Turbo Docs P-01739 - PLN WKSKT - Serious Inspection STG PLTU Asam Asam Unit #1 - Rev-0 (1-Turbine)

STEAM TURBINE GENERATOR SERIOUS INSPECTION
TOSHIBA STEAM TURBIN – ALSTOM GENERATOR UNIT 1

PT. PLN (PERSERO0 WILAYAH KALIMANTAN TENGAH
KALIMANTAN SELATAN – PLTU ASAM ASAM
SOUTH KALIMANTAN
Prepared by
Wawan Kuswardhana
Site Coordinator.
Reviewed and Approved by

Andrianto Hapsoro
Field Service Manager
Project No. P-01739
DECEMBER 2016
Rotating Equipment Services

Purwakarta Service Center
PT. Sulzer Turbo Services Indonesia
Kawasan Industri Kota Bukit Indah
Blok AII, Kav. IC-ID,
Purwakarta 41181, Indonesia
Tel. 62 264 351 920
Fax. 62 264 351 143
www.sulzer.com
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
Customer PT PLN (PERSERO) WKTKS- PLTU ASAM ASAM

Unit Location: ASAM ASAM – JURONG – SOUTH KALIMANTAN
Sulzer TSID Job No: P -01739
Equipment Type: STEAM TURBINE GENERATOR
Manufacturer: STEAM TURBINE- TOSHIBA, GENERATOR – ALSTOM, 65 MW
Model: TBA
Equipment Number: Unit 1
Speed: 3000 RPM
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.
Commissioning services were provided by Sulzer which included supporting adjustment of

actuator control valve, labor support for lube oil flushing, and assessment of temperatures,
pressures, and vibration levels during start-up .
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.
Page 2 of 35
STEAM TURBINE MACHINE DATA SHEET
Customer : PT. PLN (Persero) Wil. KalTeng & KalSel

Station : PLTU ASAM – ASAM
Unit : UNIT 1
Model / Type :
Rating : 65 MW
Control System : Service Type : Serious Inspection
Steam Pressure : bara Steam Temperature : Deg C
Speed : 3000 rpm
Stages : 16 stages.
District Office : Purwakarta – Indonesia

Job No. : P 01739
Site Coordinator : Wawan Kuswardhana
Job Start date : 23 November 2016 Completion Date : 20 December 2016
Job Type : Major Inspection Full Load
Work Scope : [Y] Turbine [Y] Generator [Y] Valves
Site Personnel
Name Position
Wawan Kuswardhana Site Coordinator
Widada Sr. Mechanic Turbine
Mohammad Anton Supervisor Generator
Page 3 of 35
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.
Reassembly and Mechanical Completion
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.
Page 4 of 35
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.
MAIN STOP VALVE – MSV
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.
Page 5 of 35
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.
MAIN OIL TANK
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.
LUBRICATION OIL FLUSHING
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.
Page 6 of 35
3.2 Summary of Inspection Findings
Finding / remark Corrective measure

3.2.1 Turbine Bearings
Inspection
 Journal bearing #1 Babbitt surfaces
 Replaced the bearing with
received UT and PT NDE, found the
the new one.
linear indication out of tolerance and
recommend to replace.
 Journal bearing #2 Babbitt surfaces  Cleaned and polished.

received UT and PT NDE, no found
any indication
3.2.1.1
 All bearing journal were measured and  Within tolerance

compare with design criteria.
 Thrust bearing pads were received UT

 Repaired active and in
and PT NDE, found crack and porosity
active pads thrust bearing.
on both active and in active side.
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.
Page 7 of 35
3.2.2 Turbine Rotor Unit 1
 The rotor steam path areas were

cleaned by mechanical power tools to
remove mineral deposits.
 Rotor journals were inspected and  Polished.
measured. Found minor rubs both on
journal rotor generator side and
Turbine Side. Both journal received a
MT NDE examination. No indications
were found.
 Thrust bearing collars were inspected  Recommend to repair due
and cracks were found. to limited time, customer
decided to leave as it is,
just polished on thrust
collar surface.
 Gland seal HP Side was inspected  Recommend to repair due
and found major erosion on HP Gland to limited time, customer
seal segment 1-4 while the others only decided to leave as it is.
minor erosion. Gland seal HP received
a MT NDE examination. No 
indications were found.
 Polished and removed high
 Gland seal LP Side was inspected and
3.2.2.1 metal if necessary.
found minor erosion only. Gland seal
HP received a MT NDE examination.
No indications were found.
 All stage blades received a MT NDE
examination and no indications were
founds
 All shrouds were inspected and found
 Recommend to repair or
major rubs on shroud stage no : 14.
replace with new spare
Depth of the rubs is 2 – 3.1 mm, while
thickness of the shrouds are +/- 5.2
mm.
 Turbine rotor were performed Low
Speed Balancing (LSB). Duration of
Page 8 of 35
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.
3.2.4 Main Stop Valves ( MSV)

Inspection
 Main Stop Valves were dismantled
 Recommended to repair,
and disassembled. All parts were
due to limited time,
cleaned by mechanical power tolls
customer decided to leave
and inspected.
as it is.
3.2.4.1  MSV Parts such as : seat, valve disk,
stem valve and pilot valves were
received a PT NDE examination and
no indications were found.
 Found the medium erosion on body
pilot valves.
Page 9 of 35
 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.
3.2.5 Control Valve

Inspection
 Control valves were dismantled and
 All existing parts were
continue to disassembled parts in
replaced with new spare
other workshop at Banjarmasin.
parts.
3.2.6.1  Blue contact checks were made on
the valve seats and valve disc and
verified almost 100 percent contact.
.
Assembly
specifications
 All gaskets were replaced.
3.2.6.2
 Setting the control valves actuator
were performed after got pressurize oil
hydraulic/ commissioning time.
3.2.7 Turning Gear

Inspection
 Backlash of all gears was checked
3.2.7.1 and found satisfactory.
 Blue contact patterns between all 
gears was checked and found
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.
specifications.
3.2.8 Bolt Couplings

 Bolt couplings were removed, cleaned  Polished.
and took NDT. No indication was
3.2.8.1
found only minor scratches on all the
bolts.
3.2.9 Gland Seal
 Gland seal upper lower both turbine
HP and LP side were removed.
 Gland Seal Both HP and LP were ship  Replaced the packing seal LP
3.2.9.1 to Workshop for replace/repair with new seal.
packing seal which erosion.  Replaced the packing seal HP
with new seal which supplied
by other contractor.
Page 11 of 35
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 :
o Manpower support during lube oil flushing.

o Verifying and adjusting main control valve actuator
o Monitoring and assessing lube oil pressure and temperatures.
o Monitoring and assessing bearing metal temperatures.
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.
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 .
 The unit was keep loaded on 58 MW with parameter vibrations as following :

 Bearing 1
 H = 25.1 micron
 V = 25.1 micron
 Bearing 2
 H = 51.8 micron
 V = 36.1 micron
 Bearing 3
 H = 97.3 micron
 V = 37.6 micron
 Bearing 4
 H = 36.0 micron
 V = 26.7 micron
Recommendation
The following recommendations are necessary for the next future.
 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).
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.
Page 14 of 35
Fig 1.After removed enclosure
Page 15 of 35
Fig 2. Turbine Name Plate
Fig 3. Un bolt turbine casing using bolt heater
Page 16 of 35
Fig 4. Prepare for upper casing removal
Fig 5. After casing removal
Page 17 of 35
Fig 6. Prepare for remove bearing #1
Fig 7. As found rotor journal bearing #1
Page 18 of 35
Fig 8. As found rotor journal bearing #2
Fig 9. Rigging for remove rotor
Page 19 of 35
Fig 10. PT NDE examination on thrust collar
Fig 11. Major rubs on shroud stage #14
Page 20 of 35
Fig 12. Unloading rotor turbine on balancing equipment
Fig 13. Turbine balancing
Page 21 of 35
Fig 14. Pilot valve MSV condition ( erosion on body )
Fig 15. Pilot valve contact check almost 100% contact
Page 22 of 35
Fig 16. Contact check Main Stop Valve, 100% contacted
Fig 17. Result of drop check between casing and diaphragm
Page 23 of 35
Fig 18. Contact Check on turning gear
Fig 19. Erosion on split line casing last stage
Page 24 of 35
Fig 21. Rotor installation for check in clearance
Fig 21. Clearance check
Page 25 of 35
Fig 22. Final installation after clearance check
Fig 23. Process Turn over casing
Page 26 of 35
Fig 24. Reassembly control valve
Fig 25. Birkosit as joint sealant casing and governor control valve
Page 27 of 35
Fig 26. Governor control valve Installation
Fig 27. Birkosit as joint sealant casing and governor control valve
Page 28 of 35
Fig 28. Upper half casing installation
Fig 29. Upper bearing housing#1 installation
Page 29 of 35
Fig 30. Cement hot insulation
Fig 31. Upper casing MOP installation
Page 30 of 35
Fig 32. Cover front pedestal installation
Fig 33. Check tightening bolt with torque wrench
Page 31 of 35
Fig 34. Final hot turbine insulation
Fig 33. Supporting during setting actuator governor control valve
Page 32 of 35
Fig 34. Condition 1000 rpm
Fig 35. Condition steam turbine on load 13 MW
Page 33 of 35
Fig 36. Condition steam turbine on load 18 MW
Fig 37. Condition steam turbine on load 51MW
Page 34 of 35
Fig 38. Condition steam turbine on load 51MW
Page 35 of 35
INITIAL
INSPECTION REPORT
This material is the exclusive property of PT. Sulzer Indonesia.

MFG/MODEL : Toshiba / SCSF
SERIAL N0. : TBA
EQUIP. N0. : Unit #1
Clearance Gland Seal CUSTOMER : PT, PLN Persero WKSKT
LOCATION : PLTU ASAM ASAM
JOB# : P - 1739
INSPECTED BY : Agung W DATE: Nov 25, 2016

STATUS : INITIAL FINAL UNIT : MM INCHI
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

PT Sulzer Indonesia
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 :
The result is still in within tolerance.
Inspected by: Checked by: Approved by :
Sukoco Mohamad Anton

Date: 17th December 2016 Date: 17th December 2016 Date:
PRODUCTION Form
PROJECT NO. : P-01739
STEAM TURBINE ROTOR CUSTOMER : PLN (PERSERO) WKSKT
BALANCE REPORT MFR/MODEL : TOSHIBA / SCSF
S/N & EQUIPMENT NO. : TBA / UNIT #1
(TWO PLANES) REPORT NO. : BLC-TURBINE-01
INSPECTED BY:YD. DATE :December 10, 2016

 BALANCE PROCEDURE:
FULL ASSEMBLY BAL. CHECK BAL. INDIVIDUAL BAL. PROGRESSIVE BAL.
 TYPE OF ROTOR:
STEAM TURBINE. COMPRESSOR PUMP. OTHER : GENERATOR
 WHEEL/DISK NUMBER: SHAFT ONLY
 TYPE MACHINE USED: H 20 BU H 40 BU H6B IRD
 CORR. METHOD: ADDITIONAL REMOVAL PERMANENT TEMPORARY OTHERS
 BALANCE SPEED: 250 RPM
INITIAL BALANCE MACHINE READING:
77 GRAMS, AT RADIUS 340 MM, AT 83 DEGREES, ON TE SIDE.
105 GRAMS, AT RADIUS 890 MM, AT 64 DEGREES, ON CE SIDE.
FINAL BALANCE MACHINE READING:

7 GRAMS, AT RADIUS 340 MM, AT 91 DEGREES, ON TE SIDE.
9 GRAMS, AT RADIUS 890 MM, AT 86 DEGREES, ON CE SIDE.
ALLOWABLE RESIDUAL UNBALANCE TOLERANCE (ACC. TO ANSI/API STANDARD):

40.1 GRAMS, AT RADIUS 340 MM, ON TE SIDE.
15.33 GRAMS, AT RADIUS 890 MM, ON CE SIDE.
 BALANCE MACHINE SETUP:

a: 1200. mm b: 2290 . mm c: 710 mm
r1: 340 mm r2: 890 mm
=ZERO MACHINE BLC,(FROM KEY PHASER 20 DEG,CCW AS VIEWED

 “ZERO” DEGREE POINT IS:
FROM CE
(BALANCING ROTATION = OPERATION ROTATION)
 KEY WEIGHTS USE (IN GRAMS): N\A
 OTHER REMARKS:
COMMENTS:
ACCEPTABLE
APPROVED BY: MO.
This material is the exclusive property of PT. Sulzer Indonesia

PRO-01FR-30 Rev.04 Page 1 of 1
PRODUCTION Form
STEAM TURBINE ROTOR CUSTOMER

MFR/MODEL
:
:
PLN (PERSERO) WKSKT
TOSHIBA / SCSF
RESIDUAL UNBALANCE INSPECTION REPORT S/N & EQUIPMENT NO. : TBA / UNIT #1
REPORT NO. : BLC-TURBINE-02
INSPECTED BY: YD DATE: DECEMBER 10, 2016
STATUS: INITIAL FINAL PLANE: 1 CE TE SINGLE
 ROTOR/PART DESCRIPTION: TURBINE

 MAXIMUM CONTINUOUS SPEED ( N ): 3000 RPM.
 JOURNAL STATIC WEIGHT LOAD ( W ): 6 441 KG
 UNBALANCE RADIUS: 340 mm. TRIAL WEIGHT: 280 Gr
 ALLOWABLE RESIDUAL UNBALANCE TOLERANCE: 13634 gr-mm.
No. AMP PHASE

1 284 Gr. 356 Degree
2 283 Gr. 62 Degree
3 286 Gr. 111 Degree 100 200 300 400 500

 TRIAL UNBALANCE : 340x280 = 95200 GR-mm.
286 -274
 Y= =6
2
286 + 274
 X=  = 280
2
 RESIDUAL UNBALANCE :
95 200 X  6
= 680 GR-mm. (PASS)
280
APPROVED BY: WK.

PRODUCTION Form
STEAM TURBINE ROTOR CUSTOMER

MFR/MODEL
:
:
PLN (PERSERO) WKSKT
TOSHIBA / SCSF
RESIDUAL UNBALANCE INSPECTION REPORT S/N & EQUIPMENT NO. : TBA / UNIT #1
REPORT NO. : BLC-TURBINE-02
INSPECTED BY: YD DATE: DECEMBER 10, 2016
STATUS: INITIAL FINAL PLANE: CE TE SINGLE
 ROTOR/PART DESCRIPTION: TURBINE

 MAXIMUM CONTINUOUS SPEED ( N ): 3000 RPM.
 JOURNAL STATIC WEIGHT LOAD ( W ): 6 441 Kg.
 UNBALANCE RADIUS: 890 mm. KNOWN WEIGHT : 288 Gr
 ALLOWABLE RESIDUAL UNBALANCE TOLERANCE: 13644 gr-mm.
No. AMP PHASE

1 287 Gr. 1 Degree
2 295 Gr. 62 Degree
100 200 300 400 500
 TRIAL UNBALANCE : 890x288 = 256320 Gr-mm.
296 – 280
 Y= =8
2
296 + 280
 X=  = 288
2
 RESIDUAL UNBALANCE :
256320x 8
= 7120 gr-mm. (PASS)
288
APPROVED BY: WK.

NDT REPORT

PRODUCTION Form
MAGNETIC PARTICLE TESTING CUSTOMER : PLN (PERSERO) WKSKT
REPORT MFR./MODEL : TOSHIBA / SCSF
S/N./EQUIPMENT NO. : TBA / UNIT #1
INSPECTED BY : PAS REPORT NO. : NDT.04/001-M/ XI”16

MT LEVEL : II DATE : DECEMBER 05, 2016
QTY PART NO. ITEM DESCRIPTION TEST PERFORMED:
1 UNIT = ROTOR AS RECEIVED REPAIR

MAIN OIL PUMP FINAL
RESIDUAL FIELD CHECK GAUSS

DEMAGNETIZATION
PROCEDURE NO. : PRO-01WI-41
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
PERMANENT SPRAY CAN (FLUORESCENT) RUST PRESERVATION
INSPECTIONS RESULTS:
NO DESCRIPTION PARTS INSPECTIONS RESULTS
1 ROTOR CRACK INDICATION ON TRUS COLLAR
HEAVY RUBING ON DISK #13
2 MAIN OIL PUMP NO INDICATION
SEE PHOTOGRAPH ON THE ATTACHMENT:
I CERTIFY THAT THE ABOVE LISTED ITEMS WERE INSPECTED

IN ACCORDANCE WITH APPLICABLE SULZER TSID STANDARD
PAS
INSPECTOR SIGNATURE
ENGINEERING/NDT LEVEL III/QC COMMENTS:
APPROVED BY : ES

PRODUCTION Form

MOP AREA
Fig.1 MT inspection on Rotor
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

PRODUCTION Form

Fig.7 No indication on journal shaft CE

Fig.8 No indication on seal CE area
area
Fig.9 No indication on blades area Fig.10 No indication on blades area
Fig.11 No indication on shroud and tenon Fig.12 No indication on shroud and tenon
area area

PRODUCTION Form

Fig.14 No indication on shroud and tenon

Fig.13 No indication on blades 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

PRODUCTION Form

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.23 Typical no indication on seal TE

Fig.24 No indication on journal shaft TE area
area

PRODUCTION Form

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

PRODUCTION Form
INSPECTED BY : PUR REPORT NO. : TBA

MT LEVEL : II DATE : Dec 2, 2016
1 UNIT = Rotor thrust Collar AS RECEIVED REPAIR

FINAL

DEMAGNETIZATION
TEST AREA :
ALL VISIBLE SURFACE
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
YOKE
FOUND CRACK INDICATION , SEE DETAIL ON THE ATTACHMENT:
I CERTIFY THAT THE ABOVE LISTED ITEMS WERE INSPECTED IN ACCORDANCE WITH
APPLICABLE SULZER TSID STANDARD

PRODUCTION Form
INSPECTED BY : PUR REPORT NO. : TBA

MT LEVEL : II DATE : Dec 2, 2016
Fig. 1 Found crack indication thrust collar Fig. 2 Found crack indication thrust collar

PRODUCTION Form
DEMAGNETIZATION CUSTOMER : PLN (PERSERO) WKSKT
INSPECTED BY : PAS REPORT NO. : NDT.004/XII-DMG/16

AS RECEIVED
1 UNIT = STEAM TURBINE ROTOR REPAIR
FINAL
TEST AREA :
ALL VISIBLE SURFACE
DEMAGNETIZER: AMPERE RESIDUAL MAGNETISM READING WITH
1000 – 1500 AMP

MOBILE UNIT / CABLE WRAP GAUSS METER AT SURFACE:
MAGNAFLUX AC 0,5 COUPLING END / DE
YOKE 6 - 0,5 CENTER
0,5 THRUST END/ NDE
INSPECTION RESULT :
DEMAGNETIZATION BELOW 2 GAUSS

PAS
OPERATOR SIGNATURE
APPROVED BY : ES

PRODUCTION Form

Fig. 1 Demag bellow 2 gauss on shaft TE side Fig. 2 Demag bellow 2 gauss on shaft TE side
Fig. 3 Demag bellow 2 gauss on trust collar TE

Fig. 4 Demag bellow 2 gauss on shaft TE side
side
Fig. 5 Demag bellow 2 gauss on seal area TE

Fig. 6 Demag bellow 2 gauss on disk area
side

PRODUCTION Form

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

PRODUCTION Form
PENETRANT TESTING CUSTOMER : PLN (PERSERO) WKSKT
INSPECTED BY : PAS REPORT NO. : NDT.04 /001P / XI-‘16

PT LEVEL : II DATE : DECEMBER 05, 2016
AS RECEIVED
1 SET = PAD BEARING ACTIVE REPAIR
1 SET = PAD BEARING INACTIVE FINAL

GENERAL PENETRANT DESCRIPTION:
ARDROX 970P25E ( FLUORESCENT )
ARDROX 985 P14 ( FLUORESCENT )
ARDROX-907 PB ( RED DYE )
MAGNAFLUX SKL – SP1 ( RED DYE )
TEST AREA :
WITNESS ON TEST/DEFECTIVE AREAS BY: --
BABBIT SURFACE
PENETRANT TYPE DWELL TIME: REMOVALL METHOD: DRYING:
MANUAL DRYER
FLUORESCENT 15 MINUTES SOLVENT WIPE ( TYPE C )
AMBIENT TEMPERATURE OTHER
RED DYE 30 MINUTES EMULSIFIER ( TYPE D / HIDRO PHYLIC )
60 MINUTES WATER WASHABLE ( TYPE A ) DEVELOPER APPLICATION:
OR MORE AQUEOUS NON AQUEOUS OTHER:
INSPECTION RESULT :
POROSITY, HEAVY RUBING AND LINIER INDICATION ON ABOVE INSPECTED PART, SEE THE
ATTACHMENT:

PAS
INSPECTOR SIGNATURE
APPROVED BY : ES

PRODUCTION Form

PAD BEARING ACTIVE
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

PRODUCTION Form

PAD BEARING INACTIVE
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
Fig. 5 Linier and heavy rubs on pad bearing

inactive

PRODUCTION Form

1 UNIT = CASING UPPER AND LOWER AS RECEIVED REPAIR

FINAL

DEMAGNETIZATION
TEST AREA :
VISIBLE SURFACE
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
YOKE
1 CASING NO INDICATION

PAS
INSPECTOR SIGNATURE
APPROVED BY : ES
This material is the exclusive property of PT Sulzer Turbo Services Indonesia

PRODUCTION Form

Fig.1 MT inspection on casing upper and lower
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.4 No indication on inspected area Fig.5 No indication on inspected area

PRODUCTION Form

Fig.7 No indication on inspected area Fig.8 No indication on inspected area
Fig.9 No indication on pit area on casing Fig.10 No indication on pit area on casing
upper and lower upper and lower
Fig.12 MT inspection on errosion lower,

Fig.11 Errosion indication on casing lower
found no crack inication

PRODUCTION Form

AS RECEIVED
1 SET = BEARING #1 REPAIR
1 SET = BEARING #2 FINAL

TEST AREA :
BABBIT SURFACE
MANUAL DRYER
INSPECTION RESULT :
FOUND LINIER AND CRACK INDICATION ON BEARING #1, SEE THE ATTACHMENT:

PAS
INSPECTOR SIGNATURE
APPROVED BY : ES

PRODUCTION Form

BEARING #1
Fig. 1 Penetrant inspection on bearing #1

Fig . 2 Penetrant inspection on bearing #1 upper
lower
Fig. 3 Linier indication on bearing #1 upper Fig. 4 Crack indication on bearing #1 lower
Fig. 6 Typicak no indication on bearing #1

Fig. 5 Crack indication on bearing #1 lower
upper and lower

PRODUCTION Form

BEARING #2
Fig. 1 Penetrant inspection on bearing #2

Fig . 2 Penetrant inspection on bearing #2 upper
lower
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

PRODUCTION Form

12 EA = COUPLING BOLT AS RECEIVED REPAIR

CASING BOLT FINAL

DEMAGNETIZATION
TEST AREA :
VISIBLE SURFACE
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
YOKE
1 COUPLING BOLT NO INDICATION
2 CASING BOLT NO INDICATION

PAS
INSPECTOR SIGNATURE
APPROVED BY : ES

PRODUCTION Form

COUPLING BOLT
Fig.1 MT inspection on coupling bolt Fig.2 No crack indication on coupling bolt
Fig.3 No crack indication on coupling bolt Fig.4 No crack indication on coupling bolt

PRODUCTION Form


PRODUCTION Form

CASING BOLT
Fig.13 MT inspection on casing bolt Fig.14 No crack indication on bolt casing
Fig.15 No crack indication on bolt casing Fig.16 No crack indication on bolt casing

PRODUCTION Form

Fig.19 MT inspection on bolt casing Fig.20 No crack indication on bolt casing

PRODUCTION Form

AS RECEIVED
REPAIR
2 AREA = ROTOR FINAL

TEST AREA :
JOURNAL BEARING AND TRUST COLLAR AREA
MANUAL DRYER
INSPECTION RESULT :
FOUND CRACK INDICATION ON TRUST COLLAR CE SIDE ON ABOVE INSPECTED PART, SEE THE
ATTACHMENT:

PAS
INSPECTOR SIGNATURE
APPROVED BY : ES

PRODUCTION Form

Fig. 1 Penetrant inspection on journal bearing and trust collar
Fig. 3 Found crack indication on trust collar TE

Fig. 4 Crack indication on trust collar TE side
side
Fig. 5 No indication on journal bearing TE

Fig. 5 Crack indication on trust collar TE side
side

PRODUCTION Form

Fig. 1 Penetrant inspection on journal bearing

Fig . 2 No indication on trust collar CE side
CE side
Fig. 3 No indication on journal bearing CE side Fig. 4 No indication on trust collar CE side

PRODUCTION Form

= DIAPHRAGM AS RECEIVED REPAIR

FINAL

DEMAGNETIZATION
TEST AREA :
VISIBLE SURFACE
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
YOKE
1 DIAPHRAGM ACCEPTED

PAS
INSPECTOR SIGNATURE
APPROVED BY : ES

PRODUCTION Form

Fig.1 MT inspection on diaphragm Fig.2 No crack indication on inspected area
Fig.3 Crack indication on blades Fig.4 Crack indication on blades
Fig.5 Crack indication on weld area Fig.6 Crack indication on inspcted area

PRODUCTION Form

Fig.7 No crack indication on shroud and

Fig.8 No crack indication on blades area
tenon area
Fig.10 No crack indication on shroud and

Fig.9 No crack indication on blades area
tenon area
Fig.11 No crack indication on blades triling Fig.12 No crack indication on blades triling
edge area edge area

PRODUCTION Form

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

PRODUCTION Form

1 UNIT = MAIN STOP VALVE AS RECEIVED REPAIR

FINAL

DEMAGNETIZATION
TEST AREA :
VISIBLE SURFACE
CONDUCTOR HRUST END
MAGNAGLO 14AM
PROD MEDIA:
YOKE
1 MAIN STOP VALVE NO INDICATION

PAS
INSPECTOR SIGNATURE
APPROVED BY : ES

PRODUCTION Form

Fig.1 MT inspection on Main Stop Valve
Fig.2 MT inspection on part of Main Stop

Fig.3 No indication on inspcted area
Valve
Fig.4 No indication on inspcted area Fig.5 No indication on inspcted area

PRODUCTION Form


Valve

Valve

PRODUCTION Form


Valve

Valve

PRODUCTION Form


Valve

Valve


Turbo Docs P-01739 - PLN WKSKT - Serious Inspection STG PLTU Asam Asam Unit #1 - Rev-0 (1-Turbine)

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Turbo Docs P-01739 - PLN WKSKT - Serious Inspection STG PLTU Asam Asam Unit #1 - Rev-0 (1-Turbine)

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STEAM TURBINE GENERATOR SERIOUS INSPECTION

TOSHIBA STEAM TURBIN – ALSTOM GENERATOR UNIT 1

Reviewed and Approved by

Project No. P-01739

Rotating Equipment Services

Customer PT PLN (PERSERO) WKTKS- PLTU ASAM ASAM

Commissioning services were provided by Sulzer which included supporting adjustment of

Customer : PT. PLN (Persero) Wil. KalTeng & KalSel

Control System : Service Type : Serious Inspection

Steam Pressure : bara Steam Temperature : Deg C

Speed : 3000 rpm

District Office : Purwakarta – Indonesia

Job Start date : 23 November 2016 Completion Date : 20 December 2016

Job Type : Major Inspection Full Load

Work Scope : [Y] Turbine [Y] Generator [Y] Valves

Reassembly and Mechanical Completion

MAIN STOP VALVE – MSV

MAIN OIL TANK

LUBRICATION OIL FLUSHING

Finding / remark Corrective measure

 Journal bearing #2 Babbitt surfaces  Cleaned and polished.

 All bearing journal were measured and  Within tolerance

 Thrust bearing pads were received UT

 The rotor steam path areas were

3.2.4 Main Stop Valves ( MSV)

3.2.5 Control Valve

3.2.7 Turning Gear

3.2.8 Bolt Couplings

o Manpower support during lube oil flushing.

 The unit was keep loaded on 58 MW with parameter vibrations as following :

The following recommendations are necessary for the next future.

Fig 3. Un bolt turbine casing using bolt heater

Fig 5. After casing removal

Fig 7. As found rotor journal bearing #1

Fig 9. Rigging for remove rotor

Fig 11. Major rubs on shroud stage #14

Fig 13. Turbine balancing

Fig 15. Pilot valve contact check almost 100% contact

Fig 17. Result of drop check between casing and diaphragm

Fig 19. Erosion on split line casing last stage

Fig 21. Clearance check

Fig 23. Process Turn over casing

Fig 29. Upper bearing housing#1 installation

Fig 31. Upper casing MOP installation

Fig 33. Check tightening bolt with torque wrench

Fig 33. Supporting during setting actuator governor control valve

Fig 35. Condition steam turbine on load 13 MW

Fig 37. Condition steam turbine on load 51MW

This material is the exclusive property of PT. Sulzer Indonesia.

INSPECTED BY : Agung W DATE: Nov 25, 2016

This material is the exclusive property of PT. Sulzer Indonesia.

The result is still in within tolerance.

Inspected by: Checked by: Approved by :

Sukoco Mohamad Anton

INSPECTED BY:YD. DATE :December 10, 2016

FINAL BALANCE MACHINE READING:

ALLOWABLE RESIDUAL UNBALANCE TOLERANCE (ACC. TO ANSI/API STANDARD):

 BALANCE MACHINE SETUP:

r1: 340 mm r2: 890 mm

=ZERO MACHINE BLC,(FROM KEY PHASER 20 DEG,CCW AS VIEWED

 KEY WEIGHTS USE (IN GRAMS): N\A

This material is the exclusive property of PT. Sulzer Indonesia

STEAM TURBINE ROTOR CUSTOMER