W912P522R0003 RTA TSpecs AppB-13.pdf

N° : H1039500 MEI 52-200 F DC-17

Cont. N° : 158400

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Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

4.0 MASS OF WELD USED

Alstom purchased six (6) 33-lb spools of welding wire for the repair of the discharge ring prior to beginning the weld overlay. The welders used five complete spools of wire and approximately 3/4 of the sixth spool to complete the weld repairs. Assuming the weight of the plastic spools can be neglected the total weight of steel welding wire used to complete the repairs was approximately 190 lbs.

5.0 CONCLUSION AND SUMMARY OF RECOMMENDATION

The quantity of weld metal required to excavated volume was estimated to be 180 lbs and the total weight of wire used to complete the repairs was approximately 190 pounds.

Alstom and the USACE agreed that the lesser of the estimated and actual quantity of weld metal required for the base metal spot repairs shall be used as the basis for payment. The base scope CLIN 0080A will be used for the first 100 lbs of weld and extra scope CLIN 0080B will be used for the additional 80 lbs of weld. Alstom requests that the USACE acknowledge the quantities to be associated with CLIN 0080A and 0080B.

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APPENDIX A

Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURE

APPENDIX A

Discharge ring surface pictures

NOTE; ALL PHOTOS IN THIS REPORT SHOW A RUSTY COLLORED ZONE. THIS WAS TESTED

WITH COPPER SULFATE TO CONFIRM STAINLESS STEEL LOCATIONS

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Figure 1 DSCN 6933 SURFACE CONDITION NOTED

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Figure 2 DSCN 6936 SURFACE CONDITION NOTED

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Figure 3 DSCN 6937 SURFACE CONDITION NOTED

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Figure 4 DSCN 6938 SURFACE CONDITION NOTED

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Figure 5 DSCN 6939 SURFACE CONDITION NOTED

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Figure 6 DSCN 6940 SURFACE CONDITION NOTED

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Figure 7 DSCN 6941 WG 6 TO WG 7. NOTE SEAM IN PHOTO SURFACE CONDITION NOTED

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Figure 8 DSCN 6942 SURFACE CONDITION NOTED

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Figure 9 DSCN 6943 SURFACE CONDITION NOTED

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Figure 10 DSCN 6945 SURFACE CONDITION NOTED

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Figure 11 DSCN 6946 SURFACE CONDITION NOTED

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Figure 12 DSCN 6947 SURFACE CONDITION NOTED

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Figure 13 DSCN 6948 SURFACE CONDITION NOTED

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Figure 14 DSCN6949 SURFACE CONDITION NOTED

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Figure 15 DSCN6950 SURFACE CONDITION NOTED

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Figure 16 DSCN6951 SURFACE CONDITION NOTED

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Figure 17 DSCN6952 SURFACE CONDITION NOTED

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Figure 18 DSCN6953 SURFACE CONDITION NOTED

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Figure 19 DSCN6955 SURFACE CONDITION NOTED

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Figure 20 DSCN6957 SURFACE CONDITION NOTED

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Figure 21 DSCN6958 SURFACE CONDITION NOTED

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Figure 22 DSCN6989 SURFACE CONDITION NOTED

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Figure 23 DSCN6992 SURFACE CONDITION NOTED, SHINY AREAS ARE IN 14INCH RUSTY BAND ARE SST.

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APPENDIX B

Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURE

APPENDIX B

Surface Mapping (Oct 5th, 2019)

U ps tr ea m La nd sid e De gr ee s f ro m U

S

3, 7, ,2

,7

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The spreadsheet is very large and so has been separated in 4 sections. The Excel version of this has been included with the submittal for additional documentation for the USACE to confirm calculations.

WG1

tr ea m Do w ns tr ea m De gr ee s f ro m U

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W G6

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Bo tt om o f m ac hi ne d zo ne 48

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S1

W G1

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Ar c le ng th

El ev at io n fr om B

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W id th

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0, 1, 0, 4, O rig in al jo in t S is op en .R ec om m en d V w el d 1' w id e

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2' ' d ee p

X

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(fr om b ot to m ri ng to dr af t t ub e)

Bo tt om o f m ac hi ne d zo ne

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4'

-3

Bo tt om o f m ac hi ne d zo ne 48

-3

Bl ad e ce nt er lin e

,3

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,3

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To p of m ac hi ne d zo ne

8'

,3

,3

To p of m ac hi ne d zo ne

''X

1/ 4'

-1 tr ea m De gr ee s f ro m U

S

3, 7, 1, 8, 2, 6, 3, 7, 1, 8, 2, 6, 3, 7, 1, 8, 2, 6, An gu la r r ef er en ce

S1

W G2

S2

W

G2

S2

W G2

S2

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G2

S2

W G2

S2

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G1 Ar c le ng th

El ev at io n fr om B

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W id th

He ig ht W id th

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2, 4, 4, 4, 4, 4, 1 9

,6

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0, 0, 0, 0, 0, 0, 0, 1, 0, 1, 0, 0, 0, 3, ,6

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Bo tt om o f m ac hi ne d zo ne

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Bo tt om o f m ac hi ne d zo ne 48

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Bl ad e ce nt er lin e

To p of m ac hi ne d zo ne

8'

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,3

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To p of m ac hi ne d zo ne

''X

1/ 4'

-1

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APPENDIX C

Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

APPENDIX C

MT Inspection Report for Lower Shelf

Magnetic Particle Test Report (MT) Page 1 of 1

Previous REV Date: 07/7/09 QFE Magnetic Particle Test Report-2 Current REV Date: 01/18/17 P:\Clients\General Electric M00411\MT 2019-12-16 CAT-64182 PO 4101777176 W912P5-17-C-0002 Defect 1 - 9.docx

Client General Electric NDE Procedure No. WTI-MT-5-15 Rev 1

Project Old Hickory Unit 4 Exam Date 12-16-2019

Project ID No. W912P5-17-C-0002 / PO# 4101777176 WTI Client ID M00411

Location Hendersonville TN WTI Lab No. NA

Acceptance Standards ASME Sec.VIII Div. 1 App. 6 NDE Specifications ASME Sec. V Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Welding Process

A cc ep t

R ej ec t

Draft Tube 6” band 360degrees

Defect # 1 W3 x crack 1.5” long

Defect # 2 W4 x crack 5” long

Defect # 3 W5 x crack 15.25” long

Defect # 4 W6 x crack 6.5” long

Defect # 5 W8 x crack 25.75” long

Defect # 6 W10 x crack 3” long

Defect # 7 W14 x crack 4.75” long

Defect # 8 W23 x crack 1.5” long

Defect # 9 W23 x crack 7.5” long

Equipment and Technique Details

MT Equipment DS 400 SN 22819 Magnetic Field Direction Circular X Longitudinal

Type of Current X A/C D/C Material Type CS

Magnetic Particles X Visible Fluorescent Material Thickness VARIOUS

Wet X Dry Lighting Equipment FLUXPRO 017

Particle Manufacturer MAGNA FLUX 8A Lifting Power Verified X

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 Field Services Manager Catalog No. 64182

Name / NDT Level Signature Name Signature Typed By LS

Marshall Ruth / II Michael Piercey

Date Date

12-16-19 12-17-2019

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APPENDIX D

Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

APPENDIX D

Photographs of MT Indications at Joint between Discharge Ring and Bottom Ring

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APPENDIX D

Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

Figure D-1: MT Indications in the Welded Joint Between the Discharge Ring and Bottom Ring – 1/24/2020

Figure D-2: Close-up of Indication #1 – 1/24/2020

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Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

Figure D-3: Close-up of Indications #2 and #3 – 1/24/2020

Figure D-4: Close-up of Indication #4 – 1/24/2020

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Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

Figure D-5: Close-up of Indication #5 – 1/24/2020

Figure D-6: Close-up of Indication #6 – 1/24/2020

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Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

Figure D-7: Close-up of Indications #8, #9, and #10 – 1/24/2020

Figure D-8: Close-up of Indication #11 – 1/24/2020

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Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

Figure D-9: Close-up of Indication #12 – 1/24/2020

Figure D-10: Close-up of Indication #13 – 1/24/2020

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Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

Figure D-11: Close-up of Indication #14 – 1/24/2020

Figure D-12: Close-up of Indication #15 – 1/24/2020

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Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

Figure D-13: Close-up of Indication #16 – 1/24/2020

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APPENDIX E

Titre / Title : NOTIFICATION OF EXCAVATED VOLUME MEASURED

APPENDIX E

MT Inspection Report for Indications at Joint between Discharge Ring and Bottom Ring

Magnetic Particle Test Report (MT) Page 1 of 1

Previous REV Date: 07/7/09 QFE Magnetic Particle Test Report-2 Current REV Date: 01/18/17 P:\Clients\General Electric M00411\MT 2020-01-24 CAT-64671 PO 4101777076 EHN-000647-01NO Old Hickory Unit 4 1-15.docx

Client General Electric NDE Procedure No. WTI-MT-1.1-15 Rev 0

Project Old Hickory Unit 4 Exam Date 01-24-2020

Project ID No. EHN-000647-01NO / PO#4101777076 WTI Client ID M00411

Location Hendersonville, TN WTI Lab No. N/A

Acceptance Standards ASME Sec.VIII Div. 1 App. 6 NDE Specifications ASME Sec. V Examination Results

Piece ID Area

Result

Discontinuity Comments Welder

ID

Welding Process

A cc ep t

R ej ec t

Discharge Ring Upper Shelf Transition

Indication # 1 ALL X LOF

Indication # 2 ALL X LOF

Indication # 3 ALL X LOF

Indication # 4 ALL X LOF

Indication # 5 ALL X LOF

Indication # 6 ALL X LOF

Indication # 7 ALL X LOF

Indication # 8 ALL X LOF

Indication # 9 ALL X LOF

Indication # 10 ALL X LOF

Indication # 11 ALL X LOF

Indication # 12 ALL X LOF

Indication # 13 ALL X LOF

Indication # 14 ALL X LOF

Indication # 15 ALL X LOF

Equipment and Technique Details

MT Equipment PARKER DA 400 22819 Magnetic Field Direction Circular X Longitudinal

Type of Current X A/C D/C Material Type CS

Magnetic Particles X Visible Fluorescent Material Thickness VARIOUS

Wet X Dry Lighting Equipment LUXPRO 017

Particle Manufacturer MAGNAFLUX Lifting Power Verified X

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 Field Services Manager Catalog No. 64671

Name / NDT Level Signature Name Signature Typed By LS

Marshall Ruth / II Michael Piercey

Date Date

01-24-2020 01-28-2020

PHOTO 1/PHOTO 2

DIRECTIVE D'INGÉNIERIE

ENGINEERING INSTRUCTION

DI N°: H1039500 MEI52-210F BH-01

Rev.: B

Contract N°: 1584

Émis par/ Issued by: Clayton Santos Date: January 06th 2020

Approuvé par/ Approved by: Date:

Ce document est la propriété de GE Énergies Renouvelables. Il ne peut être reproduit, ni communiqué à des tiers sans autorisation.

© 2019 Compagnie General Electric. Propriétaire. Tous droits réservés. GE – Information Confidentielle – Distribution autorisée seulement pour les personnes intéressées.

This document is the property of GE Renewable Energy. It may not be reproduced or transmitted to others without authorization.

© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

Page 1/ 4

H N

-D I-

2- N

-T -0

R év . B

Nom du Projet / Project's Name:

OLD HICKORY – UNIT 4 REHABILITATION

Nom / Title: N° OTP / WBS Number:

DISCHARGE RING TRANSITION REWORK PROCEDURE -

Référence / Reference: Unité / Unit:

- #4

DISTRIBUTION

ID SERVICE ID SERVICE

E ☐ Atelier Usinage Machine Shop M ☒

Montage Site Erection

G

PQP Équipes Projet PQL Project Teams N ☐

Chef de chantier Chief Erector

PQF (Pilote Qualité Fournisseur) SQL (Supplier Quality Leader) S ☒

Directeur de projet Project Director

K ☐ Atelier Enroulement Winding Shop W ☒

Représentant Client Customer Representative

L ☐ Réquisition de matériel (GDT) Request for MateriaL (TDM) ☒

Sous-Traitant Subcontractor :

Client Customer ☐

Autres/ Others :

➢ Changed minimum and maximum height of pre-machining of upper transition;

➢ Included Peening process in item 3.2.2;

➢ Changed value of pre-machining radius for upper transition in item 2A of Appendix A;

➢ Changed value of weld for upper transition in item 3A of Appendix A;

➢ Included reference value of weld for lower transition in item 3B of Appendix A;

➢ Included item 3C in Appendix A;

➢ Changed value of 0.25” in items 4 and 5 of Appendix A;

Rev. A

Ce document est la propriété de GE Énergies Renouvelables. Il ne peut être reproduit, ni communiqué à des tiers sans autorisation.

© 2019 Compagnie General Electric. Propriétaire. Tous droits réservés. GE – Information Confidentielle – Distribution autorisée seulement pour les personnes intéressées.

This document is the property of GE Renewable Energy. It may not be reproduced or transmitted to others without authorization.

© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

Page 2/ 6

1.0 DESCRIPTION

This document provides instructions for site machining and overlay welding that need to be done on the discharge ring transition zones, for Old Hickory unit #4. Take note that most of welding to be done in the transition zone must take place, before final machining starts on the discharge ring. It will be acceptable to weld in these areas after and during machining, but not extensively. The reason is that we want to make sure no void will be created behind the discharge ring after injection.

Welding shall be done in transition zones (as for the 48’’ standard reparation zone with stainless steel) in order to minimize deformations. Welding methods shall use welding sequences and technics to minimise these deformations as per past experiences and shall avoid welding all at once in one area (spread welding equally).

Peening is requested for the transition zones as it is also for the 48’’ reparation zone.

Sketches have been provided to show the work to be done in transition zones. These sketches are accurate for they are based on dimensions collected at site. Nevertheless, Alstom site specialist may slightly modify them to adapt to any unforeseen variation and to optimise the work, minimizing welding and machining to be done when possible. Transition zones shall extend on 12’’ length minimum (including the grinding zone) both over and below the 48’’ reparation zone, as presented in sketches. The work shall also be done in order to avoid removing more material than what has been shown on sketches. The goals remain to minimize material removal on existing components and respect the undulation criteria. Final dimensions shall be recorded and provide to engineering in view of as build drawings’’.

2.0 REFERENCE DOCUMENTS

NUMBER DESCRIPTION

H1039500MEI52-200FDC-03 DISCHARGE RING REHABILITATION

H1039500MEI26-211FTB DISCHARGE RING - TEMPLATE

39115 (OEM DRAWING) DETAILS OF DISCHARGE RING

Ce document est la propriété de GE Énergies Renouvelables. Il ne peut être reproduit, ni communiqué à des tiers sans autorisation.

© 2019 Compagnie General Electric. Propriétaire. Tous droits réservés. GE – Information Confidentielle – Distribution autorisée seulement pour les personnes intéressées.

This document is the property of GE Renewable Energy. It may not be reproduced or transmitted to others without authorization.

© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

Page 3/ 6

3.0 REPAIR OF TRANSITION ZONES

3.1 IDENTIFICATION OF THE DISCHARGE RING TRANSITION ZONES

The transition zones to be repaired correspond to the areas above and below the discharge ring basic repair zone (48 inches), as shown in Appendix A, item 1.

Being:

START OF UPPER TRANSITION ZONE: RUNNER CENTERLINE ELEVATION + 12 INCHES;

START OF LOWER TRANSITION ZONE: RUNNER CENTERLINE ELEVATION - 36 INCHES;

3.2 TRANSITION ZONES (GENERAL WORK DESCRIPTION)

All welding done for the transition zones shall proceed with steel. But if Alstom site manager thinks it is necessary or preferable to weld with stainless steel on some area, he can elect to do so. Before welding, Alstom site manager shall make sure that no stainless-steel welding is present on the transition zone. Based on existing original drawing, no stainless steel should be present in these areas, but this point must be validated. If any doubt subsite regarding the presence of stainless steel advise the engineering. The work to be done will then be clarified with the government. We need to remove this material to steel metal, and weld using steel. Over costs and delay shall remain the responsibility of the government.

No welding with steel must be done on stainless-steel at any time. This is also applicable for the junction between the transition zones and the contractual 48’’ stainless steel overlay added on the discharge ring. This implies that steel must be welded first on the transition zone at the junction. Else, the junction with steel shall be welded last, using stainless steel according illustrated In Appendix A, item 3C. All welding shall be done with approved and qualified welding procedures.

As the center of the unit has been shifted of 0,25’’ and as the existing discharged ring is no longer round, the existing distribution of material all around the transition zones will be unequal. On one side of the transition zone, the existing inside radius is smaller while on the opposite side, this same diameter is bigger than the expected final inside diameter of the repaired discharged ring area of 48’’.

To adjust the actual condition of the transition zones, we will machine its inside diameter, using the new unit center.

Machining will be done to a minimum to make the inside diameter uniform all around. For the upper transition zone, machining will be cylindrical and should barely touch on one side on a length of about 9’’ but will extend up to about 14.5’’ on the other side as shown in Appendix A, item 2A. For the lower transition, machining shall proceed on about 9’’. This machining will follow as well as possible the existing profile of the discharge ring on one side, removing almost nothing on this side. In Appendix A, item 2B shows this machining on the side, where most material will be removed. The machining radius of 106.925’’ is only indicative and shall be adapted to minimize material removal. After machining, inspect the area to make sure no crack or important defects are present. Advise if any defect is found.

After machining on the transition zones, welding will be performed. A uniform layer of steel shall be deposited all around for both transition zones. Welding will partly rebuild what has been removed on one side of the transition zone (where most material was removed during machining) and will add new material on the other side (where no material or almost none was removed during machining) to make this surface even thicker than what it was originally. This is illustrated in Appendix A, items 3A and 3B. Sketches do show some rather rectangular welding area, but the ideal would be to weld ‘’taper’’ area to minimize welding and deformation. Alstom site manager will look at the thing to optimize in accordance with the equipment available.

Rev. A

Rev. A

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Page 4/ 6

After welding, the profile on the transition zones shall be machined all around to obtain a uniform circular profile and to obtain smooth transitions with the existing surfaces. This machining will be done with the same unit center and the last cut on transition surfaces should be done at the same time as the last cut done on the 48’’ reparation zone.

For the upper transition zone, machining should be all around on about 9” and should proceed further up to about 16’’ maximum but machining will then finish only on one side, always with the same center. This is illustrated in Appendix A, items 4A and 5A. For the lower transition zone, machining should also be all around on about 9’’ and should then proceed further up to about 15’’ maximum but as for the upper transition zone, machining for this last portion will finish touching only on one side. This is shown in Appendix A, items 4B and 5B. The idea is to remove as little material as possible and to machine these areas in continuity with the reparation zone of 48’’ and to match the profiles with the existing profiles in order to smooth al transition and to respect the waviness profile.

After machining some local grinding will be needed to smooth the edges left by machining. The goal is simply to respect the undulation criteria as detailed in the following sections.

3.2.1 PRE-MACHINING OF EXISTING MATERIAL IN TRANSITION ZONES

As explained in section 3.2, machining shall be extended in the transition zones over and under the discharge ring repaired area of 48’’. The center to be used for this machining is the new unit center.

• For the upper transition, machining shall be performed to the dimensions given in Appendix A, item 2A. As machining progresses, much material will be removed on one side to a minimum and ideally to nothing on the other side. This machining we will produce an equal cylindrical section over 9’’ and will finish touching at one point on one side only at about 14.5”.

• For the lower transition, machining shall be performed to the dimensions given in Appendix A, item 2B. Like the upper transition, much material will be removed on one side but almost nothing on the other side.

Machining should touch all around on about 9’’ and should follow as close as possible, the minimum profile existing on the side where nothing or almost nothing will be removed. Between 9’’ and 15’’, machining will be vertical and will touch only on one side and will come to nothing.

Ce document est la propriété de GE Énergies Renouvelables. Il ne peut être reproduit, ni communiqué à des tiers sans autorisation.

© 2019 Compagnie General Electric. Propriétaire. Tous droits réservés. GE – Information Confidentielle – Distribution autorisée seulement pour les personnes intéressées.

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© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

Page 5/ 6

3.2.2 WELDING OVERLAY IN TRANSITION ZONES

After machining in the transition zone, we need to weld overlay for both transition zones. Welding will provide the material needed for the final machining to be performed on the transition zone, which machining shall allow to match surfaces with a continuous profile.

• Before welding, make sure the surface to be welded was inspected and that all defects were reported and corrected.

• A conical weld layer shall be welded according to the dimensions shown in Appendix A, item 3A for the upper transition zone and according to Appendix A, item 3B for the lower transition. This weld will be uniform all around and will be remove the step between the transition zone and the 48’’ stainless-steel overlay repair zone. Alstom site manager need to make sure that we can machine according explained in item 3.2.3 bellow.

• Peening is also required for each layer of weld except the first and the last layers. For peening, a rotary impact tool is acceptable, but not an impact drill. Overlapping beads are also important. Before adding a layer to the welds, a visual inspection shall take place to make sure defects are eliminated before welding the subsequent layer.

• After welding, we will have material all around and no step with the 48’’ reparation area. This will allow machining to match the transition zone properly with the reparation area and with the existing profiles over and below this area.

3.2.3 MACHINING OF TRANSITIONS ZONES AFTER WELDING

After welding, machining will be performed both for the upper and lower transitions zones as shown in Appendix A, items 4 and 5. The unit center shall be used to center the machine tool.

• Machining will be done in continuity with the 48’’ stainless steel over lay reparation zone and to match the existing profile as well as possible. For the welded portion of the transition zone, we will have an equal amount of material removed by machining all around, but when this portion will be machined, as we proceed, machining will progressively take place only on one side. In Appendix A, item 4A shows the top transition zone where we will remove more material (see also Appendix A, item 3A where this machining was also illustrated). In Appendix A, item 5A shows the same top transition, but for the location where we will remove less material. The idea is to remove as little material as possible and to match surfaces. A tapered section will be machined, starting 0,50’’ over the stainless-steel repair zone and decreasing progressively to zero thickness.

• For the lower transition zone, we will use the same method. In Appendix A, item 4B shows where we will remove most material. We will start in continuity with the discharge ring hydraulic profile and remove as little material as possible up to about 9’’. At this location, we will no longer remove material all around, but we will start removing no material on one side and progressively come to nothing at about 15’’ where we will theoretically remove material at only one point (see also Appendix A, item 3B where this machining was also illustrated). In Appendix A, item 5B shows the same machining, but on the side where less material will be removed.

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© 2019 Compagnie General Electric. Propriétaire. Tous droits réservés. GE – Information Confidentielle – Distribution autorisée seulement pour les personnes intéressées.

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Page 6/ 6

3.2.4 GRINDING

After machining, we will need to make sure we have no abrupt change of direction all along the machined edges of the transition zones. To do so, grind the edge left by the machining tool at the limit of the machined area. In no circumstance should this grinding be extended to touch the discharged ring 48’’ stainless steel repaired area.

• Grinding shall be done in order to avoid a too sharp transition between the machined area and the existing

(un-machined) material. This can be controlled with a flexible stick to obtain a smooth surface in accordance with the waviness requirement criteria as described in section 3.3

• Grinding shall be done in order to match the minimum distance of 12.000” according showing in Appendix A, items 5A and 5B.

• Inspect the machined area, making sure there is no defect. If some defect is discovered, they shall be reported.

3.3 WAVINESS REQUIREMENTS

After repairing the areas, control the waviness using a flexible stick. This control shall be done in all directions (vertical or horizontal). Following the criteria below:

Waviness = X / U = 0.015” / 1”

3.4 TEMPLATE TO CONTROL DISCHARGE RING PROFILE

The existing template (H1039500MEI26-211FTB) was fabricated the match the original theoretical discharge ring profile, including the upper and lower transition zones. As the center of the unit was modified and as deformations did take place over the years, this template will therefore not match the new discharge ring profile apart for the 48’’ reparation area.

Alstom will need to modify the existing template after an agreement with the government, to make sure it can be used to control the profile.

For transition zones, the minimal material remove is the target and controls should be done using a flexible stick as indicated in item 3.3 of this document, to avoid sharp discontinuities.

Ce document est la propriété de GE Énergies Renouvelables. Il ne peut être reproduit, ni communiqué à des tiers sans autorisation.

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© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

APPENDIX A

TRANSITION ZONES REWORK

(10 Pages including this one)

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1) IDENTIFICATION OF ZONES TO BE REPAIRED (SECTION VIEW)

UPPER TRANSITION

LOWER TRANSITION

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© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

2) PRE-MACHINING OF EXISTING MATERIAL IN TRANSITION ZONES

2A - UPPER TRANSITION

Re v.

A

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2B - LOWER TRANSITION

Ce document est la propriété de GE Énergies Renouvelables. Il ne peut être reproduit, ni communiqué à des tiers sans autorisation.

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© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

3) WELDING OVERLAY IN TRANSITION ZONES

3A - UPPER TRANSITION

Rev. A

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This document is the property of GE Renewable Energy. It may not be reproduced or transmitted to others without authorization.

© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

3B - LOWER TRANSITION

Ce document est la propriété de GE Énergies Renouvelables. Il ne peut être reproduit, ni communiqué à des tiers sans autorisation.

© 2019 Compagnie General Electric. Propriétaire. Tous droits réservés. GE – Information Confidentielle – Distribution autorisée seulement pour les personnes intéressées.

This document is the property of GE Renewable Energy. It may not be reproduced or transmitted to others without authorization.

© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

UPPER TRANSITION

LOWER TRANSITION

3C - WELD AT JUNCTION BETWEEN THE TRANSITION ZONES AND THE BASIC REPAIR ZONE

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© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

4) MACHINING IN TRANSITION AREAS WHICH ARE ON A SMALLER DIAMETER THAN THE FINAL DISCHARGE RING DIAMETER

4A - UPPER TRANSITION

Re v.

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© 2019 Compagnie General Electric. Propriétaire. Tous droits réservés. GE – Information Confidentielle – Distribution autorisée seulement pour les personnes intéressées.

This document is the property of GE Renewable Energy. It may not be reproduced or transmitted to others without authorization.

© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

4B - LOWER TRANSITION

Re

Ce document est la propriété de GE Énergies Renouvelables. Il ne peut être reproduit, ni communiqué à des tiers sans autorisation.

© 2019 Compagnie General Electric. Propriétaire. Tous droits réservés. GE – Information Confidentielle – Distribution autorisée seulement pour les personnes intéressées.

This document is the property of GE Renewable Energy. It may not be reproduced or transmitted to others without authorization.

© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

5) MACHINING IN TRANSITION AREAS WHICH ARE ON A LARGER DIAMETER THAN THE FINAL DISCHARGE RING DIAMETER

5A - UPPER TRANSITION

Re

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This document is the property of GE Renewable Energy. It may not be reproduced or transmitted to others without authorization.

© 2019 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

5B - LOWER TRANSITION

Re

N° H1039500 MEI 52-200 F DC-18

DOCUMENT TECHNIQUE

TECHNICAL DOCUMENT

Titre / Title WELD CRACKS DISCHARGE RING

Édition / Issue Novembre 2019 /November 2019 Rév. / Rev. - Date 2019.11.20 Par / By M. Doyon

A 2019.12.03 M. Doyon

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

Réf. / Ref. N° : SECTION 48 13 13.08, PARA 3.2.9 ITEM 6

Projet / Project : OLD HICKORY POWERHOUSE

TURBINE - GENERATOR UNIT #4 REHABILITATION

Préparé ou révisé par / Prepared or revised by

Michel Doyon

Revu et approuvé par / Reviewed and approved by

David Elwood

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-18

Rev. : A

DOCUMENT TECHNIQUE Date : 2019.12.03

TECHNICAL DOCUMENT Page : i / i

Titre / Title : WELD CRACKS DISCHARGE RING

TABLE OF CONTENTS

1.0 SCOPE

2.0 REFERENCES

3.0 MACHINING PRIOR TO UT INSPECTION

4.0 PT INSPECTION (NOVEMBER 23 2019)

5.0 UT INSPECTION (NOVEMBER 23 2019)

6.0 WELD VOLUME ESTIMATION FOR REPAIR

7.0 RECOMMENDATION

APPENDIX A: SKETCH PT INSPECTION

APPENDIX B: SKETCH UT INSPECTION

APPENDIX C: WELD DEFECT LOCATION

APPENDIX D: PICTURES OF PT INSPECTION

APPENDIX E: WORLD TESTING UT REPORT

Rev. : A

DOCUMENT TECHNIQUE Date : 2019.12.03

TECHNICAL DOCUMENT Page : 1 / 2

Titre / Title : WELD CRACKS DISCHARGE RING

1.0 SCOPE

This document presents the results of the discharge ring NDT inspection that followed the machining of the surfaces of the discharge ring (CLIN 0079A to C).

2.0 REFERENCES

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

H1039500 MEI 52-200 F DC-14 DISCHARGE RING AND CENTERING OF BORING MACHINE – BASE SCOPE MACHING

DONE

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

ORIGINAL DRAWING 39115-A DETAILS OF DISCHARGE RING

3.0 MACHINING PRIOR TO UT INSPECTION

The discharge ring was machined 0,25” eccentric (CLIN 0079A-C, H1039500 MEI 52-200 F DC-14). Another 1/8” was removed to clean all surface in preparation for the stainless steel overlay welding (CLIN 0079A-C). Then upon seeing remaining stainless steel patches, another 0.25” over a 14” band (CLIN 0079A-C) was machined.

4.0 PT INSPECTION (NOVEMBER 23 2019)

PT inspection was done over the entire circumference of the discharge ring. Cracks were found in the area of wicket gates 5, 7 and 9. See appendix A and D of the report for the location.

5.0 UT INSPECTION (NOVEMBER 23 2019)

UT inspection was done on the discharge ring per section 48 13 13.08 paragraph 3.2.11. As the entire circumference inspection would have been time consuming, it was decided to inspect pockets of approximately 12” long below each of the wicket gates location. See appendix B and E for results. The results show that crack or lack of fusion can be found on approximately 50% of the circumference. The crack or lack of fusion can sometime be found at both the top and bottom fusion faces. The crack/lack of fusion are mainly found in the region encompassing wicket gate 24 to wicket gate 11. The defects are at the middle shelf weld that can be seen on drawing 39115-A in Appendix C.

Rev. : A

DOCUMENT TECHNIQUE Date : 2019.12.03

TECHNICAL DOCUMENT Page : 2 / 2

Titre / Title : WELD CRACKS DISCHARGE RING

6.0 WELD VOLUME ESTIMATION FOR REPAIR

At this stage, it is difficult to estimate the amount of weld required to repair the defects shown in this report. An accurate estimate can be provided once COE and GE reach an agreement on the work to be done

7.0 RECOMMENDATION

GE recommends repairing the weld defects highlighted in this report.

Rev. : A

DOCUMENT TECHNIQUE Date : 2019.12.03

TECHNICAL DOCUMENT Page : APPENDIX

Titre / Title : WELD CRACKS DISCHARGE RING

SKETCH PT INSPECTION

Rev. : A

DOCUMENT TECHNIQUE Date : 2019.12.03

TECHNICAL DOCUMENT Page : APPENDIX

Titre / Title : WELD CRACKS DISCHARGE RING

APPENDIX B

SKETCH UT INSPECTION

Rev. : A

DOCUMENT TECHNIQUE Date : 2019.12.03

TECHNICAL DOCUMENT Page : APPENDIX

Titre / Title : WELD CRACKS DISCHARGE RING

APPENDIX C

WELD DEFECT LOCATION

212487354 Oval

212487354 Line

212487354 Text Box Weld Defect

212487354 Line

212487354 Text Box weld defect

Rev. : A

DOCUMENT TECHNIQUE Date : 2019.12.03

TECHNICAL DOCUMENT Page : APPENDIX

Titre / Title : WELD CRACKS DISCHARGE RING

APPENDIX D

PICTURES OF PT INSPECTION

GE Pics 3 PT Old Hickory Dam Discharge Ring 11-22-19 and 11-23-2019/

GE Pics 4 PT Old Hickory Dam Discharge Ring 11-22-19 and 11-23-2019

GE Pics 5 PT Old Hickory Dam Discharge Ring 11-22-19 and 11-23-19/

GE Pics 6 Old Hickory Dam Discharge Ring 11-22-19 and 11-23-19

Rev. : A

DOCUMENT TECHNIQUE Date : 2019.12.03

TECHNICAL DOCUMENT Page : APPENDIX

Titre / Title : WELD CRACKS DISCHARGE RING

APPENDIX E

WORLD TESTING

UT REPORT

Inspection Report Page 1 of 2

Previous REV Date: 5/21/08 QFE Inspection Report-1 Current REV Date: 10/27/09

72 East Hill Drive 5123 Navy Road Mt. Juliet, TN 37122 Millington, TN 38053

(615) 754-4147 (901) 873-4174

FAX (615) 758-6239 FAX (901) 873-4275

Client

General Electric

1200 Willis Rd.

N Chesterfield, VA 23237

ATTN: Ron Cunningham

Project

Old Hickory Dam

PO H1039500 MKB

Inspection performed at:

10 Powerplant Rd.

Hendersonville, TN

Client No. WTI No. Report No.

PO H1039500 MKB M00411 16

Inspector Report Type

Chris Ennis, CWI X Interim Final

Inspection Date(s) Report Date

11-23-2019 11-26-2019

Other Parties

Enclosures

No

X Yes If “Yes”, how many? Photos

Personnel & Company contacted during inspection

Ron Cunningham – General Electric (509) 713-4133

Description of Item(s) inspected

Discharge Ring Mid Shelf Weld

Client Authorized modifications/clarifications

X No

Yes (Noted in Narrative Report) If “Yes”, by phone? or fax?

Narrative Report of Inspection

Our inspector was at the above noted site to conduct customer informational inspections of the mid shelf discharge ring weld.

The results of that inspection are as follows:

1. Customer informational PT inspection was requested on the mid shelf discharge ring weld in order to better determine cracks and indications connected to the surface. Crack locations noted on the surface were located in windows #5, #7, and

#9. See attached photos.

2. Ultrasonic angle-beam inspection was performed after PT inspection to assist in determining the extent of cracking and lack of fusion not connected to the surface. The results were as follows:

a. Window #1: Lack of fusion/crack noted along top fusion face .750” -1.1” in depth intermittent throughout entire window.

b. Window #2: Lack of fusion/crack noted along top fusion face .500” -.800” in depth intermittent throughout entire window. Crack noted @20” from window #2, 3” in length, 1” in depth.

c. Window #3: Lack of fusion/crack noted along top fusion face .500” - 1” in depth intermittent throughout entire window.

d. Window #4: Lack of fusion/crack noted along top fusion face .700” - 1.4” in depth intermittent throughout entire window.

e. Window #5: Crack noted @17 ½” from window #4, 13” in length along top fusion face .300” - 1.875” in depth. Crack noted @17 ½” from window #4, 13 ½” in length along bottom fusion face 2.3” in depth.

f. Window #6: Crack noted @19” from window #5, 5 ½” in length along top fusion face .181” - .609” in depth. Crack noted @19” from window #5, 6” in length along bottom fusion face .139” – 2.06” in depth.

g. Window #7: Lack of fusion/crack noted along top fusion face .270” - .98” in depth intermittent throughout entire window. Lack of fusion/crack noted along bottom fusion face 0” - 1.8” in depth intermittent throughout entire window and at surface @23 ½” from window #6.

h. Window #8: Lack of fusion/crack noted @2 ½”, 7 ½” in length along top fusion face .280” - 1.25” in depth. Lack of fusion/crack noted @27” from window #7, 8 ½” in length along bottom fusion face .400” - 1.8” in depth.

i. Window #9: Crack noted @0” from window #8, 11” in length along top fusion face surface to 2.1” in depth.

Inspection Report Page 2 of 2

Previous REV Date: 5/21/08 QFE Inspection Report-1 Current REV Date: 10/27/09

72 East Hill Drive 5123 Navy Road Mt. Juliet, TN 37122 Millington, TN 38053

(615) 754-4147 (901) 873-4174

FAX (615) 758-6239 FAX (901) 873-4275

j. Window #10: Crack noted @2” from window #9, 10” in length along top fusion face .150” - 1.3” in depth. Crack noted

@2” from window #9, 10” in length along bottom fusion face .180” - 1” in depth.

k. Window #11: Lack of fusion/crack noted @7” from window #10, 10” in length along top fusion face .500” - 1.25” in depth. Lack of fusion/crack noted @2” from window #10, 10 1/2"” in length along bottom fusion face .175” - 1.3” in depth.

l. Window #12: Was found to have no notable lack of fusion or cracks.

m. Window #13: Was found to have no notable lack of fusion or cracks.

n. Window #14: Crack noted @10” from window #13, 10” in length along top fusion face .165” - .83” in depth.

o. Window #15: Was found to have no notable lack of fusion or cracks.

p. Window #16: Crack noted @18 1/2” from window #15, 1” in length running transverse surface to .3” in depth.

q. Window #17: Was found to have no notable lack of fusion or cracks.

r. Window #18: Was found to have no notable lack of fusion or cracks.

s. Window #19: Was found to have no notable lack of fusion or cracks.

t. Window #20: Was found to have no notable lack of fusion or cracks.

u. Window #21: Was found to have no notable lack of fusion or cracks.

v. Window #22: Was found to have no notable lack of fusion or cracks.

w. Window #23: Was found to have no notable lack of fusion or cracks.

x. Window #24: Crack noted @13” from window #23, 16 1/2” in length along top fusion face .275” - 1.2” in depth.

The results of our inspection were discussed with Mr. Cunningham.

Inspection Criteria used

Customer Information, ASME Section V, ASME Section VIII Div. 1 App.6

Item(s) Inspected (check all that apply) Respectfully submitted, Meets Criteria

Conclusion to Follow (Additional Inspection Required)

Meets Criteria with Authorized Modifications

X Refer to Narrative Report Michael Piercey, Field Services Manager Typed By LS

Does Not Meet Criteria World Testing, Inc. Catalog No. 63834

D R

A W

I N

G

N

O

B

C

D

4 3 2 1

R E

V I S

I O

N S

SIZE D

B

C

D

A

4 3 2 1

DIMENSION

LINEAR

DIAMETRAL

CONCENTRICAL

GEOMETRICAL

FROM

TO

0.015

0.010

>6

0.020

0.015

>20

0.050

0.020

>80

0.080

0.030

>160

0.120

0.040 3/4

3/8

5/8

5/16

>160

1/2

1/4

>80

5/16

3/16

>40

3/16

1/8

>2.000

2.000

1.000

1.000

0.375

DIAMETRAL

LINEAR

DIMENSION

TOL.

>315

Ø0.003 Ø0.005 Ø0.007 Ø0.010 Ø0.015 Ø3/32 Ø3/16 Ø1/4 Ø5/16 Ø3/8

Ø0.020 Ø0.060 Ø0.120

F A

B R

I C

A T

I O

N

0°-10'

0°-20'

0°-30'

3/8

TO

FROM

< 3/8

1°

ANGULAR

DIMENSION

M A

C H

I N

I N

G

CENTER HOLE POSITION

UNDEFINED TOLERANCE

ANGULAR

DIMENSION

SHORTEST SIDE

LENGTH

SHORTEST SIDE

LENGTH

DEGREE AND MINUTEDEGREE AND MINUTE

STRAIGHTNESS

CONCENTRICITY

ROUNDNESS

PERPENDICULARITY

FROM

TO

FROM

TO

FROM

TO

DIA.

OF HOLE

DIA.

OF HOLE

CENTER HOLE POSITION

UNDEFINED TOLERANCE

TOL.

Ø0.015 Ø0.020 Ø0.050 Ø0.080 Ø0.120 Ø1/4 Ø5/16 Ø1/2 Ø3/4 Ø1

MACHINING AND FABRICATION DEVIATIONS FOR UNTOLERANCED DIMENSIONS

INTERPRETATION OF TOLERANCES AS PER ASME Y14.5M

0.375 1

Ø1/16

1°

<2

2° 0-30' 0-20'

Ø1/8 Ø1/4

>2

TO

FROM

ALSTOM Renewable Energy Inc.

Project

DRAWN BY

REVISION

SHEET NO.

of

INI. RELEASE

SCALE

DRAWING NO.

ENG.:

RESERVED ALSTOM

ENG.:

THIRD ANGLE PROJECTION

OLD HICKORY POWERHOUSE

U.S. ARMY CORPS OF ENGINEERS

SUMNER COUNTY, TN

CONTRACT NO. W912P5-17-C-002

TURBINE - GENERATOR UNIT #4 REHABILITATION

DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED

SEE PARTS LIST: H1039500

STATOR CORE

ARRANGEMENT

H1039500 MKB 12-200 F TL

1/4"=1"

2017/06/23

JFJ

F

1 3

H

M

K B

F

T

L

MKB 12-200 F PB-01

DETAIL…