W912P522R0003 RTA TSpecs AppB-12.pdf

INSTRUMENT CALIBRATION REPORT

GE Renewable Energy

117 East Main St, ste 100 Morristown, TN 37814 E-mail: info@pcsllctn.com Phone: 866-521-3823 Website: www . pcsllctn . com

DLB44296Instrument ID

Torque WrenchDescription 8/21/2020Calibrated PCS LabPerformed At

AnnualMainStanley Proto FrequencyLocationManufacturer 15 Overlook Circle Hendersonville, TN 37075

6065CModel Number Building Certificate # GE082120MS-02

Serial Number DLB44296 GEDepartment 69FTemp QS0032BG2013Cal Procedure 45%HumidityIn ServiceStatus

Calibration Specifications

Torque

Group Name Group #

Lft As Fnd As Out Type +/- Std Accy In Type Nom In Val / In Val Acc % In Tol Out Val in-lb 200 in-lbPct of Reading 189 -----200 / 200 4.000000 No0 in-lb 200 in-lbPct of Reading ----- 203200 / 200 4.000000 Yes0 in-lb 400 in-lbPct of Reading 385 -----400 / 400 4.000000 Yes0 in-lb 400 in-lbPct of Reading ----- 402400 / 400 4.000000 Yes0 in-lb 600 in-lbPct of Reading 581 -----600 / 600 4.000000 Yes0 in-lb 600 in-lbPct of Reading ----- 600600 / 600 4.000000 Yes0 in-lb 800 in-lbPct of Reading 783 -----800 / 800 4.000000 Yes0 in-lb 800 in-lbPct of Reading ----- 799800 / 800 4.000000 Yes0 in-lb 1000 in-lbPct of Reading 985 -----1000 / 1000 4.000000 Yes0 in-lb 1000 in-lbPct of Reading ----- 9951000 / 1000 4.000000 Yes0

Test Instruments Used During the Calibration

Test Instrument ID Description Manufacturer Model Number Serial Number Last Cal Date Next Cal Date ( As Of Cal Entry Date )

Norbar Torque Tester 2-40 Nm. 46817 ProTest 40 1264046/46817TO-001 NORBAR

TORQ TESTER 40NM

Norbar 2/18/2019 2/28/2021

Norbar Torque Tester 30-1500 Nm.

43189 Pro-test 1500ER 1264051/46839TO-002 NORBAR

TORQ TESTER

1500NM

Norbar 2/18/2019 2/28/2021

Notes about this calibration

Revision Date:05/08/2020 Rev: 04

QF0016Page 1 of 2

INSTRUMENT CALIBRATION REPORT

GE Renewable Energy

117 East Main St, ste 100 Morristown, TN 37814 E-mail: info@pcsllctn.com Phone: 866-521-3823 Website: www . pcsllctn . com

DLB44296Instrument ID

Torque WrenchDescription 8/21/2020Calibrated PCS LabPerformed At

Uncertainty = ± 1.2% of Reading (95%CL; K=2)

Who Calibrated Matt Shaw

Calibration SuccessfulCalibration Result

AdministratorFinalized By Date Finalized 8/21/2020 8:14:16AM

This document may not be reproduced except in full.

Total expanded measurement uncertainties expressed are based on a confidence level of 95%; coverage factor of (k=2). Decision Rule: The statement of compliance in this certificate was issued without taking the uncertainty of measurement into consideration. The customer shall assess the results and uncertainty when determining if the results meet their needs. This is considered “shared responsibility.” This calibration was conducted using standards traceable to the SI through NIST. The results on this certificate of accuracy apply only to the item described above.

Accredited to ISO/IEC 17025: 2017.

Laboratory Authorized Signature

Revision Date:05/08/2020 Rev: 04

QF0016Page 2 of 2

ACME Report No. 14602-LTR3 Rev.0

APPENDIX 3

GAPOS Acceptance of Measured Deflection

POST-LOAD TEST NDT REPORTS

Visual Examination Report (VT) Page 1 of 4

Previous REV Date: 06/26/09 QFE Visual Examination Report-2 Current REV Date: 02/17/11 P:\Clients\General Electric M00411\Old Hickory Dam\VT 2021-04-29 CAT-70607 PO 410777176 Old Hickory Unit 4 A;luminum Platform After Load Test 8B2 - 10B1R.docx

Client General Electric NDE Procedure No. WTI-VT-1.1-20 Rev 0

Project Old Hickory Unit 4 Aluminum Platform – After Load Test Exam Date 04-29-2021

Project ID No. PO 410777176 WTI Client ID M00411

Location Chattanooga, TN WTI Lab No. N/A

Acceptance Standards AWS D1.2 NDE Specifications AWS D1.2 Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Defect

Length(s) Welding Process

A cc ep t

R ej ec t

8B2 – pa#1 to beam All X GMAW

8B2 – pa#2 to beam All X GMAW

8B2 – pk#1 to beam All X GMAW

8B2 – pk#2 to beam All X GMAW

8B2 – mb#1 to beam All X GMAW

8B2 – mb#2 to beam All X GMAW

8B2 – mc#1 to beam All X GMAW

8B2 – aa#1 to beam All X GMAW

8B2 – aa#2 to beam All X GMAW

8B2 – aa#3 to beam All X GMAW

8B2 – aa#4 to beam All X GMAW

8B2 – aa#5 to beam All X GMAW

8B2 – aa#6 to beam All X GMAW

8B2 – aa#7 to beam All X GMAW

8B2 – aa#8 to beam All X GMAW

8B2 – aa#9 to beam All X GMAW

8B2 – aa#10 to beam All X GMAW

8B2 – aa#11 to beam All X GMAW

8B2 – aa#12 to beam All X GMAW

9B1L – pa#1 to beam All X GMAW

9B1L – pa#2 to beam All X GMAW

9B1L – pm#1 to beam All X GMAW

9B1L – mb#1 to beam All X GMAW

9B1L – mb#2 to beam All X GMAW

9B1L – mc#1 to beam All X GMAW

9B1L – aa#1 to beam All X GMAW

9B1L – aa#2 to beam All X GMAW

9B1L – aa#3 to beam All X GMAW

9B1L – aa#4 to beam All X GMAW

9B1L – aa#5 to beam All X GMAW

9B1L – aa#6 to beam All X GMAW

9B1L – aa#7 to beam All X GMAW

9B1L – aa#8 to beam All X GMAW

9B1L – aa#9 to beam All X GMAW

9B1L – aa#10 to beam All X GMAW

9B1L – aa #11 to beam All X GMAW

9B1L – aa#12 to beam All X GMAW

9B1R – pa#1 to beam All X GMAW

9B1R – pa#2 to beam All X GMAW

9B1R – pm#1 to beam All X GMAW

9B1R – mb#1 to beam All X GMAW

Visual Examination Report (VT) Page 2 of 4

P:\Clients\General Electric M00411\Old Hickory Dam\VT 2021-04-29 CAT-70607 PO 410777176 Old Hickory Unit 4 A;luminum Platform After Load Test 8B2 - 10B1R.docx

Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Defect

Length(s) Welding Process

A cc ep t

R ej ec t

9B1R – mb#2 to beam All X GMAW

9B1R – mc#1 to beam All X GMAW

9B1R – aa#1 to beam All X GMAW

9B1R – aa#2 to beam All X GMAW

9B1R – aa#3 to beam All X GMAW

9B1R – aa#4 to beam All X GMAW

9B1R – aa#5 to beam All X GMAW

9B1R – aa#6 to beam All X GMAW

9B1R – aa#7 to beam All X GMAW

9B1R – aa#8 to beam All X GMAW

9B1R – aa#9 to beam All X GMAW

9B1R – aa#10 to beam All X GMAW

9B1R – aa#11 to beam All X GMAW

9B1R – aa#12 to beam All X GMAW

9B2L – pa#1 to beam All X GMAW

9B2L – pa#2 to beam All X GMAW

9B2L – mb#1 to beam All X GMAW

9B2L – mb#2 to beam All X GMAW

9B2L – mc#1 to beam All X GMAW

9B2L – pn#1 to beam All X GMAW

9B2L – pp#1 to beam All X GMAW

9B2L – aa#1 to beam All X GMAW

9B2L – aa#2 to beam All X GMAW

9B2L – aa#3 to beam All X GMAW

9B2L – aa#4 to beam All X GMAW

9B2L – aa#5 to beam All X GMAW

9B2L – aa#6 to beam All X GMAW

9B2L – aa#7 to beam All X GMAW

9B2L – aa#8 to beam All X GMAW

9B2L – aa#9 to beam All X GMAW

9B2L – aa#10 to beam All X GMAW

9B2L – aa#11 to beam All X GMAW

9B2L – aa#12 to beam All X GMAW

9B2R – pa#1 to beam All X GMAW

9B2R – pa#2 to beam All X GMAW

9B2R – mb#1 to beam All X GMAW

9B2R – mb#2 to beam All X GMAW

9B2R – mc#1 to beam All X GMAW

9B2R – pn#1 to beam All X GMAW

9B2R – pp#1 to beam All X GMAW

9B2R – aa#1 to beam All X GMAW

9B2R – aa#2 to beam All X GMAW

9B2R – aa#3 to beam All X GMAW

9B2R – aa#4 to beam All X GMAW

9B2R – aa#5 to beam All X GMAW

9B2R – aa#6 to beam All X GMAW

9B2R – aa#7 to beam All X GMAW

Visual Examination Report (VT) Page 3 of 4

P:\Clients\General Electric M00411\Old Hickory Dam\VT 2021-04-29 CAT-70607 PO 410777176 Old Hickory Unit 4 A;luminum Platform After Load Test 8B2 - 10B1R.docx

Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Defect

Length(s) Welding Process

A cc ep t

R ej ec t

9B2R – aa#8 to beam All X GMAW

9B2R – aa#9 to beam All X GMAW

9B2R – aa#10 to beam All X GMAW

9B2R – aa#11 to beam All X GMAW

9B2R – aa#12 to beam All X GMAW

9B3L – pq#1 to beam All X GMAW

9B3L – pr#1 to beam All X GMAW

9B3L – pr#2 to beam All X GMAW

9B3L – ps#1 to beam All X GMAW

9B3L – pt#1 to beam All X GMAW

9B3L – pt#2 to beam All X GMAW

9B3L – aa#1 to beam All X GMAW

9B3L – aa#2 to beam All X GMAW

9B3L – aa#3 to beam All X GMAW

9B3L – aa#4 to beam All X GMAW

9B3L – aa#5 to beam All X GMAW

9B3L – aa#6 to beam All X GMAW

9B3L – aa#7 to beam All X GMAW

9B3L – aa#8 to beam All X GMAW

9B3L – aa#9 to beam All X GMAW

9B3L – aa#10 to beam All X GMAW

9B3L – aa#11 to beam All X GMAW

9B3L – aa#12 to beam All X GMAW

9B3R – pq#1 to beam All X GMAW

9B3R – pr#1 to beam All X GMAW

9B3R – pr#2 to beam All X GMAW

9B3R – ps#1 to beam All X GMAW

9B3R – pt#1 to beam All X GMAW

9B3R – pt#2 to beam All X GMAW

9B3R – aa#1 to beam All X GMAW

9B3R – aa#2 to beam All X GMAW

9B3R – aa#3 to beam All X GMAW

9B3R – aa#4 to beam All X GMAW

9B3R – aa#5 to beam All X GMAW

9B3R – aa#6 to beam All X GMAW

9B3R – aa#7 to beam All X GMAW

9B3R – aa#8 to beam All X GMAW

9B3R – aa#9 to beam All X GMAW

9B3R – aa#10 to beam All X GMAW

9B3R – aa#11 to beam All X GMAW

9B3R – aa#12 to beam All X GMAW

10B1L – pq#1 to beam All X GMAW

10B1L – pr#1 to beam All X GMAW

10B1L – ps#1 to beam All X GMAW

10B1L – ptt#1 to beam All X GMAW

10B1L – ptt#2 to beam All X GMAW

10B1L – aa#1 to beam All X GMAW

Visual Examination Report (VT) Page 4 of 4

P:\Clients\General Electric M00411\Old Hickory Dam\VT 2021-04-29 CAT-70607 PO 410777176 Old Hickory Unit 4 A;luminum Platform After Load Test 8B2 - 10B1R.docx

Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Defect

Length(s) Welding Process

A cc ep t

R ej ec t

10B1L – aa#2 to beam All X GMAW

10B1L – aa#3 to beam All X GMAW

10B1L – aa#4 to beam All X GMAW

10B1L – aa#5 to beam All X GMAW

10B1L – aa#6 to beam All X GMAW

10B1L – aa#7 to beam All X GMAW

10B1L – aa#8 to beam All X GMAW

10B1L – aa#9 to beam All X GMAW

10B1L – aa#10 to beam All X GMAW

10B1L – aa#11 to beam All X GMAW

10B1L – aa#12 to beam All X GMAW

10B1R – pq#1 to beam All X GMAW

10B1R – pr#1 to beam All X GMAW

10B1R – ps#1 to beam All X GMAW

10B1R – ptt#1 to beam All X GMAW

10B1R – ptt#2 to beam All X GMAW

10B1R – aa#1 to beam All X GMAW

10B1R – aa#2 to beam All X GMAW

10B1R – aa#3 to beam All X GMAW

10B1R – aa#4 to beam All X GMAW

10B1R – aa#5 to beam All X GMAW

10B1R – aa#6 to beam All X GMAW

10B1R – aa#7 to beam All X GMAW

10B1R – aa#8 to beam All X GMAW

10B1R – aa#9 to beam All X GMAW

10B1R – aa#10 to beam All X GMAW

10B1R – aa#11 to beam All X GMAW

10B1R – aa#12 to beam All X GMAW

Comments

Inspections were performed after the load test.

Parts inspected were 8B2, 9B1L, 9B1R, 9B2L, 9B2R, 9B3L, 9B3R, 10B1L, and 10B1R.

Technique X Direct Visual Remote Visual Translucent Visual

Lighting Equipment Flux Pro SN 296

Equipment/Devices used for technique Fillet Weld Gauges

We the undersigned, certify that the statements in this record are correct and that the welds and/or pieces were examined in accordance with the requirements of the above specified NDE specifications and acceptance standards.

NDE Technician General Manager Catalog No. 70607

Name / NDT Level Signature Name Signature Typed By LS

Michael Piercey/CWI-12110451 Robert W. O’Neal, Sr.

Date Date

04-29-2021 05-04-2021

Visual Examination Report (VT) Page 1 of 3

P:\Clients\General Electric M00411\Old Hickory Dam\VT 2021-05-05 CAT-70676 PO 410777176 Old Hickory Unit 4 Aluminum Platform After Load Test 8B1 - 10B2.docx

Client General Electric NDE Procedure No. WTI-VT-1.1-20 Rev 0

Project Old Hickory Unit 4 Aluminum Platform – After Load Test Exam Date 05-05-2021

Project ID No. PO 410777176 WTI Client ID M00411

Location Chattanooga, TN WTI Lab No. N/A

Acceptance Standards AWS D1.2 NDE Specifications AWS D1.2 Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Defect

Length(s) Welding Process

A cc ep t

R ej ec t

8B1 #1 – pa#1 to beam All X GMAW

8B1 #1 – pa#2 to beam All X GMAW

8B1 #1 – pc to beam All X GMAW

8B1 #1 – pdr to beam All X GMAW

8B1 #1 – pdl to beam All X GMAW

8B1 #1 – maa to beam All X GMAW

8B1 #2 – pa#1 to beam All X GMAW

8B1 #2 – pa#2 to beam All X GMAW

8B1 #2 – pc to beam All X GMAW

8B1 #2 – pdr to beam All X GMAW

8B1 #2 – pdl to beam All X GMAW

8B1 #2 – maa to beam All X GMAW

8B1 #3 – pa#1 to beam All X GMAW

8B1 #3 – pa#2 to beam All X GMAW

8B1 #3 – pc to beam All X GMAW

8B1 #3 – pdr to beam All X GMAW

8B1 #3 – pdl to beam All X GMAW

8B1 #3 – maa to beam All X GMAW

8B1 #4 – pa#1 to beam All X GMAW

8B1 #4 – pa#2 to beam All X GMAW

8B1 #4 – pc to beam All X GMAW

8B1 #4 – pdr to beam All X GMAW

8B1 #4 – pdl to beam All X GMAW

8B1 #4 – maa to beam All X GMAW

8B1 #5 – pa#1 to beam All X GMAW

8B1 #5 – pa#2 to beam All X GMAW

8B1 #5 – pc to beam All X GMAW

8B1 #5 – pdr to beam All X GMAW

8B1 #5 – pdl to beam All X GMAW

8B1 #5 – maa to beam All X GMAW

8B3 #1 – pv#1 to beam All X GMAW

8B3 #1 – pv#2 to beam All X GMAW

8B3 #1 – pv#3 to beam All X GMAW

8B3 #1 – pv#4 to beam All X GMAW

8B3 #2 – pv#1 to beam All X GMAW

8B3 #2 – pv#2 to beam All X GMAW

8B3 #2 – pv#3 to beam All X GMAW

8B3 #2 – pv#4 to beam All X GMAW

8B4R – pv#1 to beam All X GMAW

8B4R – pv#2 to beam All X GMAW

8B4R – paa#1 to beam All X GMAW

Visual Examination Report (VT) Page 2 of 3

P:\Clients\General Electric M00411\Old Hickory Dam\VT 2021-05-05 CAT-70676 PO 410777176 Old Hickory Unit 4 Aluminum Platform After Load Test 8B1 - 10B2.docx

Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Defect

Length(s) Welding Process

A cc ep t

R ej ec t

8B4R – paa#2 to beam All X GMAW

8B4L – pv#1 to beam All X GMAW

8B4L – pv#2 to beam All X GMAW

8B4L – paa#1 to beam All X GMAW

8B4L – paa#2 to beam All X GMAW

10B3 #1 – pv#1 to beam All X GMAW

10B3 #1 – pv#2 to beam All X GMAW

10B3 #1 – pv#3 to beam All X GMAW

10B3 #1 – pv#4 to beam All X GMAW

10B3 #1 – pz#1 to md#1 All X GMAW

10B3 #1 – pz#2 to md#1 All X GMAW

10B3 #1 – pz#3 to md#1 All X GMAW

10B3 #1 – pz#4 to md#1 All X GMAW

10B3 #1 – pz#1 to md#2 All X GMAW

10B3 #1 – pz#2 to md#2 All X GMAW

10B3 #1 – pz#3 to md#2 All X GMAW

10B3 #1 – pz#4 to md#2 All X GMAW

10B3 #2 – pv#1 to beam All X GMAW

10B3 #2 – pv#2 to beam All X GMAW

10B3 #2 – pv#3 to beam All X GMAW

10B3 #2 – pv#4 to beam All X GMAW

10B3 #2 – pz#1 to md#1 All X GMAW

10B3 #2 – pz#2 to md#1 All X GMAW

10B3 #2 – pz#3 to md#1 All X GMAW

10B3 #2 – pz#4 to md#1 All X GMAW

10B3 #2 – pz#1 to md#2 All X GMAW

10B3 #2 – pz#2 to md#2 All X GMAW

10B3 #2 – pz#3 to md#2 All X GMAW

10B3 #2 – pz#4 to md#2 All X GMAW

10B2 #1 – pv#1 to beam All X GMAW

10B2 #1 – pv#2 to beam All X GMAW

10B2 #1 – pv#3 to beam All X GMAW

10B2 #1 – pv#4 to beam All X GMAW

10B2 #1 – pw#1 to beam All X GMAW

10B2 #1 – pw#2 to beam All X GMAW

10B2 #1 – px#1 to beam All X GMAW

10B2 #1 – px#2 to beam All X GMAW

10B2 #2 – pv#1 to beam All X GMAW

10B2 #2 – pv#2 to beam All X GMAW

10B2 #2 – pv#3 to beam All X GMAW

10B2 #2 – pv#4 to beam All X GMAW

10B2 #2 – pw#1 to beam All X GMAW

10B2 #2 – pw#2 to beam All X GMAW

10B2 #2 – px#1 to beam All X GMAW

10B2 #2 – px#2 to beam All X GMAW

Visual Examination Report (VT) Page 3 of 3

P:\Clients\General Electric M00411\Old Hickory Dam\VT 2021-05-05 CAT-70676 PO 410777176 Old Hickory Unit 4 Aluminum Platform After Load Test 8B1 - 10B2.docx

Comments

Inspections were performed after the load test.

Parts Inspected were 8B1#1, 8B1#2, 8B1#3, 8B1#4, 8B1#5, 8B3#1, 8B3#2, 8B4R, 8B4L, 10B3#1, 10B3#2, 10B2#1, and 10B2#2.

Technique X Direct Visual Remote Visual Translucent Visual

Lighting Equipment Flux Pro SN296

Equipment/Devices used for technique Fillet Weld Gauges

We the undersigned, certify that the statements in this record are correct and that the welds and/or pieces were examined in accordance with the requirements of the above specified NDE specifications and acceptance standards.

NDE Technician General Manager Catalog No. 70676

Name / NDT Level Signature Name Signature Typed By CH

Michael Piercey/CWI-12110451 Robert W. O’Neal, Sr.

05-05-2021 05-06-2021

Liquid Penetrant Test Report (PT) Page 1 of 4

Previous REV Date: 09/25/08 QFE Liquid Penetrant Test Report-1 Current REV Date: 02/17/11 P:\Clients\General Electric M00411\Old Hickory Dam\PT 2021-04-29 CAT-70608 PO 410777176 Old Hickory Unit 4 Aluminum Platform After Load Test 8B2 - 10B1R.docx

Client General Electric NDE Procedure No. WTI-PT-1.1 Rev

Project Old Hickory Unit 4 Aluminum Platform – After Load Test Exam Date 04-29-2021

Project ID No. PO 410777176 WTI Client ID M00411

Location Chattanooga, TN WTI Lab No. N/A

Acceptance Standards AWS D1.2 NDE Specifications AWS D1.2 Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Welding Process

A cc ep t

R ej ec t

8B2 – pa#1 to beam All X GMAW

8B2 – pa#2 to beam All X GMAW

8B2 – pk#1 to beam All X GMAW

8B2 – pk#2 to beam All X GMAW

8B2 – mb#1 to beam All X GMAW

8B2 – mb#2 to beam All X GMAW

8B2 – mc#1 to beam All X GMAW

8B2 – aa#1 to beam All X GMAW

8B2 – aa#2 to beam All X GMAW

8B2 – aa#3 to beam All X GMAW

8B2 – aa#4 to beam All X GMAW

8B2 – aa#5 to beam All X GMAW

8B2 – aa#6 to beam All X GMAW

8B2 – aa#7 to beam All X GMAW

8B2 – aa#8 to beam All X GMAW

8B2 – aa#9 to beam All X GMAW

8B2 – aa#10 to beam All X GMAW

8B2 – aa#11 to beam All X GMAW

8B2 – aa#12 to beam All X GMAW

9B1L – pa#1 to beam All X GMAW

9B1L – pa#2 to beam All X GMAW

9B1L – pm#1 to beam All X GMAW

9B1L – mb#1 to beam All X GMAW

9B1L – mb#2 to beam All X GMAW

9B1L – mc#1 to beam All X GMAW

9B1L – aa#1 to beam All X GMAW

9B1L – aa#2 to beam All X GMAW

9B1L – aa#3 to beam All X GMAW

9B1L – aa#4 to beam All X GMAW

9B1L – aa#5 to beam All X GMAW

9B1L – aa#6 to beam All X GMAW

9B1L – aa#7 to beam All X GMAW

9B1L – aa#8 to beam All X GMAW

9B1L – aa#9 to beam All X GMAW

9B1L – aa#10 to beam All X GMAW

9B1L – aa #11 to beam All X GMAW

9B1L – aa#12 to beam All X GMAW

9B1R – pa#1 to beam All X GMAW

9B1R – pa#2 to beam All X GMAW

9B1R – pm#1 to beam All X GMAW

9B1R – mb#1 to beam All X GMAW

9B1R – mb#2 to beam All X GMAW

9B1R – mc#1 to beam All X GMAW

Liquid Penetrant Test Report (PT) Page 2 of 4

P:\Clients\General Electric M00411\Old Hickory Dam\PT 2021-04-29 CAT-70608 PO 410777176 Old Hickory Unit 4 Aluminum Platform After Load Test 8B2 - 10B1R.docx

Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Welding Process

A cc ep t

R ej ec t

9B1R – aa#1 to beam All X GMAW

9B1R – aa#2 to beam All X GMAW

9B1R – aa#3 to beam All X GMAW

9B1R – aa#4 to beam All X GMAW

9B1R – aa#5 to beam All X GMAW

9B1R – aa#6 to beam All X GMAW

9B1R – aa#7 to beam All X GMAW

9B1R – aa#8 to beam All X GMAW

9B1R – aa#9 to beam All X GMAW

9B1R – aa#10 to beam All X GMAW

9B1R – aa#11 to beam All X GMAW

9B1R – aa#12 to beam All X GMAW

9B2L – pa#1 to beam All X GMAW

9B2L – pa#2 to beam All X GMAW

9B2L – mb#1 to beam All X GMAW

9B2L – mb#2 to beam All X GMAW

9B2L – mc#1 to beam All X GMAW

9B2L – pn#1 to beam All X GMAW

9B2L – pp#1 to beam All X GMAW

9B2L – aa#1 to beam All X GMAW

9B2L – aa#2 to beam All X GMAW

9B2L – aa#3 to beam All X GMAW

9B2L – aa#4 to beam All X GMAW

9B2L – aa#5 to beam All X GMAW

9B2L – aa#6 to beam All X GMAW

9B2L – aa#7 to beam All X GMAW

9B2L – aa#8 to beam All X GMAW

9B2L – aa#9 to beam All X GMAW

9B2L – aa#10 to beam All X GMAW

9B2L – aa#11 to beam All X GMAW

9B2L – aa#12 to beam All X GMAW

9B2R – pa#1 to beam All X GMAW

9B2R – pa#2 to beam All X GMAW

9B2R – mb#1 to beam All X GMAW

9B2R – mb#2 to beam All X GMAW

9B2R – mc#1 to beam All X GMAW

9B2R – pn#1 to beam All X GMAW

9B2R – pp#1 to beam All X GMAW

9B2R – aa#1 to beam All X GMAW

9B2R – aa#2 to beam All X GMAW

9B2R – aa#3 to beam All X GMAW

9B2R – aa#4 to beam All X GMAW

9B2R – aa#5 to beam All X GMAW

9B2R – aa#6 to beam All X GMAW

9B2R – aa#7 to beam All X GMAW

9B2R – aa#8 to beam All X GMAW

9B2R – aa#9 to beam All X GMAW

9B2R – aa#10 to beam All X GMAW

9B2R – aa#11 to beam All X GMAW

Liquid Penetrant Test Report (PT) Page 3 of 4

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Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Welding Process

A cc ep t

R ej ec t

9B2R – aa#12 to beam All X GMAW

9B3L – pq#1 to beam All X GMAW

9B3L – pr#1 to beam All X GMAW

9B3L – pr#2 to beam All X GMAW

9B3L – ps#1 to beam All X GMAW

9B3L – pt#1 to beam All X GMAW

9B3L – pt#2 to beam All X GMAW

9B3L – aa#1 to beam All X GMAW

9B3L – aa#2 to beam All X GMAW

9B3L – aa#3 to beam All X GMAW

9B3L – aa#4 to beam All X GMAW

9B3L – aa#5 to beam All X GMAW

9B3L – aa#6 to beam All X GMAW

9B3L – aa#7 to beam All X GMAW

9B3L – aa#8 to beam All X GMAW

9B3L – aa#9 to beam All X GMAW

9B3L – aa#10 to beam All X GMAW

9B3L – aa#11 to beam All X GMAW

9B3L – aa#12 to beam All X GMAW

9B3R – pq#1 to beam All X GMAW

9B3R – pr#1 to beam All X GMAW

9B3R – pr#2 to beam All X GMAW

9B3R – ps#1 to beam All X GMAW

9B3R – pt#1 to beam All X GMAW

9B3R – pt#2 to beam All X GMAW

9B3R – aa#1 to beam All X GMAW

9B3R – aa#2 to beam All X GMAW

9B3R – aa#3 to beam All X GMAW

9B3R – aa#4 to beam All X GMAW

9B3R – aa#5 to beam All X GMAW

9B3R – aa#6 to beam All X GMAW

9B3R – aa#7 to beam All X GMAW

9B3R – aa#8 to beam All X GMAW

9B3R – aa#9 to beam All X GMAW

9B3R – aa#10 to beam All X GMAW

9B3R – aa#11 to beam All X GMAW

9B3R – aa#12 to beam All X GMAW

10B1L – pq#1 to beam All X GMAW

10B1L – pr#1 to beam All X GMAW

10B1L – ps#1 to beam All X GMAW

10B1L – ptt#1 to beam All X GMAW

10B1L – ptt#2 to beam All X GMAW

10B1L – aa#1 to beam All X GMAW

10B1L – aa#2 to beam All X GMAW

10B1L – aa#3 to beam All X GMAW

10B1L – aa#4 to beam All X GMAW

10B1L – aa#5 to beam All X GMAW

10B1L – aa#6 to beam All X GMAW

10B1L – aa#7 to beam All X GMAW

Liquid Penetrant Test Report (PT) Page 4 of 4

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Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Welding Process

A cc ep t

R ej ec t

10B1L – aa#8 to beam All X GMAW

10B1L – aa#9 to beam All X GMAW

10B1L – aa#10 to beam All X GMAW

10B1L – aa#11 to beam All X GMAW

10B1L – aa#12 to beam All X GMAW

10B1R – pq#1 to beam All X GMAW

10B1R – pr#1 to beam All X GMAW

10B1R – ps#1 to beam All X GMAW

10B1R – ptt#1 to beam All X GMAW

10B1R – ptt#2 to beam All X GMAW

10B1R – aa#1 to beam All X GMAW

10B1R – aa#2 to beam All X GMAW

10B1R – aa#3 to beam All X GMAW

10B1R – aa#4 to beam All X GMAW

10B1R – aa#5 to beam All X GMAW

10B1R – aa#6 to beam All X GMAW

10B1R – aa#7 to beam All X GMAW

10B1R – aa#8 to beam All X GMAW

10B1R – aa#9 to beam All X GMAW

10B1R – aa#10 to beam All X GMAW

10B1R – aa#11 to beam All X GMAW

10B1R – aa#12 to beam All X GMAW

Equipment and Technique Details

Penetrant Method X Visible Fluorescent Cleaner Type SKC-S

Penetrant Type SKL-WP2 Cleaner Batch No. 18C22K

Penetrant Batch No. 19A22K Material Type 6061-T6

Developer Type SKD-S2 Material Thickness .500”

Developer Batch No. 19C18K Lighting Equipment Flux Pro SN296

We the undersigned, certify that the statements in this record are correct and that the welds and/or pieces were examined in accordance with the requirements of the above NDE specification and acceptance standard.

NDE Technician General Manager Catalog No. 70608

Name / NDT Level Signature Name Signature Typed By LS

Michael Piercey / II Robert W. O’Neal, Sr.

04-29-2021 05-04-2021

Liquid Penetrant Test Report (PT) Page 1 of 3

P:\Clients\General Electric M00411\Old Hickory Dam\PT 2021-05-05 CAT-70675 PO 410777176 Old Hickory Unit 4 Aluminum Platform After Load 8B1 - 10B2.docx

Client General Electric NDE Procedure No. WTI-PT-1.1 Rev

Project Old Hickory Unit 4 Aluminum Platform – After Load Test Exam Date 05-05-2021

Project ID No. PO 410777176 WTI Client ID M00411

Location Chattanooga, TN WTI Lab No. N/A

Acceptance Standards AWS D1.2 NDE Specifications AWS D1.2 Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Welding Process

A cc ep t

R ej ec t

8B1 #1 – pa#1 to beam All X GMAW

8B1 #1 – pa#2 to beam All X GMAW

8B1 #1 – pc to beam All X GMAW

8B1 #1 – pdr to beam All X GMAW

8B1 #1 – pdl to beam All X GMAW

8B1 #1 – maa to beam All X GMAW

8B1 #2 – pa#1 to beam All X GMAW

8B1 #2 – pa#2 to beam All X GMAW

8B1 #2 – pc to beam All X GMAW

8B1 #2 – pdr to beam All X GMAW

8B1 #2 – pdl to beam All X GMAW

8B1 #2 – maa to beam All X GMAW

8B1 #3 – pa#1 to beam All X GMAW

8B1 #3 – pa#2 to beam All X GMAW

8B1 #3 – pc to beam All X GMAW

8B1 #3 – pdr to beam All X GMAW

8B1 #3 – pdl to beam All X GMAW

8B1 #3 – maa to beam All X GMAW

8B1 #4 – pa#1 to beam All X GMAW

8B1 #4 – pa#2 to beam All X GMAW

8B1 #4 – pc to beam All X GMAW

8B1 #4 – pdr to beam All X GMAW

8B1 #4 – pdl to beam All X GMAW

8B1 #4 – maa to beam All X GMAW

8B1 #5 – pa#1 to beam All X GMAW

8B1 #5 – pa#2 to beam All X GMAW

8B1 #5 – pc to beam All X GMAW

8B1 #5 – pdr to beam All X GMAW

8B1 #5 – pdl to beam All X GMAW

8B1 #5 – maa to beam All X GMAW

8B3 #1 – pv#1 to beam All X GMAW

8B3 #1 – pv#2 to beam All X GMAW

8B3 #1 – pv#3 to beam All X GMAW

8B3 #1 – pv#4 to beam All X GMAW

8B3 #2 – pv#1 to beam All X GMAW

8B3 #2 – pv#2 to beam All X GMAW

8B3 #2 – pv#3 to beam All X GMAW

8B3 #2 – pv#4 to beam All X GMAW

8B4R – pv#1 to beam All X GMAW

8B4R – pv#2 to beam All X GMAW

8B4R – paa#1 to beam All X GMAW

8B4R – paa#2 to beam All X GMAW

8B4L – pv#1 to beam All X GMAW

Liquid Penetrant Test Report (PT) Page 2 of 3

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Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Welding Process

A cc ep t

R ej ec t

8B4L – pv#2 to beam All X GMAW

8B4L – paa#1 to beam All X GMAW

8B4L – paa#2 to beam All X GMAW

10B3 #1 – pv#1 to beam All X GMAW

10B3 #1 – pv#2 to beam All X GMAW

10B3 #1 – pv#3 to beam All X GMAW

10B3 #1 – pv#4 to beam All X GMAW

10B3 #1 – pz#1 to md#1 All X GMAW

10B3 #1 – pz#2 to md#1 All X GMAW

10B3 #1 – pz#3 to md#1 All X GMAW

10B3 #1 – pz#4 to md#1 All X GMAW

10B3 #1 – pz#1 to md#2 All X GMAW

10B3 #1 – pz#2 to md#2 All X GMAW

10B3 #1 – pz#3 to md#2 All X GMAW

10B3 #1 – pz#4 to md#2 All X GMAW

10B3 #2 – pv#1 to beam All X GMAW

10B3 #2 – pv#2 to beam All X GMAW

10B3 #2 – pv#3 to beam All X GMAW

10B3 #2 – pv#4 to beam All X GMAW

10B3 #2 – pz#1 to md#1 All X GMAW

10B3 #2 – pz#2 to md#1 All X GMAW

10B3 #2 – pz#3 to md#1 All X GMAW

10B3 #2 – pz#4 to md#1 All X GMAW

10B3 #2 – pz#1 to md#2 All X GMAW

10B3 #2 – pz#2 to md#2 All X GMAW

10B3 #2 – pz#3 to md#2 All X GMAW

10B3 #2 – pz#4 to md#2 All X GMAW

10B2 #1 – pv#1 to beam All X GMAW

10B2 #1 – pv#2 to beam All X GMAW

10B2 #1 – pv#3 to beam All X GMAW

10B2 #1 – pv#4 to beam All X GMAW

10B2 #1 – pw#1 to beam All X GMAW

10B2 #1 – pw#2 to beam All X GMAW

10B2 #1 – px#1 to beam All X GMAW

10B2 #1 – px#2 to beam All X GMAW

10B2 #2 – pv#1 to beam All X GMAW

10B2 #2 – pv#2 to beam All X GMAW

10B2 #2 – pv#3 to beam All X GMAW

10B2 #2 – pv#4 to beam All X GMAW

10B2 #2 – pw#1 to beam All X GMAW

10B2 #2 – pw#2 to beam All X GMAW

10B2 #2 – px#1 to beam All X GMAW

10B2 #2 – px#2 to beam All X GMAW

Liquid Penetrant Test Report (PT) Page 3 of 3

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Equipment and Technique Details

Penetrant Method X Visible Fluorescent Cleaner Type SKC-S

Penetrant Type SKL-WP2 Cleaner Batch No. 18C22K

Penetrant Batch No. 19A22K Material Type T6061-T6

Developer Type SKD-S2 Material Thickness .500”

Developer Batch No. 19C18K Lighting Equipment Flux Pro SN296

We the undersigned, certify that the statements in this record are correct and that the welds and/or pieces were examined in accordance with the requirements of the above NDE specification and acceptance standard.

NDE Technician General Manager Catalog No. 70675

Name / NDT Level Signature Name Signature Typed By LS

Michael Piercey / II Robert W. O’Neal, Sr.

05-05-2021 05-06-2021

GE RENEWABLE ENERGY

ENGINEERING

GE CONFIDENTIEL Page 1 of 3 H1039500MEI85-204FDC-01 Rev. A 2021-06-09

Subject/Project OLD HICKORY UNIT 4

Title

TURBINE MAINTENANCE PLATFORM ASSEMBLY INSTRUCTIONS

Ref. number: H1039500 MEI 85-204 F DC-02

Summary :

Client : U.S. Army Corps of Engineers

Contrat N°: 158400

Ref. : Section 05 50 14.00 item 11

Distribition : M, N, P, Q, S, Customer

(*) Available Status: PRE : Preliminary, GFR: Good For Review , GFE: Good For Execution

A 2021.06.09 J-P. Fortin J-P. Fortin J-P. Fortin Revised based comments after onsite assembly GFE

- 2021.02.16 C. Montreuil C. Montreuil B. Bradley New issue GFR

Rev Date Established Checked Approved Modification Status (*)

GE CONFIDENTIEL

GE CONFIDENTIEL Page 2 of 3 H1039500MEI85-204FDC-01 Rev. D 2021-06-09

TABLE OF CONTENTS

APPENDIX A: TURBINE MAINTENANCE PLATFORM ASSEMBLY INSTRUCTIONS

ENGINEERING

APPENDIX A

TURBINE MAINTENANCE PLATFORM ASSEMBLY PROCEDURE

GE CONFIDENTIEL Page 3 of 3 H1039500MEI85-204FDC-01 Rev. A 2021-06-09

OLD HICKORY

TURBINE MAINTENANCE PLATFORM

TMP ASSEMBLY PROCEDURE

PROCEDURE 14602-ASSY-001

Revision 0: For Approval / 02/05/2021 Revision 1: Requested changes / 06/04/2021

ACME JOB No. 14602

By: James Smith Date: February 3, 2021

ACME Procedure No. 14602-ASSY-001 Rev.1

TABLE OF CONTENTS

A. Pre-Assembly Tasks.

B. Floating Platform Assembly (Dock Blocks).

C. TMP Platform Assembly.

D. Grating Installation.

APPENDECIES

APPENDIX 1 – Floating Platform Plan (DOCK BLOCKS)

APPENDIX 2 – Framing Plan

APPENDIX 3 – Grating Plan

A. Pre-Assembly Tasks.

1. Set head gates and tail gates.

2. Adjust draft tube water level to at least 372'-9.5". If desired, the water level can be increased to as much as 373'-9".

B. Floating Platform Assembly (Dock Blocks).

1. Assemble Dock Block floating platform. It can be assembled in any sequence desired, and the assembly details are provided on GAPOS Drawing Sheet 5 of 10, Floating Platform Plan and Details. Basic configuration is provided in APPENDIX 1 - Floating Platform Plan (DOCK BLOCKS).

C. TMP Platform Assembly.

1. The tools shown in TABLE 1 are the minimum required for assembly, two sets.

TABLE 1

TMP ASSEMBLY TOOLS

Qty Tool Description

2 Ratchet w/ 1-1/16” Socket

2 1-1/16” Box End Wrench

2 Torque Wrench (set at 42 ft-lbs.)

1 1-1/16” Crows Foot (sized for torque wrench drive)

2 Tapered Line-up Pin

2. Prepare by reviewing the plan for assembling the TMP aluminum frame structure (See APPENDIX 2 – Framing Plan).

i. Important! Leave all bolts loose when assembling the frame until all framing members have been connected.

ii. The attached pictures show the TMP assembled using five special stands that are not provided. It is acceptable to assemble the TMP directly on the floor / dock block surface or elevated over wooden blocks spacers.

3. The TMP can be assembled in any order desired, but it is suggested to first set the five perimeter beams (8B2, 9B1L, 9B1R, 9B2L and 9B2R (See FIGURES 1, 2 and 3) and then loosely bolt them together with the five lift point assemblies, 8B1, using the 5/8” x 2-1/2” SS Bolts, Washers, and Nuts.

FIGURE 1

FIGURE 2

FIGURE 3

4. Connect beams 9B3R and 9B3L using the 5/8” x 2-1/2” SS bolts, washers, and nuts.

After 9B3R & 9B3L have been bolted together, lift into position and bolt together at 9B1R & 9B1L using the shorter 5/8” x 2-1/4” SS bolts, washers, and nuts. (See FIGURE 4) Last, connect 10B1R & 10B1L together and then to 9B2R & 9B2L in a similar fashion. FIGURE 4 shows the assembly of these parts.

FIGURE 4

5. Connect 10B2-1 and 10B2-2 in-between the larger 9B3 and 10B1 beams using 5/8” x 2-1/4” SS bolts, washers, and nuts (See FIGURE 5) and then connect 10B3-1 & 10B3-2 inside the 10B2 members using 5/8” x 2-1/4” SS bolts, washers, and nuts (See FIGURE 6).

FIGURE 5

FIGURE 6

6. Connect 8B3-1, 8B3-2, 8B4R, and 8B4L using 5/8” x 2-1/4” SS bolts, washers, and nuts (See FIGURE 7).

FIGURE 7

7. After all beams have been connected, begin snugging up bolts using a socket and ratchet. Starting with the perimeter and main beams. Beams should be tightened up in the same order by which they were assembled.

8. Once bolted connections have been snugged, all bolts should then be torqued to 42 ft-lbs. This will complete the assembly process for the TMP framing.

D. Grating Installation

1. The tools shown in TABLE 2 are the minimum required for grating installation, two sets.

TABLE 2

GRATING INSTALLATION TOOLS

Qty Tool Description

2 Impact Driver

2 3/16” Hex Impact Bit (for grating screws)

2. Prepare by reviewing the plan for installing the grating sections (See APPENDIX 3 – Grating Plan).

3. If the Dock Blocks will be left inside the draft tube after assembly of the platform framing, the grating can be installed in any order. If the grating is installed without the use of the Dock Blocks, we recommend the following installation sequence.

i. Place G1L onto platform frame from the draft tube manway. Loosely fasten two grating clips to hold grating in place. Use anti-seize on all grating screw threads. Note: Install grating clips loose until all grating sections is installed. This will allow for minor adjustments.

ii. Once G1L is in place, climb out onto the grating. Place G1R into place and loosely fasten two grating clips (See FIGURE 8).

FIGURE 8

iii. Install G2L, G3L, G4L, G5L, G6L, G7L, G8L, G15L, and G1R from left to right of the manway in accordance with the Grating Plan. Loosely secure two grating clips to each piece of grating (See FIGURE 9).

FIGURE 9

iv. Install G11L, G10L, G9L, and G1L from the right of the manway to the left (See FIGURE 10).

FIGURE 10

v. Install G14, G13, and G12 from the right of the manway to the left (See

FIGURE 11).

FIGURE 11

vi. Install G11R, G10R, G9R, and G1R from the right of the manway to the left (See FIGURE 12).

FIGURE 12

vii. Install G2R, G3R, G4R, G5R, G6R, G7R, G8R, G15R, and the remaining G1R and G1L pieces from left to right of the manway in accordance with the Grating Plan. Loosely secure two grating clips to each piece of grating (See FIGURE 13).

FIGURE 13

viii. Install remaining grating clips on each grating section, four clips each, and tighten all clip screws. Caution: Only tighten screws until the clips are secure. DO NOT overtighten. This completes the grating installation.

APPENDIX 1

Floating Platform Plan (DOCK BLOCKS)

APPENDIX 2

Framing Plan

Notes:

1. Leave all bolts loose until all framing members have been connected.

2. When tightening the bolts, it is suggested to begin with perimeter and main beams.

3. Final torque for bolts is 42 ft-lbs.

4. It is necessary to use a 1-1/16" crows-foot to torque the inside bolts along the perimeter flanges. (Make sure to account for any additional length that the crows-foot will add to the torque wrench. Make proper adjustments.)

APPENDIX 3

Grating Plan

NOTE: Install grating clips loose until all grating sections have been placed or installed.

This will allow for minor adjustments.

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N°

H1039500 MEI 52-200 F QC-01

DOCUMENT TECHNIQUE

TECHNICAL DOCUMENT

Édition / Issue July 2020 Rév / Rev. - Date 07.07.2020 Par / By L. Desgagne

Contrat / Contract: W912P5-17-C-0002 Client/ Customer: US Army Corps of Engineers

Ref Contrat / Contract Reference: Sec. / Sec: Section 03 64 23.00 Article / Item: 5

Projet / Project: 1584- Old Hickory U4

Kaplan Turbine Refurbishment and Generator Rewind

Préparé ou révisé par / Prepared or revised by

L. Desgagne

Revu et approuvé par / Reviewed and approved by

S. Cossette

Secteur responsable / Responsible Department QA

DISTRIBUTION (CODE)

Copie non contrôlée / Uncontrolled copy Client- I-O

X Copie contrôlée / Controlled copy

Titre / Title Epoxy injection test result, inspection and records for Discharge ring/liner

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N° :

H1039500MEI 52-200 F QC-01

Contract: : 158400

Rev. : -

DOCUMENT TECHNIQUE Date: : 07.07.2020

Titre / Title: Epoxy injection test result, inspection and records for Discharge ring/liner

1.0 SCOPE

This technical document covers Epoxy injection test result for Discharge ring/liner. Section 03 64 23.00 PARA 3.5. Note that all large voids injection records have been added in this report for complementary information. Both scope of work are linked.

2.0 RELATED DOCUMENTS

- GE Epoxy Injection procedure H1039500 MEI 52-200 F DC-02 Transmittal 03 64 23.00-1.3

- GE large voids Injection procedure H1039500 MEI 52-200 F DC-03 Transmittal 03 64 23.00-10.1

- Injection Equipment H1039500 MEI 52-200 F DC-10 Transmittal 03 64 23.00-4

3.0 DETAILS ON THE RESULT:

The test results are shown in appendix A to demonstrate that required inspection, verifications and test were completed.

a. Inspection of material delivered to the project site against approved material data.

Contractor confirm the material used was inspected and the proper one.

b. Equipment was always in good working condition and clean.

Contractor confirm the material and equipment were in good condition and clean at all the times

c. Holes was properly located and drilled to proper size and depth.

Contractor confirm the holes was properly located and drilled to proper size and depth

d. All drilled holes and voids in concrete were filled.

Contractor filled all required holes prior epoxy resin injection. See the details in the site reports sheets at Appendix

A of the present document. Contractor confirm than all the voids in concrete are filled properly.

e. All holes in discharge ring lining are repaired.

Contractor confirm than all the holes in discharge ring lining are repaired by welding. N.D.T. report to come later.

(A penetrant testing N.D.T. will be completed later on discharge ring on rough and final cut.)

f. Pressure Test. The contractor used the following equipment.

The mixing head of the injection equipment was disconnected, and the two-adhesive component delivery lines was attached to the pressure check device. The pressure check device was two independent valve nozzles capable of controlling flow rate and pressure by opening or closing the valve. There was a pressure gauge capable of sensing the pressure behind each valve. The valves on the pressure check device was closed and the equipment operated until

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g. Ratio Test.

Contractor used an equipment with mixing head. The injection equipment was disconnected, and the two adhesive components was pumped simultaneously through the ratio check device. The ratio check device was consisting of two independent valve nozzles capable of controlling back pressure by opening or closing the valve. There was a pressure gauge capable of sensing the back pressure behind each valve. The discharge pressure was adjusted to 100 psi for both adhesive components. Both adhesive components were simultaneously discharged into separate calibrated containers. The amounts discharged into the calibrated containers simultaneously during the same period was compared to determine that the volumes and ratio conform to the manufacturer's recommendations for the applicable material. The ratio test was run for each injection unit at the beginning of each period of operation but not exceeding 4-hour intervals.

4.0 VARIANCE / NCR

Section 03 64 23.00

PARA 3.5 f) Pressure test

The valves on the pressure check device shall be closed and the equipment operated until the gauge pressure on each line reads 160 psi. The pumps shall be stop and the gauge pressure shall not drop below 150 psi within 3 minutes.

The pressure used by contractor was 105 psi. The contractor used the available plant compressed air at 105 psi and this pressure test requirement is out of approved Lily injection pump operation range of 60-120 psi per manufacturer, see submittal

03 64.23.00-4 (item 2). This situation was discussed with GQAR in the field.

5.0 CLIN 0082AA & 0082AB

The report in Appendix A present cycle refill information.

Total of 2408 cycle was done by contractor.

54 cycle = 1 gallon at 2:1 ratio Contractor did 2408 cycle / 54 cycle par gallon = 44.4926 gallons 1 gallon = 0.13 cubic feet

44.4926 gallons = 5.9478 cubic feet

Contractor satisfied base scope for CLIN 0082AA Contractor has received one unit of CLIN 0082AB through letter C-0038

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Appendix A

Site record sheet

WG1 WG2 WG3 WG4 WG5 WG6 WG7 WG8 WG9 WG10 WG11 WG12

0.000 0.010 0.130 0.540 6.553 8.245 0.187 0.745 0.523 1.225 0.248 0.050

0.250 0.260 0.568 0.228 0.178 0.245 0.000 0.120 0.148 0.475 0.248 0.488

0.470 0.295 0.770 1.050 0.850 0.640 0.393 0.168 0.373 0.348 0.308 0.205

0.408 0.420 0.458 0.988 0.475 0.328 0.205 0.418 0.310 0.285 0.433 0.455

WG13 WG14 WG15 WG16 WG17 WG18 WG19 WG20 WG21 WG22 WG23 WG24

5.475 4.3725 8.6575 0.7625 1.9575 0.5475 9.715 0.035 0.455 0.275 0.405 8.795

0.4125 0.1225 0.0325 0.2625 0.7075 0.2975 0.5275 0.035 0.0175 0.2125 0.3425 0.4825

0.1325 0.245 0.405 10.51 11.87 0.405 2.6325 0.655 0.22 6.855 5.475 0.2325

0.57 0.3075 0.9675 0.51 0.37 0.28 0.445 0.4325 0.345 0.48 0.6 0.4825

Steeve Cossette 5/18/2020

Joseph Van Deusen (present)

HOLE 2 ≈ gap

HOLE 3 ≈ gap

HOLE 1 ≈ gap

HOLE 1 ≈ gap

HOLE 2 ≈ gap

HOLE 3 ≈ gap

HOLE 4 ≈ gap

HOLE 4 ≈ gap

Void Water Filling (green color only communicate all together )

N° H1039500 MEI 52-200 F DC-17

DOCUMENT TECHNIQUE

TECHNICAL DOCUMENT

Titre / Title NOTIFICATION OF EXCAVATED VOLUME MEASURED

Édition / Issue Octobre 2019 /October 2019 Rév. / Rev. - Date 2019.10.08 Par / By D. Auger-Habel

A 2020.01.16 D. Elwood

B 2020.02.28 D. Elwood

Contrat / Contract N°: 158400 CLIENT : U.S. Army Corps of Engineers

Réf. / Ref. N° : SECTION 48 13 13.08, PARA 3.4.2 ITEM 19

Projet / Project : OLD HICKORY POWERHOUSE

TURBINE - GENERATOR UNIT #4 REHABILITATION

Préparé ou révisé par / Prepared or revised by

David Elwood, PE

Revu et approuvé par / Reviewed and approved by

Ron Cunningham

Secteur responsable / Responsible Department Hydro Products, Engineering Department

DISTRIBUTION (CODE)

Copie non contrôlée / Uncontrolled copy Client I, O

X Copie contrôlée / Controlled copy

N° : H1039500 MEI 52-200 F DC-17

Cont. N° : 158400

Rev. :

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Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

TABLE OF CONTENTS

1.0 SCOPE

2.0 REFERENCES

3.0 VOLUME MEASUREMENT

4.0 CONCLUSION AND SUMMARY OF RECOMMENDATION

APPENDIX A: DISCHARGE RING SURFACE PICTURES

APPENDIX B: SURFACE MAPPING

APPENDIX C: DISCHARGE RING STIFFNER CRACK MT REPORT

APPENDIX D: DISCHARE RING TO BOTTOM RING TRANSITION PICTURES

APPENDIX E: DISCHARGE RING TO BOTTOM RING TRANSITION MT REPORT

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Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

1.0 SCOPE

This document presents the discharge ring excavated volume measurement. The measurement is performed at 3 different steps:

Initial Revision: Measurement of expected volume before excavation. October 10th, 2019 Revision A: Measurement of excavated volume after excavation and lower stiffener crack repair. Around end of December 2019.

Revision B: Measurement of excavated volume after excavation, lower stiffener crack repair, and upper stiffener crack repair. Around the end of January 2020.

The volume reported includes the mass of welding to be deposited by hand to repair the discharge ring under CLIN item 0080 before automated welding can start.

2.0 REFERENCES

H1039500 MEI 52-200 F DC-03 DISCHARGE RING REHABILITATION

H1039500 MEI 52-200 F DC-07 PROCEDURE FOR DETERMINING EXCAVATED VOLUME

H1039500 MEI 52-200 F DC-15 DISCHARGE RING DIAMETER -EXTRA SCOPE 1/8’’ MACHINING DONE

H1039500 MEI 52-200 F DC-18 WELD CRACKS DISCHARGE RING

3.0 VOLUME MEASUREMENT

Discharge ring wall was visually inspected for defect requiring manual repair before starting automatic welding.

To ensure high quality automated welding, the surface must be free from rust, stainless steel, cracks and porosities above 1/16’’ diameter.

The excavation requirement was established jointly between Matthew Johnston, Alstom mechanical supervisor, David Auger-Habel, Alstom mechanical engineer and Joseph Van Deusen, USACE quality representative between October 3rd and 5th, 2019.

To precisely locate and identify the defects, the mapping subdivided the wall surface in 192 sub areas. The stiffeners and wicket gates created 48 vertical divisions. The top & bottom of the 48’’ machined area, the blade centerline, the top & bottom of the 14’’X1/4’’ machined area (as recommended in H1039500 MEI 52-200 F DC-15 DISCHARGE RING DIAMETER -EXTRA SCOPE 1/8’’ MACHINING DONE PARAG 3.1) formed 4 horizontal divisions.

All the defects to be excavated were marked directly on the wall then mapped in an excel spreadsheet.

Each small defect considered an excavation of 1’’X1’’X1/8’’. Areas gathering large number of small defects considered complete excavation of the damaged area.

For each sub area, the surface and depth to be excavated was recorded. The size of the damage surface within the subarea was noted (For example 17X2 for a volume of 17’’X2’’X1/8’’). The number of defect 1’’X1’’X1/8’’ was noted (For example: 5D for 5 defects). The 2 opened discharge ring joints at stiffener 6 and 18 require a weld of ½’’ deep on 108’’ long to seal the joint ensuring quality weld and tightness for epoxy injection.

The excel spreadsheet was used to calculate the excavation volume from the area and depth as per approved calculation method defined under 48 13 13.08 item 23 H1039500 MEI 52-200 F DC-07 PROCEDURE FOR

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DETERMINING EXCAVATED VOLUME. The weld mass was then calculated by multiplying the expected volume by the steel density as per USACE contract 01 22 00.00 CLIN item 80 (0.285 lbs/in3).

Approximation:

All surfaces were recorded to the nearest inch. For example, each horizontal subarea has a width of 17.330’’ but a width of 17’’ was used for the calculation.

All depths were recorded to the nearest 1/8 inch. Over 95% of the defect were considered 1/8’’ deep as a weld pass is commonly considered 1/8’’. Some defects deeper than 1/8’’ were considered 1/4’’ deep for additional precision.

All excavation required to remove remaining stainless steel were estimated to 1/8’’. Although it is impossible to know the exact depth, on average, 1/8’’ should be enough to remove the stainless-steel patches.

A mass of 147 lbs of welding material was calculated. A margin of 2.5% was added, bringing the expected excavation volume to 150 Lbs. This margin of 3 lbs will be used if Alstom needs to excavate a little bit deeper some local defect and will allow to avoid reporting and approval delays.

See appendix A surface mapping.

See appendix B for surface pictures.

After excavating the defects identified in early October 2019, linear indications were uncovered on the lower shelf as documented in H1039500 MEI 52-200 F DC-18. Alstom was directed to excavate the defects to a depth no greater than 3/4” and seal weld prior to beginning the weld overlay. The total length of the linear indications to be repaired on the lower shelf was estimated to be approximately 71” based on MT inspections completed on site.

Assuming a 45-degree excavation on either side of the crack the with of the excavation could be 1.5”. The weld mass was then calculated by multiplying the expected volume by the steel density as per USACE contract 01 22

00.00 CLIN item 80 (0.285 lbs/in3). The estimated mass of the excavation to repair the linear indications was calculated to be:

MLI = L * W * D * 0.285 = (71 * 1.5 * 0.75 * 0.285 = 23 lbs

See appendix C for the MT inspection report used to develop the excavation calculation for the linear indications on the lower shelf.

During the week of January 20, 2020 linear indications we discovered in the weld joint between the discharge ring and the bottom ring while pre-machining prior to weld overlay. These indications appeared to be from lack of fusion during welding similar to the indications discovered at the lower shelf. An MT inspection indicated the length of linear indications was approximately 96”. The linear indications were removed by machining with the boring bar prior over a width of approximately 1” and to a depth of 0.25” prior to automatic weld overlay. The estimated mass of the excavation to repair the linear indications was calculated to be:

MLI = L * W * D * 0.285 = 96 * 1 * 0.25 * 0.285 = 7 lbs

See appendix D for pictures from the MT inspection used to develop the excavation calculation for the linear indications at the joint between the discharge ring and the bottom ring.