 22 Upper WO: 100591641 Code: N/A

Material: C/S Preparation: Blasted Temperature: 65

Visible: No Fluorescent: Yes Magnetism: Long.

Particles: Wet – 20B Black Light Int: >1000 um/cm2 Batch No: 09G12K

Equipment: Magnaflux Model No: P-90 Serial No: FQS-1


Position of Inspection Findings:



Blade # 1 Blade # 39

Left Joint Right Joint

Typical view of diaphragm – blades

counted left to right while

facing discharge side

Summary of Inspection Results:

Discharge Side

F.O.D. (Foreign Object Damage) noted on blades 1 – 39

Intake Side

No findings to report

Horizontal Joints

1/32” crack noted at the left horizontal joint

Example of typical F.O.D. noted on blades 1 – 39

1/32” crack noted in left horizontal joint




Component: GE LPA 22 Lower WO: 100591641 Code: N/A



Particles: Wet – 14AM Black Light Int: >1000 um/cm2 Batch No: 09G12K

Equipment: Magnaflux Model No: P-90 Serial No: FQS-1



Examiner: Jared Spada Level: II Date: 12/26/2010

Examiner: Brandon Mayne Level: II Date: 12/26/2010







Discharge Side

Moderate erosion damage noted at entire side (marked with yellow hash marks)

Steam seal damaged at blades 1-31 - edge rolled over

Steam cuts/erosion noted throughout the outer ring

3/8” crack noted at wire tie post weld

Intake Side

Moderate erosion damage noted at entire side (marked with yellow hash marks)

Horizontal Joints

Steam cuts/erosion noted at the right horizontal joint corner

Steam cuts/erosion noted at the left horizontal joint corner

Steam cuts/erosion noted at inner ring

1/8” crack noted on left horizontal joint

Example of minor erosion noted at the entire discharge side and outer ring

Example of steam seal damage noted from blades 1 – 31

3/8” crack noted at wire tie post weld

Example of minor erosion noted at the entire intake side

Minor erosion noted at left horizontal joint

Minor erosion noted at right horizontal joint

Minor erosion noted at inner ring

1/8” crack noted at left horizontal joint




Component: TE LPA 22 Upper WO: 100591641 Code: N/A




Equipment: Magnaflux Model No: Y-6 Serial No: FQS-9

Current: A/C Ampere Turns: N/A Prod Spacing: 4”










Discharge Side

Minor F.O.D. noted on all blades

Steam seal damage noted from blades 1 - 32 - edges rolled over

Blades bent/damaged from blades 3-7, 10-16, & 22-41

Intake Side


Horizontal Joints

Minor gouging noted at the left horizontal joint

Minor gouging noted at the right horizontal joint

Example of minor F.O.D. as noted on all blades

Example of steam seal damage as seen from blades 1 – 32

Example of blade damage as seen on blades 3-7, 10-16, and 22-41

General view of intake side of upper stage 22 diaphragm – no findings to report

Minor gouging on the left horizontal joint corner

Minor gouging on the right horizontal joint corner



Customer: Sample Outage Report PO: 104568912 Report No: N/A

Component: GE LPA 23 Upper WO: 100591641 Code: N/A




Equipment: Magnaflux Model No: Y-6 Serial No: FQS-9

Current: A/C Ampere Turns: N/A Prod Spacing: 4”










Discharge Side

Minor F.O.D. noted on all blades

Steam seal damage noted from blades 1 - 27 - edges rolled over

Intake Side


Horizontal Joints

Minor gouging noted at the left horizontal joint

Minor gouging noted at the right horizontal joint

Example of minor F.O.D. as noted on all blades

Example of steam seal damage as seen from blades 1 – 27

General view of intake side of upper stage 23 diaphragm – no findings to report

Minor gouging on the left horizontal joint corner

Minor gouging on the right horizontal joint corner




Component: A Shell lower WO: 100591641 Code: N/A

Material: C/S Preparation: Blasted Temperature: 60º

Visible: No Fluorescent: Yes Magnetism: Longitudinal

Particles: Wet Suspension: Oil Batch No: 09F06K

Equipment: Magnaflux Model No: Y-6 Serial No: FQS - 13

Current: A.C. Ampere Turns: N/A Prod Spacing: 4”


A Shell lower X See below

Comments: Minor multiple cracking was noted on the horizontal joint between the14th

and 16th

stage

areas on both the left and right sides.

Separation was noted, at the bolted connection of the hood extension and casing shell on turbine end

left side.

Cracking was noted in the spacer blocks welds at the 18th

stage turbine end left side.

Erosion noted on the N3 packing case on the turbine end.

Note: All noted cracks were excavated and verified for removal. All weld repairs were verified via

magnetic particle inspection for quality, no further action is required.






Component: A Shell upper WO: 100591641 Code: N/A







A Shell upper X See below

Comments: #3 door on the left side has 360º cracking on the interior weld.

#3 door on the right side has 360º cracking on the interior weld and (3) 1” cracks in the exterior weld.

The door insert also has a 1” crack on the exterior.








Component: B Shell lower WO: 100591641 Code: N/A







B Shell lower X See below

Comments: Minor multiple cracking noted at the horizontal joint between the14th

and 16th

stage areas

on both the left and right sides.

LP Condenser piping cracked on the generator end, right side.








Component: B Shell upper WO: 100591641 Code: N/A







B Shell upper X See below

Comments: #3 door on the left side has 360º cracking on the interior weld.

#3 door on the right side has 360º cracking on the interior weld and 3” crack in the exterior weld.

#2 door on the left side has a 1” void in the exterior weld.








Component: LPA & LPB upper casing WO: 100591641 Code: N/A







LPA upper casing X 1” ind. On left side GE

LPB upper casing X No indications noted

Comments:

Note: 1” indication on LPA excavated to 1/16” depth, and verified for indication removal. No weld

repair is required and no further action is needed.






Component: Upper Packing Heads WO: 100591641 Code: N/A







N4 – Packing casing - upper X No indications noted




Comments:

Examiner: Jared Spada Level: II Date: 12-21-2010





Component: Packing Cone Extensions WO: 100591641 Code: N/A







Packing Cone Extensions X See below

Comments: Bolting ends were damaged during disassembly and have extremely rough and sharp

edges.

Note: The identified sharp edges resulting from the disassembly of the packing cone extensions have

been repaired and cleared, no further action is required.






Component: Windage Covers WO: 100591641 Code: N/A

Material: Aluminum Preparation: As found Temperature: 72°F






“A” Windage Covers (1-4) X No indications noted

“B” Windage Covers (1-4) X No indications noted

“C” Windage Covers (1-4) X No indications noted




Visible red dye liquid penetrant inspection was performed on the “A,” “B,” & “C” Windage

Covers. All covers were found acceptable, with no indications noted.

“A” & “B” Windage Covers “C” Windage Covers



Customer: Sample Turbine Outage PO No: 104568912 Report No: N/A

Component: Bolting & Studs WO No: 100591641 Drawing: N/A






Transducer:








N/A N/A N/A N/A


A UT inspection was performed on selected bolting and studs from the turbine assembly, a complete

list of studs/bolts inspected, as well as the results of the inspection can be seen below.

General view of bolting & stud inspection area




“A” – Coupling Studs (12) X No loss of backwall reflection

“B” – Coupling Studs (12) X No loss of backwall reflection

Crossover Vertical Joint Studs (39) X No loss of backwall reflection

HP – Turbine End

Crossover Vertical Joint Studs (48) X No loss of backwall reflection

Inner Shell Outside Bolts (Left Side)

LP (A) – Left Side (8) X No loss of backwall reflection

LP (B) – Left Side (8) X No loss of backwall reflection

Inner Shell Outside Bolts (Right Side)

LP (A) – Right Side (8) X No loss of backwall reflection

LP (B) – Right Side (8) X No loss of backwall reflection

Upper Steam Chest Studs (41) X No loss of backwall reflection

Lower Steam Chest Studs (24) X No loss of backwall reflection

#1 Stop Valve Bonnet Studs (15) X No loss of backwall reflection


#3 Stop Valve Bonnet Studs (14*) X No loss of backwall reflection

1 stud broken during disassembly No UT performed


#1 Upper Control Valve Studs (10) X No loss of backwall reflection

#2 Upper Control Valve Studs (9*) X No loss of backwall reflection


#3 Upper Control Valve Studs (10) X No loss of backwall reflection

#4 Upper Control Valve Studs (9*)


Sketch/Comments:

General view of bolting & stud inspection area

Examiner: Brian Spada Level: II Date: 12/28/2010





Component: Fan Blades WO: 100591641 Code: N/A

Material: Aluminum Preparation: Brushed Temperature: 68°F






Turbine End – Generator Fan Blades (24) X No indications noted

Collector End– Generator Fan Blades (24) X No indications noted




Visible red dye liquid penetrant inspection was performed on the turbine end and collector end

generation fan blades (48 total). All fan blades were found acceptable, with no indications noted.

Generator Fan Blades

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