Text

Part 21 Rept Re Linear Converter Device W/Possible Generic Defect.Initially Reported on 840116.Preliminary Analysis Indicates Excessive Wear of Brass Shaft Guides.Next Rept Will Be Submitted within 90 Days.Supporting Info Encl
	ML20086L098
Person / Time
Site:	Nine Mile Point, Perry, Catawba, Byron, Braidwood, Surry, Clinton, Midland, 05000000, 05000434, 05000435, Marble Hill
Issue date:	01/17/1984
From:	Jim Dodson; PACIFIC AIR PRODUCTS CO.
To:	Potapovs U; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
Shared Package
ML20086L095	List: ML20086L092; ML20086L098;
References
	REF-PT21-84-118-000 PT21-84-118, PT21-84-118-000, NUDOCS 8402070373
	Download: ML20086L098 (68)
	v • d • e

- - - - - - -

t 3133 West Horvord Street. Santo Ana. Cottforne 92704. P.O. Box 5277. Telephone 714/557-1710. Telex Not 67-8319 January 17, 1984 United States Nuclear Regulatory Commission - Region IV 611 Ryan Plaza Drive / Suite 1000 Arlington, Texas 76011 A t te n ti o n :

Mr. Uldis Potapovs, Chief Vendor Programs Branch Regarding:

10CFR Part 21 - Notification of Concern Gentlemen:

In accordance with the requirements of 10CFR-21, Pacific Air Products Co. hereby informs the Nuclear Regulatory Commission that we are concerned about the possibility of a defect in a product we manufacture.

This noti fica-tion is supplemental to the telephone notification made on January 16,1984 to Mr. Robert Oller of your Staff.

The attached correspondence provides further details of the si tua tion ~.

Copies of this information are being sent to each of the customers shown on Attachment "A".

If you have any questions, please contact me at (714) 557-1710.

Sincerely, PACIFIC AIR PRODUCTS C0.

MJ eh %

s James P. Dodson Director of Quality Assurance JPD:dg Attachment B402070373 840130 gDRADDCK 05000280.

y il PDR J

b 10CFR PART 21 - NOTIFICATION OF CONCERN This report is submitted by:

PACIFIC AIR PRODUCTS CO.

3133 W. Harvard Street P.O. Box 5277 Santa Ana, CA 92704 Louis R. Hess, President BACKGROUND Pacific Air Products Co. has received from the Edgewater Generating Plant (Non Nuclear) a linear converter unit which shows signs of excessive wear.

Analysis of the wear and a determination of its cause is underway at the present ti me.

The preliminary analysis indicates excessive wear of the brass shaft guides on the input and output shafts.

CONCERN The linear converter is a mechanical device that converts' the linear (push-pull) motion of an ITT Electro-hydraulic actuator into rotary motion.

Pacific Air Products Co. has supplied approximately 768 of these linear converters since 1978 mounted to ITT actuators on 10 nuclear plant projects and three non nuclear projects.

A list of these projects is attached.

(See Attachment "A".)

Some of the linear converters are used in safety-related HVAC systems.

While Pacific Air Products Co. does not have any evidence of a generic defect in the linear converter, the possibility of such a defect warrants informing the users of this product.

This notification is intended to assist the users in the inspection of the units in their possession.

An inspection procedure is attached.

(See Attachment "B".)

~

(2)

ACTION

{

Pacific Air Products Co. is presently investigating the possible causes of the excessive wear to the linear converter.

A report of this investigation will be issued within 90 days.

If you have any questions, please contact Mr. James Dodson or Mr. William Nagurski.

t

,Jn LouisR.Heds President 9tu*d O$4/m

((amesP.Dodson

/Director of Quality Assurance 1/17/84

dg i

l

ATTACHMENT "A" UTILITY AND POWER PLANTS WITH LINEAR CONVERTER UNITS i

UTILITY POWER PLANT NO. OF CONVERTERS Commonwealth Edison Co.

Byron Nuclear Station 165 Commonwealth Edison Co.

Braidwood Nuclear Sta.

157 Public Service Company Marble Hill Nuclear 185 of Indiana Generating Station Illinois Power Company Clinton Nuclear Station 106 Niagara Mohwak Power Nine Mile Point Unit 2 12-Corporation Virginia Electric &

Surrey Power Station 6

Power Company Duke Power Company Catatba Nuclear Station 35 Cleveland Electric Perry Nuclear Station 52 Illuminating Co.

Consumers Power Company Midland Pcwer Station 21 Wisconsin Power & Light Edgewater Generating Plant 31 Wisconsin Power & Light Columbia Generating Plant 4

Exxon Nuclear Idaho, Inc.

6th Calcined Storage Bins 1

(INEL) 1

ATTACHMENT "B" LINEAR CONVERTER INSPECTION PROCEDUk.E r

PURPOSE To determine if excessive wear is visible on linear converter components.

PROCEDURE 1.

Inspect actuator to linear converter mounting and coupling.

All connections should be tight and aligned.

2.

Visually inspect the linear converter input shaft (this is the 3/4" diameter rod that is connected to the ITT actuator.)

The input shaft passes through brass shaft guides at the top and bottom of the linear converter.

Be sure that the input and output shafts on the linear converter are:

A.

Clean and free from dirt.

B.

Unpainted.

C.

Lubricated with either grease or medium grade oil.

l l

3.

If possible, energize the actuator and observe the linear converter.

The action should be smooth, with no binding of parts.

t i

j IF SUSPECT UNIT IS IDENTIFIED f

1.

Note damper I.D. number and size of damper.

l 2.

Note actuator Model Number and I.D. number.

I 3.

Note actuator mounting position - horizontal or vertical.

4.

Note date of initial service.

l t

(2)

TRANSMIT INFORMATION TO:

PACIFIC AIR PRODUCTS C0.

3133 W. Harvard Street P.O. Box 5277 Santa Ana, CA 92704 Attention:

Mr. James Dodson Director of Quality Assurance Telephone:

714/557-1710 f

- ~,.

.

W e ; as

- ~; A ---.

l

+

g'-

~

s.

s

\\..

m

'\\

t ';

. l, ~ ~ - - m.,. -..

't '. L ^ :l, T' );.{:'_

g.. a f ', $ c. ; ',.

3:.~b; U s '6 t.

7 n T.' - ;,

. a

..w..

y q.: i

' Q' j c 7,.. e -

., s,-.O T N.ma h _ '

^-

s.

t:

g..p

.d-'.. -

=.3

p. _,.

.d.g w

. ~. ',

.s

.[v. /-%.. %.

6.

z. -

g '

w U.

i

's

.s Jv

' ' ' ' ~. p. '..-

My ause_

s f,M.

j iy.

g i

ym!-MW1p-gun D

~

~., ~.t;Q

' T- :

h,. i <. $kt

- *i, s*cF.'g

..'. 5.

bq g,.-f*

-ct.gi..., L, * :.1

0. e

.2.......-A..t- -m d.

:: ~-

- g,g, a.,

s s

,'"./.*.8.

a h.

^

D

.* :. y ;.f. - r,,,M,.,(..,

a

(,,

t

.,s.

_ e

(:- -

Wkh.5f.?h.*,.

,,... _., M,... x... - ~.

1 x..

L

.[i%,=, 3 ' '

~

- r

- t w.:lp _%.,~;;

8 1

i l...s..- 1 A. 7m-

.u.

3 I.

^f..a v,..

4

- L t

.% p".

{D -

yt,,.,.. ; - :

3

1.,

v; ~v--- -. y w,,

,-y.. ~

.-c. x.u e

>, :. --..v..

.v.,....

.s

-n..

v.

w..r L, t : -

a,,.

.x

........t.w.

~ ~ p..-

s

-LINEER CONVERTER t '-

t

~

s s

+

k g

S g

T, y s.

'89 g.

=,

I A

s 4

I s

Si

'e s

%gJ e>%-.-

W W

\\.

\\

.g\\

.w

PACIFIC AIR PRODUCTS C Investigative Rep ~ ort No. 7043-QA-1 Linesr Converters f'

f

'1,

.,/

.(",,

INV STIGATIVE REPORT NO. 7043-1-QA Part I DATE:

January 17, 1984

' PROJECT:

Edgewater Generating Station Unit 5 Aldag Sheet Metal Purchase Order No. 001 l

l INVESTIGATION CONDUCTED BY:

L.R. Hess, President l

James Dodson, Director of Quality Assurance l

William Nagurski, Engineering

[

t COMPLAINT:

Customer reports that a linear converter has failed to operate and seal failure on the ITT Electro-Hydraulic actuator is excessive.

Inspection of two linear converters that were returned to PAPCo the week of-January 13, 1984 identified as Sample #1 and Sample #2 were inspected by PAPCo personnel and the following observations were noted:

I Sample #1:

Part - Linear Converter manufactured by Pacific Air Products Co. for Damper i.D.

No. SVM14Y failed.

There was no problem with the ITT actuator.

1 This damper was tested in our plant 3/9/83 and was subsequently shipped to the site for ins tallation on 3/15/83.

(

(2)

An inspection of this linear converter was made and the following observations were noted:

i 1.

The linear converter housing showed na signs of external damage caused by shipment er installation and the housing had been painted a medium brown.

(See Photo No. 1) 2.

The end plate was removed; no serious damage was noted to either the output gear or to the input rack.

(See Photos No. 2 and 3) 3.

Severe wear was noted on both tl.a brass shaft guide in the bottom end plate (Photo No. 4) and to the input shaft (Photo No. 5).

Note:

the shaft had been painted.

4.

The gear and the rack had an adequate supply of grease.

There were no traces of grease or oil on either the input or output shafts.

Sample No. I was disassembled and all grease and oil were removed to allow for a detailed inspection of the parts.

An inspection

(,

was made of the components and the following observations were t.o ted :

1.

Brass filings were found in the linear converter housing. (See Photo No. 6) 2.

The wear pattern on the rack seemed reascnable; there were no broken teeth or unusual signs of l

damage.

(See Photo No. 7) 3.

The wear pattern on the 0;tput gear showed some signs of abnormality; however, there were no signs of failure or broken teeth.

(See Photo No. 8) 4.

The input shaft showed severe signs of wear -

(Photo No. 9).

The wear measured.011 inches at the worst point.

The wear was conentrated at one end of the 3h" stroke.

(This may indicate that the actuator was continuously hurt'. ig. )

This will be dis-cussed.ater in this aeport.

Photo No. 10 shows the opposite side of the shaft shown in Photo No. 9.

There is no apparent

('

wear to the shaf t, only to the paint.

(3)

(

t l

5.

The output shaf t shown in Photo No. 11 shows:

i A.

Considerable corrosion on the shaft.

(This is not common; some concern that moisture was present due to storage, etc.)

B.

Severe galling on shaft where it turned in the brass bearings.

The shaft measured 1.249 inches at the point of maximum wear which indicates a wear of only.001 inches.

6.

The output shaft bearings measured 1.274 inches I.D. which indicates a wear of approximately

.019 inches.

(See Photo No. 12) 7.

The input shaf t bearings showed severe wear and the wear pattern was elongated to show a wear of

.007 inches on one axis and.084 inches on the opposite axis.

This is apparent in Photo No. 4.

Photo No. 13 shows the coupling betveen the linear converter and the ITT actuator.

The curious teeth marks o..

the coupling suggest that a tool was used

(.

to force the assembly.

(This was not done by Pacific Air P,oducts Co. personnel. )

There isn't any particular significance to these teeth marks; but, they are nevertheless, curious.

Sample #2:

Part - Linear Converter manufactured by Pacific Air Products Co. for damper I.J.

No. SVM21Y did not fail.

The inspection report on the linear converter is as follows.

The damper was tested in our plant on 12/15/82 and was subsequently shipped to the site for I

instal)ation on 12/20/82.

An inspection was made and the following observations were noted:

1.

The linear converter housing showed no signs of external damage caused by shipment or installation.

The housing had been painted a medium brown.

2.

The linear converter was disassembled and the parts were cleaned.

The gear and the rack had grease on the parts; there was no oil or grease on either the input shaf t and guides or the output shaf t and bea ri ngs.

(See Photo "A")

(

(5)

(

3.

The gear and the rack were inspected and no abnormalities were observed.

(See Photos

{

"B" and "C".)

4.

The input shaft guides were inspected and showed no wear on one axis but showed.014 inches wear on the opposite axis.

(photo "D")

5.

The output shaft showed the same defect; as sample No.1 - namely, corrosion av.d galling.

(See Photo "E".)

6.

The galling on the output shaf t apparently caused the output shaft bearing to turn in the housing.

Notice ridge on autside of the right hand bearing in Photo "F".

From the data gathered from the inspection of the linear converters, it is felt that a test should be conducted to determine:

1.

The cause of the premature failure of the input shaft guides.

(

2.

The cause of the wear on the one point on the input shaf t of Sample #1.

3.

The cause of corrosion on the output shaf t.

4.

The cause of the galling on both the input and the output shafts.

5.

The effect of the paint on the input shaft.

6.

The effect lubrication would have on the shaf t guides and bearings.

To t.1c t e n d, Pacific Air Products Co. will start a life cycle test with periodic inspections to determine wear versus com-plete or partial cycles.

This test will be conducted on two linear converters - one run dry as per sample returned and one run periodically iubricated.

The wear in both cases should be measured throughout the test.

Since there is no other it.imediate criteria governing the life cycle testing on dampers, the linear converters will be life tested in accordance with the tests required for actuators

[

(6) l

(

under IEEE STD. 383-1980.

(Copy becomes a part of this inspection report.)

Namely, Attachment "A":

Normal Service Aging Simulation - Pg. 18, Fig. 8 Operating Cycles Under Load:

Modulating Valves:

2000 at full and 100,000 at 20% stroke.

Two Position Valves:

2000 at full stroke.

This concludes Part I of this Investigative Report.

/

MH

~

' Louis R. Hess Pr[sident

, /f M d.

Rb /m J

P. Dodson, Director of Quality Assurance

(

4 (W'

William Nagurski, En'g(neering

dg i

k

A t t a..g.. me n t ch IEEE Std 3821980 IEEE STANDARD FOR QU/.LIFICATIOM OF NORMAL SERVICE TEST DATA Det flADIATION EXPOSUHE TEST DATA octRATING CYClis UNDER LOAo: Cast til asooULATING, VALVES:

2.900 AT FULL & 100.000 AT 20% STROKE

)

two rositioN VALvts: 2.SoO 1.2 x 10' RAD NUCLEAR RAolAlloN: 48 )

70 N 108 RAD 140 YE ARsl

~

1HEResAL Aolwo SEE 55.4 16 ENTERNAL PRissUR12AfloN to s5es'G FoM 3 MINUits INIIlATE sPR AY WilHfN 1 MINUTE OF sf APflNG FORsf TRANs6 TNT.

l MAINTAIN MINitaUh4 2819oUH DM AlloN.

(

-365 0F/7 ' PSI -

j 400,

At gage pressure CYCLE TEST ITEM r 115 *F/ O PSI 360 -

y

-315 'F, 70 PSI 1

280 #F/36 iSI'

== -

/

ti

\\

4

-250 0F/15 PE

/

/b 1

'" 250 - -

"o

\\ [

k [

EriD CH. b'G E CONDITli;NS ~

TEE AT 18F PE R MINU1 E gl,D 200 --

(

. f-12C

') F -

EVERY 3 HOURS m.

e t

t t 1 f t t t if f G I I f I 8 I E t

0 105 15M 2H 4115H 10S' lbM 6H 24142345'

' 10 '

15 ' ' ' ' 20 '

' ' 25 '

'30 0 sn s'wou o va"cvl I v act R s (NT F st.

NOTES: (1) 'Ihe actual qualification levels are those obtained by subtracting margins from the test profiles.

(2) Descending temperature changes must be concluded before conducting the next identified cycle tet.

(3) All steam environment during DBE simulation for temperature abose 250*F. Relative hunudity (RII) to be

> 95% when temperature is below 212*F.

(4) Chemical spray solut;ons:

(a) 1.5 percent by weight boric acid with sodium hydroxide to pli of 10.5 at room temperature.

(b) 6200 ppm boron as !! BO,50-100 ppm hydrazine sodium phosphate solution, pH 4-10.

3 3

(c) 1.146 percent boric acid by weight and 0.17 percent sodium hydroxide dissolved in water.

(5) Superheated steam conditions are required for first 12 min of each transient followed by saturated steam at initiation of spray. Spray shall be terminated at end of first transient and not reinitiated until after 12 min of second transient. If superheat steam environment is.naintained, adjust te'nperatuna and presture accordingly.

(G) The user should de advised that no single chemical spray solution is recommended during PWR testing.

Therefore, he shall assure himself that the solution selected will be acceptable for the desired qualification bemg sought.

(7) Use 2 source having average gamma cr ergy > 1.0 MeV. For qualification of an installed life less than 40 years, the normal service radiation snay be proportionately reduced, if suitably justified.

i j

(8) Chemical spray rate approximately 0.7 gal / min ft' of actuator projected herirontal cross-sectional ares.

(9) Sample actuator is to be operated under functionalload through one complete cycle (on-off actuators)or 10 i

cycles (modulating actuators) at times shown. All cycles are performed using nominal input power values, except that cycles e and f are performed at minimum input power value, and cycle g is performed at maxi.num input power value.

Fig 6 Qualification Type test Parameters LOCA Inside (PWR) Conteinment, Case III IG

IEEE Std 2821980 IEEE STANDARD FOR QUALIFICATION OF NORMAL SERVICE AGING SIMULATION DBE RADIAllON EXPOSURE TEST DATA l

OPf MK.!ING CYCLES UNotR LOAO;

$$oOULATING VALVE $2 3.000 AT Futt 6100.000

)

I AT 30s STROKE I

T150 PO58flOst VALVE 5.

2.000 0

NUCLE AR RAOtATION!

3 e 108R AD l40 YE AR$)

THERMAL AGING SEE 55.4 E NTE RN AL PRf 55UR12 Af ton DeoNE l

400 -

~

DBE TEMPERATURE. PRESSURE TEST DATA l

APPLICABLE FOR BUTH LOCA AND MSLB

~

CYCLE TEST Y

EXPOSURE

~

E 300 -

At a pressure gage g

227'F WITillN 3 MINUTE

p D

5 PSI MINIMUM e C

$ 250 -

"o

~

3 200 -

1500F/0 PSI MINIMUM g g _'

(-

(g) --

E ACH TR ANSIENT BEGIN AT 120*F f

l l s ::

:::n::::

E!4 1-2 3 4 5 6 7 e 5 to 11 12 18 24 5

to 15 20 25 30 1,DumiNo mist 0

HOURS l-DAYS i

TIME V4 tut 1 ARE SUBJtCT TO CHAhEE.

USE A $40UtO VI Alf Y ADEQUACY NOTES: (1) 'Ihe actual qualification levels are those obtained by subtracting margins from t' e test profiles.

a (2) Sample actuator is to be operated under functionalload through one complete cycle (on-off actuatcrs) or 10 cycles (modulating actuators) at times shown. All cycles are performed using nominal input power values, except that cycles e and iare performed at minimurr, input power value, and cycle g is perfort...-d at maximum input power value.

Fig 8 Qualification Type Test Parameters Outside Containment (BRW and PWR), Case V f

i IS

. - ~- %

r-SAFETY Hfl#.TED VALVE ACTUATORS ICEE Std 3821930

(

Appendix E Performance Verification Test i

'1 If an operating performance verification test E2. Pneumatic, Electrohydraulic and (see Section 6.1 of this standard) is specified, Hydraulic Actuators (Cylinders, Rams, the user shall establish the performance verifi-Rotary Vanes,and Diaphragm Double-cation test requirements. The test procedure shall be prepared by the actuator manufacturer Acting or Spring Return) with the user's concurrence. Minimum per-formance data to be taken for diffe:ent types of actuators and recorded during the test are At least the following operating performance listed below, data shall be taken and recorded during the test:

A performance verification record shall be (1) The no-load and rated-load output speeds prepared based on listed requirements. This (2) The ope sting output thrust and torque record shall include positive identification of characteristics at minimum pneumatic or the actuator tested: actuator designation, serial hydraulic pressure number, safety-related function, location, and (3) The maximum thrust ortorquecapability valve identification number if applicable. All in each direction at maximum pneumatic or operating performance data obtained during hydraulic pressures the verification test shall be recorded.

(4) The rate ofleakage of piston, diaphragm, and vane seals at maximum differential pres-sure

$(-

Hydraulic-Motor Actuators E1. Electric, Pneumatic Motor, or E3. IntegralValve-Soleno.d Type Actuators i

At least the following operating performance data shall be taken and recorded during the At least the following operatm, g performance test:

data shall be taken and recorded during the I

(1) Output speed in each direction under no-test:

)

load conditions at nominal power supply (1) Pull-in voltage at maximum operatm, g (2) The operating output torque or thrust pressure drop characteristics under the minimum specified (2) Drop-out voltage at maximum differen-power supply tial pressure and at no pressure (3) The stall torque or thrust in seating di-(3) Minimum operating pressure at nominal rection by by-passing limit control devices

- N*E' (electric motor locked rotor input at maxi-(4) Internalleakage at rated pressure mum specified power supply or at maximum (5) External leakage at 1% times rated specified pneumatic or hydraulic pressure for pressure pneumatic and hydraulic motors)

(6) Test fluid and its quality characteristics (4) Confirmation of proper torque, limit and (7) Special application requirements (such as auxiliary switch action, response time, duty cycle, flow rate, etc) 39 4-mv=--

, +,,,

hs a su %= mei-2

' ' - * - * " ^ - " - - ~ ~ - - ' ' - - - - - - ~-

k

(

TEST ANALYSIS LINEAR CONVERTER LIFE CYCLE TEST The Pacific Air Products Co. linear converter is showing abnormal wear for several reasons:

1.

Due to the heavy loading, possible misalignment, and cycle frequency being encountered, the linear converter is wearing faster than expected.

2.

We were wrong - we calculated that under normal use the linear converter could function for a long period without any maintenance, lubrication or parts replacement.

The facts shown in this report make it obvious that the lubricated unit will have an expected life span hundreds of times longer than the non-lubricated unit.

(

3.

The primary wear points are the input shaf t guides.

I realize that the output shaf t bearings failed before the shaft guides; however, the induced side load and. lack of lubrication were the cause of this.

Had the loads been rotary as they are in an installed damper, these output shaf t bearings would not fail.

The primary causes of wear on the input shaf t guides are:

1.

Lack of adequate lubrication fnr the forces acting on the input shaf t.

2.

Thrust caused by the pitch of the rack and the output gear.

3.

Possible misalignment causing the input shaf t to deflect.

If you study the comparison photographs attached showing the comparison between the lubricated and non-lubricated units, there is little doubt that the solution is lubrication; however, (i

(2)

(.

there is good reason to suspect operating conditions that are causing the cycle frequency to be much higher than those stan-dards called forth in IEEE 382.1980.

I would like to offer here suggested areas worth looking into - such as:

A.

Short Cycle or Hunting:

At system start-up, the controls may not be " balanced" and adjusted to the operating characteristics of the mechancial equipment.

Oversized mechanical equipment (boilers, heaters, fans) may have such a large capacity that when once energized by the control system, will evershoot the set. point of the controller.

The con-troller (whether two position or modulating) can bc very sensitive and set with a small differential be-tween full-load and no-load signal.

The result is that the damper actuator may be caused to cycle full-load to no-load (open to closed) con-tinuously because equilibrium between the mechanical system capaci y and timing cannot be reached with the sensitivity and timing of the control system.

The

{-

result is continuous cycling of the damper actuator;

" hunting" for a position where the mechanical system output equals the requirements demanded by the centrol system.

This continuous operation will result in stroking the actuator and damper the equivalent of tens of years of operation within a few weeks or months after start-up.

ITT and other actuator manufacturers ( Li mi to rq ue,

Raymond and Rotorque) take specific exception to con-uous cycling of their actuator at heavy loads.

ITT has a continuously ramming hydraulic pump and motor 0

within their modulating actuator which provides a 60 C.

rise.

If the actuator is placed under load, the motor current rises and the temperature rise would exceed the allowable amount if the load is continuous.

Under allow-able loading conditions, ITT devotes their modulating actuator service life to something like 50% of a two position actuator, yet the power unit is the same; the difference is only in the control circuit.

B.

Induced Loads:

Induced loads created by the installer removing the

{

actuator for ease of installation and then reinstalling

(2 )

(

it (perhaps aligned properly and perhaps not)., Those curious little teeth marks in Photo No. 13 are,still thore and unexplained.

C.

Seal Failure:

Attachment is a quick review list of some of the ITT seal failures we have been experiencing.

There is not a set pattern, no single batch, nothing you can really put your finger on.

Example We recently returned five actuators to ITT from our plant all showing the same characteristic " hydraulic oil" leak.

These actuators had never been installed or operated until the ini tial test.

The following is a sumary of the problems:

Unit #1 Model problem 1

NH95 Dump valve leaking.

2 NH95 Check valve leaking.

3 NH95 Cut on ampli fier "0"

ring.

4 NH91 Nothing wrong.

5 NH91 Low pressure dump valve leak.

There is one thing that is consistant, it seems that when ITT makes a repair, we no longer have problems with that unit.

CONCLUSION:

We feel that lubrication will be the key to most of the problems related to linear converter abnormal wear patterns.

A good maintenance and lubrication program will solve most of the prob-lems to that end.

We propose the folllowing:

(4) s

(

1.

To undertake a study and lubricant testing program at our Plant to select the most effective lubricant for use on the linear converter.

2.

Based on extended testing, we will recommend a maintenance program based on the severity of use.

3.

We will initiate a parts replacement program for those pa rts al ready damaged by wea r.

We have studied in depth the abnormal wear patterns. We feel we have substantiated our finding and our pride in our products makes us confident in the successful conclusion.

This report respectfully submitted by:

PA IFIC IR PRODUCTS CO.

l

%;n.

Louis R.

ess Dresident LRH:dg l

(

t. t.

>0 AcT-

"C" ao e, s7oc.c goes: ;s-1-3 6 'l i bSofo AlH4l(AH40 637(o Et4eue A

12-( 3 3 16462 NH41 fu t 1 it tu 6004 Mars mu. X NH91 X

NH95 M

r x,

" H 9 s...

i v

NH 45 i,;

t

.X....

.i;,

Id 3165 IWfo3 IAH4i (s386 et4suATF-R.

~

4H42 X

i BHQS At i

S-30-83 169o 1.

AH95 (o380 coGewe7EE ~

N..

S-l-6 3 JLISA NH'95 '

6009 metta u n L. X.

i 1

NH95 4

X 5 ?o-S3 l588%

NH9"a bool M rta u X, '~~,

'94-82 l 518 i NH45 6069 in5E5 ~HfU ~ X [~ ~ lo-24 6A 15065 .. tv N 4 I 56co._e>YRoo. . ' 3< ~ nH95 x. NHqs __.. _. x.. tJHQ5 X (. r4H95 X nn9s -. NH45 x. Y NH95 ,X ?c 10 15-62, 149%I tvH91 5953 PERM K S2782 19 79 % AH9i /o39 7 ~ ' ~ ~ 5 ~ t 19-92. 14 159 NH9l 9009 rnana Hiu X 7d&8L I4637 NH9i CAPTcrme Bxt 5 601 24nmocob ~X: ~ NH91 1 \\ X. OH41 X 3-Irr B L 77tl3-3 ~MRS 5500 c.ueJTop X f4H4 5 1 X 0895 X NH95 1-X 71541 N12(. . Al H9- ? 5959 CArawan K AtMTbR6 bEFECTIVF @ UNPACKIN(= 19 AcTunToa.s P.ewRimb FRcm acaseTed 19

Attachment "D" IntemationalTelephone and Teleyaph Corporation 9 \\T 1 fis (do1 GeneralControls 5\\ w b_n-Division 801 Allen Avenue Glendale. Califomia 91201 (213) 842 6131 January 23, 1984 pg Pacific Air Products Company 3133 W. Harvard Santa Ana, California 92704 Attention: Mr. F. Neal

Subject:

Inve@.igation of returned units on RGA 6254 from PAPCO. Dsar Mr. Neal: The items enclosed are the results of our investigation. Item 1.0 One of the two NH91G2002L103, serial datep8046B236323-02,per-formed to our ITT General Controls Spec. and no discrepancies were found in regards to the reported failure mode. The (- other unit failed to operate in responding to 4 to 20 ma signal, as reported, due to leakage of low pressure dump valve, which could have been caused by impurity in the hydrau-lic oil or an apparent overload ~ condition. - Item 2.0 All three NH95G6602L127, serial dates 8042B36326, had recycle problems caused by: 2.1 Leakage around the check ball of the pump caused by im-purity in hydraulic oil interfered in the seating action l of the check ball. 2.2 Leakage across the low pressure dump valve causecI by either impurity or apparent overload condition. l 2.3 Leakage around cut o-ring of the redundant amplifier caused by bad o-ring or improper assembly. NOTE: It should be emphasized that recycles will not have an effect on the function of the' actuator. Recycles are a normal occurrence and will have no effect on the actuator life or the desired final control action. S

cerely, c5)$

m Sina Mozaffari Quality Engineering SM/rc

i1rn Ffs \\7.JotesATbzr j4:00 i'n S*' } /: to j% is.

l 4.,

'I 'ra To 7" \\ U.% ; :. N Moovi.nhpG4A1 go 7; s Titone ~' O i .H T I ~ W /., L u B 6'..[,,

,L_,

l 4 tws f 4 tys comy,p 1 We, ..l pias I i 50,000 75.068 ico,000 $$$'s I 2,000; ,5,doo N' 106 CYCLE. C9%s c'tcLE.' CHAu4e c'fCt.E ; CHA96E c' tot.E E9Aut>E CYCLE CH8ME 4ese,6$7* r-I f I'h-liElf-A>RErnEMF AREA It / / A'6 B r.c H /, T f'n biW H / t/ rivlWt p / t/ g V t3, i T LJAbGD sibE OUTPuTSW\\FT HoGE I.S o i I:50 t n/C l.8WI.91 th\\l/ 01c hst ?/I.$st f os 3/ t lt t.321/t.61 t Ch/UlG l.M/ WI 1 9 31 Hic i l.fiel Hj G. - %,A m..a l1 UtJLOADEb SibE Oti!PUT SrsnFT Hot.E I.50lb ~' ~~' ~ ~"' ~ I. I, ~U PPER ltJPUT SHAFT HOLE I.o 30 ^> la -i ~ ,,L _uP ER. It2Ptyr SH6FT691bE o.b.(weripsit') 1035 "/A. i- _l u PfER.19PUT SHAFT (,Usb6 1.b. (uor susTt') 2.753_ "/4 ~ i- @4 m d g~ W.Y 'ng sp> ,%'r i,1 g indusr> l I.oADE b SibG Ou1PUT CHAFT P-.EARin ob : 1503 1.91 u .07 7 .Ndy,f[ tu I? ' 8'51

C'*

'"# *'# Id' O ' * #"** Lc4Dt D StDE OUTPUT SHof-T P,EARipG.Iby 1.255 1.'A9 6 g'30 I~ 15horstAb SibE otrTPUT SHAFT BEARING 065 1 501 1.441

.o13 IAN[N5f

.6 Q legat/p4os mstag J f.1 a54. drI/515 1/49 US.037 e i ~ [ tehtcAbeb Sibe cuiPuT SuAFT dEARiuG lb ( l.as S 1.2Sb - t.00I l.35 f.gt.co8A.id I is//.20 myg) tj5j/.45J -M,is* 1.ijs t.n2 tog -m1 l UPP ER tMPur SH AF'.' o D (THftE ADEb enM l .~l'{ 9 .~)'N .0 0_I _.11,$s stol/f#> So/.752 t.e87 000 74dM4? -.008 .71S/141. 001/,ltc ~,co i 391/aqq . f /c. _ pgg/.Tf7.sM2 ~- ~l~oke R supuT St AFT OD' %.799 , /43 .,) /C. j YJd Mcf,4 h fsf.71% l 't.W;U5/@ -#D/9.8 f PWi! -oN6d' 85fVI.26 dF/'Mi /.m/un.opfid [~ T-toAbeo sine output sHAyT oo. hahg. 1.160 10._LO. / 'g/c i.m .oo r 1.241 .co l 9/c l.15o l untoAosb cibe ou rpuT SnAsT oo 1 2.so i.a s o 9/c, i. _L __totnen. iwPur. Sun FT ct,ibe ib (iusvittus') . is s ass /,2g +/r.coi.155.v.1 /c./t.ow.lo/ ass t,st o., 757j.wo ig<,7,q,.7577,W tMoM l t> P P E P-IMPuf SH A F1 GusDE lb (8usT Att:0 .755 .151/.76 6 t.c','iA m '43/.F3 iW A et,17a/.7n tois/ on 77/ M t.oi6A ssi 7u7. 97/

t. nil /r.is, to fv

.* a a G.

u > t1 s2 Gu e,vr __/_;._ h >,q.1, M/c._ J. Sof,,,, M/ c, f,pCp_ .o o / Ie5of QC p ~ 2 LoADEo sibE oulPur5t) AFT iwt G l.501 1 50'/- I,50o col ~

2. _

uMLoAbEb Gibe OuT>uT SwAFT~ W]t E d.5 o1 t/A J ~ 2 UPPEP, INPUT' SHAFT riOLE 'l.030 i 2' ~~U PPER. JMPOT SH4FT GulOE Q4 (4cT INSTLS[O_'h :> 3/I,,_- ,,,,"( ,,e_,, ~ J e ^ '2 y;PER ipPuT SHAFTGulbE lb (PJT iusTL3 .~7 5 '3 t 3/6_, MC,_ t.500, _/u/ c,, _1,./R ,o o,, J, f l.5 o/iWo o/c./.elo 15afr f.yst, ofghn4 1_ tonoeb SIDE OUTPUT 5 HAFT BihRING ob 1500

h500, f

, 2 ,Lohb_E,b_S. ibE ouTPuf SHAFT atAR.t'.36 lb 1.255 f.2%){,n5 w/c 1.%55 e#c i.A55 n/ c._ g gc7,3lchp @f.21o..es .t,i5 1 Out4ADED SICE output SHAFT BEARio6 OD 1500

1. sot

! 9/c_._ l,Sooj "/c 1.soo ^> /c /.'/ff_ -oo / tSoo olc _ c. ) 2 UutoAbt-b SibE ouTPuf SHAFT BEARING lb 1."15 5 lasYi 2M 4/c l.M - 9/c 12.55 ,y/e. l.159 a/c 1255 u/f-J 2, 'J P Pert. In Por CH9FT-o b( THE E At.Cb ENh') .I99 .~/4 9 ,J/C .~I'I b N/C, 7e u/c_. p/q N/ c. Jag,. ,,,,00 ) cg 3 I ou;fi p. sp pot % AFT Ob i 7'19 . ~7 4 9 4/C. ,-) *H A> /C, .M4 "/4 ,h_ u/ t- ,7% g , Col ~$ l.'A5 0 fa$ct 9/ C.' l.7 5 0 /-/( f.2 5 3, f,001 f,M[f'& '.*.00 l,,g 77y3 '~hg _ ((571 ,{ Lo tt bE O SibC outf*uT S9 AFT ob 125 "/c /. 2.50

/c _

I;3 .oe2.si r+ 2 outoAneb sibe OUTPUT SH AFT ob I 1.'750 /250 9/ C: IMD v/ c. Mr/2[7_r.co[,.M @95 gf.est ;;55 757 $ #2. i 1 1.oi se a supur sunFT Guibi'[ib (iosrette n') 7d a gs a p 9/C .W 7 _f.do 2. .7 set t, 755[ 55 vc

1'i >/15: + dol

.)S5/.7y t.co / .755/ l 2. uPPen. rupor snarT ousb9 in CiusT4t.tetd ,75 5 155/.75 5 N/C f 7

; pro Cycur 1-t%'l

.J. DATE oF TP ST~ !"'" N ~ ), T E-i / ise mm e stee rm.oi 9 =: TF.;r TECHmcl Ard - JN ^ J /00000 CYCt c 190.fc'{ w ) }$G0 litn Grbn7~ ~WScutm car.pt. 2 1/0 0 tv1 120.sc { ')).fl . m. ll4gm, t.. 19t (7go) c m e n.oc., sus ,,.sim ga. s v"*** S CMD C0".t+. 87.*? o P/n ,, fik.'.'y'Rn,l's'I g g,' /fg' f le /Ini , nc <. v s v c //r.. W A Q. - z uar G-sa n w<rr uy q

=. .em j S 3, PHOTO No.1 m. + ) ,.o 7 / R' \\' %s 4 P+0'] NL c u

i ((,f, y ' ',,. yk. " 't,, f, .e. _ - -.'s. y- .-8.* '.k ,,,e,m-wx ---u--- e'g " O.[' ., '( ' (. il 2 Q%,,.;M:. 'I. ? *J'f..Y, ' D. / j'3.... 4N :./,. ' ~* y k" ,,g.,j- ',: ~.. ~ f.jQ. <5 ~,. ; ~3 7 :.. ;.yg$.. K. %. ~... y ..4 _a _(: .,..,j we ,;l a;'l W. <*u."y, y ,. ng:. h, . ~ w + em . ;,. ~_. W. :y;;r

3... :

.-. N'. - yg: 'r..:q y.,,. e, ,__..g . h,,. f?[: v ~ k a; d '. y , ~~ n

,;.. f: s. x. %+:,,..

rj ;f... m_ \\.. ^

p.., %,~

, *, N.%.. j, i.;.j m. f*- ,t...; .5 ',% w-._ 4 .. 3 'c j

^

. <,/ ', y, Nf;; '*' s,- _;, Q v.4 & y 3.. b,, " '. j.y} G. %.? - 4.1.. ' M d M s. F. ~' - ' ' [ ?, ._.V.4 [ j.Qg ', h~j~J~.. M.. @ M-QWMd. 4'.h(Q \\ f a% j.ja$ $ ' v., m ~ s...c c.,.. _.. .. ~... l [

M. $ g,&,

g.. G q. .M.. +. m. I _r..g 3 { w.A .Y".. [.,,. [ + f, ",.., ' h. .,g, . <, f- . ' [ ~ )y h6, I. - 3.h,.g..[ .)1 Q: ..[$g7 ' y< m-g ' ..,.,..y. .q. ,., %, 6, ; ',;g.'.

- w:* g': ;a% m.s

.y. EM.,. %. ;.W }.:n..,..,;:., i ' ef,..

e 1

..?w-. r. .s 1 - 9 ..;}. y [ ;; ~',< q.. . A '..a.=.v.g.: p,..,,g; ( %.an ;* ;.3 :{(;19 g,. Qg. L, - *.

s v.

re - ~ .y s.- t. .r.. :.. ~ i %. -.....,.>a. w k',.. '}(( o , '_~.'__:._=',._.. y,. w (;..... .m l, g. A. ,8 m.g

w a.

t-.,. + ~. -... u.. - 4%, s .n <=e .-n. .g g. m ::-' '.:. -s '- - ,%~ ,4 p' ,f -e.' ,g.. .'. f.,, ' /. j *.* ' to. - ?. .2... '3,.'.a.'5. r. p' v - ... x; ;e.;..; ..w a,

,, y 5

f ;.- i.; ,y, a i I

w. m., :., 5,.[ q :...

w. x *

5. j g ;;;3 a

y f.

g., y

. ' ;t. yn.,,;,4 s_

7..:.. g.: 4 -

.:: :.,.h:.. ,,.:,ye.. . s , yi. g ~ s#.,*>..E j.N., '.# ;' l".- . v.. u,4.,s .:......s. .~ ,,. q - ...r . [k ', { ,%'[' ' f 'j. 4,: .e v. a M W W) M :. $ 6 " f f M. x M M Q S g 'Qj),

f.

-g as. l y m. J n.: cv .m.v-2

.c. 3.

2.v s.M.a. . ". ae w.. m y'.2 : J.g: 4 +, 4.~ p. V - - c.<. a. 7 7.,. . ;. O )q.i'.,4.h.&p] ..c; .t l l 'ig's 1 ] * 'O; g, V Q W. m., +- - f. 5..f '.% ?. 1 .... I,t. :- 4 '_,. ~,'... _. 4 ..,, 09.. v..., . np '.. g --+ )y:':i;p. .p.. p ...g . ~.: Me, ...-*- ht. y..,.._. ; :.

s.. g -,.. - e. ~ -

..g . 9 ? ;;-. 4 7, 'g ym s

f. 9.. -

.c y r n:,.:;* f

w..'.:.~: j f. R.{. 9 ls m a al[

I ~: g. .;L.. 9; \\ ,.., %.,x... %,,... ... + .u w . M... w.:=,... Q. -. -. ~; n 3,x , L..rm

m;...

.,:.+ 1 .a.. x...... u.

+s-

- m: .n-y .s: g: -. :. - p. 2 + p I . -.. &.g.. .X.. 4.m. 4...

7.,.._ n

. t.,. s y 7 '..', ;. y : j.;.. g 7.: ...._... ;i,7., h.. 5 4_,y; y='. W...$;:w. a v. :,g. y. ;p> u x s 9,- .v. s .6,- u u _ q.q _. g.. p; .Y.,_ hfI'Y[5l - :f[ .l..;

l..

_:? *.

~ M s..u.., = y n. 'h** A34~ l

D

.,.3 -y, 4 -s n, ^ 'S g gi's - %>w%4 b Q'N / 9 4 d W Y C c e PHOTO NO. S g. J a g a s 4 i = g ~ . Q. s j. V 3 e ~ 4 4 'e e ' E i .i . ~' ~

_m a y m. =m

. = =

Y E.O 9 'FO9 % * 'f W* h ,.pp

I

? 4 1 m'g"' e ?,94},,, . g ' s-.x _ =. e v = r;;,.f ~ ,p wQ,7:3 h - <,Yg q u Q~ .%,.Q-f $^, i .y l F.h w' s4g.. 9 0 p s.4 d e, ' A ,tMsQ;.. ^, %d 4 eb., +- 9 J. 9c t 9 ke ! .e 'h v s e. a b p* GM% i e t no V. s n N, f - ^ W' !* A .WJ 1 t's; 4 j t.. h 4L. 12

m..e&-.

rc

s-4,7in

,&;?. :i.c er ..,x,. - '.e't g;. t-y e '. p D E e y b y'_ .g ' ^_' n. 4 i 2,. a Id a .k m. s + 4

P w

( ( ?.s g, as mi 3 s; sn ^M .-t^k b

c;. J@.. ;

-+- ^' tat 3p yt, ~_'. c -: :G J

_ g------;------ r- - ---y~- ~mi 7- '" ~ v 'f ; *,a h;F l; 3l:'?1 *~,

" ~$ (( '

fH 1 l +4-3 1 1

6
-Q b, r.

[- q s i '*-V 'Q,.'. l^p .,..c s f} 6e?' y ?n., Ph0IP If fl. 9 .~% e te+ r i g o f 1

4 35 ' s ' h s s 11 ~' .,,? gg;- ^ I, 4 6 4

7._ _.. - -. _ - ww ---= i.wweve us7aruarwxwMurimw.zvN6-M-a%T'M"h JE#rMrM9Q9MWWM)ll7.UTM m.,,,. v. - w _... -: m gww g g.- .,g.. r yw".. m +,, ,w., ,,,,.y . J. - C k, ; ~ %t% C 1 C, ~ c wc . -w*m. ; , t 0*-31 o ^2-~~..J" ..- 4, c.,, 'A ,o y.- .a t.< i e i,r n ' - ~ &c l \\ c: T ws+ +n r n r CL.. a.., pm 4 - %y. = t y .,n, a.., ,,,, q a s,,,,, ; ;.- n. a.J,,w~ + ~; =' -.s u.g,) m>

w.,2 s.

r.s. ( m ~.. _. cs; K Ml* .4..y.' ,7 r>. e l 3.,h,,., [b $ '. +* = d b-I ' ^ [ ~ ~ ' I. " 3 "[I h ~ l:" _ f.: ; g}},'(3.,. j, 4

m " m ~ _-

p . y:31 '- [

,w. e

-v.,, t.a, e,; 7.

m.. w.m.,.,,- k.

6- ,-. g- ~ ,.. ~. r ~..,., - a.: ..,>6 ~g ,y* m, s,, ,w ,3, , ~ - yv \\ Ls w.. s,. p c.. o. w r g-. s vg..'. >y;. s.*t,.,,o.y^.-.. c., r"2... =. ~. t A y. a y ..+4.*~ ., *. v.e - w,

,, 3.,: f. 3.,

f... i FQ g 1 f , p*.t ' l',-.c,, g 4 m..

;

g.,,, s g,','

( g * *y m.s, m.,7. 7 g4.,.a% ,,"m.,.C,: t. m :+. 7z,, n) s.v q + ms-M, ._:,,..,,.,,j w...., + =.% +, pm,,. w,.,- , ~.,-.,.; ~....., 7: w ..-- w w, t w. o ... -.s r ,;.s..,, _, a..+. ; -~ +, ".. - g x y a k +s + - , ;, ' ;,; n. ~ ; n,.

-Q

,w.; i.;, ~.,.s e,_ ;.. % [*; n es * ~*,,~n.,,.-,,.,;", g,,. v, < y ~. **.. ys e .) n 1s s,,. ~ 1r

f ^, ',, *** A y,. 4 31.#V 4 h' *y, y,
~

ls. 7YW_ f T +,.

4.f'% b-./* h h'4 N -r'h " #yw * #1

<,', h,.,; ,p',,,.,nM^. ,. s. .v e' ., p _,y ;,, <,~s..,=s,. r, g_,.~.,' /w: ,xsl ~,. y a y.,s.

w. ya,e, a

y9*ya '.3 F$

<Qg,A e '

,z* + 4-- 1 i, ' ". - u-ms .,,3 ., 4%,f-y y y. e, y g.,,... ~.,a S 'g, n p*, ~.E., +4 j.4. rC. 74 N,; , -.. - y - g,,g..ii.,6.L g. y,, y t u s p9~ + y, 4 *

t.

,m-4 . w*.. s 4 ~., r. efn.n :w*a *,,%g Wh g, _<a..n.- m* n

,,, A..- %,

y,, j g .~ % %,L - - ? t , w,. 7 4 y ">L Hg 'G ., f;,f b N',*c? tWl W. = f. j- ~n ~.. l'~~ A y r. nQf.. ~$,.C $,y.Me.S $m.,#. Y, b.mg+$ 'w,+YC,W ? . y."., YR?. $.- e ,A J M n,u s:- ~ , h;*~."., ', D.E..$, ! L if - :s~ s2 w i e, y g g.q t. c .m g,C y .r r._ ,e -*.7..',g'~,..' - b g. ^ a., ,4, s ,l %. G. e ' \\ ?*A *,g ) p g,W"'R,h y.s,tumu,4;y v f yMS',. s 'y.,, j..&. s wd.r:, # *, i4 ',y f,7' ,,s,, s... g ,.e@h }h WO ' M Q %. v hN h.h$Y' !$%'YhhDh h-k0 kR $ . Y t -i < s i n: pi,.m.w:Ma%g'amM b.Y's$ Wl'0!f h?..,. 5 h a y~&WWx um ^ %, Mc W-W yyR - n;mn 'pm.a *e@mmy ".Z. : ~.'m.y: - m i y.. O. &, w. g ' f u b nm v7 n ap. m...C.( ~g.p;,.M. m!?;g;7 f,*h... p w w s n w. ';

p.

l u 7_-_ y.W%., s.mn~ i;%:. ~ m r. %y -. ;.aw. s, ;;v %. 3 4 rwn.; ~.e m;-%,n.g .r-r % i, 7 *'. y,,a.,.1... ,? p,, u %^ a %r, - - &e, Ay ; o g+- r,y s.< ,g - N l'O, m M.*,.y, $. Y ..w GW t e m! . q ;. % s k .. wa,e. %. '...& % 4 * ."4,.h # ', w < m.,,4 1 rc q. e

W3 b f y p.su QC 49mN ( f

'N.#h4 y4g gab qg f ,0 g powNAC#- pg, ,M g j.>

[

y # *' m.,~.'*m,e sW d a e.e a

g

.-, a... -,..*- 2 <m~f a -:t,..,a p r ~.. w. - L,- +~% c_ . c.,. ..e .,ca- .n,.. m.,,w.,. w

ipz'M &n* W,.i" %"Y,e.

. r ~ w. v ,,N,,'.".i.*,-<v--A r .# 4".m n '[a 4+ Mh. e-M % q% **M"

- -- f gj d.. *.A p, ; ( "-.., --

t m. s m ,1., '8 U t m,m w.- %y f4:&,A*

- '\\.*

g.N.* g &N. A t ". .a.g'. m-ny 1 et-k,

.- sa q.t,3 g c.-

9n/,, y ..,*, 1-.#'- \\ p r ' f ,. p. v" A A.4 p'. ..a .-Q,J A- <Q** = , h+. 4 - / P . - w' S. Q4.e &.,A.4?4%RC..,MM g.r**:-N, C.,,L. D..@, -,j g-~ m.

s e

e. wq . u o -. ew ^y

- %< b;f"is%.

g* lh, glb.G n: W.d' <. M t a M']7lW W~ W J Z < f' v Rp %* g .' G &*Q @%,m - D m;5 l . p 9,.

D t: M3 W.

~ n b i s fw.., ,, y.+ 9 -sw, i - b' . *[ .. n nc ny t- .b

h

" h*"- a-U n m; YL w ).d f ~2.*K Q. n. MA.NQ';6445,.;+rbSbSQ&'Q&V&f "f. ' -'ty. ft. pn ? .' Q f' -.g.* ?sz .x W_ - O e,,, ;, p-4.m xva , y A s.F 'b< Y' .,11 p-v [n. =.y.., k .i 8e. 7 & .,.5 yi 7 6, -*34., l re g' t?af eg.d.[ ',,~ d'

-- w n %.,. 3,-,g'g n,y

,e,

h n f'e rll1

= wl..%.

9

.., # a "M

' W't b M a' 6

= -T' 8'T$' W *y*t.',l 'e +% s I l ? -V*- i p -$ #y,. p, s + si I e,,6, w k b.7 j y "g%, t' v tf g v.,. %; <. s*1f Q.p,j f- < +,' g 4- - %f.h,,n.- A %.A ;...-.. - Q=. -*. 3y l . W' .s. O v..<,. A ',' 2 .t t u, eye - w.x h :.,* + w m.,,e... Am w%s,,,,,,,, P% %p, ~/.O. W u m. r tw.,,r. *. ,m1 . + - s. f '.Ac i W Mc l' y.% b ~s .x,~e<.,..

, m. s %, s

%htm,,n, {., #., M-_ 41

,n 4 % g =

c. n, y..m g n w* -, f,. _ %. ..-e ..;*.;.. 7 r +. ,l*~,..*.J, ~ ;.Q ',.. . m n. <. a m r g h' &.c .O.O Ip

7.2 E..Q y,

~ ' * *

3'.'$ g g' y r

. -... %~ n w. p'.s., . \\ N m,1. T.' 'f% 7 ~,a.,,- ,'~T pr 4'

u 4

,K . $m 4*", ,,I t, ro,, %-,, , ~ W a, s ;,.-

r. 4,

+,4' n,n. 5 A 'O % g N y. j y "g

n 0

M r y e *' h,"* V

bE

'A e,# 4.,.l,. a'

M',

., i.i 4 3 ?, ty# e,- _d rm. m.n +, " m.- + N, ' E. r.. t's ip f l a 7" ) i x: e h .e ,f Y h; h f .. ff -*, _ O [ %. Z a*6 q-Myy@,.- W"6Q4. T.fn ~- u p;^*' V." M.*. m n* i' @.y N. ' J '@. ~ [ *'"' e,tj h e wn h*h*&; *h 1,_ v.4,b. j f. n* y w n Y b $ h, % l. n n 4ffh ~ A h,Dgan~.j f.. ' $*f.j.? " & ly ^ _ +w g ~,, % a,.y A. ~ mn uds. Au .tw-k., h,?. . }} y{. .s U. e' p rc w. 7 5 ',' G: 1 i . m a.n - w

e n

, n. g.,., e. p. we . ?'n, . p.u nm a <, + .(_e, g p. y' E' hms,2M 4,.. ', O I eN# mp.. w- ,s t y %. y a - .w au b =_ k.h Iw.m.&, f. , ~, 3 g 4, j,o l1* a y~T[.. ( -:a I W <%".' w 4.$4 M * $ **W sg -y - b h b.. *Q ?. -[ d k O.,4r i 7. M.W.T ' T M.,'~.','*P. <. 7.*V '.'j s'V.[*7"'f.3 G 7

C "*?.g"'M W *-/"f.,M'*PP.>,.~ ww ~ J e
'p.

. T.. p*- **"'1'9N..., ",,, +

V, s

q ge. - c - fy ~ r E' ~ m 1 .,.,,e .n'. m..w ' t - d., " q. s,.,,. 6 i C=M... f,

M.fs2 $$ 9 %w.j ((n N +-3. ~1.1 M( G~~gY% * "" ^"%h sv QQj l, 7,b.%, nuijW'j'/h,,. '

sv -...... . a ..D Q. : l l - w o L y n( ; y, ~. _. q.. w ~ - m ':%c..p.p g n , Lit h~.w r ;x+< ~4 a .w 5 .W. &.,e,-. R.f*fLg.d %p ;x, y ~.::.g. & pi e ;GW V

c y

n,2;- p ~- S. _; &. %, J~; ~N.QH.uM&, a.9%T M , M,* d,w. M,,, g,.%. w,

m. m<.t y

.m

,*/.

+N,, w'.'= f (, *.< % n. p, -.h

M, ;, y %..n',m.

L. a w,. -o. %y,v;3 ,r x t i . m. % m.m-e,,,, fy4,, p; r~ n ~ y j,.<,,, 4 y<s ,, y n ;,.. y

1., s 7

o. 6 a,..-

3 ,4,. m x ",*J mv "-w <.,r "ypm ~,,--9_g ;XW ;sJr**%.%, g. ,.m,, j ,,, y - l g g @,,.g.g m,y e. >', ~ p._ . t .; y, 3, , e, 7 ,u,+ g _,c~ y J W*- ?.. m. L ?,.m a 9 a.o.M i s. e..w.: + .m v~ +y

f. m'&..%_ f.,, m k y, Y.. f'l>+e,hh.$, f...l_ 5D.\\('; w.{ k l.@ _'4, 5 w,ef D f- [ f..h. Uk,W Q ;

a ~u-m -~.u a . y& ll, llW W -b-m' .J 4.M^ O M, Y.,M ; L A A, Q ' M 1 "4,.c ( ' (; 6 IS %e e ,m s. m. f-- SN $.1 * $. c *V # I. N., M 'fIIIT 4 g~- i h q[ m[1'W

_'.j- [ - $ $,.[M. /e' 4'.

g4 %e.y,..,k l.e q*DM M..n ww'gu. 4 ,.A, x;Ry.W,fw.,m.mm...,u.,m,. n, w w,. 3....pny: e*

m.. se9

- n= v y. Q,;c 9 m-m-

2

=&y ~ w .gl3wny e wn, %g;g j;,9-M mr;;. y I m vw w y,. g ~.y m,__;3.", p ; i r a . c ~ u~. .~ w n., u.mn,,,. - 3,,9 - f,.,. r-

yP,. an.,, s a w

dr <. g w.

y. a n.

a. m

e...n

.,3 3

~ ^,,;i _. P.

cw p. x.s v w-n:w '- p o 4~,% ?' . - W s N 'y+- $, L :..., m r'

k b Tf' ;.$ [',((*,7_m'. ~*i.

Nb.,,.

h. c# '

V

- - - N

>>s

-e-D D d.((-^ h < f [ 'j h. *( **.n,, s x(w - p N'

a s %

~v , }I ~p ..r_ +. w-w w n 3.n ~ x p. m. 3m -. W ^ n4 p*G,. .u. w, -v n ' A h, ~-). m.,_ w 4a n y.. ' W, - a s,a, :lx^.+ t,? r .e e,.-u.+#'t'**n ,i n.,. s.an ,,.n.mg. : em

9.. a.

n n.~ C * %s,o i W _2 % ne - y J wW*d qngw..~ mu#d ;# > %. e n ~ p;p'./ w., %,, - ym. t v.,( '* -e,. a.v_ h.. w ~s~. :,4-s,. s L,,w.- 9,: n, e - 7 l -,m**~f' c. +... m +..,,r m.c.-w M*, tv.wm~,: ~g% e a 3 uo g -s ~ r. l hs s. w<# u ~ 7 a ws <;.,c, y w ~, ~. %w ~,~.c.#%m y w,, o ~, w n-x -,wy 4. m 9' e b, '4,. y.c m. x. ~m. _L e } c %~ g* WM 'f Ch - d..<@, i ti.,.;*? 7s~y. * ; & n ;&; L,CLn,m%.m-r % m%.%W M w,A. it. ,1, m Q_N.; i ? '4 9 "m.a e.. < h *,_ M, r;c. 4* v ?,0. N<-+ 4NG,4.$- Qu e ' ~ ~,4, e RE Mm w-w- wV , g p'yW' w MP em w ~g% ~ ,2 h. b g O' ',.u,4 f,. - - ~ m. m m' - 1 [ +, 3, g'" p ;- M.s..y < +m%'I~. %': : ?. g 'A. [ k 9Yb$ i j k,, g~..n. gy.,

3. & : f-;p;y. y[Q <.w.'a ;:,y,.' V, u. > 4' d -,, yv.m %y,Im%.hoq+ wy. y.w e, + v,

h. f .-7 J 7 ' d ,a If. 4A { c w'T_ A.* q ;,4 s g(If$* 4, p 9 tg .%y.,r 3 y.mm gg; p ,4 Q ep f-p W s?.g ..> - +e A,- pt ., d ; g- %. c,.# m y.cy+eg f.m. g;p j.,u,r. 9 m,y ; . +y+

y-g-ye

%-w <.w. o ,f,. b k _... M. C,.tr 7*-*.,, # 7 d ' E.,.^ l'm% 4~ %..g - - Og,,2,Q. . i Js [N m I 4 .e . %. 7.. y_4 u 3 c o.. _* 4, _ y.r.., ,.m~ 4g *3. o*' %. w. y; [4 r t wi.. .E,,g e f,f I . ++-s<,- ,n es 4. : t.' 7. n. W. I 4 ...-4 ._p 7.m -.A m ,r. m s*s 3 s,.', \\.3.hs~ m.,.E..'T'f _.&.. ^[ n$;-$5?&.~& Y o.5 ~ .y, 3, _.x,f l.*- - 3,'%-., f.; f Y { .s $ ,'"?& .f% _2W j_ lf D ' ' ~ .m-w Ar .w ~~

~ s -

' a,$ b. % ,r kkt.W.ff$ h.s) k/h. h.h N[ M N N-

2

.[m _ g ~.&% yhh_!h5hNhhhhk. d N.*J,1.b. M w -.- .- om' wt -t%e mn-. qq. 4; '.My%.q@p'w.Q Qw :.5-.MC: f i d. v m.m y%7 m,. m. _ eg e m ^ eg y e +v ~~ u yY \\ 'dM U . Q.. vfQw #,2f*%. ' T,?b. ?, p*Wi 2~ M':W,. N 4 .-e.' a:. Y: * ?'~- y n; s~ ~c.,.... i

e. :j < ~, %.is. w sk'i y;'.n.

L 6,q .ej .c 3.. : pc.,,4. 9 *. y, ~, _ g.g Ay m g g j ; y f.' q m m w

gp-b 'i w r-y ;;; %, .m c. .f.. ' " 'Y .,j- *, 5,s. a,'l r ..'..pm r :.. m.; w-. a!,* * *.", #<%'*',*i.*-- n,.....,, 'l 4 h g Nke C e e - s .~?f s :pW N _-yjh*, kd$kO($ k T-ups p: : - g N:,e=d.. _"" c ,y.._ ll '. :Y::. f,,:Y, ao;.Y ~ #T?h? r ,, y;4. - s.....C..,k.s :y s+ =, " ' ', AM m3 y l e ?',. :.yo s.N ? 'h,'r '.+ j~ j' > ^ ,'8 OR K ~ i*r.Q*?l;9: ......u. # ,, =, . l v ', Y, N5 - 4 e: x {y;g;. .+ ix: . O ] () p.' i s. b 9 M h* 9 4 /*- (., 4 L Y. .' % p. ^ mQ c.., t M J ?'+ .s2 " 75f[l'; d6E _,f ; p/.kg%,,. + n* -- 4 4 1 ? (fi.k? x..a 't s L \\ -- 1

r<. Y f t: e, ne/. y+. a r s ?, . s. - a ~. - c

p. j gg. >

g. u -

1 e h t -:~ W s e A & es w m. PHOTO "C"

a...

ve%e. ; J3;9,,_.cf ,y -4 m .:3 s, ., X.m ', m Q w g. w;.y_;c6%,: ' v.: gs.,..Mf.,,%,9.,w' g,,p&.,m.f, !. S.C_'.y:w,,, m..

p?-

%,w. p;.y. w, y,... e k.~ m-w.r A ;x.. O.- c, u2 L ~ ' ' .,.n',",, s m me. .., g. w [..(d *: 38f +& it* gk y,"fa.4s( ,,,.a. ~ e ~

g., a,. s ;.;t.,+. p,,e, a.,. m.s. o

.c. u.,.. c o . a,%,am,

s..

w -,m, s. s n .... m,.c.,,.. Mr.-' .x a

[Q.}. n w,.s,.

~ p.- %' e, ,,, " s e.c :., ,a- -2 a,. s. . - j,gh %#;., 2.g,t,% p;* y;W> <;- J.- ) ..e.m.!#%.r?m* * .t, 1,1..;-J,;,.,v.ed%+';f,*.(lf;^* U: S mc ,e .,.c..* ...t.* +,- ^ l,. o^ As,..s.- - q i t - To . ~4 +.1 '; [. ~,qt:w l:4.JAka,%,(s{ql?-[;,y .n s., . f~i : at, Q N* w w. g.- h'h / ,,i L - 2'up *'.3 , f ~...i yu.0 %> 2.:.{6{ml.V'5 4 i .s-%

f 3 m,.'

v j - G, ,,a- ,:j w 4. ns ,,.,e.;,... a. -_v.,- e ,J.. w, wpeqp x_... v.. n., - ..s- ' Y :'l,( p~ J ~'t? Ih &, ';','. f;g ' ~ c.;,..e, s., .& ;r ,G $e*,j'? j.5.,.

T f *v.

= ., v: 5-a -r : A. T *J ',., y ~ >-.,s,,o;...u,s ,A A;.... :v, *.1. - :y q + * ' a ..y- ~ ,r a m..O~ -. .e a.- s .n ,; ; x.sm ;n.m,.. ~~.,~,.s. ,~ y .,.2- 'e D. n. -~

f *. sW.,.;,b_.lf..+?v'L' s

.n w 6 s.w, ~r u :ma.'.m: m.',a p.;p? 's s. ~ .m. w::M-.-p>..,. ,w. e : >'c, L ,...,l.'. l,,,,' s .....e. . **. :) 4? ' hk} ~ 1.! '" * ;. I.. f,',,,., .t' s , n. .~ wn.- ~ . w PHOTO "D" l . l b 1 N

qWW f W !* Ese f= 1

s Q

.t %~.,' .. e o.2.v f..c W, A T., Y,.: _>l ' yj1T A N 3 g o'/# g

0 g

7 s es dx* t 3 Na e s ) %- 4 $_ E. .g k 'k ~ + -f a 6 ^N. ' i r=*4 e 's c o. o., ' WeH R, q J p.. M gr 4 m 4v 1, ..2-3 .c .7 g, - p t >W sL.- .n r# g 3 - --. '1...,_s?* AP ^?. 4

- 3, p.

b.e* e., . W 4 e ? j e,' % enw } d .i. 4 3

iu '. * -

n t.4 4,1 .,4-s-'- -g.i., g 4.7s. <..., r w ~ s p asy "

r. ;<-

+r >.;* *g. ;, < %; g.. * ~*; T.,_ :;. w < m g .s. ..., L. i ..f * *{,f ;, f ;w?, % '% & .',.'"';v,c'+,*,g++,^- h ~. ,.e..,. ,. r;' ' ' ~, a.>\\., N N *'. 4 .'A+ -~ . _y - i. lgy, <q 'O [ = a.1 7 + "A ' Thh ).$ ? '?.* N)%<=sl, n 'l.q - n= e ' ? -j ,4.,ij ^Y%g!.^*f HsfG ^!s'.?w.' ' ?~~ ~ j p. l '. W GCA&^(# - af;y y%q;. m. l.. .a ~

L,o rj gf-($ *khi si i.F y

u n '. a g;,o %/# ~ ( i ~n : <;~*

1.z.

n. ~9

7

((g i. - s 4 =, . *.4'K.#.T.,e. - 8'[ M4

N j'

ih[h c Q, ~~' ' th f... Q.4 f'*t:,,lQ Y ~* . A.., : u y l1. .'n. .]_y}g jl._&' f,: ;.. -N t fn

~.

A.*..,e . r% ;. %. t e . = +., ,./., y 3 g " gfl t.pg.a. ae ' R(f, '? d.. a" e 4 ^ w NA-ecR..'

W t..

.y.. wn ~, e , } s.,,...f,*-. p ff. ?.p., h .,a, . p' = 4 ~ < f, ~r v], '* *j'>*[~., y

L. -r M i,1
y,f

,Z., ,e f.. r% W-. , -- p s., a .'4. t, a $f f. 4 4 's , +, m. FJ(

e y..:.

~~,1 4:g*j,,.r.,,*,g M ~~%j.ry a,01~.. g,, c.g.y w 1 . a, 3- . ', a. , y -. % :,. j ;., g... (J* b;, -* ~ g < = s- .<.,p s.,,.<*..,i ' e E,. ' C ' ^ "** s '* y a g4' f,-

K F.

s } 9;.,., ~ --i; -y,,, .w - [' +.

. ~.... ~.. -, - f l l (- l TEST PROCEDURE 3 l s' LINEAR CONVERTER LIFE CYCLE TEST DATE: January 17, 1984 PROJECT: Edgewater Generating Station Unit 5 Aldag Sheet Metal Purchase Order No. 001 TEST DIRECTORS: L.R. Hess, President James Dodson, Director of Quality Assurance William Nagurski, Engineering t :: PURPOSE: To determine cause of abnormal wear of shaf t guides and bearing of Pacific Air Products Co. l[ designed linear converter. Also - To determine effects of lubrication as rel'ated to wear. Also - To develop routine maintenance procedure to pro ong life of shaf t guides and bearings. TEST STANDARD: Cycle test per IEEE 382-1980 Normal Service Aging Test Data Operating Cycles Under Load Modulating Valves: 2,000 at Full and 100,000 at 20% stroke. Two Position Valves: 2,000 at full stroke. . (

N.. (2) ( TEST ITEMS: l Two "off the shelf" linear converters from PAPCo stock. t TEST LOADS: In the range of 400 to 500 pound inches on output shaf t. TEST CONDITIONS-Sample il linear converter to be run dry. Sample #2 to be lubricated. .ue INSPECTION DURING TESTS: Assume the IEEE Manudl.Scryice Aging Test Data represents a 40 year life. Then: A. With the test simulator operating at 30 cycles per mfnute, 2,000 full stroke cycles will occur in 66.67 minutes. On that basis, a parts / wear inspection should be made' at the end of 67 minutes to represent 40 year of wear. At this ( point, the linear converters will be disassembled and the dimensions checked on: l. The upper input shaf t and shaf t guide. 2. The lower input shaf t and shaf t guide. 3. The loaded side of the output shaft and bearing. 4. The unloaded side of the output shaf t and bearings. i B. The resul ts to be recorded - Sample #1 to be reassembled without any l ub ri ca tion. Sample #2 to be reassembled and relubri-cated.

(3) .The test continues with the additional 100,000 cycles at 20% stroke in the, same manner, except: i A. With test simulator operating at 30 cyc134,per minute, the test period will take 55 to 56 hours. There-fore, at each 13.89 hour interval, the linear converters shall be dis-assembled and the wear checked per items 1, 2, 3 and 4 above. B. The results shall be continuously monitored by Pacific Air Products Co. technical personnel and any abnor-malities so noted. f' / /, W t Louis R. Hess, Fresident ]pw'1 ch?k JapI [P. Dodson, Director of Quality Assurance N ,,/8AH NW William Nagurs'ki, Enginje/ ng

dg 0a i

2 ( INVESTIGATIVE REPORT NO. 6376-1-QA Part II i LIFE CYCLE TEST RESULTS 8 DATE: January 19, 20, 21, 22, 23 - 1984 PROJECT: Edgewater Generating Station Unit 5 Aldag Sheet Metal Purchase Order No. 001 TEST DIRECTORS: L.R. Hess, President James Dodson, Director of Quality Assurance William Nagurski, Engineering UNITS TO BE TESTED: 1 "Off the shel f" linear converter assembled without lubrication of any kind. (Photo No. 1) 1 "off the shelf" linear converter assembled l vith lubricant (Sta-Lube No. 3151 mul tipurpose lithium base grease). (Photo No. 2) l TEST FIXTURE: PAPCo designed to cycle test two linear con-verters at one time. (Photo No. 3) Unit driven by a gear drive motor with the output shaft turning at 30 RPM. t TORQUE LOADING: To incorporate into test the effects of possible output /shaf t misalignment, the torque is provideo by a spring which puts all the load on the side of the output shaf t (worst possible condition). '(Photo No. 4) The spring tension was set by calibrated torque meter (calibration through 9-2-84); a torque loading of 40 f t./lbs., 480 in./lbs. (1 was established for both linear converters. (Photo No. 5)

r .\\ e 's, y o-O PHOTO NO. 1 9 0, %Ra 1

my y 'M "' l '# y (

L

-~ -4, l h s L* T.lsl. } ', e, _'r. G (*P ',.

- S e.'

~ ^-+ p _ e + ny. n. -~ - .s, er p s 4* s. s. .s- ,4 4 '.u... < g 'y 4 j - g' - r o -.u t* -" g k>.'-+ 'f g,', s g j,. g[... / N <7- /,.A ht / 4 - p -... %. Q'~

.c

.rw%,... -4 O, f' g 4 l

' g..,

g -e; - 'g/ .,q4 - dA7 h 7, ', j b s 9 ', ' Y' 3 .~ 5 - ~ '; e l r + ~. 1 9 ~." s [ I e p .* ^ - .nn -~ y- ,e ,-A T \\ . y4 4 d i Q--.. 3 1 I_l, "4 g ~ ' ~ n a . ~ ^ b e e s t

j z,

u.- .a, 4 ,,'f ( '. - t %,g (h i q7:.q l p., ' t j s 1rF. 4 ;; m .a g w.- W ~ ' bs %P P,, $g. N. - s _ / ep, y fl,' .,Q R-p - ~ . '.jp.3,. .e a s +. 1 o, g , ? '.- /* gN e, ~ Y m. ....n. .., o, g . i a '1,

.p g-s, *j r

.h.- 3q,rg.. l 1--.9 l d 1 'p l . ' a'; ml ..i a th ~ l s . 5 l t. ... es:.., - 3 1

3g...'. w.y";.- './.[.Y n '

M.

i;i.; ? e Q.:

a f.. %:: i ", 1.c,A:. %. q :4. n ..,. - ~i% i fW ,.p., ,y 'n'sa m m,,t' ~ 1 +} gl [" x,t g y;**f. W L.*';++ @r %._m.3 - n n.,n. - ^ '4 n,,m %vL&g W. ~: L- .. y-Y ~ ;.W Y _ ~ ~ g%epl.' 3,; L g.y. R::

q :)s W...;

Wr - 4 + - .f ^ f?.f. 3 m $ f..QG* '.f&. J,. .f ' l ^ I' O y 4Gfe,. ....~..sq:g-..w y [.'

.f ;

g. p..y .. i.> ~ b ^ y w, ' Da ~ W Yd

~
g

&; y ; m.g, y;&L. rl; ' * ~ - w. M,. ..,... & &.n.-. .w.6t%e y 29_ s^,g c .+ x 'C' q. ...,hry O ~ y [ ' 'h'- l }ey j,p l ,}' ^. .o y, +. 4. .e ;.. m.,. p- ,:g s - ke - 40 *' ~ e v.m.- .. +. c. ..ac.

m....

A.- n.' -p' ~l M' . ' #k.. 7',6..."iM3 ':S. z 3.. g ?. M6 Vid c n.% .-~4p.s- %., ~ ., a .;g <p. . g 3 n ,y , g. ~,.- _ rp e - :: - s; n.

~

[ I_ [ l'

. n%4 m

a... wp..y.. ~ t..: .p x. a. -y.;; ... ? y v 4 . g 4; 1

.y r ;

g'.3 ~... . ~.. v.; Q l N.[ - _y ; 7 ].3. g.. c.w '3 i, h '.. ( : ~ ;; ' T ~ g . A gl

. y.,..,

t.

s. g~

4 4 .e '.. ... ~.*%ggg... .t. 4.g-l. y g - y am@ ,....,tM E,.", *. f ~,8

'..- %'4 C

..Ah-

-t'.

'. 4 p '. + f ? U. .'g', <s % a,[f g[.*h r9 1 '. .f ' I.-. s.As*g .; 9 .o ^ l ~ Yt 6 - i.... '. .3n ', si ?. 9k

q

'.1 M{'a. g, d.,. ' 'l ',. .( l g.g 'y, g.Q .'N'" h',.M - *. w. e p. ~ .Q %..(

q. -

.g{-g (. ,y.y' 1 i f. .se g,' d.. -N * ' ' ' 1.5, (O ae p g -- .S $ k',[. &.i ~ .. [* a

J_ '

.-r W i N Q$

n. a%.anV f

y 9 1.-., M &,- M3 WL: 9 L o ma . _.: Q., y =. ^.l.qy _ :. , n..

.~QM*M yy,,,

:.v.... y M~e ;3 w..

n g n}

-......-g g.,,

I.7 t. ,,,.g, q-

y.t.,-: s. :.

~. ,7, - < +;' s.. ya l .s 1 L ' _ g s ' -l ..l,' .'-g,' }by l z 'j *:t'E ; _ f?. 1. b,.[ ..;'f'N[ h. [ ?..[,,..N a, '.. c',4% 9.. . at g.k.. ~,,.j.h*-. m 's.J ? -[17 - e, .[

.,.....t*...s,.

' ',,,4;,, ..,. [') [@' I/ l 0.-- e. .y, i i .t.n.9 .-. :g.. I f r= vv e ,p e +.4 $, ,, 5 ~ - %4 ' g e ( [ ..j fh 't .. I ' @ -}, 7" 9 .,. D'k. . '... l- [ I, ' *8 ' tr.,. =t .. +.. a i '.. + ' Y Ak..?:'s.,... :a,. [ f Y' O.'

n. N i -

s or ,,., -.c N, 5 ~

7 l

$,J ,l (g 4'.,.,, <% - ';7 "a, fr - ~. 'y e r.; $rh 1. ' .7_a,[

n x

. 4 k. '? 2 ' $. 9 O; r m. : ,;.s. p.. p m x - a .: 2.: . a;,r e.a.,.. .z f<, a.o ,. 2.; #..,..fgr6b:c - .,..,g..-- 4., * . s.s 3 3 v s. Q.e, r .. '1 ;A, - . ;t. ,.1. - q,; 1 +- ~.y

my

.~ 43 ys -,' uq -A 3.... g l $.gspj-- V N.. . y.. _ 7 s.. n. .u <.r. 'l g,g. . [,, ' l.. c a e..* ..,. h N * ;' ' .p .g k.( [ d .i ^* ' _'.,, [ f '.,; E ? e , 4h _. O d*, O&lf.-;j &&$,N &-@$.Q'p..? Qf_L;& &QQiQ f Qf.2 ($f

(2) \\ TEST SEQUENCE:. 1-Run 2,000 cycles full stroke at 3h", observe, record comments, inspect all components. 2-Run 100,000 rycles at 20% of stroke - 700 inches. Disassemble and inspect at: 3h" cycles 2,000 13.89 hrs. .700" cycles 25,000 27.78 hrs. .700" cycles 50,000 41.67 hrs. .700" cycles 75,000 55.56 hrs. .700" cycles 100,000 INSPECTION & OBSERVATIONS - (A) At 2,000 full 3h" stroke, cycles with torque side loading at 480 in./lbs. Attached Inspection Sheet indicates: 1. .030" wear on " loaded" side output shaft I.D. of non-lubri-(' cated linear converter. while,there was no measurable wear on the same bearing in the lubricated linear converter. (Pho to " A") l 1 2. .005 wear on the upper input shaf t guide of the non-lubricated linear converter; while no wear could be measured on the lubricated linear converter. (Rhoto "B") 3. Galling of the output shaf t on the non-lubricated linear converter (Photo "C") is causing the output shaf t bearing to rotate causing wear on the 0.D. of the bearing. (Pho.to "D") On the lubricated shaft, no wear or galling is measurable (Photo E) and the output shaf t bearing does not show any signs of wear (Photo "F"). 4. There was no measurable wear on the output gear or input rack on either the non-lubricated or the lubricated linear converter. 5. Galling is beginning to occur on the loaded side of the input shaft.005" while galling is absent from the lubricated input shaft. (Photo "G") I

. -... = - -. -. c (3) (f 's 6. On the non-lubricated linear converter, there its noticeable brass wearings in both the input and output shaf ts (Photo "H") while there is a complete absense of these wearings on the lubricated linear converter. (Photo "I") 7. Shaf t wear patterns vary greatly between the non-lubricated linear converter (Photo "J") and the lubricated linear converter (Photo "K"). GENERAL OBSERVATIONS 1. Noticeable heat being generated in the non-lubricated load side, output bearing and shaft. No heat generation in lubricated load side, output bearing. 2. Light galling on input shaft of ncn-lubricated linear converter while no galling present on the lubricated linear converter. Inspection complete; units reassembled as per original mode and the test to continue.

qpyggggg?" yw gg

fkhhsb, u d$k $$ $ g$N $g$$ggggg h ; iMk g $?g 7

ww gl h{

e. mWIO c

m-- g

' T., ;Q95 y I

g*W v(dyJ', s = u i. .h f ; R+ '% yg.m 7p;e : q m ur - c . O'q tima v.- .n=se %29 l l l w[ W,~ k- $"pi ~ 'Q S 6 . : :--u,; s g,, 3,p _ ~ j E ~ m .V ~. 15'1 . k ' g ._<i r t c' F Y" Aq; Q $ Jer&_ a, Q' Q &g&Q} I ? ig - gy: DM hlh d j3g ~ r h g b Mhlfs$3df [ g ww e/a di ~ aw; s a m<$,, w. yh s- ,-rAf%wnc. c.y];f.a.t n p ,c h ~ p.) S f,ws 5 W rvb w ~. w 7 ' $[k .4 (e$bi) 8* .u y .p p m w, g. 46 = T fid. esish{f b gg ' se ma m g g@w' )"y ^ a px a 6 $ e g [n p q [ tk p Q @/ e-, f%' ff 9 i ~gr ?g w g e) g a .a n u y r ??" p h kt j j% 'j p w.mby' e m-c*w 4 su. 3 y' - =m.n w g{ge i ,wa e T S ~ 'm e a V[d22h['25[k pA! h,' rlwg -g %

w' Q gy.&%Mregww+*

"gu~ v# w J g g p % _ g g, vn --c g g &, % , KM. E 6

% gH~;<q p "
k.cp g a-

),' enpfL m~u 4 C,u. ?

Ndb h8 A

( i m y,. 169%%,, p % ; &s% w w A u n + 8u.% m .w m, ~ +,,xe.... s. m.........., w.. ge.,+, w..,. ,__m

" -+._..;j'\\..,_ .,. ; '.e ,'s w._.,7~-.; ,.z._' . m:

y. _ _... y,;

y,; , j :_ ? q,. _ ' _,,. _ , _ ___ _j y.,,. -. ;.. g _ a- ....,.,+n ( 's.5 . n. - v ,e k' 9 ?. 1,_. ... ~ < o, ~.

g :.

.... r, y[.g.g, ^ _ .i _ -g .,) f - g. qy 4 g.j f> M .g g,2.. .7 g 3 _,, ,v ' S (.; %r-4. s [_ + 6 G., ,.W 9, h.:... /

y..r-. '

g ,,V3'I r I g p )d / s a g "'g-6 i, f . '[: n D j?. =, ' &,5.., '1 hh.h _ 1.,..:' 41 .s 4, ' [, er 4 y +[ A k 4 ~ ,e i.,,4 t o., 4 ;[.C ,. / -[G '. _,A.

[.

_i' [----- I

4. :.

, f ..m y.,' y Dj [HOID ". C ' y: '- e . y* 4,, -y w' A. .44 ~ s . y. + 1.- x.- /49 g .. i *;f], a-($.s.).. i% - .i.I{.p'i w s. ' e ' ., ;.3. - . -q .n... - p,, 4 r. ..Y. 1 : ~~, ~Y,-

4

...,q,. M jfI$ b, I. 4 g gs_N. 4 ,e. q 4{ ? Q,' s - W, . ?. p'.g~..s [ q - w..

s..,. '

4 m, a u.,.;m _ 7.: 4 -

p. s

.c c. F -'u.* a.. A f'.'r_Y z .h '-. 4-w k.) ~ ' ^ *3 PHOTO "D" J.I m). k v,.. ;f Y.?N...

b.'*

SN* Q [ ' k-b $ k; [Th*k. - f.' # 6[ k,bk '_ f5Np,'f.,f '. ' b. S[.., k'[ h *' -)i#.4', ' ) [qh,b ) '.[. , L i u.-sg . s,,s. s..- ,[ q k f.. }h)'(,

v..- .:.s ,,.'s ". "g r. - A. e. ,e_ q a, '-.,.. f.., t,4.- e.... .g c,,,.4~ c .y .s. .f _q s-p s 5. {,.. [9

-... & G

.x m J.,. e. :.L w ^ 3..,:.^ '. 3. d.. . 9. ' A,.,., g*,.,% , ; -s e *g.:. ' ~.e ,'.. y. _ S. c.- f'9 . }.,';, < */ :.g. '.,, . l.,. .m., p j. g,,; _- e

* ' ' i

'y ^ v :. z

(.

.;[ _, j.l.. } t s.t. e , % i. ".9 4,.. j'. h e,' y , A. m: e .< *..r ,-. m. 'TgT* *.t 7' '^.' t 'i .3'.. 4** ._t. a _. n.ih. 3.,, 9 .,;..q d '.: -4 _ g f. >..f e

y..

8,.

. e.r.. ..,e a.; 7.. .r -a .~_, 7

.L-: 9 a.

-1:~. - - +.. t s, O. l'- .o / .w. ,a -y s.;, sy e .j g p,. ~ . ?. - ( .s:,. g 4 a),-

? s,.e

'g

M.

7 + 5 I 5 .g 7,.' i 4 v } f. .,6 n.. s ~ '.'.5 s t-s,. ' 4..

-f

_rl ..q * ~ [- 4.. 6 7 s .,.y W y-- ) ;'. N ' ;e. f 4 ~: - 9 a. -\\ f = Qh . s i-4 ti,. -d-j3 g z

5. 3..

R -.. s +.. .g.y .y _;.c e d. c a, l.

ta.

T -

e..

s y. .c 'v:- 3 -. 0 ,, q s } j i. g

. Ar ;. _

g. 7,

g t

,a a
T:. -

j ~ .d, . T';. N[g4' f 9' 4 4 g~ ~. . a..- ]' g .:t

f. '.:;-4 y

..pe 9 [.f., k. 'f'. .. 4.. l, 4 t .' gjy ' - f' k i J ',, g f es I-S a, 15 ~. .:..;-g 1 ^ .g y e . ~. N 4 -..g .j. Y l' i- , m 7 /-.... } . o. .3.%.. i .;- } ..f s ( g~4.- o. z' ;'. '.,..[- . g. _m, ....j-J;; g - g ; t.,*.n.: 5 _+.:g. L.;;;i...:.. :. :.. y,,.+ 1 $..Q

.;: e 1.w. ;_.;*,,; 1..T.. :V J

. - ' t,'.. e. p e,e;,j:..,.... i::O c,.., - 4: +r o; .r; - :.. ,., ;.,.. c: .. :... + g, . ~. -

.,.. a _.,z

.,,.....r

F?. Mp3 t..: ~ g$iOiz :; 34 I x a .,$ k. ' ... *' %' h, ' Ih 3 5," G k u. 6'E ~ ~ R sa' ;[- ~- ":4 .- A g Y yy.,I' R se . +.

%l ' ',

t I 1 I ~ (j ? E kw. 4 35 N Y 4

's.

w

,' : ; H > J g; ~ - *: ? ..n i. :r y

? Vef'x':%:

, n. ' 'r ....q.....: ! d ;:A;. N,.

'.,;[Q.,; ti*.: &..'.. s.

i.. ;'/',.5., w ' c' W: G'.. .s ' % 8 8 ~ ' Y , < _ ~ ::

i '.O f ~ 5, k Y

.O r r v' v' er'*ws*- * * ~ ' ' r e ,, ey.. ~ ~ -.,9 ( ..,.g /, w.. J..- '~ s..-,. [ ' - Jt [ %,' 4,59 2 * - -.[g g ~ g .., y y.e. 1..

...3

.., y y. s.

g..

s, y. J_ g,. c.gg q w o c g... q py pp.( y %y - yy, y,

3. a g. :s, ;4 g

3 p. 2 WW. m h:. - s 7 ^... 4, ...,4 . - Fr : 7 -t>-. y.y g .'~n . h 4. ' y '_. y _.f e c' _ [ {W,; 'f b } ( 24 g .t.. _y* ~-. f ^ -.f E'.' . ~ -.. . t,- 4- ._g }. '.. te ._, F. &. 4,, ,-... c -' ? e g-

yt, g

+ 4 6 t-4 !..[ ' j, ? - <I A v,4 s ,47 - . _= n. 3; f' ., ",. :.m .1 .l\\ .s r ~ .A

3. :.'

..i.,,;k f ' -.. } - 4 .qqw.. : ; s .e ,Y (m-. = e . j.. 1. 1";[. . f., ', V " -..n.- n ' I ~~ x y-s

i. <

n p.^ g.. v.;,- - '?'; A.. y ~ '. J u. j <N- ')W 4.. . m %.... 1- ,r: s, f y. .. [ _,s e ~

n..,. ~

~ -*i*g: .g 3 . 1. . x,_ ~ a W ; 1.' f ' : ?

q

.,,).' ~ ~ G. ~q Q(. n. '~ .. j.5 )Y;. ;. y \\

g.

( ~.. 3 - -M 6.*' 3. ials Jn,g {tf = a. ....,4 .g ?l-.s ' ,=Q r..,~. '.(a . = _. ...,., ? :c .\\ .;..{ - ~ Op ~:.' l>. f}r n. c.::.. + w ..l-, 6.. .i '> '. s . ' Jn.. ,7 4 s~ Q ^; y a ~, h .Tg. . ;.,.y 4... .:.z. _..,.7 '- J ,g ',,f-4 . ~ '. - . ' T. p M .I ..-_ ;'( i ~.' 4 ^ l c p ?_-}; ; R

- 4*g&
c

~ _~ ' } .Y -;.. ;w w e p n .y 9 r. -. s f. 3--. g .d [,.}j- - 'i . :.1 % 4 ..m. :p \\;,,. -v. 4 5 n,, .~ .v. 3. ' % {. :.. . *r Q P..: ', ' a.1 T' + . :A h.y U..?:M_f 7 ( ", [ *,f_ } ~ .} ' W. jjf .T: l /' ~ - m ..y.6 a. n y% ,,.,m.. j t' l ,,i.' ^ j.f.t..pg i .p g}. L i t-H gg 7 4g q! ,.;.. l., . s

b. ' 8. '<

. p, ;, Q; 9 - j,, k.- _ l - f, % < .' ~ h-c n t. s*

N N b. "

f c

g ?. .5.- .....fk .s . ~* 4 , h L,. W ?.Y l ^ ' g.X',4

f^

WP - g;y' _ ' ~OT '[ ~ ;. ; p,

~ p: : 4,- p -

'_g ,; _ L '*, _, 3 4 _ a -- ~ . Amt_ ' b 4? 'g g f% ~h W' ~ - y.*,. -...'m n., @' -.... l ..k.? ,.2 y w .f. R. ' y

Nb

. ~* 3 . m ,~ .g., ef %nef y ).- n w.. j!Y, a .?' -W fy, 3-fl 3 )N ) I ~ ~. fj 'o . [.. "',.-: m " '.. 'a e ' n.. % .e s. i '. '. ' 1, g. sp ' ' . o 3...

*:* ' ^ f A:,,. '

?.y f ~ ~ ,'l 5 A? ~{ ~

l4. ; ~.._.;*

l,' i t,

r i.

7" J '., ' k { 'n . *.. j. # ', y .) [ f. ^ ~ e' = s JQd C *. ', .g ' Y W. 4 In ~ x ~ J '.**O y = *

s O.'

J .^e y e .g .g. .9 '.0 s _ , f. M t 7 ', e - ~ - b o p. t 4 %...s . r 1.. ) p.g y - ~.. f 4 .4* ~ r,~ r +. - + v. ga e* - n -.- s .= j. .p .4 g 1 6. .L ~ q $.4 ' ^ ..,'W'*g'.'.; ' "..ys '.. m < ~ - E* h^ s A s. . y.; ( j 'f...N }f f. .l ' :,. a l_ . 4._ g, 4, s. .A., a. ..~. c. n v,. t-gg-. l 4 $.4..' ~ , } ~ ' 4.,. J ' k- . E i } t ~.1 -'J ~ 1 g'. av .,. i -, %...fx6f' L ' :. ?ve% e I

l ' '.y.. - f.Lp.
,f-

.}. ll} L 1 kr

O '
[QQ;p

,-1 v. y. w_.,.

y ;

..y 4 ~ .. + > G.,9 y>ggp,, ,' '..( +e ,.-.,'? L. y.e V .,&e - .t.. * ~ , y . 4 _., .e ,g.- e,. 5 h [ $,f. N I -[ T - 7.. '.%,. I ' ' ' h,., *-.., J 'i ..f .M "1-a ~ \\. y i ~ , [,

4.. t 1

[ _/*Q. [ ' p ' -Th . 4d( 1, ,f..' -f g -H. k - C.. '{ .) 9 q.A ?f,.,' t s.; y :,,...,. g v e:n .g (A:. -e ~ 4 % 4 a

bb f.

34:R.g l ~~.. g V. ..'Q. 4 ..? e; . y. - ( s . 9 .w ;y. ... Ly,,.. a .s j * :q ..\\. ..(

i. vP

p. ; ',

g II ,'4 g, [. . pf[t 'U ?, M e ./ u..'.. M..;* .J. e p f ,,g ; 1 4.g ~ ..a..gm 3. r. - t... -. ...,., e 'p s - l i, .1 k o '..h $,h,' '. .c a,

~

? v.': ~ ~ y :- ,./ y 4' ' ' 7

4

.. - e =.. e. re[ a ah M 4 1 3 ,}. f.., d .h-i

y

'k h' 9/ '/ f , k-h Yr \\). ' ? - - -A

U (4 ) INSPECTION & OBSERVATION - (B) At 2,000 full 3h" s trokes an*d 25,000 20% strokes at 480 ih./lbs., attached Inspection Sheets indicate: 1-A. Upon inspection of the non-lubricated linear converter it was determined that the " loaded side output bearing has failed", due to the amount of wear on the bearing from the induced side loaded torque. This would allow the center line of the shaf t to shif t towards the load side thereby causing serious shaft to damper misalign-ment. (See Photo 1A.) It should be noted that even with the damaged bearing on the loaded output shaft, the linear converter con-tinued to operate. The decision was made to replace only the " loaded side output bearing" without shaf t repair, etc., and to continue the test. 1-B. Our inspection of the lubricated linear converter was ( made and no wear could be measured. (See Photo 18.) 2. Galling on the non-lubricated shafts (Photo IC) is causing the bearing to rotate. The lubricated shaf t (Photo 1D) hardly shows any wear at all - (none measurable). 3. There was no measurable wear on the output gear or input rack on either the non-lubricated or the lubri-cated linear converter. (See Photo lE.) 4. Galling is continuing to build on the input shaft on the non-lubricated linea ~r converter while none is visable on the lubricated input shaf t. 5. Wear is continuing on the input and output shaf t guides i as shown below: Non-Lube Original Wear Axis Lube Wear Diameter Dia. Axis Dia. Lower Input Shaft Guide .755 .821 .757 Upper Input Shaft Guide .755 .793 .755 h -. = = = _ _ -

6 (5) / On the lower shaf t guide along the wear axis of{ the non-lubricated linear converter, we see.066" wear; while on the lubricated linear converter, we only see.002" wear. There are no other significant observaticas at this tim?. Both units were reassembled as per the original specification (except for one new output shaf t bearing in the non-lubricated linear converter) and the test continues. (- r C_. m.--mm_mm_.--.-... ----__ ----

s s.:3.y. y *. r ...u_,.. 3,. -i n g;;.. y'. n +...., ~

f ; r; y: . - ;g :

v..y ... y; ;.j'...... [s s f l f

4. w.

lih ? A..] ^*

g.z14 4.

hk ' ",,. 4

O.f 7 ;;...cl4 y_l ?E f f,. :, l- =,

.. f g.,Y, ~ g:'- w,,,; .g. } j .l '.3; .sy- .$ b'Y"x -l., ^" Y - l (5 g" *. -j %-l3 1l* w >t .. v. .(- n.. 9 e.: 9 z q,

% ' 'j,.

n..

.. 3,.y c ., 3... p 3' .y. m ~s s 2: ~ **' y[ 2y-l%Qp - ~ 6 p. aQ ... pf ' ' ' ' ' ~ ^ 't r'. (C:vC. -. ; %.3 ** [. J,p ,J p c.

M S%

l'. ' ' gg s.;p. 9 k-q <.sg.4f.M.y : 9.;.. L;.;. ^ nRt ~ 7.g ,.3hg.g ' . ~. M"i;', &. 4r ~..:. e o' S..' 'g',_ ";. f +, a -~. c .:._, A -- . [s -;-l ~ '.,:, Y,., .,5 ;,'. - .e$ %: [ .^' -c' 7 _~, (* .x 3 -; *i. g..

_. ' on

{., .'4 :i l *- e ' Q. 's, g ,q.8 3,. - s *t l' - ~ y.,. -q,,,'y, ~ ~ - - y p, .i G _E

W. -

a. 9' .g . g "R 7- . g.,;..y.,..

k. *,_ :'n it

.O, <9

'.hf, g -'.-

.4(,. v.Wl f 3 4 w. 1

w..

_ m..@.. s., 5.(:n,;V:. ?..: .j ^ ny L m s. ? ..sN:./ ..r-i

'g p:

y 1 Yn ,3 -} v.c.-- m .1 v f. k 7.Ny.x l p9 . ~ ~ ' i ,- 4 - \\ - s y ;$py ; y. At &- ~. so - - - ;, g.a, - w-f- Yl Re'.- ^ ^ e. - ' 1 .: L f}.* _,,4 /.. '*[. ' y '., g e, '(gf - [: * ~ ' ara l ~/. .l. "r. ^ ** .s Z". e

- +

fe'YY. .,% y:p.- ~~ aey.- l _., l . ~., kk s :. <~QR x d ~. % f.... ( R 8' )., "1 'l., J' .1 . -. o s f ' -3,.." ( <,,".'? .'f .. emp 41, f'- ^ i ,i.. f I *., ' m'y., -. (.. :'.. ,jh p.- g..' - s9: V. ., y,...; a.- ....;-.. 4 ,r 6

g

.-y k l N nl .u 9 {,, ~ ky[ - ~ 'g.ng 1 ..( 7,' m z~

g. ; y. a. ~q p y g~.cg;p.

a. .g. A.. .., f,, :3 g ~ s. c, _A. ~ p%, - u %~4.,%e..m; 2L W -..y< 7. v s'. 8P', -- s . % y s. l

,; gh.,,,-._....,.s. u

. e.. 3. g p. m..,.f...y - i,.., -i.. i 4

7...., fe 'j l

<* %.y s 6 2 ~ 5* ,y -} ,~?- 4 ty-s, s Y 9 _'s,.. . \\. , f h.. A y [. w.; / , w~.._ 4. g l_ ? .u - }' J 7_ n>... ~ l Y-l[v '. ^.; . A + k. ?_ !. ~ g). -. :. , p :;- w y( 3 ' - ~ 2,,s.,, - 3 .p.. t '7. r. '.

7. '.

~ . n w c.. $'*d s '

s..

t 4l; l tg. s L.j / ~

- ~

f.*,.. 5 _ *. _ ' " T,-.

} f, l

~

n. . ;.e...

. ~.. ?

_ ?g; '-;.,- _ -I ^ g

.[

,b O @ e-CE i ' (- -.,,..:,:yn,g m. q,pm.y(...>.. J:;._ n %; p__ : p 3 3 :. y,? g ;.,\\.W~K _R,-g e,.y,. 3,. .-= _.f_. s+.; t.. -.h m. ya. a.,,.g.,,. +.. - '-e.,g %z.. m.:,._y 3 ;;.&.w y;..,,.

. n*

+.-

---'-v--- g_ 4 q ( - g,- '4d'e n ;, f:a& T;f r ;, _,A.; *' f y*~ e.q p. m r.;~ a

8.

sf 1 ~ v e .8 . "r g, 'Y,I.h....*.-g M84f'. ~' ^ '

4. %

..**s o _ l 'lf-hw g _q ~- u.- u S e a q -. ';isA, g ' ;, ;4 ' f. ..Y,,' $ a-N s g7'. -1/ ,:> - 24, ; * - . :,' '..' r3.,, 2 l j

f.,4 3 I

. ;,,. ;- a.

2 <- , e.,, g r,,,. ; j.3; y. - ..ar, -,- p -* d,',. *. sl.- 'W Q... '.e .~ - ~ < t*e. p *,

p4,
{

c '.4 <...p> <E'^ .~ r, v* }_5$ ('- 9 } f~. s s : %jn N, s.g

p.. e >

y fy.1 0 9.j>.1 .;pc.,p.,*i . *. e ,y*V. g p T. .A s' , >;.s. k,?- T. 6 ~f -v o y m,.-l,,. [ %:I, * n. pe .._) m 7' 't ~ 1 m :. M %'.*::: :. ,,..'.t,,.,,. -i....9* Q: s 4.- -y;9 s '4' .,4 h e *g -- , g. ;, ' - h p g .c .N.'r. + :. e } Q> ~ g s 4 ~ } Q~$.. "f,QV - }, s e b % b e 4 g Y y* , = - g- ,g ...f. .N f ^.o;;, l /, w = r-- ,-,,.1' .'_n*.- e' 7f -

.-&. P

/ ..ns iy. J a: +7 c b l .c...

e..,

_.s.. u - l

5 '. * '

W 4 Mr y, ~. k' f.p. l,r.p ';.9 k"Y e -I' t X :,..' ' J '; '.,,. %,;J *.'

m '. ,'?..s'-. f.,. M... **4 f *. .d s', c ~ y n.... g. 4,, ',-

f.,:.i.

.n s SrA A' .4<' MuhWet.g pg

...,., p ;. ~

g,,'

4-

~' 'p, ' < m. o' ..& P-a g. r ' y. :2;p~,,Y,.,' __f }; - a. .J, T - ~ * .~ j f_ L , %:x. hx l,'I.&.}.? & QNkwl. & j.:W 8 $-p MW,?}, N.E :L A. C.'.. L $w... w3 @l ;:. ;. *d%@fg n, 1 m .pe;9..w. f. m,v x.r.. .w., rug g,je w. e a3 m .c s . w. L3. @ 4..f; QQ.Qg f.s. Q p ;. g y & W ..e 5 l [ e_ 4 f f h j!.'f k \\L f ( & ( i_ ) ! O f, h f. I> . o.<. o w. --T73.v. 3.w. , _ a. - . o ~ .g , y. s 8 .; y ' ...e p. ' L' - 84 #.; p re. ; .s.. 1 4s s, atesur-t .... Q ' 1 M ,f ,s.,-

a. -,

g. y af, .g

- x m

3 c ~ Id \\ u.g i c '...-). m. 4 {, , il} j. m !k, {. [* f J 4 4 p - 2 O"* f I, l7 , 4. T-m.';y,. ~ e ., y-2..., - sm . y s y,.. - ~" - sE '{. ', Y.N ..[,. .g' ,~

f. f..Q L

,.t e.., -. f, p

u. p,. m.,-

.n. _ .n> ? '.' "y 8e .e 84> *.&. g-( ( q '. f g, ..\\ ~ _.y w .: x .} ....t. Y.*.,f::P :5 J. ^ s'. ,( ,:g., e, ,? 4" ^t

-;g g

w. m~,,-. L. s a s. 3,;,- w ,~. ~..,.,..y,~ ,, f..* ) U.3 [ e .J.. 7 * {c.. ., a I yE,. _ j h' \\'

g

<p?-s 2; .h .I ;,. s; -..,'6' i '.Y. ~ A ? % 4'^.

e Q}

,,.g;' ^ '^ j h . E [* ~ ..J y, d f, g~ n .n ..~ -., J. - 4L. f j p.*g - . c. ... g. .]f [ 1.f.p 4., ; 1 ' 3 E.. ( _ g.. , ~.. ;...... :x.. s. - # n. y,, s.. %1. w.J 4 *.. s. e, ,q '.Wa. .; 1 u, g-. .e. 1.:. e ., '. " d 3 ,g l" 'lf, ?.,! 6 is - G s

- m, 4 >: . -

/.: 43 r ; (, g.y.g3 g;.- g _9._- _ pp. i y . : ~. +;g a.- e... .c - ~ < ;- 4 .,c g y <..n,- ..^* g g. y p.%. '. '... l2;Ih .'4, f ~. '...a 1 ..m 9'- Jp 4.< y. -n .4 y y.. ' ~ _.g* : ( ;.fg,, } {g v _,- '.'..l, J.Q Q. .;;q .i, _ .t q, o.3_.h,,. .. = ~ _n. -^ o .,.g. . *' e a ~ ,.g' 4 ' t ' -.. J. i, g ) .g '4 - ',';

Q1 g; ;

'O = .r, ?, -s

f..

c = > sa' ..s c. - ~* ^ .. :e. v . y _ t,.$r...,..g.. 1 *. - 'g g .[ -,,, ,.. u...,. .m..

- y-6

Y 1

4 '8.. j,,.gf, , -@p ...g ..T '. _ _:[ ^ ' 's 4[

h f

W' a e, w u ~.: : w c ;p w.3.4,s. u -. g. n. 4 tw~. & '.b f ky ?

. h.:?.$_ h l %.h,h f ( 'f=j.~. b l $,.l ( ).' & Y f. N ',j f W ? ( ^ A &.. Y ?) ?. y;f. k

o (6) ( i INSPECTION & OBSERVATION - (C) At 2,000 full 3h" strokes and 50,000 20% strokes at 480 in./lbs., attached Inspection Sheets indicate: Upon inspection of the non-lubricated linear 1-A. converter, the following bearings were worn (See Photo 2A.) to the point of replacement. Loaded side output shaft bearing. Unioaded side output sha f t bearing. The wear on these two bearings is accelerated by also by not only the 480 in./lb. side load; but the deteriorating output shaft (galling). (See Photo 28. ) the luLricated linear converter 1-B. An inspection / indicates: No measurable change in the loaded side output shaft bearing. No change in the unloaded side output shaf t bea ri ng. An inspection of the non-lubricated lower input shaft guide indicates replacement. (Photo 2C) 1-C. An inspection of the iubricated linear converter 1-0. lower input shaf t guide indicates only.001" wear. There was no measurable wear on the output gear or or input rack on either the non-lubricated or the 1-E. lubricated linear converter. Wear on the input shaf t guides is shown below: 1-F. Non-Lube Original Wear Axis tube Wear Diameter Dia. Axis Dia. {' i Lower Input Shaft Guide .755 .855* .757 .755 .793 .756 Upper Input Shaft Guide (* Bearing to be replaced.)

(7 ) { The loaded side output shaf t bearing was replaced along with the lower input shaf t guide bearing (and the test continues. l l ) i

.J $ E 4 %u$ @w s$y!? ?e m $ w$ $ $w a h NNW 5iN $F V 1 a %Aa t k mrw h tu m p&wm .? %y n5 Mrv sk ~nW ms%u;d:n% w w+:asa ksufM .rn en%:f 6kT:. w %m h. 4 l gw s, n omsrq q ~y ~.s. .s y-4,q n vm

. r.

1 eut; n;M-a w -@? w - FJ = F. < + = =t=- +w t , n v,,, W ~,.. Q ^,. ,;xc.+}-- p.c c a.y w - - - em. _. .-__:_e ,y.,,.; - n1 .~ {,.c.,.,y" - '=== h,'u" m g ..y. w hyf -a l'*** .e

cx.%2

~:. w & a %y.,

w, y . +- .N Mn 7, a, IGATION $ n$ E 2 m ga, 4 .} q; 't' Q g ; _ :g ~;- q_, u

i,-c 'c.5 '

M7 .i m QN N. hN. ESE@ng ! , + ' '. - 9' s-m gw#;y@?,Sf .x

/

T N si @W"e;iW.Yh.3NW ) 'L T-1 W DD3h[a? y$ ugy x NkNI g:n 3,

t g.*l

) q j istl

'*T@0.11@4 M9

g ! M;p f',-$4;g ' M'O ' a ~ FF. p[7 ? I M uS Q p' 4 ,, t t W"M 2 d4 I 1 s **.a <m h,- %. v' '. p > "Mc2ng:.n -. t. '>~ \\ o-n . mw, bO.*1i.@Wi%

~~'%,

Or 'p e% - 35 l 't ,,y t w;cy.2 y }gy i .s. ^ ;. \\ r..a., p y/gug

, e.

.n n.e v 1 , ~ e Wp 4575 v h d'. $ Yw I {hdk[f[ e 4.:, ? 1, N 'u f hy#w@ ?/ / qit ' 4;)h. ,MMW, ? V u%h'fk ,4 2 } M t,y,c. w,v%, d sc b g a; w, l,3 g "" 74 g l( I* ~\\i'

f

~4 4 r,~ .w hyx 6$ v$ih a; n s e a' e ~ 7 h I% k msm.n,, ,,,d 1 sem-rga

p. 4./

_ - h. :.p;;.~;a%m,yW"'e5.e a --9r At kwg s fys : / sk% ~ +: '?b

y. 4Ws-

? o.- w %w. o. :.. --% - j+- n., t. Nk d f :, m a $ 2 m.ip a l e 3 mg Y0 j af{irW?? l u ,, ' ' DYE? n6Ct .m m . c._ , Z,___,_;_, 4 a. .,y+Uf ( 7

y 9: _.; *; &,.y h_. iq'l(,:* & ~M' ..'f. ; t.. - J:.__.._'.8f.t ;.' __. ~ Q: y

y - M*.,[ -i ~ ;, );1r% -'
1*.. ; :R. %' ;gc -

ky,n- , l ':Q 4: s a n.- -

d W w,.

L e.', -s 3 w. - y n -s .-s .WpJ ' ,4A-W. s.7.?$.n.r,*.-

"f ec, ;

. g. +.a .. +. ,o .n ... 4-g ?. ..y 2 ..- g r 4.p , ~ 2 ,.4 .. 4.' ' ? ? : h.. ?. ~. Q. -M l 'i ~' ' m. kt> , s

4. k

. ' h..,

A.

, a ~' ~ ' *, J-u e 't Lyj 4, J = '. j., ~ ' h. ' -4. +.- f_' ' ~ Q.. 7 s. hs ~' s p / f . s ,r .') g } e plj. 3 4; r 1 f s D L,' d 6.' - ( e,,=-. uf ..!].- T V s" r _ ._) . w. f

- T 1,,.

[ g [. ^

3 Of&

j* . l ~ ~...- - ' - y. g. ? s , q ' '. 4 9 E e q p ,y T g '1 0 8 i;. o.. ~. l .. \\., -[ f 9 .,3 S g 4 =. s- ~ ,[ h - e'8 '....,,e' W,k g. e ' .4 's' ' 8" e,.g f -., . g'

av 1 - =- Syy l (U ) l i ( INSPECTION & OBSERVATION - (D) 4 At 2,000 full 3 " strokes and 75,000 20% strokes at 480 in./lbs., attached Inspection Sheets indicate: 1A. Upon inspector inspection of non-lubricated linear converter, the " loaded side output bearing was worn to a point of replacement". (See Photo 3A) Thi s i s ~ the same bearing that was replaced at 50,000 cycles. The side thrust and the galled shaft (Photo 38) are the causes of the wear. On the lubricated linear converter, the loaded side output bearing is still not showing any wear; however, slight galling is beginning on the shaf t. There was no measurable wear on the unloaded side output bearing. 18. Wear on the upper and lower input shaf t guides are as follows: Non-Lube ( Original Wear Axis Lube Wear Diameter Dia. Axis Dia. Lower Input Shaft Guide .755* .830 .757 Upper Input Shaf t Guide .755 .806 .756 (* Replaced at 50,000 cycles) (See Photo 3C) 1C. There was no measurable wear on the output gear or input rack on either the non-lubricated or the lubricated linear converter. The loaded side output shaf t bearing was replaced and the test continues. C 4 .u.

mm_,

_______-.m__

h N Y hbh ',. k: Y [ ' ' ~' "" I ~., - y ~ 1 p 4 : q. x ,+ m - p ~ r c'--.. .g ,..,,- ; s 3 .J t nn - - X3~ ' ~ ' I '. W'.Q. , Y.Y [ mf'$,- ',' h ..*Na-1.~ ; e.

.4. ', ~

f- '4. pn=[. - - :' 0 %(. ~ Q r ^^ r"

ggy y l'

4 [. ... '.-1 h

w'.

. ". ~ ' [,( N w .s .x q .g -.- j w.'. s ...2 t. sur y - =. >v g 4 ' '.,* '

4,... <. #

) f;n @. ' I*~. [' ' ",. *[ - .- [ g .g. .'/,. N e 'm ~ Q

y. -

f. y,- .s* 1_ ~ y . ef y .... 2 i [ vf.". " f *, ' f M - z. ; "J ~ - i, gp l s, f. ~..}gz. ..u ' '. - ~ ' + ys*. + " 4. p_ w. ...., ;. ne' 4 , -4.g. - n l ~ +, - <. s..- l' N 4 *.. 7 _.%. Ek [ ' V..'*,' ~ .. g. p p,_ ~ A ., w ;, - .~, -. '.< y. 1. .(- e .j-. _, j' t l, g 4. [ ~ 'k Pk*h 4 l c . _ y_ g m ,e L' x. s. i. l_ y, f ~~ !a s j 'my {- b ~ { i-V .4f., j .. r. .f s .e 3 ~ f. i f } 4 o. r. )...u [p ~. f'. h y .j.

4. e. <. '.

..y.. r t-y -. +, -- -... (, $*. $I ~ .".. f .d s s A w9 $'....f.t W. a,..samm 45 L ' r 4 ' 2 eu. 8 '"j..,C,, Y g ..q 3 ,e ~

d 4{

7 P

6 % . pt -- 4 ,1 $.. i . +-, ?$

.).;

1 y g

. ?

'. j, ' w: 2 = . 5 ~ ~ A r W l M tp e>,, J .g.. - ,} I i s, e

g 4 d

'h J

-e. 8 d h3 % l' * '45 %. Q Q. '"=^%Cly %7Q' ~js{^7Mi*fh g#Ny;W M iLW; ~fQg,Q".V;<# % y$$"*% il &^ ~ E ~)"" ~ ~ * ^i:. ~ ks -. f I $ I q;[ ,[ u~ ; nr m m N w " y$ M, x x ~ k $ S e h $ m$ $ $ $ ~$ N _ W p. . ~h NMd$$@ 8kkk Y b m #g e=C we a m y% n g. #~gs4 + q q & w w.:-wt w : q m" T.- nnN $$$wa: $ l ! 51* 0., w*e? e. WL a s = ~~ 3 . n ~g% fn, _M mc%wi %n%anda*dkb., hg%fgw*T. np. pg *"f. my era -. ymw f m hg!6% ear,g.O,Y% ~ QTh,~.. &r..n. ,v'5fy Jt%> fg,k @q,,% ) MM n fg %. d Q L kNihhhhN[bkhNE y -..:g. n, p m w. %a &m%anawsa sp%a f 2 A 4t M/A

TQM%r? 57,&&g%:ls&mw&w+$MGil%QGBQ&uymc&@%

m . N= $ Y 4 % Q dMgga[g?Q?Bh 6 w a w kis s w p % M E es W E gme QQj 44M MNERdTM N%@%E$8EM@@EMM@Ms M idh$$$$Id$$@ ,gg g ~q.sy wee % eest%,e m m p eggg p fwR;g?p QP y f1/ e at O~ 5 % w M il % :gggg&m:S. .+ p ..,j; ~;~ g n a .p q$ra:xlgf.$( r W.:6 N s..., $ D. 9 et w w @a.dM y ys y M %e g~t - f.M .+wg %a m w ~ r w;L..,:~ n u r.

an%w ne gy-e n tw

..w a . g m v%j,,..42w%v. h 2h ?.hkN k =, u y I h hh5 $?o$the f ? Mew @$ ig.w4 a W ma 2:- )J[lM$gD +Qm,% y[,[$u.a#..;$$ s y%v...m wn w emm ,,7.. g khjA f( ffys$i k if %'jY g[5%!$3?%sm;aQ, w<~l. w&% u d~E$$ l+&n, -{m e g / ~ -w. x&m%a4[%# 4 1 i wf.e,.mm

w ~n cs, e
+y,+

y.s ws N .g 4 ..g. e,

g.. 4 44 m.,

.n nn 8 a[ m a = = g p@n a ^' Y &e v @1 w5bN. w%$* Y ;h,' W-{NMW**vDAMh h %m$NfgMk[n@- ana n d M, M S F~ # WB ss MBM.Am$nsW b J M k w#$ $f[A s W Q i4 W e s % I n tw @ 9 a w[' N nn '1 mtmp3M t WghWe y?"%g n$$e$ e$@ wd&gm4gesg@p@I!6dg%ssa Y$50YNi$hb hhhh$Y $ h f k h 5 k kfS Yhb $' $h ss$gAgswh T MM NdP%RheM h a $ $i M n y kk$w%emphn%%ghhhthbN;w3P

aw%ggggg M4 4WFsS

/ 5!M ed mm% 4?egw &sw!P4 M e@$$@p$n f$E$hfh bTEQdt hrhkh$$$W JMW4hdeM&#e4d B m wmn geWW W4WMqg d EWhyeNo wp%ew yn exn m m w w a w g.. n u p megemeyenm swm%m s .a ,m rt-' .i r a p. 9 4

~ n; _ + (9) ~ INSPECTION & OBSERVATION - (E) i At 2,000 full 3h" strokes and 100,000 20% strokes at 480 in./lbs., the attached Inspection Sheet indicates: 1. The wear on the non-lubricated lower input shaf t guide is the most vulnerable point of wear. This shaf t guide had to be replaced at the mid point of the test (50,000 cycles) and the replaced shaft guide showed.035 wear on the wear axis at the con-clusion of the 100,000 cycle test. t In cor,trast to the non-lubricated linear converter, the wear on the lubricated lower input shaft guide at the conclusion of the test (100,000 cycles) was only.002". 2. The side load induced on the loaded side output shaf t bearing caused this bearing to fail at 50,000 cycles and again at 100,000 cycles on the non-lubricated linear converter. We do not feel this bearing would fail under a balanced load. In contrast to the failing of this loaded side output (, shaf t bearing on the non-lubricated linear converter, the same loaded rice output shaf t bearing on the lub-ricated linear converter showed only.015" wear at the completion of the 100,000 cycle test. It should be noted that light shaf t galling has scored thi,s bearing (not to the point of concern - but, it should be noted). -3. The unloaded side output bearing on the non-lubricated linear converter was replaced at 50,000 cycles and showed.017" wear at the conclusion of the 100,000 cycle test. This bearing failure at 50,000 cycles was due largely to the unbalanced load induced at the opposite end of the output shaf t. We do not feel that this bearing would fail under a balanced load. In contrast to this, the unloaded side cutput bearing on the lubricated linear converter showed no wear what-so-ever at the conclusion of the 100,000 cycles. 4. The upper input shaf t guide on the non-lubricated unit showed.035" wear at the conclusion of the 100,000 cycle test. k

r# d. . 2 3 ( 10 ) In contrast tc the non-lubricated unit, the upper input shaf t guide on the lubricated uni t showedi rro wear at all at the conclusion of the 100,000 cycle test. 5. Attached to this section is a series of photographs showing the non-lubricated parts and the lubricated parts at the conclusion of the 100,000 cycle test. They are identified as follows: PHOTOS 4A Upper Input Shaft PHOT 0S 4B Lower Input Shaft PHOT 0S 4C Output Shaft FH0TOS 4D Output Gear PHOT 0S 4E Input Rack PHOTOS 4F & 4G Output Shaft Bearing ( From these photos and our observations, it is obvious that lubri-cation makes the dif ference.

% +@&4> 's to k i 9# IMAGE EVALUATION //j C /% \\ F TEST TARGET (MT-3) [,fiefg, Q/// % 'f g f/ y,, /Qs k ~ + + 1.0 l# B m y l} U? 1.1 [* E=4 W '8 1.25 1 1 1.6 14 150mm 4 6" 4 ?);f_m$ ah_.,*# s 4 O 4$>

rygAg =r y 5,,,, - -+J hp N,(;, ,, f5'ik-4. ce 4l.%,' '::,, in,L ' l \\ t, -L:f,i* 'y, ii 1 I j _y,,,,,,, PHOT 0S 4A

, M2 Mi%m ;ry/r,-)p e iaff h:. '7't5 qwme wuc 4. i-W4

c j

.4 4 'Tw4f(fi.l;Vb,.-/<

?

s. l .sb., 44,, ; ~ r. . :e r _t 4 h a h i F. g E: Y-2 ~ R.t-4.iEWS . =p, v 8tMMk5i-a M PHOTOS 4B 1 l l 1 i

- - - - - - - -41

f. ?,, 3,.,.,?_-s,.

Y h ? ,. '~,, .T p h. ) ' %?W: [n:.yd$,5;;, A s[,!? f ~r cy) e: g..%,j ';ki "q s 4, 4 - .'r 6 WJN ?_, y- -.6.- 6 -_...-w a u. A i ) i 4 4 1 ,s..--.,-,._,.,,__. ~ . h b. f * "d. ad + Se.4 ,.,C^***g's.W, 9 -*4 .MoG-Q *%sRKATEb ?f 4 e, PHOT 0S 4C i

l C.iz a i{pp.* 'M.. 4..we% Q' ^ ' ~~ ' %;' fe ~ ? t k .-s ht.%;3gg 'awma yneg'w m- > -3.n Md$w. -cfAp@ 3L ,.~ ( i --upA[faffLL.s,Q

-fc<

' 'prfy.,1:M f -m. --4 $, r sr,- n S < - - W-

L'ArchWp4l?)[gy;A M

N T * 4W ;}-

p. &

3 4 **f 1, a m--

M*e :'* tj.* * ^^

_....w.g MS :. :&..im ~ - w q [e Jy..y' . _, ~ - % ~. 'fd!"I[ $d.i'2 ^ gp-y ~.., m ..'s% *W Y y j u Q.' 'AFu ~ .;,~;* - . p - -Q1,*.. J* y;. a- _ ', - .e ~ k 0 1 s (

~, v ap L, ~ ~ r l 31 7 2 y 3, b - e.!. of d d : 1s8.s e reis.s,t.ean s, m o l y" t 't 'i'l'n's ;ri e s Wf 3 girppg 8 , ~. 1 _e l et a a.:.i.e e....... .e 'I'l'l'l'I'l'I'll'1'I'I'I'fffg o g

9. + %MLykof *M

- % ' i %

I? p *.

+ W# % ', 1,. C ,7= i K... .v %,W ? .. b. # I e e .' ) vv.., r-9e, p'.- 'd# g _,\\',.' &0 ",';N '.'. r.x. [ 5 l-N

y y-

.. m., w?,t gm., $ wa.:...,.... + g w. .~m +

.., v t

,v,,. -

y:a - n e-,~ ... - n-h ' f,t.,*,,;~ . _.. s.. g.. - .M..

b 9 mew '_M.

< ' DWTM'C' &"*, l.s.? $,s 4 3c ' ', k ~'* N'J.g ?.,,.1, , i %, ~ ~% - -s 4 3 7. f

4(p,.g f,,.

g*f 4; M,'W?.'E$ % R.'NW?$'-&,if, h * " +7'% $A 9%hh?@.iW M w$hg2~,/i^.k.s.1;$u,,..';4<-U$ ?thh .m %r.3FWM-P. g.i - ( 4 o m w e. ,5 c% -u :nm L}-Jhh.hh, h,s?,L$'?h. ?h. .s p s qw y. - he... R.?*h'=; y r,,-w %@4,Y $}. l*U -4

4 d
t s.N.I.

'Q$%% h,.; %l,&c'i&Y$h..,'L 1

g-

.@ j y 7l, w. s, es 3 f RN -g* *u T. x "sig o,-m~ %yv. .y. .gc wp;.w'?. e-rg +M q:.

~g, @ ; 3.~; y-},_. g W4.1,f. v & y*.

~ 5.Yl} &h$h&ly $ ?. e h hk.,d~ YAN, W; f. ~ %%2.%QL;& ,Qm'~L

i

,}.,,- f,',' n:,,. ~., ~;,,... f ', .'e3" ( 3 pe< u, u 3-e. ,-s.- g,, ,r, - ~,

r#.

*../.*

b' Fh-n 99'*-, i s*[ ' * *. Ni hJke,"., sp amp

t.

p. -f. t;:<[M%g ,s).;gge:,,*a _h.

i',

't - s- , a' t.. "A. e, ~ g.y.. 4. .?9 9-t W.'j

70/ %

/-. 4 . e.3. 3,y 2 s q.. 2 t. . ~. .( c b pqh _.,qihp ((( eps ' 4r, ' '." J'. *;h s*..W l.uY? d.c '*s.. f.?{z.$"$hh.. e e d 8'8 g 8'P 9 4,,

h a

n 0 3 D 4 I PHOTOS 4F

p w ~?--

~ - ~ w7

4

, ~. ~.: '*2 ** y. +:...

M - r.;,3 ;,,_$',W!?;.; ",t*;Ry %'@ Q' ..p v a, -.

1's y xb y yg.,*;

l - ~ n Q:. > '.::: %g. f.;y; ;. e y, 1 .+. -,...b'd

M t

4. .s j;. M 2 [. q + -.,.4a,, gg .,g A s. qq e. 9 w a.. : y l y

, f.,,;

~ \\,.,. Y: ,,..+ g+. .u .-% (, ,- - i.$, e g '" ^ W e s'e 4, / i 4 l k s. t .g l 1% v = n} ~ e f q j w 1 4 t I = g w ,f g3 ~ y e g. h 9 f, ,t..h 4 s 344 -}}

ML20086L098

Contents

Text

Subject:

. = =

Navigation menu

ML20086L098

Text

Subject:

. = =

Navigation menu

Search