Turbo Docs P-01267 - Repair MHI ST Rotor Unit 5-1

PT.
Sulzer Turbo Services Indonesia
TABLE OF CONTENTS:
SCOPE OF WORKS
AS RECEIVED INSPECTION REPORT
LP ROTOR INCOMING VISUAL INSPECTION REPORT
LP ROTOR RUN OUT INSPECTION REPORT
LP ROTOR BEARING JOURNAL INSPECTION REPORT
LP ROTOR GLAND SEAL DIAMETER INSPECTION REPORT
LP ROTOR HARDNESS INSPECTION REPORT
LP ROTOR SURFACE ROUGHNESS INSPECTION REPORT
LP ROTOR MAGNETIC PARTICLE TESTING REPORT
FINAL INSPECTION REPORT

LP ROTOR BEARING JOURNAL INSPECTION REPORT
LP ROTOR HARDNESS INSPECTION REPORT
LP ROTOR SURFACE ROUGHNESS INSPECTION REPORT
LP ROTOR RUN OUT INSPECTION REPORT
LP ROTOR PROBE AREAS ELECTRICAL RUN OUT INSPECTION REPORT
LP ROTOR BALANCE REPORT TWO PLANES
LP ROTOR RESIDUAL UNBALANCE INSPECTION REPORT
LP ROTOR MAGNETIC PARTICLE TESTING REPORT
LP ROTOR DEMAGNETIZATION REPORT
PHOTOGRAPHS
PRO-01FR-36Rev.00
This material is the exclusive property of PT. Sulzer Turbo Services Indonesia.
PT. Sulzer Turbo Services Indonesia
SCOPE OF WORKS:
1.
RECEIVE & INVENTORY.
2.
PERFORM INCOMING INSPECTION.
3.
CLEANING BY BLASTING THE ROTOR.
4.
PERFORM INCOMING NDT INSPECTION.
5.
WELD REPAIR BOTH JOURNAL ROTOR (GEN. SIDE & GOV. SIDE)
6.
STRAIGHTENING LP ROTOR.
7.
FINAL INSPECTION & NDT.
8.
PERFORM LOW SPEED BALANCING ROTOR AS PER STANDAR SPECIFICATION.
9.
FINAL QC INSPECTION INCLUDE DEMAGNETIZATION
10. PRESERVE & PACKAGING ROTOR.

11. SHIPMENT.
12. PROVIDE REPORT.
PRO-01FR-100 Rev.01
This material is the exclusive property of PT. Sulzer Turbo Services Indonesia
AS RECEIVED
INSPECTION REPORT
CUSTOMER
MFG./MODEL
EQUIP./NO.
P.O. NO.
TSID PROJECT
:
:
:
:
:
PJB UP MUARA KARANG

MITSUBISHI / 200 MW
LP ROTOR / UNIT #5
LOI NO. 160.LOI/612/UPHB/2014
P-01267
Rotating Equipment Services

Purwakarta Service Center
PRO-01FR-44 REV.04
PRODUCTION Form
INCOMING
VISUAL INSPECTION REPORT
MFG/MODEL
S/N & EQUIP. NO.
MITSUBISHI / 200 MW
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-AR-01
DATE : MAY 21, 2014
INSPECTED BY: UMR

INSTRUCTIONS:
1.
2.
3.
4.
5.
PHOTOGRAPH COMPONENT CONDITION AS RECEIVED. TAKE INDIVIDUAL PHOTOGRAPHS OF ANY AREA WHICH EXHIBITS
ABNORMAL WEAR OR DAMAGE.
RECORD ALL F.O.D., EROSION, HANDLING DAMAGE, RUST BUILD UP OR ANY OTHER OBVIOUS DEFECTS.
VISUALLY INSPECT AND RECORD GENERAL CONDITION.
MARK EACH COMPONENT WITH THE JOB NUMBER USING METAL TAGS OR AN APPROVED MARKED.
TAKE SAMPLES OF ANY DEPOSITS.
As received visual inspection the LP ROTOR are as follow :

5
1
4
3
2
GOV SIDE
GEN SIDE
1. Coupling Gen Side exhibited medium scratches on bolt holes and axial faces, medium nick on flange, ligh
pitting, light scratch on male spigot
2. Exhibited light to medium scratches, medium pitting, medium rubs on seal area.
3. Bearing Journal Gen Side exhibited heavy rubs & pitting corrosion,deep rubs 0.5 0.28. medium rubs &
discrbration on oil deflector area, light scratch & medium pitting on probe area.
4. Gland seal Gen Side exhibited medium rubs.
5. - Stage #8 Gov & Gen side exhibited medium erosion on leading edge blades & tie wire, light to medium
pitting on disck, medium scaling.
- Stage #7 Gov & Gen side exhibited light erosion on leading edge blades, medium erosion on tie wire
- Stg #6,5,4,3,2 Gov & Gen side exhibited light pitting on blades, light rubs on shroud , medium pitting on
disk,light rubs on interstage spill strip exhibited , light rubs.
- Stg # 1 Gov & Gen side exhibited medium pitting corrosion on blades, interstage spill strip in fair conditions,
balance weight area in fair condition.
6. Gland seal Gove Side exhibited light to medium rubs.
7. Bearing Journal Gov Side exhibited heavy rubs with 0,8 deep, heavy rubs on seal area, light scratches &
pitting on probe area.
8. Coupling area Gov Side exhibted medium rubs on seal area , medium nick & dent on flange, , bolt holes
exhibited medium rubs, medium nick & dent bolt holes area, light scratches & pitting on axial face, light rubs
on male spigot.
APPROVED BY: ASP.

PRO-01FR-33 Rev.04
Page 1 of 1
PRODUCTION Form
LP ROTOR
RUNOUT INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-AR-02
INSPECTED BY: YD.

STATUS:
DATE: MAY 21, 2014
AS RECEIVED
OTHERS/.
FINAL
SURFACES:
RADIAL
10
AXIAL
UNITS:
1/100 MILLIMETERS
11
2
1
1/10,000 INCHES
18
3
12
13 14 15 16
17
19
B2
A2
GOV. SIDE
GEN. SIDE
B1
A1
NOTE:
1. ALL PHASE ANGLE RECORDED : CCW AS VIEWED FROM GOV. SIDE.
2. ZERO DEGREE POINTS IS: STAMNP 1 ON DISK
3. ROTOR/SHAFT/PART IS SUPPORTED BY: LATHE MACHINE
APPROVED BY: ASP.
PRO-01FR-56 Rev.04
Page 1 of 2
PRODUCTION Form
LP ROTOR
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-AR-02
INSPECTED BY: YD
STATUS:
DATE: MAY 21, 2014.
AS RECEIVED
FINAL
SURFACES:
RADIAL
AXIAL
UNITS:
1/100 MILLIMETERS
1/10,000 INCHES
POS
10
11
12
13
14
15
16
17
18
19
A1
A2
B1
B2
45
-1
-0.5
-0.5
-0.5
-0.5
-0.5
-1
-2
-0.5
-1
0.5
0.5
-1
-0.5
-1
90
-1
-0.5
-0.5
0.5
0.5
1.5
-1
0.5
-1
-3
-2
-1
0.5
-2
-0.5
-2
135
-1
-1
-0.5
-0.5
-1
1.5
-1
0.5
-1.5
-0.5
0.5
-1
0.5
-1
180
-1
-1
-0.5
-1.5
-0.5
0.5
-0.5
-1
-0.5
-1
-0.5
-0.5
-0.5
0.5
-1
-0.5
-1
225
-0.5
-1
-1.5
-0.5
-0.5
1.5
-2
-2
3.5
-2
-1
-1
-1.5
-0.5
-1.5
270
-1
-0.5
-0.5
-1.5
-0.5
-0.5
-2
-4
-1
0.5
-1
-2
0.5
-2
315
-1
-0.5
-1.5
-0.5
-2
-1
3.5
-1
0.5
1.5
-1
-1.5
1.5
-1.5
TOTAL
0.5
0.5
-1.5
0.5
0.5
1.5
4.5
1.5
3.5
3.5
0.5
1.5
NOTE:
1. ALL PHASE ANGLE RECORDED : CCW AS VIEWED FROM "GOV SIDE".
2. ZERO DEGREE POINTS IS: STAMP N0 "1" ON DISK.
3. ROTOR/SHAFT/PART IS SUPPORTED BY: LATHE MACHINE.
APPROVED BY: ASP
PRO-01FR-56 Rev.04
Page 2 of 2
PRODUCTION Form
LP ROTOR
BEARING JOURNAL DIAMETER INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-AR-03
INSPECTED BY: EKA

STATUS:
DATE: MAY 21, 2014
AS RECEIVED
FINAL
1 2
SURFACES:
INSIDE DIAMETER
OUTSIDE DIAMETER
UNITS:
5 6 7
3 4
MILLIMETERS
INCHES
GOV. SIDE
GEN. SIDE
POS
379.20
379.08
379.17
379.19
379.19
379.18
379.16
379.19
90
379.19
379.09
379.15
379.19
379.19
379.17
379.16
379.18
NOTE:
1. ALL PHASE ANGLE RECORDED : 0 / 90
2. ZERO DEGREE POINTS IS: STAMP 1 ON DISK
APPROVED BY: ASP.
PRO-01FR-55 Rev.04
Page 1 of 1
PRODUCTION Form
LP ROTOR
GLAND SEAL DIAMETER INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-AR-04
INSPECTED BY: EKA

STATUS:
DATE: MAY 21, 2014
AS RECEIVED
FINAL
SURFACES:
INSIDE DIAMETER
OUTSIDE DIAMETER
UNITS:
MILLIMETERS
INCHES
7
8
GOV. SIDE
GEN. SIDE
POS
418.00
508.03
508.06
508.05
508.12
508.12
508.12
417.69
90
418.00
508.03
508.05
508.06
508.12
508.12
508.12
417.70
NOTE:
APPROVED BY: ASP.
PRO-01FR-58 Rev.04
Page 1 of 1
PRODUCTION Form
LP ROTOR
BEARING JOURNAL HARDNESS INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-AR-05
DATE: MAY 21, 2014
INSPECTED BY: YN.

STATUS:
AS RECEIVED
FINAL
1 2
UNITS:
5 6 7
3 4
HRC
HRB
GOV. SIDE
GEN. SIDE
NO
HARDNESS
25.9
29.9
27.5
29.1
27.5
28.8
24.5
29.2
NOTE:
1. THE PICKUP DATA SHOULD BE DIFFERENCE MAXIMUM 3 HRC BEFORE CALCULATING AVERAGE VALUE
2. TAKE ON THE SURFACE OF CLOSE RUNNING CLEARANCE
APPROVED BY: ASP.
PRO-01FR-78 Rev.04
Page 1 of 1
PRODUCTION Form
LP ROTOR
SURFACE ROUGHNESS INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-AR-06
INSPECTED BY: EKA.

STATUS:
AS RECEIVED
DATE: MAY 21, 2014

FINAL
UNITS:
GEN. SIDE
- INCH
-M
GOV. SIDE
NO
SURFACE
ROUGHNESS (Ra)
0.57 ~ 0.92
0.82 ~ 1.19
0.72 ~1.08
0.80 ~ 1.01
APPROVED BY: ASP.

PRO-01FR-90 Rev.04
Page 1 of 1
PRODUCTION Form
MAGNETIC PARTICLE TESTING

REPORT
INSPECTED BY :
MT LEVEL
:
QTY
PART NO.
1 UNIT
HR
II
ITEM DESCRIPTION
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
DATE
NDT. 01 / 036M / IV 14
APRIL 12, 2014
TEST PERFORMED:
LP ROTOR
AS RECEIVED
REPAIR
FINAL
RESIDUAL FIELD CHECK
GAUSS
DEMAGNETIZATION
PROCEDURE NO. :
TEST AREA :
BEARING JOURNAL AREA ( GEN. SIDE & GOV. SIDE )

MAGNETIZER:
METHOD:
MOBILE UNIT
HEAD SHOT/CLAMP
COIL/CABLE WRAP
CONDUCTOR
RESIDUAL
MEDIA:
PROD
AMP.:
CONTINUOUS
AC/DC
PRO-01WI-41
WITNESS ON TEST/DEFECTIVE AREAS BY:
PARTICLE TYPE:
ARDROX 8800
KEROSENE
(SOLVENT MIX)
MAGNAGLO 14AM
RESIDUAL MAGNETISM :
GAUSS METER AT SURFACE:
COUPLING END
CENTER
HRUST END
WET BATH (FLUORESCENT)
(SPRAY CAN)
DEMAGNETIZED BELOW 2.0 GAUSS
DRY POWDER (VISIBLE)
OTHERS
PARTS WITH DISCONTINUITIES MARKED
YOKE
AC
DC
PERMANENT
SPRAY CAN (FLUORESCENT)
RUST PRESERVATION
INSPECTIONS RESULTS:
NO CRACK INDICATION ON ABOVE INSPECTED AREA, EXCEPT HEAVY RUBS. SEE THE ATTACHMENT
I CERTIFY THAT THE ABOVE LISTED ITEMS WERE INSPECTED

IN ACCORDANCE WITH APPLICABLE SULZER TSID STANDARD
HR
INSPECTOR SIGNATURE
ENGINEERING/NDT LEVEL III/QC COMMENTS:
APPROVED BY
: ES
PRO-01FR-08 Rev.03
Page 1 of 3
PRODUCTION Form

REPORT
INSPECTED BY :
MT LEVEL
:
HR
II
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
DATE
NDT. 01 / 036M / IV 14
APRIL 12, 2014
BEARING JOURNAL ( GOV. Side )
Fig.1 Steam turbine rotor after sand blasting
Fig. 2 No crack indication on bearing journal Gov. side
Fig.3 Heavy rubs on bearing journal area
Fig. 4 Heavy rubs on bearing journal area
Fig. 5 Typical deep rubs on bearing journal
Fig. 6 Typical of dent on oil seal area
PRO-01FR-08 Rev.03
Page 2 of 3
PRODUCTION Form

REPORT
INSPECTED BY :
MT LEVEL
:
HR
II
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
DATE
NDT. 01 / 036M / IV 14
APRIL 12, 2014
BEARING JOURNAL ( GEN. Side )
Fig. 7 No crack indication on bearing journal

Gen. Side
Fig.9 Heavy rubs on bearing journal area
Fig. 8 Typical of deep rub on bearing journal area
Fig. Heavy rubs on bearing journal area
PRO-01FR-08 Rev.03
Page 3 of 3
FINAL
INSPECTION REPORT
CUSTOMER
MFG./MODEL
EQUIP./NO.
P.O. NO.
TSID PROJECT
:
:
:
:
:
PJB UP MUARA KARANG

MITSUBISHI / 200 MW
LP ROTOR / UNIT #5
P-01267

PRO-01FR-44 REV.04
PRODUCTION Form
LP ROTOR
BEARING JOURNAL DIAMETER INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-FNL-01
INSPECTED BY: DNY

STATUS:
DATE: JUNE 05, 2014
AS RECEIVED
FINAL
1 2
SURFACES:
INSIDE DIAMETER
OUTSIDE DIAMETER
UNITS:
5 6 7
3 4
MILLIMETERS
INCHES
GOV. SIDE
GEN. SIDE
POS
379.25
379.24
379.25
379.25
379.25
379.24
379.25
379.24
90
379.23
379.23
379.24
379.25
379.24
379.24
379.25
379.24
NOTE:
APPROVED BY: ASP.
PRO-01FR-55 Rev.04
Page 1 of 1
PRODUCTION Form
LP ROTOR
BEARING JOURNAL HARDNESS INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-FNL-02
DATE: MAY 30, 2014
INSPECTED BY: KARNO.

STATUS:
AS RECEIVED
FINAL
UNITS:
2 3 4 5
7 8
HRC
HRB
9 10
GOV. SIDE
GEN. SIDE
POS
HARDNESS
WELDING AREA
HAZ AREA
BASE METAL AREA
HAZ AREA
WELDING AREA
10
24.4 ~ 28.5
23.2 ~ 26.5
24.0 ~ 26.9
24.7 ~ 26.4
25.1 ~ 27.0
29.1 ~ 30.1
23.6 ~ 25.8
23.2 ~ 26.5
24.2 ~ 26.5
24.1 ~ 27.2
NOTE:
1. TAKE ON THE SURFACE OF CLOSE RUNNING CLEARANCE
APPROVED BY: ASP.

PRO-01FR-78 Rev.04
Page 1 of 1
PRODUCTION Form
LP ROTOR
SURFACE ROUGHNESS INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-FNL-03
INSPECTED BY: EKA.

STATUS:
AS RECEIVED
DATE: JUNE 08, 2014

FINAL
UNITS:
GEN. SIDE
- INCH
-M
GOV. SIDE
NO
SURFACE
ROUGHNESS (Ra)
0.17 ~ 0.20
0.12 ~ 0.19
0.17 ~ 0.18
0.22 ~ 0.23
APPROVED BY: ASP.

PRO-01FR-90 Rev.04
Page 1 of 1
PRODUCTION Form
LP ROTOR
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-FNL-04
INSPECTED BY: UMR.

STATUS:
DATE: JUNE 06, 2014
AS RECEIVED
OTHERS/.
FINAL
SURFACES:
RADIAL
10
AXIAL
UNITS:
1/100 MILLIMETERS
11
2
1
1/10,000 INCHES
18
3
12
13 14 15 16
17
19
B2
A2
GOV. SIDE
GEN. SIDE
B1
A1
NOTE:
1. ALL PHASE ANGLE RECORDED : CCW AS VIEWED FROM GOV. SIDE.
2. ZERO DEGREE POINTS IS: STAMNP 1 ON DISK
3. ROTOR/SHAFT/PART IS SUPPORTED BY: V-BLOCKS
APPROVED BY: ASP.
PRO-01FR-56 Rev.04
Page 1 of 2
PRODUCTION Form
LP ROTOR
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-FNL-04
INSPECTED BY: UMR.

STATUS:
DATE: JUNE 06, 2014
AS RECEIVED
FINAL
SURFACES:
RADIAL
AXIAL
UNITS:
1/100 MILLIMETERS
1/10,000 INCHES
POS
10
11
12
13
14
15
16
17
18
19
A1
A2
B1
B2
45
-05
-0.5
0.5
-0.5
-0.5
-1
-1
-0
0.5
-1
-1
-1
90
-0.5
0.5
-1
-1.5
-0.5
-2
-1
0.5
-1
-1
-2
-1
-1.5
135
-1
-1.5
0.5
-0.5
0.5
-0.5
0.5
-0.5
-1
-0.5
-1
0.5
-1
180
-1
1.5
-0.5
0.5
-0.5
0.5
-1
-2
-0.5
-0.5
-1
-0.5
-1
0.5
225
-1.5
-0.5
0.5
0.5
-0.5
0.5
0.5
-2
-0.5
1.5
-2
270
-1
0.5
-0.5
0.5
-2
0.5
-0.5
-1
-1
-1.5
315
0.5
0.5
-2
0.5
-0.5
-1
-1
-1.5
0.5
-1.5
TOTAL
1.5
1.5
2.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
1.5
NOTE:
1. ALL PHASE ANGLE RECORDED : CCW AS VIEWED FROM "GOV SIDE".
2. ZERO DEGREE POINTS IS: STAMP N0 "1" ON DISK.
3. ROTOR/SHAFT/PART IS SUPPORTED BY: V-BLOCKS
APPROVED BY: ASP
PRO-01FR-56 Rev.04
Page 2 of 2
PRODUCTION Form
LP ROTOR
PROBE AREAS ELECTRICAL RUNOUT INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-FNL-05
INSPECTED BY: SGH

STATUS:
AS RECEIVED
ERO LOCATION
DATE: JUNE 05, 2014

FINAL
SURFACES:
RADIAL
AXIAL
UNITS:
MILLIMETERS
INCHES
: RADIAL GS
RESULT: ELC. R/O = 22 m
MAX. ALLOWABLE ELECTRICAL

RUNOT:
RADIAL = 25 m
COMMENTS:
-
ACCEPTABLE
APPROVED BY: ASP.

PRO-01FR-41 Rev.04
Page 1 of 2
PRODUCTION Form
LP ROTOR
PROBE AREAS ELECTRICAL RUNOUT INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-FNL-05
INSPECTED BY: SGH.

STATUS:
AS RECEIVED
ERO LOCATION
DATE: JUNE 05, 2014

FINAL
SURFACES:
RADIAL
AXIAL
UNITS:
MILLIMETERS
INCHES
: RADIAL TS
RESULT: ELC. R/O = 24 m
MAX. ALLOWABLE ELECTRICAL

RUNOT:
RADIAL = 25 m
COMMENTS:
-
ACCEPTABLE
APPROVED BY: ASP.

PRO-01FR-41 Rev.04
Page 2 of 2
PRODUCTION Form
LP ROTOR
BALANCE REPORT
(TWO PLANES)
MFG/MODEL
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BIFNL-06
INSPECTED BY: YD
DATE : JUNE 07, 2014
BALANCE PROCEDURE:
FULL ASSEMBLY BAL.
TYPE OF ROTOR:
STEAM TURBINE.
CHECK BAL.
TYPE MACHINE USED:

BALANCE SPEED:
INDIVIDUAL BAL.
COMPRESSOR
WHEEL/DISK NUMBER:
CORR. METHOD:
MITSUBISHI / 200 MW
PUMP.
.
H 20 BU
ADDITIONAL
PROGRESSIVE BAL.
OTHER / GENERATOR
SHAFT ONLY
H 40 BU
REMOVAL
H6B
PERMANENT
ABRO
TEMPORARY
OTHERS
200 RPM
INITIAL BALANCE MACHINE READING:

1329
GRAMS, AT RADIUS
420
MM, AT
96
DEGREES, ON
GEN/S
SIDE.
1385
GRAMS, AT RADIUS
420
MM, AT
100
DEGREES, ON
GOV/S
SIDE.
FINAL BALANCE MACHINE READING:

51
GRAMS, AT RADIUS
420
MM, AT
45
DEGREES, ON
GEN/S
SIDE.
114
GRAMS, AT RADIUS
420
MM, AT
245
DEGREES, ON
GOV/S
SIDE.
ALLOWABLE RESIDUAL UNBALANCE TOLERANCE (ACC. TO ANSI/API STANDARD):

177
GRAMS, AT RADIUS
420
MM, ON
GEN/S
SIDE.
177
GRAMS, AT RADIUS
420
MM, ON
GOV/S
SIDE.
BALANCE MACHINE SETUP:

a: 830 . mm
b: 3120 . mm
c: 770 .mm
r1: 420 .mm
r2: 420 . mm
ZERO DEGREE POINT IS:
MARKING 1 HOLE BALANCE WEIGHT

(BALANCING ROTATION = OPERATION ROTATION)
KEY WEIGHTS USE (IN GRAMS):

OTHER REMARKS:
N/A
FINAL BALANCING ROTOR ASSY
COMMENTS:
ACCEPTABLE
APPROVED BY: ASP.
PRO-01FR-30 Rev.04
Page 1 of 1
PRODUCTION Form
LP ROTOR
RESIDUAL UNBALANCE INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-FNL-07
INSPECTED BY: YD
STATUS:
DATE: JUNE 7,2014
INITIAL
FINAL
PLANE:1
COUPLING
EXCITER
GEN/S
ROTOR/PART DESCRIPTION: STEAM TURBINE ROTOR

MAXIMUM CONTINUOUS SPEED ( N ): 3000 RPM.
JOURNAL STATIC WEIGHT LOAD ( W ): 19250 Kg.
UNBALANCE RADIUS: 420 mm.
TRIAL WEIGHT:650 Gr
ALLOWABLE RESIDUAL UNBALANCE TOLERANCE: 74 340 gr-mm.

Note: If not specified, Residual Unbalance Tolerance Allowable is:
6350 W/N (gr-mm.). Acc. To ANSI / API Standard.
No.
AMP
PHASE
629
Gr.
Degree
689
Gr.
97
Degree
475
Gr.
183
Degree
470
Gr.
265
Degree
Gr.
Degree
Gr.
Degree
TRIAL UNBALANCE :
Y=
X=
420 x 650
200
400
600
800
100
00
= 273 000 Gr-mm.
MAX. READING - MIN. READING

= 109
2
MAX. READING + MIN. READING
= 659
2
RESIDUAL UNBALANCE :
273000x 109
659
= 45 155 gr-mm. (PASS)
APPROVED BY: ASP.

PRO-01FR-23 Rev.04
Page 1 of 2
PRODUCTION Form
LP ROTOR
RESIDUAL UNBALANCE INSPECTION REPORT
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
BI-FNL-07
INSPECTED BY: YD
STATUS:
DATE: JUNE 7,2014
INITIAL
FINAL
PLANE:2
COUPLING
EXCITER
GOV/S
ROTOR/PART DESCRIPTION: STEAM TURBINE ROTOR

MAXIMUM CONTINUOUS SPEED ( N ): 3000 RPM.
JOURNAL STATIC WEIGHT LOAD ( W ): 19250 Kg.
UNBALANCE RADIUS: 420 mm.
TRIAL WEIGHT: 650 Gr
ALLOWABLE RESIDUAL UNBALANCE TOLERANCE: 74 340 gr-mm.

Note: If not specified, Residual Unbalance Tolerance Allowable is:
6350 W/N (gr-mm.). Acc. To ANSI / API Standard.
No.
AMP
PHASE
655
Gr.
Degree
695
Gr.
93
Degree
645
Gr.
181
Degree
605
Gr.
274
Degree
Gr.
Degree
Gr.
Degree
200
400
600
800
100
0
TRIAL UNBALANCE : 420 x 650 = 273 000 Gr-mm.

Y=
X=
MAX. READING - MIN. READING

= 45
2
MAX. READING + MIN. READING
= 650
2
RESIDUAL UNBALANCE :
273000 x 45
650
= 18900 gr-mm. (PASS)
APPROVED BY: ASP.

PRO-01FR-23 Rev.04
Page 2 of 2
PRODUCTION Form

REPORT
INSPECTED BY :
MT LEVEL
:
QTY
PART NO.
1 UNIT
CH/ MN/ AM
II
ITEM DESCRIPTION
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
DATE
NDT. 01 / 015M / VI 14
JUNE 03, 2014
TEST PERFORMED:
LP ROTOR
AS RECEIVED
REPAIR
FINAL
RESIDUAL FIELD CHECK
GAUSS
DEMAGNETIZATION
PROCEDURE NO. :
TEST AREA :
BEARING JOURNAL AREA ( GOV SIDE GEN SIDE )

MAGNETIZER:
METHOD:
MOBILE UNIT
HEAD SHOT/CLAMP
COIL/CABLE WRAP
CONDUCTOR
RESIDUAL
MEDIA:
PROD
AMP.:
CONTINUOUS
AC/DC
PRO-01WI-41
WITNESS ON TEST/DEFECTIVE AREAS BY:
PARTICLE TYPE:
ARDROX 8800
KEROSENE
(SOLVENT MIX)
MAGNAGLO 14AM
RESIDUAL MAGNETISM :
COUPLING END
CENTER
HRUST END
WET BATH (FLUORESCENT)
(SPRAY CAN)
DEMAGNETIZED BELOW 2.0 GAUSS
DRY POWDER (VISIBLE)
OTHERS
PARTS WITH DISCONTINUITIES MARKED
YOKE
AC
DC
PERMANENT
SPRAY CAN (FLUORESCENT)
RUST PRESERVATION
INSPECTIONS RESULTS:
NO CRACK INDICATION ON ABOVE INSPECTED AREA, SEE THE ATTACHMENT :

CH
INSPECTOR SIGNATURE
ACCEPTABLE
APPROVED BY
: ES
PRO-01FR-08 Rev.03
Page 1 of 2
PRODUCTION Form

REPORT
INSPECTED BY :
MT LEVEL
:
CH/ MN/ AM
II
Fig.1 Position MT inspection on the Rotor
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
DATE
NDT. 01 / 015M / VI 14
JUNE 03, 2014
Fig. 2
MT inspection on the Rotor
Fig.3 No Crack indication on bearing

journal Gen Side
Fig. 4
No Crack indication on bearing

journal Gen Side
Fig. 5
Fig. 6

journal Gov Side

journal Gov Side
PRO-01FR-08 Rev.03
Page 2 of 2
PRODUCTION Form
DEMAGNETIZATION
REPORT
INSPECTED BY
UT LEVEL
QTY
:
:
ES
III
PART NO.
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
DATE
NDT.01 / 026D/ VI-14

JUNE 06, 2014
ITEM DESCRIPTION
TEST PERFORMED:
AS RECEIVED
1 UNIT
LP ROTOR
REPAIR
FINAL
TEST AREA :
PROCEDURE NO. : PRO-01WI-41
ALL VISIBLE SURFACE

DEMAGNETIZER:
MOBILE UNIT / CABLE WRAP
MAGNAFLUX
AMPERE
1000 1500 AMP
AC
YOKE 6
RESIDUAL MAGNETISM READING WITH

0
COUPLING END / DE
CENTER
THRUST END/ NDE
INSPECTION RESULT :
DEMAGNETIZATION BELOW 2 GAUSS, SEE PHOTOGRAPHS IN THE ATTACHMENT:

HR
OPERATOR SIGNATURE
ACCEPTABLE
APPROVED BY
: ES
PRO-01FR-102 Rev.03
Page 1 of 3
PRODUCTION Form
DEMAGNETIZATION
REPORT
INSPECTED BY
UT LEVEL
:
:
ES
III
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
DATE
NDT.01 / 026D/ VI-14

JUNE 06, 2014
Fig.2 Residual magnetism on Gov. Side

Coupling : 1 gauss
Fig.1 Demagnetization on Gov. Side LP rotor
Fig.3 Residual magnetism on Journal Gov.

Side :1.5 gauss
Fig.4 Residual magnetism on gland seal Gov.

Side :1 gauss
Fig.5 Demagnetization on Gen. Side LP rotor
Fig.6 Residual magnetism on gland seal Gen.

Side :1 gauss
PRO-01FR-102 Rev.03
Page 2 of 3
PRODUCTION Form
DEMAGNETIZATION
REPORT
INSPECTED BY
UT LEVEL
:
:
ES
III
Fig.7 Residual magnetism on Journal Gen.

Side:1 gauss
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
REPORT NO.
DATE
NDT.01 / 026D/ VI-14

JUNE 06, 2014
Fig.8 Residual magnetism on shaft Gen. Side:

1 gauss
Fig.9 Residual magnetism on shaft Gen. Side:

1 gauss
PRO-01FR-102 Rev.03
Page 3 of 3
PHOTOGRAPHS
CUSTOMER
MFG./MODEL
EQUIP./NO.
P.O. NO.
TSID PROJECT
:
:
:
:
:
PJB UP MUARA KARANG

MITSUBISHI / 200 MW
LP ROTOR / UNIT #5
P-01267

PRO-01FR-44 REV.04
PRODUCTION Forms
PHOTOGRAPHS
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
Fig 01. Incoming condition of rotor
Fig 02. Incoming condition bearing journal rotor
Fig 03. Check depth of rubs journal rotor
Fig 04. Blasting rotor preparation
Fig 05. Incoming visual inspection
Fig 06. Incoming magnetic paticle test inspection
PRO-01FR-32 Rev.04
Page 1 of 3
PRODUCTION Forms
PHOTOGRAPHS
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
Fig 07. Under cutting both journals for weld prep
Fig 08. Welding repair both journals
Fig 09. Rough cutting both journals after welding

repair
Fig 10. Ultrasonic test after rought cutting
Fig 11. Stress relieve process
Fig 12. Final machining both journals to target size
PRO-01FR-32 Rev.04
Page 2 of 3
PRODUCTION Forms
PHOTOGRAPHS
MFG/MODEL
MITSUBISHI / 200 MW
S/N & EQUIP. NO.
TBA / UNIT #5
CUSTOMER
PJB UP MUARA KARANG
TSID PROJECT
P-01267
Fig 13. Final magnetic particle test
Fig 14. Final low speed balancing
Fig 15. Preserve the rotor before shipment
Fig 16. Packaging the rotor before shipment
PRO-01FR-32 Rev.04
Page 3 of 3

Turbo Docs P-01267 - Repair MHI ST Rotor Unit 5-1

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PT.

Sulzer Turbo Services Indonesia

AS RECEIVED INSPECTION REPORT

LP ROTOR INCOMING VISUAL INSPECTION REPORT

LP ROTOR RUN OUT INSPECTION REPORT

LP ROTOR BEARING JOURNAL INSPECTION REPORT

LP ROTOR GLAND SEAL DIAMETER INSPECTION REPORT

LP ROTOR HARDNESS INSPECTION REPORT

LP ROTOR SURFACE ROUGHNESS INSPECTION REPORT

LP ROTOR MAGNETIC PARTICLE TESTING REPORT

FINAL INSPECTION REPORT

LP ROTOR BEARING JOURNAL INSPECTION REPORT

LP ROTOR HARDNESS INSPECTION REPORT

LP ROTOR SURFACE ROUGHNESS INSPECTION REPORT

LP ROTOR RUN OUT INSPECTION REPORT

LP ROTOR PROBE AREAS ELECTRICAL RUN OUT INSPECTION REPORT

LP ROTOR BALANCE REPORT TWO PLANES

LP ROTOR RESIDUAL UNBALANCE INSPECTION REPORT

LP ROTOR MAGNETIC PARTICLE TESTING REPORT

LP ROTOR DEMAGNETIZATION REPORT

PT. Sulzer Turbo Services Indonesia

RECEIVE & INVENTORY.

PERFORM INCOMING INSPECTION.

CLEANING BY BLASTING THE ROTOR.

PERFORM INCOMING NDT INSPECTION.

FINAL INSPECTION & NDT.

PERFORM LOW SPEED BALANCING ROTOR AS PER STANDAR SPECIFICATION.

FINAL QC INSPECTION INCLUDE DEMAGNETIZATION

10. PRESERVE & PACKAGING ROTOR.

PJB UP MUARA KARANG

Rotating Equipment Services

PT. Sulzer Turbo Services Indonesia

S/N & EQUIP. NO.

PJB UP MUARA KARANG

DATE : MAY 21, 2014

INSPECTED BY: UMR

As received visual inspection the LP ROTOR are as follow :

APPROVED BY: ASP.

PT. Sulzer Turbo Services Indonesia

S/N & EQUIP. NO.

PJB UP MUARA KARANG

INSPECTED BY: YD.

DATE: MAY 21, 2014

PT. Sulzer Turbo Services Indonesia

S/N & EQUIP. NO.

PJB UP MUARA KARANG

DATE: MAY 21, 2014.

PT. Sulzer Turbo Services Indonesia

S/N & EQUIP. NO.

PJB UP MUARA KARANG

INSPECTED BY: EKA

DATE: MAY 21, 2014

PT. Sulzer Turbo Services Indonesia

S/N & EQUIP. NO.

PJB UP MUARA KARANG

INSPECTED BY: EKA

DATE: MAY 21, 2014

PT. Sulzer Turbo Services Indonesia

S/N & EQUIP. NO.

PJB UP MUARA KARANG

DATE: MAY 21, 2014

INSPECTED BY: YN.