Prepared by
Wawan Kuswardhana
Site Coordinator.
DECEMBER 2016
FSD-01FR-01 Rev. 03 This material is the exclusive property of PT. Sulzer Indonesia.
Page 1 of 35
FIELD SERVICE REPORT
STEAM TURBINE GENERATOR MAJOR INSPECTION
I. Introduction
PT. Sulzer Indonesia was awarded to performs major inspection/serious inspection both steam
turbine and generator 65 MW owned by PLN (Persero) WKTKS PLTU ASAM ASAM. The unit
service is a power generation unit located in Asam asam – Jurong – South Kalimantan.
Sulzer’s scope of the work included complete disassembly. inspection, cleaning include alumina
blasting existing rotor and existing diaphragm, NDE, minor repair, and assembly all of steam
control and stop valves, turbine rotor, bearings, diaphragms, casing, and turning gears. Due to
limited time, cleaning rotor and diaphragm using alumina blasting was cancel it and changed to
mechanical or manual cleaning.
Removal and assembly of turbine and generator instrument were performed by customer E/I
technician and also the verification and calibration were done by them.
Sulzer’s workforce mobilized onsite started on November 14th , 2016 for safety induction and site
establishment. Due to operational purpose the turbine was taken off turning gear and disassembly
of the turbine began on 23rd November. Mechanical assembly of the turbine and generator were
completed on December 18th 2016. All commissioning activities were completed on December
23th when the unit reached 58 MW and the remaining personnel were demobilized on December
24th . This report will discuss the process of overhaul and commissioning Steam turbine Toshiba
Unit #1 PLTU ASAM ASAM.
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STEAM TURBINE MACHINE DATA SHEET
Model / Type :
Rating : 65 MW
Stages : 16 stages.
Site Personnel
Name Position
Wawan Kuswardhana Site Coordinator
Widada Sr. Mechanic Turbine
Mohammad Anton Supervisor Generator
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II. Technical Observation.
Dismantling
The last major overhaul was performed by other contractor in 2013 and on this major
overhaul the dismantling works was started with removed turbine enclosure, disconnect
electrical and instrument devices by customer technician , and continue with opened
turbine manhole. Then work was continue with removed turning gear, loosen bolt casing ,
lift up casing and continue to turn over upper half casing.
Rotor was lifting and put on stand after initial measurement has been taken.
Inspection works
On this overhaul, the inspection works are consist of 3 of type of inspections. They are
visual inspection, NDT inspection and dimensional inspection.
Prior to reassembly turbine, cleaning works was mandatory, cleaning works were did on all
the part which was removed in this outage. Due limited time, cleaning with alumina blast on
rotor and diaphragm were changed to mechanical cleaning by power hand tools.
Reassembly was started after all the parts that repaired on shop received at site. Started
on diaphragm installation then continue to install rotor to check contact between bearing
and rotor journal, the result said that the bearing no #2 need to correction. After the
correction the contact was checked again prior the final rotor installation. Radial, axial and
thrust clearance were checked mean while the upper half casing was turn over after the
upper half diaphragm installed and drop check measurement were performed.
Control valve installation on upper half casing and applied adequate amount of birkosit as
joint sealing to the surfaces of the horizontal flanges of the casing were done prior upper
half casing installation. Bolting and tightening were next step to performed ,tightening
started from HP side using bolt heater than continue to LP Side.
After tightening casing bolt completed, then work was continue with alignment Turbine –
Generator including install coupling bolts after alignment finished. Reinstall and setting
gland seal, oil baffle, casing man hole, cover pedestal bearing both no#1 and no#2, turning
gear and oil pipe which connected to turning gear were performed after tightening coupling
bolts finished. Turbine enclosure was installed on December 23rd , 2016 after turbine
running in normal load.
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III. Report Content
3.1 Work Summary
TURBINE ROTOR
Turbine rotor was removed, cleaning was using mechanical hand power tools, visual inspect
and NDT check were carry out after sand blasting were completed. There were found rubs on
journal both generator and turbine side, major rubs on HP gland seal. There were found heavy
rubs on shroud stage 14 and also found cracks on thrust collar that recommend to repair
before put the rotor in service.
CASING
The upper and lower casing were manually mechanical cleaned, visual inspected was
performed after cleaning activity had completed, found deep score and scale on upper and
lower casing split line last stage area. No found any indication on other area during NDT
Examination.
During casing reassembly, the horizontal joint bolts were stretched and tightened as per OEM
specification and clearance of the horizontal joint was checked to ensure the casing has close
tight. BIRKOSIT was applied as the joint sealant.
DIAPHRAGM
Stage #2, #3, #14 and 15 both upper and lower diaphragms were removed from the casing
and shipped to the Sulzer workshop for further repair, while the others still in the casing. Drop
check between casing and diaphragm was checked. Due to limited time, cleaning using sand
blasting was changed to mechanical cleaning by hand tools.
There were found minor rubs on seal all stage diaphragm. No found any indication during NDT
Examination.
The main stop valve was dismantled, all the parts were cleaned and check the NDT and found
no any indication only rubs on body pilot valves . Measurement was taken on stem valves and
found the run out within tolerance. During the reassembly contact check between the main disc
and seat valves were performed and found the contact check were 100 % contacted. Contact
check also was performed on pilot valves and the seat and found the contact check also were
100%. Prior to close the main stop valves, it was checked by inspection team to ensure the
valves were cleaned and no foreign material inside the valves.
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CONTROL VALVES
The control valves where location on upper half casing were dismantled before upper half
casing removed, dismantling part such as bushing, and stem were performed on Workshop at
Banjarmasin. All the control valve parts were replaced with new spare part. The contact check
were performed to ensure the valves have good contact.
Prior to assembly, it was checked by inspection team to ensure the valves were cleaned and
no foreign material inside the valves.
STEAM STRAINER
The steam strainer which located inside of main stop valve was dismantled, strainer was
cleaned by mechanical cleaning ( grind) and NDT check was performed to and no found any
crack or defect.
TURNING GEAR
The turning gear was dismantled, cleaned and took NDT on turning gear worm gear. It was
found no indication on turning gear worm gear, contact check and backlash were performed
also during reassembly turning gear.
COUPLING BOLTS
The coupling bolts were removed, cleaned and NDT check. There were found minor scratch
on all coupling bolts and the lock plate were damaged and need to replace with new one.
During installation elongation checked was performed to ensure the tightening bolt couplings
are within specification.
On this Overhaul, the existing main lube oil was replaced with the new one. Main lube oil was
drained and then the Tank was cleaned and visual inspected. New oil was filled to the oil tank
after get clearance from inspector team.
Oil flushing for unit #1 was started on December, 18th 2016, at afternoon . Flushing screens of
200 mesh were installed at main supply line bearing number #1, main supply line bearing #3
and main supply line bearing #4.. The screens were inspected every 1 – 4 hours or as
requested by customer. Oil Flushing was completed on December ,19 2016, around 14:00
WITA.
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3.2 Summary of Inspection Findings
Assembly
All journal bearing clearances were Adding shim 0.25 mm on
checked during assembly and found pedestal bearing no #2 and
acceptable. polished the bearings.
Thrust bearing clearance was checked
by thrusting the rotor towards the
active and inactive pads. The
3.2.1.2
clearance was found acceptable.
During the assembly, it was found the
contact check between journal rotor
and bearing was out of specification.
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Finding / remark Corrective measure
3.2.2 Turbine Rotor Unit 1
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Finding / remark Corrective measure
LSB was 2 days.
Balance weights were inspected and
found to be tight.
3.2.3 Diaphragms
Diaphragms stage #2, #3, #14, #15
were removed and shipping to the
workshop for repaired the seal fin, the
summary inspection report can be
seen on attachment. All stage diaphragms
The remaining diaphragms were replaced with spare.
cleaned by mechanical power hand
tools.
Except diaphragms #2, #3, #14, #15,
3.2.3.1 all areas accessible received a MT
NDE examination. No indications were
found.
Found the medium erosion on split
line diaphragms stage #16 both upper
and bottom halves.
Found the light to medium scratches
and nick on vanes all diaphragms.
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Page 9 of 35
Finding / remark Corrective measure
Blue contact checks were made on
the valve seats and valve disc and
verified almost 100 percent contact.
Stem valves were measured and
found the run out still within tolerance.
Assembly
All bolting was torqued to OEM
3.2.4.2 specifications.
All gaskets were replaced.
Assembly
All bolting was torqued to OEM
specifications
All gaskets were replaced.
3.2.6.2
Setting the control valves actuator
were performed after got pressurize oil
hydraulic/ commissioning time.
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Page 10 of 35
satisfactory.
Latching mechanism was inspected
and found in good condition and
operable.
NDT inspection was came with result
no found any indication.
Assembly
Overall alignment of the turning gear
assembly to the turbine shaft was
3.2.7.2 checked and found satisfactory.
All bolting was torqued to OEM
specifications.
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IV. Commissioning and Start up
The commissioning and setting of the set points for the instruments of turbine was
performed by Client, and during commissioning and startup Sulzer provided the following
support to PLN ( Persero) PLTU Asam Asam :
Turning gear on was started on December 18th , 2016, soon after adjusting control valves were
completed. Full Speed No Load 3000 RPM for the unit was achieved on December 20th, 2016
afternoon. Some protection testing such as emergency trip test oil, overspeed trip test oil, lube
oil low trip test oil and condense vacuum low test oil were performed by customer. The unit
synchronized on October 20th, 2016 at 17:30 PM, during load increasing, found the vibration at
bearing #3 was high and reached until +/- 70 - 90 µm, due of that it was decided to slowly
increased the generator load with the vibration level maintenance below 100 µm.
During generator increasing, it was found the flexible hose which oil supply bearing #4 was
leaked. Decided to shutdown the unit for repair program.
After repaired the flexible hose , the unit was started again and lowly reached 58 MW on
December 23th, 2016, generator load can not increased to maximum load 65 MW due to
vibration level at bearing #3 will be going higher more than 100 µm. Except high vibration at
bearing #3, others turbine parameters are within specification.
FSD-01FR-01 Rev. 03 This material is the exclusive property of PT. Sulzer Indonesia.
Page 12 of 35
V. Conclusion & Recommendation
Reviewing along the outage process, inspection and operation data after Inspection, it comes to
the conclusion and recommendation as follows :
Conclusion
The works previously scheduled for 23 (twenty third) Calendar day which was started on
November 26th , 2016 and shall be finished on December 20th , 2016. Unit was running with
maintenance load on 58 MW December 23rd , 2016 .
Recommendation
Rotor
o Repair the thrust collar due to found crack
o Replace shroud and blade stage #14 with new spare.
o Repair step seal which erosion on HP side ( Segment 1-4).
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Page 13 of 35
Diaphragms.
o Replace spill strips diaphragm stage #2
o Replace spill strips diaphragm stage #3
o Replace outer seal diaphragm stage #13 due to out of spesification.
o Replace outer seal diaphragm stage #14
o Weld repair split line and packing seal end area diaphragm stage #14 were having
erosion.
o Replace outer seal diaphragm stage #15
o Weld repair split line and packing seal end area diaphragm stage #15 were having
erosion.
o Provide spare interstage seal due to found some of seal already out of tolerance.
Provide spare of pilot valves Main Stop Valves due to found erosion on body pilot valves.
A sufficient amount of Belzona should be ordered for use during future outages as a sealant on
casing erosion areas.
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Fig 1.After removed enclosure
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Fig 2. Turbine Name Plate
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Fig 4. Prepare for upper casing removal
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Fig 6. Prepare for remove bearing #1
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Fig 8. As found rotor journal bearing #2
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Fig 10. PT NDE examination on thrust collar
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Fig 12. Unloading rotor turbine on balancing equipment
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Fig 14. Pilot valve MSV condition ( erosion on body )
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Fig 16. Contact check Main Stop Valve, 100% contacted
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Fig 18. Contact Check on turning gear
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Fig 21. Rotor installation for check in clearance
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Fig 22. Final installation after clearance check
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Fig 24. Reassembly control valve
Fig 25. Birkosit as joint sealant casing and governor control valve
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Fig 26. Governor control valve Installation
Fig 27. Birkosit as joint sealant casing and governor control valve
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Fig 28. Upper half casing installation
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Fig 30. Cement hot insulation
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Fig 32. Cover front pedestal installation
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Fig 34. Final hot turbine insulation
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Fig 34. Condition 1000 rpm
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Fig 36. Condition steam turbine on load 18 MW
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Fig 38. Condition steam turbine on load 51MW
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Page 35 of 35
INITIAL
INSPECTION REPORT
Actual
Position Seal Design Left Right
A B A B
1 0.50 1.7 2.1 2 1.7
2 0.50 1.6 1.6 1.7 1.7
3 0.64 2.5 3 2.5 2.9
HP
4 0.50 2.35 2.5 2.7 2.5
5 0.50 2.1 2.2 2.35 2.4
6 0.50 2.7 2.9 2.15 2.2
1 0.64 1.5 1.8 1.7 1.9
LP 2 0.64 1.7 1.7 1.8 1.8
3 0.64 1.4 1.4 1.65 1.75
FSD-01FR-03 Rev.00 This material is the exclusive property of PT. Sulzer Indonesia.
PAGE 1 OF 1
FINAL
INSPECTION REPORT
MFG/MODEL : ALSTOM
RATING : 85312 KVA
SERIAL No. : T227 250
ALIGNMENT UNIT NO. : 1
(As Left) CUSTOMER : PLN – PLTU ASAM ASAM
LOCATION : South Kalimantan
JOB NO# : P – 1739
1. Result
0.000 0.000
+0.230
R +0.260 0.011
A 0.007
Average
+0.480 0.022
REMARKS :
OTHER REMARKS:
COMMENTS:
ACCEPTABLE
APPROVED BY: MO.
TEST AREA :
WITNESS ON TEST/DEFECTIVE AREAS BY:
VISIBLE SURFACE
MAGNETIZER: METHOD: PARTICLE TYPE: RESIDUAL MAGNETISM :
MOBILE UNIT CONTINUOUS ARDROX 8800 GAUSS METER AT SURFACE:
HEAD SHOT/CLAMP KEROSENE COUPLING END
COIL/CABLE WRAP RESIDUAL (SOLVENT MIX) CENTER
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
AMP.: AC/DC WET BATH (FLUORESCENT) (SPRAY CAN) DEMAGNETIZED BELOW 2.0 GAUSS
YOKE
AC DC DRY POWDER (VISIBLE) OTHERS PARTS WITH DISCONTINUITIES MARKED
INSPECTIONS RESULTS:
PAS
INSPECTOR SIGNATURE
APPROVED BY : ES
MOP AREA
Fig.2 No indication on gear tooth CE area Fig.3 No indication on bolt hole CE area
Fig.4 No indication on trust collar CE area Fig.5 No indication on trust collar CE area
Fig.11 No indication on shroud and tenon Fig.12 No indication on shroud and tenon
area area
Fig.15 Heavy rubing on disk #13 Fig.16 Heavy rubing on disk #13
Fig.17 No indication on blade triling adge Fig.18 No indication on blade triling adge
area area
Fig.19 No indication on blade triling adge Fig.20 No indication on blade triling adge
area area
Fig.21 Found rubs on seal TE aera Fig.22 Typical no indication on seal TE area
Fig.25 Crack indication on trust bearing TE Fig.26 Crack indication on trust bearing TE
area area
Fig.27 No indication on Main Oil Pump part Fig.28 No indication on Main Oil Pump part
Fig.29 No indication on Main Oil Pump part Fig.30 No indication on Main Oil Pump part
TEST AREA :
WITNESS ON TEST/DEFECTIVE AREAS BY:
ALL VISIBLE SURFACE
MAGNETIZER: METHOD: PARTICLE TYPE: RESIDUAL MAGNETISM :
MOBILE UNIT CONTINUOUS ARDROX 8800 GAUSS METER AT SURFACE:
HEAD SHOT/CLAMP KEROSENE COUPLING END
COIL/CABLE WRAP RESIDUAL (SOLVENT MIX) CENTER
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
AMP.: AC/DC WET BATH (FLUORESCENT) (SPRAY CAN) DEMAGNETIZED BELOW 2.0 GAUSS
YOKE
AC DC DRY POWDER (VISIBLE) OTHERS PARTS WITH DISCONTINUITIES MARKED
INSPECTIONS RESULTS:
I CERTIFY THAT THE ABOVE LISTED ITEMS WERE INSPECTED IN ACCORDANCE WITH
APPLICABLE SULZER TSID STANDARD
Fig. 1 Found crack indication thrust collar Fig. 2 Found crack indication thrust collar
Fig. 3 Found crack indication thrust collar Fig. 4 Found crack indication thrust collar
Fig. 5 Found crack indication thrust collar Fig. 6 Found crack indication thrust collar
AS RECEIVED
FINAL
TEST AREA :
PROCEDURE NO. : PRO-01WI-41
ALL VISIBLE SURFACE
INSPECTION RESULT :
PAS
OPERATOR SIGNATURE
APPROVED BY : ES
Fig. 1 Demag bellow 2 gauss on shaft TE side Fig. 2 Demag bellow 2 gauss on shaft TE side
Fig. 7 Demag bellow 2 gauss on disk area Fig. 8 Demag bellow 2 gauss on disk area
Fig. 9 Demag bellow 2 gauss on disk area Fig. 4 Demag bellow 2 gauss on seal area CE side
Fig. 5 Demag bellow 2 gauss on shaft CE side Fig. 6 Demag bellow 2 gauss on gear area CE side
AS RECEIVED
1 SET = PAD BEARING ACTIVE REPAIR
1 SET = PAD BEARING INACTIVE FINAL
INSPECTION RESULT :
POROSITY, HEAVY RUBING AND LINIER INDICATION ON ABOVE INSPECTED PART, SEE THE
ATTACHMENT:
PAS
INSPECTOR SIGNATURE
APPROVED BY : ES
Fig. 1 Penetrant inspection on pad bearing Fig . 2 Found porosity indication on pad bearing
active active
Fig. 3 Porosity indication on pad bearing Fig. 4 Porosity indication on pad bearing
active active
Fig. 5 Porosity indication on pad bearing Fig. 6 Porosity indication on pad bearing
active active
Fig. 1 Penetrant inspection on pad bearing Fig . 2 Found linier and heavy rubs indication on pad
inactive bearing inactive
Fig. 3 Linier and heavy rubs on pad bearing Fig. 4 Linier and heavy rubs on pad bearing
inactive inactive
TEST AREA :
WITNESS ON TEST/DEFECTIVE AREAS BY:
VISIBLE SURFACE
MAGNETIZER: METHOD: PARTICLE TYPE: RESIDUAL MAGNETISM :
MOBILE UNIT CONTINUOUS ARDROX 8800 GAUSS METER AT SURFACE:
HEAD SHOT/CLAMP KEROSENE COUPLING END
COIL/CABLE WRAP RESIDUAL (SOLVENT MIX) CENTER
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
AMP.: AC/DC WET BATH (FLUORESCENT) (SPRAY CAN) DEMAGNETIZED BELOW 2.0 GAUSS
YOKE
AC DC DRY POWDER (VISIBLE) OTHERS PARTS WITH DISCONTINUITIES MARKED
INSPECTIONS RESULTS:
1 CASING NO INDICATION
PAS
INSPECTOR SIGNATURE
APPROVED BY : ES
Fig.2 No indication on pit area on casing Fig.3 No indication on pit area on casing
upper and lower upper and lower
Fig.9 No indication on pit area on casing Fig.10 No indication on pit area on casing
upper and lower upper and lower
AS RECEIVED
1 SET = BEARING #1 REPAIR
1 SET = BEARING #2 FINAL
INSPECTION RESULT :
FOUND LINIER AND CRACK INDICATION ON BEARING #1, SEE THE ATTACHMENT:
PAS
INSPECTOR SIGNATURE
APPROVED BY : ES
BEARING #1
Fig. 3 Linier indication on bearing #1 upper Fig. 4 Crack indication on bearing #1 lower
BEARING #2
Fig. 3 No indication on bearing #2 upper and Fig. 4 No indication on bearing #2 upper and
lower lower
Fig. 5 No indication on bearing #2 upper and Fig. 6 No indication on bearing #2 upper and
lower lower
TEST AREA :
WITNESS ON TEST/DEFECTIVE AREAS BY:
VISIBLE SURFACE
MAGNETIZER: METHOD: PARTICLE TYPE: RESIDUAL MAGNETISM :
MOBILE UNIT CONTINUOUS ARDROX 8800 GAUSS METER AT SURFACE:
HEAD SHOT/CLAMP KEROSENE COUPLING END
COIL/CABLE WRAP RESIDUAL (SOLVENT MIX) CENTER
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
AMP.: AC/DC WET BATH (FLUORESCENT) (SPRAY CAN) DEMAGNETIZED BELOW 2.0 GAUSS
YOKE
AC DC DRY POWDER (VISIBLE) OTHERS PARTS WITH DISCONTINUITIES MARKED
INSPECTIONS RESULTS:
PAS
INSPECTOR SIGNATURE
APPROVED BY : ES
COUPLING BOLT
Fig.3 No crack indication on coupling bolt Fig.4 No crack indication on coupling bolt
Fig.5 No crack indication on coupling bolt Fig.6 No crack indication on coupling bolt
Fig.7 No crack indication on coupling bolt Fig.8 No crack indication on coupling bolt
Fig.9 No crack indication on coupling bolt Fig.10 No crack indication on coupling bolt
Fig.11 No crack indication on coupling bolt Fig.12 No crack indication on coupling bolt
CASING BOLT
Fig.15 No crack indication on bolt casing Fig.16 No crack indication on bolt casing
Fig.17 No crack indication on bolt casing Fig.18 No crack indication on bolt casing
Fig.21 No crack indication on bolt casing Fig.22 No crack indication on bolt casing
Fig.23 No crack indication on bolt casing Fig.24 No crack indication on bolt casing
AS RECEIVED
REPAIR
2 AREA = ROTOR FINAL
INSPECTION RESULT :
FOUND CRACK INDICATION ON TRUST COLLAR CE SIDE ON ABOVE INSPECTED PART, SEE THE
ATTACHMENT:
PAS
INSPECTOR SIGNATURE
APPROVED BY : ES
Fig. 3 No indication on journal bearing CE side Fig. 4 No indication on trust collar CE side
TEST AREA :
WITNESS ON TEST/DEFECTIVE AREAS BY:
VISIBLE SURFACE
MAGNETIZER: METHOD: PARTICLE TYPE: RESIDUAL MAGNETISM :
MOBILE UNIT CONTINUOUS ARDROX 8800 GAUSS METER AT SURFACE:
HEAD SHOT/CLAMP KEROSENE COUPLING END
COIL/CABLE WRAP RESIDUAL (SOLVENT MIX) CENTER
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
AMP.: AC/DC WET BATH (FLUORESCENT) (SPRAY CAN) DEMAGNETIZED BELOW 2.0 GAUSS
YOKE
AC DC DRY POWDER (VISIBLE) OTHERS PARTS WITH DISCONTINUITIES MARKED
INSPECTIONS RESULTS:
1 DIAPHRAGM ACCEPTED
PAS
INSPECTOR SIGNATURE
APPROVED BY : ES
Fig.5 Crack indication on weld area Fig.6 Crack indication on inspcted area
Fig.11 No crack indication on blades triling Fig.12 No crack indication on blades triling
edge area edge area
Fig.13 No crack indication on split line area Fig.14 No crack indication on seal area
Fig.15 Visualy no crack indication on seal Fig.16 Visualy no crack indication on seal
area area
Fig.17 Visualy no crack indication on seal Fig.18 Visualy no crack indication on seal
area area
TEST AREA :
WITNESS ON TEST/DEFECTIVE AREAS BY:
VISIBLE SURFACE
MAGNETIZER: METHOD: PARTICLE TYPE: RESIDUAL MAGNETISM :
MOBILE UNIT CONTINUOUS ARDROX 8800 GAUSS METER AT SURFACE:
HEAD SHOT/CLAMP KEROSENE COUPLING END
COIL/CABLE WRAP RESIDUAL (SOLVENT MIX) CENTER
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
AMP.: AC/DC WET BATH (FLUORESCENT) (SPRAY CAN) DEMAGNETIZED BELOW 2.0 GAUSS
YOKE
AC DC DRY POWDER (VISIBLE) OTHERS PARTS WITH DISCONTINUITIES MARKED
INSPECTIONS RESULTS:
PAS
INSPECTOR SIGNATURE
APPROVED BY : ES