ML20247J941
| ML20247J941 | |
| Person / Time | |
|---|---|
| Site: | River Bend  |
| Issue date: | 02/09/1989 |
| From: | Carfagno S, Leonard L, Vacca G CALSPAN CORP. |
| To: | |
| Shared Package | |
| ML20247J897 | List: |
| References | |
| P-741-1, NUDOCS 8904050120 | |
| Download: ML20247J941 (25) | |
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4 g I a , l i l 1 l ANALYSES OF COMPONENTS IN i AN ASCO SOLEN 0ID VALVE i i i FRC REPORT P-741-1 i for i Gulf States Utilities Co. River Bend Station, MA-2 ) P.O. Box 220 t St. Francisville, LA 70775 i Attn: Mr. V. P. Bacanskas I l l Prepared by l Franklin Research Center Division of Arvin/Calspan 2600 Monroe Boulevard Norristown, PA 19403 Prepared by: Revie d by*
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l . 7 c.3g' A h 4 i O Table of Contents
'Section Description "Page
1.0 INTRODUCTION
. . . . . . . . . . . . 1 2.0 ANALYSES AND DISCUSSION . . . . . .- . . . 1 1
2.1 PLUGNUT ASSEMBLY AND CORE (SOLEN 0ID "B") . . . . 1 2.2 DISC HOLDER SUB-ASSEMBLY-(SOLENOID "B")~ . . . . '2 2.3 CORE ASSEMBLY (SOLENOID "A") . . . . . .. . 3
3.0 CONCLUSION
S AND RECOMMENDATIONS. . . . . . . . 3 O l l l l O
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(~'h Figures V Figure No. Description Page 1 Macrograph showing the ASCO double solenoid valve as received at FRC . . . . . . . . . . . 5 2 Macrograph showing mating surfaces on core and plugnut assembly from solenoid "B" . . . . . . . . . 6 3 X-ray spectrum from darkened lubricant deposit on the core-in Figure 2 . . . . . . . . . . .. . 7 i 4 X-ray spectrum from groove on plugnut assembly in Figure 2.- 8 5 SEM micrograph showing an area on the surface of the core that had contacted the plugnut assembly . . . . . 9 6 SEM micrographs contrasting the two regions on the core surface shown in Figure 5. . . . . . . . . 10 7 Macrographsshowingthedischoldersub-assemb1MOIrom solenoid "B" . . . . . . . . . . . . 11 () 8 Macrographshowingtheedisutpilotorificethathadmated with the disc shown in Figsr,e{7.gs.g . . . . . . 12 9 X-ray spectrum from a deposit oNIthe centIF'ofthe disc
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shown in Figure 7. . . . . . . . . . . 13 10 Macrograph showing deposits of darkened lubricant on the end surface of the core assembly from solenoid "A" . . . 14 11 Macrograph focusing on the base inside the solenoid base sub-assembiy . . . . . . . . . . . . 15
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- 1. INTRODUCTION i O In accordance with a request from Culf States Utilities, Co., several l
components of an ASCO valve, shown in Figure 1, were studied utilizing a scanning electron microscope (SEM) in order to characterize the nature of deposits on mating and/or sealing surfaces. It was of particular interest to identify whether there had been a transfer of elements from one mating surface to another or to a lubricant between the surfaces. Such transfer or diffusion could tv:1p to explain why surf aces had been adhering to each other and, thus, compromising the operation of the valve.
- 2. ANALYSES AND DISCUSSION 2.1 PLUGNUT ASSEMBLY AND CORE (SOLEN 0!D "B")
As shown in Figure 2, on the end of the core there was a double ring of darkened lubricant deposit that mirrored a recessed groove on the mating i plugnut assembly. The rnjority of this stiff, gummy deposit was scraped off A the surface and subjected to an infrared (IR) anitys~is which indicated that g the lubricant was silicone based. An X-ray spectrum from the remaining l deposit was obtained by SEM energy dispersive X-ray avfalysis (EDXA). As shown in Figure 3, the presence of silicon (Si) in.the lubricant was confirmed. Also in the spectrum were iron (Fe) and chromium (Cr) peaks from the stainless steel core and a small amount of copper (Cu), likely f rom the material within the groove on the plugnut assembly. Indeed, the spectrum from wiGin the groove, shown in Figure 4, contained significant Cu peaks as well as Si, Fe, Cr, and aluminum (A1). The presence of the latter element in the groove l l indicates that the groove material is a Cu-Al alloy, i.e., an aluminum bronze. The X-ray spectrum from a small patch of the deposit lifted from the core shown in Figure 2 al'1o contained Si, Fe, Cr and Cu, evidence that elements from the core's base metal had either diffused into the silicone based lubricant or that fretting between the mating surfaces under small amplitude vibrations, incurred during service, operation of the valve, had generated microscopic particulate. In fact, evidence of fretting was found on the contact surface of the core, as illustrated in Figures 5 and 6. l l l 1
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!Q q D-The stiffening or " gumming" of the lubricant could be taken as an indication of the formation of a " wear" polymer under the combined action of the wear and rubbing (i.e., fretting). Such wear polymers have often been reported to form on mating lubricated surfaces experiencing relative motion.
Accordingly, in the present case, operating the valve without the lubricant' could be a means of avoiding a sticking problem, since, although fretting l l alone could still induce some wear particles, there would be no gummy or sticky, degraded lubricant to act as a bonding agent. 2.2 DISC HOLDER SUB-ASSEMBLY (SOLEN 0ID "B") The elastomeric seal in the disc holder, shown in Figure 7, exhibited a pronounced set from contact with the mating exhaust pilot orifice surface of a r brass fitting, shown in Figure 8. EDXA of a deposit on the central region of the disc resulted in the spectrum in Figure 9 in which, in addition to Si from the lubricant, there were peaks of sulfur (S), Cr, Fe and zine (2n). The S likely was in the elastomer, while the Fe and Cr were from the posts of the disc' holder, which had been florcsced by scattered electrons and X-rays. A potential source for the 2n was the mating brass (i.e., Cu-2n) exhaust pilot orifice. Leaching or dezincification in conjunction with an interaction between the elastomer and the seat could have led to adherence between the surfaces. Traces of 2n, as well as small amounts of Si and S, were also present on a cross section cut through a segment of the disc, indicating that the elastomer compound as formulated may have contained a little 2n or that migration in service or contamination during sectioning were responsible for its presence. Another possible contributor to adherence of the disc to the orifice seat was the seat's relatively rough surface and the presence of porosity in the casting. Under sustained loading and while undergoing a permanent set, the elastomer would have flowed into any microscopic recesses on the seat. Indeed, transfer of elastomer to the seat was indicated by the presence of a. ! small S peak in the EDXA spectrum from the base orifice. Any interaction with j a lubricant would have, of course, also contributed to bonding. It appears that a critical definition of the relative roles of each of the above possible contributors to a sticking mechanism would require some testing, i.e., without , the lubricant, with a more highly polished surface, etc. j
b [f 2.3 CORE ASSEMBLY (SOLEN 0ID "A") The core assembly, shown in Figure 10, had a dark lubricant deposit on its end surface that had been in contact with the solenoid base sub-assembly.
- l. It appeared, as can be seen in Figure 10, that much of the lubricant-deposit had been.. scraped away prior to the valve's having been forwarded to FRC.
Nevertheless, there.were remnants of two circular bands, similar to what was noted on the core from solenoid "B." These bands. mirrored a recessed groove containing a copper colored ring on the mating solenoid base sub-assembly shown in Figure 11. The deposit was found to have a rubbery consistency (in contrast to the stif f, but flowable, deposit on the solenoid "B" core), and it was possible to
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peel it from the surface of the core assembly. When subjected to EDXA, the rubbery deposit yielded a spectrum similar to that from the lubc kant removed from the core in solenoid "B", that is,-in addition to the Si from the lubricant, there were peaks from Fe and Cr, likely from the base metal of the j core assembly and/or the solenoid base sub-assembly, and a trace of Cu, likely 1 from the material in the groove on the solenoid base sub-assembly. ) Furthermore, the contact surface of the core exhibited worn areas similar to those shown in Figures 5 and 6. Accordingly, it appears there had been - fretting wear and/or diffusion of elements from the various mating surfaces into and/or through the lubricant. As noted previously in Section 2.1 above, such wear or migration could have been the major factor in altering the lubricant, which in turn caused the surfaces to adhere to each other, thus- l l compromising the valve's operation. CONCLUSIONS AND RECOMMENDATIONS There was evidence that the service conditions experienced by the valve's solenoid cores fostered fretting or diffusion of elements or particles from contacting surfaces into a lubricant, the function of which was to prevent' direct contact between mating surfaces. However, in the wear or diffusion process the consistency of the lubricant was altered, and it acted as a bond between the mating surfaces, thus leading to the valve's failure to operate properly. Accordingly, it is reconsnended that solenoid cores be operated without the silicone lubricant.
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The relative roles of the lubricant and the surface finish and/or material of the seat in causing sticking between the disc and'the exhaust
=5 pilot orifice were not defined by the analyses conducted in this investigation.
However, there was evidence of transfer of Zn from the pilot orifice to the elastomeric disc. Therefore, any steps to minimize interaction between the disc and seat would, of course, be recommended. An example of such an I improvement is a polished contact surface on a less reactive material than the brass in the seat. l l, l M S '
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100X Figure 5. SEM micrograph showing an area on the surface of the core that had contacted the plugnut assembly. The region at upper left (shown at a higher magnification in Figure 6A) is as-finished, whereas the region at lower right (shown at a higher magnification in Figure 6B) had the higher points smeared over or polished away. The letter region may reflect the results of fretting between mating surfaces. _9
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2X Figure 8. Macrograph showing the exhaust pilot orifice that had mated with the disc shown in Figure 7. O
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e. 2X Figure 10. Macrograph showing deposits of darkened lubricant on the end surface of the core assembly from solenoid "A." A sample of the deposit was lifted from the surface and analyzed by EDXA in a SEM. O
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2X l Figure 11. Macrograph focusing on the base inside the solenoid base sub-assembly. The arrow points to a recessed brass colored band in the base. The three " thumb nail" marks around the inside diameter of the band are small areas cut away from the base down to the band. O
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O CALSARN CORPORATION
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FRANKLIN RESEARCH CENTER ValleyForge Corporate Center 2600 Monroe Bid. Norrrstown PA19403 216 666 3000 { February 16, 1989 l l I 1 Culf States Utilities Co. i River Bend Station, FA-2 ' P.O. Box 220 l St. Francisville, LA 70775 I Attention: Mr. Vincent P. Bacanskas
Reference:
GSU Purchase Order No. 80N73567 I FRC Project No. P741-0001
Subject:
Lubricant Analyses
Dear Mr. Bacanskas:
Enclosed is an addendum to the above referenced report, covering the results of analyses carried out on samples of lubricant used in an ASCO solenoid valve. Please contact Frank Iaconianni (215/666-3078) if you have any questions about the test method or results. Very truly yours v0 Laurence Leonard Principal Engineer LL/ih
Enclosure:
Addendum to FRC Report F-741-1 O l .
0 g O ADDENDUM TO FRC REPORT P-741-1 ANALYSES OF COMPONENTS 1N AN ASCO SOLENOID VALVE O O
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' .I .}i Infrared (IR) spectra (attached) were obtained for:
F Sample 1: End of Core (Solenoid E) Sample 2: Unused Lube Oil
-1 Scans were made from 4000 cm- to 250 cm , at 10 minute scan times, on a Perkin Elmer 521 IR Spectrophotometer. Sample 1 required mulling with I Nujol to obtain discernible absorption bands. Sample 1 mull was placed-between a Nacl plate and a KC1 plate for the " top" spectrum, and transferred I
to-a CsI plate surface for the two lower spectra. Sample 2 oil was placed between a Nacl plate and a KC1 plate for analysis. Five bands indicated on Sample i spectra correspond to those of Sample 2 in terms of wavenumber and relative intensity of absorption. All bands of Sample 2 not seen in Sample i spectra would be either masked by Nujol bands or l too small to be resolved. Sample i spectra'contain no discernible non-Nujol
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bands that are not also seen in the Sample 2 spectrum. Thus Samples 1.and 2 are probably very similar in composition. There was not enough of Sample 1 I available to determine subtle differences in composition and/or molecular structure. Sample 2 spectrum looks very similar, but not identical, to literature spectrum of poly (phenylmethylsiloxane) l j l l 0- , , ( jf/wm s- - Frank Iaconianni, Ph.D. Chemist ; O
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acamE O February 24, 1989 l l i Mr. V. Bacanskas ; GULF STATE UTILITIES River Bend Station P.O. Box 220 , St. Francisville, LA 70775 l Dear Mr. Bacanskas i Enclosed is the following Corporate Test Method which you l requested from Dow Corning Corporation: 0176 - INFRARED l SPECTROSCOPIC IDENTIFICATION - Match Standard. If you need further information on this or any other method, please contact me. Sincerely, j d i a k E. Weiler S for Quality Specialist Quality Development and Administration Mail Number 140 (517) 496-5461 JEW /j d i Enclosure O DOW CORNING CORPORATION, MIDLAND, MICHIGAN 48886-0996 TELEPHONE 517 496-4000 1
** ~
4 sCTM 0079 5- ; l Sample Preparation and Handling: 101 (w/v) in CCl4 ; 2". (w/v) in CS2 ; nomiaal, determined to 0.11. Cells: Obtain IR spectra' in 0.1 m cells; nominal, determine to 0 001 m. Use Nacl cells for 4000 to 600 cm-1 range and CsBr for 600 to 200 cm-1 range. Slit Factor: Normal Scan Speed: About ten minutes Scan Range: CC14 solution: 4000to1300cp-1,and 600 to 200 cm-CS2 solution: 1300 to 600 cm-1 Reference Cell: For CC14 solution: 0.1 m cell filled with CCl4-For CS2 solution: 0.1 m cell filled with CS2 l 09 0 % ' f( 1 l j i i j f : I AV l
~For illustration only. A standard spectrum of this material should be obtained l on the instrument used for the analysis.
Dow Corninge550 Fluid l 6/9/86 Infrared Spectrum No. 369}}