ML20106C654

Diesel Engine 1B Component Revalidation Insp, Final Rept

ML20106C654
Person / Time
Site:	Catawba
Issue date:	09/28/1984
From:	DUKE POWER CO.
To:
Shared Package
ML20106C633	List: ML20106C629 ML20106C654
References
NUDOCS 8410240255
Download: ML20106C654 (175)

Text

.

CATPMBA NDCLEAR STATION DIESEL ENGINE IB CCMPCEENT REVALIDATION INSPECTION FINAL REPGE I

h i

L l'

PREPARED BY i

DME POWER COWANY l

Septenber 28, 1984 i

l 8410240255 841016 PDR ADOCK 05000413 O

PDR l-

Table of Contents 1.0 Introduction 2.0 Sumary and Conclusions 2.1 Overview of Extended Operation Test

. 2. 2 Overview of Inspection Results 2.3 Piston Skirt Cracking 2.4 Subcovers 2.5 Cylinder Head Isaks 2.6 Fuel Injection Pung Delivery Valve Block 2.7 Conclusions 3.0 Discussion of Extended Operation Test 3.1 Operating Profile 3.2 Vibration Analysis 3.3 Lube Oil Analyses 3.4 Fuel Oil Analyses 3.5 Operating Parameters

.3.6 Problem Reports

~4.0. Discussion of Inspection Results 4.1. Inspections Related to TDI Generic Problems 4.2 Inspections Related to Catawba Specific Problems 4.3 General Inspections 4.4 Results of Engineering Validation 5.0 References i

ii L_ _.

6.0 Appendices A.

Inspection Reports B.

Engineering Validation Report Pf em rest 2-1 Cracked Fuel Ptap Delivery Valve Block Tables 2-1 A munary of Catawba Diesel IB Post Extended Operation Test Inspection Resulta b

l l

i l

l

{

I t.

i l

iii i

h

-1.0 Introduction This. report describes the results of the extended operation test and subsequent inspections and evaluations performed on the Catawba 1B diesel engine. These tests and inspections were performed as part of an overall program to verify the reliability of Transamerica Delaval, Incorporated (E I) 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 extended operation test was performed May 30, 1984 to July 9, 1984 and resulted in am'=lating a total of about 755 hours0.00874 days <br />0.21 hours <br />0.00125 weeks <br />2.872775e-4 months <br /> of operationon the IB diesel. The inspections of the IB diesel engine discussed herein were performed in July through August, 1984.

The inspections involved extensive. disassenbly 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%)=== ling inspections were performed of other inportant parts where there was no history of problems.

The scope of the inspections is essentially as described in reference 1 and 2 with the exception that link rods and bushings, and related parts, were inspected on a 100% basis rather than on a sanple basis. Also, the main bearing journals ~at three crankshaft locations were added to the inspection plan.

The diesel disassembly, reassenbly, and inspections were performed in accordance with the Duke Power Quality Assurance Program. The assembly, disassenbly 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 'IDI Owners Group program.

Detailed results of the inspections are contained in Section 6.0, Appendix -A and are rii-aed in Section 4.0.

Some parts which 'are-t inportant to diesel operability were not inspected since inspection is rat called for by the 'IDI Owners Group program and there has been no history of problens.

For such itehs an engineering evaluation of the operating and maintenance history of each was performed and is documented in A;-rvliv B of Section 6.0.

This report on the Catawba 1B diesel inspections covers over all of the inspection plan which includes over 2700 separate -inspections.

Supplemental inspections of large and amall piping, as well as conduit have been performed on behalf of the TDI Owners Group for the Phase II of the Owners Group inspection program and the results of these inspections will be released in their final form early November,1984.

l l

1-1

l

-2.0~

Sununary' and Ceminal" 2.1 overview of Extended &mH-Test Results The. extended operation test purpose was to subject diesel 1B to loads equal to or greater than required for emergency power to demonstrate its ability to operate in a reliable fashion.

The test was structured so that the diesel has experienced over 10^7 stress cycles (about 740 hours0.00856 days <br />0.206 hours <br />0.00122 weeks <br />2.8157e-4 months <br /> of operation) at its coupletion. This_ stress cycle magnitude enpirically demonstrates'the fatigue adequacy of iron and steel parts.

As noted in Section 3 of this report, the IB diesel extended operation was initiated on May 30, 1984 and coupleted en July 9, 1984. During the test about 504 hours0.00583 days <br />0.14 hours <br />8.333333e-4 weeks <br />1.91772e-4 months <br /> of de= anted run time were put on the engine with approximately 97% of this above that required for ESP or blackout load conditions.

With the time accumulated prior to the extended operation test, diesel IB has about-755 hours of total operation at Catawba.

The extended operation test of diesel 1B successfully demonstrated that the engine will meet the emargency and blackout load and duration requirements at Catawba.

The several minor problems experienced during the test did not prevent the engine from deliverying the maxinum emergency / blackout load of 5600 kw.

The minor probleus associated with

-the engine were:

e Fuel punp delivery valve block cracks that. reduced the power on a l

cylinder. During an emergency, the other cylinders would pickup the load.

e Iow pressure lube oil trips due to switching a filter.

This low pressure trip is not operational during emergency run conditions and hence would not inpair diesel operability.

Turbochargers were replaced due to worn thrust bearings, even though e

the worn bearings had not caused any operation problems.

The bearing wear is gradual and due to lack of lubrication during startup. A prelube modification has been added to the engine which l

will reduce this wear.

e Cylinder head jacket water leaks were experienced.

These leaks do not effect engine operability since they leak out of the engine to the anbient.

The engine was run with these leaks for days prior to replacement.

l l

e An intercooler jacket water pipe weld broke causing seepage of l

jacket water to the anbient.

This condition was in evidence for several days prior to shutdown for other reasons when it was L

repaired.

e A turbocharger adapter flange weld cracked allowing a minor amount l

of intake air to escape to anbient.

The engine was run for days l

with this condition with no measureable affect on diesel performance.

l 2-1

e TWo fuel line fittinga leaked during the extended op; ration test.

During an actual emergency condition, the operator would take necessary steps either to retorque the fitting or tenporarily seal it so as to allow continued operation.

Se above minor problem areas are further discussed in Section 4.0.

'2.2 Overview of TnarwHnn Results As. discussed above, the Cata@a 1B diesel engine successfully coupleted its extended operation test which resulted in about 755 total accunulated hours on the engine.

This test confirmed the ability of the diesel to operate reliably for long periods of time at high power.

Subsequent to the extended operation test, extensive disassenbly 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 staniy electric generator service.

The post extended operation test inspections are now coupleted. The results of the inspections are simmarized in Table 2-1.

Engineering and quality assurance evaluations of the inspection results have been performed.

This work is considered to have identified all significant conditions. These conditions are discussed below.

Se most significant results of the Catawba 1B diesel engine post extended operation test inspections are as follows:

e Many of the major problems experienced with other 'IDI diesel engines did not occur in the Catawba IB diesel engine.

These problens include failed crankshafts, cracked connecting rod-crankpin bearing shells, connecting rod box cracks, and cracked cylinder blocks.

e One major problem was noted on the 1B diesel.

%is problem was expected since it was experienced on the 1A engine. Two of the type AN piston skirts used in the IB diesel were found to have cracks in an internal circumferential reinforcing rib.

This problem is di m ad further in Section 2.3.

-e The turbocharger thrust bearings were found to be severely worn, even though they had continued to function satisfactorily during the test.

This condition was anticipated since similar i

problens have been experienced earlier at Cata@ a and at other stations.

As a result of this history, a redesigned Jube oil system has been installed which is expected to prevent recurrence of the problem.

e Two subcover castings were found to have cracks in an intake

' rocker arm pedestal.

These cracks are discussed in Section i

2.4.

Similar cracks were noted in the diesel lA inspection as discussed in reference 3.

I 2-2 I

4 e

.A total of four Catawba cylinder heads (one on diesel 1A and three on 1B) experienced small jacket water leaks into the fuel injector cavity. -Metallographic examinations of the head removed from the 1A diesel indicates that the leak was due to a fatigue crack. In addition, one cylinder head on diesel IB had a crack-in a stellite valve seat. This problem is discussed in Section.2.5.

e Three fuel injection pung delivery valve blocks cracked during ~

the extended operation test.

This problem is discussed in Section 2.6.

i j

e A variety of routine minor conditions were noted, and are discussed in Section 4.0 and 6.0.

None of these conditions inpact the operability or structural integrity of the diesel.

Typical conditions of this type include:

Flaked off exhaust valve stem chrome plate (Section 3.3.2)

Heads of small external bolts broken off, due to under or over torquing (Section 3.3.5) 4 2.3 Piston Slid; creirirm I

Tho type AN skirts were found to have cracks in the circumferential rib on ~ the ID of the skirt. The cracks are similar to those found on four type AN piston skirts in diesel 1A.as reported in reference 3.

An extensive failure analysis of the cracked Catawba type AN piston skirts has been nearly coupleted by Failure Analysis Associates (FaAA) as part of-the 3DI Owners Group program.

This program includes 4-determination of. residual and applied stresses, fractography, and l.

metallurgical evaluations.

Preliminary results indicate that tensile residual stresses on the order of 20 kai were found to exist in the area where the type AN piston had cracked.

I j

The cracked AN type pistons skirt in the Catawba IB diesel did not cause l

any operational problems, and 14 of the 16 skirts were free of these cracks.-

Nevertheless, all the piston skirts will be replaced with inproved design AE skirts.

The AE skirts have'been stress relieved and include inproved 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/ Owners 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 M rporate the latest inprovements in the stud boss region, which has been a problem area-in earlier piston designs at the skirt to head transition.

Tt11s problem is further discussed in Section 4.1.3.

l l

2-3 l

i

\\:

. -. - _ -.. -... - - - -.. - _ -. -.., _. _ _ _ _ _. _ _. ~ _. - -.. - _. - _. -. - -... _ _

i 2.4 Subcovers j

TWo cast iron subcovers were found to have cracks in a pedestal where the intake rocker arm shaft is bolted to the subcover, similar to those shown in Figure 2-2B of reference 3.

These cracks have not affected diesel j

operability.

FaAA has largely coupleted a failure analysis of a Catawba subcover as part of the Owners Group program. 'Ihis analysis indicates that the cracks are due to installation tolerances between bushings and the pedestal leading to excessive interference and not to service.

This problem is further discussed-in Section 4.2.7.

4 2.5 cylindar Hand Imaka Four cylinder heads at Catad>a, one on engine IA and three on engine IB, developed small jacket water leaks into the fuel injection cavity.

The 1A cylinder head has been examined by FaAA.

This investigation (reference 4) 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 as shown in Figure 2-3 of reference 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 now installed on engine IB indicates that none of them have been repair welded with a plug.

One other head on diesel IB had a crack in a exhaust valve stellite seat.

These probless are further discussed in 4.1.16.

2.6 ~ Euel InjecHnn Bmg naliverv valve Block A total of three delivery valve blocks were found to be cracked. Two were noted during the extended operation test. These were detected by a graanally ' falling cylinder tenperature. One delivery valve block was found partially ~ cracked during inspection after the extended operation test.

The cracks are axial in nature and are produced by fuel pressure induced hoop stresses.

Operationally a valve block crack results in less fuel being injected into the cylinder, i.e.

it bypasses more fuel back to the fuel oil tank. Metallurgical examination results show that the cracks were fatigue induced, initiating from the valve seat. Based on discussions with the vendor, the cracks originated from heat check cracks in the valve seat caused by excessive grinding tenperatures during manufacture.

Other. valve blocks on IB have -been magnetic particle inspected with no sign of the heat checking.

The failure is shown in

. Figure 2-1 and further discussed in Section 4.2.2.

l.

2.7 conclusions

~'

The extended. operation test and the post test inspections have demonstrated that the Catawba IB diesel will reliably provide stancby electric generation. The extended operation test was for the nost part accouplished at loads significantly greater than required for starxby i-electric generation.

As such, parts inspected have been subjected to considerably higher fatigue loads and tenperatures than will be actually seen in service. The inspections have indicated that the piston skirts nust be replaced with inproved type AE piston skirts and that a few minor damaged parts such as subcover castings with cracked pedestals should be i

replaced.

?

r 2-4 I

BEE 2-1 manumer 2 omaak MIERL 2R g EMBEME M M REEM anuda alan Pa m ent.

Part Name Part No. Class Dimen. Visual S. ICE

y. ICE Eng Ev Notes Results (Raf* Paragraph)

X 9

Satisfactory Lube Oil Pressure Regulating Valve 00-420 A

Jacket Water Standpipe, Ftngs, Gasket 00-700A B

100 8

Satisfactory

. Jacket Water Standpipe Valves 00-7008 B

X 9

Satisfactory Jacket Water Standpipe Supports 00-700C B

100 8

ttatisfactory Jacket Water Standpipe Switches 00-700E B

X 9

Satisfactory Jacket Water Standpipe Bolting Materials 00-700F B

100 8

Satisfactory Satisfactory 100 Lube Oil Internal Headers 02-307A A

Lube oil Tubing and Fittings-Internal 02-3078 A

100 Satisfactory.

3 Satisfactory Lube Oil Line Supports-Internal 02-307D B

100 100 38 3,4 Satisfactory, minor ECT indication polished out. (4.1.1)

Crankshaft 02-310A A

Cranksbeft Thrust Bearing Ring 02-310C A

100 4

Satisfactory Crankcase Assembly 02-311A A

100 Satisfactory X

9 Satisfactory can Bearing Caps and Dowels 02-311B B

Crankcass Mounting Bardware 02-311D B

X 9

Satisfactory Cylinder Block 02-315A A

25 25 Satisfactory (4.1.5)

Cylinder Liner 02-315C A.

100 100 Satisfactory (4.1.4) 1 Cylinder Block Juket Water Manifold 02-315D B

100 Satisfactory Cylinder Head Studs 02-315E B

25 Satisfactory (4.1.7)

Satisfactory Cyl. Block Jacket Wtr. Manifold Nuts 02-315F-B 100 Jacket Water Inlet Manifold Assembly 02-316A B

100 8

Satisfactory Jacket Water Inlet Manifold Coupling 02-316B B

100 8

Satisfactory Jacket Water Discharge Manifold 02-317A B

100 Satisfactory y: Jacket Water Disch. Manifold coupling 02-317B B

100 8

Satisfactory 8

Satisfactory u Jacket water Disch. Manifold Supports 02-317C B

100 Flywheel Bolting 02-330B A

100 Satisfactory Front Gear Case Bolting 02-335B C

100 Satisfactory Satisfactory (4.1.9)

Connecting Rods and Bushings 02-340A A

100 100 100 Connecting Rod Bearing Shells 02-3408 A

100 100 100 100 Sat., except 3 halves did not meet acceptance stos.(4.1.2) i i

Piston 02-341A A

100 100 AM skirts replaced with AE skirts (4.1.3)

Piston Pin Assembly 02-341C A

100 Satisfactory 1

Fuel Tappete 02-345B A.

25 Satisfactory Intake Tappets 02-345A A

25 Satisfactory j

Canshaf? Assembly 02-350A A

100 Satisfactory 5

Camshaft Supports, Bolting and Gear 02-350C A

100 Satisfactory Camshaf t Maring 02-350s B

100 4

1 Crankshaft Gear 02-355A A

100 Satisfactory Idler Gear Assembly 02-3558 A

100 Satisfactory Satisfactory l

Air Start valve 02-359 A

25 100 Satisfactory (4.1.13) 4 Cylinder Head 02-360A B

100 100 100 100 2

Sat., except for 3 leaks and I cracked valve seat (4.1.16) l Intake and Exhaust valves 02-360B B

100 Satisfactory, some valves have chipped chrome plating (4.3.1) valve Springs 02-360D B

100 1

Satisfactory, except for one cracked damper spring (4.3.5)

Subcover Assembly 02-362A B

100 100 Satisfactory,except for two cracked pedestals (4.2.7) i Fuel Injection Pump 02-365A B

100 Satisfactory, except for 3 cracked blocks (4.2.1) (4.2.2)

Fuel Injection Tubing 02-365C B

100 100 6,8 Satisfactory (4.1.11)

Fuel Injection Tubing Supports 02-365D B

100 8

Satisfactory Fuel Pump, Linkage, Bearings and Shaft 02-371B A

100 Satisfactory Intake Manifolds02-375 B

100 Satisfactory Exhaust Manifold 02-380A B

100 Satisfactory Exhaust Manifold Bolting 02-380B B

9 9

Satisfactory (4.2.6 Crankcase Cover Caskets and Bolting 02-3868 C

100 Satisfactory Intake & Interrediate 'eker Arm Asubly. 02-390A B

100 Satisfactory Eshaust Rocker Arm As> % sly 02-390B B

100 Satisfactory (4.2.10)

Intake and Exhaust Pushrode 02-390C B

100 100 Satisfactory (4.1.14)

M 2-1 mneumr 2 CM3ME MEEL la EEK EITIRmm GPER8&IW TERE REES finnla sian omre=*

Part Nana Part No. Class Dimen. Visual S. ISE V. ice Eng Ev Notes Results (Def. paragraph)

Satisfactory Connec sr Pushrod 02-390D B

100 100 Bocker Arm Bushings 02-390E B

100 Satisfactory 100 100 Satisfact'ory (4.1.8)

Rocker Arm Bolting 02-390G B

Overspeed Trip & Accessory Drive 02-4105 A

100 Satisfactory 100 Satisfactory Overspeed Trip Couplings 02-410C A

Speed Regulating Governor Drive 02-411A A

100 Satisfactory 100 Satisfactory Governor Drive Couplings 02-411B A

Governor Linkage 02-413 A

100 Satisfactory Fuel Pump Linkage-Auto Shutdown Cylinder 02-4138 B

100 Satisfactory Governor Booster Servosotor 02-4158 B

X 9

Satisfactory Intercooler Piping-Coupling, Bolt, Cskt. 02-4365 A

100 Satisfactory Turbo Cooling Water Pipe and Fittings 02-437A B

100 8

Satisfactory 8

Satisfactory Turbo Cooling Water Pipe Supports 02-437B A

100 Start Air Manifold Pipe, Tubing & Fttng. 02-441A A

100 8

Satisfactory 100 8

Satisfactory Start Air Manifold Pipe Supports 02-441C A

Start Air Distributor Tbg., Ftg., Gekts. 02-442B A

100 8

Satisfactory Fuel Oil Piping and Tubing 02-450B A

100 8

Satisfactory (4.2.113 l

Fuel 011 Piping Supports 02-450D A

100 8

Satisfactory Fuel 011 Filter Mounting Hardware 02-455C A

100 Satisfactory 8

Satisfactory External Lube 011 Lines 02-465A A

100 100 Satisfactory y Esternal Lube oil Line Supports 02-465B A

Esternal Lube oil Valves 02-465C A

X 9

Satisfactory e

Turbocharger Lube oil Piping 02-467A B

100 Satisfactory (4.2.3) (4.2.8)

Turbocharger Lube Oil Piping Supports 02-467B B

100 Satisfactory Turbocharger Bracket 02-475A B

100 Satisfactory Turbocharger Bracket Bolting 02-475D B

8 7

Sat., except 1 bolt failed during test ( 4. *. M Control Panel Cabinet 02-500A A

X 9

Satisfactory Control Air Accumulator 02-500F A

X 9

Satisfactory Control Air System Valves 02-500G A

X 9

Satisfactory Control Air System Pressure Switches 02-5008 5

X 9

Satisfactory control System Relays

• 02-500J A

X 9

Satisfactory Control System Solenoid Valves 02-500K A

X 9

Satisfactory Control Air System Piping, Tubing, Ftngs 02-500M B

100 8

Satisfactory Cottrol Panel Wiring 02-500N A

X 9

Satisfactory 100 Satisfactory Lubt 011 Sump Tank 02-540A B

j Lube 011 Sump Tank Bolting 02-5405 B

100 Satisfactory Lube oil Sump Tank Mounting Bardware 02-540C B

100 Satisfactory Instrumentation Thermocouples 02-630D_

B X

9 Satisfactory 4

i Engine & Auxiliary Module Wiring Conduit 02-688A A

100 Satisfactory Engine and Auxiliary Module Wiring 02-6888 A

X 9

Satisfactory (4.1.10)

Engine and Auxiliary Module Wiring Boxes 02-688C A

X 9

Satisfactory Engine Alarm Sensors02-690 A

X 9

Satisfactory 4

X 9

Satisfactory Off Engine Safety Alarm Sensors-Switches 02-691A B

Engine Shutdown Tubing and Fittings 02-695A B

100 8

Satisfactory F-91ne Shutdown valves, Regs. & Orifice 02-695B A

X 9

Satisfactory X

9 Satisfactory Engine Shutdown Trip Switches 02-695C A

Fuel 011 Duples Strainer 02-825D A

X 9

Satisfactory Turbocharger Thrust Bearing Lube System 02-CFR C

100 Satisfactory (4.1.15)

Thermostatic Valve C 136-40 B

X 9

Satisfactory intake Air Filter CN-106 8

X 9

Satisfactory Intake Air Silencer CN-107 8

X 9

Satisfactory Before and After Lube oil Pump CN-109 A

X 9

Satisfactory Full Flow Lube Oil Filter CM-110 A

X 9

Satisfactory l

M E 2-1 mammer 2 casamma magh 23 m mErnem 2315M M aumXms ausla sian *===t P;rt Name Part No. Class Dimen. Visual S. EE V. ICE Eng Ev Notes Resulth MRef. paragraph) a Lube 011 Beat Exchanger CM-lll B

=

X 9 Satisfactory Generator Shaft and Bearings CN-IISA A

X 9

Satisfactory X

9 Satisfactory Jacket Nater Beat Exchanger CN-120 B

X 9. Satisfactory Cil Prelube Pilter CM-122 A

X 9

Satisfactory Lube oil Eeepwara Strainer CN-131 A

100 100 Satisfactory crack in flange repaired (4.2.5)

IItercoolog P-086 A

Turbocharger NP-022/3 A

100 100

- Turbochargers & enh. man. bolts were replaced (4.2.4)(4.2.5)

X 9

Satisfactory I

Lube Oil Pull Pressure Strainer SE-025 A

I I.

J BIRE 2h 2Mhla l.

Intake and exaust valve springs have proper color code.

2.

Ultrasonic wall thkkness amasurement of fire deck area and fuel nozzle 1

area. Inspection to determine if head has been repaired.

3.

A torslograph ins dev=1npart of the crankahaft.

4.

Crartahaft web deflections and thrust clearance was==== ired with the diesel hot as well as cold.

4 Y

5.

Inspections of the e== M t bearings was not performed eince an N

inspection of the e===h=4 lches showed no atmoraal usar.

6.

IK:P i&h were limited to both ends of all high pressure injection lines.

7.

Turbocharger bracket bolting tes replaced.

8.

Nalkdomen inspections con & acted as part of proce& ares 53-57 are complete and the results are contained in Agq3endia A. Walkdoten inspections performed as part of the Omers Grong Phase II Evaluation have been completed and the results will be peliabad by the 0mers Grong at a later time.

9.

B jineering valtaattem of part is to har=N if there are any significant unresolved maintenance or operational problems associated with the part.

+

1

(

l 4

l i

f 7

A] x\\9

_g ch

-f 3

[

(

AL 'Q8

/

VALVE BLOCK

\\

./

r--

)

• f 9

Fo'

~s

[

Q G r

- D D

S T

%_E(

D M

C' Cr l o' 1.

TYPICAL CRACK AFTER SOME GROWTH SECTION OF FUEL PL,MP ASSEMBLY View A-A Figure 2-1.

Cracked Fuel Pump Delivery Valve Block 2-8

i N.

4 3.0 Dipennnion of Extended Oooration Tent he purpose of the extended operation test and the parameters sampled or measured are outlined in refererce 1.

This section will discuss the results of the test.

The IB diesel extended operation was initiated on May 30, 1984, and was successfully coupleted on July 9, 1984.

During that time period the engine operated about 504 hours0.00583 days <br />0.14 hours <br />8.333333e-4 weeks <br />1.91772e-4 months <br /> of documented run time.

S at time added to about the 252 hours0.00292 days <br />0.07 hours <br />4.166667e-4 weeks <br />9.5886e-5 months <br /> of run time accunulated prior to the extended run test and resulted in a total documented run time of about 755 hours0.00874 days <br />0.21 hours <br />0.00125 weeks <br />2.872775e-4 months <br /> for the IB diesel.

The following information summarizes the tect run results.

3.1 Operatina Profilo The Catawba 'IDI DSRV-16-4 diesels have a rated load of 7000kw.

The maxinum calculated emergency diesel generator load under black out conditions is 5600kw. During the extended operation test, the engine was operated at loads in excess of the required 5600kw approximately 97% of the test period.

Specifically, during the extended operation test the generator load was as follows:

Generator Ioad Time (Mf)

(hours) 7.6 1

7.2 1

7.1 11 7.0 432.5 6.9 11 6.8 17 6.7 2

6.6 7

4 4

2 1

1.5 2

1 2

.6 1

0 6

Varying load 5

(governor test) 3.2 Vibration Analvnin Daily vibration plots were conpared to a baseline plot to identify any abnormal or significant changes in vibration levels, any longer term trends in vibration levels, or any other anomalies. During the extended operation test period no abnormal or significant changes in vibration levels or trends were identified.

3-1

3 Imbe Oil Analyses ly sanples of lube oil were tested for viscosity and water content.

1 nnalyses showed acceptable values for lube oil viscosity and water co ent.

3.4 Euel Analynaa N

Sanples o fuel oil from the delivery tankers were tested for specific gravity percent of water and sediment.

All analyses showed acceptable v es for fuel oil specific gravity and percent of water and sediment.

Hourly sanples du ing the test of the fuel oil day tank typically showed no water was pr t.

Any small amount of water present was drained by the operator.

nrwratina Parameters \\

3.5 The diesel operating parameters, both on the strip charts and log sheet, were reviewed each day to ascertain significant or abnormal changes and to look for trends \\in the data indiating gradual degradation of the engine.

With the exception of four cases, no significant or abnormal changes or data trends 'were detected in the operating parameters.

\\

%e four cases of significant trends in data or where a trip occurred were:

(

7R fuel punp was% replaced due to low pyrometer readings on the o

The cylinder during the s utdown that connenced on June 3,

1984.

I Similarly, the SL fuel W was replaced due to low pyrometer reading during the shutdown commncing on June 15, 1984. For further details see Section 2.2.

e The engine tripped on low lube oil pressure due to changing the lube oil strainers while the diesel operating on June 12, 1984. his type of trip is blocked during rgency operation, so it has no inplication in regard to diesel rability under design condition.

l i

e Repair and adjustment of the voltag regulator was required during

(

the period June 16 through 19, 1984 d to load swings.

t l

e The engine tripped on low turbo oil pr ure due to a dirty lube oil strainer on July 3, 1984.

% is type f trip is blocked during emergency operation, so it has no inpli ation in regard to diesel operability under design conditions.

l 3.6 Problem psmnrts Several problem reports were generated g the course of the extended f owing engine parts:

run test. These reports covered the f l

o Fuel line fitting o

Turbocharger thrust bearings 3-2

Cylinder head jacket water leakage o

f Fuel injection pump delivery valve block e

Intercooler jacket water pipe weldment e

e Turbocharger adaptor e

Air distributor capscrew Further discussion of these problems is given in Section 4.

f 3-3

4.0 Diannaainn of TnanacHnn pannits his discussion of inspection results is contained in four parts.

The first part (Section 4.1) covers inspections related to the generic problems being addressed by the 'IDI Owners Group.

2e second part (Section 4.2) covers inspections performed to address concerns raised by The specific problems which have been experienced with Catawba diesels.

third part (Section 4.3) covers significant inspection results not covered by the first two parts.

Se fourth part (Section 4.4) covers results of the engineering validation review.

All of these inspections are documented in the Appendices, Section 6.0.

4.1 TnanacHnna Related.to 3DI Generic Prnblema

%e inspections related to 'IDI generic problems which were performed, and the results of these inspections, are described below.

4.1.1 cranicahaft (Part No. 02-310A)

PprmrJM:

A crankshaft failure occurred at Shoreham.

The cause of the failure was high cycle fatigue cracks initiating from fillets in the crankshaft at the junction of a crankpin and web (reference 5).

Similar cracks were found to exist on other crank-web fillets in all three diesels at Shoreham.

Se Catad>a crankshaft design differs from that originally used Shoreham.

The Catawba crankshaft has substantially lower at stresses, which meet industry standards and are not expected to problems (references 6 and 7). Due to satisfactory cause inspection of the Catawba Diesel 1A (reference 3), mly visual inspections of crankpin web fillets on Catawba Diesei 1B were performed.

At San Onofre, a 'IDI diesel engine experienced cracks in main bearing journal oil holes. W e V-16 Catawba diesel crankshafts are also different than the San Onofre V-20 crankshafts.

as this failure was nuclear service related, inspec-

However, IB tions of the highest load main bearing journal oil holes on were performed.

SCOPE & INSPECTICNS:

S e crankshaft inspections consisted of:

Web deflection measurenents.

e e

Visual inspections of the crankpin journals on all eight crankpins.

e Fluorescent dye penetrant and BCT inspection of oil holes in main bearing journals #4, #6, and 48.

4-1

No significant conditions were noted. Two small indications were detected on #6 main bearing journal oil hole by BCT. The first indication was approximately 1/16 inch in a radial direction about 2.5 inches into the hole.

We second indication was approximately 1/8 inch in an axial direction on the journal.100 inches from the oil hole.

%ese indications were polished out at a depth of less than.001 inches.

SI3emRY:

In sunnary, the inspections of the crankshaft indicate that it is free of significant defects and is not experiencing the type of problem experienced with the San Onofre crankshaft. The small indications detected by BCT in the #6 main journal oil hole are believed to be machining marks.

It was concluded that these indications were non service induced.

4.1.2 t'nnnacHna Egd Hearings (Part No. 02-3408)

PINJM:

Several connecting rod bearing shells in the Shoreham diesel engine cracked.

Analysis performed by Failure Analysis Associates (reference 7) 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.

Wus, cracking of Catawba bearing shells was considered unlikely.

Nevertheless, thorough inspections of the shells were performed to confirm freedom from problems.

SO T E & INSPECTIONS:

We bearing shell inspections consisted oft e

Visual inspection of bearing and back surfaces of all bearing shells.

PT examination of the bearing shells.

e X-ray examination of all bearing shells.

e RESUUIS & INSPECTIGE:

No cracks were detected by visual or liquid penetrant inspection.

Visual and liquid penetrant inspections indicated babbit fatigue in the area of link rod maxiram bearing his has been evaluated and found to exist on all pressures. block engines and does not affect bearing operation

'IDI vee (reference 8).

X-ray inspections indicate that three of the sixteen bearing halves inspected do not meet acceptance standards due to indications related to as manufactured material condition.

4-2

W

\\

I SWE4ARY:

Surface' inspection results' indicate that connecting rod bearing' shells are acceptable for continued operation.

X-ray inspections 'results indicate that three bearing halves do not meet acceptance ~ standards due to as manufactured material conditions. Spare bearing halves which meet all inspection standards. have been installed in place of the three.

4.1.3 :

Pistons (Part'No. 02-341A)

PK BLEM:

Inspection of the Catawba'1A diesel type AN skirts indicated

.that 4 out'of 16-skirts had cracks at the circumferential rib i

to piston pin boss fillet.

As a result, all Catawba IA and 1B piston skirts were replaced with type AE skirts.. The removed

~

IB type AN skirts were inspected for information purposes.

SCOPE T INSPECTIONS The inspection performed of the the removed type AN pistons skirts are listed below:

e Visual inspection of 100% of the piston skirts.

e PT examination of stud bosses of 100% of the piston skirts.

's e

PT examination of piston pin bosses and belleville seat surface of 100% of the piston skirts.

g e

MT examination -of areas adjacent to piston pin bosses (these are the areas where several cracks'were noted).

~

RESULTS T INSPECTIONS:

'Ihe nost significant condition noted was the presence of cracks in two piston skirts similar to those noted in-the 1A piston skirts (reference 3).

The cause of the cracking is believed to be cyclic fatigue. FaAA is performing a detailed failure analysis of type AN skirts.- A nunber of other minor-reportable indications were noted, but none of these appeared to be related to service; rather, they appeared to be due to l __

minor casting inperfections.

SmelARY:

j l'

Cracks were found to be present in two piston skirts.

All of I

the piston skirts will be replaced with type AE pistons.

In l

addition, a detailed failure analysis is being performed as L

part of the 'tDI _ Owners Group program.

l-4-3 I

.w

'5.

757 s g.,

s 4.1.4 gglicdat Liners -(Part No. 02-315C) 7 r

x.

ParmM:a -

Devere grooving has been noted in at least. one TDI nuclear 4

. " diesel engine (reference 11).

This grooving was attributed to debris tbat entered the diesel during assenbly or initial startup.

_ g SC@E & INSPECTIQE:

a-All of the cylinder liners were 100% inspected to check for the f

4 presence of grooves or other Aamage.

RRdnit'S T INSPECTIQ3S:

No significant grooves approaching the 1/16" deep grooves seen i_ f'Q

. A in'the Grand Gulf diesel were observed in the Catawba cylinder liners.

Minor scratching was observed which is normal for a

j...

~

1, diesel. which has seen substantial service.

These scratches are considered to have no effect on diesel' operability.

_g SW9tARY:

The inspections indicate that the cylinder liners are in satisfactory condition.

Honing to break up the glaze in order to allow new piston rings to seat has eliminated the scratches observed in-the liners.

4.1.5 cv14 Mar Blod (Part No. 02-315A)

QF PROBLEM:

~

Cracks have been reported on cylinder blocks in the area of the cylinder' liner landing ;and at cylinder head stud holes (reference 11).

p g-SCTE & INSPECTIQ3S:

The cylinder block inspections included the following:

e The area between the cylinder studs and the liner and the l__

area around the studs were PT examined for all-cylinders.

e-The cylinder liners were removed from four cylinders (4

L l

and 5 right; 4 and 5 left) and the cylinder liner landing L

area within the block was PT examined.

I:

RESULTS T INSPECTIQ3S:

No significant indications were noted.

SWERRY: -

Cylinder block cracks were not detected on diesel engine IB.

(

4-4 i

. - _ _ _ - - _... _ -.. _ _. - _..., ~.,, -, _,,,.,

4.1.6 Edging Base (Part No. 02-305A)

PIGEEM: -

i

Linear. indications have been reported as enanating from main bearing' stud holes in the engine base.

These problems have been attributed. to in % mte bearing cap stud preload (references 11 and 12).

SCCPE & INSPECTI(MS:

The main bearing saddle area around and between the stud holes 4

. was-PT examined for bearings 4, 5,

6, and 8 on diesel 1A. In addition,- the stud tension required'to permit removal of the nuts was measured on diesel 1A. Owing to the fact that 'all inspection results on diesel IA (reference 3) were satisfactory, these inspections were not' carried out on diesel IB.

RESULTS & INSPECTICES:

~Not applicable.

SLM ERY:

Not applicable.-

4.1.7 cvmaar Easi St;uda (Part No. 02-315E)

PRCELEM:

-Isolated failures of cylinder head studs have been reported -as occurring in non-nuclear 'IDI diesels (reference 13). Hence, visual inspections on a sangling basis were performed - of the Catawba diesels.

SCOPE T INSPECTICES:

e Studs from the four cylinders (3,4,5, and 6L) were visually inspected.

RES'LTS T INSPECTICES:

All cylinder head studs inspected satisfactorily passed the i.

visual examinations.

SLM ERY:

A sangling inspection of cylinder head studs indicates that they are acceptable.

4-5

~-

4.1.8 Bocker ADD Capacrews (Part-No. 02-390G) i PKBLEM:

A fatigue failure is reported to have occurred with a rocker arm capscrew at Shoreham (reference 11).

H is failure was attributed to undertorquing.

Reference 22 indicates that properly torqued capscrews have satisfactory fatigue resistance.

SCTE & INSPECTIWS:

he rocker arm capscrews were visually and Mr examined.

RESULTS & INSPECTI0tE:

No indications were noted in the visual or MT examin1: ion.

S0 M ARY:

The diesel engine IB capscrews were found to be satisfactory.

4.1.9 connac+4na RXia (Part No. 02-340A)

PI N JM:

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 11).

P SCTE T INSPECTIWS:

% e inspections of the connecting rods included the following:

.o Visual inspection was performed of all connecting rods.

o Magnetic -particle inspection of all connecting rod link rod and rod-to-box bolts was accouplished, o

The areas of the rod box which have been reported as being subject to cracking were LP examined.

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 assenblies.

e Connecting rod rack-teeth (serrations) degree of contact with mating part was measured by bluing the part on all connecting rods.

RESULTS T INSPECTI W All connecting rods passed the above inspections.

Degree of contact along the rack-teeth (serrations) varied between 80 and 95 %.

4-6

,,-r-

,--,.--sa.-s-e-,-n..w..,

-,,,---,-,s--ne,.wm

-,-..,-,,e.-,,t---v,,-nn,----,-----.e

-a-.

vw,se.,*,,,.,,,,,an,

,-----,-e,,,,e,v,-v v w --

w-e,

- w

,1-

~

SGMARY:

The' ' diesel-IB connectiag rods were found to be acceptable.

After reassenbly. in the engine, connecting rod capscrews were

. ultrasonically examined to assure that preloads were adequate.

s 4.1.10 R1MrW1 Cables (Part No. 02-688B)

Pp m rJM g A number of electrical cables used by TDI have been identified as-either failing insulation flame test requirements or not having sufficiently high tenperature ratings (references 11 and 19).

SOCPE & INSPECTICN:

Stone -and Webster,-- as part of TDI Owners Group activities,

. reviewed the Cata h electrical cable installation (reference 19).

RESULTS & INSPECTIQi:

The Stone E. Webster inspections (reference 14) have been coupleted with the following results:

e TDI SIM -361 had not been inplemented on the Catawba

' diesels.

This involves replacement of:

shielded cable from 'a terminal block to the tachometer relay in the engine centrol panel; shielded cable from Airpax magnetic pickup to the junction box on the side of the engine; and nulticonductor cable from an 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 controls were not manufactured between 1974 and 1976.-

SGMARY:

Following the Stone & Webster inspection TDI SIM 361 has been accouplished by Duke Power Co.

. With this replacmnent, all wiring is of acceptable tenperature rating and adequats.ly sized for circuit anpacities. Duke Power Co.

(reference 15;' has a

-program for inspecting States sliding link terminal blocks during installation and each time the link is operated.

Perfornance probleus and defective links are reported to Design Engineering.

Hence, Duke Power Co. already has a program for uncovering defective terminal blocks and therefore find it unnecessary to verify the manufacturing date of the TDI terminal blocks.

i 4-7

. - ~, _ _ _

4.1.11 Euel InjecHnn Lines (Part No. 02-365C)

Pprmr.m:

Sevetal cases of failure of high pressure fuel injection lines have occurred.

These failures have been attributed to a fatigue crack initiating at a pre-existing.006" draw seam at the tubing ID. (reference 16).

SCTE T INSPECI' ICES:

All 'of the high pressure fuel injection lines have been inspected in an area six inches from each end or from the end to the first turn using ECT methods.

RESULTS T INSPECTICES:

The results were satisfactory.

SLIWlARY:

The fuel lines have operated for over 10 million cycles without problem and are thus considered to be satisfactory.

In addition, ECT inspections have been performed to confirm their satisfactory condition.

4.1.12 Jacket Water Pungs (Part No. 02-425A)

Pprmr.m:

Several jacket water punp shaft failures occurred at Shoreham (reference 17).

'Ibe Catawba jacketwaterpunps are of a different design than the Shoreham punpc. However, even though the probleus experienced at Shoreham are not expected to apply to the Catawba diesels, detailed inspections were performed of the Catawba diesel IA jacket water pung (reference 3). Because inspections were e nsmlished on the IB jacket water punps after its extended operational test.

The NRC staff SER (reference 18) has informed Duke Power Co. that during the first refueling outage that the torque of the nut holding the external spine to the shaft taper on the jacket water punp nust be checked.

SCTE T INSPECTICNS:

Not applicable.

RESULTS T INSPECTICNS:

Not applicable.

4-8

SLM4ARY:

Duke Power Co.

considers the jacket water punps to be acceptable.

Torque measurements on the external spline nut, however, will be measured at the first refueling outage.

4.1.13 Air Start Valve capacrown (Part No.02-359)

PINM:

Capscrew bottoming out due to insufficient hole depth for the capscrew length can lead to insufficient clanping force (reference 21).

'IDI re<===nded reducing capscrew length to prevent this problem.

Catawba diesel capscrews were modified prior to the extended operation test.

SOTE & INSPEC1' ION:

h inspections for the capscrews included the following:

Measure length of capscrews for 4 valves.

e Visual inspectica of the valve seat areas on the heads for e

all valves.

RESULTS & INSPECI'IOJS:

Capscrew lengths were acceptable, and the valves showed no signs of insufficient clanpirej force.

SLM4ARY:

There agxwired to be no problems with airstart valve capscrew bottoming out in the Catawba 1B diesel.

4.1.14 B ah EQda (Part No. 02-390C)

PINM:

Originally supplied pishrods experienced cracking of the welds joining the rod to their rod ends. New design push rods with friction welds were installed in the Catawba diesels during the extended operation test and accunulated about 400 hours0.00463 days <br />0.111 hours <br />6.613757e-4 weeks <br />1.522e-4 months <br /> of operation on the lA diesel.

The push rods were then installed in the IB diesel and accunulated over 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br /> of operation.

SCOPE CF INSPECTIO3S:

h inspections of the new design push rods included the following:

e Visual inspection of the shaft end welds to verify that the desired new type friction welds were used.

e PT examination of all the welds.

i 4-9 i

+

RESULTS T INSPECTIONS:

All the push rods were confirmed as having the correct type of weld and were found to be free of defects.

SGMARY:-

The Catauba diesel engine push rods are considered to be

-satisfactory since the friction welded design has operated over 900 hours0.0104 days <br />0.25 hours <br />0.00149 weeks <br />3.4245e-4 months <br /> with no sign of cracking.

e i

4.1.15 Turbocharger Bearings (Part No. MP-022/23;. 02-CFR) 1 Severe wear of the bearings has been reported, apparently due to in%=te lubrication during diesel starts (reference 11).

An inproved lube oil supply system was incorporated on Catawba diesels in Septenber 1984.

SCTE & INSPECTION:

The bearings were visually and dimensionally inspected.

o RESULTS T INSPECTI0tE:

The turbocharger bearings were found to be severely worn. This wear was due to in W _mte lubrication during startup. It should be noted that this wear had not affected turbocharger operation during the extended operation test.

SGMARY:

The turbocharger bearings have been replaced'with new parts.

These are expected to operate as.well as the original bearings, which caused no operational problems for several hundred hours.

The new lube oil system which was incorporated will assure that the bearings get adequate lubrication during normal startups which will significantly' reduce wear.

4.1.16 cvHndar Baads (Part No. 02-360A)

Ppret:

Gree small ja::ket water leaks have been experienced on Catawba diesel 1B resulting in water leaking into the fuel injector nozzle cavity. One leak of similar origin was seen on diesel 1A. Failure analysis of one of the leaking heads has been coupleted (reference 4).

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, reference 3).

4-10

SCTE T INSPECTIN h inspections performed of the cylinder head included:

o Visual examination of valve seats.

e PT examination of valve seats in cylinder heads and the

. area betsien valve seats on the head.

e UT examination of fire deck thickness at selected locations.

e Visual inspection' of heads to determine if they have a welded in plug.

RESULTS T INSPECTIONS:

(he - head had a crack in a valve seat.

No heads had welded plugs other than the three that leaked.

SWMARY:

The head with the cracked valve seat is being replaced.

The heads with the repaired plug weld are a).so being replaced. It should be noted that neither the cracked valve seat nor the leaking heads would have affected diesel engine operability in an emergency.

4.2' Catasta Pific Prob 3ema 4.2.1 Eugl InjecHnn Bgg Nozzle Valve Holder (Part No. 02-365A)

Ppnnrsg:

fuel injection pung nozzle valve ht.1 der on Catawba diesel 1A a

cracked as a result of a material defert (reference 1).-

SC@E & INSPECTIWS:

Visual inspection of the IB valve holder bores using a boroscope was anv = 11shed to determine if there were linear l-defects.

RESULTS T INSPECTIWS:

Only one of the IB valve holders had linear indications.

h bore of this valve holder was polished to remove the indications.

ENGINEERING EVALUATION:-

[

A failure analysis was performed on the 1A fuel injection punp nozzle valve holder (reference 20).

h results of this analysis indicate that an axially oriented linear indication in the high pressure fuel oil passage of the failed part led to i

4-11

the' reported failure.

Further analysis' indicates that axial linear indications that would lead to cracking of the valve

. holder would cause cracking to occur within 10 million cycles of fuel pusp operation.

As the Catawba valve holders have withstood 10 million cycles of operation, the valve holder failure experience is considered an isolated material defect.

SCHIARY:

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 thet would cause cracking are present in -the remaining valve lolders. In addition valve holders that had indications based on boroscope inspections were removed from the engine, cleaned and/or raamari, reinspected, and found to be free of defects.

4.2.2 Rhal Injeinn Rung na14verv Valve Block (Part No. F-099-170)

PEGlLM:

During the IB extended operational test two fuel injection punp delivery valve blocks leaked bamme of axial cracks.

This type of failure does not exhaust fuel-to the anbient but allows i

fuel to bypass the injectors and be returned to the fuel oil

. tank.

SC@E & INSPECTI0tE:

The following inspections were accomplished:

e Visual examination for signs of cracks.

e NT examination in valve seat area.

RESULTS & INSPECTIGE:

(

One other delivery valve block was found partially cracked after disassembly of diesel IB. A metallurgical evaluation indicated that the cracks were fatigue induced, and initiated at the valve seat area.

Duke Power Coupany contacted the 7

l vendor of the delivery valve blocks, and the vendor indicated l

that the probable cause of the failures was heat check cracking in the valve seats due to excessive grinding l~

temperatures during manufacturing. -Results of MT inspection of l=

delivery valve. blocks which were not cracked indicated no evidence of heat check cracking.

SUM ARY:

l The fact that all of the installed delivery valve blocks that were not cracked as well as the blocks which replaced the cracked ones showed no evidence of heat check cracking assures L

l~

l-4-12 I

s that this will not be a problem on the return to service of diesel 1B.

In addition, such failures would not affect diesel operability in an emergency situation.

The failure results in gradually declining cylinder tenperatures in the effected cylinder and the remaining cylinders will assume the load.

No inspections of the fuel injection punp delivery valve blocks are planned for diesel IA since it is felt that with over 10^7 fatigue cycles on the blocks that any heat check cracks would have propagated to the point of failure and been detected based on reduced cylinder tenperature.

4.2.3

'nirhncharger Prolnhe Oil Lines (Part No. 02-467A)

PIEBLEM:

Two failures of the prelube oil lines occurred during the 1A extended operation test due to fatigue cracking at conpression fittings.

%e lines have been replaced using an inproved procedure and using additional clanps, vibration danpening

devices, inproved conpression fittings and heavier wall stainless steel tubing.

The same modificatioras to the turbocharger prelube oil lines on diesel IB were trade prior to the extended operation test.

No leakage was noted from the IB lines during its extended operation test giving assurance that the design modifications have adequately addressed the problem.-

Hence, no inspections of these lines were specified on diesel 1B.

SCTE T INSPECTI0tE:

Not applicable.

RESULTS T INSPECTIONS:

Not applicable.

SCMMARY:

Not applicable.

4.2.4

'nn+vv harger AAartor (Part No. 00-495A) l Ppm uM:

l A turbocharger to air inlet adaptor cracked at a flange weld. A similar problem occurred on diesel 1A.

In addition, the internal air flow divider (flow distributor) had a small crack at the junction to the case of the adaptor.

This problem was not seen on diesel IA.

An engineering evaluation indicates that the cracks are caused by excessive displacements of the 4

case.

SCTE T INSPECTICNS:

f

%e adaptor welds were visually and Mr examined after repair.

4-13 1

ey+-,.r---

---,,,.------.-.,----,..-----.,e-

.,.e-,-

m.-

RESULTS & INSPECTIQ4S:

No defects were noted.:

SWBIARY:

'A redesign has been inplemented on both. Unit 1 diesels consisting-of a flexible connection between the adapter and turbocharger to absorb displacements.

In addition, on' both Unit 1 diesels, strongbacks have been welded to the case to eliminate the flexing which caused the air flow divider weld failure.

This redesign will assure that in the future the adapter will not crack.

4.2.5 Intercooler M Water Elange (Part No. 136F-068)

PRCBLEM:

A.

jacket water penetration into the water box on the intercooler seeped water during the extended operation test on diesel 1B.

Jacket water piping to this penetration was vibrating at the diesel fundamental frequency. The penetration was weld repaired.

A rigid hanger was added to the external piping to change its characteristic frequency.

j SCTE & INSPECTICN Not applicable.

RESULTS T INSPECTION:

Not applicable.

SENIARY:

A rigid pipe hanger has been installed on both Unit 1 diesels to change the natural frequency and limit displacements.

This modificatic1 will eliminate pipe weld cracking at the penetrati m in to the water box of the intercooler.

4.2.6 crankcase and Camahaft Cmer Capscrews (Part No. 02-386B)

Ppret:

t Occasional failures of these capscrews has occurred due to fatigue (reference 20) because of over or under torque.

2 SCTE & INSPECTIGE:

All of these capscrews are being replaced with capecrews with inproved fatigue strength and of known chamical and physical properties. Accordingly, inspection is not applicable.

4-14

-. -. -..... -... ~

SLEGIARY:

his problem has been resolved by replacement of the capscrews using capscrews of appropriate quality and by revising installation procedures to control torques to appropriate values..

4.2.7 nrxier Egg (m*vvver) Subassenbly (Part No. 02-362A)

Pyrmrm:

A 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.

A similar problem was detected on diesel 1A (see Figure 2-2B, reference 3). The cause of the problem is believed due to installation tolerances between bushings and the pedettal leading to excessive interference fits.

SC @ E T INSPECTION:

e The bosses on all of subcover assenblies were PT examined.

RESrLTS @ INSPECTI0tE:

Two subcovers were found to have cracked bosses following the extended operation test. All of the others were free of defects.

SIEtlARY:

Several cracked bosses were found and the affected subcover assenblies have been replaced. These cracks have not caused a loss of operability of the engines.

A failure analysis. has been performed by FaAA under 'IDI Owners Group direction. Wis indicates that the cracks were due to installation or manufacturing errors and not due to service. Ttus, replacement of the defective subcover castings resolves the problem.

4.2.8

'nhhargar Imbe Dil Drain Line (Part No. 02-467A)

Parmrm:

A tenporary drain line on diesel IA leaked during the extended operation test due to fatigue.

It was replaced with an inproved design as part of the diesel' reassenbly.

The IB turbocharger lube oil draln line was replaced prior to its extended operational test.

SCTE T INSPECTICE:

Not applicable.

4-15

. - = -

9 Smeer:

his problem has been resolved by. installation of a permanent drain line. Se fact that this permanent drain line design did not.Jeak during the 1B extended operation test provides assurance that the problem has been eliminated.

4.2.9 Turbocharger Exhaust fama Inlah Bolta (Part No. 02-380B)

PIGLEM:

One 1/2 inch stainless manifold to tu h harger adaptor bolt was found broken during disassembly of diesel IB.

his i.3 similar to diesel IA (reference 3) where four were found

'brob n.

The investigation shows that the bolts failed from creep rupture (reference 20).

SCTE & DEPBCTICE:

Not applicable.

RESULTS T DEPBCTICE:

Not applicable.

SWeMrs

% ese bolts have been replaced with creep resistant SA 453, Grade

660, Condition A material.

In

addition, bolt installation procedures have been revised to insure tlnt proper preloads are applied during this installation.

Also, improved thread lubricant will be used on reassembly to ease removal in the futr e.

4.2.10 nocker AER Adinating ScKar !hrival Rad (Part No. 02-3908)

PNBLEM: -

' (he of the swivel pads was found cracked during operation on diesel IB.

his occurrence was reported in reference 3.

Failure analysis (reference 20) indicates that the cracking occurred due to a one time overload.

It is believed that the swivel pad cracked due to inproper swaging at the factory during manufacture.

Another swivel pad was 'found cracked during reassembly following the inspections.

This pad is believed. to have been cracked when the rocker arm was knocked over in storage.

SCOPE & INSPBCTI0t6:

All swivel pads were visually inspected.

4-16

F RESULTS T INSPEC1'IOiS:

No defects were found and the sockets were found to be corractly swaged.

SG E RY:

The swivel pads are considered to be in satisfactory condition.

4.2.11 Euel Line Fittinan (Part No. 02-4508)

PP N JM:

Failures have been reported as occurring on

fittings, apparently as a result of vibration induced fatigue due to the

- absence of the supports required by the 7DI drawing (reference 11).

During the extended operation test one high pressure and one low pressure fuel line fitting leaked The high pressure fitting was retorqued eliminating the leak.

h low pressure fitting had teflon tape added to eliminate the leakage.

SCTE & INSPECTIONS:

The inspections of the fuel lines include a walk down inspection to verify that the piping is installed per the applicable design drawing and properly supported to suppress vibration.

RESULTS & INSPEC1'I0tE:

The inspection of the fuel lines was satisfactory.

SWERY:

During reassenuly of the engine fuel lines, fittings were installed to Duke Power Conpany procedures to prevent ' inproper torque values from being applied.

In addition, walkdown inspections of the fuel lines have insured that the lines are properly attached, such that vibration problens are not expected.

4.3 General Tm = & inn In addition to inspections related to 7DI generic problems and to Catawba specific problens, inspections have been performed of numerous other parts in order to verify the operability of the Catawba IB diesel engine.

N results of these inspections showed that the 1B diesel engine was in excellent condition, with a few relatively minor problems in addition to the problems discussed in sections 4.1 and 4.2 above. The only additional probleus noted were as follows:

Valve stens had chigal chrome plate and areas where the chrome e

thickness had been reduced.

4-17

e the main bearing was found to have a circumferential score in it,

~

Several bolts and capscrews were found to have missing heads or o

cracks.

e A valve danger spring was found to be cracked.

S ese problems are discussed below.

4.3.1 YAlmt Etsgi (Part No. 02-360B)

PI N JM:

Eight valve stems had areas with chippel or reduced thickness chrome plate.

W is occurred at about 6 to 8 inches above the valve seat, at a location corresponding to where the sten enters the valve guide.

Se chrome plate chipping had no affect on diesel operability, and caused no observable damage to the valve guides. henty valves had non-relevant scratching of the chromium plating.

SCTE & INSPECTIGE:

All 64 valve stens were visually inspected.

RESUUPS T INSPECTI0tE:

As discussed above, 8 exhaust valve stems had chipped or removed chrome plating in areas about 6 to 8 inches above the valve seat and 20 had non-relevant scratching of the chrome plate. No structural damage was observed.

Sl391ARY:

Valve stem chrome plate chipping or scratching of a cosmetic nature occurred. Se eight valve stems with chipped or removed chrome plate are being replaced. Wis condition will be monitored in the future during routine maintenance inspections.

Main aaring (Part No. 02-305A) 4.3.2 n

PMBLEM:

One main bearing (66) was found to have a circumferential score. S is was detected in pulling bearings 4,6,and 8 for ECT and PT of the journal oil holes.

SCTE & INSPECTI0tEr 4

Since the bearing was acceptable for continued use no other bearings other than 4 and 8 were removed.

t 4-18

r--

RESULTS T INSPECTICES:

%e only problem noted was the scoring of this bearing.

StMem:

Iower main bearing 6 is being replaced, even though the score did not affect operability. h is problem is considered to have been an isolated case of damage by a piece of debris at initial assembly.

-4.3.3 lbrbacharger nn1Hna (Item 7, TDI dwg. 02-475-22)

PMBLEM:

One turbocharger to bracket, 5/8 x 11 NC x 2 long capscrew failed on diesel 1B. Engineering evaluation of the capscrew indicated fatigue failure.

SCTE & INSPECTI0tE:

% ese bolts were replaced on die.3e1 1A and 1B. Inspections were therefore, not applicable.

RESULTS & INSPECTIOG:

Not applicable.

SLM9m:

We capscrew apparently failed due to fatigue.

All capecrews have been replaced with new material of increased fatigue resistance.

Reassembly procedures have been revised to assure that proper preloads are applied.

4.3.4

!&arHna Air nintrihntor cover CapacIsu (Item 12-4DI dwg. 00-442-08)

PprmrJM:

he head on one of six 1/2 inch capscrews on the right bank starting air distributor cover fell off.

%is problem was noted during a routine visual inspection of the engine during shutdown.

It is believed that the likely cause of the problem is fatigue due to under or over-torquing of the capscrew.

SCTE T INSPECTION:

Sese bolts have been replaced and inspections are therefore not applicable.

RESLKlfS & INSPECTI0tE:

Not applicable.

4-19

p,-

SW9ERY:

All capscrews are being replaced with a new material of in creased fatigue resistance. During reassenbly, proper preloads are applied to the capscrews.

4.3.5 Intake Valve Danset snrina (Part No. 03-360-04AF)

ParWJMg l

Che damper spring (Cylinder 7L) was found broken in two on disassenbly of the heads.

The danper spring was designed and installed on TDI engines about 15 years ago when intake valve springs were cracking.

Subsequently, 'IDI learned that the problem with cracked valve springs was in the shot peening processes.

Today with proper shot peened valve springs, the danper spring is superfluous and new TDI heads are supplied without the danper springs.

SCOPE & INSPECTIOtB All intake danger springs were visually inspected.

RESULTS T INSPECflotG All intake danper springs other than the one that-was cracked appeared satisfactory.

RM4ARY The danper spring is a superfluous couponent that is coupletely captured by the valve spring.

Hence, if the danper spring failed it would not effect diesel engine operability, as was the case with engine IB with over 750 hours0.00868 days <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br /> of operation.

Because of this, no additional failure analysis was done on the cracked danper spring. Duke Power Co.

is in the process of preparing instructions to Catawba to remove these danper springs whenever work involves disassenbly of the valve springs.

4.4 Beault of Enainmorina validaHnn In section 6.0, Appendix B,

an engineering validation of parts not inspected by traditional non-destructive techniques was performed.

The engineering validation included thoroughly reviewing operational and maintenance records to assure that no problems have been experienced.

i The only problem found that is not mentioned elsewhere in this report was two intermittent shorts in thermocouples found during engine heatup. The effected thermocouples were replaced.

This problem was also in evidence on diesel IA (reference 3).

As thermocouples do not effect engine operability in a emergency run situation, these failures are not considered significant.

I 4-20 t

\\

5.0 References 1.

' Duke Power Co. letter dated April 5, 1984 to H.R.

Denton, NRC, with atteharl drmaarit entitled "Catauba helear Station Extended Operation Tests and Inspections of Diesel Generators"..

2.

Duke Power Co. letter dated July 6,'1984 to H.R. Denton, NRC, containing detailed IB diesel inspection plans.

3.

Duke Power Co. letter dated June 29, 1984 to H.R. Denton, NRC, enclosing

" Catawba Nuclear Station, Diesel Engine 1A C&t Revalidation Inspection".

4.

Failure Analysis-Associates, " Metallurgical Analysis of Catauba Injection Port Leak", June 1984.

5.

IE Information Notice No. 83-58, "Transamerica Delaval Diesel Generator Crankshaft Failure", NEC, August 30, 1983.

6.

Bechtel Power Corporation, " Evaluation of Crankshaft Stresses for Duke Power Corporation, Catawba Nuclear Station", March 19, 1984.

7.

Failure Analysis Associates, " Design Review of Connecting Rod Bearing Shells for Transamerica Delaval hterprise Engines", March 12, 1984.

8.

Duke Power Co. Meeting Minutes, Diesel Generator Owners Group. Shoreham helear Power Station, S. R. Ward author, May 24, 1984 9.

Delaval minutes of Novenber 30, 1983 meeting with TDI Owners Group.

10. F.silure Analysis Associates, " Investigation of Types AF and PE Piston Stirts", May. 27, 1984.

'll.

Mississippi Power 4 Light Co.,

" Comprehensive report on Stanchy Diesel Generators -Significant Activities to Enhance and Verify Reliability",

February 1984 transmittal to NRC by letter deted February 20, 1984.

12. Failure Analysis Associates, " Design Review of h gine Base and Bearing Caps for Transamerica Delaval Diesel hgine", April 1984.

13. Stone and Webster Engineering Corporation, "Bnergency Diesel Generator Cylinder Head Stud Stress Analysis", March 1984.

l 14 Stone and Webster Engineering Corporation, " Supplement to Bnergency Diesel Generator Auxiliary Module Control Wiring and Termination Qualification Review". June 1984

15. Duke Power Co. letter from G.T.

Ianb to K.S.

Canady, " Catawba Nuclear 4

Station IE Information Notice 80-08 States Sliding Link Terminal Block",

File CN1412.ll-1; EGS N-14.01, May 7, 1980.

i

16. Stone and Webster Engineering Corporation, "Bnergency Diesel Generator, Fuel Oil Injection Tubing, Qualification Analysis", April 1984.

5-1

. ~.

E

17. Stone 'and Webster Engineering Corporation, "Dnergency Diesel Generator, lbgine Driven Jacket Water Pung, Design Review", April 1984.

18. Imc letter of August 14, 1984 to H.

B. Tucker of Duke Power Co. forward I_

Staff Safety Evaluation Report pertaining to Catad a diesel generators.

19. Stone and Webster Engineering Corporation, "Dnergency Diesel Generator, Auxiliary Module Control Wiring and Termination, Qualification Review",

April 1984.

2

- 20. Duke Power Co.,- " Failure Analysis Report Catada Nuclear Diesels IA and IB", June 26, 1984.

and Webster Engineering Corporation, "Bnergency Diesel Generator

-21.

Stone Air Start Valve Capscrew, Dimension and Stress Analysis", March 1984 and Supplement, April 1984.

22. Stone and Webster. Engineering Corporation, "Bnergency Diesel Generator Rocker Arm Capscrew Stress Analysis", dated March 1984, and Supplement dated April 1984.

4 1

B b

i F

5-2

., -._ _..-- _ - -.. _.., _.. _ _. ~. -. - -..

r 6.0 Amenatces A.

Inspection Reports B.

Engineering Validation Report 6-1 L

APPf10IX A INSPEEPIN REEmrS l

A-1

ff"i Table of Contents.

h 21 2mEL h Rast Man clama 37 02-359 Air Start Valve A

37 02-360B Intake and hhint Valves B

37' 02-360D Valve Springs B

37 02-360h Cylinder Bead B

37 02-362A Subcover Assembly B

37 02-3904 Rocker Arm Assembly B

37 02-3905 Rocker Arm *=Mnas B

37-02-390B hhint Rocker Arm Assembly B

37 02-390C Pushrods B

37 02-390D Connector Pushrods B

37 02-390G Rocker Arm Bolting B

38 02-340A Connecting Rods and Bushings A

38 02-340B Connecting Rod Bearing Shells A

38 02-341A Piston A

38 02-341C Piston Pin Asse61y A

Cras ahaft Thrust Bearing Ring A

39 02-310C s

39 02-310h Crankshaft A

39 02-311A Crankcase Assembly A

39 02-386B Crankcase Covers Gasket & Bolting C

40 02-355A Crankshaft Pump Drive Gear A

40 02-355B Idler Gear Assembly A

41 02-335B Front Gear Case Bolting C

41 02-395B Gear Case Covers, Gaskets and Bolting C

42 02-371B Fuel Pung Linkage Bearings & Shaft A

42 02-365A Fuel Injection Pung B

42/55 02-455C Fuel Oil Filter Mounting Hardware A

43 02-307A I4be Oil Internal Headers A

43 02-307B Lube 011 TLbing and Fittings A

43 02-307D I4sbe Oil Line Supports B

43 02-465A External I4be Oil Lines A

43 02-465B External Lube Oil Supports A

43 02-467A Turbocharger I4be 011 Piping B

43 02-467B

'angbo I4be Oil Piping Supports B

43 02-5404 I4sbe 011 Susp Tonk B

43 02-5408 Lube Oil Susp Tank Bolting B

43 02-540C I4be Oil Sung Tank Mounting Hrdwre.

B 43 02-CFR Turbo ihrust Bearing I4be Oil System C

44 02-315A Cylinder Block A

44 02-315C Cylinder Liner A

44 02-315E Cylinder Head Studs B

44 02-315F Cyl. Block Jacket Water Manifold Ittts B

44 02-315D Cylinder Block Jacket Water Manifold A

44/53 02-317A Jacket Water Discharge Manifold B

c A-2

Table of Contents Pmnaharm h 2Bgt h Ragt 3mm Claam

'45 02-3504 cmmhaft Assembly A

45 02-350B cm== haft Bearing A

45 02-350C Camshaft thyports, Bolting and Gear A

45 02-345A Intake Tappets A

45 02-3458 Fuel Tappets A

46 02-375 Intake Manifolds B

46 02-383 hhaust Manifold Bolting B

46/56 02-3804 hhanat Manifolds B

47 02-410C Overspeed Trip Drive Coupling A

47 02-410B Overspeed Trip and Accessory Drive A

47 02-411A Speed Regulating Governor Drive A

47 02-411B Speed M 'Inting Governor Coupling A

47 02-413B Fuel Puey Linkage'and Shutdown cylinder B

@ eed W ? ating Governor Linkage A

l 47 02-413A 48 C2-330B Flyuboel Bolting A

49 MP/022/3 TuMharger A

49 02-475A W M harger Bracket B

49 02-475D Tu M harger Bracket Bolting B

49 F-086 Intercooler B

49 02-436B Intercooler Piping Coop., Bolts, Gekts.

B 53-00-7004 Jacket Water Stan@ipe Fittings B

53 00-700C Jacket Water Standpipe Supports B

53 00-700F Jacket Water Standpipe Bolting Materials B

53 02-316h Jacket Water Manifold Assembly B

53 02-316B Jacket Water Manifold Coupling B

53 02-317B Jacket Water Discharge Manifold Coupling B

53 02-317C Jacket Water Discharge Manifold Supports B

53 02-437A Turbo Cooling Water Pipe & Fittings B

53 02-437B Turbo Cooling Water Pipe Supports A

54 02-441A Start Air Manifold Tubing & Fittings A

54 02-441C Start Air Manifold Pipe Supports A

54 02-442B Start Air Dist. Tubings, Fttngs, & Gekts. A 55 02-365C Fuel Injection Tubing B

55 02-365D Fuel Injection Tubing Supports B

55 02-458 Fuel Oil Piping and Tubing A

55 02-450D Fuel Oil Piping Supports A

57 02-50W Control Penel Piping, Tubing & Fittings C

57 02-688h Ehgine & Aux Module Wiring Conduit A

57 02-695A Engine Shutdoun Tubing and Fittings B

A-3

Catahba Dianal M Tna-Hnn Bagott Part Names Air at;agt.Valyn Class:

A Part Nunber: 02-359 Work Request No. M Q2 MNE No. of Separate Inspections:

.40.

Attributaa Verified mod Sagle Siza 1.

Measure length air start valve cap screws per 11.3.2, ref. 1, 8 insp.

2.

Visual inspect valve seat area each valve per 11.3.3, ref. 1, 16 insp.

3.

Visual inspect valve internal surfaces per 11.3.4, ref. 1, 16 insp.

anfarancan 1.

MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection TnawHnn M 1.

'Ihe lengths of the air start valve capscrews were found to be satisfactory.

2.

Visual inspections of the valve seating surfaces were satisfactory.

3.

Visual inspections of the valve internal surfaces were satisfactory.

nienneit inn of Tnn-Hnn Pindtnan There were no significant findings.

A-4

Catamba Dianal 3R Inspection BSDKt PRrt b OMMh Class:

E Part Itsber: jl2.3EB Work Request No.1Q02 MMr No. of Separate Inspections: XL4 i

Attributan.YaKified and Sample Siga 1.

Visual inspections on seat area, valve guides, valve stem surface and top per 11.4.2,3,4,5 ref.1, 256 insp.

2.

Visual exam of valve head weld per 11.4.6 ref. 1, 8 insp.

anfarancan t

1.

MP/0/A/1000/37 Diesel'Ehgine Cylinder Head and Associated Parts special Inspection j

f Insgestica Banulta

1. -

Visual inspections of the valve surfaces showed numerous area of pits and scratches. Eight valves had chiW or peeling chrome plating.

. 2..

Visual inspections of the friction welds were satisfactory.

Disposition af Inspection Findinga 1.

The majority of the reported pits and scratches were evaluated as being the result of normal wear and valves with these indications have been determined to be we*le for reuse.

The valves with peeling and i

flaking chrome plating as well as valves with indications of the onset of chrome plating peeling are to be replaced with new valves.

.) -

A-5 i

Catabba Dianel jg Tnnnect{nn Report Part Name Valve k rinas Class:

B Part Number: 02-362 Work Reg 2 cot No.1Q02 MtE No. of Separate Inspections:

12R Attributaa Verified axl Sangle SiER 1.

Check spring color code per 11.4.7, ref.1, 64 insp.

'~

2.

Visual check intake and exhaust valve spring per 11.4.8, ref. 1, 64 insp.

naferences 1.

MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection Tnanact{nn M 1.

Several valve springs were found to have possibly incorrect color codes.

/

2.

One valve (7L intake) was discovered to have a cracked danper spring.

(part no. 03-360-04AP) nlannai&(nn g Tnannet{nn M 1.

'the acceptance standards for the valve spring color codes was a white stripe down the side of the spring.

In some instances the white stripe has been discolored by heat or oil staining.

The valve springs were evaluated as being acceptable for re-use 2.

'the cracked danper sprinn was replaced.

A-6

Catanha Dianal 3 rna y & inn g g ggt Part Name Cylinder jiand Class:

B

[

Part NLaber: 02-360A Work Request No. 1QQ2 MMf No of Separate Inspections:

32Q Attributan Varified and Saggle Siga 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 11.5.3, ref. 1,80 insp.

3.

Perform ultrasonic thickness measurement of fire deck per 11.5.4, ref. 1, 96 insp.

4.

Visual inspect fire deck area for evidence of weld repairs per 11.5.5, ref. 1, 16 insp.

5.

~Ticual inspect fuel injection nozzle studs per 11.13, ref.1, 32 insp.

6., NT'Jnspect fuel injection nozzle studs per 11.13.2, ref 1, 32 insp.

. },., f <

Jinfarances-7 1.

'MP/0/M1000/37 Diesel Engine Cylinder Head and Associated Parts a 7; e

Special Inspection 4,..

2 N ctict Easulta 1

j '1 j 1.

, ViarA. inspections of the valve seat contact areas showed four seats

/

' C T tith scratches and pits.

p.

i3ne linear indication was noted on the #4 seat of cylinder head 2R.

3r Thichtaa of the fire deck ranged from.486 to.952 inches.

4.

At tivt time of inspection, no cylinder heads showed signs of having been p

weld repaired. Three cylinder heads that were removed due to leaks

'showed evidence of weld repair.

5 Visual laspections of the fuel injector studs were satisfactory.

t o.

.MT inspection demonstrated no rejectable indications.

~

I '.

Jaition gf Ynnytinn Pi_nd{nna s 1.

The galve seats with the defects noted above were resurfaced, lapped and v dvx were reinstalled.

2.

Cylihjer head 2R is to be replaced.

3.

No unusually thin wall thicknesd were observed and all of the wall thicknescus are considered to be acceptable.

4.

All. cylinder heads replaced on the B engine were free from welded plugs.

(

s s

-(t A-7

/l

(

N l, (,

a-

.l,,

h.. <

-.--.-------.,m,,,,

_,--w-.-m,.e

Catamba Diesel la Tnanacrinn Report Part Name Subcover Assenbly Class:

B Part Nanber: 02-362A Work Request No.1002 E No. of Separate Inspections: AQ Attributes Verified agl Sample Size 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.

References 1.

MP/0/A/1000/37 Diesel Engine Cylinder Ecad and Associated Parts Special Inspection Tnanactinn Results 1.

Visual inspections of the subcovers revealed minor chips and scratches.

2.

Subcovers 1R and 7R showed 1 inch long indications in the pedestal sections by PT examination niennait-inn g Tnanact inn Findinan 1.

'1he amall chips and scratches were evaluated as being of no significance.

2.

'1he subcovers with PT indications have been replaced.

A-8

This Page Was Left Blank l

1 i

I i

f L..

t 1

I A-9

Q7h Diesel ja Tnanar+4nn Dannrt Part Names Intake And Intermediate Rocker AIE Assembly Class: R Part No.:

02-390A Work Request No.: lQD2 MNE No. of Separate Inspections:

192 Attributaa Verified add Sanple Siza 1.

Visual inspect intake and int. rocker shaft assenbly 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.

Visual inspect adjusting screw swivel pads per 11.7.6, ref. 1, 32 insp.

References 1.

MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection Tnanar+1nn Results

-1.

Visual inspections of the rocker shaft assenblies were satisfactory.

2.

Visual inspections of the rocker arm lips were satisfactory.

3.

No lips were ground, so this procedure was not applicable.

4.

Visual inspections of the sockets were satisf rtory.

5.

Visual inspections of the adjusting screw feec were satisfactory, however one swivel pad was found to be cracked during operation.

ninnnait-inn g Tnanar+4nn Findinan 5..

The cracked swivel pad was determined to be the result of a

manufactoring error. This part was replaced. 01e other swivel pad cracked when the rocker arm was knocked over in storage. This part was also replaced.

1 A-10

r:

Catamba Diesel la Tnamw+1nn Report Part Name:

Rocker Am nahinan Class: R n

Part No.: 02-390E Work Request No.: 1Q02 EtE No. of Separate Inspections: 48' Attributes Verified ggl Sggle fiiga 1.

Visual inspect Rocker Arm bushings per 11.7.7 and 11.8.7, ref.

1, 48 insp.

References 1.

MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection T - Finn Results 1.

Several of the rocker arm bushings inspected showed minor defects consistant with wear.

Diannai g of Tnanactinn Pindinan 1.

'Jhe defects in these parts have been determined to be resultant of normal wear and the parts are considered acceptable for continued use.

l t

A-ll

Catads Dianel JB Iparw+4nn Report Part Name:

Pvha1st Rocker Am Assambly Class: B Part No.:

02-390B Work Request No.: 1002 MNr No. of Separate Inspections: Afi Attributrs Verified Juxi Sample Sign 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.

Visual inspect adjusting screw swivel pads per 11.8.6, ref. 1, 32 insp.

References 1.

MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection TnanacFinn Results 1.

Visual inspection of the exhaust rocker arm shafts was satisfactory.

2.

Visual inspections of the rocker arm lips were satisfactory.

3.

No rocker arm lips were measured as none were ground.

4.

Visual inspections of the rocker arm sockets were satisfactory.

5.

Visual inspections of the adjusting screw pads were satisfactory.

Diannaitinn of Tnnnectinn Pirvlinan There were no significant findings.

A-12

[

Cat;mtan Diesel 2R Tna-Hnn Report Part Name: Intake and h Pushrods Class: B Part No.'s 02-390C Work Request No.: 1002 ]DK No. of Separate Inspettions: 192 Attrikkites Verified add Sanple Sitit

-1.

Visual inspect intake and erhanat pushrods per 11.9.2, ref.1, 64 insp.

2.

Liquid penetrant exam friction welds per 11.9.3, ref.1, 64 insp.

3.

Visual inspect spherical surfaces per 11.9.4, ref.1, 64 insp.

References 1.

MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection Tnener+4nn Beaults

' l.-

All pushrods were found to be friction welded on visual inspections.

l-2.

PT exam of intake and exhaust pushrods showed no rejectable indications.

l 3.

Visual inspections of pushrod spherical surfaces, showed one pushrod with minor defects.

nisennn4 Finn gf TwHnn Findinna 3.

The minor defects shown on visual examination were evaluated to be the j

result of normal wear and the part will be re-used.

l l

i l

l i

A-13

^

1

Catakba Dianel JB Tnsnect inn Report Part Name: Connector Pushrod Class: H

.Part No.: 02-390D Work Request No.: 1Q02 E No. of Separate Inspections: 10.

Attiibutes Verified axl Sggle Size 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.

References 1.

MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection Tnnnect-inn Results 1.

All pushrods were found to be friction welded.

2.

PT exam of connector pushrods showed no rejectable indications.

3.

Visual inspections of the pushrods were satisfactory.

Dinnnait-inn of Tnaneci-inn Findinan There were.io significant findings.

i A-14

1 Catakba Diesel la Tnnnect-inn Report Part Name:

Rocker AEm Boltlag Class: B Part No.: 02-390G Work Request No.: 10.02 MMI' No. of Separate Inspections: 128.

Attributaa Verified ad Sample Size

1..

Magnetic particle test per 11.11.2, ref.1, 64 insp.

2.

Visual inspect capscrews per 11.11.3 ref.1, 64 insp.

References 1.

MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Innnectinn Results 1.

MT examinations of the rocker arm capscrews showed no rejectable indications.

2.

Visual inspection of the rocker arm capscrew showed a nick in the threads on cylinder 1R, otherwise the inspections were satisfactory.

Diarwwitinn Df Tnawtinn Findinan 1.

The minor defect noted above was considered to be the result of normal wear and the part was evaluated as acceptable for re-use.

l l

l l

A-15

Catata Dianal 2R Tnnmw+1nn Report Part Neune: Connecting Jhada mxl Bushings Class:

A Part Raberg 02-340A Work Requast No.10.01 ME No. of Separate Inspections: 264-Attributes Verified axl Sanple lii2A

-. Visual inspect connecting rods per 11.3.2, ref.1, 24 insp.

1..

i 2.

Perform PT test per 11.3.4 and 11.5.3r ref. 1,-8 insp.

. 3.

Inspect connecting rod bolt contact' surfaces per 11.4.1, ref.1, 40 insp.

4.

Mr inspect cus4:cting rod bolts per 11.4.2, ref.1, 40 insp.

'5.

Visual ins p master rod and link rod piston pin bushings per 11.5.2, 16 insp.

6.-

Measure : surface contact on each connecting rod serration by blue hg per 11.11, ref.1 8 insp.

7.

Measure connecting rod bushing demensions per 11.13, ref. 1, 120 insp.

8.

Visual inspect link rod dowel per 11.14, ref. 1, 8 insp.

c References 1.-

MP/0/A/1000/38 Diesel Ehgine Piston, Rod, Bushing axl Shells Special Inspection Inspection Results 1.

Visual inspection of connecting rods showed several instances of i

minor scratches.

l 2.

PT - ex=inakinna showed areas of pitting on piattm pin bushing 8L, otherwise there were no rejectible indications.

3.

Connecting rod bolt contact surfaces were satisfactory.

4.

MT araminations of the connecting rod bolts showed no rejectable indic2&inna. Five connecting rod bolt washer had linear indications.

5..

Visual inspection of cuni::cting rod bushings showed several instances of minor pits, scoring and scratches.

6.

Surface contact of the cuid:cting rod serrations was measured to be 80-954.-

L 7.

All connecting rod bushing dimmsions were satisfactory.

8.L Visual inspections of the link rod dowels were satisfactory.

Dispnaition gf Tnanar+{nn Findings 1.

The minor scratches on the connecting rods were considered acceptable.

2.

The pitting shown on the PT examination was determine to be resultant of normal wear-and is considered acceptable.

A-16

4.

The linear indications on one washer polished out in aprox.

.010 inches, i.e., were insignificant. Metallurgical exam showed no indication in the other four washers.

5.-

The indications noted were evaluated to be the result of normal wear and the biahings are acceptable for re-use.

6.

Surface contact is within the TDI recomended clearances.

i A-17

Catad m Dianel la Tnn y tinn Report Part Name: cnnnecting Egd Roarino Rhs.lla Class:

A Part Nunber: 02-3403 Work Request No. 10D3 E No. of Separate Inspections: 212 Attributes Verified add Ramle Size 1.

Visual inspect crankpin shells per 11.5.2, ref.

1, 20 insp.

2.

Liquid penetrant inspect per 11.5.3, ref. 1, 16 insp.

3.

X-ray inspection per 11.5.4, ref.' 1, 8 insp.

References 1.

MP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shell Special Inspection TnanecFinn Results 1.

Visual inspection of the crankpin bearing shells showed nultiple instances of minor scratching, pitting, and gal-ling.

- 2.

PT exans showed no rejectable indications.

3.

Er examination showed one bearing shell half to be rejectab-le and two others which are limited to use as upper shells.

Diannaition Df IDSDEChiQn Findingn 1.

The minor defects listed above were not considered to be excessive wear and not detrimental to engine performance.

3.

'Ibe shell with a rejectable RT indication was will be l

replaced.

l 1

A-18

a Cataba Diesel AB TnanacFinn Report Part Name: Piston Class:

A Part Number: 02-341A Work Request No.10.031RE No. of Separate Inspections:

Afi.

Attributes Verified add Sample Size 1.

Visual inspect fitup of crown to skirt per 11.6.1, ref. 1, 16 insp.

2.

~ Liquid penetrant inspect stud bosses in crown and skirt area per 11.6.5, ref. 1, 160 insp.

3.

Measure surface hardness of piston skirt per 11.8.4, ref. 1, 16 insp.

References 1.-

MP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shells Special Inspection Tnanar+4nn Mts 1.

Visual inspections of crown to skirt fitup were satisfactory.

2.

.PT exans of the piston stud bosses showed no rejectable indications.

3.

The surface hardness of the piston skirt ranged from BHN 199-289.

4.

PT inspections showed two areas of small rejectable indications in the piston pin race areas of pistons 3R and 6R.

These appear to be areas of porosity and/or casting defects.

5.

MT. inspections showed two skirts with indications in the pad areas of belleville spring contact (lL,3L), two skirts with indications on the exterior surface ' (2L,2R),

one skirt with a amall circumferential indication in an interior rib (lL) and two skirts with axial indications

in the interior ribs (1R,6L). 'All indications except the last two appear to be porosity and/or minor casting defects.

n Diannaitinn gf Tnarww+1nn Findinon 3.-

The hardness of the piston skirts were on the average 12% less than those measured at the '1DI factory.

This discrepancy is thought to be the result of such effects as surface roughness and probe positioning and is considered acceptable.

4&5 These inspections were performed on the AN skirst removed from the engine. As the AN skirts were replaced with AE skirts, these inspections

.are provided for information only.

t' A-19 ll'

~_..._._-.r_

,,...,,m.-._._m.__,-_,,

._,....._.m.______,.....,..,,_.,_..,_m_

Catakba Diesel 3 Tnanectinn Report Part Name: Pinton lin Annochiv Class:

A Part Nunber: 02-341c Work Request No. 1003 HNr No. of S. wate Inspections:

H Attributes Verified 20$1 R^ T

• SiKR l

1.

Visual inspect per 11.7.2, ref.1,16 insp.

Refereux:e6 1.

MP/0/M1000/38 Diesel Engine Piston, Rod, Bushings and Rhplin Special Inspection Tnanectinn Rwn1tg 1.

Visual inspcction of the piston pins denonstrated one pin with a small chip and another with a small scratch, all others were satisfactory.

Digposition Of Tnanactinn Findinan 1.

Defects noted on visual inspection were evaluated as being cosmetic and the parts are considered acceptable for re-use.

l l

l A-20

r __

Catamba Diesel 3B Tnnnocrinn Report Part Name: Crankshaft % rust harino EiDg Class:

A Part Nunber: 02-310C Work Request No.:10.01 m No. of Separate Inspections:

2 Attributes Verified add Ra ? a Size l

1.

Measure thrust clearance per 11.3.1, ref. 1, 2 insp.

References 1.

MP/0/A/1000/39 Diesel Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase Asserbly and Crankcase Covers Special Inspection Tnmi-inn Results 1.

Hot and cold clearances were found to be satisfactory.

Diarmitinn gf Tnamw+4nn Findinan There were no significant findings.

4 I

i 1

l i

I I

f A-21 l

L

J

^

Catahba Dianel Jg Tnunar+1nn Report.

Part Name Crankshaft

. Class:

A-Part Mmber: 02-310A Work Request No.10.02 HNE No.,of SepLrate Inspections: Et Attributaa Verified 331 Sugale Size l..

Visual inspect crankpins 1-8 per 11.4.1, ref. 1, 8 insp.

2.

Measure web clearance per 11.3.1, ref. 1, 16 insp.

i

.3.

PT inspect oil holes of main bearing journals per 11.6.1, ref.l. 6 insp.

4.

BCT inspect oil lules per 11.6.2, ref. 1. 6 insp.

Rafarances l.

MP/0/W1000/39 Diesel' Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase Assenbly, and Crankcase Covers Special Inspection Inspection Beaults 1.

Results of the visual inspections of the crankpins were satisfactory.

2.

Hot and cold clearances were satisfactory.

3.

The results of the PT inspection of the oil holes were satisfactory.

4.

- Two small indications were found in oil hole 6 by BCT.

ninnnaiFinn gf Tnenar+4nn Findinna 4.

The ECT indications were found in an area of machining marks. These indications were removed after polishing less than.001 inches.

l l

(

?

l l

L i

A-22 l

(

z

.r,n

...-...e.+em,--.-,-.y-,,,2w--

,..-wr.e.._--,-,.m...,_.--e-,,m, mw,,.-,,w,,,...-,y, 3.-,e-,-,.--y,-mm.~,.,,..,,,.---

.ww-,-.

Catahba Diesel la Innnectinn Renort Part Name: Crankcase Annanbly Class:

A Part Nunber: 02-111A Work Request No. 1007 MtE No. of Separate Inspections:

la Attributes Verified axl Sanple Size 1.

Visual inspect area between machined bolt hole surfaces and cast surfaces for smooth radii per 11.5.1, ref.1,18 insp.

References 1.

MP/0/A/1000/39 Diesel Engine Crankshaft and 'hlrning Gear, Gear, Crankshaft

Bearings, Crart. case Assenbly and Crankcase Covers Special Inspection Tnaret-inn Results 1.

Visual inspections of the bolt hole matched surfaces were satisfactory.

Diannait-inn of Tnarwt-inn Findinan There were no significant findings.

A-23

Catamba Diesel R InanacFinn pannrt Part Name: Crankcase Covers Gukais md Bolting Class: C Part No.: 02-386B Work Request No.: 10.01 E No. of Separate Inspections:' li Attributes Verified ad Sanple Size 1.

Visual inspect :rankcase covers per 11.5.2, ref 1, 16 insp.

References 1.

MP/0/A/1000/39 Diesel Engine Crankcase and Turning Gear, raar Crankshaft Bearings, Crankcase Assenbly and Crankcase Covers Special Inspection TnanacFinn Resu.tr.s

-1.

Visual inspections of the crankcase covers were satisfactory.

DinnnaiFinn gf Tnanantinn Findinas There were no significant findings.

i i

i l-A-24

+

-r w

e r-,

r--

,sm-

,.-e-,-n-

.---,-,,-..,,r e,rw,w

-n--_,

-,,, -..,, ~,, -

n

.m

,,..,-.v-,,w,

,---e..,,

Catahba Diesel JB InaneHnn Report Part Names Crankahaft Bgig Drive h Class:

A Part NLaber: 02-355A Work Request No. 10.01 MNE No. of Separate Inspections:

2 Attributes Verified add SulGlR SiZR 1.

Visual inspect crankshaft gear per 11.2.2 ref.1 1 insp.

2.

Visual inspect punp drive gear per 11.2.4 ref.1 1 insp.

References 1.

MP/0/A/1000/40 Diesel Engine Idler Gears and Punp Drive Gears Inspections and Adjustments TnaneHan Results 1 & 2.

Visual inspections of the two crankshaft gears were satisfactory.

DiannaiHnn of TnaneHnn Findinan There were no significant findings.

A-25

t Catanba Diesel 3B Innet-inn Report Part Names Idler faAAg Annenhly Class:

A Part Nunber: 02-355B

' Work Request No.lDQ11912'

- No. of Separate Inspections: A Attributes Verified E d Sanple Sizgt 1.

Visual inspect idler gears per 11.2.3, ref.1, 2 insp.

2.

Measure backlash of assembly per 11.3, ref. 1, 6 insp.

References 1..

MP/0/A/1000/40 Diesel Engine Idler Gears and Pung Drive Gears Inspections and Adjustments Tnarw+{nn Results 1.

Visual inspections of the idler gears were satisfactory.

2.

Gear backlash was measured and found to be satisfactory for an engine that has seen extended service.

Diannaltigg g Tnnet-inn Results There were no significant findings.

A-26

catadue Diesel la Tnanant inn Re9 ort Part Name: Front faSRI Cagg unitina Class:

C Part Nanber: 02-335B Work Request No.:1005 MHP No. of Separate Inspections:

2 Attributes Verified mgl Saggle Sigg 1.

Examine periphery for oil leakage per 11.1, ref. 1, 1 insp.

2.

Visual. inspect gear case capscrews per 11.2, ref.1,1 insp.

References 1.

MP/0/A/1000/41 Diesel Engine Gear Case Gaskets and Bolting Special Inspection Tnanar+1nn Results 1.

%e left front cover showed a concentration of oil near the gaskets.

2.

Chie capscrew was found with no markings.

Dinnnait-inn of TnanacFinn Findinan 1.

S e concentration of oil was determined to be the result of previous maintenance work and was not consider (d to be indicative of gasket leaks.

2.

Capscrews found without markings were replaced with screws of appropriate j

grade.

l i-i l

l A-27 l

Catanba Diesel JB Tnnnactinn Report Part Name: faeRE CRae covern/cankern add Bolting Class: C Part No.: 02-395B Work Request No.:1005 HNE No. of Separate Inspections: 2 Attributes Verified add Sanple Size 1.

Visual inspect for oil leakage per 11.1, ref.1,1 insp.

2.

Visual inspect capscrews per 11,2, ref. 1, 1 insp.

References 1.

MP/0/A/1000/41 Diesel Engine Gear Case Gaskets and Bolting Special Inspection Tnanact inn Results 1.

.The left side cover was found with a concentration of oil near the gaskets.

2.

Five capscrews were found to have no markings.

DiannaiFinn g Tnanact-inn Findinan 1.

The concentration of oil was determined to have been the result of previous maintenance work and is not considered indicative of leaks.

, 2.

Capscrews found with no markings were replaced with s., crews of appropriate grade.

A-28

Catanba Diesel la Tnanact-inn Report Part Name:

Eual Bag rankane. naarinna and shaft Class: A Part No.: 02-371B Work Request No.:1012 MHI' No. of Separate Inspections:

3.

Attributes Verified add SAEGlR SiER 1.

Visual inspect fuel pung linkage per 11.1.2, ref.1, 2 insp.

2.

Check site h = ntation to ensure M ate lubrication per 11.1.3, ref 1, 1 insp.

References 1.

MP/0/A/1000/42 Diesel Engine Fuel Punp and Linkage Special Inspection TnanacFinn Results 1.

Visual inspections of the fuel pung linkage were satisfactory.

2.

Site h-ntation was checked and an adequate lubrication schedule is in place.

niennait-inn Of Tnanect-inn Pindinam There were no significant findings l

I i

A-29 I

---

+%,g--

e

,,--9en

,.---_-.---p

,--.,,,__g

_p,eA-,e,s

,,nw_,.p.,----m yepm,,w%g,.r wg%-,.7-ew7.n

1 Catadm Diesel 23 Tnnnect-inn Egggt Part Names Eucl Inject inn Bay Class: H Part No.:

02-365A Work Request No.:1Q1Q MMt 1

No. of Separate Inspections: 32

. Attribt*en Verified 3;)d Ramnlo gigg 1.

Visual inspect for punp valve holder per 11.2.2, ref.1, 16 insp.

2.

MT inspect delivery valve assenbly per 11.4.3, ref. 1, 16 insp.

References 1.

MP/0/A/1000/42 Diesel Engine Fuel Punp and Linkage Special Inspection inanact-inn Results 1.

Visual inspections of the fuel pump valve holders were satisfactory.

2.

MT inspections of the delivery valve blocks showd no rejectable indications.

niennait-inn g Tnanant-inr Findinna 2.

Three delivery valve blocks were found cracked during or after the extended run test. All valve blocks replaced on the engine were MT inspected and no rejectable indications were found.

l A-30

Catanba Diesel la Tnanaction Jggg t, Part Names DML1 Q11 Filter mmtina Hardware Class: A Part No.: 02-455C Work Request No.:1DlQ HNE No. of Separate Inspections: 2 Attributes Verified ggl Sanple Size 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 11.3.1. ref. 2.

1 insp.

References 1.

'MP/0/A/1000/55 Diesel Engine Fuel Piping System Special Inspection 2

MP/0/A/1000/42 Diesel Engine Fuel Punp and Linkage Special Inspection TnanacFinn Results 1.

Visual inspections of the mounting hardware were satisfactory.

2.

Torque of the fuel oil filter bolt was found to be correct.

DiannaiFinn g TnanacFinn Findinna There were no significant findings.

l A-31

Cataiba Diesel la Tnanaction Report Part Name:

Isaba Qi1 Tnearnal Headers Class: A Part No.:

02-307A Work Request No.:1015 MtlE No. of Separate Inspections: 1 Attributes Verified ggl Rannle Size 1.

Visual inspect headers per 11.3, ref. 1, 1 insp.

stferences 1.

MP/0/A/1000/43 Diesel Engine Inbe Oil System Piping and Sunp Special Inspection Tnanact-inn Results 1.

Visual inspections of the lube oil internal headers were satisfactory.

Diannait-inn of Inspss: tion Findinna i

% ere were no significant findings.

l l

r i

l I

A-32 l

Catanba Diesel 111 Tnanactinn Report Part Name:Intut Oil Tubino m31 Fittinan Class:A Part No.: 02-307B Work Request No.:1015 MbE No. of Separate Inspections 2 Attributes Verified agi Sample Size 1.

Visual inspect internal lube oil system tubing and fittings per 11.3, ref. 1, 1 insp.

2.

Visual inspect external lube oil system tubing and fittings per 11.4.1, ref.1, 1 insp.

References 1.

MP/0/A/1000/43 Diesel Engine Imbe Oil System Piping and Supports Special Inspection Tnanactinn Results 1&2 Visual inspections of the internal and external lube oil tubing and fittings were satisfactory.

Diannaitinn of Tnanactinn Findinan There were no significant findings.

A-33

~_.

Catahta Diesel la Insnecth Report Part Name:

Iaba Dil Line Suoports Class: B Part No.:

p2-307D Work Request No.:1015 HNE No. of Separate Inspections: 1 M.utes verified add Ra"nla Size 1.

Visual inspect supports per 11.3, ref. 1, 1 insp.

References 1.

MP/0/A/1000/43 Diesel Engine Imbe Oil System Piping and Sung Special Inspection Tnansv+b Results 1.

Visual inspections of the lube oil line supports were satisfactory.

Diarvwaltion gf Tnawt-inn Firvlinan There were no significant findings.

A-34

!~f

. i!lif V

.g ll l Catahba Dianel M Tnsnect inn Dannrt

~

/,

/

Part Names'.

External Id2Mt Qil Linen Class: A

,.Part No.:

02-465A Work Request No. 10H MMt

/ No.,of.,

ate Inspections: 1 r.

,~

Attributes Verified m)d Sanple Sigg 1.

Visaal inspect lube oil lines per 11.4, ref.1,1 insp.

/

Referencoa 1.

MP/0/P/1000/43 Diesel Engine Lube Oil System Piping and Sung Special Inspection

.'d Tnaprrtisan Results I:

1. Visual inspections of the external lube oil lines were satisfactory.

J.s 11 1,

,(

~.l -

o

/- (

Disponitio9 Df Tnanar+4nn Findinna s.

r,j

'there were no significant findings.

t e

e 4.

,f;f i

.~

lr'.

I 4

/

\\

\\.

A-35 i

?

r Catahba Diesel la InsnecHnn Report Part Name:

External Igbg Qil mmnnrts Class: A Part No.:

02-465B Work Request No.:1015 MHC No. of Separate Inspections: 1 Attributes Verified add Sanple Size 1.

Visual inspect supports per 11.4, ref. 1, 1 insp.

References 1.

MP/0/A/1000/43 Diesel Engine Lube Oil Systan Piping and Sunp Special Inspection Tnspection Results

1. -

Visual inspections of the external lube oil supports were satisfactory.

Dismnnition d TnanacHnn Findinan There were no significant findings.

l i

I-l l

A-36 y

x..

-...-,r,..

e.m-.e

,-.,w.~-,-.,

-.,,,-,y

Catakba Diesel JR Tnanact inn Report-Part Name:

w-hncharger Imbe Qil Pipina Class: H Part No.:

02-467A Work Request No.: 1015. MMI' No. of Separate Inspections: 1 Attributes Verified axl & g Size 1.

Visual inspect piping, tubing and fittings per 11.5, ref. 1, 1 insp.

References 1.

MP/0/A/1000/43 Diesel Engine Inbe Oil Piping and Sunp - Special Inspection Tnanant-inn Results 1.

Visual inspections of the turbocharger lube oil piping were satisfactory.

Diannait inn gf Tnanact-inn Findinon There were no significant findings.

l-l l

l l

A-37 i

,. -. -, ~., -.. - -...

Catahba Dianel 3 Tnanetinn Report Part Name:

Ttirbo I412g Qil Pinino Supports Class: H Part No.: 02-467B Work Request No.:1015 MNE No. of Separate Inspections: 1 Attributes verified m3d Sanple Size 1.

Visual inspect turbo lube oil piping supports per 11.5, ref. 1, 1 insp.

References 1.

MP/0/A/1000/43 Diesel Engine Lube Oil Piping and Sung - Special Inspection T - tinn Results 1.

Visual inspections of the turbo lube oil piping supports were satisfactory.

Dinnnaitinn of TnaneFinn Findinan There were no significant findings.

A-38

Cata@ a Diesel JB Tna w tinn Report Part Nans:

IJJbR Dil SEID TaDL Class: R

.Part No.:

02-540A Work Request No.:1015 MNE No. of Separate Inspections: 1 Attributes Verified W Suggle Size 1.

Visual inspect lube oil sunp per 11.4, ref.1,1 insp.

References 1.

.MP/0/A/1000/43 Diesel Engine Inbe Oil System Piping and Sunp Special Inspection Tnstw+ inn Results 1.

Visual inspections of the lube oil sung tank were satisfactory.

Diarwtition of IrLP'i-inn Finelinan There were no significant findings.

A-39

i Catamba Diesel 23 Tnnweinn Report Part Nane:

Imbst Oil Sag Tank Bolting Class: R Part No.:

02-540B Work Request No.:1015 ENE No. of Separate Inspections: 1 AttribuFan Verified ggi Sgglgt Siggt 1.

Verify mounting bolts are correctly installed per 11.4.2, ref.1, 1 insp.

References 1.

MP/0/A/1000/43 Diesel Engine Inbe Oil System Piping and SU)mp -

Special Inspection TnarwFinn Results 1.

Visual inspections of the lube oil sunp tank bolting were satisfactory.

Diannaitinn of Tnarwtinn PinrFnon There were no significant findings.

A-40

Catanba piesel la Insnectinn Peport Part Name: J.MbR Qil SElp TaDk Mounting Hardware Class: H Part No.: 02-540C Work Request No.:1015 MNE No. of Separate Inspections: 1 Attributan Verified add rat

• SIZE l

. l..

Visual inspect sung tank supports per 11.4.1, ref.1,1 insp.

References 1.

EP/0/A/1000/43 Diesel Engine Inbe Oil Systen Piping and Sung -

Special Inspection TnareFinn Results 1.-

Visuel inspections of the lube oil sunp tank mounting hardware were satisfactory.

Diarww.itinn Df Tn.-Finn Findinan

'1here were no significant findings.

A-41

_ _ -,..... -. - -.., = _ -

Catanba Dianel JH Innretion Report Part Name: 'Birho. Thrust naarina Inbe Oil Svn&am Class:C Part No.: 02-CPR Work Request No.:1015 E No. of Separate Inspections:1 Attributes Verified mgl Sanple Size 1.

Visual inspect turbo. thrust bearing lube oil system per 11.5, ref.1, 1 insp.

References 1.

MP/0/A/1000/43 Diesel Engine Inbe Oil Piping and Sunp Special Inspection Tnanactinn Results 1.

Visual inspections of the turbo thrust bearing lube oil system were satisfactory.

Diannaihinn gf Innnectirm Findinan There were no significant findings.

A-42

Catamba Diesel ja Tnamw+ inn Report Part Name: Cvi%r BlodL Class:

A Part Ntaber:.

02-315A Work Request No. 10.01 MtE l

No. of Separate Inspections:

SA Attributes Verified add Sample Eigg 1.

Liquid penetrant inspect cylinder block top per 11.2.1, ref. 1, 16 insp.

2.

UT inspect cylinders per 11.2.3, ref. 1, 16 insp.

3.

Dimensional inspect cylinder liner landing area per 11.6.1, ref. 1, 32 insp.

4.

PT inspect cylinder liner landing area per 11.6.2, ref.1, 4 insp.

References 1.

MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspections Tnanent-inn Results 1.

Liquid penetrant of the cylinder block tops showed no rejectable indications.

2.

-UT was not necessary as PT results were satisfactory.

3.

Dimensions of the cylinder liner landing area were taken and will be forwarded to the Owners Group.

. 4.

PT examinations of the cylinder liner landing areas showed no rejectable indication.

4 ninnnait-inn gf Tnanact inn Finclinna There were no significant findings.

A-43

Catamba Diesel E Tnanact-inn Report Part Name: Cvlindar Liner Class:

A Part Nunber: 02-11'M' Work Request No. 1003JgE No. of Separate Inspections:

1Pd Attributes Verified and Sanple Size 1.

Visual inspect cylinder liner per 11.3.1, ref. 1, 16 insp.

2.

Measure bore per 11.3.2, ref. 1, 96 insp.

3.

Measure dist. cylinders protrude above block per 11.3.3, ref. 1, 64 insp.

4.

Supplement visual inspections of liner per 11.6.3, ref. 1, 4 insp.

5.

Dimensional insp. cylinder liner per 11.6.4, ref. 1, 4 insp.

References 1.

MP/0/A/1000/44 Diesel Engine Cylinder Blcck, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection Tnaneci-inn Results 1.

Visual inspections of the cylinder liners showed minor scratches and scoring.

2.

Measurements of the cylinder liner bore were within specified tolerances.

3.

-23 of 64 measurements of cylinder liner protrusion were lower than nominal tolerances of.005 to.007 inches.

4.

Supplemental visual inspections of the cylinder liners showed scuff marks and discolorations.

6.

The dimensional inspections yielded the following results:

O.D Lip -

19.497" - 19.499",

O.D.

seat surface - 18.988" - 18.993",

Height 1.504" - 1.505".

niennaitinn of Tnanant-inn Findinam l

1.

Minor scratches in the cylinder liners wese polished out by honing. %e liners are considered acceptable for re-use.

3.

Measured protrusion of the 23 measurements which were lower than the nominal ranged from.002 to.0045. This is considered acceptable for i

continued operation.

I 4.

S e scuff marks and discolorations found on supplemental inspections of the cylinder liners are considered to be the result of normal wear and are acceptable.

l-I A-44 l

-. _., _ _ _ ~ - -. _ _ - - - - - ~ _ _. _. -

Catanba Diesel ja Tnnnection Report Part Name: cylinaar Hebd Studa Class:

H Part Nunber: 02-315E Work Request No.1023 Hbu' No. of Separate Inspections:.61 Attributes Verified add Sanple Size 1.

Inspect head studs for ID marks per 11.4.1, ref. 1, 32 insp.

2.

Visual inspect head studs per 11.4.2, ref. 1, 32 insp.

References 1.

MP/0/A/1000/44 Diecel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection Tnnretinn Results 1.

Inspections of head studs showed appropriate identification nunbers.

2.

Visual inspections of cylinder head studs were satisfactory.

Diarmit-inn gf Tnarwi-inn Findinan There were no significant findings.

A-45

Cata h Dienel JH Tnanaction Report Part Name: Cvlindar Block Jacket Water Manifold Nuts Class: H Part Nunber: 02-315F Work Request No.10.03 E No. of Separate Inspections:

2E Attributes Verified m)d Ramle h 1.

Visual inspect all 5/8" nuts per 11.5.1, ref. 1, 22 4.nsp.

2.

Visual inspect 25% water manifold nuts per 11.5.2, ref.

1, 4 insp.

References 1.

MP/0/A/1000/44 Diesel Engine Cylinder Bleck, Cylinder Jacket Water Manifold and Piping Special Inspection Tnanactinn Results 1.

No identification marks were found on visual inspection.

2.

No evidence of cracks or forging laps were found on visual inspection.

niennaitinn g inanaction Findinga 1.

Nut identification markings were for information only.

No marks on the nuts were found.

The nuts have performed satisfactorily in service and are therefore considered acce-ptable. There were no significant finds.

A-46

- - - - - _ _ =. -

Catahba Diesel la Tnanectinn Report Part Name: cylindar Bloc lL Jacket Water Manifold Class: A Part Nunber: 02-11 cin Work Request No.10.03. HNE No. of Separate Inspections:

1 Attributes Verified mod Suple Size t

1.

Visual inspect water manifold and piping per 11.5.4, ref. 1, 1 insp.

References 1.

MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspec'lon c

Tnanar+1nn Results 1.

Visual inspections of the jacket water manifold were satisfactory.

Diarmia-inn gf Tn-Finn Findinna

'there were no significant findings.

i 4

A-47

4 M Digel JR Tnamr+1nn Raiport Part Name: M Hatag Dischagga Manifold Class:

B Part Number: 02-317A Work Request No.1Q0a stE 1

No. of Separate Inspections:

2 4ttributes Verified,and Sample Siza 1.

Visual inspect jacket water manifold per 11.5.4, ref.1,1 insp 2.

Visual inspect manifold per 11.5, ref. 2, 1 insp.

4' naferences 4

1.

MP/0/V1000/44 Diesel Ehgine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection 2.

MP/0/V1000/25 Diesel Engine Jacket Water System Piping Standpipe and Manifold Special Inspection Inapaction flasulta

'l.

Visual inspections of the jacket water discharge manifold were satisfactory.

2.

Walkdown inspections of the jacket water discharge manifold were satisfactory.

Dispositinn gf Tnanar+4nn PinrHnna There were no significant findings.

A-48

Catamba Diesel 3 Tnan crinn Rgort Part Name M Aasenbly Class:

A Part Nunber: 02-350A Work Request No. 1021 stE No. of Separate Inspections:

M Attributes Verified add Sanple Sigg 1.

Visual inspect camshaft lobes per 11.3, ref. 1, 48 insp.

2.

Inspect locking clips both camahafts per 11.4.3, ref.1, 2 insp.

References 1.

MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Assenbly Special Inspection in=nacFinn Results 1.

Visual inspection of the camshaft lobes was satisfactory.

2.

The inspection of the locking clips was satisfactory.

niannalFinn g Tnanactinn Findinna 1.

'Ihere were no significant firdings.

A-49

Catahba Diesel 3 Inarw+1nn Report Part Names fanshaft %rina Class:

A Part Nanber: 02-350B Work Request No. 1Q11 MtD' No. of Separate Inspections

.1 Attributes Verified mui Sanple Siga 1.

Visual inspect left and right outboard support bushings per 11.4.2, ref.1, 4 insp.

References 1.

MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Assenbly Special Inspection Tnan etinn Results 1.

Visual inspection of the outboard support bushings was satisfactory.

Dinnnaition Of Inarut-inn Pindinas

'Ihere were no significant findings.

i A-50

[

Catatla Diesel 23 Tnan etinn Report Part Name: Cunhaft mmnrts, hitina mM1 h Class:

A Part Nunber: 02-350C Work Request No. 1011 Mtg No. of Separate Inspections:

2 Attributas Verified axl Femple Size 1.

Visual inspect left and right camhaft gears per 11.5.4, ref.1, 2 insp.

References 1.

MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Assenbly Special Inspection Tnanerinn Ensulta 1.

Visual inspection of the camshaft gears was satisfactory.

Dinnnaitinn gf Tnanetinn Findinan There were no significant findings.

1 F

A-31

Catamba Diesel la Inspection Report Part Name: Inhalte Tappeta Class: A Part Ntaber: 02-345A Work Request No. 1Q11 MtE No. of Separate Inspections:

12 Attributes Verified And Sanple Size 1.

Visual inspect tappet rollers per 11.6.1, ref. 1, 12 insp.

References

-1.

MP/0/A/1000/45 Diesel Engine Canshaft, Canshaft gear and Tappet Assembly Special Inspection T e t-fem M 1.

Visual inspections of the intake and exhaust tappet rollers were satisfactory.

niernait inn gf Tnanant inn Findinna

~

Sere were no significant findings.

l A-52 l

~. _..

Catahba Diesel 2R Tnanactinn Report Part Name Euel Ta; meta Class:

A Part Itaber: 02-345B Work Request No. 1Q11 MtE No. of Separate Inspections:

12 Attributes Verified Jed Sanple Siza 1.

Visual inspect tappet rollers per 11.6.1, ref. 1, 12 insp.

Befarances 1.

MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Assenbly Special Inspection T w &4nn Results 1.

Visual inspection of the fuel tappet rollers was satisfactory.

Dinnnaltinn g Tnanactinn Findinna There were no significant findings.

A-53

Catahba Diesel 3 inanactinn Report Part Name: Intake Manifolds Class:B Part No.: 02-375 Work Request No.:1QQ2 HNE No. of Separate Inspections 32 Attributaa Verified mgl Sanple Size 1.

Visual inspect surfaces and bolt holes per 11.2.2, ref. 1, 32 insp.

References 1.

MP/0/A/1000/46 Diesel Engine Intake and Exaust Manifolds Special Inspection TnanacF{nn M 1.

Visual inspections of the intake nanifolds showed several instances of nicks, scratches and burrs.

Dinnnalt inn gf Tnanact inn Pind{nna 1.

The minor scratches and nicks found on visual inspection are the result of normal wear and are considered acceptable.

A-54

Catatha Diesel la Tnnrweinn Report Part Name: h Manifold noitina Class: B Part No.: 02-383 Work Request No.:1QQ2 MME No. of Separate Inspections:1 Attributes Verified add Sanple Size 1.

Visual inspect capset s 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.

References 1.

MP/0/A/1000/46 Diesel Engine Intake and Exaust Manifolds Special Inspection Tnnretinn Results 1.

Iangths of the capscrew were within specified tolerances.

2.

Depths of the capscrew holes were satisfactory.

Diannaitinn gf Tnarekinn Findinna There were no significant findings l

A-55

~_

Catakta Diesel JB inanactinn Report Part Name:

Exhaunt Manifold Class: H Part No.:

02-380A Work Request No.:10.02 E No. of Separate Inspections: 11 Attributes Verified add SaBGlR 3132 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.

F2/0/A/1000/46 Diesel Engine Intake and Exhaust Manifolds - Special Inspection 2.

MP/0/A/1000/56 Diesel Engine Exhaust Manifold - Special Inspection inanactinn Results 1.

Visual inspections of the exhaust manifold to flange weld were satisfactory.

2.

Visual inspections of the exhaust manifold were satisfactory.

?

l.

D{nnnaition g Tnnnect inn Pind{ nan There were no significant findings.

l i

l l

A-56

Catahba Diesel JR Tnumw+1rm Report Part Name:O mrapeed TIjg Drive c< m lina Class: A Part No.: 02-410C Work Request No.:1008 MNc No. of Separate Inspections: 1 Attributes Verified axl Sample Size 1.

Note condition of elastomer piece per 11.3.1.1, ref.1, I insp.

References 1.

MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassenbly Inspection and Reassenbly Tn - tirm Results 1.

'Ihe elastomer piece was found in satisfactory condition.

Dinnnait fem gf Tnaret len Pirvlinan

'1here were no significant findings I

A-57

Catanha Diesel 13 Tnanactinn Report Part Names Overspeed Trig mgl Accessorg Drive Class: A Part No.:

02-410B Work Request No.:1Q0H MtE No. of Separate Inspections: 2 Attributaa Verified mgl Sanple Size 1.

Visual inspect O.S. trip drive drive gear per 11.3.2.1, ref.1,1 insp.

2.

Visual inspect O.S. trip drive driven gear per 11.3.2.2, ref.1,1 insp.

Referencec 1.

MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drive - Disassenbly, Inspection, and Reassenbly Tnanaction Results 1&2 'Ihe visual inspections of the drive and driven gears were satisfactory.

D{annnitinn gf TnanacFinn F1ndinan

'1here were no significant findings.

A-58

Catanha Diesel la TnareHnn laannrt Part Name % sed naanlaHno Governor Drive Gear / Shaft Class:A Part No.: 02-A11A Work Request No. 1QQS HNC No. of Separate Inspections:2 Attributaa Verified add Sanple Size 1.

Visual inspect larger horizontal shaft drive gear per 11.5.2.1, ref. 1, 1 insp.

2.

Visual inspect snall horizontal shaft drive gear per 11.5.2.2, ref.1, 1 insp.

Haferences 1.

MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drive-Disassenbly, Inspection, and Reassenbly inar-Hnn m 1&2 Visual inspections of the drive gears were satisfactory.

Diannnitinn g Tnaret-inn Findinan There were no significant findings.

l l

A-59 i

Catabba Diesel la Tnnet-inn Report Part Name:% sed Dannlatina Gay Drive ennnlina Class:A Part No.: 02-411B Work Request No.:1008 MNE No. of Separate Inspections:2 Attributes Verified add Sanple Size 1.

Visual insp e t coupling hidves, shaft ends and spacers per 11.5.2.3, ref. 1, 2 insp.

References 1.

MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassenbly Inspection and Reassenbly.

Tnn w tinn Results 1.

Visual inspections of the coupling couponents were satisfactory.

D{annait inn gf Tnn-t inn Find { nan There were no significant findings.

A-60

Catahtn Diesel la Tnanactinn Report Part Names Eual Puno L{nkane Jggi Shutdan cylinder Class: R

-Part No.:

02-413B Work Request No.:100A HMc No. of Separate Inspections: 2 Attributen Verified add Sanple Size 1.

Check linkage action per 11.6.1, ref. 1, 1 insp.

2.

Visual inspect cross shaft assenbly per 11.6.2, ref. 1, 1 insp.

References 1.

MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives - Disassetbly, Inspection, and Reassenbly Tn - Finn Results 1.

The extensible linkage action was found satisfactory.

2.

Visual inspections of the cross shaft assenbly were satisfactory.

Blannaitinn of Tnannetinn Findingg There wre no significant findings.

A-61

l Catad)a Diesel AB Tnanactinn Report Part Name:4mm1 Raquiatines h rinkyo Class:A Part No.: 02-413A Work Request No.:100R MtE No. of Separate Inspections 2 AM;Ejhutsg Verified ami Sanple Slag 1.

Check linkage action per 11.6.1., ref. 1, 1 insp.

2.

Vianal inspect cross shaft per 11.6.2., ref.1,1 insp.

amferences 1.

MP/0/A/1000/47 Diesel Engine Governor and 0.vrspeed Trip Accessory Drives Disassenbly Inspection and Reassembly TnanacFfnn M 162 Linkage and shaft visual inspections were found to be satisfactory.

Disposition gf Tnanactinn Findinam There were no significant findings.

(

A-62

j5,

~t qly c 3

,- /.,

. li!.

' k,[' N ft.mba Dianel IB Tn==+im Egor.t ur

(

^

Part Nane: ElyMhaal h1eim Class:

A Part Nu.nter: 02-330B Work Request No. 10.09.190' i.

No. of Separate Inspections:

2d Atirlbad.ag tJarified agi Sanple Siza 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 I

cennartted,12 insp.

Bafararn?a 1.

.MP/0/A/1000/48 Diesel mgine Flywheel Bolting Special Inspection Tnawl*em g @

c 3.

Viaual inspection for loose roll pins showed all roll pins to be

~

satisfactory.

2.

Correct torques for the flywheel bolting were established by m

documentr. tion.

ni-mateinn gg in.-einn Finainon I

i'nere were no significant findings.

s i

)

e' s

'. l i

I' q.

s s

i e'

s A-63

Cat;mba Diesel la Tnanactinn amport Part Names W h harnar Class: A Part No.: MP/022/3 Work Request Nc.:1002 MNt

)

No. of Separate Inspections: 20.

Attributas Verified agl Sample Eige 1.

Visual inspect assenbly 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 11.6.1, ref.1,16 insp.

References 1.

MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler - Special Inspection Tnanactinn Results The inspections of the turbochargers were not performed as the turbo-chargers were replaced due to severely worn thrust bearings. Che turbo-exhaust manifold bolt was found cracked.

Diannnitinn gf Inannetinn Findinna The turbochargers were replaced with newly rebuilt units.

'the turbo-exhaust manifold bolts were replaced with inprovad bolts.

A-64

LP Part Neme:

'n h haraec Bracket Class: B Part No.: 02-475A Work Regaect No. 10.0.4 190' No. of Separate Inspections: 1

.c.

Attributes Verified mgl Sample Elze 1.

Visually inspect support bracket per 11.3.2, ref.1,1 insp.

References 1.

MP/0/A/1000/49 Diesel Engina Turbocharger and Intercooler - Special Inspection Tnanectinn Results 1.

Visual inspections of the turbocharger bracket were satisfactory.

Diannnitinn of Tngnetinn Findinan There were no significant findings.

A-65

Catahba Diesel JS TnarwHnn Report l

~

Part Name:

'Nr+wharger Bradtet Bolt ing Class: B Part No.: 02-475D Work Request No.:10A4 MNE No. of Separate Inspections: 2 Attributes Verified mgl SgEple SiZR 1.

Visual inspect bolted joint per 11.4.3, ref. 1, 2 insp.

References 1.

MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler - Special Inspection TnarwHnn Results 1.

One turbocharger to bracket capscrew was found broken before the extended run test. All screws were replaced before the extended run and have performed well.

Dinrwwitinn of Tnarwt-inn Findinan There were no significant findings.

A-66

Part Names Intercnnlar Class: B Part No.:

F-086 Work Request No.:10DA MtEI' No. of Separate Inspections: 1 Attributen Verified mgl Sanple Size 1.

Visual inspection of intercooler and inlet and outlet adaptors per 11.5.2, ref. 1, 6 insp.

2.

Perform PT or MT exam of each intercooler inlet adaptor flange weld per 11.5.3, ref. 1, 2 insp.

Haferences 1.

MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler - Special Inspection Insenant inn Results 1.

. Visual inspections of the intercoolers and inlet and outlet adaptors were satisfactory.

2.

The right bank flange veld had a crack which was found visually. The left bank showed no rejectable indications. A small crack was also noted in the air flow divider to case junction.

Dinnnaitinn gf TnanacFinn EipgliDSS 2.

A flexible coupling and strongbacks were installed at this location to ensure that these problems will not reoccur.

A-67 i

^

Catanba Diesel IB Innn etinn Report Part Name: Intercooler Elping ennnlina, Boltina/canket Class: A Part No.:

02-436B Work Request No.:1004 ME No. of Separate Inspections: 1 Attributes Verifindt mg1 Rawnle size 1.

Check dresser coupling on piping per 11.5.4, ref. 1, 1 1.w.

References 1.

MP/0/A/1000/49 Diesel Engine Wrbocharger and Intercooler - Special Inspection Tnanet-inn Rennita 1.

The dresser coupling found on inspection was a 90 degree elbow straight coupling. This infornation will be forwarded to the Owners Group.

Dismnaitinn of Tnanet inn Pirvlinan There were no significant findings.

A-68 c

Catanba Dianel JR Inarwet-inn Report Part Name: Jacket Water Stimdp3,gg Fittingn i Gaskets Class: B Part No.:

D.Q-10.CA Work Request No.:10BR MMI' No. of Separate Inspections: 1 Attributes Verified mid Saggle gigg 1.

VJsual inspect systect per 11.2, ref. 1, 1 insp.

References 1.

MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Tnanact inn Results 1.

Visual inspections of the jacket water standpipe fittings were satisfactory.

l l

Diannnitinn of Trarst-inn Findinga

'1here were no significant findings.

L 1

o A-69

Catanba Dianel 23 Tnnret inn Report Part Name: Jacket Water Standoine mrrnrts Class: B Part No.:

00-700C Work Request No.:10f1 HtE 1

l No. of Separate Inspections: 1 l-Attributes Verified agl hT a Size l

1.

Visual inspect supports per 11.3, ref.1,1 insp.

References 1.

MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Tnarwetion Results 1.-

Visual inspections of the jacket water standpipe supports were satisfactory.

Diarnnition of Igmectinn Finelinan There were no significant findings.

p.

A-70

Catanba Diesel la Insnectinn Report Part Name: Jacket Water Standpipe Boltina MateIlala Class: H Part No.:

00-700F Work Request No.:1GBH MtE No. of Separate Inspections: 1 Attributes Verifled ADilSAEDlR Sist 1.

Visual inspect bolting per 11.2, ref. 1, 1 insp.

References 1.

MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Tnsneci-inn Results 1.

Visual inspections of the jacket water standpipe bolting were satisfactory.

Diarmitinn gf Tnsnect-inn Pirvlinas

'1here were no significant findings.

I A-71

~.

Catahha Diesel JB TnsmecHnn Report Part Name: Jacket Water Manifold harbly Class: B Part No.:

02-316A Work Request No.:1088 HNT No. of Separate Inspections: 1 Attributes Verified add SAEgle SiZR 1.

Visual inspect assenbly per 11.3, ref. 1, 1 insp.

References 1.-

MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Tnsmectinn Results 1.

Visual inspections ofthe jacket water manifold assenbly were satisfactory.

Dismnaition of TnsnecHnn Findinam There were no significant findings.

A-72

Cat;aht3A Diesel JB Tnsmact-inn Egggrt Part Name: Jacket Water Inlet Manifold carlino class: a Part No.:

02-316B Work Request No.:1088 MME No. of Separate Inspections: 1 Attributes Verified add Sanple Size 1.

Visual inspect coupling per 11.4, ref. 1, 1 insp.

References 1.

MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Tnanact-inn Results 1.

Visual inspections of the jacket water inlet manifold coupling were satisfactory.

Dinnnait-inn gf Tnanact-inn Findinas:

There were no significant findings.

l l

I A-73 l

Catadm Diesel la TnnwHnn Report Part Name: Jacket Water Dieharae Manifold ('mnlina Class: B Part No.:

02-317B Work Request No.10.88 MtZE No. of Separate Inspections: 1 Attr2butee verified and Ramla Size 1.

Visual inspect coupling per 11.5, ref.1,1 insp.

References 1.

MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Tnaretinn Results 1.

Visual inspections ofthe jacket water discharge manifold coupling were satisfactory.

Dinnnaition gf TnnneHnn Findinan There were no significant findings.

l' l

l l

I j

A-74

Catahba Diesel M Tnanactinn Report Part Name: Jacket Re,I Di= charge Manifold Suonorts Class: B

'Part No.:

02-317C Work Request No.:10BH MNI' No. of Separate Inspections: 1 Attributas Verified ad Sanple Sigg 1.

Visual. inspect supports per 11.4, ref. 1, 1 insp.

References 1.

MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Inanectinn Results 1.

Visual inspections of the jacket water discharge manifold suprts were satisfactory.

Diannaitinn gf Tnnpeci-inn Finclinan There were no significant findings.

A-75

\\

Catat2a Diesel 3B TnWinn Report Part Name: h coolina Water Eipe add Pittinan Class: B Part No.:

02-437A Work Request No.:10HR HME No. of Separate Inspections: 1 Attributes Verified add SABple Si2dt 1.

Visual inspect system per 11.5, ref.1,1 insp.

References 1.

MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold - Special Inspection Tnaretion Results 1.

' Visual inspections of the turbo cooling water piping were satisfactory.

Diarmition gf Tnaretinn Findinan There were no significant findings.

A-76

Cataba Diesel 1B Tnarw+ inn Report Part Name: Turbo Coolire h Pjpg Ayrts Class: A Part No.:

02-437B Work Request No.:1DRS HNE No. of Separate Inspections:1 Attributaa Verified add R"S

• S11C l

1.

Visual inspect supports per 11.5, ref. 1, 1 insp.

References 1.

MP/0/A/1000/53 Diesel Engine Jacket Water System Piping Standpipe and Manifold - Special Inspection Tnanectinn Results 1.

Visual inspections of the turbo cooling water pipe supports were satisfactory.

Diarwwitinn gf, Innrw+ inn Findinan There were no significant findings.

i l

l i

l A-77

Cataid:e Dianal IB Inspect ion Report Part Name: St; art Air Manifold h Tubina & Fittinas: Class: A Part No.:

02-441A Work Request No.:1082 E No. of Separate Inspections: 'l Attributes Verified add Ramle gigg 1.

Visual inspect system per 11.3, ref. 1, 1 insp.

References 1.

MP/0/A/1000/54 Diesel Engine Air Start Piping Systen -

Special Inspection Tnanact-inn Results 1.

Visual inspections of the start air manifold system showed the pipe to be in conformance with tle drawings.

Diannaihinn of Tnanachinn Findinna 1.

No discrepancies were found.

A-78

Catalba Diesel Ja insmaction Report Part Name:

Start & Manifold Plpe

• marts Class: A Part No.: 02-4dic Work Request No.:10B2 HNI' No. of Separate Inspections: 1 Attributes Verified And SAEGlR SiER 1.

Visual inspect supports per 11.3, ref. 1, 1 insp.

References 1.

MP/0/A/1000/54 Diesel Engine Air Start Piping System - Special Inspaction inanection Results 1.

Results of the visual inspections of the air start manifold pipe supports showed minor discrepancies with the drawings.

Dismnaition Of Tnanactinn Findinas:

1.

The minor discrepancies revealed by the inspections have not affected the start air system and are not considered a problem.

A-79

Catahba Diesel JB Tnnnection EgggIt Part Name: Start Air Distributor Tubing, Ptngs, i Gskts Class: A l

Part No.:

02-442B Work Request No.:10B2 EZE l

No. of Separate Inspections: 1 Attributes Verified a d Ramnle Size 1.

Visual inspect distributor tubing system per 11.4, ref.1, 1 insp.

References 1.

MP/0/A/1000/54 Diesel Engine Air Start Piping System -

Special Inspection inanact-inn Results l

1.

Visual inspections of the start air distributor tubing, i

I fittings and gaskets showed them to be in conformance with the drawings.

Diannnition of Tnanactinn Findinan 1.

No discrepancies were found.

A-80

Catadm Diesel ja Tnnnactinn Report Part Name: Fuel Injectinn Tubino Class:B Part No.: 02-365C Work Request No.:1020 HNI' No. of Separate Inspections: 17 Attributes Verified add Sanple Size 1.

Visual inspect tubing per 11.2 ref. 1, 1 insp.

2.

Eddy current inspect tubing per 11.3 ref.1,16 insp.

References 1.

MP/0/A/1000/55 Diesel Engine Fuel Oil Piping Systent-Special Inspection.

Tnanactinn Results 1.

Visual inspections of the fuel injection tubing was satisfactory.

2.

Eddy current inspections demonstrated no rejectable indications.

Dinnnaitinn g Tnanactinn Findinan There were no significant findings.

A-81

Catatba Diesel la TnanacFinn Report Part Name: Bael InjecFinn Tubing Suncorts Class:H Part No.: 02-365D Nor.k Request No.:1012 E No. of Separate Inspections: 1 i

Attributes Verified ADgl Sanple Size 1.

Visual' inspect tubing supports per 11.2, ref. 1, 1 insp.

References 1.

MP/0/A/1000/35 Diesel Engine Fuel Oil Piping System - Special Inspection.

Tnannetinn Results 1.

Visual inspections of the fuel injection tubing supports were satisfactory.

Diannnitinn of InanacFinn Findinna There were no significant findings.

A-82

f Catasha Diesel JB Tnanactinn Report i

Part Names Engl 011 Pinina mgl Tubing Class: A Part No.: 02-450B Work Request No.:109R MNE No. of Separate Inspections: 1 Attributes Verified mgl Sagple Size 1.

Visual inspect systen per 11.2, ref.1,1 insp.

References 1.

MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System - Special Inspection TnanscFinn Results

.1.

Visual inspections of the fuel oil piping and tubing were satisfactory.

Diannnition of Tnanactinn Finclinam There were no significant findings.

A-83

i l

Catanba Diesel la Insnection Report Part Name:

Eucl Dil Piping Surx)orta Class: A Part No.: 02-450D Work Request No.:1010.BHE No. of Separate Inspections: 1 Attributaa Verified and Sanple Size 1.

Visual inspect supports per 11.2, ref. 1, 1 insp.

References 1.

MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System - Special Inspection Insnectinn Results 1.

Visual inspections of the fuel oil piping supports were satisfactory.

J)ismositinn of Insnectinn Findings There were no significant findings.

A-84

Catatha Diesel ja Tnsnection Report Part Name: Control Panel Pinina. Tubina. 331 Fittinan Class:H Part No.: 02-500M Work Request No :1089 MHI' No. of Separate Inspections: 1 Attributes Verified 331 Rannla Size 1.

Visual inspect tubing and fittings per 11.4, ref.1,1 insp.

References 1.

MP/O/A/1000/57 Diesel Engine Shutdown Tubing and Electrical Corduit - Special Inspection.

Tnanactinn Results 1.

Results of the visual inspections of the control panel tubing and fittings were satisfactory.

ninnnaition of Tnanactinn Findinan l

There were no significant findings, i

A-85 l

Catanba Diesel la Tnanactinn Eig ut Part Name:

Engine add Anviliarv Module Wirino Conduit Class: A Part No.: 02-688A Work Request No.:1Q82 HNC No. of Separate Inspections: 1 Attributes Verified add Sangle Size 1.

Visual inspect conduit per 11.4, ref.1,1 insp.

References 1.

MP/0/A/1000/57 Diesel Engine Shutdown Tubing and Electrical Conduit Special Inspection Tnanaction Results 1.

Visual inspections of the engine and auxiliary module wiring conduit were satisfactory.

Diannaitinn gf Tnanaction Findinna There were no significant findings.

A-86 i

j

Catanba Dianel JB Tnanectinn Report Part Names Ehgine Shutdown Tubina add Pittings Class: H Part No.: 02-695A Work Request No.:10B2 HNI' No. of Separate Inspections: 2 Attributes Verified add Simple 31Z2 1.

Visual inspect engine mounted tubing per 11.2, ref.1,1 insp.

2.

Visual inspect panel mounted tubing per 11.3, ref. 1, 1 insp.

References 1.

MP/0/A/1000/57 Diesel Engine Shutdown Tubing and Electrical Conduit Special Inspection Tnanetinn jhtsults 1&2 Visual inspections of engine and panel mounted shutdown tubing and fittings were satisfactory.

Dinnnait inn of Tnnnect-inn Findinam There were no significant findings.

A-87 i

APPE!OIX H ENGINEERING VALIDATION REPOle SELEC1'ED CATAWBA IB DIESEL PARTS B-1

B BLE & CONTENTS 2AGidQn TitlR

.Bl.0 Introduction B2.0 Identification of Parts B3.0 Detailed Review of Part Validation B4.0 References Tables B2-1 List of Parts Covered by Engineering Validation Review P

=

B-2

Bl.0 Tntrevinctinn The purpose of this report is to hn=nt the results of the J

engineering validation performed for selected parts of the Cataba IB Diesel. The parts were selected for this review if their quality.

was not being verified by detailed inspections. This validation was performed for the parts listed in Table B2-1.

Information for the the validation was obtained by some visual observation ofrecords, parts, review of test results,

' review of maintenance and discussions with operating and maintenance personnel regarding performance of the parts.

An engineering evaluation of of this information was then performed to assess the condition and quality of.the parts. Items appearing in Table B2-1 are an abbreviated list of the engineering validation couponents checked on diesel 1A (See Table B2-1, reference 3).

The maintenance and operating logs 'for diesel IB were searched to ascertain whether any of the diesel 1A' couponents not appearing herein had any problems.

No problems were uncovered.

The detailed results of this review are presented in Section B3.0.

e-(

B-3

.--c

..----,--e

.,---,.-,--w---

,.,..-.-,,_,-.-.,,y-

--+.-,,w--v.

B2.0 ThHficaHnn of Parts 9 ~

i The jparts covered by this review are listed in Table B2-1.

Parts

..,ere listed in Table B2-1 if they met the following criteria:

w 5s*

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 v

i, 4 - detailed inspections (e.g.,

per Catawba Special Inspection t Procedures MP/0/V1000/35 through 51); and t,

The quality of the parts is not being verified as part of piping installation checks covered by Catat a Special

. Inspection Procedures MP/0/A/1000/53 through 57).

la essence, the parts listed in Table B2-1 are intended to cover items inportant to operability of the diesels but which have not been covered by detailed inspections bacanae no specific need for inspection was developed owing to failure history or general diesel experience.

y

' 6 1

s I

e,

's

\\

\\

D..

\\

\\

D s

6

l. 5

'i B-4

, ~,,.

k

\\-

TPBLE B2-1 List af Parts Covered hg Enainwrina Validation Review 2Rd; Bla.

PEL Mang Class00-420 LUBE OIL PRESSURE REGUIATING VALVE A

00-700B~

JACKET WATER STMOPIPE VALVES B

. 00-700E JAOWT WATER STMOPIPE SWI'ICHES B

. 02-311D CRPMCASE MOWTING HARDWARE B

02-311B CAM ~ BEARING CAPS AIO DONELS B

02-415B GOVERNOR BOOSTER SERVGG0R B

02-465C EKTERNAL IUBE OIL' VALVES A

02-500A CWTROL PANEL CABLNET A

02-500F CONTROL AIR ACCWUIATOR A

02-500G ONTROL AIR SYSTM VALVES A

02-500H OWPROL AIR SYSTM PRESSURE SWITCHES B

02-500J (XNTROL SYSTEM RE[AYS A 500K CONrBOL SYSFM SOLENDID VALVES A

02-500N ONTROL PANZ WIRING A

02-630D INSTRWENRTION THEHM0 COUPLES B

02-688B

-ENGINE AIO AUX'M(EULE WIRING A

02-688C ENGINE A)0 AUX MGXILE WIRING BOKES A

02-690 ENGINE AIABM S M SORS B

02-691A 0FF ENGINE SAFETY AIAM SENSORS-SWITCHES B

02-695B ENGINE GUIDWN VALVES, REGUIATORS, ORIFICES A

02-695C ENGINE SHUIDOWN TRIP SWITCHES A

02-825D FUEL OIL DUPLEK STRAINER B

C 136/40 THERM 0 STATIC VALVE B

CtF106 INMKE AIR FILTER B

01-107 INTAKE AIR SILENCER B

CN-109--

BEFORE A!O AFTER IDBE OIL PG4P A

CN-110 FULL FILM IDBE OIL FILTER A

01-111 LUBE OIL HEAT EKCHA!GER B

Oi-119A GENERATOR SHAPT AIO BEARINGS A

CN--120 JAGET WATER HEAT EXCHANGER B

CN-122 OIL PRELUBE FILTER A

CN-131 LUBE OIL KEEPNABM STRAINER A

SE-025 IUBE OIL FULL PRESSURE STRAINER A

4 A

B-5

.,.. ~... -.. _ _......

.B3.0 Detailed Review Of RAIt ValWHnn 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 noted that 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.

/

W B-6 e

,.e--

---,-..-,,-,e,a-,---

w-

B3.1 2ar.t h : 00-420 Par.t Egag: Lube Oil Pressure Regulating Valve Pinv+1nn: This valve controls lube oil pressure.

nrawinna: 'JDI Drawing 00-420-01, Valve Assenbly-Pressure Regulator P ratina Riatorv: This valve has performed satisfactorily with no reported problems.

Maintenance Riatorv: '[he valve leaked at one of the flanges during July 1983.

The flange was retorqued which stopped the leak.

No unad=1nled maintenance was required during extended run.

Vianal m servation: The valve was visually observed by T.

R.

Jennings on Septenber 21, 1984, Comclusions: Pressut= regulating valve 00-420 is considered to be satisfactory as demonstrated by satisfactory performance for extended periods of operation.

1 a

B-7 l

B3.2 Eart Bl : 00-7008 Ratt Emma: Jacket Water Standpipe Valves Fnetinn: These valves serve to isolate the jacket water standpipe when needed.

(

nrawinan: TDI drawing 100546, Jacket Water Piping R hematic nnaratina niatorv: These valves have performed satisfactorily with no reported problems.

Maintenance niatorv: No maintenance has been performed on these valves.

Visual thaarvatinn: No visual observations were conducted.

==

Conclusions:==

The valves are considered to be satisfactory as demonstrated by the absence of any reported prcblems and the satisfactory operating history of the jacket water system for extended periods of operation.

1 B-8

B3.3 Eart h : 00-700E RAEt Bl lag: Jacket Water Standpipe Switches Pinv+1nn: The jacket water standpipe switch is a pressure switch which indicates a low level of water in the jacket water standpipe.

Drawings: 'IDI drawing No. 09-691-75017 h ratina Hiatorv: The switches have operated satisfactorily with no reported problems.

Vinnal Ohnorvahinnn: Since no problems with the switch itself have been reported, observation of this device is not considered appropriate.

==

Conclusions:==

'Ite jacket water standpipe switch, Part No.

00-700E, is considered to be satisfactory for its intended service ' by the absence of any reported problems with the switch and its satisfactory performance for extended periods of operation.

B-9

B3.4 But h: 02-311D But Fman crankcase Mounting Hardware Punction: This hardware consists of the main crankcase studs, nuts and washers (parts 19, 20, 21, 22, 23, and 29 on TDI drawing 02-311-03) and capscrews (part 18 on 'IDI drawing 02-311-03). The main studs serve to hold the crankcase to the base, while the capscrews serve to clamp the crankcase seal.

Drawinna: TDI drawing 02-0311-03, crr.nkcase Assenbly (wrat-ina Hiatorv: This hardware has performed satisfactorily without adjustment since initial delivery frun TDI.

Maintenance Hiatorv: No maintenance has been performed on this hardware.

No adjustment has been required since initial delivery from TDI.

Visual Observation: The hardware was not visually observed.

==

Conclusion:==

The crankcase mounting hardware is considered to be satisfactory as demonstrated by satisfactory performance for extended periods of operation.

B-10 1

\\

B3.5 P.ar.t h: 02-311B Part BREg: Cam Bearing Caps and Dowels PuncFinn: '1his hardware consists of the bearing assenblies used to position the camshafts in the crankcase assenbly.

DrawiMa: TDI Drawing 02-311-03, Crankcase Assenbly p rnFinn niatorv:

This hardware has performed satisfactorily since initial delivery as evidenced by inspection of the camshafts after 755 hours0.00874 days <br />0.21 hours <br />0.00125 weeks <br />2.872775e-4 months <br /> of operation.

c'amahafts showed no wear of cam lobes, hence cam bearings are fullfilling their function.

l Maintenance niatorv: No maintenance has been performed or required on this hardware.

vinnal chaarvatinn:

Due to camshaft inspection results, no visual I

obaervation of the cam bearings is required.

==

Conclusions:==

'1he cam bearing caps and dowels are considered to be satisfactory as demonstrated by satisfactory performance for extended periods of operation.

l

[

B-11

1 B3.6 2att h : 02-4153 Ragt Mana: Governor Booster Servomotor Punceinn: The governor booster servosotor uids in starting the engine by using starting air to increase governor oil pressure which in turn results in the governor going to the full fuel on position.

nravinna: Woodward Service Bulletin 36684 B and 'IDI dwg. 101414 nnaratina Hiatorv: This servosotor has performed satisfactorily with no rem rted problems.

Maintenance Hiatorv:- No maintenance has been performed on this Part.

vinnal Chamrvatinn: No visual observations have been M m lished.

==

Conclusion:==

The governor booster servomotor is considered to be satisfactory for its intended service as denenstrated by satisfactory performance for extended periods of operation.

B-12

. B3.7 M Ma : 02-465C M Famg: External Lube Oil Valves PuncHnn: '[hese valves are used to direct lube oil flow, isolate components, etc.

nrawinna: TDI drawing 09-820-75017-E, Lube Oil Piping Rehamatic nnaraHna niatorv: These valves have operated satisfactorily with no problems.

Maintenance niatorv: No maintenance has been required.

Yisual maarvaHnn: These valves were observed by T. R. Jennings on Septenber 19, 1984 and appeared normal.

concinainna: These valves are considered to be satisfactory as dononstrated by satisfactory performance during extended operation.

O s

t-B-13

P B3.8 ERI1 Ma : 02-500A EREL Magas Control Panel Cabinet Function: The control panel cabinet houses essential control components for both off-engine electrical and off-engine pneumatic systems :and provides barriers between Class lE circuits and components within the cabinet and non lE circuits and couponents.

Drawingar 'JDI drawing 52213 Operating History:

No problems have been encountered -with the panel.

EMntanance m torva No maintenance has been performed on the Panel.

Vipual Chaarvation: Since -the panel has had no maintenance or

. operating problems, no visual observations were deemed neceaaary.

Conclusion

• The control panel cabinet, Part No. 02-500A, is considered. to be satisfactory for its intended service as demonstrated by satisfactory performance.

B-14

'B3.9 pet h: 02-500F ERLt Hamg: Control Air Ami=1ator PuncFinn: 'Ihe Control Air Ami_=_ilator 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.

nrawiM=:

'Ihere are no drawings available describing the m =_ilators.

The capacity and circuit locations are described on

'IDI Drawing 52216, Panel Pneumatic Schematic.

nnovatina Nintorv:

'Ibe three control air ami-lators have performed satisfactorily with no reported problems.

Maintenanca Hiatorv: No maintenance has been performed on the control air acci = lators.

vinnal chnarvatinna: No visual observations have been acconplished as a part of this engineering validation.

('nncinninna: The control air accumulators, part no. 02-500F, are considered to be satisfactory for their intended service as demonstrated by their satisfactory performance for extended periods of operation.

l l

B-15

B3.10 2att h: 02-500G Ragh Magut: Control Air Systen Valves Punction: The Control air system valves open and close upon a

- signal (pneumatic) from the pneumatic shutdown logic board, either permitting the engine to start and run or trip the engine by actuating the auto shutdown cylinder.

Drawingas 1DI Drawings 52216, Panel Pneumatic Schematic, and 52215, Engine Pneumatic Schematic.~

nnormeinn n4=torv:- The control air system valves have performed satisfactorily with no maintenance required.

Maintenance niatorv: No corrective maintenance has been performed.

on the valves.

Visual meervation: 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.

B-16

B3.ll Ear.t h : 02-500H 2RE.t liaan: Control Air System Pressure Switches Punction: The control air system pressure switches open and close depending on control air pressure in the pneunatic control system.

These devices are also actuated by control air and serve both control system functions and supervisory functions.

Drawings: 'IDI drawing 52216, Panel Pneumatic Schematic rhwratino ufatorv:

All pressure switches have demonstrated satisfactory performance with no problens.

Maintenance ninterv: No unintenanco has been performed on the control air system pressure switches.

Yiaual maervation:

As the pressure switches have operated satisfactorily, no visual observaticn 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 5

B-17

.-,,...,,_..,n_,,

_.-,._.-..,n,,......

.-.n.....-n.,

B3.12 ERIT Bh.: 02-50GJ 2 ret Emma Control System Relays Punction: '1he Control System Relays provide electrical signals to various elenents of the engine control system.

Drawings: 'IDI Drawing 52218, Panel Electrical Schematic.

T Hiatorv: The control system relays have demonstrated hraH satisfactory performance with no probleus since modifications were made to the control panel wiring. (See Part No. 02-500N)

Maintermoca Hiatorv: '1here has been no required maintenance on these relays since the wiring modification.

Y.iauAl Chaarvation: No visual observations were conducted as part of this engineering validation.

==

Conclusion:==

The control system ^ relays are considered to be satisfactory for their intended service as demonstrated by their satisfactory performance during extended operation since the wiring modification.

B-18

LB3.13' Eart h: 02-500K Intt Hama Control System Solenoid Valves Function: '1he control systtsu solenoid valves open or close when energized by the pneumatic or electrical control system, permitting the flow of control air in the system.

namingar 'IDI Drawing 52216, Panel Pneumatic Schematic, and 52218, Panel Electrical Schematic.

n=raHna ninterv:

'Ihe control system solenoid valves have performed satisfactorily with no problems.

Maintenance m atorv: No maintenance has been required or performed on the control systen solenoid valves.

Ylaual Chaervation: No visual observations were conducted as part of this engineering validation.

==

Conclusion:==

'1he control system solenoid valves are considered to be satisfactory for their intended service as demonstrated by their satisfactory performance during extended operation.

6 1

1 i

B-19

B3.14 M hs 02-500N M limt: Control Panel Wiring Function: The control panel wiring interconnects the electrical couponents in the control panel systen.

Drawings: 'IDI Drawing 52218,-Panel Electrical Schematic.

Operating Hiatorv 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.

Since these modifications, the wiring has performed satisfactorily and required no maintenance.

Maintenance nintorv: No maintenance has been required or been performed since the modifications to the control panel wiring.

Visual Chaarvationar No visual 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 problens for an extended period of operation.

1 i-i l

B-20 3

-,-m-w,.m,---.....-,..-w.,r my.w-m---,e

,y

,,,.&y.

,,_-.y w w www- %

B3.15 Enth h s.02-630D Rath Mana: Instrumentation Thermocouples punction: 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 anrrm:iators where appropriate.

The ther-eles cannot cause the engine to trip or to fail to start on an emergency signal.

Dsaadaggs TDI Drawing 09-688-75017, Engine Electrical Diagram and

• hamatic, and 09-691-75017, Off-Engine Electrical.

Operating History: Instrumentation thermocouples have indicated erroneous readings when the engine heated up (jacket water and lube oil).

This situation was corrected by replacing the thermocouples on March 6,

1984. The replacement thermocouples have performed satisfactorily.

Maintenanca History: Other than the replacamartts described above, no other maintenance has been performed on the instrumentation thermoccuples, visual chmarvation: No visual observations have been made.

Concluainn:

The instrumentation thermoccuples are considered satisfactory for their intended service as demonstrated by their satisfactory performance (since replacement) for extended periods of operation.

. i-B-21 6.

B3.16 Ratt h : 02-688B Ratt Mama: Engine and Auxiliary Module Wiring Punction: 'lhe 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.

Drawings: 'IDI drawing 09-688-75017, Engine Electrical Diagram and Schematic h ratina nintorv:

The engine and auxiliary module wiring have performed satisfactorily and required no maintenance.

Maintenance Hiatorv: No maintenance has been required or performed on the engine and auxiliary module wiring.

Vlaual maervation: 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 indicates that three cables nust be replaced (see section 4.1.10)

Concluainn Preliminary conclusions indicate that the engine and auxiliary wiring is satisfactory for its intended service as demonstrated by its satisfactory performance during extended periods of operation. The three cables which did not meet class 1E cabling requirements have been replaced.

B-22

B3.17 P.att h: 02-688C Ratt Nannt: Engine and Auxiliary Module Wiring Boxes env+ inn: 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.

Drawings: 'IDI Drawing 09-688-75017, Engine Electrical Diagram and Schematic P ratina nintorv:

The engine and auxiliary module wiring boxes have performed satisfactorily and required no maintenance.

Maintenance ninterva No maintenance has bem required or performed on the engine and auxiliary module wiring boxes.

Visual Chaervations:

'Ihe engine and auxiliary module wiring boxes are to be inspected as part of the walkdown of engine conduit, Special Inspection Procedure No. MP/0/A/1000/57.

==

Conclusions:==

Preliminary conclusions indicate that the engine and auxiliary module wiring boxes are satisfactory for their intended services as demonstrated by satisfactory performance for extended periods of operation.

B-23

B3.18 pet h: 02-690 EREt Mang: Engine Alarm Sensors Punction:

The engine alarm sensors provide signals to the supervisory alarms on the engine control panel during an emergency 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 att eh -it to this section.

Refer to Part No. 02-360D for thermocouples derived from this section.

nrawima: TDI drawings 52218, Panel Electrical Schematic, 52216, Panel Pneumatic Schematic, and 52215, Engine Pneumatic Schematic.

% rat-ig nintorv The engine alarm sensors have performed satisfactorily and required no maintenance.

Maintenance nintorv: No maintenance has been performed on the engine alarm sensors other than thermocouples.

(See Part No. 02-360D)

Yianal Chaarvation: No visual observation has been made.

==

Conclusion:==

The engine alarm sensors are considered satisfactory for their intended service as demonstrated by their satisfactory

~-

C performance for extended periods of operation.

B-24

L WISCIBENT TO B3.18 i

EBELE AIAMS High Differential Pressure Inbe Oil Filter High Differential Fressure Lube Oil Strainer Iow Pressure I4be Oil Iow Temperature Oil Inlet Iow Torperature Oil Outlet High Temperature Oil Inlet High Temperature Oil Outlet Iow Pressure Ttirbo Oil RP Iow Pressure Turbo Oil IE Fuel Pump Overspeed Dri t Failure High Differential Pressure Fuel Oil Filter High Differential Pressure Fuel Oil Punp Strainer

. Iow Pressure Fuel Oil Iow Pressure Jacket Water High Temperature After Cooler Water In Iow Temperature Jacket Water In High Temperature Jacket Water In Erhaunt Temperature High/Iow Barring Device Engaged B-25

.'B3.19 East h s 02-691A-EnEL Egent: Off Engine Safety Alarm Sensors-Switches Punction The off engine safety alarm sensors provide signals to l

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 tabulated in the attachement to this section. Ther gle sensors in the attachment are under Part No. 02-630D.

nravingar 'IDI drawings 52218, Panel Electrical Schematic, 52216, Panel Pneumatic Whsenatic, 52215, Engine Pneumatic Schematic, and 09-691-75017, Off Engine Electrical.

Operatim. ni=torv: The off engine safety alarm sensoro have performed satisfactorily with only periodic recalibration required.

Maintenance nintarv: The only maintenance performed on the off engine safety alarm sensors has been periodic recalibration.

Vianal Chaarvatinnt Because of their satisfactory past performance and the non-critical nature of these items, visual observation is not required.

conclusion: The 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.

B-26

XDCBEINE TO B3.19 Tit 1 Mille SAFEFY NA]E EMES

. Low Invel I4be 011 Tank High Invel Main Fuel Tank Iow Invel Main Fuel Tank Main Fuel Oil Tank Tech. Spec. NMN

. High Invel Day Tank Iow Imvel Day Tank Iow Invel Jacket Water Iow Temperature Jacket Water Out High Temperature Jacket Water Out Panel Intrusion Aux Equip Not In Auto Refer To Operational Mode Building Ventillation Malfunction High Invel Deisel Generator Sunp High High Invel Diesel Generator Sung thit Failed To Start Iow Pressure Starting Air Iow Pressure Control Air B-27

_ _. - ~ _ _ _ _

_ _. _. _ _.. _. - _. ~ _ _ _...,. _, _. _ _ _... _ _ _ _ _ _ _ _ _ _ _. _ _ _, _

B3.20 East h: 02-695B 2ast Hama: Engine Stutdown Valves, Regulators, Orifices Punction: The engine slutdown valves,, regulators and orifices control the flow of air in the pneumatic' shutdown control system on the diesel engine.

nrawima: TDI drawing 52215, Engine Pneumatic & W tic, and 52216, Panel Pneumatic Schematic.

P ratina Hiatorv:

The valves, regulators and orifices have O

demonstrated. satisfactory perfo.aance recuiring no corrective maintenance.

Maintenance Hiatorv: No maintenance has been performed or required on the engine shutdown valves, regulators and orifices.

Visual h rvarinn: No visual observations were made.

cnncinninna: The engine shutdown valves, regulators and orifices are considered satisfactory for their intended service as dcanonstrated 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.

B-28

'B3.21 EREt En : 02-695C RaEt Eme Ehgine Shutdown Trip Switches eng ne shutdown trip switches shut the engine down and j

Function: The annunciate the cause of the trip. During emergency run only three trips shut down the engine, low low lubricating oil pressure, and generator to switch==_r differential (fault).

During over or remote run, six other trips in addition to -the three mentioned above shut the engine down, two low pressure lube oils, high temperature lube oil out, high pressure crankcase, high tenperature 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.

Drawingar TDI drawings 52218, Panel Electrical Schematic, 52216, Panel Pneumatic Schematic and 52215, Engine Pneumatic Schematic.

Operating History: The engine shutdown trip switches have performed satisfactorily requiring no maintenance.

Maintanance nintorv: No maintenance has been performed on the engine shutdown trip switches.

Vianal (baarvations nacanae of their satisfactory performance of their. function, visual observation of the engine shutdown trip switches is not required.

Conclusion

'1he. engine shutdown trip switches are considered satisfactory for their intended service as demonstrated by their satisfactory performance for extended periods of operation.

I

.i 4

N B-29 I

---..~,..,_.___..,_m_

B3.22 EaLt h: 02-825D PAtt Emma: Fuel Oil Duplex Strainer Function: This strainer filters fuel oil which is supplied to the auxiliary (engine mounted) fuel oil punp.

nrawima: 'IDI drawing 09-825-75017-H, Fuel Oil Piping Pratina Biat.qzy: The duplex strainer has performed satisfactorily as evidenced by the satisfactory perfornance of the fuel oil system.

Maintenance Hiatorv: h only naintenance required has been the periodical cleaning of the strainer elenents and repair two fuel oil leaks.

Yiaual fhaarveinn: The strainer was observed by T. R. Jennings on Septenber 19, 1984 and appeared nornal.

enelnainn: h fuel oil duplex strainer is considered to be satisfactory as demonstrated by satisfactory perfornance.

4 I

f w

I l

l l

n-30

x B3.23 M hs C 136/40 s

M Mana: Thermostatic Valve Function: 'Ihis valve automatically controls the flow of jacket water through the jacket water heat cxchanger in order to control jacket water tenperature.

nrawinna: 'IDI drawing 100546, Jacket Water Piping Schematic nnaraHno matorv: This valve has worked satisfactorily.

Maintenance m atorv: No maintenance has been required.

Visual m aarvation: No visual observation was made.

==

Conclusion:==

'Ibe valve is considered to be satisfactory as demonstrated by its satisfactory performance for extended periods of operation.

I e

p k

t B-31 3

- _. -... ~. _ _ _ -. - _.. _ _., _ - _ _ - - - - _ - - - _. - - - - - - _ _ _. - -

\\ -

a y

\\$(r,.t h:

B3.24 t CN-106 and CN-107 i.

$ 2att Rat Intake Air Filter hiancticn: This component serves to filter the intake air.

\\[

Drawin3a:lAnerican Air Filter Co. Drawing A-92553 cd.

s e 1

aparatina Hintnrvg The intake air filter has performed satisfactorily as evidenced by the satisfactory operation of the diesti em ine.

~

o Maintanarce Riatorv Filters have been replaced periodically as required based on pressure drop increases.

Ylaual m aarvation: No visual observation was made.

Conclusionat The intake air filter is considered to be satisfactory as desenstrated by satisfactory performar:ce for

.,<N.

extended periods of operation.

s,

\\

l

\\

1 cv s-

\\,

t 1 1Y

~

\\*

(

e h'

ty

' -s s

' N.

3 nI i

.\\.

\\

s-s.

4

~t

\\\\\\

i s

\\

3 k(

k I

l; e

g s

B-32 L

l i

s

B3.25 East h : CN--107 BK.t Emma Intake Air Silencers Punction: The silencers minimize noise generated by intake air.

Drawings: None available.

Operating niatorv:

There have been no problems with these silencers..

Maintenance niatorv: No naintenanc; 6as been required.

Vianal Chaervation: 'Ibe silencers were observed on Septenber 20, 1984 by T.R. Jennings and appeared normal.

==

Conclusion:==

.The silencers are considered to be satisfactory as demonstrated by satisfactory performance for an extended period of operation.

s I

I l

l I

G 44, g

B-33

.c.

. B3.26 Eszt h CN-109 Ratt Emma Before and After Lube Oil Punp Function:' S ia pump provides heated lube oil to the diesel engine 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 punp.

Drawings: TDI drawing 09-820-75017-E, Inbe Oil Piping Whamatic Operatina History: The before and after lube oil punp 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.

Maintenance nintarv:

Chly. routine preventive maintenance was performed on this pump.-

visual maarvation: Se pung installation was' observed and appeared normal.

==

Conclusion:==

The before and after (kyrmi lube oil pung is considered to be satisfactory as demonstrated by satisfactory performance during the stal' m testing start /stop engine operations..

s B-34

.. _. _. ~ _.. _ _ _. _... -. _.,, _.. _.. _. _ _ _ _... _. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

B3.27 pet h: CN-110 pet flames Full Flow Lube Oil Filters -

Pumkinn: 'lhese CoGponents filter the lube oil at the discharge of the lube oil pump.

Dravirgs: TDI drawing 09-820-75017-E, Lube Oil Piping Schematic h ratina Hiatorv: The full flow 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 Hiatorv:

Filter elements and o-rings have

'cseen periodically replaced.

vianal Cbservation: The filters were observed on September 19, 1984 by T. R, c,mnings and appeared normal.

==

Conclusions:==

'the full flow lube oil filters are considered to be satisfactory as demonstrated by satisfactory performance for extended periods of operation.

l

=

l B-35 l

i

B3.28 Eart h: CN-lll PRIt liMDR Imbe Oil Heat Exchanger (Cooler)

Punction: Se lube oil imat exchanger serves to cool lube oil to keep it in the desired tenperature range.

nrawinaa: 'IDI drawings 09-820-75017-E, Inbe Oil Piping Schematic; and 100546, Jacket Water Piping Schematic P ratina niatorv This heat exchanger has performed satisfactorily as evidenced by the satisfactory condition of the diesel bearings, and satisfactory lube oil tenperature.

Maintenance niatorv: The head bolts had to be torqued to stop a cooling water leak.

vian=1 mservation: We heat exchanger installation was observed on Septenber 19, 1984 by T. R. Jennings and appeared to be normal.

cnncinaions: The lube oil heat exchanger is considered to be satisfactory as demonstrated by satisfactory operation for extended periods of operation.

B-36

- B3.29 East Ha : CN-119 A Engt Magut: Generator Shaft and Bearing Function: The generator shaft and bearing serve to support the generator.

nrawingar None available.

aparating nintorv: No problems have been experienced with the

~ generator shaft and bearing.

Maintenance ninterv: No maintenance has been required except for

~

periodic oil changes and pedestal torque checks. Alignment of the generator shaft: is checked during routine web deflection measurements made on the diesel.

Yianal Chaervation: The generator shaft and bearing were observed, to the extent accessible without disassenbly, on Septenber 19, 1984 by T. R. Jennings and appeared normal.

Concluninna: The generator shaft and bearings are considered to be

. satisfactory as demonstrated by satisfactory operation of the l

generator for an extended period of operation.

i l

l l

i B-37 L

_--.m--,_

.~.

_. _. -, _. _ -. _ - - ~.. -,

B3.30 Pnt Ha : CN-120 (75017-120)

PEL Enmit: Jacket Water Heat Exchanger (Jacket Water Cooler)

Function: his 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 renove heat.

A thermostatic 3-way valve directs as auch of the jacket water flow as required through the cooler to keep the jacket water at the desired tenperature.

nrawirea: TDI drawing 100546-F, Jacket Water Piping Schematic (no part drawing is available) n=rai-ina niatorv: This heat exchanger has performed satisfactorily as evidemed by satisfactory jacket water tecperatures during diesel t-operation.

Maintenance Hiatorv: No corrective maintenance has been required.

Vianal maervation: The jacket water heat exchanger installation was observed and appeared to be normal.

enreinainn: Se jacket water heat exchanger is considered to be satisfactory as demonstrated by satisfactory operation for extended periods of operation.

L l

l l

B-38 i.

t

- B3.31 pet h: CN-122 (75017-131)

E E t Jimme: Oil Prelube Filter Punctinn: This filter is located downstream of the ket 7" arm pump and upstream of the keepwarm strainer (CN-131).

It aerves to filter the keepwarm lube oil (prelube system).

Drawinaa: 'JDI drawing 09-820-75017-E, Lube Oil Piping & hematic (no part drawing is available) h ratina Riatorv: This filter has performed satisfactorily with no problems.

Maintanar e Hiatorv: No corrective maintenance has becn required.

The filter element and 0-ring seal have been replaced periodically.

Vianal h arvarinn:

'Jhe filter installation was not observed as part of the engineering validation.

cnnelnainna:

'Ihe prelube oil filter is considered to be satisfactory as demonstrated by satisfactory operation for extended periods of operation.

B-39

B3.32 M Rt: CN-131 (75017-131)

M Hama: Lube 011 Keepwarm Strainer Punction: W is strainer is located downstream of the filter on the keepwarm prelube lube oil line.

It serves to filter the lube oil prior to its introduction to the main lube oil header.

nrawima: EI drawing ~ 09-820-75017, Iube Oil Piping Schematic; and Air Maze Drawing "Model 07W231735 Singlex Lube Oil Strainer" hrahim Hiatorv: his strainer has performed satisfactorily with no problene.

Maintenance Hiatorv: No corrective maintenance has been required.

Periodic strainer cleaning and occasional filter element replacement have been performed.

vian=1 h arvatinn: The keepwarm strainer installation was not observed as part of the engineering validation.

cnncinainn: he keepwarm strainer is considered to be satisfactory as denonstrated by extended periods of satisfactory operation.

B-40

B3.33 Ear.t h : SE-025 Bg.t Mama: Lube Oil Full Pressure Strainers Punction: These two strainers filter the lube oil downstream of the main. lube oil filters prior to the lube oil being introduced into the unin lube oil headers, nrawingar 3DI drawing 09-820-75017-E, Lube Oil Piping Schematic; and Air Maze drawing E-00736-R9W1752, Strainer, Lube Oil-Singlex Operat N ufatorv:

These strainers have performed satisfactorily with no problene, as evidenced by the satisfactory condition of the diesel bearings.

Maintenance ninterv: No corrective maintenance has been required.

Periodic strainer cleaning and occasional filter element replesment have been performed.

Vianal maervations The lube oil full pressure strainers were observed by T. R. Jennings on Septenber 20, 1984 and appeared to be installed normally.

Conclusions she lube oil full pressure strainers are considered to be satisfactory as demonstrated by satisfactory perfornance for an 2

extended period of operation.

1 J

l-f i

B-41 l

o i

~

'B4.0 References 1.

Duke Power Coupany letter to NRC dated April 5,

1984, Re:

Catawba Nuclear Station, Docket Nos. 50-413 and 50-414, forwarding report entitled " Catawba Naclear Station, Extended Operation Tests and Inspection of Diesel Generators".

B-42

_