questions and answers for engine overhaul

QUESTIONS AND ANSWERS FOR RFP FOR LM6000 GAS TURBINE OVERHAUL ESN 191‐498

Questions and Answer for the RFP for LM6000 Gas Turbine Overhaul ESN 191-498 of 1

1) Confirm if MTU Field Service for Engine Removal/Installation is required and to be a part of the Proposal. A. No field service for removal/installation is required as part of this proposal.

2) Does Santa Clara have its own LM6000 Shipping Container for the movement of the

Engine? A. Engine 191-498 is in Santa Clara’s shipping container ready to ship.

3) Does the Engine have SPRINT? If yes: Sprint for HPC (regular SPRINT) or for

LPC&HPC (enhanced SPRINT)? A. Yes, Enhanced SPRINT.

4) Travel time to and from the repair facility: Is the 5 days permitted for each way?

A. Yes.

5) Confirm the estimated timing of the Engine Overhaul Project (when would the Engine be removed from Service for the Overhaul Program?) A. Engine is removed from service in the shipping container ready to ship.

6) Is there a recent Borescope Report available for MTU to review?

A. Yes, a borescope inspection was performed when the engine was removed from service.

7) Is the Engine equipped with Fuel Nozzle Water Injection for Emissions Reduction? A. Yes, the engine is equipped with fuel nozzles for water injection.

8) Is there any non-OEM hardware in the engine? A. None that I am aware of.

9) Can SVP share any non-confidential or non-proprietary information regarding the hot

section repair executed in the last 3 years? Depot report? Inspections? A. Working on getting a depot repair.

10) When is SVP planning to induct the engine?

A. July-August.

11) Will SVP have the MSAs with GEII and GEPPI signed prior to June 15th, 2017 A. No.

12) Can SVP share any non-confidential or non-proprietary information regarding the hot

section repair executed in the last 3 years? Deport report? Inspections? A. The Depot Report TCT issues Customers after any Depot visit is considered

proprietary as it contains commercially sensitive pricing on parts, any rotable modules or components used, etc. Therefore we do consider the Customer Depot Reports confidential.

Aero Energy LMS100 Report

LM6000PC

Engine Borescope

Report

April 6, 2017

For

SILICON VALLEY POWER

San Jose, CA Unit #2

ESN 191-498

Under

GE Oracle Project 7272038

Customer Representative: Rick Sandau GE Field Service Representative: Moses Castillo

Aero Energy LMS100 Report All technical recommendations and information contained in this report are based on GE manuals that have been developed and approved for use with GE engines and parts that have been operated and maintained in accordance with GE technical documentation and recommendations. GE has no technical knowledge of, nor obligation for, non GE-approved parts and repairs. Accordingly, this report is not intended to apply to non GE-approved parts and repairs, nor to any parts that may be directly or indirectly affected by non GE-approved parts and repairs.

SUMMARY The purpose of this visit was to perform a Periodic Borescope Inspection and to give Costumer a general view and indication of the condition of the engine before it goes for full overhall. Outage Data: Engine Data:

ESN 191-498 Engine Fired Hours

N/A Package Hours N/A

Model

LM6000PC Engine Fired starts

N/A Package Fired Starts N/A

Aero Energy LMS100 Report

Inspection Details

Menu Directed LM6000PC Engine Serial Number 191-498

Date 7 04 2017 Time 09:48:55

Inspection Summary

No Images No Flagged Images Flagged Images

Inspection Points Images Flagged Images

LPC 9 16 0

IGB-If S/B 220

not C/W 0 0 0

HPC1-7 17 22 0

HPC8-14 15 11 0

Comb 8 3 0

Fuel Nozzle 0 0 0

HPT 15 21 0

HPT Diff-If S/B

216 not C/W 0 0 0

Stg 11 Check

Valves 0 0 0

S7-1 and S7-2 Borescope Plugs

0 0 0

LPT 8 11 0

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LPC_Stage0_LE001.JPG

Section LPC Stage Stage0_LE

Comments No damage found







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LPC_Stage1_TE001.JPG

Section LPC Stage Stage1_TE


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HPC1-7_Stage1_LE001.JPG

Section HPC1-7 Stage Stage1

Component LE Comments No damage found




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HPC1-7_Stage1_TE001.JPG


Component TE Comments No damage found

HPC1-7_Stage1_CarbWearPad001.JPG


Component CarbWearPad/Mid Span Damper Comments No damage found

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Component CarbWearPad/Mid Span Damper Comments

No damage found



Component TE Comments

No damage found




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Component L E Comments No damage found







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Comb_Inner_Liner001.JPG

Section Comb Stage Inner Liner





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HPT_Stage_1_Nozzle_LE001.JPG

Section HPT Stage Stage 1 Nozzle





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HPT_Stage_1_Nozzle_TE001.JPG






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HPT_Stage_1_Blade_LE001.JPG

Section HPT Stage Stage 1 Blade


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HPT_Stage_1_Blade_TE001.JPG



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HPT_Stage_1_Blade_Shroud001.JPG


Component Shroud Comments No damage found




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LPT_Stage1_LE001.JPG

Section LPT Stage Stage1_LE


LPT_Stage1_TE001.JPG

Section LPT Stage Stage1_TE


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Comments

Honeycomb Airseals worn No damage found







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Comments

No damage found



Comments

No damage found



Comments

No damage found

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Aero Energy LM6000PC Report

Report completed by – Hernan Mao Granada

Semi-annual Borescope Inspection Report

November 8th, 2016

For

SVP

Donald Von Reasfeld Power Plant

Unit 2 ESN 191-498

Under

GE Oracle Project 7270092

Customer Representative: Chet Manchester GE Field Service Representative: Hernan Mao Granada

All technical recommendations and information contained in this report are based on GE manuals that have been developed and approved for use with GE engines and parts that have been operated and maintained in accordance with GE technical documentation and recommendations. GE has no technical knowledge of, nor obligation for, non GE-approved parts and repairs. Accordingly, this report is not intended to apply to non GE-approved parts and repairs, nor to any parts that may be directly or indirectly affected by non GE-approved parts and repairs.



CONCLUSIONS & RECOMMENDATIONS

-This Semi-annual Borescope inspection was completed in accordance with IAW GEK 105059, Chapter 12 WP 4015 00 and unit is serviceable and available for continued operation. -It is recommended to have a longer water-wash or implement a better procedure. -Found visible wear of igniter plug. Igniter was replaced. -Stage 11 check valve’s flap at 6’ is missing (see Pic) replacement of piping is recommended. -Continue monitoring missing coating found on HPT stage 1 blade. No oxidized, holes or cracks found. Serviceable. -Inlet temperature sensor (t48) found broken at 12’. Thermocouple was replaced. -Continue Maintenance checks recommended in GEK 98493 Vol. I Table 12-1 Outage Data: Engine Data:

ESN 191-498 Engine Fired Hours

47526.1 Combustor Hours N/A

Model LM6000 PC Engine Fired starts

1336 Engine Fired starts attempts

1426

Maintenance Data:

WP, SB, SL, PB, PL Performed

Revision/manual reference Date completed

Comments

GEK 105059 Borescope Inspection 10.28.16

Chapter 12

Parts Data:

Description PN Removed

SN Removed

Qty Disposition PN Installed

SN Installed

igniter n/a n/a 1 Upper igniter 9392M95P04 J6U908

thermocouple n/a n/a 1 862-7-19 50918



Purpose of visit:

-The purpose of this visit was to perform a Periodic Borescope Inspection IAW GEK 105059, Chapter 12

Work performed:

A borescope inspection of the engine was performed using a flex scope and a turning tool.

Daily Activity report: -Friday 11.04.16 Moved form unit one to unit 2 Interacted with site manager Joe, reviewed work scope and timeline Completed Granite JSA and EHS forms. Walked down LOTO and applied lock. Conducted borescope inspection. -Saturday 11.05.16 Conducted borescope inspection. -Thursday 11.06.16 Finished LPC and LPT inspection Removed LOTO Assist site personnel with variable geometry calibration on units 1 and 2 Released from site Report writing

Inspection Summary

No Images No Flagged Images Flagged Images

Inspection Points Images Flagged Images

LPC 8 33 0

Inlet Gear Box 1 6 0

HPC1-7 17 67 0

HPC8-14 15 24 0

HPT Diffuser 1 0 0

Comb 8 31 2

Fuel Nozzle 1 4 0

HPT 15 56 6

Stg 11 Check Valves 1 4 2

LPT 8 35 1



Low Pressure Compressor BSI Ports

Right Hand Side Left Hand Side

Low Pressure Compressor

Inspection Area Comments

LP Sprint Nozzle No discrepancies found

Inlet FOD screen No discrepancies found

FIX IGV OR VIGV No discrepancies found

Inspect stages 0 through 4 blades and vanes for cracks, nicks, burrs, tears, curl, missing material, dents, scratches, pits.

No discrepancies found

VIGV flaps No discrepancies found

Stage 0 Blades & Vanes, No discrepancies found





Inspect for airfoil erosion, corrosion or deposits No discrepancies found

Use flexscope to inspect visible portion of stage 0-3 vane inner bushing for cracking, protrusion into air stream, or missing pieces.


Use flexscope to inspect stage 4 vane inner bushing for cracking, protrusion into air stream, or missing pieces





Section LPC

Stage Stage0_LE

Comments




Section LPC

Stage Stage0_LE

Comments


Section LPC

Stage Stage0_LE

Comments


Section LPC

Stage Stage1_TE

Comments




Section LPC

Stage Stage1_TE

Comments


Section LPC

Stage Stage1_TE

Comments


Section LPC

Stage Stage2_LE

Comments




Section LPC

Stage Stage2_LE

Comments


Section LPC

Stage Stage2_TE

Comments


Section LPC

Stage Stage2_TE

Comments




Section LPC

Stage Stage2_TE

Comments


Section LPC

Stage Stage2_TE

Comments


Section LPC

Stage Stage3_LE

Comments




Section LPC

Stage Stage3_LE

Comments


Section LPC

Stage Stage3_LE

Comments


Section LPC

Stage Stage3_TE

Comments




Section LPC

Stage Stage3_TE

Comments


Section LPC

Stage Stage3_TE

Comments


Section LPC

Stage Stage4_LE

Comments




Section LPC

Stage Stage4_LE

Comments


Section LPC

Stage Stage4_LE

Comments

LPC_General001.JPG

Section LPC

Stage General

Comments



LPC_General002.JPG

Section LPC

Stage General

Comments

LPC_General003.JPG

Section LPC

Stage General

Comments

LPC_General004.JPG

Section LPC

Stage General

Comments



LPC_General005.JPG

Section LPC

Stage General

Comments

Inlet_Gear_Box001.JPG

Section Inlet Gear Box

Comments





Comments



Comments

High Pressure Compressor BSI Ports

Right Side – Low Boss Case Left Side – Low Boss Case



High Pressure Compressor


Inspect stages 1 through 14 blades for cracks, nicks, tears, burrs, dents, missing material, evidence of tip clang, curl or deformation.

IGV from BSI ports S5-0 NO discrepancies found

Stage 1 Blades (Qty 36) & Vanes NO discrepancies found







Stage 8 Blades (Qty 64) & Vanes No accessible at this time







Inspect the stage 1 mid-span shroud interlock wear, shingling, a gap or a missing pad.

NO discrepancies found

Inspect for erosion, corrosion or deposits. NO discrepancies found

Inspect for platform shingling, bowing, distortion or cracks NO discrepancies found



HPC1-7_General004.JPG

Section HPC1-7

Stage General

Comments


Section HPC1-7

Stage General

Comments


Section HPC1-7

Stage General

Comments




Section HPC1-7

Stage General

Comments


Section HPC1-7

Stage Stage1

Component LE

Comments


Section HPC1-7

Stage Stage1

Component LE

Comments




Section HPC1-7

Stage Stage1

Component LE

Comments


Section HPC1-7

Stage Stage1

Component TE

Comments


Section HPC1-7

Stage Stage1

Component TE

Comments




Section HPC1-7

Stage Stage1

Component TE

Comments


Section HPC1-7

Stage Stage1

Component TE

Comments




Section HPC1-7

Stage Stage1

Component CarbWearPad

Comments


Section HPC1-7

Stage Stage1


Comments


Section HPC1-7

Stage Stage1


Comments




Section HPC1-7

Stage Stage2

Component LE

Comments


Section HPC1-7

Stage Stage2

Component LE

Comments


Section HPC1-7

Stage Stage2

Component LE

Comments




Section HPC1-7

Stage Stage2

Component TE

Comments


Section HPC1-7

Stage Stage2

Component TE

Comments


Section HPC1-7

Stage Stage2

Component TE

Comments




Section HPC1-7

Stage Stage2

Component TE

Comments

HPC1-7_Stage2_WeepHole001.JPG

Section HPC1-7

Stage Stage2

Component WeepHole

Comments

HPC1-7_Stage2_WeepHole002.JPG

Section HPC1-7

Stage Stage2

Component WeepHole

Comments




Section HPC1-7

Stage Stage3

Component LE

Comments


Section HPC1-7

Stage Stage3

Component LE

Comments


Section HPC1-7

Stage Stage3

Component LE

Comments




Section HPC1-7

Stage Stage3

Component TE

Comments


Section HPC1-7

Stage Stage3

Component TE

Comments


Section HPC1-7

Stage Stage3

Component TE

Comments




Section HPC1-7

Stage Stage3

Component TE

Comments


Section HPC1-7

Stage Stage4

Component LE

Comments


Section HPC1-7

Stage Stage4

Component LE

Comments




Section HPC1-7

Stage Stage4

Component LE

Comments


Section HPC1-7

Stage Stage4

Component TE

Comments


Section HPC1-7

Stage Stage4

Component TE

Comments




Section HPC1-7

Stage Stage4

Component TE

Comments


Section HPC1-7

Stage Stage4

Component TE

Comments


Section HPC1-7

Stage Stage5

Component LE

Comments




Section HPC1-7

Stage Stage5

Component LE

Comments


Section HPC1-7

Stage Stage5

Component LE

Comments


Section HPC1-7

Stage Stage5

Component LE

Comments




Section HPC1-7

Stage Stage5

Component LE

Comments


Section HPC1-7

Stage Stage5

Component TE

Comments


Section HPC1-7

Stage Stage5

Component TE

Comments




Section HPC1-7

Stage Stage5

Component TE

Comments


Section HPC1-7

Stage Stage6

Component LE

Comments


Section HPC1-7

Stage Stage6

Component LE

Comments




Section HPC1-7

Stage Stage6

Component LE

Comments


Section HPC1-7

Stage Stage6

Component TE

Comments


Section HPC1-7

Stage Stage6

Component TE

Comments




Section HPC1-7

Stage Stage6

Component TE

Comments


Section HPC1-7

Stage Stage6

Component TE

Comments


Section HPC1-7

Stage Stage7

Component LE

Comments




Section HPC1-7

Stage Stage7

Component LE

Comments


Section HPC1-7

Stage Stage7

Component LE

Comments


Section HPC1-7

Stage Stage7

Component LE

Comments




Section HPC8-14

Stage Stage11

Component TE

Comments


Section HPC8-14

Stage Stage11

Component TE

Comments


Section HPC8-14

Stage Stage11

Component TE

Comments




Section HPC8-14

Stage Stage11

Component TE

Comments


Section HPC8-14

Stage Stage12

Component LE

Comments


Section HPC8-14

Stage Stage12

Component LE

Comments




Section HPC8-14

Stage Stage12

Component LE

Comments


Section HPC8-14

Stage Stage12

Component LE

Comments


Section HPC8-14

Stage Stage12

Component LE

Comments




Section HPC8-14

Stage Stage13

Component LE

Comments


Section HPC8-14

Stage Stage13

Component LE

Comments


Section HPC8-14

Stage Stage13

Component LE

Comments




Section HPC8-14

Stage Stage13

Component LE

Comments


Section HPC8-14

Stage Stage13

Component TE

Comments


Section HPC8-14

Stage Stage13

Component TE

Comments




Section HPC8-14

Stage Stage13

Component TE

Comments

HPC8-14_Stage14_OGV001.JPG

Section HPC8-14

Stage Stage14

Component OGV

Comments


Section HPC8-14

Stage Stage14

Component OGV

Comments




Section HPC8-14

Stage Stage14

Component OGV

Comments


Section HPC8-14

Stage Stage14

Component OGV

Comments


Section HPC8-14

Stage Stage14

Component LE

Comments




Section HPC8-14

Stage Stage14

Component LE

Comments


Section HPC8-14

Stage Stage14

Component LE

Comments

Combustor Inspection Area Comments

Inspect combustor for burning, cracks, erosion, discoloration, wear and missing metal.


Venturi’s No discrepancies found

Swirler Cups No discrepancies found

Trumpets Minor erosion, around the contour

Dome Plates No discrepancies found

Inner/Outer Rivet Bands No discrepancies found

Inner/Outer Liners No discrepancies found

Igniter Tube Area No discrepancies found

Inspect 15 fuel nozzle tips (even numbers) for contamination or damage from all CRF BSI ports or with flex scope

Inspected, no discrepancies Found

Remove the remaining 15 fuel nozzles (odd numbers) and check outer cowl for cracks or missing material. Inspect secondary swirlers for water erosion, missing material or deposits.

Removed, inspected, no discrepancies found.




Section Comb

Component Inner Liner

Comments


Section Comb

Component Inner Liner

Comments



Comb_Outer_Liner001.JPG

Section Comb

Component Outer Liner

Comments


Section Comb


Comments


Section Comb


Comments




Section Comb


Comments

Comb_Dome_Plate001.JPG

Section Comb

Component Dome Plate

Comments




Section Comb


Comments


Section Comb


Comments


Section Comb


Comments




Section Comb


Comments


Section Comb


Comments



Comb_Venturis002.JPG

Section Comb

Component Venturis

Comments


Section Comb

Component Venturis

Comments


Section Comb

Component Venturis

Comments



Comb_Swirler_Cup001.JPG

Section Comb

Component Swirler Cup

Comments


Section Comb


Comments


Section Comb


Comments



Comb_Trumpet_SP001.JPG

Section Comb

Component Trumpet_SP

Comments


Section Comb


Comments


Section Comb


Comments




Section Comb


Comments

Comb_General001-FLAG.JPG

Section Comb

Component General

Comments Out of limits. Replaced.



Comb_General002-FLAG.JPG

Section Comb

Component General

Comments Replaced.

Comb_General003.JPG

Section Comb

Component General

Comments

Comb_General004.JPG

Section Comb

Component General

Comments



Comb_General005.JPG

Section Comb

Component General

Comments

Comb_General006.JPG

Section Comb

Component General

Comments



Comb_General007.JPG

Section Comb

Component General

Comments



Fuel_Nozzle001.JPG

Section Fuel Nozzle

Comments

Fuel_Nozzle002.JPG

Section Fuel Nozzle

Comments

Fuel_Nozzle003.JPG

Section Fuel Nozzle

Comments



Fuel_Nozzle004.JPG

Section Fuel Nozzle

Comments

High Pressure Turbine Stage One Nozzles

Inspection Area Comment

Convex and concave airfoils for cracks, burns or erosion.


Leading edge for burning, cracks, erosion or missing metal.


Leading edge for burning, cracks or erosion or missing metal


Trailing edge for burning, cracks or erosion or missing metal


Thermal barrier coating missing No discrepancies found




Section HPT

Stage Stage 1 Nozzle

Component LE

Comments


Section HPT


Component LE

Comments


Section HPT


Component LE

Comments




Section HPT


Component TE

Comments


Section HPT


Component TE

Comments


Section HPT


Component TE

Comments




Section HPT


Component TE

Comments

HPT_Stage_1_Nozzle_Inner_Plat001.J

PG

Section HPT


Component Inner Plat

Comments


PG

Section HPT



Comments



HPT_Stage_1_Nozzle_Outer_Plat001-

FLAG.JPG

Section HPT


Component Outer Plat

Comments

HPT_Stage_1_Nozzle_Outer_Plat002.J

PG

Section HPT



Comments

High Pressure Turbine Stage One Blades


Leading edge concave and convex areas for impact, cracks, dents, holes or missing material.

No Discrepancies found

Leading edge for clogged cooling holes’ air passages. No Discrepancies found

Leading edge for erosion and coating penetration (blue or green areas) TBC loss.


Concave and convex airfoil areas for burns, erosion, cracks or discrepancies


Trailing edge for impact, cracks, dents. No Discrepancies found

Trailing edge for erosion or missing metal. No Discrepancies found

Blade tips for cracks, bent, erosion or missing material. No Discrepancies found

Blade platform, forward and aft seal areas No Discrepancies found

HPT shrouds for cracks, erosion/oxidation or rubs. No Discrepancies found




Section HPT

Stage Stage 1 Blade

Component LE

Comments




Section HPT

Stage Stage 1 Blade

Component LE

Comments

HPT_Stage_1_Blade_LE006-FLAG.JPG

Section HPT

Stage Stage 1 Blade

Component LE

Comments



HPT_Stage_1_Blade_LE008-FLAG.JPG

Section HPT

Stage Stage 1 Blade

Component LE

Comments


Section HPT

Stage Stage 1 Blade

Component LE

Comments


Section HPT

Stage Stage 1 Blade

Component TE

Comments




Section HPT

Stage Stage 1 Blade

Component TE

Comments

HPT_Stage_1_Blade_Shroud001-

FLAG.JPG

Section HPT

Stage Stage 1 Blade

Component Shroud

Comments


Section HPT

Stage Stage 1 Blade

Component Shroud

Comments



HPT stage two nozzles

Inspection Area: Inspected this area thru the compressor rear frame utilizing a flex scope 360 degrees and HPT stage two port.

Comments

Convex and concave airfoils for cracks, burns or erosion. No discrepancies found

Inner and outer platform or burning, cracks, erosion or missing metal


Trailing edge for burning, cracks or erosion or missing metal No discrepancies found

Thermal barrier coating missing No discrepancies found




Section HPT


Component LE

Comments


Section HPT


Component LE

Comments

HPT_Stage_2_Nozzle_LE003-

FLAG.JPG

Section HPT


Component LE

Comments




Section HPT


Component TE

Comments


Section HPT


Component TE

Comments


Section HPT


Component TE

Comments




Section HPT


Component TE

Comments


PG

Section HPT



Comments


PG

Section HPT



Comments




PG

Section HPT



Comments


PG

Section HPT



Comments


PG

Section HPT



Comments



HPT stage two blades

Inspection Area thru stage two HPT port. Comments

Leading edge concave and convex areas for impact, cracks, dents, holes or missing material.


Leading edge for clogged cooling holes’ air passages. No discrepancies found

Leading edge for erosion and coating penetration (blue or green areas) TBC loss.


Concave and convex airfoil areas for burns, erosion, cracks or discrepancies.


Trailing edge for impact, cracks, dents. No discrepancies found

Trailing edge for erosion or missing metal No discrepancies found

Blade tips for cracks, bent, erosion or missing material. No discrepancies found

Blade platform, forward and aft seal areas for any discrepancies No discrepancies found

HPT shrouds for cracks, erosion/oxidation or rubs. No discrepancies found




Section HPT

Stage Stage 2 Blade

Component LE

Comments


Section HPT

Stage Stage 2 Blade

Component LE

Comments


Section HPT

Stage Stage 2 Blade

Component LE

Comments




Section HPT

Stage Stage 2 Blade

Component LE

Comments


Section HPT

Stage Stage 2 Blade

Component LE

Comments


Section HPT

Stage Stage 2 Blade

Component TE

Comments




Section HPT

Stage Stage 2 Blade

Component TE

Comments


Section HPT

Stage Stage 2 Blade

Component TE

Comments


Section HPT

Stage Stage 2 Blade

Component Shroud

Comments




Section HPT

Stage Stage 2 Blade

Component Shroud

Comments



HPT_General001.JPG

Section HPT

Stage General

Comments

HPT_General002.JPG

Section HPT

Stage General

Comments



Stg_11_Chk_Valves001.JPG

Section Stg 11 Chk Valves

Comments

Stg_11_Chk_Valves002.JPG


Comments

Stg_11_Chk_Valves003-FLAG.JPG


Comments



Low Pressure Turbine




Stage 1 LPT Nozzle No discrepancies found

Stage 1 LPTR Blades (Qty 118) No discrepancies found




Stage 5 LPTR Blades (Qty 74)


Inspect blade shroud interlocks for wear and shingling. No discrepancies found

Inspect for erosion, corrosion or deposits. No discrepancies found




Section LPT

Stage Stage1_LE

Comments


Section LPT

Stage Stage1_LE

Comments


Section LPT

Stage Stage1_LE

Comments




Section LPT

Stage Stage1_LE

Comments


Section LPT

Stage Stage1_LE

Comments


Section LPT

Stage Stage1_TE

Comments




Section LPT

Stage Stage1_TE

Comments


Section LPT

Stage Stage1_TE

Comments


Section LPT

Stage Stage1_TE

Comments




Section LPT

Stage Stage2_TE

Comments


Section LPT

Stage Stage2_TE

Comments


Section LPT

Stage Stage2_TE

Comments




Section LPT

Stage Stage2_TE

Comments


Section LPT

Stage Stage3_TE

Comments


Section LPT

Stage Stage3_TE

Comments




Section LPT

Stage Stage3_TE

Comments


Section LPT

Stage Stage4_LE

Comments


Section LPT

Stage Stage4_LE

Comments




Section LPT

Stage Stage4_LE

Comments


Section LPT

Stage Stage5_TE

Comments


Section LPT

Stage Stage5_TE

Comments




Section LPT

Stage Stage5_TE

Comments


Section LPT

Stage Stage5_TE

Comments

LPT_General001.JPG

Section LPT

Stage General

Comments



LPT_General002.JPG

Section LPT

Stage General

Comments

LPT_General004-FLAG.JPG

Section LPT

Stage General

Comments



LPT_General005.JPG

Section LPT

Stage General

Comments

LPT_General006.JPG

Section LPT

Stage General

Comments

LPT_General007.JPG

Section LPT

Stage General

Comments



LPT_General008.JPG

Section LPT

Stage General

Comments

LPT_General009.JPG

Section LPT

Stage General

Comments

Hernan Mao Granada West Coast Field Service Representative Granite International Inc. 3300 Unicorn Road Bakersfield, California 93308 Mobil: 813.373.2743 E-mail: [email protected]

Aero Energy

Borescope Inspection Report

April 16th 2016

For

City of Santa Clara

Silicon Valley Power-Donald Von Raesfeld Power Plant

Unit # 2 ESN 191-498

Under

GE Oracle Project 7267312 Customer Representative: Chet Manchester GE Field Service Representative: Guy Blanchard

All technical recommendations and information contained in this report are based on GE manuals that have been developed and approved for use with GE engines and parts that have been operated and maintained in accordance with GE technical documentation and recommendations. GE has no technical knowledge of, nor obligation for, non GE-approved parts and repairs. Accordingly, this report is not intended to apply to non GE-approved parts and repairs, nor to any parts that may be directly or indirectly affected by non GE-approved parts and repairs.


Report completed by – Guy Blanchard Granite Field Service 2

SUMMARY -The purpose of this visit was to perform a Periodic Borescope Inspection. -This Periodic Borescope inspection was completed in reference with WP 4015 00. -We replaced the T48A (Loose tip), T48F (Missing tip) and T48G probes (missing sleeve). -We replaced the 11th Stg check valve at 1 o’clock position on the HPT Stg 2 nozzle case. We retrieved the loose flap resting on the inner case at 1 o’clock position. However, we would require the retrieving tool to remove the flap resting in the cavity between both cases at 6 o’clock position. -We replaced the HPT Stg 2 nozzle borescope plug (Seized tip). -The Stg 2 HPT Nozzle with the dent on trailing edge did not worsen since last inspection. It appears like it is cracked around the contour on the convex side. There is no crack through on the concave side. To be monitored regularly for the risk of a piece liberation. It is located below the HPT Stg 2 nozzle Borescope port S7-2. -Noted missing TBC on four (4) HPT Stg 1 blades convex side within serviceable limits. The parent metal is not affected. -We performed the LPT Cooling Air Orifice Plates Inspection and found compliant with S/B IND-0317. Both orifice diameters are 1.5”.

Components found NOT serviceable: (fill this section out if you found unserviceable components)

Detail Findings: Returned in service

PAC Number (if available): Enter PAC case NOT as documentation – N/A Notifications

(SM/CPM/PM/ENGR/SL or FSRM):

Follow Up Action Items Engineering:

N/A

Follow Up Action Items SM/CPM/PM:

N/A

Outage Data: Engine Data:

ESN 191-498 Engine Fired Hours 64122.6 Package Hours Model LM6000PC Engine Fired starts 1377 Package Fired Starts



Maintenance Data: WP, SB, SL, PB, PL

Performed Revision/manual reference Date

completed Comments

WP 4015 00 GEK 105059 15 May 2008

Change 8 15 August 2015

April 17th 2016 Serviceable

LM6000-IND-0317 LPT Cooling Air Orifice Plates Inspection

April 17th 2016 Both orifice plates have an orifice diameter of 1.500

Inches. Found compliant with S/B

Parts Data:

Description PN Removed SN Removed

Qty Disposition PN Installed

SN Installed

VALVE, CHECK 11TH STAGE-

ELBOW

L61842G02 1 To be repaired

L61842G02

PROBE, THERMOCOUPLE

1696M81P13 1 Scrap 1696M81P13

PROBE, THERMOCOUPLE

1962M86P02 2 Scrap 1696M81P13

GASKET 9379M93P01 3 Scrap 9379M93P01



Results:

WP 4015 00 Borescope Inspection:

Low Pressure Compressor BSI Ports

Right Hand Side Left Hand Side

Low Pressure Compressor



Noted light dirt on all blades

VIGV flaps from inlet plenum or BSI ports S4-1 & S4-4. Found serviceable, The picture is on the GT external inspection report

Stage 0 Blades & Vanes, BSI ports S4-1 & S4-4. Serviceable

Stage 1 Blades & Vanes, BSI ports S4-2. Serviceable

Stage 2 Blades & Vanes, BSI ports S4-2 & S4-5. Minor blade tip rubbing on casing.

Stage 3 Blades & Vanes, BSI ports S4-3 & S4-5 Serviceable

Stage 4 Blades & Vanes, BSI ports S4-3.

Serviceable

Inspect for airfoil erosion, corrosion or deposits.

Light dirt on airfoil

Use flexscope to inspect visible portion of stage 0-3 vane inner bushing for cracking, protrusion into air stream, or missing pieces.

In good condition

Use flexscope to inspect stage 4 vane inner bushing for cracking, protrusion into air stream, or missing pieces.

In good condition

Add notes here on findings



Low Pressure Compressor Photos

LPT Stg 1 blade tip Stage 1 blade platform

Stage 2 blade platforms Stage 2 blade path on casing

Stage 2 blades L.E. Stage 2 T.E.



Stage 3 blades Stage 3 shroud bushings in good condition

Stage 4 blades Stage 4 vane bumpers in good condition



High Pressure Compressor BSI Ports

Right Side – High Boss Case Left Side – High Boss Case

High Pressure Compressor


Inspect stages 1 through 14 blades for cracks, nicks, tears, burrs, dents, missing material, evidence of tip clang, curl or deformation. * BSI Port are inside manifold

IGV from BSI ports S5-0 In good condition

Stage 1 Blades (Qty 36) & Vanes, BSI ports S5-0 & S5-1. In good condition




Stage 5 Blades (Qty 48) & Vanes, BSI ports S5-4 & S5-5. In good condition Stage 6 Blades (Qty 54) & Vanes, BSI ports S5-5 & S5-6. In good condition Stage 7 Blades (Qty 56) & Vanes, BSI ports S5-6 & S5-7*. In good condition Stage 8 Blades (Qty 64) & Vanes, BSI ports S5-7* & S5-8*. In good condition Stage 9 Blades (Qty 66) & Vanes, BSI ports S5-8* & S5-9*. In good condition Stage 10 Blades (Qty 66) & Vanes, BSI ports S5-9* & S5-10. In good condition Stage 11 Blades (Qty 76) & Vanes, BSI ports S5-10 & S5-11*. In good condition Stage 12 Blades (Qty 76) & Vanes, BSI ports S5-11* & S5-12. In good condition Stage 13 Blades (Qty 76) & Vanes, BSI ports S5-12 & S5-13. Tip rub free of cracks Stage 14 Blades (Qty 76) & Vanes, BSI ports S5-13 In good condition

Inspect the stage 1 mid-span shroud interlock wear, shingling, a gap or a missing pad.

In good condition

Inspect for erosion, corrosion or deposits. NONE

Inspect for platform shingling, bowing, distortion or cracks NONE

Inspect the IGB for sludge NONE



High Pressure Compressor Photos

IGB area at 10 o’clock position free of DOD IGB free of sludge at 10 o’clock position

IGB area at 2 o’clock position free of DOD IGB free of sludge at 2 o’clock position

Mid-span Damper in serviceable condition HPC rotor weep holes free of leakage



IGV IGV inner shroud

HPC Stg 1 blade platforms HPC Stg 1 blades L.E.

Stg 1 blades tips concave side VSV 1 inner shroud



HPC Stg 2 blade platform L.E. HPC Stg 2 concave side

HPC Stg 3 blade platform HPC Stg 3 blade tips concave side

Stg 4 blade platform Stg 4 blade L.E.



Stg 5 blade platform Stg 5 concave side

Stg 6 concave side Stg 7

Stg 8 Stg 9



Stg 9 Stg 10

Stg 10 blade platforms L.E. Stg 10 blade Platforms L.E.

Stg 11 Stg 12



Stg 13 Stg 13 convex side with tip rub free of cracks

Stg 13 concave side Stg 14

Stg 14 Stg 14



OGV OGV

CRF sump clamping arrangement in good condition CRF sump clamping arrangement in good condition



Combustor and HPT Borescope Ports

Combustor – Left Side Combustor – Right Side

Combustor


Inspect combustor (All Surfaces) and 1st stage HPTN Leading Edge from all CRF BSI ports S6-1 to S6-6 (or with flex scope) for burning, cracks, erosion, discoloration, wear and missing metal.

In serviceable condition

Venturi’s Serviceable

Splash Plate Erosion around the contour

Trumpets Erosion around the contour

Dome Plate Serviceable Inner/Outer Rivet Bands Serviceable Inner/Outer Liners Panels Primary swirlers for Bore wear

Minor wear within serviceable limits at locations #5 and #23

Anti-rotation tab for wear Free of wear

Inspect all visible fuel nozzle tips for contamination or damage from all CRF BSI ports or with flex scope

In good condition

Remove 2 fuel nozzles and check outer cowl for cracks or missing material. Inspect secondary swirlers for water erosion, missing material or deposits.

Minor wear on fuel nozzle shrouds #5 and #23. Free of erosion, missing material and deposit

Igniter Tube Area Inspect Igniters for Visible wear or grooving on plug tip area WP 1516 00

In serviceable condition

Add notes here on findings



Combustor Photos

Trumpets with minor erosion around the contour Dome Assembly with dark coloration, free of burn

and erosion

Inner Liner with small patch of missing TBC, base coat and parent metal is not affected

Outer Liner in good condition

Trumpets in serviceable condition Trumpets with eroded TBC within serviceable limits



HPT Stg 1 nozzle L.E. and airfoil in serviceable condition

Blue coloration on one of the HPT Stg 1 nozzle concave side shown from Port S6-5

Upper igniter with 0.011” wear (Max limits 0.015”) Lower igniter with wear marks; no measurable

depth

Anti-rotation arms at location #5 Bore primary swirler with wear within serviceable

limits



Venturi swirler in good condition Fuel nozzle at location #5 with wear on shroud

within serviceable limits

Fuel nozzle at location #23 with scratches at the tip within serviceable limits

Bore primary swirler with wear within serviceable limits at location #23



High Pressure Turbine

HPT STAGE 1 BLADE

HPT STAGE 2 BLADE

High Pressure Turbine

Inspection Area Comment Inspect stage 1 and 2 shrouds for cracks, missing material, wear and erosion.

Stage 1 HPT Shrouds, BSI port S7-2 Tip rub within serviceable limits

Stage 2 HPT Shrouds, BSI port P48 & T48 probe Minor tip rub marks within serviceable limits

Inspect stage 1 and 2 blades for missing TBC coating, oxidation parent material, plugged cooling holes.

Cooling holes are all clear

Stage 1 HPT (Qty 80) Leading Edge, BSI port S7-1 and Trailing Edge, S7-2

Four blades with Missing TBC on convex side close to leading edges within serviceable limits. Parent metal is not affected

Stage 2 HPT (Qty 74) Leading Edge, BSI port S7-2 and Trailing Edge, P48 or T48 probe

In good condition

Inspect stage 1 and 2 blade airfoils for cracks, nicks, tears, burrs, dents and missing material,

NONE found

Stage 1 HPT (Qty 80) Leading Edge, BSI port S7-1 and Trailing Edge, S7-2

NONE found NONE found

Stage 2 HPT (Qty 74) Leading Edge, BSI port S7-2 and Trailing Edge, P48 or T48 probe

NONE found

Inspect the stage 1 and 2 blade platform for bowing and cracks.

Stage 1 HPT (Qty 80) platform, BSI port S7-1 and S7-2 Free of bowing and cracks Stage 2 HPT (Qty 74) platform, BSI port S7-2 and P48

probe Free of bowing and cracks

Inspect S7-1 and S7-2 Borescope Plugs for Plunger or spring separation from assembly

The plug at port S7-1 is serviceable. The tip of the plug at port S7-2 was seized. We replaced with a serviceable plug from engine 191-555



High Pressure Turbine Stage 1 blades

HPT Stage 1 blade platforms HPT Stage 1 tip concave side

HPT Stage 1 HPT Stage 1 with missing TBC within serviceable

limits, parent metal is not affected

HPT Stage 1 with missing TBC within serviceable limits, parent metal is not affected





HPT Stg 1 blade convex side in serviceable condition. Cooling air holes free of obstruction

Blade tip rub within serviceable limits. Blade tip rub within serviceable limits. HPT NOZZLES



HPT STAGE 1 NOZZLES

HPT Stage 1 nozzle T.E. HPT Stage 1 shrouds and nozzles outer platform L.E.

HPT Stage 1 nozzle HPT Stage 1 nozzle inner platform

Cavity between CRF case and HPT Stg 1 nozzle outer platforms at 6 o’clock position free of loose objects

Stg 1 borescope plug in serviceable condition



HPT STAGE 2 BLADES

HPT STG 2 BLADE L.E. in good condition HPH Stg 2 platforms L.E. in good condition

HPT Stg 2 blade platforms T.E. free of cracks and wear

HPT Stg 2 blades T.E. and concave sides in good condition



HPT STAGE 2 NOZZLE

SMALL CRACK at T.E. close to the outer platform within serviceable limits

Eroded shroud surface free of burn through.

The dent mentioned in the last report appears like it is cracked around the contour.

Same nozzle; The contour is not cracked on the concave side.



Cavity Outboard of Stage 2 HPT Nozzles Inspection

Inspect Cavity for pieces of broken flaps from 11th stage check valves

Comments: Found broken flaps resting in cavity

Inspect 11th stage check valves for broken or missing flaps We replaced the check valve at 1 o’clock position

A retrieving tool is needed to remove the flap resting at 6 o’clock position

The loose flap at 1 o’clock position is retrieved. We installed a new check valve at that location



Low Pressure Turbine BSI Ports

Low Pressure Turbine

Low Pressure Turbine Inspection Area Comment


Stage 1 LPT Nozzle, BSI ports S8-1 & P48 probe. In good condition

Stage 1 LPTR Blades (Qty 118) & Vanes, BSI ports S8-1 & S8-3. In good condition

Stage 2 LPTR Blades (Qty 124) & Vanes, BSI ports S8-3. In good condition



Stage 5 LPTR Blades (Qty 74) & Vanes, BSI ports S8-2.

Picture is on GT external inspection report

Inspect blade shroud interlocks for wear and shingling. NONE

Inspect for erosion, corrosion or deposits. NONE Add notes here on findings



Low Pressure Turbine Photos

P48 probe in good condition T48A probe with loose pin. We replaced the probe

T48G PROBE with missing pin. We replaced the probe

T48F PROBE with missing sleeve. We replaced the probe

LPT INLET Stg 1 nozzle outer platform free of cracks LPT INLET Stg 1 nozzle outer platform free of cracks



Honeycomb seal Cavity at 6 o’clock position found free of loose object like thermocouple pin.

LPT Stg 1 blade platforms

LPT Stg 1 blades LPT Stg 1 interlocks

LPT Stg 2 blades with blending on L.E. The S3 annotation on the picture is a typo.

LPT Stg 2 blade interlocks



LPT Stg 3 blade platforms LPT Stg 3 blade interlock and honeycomb

LPT Stg 4 blades LPT Stg 4 blade interlocks

BLANK

LPT Stg 5 blades INPECTION is recorded on the GT external inspection report

END OF THIS REPORT

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