ML13310B654
| ML13310B654 | |
| Person / Time | |
|---|---|
| Site: | San Onofre  |
| Issue date: | 08/28/1984 |
| From: | Medford M Southern California Edison Co |
| To: | Paulson W Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 8408300232 | |
| Download: ML13310B654 (12) | |
Text
Southern California Edison Company P. 0.
BOX 800 2244 WALNUT GROVE AVENUE ROSEMEAD. CALIFORNIA 91770 M.O. MEDFORD TELEPHONE MANAGER, NUCLEAR LICENSING August 28, 1984 (213) 572-1749 Director, Office of Nuclear Reactor Regulation Attention:
Mr. W. A. Paulson, Acting Chief Operating Reactors Branch No. 5 Division of Licensing U. S. Nuclear Regulatory Commission Washington, D.C. 20555 Gentlemen:
Subject:
Docket No. 50-206 Return to Service Requirements Regarding Transamerica Delaval Emergency Diesel Generators San Onofre Nuclear Generating Station Unit 1
References:
(A) Letter M. 0. Medford (SCE) to D. M. Crutchfield (NRC),
June 29, 1984, Return to Service Requirements Regarding Transamerica Delaval Emergency Diesel Generators (B) Letter D. M. Crutchfield (NRC) to K. P. Baskin (SCE),
July 26, 1984, Transamerica Delaval Diesel Inspection Requirements for Restart of San Onofre Unit 1 By Reference A, in response to an NRC request, Southern California Edison Company submitted detailed information on the operating history, inspection results, and analyses results concerning the San Onofre Unit 1 emergency diesel generators. During a telephone conversation with the NRC staff on July 13, 1984, the NRC's evaluation of the Reference A information was discussed. In this discussion, the NRC staff identified additional inspections, maintenance and surveillances and pre-operational testing to be performed prior to San Onofre Unit 1 restart.
Reference B formally transmitted this NRC position and requested that Southern California Edison Company provide a description of the program to implement the required actions, along the lines suggested in the NRC letter.
Enclosures I and II to this letter describe our program covering inspections, tests, and maintenance and surveillance activities between the present time and the next refueling outage.
8408300232 840828 PDR ADOCK 05000206 PDR
Mr. W.
August 28, 1984 During the conversation of July 13th, the NRC staff also expressed interest in the basis for, and method used to determine, the ESF loads.
This information is included as Enclosure III.
Additionally, we agreed to provide the results of stress analyses performed by Failure Analysis Associates (FaAA) regarding pistons, blocks and liners, crankshafts, connecting rods and bearing shells, specific to the San Onofre Unit 1 diesel generators under the nameplate rating condition of 6000 kW.
These reports are in the final stages of preparation, and upon review by the TDI diesel generator owners group and Southern California Edison Company, they will be forwarded to you.
If you have any questions, please call me.
Very truly yours, cc:
USNRC Document Control Desk, Washington, D.C.
20555 A. E. Chaffee (USNRC Resident Inspector Units 1, 2 and 3)
C. L. Ray (TDI Diesel Generator Owners Group)
ENCLOSURE I A -
INSPECTIONS Southern California Edison Co. will implement the following diesel generator inspections, retorquing, and component replacement program prior to returning San Onofre Unit 1 to service:
- 1) Inspect Nos. 9 and 10 main bearing journals near the oil holes visually and with eddy current non-destructive examination.
- 2) Retorque all connecting rod bolts to current TDI recommended values. Augment retorquing with the ultrasonic technique being developed by FaAA to measure bolt stretch.
- 3) Retorque air start valve capscrews to the current TDI recommended values.
- 4) Replace cylinder heads known to have valve seat cracks with cylinder heads that meet TDI's current acceptance criteria.
B -
TESTS Prior to returning San Onofre Unit 1 to service, the following tests will be performed on one diesel generator:
- a. Ten modified starts to 4500 kW load. A modified start includes turbocharger prelube and a three to five minute loading to 4500 kW with engine run for a minimum of one hour.
- b. Two fast starts to 4500 kW. A fast start simulates an ESF signal with the engine in ready-standby status.
- c. One 24-hour run at 4500 kW.
ENCLOSURE II MAINTENANCE PROGRAM Table A provides a listing of the periodic checks and inspections that currently comprise the preventative maintenance program for the San Onofre Unit 1 diesel generators.
This program is based on the Technical Specification requirements, TDI recommendations, good engineering practices and general utility experience with emergency diesel generators in nuclear service. Those specific items where vendor recommendations have been modified are listed under "Footnote to Table A".
Table B is a list of additional features to augment the effectiveness of the existing maintenance program.
TABLE A San Onofre Unit 1 Existing Maintenance & Surveillance Program Maintenance Action Frequency Procedure The following temperatures and Monthly
- SOI-12.3-10 pressures are recorded and trended.
A. Jacket water temperature B.
Lube oil temperature C.
Lube oil pressure D. Crank case vacuum E. Air manifold pressure F. Fuel oil pressure G. Turbo charger oil pressure H.
Lube oil consumption Exercise test of intake air strangulation Monthly
- SOI-12.3-10 governor and pedestal bearing.
Inspect fuel oil pump rack and linkage Monthly SOI-12.3-10 Clean and inspect starting air "Y" Quarterly
- S01-I-6.47 strainers Clean and inspect fuel oil strainers Quarterly SO1-I-6.47 Drain water and sludge from lube oil Quarterly
- SO1-I-6.47 filter Lubricate air strangulation valves Quarterly
- SOl-I-6.47 Lubricate fuel pump control shaft Quarterly
- S01-I-6.47 and linkage Oil rack assembly Quarterly
- 501-1-6.47 Lubricate radiator fan vibration Quarterly SOl-I-6.47 switch Obtain fuel oil sample for analysis Quarterly Maintenance Order Obtain lube oil sample for analysis Quarterly
- S0123-III-3.13 Inspect generator brushes Quarterly SO1-I-5.46 Inspect and adjust V-belts on instrument Quarterly Maintenance and air start compressor Order
- Items recommended by vendor
K g
-2 Maintenance Action Frequency Procedure Check compressor head and base bolts for Quarterly Maintenance tightness Order Check level in air line lubricators Quarterly SO-I-6.48 Clean or replace air compressor air Semi Annually Maintenance filters Order Clean compressor externally Semi Annually Maintenance Order Change compressor crankcase lube oil Semi Annually Maintenance Order Lubricate compressor after cooler motor Annually Maintenance Order Clean and inspect engine intake air Annually
- S01-I-6.48 filters Change governor oil Annually
- S01-I-6.48 Clean and inspect oil separator Annually S01-I-6.48 Megger crankcase vent fan motor Annually SO1-I-6.48 Inspect and clean filter in starting Quarterly S01-1-6.47 air distributor Measure the insulation resistance of At Refueling S01-I-5.37 each of the following pumps and motors:
A. Standby lube oil pump motor B. Fuel oil transfer pump motor C. Fuel oil standby pump motor circuit D. Lube oil heater E. Jacket water heater F. Radiator fan motors Inspect the shaft seals, casings, piping At Refueling S01-I-5.37 flanges and oil seals of the following pumps for leakage:
A. Standby lube oil pump B. Jacket water pump C. Fuel oil transfer pump D. Fuel oil standby pump E. Main fuel oil pump F. Main lube oil pump G. Jacket water keep warm pump
- Items recommended by vendor
-3 Maintenance Action FrequencyProcedure Lubricate pump and motor bearings At Refueling SOl-I-5.4 Change oil in standby lube oil pump motor At Refueling S01-I-5.4 Lubricate radiator fan motors At Refueling S01-I-5.4 Inspect fuel oil standby pump motor At Refueling S01-I-5.42 commutator and brushes Inspect engine foundation and bolts, At Refueling S0l-I-2.2 check torque, Inspect crank case, including bump test At Refueling SOl-I-2.2 on connecting rods Measure crankshaft web deflection At Refueling S0l-I-2.2 Inspect cam shafts tappets, rollers, At Refueling SO-I-2.2 rocker arms, push rods and valve springs Adjust hydraulic valve lifters At Refueling SOI-I-2.2 Inspect cam and idler gears At Refueling S0l-I-2.2 Remove fuel injectors and pop test At Refueling Maintenance Order Inspect governor drive coupling for wear At Refueling S01-I-2.2 Record firing and exhaust temperatures At Refueling SOl-I-2.2 Adjust temperature per Delaval Instruction Manual Inspect intake air filters Annually S01-I-6.48 Clean and inspect generator winding At Refueling S01-I-5.46 brushes and slip rings Measure insulation resistance of rotor At Refueling S01-I-5.46 and stator windings Change pedestal bearing oil At Refueling S01-I-5.46 Clean and inspect A.C. outlet box At Refueling SOI-I-5.46 Check generator foundation bolt torque At Refueling SOI-I-5.46 Inspect and lube auxiliary skid valves At Refueling SOl-I-6.49 and piping
- Items recommended by vendor
-4 Maintenance Action Frequency Procedure Disassemble and repair jacket water At every other Maintenance keep warm and main pump discharge Refueling Order check valves Remove fuel injection pump send pumps At every other
- Maintenance to shop for rebuild and calibration Refueling Order Disassemble, repair and repack auxiliary At every other Maintenance skid valves Refueling Order Disassemble and repair jacket water Every 5 years SO-I-5.64 keep warm pump Disassemble and repair lube oil keep Every 5 years SOl-I-5.64 warm pump Change lube oil in sump, clean At every other
- SO-I-6.53 strainers and change lube oil and keep Refueling (or warm filters earlier, based on lube oil analysis)
Disassemble, inspect and repair fuel Every 10 years SOl-I-5.63 oil standby pump Disassemble, inspect and repair turbo Every 10 years SOl-I-5.71 charger Disassemble, inspect and repair heat Every 10 years Maintenance exchangers and intercoolers. Trending Order of temperature and pressure Check gear train backlash Every 10 years S01-I-5.70
- Items recommended by vendor
Footnote to Table A The following vendor's recommendations have been modified, as explained below:
SCE's Alternative Checks and Vendor's Recommendations and Inspections Check main bearing thickness during Due to low operating hours, every other refueling
- 1. Use vibration analysis to evaluate bearing (annually).
- 2. Review crankshaft web deflection data (annually).
- 3. Document whether or not bearing temperature alarms have occurred as part of trending (annually).
- 4. Check lube oil analysis (annually).
Check idler gear bushing every Due to low operating hours, check gear other refueling lash and idler bushing every ten years.
Check rod bearings every other At refueling, the connecting rods are refueling bump tested which indicates bearing wear.
Replace governor drive coupling At refueling, the governor drive during refueling coupling is checked for wear. Also based on low operating hours.
Check gear case lube oil jets The gear case must be removed in order during refueling to check oil jets, as gear case has no inspection covers. This check will be done during 10 year gear case inspection.
TABLE B San Onofre Unit 1 Augmented Maintenance & Surveillance Program Action Frequency a)
Record engine operating parameters:
Once per hour, during surveillance testing.
- 1. engine inlet lube oil pressure
- 2. turbo lube oil pressure
- 3. fuel oil pressure
- 4. fuel oil filter differential pressure
- 5. air manifold pressure L.B.
- 6. air manifold pressure R.B.
- 7. lube oil filter differential pressure
- 8. jacket water pressure (inlet and outlet)
- 9. crankcase vacuum
- 10. all cylinders exhaust temperatures
- 11. exhaust manifold temperatures at turbine inlet
- 12. lube oil temperature (inlet and outlet)
- 13. jacket water temperature (inlet and outlet)
- 14. tachometer
- 15. hourmeter
- 16. generator load b) Air roll engine At 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> and 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> following engine shutdown and prior to planned start.
c)
Visually inspect external engine block and base Monthly or after every 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> of engine for oil and water leakage operation, whichever comes first.
d)
Perform laboratory analysis of lube oil samples Quarterly.
taken from the following locations:
- 1. Lube oil supply tank
- 2. Bottom of sump (includes check for presence of water) e)
Clean and inspect "Y" strainer in starting air system Quarterly.
f)
Visually inspect all connecting rods and check for Refueling outage.
preload relaxation
-2 g) Check preload relaxation on 25% of cylinder head studs, Refueling outage.
25% of rocker arm bolts, and 50% of air start valve capscrews h) Visually check cams, tappets, and push rods Refueling outage.
i) Check hot and cold crankshaft deflections Refueling outage.
J),
Check rotor float and inspect stationary nozzle Refueling outage.
ring bolts for one turbo-charger k) Flush jacket water system Alternate refueling outages.
IAA:2148F
ENCLOSURE III ESF LOADS
Reference:
A) Letter M. 0. Medford (SCE) to D. M. Crutchfield (NRC),
June 29, 1984, Return to Service Requirements Regarding Transamerica Delaval Emergency Diesel Generators A copy of the procurement specification for the San Onofre Unit 1 diesel generators was transmitted to the NRC as Enclosure No. 24 to Reference A.
Table 4-III in this specification lists all the time-sequenced loads connected to the emergency diesel generators after actuation of the safety injection signal.
These loads are based on the motor size rating of the connected equipment (pumps, valves, compressors, fans, etc.), or in the case of the battery chargers, on the electrical rating.
A comparison between the present actual diesel generator loading and the loads originally included in the procurement specification was transmitted to the NRC in response to Question No. 9 in Enclosure No. 2 to Reference A. As explained in this response, the maximum postulated ESF loads presently associated with safety injection are:
4350 kW (Train 1) 4443 kW (Train 2)
The diesel generators have margins of 27.5% and 26% based on the qualified continuous generator rating of 6000 kW.
For the monthly surveillance test, the diesel generators are typically loaded to 4500-5000 kW.