Issued 17 March 2016

Title: Rotor Life Management of Fuji 66 MW Geothermal Rotor
Client: Chevron Geothermal Indonesia

Sentral Senayan-l Office Tower
11th Floor
Jl. Asia Afrika No. 8
Jakarta, 10270
Indonesia
Attention: Dachry Antoni
Proposal Number: 109443.10
Confidential To: Client
Date Issued: 17 March 2016
Valid for: 30 Days
Prepared By: Stephen Rowbotham
Checked and Approved By: Andy Saunders-Tack
www.QuestIntegrity.com
Quest Integrity NZL Limited, a TEAM Industrial Services Company
This proposal is provided to the Client by Quest Integrity NZL Limited on the understanding that the information herein
is “Commercial in Confidence”. This proposal is the intellectual property of Quest Integrity NZL Limited and may not be
used as a whole, or in part, or disclosed to any third party or agent without Quest Integrity’s written consent.
Assessment of Fuji Rotor
1 Introduction .................................................................................................................3
2 Scope of Work ............................................................................................................4

2.1 Phase 1: Condition Assessment and Inspection ..............................................4
2.2 Phase 2: Rotor Engineering Critical and Remnant Life Assessment ................ 7
2.2.1 Life limiting factors and remnant life or rotor .................................... 7
2.2.2 Global Rotor Finite Element Stress Analysis .................................... 8
2.2.3 Identifying the Possible Cracking Mechanisms ................................ 8
2.2.4 Critical Flaw Calculation...................................................................9
2.2.5 Crack Growth Calculations ..............................................................9
3 Deliverables ..............................................................................................................10
3.1 Phase 1: Rotor Condition Assessment, Inspection and Repair Specifications 10
3.2 Phase 2: Rotor Fitness for Service and Remnant Life Assessment ............... 10
4 Quest Integrity Expertise and Experience ................................................................. 12
5 Price and Project Schedule .......................................................................................12
6 Payment Requirements.............................................................................................12
7 Acceptance of Proposal ............................................................................................13
8 Quality System ..........................................................................................................13
9 Safety 13
10 Contact Details..........................................................................................................15
11 Confidentiality Clause ...............................................................................................15
Appendix A: Curricula Vitae ...............................................................................................16
Appendix B: Terms and Conditions....................................................................................29
Appendix C: Revision Summary ........................................................................................33
109443.10 Proposal issued 17 March 2016 Page 2 of 33

1 Introduction
Quest Integrity NZL Limited (Quest Integrity) was requested by Chevron Geothermal
Indonesia to provide a proposal for the rotor life management.
This document outlines a proposed work scope for the initial condition assessment,
inspection, rotor engineering critical and remnant life assessment.
The rotor to be assessed was a Fuji Electric Co. 66 MW double flow rotor with 9 stages on
each side, see Figure 1.
Figure 1: Photograph showing Fuji Rotor.
The information shown in Table 1 was made available by Chevron.
Table 1: Information supplied for rotor
Stages 2 x 9 Stages Double flow
Type of blading Reaction
Rotor type Drum
Manufacturer Fuji Electric Co.
Commission 1996

Rated speed 3000rpm
Inlet pressure 5.86 Barg
Inlet temp 159 °C
Bearing Type Journal Bearing and thrust bearing
Rotor material 30CRMoNIV411
Rotating blades material X20Cr13 (SS) ASTM478 420
Blade fixing Stages 1 - 6 T Mount to drum- machined shroud bands
Blade Fixing Stages 7 - 9 Axial fir tree mount to drum
Erosion protection Stellite strips on Stages 8 and 9
2 Scope of Work
The proposed scope of work has been broken down into two phases both are required to
generate the rotor life management plan.
2.1 Phase 1: Condition Assessment and Inspection
 Visual examination of the rotor and components, including (but not limited to)
bearing journals, thrust bearing faces, coupling flange, blade fixings (drum type
rotors limit the inspection of T hook blade fixings with blades in-situ).
 Visual inspection of blade root fixings (fir trees), shrouds / coverbands and tenons.
 Visual inspection of diaphragms associated with rotor.
 Review of documentation and drawings held for rotor and blades.
 Dimensional survey, including diametral measurements in order to undertake rotor

growth calculations and dimensions for life assessment.
 Field metallographic techniques including metallurgical replication and hardness

testing.
 Chemical analysis, using a portable X-ray Fluorescent (XRF) analyser, of the rotor,
blades and service deposits.
 Magnetic particle inspection (MPI) of the rotor and blades. This will be normally
arranged by client using an approved subcontractor under the supervision of Quest

Integrity. The MPI will be undertaken on the rotor blade fir tree fixings, gland seals
bearing journals. The rotor should be degaussed after testing by the subcontractor.
 Ultrasonic Inspection (manual and phased array) of the rotor in particular bearing
journals gland seal and interstage areas where access permits. On the last three
stages the blades will be inspected. This requires probes to be manufactured to
enable inspection of the blade root to be satisfactory completed.
The rotor will be required to be removed from the bottom casing and placed ideally on a
rotatable stand. The following equipment and supplies will also be required to be made
available by the client to facilitate the above work to be completed:
 Acetone.
 Concentrated nitric acid.
 Concentrated hydrochloric acid.
 Ethanol.
 Power supply and table and chairs located near rotor stand.

Table 2 shows the extent of the testing and inspection normally carried out during the first condition assessment. Note: The extent of the
inspection may be restricted by access issues.
Table 2: Typical work scope/inspection areas on geothermal rotors
Dimensional XRF- UT Phase UT

Description Part Visual MPI Eddy Current Hardness Test Replication Corrosion Deposit
Survey PMI Array Conventional
blade
wheel
yes yes yes yes yes If required no yes yes yes
discs for
all stages
discs posts
/steeples
yes yes yes yes Yes Yes, if required yes yes yes yes
for all
stages
Bearing
yes yes yes yes yes If required no no no yes
journals
Thrust
bearing yes yes yes yes yes If required no no no yes
runner
Rotor Coupling
flanges
Gland
Seals
Groove for
Balancing yes yes no yes no no no no no yes
Weight
Shaft yes yes yes yes yes If required no yes yes yes
Tenons yes yes yes No no yes no yes yes yes
Shroud
yes yes yes No no no no yes yes yes
Band
Blades (All stages ) Blade
yes yes yes No no no no No no no
Root
Blades yes yes yes no no no no No yes yes

2.2 Phase 2: Rotor Engineering Critical and Remnant Life Assessment
Following completion of the initial condition assessment and inspection the data collected will
be used to enable the life limiting factors and the remnant life of the turbine rotor to be
identified so that the future safe and reliable operation can be planed.
In phase 2, the following services shall be carried out:
2.2.1 Life limiting factors and remnant life or rotor
Contractor will attend site with the view to inspect the basic layout and operation of the
turbine and to gather the required information. This will be undertaken during the site visit for
the condition assessments of the rotor and moving blade set, and will include but not be
limited to the gathering of the following information:
 General arrangement drawings for the turbines.
 Detailed dimensional drawings of the rotor and blade interaction areas.
 Details on blading – weights, moments etc.
 Material grade, including mill certificates and other information such as batch testing
results.
 Details with regards to heat treatments.
 Assembly details for the rotor and blades.
 Operating conditions.
- Temperature and rotation speeds for starts and shutdown and during operation.
- Operating history, number of service hours and starts per turbine.
- Steam chemistry (current and historic).

 Service records.
 History of control anomalies (e.g. over temperature or/ and speed).
 History of failures or known damage mechanisms in the turbine or related equipment.
 Maintenance records and history.
Upon return from site the information will be reviewed with respect to input into the
Engineering Critical assessment.

2.2.2 Global Rotor Finite Element Stress Analysis
A thermo-mechanical stress analysis will be carried out considering the overall rotor
geometry. The aim of this analysis it to identify the temperature distribution associated with
each rotor stage during cold, intermediate temperature and hot starts in order to determine
the thermal stresses for each stage.
The initial stress temperature will be used as thermal boundary conditions on the rotor and
these will be obtained employing an enthalpy-entropy diagram for steam temperature/
pressures.
The stress analysis will be carried out using the latest version ABAQUS(currently v. 6.14), a
general purpose finite element package. The analysis will be carried out as a 2D
axisymmetric model assuming a linear elastic material response.
The stress results of the analysis will be used to determine the stresses in the areas where
cracking is identified. The stress analysis will consider:
 Centrifugal mechanical loads during operation.
 Thermal transients stress profiles during start-up/ significant load changes, (worst
case data need to be provided by client).
 Stress concentrating effect of the blade fixings.
2.2.3 Identifying the Possible Cracking Mechanisms
Current and historic information with regards to operation and steam chemistry will be
reviewed and the possible cracking mechanisms identified. Disc alloy and heat treatment
considerations, mechanical and thermal fatigue cracking loading and the geothermal steam
environmental effects will be used to assess the potential cracking mechanisms.
In addition, the impact of recent changes in the corrosion chemistry will be evaluated using
Contractor’s model for determining corrosion characteristics of geothermal steam and the
existing database for material testing in geothermal fluids held by Contractor. Should
additional material testing be required these test will be specified and costs will be provided
separately.

2.2.4 Critical Flaw Calculation
Critical flaw sizes will be determined for the high stress locations as identified in the stress
analysis. These areas will be of greatest risk either of developing critical defects. A specific
assessment in each of the known defect locations will also be undertaken if these areas do
not coincide.
A sensitivity study will be carried out with respect to the relation between critical flaw size,
material fracture toughness and yield properties.
The maximum acceptable defect size will be determined using a Level 2 defect assessment
in accordance with BS7910:2013 “Guide on methods for assessing the acceptability of flaws
in metallic structures”. These procedures consider failure from a combination of plastic
collapse and brittle fracture. These calculations will be based on the worst case loading
scenario, (highest mechanical load and lowest temperature) and a sensitivity analysis will be
carried out. The calculations will be carried out using Quest Integrity’s proprietary software
Signal FFSTM. This software is compliant with BS7910:2013.
2.2.5 Crack Growth Calculations
Depending on the crack growth mechanism, a suitable crack growth law will be identified.
The crack growth law will be used to calculate the time for an initial crack to grow to the
critical flaw size. The initial flaw size will be the maximum flaw size that could be missed
during a rotor inspection using the inspection techniques outlined in Table 2
A sensitivity study addressing the influence of crack growth rates and initial flaw size on
remnant life will be undertaken.
The crack growth law used for calculations of the remnant life will depend on the crack
growth mechanisms that are proposed. Very few standardized procedures exist for
evaluation of crack growth due to an environmental crack mechanism in turbines. However, if
possible, guidance in accordance with API579/ ASME FFS-1 “Fitness-For-Service” and other
supporting references will be used.
Future safe inspection periods using Contractor experience (fracture mechanics and
applicable reserve factors) and an Quest Integrity’s in-house database on corrosion rates for
rotors in geothermal service may also be specified.

3 Deliverables
The deliverables shall be the following:
3.1 Phase 1: Rotor Condition Assessment, Inspection and Repair Specifications
 On-site reporting (including close out presentation) describing initial findings and
scope of any further work to be performed off-site. The presentation will identify
work required to return the rotor and blading to service - the “Go” or “No Go”
situation of the rotor.
 Ultrasonic data files generated from the inspection (for historic records).
 A formal report, to be submitted four (4) weeks from visit completion, covering:
- Findings of the on-site visit.
- Method used (including applicable engineering codes of practices and standards,

where applicable).
- Validated data gathered during the visit.
- Review of the rotor performance and history.
- Summary of findings and recommendations based on relevant standards and/or

codes of practices and actual experience for similar activities.
 If required a repair specifications can be produced.
3.2 Phase 2: Rotor Fitness for Service and Remnant Life Assessment
The overall aim of the Phase 2 turbine life assessment is to develop an inspection
management programme for the rotor that is based on a sound technical approach as
outlined in technical publications based on fitness for service guidelines (i.e. BS7910 or
API579).
The inspection frequencies for the rotor depend on the current condition and the damage
detected during the condition assessment and inspection. On completion of rotor life
assessment a safe re-inspection interval will be provided as well as an overall remaining life
of the rotor. These assessments will be based on a technical approach outlined in published
standards and guidelines. Hence, at the end of the turbine assessment a formal report will be
completed outlining the following:

 Background for the model generation and any assumptions that might have been
made.
 Dimensional measurements used in the model.
 Identifying shortcoming in the obtained measurements and therefore assumptions
have been made regarding the geometry generation.
 Referencing the software packages used in the model generation. Technical
approach with the following topics:
- The assumptions with regards estimating pressure distribution, temperatures and

material properties used for the finite element analysis.
- References and methods for calculation of the fracture toughness and crack
growth rate.
- Estimating the largest defects that might have been missed during inspection and
the implication in terms of the integrity.
- Explaining the methods used for calculation of the limiting damage.
- Outlining the method used for the remaining life calculation.
- Highlight the basic for calculating the re-inspection period.
- Explaining the conservatism and safety factors behind the calculations.
- Referencing the software packages used for the finite element analysis as well as
the fitness for service and remaining life calculations.
-
Results and recommendations including the following;
 Outlining areas or regions of concerns in the rotor as identified by the finite element
stress analysis (i.e. areas where high stresses exist and previously not inspected).
 Areas or region where damage has been found.
 Providing the re-inspection period based on the reserve factor method as outlined in
BS7910 and previous techniques employed successfully in geothermal steam
turbines by Quest Integrity.
 Provision of recommendations for additional inspection or condition assessment work
that might be required at subsequent outages for refinement of the assessment.

4 Quest Integrity Expertise and Experience
Quest Integrity has undertaken extensive assessments of geothermal rotors in New Zealand
and in South East Asia.
Curricula Vitae of the Quest Integrity personnel likely to be assigned to the project are
detailed in Appendix A.
5 Price and Project Schedule
The scope of work described in Section 2 is offered for the price of:
Fixed Service Fee per Rotor Two Hundred and Five Thousand and Seven Hundred and
Fifty Four United States Dollars (205,754.00 USD).
This price is inclusive of mobilisation costs to Indonesia and internal flights to nearest airport.
It does not include transfers from airport to site, local accommodation which will be arranged
by client and daily transfers from accommodation to site.
This price excludes any applicable taxes, withholding taxes, service taxes, import duties or
other fees such as bank payment fees, etc. which shall be met separately by the client.
Any additional expenses shall be charged at a non-negotiable rate of cost plus 15%.
At this time the work is provisionally scheduled for (insert dates). This has yet to be
confirmed.
6 Payment Requirements
The work will be invoiced as follows:

Upon receipt and acceptance of PO (100%).
Payment must be made in United States Dollars payable to Quest Integrity NZL Ltd to our
New Zealand bank account.

7 Acceptance of Proposal
Written acceptance of this proposal is required, via fax or email. In order for Quest Integrity
to provide the services outlined in this document a "hardcopy" Purchase Order (PO) must be
issued and accepted within thirty (30) days of the proposal issue date, with the following
items specified:
1. All work will be performed in accordance with this proposal,
2. All work will be performed in accordance with the Quest Integrity Terms of Business
attached in Appendix A, which will supersede any other Terms of Business issued.
3. The PO must be issued on company letterhead.
8 Quality System
Quest Integrity has procedures in place equivalent to those required to operate a quality
system compliant with ISO9001:2008. It is Quest Integrity’s policy to develop, review,
improve and, if necessary, amend its business systems. This process ensures that
customers’ needs and expectations are met consistently and efficiently.
Quest Integrity can provide electronic copies of our Quality Manual and associated
documentation if required.
9 Safety
All Quest Integrity staff provided for this project will have previously worked on site, both
during shutdowns and in operating plant. Our personnel will attend site inductions required
to enter client sites, and will complete up-to-date confined space training as well as first aid
courses.
Quest Integrity will endeavour to meet site safety and procedural requirements. Specifically,
Quest Integrity staff will:
1. Attend site induction training and emergency evacuation training and will adhere to
local requirements.
2. Adhere to specific safety requirements related to the equipment being inspected.

3. Require a mutually agreed safety plan to be in place for special tasks where unique
safety issues are defined, such as confined space entry.
Quest Integrity will provide required personal protective safety equipment for its employees.
Any additional site specific safety equipment shall be provided by the Client or purchased by
Quest Integrity who reserve the right to offset this cost as an additional expense* to this
project.
Quest Integrity has previously prepared extensive hazard management plans for similar
projects. One of these can be reviewed to cover this project.
* Please note it is Quest Integrity’s company policy to charge expenses at a non-negotiable

rate of cost plus 15%.

10 Contact Details
For enquiries regarding this proposal please contact:

Stephen Rowbotham- Team Leader Condition Assessment
Phone: + 64 4 978 6656
Mobile: + 64 21 229 9508
Email: S.Rowbotham@QuestIntegrity.com
Annette Karstensen – Manager Structural Integrity
Phone: + 61 7 5507 7900
Mobile: + 61 409 405 700
Email: A.Karstensen@QuestIntegrity.com
Asia-Pacific Contracts Manager (Asia-Pacific)

Phone: + 64 4 978 6630
Email: Contracts-APAC@QuestIntegrity.com
Quest Integrity NZL Limited – Wellington Office

Phone: + 64 4 978 6630
Fax: + 64 4 978 9930
Email: Info@QuestIntegrity.com
Website: www.QuestIntegrity.com
Address: Gracefield Research Centre
69 Gracefield Road
PO Box 38096
Lower Hutt 5045
11 Confidentiality Clause
This proposal is provided by Quest Integrity NZL Limited on the understanding that the
information herein is “Commercial in Confidence”. Written permission is required if any part
of this proposal is to be disclosed to parties other than Quest Integrity NZL Limited, any
Quest Integrity Group company or its authorised agents. This proposal is the intellectual
property of Quest Integrity NZL Limited and may not be used as a whole or in part without
Quest Integrity’s written consent.

Appendix A: Curricula Vitae
STEPHEN ROWBOTHAM
BEng, CEng, MIMMM
SPECIALISED PROFESSIONAL COMPETENCE

Stephen is a chartered metallurgical engineer (UK) with specialist expertise in material failure
investigations and material characteristics in relation to wear mechanisms, rolling contact
fatigue, cracking mechanisms, mechanical damage, impact, and fatigue. He has experience
in providing independent advice and expert witness reports for legal (criminal and civil) and
insurance cases in the UK.
PROFESSIONAL BACKGROUND
Before joining Quest Integrity Stephen worked for Bureau Veritas UK in their materials
consultancy division in the UK providing consultancy services to external clients and within
the Bureau Veritas Group worldwide. The areas covered ranged from shipping, power
generation, petrochemical to infrastructure both in the UK, Europe and the Middle East. The
materials consultancy division of Bureau Veritas UK provide expert witness to clients and
Stephen attended court on several occasions.
Prior to this he was employed by Rolls Royce in the Military Engine Group (small engine
Division) in the UK. This involved providing materials advice to the engineering group in
engine development and undertaking service failures when they occurred. The engines in
service or in development during the period of employment were Rolls Royce Gnome and
Gem, RTM322 and the MTR390. During RTM322 and MTR390 development and launch
stages, extensive destructive testing on the test bed was undertaken as part of the
engineering team Stephen was involved in the subsequent laboratory examination of the test
engine.
On graduating Stephen was employed by INCO at their forging facility in Leeds, UK as the
graduate metallurgist working on the development of the isothermal forging process route for
high pressure turbine stage 1 disc for the EJ200 engine (Eurofighter project). This required
working closely with Rolls Royce on the forging parameters required.

PROFESSIONAL MEMBERSHIPS AND QUALIFICATIONS
 BEng (Hons) in Metallurgy, Leeds University, UK.

 Member of the Institute of Materials, Minerals and Mining (MIMMM).
 Chartered Engineer UK (C.Eng).
SELECTED PUBLICATIONS AND REPORTS

 Condition Assessment of Frame 6 (July 2009).
 Examination of Frame 6 Compressor Blades Pitting (July 2009 and July 2012).
 Water Ingress Damage to Steam Turbine (September 2009).
 Metallurgical Analysis of Turbine Vane Carrier (December 2009).
 Condition Assessment of GT13 E2 (December 2009).
 Investigation of Cracking on Alstom LP Steam Turbine (December 2009).
 Investigation of Cracking on Siemens LP Steam Turbine (February 2009).
 Boroscope Inspection of LM6000 (January 2010).
 Failure investigation of LM6000 Fuel Nozzles (July 2010).
 Examination of LM5000 Stage 3 Compressor Blade Failure (July 2010).
 Investigation of LM5000 Stage 8 Compressor Vane failure (February 2011).
 Examination of LM2500 Stage 1 Compressor Blade failure (February 2011).
 Examination of LM2500 Cracked HPT Pressure Tube (March 2011).
 Investigation of LM2500 HPT Stage 1 Blade Failure (October 2011).
 Examination of LM5000 4B Bearing Failure (December 2011).
 Examination of GT11 Stage 1 Bucket Failure (February 2012).
 Examination of LM5000 Air Cooling Vent Seal Failure (February 2012).
 Review of RCA Reports and Operation of three LM6000 in Relation to HPC Blade
Failures (2012).
 On-site condition assessment of Geothermal Steam Turbines (2011 to 2015)
 Examination of LM2500 Compressor Discharge Pressure (CDP) Components
(September 2012).
 Examination of LM5000 Compressor Front Frame (CFF) Cracking (October
2012).
 Examination of LMS100 Booster Compressor issues (Sept 2012 and 2013).
 Failure investigation of Steam Turbine Coverbands (July 2013).
 Condition Assessment of Frame 5 Transition Pieces (Dec 2013).
 Failure analysis of Steam Turbine Blade Root (Feb 2014).
 Examination of LM5000 Stall Event (October 2014).
 Examination of LM5000 No 4R Bearing (Sept 2014).
 Examination of LM2500 No 4B Bearing (Nov 2014).
 Condition Assessment of Frame 5 Combustion Liners (Dec2014).
 Stephen Rowbotham. Critical spares who needs and them and when Australia
Gas Turbine Conference Nov 2013.
 Stephen Rowbotham, Olivia Chung, Monika Ko and Jess Wong. “Failure
Mechanisms Encountered by Rotating Equipment in Geothermal Steam Service”,
World Geothermal Congress, Melbourne, Australia, April 2015.
OLIVIA CHUNG
BE (Hons), CPEng, IntPE(NZ), MIPENZ
Olivia is a Consultant Engineer specialising in materials engineering. Her experience

includes condition assessment and remnant life assessment of power plant equipment and
petrochemical plant equipment, failure analysis, materials testing and metallurgical
assessments. In addition, Olivia has carried out numerous on – site metallurgical projects
and is proficient with mechanical testing and high temperature materials testing.
Olivia is based at the Quest Integrity head office located in Lower Hutt (Wellington), New
Zealand.
Education:
 BE (Hons), Mechanical Engineering, University of Canterbury, New Zealand, 2007.
Professional memberships and qualifications:

 Chartered Professional Engineer (CPEng).
 International Chartered Professional Engineer (IntPE(NZ)).
 Member, Institute of Professional Engineers New Zealand (IPENZ).
 Member, Mechanical Engineering Group (technical interest group in IPENZ).
 Member, Society for Materials New Zealand Inc. (technical interest group in IPENZ).
 Member, ASM International.
Relevant training courses completed:

 AINDT Eddy Current Level 1 Qualification, May 2010.
 Workplace Health and Safety Western Australia Construction Induction, October
2011.
 Oil Analysis, April 2012.
 St. John First Aid Refresher, February 2016.

 Confined Space Entry and Planning (Unit Standard 18426 and 17599), May 2015.
 Hazard Identification (Unit Standard 17602), September 2014.
 Approved Handler (for Hazardous Substances and New Organisms), July 2013.
 Spill Response Training (for Hazardous Substances and New Organisms), April 2009.
SELECTED PROJECTS AND REPORTS
 Condition assessment and non-destructive testing of various geothermal steam

turbine rotors.
 Condition assessment, creep testing and remnant life assessment of boiler tubes
from various coal-fired power generation facilities.
 Condition assessment, Omega creep testing and remnant life assessment of heater
tubes from various refineries.
 Condition assessment, creep testing and remnant life assessment of reformer tubes.
 Condition assessment and materials testing of steam turbine rotor material.
 Failure analysis of a flare tulip ring from a gas processing plant.
 Condition assessment and non-destructive testing of Frame 6B Rotor (at various
power stations).
 Failure analysis of Frame 6B buckets (blades).
 Condition assessment, metallurgical examination and hardness test survey of
W501D4 gas turbine discs.
 Metallurgical examination and assessment of creep properties of thermo –

mechanically processed 800HT for a reformer outlet system.
 Failure analysis and condition assessment of reformer tubes and petrochemical plant
equipment.
 Condition assessment of main steam, high pressure, intermediate pressure, hot
reheat and cold reheat pipework.
PUBLICATIONS AND PRESENTATIONS

 Ohgeon Kwon, Olivia Chung, Darrell Meinen and Ryan Corn. “Remaining Life
Assessment of Coker Furnace Tubes Using Omega Methodology”, presented at the
2015 API Inspection Summit, Galveston, Texas.

 Stephen Rowbotham, Olivia Chung, Monika Ko and Jess Wong. “Failure Mechanisms
Encountered by Rotating Equipment in Geothermal Steam Service”, World Geothermal
Congress, Melbourne, Australia, April 2015.
 Olivia Chung. “LM Series Compressor Damage Mechanisms and Failure Analysis”,
presented at the 16th Annual Australian Gas Turbines Conference, Sydney, Australia,
November 2015.

Dr Sean Norburn
Ph.D., CEng, MIMechE

Sean is a Senior Consultant with Quest Integrity and has over 15 years of experience in the
application of Finite Element Analysis (FEA) based techniques in mechanical and structural
engineering disciplines. Sean currently oversees and supervises the structural and
mechanical analysis performed at Quest Integrity’s Queensland office and has also led large
complex analysis projects related to structures, rotating equipment and pressure equipment
across the Asia-Pacific offices.
Before joining Quest Integrity, Sean worked for QinetiQ Australia and led the FEA workflow,
supporting international clients mainly in the aerospace industry (both airframes and
propulsion).
Sean possesses specialist experience in the analysis of thermal mechanical processes

involving non-linear material behaviour. This experience was mainly gained from working at
Alstom Power and Rolls Royce Aerospace in the UK.
At Alstom, Sean was a Principal Engineer and Project Leader in the hot section lifing group,
and was responsible for providing lifetime assessment support for Alstom projects such as
GT13E2 and the GT24/26 gas turbines. Sean also spent significant time at Alstom working
on the development of constitutive material models for application in commercial FEA code
and also supporting research programmes targeted at the development of lifing methods for
advanced materials typically used in gas turbines.
Whilst at Rolls-Royce, Sean was responsible for the development of modelling

methodologies to support advanced manufacturing techniques being developed by Rolls-
Royce at the time in the manufacture of gas turbines.
Sean has a Ph.D. in the theory and application of finite element analysis and his core
capabilities include computational solid mechanics, analysis of structural and thermal
mechanical fatigue, constitutive material modelling, technical leadership and capability
development.
RECENT PROJECTS
 Quest Integrity: GT13E2 MXL gas turbine rotor life management on behalf of the
Australian Gas Turbine User Forum (in progress).
 Quest Integrity: Steam turbine blade design verification on behalf of Siemens Energy.
 Quest Integrity: Steam turbine blade design verification on behalf of EDC.
 Quest Integrity: Preparation of a dynamic stress analysis of dovetail root cracking of a
Frame 6B row one compressor blade to determine safe inspection period.
 Quest Integrity: Technical lead for steam turbine rotor and casing assembly Finite
Element modelling and Life Assessment, on behalf of Verve Energy, Australia.
 Quest Integrity: Verification of a gas turbine transition duct design subjected to
compressor surge loading and development of design modifications to overcome
design limitations.
 QinetiQ: Technical oversight of the structural integration and certification of a Saab
electronic countermeasure dispenser system onto the RAAF F/A-18 fleet.
 QinetiQ: Specialist technical support to the ATSB for various investigations such as
the Boeing 747-400 mid-air depressurisation that occurred in 2008 (Hong Kong to
Melbourne).
 QinetiQ: Project Managed the Usage Monitoring Rectification Programme for the
C-130 J RAAF Fleet on behalf of the Royal Australian Air force.
 Alstom: Numerous Life assessments of gas turbine hot gas path components
(GT13E2, GT24/26) – Blades, Casings, Combustors and Rotors.
 Alstom: Development of Lifing methodologies for blade-root fixings on behalf of
Siemens Industrial Gas Turbines.
 Alstom: Development and implementation of a ‘lifetime consumption’ tools for GT24/26.
These tools provided the capability to calculate ‘on-line’, the life consumed for over
twenty critical components of the GT24/26 Power Gas Turbines.
 Rolls-Royce: Development of process modelling technologies for Rolls-Royce.
Responsible for technology transfer of weld modelling capability from academia into
Rolls-Royce.
 Rolls-Royce: Development of residual stress modelling of aerospace discs for various
engine programmes (Trent 900, Trent 600, EJ200, V2500, Trent 500), to support disc
forging design and engine lifing.
 Rolls-Royce: Developed Residual Stress Models to support an investigation into failure
of welding on a Trent 700 Combustion casing.
 Rolls-Royce: Development of Residual Stress Models to support an investigation into
the distortion of various components of Concord’s Olympus engine during overhaul.
Performed on behalf of British Airways.

Professional Experience:
Quest Integrity (April 2011 – Present)
 Senior Consultant – Structural Integrity
- Line Management Responsibility.
- Coach and mentor FEA staff in New Zealand and Australia.
- Prepare, Check and Approve technical and commercial projects for structural
integrity.
- Technical management of structural integrity projects.

QinetiQ - Aerostructures (February 2006 – April 2011)
 Senior Principal Engineer

- Lead of Finite Element Analysis Capability. Technical oversight of all FEA work
performed within the company. Ensure compliance with ISO9001 and Australian
Defence Force (ADF) design authority accreditation.
- Support design repair and modifications of airframe structure in accordance with

ADF Technical Airworthiness procedures.
- Awarded checking Engineering Authority (EA) across all RAAF platforms.
- Responsible for the development and mentoring of all FEA specialist staff.
- Procedural development of FEA processes within the company.

ABAQUS (November 2004 to February 2006)
 Senior Support Engineer

- Provided ABAQUS support on site at Jaguar Land-Rover. Worked across all CAE
teams (Chassis, Body and Powertrain Departments).
- Project managed the delivery of ABAQUS based solutions focused on CAE lead
time reduction.
Alstom Power (October 2001 – to November 2004)
 Principal Engineer –Lifing Hot Section

- Project Lead. Both technical and project management of a variety of projects
mainly focused on the Lifing of Alstom gas turbine components.

- Delivered Lifing support to clients such as Siemens and Rolls Royce – work
mainly focused on industrial gas turbines.
- Provided FEA based support to research based projects such as the

development of Lifing methodologies for Ceramic Matrix Composites.
Rolls-Royce Aerospace (September 1999 – October 2001)
 Advanced Technologist
- Developed and deployed FEA based modelling of manufacturing processes
within Rolls-Royce.
- Support Manufacturing technology to develop new and trouble shoot existing

manufacturing processes.
- Transferred weld modelling capability into RR to assist with the reduction of scrap
and concessions associated with the welding of Trent 800 compressor drums.
- Developed FEA software to assist manufacturing engineers to design machining

sequences for aerospace discs.
Education:
 Ph.D. Mathematics. The Numerical Analysis of Mixed Finite Element Methods for
Incompressible Flow. University of Manchester Institute of Science and Technology
1996-1999.
 MSc Mathematics and Computation. Numerical Analysis. Specialised in Finite Element
Theory. University of Manchester Institute of Science and Technology 1995-1996.
 BSc (Hons). First Class. Mathematics. Awarded IMA first prize for excellence in final
year (highest score in the year). University of Manchester Institute of Science and
Technology 1992-1995.
Professional memberships and qualifications

 Registered as a Chartered Engineer with the UK Engineering Council and a member of
the Institute of Mechanical Engineers (IMechE).
Recent major publications, conferences and workshops

 Optimising Inspection Planning and Asset Integrity Management using Fitness for
Service Methods, Australian Welding Volume 58, Third Quarter 2013.
 Lifing Strategies for High Temperature Critical Components. Workshop at Singapore
Gas Turbine Conference 2012.
 Turbine Disc/Rotor Life Assessment for Industrial Gas Turbines. Workshop at
Singapore Gas Turbine Conference 2012.
 P3 Fastener Modelling Study. 32nd Conference of the International Committee on
Aeronautical Fatigue 2011.
 Fatigue Analysis of the C-130 Rainbow Fitting. 32nd Conference of the International
Committee on Aeronautical Fatigue 2011.
 Verification of Numerical Design of Optimal Rework Shapes for F/A-18 Y598 Fin
Attachment Stub. 30th Conference of the International Committee on Aeronautical
Fatigue 2007.
 Fourier analysis of stabilized Q1-Q1 Mixed Finite Element Approximation. SIAM
JOURNAL ON NUMERICAL ANALYSIS. 2001 August; 39: 817-833.
 Stabilized vs. stable mixed methods for incompressible flow. COMPUTER METHODS
IN APPLIED MECHANICS AND ENGINEERING. 1998 November; 166: 131-141.

Dr. ANNETTE D. KARSTENSEN
PhD, CEng, EurIng, MWeldI, MIPENZ
Annette is a Chartered Engineer with more than 18 years’ experience in structural integrity
assessments and is the Global Manager for Quest Integrity Group’s Structural Integrity Division. Her
expertise covers assessments of engineering components related to power, petrochemical and other
engineering constructions, with a strong focus on hydro power related equipment. Annette has also
previously acted as a competent person on several power and petro-chemical plants in South East
Asia. This involves making safety cases for extending the inspection frequency of boilers and plant
equipment.
Her main line of work involves carrying out examination, fitness for service and remaining life
assessment of engineering components. The work involves calculating maximum tolerable flaw sizes
and/or time-to-failure under high temperature or cyclic exposure. The results assist the understanding
failures and/or plant owner in establishing safe inspection intervals and/or making decisions with
regard to repairs and replacement of the equipment. The assessments typically involve assessing for
creep, corrosion, fracture and/or fatigue. Having previously spent 7 years at TWI (formerly The
Welding Institute) in the UK, Annette has achieved an in-depth knowledge of assessments, particularly
related to welds, using BS7910 “Guide on methods for assessing the acceptability of flaws in metallic
structures”. Annette has considerable experience in the application of API579 (American petroleum
fitness for service code), R5/R6 (British Energy assessment procedures) and pressure vessel design
codes (PD5500 and ASME). Annette also teaches training courses covering fitness for service and life
assessment techniques to power and petro-chemical plants. The teaching is based on published
standards such as BS7910 and API579 and assisted by case studies of some of the many fitness for
service projects that she has been involved in.
A recent selection of major hydro projects Annette has been involved in includes:
 Assessment of a turbine head cover with internal erosion damage.

 Options for design modifications of rotor spider for a hydropower station.
 Fatigue assessment of a pelton wheel shaft.
 Stress analysis and critical assessment of penstocks.
 Assessment of spiral casing.
 Corrosion assessment of a penstock.
 Erosion assessment of wicket gates.
Professional background
Professional memberships and qualifications
 Professional Member of the Welding and Joining Society in the UK, (CEng, MWeldI).
 Eur Ing awarded by the European Federation of National Engineering Association.
 Member of Institute of Professional Engineers in New Zealand (MIPENZ).
Education
 PhD, Constraint Estimation Schemes in Fracture Mechanics, Department of

Mechanical Engineering, Glasgow University, UK (1996).
 MSc, Active Vibration Control of Engineering Structures subjected to Earthquake (in
Danish), Aalborg University, Denmark, (1990).
Selected reports and publications

Selected recent reports for the hydro power industry
 Fitness for Service Assessment of a Turbine Headcover with Internal Erosion Damage:
A turbine headcover was found to suffer from internal erosion-corrosion. Quest Integrity
carried out a level 3 fitness for service assessment in accordance with API 579/ASME FFS-1
to determine whether the wall loss was acceptable according to code requirements. This
involved Finite Element Stress Analysis. It was concluded that the headcover erosion damage
was acceptable for continued service.
 Fatigue assessment of a pelton wheel shaft: A stress analysis, critical flaw and fatigue
assessments were carried out on the pelton wheel turbine shafts. Circumferential cracks
which developed in the shaft near the runners had been ground out during several of the last
shut downs. It was a concern that the shafts are approaching the end of serviceable life and
the assessment provided the client with an inspection period for future safe running of their
unit.
 Stress Analysis and Critical Assessment of Penstocks: Quest Integrity carried out a
critical engineering assessment to assess the structural integrity of a number of penstocks.
Quest Integrity conducted a site walk down, at which time it was noted that the penstock
pedestals were in very poor condition. Mechanical testing was then employed to determine the
properties of the penstock material. This involved a series of tensile and Charpy V-notch
(CVN) impact tests. Following this, Finite Element Analysis was used to determine the stress
state of the pipes and the build-up of local stresses due to the relative movement between the
penstock and supporting pedestals. Finally a critical defect assessment was carried out to
provide inspection criteria guidance for future inspection of the penstocks
 Assessment of spiral casing: A fitness for service assessment of a spiral casing was carried
out with a view to review if it was designed as intended and to determine if it was susceptible
to failure caused by cracking in the welds. A review of the material in combination with the
stress analysis showed that the spiral casing was fit for service.
 Corrosion assessment of a penstock
 Corrosion damage was discovered in a penstock and a Level 3 corrosion assessment was
carried out to determine the effect of localized corrosion and pitting. The maximum allowable
corrosion and pit depths were calculated for a number of locations on the penstock. Based on
the results guidelines for future inspection were developed.
 Erosion assessment of wicket gates: Severe erosion was discovered in the wicket gates of
a vertical Fransis turbine. The worst corroded wicket gate was identified and a comprehensive
remaining wall thickness survey was undertaken. A finite element analysis was undertaken
modeling the corrosion in the wicket gate and the results was assessed to determine if the
wicket gate was fit for service. It was found the wicket gates were fit for service and the
remaining life was estimated based on known corrosion rates.
 Options for Design Modification of Rotor Spider for a Hydro Power Station: Quest
Integrity conducted an analysis to identify the stresses inherent in a rotor spider at a hydro
power station. Two repair methods to decrease the stresses in the rotor spider were proposed
in an attempt to mitigate fatigue damage. In terms of the life assessment, the two proposed
redesigns would decrease the stress range by about 50% according to Finite Element models.

Strain gauging was also implemented in this project to try and validate the stresses found in
the FE models.
Selected Recent publications
 A. Karstensen, Management of defects in high temperature /high pressure

components, IIW Sydney, 2007.
 A. Karstensen, J. Guerra, O. Kwon and D. Knowles, Ligament Cracks in Super
Heater Headers, PVP 2006 Vancouver, Published in Journal for Piping and Pressure
vessels. 2006.
 Ohgeon Kwon, Mike Myers, Annette Karstensen and David Knowles, “The effect of
the steam temperature fluctuations during steady state operation on the remnant life
of the superheater header-Part 1. Stress analysis” The 8th Operating Pressure
Equipment conference, Melbourne April 2005.
 Annette Karstensen, Ohgeon Kwon, David Knowles, “The effect of the steam
temperature fluctuations during steady state operation on the remnant life of the
superheater header-Part 2. defect assessment” The 8th Operating Pressure
Equipment conference, Melbourne April 2005.
 Annette Karstensen, Mike Pearson and David Firth “Structural Integrity of the
Waikaremoana Penstocks”, 11th Hydro Power engineering Exchange, Taupo
October 2004.
 Jade Wilson and Annette Karstensen, “Fitness for Purpose of Ohau A G5 Generator
Rotor with known Propagating Defects” 11th Hydro Power engineering Exchange,
Taupo October 2004.
 Karstensen, A. and Firth, D. “The use of an engineering critical assessment to
determine the criteria for weld repair during offshore pipeline construction.” In
proceedings from the International conference on pipeline integrity and repair, WTIA
March 2004.
 Karstensen, A.; Smith, A. and Smith, S. "Corrosion damage assessment and burst
Test Validation of 8in X52 linepipe", In proceedings from the Piping and Pressure
Vessel Conference, (PVP) Atlanta, August 2001.

Appendix B: Terms and Conditions



Appendix C: Revision Summary
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Title: Rotor Life Management of Fuji 66 MW Geothermal Rotor

Client: Chevron Geothermal Indonesia

Confidential To: Client

Date Issued: 17 March 2016

Valid for: 30 Days

Prepared By: Stephen Rowbotham

Checked and Approved By: Andy Saunders-Tack

2 Scope of Work ............................................................................................................4

4 Quest Integrity Expertise and Experience ................................................................. 12

5 Price and Project Schedule .......................................................................................12

7 Acceptance of Proposal ............................................................................................13

8 Quality System ..........................................................................................................13

11 Confidentiality Clause ...............................................................................................15

Appendix A: Curricula Vitae ...............................................................................................16

Appendix B: Terms and Conditions....................................................................................29

Appendix C: Revision Summary ........................................................................................33

109443.10 Proposal issued 17 March 2016 Page 2 of 33

Figure 1: Photograph showing Fuji Rotor.

The information shown in Table 1 was made available by Chevron.

Table 1: Information supplied for rotor

Stages 2 x 9 Stages Double flow

Type of blading Reaction

Rotor type Drum

Manufacturer Fuji Electric Co.

109443.10 Proposal issued 17 March 2016 Page 3 of 33

Rated speed 3000rpm

Inlet pressure 5.86 Barg

Inlet temp 159 °C

Bearing Type Journal Bearing and thrust bearing

Rotor material 30CRMoNIV411

Rotating blades material X20Cr13 (SS) ASTM478 420

Blade fixing Stages 1 - 6 T Mount to drum- machined shroud bands

Blade Fixing Stages 7 - 9 Axial fir tree mount to drum

Erosion protection Stellite strips on Stages 8 and 9

2.1 Phase 1: Condition Assessment and Inspection

 Visual inspection of diaphragms associated with rotor.

 Review of documentation and drawings held for rotor and blades.

 Dimensional survey, including diametral measurements in order to undertake rotor

 Field metallographic techniques including metallurgical replication and hardness

109443.10 Proposal issued 17 March 2016 Page 4 of 33

 Concentrated nitric acid.

 Concentrated hydrochloric acid.

109443.10 Proposal issued 17 March 2016 Page 5 of 33

Table 2: Typical work scope/inspection areas on geothermal rotors

Dimensional XRF- UT Phase UT

109443.10 Proposal issued 17 March 2016 Page 6 of 33

2.2 Phase 2: Rotor Engineering Critical and Remnant Life Assessment

2.2.1 Life limiting factors and remnant life or rotor

- Operating history, number of service hours and starts per turbine.

- Steam chemistry (current and historic).

109443.10 Proposal issued 17 March 2016 Page 7 of 33

2.2.2 Global Rotor Finite Element Stress Analysis

2.2.3 Identifying the Possible Cracking Mechanisms

109443.10 Proposal issued 17 March 2016 Page 8 of 33

2.2.4 Critical Flaw Calculation

2.2.5 Crack Growth Calculations

109443.10 Proposal issued 17 March 2016 Page 9 of 33

The deliverables shall be the following: