ML20138P480

Diesel Engine 2B Component Revalidation Insp

ML20138P480
Person / Time
Site:	Catawba
Issue date:	12/17/1985
From:	DUKE POWER CO.
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ML20138P472	List: ML20138P469 ML20138P480
References
NUDOCS 8512260132
Download: ML20138P480 (131)

Text

F l CATAW8A NUCLEAR STATION DIESEL ENGINE 28 COMPONENT REVALIDATION INSPECTION 1

Prepared by DUKE POWER COMPANY December 17, 1985 lg22ggfKggaj4 Q

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Table of Contents i

i 1.0 Introduction 2.0 Summary and Conclusions 2.1 Overview of Operations 2.2 Overview of Inspection Results j 2.3 Lessons Learned from Unit 1 Inspections 2.4 Conclusions 3.0 Discussion of Inspection Results j 3.1 Inspections Related to TDI Generic Problems 3.2 Inspections Related to Catawba Specific Problems 3.3 General Inspections I

3.4 Engineering Evaluations 4.0 References 5.0 Appendices j APPEN0!X A Inspection Reports

]

APPEN0!X B Engineering Evaluations Tables 2-1 Summary of Catawba Diesel 28 Revalidation Inspection Results

r 1.0 Introduction This report describes the results of inspections and evaluations performed on the Catawba 28 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 the table included in Section 2.

The inspections of the 28 diesel engine discussed herein were performed in September through November 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 iN pections are as described in reference 1.

The diesel disassembly, reassembly, and inspections were performed in 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.

Some parts which are important to diesel operability were not inspected since inspection is not called for by the TDI Owners Group program and there has been no history of problems. For such items an engineering evaluation of the operating and maintenance history of each was performed and is discussed in Section 5.

1-1 u__________--______________--_---_-______--_-_-_.

I 2.0 Summary and Conclusions 2.1 Overview of Operations The Unit 2B diesel generator is essentially a new engine which had been run at Catawba only for acceptance testing required by the technical specifications. At the time of the revalidation inspections, the engine had 183 hours0.00212 days <br />0.0508 hours <br />3.025794e-4 weeks <br />6.96315e-5 months <br /> of operation at Catawba.

2.2 Overview of Inspection Results Although the 28 engine did not have a significant operating history, i

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 i

l value since the diesel had only been operated during factory tests, and during preliminary acceptance testing at the plant. Therefore, significant service induced degradation 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 the table accompanying this section. 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 conditions noted as a result of the inspections were that:

o The bearings in the turbochargers were severely worn due to oil starvation. The bearings were replaced on the right turbocharger.

The lef t turbocharger was replaced. The problem was due to heavy walled tubing that had been installed in the lube oil runs of this engine. This tubing has been replaced. This problem is further discussed in Section 3.1.15.

o Two rocker arm swivel pads were cracked necessitating replacement.

At the time of inspection, the swivel pads although cracked part way were still functional and did not affect operability of the engine. This problem is further discussed in Section 3.2.10.

o One valve guide was found cracked necessitating replacement. The guide was completely captured in the engine and did not affect engine operability. This problem is further discussed in Section 3.3.2.

2-1

Referring to the table of this section, some parts were to be subject to an engineering validation. These pads, which are importart 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. An engineering validation consisting of an evaluaticn of the operating ano maintenance history of these parts was performed to assure that there were no problems. On the 2B diesel since the engine had very few I hours there was little operating or maintenance history. The engineering validation of the parts is listed in the table of this section is included as Appendix B in Section 5. ,

2.3 Lessons Learned from Unit 1 Inspections The extended operation tests and revalidationzinspections of the 1A

and 18 diesels (references 2 and 3) resulted in certain modifications or changes to these diesels. These same modifications and changes have been accomplished on the 28 diesel, except for one item, which will be accomplished by the end of the first refueling availatility.

These items include the following:

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

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

o Modifications to the turbocharger prelute oil lines were accomplished to reduce vibration.

o Permanent turbocharger lube oil drain lines'have b7.an incorporated.

o Turbocharger exhaust gas inlet bolts have been changed to SAS43,

' Grade 660 to guard against creep rupture failures.

o Turbocharger to bracket mounting bolts have been changed to a new material of increased fatigue resistance, o New turbocharger air inlet adapters with flexible couplings were installed, o Rigid hangers were added to the jacket water piping going to the intercooler to reduce vibration.

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

o Starting air distributor cover capscrews will be changed to a  !

material of improved fatigue strength during the first availability I and prior to the end of the first refueling outage.

I 2-2

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2.4 Conclusions With the exception of the turbocharger bearings, the results of the revalidation inspections of diesel 28 have shown the engine to be in excellent working order. The failure of the turbocharger bearings was due to an installation error on tubing which has now been corrected.

Lessons learned from the' extended operation tests of both the Catawba diesels 1A=ind 16 have been incorporated into the 2B diesel such that it will be capable.of producing reliable standby electric power, a

9

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Mu t'Jt stetaas Ijea a t *. den %pt e t i un 4.s t r 3 3: _

Sa.nple Sa.o Eper cemt ) page 1 -

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Part Rose Part to. Class Wassal tieen. 5.eGE V.iSt ' leg. Eval. Estes assetts tete til Pressere Gegelatang Valve 66-420 4 - - - -

I g Julet meter Standpape,Fttags,5ettet 04-74e4 8 800 - - - -

0 Satisf atory Jutet bater Standpipe Valves 04-7000 B - - - -

I f Juket Water 5tandpape Sepperts 04-700C D IM - - - -

8 htasintory Julet Mater Standpipe Seitches $$-70dC 9 - - - -

I T Julet gater Standyspe helting Reterials 06 700F 0 lee - - - -

0 Satisf atory asse Searing to. Annestly 02-3854 4 30s - -e - - -

Satisintary Base learing Stees and Bets 02-305C A -e 30s - - - -

Satisfatery Rais Bearing Caps 92-3850 A . 36e - - - - -

Setislater y Lehe til Internal naaders42-30M A in - - - -

8 5etisintery tube til leAnag and Fittings-latereal 02-M70 A 100 - - - -

8 Setisinter y tube til (see Supports-laternal 42-3470 t IN - - - -

4 Satisf actory Cree 6stset 02-3844 A 100 teos 30 - -

3 Satisf actory Raae tearneg Shells 02-3100 A 36* 30s - - - -

Settslutary Craatthef t Ihrest Searing Sieg 02-384C 4 -

see - - - -

54tisfatory Craattese Assembly 42 3114 A les - - - - -

htssf atory Craetcase Asseting leerdeare 82-3180 0 - - - -

I t -

Cylinder tiect 42-38M A. -

25 late - -- 4 hteslutary Cae Bearneg Cape and bemel 02-31M 6 - - - -

I t ,

Cylinder Liner 62-315C A Ne 4M - - - -

5.tasantary Cylinder Blatt Julet noter asesfeld 42-3158 8 lee - - - - -

Satisfactory Cylinder used Steds 02-385E 3 25 25e - - - -

htisfattery

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Cylander need Bets 02-315F S lee - - - - -

Satisfactory Cylieder tieck Seals and 5estets 42-3854 8 IG4e - - -

la t lettslactory Jactet aster telet sensis:d Assently 02-3164 8 lee - - - -

4 Setisistar y Jubet beter Inlet Banaleid toepting 42-316f 8 lee - - - -

8 Satisfatory Jm6et ester Deuterge seenfeld 62-3874 0 100 - - - - -

Satisf atory Amtet unter Baut. Bae feld Compting 42-3RR 9 let - - - -

3 Setistattery .

Julet unter Disch. Sansleid Espports 3447C 8 l# - - - -

0 Satisf actory Flyeheel 02-3344 4 - - - -

Is t Flyeheel betting e2-33es a 100 - - - - -

Satisentar y Front Gear Case Baltang 62-3358 C lee - - - - -

Sata slutar y Cannecting toes and Santangs 82-3444 A IM 190 led - - -

ase lio6 red bassing eas sepined

, Cannecting Red tearing Shells 62-3440 A 800 let l# 104 - -

Satisf atery 1 Pastens 02-3414 4 100 lies les - - -

Satisf ator y Pasten tiegs 42-3410 4 -

106 - - - -

see riass aestalled Pisten Pie Asseetly 42-341C A 106 - - - - -

Satssintor y lat sne lappets 42-345A 6 254 - - - -

Satisf atory

feel Iappets 42-3458 4 25e - - - - -

Sat esamter y

feel Peep asses 02-345C 0 - - - -

le t Caetheit Assently 82-2544 4 100 - - - - -

htisf actor y Caetheit tenhang 02-3248 5 000 - - - - 5 54tisf atory 4 Caeshaf t Gears 92-35dC 4 190 - - - - - - Sata nf utar y Pump trave 6 ear 62-335A A to6 goes - - - - Settslutary l

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Sample S ze spesrcesit ) p.sge .

Part hees Part Or. Class Vine st ees. 5.30( v.uBE (eg.(val. listes Gesells taler Gear Asseebly $2-3558 4 let love - - - -

htistutory Air Start Va've 62-359 a los 25e - - - -

Satisf ater y Cylinder stead 42-3604 8 800 lee 100 104 -

2 See seaale sted eas replund due to si sedicaties letda and (sheest Valves 02-3600 8 IM 804 160s - - -

See salve geade nas fened nades, I esive reptued Cylinder 14:a4 8ettseg and Eastets 62-364C 8 - - - -

la 9 Valve Springs 62-3600 8 104 - - - -

I htsslutary Subcever Assently 62-3624 0 000 -

100 - - -

htssfactory Feel talectnee Peep 82-3454 8 890 -

l#e - - -

les salve holder was replued-linear indications feel lesecties Isps 42-3450 5 - - - -

Io y Feel lesecties lubing 62 365C B 100 -

let - -

6 htsslutary feel lesecties Idaag Supports 62-3650 8 800 - - - -

5 Satisfutary Feet Peep Ladage 62-3714/B e 140 - - - - - htistutory letde Bonifolds82-375 B 106 - - - - -

Setssf ater y (shaest seenfelds 02-3004 8 let - - - - -

Satistutory (abasst Amenfeld Soltaeg 02-3000 8 800 t - - - -

Satislutary Craetcase Covers Saskets and betting 42-3068 C 800 - - - - -

Satislutary letde and latereediate tscher Ars ennee 42 3906 4 104 - - - - - Iso sesvel pads sere trated and replued (shamst Sector are essently 42-3900 B 100 - - - - -

Satistutory lates and (abasst Pembreds 82-390C D let -

104 - - - Satistutory Cassecter Pushreds 42-3908 8 144 -

104 - - -

Satistutory funer are teshinge 02-39e( 8 500 - - - - - Satisfutary secter are Betting 42-3906 8 100 -

100 - - - See capecree oas replaced due to se El tedicaties Sverspeed trip levereer 02-4106 & - - - -

se g tverspeed Irip and Accessary trave 42-4848 6 800 - - - - -

Satist utor y Sverspeed Irap Compliege 82-418C 4 100 - - - - -

Asplued due to esipped spots se visual sospectise Sverspeed Irap test Valves 42-4100 & - - - -

le p Speed togalattag Govereer trave 82-4114 A 100 - - - - - htssfutary leverser trave Compliegs 42-4118 6 IM - - - - - 5etsslutary Severser tantage 02-4134 4 100 - - - - - Satisfutory fuel Peep tidage-Aute Shotesse Cylinder 42-4134 8 190 - - - - -

$disf ater y Speed Segolating Govereer 02-415e 4 - - - -

se g Eevereer toester Servenster 02-4156 8 800 - - - - -

Satisf actory Gove ear meat Enchanger Assembly 42-415C 4 104 - - - - - htistutory Lebe til Pues42-429 e - - - -

Is t Jacket eder Peep 82-4254 4 loos 400s - - - -

hissfactory laterceeler tipieg-Campling telt.6dts 42-4368 A 800 - - - - -

hteslutary forte Caeling Eater Pape and fittlegs 42-4378 8 160 - - - -

8 Satisf utor y forte Casting tdar Supports 42-4370 A 104 - - - -

8 htsstutor y Start air semifold Pipe, innes & Fitegs 42-441A 4 160 - - - -

8 hts.... ,

Start Air Bassfeld-Valves. Falters 42-4410 4 - - - -

as t j Start est seenfeld Pipe Supperis 02-441C A 100 - - - -

8 htistutory Start Air listraheter Iding 42 4420 4 lee - - - -

I httsf actory feel til teoster Peep 42-445 & - - - -

le 9 feel til Falters 42-445A B - - - -

le 9 Feel til Strassers 42-4456 8 - - - -

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t e a.np l et 'ia zer t oes omt ) li syu 5 Part haee Part es. Class Vis at tieen. 5.NBf V.tBE [ag.(val. hates tesults feel lasection Piping 02 45v6 a 190 - - - -

8 Satisf atery fuel 0 I Pising Supperts 42 4540 A Ifro - - - -

O htisf atary feel 0.1 filter ik. mating aus.me 02-455C A 100 - - - -

8 htisfactory (sternal ide Gil times 42- 4 54 A lie - - - -

4 Sat Slutar y f aternal tes,e Gil Line hpperts 42- 4 54 & 110 - - - -

8 Satisf actory faternal Late til Valves v2 45C A - - - - I I lertackager tube Oil Pipist 62-4?A B 104 - - - - 8 Satisintar y twtecharger Lee dal Pistag Supports 42-4476 0 10e - - - - 0 Satisf atory lattecharger trattet $2-425A $ 140 - - * *

• ktisfactory Turbettarter traclet laittag v2 4754 6 8 - - - -

2 Satisf atary Central Panel Cdanet d2-Suva 4 - - - -

I T Centrol Air Accueulater 42-560F A - - - -

8 9 Ccatrel Air Systee taleet 92-50uS A - - - -

I t (astrel air Srstes Pressure Seitches 42-50001 0 - - - - I t

. Centrol Systee 6elays 42-50eJ A - - - - I 1

- - - - t Car. trol Srstes Seleness valves v2-56er A I Central air Systes Pipist Iuetag Fttag 02 50 vel 6 two - - - -

8 Satistutary Cer. tral Panel eating *2- Na A - - - -

I t tae Dit hag. Ise. d 5494 6 14 - - - -

3 Satisf uter y (de til 5 sap lant letting e2-5466 0 lue - - - -

8 Satisf atory tube til Suas laat ne.ating liare.4*e 42-540C 6 190 - - - -

t latisfutory funeatian tetts ane Anchers42-554 6 - - - -

le t lastrumentatina theraetouples 42-6396 6 - - - - I t E.gine & Amaiti.ry Re!61e string Cene6st 62-640A A 10e - - - -

0 Satisfactory Egnae & Assiliary Aedule #irsag 02-6866 4 -

I t (squee 4 Austliary Reevle taring teses 42 640C A - - - - 1 1 Ste Engine Saf ter Alare Seesers girang 62-649 6 - - - -

le t triare elara Se*sers $2-694 A - - - -

I t Ca. f agite Salter Alars Seesers-5 ittnes 92-691A B - - -

8 9 En; age htsama fussag and fittings 42-6954 6 19 - - - -

t latisf ester y it.gine Naso.e Valves, megs, & Grshte 62-6958 A - - -

I 9 (agine htJean trip Seitches 42-695C A - - -

8 9 feel gal Supies Strasser 42-1250 A - - - -

I 9 larbechager li. rest tearer.g tune Systee 4MFB C 604 - - - - -

1stislutary lata 6e Air filter C5-lh 6 I 9 latane &ar Silencer CR-lei 4 - - - -

I 9 tefere and af ter tae til Peep [E - It* A - - - -

I t Ival fle. Lune Oil filter (R- tl4 A - - - -

I t Lae Sal stret (attaager Ch-lil 6 * - - -

B 9 6eseratar Att sna bearings [a-llfA A - - - -

I t Jaclet sater deal f aceanger Cu-120 6 - - -

I t dal Preide filter ' Cu-122 & - - - -

B 9 tote til seep.ars 5trasser Cm-l!! A - - - -

8 9 Ibereestatat Valee Cu 136/49 6 -e - - - le t laterteeler F-tet A let -

let - - - Satisf actory i

Ca t .mes., Ihis I .* i s . a s. . t i s.

. . tlas e e Sam.ple ins.u tgwe r eiet e pa.go l Part lis. Class Visual Ba ses. 5. net v.uti Eng.tval. totes gesults Part maae _ , , , _ , , , , , ,

nP-422s3 h tw 100 IM - -

le Severe hearing seat Iernocharger 9

- - - - 8 tube til full Pressere Strainer SE-425 A Mit it Idit

1. letate and enhaust valve sersegs have proper celer code.

e 2. Ultratesic mall tbscheets seateresent el fire doct. ECI and visual osanneataan el feel seaale wee to detername if the head has been partist penetratten sold repaired.

e 3. Creatsbeit ash deflections and thrust clearaeces to be seasured enth the diesel bet and celd.

et. Racrestractere of the blott sill be dotateseed by replicaties techanges.

e5. Casebalt beariegs onll be inspected only al the saa lobes shoe ahmersal escr. $ntheard seppert boshing sill be inspected regardless el caestatt conditions.

6. ECI nospections sell be dame ei both ends el high pressere injecties lanes.

7. Iwhecharger tracket heilleg stil be replMed il secessary.

8. tal6 deen inspection te verify as-tailt cuadaties.

9. fegaaeornet validattaa el part to deteresse if there we any signaticant omresolved maintenance er operatsanal problems associated enth the part.

St. leatseen and aespectaen et see er robssit twbecbargers chach heet accesslated less than 50 bears e4 eparation otti est be performed.

e hepresents changes beteres amitial unit 2 sospecties precedwe sabeatted April M.1985 and the final unit 2 asipectase pr oceder es.

l

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 Appendix A, Section 5.0. In addition, Section 3.4 provides results of an engineering evaluation of parts not inspected by traditional nondestructive techniques. These engineering evaluations are documented in Appendix B, Section 5.

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

3.1.1 Crankshaft (Part No. 02-310A)

PROBLEM:

A crankshaft failure occurred at Shoreham. The cause of the failure 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 problem.t (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 2B were performed.

At San Onofre, a QI 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 2B were performed.

SCOPE OF INSPECTIONS:

The crankshaft inspections consisted of:

o Web deflection measurements.

l o Visual inspections of the crankpin journals on all eight crankpins.

3-1

l o Liquid penetrant inspection of oil holes in main bearing journals #4, #6, and #8.

o Eddy current testing of main bearing journals #6, #7 and

1. 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 shells 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 performad to confirm freedom from problems.

SCOPE OF INSPECTIONS:

The bearing shell inspections consisted of:

o Visual inspection of bearing and back surfaces of all bearing shells, o Dimensional inspection of shell thickness.

o PT examination of the bearing shells, o X-ray examination of all bearing shells.

RESULTS OF INSPECTIONS:

Visual and dimensional inspections of the bearing shells were satisfactory. No cracks were detected by liquid penetrant inspection. One bearing shell was rejected by X-ray inspection.

SUMMARY

Penetrant inspection results indicate that connecting rod bearing shells are acceptable for operation. The shell l

3-2

l rejected by X-ray inspection was replaced. All other shells were evaluated as acceptable for reuse.

3.1.3 Pistons (Part No. 02-341A)

PROBLEM:

Inspection (reference 3) of the Catawba 1A 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 2B the replacement type AE skirts were inspected.

SCOPE OF INSPECTIONS The inspection performed on all the replacement type AE pistons skirts for diesel 28 are listed below:

o Visual inspection of fitup of crown to skirt.

o PT examination of stud bosses on the piston crowns.

o PT examination of piston pin bosses, belle.ille seat surface and the 0.D. of the skirt next to the piston pin bosses.

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

o 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 (Part No. 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.

3-3

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 no rmal . 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 (Part No. 02-315A)

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:

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

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

o 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 l blocks indicated normal grey cast iron, Class 40.

SUMMARY

Cylinder block cracks wer1 not detected on diesel engine 28.

Replica tests of the micrastructure 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 tetween the stud holes was PT examined for bearings 4, 5, 6, and 8 on diesel 1A. In addition. the stud tension required to pemit removal of the nuts was measured on diesel 1A. Owing to the fact that all inspection results on diesel 1A (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 on follow engines.

RESULTS OF INSPECTIONS:

Results of inspections were satisfactory.

SUMMARY

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

3.1.7 Cylinder Head Studs (PartNo.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. In addition, the free length of the studs were measured.

SCOPE OF INSPECTIONS:

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

RESULTS OF INSPECTIONS:

All cylinder head studs inspected satisfactorily passed the visual examinations and were of correct length.

SUPHARY:

A sampling inspection of cylinder head studs indicates that

.they are acceptable.

3-5

3.1.8 Rocker Arm Capscrews (Part No. 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 examinations. One axial indication was found by MT examination. This indication was not in the threaded area.

SUMMARY

The capscrew with the MT indication was replaced. All other screws were satisfactory.

3.1.9 Connecting Rods (Part No. 02-340A)

PROBLEM:

Cracking of connecting rods is repcrted to hue 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:

o Visual inspection was performed of all connecting rods.

o Magnetic particle inspection of all connecting rod link rod and rod-to-box bolts was accomplished.

o The areas of the rod box which have been reported as being subject to cracking were LP examined, o Areas of the connecting rod which would be subject to fretting or wear if looseness developed were visually inspected (rack-teeth, washers, seating surfaces) on all connecting rod assemblies.

3-6

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

o Dimensional inspection of link rod to pin with link rod bolts torque to 1050 ft.lbs. was accomplished'.

o Additional ECT inspections were performed by Failure Analysis Associates at female -od box threads on four connecting rods.

RESULTS OF INSPECTION All connecting rods passed the above inspections with the exception of one link rod bushing that was found heavily gouged. The gouges were circumferential and limited to one end of the bushing. It is thought that the gouging was possibly the result of foreign material introduced at the time of manufacture. On inspection, ao foreign material could be found. The degree of contact along the rack-teeth (serrations)was greater than 80%, which is considered acceptable. The ECT inspections were satisfactory.

SUMARY:

The damaged link rod pin and bushing were replaced. All oil holes were checked and found to be clear. After reassembly in the engine, connecting rod capscrews were checked to assure that preloa'ds were adequate.

3.1.10 Electrical Cables (PartNo.6888)

PROBLEM:

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:

Stone and Webster, as part of TDI Owners Group activities, reviewed the Catawba electrical cable installation (reference 19).

RESULTS OF INSPECTION:

The Stone & Webster inspections (reference 14) were completed in May 1984 with the following results.

3-7

1 4

4 o TDI SIM 361 had not been implemented on the Catawba diesels. This involves replacement of: shielded cable from a terminal block to the tachometer relay in the engine control panel; shielded cable from Airpax magnetic pickup to the junction box on the side of the engine; and multicanductor cable from an engine mounted junction box to the Woodward governor actuator, o 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.

SUMMARY

4 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:

All lines were satisfactory on visual and ECT inspection.

SUMMARY

The diesel engine 28 fuel injection liner were satisfactory.

3-8

3.1.12 Jacket Water Pumps (Part No. 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 Shoreham 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, insp$ctions of the 2B pump were ,

abbreviated.

SCOPE OF INSPECTIONS:

o Visually inspect coupling and spline o Verify torque on impeller nut is 80 ft.lbs.

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

RESULTS OF INSPECTIONS:

All inspections were satisfactory. Torque on impeller nut i was 80 ft.lbs. and torque on spline nut was 120 ft.lbs.

SUMMARY

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

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

PROBLEM:

Capscrew bottoming out due to insufficient hole depth for the capscrew length can lead to insufficient clamping force (reference 21). TDI noted that capscrews should be 2 3/4 inch long rather than 3 inches.

SCOPE OF INSPECTION:

The inspections for the capscrews included the following:

o Measure breakaway torque 3-9

t l

l l

l o Measure 1 ngth of capscrews for 4 valves as a check that c1pscrews were of the correct length o Visual inspection of the valve seat areas on the heads for all valves RESULTS OF INSPECTIONS:

Capscrew lengths were acceptable, and the valves showed no signs of insufficient clamping force. The capscrew torques

ranged from 35-105 ft-lbs. All capscrews were torqued to 150 ft-lbs on reassembly. In addition, capscrews have been

. checked during engine operation and retorqued where necessary to achieve 150 ft-lbs.

SUP9tARY:

There appeared to be no problems with airstart valve i capscrew bottoming out in the Catawba 28 diesel.

1 3.1.14 Push Rods (Part No. 02-390C)

PROBLEM:

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.

SCOPE OF INSPECTIONS:

The inspections of the new friction velded design push rods included the following:

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

o PT examination of all the welds

! RESULTS OF INSPECTIONS:

All the push rods were confirmed as having the correct type 4

of weld and were found to be free of defects.

SUP99ARY:

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

j 3-10

1 f

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.

j SCOPE OF INSPECTION:

The bearings were visually and dimensionally inspected, i " RESULTS OF INSPECTIONS:

.The bearings were found severely worn. The cause of this wear was determined to be lube oil starvation. On installation of the engine, the lube oil supply tubing was damaged on the turbochargers. The tubing was replaced with

! tubing of equivalent 0.D. but thicker walls. This resulted in a decrease in lube oil flow to the bearings which resulted in the bearing damage. Our records show that this problem was unique to diesel 28.

SUPMARY:

The bearings on the right bank turbocharger were replaced.

The left bank turbocharger was replaced entirely due to lack of spare parts. The lube oil tubing was replaced to original specifications.-

t 3.1.16 Cylinder Heads (PartNo.02-360A) i i 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 i, 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 i

a corner where a partial penetration welded plug was installed in.the fuel injector nozzle seating area. This welded plug was used to repair the injector bore during manufacture.

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

o Visual examination of valve seats.

l

.3-11 i

, _ _ _ , _ _ ,_ , _ _ _ , , _ _ _ _ . , , ._ , _,.,,,m__ , , _ _ , , , _ , , , , , _ _ _ . _ . _ , , _ , _ _ , _ , _ _ _ _ -

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

o UT examination of fire deck thickness at selected

. locations.

o Eddy current inspections of heads to determine if they have a partial penetration welded in plug.

o Visual inspection of heads to determine if they have a partial penetration welded in plug.

RESULTS OF INSPECTIONS:

All cylinder heads successfully passed all examinations.

SUMMARY

The cylinder heads on diesel 2B were satisfactory.

j 3.2 Catawba Specific Problems i 3.2.1 Fuel Injection Pump Nozzle Valve Holder (Part No. 02-365A)

PROBLEM:

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

SCOPE OF INSPECTIONS:

1 j Visual inspection of the 2B 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 two had no linear

, defects. One valve holder with indications was reamed, which removed the indications, the other valve holder was

, replaced as reaming did not remove the indication. The new unit passed all inspections.

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 i cracking of the valve holder would cause cracking to occur

. within 10 million cycles of fuel pump operation. As the l 3-12

1 l

l Catawba Unit i valve holders have withstood 10 million cycles of operation, the valve holder failure experience is considered an isolated material defect on these engines.

Inspection of valve holders on other engines and reaming or replacement of holders with defects should assure that cracking does not occur.

SUMMARY

It is concluded that the valve holder failure on diesel 1A was due to a material defect. The 28 diesel valve holders have been inspected to uncover such defects. The one valve holder (on diesel 28) that had an indication was reamed and then found to be free of defects. The other valve holder was replaced as after reaming the defect was still evident.

Hence all valve holders on the 2B engine are free of defects which would cause the problem experienced on diesel 1A.

3.2.2 Fuel In:ection Pump Delivery Valve Assembly (Part No.

F-099-liO)

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 INSPECTL NS:

The following inspections were accomplished:

o MT examination in valve seat area.

RESULTS OF INSPECTIONS:

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

SUMMARY

Diesel 2B 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 3-13

0 clamps, vibration dampening devices, improved compression fittings and heavier wall stainless steel tubing on diesels 1A 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 2B 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.

SUPNARY:

Since the 2B diesel has had additional clamps and vibration dampening devices installed no problems with vibration induced damage are expected.

3.2.4 Turbocharger Adaptor (Part No. 00-495A)

PROBLEM:

A turbocharger air inlet adaptor cracked at a flange weld on diesel 1B (reference 2). A similar problem occurred on diesel 1A (reference 3). In addition, the internal air flow divider on diesel 1B (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 on both Unit I diesels that installs a flexible connection between the adaptor and turbocharger on the right bank to absorb displacements. In addition, on both Unit I diesels, strong, backs have been welded to the case to eliminate the flexing which caused the air flow divider weld failure. This redesigt, will assure that in the future the adaptor will not crack.

Duke Power Company manufactured a new adaptor for diesel 2B with a strong back included. In the process of manufacture all welds were MT examined. The new adaptor with a flexible connection was installed on the right bank of diesel 28.

Hence additional inspections on diesel 2B were not accomplished.

3-14'

l i

l l

)

SCOPE OF INSPECTIONS:

Not applicable.

RESULTS OF INSPECTIONS:

Not applicable.

SUMMARY

With the new adapter and flexible connection installed on diesel 2B, it is concluded that problems initially seen on the Unit I diesels will not occur on diesel 28.

3.2.5 Intercooler Jacket Flange (Part No. 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.

3-15

(

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.

SUMARY:

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

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:

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

RESULTS OF INSPECTIONS:

No crack likp indications were found on visual or PT inspections. One subcover appeared to have an incorrectly drilled hole for a bolt guide.

SUMARY:

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 perforined 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 28 no such cracks were found~and thus these subcovers are considered acceptable for continued use. The incorrectly drilled hole was evaluated

, as having no effect on diesel operability.

3-16

l 3.2.8 Turbocharger Lube Oil Drain Line (PartNo.02-467A)

PROBLEM:

A temporary drain line on diesel 1A (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.

SCOPE OF INSPECTION:

Not applicable.

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 (Part No. 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.

I RESULTS OF INSPECTION:

Not applicable.

SUMMARY

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

3-17

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 1B. This occurrence was reported in reference 2.

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

SCOPE OF INSPECTIONS:

All swivel pads were visually inspected.

RESULTS OF INSPECTIONS:

. Two swivel pads on diesel 2B were found to have small cracks. The cracks appear to have origt.ated from die marks on the pads. Other pads were inspected and found to have these marks with no cracks associated with them. It is thought that the marks originated from upset metal on the die used to swage the pads.

SUMMARY

The rocker anns with the cracked swivel pads were replaced with ones which were correctly swaged and free from cracking. Inspections of diesel 2A did not show the same problem. However, at the time,of the 2A inspection it did

. not have the op6 rating hours on it that 2B has. Diesel 2A

'i now has about the same hours on it as 28. Hence the swivel I pads on 2A will be reinspected. In addition, the swivel

pads will be reinspected after 6 months of operation on the 2B engine to ensure that cracks are not reoccurring.

Finally, both engines 2A and 2B will be inspected at the first refueling as well.

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 eliminate the leakage.

3-18

J 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.

1 t

RESULTS OF INSPECTIONS:

The inspection of the fuel lines was satisfactory.

SUMMARY

i . 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 j lines are properly attached, such that vibration problems are not expected.

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 2B

. diesel engine. The results of these inspections showed that the 28 diesel engine was in excellent condition, with only two additional i

problems in addition to the problems discussed in sections 3.1 and 3.2 above. The only additional problems noted were that a fuel injector nozzle stud had linear indications and one valve guide was found broken. These problems are discussed below. -

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

PROBLEM:

MT inspection revealed that one fuel injector nozzle stud had linear indications.

i SCOPE OF INSPECTIONS:

All studs were visually and MT inspected.

RESULTS OF INSPECTIONS:

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

SUMMARY

The rejected stud was replaced by'a spare stud which had passed both visual and MT examination.

i 1

3-19

- -- - n - - - + , , - - ,,. ~ < - . - ,.-w.e n ,,ane.- em- w-- - > - , e.m,,,,-- - , ,

U 3.3.2 Intake and Ex'iaust Valves (Part No. 02-360B)

PROBLEM:

One valve guide was found to be broken.

SCOPE OF INSPECTIONS:

The valve guides were visually inspected.

RESULTS OF INSPECTIONS:

One of the valve guides vas found to be cracked in half in the cylinder head casting. The crack had proceeded circumferenitally through the wall of the guide just below the seating surface of the guide. The valve guide is shrunk into the head with a mild interference fit. The upper section with the collar on it was captured by the valve spring and the lower section was retained by an interference fit in the head. The guide was functioning well although cracked and presented no safety problems.

SUMMARY

Preliminary evaluations indicate that the failure could have resulted from a tolerance build or freeze damage. The cracked guide was removed from the head and replaced. Duke Power Co. is performing a failure analysis of this part.

3.4 Engineering Evaluation In Section 5.0, Appendix B, an engineering evaluation of parts not inspected by traditional nondestructive techniques was performed. The engineering evaluation included reviews of operational and maintenance records to assure that no problems have been experienced.

The results of the engineering evaluation showed diesel 2B to be in excellent condition. Little nonscheduled maintenance had been performed on the engine mainly due to the small number of hours of service. Only two minor problems were discovered; several thermocouples were found defective and had to be replaced and one controlling relay was found defective and replaced. These failures

.were considered isolated and had no effect on engine operability in an emergency situation, and are therefore not considered significant.

3-20

4.0 References

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

2. Duke Power Co. letter dated October 16, 1984 to H. R. Denton, NRC, enclosing " Catawba Nuclear Station, Diesel Engine 1B 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. Sbchtel Power Corporation, " Evaluation of Crankshaft Stresses for Duke Power Corporation, Catawba Nuclear Station", March 19, 1984.

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

8. Catawba Diesels "0wners Group DRQR Fuel Report - Sunnary of Recommendations", June 21, 1985.

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 Notica 80-08 States Sliding Link Terminal Block", File CN1412.11-1; EGS N-14.01, May 7, 1980.

4-1

I l

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 Pcwer Co., " Failure Analysis Report Catawba Nuclear Diesels 1A and 1B", 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 i

a 4-2

l l

Appendix A Inspection Reports d

1 a

0

(

l

{

l l

^-

Catawha Qittti 22 101EREtiGG BRE9tt Eatt NgmttJacket Water Standpipe Fittings and Gaskets Entt UumattiOO-700A ClelliB W9CE B22M511 Ugu2176MNT 6titikhiti Mttiiltd

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

1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 101EREli90 BREWil1

1. Visual inspections of the jacket water standpipe fittings and gaskets were satisfactory.

Qi1291iti90 Si 101EREti20 EiQdiO91 There were no significant findings.

j 1

1 lb v y + -

e Getenks QitBri GE Innerstise EnE9tt Eett UnetiJ acket Water standpipe supports Bett dueksti 00-700c GlenntB W9th EtSumat Ugz2176MNT etitikutta Yttiited '

1. Visually inspect supports per 11.2, ref. 1.

EnftC=OGt1

'l l

1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Etandpipe and Manifold Special Inspection 1019tGliGO Enlulta

1. Visual inspections of the jacket water standpipe supports were satisfactory.

Ei29911tl90 9f 102EREtiSQ EiQdlGER There were no significant findings. *

.] ,

k n

[ . h

.' j 4 ' ,

N ,

i J

h \

i i

GitBWQA ELESEl 2E IQ1EREti90 BRQ9Ct Egtt NgmgiJ acket Water Standpipe Bolting Materials Eatt Nyeksti OO-700F GletitB W9th 6t99311 Ngz2176MNT 6ttCLkWtti MRCliitd

1. Visually inspect bolting per 11.2, ref.1.

BRfRCEOGRE

1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 10192E1190 BE1Wiki

1. Visual inspections of the jacket water standpipe bolting

. materials were satisfactory.

Di1991Lii90 91 1019R9tl90 ElGdiG91 There were no significant findings.

,- + - --n- ~ , -g e,r-,- esw- -

4.

CA1AWha Q12591 2E 101ERE1190 BE29C1 Egtt Ngmg1M ain Bearing Bases BAtt Nymhet102-305A Gla111A WQth Bt9Mt31 MQt2172MNT etitikutta Yttified

1. Visually inspect mating surfaces per 11.5.3, ref. 1 (Bearings 4,6,8)

Beintansan

1. MP/0/A/1000/52 Diesel Engine Main Dearing Disassembly for Special Inspection 101E951190 BEault1

1. Visual inspections of the main bearing bases were satisfactory.

QinEemitiwa91InfanstianEind[nn:

There were no significant findings i

t

I Gatenha Dismal 2a innes'iti9o Bensch Egti Namg1 Main Bearing Studs Bett Numust102-305c GlasalA W9th 6t9ummt Ngz2172MNT Sittikutta Yttified

1. Verify stud elongation on reassembly per 11.7.10, ref. 1 (Bearings 4,6,8)

BifttRGEtt

1. MP/0/A/1000/52 Diesel Engine Main Bearing Disassembly for Special Inspection 10122s1190 Beaulta

1. Stud elongations were satisfactory Di1E91iti2G Qi 101EREtiGQ ElGdlGER There were no significant findings

- --- - - - - - - - - -, es , ,,,--.--r r w , , ,. p-,

l GA1AWha 9121R1 2E 101EREli90 8tE9C1 1

l i

Pact N Amg1 Main Bearing Caps  !

l BBCt Nymugc102-305D l

Gla121A W9Ch 8EEWtti NQs2172MNT 611CikMARE MRCliith

1. Visually inspect mating surfaces per 11.5.3, ref. 1 (Bearings 4,6,8) 8tfRCEGEtt

1. MP/0/A/1000/52 Diesel Engine Main Bearing Disassembly for Special Inspection insaastisc BasMits

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

Dianentilen 91 Innanstian Eincinan There were no significant findings

Gittwkt Qit1Rl 2E IGHERE119Q 6 testa Pgtt Nemailube Oil Internal Headers Eatt Nymugtt02-307A GLnnnte W9th Benuant Ngz2186MNT 8tttikutta Vatifing

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

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

Special Inspection IONERGt190 8R2W111

1. Visual inspections of the lube oil internal headers were satisfactory.

2 Dinnemitten 91 letanstian Etediusa There were no significant findings

I l

Gatanka Ditant 2E 101EREtiSQ BREQC1 Egtt NamtiLube Oil Tubing and Fittings Etti NumhetiO2-307B Gia11LA WQCh 8R9WR11 Ugt2186MNT 6ttCikWitt MitifiHd

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

2. Visually inspect external lube oil system pipirg, tubing and fittings per 11.4.1 ref. 1 6RfRCEGEEE

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IO!ERE1190 BREMlta 1?s2 Visual inspections of the lube oil tubing and fittings were satisfactory.

Dimannitten of Intatstien Eindinna There were no significant findings.

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ggtgwbg Qigggi EB 103Eggtige Beg 9C1 P 3tt NgmgiL ube Oil Line Supports Esti Numettio2-3070 Class 1B W9th Seguest Ugz2186MNT etitikuten Vatiiled

1. Visually inspect supports per 11.3, ref. 1 Baittt0ssa

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection 10 HERG 1190 BREW 119

1. Visual inspections of the lube oil line supports were satisfactory.

DIME 91ll190 91 IGHEREll90 ElGdlCSE There were no significant findings.

9

i GAlanha QiR191 CE 101ERGli90 SE29C1 Pgtt Namg1 Crankshaft ERCt Nymugt102-310A Clggg1A W9Ch 819MR11 Ngz2172MNT 611CihM121 MRClilRd

1. Measure web deflection per 11.3.1, ref. 1 (All webs)

2. Visually inspect crankpins per 11.4.1, ref. 1 (All)

3. PT inspect oil holes in crankshaft per 11.6.1, ref. 1 (Journals 4,6,8)

4. ECT inspect oil holes in crankshaft per 11.6.2, ref. 1 (Journals 6,7,0)

5. Visually inspect crankshaft gear per 11.2.2, ref. 2 6EISC20522

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 101EEEti90 622Ml%2

1. Cold web deflections were satisfactory.

2. Visual inspections of the crankpins were satisfactory

3. PT inspection of the oil holes were satisfactory

4. ECT inspections of the oil holes were satisfactory.

5. Visual inspections of the crankshaft gear were satisfactory 1

Di2E9511!90 91 101EREtiGQ EiOdlO91 There were no sign!ficant findings. Hot web deflections could not be taken due to the #7 main bearing failure. ]

1

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l Catawha Ditatl 2a Insatstien Btasti Egti N3mg1M ain Bearing Shells Eatt dymhtt102-310B Gla121A W9th BREMR11 N9s2172 PINT 6tttikM1R1 Mttiilte

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

(Shells 4,6,8)

2. Measure thickness of the main bearing shells per 11.5.2, ref.1. (Shells 4,6,0)

BRitCtasti

1. MP/0/A/1000/52 Diesel Engine Main Bearing Disassembly for Special Inspection Inmatstien 6tsulin

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

Qinasait19n af Innenstien Eindinna

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

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1 Catawbg Qigggl 22 lO99tst190 69E9C1 i

Egtt Nggg1C rankshaft Thrust Bearing Ring .

i Eatt Ngebgt102-310C Gla221A W9th SEQuest Ngz2172MNT 011tibuita Yacified

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

5 BRiSCRC?ti

1. MP/0/A/1000/39 Diesel Engine Crankshaft and Turning Gear.

Gear, Crankshaft Bearings, Crankcase Assembly, and Crankcase Covers Special

}

. Inspection IQanssit90 Beaulta

1. Measurements of thrust clearance performed in the cold condition were satisfactory.

E11E9111l90 91 lGRESEllGQ EiGQLQQ1 l There were no significant findings. Hot thrust bearino 4

clearance could not be taken due to the #7 main bearing failure.

i l

Gatgweg Digggt 40 Inspection SepgCt Egtt NgmetCrankcase Assembly COC1 NMThEClO2-311A Gl?.EHLA W9CL 8e9Me91 N9s2172MNT 6ttCihMtE5 MSCtfiCd

1. Visually inspect cast surfaces of crankcase per 11.5.1, ref.1 (All surfaces)

2. Visually inspect crankcase arch wall per 11.5.2, ref.1 (All surfaces)

3. Verify crankcase material from foundry records per 11.5.4, ref. 1.

StiECEDEe2

1. MP/0/A/1000/39 Diesel Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crenkcase Assembly, and Crankcaso Covers Special Inspection 10992Ghi90 8929115

1. Visual inspections of the cast surfaces were satisfactory.

2. Vtuual inspections of crankcase arch wall will be performed prior to plant operation.

3. The material was verified as being A-46 Gray Cast Iron Qi2E92Lil90 91 lOLDEstt90 Etudican There were no significant findings.

l-Gatawha Dinami 28 innuestien Benett Eitt NA*R1C ylinder Block EAtt NuthfC102-315A GlASE1A Weth Benuent 69s2171MNT esitthutan Yacified

1. PT inspect cylinder block top per 11.2.1, ref. 1 (All i blocks)

J

2. Measure liner landing area per 11.6.1, ref. 1 ( Cyls 4,5-R/L)

3. PT inspect liner landing area per 11.6.2, ref. 1 (Cyls 4,5-R/L) j 4. Replica inspect cylinder block per 11.7, ref. 1 (R/L Banks)

Beintnosez

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

1. PT inspections of the cylinder block top were satisfactory.

2. Dimensions of the cylinder liner landing area were taken for informantion only - no acceptance standards were given.

Liner and block landing area dimensions fell within .003 to j .0055 in. proudness.

l 3. PT inspections of the liner landing area were satisfactory. i j 4. Replicas of the cylinder block demonstrated typical gray

cast iron, class 40.

Dimensitino 91 losanstien Eindians There were no significant findings i

e-*e - -- - - - - cwa' - ,- < - - - . p-,-i - - -- +w - -- . + - - - , - 1wg. p -fm

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l GAttwkA Qititl 2E JCSERG1LQQ 8tEEC1 i

Egt1 Ngmg1C ylinder Liner EAC1 UMTQRC102-315C GlA111A WGCh 6tEWR11 UQs2171MNT 611Cikutt1 Mttiiltd i 1. Visually inspect cylinder liners per 11.3.1, ref. 1 (All)

2. Measure bore of cylinder liner per 11.3.2, ref. 1 (1,4,5,8 R/L)

3. Measure distance liner protrudes per 11.3.3, ref. 1 (All)

.l, 4. Perform supplemental visual inspection of cylinder liners per 11.6.3, ref. 1 (4,5 R/L) i 5. Perform supplemental dimensional inspections of cylinder liners per 11.6.4, ref. 1 (4,5 R/L)

EffRctosti i

1. MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner t

and Jacket Water Manifold and Piping Special Inspection 101ERE1190 BREW 111

1. Visual inspection of the cylinder liners were satisfactory.

2. Cylinder liner bores ranged from 16.995 to 16.999 inches.

3. Cylinder liner average protrusions were satisfactory.

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

5. Supplemental measurements of the cylinder liners were taken for information only.

Q11Ee11tien 91 lofEtst190 Eindiant

2. The liners were evaluated as satisfactory and acceptable for continued service.

5. There were no acceptance standards for these measurements, the data is for information only. See item 2, 02-315A.

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a Catanka QLestl 2E Innanstien Beasti EEC1 NATgtCylinder Block Jacket Water Manifold EAtt NWTutC102-315D ClA111A W9th 8tSMR11 39t2171MNT 611CikMitt Mttifits

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

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

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

Disnemitten of Innanstien Eindican There were no significant findings J

_ _ _ _ _ _ _ _ _ _ _ __ __._____m _ _ ______. .__ _..____ _. -. _ . _ _ . - . . _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ . _ _ _ _

I Getawbe Diesel 20 10sa9Gt190 B229tt Pact Ngsg1 Cvitneier Head Studs filCt Nyebstt02-315E GifD318 ljgth Egguest Ngt2170MN1, 2171MNT U$$C1kMt22 MeCiflRd

1. Measure breakaway torque per 11.2.7, ref. 1. (3,4,5,6 L)

2. Verify proper installation per 11.6.3, ref. 1. (3,4,5,6 L)

3. Chr,k free length per 11.6.4, ref. 1. (3,4,5,6L)

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

(3,4,5,6 L)

5. Visually inspect tor ID marks per 11.4.1, ref 2. (4,5 R/L)

BTi2CSOGT3

1. MP/0/A/1000/35 Diesel Engine Cylinder Head Removal.

Dinoszembly. Inspection and Reassembly

. MP/0/A/t000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Mantfold and Piping Special Inspection

( O $ 992$1. 90 0259133

1. breake.wav torques wera found to be 1057 to 1965 ft-lbs on the above sample.

. All studs in the engine were removed and then reinstalled by snuerting and backing out 1 turn.

'. The tree lengths of all studs in the engine were vt-ified as satisfactory (14-7/8 inches +1/4,-0) 6 Visual inspections of the cylinder head studs were satisfactory S. Visual inspections showed appropriate ID markings.

OL 5G92it190 91 10209Gh190 E10dl092 Thoro were no signi fic ant findings.

GEtewbg Diggel ;B losggchtOO 6229CL

[gth NamgtC ylinder Head Nuts EdCt UM0betiO2-315F ClanstB Wgth Egggest Ng._2170MNT, 2171MNT 8tittuutes Vettiind

1. Measure breakaway torque per 11.2.id, ref. 1 (All nuts)

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

3. Visually inspect nuts for forging laps per 11.4.4, ref. 2 (257 sample)

4. Reassemble to TDI specifications per 11.6.10, ref. 1.

BuiSCEOG92

1. MP/0/4/1000/35 Diesel Engine Cylinder head Removal.

Disausembiv, Insoection and Reassembly

2. MP/0/n/1000/14 Dtotel Engine D linder F.41 oc k , Cyltnder Liner and .facket Water Mont'old and Piptng Special Inspection 101G2G1190 8212112

1. breakaway torques of the cyl1nder head nuts were 2390 to 3450 ft-lbs.

2. Visual inspections of ID numbers was satisfactory.

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

4. The nuts were reassembled and torqued to TD1 specifications 913R911ti90 91 102G25h190 EiOd!OGM Thero were no nigni ficant findinqu.

Getanha Qianni 2E Inmatstien Stastt Egtt Ngmg1C ylinder Head Gaskets Entt NumkatiO2-315G (02-360C)

GleanLB Weth Benutzt 69t2170MNT esitthutta Yattiled

1. Visually inspect cover gaskets per 11.2.0, ref. 1 (All)

2. Varify correct gasket installation per 11.6.5, ref. 1 (All) i SaintacEns

1. MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, 1 Disassembly, Inspection and Reassembly 101anst190 Beaults

1. Visual insections of the cylinder head gaskets showed two instances of gaskets parting at seams.

2. Gaskets and seals were verified as properly installed Q12E911ti90 91 103ERE1190 Eind1091

1. All cylinder head cover gaskets were replaced on reassembly.

The defects found had no effect on diesel operability

GAttwkA Q13231 GE 101 ERG 1190 BRE9Ct I

BAtt NASR1 Jacket Water Manifold Assembly EACI UWSQRC102-316A GlA1119 WGCE BtSutti Ngz2176MNT 8titikutes'Yetified

1. Visually inspect assembly per 11.3, ref. 1 I

Beittt0Enz

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

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

Qinnenitten et lesenstien Eicdicen There were no significant findings.

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I Gatawha Qianni 2B lonatstian Braect BaCt UATEL J acket Water Inlet Manifold Coupling EaCt UMTktC102-316B ClansLB WQCh BREWRat dQA2176MNT etttikutta Mstified

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

l Baintnessa

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

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

Qinagnitten of Innenstien Elogions There were no significant findings.

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Gatanka Qianal 2B loanestien Sneett Pgti Ngmg1J acket Water Discharge Manifold Bett Nwetet102-317A Gisan1B 4

Wech Sneuent Nes2176MNT,2171MNT etitthutan Metified i 1. Visually inspect jacket water manifold per 11.5.1, ref. 1 l 2. Check Dresser coupling per 11.5.1, ref. L

3. Visually inspect jacket water manifold per 11.4, ref. 2 Beintensen

! 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 4 Innenstien 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.

Qineenttien ei inneestien Eindices There were no significant findings.

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1 Catawba Qinssi 2a insenstien Beasti Egtt Nggg1J acket Water Discharge Manifold Coupling Esta NWehnC102-3179 Glass 1B W9th Bn9 Meat des 2176MNT etitihutan Mattfind

1. Visually inspect coupling per 11.5.1, ref. 1.

Beintensen

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

Innenstien Ensulta

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

Qinanattien 91 innansitun Eindices l There were no significant findings.

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Getenha Qianal 2R Innanntien Benett Etti UtstLJacket Water Discharge Manifold Supports EACt UMTktCLO2-317C GlitiLB WeCh 8tSutSt Ugm2176MNT etttituten Yattiled

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

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

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

Qiteenttien 91 losamstten Eindican ,

There were no significant findings.

W--

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

f

Gatauha Qianel 2R innaastlec Beantt Rett Nggg1F lywheel Bolting [

, EaC1 NWSktCLO2-330B i

l GlamatA ,

I W9th StSutSt NQa,2190MNT etttihWien Ystliisd l 1. Verify correct torque is applied to flywheel bolts per 11.1, I ref. 1 (All bolts)

2. Visually inspect flywheel for loose roll pins per 11.2.1, i ref. 1 (All roll pins) i

Beintsonen i

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

t lozenstien Besulta

• i

- 1. Correct torque was verified through consbuction f documentation.

, .. Visual inspections of the roll pins were satisfactory Disnesitten 91 Insaastino Elodinna There were no significant findings.  ;

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l Gatanka Qiesel 2a lennestien Benett Eati NgggtF ront Gear Case Bolting Eati Nuehnt102-335B CLanntC Weth Ensuell Ugx2173MNT 8tttitutes Yttified

1. Visually inspact gear case covers for evidence of oil leaks per 11.1, ref. 1. (All covers)

2. Verify bolting is of appropriate material per 11.2, ref. 1 (All bolts)

Esistansen

1. MP/0/A/1000/41 Diesel Engine Gear Case Gaskets and Bolting Special Inspection Insenstien Bezults

1. Visual inspections for evidence of leakage were satisfactory.

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

Dinanzittaa 91 Innenstien Eindices There were no significant findings.

l 9

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

9 Gatewbg QLgggL 2k IngangtLqn Bgggtt EgtL NamgiConnecting Rods eact UymbetiO2-340A-GlessiA

_ Wgth Sgguest Ng.2171MNT etttibuken Mattiled

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

2. Check oil passages per 11.2.13, ref. 1 (All)

3. Measure torque-of link rod bolts per 11.17.1, ref. 1 (All)

4. Measure link rod clearance per 11.18.6, ref. 1 (All)

5. Vic-ially inspect connecting rods per 11.3.2, ref. 2 (All)

6. PT inspect rod box sides per 11.3.5, ref. 2 (All)

7. Visually inspect bolt wasners per 11.4.1, ref. 2 (All)

8. MT inspect rod bolts por 11.4.2, ref. 2 (All)

9. Visually inspect bushings per 11.5.2, ref. 2 (All)

10. PT inspect con rod bushings per 11.5.3. ref. 2 (All)

11. Blue check serrations per 11.11.1, ref. 2 (All)

12. Measure con rod bushings per 11.3.3. ref. 2 (All Link Rods. Piston Ptns 1 L ,5R ,8l . ,8R )

13. Visually inspect link rod.dowell per 11.3.4 ref. 2 (Alli

14. Reassemble per IDI specifications per 11.15.10/11. ref 1.

BMf2C20 GDS

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

2. MP/0/A/1000/30 Diesel Engine Piston, Rod, Bushing and Shell Special Inspection 10SERGil90 6929112

1. Torques of the master rod bolts ranged from 1010 to 2040 ft-Ibu.

2. Inspections of the oil passages were satisfactory

3. Torques of the link rod bolts ranged from 760 to 1170 ft-lbs.

4. Measurements of link rod clearance were nattufactorv

5. Vinual inspections of-the connecting rods showed minor scratchen.

6. PT inspections of the rod box sides were satisfactory

7. Inspections of the rod washers and contact surfaces were satisfactory G. MT inspections of the bolts were satisfactory

9. Visual inspections of the. bushings showed minor scratches.

One bushing (2L link rod ) .was heavily gouged i

10. PT inspections of the bushings were satisfactory l 11. All'serrations showed > 80*/. contact-satisfactory

12. Dimensions of the con rod bushings were satisfactory L.

Connecti ng F<ods , 02-340A- continued

13. Visual inspections of the con rod dowells were satisfactory

14. The connecting rods were reassen) bled per appropriate TDI specif1 cations.

OL?iD.05tL _Lt2n i.2t Ignprjgtl.gn, E ter!1.ggg

b. The mtnor scratches that showed on visual inspection were evaluated as normal and it was determined that the parts are acceptable for continued service.

9. The 2L link rod bushing was replaced.

A

I c etewba oisset .;p insaesttga Beag.ct P trt h mg:_ Connecting Rod Bearings COCA UMmbgtiO2-340D Gl445LA W9CP_ Sgguest Ug._2171MNT Ottttbuteu Vett11ed

1. Visually inspect bearing shells per 11.5.2, ref. 1 (All)

2. PT inspect bearing shells per 11.5.0, ref. 1 (All)

3. RT inspect bearing shells per 11.5.4, ref. 1 (All)

4. Measure shell thickness per 11.5.5, ref. 1 (All) 695eCCOGG5

1. MP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shell Special Inupaction loanschiou Ecavl.tn

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

^

. PT inspections of the bearint) shells showed no defects

". RT inspections of the be aring shells showed one shell that could not be read to the acceptance standards.

4. Shell thicknesses were satisfactory Ol5293LtLOO Qi 105C25tlGO EiOdiOGO

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

3. The shell was replaced even though it could not be determined to be onacceptatale.

, Gatewha Qinssi 2E Inmatstien Staett

, 'e .

Eft 1 Namg1 Pistons EAtt'U9.TkRC102-341A Gle111A WQCh ERQWR11 Ugg2171MNT etitikWisa Yetified 1.- Visually inspect fitup of crown to skirt per 11.6.1, ref. 1 (All pistons)

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

3. MT inspect pisten skirts per 11.6.3, 11.8.3, ref. 1 (All)

4. Measure hardness of piston skirts per 11.8.4, ref. 1 (All) j Enfattesan

1. MP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shell Special Inspection Icmanst190 Benuitz

1. Visual inspections 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 243 BHN 91229311190 91 Innanstien Einginna s

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.

s

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I GatAwka Qitual 2E InnanstLQQ Beasta EAtt UAmg1P iston Rings EAtt UWmkgC10 2-341B GlA321A W9th 8tSWR11 UQs2171MNT etitikutta Mattiled

1. Inspect ring installation and measure per 11.11 ref. 1 (All rings)

Smittansta

1. MP/0/A/1000/36 Diesel Engine Piston, Rod, and Liner Removal, Disassembly, Inspection and Reassembly 101EREli90 8229112

1. New rings were installed in the engine to TDI specifications.

Qinannitten 91 Innanstien Eindican There were no significant findings.

i

CAtRWh! DiR191 2E IQ1EREti20 BRE9Ct Egtt Ngmg1 Piston Pins EACt NumkRC102-341C GlAMEiA WsCh Staumat Ngz2171MNT 6ttCihutt1 YttifiRd

1. Visually inspect piston pin assembly per 11.7.2, ref. 1 Check rolled in Oil Plugs and inspect for distress. 'All pins)

Saintansas

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

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

i Qi2e911119n 91 lomanstige Eindicen

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.

+-c ..- . . ,

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Gatawha Ritani 22 Innanstien Stastt EAC1 demg1 I ntake Tappets EAtt dumggc102-345A GlA111A WQCh 6ESMnEt des 2173MNT eittikutta Vatified

1. Visually inspect intake tappets per 11.6.1, ref. 1 (1L,5L,BL,8R)

SaintacEnn

1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection In!ERGli9n 8m2Wil1

1. Visual inspections of the intake tappets showed one tappet

~

that was marked unsatisiactory because the tappet did not move freely outside of its normal range of travel. The tappet moved f reely withire its normal range of travel.

Qinasaition 91 Innatstien Eindican

1. This part was evaluated as satisf actory as it moved freely over its normal range of travel and is considered acceptable for continued use.

4 4

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Gatenha QLearl 2R 10maesti90 Benett EACA NATRiF uel Tappets EAC1 UWehtCi 02-345B Gl!EEiA M9th BBQWmSt U9z2173MNT 6titihWitt Mttiiltd

1. Visually inspect fuel tappets per 11.6.1, ref. 1.(1,5,8L, OR)

StitCEGERE

1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection 101ERE1190 822W111

1. Visual inspections of the fuel tappets were satisfactory.

Disa9mit190 91 Ionatstisc Eindiosa There were no significant findings

1 I

Gatanka Rimani 2E lenEast190 EnEstt  !

I Entt NATS1Camshaft Entt Numk=c102-350A l i

Glass 1A Weth Benutzt Ugz2173MNT 8titikuten Yttified

1. Visually inspect camshaft lobes per 11.3, ref. 1 (All)

2. Visually inspect camshaft locking clips per 11.4.3, ref. 1 (All)

BRfRCROGRE

1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection 102E951190 622Miti

1. Visual inspections of the camshaft lobes showed one lobe with minor pitting.

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

Qi1291iti90 9f IQ1EREli20 EiQdlGER The minor pitting seen on visual inspection was evaluated as a normal wear pattern. The camshaft was evaluated as satisfactory for continued use.

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l GA$AWQA DiRREl 2E In2ERE119n 6fE9Ct

'Esti NA mR1C amshaft Bushings EAC$ NW2hfC10 2-350B GlA251A WeCh SEQWtit U9s2173MNT 6titihutti MRCliitd

1. Visually inspect camshaft outboard support bushings per 11.4.2, ref. 1. (R/L)

Befstanssa

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

, 1. Visual inspections of the camshaft bushings showed instances of minor scratches and gouges.

Qinnanttien of Innnastien Eingicam

1. The minor scratching and gouging reported on visual inspection were evaluated as normal wear patterns. The camshaft bushings were considered acceptable for continued service.

1 Getaube Qianti ZE 10matstien Staett Egti NamgiC amshaft Gears Eftt Nymbgt102-350C GlA221A Wech Benutzt Ng_2173MNT 6titihutRE Mitiiltd

1. Check web to gear torque per 11.4.4, ref. 1. (R/L)

2. Visually inspect cam gears per 11.5.4, ref. 1. (R/L)

Emintensan

1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection 10anesti90 B=191t2

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.

Q11E911t190 91 101ERGli90 EiQdiD91 There were no significant findings.

GA1AWhA Q12131 2E 10!ERGt190 BRE9Ct Egtt Ugmgi Pump Drive Gear BAct Nymkgc102-355A GLAan1A W9th 8tsunut 6912173MNT 6titihutna Vatified

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

2. Measure backlash per 11.3, ref. 1.

BEftCROGER

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

1. Visual inspections of the pump drive gear were satisfactory.

2. Backlash measurements were satisfactory.

Ei2E91itl90 9f IQ1EREti20 BindiO91 There were no significant findings.

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

GateWha EiRER1 2E 1052RG1190 BEQ9C1 Egtt Ngmg1 I dler Gears EaCl UMmkgc102-355B Gla211A W9th St9Went Ugt2173MNT 611CikW121 MttifiRd

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

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

EmintnOGen

1. MP/0/A/1000/40 Diesel Engine Idler Gears and Pump Drive Gears Inspections and Adjustments 1019951190 8919112

1. Visual inspections of the idler gears were satisfactory.

2. Back1.'sh measurements of the idler gears were satisfactory Ei1991ill90 91 1019tEllEQ EiOdiO91 There were no significant findings.

7

- , -,-,,n- . - - , - -w--,, .--..

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

Cat 3wbg iD gggi 29 leggectigg 6gggtt Pact N3 mg1Atr Start Valves j EdCt Ugmugt102-359 clasatA i

, -W9CM Be9usut N9_2170MNT i

5 OkiCihMieE MRCLiied

. 1. Measure. breakaway torque of'capstrews per 11.2.13, ref. 1.

l (All)

2. Measure capscrew length per 11.3.2, ref. 2.(1,5,8L,8R)

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

j' 3.

(All)

4. Visually inqpect valve i nternal surfaces per 11.3.4, ref. 2.

(All)

BEiECEOGeh ,

) 1. 'MP/0/H/1000/35 Diesel Engine Cylinder Head Removal.

Disassembly,- Inspection and Reassembiv l

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

10SR9ChiOO 893Mith

! - 1. Breakaway torques ranges from 35-105 ft-lbs.

2. Capscrew lengths were verified as acceptable.

3. Visual.inspectinns of the-seat areas showed four valves that

'were unsatisfactory. .

74. Visual inspections of.the valve internal' surfaces showed'sia valves that were unsatisfactory.

i

DiEG95LtLOO-91 lO5GEELL90 ELOdiO92 1.- Breakaway torques were considered in the range of.1A. These i screws were.insta11'ed by TDI. All screwsthave been.

, reinstalled to correct torque values.

3t<4. The resul_ ts of those inspections were evaluated to.be

.'the result of normal wear for an engine that has seen I- service. These' components were cleaned, reinstalled.and' evaluated _as satisfactory for. continued use.  !

+

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I' catawha Dismai :n innanstiso BrasCt 4

Pgct Ngmg1C ylinder Heads Batt NWmbat102-360A CiaallA W9th 829WR11 6912170MNT 61tCikWARE Mttiilgd (All steps inspect all 16 heads)

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.

1 5. Visually inspect injection studs per 11.13.1, ref. 1.

6. MT inspect nozzle studs per 11.13.2, ref. 1.

7. ECT inspect nozzle cavities per ref. 2.

1 BEIRCROGRE

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

' Parts Special Inspection

2. Special Engineering Evaluation " Eddy Currrent Inspection to Determine Catawba Diesel Cylinder Head Casting Weld Repairs" November, 1984 101afG1190 BREWitt j 1. Visual inspections of the valve seats were satisfactory.

2. 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 .50 .52 inches thick.

4. All heads were free from partial penetration welded plugs.

5. All studs were found to be satisfactory.

6. One stud showed a linear indication on MT inspections which was on the shank.

7. All heads were satisfactory on ECT inspection.

Disnenition si Ioansstien Eindican

6. The stud with the linear indication was replaced.

f

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

Calgwba Digggi 2B 102996ti90 BSQ9CA Part Namg1I ntake and Exhaust Valves Eati Ugmbgt102-360B Cla221B WCCh 629995$ 69s.2170MNT AllCibutgg Vgtifigd

1. Check valve clearance per 11.5.4.2, ref. 1. (All)

2. Check valve seating per 11.5.4.3, ref. 1. (All)

3. Visually inspect seat area per 11.4.2, ref. 2. (All)

4. Vtiaally inspect valve guides per 11.4.3, ref. 2. (All)

5. Visually inspect valve stems per 11.4.4, ref. 2. (All) 6.- Visually inspect valve stem top per 11.4.5, ref.2. (All)

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

(1,5,9L/8R)

8. PT inspect valve stem-head radius per 11.4.9, ref. 2. (All) 6212CTOE25

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 1029961190 69E91$2 i

1. Valve clearances were within normal limits.

2. All valve seating was checked and found satisfactory.

. 3. Visual inspections of the valve seat areas were satisfactory

4. Visual inspections of the valve guides showed valve guide 8L to be broken.

5. Visual inspections of the valve stems snowed one valve stem '

to be unsatisfactory.

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

.1cen al wear.

7.- Visual. inspections of the friction welds were satisfactory.

.G. PT inspections of the valve stem radii were satisfactory.

UihachillQn at Jennecti9n ELOdinun

4. The broken valve guide is being analyzed to determine the cause if failure. Preliminary observations indicate that the i failure could have been the result of installation error.

The pieces of the guide were captured by the head casting at all times and the guide functioned well although broken. The guide was replaced.

Intake and E:< h au s t Valves, 02 -360Et , continued S. One valve had a slight amount of displaced metal on the stem top. This valve was replaced, f

i e

GetAWh! 912121 2E 101E251190 BRQ9C1 EAct Nggg1 Valve Springs EAtt UMOkRC102-360D GlA151B W9CE 6199111 69s2170MNT 611CikWitt MRCliitd

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

2. Visually inspect the valve springs per 11.4.0, ref. 1.(A11) 6titCEGEta

1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection IOSEREli90 6R19111

1. The color code found on the valve springs was correct.

2. Visual inspections of the valve springs were satisfactory.

Ditnetitien 91 101EREtien Eindin95 There were no significant findings, i

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GAtenkA Dismal 2a IQmenst190 Ben 9tt Eatt demg1S ubcovers EAtt Nymggc102-362A CIA 121B WGCE 8t99111 69s2170MNT etitikutta Mattiing

1. Visually inspect subcovers per 11.6.2, ref. 1. (All)

2. PT inspect rocker arm pedestals per 11.6.3, ref. 1. (Al')

BRfRCRQERE

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

1. Visual inspections of the subcovers showed one subcover to have a possible manufacturing defect.

2. PT ta'.:mactinac vi the rocker arm pedestals showed no defects.

DiMa91iti90 91 IQ1QtEtiGQ EiQdlGER

1. The defect found on visual inspection was an incorrectly drilled hole for a bolt guide. This was evaluated as having no effect on diesel operability and ths part was determined to be acceptable for continued use.

1 l

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r ---.e - - , - ,c --,,.r --

Gatewke Qinati 2R Inmatchien Beastt Entt UtmetF uel Injection Pump EAtt UMGuttLO2-365A GlARELB W9CE BREWR11 UQt2170MNT Statikuten Yetitied

1. Visually inspect the ID of the valve holder us:.ng a borescope per 11.2.2, ref. 1. (All)

2. MT inspect the delivery valve assembly per 11.6.3, ref. 1.

(All)

Smittensen

1. MP/0/A/1000/42 Diesel Engine Fuel Pump and Linkage Special Inspection Ic1ERGli90 892W112

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

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

Disaenitten 91 Innanstian Eindiana

1. One valve holder was reamed out and the inspection was repeated with satisfactory results. The other valve holder was replaced.

i

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GatAuke Qimmei ;E 10annstien Benett Egtt Nemgt F uel Injection Tubing Eatt Nymkatt02-365C CLARELB W9th 829M311 69s2178MNT

etitikulam Metified

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

2. ECT inspect tubing per 11.3, ref. 1. (All)

Baintressa

1. MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special Inspection 102E9s1190 BREWitz

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

2. ECT inspections showed no indications.

91mEssitisc 91 Iczenst190 Eindican

1. The discrepancies found on the visual inspections were determined to have no effect on engine performance. The tubing was reassembled and the determined to be satisfactory, i

6 0

.,--._e , _ , -

11 l

l Catanka Qinant Za lenanstien EnEstt Entt UgmgtF uel Injection Tubing Supports Eftt dyshgtt02-365D GlA1118 WQCh 6tSut31 69s2178MNT 6ttCikMtRE MRCliltd

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

SmittenEnn

1. MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special Inspection IO!ERGt19G BREM111

1. Visual inspections of the fuel injection tubing supports were satisfactory.

9i1E9111190 91 101ERE1190 EindlGER There were no significant findings.

S l

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1 GA1Aube Q19331 2a 102E951190 BRQ9C1 EACA NAst1F uel Pump Linkage EAtt NWTERC1 02-371A/B GLA221A W9Ck Egggggi Ugs2170MNT Gittinutta McCliind

1. Visually inspect linkage per 11.1.2, ref. 1. (All)

2. Ensure that an adequate lubrication schedule is in place per i

11.1.3, ref. 1.

l BtitCEDERE

1. MP/0/A/1000/42 Diesel Engine Fuel Pump and Linkage Special Inspection 10matst190 Btzults

1. Visual inspections of the fuel pump linkage were satisfactory.

2. An adequate lubri, cation schedule was verified as in place.

Dimagnit190 91 10matEt190 Eind109m There were no significant findings.

--- - , - - ,- ,,s - ,e.-- , w 4 ,r- ,w - .+-y+, g+ x y 4r- x

I CA1AwQA EiRERl 2% IQ1EREliGQ BRE9C1 Esti N3mg1 I ntake Manifolds Eatt Nymggc102-375 Gleff1B j

W9th 859WR11 Ngz2170MNT Gattihutta Vatified

1. Visually inspect surfaces and bolt holes per 11.2.2, ref. 1.

(All)

2. Visually inspect gasket fitup and alignment on installation per 11.2.3, ref. 1. (All)

3. Verify correct installation per 11.6.14, ref. 2. (All)

BRiSCEQERS

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

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

10122E1190 8919111

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

2. Visual inspections of gasket fitup were satisfactory.

3. The manifolds were installed to TDI specifications.

Ei1E911ti90 91 101EREtl90 EiQdiGER

There were no significant findings.

l

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

c- --

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

1 P

Cgtawbg Diggel 2@ 10ggegtign Egggth i

Egth Naeg1 Exhaust Manifold f

. Batt UM99EC1 02-300A GlassiB W9th Be9MEst N952170MNT l'

l AtlCibygg3 Vgtified j 1. Check alignment on disassembly per 11.2.11.1, ref. 1. (All) 1

2. Visually inspect flange welds per 11.3.4, ref. 2. (All) j 3. Visually inspect system to verify as built condition per 11.2, ref. 3.

/ 4 Verify proper reassembly per 11.6.13, ref.1. (All) 82i9CEDG21

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 Menifold Special Inspection i 102299t190 895M1t5

1. Alignment on disassembly was natisfactory.

2. Visual inspections of the flange welds were satisfactory.

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

4. . .The manifolds were installed to TDI speci-fications.

?-

i y Digggsitige gi legggglign Eindings 1

2' There=were no significant findings.

i e

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1 L

4

• -- ._--a-,,-. , ,, ,.m- mw # . . , , , . , - , . . - - - , v., ,rw w ..- ., -e-.- +-+ .e-. , - - . . -

l GA1AwkA Dit1Ri 2a 102 ERG 1190 BtG9th Egtt N Asg1 Exhaust Manifold Bolting Egtt Nyeggt102-380B GlA251B Weck Benutzt Ngs2170MNT etttthutta Macified (Accomplish 1,2, and 3 on one bolt from cyls 1L,5R and OR)

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.

4. Viqually inspect bolts per 11.2, ref.2 (All)

Esistnessa

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

2. MP/0/A/1000/56 Diesel Engine Exhaust Manifold Special Inspection l IOSERE1190 BREWill

1. Visual inspections of the exhaust manifold bolts were satisfactory.

2. All bolts were 1.5 inches long - satisfactory.

l Bolt hole depths were found to be satisfactory.

3.

4. Visual inspections of the as built condition were satisfactory.

Disnemitten ei Innenstien Eindican There were no significant findings.

l

t l

Gattuka Digggl 2R IQ3RREtigg 8tagCt Egtt NamgtCrankcase Covers Efti UgmugC102-386B GLA11LC W9th 8R99911 69s2170MNT etttikutta Matified

1. Visually inspect bolt holes per 11.5.2, ref. 1. (All)

2. Reassemble covers per 11.16, ref. 2. (All)

StitCROERE

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/1000/36 Diesel Engine Piston, Rod and Liner Removal, Disassembly, Inspection and Reassembly 10manstiso Beaults

1. Visual inspections of the crankcase cover bolt holes were satisfactory.

2. The covers were reinstalled to TDI specifications.

912E9311190 91 10sanst190 Eindienn There were no significant findings.

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GatAwka Qittfl 2E Ic1EREti90 BRE2Ct Egt t Ngmgt Intake/ Intermediate Rocker Arms Entt Nymust102-390A

.l GlA111B I Weth Benutti Ngs2170MNT 611Cikutti MRCifigg (Accomplish on all Rocker Arms)

1. Visually inspect rocker arm shafts 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.

l Brittenset

1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated i

Parts Special Inspection In1ERE119e 651u111

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 showed two pads with cracks.

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

Qttnefitten 91 Infatstian Eindica1

1. The amount of nicking and 3coges found on visual inspection of the rocker arms was detetmined to be normal and would have no effect on ergine per+ormance. These parts were evaluated as being acceptable for continued use.

4. The cracks found in the swivel pads were determined to be the result of improper swaging. The cracked pads were

replaced with new pads.

GAtawet Qititl 2E 101EREtiGQ BREQC1 EAtt UAmstE xhaust Rocker Arms EAtt UWmhett02-3908 GlA11LB Hgtk Bgggggt Ngs2170MNT 6ttClhWitt MRCliigg (Accomplish on all Rocker Arms)

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 11.8.8, ref. 1.

BtfRCROGRE

1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection 10matst190 82su112 i

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.

Qinanzitten of Innatstina Eindiana

1. The amount of 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.

GatAwka Qienst 22 10maestien Stasch Pgtt Ugmgi I ntake/ Exhaust Pushrods Pgtt Ugmggtt02-390C GLASILB W9CE 6REWtit des 2170MNT etttikutta Vatifing (Accomplish on all Pushrods)

1. Verify pushrods are of iction 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.

BefstacEsa

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

IONEREti90 BREMita

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.

912a921119n 91 Insane 119e Einginam There were no significant findings.

Cattwha QiRERl 2E IORERGliGQ 8EE9Ct Pact Naeg1C onnector Pushrods ,

Entt NgehgCLO2-390D GlastiB Wsth Ensummt Ngz2170MNT 6titibutRE Mitifigg (Accomplish on all Pushrods)

1. Verify pushrods are of friction welded design per 11.10.2, ref. 1.

2. PT inspect friction weld per 11.10.3, ref. 1.

3. Visually inspect spherical surfaces per 11.10.4, ref.1.

BRitCEGEtt

1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection IOSERG119n 8219112 .

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.

212n911119n 9f lonEnst19e Eingicas There were no significant findings.

t l l

Getawha Dietal 28 101a:st190 Benett Egtt NgmgtR ocker Arm Bushings  ;

EaCl UWOktC102-390E GlatitB WQCE BREWR11 UQs2170MNT 611CihW1RE MRCliits

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

(All)

2. Visually inspect exhaust rocker arm bushings per 11.8.7, ref. 1. (All)

)

Baintensen '(

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

\;t h

In!EREliGo 622W1$1

, 1,2 Visual inspections'of the intake / intermediate and exhau3t rocker arns were satisfactory. '

Qitannitien et innanstien Eindinna There were no significant findings.

T i

,- /

9 r' ,

f i

l l - , -

1-4-

l Calgwba Diggei 2B Igggggtige Egggth Pact Ngmg1R ocker Arm Boltinq Bett Nymhgt102-390G IGlA221B HgCE Sgggggt Ngz2170MNT 9titibyggg VgtLiigd

1. MT inspect capscrew thread roots per 11.11.2, ref. 1. (All)

2. Visually inspect rocker arm capscrews per-11.11.5, ref. 1.

(All)

3. Verify reassembly torque per 11.6.17, ref. 2. (All)

, 82i2CROE22-j 1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection

2. MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, Disassembly,' Inspection and Reassembly 4 IO2G2Gt190'8229112~

l '. thread roots MT-inspections showed one defectof the in' rocker the capscrew arm capscrew~All shaft. threads were catisfactory.

'2. . Visual i nspections of the' rocker arm capscrews were evaluated as satisfactory.

3. The capscrews were torqued to TDI specifications on reassembly.

Digggnitign gi Ingggqtige Eindiegg

1. The.capstrew'with the MT defect ~in the shaft was replaced.

)

1 4.

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mgy9 e+m-g-r-' -

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GA1AWha 9i2521 2E 101E29ti90 6tE9C1 Egtt Ngmt10 verspeed Trip and Accessory Drive Batt Nysktt102-4105 GlassiA W9tk 6299 tat Ng_2184MNT 6ttCikutti MRCliits

1. Visually inspect drive gear per 11.3.2.1, ref. 1.

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

8titCEGEtt

1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly 1019291190 6tiglia

1. Visual inspections of the drive gear were satisfactory.

2. Visual inspections of the driven gear were satisfactory.

9i129111i90 Qi IQ2EREti90 EiOdiO91 There were no significant findings.

O

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GatAWha Dit!!1 EE In1ERsti90 BRE9C1 Egtt Ngmg10 verspeed Trip Drive Coupling BBC1 Nymtgc10 2-410C

'ClA32iA W9CE BE9Mtil U9z2184MNT 6titikWiti MRCliite

1. Visually inspect coupling elastomer per 11.3.1.1, ref. 1.

Beincanssa

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

1. Visual inspections of the coupling elastomer were satisfactory.

Qina911tien 91 Innanstien Eindin9m There were no significant findings, i

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l Gatawha Dismal 2D Innanstisc Beasti Egti Ngmg1S peed Regulating Governce Drive EBCt Nyeggt102-411A l l

Gla12iA l Wnth Snsumat Net 2184MNT 8tttikuten Matified

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.

Emintangan

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

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

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

Diansmition of Innanstien Eindican There were no significant findings.

l i

. - . _ . _ - - . _ - . _ _ _ . . _ - _ , , - . , , ,, r

i

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GAttwha Qitatl 2E 101EREti90 BRE9Ct Egtt NgmgiS peed Regulating Governor Drive Coupling Eatt Nymkat1 02-411B GlanntA W9th St99211 Ngz2184MNT etttikutts Vattittd

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.

EffttRGEtt

1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly IO2EREh190 BR2Wita

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

2. The coupling material was verified am neoprene.

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

QiEE911tiGQ 91 IOSEREliGQ EiQdiO91

2. There were no significant findings.

l Getawks D1===1 2a Innenstise Beasta Pgtt Ngmg1S peed Regulating Governor Linkage BBCt gymggtt02-413A Gla111A W9CE BE9MR11 Ugu2184MNT 9tttikMtta Yatified

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.

BffECROGRE

1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly 102EtGt190 BESMita

1. The linkage action was checked and found sati sf actor.y.

2. Visual inspections of the cross shaft were satisfactory.

3. Locktite was installed to procedural requirements.

D1129211190 91 102EEEt190 E10diO91 There were no significant findings.

I <

t  ;

i i

! I l

I

-. ~

GalAWh! Dititl 2E 101ERE1190 8tE9C1 Pgtt Ngmg1F uel Pump Linkage and Shutdown Cylinder 8ett GymQgt102-413B CLA211B W9CE 8E99t11 69s2184MNT Bittikutta Mttifits

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

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

8titCEGEtn

1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly 10safst190 8tzults

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

2. Visual inspections of the cross shaft were satisfactory.

Qinasnitien 91 Ionatst19n Eindin9m There were no significant findings.

1 l

l i

i

, 1 i

4 1

GetawkA Qltitl 2E 101EREtiEO 6tE9C1

]

Egtt NgmeiG overnor Booster Servomotor Enti Nymkatt02-415B G14111B l W9th 639WR11 69t2184MNT etttikutal Entitled

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

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

Reassembly 1 101EREli90 891W111

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

QiME911ti90 91 IOREREli90.E10diO91 There were no significant findings.

.2 4

i l

l 4

, _ _ _ - . _ . . . _ _ . , _ _ - __ _ - _ __..__-.__m., ,-,---., _ _ ,..., _ . , , , , . . . . . . , , , . . _ ,_...__.-,-..m. . . _ . , , , - , , . _ . -

GAIAWQA DiRERl 2E 10199E$190 BRQ9C1 1

Entt NgmR1 Governor Heat Exchanger EAC1 UMmutt102-415C Gid191A Weck EnsuR11 det2184MNT l 6titiQuitt Mttiiltd

1. Verify proper installation per 11.2.2, ref. 1.

4 BffRCE"GRE

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

1012951190 BREWit!

1. The installation of the governor heat exchanger was verified 4 as satisfactory.

i Qi1EQ1itiGQ 91 IGNEREtiSQ ElGQLQQ1 There were no significant findings..

j 1

l

._ .-_._,.,_m. _ .._,_,. _ _ . . _ , .

Cgigwbg Digsgl 20 10M9991190 8999th Pgrt NamgiJ acket Water Pump Eatt NymQgtiO2-425A

'Gld22iA Wgtt Sgggggt Ngs2183MNT .

8tttihytgg Vgt[iigg

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

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

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

4. Vertfy torque of spline nut per 11.5, ref. 1.

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

69f9C90G92

1. MP/0/A/1000/59 Diesel-Engine Jacket Water Pump Special Inspection 10290s1t90 E9291h2

1. The gear carrier assembly was inaccesible for inspection.

2. Vi'3ual inspections of the coupling and spline were satisfactory. Driven gear was inaccesible for inspection.

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

4. Ttie torque of the spline nut was found to be at least 120 ft-lbs.

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

DLE292LklGQ Qi 1GEREELL90 E!QdlOGM There were no significant findings.

i l

Gatawha Qitual 2B 10annstisc Bresti Entt Ngmgt I ntercooler Piping Coupling Bett Numetti 02-436B GittiLA W9CE B29W311 Ugz2185MNT 6titikW1R1 Mttified

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

Briettosas

1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection 101ERGilen BREWila

1. The Dresser coupling on the intercooler piping was inspected

! and found to be the correct type.

Qltaesitten 91 Innenstlen EindinEn j There were no significant findings.

i l

1 a

y -,s ,. . ~. - -

GA1AWh4 Qit1Rl 2E 1019R91190 BRE9C1 Egtt NgegtTurbocharger Cooling Water Piping and Fittings Bett dumhttiO2-437A GlA11tB dQCh 6t9MRit d9s2176MNT etttituttR Yttifite

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

6tfRCtGQtt l 1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection IQ19f9tisQ BR19111

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

i Ql1E91L$i90 91 101929119Q 6104l091

^

There were no significant findings.

I I

i J

GAtthkA Qititl 20 101ERGil90 8tE9Ct Egtt Ngmat T urbocharger Cooling Water Piping Supports Etti Nymugtt02-437B GLARELA W9Ch 829WR11 09t2176MNT 6titikutRE MRCliitd

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

8EftCEGERE 1.. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 101E25t190 BREWlta

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

Q11E911119Q 91 IQ1EREllEQ EiQdl091 There were no significant findings.

A r

9 e

9

i Gatanka Dinami Za 10manstieQ Benett Egtt NgmetStart Air Manifold Tubing Bett Numhett 02-441A GlamatA WQth BnQuant ugt2175MNT l'

6tttihutti Metified

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

11.2 ref. 1.

t Baintact:1

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

101 ERG 1190 BR2uill

1. Visual inspections of the start air manifold tubing were satisfactory.

i 911E9111190 Qi 101EEEt190 EiQdlGER There were no significant findings.

i

~ .,.

Gatawha Qit1RL 2R 101EtEtieQ BtEsta

Egtt NgmgtStart Air Manifold Pipe Supports Eatt UWmhttiO2-441C ClattiA W9Ck StGWtit 69t2175MNT 8titikWitt MRtified

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

8titCROERE

1. MP/0/A/1000/54 Diesel Engine Air Start Piping System Special Inspection IQ1ERGtiGO 621W111

1. Visual inspections of the start air pipe supoorts were satisfactory.

Qi1E91ltiGQ Qi 101E2E1190 EiGdLQQ1 There were no significant findings.

i i

1

. - - .,-e

Catanke Qinist 2B 101EsstiQn 8tEQtt Egtt NgmgtS tart Air Distributor Tubing Bett UMmhttiO2-442B Git 11LA WQCh 859MR11 UQs2175MNT 6ttClkMitt MRCliitQ

1. Visually inspect system to verify as built condition per

11.3 ref. 1.

BeintacEn1

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

Inspection t

i 101 ERG 1190 BR1Miti

1. Visual inspections of the start air distributor tubing were satisfactory.

Ei1EQ1LilGQ Qi 1GREMEllGQ EiGQLQQ1 l There were no significant findings.

1 .

GAttwkA Qititl 2E in1EREtiQn 6tE9Ct Etti Ngmg1 F uel Injection Piping Eftt Ugmegtt02-450B CLA111B W9th Braunut Net 2178MNT Otttikuten Matified

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

8tfRCRcEtt

1. MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special Inspection Innenst190 Beaultz

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

Qisnemitien 91 InnEnEtien Eindican

1. The discrepancies found on the visual inspections were evaluated as having no effect on the performance of the diesel. The *uel injection system was reassembled and determined satisfactory for continued use.

I l

1 l

l l - -

GAtAwuA 9191912E lONERGli!!G BEE 9Ct Egtt NgmgiF uel Oil Piping Supports Batt SymugtiO2-450D GLA!!iA W9th 6t9Wtit U9s2178MNT 4

etttikutta Metified

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

6tfRCEGEtt

1. MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special Inspection IONEREti90 BREWit!

1. Visual inspections of the fuel oil piping supports were satisfactory.

Qianenttien 91 In1Eastten Eindiens There were no significant findings.

(

-e - - , - - - - - - ,1e,,- r -- -- -., ,-r e

As- a 4 - aw .-a -- a 4 Gatanka Qitant 2E Insetstien 6manti i

Pgtt NgmgtF uel Oil Filter Mounting Hardware EaCl UWmkECLO2-455C GlaR11A W9Ch 829 WEST USz2173MNT 6titikutt1 MRCliite

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

2. Visually inspect system to verify as-built condition per 11.2, ref. 2.

t i Etitttc:ta

/

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

2. MP/0/A/1000/55 Diesel Enginw Fuel Oil Piping System Special Inspection i

101 ERG 1190 BREWiti

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

2. Visual inspections of the fuel oil filter mounting hardware were satisfactory.

i j Qinanzition 21 lunatstian Eindinna l

There were no significant findings.

J t

- - , - _ ,_,,~...,_,.,_---_g c - , , , , , ,.. _,,,7 . -

,__,-,_r.- ,. , , -

l Catanka Qianal 2B 10matstLQc Beastt <

l f Enti NgmstE xternal Lube Oil Lines EAtt NWetttt02-465A l

CitBILA W9th BESW111 NGs2196MNT 6tttikWita Yttiiltd

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

11.4 ref. 1.

Beistensen

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

insesstlec Beaults

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

Disaenitten ei innanctien Eingican i There were no significant findings.

4 0

9

- . - , - , - _e, , , , . . -.. _

,,_,w.,.-__,,,,_..,%, _

, - , , . . , . - , , , , ym,.., m.~.w., _,%

Gateeke Qttnal 2E IQuaestigQ 8enett Egtt NgmgtExternal Lube Oil Line Supports Enti Ugmhtt102-465B Gle111A WQCh 8199t11 69t 186MNT etitikuten Yacified

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

StiettQsta

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

1. Visual inspections of the external lube oil line supports were satisfactory.

Di1EQ1ltlGQ Qi IQ1EREllGQ EiGQiGQE There were no significant findings.

i l

i 1

)

GRinwke Qititl 2E Ic1ERGilQc BREQCt Egt1 Ngmgt T urbocharger Lube Oil Piping Bitt Ugmugtt02-467A GLt1ELB WQCh StSutil U9s2186MNT 6titikutti MRCliltd

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

SmittacEtt

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection 10sanst190 Bitulit

1. Viusual inspections of the turbocharger lube oil piping were satisfactory.

Qi1E9111190 Si Intatstlec Eindicat There were no significant findings.

e e

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GA1AWke QiERR1 2E IcEEtstiQc 6taQC1 Egtt NemetT urbocharger Lube Oil Piping Supports CAtt NumhtC102-467B GlennLB WQCh SREWtil N9t2186MNT i

etitikuten Yetifing

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

I

\

i 8mittensen

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

1. Visual inspections of the turbocharger lube oil piping supports were satisfactory.

Disnsmition 91 Inmaestien Einginem There were no significant findings.

GetAuke Qit!El 2E 101ERGli90 8EE9C1 Egtt $3sg1Turbocharger Bracket EAct UWebEC102-475A GlA13 r,B WQCh BREWtit des 2185MNT 611CikWARE YtCliifd Visually inspect turbocharger bracket per 11.3.2, ref. 1.

i 1.

(All brackets and bar supports)

Stiftens:1

1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection 101Ef51100 BR1Mlll

1. Visual inspections of the turbocharger bracket were satisfactory.

Ei1EQ1iliGG Qi IQ1EREliGQ EiQd1091 There were no significant findings.

i l T

Gittwke Qiftfl IE 101Etsti90 6tE9C1 Egtt Nggg1T urbocharger Bracket Bolting Bett duTktC102-475D GLA11LB W9th 639u311 N9s2185MNT etitikutta Yettiing

1. Visually inspect bolted joint per 11.4.3, ref. 1.(R/L Banks) l 2. Verify proper torque is applied to bolts per 11.4.4, ref.1.

(Sample of 6 bolts)

Beintnesen

1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection Insasst190 Besults

1. Visual inspections of the joints were satisfactory.

2. The bolts were retorqued to the required values on reassembly.

QinE9mit190 91 lonEsst190 Einginen There were no significant findings.

1 4

%.-- - y -. w ,.e -e--. , - e, s.- er +r- -- - s - - .- --- - -

Catawha Diens1 2B Innenst190 Benett Pgtt Ngmg1C ontrol Panel Tubing Batt NyghttiO2-500M Glass 1B

! WQCh 859WRat Ngz2177MNT etitikutta Vacified

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

! Baintensen

1. MP/0/A/1000/57 Diesel Engine Shutsown Tubing and Electrical Conduit Special Inspection i

innanstien Beaulta J

1. Visual inspections of the control panel tubing were satisfactory.

! Dinas-4tien 91 losanstian Eingicas There were no significant findings.

j 6

- - -,_r.__.. _ _ . _ _ . , . _, _.. . ___, ., , _

a Gatanha Qianal 2R IQuanGtL90 6ta9th Eatt Namti Lube Oil Sump Tank Eatt Uumkttt02-540A GlammLB W9th St9unst Ugs2186MNT 8tttikutta Vattiled

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

Stiettants

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IQsanstisQ 6tsults

1. Visual inspections of the lube oil sump tank were satisfactory.

DiEE91iti90'Gi 103ERGil9Q EiQdlGER There were no~significant findings.

T.

J e . - - .,nn-7 ,, ,,, -..-..,n - , --- y 4---- , - - ,

i

?!

Gettwkt Qititl 2E IQ1ERGliGQ BRE9C1 Entt NgmitLube Oil Sump Tank Bolting ERCt Ugmhttt02-5400 CLA11LB

.W9th 639Wtit Ugs2186MNT s

etititutta YMClittd

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

EtitCEGERE

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection 101E951190 62191t3

1. Visual inspections of the lube oil sump tank colting were satisfactory.

.i Qi1E91LiiGQ Qi 101EREti20 EiOdLQQ1 There were no significant findings.

.{J

,/ -

e L

l

_ _ -,. _ - . . - - .o . _ _ . _

Cettwkt Qititl 2E 101EREtie0 BRE2C1 Pgtt Ngmg1 Lube Oil Sump Tank Mounting Hardware Bett Nymhett02-540C Citt1LB W9th 639M911 N9t2186MNT etttikutta vttiittd

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

Smitttqsta

1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IOSEREli90 6352111

1. Visual inspections of the lube oil sump tank mounting hardware were satisfactory.

Rime 9 mitten 91 10annstien Eindinem There were no significant findings.

GatewkA Qititl 2E 101ERGil90 BeESC$

Egtt NamttEngine/ Auxillary Module Wiring Conduit BAtt NughgtLO2-600A GLA11LA W9th 8199R11 Ngt2177MNT 6tiCikutti Mitifits

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

8titCROGRE

1. MP/0/A/1000/57 Diesel Engine Shutdown Tubing and Electrical Conduit Spccial Inspection 4

101EREti90 811Will

1. Visual inspections of the engine / aux wiring conduit showed satisfactory comparison with as-designed drawings.

DIME 91lti90 91 101ERGliGQ 8l041091 There were no significant findings.

~

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/

GALAWha QlERRl SE 1019291l90 8999C1 EAtt N AmstEngine Shutdown Tubing EACt Egmagtt02-695A GlARELA W9th 8R9Mtst 69t2177MNT 6ttCikWiti Mttliitd

1. Visually inspect system to verify as built condition per 11.2 and 11.3, ref. 1.

BeinctO921

1. MP/0/A/1000/57 Diesel Engine Shutdown Tubing and Electrical Conduit Special Inspection 1029991190 BREM111

1. Visual inspections of the engine shutdown tubing showed minor discrepancies with as-designed drawings.

Ei19911ti90 91 1019E91i90 EiOdiG91

1. The discrepancies found on visual inspections were evaluated as having no effect on diesel operability. The tubing will be reassembled to the correct configuration.

)

f I

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CitaWh4 Qititl 2E 101ERGliGO 6tEQC1 Egtt Ngmg1T urbocharger Thrust Bearing Lube System Eft 1 NymugtiO2-CFR ClR11LC WQth Bn9 unit Ngt2186MNT 8tttihutel Vatified

1. Visually inspect system to verif y as built condition per 11.5 ref. 1.

Saintensai

1. MP/0/A/1000/43 Diesel Engi ne Lube Oil System Piping and Sump Special Inspection Insnestisc Betuiti

1. Visual inspections of the turbocharger thrust bearing lube system were satisfactory.

Ei1291i1i90 Qf IQ1gggtige Eingingg There were no significant findings.

1

- - - , _ . , , _ , . , _ , , _ . . , . , , - . _ . - r., , r__ -. . . . .v. .- - . .

GA1Anh4 Disani 2B 10manst190'8mastt Bitt NATti ntercooler I

BAtt NWThRtiF-068 GlA211B W9CE 839 Mitt dQs2185MNT Otttinuten Ymtified

1. Visually inspect intercooler per 11.5.2, ref. 1. (L/R)

2. PT or MT inspect intercooler adaotor flange weld per 11.5.3, ref. 1 (L/R) 8sincrosen

1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection IQ1ERE1190 SE1WitE

1. Visual inspections of the intercooler were satisfactory.

2. MT examinations of the adaptor flange weld were satisfactory.

91199111i90 91 101ERGil90 E10diO91 There were no significant findings.

l t ,

i 1

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1 l

1 I

l Gatawns 91=1=1 2a in1Enst19e SnE9tt Pgtt Ngmg1 Turbocharger Bett U9mbEtiMP/022/3 Cla111A WQCh 6t9WR11 Ugz2185MNT 6ttCinutRE Mttiilgd (Perform inspections on all turbochargers with > 50 hours5.787037e-4 days <br />0.0139 hours <br />8.267196e-5 weeks <br />1.9025e-5 months <br /> service)

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 nozzle 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. 1.

8. Visually inspect exhaust gas inlet bolts per 11.6.1, ref.

BEfRCEQERE

1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection 105E9G1190 8919111

1. Visual inspections of the left bank turbocharger were unsatisfactory.

2. The turbocharger bearings were found severly worn.

3. The rotor float clearances were found satisfactory.

4. The inlet casing bolts were found satisfactory.

5. PT inspections were performed by the manufacturer. The documentation was reviewed and found satisfactory.

6. The bearing diameters were unsatisfactory due to severe wear

7. The casing bolts were torqued to 60 ft-lbs on reassembly.

8. Visual inspections of the exhaust gas inlet bolts were satisfactory.

9i129111190 9f 10129Gt190 EiQdiO91 The bearing wear found was determined to be the result of inadequate lubrication. The turbocharger had been run with inadequate oil flow due to the oil being supplied through piping with thicker than normal wall thickness. The bearings on the right bank turbocharger were replaced. The left bank turbocharger was replaced entirely due to lack of spare i parts for repair. The thick wall piping was replaced with

5.0 Appendices 5-1

1 l

Appendix B Engineering Evaluations

APPENDIX B Introduction The purpose of this appendix is to document the results of the engineering evaluations performed for selected parts of the Catawba 28 diesel. The parts were alected for this review if their quality was not being verified by detailed inspections. Information for the evaluation was obtained by reviews of maintenance records, discussions with diesel maintenance personnel and in some cases, visual observations. The maintenance and operating logs for diesel 2B were evaluated to ascertain if any problems had existed on the engine. The parts evaluated in this appendix are listed in Table B1 at the end of the appendix.

As diesel 2B had only about 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> of operation, very little maintenance has been perfonned on the engine. For this reason, only the parts with an operational problem or maintenance history will be discussed below. All other parts listed in Table B1 are considered to be satisfactory.

Detailed Review of Part Validation Part No: 02-365B Part Name: Fuel Injection Tips Evaluation: The fuel injection tips were replaced with ones of a more efficient spray pattern. This modification was done to produce more uniform firing pattern on the piston and the tips that were removed were satisfactory.

Part No: 02-500J Part Name: Control System Relays Evaluation: One controlling relay was found defective. This defect had the effect of causing the engine speed to vary. The speed regulating governor was checked and found satisfactory. The defective relay eas replaced and the speed control system has been satisfactory. This is considered an isolated failure.

Part No: 02-550 Part Name: Foundation Bolts and Anchors Evaluation: A modification was made to strengthen the mounting surface for the generator pedestal bearing. A i inch plate was installed on top of the pedestals. This modification prevents deformation of washers under bolt torque when in contact with the slotted mounting surface.

B-1

6 Part No: 02-630D Part Name: Instrumentation Thermocouples Evaluation: During initial engine operation, several thermocouples were noted to have readings that were inconsistent. These thermocouples were replaced with new ones. These failurs are considered to be those assoc 4.ated with infant mortality of electrical devices.

Part No: CN-107 Part Name: Intake Air Silencers Evaluation: During initial engine operation, it was discovered that one end cap was improperly welded. This has since been repaired and operating satisfactorily.

Part No: CN-111 Part Name: Lube Oil Heat Exchanger Evaluation: This component was not supplied with a vent that would allow the heat exchanger to be fully filled with water. The heat exchanger was modified to include the vent and has performed well.

B-2

ti Table B-1 List of Parts Covered by Engineering Validation Review Part No. Part Name_ Class00-420 Lube Oil Pressure Regulating Valve A 00-700B Jacket Water Standpipe Valves B 00-700E Jacket Water Standpipe Switches B 02-311D Crankcase Mounting Hardware B 02-315B Cam Bearing Caps and Dowels B 02-315E Cylinder Block Structural Bolts B 02-315G Cylinder Block Seals and Gaskets B 02-330A Flywheel' A 02-345C Fuel Pump Base B 02-360C Cylinder Head Bolting and Gaskets B 02-365A Fuel Injection Pump B 02-365B Fuel Injection Tips B 02-410A- Governor - Overspeed Trip A 02-410D Overspeed Trip Vent Valves A 02-415A. Speed Regulating Governor A 02-415B Governor Booster Servomotor B 02-420 Lube Oil Pump A 02-441B Start Air Manifold Valves, Strainers, Filters A 02-445 Fuel Oil Booster Pump A 02-455A Fuel Oil Filters B 02-4558 Fuel Oil Strainers B 02-465C External Lube Oil Valves A 02-500A Control Panel Cabinet A 02-500F Control Air Accumulator A 02-500G Control Air System Valves A 02-500H Control Air System Pressure Switches B 02-500J Control System Relays A 02-500K Control System Solenoid Valves A 02-500N Control Panel Wiring A 02-550 Foundation Bolts and Anchors B 02-6300 Instrumentation Thermocouples B 02-688B Engine and Aux Module Wiring A 02-688C Engine and Aux Module Wiring Boxes A 02-689 Off Engine Safety Alarm Sensors-Wiring B 02-690 Engine and Sensors B 02-691A Off Engine Safety Alarm Sensors-Switches B 02-6958 Engine Shutdown Valves, Regulators, Orifices A 02-695C Engine Shutdown Trip Switches A 02-8250 Fuel Oil Duplex Strainer B C 136/40 Thermostatic Valve B CN-106 Intake Air Filter B

, CN-107 Intake Air Silencer B l CN-109 Before and After Luce Oil Pump A CN-110 Fuel Flow Lube Oil Filter A CN-111 Lube Oil Heat Exchanger B B1-1 i

r-Table B-1 (continued)

Part No. Part Name Class CN-119A Generator Shaft and Bearings A CN-120 Jacket Water Heat Exchanger B CN-122 011 Prelube Filter A CN-131 Lube Oil Keepwarm Strainer A F-068 Intercooler 8 SE-025 Lube Oil Full Pressure Strainer A 1

B1-2