Text

Diesel Engine 2A Component Revalidation Insp
	ML20137V914
Person / Time
Site:	Catawba
Issue date:	09/25/1985
From:	; DUKE POWER CO.
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	NUDOCS 8510040168
	Download: ML20137V914 (122)
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^ CATAWBA NUCLEAR STATION DIESEL ENGINE 2A COMPONENT REVALIDATI.0N INSPECTION

.l PREPARED BY DUKE POWER COMPANY September 25, 1985 Y

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Table of Contents 1.0 Introduction 2.0 Sumary and Conclusions 2.1 Overview of Operations 2.2 Overview of Inspection' Results 2.3 Lessons Learned from Unit 1 Inspections 2.4 Cylinder Head Leaks 2,5 Conclusions 3.0 Discussion of Inspection Results 3.1 Inspections Related to TDI Generi_c Problems (

3.2 Inspections Related to Catawba Specific Problems 3.3 General Inspections 4.0 References 5.0 Appendices 5.1 Inspection Reports Figures 2-1 Cylinder Head Repairs

Tables 2-1 Sumary of Catawba Diesel 2A Revalidation Inspection Results i

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1.0 Introduction This report describes the results of inspections and evaluations performed on the Catawba 2A diesel engine. These tests and inspections were performed as part of an overall program to verify the reliability of Transamerica Delaval, Incorporated (TDI) diesel engines used for safety-grade power supplies at Catawba. The ,

overall program is described in an April 30, 1985 letter to the NRC, I reference 1. The scope of the inspections meets or exceeds the TDI Owners Group' inspection program.

The inspections of the 2A diesel engine discussed herein were performed in May through August, 1985. The inspections involved extensive disassembly of the diesel and 100% inspection of parts for which there was a history of problems or other reasons for special concern. Substantial (e.g., 25%) sampling inspections were performed of other important parts where there was no history of problems.

The scope of the inspections are as described in reference 1. About 2700 separate inspections were conducted.

Thedieseldisassembly, reassembly,andinsjectionswereperformedin accordance with the Duke Power Quality Assurance Program. The disassembly, inspection work and assembly was largely performed by Duke Power personnel, with selected inspections performed by Failure Analysis Associates (FaAA) and Law Engineering personnel.

Detailed results of the inspections are contained in Section 5.0 and are discussed in Section 3.0. Summary and conclusions resulting from the inspections is contained in Section 2.0 of this report.

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2.0 Summary and Conclusions 2.1 Overview of Operations The Unit 2A diesel generator is a new engine which had not been run at

-- Catawba prior to the revalidation inspections.

2.2 Overview of In:pection Results As discussed above, the Catawba 2A diesel engine is a new engine which had never been run at Catawba. However, extensive disassembly and inspection of this diesel engine has been performed to confirm the satisfactory condition of various parts' and to identify any parts requiring repair, replacement, and/or redesign to ensure highly reliable standby electric generator service. It should be noted that the inspections of some items were of limited value since the diesel had only been operated during factory tests, and service induced degradaticn would not be expected to have occurred. However, the inspections did serve to verify that manufacturing or material flaws are not present. Also, re-assembly of parts following the inspections using controlled procedures served to provide increased assurance that the diesel is properly assembled, e.g., that bolts have the correct torque.

These inspections are now completed. The results of the inspections are summarized 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.

The only significant condition noted as a result of the inspections

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was that five heads on the 2A diesel were plug welded using partial penetration welds. On unit 1 diesels, some heads with such partial penetration plug welds leaked and were replaced. Accordingly, the heads on the 2A diesel with partial penetration plug welds were replaced. This problem is further discussed in Section 2.4.

Referring-to Table 2-1, some parts were to be subject to an engineering validation. These parts, which are important to diesel operability, were not inspected to conventional non-destructive techniques since they were not specified in the TDI Owners Group program and there has been no history of problems. On Catawba Unit 1, engineering validation consisted of an evaluation of the operating and maintenance history of these parts to assure that there were no problems. On the 2A diesel since the engine had never run there was no operating or maintenance history. Hence, engineering validation of the parts listed in Table 2-1 was'not performed.

2.3 Lessons Learned from Unit 1 Inspections The extended operation tests and revalidation inspections of the 1A and IB diesels (references 2 and 3) resulted in certain modifications 2-1 b

or changes to these diesels. These same modifications and changes have been accomplished on the 2A diesel, except for one item, which will be accomplished by the end of the first refueling availability.

These items include the following:

o Piston skirts were changed from the AN type to the AE type.

e A new turbocharger prelube system was installed to assure that the turbocharger bearings get adequate lubrication during engine starting.

e Modifications to the turbocharger prelube oil lines were accomplished to reduce vibration, e

Permanent turbocharger lube oil drain lines have been incorporated.

e Turbocharger exhaust gas inlet bolts have been changed to SA543, Grade 660 to guard against creep rupture failures.

e Turbocharger to bracket mounting bolts have been changed to a new material of increased fatigue resistance, e New turbocharger air inlet adapters with flexible couplings were installed.

e Rigid hangers were added to the jacket water piping going to the intercooler to reduce vibration.

e Crankcase and camshaft cover capscrews were replaced with improved fatigue strength materials.

e Starting air distributor cover capscrews will be changed to a material of improved fatigue strength during the first availability and prior to the end of the first refueling outage.

2.4 Cylinder Head Leaks Four cylinder heads at Catawba, one on engine 1A and three on engine 18, 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 2-1A. This welded-in plug is reported by TDI to have been used to repair the casting around the fuel injector hole.

Duke Power Company has developed both visual and ECT inspection techniques to detect the partial penetration plug weld in a cylinder head. On diesel 2A five heads had been ropaired with the partial penetration plug welds. These heads have been replaced. Of the heads replaced three heads (cylinders 6L, 7L and 8L) are heads with no weld repair. The other two replacement heads (cylinders 2R and 3R) have been repaired per Figure 2-18.

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o Referring to Figure 2-18, the weld repair of the cylinder heads consists of welding a plug into the head, stress relieving the weld and machining the injector port back side of the plug out such that the repair is a full penetration weld. This~ repair is described on TDI drawing 102718, Rev. O. Cylinder heads at Catawba that have been repaired in this fashion are stamped 1NR. The full penetration weld eliminates the crack starter found in previous partial penetration weld repaired heads. Post weld stress relieving reduces welding residual stresses to low levels. Thus, weld repaired castings with full penetration welds are considered equivalent in quality to non weld repaired castings. Hence, Duke Power Company will replace partial penetration repair welded heads with heads with no repair or with full penetration weld repairs as shown in Figure 2-18.

2.5 Conclusions

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The results of the revalidation inspections of diesel 2A have shown the engine to be in excellent working order. Lessons learned from the extended operation tests of both the Catawba diesels 1A and 18 have been incorporated into the 2A diesel such that it will be capable of producing reliable standby electric power.

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Catawtsa una t 2 Inspect on Matr a x Sample Size (percent) page 1 Part Base fart h. Class visual timea. 5.HE V.R8E Eng. Eval. astes Results Late til Pressere Regulating Valve 00-120 A - - - -

3 g

Jacket hter Standpipe.Fttets.Eastet 00-7004 3 t00 - - - -

Jacket sater Standpipe Valves 8 settsf actorp as reassentled 00-7003 3 - - - -

1 1 Jacket later Standpipe Supports 00-700C 3 100 - - - -

Jacket aster Standespe Seitches 8 Satisf actory as reassentled 00-700E 8 - - - -

I t Jacket later $tandnpe letting Materials 00-700F 3 100 - - - -

Rain karieg Base Assedly 82-3054 3 Satisf actory as reastedled A 100 - - - -

Rais Searing Stads and hts Satisfactory 02-305C A 100 - - -

Rate haring Caps latisfactory

~ 02-3053 4 800 - - - -

late oil laternal Headers Satisfactory 42-1474 A 100 - - -

ide Oil futing and Fittings-Internal 8 Satisfxtery as re:sseebled 02-3071 4 100 - - - -

Lste Oil Lise Supports-laternal 4 Satistutory as reasseabled 02-3078 8 800 - - - -

Crantshaft 0 Satisf actory as reassedled 02-3104 A 100 -

38 - -

Rais learing Shet!s 3 Satisfactory 02-310B A 100 100- -

Crankshaft Thrust learing ting

- - - $atisfutary 02-310C 4 -

100 - - - -

Craaktase Assently Satisf actory 02-Ill A A 100 - - - -

Cas learing Caps and 6evels

- Satisfactory 02-3118 3 - -

Crantcase Ravating hrdeare t 9 02-3113 3 - -

Piston Atags I t 02-1143 4 100 - - - - -

Cylinder Block 02-3154 nee riots installed-ne inspection done 4 -

25 25 -

Cytteder Liner 4 Satisfactory 02-315C A 100 800 - -

Cylinder I oct Jaclet sater heifeld

$atisfactory 02-3158 8 100 - - -

Cylinder Need Steds

$atisfactory 02-3 5E t 25 - - - -

Crtisser Prad sets Satisf actory 02-315F I 100 - - - - -

Satisfactory Jaclet later talet Ransfeld Asseetly 02-3164 4 tot - - - -

I latisf actory as reassembled Jacket gater talet Natifald Coupling 02-3160 8 100 - - -

Jacket uater 8tscharge Ranifold 8 Satisfactory as reassembled 02-3174 8 ISO - - * -

Jacket sater 8 isch, kniisti Couplist Satisfactory 02-3173 5 100 - - - -

3 Satisf actory as reassentled Jacket uater Bisch. haif ald Supports 02-387C 3 100 - - - -

Firseert letting 8 Satisfactory as reassentled 02-1309 4 100 - - -

Freat Gear Case latting

- - Satisfactory 02 335I C 100 - -

Connecting Rods and lashings Satisfactsry 02-3404 A 100 100 Connecting Rod learing Snetts 800 - - -

tatisfactory 02-3408 4 100 -

100 Pistsas 100 - - Satisf actory 02-3414 A 100 -

100 -

Paston Pie Assently Satisfactory 02-34tc let A . - -

l ! state Tapsets Satisf actory 42-345A 4 100 - - -

I fuel Tappets Satisfactory 42-3459 4 100 - - -

Caesnaft Assently Satisf actory 02-350A A 100 - - -

Caeshaf t learsag Satisfactory

'02-1508 0 100 - - - -

$ Satisf actory Caeshaf t Sears 02-350C 4 100 - - - - -

Satisfactory Pues Drive Sear 02-355A A 100 - - - - -

Satisf actory Idler fear Assently 02-3558 A 100 - - - - -

$atisfactsry Air Start Valve 02-359 A 100 100 - -

Cylsader Nead Satisf actory

, 02-3604 8 800 100 100 !00 -

2 Five heads replaced due to selded plugs I

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Catawba Unst 2 Inspection Matrix Sample Size (percent) page 2 Part hae Part No. Class Visaat It sen. $.blE V.EDE Eng.Evat. Notes tesults Istate and Enhaast Valves 02-3604 8 100 103 - -

valve Springs

$stisfactory

" 02-3609 8 100 - - -

Sutcover Assently 1 Satisfactory 02-3624 3 300 -

100 - -

Feet lajection Pueo Satisfactory 02-3454 5 100 - - - - - $atisf attery feel lejection Tubing o 02-365C 0 100 -

100 - -

4 three F.1. lines sere replaced Feel Injection Tubing Supports 02-3658 8 800 - - -

Fuel Pues Linkage I Satisfactory as reasseekled 02-371A/8 A 100 - - - - -

Satisfactory Istate halloids02-375 8 100 - - -

Eskaust Ranifstis Satishttery 02-3804 3 100 - - -

Estaust Ranifold talting Satisfactory 02-3003 8 100 - -

t - - . Satisf actory trantcase Covers Eastets and Bottlag 02-3868 C 100 - - - - - Satisf actory latde and Intereediate Bacter Are essee 02-3904 9 100 - - -

Estaust Rocker are Assembly

- - Satisfactory 02-3908 I too - - - - - Satisf actory Istate and Enhaust Pushreds 02-390C 3 100 -

100 - - - Satisf actory Connector Pushrods 02-3900 I 100 -

too - - -

Satisfactory Rocker Ars Bushings 02-390E 8 100 - - -

Recter Are Solting Satisfactory 02-1906 8 800 -

100 - - -

Satisfactory Overspeed Trip and Ac:essary 3 rive 02-4102 A 100 - - - - -

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

Speed Regulating Governor Satisfactory 02-4 tl4 A 100 - - - - - Satisf actory Governor Drive Couplings 02-411B A 100 - -

Eevernor Listage

- - - $atisfattery 02-4134 A 100 - - - - -

Sattsf actory fuel Pump Listage-Auto Shudows Cylinder 02-4138 8 100 - - - - -

Satisfactory Governor 8 coster Servosotor 02-4158 5 100 - - - - - Satisf actory Governor liest Enchanger Assee61y 02-415C A 100 - - - - -

Satisfactory Intercooler Paping-Coupling,8elt,5stts 02-4348 A 100 - - - - -

Satisfactory Turbo Cooling gater Pipe and Fittings 02-437A 8 100 - - -

Tarte Cooling water $spports 3 $atisfactory as reassented 02-4378 4 100 - - - -

3 Satisf actory as reassembled Start Air Ras:(sid Pipe, Tuning & Fttags 02-4414 A Start Air Manifold Pipe 5spports 100 - - - -

I $atisf actory as reassembled 02-441C A too - - - -

3 Satisf actory as reassembled Start Air listributor Tuning 02-4428 4 100 - - - -

8 $atisf actory as reassembled Feel lajection Piping 02-4505 A 100 -

fuel est Paping Supports I Satisf actory as reassembled 42-4508 A 100 - - - -

t $atisf actory as reassembled Fue! Cat filter nousting Nardeare 02-455C 4 100 - - - - - Satisfactory Esternal tube pit Lines , 02-4654 4 500 - - - -

8 Satisf actory as reasseebled Esternal tube Cal N Supports 02-4458 A 100 - - - -

t latisf actory as reassembled Enternal Luke Oaf Vevas 02-465C 4 - - - -

g t

furtockarger Lube Oil Piping 02-4&7A i 100 - - - -

8 Satisf actory as reassesbled Turbocharger Lune Cat Paging Supports 02-4678 8 100 -- - -

Isrtscharger tracket 8 $atisf attery as reassembled 02-4754 8 100 - - - - - Satisf actory furbocharger tractet Botting 02-4758 8 0 - - - -

1 Satisfactory Control Panel Catteet 02-5004 4 - - - -

I t Centret Air Accumulator 02-500F A - - - -

1 1 Control Air Systre Valves 02-5006 A -

Control Air Systes Pressure $. itches t i 42-500N 5 - - -

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Catawba Unit 2 Inspection Matrix Sample Size tpercent) page 3 Part #ase Part lio. Class visual 8:een. S.NDE V.NIE Eng.Esal. attes Results Contrs! Systes Relays 02-500J A - - - -

Contral Systee Solenoid Valets02-500(

1 1

<* 4 - -

Contral Air Systes Piping, Tubing, Fttag 02-500't I t i 100 - - - -

Control Panel viring 02-50cu A - -

t $stisfactory Lane til Sue, f ast , 02-5404 I t 3 100 - - - -

Lane Oil Suas fant Bolting 02-5408 I $atisf actory as reassembled 8 100 - - - -

Late Ott $uap fant Founting liardeare 02-540C O $atisfactory as reasseebled 8 100 - - - -

lastrasentation Thereocouples 8 Satisfactory as reassentled 02-6309 8 - - - -

1 1 Ingine & Ausillary flodule tiring Cond it 02-6884 A 100 - - - - -

Engine 4 Ausiliary flodule Niring 02-6888 A - -

Satisfactory Engine & Ausiliary Flodufe Birtsg loses 02-486C 4 - -

I t Engine Alare lessars t 1 02-690 4 - -

off fagine $af ter A! ara Sensers-Seitches 02-4918 I t 9 - - - -

1 1 Engine Shutdoso Tabing and Fittings 02-6954 8 t00 - - - -

Engine Shutdoen Valves. Regs e 4 Orifice 02-6958 A - -

I $atisfactory Engine Shstdoen Trip Seitches t 1 02-695C A - -

' Fuel Oil Duple Strainer I f

4. 02-8250 4 - - - -

I t Tortocharger Thrust learing Lebe $ystes 02-CTR C 100 - - -

fatate Air Filter D-106 8 - -

- . Satisf actory latate Air Silencer I t D-107 8 - -

lefore and Af ter tube Dal Puap I t CN-101 A - - - -

T Fall Floe Late Oil Filter CN-Il0 A - - - -

I Lune Oil heat E changer I t D-It! I - - - -

1 Senerator $nait and leartags ?

CN-lita A - - - -

Jacket gater heat fachanger I t CA-120 0 - -

Cil Prelvbe Filter I f D-122 A - - - -

Lune tal Keepeara Straiser D-131 1 I A - - - * -

, I t thermostatic Valve CN-136/40 0 - -

Intercooter I t F-068 4 100 - - - - -

Isrbocharger $4tisf actory FIP-022/3 A 100 100 100 - -

Late Oil Fe!! Pressure $ trainer SE-025 A - -

10 llot accesplashed-nes turbocharger I 1

'llti lg 19111

1. letate and estaest salve springs have the proper colar reas. 7. Imrtscharger braclet beltleg stil be replaced.

2. Ultrasenic eall thisteess seaseresent of fire sect ame feet 8. Wallde** laspecties te deterates as-tellt conditten.

settle area. laspectlan to determine if head has been 9.

. rep aired. Eagtererleg validation of part to deteraise is there are any

1. sagelficant unresolved estatence er operational pro 6 tees Craandaf t een deflections and thrust clearances te be associated eith the part. Ibis salidation oss Att perfereed senswed ettn the diesel het and ce18. as the engine had not been run at Catasta and there oss se 4

A sample elli ne removed free the llsch for esterial estatenance er aperational history.

vertittatten.

3. it. leardene and inspection of een er tensilt turbochargers Canthaf t nearings eill be inspected only of the taas snoe etica have accuselsted less thaa 54 hours6.25e-4 days 0.015 hours 8.928571e-5 weeks 2.0547e-5 months of operaties eill ahnstsal sear. set be perfereed.

6. ECT lespections sill be done of teth eads of high pressere lelecties lines.

3.0 Discussion of Inspection Results This discussion of inspection results is contained in three parts.

The first part (Section 3.1) covers inspections related to the generic problems being addressed by the TDI Owners Group. The second part (Section 3.2) covers inspections performed to address concerns raised by specific problems which have been experienced with Catawba diesels.

The third part (Section 3.3) covers significant inspection results not covered by the first two parts. All of these inspections are documented in the Appendix, Section 5.0.

3.1 Inspection Related to TDI Generic Problems The inspections related to TOI generic problems which were performed, and the results of these inspections, are described below.

3.1.1 Crankshaft (Part No. 02-310A)

PROBLEM:

A crankshaft failure occurred at shoreham. The cause of the failure 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.

The Catawba crankshaft design differs from that originally used at Shoreham. The Catawba crankshaft has substantially lower stresses, which meet industry standards and are not expected to cause problems (references 6 and 7). Due to satisfactory inspection of the Catawba Diesel 1A (reference 3), only visual inspections of crankpin web fillets on Catawba Diesel 2A were performed.

At San Onofre, a TDI diesel engine experienced cracks in main bearing journal oil holes. The V-16 Catawba diesel crankshafts are also different than the San Onofre V-20 crankshafts. However, as this failure was nuclear service related, inspections of the highest load main bearing journal oil holes on 2A were performed.

SCOPE OF INSPECTIONS:

The crankshaft inspections consisted of:

e Web deflection measurements, o Visual inspections of the crankpin journals on all eight crankpins.

3-1 0

e Fluorescent dye penetrant inspection of oil holes in main bearing journals #4, #6, and #8, RESULTS OF INSPECTIONS:

The results of all inspections were satisfactory.

SUMMARY

In summary, the inspections of the crankshaft indicate that-it is free of significant defects.

3.1.2 Connecting Rod Bearings (PartNo. 02-3408)

PROBLEM:

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 shelIs are about one half or less of those that were present in the original Shoreham engines. Thus, cracking of Catawba bearing shells was considered unlikely. Nevertheless, thorough inspections of the shells were performed to confirm freedom from problems.

SCOPE OF INSPECTIONS:

The bearing shell inspections consisted of:

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

e PT examination of the bearing shells.

e X-ray examination of all bearing shells.

RESULTS OF INSPECTIONS:

a

Visual inspections of the bearing shells indicated minor scratches on the back side. No cracks were detected by liquid penetrant inspection. All bearing shells passed the X-ray inspection.

SUMMARY

Penetrant inspection results and X-ray inspection results indicate that connecting rod bearing shells are acceptable for operation. The minor scratches on the back side of'the bearings were smoothed out. All bearing shells were !

installed in the engine. '

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3.1.3 Pistons (PartNo.02-341A)

PROBLEM:

Inspection (reference 3) of the Catawba IA diesel type AN skirts indicated that 4 out of 16 skirts had cracks at the circumferential rib to piston pin boss fillet. As a result, all Catawba piston skirts are being replaced with type AE skirts. In diesel 2A the replacement type AE skirts were inspected.

SCOPE OF INSPECTIONS The inspection performed on all the replacement type AE pistons skirts for diesel 2A are listed below:

e Visual inspection of fitup of crown .to skirt.

~

e PT examination of stud bosses on the piston crowns.

e PT examination of piston pin bosses, believille seat surface and the 0.D. of the skirt next to the piston pin bosses.

e MT examination of areas adjacent to piston pin bosses on the I.D. of the skirts.

i e Hardness tests of piston skirts.

RESULTS OF INSPECTIONS:

Results of all inspections performed on the pistons with new AE skirts were satisfactory.

SUMMARY

No problems were found with the existing piston crowns or the replacement type AE skirts.

'3.1.4 Cylinder Liners (PartNo.02-315C)

,_ PROBLEM:

Severe grooving has been noted in at least one TDI nuclear diesel engine (reference 11). This grooving was attributed to debris that entered the diesel during assembly or initial startup.

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SCOPE OF INSPECTIONS:

All of the cylinder liners were 100% visually inspected to check for the presence of grooves or other damage.

RESULTS OF INSPECTIONS:

No significant grooves approaching the 1/16" deep grooves seen in the Grand Gulf diesel were observed in the Catawba cylinder liners. Minor scratching was observed which is normal. These scratches are considered to have no effect on diesel operability.

SUMMARY

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.

3.1.5 Cylinder Block (PartNo.02-315Aj PROBLEM:

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

SCOPE OF INSPECTIONS:

The cylinder block inspections included the following:

e The area between the cylinder studs and the liner and the area around the studs were PT examined for all cylinders.

e The cylinder liners were removed from four cylinders (4 and 5 right; 4 and 5 left) and the cylinder liner landing e area within the block was PT examined.

e Replica tests of the blocks at each end and in the middle were taken.

RESULTS OF INSPECTIONS:

No significant indications were noted. Replica tests of the blocks indicated normal grey cast -iron, Class 40.

SUMMARY

Cylinder block cracks were not detected on diesel engine 2A.

Replica' tests of the microstructure were within normal limits.

3-4

3.1.6 Engine Base (Part No. 02-305A)

PROBLEM:

Linear indications have been reported as emanating from main bearing stud holes in the engine base. These problems have been attributed to inadequate bearing cap stud preload (references 11 and 12).

SCOPE OF INSPECTIONS:

The main bearing saddle area around and between the stud holes 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, only visual inspections of the main bearing caps and the base were carried out on main bearings 4, 6, and 8 of diesel 2A.

RESULTS OF INSPECTIONS:

Results of inspections were satisfactory.

SUMMARY

No cracking around stud holes on diesel 2A was found.

3.1.7 Cylinder Head Studs (Part No. 02-315E)

PROBLEM:

Isolated failures of cylinder head studs have been reported as occurring in non-nuclear TDI diesels (reference 13).

Hence, visual inspections on a sampling basis were performed of the Catawba diesels.

SCOPE OF INSPECTIONS:

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

1 RESULTS OF INSPECTIONS:

All cylinder head studs inspected satisfactorily passed the visual examinations.

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SUMMARY

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

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3.1.8 Rocker Arm Capscrews (PartNo.02-390G)

PROBLEM:

A fatigue failure is reported to have occurred with a rocker arm capscrew at Shoreham (reference.11). This failure was attributed to undertorquing. Reference 22 indicates that properly torqued capscrews have satisfactory fatigue resistance.

SCOPE OF INSPECTIONS:

The rocker arm capscrews were visually and MT examined.

RESULTS OF INSPECTIONS:

No indications were noted in the visual or MT examination.

SUMMARY

The diesel engine 2A capscrews were found to be satisfactory.

3.1.9 Connecting Rods (PartNo.02-340A)

PROBLEM:

Cracking of connecting rods is reported to have occurred, apparently due to relative motion between the two halves of-the connecting rod at the " rack-teeth" joint (reference 11).

SCOPE OF INSPECTIONS:

' The inspections of the connecting rods included the following:

e Visual inspection was performed of all connecting rods.

e Magnetic particle inspection of all connecting rod link rod and rod-to-box bolts was accomplished, e 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,seatingsurfaces)onall connecting rod assemblies.

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

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e Dimensional inspection of link rod to pin with link rod

, bolts torque to 1050 ft.lbs. was accomplished.

RESULTS OF INSPECTION All connecting rods passed the above inspections with the exception that one cotter pin was found missing on disassembly. A search of the engine internals was !

accomplished to look for the cotter pin which could not be found. It was therefore' concluded that the cotter pin was not installed at the factory. Degree of ' contact along the rack-teeth (serrations) varied between 80 and 95% which is

considered acceptable.

SUMMARY

" The diesel 2A connecting rods were found to be acceptable.

After reassembly in the engine, connecting rod capscrews were ultrasonically examined to assure that preloads were adequate.

, 3.1.10 Electrical Cables (Part No. 68880 PROBLEM:

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

SCOPE OF INSPECTION:

i i

Stone and Webster, as part of TDI Owners Group activities, reviewed the Catawba electrical cable installation

(reference 19).

RESULTS OF INSPECTION:

\

j-TheStone&Websterinspections(reference 14)were i completed in May 1984 with the following results.

i i

e TDI SIM 361 had not been implemented on the Catawba t i

diesels. This involves replacement of: shielded cable i,

from a terminal block to the tachometer relay in the '

l engine control panel; shielded cable from Airpax magnetic

' pickup to the junction box on the side of the engine; and multiconductor cable from an engine mounted junction box to the Woodward governor actuator. -

I e Duke Power should certify that States type NT sliding link terminal blocks used in the starting air solenoid

{

controls were not manufactured between 1974 and 1976.

1 3-7

b

SUMMARY

Replacement'of wiring to implement TDI SIM 361 has been completed on all Catawba diesels. With this replacement, all wiring is of acceptable temperature rating and adequately sized for circuit ampacities. Duke Power Company (reference 15) has a program for inspecting States sliding link terminal blocks during installation and each time the link is operated. Performance problems and defective links are reported to Design Engineering. Hence, Duke Power Company already has a program for uncovering defective terminal blocks and therefore find it unnecessary to verify the manufacturing date of the TDI terminal blocks.

3.1.11 Fuel Injection Lines (PartNo.02-365C)

PROBLEM:

Several 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).

SCOPE OF INSPECTIONS:

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 OF INSPECTIONS:

Three lines had recordable indications and were rejected.

SUMMARY

The lines that were rejected have been replaced with spare lines that have passed the ECT tests.

3.1.12 Jacket Water Pumps (PartNo.02-425A)

PROBLEM:

Several jacket water pump shaft failures occurred at Shoreham (reference 17). The Catawba jacket water pumps are of a different design than the Shoreham pumps. However, even though the problems experienced at Shorehan are not expected to apply to the Catawba diesels, detailed inspections were performed of the Catawba diesel 1A jacket water pump (reference 3). Because of satisfactory inspections of diesel 1A, inspections of the 2A pump were abbreviated.

3-8

.t

4 SCOPE OF INSPECTIONS:

e Visually inspect gear carrier e Visually inspect gear, coupling and spline e' Verify. torque on impeller nut is 80 ft.lbs.

e Verify torque on spline nut is 120 ft.lbs or greater e Check end play of external spline

RESULTS OF INSPECTIONS

All inspections were satisfactory. Torque on impeller nut was 80 ft.lbs and torque on spline nut was 140 ft.lbs. ,

SUMMARY

I i

The 2A jacket water pump met all . inspection requirements and was returned to service.

I 3.1.13 Air Start Valve Capscrews (PartNo.02-359)

!. PROBLEM:

i

' Capscrew bottoming out due to insufficient hole depth for the capscrew length can lead to insufficient clamping force

,; (reference 21). TDI recommended reducing capscrew length to prevent this problem. All Catawba diesel capscrews have j been modified.

, SCOPE OF INSPECTION:

i .

[ The inspections for the capscrews included the following:

, e Measure breakaway torque

e Measure length of capscreas for 4 valves as a check on h

the modification e Visual inspection of the valve seat areas on the heads '

i for all valves ,

RESULTS OF INSPECTIONS:

Capscrew lengths were acceptable, and the valves showed no signs of insufficient clamping force. One capscrew had a

breakaway torque of 20 ft.lbs. All others were satisfactory. The torque on these capscrews would have been checked prior to engine operation. Hence the factory torque

would have been corrected. ,

i l

3-9 k k.

i

SUMMARY

There appeared to be no problems with airstart valve capscrew bottoming out in the Catawba 2A diesel.

3.1.14 Push Rods (PartNo.02-390C)

PROBLEM:

I Originally supplied pushrods 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.

1 SCOPE OF INSPECTIONS:

The inspections of the new friction welded 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 RESULTS OF. INSPECTIONS:

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

SUMMARY

The Catawba diesel engine push rods are considered to be satisfactory since the friction welded design has operated over 900 hours0.0104 days 0.25 hours 0.00149 weeks 3.4245e-4 months with no sign of cracking on the Unit I diesels.

3.1.15 Turbocharger Bearings (Part No. MP-022/23; 02-CFR)

PROBLEM:

Severe wear of the bearings has been reported, apparently due to inadequate lubrication during diesel starts (references 2, 3 and 11). An improved lube oil. supply system was incorporated on Catawba diesels to furnish more lube oil flow to the turbochargers during startup.

SCOPE OF INSPECTION:

As the turbochargers on diesel 2A are new without any starts at Catawba on them, no inspections were accomplished.

l 3-10 t.

RESULTS OF INSPECTIONS:

n Not applicable.

SUMMARY

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

3.1.16 Cylinder Heads (Part No. 02-360A)

PROBLEM:

Three small jacket water leaks have been experienced on Catawba diesel IB (reference 2) resulting in water leaking into the fuel injector nozzle cavity. One leak of similar origin was seen on diesel 1A (reference 3). Failure analysis of one of the leaking heads has been completed (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 and Figure 2-1A, this report).

SCOPE OF INSPECTION The inspections performed of the . cylinder head included:

e Visual examination of valve seats.

e PT examination of valve seats in cylinder heads and the area between valve seats on the head.

e UT examination of fire deck thickness at selected locations.

e Eddy current inspections of heads to determine if they have a welded in plug.

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

RESULTS OF INSPECTIONS:

All cylinder heads successfully passed all examinations except for the inspections related to whether the head had a partf al penetration welded in plug. It was determined that five cylinder heads had partial penetration weld plugs.

These heads were rejected and replaced.

3-11 d

SUMMARY

To guard against external Jacket water leakage after the engine has been operated, five cylinder heads on engine 2A ware replaced with heads that did not have partial penetration welds.

3.2 Catawba Specific Problems 3.2.1 Fuel Injection Pump Nozzle Valve Holder (PartNo.02-365A)

PROBLEM:

A fuel injection pump nozzle valve holder on Catawba diesel 1A cracked as a result of a material defect (reference 3).

SCOPE OF INSPECTIONS:

Visual inspection of the 2A valve holder bores using a boroscope was accomplished to determine if there were linear defects.

RESULTS OF INSPECTIONS:

All valve holders with the exception of one had no linear defects. The one valve holder with linear indications was reamed, which removed the indications.

ENGINEERING EVALUATION:

A failure analysis was performed on the 1A fuel injection pump nozzle valve holder (reference 20). The results of this analysis indicate that an axially oriented linear indication in the high pressure fuel oil passage of the failed part led to the reported failure. Further analysis indicates that axial linear indications that would lead to cracking of the valve holder would cause cracking to occur within 10 million cycles of fuel pump operation. As the Catawba Unit 1 valve holders have withstood 10 million cycles of operation, the valve holder failure experience is considered an isolated material defect.

SUMMARY

It is concluded that the valve holder failure on diesel 1A was due to a material defect. The 2A diesel valve holders have been inspected to uncover such defects. The one valve holder (on diesel 2A) that had a linear indication was reamed and then found to be free of defects.

3-12 Y

3.2.2 Fuel Injection Pump Delivery Valve Assembly (Part No.

F-099-170)

PROBLEM:

During the IB extended operational test (reference 2) two fuel injection pump delivery valve assemblies leaked because of axial cracks. This type of failure does not exhaust fuel to the ambient but allows fuel to bypass the injectors and be returned to the fuel oil tank.

SCOPE OF INSPECTIONS:

The following inspections were accomplished:

e MT examination in valve seat area.

RESULTS OF INSPECTIONS:

No rejectable linear indications were found during MT examination of the valve assemblies.

SUMMARY

Diesel 2A valve assemblies have been found free of the type defect found in diesel 18.

3.2.3 Turbocharger Prelube Oil Lines (PartNo.02-467A)

PROBLEM:

Two failures of the prelube oil lines occurred during the 1A extended operation test due to fatigue cracking at compression fittings (reference 3). The lines have been replaced using an improved procedure and using additional clamps, vibration dampening devices, improved compression fittings and heavier wall stainless steel tubing on diesels lA and 18. As the Unit 1 diesels have passed their extended operation tests with no signs of leakage after the above modifications, no inspections of diesel 2A were accomplished. Diesel 2A and 2B lines have had additional clamps and vibration dampening devices installed to prevent vibration induced damage.

SCOPE OF INSPECTIONS:

Not applicable.

RESULTS OF INSPECTIONS:

Not applicable.

3-13 b

SUMMARY

Since the 2A diesel has had additional clamps and vibration

. dampening devices installed no problems with vibration induced damage are expected.

3.2.4 Turbocharger Adaptor (PartNo.00-495A)

PROBLEM:

~

A turbocharger air inlet adaptor cracked at a flange weld on diesel'1B (reference 2). A similar problem occurred on diesel IA (reference 3). In addition, the internal air flow divider on diesel IB (flow distributor) had a small crack at the junction to the case of the adaptor-(reference 2). This problem was not seen on diesel 1A. An engineering evaluation. indicates that the cracks are caused by excessive displacements at a location with limited flexibility.

A redesign has been implemented ort both Unit 1 diesels that installs a flexible connection between the adaptor and turbocharger to absorb.displa~ cements. In addition, on both Unit I diesels, strong backs have been. welded to the case-to eliminate the flexing which caused .the ' air flow divide'r weld failure. This redesign will assure that in the future the adaptor will not crack. In accomplishing this, the left adaptor from diesel 2A was used on diesel 1A and the diesel 2A right adaptor was used in diesel 18.

Duke Power Company manufactured two new adaptors for diesel 2A with strong backs included. In the process of manufacture all welds were MT examined. The two.new adaptors with flexible connections were installed on diesel 2A. Hence additional inspections on diesel 2A were not accomplished.

SCOPE OF INSPECTIONS:

Not. applicable.

RESULTS OF INSPECTIONS:

~

Not app 11 cable.

SUMMARY

With the new adap$ers and flexible connections installed on diesel 2A, it is concluded that pechlems initially seen-on .

the Unit 1 diesels will not occur on diesel 2A. j l

3-14

. 3

3.2.5 _Intercooler Jacket Flange (PartNo.136F-068)

PROBLEM:

A jacket water penetration into the water box on the intercooler seeped water during the extended operation test on diesel IB (reference 2). 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. The same rigid hanger was added to the Unit 2 diesels.

SCOPE OF INSPECTION:

Not applicable.

RESULTS OF INSPECTION:

Not applicable. .,

SUMMARY

- A rigid pipe hanger has been installed on both Unit 1 and Unit 2 diesels to change the natural frequency and limit displacements. This modification will eliminate pipe weld cracking at the penetration in to the water box of the intercooler.

3.2.6 Crankcase and Camshaft Cover Capscrews (PartNo. 02-3868)

PROBLEM:

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

SCOPE OF' INSPECTIONS:

-All .of these capscrews are being replaced with capscrews with improved fatigue strength and of known chemical and physical properties. Accordingly, inspection is not applicable.-

SUMMARY

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

3-15

3.2.7 Rocker Box (Subcover) Subassembly (Part No. 02-362A)

PROBLEM:

A problem was detected in the post extended operation test inspections of diesel IB (reference 2), 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 2-28, reference 3). The cause of the problem is believed due to installation tolerances between bushings and the pedestal leading to excessive interference fits.

SCOPE OF INSPECTION:

e Visual inspection of subcovers e The bosses on all of subcover assemblies were PT examined.

RESULTS OF INSPECTIONS:

All inspections were satisfactory.

~

SUMMARY

Several cracked bosses were found and the affected subcover assemblies have been replaced on Unit 1. These cracks have not caused a loss of operability of the engines. A failure analysis has been performed by FaAA under TDI Owners Group direction. This indicates that the cracks were due to installation or manufacturing errors and not due to service.

Thus, replacement of the defective subcover castings resolves the problem. On diesel 2A no such cracks were found and thus these subcovers are considered acceptable.

3.2.8- Turbocharger Lube Oil Drain Line (Part No. 02-467A)

PROBLEM:

A temporary drain line on diesel IA (reference 3) leaked during the extended operation test due to fatigue. It was replaced with an improved design as part of the diesel reassembly. Permanent lube oil drain lines have been ,

installed on all Catawba diesels.

SCOPEOFINSPECTIUN:

Not applicable.

3-16 t.

SUMMARY

This problem has been resolved by installation of a permanent drain line on all Catawba diesels. The fact that this permanent drain line design did not leak during the IB extended operation test provides assurance that the problem has been eliminated on all Catawba diesels.

3.2.9 Turbocharger Exhaust Gas Inlet Bolts (PartNo. 02-3808)

PROBLEM:

One 1/2 inch stainless manifold to turbocharger adapter bolt was found broken during disassembly of diesel IB (reference 2). This is similar to diesel 1A (reference 3) where four-were found broken. The cause of the failure indicates that the bolts failed from creep rupture (reference 20).

SCOPE OF INSPECTION:

Not applicable.

RESULTS OF INSPECTION:

Not applicable.

SUMMARY

On diesel 2A these bolts have been replaced with creep resistant SA 453, Grade 660, Condition A material. In addition, bolt installation procedures have been revf sed to insure that proper preloads are applied during this installation. Also, improved thread lubricant was used on reassembly to ease removal in the future.

3.2.10 Rocker Arm Adjusting Screw Swivel Pad (PartNo. 02-3908)

PROBLEM:

One of the swivel pads was found cracked during operation on diesel 18. This 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 improper swaging at the factory during manufacture. Another swivel pad was found cracked during reassembly of diesel 1B following the inspections. This pad is believed to have b' en e cracked when the rocker arm was knocked over in storage.

+

3-17

SCOPE OF INSPECTIONS: ,

All swivel pads were visually inspected.

RESULTS OF INSPECTIONS:

No defects were found and the sockets were found to be correctly swaged. 1

SUMMARY

The swivel pads are considered to be in satisfactory condition on diesel 2A.

3.2.11 Fuel Line Fittings (PartNo. 02-4508)

PROBLEM:

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 TDI . drawing (reference 11). During the extended operation test on diesel IB (reference 2) one high pressure and one low pressure fuel line fitting leaked. The high pressure fitting was retorqued eliminating the leak. The low pressure fitting had teflon tape added to elimirate the leakage.

SCOPE OF 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 OF INSPECTIONS:

The inspection of the fuel lines was satisfactory.

SUMMARY

During reassembly of the engine fuel lines, fittings were installed to Duke Power Company procedures to prevent improper torque values from being applied. In addition, walkdown inspections of the fuel lines have insured that the lines are properly attached, such that vibration problems are not expected.

3-18 b

3.3 General Inspection In addition to inspections related to TDI generic problems and to Catawba specific problems, inspections have been performed of numerous other parts in order to verify the operability of the Catawba 2A diesel engine. The results of these inspections showed that the 2A diesel entne was in excellent condition, with only one additional ,

problem in addition to the problems discussed in sections 3.1 and 3.2 l above. The only additional problem noted was that several fuel injector nozzle studs had linear indications. This problem is discussed below.

3.3.1 Fuel Injector Nozzle Studs (PartNo.02-360A)

PROBLEM:

MT inspection revealed that four fuel injector nozzle studs had linear indications.

SCOPE OF INSPECTIONS: .

All studs were visually and MT inspected.

RESULTS OF INSPECTIONS:

All studs passed visual examination. As mentioned above, 4 of the 32 studs MT examined had linear indications and were rejected.

SUMMARY

All rejected studs were replaced by spare studs which have passed both visual and MT examination, e

3-19 b

4.0 References

1. Duke Power Co. letter dated April 30, 1985 to H. R. Dent.on, NRC, with attached document entitled " Catawba Unit 2 Inspection Matrix."

2. Duke Power Co. letter dated October 16, 1984 to H. R. Denten, NRC, )

enclosing " Catawba Nuclear Station, Diesel. Engine IB Component Revalidation Inspection." :=

~

3.. Duke Power Co. letter dated June 29, 1984 to H. R. Denton, NRC, enclosing " Catawba Nuclear Station, Diesel Engine 1A Component Revalidation Inspection.'"

4. Failure Analysis Associates, " Metallurgical Analysis of Catawba Injection Port Leak", June 1984.

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

6. Bechtel Power Corporation, " Evaluation of Cfankshaft 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 Enterprise Engines", March 12, 1984.

8. (Deleted)

9. (Deleted)

10. (Deleted)

11. Mississippi Power & Light Co., " Comprehensive report on Standby Diesel Generators-Significant Activities to Enhance and Verify Reliability",

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

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

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

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

15. Duke Power Co. letter from G. T. Lamb to K. S. Canady, " Catawba Nuclear Station IE Information Notice 80-08 States Sliding Link Terminal Block", File CN1412.11-1; EGS N-14.01, May 7, 1980.

4-1 0

4

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

17. Stone and Webster Engineering Corporation, " Emergency Diesel Generator, Engine Driven Jacket Water Pump, Design Review", April 1984.

18. (Deleted)

19. Stone and Webster Engineering Corporation, " Emergency Diesel Generator, Auxiliary Module Control Wiring and Termination, Qualification Review", April 1984.

20. Duke Power Co., " Failure Analysis Report Catawba Nuclear Diesels 1A and IB", June 26, 1984.

21. Stone and Webster Engineering Corporation, " Emergency Diesel Generator Air Start Valve Capscrew, Dimension and Stress Analysis", March 1984 and Supplement, April 1984. .,

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

e 4-2 i b ,

. , _ . , . _ . - , __ . _ - _ _ _ _ _ ._. _. . O

5.0 Appendix 4

I e

i i

4 e

1 5-1 s

_ _ . _ . _ ._-,, , . _ _ . - ---y. - - - -

Qatgybg Dig'sgi 28_10sggctigg Be99C1 Eact Namg1 Jacket Water Standpipe Fittings and Gaskets Bati Nymbgc100-700A ClaSE1B W9th BE99est U9s Gittibutes yecified

1. Visually inspect system per 11.2, ref. 1 BefeCsoces

1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 10sgect190 Besuits

1. Visual inspections of the jacket water standpipe fittings and gaskets showed minor discrepancies with the as-designed drawings.

Disagsitige gi Inggegtigg Eindiggg

1. The discrepancies were determined to have no effect on engine performance. The jacket water. system was reassembled, leak teste,d and found to be satisfactory, w &6

?

GstBWha die 591'26 lOSEEGli90 BRE9C1 Egtt Ngmg1J acket W'ater Standpipe Supports Eart Numbgti OO-700C GlA551B

'W9th Es99mst Nez r

6ttCihWIRS M9tifigd

1. Visually inspect supports per 11.3, ref. 1.

t I, BEfRCROcgs

1. MP/0/A/1000/53 Diesel Engine Jacket Water System,_ Piping, Standpipe and Manifold Special Inspection 10599E1190 Bgsgits

1. Visual inspections of the jacket water standpipe supports showed minor discrepancies with the as-designed drawings. ;

3 DiSR9Eiki90 9f lOHEEchi90 EiOdings

1. The discrepancies were determined to have no effect on engine perfomance. The Jacket water system was reassembled,. -

leak tested, and found satisfactory.

4 4

1,.

i b

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

.ggiawba Qiegel 26 Insgggtign Sgggtt Eact Namg1 J acket Water Standpipe Bolting Materials Eact Nymbgti OO-700F glasg1B W9th Be99mst N9-8ticibytes yetifigg 1.- ' Visually inspect bolting per 11.2, ref.l.

'89fetEOERS

1. MP/0/A/1000/53 Diesel Engine Jacket W$ter System, Piping, Standpipe and Manifold Special Inspection 10292G$190 8959115

1. Visual inspections of the jacket. water standpipe bolting materials showed minor discrepancies with the as-designed drawings.

EiER9Eili90 9f lOSEEEtiGO-ELOd ings

1. The discrepancies were determined to have no effect on engine performance. The jacket water system was reassembled, leak tested and found to be satisfactory.

Getawbe-Dienst 28 Insnect190 Benett Eatt Namg1 Main Bearing Bases

<- BAtt Numbgt102-305A s

GlaE!1A W9th-Beaungt Ngzi385MNT i

elitibuigg yetifidd

1. Visually inspect mating surfaces per 11.5.3, ref. 1 Befecrec=1

1. 'MP/O'/A/1000/52 Diesel Engine Main Bearing Disassembly for Special Inspection IOsaggtige Bggylig

1. Visual inspections of the main bearing bases were 4

. satisfactory.

Diggggitign gi Ingagetign Eindingg There were no significant findings '

4

?-

___.._.___,,-_,___.____._,,_.,,___.___._-,,___.___,_,.,,._,.,_._,,_....,_m _ , _ _ _ _ _ _ . . _ , , _ , _ . _ _ . . . _ _

Ggigwbg Digsgl 26 10sggctige Bgggtt Egtt NamgiMain Bearing Studs EBCt Nymhgc102-305C Cla551A W9th BE9M25i N9s1585MNT i

etttihutes yectited

1. Verify stud elongation per 11.7.10, ref. 1 89f?Cggcgg

1. . MP/0/A/1000/52 Diesel Engine Main Bearing Disassembly for Special Inspection 10599Et190 822M112

1. Stud elongations were satisfactory DiSE95iti90 9f lOERREti90 Eindingg There were no significant findings e

1

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

n Gatanbg Digggi 26 Insgggtigg 8gggtt Eatt NamgiM ain Bearing Caps EBCt NymbgtiO2-305D Giags1A Wech Bgguest Ngz1585MNT 6titibyggg ygtifigd

1. Visually inspect mating surfaces per 11.5.3, ref. 1 BEfECHOGES

, 1. .

MP/0/A/1000/52 Diesel Engine Main Bearing Disassembly for Special Inspection 105E25$i90 B2591$5

1. Visual inspections of the main bearing cap mating surfaces were satisfactory.

ELSR91LIL9G 9f'1GEGEctL90 EindLQ95 There were no significant findings O

4 9

't b:

d Gatawba Di2221 _20'105995$i90 BER9Ct EECt N20Sil ube Oil ~ Internal Headers Eatt Numbecio2-so7A

' GLAE11A Weth Beaunst N9z 8ttribut2s Verified -

1. Visually inspect headers per 11.3, ref. 1.

BEfGC20 GEE

~ 1.

MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and_ Sump.

Special inspection 102G251190 BESulla

1. Visual inspections of the lube oil internal headers showed-minor discrepancies with the as-designed drawings.

, Diggggitign g[ Ingangtign Eind_(ngg I

1. The discrepancies were determined to'have no effect on engine performance. The lube oil system was reassembled and determined to be satisfactory.

e w

e h,

a

. .__ _ ,-, . , _ . . . - - -.-- -- - - -- ~ ~ -- - - ~ ~ ~ ~ ~ ~ *-~'~ ~~ ~ ~* ~ ~ ~ "' ~ ~ ' ~

Ggtep;a Qiggei 28 Inggettign.Beggtt Eatt Namg1 L ube Oil Tubing and Fittings Eact Numbgt10 2-307B GlaE51A Wech Begunst Ngm 8tttibuggs yetifigd

1. Visually inspect internal lube oil system piping, tubing and fittings per 11.3, ref. 1 2.

Visually inspect external lube oil system p1 ping, tubing and fittings per 11.4.1 ref. 1

~

_f Beiet2ntes

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special. Inspection lOHREEti 90 8e59115 162 Visual inspections of the lube oil tubing and fittings showed minor discrepancied with the as-designed drawings.

ELSE95Lii90 91 1GEQectiOO EiOd ingg 1&2 The discrepancies were evaluated as having no effect on

~

engine performance. The lube oil system was reassembled and determined to be satisf actor y.

l l

Ggigwba Digsgi 28 losggetigg Bgggtt Egtt Ngmg1 L ube Oil Line Supports

Bett Nymbgti O2-307D G12EEiB W9th BR9995t N9s 4 8titibutes verified

1. Visually inspect supports per 11.3, ref. 1 BRfREROGRE

1. MP/0/A/1000/43 Diesel Engine Lube Oil, System Piping and Sump Special Inspection 1

j 10saecti90 Beguita

1. Vi sua." inspections of the lube oil line supports showed minor discrepancies with the as-designed drawings.

J .

Di2291lti90 9f lOsaggtige Eindings

1. The discrepancies were determined to have no effect on engine performance. The lube oil' system was reassembled, and determined to be satisfactory.

4 4

I #

W f

b.

Getswks Diesel 28 10sanstien BensCt Egti Ngmg1 Crankshaft EBCt Nymheg1 02-310A Glass 1A M9th Egggest Ugzi585MNT 6thCibuigg yggifigd

1. Measure web deflection per 11.3.1, ref. 1

2. Visually inspect crankpins per 11.4.1, ref. 1

3. PT inspect oil holes in crankshaft per 11.6.1, ref. 1

4. ECT inspect oil holes in crankshaft per 11.6.2, ref. 1

5. Visually inspect crankshaft gear per 11.2.2, ref. 2 82f2CEOc25

1. MP/0/A/1000/39 Diesel Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase Assembly, and Crankcase Covers Special Inspection

2. MP/0/A/1000/40 Diesel Engine Idler Gears and Pump Drive Gears Inspections and Adjustments Insnectigo Busults

1. Cold and hot web deflections were saticfactory.

2. Visual inspections of - the crankpins were satisf actory

3. PT inspection of the oil holes were satisfactory

4. ECT inspections were not necessary as the PT inspections demonstrated no indications

5. Visual inspections of the crankshaft gear were satisfactory Diggggitign.gf l'aggggtige Eindtogg There were no significant findings 1

1

=-

l

Getgwbg Digsgi 28 losgectige Bgggtt Ectt NgmetMain Bearing Shells Bett NymkgtLO 2-3108 Gla5ELA'

. W9th 829ME5h d9s1585MNT .

L

'6tttihytgs Mgtifigd

1. Visually inspect main bearing shells per 11.5.1, ref. 1.

2. Measure thickness of the main bearing shells per 11.5.2, ref.1.

4 82fRCEOCES .,

1. MP/0/A/1O'OO/52 Diesel Engine Main Bearing Disassembly for Special Inspection 105GECli90 89291t5

1. Visual inspections of the main bearing shells showed several 2

instances of minor scratching, otherwise the bearings were satisfactory

2. Measurements of the thickness of the main bearing shells' ,

were satisfactory. The thickness of all shells was greater than .614 inches.

4 Disposition of Insggctige Eindings

1. Scratches on the main bearings were determined to be normal and the bearings were evaluated as satisfactory for reuse.

k.

Gdledhe Digggl 26 Ignggetigg Egggtt Cett NamtliCrankshaf t Thrust Bearing Ring EaCt.UM0hECLO2-310C GleSHLA WOCk BCGuggt Ngt1505MNT Btttiquien MeCliLed

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

B9fCCCOG25

1. MP/0/A/1000/39 Diesel Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase Assembly, and Crankcase Covers Special Inspection 102G251190'B0291ID

1. i-ieasur ements o f thrust clearance performed in the cold and hat conditicos were satisfactory.

Dineggiking gi Ingegctige Eindiggg There were no significant findings.

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Cat 9Mh2 Di2291 26 IO29Ecti20 BEggCt 1- EECt Ugsg1C rankcase Assembly

_ ESCt UM0haciO2-311A Cla22iA M9CA BREMEEt'N9 tis 85MNT 6ttClhutEE YEtifiGd

- 1. Visually inspec't cast surfaces of. crankcase per 11.5.1, ref.1

! 2. ' Verify crankcase material from foundry records per 11.5.3, ref. 1.

.8EfRCEGEEE '

' 1. MP/0/A/1000/39 Diesel Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase Assembly, and Crankcase Covers Special Inspection

, 102G25ti90 8929112

1. Visual inspections of the cast surfaces were satisfactory

2. ' The material was verified as being A-48 Gray Cast Iron i

l DiSE92LiiGG 9f IONERGhi90 EiO dings

i. There were no significant findings 1

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Catawbg gigsei 2e Insagetiga agagtg Egtt Namg1 Cylinder Block Egtt-Nymbgt1 02-315A Cla2siA W9Ch Begugst Ngz1583MNT 6thCihMARE YECifigd

1. PT inspect cylinder block top per 11.2.1, ref. 1

2. Measure liner landing area per 11.6.1, ref. 1

3. PT inspect liner landing area per 11.6.2, ref. 1

4. Replica inspect cylinder block per 11.7, ref. 1 BEfRCEQcgg ,

1. MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection lesenstige Besults 1.

2.

PT inspections of the cylinder block top were satisfactory.

Dimensions of the cylinder liner landing area were forwarded to the Owners Group- No acceptance standards were given.

3. PT inspections of the liner landing area were satisfactory.

4. Replicas of the cylinder block demonstrated typical gray

. cast iron, class 40.

EiER9Eiki90 91 IGsRREti90 ELGdingg There were- no significant findings

Geigwbg Qiggei ;G losgestige Bgggtt Patt N3mg1 Cylinder Liner b Eatt Nymbgt102-315C

/

91aE2iA M9th Be9MeEi U9t1583MNT 6ttCibutes yetified

1. Visually inspect cylinder liners per 1 1 . 3 .'1 , ref. 1

2. ' Measure bore of cylinder liner per 11.3.2, ref. 1 3.- Measure distance liner protrudes per 11.3.3, ref. 1

4. Perform supplemental visual ' inspection of cylinder liners per 11.6.3, ref. 1

5. Perform supplemental dimensional inspections of cylinder liners per 11.6.4, ref. 1 BEf2CEOC25

1. MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manif old and Piping Special Inspection 1059951190 82291$5 1.- Visual inspection of the cylinder liners were satisfactory.

2. Cylinder liner bores ranged from 16.995 to 17.0025 inches.

3. Cylinder. liner protrusions ranged from .004 to .008 inches.

.4. Results of the supplemental. visual inspections of the cylinder liner were satisfactory

5. Supplemental measurements of the cylinder liners will be forwarded to the Owners Group Di299511190 9f 105G95$190 EiOd iggg'

2. Cylinder liner bares were reviewed with personnel at TDI and were found to be satisfactory and acceptable for continued service.

5. There were no acceptance standards for these measurements, the data is for informatien only

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Qgtgwha Diesei 28 Insgectign Bengtt Pgt t NemgtC ylinder Block Jacket Water Manifold Batt'NumhetiO2-315D GlassiA I W9Ck Begggst Ngzi383MNT i 6titihMtES Metified

1. Visually inspect the jacket water manifold per 11.5.1, ref.1 BeiRCEOGE5 1.- MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water. Manifold and Piping Special Inspection lO59EEti90 BE29115

1. Visual inspections of the jacket water manifold were satisfactory.

Digggsitign gi lusggctign Eindingg There were no significant findings

b. .

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i Ggtgwbg Digsel 20 Insgectign Beggtt Pact Namgi Cylinder Head Studs EACt Nymbgt102-315E Clgss1B Wech Bggugst Ngzi383MNT, 1784MNT 6ttt i butes tetified

1. Measure' breakaway torque per 11.2.14, ref. 1.

2. Verify proper installation per 11.6.3, ref. 1.

3. Check free length per 11.6.4, ref. 1.

4. Visually. inspect cylinder head studs per 11.4.2, ref. 2.

BRfECEnCEs

1. MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, Disassembly, Inspection and Reassembly

2. MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection .

10seecti90 Beaulta

1. Breakaway torques were found to be 860 to 1340 ft-lbs.

2. Studs were installed by inserting,. backing out 1 turn and verifying free length of 14-7/8 inches.

3. The free length of the studs.was verified as satisfactory (14-7/8 inches +1/4,-0)

4. Visual inspections of the cylinder head studs showed minor scratches-and nicks Disnesition gi 10saect19e Eindinen

4. The scratches on visual inspection were determined to be normal and the result of stud removal. The studs were evaluated as satisfactory for reuse I:

i Gatgwbg Diesel 28 Igggggtigg Beggtt Pact Name1C ylinder Head Nuts EaCt Jymbet10 2-315F Glans 1B W9th Begyggt Ngzi784MNT, 1583MNT 8tttibyteg ygtLiied

1. Measure breakaway torque per 11.2.12, ref. 1

2. . Visually inspect nuts for ID markings per 11.4.3, ref. 2

3. Visually inspect nuts for forging laps per 11.4.4, ref. 2 BEfaceOEe5 -

1; MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, Disassembly, Inspection and Reassembly

2. .MP/0/A/1000/44 Diesel Engine Cylin' der Block, Cylinder Liner and Jacket Water Manifold and Piping Gpecial Inspection IO22ecti90 Be29115

1. Breakaway torques of the cylinder head nuts were 2630 to 3510 ft-lbs. -

2. Visual inspections of ID numbers was satisfactory.

3. Visual inspections of the nuts for forging laps were satisfactory.

Diangsiti9o si 10meeSt190 E10dinga There were no significant findings.

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GatEWha Digsgi 28 Insgeglige Bggget Eggt NamgtC ylinder Head Gaskets Eatt.Nymygg102-315G ClasalB W9th BR99951.Ngzi784MNT 4

6ttCihMtEE MetifiRd

1. Visually inspect gaskets per 11.2.2, ref. 1 89feC90ERE

1. MP/0/A/1000/35 Diesel Engine Cylinder., Head Removal, Disassembly, Inspection and Reassembly 102G9E1190 B25M112

1. . Visual insections of the cylinder head gaskets were satisfactory.

Disagsilige gi leggggtigg Elgdingg There were no significant findings.

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.Getaube Diessi 20 105acEti90 8999th EdCi Namg1 J acket Water Manifold Assembly

.Eett Ugmhgc102-316A E19221B M9th Es99e21.69z

.8ttributes yetified

1. Visually inspect assembly per 11.3, ref. 1 82fEcEOGE2

1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection IOSDUEAi90 8229115

1. Visual inspections of the jacket water manifold assembly

.showed minor discrepancies with the as-designed drawings.

Digggnitige g[ leggggligg'Eindiggg

1. The discrepancies noted were evaluated as not affecting diesel performance. The Jacket water system was reassembled, leak. tested and determined to be satisfactory.

e g .'

- _. . . ._ . _ .___ _ . _ _ _ _ . - . ~_ ___. __ __ .

1 a

Galabha Di2221 20'1059255i90 BS99C1 P 2Ct.Namg1 J acket Water Inlet Manifold Coupling EECt NW$b2ClO2-316B Gia221B H9th 8299221 M9z 4

Attribytgs ygtifigd

- 1. Visually inspect coupling per 11.4, ref.1.

82f9CEOG22

1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection f

IO902Ghi90 B25Mlia 4

1. Visual inspections of the Jacket water manifold couplings were satisfactory.

. Ol5E9EitlOO Gi lOEREEll90-EiOdiO95

~

There were no significant findings.

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N, e- -r -m--e-rg-S&g..~-ew=*W r+ w -h--tw e g 3-r -w t--set- N - M w --- n- wr t ve--- ww7ie v e- ge -+ pe--ev y - w e t-e e -wy - e '-r. = -us eF 7 F W MPT**N-*

Cgtswkg Digggi 26 10gggg1190 Bgggtt Part NgmgiJ acket Water Discharge Manifald Eatt Nymygc102-317A Clasg1B W9tt.Bgggggt Ngz 8ttributes Vecified

1. Visually inspect Jacket water manifold per 11.5.1, ref. 1

2. Check Dresser coupling per 11.5.1, ref. 1

'3. . Visually inspect jacket water manifold per 11.5, ref. 2 Befetensen -

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

1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 10299st190 Beaults

1. Visual inspections of the jacket' water manifold were satisfactory.

2. The Dresser coupling was marked D 21102-2ST66-B

3. Visual inspections of the manifold were satisfactory.

Disags[t19Q Qi 10922G1190 ElGdiO9E There were no significant findings.

t. .

Cal 3Whs DiESS1 26 1052eG1190 BeR9Et EgCt Namg1 J acket Water Discharge Manifold Coupling ESCt Nymhgt102-317B ,

Cla2ElB 99Ck 8g99931 Ngz etitibuiss Vecified

1. Visually inspect coupling per 11.5, ref. 1.

821EC20525

1. MP/0/A/1000/53 Diesel Engino Jacket Water System, Piping, Standpipe and Manifold Special Inspection 1020051190 8929112

1. Visual inspections of the jacket water manifold coupling were satisfactory.

EinEGEltiOO 91 lO2EEGilGG ElGdiOG5 There were no significant findings.

e

Getanha Diesel 28 1029esti90 Ben 9tt Part Ngmg1J acket Water Discharge Manifold Supports

'Bett Uymhgg102-317C G10SaiD ,

j M9Ch B299921 UOz 8ttributsa Ystified

1. Visually inspect supports per 11.4, ref. 1 B218CSDG92

1. MP/0/A/1000/53 Diesel Engine Jacket Whter System, Piping, Standpipe and Manifold Special Inspection 10202G1190 BE59132

1. Vicual inspections of the jacket water manifold supports showed minor discrepancies with the as-designed drawings.

Diggggliign gf leggggligg Eigdiggg

1. The minor discrepancies were determined to have no effect on the performance of the diesel. The Jacket water system was reassembled, leak tested and determined to be natisfactory.

4

c Geteeks Diss=1 20 10saest190 Bseett Egtt NgmgiFlywheel Bolting

- Eett NymbgtiO2-330B Gle!!iA W9th Bggggst Ngt1757MNT l

l Atttihytgg Vgt i figd i .,

'.i Verify correct torque is applied to flywheel bolts per 11.1, ref. 1

2. Visually inspect flywheel for loose roll pins per 11.2.1, j- ref. 1 i

i. BRfECROGRE

1. MP/0/A/1000/48 Diesel Engine Flywheel Bolting Special '

Inspection i'

I 10assst190 Bgguits-j 1. Correct torque was verified through construction

i. documentation.

2. Visual inspections of the roll pins were satisfactory 4

i D19n9511190 91 Innasst190 Elodinan There were no significant findings.

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Ggtewha Qigggi 26 Inseggtign Bgggtt

.Pett Ngmg1 Front Gear Case Bolting Part Number:02-335B GlBERLC W9th 89999E1 N9t1586MNT 6ttClhMtRE VEtifigd

1. Visually inspect gear case covers for evidence of oil leaks per 11.1, ref. 1.

2. Verify. bolting is of appropriate material per 11.2, ref. 1, Beintressa -

1. MP/0/A/1000/41 Diesel Engine Gear Case Gaskets and Bolting Special Inspection 10nesst190 BenWita

1. Visual inspections for evidence of leakage were 7

satisfactory.

2. All capscrews were verified as class 5 or better quality.

Disn9mit190 of Innnectigo Eindic9s There were no significant findings.

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Gatabb e Diesel 28 legggetign Beggtt Pact NamgiConnecting Rods Eatt Numbet102-340A glagg1A M9th 8g9Mest N9t1583MNT 8tttibutes yettfied

1. Measure torque of master rod bolts per 11.2.5, ref. 1

2. Check oil passages per 11.2.13, ref. 1

3. Measure torque of link rod bolts per 11.17.1, ref. 1

4. Measure link rod clearance per 11.18.6, ref. 1

5. Visually inspect connecting rods per 11.3.2, ref. 2

6. ECT inspect female rod box threads per 11.3.3, ref. 2

7. PT inspect rod box sides per 11.3.4, r_ef. 2

8. Visually inspect bolt washers per 1 1 .'4 . 1 , ref. 2

9. MT inspect rod bolts per 11.4.2, ref. 2

10. Visually inspectbushings per 11.5.2, ref. 2

11. PT inspect con rod bushings per 11.5.3, ref. 2

12. Blue check serrations per 11.11.1, ref. 2

13. Measure con rod bushings per 11.13.1, ref. 2

14. Visually inspect link rod dowell per 11.14.1, ref. 2 Beintensen

1. MP/0/A/1000/36 Diesel Engine Piston Rod and Liner Removal, Disassembly, Inspection and Reassembly

2. MP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shell Special Inspection 1059est190 Beguita

1. Torques of the master rod bolts ranged from 1270 to 1850 ft-lbs. ?

2. Inspections of the oil passages were satisfactory

3. Torques of the link rod bolts ranged from 830 to 1110 ft-lbs.

4. Measurements of link rod clearance were satisfactory

5. Visual inspections of the connecting rods showed minor scratches.

6. Not accomplished based on results of insps. 1,5,7,and 9.

7. PT inspections of the rod bon sides were satisfactory O. Inspections of the rod washers and contact surfaces were satisfactory

9. MT inspections of the bolts were satisfactory

10. Visual inspections of the bushings showed minor scratches

11. PT inspections of the bushings were satisfactory

12. All serrations showed > 00% contact-satisfactory

13. Dimensions of.the con rod bushings were satisfactory

14. Visual inspections of the con rod dowells were satisfactory t.

Connecting Rods, 02-340A- continued D1329315190 91 IOSEEcli90 Eindiggg 5,10 The minor scratches that showed on visual inspection were evaluated as normal and it was determined that the parts are acceptable for continued service.

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Gatewke Dieset 28 10snecht90'Benett Eatt Nemg: Connecting Rod Bearings Eftt NMmkRC102-340B GlAEELA W9th 829MREt N9s1583MNT t

8tittkutta Ytttiled

1. Visually inspect bearing shells per 11.5.2, ref. 1

2. PT inspect bearing shells per 11.5.3, ref. 1

3. RT inspect bearing shells per 1.1 . 5 . 4 , ref. 1 Bristensen -

1. NP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shell C scial Inspection Iannsst190 Beaults

1. Visual inspections of the bearing shells showed minor scratches.

2. PT inspections of the bearing shells showed no defects

3. RT inspections of the bearing shells showed no defects Dinnenttien 9f lonnestten Etudless

1. The scratches that were discovered on visual inspections were determined to be normal and the bearing shells were evaluated as acceptable for reuse.

O

EBlEWha E19591 26 IONESC$i90 8999th EBCt Ugmg1 Pistons Egth UymhgtiO2-341A GlBSELA W9th Egguest Ugs1583MNT 6titthutun Vettiled

1. Visually inspect fitup of crown to skirt per 11.6.1, ref. 1

2. PT inspect piston skirt and crown per 11.6.2,11.8.1, ref. 1

3. MT inspect piston skirts per 11.6.3, 11.8.3, ref. 1

4. Measure hardness of piston skirts per 11.8.4, ref. 1 BEfttEGERS -

1. MP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shell Special Inspection 102anst190 B9sults

1. Visual i nspections of the piston crown and skirt were satisfactory.

2. PT inspections of the piston skirts and crowns were satisfactory.

3. MT inspections of the piston skirts were satisfactory.

4. Hardness inspections showed uniform hardness in a range of 206 to 241 BHN Dinnonit19e 91 loangst19e Eindican

4. The hardness data is affected by the surface roughness of the material measured. The hardness data is considered reasonable within the limits of accuracy of the measuring device.

. __ .__ ~ _ - . . _ _ . ..-__. - _ - - . . - - -- .- _ ._- . _

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t GA1Ahha gigsgl 28 10saggtigg Bgggth f t

l Eatt Nemg1 Piston Pins t

EAtt NumbRt102-341C i

GlARELA Neth Benutzt Ngt1583MNT 8tttikuten Yettiled

1. Visually inspect piston pin assembly per 11.7.2, ref. 1 s l

l

! Beintrosas

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

Innuest190 Beaulta '

1. Visual inspections of the piston pins showed minor scratchos; otherwise,_the piston pins were satisfactory.

4 DinnQattloo 91 Innanstlen Eindican :

1. The minor scratches that showed on visual inspection were [

determined to be normal and the piston pins were evaluated as acceptable for continued use. l i

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i 1 i CALAWha Diggel 28 Ingagstigo Bgggtt Entt Nggg1I ntake Tappets t

EAtt NumyEC102-345A GlARELA N9th St9uent N9t1586MNT 8tittkuten Yettitud

1. Visually inspect intake tappets per 11.6.1, ref. 1 BeinCansen

1. MP/0/A/1000/45 Diesel Engine Camshaf t,- Camshaf t Gear and Tappet Special Inspection i

lonenst190 Beaulta

1. Visual inspections of the intake tappets were satisfactory, t

4 DinRenitL90 si Insnest190 Eindienn '

There.were no significant findings. ,

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I cateena otesst ge insanctten gnagtt Entt Ngmg1 Fuel Tappets-EaCt_Nymbgti 02-345B GlAEBLA W9th Benuant Nes1586MNT 8titikuten Ytttiled

1. Visually inspect fuel tappets per.11.6.1, ref. 1.

Bristansen

1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection Innesstien Besuits

1. Visual inspections of the fuel tappets were satisfactory.

Disn9nitten 91 loannstion Eindienn There were no significant findings i

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gatawba-Qigsgl 28 insqqqttgg Egggtt EBCt~Namg1 C amshaft EBCt Nymbgti O2-350A glagg1A W9th Begunst Ngz1586MNT 61ttibutgs ygtLilgd

1. Visually inspect camshaft lobes per 11.3, ref. 1

2. Visually inspect camshaft locking clips per 11.4.3, ref. 1 BEfRCEGERS

1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection IO5REGA190 BESMlts

1. Visual inspections of the camshaft lobes were satisf actory.

2. Visual inspections of the camshaft locking clips were satisfactory.

D152951$190'91 IO5REGil90 E10diO99 There were no significant findings.

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Cgtggbg Diesgi 28 losgettige Beggtt i

Eatt NamgiCamshaft Bushings Eftt Ugmbgtt02-350B ClaEsiA W9th Benussi Ngs1586MNT 6kitibutgs ygtifigg

1. Visually inspect camshaft bushings per 11.4.2, ref. 1.

BRIECEOG9E

1. MP/0/A/1000/45 Diesel Engine Camshaf t, Camshaf t Gear ar.ci j Tappet Special Inspection

10anect190 Besults

1. Visual inspections of the camshaft bushings were satisfactory.

ELE 292ill90 91 lOEREEtiGQ ELQdlG92 There were no significant findings.

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Gataubg Dieggl 26 Ingggstign Bgggth Egtt Namg1Camshaft Gears Eatt Ngmhgc102-350C-GlBRELA W9th 8tnuest-Ngzi586MNT 1

6titibyggg Mgttilgd-

1. Check web to gear torque per 11.4.4, ref. 1.

2.- Visually inspect cam gears per 11.5.4, ref. 1.

BRfRCEGEEE 1.- MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection 102E2G$i90 822911E'

1. The torque of the cam gear bolts was 80 (+10/-0) ft-lbs on

' reassembly.-

2.

Visual inspections of the cam gears were satisfactory.

Disegnitisc 91 lesnestien Eindinna 4

There were no significant findings.

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GatAWha QlE5El 26 lOEERGil90 BRR9Ct EBCt Namg1 Pump Drive Gear

.EAtt-NymhgtiO 2-355A GlAE51A W9th Steutst 69t1586MNT 8tttthute1 Estified

1. Visually inspect pump drive gear per 11.2.4, ref. 1.

BRfRCEOGES

1. MP/0/A/1000/40 Diesel Engine Idler Gears and Pump Drive Gears Inspections and Adjustments 10522E1190 BE29111 1.

Visual inspections of the pump drive gear were satisfactory.

E15092lti90 91 105995t190 Eindiggg There were no significant findings.

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ggiauge QLgggl 26 10ggggtige Bgggtt ,

Egtt Namg1 Idler Gears Efth Ugmhet102-355B GlAMELA W9th BRQMERL M9t1586MNT 6thClkMARE MRClflRd

1. Visually inspect idler gears per 11.2.3, ref. 1.

2. Measure backlash of the idler gears per 11.3.4, ref. 1.

BRfRCRGERE

1. MP/0/A/1000/40 Diesel Engine Idler Gears and Pump Drive Gears Inspections and Adjustments ,

IOSREGhi90 BREWlh3

1. Visual inspections of the idler gears were satisfactory.

2. Backlash measurements of-the, idler gears were within normc1 limits.

QinnenttL90 91 lonuncit90 Eindinun .

There were ne significant findings.

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Gatawba Diessi 26 Insenst190 Beastt Pgtt Namg1 Air Start Valves Eett Numbat102-359 Gl!!11A Wgth Bggugst Ngt1784MNT,1584MNT 6tttibuten Vatified

1. Measure breakaway torque of capscrews per 11.3.10.1, ref. 1.

2. Measure capscrew length per 11.3.2, ref. 2.

3. Visually inspect seat areas of valves per 11.3.3, ref. 2.

4 '. . Visually' inspect valve interna 1' surfaces per 11.3.4, ref. 2.

Beint=0Enn -

1. MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, Disassembly, Inspection.and Reassembly

2. MP/0/A/1000/37 Diesel Engine Cylinder Headand Associated Parts Special Inspection 1n209G1100 BREWita

1. Breakaway torques ranges from 20-160 ft-lbs.

2. Capscrew lengths were verified as acceptable.

3. Visual inspections of the seat areas were satisfactory.

4. Visual inspections of the valve internal surfaces were satisfactory.

D120021t190 91 102REGt19e Eindinga

1. Breakaway torques were considered low. These screws were installed by TDI. These screws would have been checked prior to engine operation. All screws were torqued to specified values on reassembly.

c Catquba Digsel 28 losgestige Bgggtt l

Pact NamgiC ylinder Heads Egtt Nymbgc102-360A Class 1A l W9Ch Bequest N9s.1584MNT 6ttCibutes Vetitiet.

1. Visually inspect valve seats per 11.5.2, ref. 1.

2. PT inspect valve seats and fire deck per 11.5.3, ref. 1.

3. Measure thickness of fire deck using UT per 11.5.4, ref. 1.

4. Visually inspect heads for weld repairs per 11.5.5, ref. 1.

5. Visually inspect inje.ction studs per 11.13.1, ref. 1.

i 6. MT inspect no::le studs per 11.13.2, ref. 1.

( 7. ECT inspect nozzle cavities per ref. 2.

L B2fEC90GEs

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

2. Special Engineering Evaluation " Eddy Currrent Inspection to l Determine Catawba. Diesel Cylinder Head Casting Weld Repairs" l November, 1984 10D09Eti00 8919112 l 1. Visual inspections of the valve seats showed minor pitting.

PT inspections of the valve seats and fire deck were

(

satisfactory.

3. UT thickness measurements of the fire deck showed the. fire deck to be'.40 - 1.4 inches thick.

4. Five heads, 6L,7L,OL,2R and 3R, had welded plugs.

5. All studs were satisfactory on original heads. New studs were installed on the heads that were replaced.

j 6. Four studs showed linear indications on MT inspections.

7. Five heads were rejected (same as 4, above)

D120921t190 91 Ioannst19e E10dions

1. The minor pitting found on visual inspections of the valve seats was determined to be normal and the heads were evaluated to be satisfactory for continued service.

3. No unusually thin wall thicknesses were observed and all head wall thicknesses are considered satisfactory.

6. The studs that showed linear indications were replaced.

4,7 Five heads were replaced.

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i Catawhg Diesel 28 leggettigG Bengtt Pact NametI ntake and Exhaust Valves Eatt NymhetiO2-360B-GlasstB W9th BERMEst N9t1784MNT, 1584MNT 8titthutgg ygtLiigd

1. Check valve clearance per 11.5.4.2, ref. 1.

2. Check valve seating per 11.2.4.3, ref. 1.

3. Visually inspect seat area per 11.4.2, ref. 2.

4. Visually inspect valve guides per 11.4.3, ref. 2.

5. Visually inspect valve stems per 11.4.4, ref. 2.

6. Visually inspect valve stem top per 11.4.5, ref.2.

7. Visually inspect friction weld per 11.4.6, ref.2.

B. PT inspect valve stem-head radius per 11.4.9, ref. 2.

BEf2CEGEEE

1. MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, Disassembly, Inspection and Reassembly

2. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection 10229E$190 8ggylts

1. Valve clearances were within normal limits.

2. Valve seating was checked and found to be satisfactory.

3. Visual inspections of the valve seat areas showed minor amounts of chipping.

4. Visual ins'pections of the valve guides showed small amounts of scratching.

5. Visual inspections of the valve stems showed minor amounts of scratching.

6. Visual inspections of the valve stem tops showed evidence of normal wear.

7.

O.

Vi sual inspections of the friction welds were satisfactory.

PT inspection's of the.v'alve stem radii were satisfactory.

ELEP.9ElllOQ Qi 1GEQCGll9Q ElGdLQG3 3,4,5 The amount of scratching and/or pitting found on these inspections was determined to be normal and the parts were evaluated as acceptable for continued use.

1:

t_______._____________.____________ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _

I l

1 Getgwbg Diggel 28 10sgestign Bengtt j ERCA damei V alve Springs

! Eatt NumhetiO2-360D Gla2ElB M9th BREMEEk M911584MNT 8titikutes yerified

1. Check color code on valve springs per 11.4.7, ref. 1.

2. Visually. inspect the valve springs per 11.4.8, ref. 1.

8EfECEnERs

1. MP/0/A/1000/37 Diesel-Engine Cylinder Head and Associated Parts Special Inspection lOHgEGhi90 Be2Mita

1. The color code found on~the valve springs was consistant with the expected correct code, accounting for the effects of heat, time and oil staining.

2.

Visual inspections of the valve springs were satisfactory.

QinnonitLEn 91 lennection Eindinns There were no significant findings.

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s Getabb g Qigggi 26 Ingagghign Bgggtt Eatt NamgiSubcovers EACt Nymbgt1 02-362A G12521B W9th 6E99E11 69z1584MNT 61stibutgs ygtifigd

1. Visually inspect subcovers per 11.6.2, ref. 1.

2. PT inspect rocker arm pedestals per 11.6.3, ref. 1.

BEfECEnGES

1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection In5GEEt19e BEH9112

1. Visual inspections of the subcovers were satisfactory.

12. PT inspections of.the rocker arm pedestals showed no defects.

Qinnonitien ei lesnEntina Eindinnn There were no significant findings.

?

Gatggbg Digggi 28 InsgEGhi90.8999CI~

Egtt Namg1Fuel Injection ~ Pump EaCt NymbgtLO2-365A giggsiB W9th 8E9991t Ngz1756MNT

'l 8titibyggg Mgtifigd

1. Visually inspect the ID of the valve holder using a borescope per 1 1 . 2 . 2', ref. 1.

2. MT inspect the delivery valve assembly per 11.4.3, ref. 1.

69f9E90G92 '

1. MP/0/A/1000/42 Diesel Engine Fuel Pump and Linkage'Special Inspection 10599Gt190 Bes91tE-

1. Visual inspections of the ID of the valve holders were satisfactory with the exception of one holder.

2. MT inspections of the delivery valve assemblies were satisfactory.

Diggggitign gi Inggecting Eindings

1. The valve holder was reamed-out and the inspection was repeated with satisfactory results.

O a

gatawkg.Digsgi 2h Insgegtign Egggtt Eatt NametF uel. Injection Tubing Eatt dumhett02-365c GiesmLB Wgth Egguest Ngzi756MNT 6thCikMIES MRCifigd

1. Visually inspect as built condition per 11.2, ref. 1. !

2. . ECT inspect tubing per 11.3, ref. 1.

BRfRCEGEet

1. MP/0/A/1000/55' Diesel Engine Fuel Oil Piping System Special Inspection lO2neGhigO Be29115

1. Visual inspections of the fuel injection tubing showed minor discrepancied with the as-designed drawings.

2. ECT inspections showed'three indications.

Disaggitige gi leggegtign Eindings 1.- The iiscrepancies found on the visual inspections were determined to have no effect on engine performance. The tubing was reassembled and the determined to be satisfactory.

2. The fuel injection tubing with the indications were replaced with new tubing that was inspected by ECT and found satisfactory.

t J 5 t 6

1

Cetadhe Dieggi 28 leggggtige Bengti Egtt Ugmg1 F uel Injection Tubing Supports Cett Ugebgt1 02-365D Cle2 sib M9th Beguggt Ugs1756MNT 8tttibutna Vetitied

1. Visually inspect tubing supports to. verify as-built condition per 11.2, ref. 1.

BEiRCEGGES

.1.

MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special' Inspection IOEG2Gt190 8259L15

1. Visual inspections of the fuel injection tubing suppcets showed several discrepancies with as-designed drawings.

GLER97.itiGG Qi 102GEGhi90 EiGdLGDE

1. The discrepancies found on the visual inspections were evaluated as having no effect on the performance of the diesel. The fuel injection system was reassembled and evaluated as satisfactory.

Getzube DLunet 2G IOnaection'Beantt Pgtt NametFuel Pump Linkage Batt UMOh2CL 02-371A/B GldHELA W9th BGGMeEt Ugzi756MNT 6ttCihMtEE MEClilGd

1. Visually inspect linkage per 11.1.2, ref. 1.

2. Ensure that an adequate lubrication schedule is in place per 11.1.3, ref. 1.

B9f9E20G99 '

1. MP/0/A/1000/42 Diesel Engine Fuel Pump and Linkage Special Inspection 105295t190 B22B119

1. Viuual inspectionms of the fuel pump linkage were satisfactory.

2. An adequate lubrication schedule was verified as in place.

D12295i1190 9f 105R2G1190 EiOdiO95 There were no significant findings.

O

Qatawbg Digsgi 26 Insagsting Bgggth

.Egtt NamgtIntake Manifolds Egth NymbgtiO2-375

~QigsstB

~M9th Begunst Ngz1584MNT etttibutem-Yttified 1.- Visually inspect surf aces and bolt holes per 11.2.2 ref. 1.

2. Visually inspect gasket fitup per 11.2.3, ref. 1. 3 SeitteQCRE

1. MP/0/A/1000/46 Diesel Engine Intake and Exhaust Manifolds Special Inspection Insgestion Besuits

1. ' Visual inspections of the manifold surfaces-and the bolt holes were satisfactory.

2. Visual. inspections of gasket fitup were satisfactory.

Disggsitign gi Igggggtigg Eindiggg There were no significant findings.

e 4

T Gatagha Digggt 28 ingagcting Beggtt Pact Namgi Exhaust Manifold EeCt Ugmheti 02-380A' GlensiB' WGCE Bgggggt Ngt1784MNT,1584MNT Attributgg Vgt i figd

1. Check alignment on reassembly per- 11.2.10.1,-ref.'1.

2. Visually inspect flange welds per 11.3.4, ref. 2.

3.

Visually 11.2, ref.

' inspect system to verify as built condition per 3.

Referencgg

1. MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, Disassembly, Inspection and Reassembly 2.- MP/0/A/1000/46 Diesel Engine Intake and Exhaust Manifolds Special Inspection

3. MP/0/A/1000/56 Diesel Engine Exhaust Manifold Special Inspection IO2G2Gli90 8229115

.1. Alignment on reassembly was satisfactory.

2.

Visual inspections of the flange welds'were satisfactory.

3. Visual inspections of'the as-built system were satisfactory.

Diggggitigg gi Insgggiign Eiggiggg There wer no.significant findings.

9 a,a

l.

Gatgwbg Diesel 28 lesgestigg Bgggtt Egtt NamgtE xhaust Manifold Bolting EBCt Ngmbgtt02-380B GlBE51B W9th Be9MEst N9x1584MNT 6titibgtgs ygtifigd 1.- Visually inspect bolts per 11.3.2, ref. 1.

2. Measure bolt length per 11.3.2, ref. 1.

3. Measure depth of bolt holes per 11.3.3, ref. 1.

891RCEDE22 e

1. MP/0/A/1000/46 Diesel Engine Intake and Exhaust Manifolds Special Inspection i

IOaQecti90 BEEMita

1. Visual i nspections of the exhaust manifold bolts were satisfactory.

2. All bolts were 1.5 inches long - satisfactory.

3. , Bolt hole depths were found to be satisfactory.

DiER95iti90 9f lOERecti20 EiO Logs d There were no significant findings.

f a

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

. . _ . _ _ . _ _ _ . . . _ . . __s ,

A

gatagbg Qieggi 26 IOS29Eti90 BRE9Ct EECt Namg1 Crankcase Covers 1 EBC1 Numbgt10 2-386B 91aHEIC' W9Ck 8gguest Ngzi385MNT 1

6titihMIRE YRCifigd i-

1. -Visually inspect bolt holes per 11.5.2, ref. 1.

Beferenggs

(- 1. MP/0/A/1000/39 Diesel Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase

~ Assembly, and Crankcase Covers Special Inspection 10!anEti90 Bgguits

1. . Visual in,spections of the crankcase cover bolt holes were satisfactory.

r Digggsitign gi Inggggtige Eindings There were no significant findings.

f s

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i 1

1.

_ _ . ~ . _.

ggtawbg giggel 28 Insgestige Bgggtt J Eatt Namg1 Intake / Intermediate Rocker. Arms Batt Nymbgt102-390A 2-Glags1D.

W9th Beguest Ngt1584MNT 8ttttbuten vecified

1. Visually inspect rocker arm shaf ts per 11.7.2, ref. 1.

2. Visually inspect rocker arm lips per 11.7.3, ref. 1.

3. Visually inspect sockets per 11.7.5, ref. 1.

4. Visually inspect swivel pads per 11.7.6, ref. 1.

5. Visually inspect drive studs per 11.7.8, ref. 1.

BEfECEDEE5

1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection lO5EEGli90 8e29112

1. Visual inspections of the rocker arms showed minor amounts of nicking and gouges.

2.

Visual inspections of the rocker arm lips were satisfactory.

3. Visual inspections of the rocker arm sockets were

. satisfactory.

4. Visual inspections of the rocker arm swivel pads were satisfactory.

Visual inspections of the rocker arm drive studs were 5.

satisfactory.

DiEE9Eitl90 9f lO5ReEti90 Eindin95

1. The amount of nicking and gouges found on visual inspection of the rocker. arms was determined to be normal and would have no effect on engin'e performance. These parts were evalu'ated as being acceptable for continued use.

t

GatGWhd EiGggi 20 leggestige Bgagth

.Eatt da02L Exhaust Rocker Arms EECt UU$hECLO2-390B

.. Gle5EiB

'Wgtk-8gggggt Ngt1584MNT

.6LttlkdtE2 MECliigd.

1. Visually inspect rocker arm shafts per 11.8.2, ref.-1.

2. - Visually inspect rocker arm lips per 11.8.3, ref. 1.

3. ' Visually inspect-sockets per 11.8.5, ref. 1.

4. Visually inspect swivel pads per 11.8.6, ref. 1.

5.

Visually inspect drive studs per 11.g.8,ref. 1.

-BELSCEDGt5

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

.In;esssisu~Scaults

1. Visual inspections of the exhaust rocker arms showed minor amounts of scratching.

2. Visual inspections of-the exhaust rocker arm lips were satisfactory.

3. Visual inspections-of'the exhaust rocker arm sockets were satisfactory.

4. Visual inspections of the exhaust rocker arm swivel pads were satisfactory.

- 5. Visual inspections of the exhaust rocker arm drive studs were satisfactory.

ELEGQ2iti90 Of 1G222 Chi 20 EiQd iggg

.1. The amount off scratching'found on visual inspection of the rocker arms was-determined to be normal and would have no effect on engine performance. These parts were evaluated as' being acceptable for continued use.

2:

Calabbg Qigggt 26 Inggggtign Bgggtt Egtt Namgi Intake/ Exhaust Pushrods Eatt Numbgtto2-390c GlasstB ,

Weck Begugst'Ngz1584MNT 6ttttbuten Vettitag

1. Verify pushrods are of friction welded design per 11.9.2, ref. 1.

2. PT inspect friction weld per 11.9.3, ref. 1.

3. Visually inspect spherical surfaces per 11.9.4, ref.1.

s BEiECEGEe2

1. MP/0/A/1000/37 Di esel Engine Cylinder Head and Associated Parts Special Inspection lennecti90 Begults

1. The pushrods were' verified as being of friction welded design.

2. PT inspections of the friction weld were satisfactory.

3. Visual inspections of the spherical surfaces were satisfactory.

E129921$i90 91 IOSEeSti90 EiOd iggg There were'no significant findings.

I Gatswog Digsei 28 leggggtige Bgggtt Pact NamgiC onnector Pushrods Eatt HugbgtiO 2-390D GLARELB Weck Bggugst Ngt1584MNT Attri_butgs Veti figd

1. Verify pushrods are of friction welded design per 11.9.2, ref. 1.

2. PT inspect friction weld per 11.9.3, ref. 1.

3. Visually inspect spherical surfaces per 11.9.4, ref.1.

BefECEGERS

1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection 10maes'tien Besuits

1. The pushrods were verified as being of friction welded design.

2. PT inspections of the friction weld were satisfactory.

3. Visual inspections'of the spherical surfaces were satisfactory.

Digggsitiga gi Inggestige Eindings There were no significant findings.

\ ^

i Qatgwba Digsgi 28 Insegglign Bgqqtt 1

Batt NametRocker Arm Bushings EBCt.Numbgtt 02-390E.

GLEE 5LB

-Wgth Bggggst Ngz1584MNT

. 8titibutes ygrified

1. Visually inspect rocker arm bushings per 11.7.7, ref. 1.

2. Visually inspect exhaust rocker arm bushings per 11.8.7, ref.'1.

82fECHOGES -

1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection lOHGeGli90 Besults 1,2 Visual inspections of the intake / intermediate and exhaust .

rocker arms showed minor instances of nicking and scratching.

Diggggitigg gf Insgggtige Eigdings 1,2 The minor scratching.and nicking found on visual inspection was determined to be normal.and the bushings were evaluated as being acceptable f or continued use.

d h

Qatgwha Qigggl 28 Insagetige Bgggtt BECt Namgt R ocker Arm. Bolting Eatt NymhetiO2-390G glasstB W9th BE9uEst N9s1584MNT 8tttihutes Yetified

1. MT inspect capscrew thread roots per 11.11.2, ref.'1.

- :2.~ Visually inspect rocker arm capscrews per 11.11.3, ref. 1.

Beitte0CRs

, 1. MP/0/A/1000/37 Diesel Engine. Cylinder Head and Associated Parts Special Inspection 10s99ct190 Beaults

1. MT inspections of the rocker arm capscrew thread roots were

, satisfactory.

2. Visual inspections of the rocker arm capscrews were evaluated as satisfactory.

El1R9sliiGG 91 lOs9EEli90 Eindings There were no significant findings.

t.

Gatawbg Digggi 28 Inggestign Bgggtt Egtt Ngmg10 verspeed Trip and Accessory Drive Batt Numhgti O2-410B

- GleHELA Weth Beguest Ngzi760MNT

. 6thCihMIRE met i fied

1. Visually inspect drive gear per 11. 3.2.1, ref. 1.-

2. Visually inspect driven gear per 11.3.2.2, ref. 1.

e-BEfRCEGEEE

1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly i

10saestien Besulta 4

1. Visual inspections of the drive gear were satisfactory.

2. Visual inspections of the driven gear were satisfactory.

Disnggitign gi Ingnegtign Eindings There were no significant findings.

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i Gatggbg piggel 28 Inggggtigg Beggtt ,

t Eett NamgiOverspeed Trip Drive Coupling Eatt Nymbgt102-410C GleEHiA Weck Beguest Ngt1760MNT 8tittbyggs yerified

1. Visually inspect coupling elastomer per 11.3.2.2, ref. 1.

Befetensg=

1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip

' Accessory Drives Disassembly, Inspection.and Reassembly ,,

Insaestige Begulta

., 1. Visual inspections of the coupling elastomer were satisfactory.

Disnemitten 91 Inanection Eindinga j There were no significant findings.

e 9

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.Qgtgwhg Digsgl 28 Insagstign Bgagtt Egtt NgmgiS peed Reducing Governor Drive Egtt Nymhet10 2-411A

.GiggsiA Wgth Eggggst.Ngz1760MNT 6titibyggs Vgrified

1. Visually inspect 'large horizontal . drive gear per 11.5.2.1,

.ref. 1.

2. Visually inspect small horizontal drive gear.per 11.5.2.2, ref. 1.

BRfECROC95 '

1. MP/0/A/1000/47. Diese: Engine Governor and Overspeed Trip Acce:.,sary Drives Disassembly, Inspection and Reassembly lOsgggtign Bgsgits

1. Visual inspections of the large horizontal drive gear were satisfactory.

2 .' Visual inspections of the small horizontal drive gear were satisfactory.

Diggggitign gi Insaggtign Eindingg There were no significant findings.

9

Gatauba Disnni 26 Innnection Enantt 8

Enc NametS peed Regulating Governor Drive Coupling Ecct Numbeti O2-411B Gian1LA WECL BCQugnt Ugt1760MNT 6tttibuten Mettfied

1. Visually inspect coupling per 11.5.2.3, ref. 1.

2. Verify coupling material is neoprene per 11.7.2, ref. 1.

3. Verify correct assembly of set screws and drive pins per 11.7.3, ref. 1.

8CfEtEnGEn

1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly lusnest190 Benuits

1. Visual inspections of the governor drive coupling were satisfactory.

2. The coupling material was verified as neoprene.

3. The coupling set screws and drive pins were reassembled to proper procedural requirements.

Ei2R92iti90 9felO2GOEti90 EiOdiO92 There were no significant findings.

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

Ggtgweg Diesgi 28 Inggggtigg Bgggth i

Pgt t UgmetSpeed Reducing Governor Linkage Egtt NymketiO 2-413A CLEEELA Neth Smautst Ngz1760MNT J

etttihutes Yettiled

1. Check linkage action per 11.6.1, r.ef. 1.

2. Visually inspect cross shaft per 11.6.2, ref. 1.

3. Verify locktite installation per 11.6.4, ref. 1.

BEiECEOGe2 -

1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly IDEReEli90 BEHult2

1. The linkage action was checked and found satisfactory.

2. Visual inspections of the cross shaft were satisfactory.

3. Locktite was installed to procedural requirements.

Dina9miti90 91 loseeEtien Eindican There were no significant findings.

o 4

4

Gaiaghg Diesei g6 Insgegtign geggtt Eact NamgtF uel. Pump Linkage and Shutdown Cylinder BBC1 NMmhet10 2-413B Gles2iB -

Weth Benuest.Ngt1760MNT 6titibutes MgtLiigg

1. Check linkage action per 11.6.1, ref. 1.

2. Visually inspect cross shaft per 11.6.2, ref. 1.

BEfeteQces 1.

MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly

'1029e51190 BesMitS

1. The linkage action was checked and found to be satisfactory.

2. Visual inspections of the cross shaft were satisfactory.

Diggggliign gf 1gggectigg Eingingg.

There were no significant~ findings.

9 1

Qgtgebg Qigsel 28 Insagstign Egggth Sgtt Ngmg1G overnor Booster Servamotor

~EACt Nymbgt10 2-415B ClBEEiB M9th'8E99E21 69t1760MNT

'6ttClkstRS MRCiflgd

1. Verify proper installation per 11.2.1, ref. 1.

89fECROGR5

- 1. . MP/0/A/1000/47 Diesel Engine Governor -and Overspeed Trip ~

Accessory Drives Disassembly, Inspection and Reassembly IOsgggtige Bgsgits

1. .The installation of the servamotor was verified as correct.

EiEG95iti90'91 10EGE5ti90 EiOd ings There were no.significant findings.

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

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

GateWhig DigggL 26 Ingggstign Beggtt Egth NamgiGovernor Heat Exchanger Egtt NgmugtLO2-415C GlaEELA L

W9th Be9MREt N9z1760MNT 6titihMtR5 MRCiflRd

1. Verif y proper installation per 11.2.2, ref. 1.

Ref_erenegg 1.-

MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip

' Accessory Drives Disassembly, Inspection and Reassembly IDE9Ecti90 BeEMitE

1. The installation of the governor heat exchanger was verified as satisfactory.

Disagsitige gi ingggettgn Eindisgg There were no signi ficant -findings.

5 I:

Gatawha Diesel 28 losagctige Bgggth Eatt Namgi Jacket Water Pump ,

Bett Nymbgt102-425A gigss1A W9th 8E99951 69t1767MNT 8tttibuten Vettiind

1. Visually inspect gear carrier per 11.2, ref. 1.

2.

Visually inspect gear, coupling, and spline per 11.3.1, ref. 1.

3.

4.

Verify torque of impeller nut per 11.4, ref. 1.

Verify torque of spline nut per 11.5, ref. 1.

5. Check end play of external spline per 11.5.1, ref. 1.

BBf9C90925

1. MP/0/A/1000/59 Diesel Engine Jacket Water Pump Special Inspection IOS20Gil90 Be59113

1. Visual inspections of the gear carrier were satisfactory.

2. Visual inspections of the gear, coupling and spline were satisfactory.

3. The torque of the impeller nut was found to be 80 ft-lbs.

4. The torque of the spline nut was found to be 140 ft-lbs.

5. The external spline was reassembled with the correct amount of end play.

Disagsttigg g[ Insgggtigg Eing[ggs There were no significant findings.

1 Cateube Diesel 28 10maest19n Ban 9Ct Egtt NamgiIntercooler Pining Coupling Eatt Nymkgti 02-436B

.Gla251A Ngth Bggggst Ngzi759MNT Attr_ikutgg ygtified

1. Check Dresser coupling on piping per 11.5.4, ref. 1.

BRfECROGES 1

1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection 105E2E1190 6229112 i 1. The Dresser coupling on the intercooler piping was inspected and found to be the correct type, s

4 Disaggitign gi Ingagglige Eindiggg There were no significant findings.

1 1

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Gatgehg Digggi 28 InsEEGhi90 BE29Ct Egtt Namg1 T urbocharger Cooling Water Piping and Fittings EECt Nymbgc102-437A Glagg1B

.W9th Bgguest Ngz 8titihutes Yerified

1. Visually inspect system to verify,as built condition per 11.5, ref. 1.

Beierences- _-

-1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 10snecti90 Besults

1. Visual inspections of the turbocharger cooling water piping and fittings were satisfactory.

Ei2R9Eili90 9( IESREChi90 EiQd iggg

.There were no significant findings..

b-

Gatawbg giggei 26 Insgegtige Bgggtt Eatt Namg1 Turbocharger Cooling Water Piping Supports Efth NymbetiO2-437B glaggiA W9th Beguest Ngz Gittibutes vecified

1. Visually inspect system to verify as built condition per 11.5, ref. 1.

BRietRQERE '

1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 105EeGli90 895M115

1. Visual inspections of the turbocharger cooling water piping supports were satisfactory.

El5R95LiiGG 9f 105EeEti90 EiQdings

.There were no significant findings.

e

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I

Gatgwbg Diegei 28 losgestige Bength Pact Namg1 Start Air Manifold Tubing BBCt Nymbgti 02-441A-GlB551A Weth 8eguest Ngt1762MNT 8ttttbutes votified

1. Visually in'spect system to verify as built condition per.

i 11.2 ref. 1.

BRfRCRQces

1. MP/0/A/1000/54 Diesel Engine Air Start Piping System Special Inspection

- 1029251190 Be29115

1. Visual inspections of the start air-manifold tubing showed

-several discrepancies with the as-designed drawings.

Disagsittgg gi Insgettign Eing(egs

1. The descrepancies have-been determined to have no effect on

'. engine performance. The start air system has been reassembled and has been evaluated as satisfactory for re-use.

e

Gatawha Qigsgi 26 Iggggetigg geggtg Pact NamgtStart Air Manifoid Pipe Supports Eatt NumhgtiO 2-441C '

GleEELA W9th Begugst Ngzi762MNT 6tttinutgE yetified

1. Visually inspect system to verify as built condition per 11.2 ref. 1.

BefEtROcgs

.1. MP/O/A/1000/54 Diesel Engine Air Start Piping System Special Inspection IDE99 Chi 90 89E9115

- 1. Visual inspections of,the start air pipe supports showed minor discrepancies with the as-designed drawings.

ELER9EitiGO Of lOSEREti 90 Ei O diggs

1. The discrepancies found on visual inspection were evaluated ~

as having no effect on diesel performance. The start air system was reassembled and determined to be satisfactory for continued service.

gatawbg Diegel 28 leggestign'Bength

.Eatt NamgiS tart Air: Distributor Tubing Egtt Numbett0 2-442B GlaE5LA Wgth Egguggt Ngzi762MNT ettttbutes yetitied

.1.

Visually inspect system to verify as built condition per 11.3 ref. 1.

4 Beferenggg

1. MP/0/A/1000/54 Diesel Engine Air Start Piping System Special Inspection

(

1GEgetti90 BeEMlIS

1. Visual inspections of the start air distributer tubing showed. minor ~ discrepancies lwith the as-designed drawings.

Diggggitign gi Insgectign Eindings-

1. The discrepancies found on virsal inspection were evaluated as having no effect on engi ,9 .er armance. The start air system was reassembled and tv ,3 5 tarmined to be satisfactory for continued use.

e 9

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ni -

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Gatewha Digsgl 28 leggggtige Beggtt

.Eatt,NametF uel Injection Piping Egtt Nymheg102-450B

-GiesstB W9th BeGMesi N9s1756MNT 8tttihutes Vetified

1. Visually inspect system to verify as, built condition per 11.2 ref. 1.

References

1. MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special Inspection

.lO5GeGhi90 855Mlta

1. Visual inspections of the fuel injection piping showed minor discrepancies with as-designed drawings.

1; '

Disaggitige gf Insgggtigg'Eindings

1. The discrepancies found on the visual inspections were evaluated as having no ef f ect on- the perf ormance of the diesel. The fuel injection system was reassembled and determined satisfactory for continued use.

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K Gatadhg Dieggi 28.10sgectige Bgggtt Egtt Namgi Fuel Oil Piping Supports.

Eatt NgmheciO2-450D GlaEsiA WQCh-Bgguest Ngz1756MNT 8tttihuten-2nrified.

1. Visually; inspect' system to verify as built condition per 11.2 ref. 1.

BRieCEGEes 1.- MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special ~

Inspection lesnschi90 Besults

1. Visual inspections of. the fuel oil piping supports showed minor discrepancies with as-designed drawings.

Dine 9sitL9n 91 Inanestien Eindings

1. 'The discrepancies that showed on visual inspection were evaluated as having no effect on diesel performance. The fuel. oil system was reassembled and it was determined to be satisf actory f or continued use.

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Qgtgwbg Digggi 28 10sagetigg Bgggtt

.Pett NgmgiF uel Oil Filter Mounting Hardware

- Eatt Numq=tt0 2-455c -

GlematA W9th Egguggt_Ngt1756MNT 8tittauten ve ttitag

.1. Verify correct torque is applied to bolt per 11.3.1, ref. 1.

BEfRCEOGES

1. 'MP/0/A/1000/42 Diesel Engine Fuel Pump and Linkage Special Inspection IOSEREti90.Beguiis

1. The fuel oil filter mounting bolt torque was verified as 60 ft-lbs.

Disqqsitige gi Insgectige Eingingg There were no significant findings.

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

Catawbg Digggi 28 leggggtige Bgggtt Egtt Namg1 E xternal Lube Oil Lines Eatt Ngmbgc102-465A Cla551A W9th B99999t Nez i 6titibutes Setified

1. Visually inspect system to verify as built condition per 11.4 ref. 1.

BRiECREERs-J *I

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IOSERGli90 BE291ts

1. Visual inspections of the external lube oil lines showed minor discrepancies with the as-designed drawings.

Digggnitiga gi legggctiga Eindingg

1. The discrepancies found on the visual inspection were evaluated as having no effect on the performance of the di esel . The lube oil system was reassembled and determined to be satisfactory for continued use.

4 t

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

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

__----.-.u-,_--.._ _ . _ . . . . - . -_

Qatawbg Digset 26 losgettign Bength Egtt NamgiE xternal Lube Oil Line Supports

'Batt ugmbgtLO 2-465B Gla55LA~

Wgtk Begunst ugs Attributgs Vgtified

1. Visually inspect system to verify as built condition per 11.4 ref. 1.

BefECEQCRs

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IOSGEchigO BeSWitE

1. Visual i nspections of the e:<ternal lube oil line supports showed minor discrepancies with the as-designed drawings.

Digqqsitign gi legggetign Eindings

1. The discrepancies found on the visual inspections were evaluated as having no.effect on diesel performance. The diesel was reassembled and determined satisfactory for continued service.

t

O GatBWhe EiEsEl 20 lO5EEEti90 BRE9Ct

, Egtt;Ngmgt Turbocharger" Lube Oil Piping EBCt NumbgtiO 2-467A GLASELB

' Weck'8E9uREt Nez atitikutEE YEttiied

1. Visually. inspect system'to verify as built condition per 11.5 ref. 1.

- 8EfECEGEEE

1. MP/0/A/1000/43 Diese1' Engine Lube Oil System Piping and Sump Special Inspection 1

.lOsggeliga Bgsglig

1. Viusual inspections of the turbocharger lube oil piping showed minor discrepancies with the as-designed drawings.

EiER95Lli90 9f lOEREcli90 EiQdingg 1.- The discrepancies found on the visual inspections were evaluated as'having no effect on the diesel performance. The lube-oil system was reassembled and determined to be satisfactory for continued use.,

?

I

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

GatdEb g Diegel 26 Ingp_ggtign Egggtt Eatt UgmetT urbocharger Lube Oil Piping Supports Eatt UgmbetLO 2-467B

.Gle1 HLB Weck Ee9uent Met etitihutan Vettiled;

.1. . Visually inspect system to verify as built condition per 11.5 ref._ 1.

82fEtEEGEE

.t

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IODR2Ghi90 B259115 1.

Visual inspections of the turbocharger lube oil piping supports showed minor discrepancies with the as-designed drawings.

OLEEGMitlOG Of 1GEREG1LQQ EiQdLQ92

1. The discrepancies found were evaluated-as not having an effect on the diesel performance. The turbocharger lube 01.1 system; wag reassembled and determined to be satisfactory.

4 g, 1

________________1___________._____.__.__._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ ._. _ . _ _ _ _ . . _ . _ . _ _ _ _ _ . _ _

Calabb g Digggl 28 Inggestige Bgggtt Egtt Ngmg1 Turbocharger Bracket BBCt NymbgtiO2-475A Gle!ElB.

W9th BE9utst'd9s1759MNT ettttbutes Yttlitud

1. Visually inspect turbocharger bracket per 1 1 . 5 .' 3 , ref. 1.

Bef=C= Ogen

1. MP/0/A/1000/49 Diesel- Engine Turbocharger and Intercooler Special Inspection 105EEGhiGO-825M1t2

1. Visual-inspections of the turbocharger bracket were satisfactory.

Digggsttign'gf Ingggetign Eingingg There were no significant findings.

9 g e f

Geigehg Digsc<l 20 loggggtign Bgggtt Estt Ugeg1T urbocharger Bracket Bolting EBCt UMTh2C10 2-475D G13551B M9th 829Milhi U9t1759MNT 6tttibuten Vetified

1. Visually inspect bolted joint per-11.4.3, ref. 1.

2. Verify proper torque is applied to bolts per 11.4.4, ref.1.

82iEteGEEE

1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection 105D2C1190 895M113

1. Vi; sual inspections were satisfactory and the bolts were r43 torqued to required values.

DisG9L.itiGG 91 IGSERGil90 ElGdLG95 There were no significant findings.

e 4 4

~~.

.Gatgybg Digggi _28 Igggggtige Bgggtt Egtt Ngmg1 Control Panel. Tubing 89Ct Ngebec102-500M GleS21B M9th 8999021 09:

6ttributes verified

1. Visually inspect system to verify as built condition per 11.4 ref. 1.

References

1. ,MP/0/A/1000/57 Diesel Engine Shutsown Tubing and Electrical Conduit Special Inspection lumesstien Beaulta

1. Visual inspections of the control-panel tubing were satisfactory.

Digeggiting gi Inggestige Eindiggg There were no significant findings.

e

F-.-

Getgwbg Qigggl 26 103g991190 Bgggth

.Pett Ngmgilube Oil Sump Tank Part NumbgtLO2-540A

'GlAE11B.

W9th B= guest-Ng1 etitibutes Yetified

1. Visually inspect system to verify as built condition per 11.4 ref. 1.

BEfECEGEgs

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection 105R2G1190 89E9113

- 1. Visual inspections of the lube oil sump tank showed minor discrepancies with the as-designed drawings.

.s

\

QisR9EitL90 91 IQhnEELL90 Eindin95

1. The discrepancies found on. visual inspection were evaluated as having no effect on the diesel performance. The lube' ail system was reassembled and determined to be natisfactory for continued use.

?

4

Gatahka Qigggl 28 leggggtigg Bggggt Bett NASRiL ube Oil Sump Tank Bolting i Batt Numbetto2-540s GLtEELB

-N9th Beaugmt N9s etttikuten Metified

1. Visually inspect system to verify as built condition per 11.4 ref. 1.

Beintences

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IDER991190 Bgsgits

1. Visual inspections of the lube oil sump tank bolting showed minor discrepancies with the as-designed drawings. -

Digggsttige gi ingqqqtign Eindiggg

1. The discrepancies found on visual inspection were evaluated as having no effect on the diesel performance. The lube oil system was reassembled and determined satisfactory for continued use.

k:

Qatawbg Qlgggt 26 Inggggtigg Egggtt Egtt Ngmg1 Lube Oil Sump Tank Mounting Hardware Eftt NymbgtiO2-540C s

GlaEELB Weth Benuent Nez 8titibuten Metified

1. Visually inspect system to verif y as built condition per-11.4 ref. 1.

'Befettunes

1. MP/0/A/1000/43 Diesel Engine. Lube Oil System Piping and Sump Special Inspection 10manstige Bggultg

1. Vi sual inspections of the lube oil sump tank mounting hardware showed minor discrepancies with.the as-designed drawings.

E.i EE91LilGQ Qi 1GERREki90 EiQ dlegg

1. The discrepancies found were evaluated as having no effect on the performance of the diesel. The lube oil system was reassembled and determined to be satisfactort for continued use. I R. t

Gatenbg pigggi _28 IO2ngsti90 Bgg 9Ct EgCt Egmg1 Engine / Auxillary Module Wiring Conduit Esti UUGhEtiO2-608A Gia22iA M9th 899922t d9s s.

OthCihMLES M2CifiEd

1. Visually inspect system to verify-as built condition per 11.4 ref. 1.

BGi2CEOG22 ,

1. MP/0/A/1000/57 Diesel Engine Shutsown Tubing and Electric ~at Conduit Special Inspection IO2ESGliOO 8029112

1. Visual inspectionc of the engine / auxillary module wiring conduit were satisfactory with the exception of a connector box Lhat wan missing a cover.

012G92itiOO 91 IO292Ghi90 EiOdiO92 The connector box cover has been replaced. The missing cover would have had no effect on engine operability. Thus, there were no n(gnificant findings.

t.

Getenhe Dienet 26 InnacEtton Beantt Eggt UgmgiEngine Shutdown Tubing ESEL NumbgtiO2-695A GldEELD Wett Beauest Net 8tttihutun ygctitud

1. Visually inspect system to verify as built condition per 11.2 and 11.3, ref. 1.

BEftCEGEEE

1. MP/0/A/1000/57 Diesel Engine Shutsown Tubing and Electrical Conduit Special Inspection 102G251190 825M115

1. Visual inspections of the engine shutdown tubing were satisfactory with the exception of an accumulator (F-573-326) which was found to be manufactured by Humphrey rather than Bimba, per the drawing.

Digaggiting gi Ingggq(ign Eindingg TDI has advised Duke that the Humphrey accumulators are used interchangeably with the Bimba accumulators. Thus, there were no si'gnificant findings.

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getgeba Qigggi 28 Inseggtign Bgggtg Egtt Namg1T urbocharger Thrust-Bearing Lube System BBtt NymhgtiO 2-CFR GLEEELC W9th Beauant.Nez 8tttibuten Yetified

1. Visually inspect system to verify as built condition per 11.5 ref. 1.

BELECEGEEn

.9

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IDE9EGlie0 82E9112

1. Visual inspections of the turbocharger thrust bearing lube system were satisfactory.

' Qiggggitten et Inan=Etien Eindtnen There were no significant findings.

4

p. n'

c' Catawba Diesel 28 102E9Et190 bee 9Ct' Eatt Namg1Intercooler Entt NumhttiF-068 G1A221B -

W9th Egguggt Ngt1759MNT 8tttikuten Mattfied

1. Visually inspect intercooler per 11.5.2, ref. 1.

Befet=0Eas

'1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection 1020951190 B229113

1. Visual inspections of the intercooler were satisfactory.

9122911t190 91 102R951190 EindiO9n There were no significant findings.

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ggggwhg Digggi 26 Ingaggtige Bgggtt EaCt Ngmg1 Turbocharger EECt NymbgtiMP/022/3 Glas!iA Weth'Bggugst Ngzi759MNT 8titikuten Metified

1. Visually inspect turbocharger assembly per 11.2.2, ref. 1.

2. Visually inspect Journal bearings per 11.2.3, ref. 1.

3. Measure rotor float end clearance per 11.2.4, ref. 1.

4. Verify correct number of bolts in place on inlet casing per 11.2.5, ref. 1.

5. PT inspect stationary no::le ring per.-11.2.6, ref. 1.

6. Measure ID of journal bearings per 11.2.7, ref. 1.

7. Verify correct torque on casing bolts per 11.2.8, ref. 1.

8. -Visually inspect exhaust gas inlet bolts per 11.6.1, ref. 1.

-BEfeteOGRE

1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection .

IOSReEti9G 89E9111 1-8 No inspections were accomplished on the turbochargers.

Disn9 sit 190 91 loanschien Eindican The inspections were not considered necessary as the turbochargers are new units with no operational hours.

Inspections of the~turbochargers will be done as part of the

-preventive maintenance program.

4

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ML20137V914

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