AECM-84-0473, Forwards Response to Generic Ltr 84-15 Re Proposed Actions to Improve & Maintain Diesel Generator Reliability.Comments & Recommendation Encl

Forwards Response to Generic Ltr 84-15 Re Proposed Actions to Improve & Maintain Diesel Generator Reliability.Comments & Recommendation Encl

ML20098F786
Person / Time
Site:	Grand Gulf
Issue date:	09/28/1984
From:	Richard J MISSISSIPPI POWER & LIGHT CO.
To:	Harold Denton Office of Nuclear Reactor Regulation
References
AECM-84-0473, AECM-84-473, GL-84-15, TAC-55863, NUDOCS 8410030377
Download: ML20098F786 (16)

Text

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c- _~4 MISSISSIPPI POWER & LIGHT COMPANY Helping Build Mississippi P. O. B OX 164 0, J A C K S O N, MIS SIS SIP PI 3 9 2 05 September 28, 1984 b o.*EU[IS ., . r. ve m .

U. S. Nuclear Regulatory Commission Office of Nuclear Reactor Regulation Washington, D. C. 20555 Attention: Mr. Harold R. Denton, Director

SUBJECT:

Grand Gulf Nuclear Station Unit 1 Docket No. 50-416 License No. NPF-13 File: 0290/L-800.0 Response to Generic Letter 84-15 AECM-84/0473 This letter provides the Mississippi Power & Light Company (MP&L) response to Generic Letter (GL) 84-15, dated July 2, 1984, pertaining to proposed staff actions to improve and maintain diesel generator (D/G) reliability. Attached to this letter is MP&L's response to each of the items addressed in GL-84-15, with respect to Grand Gulf Nuclear Station (GGNS)

Unit 1.

MP&L recognizes the significant safety benefit of maintaining high reliability of diesel generators at operating nuclear plants to mitigate the consequences of a loss of offsite power event. To realize this benefit, MP&L has developed a long term D/G maintenance testing program (attached) to maintain the high reliability experienced to date.

Also, included in the attached response are MP&L's comments /

recommendations on the proposed staff actions of GL-84-15.

Please contact this office if questions arise concerning this submittal.

Yours tr ,

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JBR:rg Attachments cc: See next page O ( g P i Member Middle South Utilities System

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AECM-84/0473 MISSISSIPPI POWER & LI2HT COMPANY #E' '

.cc: Mr. J. B.. Richard (w/a)

'Mr.'R. B. McGehee (w/o)

Mr. N. S. Reynolds -(w/o)

--Mr.'G.-B. Taylor (w/o)

Mr. Richard.C. DeYoung, Director (w/a)

Office of Inspection & Enforcement U. S. Nuclear Regulatory Commission Washington,.D. C. 20555 Mr. J. P. O'.Reilly, Regional Administrator (w/a)

U.S. Nuclear Regulatory Commission Region Il 101 Marietta St., N.W., Suite 2900 Atlanta, Georgia 30323

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BEFORE THE UNITED STATES NUCLEAR REGULATORY COMMISSION LICENSE NO. NPF-13 DOCKET NO. 50-416 IN THE MATTER OF MISSISSIPPI POWER & LIGHT COMPANY

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MIDDLE SOUTH ENERGY, INC.

and SOUTH MISSISSIPPI ELECTRIC POWER ASSOCIATION AFFIRMATION I, J. B. Richard, being duly sworn, stated that I am. Senior Vice-President,. Nuclear of Mississippi Power & Light Company; that on behalf of Mississippi' Power & Light Company, Middle South Energy, Inc., and South Mississippi Electric Power Association I am authorized by. Mississippi Power &

_ Light' Company to sign and file with the Nuclear Regulatory Commission, this

. response to Generic Letter 84-15 for the Grtad~ Gulf Nuclear Station in

.accordance with 10CFR50.54(f); that I signed this submittal as Senior Vice

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President, Nuclear of Mississippi Power & Light Company; and.that the statements made and the matters set forth'therein are true and ect to the best of my knowledge,-information and belief.

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J. . Rithard p _ . STATE OF MISSISSIPPI COUNTY.0F HINDS SUBSCRIBED AND SWORN TO before me, a Notary Public, in and for the County and State above named, this - 2Pf4 day of .Nf,/%/f r" , 1984.

(SEAL) c'. ,

Notarypb1N My commission expires:

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Attachment to AECM-84/0473

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MP&L RESPONSE TO GENERIC LETTER 84-15 V

i1. .NRC1 REQUEST No.i1: ,

' Reduction in Number of Cold Fast Start Surveillance Tests for Diesel Generators This item -is directed towards reducing the number of cold fast start

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, surveillance tests for diesel-generators which the staff has determined e .results-in' premature diesel engine degradation. Tne details relating to

~7 this subject'are provided in Enclosure 1. Licensees are requested-to rdescribe.their current programs:to avoid cold fast start surveillance

. testing or their-intended actions to reduce cold fast start surveillance-testing for diesel generators.

'MP&L RESPONSE:

MP&L'has in place procedures which serve to reduce the number of cold fast

' starts experienced by the diesel generators (D/Gs) at the Grand Gulf

. Nuclear Station (GGNS). These procedures were developed based on recommendations by the-diesel manufacturers and include the fo11 swing

. practices:

(1). The engines are maintained in a warm condition with heated lube oil and jacket water circulating. . This keeps some of the -internal components lubricated and warm reducing-friction and thermal stresses during startup.

.(2) Prior.to each ' planned surveillance, the Division I and II. diesel

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engines are air rolled to inspect for water accumulation in the

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- cylinders. Drip systems have also been added to the lubrication systems of the turbochargers on Division I and 11 to maintain- the

' thrust bearings in a lubricated condition while the engines are'in-

. standby. . The Division I, II, and III diesel engines and turbochargers are prelubed prior to planned ' starts for surveillance-Etesting to ensure that'c itical' engine components are well lubricated.

J(3)~ The Division'III-diesel is also hand rolled and prelubed on a weekly-

' basis to' ensure that critical components are lubricated if an unplanned automatic start occurs and the independent air start nystems are tested'on a rotating basis to assure operability of each'

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system.-

MP&L considers that the current GCNS D/G design and maintenance practices.

, : described abovefreduces the number-of cold starts more than the proposed changes incorporated in the attachment to-Enclosure 1 of Generic Letter

.; 84-15.

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'AECM-84/0473

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MP&L- Comments / Recommendations on NRC Proposed D/C Technical Specifications -

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Cold _' starts (without prelubing the diesel engine an'd'in some instances.

>turbochargers) arp not reccamended. To avoid unnecessary demands, wear and stress;on.the diesel-generator. system, all preplanned starts should be ~

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Jpreceded by appropriate prelubes, with the exception.that a' cold fast-(non prelubed). start:should be. demonstrated at'least once each-18 months. The

' ability 2of<the engine, generator,and support systems to operate properly

- is fadequately,. demonstrated with' the 31 day and 18 moath surveillance

' tests.

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-;MP&L'recommen'ds'that.the footnote requiring cold fast (non-prelubed) totartsfonce each six months be deleted and the above recommendation for a 18 month surveillance period be adopted. This action will further serve to avoid unnecessary cold fast start surveillances.

In addition, ' the :" continuous rating" ' referenced in Section 4.8.1.1.2.a.5 ~

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. should:be based on the maximum expected loao following a loss of coolant eaccident (LOCA)=or loss ofLoffsite power (LOSP) and not on the maximum rating of the diesel generator.

Note that loading to the continuous. rating'within 60 seconds (as' required .

by the GGNS Technical Specification) produces high stress levels on the diesels. : MP&L1 recommends'thatzfast' starts and loading to." continuous

. rating" within 60 seconds should be performed on a six month schedule-as

part:of.rection 4.8.1.1.2.a.5.instead of on the frequency as specified in

- Table 4.8-1 E(once every.31 days).: Thirty-one day surveillances should 'be

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. performed during " fast' starts and slow loading". By loading the diesel

. generators over a 10 to 15 minute time frame the stress levels would be great 1 y reduced'and;the ability of'the dieself to carry the required LOCA/

LOSP:. loads would be adequately demonstrated. MP&L's recommendations are

~- . ' summarized in Table 1 attached.

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'TA5LE l'

SUMMARY

OF MP&L RECOMMENDATIONS.ON NRC PROPOSED D/G TECH SPECS ITEM- NRC PROPOSED MP&L RECOMMENDATIONS JUST1FICATION Failures Frequency.

1. 31 Day Surveillances :E l 31 uays $1 31 days The.NRC proposal requires testing at four times the.

Ref: _T.S. 4.8.1.1.2.a 2: 2 7 days 2 14 days. frequency if,more than 1 (Test Frequency) failure occurs. -Doubling the Table ~4.8.1 2: 3 7 days frequency of testing for.

subsequent failures adequately tests:the diesels and will-reduce the testing demands-on the D/G system.-

2. Ambient Starts Ref: T.S. 4.8.1.1.2.a.4 and asterisk subnote (e) Prelubed Starts (a) Perform " ambient" (a) Same (a) No change proposed prelubed starts every 31 days minimum (b) Non-prelubed Starts (b) Perform " ambient" (b) Perform " ambient" (b) There is no justification non-prelubed starts non-prelubed starts for subjecting D/Gs once each 184 days at least once each repeatedly to non-minimum- 18 months prelubed starts. This should be performed on a less frequent basis than the NRC proposal because-of the added wear and stresses on critical D/G components. Unplanned LOSP/LOCA starts and 18 month test adequately demonstrate ability to start the diesel " dry".

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SUMMARY

OF MP&L RECOMMENDATIONS ON NRC. PROPOSED D/G TECH SPECS ITEM NRC PROPOSED MP&L RECOMMENDATIONS- JUSTIFICATION.

3. Cenerator Synchronization

.Ref: T.S. 4.8.1.1.2.a.5 (a) Continuous ~ Rating (a) Verify generator- (a) " Continuous rating" (a) There is no justification synchronization bys should be defined as for loading diesels.to-loading to maximum expected 100% of their engine or

" continuous rating" site LOSP/LOCA Load- generator loading rating (not engine rating). after pre-operational and shop-testing has demon-strated their capability.

Tests performed during surveillance only need to demonstrate load carrying capacity to maximum expected er.orgency loads.

(b) Time to Load (b) Verify loading to (b) Current CCNS T.S. '(b) One of the most severe

" continuous rating requires 160 transients on diesel in ( ) seconds" seconds. All generator equipment is planned starts fast. loading to full should verify fast rated power. Once the start (510 seconds capability of the-D/G to to. volts / frequency) perform this function has and slow loading to been demonstrated, it is above continuous not necessary to reverify rating in 515 this capability each 31 minutes. days.- Slow loading is preferred which reduces l thermal transients and stresses. Fast loading la $60 seconds should only be demonstrated at least once each 18

. months.

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Attcchment to AECM-84/0473

2. NRC REQUEST No. 2:

Diesel Generator Reliability Date

'This item requests licensees to furnish the current reliability of each diesel generator at their plant (s), based on surveillance test data.

Licensees are requested to provide thn information requested in Enclosure 2.

MP&L RESPONSE:

The GGNS procedures include a detailed set of instructions on the start and run history of the Division I, II, and III diesel generators. All starts and attempted starts are logged and run time / loads are recorded. A diesel' generator valid start / failure determination sheet based on the criteria in Regulatory Guide 1.108 position C.2.e is completed for all failures. At least each 18 months the cumulative operating data and any trends are reviewed and documented. Repeat failure mechanisms, repeat human errors, or common mode failures are described in the documentation process.

The reliability data for the GGNS Division I, II and III diesel generators through September 20, 1984 is provided in Table 2. The combined relia-bility of the diesel generators at GGNS is 98% over the last 100 valid tests, which demonstrates that the current GGNS program is effective in maintaining high diesel generator reliability.

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TABLE 2 -

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CGNS DIESEL CENERATOR' RELIABILITY

, , t DIVISION VALID FAILURES ' TIME PERIOD ' TOTAL VALID TESTS TOTAL VALID FAILURES RELIABILITY' BASED ON TOTAL IN LAST 20. -0F 20 VALID FROM DATE OF % N DAH OF %3 TO' ' WD USTS m VALID FARMS 3

VALID TESTS TESTS' .TO 9/20/84 9/20/84 I 2 '1/28/84 93 3 97%~

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9/20/84' II. 0 2/3/84 69 0 100% ,

to-9/20/84.

III O .1/26/84- .78 .2 97%

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-9/20/84-Data as of. September 20, 1984.-

Valid tests and valid failures based on' criteria in Regul'atory Guide 1.108.

Operating License received 6/i6/82.

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Attachmont to m E: - AECM-84/0473' y -

'i3. ~ NRC REQUEST No. 3:

Diesel Generator Reliability-

. Licensees'are~ requested:to describe their program, if any, for attaining

=and maintaining a reliability-goal for their diesel generaters. An example ~of~a performance Technical Specification to support a desired diesel reliability. goal has been provided by the staff in Enclosure 3.

Licensees are requested to comment on, and compare their existing program or:any proposed program with the example performance specification.

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- MP&L' RESPONSE:

The GGNS program for_ improving the reliability of the diesel generators is ibased on a planned schedule of inspections and tests developed to provide a high degree of' reliability while maintaining the diesels available for tuse if needed. The reliability goal of the program is to maintain the

diesel generator reliability as high as possible. This program meets or

exceeds the intent of Regulatory Guide 1.108 and is based on s '

manufacturers' recommendations and past operating experience. Frequent sampling of lube oil and' cooling water is performed _to provide early warning of potential problems. Table 3 provides the long term GGNS D/G

-Maintenance Testing Program for the two standby; diesel engines and Table 4

.the program for the Division III diesel engines. The effectiveness of this program has been empirically _shown by the high reliability.

experienced to date as presented in Table 2 of this submittal.

The~ recommendations of NUREG/CR-06f0, " Enhancement of Onsite Emergency Diesel Generator Reliability,' February 1979" were considered in the development:of the diesel generator reliability program.' Each of the

{,  ; recommendations is addressed in Chapter 9 of the GGNS FSAR.

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,Section 3.8.1.1 of the propcsed Technical Specifications would allow a

delay up to 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> under certain conditions before demonstrating diesel

generator operability, given that one offsite a.c. source or'one diesel generator.is inoperable. This additional delay provides greater opportunity for a. determination to be made of the cause of inoperability, if unknown, without placing undue demands on the operable diesel'

.. generator (s). The recently amended Full Power GGNS Technical

! Specifications allow only a 2 hcur. delay. The proposed change to the L Action statement ~also' indicates that only one start is required within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> while 'in the '72 hour8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> Limiting Condition for _ Operation (LCO). GGNS

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Technical ~ Specifications require a start within 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> and then once

,every 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> thereafter while in the LCO. Thus, this proposed Technical L

Specification change is expected to significantly reduce the number of-starts experienced.

p MP&L comments on Section 4.8.1.1.2 of.the proposed Technical Specification

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are discussed in response to NRC Request No. 1. Table 4.8.1, however, does~ require some clarification. It should be explicitly stated that in the event that a diesel generator has two or mote valid failures in the L last: twenty valid demands, only that diesel generator is tested on a more

<- .' frequent basis. If the other diesel generators at c given unit have not i ,  : experienced a higher failure frequency there is no need for more frequent ftesting of those' diesels.

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Atttch snt to AECM-84/0473 R

- A comparison.of the proposed test frequencies with the current GGNS t'est frequenciesHis given in Table 5.

!The GCNSiTechnical-Fnecifications contain specific reporting requirements

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in the event of a valid _or non-valid diesel generator failure. The.

~ > information listed.inLSection 6.3.b of Regulatory Guide 1.108 is required

- to be sent to;the-NRC.. This information'is similar to that being

proposed.- In addition, a statement on the' basis for continued operation is required as well.as the length'of time that th'e diesel generator was

,unavailableh;0nly the' evaluation of the~ recommendations of NUREG/CR-0660 t

l is not included. Because the reporting requirements currently embodied in

the GCNS Technical Specifications exceed the' proposed requirements, no

[ changes are deemed necessary;to keep the NRC abreast of any diesel 1

' f* generator problems.

The proposed requalification of a diesel generator as described in Attachment 2 to Tab?a'4.8-2 provides a reasonable means for obtaining-evidence that the diesel generator in qttestion is again reliable.and able

'to perform its intended function. Currently no standard'requalification

- scheme is contained in' the GGNS Technical Specifications, although MP&L'is

participating in the Transamerica Delaval Incorporated, Diesel Generator Owners' Group diesel.requalification/ revalidation effort.

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-Maintenance Action Frequency.

1~ month'

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Check. lubricating oilifor fuel dilution with a viscosimeter.

!' Send lubricating' oil. sample to: laboratory fortanalysis.- '

-1 month.

i l- Drain. lubricating' oil system. Clean sump.and strainers,' refill'with ~

.18Jmonths (1)'

l new oil..

l Check pH factor of ja'cket water. -1 month L

l Remove alternate left side doors and examine inside of engine'for any 18 months-

! abnormal conditions.

Check hydraulic valve,lif ters .for operation and proper adjustment. 18 months Remove fuel injector nozzles. clean, reset, and reinstall. 18 months Check connecting rods and link rod bearing clearance. -18' months (2)

Check and record crankshaft deflections. 18 months-

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Visually inspect? foundation for. breaks.in bond.between sole plates'and 18 months (3) grout, ,

Check foundation bolts..for correct torque. Retorque as necessary then 18 months recheck crankshaft' deflections.

l Check lubricating oil jets at gears for plugged or broken lines. 18 months.

Remove can covers and cylinder head covers. Inspect cams, tappets, ~18 months rollers, rocker arms., push rods, springs,'and. valve guides.

Drain governor oil, clean, flush refill with new oil. If necessary, 18 months replace governor drive coupling.

NOTE 1: .This item performed only.if deemed necessary'as a result of lube oil analysis.

NOTE 2: Bearing wear is determined by. analysis of metal concentration in lube oil analysis.

NOTE 3: -This inspection is performed during. foundation bolt torque check and crankshaft deflection check.

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Maintenance Action Frequency .

Remove turbocharger (s).: Disassemble and clean.- .S years

-18 months Check cold compression pressures, maximum firing' pressures.-

If indicated, remove . cylinder heads, grind valves. ' Check valves and~ liners. ,

Inspect gears for general condition. . Check backlash and replace worn- 18 months gears exceeding maximum clearance.

Remove fuel injection pumps. . Disassemble, clean, repair, and adjust. 18 months as necessary..

Remove end plates from heat exchangers and intercoolers. Examine and '18 months'~

clean as necessary.

Check main bearings. 18 months Inspect intake' air f11ter oil distribution plate. Change oil in 18 months-(4).

-filter.

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- NOTE 4: Oil in the air filter is sampled and changed only when deemed necessary by oil analysis results.

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- Attachment to AECM-84/0473 TABLE 4 GGNS D/G MAINTENANCE TESTING PROGRAM

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DIVISION III' DIESELS

' Check jacket water coolant level Every 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> Check starting' air pressure Every 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> Drain low point water collector, "Y" strainers once/24 hr.

.and air receiver-tanks in starting air system Check pH and alkalinity of, jacket. cooling water 1 month

Inspect starting air compressor 3 months Clean andlinspect' starting air' lubricator 6 months

Clean and inspect "Y" strainers in starting air system 6 months

(( < Take oil'~ sample 11n. air intake filter reservoir. 6 months Clean and change oil in air intake filter 6 months Sample crankcase lube oil 1 month Inspect, clean,'and calibrate lube oil relief valves 3. years

Remove condensate from fuel oil storage tanks 3 months

.Take-oil sample from starting air compressor 3 months-

-Inspect lube oil separator 1 year Adjust valves on starting air compressor' 1 year

. Inspect.pnd lubricate Woodard governor 18 months Inspect and clean fuel oil-and auxiliary fuel oil strainers 18 months

. Replace fuel and auxiliary fuel filters 18 months Replace turbocharger lube oil filter element 18 months Clean lube oil strainers 18 months Test fuel injectors 18 months

Inspect and adjust fuel injector linkage 18 months P

Inspect turbochargers 5 years X38rg6 s

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Attachmsnt to

- - AECM-84/0473 e , TABLE 5 DIESEL CENERATOR TEST SCHEDULE

-CENERIC LETTER- CURRENT GCNS TECH. SPEC.

84-15 p.

No.lof Failures in ' Test 'No. of' Failures in Test'

!Last 20 Valid Tests' Frequency Last 100 Valid Tests Frequency ik ~ 1 once/31 days 61 once/31 days Jt'2 once/7 days 2 once/14 days 3 once/7 days 2: 4 ' once/3 days k s' f

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