W912P522R0003 RTA TSpecs AppB.pdf

1. PURPOSE Page : 3

2. ASSUMPTIONS Page : 3

2.1 Units Page : 3

2.2 References Page : 3

2.3 Kind of analysis Page : 3

2.4 Criteria Page : 3

2.5 Material Page : 3

2.6 Loading Page : 3

3. TOOLING DIMENSIONING Page : 4

3.1 Threaded rod verification Page : 4

3.2 Washer verification Page : 5

4. CONCLUSION Page : 6

Internal number REV. Page

Customer number (If different)

H1039500 MEI 83-301FED-01

A 2

CONTENTS

1. PURPOSE

2. ASSUMPTIONS

2.1 Units Dimensions: Inch

Force : lbf Stress : psi

2.2 References

(1) Technical specifications : W912P5-17-C-0002 Unit 4 Rehabilitation

(2) Reference drawing : W912P5-16-R-0002

(3) A572/A572M :Standard specification for High-Strengh Low-Alloy Columbium-Vanadium Structural Steel

(4) A354 Quenched and Tempered Alloy Steel Bolfts, Studs, and Other Externally Threaded Fasteners

(5) CM66 rules for calculation of steel constructions

2.3 Kind of analysis

This analysis is performed analytically.

2.4 Criteria

Regarding to the technical agreement we take a worst weighting of :

σadm = Ys / 3 Uts / 5

2.5 Material

At least selected materia is used, his mechanical properties are the following :

Ys Uts

Diameter d Ys Uts

2.6 Loading

210000 kg

Coupling of the turbine shaft line to the generator line is build with 6 rod.

Each rod must take a force equal to : 35000 kg = 77162 lbs

For the rod verification, we assumed a perpendicular load equal to :

20 % of the total tension rod load

Acceleration of gravity : SI 9,81 m/s² Imperial 32,17 ft/s²

Internal number REV. Page

Customer number (If different)

A354 GRADE BD

965 MPa 793 MPa

2 1/2 in < d

140000 psi 115000 psi 2 1/2 in < d

According to ref 2, total jacking system must suppot a weight estimated to 201 tons. Conservatively, we consider a weight of :

50000 psi 65000 psi 448 MPa

345 MPa ASTM 572 Gr 50

Aim of the calculation note is to validate center hole jacking system necessary to coupling turbine shaft to intermediate shaft.

At least, the Maximum unit stresses in shear shall not exceed 60% of the allowable stresses in tension. Conservatively, we consider Von Mises criteria to include this point.

H1039500 MEI 83-301FED-01

A 3

3. TOOLING DIMENSIONING

3.1 Threaded rod verification

Imperial SI 77162 lbf 343233 N 15432 lbf 68647 N

Verification of bolt holding in tension and shear according CM66 :

Imperial SI 4,827 in² 3114 mm²

Verification formulas :

Verification :

Imperial 19983 PSI < 28 000 PSI SI 138 MPa < 193 MPa

Verification formulas :

Verification :

Imperial 16724 PSI < 28 000 PSI SI 115 MPa < 193 MPa

Internal number REV. Page

Customer number (If different)

Shear force : Fs = Axial force : Fa =

A 4

Material : Ma = Stress cross section : As =

A354 GRADE BD

H1039500 MEI 83-301FED-01

red As max t F 1.25 red sA

FcFt

²max36.2²max

3.2 Washer verification

Calculs et vérifications a b r0 t n E r w D L9 C7 ob F7 G9 Mr F4 G6 o Mt 272,105906 10,7128309 Q Q 343 233 N sMr 77 162 lbf sMt τQ

SI Imperial 82 MPa 11890 psi 90 MPa 13000 psi

Calculated stress are lower that the criteria.

Internal number REV. Page

Customer number (If different) σeq = [(σ)²+3{τ}²]^0.5 =

1,70 in

Washer test criteria are taken from Roark's Formulas for Stress and Strain (7th Edition). Section 11.14 page 455.

27,59 N/mm² 56,12 N/mm² 10,49 N/mm² 1261 N/mm 19552,09 (-) 0,0005 rad

0,00 (-) 0,96 (-)

3653,57 (-) 0,00 (-) 0,18 (-)

0,0005 rad 0,27 (-) σadm =

47,63 mm

SI

4002 psi 8140 psi 1521 psi

7203 lbf/in 4395,49 (-) 0,0005 rad

0,00 (-) 0,96 (-)

821,36 (-) 0,00 (-) 0,18 (-)

0,0005 rad 0,27 (-) 0,09 (-)

16266540 lbf.in 7224 lbf/in

1,71 in 30457925 psi

0,30 (-) 1,80 in

0,09 (-) 1837872255 Nmm

1265 N/mm

43,31 mm 210000 N/mm²

0,30 (-) 45,72 mm

1,40 in 1,88 in

Imperial

H1039500 MEI 83-301FED-01

A 5

43,18 mm 35,56 mm

4. CONCLUSION

Center hole jacking system is correctly dimensionned.

Internal number REV. Page

Customer number (If different)

H1039500 MEI 83-301FED-01

A 6

Name : H1039500MEI85-201FTU Rev : A Release : 2017/10/20 09:19 AM

Name : H1039500MEI85-202FTU Rev : A Release : 2017/10/20 09:19 AM

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N° H1039500 MKB 84‐301 F DC‐01

DOCUMENT TECHNIQUE

TECHNICAL DOCUMENT

Titre / Title GENERATOR SHAFT LIFTING DEVICE‐ INSPECTION REPORT

Édition / Issue January 2019 Rév. / Rev. ‐ Date 01.29.2019 Par / By L.Thibault

A 02.07.2019 L.Thibault

B 02.25.2019 L.Thibault

Contrat / Contract N°: W912P5‐17‐C‐0002 CLIENT : U.S. Army Corps of Engineers

Réf. / Ref. N° : SECTION 01 10 10 , item 42

Projet / Project : 1584‐ OLD HICKORY TURBINE‐GENERATOR UNIT 4 REHABILITATION

Préparé ou révisé par / Prepared or revised by

Lynda Thibault

Revu et approuvé par / Reviewed and approved by

Secteur responsable / Responsible Department QA

DISTRIBUTION (CODE)

Copie non contrôlée / Uncontrolled copy Client, M, N, O, S x Copie contrôlée / Controlled copy

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N° : H1039500 MKB 84‐301 F DC‐01

Cont. N° : 158400

Rev. : B

DOCUMENT TECHNIQUE Date : 02.25.2019

Titre / Title : GENERATOR SHAFT LIFTING DEVICE‐ INSPECTION REPORT

1.0 SCOPE

This submittal is the Inspection Report for Generator Shaft Lifting Device, as per drawing H1039500 MKB 84‐301 FTB.

Included in this report are:

‐ Final Inspection Report‐ fabrication ‐ Load Test procedure ‐ Load Test certificate (including inspection after load test) ‐ NDT Inspector Qualifications ‐ NDT procedures ‐ Welding Procedure

Also included in this submittal item are:

‐ PE letter ‐ Calculations notes, H1039500 MKB 84‐301 F ED‐01 ‐ Drawings o H‐1039500 MKB 83‐206 F PB_C o H‐1039500 MKB 83‐206 F TE_D o H1039500 MKB 84‐301 F DC‐01 o H‐1039500 MKB 84‐301 F TB_F

‐ Comments file

2.0 VARIANCE DETAILS

Rev. B

Rev. B

Rev. B

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Client Intervention Adresse / Address Date Ville / City (Province) Site Code postal / Postal Code BC / PO Responsable / Contact

PROJET / PROJECT

N/DOSSIER / O/FILE

TYPES D'INTERVENTION / INTERVENTION TYPES

Inspection visuelle / Visual Inspection Surveillance / Monitoring Documentation Système / System Témoignage d'essais / Tests Witnessing Soudage / Welding Plan qualité / Quality Plan Relance / Call back boulonnage / Bolting Dossier qualité / History Docket Conversation téléphonique / Phone Call Dimensionnelle / Dimensional Galvanisation / Galvanization Autre / Other:

Peinture / Paint

NORMES DE RÉFÉRENCE / STANDARDS:

PERSONNE (S) CONTACT / CONTACT PERSON (S):

1.0 Mandat / Order

2.0 Documents de référence / Reference documentation (Codes & Normes / Standards)

3.0 Équipements utilisés / Equipment used

Rapport / Report - date :

Inspecteur / Inspector: Approbateur / Approver:

Certification: Certification:

Comparative of standards AWS D1.1 and AWS D14.1 Project: Lifting device at ACME

B2MA RAPPORT D'INTERVENTION

INTERVENTION REPORT

Page (s): 1 de/of 3

GE Canada 5005, boul. Lapinnière - suite 6000 2019-02-06 and 07 Brossard (Québec) N / A

J4Z ON5

Lynda Thibault

Drawings on welding map 14875

N/A N/A

19001-03-002

AWS D1.1 and AWS D14.1

Lynda Thibault

Technical comparative between AWS D1.1 and D14.1 for welding procedures and welding inspection in reference of lifting device project at ACME.

Benoit Hotte, P. Eng.Pier-Hughes Fortin, P. Eng.

2019-02-07

CSA W-178.2 lev 3 CSA W-178.2 lev 3

AWS D1.1 and D14.1, latest edition Technical specifications H1039500MEI00-200FDC-04 rev.- of GE including Appendix A, B, C and D

WPS # PQR-GMAW-3-CS/FCAW-G

B2MA inc.

12356 Miséricorde Montréal (QC) Canada H4J 2E9

1-514-820-8044 www.b2ma.ca

Termes et conditions:

www.b2ma.ca/termes_et_ conditions

B-008

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Dossier / file 19001-03-002 Page (s) 2 de/of 3

3.0 Équipements utilisés / Equipment used

4.0 Résultats / Results

Rapport / Report - date :

Inspecteur / Inspector: Approbateur / Approver:

Certification: Certification:

N/A N/A

B2MA RAPPORT D'INTERVENTION

INTERVENTION REPORT

Welding procedure qualification comparative between AWS D1.1 and D14.1 Both standards has requierements for prequalified welding procedure specifications and essencial variables. When all of the requierements for the prequalifications of WPS is respected, there no qualifications test to perform. When there a requierement not respected, qualification test must be done and the WPS is produced to weld with all essencial variable as per qualification records.

There many small difference in prequalification requierements and essencial variables between the standards AWS D1.1 and D14.1. In this report, only the relevant differences and applicable part of the standards are specified.

First: In AWS D14.1 part 9.1.4, it is indicate that the welding procedure qualified under specification AWS D1.1 or ASME for equivalent welding shall be acceptable.

With this point, we consider that the WPS # PQR-GMAW-3-CS/FCAW-G is acceptable as per ASW D14.1 standard. This WPS is conforming to the AWS D1.1 standard.

Difference of material to weld In the case of lifting device, the material to weld on drawing of welding map 14875 is material A572 gr.50 with thichness of 4 and 5 inches. The qualification tests in WPS # PQR-GMAW-3-CS/FCAW-G were performed with material A36 with thickness of 1 inch.

In the AWS D1.1 table 3.1, The material of qualification test (A36) and material to weld (A572 gr.50) are in same class. The essencial variable is respected.

In the AWS D14.1, the material to weld (A572 gr.50 higher that 2 inch) is not in table 1 for weldability classification. In this case, the essencial variable and requierement for prequalification are not respected. The standard AWS D14.1 require qualification test with the material to weld.

Welding inspection comparative between AWS D1.1 and D14.1

See table in page #3 for comparative of visual inspection between AWS D14.1 and AWS D1.1 (dynamically loaded).

2019-02-07

Pier-Hughes Fortin, P. Eng. Benoit Hotte, P. Eng.

CSA W-178.2 lev 3 CSA W-178.2 lev 3

B2MA inc.

12356 Miséricorde Montréal (QC) Canada H4J 2E9

1-514-820-8044 www.b2ma.ca

Termes et conditions:

www.b2ma.ca/termes_et_ conditions

B-008

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212523552 Texte tapé à la machine Welding procedure qualification comparison between AWS D1.1 and D14.1

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212523552 Texte tapé à la machine Difference of material to weld

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212523552 Texte tapé à la machine In case of the lifting device, the material to weld in drawing of welding map 14875 is material A572 Gr.50 with a thickness of 4 and 5 inches, respectively. The qualification tests in WPS # PQR-GMAW-3-CS/FCAW-G were performed with material A36 with a thickness of 1 inch.

In the AWS D1.1 Table 3.1, the material of qualification test (A36) and material to weld (A572 Gr.50) are in same class. The essential variable is respected.

In the AWS D14.1, the material to weld (A572 Gr.50 greater than 2 inch) is not in Table 1 for weldability classification. In this case, the essential variable and requirement for prequalification are not respected. The standard AWS D14.1 require qualification test with the material to weld.

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212523552 Texte tapé à la machine Welding inspection comparison between AWS D1.1 and D14.1

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212523552 Texte tapé à la machine See table in page #3 for the comparison of visual inspection between AWS D14.1 and AWS D1.1 (dynamically loaded).

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212523552 Texte tapé à la machine Both standards have requirements for prequalified welding procedure specifications and essential variables. When all the requirements for the prequalification of the WPS are met, no qualifications test need to be performed. When a requirement is not met, qualification test must be done and the WPS is produced to weld with all essential variable as per qualification records.

There are many small differences in the prequalification requirements and essential variables between the standards AWS D1.1 and D14.1.

In this report, only the relevant differences and applicable part(s) of the standards are specified.

First: AWS D14.1 Part 9.1.4, indicates that the welding procedure qualified under specification AWS D1.1 or ASME for equivalent welding shall be acceptable.

With this point, we consider that the WPS # PQR-GMAW-3-CS/FCAW-G is acceptable as per AWS D14.1 standard. Therefore, this WPS is conforming to the AWS D1.1 standard.

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Dossier / file 19001-03-002 Page (s) 3 de/of 3

Rapport / Report - date :

Inspecteur / Inspector: Approbateur / Approver:

Certification: Certification:

B2MA RAPPORT D'INTERVENTION

INTERVENTION REPORT

Comparative between AWS D1.1 and AWS D14.1 Visual inspection

CSA W-178.2 lev 3 CSA W-178.2 lev 3

2019-02-07

Pier-Hughes Fortin, P. Eng. Benoit Hotte, P. Eng.

B2MA inc.

12356 Miséricorde Montréal (QC) Canada H4J 2E9

1-514-820-8044 www.b2ma.ca

Termes et conditions:

www.b2ma.ca/termes_et_ conditions

B-008

PROJET / PROJECT N°

158300

Ligne Item Qté prête pour expédition / Dessin / Drawing Rev.

Line Qty ready for

H1039500 MEI 84-301 FTB B

Job 14875

ACC.

N/A

X

X

X

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

X

Vérifié et approuvé par /

2018-10-26 Signature Date

PQL / SQL Date

Acheteur / Buyer Date

RIF / FIR Rev. # :

2- Certificats des Matériaux & Traçabilité / Materials Certificate & Traceability

3- Inspections Dimensionnelles / Dimensional Inspections

Commentaires / Comments

7- Essais Diélectriques / Dielectric Tests

6- Essai de Pression / Pressure Tests

1- P.R.I.E. complété et signé / Completed and signed R.I.T.P.

12- Listes d'Emballage / Packing Lists

11- Manuel d'Entretien / Maintenance Manual

9- Sablage-Peinture / Sandblasting-Painting

8- Nettoyage / Cleaning

Painting not done

RAPPORT D'INSPECTION FINAL

FINAL INSPECTION REPORT

COMMANDE / PO

Anomalie / Non-conformité N°

Documents inclus, vérifiés et acceptés par le fournisseur Documents included, verified and approved by the supplier

NOM DU PROJET / PROJECT NAME

FOURNISSEUR / SUPPLIER UNITÉ / UNIT N°

NOM DE LA PIÈCE / PART NAME

Anomaly / Non-conformance N°

Old Hickory

Generator Shaft lifting device

ACME

RAPPORTS / REPORTS :

4- Essais Non-Destructifs / Non-Destructive Tests

5- Traitement Thermique / Heat Treatment

4101689216

Commentaires / Comments : Partial- Part to be shipped without painting. Needed at site- to be done after

Autorisation d'expédier par / Authorization to ship by

(LETTRES MAJUSCULES / CAPITAL LETTERS)

10- Anomalies - Non-conformités / Anomalies - Non-Nonformances

13- Autres (Spécifiez) / Others (Specify) Load test reports

MIGO:

Verified and approved by :

Nom / Name Hank Craig

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

© 2016 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.

© 2016 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

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515484 G47351 ()

HEAT NUMBER: D4014 CUSTOMER PO: PAGE 1 OF 2

515484 G47351 ()

HEAT NUMBER: D4014 CUSTOMER PO: PAGE 2 OF 2

515484 G47324 ()

HEAT NUMBER: G3139 CUSTOMER PO: PAGE 1 OF 2

515484 G47324 ()

HEAT NUMBER: G3139 CUSTOMER PO: PAGE 2 OF 2

4301 Rossville Blvd.

Chattanooga, TN 37407

JOB 14875

GE Old Hickory Generator Shaft Lifting Device.

Preheat Treatment Procedure:

Reference: AWS D1.1 / 5.6

Materials P-No. 1 Groups 1, 2, 3

Base metal shall be preheated to a temperature not less than 225˚F for the cylinder longitudinal seam weld. The preheat of all parts thicker than 1 ½” shall be 225 deg. F minimum and 250 deg. F is preferred.

This preheat and all subsequent minimum interpass temperatures shall be maintained during the welding operation for a distance at least equal to the thickness of the thickest welded part ( but not less than 3 in.) in all directions from the point of welding.

Minimum interpass temperature requirement shall be considered equal to the preheat requirements, unless otherwise indicated on the WPS.

The preheat and interpass shall be monitored just prior to initiating the arc for each pass.

PROJET / PROJECT N°

H-5835

Ligne Item Qté prête pour expédition / Dessin / Drawing Rev.

Line Qty ready for

10 1 H-1039500 MKB 84-301 F TB D

ACC.

N/A

N/A

N/A

X

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

X

Vérifié et approuvé par /

2019-01-22 Signature Date

2019-02-23

PQL / SQL Date

Acheteur / Buyer Date

4101761466

Commentaires / Comments : The NDT report will follow later, must be done at site.

Autorisation d'expédier par / Authorization to ship by

(LETTRES MAJUSCULES / CAPITAL LETTERS)

10- Anomalies - Non-conformités / Anomalies - Non-Nonformances

13- Autres (Spécifiez) / Others (Specify) Load Test

MIGO:

Verified and approved by :

Nom / Name Hank Craig

RAPPORTS / REPORTS :

4- Essais Non-Destructifs / Non-Destructive Tests

5- Traitement Thermique / Heat Treatment

RAPPORT D'INSPECTION FINAL

FINAL INSPECTION REPORT

COMMANDE / PO

Anomalie / Non-conformité N°

Documents inclus, vérifiés et acceptés par le fournisseur Documents included, verified and approved by the supplier

NOM DU PROJET / PROJECT NAME

FOURNISSEUR / SUPPLIER UNITÉ / UNIT N°

NOM DE LA PIÈCE / PART NAME

Anomaly / Non-conformance N°

Old Hychory

Gen Shaft Lift Dev Repair & Load Test

ACME Industrial piping

12- Listes d'Emballage / Packing Lists

11- Manuel d'Entretien / Maintenance Manual

9- Sablage-Peinture / Sandblasting-Painting

8- Nettoyage / Cleaning

RIF / FIR Rev. # :

2- Certificats des Matériaux & Traçabilité / Materials Certificate & Traceability

3- Inspections Dimensionnelles / Dimensional Inspections

Commentaires / Comments

7- Essais Diélectriques / Dielectric Tests

6- Essai de Pression / Pressure Tests

1- P.R.I.E. complété et signé / Completed and signed R.I.T.P.

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

© 2016 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.

© 2016 General Electric Company. Proprietary. All rights reserved. GE Confidential – Distribution authorized to individuals with a need to know only.

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Hank Craig

From: Edwin T Yancy <andersonmachinecompany@gmail.com>

Sent: Monday, January 21, 2019 11:37 AM

To: Hank Craig

Subject: Re: Tolerancing on ACME JOB 14990

Hank

Thank you for the opportunity to work with you on the lifting device modifications project.

To follow is the scope of the work:

-- Lifting device was set up to maintain original hole locations

-- Revised dimensions were held as follows:

-- 26" diameter bolt circle +.000" / -.010"

-- 1.625" diameter holes + .010" / -.000"

-- Flatness of mounting surface was corrected by machining from existing .015" crown to flatness tolerance of .002"

-- Bolt head side of device was checked for flatness at the bolt location and found to be flat within .002" , no machining ( spot facing ) was required.

Edwin T Yancy

Anderson Machine Company, Inc.

On Fri, Jan 18, 2019 at 9:28 AM Hank Craig <hcraig@acmeindustrialpiping.com> wrote:

FYI-- Tolerancing provided

Hank Craig

ACME Industrial Piping

423-847-5271

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RAPPORT D'ANOMALIE

ANOMALY REPORT

DER NC

AR CC

Detection Chantier/ Site Erection Fournisseur/ Supplier Inspection à la réception / As Found Garantie/ POC (*) Obligation par le fournisseur de compléter cette information/Supplier must complete this mandatory information

Numéro Projet / Project N° Unité / Unit Fournisseur / Supplier Réf. Fournisseur / Supplier Ref. : Réf. Chantier / Site Ref. :

H-10395 1 ACME

Nom du Projet / Project Name (*) # OA / PO Ligne/Line TRA 190157 Rev. : - Old Hickory WBS # (Budget) : Responsabilité/Responsibility

No. Dessin / Drawing Rev. # Item Engineering

H-1039500 MKB 84-301 F TB B 407

Titre d’anomalie / Anomaly Title : QTÉ/QTY

Ém et te ur

Is su er

DESCRIPTION :

The drawing asks for 1 ¼” welding. You can see on the drawing that there is no room enough between the item 408 and the whole on item 407. And on top of that remember that we need to install the bolts and washers to connect the tool to the shaft.

INSPECTEUR / INSPECTOR : DATE :

TRAITEMENT SUGGERE / DISPOSITION PROPOSAL :

PLEASE SEND WORD FORMAT ONLY TO : hydro.ncr@ge.com

À réapprovisionner / Re-Order (AR) À réparer / repair: GE Fourn/Supplier (NC) Accepté dans l’état / Use as is (NC) À refaire / Rework (AR) Accepté matériel équivalent/ Use equivalent material (DER) Modif de la conception/ Design modif (NC) Mise au rebut / Scrap (NC) Changement au contrat / Contract Change (CC) Autres/ Others

Type de défaut / Defect Type : (voir / see HN-LS-2-Q-T-052) Code : 10-3 A B C

G E

DETAILS DE LA DISPOSITION / DISPOSITION DETAILS :

Proceed with a spot face where the bolts and washers will interfere as shown on pictures. The spot face should be 3-1/8” dia x 1/8" deep maximum.

The remaining weld is strong enough for the lift as the weld at the extremity of the lifting lug (portion of the weld removed) was not considered in the calculations.

PRESCRIT PAR / PRESCRIBED BY : Marc McDuff DATE : 15 octobre 2018

Di st rib ut io n Fournisseur / Supplier Client : Information Approbation / Approval Traitement/ treatment

PQL / SQL / BUYER Info Action Équipe GDT / GDT Team

Montage / Site Erection Info Action Autres / Others

CL

IE

NT

Si re qu is

If re qu ire d

Ap pr ob at io n

A p pr ov al

Section réservée pour Client et GE / For Client & GE use only Accepté / Accepted Commentaires / Comments :

Accepté tel que noté / Accepted as noted

Refusé / Rejected Signature : Date :

Ré-inspecté par / Re-inspected by Date Ré-inspecté par / Re-inspected by : Client (Optionnel / Optional) Date

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DOCUMENT TECHNIQUE Date : 01.29.2019

LOAD TEST PROCEDURE

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212523552 Texte tapé à la machine station9 Typewritten Text Test results attached HHI Order H1073141 performed 1/22/2019 station9 Typewritten Text Note- Editorial changes made 2/26/2019 Corrected item description in 4.1-5) and 4.2-5)

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Generator Shaft Lifting

For results- reference

Snapshot

Generator Shaft Lifting

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LOAD TEST CERTIFICATE

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Ivey Cooper

SERYICES, LLC

Magnetic Particle Insp ection Report Report Number: 195008-MT-01(C) Page_ of_

ACME customer Job #: 14360-14990 Date: Ll24/20rg ob Location: old Hickory Dam ICS WO#: 195008 Drawing Number: H-1039500 MKB g4-301 F TB

9-MT-1 Rev: 6 Acceptance Standard: AWS Dl.l

Generator Shaft Lifting Device Material Carbon Steel Surface Conditions: As Brushed : See Dwg Diameter: See Dwg Length: See Dwg Coating: None ity (Foot-Candles): >100 Fc post : >l00Fc ranlcle lype

Dry

Wet

Visible

Fluorescent

Certification #: 10Fl4K l'echnique flcoir # orrurns:

lx-lvot"U flrrods Spacing:

I lgeaa snotU I lCentrat Condutor Dia:

Current/Equipment

Alternating Current

Direct Current

Direct Current Rectified

Amps: 6 AMPS ualrbratlons (Daily)

Cal Date: ll24l20l9 Model:

Yoke Lift Test Serial:

l0 Lb PASS Cal Date:

10 Lb al Due:

Model & S/1.,1: 8100 / 3044 wT s/N 12738 I xlverifi cation on i.*ra

Weld ldentification or Part

Number oE o

q) c) I c)o 6J'il

Type olDiiconiinuliy Remarks o6 O o d

'l t!

q ,l o o o-do U) o0 a o oE D o

I &

E

.g! E '5 s bI)

J

Accept= / Reject: X No Apparent Defects: NAD

1069690-r-r NAD ng/Location of Discontinuity Images Attach

Test Witnessed By: Lucas Reed, GE Renewable rhomas H. Bowlins -21'7#Je ilrffi ffiGi- Customer Reviewer

Authorized Insnector

I 1 0323

Certification Number

11135 Dayton Pike Soddy-Daisy, TN 37379 Phone: (423) 493-0097 Fax: (423) 435-9620 Form 6/30/13

Lrght Meter

Test Witnessed By: Victor Young, USACE

Post Lift Test lnspection

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NDT QUALIFICATION

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Ivey Cooper Cert Form 9/17

SERVICES, LLC

NDT PERSONNEL CERTIFICATION SNT-TC-1A

This is to certify that the named individual has satisfactorily completed the requirements of the

IveyCooper Services, LLC NDT Personnel Certification Program, QOP 18-1, Rev. 13

Name Thomas Bowling SSN On File

TECHNICAL CERTIFICATION

Method/Level Magnetic Particle Level III Limitation NA Endorsements NA Certification Date 2/2/2018 Certification Expires 9/1/2021

Verification of Continuity Date Initials Job Number

EXPERIENCE

MT II United States Army 1/1/84 to 1/1/01 MT II IveyCooper Services 2/4/04 to 7/13/12 MT III IveyCooper Services 7/13/12 to Present

EDUCATION / TRAINING

Scott County High School Diploma Huntsville, TN 1983

MT I and II MT Basic and Advanced 40 hrs U.S. Army 2/1/84 MT I and II MT Basic and Advanced 30 hrs U.S. Army 3/1/94 MT I and II MT Basic and Advanced 20 hrs U.S. Army 2/1/96 MT III MT III 20 hours Kraft Technology Resources 7/24/11

EXAMINATION

Level I Level II Level III X

Grade Date Grade Date General Basic 80% 9/1/2016 Specific Method 80% 9/1/2016 Practical Specific 90% 9/30/2016

Practical 80% 9/1/2016 Composite Score Demonstration 100% 2/2/2018

Composite Score 86%

Level III James Smith Quality Manager Date 2/2/2018 Notes ASNT Certificate Number 110323 expires 9/21

11135 Dayton Pike Soddy Daisy TN 37379 Phone 423-493-0097 Fax 423-435-9620 130 East Division Rd. Suite E Oak Ridge, TN 37830 Phone 865-482-2322 Fax 865-482-3949

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NDT PROCEDURE

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Quality Operating Procedure

IveyCooper

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

11135 Dayton Pike Soddy Daisy, TN 37379 Phone: (423) 493-0097 Fax: (423) 435-9620

Procedure: 9-MT-1

For

Magnetic Particle Inspection And Acceptance Standards For Ferromagnetic Welds, Base Materials And Components

Revision Date Reviewed By Approved By Issue Date 6 8/31/15 8/31/15

Revision Description

1 Incorporate changes requested by customer “ Hale Iron” for NAVSEA work for compliance withT9074-AS-GIB-010/271 requirements which replaces Mil Std 271 Paragraphs: 2.5, 9. 5 .13, 9. 5. 25, 12.1.1. 1, 12.1.1.2, 12.1.1.3, 12.3.3, 12.4.1, 12. 5

13. 5, 13.5.1, 13.5.1.1, 13.5.1.2, 13.5.1.3

2 Revised para. 13.1 to read 100 foot candles.

3 Added 3.1, and 3.2; Revised 7.3 an 9.7.5, 13.1, 19.0, and Attachment 1 to comply with 2004 ASME Section V, Article 7, 2005 Addenda.

4 Revised para. 1.0 to reference para. 2.0, and paragraph 14.0 to read Appendix 6. Added para.

16.5.

5 Changed pH in para. 9.5.2 to read 7.0 to 10.5. Para. 41.1 #4 designates criteria for B31.1 and Section III use only. Added para. 14.3.1.

6 Revised 12.5.1 for calibration of yoke requirement to comply with 2015 ASME Section V, Article 7. Instructional note moved to 13.3. Updated 9.7 to include LED ultraviolet lighting.

References to ASME Section III removed. Updated form attached.

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

1.0 Scope:

Procedure 9-MT-1 contains the specified minimum requirements that shall be used in performing Magnetic Particle testing of ferromagnetic welds, base materials and components when Magnetic Particle inspection is required by contract requirements and/or code specifications. IveyCooper SERVICES, LLC, hereafter ICS, certifies that this procedure shall meet the minimum requirements of the applicable code or standard as listed in Paragraph 2.0 of this procedure. All Magnetic Particle inspection shall be performed in accordance with contract specifications and/or governing code requirements.

2.0 Applicable Codes and/or Requirements:

The following codes shall be made part of this procedure to the extent specified. The latest edition of the code shall be used unless otherwise required by contract.

2.1 American Society For Mechanical Engineers (ASME):

1. SECTION I - Power Boilers

2. SECTION V - Nondestructive Examination

3. SECTION VIII - Pressure Vessels

4. B31.1 - Power Piping

5. B31.3 - Chemical Piping

2.2 American Society For Testing And Materials (ASTM):

1. E-109 - Dry Powder - Magnetic Particle Inspection

2. E-125 - Standard Reference Photographs for Magnetic

Particle Inspections of Ferrous Castings

3. E-709 - Magnetic Particle Examination

2.3 American Petroleum Institute (API):

1. API 620 - Low Pressure Storage Tanks

2. API 650 - Storage Tanks For Oil Storage

3. API 653 - Tank Inspection, Repair, Alteration, and

Reconstruction

4. API 1104 - Pipelines and Related Facilities

2.4 American Welding Society (AWS):

1. AWS D1.1 - Structural Welding

2.5 Military Standards (Mil Std):

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

1. NAVSEA - T9074-AS-GIB-010/271

2. Mil-Std - 6868 D

3. Mil-Std - 2035 A(SH)

3.0 Qualification Requirements:

3.1 Personnel

When Magnetic Particle inspection is to be performed in accordance with this procedure, personnel shall be qualified and certified as required by ICS QOP 18-1 or

QOP 18-2.

3.2 Procedure

When procedure qualification is specified, a change of a requirement identified as an essential variable in Table T-721 of ASME Section V, Article 7 shall require re-qualification of the written procedure by demonstration. A change of a requirement identified as a non-essential variable does not require re-qualification of the written procedure. All changes to this written procedure, whether essential or non-essential shall require revision or addendum to document change.

4.0 Safety Requirements:

4.1 When Magnetic Particle inspection is to be performed in accordance with this procedure, personnel shall make certain that the electrodes are firmly placed on the surface to be inspected prior to switching on the current and that the current is switched off prior to electrode removal to prevent arc strikes.

4.2 When Magnetic Particle inspection is to be performed in accordance with this procedure utilizing high intensity black-light, examiners shall wear safety goggles designed to absorb UV wavelength radiation.

5.0 Components For Inspection:

Ferromagnetic materials of all shapes and sizes may be examined by Magnetic Particle Testing provided the material is accessible and meets all code and/or contract requirements.

6.0 Time Of Inspection:

Final inspection shall be performed after weld or component is completed to code and/or contract specifications and final post weld heat treatment, unless otherwise specified by code and/or contract requirements.

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

7.0 Preparation Of Surface:

7.1 Welds: The weld surface and a minimum of one inch (25mm) on each side of the weld shall be dry and free of all dirt, grease, lint, scale, welding slag and spatter that could mask possible indications or interfere with interpretation.

7.2 Components: The surface to be examined shall be free of loose scale, oil, or grease. Cleaning may be accomplished using detergents, organic solvents, sand or grit blasting, etc. The method used to prepare surfaces for inspection shall be approved by code and/or contract requirements.

7.3 For “ASME Code” required inspections, all coatings must be removed prior to examination.

8.0 Magnetizing Current:

Alternating, direct, or rectified (half wave rectified or full wave rectified) current shall be used for magnetization during examination. The magnetic field must be of sufficient strength to indicate discontinuities that are unacceptable, and at the same time not be so strong as to cause excess particles to accumulate locally, possibly masking relevant indications. Alternating current shall be used for demagnetization after testing when required by code and/or contract specifications.

9.0 Magnetizing Equipment:

9.1 The following equipment shall be used for magnetization during examination:

1. 750 or 1,000 amp AC/DC half-wave low voltage machine

2. 3,000 or 4,000 amp AC/DC full-wave machine

3. Alternating current electromagnetic yoke

4. Direct current electromagnetic yoke

9.2 Cables: Size 2/0 or 4/0

9.3 Prods: Portable prod type electrical contacts usually with copper or brass tips and with a maximum open circuit voltage at prods of one (1) volt or less with a remote control switch which may be built into the handle.

9.4 Dry Magnetic Particle: Finely divided dry ferromagnetic particles manufactured by Magnaflux Corporation or equivalent. The particles shall possess high permeability and low retentivity characteristics. The particles are available in several colors and the color selected for each examination shall be one that provides the greatest contrast to the test specimen. The particles shall be applied to the test

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 specimen and excess particles removed in accordance with Paragraph 11.3.

9.5 Wet Magnetic Particle: Finely divided ferromagnetic particles manufactured by Magnaflux Corporation or equivalent. The particles shall possess high permeability and low retentivity characteristics. The particles shall be treated to impart color, fluorescent or non-fluorescent, such that they provide contrast to the test specimen. The particles shall be designed for use in a suspension vehicle. Low viscosity oil or conditioned water shall be used as the suspension vehicle. The suspension vehicle shall be applied to the test specimen in accordance with Paragraph 9.6.

9.5.1 Petroleum Distillate Vehicles: Low -viscosity light petroleum distillate vehicles shall possess the following characteristics:

1. Viscosity shall not exceed 3.0 cSt (3 mm squared/s) at 100 degrees F (37 C) and 5.0 cSt (5 mm squared/s) at the lowest temperature at which the vehicle will be used.

2. Shall have a minimum flash point of 200 degrees F (93C) so as to reduce risk of fire.

3. Shall be nonfluorescent if used with fluorescent particles.

4. Shall be non-reactive so as not to degrade suspended particles.

9.5.2 Water vehicles: Water may be used as the a suspension vehicle provided a suitable conditioning agent is added as to provide proper wetting and the following characteristics exist:

1. The vehicle shall have good wetting characteristics as to provide complete coverage of test specimen without evidence of de-wetting.

2. Shall not produce excessive foam that could interfere with the formation of indications.

3. Shall not be corrosive to test specimen or equipment in which it is used.

4. Viscosity shall not exceed 3 cSt (3 mm squared/s) at 100 degrees F (37C).

5. Shall be nonfluorescent if used with fluorescent particles.

6. Shall be non-reactive so as not to degrade suspended particles.

7. Shall have a pH balance between 7.0 and 10.5.

9.5.3 Bulk wet magnetic particle solutions shall be checked for content of ferromagnetic particles, discoloration and contamination at least once each day, when in use. Discoloration or contamination of the suspension with foreign materials that interfere with distribution, concentration, intensity, character or definition of the magnetic deposit shall require that the solution

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 container be drained, thoroughly cleaned and refilled with clean solution.

9.5.4 Concentration of bulk wet magnetic particle suspensions shall be checked prior to initial use by settling volume measurements and maintained on a daily basis. The concentration of suspended magnetic particles shall be checked in the following manner:

1. Allow re-circulating system to run for at least thirty minutes prior to testing the solution or shake container thoroughly to disperse particles in suspension.

2. Take a 100-ml portion of solution directly from hose or other device used to apply solution to test specimen, or from immersion tank, demagnetize and allow it to settle for 60 minutes for petroleum distillates or 30 minutes for water based solutions before reading.

3. The amount of particles settling at bottom of tube is indicative of particle concentration in the bath.

9.5.5 The concentration of the wet suspension shall be from 0.1 to 0.4-mL in a 100mL bath sample for fluorescent particles and from 1.2-mL to 2.4-mL in a 100-mL bath sample for non-fluorescent particles.

9.6 Wet magnetic particles, fluorescent or non-fluorescent, shall be applied to test specimen by spraying or flowing the solution over the area being examined.

9.7 With fluorescent particles, the examination is performed using ultraviolet light called black light. The following steps shall be taken when performing black light inspection:

1. Examination shall be performed in a darkened area.

2. The examiner shall remain in the darkened area a minimum of five minutes prior to performing the examination to enable his eyes to adapt to dark viewing.

3. The examiner shall not wear photochromic or permanently tinted lenses.

4. The black light shall be allowed to warm up for a minimum of five minutes prior to use or measurement of ultraviolet light intensity emitted.

Warm up minimum not required when LED ultraviolet light is used for examination.

5. The black light intensity at the surface of the test specimen shall be measured prior to use, at least once every eight hours, whenever the light power source is changed or interrupted, and upon completion of inspections.

6. A black light meter shall be used to measure black light intensity.

7. The black light intensity at the surface of the test specimen shall be a minimum of 1000 micro W/cm squared.

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

10.0 Temperature Of Test Specimen:

10.1 For Dry Magnetic Particle examination, the surface of the test specimen shall not exceed 600 degrees F (315C).

10.2 For Wet Magnetic Particle examination, the surface of the test specimen shall not exceed 135 degrees F (57C).

11.0 Sequence Of Operations:

11.1 Magnetic Particle Inspection shall be performed by the continuous method;

that is, the magnetizing current shall remain on while the test medium is being applied.

11.2 Direct or Indirect magnetization shall be used. Where the direct contact method is used, the magnetizing current is passed directly through the part creating a circular field within the part. Where the indirect method is used, a magnetic field is induced into the part creating a circular, longitudinal, or multidirectional magnetic field within the part.

11.3 Dry Continuous Technique: The flow of magnetic current shall be initiated prior to application of dry magnetic particles and terminated only after the application of powder has been completed and the excess powder has been removed. Dry magnetic powder shall be applied by means of a hand powder applicator in such a manner that a light, uniform, dust-like coating settles on the surface under test.

Excess particles shall be removed by means of dry air of sufficient force to remove the excess particles without disturbing those that are indicative of discontinuities.

Excess particles shall be removed by using a hand-actuated rubber bulb or specially designed applicator.

11.4 Wet Continuous Technique: Wet magnetic particles, fluorescent or non-fluorescent, shall meet requirements or Paragraph 9.5 and be applied to test specimen in accordance with Paragraph 9.6. The flow of magnetic current shall be initiated prior to application of wet magnetic particles and terminated only after the application of solution has been completed and the excess flow of solution has subsided.

11.5 Magnetic Field Adequacy: When it is necessary to verify magnetic field strength adequacy, a pie shaped magnetic field indicator shall be used. The indicator shall be positioned on test specimen so that the copper- plated side is away from surface of test specimen. When magnetic particles are applied simultaneously with the magnetizing force, a clearly defined line (or lines) of magnetic particles forming across the copper face of the indicator shall be considered evidence of suitable field

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 strength.

11.6 Examination Coverage: All examinations shall be conducted with sufficient overlap to ensure 100% coverage of area to be examined at the required sensitivity.

11.7 Small holes and openings leading to obscure passages or cavities shall be plugged or masked with suitable material to prevent test medium from coming in contact with components that may be damaged by particles or particle suspensions, unless prohibited by contract and/or code requirements.

11.8 Surface Contrast Enhancement: When coatings are temporarily applied to surface of test specimen, the coating shall only be in amounts sufficient to enhance particle contrast. When coatings are applied for particle contrast, it shall be demonstrated, in accordance with Paragraph 11.5, that indications can be detected through the enhancement coating.

12.0 Magnetization Techniques:

12.1 Longitudinal Magnetization Coil Technique: With this technique, magnetization is accomplished by passing current through a multiple-turn fixed coil (or cable) that is wrapped around the part or section of the part to be examined. This produces a longitudinal magnetic field parallel to the axis of the coil. If a fixed or pre-wound coil is used, the test specimen shall be placed near the inside surface of the coil during inspection. This is especially important if the coil opening is greater than ten times the cross-section of the test specimen (low fill factor coil).

12.1.1 When using the longitudinal technique in accordance with this procedure, direct or rectified magnetizing current shall be used. The required field strength shall be calculated based on the length (L) and the diameter (D) of the part in accordance with 1, 2, or as established in 3. below. Long parts shall be examined in sections not to exceed 18 inches (460 mm), and 18 inches (460 mm) shall be used for the part (L) in calculating the required field strength. For non-cylindrical parts, (D) shall be the maximum cross-sectional diagonal:

1. Parts with L/D Ratios Equal to or Greater than 4:

(Exception- for work to Military Standards use 12.1.1.2)

The magnetizing current shall be within +/- 10% of the ampere-turns value determined as follows:

Ampere-turns = 35,000 (L/D) + 2

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

For example, a part 10 inches (250 mm) long x 2 inches (50 mm) diameter has an L/D ratio of 5.

35,000 (5+2) = 5,000 ampere-turns

2. Parts with L/D Ratios Less Than 4 but not Less Than 2 and all work to Military Standards:

The magnetizing ampere-turns shall be within +/- 10% of the ampere-turns value as follows:

Ampere-turns = 45,000 L/D

3. Parts with L/D Ratios Less Than 2:

(Exception- for work to Military Standards use 12.1.1.2) An alternate form of magnetization shall be used.

12.1.2 Magnetizing Current: The current required to obtain the necessary magnetizing field strength shall be determined by dividing the ampere-turns obtained in steps 1 or 2 in Paragraph 12.2.1 by the number of turns in the coil as follows:

Amperes (meter reading) = ampere-turns turns

For example, if a 5-turn coil is used and the ampere-turns required are 5,000

5,000 5 = 1,000 amperes (+/- 10%)

12.2 Longitudinal Yoke Technique: With this technique, alternating or direct current electromagnetic yokes shall be used. This method shall only be used to detect discontinuities that are open to the surface of the test specimen. When possible, the yoke shall be rotated 90 degrees with respect to the original location and yoke leg placements shall overlap 1 (25mm) to 1 ½ inches (38mm) to assure all existing surface discontinuities are revealed. Leg spacing on yokes shall be 3 inches minimum and 8 inches maximum.

12.2.1 Each alternating current electromagnetic yoke shall have a lifting

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 power of at least 10 lb. (45kg) at the maximum pole spacing that will be used.

12.2.2 Each direct current yoke shall have a lifting power of at least 40 lb.

(181kg) at the maximum pole spacing that will be used.

12.3 Circular Magnetization Techniques: With this technique, magnetization is accomplished by passing current directly through the part to be examined or indirectly by use of a central conductor. This produces a circular magnetic field that is approximately perpendicular to the direction of current flow in the part.

12.3.1 When using the direct contact technique in accordance with this procedure, direct or rectified (half-wave rectified or full-wave rectified) magnetizing current shall be passed directly through the part being examined. The required current shall be determined using the following guidelines:

1. The current shall be 300 amp/in. (12 A/mm) to 800 amp/in. (31 A/mm) of outer diameter of part.

2. For parts with geometric shapes other than round, the greatest cross-sectional diagonal in a plane at right angles to the current flow shall determine the inches to be used in 12.3.1 (1).

3. If the current levels required for 12.3.1 cannot be obtained, the maximum current obtainable shall be used and the field adequacy shall be demonstrated in accordance with Paragraph 11.5.

12.3.2 When using the central conductor technique in accordance with this procedure, direct or rectified (half wave rectified or full wave rectified) current shall be used. The central conductor is used to examine the surfaces of ring or cylindrically shaped parts. The central conductor technique may also be used for examining the outside surfaces of these shapes. Where large diameter cylinders are to be examined, the conductor shall be positioned close to the internal surface of the cylinder. When the conductor is not centered, the circumference of the cylinder shall be used to determine the extent of the arc that may be examined for each conductor position.

12.3.3 The field strength required shall be equal to that determined in Paragraph 12.3.1 for a single turn central conductor. The magnetizing force shall be decreased in proportion to the number of times the central conductor cable passes through a hollow part. For example, if 6000 amperes are required to examine a part using a single central conductor, 3000 amperes are required when 2 turns of the through cable are used; and 1200 amperes are required if 5 turns are used. When the central conductor technique is used, magnetic field adequacy shall be verified using a magnetic particle field indicator in accordance with Paragraph 11.5. Note: All work to Military Standards must

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 be done using a single turn central conductor.

12.4 Circular…