Little_Goose_U5_Rotor_Frame_Upgrade_Repair_Recommendations.pdf

Repair Recommendation Report

ATR

Prepared By:

US Army Corps of Engineers Hydroelectric Design Center

August 2014

US Army Corps of Engineers Northwestern Division

H Y

D R

O E

L E

C T

R

IC

D

E

SI

G N

C E

N T

PR

PA

R

ED

B Y

Engineers Northwestern Division

Little Goose Lock and Dam Unit 5 Repair

Little Goose Unit 5 Recommendations

Table of Contents

1. Executive Summary

2. Introduction

2.1. Previous Inspections

2.1.1. Little Goose Unit 5 Generator Rotor Inspection – October 2010

2.1.2. Little Goose Unit 5 Vibration Measurement – February 2012

2.1.3. Little Goose Unit 5 Rotor Spider Crack Analysis – May 2012

2.1.4. Little Goose Unit 5 Upper Bearing Bracket Crack Analysis – May 2012

2.1.5. Little Goose Unit 5 Crack Inspections –March 2014

2.1.6. Little Goose Unit 5 Oxarc Weld Inspections – February and March 2014

2.2. HDC Operational Recommendations and Limitations -

3. Repair Discussion

3.1. Requirements

3.2. Risks

3.3. Assumptions

1. EXECUTIVE SUMMARY

Little Goose Unit 5 has excessive vibration, cracking in the upper bearing bracket, and cracking in the rotor spider. These phenomena have been studied and closely observed over time by Little Goose Project personnel, and they continue to grow and be problematic. They will require substantial repair to avoid unit damage in the future. The time frame for ultimate failure is not practicably estimated. To avoid a potentially more substantial and emergency repair than what is documented here, it is recommended that funding for the efforts documented below are procured, and design efforts begin.

The ROM estimated cost for the efforts listed above is #, and is estimated to take approximately 1.5 years to completion, after award of the contract.

2. INTRODUCTION

Over the past 5+ years, rotor spider cracks, upper bearing bracket cracks, and more-than-normal vibration have been observed on Unit 5. Little Goose Project has, over the course of those years, requested assistance from HDC in order to identify the source of the issues, as well as prepare a long-term solution so that Unit 5 can be brought into a state of normal operation with minimized risk of continued damage due to the vibrations and weld cracks. This document may be used as a starting point for designing the long-term solution, and encapsulates pertinent findings from previously executed studies and inspections. Most of these studies and inspection reports are included as appendices to aid the understanding of the reader.

2.1. PREVIOUS INSPECTIONS

Included in this section is a list of previously executed inspections, tests, and trip reports performed by HDC, as well as Oxarc, Inc. Key findings are denoted below.

2.1.1. Little Goose Unit 5 Generator Rotor Inspection – October 2010 This site visit was conducted following completion of the recommended procedure in 2009 to drill stress-relieving holes in order to limit crack growth. Some key findings from this report are:

- Crack growth appears to be time based, not start/stop cycle based.

- Inspection schedule should be 3 months apart.

- Recommended to obtain sweep air-gap readings, during service.

- First recommendation for making future plans for an in-depth and substantial repair.

The trip report can be found in Appendix A.

2.1.2. Little Goose Unit 5 Vibration Measurement – February 2012 After taking vibration data on the unit, and performing some analysis, the following recommendations were documented in this report:

- Adjust upper and lower guide bearing to design clearances.

- Avoid running Unit 5 at loads of 40MW or less as much as possible.

- Check alignment of the unit.

- Modify rotor spider arms as suggested by the FEA to avoid fatigue cracks.

- Repair rotor spider arm cracks.

- Repair upper bearing bracket cracks.

The trip report can be found in Appendix B.

2.1.3. Little Goose Unit 5 Rotor Spider Crack Analysis – May 2012 After performing Finite Element Analysis on the rotor spider, it was found that the biggest contributor to high stress at the rotor spider crack location is due to the force imposed by the weight of the rotor itself. Torque also has an effect on stress. Alternating stress can occur due to air gap variation and load and excitation changes. The spider arm cracks on this unit are very similar to cracks on Bonneville unit 11. Some stop drilling was done on the cracks in the fall of 2009, but that is only a temporary solution. Recommended repairs include adding a large radius cutout to reduce stress concentration, repair the welds, and verify weld quality with NDT. This type of modification was done to Bonneville unit 11 when it was repaired recently by Alstom.

The analysis can be found in Appendix C.

2.1.4. Little Goose Unit 5 Upper Bearing Bracket Crack Analysis – May 2012 Finite Element Analysis was performed on the upper bearing bracket. Both the FEA and hand calculations show tensile stresses to be relatively low, <5000 psi, in the crack location when the weight of the unit plus operating loads are applied. These probably started as original weld cracks.

Once cracks are initiated, they can continue to grow by fatigue.

The analysis can be found in Appendix D.

2.1.5. Little Goose Unit 5 Crack Inspections –March 2014

In conjunction with weld inspections (see section 2.1.6), Little Goose Project visually inspected the progress of the cracks in the spider rotor and the upper bearing bracket.

This inspection report can be found in Appendix E.

2.1.6. Little Goose Unit 5 Oxarc Weld Inspections – February and March 2014 Little Goose Project contracted Oxarc to perform several phased array weld inspections.

These reports can be found in Appendix F.

2.2. HDC OPERATIONAL RECOMMENDATIONS AND LIMITATIONS -

After receipt of the Oxarc Weld Inspections, HDC held the stance that the following operational restrictions should apply to Unit 5:

- Unit 5 is last on, first off, attempting to avoid low and no load runs to reduce further vibration damage.

- Every opportunity to re-take crack length measurements should be taken advantage of, and those should be closely monitored. Any change in their current state should be reported to us.

- Any DRASTIC or non-trending changes should be reported.

- Plans should be made to secure funding for the full repair of the rotor and upper bearing bracket.

3. REPAIR DISCUSSION

Over the course of the Inspections listed above, it has been noted that a more thorough and substantial repair should be performed in order to bring Unit 5 back to a normally functional status.

This section will indicate the Requirements, Risks, and Assumptions associated with this repair.

3.1. REQUIREMENTS

The basic scope of work for the repair of Unit 5 will incorporate the following items:

- Modify rotor spider arms.

- Repair rotor spider arm cracks.

- Repair upper bearing bracket cracks.

- Check alignment of the unit to ensure it is still within acceptable limits.

- Install vibration monitoring and dynamic air gap measurement equipment.

3.2. RISKS

The table below indicates the risks and impacts that may be part of this work effort:

RISK IMPACT MITIGATION

Rim keys stuck in place. Keys gall, cause damage to rim and keyways.

Additional repair time and effort required.

Ensure level working surface during rim removal.

Ensure rim keys are not indexed prior to work.

Paint / weld removal before weld repair.

Unwanted debris in rotor / stator, potentially causing major damage to unit.

Recommended to remove rotor from unit, and remove weight of rim from spider before repair work is conducted.

Spider arms warp during weld repair.

Loss of concentricity and fit with the existing rim.

Careful control on weld details and extra caution to be taken during heat treatment / stress relief.

3.3. ASSUMPTIONS

As of the creation of this document, the following assumptions are made:

- The work is intended to be contracted.

o If the work is to be done in-house, it will change the way the repair is designed and specified.

- The unit will be able to be offline for the duration of the repair.

- The cracks have not shown appreciable growth since the last report sent to HDC.

- Unit 5 is still being operated as per HDC recommendations.

- The rim keys will be checked in advance to assure there has been no indexing.

Due to the complexity and extent of the weld repairs to be performed, and to ensure the welds can be properly prepared, performed, inspected, and painted without potential harm to other parts of

APPENDIX E

Little Goose Unit 5 Crack Inspections

March 2014

Unit 5 Inspection Results March 2014

Unit 5 rotor and upper bearing bracket were inspected in March 25, 2014.

1. Spider Arm:

Figure 1. Spider Arm Locations

Perform MT testing of spider arm in areas of cracks that were last reported present in arms 4, 8, and 14 (both sides). The latest measurements are provided below:

Length of Cracks in Unit 5 Rotor Spider Arms

Arm 8/2008 10/2009 5/5/2010 7/7/2010 10/26/2010 3/1/2011 7/7/2011 9/23/2013 3/25/2014

4 16-1/8” 16-1/2” 17-15/16'' 18-1/16'' 18-1/16'' 18-5/8" 19-11/16"* 19-11/16"* 19-11/16"*

4A 13” 14-5/8” 14-5/8'' 14-5/8'' 15-1/4'' 16-1/2"* 16-1/2"* 16-1/2"* 17-3/4”

8 9-5/8” 10-7/16” 10-3/4'' 10-3/4'' 10-3/4'' 10-7/8" 11-3/16" 11-3/4” 11-3/4”

8A 12-1/2” 13-7/16”* 13-7/16''* 13-7/16''* 13-7/16''* 13-7/16"* 13-7/16"* 13-7/16"* 13-7/16"*

14 7-1/8” 7-1/4” 7-1/4'' 7-3/4'' 7-3/4'' 8-7/8" 9-1/8"* 9-1/8"* 13-3/4”

14A 8-1/8” 8-1/8'' 8-1/8'' 8-1/8'' 9-1/2''* 9-1/2"* 9-1/2"* 11-1/8” 11-1/8”

1 6-3/4” 6-3/4”

1A 7-3/4” 7-3/4”

*Indicates crack propagated to hole and stopped Red measurements indicate changes from last measurement.

Figure 2. Rotor Arm 14

Propagated Crack

2. Inspect Upper Bearing Bracket-Hub

Inspected the upper bearing bracket hub on the upper side of the lower horizontal structure using phased array equipment to determine the depth of the cracks that are seen on the structure.

Figure 5. Upper Bearing Bracket Hub (Lower plate)

3. Inspect Upper Bearing Bracket-Hub and Arms

Inspected the upper bearing bracket hub and arm on the bottom side of the lower horizontal structure using phased array equipment to determine the location of cracks. No surface cracks were discovered. In most cases, the weld on the arm was 1-1/4” deep on each side of the lower horizontal structure, which resulted in a ½” gap between the welds (total structure thickness was 3”).

Figure 6. Upper Bearing Bracket Inspections (Red: Subsurface cracked welds, Yellow: weld indications, White: inspected, no indications or cracks).

APPENDIX F

Oxarc Weld Inspections February and March 2014

Repair Recommendation Report

ATR

Prepared By:

US Army Corps of Engineers Hydroelectric Design Center

August 2014

Engineers Northwestern Division

H Y

D R

O E

L E

C T

IC

D

SI

G N

C E

N T

PR

PA

R

ED

B Y

Northwestern Division

Little Goose Lock and Dam Unit 5 Repair

Table of Contents

1. Executive Summary

2. Introduction

2.1. Previous Inspections

2.1.1. Little Goose Unit 5 Generator Rotor Inspection – October 2010

2.1.2. Little Goose Unit 5 Vibration Measurement – February 2012

2.1.3. Little Goose Unit 5 Rotor Spider Crack Analysis – May 2012

2.1.4. Little Goose Unit 5 Upper Bearing Bracket Crack Analysis – May 2012

2.1.5. Little Goose Unit 5 Crack Inspections –March 2014

2.1.6. Little Goose Unit 5 Oxarc Weld Inspections – February and March 2014

2.2. HDC Operational Recommendations and Limitations -

3. Repair Discussion

3.1. Requirements

3.2. Risks

3.3. Assumptions

1. EXECUTIVE SUMMARY

Little Goose Unit 5 has excessive vibration, cracking in the upper bearing bracket, and cracking in the rotor spider. These phenomena have been studied and closely observed over time by Little Goose Project personnel, and they continue to grow and be problematic. They will require substantial repair to avoid unit damage in the future. The time frame for ultimate failure is not practicably estimated. To avoid a potentially more substantial and emergency repair than what is documented here, it is recommended that funding for the efforts documented below are procured, and design efforts begin.

The ROM estimated cost for the efforts listed above is #, and is estimated to take approximately 1.5 years to completion, after award of the contract.

2. INTRODUCTION

Over the past 5+ years, rotor spider cracks, upper bearing bracket cracks, and more-than-normal vibration have been observed on Unit 5. Little Goose Project has, over the course of those years, requested assistance from HDC in order to identify the source of the issues, as well as prepare a long-term solution so that Unit 5 can be brought into a state of normal operation with minimized risk of continued damage due to the vibrations and weld cracks. This document may be used as a starting point for designing the long-term solution, and encapsulates pertinent findings from previously executed studies and inspections. Most of these studies and inspection reports are included as appendices to aid the understanding of the reader.

2.1. PREVIOUS INSPECTIONS

Included in this section is a list of previously executed inspections, tests, and trip reports performed by HDC, as well as Oxarc, Inc. Key findings are denoted below.

2.1.1. Little Goose Unit 5 Generator Rotor Inspection – October 2010 This site visit was conducted following completion of the recommended procedure in 2009 to drill stress-relieving holes in order to limit crack growth. Some key findings from this report are:

- Crack growth appears to be time based, not start/stop cycle based.

- Inspection schedule should be 3 months apart.

- Recommended to obtain sweep air-gap readings, during service.

- First recommendation for making future plans for an in-depth and substantial repair.

The trip report can be found in Appendix A.

2.1.2. Little Goose Unit 5 Vibration Measurement – February 2012 After taking vibration data on the unit, and performing some analysis, the following recommendations were documented in this report:

- Adjust upper and lower guide bearing to design clearances.

- Avoid running Unit 5 at loads of 40MW or less as much as possible.

- Check alignment of the unit.

- Modify rotor spider arms as suggested by the FEA to avoid fatigue cracks.

- Repair rotor spider arm cracks.

- Repair upper bearing bracket cracks.

The trip report can be found in Appendix B.

2.1.3. Little Goose Unit 5 Rotor Spider Crack Analysis – May 2012 After performing Finite Element Analysis on the rotor spider, it was found that the biggest contributor to high stress at the rotor spider crack location is due to the force imposed by the weight of the rotor itself. Torque also has an effect on stress. Alternating stress can occur due to air gap variation and load and excitation changes. The spider arm cracks on this unit are very similar to cracks on Bonneville unit 11. Some stop drilling was done on the cracks in the fall of 2009, but that is only a temporary solution. Recommended repairs include adding a large radius cutout to reduce stress concentration, repair the welds, and verify weld quality with NDT. This type of modification was done to Bonneville unit 11 when it was repaired recently by Alstom.

The analysis can be found in Appendix C.

2.1.4. Little Goose Unit 5 Upper Bearing Bracket Crack Analysis – May 2012 Finite Element Analysis was performed on the upper bearing bracket. Both the FEA and hand calculations show tensile stresses to be relatively low, <5000 psi, in the crack location when the weight of the unit plus operating loads are applied. These probably started as original weld cracks.

Once cracks are initiated, they can continue to grow by fatigue.

The analysis can be found in Appendix D.

2.1.5. Little Goose Unit 5 Crack Inspections –March 2014

In conjunction with weld inspections (see section 2.1.6), Little Goose Project visually inspected the progress of the cracks in the spider rotor and the upper bearing bracket.

This inspection report can be found in Appendix E.

2.1.6. Little Goose Unit 5 Oxarc Weld Inspections – February and March 2014 Little Goose Project contracted Oxarc to perform several phased array weld inspections.

These reports can be found in Appendix F.

2.2. HDC OPERATIONAL RECOMMENDATIONS AND LIMITATIONS -

After receipt of the Oxarc Weld Inspections, HDC held the stance that the following operational restrictions should apply to Unit 5:

- Unit 5 is last on, first off, attempting to avoid low and no load runs to reduce further vibration damage.

- Every opportunity to re-take crack length measurements should be taken advantage of, and those should be closely monitored. Any change in their current state should be reported to us.

- Any DRASTIC or non-trending changes should be reported.

- Plans should be made to secure funding for the full repair of the rotor and upper bearing bracket.

3. REPAIR DISCUSSION

Over the course of the Inspections listed above, it has been noted that a more thorough and substantial repair should be performed in order to bring Unit 5 back to a normally functional status.

This section will indicate the Requirements, Risks, and Assumptions associated with this repair.

3.1. REQUIREMENTS

The basic scope of work for the repair of Unit 5 will incorporate the following items:

- Modify rotor spider arms.

- Repair rotor spider arm cracks.

- Repair upper bearing bracket cracks.

- Check alignment of the unit to ensure it is still within acceptable limits.

- Install vibration monitoring and dynamic air gap measurement equipment.

3.2. RISKS

The table below indicates the risks and impacts that may be part of this work effort:

RISK IMPACT MITIGATION

Rim keys stuck in place. Keys gall, cause damage to rim and keyways.

Additional repair time and effort required.

Ensure level working surface during rim removal.

Ensure rim keys are not indexed prior to work.

Paint / weld removal before weld repair.

Unwanted debris in rotor / stator, potentially causing major damage to unit.

Recommended to remove rotor from unit, and remove weight of rim from spider before repair work is conducted.

Spider arms warp during weld repair.

Loss of concentricity and fit with the existing rim.

Careful control on weld details and extra caution to be taken during heat treatment / stress relief.

3.3. ASSUMPTIONS

As of the creation of this document, the following assumptions are made:

- The work is intended to be contracted.

o If the work is to be done in-house, it will change the way the repair is designed and specified.

- The unit will be able to be offline for the duration of the repair.

- The cracks have not shown appreciable growth since the last report sent to HDC.

- Unit 5 is still being operated as per HDC recommendations.

- The rim keys will be checked in advance to assure there has been no indexing.

Due to the complexity and extent of the weld repairs to be performed, and to ensure the welds can be properly prepared, performed, inspected, and painted without potential harm to other parts of

(This page left intentionally blank.)

APPENDIX A

Generator Rotor Inspection October 2010

APPENDIX B

Vibration Measurement February 2012

APPENDIX C

Rotor Spider Crack Analysis May 2012

APPENDIX D

Upper Bearing Bracket Crack Analysis May 2012

APPENDIX E

Crack Inspections

March 2014

Unit 5 Inspection Results March 2014

Unit 5 rotor and upper bearing bracket were inspected in March 25, 2014.

1. Spider Arm:

Figure 1. Spider Arm Locations

Perform MT testing of spider arm in areas of cracks that were last reported present in arms 4, 8, and 14 (both sides). The latest measurements are provided below:

Length of Cracks in Unit 5 Rotor Spider Arms

Arm 8/2008 10/2009 5/5/2010 7/7/2010 10/26/2010 3/1/2011 7/7/2011 9/23/2013 3/25/2014

4 16-1/8” 16-1/2” 17-15/16'' 18-1/16'' 18-1/16'' 18-5/8" 19-11/16"* 19-11/16"* 19-11/16"*

4A 13” 14-5/8” 14-5/8'' 14-5/8'' 15-1/4'' 16-1/2"* 16-1/2"* 16-1/2"* 17-3/4”

8 9-5/8” 10-7/16” 10-3/4'' 10-3/4'' 10-3/4'' 10-7/8" 11-3/16" 11-3/4” 11-3/4”

8A 12-1/2” 13-7/16”* 13-7/16''* 13-7/16''* 13-7/16''* 13-7/16"* 13-7/16"* 13-7/16"* 13-7/16"*

14 7-1/8” 7-1/4” 7-1/4'' 7-3/4'' 7-3/4'' 8-7/8" 9-1/8"* 9-1/8"* 13-3/4”

14A 8-1/8” 8-1/8'' 8-1/8'' 8-1/8'' 9-1/2''* 9-1/2"* 9-1/2"* 11-1/8” 11-1/8”

1 6-3/4” 6-3/4”

1A 7-3/4” 7-3/4”

*Indicates crack propagated to hole and stopped Red measurements indicate changes from last measurement.

Figure 2. Rotor Arm 14

Propagated Crack

2. Inspect Upper Bearing Bracket-Hub

Inspected the upper bearing bracket hub on the upper side of the lower horizontal structure using phased array equipment to determine the depth of the cracks that are seen on the structure.

Figure 5. Upper Bearing Bracket Hub (Lower plate)

3. Inspect Upper Bearing Bracket-Hub and Arms

Inspected the upper bearing bracket hub and arm on the bottom side of the lower horizontal structure using phased array equipment to determine the location of cracks. No surface cracks were discovered. In most cases, the weld on the arm was 1-1/4” deep on each side of the lower horizontal structure, which resulted in a ½” gap between the welds (total structure thickness was 3”).

Figure 6. Upper Bearing Bracket Inspections (Red: Subsurface cracked welds, Yellow: weld indications, White: inspected, no indications or cracks).

APPENDIX F

Oxarc Weld Inspections February and March 2014 sotarc.INSPECTION REPORT

PROJECT NAME

Little Goose Dam Unit 5 Spider Rotor Arm Crack Inspection

DATE

2-19-14

PAGE

1 o f 3

PROJECT LOCATION

Little Goose Dam, Whitman Countv, WA P O # Attached PA Reports t-12

CLIENT

US ACE / Little Goose Dan FABzuCATION FACILITY

N/A

GENERAL CONTRACTOR/SUPERINTENDENT

N/A SUBCONTRACTOR,f OREMAN

N/A INSPECTION ryPE (S) / COVERAGE: Check appropriate box(s)

LocArIoN oF INsPEcrloN: Lig!9J@DgEJI4!

INSPECTION REQUESTED BY: US ACE / Martin Evans

I wetoing ! N/a fl continuous Ll refloorc

X other: NDT

I Not testing n N/A nMr Xur Epr Ev r

INSPECTION DETAILS:

Arrived on site at Little Goose Dam as requested by Martin Evaas to perform NDT on Unit 5.

Met with Martin Evans to review the details of the inspection. Martin has requested Phased Anay Flaw Imaging, (PA) on areas of cracking on the Spider Rotor Arm Cracks on unit #5.

Performed PA on all 12 wedge locations on the Spider Rotor Upper Groove Welds.

All Welds were actually Partial Penetration Groove Welds. Not CJP welds.

Indications of Cracking were noted at Swedge locations:2,3,4,5, 6, 7, 8 and 10.

See UT Examination Report on pages 2 and 3. Ald attached PA Reports 1-12.

To the best of mv knowledse all NDT was performed as per Oxarc PA-UT-I, and was reported to the same.

Comments:

INSPECTOR'S SIGNATURE

.1'-- t .-z r&z-*/ F<.^

PRINTED NAME

David Parr*""*x5h DATE

3-d? s

OXARC,lnc.

4003 E. Broadway Ave.

Spokane. Washinglon 99202 Phone 509/535-7794 Toll Fr€€ 800/765-9055 Fax 509/535-0368 rev. 09/10

ULTRASONIC EXAMINATION REPORT

CUSTOMER CONTACT

US ACE Little Goose Dam / Martin Evans

DATE

2-19-t4

PAGE

2 o f 3

PROJECT LOCATION

Little Goose Dam - Powerhouse / Unit 5

P O # TJNIT/SYSTEM

Unit 5

ITEM DESCRIPTION

Groove Weld PA-UT on Little Goose Dam Unit 5 (12 Wedge areas with cracking on PP Groove Welds)

MATERIAL

Steel Plate

THICKNESS

3', QTY.

12 areas

SURFACE CONDITION

Painted Steel

PROCEDURE

Oxarc PA-UT-I

ACCEPTANCE STANDARD

ASME sec. VlUArticle 12

ITEM TEMP/CAL BLOCK TEMP.

7 0 0 F / 7 0 0 F

STAGE OF

MANUFACTURE

LI INITIAL COMMENT:

! FINAL Crack pA-UT Exam

X REPA-IR

SURFACE PREPARATION:

Smoothed with hand file

XLONGITUDINAI LI OTHER

X SHEARwAvE PA Flaw Imasins

TYPE OF EXAM

Phased Array Flaw Imaging 40o-70o Angle beam 0" Straieht Beam

COUPLANT

Sonotrace 30

INSTRUMENT MFC.MODEL-SN

OMNl-Scan - MX / 100631

TRANSDUCER FREQ. 5 MH?./2.25 MHz SIZE 1.5" / l"

SSINGLE WEDGE ANGLE 45"-70" / 0" MEAS. ANGLE 45'-70"10"

EDUAr MFG, S,N Olvmpus-5l64 SA2 IHC DELAY None c/E / 0lYDlw

CAIIBRATION BLOCK

SBLocK f]CURVED

TYPE

DSC

MATEzuAL Steel

MFG

Insp€ction Technolosies

SN

07-6t4E

COMMENTS INCLUDE ACCEPT,REJECT SKETCH

Little Goose Dam - Unit 5 SDider Rotor Groove Weld Cracks

See attached Phased Array Flaw Imaging Report I

See attached Phased Array Flaw lmsging Report 2

See attached Phased Array Flaw lmaging Report 3

See attached Phased Array Flaw lmaging Report 4

See attached Phased Array Flaw lmaging Report 5

See attached Phased Arrry Flaw Imaging Report 6

W€dse 2 - Cracked all the wav throueh both Upner PP Groov€ welds

Wedse 3 - Cracked all the wav throush both UDDer PP Groove welds Wedge 4 - Crack€d all the way through one (Left Side) Upper PP Groove weld / Crackins from root on Risht Side

Wedee 5 Cracked all the wav throush both UDDer PP Groove welds

Wedse 6 Cracks startins from rool on both UDDer PP Groove welds Wedg€ 7 - Cracked Sporadically most ofthe way through both Upper PP Groove welds

PRINTED NAME

David Parr Torrr/ ,Ar.

OXARC, Inc.

4003 E. Broadway Ave.

Spokare, washinsron 99202 Phone 509/535-?794 Toll Frce 800/765-9055 Fax 509/535-0368 rev.03/13

ULTRASONIC EXAMINATION REPORT s ohtt.

CUSTOMER CONTACT

US ACE Little Goose Dam / Martin Evans

DATE

2-19-14

PAGE

3 o f 3

PROJECT LOCATION

Little Goose Dam - Powerhouse / Unit 5

P O # UNIT/SYSTEM

Unit 5 ITEM DESCzuPTION Groove Weld PA-UT on Little Goose Dam Unit 5 (12 Wedqe areas with cracking on PP Groove Welds)

MATERIAL

Steel Plate

THICKNESS

f , "

QTY,

12 areas

SURFACE CONDITION

Painted Steel

PROCEDURE

Oxarc PA-UT-I

ACCEPTANCE STANDARD

ASMf, sec. VlVArticle 12

ITEM TEMP/CAL BLOCK TEMP.

700 f,' / 700 F

STAGE OF

MANUFACTURE

LI INITIAL

E FINAL

E REPAIR

COMMENT:

Crack PA-UT Exam

SURFACE PREPARATION:

Smoothed with hand file

X LONGITUDINAL LI OTHER

X SHEARWAVE PA Flaw Imasins

TYPE OF EXAM

Phased Array Flaw Imaging 40o-70o Angle beam 0" Straieht Beam

COUPLANT

Sonotrace 30

INSTRUMENT MFG-MODEL.S/N

OMNI-Scrn-MX/100631

TRANSDUCER FREQ. 5 MHz/2.25 MHz SIZE !E/ !:

ESINGLE WEDGE ANGLE 45"-70" | 0o MEAS. ANCLE 4s'-10'l 0" fIDUAL MFG, SN Olvmpus-5l64 SA2IHC DELAY N9r9

G/E / OIYD1W

CALIBRATION BLOCK

XBLOCK ECURVED

TYPE

DSC

MATERIAL

Steel

MFC

Inspection Technolosies

SN

07-6148

COMMENTS INCLUDE ACCEPT/REJECT SKETCH

Little Goose Dam - Unit 5 SDider Rotor Groove Weld Cracks

See attached Phased Array Flaw Imaging Report 7

See aftached Phased Array Flaw Imaging Report 8

See attached Phased Array Flaw Imaging Report 9

See attached Phased Array Flaw Imaging Report l0

See attached Phased Array Flaw Imaging Report ll

See attached Phased Array Flaw Imaging Report 12

Wedge 8 - Cracked all the way through one (Left side) Upper PP Groove weld / Rieht side -OK

Wedg€ 9 - No Cracks Noted, Weld Discontinuities noted on both Upner PP Groove Welds Wedg€ 10 - Cracked all the way through on€ (Right side) PP Groove Weld / Left side - OK Wedge 11 - No Cracks Noted, Weld Discontinuities not€d on both Upner PP Groove Welds Wedge 12 - No Cracks Noted, W€ld Discontinuities not€d on Left side UDDer PP Groove Weld / Risht Side - OK

Wede€ I - No Indications noted

LEYEL

il 7d ft, PRINTED NAME

David Parr

OXARC,Irc.

4003 E. Broadway Ave Spokane, Washinglon 99202 Phon€ 509/535-7794 Toll Free 800165-9055 Fax J09l535-0368 rev.03/13

P A - I

2 . 4 % l(m-r)

0 000 in u(m-r) 2 . 4 % -- in

2-19-14 L ' t l l c Goose Dm Ur i l5

Wedge 2 ' Cracked all the way ikough bolh Uppcr PPBloolc wclds

D P<rc

U S A l E

2- t7-tu fi le:/,{E.:\User\Report\LGU5- 1.htm

P A - 2

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Wedse 6 - Cracks Slartine fiom roor on both Upper PP Groove welds

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Report #

U5SRADP32514 .@-

otalcINSPECTION REPORT

OXARC,Inc.

4003 E. Broadway Ave.

Spokane, Washjneton 99202 Phone 509/J35-7794 Toll Fr€e 800/?65-9055 Fax 509/535-0368

PROJECT NAME

Unit 5 Spider Rotor Arm Fillet Weld Cracks Inspection

DATE

3-2s-14

PAGE

l o f 2

PROJECT LOCATION

Little Goose Dam, Whitman County, WA P O # Attached PA Reports

N/A

CLIENT

US ACE / Little Goose Dam

FABRICATION FACILITY

NiA

GENERAL CONTRACTOR/SUPERINTENDENT

N/A

SUBCONTRACTOR/FOREMAN

N/A INSPEC flON TYPE (S) / COVERACE: Check appropriare box1.

X wetoing n Nta I Not testing n Nla E continuous X MT E ur I Periodic E PT E vT X Otheri NDT

LoCATIoN oF INSPECTIoNT LilUg.t@9SgDAlq:.M

INSPECTION REQUESTED BY: US ACE / Martin Evans

INSPECTION DETAILS:

Arrived on site at Little Goose Dam as requested by Martin Evans to perform Magnetic Particle Inspection (MT) on Unit 5 Spider Rotor Arm Upper Fillet Weld Cracks.

Met with Martin Evans to review the details of the inspection.

Martin has requested MT on the Spider Rotor Arm Upper Fillet Welds.

Performed Magnetic Particle on all 14 wedge locations on the Spider Rotor Arm Upper Fillet Welds.

Indications of Cracking were noted at 8 wedge locations: 1A, 18,4.A, 4B, 8A, 8B, 14A and 14B.

2 locations showed a growth in crack length: wedge locations 4A - 2-114" inches longer.

l4B - 2-5/8" inches longer.

See MT Report on page 2.

To the best of my knowledge all NDT was performed as per Oxarc MT-l, and was reported to the same.

Comments:

INSPECTOR'S SIGNATURE

,E-

PRINTED NAME

David Parr

REVIEWED BY

/iz-nt sk ga

DATE

0J- a?-/L/ rev.09/10

MAGNETIC PARTICLE INSPECTION

s o|atc

PROJECT NAME

Little Goose Unit 5 Spider Rotor Arm Cracls

DATE

3-25-14

REFERENCE REPORT NO.

U5SRADP32514

JOB LOCATION

Little Goose Dam / Unit 5

INSPECTION TYPEI

E roo% I Spot - Areas ofcracking l-l As oer oroiect soecification

MAT'L TYPE/TEMP,

Ferrous / 80oF

PAGE

2 o r 2

INSPECTION STD. #

E-709

NDT PROC. #

OXARC MT-l

ACCEPTANCE STD. #

AWS D1.1 / Table 6.1

PRE EXAMINATION

SurfacePreparation: None

EQUIPMENT

lnstrument Maker Parker Contour Probe Ki t#8

METHOD OF INSPECTION: X Dry Ll Wet X Visible Ll Fluorescent How Media Applied: Manual Maenetic Particle blower

Calibrationl

I Cu.rent I Continuous ! Half Wave 8 A c X D C

! Other: Unit Tesred Prior to [l Vote n Other:

Direction for fietd: ! Circular X Longitudinal

WELD or

LOCATION

TYPE OF

WELD OR PART ACCEPT REJECT REMARKS

Unit 5 Spider Rotor Arm Upper Fillet Weld Cracks

IA Fillet XX

4A srowth - 2-114" l4B erowth - 2-518"

1B Fillet xx 4A Fillet xx 4B Fillet XX

8A Fillet xx 8B Fillet xx l4A. Fillet xx 148 Fillet xx

2A. / 28 / 3A. / 3B / 5A I 5B | 6A / 68 I 7A t7B /94 /98 / tOA / tOB / t tA / t tB/ tz l / tzB/13A/138 Fillet xx No cracks were noted at theses locations

SKETCH/DRAWINC:

REMARKS:

PzuNTED NAME

David Parr

'/ -a--h4t 'k cs-a7- / q

OXARC, Inc.

4003 E Broadway Ave.

Spokane, Washington 99202 Phone 509/535-7794 Toll Free 800/765-9055 Fax509/535-0368 www.oxrrc.com 10/10 Rev.l

LGU5DP32514

INSPECTION REPORT

OXARC,Inc.

4003 E. Broadway Ave.

Spokane, washinBon 99202 Phone 509/535-7794 Toll Free 800/?65-9055 Fax 509/535-0368

PROJECT NAME

Unit 5 Upper Bearins Bracket Hub Crack Insnection

DATE

3-25-L4

PAGE

l o f 4

PROJECT LOCATION

Little Goose Dam, Whitman County, WA

P O # Attached PA Reports

CLIENT

US ACE / Little Goose Dam

FABRICATION FACILITY

N/A

GENERAI- CONTMCTOR/SUPERINTENDENT

N/A

SUBCONTRACTOR/TOREMAN

N/A INSPECTION TYPE (S) / COVERAGE: Check appropriate box(s)

LOCATION OF INSPECTION: Little Goose Dam. WA

INSPECTION REQUESTED BY: US ACE / Martin Evans

I wetotg ! Nta E Continuous E Periodic X Other: Phased Array

X NDT Testing

I M r I P T

NDT

nNla X U T E V T

INSPECTION DETAILS:

Arrived on site at Little Goose Dam as requested by Martin Evans to perfonn Phased Array NDT on Unit 5.

Met with Martin Evans to review the details of the inspection. Martin has requested Phased Array Flaw Imaging, (PA) on areas of cracking on the Unit 5 Upper Bearing Bracket Hub Cracks.

Performed PA on 6 wedge locations on the Spider Rotor Lower Groove Welds on the bottom surface.

6 locations on the 5" plate and 6 locations on the 3" plate.

All Welds were actually Partial Penetration Groove Welds. Not CJP welds.

Indications of Cracking were noted at 3 wedge locations: 415, 6/7 (5 inch plate,) and 415 (3 inch plate).

See UT Examination Report on pages 2-4. And attached PA Reports 1-12.

To the best of my knowledge all NDT was performed as per Oxarc PA-UT-I, and was reported to the same.

Comments:

INSPECTOR'S SIGNATURE

"1---_\l2*/ tr

PRINTED NAME

David Parr*""*Y7tz DATE

3 r9E-tz( rev. 09/10

ULTRASONIC EXAMINATION REPORT

LGU5DP32514 oilarc

CUSTOMER CONTACT

US ACE Little Goose Dam / Martin Evans

DATE

3-25-t4

PAGE

2 o f 4

PROJECT LOCATION

Little Goose Dam - Powerhouse / Unit 5 P O # lJl\llT/SYSTEM

Unit 5

ITEM DESCRIPTION

Groove Weld PA-UT on Little Goose Dam Unit 5 (12 Wedee areas with crackins on PP Groove Welds)

MATERIAL

Steel Plate

THICKNESS

5" 13"

QTY.

6 areas / each thickness

SURFACE CONDITION

Painted Steel

PROCEDURE

Oxarc PA-UT-I

ACCEPTANCE STANDARD

ASME sec. VlUArticle 12

ITEM TEMP/CAL BLOCK TEMP,

7 0 0 F / 7 0 0 F

STAGE OF

MANUFACTURE

I INITIAL COMMENT:

I FTNAL Crack pA-UT Exam

X REPAIR

SURFACE PREPARATION:

Smoothed with hand file

X LONGITUDINAL LI OTHER

I SHEARwAvE PA Flaw lmaerns

TYPE OF EXAM

Phased Array Flaw Imaging 40o-70o Angle beam 0' Straisht Beam

COUPLANT

Sonotrace 30

INSTRUMENT MFG-MODEL.SN

OMNI-Scan - MX / 100631

STZE 1,5" I 1"

MEAS. ANGLE 45"-10"/O'

DELAY None

TRANSDUCER FREQ. 5 MHz/2.25 MIIZ XSTNGLE WEDGEANGLE 45.-70. / Oo EDUAL MFG, S,N Olvlnpus-5l-64 SA2 IHC

G/E / OlYDlW

CAIIBRATION BLOCK

SBLOCK ECURVED

TYPE

DSC

MATERIAL

Steel

MFG

Inspection Technologies s,oJ 07-614E

COMMENTS INCLUDE ACCEPT/REJECT SKETCH

Little Goose Dam - Unit 5 SDider Rotor Groove Weld Cracks See attached Phased Array Flaw Imaging Report I

See attached Phased Array Flaw Imaging Report 2

See attached Phased Array Flaw lmaging Report 3

See attached Phas€d Array Flaw Imaging Report 4

See attached Phased Array Flaw Imaging Report 5

See attached Phased Array Flaw lmaging Report 6

Wedse - l/2 (3'" bolt) - sinsle discontinuitv indication @ l-1/2" deeo

WedEe - ll2 Uth bolt) - PA-OK

Wedee - 2/3 (lst bolt) - 2 sinsle discontinuitv indication @ l-112" deeo

Wedge - 2/3 (2nd bolt) - PA-OK

Wedse - 2/J (3rd bolt) - sinsle discontinuitv indication @ l-l14" deeo

Wedse - 2/3 (4th bolt) - sinsle discontinuitv indication @ l" deeD

Wedse - 3/4 (boltsl-4) - PA-OK

W€dse - 4/5 (lst bolt) -crack@3/4"deep

Wedee - 4i5 (2nd boll) - sinsle discontinuitv indication @ l" deep

Wedse - 4/5 (3rd bolt) - PA-OK

INSPECTOR'S SIGNATURE PRINTED NAME

David Parr

LEVEL

il

DATE

sCf tq

OXARC, Inc.

4003 E Broadway Ave.

Spokane, washington 99202 Phone 509/53J-7794 Toll Free 800/?65-9055 Fax 509/535-0368 rcv.03113

ULTRASONIC EXAMINATION REPORT s o|tatc.

Report # LGU5DP325l,l

CUSTOMER CONTACT

US ACE Little Goose Dam / Martin Evans

DATE

3-25-14

PAGE

3 o f 4

PROJECT LOCATION

Little Goose Dam - Powerhouse / Unit 5

P O # LTNIT/SYSTEM

Unit 5

ITEM DESCRIPTION

Groove WeId PA-UT on Little Goose Dam Unit 5 (12 Wedse areas with crackins on PP Groove Welds) MATERIAl- Steel Plate

THICKNESS

5" 13"

QTY,

6 areas / each thickness

SURFACE CONDITION

Painted Steel

PROCEDURE

Oxarc PA-UT-I

ACCEPTANCE STANDARD

ASME sec. VlVArticle 12

ITEM TEMP/CAL BLOCK TEMP,

7 0 0 F / 7 0 0 F

STAGE OF

MANUFACTURE

LI INITIAL COMMENT:

n FrNAL Crack pA-UT Exam

X REPAIR

SURFACE PREPARATION:

Smoothed with hand file

X LONGITUDINAL L-I OTHER

El SHEAR wAvE pA Flaw Imasine

TYPE OF EXAM

Phased Array Flaw Imaging 40"-70" Angle beam 0" Straight Bean

COUPLANT

Sonotrace 30

INSTRUMENT MFG-MODEL-S/N

OMNI-Scan-MX/100631

TRANSDUCER FREQ. 5 MHzl2.25 MHz XsrNcLE wEDcE ANGLE 4s'Jo' tqo MEAS. ANGLE !5'-201_0!

EDUAI MFG, S,4\1 Olympus-5l64 SA2 IHC DELAY None

G/f, / olYDlw

CALIBRATION BLOCK

XBLocK ECURVED

TYPE

DSC

MATERIAL

Steel

MFG

Inspection Technolosies

SN

07-6148

COMMENTS INCLUDE ACCEPT/REJECT SKETCH

Little Goose Dam - Unit 5 SDider Rotor Groove Weld Cracks - 5" plate See attached Phased Array Flaw Imaging Report 7

(W€ld was not completed and was visually unacceptable)

See attached Phased Array Flaw Imaging Report 8

See attached Phased Array Flaw Imaging Report 9

See attach€d Phased Array Flaw Imaging Report l0

Wedge - 4/5 (4th bolt) - 2 single discontinuity indication @ 3/4" and l" deeD wedse - 5/6 (bolts 1-4) - PA-OK

Weds€ - 6/7 (lst bolt) - crack @ 3/4" deeD

Wedse - 6/7 (bolts 2-4) - PA-OK

Little Goose Dam - Unit 5 SDider Rotor Groove Weld Cracks - 3" Dlate

Wedse - 6/7 (bolts t-4 ) - PA-OK

Wedse - 5/6 (1" bolt) - sinsle discontinuity @ 3/8" deeD

Wedse - 5/6 (2nd bolt) - sinsle discontinuitv @ 3/4" deeD

W€dee - 5/6 (bolts 3&4 ) - PA-OK

PRINTED NAME

David Parr

LEVEL

II

REv'E*EDBYIA

Srk

DATE

,7 ef -/?

OXARC, Inc 4003 E. Broadway Ave.

Spokane, Washinglon 99202 Phone 509/515-7794 Toll Free 800/765-9055 Fax 509/535-0366

ULTRASONIC EXAMINATION REPORT s, ilarc

Report #

LGU5DP325I4

CUSTOMER CONTACT

US ACE Little Goose Dam / Martin Evans

DATE

3-25-t4

PAGE

4 o f 4

PROJECT LOCATION

Little Goose Dam - Powerhouse / Unit 5

P O # TJNIT/SYSTEM

Unit 5

ITEM DESCRIPTION

Groove Weld PA-UT on Little Goose Dam Unit 5 (12 Wedee areas with cracking on PP Groove Welds)

MATERIAL

Steel Plate

THICKNESS

s" /3"

QTY.

6 areas / each thickness

SURFACE CONDITION

Painted Steel

PROCEDURE

Oxarc PA-UT-I

ACCEPTANCE STANDARD

ASME sec. \{IVArticle 12

ITEM TEMP/CAL BLOCK TEMP.

7 0 0 F / 7 0 0 F

STAGE OF

MANUFACTURE

J INITIAL COMMENT:

f FrNAL Crack pA-UT Exam

X REPA]R

SI-IRFACE PREPARATION :

Smoothed with hand file

X LONGITUDINAL LI OTHER

X SHEAR WAVE PA Flaw Imasing

TYPE OF EXAM

Phased Array Flaw Imaging 40o-70o Angle beam 0' Straisht Beam

COUPLANT

Sonotrace 30

INSTRUMENT MFG.MODEL.S,N

OMNI-Scan-MX/100631

TRANSDUCER FREQ. 5 MHz/2.25 MHz SIZE 1.5" / l" XSTNGLE WEDGE ANGLE 4s'-10" tqo MEAS. ANGLE 4s'-70"t0o EDUAr MFG, S,Atr Olvmpus-5l64 SA2 IHC DELAY N9!9 c/f, / olYDlw

CALIBRATION BLOCK

XBLoCK ECURVED

TYPE

DSC

MATERIAI

Steel

MFG

Inspection Technolosies s,,N 07 -6148

COMMENTS INCLUDE ACCEPT/REJECT SKETCH

Little Goose Dam - Unit 5 Spid€r Rotor Groov€ Weld Cracks - 3" nlate

See rttsched Phased Array Flaw Imaging Report l1

See attached Phased Array Flaw Imaging Report l2

Wedee - 4/5 (lst bolt) - cracked from root @ l" to 2" deeD

Wedse - 4/5 (2nd bolt) - 2 sinsle discontinuities @ l-l12" & 2" deeo

Wedse - 4/5 (bolts 3&4 ) - PA-OX

Wedse - 3/4 (bolts l-4) - PA-OK

Wedee - 2/3 (1" bolt) - sinsle discontinuity @ l-l/2" deeo

Wedse - 2/3 (bolts 2-4 ) - PA-OK

Wedee - l/2 (bolts 3&4 ) - PA-OK

INSPECTOR'S SIGNATURE

//4*z

PRINTED NAME

David Parr

LEVEL

II

DATE

,i 'A7F- / tl

O)GRC,Inc.

4003 E. Broadway Ave.

Spokane, Washinslon 99202 Phone 509/535-7794 Toll Free 800165-9055 rev.03/13

OmniScan Report Rcport Dit

2014 | 03 t27

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3'25-14 Linle Goose Dm Unit 5 Upper Beding tsracletHub Cracks 5 lldte/ Wedge Locatio. l/2/ 3rd Bolt discontinuiiy at I5 deep

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