IR 05000387/1989037
| ML17156B609 | |
| Person / Time | |
|---|---|
| Site: | Susquehanna  |
| Issue date: | 01/19/1990 |
| From: | Anderson C, Woodard C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML17156B608 | List: |
| References | |
| 50-387-89-37-MM, 50-388-89-36, NUDOCS 9002070259 | |
| Download: ML17156B609 (100) | |
Text
U.S.
NUCLEAR REGULATORY COMMISSION
REGION I
50"387/89-37 Report Nos.
50-388/89-36 50-387 Docket Nos.
50-388 NPF-14 License Nos.
NPF-22 Licensee:
Penns lvania Power 8 Li ht Com an 2 North Street Allentown Penns 1 vani a 18101'acility Name:
Sus uehanna Units 1 5
Meeting At:
USNRC Re ion I 475 Allendale Road Kin of Prussia PA Meeting Date:
December
1989 Meeting Topic:
Sus uehanna Emer enc Diesel Generator Crankcase Ex losions of Coo er EDGs Prepared by:
rlP0 Carl Moodard, Reactor Engineer, PSS',
EB, DRS date Approved by:
C. J.
Anderson, Chief, Plant Systems Section, EB, DRS
/f FD date P
i P
i
>>t I)
i d
presentation of their preliminary root cause findings for recent EDG crankcase explosions at Susquehanna along with possible corrective actions to prevent recurrence.
They confirmed their commitment to submit a formal report to the NRC by January 8,
1990.
5'0020702.i9 9v0i~4 PDR ADC~CK 0 000 87 Pbc
1.0 Meetin Attendees Penns lvania Power and Li ht Com an (PP&L)
C. Boschetti, Project Engineer, Risk Assessment J.
Kenny, Licensing Supervisor S.
Kuhn, Technical Electrical Supervisor D. Roth, Senior Compliance Engineer B. Swoger, Project Engine'er L. Willertz, Senior Consulting Engineer United States Nuclear Re ulator Commission NRC C. Anderson, Chief, Plant Systems Section, RI CD Berlinger, Chief, Generic Branch, NRR J. Strosnider, Chief, Materials and Processes Section, RI P.
Swetland, Chief, Reactor Projects Section, RI E.
Tomi lson, Project Engineer, NRR/PDIV M. Thadani, Project Manager, NRR R. Winters, Senior Engineer, RI C. Woodard, Reactor Engineer, RI 2.0 Bac'k round and Pur ose This meeting was called at the request of Region I in response to Emergency Diesel Generator ( EDG) crankcase explosions that have occurred at the Susquehanna Power Plant (the most recent explosions occurred on September 16 and October 7,
1989).
,Since the cause of the recent explosions could not be identified during Region I inspections of the explosions, the licensee committed to submitting a root cause analysis report to the NRC by January 8,
1990.
The licensee had essentially completed their evalua-tions and root cause analysis of the failures.
This meeting included a
presentation of their findings prior to.the submission of the formal report.
The licensee presentations are detailed in the enclosures:
Diesel Generator Failure Team Objective, Operability, and Photographs.
The licensee identified several potential causes of the explosions and corrective actions under consideration to prevent recurrence.
Corrective actions being considered include equipment design changes to remove the piston pin end cap covers to eliminate a source of cylinder liner gouging, the removal of the bottom piston skirt oil scraper ring to provide for better piston/cylinder liner lubrication, procedural changes to eliminate the surveillance test fast start immediate overloading of the EDG to reduce engine stresses, maintenance changes to provide for proper engine break-in following major maintenance for parts "seating,"
and change to a non-foaming engine lubricating oi.0 Conclusions The licensee identified several issues that could have contributed to the engine failures.
They also identified corrective actions under consideration.
A formal report will be issued in the near term addressing these issue TEAM OBJECTIVE
. TO DEVELOP AND IMPLEMENT A PLAN THAT ASSURES ALL DIESEL GENERATORS CONTINUE TO MAINTAIN AN OPERABLE STATUS.
THE PLAN MUST ADDRESS BOTH THE OPTIONS OF FINDING THE ROOT CAUSE AND NOT FINDING THE ROOT CAUSE.
THE PLAN MUST ALSO ADDRESS THE LONG AND SHORT TERM IMPLEMENTATIONITEMS,
DIESEL GENERATOR TASK FORCE TEAM LEADER W.
RHOADES LICENSING D WALTERS MECH ENGR F CZYSZ METALLURGICAL ENGR L WILLERTZ SYSTEM ENGR C BOSCHETTI MAINT ENGR D.
GANDENBERGER TECH STAFF S
KUHN INDEPENDENT ASSESSMENTS SOUTHWEST RESEARCH RICARDO ASSOCIATES
SUSQUEHANNA DIESEL GENERATOR PLAN/TASKS o
DEVELOP DG RUN HISTORIES FOR ANY TRENDS o
DEVELOP INSPECTION CRITERIA/INSPECTION PLAN o
DETERNINE DESIGN LOADING ON EACH ENGINE o
DETERMINE LOAD LIMITATIONS OF DG's o
ASSESS INDUSTRY INFORMATION ON COOPER CRANKCASE EXPLOSIONS o
ASSESS INDUSTRY INFORMATION ON LOADING AND LENGTH OF RUNS o
COOPER FAILURE REPORTS o
PPRL ROOT CAUSE ANALYSIS/FAILURE REPORT/BRC ENGINES o
INDEPENDENT ANALYSIS SOUTHWEST RESEARCH INSTITUTE o
INDEPENDENT ANALYSIS RICARDO CONSULTING ENGINEERS o
ASSESS PPaL MAINTENANCE PRACTICES o
COMPARE FOAMING OF OIL o
.
REVIEW PPaL DG START AND LOAD RECORDS/MAINTENANCE RECORDS/ENGINE ANALYSIS RECORDS
OUTLINE OF THE ROOT CAUSE DIESEL FAILURE REPORT
++++++++++++++++++++++++++++++++++++++++++++++++
Chapter Subject ABSTRACT EXECUTIVE SUMMARY A.
PROBLEM B.
FINDINGS C.
CONCLUSIONS D.
RECOMMENDATIONS FAILURE HISTORY A.
TABULATION OF ALL D/G PISTON FAILURES B.
TABULATION OF AIL INSPECTION RESULTS RELATED TO FAILURES C.
DISCUSSION OF FAILURES IN GENERAL D.
CONSULTANTS ANALYSIS E.
MAINTENANCE PROCEDURES F.
FAILURE SCENARIOS IV.
METALLURGICALANALYSIS OF "B" DIESEL 7L FAILURE A.
BRIEF DISCUSSION OF FAILURE AND OBSERVATIONS B.
SPECIFIC OBSERVATION OF METALLURGICALCONDITION OF EACH PART C.
DISCUSSION OF RESULTS D.
CONCLUSIONS VI.
METALLURGICALANALYSIS OF iiC'i DIESEL 5R FAILURE
+ SAME AS SECTION V.
ABOVE VII.
MISCELLANEOUS FINDINGS A.
PISTON RING FINDINGS B.
PISTON PIN FINDINGS e
C.
OIL FOAMING DISCUSSION D.
OBSERVATIONS OF "C" DIESEL INSPECTIONS 12/15/89 E.
OBSERVATIONS OF "B" DIESEL INSPECTIONS 10/20/89 F.
OBSERVATIONS OF "A" DIESEL INSPECTIONS 11/15/89 VIII. APPENDIXES
, A.
INCOMPLETE WORK B.
FUTURE DIRECTION C.
FORMATION OF OWNERS GROUP D.
CONSULTANTS FINDINGS E.
QUALITY ASSURRANCE REVIEW OF COOPERS PROGRAM
CRANCKASE EXPLOS ONS A.
BACKGROUND ENGINE DESIGN CRANKCASE EXPLOSIONS AT SSES CRANKCASE EXPLOSIONS AT OTHER UTILITIES (C-B OIESELS)
B.
INVESTIGATION SUMMARY INCORRECT COMPRESSION RINGS WORN RINGS (FLAT)
PISTON TIN LOSE END CAPS NOT SEATED BLUED PISTON PINS OIL FOAM TEST C.
CURRENT THEORY OF THE CAUSE OF SSES FAILURES D.
OTHER UTILITY DIESEL PROBLEMS E.
OUR OPINIOHS ON THE RELATIONSHIP WITH SSES
r G
0
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~ {.
J
1.
tiatoa 2.
Cosy reaaim Lhiia
~3.
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Pin Sushi'.
Pin Cay 6.
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Event No.
Unit
8
Event Loose piston pin bolt 5L.
Oue to looseness of pin on rod oil "spilled" through pin to rod clearance ther'eby precluding adequate piston cooling, Piston skirt distress 7L.
Unknown source of material
"rolled" between piston and liner.
Oate
.
Jan.
18, 1986 Sept.
16, 1989
C Piston skirt distress
.5R.
Oefect in piston skirt - unique.
Lube oil pump bearing failure on initial start-up.
Fuel oil dilution of lube oil in cylinder 2L caused high friction between piston and liner.
Oct.
7, 1989 Nov. 29, 1981 Jan.
14, 1984
A.
PALO VERDE DUE TO IMPROPER BLUING OF PISTON PIN BUSHING B.
BRAIDWOOD DUE TO METAL CUTTINGS IN PISTON PIN OIL GROOVES C.
BYRON CAUSE WAS NOT CONCLUSIVELY DETERMINED D.
ZION DUE TO PISTON BUSHING FAILURE E.
COOPER THREE OVERPRESSURIZATIONS DUE TO WATER LEAKS
'ATfACNKIITA PISTON RING DINENSIONAL DATA
~DG
C
PISTON 7L 5R BR A
Exact Piston Location Unknown b
Exact Piston Locati on Unknown 1R RING 0
2 3.4 RADIAL MIDTHS INCHES
.450
.454-.460
.437
.448
.449-.450
.429
.429
.445
.454
.455-.460
.453-.455
,450-.456
.454-.463
.42I-.432
.455-.460 (.4357)-.45B
.451-.459
.425-.42B
.420-.432
.448-.454
.450-.450 CCNIEIIT Hissing Wrong Ring OK Hissing Nissing OK OK OK OK OK OK OK Qrong Ring Wrong Ring OK OK OK Mrong Ring OK OK
. 424-. 430 OK
.422-.430 OK
. 442-. 450 OK
.450-.455 OK 7R
.440-. 446
.443-.452
.456-.460
.450-.461
. 449-.456
.462-. 464
.451-.456
.455-.45I Nay Ba Mrong Ring Nrong Ring OK OK Nrong Ring sarong Ring OK OK
ATTACH%MT A PISTON RING OIHEHSIONAL DATA
~DG B
P ISTOH 5L 3R RIHG i RADIAL llIOTHS INCHES
.436-.437
.437-.438
.456-.459
.459-.460
.429-.434
.432-.433
.464-.466
.457-.460 CONELET OK OK OK OK OK OK OK OK New (free stock)
.436-.437
.437-.438
.457-.462
.459-.460 OK OK-OK OK f$c/mskll4i(32)
~
REVIEW OF RING SET SD-94-KSV-9 COOPER TOP COMPRESSION IN C
~~@
2ND COMPRESSION RING TYPE:
TAPER FACE/TWISTED PART NO:
2-20R-005-001 WIDTH:
.2465/.2480 RADIAL THICKNESS: 0.430/0.450 END GAP:
0.080/0.105 DIA. TENSION:
50-60 LBS (7e e:~e<)
MATERIAL'-28, PARCO p ~
BACK CL. IN GROOVE:
0.020/0.050 MIN. GROOVE DEPTH:
0.470 MIN. SIDE CLEARANCE:
0. 007 3RD COMPRESSION RING 4TH COMPRESSION RING KAYDON da+>>
A5701
.2475/.2490 0.455/0 '70 0.054 MIN.
50-60 LBS K-28, PARCO 0.054 MIN.
0.524 0.008 TYPE:
TAPER FACE/TWISTED PART NO:
WIDTH:
RADIAL THICKNESS:
END GAP DIA. TENSION:
MATERIAL:
BACK CL. IN GROOVE'IN.
GROOVE DEPTH'IN.SIDE CLEARANCE:
5TH OIL RING 6TH OIL RING 7TH OIL RING 2-20R-354-001
.2465/.2480 0.445/0.465 0.080/0.105 34-44 LBS.
K-IRON, PARCO 0.005/0.035 0.470 0.004 80731
.2475/.2490 0.455/0.470 0.054 MIN.
34-44 LBS.
K-IRON, PARCO 0.054 MIN.
0.524 0.008 CONFORMABLE DOUBLE HOOK SCRAPER, VENTILATED PART NO:
WIDTH:
RADIAL THICKNESS'ND GAP UNIT PRESSURE:
MATERIAL:
BACK CL. IN GROOVE:
MIN. GROOVE DEPTH:
MIN. SIDE CLEARANCE 2-20R-652-001 0.372/0.3735 0.290/0.310 0.040/0.065 188 PSI K6E PARCO NA 0.544 0.0035/0.0065 86188 RING 86139 SPRING 0.3715/0.373 NO INFO 0.03375 MIN.
188 PSI K6E PARCO NA NA 0.0025 MI OBSERVATIONS ON REIIWEO PISTNS 5R Piston involved fn crankcase explosion.
Non-thrust side tfn saearing noted in previous inspection.
Tin Saear on Non-
~DS
~tlinder Thrust Side ns liner Blued Pfn Yes.
~End Cn s Not seated.
CQtKNTS BR 1R Piston fnvolved fn crankcase explosion.
Yes'es.
Slight bluing.
Not seated.
Not blued, but pin fs 5 afls out of round.
Yes.
Pin needed Not seated.
to be hamered out.
A 2R 7R 1R 6L 7R Yes.
Yes.
Yes.
Yes.
No tin swear.
Burnishing due to end-cap rubbing.
Yes.
Yes.
No bluing, but pin fs worn.*
Scratched parallel to pin axis.
Shotded signs of wear.
Pin was replaced.
Not seated.
Not seated.
Not seated.
Not seated.
Liner replaced.
Piston replaced (non-thrust tin reaoved).
C BR A
3R Yes.
Good pfston pulled for fnspectfon.
Stee bur-nishing of tfn on non-thrust side.
No. bushing needed to be scraped to obtain proper bluing.
~ Per Hike Schleigh of C-B.
fJc/tbkl09c(9)
C 5R PISTON AFTER CRANKCASr'. EXPLOSIO PISTON AFTER CRANKCASE EXPLOSION.
NOTE:
CASTING DEFECTS LOWER RIGH LINER AFTER CRANKCASE EXPLOSIO i 4 C
SR PISTON END CAP UNSEATE C-5R BLUED PI C-6L TIN SMEAR ON LINE 'r C 6L WORN PISTON RINGS FLAT LOSS OF TIN ON NON THRUST SID ~
ROOT CAUSE INVESTIGATION
~ RISK ASSESSMENT
~ OPERABILITY TESTS
~ RELIABILITYASSURANCE
ROOT CAUSE INVESTIGATION
~ NO SINGLE POSITIVE CAUSE
+ SEVERAL POTENTIAL CAUSES-LUBRICATION-RING NEAR-PIN BLUING-PISTON END CAP SCUFFING-TESTING
. ~ LIMITINQ~ IS LOOP
- LOCA n Probable NURE8/ R-4792
- Age Rel~
- A or 8 DQ Required
~ DG PERFORMANCE
- Welbull Oietrlbutlon
- Increaalng Failure Rate
- Wearout
+ LOCA - FRACTURE MECHANICS/
PROBABILISTIC MODEL
- ~10 yrs - Negligible-1x.001/yr at 10 yr
- 2 x.001/yr at End
- Coneervatlve
~ LOOP - NUREG-1032
- 0;052 Dec, Jan, Feb
- Plant / Grid Centered
- Satere / Extremely Severe Weather
- 24 hr Max Duration-AorBDG
~
o i4R4 o
~
~
~
~
~
~
~
~
~
~ ~
o 16%
o 3585
. 348i...
o
~
~
~
~
~
~
~ ol5 D
~ ~o DGG IXs 8 SG h 010 MIN 1060 bEIN 60 min+
Beyond DG LOADING U1 LOCA U2 FORCED S HUTD0%N ALL LOADS ASSUMED ON.
APPROX ROAOkw LAAD h<~TT.>~~ +
4193 legend
~
~
~
~
~
~
~
e i DG A ewe
~ ~
o ~ DG C DG S 010 MIN 1060 MIN 60 min+
Beyond I
0-10 min 10-60 min
>80 min DQ soss 3669 8384 3907 3087 8940 3761 3668 C
DQ ssos 4178 4188 8787 D DQ a7ss 437 495 DG LOADING 1 DG FAILURE
@<1 Infant Mortality P =1 Random Failure Rate 1gt<4 Wearout B)4 Rapid Wearout
gl >1
OPERABILITY TES TS
~ 24 hr CAPABILITY
~
LOCA / LODP
~
LOOF
~ MONTHLY SURVEI CE ia/is/ns
RELIABILITYASS URANCE
~ INSPECTIONS DG DATE ggPLACEMENTS s/as io/a6 10/22 7L/R PISTON/LINER 1R PISTON/LINER GR PISTON/LINER SL PISTON'1/4 BR PISTON
\\
A 12/1 1R. 7R PISTON 12/iQ/89
RELIABILITYASS URANCE
~ POST RRFKACEMEHT TRSTBfG 2 hr Idle 4 hr 25Fo 2 hr 56,75,iOOX zs/aa/oo i2 hr Total
~ pmm MICA Seats riage Proves CapiMRty
~ TOPkK M3Ã TARN k 48.5 hra
5.i has
- C en.shr
- 9 4V.i hre E
iV;4 hrs TION
RELIABILITYASS URANCE
~
2 4 hr SURVEI CE
~
TECH SPEC CHANGES
~ FUTURE. INSPECTIONS
~ MODIFICATIONS 12/11/SQ
10/10/&
OPERABHZlY BkSED 0¹
~ OPERLBIIZFY TESTING Moota kll Teoh Specs Pre@ca Capability To Partorm Donga tuILottoaa
~ INSPECTED an4 REFLkCED VORN COMPONENTS OPEMBHZiT SY
~ INSPECTION PROGRAM
~ LESS SEVERE TESTING
~ DESIGN CKNGRS
Figure B-1 Picture of the skirt of the B diesel 7L piston showing heavy wear and metal distortion in the lower ring are ~
~
~ q~w I yl f
A
'
E ~
~
~
~
()
l J
h A%I Figure B-2.
Cross-section of the B diesel 7L piston skirt area showing deposited metal in the upper micrograph and martensite formation in the microstructure in the lower micrograph.
The latter indicates temperatures in excess of 1350 deg F were experienced by the material locall ~ I ~
');p
~*
<<M i ~
wrM Figure B-3.
Enlarged section of the deposits on the skirt of the D
diesel 7L cylinder showing the layering evident there.
'
l500 cts
,
SQ920D Spectrum of Particle Photo
CAO P
0.0 ZH rx I
2.0 4.0 6.0 ENERGY (KEV)
8.0 Figure B-4.
Micrograph and EOS analysis results of non-magnetic debris taken from the head of the B diesel 7L pisto ~
~
II 500 cts CAO SQ920E Spectrum of Particle Photo
'ZE EA
P S
i FEZ'
i 0.0 2.0 4.0 6.0 EEERCY (KEV)
8.0 Figure B-5.
Micrograph and EDS analysis results of non-magnetic debris taken from the head of the 8 diesel 7L piston on another particle from that analyzed in the figure B-Figure B-6.
Cross-section of a cracked area of. the B diesel 7L piston skirt showing metal deposits on the surfac ~
'% ~
~ ~
Figure 8-7.
Enlarged area of the bottom right portion of figure 8-6 showing where analysis 'P'as take cts SQ921P llhlta Area in Sur Lace Area FE CR C hi'X 0.0 2.0 4.0'.0 ENERGY (EEV)
8.0
&000 cts SQ921 Gray Phasa at Zntor1aca Q
PE CR cxrz Si 0.0 2.0 4.0 6.0 EEERGY (KEY)
8.0 Figure B-8.
EDS analysis of areas 'P'nd 'Q'n figures B-7 and B'-,2500 cts SQ9210 Dark Gray Layor Suriaca
"5" CR CR carx SSCa I
0.0 2.0 4.0 6.0 XRERCY (KEV)
8.0 20000 cts SQ9218 Light. Gray Layar Surface-S CR rE CR Cars
A 0. 0 2.0 4.0 6.0 ENERGY (KEV)
8.0 Figure B-9.
Spectra of the light and dark phases in figure B-X 800 X Figure B-10.
Microstructure of the head of the B diesel 7L piston
'howing a normal pearlitic, graphite flake condition
'.
Thick section b.
Thinnest section
Figure B-11.
Portions of the top wiper ring of the B diesel, 7L piston showing the pickup of metal and debris on the surfaces touching the line Figure B-12.
Gross section of the lower oil r ing from the B diesel 7L piston showing the wear and deformation on the two wiper surface Figure 8-13.
Picture of oil ring profile at high magnification.
To be taken later.
Hagnified image of oil ring finger from 8 diesel, 7L piston lower oil ring showing structure deformation and size of the finger.,
10000 ets SQ920A Susq Oil Ring Deposits Fc.
HR CRrx 0.0 2,. 0 4.0
~
6.0 ENERGY (KEV)
8.0 Figure 8-14.
Debris EDS analysis from the spring behind the lower oil ring from the 8 diesel 7L pisto Figure 8-15.
Smeared metallic deposits found on the 84 compression ring of the 8 diesel, 7L piston are shown here as the dark gray area labeled 'A'.
EDS analysis of area 'A'hows it to contain Cr, Fe, Si(trace)
and Sn(trace).
Area '8'hows only Fe with a trace of C CRrx I
4.0 8.0 10.0 20000 cts Q9212'pot "I" 1n dEB Photo 0001 FE CR CU SZ
CR 0.0 2.0 4.0 6.0 XÃ'ERGY (KKV)
S.O 10. 0 Figure 8-16.
EDS analysis of the 84 compression ring from the B
diesel 7L piston in areas 'A'nd 'B'f Figure B-1 ~
~ r CV PB 5 I SZ E'ECU I iI 0.0 2.0 4.0 6.0 ENERGY (REV)
8.0 10.0 Figure B-17.
An unusual spot of foreign material found embedded in the h'4 compression ring from the B diesel 7L piston.
EDS analysis shows it to contain Cu, Fe, Sn, Pb, and N Figure B-18.
Pictures of the end caps as found on the B diesel 7L piston showing the scraping and local heating experienced by these parts during the failure sequenc '
~ e
~
g
~
~
~
~ A+
10000 ct.s SQ916A Spectrum of Phot.o 0001 FZ CR I
I CR CAF E (
I
)
0.0 P
2.0 CA SN 4.0 6.0 LNLRQY (KEV)
8.0 10.0 Figure B-19.
Picture and EDS analysis of a piece of smeared metal removed from end cap 'A'rom the 8 diesel 7L pisto ~ a ~A ~
M4
Y'
~a ~
~
~
~
~
~
~
~
~ ~
20900 cts BQ9 16B Spectrum of Phot.o 0002 CR CR
,C A F E SBCA 0.0 4.0 6.0 ENERGY (KKV)
8.0 10.0 Figure B-20.
Particle of smeared metal removed from pin end cap
'B'rom the B diesel 7L piston.
The EOS analysis shows that it consists primarily of Cr with some Fe and a trace of Ca and S 'Figure 8-21.
Abrasion and wear found on the 8 diesel 7R piston pin end cap Figure 8-22.
Photograph of the B diesel 7R piston end cap which showed the worst amount of wear, heating and metal transfe.5 X 15 X Figure 8-23.
8 diesel 7R end cap showing the least amount of wear, but does show that the cap was touching the surface of the liner as evidenced from the light scratch marks on the surface perpendicular
- to the machining mark Figure B-24.
Photographs of both ends of the B diesel 7L piston bronze bushing showing the heat tinting and decomposed oil products near.the ends 90 degrees to the top of the bushin II-0.'
'
~
%JL%%
I Figure B-25.
Full length view of the B diesel 7L liner sur face on the thrust side of the liner(identified as piece B-1)
ic D
Ig+
Figure B-26.
Sketch of the thrust side of the B diesel 7L liner showing the location and orientation of the sections removed for metallurgical cross-sectioning(part labeled B-l).
Figure B-27.
Transverse cross-sectional views of the thrust side of the B diesel 7L liner 22 7/8 inches from the bottom(piece 'A').
The chromium plating is cracked and some of the pores are filled with metallic particle jy X q(<
t.
7~~//g ]
kY ioox
,)
100 X Figure B-28.
Longitudinal view of the B diesel 7L liner on the thrust side 11 1/2 inches from the bottom showing metallic deposits, filled pores and cracking in the Cr plating(piece labeled '8').
~
~
f.'
'g,(
~ 4
/ ~
Figure B-29.
Longitudinal cross-section (labeled 'C') taken
inches from the bottom of the B diesel 7L cylinder liner showing a
rough fractured surface with pieces missing and some debris in the pores of the chromium plating laye ~ ~
E
'
R ~
~
Figure B-30.
Transverse cross-section(labled area 'D') taken 7 1/2 inches from the bottom of the B diesel 7L liner showing depressions in the Cr plating surface, cracking of the base metal casting and deposited meta ~
~
Figure 8-31.
Transverse cross-section (Labeled area 'E') of the thrust side of the 8 diesel 7L liner taken 7 1/2 inches from the bottom showing depressions in the Cr plating and deposited meta ~I'
I'("I'
9$
)
I
)
4kn I ()0'll l.-:
< ()Lltlr>.i r'<ii
>;:-,;i'igure 8-32.
Views of the length of the 8 diesel 7L cylinder liner in the area of pin end cap scraping (part 8-2) showing heavy longitudinal marks and overheating over 20.5 inches of the center sectio Bott ow Figure 8-33.
Sketch of the end cap side of the 'B'iesel 7L liner showing the locations of the metallurgical samples taken for cross-secti onal examinations(part labeled B-2).
15000 cts Q924G Throe dots in Photo 0000 CR I
CR FEB I SZ J
I 0.0 2.0 4.0 iRiRCY (KEV) 6.0 8.0 Figure B-34.
Longitudinal section of B diesel 7L liner (labeled
'A'f part B-2) showing cracking in the Cr plating surface and the presence of Sn at the Cr-Fe base metal interfac Area Elements(
greatest to least)
'R'ase. of pit Cr, Fe, and Sn
'O'op of pit Fe, Sn, and Cr
'P'enter layer Fe, Cr, and (Sn)
'P'opmost layer Fe, cr, and Si Figure 8-35.
Transverse cross-section of the 8 diesel 7L liner (labeled 'C'f part 8-2) showing areas of metal buildup and filling of pores with Cr,Sn and F cts Q924I Area q
xn Photo
CR FX S I 0.0 2.0 4.0 6.0 ENERGY (KEV)
2 0000,cts Q924J Area R xn,Photo
CR CR FZ S I SH I
0.0 2.0 4.0 6.0 ENERGY tKEV)
8'. 0 Figure B-36.
EOS analysis of areas g and R shown in figure 8-3 cts.-
Q924K Outer hraa above P Photo
ZE CR jE I
C.O 2.0 4.0 ENERGY (KEV)
25000 cts Q924H Area P
xn Photo
FE CR 0.0 CR FL S I I
'.
2.0
0 ENERGY (KEV) 6.0 Figure 8-37.
EDS analysis of area P and the Dark layer above P in figure 8-3 Figure 8-38.
Longitudinal section rom 8 diesel liner 7L piece 8-2 taken 24 5/8 inches above the bottom.
This section does not show any pores filled or otherwise, but does show several cracks through the thickness of the Cr plat cts Q924T'rea V in photo
ZE CR CR tX SI 0.0 2.0 4.0 6.0 EEERCY (KEV)
8; 0 Figure B-39.
Longitudinal section of B diesel 7L liner taken from the end cap side 24.625 inches from the bottom showing the layer of deposited metal and the EDS analysis of the lighter grey are Layer Elements in decending order.
Z Y
U X
W Base metal casting Plating layer Content of pore Thick dark layer Top layer Fe Cr
" Cr, Fe, Sn(Trace)
Cr< Fe, Si Fe, Cr, Sn(Trace)
Figure 8-40.
End cap side of the 8 diesel 7L liner taken from transverse section H showing damage to the chromium liner and deposited metal.
EDS analysis of the various layers are shown in figures 8-41 and 8-4 ~
~
~
~
10000 cts Q924D hroe U
xn Photo ll CR ZX CRUX SZ I
0.0
,
2 '
I E.O C.O XFERCY (KEv)
8.0 10. 0
<<. t:
. ~
CsO <<NSiI
';",4 10000 cts Q924E hraa
xn Photo lh CR FX SZ 0.0 2.0 E.O 6.0 XSXROY
<aZV)
8.0 LO. 0 Figure B-41.
EDS analysis of areas U and M shown in figure B-4 cts Q924C Area X
1n Photo
CRtX E
0.0 2.0 4.0 6.0 ENERGY (EEV)
8.0 10.0 20000 cts Q924b Aron Y
1n Photo
CR CREE SZ I
I 0.0 2. 0 ~
4.0 6.0 ENERGY (KEV)
8.0 10.0 Figure B-42.
EDS analysis of areas x and y shown in figure B-4 Figure 8-43.
General surface condition of the non-thrust side of the B diesel, 7L line Figure B-44.
Magnified image of the surface condition of the non-thrust side of the B diesel 7L liner near the upper position of the top compression ring.
Both iron and tin are seen embedded in the chromium liner pore Boffo~
8-3 Figure 8-45.
Sketch of the non-thrust side of the 8 diesel 7L liner(designated 8-3), showing the location and orientation of the metallurgical sections A, 8, C, D, E, and F.
Section E was for surface examinations, while the others were for cross-section ~
~
Figure B-46.
Longitudinal section of the B diesel
L liner taken from an area 7 5/8 to 8 3/8 inches from the bottom.
EDS analysis results are shown in figures B-47 and B-4 its Q9248 Area A in Photo 0002 PE CR I
SZ CR PL P
S 0.0 2.0 4.0 6.0 LHEBGY (KEV)
8.0 10. 0 BOOOO cts Q9248 Araa 5 in Photo 0007.
PL CRHI P
5Z S
CRBH 0.0 4.0 6.0 LNEBGY (KEV)
8. 0 10.0 Figure 8-47.
EDS analysis of areas a and b in figure 8-4 )25000 its Q9248 l
I Area C
xn Photo 0001
~+
I CRtE NH P
SI S
CR HH 0.0 2.0 4.0 6.0 ENERGY (KEV)
8.0 10.0 15000 ats Q9248 Aron
xn Photo 0001 ZE CR FE P
S BS SZ CR
I 0.0 2.0 4.0 6.0 ERERCY (KEV)
10.0 Figure B-48.
EDS analysis of areas c and d in figure B-4 Figure B-49.
Enlargement of area c in figure B-46 showing light and dark phases present.
,EDS analysis of these areas are shown in figure B-5 j12500 cts I
I I
I Q924H Aran Cl xn Photo 0003 YE 6L CR FL p
15000 cts I
L Q9248 Aroa C2 x.n Photo 0003
0.0 rL
SZ S
I CRASH 4.0 6.0 LHLRCY (KLV)
10. 0 Figure B-50.
Analysis of the pore from figure B-46 center right, showing that it contains mainly iron with only a trace of the elements Cr, S and M Figure 8-51.
Longitudinal cross-section of the 8 diesel 7L liner taken 7 5/8 inches from the bottom showing a very thick layer of metallic deposits covering the chromium platin ~f ~ ~
I
~
~ 5 100 X Figure B-52.
Transverse cross-section of a typical area of the non-thrust side of 8 diesel 7L liner 16 inches from the bottom (B-3 area B) showing the filled pores and the deposited metal from this locatio P
\\
I r
/
ioo X Figure B-53.
Longitudinal cross-section of the non-thrust side of the B diesel 7L liner taken 16.5 inches from the bottom of the liner.
Typical examples of the metal deposited from the piston and rings on the Cr platin ~)
&MQ
~ -
~
Pi P
Figure 8-54.
SEM micrographs of longitudinal cross-section 'C'art B-3 of the B diesel liner at a level 16.5 inches from the bottom.
Elements shown were identified as being present in the pores indicate V
~
~
'1g I
J,'l I
Ji,i("
I
~'k+(
q s
'
~ +>r
'N r
m, g4.">'
~
t $
"."~+tP
~
+>-'
-~>~
~
%i's
~
Figure B-55.
Another area of pore deposits and elements found present in longitudinal cross-section 'C'art 8-3 of the B diesel liner 16.5 inches from the botto ~
~
~
spI h
J
~
~
Figure B-56.
Various elements and their location found in a pore from the B
diesel liner 7L, part 8-3, area 'C'.
~ 'r.
~
~
~
~
,:if'
~
Figure B-57.
Elemental contents of two pores filled with metal in the B diesel 7L liner 16.5 inches from the bottom of part 8-3, area ICI
~
~
s fi r P4 P
Figure B-58.
Additional areas of filled pores found in area 'C'f part B-3 of the B diesel 7L cylinder.