ML20198J407
| ML20198J407 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 04/30/1986 |
| From: | DUKE POWER CO. |
| To: | |
| Shared Package | |
| ML20198J401 | List: |
| References | |
| NUDOCS 8606030106 | |
| Download: ML20198J407 (127) | |
Text
,
x CATAW8A NUCLEAR STATION DIESEL ENGINE 2A COMPONENT REVALIDATION INSPECTION 1
PREPARED BY DUKE POWER COMPANY September 25, 1985 Revision 1 April 30, 1986 8606030106 060528
. PDR O
ADOCK 05000414 PDH
Table of Contents 1.0 Introduction 2.0 Summary and Conclusions 2.1 Overview of Operations 2.2 Overview of Inspection Results 2.3 Lessons Learned from Unit 1 Inspections 2.4 Cylinder Head Leaks 2.5 Results of Subsequent Inspections 1 2.6 Conclusions 3.0 Discussion of Inspection Results 3.1 Inspection Related to TDI Generic Problems 3.2 Catawba Specific Problems 3.3 General Inspection 4.0 References 5.0 Appendices 5.1 Inspection Reports i
Figures 2-1 Cylinder Head Repairs Tables 1 Summary of Catawba Diesel 2A Revalidation Inspection Results
I" 1.0 Introduction This report describes the results of inspections and evaluations performed on the Catawba 2A diesel engine. These tests and inspections were performed as part of an overall program to verify the reliability of Transamerica Delaval, Incorporated (TDI) diesel engines used for safety-grade power supplies at Catawba. This report was initially submitted to the NRC on October 2, 1985, Reference 1.
Subsequent to this submission, a audit of Owners Group DR/QR requirements was performed. The results of this audit were documented 1 in a letter to the NRC on January 13, 1986, Reference 8. As a result of Reference 8, further inspections were accomplished on the 2A diesel. Further, in the issuance of the Facility Operating Licenses for Catawba Unit 2, the NRC in Reference 9 requested confirmatory information on the Catawba 2A diesel engine which required additional inspections. The purpose of this revision to the report is to update the original submission to describe work accomplished per References 8 and 9.
The initial inspections of the 2A diesel engine were performed in May through August, 1985. The inspections involved extensive disassembly of the diesel and 100% inspection of parts for which there was a history of problems or other reasons for special concern. Substantial (e.g., 25%) sampling inspections were performed of other important parts where there was no history of problems. The scope of the inspections are as described in Table 2-1. About 2700 separate inspections were conducted. Subsequent inspections, per References 8 1 and. 9, were accomplished in January and February 1986. The subsequent inspections, per Reference 8, included eddy current tests on a sampling basis of main bearing crank shaft oil holes and con-rod box bolt hole threads; material comparator tests of intake and exhaust valves on a sample basis, and material comparator and hardness tests of rocker arm cupscrews. The subsequent inspection, per Reference 9, included end float measurements of the turbochargers and verification of engine base material. ,
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 1 Ouke Power personnel, with selected inspections performed by Failure Analysis Associates (FaAA), Law Engineering and Stone and Webster personnel.
Detailed results of the inspections are contained in Section 5.0 and are discussed in Section 3.0. Summary and conclusions resulting from the inspections is contained in Section 2.0 of this report.
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t 2.0 Summary and Conclusions 2.1 Overview of Operations The Unit 2A diesel generator was a new engine which had not been run at Catawba prior to the initial revalidation inspections. Results of these initial inspections are discussed in Sections 2.2 through 2.4. 1 The Unit 2A engine had in excess of 140 hours0.00162 days <br />0.0389 hours <br />2.314815e-4 weeks <br />5.327e-5 months <br /> of operation during the subsequent inspections. Results of these inspections are summarized in Section 2.5.
2.2 Overview of Initial Inspection Results As discussed above, the Catawba 2A diesel engine was a new engine which had never been run at Catawba at the time of initial inspections. However, extensive disassembly and inspection of this diesel engine has been performed to confirm the satisfactory condition of various parts and to identify any parts requiring repair, replacement, and/or redesign to ensure highly reliable standby electric generator service. It should be noted that the inspections of some items were of limited value since the diesel had only been operated during factory tests, and service induced 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.
The results of the initial inspections are summarized in Table 2-1.
Engineering and quality assurance evaluations of the inspection results have been performed. This work is considered to have identified all significant conditions.
The only significant condition noted as a result of the inspections was that five heads on the 2A diesel were plug welded using partial penetration welds. On unit 1 diesels, some heads with such partial penetration plug welds leaked and were replaced. Accordingly, the heads on the 2A diesel with partial penetration plug welds were replaced. This problem is further discussed in Section 2.4.
Referring to Table 2-1, some parts were to be subject to an engineering validation. These parts, which are important to diesel operability, were not inspected to conventional non-destructive techniques since they were not specified in the TOI Owners Group program and there has been no history of problems. On Catawba Unit 1, engineering validation consisted of an evaluation of the operating and maintenance history of these parts to assure that there were no problems. On the 2A diesel since the engine had never run there was no operating or maintenance history. Hence, engineering validation of the parts listed in Table 2-1 was not performed.
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2.3 ' Lessons Learned from Unit 1 Inspections The extended operation tests and revalidation inspections 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 2A diesel, except for one item, which will be accomplished by the end of the first refueling availability.
These items include the following:
o Piston skirts were changed from the AN type to the AE type.
o A new turbocharger prelube system was installed to assure that the turbocharger bearings get adequate lubrication during engine starting.
o Modifications to the turbocharger prelube oil lines were accomplished to reduce vibration.
o Permanent turbocharger lube oil drain lines have been incorporated, o Turbocharger exhaust gas inlet bolts have been changed to SA543, 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.
fatigue strength materials, o Starting air distributor cover capscrews will be changed to a material of improved fatigue strength during the first availability and prior to the end of the first refueling outage.
2.4 Cylinder Head Leaks Four cylinder heads at Catawba, one on engine 1A and three on engine 18, developed small Jacket water leaks into the fuel injection cavity.
The 1A cylinder head has been examined by FaAA. This investigation (reference 4) revealed that the leak was caused by a crack initiating from the corner of a welded-in plug where it was seated in the cylinder head as shown in Figure 2-1A. This welded-in plug is reported by TDI to have been used to repair the casting around the fuel injector hole.
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Duke Power Company has developed both visual and ECT inspection techniques to detect the partial penetration plug weld in a cylinder head. On diesel 2A five heads had been repaired with the partial penetration plug welds. These heads have been replaced. Of the heads replaced three heads (cylinders 6L, 7L and 8L) are heads with no weld repair. The other two replacement heads (cylinders 2R and 3R) have been repaired per Figure 2-1B.
-Referring to Figure 2-18, the weld repair of the cylinder heads consists of welding a plug into the head, stress relieving the weld and machining the injector port back side of the plug out such that the repair is a full penetration weld. This repair is described on TDI drawing 102718, Rev. O. Cylinder heads at Catawba that have been repaired in this fashion are stamped 1NR. The full penetration weld eliminates the crack starter found in previous partial penetration weld repaired heads. Post weld stress relieving reduces welding residual stresses to low levels. Thus, weld repaired castings with full penetration welds are considered equivalent in quality to non weld repaired castings. Hence, Duke Power Company has replaced all partial penetration repair welded heads with heads with no repair or with full penetration weld repairs as shown'in Figure 2-1B.
2.5 Results of Subsequent Inspections Results of subsequent inspections, outlined in Section 1, performed on the Unit 2A diesel generator are summarized below:
o Crankshaft Oil Holes - Reference 8 indicated that additional eddy current tests of crankshaft oil holes 4, 6 and 8 would be accomplished to assure the absence of cracks in the oil holes. Due to engine availability oil holes 6, 7 and 8 were ECT inpsected by FaAA to Procedure NDE 11.3, Rev. 2 on the 2A engine. FaAA has also indicated that sampling oil holes 6, 7 and 8 was equivalent to the Owners Group requirement of sampling 4, 6 and 8 as the 7 oil hole stresses are about the same as those of the 4 oil hole.
, The results of these tests were satisfactory. Hence the ECT test 1 performed as well as other tests performed during initial inspection of the engine (see 3.1.1) assure that the crankshaft is
!- fit for service. ,
, o Rod Box Threads - Reference 8 indicated that a sample ECT
! inspection of four connecting rods would be accomplished on engine i 2A. Accordingly, connecting rods 5, 6, 7 and 8 rod box threads 1
l The results of these tests were satisfactory. These ECT
- inspections reinforce the results of the initial inspections (see 1 3.1.9) of the connecting rods which showed them fit for service.
l
[ 2-3 L
o Intake and Exhaust Valve Material - Reference 8 indicated that material comparator tests of intake and exhaust valves would be accomplished on a sample of four cylinder heads on engine 2A.
Sixteen intake and exhaust valves from cylinder heads 6R, 7L, 8L 1 and 8R were material comparitor tested by Stone and Webster.
Results of the tests indicated that all valves were of the same material . These test results along with initial test results on the valves (see Section 5, Part 02-3608) show that the valves are functioning properly.
o Rocker Arm Bolting Material - Reference 8 indicated that four rocker arm capscrews would be removed from engine 2A and subjected to material comparator and hardness tests. Material comparator 1 tests were performed by Stone and Webster and hardness test were performed by DPC on four rocker arm capscrews from engine 2A.
Results of the tests indicated that all capscrews gave a similar response to alloy 4140 and were of the same hardness. These tests along with initial tests performed (see 3.1.8) indicate that the rocker arm capscrews are satisfactory.
o Engine Base Material - Reference 9 specified that an engineering verification should be performed on the base to show that the base is normal class 40 grey cast iron which is free of Widmanstaetten graphite microstructure. Replicas were taken at two locations on the base by DPC and the microstructure evaluated.
The graphite morphology per ASTM A247 of the base indicated that it was typical flake graphite with a uniform and randomly oriented I distribution which is typical of grey cast iron. There was no evidence of Widmanstaetten graphite. Hence, the results of the i above tests are considered satisfactory.
, o Trubocharger End Float - Reference 9 specified that rotor float j measurements be taken on both engine 2A turbochargers. Rotor float i measurements had not been taken on engine 2A during initial inspections as the turbochargers were new. During the subsequent inspections rotor float measurements were accomplished by DPC.
The r sults of these inspections indicated that the rotor float on 1 both turbochargers was well within the turbocharger manufacturer limits of .008" to .016". As the turbochargers had over 140 hours0.00162 days <br />0.0389 hours <br />2.314815e-4 weeks <br />5.327e-5 months <br /> of operation, these rotor float measurements are considered satisfactory.
2.6 Conclusions The results of the revalidation inspections of diesel 2A have shown the engine to be in excellent working order. Lessons learned from the extended operation tests of both the Catawba diesels 1A and 18 have been incorporated into the 2A diesel such that it will be capable of producing reliable standby electric power.
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3.0 Discussion of Inspection Results This discussion of inspection results is contained in three parts. The first part (Section 3.1) covers inspections related to the generic problems being addressed by the TDI Owners Group. The second part (Section 3.2) covers inspections performed to address concerns raised by specific problems which have been experienced with Catawba diesels.
.The third part (Section 3.3) covers significant inspection results not covered by the first two parts. All of these inspections are documented in the Appendix, Section 5.0.
3.1 Inspection Related to TOI 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 (PartNo.02-310A) PROBLEM: A crankshaft failure occurred at Shoreham. The cause of the failure was high cycle fatigue cracks initiating from fillets in the crankshaft at the junction of a crankpin and web (reference 5). Similar cracks were found to exist on other crank-web fillets in all three diesels at Shoreham. The Catawba crankshaft design differs from that originally
- used at Shoreham. The Catawba crankshaft has substantially lower stresses, which meet industry standards and are not expected to cause problems (references 6 and 7). Due to '
satisfactory inspection of the Catawba Diesel 1A (reference 3), only visual inspections of crankpin web fillets on Catawba Diesel 2A were performed. At San Onofre, a TDI diesel engine experienced cracks in main bearing journal oil holes. The V-16 Catawba diesel crankshafts are also different than the San Onofre V-20 crankshafts. However, as this failure was nuclear service related, inspections of the highest load main bearing journal oil holes on 2A were performed. I SCOPE OF INSPECTIONS: The crankshaft inspections consisted of: P o Web deflectior, vaasurements. I i o Visual inspections of the crankpin journals on all eight , crankpins. ' 1 i 1-3-1
o Material records of the crankshaft were checked. 1 o Fluorescent dye penetrant inspection of oil holes in main bearing journals #4, #6, and #8. 1 o ECT inspection of oil holes in main bearing journals, 6, 7, and 8 were accomplished to FaAA procedure NDE 11.3, I Rev. 2. RESULTS OF INSPECTIONS: The results of all inspections were satisfactory.
SUMMARY
In summary, the inspections of the crankshaft indicate that 1 it is free of significant defects and made of the correct material . 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 performed 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 PT examination of all bearing shells. 1 o X-ray examination of all bearing shells. o Thickness measurements of all shells. 1 RESULTS OF INSPECTIONS: Visual inspections of the bearing shells indicated minor scratches on the back side. No cracks were detected by liquid penetrant inspection. All bearing shells passed the 1 X-ray inspection. Thickness measurements were in accordance with TDI specifications. 3-2
d
SUMMARY
Penetrant inspection results, X-ray inspection results and dimension results indicate that connecting rod bearing shells are acceptable for operation. The minor scratches on i the back side of the bearings were smoothed out. All bearing shells were installed in the engine. 3.1.3 , Pistons (PartNo.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 2A the replacement type AE skirts were inspected. SCOPE.0F INSPECTIONS The inspection performed on all the replacement type AE pistons skirts for diesel 2A 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, belleville seat surface and the 0.0. 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 TOI nuclear diesel engine (reference 11). This grooving was attributed 3-3 >
I to debris that entered the diesel during assembly or initial startup. SCOPE OF INSPECTIONS: All of the cylinder liners were 100% visually inspected to check for the presence of grooves or other damage. RESULTS OF INSPECTIONS: No significant grooves approaching the 1/16" deep grooves seen in the Grand Gulf diesel were observed in the Catawba cylinder liners. Minor scratching was observed which is normal. These scratches are considered to have no effect on diesel operability.
SUMMARY
The inspections indicate that the cylinder liners are in satisfactory condition. Honing to break up the glaze in order to allow new piston rings to seat has eliminated the scratches observed in the liners. 3.1.5 Cylinder Block (PartNo.02-315A) 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 blocks indicated normal grey cast iron, Class 40. 3-4
- -g . - . - ,-- -
SUMMARY
Cylinder block cracks were not. detected on diesel engine 2A. Replica tests of the microstructure were within normal limits. 3.1.6 Engina Base (Part No. 02-305A) PROBLEM: Linear indications have been reported as emanating from main bearing stud holes in the engine base. These problems have been attributed to inadequate bearing cap stud preload
, (references 11 and 12).
SCOPE OF INSPECTIONS: The main bearing saddle area around and between the stud holes was PT examined for bearings 4, 5, 6, and 8 on diesel 1A. In addition.,the stud tension required to permit removal of the nuts was measured on diesel IA. 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 of diesel 2A. In addition to the normal quality revalidation inspections,
~
the NRC. in Reference 9 specified that an tengineering 1 evaluation of the base should be done to determine if there was any-Widmenstaetten graphite. RESULTS OF INSPECTIONS: s Results :f ' visual inspections showed no cracking around stud holes or signs of upset metal. Replicas of~the base 1 indicated that it was typical of grey cast iron with no signs of Widmanstaetten graphite.) , SL19tARY: No cracking around stud holes on diesel 2A was found. I Replicas of the base indicated normal material. r 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 i of the Catawba diesels. 3-5
-'-k'B d +4 W -~7- 1 E- T 4' -t -mtr- -wi ---'T-'1 -W'-+-+-t 4*---W-z-3+-- F
- NV N"-vvsu
~ 4 SCOPE OF INSPECTIONS: o Studs from four cylinders (3, 4, 5, and 6L) were removed and visually inspected. RESULTS OF INSPECTIONS: All cylinder head studs inspected satisfactorily passed the visual examinations.
SUMMARY
A sampling inspection of cylinder head studs indicates that they are acceptable. 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:
. o Visual inspection was performed on all capscrews.
o MT inspection was performed on all capscrews, o Four capscrews were removed for hardness and material 1 comparator analysis. RESULTS OF INSPECTIONS: No indications were noted in the visual or MT examination. Material tests indicated that capscrews were quivalent to I alloy 4140 and of the same hardness.
SUMMARY
The diesel engine 2A capscrews were found to be satisfactory. 3.1.9 Connecting Rods (PartNo.02-340A) PROBLEM: Cracking of connecting rods is reported to have occurred, apparently due to relative motion between the two halves of the connecting rod at the " rack-teeth" joint (reference 11). 3-6
SCOPE OF INSPECTIONS: The inspections of the connecting rods included the following: f a 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, o Connecting rod rack-teeth (serrations) degree of contact with mating part was measured by bluing the part on all connecting rods. o ECT of rod box threads per FaAA procedure NDE 11.9, Rev. I 1 on connecting rods 5, 6, 7 and 8. o Dimensional inspection of link rod to pin with link rod bolts torque to 1050 ft.lbs. was accomplished. RESULTS OF INSPECTION All connecting rods passed the above inspections with the exception that one cotter pin was found missing on disassembly. A search of the engine internals was i accomplished to look for the cotter pin which could not be found. It was therefore concluded that the cotter pin was not installed at the factory. Degree of contact along the rack-teeth (serrations) varied between 80 and 95% which is considered acceptable.
SUMMARY
The diesel 2A connecting rods were found to be acceptable. After reassembly in the engine, connecting rod capscrews were ultrasonically examined to assure that preloads were adequate. 3.1.10 Electrical Cables (Part No. 02-6888) PROBLEM: A number of electrical cables used by TDI have been identified as either failing insulation flame test 3-7
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. 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 multiconductor 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
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. Henca, 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 (Part No. 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). l 3-8
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. 3 RESULTS OF INSPECTIONS: Three lines had-recordable indications and were rejected.
SUMMARY
The lines that were rejected have been replaced with spare lines that have passed the ECT tests. 3.1.12 Jacket Water Pumps (PartNo.02-425A) PROBLEM: Several jacket water pump shaft failures occurred at Shoreham (reference 17). The Catawba jacket water pumps are of a different design than the Shoreham pumps. However, even though the problems experienced at 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, inspections of the 2A pump were abbreviated. SCOPE OF INSPECTIONS: o Visually inspect gear carrier o Visually inspect gear, 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 RESULTS OF INSPECTIONS: All inspections were satisfactory. Torque on impeller nut was 80 ft.lbs. and torque on spline nut was 140 ft.lbs.
SUMMARY
The 2A jacket water pump met all inspection requirements and was returned to service. 1 3-9
3.1.13 Air Start Valve Capscrews (Part No. 02-359) PROBLEM: Capscrew bottoming out due to insufficient hole depth for the capscrew length can lead.to insufficient clamping force (reference 21). TDI recommended reducing capscrew length to prevent this problem. All Catawba diesel capscrews have been modified. SCOPE OF INSPECTION: The inspections for the capscrews included the following: o Measure breakaway torque o Measure length of capscrews for 4 valves as a check on the modification 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. One capscrew had a breakaway torque of 20 ft.lbs. All others were satisfactory. The torque on these capscrews would have been checked prior to engine operation. Hence the factory torque would have been corrected.
SUMMARY
There appeared to be no problems with airstart valve capscrew bottoming out in the Catawba 2A diesel. 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 welded 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. 3-10
o PT. examination of all the welds RESULTS OF INSPECTIONS: All the push rods were confirmed as having the correct type of weld and were found to be free of defects.
SUMMARY
The Catawba diesel engine push rods are considered to be satisfactory since the friction welded design has operated
.over 900 hours with no sign of cracking on the Unit I diesels.
3.1.15 Turbocharger Bearings (Part No. MP-022/23; 02-CFR) PROBLEM: Severe wear of the bearings has been reported, apparently due to inadequate lubrication during diesel starts (references 2, 3 and 11). An improved lube oil supply system was incorporated on Catawba diesels to furnish more lube oil flow to the turbochargers during startup. SCOPE OF INSPECTION: As the turbochargers on diesel 2A were new without any
. starts at Catawba on them, the only work accomplished during 1 initial quality revalidation inspections was:
o Verification of correct number of bolts in place on inlet I casing o Replacement of exhaust gas inlet bolts (see 3.2.9) 1 During.the subsequent inspection of the turbochargers work accomplished was as follows: o Review PT inspection results done by turbocharger 1 manufacturer of stationary nozzle ring o Measure rotor end float. RESULTS OF INSPECTIONS: All inspections were satisfactory. Both turbocharger end floats were well within manufacturers specifications. I
SUMMARY
The new lube oil system which was incorporated will assure that the bearings get adequate lubrication during normal 3-11
o startups which will significantly reduce wear on the turbochargers. Results of end float inspections after over 140 hours of operation support that the bearings are I
< receiving adquate lubrication.
3.1.16 Cylinder Heads (Part No. 02-360A) PROBLEM: Three small jacket water leaks have been experienced on Catawba diesel IB (reference 2) resulting in water leaking into the fuel injector nozzle cavity. One leak of similar origin was seen on diesel 1A (reference 3). Failure analysis of one of the leaking heads has been completed (reference 4). The leak was due to cracks propagating from a corner where a welded plug was installed in the fuel injector nozzle seating area. This welded plug was used to repair the injector bore during manufacture. (Figure 2-3, reference 3 and Figure. 2-1A, this report). SCOPE OF INSPECTION The inspections performed of the cylinder head included: o Visual examination of valve seats. 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 welded in plug. o Visual inspection of heads to determine if they have a welded in plug. RESULTS OF INSPECTIONS:
- All cylinder heads successfully passed all examinations
- except for the inspections related to whether the head had a partial penetration welded in plug. It was determined that five cylinder heads had partial penetration weld plugs. These heads were rejected and replaced. E
SUMMARY
To guard against external jacket water leakage after the engine has been operated, five cylinder heads on engine 2A were replaced with heads that did not have partial penetration welds. 3-12
r-3.2 Catawba Specific Problems 3.2.1 Fuel Injection Pump Nozzle Valve Holder (Part No. 02-365A) PROBLEM: A fuel injection pump nozzle valve holder on Catawba diesel 1A cracked as a result of a material defect (reference 3). SCOPE OF INSPECTIONS: Visual inspection of the 2A valve holder bores using a boroscope was accomplished to determine if there were linear defects. RESULTS OF INSPECTIONS: All valve holders with the exception of one had no linear defects. The one valve holder with linear indications was reamed, which removed the indications. ENGINEERING EVALUATION: A failure analysis was performed on the 1A fuel injection pump nozzle valve holder (reference 20). The results of this analysis indicate that an axially oriented linear
' indication in the high pressure fuel oil passage of the failed part led to the reported failure. Further analysis indicates that axial linear indications that would lead to cracking of the valve holder would cause cracking to occur within 10 million cycles of fuel pump operation. As the Catawba Unit i valve holders have withstood 10 million cycles of operation, the valve holder failure experience is considered an isolated material defect.
SUMMARY
It is concluded that the valve holder failure on diesel 1A was due to a material defect. The 2A diesel valve holders
. have'been inspected to uncover such-defects. The one valve holder (on diesel 2A) that had a linear indication was reamed and then found to be free of defects.
3.2.2 Fuel Infection Pump Delivery Valve Assembly (Part No. F-099-lTO) 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. 3-13
SCOPE OF INSPECTIONS: The following inspections were accomolished: o MT examination in valve seat area. RESULTS OF INSPECTIONS: No rejectable linear indications were found during MT examination of the valve assemblies.
SUMMARY
Diesel 2A valve assemblies have been found free of the type defect found in diesel 18. 3.2.3 Turbocharger Prelube Oil Lines (Part No. 02-467A) PROBLEM: Two failures of the prelube oil lines occurred during the 1A extended operation test due to fatigue cracking at compression fittings (reference 3). The lines have been replaced using an improved procedure and using additional clamps, vibration dampening devices, improved compression fittings and heavier wall stainless steel tubing on diesels 1A and 1B. As the Unit 1 diesels have passed their extended operation tests with no signs of leakage after the above modifications, no inspections of diesel 2A were accomplished. Diesel 2A and 2B lines have had additional clamps and vibration dampening devices installed to prevent vibration induced damage. SCOPE OF INSPECTIONS: Not applicable. RESULTS OF INSPECTIONS: Not applicable.
SUMMARY
Since the 2A diesel has had additional clamps and vibration dampening devices installed no problems with vibration induced damage are expected. 3.2.4 Turbocharger Adaptor (PartNo.00-495A) PROBLEM: A turbocharger air inlet adaptor cracked at a flange weld on diesel IB (reference 2). A similar problem occurred on 3-14
r diesel 1A (reference 3). In addition, the internal air flow divider on diesel IB (flow distributor) had a small crack at the junction to the case of the adaptor (reference 2). This problem was not seen on diesel 1A. An engineering evaluation indicates that the cracks are caused by excessive displacements at a location with limited flexibility. A redesign has been implemented on both Unit 1 diesels that installs a flexible connection between the adaptor and turbocharger to absorb displacements. In addition, on both Unit 1 diesels, strong backs have been welded to the case to eliminate the flexing which caused the air flow divider weld failure. This redesign will assure that in the future the adaptor will not crack. In accomplishing this, the left adaptor from diesel 2A was used on diesel 1A and the diesel 2A right adaptor was used in diesel 18.
. Duke Power Company manufactured two new adaptors for diesel 2A with strong backs included. In the process of manufacture all welds were MT examined. The two new adaptors with flexible connections were installed on diesel 2A. Hence additional inspections on diesel 2A were not accomplished.
SCOPE OF INSPECTIONS: Not applicable. RESULTS OF INSPECTIONS: Not applicable.
SUMMARY
With the new adapters and flexible connections installed on diesel 2A, it is concluded that problems initially seen on the Unit 1 diesels will not occur on diesel 2A. 3.2.5 Intercooler Jacket Flange (Part No. F-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. l 3-15 L
m y-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 (Part No. 02-386B) PROBLEM: Occasional failures of these capscrews has occurred due to fatigue (reference 20) because of over or under torque. SCOPE OF INSPECTIONS: All of these capscrews are beina replaced with capscrews with improved fatigue strength.and of known chemical and physical properties. Accordingly, inspection is not applicable.
SUMMARY
This problem has been resolved by replacement of the capscrews using capscrews of appropriate quality and by revising installation procedures to control torques to 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 1B (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 2-2B, reference 3). The cause of the problem is believed due to installation tolerances between bushings and the pedestal leading to excessive interference fits. 3-16
c a SCOPE OF INSPECTION: o Visual inspection of subcovers o The bosses on all of subcover assemblies were PT examined. RESULTS OF INSPECTIONS: All inspections were satisfactory. 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 performed by FaAA under TDI Owners Group direction. This indicates that the cracks were due to installation or manufacturing errors and not due to service. Thus, replacement of the defective subcover castings resolves the problem.. On diesel 2A no such cracks were found and thus these subcovers are considered acceptable. 3.2.8 Turbocharger Lube Oil ' Drain Line (Part No. 02-467A) PROBLEM: A temporary drain line on diesel 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 1B 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: I One 1/2 inch stainless manifold to turbocharger adapter bolt was found broken during disassembly of diesel 1B (reference 2). This is similar to diesel 1A (reference 3) where four l l 3-17
were found broken. The cause of the failure indicates that the bolts failed from creep rupture (reference 20). SCOPE OF INSPECTION: Not applicable. RESULTS OF INSPECTION: Not applicable.
SUMMARY
On diesel 2A these bolts have been replaced with creep resistant SA 453, Grade 660, Condition A material. In addition, bolt installation procedures have been 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. 3.2.10 Rocker Arm Adjusting Screw Swivel Pad (PartNo. 02-3908) PROBLEM: One of the swivel pads was found cracked during operation on diesel 18. This occurrence was reported in reference 3. Failure analysis (reference 20) indicates that the cracking occurred due to a one time overload. It is believed that the swivel pad cracked due to improper swaging at the factory during manufacture. Another swivel pad was found cracked during reassembly of diesel 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: No defects were found and the sockets were found to be correctly swaged.
SUMMARY
The swivel pads are considered to be in satisfactory condition on diesel 2A. 3-18
r 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 tiie 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. SCOPE OF INSPECTIONS: The inspections of the fuel lines include a walk down inspection to verify that the piping is installed per the applicable design drawing and properly supported to suppress vibration. RESULTS OF INSPECTIONS: The inspection of the fuel lines was satisfactory. SUleARY: During reassembly of the engine fuel lines, fittings were installed to Duke Power Company procedures to prevent improper torque values from being applied. In addition, walkdown inspections of the fuel lines have insured that the. lines are properly attached, such that vibration problems are not expected. 3.3 General Inspection In addition to inspections related to TDI generic problems and to Catawba specific problems, inspections have been performed of numerous other parts in order to verify the operability of the Catawba 2A diesel engine. The results'of these inspections showed that the 2A diesel enine was in excellent condition, with only one additional problem in addition to the problems discussed in sections 3.1 and 3.2 above. The only additional problem noted was that several fuel injector nozzle studs had linear indications. This problem is discussed below. 3.3.1 Fuel Injector Nozzle Studs (Part No. 02-360A) PROBLEM: MT inspection revealed that four fuel injector nozzle studs had' linear indications. 3-19
m SCOPE OF INSPECTIONS: All studs were visually and MT inspected. RESULTS OF INSPECTIONS: All studs passed visual examination. As mentioned above, 4 of the 32 studs MT examined had linear indications and were rejected.
SUMMARY
All rejected studs were replaced by spare studs which have passed both visual and MT examination. 3-20
n , k 4.0 References
- 1. Duke Power Co. letter dated October 2,1985 to H. R. Denton, NRC, 1 forw'arding report " Catawba Nuclear Station, Diesel Engine 2A Component-Revalidation Inspection", dated September 25, 1985. ;
1
- 2. Duke Power Co. letter dated October 16, 1984 to H. R. Denton, NRC, l enclosing " Catawba Nuclear Station, Diesel Engine IB Component
-Revalidation Inspection."
- 3. Duke Power Co. letter dated June 29, 1984 to H. R. Denton, NRC, enclosing " Catawba Nuclear Station, Diesel Engine 1A Component Revalidation Inspection."
l
- 4. Failure Analysis Associates, " Metallurgical Analysis of Catawba Injection Port Leak", June 1984.
- 5. IE Information Notice No. 83-58, "Transamerica Delaval Diesel Generator Crankshaft Failure", NRC, August 30, 1983.
- 6. Bechtel Power Corporation, " Evaluation of 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 .' Duke Power Co. letter dated January.13,1986 to H.R. Denton regarding 1 quality revalidation insp'ections of Catawba Unit 2 diesels.
- 9. NRC letter dated February 24, 1986 regarding " Issuance of Facility 1 Operating License No. NPF-48-Catawba Nuclear Station, Unit 2."
- 10. (Deleted)
- 11. Mississippi Power & Light Co., " Comprehensive report on Standby Diesel Generators-Significant Activities to Enhance and Verify Reliability",
February 1984 transmittal to NRC by letter dated February 20, 1984. .
- 12. Failure Analysis Associates,." Design Review of Engine Base and Bearing Caps for Transamerica Delaval Diesel Engine", April 1984.
- 13. Stone and Webster Engineering Corporation, " Emergency Diesel Generator Cylinder Head Stud Stress Analysis", March 1984.
- 14. Stone and Webster Engineering Corporation, " Supplement to Emergency Diesel Generator Auxiliary Module Control Wiring and Termination Qualification Review". June 1984.
! 15. Duke Power Co. letter from G. T. Lamb to K. S. Canady, " Catawba Nuclear Station IE .Information Notice 80-08 States Sliding Link Terminal Block", File CN1412.11-1; EGS N-14.01, May 7, 1980. 4-1
- 16. Stone and Webster Engineering Corporation, " Emergency Diesel Generator, Fuel Oil Injection Tubing, Qualification Analysis", April 1984.
- 17. Stone and Webster Engineering Corporation, " Emergency Diesel Generator, Engine Driven Jacket Water Pump, Design Review", April 1984.
- 18. (Deleted)
- 19. Stone and Webster Engineering Corporation, " Emergency Diesel Generator, Auxiliary Module Control Wiring and Termination, Qualification Review", April 1984.
- 20. Duke Power Co., " Failure Analysis Report Catawba Nuclear Diesels 1A and 18", 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.
4-2
i
-p.
5.0 Appendix I ) I i 5-1
r Gatabbe Qi21RL 26 101EREti20 8EE9th Eatt daggi Jacket Water. Standpipe Fittings and Gaskets
'ERCA UM@httiOO-700A Gla211B W9th 8R99E11 09s 8tttikuten Mutified
- 1. _ Visually' inspect system per 11.2, ref. 1 Beisteesta
- 1. MP/0/A/1000/53 Diesel Engine Jacket. Water System, Piping, Standpipe and Manifold Special Inspection Ins 9esti90: BasMits
- 1. Visual inspections of the jacket. water standpipe fittings and gaskets were satisfactory., 1 QiH992iti90 91 lEEERGli90 ElOdlG91
-There were no significant findings. .
I GataWha Qie2El 26 lOMEEEh!90 8229CA E3tt Name!. Jacket Water Standpipe Supports Ecct Uueksti 00-700C cican;_s NGCh 8RGU221 U9t etttitutna V9tified
- 1. Visually inspect supports per 11.2, ref. 1.
Vist9C90GGn
- 1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Stanapipe and Manifolo Speciai Inspection
.!OHE951190 BTEMlta !. Visual inspections of the jacket water standpipe supports showed minor discrepancies with the as-designed drawincs.(1, DinR9MiliGO Qi lOEE2Gli90 EindiO95
- 1. -The discrepancies were corrected. (1) s
7_ . Catggua Di2221 28 105GSit190 SMEOCt Egtt Ugmgi dacket L4ator Standpipe Bolting Materials Batt dymbgti 00-700F Clf2318 Wech Bs9995t Unz ettticuten Vatified
- 1. Visually inspect bolting per 11.2, ref.1.
ESittCSOC23
- 1. MF/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 10222ChiGO 685M153
- t. Visual inspections of the jacket water standpi pe boi r.i ng i materials showed one minor discrepanc.y with the as-dasigned drawings.
RiSG9sitiOO Oi 10SEeGli90 EiOdiO95
- 1. The discrepancy was corrected.
f
,e gatgeba oigngt ge Ingggstige Beggtt Pgtt Namgi Main Dearing Basas Eatt Numbutio2-305A GLaagtA UstS Senusat 09z1585MNT 6titibutem Vetitind
- 1. Visually inspect mating surfaces per 11.5.5, ref. 1 (Bearings 4,6,0)
- 2. Engineering evaluation of base meterial (t$
69f2t90G99
- 1. MP/0/A/1000/52 Diesel Engine Main Bearing Disassembly for Spe:ial Inspection 10MGSGli90 8259133
- 1. Visual inspections of the main bearing baccc w.are satisfactory. ,
- 2. Replicas taken on the base .natorial indicated no signs at Widmenstatten graphite. (1) dis 292iki 90 91 lO3R9 Chi GG EiQdiOG2 There were no significant findings
p-i, _ CatAWha R12221 28 10222Gli90 6229C1
~
Eatt'Namg1 Main Bearing Studs 82Ct Numbgt102-305C Gla22iA Ugtk 83g9331 Ugzi385MNT etttikutta Yetified
- 1. Verify stud elongation on reassembly per 11.7.10, ref. 1 (Bearings 4,6,8)
BRitCROGRE
- 1. MP/0/A/1000/52 Diesel Engine Main Bearing Disassembly for Special Inspection 10suesti90 Bezulta
.1. Stud elongations were satisfactory Rimanaitien 91 lesenEtien Eindings There were no significant findings
4 CBlanka D12191 26 In2EREti9e 8229Ct E3Ct dagg1 Main Bearing Caps r ESCt UMEk2C102-305D Cl2221A W9th EEEM211 Ngt1585MNT 6thCikutRE MRCiiltd
- 1. Visually inspect mating surfaces per 11.5.3, ref. 1 (Bearings 4,6,8)
Esistneses
- 1. MP/0/A/1000/52 Diesel Engine Main Bearing Disassembly for Special Inspection inmasst190 Besults
- 1. Visual inspections of the main bearing cap mating surfaces were satisfactory. .
Dineeniti90 91 lemanstinn Eindinem There were no significant findings
c-G3$3bbs 919221 26 IOSESGhiGO 82GGth Catt U3cg1L ube Oil Internal Headers Each duchat102-307A GicSSIA dGCh EEGyggt Ug 175GMNT ettc129te2 Vatified
- 1. Visually inspect headers per 11.3, ref. 1.
G210COGCO2
- 1. Pl?/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection 1020S5$iC0 BC191h2
- 1. Visual inspections of the lubo oil intcenal headers showerl itinne discrepancios with the as-designed drawings.
Qi2R92itiGO 9f IOSEMGliGO EiOdiO92
- 1. The discrepancies were corrected 1
1
'f e
'?
C2hddD3 919531 33 IO5G2GliGO 6EGGCI t.'. ., r 'a . ---- i t.mn.:. Lube Gi l TubintJ and Fittings rart M
-- - -.a .m.h .e r.: 0 2 - 3 0 7 B C__.T a..n..s..:. A 00th ?.?.5n221 U92175GMNT Ct$CiblI2d MeCi.f,.i.9d 1, '/i sually incpect internal lube oil system piping, tubing and
' t.ings per 11.3, ref. 1 ,
- 1. . ; t, Ti l y inspect external lube oil system pi pi nr;, tuning and
*':. .ngc p r 11.4.1 ref. 1 ,
Re F ec em:oi.
., ', 'M 100 * / 43 Diesel Engino Lube Oil System Piping and Sump Opecial :nspection
-r.aa
, w:i - - ,
p y,: t t t.t. i#:2 o ,1 in-spacti ons of the lubo cil tubing arvi + i ttings
- ~ .e d m i n.t r rii'icrepancied with the as-de:ignea drawings.
r
- k. E3. C .. . . .. ,. A. . J.. It . ' .I L h .e(s-~ 1On . b . n OY)
2 : ~- ii ac rupanci .r3 were corretted. . l 6
r-t F .w. n ..,. C_ _.a _Q_i_ _n _:s e_2_.S. _?
. _T_.r.a_ c _7c__t _i.o.n ' __
G e_oc u r_ _t
'_; r_.: ! .w: a G !. 7 Line GuPrcrts r P_ _r .F .
p.L __ga . . e . ,,, , e.) .. t >
* , *.;"< g
-+ _ . . . ~ .
. './.l 23 3.d .:. '"
N.
. .. ~ . . . . .. ' ? ?. ._ .!_N O.,_ u .i- rve.
.-- - In. i.
.A...f.. .l. F. . .i. ' .. . .. 5 :~, 1/-h* i .'* O'}
- 1. "
711y inspect supporta pet- 11.3, ref. 1 F: _6_> r_. _* '. ._. ._ _:
.. '."cS/1000/C Diocel Engine Lubo Oil Gyctem Piping and Gump Spacial Inspection
_,a L e ., . _'._ _'. _. _ P .:.:.. _ - ., if , . . .
.ncpacticas of the ' ube oil line supports 2ncwed .
- d i r a- -:.n c i ec wi th the as-deali,;nad drawings.
- v. . ... u. ._n o. '
_. : _ n_. o_ _' .i. n. .yma.c .s t._i
. o_n_. F .i.n_ _d._i n..,s__
' i s .c a,,ancias were determined to have no e'fect on
* ;; 0 certarmance. The lube oil Gy2 tem was roassembled, and e uni w J .a 50 satisfactory.
F'
~
.- i s
gatauba Drgggi ge Iggagstigo 3gggtg Egtt Uasg1C rankshaft E3Ct UM0bSC102-310A Cl2331A Wgth Sgggggt Ugzi585MNT.lR795MNT - t. 6ttCiqutgs Vgt(figd
- 1. Measure web deflection per 11.3.1, ref. 1 (all webs)
- 2. Visually inspect trankpins per 11.4.1, ref. 1 (All)
- 3. PT inspect' oil holes in crankshaft per 11.6.1, ref. 1 (Journals 4,6,0)
- 4. ECT inspect oil holes in crankshaft per 11.6.2, ref. 1 (Journal s 6',7,8) <
(1)
- 5. Visually-inspect crankshaft gear per 11.2.2, ref. 2
- 6. Engineering review of crankshaft material (1)
GGi2C2GG2E
- 1. MP/0/A/1000/39 Diesel Engine Crankshaft and Turnino Gear, Gear, Crankshaft Bearings, Crankcase Assembly, and Cr,ankcase Covers Speci al Inspection
- 2. MP/0/A/1000/40 Diesel Engine Idler Gears and Pump Drive Gears Inspections and Adjustments 10sG2st190 Eesults
- 1. Cold and hot web deflections were satis 4actory.
- 2. Visual inspections of the crankpins were satisfactory
- 3. PT inspection of the oil holes were satisfactorv
- 4. ECT inspections of the oil holes were satisfactory. (1)
- 5. Visual inspections of thd crankshaft gear were satisfactorv
- 6. Crankshaft material was satisfactory based on engineering review. (1; Ei39921$1GO of 105G99$i00 EiCdigga There were no significant findings
Catawba Qiggg1 28 10sE2E1190 BRE9Ct Egtt NgmgtM ain Bearing Shells EaCl Numk2ClO2-310B Ciad31A W9CE 822u221 69s1585MNT 8tttikut=1.Yetifimd
- 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 4,6,8) 82iRCEGEEE
- 1. MP/0/A/1000/52 Diesel Engine Main Bearing Disassembly for Special Inspection Inseestima Beautta
- 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.
Disassitisc 91 lesenstien Eindiana
- 1. Scratches on the main bearings were determined to be normal and the bearings were evaluated as satisfactory for reuse.
Cetguhg Digsgl 23 Ingqqqtign Bength Pact date4C rankshaft Thrust Bearing Ring Entt UgmbgtLO2-310C ClagstA r]gth, Beggest Ngzi585MNT, 2795MNT (1) AhttikM122 MeCliL2d
- 1. Measure thrust clearance per 11.3.1, ref. 1.
89f9C20592
- 1. MP/0/A/1000/39 Diesel Engine Crankshaft and Turnina Gear, Gear, Crankshaft Bearings, Crankcase Assembly, and Crankcase Covers Special Inspection IO292Gli90 BeaMita
- 1. Measurements of thrust clearance performed in the cold ane hot conditions were satisfactory.
Q12129E1$i00 9i 101ERGhiGE EiOdiO92 There were no significant findings. l
7
.v-Q3ggwbg D,iggel 26 IOERRCt_i_9G Be29Ct Entt UqmgtC rankcase Assembly Pgtt Numbet102-311A C1agg; A
_Wgtk 8equgSt Ugt1585MNT, 2796dNT SittikMARE M2CifiRd
- 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.
8EfGCMGGt3
- 1. -MP/0/A/1000/39 Diesel Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase Assembly, and Crankcase covers Special Inspection 102E2GE190 825Mit3
- 1. Visual inspections of the cast surf aces wera satisf acterv
- 2. Visual inspections of crankcase arch wall were satisfactory. (1)
- 3. The material was verified as being A-48 Gray Cast Iran DiER91ltiGQ 21 LQ2EMGil90 ELCdingg fhere were no significant findings.
s
c-Cetgwbg D i gggi 20 IOggggtige Bgggtt Egtt dgmg4C ylinder Block Catt dM0b2C102-315A Cls321A WOCh 820MESL M9t1583MNT OthCihM19s MRCifits
- 1. PT inspect cylinder block top per 11.2.1, ref. 1 (All blocks)
- 2. Measure liner landing area per 11.6.1, ref. 1 ( Cyls 4,5-R/L)
- 3. PT inspect liner le.nding area per 11.6.2, ref . -1 (Cyls 4,5-R/L)
- 4. Replica inspect cylinder block per-11.7, ref. 1 (R/L.Eanks) 32fSC20E22
- 1. MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifolo and Piping Special Inspection 102D25t190 8999113
- 1. PT inspections of the cylinder block top were saticfactory.
- 2. Dimensions of the cylinder liner landing area were taken for information only - no acceptance standards were given.
- 3. PT inspections of the liner landing area were satisfactory.
- 4. Replicas of the cylinder block demonstrated typical A-49 gray cast iron. (1) 912G92LiiOO Gi 10529Gt190 EiOdiO92 There were no significant findings
F Gatabbe Digggi 26 103g3g1190 Bgggtt Pact Namgi Cylinder Liner Catt Nymbgt102-315C Cla2SiA WQCh 829MRH1 U9s 1583MNT 6tttikMtRE MEElilRd
- 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)
- 4. Perform supplemental visual inspection of cylinder liners per 11.6.3, ref. 1 (4,5 R/L)
- 5. _ Perform supplemental dimensional inspections of cylinder liners per 11.6.4, ref. 1 (4,5 R/L) 82fdCSnGSM
- 1. MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and-Piping Special Inspection .
10aGEGti90 82291h3
- 1. Visual inspection of the cylinder liners were satisfactory.
-2. Cylinder liner bores ranged from 16.995 to 17.0025 inches.
- 3. Cylinder liner protrusions ranged from .004 to .008 inches.
These measurements were taken with the liners uncompressed.
- 4. Results of the supplemental visual inspections of the cylinder liner were satisfactory
- 5. Cylinder liner and cylinder block dimensions showed a proudness of .000 to .0055 inches. 1 Disnemitten et Innenstien Eindiana
- 2. Cylinder liner bores were reviewed with personnel at TDI and were found to be satisfactory and acceptable for continued service.-
- 5. There were no acceptance standards for these measurements, the data is for information only s
o GAtAWha~DiRERl 26 in1EREti90 BRE9Ct Egth NemgiCylinder Block Jacket Water Manifold t.
.BAtt NMmhtC102-315D CLARELA-W9 th Basumat Ugs1583MNT 611CikMitt MRCiiitd
- 1. Visually-inspect the Jacket water manifold per 11.5.1, ref.1 BeimCans=2
- 1. MP/0/A/1000/44 Diesel-Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection lesenstige Benulta
- 1. Visual inspections of the Jacket water manifold were satisfactory.
Disnemitten 91 innanstisc Eindinna There were no significant findings
Calgwbg Qigggi 26 IOggggtige Bgggtt Eatt Naeg1 Cylinder Head Studs Egtt Nymbgt102-315E Ciassie Wgth Reguest Ngt1583MNT, 1784MNT 8tttihuten Vhti. find
- 1. Measure breakaway torque per 11.2.14, ref. 1. (3,4,5,6 L)
- 2. Verify proper installation per 11.6.3, ref. 1. (3.4,5,6 L)
- 3. Check free length per 11.6.4, ref. 1. (3,4,5,6 L) (1)
- 4. Visually inspect cylinder head studs per 11.4.2, ref. 2.
(3,4,5,6 L)
- 5. Vi sually inspect f or ID marks per 11.4.1, ref 2. (4,5 R/L) 82fSCHOE22 1 MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, Disassembly. Inspection and Reassembly
- 2. MP/0/A/1000/44 Diesel Engine Cylinder Block. Cylinder Linor and Jacket Watec Manifold and Piping Special Inspection 105G25$i90 89291$2
- 1. Breakaway torques were found to be 860 to 1340 ft-lbs.
- 2. Studs were installed by inserting, backing out 1 turr. and verifying free length of 14-7/8-inches.
- 3. The free length of the studs was verified as satisfactory (14-7/8 inches +1/4,-0) (O
- 4. Visual inspections of the cylinder head studs showed minor scratches and nicks.
- 5. Visual inspections showed appropriate ID marks.
9139921$i90 91 10292Gt190 EiOdiO93
- 4. The scratches on visual inspection were determined to be normal and the result of stud removal. The studs wern evaluated as satisfactory for reuse
r-Casadha 912221 26 102E2stiOO B299Ct P3ct N3mg1 Cylinder. Head Nuts B3CL Nyehgc102-315F GLasnLB W9th Egggggt Ngt1784MNT, 1583MNT 8tttinutm2 Vetified
- 1. Measure breakaway torque per 11.2.15, 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 j
~(25% sample)
- 4. Reassemble per TDI specifications per 11.6.10, ref. 1-(All)
B2f2CSOSES
- 1. .MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, Disassembly, Inspection and Reassembly
- 2. MP/0/A/1000/44 Diesel Engine Cylinder Block, Cylinder Liner and Jacket Water Manifold and Piping Special Inspection -
losamstian Besults
- 1. Breakaway torques of the cylinder head nuts were 2600 to 3510 ft-lbs. 1
- 2. Visual inspections of ID numbers was satisfactory.
- 3. Visual inspections of the nuts for forging laps were satisfactory.
- 4. The nuts were installed and torqued to TDI specifications.
Disn921tigo 91 losamstigo Eindings There were no significant findings. 1
.w.
CataWha Digggl 26 Iggggettgg Egggtt Enti NematC ylinder Head Gaskets Egtt Nymkgt102-315G (02-360C.' GlaSalB W9th.BEGM221 U9s1784MNT 6ttCikMARE MECliits
- 1. 4 Visually inspect cover gaskets per 11.2.2, ref. 1 (All)
-2. Verify correct gasket installation per 11.6.5, ref. 1 (All) 8mintmOsam
- 1. MP/0/A/1000/35 Diesel Engine Cylinder-Head Removal, Disassembly, Inspection and Reassembly 102ERGli90 8E2M111
- 1. Visual insections of the cylinder head gaskets were satisfactory. ,
- 2. Gaskets and seals were verified as properly installed.
Q12E9211190 91 102E9Eti90 EiOdiO22 There were no significant findings.
Catadha 912221 E-6 IO3925ti90 E299Ct EdC1 U202i J acket Water Manifold Assembly E2C1 U20h2C100-316A CidSSIB WOCE B299331 U2s Ottributsa MMC 111sd
- 1. Visually inspect assembly per 11.3, ref. 1 d21dCSOGS5
- i. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Mani f old speci al Inspectico 10599S1190 E259133
- 1. Visual inspections of the jacket water manifold assembiv showed minor discrepancies with the as-designed drawings.
Ei2R25iLL90 Gi 10522G$190 EiOdlOQ2
- 1. The discrepancies noted were evaluated as not affecting diosal performance. The Jacket water system was reasuombloc, leak tested and determined to be satisfactory.
r- - c GatEWha QiEEEl 20 lQ1EREli20 EEGOC1 EgttfdgmetJ acket Water Inlet Manifold Coupling
- Eatt'UWOkECLO 2-316B ClaEELB Wech Enouest usu
'8titikutta Yacified
- 1. 1 Visually inspect coupling per 11.3, ref.1.
E2fSC30GES
-1. . MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection loansstico Besults 1.' Visual inspections of the Jacket water manifold couplings were satisfactory.
- Qi2E91itiOO Qi IQ1EREtiGQ EiQdiGGE There were no significant findings.
9 w _ _ _ _ - _______.__.______._.______.m_.___ _ . _ . _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . . _ ._ - _ _ _ _ _ _ _ _ _ . _ _ . . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _
Gatawba Dissal _26 Insnestigo Sensch P3t1 Name: Jacket Water Discharge Manifold EaCt dymhgc102-317A Gleam 1D W9th Besusst daz 8tttibuten Matilled
- 1. Visually inspect jacket water manitold per 11.5.1, ref. 1
- 2. Check Dresser coupling per 11.5.1, ref. 1
- 3. Visually inspect Jacket water manifold per 11.4, ref. 2 8912CBDs2D
- 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 10samsti20 B229112
- 1. Visual inspections of the Jackat water manifold were sati sf actory.
- 2. The Dresser coupling was marked D 21102-2ST66-D
- 3. Visual inspections of-the manifold were satisfactory.
Diansnitten et losunstten Eindtags There were no significant findings.
e: 4 0
'GatAWh2 Q19s21 28 10392st190 8290C1 E2tt Umsg4J acket Water Discharge Manifold Coupling 82Ch'UM@h2C102-3179 Cl31210 W9th Basumat U9z 8tttikuten Msrified 1.' Visually. inspect coupling per 11.4, ref. 1.
82fSCROG92
- 1. MP/0/A/1000/44 Diesel Engine Cylinder Block, Liner and Jacket Water Manifold Special Inspection 10sesst190 Besults
- 1. Visual inspections of the jatket water manifold coupling were satisfactory.
Qtancaltten ef Insnestien Eindienn There were no significant findings. s
( . Gatadhd Di2221 _26 1052SGt190 E2G2C1 E2C1 U2mg Jacket Water Discharge Manifold Gupports EdCh U20hSC10 2-317C G12331D 99th ENGMSat UGA Otttibutss YsC111=d
- 1. Vicually inspect supports per 11.4, ref. 1 EWL2CdDG23
- 1. MP/0/A/1000/37 Diesel Engine Jacket Water System. Piping, Standpipe and Manifold Special Inspection 102005t100 ESJMits
- 1. Vicual inspecticms of the Jacket water manifold supports showed minor discrepancies with the as-designed drawings.
QiaEG3kiLOG Qi lOEGREllGQ ElGdiOGH
- 1. Tha minor discrepancies were determined to have no effect on the performance of the diesel. The jacket water system was reassembled, leak tested and determined to be satisf actory.
r-a
.v.
Catawka Qiantl 28 IOggggtigo Egggtt EAtt UAmg4 Flywheel' Bolting Eatt Numkatio2-3300
- Gla1ELA Wett Besuust det1757MNT 8titikuten Matified
- 1. Verify correct torque is applied to flywheel bolts per 11.1, ref. 1 (All bolts)
- 2. Visually inspect flywheel for loose roll pins per 11.2.1, ref. 1 (All roll pins)
Beintensus
- 1. MP/0/A/1000/48 Diesel Engine Flywheel Bolting Special Inspection 10sesst190 Beaulta
- 1. Correct torque was verified through construction documentation.
- 2. Visual inspections of the roll pins were satisfactory Diansmitino 91 Insaastisc Eindiosa There were no significant findings.
N
GatawhA Qititl 28 1GREBEti20 8EEQC1 Egtt Namg1 F ront Gear Case Bolting
' ESC 1 dumhtC102-335B ClAERLC Weck Besumat Ugt1586MNT 8tttikutta Vatified
- 1. Visually inspect 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)
BR12C20E22
- 1. MP/0/A/1000/41 Diesel Engine Gear Case Gaskets and Bolting Special Inspection losamst190 Ba2Witz
- 1. Visual inspections for evidencq of leakage were satisfactory.
- 2. All capscrews were verified as class 5 or better quality.
Diansmitisc 91 Insenstign Eindluna There were no significant findings. s
r
-w, Gatewus QL952l 26 1022EG1L90 8929C1 P 2Ct Ngmg1 Conn,ecting Rods 82Cl U9GhMC102-340A G1232iA M9th Ffggggst Ng,,1583MN1, 2844MNT (1)
Ot1CihukM1 MRCified
- 1. Measure torque of master rod bolts per 11.2.5, ref. 1 ( A1.1 )
- 2. Check oil passages per 11.2.13, ref. 1 (411)
- 3. Measure torque at link red bolts per 11.17.1, ref. 1 (All) 4 Measure link rod clearance per 11.18.6, ref. 1 (All)
- 5. Visually inspect connecting rods per 11.3.2, ref. 2 (All'
- 6. PT inspect rod box sides per 11.3.4, ref. 2 (All)
- 7. Vi sually inspect bolt washers per 11.4.1, ref. 2 (All)
G. MT inspect rod bcits per 11.4.2, ref. 2 (All)
'? . Visually inspect bushings per 11.5.2, ref. 2 (All)
- 10. PT inspect con rod bushings per 11.5.3, ref. 2 (All)
- 11. Dlue check serrations per 11.11.1, ref. 2 (All)
- 12. Measure con rod bushings per 11.3.1, ref. 2 (All L.R -
Sample piston pin bushings)
- 13. Visually inspect link rod dowell per 11.14.1. ref. 2 (Alli 14 Reassemble per TOI specificatic,ns per 11.15.10/11 raf. 1
- 15. ECl inspection et rod box threads por FaAA NDE 1 1. '/ , rav. 1 (5,6,7,8) (1) 69fSCOOG2S
- 1. MP/0/A/1000/36 Diesel Engine Pisten Rod and Liner Removal, Oisassembly, Inspecticn and Reassembly
- 2. PP/0/A/1000/38 Diesel Engine Pi ston , Rod, Bushing and Shell Special Inspection 100GSGt190 Rggylig
- 1. Torques of the master rod bolto ranged from 1270 to IMO it-lbs.
- 2. Inspections of the oil pissaqus were satisfactory
- 3. Torques of the link rod bolts ranged from 750 to 1110 5t-lbs. (1)
- 4. Measurements of link rod clearance were satisfactcry
- 3. Visual inspections of the connacting rods snowed minor scratches.
- 6. PT inspections oJ the rod box sides were satisfactcry
- 7. Inspections of the rod washers and contact surfaces were satisfactory G. HT inspections of the bol ts were satisf actory 9 Visuat inspecttons of the bushtngs showed mi ~
scrotches
- 10. PT inspections of the bushings aere satisfactory
?t. Ai1 serrations showed > 80% contact-sattsfactory
- 12. Dimensions of the con rod bushings were satis actcry
r-Connecting Rods, 02-340A- continued
- 13. Visual inspections of the con rod dowells were sati Mactory
- 14. The connrecting rods were reassembled to appropriate TDI specifications.
- 15. ECT inspection results were satisf actory. (1)
D129021t100 91 leanestige Eiodioss 5,9 The minor scratches that showed on visual inspection were evaluated as normal and it was determined that the par:s are acceptable for continued service. O
7-
,v, CateWkA die 121 26 101E2G1190 8229Ct Egtt NamgiConnecting Rod Bearings Batt UMOkRC10 2-340B Gla21LA W9th BREM22% N9t1583MNT 6ticikutna Matified
- 1. Visually inspect bearing shells per 11.5.2, ref. 1 (All)
- 2. PT inspect bearing shells per 11.5.3, 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)
BEiSC2GERE 1.- MP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shell Special Inspection Innenst19n Besuita
~
- 1. Visual inspections of the bearing shells showed minor scratches.
- 2. PT inspections of the bearing shells showed no defects
- 3. RT inspections of the bearing shells showed no defects
- 4. Shell thicknesses were satisfactory Diangaitiac 91 losasstige Eindings
- 1. The scratches that were discovered on visual inspections were determined to be normal and the bearing shells were evaluated as acceptable f,or reuse.
~
<w.
CA1AMkB Qiff.El 26 In1EREti90 6229Ct EAtt NATELPistons EAtt Nymhet102-341A ClA321A W9th BRQWR1t_Ngu1583MNT 6ttCikus21 MitifiRd
- 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 (A11)
Befstansma
- 1. MP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shell Special Inspection Inmusstigo Besuita .
- 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 241 BHN Dinasait19n 91 10manst190 Eindings
- 4. The hardness data is affected by the surface roughness of the mater'.a1 measured. The hardness data is considered reasonable within the limits of accuracy of the measuring device.
r: Catsuke QiTHEl 26 lO3RREllGQ 89EQCt ESCt da0MiPtston Rings E3C1 U90hBClO2-3418 Cid321A WGCh 8eG025% Ng3.1583MNT Stttihutus Vecitted
- 1. Inspect ring installat e cri per 11.11 ref. 1 (1) 6SfCC90GCA
- 1. MP/0/A/1000/36 Diesel Engine Piston, Rod , _ and Li ner Re.ncval ,
Disassembly, Inspection .and Reassembly IQ3D9Gt190 8229112
- 1. New rings were installed in the engine to TDI specifications. .
QL3293ltl90 91 1GDR2GilGQ EiQdiGG2 There were no signiticant findings. O
r Catawha Diensi 28 lonenstigo Benett BAtt Namg4 P iston Pins E2Ct Nymkgt102-34LC Cl2231A Weck Benuent Ngzi383MNT 8tatikutna Mattilmd
- 1. Visually inspect piston pin assembly per 11.7.2, ref. 1 Check rolled in Oil Plugs and inspect for distress. (All pins)
Baintmanns
- 1. MP/0/A/1000/38 Diesel Engine Piston, Rod, Bushing and Shell Special Inspection 102Q25h19G BR2 ult 2
- 1. Visual inspections of the piston pins showed minor scratches; otherwise, the piston pins were satisfactory.
Dimannition 91 lunanstien Eindienn
- 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.
GattwkB Disani 28 inmaastine Bengtt EAtt NAmt1 Intake Tappets Batt NWSkEC102-345A ClanalA WQCh BRQWRH1 NQt1586MNT 8titikutta Yatified
- 1. Visually inspect intake tappets por 11.6.1, ref. 1 (1L,5L,8L,0R)
Esistungen
- 1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection -
losenstigo Beaulta
- 1. Visual-inspections of the intake tappets were satisfactory.
Disa9mitico of lonenstisc Elodioen There were no significant findings. 9
's k .
GatAnka Rissal 28 Ionenstico Beastt BAtt demf1 Fuel Tappets EAtt NWGkRC1 02-3459 GLAEELA WGCE BR99951 UQs1586MNT k etttitutes Mstified i 1. Visually inspect fuel tappets per 11.6.1, ref. 1.(1,5,8L, OR) fc' Beistensen
- 1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection Innenst190 Benuitz
- 1. Visual inspections of the fuel, tappets were satisfactory.
Disegnition 91 Ioannst190 Eindians There were no significant findings
i Getanha Disnel 26 102Enstigo Benett 82C1 NAmm4 Camshaft ESCt UWEhtC102-350A GlA321A W9Ch 8R2WRH1 dQt1586MNT ettCikuten Yetified
- 1. Visually. inspect camshaft lobes per 11.3, ref. 1 (All)
- 2. Visually inspect camshaft locking clips per 11.4.3, ref. 1 (All) 6212CRQsta
- 1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection
! Innanstien Beaulta
- 1. Visual inspections of the camshaft lobes were satisfactory.
- 2. Visual inspections of the camshaft locking clips were satisfactory.
Dianamition 91 102ntst190 Eindians There were no significant findings. 1 l I l i 1 [
v 7
-\ >
6 n GetAbha 912291 20 lO2ERGti20 8222Ct k Egtt Nggg Camshaft Bushings EgttNyghgc[02-350B Glass 1A ,
.Weth Beaumat Ngs1586MNT ,
sittikuten Yacilind 4 - >
- 1. Visually inspect camshaft outboard support bushings per 11.4.2, ref. 1. (R/L) -
Beintensen
- 1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection i
lamanstion Beaulta
\\'-
- 1. Visual inspections of the camshaft bushings were satisfactory. .
Qiansmitten 91 losanctino Elodican There were no significant findings. 4
Gat 2 Wha Q12191 26 loEEiEtl90 BREQCi Egtt Nggg1 Camshaft Gears EAC1 UM9k2C102-350C Cl2321A W9th B299911 Ugs1586MNT 8titthutan Yectiind
- 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)
Beistungen
- 1. MP/0/A/1000/45 Diesel Engine Camshaft, Camshaft Gear and Tappet Special Inspection lozanntiec Basults
- 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.
Dinnesit190 91 Innanct190 Elodienn There were no significant findings. e_______________________._._.___._ .-___J
Catawha Disumi 20 innenstian Benett Egtt Negg1P ump Drive Gear Eatt UWWhtC102-355A CLASELA WGCE BESWEE1 SQs1586MNT etitikuten Yacified
- 1. Vir.ually inspect pump drive gear per 11.2.4, ref. 1.
- 2. Measure backlash per 11.3, ref. l.
Esistansan
- 1. MP/0/A/1000/40 Diesel Engine. Idler Gears and Pun.p Drive.
Gears Inspections and Adjustments Insaastien Bamults
- 1. Visual inspections of the pump drive gear were satisfactory.
- 2. Backlash measurements were satisfactory.
Dime 9mition of Innenstian Eloginan There were no significant findings.
I GataWha DiRREl 20 101E2E1190 8EE9th Eatt Namg1 I dler Gears Eact NymQgt102-355B G1A151A
'W9th Esauent Ugs1586MNT eticikuten Yttified
- 1. Visually inspect idler gears per 11.2.3, ref. 1.
- 2. Measure backlash of the idler gears per 11.3.4, ref. 1.
SaintacEnn
- 1. MP/0/A/1000/40 Diesel Engine Idler Gears and Pump Drive Gears Inspections and Adjustments lonnsst190 Benulta
- 1. Visual inspections of the idler gears were satisfactory.
- 2. Backlash measurements of the idler gears were within normal limits.
QLEE91iti90 Qi 1GEEEEtiQn Eindican There were no significant findings. s
CSifMh2 Di2S2l 26 105E0Gt100 EEECCt Egtt UnegtAir Start Valves ESCt NumhtCLO2-359 Cld11LA W9th E2gyggt Ugzi784MNT,1584MNT 65ttihutEE MRCliifd
- 1. Measure breakaway torque of capscrews per 11.2.13, ref. 1.
(011)
- 2. Measure capscrew length per 11.3.2, ref. 2.(1,5,8L,8R)
- 3. Visually inspect seat areas of valves per 11.3.3, ref. 2.
(All)
- 4. Visually inspect valve internal surfaces per 11.3.4, ref. 2.
(All) BEftC2GE9a
- 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 Gpecial Inspection 10saast190 Beaults
- 1. B'reakawey torques ranges from 20-160 ft-lbs.
- 2. Capscrew lengths were verified as acceptable.
- 3. ' Visual inspections of the seat areas were satisfactory.
- 4. Visual inspections of the valve internal surfaces were satisfactory.
Disassitiso 91 10nnectigo E10diosa
- 1. Breakaway torques were considered low. These screws were installed by TDI. These screws would have been checked prior to engine operation. All screws were torqued to specified
. values'on' reassembly.
Gatawba Q1222i 26 1012251190 EEE9Ct ESCt UATg4 C ylinder Heads EaCt UMDbEC102-360A G12321A W9Ch Benunut U9_1584MNT GittihMtRE MRCliigg (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.
- 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 no :le cavities per ref. 2.
62ifC20GE2
- 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 IO3E2Ghi90 8R2W112
- 1. Visual inspections of the valve seats showed minor pitting.
- 2. Pi inspections of the valve seats and fire deck were satisfactory.
- 3. UT thickness measurements of the fire deck showed the fire deck to be .48 - 1.4 inches thick.
- 4. Five heads, 6L,7L,8L,2R and 3R, had welded plugs.
- 5. All studs were satisfactory on original heads. New studs were installed on the heads that were replaced.
- 6. Four studs showed linear indications on MT inspections.
- 7. Five heads were rejected (same as 4, above)
D12292it190 si 102Esst190 Elodiosa
- 1. The minor pitting found on visual inspections of the valve seats was determined to be normal and the heads were evaluated to be satisfactory for continued service.
- 3. No unusually thin wall thicknesses were observed and all head wall thicknesses are considered satisfactory.
- 6. The studs that showed linear indications were replaced.
4,7 Five heads were replaced. s
F' Catahba 919321 S6 102225$190 8229CI P2Ct Name1 I ntake and Enhaust Valves 20CI UM952C10 2-360B ClaggiD. Wgr_t Bgggggt Ugt1784MNT, 1584MNT dhttihukO2 Y2tifiCd
- 1. Check valve clearance per 11.5.4.2, ref. 1. (All)
- 2. Check valve seating per 11.2.4.3, ref. 1. (All)
- 3. Visually inspect seat area per 11.4.2, ref. 2. (All)
- 4. Visually 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,GL/8R)
- 8. PT inspect valve stem-head radius per 11.4.9, ref. 2. (All)
- 9. Engineering tests of the intake and enhaust valves to assure that valves are of the same material (6R,7L,8R,SL) (1) 62i2C20G25 L. MP/0/A/1000/35 Diesel Engine CV.linder Head Removal, Disassembly, Inspection and Aeassembly
- 2. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection 103G9Gli90 82291h2
- 1. Valve clearances were within normal limits.
- 2. Valve seating was checked and found to be satisfactory.
- 3. Visual inspections of the valve seat areas showed minor amounts of chipping.
- 4. Visual insoections of the valve guides showed small amcunts of scratching. ,
- 5. Visual inspections of the valve stems showed minor amounts of scratching.
- 6. Visual inspections of the valve stem tops snowed evidence of normal wear.
- 7. Visual inspections of the triction welds were satisfactory.
G. PT inspections of the valve stem radii were satisfactory.
- 9. Material comparitor tests concucted by Stone and Webster concluded all valves of same material (1)
OiERG5itl90 91 lO3R2GhiOO ELOdlOQS 3,4,5 The amount of scratching and/or oitting tound en these inspectionu was determined to be normal and the parcs were evaluated as acceptable for continued use.
rv l CA1Abhi Ql2Egi 26 IQEgggliga Egggtt EAtt Nggg4V alve Springs Eati UWebstiO2-360D Gle2218 Wgth Egggggt Ugz1584MNT 611CikWARE YECliifd
- 1. Check color code on valve springs per 11.4.7, ref. 1. (All)
- 2. Visually inspect the valve springs per 11.4.8, ref. 1.(A11)
Eminc=Ggn2
- 1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection IQ2ERE1190 BREWita-
- 1. The color code f ound on the valve springs was consistant-with the e:<pected correct code, accounting f or the ef f ects of heat, time and oil staining.
- 2. Visual inspections of the valve springs were satisfactory.
Q12E92l1i90 Qi IQ2EREti90 EindiGE2 There were no significant findings.
P 1 GatEMkA Di2221 26 102ESGli90 8929C1 Egtt-U3mg1 Subcovers 82C1 UMEkRC102-362A ClA131B M9th BREME21 N9t1584MNT 6tttikutm2 Vecified
- 1. Visually inspect subcovers per 11.6.2, ref. 1. (All)
- 2. PT inspect rocker arm pedestals per 11.6.3, ref. 1. (All)
Befstensen
- 1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection 103E2Gt190 BREWit2
- 1. Visual inspections of the subcovers were satisfactory.
- 2. PT inspections of the rocker arm pedestals showed no defects.
RinE921ti9n 9f lennectisa Einginen There were no significant findings.
r o
. .j GatEWha Qi2121 26 InEEEEti20 BEE 9Ct EAtt'destL F uel Injection Pump Eatt NumkscLO2-365A GLannLB 'W9th SR9utal U9s1756MNT 8tttikutna Vatified
- 1. Visually inspect the ID of the valve holder using a borescope per 11.2.2, ref. 1. (All)
- 2. 'MT' inspect the delivery valve assembly per 11.4.3, ref. 1.
(All) BRf2CenERE
- 1. MP/0/A/1000/42 Diesel Engine Fuel Pump and Linkage Special Inspection Innenst190 Basults
'1. Visual inspections of'the ID of the valve holders were satisfactory with the exception of one holder. '2. MT inspections of the delivery valve assemblies were satisfactory.
Qina9miti9n Qi Innanst19e Eindinna
- 1. The valve holder ~was reamed out and the inspection was repeated with satisfactory results.
F a e, C2tabb3 919321 28 105R95t190 8999Ct E3tt gamg1 Fuel Injection Tubing Caci dumbst102r365C G132SID M9th BEGuest Ugzi756MNT 8titibutes Mgtifigd
- 1. Visually inspect system to verify as built condition per 11.2, ref. 1.
- 2. ECT inspect tubing per 11.3, ref. 1. (All) 6952C90522
- 1. MP/0/A/1000/55 Diesei Engine Fuel Oil Piping System Special Inspection 10.599S1190 895W113
- 1. Visual inspections of the fuel , injection tubing snowed minor routing discrepancies with the au-designed dr-awings. (1)
- 2. ECT inspections showed three indications.
915E9511190 9f 1022951190 EiOdiO95
' 1. The discrepancies found on the visual inspections were determined to have no effect on engine performance. The tubing was reassembled and determined to be satisfactcry.
- 2. The fuel injection tubing with the indications were replaced with new tubing that was inspected by ECT and found satisfactory.
t s
Gelehke 9i2221 28 1GREEEti90 8EE9Ct Egtt NamgtF uel Injection Tubing Supports EEC1 UWEkECLO2-365D ClR51LD
-WGCh'BRQUEat U9t1756MNT 8ttttkutem Natified
- 1. -- Visually inspect tubing supports to verify as-built condition-per 11.2, ref. 1.
8EiECEGERE 1.; _MP/0/A/1000/55 Diese1' Engine Fuel Oil Piping System Special Inspection 102nsstiOO Beaulta
- 1. Visual inspections of the fuel injection tubing supports
! showed several' discrepancies with as-designed drawings. DiHE9EitiGG 91 102EREtiOG EiGdlG95
'1. The. discrepancies found on the visual inspections were
-corrected. 1
Gatahka 9122R1 26 IQ2EEEti90 BEE 9C1 Entt Ugmgt Fuel Pump Linkage Batt Nymugtt 02-371A/B Gla2ELA M9th BEQMR51 N9s1756MNT
.6thCikMtRE MRCifiRQ
- 1. Visually inspect linkage per 11.1.2, ref. 1. (All)
- 2. Ensure that an adequate lubrication schedule is in place per 11.1.3, ref. 1.
Saintnesen 1.- MP/0/A/1000/42 Diesel Engine Fuel Pump and Linkage Special Inspection 102E2S$100 BE2Mita
- 1. Visual inspectionms of the fuel pump linkage were satisfactory.
- 2. An adequate lubrication schedule was verified as in place.
Disegaitisa 91 Innenstigo Eindinsa There were no significant findings.
I" Gatawba Q19191 26 10nERGli90 82E9Ct Eact-03mgiIntake Manifolds EaCt Uymugt102-375 G132218 W9th 8299211 d9s1584MNT 6titikMtEE YEtifiRd
- 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) 82f2C20GRE
- 1. MP/0/A/1000/46 Diesel Engine Intake and E:<haust Manif olds Special Inspection
- 2. MP/0/A/1000/35 Diesel Engine Cylinder Head Removal, Disassembly, Inspection and Reassembly.
10sEsstise Besulta .
- 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.
DiEE91iti90 9f 102ERGliGO EiOdiO92 There were no significant findings, s
Gatedhe Qi2 eel 26 lO2EEGliOO BERGCt Egtg Namgi Exhaust Manif old Catt UMGh2CL 02-380A Gla21LB WGCh.629MC11 UOs1784MNT,1584MNT 611:i4M122 MRCliitd
- 1. Check alignment on disassembly per 11.2.11.1, ref. 1. (All) 2.- Visually inspect flange welds per 11.3.4, ref. 2. (All)
- 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)
.6252CSDGES
- 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 Manifold:
Special' Inspection
- 3. .MP/0/A/1000/56 Diesel Engine Exhaust Manifold Special Inspection -
10sonstigo Besulta-
- 1. Alignment on disassembly was satisfactory.
- 2. Visual inspections of the flange welds were satisfactory.
- 3. Visual inspections of the as-built system were satisfactory.
- 4. The manifolds were installed to TDI specifications.
QiEE91itiGQ Qi lO2ERELL90 EiGdiGG2 There were no significant findings.
~
I ) i o GataWks Q12221 26 IO299Gt190 8299C1 Egti Namg1 Exhaust Manifold Bolting EACt gymhet102-380B Cl2511B M9th Eggugnt Ngz1584MNT 6tttihutan Yetified (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. I
- 3. Measure depth of bolt holes per 11.3.3, ref. 1.
- 4. Visually inspect bolts per 11.2, ref.2 (All)
I 82f2CROGE2
- 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
1029sGti90 Beaults . ! l l
- 1. Visual inspections of the exhaust manifold bolts were satisfactory.
- 2. All bolts were 1.5 inches long - satisfactory.
- 3. Bolt hole depths were found to be satisfactory.
- 4. Visual inspections of the as built condition were l satisfactory.
Qi19911119Q 9f 1019EGil90 ELOdiGQ2 There were no significant findings. s
p. GGladb g Digggi 28 [Ogaggtign 8g29C1 Pact NemgiC rankcase Covers EeCh NumbstLO2-386B CL&&sLC Egth Segyggt No.1585MNT, 2488MNT (1) Otttih yggs yectilgd
- 1. Visually inspect bolt holes per 11.5.2, ref. 1. (All)
- 2. Reassemble covers per ref. 2. (All) (1)
Refetgeggg
- 1. MP/0/A/1000/39 Diesei Engine Crankshaft and Turning Gear, Gear, Crankshaft Bearings, Crankcase Assembly, and Crankcase Covers Special Inspection
- 2. MP/0/A/7400/58 Diesel Engine Inspection Covers, Renoval aid Replacement. (1-109G99$190 8229112 -
- 1. Visual inspections of the crankcase cover bolt holes were satisfactory.
- 2. The covers were reinstalled to TDI specifications.
91s99911190 gi 10samstigo Eindiosa There were no significant findings.
GalahEE QiEERl 20 lO2EEEt190 8EE9th Egtt Ngmgi I ntake/ Intermediate Rocker Arms Bett Numantto2-390A Gla111B W9th Besussi ugs1584MNT etitikutss Vatified (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.
BRfRtEOGRE
- 1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection 103ERGli90 8229112 ,
- 1. Visual inspections of the rocker arms showed minor amounts of nicking and gouges.
- 2. Visual inspections of the rocker arm lips were satisfactory.
- 3. Visual inspections of the rocker arm sockets were satisfactory.
- 4. Visual inspections of the rocker arm swivel pads were
~
satisfactory.
- 5. Visual inspections of the rocker arm drive studs were satisfactory.
Disnesitien 9110nnesti90 Eindin9m
- 1. The amount of nicking and gouges found on visual inspection of the rocker arms was determined to be normal and would have no effect on engine performance. These parts were evaluated as being acceptable for continued use.
F. Catawka D121g1 28 Ingagglign Egggtt Egtt NgmetE xhaust Rocker Arms Batt UWmkRC102-390B GlataiB Weck BenWust dgt1584MNT 8titikMtRE MRCliigd (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.
82f2CRnERI
-1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated
. Parts Special Inspection
~1n!ERGli9n B259115 -
- 1. Visua1' 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.
Dimannitten ei-Inanestien Eindinna 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.
r Gatewha Qianni 28 innenElige Benett Esti Namgt Intake/ Exhaust Pushrods Eatt UumbatiO2-390C GlaERLB Weth Besuant Ugt1584MNT 8tttikutti Vttified (Accomplish on all Push' rods)
- 1. Verify pushrods are of friction welded design per 11.9.2, ref. 1.
- 2. - PT inspect friction weld per 11.9.3, ref. 1.
- 3. Visually inspect spherical surfaces per 11.9.4, ref.1.
BRiRCEOGES
- 1. - MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection lossestige Beaulta
- 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.
912EQHiti90 91 IOEERG1190 EiOdiO91 There were no significant findings. s +
. _ - ~. ,
I CStadia Di22mi 28 losamstine Ess9Ct P3tt Ugeg1C onnector Pushrods
'8ett UMGb2C102-390D G13S21B WOth BE99E21 d9s1504MNT 6ttClkMtEE VECifigd (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.
BEfECEGERE
- 1. 'MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection 10592stiOO 633W115
- 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. Disassitiso si 10samst190 Eindiess There were no significant findings., 5
t r Galawka Ql21Cl 26 10EEEEtiGO BRE9th Egth Ngmgt Rocker Arm Bushings Batt Numkat102-390E giggstB-W9th Be9unst 09t1584MNT 6tttibuten Vatified
- 1. Visually inspect rocker arm bushings per 11.7.7, ref. 1.
(All)
- 2. 8 Visually inspect exhaust rocker arm bushings per'11.;.7, ref. 1. (All)
BRiRC2GEEE
- 1. MP/0/A/1000/37 Diesel Engine Cylinder Head and Associated Parts Special Inspection lesenst19n Basults 1,2 Visual inspections of the intak'e/ intermediate and exhaust rocker arms showed minor instances of nicking and scratching.
Q12E91it190 9i 101EREtiGO E10diO92 1,2 The minor scratching and nicking found on visual inspection was determined to be normal and the bushings were evaluated as being acceptable for continued use.
r:.
- c Getawhg Diggql 28 J.G2R2 GAL 90 8929C$
Entt UgmggRocker Arm Bolting CaCt UMGhECLO2-390G Cis22iBL
-WQCh EE99821 89z1584MNT, 2844MNT :1) 6thClhMtE2 M2CliiEd
- 1. MT inspect capscrew thread roots per 11.11.2, ref. 1. (All)
- 2. ' Visually. inspect rockor arm capscrews per 11.11.3, ref. 1.-
(All)
.3. Verify reassembly torque per 11.6.17, ref. 2. (All)
- 4. (Engineering tests of the material and hardness on four capscrews (1)-
8212C20GES
- 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
-101G9G1190 6229112
- 1. tff inspections of the rocker arm capscrew thread roots were satisfactory.
- 2. Visual inspections of.the rccker arm capscrews were evaluated as satisfactory.
- 3. The capscrews were torqued to TDI specifications on reassembly.
- 4. Results of engineering tests indicated that capstrew material was equivalent to alloy 4140. Hardness of all capscrews tested.was uniform. (1)
Di2R921ti90 91 IQ2ERGIi90 EiOd1095 I There were no significant findings. a N
r.
.e.
Catawha Qinagl 28 Inggggtign Bgggtt Eatt NamgiO verspeed Trip and Accessory Drive EAtt Nymygc102-410B Gla251A W9th Bn9unst Ngzi760MNT 8titihutan Yttified
- 1. Visually inspect drive gear per 11.3.2.1, ref. 1.
2 .' Visually inspect driven gear per 11.3.2.2, ref. 1. Baintances
- 1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly lon9mst190 Besulta
- 1. Visual inspections of the drive gear were satisfactory.
- 2. Visual inspections of the driven gear were satisfactory.
QiME91iti90 Ef 1GREnEll90 ElGdiO91 There were no significant findings.
T GatAbbA 912291 20 102E2G1190 SRGGCh E3Ct.Name Overspeed_ Trip Drive Coupling EdCt UWeh2C102-410C Gla22iA WGCE BEQWRE1'N9t1760MNT 6titihW1RE M2CifiSd.
- 1. Visually inspect coupling elastomer per 11.3.1.1, ref. 1.
Bsistnessa
't. MP/0/A/1000/47 Diesel Engine Governor and.0verspeed Trip Accessory Drives Disassembly, Inspection and Reassembly 102925$190 SS2Wita
- 1. Visual inspections of the coupling elastomer were satisfactory. .
Qi2E911tiGQ 91 IQ2ERGil90 EiQdiOE1 There were no significant findings. 4 e t
r-Calabba'Di2221 28 IO2ERSti90 BRE9C1 Egtt Ugmg Speed Regulating Governor Drive Batt UMTb2C102-411A GlA221A M9th BEGMESt 69t1760MNT 8tttihMten Mutified
- 1. Visually inspect large horizontal drive gear per 11.5.2.1, ref. 1.
- 2. Visually inspect small horizontal drive gear per 11.5.2.0, ref. 1.
8212C20G22
- 1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Driven Disassembly, Inspection and Reassembly 10$GR5tiGO 89E9113
- 1. Visual inspections of the large hori: ental drive gear were satisfactory.
- 2. Visual inspections of the small horizontal drive gear were satisfactory.
Dian9sition si 10nnestien Eindicen There were no significant findings. 3 1 5
- , - - - - - - , < , , - - , , ., .,- - ,- ,.r - -, e
r
.e.
Cetgwbg Digggt 28 Ingggttige Sqngtt Eatt Ngmgi Speed Regulating Governor Drive Coupling Entt Numbgtt02-411B GlegsLA Wgtk Egquggt Ngs1760MNT, 2797MNT (1) 6titibuteg vatifigg
- 1. Vi sually 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 at set screws and drive pins per 11.7.3, ref. 1.
ERf2CHQG21
- 1. MP/0/A/1000/47 Diecel Engine Governer and Overepced Trip Accessory Drives Disassembly, Inspection and Reassembly inanest190 Bes91t2 .
- 1. Visual inspections of the governor drive couplir nere satisfactory.
- 2. The coupling material was verified as neoprene.
- 3. The coupling set screws and drive pins were reassembled to proper procedural requirements.
2159 '*.1190 Gi 102G9Et190 EiOd1093 There were no significant findings.
GataWha 919291 20 102E95$i90 6229CA P3tt U3mg4Epeed Regulating Governor Linkage EEC1 UWOh2C102-413A Cla111A WQCM Bgggggt Ugt1760MNT 8tttitutta Metified
- 1. Check linkage' action per 11.6.1, ref. 1.
- 2. Visually inspect cross shaft per 11.6.2, ref. 1.
- 3. Verify locktite installation per 11.6.4, ref. 1.
BeimCecces
- 1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Rearsembly 10sessti90 Bssuita
- 1. The linkage action was checked and found satisfactory.
- 2. Visual inspections _of the cross shaft were satisfactory.
- 3. Locktite was installed to procedural requirements.
Dianguitiso 91 lesenstisa E10d10sa There were no significant findings. s
r - GatAWha QiREEl 28 IQ5EEEti90 8EE9Ct Egch NamatF uel Pump Linkage and Shutdown Cvlinder r EAC1 NMmhtCLO2-4138 GlARELB W9th'BR9WR11 Ngs1760MNT 8tttikuten Yttified
- 1. Check linkage action per 11.6.1, ref. 1.
- 2. Visually insnect cross shaft per 11.6.2, ref. 1.
BeintenEnn
- 1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly 10senEt190 Banulta
- 1. The linkage action was checked and found to be satisfactory.
- 2. Vist al inspections of the cross' shaft were satisfactory.
DIME 9Eitl9G Qf lOSEREti20 EiOdiO91 The e were no significant findings. I h w w
o CAtAbba Q12591 26 102ERsti90 BRE9C1 EACA NASR1 G overnor Booster Servomotor EAC$ NWSkRCIO2-4150 CLAMElB W9CE Ensunut Ngzi760MNT 61stikutR1 Mitifitd
-1. Verify proper installation per 11.2.1, ref. 1.
8tfRCRusRE
- 1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip-Accessory Drives Disassembly,' Inspection and Reassembly 10senst190 Snzuita
- 1. The installation of the servomotor was verified as correct.
Dime 9mitise sf 10manst190 Eindiosa There were no significant findings. r -.. , - . - - . . - - _.. . . . - . . , .,, , , . .m ,,,- , , _,- _. --, ...---___ -- -.-,,- - _ ,,,_,ym,,
,.,, ,, ,.,n
r GateWhg Digggl 26 Ingaggtige Beggtt Entt NamgiG overnor Heat Exchanger e Eatt GymugtLO2-415C glr 111A , W9th BR99EEt U9s1760MNT 6titikutsu MatifiRd
- 1. Verify proper installation per 11.2.2, ref. 1.
89fRCROGRE
- 1. MP/0/A/1000/47 Diesel Engine Governor and Overspeed Trip Accessory Drives Disassembly, Inspection and Reassembly lesenst190 Basults
- 1. The installation of the governor heat exchanger was verified as satisfactory.
Digggnitige gi Inggggtign Eingingg There were no significant findings. G l
r CataWha Q12291 26 IONEREt190 BRE9C1 Eatt Ugmg1 Jacket Water Pump p . EaC1 Numh=ct02-425A Clamm1A W9 th E=9un11 Ngz1767MNT 6titihutta Yetified
- 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. Verify torque of spline nut per 11.5, ref. 1.
- 5. Check end play of external spline per 11.5.1, ref. 1.
BEf9CSGGRE
- 1. MP/0/A/1000/59 Diesel Engine Jacket Water Pump Special Inspection IcaEsst190 Beaulta -
- 1. Visual inspections of the gear carrier were satisfactory.
- 2. Visual inspections of the gear, coupling and spline were satisfactory.
- 3. The torque of the impeller nut was found to be 80 ft-lbs.
- 4. The torque of the spline nut was found to be 140 ft-lbs.
- 5. The external' spline was reassembled with the correct amount of end play.
DiEE91itL90 9i IONEREti90 EiQdiG91 There were no significant findings. s
GAtAWDA Q102R1 26 10599E$i90 BRE9Ct
.Egtt Nest 1I ntercooler Piping Coupling Estt UWGkRC1 02-436B Gl!221A 'W9th BR9WRE1 UQzi759MNT GlitikMiti YECifiEd
- 1. Check Dresser coupling on piping per 11.5.4, ref. 1.
BRf9CROGES
- 1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection 10samstige Beaults
- 1. The Dresser coupling on the intercooler piping was inspected and found to be the correct typ,e.
QiHE91iti90 9f 101EREti9Q EiQdiG9E There were no significant findings.
,, ,m, , --. . , . ~ r ,--m-- -,
w- . . , - - y%r --- - . . . - . . . . m, - ,. r
r .- GatAWh! C12991 28 101EEst190 BRE9Ct Egtt Nggg1T urbocharger Cooling Water Piping and Fittings EAtt'NWGkfCiO2-437A GlBRB1B W9th Bn9went Nez 8tttihutti Yetifine
- 1. Visually inspect system to verify as built condition per 11.5, ref. 1.
BRiRCRGER1
- 1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 10anest190 Beaulin
- 1. Visual inspections of the turbocharger cooling water piping and fittings were satisfactory.'
Qi2E91itiGQ Qi 1GREMEli20 EiQdiOQ1 There were no significant findings.
r a CatawhA Diesel 28 105Esst190 BRE9th Egtt Ngmg1 Turbocharger Cooling Water Piping Supports BACH'Uymegc102-437B ClA211A W9th Besuant U9z
.etttibuten Vatified
- 1. Visually inspect system to verify as built condition per 11.5, ref. 1.
BaintaQEns
- 1. MP/0/A/1000/53 Diesel Engine Jacket Water System, Piping, Standpipe and Manifold Special Inspection 10sE=Et190 Banulta -
.l. Visual inspections of the turbocharger cooling water piping supports were satisfactory.
Dl1E9aitiGQ Qi 101EREti90 ElOdiGER There were no significant findings.
F-Galabhg Digggi 28 Inggggtige Bgggtt
. Egtt NgmgiStart Air Manifold Tubing BBCi Nymheti 02-441A Gla251A W9th 8999R11 N9t1762MNT 8tttikutna Yetified
- 1. Visually inspect system to verify as built condition per.
11.2 ref. 1. BEfttRGERE
- 1. MP/0/A/1000/54 Diesel Engine Air Start Piping System Special Inspection 10nenst190 Basulta
- 1. Visual inspections of the start air manifold tubing showed several discrepancies with the,as-designed drawings.
Diggggitige gi Inggggtign Eindings i 1. .The descrepancies have been determined to have no effect on l engine performance. The start air system has been reassembled and has been evaluated as satisfactory for re-use. l t l l
F-nea . CataW54 Qi212l 20 10E22E1190 82E9C$ Entt dam 21 start Air Manifold Pipe Supports Entt Ugmqqt102-441C' Cla21LA WQCh 822 MEET U9t1762MNT
.OttCikWtR2 MRCifiEd
- 1. Visually inspect system to verify as built condition per 11.2 ref. 1.
Befetences
- 1. MP/0/A/1000/54 Diesel Engine Air Start Piping System Soccial Inspection 102G2GtiGO 822Wita
- 1. . Visual inspections of the start air pipe supports showed minor discrepancies with the as-designed drawings.
Qiansmition et lennestien Eindican 1.. The discrepancies found on visual inspection were corrected. t t
r-Gatewha Qinami 28 Inmaestige Benett Eatt-NgmatStart Air Distributor Tubing Bett Numggtt02-4428 GianntA W9th Bequent Ngzi762MNT 8tttikutta Yttified
- 1. Visually inspect system to verify as built condition per 11.3 ref. 1.
Baistances
- 1. MP/0/A/1000/54 Diesel Engine Air Start Piping System Special Inspection 10senet190 Beaults
- 1. Visual inspections of the start air distributer tubing showed minor discrepancies with the as-designed drawings.
QiEn91Ltige gf legggglige Eingings
- 1. The discrepancies found on visual inspection were evaluated as having no effect on engine performance. The start air system was reassembled and was determined to be satisfactory for continued use.
l \ l i l l l s L
D Gattwbg QLgggt 26 legggglign Bgggtt Egtg Ugmgt Fuel Injection' Piping Eatt Numhett02-450s GianntB Weck Esawant Ugt1756MNT 8tttikutta Vatified
- 1. Visually inspect system to verify as built condition per 11.2 ref. 1.
BRitCREEEE
- 1. MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special Inspection 10senst190 Basulta
- 1. Visual inspections of the fuel injection piping showed minor discrepancies with as-designed drawings.
Qi1EQ1itiGO Qi 101EREllGQ ElGdlG91
- 1. .The discrepancies found on the visual inspections were evaluated as having no effect on the performance of the diesel. The fuel injection system was reassembled and determined satisfactory for continued use.
t
r i' Catabha 912221 29 Insggstige Bgggtt P2tt damg1F uel Oil Piping Supports E3C1 UMOb2C102-450D Gla121A WOCE BEGM25$ MOs1756MNT 6ttriqutgg ygtifi 2d
- 1. Visually inspect system to verify as built condition per 11.2 ref. 1.
ESiECEGEC2
- 1. MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special Inspection 102E2G$190 8229112
- 1. Visual. inspections of the fuel oil piping supports showed minor discrepancies with as-designed drawings.
Ql2E91Lti20 Qi 103EEGtion EiQdiGG1
- 1. The discrepancies that showed on visual inspection were corrected. 1 O
ka
r-Gatawka QiE221 26 inEEEEti9n BEE 9Ct Eatt NgmgiF uel Oil Filter Mounting Hardware EAtt NMmkRCLO 2-455C Cla111A W9th BREMggt Ugzi756MNT 6tttikutta Matified
- 1. Verify correct torque is applied to bolt per 11.3.1, ref. 1.
- 2. Visually inspect system to verify as-buiti condition per 11.2, ref. 2.
8212C2nGES
- 1. MP/0/A/1000/42 Diesel Engine Fuel Pump and Linkage Special Inspection
- 2. MP/0/A/1000/55 Diesel Engine Fuel Oil Piping System Special Inspection InaERG119e BREWita
- 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.
QLsEsaitian 91 InnEsstisc Eindiana - There were no significant findings.
.w, GatEhh8 Q12221 26 lO2EEEtiGQ EEE2th Egtt NgmgiE xternal Lube Oil Lines ESCt Ugmhett02-465A G1022iA d2th 82GMESt 89t1758MNT GittihMLEE MECliiEd
- 1. Visually inspect system to verify as built condition per 11.4 ref. 1.
6CiSC20EES
- 1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IO2G2Gt1GO 8929112
- 1. Visual inspections of the external lube oil lines showed minor discrepancies with the as-designed drawings.
912G951tiGO Qi IO2EEEtiGG EiQdiGGE
- 1. The discrepancies found on the visual inspection were evaluated as having no effect on the performance of the diesel. The lube oil system was reassembled and determined to be satisfactory for continued use.
f GatAwkA Ql2 eel 26 IQ12EGtL90 BEE 9Ct-Eatt NgggtExternal Lube Oil Line Supports EAtt Gu@kEC102-465B GLA21LA Wstk EQsunst 89t1758MNT Ottttkuten YmCified 1.. Visually inspect system to verify as built condition per 11.4 ref. 1. 62fECROGRE
- 1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IQsamst100.Besults
- 1. Visqa1' inspections of the e::ternal lube oil line supports showed minor discrepancies with the as-designed drawings.
QLSEOiltlGQ Qi 1GREEEll20 EiQdlGSM
,1. The discrepancies found on the visual incpections were corrected. 1 1 +
m
f,: o
'Galahka Digggi 28'Itaggstign Egggtt Pgtt NgggtTurbocharger Lube- Oil- Piping Eact Numkatto2-467A GiammiB Wect Staunat Ngz1758MNT etttikuten Yatified
- 1. Visually inspect system to verify as built condition per 11.5'ref.'1.
'6EftcRcEEE,
,1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection losesstion Beaults
- 1. Visual inspections of the turbocharger lube oil piping were satisfactory. -
1 Dinnemitien et losgestion Eindinna There were no significant findings. 1 i ) i
T t CatAbbs 9123g1 28 10ggggtige Bgggtt Egtt N3 mgiTurbocharger Lube Oil Piping Supports Eatt N9Eb2C102-467B
. ClA3218
-WGCh 8tGM2Hi N9t175GMNT 6ttttbuten Yetifled
' 1. Visually inspect system-to verify as built condition per
'11.5 ref. 1.
B2f2tteE21-
- 1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection loanestion Benulta
' 1. Visual inspections of the turbocharger lube oil piping-supports showed minor discrepancies with the as-designed drawings.
Dien9attinn si lenantaten Etudienn
- 1. The discrepancies found were corrected. 1 9
lhhw,, am_______,.
F 4 CatAWha Qi2191 26 InnEREti2G BRE9C1 Egtt NamgiT urbocharger Bracket f ESCt dumetCLO2-475A ClB1miB M9CE BtQutSt 69t1759MNT 6tttihutan Yetified
- 1. _ Visually inspect turbocharger bracket per 11.3.2, ref. 1.
(All brackets and bar supports) Beistenses-
- 1. MP/0/A/1000/49 Diesel. Engine Turbocharger and Intercooler Special Inspection Insenstien Beaults
- 1. Visual inspections of the turbocharger bracket were satisfactory.
DinnenttL9n 91 Innenstien Eindican There were no significant findings. t 5
V F GataWha QLEERL G6 10222Et190 6029Ct Egtt Nemg:, Turbocharger Bracket Bolting CGCt U90hMCLO2-475D Glausta W9th Eqqqggt Ngt1759MNT, 2334MNT (1) 6tttihMitil MEtifiEd
- 1. Visually inspect bolted joint per 11.4.3, ref. 1.(R/L Hanks)
- 2. Verify proper torque is applied to colts per 11.4.4, ref.t.
(Gample of 6 bolts) E9f2CEDESS
- 1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection 103925t190 8939112
- 1. Visual inspections of the joints were satisfactory.
- 2. The bolts were retorqued to the required values on reassembly.
Q1329311100 91 103E2Gt190 E10diO92 There were no significant findings. l
( Gatadba D12221 26 IOSESStiGO B229C1 Egtt Ugsg1Control Panel Tubing EECt UM0b2CiO2-500M G13251B W9th BS99221 U9m OttCib9tss Ystified
- 1. Visually inspect system to verify as built condition per 11.3 ref. 1.
GG12CRGERS
- 1. MP/0/A/lOOO/57 Diesel Engine Shutsown Tubing and Electrical Conduit Special Inspection 1039251190 BDSMita
- 1. Visyal inspections of the control panel tubing were satistactory.
Disn9mitint of Innanstion Eindings There were no significant findings.
~
L - -. _ _ _
i ri CataWh3 Q12221 26 102E253190 8229th Eatt UsG91L ube Oil Sump Tank Estt Numbst102-5404 Gla2218 W2th Benuest Ugt1758MNT etttibuten Yenified
- 1. Visually inspect system to verify as built condition per 11.4 ref. 1.
EtitCEnGER
- 1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection 102Q251190 6929112
- 1. Visual inspections of the lube oil sump tank showed minor discrepancies with the as-designed drawings.
Dian95itien ef Inannstinn Eindicas
- 1. The discrepancies found on visual inspection were evaluated as having no effect on the diesel performance. The lube oi.1
. system was reassembled and determined to be satisfactory for continued use.
lu $=
GBidhhd Digggi ZG Ingagstien Egagct Egth Gaegi L ube Oil Sump Tank Bolting ESCt duehEClO2-540B Gld25LB W9CE 8gggggt Ugs1758MNT 6titibutgg ygtified
- 1. Visually inspect system to verify as built condition per 11.4 ref. 1.
8Ci2CCQE92
- 1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection lesnestise 82591ts
- 1. Visual inspections of the lube oil sump tank bolting showed minor discrepancies with the as-designed drawings.
EinE92iti90 91 IQ5GREllGQ EiQdiGG2
- 1. The discrepancies found on visual inspection were corrected.
1 s
r-
?
Catlwes DiSES1 26 105E2Gt19e 69E9Ct Eact Ugmg1 Lube Oil Sump Tank Mounting Hardware datt UWGb2ClO2-540C Cl2221B WGCh'82EM251 UQt1758MNT dittikut21 MRCifL2d 1.- Visually inspect system to verify as built condition per 11.4 ref. L. Edi2C2 net 2
- 1. MP/0/A/1000/43~ Diesel Engine Lube Oil System Piping and Sump i Special Inspection 10nn2stigo Beaults
. 1. Visual inspections of the lube oil sump tank mounting hardware were satisfactory. . 1 015annitL90 of Innanstien Eindluna lhere were no significant findings.
"4
p 92tehus Di2221 20 10annstise Esastt Egti Odeg1 Engine/ Auxillary Module Wiring Conduit 2001 UMOkRC102-600A GidaalA Wech Buswant U9z alttinutsa Ystified
- 1. _ Visually inspect syste.n to verify as built condition por 11.4 ref. 1.
GRiMCEQCE'd
=1. MP/0/A/1000/57 Diesel Engine Ghutsown Tubing and Electrical Conduit Special Inspection IQ2EdGt190 62291t2
- 1. Vicual inspections of the engine / auxillary module wiring conduit were satisfactory with ,the exception of a connector box that was missing a cover.
Diansmit190 91 10nerstigo E10diosa The connector box cover has been replaced. The missing cover would have had no effect on engine operability. Thus, there were no significant findings.
Gateche Qiuhti Ed lOLE251 LOG 82E9Ct Edct rJamstE ngine shutdown Tubing CdCL UMOEUCLO2-695A Gldh2LD Wuct Eanuent Us_ 6titthutan Ystiitud
- i. Visually inspect system to verify as built ccndition per 11.2 and 11.3, ref. 1.
GuidC2GG2n
- 1. MP/0/A/1000/57 Diesel Engine Shutsown Tubing and Electrical Conduit Special Inspection IQ229stiOG B229133
- 1. Visual inspections of the engine shutdown tubing were satisfactory with the exception of an accumulator (F-573-32c) which was found to be manufactured by Humphrev rather than Bimba, per the drawing.
QLHQ2SitLQQ Qi 1GEERGhiGG EindlG22 TDI has advised Duke that the Humphrey accumulators are used interchangeably with the Bi.r.ba accumulators. Thus, there were no significant findings. _-_.-_--___s
f Gatad2a Qi252i 26 IQ2RECtlOO BE29CL Egth N3mg.:Intercooler EdC1 UMI'hMCiF -068 Gi&331B M9th EEGMR11 Ugu1759MNT 6tttihMtR2 YRCliiid
- 1. Visually inspect intercooler per 11.5.2, ref. 1. (L/R)
- 2. PT or MT inspect intercooler adaptor flange weld per 11.5.3.
ref.1, (L/R) Baf2C20GR2
- 1. MP/0/A/1000/49 Diesel Engine Turbocharger and Intercooler Special Inspection 105D2G1190 6929112
- 1. Visual inspections of the intercooler were satisfactsrv.
- 2. Not accomplished as intercoolers were new and rigid pipo hangers have been added to prevent adapter fle.nge crackina.
(t) 9130921t190 of 10na2Gt190 E10d1092 4 There were no significant findings.
**s
w CAtaWha 912291 26 103E2Gtl90 BRE9C1 Egtt Nggg1 T urbocharger Thrust Bearing Lube System Eftt UWOkRC102-CFR ClA231C-WGCh 822MH11 UQs1758MNT Otttikuten YeClfled
- 1. Visually inspect system to verify as built condition por 11.5 ref. 1.
8212C9Q5C2
- 1. MP/0/A/1000/43 Diesel Engine Lube Oil System Piping and Sump Special Inspection IQaanGt190 82291t3
- 1. Vinual inspections of the turbocharger thrust bearing lube system were satisfactory. -
Ql1EQ2ltl2O 91 IQ1ERGilGQ ElQdlGQ2 There were no significant findings. D
f5 Getgwbg Qi229L 28 10322Et100 6029Ct Ostt NgmgfTurbocharger Egtt Nyehgt1MP/022/3 G12221A d9Ck 82Guggt Ng._1759MNT, 2672MNT (1) OthCihutta V.RC[Ligg (Perform inspecticns on all turbochargo.a with > 50 hours service)
- 1. Visually inupect turbocharger assembly per 11.2.2, ref. 1.
- 2. Visually inspect journal bearings per 11.2.3, ref. 1.
- 3. Measure rotor flocat end clearance per 11.2.4, ref. 1.
- 4. Verify correct number of bolts in place en inlet canino per 11.2.0, raf. 1.
- 5. Pf inspect stationary no :le ring per 11.2.6, ref. 1.
- 6. Measure ID of journal bearings per 11.2.7, ref. 1.
7 Verify correct torque on casing beltu per 11.2.8, ref. 1. li . Visually in.spect onhaust ga3 ini st bol ta per 11.6.1, ref. 1. EdiciCfCESS
- 1. MP/0/A/1000/49 Diesel Engine Turbocharger e.nd Interrocter Special Inspection 1020sst190 Beaults 1,2,6,7 Incpections were not accomplished cr. new tureochargers.
;1)
- 3. Rotor flaat indicated that cath turbochargers .not specification and were satisfactory. (;
- 4. Inspection was satisfactory. ( '. )
- 5. PT rosultu accomp1i shed by turbocharqor manuf acturer v er e satisfactory. C '. )
- 3. Poltu replaced with SA 453, Grade 660 Condition A raaturi al an a design modification. (t)
QLancaihtoo 91 LennentL20 Eindtuou 1,2,6,7 The inspections were not considered neccusary ass tha tur bocharttru were new units with no oparational hourti d the time of inspection. 't) 7.4,5,0 Resulta aro considerad acceptable. (1)
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