ML13324A896
| ML13324A896 | |
| Person / Time | |
|---|---|
| Site: | San Onofre  |
| Issue date: | 06/20/1986 |
| From: | Medford M Southern California Edison Co |
| To: | Lear G Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 8606240179 | |
| Download: ML13324A896 (21) | |
Text
Southem California Edison Company P. O. BOX 800 2244 WALNUT GROVE AVENUE ROSEMEAD, CALIFORNIA 91770 M.O.MEDFORD TELEPHONE MANAGER. NUCLEAR LICENSING June 20, 1986 (818) 302-1749 Director, Office of Nuclear Reactor Regulation Attention.
G. E. Lear, Director PWR Project Directorate No. 1 U. S. Nuclear Regulatory Commission Washington, D.C.
20555 Gentlemen:
Subject:
Docket No. 50-206 Inspection Report on Emergency Diesel Generator No. 2 San Onofre Nuclear Generating Station Unit 1
Reference:
(A) Letter, M. 0. Medford (SCE) to G. E. Lear (NRC), dated May 19, 1986, Inspection Report on Emergency Diesel Generator No. 1 Enclosed for your review are the results of inspections performed on emergency diesel generator no. 2 at the San Onofre Nuclear Generating Station, Unit 1. These inspections were performed during the current Unit 1 refueling outage in order to comply with the recommendations of the TOI Diesel Generator Owners Group, as contained in the San Onofre Unit 1 Design Review and Quality Revalidation (DR/QR) Report dated February 1985.
The inspection results for diesel generator no. 1 were submitted to you by the referenced letter.
If you have any questions, please call me.
Very truly yours, Enclosure cc: R. Dudley, NRC/NRR San Onofre Unit 1 Project Manager F. R. Huey, NRC Senior Resident Inspector, Units 1, 2 and 3
- 3. B. Martin, NRC Region V, Regional Administrator D. E. Broeils, Duke Power Co., TDI DG Owners Group
.V2'3 05 Obo206 666419Q02
DG2 INSPECTION REPORT EMERGENCY DIESEL GENERATOR NO. 2 SAN ONOFRE NUCLEAR GENERATING STATION UNIT NO. 1 INTRODUCTION:
SCE has performed a major inspection on the emergency diesel generator no. 2 at San Onofre Nuclear Generating Station, Unit 1. The inspection occurred from March 1986 to May 1986. This inspection was performed to comply with the recommendations of the TDI Diesel Generator Owners Group Design Review/Quality Revalidation (DR/QR) report. The DR/QR report was submitted to the NRC on September 3, 1985.
MaJor 16 Components/Phase I Sixteen components were originally identified as the most significant affecting the safety function of the diesel generators. The following work was performed to meet all of the DR/QR report recommendations:
Air Start Capscrews Dimensional checks were performed on all air start capscrews. Material and hardness checks were made on four capscrews.
Torque (cold and hot) was verified on reassembly. Service Information Memo (SIM) 329 was implemented during the previous outage and SIM 360 performed during the current outage.
All inspections were satisfactory.
Auxiliary Module Wiring and Terminations Wiring and terminations were replaced during a previous outage in accordance with TDI's SIM 361 and 10 CFR 21 notification. No work was performed during the current inspection.
Connecting Rods An NDE of all connecting rod assemblies was performed.
No linear indications were found. All bushings and pins were dimensionally checked and are satisfactory.
A sample of four connecting rods was checked for material and hardness and found to be satisfactory.
An eddy current test was performed on all rod box female threads with no defects found.
NDE was performed on all connecting rod bolts with satisfactory results.
Inspection of link rod alignment was performed in accordance with SIM 349. Alignment was found to be satisfactory.
-2 Connecting Rod Bearing Shells All connecting rod bearing shells were visually inspected and were satisfactory. All shell dimensions were checked satisfactorily.
Crankshaft Main bearing journal holes #1 through #12 were examined by penetrant test (PT) and no cracks were found.
All main and crank pin journal fillets and crank pin oil holes were NDE inspected with no indications found.
Crankshaft connecting rod pins were dimensionally checked and visually inspected and main journals were visually inspected with satisfactory results.
Web hot and cold deflection measurements were performed satisfactorily.
All cross-drilling oil hole plugs were inspected in accordance with 10 CFR 21 notification dated 3/18/85. 16 gauge plugs were found and no deficiency noted.
Engine Base and Bearing Caps The entire base and bearing caps were visually inspected.
No indications were found.
Fuel Oil Injection Tubing 100% eddy current examination was performed by our consultant Failure Analysis Associates. A visual exterior inspection was also performed. The results were satisfactory and met SCE's commitment to the NRC in letter dated June 29, 1984.
Jacket Water Pump Dimensional, material, hardness and PT checks were performed on the shaft and gear. The shaft was found to be 410 stainless steel instead of 303 stainless steel, as assumed by the DR/QR report revalidation criteria. The shaft was accepted as is based on TDI's recommendation.
Cylinder Liners All cylinder liners were visually inspected and found satisfactory. All liner diameters except 1L, 2L, 3L, 7L are slightly less than the acceptance criteria of 17.000" to 17.080". The average undersize is 0.001", which provides for a slightly tighter fit. Cross hatch and ring wear are normal.
There is no effect on function and the liners are acceptable.
Liner 7R was removed due to a water leak from the lower "0" ring seals.
The liner was visually inspected and its dimensions checked.
Results were satisfactory.
-3 Piston Skirts 75% of the pistons were disassembled and inspected (25% done during a previous outage).
The break away torque of the crown nuts could not be measured due to castle nut lock pin not being removable. Piston skirt outside diameters (OD) and pin clearances were measured and are satisfactory.
Piston 4R skirt spot face depths (3 of 4) are insignificantly out of tolerance and are acceptable, based on SCE's engineering evaluation.
Cylinder Block NDE was performed on the liner landing with liner 7R removed. NDE was performed between adjacent studs and the stud to liner areas on both block tops.
No indications were found.
Liner landing dimensions were not fully checked due to no indication of overstress on the liner landing.
Cylinder Heads The following inspections were performed on all heads:
- 1.
Visual
- 2.
Liquid penetrant of valve seating surfaces
- 3. Ultrasonic to determine fire deck thickness.
- 4. Magnetic particle examination of fire deck surfaces.
- 5. Maintenance matrix recommendations were performed satisfactorily during post maintenance testing.
13 heads were found by magnetic particle examination to have linear indications on the firing deck.
Two of these heads had additional visual cracks in the air start valve assembly opening. Three heads were repaired by grinding to remove indications and were reused.
Ten new heads qualified to Group III standards were obtained from TDI and installed to replace heads not repairable onsite.
The current status of all installed heads is as follows:
50% (10) heads have been qualified to current standards for Group III heads.
35% (7) are original heads that satisfactorily met all DR/QR inspections.
15% (3) are repaired heads that satisfactorily met all DR/QR inspections.
The 10 heads not qualified to Group III standards will be replaced in subsequent outages, as committed to in SCE's letter to the NRC dated December 19, 1984.
-4 Cylinder Head Studs Visually inspected head studs for signs of distress for cylinders 4R, 4L, 6R and 6L. Material analysis identification tests were performed on four randomly selected studs. Hardness test was performed on 2L#4.
All studs were found satisfactory.
Push Rods Liquid penetrant examination was performed on all pushrod ends. Visual inspection for full insertion of forged head into tubes was performed. Four push rods which had linear indications were replaced with spares.
Previous work had replaced all ball head push rods with friction welded push rods.
Future purchases will include sample radiograph inspection or destructive examination.
Rocker Arm Capscrews Performed magnetic particle test of the thread root area of all capscrews for linear indications. Also performed material comparator and hardness test on four capscrews.
All capscrews were found to be satisfactory. A visual inspection on the drive studs was performed for signs of irregularity.
Torquing was verified on reassembly.
Turbochargers Performed turbocharger rotor end play inspection on all four turbochargers with satisfactory results.
All four turbochargers were fully disassembled for an internal inspection.
This inspection included:
- 1) visual inspection,
- 2) verification of proper number of bolts on the turbine inlet casing,
- 3) verification of proper torques, and
- 4)
PT on stationary nozzle ring for signs of adverse wear and cracking.
The right front turbocharger was found to have blade damage on the turbine disc.
The rotor assembly was replaced by a qualified in kind spare. The rotor blade damage is believed to have been caused by a foreign object. The right rear turbocharger shaft seal diameter was found out of tolerance. The shaft seal was replaced with a qualified in kind spare.
Right rear, left rear and left front turbochargers were found to have worn bearings, cracks and some other surface indications on the shaft thrust collar face. The shaft is made from 4140 carburized steel.
The thrust collar face is finish ground and has a Rockwell hardness of 55-60 RC.
The cracks were radial, approximately 1/4 inch long and located on the outer edge of the
pressure face, adjacent to the seal groove. The other indications were approximately 1/2 inch in diameter and 0.002 inch deep and were located on the pressure face, extending from approximately halfway out on the diameter to the outer edge.
The bearing wear was most likely caused by lack of lubrication (a service condition which no longer exists). A meeting with the turbocharger manufacturer (Elliot Company) failed to clarify the specific cause of the thrust collar cracks or of the other indications. No discoloration typical of metal overheating was observed.
Two of the above turbochargers were replaced with qualified in kind spares.
One was rebuilt by the manufacturer and then re-installed.
Base line vibration data were taken on all four turbochargers.
Balance of Reviewed Components/Phase II The balance of the components reviewed by the Owners Group (Phase II) is tabulated by major categories with summaries of the recommended actions and the work performed during the current outage.
IAA:6889F
DG2 PHASE II REVIEW Component Owners Group Recommended Action Summary of Work Performed TURBO, INTAKE, INTERCOOLER AND EXHAUST Turbocharger (MM 19/20)
Additional maintenance and inspection See Phase I.
recommendations.
Prelubrication procedures should be followed.
Turbocharger Thrust Addition/modification of supports.
Refer Modification not required. 1 Flow orifice was cracked Bearing Drip Lube System to DR/QR report 02-CFR for details during reassembly and was replaced with an in kind (Small Bore Scope Only) qualified spare.
(02-CFR)
Intake Manifold and Additional maintenance recommendations.
Visually inspected air intake manifold elbow flange faces Piping (Large Bore Additional Quality inspections recommended, and increased bolt hole size to 1/8" oversize (5/8" ID)
Scope Only) (02-375) in accordance with design review recommendations.
Insta*
intake manifolds drain lines.
Inspection and modification completed satisfactorily.
Exhaust Manifold Piping Flat bar which connects the shroud to the engine Modifications not required. 1 Visually inspected.
(02-380A) should be modified to allow for axial thermal-NE of a sampling of pipe welds was performed.
Results expansion.
Addition of slip joints.
Additional acceptable.
maintenance recommendations.
Inspections of cap screws recommended.
Replace 3/B-inch bolts that connect the water jacket shroud to the manifold assembly with 1/2-inch bolts.
Exhaust Manifold:
Gasket Additional Quality inspections recommended.
Verified torque on exhaust manifold bolting.
and Bolting (02-3808)
Performed visual inspection of exhaust manifold to verify freedom from binding and flange fillet welds are free from cracks.
All found satisfactory.
Turbocharger Bracket, Additional design review inspection recommended.
Inspected turbocharger brackets mounting bolts to verify Bolting and Gaskets torque and thread engagement.
(02-475A&D)
Air Butterxfly Valve Addition of grease fittings per TDI SIM 322.
Disassembled and performed inspection on air strangulati Assembly (02-475B)
Additional maintenance requirements.
Additional valves.
All satisfactory.
ofM 322 was implemented Quality Revalidation inspections recommended, previously.
Turbocharger Brackett-Air Each crossover piping syst em should be supported None required. 1 Intake Piping (02-475C) by two flexible anchors only.
Remove all U-bolts and strap supports lurbocharger Bracket Pipe None None required.
Supports (Large Bore Scope Only)
(02-.4751E)
[lex Connections (02-.805C)
Additional maintenance recommendation.
Visually inspected.
Intake Air Silencer None inspected interior of each silencer to ensure both ends of rcenterline 'bullet are welded on.
Inspected for end cap using mirrors in accordance with 10 CFR 21 dated 11/10/85.
All end caps welded.
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DG2
-2 Component Owners Group Recommended Action Summary of Work Performed Intercooler (41-127A)
Additional maintenance recommendations.
Inspected condition of tubes and shell for scaling, sediment or corrosion and cleaned as required. Pressure tested all intercoolers.
Intercooler Piping and Addition/modification of supports.
Refer None required. 1 Piping Couplings, Gaskets to DR/QR report 041-127B&C for details.
and Bolting (041-127B&C)
LUBE OIL Lube Oil Full Pressure Inspect and clean the strainer element at any Cleaned and inspected strainer for holes or physical Strainer (SE-014) significant increase in differential pressure damage.
and at each refueling outage. Check differential pressure during each engine operation.
Lube Oil Pressure Disassemble and clean the value annually or at Disassembled, cleaned and inspected two valves.
Regulating VJalve (00-.420) each refueling outage.
To ensure proper Spool spring compression retainer on one valve was found clearance, the dimensions of the value internal cracked and was replaced with qualified in kind spare.
parts should be chocked.
Lube Oil Fittings -
None None required.
Internal Headers (Large Bore Scope Only)
(02-307A--LB)
Lube Oil Fittings -
Modify supports.
Refer to DR/QR report Refer to item 02-307D.
Internal:
Headers 02-30/D for details.
(02-307A--SB)
Lube Oil Fittings Internal Check tubing for dents or crimps.
Perform gear Checked tubing for dents and crimps.
Cam bearing lube Tube and Fittings (Small train spray check.
oil supply line was dented during the overhaul and was Bore Scope Only) (02-3078)
NDEd and pressure tested and reused.
Performed gear train spray check.
All inspections were satisfactory.
Lube Oil Fittings Internal Replacement of all 1/4-inch U-bolts with None required. 1 Supports (Small Bore 3/B-inch U-bolts on the auxiliary internal lube Scope Only) (02-30sp) oil header.
Installation of suitable locking devices on nuts.
Engine Driven Lube Oil None Disassembled and inspected with satisfactory results.
Pump (02--420)
Lube Oil Lines External:
Addition of support to provide a stiffer load None required. 1
- 3ubing, Fittings and path a-d to relieve seismic stresses on the Couplings (Large Bore external header.
Recommendation for a Scope Only) (02--465LB) minimum installation gap between the pipe ends of 0.1/1 inch.
Lube Oil Lines -- External Modify supports.
Refer to R/QR report None required. 1 fubings, Fittings, Couplings 02-465B for details.
I Refer to SCE La NRC letter dated Septombor 3, 191) frclosure IT.
DG2
'-3 Co2mponent Owners Group Recommended Action Summary of Work Performed Lube Oil Lines -
External None None required.
Supports (Large Bore Scope Only) (02-4658-LB)
Lube Oil Lines External:
Modify supports, U-bolts and locking devices.
None required. 1 Supports (Small Bore Scope Refer to DR/QR report 02-4658 for details.
Only) (02-465B-SB)
Lube Oil Perform a comparison of the as-built None required.1 Fitting -
Pipe, Tubing and configuration with the assembly details.
Flexible Coupling (Large Bore Scope Only) (02-467A-LB)
Turbocharger Lube Oil Addition/modification of supports.
Refer None required.1 Fitting:
Pipe, Tubing, to DR/QR report 02-4678 for details.
0 Fittings and Flexible Coupling (Small Bore Scope Only) (02-467A-GB)
Fitting and Supports (Large Bore Scope Only)
Lube Oil Addition/modification of supports. Modification None required. 1 Fittings:
Supports of U-bolts.
Installation of locking devices.
(Small Bore Scope Only)
Refer to DR/QR report 02-4678 for details.
Lube Oil Sump Tank with Visual inspection of the tank seam and assembly LO. System Inspection:
Strainer Assembly and welds recommended.
Recommendation to measure
- 1. Sump Mounting Hardware engine, tank and pipe displacement at next
- a. Interior for rust, corrosion and weld seam integrity (02-540A&C) refueling outage.
Verify proper bolt torque.
- b. Suction strainer
None None required.
Fittings, Gaskets, Bolting Material, Valves (Small Bore Scope Only) (02-540B)
Lube Oil System Auxiliary None None required.
Lube Oil Pump (02-545)
Auxiliary Sub base and Oil Addition/modification of supports.
Refer Modification not required. 1 Keep warm pump suction aid Water Piping Lube Oil:
to DR/QR report 02-717F for details, strainer inspected and cleaned.
Pipe/Fittings (Small Bore Scope Only) (02-717F)
I Refer to SA to NRC Jt. Lor dated Septmdr 3,
1981, EnrcOsure S.yn.
DG2 ompnent Owners Qrgu Recommended Action Summary of Work Performed Auxiliary Sub Base and Oil Additional maintenance requirements.
Relief valves 200 and 201 were tested and reinstalled.
and Water Piping:
Lube Oil Valves (02-717G)
Auxiliary Sub Base and Oil The auxiliary piping should be walked down daily Performed routinely.
and Water Piping:
Lube to verify the leak tightness of the lube oil Oil:
Gaskets & Bolting piping flanges.
(02-717H)
Intake Air Filter (02-805B)
Additional maintenance requirements.
Inspected distribution plates and changed oil.
Miscellaneous Equipment -
Additional maintenance recommendations.
Inspection and work included:
- 1. Measuring heater insulation resistance.
Tank (02-820A)
- 2. Replacing heater elements.
- 3. Checking calibration and inspecting condition of thermostat.
Lube Oil Heat Exchanger Additional maintenance recommendations.
Disassembled, cleaned and inspected L.O. heat exchanger.
(02-820B)
Full Flow Lube Oil Filter Additional maintenance requirements Changed filters.
(02-820C)
Prelube Oil Pump (02-8200)
Additional maintenance recommendation.
Overhauled.
Oil Prelube Filter (02-820E)
Additional maintenance recommendations.
Changed filters.
ENGINE BASE AND BEARING CAPS Base and Bearing Caps -Additional maintenance recommendations Additional See Phase I.
Base Assembly, Main Quality inspections recommended.
Bearing Studs and Nuts and Main Bearing Caps (02-305A,C,D)
CRANKSHAFT AND BEARINGS Crankshaft (02-310A)
See Phase I.
Main Bearings (02-310B)
Additional Quality inspections recommended.
Measured all main bearing shell thicknesses.
PF performed on all main bearing shells.
Indications were noted in three bearing halves due to babbit flaking. The affected bearing halves wore replaced.
Crankshaft and Bearings:
Additional maintenance recommendations.
Performed thrust check and visually inspected thrust Thrust Bearing Ring bearing ring.
(02.-310CG)
Crankcase:
Crankcase Additional Quality inspections recommended.
Visually inspected crankcase. Insignificant casting flaws Assembly (02-311A) noted.
I Rfer to SCE to NRC letter dated Septombor 3, 1985, Enclosure III.
0G2 ComEonent Owners Group Recommended Action Summary of Work Performed Crankcase:
Crankcase None None required.
Mounting Hardware (02-311D)
Crankcase:
Crankcase Additional Quality inspections recommended.
Inspected bolt holes on crankcase covers for cracks.
Gaskets and Mounting No deficiencies noted.
Hardware (02-3868)
Crankcase Relief Valve Additional maintenance recommended.
Disassembled and inspected crankcase vent fans and Vacuum Fan (02-385A) and measured insulation resistance. Cleaned flame arrestor portion of relief valve.
CYLINDER BLOCK, LINERS AND WATER MANIFOLD Cylinder Block (02-315A)
Verify cylinder liner bore and mating block See Phase I dimensions.
Additional Quality inspections recommended. Additional maintenance inspections recommended.
Cylinder Block Liners and Additional maintenance recommendations.
See Phase I Water Manifold -
Cylinder Additional Quality inspections recommended.
Liners (02-315C)
Jacket Water Manifold Perform a non-destructive examination of Performed NDE of large bore jacket water piping welds.
Piping (Large Bore Scope subject piping component to ensure the integrity No indications noted.
Further seismic restraint Only) (02-315D) of pipe welds. Inspect inaccessible piping to inspection not warranted. 1 ensure adequate seismic restraint.
Cylinder Block Liners and Modify head stud installation procedure to See Phase I Water Manifold:
Studs lower the stresses in the cylinder block (02-315E) stud boss area. Additional Quality inspections recommended, Cylinder Block Liner and Additional Quality Revalidation inspections Performed a visual examination for forging laps Water Manifold -
Cylinder recommended, and identification markings on cylinder head nuts.
Head Nuts (02--315F)
No problems noted.
Verified torque on reassembly.
Cylinder Block -
Liners and Verify installation of proper cylinder liner The cylinder liner 7R that was removed was reinstalled Water Manifold:
Seals and seals (101 P/N JF-019-.0) in diesel generators.
using TDI part number JF-019-OOO.
Gaskets (02-315G)
Cylinder Block Covers:
Verify that the proper torque is applied and the Visually inspected cylinder block cover gaskets for signs Gaskets and Bolts (02-3858) specified material is installed.
Additional of elastometric compound breakdown and cracking.
No Quality inspections recommended, problem noted.
Verified torque on reassembly.
AIRSIART AND BARRING DEVICE Starting Air Distributor:
Additional Quality Revalidation inspections Visually inspected the poppet valves spool ends and Distributor Assembly recommended.
Additional maintenance timing. No problems noted.
(00--442A) recommendations.
I Refer to SAE to NRC let.Ler dat~ed Sept.embor 3,
19,5, Enclosure III.
DG2
-6 Component Owners Group Recommended Action Summary of Work Performed Starting Air Distributor -
All Air Distributor Tubing is addressed under See component numbers 02-441A&C.
Tubing, Fittings and Gaskets component numbers 02-441A&C.
(00-4428)
Air Start Values (02-359)
Implementation of SIMs 329 and 360.
Additional All twenty air start valves were inspected. Eight valve faces maintenance recommendations.
Additional had cracks per penetrant test results.
- 9L failed to close.
Quality inspections recommended.
Two valves failed blue check and were replaced.
All other valves were polished, reinspected and found satisfactory for continued service.
See Phase I for capscrews.
Starting Air Manifold:
Addition/modification of supports.
Refer None required. 1 Piping, Tubing and Fittings to DR/QR report 02-44lA--LB for details.
(Large Bore Scope Only)
Starting Air Manifold -
Modify supports.
Refer to DR/QR report None required.1 Piping, Tubing and Fittings 02-441C for details.
(Small Bore Scope Only)
(02-44 lA-.SB)
Starting Air Manifold:
Additional maintenance requirements.
Changed filter elements.
Cleaned, inspected and Valvesv Strainersp Filters refurbished block valves.
(02-4416)
Starting Air Manifold None None required.
Support (Large Bore Scope Only) (02-441C-LB)
Starting Air Manifold -
Addition of two-directional supports to None required.1 Supports (Small Bore Scope the tubing running from the distributor Only) (02-44C-SB) to the horizontal tubing runs on top of the engine.
Addition of a two-directional lateral support to each 1/2-inch tube entering arid exiting the air filter.
Barring Device -
None None required.
Pneumatic Regulator Valve/
Shutoff Valve (02-525B)
Barring Device --
None None required, Pneu(atic:
Mounting Bracket/Supports (02-525s)
Starting Air, Tank (02-835E)
Additional maintenance recommendations.
Inspected tanks.
Cleaned flow traps and calibrated pressure switches.
Tanks were State recertified.
Air Start iank Relief None None required.
Valves (02-835G)
I Baror in o
g CC to NRC Nntter dated SepNembor 3, 1985, Ericruosure d.
DG2 Comgnent Owners Group Recommended Action Summary of Work Performed Skid Base -
Starting Air Additional maintenance recommendations.
Replaced leaking inlet check value.
Equipment (02-835A,F&H)
Air compressor crankcase oil sampled, drained, flushed and refilled.
Verified pressure relief value spring and changed setpoint per FCN S1109-M. Inspected and cleaned compressors.
Replaced belts. No problems noted.
Inspected and serviced moisture traps in starting air system. All drain traps were cleaned and are in satisfactory condition.
CONNECTING RODS Connecting Rods: Connecting Additional inspections recommended.
See Phase I Rods and Bushings (02-340A)
Connecting Rod:
Bearing Additional maintenance requirements. Additional See Phase I Shells (02-3408)
Quality Revalidation inspections recommended.
PISTONS Piston (02-341A)
Additional inspections of the stud boss See Phase I attachment area recommended.
Additional Quality inspections recommended.
Pistons:
Rings (02-341B)
Additional maintenance and Quality Revalidation Disassembled pistons and inspected rings.
Two oil rings inspection recommendations.
on OR piston were damaged during maintenance and were replaced.
Piston:
Piston Pin Replacement of spiral ring retainers with All piston pin dimensions were checked and found (02-341C)
Waldos SNAP ring retainers (P/N GE-003-067).
satisfactory. Pin to bushing clearance was calculated; Additional Quality inspections recommended.
14 pin clearances were undersized but acceptable as is.
Additional maintenance recommendations.
Chrome finish and end plugs inspected. Two end plugs were rerolled.
Installed Waldes SNAP ring retainers.
CAMSHAFT AND VALVE TRAIN Tappets and Guides:
Additional maintenance recommendations.
Tappet roller to tappet roller pin clearance was checked.
Intake and Exhaust Additional Quality inspection recommended.
T'appet rollers wore visually inspected.
Freedom Tappet Assembly (02-345A) of rotation was checked and found satisfactory.
Tappets and Guides:
Additional maintenance recommendations.
Work performed similar to 02-345A.
Fuel lappet Assembly Additional Quality inspections recommended.
(02--345B)
Tappets and Guides:
Fuel None None required.
Pump Base Assembly (02--345C)
Camshaft:
Camshaft Additional maintenance and Quality Revalidation Visually inspected for premature wear.
Assembly (02--350A) inspection rocummendations.
1 Hefer to S(.
to NHC letter dated Septeimbor 3, 1I.11.
DG2
-8 Componen Owners Group Recommended Action Summary of Work Performed Camshaft:
Camshaft None Completed cam and thrust bearing inspection Bearings (02-3508) satisfactorily.
Camshaft-Supports, Additional maintenance recommendations.
Cam gear nut torqued.
Performed visual inspection Bolting and Gears; Idler Additional Quality inspections recommended.
with satisfactory results.
Gear Assembly -
Crank to Pump Gear; Idler Gear (02-350C, 02-355A&B)
Subcover (02-362A)
Additional inspections and Quality Revalidation Four subcovers (assembly web area) were visually inspections recommended, inspected.
Performed NDE on all subcovers on the machined surfaces of the rocker shaft assembly bolt bosses.
Replaced subcovers 10R, 3L, BR due to linear indications.@
Rocker Shaft Assemblies:
Additional Quality Rovalidation inspections Performed dimensional check of rocker arm shafts and Intake/Intermediate &
recommended.
bushings and inspected bushings.
Performed inspections Exhaust (02-390A&B) of rocker shaft assemblies.
Rocker arm exhaust pushrod cup in subcover 2R was chipped.
Replaced associated rocker arm with in kind qualified spare.
Performed material comparator test of intake and exhaust rocker arm shaft for bR.
Main and connector Additional Quality Revalidation inspections See Phase I pushrods (02-39OC&D) recommended.
Rocker Arm and Pushrods:
Additional maintenance requirements.
See 02-39pA&B Bushings (02-390E)
Rocker Arms and Pushrods:
Additional Quality Revalidation inspections All lifters were inspected and verified to be in the Lifters (02-39UF) recommended, correct position. Reinstalled and adjusted lifters.
Rocker Arms and Pushrods Additional maintenance recommendations.
See Phase I.
Miscellaneous Bolts and Additional Quality inspections recommended.
Drive Studs (02-390G)
IDLER GEAR ASSEMBLY AND FRONT GEAR CASE ront Gearcase Boling Additional inspections of bolts.
Addition of Verified proper installation and torque (o2-335B) positive locking features (bent tab or lockwire).
of internalgearcase bolting.
Additional Quality inspections recommended.
FLYWHEEL Flywheel (02-330A)
None None required.
Flywheel Bolting (02-330B)
Recommended that the assembly procedures include Flywheel bolting torque was verified.
an effort to keep the flange faces of the flywheel, crankshaft and generator shaft free of antisioze compound.
IDI bolt torque requirements should be documented.
I Refer to SCE to NRC letter dated September 3, 1985).
Fnclosure I.I..
002
-9 Component Owners Group Recommended Action Summary of Work Performed ENGINE INSTRUMENTATION AND WIRING Pyrometer Conduit Assembly:
Additional maintenance recommendations.
Verified thermocouples indicated ambient temperature when Thermocouples (02-630D) engine was cold.
Engine and Auxiliary Module Upgrade conduit supports. Addition of supports Conduit supports were reviewed as part of a site walkdown/
Wiring Material and for Category I rigid and flexible conduits, inspection and were found adequate with respect to seismic Fittings:
Pyrometer Conduit considerations. Walkdown covered both diesel generators Assembly -
Conduit, Fittings no. 1 and no. 2.
and Supports (02-688A, 02-630A, B, C)
Engine and Auxiliary Module Implementation of TOI SIM No. 361 on Engine See Phase I.
Wiring Material:
Wiring No. 1 should be confirmed.
and Terminations (02-6888)
Engine and Auxiliary Module None None required.
Wiring Material -
Boxes and Terminals (02-688C)
On Engine Alarm Sensors None None required.
(02-690)
Off Engine Alarm Sensors None None required.
(02-691A)
OVERSPEED TRIP AND GOVERNOR Overspeed Trip:
Governor Additional maintenance requirements and Trip setpoint was verified.
Set screws were marked (02-410A)
Quality Revalidation inspections recommendations.
with torque-seal.
Overspeed Trip:
Governor Evaluation of crankshaft torsional response and Inspected and performed NDE on overspeed trip governor and Accessory Drive its effect on the governor and accessory drive and accessory drive with satisfactory results.
Assembly (02-410B) assembly is required.
Additional Quality Inspection included:
Revalidation inspections recommended.
o Confirmation that the material of the accessory drive gear was AISI 4340.
o Visual inspection of assembled accessory drive gear for wear.
o Measurement of accessory drive gear shaft-to-bearing clearance.
o Visual and LP inspection of the governor shaft.
o Dimensional check of the governor shaft in the bearing area.
o Superficial hardness tests on outer gear tooth flat (top land) of overspeed governor drive gear.
Overspeed Trip:
Couplings Additional Quality inspections recommendod.
Now spider and coupling were installed.
This meets the (Flexible and Spider)
Additional maintenance recommendations.
requirements of SIM 363.
(02-410C)
I efer toi SCf La NRC let.ter dAted Septemboiber 3,
titlr sure I.1
DG2 Component Owners Group Recommended Action Summary Of Work Performed Vent Value:
Overspeed Valve "O" ring should be changed every 5 years.
Cleaned, inspected and replaced "0" rings.
Trip (02-4100)
Governor Drive:
Governor Additional Quality inspections recommended.
Inspected and performed NDE on governor drive gear and and Tachometer Drive Gear shaft.
Also inspected for key to keyway clearance.
and Shaft (02-411A)
Examination results were satisfactory.
Governor Drive:
Couplings, Additional maintenance recommendations.
Verified set screws and lock pins are locked in place.
Pins and Keys (02-4118)
Additional Quality inspections recommended.
Verified coupling grid color code.
Also see 02-411A.
Redowled mounting bracket and plate to restore governor drive assembly clearance and alignment per TDI drawing.
Governor Linkage (02-413A)
Additional maintenance recommendations.
Greased rod end fittings.
Inspected linkage assembly.
Additional Quality inspections recommended.
Installed positive locking hardware.
Fuel Pump Linkage:
Additional maintenance recommendations.
Checked automatic shutdown cylinder for extension and Automatic Shutdown return.
Checked tailrod vent for leakage.
Checks were Cylinder (02-413B) satisfactory.
Governor Assembly:
Additional maintenance recommendations.
Operating procedure reviewed to verify compliance with Woodward Governor (02-415A)
Additional quality inspections recommended, manufacturers recommendations and required testing.
Replaced governor assembly.
Changed governor oil.
Verified control knob settings.
Governor linkage oscillation no longer observed after governor assembly was replaced.
Governor Assembly Booster Additional Quality inspections recommended.
Verified correct installation of governor servomotor Servomotor (02-4158) following replacement with a qualified spare.
ENGINE SHUTDOWN AND EQUIPMENF Engine Shutdown Equipment -Addition of two and three direction supports.
None required. 1 Tubing/Fittings & Supports Reinforcement or redesignment of interface (Small Bore Scope Only) bulkhead between engine and off engine tubing (02--695A) to increase vertical load capacity.
Refer to DR/QR report 02-695A for details.
Engine Shutdown Equipment -Additional maintenance requirements.
Pressure regulator will be replaced when parts are Valves, Regulators, Orifices available from i81.
(02-695B)
E~ngine Shutdown Trip Additional maintenance requirements.
Verified switch setpoints.
Switches (02-Q695C)
JACKET WATER Jacket Water Manifold -
Perform a non-destructive examination of subject See 02-315D.
Manifold Assembly with piping component to ensure the integrity of Hardware, Coupling and pipe welds.
linspect inaccessible piping to Gaskets (Large Bore Scope ensure adequate seismic restraint.
Only) (02-316A&8)
I Refer to SCE to NRCx letter dated Septxamuir 3o r98el Enclosure stf
DG2 Component Owners Group Recommended Action Summary of Work Performed Water Discharge Manifold:
Additional maintenance requirement.
Inspection performed routinely, Jacket Water Discharge Manifold, Couplings and Seals (Large Bore Scope Only) (02-317A&B)
Water Discharge Manifold:
None None required.
Supports (Large Bore Scope Only) (02-317C)
Jacket Water Pump (02-425A)
Modify torque values for nuts on impeller and See Phase I.
shaft. At the drive gear end of the pump shaft, a second hole should be drilled in the threaded end, 90 dog from the existing one to minimize nut rotation required to insert the locking cotter pin. Additional Quality inspections recommended.
Jacket Water Fittings -
Additional maintenance requirement.
Inspection performed routinely.
Pipe and Fittings (Small Bore Scope Only) (02-435A)
Turbo Water Piping -
Pipe Replacement of 1/4-inch diameter U-bolts with Modification not required. 1 Inspection performed and Fittings (02-.437A-SE3) 3/6--inch diameter U-bolts on turbo water inlet routinely.
(Small Bore Scope Only) supports for Engine 2, generator end.
Addition of two-direction supports on the 1/4-inch tubing from the jacket water outlet headers to the combustion air coolers on both engines.
Turbo Water Piping -
Pipe &
Addition of a rigid anchor on the 2 1/2-inch Modification not required.1 Inspection performed Fittings (Large Bore Scope diameter header at the location of the routinely.
Only) (02-437A-LB) intersection with the two 1 1/2-inch diameter branches.
Thermostatic Valves (02-515)
Replacement of the power elements at 3 to 5 year Replaced jacket water thermostatic valve.
intervals.
Additional inspections recommended.
Verified exhaust ports are centerline horizontal on both valves.
Replaced thermopower elements on lube oil valve.
Visually inspected for leaks.
Jacket Water Standpipe None.
None required.
Pipe, Fittings, Gaskets (02-700A)
Jacket Water Standpipe Additional inspections recommended.
Visually inspected.
and Miscellaneous Bolting Material (02--700F)
Auxiliary Sub Base, Oil and Monthly inspections for leakage at packing.
Visually inspected.
Water Jacket Water Valves (O2-717B)
I Refer to SCE to NC letter dated Septomber-3, 1985, Enclosure I.
DG2
-12 qmponent Owners Group Recommended Action Summary of Work Performed Auxiliary Sub Base & Oil Monthly visual inspections for leaks.
Visual inspection routinely performed.
& Water Piping -
Jacket Water:
Pipe, Couplings, Fittings, Orifices Y-Strainers (Small Bore Scope Only)
(02-717C)
Auxiliary Sub Base and Oil None None required.
and Water Piping -
Jacket Water:
Gaskets and Bolting (02-717D)
Auxiliary Sub Base and Oil Addition/modification of supports, U-bolts and None required. 1 and Water Piping -- Jacket Water:
locking devices. Refer to DR/QR report 02-717E Supports (Small Bore Scope for details.
Only) (02-717E)
Miscellaneous Equipment -
Additional maintenance recommendations Jacket water heater was replaced. New heater was Heater, Jacket Water meggered and controller calibrated.
Standpipe (02-810A)
Jacket Water Heat None None required.
Exchanger (02-810B)
Jacket Water Standby None Jacket water keep-warm pump was inspected.
Heater Pump (02-810C)
CYLINDER HEADS AND VALVES Cylinder Heads (02-360A)
Additional maintenance recommendations.
See Phase I Additional Quality inspections recommended.
Cylinder Head Valves:
Additional inspections and Quality evalidation Inspected intake and exhaust vales and vale to guide Intake and Exhaust Valves inspections recommended.
clearance.
NDE performed on valves with all found satis (02-3608) factory.
Visually inspected subcover for valve guide blowby.
Valve inspections:
Visual inspection to verify adequate valve seating (all)
Visual inspection of valve for scuffing, pitting and erosion (all)
Liquid penetrant test on blended radius of stem head for cracking (all)
Valve and valve ring material determination (metal comparator) (16 valves) 4 exhaust valves showed pitting and scuffing on tip.
8 exhaust valves did not show continuous metal seating surface.
1 intake valve had a tip cracked and was replacede 12 valves only required minor reconditioning and were reused.
Cylinder Head and Valves:
Replacement of affected seals with those called All seals meet SIM 315.
Visually inspected for signs Bolting and Gaskets out in SIM 315.
Additional Quality inspections of distress.
(02--360C) recommended.
I Refer to SCE to NRC letter dated September 3.
- 198,
.nclosure 1.11
DGZ
-13 ComPo9nt Owners Group Recommended Action Summar of WorkPerformed Cylinder Head and Valves:
Visually inspect and document the color code Inspected for broken or cracked valve springs and Spring (02-360D) of the valve springs.
verified color code.
FUEL OIL INJECTION Fuel Oil Drip Tank Nono Repacked fuel oil drip tank pump discharge valve.
Assembly (00-621A)
Fuel Oil Day lank (OO-621C)
None None required.
Fuel Injection Pump Additional maintenance recommendations.
Calibration/operational testing performed on all pumps by (02-365A) offsite contractor. Visually checked pressure bleed screws for erosion. 3R fuel oil injection pump failed calibration test and was replaced with a qualified spare.*
Fuel Injection Nuzzle Additional maintenance recommendations.
Inspected and cleaned tips.
Checked nozzle pop Assembly (02-365B) pressure. Checked spray pattern. Checked assembly for leakage. Replaced nozzle spray tip on 7L. Disassembled, cleaned and retested on 9L and 6R.
Fuel Injection Equipment Additional maintenance recommendations.
See Phase I Tube Assembly (02-365C)
Additional Quality inspections recommended.
Fuel Injection Equipment Perform a visual inspection of the support Visual inspection was performed and all support Supports (Small Bore Scope elastomer to check for signs of deterioration elastomers replaced due to deterioration and degradation.
Only) (02-365D) or degradation.
Fuel Pump Control Shaft, Additional maintenance recommendations.
Inspected fuel pump linkage and bearings for freedom of Linkage Assembly and Additional quality inspections recommended.
movement.
Greased swivel link on fuel pump assemblies.
Bearings (02-371A&B)
Routinely inspect and lubricate oil cups.
Engine Driven Fuel Oil Additional quality inspections recommended.
Visually inspected pump gears for pitting and galling Booster Pump (02-445) and found the gears satisfactory.
Fuel Oil Header -
Piping Replacement of fabricated cross on the fuel oil Inspected fuel oil valves, piping and components.
and Tubing (Small Bore supply crossovor header en the governor end of Modification not required. 1 Engine fuel oil pump Scope Only) (02-450B)
Engine 1 with appropriate wrought fittings discharge valve inlet fitting had a seepage leak and (socket welding or butt welding tee and reducers),
was repaired.
Fuel Oil Headers -
Fuel Modify supports and U-bolts.
Install suitable None required. 1 Oil Tubing Supports locking devices on nuts.
Refer to DR/QR report (Small Bore Scope Only) 02-450D for details.
(02-4 50D)
Fucl Oil Filters and Additional maintenance recommendations.
Replaced filters.
Verified bowl bolt torquing.
Vented Strainers:
Filters on refill.
(02-455A)
Fue] Oil Filters and Additional maintenance recommendations.
Cleaned and inspected.
Verified bowl bolt torquing.
Strainers:
Strainers Vented and refil d.
(02-4550)
I Refer to Vonte to NdC letter dated Septtmbor 3,
19i5, Elcllsure 1d1.
DG2 Component Owners Group Recommended Action Summary of Work Performed Fuel Oil Filters and None None required.
Strainers:
Mounting Hardware (02-455C)
Auxiliary Sub Base and Oil Addition/modification of supports, U-bolts and None required.1 and Water Piping Fuel Oil:
locking devices.
Refer to DR/QR report 02-717J Piping and Fittings (Small for details.
Bore Scope Only) (02-717J)
Auxiliary Sub Base and Oil Additional maintenance requirements.
Inspected installation position of fuel and Water Piping:
Fuel Additional Quality inspections recommended oil relief valves.
Oil Valves (02-717K)
Auxiliary Sub Base and Oil The auxiliary piping should be walked down Inspection routinely performed.
and Water Piping -
Fuel daily to verify the leak tightness of the fuel Oil:
Gaskets and Bolting oil piping flanges.
(02-717L)
GENERATOR Generator: Generator Additional maintenance recommended.
Checked operation of brushes and slip rings.
Cleaned (50-101) and inspected all accessible parts of the generator. Meggered rotor and stator. Verified operation of space heaters.
Measured vibration and checked against base line data.
Generator:
Generator None None required.
Controls (SO-102)
Generator -
Shaft and Additional maintenance recommended.
Checked ring oilers for proper operation and verified Bearing (SO-103) oil level.
Drained, flushed and refilled bearing housing.
Measured bearing housing insulation resistance.
Disassembled and inspected bearing and checked clearances.
CONIROL PANEL ASSEMBLY Control Panel Assembly -
Additional maintenance recommendations.
Inspected and replaced control panel air filter bowl in Cabinet/Sy stem (02--500A) accordance with 10 CFR 21 notification dated January 22, 1985.
Inspected interior of cabinet for cleanliness and cleaned as required. Visually checked wiring for insulation degradation. Visually checked instrument tubing for leaks.
Functionally checked cabinet heater and calibration of thermostat. Tested pneumatic S/D board logic.
Pressure regulator will be replaced when parts are available from TDI.
Control Panel Assembly -
Additional maintenance recommendations.
Checked all terminals and cleaned and tightened as Circuit Breakers and required.
Visually checked wiring insulation for Contact Blocks (02-500C) degradation. Trip checked circuit breakers.
Control Panel Assembly -
None None required.
Accumulator (02-500F)
I Refer to S(
to NHC letter date.od eptmber 3, 195, Friclosure III.
DG2
-l 5 Component Owners Group Recommended Action Summary of Work Performed Control Panel Assembly -
Additional maintenance requirements.
System cleanliness maintained by filters and driers.
Valves (02-500G)
Inspection not warranted.
Control Panel Assembly -
None None required.
Pressure Switches (02-500H)
Control Panel Assembly -
Additional maintenance recommendations.
Serviced and tested relays in panels and checked Control Relays (02-500J) associated alarms.
Inspected, cleaned and adjusted as needed.
Control Panel Assembly -
None None required.
Solenoid Valves (02-500K)
Control Panel Components -
None None required.
Piping, Tubing, Fittings (02-500M)
Control Panel Assembly -
Additional maintenance recommendations.
Cleaned terminal boards and switch contacts. Visually erminal Boards/Swi tches, chocked wire insulation and terminals for tightness and Wiring (02-5OON) degradation. Inspected for arcing and overheating.
ENGINE AND AUXILIARY SUB BASE AND FOUNDATION BOLIS Foundation Bolts (02-550)
To ensure continued reliability, the foundation Torqued generator foundation bolts to 600 ft/lbs.
bolts for both ongines should be torqued to Visually inspected foundation for breaks in the bond 600 ft/lbs at the next refueling outage.
between the sole plates and grout.
Additional maintenance recommended.
Auxiliary Sub Base and Oil None None required.
and Water Piping:
Auxiliary Sub Base (02-717A)
IAA:6890F I
Refer to SCE to NRC late.tr dated September 3, 1985, FrIclosure 11.