ML13324A565
| ML13324A565 | |
| Person / Time | |
|---|---|
| Site: | San Onofre  |
| Issue date: | 03/08/1985 |
| From: | Medford M SOUTHERN CALIFORNIA EDISON CO. |
| To: | Zwolinski J Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 8503120355 | |
| Download: ML13324A565 (10) | |
Text
Southern California Edison Company P. 0. BOX 800 2244 WALNUT GROVE AVENUE ROSEMEAD. CALIFORNIA 91770 M.O.MEDFORD TELEPHONE MANAGER, NUCLEAR LICENSING (818) 302-1749 March 8, 1985 Director, Office of Nuclear Reactor Regulation Attention:
Mr. J. A. Zwolinski, Chief Operating Reactors Branch No. 5 Division of Licensing U. S. Nuclear Regulatory Commission Washington, D.C.
20555 Gentlemen:
Subject:
Docket No. 50-206 Transamerica Delaval Inc. Emergency Diesel Generators Revised Maintenance and Surveillance Program San Onofre Nuclear Generating Station Unit 1
References:
(A) Letter M. 0. Medford (SCE) to W. A. Paulson (NRC),
August 28, 1984, Return to Service Requirements Regarding TDI Emergency Diesel Generators (B) Letter D. M. Crutchfield (NRC) to K. P. Baskin (SCE),
November 19, 1984, TDI Diesel Engine Reliability and Operability (C) Letter M. 0. Medford (SCE) to 3. A. Zwolinski (NRC),
December 19, 1984, TDI Diesel Engine Reliability and Operability By Reference A, Southern California Edison (SCE) submitted a description of our program covering maintenance and surveillance activities for the San Onofre Unit 1 emergency diesel generators during the period between the recent plant restart and the next refueling outage. By Reference B, the NRC advised us that a revision to this program was necessary in light of recommendations contained in Pacific Northwest Laboratory Report PNL-5304, dated November 1984, and that such a revision should be submitted for NRC review. By Reference C, SCE agreed to submit a revision that considers Section 4.0 of PNL-5304.
Enclosed Table A to this letter constitutes our revised maintenance and surveillance program description, which incorporates the results of our review of Section 4.0 of PNL-5304. In some instances we have deviated from the PNL-5304 recommendations because of the lack of feasibility of the recommendation or because a clear advantage in terms of enhanced diesel engine reliability was not seen in adopting the recommendation.
8503120355 850309 PDR ADOCK 05000206 S
Mr. J.
March 8, 1985 Revised plant procedures to implement Table A will take effect as soon as practicable, but no later than the end of the next refueling outage.
If you have any questions, please call me.
Very truly yours, cc:
USNRC Document Control Desk, Washington, D.C.
20555 F. R. Huey (USNRC Senior Resident Inspector Units 1, 2 and 3)
D. E. Broeils (TDI Diesel Generator Owners Group)
TABLE A Description of Revised Maintenance & Surveillance Program Section I Action Frequency The following temperatures and Monthly 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 valves Inspect level of lube oil in sump tank, Monthly governor and pedestal bearing.
Inspect fuel oil pump rack and linkage Monthly Clean and inspect starting air "Y" Quarterly strainers Clean and inspect fuel oil filter Quarterly and strainers Also at pressure drop of 20 psi Drain water and sludge from lube oil Quarterly filter Change lube oil filter At Refueling. Also at pressure drop of 20 psi.
Lubricate air strangulation valves Quarterly Lubricate fuel pump control shaft Quarterly and linkage Oil rack assembly Quarterly Lubricate radiator fan vibration Quarterly switch Obtain fuel oil sample for analysis Quarterly
-2 Action Frequency Obtain and analyze lube oil sample Quarterly or from lube oil filter inlet with engine after 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> running, immediately prior to engine of continuous shutdown operation, whichever comes first Inspect generator brushes Quarterly Inspect and adjust V-belts on instrument Quarterly and air start compressor Check compressor head and base bolts for Quarterly tightness Check level in air line lubricators Annually Clean or replace air compressor air Semi Annually filters Clean compressor externally Semi Annually Change compressor crankcase lube oil Semi Annually Lubricate compressor after cooler motor Annually Clean and inspect engine intake air At Refueling filters Change governor oil At Refueling Clean and inspect oil separator Annually Megger crankcase vent fan motor Annually Inspect and clean filter in starting Quarterly air distributor Measure the insulation resistance of At Refueling 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
-3 Action Frequency Inspect the shaft seals, casings, piping At Refueling 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 Lubricate pump and motor bearings At Refueling Change oil in standby lube oil pump motor At Refueling Lubricate radiator fan motors At Refueling Inspect fuel oil standby pump motor At Refueling commutator and brushes Inspect engine foundation and bolts, At Refueling check torque Inspect crank case, including bump test At Refueling on connecting rods Measure crankshaft web deflection At Refueling Inspect cam shafts tappets, rollers, At Refueling rocker arms, push rods and valve springs Adjust hydraulic valve lifters At Refueling Visually inspect cam and idler gears At Refueling Remove fuel injectors and pop test At Refueling Also verify spray pattern of injector Inspect governor drive coupling for wear At Refueling Record firing and exhaust temperatures At Refueling and firing peak pressures Adjust temperature per Delaval Instruction Manual Clean and inspect generator winding At Refueling brushes and slip rings
-4 Action Frequency Measure insulation resistance of rotor At Refueling and stator windings Change pedestal bearing oil At Refueling Clean and inspect A.C. outlet box At Refueling Check generator foundation bolt torque At Refueling Inspect and lube auxiliary skid valves At Refueling and piping Disassemble and repair jacket water At every other keep warm and main pump discharge Refueling check valves Disassemble, repair and repack auxiliary At every other skid valves Refueling Disassemble and repair jacket water Every 5 years keep warm pump Disassemble and repair lube oil keep Every 5 years warm pump Change lube oil in sump Based on results of quarterly lube oil analysis Clean lube oil strainers At Refueling Change lube oil keep warm filter At Refueling or at 20 psi pressure drop Disassemble, inspect and repair fuel Every 10 years oil standby pump Disassemble, inspect and repair turbo Every 10 years charger Disassemble, inspect and repair heat Every 10 years, exchangers and intercoolers.
Trending or as required of temperature and pressure by temp, pressure trendihg Check gear train backlash Every 10 years (An inspection of backlash and thrust will be performed at next refueling).
-5 Section II Action Frequency
- 1) (A) Record engine operating parameters:
Once per hour, during surveillance
- a. engine inlet lube oil pressure testing.
- b. turbo lube oil pressure
- c. fuel oil pressure
- d. fuel oil filter and strainers differential pressure
- e. left bank air manifold pressure
- f. right bank air manifold pressure
- g. lube oil filter differential pressure
- h. jacket water pressure (inlet and outlet)
- i. crankcase vacuum
- j. all cylinder exhaust temperatures
- k. exhaust manifold temperatures at turbine inlet
- 1. lube oil temperature (inlet and outlet)
- m. jacket water temperature (inlet and outlet)
- n. tachometer
- o. hourmeter
- p. generator load
- q. fuel oil transfer pump filter differential pressure (B) Check following operating parameters:
- a. starting air pressure
- b. fuel oil day-tank level
- 2) 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 at 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> following engine shutdown. Also prior to a planned start, unless the engine has run and/or been air rolled in the 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> immediately preceding the start.
- 3)
Visually inspect external engine 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 block and base for oil and water engine operation, whichever comes leakage (engine running) first.
- 4)
Perform laboratory analysis of lube Quarterly oil sample taken from the bottom of sump to check for presence of water.
- 5) Visually inspect all connecting rod At refueling or after every boxes and check for bolt preload relaxation 285 hours0.0033 days <br />0.0792 hours <br />4.712302e-4 weeks <br />1.084425e-4 months <br /> of operation, whichever comes first.
- 6) Check preload relaxation on 25% of cylinder At refueling.
head studs, 25% of rocker arm bolts, and 50%
of air start valve capscrews
Action Frequency
- 7)
Visually check cams, tappets, and push rods At refueling.
- 8)
Check hot and cold crankshaft deflections.
At refueling.
Measurements to be done once each refueling cycle.
Hot to start immediately after engine shutdown.
- 9) Check rotor float and inspect stationary At refueling. (One turbocharger nozzle ring bolts for one turbo-charger will be disassembled and inspected at next refueling).
- 10)
Flush jacket water system*
At ten (10) year intervals, or earlier if required by coolant analysis.
- 11)
Inspect DG #1 crankshaft oil holes for At next refueling.
At every cracks.
Also conduct visual and thickness second refueling thereafter.
checks of two highly loaded bearings on a sampling basis.
- 12)
Conduct magnetic particle examination of top At next refueling. If negative, surface of cylinder blocks for cracks between then no other.
the No. 4 and No. 7 heads, with the cylinder heads removed.
- 13)
Disassemble two sets of pistons (four pistons)
At refueling.
and inspect for cracks per Owners Group recommended procedures.
- 14) (a) Visually inspect cylinder liners for (a) At refueling.
scuffing or metal deposition.
(b) Measure/record dimensions of cylinder (b) At each disassembly.
liners for wear and trend analysis.
- 15)
Disassemble air start valves to check proper At refueling.
seat contact.
- 16)
Check fuel oil drip tank. Clean as required.
Quarterly This is a closed system in which chemical additives are maintained within specified limits.
During a jacket water system inspection in 1984, no corrosion or scaling due to 7 years of operation could be found.
IAA:3639F
-7 Section III Item Surveillance
- 1. Starting air pressure Visual checks every 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />
- 2. Lube oil temperature in/out
- 3. Jacket water temperature in/out
- 5. Fuel oil day-tank level
- 6. Annunciator Test every 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.
- 7. Compressor air trap operation Check daily
- 8. Fuel rack and linkage operation Inspect and lube monthly
- 9. Governor oil level Check daily
- 10.
Visually inspect engine assembly for Monthly oil and water leakage
- 11.
Keepwarm oil filter differential Check weekly pressure
- 12.
Test jacket water for pH, After makeup or monthly conductivity, corrosion inhibitor
- 13.
Air start admission valve Clean and inspect quarterly strainer IAA:3639F
-8 Section IV The following vendor's recommendations, as modified below, are also included in the revised maintenance and surveillance program.
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.
(A visual inspection of cam and idler gears and bushing will be done at the next refueling).
Check connecting rod bearings every At refueling, the connecting rods are other refueling bump tested which indicates bearing wear. In addition, inspection and radiograph of four half bearing shells will be performed at next refueling.
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 normally be done during 10 year gear case inspection. However, a visual inspection of oil jets will be done at the next refueling.
Remove fuel injection pumps and At every third refueling, have pumps send to shop for rebuild and checked for proper operation and calibration calibration at a qualified diesel service center IAA:3639F