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-4 – 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-4 – Acceptable, no findings to report.
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.
L-1 – Acceptable, no findings to report.
L-2 – Acceptable, no findings to report.
L-3 – Acceptable, no findings to report.
L-4 – Acceptable, no findings to report.
L-5 – Acceptable, no findings to report.
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.
L-1 – Acceptable, no findings to report.
L-2 – Acceptable, no findings to report.
L-3 – Acceptable, no findings to report.
L-4 – Acceptable, no findings to report.
L-5 – Acceptable, no findings to report.
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
o N5 – Acceptable, no findings to report
o N6 – Acceptable, no findings to report
o N7 – 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
FIRST QUALITY SOLUTIONS
LIQUID PENETRANT EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: S1
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
Component Acc. Rej. Remarks/Indications
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)
Summary of Inspection Performed:
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
FIRST QUALITY SOLUTIONS
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
Summary of Inspection Performed:
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.
FIRST QUALITY SOLUTIONS
ULTRASONIC EXAMINATION REPORT – PAGE 2
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
(Acceptable - No cracking noted)
Sketch/Comments:
Examiner: Gordon Austin Level: II Date: 12/22/2010
Examiner: Level: Date:
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: S1
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
Component Acc. Rej. Remarks/Indications
Generator End – L-0 X See below
L-1 X No indications noted
L-2 X No indications noted
L-3 X No indications noted
L-4 X No indications noted
L-5 X No indications noted
Turbine End – L-0 X See below
L-1 X No indications noted
L-2 X No indications noted
L-3 X No indications noted
L-4 X No indications noted
L-5 X No indications noted
Summary of Inspection Performed:
Examiner: Gordon Austin Level: II Date: 12/28/2010
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
FIRST QUALITY SOLUTIONS
LIQUID PENETRANT EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: S1
Component: B 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
Component Acc. Rej. Remarks/Indications
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
Summary of Inspection Performed:
Examiner: Mike Schantz Level: II Date: 12/22/2010
Examiner: Josh Porter Level: II Date: 12/22/2010
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 “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
FIRST QUALITY SOLUTIONS
ULTRASONIC EXAMINATION REPORT – PAGE 1
Customer: Sample Turbine Outage PO No: 104568912 Report No: S1
Component: B 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
Summary of Inspection Performed:
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.
FIRST QUALITY SOLUTIONS
ULTRASONIC EXAMINATION REPORT – PAGE 2
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
(Acceptable - No cracking noted)
Sketch/Comments:
Examiner: Gordon Austin Level: II Date: 12/22/2010
Examiner: Level: Date:
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
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
Current: A/C Ampere Turns: 800 Prod Spacing: N/A
Position of Inspection Findings:
Examiner: Gordon Austin Level: II Date: 12/26/2010
Examiner: Josh Porter Level: II Date: 12/26/2010
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
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
Component: GE LPA 22 Lower WO: 100591641 Code: N/A
Material: C/S Preparation: Blasted Temperature: 65
Visible: No Fluorescent: Yes Magnetism: Long.
Particles: Wet – 14AM Black Light Int: >1000 um/cm2 Batch No: 09G12K
Equipment: Magnaflux Model No: P-90 Serial No: FQS-1
Current: A/C Ampere Turns: 800 Prod Spacing: N/A
Position of Inspection Findings:
Examiner: Jared Spada Level: II Date: 12/26/2010
Examiner: Brandon Mayne Level: II Date: 12/26/2010
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
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
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
Component: TE LPA 22 Upper WO: 100591641 Code: N/A
Material: C/S Preparation: Blasted Temperature: 65
Visible: No Fluorescent: Yes Magnetism: Long.
Particles: Wet – 14AM Black Light Int: >1000 um/cm2 Batch No: 09G12K
Equipment: Magnaflux Model No: Y-6 Serial No: FQS-9
Current: A/C Ampere Turns: N/A Prod Spacing: 4”
Position of Inspection Findings:
Examiner: Jared Spada Level: II Date: 12/26/2010
Examiner: Brandon Mayne Level: II Date: 12/26/2010
Blade # 1 Blade # 44
Left Joint Right Joint
Typical view of diaphragm – blades
counted left to right while
facing discharge side
Summary of Inspection Results:
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
No findings to report
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
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Outage Report PO: 104568912 Report No: N/A
Component: GE LPA 23 Upper WO: 100591641 Code: N/A
Material: C/S Preparation: Blasted Temperature: 65
Visible: No Fluorescent: Yes Magnetism: Long.
Particles: Wet – 14AM Black Light Int: >1000 um/cm2 Batch No: 09G12K
Equipment: Magnaflux Model No: Y-6 Serial No: FQS-9
Current: A/C Ampere Turns: N/A Prod Spacing: 4”
Position of Inspection Findings:
Examiner: Jared Spada Level: II Date: 12/26/2010
Examiner: Brandon Mayne Level: II Date: 12/26/2010
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
Minor F.O.D. noted on all blades
Steam seal damage noted from blades 1 - 27 - edges rolled over
Intake Side
No findings to report
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
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
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”
Component Acc. Rej. Remarks/Indications
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.
Examiner: Mike Schantz Level: II Date: 12/24/10
Examiner: Gordon Austin Level: II Date: 12/24/10
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
Component: A Shell upper 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”
Component Acc. Rej. Remarks/Indications
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.
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.
Examiner: Mike Schantz Level: II Date: 12/24/10
Examiner: Gordon Austin Level: II Date: 12/24/10
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
Component: B 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”
Component Acc. Rej. Remarks/Indications
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.
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.
Examiner: Mike Schantz Level: II Date: 12/24/10
Examiner: Gordon Austin Level: II Date: 12/24/10
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
Component: B Shell upper 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”
Component Acc. Rej. Remarks/Indications
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.
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.
Examiner: Mike Schantz Level: II Date: 12/24/10
Examiner: Gordon Austin Level: II Date: 12/24/10
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
Component: LPA & LPB upper casing 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”
Component Acc. Rej. Remarks/Indications
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.
Examiner: Mike Schantz Level: II Date: 12/24/10
Examiner: Gordon Austin Level: II Date: 12/24/10
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
Component: Upper Packing Heads 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”
Component Acc. Rej. Remarks/Indications
N4 – Packing casing - upper X No indications noted
N5 – Packing casing - upper X No indications noted
N6 – Packing casing - upper X No indications noted
N7 – Packing casing - upper X No indications noted
Comments:
Examiner: Jared Spada Level: II Date: 12-21-2010
Examiner: Level: Date:
FIRST QUALITY SOLUTIONS
MAGNETIC PARTICLE EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
Component: Packing Cone Extensions 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”
Component Acc. Rej. Remarks/Indications
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.
Examiner: Mike Schantz Level: II Date: 12/24/09
Examiner: Gordon Austin Level: II Date: 12/24/09
FIRST QUALITY SOLUTIONS
LIQUID PENETRANT EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: S1
Component: Windage Covers WO: 100591641 Code: N/A
Material: Aluminum Preparation: As found Temperature: 72°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
Component Acc. Rej. Remarks/Indications
“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
Summary of Inspection Performed:
Examiner: Mike Schantz Level: II Date: 12/22/2010
Examiner: Josh Porter Level: II Date: 12/22/2010
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
FIRST QUALITY SOLUTIONS
ULTRASONIC EXAMINATION REPORT – PAGE 1
Customer: Sample Turbine Outage PO No: 104568912 Report No: N/A
Component: Bolting & Studs WO No: 100591641 Drawing: N/A
Material: C/S Prep: Blasted Temp @ Test: 65° 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 54 dB N/A + 2 dB N/A
Transducer:
Manufacturer: Frequency: Wave Mode: Size & Shape: Angle:
KBA 2.25 Long. 1/2” 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: 18:00
Scanning: 100% Weld: 100% Base Mat.: Parallel to Weld: Trans. To Weld:
N/A N/A N/A N/A
Summary of Inspection Performed:
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
FIRST QUALITY SOLUTIONS
ULTRASONIC EXAMINATION REPORT – PAGE 2
Item/Weld No. A R Remarks/Indications
“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
#2 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
#4 Stop Valve Bonnet Studs (15) X No loss of backwall reflection
#1 Upper Control Valve Studs (10) X No loss of backwall reflection
#2 Upper Control Valve Studs (9*) X No loss of backwall reflection
1 stud broken during disassembly No UT performed
#3 Upper Control Valve Studs (10) X No loss of backwall reflection
#4 Upper Control Valve Studs (9*)
1 stud broken during disassembly No UT performed
Sketch/Comments:
General view of bolting & stud inspection area
Examiner: Brian Spada Level: II Date: 12/28/2010
Examiner: Level: Date:
FIRST QUALITY SOLUTIONS
LIQUID PENETRANT EXAMINATION REPORT
Customer: Sample Turbine Outage PO: 104568912 Report No: N/A
Component: Fan Blades WO: 100591641 Code: N/A
Material: Aluminum Preparation: Brushed Temperature: 68°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
Component Acc. Rej. Remarks/Indications
Turbine End – Generator Fan Blades (24) X No indications noted
Collector End– Generator Fan Blades (24) X No indications noted
Summary of Inspection Performed:
Examiner: Mike Schantz Level: II Date: 12/21/2010
Examiner: Josh Porter Level: II Date: 12/21/2010
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