ATS 2010 GE MS6001B Sample Borescope Inspection Report

Advanced Turbine Support, Inc.

Unit -2

Advanced Turbine Support Gas Turbine Borescope Inspection Report Utility Unlimited Energy

Inspector(s) Robert Burkhart

Inspection Date September 16, 2010

Serial Number 295XXX/ 336X447

Site Unit No. Unit 2

Manufacturer General Electric

Model MS6000B

Type of Fuel Natural Gas / Distillate

Inspection Type Borescope Inspection

Site Contact Plant Manager

Total Fired Hours 2380.9

Manual Starts 508

Total Starts 578

Fired Starts 456

Unit Trips 19

Scope This report describes and documents the September 16th, 2010 borescope examination of the General Electric Frame MS6000B combustion turbine. This inspection included the compressor section, the turbine section, the combustion section and a limited exhaust inspection. The access to the turbine section and the components in combustion chambers 2 and 8 was achieved by removal of the fuel nozzles and the borescope ports in the case. A general inspection of combustion chambers 1, 3, 4, 5, 6, 7, 9 and 10 was performed by access through the crossfire tubes. The generator rotor end windings were inspected for insulation migration on both the turbine and excitor ends. Both of the main leads from the shaft to the rotor windings were inspected. The lead that is aligned with the three bolts on the shaft in the brush compartment is lead “A”. The purpose of this borescope examination was to look for conditions considered to be abnormal to the unit and to gather trending data. Photographs The photographs included in this report were selected from the inspection to best represent the condition of the unit. Selected photographs that show problem areas and typical views of the components observed are included as part of this report for documentation and comparison during future examinations. Magnification of the distal tip lens may make objects appear larger. A surface that is actually straight or true may appear slightly wavy or curved in a photograph. Due to the possibility of optical distortion, someone familiar with borescope photography should be involved in the final engineering review of this report.

1

Advanced Turbine Support, Inc.

Unit -2

Observations Compressor Section 1. There are deposits on the variable inlet guide vanes through the stage S-8 stator vanes. 2. There is impact damage to the leading edge of several stage R-1 rotor blades. The damage appears to be within the OEM’s limitations. 3. No shims were identified at the stage S-1 through S-4 ring segments. Combustion Section 1. The combustion caps, fuel nozzles, crossfire tubes and liners appear to be in good condition with typical carbon buildup on the primary fuel nozzles. 2. The transition pieces, floating seals and side seals on the transition pieces appear to be in good condition. Turbine Section 1. There are cracks in the trailing edge and outer platform on several of the first stage nozzles in the lower half of the unit. The cracks range in length from approximately 1/4 inch to 1/2 inch. 2. The first stage nozzle seal slots and discourager seals appear to be in good condition. 3. There are multiple tight cracks in the coating on the platforms and leading edge of the first stage rotor buckets. 4. The first stage buckets have rubbed against the shroud blocks at the four o’clock position. This has resulted in discoloration along the bucket tips. Smeared metal is evident on the shroud blocks in this location. 5. The second stage nozzle seal slots and discourager seals on the trailing edge of the second stage nozzles appear to be in good condition. 6. There are cracks in the trailing edge of the second stage nozzles in the lower half of the unit. 7. The second stage buckets, bucket tip shrouds and knife edge seal on the shroud blocks appear to be in good condition. 8. The third stage nozzles, seal slots, and discourager seals appear to be in good condition. 9. The third stage buckets, bucket tip shrouds and honeycomb seal on the shroud blocks appear to be in good condition. Exhaust Section 1. The exhaust appears to be in good condition. Generator Rotor- Turbine End Windings 1. The insulation migration from between the rotor end windings at the turbine end of the rotor doesn’t appear to have changed since the inspection in 2009. 2. There are no signs of any significant movement of the blocking between the end windings 2

Advanced Turbine Support, Inc.

Unit -2

Observations Continued Generator Rotor- Excitor End Windings and Main Leads 1. The insulation migration from between the rotor end windings at the excitor end of the rotor doesn’t appear to have changed since the inspection in 2009. 2. There is impact damage on lead “A”. 3. There is evidence of wear and copper leaf separation on leads “A” and “B”. 4. There are no signs of any movement of the blocking between the end windings. Recommendations 1. Have engineering disposition the items listed in the observation section. 2. Continue to inspect the unit on an annual basis to monitor its condition. Limitation of Liability A borescope inspection is intended to provide a representative sample of the unit condition. While every attempt will be made to identify all items considered to be abnormal, items may be missed that could cause future damage. In no event shall ATS, Inc. be liable for compensatory, consequential, incidental, special, punitive or other damages whether the claim for damages is based on contract, tort, or otherwise. ATS, Inc. limits its liability to the value of this contract. Robert Burkhart Inspection Specialist Advanced Turbine Support, Inc. Mobile 352-586-7684 Office 352-332-4061 www.borescopeinspections.com

3

Advanced Turbine Support, Inc.

Unit -2

Section Component

Inlet Plenum Bellmouth

Comments

Section

Compressor

Stage

Inlet Guide Vanes

Comments

4

Deposits

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component

1 Rotor Blade

Location

General

Comments

Impact Damage

Section Stage Component Location Comments

5

Compressor

Compressor 1 Stator Vane General

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component

2 Rotor Blade

Location

General

Comments

Deposits

Section Stage Component Location Comments

6

Compressor

Compressor 2 Stator Vane General

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component

3 Rotor Blade

Location

General

Comments

Deposits

Section Stage Component

7

Compressor

Compressor 3 Stator Vane

Location

General

Comments

Deposits

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component

4 Rotor Blade

Location

General

Comments

Deposits

Section Stage Component Location Comments

8

Compressor

Compressor 4 Stator Vane General

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component

5 Rotor Blade

Location

General

Comments

Deposits

Section Stage Component

9

Compressor

Compressor 5 Stator Vane

Location

General

Comments

Deposits

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component

6 Rotor Blade

Location

General

Comments

Deposits

Section Stage Component Location Comments

10

Compressor

Compressor 6 Stator Vane General

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component

7 Rotor Blade

Location

General

Comments

Deposits

Section Stage Component

11

Compressor

Compressor 7 Stator Vane

Location

General

Comments

Deposits

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component

8 Rotor Blade

Location

General

Comments

Deposits

Section Stage Component

12

Compressor

Compressor 8 Stator Vane

Location

General

Comments

Deposits

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component Location

Compressor 9 Rotor Blade General

Comments

Section Stage Component Location Comments

13

Compressor 9 Stator Vane General

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component Location

Compressor 10 Rotor Blade General

Comments

Section Stage Component Location Comments

14

Compressor 10 Stator Vane General

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component Location

Compressor 11 Rotor Blade General

Comments

Section Stage Component Location Comments

15

Compressor 11 Rotor Blade General

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component Location

Compressor 11 Stator Vane General

Comments

Section Stage Component Location Comments

16

Compressor 12 Rotor Blade Trailing Edge

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component Location

Compressor 12 Stator Vane General

Comments

Section Stage Component Location Comments

17

Compressor 13 Rotor Blade General

Advanced Turbine Support, Inc.

Unit -2 Section Stage Component Location

Compressor 13 Stator Vane General

Comments

Section

Combustion

Component

Combustion Cap

Location Comments

18

General

Advanced Turbine Support, Inc.

Unit -2 Section

Combustion

Component

Primary Fuel Nozzle

Location

General

Comments

Section Component Location Comments

19

Combustion Crossfire Tube General

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Combustion Liner Liner 4

Comments

Section Component Location Comments

20

Combustion Left Side Picture Frame TP 8

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Combustion Right Side Picture Frame TP 8

Comments

Section Component Location Comments

21

Combustion Side Seal General

Advanced Turbine Support, Inc.

Unit -2 Section

Combustion

Component

Floating Seal

Location

General

Comments

Section

Turbine Stage 1

Component

Nozzle Leading Edge

Location Comments

22

General

Advanced Turbine Support, Inc.

Unit -2 Section

Turbine Stage 1

Component

Nozzle Leading Edge

Location

General

Comments

Section Component Location Comments

23

Turbine Stage 1 Nozzle Seal Slot General

Advanced Turbine Support, Inc.

Unit -2 Section

Turbine Stage 1

Component

Nozzle Trailing Edge

Location

General

Comments

Section

Turbine Stage 1

Component

Nozzle Trailing Edge

Location Comments

24

General Crack

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Bucket Platform

Comments

Coating Cracks

Section

Turbine Stage 1

Component Location Comments

25

Turbine Stage 1

Bucket Platform Coating Cracks

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Bucket Platform

Comments

Coating Cracks

Section

Turbine Stage 2

Component Location Comments

26

Turbine Stage 1

Nozzle Leading Edge

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 1 Bucket Leading Edge

Comments

Section Component Location Comments

27

Turbine Stage 1 Bucket Cooling Hole

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 1 Bucket Trailing Edge

Comments

Section Component Location Comments

28

Turbine Stage 1 Bucket Shroud Block Rub

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 2 Nozzle Leading Edge

Comments

Section Component Location Comments

29

Turbine Stage 2 Nozzle Trailing Edge Crack

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 2 Nozzle Discourager Seal

Comments

Section Component Location Comments

30

Turbine Stage 2 Bucket Leading Edge

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 2 Bucket Tip Shroud

Comments

Section Component Location Comments

31

Turbine Stage 2 Bucket Interlocks

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 2 Bucket Knife Edge Seal

Comments

Section Component Location Comments

32

Turbine Stage 2 Bucket Trailing Edge

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 3 Nozzle Leading Edge

Comments

Section Component Location Comments

33

Turbine Stage 3 Nozzle Leading Edge

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 3 Nozzle Trailing Edge

Comments

Section Component Location Comments

34

Turbine Stage 3 Nozzle Trailing Edge

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 3 Bucket Leading Edge

Comments

Section Component Location Comments

35

Turbine Stage 3 Bucket Leading Edge

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 3 Bucket Interlocks

Comments

Section Component Location Comments

36

Turbine Stage 3 Bucket Trailing Edge

Advanced Turbine Support, Inc.

Unit -2 Section Component Location

Turbine Stage 3 Bucket Trailing Edge

Comments

Section

Exhaust

Component

Diffuser

Location Comments

37

Top

Advanced Turbine Support, Inc.

Unit -2 Section

Generator

Component

End Winding Insulation

Location

Turbine End

Side

Right Side

Comments

Section Component

End Winding Insulation

Location

Turbine End

Side Comments

38

Generator

Right Side

Advanced Turbine Support, Inc.

Unit -2 Section

Generator

Component

End Winding Insulation

Location

Turbine End

Side

Right Side

Comments

Section Component

End Winding Insulation

Location

Turbine End

Side Comments

39

Generator

Right Side

Advanced Turbine Support, Inc.

Unit -2 Section

Generator

Component

End Winding Insulation

Location

Turbine End

Side

Left Side

Comments

Section Component Location Side Comments

40

Generator End Winding Blocking & Insulation Turbine End Left Side

Advanced Turbine Support, Inc.

Unit -2 Section

Generator

Component

End Winding Insulation

Location

Turbine End

Side

Left Side

Comments

Section Component Location Side Comments

41

Generator End Winding Blocking & Insulation Turbine End Left Side

Advanced Turbine Support, Inc.

Unit -2 Section Component Location Comments

Section Component Location Comments

42

Generator Rotor Lead B Excitor End Impact Damage

Generator Rotor Lead A Excitor End Impact Damage

Advanced Turbine Support, Inc.

Unit -2 Section Component

Rotor Lead A

Location

Excitor End

Comments

Leaf Separation

Section

Generator

Component Location Comments

43

Generator

Rotor Lead B Excitor End

Advanced Turbine Support, Inc.

Unit -2 Section Component

Rotor Lead B

Location

Excitor End

Comments

Leaf Separation

Section

Generator

Component

End Winding Insulation

Location

Excitor End

Side

Right Side

Comments

44

Generator

Advanced Turbine Support, Inc.

Unit -2 Section Component

Generator End Winding Insulation

Location

Excitor End

Side

Right Side

Comments

Section Component

End Winding Insulation

Location

Excitor End

Side

Right Side

Comments

45

Generator

Advanced Turbine Support, Inc.

Unit -2 Section Component Location Side

Generator End Winding Insulation Excitor End Left Side

Comments

Section Component Location Side Comments

46

Generator End Winding Insulation Excitor End Left Side

Advanced Turbine Support, Inc.

Unit -2 Section Component Location Side Comments

47

Generator End Winding Blocking & Insulation Excitor End Left Side