PLANT VISIT AND MANUFACTURING INSPECTION GE (ALSTOM ...

i August 15, 2016

25501457 ` May 2016 Visit to GE Plant in U.K. – LCP

PLANT VISIT AND MANUFACTURING INSPECTION

GE (ALSTOM GRID) FABRICATION FACILITY IN

STAFFORD, U.K.

MAY 26, 2016 Prepared for: Natural Resources Canada and Nalcor

Project Lead: Nik Argirov

Date: June 17, 2016

Quality Assurance Statement

Office Address 740-1185 W Georgia Street, Vancouver BC, V6E 4E6

Prepared by Vladimir Kahle and Nik Argirov

Reviewed by Nik Argirov and Howard Lee

Approved for Issue by Howard Lee

This document contains information

from MWH which may be confiden-

tial or proprietary. Any unauthor-

ized use of the information

contained herein is strictly prohib-

ited and MWH shall not be liable

for any use outside the intended and

approved purpose.

ii August 15, 2016


This page left intentionally blank

iii August 15, 2016

25501457 May 2016 Visit to Alstom Grid Plant in U.K. – LCP

TABLE OF CONTENTS

1. General.............................................................................................................................. 1 2. Formal Presentations at the GE’s Grid Solutions UK ....................................................... 1 3. Meeting at the HVDC Centre of Excellence (CoE) Facility ............................................... 2

Appendix 1: Photographs

iv August 15, 2016


This page left intentionally blank

August 15, 2016

25501457 1 May 2016 Visit to GE Plant in U.K. – LCP

1. General

On May 26, 2016, the Independent Engineer (IE) MWH, represented by Nik Argirov and Vladimir Kahle, together

with a senior management representative from Nalcor and GE’s Canadian Transformer Service group representa-

tive met with the GE’s (formerly Alstom Grid) plant management and conducted tours of select production facilities

in Stafford, U.K.

GE has been contracted to carry out the HVDC converter facilities turnkey project for the Lower Churchill Project

and will supply, install and commission the power transformers, control cubicles and thyristor valves.

The purpose of the plant visit/inspection was to verify the status of GE/Alstom’s work and to review their QA/QC

process relative to the manufacturing of the equipment supplied under this Contract.

2. Formal Presentations at the GE’s Grid Solutions UK

The GE Project Manager, Mr. Kishor Mistra started the meeting with an introduction of the GE Transformer Service

team working on the Lower Churchill Project. The presentation that followed provided an overview of the Project

Scope. In total, seven transformers for Muskrat Falls, seven transformers for Soldiers Pond (one prototype/spare

transformer at TST, Stafford, UK and six other units at TCT, Canoas, Brazil). The installation will be performed by

GE’s Canadian Transformer Service (TDC) group.

Notes taken by the IE at the presentation include the following;

a) Project achievements, manufacturing status and logistics overview:

Last unit is expected to be assembled in January 2017.

GE’s Canadian Transformer Service (TDC) group out of Montreal will take over the equipment de-

livery, conduct ‘after arrival’ inspection, installation and oiling. TDC already completed their training

in UK.

Testing of the prototype unit (the spare one for Soldiers Pond (SOP)) has been completed and three

Muskrat Falls (MF) units testing is expected to be completed as of this day (Photos 1-4).

Transformers manufacturing status is as follows: MF seven units are in the shop, the 8th (proto-

type/spare for SOP) unit has already been shipped FOB UK port. Three MF units and the spare

SOP unit are expected to be shipped to site (FOB MF) by the end of July’16 with the remaining four

MF units plus ancillaries to be shipped to site by mid-September’16. The balance of six SOP units

are manufactured in GE shop in Canoas, Brazil (TCT) and their deliveries to site are to start in

October’16 (3 unites) and to be completed (remaining 3 units) by the end of January’17.

b) It was indicated that the GE is on track and any potential issues are being addressed in prompt and trans-

parent manner. Mr. Mistra assured the meeting participants of continual Senior Management support.

c) Canadian Transformer Service (TDC) representatives indicated they will have the necessary resources to

meet the project deliverables and schedule.

August 15, 2016


Visit to Grid Power Transformer Plant

Manufacturing Manager Mr. Simon Roberts guided the tour and responded to the enquiries.

Personal Protection Equipment (PPE) is available and is worn by the employees.

Housekeeping appears very good; we observed clean floors, no loose material or tools, equipment

in apparently good order.

We observed transformer coil and core manufacturing process and visited several work stations. Hi-

grade steel is reported to be used for the core laminations. Inspection and presentation of trans-

former ‘DC’ winding insulating techniques indicated use of hi-grade molded insulating materials.

Quality control process is in place. Mr. Roberts described both top-bottom manufacturing issues

resolution process and bottom- up incident reporting.

Conclusion

Formal presentations and visits to the manufacturing and test facilities indicated that GE’s staff key com-

petencies, organization and processes appear appropriate for carrying out the manufacturing contracts.

Progress demonstrated to date and projected schedule should permit GE to meet the delivery timelines.

No outstanding issues were identified.

3. Meeting at the HVDC Centre of Excellence (CoE) Facility

DC Wall Bushing (WB) freezing tests were discussed at length. GE engineers reported that due to

the expected asymmetrical snow/ice loading, these horizontal WBs were intentionally designed

oversized. Their size and the required high DC test voltage apparently preclude actual testing in

the environmental lab.

GE is pursuing alternative methods of testing or modeling the specified freezing range and condi-

tions. They apparently engaged outside experts to assist them.

Mr. Argirov (IE) suggested an alternate WB freezing test method that does not require use of the

environmental chamber. GE will pursue this further.

Harmonic Filters (HF) are on the critical path. HF drawings are being finalized.

HVDC line and cable voltage profile was discussed; GE stated that although the terminal voltage

at the rectifier end is now higher than originally anticipated, transmission line voltage drop will re-

duce the voltage to the undersea cable design value.

Circuit resonance issue due to reduction of the cable length has apparently been resolved.

One Thyristor Valve assembly has been shipped to China for testing at full line voltage (Photo 5).

Visit to Control and Protection Test Facility

NALCOR electric system has been modeled and verified by the engineering group.

Control and Protection (C&P) panels are complete, interconnected and the relay settings and con-

trol parameters have been applied by the test lab staff.

Testing on site will consist of two phases, pre- commissioning and testing on load.

August 15, 2016


Conclusion

Visit to the test facilities indicated that GE’s staff key competencies, organization and processes appear

appropriate for carrying out the manufacturing contract for the C&P. Harmonic Filters are on the critical

path. Wall Bushing freezing test methodology development is pending. Thyristor Valves have not yet been

completed but testing is in progress.

APPENDIX NO. 1

Photographs (provided by GE)

Photo 1 Muskrat Falls Convertor Transformer (Unit 3) – In Test (Cooler Side).

August 15, 2016


Photo 2 Muskrat Falls Convertor Transformer (Unit 3) – In Test (Radiator Side).

Photo 3 Muskrat Falls Convertor Transformers testing – Unit 1 (left), Unit 2 (right) and Unit 3 (back).

August 15, 2016


Photo 4 Soldiers Pond Convertor Transformer – In Test.

August 15, 2016


Photo 5 Thyristor Valve Module in preparation for type testing in China.

PLANT VISIT AND MANUFACTURING INSPECTION GE (ALSTOM ...

Documents

Transcript of PLANT VISIT AND MANUFACTURING INSPECTION GE (ALSTOM ...