GE Power Services

GENERATOR INTERIM REPORT GIR No. Page 01

TVI-002_R1
Plant/Site Unit No. Disassembly or Component Submitted By Date
TVI Toledo/ Unit 2 Gen. NDE Inner Enclosure Ganesh Kumar 08-Feb-2021
Philippines Lower Half Bolts

Customer Reference: KKS No.:

REPORT FROM SITE:

Gen. Enclosure Disassembly Explanation

GE recommends a field procedure (FP5AA21710) for Geno Mech TFA about Gen. outer
enclosure, inner enclosure, air guide ring and shaft seal disassembly for preparation to Gen.
inspection. This procedure requires visual inspection from Geno Mech TFA for fact findings report
to know the status of parts disassembled, and other mechanical parts that is not disassembled.

NDE Inner Enclosure As Found Missing Bolts - Discovery

1. Upon visual inspection of the NDE inner enclosure before removal, found 3 pcs. missing
M12 bolts between split ends on the lower half. That is the reason to stop the inner
enclosure dismantling work, and then the as found issue was reported to TVI around
14:00H. TVI verify it visually, and they conduct their borescope inspection around 15:30H at
NDE, and found something inside according to their claim (need to verify) since no formal
report has been received yet. That is the reason to stop the dismantling of the NDE
enclosure lower half and need to continue again at 16:30H.

As found 3 pcs. missing/lost bolts at NDE inner

enclosure lower half
 GE Power Services

GENERATOR INTERIM REPORT GIR No. Page 01

TVI-002_R1

Original nut & bolts

disassembled

Borescope Inspection.
Upon arrival of GE Diagnostic engineer, stator visual inspection was conducted and finding based on the inspection is
as per the attached report from our GDE.

Current status of the missing bolt and nuts as below.

Bolt at NDE side Missing - 3 pcs Found – 2 pcs (found another

but with shorter dimension so
we assume this is not the initial
missing bolt)
Washers at NDE side Missing - 2 flat washer and 1 Found – 5 washer
conical washer per bolt.
Total 9.
Nut at NDE side Missing – 3 pcs Found – 2 pcs
 GE Power Services

GENERATOR INTERIM REPORT GIR No. Page 01

TVI-002_R1
OPTIONS/RECOMMENDATIONS :

ER-20210204-1300

Based on discussion with engineering, it is recommended to perform rotor pull out and cooler
disassembly. This is to further investigate and find the remaining bolts and nuts. The stator was
also found with lots of metal debris as shown in the attached report and this condition is
considered unsafe for the stator operation. Thorough stator slot inspection has to be carried out.

GE currently accessing the parts required to perform this inspection and shall advise TVI on the
status.

PRICE / SCHEDULE IMPACT:

It is estimated around 4 shift to remove the rotor. This potentially will delay the outage end date
based on the availability of the spare parts and further finding.

Inspected: Sonny Vergara – Geno TFA Date: 08th Feb. 2021

Reported: Ganesh Kumar -Outage Manager

CUSTOMER DISPOSITION/RESPONSE: (Response required within 48 hours)

Signed By: Date:

 Title: Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Inspection conditions:

Rotor Installed
Accessibilty:
Rotor Removed

Inspection results:

Checked
Item (if not applicable, cross out ) Comment
(No  / Yes )

1. Stator end winding DE NDE

1.1 Winding surface   Contaminated with oil;

1.2 Phase separation   Normal condition;

Light yellowish (indication of corona
1.3 Corona protection   discharge) observed at HV top bars;
Normal condition; No sign of cracking
1.4 Insulating end caps   or overheating marks.
1.5 End winding support   Normal condition;

1.6 Ring connections   Normal condition;

1.7 Flexible connections   Normal condition;

1.8 Slot exits   Normal condition;

Remarks:

Highlights / Findings from mechanical team;

3 sets of bolts missing at bottom half (split line area) inner casing. Refer ER case for details; Power ER-20210204-1300.

Visual inspection;
- All missing parts were found outside end winding area.
- No impact observed on the end winding area.
- Borescope inspection as far as accessible, at slot exits (special attention from 4 to 8 o'clock position) - normal
condition, nothing found.
- Borescope inspection as far as accessible; further inside stator at 6 o'clock position; winding slot - normal condition,
nothing found.
- Fan blades; impact marks can be seen at the outer area (facing outside). No impact mark observed at inner area
(facing stator winding).
- Borescope inspection underneath retaining rings; all parts were found to be in normal condition. None of these
missing particles observed inside rotor end winding area.

Unit / System Name

Test Decision Accepted* X Rejected*
(as required/acc. to specification) NC-Report* Rework* THERMA VISAYAS / STG 2
NCR No.* Part Text Quantity

- 60WX21Z-085 1
Checked by** Part Idnr Rev. Power Station Designation

2021-02-06 OSS / GDE M. AMIRUL IEN-001156-2 - MKA10

Approved by** I & T Plan ID Rev. Test Step Material Test No.

- QCP5AA1061 - - -
Authority / Customer** Order No. Factory Order

2021-02-06 THERMA VISAYAS INC. - -

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 1 16 HTCZ657387 -

* Mark/Fill in if applicable ** Name / dept. / date / initials
 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Inspection results - continuation:

Checked
Item (if not applicable, cross out ) Comment
(No  / Yes )
2. Stator iron core DE NDE

2.1 Stator bore   Normal condition;

Check as far as accessible; Normal
2.2 Stator slot wedges  
condition;
Normal condition; Check with
2.3 Stator end wedge fixation  
borescope inspection;
2.4 Core back   NA

2.5 End plates   Normal condition;

3. Stator housing

3.1 Generator housing   Normal condition;

3.2 Air / water coolers   Normal condition;

3.3 RTD's for slot temperature   Normal condition;

Normal condition; Missing bolts; See
3.4 End shields  
mechanical repor for details.
3.5. Standstill heater   Heaters ON for the whole outage;

3.6 Leakage air filter   Dusty;

3.7 Oil deflectors   See mechanical report;

Remarks:

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 2 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Checked
Item (if not applicable, cross out ) Comment
(No  / Yes )
4. Terminal box

4.1 Bushings  Normal condition;

4.2 Phase leads  Normal condition;

4.3 Corona protection  Normal condition;

4.4 Flexible copper links  Normal condition;

5. General condition

 little
5.1 Dirt contamination  medium
 strong

 little
5.2 Oil contamination  medium
 strong

Remarks:

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 3 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Generator nameplate; 60WX21Z-085

NDE overview

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 4 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

DE overview

NDE; overhang support; Normal condition; No sign of abrasion or looseness marks.

No action required.

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 5 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

DE overhang support; Normal condition.

No action required.

Phase connection; All 12 phase connections were found to be in normal condition.

No action required.

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 6 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Phase rings; Normal condition.

No action required.

Inner flexible links; Normal condition.

No action required.

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 7 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Loosed cord - Not secured with resin.

Recommendation; Apply epoxy resin, re-tight.

End winding; Light dust contaminated on winding surfaces.

Recommendation: Clean the whole stator as far as accessible

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 8 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

HV top bars - ligh dust contamination

Recommendation; Clean as far as accessible.

HV top bars – yellowish marks (minor sign for corona discharge)

Recommendation; Clean.

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 9 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

HV top bars – yellowish marks (minor sign for corona discharge)

Recommendation; Clean.

DE end winding; 6.30 o’clock position; Impact mark near to end cap.
Recommendation; Clean, apply epoxy resin mix with mica flakes.

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 10 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Oil contamination;

Oil contamination

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 11 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

All end wedges secured; Normal condition.

Iron core packet; Borescope inspection as far as accessible; Normal condition.

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 12 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Stator slot exits; Normal condition; No sign of protruding HGW strips.

Stator-rotor air gap; normal condition.

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 13 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Highlights / Findings from mechanical team;

3 sets of bolts missing at bottom half (split line area) inner casing. Refer ER case for details; Power ER-20210204-1300.

Visual inspection;
- All missing parts were found outside end winding area.
- No impact observed on the end winding area.
- Borescope inspection as far as accessible, at slot exits (special attention from 4 to 8 o'clock position) - normal
condition, nothing found.
- Borescope inspection as far as accessible; further inside stator at 6 o'clock position; winding slot - normal condition,
nothing found.
- Fan blades; impact marks can be seen at the outer area (facing outside). No impact mark observed at inner area
(facing stator winding).
- Borescope inspection underneath retaining rings; all parts were found to be in normal condition. None of these
missing particles observed inside rotor end winding area.

1st bolt found. 1 nut found. (6 o’çlock position) Close up view.

2nd bolt. (6 o’clock position) Close up view.

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 14 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

1st washer found. (6 o’clock position) Close up view.

2nd washer found. (NDE 8 o’clock position) 3rd washer found. (NDE 9 o’clock position)

Part of washer. (NDE 9 o’clock position) Part of washer. (NDE 3 o’clock position)

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 15 16 HTCZ657387 -

 Title Report No.: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use

Test Certificate Visual inspection stator

or disclosure to third parties without express authority is strictly forbidden. © ALSTOM 2021

WX/Y/G 14-21 E01

Debris- scattered pieces

Debris- scattered pieces

Debris- scattered pieces

Unit / System Name Part Text. Part Idnr.

THERMA VISAYAS / STG 2 60WX21Z-085 IEN-001156-2

Sheet No. No. of Sh. Document No. Rev.

GE Power Services 16 16 HTCZ657387 -