ML20092N702
| ML20092N702 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 06/29/1984 |
| From: | DUKE POWER CO. |
| To: | |
| Shared Package | |
| ML20092N701 | List: |
| References | |
| NUDOCS 8407030456 | |
| Download: ML20092N702 (198) | |
Text
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CATAWBA NUCLEAR STATION DIESEL ENGINE 1A COMPONENT REVALIDATION INSPECTION PINAL REPORT i
PREPARED BY DUKE POWER COMPANY June 29, 1984 t.
I 8407030456 840629 gDRADOCK'05000413 PDR
Table of Contents 1.0 Introduction 2.0 Summary and Conclusions -
2.1 Overview of Inspection Results 2.2 Piston Skirt Cracking 2.3 Subcovers 2.4' Cylinder-Head Leaks ,
2.5 Conclusions 3.0 Discussion of Inspection Results 3.1 . Inspections Related to TDI Generic Problems 3.2 Inspections Related to Catawba Specific Problems 3.3 General Inspections 4.0 References 5.0 Appendices A. Inspection Reports B. Engineering Validation Report Figures 2-1 Cracked Type AN Piston Skirt 2-2 Cracked Subcover Castings 2 Crack in cylinder Head
. Table 2-1. Summary of Catawba' Diesel 1A Post Extended Operation Test Results b
l l
1.0- Introduction This . report describes the results of inspections and evaluations gy performed on the Catawba 1A diesel engine. These inspections were performed as _ part of an overall program to verify the reliability of Transamerica Delaval, Incorporated (TDI) diesel engines used for safety-grade power supplies at Catawba. The overall program is described in an April 5, 1984 letter to the NRC, reference 1. The scope of the inspections meets or exceeds the TDI Owners Group inspection program.
The inspections of the LA diesel engine discussed herein were performed
. in April through June, 1984 The inspections involved extensive disassembly of the diesel and 100% inspection of parts for which there was a- history 'of problems or other reasons for special concern.
Substantial (e.g. 25%) sampling inspections were perforred of other important parts where there was no history of problems. The scope of the inspections is essentially as described in reference 1, with the exception that - pistons , connecting rods, and related parts were
. inspected on a 100% basis rather than on a sample bas is . Also, one
' additional main bearing and three additional cylinder liners were added to the inspection plan.
The diesel disassembly, reassembly, and inspections were performed in accordance with the Duke Power Quality Assurance Program. The assembly, disassembly and inspection work was largely performed by Duke Power personnel, with selected inspections performed by Failure Analysis Associates (FaAA) and Stone and Webster (S&W) personnel in conjunction with the TDI Owners Group program.
Detailed results of the inspections are contained in Section 5.0, Appendix A and are discussed in Section 3.0. Some parts which are important to diesel operability were not inspected since inspection is not called for by the TDI Owners Group program and there has been no history of problems. For such itema an engineering evaluation of the ,
operating and maintenance history of each of these parts was performed >
and is documented in Appendix B of Section 5.0.
This report on the Catawba lA diesel inspections covers over 99% of the
. inspec tion plan which includes over 4780 separate inspections.
j Inspection results not covered in this report.are as follows:
e Material comparitor tests on valves. These tests are awaiting a material sample from FaAA.
I o Eddy-current (ECT) test of fuel line tubing. These tests are awaiting FaAA scheduling. [
r This report- is the final report on the Catawba lA inspections. A supplemental letter type report will be submitted covering results of
[
the material comparitor and eddy current inspections mentioned above.
! Upon reassembly of the Catawba lA engine, walkdown inspections of the
! various piping, tubing, and electrical conduit runs on the engine will .
f L be accomplished. Results of these inspections will be factored into the Owners Group Phase II program. .
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i.
'2.0 Summary and Conclusion.
i 2.1211EliEE 91 Inspection Results l I
In March 1984, the Catawba 1A diesel engine successfully completed !
(reference 1) its extended operation test which resulted in more than i
800 total accumulated hours on the engine. This test confirmed the :
I ability of the diesel to operate reliably for long periods of time at Subsequent to the extended operation test, extensive l high power. !
disassembly and inspection of this diesel engine has been performed to confirm the satisfactory condition of various parts and to identify any parts requiring repair, replacement, and/or redesign to ensure highly reliable standby electric generator service. ;
The post extended operation test inspections are now nearly completed, ';
with the only exceptions being as outlined in Section 1.0. The results o f - t he . inspections are summarized in Table 2-1. Engineering and i quality assurance evaluations of the inspection results have been performed. This work is considered to have identified all significant condit ions . These conditions are discussed below. ,
i The most significant results of the Catawba 1A diesel engine post ,
extended operation test inspections are as .follows-e Many of the major problens experienced with other TDI diesel !
engines did not occur in the Catawba IA diesel engine. These l problems include failed crankshafts, cracked connecting rod- !
crankpin bearing shells, connecting rod box cracks,and cracked l cylinder blocks. .
r One major problem was noted on the 1A diesel. Four of the i type AN piston skirts used in the 1A diesel were found to have !
one or more crack s in the region where an internal ;
circumferential reinforcing rib intersects the piston pin boss (Figure 2-1). This problem is discussed further in Section ;
2.2. }
e The turbocharger thrust bearings were found to be severely i worn, even though they had continued to function !
satisfactorily during the test. This condition was ,
anticipated since similar problema have been experienced at l other s tat ions. As a result of this history, a redesigned !
lube oil system is'being developed which it expected to prevent recurrence of the problem. It will be installed by September 1, 1984 In the meantime, the bearings are being i replaced as necessary to ensure operability. l e Several other problems of potential significance to diesel ;
operability were detected and are being further investigated l as part of the TDI Owners Group program. These are: ;
f l,
f
- Two subcover castings were found to have cracks in an intake rocker are pedestal (Figure 2-2). These cracks are discussed in Section 2.3.-
- :Two- Catawba cylinder heads (one on diesel 1A and one on IB) experienced ses11 jacket water leaks into the fuel injector cavity. Meta 11ographic examinations of the head removed from the 1A diesel indicates that the leak was due to a fatigue crack (Figure 2-3). This problem is discussed in Section 2.4.
^
e A small eddy-current test (ECT) indication was detected in crankpin to web fillet #7 (generator end) on the crankshaft.
Metallurgical examination using replicas indicates that the indication was due to a .027 and a .021 inch long linear defects located about .105 inches apart. The .021 defect was polished out at a depth of -less than .005 inch. The .027 inch indication was polished out in about .020 inches of depth.
Another indication was detected by fluorescent dye penetrate in the #8 main journal oil hole. This indication was approximately a quarter inch long and made up of a s tries - of extremely small pores. This indication was polished out in less than .005 inches. Evaluation of these indications shows that they are due to initial fabrication. This problem is ,
discussed Section 3.1.1.
e A variety of routine minor conditions were noted, and are discussed in Section 3.0 and 5.0. None of these conditions impact the operability or structural integrity of the diesel.
Typical conditions of this type include: ;
- Chipped and cracked edges of rocker are sockets. (Section 3.3.1)
- Chipped and removed valve stem chrome plate. (Section i 3.3.2) ,
- Jammed air start valve adjusting nut. (Section 3.3.3) ,
t
- Heads of small bolts broken off, due to under or over I torquing. (Section 3.3.5)
I 3.2 Fiston Skirt Cracking .
-Four type AN skirts were found to have cracks adjacent to piston pin !
bosses. (Figure 2-1) These cracks run approximately vertically, and I appear to initiate on the inside of the skirt where a circumferential
. reinforcing rib intersects the piston pin boss. The largest crack, on skirt 3L, was through wall and was about 3 to 4 inches long on the outs ide.
t i
~. . . .. , _ , . - .__,.....o_._ , . _ _ _ . ._ _ _ , _ , _ _ _ _ _ . _
It is understood from TDI that this type of crack has never before been reported to TDI for stress relieved piston skirts. However, similar cracks have occurred on non-stress relieved type AN skirts and, as a result, TDI recalled non-stress relieved skirts for stress relief.
Those Catawba IA skirts which had not been originally stress relieved were returned to TDI and stress relieved in 1983, prior to the extended operation test and other tests. Thus, the cracking of the Catawba 1A skirts indicates that this type of cracking is possible even with stress relieved type AN piston skirts. ;
An extensive failure analysis of the cracked Catawba type AN piston skirts is now being performed by Failure Analysis Associates (FaAA) as i part of the - TDI Duners Group- program. This program ' includes determination of' residual and applied stresses, fractography, and ,
metallurgical evaluations. Prelirf ty results indicate that tensile residual stresses on the order of 2' asi were found to exist in the area where the type AN pistons had crac'.ed.
The cracked AN type piston skirts in the Catawba IA diesel did not cause any operational problems, and 12 of the 16 skirts were free of cracks.
Nevertheless, all the piston skirts will be replaced with improved design AE skirts. The AE skirts have been stress relieved and include improved . design features such as a thicker reinforcing rib and better .
rib piston boss intersection details. These improvements are expected to adequately reduce the stresses and propensity for cracking in the '
area which experienced cracking at Catawba. The FaAA/0wners Group program will quantify the benefits achieved by use of- AE piston skirts.
It is anticipated that this will show that no cracking is expected during the life of the Catawba diesels. The AE piston skirts also incorporate the latest improvements in the stud boss region, which has been a problem area in earlier piston designs at the skirt to head transition.
2.3 Subcovers Two cast iron subcovers were found to have cracks in a pedestal where ,
the intake rocker are shaft is bolted to the subcover (Figure 2-25).
Prior to 'the extended operation test, another rubcover was found to have a piece of this pedestal missing (Figure 2-2C) . None of these cracks I
- have affected diesel operability. However, since similar problems have i been reported with other diesels, FaAA has initiated a failure analysis i of a Catawba aubcover as part of the Owners Group program. Preliminary ;
I studies indicate that the cracks are due to installation tolerances -
L between dowels, bushings and the pedestal leading to excessive interference and possibly fatigue cracking.
L 2.4 Cv1(= der Eggd Leaks ,
i i Two cylinder heads at Catawba, one on engine 1A and one on engine IB, [
l developed small jacket water leaks into the fuel injection cavity. The :
i- 1A leak developed during the extended operation test and the engine was l l
shut down due to other problems three days after detection of the leak. i The 1A leak did not affect engine operability. The leak on the IB ;
e
engine was of similar magnitude to that of 1A. The 1A cylinder head has recently been examined by FaAA. This investigation (reference
, 20) revealed that the leak was caused by a crack initiating from the corner of a welded-in plug where it was seated in the cylinder head (Figure 2-3). This welded-in plug is reported by TDI to have been used to repair the casting around the. fuel injector hole. Evaluation of all heads insta71ed on Engine 1A (reference 22) indicates that one other head (6 left) has been repair welded with a plug.
The leaks caused by the cracks have not affected diesel operability
- since they result in small amounts of water leaking into the fuel injector cavity and then off of the diesel. As all of the heads now on diesel 1A have experienced no cracking and were not leaking after the extended operation test, the heads are considered acceptable for continued operation. However, the repaired head (6 left) will be replaced as a matter of conservative judgement.
2.5 Conclusions
'This is the final report on the post extended operation test inspections of the critical areas of .the Catawba 1A diesel. The extended operation test and the post test inspections have demonstrated that the Catawba 1A diesel will reliably provide standby electric generation. The extended
. operation test was for the most part accomplished at loads significantly greater than required for standby electric generation. As such, parts inspected have been subjected to considerably higher fatigue loads and temperatures than will be actually seen in service. The inspections have indicated that the piston skirts must be replaced with inproved type AE pirton . skirts and that a few minor damaged parts such as subcover castings with cracked pedestals should be replaced. In addition, the diesel engine preventative maintenance program will be re-evaluated
- based .on the results of these inspections to determine whether additional periodic inspections are required. Future correspondence on the Ca.tawba diesels will include: return to service operational t es t
! plan once diesel 1A is reassembled; preventive maintenance and periodic surveye of the diesel; and periodic tests of the diesel.
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?I Elevation view of skirt Cylinder Hib Bou Crack 4
V skirt Shen 7,
View A-A Detail of crack initiation FIGURE 21 CRACKED TYPE AN PISTON SKIRT c.
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Cracked Pedestal __. g3 - m W5h\
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\ Tapped hole for Bushing OowelHole \ p
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- 8. Crack in web between bolt hole and surface C. Cracked off Edge of Pedestal i
FIGURE 2 2 CR ACKED SUBCOVER CASTINGS l
Non Welded Sosting i
Sudeos W Mus Surface of Water Passage y
Fuel iniector Water leek Path Senting Surface i
s.f w y
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77 77 c,. c.,, r - c.sti,
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weid Fire Deck FIGURE 2 3 CRACK IN CYLINDER HEAD
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} Jeest w Inlet m in-u Asambir 03-3ua - 100 - - - - - -
amm8% - Ommre Gmag Phase II Bushetion Juchst maar Isht maisou capHus 03-3Ms - me - - - - - -
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03-M5s A 25 - - - - nat i ='-*-y muciet for sem mianc =e.=**==.
het Tappets - - -
autisfactory het FM amme Assembly 03-MSc a - - - - - - Z 9 03-350L & - 100 - - - - - - antisfactory cammhaft Assembly
>- *actory cumbedt am. ries M-350s - 100 - - - - -
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'anta h tory j cemhaft &gparts, salting and Gear 03-350C A - IN - - IN 10G - -
03-35 % A - 100 - - - - - - satisfactory 4 cr-*a=* Gear setlefactosy i Idler Gear Asambly 03-355s A - m0 - - - 100 - -
amt. acept for one jammed at & missing pia 0.3.3,3.1.13) j Air kart h1w 03-359 A 100 100 - - - - - -
satisfactosy acept for ame luk U.4, 3.1.M) cyliment amad 03-3s0L a me 100 100 100 - -
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satisfactosy Cylinder Essa molties and Gaskate 03-3sec 5 - - - - - - 1 -
antisfactosy the springs 03-31 8 s - 100 - - - - - 1 antisfactory mesyt for tem cracked pedestals (2.3,3J.6) subcover Ammmmbly 03-M2L a - 100 100 - - - - -
the hoMars to be refurbished OJ.1) het Injection Fw 03-36M s - IN - 100 - Im X 9 satisfactasy het Injmetian Tipe 03-M5s a - - - - - - I 9
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- 1. Tatake and exaust valve erriage han proper color code.
- 2. Ultrasonic well thicknese mesesremest of fire deck area and fuel mossle area, seg av to determine if head has been repaired.
! 3. A terciograph was developed of the creakehaft. l 4. Creakehaft web deflectices and thrust clsarance wee esasered with the i diesel hot and will be measured cold. ! 5. Nessure torque es believille sprias loaded volte. l 6. mardsees of the speels see not messered elace escoesive west had not l occurred. l 7. Isopec times of the camsbeft hearings wee met performed elace as l inspection of the camshaft lebes showed no abnormal wear.
- e. act inspections were limited to both ende of all high pressure injection lines.
- 9. sagineering validaties of part is to determine that the part is per bill of meterials and a review of unscheduled asistenance reporte associated with part.
I I ( r
I E i i 3.0 Discussion 21 Inspecti21 Results I This discussion of inspection results is contained in three parts. The
- first part (Section 3.1) covers inspections related to the 16 generic ;
!. problems being addressed by the TDI owners Group. The second part (Section 3.2) covers inspections performed to address concerns raised by specific problems which have been experienced with Catawba diesels. The third part (Section 3.3) covers significant inspection results arising . from a general inspection of the engine. All of these inspection results ! are documented in the Appendices Section 5.0. j
- 3.1 Inspections Related 19. IH1 Generic Problems The inspections related to TDI generic problems which were performed, and the results of these inspections, are described below.
3.1.1 Crankshaft (Part No. 02-310A) PROBLEM: A crankshaft failure occurred at Shoreham. The cause of the ; failure being high cycle fatique cracks initiating from F fillets in the crankshaft at the junction of a crankpin and [ web (reference 2). Similar cracks were found to exist on i other crank-web fillets in all three diesels at Shoreham. l r The Catawba crankshaf t design differs from that originally used at Shoreham. The Catawba crankshaft has substantially i Iower stresses, which meet industry standards and are not [
- expected to cause problems (references 3 and 12). .[
Nevertheless, it was considered prudent to inspect a sample of : crankpin-web and main bearing journal-web fillets. l SCOPE OF INSPECTIONS: The crankshaft inspections consisted of: e Web deflection measurements. e Visual inspections of the crankpin journals and the ; fillets at either end of all eight crankpins. t e Eddy-current inspection of crankpin-web fillets for all ! crankpins except f2. f o Visus 1 inspection of main bearing journals and journal to I web fillets for main bearings #4, f5, #6, and #8. ! l e Flourescent dye penetrant inspection of oil holes in main l bearing journals #4, #6, and #8. l l o Torsiograph tests. h p l l . I + a e + - - , ..- ,.gm.,w,,w.---- .,m.. __,e,_.w,w.,,,. ,m. -.,.-..o__, __,.,..,y,,me %,,e.._ , ,.,..o-...m.., _ _ . _ , _ _ _ , _ _ ... ____ __
._ - - _ . . . _ . . _ - = . _ . . - -
No unusual or reportable conditions were noted, with two exceptions. A small indication was detected by ECT on the generator end of the crankpin-web fillet for c::ankpin #7. Detailed examination by polish kg and taking of replicas indicates that the ECT indication was caused by a .027 and a
.021 inch defect linear defects. The .021 inch defect was I polished out at a depth of .005 inches. The .027 inch indication was polished out at a depth of about .020 inches.
1 A small indication was detected on the #8 main journal oil hole by fluorescent dye penetrate. This indication was approximately a quarter inch long made up of a line of small pores. The indication was polished out at a depth of about
.005 inches.
Torsiographic tests were conducted by FaAA. Results, reference 16, indicate that torsional vibration frequencies and stresses were almost identical to the Grand Gulf tests and also that calculated by TDI. These stresses meet industry standards.
SUMMARY
-j.
In summary, the inspections of the crankshaft indicate that it is free of significant defects and is not experiencing the type of problem esperienced with the Shoreham crankshaft. One 4 emell indication was detected by ECT in a crankpin fillet. Results of a FaAA analysis (reference 24) indicate that the indication was non-service induced. The small indication on main journal oil hole #8 was porosity or a machining mark and therefore not service induced. , 3.1.2 Connectina Bad pearinas (Part No. 02-3408) PROBLEM: Several connecting rod bearing shells in the Shoreham diesel engine cracked. Analysis performed by Failure Analysis
- Associates (reference 4) indicates that stresses in the Catawba diesel engine bearing shells are about one half or less of those that were present in the original Shoreham
' engines . Thus, cracking of Catawba bearing shells was 7 - considered unlikely. Nevertheless, thorough inspections of ! the shells were performed to confirm freedom from problems. SCOPE OF INSPECTIONS: I The bearing shell inspections consisted of: t e Visual inspection of bearing and back surfaces of all j 4 bearing shells. i e Measurement of the thickness of all bearing shells. f 1
e FT examination of the bearing shells. e X-ray examination of all bearing shells. RESULTS OF INSFECTIONS: No - cracks were detected by visual, or liquid penetrant inspection. Visual and liquid penetrant inspections indicated ' babbit fatigue in the area of link rod mazinum bearing pressures. This has been evaluated and found to exist on all TDI vee block engines and not to affect bearing operation (reference 17). X-ray inspections indicate that five of the sixteen bearing halves inspected do not meet acceptance standards.
SUMMARY
s ' Surface inspection results indicate that connecting rod bearing shells are acceptable for continued operation. X-ray inspections results indicate that five bearing halves do not aset acceptance standards. They will not be installed in the engine. These bearing halves will be retained for further investigation. Spare bearing halves which meet all inspection standards will be installed in their place. 3.1.3 Fiatama (Part No. 02-341A) FROBLEM: Cracks were experienced at stud attachment bosses in 94odified AF" piston skirts at Shoreham (references 5 and 6). 23 out of 23 " Modified AF" skirts experienced such cracks, while one AN skirt did not (reference 6). TDI indicated that type AN skirts have been widely used and, if properly heat treated, would perform satisfactorily. During the extended operation test, Catawba diesel 1A had type AN skirts which had been heat treated at the factory. Because of the freedom from reported problems with AN skirts, no problems were espected with the Catawba piston skirts, and Laspections were originally planned on a sample basis. SCOPE OF INSFECTIONS The inspections of piston skirts listed below were directed . at assessing 'their structural integrity. Some of these inspections were planned on a sample basis. Nowever, as a result of cracks found near the piston pin bosses, 100% inspections were performed. e Visual inspection of 100% of the pistons skirts. e FT examination of stud bosses of 100% of the piston skirts. I
e PT examination of piston pin bosses of 100% of the piston skirts. e FT or NT examination of areas adjacent to piston pin bosses (these are the areas where several cracks were noted). e Ultrasonic (UT) and radiography (RT) examinations were performed if PT or NT indications were observed. RESULTS OF INSFECTIONS: The most significant condition noted was the presence of cracks in four piston skirts adjacent to piston pin bosses. The largest crack was 3 or 4 inches long and was through the wall. The cracks appear to originate at the skirt ID, on the fillets where a reinforcing rib intersects the piston pin bosses, and to run in an approminately axial direction. The cause of the cracking is unknown at this time but is believed to be due to cyclic fatigue. Skirts have been sent to FaAA for failure analysis. One sus 11 (1/2" long) linear indication was also noted in the bore of a piston pin boss. No indications were found at stud bosses. SUNNARY: Cracks were found to be present in piston skirts near piston pin bosses. As a result, all of the piston skirts will be replaced with type As pistons. In addit ion, a detailed failure analysis has been initiated, as part of the TDI Owners Group program. 3.1.4 Cylinder kinar.s.(Part No. 02-315C) PROBLgN: Severe grooving has been noted in at least one TDI nuclear diesel engine (reference 7). This grooving was attributed to . debris that entered the diesel during assembly or initial startap. SC0Fs OF INSFECTIONS: All of the cylinder liners were 100% inspected to check for the l presence of grooves or other damage. t t [ ! l l l i i L _ _ _ _ _
RESULTS OF IWSPECTIONS: No significant grooves approaching the 1/16" deep grooves seen in the Grand Gulf diesel were observed in the Catawba cylinder liners. Minor pitting and scratching were observed which is normal for a diesel which has seen substantial service. These pits and scratches are considered to have no effect on diesel operability.
SUMMARY
The inspections indicate that the cylinder liners are in satisfactory condition. 3.1.5 Cylinder }Jssjt (Part No. 02-315A) PERLM: Cracks have been reported on cylinder blocks in the area of the cylinder liner landing and at cylinder head stud holes (reference 7). SCOPE OF INSPECTIONS: The cylinder block inspections included the following: 4 e The area between the cylinder stude and the liner and the area around the stude were PT examined for all cylinders. e The cylinder liners were removed from seven cylinders (3,
- 4. 5 and 6 left; 3, 4 and 5 right) and the cylinder liner landing area within the block was PT examined.
e The stud holes were examined by ECT for the seven cylinders identified above. RESULTS OF INSPECTIONS: 1 No significant indications were noted.
SUMMARY
Cylinder block cracks were not detected on diesel engine 1A. 3.1.6 Ensina jaan (Part No. 02-305A) PROBLEM: j Linear indications have been reported as enanating from main bearing stud holes in the engine base. These problems have been attributed to inadequate bearing cap stud preload (references 7 and 13). i I L
SCOPE OF INSPECTIONS: The main bearing saddle area around and between the stud holes was PT ' examined for bearings 4, 5, 6, and 8. In addition, the stud tension required to permit removal of the nuts .was measured. RESULTS OF INSPECTIONS: No linear indications have been found, and stud tensions were in the normal range.
SUMMARY
Inspections indicate that this problem has not occurred in the Catawba 1A diesel. 3.1.7 Cylinder Egad Studs (Part No. 02-315E) PROBLEM: Isolated failures of cylinder head studs have been reported as occurring in non-nuclear TDI diesels (reference 8). Also, improper torquing of these studs has been reported as contributing to the cylinder block cracking problem discussed in paragraph 3.1.5. SCOPE OF INSPECTIONS: Inspections of the cylinder head studs included the following: e The breakaway torque was measured for the head stude of three cylinders (4L, 5L, and 6L). e The removed studs from the three cylinders identified above were visually inspected. e One stud from each of four cylinders was checked by material comparitor and hardness measurement. RESULTS OF INSPECTIONS: Measured breakaway torques all were above 1100 ft-lbs. These torques indicate that required torque (1500 ft-lbs) was originally applied and that the torque has remained at acceptable values after extended operation. No significant visual indications were noted. Material comparitor and hardness test results indicated that stude are made of acceptable material.
SUMMARY
A sampling inspection of cylinder head studs indicates that they are acceptable and that they had been correctly torqued. 3.1.8 Rocker aim Canscrews (Part No. 02-390G) PROBLEM: A fatigue failure is reported to have occurred with a rocker arm capscrew at Shoreham (reference 7). This failure was i ~ attributed to endertorquing . Reference 8 indicates that properly torqued capscrews have satisfactory fatigue res is tance. SCOPE OF INSPECTIONS: i Inspections of the rocker arm capscrews included the following: e The breakaway torque of all the capscrews was measured. e All capscrews were visually and NT examined. e All the capeerews were checked by superficial hardness test methods and material comparitor tests. RESULTS OF INSPECTIONS: t The breakaway torques of the intake / intermediate capscrews varied between 276 and 336 ft.-lbs., and the torques of the exhaust capocrews ranged between 324 and 498 ft.-lbs. These values indicate that the required torque of 365 f t.-lbs. had been originally applied and that acceptable torque values were still present af ter extended service. No . indications were noted in the visual or NT examination. The material comparitor and hardness tests indicate that the capocrews material is satisfactory.
SUMMARY
The diesel engine 1A capscrews were found to be satisfactory and to have been properly torqued. 3.1.9 Connectina EgAR (Part No. 02-340A)
, PROBLEM:
Cracking of connecting rods is reported to have occurred, apparently due to relative motion between the two halves of the connecting rod at the " rack-teeth" joint (reference 7). l I
SCOPE OF INSFECTIONS: The inspections of the connecting rods included the following: e Breakaway torque was measured on the connecting rod bolts for all eight master / link rod / rod box assemblies. e Magnetic partic'le inspection of all connecting rod bolts was accomplished. e The threaded holes on the rod boxes of all connecting rod assemblies were ECT inspected. e The areas of the rod box which have been reported as being subject to cracking were LP examined. e Material comparitor and hardness tests were performed on master rod, rod box, and link rod for four connecting rod assemblies. e Areas of the connecting rod which would be subject to fretting or wear if looseness developed were visually inspected (rack-teeth, washers, seating surfaces) on all connecting rod assemblies. e Connecting rod rack-teeth (serrations) degree of contact with mating part was measured by bloeing the part on all connecting rods. RESULTS OF INSPECTIONS: Normal torque values were found, and no significant indications were de tected . Material properties were accep table, and no signs of joint looseness or fretting were Degree of contact between serrations varied from 80 to seen. , 100%.
SUMMARY
The connecting rods on diesel 1A have seen over 800 hours of operation. Reports of fretting wear, cracks in the connecting rods, loose capocrews and cracks in tapped threads were not seen on the Catawba LA diesel. The fact that these reported incidents were not seen on the Catawba 1A diesel as well as the fact that the connecting rod bearing shells did not show any typo of wear associated with connecting rod looseness indicates that the reported incidents did not take place on the Catawba IA diesel during it extended run operat ion. During reassembly of the engine, elongation of the connecting rod bolts will be measured and compared with TDI recommended values. This will be done in addition to torquing the bolts ' to TDI recommended values. ,
3.1.10 Electrical Cables (Part No. 02-6885) FROBLEM: A number of electrical cables used by TDI have been identified as either failing insulation flame test requirements or not having sufficiently high temperature ratings (references 7 and 14). SCOPE OF INSFBCTION: s Stone and Webster, as part of TDI Owners Group activities , reviewed the Catsuba electrical cable installation. EgSULTS OF INSFECTION:
.The Stone & Webster inspections (reference 18) have been completed with the following results.
o TDI SIN 361 has not been implemented on the Catawba s diesels. This involves replacement of: shielded cable
' from a terminal block to the tachometer relay in the engine control panel; shielded cable from Airpas magnetic
+> pickup to the junction bon on the side of the engine; and multiconductor cable from as engine mounted junction box to the Woodward governor actuator.
e Certification that States type NT sliding link terminal
;- - blocks ' used in the starting air solenoid controle were
. not manufactured between 1974 and 1976.
s , (
SUMMARY
4 x Repincemmet of wiring to .141ement TDI SIM 361 will be done by 1ep ct sc>ar -1964 '. With this replacement, all wiring will be of
- ' acceptable tempe.ature reting and adequately sized for circuit aspec itle~s. Duke Power Co.- (reference 19) has a program for inspectin' s ' Seates - sliding link te rminal blocks during s " installation and each time the link is operated. Performance
. prob'less , and ' defective links are reported to Design Engineering. . Eenco Duke Power Co. already has a program for n(covering defective _ terminal blocks and therefore find it
' ,nnneccesary to verify the manufacturing date of the TDI terminal blocks. <;
s 3.1.11 lus.L IAlsitita ldaat (Part No. 02-365C)
, s ,
s PROBLEMi a, Several. cases lof failure of high pressure fuel injection lines have' occurred. These failures have been attributed to a fat isse ersek initist'ing at pre-existing .006" draw seau at the tubing ID. (reference 10). I + 0 4 4 % 1 . . L
I SCOPE OF INSPECTIONS: All of the .high pressure fuel injection lines will be E inspected in an area six inches from each end or from the end to the first turn using ECT methods in early July. RESULTS OF INSFECTIONS: The inspections have not yet been performed. SIDGIARY: The fuel - lines - have operated for over 10 million cycles without problem and are thus considered to be satisfactory. In addit ion, ECT inspections will be performed to confirm their satisfactory condition. t 3.1.12 Jacket ](agst ZEERA (Part No. 02-425A) PROBLEM: Several jacket water pump shaft failures occurred at Shoreham . (reference 11). The Catawba jacket water pumps are of a different design than the Shoreham pumps. However, even though
.the problema esperienced at Shoreham are not espected to apply to the Catawba diesels, detailed inspections were performed of the Catawba jacket water pumps.
1 SCOPE OF INSPECTIONS: The engine driven jacket water pump inspections included the following e Visual and FT examination of coupling. , e Visual inspection of clearance ring. e Verification of shaft material by material comparitor and i hardness checks. [ e PT and RT of pump impeller. ; RESULTS OF INSPECTIONS: ! All pisoned testing has been completed. The only significant l ccadition noted was some porosity in the impeller cas ting . l Based on RT examination, the porosity was evaluated as i acceptable. ; l SIDOIARY: l The jacket water pump was inspected and found to be I satisfactory. j . i I r
l 3.1.13 Ah, Start Iabi anacrews C (Part No. 02-359) PROBLEM: Capscrew bottoming out due to insufficient hole depth for the capscrew length can lead to insuf ficient ,. clamping force (reference 7). TDI recommended reducing capscrew length to prevent this~ problem. Catawba diesel capscrews were modified prior to the extended operation test. SCOPE OF INSPECTION: The inspections for the capscrews included the following: o Measure breakaway torque on all capscrews.
- e. Measure Jetsgt.2 of capscrews for 4 valves.
RESULTS OF INSPECTIONS:
. Breakaway torquen and capocrew lengths were acceptable, and the valves showed no signs of insufficient elemming force.
SUlstARY: - There. appeared to be no problems with airstart valve : capocrew bottoning out in the Catawba 1A diesel. t
+ , 3.1.14 Push Anda (Part No. 02-3.90C) s
-PAOBLEM: . ,
Original yl supplied _pushrods experienced cracking of the welds joinipg the rod to their rod ends. New design push rods with
'" friction welds were- installed in the Catawba diesels during j - - *be extended operation test- and accumulated about 400 hours of
- operation. : -
t
=
SCOPE dF INSPECTIONS: , The - inspections of the ~new de' sign push rods included the ~ following:' s ee Visual inspection of the shaft end welds to verify that the desired new type of friction welds were used. e- PT examination of all the welds. NESULTS OF INSPECTICN3: r All the push rbds were confirmed as having the correct type of weld -and vero foun,d to be free of. defects. y , t
" /
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SUMMARY
l
- The Catawba diesel engine push rods are considered to be
. satisfactory. ,
{ l 3.1.15 Turbocharmer Bearines (Part No. MP-022/23; 02-CFR) l' ' l PROBLEM: Severe wear of the bearings has been reported, apparently due to inadequate lubrication during diesel stan ts (reference 7). An improved lube oil supply system is being developed for Catawba, with installation by September 1,1984. SCOPE G/ INSPECTION: e The bearings were visually and dimensionally inspected. RESULTS OF INSPECTIONS:
'The thrust faces of the turbocharger bearings were found to be severely worn. It should be noted that this wear had not -
affected turbocharger operation during the extended operation test.
SUMMARY
The turbocharger bearings are being replaced with new parts, and are expected to operate as well as the original bearings, which caused no operational problems for several. hundred hours. Dn til the new lube oil system is installed, the bearings will be inspected as necessary to ensure that they remain in operable condition. 3.1.16- Cylinder Heads (Part No. 02-360A) PROBLEM: Two small jacket water leaks have been experienced at Catawba resulting in water leaking into the fuel injector nozzle cavity. Failure analysis of one of the leaking heads has been completed (reference 20). The leak was due to cracks
- propagating-from a corner where a welded plug was installed in the fuel injector nozzle seating area. This welded plug was used to repair the injector bore during manufacture. (Figure 2-3)
SCOPE OF INSPECTION: The inspections performed of the cylinder head included: o PT examination of valve seats in cylinder heads. e UT examination of fire deck thickness at selected locations.
RESULTS OF INSPECTIONS: No cracks were detected and all thicknesses were acceptable. ENGINEERING EVALUATION: An engineering evaluation (reference 22) was done to determine if any of the heads now installed on the 1A diesel were repaired. This evaluation consisted of using a boroscope to see if there was a parting line at the bottom of the fuel injector cavity indicating the presence of a plug. In addit ion, the fire deck area of the head was visually inspected for the presence of weld metal indicating a plug was installed. The results of this engineering evaluation indicated that the head installed on cylinder 6 left was
- 3. repaired with a welded plug. This head was factory installed on the engine and has seen over 800 hours.
SUMMARY
The currently installed heads in the 1A diesel engine are considered to be satisfactory since they were not leaking when last used and exhibit no cracks in inspectable areas. Further, the type of leaks caused by cracks due to plug velding do not affect diesel operation and are not significant. However, the repaired head (6 lef t) will be replaced. r s
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3.2 Catawba Snecific Probless 3.2.1 Igel Iniection PEEg (Part No. 02-365A) - PROBLEM: A fuel injection pump nozzle valve holder at Catawba cracked as a result of a material defect (reference 1). SCOPE OF INSPECTIONS: The inspections performed to date related to the problem included: e Measuring the hardness of each valve holder. e Performing a UT examination of each fuel pump valve holder. i RESULTS OF INSPECTIONS: All the fuel pump valve holders were found to be acceptable
. based on the inspections conducted.
ENGINEERING EVALUATION: A failure analysis was performed on the fuel injection pump nossle valve holder (reference 21). The result's of this analysis indicate that an axially oriented linear indication in the high pressure fuel oil passage of the failed part - led , to the reported failure. Further analysis indicates that axial linear indications that would lead to cracking of the valve holder would cause cracking to occur witbin 10 million , cycles of fuel pump operation. As the remaining valve holders I on diesel 1A have withstood 10 million cycles of operation, , the valve holder failure experience is considered an isolated ,
' material defect. In addition to this analysis, a boroscope !
evaluation (reference 23) of the high pressure fuel oil : passage was made. Results of this evaluation indicate .that ' I several of the valve holder bores were rough machined with protrusions, counter bore type steps and tool marks. One valve holder, cylinder 6R, appeared to have a linear e indication. Three valve holders (5R, IL, and 8L) had recesses, i i
SUMMARY
I It is concluded that the valve holder failure is due to a
- material defect. Failure analysis indicates that due to extended operation of the diesel, no defects that would cause i cracking are present in the remaining valve holders. One valve holder, based on boroscope inspection, appears to have a l linear indication. Three other valve holders appear to have i recesses. These four valve holders will be removed from the !
I i : i
eng ine , cleaned, rechecked by boroscope and reamed to a diameter of 0.170 inches if indications are still present after cleaning. Valve holders that have indications after reaming will be replaced. 3.2.2 Iyrbocharmer Prelube Oil Lines (Part No. 02-307B) PROBLEM: . Two failures of .the prelube oil lines occurred during the 1A extended operation test, due to fatigue cracking at compression fittings (reference 21). The lines have been replaced using an improved procedure, using additional clamps, vibration dampening devices, improved compression fittings and heavier wall stainless steel tubing. A further improved prelube system will be _ installed to correct turbocharger bearing lubrication problems. SCOPE OF INSPECTIONS: The piping will be visually inspected to verify that it has been installed in accordance with the latest approved drawings, and to verify that there is no evidence of vibration induced damage (fretting, etc.). RESULTS OF INSPECTIONS: Inspection of this piping has not yet been performed. SUMMART: After the diesel is reassembled, the system will be inspected to verify that it is properly installed so as to prevent vibration problems. 3.2.3 Turbocharmer Adaptor (Part No. 00-495A) PROBLEM: A turbocharger' to intercooler adaptor cracked at a . flange weld. This is assumed to have been caused by poor flange alignment with mismatched bolt holes. Catawba now uses improved alignment practices when torquing' turbocharger flange bolts (reference 1). SCOPE OF INSPECTIONS: The adaptor veld joints were visually and NT examined. RESULTS OF INSPECTIONS: No defects were noted. t
SUMMARY
These welds are considered to be satisfactory. I 3.2.4 Lg]ts. OJ1 mL Jacket Water Thermocouples (Part No. 02-630D)
- PROBLEM:
Several failures have occurred with these thermocouples as a result of intermittent shorts (reference 1). SCOPE OF INSPECTIONS: Inspections of thermoccuples are not considered useful. RESULTS OF INSPECTIONS: Not applicable.
SUMMARY
Occassional _ thermocouple failures' are a norms 1 occurrence and do not affect diesel operability under emergency run conditions. Failed thermocouples are repaired or replaced at the first opportunity. 3.2.5 Crankcase And. Camshaft Cover Caoscrews (Part No. 02-3865) PROBLEM: [ L Occasional failures of these capscrews has occurred due to facigue (reference 21) because of over or under torque. I r SCOPE OF INSPECTIONS: All of these capscrews are being replaced with capscrews - with improved fatigue strength and of known chemical and physical i properties . Accordingly, inspection is not applicable. i I i
SUMMARY
This problem has been resolved by repincement of the capscrews ! using capscrews of appropriate quality and by revising i inatallation procedures to control torques to appropriate i values . i t I s 6
- - - - . ~,..,n. -
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3.2.6 Rocker 191 (Subcover) Subassembiv (Part No. 02-362A) PROBLEM: Two types of problems have been experienced with these components. The first type was reported'in reference 1 and involves fracturing off of a piece of the boss (also called a pedestal), apparently due to installation with a misaligned dowel pin. The second type of problem was detected in the post extended operation test inspections, and involves tight cracks running down the boss in the web between the bolt hole and the boss surface. The cause of the second type of problem has not been firmly established but may be due to installation tolerances between bushings or dowels and the pedestal leading to excessive interference fits. SCOPE-OF INSPECTION: e All of the bosses on all of subcover assemblies were PT examined. RESULTS OF INSPECTIONS: Two subcovers were found to have cracked bosses following the extended operation test. All of the others were free of defects. ,
SUMMARY
Several cracked bosses were found and the affected subcover assemblies have been replaced. These cracks have not caused a. loss of operability of the engines. A failure analysis is being performed by FaAA under TDI Owners Group direction.
-Until the cause of failure and the frequency'of cracking are better established, the Catawba subcovers will be inspected as necessary to verify that additional cracking has not occurred.
3.2.7 Turbocharmer L.uba 9.11 Drain Ligg (Part No. 02-467A) PROBLEM: A temporary drain line on diesel 1A leaked during the extended operation test due to fatigue. It is being replaced with an improved design as part of the diesel reassembly. SCOPE OF INSPECTION: Not applicable.
SUMMARY
This problem is being resolved by incorporation of an improved design. 4 a e -- + - - -- .- ,, t- --y v - 3 .,,,-.-,----,--,.v.--,1,7-------e-w-,..--w,v...c...,-,y.,--ww-.,.,,.--.m----ww..v,- ,w.%wer.w.-- , , , - , - - - . . -
3.2.8 ' Turbocharter Exhaust ggt Inlet Bolts (Part No. 02-380B) PROBLEM: Four 1/2 inch stainless mounting bolts were found broken (reference 1). The cause of the failure indicates that one bolt to have failed from creep rupture while the others failed from torsional overload (reference 21). SCOPE OF INSPECTION: All of the intact bolts and those replaced have been inspected by visual methods at a magnification of 5x to assure that no new cracks have initiated. RESULTS OF INSPECTION: Bolt inspections indicate no defects on installed bolts.
SUMMARY
All bolts will be temporarily replaced with the same material. Bolt installation procedures have been revised to insure that proper preloads are applied during this installation. Long term fix is to replace these bolts with creep resistant A 286 material. 3.2.9 Exhaust Valve Tannet (Rocker Arm Adiustine Screw Swivel ladl (Part No. 02-3905) PROBLEM: One of the swivel pads was found cracked on diesel 1B. Failure analysis (reference 21) indicates that the cracking occurred due to a one time overload. It is believed that the swivel pad cracked due to improper svaging at the factory during manufacture. SCOPE OF INSPECTIONS: All swivel pads were visually and liquid penetrant inspected on diesel 1A. RESULTS OF INSPECTIONS: No defects were found and the sockets were found to be correctly swaged. l
SUMMARY
The swivel pads are considered to be in satisfactory condition. l l o i l t
3.2.10 Fuel LiR1 Fittinas (Part No. 02-450B) PROBLEM: Failures have been reported as occurring on fitt ings , apparently as a result of vibration induced fatigue due to the absence of the supports required by the TDI drawing (reference 1). One fuel line had to be replaced on the Catawba 1A diesel due to leakage. However, inspection of the fuel line indicated that it was improperly svaged rather than failing from fatigue. A flat spot in the cone portion of the tube had been eroded away causing the leakage. SCOPE OF INSPECTIONS: The inspections of the fuel lines will include a walk down inspection to verify that the piping is installed per the applicable design drawing. RESULTS OF INSPECTIONS: This inspection will be performed after the engine is reassembled.
SUMMARY
This inspection has not yet been performed; it will be performed when the engine is reassembled. Reassembly procedures will use Duke Power Co. special fitting installation instructions to guard against improper swaging. 3.3 General Insnection In addition to inspections related to TDI generic problems and to Catawba specific problems, inspections have been performed of numerous other parts in order to verify the operability of the Catawba IA diesel engine. -The results of these inspections showed that the 1A diesel engine was 'in' excellent condition, with a few relatively minor problems in addition to the problems discussed in sections 3.1 and 3.2 above. The only additional problems noted were as follows:
, e Two intermediate rocker arm sockets had chipped or cracked edges .
o Nine valve stems had chipped or removed chrome plate. e One air start valve had a jammed spring retaining nut and another had a missing roll pin, e One rod box bushing was found to have a heavy circumferential gouge in it. e Several bolts and capscrews were found to have missing heads or cracks.
These problems are discussed below. 3.3.1 Cracked Intermeding Rocker AIja Sockets (Part No. 02-390A) PROBLEM: Two sockets were found to have chipped and/or cracked lips. These chips and - cracks did not affect functionirg of the sockets since the push rods seat further in the socket, well inside the area with chips or cracks. The chips and cracks show no evidence of propagating into the functioning part of the socket. The problem is believed to be due to improper installation of the rocker arm prior to valve adjustment, such that excessive clearance existed, allowing pushrods to move in and contact with the lips. SCOPE OF INSPECTION: All of the sockets were visually examined. , RESULTS OF INSPECTIONS: - The two sockets mentioned above were found to be chipped and/or cracked. No other problems were noted. SUIOl&RY: The chipped and cracked sockets are considered to be a cosmetic problem and to not affect diesel operability. The affected socket lips will be ground smooth. In addition, procedure changes are being made to ensure that excessive clearance does not exist in the rocker arm at assembly; this is expected to preclude recurrence of this problem. 3.3.2 Valve SLRB (Part No. 02-3605) PROBLEM: , Nine exhaust valve stems had areas with chipped or removed chrcae plate.- This occurred at about 6 to 8 inches above the valve seat, at a location corresponding to where the stem. enters the valve guide. The chrome plate chipping had no , affect on diesel operability, and caused no observable damage to the valve guides. SCOPE OF INSPECTIONS: All valve stems were visually inspected. ( l l i
RESULTS OF INSPECTIONS: As. discussed above, 9 exhaust valve stems had chipped or removed chrome plating in areas about 6 to 8 inches above the valve seat. No structural damage was observed.
SUMMARY
Valve stem chrome plate chipping of a cosmetid nature occurred. The affected valve stems are being replaced. This condition will be monitored in the fu ture during routine maintenance inspections. 3.3.3 .Sprima Retaining N,it 131 Roll _P.lg pg fig _ Starc Valves (Part No. 02-359)- PROBLEM: The spring retaining nut on an air start valve was found to be jammed due to galled threads. A spring retaining nut roll pin was found to be missing on another valve. The galled threads and missing roll pin had not affected diesel operability. . SCOPE OF INSPECTIOBS:
-All of the air start valves were disassembled and visually inspected.
RESULTS OF INSPECTIONS: The one jammed nut and one missing roll pin were the only inspection deficiencies found.
SUMMARY
The jassed nut and missing roll pin are believed to be due to installation errors. These items have been replaced. Current installation procedures provide assurance that these problems will not recur. 1
- 3.3.4 Rg1 M Bushina (Part No. 02-340A)
PROBLEM: A rod box bushing (IL) was found to have a circumferential
' gouge over about 1/3 of the circumference, with a depth of 1/16-inch.
SCOPE OF INSPECTIONS: , All of the rod box bushings were visually and PT examined.
2 RESULTS OF INSPECTIONS: The only problem noted was the one gouge described above.
SUMMARY
The gouged rod box bushing is being replaced, even though the gouge did not affect operability. This problem is considered to have been an isolated case of damage by a piece of debris. 3.3.5 Clamo Bolts (Part No. 02-450D) PROBLEM: Several bolts on the fuel / lube oil triple clamp were found to have heads brokeu off or cracks. SCOPE OF INSPECTIONS: These bolts are being replaced and inspection is therefore not applicable. RESULTS OF INSPECTIONS: Not applicable.
SUMMARY
i Failure analysis of these bolts (reference 21) indicates that they failed due to fatigue as a result of under or overtorquing. The bolts are being replaced using new bolts of increased fatigue resistance. Reinstallation procedures i include the provision to assure that under and overtorquing l do not occur.
- 3.3.6 Inal Iniector Nozzle Holder Studs (Item 3, TDI 1 dwg. 03-360-08)
PROBLEM: l ! While removing a cylinder head (7L) with the pulling fixture, , the nozzle holder studs sheared off. During disassembly these < j studs hold the pulling fixture to the head. The pulling [ fixture is used both for reacting cylinder head stud l l torquing /untorquing loads and to lift the head. Investigation [ l indicates that these capscrews were bent during untorquing of l l the heads lesding to failure due to overload (reference 21) ! when the head weight was put on them during head removal. The ,~ l reason the studs were bent is that the head was not cleaned properly prior to seating the handling fixtures so that the - handling fixture rocked on the head. . i
SCOPE OF INSPECTIONS: e Visual inspection of studs to determine if they are bent,. e Magnetic particle of studs to determine if they are cracked. RESULTS OF INSPECTIONS: e Studs in head-7L were sheared off (see above). e Stud in head SR had bad threads. e Stud in head 61 was missing.
SUMMARY
Defective and missing studs are being replaced. Procedure for installing head pulling fixture will assure that improper loads are not being applied. Problem occurred during disassembly and did not affect engine operation. 3.3.7 Turbocharmer Bolting (Item 7, TDI dwg. 02-475-22) PROBLEM: one turbocharger to bracket, 5/8 x 11 BC x 2 long capscrew failed on diesel IB. Failure analysis of the capscrew indicated fatigue failure. SCOPE OF INSPECTIONS: These bolts are being replaced on diesel 1A esd inspections are therefore not applicable. RESULTS OF INSPECTIONS: Not applicable. .
SUMMARY
Failure analysis of the capscrew indicated that it failed due to fat igue. All capscrews are being replaced with new material of increased fatigue res istance. Reassembly procedures have been revised to assure that proper preloads are applied. I 4
.. - . - ~ , , _ - . ~ . . _ _ - - _ , _ _ _ _ - - - . , _ - _ _ _ _ _ _ _ , _ , . _ , , ,__
d 4.0 References
- 1. Duke Power Co. letter dated April 5, 1984 to H.R. Denton, NRC, with attached document entitled " Catawba Nuclear Station Extended Operation Tests and Inspections of Diesel Generators".
- 2. IE Information Notice No. 83-58, "Transamerica Delaval Diesel Generator Crankshaft Failure", NRC, August 30, 1983.
- 3. Bechtel Power Corporation, " Evaluation of Crankshaft Stresses for Duke Power Corporation, Catawba Nuclear Station", March 19, 1984.
- 4. Failure Analysis Associates, " Design Review of Connecting Rod Bearfug Shells for Transamerica Delaval Enterprise Engines", March 12, 1984.
- 5. Delaval minutes of November 30, 1983 meeting with TDI Owners Group.
- 6. Failure Analysis Associates, " Investigation of Types AF and AE Piston Skirts", May 27, 1984.
t
- 7. Mississippi Power & Light Co., " Comprehensive report on Staadby Diesel Generators -Significant Activities to Enhance and Verify - Reliability",
February 1984 transmittal to NRC by letter dated February 20, 1984.
- 8. Stone and Webster Engineering Corporation, " Emergency Diesel Generator Cylinder Head cap stud Stress Analysis", March 1984.
- 9. Stone and Webster Engineering Corporation, " Emergency Diesel Generator,
. Rocker Arm Capscrew, Stress Analysis", dated March 1984, and Supplement dated April 1984.
- 10. Stone and Webster Engineering Corporation, " Emergency Diesel Generator, Fuel Oil Injection Tubing, Qualification Analysis", April 1984.
- 11. Stone and Webster Engineering Corporation, " Emergency Diesel Generator, Engine Driven Jacket Water Pump, Design Review", April 1984.
- 12. Failure Analysis Associates, " Evaluation of Emergency Diesel Generator Crankshaf ts at Shoreham and Grand Gulf Nuclear Stations", April 19, 1984.
- 13. Failure Analysis Associates, " Design Review of Engine Base and Bearing Caps for Transamerica Delaval Diesel Engine", April 1984.
- 14. Stone and Webster Engineering Corporation, " Emergency Diesel Generator, Auxiliary Module Control Wiring and Termination, Qutlification Review",
April 1984.
- 15. Stone and Webster Engineering Corporation, " Emergency Diesel Generator Air Start Valve Capscrew, Dimension and Stress Analysis", March 1984 and Supplement, April 1984, i 16. ~ Failure Analysis Associates, "Torsiograph' Test of Emergency Diesel Generator 1A at Catawba Nuclear Power Station," May 29, 1984.
- 17. Duke Power Co. Meet ing Minutes, Diesel Generator Owners Group.
Shoreham Nuclear Pcwer Station, S. R. Ward author, May 24, 1984.
- 18. Stone & Webster Engineering Corporation, " Supplement to the Emergency Diesel Generator Auxiliary Module Control Wiring and Termination Qualification Review," June 1984
- 19. Duke Power Co. letter from G. T. Lamb to K. S. Canady, " Catawba Nuclear Station IE Information Notice 80-08 States Sliding Link Terminal Block,"
File CN1412.11-1;EG3 N-14.01, May 7, 1980.
- 20. -Failure Analysis Associates , " Metallurgical Analysis of Catawba Injection Port Leak," June 1984.
- 21. Duke Power Co., " Failure Analysis Report Catawba Nuclear Diesels IA and IB," June 25, 1984.
- 22. Dune Power Co., "Special Procedure for Engineering Evaluation of Cylinder Heads on Catawba Diesel Generators," June 12, 1984.
- 23. Duke Power Co., "Special Procedure for Engineering Evaluation of Fuel Fump Valve Bolder on Catawba Diesel Generator," June 19, 1984
- 24. Failure Analysis Asnociates, " Metallurgical Evaluation of Eddy Current 1 Indications Found on DG 1A Crankshaft at Duke Power Co., Catawba Nuclear Power Station," FaAA-84-6-63, June 1984.
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l4 t i r B p .. .. 5.0 Appendices t t ? v e d - - , ,
APPENDIX A INSPECTION REPORTS e
Table of Contents Procedure b Zarl h ZAIX ! ant. Class 04/01 02-359 Air Start Valve A
-04 02-3605 Intake and Exhaust Valves B 04 02-360D Yalve Springs B 04 02-360A Cylinder Head B 04/01 -
02-362A Subcover Assembly B 04 02-390A Rocker Arm Assembly B 04- 02-390E Rocker Arm Bushings B
-C4 02-3905 Exhaust Rocker Arm Assembly B
'04 02-390C Pushrods B 04 02-390D Connector Pushrods B 04/01 02-390G Rocker Arm Bolting B 05/02 02-340A Connecting Rods and Bushings A 05- 02-340B Connecting Rod Bearing Shells A 05/02 02-341A Piston A 05 02-341C Piston Pin Assembly A 05 02-3415 Piston Rings A 06 02-310C Crankshaft Thrust Bearing Ring A 06 01-305D Main Bearing Caps A 06 02-305A Main Bearing Base Assembly A 06/03 02-3105 Main Bearing Shelle A 06 02-310A Crankshaft A 06 02-311A- Crankcase Assembly A 06 - 02-3865 Crankcase Covers Gasket & Bolting C 06/03 02-305C Main Bearing Cap Studs and Nuts A 07 02-355A Crankshaft Pump Drive Gear A 07 02-355B Idler Gear Assembly A 08 02-335B Front Gear Case Bolting C 08 02-3955 Gear case covers, Gaskets and Bolting C 09 02-371A Fuel Pump Control Shaft A 09 02-371B Fuel Peup Linkage Bearings & Shaft A 09 02-365A Fuel Injection Pump B 09/27 02-455C Fuel Oil Filter Mounting Hardware A 10 02-307A Lube Oil Internal Headers A 10 02-307B Lube Oil Tubing and Fittings A 10 02-307D Lube Oil Line Supports B 10 02-465A External Lube Oil Lines A 10 02-4655 External Lube Oil Supports A 10 02-467A Turbocharger Lube Oil Piping B 10 02-467B Turbo Lube Oil Piping Supports B 10 02-540A Lube Oil Sump Tank B 10 02-5405 Lube oil Sump Tank Bolting B 10 02-540C Lube Oil Sung Tank Mounting Hrdwre. B 10 02-CFR Turbo Thrust Bearing Lube Oil System C 11 02-315A Cylinder Block A
. 11 02-315C Cylinder Liner A 11/01 02-315E Cylinder Head Studs B 11 02-315F Cyl. Block Jacket Water Manifold Nuts B 11 02-315D Cylinder Block Jacket Water Manifold A 11/25 02-317A Jacket Water Discharge Manifold B 12 02-442A Starting Air Distributor Assembly A 13 02-425A Jacket Water Pump A I
- I
6 Table of Contents Procedure h fail E9 . Earl Esas. Class 14 02-3855 Cylinder Block Cover Ga'skets & Bolts C 14 02-350C Cassbaft Supports, Bolting and Gear A 14 01-350A Camshaft Assembly A 14 02-350B Camshaft Bearing A 14 02-3455 Fuel Tappets A
-14 02-345A Intake Tappets A 15 02-375 Intake Manifolds B 15 02-380B Bxhaust Manifold Bolting B 15/28 02-380A Exhaust Manifolds B 16 02-410C Overspeed Trip Drive Coupling A
'16 02-410B Dverspeed Trip and Accessory Drive A 16 02-415C Governor Heat Exchanger Assembly A 16 02-411A Speed Regulating Governor Drive A 16 02-411B Speed Regulating Governor Coupling A 16 02-413B Fuel. Pump Linkage and Shutdown cylinder B 16 02-413A Speed Regulating Governor Linkage A 17 02-330B Flywheel Bolting A 18 MP/022/3 Turbocharger A
'18/22 02-475B Turbocharger Air Butterfly Valve A 18 02-475A Turbocharger Bracket B 18 02-475D Turbocharger Bracket Bolting 5 10 F-068 Intercooler B 18 02-436B Intercooler Piping Coup., Bolts, Gokts. B 25 00-700A Jacket Water Standpipe Fittings B 25 00-700C Jacket Water Standpipe Supports B
- 25 00-700F Jacket Water Standpipe Bolting Materials B 25 02-316A Jacket Water Manifold Assembly B 25 02-316B Jacket Water Manifold Coupling B 25 02-317B Jacket Water Discharge Manifold Coupling B 25 02-317C Jacket Water Discharge Manifold Supports B 25 02-437A Turbo Cooling Water Pipe & Fittings B 25 02-437d Turbo Cooling Water Pipe Supports A 26 02-441A Starc Air Manifold Tubing & Fittings A
- ' 26 02-441C Start Air Manifold Pipe Supports A 26 02-442B Start Air Dist. Tubings, Fttngs, & Gskts. A 27- 02-365C Fuel Injection Tubing B 27 02-365D Fuel Injection Tubing Supports B 27 02-450B Fuel Oil Piping and Tubing A 27 02-450D Fuel Oil Piping Supports A 29 02-500M Control Panel Piping, Tubing & Fittings C 29 02-688A Engine & Aux Module Wiring Conduit A 29 02-695A Engine Shutdown Tubing and Fittings B t
f 2
Catawb a Diesel lA Inspection Renort Pcrt Name: Air 31arl Valve Class: A Pcrt Number: RhU3, Work Request No. 0772 MNT No. of Separate Inspections: 22. Attributes Yarified and. Sample Elza.
- 1. Measure as found torque of air start cap screws ,
per 11.3.1, ref. 2, 32 insp. ' 2.- Measure length air start valve cap scrsus - per 11.3.2, ref.1, 8 insp. ;
- 3. Visual inspect valve seat area ea.n valve per 11.3.3, ref. 1, 16 insp.
- 4.
- Visual inspect valve internal surfaces per 11.3.4, ref.1,16 insp.
References ; 1.- .MP/0/A/1000/04 Diesel Engine Cylinder Head and Associated Parts Special Inspection ,
- 2. MP/0/A/1000/01 Diesel Engine Cylinder Head Removal, Disassembly.
Inspection and Reassembly Inspection Results .
- 1. Capscrew as found torques - values ranged between 45-134 f t.-lbs.
- 2. Capscrew length - all capscrews met tolerance limits. j
- 3. Valve seat area - several nicks and grooves were observed. ,
1 4. Valve internals - several valve stems were discolored or had slight 7 carbon buildup on them. The spring retaining nut on one valve r was galled. I i ! l Disnosition 21. Insoection Findinas f
- 1. Capscrew as found torques - the observed values are acceptable
- 3. Valve seats - The observed seat conditions are considered normal ,
considering the number of starts. The worst seat will be reground. [ 4 Yalve internals - The amount of carbon buildup is normal considering the i amount of operation. The galled spring retaining nut was replaced. i i
Catawba pisAs.L,Q Inanection Renort Part Name: Intake and Exhaust Valves Class: ). Part Number: 02-3605 Work Request No. 9222. 2 E No. of Separate Inspections: jft9. Attributes Verified Aad. Sample ling.
- 1. Visual inspections on seat area, valve guides, valve stem surface and top per 11.4.2,3,4,6 ref.1, 256-insp.
- 2. Measure valve steam length per 11.4.5 ref.1*, 16 insp.
- 3. Visual exam of valve head weld per 11.4.7 ref.1*, 8 insp.
- 4. PT exam of valve head radius per 11.4.7.1 ref.1, 64 insp. >
- 5. Perform material comparator test per 11.4.10, ref.1*,16 insp.
* . 25% sample - valves from 4 cylinders References
- 1. MP/0/A/1000/04 Diesel Engine Cylinder Head and Associated Parts Special Inspection l
Insoection Results
- 1. a. Seat Areas - Minor pitting was present in many seats; there was one large pit in the right intake of 7R.
! b. Valve Guides - No significant conditions were observed.
- c. Valve stems - The chrome plate had peeled off at spots located 6"
! to 8" above the valve seat for 9. exhaust valves. The chrome l plate also exhibited a dull color in this area. Miscellaseous l , scratches were observed in the chrome plate. l d. Top of Stem - A variety of scratches, p its , grooves, etc., were , observed. 2.' Valve stem: length - These results were obtained for information purposes.
^3. Visual exam of valve head weld - No significant conditions were i observed.
l -4. PT exam of valve head radius - No rejectable indications observed.
- 5. - Material comparitor tests of the valves will be done when the standard material arrives from the Owners Group.
1 Disnosition' 2f. Inspection Findinas
~
L
- '.1. a. Valve seat pitting - The minor pitting of the valves seat areas is i
normal and the valves will be reused as-is. The 71 intake valve with a large pit was still functional (the pit spanned less than
'50% of the land width), but is being replaced because of chrome plate peeling (see 1. c. below).
- c. Yalve Stems - The peeling chrome _ plate has not caused any operational problems , and is not considered to be a cause for concern. However, valves with peeling chrome plate are being replaced.
d'. Top of Yalve Stem - The scratches, grooves, etc., in the top of the valve stem are considered normal and have not had any _ effect on diesel operation. The valve stems will be used as-is. 4
Catawba Diesel JA Inspection Reoort Pcrt Name: Valve Springs Class: B Pcrt Number: 02-360D Work Request No. 0772 MNT
- No. of Separate Inspections: M
' Attributes Yerified M Saanle ling.
~
- 1. Check spring color code per 11.4.8, ref.1, 64 insp.
- 2. Visual check intake and exhaust valve spring per 11.4.9, ref. 1, 64 insp.
References
- 1. MP/0/A/1000/04 Diesel Engine Cylinder Head and Associated Parts Special Inspection Insoection Results
- 1. Spring color code - Springs for seven right cylinders have a yellow rather than white stripe.
2 Visual check - No cracks or other defects were detected. Disposition 9.1 Inspection Results 1.' . TDI indicates that only springs painted grey with a brown stripe are unacc ept able. Springs with a yellow stripe were supplied by an alternate acceptable vendor. l l
7 Catawba Diesel 1A Insnection Renort Pcrt Name: ' Cylinder Eggi Class: A Pert Number: 02-360A Work Request No. 9))l Mg, No. of Separate Inspections: JJ), v Attributes Verified Anst Samnie lias.
- 1. . Visual inspect intake and exhaust valve seats per 11.5.2, ref.1, 64 insp.
- 2. : Perform PT exam of intake & exhaust valve seats and fire deck area per 11.5.4, ref. 1, 80 insp
- 3. Perform ultrasonic thickness measurement of fire deck per 11.5.5, ref.1, 96 insp. .
Perform ultrasonic thickness measurement of fuel nozzle cavity per 11.5.6, 4. 4 ref. 1, 32 insp.
- 5. Visual inspect fuel injection norsie studs per 11.12.1, ref.1, 32 insp. -
- 6. Mr inspect fuel injection nossle studs per 11.12.2, ref 1, 32 insp.
References
- 1. MP/0/A/1000/04 Diesel Engine Cylinder Head and Associated Parts Special Inspection ,
- 181Paction Results 162 Valve seats - minor pitting observed in many seats. One large pit observed in the intake valve seat for 7R. No rejectable PT indications were observed.
3.- Fire deck thickness - thickness ranged from 0.460" to 0.939". l ' 4. Fuel nossle cavity. thickness - thickness ranged from 0.440" to 0.560". p 5. Visual inspections showed bad threads on cylinder head 5R - left stud. The right stud in cylinder head 6R was missing.
- 6. MT examinations of the fuel injector nozzle studs showed no linear indications .
( Disnosition s.1 Insnaction Findingts
- 1. Valve seats - The minor pitting observed in many seats is considered normal and the seats can be used as-is. The large pit in 7R spans less than 50% of the land width and can be used as-is; it should be observed at the next routine maintenance period.
364. Wall thickness - No unusually thin wall thicknesses were observed and all of the wall thicknesses are therefore considered to be acceptable.
- 5. The defective and missing studs will be replaced.
. - . - _ - , ~ _ . _ ~ . _ _ _ . _ . _ . , _ _ - _ _ _ _ _._ ___ _ __ _________ _
Catawba Diesel 1A Inspection Renort
-Pcrt Name: Subcover Assenb1v Class: B Pcrt Nunber: 02-362A Work Request No. 0772 MNT
. No. of Separate Inspections: 216 Attributes Verified and. Saanle 1i38.
- 1. Visual inspect subcover per 11.6.2, ref.1,16 insp.
-2. - PT exam on each subcover per 11.6.3, ref.1, 64 insp.
- 3. Record as found torques per 11.2.8, ref. 2,176 insp.
References
- 1. MP/0/A/1000/04 Diesel Engine Cylinder Head and Associated Parts Special Inspection
~2. MP/0/A/1000/01 Diesel Engine Cylinder Head Removal, Disassembly Inspection and Reassembly Insnaction Results
- 1. Visual inspection - No visus 1 defects were observed.
- 2. PT of pedestals - Subcovers 3L and 6L had l" and 1 1/4" long cracks in the thin web between the bolt hole in the pedestal and the side surface.
- 3. Subcover bolt torques ranged from 30 to 194 ft-lbs. .
Disposition sf. Inspection Findinas
. 2.- PT of pedestals - The two cracked subcovers will be replaced. These cracks are also discussed in Section 3.
3.- The bolt torques are considered acceptable. These bolts have been
' removed and, reinstalled numerous times, using torque wrenches during reinstallation. There have been no problems as a result of low torque values. The bolts will be reinstalled, again using torque wrenches in .
order to assure that proper torques are used. 1 l l i l I I u- )
Catawba Diesel R Inspection Resort Pcre Name: Rocker AIEL Assembiv Class: 1 Part No.: 02-390A . Work Request No.: 2]R [fE No. of Separate Inspections: - R4, 4 Attributes Verified and Saanle 1133.
- 1. Visual inspect intake and int. rocker shaft assembly per 11.7.2, ref.1, 16 insp.
2.- Visual inspect intake and int. rocker arm lips per 11.7.3, ref. 1, 48 insp.
- 3. . Measure distance lip to push rod socket per 11.7.4, ref.1, 48 insp.
- 4. Visual inspect push rod sockets per 11.7.5, ref.1, 48 insp.
- 5. -PT exam adjusting screw swivel pads per 11.7.6, ref.1, 32 insp.
6.. Perform material comparitor test per 11.7.8, ref.1,16 insp.
- 7. Measure- superficial hardness per 11.7.9, ref.1,16 insp.
References
- 1. MP/0/A/1000/04 Diesel Engine cylinder Read and Associated Parts special Inspection Insoection Results
- 1. Visual inspection of shaft assembly - No significant conditions were noted (sona minor pitting was noted on 7R, which was judged to be of no consequence).
Visual inspection of rocker arm lips - No significant conditions were
- 2. -
noted. '~
- 3. Nessurement of distance from lip to socket, if ground - None were measured since none were ground..
- 4. Visual inspection of intermediate rocker arm sockets -Edges of sockets on 4R and 6L were chipped and cracked.
l 5. PT of swivel pads - No indications were noted.
- 6. Material comparitor check of shafts - All shafts were acceptable.
- 7. Hardness check of shaf ts - Shaft hardness ranged from BEN 253 to 299.
Discosition 91 Inspection Findinas
~4. . Chipped and cracked socket lips have no affect on diesel operation, but will be ground smooth for cosmetic reasons.
7.- .The specified hardness for the rocker arm shafts is BEN 260-331. The l test results are considered acceptable within the limits of accuracy of the testing device.
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Part Name: Socker ale Bushic.u ,7 i Class: B s- u ._ , Part No.: 02-390E- 'n > . , Fork Request No.: 0772 MNT
< + , u j No. ..uf Separate Inspections: 48 3
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- 1. Visua%l .iys%pedt Rocker Arm bushings per' 11.7.7 and 11.8.7, ref. 1, 48 insp. y w a ,
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~
P:rt Name: Eghapit Rocker Aga Assenbiv Class: B P rt No.: 02-3905 Work Request No.: 0772 ME.
' N3. of Separate Inspections: 112.
Attributes Verified ed. Sample 1133.
- 1. Visual inspect exhaust rocker arm shaft per 11.8.2, ref. 1, 16 insp.
2.- Visual inspect exhaust rocker arm lips per 11.8.3, ref. 1, 16 insp.
- 3. . Measure distance lip to push' rod socket per 11.8.4, ref.1,16 insp.
4.- Visual inspect push rod sockets per 11.8.5, ref.1,16 insp.
- 5. PT exam adjusting screw swivel pads per 11.8.6, ref.1, 32 insp.
- 6. Perform material comparitor test per 11.8.8, ref.1,16 insp.
References 1.. MP/0/A/1000/04 Diesel Engine' Cylinder Head and Associated Parts Special Inspection Insoection Results
- 1. Visual inspection of shaft assembly - No significant conditions were 4 noted (some machine marks sere noted around the socket of IR; these were judged to be of no consequence).
- 2. Visual inspection of rocker arm lips - No significant conditions were noted.-
- 3. Measurement of distance from lip to socket, if ground - None were measured since none were ground.
- 4. Visual- inspection of sockets - No significant conditions were noted.
- 5. PT of swivel pads - No indications were noted.
'6. Material comparitor check of shafts - All shafts were acceptable.
- 7. Hardness of shafts - Shaft hardness ranged from BHN 241 to 311.
Dianosition af, Inspection Findines
- 7. Although no hardness testing was required by the procedure, the hardness results are considered acceptable. (See Rocker Arm Assembly Part #02-390A)
.1 1 I i
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Part Naise: Pushrods' ' Class: .B_
- Part No.: 02-390C Work /itequest No.: 0772 MNT No. of Separata Inspections \, W12
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- Attributes Verified'g i jage,lg ), igg 7 -
1.: Visual inspect intake and exhaust pushrods per 11.9.2, ref.1, 64 insp. 1 2. - ~ Liquid penotrant exam 1fricti.on welds per 11.9.3, ref.1,, 54 insp.
- 3. . Visual ins;)ect spherical surfaces per- 11.944, ref.1, 64 insp.
References
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i :.
- 1. - MP/0/A/1000/04 '
Dies el Engine , Cylinder Head. andM Associsted Parts Special Inspection v g :- .e r .
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;1b . Visual Linspectica of.pushrods - No significant conditions noted.
D> :2, :FT of friction selds + Nd indications were noted.
'3 . Visual ins'pectisii of"apherical surfaces No significant conditions were
~ noted . (some (11i:htll ecratches' yore udted on,3L -intake pushrod; these are considered! normal). ' q - -<
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i Catawba Diesel M Insoection Report l l: I l Pcrt Name: Connector Pushrod Class: B Pcrt No.: 02-390D Work Request No.: 0772 MNT N3. of Separate Inspecticas: 19.
- Attributes Verified ed. Sample 1133.
- 1. Visual inspect connector pushrods per 11.10.2, ref.1, 16 insp.
- 2. Liquid penetrant exam friction welds per 11.10.3, ref.1, 32 insp.
'3. . Visual inspect spherical surfaces per 11.10.4, ref.1, 32 insp.
Referencqa,
- 1. MP/0/A/1000/04 Dies el Engine Cylinder Head and Associated Parts Special Inspection Insnaction Results
- 1. . -Visual inspection of pushrods - No significant conditions noted.
- 2. PT of friction welds - No indications were noted.
- 3. Visual inspection of spherical surfaces - No significant conditions were noted (3 pushrod-spherical surfaces had light scratches or grooves, which are considered normal and not deleterious).
5 Disposition 91 Inspection Findines There were no significant findings.
p l l S.11A3dt1 Diesel jf. Insnection Renort Part Name: Rocker AIEL Boltina Class: B f l: -Part No.: 02-390G Work Request No.: 9))1 E i-
~ No. of Separate: Inspections: J.2.00 Attributes Verified gl Sasele fi31 f
l: -1. Measure breakaway torque per 11.2.7, ref.1, 64 insp.
-2. Perform asterial comparitor test per 11.11.2, ref. 2, 64 insp.
- 3. Measure superficial hardness per 11.11.3, ref. 2, 64 insp.
4.- Magnetic particle test per 11.11.4, ref.2, 64 insp.
- 5. Visual inspect. capscrews per11.11.5 ref.2, 64 insp.
References
-1. 'MP/0/A/1000/01 Diesel Engine Cylinder Head Removal and Disassembly
- 2. MP/0/A/1000/04 Diesel Engine Cylinder Head and Associated Parts Insnaction Results
- 1. Bolt torques - Intermediate / intake assembly - bolt torque ranged between 276 and 336 ft-lbs. Exhaust assembly - bolt torque ranged between 324
- and 336 ft-lbs. These values are considered acceptable.
l 2. Material comparitor - All results were acceptable.
- 3. Hardness ranged from Rockwell C 20 to 28 4.: Magnetic. Particle - No indications were noted.
- 5. Visual Inspection .No indications were noted.
l -
- p. > : Disoosition 21 Insnection Findinas l
- 3. -The specified hardness for the rocker arm bolts is Rockwell C 25 to 30.
The results are con 'dered acceptable within the limits of accuracy of the measuring device. This is further evidenced by the satisfactory operation of the bolting for extended periods. l l l l L I i
L Catawba Diesel lA. Inspection Renort i I
'Part Name: Connectina Ep.d1 Agd. Bushines Class: A Part Number: 02-340A' Work Request No. 0773 MNT No. of Separate Inspections 1Z6 Attributes Verified Ap.d.Samp16 1133. 100% inspection except where noted 1.- Visual. inspect per 11.3.2, ref.1, 24 insp. ~ 2 .- Measure rod dimensions per 11.3.3, ref.1+,168 insp.
- 3. Perform material comparator test per 11.3.5, ref.1*,16 insp.
.4.- . Perform hardness test per 11.3.6, ref.1*,12 insp.
- 5. . Perform PT test per 11.3.7 and 11.5.4, ref. 1, 8 insp.
- 16. . Eddy current test per 11.3.4, ref.1,16 insp.
- 7. . Measure breakaway torques per 11.3.5 and 11.5.1, ref 2, 80 insp.
-8 : Inspect connecting rod oil passages per 11.3.13, and 11.4.7 ref. 2,16 insp.
- 9. Inspect connecting rod bolt contact surfaces per 11.4.1, ref.1, 40 insp.
- 10. MT inspect connecting rod-bolts per 11.4.2, ref.1, 40 insp.
' 11.
Measure surface contact on each connecting rod . serration by blueing [ special engineering evaluation ] 8 insp.
- 12. . Measure connecting rod bolt elongation by UT [ special engineering evaluation ] 48 insp.
* ~ 25% cample basis inspection 7
+ 25% sample basis for piston pin bushing References
~1. MP/0/A/1000/05 Diesel Engine Piston, Rod, Bushing and Shells Special Inspection
'2. MF/0/A/1000/02 Diesel Engine Piston Rod and Liner Disassembly l
! Insoection Results
- j. 1.. -Visual inspection of connecting rod boxes, master rods and link rods
-show several instances of scratching and pitting.
- 2. . Measurement of piston pin bushings shows three bushings out of tolerance byf.002".
- 3. Results of the material comparitor test of the connecting rod components l
were acceptable. ' [. '4. Hardness of the link rod pin was BHN 186-256. All other hardness tes t l results ranged from BHN 241 to 291.
- 5. PT: exam results showed one 1 1/4" long scratch on link rod bushing IL.
This is thought to have been caused in manufacture and is not considered a problem. All other results were satisfactory.
- 6. Eddy current tests of the rod box bolt holes showed no indications
.._.____-.._-.__..-_.___.-.-_,.._--__m, _ _ . . . . ~ - - , , _ . _ - - - - - .
- 7. Master rod breakaway torques ranged from 1260 to 2150 ft-lbs. One lock wire was found loose on cylinder #3. Link rod torques ranged from 880 to 1470 ft-lbs.
- 8. All connecting rod oil passages were found to be satisfactory.
- 9. 'Visusi inspection of the connecting rod contact surfaces demonstrated galling under the bolt heads.
- 10. NT examinations of the connecting rod bolts found no rejectable indications.
- f. 11. . Blueing results for connecting rods 1-8 showed the following percentage
' contact:- 85,- 99, 90, 95, 90, 90, 80, and 100 percent, respectively. !
- 12. Bolt . elongation measurements will be taken during engine reassembly.
-Discosition 3,1 Inspection Findinas
- 1. ' Visual inspection of connecting rod boxes, master rods, and link rods-these small pits and scratches are normal and have no adverse effects.-
- 2. ' Piston pin bushings - The tolerance limits used for the inspection were for new parts. The small deviations noted are normal for parts that have been in service and have no effect on diesel operation.
- 4. Although no specified hardness values are available for this material, the measured values appear reasonable for the component materials and are considered acceptable.
7._ The lockwire found on disassembly inspection had been loosened before final inspection and is not considered significant. 9.' The extent of the observed bolt contact surface galling is believed to have been caused by torquing the bolts and is considered normal and acceptable.
' 11. As-machined , TDI standards are 75% minimum contact area; hence, the results of thn engineering evaluation are acceptable.
[ f i b
1 Catsuba Diesel 1A Insoection Report
- Part Name: Sggnactina End. Bearina h Class:- A
~
Part Number: 02-3403 Work Request No. 9.2)). E No. of Separate Inspections: 2,2,3, . Attributes Verified mad. Sample j,ing. 100% inspection except where noted
- 1. ' Visual inspect crankpin shells per 11.5.2, ref.1, 20 insp.
- 2. Measure crankpin shells per 11.5.3, ref.1,160 insp.
- 3. .- Liquid penetrant inspect per 11.5.4, ref.1 *, 32 insp.
- 4. I-ray inspection per 11.5.5, ref. 1, 8 insp.
- 5. Eddy current inspection per 11.5.6, ref.1, 8 insp.
- 25% sample basis inspection for link rod end References MP/0/A/1000/05 Diesel Engine Piston, Rod, Bushing and Shell 1..
Special Inspection Inamention Rasmits 1.~ Results of the visual inspection showed some light scratches and galling in several shells; otherwise, the inspection was within normal limits. J2. Measurement of crankpin shells - All measurements of crankpin shells
- meet acceptance standards.
- 3. - PT examination of shells revealed no indications.
- 4. Radiography of the bearing shells meet acceptance standards with the excaption' of five. These five shells have what anpears to be crack like indications .
- 5. Eddy current inspection has not been accomplished.
Disposition g,1 Insnection Findinas
~ ~
- 1. ~ These small scratches and gal 1ed areas are considered a result of normal wear and are acceptable. (
.,4. The bearing shells with rejectable conditions will be replaced . The rejectable shells will be the subject of further evaluation.
m...... ..
l
. Catawba- Diesel J_A.
A Inspection Report Part Name: Piston Class: A. Part Number:~ 02-341A Work Request No. p))71 MNT No.~of Separate Inspections:- jftQ Attributes Verifind Anal. laMpit. #133.
- 1. Visual inspect ;fitup of crown to skirt per 11.6.2, ref.1,16 insp.
- 2. Inspect rings in grooves and measure axial clearance per 11.6.3, ref. 1, 288 insp.
.3. Visually inspect pistons and piston rings for normal wear per 11.6.4, ref.
1, 16 insp.
- 4. Liquid ' penetrant inspect stud bosses in crown and skirt area and piston
-pin bosses on skirt per 11.6.5, ref. 1, 160 insp.
- 5. UT piston skirts per 11.9.2 if unsat. results from 11~.9.1
- 6. FT/MT exam piston skirt ' per 11.9.1', and 11.9.3, ref.1,16 insp.
- 7. Measure crown to skirt bolt breakaway torque per 11.7.3, ref. 2, 64 insp.
Rafarances
- 1. MF/0/A/1000/05 Diesel Engine Piston, Rod, Bushing and Shells Special Inspection 1- 2. .MF/0/A/1000/02 Diesel- Engine ' Piston, Rod. and Cylinder Liner Disassembly i Insoection Results
- 1. All visual inspections of crown to skirt fitups were satisfactory.
3
.2.- . Axial clearance of piston rings in grooves were measured, Twenty rings
! out of 96 were out of tolerance' by as nach as .006".
- 3. Eight of sixteen piston assemblies demonstrated pitting or scratching on visual inspection..
- 4. FT exam of piston crown showed no indications. One' 1/2" linear
. indication was found on piston skirt pin boss #1L.
UT not necessary as skirts will be replaced. 5.
- 6. .PT/MT exam ' demonstrated cracks in four of the piston skirts. ;
~
g . 7. Torques of piston crown to skirt bolts ranged from 80 to 200 foot-pounds - l* Disposition 2f. Inanection Findinas ; i - i' ! 2.. Axial clearance of piston rings in grooves - The tolerance used for this
' inspection .were for new parts. The small deviations noted are normal ,
for parts which have seen service and are considered acceptable, i L !
- 3. . . Visual inspection of pistons and rings - The small scratches and pits }
observed are normal for parts which have seen service, have no effect on i l- diesel _ operability, and are considered acceptable. 4,5,6. The piston skirts are to be replaced. [ I i
w Catawba Diesel J.& Insnaction Renort Part Name: Piston Zig Assemb1v Class: A Part Number: 02 -341C - Work Request No. 2Z21 ]gg. 9
- No.' of Separate Inspections: 13, Attributes Verified Anst Sample Size 25% sample size except where noted i
l1.- Visual inspect per 11.7.2, ref.1*,16 insp.
- 2. ~ Dimensional inspect per 11.7.3, ref.1, 4 insp.
- 3. Materials verification test per.11.7.4, ref. 1, 4 insp.
- 4. Hardness test per 11.7.4, ref. 1, 4 insp.
- 100% inspection ,
I References i l.- MP/0/A/1000/05 Diesel Engine Piston, Rod, Bushings and Shells Special Inspection Inanention Rasnits Results of the visual inspection of the piston pins were satisfactory. I '. .
- 2. Dimensional inspection shows all dimensions satisfactory.
- 3. Material composition tests showed no significant findings.
- 4. -Hardness test-results for the piston pins were within the range of Rockwell.C 54_to 58.
I Discosition 21. Insneetion Findinns I -4.- The specified hardness is Rockwell C 57 to 60. The measured hardness is considered acceptable within the limits of accuracy of the testing ; device'- L t l l y --3-n----r-maew ,m-e,w,
-wr---+----- ---e-rw$,-r,,.,,-,e ., e,-e--,---ww.e-m-----,., .ww.rm,.,-r,,---,,--.,s--.-- - . . - ~.--,-
r . l l Catsvba Diesel 1A Insnection Report ! . Part Name:- Piston Riggg Class: & LPart. Number: 02-341B Work Request No. 9))],ME, No. of Separate Inspections: 16. 25% sample basis inspection Attributes Yerified aggL Sample h
- 11. -Install rings in cylinders & measure butt gap per 11.8.2, ref.1,
- 96. insp.
References
- 1. MP/0/A/1000/05 Diesel Engine Piston, Rod, Bushing and Shells Special Inspection Inspection Results 1.- 56 pietos rings were 'found to have a butt gap wt of tolerance.
Dianet ition gi Insnaction Findings
- 1. The tolerances used for the inspection were for new rings and pistons.
The .small ~ deviations from these will not adversely affect the eng ine. However, the piston rings will be replaced before resssembly'for other reasons. i
~ .- ,,-,---,.--,--,,-----.,-n,-,,--,-,,-,---ra,,,-,n.,,,,,,..-.,..
C.atawba Diesel 1A Insoection Resort - 4 Part Name: Cranksbaft Thrust Bearina Ring Class: A
'Part Number: 310C Work Request No. 9114.,Mlf! 4 No. of Separate Inspections: 2.
Attributes Verified AmL Sample 1133.
- 1. Nessure thrust clearance per 11.3.2A, ref. 1, 2 insp.
References 1.. MP/0/A/1000/06 Diesel Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase Assembly and Crankcase Covers Special Inspection Inspection Results
~
1.- Bot inspections have been performed, with satisfactory results. The cold inspections will be done later. Disnosition SI. Inspection Findinns
- 1. There have been no significant findings to date, the cold inspections will follow.
l l l
i Catauba Diesel JA Inspectioq Renort Part Name: Maig Bearina Capi Class: A Part Number: :02-305D Work Request No. 0774 MNT No. of Separate Inspections: ), Attributes Verified and Sample 1133.
-1. Visual inspect main bearing cap #4,5,6,8 per 11.4.1, ref.1, 4 insp.
-2.- Liquid penetrant main bearing cap #4,5,6,8 per-11.4.2, ref. 1, 4 insp.
References
- 1. - MP/0/A/1000/06 Diesel Engine Crankshaft and Turning Gear, Gear, Crackshaft Bearings, Crankcase Assembly and Crankcase Covers Special Inspection Inanection Results
- 1. ; Visual inspections of the main bearing caps were satisfactory.
- 2. . Lignid penetrant inspections of the main bearing caps was satisfactory.
Disposition sf. Inspection Findinas l' There were no significant findings. l. l-L t I
l l 1 Catawba Diesel J.A Inspection Reoort
.Part Name: Maia. Bearica Base Assemb1v Class: A Part Number: 02-305A Work Request No. 0774 MNT - No. of Separate Inspections: ), - Attributes Verified and Sample Jin 1 l
1.' ' Visual inspect main bearing base around main bearings 4,5,6,8 per 11.4.1, ref. 1, 4 insp.
- 2. Liquid penetrant examine base material around main bearings 4.5,6,8 per 11.4.4, ref.1, 4 insp.
References
- 1. MP/0/A/1000/06 Diesel Engine Crankshaft and Turning Gear, I Gear, Crankshaft Bearings, Crankcase Assembly and Crankcase Covers Special Inspection Insnaction Rannits
- 1. Visual inspections the of usin bearing bases were satisfactory.
- 2. - Liquid penetrant inspections of the main bearing bases were sat isfactory.
i Discar ti jgg .gf Insoection lindinns ! There were no significant findings. l l [
. - - - - . - _ _ ~ . - --~...--- -.-- -
l l Catawba Diesel JA Inspection Resort Part Name: Mais, Bearina Shells Class: A Part Number: 02-3105 Work Request No.0774 MNT No.' of Separate Inspections: 1Q Attributes Yerified And Sample lima
- 1. Measure breakaway torque of upper bearing shell capscrews per 11.3.1, ref.2, 48 insp.
- 2. Visual inspect bearings 4,5,6,8 per 11.5.1, ref.1,
- a. Upper main bearing shell, 4 insp.
- b. Lower main bearing shell, 4 insp.
- c. Crankshaf t journal, 4 insp.
- 3. Measure thickness of lower main bearing shell #4,5,6,8 per 11.5.2, ref. 1, 30 insp.
4 gaferences
- 1. -MP/0/A/1000/06 Diesel Engine Crankshaft and Turning Gear, Gear
, Creakshaft Bearings, Creakcase. Assembly 'and Creakesse Cover: Special Inspection
- 2. MP/0/A/1000/03 Diesel Engine Main Bearing Disassembly for Special Inspection and Reassembly L f==nection Psults
. 1.- Breakaway torque was sero for capscrews in bearing shells #5 & 8.
- 2. Visual inspections of main bearing shells and crankshaft journals were satisfactory.
l 3. Thickness measurements of the main bearing shells were l acc eptable. . I Dismositinn gi Insnection Findinns l- 1. Cause of low breakaway torque is not known. Capocrews only serve to hold shell in place during assembly, and low torque does not affect diesel operability. The reassembly procedure assures that the proper torque is applied. ,
----,-.,---n__ -
l Catawba Diesel IA Inenection menort Part Name: Crankshaft Class: A
-Part Number: 02-310A Work Request No. p)),4,t]Gl1 /
No. of Separate Inspections: }1 Attributes Verified gad, Sample J.iES.
- 1. Visual inspect crankpins 1-8 bearing surfaces and crankpin fillets per 11.6.1, ref. 1, 8 insp.
- 2. Eddy current test crankplus fillets between crankpin journals and webbing per 11.6.2, ref.1,12 insp.
- 3. Sensitive PT test oil holes on main bearing journals #4,6,8 with L supplemental eddy current and visual exams as necessary per 11.6.3 and 11.6.4, ref.1, 3 insp.
- 4. Measure web clearance per 11.3.2B, ref.1, 8 insp.
Rafarances l
- 1. MF/0/A/1000/06 Diesel Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase Assembly, and Crankcase Covers Special Inspection -
Insnection Results
- 1. Visual inspection of the crankpin fillets was satisfactory
- 2. One indication was found on the generator end of rod journal #7 by addy
! current testing; otherwise, no relevant indications were found.
- 3. Fluorescent PT inspection of oil holes showed an indication on #8 main bearing which was made up of a line of small pores a 1/4" long.
- 4. Hot inspections of web clearance were satisfactory, a cold ' inspection will be done later.
l Disoositior 21 Insnection Findinas -
- 2. The indication demonstrated by eddy current testing were ground out in .005 inch increments with metallosraphic replicas taken at each L stage. The eddy current indication disappeared after polishing about i .020" from the crackpin fillet.
l 3. The indication was polished out in less than .005" of depth. i e i r7-* N- -+t-9 ----*pweg my -,m--m g---we--m---gww ---&--mW--evee = wwey-y- ww--mi-en-mmp-ee.---we,wwN-r ---w- ----w-----w- ---m v-- ' - - - - - '~w"*'m----'M
Catawba Diesel JA Inspection Report Part Name: Crankcase Agigahly. Class: A Part Number: 02-311A Work Request No. 0774 MNT No. of Separate Inspections: 13. Attributes Verified and, Samole )133,
- 1. Visual inspect area between machined bolt hole surfaces and cast surfaces for smooth rodii per 11.7.1, ref.1,18 insp.
' References
- 1. MP/0/A/1000/06 Diesel Engine Crankshaft and Turning Gear, Gear,
. Crankshaft Bearings, Crankcase Assembly and Crankcase Covers Special Inspection Insoection Results
- 1. Results of the visual inspection of the crankcase assembly machined surface were satisfactory.
~
Disposition g.1 Insoection Findinas There were no significant findings O l l l i l l
Catawba Diesel M Inspection Renort Part Name: Crankcase Covers Gaskets AEst Boltina Class: ._ C Part No.:- 02-3865 Work Request No.: Q))_4 4 E - No. of Separate Inspections: if, Attributes Verified Anst Sample 3.13g.
- 1. Visual inspect crankcase covers per 11.7.2, ref 1, 16 insp.
References
- 1. MP/0/A/1000/06 Diesel Engine Crankcase and Turning Gear, Gear Crankshaft Bearings, Crankcase Assembly and Crankcase Covers Special Inspection Inspection Results
- 1. The results of the visual inspection of the crankcase cover bolt holes were satisfactory Discosition gi Insneetion Findinns There were no significant findings l
l l l l w &,-a-----g--gec%y.ww ,g-e-,-,--p,p-,%-qwmwey-,yy,pww-,p,.,-. y ..k-,vagap-- p-ywm,m -.%,._y- , . .-w-e,- *.,w%-m - w wwwwwh+*--W
Catawba Diesel .lA Insnection Report
' Part Name: jigin. Bearina .9.ag Studs AmL JhL'il Class:A_
Part No.: 02-305C Work Request No.0774 MNT No. of Separate Inspections: 57 Attributes Verified agt Samola jing.
- 1. Measure breakaway hydraulic pressure per 11.2.7, ref. 2, 42 insp.
L2. Visual inspect main bearing nuts for forging laps 11.8.1, ref. 1, 12 insp.
- 3. Measure length one stud M.B. 5 per 11.8.2, ref. 1, 1 insp.
4 Measure height of cap where stud passes through per 11.8.2, ref. 1, 2 insp. References
- 1. 'MF/0/A/1000/06 Diesel Engine Crankshaft and Turning Gaar, Gear, Crankshaft Bearings , Crankshaft Assembly and Crankcase Covers Special Inspection
- 2. MP/0/A/1000/03_ Diesel Engine Main Bearing Disassembly for Special Inspection and Reassembly Insnection Results
- 1. Breakaway hydraulic pressure was within normal limits.
2.. Visual inspection of the nuts was acceptable. 3&4 Stud length and cap height measurements are satifactory. Disposition gf. Insnection Findinas There have been no significant findings L I' l l l l i-l l l t
, v. . - - - - -
s: Catawba Diesel ]A Insoection Report Part Name: Crankshaf t Zum. PIiY.s. .GasI Class: A
-Part Number: 02-355& Work Request No. 0778MNT .No. of Separate Inspections: 4, t
Attributes Yerified Aad. I.AB.lt. J.lat. L 1. Visual inspect crankshaft gear per 11.2.2 ref.1 1 insp. ( 2.- - Visual' inspect pump drive gear per 11.2.4 ref. I 1 insp. ! 3. Material comparitor inspect pump drive gear per 11.11.1, ref. 2,
- 1 insp.
- 4. 'Eardness test pump drive gear per 11.11.2, ref. 2,1 insp.
Rafarences
- 1. MP/0/A/1000/07 Diesel Engine Idler Gears and Pump Drive Gears Inspections and Adjustments
-2.. MF/0/A/1000/06 . Diesel Engine Crankshaft and Turning Gear, Gear, Crankcase Bearings, Crankcase Assembly and Crankcase Covers, Special Inspection f
Insmantion Basalts , , 1. The crankshaft gear was visually inspected and found to be in satisfactory condition.
- 2. The pump drive gear was visually inspected and found to be in
~
satisfactory condition.
- 3. The material comparitor esam showed the pump drive gear to be of a different asterial than the sample supplied by the Owners Group.
- 4. The hardness of the pump drive gear was BEN 284.
1 Disposition gf. Inspection Findinas , 3. Although the material of the pump drive gear was different - from the standard supplied by the Owners Group, the gear has performed satisfactorily under service and is considered acceptable. l 4 No hardness was specified for this component. However, the part has performed well in service and is considered acceptable. l I I I
Catawba Diesel 1A, Inspection Report Part Name: Idler G3Jg; Assembiv Class: A, Part Number: 02-3558 Work Request No. 0778MNT No. of Separate Inspections:
~
2, Attributes- Verified ud, Sample jigt
- 1. Visual inspect idler gears per 11.2.3, ref. 2, 2 insp.
- 2. Measure superficial hardness of idler gears per 11.2.5, ref.1, 6 insp.
- 3. Perform material comparitor test on idler gears per 11.2.6, ref.1, 2 insp.
- 4. Measure backlash of assembly per 11.3, ref.1, 7 insp.
References
- 1. MP/0/A/1000/07 Diesel Engine Idler Gears and Pump Drive Gears Inspections and Adjustments Inspection Easults _.
1.- The left and right idler gears were found to be in satisfactory condition.
- 2. The hardness of the gears was found to be BHN 320 - 360
- 3. Material comparitor exam results were satisfactory.
= 4. The backlash was found to range from .004" to .014".
Disoosition gi Insoection Results 2.. The specified hardness for the idler gears is BHN 380 - 405. The test result is considered acceptable within the limits of accuracy of the testing device. All other results showed no significant findings i l I k
Catawba Diesel JA Insnection Report i Part.Name: I.IARL GRAK. ESA.R. Bolt ina Class: 9. l l- Part Number: 02-3355 Work Request No. 077 mort i t' LNo. of Separate Inspections: 2, l: Astributes Verified 'Angl Sample lias. 1.- Examine periphery for oil leakage per 11.1, ref.1,1 insp. l .2. Visual in6pect gear case capscrews per 11.2, ref. 1, 1 insp. References
- 1. MP/0/A/1000/8 Diesel Engine Gear Case Caskets and Bolting Special Inspection
+ Insnaction Results
- 1. No significant gear case cover leakage was found on visual inspection.
- 2. J A11 gear case cover capocrews were found to be satisfactory.
Disposition gi Inspection Findinas There were no significant findings l l a,--- , --. .
- , - - - . . , - , , . . , , . - . . . . . . _ , , . , - . . . , , . - n.,,,,,_,,--,,_-- ,, -,--,,__w.n-r.-._ -,. _ , ,__,-. --- . . . - , - - . -.
Catawba Diesel JA Insnection 12291.1. F rt ifeme: 9, tar .qgit Covers / Gaskets gul Boltina Class: 9,, Pcre No.: 02-3958 Work Request No.:0778HNT No. of Separate Inspections: 2. Attributes Verified MUL Sample lias.
- 1. Visual inspect for oil leakage per 11.1, ref.1,1 insp.
- 2. Visual inspect capocrews per 11.2, ref.1,1 insp.
Referenc.,as,
- 1. MF/0/1/1000/08 Diesel Engine Gear Case Gaskets and Bolting Special Inspection Inanaction Rasults
- 1. No significant leakage around the gear case covers was found on visual inspect ion.
- 2. All gear case cover capscrews were found to be satisfactory.
! Disposition gi Inspection Findinas There were no significant findings l 4
Catawba Diesel 1&, Insoection Renort P rt Name: Eggj, ZgEL Control Shaft Class: 4. P rt No.: 02-371A Work Request No.: 0842 HEL No. of Separate Inspections: f, Attributes Verified mul. Sample h
- 1. Measure superficial hardness both shafts per 11.2.2, ref.1, 2 insp.
- 2. Perform material comparitor test per 11.2.3, ref.1, 2 insp.
References
- 1. MP/0/A/1000/09 Diesel Engine Fuel Pump and Linkage - Special Inspection Insnaction Results
- 1. Nardness test results ranged from BEN 216 to 229.
- 2. Material comparitor examination results were satisfactory.
I 1 1 Dianosition 21 Inspection Find (nes
- 1. The measured hardness corresponds to a tensile strength of about 105 l kei. There were no specific acceptance standards available, however this strength is considered acceptable for the 4140 steel used.
l l l l
Catawba Diesel IA Inspection Renort Part Name: Eggi F m Linkare. Bearings and Shaft Class: A Fart No.: 02-3715 Work Request No.: 9),41 M No. of' Separate Inspections: 1 Attributes Yerified And Samole lin
- 1. Visual inspect fuel pump linkage per 11.3.2, ref.1, 2 insp.
- 2. Check site docussatation to ensure adequate lubrication per 11.3.3, ref 1, 1 insp.
Referenc es
- 1. MF/0/A/1000/09 Diesel Engine Fuel Fump and Linkage - Special Inspection i= Inamestinn Results 1.- Visual inspection of fuel pump linkage was satisfactory.
- 2. An adequate lubrication schedule was found to be established.
Dianosition gi Inspection Findinas There were no significant findings. r O f i l
Catsuba Diesel R Insoection Report
.Part Name: Igg,1, Infection Zust Class: 1 Part No.: . 92-365A Work Request No.: 9)_4J, 4 E No. of Separate Inspections: 21 Attributes Verifind Aad.1.4MLIS. I.iER.
- 1. Measure superficial hardness of each fuel pump valve holder per 11.4.2, ref.1,16 insp.
- 2. Perform UT inspection each fuel pump valve holder per 11.4.3, ref.1, 16 insp.
Naferences
- 1. MF/0/A/1000/09 Diesel Nagine Fuel Fump and Linkage Specist Inspection Inanection Rasults
-1. Nardness test results ranged from Rockwell C 29 - 32.5.
- 2. Ultrasonic testing of the fuel pump valve holders was satisfactory Dianosition 21. Insnection Findinas There were no significant findings. The hardness results agree with those '
identified in the B W failure analysis report (dated March 1, 1984) for , typical " fatigue proof" medium-carbon free-machining steel of which the valve l holders are made. Therefore, they are considered acceptable. 1
Catawba Diesel 14. Insnection Resort Fcrt Name: Engl-gil Filter Mount he Hardyare Class: 4. Fcrt No.: 02-455C Work Request No.: 9j41 ME No. of Separate Inspections: 1 Attributes Yerified sad. Saanle flag. 1 Visual inspect mounting hardware per 11.4, ref.1,1 insp.
- 2. Measure or verify torque of bolt holding filter to side of engine per
'11.5.1. ref. 2. 1 insp.
x Rafarances
- 1. MF/0/A/1000/27 Diesel Engine Fuel Piping System Special Inspection 2 MF/0/A/1000/09 Diesel Engine Fuel Pump and Linkage .
Special Inspection Inanection Rannits
- 1. This inspection will be performed when the engine is reassembled.
- 2. The fuel oil filter mounting bolt torque was verified as correst.
4 Dianositinn 21 Inanection Findingts There are no significant findings to date l l l l t _ _ ~ , , _ _ _ _ _ _ . _ . . . _ -
Sagayjts Pisasi JA Insooction EgypIl Part Neee: Lulti 911 InternAJ HssisIt class: A Fr:t No.: 02-307A Work Request No.: pfjl Mg No.'of Separate Inspections: 1 Mribg31.YsrJfisd and 13ppJs JJJs
- 1. Visual inspect headers per.11.3, ref. 1, 1 insp.
Rafarances
- 1. MF/0/A/1000/10 Diesel Engine Lube Oil System Piping and Sump Special Inspection Imanection Rasults
- 1. Visual - examination of the lube oil internal headers showed some minor disagreement with the owners group isometric drawings.
D anos111sta 21. Inspssliga Findinns
- 1. Plant-sp ecific drawings were obtained and the walkdown was repeated.
l. The results of this second walkdown were satisfactory pending Stone and Webster review. L i l l L
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' ' s. W rk Esquess,No.: 9812 ]EI,
.,., };' %' 's, No. of Separate Inspections:1 t
, , (
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Attributad Y.aKM, tad. med jamis,liis s L, s.', , 1 43 ' .. + s , + ,y ,
- 1. Visual inspect int,ernal lub '
oil system ' piping,l tubing and fittings per 11.3) ref.1) .1 insp. 's -'
, i 2,,
- 2. . Visual inspect external I'ube ' oil system piping, tubing and fittings per 11.4'.1, ref .1', *1 insp . '
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1&2 The visual ez'assia.stion of the internal'and esternal lobe oil tubing and 9
'fittiads was'satisihtory
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e Disnosition 21JJttnacileA b "- [ s,g s y > , , s'1 There were no significant fk; tiago ,, 4
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Catawba Diesel R Insoection Resort Part Name: Jedta 9,11Idag Suonorts Class: ), Part No.: 02-307D Work Request No.: 9.831 ]El
.No. of Separate Inspections: l' Attrihetes Yerifind Aad. lastle. lias.
I. Visual inspect supports per .11.3, ref.1,1 insp. References
- 1. 'MF/0/A/1000/10 Diesel ' Engine Lube oil System Piping and Sump Special Inspection Inspection Results
- 1. Visual' inspection of the lube oil line supports demonstrated two supports that were loose. Otherwise , the examination was within normal limits. ,
Disposition gi Inanection Findinas
- 1. The loose supports will be retorqued using torque wrenches to prevent reoccurrence.
l
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~'
i Ji .QAtawba DJgpil 14. I.9nection EggsII.
/, ,,
+s..
c Pcrt Name: " External .Idiht. Oil L1E14. , Class: $_ Pcrt No.: jfdQA , Work Request No.: 0832 }0!I. No. of Seps:ste -Inspections: 1. Attributes Verified ed. Samol'c 1333.
- 1. Visual inspect lube oil lines per 11.4, ref.1,1 insp.
.4, r. ,
References
- 1. MP/0/A/1000/10- Dies el Engine Lube Oil S;ates Piping and Sump Special Inspection Inspection Results
- 1. Visual examination of the external lube oil lines was satisfactory.
i- , Disoosition gf. Insoection. FinMnes There were no significant findings.
. - . _ . - - =
Catawba Diesel R Insnection Resort Pcrt Name: External }dthi 9.11 Sunnorts Class: A Pcrt No.: 02-4655 Work Request No.: 98)1 ]SI, No. of Separate Inspections: j, Attributet Verified And. Sample Jias.
-1. Visual inspect supports per 11.4, ref.1,1 insp.
4 References,
- 1. MP/0/A/1000/10 Diesel Engine Lube Oil System Piping and Susp Special Iaspection Inspection Results
- 1. -Visual ~ examination of the external lube oil supports was satisfactory with the exception of the triple header clamp bolts or. cylinders 81 and
'IR. Some of these bolts were found broken off.
Discosition 21 Insneetion Findinns l i
- 1. All triple header clamp bolts were replaced with higher quality bolts and retorqued to specifications. Also, the associated pipe lines will be reinspected to verify proper support to prevent excessive vibration.
l
Catawba Diesel JA Inspection Report Part Name: Turbocharter ]dt).g Oil Pininn Class: B Part No.: 02-467A Work Request No.: 0832 MNT No. of Separate . Inspections: - j, Attributes Jerified And.Saanle Jimg. 1 ~. Visual inspect piping, tubing and fittings per 11.5, ref.1,1 insp. References
- 1. MP/0/A/1000/10 Diesel Engine Lube Oil Piping and Sump - Special Inspection Inspection Results
- 1. The turbocharger lube oil piping will be inspected when the turbocharger is reassembled.
l i Disposition p.1 Inspection Findinas
Catawba Diesel JA Insoection Reoort Part Namn: IEEh1 lub.1 911.Pininn Supports C1 dss: B Part No.: 02-M75 Work kequest No.:g!}.2 MNT No. of Separate Inspections: J
- Attributer Verified amt sample 1. ins.
' 1. . Visual inspect turbo lube oil piping supports per 11.5, ref.1,1 insp.
References 1.- MP/0/A/1000/10 Diesel Engine Lube Oil Piping and Sump - Special Inspection . Inanection Results
- 1. The turbocharger lube oil piping supports will be inspected when the l turbocharger is reassembled.
i' Disoosition g[ Insoection PindinrJ. b
.y, --,~- , - , - - , - - - , y - , - - . ,---*,*,------y-
Catawba Diesel .4 Insoection Report
-Pcrt Nams: W gil JEEE 1831 Class: B
. Pert No.:. 02-540A Work Request No.: 2331 ME No. of Separate Inspections: 1 Attributes' Verified ed. SanDie ji33.
- 1. Visual inspect lube oil sump per 11.4.2, ref.1,1 insp.
References
- 1. - MP/0/A/1000/10 Diesel Engine Luke Oil System Pipinr, and Sump -
Special Inspection T==nec tion Results
- 1. - Visual inspection of the lube oil sump tank was satisfactory.
l- , Disposition af. Inspection Findinas There were no significant findings. l-i f i i
Catawba Diesel 1A. Insoection Report
.Part Name: Ig)1 pil.IEEE.Ig_nk Boltina Class: B Part No.: 02-5405 Work Request No.: ps)J MNT No. of Separate Inspections: 1.
Attributes Verified mul, Sample lias.
- 1. Verify mounting bolt torque per 11.4.2, ref.1,1 insp.
References
- 1. MP/0/A/1000/10 . Diesel Engine Lube Oil System Piping and Sump -
Special-Inspection Inspection Results
- 1. The lube oil sump tank mounting bolts were verified from existing l- documentation as having the correct applied torque.
I Disposition 31. Inspection Findinas There were no significant findings
, ~ , - , , -, , , . _ . , . _ .- . . , - . - - - . - - . . , , , , . - . - - -,-,-
Catawba Diesel JA Inspection Renort P:rt Name: 1shi pil.IMEE.Iggk Mountinz Hatdwari Class: B P rt No.: 02-540C Work Request No.: 9)8)1 MNT No. of Separate Inspections: 1-Attributes Verified ed. Sample jing.
- 1.. -Visual' inspect sump tank supports per 11.4.1, ref. 1, 1 insp.
References
- 1. MP/0/A/1000/10 Diesel Engine Lube Oil Systen Piping and Sump -
Special Inspection Insnection Results
- 1. Visual . . inspection of ~ the lube oil sump tank mounting hardware was satisfactory.
l l l l _- I t Discosition gl, Inspection Findinas There were no significant findings I: I
Catsuba Diesel 1A Inspection Report Part Name: Turbo. Thrust ]ggrigg Je]ts, Oil Sy_e.tein Class:C, Part No.: 02-CFR Work Request No.:0832 MNT No. of Separate Inspections:1,. Attributes Verified and, Sa= ale jing.
- 1. : Visual inspect turbo. thrust bearing lube oil system per 11.5, ref.1, 1 insp.
Peferences
- 1. MP/0/A/1000/10 Diesel Engine Lube Oil Piping and Sump Special Inspection
-Insoection Results
- 1. The turbocharger t!hrust bearing lube oil system will be inspected when
- the turbocharger is reassembled. Disoosition p.f Insoection Findinas i' - t
Catawba Diesel JA Inspection Reoort Part Name: ,Q.yligdgr Block Class: A t - Part Number: ,02-315A Work Request No. 0773 MNT
~ No.-of Separate Inspections: 122, Attributes Verified and, Sample ling,
- 1. Liquid penetrant inspect cylinder block top per 11.2.1, ref.1, 16 insp.-
- 2. Eddy current inspect cylinder block holes per 11.2.2, ref.1, 32 insp.
- 3. UT inspect cylinders per 11.2.3, ref.1,16 insp.
- 4. Dimensional inspect cylinder liner lending area per 11.6.1, ref.1, 56 insp.
- 5. PT inspect cylinder liner lat. ding area per 11.6.2, ref.1, 7 insp.
References
- 1. MP/0/A/1000/11 Diesci Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspections Insnection Rest its
._ l.- - The PT examination of cylinder block top was satisfactory. l- ..2. Eddy current exam of the cylinder head stud holes showed no indications. l 3. Ultrasonic exam was not required due to satisfactory ECT and PT exsan.
- 4. Dimensions of the liner landing areas were taken and will be forwarded to the Owners Group.
- 5. The PT' examination of the liner landing area were satisfactory.
Disposition 21 Insnection Findinas l
' There were no significant findings.
i l'
Catauba Diesel 1A_ Inspection Report Part Name: Cylinder 11ggr Class: A
'Part Number: _02-315C Work Request No. 0773 MNT Eo.-of Separate Inspections: 226 Attributes verified angt Sample Sims.
'1. Visual inspect. cylinder liner per 11.3.1, ref.1,16 insp.
t- 2. . Measure bore per 11.3.2, raf.1,120 insp.
- 3. . Perform Materials Comparator Test per 11.3.3, ref. 1, 6 insp.
4 Perform hardness test per 11.3.3, ref.1, 6 insp.
- 9. Measure dist. cylinders protrude above block per 11.3.4, ref.1, 64 insp.
-6. Supplement viwual inspect liner per 11.6.3. ref. 1, 7 insp.
- 7.- Dimensional . insp. cylinder liner per 11.6.4, ref.1, 7 insp.
References
- 1. 'MP/0/A/1000/11 Diesel Engine Cylinder Block,- Cylinder Liner and Jacket Water Manifold and Piping Special Inspection Insoection Results
- 1. 'All cylinders have ring scuffing and scratching. Seven cylinders
~s howed polish lines.
( '2. Twenty eight of 120 measurements of cylinder liner bore were not to specification. The dimensions ranged from 16.994" to 17.009".
- 3. - Material comparitor tests showed discrepancies with the Owners Group standard.
4 .- Hardness test results ranged from BHN 241 to 275. The specified hardness is BEN 277-311.
- 5. Twenty one of 64 - measurements of liner protrusion were not to l specifications. The protrusions ranged from .003" to .009".
' 6 .- The supplementa,1 visual inspection of cylinder liners were satisfactory.
- 7. .The dimensional inspections yielded the following results: 0.D. Lip -
'19.494"-19,498", 0.D. Seat Surf. - 18.991"-18.998", Height 1.505"-
1.506". Disoosition p.f. Inspection Findines
- 1. The - various scratches and marks are the results of normal wear and are not a problem.
265. The specifications were for new parts. The sma)1 discrepancies are considered norm 1 for parts that has seen service and are acceptable.
- 3. AM.nogh the material of the cylinder liner is not the same as that of the standard supplied by the Owners Group, the liners have performed well in service and are considered acceptable.
- 4. The hardness is considered acceptable within the limits of accuracy of the measuring device.
1
- ~ ~ _ . . . _ . . _ _ _ . _ _ , _ . . . . . , , _ . . . _ . . . . . . _ . - _ . _ _ _ _ _ . . . _ _ _ - -
$3 i Catawba Diesel 1A_ Inspection Report Part Name: Cylinder Eggl jl.udf. Class: B Part Number: 02-315E Work Request No. 0773MNT
.No. of Separate Inspections: ))2 Attributes Verifind mgl Jnis. King, u
i 1. -Record breakaway torque evlinder head nuts per 11.2.12, ref. 1, i 128 insp.
- 2. : Record breakaway torque cylinder head studs per 11.2.14, .ref.1, 32 insp.
3.- -Inspect head studs for ID marks per 11.4.1, ref. 2, -32 insp.
- 4. Visual inspect head studs per 11.4.2, ref. 2, 32 insp.
5._ Perform material test comp. per 11.4.3, ref. 2, 4 insp.
- 6. Perform superficial hardness test per 11.4.3, ref. 2, 4 insp.
References
- 1. MP/0/A/1000/01 Diesel Engine Cylinder Head Removal and Disassembly
- 2. MP/0/A/1000/11 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection Inspection Results
- 1. The breakaway' torque of the cylinder head nuts was measured and found to range from 2780 to 4190 ft-lbs.
- 2. . The breakaway torque of the cylinder head studs was measured and found to range from 1100 to 1930 ft-lbs.
l 3. The head stud ID numbers were inspected and found satisfactory.- l 4. Nine' studs showed pitted areas, One stud had a nick in the threads. L 5. The material comparitor tert results were satisfactory. l- 6. Hardness test 2esults ranged from Rockwell C 29 to 30 l Disposition p.f. Inspection Findinas
'4.- The indications described above were determined to have resulted from normal ~ service . . and to not affect stud integrity; the studs will be reused.
- 6. The hardness results are within normal limits.
Catawba Diesel ,lA Insnection Renort Pirt Name: L Cvlinder Block Jacket ][g3.31. Manifold _N.g11 Class: B Part Number: 02-315F Work Request No. 9)).3 .ME
' No. of Separate Inspections: 2,s.
Attributes Verified and. Sample J. ins.
~1. Visual inspect all'5/8" nuts per 11.5.1, ref. 1, 22 insp.
- 2. . Visual inspect 25% water manifold nuts per 11.5.2, ref.1, 4 insp.
References
- 1. MP/0/A/1000/11 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection .
Insnection Results 162. Visual inspections of the jacket water manifold nuts were satisfactory.
~
Disnosition pf. Inspection Findinas There were no significant findings. i i-I I l l [ i l
.. . . _ , .,_. , m. . _ . . , . _ . . . . _ _ _ _ , . . _ _ . . _ . _ _ . _ _ _ . _ _
Catswba Diesel 1A Inspection Report Pcrt Name: Cylinder Block Jacket h Manifold Class: & Ecrt Number:. 92-315D Work Request No. 0773 MNT No. of Separate Inspections: J. Attributes Verified ed. Sample h ! .1. Visual inspect water manifold and piping per 11.5.4, ref.1,1 insp. References
- 1. MP/0/A/1000/11 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection Inspection Results
- 1. The jacket water manifold - and . piping were inspected and found to be satisfactory.
' Disposition gf_ Inspection Findinas .There were no significant findings.
Catawba Diesel J.A.. Inspection Report Part Name: Jacketi ][g.tgg Discharme Manifold Class: E_ Part Number: 02-317A Work Request No. 0773MNT No. of Separate Inspections: 1 l Attributes Verified ap.d Samole #133, i 1.- Visual inspect jacket water manifold per 11.5.4, ref.1,1 insp
- 2. ~ Yisual inspect manifold per 11.5, ref. 2,1 insp.
References 1* 1. MP/0/A/1000/11 - Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection
- 2. MP/0/A/1000/25 Diesel Engine Jacket Water System Piping Standpipe and Manifold Special Inspection Insnection Results i 1. Visual-inspection of the jacket water manifold was satisfactory.
- 2. Walkdown inspections of the jacket water manifold were satisfactory.
l Disoosition g.1 Insoectios, Findines There are no significant findings to date. I t-
Catauba Diesel JA Insoection Report . Part Name: Startina A,ir Distributor Assembiv Class: A Part No.: 02-442A' Work Request No.: p]ll, M
- No. of Separate Inspections: },2, Attributes Verified and, Sample ling,
- 1. Visual . inspect each spool per 11.7, ref.1,16 insp.
- 2. Measure smallest diameter of each spool per 11.10, ref.1,16 insp.
3.- Measure superficial hardness of each spool. per 11.11, ref. 1, if diameter ratios are not within specifications Agigtancas..
- 1. MF/0/A/1000/12 Diesel Engine Starting Air Distributor Disassembly and Special Inspection Imaggraig.g Results 1
- 1. Visual inspection of the spools was satisfactory.
- 2. All spool diameter ratios are within specified limits.
i- 3. Hardness not required since diameter ratios were satisfactory. ! Disposition 21. Inspection Findinas
- 1. There were no significant findings.
i I l
- -wy m e,- = , , .v.,. ,, . -~-we . . , +..%.,.,e - e, ,,. . , . . - - - - - ,. _ - , -.-w,,--r.., .,,,cy, ,,,,,.- .-<--,,,.-.=,-._--.&-- -
Catawba Diesel 1A Insoection Report Part Name: Jacket Egigg PHEP. Class: ,A_
.Part No.: 02-425A Work Request No.:0776 MNT No. of Separate Inspections: 1 Attributes Verified And. Sample J. ins.
'1. Visual inspect' driven gear, coupling and spline par 11.3.1, ref.1, 1 insp.
- 2. PT coupling and externsi spline per 11.3.2, ref.1,1 insp.
- 3. Visual inspect volute wear ring per 11.4.1, ref.1,1 insp.
- 4. ~Yisusi inspect and PT inspect shaft per 11.4.2, ref.1, 2 insp.
-5. Perform material comparitor test per 11.4.3, ref.1, 2 insp.
6.-. Perform superficial hardness test per 11.4.3, ref.1, 2 insp. References , 1. NP/0/A/1000/13 Diesel Engine Jacket Water Pump - Special Inspection Inspection Rasults
- 1. Visual inspection of the driven gear, _ coupling and external spline was satisfactory.
- 2. PT examination of the coupling and external spline was satisfactory.
- 3. Visual inspection of the volute wear ring was satisfactory.
- 4. Visual inspection of the impeller shaft was satisfactory. PT examinations of the shaft and impeller were satisfactory.
5._ Material comparitor exams of the jacket water pump was satisfactory.
-6.- Bardness of the shaft was found to be BEN 170.
. Disnosition 21. Inspection Findinas
- 6. Although no hardness was specified for this component, a minimum
, hardness for the shaft material .was found to be BEN 160. In light of this, the hardness is considered satisfactory. E
g . _ - + ~, - 4m . .* _ I Catawba Diesel JA Instection Renort Part.Name: Cylinder Block Cover. Gekts. An!L Bolts Class: _C_ Part No.: 02-3855 Work Request No.: 0777 MNT No. of Separate Inspections: JJ2 Attributes Verified ggt Samole ling, I' _1. Record breakaway torque per 11.2.2, ref.1, 242 insp.
-2. Inspect gaskets for damage per 11.2.4, ref.1,10 insp.
References
- 1. MF/0/A/1000/14 Diesel Engine Camshaft. Camshaft Gear and Tappet Assembly Special Inspection.
~
Insoection Lasults
- 1. Can cover bolt breakaway torques ranged from 0 to 86 ft.lb2. Cam gear cover torque ranged from 9 to 42 ft.lbs.
- 2. Visual inspection of all gaskets showed no signs of leaks or damage.
l Disposition 3.1 Inspection Findinas
- 1. The can and can cover bolting is being replaced with higher strength
! bolts and will be reinstalled to specifed torque. I i
~
i
l s-Catawba Diesel JA Inspection Report Part Name: Camshaft Suonorts. Bcitinn Agst Ggar Class: A Part Number: 02-350C Work Request No. 0777 MNT No. of Separate Inspections: 1 Attributes Verified And. ).aEllS.11ES.
- 1. Visual inspect left and right camshaft gears per 11.5.4, ref.1, 2 insp.
- 2. Perform Material Comparator Test camshaft gear per 11.5.5, ref.1, 2 insp.
- 3. Perform herdness test camshaft gear per 11.3.5, ref.1, 2 insp.
References 1
- 1. MP/0/A/1000/14 Diesel Engine Camshaft, Camshaft Gear and !
Tappet Assembly Special Inspection ! I Inspection Results
- 1. Visusi inspection of camshaft gears show only a slight amount of pitting in the gear contact surface. 1
- 2.- The results of the material comparitor test showed material different l from the sample supplied by the Owners Group.
- 3. 'Bardness of the camshaft gear was found to be BHN 269-339. The specified hardness was BBN 290-320.
- Disoosition pf, Insoection Findians
- 1. The can and can gear cover bolting is being replaced with higher strength bolts and will be reinstalled to specified torques.
- 2. Although the material of the can gear is different from the sample supplied by the Owners Group, the part has performed well in service ~
and is considered acceptable. The reported hardness is considered acceptable within the limit s of l 3. l accuracy of the testing device. i I l. t I I
\
1 l __.. _ _ . , _ . . _ . _ _ _ - - - - _ , . , , _ _ , _ _ . . . . , . . . . _ _ . . . . _ _ _ _ _ _ _ . . . _ . _ _ _ _ _ _ _ . . . _ _ _ _ . _ _ _ . _ . . ---._--..I
Catsuba Diesel 1_A A Inspection Reoort P;rt Name: Camshaft Assemb1v Class: A_ Pcrt Number: 02-350& Work Request No. 0777 MNT No. of Separate Inspectios,s 1Q Attributes Verified And. Sample j,133, l l 1. Visual inspect camshaft lobes per 11.3, ref.1, 48 insp.
- 2. Inspect locking clips both camshafts per 11.4.3, ref.1, 2 insp.
Referenc es
- 1. MP/0/A/1000/14 Dies 91 Engine Camshaft, Camshaft Gear and Tappet Assembly Special Inspection Inspection Results
'1. The visual inspection of the camshaft was satisfactory with the exception of two small pits in one lobe, which are not significant.
. 2. Visual inspection of the locking clips showed the locking clips to be in place. '. Disposition pf Inspection Findines There were no significant findings ( l I i-
Catawba Diesel _1& Inspection Report
, P:rt Nane: Camshaft Bearina Class: A_
Pcrt Number: 02-3505 Work Request No. 0777 MNT
- No.~ of Separate Inspections: 4, Attributes Verified angt Sample J. ins.
- 1. Visual inspect left and right outboard support bushings per 11.4.2,
!- t ef.1, 4 insp . References
- 1. MP/0/A/1000/14 Diesel Engine Camshaft, Camshaft Gear and Tappet Assembly Special Inspection Insoection Resnits 1.. Visual inspection of the outboard support bushings was' satisfactory.
l ! Discosition 2f. Inspection Findinns !- There were no sisnificant findings. I r o I A s L l-
4 - Catawba Diesel ,1A Inspection Report
' Pcrt Name: Eng1 Tannets Class: A
~
Pcrt Number: 02-345B Work Request No. 0777 MNT No. of Separate Inspections: 1,2.,2
. Attributes Verified Aggl Sannie list
- 1. Visual inspect tappet rollers per 11.4.1, ref.1,12 insp.
Referenc es
. 1. NP/0/A/1000/14 Diesel Engine Camshaft, Camshaft Gear and Tappet Assembly Special Inspection Insnaction Results 1.. Visual inspection of the fuel tappet rollers showed one scratch in the 8L roller, otherwise they were satisfactory.
l l Disoosition Af. IRAPaction Findines t [ - 1. The scratch was evaluated as being the result of normal service and the l-tappet roller was evaluated as being acceptable. 1 1 i { i l l i
,, - - . , . _- . . _ . , , . . _ , . _ , , , , - , y__, . . _
. _ , . , . , , , , . . , _ _ , _ . . . _ y_,._ - , - _ . _ . _ _ _ _ , , - .
Catswba Diesel 14 Inspection Renort Part Name: Intake Tannets Class: Ag Pcrt Number: 02-345A ' Work Request No.0777 MNT No. of Separate Inspections: J2 Attributes Verified mut Sample jia
- 1. Visual inspect tappet rollers per 11.6.1, ref.1,12 insp.
Referenc es
- 1. MP/0/A/1000/14 Diesel Engine Camshaft, Camshaft gear and Tappet Assembly Special Inspection Insnection Results _
- 1. Visual inspection of the intake and exhaust tappet rollers was satisfactory.
l Discosition 21 Insoection Findines ! There were no significant indicationa
Catawba Diesel lA Insoection Resort Perr. 5:=c: Intake Manifolds Class:B, Pcrt No.: 02-375 Work Request No.: 0772 MNT No. of Separate Inspections:M Attributes Verified myL Samole_ jilt.
- 1. Visual inspect surfaces and bolt holes per 11.2.2, ref. 1, 32 insp.
References
- 1. MP/0/Afl000/15 Diesel Engine Intake and Exaust Manifolds Special Inspection Inspection Easults
-1.- . Visual inspection of the manifold surfaces and bolt holes was satisfactory.
l Discosal p.1 Insnection Find ines
' There were no significant findings.
l I-d 9 _ , * - ,- ..-- - -- , ,y_ - . . _ . - , _ - - ~ - - ,m--,.e, _ , , - _ _ . - .~- _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ . -
Catsyba Diesel le_ Inspection Renort Part.Name: Exhaust Map _ifpJi Boltina Class B Part No.: 02-3805 Work Request No.:0772 M]g
.Nd . of Separate Inspections:j, Attributes iszifiss sai Sample Riza.
- 1. Visual inspect capscrews per 11.3.2, ref.1, 3 insp.
- 2. Measure depth of capscrew hole and flange thickness per 11.3.3, ref.1, 3 insp.
Esterences
-1. MP/0/A/1000/15 Diesel Engine Intake and Exaust Manifolds Special Inspection Insnection Results -1. Visual inspection of the capscrews was satisfactory. -
- 2. The depth of the flanges plus the capscrew holes in the exhaust manifolds were satisfactory.
l Discossi gf. Insnection FJndines I-There were no significant findings. I l l l I' t f
Catawba Diesel JA Inspection Report Part Name: Exhaust Manifold Class: B Part No.: 02-380A Work Request No.: 0772 MNT/0921 MNT No. of SeparateLInspections: J1 Attributes Verified Albl. Saanle Sing. ,
- 1. Visual. inspect exhaust manifold to flange weld per 11.3.4, ref.1,16 insp. .
- 2. Visual inspect exhaust manifold per 11.3, ref. 2,1 insp.
References
- 1. MP/0/A/1000/15 Diesel Engine Intake and Exhaust Manifolds - Special Inspection
- 2. MP/0/A/1000/28 Diesel Engine Exhaust Manifold - Special Inspection 4 Inspection Results 1.- Visual inspection of the exaust manifold to flange welds was satisfactory.
- 2. Walkdown inspections of the exhaust manifold were satisfactory.
l l (. Disoosition sf. Inspection Findinas !~ ~ There were no significant findings l I o l I i i
Catawba DisssJ lA Inspection Recort Part Name:OversneedIT jg priya Coun1 inn Class: 4.
'Part No.: 02-410C Work Request No.:984]E No. of Separate Inspections: 4, attributes Verified Aad. Sample liga. s
- 1. ' Verify coupling halves are snug against - spider per 11.2.7, ref.1, 1 insp.
- 2. Check both couplings to ensure tapered pin is tight per 11.3.1.1, ref 1, 2 insp.
- 3. Note condition of elastomer piece per 11.3.1.4, ref.1,1 insp.
References
- 1. MP/0/A/1000/16 Diesel Engine Governor and Overspeed Trip -
Accessory Drives Disassembly Inspection and Reassembly-Insnection Rasults
- 1. The coupling snugness was checked and found to be satisfactory,
- 2. The tapered pin was found to be satisfactory.
L 3. The elastomer piece was found to have small indentations. Dissosal gf. Insnection Findinga
- 3. The ind'entations in the elastomer piece do not affect the operability of .
the engine. However, it will be replaced as part of routine annual maintenance. I i: (^ . . - -. - - . . _ . - .-.-. - - - - - --
y- . - .- h'-. t
+ x l' 3 , t. ' l ,
t r - f % g 4
, 3 '
J. Catawba D_M JA Jusocction Report M s ,- e. s () " y m 3, tu ,
-Part.Name: Overspeed Irla and. Arase1912 Driys . class: A
,t Part No.: 02-4105 1 q '
Work R. quest No.:0841 MNT No. of Separate Inspections: .js. i Attributes Verified and Sasele 1131 l 1. . Remove drive assembly per 11,2, ref.1,13 insp'.
.2. Disassemble overspeed trip drive per 11.3, ref.1, 3 insp.
'3. Visual. inspect 0.S. trip' drive drive shaft $for deterioration psc 11.3.10.1 ref.1,1 insp. ,
+ ^ .,
.4. -Perform material comparitor on 0.S. trip drive drive shaft per 11.3.10.2, ref. 1, 1 insp. i
- 5. PT inspect 0.S. . trip drive drive shaft per 11.3.10.3, ref.1, 1 insp.
6.: Visual inspect 0.S. trip drive drive shaft per 11.3.10.4, ref.1,1 insp.
- 17. Perform . material comparitor test'.on'O.S. trip drive driven shaft per 11.3.10.5, ref. 1, 1 insp.
- 8. PT inspect 0.8. -trip drive driven shaft per 11.3.10.6, ref.1, 1 insp.
- 9. Visus 1 inspect 0.5. trip drive drive gear per 11.3.10.7, ref.1,1 insp.
- 10. . Perform material comparitor test on 0.f trip drive drive gear per 11.3.10.8, ref.1,1 insp. ,
- 11. Perform hardness test on 0.8. trip drive drive gear per 11.3.10.9, ref.
1, 1 insp.
-12. Visual. inspect 0.S. trip drive driven gear per 11.3 10.10, .ref.1, 1 insp.
L 13. Perform material comparitor on 0.S. trip drive driven gear per
- i. .
11.3.10.11, ref.1,1 insp. L 14. Perform hardness test on 0.S. trip drive driven gear per 11.3.10.12, L ref.1, 1 insp.
- .15. - Visual inspect 0.8. drive antifriction bearings per 11.3.10.13, ref.1, 1
, insp.
~16. Measure end play of accessory drive drive shaft per 11.4.2, ref. 1, 1 l insp.
l 17. Visual inspect accessory drive shaft per 11.4.5.1, ref.1,1 insp. l.
- 18. Perform material comparitor test on Accessory drive shaft per 11.4.5.2,
- t. ref. 1, 1 insp.
- 19. _ PT inspect accessory drive shaft per 11.4.5.3, ref.1,1 insp.
- 20. Visual inspect accessory drive gear per 11.4.5.4, ref.1,1 insp.
- 21. Perform material comparitor on accessory drive gear per 11.4.5.5, ref.
1, 1 insp. -
- 22. Perform hardness test on accessory drive gear per 11.4.5.6, ref. 1, 1 insp.
References l 1. MP/0/A/1000/16 Diesel Engine Governor and Overspeed Trip Acressory (- , Drive - Disassembly, Inspection, and Reassembly i
. - , , , _ _ . _ _ _ ~ . _ . . . _ _ _ _ . . . - _ , _ _ _ _ . _ _ . _ _ _ _ _ _ _ _ _ _ _ - - _ _ __ _ __
Inspection Results
- 1. The drive assembly was removed according to procedure.
- 2. The overspeed crip drive was disassembled according to procedure.
- 3. The visual inspection of the OS trip drive shaft was satisfactory.
- 4. The material comparitor results on the OS trip drive showed material different from the sample supplied by the Owners Group.
- 5. The PT inspection of the OS trip drive was satisfactory.
- 6. Visual inspection of the OS trip driven shaft was satifactory.
- 7. The material comp. results of the OS trip driven shaft showed material different from the sample supplied by the Owners Group.
. 8. The PT inspections of the OS trip driven shaf t were satisfactory.
- 9. Visual inspections of the OS trip drive gear were satisfactory.
- 10. Material comp. results of the OS trip drive gear showed material different from the sample supplied by the Owners Group.
- 11. The hardness of the OS trip drive gear was BHN 252 (UTS about 124 kai.)
- 12. Visual inspection of the 03 trip driven gear was satisfactory.
- 13. Material comp. results for the OS trip driven gear showed material different from the sample supplied by the Owners Group.
14 .The hardness test result for the OS trip driven gear was BHN 218 (UTS , about 106 ksi.)
- 15. Visual inspection of the OS trip drive antifriction bearings showed a
. rough spot in the bearing.
- 16. The end play of the accessory drive shaft was satisfactory.
- 17. Visual inspection of the accessory drive shaft was satisfactory.
- 18. Material comp. results for the accessory drive shaft showed material different from the sample supplied by the Owners Group. -
- 19. The PT inspection of the accessory drive shaft was satisfactory.
- 20. Visual inspection of the accessory drive gear was satifactory.
- 21. Material comp. inspection results of the accessory drive gear were satisfactory.
- 22. Hardness of the accessory drive gear was BHN 321.
Disposition gf Insoection Findinas 4,7,10,13,18 Although these components had material different from the samples supplied by the Owners Group, they have performed well under extended service and are therefore considered acceptable. 11,14,22 No hardness values were specified for these components. However, the parts have performed well in service and are considered acceptable.
- 15. The damage to the bearing occurred during disassembly. The bearing has been replaced.
o l t
Catswba Diesel _11 Insnection Renort , iPcrt Name: Governor Eggi Exchanner Assembiv Class:A Part No.: 02-415C. Work Request No.:0841MNr No. of Separate Inspections:1, Attributes Verified mad. Sample fing.
- 1. Verify oil. cooler is mounted below oil level per 11.5.1, ref.1, 1 insp.
References
- 1. ' MP/0/A/1000/16 Diesel Engine Governor and Overspeed Trip
' Accessory Drives Disassembly Inspection and Reassembly Insnection Results L ~~1.- The ' location ' of _ the oil cooler was inspected and found to be satisfactory.
Disnosition 21 Insnection Findinns There were no significant findings. I ls l t. r I
-- . . . _ . . .. _ . _ . . - , - - . _ . , . _ , _ . . _ _ . _ _ _ . - . . - . _ _ _ , . _ _ _ , _ _ . . . _ . . . ~ _ . . . . , ~ . - . . . - . . . - _ . .
Catawba Diesel JA Inspection RcDort L Part Name:Spe g gt Renulatina' Governor Drivt Gear / Shaft Class:A Part No.: 02-411A. Work Request No.:984l,MNT _ No.. of. Separate Inspections:l],
- Attributes Verified Aust Sample Ji.31 i
- 1. Measure end play of horizontal shaft per 11.6.4, ref.1,1 insp.
2 . '- Visual inspect larger horizontal shaft drive gear per 11.6.7.1, ref.1, 1 insp.
- 3. Perform : material comparitor test on larger horizontal shaft drive gear
_ per 11.6.7.2, ref.1,1 insp.
- 4. Perform hardness test on larger horizontal shaft drive gear per 11.6.7.3, 1. insp .
- 5. Visual - inspect small horizontal shaft drive gear per 11.6.7.4, ref.1, 1 insp. -
'6. ' Perform material comparitor test on small horizontal shaf t drive gear per 11.6.7.3, ref.1,1 insp.
-7.. Perform hardness test on small horizontal shaft drive gear per
- 11.6.7.6, ref.1, 1 insp.
- 8. Visual inspect horisontal shaft per 11.6.7.7, ref.1,1 insp.
-9.. Perform material' comparitor test on horisontal shaft per 1.6.7.8, -
ref. l. 1 insp.
- 10. - PT exam horizontal shaf t per 11.6.7.7, ref.1,1 insp.
' 11.. - Visual inspect vertical shaft per 11.6.7.10, ref.1,1 insp. ,
- 12. Perform material comparitor test on vertical shaft per 11.6.7.11, ref. '1,1 insp.
-13 . PT exam vertical shaft per 11.7.7.12, ref.1,1 insp.
E References
- 1. MP/0/A/1000/16 Diesel Engine Governor and Overspeed Trip Accessory Drive-Disassembly, Inspection, and Reassembly Insoection Results
,,t 1. The end play of the horizontal shaft was satisfactory. 2.- . .The visual inspectior. of the large horizontal shaft drive gear was l' satisfactory.
- 3. Material ~ comparitor results for the large horizontal shaft drive gear showed asterial different from the standard supplied by the l
Owners' Group.
.4. The hardness of the large horizontal shaf t drive gear was BHN 468-472 (UTS if about 240 kei) vs. an expected hardness of Rockwell A 76-79 (UTS of abour. 250 to 300 kai).
- 5. Visual inspection of the small , horizontal shaft drive gear was satisfactory.
- 6. Material comp. test results for the small horizontal shaf t drive gear were acceptable.
- 7. The hardness of the small horizontal shaft gear was BHN 457 to 460 (UTS of .about 235 ksi) vs. an expected Rockwell A hardness of 76-79 (UTS of
.about 250-300 kai).
- 8. ' The visual inspection of the horizontal shaft was satisfactory.
.9. Material comp.. test results for the shaft were satisfactory.
10.- PT exam results of the horizontal shaft were satisfactory.
- 11. Visual inspection of the vertical shaft was satisfactory.
- 12. Material comp. test results for the vertical shaft were satisfactory.
- 13. The PT inspection of the vertical shaft was satisfactory.
Disposition 91 Inspection Findinas
- 3. Although the material is different .from the standard supplied by the Owners Group, the component has performed well in service and is considered acceptable.
4&7 The measured hardness is considered acceptable within the limits of accuracy of the mesauring device. I l b (' I-l- l l l l-l f
c l Catawba Diesel 1A Insoection _ Report
.j Part Name:Aggal Reaulatina h Drive Coucline Class:A_ .
Part No.: 02-411B Work Request No.:0841MNT No. of Separate Inspections Q , Attributes Verified ggL Sample ji33. i- 1. Visual inspect coupling halves, shaft ends and spacers per.11.6.7.13, ref.1, 2 insp.
- 2. Visual inspect female drive coupling per 11.6.7.14. ref.1, 1 insp.
References
-~1. MF/0/A/100D/16E ' Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly Inspeccion and Reassembly.
Insnaction Results L l&2. -Visual inspections of the governor drive couplings and related hardware were satisfactory. l Disposal' Af. Insoection Findinas
- There were no significant findings.
l l i I
- . ._-...--.._.-________-.-.--__.-__.____..-.m.._. . , _ _ . . . _ _ - _ _ . . , _ - . _ . . . , - .
Catawba Diesel M Inspection Renort Pcrt Name: Zugl. h Linkare 3gst Shutdown Cylinder Class: B. Pcrt No.: 02-413B Work Request No.: 0841 ,Mgg_ No. of Separate -Inspections: 1 Attributes Verified and. Sample 1133. l .1. ~ Check linkage action per 11.7.1, ref.1,1 insp.
- 2. Visual inspect cross shaft assembly per 11.7.2, ref.1,1 insp.
References
- 1. ..MP/0/A/1000/16 Diesel Engine Covernor and Overspeed Trip Accessory Drives - Disassembly, Inspection, and Reassembly Inspection Results 1.: . The linkage action was inspected and found to be satisfactory.
- 2. The visual.. inspection of the cross shaft assembly was satisfactory.
l 1 Discosition 21 Inspection Findines There were no significant. findings. l .. t I. l' o l'
Catawba Diesel JA Inspection Report
. Part Name:Soeed Regulatina 92Y_m. Li"k"*e Class:L
- Part No.: 02-413A' Work Request No.:0841MNT No. of- Separate Inspections:2, Attributes Verified mut Sample jing.
11.1 Check Linkage Action per.11.7.1., ref.1,1 insp.
~2.- :. Visual inspect cross shaft per 11.7.2., ref.1,1 insp.
References
- 1. MP/0/A/1000/16- -Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly Inspection and Reassembly Insnaction Rannits
~1. . The linkage was inspected and found to be acceptable.
2.- The visual inspection of the cross shaft assembly was satisfactory. Dianosition' af. Insnecting Findinas
. There were no. significant findings .
r I~ l
?
l I
. _ _ . . .. , - ._. __.._... . .. _ ____ . -._ _.. ___ ,_.. . ..., _ .. ......__.-._ _ _ _ .. ,_ ~ ,_ _ _ _ _ ,_ _ ,.
Catawba Diesel JA Insnection Renort P:rt Name:~Fivwheel Boltine Class: A P:rt Number: 02-330B Work Request No. 0841MNT No. of Separate' Inspections: 24, Attributgg, Verified ed. Samole #133.
- .1. Visual inspect for loose roll pins per 11.2.1, ref. 1, 12 insp.
- 2. Torque test per 11.2.3, ref.1, if correct torque was not previously documented,12 insp.
References
- 1. MP/0/A/100017 Diesel Engine Flywheel Bolting Special Inspection Insoection Results
- 1. Visual inspections of the roll pins were satisfactory.
- 2. . ; Documented terque values were located in documentation of previous work
!> . with the minimum torque being 4500 foot-pounds. .. , i Risposition 21 Insnection Find 4nes There tyre no specific findings t s A
. , - y . _ . . - .. _ _ _ . . _ . . . ~ _ . _ , . , , . . - - . _ . . , , _ _ . . . . . . , . , , , , - , _ . . , . - . _ , . _ _ _ . , . . . . . . . , . . _ , _ . _ . . . - _ , , , , _
Catawba Diesel JA Insnectipp RgypIl Part Name: Turbocharmer Class: A Part No.: KP/022/3 Work Request No.:9))51917 No.rof Separate Inspections: 22. Attributel 19511124 ADA.1989.1L Eilt.
. 1. Visual inspect assembly per 11.2.2, ref.1, 6 insp.
- 2. Visual inspect journal bearings per 11.2.3, ref.1, 4 insp.
- 3. Measure ID of journal bearings per 11.2.4, ref.1, 4 insp.
4 Visual inspect turbo exhaust gas inlet bolts per 11.7.1, ref.1,16 insp. References
- 1. MP/0/A/1000/18 Diesel Engine Turbocharger and Intercooler - Special Inspection Inanastion Eppults 1.. The right nossle of the right bank turbocharger has a chipped spot, otherwise the visual exam is satisfactory.
2 The right journal bearing hae a chip in it and the left journal bearing is satisfactory. The thrust bearings are severely worn and damaged.
- 3. The I.D. of the journals was measured with satisfactory results.
4 The turbocharger exhaust gas inlet bolts were inspected and found s atisfact ory. However, the bolts are to be replaced with ones of improved material. Discosition 91 Jaspection fjpdjpg3
- 1. . The chip on 'the nozzle was evaluated as not being significant.
- 2. New bearings will be installed. In addition, a new lubrication system will be installed to prevent recurrence of this problem. .
O h
l Catawba-Diesel R Inspection Renort i.
- Pcrt Name: Turbocharmer Ait Butterfiv Valve Class: A
.Pcrt No.:. 02-4755
~
Work Reqcest No.: 91Z1 E
' No. of Separate' Inspections: .L4.
Attributes Verified md. Sample ling. l
- 1. -Perfora disassembly inspection-per 11.3, ref. 2, 2 insp.
~2.. Visual inspect roll pins per 11.3.2, ref.1, 8 insp.
'3. ' Visusi inspect valve shaft per 11.3.3, ref.1, 2 insp.
- 4. ' Check - to ensare no' cold springing required on reassembly per 11.3.4, ref.1, 2 insp.
References 1.- MP/0/A/1000/18 Diesel Engine Turbocharger and Intercooler - Special Inspection 1
- 2. MP/0/A/1000/22 Diesel Engine Air Butterfly Valve 2emoval-
- - Disassembly, Reassembly and Inspection Inanection Results
-1. Disassembly of the butterfly valve was done according to procedure, and
_ revealed no problems
- 2. Visual inspections of roll pins were satisfactory.
- 3. ' Visual _ inspections of the shafts indicated they were satisfactory.
l 44 Cnecks 'of cold spring indicated that the piping was satisfactory. I Disnosition 31. Insnaction Findinas There were no significant findings. i_ t (. L L c _
?
2 Catawba Diesel R Inspection denort [ Pcrt Name: Turbocharmer Bracket Class: B Pert.No.:'02-475A Work Request No.: 92Zi M No. of' Separate Inspections: 1 Ch Verified mL Sample liga 1.: Visually . inspect support bracket per 11.4.2, ref.1,1 insp. References
- 1. MP/0/A/1000/18 Diesel Engine Turbocharger and Intercooler - Special Inspection.
Inspection Results
- 1. . Visual inspection of turbocharger bracket shows no signs of distress or
- dis tortion.
s [. i l e l Disnosition 21. Insoection Findings l' There were no significant findings i I I l l l l
Sag 3jdta Diesel R Insoection Renort Fcre Name: Turbocharner Bracket }gl3.hg Class: 1 Pcre No.: 02-475D Work Request No.: 9))1 ME. No.'of Separate Inspections: 29, b Attributes Verified And.Samole 3.133,
- 1. Measure breakaway torque per 11.5.2, ref.1, 6 insp.
- 2. Material comparitor test per 11.5.3, ref.1, 6 insp.
p 3. Visual inspect bolted joint per 11.5.4, ref.1, 2 insp.
- 4. Check torque on reassembly per 11.5.5, ref. 1, 6 insp.
References
- 1. MF/0/A/1000/18 Diesel Engine Turbocharger and Intercooler - Special Inspection Insnaction Rasults
- 1. Breakaway torque of turbocharger bracket bolts rangad from 0 to 250 ft .
Ibs.
- 2. . Material comparitor test of turbocharger bracket bolts were acceptable.
- 3. . . Visual inspection of the bolt joint was satisfactory.
- 4. The turbo bracket bolts were reinstalled according to procedure. -
l
. Fiscosition gi Inspection Findinas Several of the bracket bolts were found to have low torques. All of the 1.
bolts will be checked and bolts with low torques will be retorqued R using a torque wrench and loctite. L^ t 4 0 f
, - - - - - + , - ,. - . . - - , , .-,w,,m,.-...,.,--w,y .--,w-m_,-w-~,---,-,,-,----.,w%, , , , , . . -_ w._...e--., ,
Catawba Diesel R Insnection Report Pcrt Name: Intercooler Class: 1 Part No.: F-086 Work Request No.: 91Z1 m No. of S'e parate -Inspections: 1 Attributes Verified aggL Saanle h
'1. Visual inspection of intercooler and inlet and outlet adaptors per 11.6.2, ref.1, 6 insp.
, 2. Perform PT or MT exam of each intercooler inlet adaptor flange weld per 11.6.3, ref.1, 2 insp. References
- 1. MP/0/A/1000/18 Diesel Engine Turbocharger and Intercooler - Special Inspection Inspection Results
- 1. Visual inspection of the intercooler was satisfactory.
-2. MT examination of the weld was satisfactory l
i il Disnosition g.L Insnection Fin /Ines There were no significant findings L l l 1 l l l l l-
Catawba Diesel M Insoection Reoort Part Name: Intercooler Pininn Couclina u Boltine/ Gasket Class: 4_ Part No.: 02-436B Work Request No.: 022) M!rr No. of Separate Inspections: 1. Attributes Verified and. Sample J.13g.
- 1. Check dresser coupling on piping per 11.6.4, ref.1,1 insp.
References
- 1. MP/0/A/1000/18 Diesel Engine Turbocharger and Intercooler - Special Inspection Inspec_t;,ign Results
.1. Dresser coupling found on inspection was a 90 degree elbow straight coupling . This information will be forwarded to the Owners Group.
Disposition 21 Inanection Findines
- 1. There were no significant findings.
l l l .
, - .. _~_
[31.gyle, Diesel M Inspection Renort Part Name: W F.ag.gr Standpipe Fitt ians i Gaskets Class: B Part No.: 00-700A Work Request No.: 1921 MNT
- No. of Separate Inspections: 1 Attributes Verified agt Sassle lia.C.
1.. ; Visual-inspect system per 11.3, ref. 1,~1 insp. RainLSEAn. 1.. MP/0/A/1000/25 ' Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Insoection Results
- 1. Results of the visual examination of the jacket water standpipe fittings and gaskets were satisfactory.
Disnosition af Insnection Findinas There were no significant findings. i i l
- _ . . - , . - , . . ~ , , . _ . , , _ . - _ _ , . - ~ , , _ , _ _ , . . . . . . - _ _ _ . . - . _ . _ _ . _ _ _ , , , , , , _ , _ . _ _ _ , . . _ , - - , - _ . - - , .
Catawba Diesel M Inspection Report Part Name: Jackst Was.gr Standnine Suonorts Class: . B_ Part No.: 00-700C Work Request No.: 9220 MNT
- No. of Separate Inspections: .1, Attributes Verified and, Sanole 1.1,33.
1.: Visual inspect supports per 11.3, ref. 1, 1 insp. References
. 1.- MF/0/A/1000/25 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection i
Inanection Esaulsa
- 1. Result of the visual inspection of the jacket water standpipe
> supports were satisfactory. ,
i Disposition .g,L Inanection Findinas There were no significant findings.
.r lv .
J Catawba Diesel M Inspection Report Part Name: Jacket ]!sigr, Standnine Boltina Materials Class: 5 Part No.: 00-700F Work Request No.: 912_Q MNT No. of_ Separate Inspections: 1 Attributes Verified amt Sample 1133.
- 1. Visual inspect bolting per 11.4, ref. 1, 1 insp.
References
. 1. MF/0/A/1000/25 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Inspection Rasults
- 1. Results of the visual inspection of the jacket water standpipe bolting material were satisfactory.
)
i - i
- ][ignosition gi Insoection Findinas
~
j There were no significant findings. i l-l l l' i t
= - - _ -
Catawba Diesel JA Inspection Report Part Name: Jacket j!gitt, Manifold Assembly Class: .B_ Part No.: 02-316A Work Request No.:0920 MNT No. of Separate Inspections: .1, At.tributu Verified And.Saanle 1133.
- 1. Visual inspect assembly per 11.3, ref. 1, 1 insp.
Rafarences
- 1. .MF/0/A/1000/25 Diesel Engine Jacket Water System. Piping, Standpipe and Manifold - Special Inspection e
Insoection Results
'1. Resulta of the visual inspection of the jacket water manifold assembly were satifactory.
t l l Ritapsition gf. Insoection Findinas
-There were no significant findir. s.
I i i o I l i E _ _ . _ ~ . -_ ..-._ _ _,_ ___ _.__ _ _.__ _ _ _--._____.- _ ... -
Catawba Diesel JA, Insoection Report Part Name: Jachst MaltI J.alti Manifold Couclina Class: B, Part No.:- 02-3165 Work Request No.:pj29, MNT No. of Separate Inspections: J. Attributes Verified And. AAE12.1153.
^ 1. Visus 1 inspect coupling per 11.4, ref. 1, 1 insp.
kaferences
- 1. MF/0/A/1000/25 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Insnaction Results 1.- Results of the visual inspection of the jacket water inlet manifold coupling were satisfactory.
I Dianosition 9.f. Inanection Findinas i There were no significant findings. l l l L
Catawba Diesel M, Inspection Renort Part Name: Jacket Majitg Discharme Manifold Couclina Class: 5
, Part'Jo.: 02-3175 -Work. Request No.:Q)lg M No. of Separate Inspections: 1.
Attrihutas Verified 334,13313, ling,
'1. Visual. inspect coupling per 11.5, ref. 1, 1 insp.
t References
- 1. MP/0/A/1000/25 Diesel Engine Jacket Water System, Piping Standpipe 4
and Manifold - Special Inspection 4 - Igenaction Results
- 1. Result of the visual inspections of the jacket water discharge manifold couplings were satisfactory.
Dissosition 21 Insoection Findinas There were no significant findings. I l l' t
n. SalgNhs. Diesel JA Insoection Report Part Name: Jacket Waigr. Discharge Manifold Supports Class: B Part No.::- 02-317C Work Request No.:222Q 1981 ' No. of'Seper.ste Inspections: 1 Attributes Yerified sad. Sample ling
- 1.~ Yisual inspect supports per 11.5, ref.1,1 insp'.
References
- 1. ^ MF/0/A/1000/25 Diesel Engine Jacket Water System, Piping, Standpipe
. and Manifold - Special Inspection Insnaction Rasults
- 1. Results of the visual inspection of the jacket water discharge manifold
- supports were satisfactory.
t .. l Dismosition 21 Insnection Findinas There were no significant findiage. i t i
*--.em---e ~ - ,, , _ . , , , , _ , , , _ , , , , + , _ , _ _ _ _ , _ _
1 Catawba R1 331 j& Insnection Resort Part Name: Ing)g. Coolina Egg,gg. Eigg and Fittines Cisss: 5 . Part No.: 02-437A Work Request No.:Q1g,Q R
- No. of Separate Inspections: j.
l Attributes Yerified and. Samole J.ina.
- 1. Visual inspect system per 11.6 ref.1,1 insp.
References
- 1. MP/0/A/1000/25 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Inanection Results This inspection will be performed when the engine is reassembled.
j Disnositica 21 Insnection Findinas l l I
- -.._..,__ ~ ...- . _.-. _ _ _ _ _ _ _ _ _ _ . . _ . . . _ _ ~ , _ _ _ _ _ . . . _ . . - - . . - - - _ _ .
-. .~
Catawba Diesel 14. Insnaction Report
.Part Name: Iggjte, Coolina ]!s,gsr Zipa Sunoorts Class: A_
Part No.: 02-437B Work Request No.:9121 MNT
.No. of Separate Inspections:1, Attributes Yerified Aad. Sample 1.133.
l _1.. . Visual'inspe=t supports'per 11.6, ref. 1, 1 insp. References
- 1. MP/0/A/1000/25 Diesel Ragine Jacket Water System Piping Standpipe and Manifold - Specist Inspection y
Insoection Results This inspection will be performed when the engine is reassembled. l Disposition 21. Insoection Findinas L l I. t I .. l l l t
s f Catawba Diesel JA Insoection Report Part Name: jigy_t Air Manifold Pipe. Tubina ), Fittinas Class: A Part No.: 02-441A Work Request No.:M MNT No. of Separate Inspections: 1 Attributes Verified and. Saanle jlAg.
- 1. Visual inspect system per 11.3, ref. 1, 1 insp.
References
- 1. MP/0/A/1000/26 Diesel Ragine Air Start Piping System - Special Inspection Inspectiga,Results
- 1. Results of visual inspections of the start air manifold system showed several minor discrepancies with the drawings.
i __ Disnosition 2f. inspection Findinns ! 1. _ The minor discrepancies found on inspection have not affected the start air system to date and are not considered a problem. l
e. S.a.133113. Diesel lA Insoection lanpr.t. Part Name:- Ag,gg.g. Air Manifold P.jp.g. Supports Cisse: A Part No.:.02-441C- Work Request No.:9.2,Q ]gg, No. of' Separate-Inspections: 1 Attributes Verified g Sample lier. 7 :- 1. . Visual inspect supports per 11.3, ref.1,1 inop. References
- 1. --NF/0/A/1000/26 Diesel Engine Air Start Piping System - Special Inspection Insnartion Results 1.- Visual inspection of the start air manifold pipe supports showed several minor discrepancies with the drawings.
t Rianesition 91 Inspection Findinas ' The minor discrepancies revealed by the inspections have not affected the start air system and are act considered a problem.
~
t l l l 6 i
Catawba Diesel 16. Inspection Renort 4 Part Name: }.g,31,$. Air Distributor Tubina. Ftnas.1 Gokts Class: A Part No.: 02-4425 Work Request No.:9,21.1 ]gg_
- No. of Separate Inspections: 1, Attributes Verified Aad. Samols }.13s. . 1. Visual inspect distributor tubing system per 11.4, ref.1,1 insp.
i References
- 1. MF/0/A/1000/26 ~ Diesel Ragine Air Start Piping System - Special Inspection Insoection Results
' 1. Visual inspection of the start air distributor tui.ing , fittings and gaskets showed 'several minor discrepancies with the drawing.
r Disposition sf. Inanection Findinas
- 1. The minor discrepancies found on inspections have not affected performance of the start air system and are not considered a problem.
5
Catawba Dias.el 1A Inanection Report Part Name: Engl Inlaction Tubina -Class:1
'Part No.: 02-365C Work Request No.:
No. of Separate Inspections: 17 Attributes Yerifled mad. M j.133.
- 1. . Visual inspect tubing per 11.3 rei.1,1 insp.
- 2. Eddy current inspect tubing per 11.5 ref.1,16 insp.
References l '. *MF/0/A/1000/27 Diesel Engine Fuel Oil Piping System-Special Inspection. Inspeatlan 3385118. - -
- 1. This inspection will be performed when the engine is reassembled. ,
- 2. This- inspection will be performed by Failure Analysis Associates in l early July.
t
- y l
Disposition gi Insnection Findinas ! r [ t l I t t I b i i t E
+-
r
- - _ _ . _ _ _ _ . _ _ _ . _ . _ _ _ _ _ _ _ _ _ ___._ __ _ w
- 4 Catavba Diesel R Insnection Renort Part Name: Egal Iniection Tubina Suonorts Class:1
- Part No.: 02-365D Work Request No.:
-' No. of Separate Inspections: 1 Attributes Verified AadL laania.1138.
- 1. Visual inspect tubing supports per 11.3, ref.1,1 insp.
[ L References ! 1.. MP/0/A/1000/27 Diesel Engine Fuel Oil Piping System - Special Inspection.
- i i
1 Inanantion Egaulta.
. 7u 1.. This ' inspection will be performed when the engine is re'sasembled.- --- s-~-:
l t I Disposition 21 Inspection Findingts (; f f b l' I l i ! t P b o ,. f F I *
~
V ri-t a Catauba Diesel M Inspection Report Part Name: Ingl gil Pinine ad Tubina Class: 4. Part No.: 02-4505 Work _ Request No.:
~ No. of Separate -Inspections: 1 Attributes Verified milasPli h
- 1. - Vi sual inspect system per 11.3, ref.1, I insp.
l l References 1.- MP/0/A/1000/27 Diesel Engine Fuel Oil Piping System - Special Inspection Insmention Results
- 1. This inspection vill be performed when the engine is reassembled.
Disposition 21 Insnection Findings ( i l \ L
Catawba Diesel JA Insnection Renort Part Name: 1g31011 Pinine Sunnorts Class: A Part No.: 02-450D Work Request No.: . No. of Separate Inspections: 1 Attributes Verified sad.133g13. Jhs.
- 1. Visual inspect supports per 11.3, ref.1,1 insp.
BalSI.taGas.
- 1. MP/0/A/1000/27 Diesel Engine Fuel Oil Piping System -
Special Iuspection i Inanection Results
- 1. This inspection will be performed when the engine is reassembled.
I i 1 Disnosition 21 Insnection Findinas l [ l i l i r
,+,..-,,,--,.,--,----w,a,,g.-,,-n ,----r,,-,,,,----w-, we ,.-w , n-,-,--n,,---w-,.m-y _.,-nm-_,
4 Y
- Catarbs Diesel 1A_ Inspection Report Part Name: Control 13331 Pinina. Tubi ==.' agl Pittinas Class:5 Part No.:.02-500N Work Request No.: 92jl2 MlE No. of Separate Inspections: 1 Attributes Yerified and 1.3313. j,133,
- 1. Visual inspect tubing and fittings per 11.4, ref.1,1 insp.
C References l'. MP/0/A/1000/29 Diesel Engine Shutdown Tubing and Electrical Conduit - Special Inspection. Inanach Rannits _
- 1. Visual inspection of the control panel piping, tubing, and fittings were satisfactory.
Dianosition 21Inanaqtion Zirulinas. There were no significant findings.
~
t l t I f i I l b i [ l t ! t h _ _ _ _ L
Catawbt Diesel 1A Inspection Report Part Name: Engine M Auxiliary Module Wirina Conduit Class: A Part No.: 02-688A Work Request No.: 0922 MNT No. of Separate Inspections: 1 Attrib 31aa, Verified And. Sample lins.
- 1. Visual inspect conduit per 11.5, ref.1, 1 insp.
References
- 1. MP/0/A/1000/*9 Diesel Engine Shutdown Tubing and Electrical Conduit Special Inspection Insnection Ep3 sit.a.
- 1. Visual inspection of the Electrical Conduit was satisfactory.
Disposition gi Insoection Findines l~ There were no significant findings. l l
Catsuba R13331 R Jnspection Recort Part Nams: Inging. Shutdown Tubina AmL Fitthes Class: 1
. Part No.: 02-695A Work Request No.: A121 }glI, No. of Separate Inspections: 1 Attributes Verified amL lamis.11as.
- 1. Visual' inspect engine mounted tubing per 11.3, ref.1,1 insp.
- 2. Visual inspect panel mounted tubing per 11.4, ref.1,1 insp.
i e References
- 1. MF/0/A/1000/29 Diesel Engine Shutdown Tubing and Electrical Conduit Special Inspection i
i Insocetion Rasults
- 1. The engine mounted tubing will be reinspected after reassembly. l
- 2. Visual inspection of the panel mounted tubing was satisfactory. ;
f l Dissosition 31. Insnaction Findinas t There have been no significant findiage to date. l i i i ! l l l i
~ _ _ _ ._ ._ _. _ . - _ _ . . _ _ _ . _ . _ _ _ . -
APPENDIX B ENGINEERING VALIDATION REPORT SELECTED CATAWBA 1A DIESEL PARTS 9
- , , , , . , ~ v,--- - - - , - - - ---,~ ,- - - . , ----- c.,- - --.---
m 4 TABLE OF CONIENTS Section , T.iL11 31.0 Introduction 52.0 , Identification of Parts 53.0 Detailed Review of Part Yalidation B4.0 References Tables . 32-1 List of Parts Covered by Engineering Validation Review t 4 o 9 1 r e r
31.0 Introduction The purpose of this report is to document the results of the engineering validation performed for selected parts of the Catavlia 1A- Diesel. The parts were selected for this review if their quality was not being verified by detailed inspect ions . This validation was performed for the parts listed in Table B2-1; Information for the validation was obtained by visual observation of the parts, review of test results, review of maintenance retords, and - discussions with operating and maintenance personnel regarding performance of the parts. An engineering evaluation was then performed of this information to assess the condition and quality of the parts. The detailed results of this review are presented in Section B3.0. f I i
Ideatification 21. IAKla. } B2.0 -
-The parts covered by this review are listed in Table B2-1. Parts were listed in Table B2-1 if they met the following criteria:
- The parts are identified as category A or B per reference 1 (or approved modifications); and
- The quality of the parts is not being verified as part of detailed inspections (e.g., per Catawba Sp ecial Inspection Procedures MF/0/A/1000/01 through 18); and
- The quality of the parts is not being verified as part of piping installation checks covered by Catawba Sp ecial Inspection Procedures MF/0/A/1000/2's through 29).
In essence, the parts listed in Table B2-1 are intended to cover
'itema important to operability of the diesels but which have not been covered by detailed inspections because no specific need for inspection was ' developed owing to failure history or general diesel experience.
O e 9 9
TABLE B2-1 s IniRL 21laEla. Covered hy, Enaineerina Yalidation ERY. IRE , IAEL Es - laEL EamE. 9.1Rai 00-420 LUM OIL PRESSURE HGUALTING VALVE A 00-7005 JACERT MTR STANDFIFE VALVES B L 00-7005 JACRET M TER STA BFIFE SWITC B S B ' 02-311D CRANCASE MOUNTING EARDERE B 02-3153 CAN BEARING CAPS AB DOWELS B 02-315E CTLIBER BLOCK STRUCTURAL BOLTS B 02-315G CTLIBER BLOCK SEALS AND GARETS B 02-330A FLYWEIL A 02-345C FML PUMP B&SR R 02-360C CTLIB ER READ BOLTING AM GA RETS B 02-365A FML INJECTION PUHF B 02-3655 F ML INJECTION TIFS B 02-410A GOVERNOR - OVERSP MD TRIP A i 02-410D OVERSP MD TRIP VEM VALM S A 02-415A SPMD REGUIATING GOMENOR A 02-4153 00nRN0R 500STu SuvcNOTOR S
, 02-420 LUM OIL FMF A 02-4415 START AIR ENIFORLD VALVES, STRAINERS. FILTERS A l 02-445 F M L OIL B0OSTER FUMP A 02-455A FML OIL FILTIES B '
02-4553 FUEL NIL STRAI ERS ' B l 02-465C EETERN&L LUM OIL VALVES A 02-5004- CORROL PANEL CABINET A j 02-500F CORROL AIR ACCUMUL& TOR A 02-500G- CO RROL AIR SYSTEM VALVES A 02-5005 CORR 0L AIR SYSTM PRESSURE SWITCMS B 02-500J CO RROL SYSTEM RELAYS A 02-500K C0KROL SYSTM SOLH01D VALVES A 02-5005 CORROL FAML WIRING A 02-550 FOUNDATION BOLTS A W ANCEORS B 02-630D INSTRMENATION TEM 0 COUPLES B 02-4843 ENGINE A B AUI MODULE WIRING A ! 02-688C ENGI H A m AUX MODULE WIRING BCEES A 02-689 0FT ENGI R SAFITY ALARM SENSORS-WIRING B 02-690 HGIN AIAEM Sus 0RS B 02-691A 0FF ENGIN SAFETT AIARM SMSORS-SWITCHS B 02-4958 ENGIM SNUTDOWN VALMS, REGUIATORS, ORIFICES A 02-695C INGIN SEUTDOWN TRIP SWITCEIS A 02-825D FML OIL DUPLEI STRAIRR R i P l t I l
c: Table 32-1 coat. t c 136/40 THEMosTATIC VALVE B CN-106 INEARE AIR FILTER B CN-107 INTAKE AIR SILENCER R CN-109 BRORE AF MER LUBE OIL PUMP A
~CN-110 FUEL FLOW LUBE OIL FILTER A CN-111 LUBE OIL NEAT EECHANGER B CN-119A GIMBATOR 3EAFT AND MARINGS A CN-120 JACRET liATER REAT BCNANGER B CN-122 OIL PULUM VILTER A CN-131 LUM OIL REptiARM STRAINER A F-068 - INTERCOOLER R 8E-025 LUBE OIL FULL PRESSURE STRAINER A l
4 I r l 5 L
33.0 Datailed Raxism si Zarl Validation This section contains the results, detailed review and engineering validation of the quality of parts indentified as requiring quality validation per Section 1.0. It should be notedt ' hat the " visual observation" listed in this section was not done using detailed checklists and quantified acceptance criteria. Rather, it was a brief qualitative engineering scan directed at detecting obvious abnormalities. 9 J
53.1 lAE1. h: 00-420 lagi h e Lube Oil Fressure Regulating Valve Function: This valve controls lube oil pressure. Drauipas TDI Drawing 00-420-01, Valve Assembly-Fressure Regulator Omaratian Eigingzt This valve has perforasd satisfactorily with no
' reported problems.
h Eistory: Valve was disassembled and adjusted prior to initial diesel operation at Catawba per recommendations of TDI represcatative. Ilo unscheduled maintensace has been required. Yianal Observation: The valve was visually observed by J. Gorman on May 10, 1984 and found to be of the type shown on TDI drawing 00-420-01. Ilo abnormal conditions were noted.
Conclusions:
Pressure regulatias valve 00-420 is considered to be satisfactory as demonstrated by satisfactory performance for estended periode of operatlos. f-I I i l
53.2 ZAEL h r 00-7005 lagi ),333 Jacket Water Standpipe Valves Egagling: These valves serve to isolate the jacket water standpipe when needed. Drawinant TDI drawing 100546, Jacket Watur Piping Schematic Omaratina 11 story: These valves have performed satisfactorily with no reported problems. Maintenance 51storvt No maintenance has been performed on these valves.
,Y,lagal Chaarvation: The valve installations were observed on May 10, 1984 by J. German and appeared to be normal.
Cnasiusionat The valves are considered to be satisfactory as demonstrated by the absence of any reported problems and the satisfactory operating history of the jacket water system for entended periods of operation. O L_..
.r~ 33.3 EAE1. h s 00-7005 lagt, h s Jacket Water Standpipe Switches Fmaatian The jacket water standpipe is a pressure switch which indicates a low level of water la the jacket water standpipe. Draviana: TDI drawing No. 09-491-75017 Gaaratian 11313g1: Tubias to the switch has clogged several times e due to precipitation of chromates. The tuhlag is not considered part of the jacket water standpipe switch, and was supplied by Duke Power Company. Periodic inspection and malatenance has corrected , this situation. l flamal Chaarwatiana: Since so problems with the switch itself have l been reported, observation of this device is not considered l appropriate. ; i Canalmalama The jacket water standpipe switch, Part No. 00-700s, f is considered to be satisfactory for its latended service by the ' absence of any reported problems with the switch and its satisfactory ' performance for entended periods of operstlos. I f e l i { k
= ,?
73.4 Eggi Es.a.: 02-311D lagt ht Creakease Mounting Eardware l i Imag11 gat This hardware consists of the asia crankcase stude, aute i and washers (parts 19, 20, 21, 22, 23, and 29 on TDI drawing 02- ! 31143) and capscrews (part 18 on TDI drawing 02-311-03). The main j stude serve to hold the creakease to the base, while the capocrews i serve to clamp the creakease seal. l i Dranimaat TDI drawing 02-0311-03 , Creakcase Assembly l l Gaaratian E1313:1t This hardware has performed satisfactorily without adhstment since initial delivery from TDI. I Malatamassa 11313g2: No malatenance has been performed on this hardware. No adhstment has been required since initial delivery from TDI. l XiaEAL Chaarmath: The hardware was visually observed on May 2, 1984 by J. Gormes, and was found to all he properly la place and of the type sheva on the drawing. Cantimalant The creakcase mounting hardware is considered to he satisfactory as doesastrated by satisfactory performance for estended perlede of operaties. e
#D
83.5 l a E R. h i 02-3155 legg, he can Bearing Caps and Doveis [n3g1133: This hardware consists of the bearing assemblies used to position the camshafts in the crankesse assembly. Branimaat TDI' Drawing 02-311-03, Crankcase Assembly Gaaratian Riatervt This hardware has performed satisfactority since initial delivery as evidenced by inspection of the camshafts after 810 boars of operation. Camshaf ts showed no wear of cam lobes, heese eas bearlase are fu11f1111ag their fuactloa. Maia&assaga Eg&gnt No malatessace has been performed or required on this hardware. Yianal chaarvatian: Due to camshaft inspection results, ao visual observation of the can bearings is required. Canalmalama The can bearing cape and dowels are considered to be satisfactory as deseastrated by satisfactory performance for eatended periods of operation. . b L
4 33.6 23g1 h s 02-315E, 02-315G i lagt Eame.: Cylinder stock seals, caskets and structural soles i 153g113g: The cylinder block seals and gaskets provides
- 1. As oil seal between the cylinder block and crankcase '
(part 8 of TDI dravias 02-315-04)
- 2. A water seal between the cylinder block and cylinder liner (part 6 of TDI drawing 02-315-5001); and
- 3. A seal between the cylinder block and water manifold (part 14 of TDI drawing 02-315-5001). !
- 4. The bolts serve as structural bolting holding the cylinder block to the creakease. (part 10 of TDI dwaving 02-315-04) 33N1381: TDI drawings 02-315-04, Cylinder Block Assembly, and 02- '
315-5001, Cylinder Block and Liner Assembly. Gaaratian hs The cylinder block to crankcase bolts and oil o seal *have performed satisfactorily without any evidence of oil leakage. The water seals are hydrostatically tested after each reassembly to eass.:e that there is as water leakage. All o-rings , and gaskets are replaced each time the joint is disassembled. ! Malatammaan Eintamms Me correstive asiatoaanse has been performed ; es any of the joints. The sylinder bleek to erankease oil seal and t belte have met been disturbed stase shipasst is the assembled > condities from TDI. As stated above the o-rlage and gaskets are replaced each time a water joint is disassembled. ; Ilanal chaarvatian These parts are laaccessable for visual l observation. Canalmalamat The cyllader block bolts, seals and gaskets are I considered to be natisfactory as doesastrated by satisfactory performance for entended periods of operation. I I
53.7 Ent No.a.: 02-330A laEL Hans.: Flywheel . Function: The flywheel provides rotating momentum for smooth operation of the diesel engine. Drayinast TDI drawing 101505, Flywheel Assembly Omaratina Eistory: The flywheel has performed satisfactorily during engine operation. Maintenance History: No maintenance has been performed on this part.
.Y.lanal Observation: The flywheel was visually observed on May 10, 1984 by J. German and appeared to be normal.
Conclusion:
The flywheel is considered to be satisfactory as f demonstrated by satisfactory performance for extended periods of operat ion. l l I
.53.8 13g1 h : 02-345C , 13g1 h : Fuel Pump Base Assembly Functient This assembly provides a base to which the fuel injection pump is attached. Drawimmat TDI drawings 02-345-05, Tappets and Guides; and 02-345-3443. Base Assembly-Fuel Pump. Omaratina Eistory: The fuel pump base assemblies have performed satisfactorily as evidenced by the satisfactory operation of the fuel injection pumps during ensine operation. No problems have been reported for this part. Maintenance Elazar.It No maintenance has been performed on the fuel pump base assemblies. The assemblies have not been disturbed since initial delivery from TDI. 114181 Observation: A sample of bases was visually observed on May 10, 1984 by J. Gorman and appeared to be normal.
Conclusions:
The fuel pump base assemblies are considered to be satisfactory as demonstrated by satisfactory performance of the fuel injection pumps for estended periods of operation.
IP-33.9 Engi 19 : 02-360C lagt h: Cylinder Head Bolting Func tion: This bolting attaches the subcover assen*ulies to the cylinder heads. Drawings: TDI' drawing 02-362-04, Covers Assembly-Cylinder Head Operatina History: The cylinder head bolting has performed satisfactorily as evidenced by the satisfactory functioning of the intake valves, exhaust valves, and rocker arms that attach to the subcover assemblies. Maintenance History: No maintenance has been performed on the cylinder head bolting. No cylinder head bolting has been replaced. Visual Observation: A sample of this bolting was visually observed on hay 11, 1984, by J. Gorman and appeared normal.
Conclusion:
The cylinder head bolting is considered to be satisfactory as demonstrated by satisfactory performance for extended periods of operation.
-~ -----,..----- s
' B3.10 lati h : 02-365A IAE1 h: Fuel Injection Pump F =rtion: The fuel injection pump increases fuel oil pressure to inject it into the cylinder. It is operated by tappet motion induced by camshaft rotation.
Drawinas: TDI drawing 02-365-01, Fuel Injection Equipment Omeratina History: The valve holder of one fuel injection pump cracked. Consequently, the valve holder of each pump was ultrasonically inspected and tested for hardness as part of the inspec tion program. Otherwise, the fuel injection pumps have operated satisfactorily with no other problems reported. 7 Maintenance History: The only maintenance performed on the fuel injection pumps has consisted of:
- 1. Replacement of the pump with the cracked valve holder as identified above, and
- 2. disassembly of all 16 pumps prior to engine operation to l
ensure that the pumps were free from summy inel oil residues after long periods (well over one year) of inoperat ion. Yianal Obaarvations: Several pumps were visually observed on May 10, 1984 by J. Germas and appeared to be moraal.
Conclusions:
The fuel - injection pumps are considered to be satisfactory as demonstrated by satisfactory performance for extended periods of operation. , d 6 i f
- I.-,-. - ,-,_. ...,- _ _ . , , , ..__._.,..___-_.~.m.--.
~33.11 Zagt h : 02-3653 Zagt 3333,: Fuel Injection Tips function: The fuel injection tips spray high pressure fuel oil into the cylinders.
Drawinas: TDI drawing 02-365-01, Fuel Injection Equipment Oneratina Ristory: These tips have performed satisfactorily with no problems. Maintenance History: The tips have been periodically removed for routine cleaning. { Jignal Observation: One tip was visually observed on May 10, 1984 by J. Gorman and appeared normal.
Conclusion:
The tips are considered to be satisfactory as demonstrated by satisfactory performance for extended periods of operation.
33.12 ZAIL h : 02-410A I lati h: Governor - Overspeed Trip Function: The overspeed trip governor senses engine speed (revolutions) by direct mechanical coupling to the drive train of ; the engine. When the engine speed exceeds the setting on the device , the centrifugal force of the internal flyweights actuate a , lever which causes a vent valve to open in the control air system, I and shutdown the engine via the auto shutdown cylinder. j 1 nrawinna Woodward Bulletin No. 04026A Oneratina Bla.taEx: The overspeed trip governor has demonstrated satisfactory performance since initial adjustments were made during startup. No further adjustments have been required. Maintenance History: No maintenance has been performed or been : required on the overspeed trip governor since initial adjustments were made during startup. ; Yianal Obaarvatinas: The overspeed trip governor has been 1 completely removed from the engine for the inspection of the drive mechanism as required by Special Inspection Procedure No. MF/0/A/1000/16. No abnormal conditions have been reported. Casalmalama: The overspeed trip governor is considered to be , satisfactory as demonstrated by its satisfactory performance during extended periods of operation. s 0 t
, . - . - , . . . . . - . , . , .__.c.._._,._,_..--,e-- - - - , . , .,.r_....,,_ .--.m% . , _ ..,,y
l I 33.13 lagt h s 02-4100 i IAEL Ea m: overspeed Trip vest valves , F - tla=: Upon actuation by the governor overspeed trip mechanism (Woodward Gove rnor), the ove rspeed trip went valves vent the ! control air thus causing actuation of the fuel shutdown cylinder, ; trippias the engine. REauintA' Anot Controle Corp. Fors 675 Rev.1. Model 40958 Vest valve. , omeratian datory: This vent valve has performed satisfactority [ with no reported problems. ! Maintenance 1131g3: No malatenance has been performed on these { vest valves. t l Yianal Obaarvation: No visual observation of these valves have been made.
, i The overspeed trip vent valves are considered to be Seatluaidle satisfactory for intended service as demonstrated by satisfactory performense for entended perlede of operaties.
t i l
83.14 lagt ht 02-415A 13g1 Magg,t Speed Regulatlag Governor (umat ina The speed naulating governor controls the engine speed by regulating the fuel supply based on load demand on the generator (vie se electrohydraulic actuator) 4.ad current engine speed (via direct mechanical coupling to the, drive train and internal flyweight s) . Rganisaat Woodward Bulletin No. 25004M haratiaqt 1181232: Over all, the speed regulating governor has performed satisfactority. An adjustment to set droop at 5 I was m de by the Woodward factory service represcatative during the entended run test (2-21-84). No other adjustments have been required since startup. Malatamaaca tinterva No malatenance has been performed on the speed regulating governor other than the factory representative adjustment described above.
.IlaEA1 Chaarvatiaat The speed regulating governor has been disassembled to the estest neccesary to perform the laspection on the drives se required by Special Inspecties Frecedure W/0/A/1000/16. We abeerealities have been reported.
Canalmalamat The speed regulating severser is considered to be satisfactory se demonstrated by its satisfactory performance for entended operating periode. L
9 C.15 Fast hr 02-4155 t fast Maast severner seester servenster , i. Emmatlant The governor beester servosetor aide in starting the , easiae by using starties air to increase governor oil pressure I which is tura results in the sovener enstae soing to the tutt fust , en posities. t Raanniastar Weedward Servise Sulletia 34444 3 and TDI dus. 101414 h 31313gg This servoaster has performed eatisfactorily l i with ne repcrted problees. Mala &anasta h e lie malatenance has been performed on this , part. l tianal Ghaanatiaat Ile visual eboervations have been accompliebed. SamtlE&lats The governor beester servenster la considered to be satistastery for its intended service se desenstrated by estisfactory performance for eatended periods of operation. i.
)
l t i I r I l t
l l l B3.16- Egn, Jip,,,: 02-420 Z A E 1 5 A a r.: Lube Oil Pump Func t ion: This pump is, a diesel engine attached pump that supplies engine lube oil during engine operation. Drawinas: TDI drawings 02-420-2674, Pump Assembly-Lube Oil, and Figure titled "Model 35K-437 IMO Lube Oil Pu'ap" in Volume III of l the TDI diesel manual.- Oneratina History: The lube oil pttap has performed ' satisfactorily as - evidenced by the satisfactory operation of the lube oil system. No engine bearings show degradation resulting from a lack of lube oil during diesel operation. Maintenance History: No maintenance has been performed on the lube oil puny. Visual Observation: The lube oil pump was observed on May 10, 1984 by J. Gorman and appeared normal.
Conclusion:
The lube oil pump is considered to be satisfactory as demonstrated by satisfactory performance for' extended periods of , operation. ar _ y %
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B3.17. Engs, h : '02-441B Par.g ERER.: Starting Air Manifold Valves, Strainers and Filters Function: Starting air is used to turn the engine during s t artup . The starting air system is comprised of the starting air manifolds, manifold valves,- strainers and filters, starting air distributors, piping .from the distributors to the air start valves and the air starting valves. Inspections for various parts of the starting air system -are as follows: Starting Air Manifold and Distributor Piping (Procedure MP 0/A/1000/26); Air Starting Valves (Procedure MP 0/A/1000/04); and Starting Air Distributor (Procedure MP 0/A/1000/12). Hence, this engineering validation is limited to the manifold valves, strainer, and fillets. Drawinas: TDI drawing 101815 Starting Air Manifold (Valves ~ and Strainers), and TDI drawing 51825, Tubing Arrangement Starting Air
-Distributor (Filter).
Operating History: The starting air manifold valves, strainers and filters have performed satisfactorily with no problems. Maintenance History: No maintenance other than periodic cleaning as part of routine maintenance procedures have been performed on these items. Visual Observation: The components listed on the attachment were observed by R. Reyns on May 23, 1984 with the results indicated on
.the attachment.
Conclusioc: The starting air manifold valves, strainers, and filters are considered to be satisfactory as demonstrated by extended periods of satisfactory operation. 9
-Attachment to 53.17 Manufacturer
.Part No. Description Qty. Visual Observations KE-800-000 Check Valve-3" 4 Valves were observed to be of the type shown on the reference Drawing. No abnormal conditions were noted other than the absence of factory " Blue" paint.
SE-007-001 Strainer 4 Strainers were observed to be of the type shown on the reference drawing. No abnormal conditions were noted. KR-002-000 Valve, Air Start 4 Valves were observed to be of the type shown on the reference drawing. No abnormal conditions were noted. SB-006-000 Filter (Air Supply 2 Filters were observed to be of J Line to Distributor) the type shown on the reference draving. No abnormal eonditions were noted. It was noted that some pipe fittings had been replaced. F-573-413 Valve, Shuttle 1 The shuttle valve to the governor. oil boost was observed to be the type. designated on parts list 02-441 for 75017. No abnormal conditions were noted. F-573-348 Valve, Check 2 The check valve on the line to the starting air distributors were observed to be the type designated on Parts List 02-441 for 75017. No abnormal conditions were noted. 1 l [ i. r I i i i - _ . _ . . _ _ _ _ . . . _ , . . ~ . _ _ . - _ _ _ _ . . . _ . _ . _ . _ - _ _ . . _ _ . _ .
B3.18' . gart Jim,: 02-445
' l a g,t, h : Fuel Oil' Booster Pump Punction: The fuel oil booster. pump transfers fuel oil from the day :
. tank to the diesel. Drawinas: 02-445-06, Fuel Oil Booster Pump Operatina History: The fuel oil booster pump has performed satisfactorily as evidenced by the satisfactory diesel engine operation for extended periods. Maintenance History: No major maintenance has been performed on this pump, other than tightening a fitting to correct a leakage problem..(Ref. W.R. No. 8058 OPS, 2-2-84). Visual Observations: The fuel oil booster pump was observed on May 10, 1984 by J. Gorman and appeared normal.
Conclusions:
The fuel oil pump is considered to be satisfactory as demonstrated by satisfactory performance for extended periods of s
~ operation.
L f l l t f h p r l t
?
i ; L . l
- l. !
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. ,. .- ~... -..,, . ,_.-_ . .....,, . m. . . _ . . . . , . . - . - - , _ . - , _ _ - . _ , . _ . _ . - , . . . - . . _ _ . . _ . . .
B3.19 Earl h : 02-455A larl RAER.: Fuel Oil Filter Function: This filter is a duplex cartridge filter which removes particles from the fuel oil prior to its introduction to the fuel oil headers. Drawinas: The Hilliard Corp. Drawing DD-297-46, and TDI drawing 09-825-75017-H, Fuel Oil Piping Schematic Operatina History: The fuel oil filter has performed satisfactorily as evidenced by the satisfactory performance of the fuel oil system and the diesel engine. Maintenanc e History: No corrective maintenance has been required. Filters are periodically replaced as needed based on increasing pressure drop. Visual Observations: The installation of the filter was observed on May 10, 1984 by J. Gorman and appeared normal.
Conclusions:
The fuel oil filter is considered to be satisfactory as. demonstrated by satisfactory performance for extended periods of operation. I + l' l t
3 B3.20 f.AKl. E2a.:. 02-455B
!ag1. ESER.: Fuel Oil Strainers Function: These strainers filter the fuel oil to the fuel oil booster pump.
Drawinas: ' Air Maze Drawing R9W1752 and TDI drawing 09-825-75017-H, ; Fuel Oil Piping Schematic Operatina History: The fuel oil strainer has performed satisfactorily as evidenced.by the satisfactory performance of the fuel oil system and the diesel engine. Maintenance History: The only maintenance required has been to periodically clean the filter elements. Visual Observation: The installation of the strainer was observed on May 10, 1984 by J. Gorman and appeared normal.
Conclusions:
The fuel oil strainer is considered to be satisfactory as demonstrated by satisfactory performance for extended periods of operation. : l ( ... i I fi !~ [ l' ' l l !- 5 i L L m . ..-..... _ --_ _ ._._._..._...__ _ . . _ _ _ _ __
33.21~ Ear.L h: 02-465C Enri lang.: External Lube Oil Valves Function: These valves are used to direct lube oil flow, isolate components, etc. Drawinas: TDI drawing 09-820-75017-E, Lube Oil Piping Schematic Operatina History: These valves have operated satisfactorily with
- no problems.
Maintenance History: No maintenance has been required. Visual Observation: These valves were observed by J. Gorman on May 10, 1984 and appeared normal.
Conclusions:
These valves are considered to be satisfactory as L demonstrated by satisfactory performance during extended operation. J f e 4 9 i
=
l t'. N. L -
4 53.22' Earl. ER.s.: 02-500A $ ~ PgII, jl, ggt: Control Panel Cabinet Func tion: The control panel cabinet houses essential control components for both off-engine electrical and off-engine pneumatic systems and provides barriers between Class 1E circuits and components within the cabinet and non IE circuits and components. Drawinas: TDI drawing 52213 Onerat ina Bistory: No problems have been encountered with the panel. Maintenance History: No maintenance has been done on the panel. Visual Observation: Since the panel has had no maintenance or operating problems, no visual observations were deemed necessary.
Conclusion:
The control panel cabinet, Part No. 02-500A, is considered to be satisfactory. for its intended service as demonstrated by satisfactory performance. 1 - - - - -
.e --
. - . - - - . ~ . .- -
l I l B3.23- Zagt h : 02-500F Pagt ]!aER.: Control Air Accumulator ; Func tion: The Control Air Accumulator acts as a timing device for some engine pneumatic control functions. Control air is admitted to . these devices allowing a time delay for pressure to build which will then actuate other pressure activated devices in the pneumatic control system. Drawinas: There are no drawings available describing the
-accumulators. The capacity and circuit locations are described on TDI Drawing 52216, Panel Pneumatic Schematic.
Oneratine ' History: The three control air accunnslators have performed satisfactorily with no reported problems. Maintenance History: No maintenance has been performed on the control air accumulators. Visual Observations: No visual observations have been accomplished
- as a part of this engineering validation.
Conclusions:
The control air accum 1stors, part no. 02-500F, are considered to .be satisfactory for their intended service as demonstrated by their satisfactory performance for extended periods of operation. A e i t s e- re.- - --r, . - , . . - . - . - - - - .
i i 6
. h
- I t
, B3.24 Pagl h: 02-500G l P_gy1 Magg.: Control Air System Valves f Function: The control air system valves open and close upon a l signal (pneumatic) from the pneumatic shutdown logic board, either .
permitting the engine to start and run or trip the engine by l actuating the auto shutdown cylinder.
- Drawinas: TDI Drawings 52216, Panel Pneumatic Schematic, and 52215 Engine Pneumatic Schematic.
Operatina Ristory: Most of the control air system valves have performed satisfactorily with no maintenance required. One shuttle valve in the low lov lube oil pressure circuit periodically stuck, preventing the engine from starting. This was corrected by replacing the valve. Maintenance History: Other than the valve replacement described above, no maintenance has been required on the control air system valves. Visual Observation: Visual observations have not been conducted as a part of the engineering validation.
Conclusions:
These valves are considered to be satisfactory for their indended service as demonstrated by satisfactory performance for extended periods of operation. Note-This review and discussion applies only to control air valves essential- for engine operation and engine trip.
. B3.25 Zar.g., jb.: 02-500H P,,,gyg,, ESER.: Control Air System Pressure Switches Function: The control air system pressure switches open and close depending on control air pressure in the pneumatic control system.
These ~ devices are also actuated by control air and serve both l control system functions and supervisory functions. Drawinas: TDI drawing 52216, Panel Pneumatic Schematic ,. Operatina History: All pressure switches have demonstrated satisfactory performance with no problems. Maintenance History: No maintenance has been performed on the control air system pressure switches. Yisual Obsetvation: As the pressure switches have operated satisfactorily, no visual observation was deemed necessary for this engineering evaluation.
Conclusion:
The control air system pressure switches are considered to be satisfactory for their intended service as demonstrated by their satisfactory performance during extended operation.' I. f 4 4 l . L:
B3.26 Earj;. h: 02-500J Zarl, NABS.: Control System Relays , Func tion: The Control System Relays provide electrical signals to ) various elements of the engine control system. J Drawinas: TDI Drawing 52218, Panel Electrical Schematic. Operatina History: The control system relays have demonstrated
> satisfactory performance with no problems since modifications were made to the control panel wiring. (See Part No. 02-500N)
Maintenance History: There has been no required maintenance on these relays since the wiring modification. Visual Obs'ervation: No visual observations were conducted as part of this engineering validation.
Conclusion:
The control . system relays are considered to be satisfactory far their intended service as demonstrated by their satisfactory performance during extended operation since the wiring modification. 4 6
+ - - , - - -
. -..,-mv. ~ - . , ,.--.-...--..._._._,-...-.r._, 7- .~,.,mm .
mm. - -,,- ,- - -.,-.y- , - . _ - .
B3.27 Earl E9.4.: 02-500K Zarl NgBR.: Control System Solenoid Yalves i Function: The control system solenoid valves open or close when energized by the pneumatic or electrical control system, permitting the flow of control air in the system. Darwinas: TDI Drawing 52216, Panel Pneumatic Schematic, and 52218, Panel Electrical Schematic. Doerat 4 == History: The control system solenoid valves have performed satisfactorily with no problems. Maintenance History: No maintenance has been required or performed on the control system solenoid valves. Visual Observation: No visual observations were conducted as part of this engineering validation.
Conclusion:
The control system solenoid valves are considered to be satisfactory for their intended service as demonstrated by their
- satisfactory performance during extended operation. .
9 9
[ B3.28 P.ggi h : 02-500N I
. P,gri EgEg.: Control Panel Wiring Function: The control panel wiring interconnects the electrical components in the control panel system.
Drawinas: TDI . Drawing 52218, Panel Electrical Schematic and the attached listing of Duke Power Co. drawings. Operat ina History: The control panel wiring was extensively modified by Duke Power Company at installation, startup and check out. Panel wiring changes installed by Duke Power Co. under their quality assurance system are documented in Duke Power Co. drawings listed in the attachment. Since these modifications, the wiring has performed satisfactorily and required no maintenance. Maintenance History: No maintenance has been required or been performed since the modifications to the cor; trol panel wiring. Visual Observations: No visus 1 observations of the control panel wiring were made during this engineering validation as Duke Power Co.- Quality Assurance has inspected all wiring modifications.
Conclusion:
The control panel wiring is considered to be
- satisfactory as demonstrated by the absence of problems for an extended period of operation.
I l t 1 ( l
~
L__ ..
_ _ _ . __ _ .____ _ _ _ . _ _ ~ _ . __ _ _ _ _ _ _ _ _ _ _ . . . ATTAC MENT TO B3.28 i i Duke Power Company Elementary Diagrams updated for Control Panel Wiring f changes *
- CRE-0120-01.01-01 j CHE-4120-01.01-02 i
. - CHE-4120-01.01-03
- CHE-0120-01.01-04 CHE-0120-01.01-05 C HE-0120-01.01-06 i CBE-0120-02.01 !
C HE-0120-02.01-01 CHE4120-03.01 ' ; CBE-0120-04.01 C RE-0120-04.01-01 f 4 C HE-0120-04.01-02 ! CHE4120-05.01 l CHE-0120-05.01-02 i CEM -0120-05.01-03 ! CHE-0120-05.01-04 i CRE-0120-05.01-05 ' C RE-0120-05.01-06 . C HE-0120-05.02-01 ' I C ME-0120-06.01 C HI-0120-07.01 { C HI-0120-07.01-01 CRE4120-07.01-03 t r
+
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- B3.29 East h : 02-550 Zagt Nam: Foundation Bolts and Anchors Zuggilag: The foundation bolt and anchor assemblies serve to fasten the diesel base to the diesel room floor structure. i Drawinas: TDI drawings 02-550-03, Engine Mounting; and 00-550-6005, Anchor, Foundation Bolt, Front and Rear Operatina History: These bolts and anchors have performed satisfactorily with no problems.
Maintenance History: No maintenance has been required. Visual Observations: All of the bolts were observed on May 10, 1984 by J. Gorman and appeared normal. Conclusions : The foundation bolts and anchors are considered to be satisfactory as demonstrated by the absence of problems for an extended period of operation. S 9 }'.-~ , .,g- .w.,,
,,,, .--m,-g- ..,-.,n, ,. ,
ey,..e.,, ,,,,,,,,,-m,-,--, ,.m_..,,-,,n..ww.,,,,._.,,n_.,.~.-_ n.,---... ,
_. ~._ .__ . _ _ . . __ -. . - . _ _ . _ _ _ _ _. . _ _ _ _ _ _ . _ _ . _ _ _ _ _ _ _ . _ _ _ . _ _ i B3.30 Ragt 19 : 02-630D l3gi Nag: Instrumentation Thermocouples Function: The instrumentation thermocouples sense the temperatures , in the lube oil system, jacket water system and exhaust. system and provide signals to the control panel, giving indications and activating . annunciators where appropriate. The thermocouples cannot_ cause the engine to trip or to fail to start on an emergency
- signal.
Drawinas: TDI Drawing 09-688-75017 Engine Electrical Diagram and i Schematic, and 09-691-75017, Off-Engine Electrical. Oneratina History: Instrumentation thermocouples have indicated
~
erroneous readings when the engine heated up at full load (Jacket
; water' and lube oil), and read accurately at slightly below full load . This situation was corrected by replacing the thermocouples. ;
The replacement thermocouples have performed satisfactorily. i 1 Maintenance Rist.or.v Other than the replacements described above, no other maintenance has been performed of the instrumentation thermocouples.
.Y.,ianal Observation: No visual observations have been made. .
f
Conclusion:
The instrumentation thermocouples are considered satisfactory for their intended service as demonstrated by their satisfactory performance (since replacement) for extended periods , of operation. , b I b l s e I t I s t t I i
?
r l B3.31 gagt h : 02-6888 Zagt Eggs: Engine and Auxiliary Module Wiring Func tion: The engine and auxiliary module wiring connects the engine electrical sensors to the termination boxes. Also, power is provided to the engine electrical controls (solenoids, etc.) via this wiring. ; Drawinas: TDI drawing 09-688-75017, Engine Electrical Diagram and Sebesatic i , t Oneratina History: _ The engine and auxiliary module wiring have performed satisfactorily and required no maintenance. r Maintenance History: No maintenance has been required or performed l on the engine and auxiliary module wiring. ; J,igual Observation: The engine and auxiliary module wiring was , inspected by representatives of the diesel generator Owners Group during the week of May 7 1984. Their report is expected to be ; available on June 15, 1984. ; t
Conclusion:
Preliminary :onclusions indicate that the engine and , auxiliary wiring is satisfactory for its intended service as l demonstrated by its satisfactory performance during extended i periods of operation. . 4 i k. i I
. .. . _ . - ._ - __ __. _ _ _ _ _ _ . . -_ - _ - _ . ~ _ _ _ _ _ . . _ _ . _. _ _ _
33.32 f.ar.L h: 02-688C l Pagt Ham: Engine and Auxiliary Module Wiring Boxes j Punc tion: These boxes serve as termination points for the engine and auxiliary module wiring , via the engine mounted conduit. These boxes .are connected to the control panel via Duke Power supplied conduit. Drawinas: TDI Drawing 09-688-75017 Engine Electrical Diagram and Scbesatic 3 t Oneratina History: The engine and auxiliary module wiring boxes have performed satisfactorily and required no maintenance. f 4
.Maintenanct History: No mait.tenance has been required or performed ,
on the engine and auxiliary module wiring boxes. ' i E J.ianal Observations: The enginu and auxiliary module wiring boxes are to be inspected as part of the walkdown or engine conduit , i Special Inspection Procedurs No. MP/0/A/1000/29. r i
?
u
Conclusions:
Preliminary conclusions indicate that the engine and l-auxiliary module wiring boxes are satisfactory for their intended services as demonstrated by satisfactory performance for extended . periods of operation. I f l t i l !
,- . - - , , p ,.,--,.,_-.,_.,-n - . , _ , , , , , , , , , , , , . , ,,,,,,,.m,,__ _ _ _ _ _ _ _ _ _ , , _ . _ _ , , , . , , , _ _ , . , . , . , , , , ,_,__,,,y, _ _
=. _ _ . - - _ - _ _ . _ - - . - _ . - -. . 53.33 Zay1 h : 02-689 Zagl h : Off Engine Safety Alarm Sensors-Wiring Func tion: The off engine safety alarm sensor wiring connects the sensors which are located off the engine to the local engine l control panel. This wiring was supplied by Duke Power Company and is not part of the engineering validation.
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33.34 Earl h : _02-690 lagl NAER.: Engine Alarm Sensors Func t ion: The engine alarm, sensors provide signals to the supervisory alarms on the engine control panel during an energency startup and run. These alarms do not shut the engine down during an emergency run. The sensors for these alarms are mounted on the engine. These. alarms. are tabulated in the attachment to this section. Refer to Part No. 02-360D for thermocouples derived from this section. Drawinas: TDI drawings 52218, Panel Electrical Schematic, 52216, Panel Pneumatic Schematic, and 52215, Engine Pneumatic Schematic. Oneratina History: The engine ' alarm sensors have performed satisfactorily and required no maintenance. i
- -_ Maintenance History
- No maintenance has been performed on the engine alarm sensors other than thermocouples. (See Part .No. 02-360D)
Tianal Observation: No visual observation has been made. A
Conclusion:
The engine alarm sensors are considered satisfactory for their intended service as demonstrated by their satisfactory performance for extended periods of operation.
,n. _-.,-----_,m,.+,,,,,,,,_.,,,.,_,,n_
, - - - - , , - , _ __p.,a, ,n,,-- .,,,-engone,,p,,
ATTACEMENT TO B3.34 ENGINE MdjHE Eigh Differential Pressure Lube Oil Filter
~'
High Differential Pressure Lube Oil Strainer Low Pressure Lube Oil Low Tegerature 0i1 Inlet
' Low Temperature Oil Outlet High Temperature: Oil Inlet .
- High Temperature 011 Outlet Low Pressure Turbo Oil RF
- Low Pres'sure Turbo Oil LF Fuel Fump Overspeed Drive Failure High Differential Pressure Fuel Oil Filter High Differential Pressure Fuel Oil Pump Strainer Lov. Pressure Fuel Oil Low Pressure Jacket Water
- High Temperature After Cooler Water In Low Temperature Jacket Water In Righ Temperature Jacket Water In Exhaust Temperature Bigh/ Low Barring Device Engaged'
- i l r'
i B3.35. P,gtg. No . : 02-691A Part Namg: Off Engine Safety Alarm Sensors-Switches ' Function: The off engine safety alarm sensors provide signals to the supervisory alarm annunciators on the engine control panel. ; These alarms do not trip the engine during an emergency run. The ! sensors are located off the engine and are t abulated in the , attachment to this section. Thermocouple sensors in the attachment l are under Part No. 02-630D. j Drawinas: TDI drawings 52218, Panel Electrical Schematic, 52216, Panel Pneumatic Schematic, 52215, Engine Pneumatic Schematic, and
'09-691-75017, Off Engine Electrical.
Operat ina History: The off engine safety alarm sensors have ; performed satisfactorily. e I Maintenance History: No maintenance has been performed on the off engine safety alarm sensers. e t Jigga19hpervation: Becausa of their satisfactory past performance - and the non-critical nature of these items, visual observation is not required. i
Conclusion:
he off engine safety alarm sensors and switches are considered to be satisfactory for their intended service, as demonstrated by their satisfactory performance for extended periods of operation. . i I
i ATTACHMENT TO B3.35 0FF ENGINE SAFETY ALARM SENSORS Low Level Lube Oil Tank ; High Level Main Fuel Tank Low Level Main Fuel Tank Main Fuel Oil Tank Tech. Spec. WARN High Level Day Tank ,
. Low Level Day Tank Low Level Jacket Water Low Temperature Jacket Water Out High Temperature Jacket Water Out !
-Panel Intrusion Aux Equip Not In Auto Refer To _ Operational Mode Building Ventillation Malfunction
- High Leve:1 Deisel Generator Sump.
High High Level Diesel Generator Sump
' Unit Failed To Start .
Low Pressure Starting Air I
. Low Pressure Control Air 6
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.35.3'6 lagt h : 02-6958 Zarl Haag.: Engine Shutdown Valves, Regulators, Orifices Func t ion: The engine shutdown valves, regulators and orifices control the . flow of air in the pneumatic shutdown control system on the diesel engine.
Drawinas: TDI drawing 52215 Engine Pneumatic Schematic, and 52216, Panel Pneumatic Schematic.
- =
Operatina History: During the extended run test, an orifice supplying . air to the low low lube oil pressure sensor clogged, causing the pressure sensor to trip the engine. The orifices were i cleaned and the engine performed satisfactorily. All other orifices, valves and regulators have demonstrated satisfactory performance requiring no maintenance. Maintenance History: Other than cleaning the orifices described above, no maintenance has been performed or required on the engine ahntdown valves, regulators and orifices. Visual Observation: No visual observations were made.
Conclusions:
The engine shutdown valves, regulators and orifices are considered ' satisfactory for their intend ed - service as demonstrated by their. satisfactory performance for extended periods of operation,. with the one exception described above. Preventive
. maintenance schedules will be reviewed to assure that procedures are being followed to keep the air adequately filtered. ,
i. ir k
T B3.37 lat.t. Jhts.: 02-695c lat.t. h: Engine Shutdown Trip Switches Punction:- The engine shutdown trip switches shut the engine down and annunciate the cause of the trip. During emergency run only three trips shut' down the engine, low low lubricating oil pressure, overspeed, 'and generator to switchgear differential (fault). During l manual or remote run ,' six other trips in addition to the thre's i mentioned above shut the engine down, two low pressure lube oils, high ! temperature- lube oil out, high pressure crankcase, high temperature bearings, high temperature jacket water out, low pressure turbo oil [; and high vibration. The six manual run trips cannot shut down the engine during an emergency run. i. Drawinas: TDI drawings 52218, Panel Electrical Schematic. 52216, l 4
. Panel Pneumatic Schematic and 52215 Engine Pneumatic Schematic. ,
i Oneratina History: The engine shutdown trip switches have performed ; satisfactorily requiring no maintenance. . I i Malatemance History: No maintenance has been performed on the ! engine shutdown trip switches. P 1 Y,igual Observation: Because of their satisfactory performance of- ; their func tion, visual ' observation' of the engine shutdown trip ! switches is not required. ! I
Conclusion:
The engine shutdown trip switches are considered I satisfactory for their intended service as demonstrated by their [ satisfactory performance for extended periods of operation. , t i s-I L i i k l l
-_ __- _ . _ _ _ _ _ _ _ _ . . _ _ . _ _ . . . . _ . _ _ _ _ _ _ - _ _ . . _ . - _ _ _ _ _ _ _a
t I i
.33.38 f.an.Es : 02-825D l.3G. HaBa.: Fuel Oil Duplex Strainer Func t ion: This strainer filters fuel oil which is supplied to the auxiliary (engine mounted) fuel oil pump.
Drawinas: TDI drawing 09-825-75017-H Fuel Oil Piping Oneratina History: The duplex strainer has performed satisfactorily i
-as evidenced by the satisfactory performance of the fuel oil !
L system. r Maintenance History: The only maintenance required has been to ! periodically clean the strainer elements. [ Visual Observation: The installation of the strainer was observed ; . on May 10, 1984 by J. Gorman and appeared normal. i f
Conclusion:
The fuel oil duplex strainer is considered to be ! satisfactory as demonstrated by satisfactory performance. l f l l l t i i l i I i I n - - , - - - - - ,----.r-~. - ,, , - - - , - - , - c,_ .-n-- ,-
g
-33.39 14E1. En.a.: c 136/40 lagt, h s Thermostatic Valve .
tanation: This valve automatically controls the flow of jacket water through the jacket water heat exchanger la order to control jacket water temperature. ,l Drawinas: TDI drawing 100546, Jacket Water Piping Schematic Gaaratina Eintory: This valve has worked satisfactorily after an initially incorrect installation direction was corrected. Maintenance Elatnry: No maintensace has been required other than to correct the valve's initially inco-rect flow direction. 11:331, observation: The valve was observed by J. Gorman on May 10, 1984 and appeared normal. Canciasion: The valve is considered to be satisfac ory as demonstrated by its satisfactory performance for estended periods of operation.
~ .. .~;
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; -~ si-s 53.40 Phj;, b;,CN-104 and CN-107 3 .; 3 "
's. '
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Part N,jp's -Intake Air Filter ' 3 Function:!'1his ,s component serves to filter Ihe intake aif. , _ x ', DrNi s; American' Air Filter Co. Drawing A-92553 -
. \
- w. 'N Operating History: The intake air filter has _ performed satisfactorily; as evidenced by-the satisfactcry operation of the diesegengtue. *O' s ,
>~
g Erinthnance History: Filters 'have been replaced peri 36ically as
. requires based = on, pressure drop sincreas es . . -
a w Vi.sua),Observh$2g: No visual observation was made.
.yy~ *
~
. gyr ' \ w% /a 4 Conc lusions : "The intake air filter is considered to be satisfact6fy as demonstric"ed -by satisfactory performance for '
extended periods of operation. " s , , 3
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-. v. , . ---,,-..-,.,-s , , . . . , , , , , ss..- , . _ - . , , . , _ _ . , -. _ , . , - - , - - - --..,.a ----.,,.--.mn_.,.,, n,.,-.---,,...,--- - - - - ---,_n,
~B3.41 F, ggt;.En : cN-107 ,
P,gg,g, Namg: Intake Air Silencers ! Func tion: The silencers minimize noise generated by intake air. ; Drawings: None available, i i Operatina History: There have been no problems with these silencers. Maintenance History: No maintenance has been required. Visual Observation: The silencers were observed on May 10,1984 by J. Gorman and appeared normal. Conc lus ion: The silencers are considered to be satisfactory as demonstrated by satisfactory performance for an extended period of operation.
~
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~ . . _ . . . , . _ _ _ _ _ _ _ _ _ _ _ _ . . -
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l P [ B3.42 Pggi h : CN-109 Part Name: Before and After Lube Oil Pump l Function: -This pump provides heated lube oil to the diesel engine i,
. parts prior to engine operation and after the engine has shut down.
This lube oil pump is also known as the keep warm lube oil pump. ; i Drawinas: TDI drawing 09-820-75017-E, Lube Oil Piping Schematic l Operatina History: The before and after lube oil pump has performed satisfactorily as evidenced by the satisfactory condition of the ! diesel engine bearing surfaces. The diesel has experienced a large ! number of start /stop operations during startup testing. l Maintenance History: The pump motor was replaced due to suspected ! water damage (W.R. No. 60000PS, 9-6-83). 7 Visual Observation: The pump installation was observed on May 10, l 1984 by J. Gorman and appeared normal. l 4 s i G9EgJngign: The before and after (keepwarm) lube oil pump is l considered to be. satisfactory as demonstrated by satisfactory ! performance during .the startup testing start /stop engine ; operations. 9 f 1 p 9 6 1 - L i l. g i. l l I i _ . _ . . , - . . _ _ .,-_s.___.._, -
--..._.-...__.,___.__..__._.-._._.._.._.....-._.__.J
-B3.43 Pagg. h : CN-110 Part Name: Full Flow Lube Oil Filters Function: These components filter the lube oil at the discharge of
,the lube oil pump.
Drawings: TDI drawing 09-820-75017-E, Lube Oil Piping Schematic Operat ing History: The full fov lube oil filters have performed satisfactorily as evidenced by the satisfactory operation of the lube . oil system. No engine bearings showed degradation attesting to the lack of particulate matter in the lube oil. Maintenance History: No corrective maintenance has been required. - Filter elements have been periodically replaced. Visual Observation: The filter installation was observed on May 10, 1984 by J. Gorman and appeared normal. Eg,gelusions: The . full flow lube oil filters are considered to be
> satisfactory as demonstrated by. satisfactory performance for extended periods of operation.
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~
B3.44 Pagt h : CN-lli f Part Nggg.: Lube Oil. Heat Exchanger (Cooler) Func tion: The . lube oil heat exchanger serves to cool lube oil to keep it in the desired temperature range. [ Drawinas: ' TDI drawings 09-820-75017-E, Lube Oil Piping Schematic; [ and 100546, Jacket Water Piping Schematic l Operatina History: This heat exchanger has performed satisfactorily i
'as evidenced by the satisfactory condition of the diesel bearings, and satisfactory lube oil temperature.
r Maintenance History: No maintenance has been required. I Visual- Observat ion: The heat exchanger installation was observed on May 10, 1984 by J. Gorman and appeared to be normal. !
Conclusions:
The lube oil heat exchanger is considered to be i satisfactory as demonstrated by satisfactory operation for extended ; periods of operation. . i [ t ( l i i a b l i l I i t I f I> _ . ~ , . . - - . - . . , . _ , _ . . . _ _ . . . , _ . . - - _ . . ~ _ . . . , - . - - . - . _ _ . . . _ . . . . . . - . . _ _ - . . - -
- . . _ _ __ _= __
i B3.45' Pagg, ]b : CN-119 A Par,1, NAER.: Generator Shaft and Bearing ; Func tion: The generator shaft and bearing serve to support the generator. Drawinas: None available. { Operatina History: No probleas'have been experienced with the ) generator shaft and bearing. l Maintenance History: No maintenance has been required except for . periodic oil changes. - Alignment of the generator shaft is checked i during routine web deflection measurements made on the diesel. : Visual Observation: The generator shaft and bearing were observed, , to the extent accessible without disassembly, on May 10, 1984 by J. ; Gorman and appeared normal.
Conclusions:
The generator shaft and bearings are considered to be ! satisfactory as demonstrate! by satisfactory operation of the .. I generator for an extended period of operation. l i l l l I 1 5 i l t h i
I s L B3.46 EALL E24.: CN-120 (75017-120) latt Naan.: Jacket Water Heat Exchangar (Jacket Water Cooler) , Func t ion: This is a shell and tube heat exchanger which serves to cool jacket water during engine- operation. Service water is supplied' to the tube side to remove heat. A thermostatic 3-way valve' directs as much of the jacket water flow as required through i the cooler to keep the jacket water at the desired temperat'ure. ! Drawinas: TDI drawing 100546-F, Jacket Water Piping Schematic (no t part drawing is available) , Oneratina History: This heat exchanger has performed satisfactorily (except for .one minor head to shell gasket leak - see below) as evidenced by satisfactory jacket water temperatures during diesel ,. operat ion. t r Maintenance History: The head' to gasket bolts were retorqued to f correct a minor head-shell' gasket leak. (The bolts had initially [ not been torqued to specific values).- l Yisual EhAST2AE.ign:' The jacket water heat 'esehanger inatallation . was_ observed on May 10, 1984 by J.. Gorman and appeared 'to be normal.
}
Conclusion:
The jaczet water heat exchanger is considered to be i satisfactory as demonstrated by satisfactory operation for extended ! periods of operation. ~ i l t r k ~ i i i i f-t F s i ! p , l ,
l l l l
~ B3.47. gatt Egt: CN-122 (75017-131) lagL Eamg: Oil Prelube Filter j Func t ion: This filter is located downstream of the keepwarm pump ;
and upstream 'of the keepwarm strainer (CN-131). . It serves to ' filter the keepwsra lube oil- (prelube system). j Drawinas: TDI drawing 09-820-75017-E, Lube Oil Piping Schematic (no part drawing is available) ; SERIELNNL History: This filter has performed satisfactorily with no i problems. ; Maintenance History: No corrective maintenance has been re quired . The filter element and 0-ring seal have been repisced periodically. Visual Observation: The filter installation was observed on May 10, 1984 by J. Gorman and appeared to be normal. ;
Conclusions:
The prelube oil filter is _ considered to be , satisfactory as demonstrated by satisfactory operation for extended periods of operation. [ r i i
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P h i l l !- t i l t t r I i F
i l
~B3.48 P.S.El. b :.CN-131 (75017-131)- !
l P.,3,gi, MBER.: 1.ube Oil Keepwarm Strainer . InnCli2R: This strainer is located downstream of the filter on the keepware prelube lube oil line. It serves to filter the lube oil ! prior to its introduction to the main lube oil header. j Drawinas: TDI drawing 09-820-75017, Lube Oil Piping Schematic; and , Air Maze Drawing "Model 07W231735 Simplex Lube Oil Strainer f Operatina Rigl.olY.: This strainer has performed satisfactorily i with no problems. l Maintenanc e History: No corrective maintenance has been required. !
. Periodic strainer . cleaning and occasional filter element l replacement have been performed.
Visual Observation: The keepwarm strainer installation was observed { on May 10, 1984 by J. Gorman and appeared to be normal. ;
Conclusion:
. The keepwarm strainer is considered to be satisfactory l as demonstrated by extended periods of satisfactory operation. f f p i [ I 7 l . i i I i i t- ; l 6 P I, - l L !
b
.33.49- f.Ar.t.19.s.: F-068 Z,ar.g. ESER.: Intercoolers Function: These are air-water heat exchangers located between the turbochargers and the engine intake air manifolds which cool the turbocharged air to the desired temperature.
Drawinas: Young Radiator Co. drawing D 264836, Intercooler Assembly Oneratina History: The intercoolers have performed satisfactorily with no problems. Maintenance gigten,: No maintenance has been required. Visual Observation: The intercoolers were observed on May 10, 1984 by J. Gorman and appeared normal. Conclu sions: The intercoolers are considered to be satisfactory as F demonstrated by satisfactory performance for an extended period of operation. 4 1 ( _ l l l
l 33.50 larl h : SE-025 Pggt N_gER.: Lube Oil Full Pressure Strainers Fanetion: These two strainers filter the lube oil downstream of the !
- main lube oil filters prior to the lube oil being introduced into i 6 the main lube oil headers. !
Drawinas: TDI drawing 09-820-75017-E, Lube Oil Piping Schematic; , - and Air Nase drawing E-00736-19W1752, Strainer, Lube Oil-Simplex j Onoratina History: These strainers have performed satisfactorily ! with no problems, as evidenced by the satisfactory condition of the l diesel bearings. } i Maintenance Histor": No corrective maintenance has been required .
, I Periodic strainer- cleaning and occasional filter element !
' replacement lave been ptrformed.
Yisual Obser vation: The lube oil full pressure strainers were [ observed on May 10, 1984 and appeared to be installed normally.
Conclusion:
The lube oil full pressure strainers are considered to be satisfactory as demonstrated by satisfactory performance for an ! entended period of operation. j l I t 5 I i
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.B4.0 References 1.- Duke Power Company letter to NRC dated April 5 1984, Re:
Catawba Nuclear Station, Docket Nos. 50-413 and 50-414, forwstding report entitled " Catawba Nuclear Station, Extended Operation Tests and Inspection of Diesel Generators". f t 4}}