3F0889-04, Forwards Response to NRC 890721 Request for Addl Info Re Plant Emergency Diesel Generator Upgrade Program.Util Anticipates Finalizing Resolution of NRC Concerns at Meeting

Forwards Response to NRC 890721 Request for Addl Info Re Plant Emergency Diesel Generator Upgrade Program.Util Anticipates Finalizing Resolution of NRC Concerns at Meeting

ML20245H092
Person / Time
Site:	Crystal River
Issue date:	08/11/1989
From:	Widell R FLORIDA POWER CORP.
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
3F0889-04, 3F889-4, NUDOCS 8908160309
Download: ML20245H092 (18)

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.. F Florida Power C O R PO R A1IO N August 11, 1989 3F0889-04

Document Control Desk U. S. Nuclear Regulatory Commission

. Washington,'DC 20555

Subject:

Crystal River Unit 3.

-Docket No. 50-302 Operating License No. DPR-72 Emergency Diesel Generator Upgrade Program '

Dear Sir:

.The Attachment to this letter provides Florida Power Corporation's (FPC's) responses to your letter ' dated July 21, 1989 which requested additional information regarding the CR-3 Emergency Diesel Generator (EDG) upgrade program. FPC is not requesting explicit approval but understands that the staff is planning to assure an adequate test program is undertaken. We anticipate finalizing resolution of your concerns at

.our meeting' scheduled later this month.

Should there be any questions, prior to our meeting, please contact this office.

Sincerely, I

Rolf . Widell, Director Nuclear Site Support AEF:

xt: Regional Administrator, Region II Senior Resident Inspector 8908160309 890811 PDR ADOCK 05000302 I n P PDC POST OFFICE BOX 219 + CRYSTAL RIVER. FLORIDA 326290219 * (904) 563-2943 A Florida Progress Company

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ATTACHMENT 1 RESPONSES TO NRC QUESTIONS EMERGENCY DIESEL GENERATOR UPGRADE PROGRAM NRC Ouestion:

You stated that you have completed load testing at 3500 kw. It is not clear from your letter which unit was tested at 3500 kw and for what period of time.

FPC Response:

Load testing was performed on a six cylinder, turbo series engine (SN 38D872029TDS6, Model # 38TD8-1/8) at the Colt factory. An equivalent load was determined by taking the ratio of the number of cylinders. This results in the test machine being operated L

at the same horsepower per cylinder as the upgraded machines at CR-3. The six cylinder engine was tested for 275 hours0.00318 days <br />0.0764 hours <br />4.546958e-4 weeks <br />1.046375e-4 months <br /> at the equivalent of 3250 kw to obtain the 200 hour0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> rating of 3250 kw and for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> at the equivalent of 3500 kw to obtain the 30 minute rating of 3500 kw. This test was specified by Colt Industries.

NRC Ouestion There is still some uncertainty about the automatically connected load. We request that you verify the total automatically connected load and compare this load to the EDG rating. Furthermore, we request that you compare the increased continuous rating to the estimated EDG long term load.

FPC ResDong There will always be some uncertainty associated with the loads on the diesel l generator. Loads may be characterized more accurately as a result of more detailed calculations or testing. Also, loads may change as a result of maintenance or modifications. FPC has an ongoing EDG load management program to monitor these loads and assure they stay within the capabilities of the machines. Thus, in response to requests for listings of EDG loads, FPC provides the best information available at the time. Therefore, a later request for the same information may not yield exactly the same numbers. The laading tables described below are based on currently available EDG loading data. The loading for all tables is calculated at one minute internal into the accident and, therefore, does not include momentary loads such as motor operated valves.

Short Term Loads Table 1 shows the automatically and manually connected loads for the "A" EDG. The "A" EDG automatically connected loads are currently in the existing 30 minute rating.

Table 2 shows the automatically and manually connected loads for the "B" EDG. The "B" EDG automatically connected loads for the present conditions are within the 2000 hour0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br /> rating.

Table 3 shows the automatically and manually connected loads for the "A" EDG following Refuel 7. The "A" EDG automatically connected loads for the post Refuel 7 conditions are within the new 2000 hour0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br /> rating. Table 4 shows the automatically and manually connected loads for the "B" EDG following Refuel 7. The "B" EDG automatically PAGE 1 of 8

connected loads for the post Refuel 7 conditions are within the new continuous rating.

The "A" EDG loading tables utilize both calculated and test values. The "B" EDG loading tables utilize only calculated values. FPC plans to run a test to measure the major loads on the "B" EDG during Refuel 7. Subsequent to that test, a table showing the "B" EDG loading test values will be created and Table 8-2 of the CR-3 FSAR will be updated.  ;

Lona Term Loads FPC submitted tables showing the long term post-accident EDG loads in a letter dated September 15, 1988. The comparison of Tables 1 and 3, and 2 and 4 from that letter, shows how the modifications to be completed during the upcoming outage will affect the loading of the diesels. '

Following completion of the modifications the long term (30 minutes to 7 days) loading I on the "A" EDG is generally less than the increased continuous rating of 2850 kw.

In certain limited cases ' a loading on the "A" EDG is projected to be in the 2000 hour0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br /> rating of 2850 to 30.0 kw. The longest duration for which the "A" EDG is in the 2000 hour0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br /> rating is 23 hours2.662037e-4 days <br />0.00639 hours <br />3.80291e-5 weeks <br />8.7515e-6 months <br /> and the loading is calculated to be 2879.4 kw which FPC considers to be acceptable.

After the modifications the long term loading on the "B" EDG is generally less than the increased continuous rating of 2850 kw. In certain very limited cases the loading on the "B" EDG is in the 2000 hour0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br /> rating of 2850 to 3000 kw. The longest duration for which the "B" EDG is projected to be in the 2000 hour0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br /> rating is 21 hours2.430556e-4 days <br />0.00583 hours <br />3.472222e-5 weeks <br />7.9905e-6 months <br /> and the loading is calculated to be 2894.5 kw which FPC considers to be acceptable.

NRC Comment:

The FPC conclusion "...that testing of the EDG per IEEE Standard 387 should not be performed..." is not in accordance with the IEEE Standard which was endorsed by NRC in Regulatory Guide (R.G. 1.9). The staff is willing to reconsider certain requirements and the number of tests (starts) to accommodate the available time for testing during a refueling outage. In addition, the proposed requalification of the EDG's by " ...either test of identical components, analysis or engineering '

judgement..." does not replace an integrated test to requalify the upgraded EDG's at Crystal River 3. ,

1 FPC Response '

FPC's statement that testing per IEEE-387 "...should not be performed..." was a poor choice of words. FPC does not consider RG 1.9/IEEE-387 to be directly applicable to CR3 for this particular activity. Nevertheless, we agree that a testing program which meets the intent of the Standard is desirable and should be undertaken to the extent possible.

Qualification of the modified CR-3 EDG's has been done through a combination of factory testing, qualification by analysis / evaluation, site run-in and load testing.

Although these methods are not in strict adherence with IEEE-387 (1984), the intent of Section 6 of that standard will have been met. The following comparison is intended to show that the planned testing program meets the intent of the Standard PAGE 2 of 8

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in those areas where the validity of the original testing may have been brought into question as a result of the modifications.

Section 6.1.2 describes the documentation that should result from the test program.

With the exception of Section 6.1.2 (4) (a) (Test Objective), testing at Colt's i factory was in accordance with 6.1. j

' Section 6.2 describes the minimum factory production tests. Testing at Colt's factory exceeded the requirements of Section 6.2 with the exception of 6.2.2 (Generator Tests) and 6.2.3 (Excitation, Control, and other Accessories / Auxiliaries). 1 Performance of the testing as described in Section 6.2.2 is not necessary since the generator was qualified by the original equipment manufacturer (OEM) for the higher ratings by evaluation and is not being modified. Testing of the auxiliaries listed in Section 6.2.3 is not necessary since the excitation auxiliaries and controls are not affected by the upgrade.

Section 6.3 describes the site test categories. Sections 6.3.1 (Starting Test) and 6.3.2 (Load Acceptance Test) will be accomplished with FPC's routine surveillance procedures, SP-354, Monthly Functional Test of the Emergency Diesel Generators; SP-417, Refueling Interval Integrated Plant Response to an Engineered Safeguards Actuation; and SP-457, Refueling Interval ECCS Response to a Safety Injection Test Signal. Copies of these procedures have been forwarded to our Project Manager for staff review. Section 6.3.3 (Rated Load Test) will be accomplished with the site run-in-(Attachment 1), load test at slightly less than 3250 kw and Technical Specification required surveillance tests. Section 6.3.4 of the Standard requires a full load

. rejection test. A load of 500 to 600 kw will be rejected as part of SP-457 to demonstrate that if a high pressure injection pump (the largest single load) tripped during an engineered safeguards (ES) actuation the diesel will not overspeed and trip.

A full load (i.e. short-time load) rejection will not be accomplished. The intent of Section 6.3.5 (Electrical Test) will be met through a combination of the OEM evaluation, the load test and the routine surveillance test. Testing of the systems listed in Section 6.3.6 (Subsystem Test) are unnecessary since these systems are not affected by the upgrade.

Section 6.4 of the Standard describes site acceptance testing. The testing required by Section 6.4 will be accomplished through FPC's routine surveillance procedures.

Sections 6.4.1 (1) (Starting Tests), 6.4.1 (2) (Load Acceptance Tests), 6.4.1 (3)

(Rated Load Tests), 6.4.1 (4) (Load Rejection Tests), 6.4.1 (5) (Electrical Tests),

and 6.4.1 (6) (Subsystem Tests) will be addressed as described above. The loading required by Section 6.4.2 (Test Loads) is addressed by SP-417.

Section 6.5 (Periodic Tests) including availability and operational testing are conducted in accordance with Technical Specifications.

NRC Riuestion:  ;

The staff requests that the following items be submitted for our review:

1. a) A list of the components which are to be requalified by testing.

b) A list of the components which are to be requalified by analysis.

PAGE 3 of 8 I

I

i c)1 A list of the components which are to be requalified by engineering judgement.

'2. Describe the expertise of those who will do the requalification by engineering judgement, and provide the documented basis on which the requalification will be -

decided.

3. State the time period allocated during shutdown for testing of the fully modified  ;

machine' and state how many start-stop tests will be made to requalify the EDG's.

4. Your acceptance criteria, based on. R.G.1.9 (IEEE STD-387) and FPC Technical Specifications.

FPC Response:

'1. a) Components Qualified by Testino

1. Bearings

2. Cylinder Liners

3. ' Fuel Injection Nozzles

4. Upper / Lower Piston Assemblies

5. Upper / Lower Connecting Rod Assemblies b) Components Qualified by Analysis

1. Combustion Air Supply

2. Exhaust system

3. Radiators

4. Engine driven Lube Oil Pump

5. Jacket Water Pump

6. Lube Oil Coolers The combustion air supply is being modified to increase air flow in accordance with Colt's requirements. The air inlet and exhaust were analyzed by Giibert/ Commonwealth Inc. (G/CI), using Colt's input, to ensure the pressure losses are within Colt's specifications.

Thermodynamic analysis -(by Colt) concluded that additional lube oil coolers are required to remove additional heat in the lube oil system due to higher loads. The same analysis concluded that the existing skid mounted radiators are acceptable to use as-is since they will cool jacket water within Colt's specifications.

The engine mounted / driven jacket water and lube oil pumps were evaluated to ensure the increased friction losses associated with the additional lube oil-cooler tube length, etc., are within the pump capabilities. This : was accomplished by Colt Industries.

c) Components Qualified by Evaluation

1. Generator l

2. Fuel Oil Storage Tank .

3. Fuel Oil Day Tank PAGE 4 of 8

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The generator was evaluated by the OEM (Louis-Allis) and Colt (see Attachment

2) and concluded that the generator is acceptable to use as-is. This is based on a minimum power factor of 0.842 at the new loads.  :

Colt is finalizing an evaluation on the original 99 out of 100 start tests and the 10 second fast start capability of the upgraded engines. The fast start capability will be confirmed subsequent to the engine upgrade.

The fuel oil storage and day tank capacities were evaluated by FPC based on fuel consumption rates provided by Colt. The existing tanks are adequate to supply the fuel required for seven days at design basis loads.

2. Requalification by engineering evaluation is being accomplished by Colt personnel who have approximately 12 to 20 years of experience in research and development, component design, testing, systems engineering or analysis. The basis for requalification is consistent with the original design basis for the diesel generator, the accident analysis for CR-3, and the CR-3 FSAR.

3. Approximately 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> per diesel is currently allocated during shutdown for run-in and testing of the modified diesels. The run-in will be performed in accordance with Attachment 1. A twenty four hour load test will follow. The run-in and load test is in accordance with Colt's requirements. This load test may be accomplished as part of the refueling interval surveillance testing required by Technical Specifications.

During site run-in and load test, each machine will be started approximately six times.

4. The acceptance criteria for the qualification test previously completed at the Colt factory was to successfully run the engine continuously for 275 hours0.00318 days <br />0.0764 hours <br />4.546958e-4 weeks <br />1.046375e-4 months <br /> at the equivalent of 3250 kw and to run continuously for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> at the equivalent of 3500 kw as specified by Colt Industries.

The acceptance criteria associated with the periodic diesel surveillance include:

1. For slow starts, the diesel is started from engine ambient conditions and the engine accelerates to at least 900 rpm.

2. For fast starts, the diesel is started from engine ambient conditions and the engine accelerates to at least 900 rpm in s 10 seconds.

3. The diesel is synchronized to its respective 4 kv Engineered Safeguards (ES) bus, loaded to 2 1500 kw, and operated for 2 60 minutes.

4. The diesel is aligned to provide standby power to the associated emergency ,

buses.

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5. The diesel generators shall reject a load of 2 515 kw without tripping.

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4 NRC OUESTION:

Tables 1 through 4 of the attachment to Reference 2 tabulate the "A" and "B" EDG's 1 30 minute to 7 day extended time loads, including both the automatically and the manually applied loads. Submit sample calculations for the largest loads from each of these tables showing how these loads were derived, i.e., measured values that were extrapolated to reflect the actual LOCA spectrum of parameters, calculations only, equipment rated nameplate data for the expected environmental condition:, etc.

Because of the lack of design margins and conservatism, the staff must establish, very accurately, the actual EDG loading expected for the worst case LOCA condition.

FPC RESPONSE The thermal hydraulic conditions assumed in the long term loading study of the EDG's were derived from required accident scenarios. The individual component loads were initially on calculated values. Samples of these calculations are included as Attachment 3.

The calculated worst case loads on "A" EDG of 2924.4 kw was recalculated using measured values extrapolated to reflect the projected LOCA conditions in accordance with methodology described in FPC's submittal dated February 29, 1988. This recalculated value was 2938.8 kw. Such a recalculation was not done for the "B" EDG since measured values are not currently available for B-train components.

NRC OUESTION In Paragraph 4 of the attachment is stated that " Failure of the Steam Driven Feedwater Pump (EFP-2) results in sharing of loads between "A" and "B" EDG's..." Further, you stated that "...the "B" EDG failure will bound all scenarios for the "A" EDG loading protected for seven days. . . ." Explain which loads are shared and how they can be shared if the "B: EDG fails. Also, submit the following documents relating to EFP-2:

1. P&ID's

2. Electrical Schematics

3. Operating Procedures for ESF loads

4. Test procedures to verify load sharing as a result of an EDG failure.

FPC Response:

The statement regarding the sharing of loads is based on FPC's assumption that no more than one component would be assumed to fail at any given time. That is, if EFP-2 is ,

considered to fail, then both EDG's will be operable, as well as both trains of '

safeguards equipment. With both trains operable the resulting EDG loads are reduced from the single train operating case because two systems, Nuclear Service and Decay Heat Sea Water (RW) and Nuclear Services Closed Cycle Cooling Water (SW), have redundant pumps operating in parallel to supply water through a common piping system.

With two parallel pumps operating, the flow of each pump is reduced as well as its ,

power requirements and thus the resulting EDG loads. In addition, with both EDG's l l

PAGE 6 of 8 l l

9 operable the operator has the option to apply the manual loads to either EDG. Only one component of each redundant manual load is required to satisfy the accident function. This further reduces the long term loading for the EFP-2 failure case.

The only load sharing available with any EDG failure case is between the Emergency feed Water Pumps (EFP's) with the "B" EDG failure. In this case the turbine driven pump (EFP-2) which does not depend on the "B" EDG will operate in parallel with the motor driven pump (EFP-1) through common piping. This reduces the flow of both pumps as well as their power requirements which in turn reduces "A" EDG loading.

As discussed above, the EFP-2 failure case is not the most limiting because of the shared flows. The "A" EDG failure cases are not the most limiting because there is no comparable load to the motor driven emergency feedwater pump on the "B" EDG (i.e.

the EFP-1 on the "A" EDG is the major difference between loadings of the EDG's).

FPC's response to the request for documents is as follows:

1. The Flow Drawings (P&ID) for the systems in question are figures in the FSAR.

FPC's drawing system does not include typical P&ID's.

System FSAR Fiaure Nuclear Service and Decay Heat Seawater System 9-7 Nuclear Services Closed Cycle Cooling Water System 9-8 Emergency Feedwater System 10-3 Auxiliary Steam System 10-5

2. EFP-2 has no electrical schematics because it is a self-contained turbine driven pump.

3. AP-770, Emergency Diesel Generator Actuation, have been sent with the surveillance test procedures mentioned earlier.

4. There are no test procedures for load sharing verification. The RW & SW System flows were determined from system hydraulic curves which are based upon actual system operational data and compared with pump head / flow curves from the manufacturer to determine individual pump flows. The EFP flow sharing was confirmed by actual data from Emergency Feedwater (EFW) System actuations which demonstrated that with both pumps operating flows are relatively equal.

NRC OVESTION1 Describe in detail the electrical system EDG modifications planned for refueling outage 7.

FPC Respons_e_;.

The following EDG loading related modifications are planned for Refuel 7.

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4

1. A modification will be installed to trip EFP-1 and start the "A" and "B" low l' pressure injection pumps (DHP-1A & IB) at an Reactor Coolant System (RCS) pressure of 500 psig. This modification prevents simultaneous loading of both EFP-1.and DHP-1A, thereby reducing the loading on "A" EDG. .This project also rearranges and increases the number of load blocks from 5 blocks to 6 blocks in order to reduce voltage dips and improve the frequency recovery profile. A similar' modification will be installed on the "B" EDG to increase the number of load blocks from 4 to 5.- FPC plans to measure the voltage dips resulting from load block rearrangement during the ES actuation testing.

2. A modification will be installed which will provide selectability' to Reactor Building air handling fan AHF-1C for LOCA mitigation. Although, only one RB fan and one RB spray are required, currently two RB fans and one RB spray are auto-loaded on "B". EDG. This modification will cause only one RB fan and one RB spray to be auto-loaded on "A" and "B" EDG's. .This will reduce the "B" EDG loading by 61 KW.

3. A modification will' be installed to trip the "B" heat tracing to reduce "B" EDG loading by approximately 40 KW.

4. A modification will be installed to change the EFW control valve signal to limit the initial (transient) EFP-1 flow to 860 gpm in all scenarios where this pump is required. Presently this initial flow can be as high as 1070 gpm. The reduction in flow reduces loaoing on the "A" EDG during these initial conditions.

5. A modification will be installed to provide timers and alarms on "B" EDG to alert the operator if the EDG is loaded in the 30 minute rating. This will prompt him to take appropriate steps to shed loads and exit from this rating.

6. The temporary circuitry which trips the "A" battery chargers on a concurrent loss of off-site power and Engineered Safeguards Actuation System (ESAS) actuation will be removed. This will return them to their auto connected status.

PAGE 8 of 8

. TABLE 1 PRESENT LOADING Auto Connected loads on "A" Emergency Diesel Generator.(LB LOCA)

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CALC. TEST EQUIPMENT FLOW KW KW BSP-1A .................................... 1600 197 185.7 (1)

SWP-1A .................................... 8500 480.5 485.5 (1)

MUP-1A .................................... 600 600 615.5 (1)

RWP-2A .................................... 15500 507.7 537.8 (1)

RWP-3A .................................... 10500 195 194.5 (1)

DHP-1A .................................... 3250 282 273.6 (1)

EFP-1 .................................... 430 522 527.9 (1)

DECAY HEAT CL CYCLE COOLING WATER PUMP DCP-1A 3400 74 74 (2)

CONTROL COMPLEX LIGHTING ............................ 32.6 32.6 (2)

INVERTERS.............................................. 58.9 58.9 (2)

MISC AC DISTRIBUTION PANELS............................ 14.7 14.7 (2) ,

MISC PUMPS AND SMALL MOTOR LOADS ................... 34.3 34.3 (2) l REACTOR BLDG FAN AHF-1A ............................ 61 61 (2)

DECAY HEAT CLOSED CYCLE COOLING FAN AHF-15A .......... 2.8 2.8 (2)

FLUSH WATER PUMP D0P-2A ............................ 8.9 8.9 (2)

TRANSFORMER AND CABLE LOSSES ................... 5.1 5.1 (2)

TOTAL LOAD ON EDG 3A AT 1 MINUTE 3076.5 3112.8 Manually connected loads applicable to both "A"_and "B"_ Diesel Generators EQUIPMENT KW SPENT FUEL COOLANT PUMP ............................ 41 CHILLED WATER SUPPLY PUMP ............................ 17 CONTROL COMPLEX WATER CHILLER ................... 193 EFIC CONTROL COMPLEX FAN ............................ 13

' CONTROL COMPLEX EMER DUTY SUPPLY FAN................... 50 CONTROL COMPLEX RETURN AIR FAN ................... 17 EDG "A loads that are tripped and must be reconnected by Operator action EQUIPMENT KW HEAT TRACING ..................................... 40.9 BATTERY CHARGERS ..................................... 93.1 NOTES

1. TEST VALUES CORRECTED FOR KW INSTRUMENT ERROR.

2. DURING SP-417 THESE LOADS TESTED AT 134.7 KW(ERROR CORRECTED).HOWEVER, THE MORE CONSERVATIVE CALCULATED VALUE OF 292.3 KW IS BEING USED TO CALCULATE THE TOTAL EDG "A" LOAD.

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TABLE 2

. PRESENT. LOADING Auto Connected loads on Emergency Diesel Generator during LB/LOCA.

"_B" CALC.

EQUIPMENT FLOW KW BSP-1B .................................... 1600 197 SWP-1B .................................... 8500 480.5 MVP-1C ..................................... 600 600 RWP-2B .................................... 15500 507.7 RWP-3B .................................... 10500 195 DHP-1B .................................... 3250 282 DECAY HEAT CL CYCLE COOLING WATER PUMP DCP-1B 3400 74 CONTROL COMPLEX LIGHTING ............................ 30.5 INVERTERS.............................................. 62.6 MISC AC DISTRIBUTION PANELS............................ 19 MISC PUMPS AND SMALL MOTOR LOADS ................... 110.5 REACTOR BLDG FAN AHF-1B,.1C ............................ 122 DECAY HEAT CLOSED CYCLE COOLING FAN AHF-15B .......... 2.8 FLUSH WATER PUMP DOP-2B ............................ 8.9 TRANSFORMER AND CABLE LOSSES ................... 9.4 HEAT TRACING ..................................... 40.2 BATTERY CHARGERS ..................................... 93.1 EMERGENCY LIGHTING..................................... 24.4 TOTAL LOAD ON EDG 3B AT 1 MINUTE 2859.6 Manually connected loads applicable to both "A"_and "B" Diesel Generators EQUIPMENT KW SPENT FUEL COOLANT PUMP ............................ 41 CHILLED WATER SUPPLY PUMP ............................ 17 CONTROL COMPLEX WATER CHILLER ........... ....... 193 EFIC CONTROL COMPLEX FAN ............................ 13 CONTROL COMPLEX EMER DUTY SUPPLY FAN................... 50 CONTROL COMPLEX RETURN AIR FAN ................... 17

TABLE 3 POST REFUEL VII. LOADING 1 l

l Auto Connected loads on "A" Emergency Diesel Generator.(Int.Br.LOCA)

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CALC. TEST EQUIPMENT FLOW KW KW BSP-1A .................................... 1600 197 185.7 (1)

SWP-1A .....................,.............. 8500 480.5 485.5 (1)

MVP-1A .................................... 600 600 615.5 (1) i RWP-2A ................................ ... 15500 507.7 537.8 (1)

RWP-3A .................................... 10500 195 194.5 (1)

DHP-1A .................................... 0 0 0 EFP-1 .................................... 346 488 495.2 (1)

BATTERY CHARGERS ..................................... 93.1 93.1 (2)

DECAY HEAT CL CYCLE COOLING WATER PUMP DCP-1A 3400 74 74 (2)

CONTROL COMPLEX LIGHTINC ............................ 32.6 32.6 (2)

INVERTERS.............................................. 58.9 58.9 (2)

MISC AC DISTRIBUTION PANELS............................ 14.7 14.7 (2)

MISC PUMPS AND SMALL MOTOR LOADS ................... 34.3 34.3 (2)

REACTOR BLDG FAN AHF-1A ............................ 61 61 (2)

DECAY HEAT CLOSED CYCLE COOLING FAN AHF-15A .......... 2.8 2.8 (2)

FLUSH WATER PUMP 00P-2A ............................ 8.9 8.9 (2)

TRANSFORMER AND CABLE LOSSES ................... 5.1 5.1 (2)

TOTAL EDG 3A AUTO LOADS AT 1 MINUTE 2853.6 2899.6 Manually connected loads applicable to both "A" and "B" Diesel Generators EQUIPMENT KW SPENT FUEL COOLANT PUMP ............................ 41 CHILLED WATER SUPPLY PUMP ............................ 17 CONTROL COMPLEX WATER CHILLER ................... 193 l EFIC CONTROL COMPLEX FAN ............................ 13 CONTROL COMPLEX EMER DUTY SUPPLY FAN................... 50 CONTROL COMPLEX RETURN AIR FAN ................... 17 EDG "A" loads that are tripped and must be reconnected by Operator action EQUIPMENT KW l

! HEAT TRACING ..................................... 40.9 l

l The following load is a manually applied swing load which is normally aligned to the "B" side. The load on EDG "A" must be reduced to allow realignment of this load to the "A" side.

EQUIPMENT KW ES MCC 3AB ..................................... 91 (3)

NOTES

1. TEST VALUES CORRECTED FOR KW INSTRUMENT ERROR.

2. DURING SP-417 THESE LOADS TESTED AT 134.7 KW(ERROR CORRECTED).HOWEVER, THE MORE CONSERVATIVE CALCULATED VALUE OF 292.3 KW IS BEING USED TO CALCULATE THE TOTAL EDG "A" LOAD.

3. INCLUDES ES SELECTABLE FAN AHF-1C.

TABLE 4 I

POST REFUEL VII LOADING Auto Connected loads on "B"_ Emergency Diesel Generator during LB/LOCA.

CALC.

EQUIPMENT FLOW KW BSP-1B .................................... 1600 197 SWP-1B .................................... 8500 480.5 MUP-1C .................................... 600 600 RWP-2B .................................... 15500 507.7 RWP-3B .................................... 10500 195 DHP-13 -................................... 3250 282 DECAY HEAT CL CYCLE COOLING WATER PUMP DCP-1B 3400 74 CONTROL COMPLEX LIGHTING ............................ 30.5 INVERTERS.............................................. 62.6 MISC AC DISTRIBUTION PANELS............................ 19 MISC PUMPS AND SMALL MOTOR LOADS ................... 110.5 REACTOR BLDG FAN AHF-1B ............................ 61 DECAY HEAT CLOSED CYCLE COOLING FAN AHF-15B .......... 2.8 FLUSH WATER PUMP 00P-2B ............................ 8.9 TRANSFORMER AND CABLE LOSSES ................... 8.7 BATTERY CHARGERS ..................................... 93.1 EMERGENCY LIGHTING..................................... 24.4 TOTAL LOAD ON EDG 3B AT 1 MINUTE 2757.7 Manually connected loads EQUIPMENT KW SPENT FUEL COOLANT PUMP ............................ 41 CHILLED WATER SUPPLY PUMP ............................ 17 CONTROL COMPLEX WATER CHILLER ................... 193 EFIC CONTROL COMPLEX FAN ... ........................ 13 CONTROL COMPLEX EMER DUTY SUPPLY FAN................... 50 CONTROL COMPLEX RETURN AIR FAN ................... 17 EDG "B l

_______"________________..._______ _____ ..._____ .______.. ______ LOADS THA HEAT TRACING ..................................... 40.2

ATTACHMENT 1 1 1

l ENGINEERING INSTRUCTIONS not1or3 J

@ Florida M Crystal River Unit 3 Sheet g of 27 j

RD/ MAR NUMBER 1

88-01-12-01 EDG ENGINE UPGRADE J G. TESTING

)>

Prior to reinstalling intercoolers, hydro to 25 psig and hold for 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br />.

Acceptance criteria is zero (0) gpm. -

After the engine modification is complete, a break-in run, as outlined below is to be performed. <

l NOTE: During engine run-in, governor load limit should be set to prevent '

accidental engine overload.

BREAK-IN RUN SPEED IJE L(LAD CHECK RE0VIRED MINIMUM 5 MIN NO LOAD 2 500 15 MIN NO LOAD 2;4 600 15 MIN NO LOAD 700 15 MIN NO LOAD 800 15 MIN NO. LOAD 900 15 MIN NO LOAD 1, 2 900 1 HOUR 712 KW (25%)

. 900 1 HOUR 1068 KW (37.5%)

900 2 HOURS 1425 KW (50%)

900 3 HOURS 1781 KW (62.5%)

900 3 HOURS 2137 KW (75%) 1 900 3 HOURS 2493 KW (87.5%)

900 3 HOURS 2850 KW (100%) 1, 2, 3

1. Check pistons, rings and cylinder liners through the air receiver ports after the runs.

2. Check bearings for overheating after the runs. See Enclosure 13.

3. Check cylinder firing pressures and record. Acceptable firing pressure range is 1300-1340 psig. Adjust injection timing as required to obtain the firing pressure range. Variation between cylinders is 100 psig or less.

4. In service leak test the engine. Check for air leaks, with hand, around new engine piping, blowers, turbo etc.

N211RS4-2 DEstGN ENGINEER DATE VERIFICATION ENGINEER DATE SUPERVISOR, NUCLEAR ENGINEERING DATE Re. 438 RET use of Ptam RESP. Nuclea Ops Engineering 912 243

ATTACHMEET 1 Florida ENGINEERING INSTRUCTIONS PAGE 2 of 3

[ Crystal River Unit 3 Sheet g of 27 HEl/ MAR NUMBER 88-01-12-01 EDG ENGINE UPGRADE G. TESTING - (Continued)

Run each engine for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> at a rating of 2500-2850 kw. Record lube oil, jacket water and air receiver temperatures every two (2) hours. At the end of the 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> run check the bearings for overheating in accordance with Enclosure 13.

H. ISI The ISI Engineer should review this package for applicability to the ISI program.

DESIGN ENGINEER DATE VERIFICATION ENGINEER DATE SUPERVtSOR. NUCLEAR ENGINEERING DATE Rev N88 RET; Life of Plant RESP: Nuclear Ops. Engineenno 912 243

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ATTACHMENT 1-9M Florida ENGINEERING INSTRUCTIONS PAGE 3 of 3 Crystal River Unit 3 Sheet 26 of 27 CEl/ MAR NUMBER 88-01-12-01 EDG ENGINE UPGRADE ENCLOSURE 13 MAIN BEARING INSPECTION

1. Aluminum main and thrust bearings which have flashed or ' failed can be easily detected.

2. Use a .002" feeler gage to check for clearance between the bearing shell and the bearing cap near, and at, the parting line.

3. E the feeler gage can be inserted.

THEN the bearing has flashed and must be removed.

4. The parting lines between the two shells of a flashed bearing will also be open so that the .002" feeler gage can be inserted.

5. E inspection reveals that a failure exists, THEN remove the main bearing cap and shells.

6. Remove the adjacent connecting rod and piston assembly if the failure is on the lower shaft. If the failure is on the upper shaft, disconnect the adjacent connecting rod from the crankshaft. By adjacent, it is meant the connecting rod and piston assembly that is lubricated and cooled by oil that is relayed through the failed main bearing. No.1 main feeds No.1 piston, No. 2 main feeds No. 2 piston, etc. (The reason for removing this adjacent assembly is to prevent the sodium hydroxide solution used in cleaning the crankshaft journal from entering the interconnected oil tube and damaging the connecting rod bearing. Also, check the connecting rod bearing for any aluminum particles.)

l I

N211RS4-2

]

me,e~ ~,~ue om u ,m.1,e~ ~,m. om seeE.,see. ~em. -,~ue,~e om l l

4 esv. 4/86 RET Ute of P, ant RESP: Nuclear Ops. Engineeren0 912 243 j l

7 ATTACHMENT 2 d"It r'idustri2s- Fairbanks M rs) {

Engine Division j 701 Lawton Avenue J

Beloit, Wisconsin 535115492 Telephone: 608/364 4411 Telecopier: 608/364 8417 May'9, 1989 Florida Power Corporation j 3201 34th Street South i P O Box 14402 St. Petersburg,' Florida 33733 ,

Attention: Matee U. Rahman

Subject:

Crystal River Unit 3 FPC PO F800018D' Colt Order 35-729995 M10 Standby Diesel Generators Generator Information

Reference:

(a) Colt letter dated 4/4/89 (b) Colt letter dated 3/20/89 (c) FPC letter NEA89-0371 dated 3/13/89 Gentlemen:

This letter is written-to supercede references (a) and (b) and is in response to reference (c).

The minimum acceptable power factor for the new ratings of 3250 KW (4062.5 KVA) for 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> and 3500 KW (4166 KVA) for 30 minutes is 0.842 power factor.

If you have any questions or require additional information please contact the writer.

Very truly yours, k

T. M. Stevenson, Manager Parts Marketing .

TMS/jcj cc: R. Calud t

I l

u- .

ATTACHMENT 3-Sample EDG lona term loading evaluation calculations

Reference:

FpC submittal to NRC 3F0988-11, dt. 9/15/88 On table 1, the loading of 2879.4 KW occurs at time T=30 minute during Intermediate break LOCA (0.07 sq.ft). The largest single load in this 2879.4 KW-loading is Makeup pump 1A with a loading of 600 KW at 600

-gpm. This loading of 600 KW is calculated as follows:

From manufacturer's pump curve the BHP required by MVP-1A at 600

.gpm at a specific gravity of 0.988= 731

~The specific gravity of makeup water at 70 degree F= 1.017 Therefore BHP at sp. gravity of 1.017=731*(1.017/0.988)= 752.5 Per manufacturer data the BHP required by pump gear drive = 12 Total BHP required by pump = 764.5 Motor nameplate efficiency = 95.1%-

KW required by motor: BHP *.746/ efficiency =764.5*.746/.951=- 600 On table 2, the loading of 2924.4 KW occurs at time T= 30 minute during Steam Line Break outside Reactor Building. The largest single load in this 2924.4 KW loading is motor driven emergency feedwater pump EFP-1 with a loading of 602 KW at 665 gpm. This loading of 602 KW is calculated as follows:

From manufacturer's pump curve the BHP required by EFP-1 at 665 gpm= 740 Per manufacturer information the BHP required by pump gear assembly = 2 % of BHP. required by pump = 0.02*740= 14.8 Total BHP required by pump = 754.8 Motor nameplate efficieny= 93.6%

KW required by motor: BHP *.746/ efficiency =754.8*.746/.936= 602 On table 3, the loading of 2894.5 KW occurs at time T= 3 hour3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> during Intermediate Break LOCA (0.04 sq. ft). The largest single load in this 2894.5 KW loading is Makeup pump 1C with a loading of 600 KW at 600 gpm. The calculation for MVP-1C is similar.to calculation for MUP-1A as described above.

On table 4, the loading of 2938.9 KW occurs at. time T= 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> during Intermediate Break LOCA (0.07 sq.ft). The largest single load in this 2938.9 KW loading is Makeup pump 1C with a loading of 600 KW at 600 gpm. The calculation for MVP-1C is similar to calculation for MVP-1A as described above.

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