ML13311A412

Vols 1-4 of Rev 1 to Tdi Diesel Generator Design Review & Quality Revalidation Rept

ML13311A412
Person / Time
Site:	San Onofre
Issue date:	01/31/1985
From:	Rick Deese, Ray C TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP
To:
Shared Package
ML13311A410	List: ML13311A409 ML13311A412
References
NUDOCS 8509050059
Download: ML13311A412 (53)

Text

TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT Prepared For SOUTHERN CALIFORNIA EDISON SAN ONOFRE NUCLEAR GENERATING STATION By TDI DIESEL GENERATOR OWNERS GROUP 8509050059 850903 PDR ADOCK 05000206 VOLUME 1 g

PDR

TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT prepared for SOUTHERN CALIFORNIA EDISON SAN ONOFRE NUCLEAR STATION -

UNIT 1 by TDI DIESEL GENERATOR OWNERS GROUP REVISION 1 JANUARY 1985 Reviewed by:

N' T R. J. Deese Licensing Coordinator TDI Diesel Generator Owners Group Approved by:

C. L. Ray Tech ical Program Director TDI Diesel Generator Owners Group S02403

TABLE OF CONTENTS EXECUTIVE

1.0 INTRODUCTION

2.0 PROGRAM PLAN OVERVIEW 2.1 GENERIC PROBLEM RESOLUTION -

PHASE I 2.2 COMPONENT SELECTION 2.3 TASK DESCRIPTION PREPARATION 2.4 DESIGN REVIEW 2.5 QUALITY REVALIDATION 2.6 FINAL DOCUMENTATION 3.0 RESULTS OF DESIGN REVIEW AND QUALITY REVALIDATION 3.1

SUMMARY

RESOLUTION OF SIXTEEN GENERIC COMPONENTS (PHASE I) 3.2

SUMMARY

RESOLUTION OF PHASE II COMPONENTS 4.0

SUMMARY

/CONCLUSIONS 5.0 RECOMMENDATIONS

6.0 REFERENCES

APPENDICES I.

DR/QR

SUMMARY

REPORTS II.

MAINTENANCE & SURVEILLANCE RECOMMENDATIONS III.

INCLUDED REFERENCES S02403

EXECUTIVE

SUMMARY

Thirteen U.S. nuclear utilities have formed the Transamerica Delaval, Inc (TDI)

Diesel Generator Owners Group in order to address operational and regulatory issues relative to Transamerica Delaval diesel generator sets used for backup power supplies in U.S. nuclear power plants. The TDI Diesel Generator Owners Group established a comprehensive program, through a combination of design reviews, quality revalidations, engine tests and component inspections, to provide an in-depth assessment of the adequacy of the respective utilities' TDI diesel generators to perform their intended safety related functions.

The first major program element was characterized as Phase I and involved the resolution of generic known problems. A review of the accumulated operational experience resulted in the conclusion by the Owners Group Technical Staff that a limited number of components warranted priority attention and consideration as significant known problems with potentially generic applicability. Final reports for each of these components were submitted by the Owners Group to the NRC for review. The purpose of this accelerated review was to establish a basis for licensing plants with TDI diesel generators prior to completion of the follow up effort described below. This review has shown that with imple mentation of the Phase I report recommendations, TDI diesel generators can reliably perform their intended function.

The second major program element involved design reviews and quality revalida tions of selected engine components. The Owners Group Design Review and Quality Revalidation Program (DR/QR) was established to perform these exami nations for each owner's engine in order to assess each engine's ability to reliably perform its intended design function. The effort was conducted by a centralized team of engineering personnel with specialized skills in appropriate fields including diesel generator design, operation, and manufacture.

The first portion of the DR/QR Program involved reviewing the Engine Parts List and selecting the components of each engine that warranted a detailed design review and/or quality revalidation. Following component selection these components were subjected to either a design review, a quality revalidation, or both. Upon completion of these reviews, the inspection results, document packages, design review findings and calculation results were reviewed and approved by the Owners Group Technical Staff.

The third major program element involved specific component tests and inspec tions.

The Owners Group Technical Staff, in evaluating specific engine compo nents, provided technical recommendations to each Owner regarding special component inspections, preventive maintenance, and surveillance recommendations which will give added assurance that the engines and components perform their intended operational functions over the life of the plant. The implementation of these recommendations is a plant-specific function.

This final report for Southern California Edison (SCE) provides the results of this extensive investigation of 160 components of the TDI DSRV-20 diesel generators at San Onofre Nuclear Generating Station Unit 1. It forms the basis for the conclusion that the TDI diesel generators presently installed are fully capable of reliably performing their intended safety function.

i S02403

1.0 INTRODUCTION

This report has been prepared for Southern California Edison by the TOI Diesel Generator Owners Group.

The results of the Design Review and Quality Revalidation Program are specifically applicable to San Onofre and are based on the generic program methodology briefly discussed in Section 2.0.

The purpose of this report is to provide the results of an extensive investigation of the design and manufacture of 160 components of the TDI DSRV-20 diesel generators at San Onofre.

This report forms the basis for the conclusion that the TDI diesel generators presently installed are fully capable of performing their safety function as described in the San Onofre Final Safety Analysis Report.

S02403 1-1

2.0 PROGRAM PLAN OVERVIEW The TDI Owners Group Program Plan (the Plan) has been previously provided by reference (1).

This overview of the Plan is provided to assist the reader in understanding the generic methodology by which the plant specific results of Section 3.0 were obtained.

The Plan consists of two phases comprised of the following major elements:

Phase I Generic Problem Resolution Phase II Component Selection Task Description Preparation Design Review Quality Revalidation Final Documentation Each element is briefly discussed in the following sections.

S02403 2-1

2.1 GENERIC PROBLEM RESOLUTION - PHASE I Using input from various nuclear data sources (INPO, SOERs,

LERs, 10CFR50.55e reports & 10CFR21 reports, etc) as well as non-nuclear sources (marine and stationary TDI engine applications), a substantial data base of TDI engine/component operational experience has been accumulated.

A review of this of data by the TDI Diesel Generator Owners Group Techni cal Staff resulted in the conclusion that a limited number of TDI engine components had evidenced sufficient adverse operating experience in one or more applications, such that they warranted priority attention and consid eration as significant known problems with potentially generic applicabil ity. Therefore, the Owners Group technical resources were heavily applied to these problem areas in order to expedite the reviews, tests and/or analyses necessary to resolve them.

The purpose of this accelerated review was to establish a basis for licensing those plants with near term licensing needs prior to the completion of the Phase II effort.

Resolution of these problems has been pursued on a priority basis and was termed the Phase I effort.

The generic known problem listing is generic only to the extent that a body of experience exists to suggest that a design type (or several design types) of a particular component in service in one or more TDI engine applications has not performed acceptably or may not have been designed adequately.

A listing of the identified generic components is included as Table 2.1.

Reports on these components have been previously submitted to the NRC for review.

Summary Phase II reports for the generic problems (Phase I

components) as they apply to San Onofre are included in Appendix I of this report.

The results of the reviews of these components are summarized in Section 3.0.

S02403 2-2

2.2 COMPONENT SELECTION The diesel generator components to be subjected to the OR/QR Program were determined by a Component Selection Committee. Selection was based on the component's function and role in the overall operation of the engine, the component's nuclear and non-nuclear industry experience, and the Commit tee's engineering judgement.

The selection process included a review of available operating information on TDI diesels and TDI recommended product improvements to ensure that relevant experience was considered.

As part of the component selection process, components were classified as either type A, B, or C.

These classifications are based on the effect of the component's failure on the diesel generator performance. Type A components are those whose failure would result in diesel generator shutdown or failure to start in an accident mode.

Type B components include those whose failure would result in reduced capacity of the diesel generator or the eventual failure of a Type A component if not detected.

Components whose failure have little or no bearing on the effective use or operation of the diesel generator are classified as Type C.

Following classification, the Committee established appropriate design review and quality revalidation requirements.

These requirements were then forwarded to the Design Review Group and Quality Revalidation Group for preparation of task descriptions.

Table 2.2 lists those components of the San Onofre diesel generators which were reviewed by the Component Selection Committee.

The Table identifies the results of the Component Selection process by showing which components required a design review (DR) and/or a quality revalidation (QR),

and those components requiring no review.

The Category identified in Table 2.2 refers to the Appendix I heading under which that component's DR/QR Summary Report is found.

S02403 2-3

2.3 TASK DESCRIPTION PREPARATION The Design Review Group and the Quality Revalidation Group prepared task descriptions to define the tasks (reviews, inspections, calculations, etc.) to be performed to determine the adequacy of each component.

The task descriptions included recommendations identified in the selection process as well as Design Review Group and/or Quality Revalidation Group recommended component inspections.

These task descriptions provide, as applicable:

A.

DR Task Descriptions

1.

Primary component function and required attributes,

2. Applicable codes and standards,

3. Alternative codes, standards, or analytical techniques,

4.

Analysis or evaluation to be performed to assure satisfactory

design,

5. Available verifications of TDI analysis (if any), and

6.

Final documentation requirements.

B. QR Task Descriptions (Component Revalidation Checklist)

1.

Component to be validated

2. Attributes to be verified

3.

Methodology to be used (documentation review, NDE techniques, etc.)

4. Acceptance criteria

5.

Final documentation requirements In some cases the Design Review Group and the Quality Revalidation Group prepared task descriptions which required no additional Design Review or Quality Revalidation for certain components. The individual task descrip tions in Appendix I contain the justification for this reduction in scope.

In general, the basis for not requiring a Design Review and/or Quality Revalidation Report is the following:

Lead Engine Component Reviews - This component was reviewed on a lead engine.

Any recommendations which supported the conclu sions in the lead engine report are evaluated for applicability to the follow on engine component and included in the task description.

Experience

- Either no adverse site or industry experience exists or if it does exist, the task description addresses its resolution.

Task descriptions for all components are included with each component's DR/QR Summary Report in Appendix I.

Figure 2.1 graphically depicts the process followed in the DR/QR Program.

S 502403 2-4

2.4 DESIGN REVIEW The Design Review Group completed the design review in accordance with the task descriptions.

Due to the number and diversity of the components and standards involved, the design review was tailored to each component. The actual design review was accomplished by using any one or more of the following methods, including:

a) an independent calculation performed by the Design Review Group; b) an independent review of the adequacy, appro priateness or correctness of existing vendor and/or subvendor calcula tions; c) testing specified by the Design Review Group; or, d) other methods specified and approved in the task descriptions.

During implementation of the task descriptions, the Design Review Group specified quality attributes (in addition to those identified during the component selection process) for incorporation into the quality revalida tion process.

The Design Review Group also identified any components which may require corrective action to improve reliability of the diesel generators. This included recommendations such as increased frequency of component replacement and/or maintenance, or additional in-service inspection.

2.5 QUALITY REVALIDATION The Component Quality Revalidation Group was provided with the quality attributes required to be revalidated.

QR Task Descriptions were devel oped to identify methodology for verification of attributes.

These task descriptions include applicable component descriptions, attributes to be verified, methodology, acceptance criteria, and type of documentation to be provided.

Each component required to undergo Quality Revalidation was subjected to a documentation review.

This process identified and catalogued all appro priate documentation (e.g.

material test reports,

NDE, vendor/subvendor records, site records, etc) associated with the component.

With assis tance from Quality Engineering, each document was reviewed for acceptabil ity.

These document packages were then made available to the Design Review Group to assist in the engineering review.

Important attributes identified by the Design Review Group, for which acceptable documentation did not exist in the component file, were verified by tests and/or inspec tions performed by the Quality Group.

Tests or-inspections required to be performed on components were then forwarded to Quality Engineering to develop detailed methodology and procedures to be followed.

These instructions were issued to Quality Inspection via the task description.

Field inspections and tests were performed by qualified personnel.

Depending upon the specified test or inspection, spare parts or surplus parts in lieu of installed parts were used as the test/inspection article.

Results of inspections and tests were summarized by the Quality Revalidation Group and reviewed by the Design Review Group as necessary.

S02403 2-5

2.6 FINAL DOCUMENTATION The DR/QR program has been completed for Southern California Edison.

A summary of the results of this effort are contained in Section 3.0.

Appendix I contains component DR/QR Summary Reports which provide a detailed summary of the review and analysis performed on each component including references to supporting documentation and the recommendations and conclusions resulting from this effort.

Appendix II contains a comprehensive set of maintenance and surveillance recommendations for each component.

These recommendations were derived from existing vendor recommendations and the individual component DR/QR Summary reports. The purpose of this Appendix is to provide the utility a basis for its maintenance and surveillance program which will maintain the.

qualification of its diesel generators for the life of the plant.

This entire report constitutes final documentation of the completion of the DR/QR Program on the San Onofre TDI diesel generators.

1 502403 2-6 REV.

1

TABLE 2-1 PHASE I COMPONENTS (GENERIC PHASE I)

COMPONENT NUMBER COMPONENT MP-017 Turbocharger 03-305A,C,D,E Base & Bearing Caps 03-310A Crankshaft 03-315A&C Cylinder Block & Liners 03-315E Cylinder Head Studs 03-340A Cylinder Rods 03-340B Connecting Rod Bearing Shells 03-341A Pistons03-359 Airstart Valve Capscrews 03-360A Cylinder Heads 03-365C Fuel Oil Injection Tubing 03-390C&D Main and Connecting Pushrods 03-390G Rocker Arm Capscrews 03-425A Jacket Water Pump 03-688B Wiring & Termination 502403 2-7

TABLE 2-2 SAN ONOFRE COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Req'd Req'd Review Category MM19/20 Turbocharger X

X Turbo, Intake, Intrclr. & Exhaust SE-014 Lube Oil Full Pressure X

X Lube Oil Strainer SO-101 Fuel Oil Filters &

X X

Generator Emergency Diesel Generator SO-102 Generator - Generator X

X Generator Control SO-103 Generator:

Shaft and X

X Generator Bearings00-420 Lube Oil Pressure Regulating X X

Lube Oil Valve 00-442A Starting Air Distributor:

X X

Air Start & Barring Distributor Assembly Device 00-442B Starting Air Distributor:

X X

Air Start & Barring Tubing, Fittings, Gaskets Device 00-491A Turbocharger -

Air Inlet X

Adapter:

Adapter 00-491B Turbocharger - Air Inlet X

Adapter:

Mounting Hardware W/Flexible Connector 00-520 Instruction Plate - Warning X

Plate 00-621A Fuel Oil Drip Tank Assy X

X Fuel Oil Injection 00-621B Fuel Oil Drip Tank Assy -

X Misc Hardware, Gasket, Switch 00-621C Fuel Oil Day Tank X

X Fuel Oil Injection S02403 2-8

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Rey'd Review Category 02-CFR Turbocharger Thrust Bearing X

X Turbo, Intake, Drip Lube System Intrclr. & Ex haust 02-305A Base and Bearing Caps: Base X

X Engine Base Assembly

& Bearing Caps 02-305B Base and Bearing Caps:

X Dowels 02-305C Base and Bearing Caps:

X X

Engine Base Main Bearing Studs & Nuts

& Bearing Caps 02-305D Base and Bearing Caps:

X X

Engine Base Main Bearing Caps

& Bearing Caps 02-307A Lube Oil Fittings:

X X

Lube Oil Internal -

Headers 02-307B Lube Oil Fittings:

X X

Lube Oil Internal -

Tube & Fittings 02-307C Lube Oil Fittings Internal:

X 0

Seals 02-307D Lube Oil Fittings Internal:

X X

Lube Oil Supports 02-310A Crankshaft X

X Crankshaft &

Bearings 02-310B Main Bearings X

X Crankshaft &

Bearing 02-310C Crankshaft & Bearings:

X X

Crankshaft &

Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy X

X Crankshaft &

Bearing 02-311B Cylinder Block Liners & Water X

Manifold: Cam Bearing Caps &

Dowels 02-311C Crankcase: Crankcase Seal X

S02403 2-9

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-311D Crankcase: Crankcase X

X Crankshaft &

Mounting Hardware Bearings 02-315A Cylinder Block Liners &

X X

Cyl. Block &

Water Manifold: Cylinder Liners & Water Block Manifold 02-315B Cylinder Block: Block To X

Crankcase Dowel 02-315C Cylinder Block Liners &

X X

Cyl. Block &

Water Manifold -

Liners &

Cylinder Liner Water Manifold 02-315D Water Manifold: Jacket X

X Cyl. Block &

Water Manifold & Piping Liners &

Water Manifold 02-315E Cylinder Block Liners &

X X

Cyl. Block &

Water Manifold: Studs Liners &

Water Manifold 02-315F Cylinder Block Liner X

X Cyl. Block &

& Water Manifold:

Liner & Water Cylinder Head Nuts Manifold 02-315G Cylinder Block Liners &

X X

Cyl. Block &

Water Manifold: Seals &

Liners &

Gaskets Water Manifold 02-316A Jacket Water Inlet Manifold: X X

Jacket Water Manifold Assembly W/Hardware and Coupling and Gaskets 02-316B Jacket Water Inlet Manifold:

X X

Jacket Water Coupling and Gaskets 02-317A Water Discharge Manifold:

X X

Jacket Water Jacket Water Discharge Manifold, Coupling and Seals 02-317B Water Discharge Manifold:

X X

Jacket Water Coupling & Seals 02-317C Water Discharge Manifold:

X X

Jacket Water Supports S02403 2-10

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-330A Flywheel X

Flywheel 02-330B Flywheel Bolting X

X Flywheel 02-331A Guards: Flywheel Guard X

Assembly 02-335A Front Gear Case: Gear Case X

02-335B Front Gear Case Bolting X

X Idler Gear As sembly & Front Gear Case 02-335C Gear Case Opening Cover X

02-340A Connecting Rods:

Connecting X X

Connecting Rods & Bushings Rods 02-340B Connecting Rods: Bearing X

X Connecting Shells Rods 02-341A Pistons X

X Pistons 02-341B Pistons: Rings X

X Pistons 02-341C Piston: Pin Assembly X

X Pistons 02-345A Tappets and Guides:

Intake X

X Camshaft &

& Exhaust Tappet Assembly Valve Train 02-345B Tappets and Guides: Fuel X

X Camshaft &

Tappet Assembly Valve Train 02-345C Tappets and Guides: Fuel X

X Camshaft &

Pump Base Assembly Valve Train 02-350A Camshaft:

Camshaft X

X Camshaft &

Assembly Valve Train 02-350B Camshaft:

Camshaft X

Camshaft &

Bearing Valve Train 02-350C Camshaft: Supports, Bolting X

X Camshaft &

and Gear Valve Train 02-355A Idler Gear Assemble: Crank X

X Idler Gear As To Pump Gear sembly & Front Gear Case 502403 2-11

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-355B Idler Gear Assembly:

X X

Idler Gear As Idler Gear Assembly sembly & Front Gear Case 02-355C Idler Gear Assembly:

X Gaskets & Bolting 02-359 Air Start Valve X

X Air Start &

Barring Device 02-360A Cylinder Heads X

X Cylinder Heads

& Valves 02-360B Cylinder Head Valves:

X Cylinder Heads Intake & Exhaust Valves

& Valves 02-360C Cylinder Head and Valves:

X X

Cylinder Heads Bolting and Gaskets

& Valves 02-360D Cylinder Head and X

X Cylinder Heads Values:

Springs

& Valves02-361 Indicating Cocks X

02-362A Subcovers X

X Camshaft &

Valve Train 02-362B Cylinder Head Covers:

X Gaskets and Bolting 02-365A Fuel Injection Pump X

Fuel Oil In jection 02-365B Fuel Injection Nozzle Assy.

X Fuel Oil In jection 02-365C Fuel Injection Equipment -

X X

Fuel Oil In Tube Assembly jection 02-365D Fuel Injection Equipment:

X X

Fuel Oil In Supports jection 02-371A Fuel Pump Control Shaft, X

X Fuel Oil In Linkage Assembly & Bearings jection 02-371B Fuel Pump Linkage: Linkage X

X Fuel Oil In Assembly and Bearing jection S02403 2-12

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-375 Intake Manifold and X

X Turbo, Intake, Piping Intrclr. & Ex haust 02-380A Exhaust Manifold Piping X

X Turbo, Intake, Intrclr. & Ex haust 02-380B Exhaust Manifold:

Gasket X

X Turbo, Intake, and Bolting Intrclr. & Ex haust 02-385A Cylinder Block Covers:

X Covers and Relief Valves 02-385B Cylinder Block Covers:

X X

Cyl. Block &

Gaskets and Bolting Liners & Water Manifold 02-386A Crankcase Covers: Crankcase X

Cover Assy 02-386B Crankcase:

Crankcase X

X Cranshaft &

Gaskets and Mounting Bearings Hardware 02-387A Crankcase Ventilator:

X Crankcase Vacuum Fan 02-387B Crankcase Ventilator - Oil X

Separator 02-387C Crankcase Ventilator -

X Fittings, Bolting, Supports 02-387D Crankcase Ventilator:

X Crankcase and Fluid Manometer 02-390A Intake & Intermediate and X

X Camshaft &

Exhaust Rocker Shaft Assembly Valve Train 02-390B Rocker Arms and Pushrods:

X X

Camshaft &

Exhaust Rocker Shaft Valve Train Assembly 02-390C Main and Connector X

X Camshaft &

Pushrods Valve Train S02403 2-13

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-390D Rocker Arms and Pushrods:

X X

Camshaft &

Pushrods Connector.

Valve Train 02-390E Rocker Arms and Pushrods:

X Camshaft &

Bushings Valve Train 02-390F Rocker Arms and Pushrods:

X X

Camshaft & Valve Lifters Train 02-390G Rocker Arms and Pushrods:

X X

Camshaft &

Miscellaneous Bolts &

Valve Train Drive Studs 02-395A Gear Case Covers: Cover X

02-395B Gear Case Covers: Gaskets X

and Bolting 02-410A Overspeed Trip:

Governor X

XOverspeed Trip

& Governor 02-410B Overspeed Trip: Governor X

X Overspeed Trip and Accessory Drive Assembly

& Governor 02-410C Overspeed Trip: Coupling X

X Overspeed Trip (Flexible & Spider)

& Governor 02-410D Vent Valve:

Overspeed Trip X

X Overspeed Trip

& Governor 02-411A Governor Drive:

Governor &

X X

Overspeed Trip Tachometer Drive Gear and Governor Shaft 02-411B Governor Drive: Couplings, X

X Overspeed Trip Pins & Keys

& Governor 02-413 Governor Linkage X

X Overspeed Trip

& Governor 02-413B Fuel Pump Linkage:

X X

Fuel Oil Injection Automatic Shutdown Cylinder 02-415A Governor Assembly: Woodward X

X Overspeed Trip Governor

& Governor 02-415B Governor Assembly X

X Overspeed Trip Booster Servomotor

& Governor 02-420 Engine Driven Lube Oil Pump X

X Lube Oil S02403 2-14

TABLE 2-2 (continued)

Component Component DR QR No Number Description Reg'd Req'd Review Category 02-425A Jacket Water Pump X

X Jacket Water 02-435A Jacket Water Fittings:

X X

Jacket Water Pipe & Fittings 02-437A Turbo Water Piping:

X X

Jacket Water Pipe & Fittings 02-437B Turbo Water Piping:

Supports X

02-441A Starting Air Manifold:

X X

Air Start &

Piping, Tubing and Fitting Barring Device 02-441B Starting Air Manifold X

X Air Start &

Valves, Strainers, Filters Barring Device 02-441C Starting Air Manifold:

X X

Air Start &

Supports Barring Device 02-445 Engine Driven Fuel Oil X

X Fuel Oil In Booster Pump jection 02-450B Fuel Oil Header:

X X

Fuel Oil In Piping/Tubing jection 02-450D Fuel Oil Header:

Fuel X

X Fuel Oil In Oil Tubing Supports jection 02-455A Fuel Oil Filters &

X Fuel Oil In Strainers: Filters jection 02-455B Fuel Oil Filters &

X Fuel Oil In Strainers:

Strainers jection 02-455C Fuel Oil Filters &

X X

Fuel Oil In Strainer: Mounting Hardware jection 02-465A Lube Oil Lines External:

X X

Lube Oil Tubing, Fittings, Couplings 02-465B Lube Oil Lines - External X

X Lube Oil Supports 502403 2-15

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-467A Generator Large Bore X

X Lube Oil Turbocharger: Lube Oil Fitting -

Piping 02-467B Turbocharger: Lube Oil X

X Lube Oil Fittings - Supports 02-475A Turbocharger: Bracket X

X Turbo, Intake, Intrclr. & Ex haust 02-475B Turbocharger - Bracket -

X X

Turbo, Intake, Air Butterfly Valve Intrclr. & Ex Assembly (With Actuator) haust 02-475C Turbocharger Bracket -

X X

Turbo, Intake, Air Intake Piping Intrclr. & Ex haust 02-475D Turbocharger - Bracket -

X X

Turbo, Intake, Bolting & Gaskets Intercooler &

Exhaust 02-475E Turbocharger Bracket X

Turbo, Intake, Pipe Supports Intercooler &

Exhaust 02-495A Turbocharger - Air Outlet X

Adapter - Adapter 02-495B Turbocharger - Air Outlet X

Adapter:

Mounting Hardware 02-500A Control Panel Assembly:

X X

Control Panel Cabinet/System Assembly 02-500B Control Panel Assembly:

X Annunciators 02-500C Control Panel Assembly:

X Circuit Breaker/Contact Blocks 02-5000 Control Panel Assembly:

X Pressure Gauges S02403 2-16

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-500E Control Panel Assembly:

X Hourmeter 02-500F Control Panel Assembly X

X Control Panel Accumulator Assembly 02-50OG Control Panel Assembly X

X Control Panel Valves Assembly 02-500H Control Panel Assembly X

X Control Panel Pressure Switch Assembly 02-500J Control Panel Assembly:

X X

Control Panel Control Relays Assembly 02-500K Control Panel Assembly:

X X

Control Panel Solenoid Valves Assembly 02-500L Control Panel Assembly:

X Tachometer 02-500M Control Panel Components:

X Control Panel Piping, Tubing, Fittings Assembly 02-50ON Control Panel Assembly:

X Control Panel Terminal Boards/Switches/

Assembly Wiring 02-515 Thermostatic Valve X

X Jacket Water 02-520 Instruction Plate:

X Nameplate 02-525A Barring Device -

Pneumatic:

X Barring Device Assembly 02-525B Barring Device -

Pneumatic:

X X

Air Start &

Regulator Valve/Shut Off Barring Device Valve 02-525C Barring Device -

Pneumatic:

X Misc. Fitting, Hose, Filters Tubing 02-525D Barring Device -

Pneumatic:

X Air Start &

Mounting Bracket & Supports Barring Device S02403 2-17

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-530A Platform -

Front & Side:

X Side Platform Assembly 02-530B Platform -

Front & Side:

X Front Platform Assembly 02-530C Platform -

Front & Side:

X Platform -

Bracing (with Attachments) 02-5300 Platform Ladder Front:

X Platform Assembly 02-540A Lube Oil Sump Tank X

Lube Oil with Strainer Assembly and Mounting Hardward 02-540B Lube Oil Sump Tank: Misc.

X X

Lube Oil Fittings, Gaskets, Bolting Material, Valves 02-540C Lube Oil Sump Tank:

X X

Lube Oil Mounting Hardware 02-545 Lube Oil System - Aux Lube X

Lube Oil Oil Pump 02-550 Foundation Bolts X

X Engine & Aux.

Sub Base &

Foundation Bolts02-590 Special Tools: Asst.

X Engine Assembly Tools 02-630A Pyrometer Conduit Assembly:

X X

Engine Instru Conduit mentation &

Wiring 02-630B Pyrometer Conduit Assembly:

X X

Engine Instru Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly:

X X

Engine Instru Support mentation &

Wiring 02-6300 Pyrometer Conduit Assembly:

X Engine Instu Thermocouples mentation&

Wiring S02403 2-18

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-630E Pyrometer Conduit Assembly:

X Gaskets 02-688A Engine & Aux Module Wiring X

X Engine Instru Material-Conduit & Fittings; mentation &

Pyrometer Conduit Assembly-Wiring Conduit, Fitting, Supports 02-688B Engine & Aux. Module X

X Engine Instru Wiring Material mentation &

& Terminations Wiring 02-688C Engine & Aux. Module Wiring X

Engine Instu Material: Boxes & Terminals mentation &

Wiring 02-690 On Engine Alarm Sensors X

X Engine Instru mentation &

Wiring 02-691A Off Engine Alarm Sensors X

X Engine Instru Level & Pressure Switches mentation &

Wiring 02-695A Engine Shutdown Equipment:

X X

Engine Shut Tubing/Fittings & Supports down & Equip ment 02-695B Engine Shutdown Equipment:

X X

Engine Shut Valves, Regulator, Orifices down & Equip ment 02-695C Engine Shutdown Trip X

X Engine Shut Switches down & Equip ment 02-700A Jacket Water Standpipe:

X X

Jacket Water Pipe, Fittings, Gaskets 02-700C Jacket Water Standpipe:

X X

Jacket Water Supports 02-7000 Jacket Water Standpipe:

X Gauges 02-700F Jacket Water Standpipe:

X X

Jacket Water Misc. Bolting Mat.

02-717A Aux Sub Base & Oil & Water X

X Jacket Water Piping -

Aux. Sub Base S02403 2-19

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-717B Aux Sub Base & Oil & Water X

X Jacket Water Jacket Water:

Valves 02-717C Aux. Sub Base & Oil & Water X

X Jacket Water Piping - Jacket Water -

Pipe Couplings, Fittings, Orifices and Strainers 02-717D Aux Sub Base & Oil & Water X

Jacket Water Piping - Jacket Water:

Gaskets & Bolting 02-717E Aux Sub Base & Oil & Water X

Piping - Jacket Water:

Supports 02-717F Aux. Sub Base & Oil & Water X

X Lube Oil Piping -

Lube Oil:

Pipe and Fittings 02-717G Aux Sub Base & Oil & Water X

X Lube Oil Piping -

Lube Oil Valves 02-717H Aux Sub Base & Oil & Water X

X Lube Oil Piping -

Lube Oil Gaskets & Bolting 02-717J Aux Sub Base & Oil & Water X

X Fuel Oil Piping -

Fuel Oil Piping and Fittings 02-717K Aux Sub Base & Oil & Water X

X Fuel Oil Piping -

Fuel Oil Valves 02-717L Aux Sub Base & Oil & Water X

X Fuel Oil Piping -

Fuel Oil -

Gaskets

& Bolting 02-805B Intake Air Filter X

X Turbo, Intake, Intercooler &

Exhaust 02-805C Flex Connections X

Turbo, Intake, Intercooler &

Exhaust S02403 2-20

TABLE 2-2 (continued)

Component Component DR QR No Number Description Req'd Req'd Review Category 02-805D Intake Air Silencer X

Turbo, Intake, Intercooler &

Exhaust 02-810A Misc. Equipment - Heater, X

Jacket Water Jacket Water Standpipe 02-810B Jacket Water Heat Exchanger X

X Jacket Water 02-810C Jacket Water Standby Heater X

Jacket Water Pump 02-820A Misc. Equipment -

Heater, X

Lube Oil Lube Oil Sump Tank 02-820B Lube Oil Heat Exchanger X

X Lube Oil 02-820C Full Flow Lube Oil Filter X

X Lube Oil 02-820D Prelube Oil Pump X

X Lube Oil 02-820E Oil Prelube Filter X

X Lube Oil 02-835A Starting Air Compressor X

02-835B Misc Equipment:

After Cooler X

02-835C Misc Equipment:

After Cooler X

Support 02-835D Misc Equipment:

After Cooler X

Bolting 02-835E Starting Air Tank X

X Air Start & Barring Device 02-835F Air Dryer X

02-835G Air Start Tank Relief X

X Air Start & Barring Valve Device 02-835H Skid Base - Starting X

X Air Start & Barring Air Equipment Device 041-127A Intercooler X

X Turbo, Intake, Intercooler &

Exhaust 041-127B&C Intercooler Piping &

X X

Turbo, Intake, Piping, Couplings, Intercooler &

Gaskets & Boltings Exhaust S02403 2-21

FIGURE 2.1 Component Selection DR Task Description QR Task Description Design Analysis and----

Quality Documentation Technical Backup and Inspection Data DR Results and QR Results and Conclusions Conclusions Component DR/QR Summary Report Engine DR/QR Report S02403 2-22

3.0 Results of Design Review and Quality Revalidation The OR/QR Program implemented for the San Onofre Nuclear Generating Station - Unit 1 TDI diesels was consistently performed with the generic methodology described in Section 2.0.

The results of these reviews are summarized in this section.

More detailed component summary reports are contained in Appendix I of this report.

Section 3.1 and 3.2 list the components of the San Onofre diesel generators which have been reviewed under Phase I and Phase II respectively.

The majority of these components are assessed to be acceptable for their intended service with unlimited life provided the recommendations identified are followed.

These recommendations deal mainly with additional inspection requirements, and installation, operating and maintenance procedure improvements.

In some

cases, procurement specification recommendations are identified to aid the utility in its spare parts program.

Some of the components required modifications as identified in the recommended actions.

The implementation of these recommended actions by the utility will result in a component which is acceptable for its intended service with unlimited life.

S02725 3-1

3.1 Summary Resolution of Sixteen Generic Components (Phase I)

The results of the Phase I program have been submitted to the NRC in a series of reports and supplements (Refs.

2 through 34) which covered the 16 generic components. The results of these reviews are summarized below.

Component Acceptability Recommended Action Turbocharger Unlimited Life Additional testing and (MP-022/3) maintenance requirements.

Revision of operating procedures.

Base and Bearing Unlimited Life Additional maintenance and Caps (03-305A, inspection requirements.

03-305C, 03-305D)

Crankshaft Unlimited Life None (03-310A)

Cylinder Block Unlimited Life Additional maintenance and and Liner inspection requirements.

(03-315A, 03-315C)

Cylinder Head Unlimited Life None Studs (03-315E)

Connecting Rods:

Unlimited Life Additional inspection Connecting Rods requirements.

and Bushings (03-340A)

Connecting Rod Unlimited Life Additional maintenance Bearing Shells requirements.

Additional (03-340B) inspections recommended.

Pistons (03-341A)

Unlimited Life AN piston skirt should be replaced with AE piston skirt.

Air Start Valve Unlimited Life Additional maintenance (03-359) requirements.

Cylinder Heads Unlimited Life Additional maintenance (03-360A) requirements.

Verification of dimensions recommended.

Fuel Injection Unlimited Life Additional testing and Equipment: Tube maintenance requirements.

Assembly (03-365C)

Procurement specification requirement.

S02725 3-2 REV 1

Component Acceptability Recommended Action Main and Connector Unlimited Life Additional procurement Pushrods (03-390C, requirement. Additional 03-390D) inspections recommended.

Random destructive testing recommended.

Rocker Arm Unlimited Life Additional maintenance Capscrews requirements.

(03-390F)

Jacket Water Unlimited Life Additional maintenance and Pump (03-425A) inspection requirements.

Wiring and Unlimited Life None Terminations (03-688B)

S02725 3-3 REV 1

3.2 Summary Resolution of Phase II Components Component Acceptability Recommended Action TURBO, INTAKE, INTERCOOLER & EXHAUST Turbocharger Unlimited Life Additional maintenance and (MM 19/20) inspection recommendations.

Prelubrication procedures should be followed.

Turbocharger Thrust Bearing Drip Lube System (Small Bore Scope Modifications Addition/modification of Only) supports.

Refer to DR/QR (02-CFR) report 02-CFR for details.

Intake Manifold &

Unlimited Life Additional maintenance recommed Piping (Large ations.

Additional Quality Bore Scope Only) inspections recommended.

(02-375)

Exhaust Manifold Modifications Flat bar which connects Piping the shroud to the engine (02-380A) should be modified to allow for axial thermal expansionl. Addition of slip joints.

Additional maintenance recommendations.

Inspections of cap screws recommended.

Replace 3/8-inch bolts that connect the water jacket shroud to the manifold assembly with 1/2-inch bolts.

Exhaust Manifold:

Unlimited Life Additional Quality inspections Gasket & Bolting recommended.

(02-380B)

Turbocharger Bracket, Unlimited Life None Bolting and Gaskets (02-475A&D)

Air Butterfly Modifications Addition of grease fittings per Valve Assembly TDI SIM 322.

Additional main (02-475B) tenance requirements.

Addi tional Quality Revalidation inspections recommended.

S02725 3-4

Component Acceptability Recommended Action Turbocharger Modifications Each crossover piping system Bracket-Air should be supported by Intake Piping two flexible anchors only.

(02-475C)

Remove all U-bolts and strap supports.

Turbocharger Unlimited Life None Bracket Pipe Supports (Large Bore Scope Only)

(02-475E)

Flex Connections Unlimited Life None (02-805C)

Intake Air Silencer Unlimited Life None (02-805D)

Intercooler Unlimited Life Additional maintenance recom (41-127A) mendations.

Intercooler Piping Modifications Addition/modification of and Piping Couplings, supports.

Refer to DR/QR Gaskets and Bolting report 041-127B&C for details.

(041-127B&C)

LUBE OIL Lube Oil Full Unlimited Life Inspect and clean the strainer Pressure Strainer element at any significant (SE-014) increase in differential pressure and at each refueling outage.

Check differential pressure during each engine operation.

Lube Oil Pressure Unlimited Life Disassemble and clean the valve Regulating Valve annually or at each refueling (00-420) outage. To ensure proper clearance, the dimensions of the valve internal parts should be checked.

Lube Oil Fittings-Unlimited Life None Internal Headers (Large Bore Scope Only)

(02-307A-LB)

Lube Oil Fittings -

Modifications Modify supports.

Refer to Internal:

Headers DR/QR report 02-307D for (02-307A-SB) details.

S02725 3-5 REV 1

Component Acceptability Recommended Action Lube Oil Fittings Unlimited Life None Internal Tube and Fittings (Small Bore Scope Only)

(02-307B)

Lube Oil Fitting Modifications Replacement of all

-inch Internal -

Supports U-bolts with 3/8-inch U-bolts (Small Bore Scope on the auxiliary internal lube Only) oil header. Installation of (02-3070) suitable locking devices on nuts.

Engine Driven Unlimited Life None Lube Oil Pump (02-420)

Lube Oil Lines Modifications Addition of support to provide 1

External:

Tubing, a stiffer load path and to Fittings, and relieve seismic stresses on the Couplings (Large external header.

Recommendation Bore Scope Only) for a minimum installation gap (02-465A-LB) between the pipe ends of 0.171 inch.

Lube Oil Lines -

Modifications Modify supports.

Refer to DR/QR External Tubings, report 02-465B for details.

Fittings, Couplings (02-465A-SB)

Lube Oil Lines -

Unlimited Life None External Supports (Large Bore Scope Only)

(02-465B-LB)

Lube Oil Lines Modifications Modify supports, U-bolts, and External:

Supports locking devices.

Refer to DR/QR (Small Bore Scope report 02-465B for details.

Only)

(02-465B-SB)

Turbocharger-Unlimited Perform a comparison of Lube Oil Fitting-the as-built configuration Pipe, Tubing, and with the assembly details.

Flexible Coupling (Large Bore Scope Only)

(02-467A-LB)

S02725 3-6 REV 1

Component Acceptability Recommended Action Turbocharger Lube Modifications Addition/modification of supports.

Oil Fitting:

Pipe, Refer to DR/QR report 02-467B Tubing, Fittings, for details.

and Flexible Coupling (Small Bore Scope Only)

(02-467A-SB)

Turbocharger -

Lube Unlimited Life None Oil Fitting &

Supports (Large Bore Scope Only)

(02-467B-LB)

Turbocharger - Lube Modifications Addition/modification of supports.

Oil Fittings:

Sup-Modification of U-bolts.

Instal ports lation of locking devices.

Refer (Small Bore Scope to DR/QR report 02-467B for details.

Only)

(02-467B-SB)

Lube Oil Sump Tank Visual inspection of the tank with Strainer Assembly seam and assembly welds recommended.

and Mounting Hardware Recommendation to measure engine, (02-54RA&C) tank, and pipe displacement at fropr de tls.

Ieniy n Nnetrfeigotg. Vrf reconcil mechanism of strain relief.

propercatltntorque.oltsntifytand Lube Oil Sump Tank Unlimited Life None Misc. Fittings, Gaskets, Bolting Material, Valves (Small Bore Scope Only)

(02-540B)

Lube Oil System Unlimited Life None Auxiliary Lube Oil Pump (02-545)

Auxiliary Sub Base Modifications Addition/modification of supports.

& Oil & Water Piping Refer to DR/QR report 02-717F for Lube Oil:

Pipe/Fit-details.

tings (Small Bore Scope Only)

(02-717F)

S02725 3-7

Component Acceptability Recommended,Action Auxiliary Sub Base Unlimited Life Additional maintenance require

& Oil & Water Piping:

ments.

Lube Oil Valves (02-717G)

Auxiliary Sub Base Unlimited Life The auxiliary piping should be

& Oil & Water walked down daily to verify the Piping:

Lube Oil:

leak tightness of the lube oil Gaskets & Bolting piping flanges.

(02-717H)

Intake Air Filter Unlimited Life Additional maintenance require (02-805B) ments.

Miscellaneous Equip-Unlimited Life Additional maintenance recoi ment -

Heater, Lube mendations.

Oil Sump Tank (02-820A)

Lube Oil Heat Unlimited Life Additional maintenance recommend Exchanger ations.

(02-820B)

Full Flow Lube Oil Unlimited Life Additional maintenance require Filter ments.

(02-820C)

Prelube Oil Pump Unlimited Life None (02-820D)

Oil Prelube Filter Unlimited Life Additional maintenance recommend (02-82mE) ations.

ENGINE BASE & BEARING CAPS Base and Bearing Unlimited Life Additional maintenance recommend Caps -

Base Assembly, ations. Additional Quality Main Bearing Studs inspections recommended.

and Nuts, and Main Bearing Caps (02-305ACD)

CRANKSHAFT & BEARINGS Crankshaft Unlimited Life None (02-310A)

Main Bearings Unlimited Life Additional Quality inspections (02-310B) recommended.

S02725 3-8

Component Acceptability Recommended Action Crankshaft &

Unlimited Life Additional maintenance recommend Bearings:

Thrust ations.

Bearing Ring (02-310C)

Crankcase:

Unlimited Life Additional Quality inspections Crankcase Assembly recommended.

(02-311A)

Crankcase:

Unlimited Life None Crankcase Mounting Hardware (02-311D)

Crankcase:

Unlimited Life Additional Quality inspections Crankcase Gaskets recommended.

and Mounting Hard ware (02-386B)

CYLINDER BLOCK, LINERS & WATER MANIFOLD Cylinder Block Unlimited Life Verify cylinder liner bore and (02-315A) mating block dimensions. Addi tional Quality inspections rec ommended. Additional mainten ance inspections recommended.

Cylinder Block Unlimited Life Additional maintenance recommend Lines & Water ations. Additional Quality Manifold -

inspections recommended.

Cylinder Liners (02-315C)

Jacket Water Unlimited Life Perform a non-destructive Manifold Piping examination of subject piping (Large Bore Scope component to ensure the integrity Only) of pipe welds.

Inspect (02-315D) inaccessible piping to ensure adequate seismic restraint.

Cylinder Block Modifications Modify head stud installation Liners & Water procedure to lower the stresses Manifold:

Studs in the cylinder block stud boss (02-315E) area. Additional Quality inspec tions recommended.

Cylinder Block Unlimited Life Additional Quality Revalidation Liner & Water Mani-inspections recommended.

fold - Cylinder Head Nuts (02-315F)

REV. 1 S02725 3-9

Component Acceptability Recommended Action Cylinder Block -

Unlimited Life Verify installation of proper Liners & Water cylinder liner seals (TDI P/N Manifold:

Seals and JF-019-000) in diesel generators.

Gaskets (02-315G)

Cylinder Block Unlimited Life Verify that the proper torque is Covers:

Gaskets applied and the specified

& Bolts material is installed. Additional (02-385B)

Quality inspections recommended.

AIRSTART & BARRING DEVICE Starting Air Distri-Unlimited Life Additional Quality Revalidation butor:

Distributor inspections recommended. Addi Assembly tional maintenance recommendations.

(00-442A)

Starting Air Distri-All Air Distributor Tubing is addressed under compo butor - Tubing, Fit-nent numbers 02-441A & C.

tings and Gaskets (00-442B)

Air Start Valves Modifications Implementation of SIMs 329 and (02-359) 360. Additional maintenance recommendations. Additional Quality inspections recommended.

Starting Air Mani-Modifications Addition/modification of supports.

fold:

Piping, Refer to DR/QR report 02-441A-LB Tubing, and Fittings for details.

(Large Bore Scope Only)

(02-441A-LB)

Starting Air Mani-Unlimited Life Modify supports.

Refer to DR/QR fold -

Piping, Tub-report 02-441C for details.

ing, and Fittings (Small Bore Scope Only)

(02-441A-SB)

Starting Air Mani-Modifications Addition of free flowing drains fold:

Valves, to air distributor filter.

Strainers, Filters Additional maintenance require (02-441B) ments.

S02725 3-10

Component Acceptability Recommended Action Starting Air Unlimited Life None Manifold Supports (Large Bore Scope Only)

(02-441C-LB)

Starting Air Mani-Modifications Addition of two-directional sup fold - Supports ports to the tubing running from (Small Bore Scope the distributor to the horizontal Only) tubing runs on top of the engine.

(02-441C-SB)

Addition of a two-directional lateral support to each -inch tube entering and exiting the air filter.

Barring Device -

Unlimited Life None Pneumatic Regulator Valve/Shutoff Valve (02-525B)

Barring Device -

Unlimited Life None Pneumatic:

Mounting Bracket/Supports (02-525D)

Starting Air Tank Unlimited Life Additional maintenance recom (02-835E) mendations.

Air Start Tank Unlimited Life None Relief Valves (02-835G)

Skid Base -

Start-Unlimited Life None ing Air Equipment (02-835H)

CONNECTING RODS Connecting Rods:

Unlimited Life Additional inspections recom Connecting Rods &

(pending satisfac-mended.

Bushings tory results from (02-340A) the Quality Revali dation inspections)

Connecting Rod:

Unlimited Life Additional maintenance require Bearing Shells ments. Additional Quality Revali (02-340B) dation inspections recommended.

S02725 3-11

Component Acceptability Recommended Action PISTONS Piston Unlimited Life Additional inspections of the (02-341A) stud boss attachment area recommended. Additional Quality inspections recommended.

Pistons:

Rinas Unlimited Life Additional maintenance and (02-341B)

Quality Revalidation inspection recommendations.

Piston:

Piston Pin Modifications Replacement of spiral ring (02-341C) retainers with Waldes SNAP ring retainers (P/N GE-003-067).

Additional Quality inspections recommended. Additional main tenance recommendations.

CAMSHAFT & VALVE TRAIN Tappets and Guides:

Unlimited Life Additional maintenance recom Intake & Exhaust mendations. Additional Quality Tappet Assembly inspection recommended.

(02-345A)

Tappets and Guides:

Unlimited Life Additional maintenance recom Fuel Tappet Assembly mendations. Additional Quality (02-345B) inspections recommended.

Tappets and Guides:

Unlimited Life None Fuel Pump Base Assembly (02-345C)

Camshaft:

Unlimited Life Additional maintenance and Quality Camshaft Assembly Revalidation inspection recom (02-350A) mendations.

Camshaft:

Unlimited Life None Camshaft Bearings (02-350B)

Camshaft-Supports, Unlimited Life Additional maintenance recommend Bolting and Gears; (pending satis-ations.

Additional Quality Idler Gear Assembly-factory results inspections recommended.

Crank to Pump Gear; from the transient Idler Gear torsional response (02-350C, evaluation) 02-355A&B)

S02725 3-12

Component Acceptability Recommended Action Subcover Unlimited Life Additional inspections and Quality (02-362A)

Revalidation inspections recom mended.

Rocker Shaft Unlimited Life Additional Quality Revalidation Assemblies:

Intake/

inspections recommended.

Intermediate &

Exhaust (02-390A&B)

Main and connector Unlimited Life Additional Quality Revalidation pushrods inspections recommended.

(02-390C&D)

Rocker Arm & Push-Unlimited Life Additional maintenance require rods:

Bushings ments.

(02-390E)

Rocker Arms and Unlimited Life Additional Quality Revalidation Pushrods:

Lifters inspections recommended.

(02-390F)

Rocker Arms and Push-Unlimited Life Additional maintenance recommen rods -

Miscellaneous dations.

Additional Quality Bolts and Drive Studs inspections recommended.

(02-390G)

IDLER GEAR ASSEMBLY & FRONT GEAR CASE Front Gearcase Unlimited Life Additional inspections of bolts.

Bolting Addition of positive locking (02-335B) features (bent tab or lockwire).

Additional Quality inspections recommended.

FLYWHEEL Flywheel Unlimited Life None (02-330A)

Flywheel Bolting Unlimited Life Recommended that the assembly (02-330B) procedures include an effort to keep the flange faces of the fly wheel, crankshaft and generator shaft free of antisieze compound.

TDI bolt torque requirements should be documented and verified by Southern California Edison.

S02725 3-13

Component Acceptability Recommended Action ENGINE INSTRUMENTATION & WIRING Pyrometer Conduit Unlimited Life Additional maintenance recommend Assembly:

ations.

Thermocouples (02-630D)

Engine and Auxiliary Modifications Upgrade conduit supports.

Module Wiring Materi-Addition of supports for al and Fittings:

Category I rigid and flexible Pyrometer Conduit conduits.

Assembly - Conduit, Fittings and Supports.

(02-688A, 02-630A,B,C)

Engine & Auxiliary Unlimited Life Implementation of TDI SIM No. 361 Module Wiring on Engine No. 1 should be confirmed.

Material:

Wiring

& Terminations (02-688B)

Engine & Auxiliary-Unlimited Life None Module Wiring Materi al -

Boxes & Termin als (02-688C)

On Engine Alarm Unlimited Life None Sensors (02-690)

Off Engine Alarm Unlimited Life None Sensors (02-691A)

OVERSPEED TRIP & GOVERNOR Overspeed Trip:

Unlimited Life Additional maintenance require Governor ments and Quality Revalidation (02-410A) inspectons recommendations.

Overspeed Trip:

Unlimited Life Evaluation of crankshaft Governor &

torsional response and its Accessory Drive effect on the governor and Assembly accessory drive assembly is (02-410B) required. Additional Quality Revalidation inspections recommended.

S02725 3-14

Component Acceptability Recommended Action Overspeed Trip:

Unlimited Life Additional Quality inspections Couplings (Flexible recommended. Additional main and Spider) tenance recommendations.

(02-410C)

Vent Valve:

Unlimited Life Valve 0-ring should be changed Overspeed Trip every 5 years.

(02-410D)

Governor Drive:

Unlimited Life Additional Quality inspections Governor and Tacho-recommended.

meter Drive Gear and Shaft (02-411A)

Governor Drive:

Unlimited Life Additional maintenance recommend Couplings, Pins ations.

Additional Quality

& Keys inspections recommended.

(02-411B)

Governor Linkage Unlimited Life Additional maintenance recom (02-413A) mendations. Additional Quality inspections recommended.

Fuel Pump Linkage:

Unlimited Life None Automatic Shutdown Cylinder (02-413B)

Governor Assembly:

Unlimited Life Additional maintenance recom Woodward Governor mendations. Additional Quality (02-415A) inspections recommended.

Governor Assembly Unlimited Life Additional Quality inspections Booster Servomotor recommended.

(02-415B)

ENGINE SHUTDOWN & EQUIPMENT Engine Shutdown Modifications Addition of two and three direction Equipment - Tubing/

supports. Reinforcement or re Fittings & Supports designment of interface bulkhead (Small Bore Scope between engine and off engine Only) tubing to increase vertical load (02-695A) capacity. Refer to DR/QR report 02-695A for details.

Engine Shutdown Unlimited Life Additional maintenance require Equipment -

Valves, ments.

Regulators, Orifices.

(02-695B)

S02725 3-15

Component Acceptability Recommended Action Engine Shutdown Unlimited Life None Trip Switches (02-695C)

JACKET WATER Jacket Water

\\Unlimited Life Perform a non-destructive Manifold - Manifold4 Assembly i fl examination of subject piping Assemby withComponent to ensure the integrity Hardware, Coupling of pipe welds.

Inspect and Gaskets inaccessible piping to ensure (Large Bore Scope

!adequate seismic restraint.

Only)

(02-316A&B)

Water Discharge Unlimited Life None Manifold:

Jacket Water Discharge Manifold, Couplings, and Seals (Large Bore Scope Only)

(02-317A&B)

Water Discharge Unlimited Life None Manifold:

Supports (Large Bore Scope Only)

(02-317C)

Jacket Water Pump Modifications Modify torque valves for nuts on (02-425A) impeller and shaft. At the drive gear end of the pump shaft, a second hole should be drilled in the threaded end, 90 deg from the existing one to minimize nut rota tion required to insert the lock ing cotter pin.

Additional Quality inspections recommended.

Jacket Water Unlimited Life None Fittings -

Pipe and Fittings (Small Bore Scope Only)

(02-435A)

S02725 3-16

Component Acceptability Recommended Action Turbo Water Piping -

Modifications Replacement of -inch diameter Pipe and Fittings U-bolts with 3/8-inch diameter (02-437A-SB)

U-bolts on turbo water inlet (Small Bore Scope supports for Engine 2, generator Only) end. Addition of two-direction supports on the 4-inch tubing from the jacket water outlet headers to the combustion air coolers on both engines.

Turbo Water Piping -

Modifications Addition of a rigid anchor on the Pipe and Fittings 2 -inch diameter header at the (Large Bore.Scope location of the intersection with Only)'

the two 1 -inch diameter branches.

(02-437A-LB)

Thermostatic Valves Unlimited Life Replacement of the power elements (02-515) at 3 to 5 year intervals.

Additional inspections recommeded.

Jacket Water This component was supplied by Southern California Standpipe Pipe, Edison.

Therefore, it is beyond the scope of this Fittings, Gaskets design review.

(02-700A)

Jacket Water Stand-These supports were supplied by Southern California pipe:

Supports Edison.

Therefore, they are not in the scope of this (Small Bore Scope design review.

Only)

(02-700C)

Jacket Water Stand-Unlimited Life Additional inspections recommended.

pipe and Miscellane-(pending resolu ous Bolting Material tion of engine (02-700F) vibration loads)

Auxiliary Sub Base, Unlimited Life Monthly inspections for leakage Oil, and Water at packing.

Jacket Water Valves (02-717B)

Auxiliary Sub Base Unlimited Life None

& Oil & Water Pip ing - Jacket Water:

Gaskets & Bolting (02-7170)

S02725 3-17 REV 1

Component Acceptability Recommended Action Auxiliary Sub Base Modifications Addition/modification of supports,

& Oil & Water Pip-U-bolts, and locking devices.

ing - Jacket Water:

Refer to DR/QR report 02-717E for Supports details.

(Small Bore Scope Only)

(02-717E)

Miscellaneous Equip-Unlimited Life Additional maintenance recom ment -

Heater, Jacket mendations.

Water Standpipe (02-810A)

Jacket Water Heat Unlimited Life None Exchanger (02-810B)

Jacket Water Standby Unlimited Life None Heater Pump (02-810C)

CYLINDER HEADS & VALVES Cylinder Heads Unlimited Life Additional maintenance recommend (02-360A) ations.

Additional Quality inspections recommended.

Cylinder Head Unlimited Life Additional inspections and Quality Valves:

Intake Revalidation inspections reco and Exhaust Valves mended.

(02-360B)

Cylinder Head and Unlimited Life Replacement of affected seals Valves:

Bolting with those called out in SIM 315.

and Gaskets Additional Quality inspections (02-360C) recommended.

Cylinder Head and Unlimited Life Visually inspect and document Valves:

Spring the color codeof the valve (02-360D) springs.

FUEL OIL INJECTION Fuel Oil Drip Unlimited Life None Tank Assembly (00-621A)

Fuel Oil Day Tank Unlimited Life None (02-621C)

Fuel Injection Pump Unlimited Life Additional maintenance recommend (02-365A) ations.

S02725 3-18

Component Acceptability Recommended Action Fuel Injection Unlimited Life Additional maintenance recommend Nozzle Assembly ations.

(02-365B)

Fuel Injection Unlimited Life Additional maintenance recommend Equipment Tube ations.

Additional Quality Assembly inspections recommended.

(02-365C)

Fuel Injection Unlimited Life Perform a visual inspection of Equipment Supports the support elastomer to check (Small Bore Scope for signs of deteriation or Only) degradation.

(02-365D)

Fuel Pump Control Unlimited Life Additional maintenance recoi Shaft, Linkage mendations. Additional Quality Assembly & Bearings inspections recommended.

(02-371A&B)

Fuel Pump Linkage:

Unlimited Life None Automatic Shutdown (02-413B)

Engine Driven Fuel Unlimited Life None Oil Booster Pump (02-445)

Fuel Oil Header -

Modifications Replacement of fabricated cross Piping and Ti~Ping on the fuel oil supply crossover (Small Bore Scope header on the governor end of Only)

Engine 1 with appropriate wrought (02-450B) fittings (socket welding or butt welding tee and reducers).

Fuel Oil Headers Modifications Modify supports and U-bolts.

Fuel Oil Tubing Install suitable locking devices Supports on nuts.

Refer to DR/QR report (Small Bore Scope 02-450D for details.

Only)

(02-450)

Fuel Oil Filters Unlimited Life Additional maintenance recommend

& Strainers:

ations.

Filters (02-455A)

Fuel Oil Filters Unlimited Life Additional maintenance recommend

& Strainers:

ati ons.

Strainers (02-455B)

S02725 3-19

Component Acceptability Recommended Action Fuel Oil Filters Unlimited Life None and Strainers:

Mounting Hardware (02-455C)

Auxiliary Sub Base Modifications Addition/modification of supports,

& Oil & Water Pip-U-bolts and locking devices.

ing Fuel Oil:

Pip-Refer to DR!QR report 02-717J for ing and Fittings details.

(Small Bore Scope Only)

(02-717J)

Auxiliary Sub Base Unlimited Life Additional maintenance require

& Oil & Water Pip-ments.

Additional Quality inspec ing:

Fuel Oil tions recommended.

Valves (02-717K)

Auxiliary Sub Base Unlimited Life The auxiliary piping should be

& Oil & Water walked down daily to verify the Piping - Fuel Oil:

leak tightness of the fuel oil Gaskets and Bolting piping flanges.

(02-717L)

Auxiliary Sub Base Unlimited Life Additional maintenance and Quality

& Oil & Water Pip-inspection recommended.

ing:

Fuel Oil Valves (02-717N)

GENERATOR Generator:

At the request of Southern California Edison, design Generator review and Quality inspections were not performed (SO-l01) on the generator at San Onofre.

Generator:

At the request of Southern California Edison, design Generator Controls review and Quality inspections were not performed (SO-102) on the generator controls at San Onofre.

Generator -

Unlimited Life None Shaft and Bearing (SO-103)

CONTROL PANEL ASSEMBLY Control Panel Unlimited Life None Assembly -

Cabinet!

System (02-500A)

S02725 3-20

Component Acceptability Recommended Action Control Panel Unlimited Life None Assembly - Accumu lator (02-500F)

Control Panel Unlimited Life Additional maintenance require Assembly -

Valves ments.

(02-500G)

Control Panel Unlimited Life None Assembly -

Pressure Switches (02-500H)

Control Panel Unlimited Life None Assembly -

Control Relays (02-500J)

Control Panel Unlimited Life None Assembly -

Solenoid Valves (02-500K)

Contro Panel Compo-Unlimited Life None nents -

Piping, Tub ing, Fittings (02-500M)

Control Panel Assem-Unlimited Life None bly - Terminal Boards/Switches, Wiring (02-500N)

ENGINE & AUXILIARY SUB BASE & FOUNDATION BOLTS Foundation Bolts Unlimited Life To ensure continued reliability, (02-550) the foundation bolts for both engines should be torqued to 500 ft-lbs at the next refueling outage.

Auxiliary Sub Base Unlimited Life None

.& Oil & Water Piping:

Auxiliary Sub Base (02-717A)

S02725 3-21

4.0

SUMMARY

/CONCLUSIONS The TDI Diesel Generator Owners Group has completed its review of the TDI diesel generators installed at San Onofre.

The scope and depth of this review as outlined in this report represents a significant effort by the TDI Diesel Generator Owners Group Technical Staff and Southern California Edison personnel.

Nuclear standby diesel generator reliability has been a major concern of the industry and the NRC. Although previous programs have been sponsored by the NRC,

EPRI, and other industry groups to quantify and improve this reliability, the Design Review and Quality Revalidation effort summarized in this report is unprecedented in its approach and analytical detail.

This effort has produced a detailed assessment of 160 TDI diesel generator components.

Many of these components have been analyzed using analytical techniques which exceed the detailed engineering effort of the original design.

Extensive component inspections are an integral part of the DR/QR program.

The performance of these inspections leaves no doubt as to the quality of these critical diesel generator components.

Thus, the TDI Diesel Generator Owners Group effort has gone a long way toward quantifying the reliability of the TDI Diesel Generator by estab lishing the acceptability of these critical engine components.

In many

cases, recommendations are made to improve component reliability and therefore improve overall diesel generator reliability.

The TDI Diesel Generator Owners Group believes that this extensive effort verifies the acceptability of the TDI diesel generators for nuclear service.

The results of this review, as outlined in Section 3.0 of this report, show that the important components of the TDI diesel generator have been assessed to be adequate for their intended function.

In cases where component adequacy has been judged to be marginal, corrective action is recommended which will ensure the adequacy of the component.

This report supports the conclusion that the TDI diesel generators in stalled at San Onofre are acceptable for their intended safety related function and, in addition, the incorporation of the maintenance and surveillance recommendations into the plant's existing program provides added assurance that these diesel generators will continue to perform their intended function for the life of the plant.

S02403 4-1

5.0 RECOMMENDATIONS The purpose of the TDI Diesel Generator Owners Group Program was to assess the acceptability of the TDI Emergency Diesel Generator at San Onofre and to make recommendations as required to improve the reliability of given components. These recommendations are summarized in section 3.0 and given in detail in Appendix I.

Additionally, the TDI Diesel Generator Owners Group Program has made recommendations concerning component maintenance and surveillance.

These recommendations have been assembled from manufacturers manuals and the component DR/QR summary reports.

These maintenance and surveillance recommendations are outlined in Appendix II.

Although the recommendations of this report are not requirements, their adoption by Southern California Edison will give added assurance that the TDI Emergency Diesel Generators installed at San Onofre will perform their intended function for the life of the plant.

These recommendations repre sent a conservative approach to insuring diesel generator reliability, and in accordance with the intent of the Owners Group Program Plan, it is anticipated that these recommendations will be incorporated subsequent to commercial plant operation but prior to restart from the first plant refueling outage. In some cases, the utility may propose alternate means of insuring the reliability of their emergency diesel engines.

Justifica tion of these alternate means is the responsibility of the utility.

S02403 5-1

6.0 REFERENCES

Component DR/QR Summary Reports list references directly related to that component.

Ref. #

1 TDI-3 3-2-84 TDI Owners Group Program Plan 2

TDI-2 2-27-84 Investigation of Types AF and AE Piston Skirts 3

TDI-4 3-12-84 D.R. of Connecting Rod Bearing Shells 4

TDI-5 3-13-84 TDI D.G. Rocker Arm Capscrew Stress Analysis Report 5

TDI-6 3-23-84 TDI D.G. Air Start Valve Capscrew Dimensional and Stress Analysis Report 6

TDI-8 3-30-84 TDI D.G. Cylinder Head Stud Stress Analysis 7

TDI-14 4-13-84 TDI D.G. Supplement to the Cylinder Head Stud Stress Analysis and Supplement to the Air Start Valve Capscrew Dimension and Stress Analysis 8

TDI-15 4-16-84 TDI D.G. Report on Engine Driven Jacket Water Pump Design Review 9

TDI-16 4-19-84 TDI D.G. Report on Push Rods 10 TDI-17 4-20-84 TDI D.G. Report on the Evaluation of Emergency D.G. Crankshafts at Shoreham 11 TDI-18 4-24-84 TDI D.G.

Report on the Evaluation of Emergency D.G. Wiring and Terminations of Shoreham 12 TDI-19 4-24-84 TDI 0.G. Supplement to the Rocker Arm Capscrew Stress Analysis 13 OGTP-8 4-27-84 TDI D.G. Report on Fuel Injection Tubing Qualification Analysis 14 OGTP-9 5-14-84 TDI D.G.

Report on D.R. of Connecting Rods of Inline DSR-48 Emergency D.G.

15 OGTP-10 4-27-84 TDI D.G. Report on D.R. of Engine Base and Bearing Caps 16 OGTP-25 5-14-84 TDI 0.G. Cylinder Head Report S02403 6-1

Ref. #

17 OGTP-26 5-14-84 TDI D.G. Turbocharger Report 18 OGTP-39 5-24-84 Evaluation of Emergency D.G. Crankshafts at Shoreham and Grand Gulf Nuclear Power Station 19 OGTP-40 5-24-84 D.R. of Connecting Rods for TDI DSRV-4 Series Diesel Generators 20 OGTP-41 5-24-84 Investigation of Types AF & AE Piston Skirts 21 OGTP-57 6-05-84 Emergency D.G. Aux. Module Control Wiring and Termination Qualification Report for G.G.N.S.

22 OGTP-70 6-13-84 Emergency D.G. Aux. Module Control Wiring and Termination Qualification Report for C.P.S.E.S.

23 OGTP-72 6-14-84 The Infulence of Thermal Distortion on the Performance of AF and AE Piston Skirts 24 OGTP-74 6-15-84 EDG Aux. Module Control Wiring and Termination Qualification Report for San Onofre Nuclear Power Station Unit I 25 OGTP-76 6-15-84 Evaluation of E.D.G. Crankshafts at Midland and San Onofre Nuclear Generating Stations 26 OGTP-77 6-15-84 DR of Elliott Model 656 Turbocharger used on TDI DSRV-12-4 and DSRV-20-4 EDG sets 27 OGTP-79 6-18-84 DR of Connecting Rods of TDI Inline DSR-48 EDG 28 OGTP-80 6-18-84 DR of Engine Base and Bearing Caps for TDI DSRV-16 Diesel Engines 29 OGTP-90 6-25-84 DR of TDI R-4 and RV-4 series EDG Cylinder Blocks and Liners 30 0GTP-89 6-22-84 DR of Connecting Rod Bearing Shells for Transamerica Delavel Enterprise Engines 31 0GTP-111 7-6-84 Supplement to the Emergency Diesel Generator Engine Driven Jacket Water Pump Design Review 32 OGTP-129 7-24-84 Emergency D.G. Rocker Arm Capscrews Stress Analysis 33 OGTP-140 7-27-84 Report on Emergency D.G. Auxiliary Control Module Control Wiring & Termination Review 34 OGTP-147 8-1-84 Design Review of Elliott Model 65G Turbocharger used on TDI DSRV-12-4 & DSRV-20-4 Emergency D.G.

Sets 102403 6-2

Ref. #

35 OGTP-181 8-10-84 Design Review of Engine Base and Bearing Caps for TDI DSRV-16 Diesel Engines 36 OGTP-190 8-14-84 Design Review of Elliott Model 90G Turbo charger used on TDI DSR-48 and DSRV-16 Emergency Diesel Generator Sets 37 OGTP-260 9-7-84 Design Review of Connecting Rods for TDI DSRV-4 Series Diesel Generators 38 OGTP-261 9-7-84 Design Review of Engine Base and Bearing Caps for TDI Diesel Engines 39 OGTP-263 9-7-84 Evaluation of Cylinder Heads of TDI Series R-4 Diesel Engines 40 OGTP-306 9-28-84 Survey of Start Experiences and Cause of Unscheduled Shutdowns of TDI Diesel Engines 0

S02403 6-3