Text

Applicant Exhibit A-P-8,consisting of E Nicholas 841114 Trip Rept on NDE of Ae Piston Skirt,Piston Skirt,Insp Requirements,Certificates of Compliance & Insp Documentation
	ML20100P659
Person / Time
Site:	Shoreham File:Long Island Lighting Company icon.png
Issue date:	09/10/1984
From:	Nicholas E; STONE & WEBSTER ENGINEERING CORP.
To:	;
References
	OL-A-P-008, OL-A-P-8, NUDOCS 8412140377
	Download: ML20100P659 (43)
	v • d • e

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Novmber 14. 1983

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T0s J. N. Ke11y y #,.@ , w-g ~

sP p 73 FROMi

Subject:

E. J.' Nicholas

[ 9 I i Trip Report Cn Mondestructive Examination (PT) of f$ , 1 v & ;

th November 9.1983 I was re:1uested to virf t Transamerfca Delaval in Oaktar.d.

California to witness the Lfquid Penetrant (PT) Nondestructive Examination performed on the piston skirt bolt holes. The extent of the osamination is as identtffod in Engineerfrg & Design Coordination Report (E80CR) F-46324 Section !! (Ref. Attach.!). Attac! ment !! identif fes the piston skirts which ears examined and wf taessed by vsolf and the results.

Surfage defects were renoved utflfzfag 70!'s " Spring Doss. Two Pc. P,fston Skfet Repair Procedure for Removing surface Defects Observed after Ponstrant Inspection (PT)* (Attachment !!!). Defect renoval was veriffed by Ligafd Penetrant Exantna-tion of the ground areas, in addition dimensional inspections of the Trust Collar area were performed. These inspections *. sere performed by the SAW PGA inspector and witnessed by myself. The results of the Liquid Penetrant Draminations were photographed. These pictographs will be turned over to 0QA.

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E.J. llicholas g ,

Field QA Section Supervisor ces A. R. Muller - uQA .

J. Masseyer - SED M. Schuster - UNICO ,

,R. Perra - S&W FQC OPS *

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. To expe. lite the arraval of new piston aktrts or, ss tej it be deter.9ined that new skrets aro reqs.ared. L5'.; will issuo purchase requisition for a.cns plet.o sot, cf piston skirts, part r.o .

. 03-c.i new N i-04-AE, for each piston skiets J ongine pliau two' spar ~e:s (total-J61. Purchasc

. on a risk basis pundir.g ior.ulth' of fatlure analysad mentat3on by T3Z. by Fa.V., and submittal and evni.taticr. of roqua. red docu-attached pogas f., Inspection and Docusantation requirements per to 4 .

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Tf.htCoPY DATC.

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NE,. t,;ETToe A_ttachment to_ E&liCR f*-4G3N

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1 = Shop Insri.*etions/Vt rificationst ,

4 ;....,

prior to shirr drat, the inspectione and verific.itions as describcd below,the t.

en Certificate of conformance ta specification 5111-060 is required for all parts:

(A) Generals .

(1) EDE .

been performed and results acceptablu. verify all itDE documl Verify and documen.

use in accordance with $111-089.that WDE procedures used ar *

. . original requirements. If any procedure deviataa from thosu approved under original ,

eentract (alther revision level or alternate procedural t.ho <

procedure octually used shall becon:o part of the as shipped documentation to s&W for review. package on a risk basis and shall be subc ticd 9

applicable"eaucropancias (i.e. procedure used but notInspecto approved) to S&W Soston directly.

Verify that perisonnel certifiud to appropriato st:T-TC-1A levals have performed MCC as required. 5 *

(2) H).*A," TIG'.ATMC*17 ** .

Shop routing lodJer has been performod and accep Procedures used shall be reviewed for changos tr

- under SW1-039.

i proved under original contract,If any procedura deviatos from those ap the p:ocedure actuai.ty used a risk basis and shall be submitted to S&W for rev ;

,. Inspection (i.e. procedura shallusedprovide a list of applicable discrcps.:les but no:: .

approvet) to St.W diro::tly.

. .. (3) 1110p ROUTING I,ED';1:R SHEETS .

hl.. Verify Shop Routing Lodger Sheet has been properly

., filled out and each applicable station task has been per-formed.

,: . Review in detnit for any non-conformance o 1

details of ony much defeus/ resolution acceptance Co.9picte critu U.the as shipped documentation package on a risk bas

9. *' Copies of.all such documentat. ion, as well ac the shop

}f * .

routing lodger shall be provided to S&W moston for review.

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"^ce *- TO E& D CR g.Ndlb oe d::

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,(4) E P CLEANING SUIPPINC/ CRATING '

The inst.'eter shall review and verity the method of' el'eaning,

. in accordance shipping and crating is appropriate and acceptable with SIII-089.

(3) VIst/AL INSPECTkON The inspector shall perform a complete visual in- -

from the detail shop fabrication drawings.spectica A dimensional *

. of

..- all pa

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verify the parts are in accordance with the shop d .

. All items checked shall be documented.Any deviations

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should be engineters. brought to,the $sme$iate attention of the , -

' f surface finish as specified on the shop drawing shall be verLfied. -

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'. (6)

NDE TEST REPORTS *

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and accuracy and shall become.part.of.the documen

.: Packa98 -

(7) g (if applicable)

pac 1ateness

e. and shall become part of the documenta

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12

. shoreham Specific NDE Requirements

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'* . contrast skirt b penetrant test will be performed on trach p i

dures. y This TDI may personnel,,'n accordance with approved proca-p; ,,, . . . .

procedures /persoonal. pplemented by the, use of LILCO HDE be su

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The location to be inspected is the machined area on

! f.;* * *' . .with theparticular boss around the four bolt holas inside the piston skirt. -

surfaces, emphasis on the vertical blended radii s

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11Lc0 The FQC.penetraat test wiil be witnessed by SWEC PCA 4

4t.'t',. .*4 O or 1.11c0Acceptance procedures as applicabl

- criteria will be per TDI procedures .

- e, however linear , ') ,

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Oindications will not be accepted without swEc Engineering '

b' ,

approval. 'h11 indications will be mapped by LILCO FQC *

, personnel, clearly identif,iable to the piston in question.

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ATTAClit.1ENT TO E (1 D Cil #. W.

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PAGE..

1 Page 3- ,

xxx nocunernenon -

(A) The following documentation will be included with the shipment:

1. C of C to 'strocification 8111-089

. 2. CMTRs if applicable .

. .. 3. Heat Treatment records

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4. Shop routing sheets *

5. Results of MPI ,

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")h;. M (31' Documentation ' to be supplied by TDI, following

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, shipment ' ,

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.. ....- .- 1. seismic qualification per SH2-089 .

l ' : '.b h'[ .p'! 'E , D[V- .

2. l32EE-387 qualit;icati,onsanalysis or testing ,..:$').

. per s.otion s.4.4.

.; Q['Y r ,h.: ;.p'..;. . :. .T;.-3. . i . #.'.);,g;4,;c.:..:r:. d. -

. . . ... zn.t. nanuai insert. i

'ti:, 1 , sg,.;..f4f 4. 'Monoonformance & disposition records .

9

q 0 - 5. 341'-AE piston service history. To incl,uded i g.$

-r !a ? l:. y p/p. :.

details.of both shop testing and field e 4.-

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history -(number in field, operating hours, -

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6. - TDI to perform review and documeist the f .

.- . *F ... effects, if any, of piston skirt changeout on 'sl.R ...

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- the ability of the unit to achiave rated lead

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. *and speed in the required time, siid on the 4l.!-

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- . Torsional.and Iaterial critical speed '..*

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.* j ATTACHMErtr'II l gerial No.

Ncat No. I

1. C88K Accent /Relecc

2. 827J Accept C89 811J I

3. D42 937J Accept

4. D49 .

937J Accept .

5. E5 104K REJECT 6.

ES REJECT

7. F7 104K accept 181K Accepc

8. F12 181K

9. F15 200K Accept I

10. F18 .

Accepc *

11. F21 200K Accept .

12. 724 -

200K Accept *

13. F27 -

200K Accept 3 20$E

14. F29 - 205K REJECT i

13. F32 205% RKJECT

16. #33 .

205K REJEcr

17. F53 256K Accept

18. F56 256K REJECT

19. F58 256K Accept

20. 787 289K Accept

21. 797 289K Accept

22. F98 289K Accept

23. G1 298K - Accept

24. 02 Accept 825.G4 26. G5 198K 198K 298K Accept Accep.c

27. G26 312K A~ccept .. .

28. 029 312K Accepc -

29. G30 312K Accapt ..

30. C33 312K Accept

31. G34 312K Accepc

32. G35 312K Accept

. Accept e

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T H RU ST COLLA R. $ AT PfsitN KXIRT W.

SPRIE RYM. TW1 M*.

9y - l IFPAIR MciFiiN!F Rit R90lfE KbRFAM ffWCTS ,

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' t (RTRWD WTFR IGfTiWil' iitwCTICN &D 9g,

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D HNC GR!pe EAOf DEFECT WITHIN BDLMRY LIMITS CAREFULLY ,-

l IWCV!NG E SHNtp EDGE 5 WITH 3L90 RADII.

2) Frntsu rettsu a nErAtas wITw % tex #1350C" GRIND!tG ME!!..-

1

3) @ NOT v10 LATE W* LIMITINE D!!ENSION SH@mfat Ttft,U5T COUR SEATING SLfFACE. .

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30. DO NDT DCIEDN LIMI75'SHGet FRCM' CAST SUFACES.- ,

- - REE,j.

D %.T!PLE DEFECTS MAY E CNFLETELY REMQYED BY M4C GRitC1tc -

5GIRE LIP WITHIN,3230tYg9ttT3 .

2) Usa Tm see, mim me 8se essesuis me cassu n LintTs spectetEn reit sina.: q -

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DRDER J.'0. 73800.93 , NGlgD 31GHTING CggANY g-O.

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DDD t 777679/7.1rown a 11/10/83 310552 32 1

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CA ML 2NC. O "' " C " ** *ita o.

550 35th Ave.

F.'O. Sea 2181 *"

Dakland 1:a111.14821 .uca m .,

fats) rr7. woo AFsgr "'"".'i',,",,'*~ J ," *;' ",,,,

$.a 5kt.cpfag Paint 3,~

- .. Air Freight a ca dial - movember 12 ........w. -

acca".

anos e*s voim n alance

- Novembersss3 33.1983 > **'***""'

.. : .. mw =. Telecen of nove=6er 1D.1983 C.';;; ,

us . . u v .co ,.7 asanx: 310552-32 rwso===

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CDNFIRMIN4tDO 307 VUPLICATE-START-11P Itodif.y ear 7srchase Drder 310532 for Diesel Generator Sets (Spec.1-089) for Shoreham acelear Power station 12:

the following.edditionst12 ao.1 'to incorporate C ,sd g8 y 44 3.) ?$ston Skirt P/N D3-341-04-AE 6 -

26 ea. 36.323.00/aa.

2.) 7hrust Collar 7/N 03 34104-AC q eht,-

104 ea. , 35.35/ea. G 'l 'I /84 3.) Spring Suide P/M D3-341-04-AF 40 n / te 104 ea. 53.60/aa.t y i,/t.?

4.) 1ock Tab P/M D3-341-04-ad .

104 ea. av orro w 5.) lock Pin P/M GC-023 000 6.90/aa.(,, y n /, 7 104 ea.

40 lo ftse 5.) . ..t.S 1.00/ea.r.,4 y/fg Cotter Pin GC-002-055 t,.4 (I o ) e # ** 'f u .

100 ea. 1.00/e a. ,oo ,4u, 7.) Stud P/M 03-341-04-AD ,. y 104 ea. 86.55/sa.I,*4 nic Certificate of Compliance is required to state Ho ul4 the saterial su

$pec. 3H1-089. pplied is in accordance with for item 1. Piston Skitt.PQA inspection is required only t SHOltEHAM NL, CLEAR Powt7 STATION

. '/\ DFC M1 A\ /r m L A CATEGORY: 3 \.) V C*.LJ LILCO ISC-7D detailing reporting requirements under I.i. ' :. 0 %83 30CFA21 attached hereto forms a part of this order.

t g;3 L vis(FC4t?41 Daft EJE,_D QUALITY CO NTROL O

E x TRA COPt:5 08 P Q 10 n j.'u.9..se o.os G

.0NTHLvittPORT FORuPREPARtc _ C *.0T Rtcu Rto gMTmActiopacatCTs LJ.f JJMee

, , O **VRANCEDiv.

ePO RECOR D . CATE GOR Y_ ,-- g g O PROPERTY RECORDS t -

Q ACMtNISTRATIVESERV

.PO tKPIRAft0N POLLOW.UP DATA Q 099sCE SERVICES O rRc'Atta'ac ,

I"") TA N 8' b'f

_....______.,. f- 5-1 .

17s Y OA OC98 W I. Y I 8 PURCHASE ,-

, ORDER - * . . . M~

...... a. = ...; .....

PQA hspectica/ Documentation requirements in accordance with I&DCR 746324 copy of which is attached 3MPORTANT This order is issued subject to the following stipulations:

16cthing in this Order er Supplement shall be deemed to telease er prejudice any claims or tauses of action {whether.in contract. tort er otherwise) er to waive arty . prior rights or tenedier that L2Ltc any have against Transamerica 2hlaval.

12tCDexpressly reserves the right to pursue any such < claims causes af action, rights and remedies that it my have. including but mot limited to

. damages sr. claims err refund af monias paid pursua rit to this order.

Jul ather terms and conditions remain the same as stated in the erf;:nal purchase order.

O COPIES ONLT:

TOTAL ISTIMATED LUMP sum COST O'F THIS ORDER THRU 31. . SU'PLEMENT . 54,953,664.2 0 TOTAL 10MP SUM IDST OF THIS SUPPLEMENT ..... ...... . . . . 183,634.C0 TOTAL ISTIMATED LUMP SUN COST OF THIS ORDER .... TO .... DATE 5.137.298.2 3 TOTAL AUTHORIZED YALUE OF THIS PURCHASE .... ORDER.... . . . 2,173,000.C0 I

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T Iz Paoc i w 4 g/y# ,., STONE C. WEBSTER ENGINEEHir4G CORPORATION ao. .

. ~ ' , . ENGINEERING f. DESIGN COORDINATION REPORT r h 324 .

.700 NO.

en tb.le CT/ Ca~ .lf t;T sacosiveAtA NutitE Ah 8 Di418 STA1'OYUran t 1 til00 3 _,_

tomo,ip Ano tit Hierati t Cf.ter.Nv .

3 RC7tRENC $a

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i PROS L.EW DCSCRIPTION:

i Inspections performed on piston skirts for Enginc 101 revealc

,P .

numerous indientions in the m'achined area on Boss around bolt holes, i reference LDR.1811.

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' Attachment to E&DCR r-4G324 *'-=*ti.,,5,,,(

"2.

Pagc 1 .;;;;g ,

I - Shop Inspections /verifientions: T P.rior t.o shipment, the engineer's inspector shall perform the inspections and verifications as describcd below. I.

Certificate of Conformance to specification 51!1-029 is required for all parts:

(A) General:

(1) UDE' verif771111DE documented on Shep rout.ing ledger nas been perfo ::cd and re.sults .acecptablo. Verify and doeur:cnt that NDE procr' dura: ut6ed ars the name as those approvud f:fr 12se in accordance uith 5111-0119 3riginal rec {uirements. 2t any procedure devi.stes from those approved undar origind.

contract (eithar revision icval or alternate prce= dure) the procedure actually used shall becc=e part of the as s hi,:p:,.*

cocumentatics package on.a risk bacic and shall be cubmit ecd to S&U for rt-view. Inspector chall provide a list of applicabit discrepancies (i.e.. procedure used but not approved) to S&W Busten dircetly.

Verify 'thet pc:s:nnc3 ccrtified te appropriats SdT-TC-17.

levcis have pcx!cr:nu I:r2 a: rer,uitec:. .

(2) 1:0*.*: 7:7.N.r. ;:*?

Verify thr.t ac/ 5 c'-i- tr.ct:aon at encumented en the s! op reutf i.r- ledger 5.u bc<rn pr v*o: sae 4 n'id t.ccepte:*..

Procedu-ct i rc$ r. hall 5.io rov. ?.ref fe v cher.t;cr. ( c 3 rl e.:-

lovc1 er @ <:: nn*.c prece6arrk! i>cs.; there erproved fer use under S'!3 -0 .0 II ar) picccc.u. e dev

t.tns trom tho:ac al.-

proved vns::.- c'rieji-m1 coritrae t , t hc p ocMurc nt:ted11; c:a c whall bec.. yr.rt of th? .s .,hti p.id <!r tmue::tc.t.3.m paci: .c .

<e rish beri: cnd shil be a..M.it.ed to 4t.U fo: r+ vi ct: .

Inspection sh, ell pro. $de a lir t or applicable dir c:ccy . .t r (i.e. proc 0 dure ured but nct epprcve6) to St.W directly.

(3) p1'0? ROUTING LnaC1M Sutr r; Verify Shop Rout ing f cdejer Sheet han be $n properJy fillad out and cach applicabic station task ha.* becn per-ferr.ed. heview in detail fer any non-ennicar.ance or ruwor::

required during the manuf acturine-r ac. ting precon:.:. Completo details of any cuch defcet/ rect.Jution ace;cpt..nce criteris cnt final veceptance r.h..11 he obtr.t:.ed and kee :r:t- po rt <>r the an shi! ped dccum:nti tion pochece e,n ri r.h 1.. nin.

Copics of n11 such documsnt. tion. Oc w?.11 an i.he r h e,*,-

routing ledger shh31 be previded to Ssu Co.non tc,r st' view.

i .

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- , .a i.,CHMENTTO E & D CR h / 'tD2 :

ncs

-- 3 ora-- ,

Page 2 (4) SHIP CLEANING SilIPPING/ CRATING

, The inspector shall review and verifp the method of c1 caning, shipping and crating is appropriate and acceptable

, in accordance with SU1-089.

(5) VISUAL INSPECTION 1

The inspector sh'all perform a completa visual in- '

spection of all parts for obvicus defects and/or deviation from the detail shop fabrication drawings. A dimensional check of a sufficient number of points shall be perforr.cd to i verify the parts are in.acccrdance with the shop drnwinge.

All items checked shall.be documented. Any deviations should be brought to the immediste attention of the engineers.

Surface finish a: specified on 'the shop drawing = hall be verified.

i (6) truc Tns? REPonTS ,

i All KDn Test Mporte sha:31 oc reW.cwed for completence:s

cnd pachkgc.

accurecy and shn11 beer::.e part of the docuper. ation (7) C;1TRs (if ppliet.ble)

~

Certifico **ateriol Test Reports shall be evicued for cett03cter.ces and cha.11 bevor. n p..rL o' thc. (oeu.*enta tion 4

package. .

II Sherr.shc9 .e.tice.i fic NDE 11 coni rc~ent:-

In addition to the St:ndard T!1I p!ston nhirt ;IDE, c color contrast ponctrant test will be prrforrad on ecch piston skirt by TDI perronnel, in accord: ace with approved proco-dures. Thi.s ecy be supplcact.ted by the use of LILCO !DE j procedures / personnel.

The location to bo inspected is the machined are: un the bows around the four bolt hulca inside the pisi:en shirt, with particulcr emphasis on the vertical bicaded racii surfucos.

The penetr nt test will' Le witnenned by SWJ'/ r0A &

L1LCO FQC. Acceptanco criteria vill hu por TD1 ;<.ocedurcu er LILCO procedure: au applicabic, how.*v>r line.w indiention will not be accepted witheut. ::WP.C En-ir.cerin,;

i approval. All indicationn will be mapped by LT1.CO FQC personnel,.cJens.ly identifiable to the piston in question.

i

_ - . _ . . . - - 7 s=e me P u % ..*>yes % g ,.p q w ,. g g.g. ,

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ATTACHMENTTO E & D CN # -

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( .

Jc-page 3 III DOCUME!!TATION

.' (A) The following documentation will be included with the shipment: l

1. C of C to specification 5111-089 /

2. Ct!TRs if applicabic

3. -Heat Trcatment records

4. Shop routing sheetc /

_. 5. Results of H7I (n) Dceti.ventatien to be r.itpplied by TDI, following shipr.cnt: .

1. seismic qualifiectin. por SIII-089 2.

II23-307 qualificat lon;an.21yt iu or tcsting per Sectica 5.4.4.

'3. Inst. Ma: mal Ir.hs.ct.a.

4. Wonconfermance 4 di:1pc::.ition r(scordn

5. 341-AE pi sten sc rc. ice hictory. To inc31.dca detalle e.,f be.,th h.T testing asid field history etc).

(nurocr ils field, opezating hours,

6. TIE i;c, perfocm rev.3aw and cocunics.t the effcetr., if any. c pisvot. c?.irt ch..nceout c>.

t.hc.abj2i n of 1.!.e unit tr~. c.chieve ided ler.d and' unect.* P. ! th.: rce;uired tiir.v., cnd c.a the "T(irs;on::3 cnd I7terial Criiical. St ced Analy sic .

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M FERENCE PORCMASE ORDER mlMBER: 3/effE--32 SUPPLIER: [m- 24 I I.

j lE MERESY CERTIFY TNAT THE PRODUCTS OR SERVICES FURulSMER em l MFERENCE PURCNASE GRDER NEET TWE ltEQUIREMENTS OF THE APPLICA l AND/04 SPEEIFICATIONS.-- #i/.

i Q PARTS LISTED On THE ATTACMER PACRINS LIST ARE SPEEIFICALL SY TNIS CERTIFICATE. .

l 1 Q PAATS LISTES SELOW ARE SPECIFICALLY COVERED BY TWIS CER C 90CUMENTAT1000 AT A LATER BATE.

lit MRIRAFAETURERS FILE TO M SUSMITTES AS R t

Q DOCUMENTATION 9/ SNIPPED SEPARATELY. '

g TNAR THAT latlC# WRs OAltlNALLY ORMMs.(S) F8-IM/*8M-i *

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Stone & Webster T.ncir.veritia C.tepare d *,s.*a d s. ,

Bee on ha achusetts 02107 Attention Mr. N. W. Wa*=efiuld i MM -

Subject:

Shoreb..:t Nu.-Icar Po.*er 8tetj en - t'ntt !

Stand 5v Dier.1 Cener. ster Sets 7.31 ** * ;

Lona Islan.! '.tehtin Cermar.v

'.'0AO-!. 5923 hferences Certificate of Cocaliance - cranksha#t replacements yrur letter dated October 20 14 8.* .

Centlement 3 Flense find four (4) copivt of our Curtificate af Oeerlaane. fer the recent field endiffratione to your engines. At patt of tr.e i :ertificate of compliance, we have includad back-:e dats art, tustificatter. cormartn :

that of the re,1.scen n: the crepone-i oricanal .e . et* foliv? e? emtienenta .:it5

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.!= CERTITICATE OF COMPl.IANCE -

RyIjt{NCE: SFQ:ITICATION NO. 331-89 *"'

l Stone & L'abster Engineering Corp.

FOR Shoreham Nuclear Fever Station Unit #1 Long Island Lightina Conwany 1,ont Island. New York l

I SUFFLIER: _Tracsamerica Delavs1 Inc. - Engine & Co e ressor Division COMPONENTS: En:ertency Diesel Generator Encines fit'ted with:

3 es. 1A-7046 Crankshaf t Assembly 24 es. 03-341-04-AE Skirts, Fiston i 24 es. 1A-3718 Con Rod Assembly 44 es. 03-340-05-AE Shells, Con Rod

! 2 es. 03-310-03-AE Shell,' T. ear Main .080" 0.S. on 0 D.

24 es. 03-441-01-0F Pipe, Cyl. Head to A/S Manifold h

96 es. 02-390-01-QJ Rocker Arm Shaf t Bolt 3 es. AK-007-000 Coupling 3 ea. 03-402-04-AA coupling Adapter * ' ~

, 3 ea. 03-402-04-AA Covernor Drive Couplinc 3 es. 102568 Idler cc.1r Locknut (Fictd Revork.).

We have reviewed the above drawint.s and r.ade comparisons to those originally supplied. Since the ' engine generator system as originally

' supplied was covered by a Certificate of Compliance, this document will address only the above listed parts.

As detailed in the attachments, we conclude that the new components l either retain or improve on their functional and seis::ic adequacy over l those originally supplied. The attachments consist of eleven pages.

/ A **

Date

'Reiand T.M. Yang Hanager, Applied Mechanics i

_wG S *4 "k Data

G.I. T(ussell Manager, Engineering & Customer Service i

O !, nnu aum Q __

7-s 'M r- - - - - - - - - - - - - - - - - - - - - ---

O.3 aus Transamenca engine caicuiations E Delaval 74e10

'a~' ^$"

COMPARISON OF AS DELIVERED ENGINE

COMPONENTS t.'!TH satti 1 c' 2 REPLACEMENT ENGINE COMPONENTS .

cats January 9.1984 esar s.o.

PISTON SKTRT ev David Beck The engine components compared will be denoted as:

Old - As delivered engine components New = Replacement engine components Old: New:

03-340 AF 03-341-04-AE

' Wall thickness at rirg grooves: .75" Wall thickness at ring grooves: .97" Boss radius at piston pin: 4.375" Boss radius at piston pin: 4.5" Pin bore hardness: 217-270-BHN Pin bore hardness: 255-293 BHft 1

Material is the same for both piston skirts. Changes were made to improve rigidity, reduce stress and factif tate casting:

Section C-C on drawing 03-341-04 AE shows the boss outside radius to be l

Og 4-1/2". (from 4-3/8" for the old design). This was done to climinate the rib in the old design and still maintain structural integrity.

Section Y-Y on drawing 03-341-04-AE shows the increased. " Tie" between the bolt boss and the skirt. This was done to imcrove the bolt boss rigidity and reduce stress concentration.

Section C-C on' drawing 03-341-04-tE shows a ta,aered rib'to the left of the piston pin centerline. This tapered rib was added to improve the rigidity of the piston skirt.

The nodular iron skirt has passed through several design changes. The following identifies and describes several design iterations of the piston skirts:

1. "AF" piston,03-340 AF

a. This design was supplied in the LILCO/S.horehar., Southern California Edison / San Onofre and Mid South Energy / Grand Gulf engines.

Oui'ing field testing several "AF" modified skirts at LILC0 were found to have linear

indications and one was found to have a crac.k near a stud bore. This crack finding is the reason for our 10CFR21 letter of November 16, 1983. At this writing, four (4) skirts have been exar.ined at Grand Gulf where linear casting indications were found on two (2) skirts. The indications were easily removed by light grinding and polishing.

There is abso1utely no evidence of cracks with any depth.

Linear indications should not be taken lightly, howeser they should not be regarded indiscriminately as " failures". Indications may be casting . surface imperfections, scratches, or machining marks. They could contribute to fatigue cracks and should therefore be tested by grinding or polishing. Generally faint indications are not Oh crack contributors and through experience may be lef t as found. Overly zealous inspections with very sensitive instruments of ten mislead one to assume there are cracks were none exist.

' ILOTE8 dit 2 4 L. . J.b .

-_.Q _ . _ _ . _ _ . _ _ _ _ . _ . . _ _ _ _ _ . . _ _

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v m Transamenca Engine Calculations

, T neiani ,nin

-- -- ~=

COMPARISON OF AS del.IVERED ENGIttE COMP 0flEf1TS WITH sweev 2 or 2 REPLACEMENT ENGINE COMPONENTS. i oat January 9,1984 [

Y" PISTON SKIP.T

~

ev David Beck 2.

All "AF" style piston skirts were cast using the following heat treatment,

4. i Heat to 1750 degrees F. (near the upper critical temperature) for 3 hours3.472222e-5 days 8.333333e-4 hours 4.960317e-6 weeks 1.1415e-6 months .

Normalized (air cooled) in still air. Result: a pearlitic structure and 3 100,000 PSI tensile strength.

b.

Re-heat to 1050 degrees F. (slightly below the lower critical temperature)

~

{'

for 3 hours3.472222e-5 days 8.333333e-4 hours 4.960317e-6 weeks 1.1415e-6 months and cool in still air. This is a tempering process used to produce the desired ductility in the nodular iron. ,

j

3. "AE" 03-341-04-AE .

\

l This is the present standard R-4 piston skirt design. The design incorporates '

as well as from our uprated R-5 series engine, just concludin development testing.

~

All "AE" skirts are heat treated to' product stress relieved 100,000 P I tensile Og strength nodular iron. Successful operating experience with the "AE" skirts includes a 16 cylinder R-4 unit rated 7000 kw, 450 rpm, 225 bmen which.has.

t accumulated over 7000 hours0.081 days 1.944 hours 0.0116 weeks 0.00266 months of operating without a problem, and 687 hou'rs- .

f operation on the R-5 test engine at 514 rpm, and 302 bmep.

~

The "AE" style skirt is interetangeable with existing R-4 piston crown and requires only minor hardware c'.anges.

The connection of the bolt boss to'the skirt wall with a more substantial section on piston skirt "AE" is an improvement designed to eliminate the indications found in this area on skirt "AF".

The new piston skirt's adequacy is improved as noted above and offers a l substantial refinement in the "AE" skirt design.

i 0

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.

ML20100P659

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