ML17298A543

Failure Analysis of 54-26-1770 Steel Rotor Returned on NPR-97152 from Palo Verde Nuclear Station.

ML17298A543
Person / Time
Site:	Palo Verde
Issue date:	10/22/1982
From:	Bissett T, Foote R, Jerome Murphy JOY MANUFACTURING CO.
To:
Shared Package
ML17298A542	List: ML17298A541 ML17298A543
References
X-992, NUDOCS 8309090307
Download: ML17298A543 (90)

Text

Table 3.5-3 INTERNALLY GENERATED ROTATING COMPONENT FAILURE MISSILES INSIDE CONTAINMENT Calculated Thickness Nissile Characteristics Wise(le of Surrounding Calculated Residual Naterial to Prevent Naxinun Velocity Eq Steel Casing Casing After Casing Concrete Steel Nissile Dia. We(ght Perforation Thickness Perfuse Perforation Spelling Perforation Identification Source of Nissile Location (ft/s) (in.) (lbs) Depth (in.) (in.) .t ion (ft/s) (in.) (in.) Renarks Fan blade Conte innent nornal El'20'elocity Containnent 318.9 12.7 0.55 0.375 yes ..210.8 7.2 0 ' Nisei le cannot fully ACD ran building perforate due to stiffening rin s Fan blade Conte innent Containnent 12.2 0 ~ 29 0 '75 preaccess building nornal AFU fan El.

140'ontainsent

' '

Fan blade CEDN ACD noma) unit fan 80'00.

building El.

266, 7 0 0.375 Fan blade Reactor cavity 200'ontainnent 211 ~ 2,5 18. 3 0 ~ 33 0 '75 nornal cooling building fan El.

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PROJECT FI I E D.4.30 PALO VERDE NUCLEAR GENERATING STATION REPORT No.

PROJECT EVALUATION DEFICIENCY EVALUATIONREPORT REV./DATE LOS ANGELES JOB NO. 10407 POWER DIVISION PAGE OF PREPARED BY Q CLASS UNIT REFERENCE DOCUMENTS K. Stwerteik -$ 43 1 NCR CC-3698 NAME DATE PART 21 REPORTABILITY: IF THE ANSWER TO ANY OF THESE CRITERIA (SEE PQPM I6.2 FOR DEFINITIONS) ARE NO THEN THE CONDITION IS NOT REPORTABLE UNDER PART 21.

1. DOES THE DEFECT EXIST IN A BASIC COMPONENT7 No Ej YES Q

2. DOES THE DEFECT PRESENT A SUBSTANTIAL SAFETY HAZARD7

3. HAS THE COMPONENT BEEN DELIVERED OR OFFERED FOR ACCEPTANCE7 QX YES Q YES g NO Q No P INTERIM REPORT 50.55(8) FINAL REPORT P PART 21 REPORT I ~ CONDITION DESCRIPTION A vane axial fan (Tag No. 1-M-HCN-A01B); installed in the Unit 1 Containment Building, was shut down after over 1,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br /> of operation when a high amperage condition was noted. Inspection of the fan (54" diameter) showed that three blades had failed. The failures resulted in damage to the fan housing and a blade piece had penetrated the containment liner plate, causing a 2"L x 1/2"W rupture. The fan assembly was removed and returned to the manufactur'er, Joy Manufacturing, for examination.

The Joy Manufacturing examination determined the cause of the blade failures to be the result of blades being loose (Reference 1). An inspection performed by Bechtel's Materials and Qua3.ity Services concluded the same (Reference 2).

Reference 1 provides a definitive analysis of how loose blades allowed a load transferal, leading to a fatigue crack in one blade. This blade ultimately failed, with two additional blades failing upon impact with a section of the first failed blade.

Reference 1 attributes the loose blade condition to undertorqued blade attach-ments. Reference 3, which contains inspection results of all applicable fans in Unit 1 (blade locknut torque and tip angle values), substantiates this evaluation.

Reference 3 further indicates this undertorqued blade attachment condition to .

be recurrent.

II. ANALYSIS OF SAFETY IMPLICATIONS An engineering evaluation of the subject fan blade failure, performed by Bechtel Engineering, determined that structures, systems and components necessary to maintain safe shutdown remain fuctional following postulated internally gener-ated missile scenarios.

Specifically, the loss of the normal Containment Building HVAC System has no adverse effect upon plant safe shutdown capability since the system is not an essential system.

IDENTIFY CALCULATIONOR OTHER DESIGN DOCUMENT WHICH WILL BE INITIATEDOR REVISED To SUPPORT THIS EVALUATION ~

SAR IMPACT

+ YES Q NO See References DOCUMKNT TITLE. NIJM 0E R. AND REVISION AND FORECAST COMPLETI ON DATE NGS PEM EVALUATIONAND REPORTABILITY RECOMMENDATION P REPORTABLE NOT REPORTABLE PKM DATE PF 7 I SIC I I 04071 I0/!0

Report No. 82-53 Rev./Date 1 7/7/83 Page 2 Final Report Furthermore, in a review of all fans located within the containment, no struc-ture, system, or component necessary for a safe plant shutdown was, nor could be, adversely affected by any internally generated rotating missile. {The fact that the containment liner was damaged is immaterial since the liner provides no safety function during this event.)

Finally, an evaluation of similar fans located outside the containment shows that missiles from these fans will not adversely affect structures, systems or components required for safe plant shutdown.

Based upon the above discussion, if left uncorrected, the subject condition would not adversely affect the safety of operations of the plant during the lifetime of the plant. Therefore, this condition is evaluated as not reportable under the requirements of lOCFR50.55{e).

III. CORRECTIVE ACTION

1. The containment liner plate has been repaired per the disposition of NCR CC-3698. The gouges not penetrating the liner plate were ground clean, filled with weld material and smoothed to the original configur-ation. To repair the cut penetrating the liner plate, some concrete behind the cut was first removed, a steel bar was fitted to provide a base for welding, and the cut was then filled with weld material and ground flush.

2. The failed fan has been replaced as documented by NCR SM-1167.

3~ SAR Change Notice 1089 has been initiated to correct a comment to FSAR Table 35-3 indicating a missile cannot leave the casing due to stiffening rings (FSAR Section,3.5.1.2). Missiles from the contain-ment normal air circulation unit fans can penetrate the fan casing (through a neoprene boot connecting the fan to the ducting), but based on a subsequent review, there are no adverse consequences to structures, systems, or components required for safe plant shutdown. This change will be incorporated in a future amendment to the FSAR. No changes have been identified as needed to FSAR Section 3.5.1.1, which addresses internally generated missiles from fans located outside containment.

4. As indicated by Reference 3, all Unit 1 fans in containment have been reinspected to assure conformance with correct attachment and correct blade angle.

5. Assurance that this condition will be precluded is being pursued by Bechtel Engineering. A meeting is scheduled to be held with repre-sentatives from Joy Manufacturing, The Waldinger Corporation, CVI Corporation and Bechtel Engineering to clarify and assign responsi-bili.ty for assuring that Joy vane axial fan blades are adjusted and torqued per specification requirements prior to being activiated for Units 2 and 3.

Report No. 82-53 Rev./Date 1 7/7/83 Page 3 Final Report

6. Based upon the evaluation of this failure, it has been determined that no additional physical protection of safety related equipment is required.

REFERENCES

1. Joy Manufacturing Co. Report No. X-992, "Failure Analysis of 54-26-1770 Steel Returned on NPR-97152 from Palo Verde Nuclear Station", dated 'otor October 22, 1982.

2. Bechtel's Material and Quality Services Trip Report, M&QS Log No. 280157, dated October 1, 1982.

3. The Waldinger Corporation "Verification Report" for Joy fans, attachment to Bechtel Power Corporation Letter B/CVI-E-42846 to CVI Corporation, dated December 6, 1982.

4 REFERENCE 1 to DER 82-53 REPORT NO.

gATE October 22, 1982 JOY V(ANUFACTURING CO.

NEW PHtLADELPHIA. OHlO FA I LlJPS ANALYSIS OF 54-26-1770 STEEL POTOR Rl:TlJB.'!)ll) 0:l NPR-!)7}5?

FRO'. l PALO VERDE Nl)CLEAR STATION pREpARED BY T.A. Jlissettl CHECKED BY p,ppROppD By Dr. J.A. t'.urphy//.

RKVlSlONS DA7K PAGEOS AFFEC7KD REMARKS 8309090307 830901 PDR. ADOCK 05000528 8 . PDR

JOY MANUFACTURING CO. FACrR ~

CNP NEN PHILADELPHIA, OHlo %FAT RO, >; no2

~PQPQp ~ I . A. l3issot l CHKCtCED W ":nnt e GATE Actoher 22, )982 BAC)'GROUND Fan Unit GF-21587 (Customer Mark No. 1-M-!le"-A01-B) was shut do>>n on 9-13-82 when a high amperage condition was noted. Investigation revealed that there had been a blade failure. This fan is a Model 54-26-1770 >>itl a cast stainless steel hub and blades. It was shipped on ?- 19-79 on JOY Shop Order hlPX-60083. The operating dut> is listed at 80,000 CF."l at 7.15 inches total pressure. Factory setting based on an AMCA test performed on the first unit is 15 tip angle (hub angle 45-3/4 ). The customer has reported a total running time of the unit of 1116 hours0.0129 days <br />0.31 hours <br />0.00185 weeks <br />4.24638e-4 months <br />.

The entire unit, including failed blades, >>as returned to JOY Manufacturing Company for inspection and repair.

I.'~S PECTI O.'l The unit >>as inspected on 9-28-72. Initial inspection showed that three (3) blades had brol'en; one (1) on the airfoil and two (2) in the threaded shank. There was some damage to the casing but nothing that cannot be repaired. (See photos 1 thru 5). One (1) of the vanes

>>as bent but it can be straightened. The conduit pipe was missing and the motor load wires completely covcrecl with grease. Two (2) of the rear support rods were bent but not broken although the eyes on the ends had split.

The rotor could still be rotated by hand but it >>as tight indicating that the bearings were in a failure mode. The nose was then removed. The safety wire was still in place although one (1) piece had been damaged. The two (2) blade shanks with nuts were still inside the nose., It was noticed that of the thirteen (13) remaining blades, ten (10) werc loose in the hub. The thrcc (3) blades that were still tight were at a somewhat lo>>er angle than the unit had been operating as indicated by the dirt pattern on the hub (see photo 6). This same dirt pattern was visible on all socl ets except one (1),

hleasurements were made for both settings. See Figure 2 for results.

JOY MANUFACTURING CO. PAGE 2 OF

'n~

REPORT NO.

NEW PHILADELPHIA, OHIO PREPARED BYF ~.

CHECKED BY DATE October 22 ]9%>

A crack>>as also noticed on the convex surface of one (1) of the airfoils. See photo 7.

The blades were numbered consecutively starting at the key>>ays and proceeding clockwise as one looks at the leading edge of the rotor. See Figure 1. The airfoil with the crack became Ko. 11. The blades >>ere then re-moved from the hub.

ANALYSIS Inspection of the failed blades revealed that the airfoil failure (Blade No. 5), photos 8 and 9, and one (1) shank failure (Blade No. 3), photos 10 and 11, were overload failures resulting from impact. Blade Yo. 7, ho>>ever, had the appearance of a classic fatigue failure. See photos 11 and 12. Blade Ko. 11 was sawed so that the crack could be broken out. See photo 13. - This crack

>>as also a fatigue crack which had initiated in a casting flaw on the convex surface of the airfoil.

Chemical analysis was performed on the sample blades.

Results are listed in Table 1. Specimens were obtained from the shanks of the blades. Results indicate that the material is 17-4PH. Some variability is evidenced but none can be considered significant enough to affect the physical properties, response to heat treatment, or resistance to corrosion.

Physical test results are shown in Table 2 and are in agreement with the requirements for 17-4PH material.

Hardness testing revealed all five (5) blades to be within the range of 32 to 36 HRC.

PAGE 3 OF JOY MANUFACTURING CO. REPORT NO. '-on~

NEW PHlLADELPHlA, OHlO PREPARED BYT'A. Bi <<c CHFCgED By R. D. Foote DATF October 22 1982

,Sections of the blade shank were polished and etched to reveal the microstructure. No undesirable constituc))ts such as eutectic carbides, grain boundary films, etc.,

were detected. Some interdendritic micro-porosity was present in small amounts. The microstructure consisted of lo)i carbon martensite )iith a second phase of retained delta ferrite, which is typical.

Yormal operating stress in the blade shank is 20,4!)0 l'Sl resulting from the centrifugal force of tl)o bl))dc.

Normally, bending does not exist at this location because of the method of attachment. For Blade No. 7, the final overload section (center) was approximately .97 inches by

.14 inches or .136 square inches. For a tensile stress of 160,000 PSI (tested value), this would support a load of 22,000 lbs. This compares reasonably with the known centrifugal load of 17,540 lbs. This is also strong evidence that the failure was relatively high cycle with low bending stress since a l)igl) bcndi))g loa<l )~~>>)ld I):)ve caused failure with a much larger center area remaining.

SLhl fractography of this surface did not reveal any defects at either crack origin that would be responsible for easy fatigue crack, initiation. This same SEhl fractography reveals a striation spacing that is shown in Table 3. This spacing is apparently in conflict with the rest of the evidence since it would imply a relativel> low number of cycles. However, calculating the number of cycles from striation spacing is not very accurate especially with a relatively high mean stress.

For the stress at the base of the airfoil, refer to Figure

3. At the radial location of the crack found in Blade Ko.

the stresses are 15,300 PSI on tl)c concave surface anti '1, negative 300 PSI on the convex surface. Note that the crack initiated on the convex side which has practically no normal operating stress. SEhl fractography of the fatigue surface reveals the presence of striations with spacings as shown in Table 4. One cannot calculate the number of cycles exactly for this case either. However, tests indicate that for similar types of loading, the actual number of I

cycles is approximately- 30 times the number of striations.

Assuming an average striation spacing of .0003 inches yields a number of cycles of 47,000. At 1770 RPM, the total time for crack propagation is from 13 to 26 minutes depending on whether there was 1 or 2 cycles per revolution.

PAGE 4 OF 26 JOY MANUFACTURING CO. REPORT NO NEW PHILADELPHIA, OHIO BY i . A. Bi X-W'REPARED s et t CHECKED BY R.D.

DATE October 22 1982 Comparing normal operating loads to the type of loads necessary to create the failure quickly leads one to the conclusion that there were obviously significant variations from normal operating conditions to lead to the failure sequence.

From previous information, we know tl>at the inlet conditions for this particular fan are such that a considerable flow distortion will be present. This, of course, imposes additional cyclic load on the blades. This fact alone would probably not )>ave caused a 1>1;>dc p>ol>je>I>. Ilo>>eve>.,

t)>e inspection revealed that the blades wore loose in the h>>b. This allows all cyclic loads to be transferred to the threaded blade shank >>'hich is not intended to carry such loads. 4'ith the blade being free to rock in the hub, it is possible to calculate stresses as high as 150,000 PSI, depending on the amount of tipping that is assumed. In addition, once the blade is loose, the stress concentration factor in the threads becomes a significant factor on bending stress.

COYCLUSIOiS P

Based on the above, the most likely sequence of events seems to be:

1. Inlet conditions>>ere such that flow distortion existed and imposed additional cyclic load on the blades.

At least ll of thc IG fan I>);>>les I>ec;>>>>c 1<>>>s>> i>> tl>c I>>>l>..

This allowed the cyclic load to t>o trans crrod to tl>e threaded shank leading to a fatigue crack on Blade No. 7, which progressed from both sides (reverse bending) of the shank until there was not enough area left to carry the centrifugal force. Overload failure of the center section of the shank occurred at this point.

JOY MANUFACTURING CO. PAGE S OF 26 REPORT NO. X-99 NEW PHILADELPHIA, OHIO PREPARED BY CHECKED BY R.D: Footo DATE October 22 19 2:

4. Impact with the airfoil section of Blade No. 7 caused the overload failures on Blades No. 3 and No. S.

P S. The extremely high unbalance force created by three (5) blades missing in one quadrant caused a hcavy tip ~ub on these blades opposite this quadrant. Looking at photos 4 and 5 i t llpI)oa rs tl)at' hi s h<<nvy rIIh o<<<<uI'I'<<d at two (2) locations on the casing. This means there would be a very high intermittent bending load applied twice per revolution. This intermittent load led to fatigue crack at the weak point, which was the casting defect near the base of the airfoil on Blade No. 11.

This fatigue crack would not have initiated without the very heavy tip rub created by the initial blade failure. This is also consistent with the findings of the SEM fractography where the striation spacing indicates a relatively high stress, lo>> cycle fatigue crack.

The only question left unanswered is why did the blades become loose in the hub. This is totally inconsistent with the operating history of this fan design. To our knowledge, this is the first instance of this occurring.

The most plausible explanation is that the blades were not properl> tightened. See photo 6. It is apparent from the dirt pattern on the hub that this unit was operated for some period at two (2) different settings.

One (1) setting corresponds to the factory setting. The other is about 9 lower (see Figure 2). This angle is much too uniform to have occurred randomly as the blades loosened. In addition, Blades No. 11 and 14 were still tight but at the same angle. 9, 4'e are, therefore, forced to the conclusion that someone adjusted the bind<< <<ni,les nnd in doing so noi,i <<ct<<d to properly tighten the blade nuts. This allowed the blades to work loose and thus led to the fatigue failure on Blade No. 7 by the sequence of events explained previously.

' OF JOY MANUFACTURING CO. PAGE NEW PHILADELPHIA, OHIO REPORT NO.

PREPARED BY '. ""so't CHECKED BY R. D. Foote DATE Oc Note that the inspection revealed that the motor leads were covered with grease. In addition, there was a considerable amount of grease on the back side of the C-face mounting plate. This obviously had nothing to do with the blade problem, however, it does indicate that the motor has been ovorgroasod nnd Is l)ujtc likely full of grease. If this is the case, it lead to overheating of the motor, since air cannot could circulate properly inside the motor. Natuially, this motor must be checked and cleaned if necessary.

addition, all other motors at the job site should be In checked for this overgreasing condition to avoid premature winding failures.

7 OF 25 JOY MANUFACTURING CO. PAGE REPORT NO.

NEW PHILADELPHIA, OHlO pREpARED By I'.A. 1$ > sect<

By R. D. Foot e DATE October 22, 19S2 TABLE 1 CHEh/ICAL ANALYSIS RAliGE 2428hf 2731hh 2355hh 3240hh 2370il ll4 II 5 II 7

.06 max. . 053 . 049 . 049 .050 0 1'I

.70 max. .66 .56 .74 .69 Si .50-1.0 .92 1.0 1.0 .71 .97

.03 max. .018 .013 .017 .013 .016

.04 max. .019 .016 .021

'5

. 014 . 018 Cr 15.5-16.7 15 6 7 15.5 15.4 15. 5 3.6-4.6 4.1 3.6 D~ 7 3.8 CU 2. 8-3. 5 3.0 2.8 2.8 2.8 2.8 J

Cb+ .15-.40 .15 .10 .16 .21 .16 ja

8 26 JOY MANUFACTURING CO. PAGE OF REPORT NO NEW PHlLADELPHlA, OHlO PREPARED BY T A- Bissett CHECKED ~Y R.D. Foote DATE October 22 1982 TABLE 2, PHYSICAL PROPERTIES S/N 2731M 'S/i4 3240 H Tensile Strength (ksi) 167 160 105 min.

Yield Strength (ksi) 151 150 85 min.

Elongation ('-') 9.5 Reduction of Area ('o) 19 3b Hardness HRC 33 33 36 max.

9 OF 26 JQY MANUFACTURlNG CO. PAGE REPOW No. >'->>2 NEW PHILADELPHIA, OHIO PREPARED BY l'.A. >>>>ett CHECKED BY DATE October>> o TABLE 3 STRIATION SPACING ON BLADL SllANK BLADE NO. 7 STRIATION SPACING CRACK LENGTH (a) inches inches

. 0005 .25

.0006 . 34 ( I)

. 0010 . 34 (I)

.OOOG .44

.OOOS .47 (I) TllESE TWO POINTS li'ERE VERY CLOSELY SPACED.

xo OF JOY MANUFACTURING CO. PAGE REPORT NO. X-egg 2

NEW PHILADELPHIA, OHIO PREpARED BY T.A. B jsset t CHECKED BY DATE October 2> o ~

TABLE '4 STRIATION SPACING AT BASE OF AIRFOIL BLADE NO. 11 STRIATION SPACING CRACK LENGTH (a) inches inches

.00025 .10

.00050 .1S

~ 00070 .41

.00067 .47

JOY MANUFACTURihJG CO. ~K >i OP RK PCS T BQ,~ovr NEW PHILADE.LPMlA, OHIO Fft~P~P 5Y T.A. I'issett CVCCWF.O Sv QATK Octo'net 22 1<782 VERY SYUG BUT VERY hQVABLE LOOSE SIIA;:K VEP.Y 16 FAI LOOS"" Llll!L'nVFRLOAO) 15 VEP.Y TIGIIT LOOSL 14 4 AI RR)I L VEPY FAI I.URE LOOSE Vl:PY VERY A ~ LnnsE LOOSE 7

SHA.'I TI Gl IT AIRFOIL) FAI LAIR.":

(CPACK 0.'i 10 (I AT I Gill!)

S.':UG BUT VERY hlOVABLE LOOSE TI Gl I.

LOFTI'ING AT LEADING EDGE OF ROTOIi FIGURE 1 SUhlrIARY OF BLADE STATUS D'IUB

JOY MANUFACTURING CO. &OK >2 OP RP.PORT KCL NEW P H I LADE L P H I A, QH IO PRKPAPZO BY 3<'~t t CHECVEOSY R.D. F DATE October 22 19S2 4 50/35 44 /37 45 /35

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16 4 60/3 45 /37 43 /9o 0

43 /34 0

I 13 45 /37 43 /35~q

~12 6

~ 45 o

/37 11 7

430/34o . ~45/36 an 9

43 /36 45 /36 450/36 HUB Ai'GLES AS 33EASURED FROll DIRT PATTEP" ON 33UB. A'.lGLES ESTABLIS33ED BY INSTALLING A BLADE > LINING UP 3 'Tl 3 T33E DI RT PATTEVi T}3EN MEASURING G A lGLE ~

FIRST NUllBER CORRESPONDS TO ORIGI."lAL SETTIl'G. SECOND PATTERN ON BLADE NO. 4 3'I'AS NOT SUFFICIENTLY VISIBLE TO ESTABLISll A.<GLE, FIGURE 2 33UB ANGl.E VS. BLADE NUi~lBER

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JOY MANUFACTURING CO. PAGE 16 OF 26 NEW PHiLADELPHIA, OHIO REPORT NO.

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JOY MANUFACTURING CO. PAGE 25 OF 26 REPORT NO. X-99 NEW PHlLADELPHIA, OHlO PREPARED BYT.A. Bissett CHECKED BY R.D. Foot DATE October 22 Ig

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11

REFERENCE 2 to DER 82 53

'ECN1 ..L'ROUP, INC.

'esearch and Engineering Materlals and guallty Services Letter File No.

~TT.

October Date 1 1982 To: R. A. Keidel From: R. A. White 1 L

Subject:

%RIP REPORT Project Name Palo Verde Project No. 10407-002 Project Spec. No..

MhgS 13-hD-620 Log No. 280157

~OT F ~T Destination:

1 ew Phil del hia io Copies to: B. D. Hacknl;y/R. A, Manley Z. Milatovic'.

T eof Tri:

A. Fakhri Y, G. Bingham Q] Supplier arne C3 Client C3 Jobsite PURPOSE OF TRIP:

To determine cause of blade failure on a vaneaxial air conditioning fa 108 l0407 nR INTRODUCTION/DESCRIPTION OF PROBLEM:

~

A vaneaxial fan failed at the Palo Verde jobsite after 11,016 hours1.851852e-4 days <br />0.00444 hours <br />2.645503e-5 weeks <br />6.088e-6 months <br />. utilt+.~au was removed and shipped back to Joy Mfg. for examination, 8 Sh(SS IJT %tliH The fan blades are cast 17-4PH made by Valcast. The hubs are CA40.

washers that hold the blades to the hub'are galvanized steel.

CONCLUSIONS AND RECOMMENDATIONS".

1. The blade failures were a result of the blades being loose.

2. The motor appeared to be overgreased.

All similar fans at the jobsite should be checked for torque, blad g for cracks visually. The blades in the fan that has operated the on estWoa be liq u'd x p enetrant t e st e d (PT) (wxtho ut dxssassemblxng) on both sides. All examinations should be witnessed by a Joy representative.

4~ The motors should be checked to determine if any others are over greased.

Zl h 0 0 C

g Page 1 of >

with Attachment

SECHTEL GROUPS INC.

Research and Engineering

teria1s and gua1ity Services Letter F(1e No.

October 1, 1982 To: R. A. Keidel Froal: R. A. Mite SubJect: .TRIP REPORT (continued)

ProJect Name Palo Ver e I J <<II PART I C I PANTS: COHPANY OR 'PR(MECT AFFILIATION AND TITLES HARE See Attached Sheet OETAILS OF INVESTIGATION (discussion of observations, action taken and other pertinent data):

At the time of our arrival the fan had been removed from the housing. The condition was as follows:

All blades (or pieces of blades) were loose on the hub.

There is dust evidence that the blades ran at two different pitches.

3. One blade failed in the threaded shank by alternating tension - compression.

4. One blade failed in the threaded shank by overload.

5. One blade failed away from the shank from overload.

6. One blade was severely deformed and had a piece missing.

7. One blade had a straight crack away from the hub, parallel to the tip.

8. The remaining blades had various nicks and other signs of mechanical damage.

9. Tip rubbing was evident on most blades except the ones that failed.

lO. There were two holes in the housing where failed blades had penetrated.

N5(S EPRESENTATIVE:

e 0 Page 2 of 3

Trip Report Job No. 10407 DETAILS OF INVESTIGATION CONTINUED

11. .The motor electrical leads were covered with grease. Joy reported the bearings were "gone", i.e. badly worn.

12. The hub had only a couple of very minor gouges.

The blades were removed from the hub and fluorescent penetrant inspected. There were some minor surface indications but no additional cracks were detected. The blade that was cracked was cut and broken to reveal the fracture face. This revealed a semi-elliptical crack typical of fatigue from one side. s Valcast agreed to take 5 of the 16 blades (representing the three heats involved) and run chemistry and tensile properties. They also agreed to run scanning electron microscope examinations of the two fatigue failures. This will reveal striation spacing so that a stress level and a stress intensity range (hK) can be estimated. Results should be available about October 8.

I Joy agreed to get a representative to the jobsite about October 4 so the remaining similar fans can be checked.

The fan at Joy should be repaired in about two weeks. The time required to clean the motor governs this schedule.

Joy mentioned that tip rub may not result in a surge in amperage, which was the reason the fans were shut off and examined.

RAN/nl j page 3 of 3

Trip Report Job 10407 PARTC I PANTS:

NAME C(MPAhY OR PROJECT AFFILIATION AND TITLES a

Thomas Bissett Joy, Project Engineer John Neurnyer Valcron (Valcast), Sales Eng.

Leonard Ceriotti Valcast, Division Mgr.

Joe Gersinger Valcron/Valcast, Sales Dept.

Loren Milatovic'.

Bechtel, HVAC Group Ldr.

A. h'hite Bechtel, Materials 5 Corrosion Group Mgr.

John Murphy Joy, Mgr.-Engr.

Barry Scholles Joy, Product Mgr. - Nuclear Frank Pietro Joy, Appl. Engineer - Nuclear Mel McAfee Joy, Q.A. Analyist

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REFERENCE 3 to DER 82-53 bcc: W. G. Bingham R. R. Stiens D. R. Bonano V. Najarian J. R. Schuh All v/o encl.

B/CVI-E-42846 MDC 230177 December 6, 1982 CVI Corporation P. 0. Box 2138 Columbus, Ohio 43216 Attention: hr. Gene ayers Prospect Engineer

Subject:

hrirons Nuclear Pover Pro)ect Bechtel Job 10407 Verification Report for Joy Fans File: M-620

Dear Nr. ayers:

Please find enclosed the Verification Report of blade angle and loci. nut torque for Containment Building Joy vane-axial fans'his rcport vas prepared by Waldingcr s personnel in con)unction vith Joy s representative.

This report covers Unit 1 fans only. We request that you provide us your plan of action to assure that a similar problem does not occur on Units 2 and 3.

Please respond by December 15, 1982.

Very truly yours, BECHTEL POWER CORPORATION ORIGINAL SGNED BY.'.

NAJAfgAN M. C. Bingham Pro)ect Engineering Manager Los Angeles Pover Division yes gRGB: ZM: gt

Enclosure:

Verification Report (31 pages, 1 copy) cc: K. K. Van Brunt, Jr. v/encl.

C. C. hndognini v/encl.

J. R. Bynum v/o encl.

D. B. Pasnacht v/encl.

J. M. Allen v/encl' v/encl'PS/DDC

'.lE HEREBY CERTIFY THAT EACH BLADE LOCKNUT HAS BEEN VERIFZFD OR RE-TORQUED TO A'ALUE OF 400 FT.(LBS., AND EACH BLADE TIP ANGLE (AS SPECIFIED BEl.OW) VERIFIED OR RESET, ON THE FOLLOWING FANS:

~

FAN UNIT TAG NO ~ SERIAL NO. TIP ANGLE 0

~1-M-HCN-FOlA (2-STAGE)

~

GF-21598 264'64'5

-I-M-HCN-FOIB (2-STAGE) GF-21599

<<1-M-HCN-AOIA (SINGLE STAGE) GF-'L1586 M<<M"HCN-A01B (SINGLE STAGE) GF-21595 W-M-HCN-AOlC (SINGLE STAGE) GF-21588 1-M-HCN-A01D (SINGLE STAGE) GF-21589

+1-M-HCN-A02A (2-STAGE) GF-21608

~ 1-M-HCN-A02B (2-STAGE) GF-21609

,' 1-M-HCN-A02C (2-STAGE) GF-21610

• 1-M-HCN-A02D (2-STAGE) GF-21611 I-M-HCN "A03A (SINGLE STAGE) GF-21616 15'5'5'4'4'4'4'9'>'94'9'>'9'.'SECOND

~ I-M-HCN-A03B (SINGLE STAGE) GF-21617 1-M-HCN-A03C (SINGLE STAGE) GF-21618 1-M-HCN-A03D (SINGLE STAGE) GF-21619 STAGE ROTOR HAS NOT BEEN VERIFIED.

CL DE LESTER ETHRIDGE DATE JOY MFG. FIELD SERVICE

~

REPRESENTATIVE R.e, R. B. (BUCK) K1SSEL DATE ASSISTANT PROJECT ENGINEEK THE WALDINGER CORPORAT10N

JOY VANEAXIAL FAN QUALlTY CLASS

< UNIT TAG NO. I-M-HCN-FOIA SERIAL NO. GF-21598

~ 34" DIA. 26" S.S. HUB SERIES 2000 2 STAGE BLADE LOCKNUT TORQUE: 400 FT./LBS.

TIP ANGLE: 26'p R 8 c; T I

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VERIFIED BY:

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Cl DL LEST>.R ETH IDGE JOY MFG. FIELD SERVICE REPRESENTATIVE BLADE LOCKNUT TORQUi: 6 TliN(:l.i'. VERIFIED i>:

Blade No. +1 - 280 - 300 Ft./I.hs. 9 - 400 Ft./Lbs.

2 400 Ft./Lbs. 10 - 400 Ft./Lbs.

3 - 400 F t . /I.bs. 11 - 400 Ft./Lbs.

4 - 400 Ft./Lhs ~ 12 - 400 Ft./Lbs.

5 - 400 Ft./Lhs. 13 400 Ft./Lbs.

6 - 400 Ft./Lbs. 14 - 400 Ft./lbs.

7 - 400 Ft./Lbs. 15 - 400 Ft./Lbs.

8 - 400 Ft./Lbs. 16 - 400 Ft./Lbs.

• Indicates Balanci>>g Height L'as Added To Blade.

'OY ViNEAXIAL FAN QUALITY GLASS "R"

UNIT TAG NO. 1-N-HCN-F01A SERIAL NO. GF-21598 34" DIA. 26 ' ~ S ~ HUB SERIES 2000 - 2 STAGE BLADE LOCKNUT TORQUE: 400 FT/LHS.

TIP ANGLE:

26'.'ECQYD TAGE

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/

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J .. w . ~ vERIF1ED B'l:

r

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C DE LESTER ETHRIDGE JOY HFG. FIELD SERVICE REPRESENTATIVE BLADE LOCKOUT TORQUE b TIP ANGLE VERIFIED (~:

BLADE NO. - 400 Ft./Lbs. 9 - 400 Ft./Lbs.

2 1

- 400 Ft./Lbs. 10 - 400 Ft./Lbs, 3 - 400 Ft./Lbs. 11 . 400 Ft./Lbs.

4 - 400 Ft./Lbs. 12 400 Ft./Lbs.

5 - 400 Ft./lbs. 13 400

- 400 Ft./Lbs.

- Ft./Lbs.

6

-

400 Ft./Lbs.

Ft./Lbs.

14

- 400 Ft./Lbs. 2'ff 7

8 -

400 400 Ft./Lbs. 2'ff 15 16 << 400 Ft./Lbs.

,JOY VANEAXIAL FAN - QUALITY CLASS "R" UNIT TAG NO 1 M HCN FO 1B SLRIAL NO ~ GF-2 1 599 34" DLK. 26" S.S. HUB SERIES 2000 - 2 STAGF BLPJ)E LOCKNUT TORQUE: 400 FT./LBS.

TIP ANGLE:

26'IRSTS

/~ TAG E I

O X., "/

r'ERIFIED BY:

t

.r / DATE erg 8' YDE LESTER ETH DGE JOY MFG. FIELD SERVICE REPRESENTATIVE BLADE LOCKNUT TORQUE 6 TIP hNGLE VERIFIED (a:

Blade No. *I 360-380 Ft./Lbs. 9 - 400 Ft./Lbs.

2 - 400 Ft./Lb&. 10 - 360-380 Ft./Lbs.

3 - 400 Ft./Lbs. 11 - 400 Ft./Lbs.

• 4 - 400 Ft./Lbs. 12 - 400 5 - 400 Ft./Lbs.

Fr./Lb'3 400 Ft./Lbs.

6 - 400 Ft./Lbs. 14 - 400 Ft./Lbs.

7 - 400 Ft./Lbs. 15 - 400 Ft./Lbs.

- 400 Ft./Lbs. 16 - 400 Ft./Lbs.

l l *indicates Balancing l'~igbt Was Added To Blade.

JOY VANEAXIAL FAN - gl'ALITY CLASS'R" UNIT TAG NO 1 H HCN FOlB SERIAJ NO ~ ('F 21599 34" DIA. 26" S.S. HUB SERIES 2000 - 2 STAGE BLADE LOCKNUT TORQUE: 400 FT./LBS.

TIP ANQLE: 26'g SECOND STAGE I

~ ~

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VEkIFIED BY:

C 6M

'DE LESTER ETHRTDGE '

~ J::/'M~-~

JOY MFG. FIELD SERVICE REPRESE"TATI VE BL',DE LOCK'.:UT TORti"E 6 Tl p ANGLE VERlFIED 0:

Blade No. *1 - 400 F t . /l.bs. 5'g" i 9 400 Ft./Lbs. 5g'ff 2 - 400 Ft./Lbs. 5' Off lo - 400 Ft./Lhs. 5'~'i f 3 340-360 Ft./J.bs. 5sg'f 11 - 400 Ft./Lbs. 5'e'f f 54'ff C

- 400 Ft./Ll s. 5l..' Off 12 - 400 Ft./Lbs.

5 400 Ft./Lhs. 5'~' Off 13 400 Ft./Lbs. 5Q'f f 6 400 Ft./Lbs. 5'"' Off 5','f 14 - 400

- 400 Ft./Lbs. 5o'ff 7 400 Ft./Lbs. 5' Off 15 Ft./Lbs. 5'0 Of f 8 400 Ft./Lbs. Off 16 - 400 Ft./Lbs. 5" Off Note: See Attached Verification Report Concerning Tip Anglos.

"Indicates Balancing I'eight V;:s Added To Blade.

VERIFICATION REPORT UNIT TAG NO. 1-M-HCN -F01B SECOND STAGE

REFERENCE:

A) CVI FINAL ASSEMBLY DRAtA',ING FF-1S624 Rt:V. A BL'CHTEL LOG NO. 13-10407-M620-63-2 B) JOY BLADE SETTING VS. HUB/TIP ANGLE DRAhIING NO. FF-12088 RZV. D SHEET 3 of 10 - ATTACHED VERIFICATION OF TIP ANGLES HAS PERFOR-"FD ON SECOND STAGE ROTOR ARITH THE FOLLOWING RESULTS:

(1) LAYOUT OF TIP ANGLE ON SECOND STAGE REFLECTED A 32'NGLE.

(2) LAYOUT OF TIP ANGLE ON FIRST STAGE RESULTED IN A 26 ANGLE.

(3) REFERENCE A) DRAVING FAN DATA SPECIFIES A 4 3/4 BLADE.SETTING.

STAINLESS STEEl- ROTORS DO NOT HAVE SETTING INCREMENTS AT ROOT OF BLADE. CROSS-REFERENCING ATTACHED REFERENCE B) DRAVING INDICATES AN APPROX. 26~'EQUIRED TIP ANGLE FOR A 4 3/4 BLADE SETTING. LES ETHRIDGE (JOY NFG. FIELD SERVICE REPRESENTATIVE)

CONFIRl'LED THE 26'~'IP ANGLE L~IITH INFOR."MTION SUPPLIE.D, FRO" JOY ENGINi;iRING.

TIP ANGLES MERE CORRECTED ON SECOND STAGE REFLECTING REQUIRED TIP ANGLE AND FIRST STAGE ROTOR.

R. B. (BUCK) KISSEL

'SSISTANT PROJECT ENGINEER DATE

-. i UNLESS OTHERWISE NDTED ALL DIMI:N Ir'NS IN lNEIIES; MAElllllur. OIMrNRlONS LINlrrO TD TRACTIONAL E MAR HARDEN 4 I.N OVEN CK OUENCH Ilai, AVI.

MARONESS trECIA8AL + .009, ANISIJLArt .:

II . TE.VC'TI <RAI. OIKI N9ION.. LI88ITI'0 TO ' I IO. T30 NOT SCALE THIS ORAWINCI.

~

~rRtrS "rDII - rf~SnL SITI TVI, VS Blede P/H 3387210-2 Contralleble PitcIT Ill%  % TIP hNINLLS Glade P/N 3387ZII3-1 26~ Hub Setting 0

Hub Angle De Kreee 63~

34 50 i 47 3R '2lI TI)'NGLI: -

400 I II 5 Of:GRf.rS 54 60 '6 25 58 A IIZ I geI) I r 8r<

40 15 I

32 '9", Z39 ZL 17

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43 . 30 27 Z lf4 ~

'. ZII" 38 25 ZZ 0 6 20 17 I,IIL i 18$ 8$

- 'MI zs 9i P 51.

10 i -1t+

7

-~ -lst~ -8i 8 I I<sr 2~3 9 18 5 2 -13 I -16 t5 I

0 88 isi K

ir9 I Cn psi 1 II<s d<8wsng And All <nfntrsit<<in ~ 'sesr <<" Its prnpelsi ill <lie It ll'll ts ('(I ~ ILL<I<<I<de<<t<SI 8<<dmuit n<<t Isc made ps<NIL <rr As'p<ed I: si I<Tasse<I <<st Ie.t:Ai Ietu<<<<<IH<<s din<8<id. IL n"< I<<he uEed dltedir ut <ndsr. Rh in ane PATTERN N M83 Jets<<nertal ti~ nut <merci<

I f INlbM SYMSOL5 JOY MANUFACTURlNG CO. SL'RIES ZtNIO BLADF. SETTINC VS IIBtTIP 58 ArrO ANGLF. FOR AJ.L FAN DXhWTFRS

'CtSCIIIPTIOH S O'E5CNIPTIOH PLANT LOCATION AS INCI<t TIL LOW INCH55 I,s Du Or Is' I s Crt. by APPD. Or ~ IA H~

Pnf CISIOII POLI5H C 250 NCIIGH 888CII nurl ALO. N r 'sf 8s I' ll A'rl PI

~ ~

<A CAtt fliTt DArt bitt Af first POLISH H 500 Htiyr nCIIIIAH t LANI NONT. N H.

ACALC CLASS buVERSEOE ..

CCIINON POLISH 5 1000 ta HTAVe ROIICH rRJNNLIN. PA:

CIRHD OR tOUAL t'L ONTARIO. CA<I, SIIPKRSEOEQ Oy F F ling a~.

TI fl SNPOTH itACH. 8. rrtsrt si,O .It!TLAL E I

Joy vaneaxzal. Fan - Quality Class "R"

'nit

.

Tag No. 1-M-HCN-AOlA Serial No. GF-21586 54" Dia. 26" S.S. Hub Series 2000 - Single Sta>e Blade Locknut Torque: 400 Ft./Lbs.

Tip Angle: 15 I P~

.,// /

YERIF1ED BY:

.r' I ~ )

C e Lester Et ri ge Joy Mfg. Field Service Representative Blade Locknut 7or ue 6 Ti An le Verified 9:

Blade No. *1 - 280 - 300 Ft./Lbs. 9 - 400 Ft./Lbs.

2 400 Ft./Lbs. 10 - 400 Ft./Lbs.

• 3 320 - 340 Ft./Lbs. 11 - 400 Ft./Lbs.

4 400 Ft./Lbs. 12 - 400 Ft./Lbs.

5 400 Ft./Lbs. 13 - 400 Ft./Lbs.

6 400 Ft./Lbs. 14 - 400 Ft./Lbs.

7 - 400 Ft./Lbs. 15 - 400 Ft./Lbs.

8 320 - 340 Ft./Lbs. 16 - 400 Ft./Lbs.

• Indicates Balancing height Has Added To Blade

JOY VANEAXIAL FAi< - guALI'l'Y CLASS UNIT TAG NO. 1-l'l-HCN-A01B SERIAL NO, GF=215)5

" 'TAGGED 3-li-HCN-A01B DUE TO NCR NO. SH-]167)

( 54 DIA 26 S S

~ HUB SERIES 2000 SINCLE STAGE BLADE LOCKNUT TORQUE: 400 Ft./Lbs.

TIP ANGLE: 15' f/ ~

VERIFIED BY:

TEgj. ',

YDE LESTER EL5 IDGE JOY liFG. FIELD SERVICE REi'RESENTATIVE BLADE LOCKNUT TOROU" & T1P ANGLE VERIFIED g; BLADE NO. 1 - 400 Ft./Lbs. 9 400 Ft./Lbs.

2 - 400 Ft./Lbs. 10 400 Ft./Lbs.

• 3 - 340-360 Ft./Lb *11 340-360 Ft./Lbs.

4 - 400 Ft./Lbs. 12 400 Ft./Lbs.

5 - 400 Ft./I.bs. 13- 400 Ft./Lbs.

6 - 400 Ft../I.bs. 14 400 Ft./Lbs.

• 7 - 360-380 Ft./Lbs. 15 400 Ft./Lbs.

8 - 400 Ft./Lbs. 16 400 Ft./Lbs.

• Indicates Balancing Weight Was Added To Blade

JOY VANEAXIAL FAN - QUALITY CLASS "R" UNIT TAG NO. 1-H-HCN-AOID SERIAL NO. GF-2]589 54"'DIA. 26" S.S. HUB SERIES 2000 - SINGLE

(

BLADE LOCKNUT,TORQUE:

~

400 Ft./Lbs.~

TIP ANGLE: 15

'

/

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.

/

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F IE3 BY:

VERI." Y

/

rrC/c4'DAT" 'i'-C.".

~YDE LESTER ETH IDGE JOY HFG. FIELD SERVICE REPRESENTATIVE BLADE LOCKNUT TOR UE & TIP ANGLE VERIFIED g:

BLADE NO. 1 - 340-360 Ft./Lbs. 9 320-340 Ft.!Lbs.

2 400 Ft./Lbs. 10 400 Ft./Lbs.

3 400 Ft./Lbs. 11 320-340 Ft./Los.

• 4 280-300 Ft./Lbs. 12 400 Ft./Lbs.

5 400 Ft./Lbs. 13 400 Ft./Lbs.

6 400 Ft./Lbs. 14 400 Ft./Lbs.

7 - 400 Ft./Lbs. 15 320-340 Ft./Lbs.

• g 320-340 Ft./Lbs. '"16 320-340 Ft./Lbs.

JOY 'VANEAXIAL FAN QUALITY CLASS "R" UNlT TAG NO. I-N-ilCN-AO A Sl'.RlAL NO. GF-21608 45" DIA. 26" S.S. HUB SER1ES 2000 2 STAGE BLADE LOCKNUT TORQUE: 400 FT./LBS.

TIP ANGLE: 24 F I RST STAGE

,

,/,/,

VERIFIED BY:

C DE I-ESTER ETHRIDGE JOY MFG. FIEI.D SERVICE REPRESENTATIVE BLADE LOCVNUT TOROUL' Tll'NGl.l; VL'RIFIED g:

Blade Nc. *I - '400 Ft./Lbs. 9 - 400 Ft./1 bs.

2 - 400 Ft./I.bs. 10 400 Ft./Lbs.

3 - 400 Ft./Lbs. 11 - 400 Ft./Lbs.

4 - 400 Ft./Lbs. 12 280-300 Ft./Lbs.

5 - 400 Ft./Lbs. 13 400 Ft./I,bs.

6 - 400 Ft./Lbs. 14 - 400 Ft./Lbs.

? - 400 Ft./Lbs. 15 - 400 Ft./Lbs.

8 - 400 Ft./Lbs. 16 400 Ft./Lbs.

• Indicates Ba)ancing Meigbt 4'a~ Added To Blade.

JPY VANEAXIAL FAN QUALITY CLASS "R" UNIT TAG NO. 1-1'-HCN-A02B SERIA1. NO. GF 21609 45" DIA. 26" S.S. HUB SERIES 2000 - 2 STAGE BLADE LOCKNUT TORQUE: 400 FT./LBS.

TIP ANGLE:

24'IRSTS TAGE

/ '/

r' gd

~ale~=a~

VERIFIED BY:

CP'DE Ll'.STER ETllhIDgP DATE:// l~~-

JOY NFG FIELD SERVICE

~

REPRESENTATlVE BLADE LO"KNUT TOR(>UL b Tll'NGLE VERIFIEI)

- 400 Ft./L'. s.

i~.'lade Xo. 1 400 Ft../Lbs. 9 2 400 Ft./Lbs. 10 - 400 Ft./Lhs.

3 400 Ft./u s. ll -- 400 Ft./Lbs.

• 4 280-300 Ft./1.bs. 12 400 Ft./Lbs.

5 400 Ft./lbs. *13 See Attached Ver. Report 6 400 Ft./Lhs. +14 - 360-380 Ft./Lbs.

7 400 Ft./l.bs. ~15 - 400 Ft./Lhs.

8 400 Ft./t.bs. 16 400 Ft./Lbs.

• Indicates Balancing Ma:ight Was Added To Blade.

VERIFICATION REPORT UNIT TAG NO.

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- I-N"HCN-A02B FIRST STAGE

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VERIFICATION OF "AS INSTALLED" BLADE NO. 13 WAS UNABLE TP BE RECORDED. DUE TP INACCESSIBI1.ITY 'hITH THE TORQUE WRENCH (SOCKET) . THE CONFIGURATION <>F THE BALANCING WEIGHT ELIHINATED ANY POSSIBILITY OF OBTAINING A TORQUE VALUE FOR SUBJECT BLADE DUE TO THE ABOVE SITUATION, LOCKNUT VAS TIGHTENED VITH A (24") CRESCENT WRENCH, AND WE hERE UNAB E TO TURN THE LOCKNUT PREVIOUSLY ~ I HAD INSTRUCTED CRAFT TO TRY AND TIGHTEN A LOCKNUT THAT h'AS VERIFIED 9 400 FT./LBS ~ WITH THE SA'lE (24) CRESCENT WRENCH. CRAFT hAS UNABLE TO TURÃ THE LOCKNUT WITH SUBJECT WRENCH.

~s R. B. (BUC ') KISSEL ASSISTANT PROJECT ENGINEER

~ri DATE

Joy Vaneaxial Fan - Quality Class "R" Unit Tag No. I-l1-HCN-A03A Serial No. GF-21616 36" Dia. 26" S.S. Hub Series 2000 - Single Stage Blade Locknut Torque: 400 Ft./Lbs.

Tip Angle: 293,"

j7'g.

VERIFIED BY:

-~x': 2 DAT:~(" - .

C DE ESTER ETHRID z.

JOY MFG. FIELD SERVICE REPRESENTATIVE

'LADE LOCKOUT TOR UE 6 TIP ANGLE VERIFIED 9:

Blade No. *1 320 340 Ft./Lbs. *Cj 360 - 380 Ft./Lbs.

• 2 400 Ft./Lbs. *10 400 Ft./Lbs.

3 400 Ft./Lbs. 11 400 Ft./Lbs.

4 400 Ft./Lbs. *12 - 400 Ft./Lbs.

5 400 Ft./Lbs. 13 400 Ft./Lbs.

6 400 Ft./Lbs. 14 400 Ft./Lbs.

7 400 Ft./Lbs. 15 400 Ft./Lbs.

8 400 Ft ~ /Lbs. 16 400 Ft./Lbs.

"Indicates Balancing Height Was Added To Blade.

Joy Vaneaxial Fan - Quality Class Unit Tag No. I-M-HCN-A03B Serial No. GF 21617 36" Dia. 26" S. S. Hub Series 2000 - Single Stage Blade Locknut Torque: 400 Ft./Lbs.

Tip Angle: 29$

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YDE 1.ESTER ETHRIDG JOY HFG. FIELD SERVICE REPRESENTATIVE VERIFICATION OF TORQUE $ TIP ANGLES WAS UNABLE TO BE PERFORIKD ON SUBJECT FAN: DUE TO CRAFT INADVERTENTLY STARTING TORQUEING PROCESSES WHILE LES ETHRIDGE AND lESELF WERE INVOLVED IN VER-IFICATlON AT ANOTHER LOCATION. TIP ANGLES MERE CORRECTED AND EACH LOCKNUT TORQUED TO THE SPECIFIED VA1UE.

R. B. Kissel Assistant Project Engineer Date

Joy Uaneaxial Fan - Quality Class "R" Unit Tag No. 1-N-HCN-A03D Serial No. GF-21619 36" Dia. 26" S.S. Hub Series 2000 - Single Stage Blade Locknut Torque: 400 Ft,/Lbs.

Tip Angle: 295' l

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UERIFIED BY:

ic' DATE:~~ -: "

DE LESTER ETH ID FI JOY MFG. FIELD SERVICE REPRESENTATIVE BLADE LOCKNUT TOR UE 6 TIP ANGLE UERIFIED BLADE NO. >>1 360-380 Ft./Lbs. >>9 - See Attached Uer. Report 2 400 Ft./Lbs. 10 - 400 Ft./Lbs.

3 400 Ft./Lbs. 11 - 360 - 380 Ft./Lbs.

4 400 Ft./Lbs. 12 - 400 Ft./Lbs.

5 400 Ft./Lbs. 13 - 400 Ft./Lbs.

6 340 - 360 Ft./Lbs. 14 - 340 - 360 Ft./Lbs.

7 400 Ft./Lbs. 15 - 400 Ft./Lbs.

• 8- 360-380 Ft./Lbs. 16 - 400 Ft./Lbs.

I

• Indicates Balancing Weight Was Added To Blade.

VERIFICATION REPORT UNIT TAG NO. I-M-HCN-A02D FIRST STAGE VER IFICATION Or--"AS INSTALLED" BLADE NO 1 AND NO. 15 WAS UNABLE TO BE RECORDED.

DUE TO INACCESSIBILITY WITH TllL TORQUE WRENCH (SOCKET). THE CONFIGURATION OF THE BALANCING WEIGHT ELIMINATED ANY POSSIBILITY OF OBTAINING A TORQUE VALUE FOR SUBJECT BLADE.

Dl:f. TO THE ABOVE SITUAT10N LDCKNUTS hEkE TIGHTENED h'ITH A (24") CRESCENT h'R CH

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Al'D Wiki ABLE Ti OBTAIN A (1/2) TURN 0'i BLADE NO ~ 1 AND (3/4) TURN ON BLADE NO.

15. IN ADDITION, 1 INSTRUCTED CRAFT TO TRY AiD TIGHTEN A LOCKNUT PREVIOUSLY VERIFIED ~ 400 FT./LBS ~ WITH THE SA.lE (24") CRESCENT WRENCH. CRAFT WAS UNABLE TO TURN THE LOCKNUT W1TH SUBJECT WRFNCH ~

R. B. (BUCK) KISSEL ASSISTANT PROJECT ENGINEER DATE

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JOY VA iEAXIAL FAN QUALITY CLASS R UNIT TAG NO. I->I-HCN"A02D SERIAL YO. GF-21611 45" DIA. 26" S.S. HUB SERIES 2000 - 2 STAGE BLADE LOCKNUT TORQUE: 400 FT /LBS.

TIP ANGLE: 24 F IRST STAGE

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i VERIFIEU BY'ATE:/g -/g-:. 'i IL'LT E LETTER E .E1DGE JOY HFG. FIELD SERVICE RFPRESENTATI VE BLADL LOCKOUT '1'DRQUE 6, T'IP ANGLE VERIFlFD f:

Blade No. *1 - See Attached Ver. Report *1 " 340-360 Ft./Lbs.

2 - 400 Ft./Lbs. 10 - 400 Ft./Lbs.

3 - 400 Ft./Lbs. 11 - 400 Ft./Lbs.

• 4 - 340-360 Ft./Lbs. 1" - 400 Ft./Lbs.

5 - 400 Ft./Lbs. 13 - 400 Ft./Lbs.

6 - 400 Ft./Lbs. 14 - 400 Ft./Lbs.

7 - 400 Ft./Lbs. *15 - See Attached Ver. Report 8 - 400 Ft./Lbs. 16 - 400 Ft./Lbs.

"Indicates Balancing Hei ght. has Added To Blade.

VER IF I CATION REPORT UNIT TAG NO. ]-Pf-HCN-A02C FIFST STAGE VERIFICATION OF "AS INSTALLED" BLADE NO. I WAS UNABLE TO BE RECORDED: DUE Tv INACCESSIBILIT'PWITH THE TORQUE WRENCH (SOCKET). THE CONFIGURATION llF THE BALANCING WEIGHT ELIMINATED ANY POSSIBILITY OF OBTAINING A TORQUE VAl.UE FOR SUBJECT BLADE.

DUE TO THE ABOVE SITUATION, LOCKNUT WAS TIGHTENFD WITH A (24") CRESC"qT WRENCH AND WE WERE ABLE TO OBTAIN A (1/2) TURN OF THE LOCK".:UT. PREVIOUSLY NOTED, I INSTRUCTED CRAFT TO TRY AND TIGHfEN h LOCKNUT THAT HAD BEEN VERIFIED 9 400 FT ~ /L"ST WITli TiiE SAME (24") CRESCENT WR 'NCH. CRAFT WAS UNABLE TO TURN THE LOCK"UT WITH SUBJECT hRENCH ~

R. B. (BUCK) KI SHEL ASSISTANT>>ROJECT ENGINEER DATE:

a~v. 1-fl-N LN-AULD SERIAL NO. GF-21588

'5~" DIA. 26" S.S, HUB SeRIES 2000 - SINGLE STAGE BLADE LOCKNUT TORQUE: 400 FT./LBS.

TIP ANGLi: 15'.

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VERIFIED BY:

g. QpZc~ ~i'~i~W D 4.E:~r~-~.

Pz YDE L JOY I IFG.

"T'l i i l'RIDGE fIZLD SERVICE MPP,ESEKTATI VE BLADE LOCKOUT TOR UE 6 TIP ANGLE VERIFIED .g:

B LADE NO. 1 - 400 Ft./Lbs.

• 2 - 320-340 Ft./Lbs.

9 10 400 Ft. /Lbs.

400 Ft. /Lbs.

1'f ff 2'f 3 - 400 Ft./Lbs.

• 4 - 280-300 Ft./Lbs.

5 - 400 Ft./Lbs.

2'ff 11 12 13 400 Ft,. /Lbs.

320-340 400 Ft./Lbs, Ft. /Lbs.

f 6 - 400 Ft./Lbs. 14 400 Ft. /Lbs.

7 - 400 i',./Lbs. 15 400 Ft. /Lbs.

8 - 400 Ft./I.bs. 16 400 Ft. /l.b s.

• Indicates Balancing Meighi. '~as Added to Blade.

JOY VANEAXIAL FA'8 - QUALITY CLASS "R" UNIT TAC NO. I-$1-HCN-A02C SERIAL NO (:F-21610 45" DIA. 26" S.S. HUB SER1L'S 2000 - 2 STACE BLADE LOCKNUT TORQUE: 400 FT./I.BS.

TIP ANGLE: 24 FLRST STAGE l

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VERIFIEU bY:

1)ATE:g:./p g g.YDE LESTER FTHR CE

.IOY HFC. FIEI.D SERVICE REPRESENTATIVI:

BLADE I.OCKNUT TORQUL' TII'N(>I.I: VER1FIFD g:

BI.ADL'O. <<I - See Attached V<<r. Report 9 - 400 Ft./Lbs.

2 - 400 Ft./Lb&. 10 - 400 Ft./Lbs.

3 - 400 Ft./Lbs. 11 - 340-360 Ft./Lbs.

4 - 400 Ft./Lbs. 12 - 400 Ft./Lbs.

5 - 400 Ft./Lb& ~ 13 400 Ft./Lbs.

6 - 360 - 380 Ft./Lbs. 14 - 400 Ft./Lbs.

/r - 400 Ft./Lbs. 15 340-360 Ft./Lbs.

8 - 400 Ft./Lbs. 16 - 400 Ft./Lb&.

• Indicates Balancing Vcigl>t Was Added To Blade.

Joy Vaneaxial Fan - Quality Class "R" Unit Tag No. 1-M-HCN-A03C Serial No. GF-21618 36" Dia. 26" S.S. Hub Series 2000 - Single Stage Blade Locknut Torque: 400 Ft./Lbs.

- Blade Tip Angle: 29$ '

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VERIFIED BY:

D TE,~l. ct..: .

YDE LE E'ER ETHRIDGE JOY MFG. FIELD SER('ICE REPRESENTATIVE BLADE LOCKNUT TOkOUE E TIP ANGLE VERIFIED Blade No. *I 400 Ft./Lbs. %9 - 320-340 Ft./Lbs.

2 400 Ft./Lbs. 10 400 Ft./Lbs.

3 400 Ft./Lbs. 11 - 400 Ft./Lbs.

4 - 400 Ft./Lbs. "12 400 Ft./Lbs.

5 - 400 Ft./Lbs. *13 400 Ft./Lbs.

6 400 Ft./Lbs. 14 400 Ft./Lbs.

7 - 400 Ft./Lbs. 15 400 Ft./Lbs.

8 - 400 Ft./Lbs. 16 400 Ft./Lb' "Indicates Balancing Weight

~ ~

~ Was Added To Blade

VERIFICATION REPORT U~TN . I - H.IICN-AII3D

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VERIFICATION OF "AS INSTALLED" BLADE NO. 9 WAS UNABLE TO BE RECORDED; DUE TO INACCESSIBILITY WITH THE TORQUE WRENCH (SOCKET).

THE CONFIGURATION OF THE BALANCING WEIGHT ELIMINATED ANY POSSIBLITY OF OBTAINING A TORQUE VALUE FOR SUBJECT BLADE.

DUE TO THE ABOVE SITUATION, LOCKNUT WAS TIGHTENED WITH A (24")

CRESCIT>TWRENCH, AND WE WERE ABLE TO OBTAIN A (3/4) TURN OF THE LOCKNUT. IN ADDITION, I INSTRUCTED CRAFT TO TRY AND TIGHTEN A LOCKNUT PREVIOUSLY VERIFIED Q 400 FT./LBS. WITH THE SA'.K (24") CRESCLN1 WRENCH, CRAFT WAS UNABLE TO TURN THE LOCKNUT WITH SUBJECT WRENCH.

R. B. (Bu" ) Kisse Assistant Project Engineer Date

JOY VANEAXIAL FAN - QUALITY ".R" UNIT TAG NO. I-M-HCN-A02A SERIAL NO. GF-21608 45" DIA. 26" S.S. HUB SERIES 2000 2 STAGE BLADE I OCKNUT TORQUE- 400 FT ~ /LBS.

TIP ANGLE: 24 SECOND STAGE

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VERIFIED BY:

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r. L S ER ETHRIDGE JOY MFG. FIELD SERVICE REPRESENTATIVE BLADE LOCKNL'T TORQUE fi TIP ANGLE VERIFIED 9:

Blade No. *I - 400 Ft./Lb&. 9 - 400 Ft./Lbs.

2 - 400 Ft./Lb&. 10 - 400 Ft./Lbs.

3 -

4 -

400 400 Ft./Lbs.

Ft./Lbs.

ll -

12 400 400 Ft./Lbs.

Ft./Lbs.

• 5 - 280-300 Ft./Lbs. 13 400 Ft./Lbs.

6 - 400 Ft./Lbs. 14 - 400 Ft./Lbs.

7 - 400 Ft./Lbs. 15 - 400 Ft./Lbs.

8 - 400 Ft./Lbs. 16 - 400 Ft./Lbs.

• Indicates balancing weight was added to blade.

JOY VANEJQEALFAN - QUALITY CLASS UNIT TAG NO. 1M-HCN-A02D SERIAL NO. GF 2y611 45" DIA. 26" S.S. HUB SERIES 2000 - 2 STAGE BLADE LOCKNUT TORQUE: 400 PI'.'/LBS.

TIP ANGLE:

24'ECOND STAGE jr'

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$ ~pl

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'DE LESTER ETHRIDG DATE~~

OY MFG. FIELD SERVICE REPRESENTATIVE BLADE LOCKNUT TOR UE6 TIP ANGLE VERIFIED 8:

Blade No. 1 - 400 Ft./Lbs. 9 - 400 Ft./Lbs.

• 2 - See attached ver. report 10 - 400 Ft./Lbs.

3 - 400 - Ft'./Lbs. 11 - 400 Ft./Lbs.

4 400 - Ft./Lb' 12 - 400 Ft./Lbs.

S 400 Ft./Lbs. 13 - 400 Ft./Lbs.

6 - 400 - Ft./Lbs. 14 - 400 Ft./Lbs.

7 - 400 - Ft./Lbs. 15 - 400 Ft ~ /Lbs.

8 - 400 - Ft./Lbs. 16 - 400 Ft./Lbs.

+Indicates balancing veight was added to blade.

VERIFICATION REPORT UNIT TAG NO ~ I-M-HCN-h02D SECOND STAGE VERIFICATION OF "AS INSTALLED 'LADE NO. 2 MAS UNABLE, TO BE RECORDED DUE TO INACCESSIBILITY MITH THE TORQUE WRENCH (SOCKET). THE CON-FIGURATION OF THE BALANCING WEIGHT ELIMINATED ANY POSSIBILITY OF OBTAINING h TORQUE VALUE FOR SUBJECT BLADE.

DUE TO THE ABOVE SITUATIONS LOCKNUT MAS TIGHTENED WITH h (24")

CRESCENT MRENCH~ AND ME MERE UNABLE TO TURN THE LOCKNUT ~ PREVIOUSLY I HAD INSTRUCTED CRAFT TO TRY AND TIGHTEN A LOCKNUT THAT WAS VERIFIED AT 400 FT./LBS. MITH THE SAME (24") CRESCENT WRENCH. CRAFT MAS-UNABLE TO TURN THE LOCKNUT MITH SUBJECT MRENCH.

R. B. (BUCK) KISSEL ASSISTANT PROJECT EGINEER THE MALDINGER CORPORATION DATE

QUALITY CLASS "R" UNIT TAG No.l-M-HCN-A02C SERIAL NO. GF-216l0 45" DIA. 26" S.S. HUB SERIES 2000 - 2 STAGE BLADE LOCKNUT. TORQUE: 400 FT./1 BS.

TIP ANGLE:

24'i' I

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DATE/g~g-~

C E ESTER ETHRI E JOY MFG. FIELD SERVICE REPRESENTATIVE BLADE LOCKNUT TOR UE & TIP ANGLE VERIFIED 6:

- 400 Ft./Lbs. 9- Ft./Lbs.

>> 400 Ft./Lbs. - 4'ff Blade No. 1 400 10- 400 - off 2

3 4

- 280-300 Ft./Lbs.

- 400 Ft./Lbs.

ll- 400 12- 400 Ft./Lbs.

Ft./Lb&.

Ft./Lbs.

2~

5 400 Ft./Lbs. 13- 400 Ft./Lba.

6 - 400 Ft./Lb&. *14- See attached ver. report

- 400 Ft./Lbs. Ft./Lb&.

- 400 Ft./Lbs. - 2'ff 7 *15 340>>360 8 *16 See attached ver. report

• Indicates balancing weight vas added to blade.

NOTE: See attached report concerning Blade No. 2,8,10,14 6 16.

VERIFICATION REPORT UNIT TAG NO. 1-M-HCN-A02C - SECOND STAGE r

SUBJECT NO. 1 : INACCESSIBLE LOCKNUTS VERIFICATION OF "AS INSTALLED" BLADE NO. 14 and N0.16 WAS UNABLE TO BE RECORDED:

DUE TP INACCESSIBILITY MITH THE TORQUE MRENCH (SOCKET). THE CPNFCGURATION OF THE BALANCING MEIGHT ELIMINATED ANY POSSIBLITY OF OBTAINING A TORQUE VALUE FOR SUBJECT BLADES.

DUE TO THE ABOVE SITUATION ~ LOCKNUTS MERE TIGHTENED WITH A (24") CRESCENT WRENCH ~ AND ME WERE UNABLE TO TURN BLADE NO 14 ~ HOWEVER ~ WE MERE ABLE TO OBTAIN A ( 1 /4) TURN ON BLADE NO 1 6 ~ PREVIOUSLY y I HAD INSTRUCTED CRAFT TO TRY Ah+TIGHTEN A BLADE LOCKNUT THAT MAS VERIFIED 9 400 FT./LBS. MITH THE SANE (24)guESCENT MRENCH. CRAFT MAS UNABLE TO TURN THE LOCKNUT WITH SUBJECT WRENCH.

SUBJECT NO. (2 : BLADE TIP ANGLE RESULTS

1. "AS INSTALLED" BLADE NO.~ TIP ANGLE MAS VERIFIED 9 28 ~ AND

2. "AS INSTALLED" BLADE NO ~ 8 6 10 TIP ANGLES MERE VERIFIED 9 22 RESULTING IN A 6'IFFERENCE BETWEEN REFERENCED BLADES ~ BLADE TIP ANGLES CORRECTED, TO THE SPECIFIED 24 TIP ANGLE, AND RECORQUED TO 400 FT./LBS.

-'ERE R. B. (BUCK) KISSEL ASSISTANT PROJECT ENGINEER THE MALDINGER CORPORATION DATE CLY LES ER ETHRIDG JOY MFG. FIELD SERVICE REPRESENTATIVE DATE

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JOY VANEjQEALFAN QUALITY CLASS "R" UNIT TAG NO. 1-M-HCN-A02B SERIAL NO. GF-21609 45" DIA. 26" S. S. HUB SERIES 2000 - 2 STAGE BLADE LOCKNUT'ORQUE: 400 FT./LBS.

TIP ANGLE:

24'ECOND STAGE g/

y'en ",: f I

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/ VERIFIED BY:

CL E LESTER ET I E DAT~2~6 JOY MFG. FIELD SERVICE REPRESENTATIVE BLADE LOCKNUT TOR UE & TIP ANGLE VERIFIED 8:

Blade No. 1 - 400 Ft./Lbs. 9 - 400 Ft./Lbs.

2 400 Ft./Lbs 10 - 400 Ft /Lbs.

3

-

- 400 400 Ft./Lbs.

Ft./Lbs.

ll -, 400 Ft./Lbs.

~

• 12 - 400 Ft./Lbs.

2'ff 4

5 -

-

400 Ft./Lb& ~ 2'ff 13 - 400 Ft./Lbs.

6 400 Ft./Lbs. 14 - 400 Ft./Lbs.

7 - 400 Ft./Lbs. 15 - 400 Ft./Lb'

• g - 400 Ft./Lbs. 16 400 Ft./Lbs.

• Indicates balancing veigh t +as added to blade.

NOTE: See attached report concerning blade No. 5 & 11.

IE C ~~

UERIFICATION REPORT UNIT TAG NO. 1-M-HCN-A02B SECOND STAGE SUB JECT: BLADE TIP ANGLE RESULTS 1~ AS INSTALLED BLADE NO 5 TIP ANGLE WAS VERIF IED Q 22 ~ AND

2. "AS INSTALLED" BLADE NO. 11 TIP ANGLE WAS VERIFIED 8 26'ESULTING IN A 4 DIFFERENCE BETMEEN REFERENCED BLADES.

BLADE TIP ANGLES WERE CORRECTED TO THE SPECIFIED 24 TIP ANGLE, AND RE"TORQUED TO 400 FT./LBS.

R B. (BUCK ) KISSEL ASSISTANT PROJECT ENGINEER THE WALDINGER CORPORATION DATE

. CL E LESTER ETHRIDGE JOY MFG. FIELD SERUICE REPRESENTATIUE DATE

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.. We hereby certify that each blade 1ocknut has been verified or re-torqued to a value of 400 ft./lbs., and each blade tip angle

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(as specified below) verified or reset, applicable to the second stage, on the following fans:

Fan Unit Ta . No. Serial No. Ti An le 04 1-M-HCN-A02A (2-stage) GF-21608 1-M-HCN-A02B (2-stage) GF-21609 24'4'4 1-M-HCN-A02C (2-stage) GF-21610 0 1-M-HCN-A02D (2-stage) GF-21611 240 tP'-'L5-C de Lester Et ri ge Date Joy Mfg. Field Service Representative

.6 B. (Buc ) Kisse Date Assistant Project Engineer The Waldinger Coporation

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