Information Notice 1991-62, Diesel Engine Damage Caused by Hydraulic Lockup Resulting From Fluid Leakage Into Cylinders

Diesel Engine Damage Caused by Hydraulic Lockup Resulting From Fluid Leakage Into Cylinders

ML031190183
Person / Time
Site:	Beaver Valley, Millstone, Hatch, Monticello, Calvert Cliffs, Dresden, Davis Besse, Peach Bottom, Browns Ferry, Salem, Oconee, Mcguire, Nine Mile Point, Palisades, Palo Verde, Perry, Indian Point, Fermi, Kewaunee, Catawba, Harris, Wolf Creek, Saint Lucie, Point Beach, Oyster Creek, Watts Bar, Hope Creek, Grand Gulf, Cooper, Sequoyah, Byron, Pilgrim, Arkansas Nuclear, Three Mile Island, Braidwood, Susquehanna, Summer, Prairie Island, Columbia, Seabrook, Brunswick, Surry, Limerick, North Anna, Turkey Point, River Bend, Vermont Yankee, Crystal River, Haddam Neck, Ginna, Diablo Canyon, Callaway, Vogtle, Waterford, Duane Arnold, Farley, Robinson, Clinton, South Texas, San Onofre, Cook, Comanche Peak, Yankee Rowe, Maine Yankee, Quad Cities, Humboldt Bay, La Crosse, Big Rock Point, Rancho Seco, Zion, Midland, Bellefonte, Fort Calhoun, FitzPatrick, McGuire, LaSalle, Fort Saint Vrain, Shoreham, Satsop, Trojan, Atlantic Nuclear Power Plant
Issue date:	09/30/1991
Revision:	0
From:	Rossi C E Office of Nuclear Reactor Regulation
To:
References
IN-91-062, NUDOCS 9109240248
Download: ML031190183 (7)

UNITED STATESNUCLEAR REGULATORY COMMISSIONOFFICE OF NUCLEAR REACTOR REGULATIONWASHINGTON, D.C. 20555September 30, 1991NRC INFORMATION NOTICE 91-62: DIESEL ENGINE DAMAGE CAUSED BY HYDRAULIC LOCKUPRESULTING PROM FLUID'LEAKAGE INTO CYLINDERS

Addressees

All holders of operating licenses or construction permits for nuclear powerreactors.

Purpose

The U.S. Nuclear Regulatory Commissionj(NRC) is issuing this information noticeto alert addressees to the possibility of severe damage to the emergency dieselgenerator (EDG) engine caused by hydraulic lockup resulting from fluid whichhas leaked into cylinders of the diesel engine. It is-expected that recipientswill review the information for'applicability to their facilities and consideractions, as appropriate, to avoid similar problems. However, suggestionscontained in this information notice are not NRC requirements; therefore, no.,..:specific action or written response is required.

Description of Circumstances

On June 16, 1991, during a precautionary check in preparation for a routinesurveillance test of a Unit 2 emergency diesel generator (EDG), SouthernCalifornia Edison, the licensee at the San Onofre Nuclear Generating Station,found several pints of water in an engine cylinder. This precautionary checkallowed the licensee to avert severe engine damage. The licensee immediatelystopped the surveillance, declared the EDG inoperable, and initiated a workorder to determine the cause..'After removing the cylinder module, the licenseefound that a small leak path had slowly developed on the head gasket, allowingthe jacket 'cooling water to intrude.into the cylinder. The licensee hadoperated this engine 7 days earlier without difficulty. Apparently, a suf-.ficient amount of fluid had leaked after this previous test to partially fillthe cy-li.nder with water. The licensee determined that if the EDG had been~9O2428ZA IN 91-62September 30, 1991 started on this occasion without first being checked for water in the cylin-ders, the EDG would have been severely damaged by hydraulic lockup of thecylinder. While performing a similar precautionary check in 1987, the licenseediscovered a similar condition on a Unit 1 EDG that was caused by a crackedcylinder. Furthermore, an EDG at the Palo Verde Nuclear Generating Station wasseverely damaged in 1986 because it was started after water leaked into acylinder through a cracked cylinder wall.DiscussionBecause of the incompressible nature of water and fuel oil, the presence ofsignificant amounts of fluid in an engine cylinder can cause hydraulic lockupduring the compression stroke. When the force from the starter and otherfiring cylinders tries to overcome this lockup, the engine could be severelydamaged. The fluid can come from a number of sources such as a leaking headgasket, a cracked cylinder or head, or a defective fuel injector or lube oilsystem. EDG vendors such as Transamerica Delaval, Incorporated (TDIInstruction Manual, Volume 1, Model DSRV-20-4 Diesel Engine/Generator,page 4-2) and the General Motors Company, Electro-Motive Division (GM/EMDScheduled Maintenance Program, Stationary Power Units with TurbochargedEngines, Maintenance Instruction 1728, Revision C, November 1977), haverecognized the significance of this hazard and have recommended that theirclients first check for fluid in the cylinders before starting the engine ifthe-engine-has -been-shut-down-and-coo-led-for-aprolonged-periokd The- NRChas discussed this problem with experienced diesel engine operators andunderstands that this is also a common practice in non-nuclear industries.To prepare the engine for each surveillance start, the operators at San Onofrelock out the engine's automatic-start feature, open the indicator petcocks(test valves) on all cylinders, and rotate the engine slowly to check forfluid in the cylinders. After verifying the absence of fluid in the cylinders,the operators start the EDG. The NRC conducted an informal survey of residentinspectors at plants of other NRC licensees and found that not all NRClicensees are following this practice, possibly because the EDG becomes tempo-rarily inoperable while it is locked out with the cylinder petcocks open.The NRC has also addressed this issue in its "Safety Evaluation Report Relatedto the Operability and Reliability of Emergency Diesel Generators Manufacturedby Transamerica Delaval, Inc.," NUREG-1216, August 1986, beginning on page B-4,and in a contract study "Review of Resolution of Known Problems in EngineComponents for Transamerica Delaval Inc. Emergency Diesel Generators," PNL-5600,December 1985, on page 4.160. These documents are available in the NRC PublicDocument Room at 2120 L Street N.W., Washington, D.C. 2055 IN 91-62 ^ .September 30, 1991 This information notice requires no specific action or written response. Ifyou have any questions about the information in this notice, please contact oneof the technical contacts listed below or the appropriate Office of NuclearReactor Regulation project manager.Charles E. Rossi, DirectorDivision of Operational Even ssessmentOffice of Nuclear Reactor RegulationTechnical contacts:Andrew Hon, RV(714) 492-2641Peter Prescott, NRR(301) 492-1011Vern Hodge, NRR(301) 492-1861

Attachment:

List of Recently Issued NRC Information Notices -AttachsentIN 91-62Septeber 30, 1991 LIST OF RECEINTLY ISSUEDIlRt IFORIATION NOTICES.Imforertion Date ofRotice No. Subject Issuance Issued to9141 Preliminary Results oftelidation Testing ofMotor-O ated ValveDiagnostic Equipment91-60 False Alarms of AlarmAat ters Because ofRadiofrquency Inter-ference91-59 Probles with AccessAuthorization Progres91-58 Dependency of OffsetDisc Butterfly Valve sOperation on Orientationwith Respect to Flow9147 Operational Exparienceon Bus Transfers91-56 Potential RadioactiveLeakage to Tank Ventedto Atmosphere91-65 Failures Caused by AnImproperly Adjusted TestLink In 4.16 KY GeneralElectric Switchgear*5-18 Failures of lndervoltageSupp. I Output Circuit Boards Inthe Mestinghouse4esigtedSolid State ProtectionSystse914 Feresn Experience Regard-Ing moron Dilution09/30/91 All holders of OLs or CPsfor nuclear power reactorsand metor-operated valve(NOV) diagnostic equiprentvendors identified herein.09/24/91 All Nuclear Regulatory Com-mission (NRC licenseesauthorized to ase sealedsources for Industrialradioragphy.09/23/91 All holders of OLs or CPsfor nuclear power reactors.09/20/91 All holders of OLs or CPsfor nuclear power reactors.09/19/9109/19/91All holders of OLs or CPsfor nuclear power reactors.All holders of OLs or CPsfor nuclear power reactors.09/16/91 All holders of OLs or CPsfor nuclear power reactors.09/10/91 All holders of OLs or CPs forWestinghouse (i)-designednuclear power reactors.09/06/91 All holders of OLs or CPsfor pressurized waterreactors (PWRs).DL

• perating LicenseCF

• Ce straction Permit IN 91-XXS-eptember xx, 1991_,Ege 2 of 2DiscussionBecause of the incompressible nature of water and fuel oil, the presence ofsignificant amounts of fluid in an engine cylinder can cause hydraulic lockupduring the compression stroke. When the force from the starter and otherfiring cylinders tries to overcome this lockup, the engine could be severelydamaged. The fluid can come from a number of sources such as a leaking headgasket, a cracked cylinder or head, or a defective fuel injector or lube oilsystem. EDG vendors such as Transatnerica Delaval, Incorporated (TDI) and theGeneral Motors Company, Electro-Motive Division (GM/EMD), have recognized thesignificance of this hazard and have recommended that their clients first checkfor fluid in the cylinders before starting the engine if the engine has beenshut down and cooled for a prolonged period (8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> or more). This is also acommon practice among EDG users in non-nuclear industries.To prepare the engine for each surveillance start, the operators at San Onofrelock out the engine's automatic-start feature, open the indicator petcocks(test valves) on all cylinders, and rotate the engine slowly to check forfluid in the cylinders. After verifying the absence of fluid in the cylinders,the operators start the EDG. The NRC conducted an informal survey of residentinspectors at plants of other NRC licensees and found that not all NRClicensees are following this practice, possibly because the EDG becomes tempo-rarily inoperable while it is locked out with the cylinder petcocks open.The NRC has also addressed this issue in its "Safety Evaluation Report Relatedto the Operability and Reliability of Emergency Diesel Generators Manufacturedby Transamerica Delaval, Inc.," NUREG-1216, August 1986, beginning on page B-4,and in a contract study "Review of Resolution of Known Problems in EngineComponents for Transamerica Delaval Inc. Emergency Diesel Generators,"PNL-5600, December 1985, on page 4.160.This information notice requires no specific action or written response. Ifyou have any questions about the information in this notice, please contact oneof the technical contacts listed below or the appropriate Office of NuclearReactor Regulation project manager.Charles E. Rossi, DirectorDivision of Operational Events AssessmentOffice of Nuclear Reactor RegulationTechnical contacts: Andrew Hon, RV(714) 492-2641Peter Prescott, NRR(301) 492-1011Vern Hodge, NRR(301) 492-1861

Attachment:

List of Recently Issued NRC Information Notices*SEE PREVIOUS CONCURRENCES Document Name: INFO NOTICE -HON, HODGED/DOEA:NRR C/OGCB:DOEA:NRR*RPB:ADM D/DLPQ:NRRCERossi CHBerlinger TechEd JWRoe09/ /91 09/ /91 09/17/91 09/ /91*OGCB:DOEA:NRR*RI/RV *SC/RV LPEB:DLPQ:NRR C/LPEB:DLPQ:NRRCVHodge AHon PJohnson PPrescott4"O EWBrach09/17/91 09/17/91 09/18/91 09/l'7/91 09/ /91 IN 91-XXSeptember xx, 1991 during the compression stroke. When the force from the starter and otherfiring cylinders tries to overcome this lockup, the engine could be severelydamaged. The fluid can come from a number of sources such as a leaking headgasket, a cracked cylinder or head, or a defective fuel injector or lube oilsystem. EDG vendors such as Transamerica Delaval, Incorporated (TDI) and theGeneral Motors Company, Electro-Motive Division (GM/EMD), have recognized thesignificance of this hazard and have recommended that their clients first checkfor fluid in the cylinders before starting the engine if the engine has beenshut down and cooled for a prolonged period (8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> or more). This is also acommon practice among EDG users in non-nuclear industries.To prepare the engine for each surveillance start, the operator at San Onofrelocked the engine's automatic-start feature, opened the indicator petcocks(test valves) on all cylinders, and rotated the engine slowly to check forfluid in the cylinders. After verifying the absence of fluid in the cylinders,the operator started the EDG. The NRC conducted an informal survey of residentinspectors at plants of other NRC licensees and found that not all NRClicensees are following this practice, possibly because the EDG becomes tempo-rarily inoperable while it is locked with the cylinder petcocks open.The NRC has also addressed this issue in its "Safety Evaluation Report Relatedto the Operability and Reliability of Emergency Diesel Generators Manufacturedby Transamerica Delaval, Inc.," NUREG-1216, August 1986, beginning on page B-4,and in a contract study "Review of Resolution of Known Problems in EngineComponents for Transamerica Delaval Inc. Emergency Diesel Generators,"PNL-5600, December 1985, on page 4.160.This information notice requires no specific action or written response. Ifyou have any questions about the information in this notice, please contact oneof the technical contacts listed below or the appropriate Office of NuclearReactor Regulation project manager.Charles E. Rossi, DirectorDivision of Operational Events AssessmentOffice of Nuclear Reactor RegulationTechnical contacts: Andrew Hon, RV(714) 492-2641Peter Prescott, NRR(301) 492-1011Vern Hodge, NRR(301) 492-1861

Attachment:

List of Recently Issued NRC Information NoticesDocument Name: INFO NOTICE -HON, HODGED/DOEA:NRR C/OGCB:DOEA:NRR RPB:ADM D/DLPQ:NRRCERossi CHBerlinger TechEd :1'fa;n97hAJWRoe09/ /91mJi09/ /91 09 f9 /91 09/ /91OGCB:DOEA zRR RI/RV'R'V. , eSC/RV 'EftttfA ? EB:DLPQ:NRR C/LPEB:DLPQ:NRRCVHodge i AHon 4 PJohnson A PPrescott EWBrach09/tl/91 09//7/91 09/18/91 09/ /91 09/ /91 IN 91-62September 30, 1991 This information notice requires no specific action or written response. Ifyou have any questions about the information in this notice, please contact oneof the technical contacts listed below or the appropriate Office of NuclearReactor Regulation project manager../,Aharles E. Rossi,d Division of Operational Events AssessmentOffice of Nuclear Reactor RegulationTechnical contacts:Andrew Hon, RV(714) 492-2641Peter Prescott, NRR(301) 492-1011Vern Hodge, NRR(301) 492-1861

Attachment:

List of Recently Issued NRC Information Notices*SEE PREVIOUS CON RD/dQR:tCERosifo09 1*OGCB:DOEA:NRR*RI VCVHodge AHon09/17/91 09/17/91DOCUMENT NAME: IN 91-62*C/OGCB:DOEA:NRR*RPB:ADMCHBerlinger TechEd09/23/91 09/17/91*SC/RV *LPEB:DLPQ:NRRPJohnson PPrescott09/18/91 09/19/91D/DLPQ:NRRJWRoe09/ /91C/LPEB:DLPQ:NRREWBrach09/ /91 IN 91-XXSeptember xx, 991This information notice requires no specific action or written response. Ifyou have any questions about the information in this notice, please contact oneof the technical contacts listed below or the appropriate Office of NuclearReactor Regulation project manager.Charles E. Rossi, DirectorDivision of Operational Events AssessmentOffice of Nuclear Reactor RegulationTechnical contacts:Andrew Hon, RV(714) 492-2641Peter Prescott, NRR(301) 492-1011Vern Hodge, NRR(301) 492-1861

Attachment:

List of Recently Issued NRC Information NoticesDocument Name: INFO NOTICE -HON, HODGE*SEE PREVIOUS CONCURRENCES ( 4I--D/DOEA:NRR C/OGCB:DOEA:NRR*RPB:ADMCERossi CHBerlinger TechEd09/ /91 09/43/91 09/17/91*OGCB:DOEA:NRR*RI/RV *SC/RV *LPEB:DLPQ:NRRCVHodge AHon PJohnson PPrescott09/17/91 09/17/91 09/18/91 09/19/91D(;3SQ:.NRR lacJWRV)nC4/r LPQ:NRRE9/i9