ML17320A901

Responds to Generic Ltr 83-41, Fast Cold Starts of Diesel Generators. Maint of Preheat & Prelubrication Eliminates Engine Stresses Caused by Cold Starts.Fast Start Engine Stress Mitigated Only by Reducing Frequency of Starts

ML17320A901
Person / Time
Site:	Cook
Issue date:	01/06/1984
From:	Alexich P INDIANA MICHIGAN POWER CO. (FORMERLY INDIANA & MICHIG
To:	Harold Denton Office of Nuclear Reactor Regulation
References
AEP:NRC:0862, AEP:NRC:862, GL-83-41, NUDOCS 8401130292
Download: ML17320A901 (12)

Text

REGULATO V

INFORMATION DISTRIBUTION SYSTEM (RIDS)

ACCESSION NBR;8001130292 DOC ~ DATE: 84/01/06 NOTA IZED:

NO DOCKET 0'ACIL!50-315 Donald C,

Cook Nuclear Power Plant~ Unit 1i Indiana 8

05000315 50-316 Donald C ~

Cook Nuclear Power Plant< Unit 2~ Indiana 8

0500'0316 AUTH,NAME AUTHOR AFFILIATION ALEXICHgP ~

Indiana L Mschsgan Electric Co ~

REC IP ~ NAME RECIPIENT AFFILIATION DENTONgH ~ RE Office of Nuclear Reactor Regulationi Director

SUBJECT:

Responds to Generic Ltr 83 Q1, "Fast Cold Starts of Diesel Generators,"

Maint of preheat K prelubrication eliminates engine stresses caused by cold starts'ast start engine stress mitigated only by reducing frequency of starts, DISTRIBUTION CODE:

A056S COPIES RECEIVEDeLTR ENCL SIZE:

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INDIANA 8 MICHIGAN ELECTRIC CON PANY P.O. BOX 16631 COLUMBUS, OHIO 43216 January 6,

1984 AEP:NRC:0862 Donald C. Cook Nuclear Plant Unit Nos.

1 and 2

Docket Nos.

50-315 and 50-316 License Nos.

DPR-58 and DPR-74 FAST COLD STARTS OF DIESEL GENERATORS (Generic Letter 83-41)

Mr. Harold R. Denton, Director Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, D. C.

20555

Dear Mr. Denton:

This letter is in response to your request for information in Generic Letter 83-41, "Fast Cold Starts of Diesel Generators".

In response to item (1) of that letter please note that we do not start our diesels in the "cold" condition.

Nevertheless, we have had several fast starts over the specified period, principally due to surveillance/technical requirements.

These starts are listed on Table 1, by category as you requested.

In response to Item (2), our assessment of fast and cold starts is presented below.

The diesel engines at D. C. Cook Plant are always started fast from the Control Room, except for maintenance operations following certain inspections or overhaul.

(These "slow" starts are not included in Table 1.)

However, the diesel engines are never started entirely cold or unlubricated because of the following preventive maintenance policies.

1) The cooling jacket water is heated to about 160F and circulated through the engine to maintain the engine at its approximate operating temperature.

2)

The crankshaft and lower engine is continuously pressure lubricated by oil maintained at. about 140F.

and 3)

The upper valve gear assembly is intermittently lubricated to assure an ample supply of lube oil for fast starting of the engine.

The diesel engine manufacturer recommends operation of the auxiliary lube oil pump for several minutes before starting the diesel engine and a slow and controlled acceleration with limited fuel injection to rated speed if maximum service life is to be expected from the engine.

Operation of unloaded diesel engines for extended periods of time is not recommended by the manufacturers.

This is an additional reason for not starting the engines unless necessary.

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Mr. Harold R. Dent The diesel fuel injector is timed to inject before top dead center to allow time for ignition to occur when the 'piston is at top dead center while operating at rated speed.

The expanding products of combustion force the piston down at a time when the crankshaft has turned far enough to be rotated by the downward force.

During starting, the crankshaft rotation is much slower than rated and the fuel injection timing is early enough to permit combustion to occur while the piston is still approaching top dead center (up stroke).

This, coupled with the injection of a full fuel charge to achieve maximum acceleration for fast starting, results in the piston being forced down by the combustion of the full fuel charge at the same time the piston is being forced up by the engine cranking power.

This produces more stress on the connecting rod bearing and main bearing at.'the crankshaft than any other operating condition.

Therefore, even though we run the auxiliary lube oil pump continuously, numerous fast starts will result in less service life than can be achieved in following the manufacturers slow and controlled acceleration recommendations.

During the initial reliability tests of the Unit 1 diesel generators we found that intermittent lubrication was inadequate to

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prevent engine crankshaft, bedplate and connecting rod bearing damage.

One engine was badly damaged.

The engine was rebuilt and the lubrication system revised to provide continuous lubrication for the crankshaft and connecting rod bearings.

We believe that by maintaining pre-heat and pre-lubrication we have eliminated the engine stresses caused by cold starts as much as possible.

The stresses caused by "fast starts" can only be mitigated by reducing the frequency of starts.

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J The monthly surveillance tests provide the necessary exercise to assure, operability.

In addition, the refueling surveillance tests demonstrate the ability of the engines to perform their intended function.

The remaining, surveillance tests such as those required to demonstrate operability of the redundant engine when one engine is removed from service or one offsite power source is de-energized are examples of requirements that could be deleted without deliteriously affecting the Diesel Generator Safety function.

This letter has been prepared following Corporate procedures which incorporate a reasonable set of controls to insure its accuracy and completeness prior to signature by the undersigned.

Very truly yours 1

z'.

exich )(k ice President MPA/cam cc:

John E. Dolan W. G. Smith, Jr. - Bridgman R. C. Callen G~ Charnoff E.

R.

Swanson, NRC Resident Inspector Bridgman

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TABLE 1 NUMBER OF FAST DIESEL ENGINE STARTS December 1,.1982 thru December 1,

1983 Number of Fast Starts (1)

REASON FOR START/TEST UNIT 1 Generators AB CD UNIT 2 TOTAL Generators AB CD SURVEILLANCE Monthly Surveillance 18 Month Surveillance Other Tech Spec Requirements MAINTENANCE Maintenance Runs Post Maint. Runs To Prove Operability ACTUAL DEMAND TOTAL STARTS ll 4

11 10 5

0 41 12 4

8 3

4 3

34 12 7

19 12 47 7

22 21 59 5

7 25 1

2 12 2

4 9

46 53 174 (1)

The diesel 'engines at D. C.

Cook Plant are never started cold.

(2)

The D. C. Cook Plant did not experience Offsite Power Loss.

Actual Demand was caused by Safety Injection Initiation or bus switching.

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January 5,

1984 DOCKET NO(S).

50 315/316 Nr. John Dolan, Vice President Indiana and Michigan Electric Company Bgo04mBrican Electric Power Service Corporation 1 Riverside Plaza

Columbhe, Ohio 43215

SUBJECT:

DONALD C.. COOK NUCLEAR PLANT UNITS 1 AND 2 DISTRIBUTION

~Doakes-Fi-l~

ORB81Rdg CParrish Facility Operating License No.

, Amendment No.

Order Extending Construction Completion Date, dated l3 Other(Spec/fy)

~onthl Notice coverin eriod throu h

D.

b

, dated Ex iration date for hearin re uests and omm t Ja The following documents concerning our review of the subject facilityare transmitted for your information.

'otice of Receipt of Application.

Draft/Final Environmental Statement, dated Notice of Availabilityof Draft/Final Environmental Statement, dated Safety Evaluation Report, or Supplement No.

, dated Notice of Hearing on Application for Construction Permit.

Notice of Consideration of Issuance of Facility Operating License.

Application and Safety Analysis Report, Volume Amendment No.

to Application/SAR dated Construction Permit No. CPPR-

, Amendmerit No.

, dated

Enclosures:

As stated Division of Licensing Office of Nuclear Reactor Regulation

'/enclosure OFFICE/

SURNAME/

DATEP ORB81;DL CParrish; 1/6 /84 ps I 0 ~

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NRC FOAM 3I8 (IO/80) NRCM 0240 OFFICIAL RECORD COPY

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lg~o UNITEO STATES NUCLEAR REGULATORY COMNlfSSION WASHINGTON, D. C. 20555 January 5,

1984 DOCKET NO(S).

5O315/316 Mr. John Dolan, Vice President Indiana and Michigan Electric Company c/o american Electric Power Service Corporation 1 Riverside Plaza

Columbus, Ohio 43215

SUBJECT:

DONALD C.

COOK NUCLEAR PLANT UNITS 1 AND 2 The following documents concerning our review of the subject facilityare transmitted for your information.

Notice of Receipt of Application.

Draft/Final Environmental Statement, dated Notice of Availabilityof DraftiFinal Environmental Statement, dated Safety Evaluation Report, or Supplement No.

, dated Notice of Hearing on Application for Construction Permit.

Notice of Consideration of Issuance of Facility Operating License.

Application and Safety Analysis Report, Volume Amendment No.

to Application/SAR dated Construction Permit No. CPPR.

, Amendment No.

, dated Facility Operating License No.

, Amendment No.

, dated Order Extending Construction Completion Date, dated

!3 Other(Specify)

Monthl Notice coverin eriod throu h December 21 Ex iration date for hear in re uests and comments Januar 2

Division of Licensing Office of Nuclear Reactor Regulation

Enclosures:

As stated cc: w/enclosure

Indiana and Michigan Electric Company Donald C.

Cook Nuclear Plant, Units 1 and 2

cc:

Mr.

M.

P. Alexich Yice President Nuclear Engineering American Electric Power Service Corporation 1 Riverside Plaza

Columbus, Ohio 43215 Mr. William R.

Rustem (2)

Office of the Governor Room 1 - Capitol Building

Lansing, Michigan 48913 Mr. 'Wade Schuler, Supervisor Lake Township

Baroda, Michigan 49101 W.

G. Smith, Jr., Plant Manager Donald C.

Cook Nuclear Plant Post Office Box 458 Bridgman, Michigan 49106 U.S. Nuclear Regulatory Commission Resident Inspectors Office 7700 Red Arrow Highway Stevensvi lie, Michigan 49127 Gerald Charnoff, Esquire Shaw, Pittman, Potts and Trowbridge 1800 M Street, N.W.

Washington, DC 20036 Honorable Jim Catania, Mayor City of Bridgman, Michigan

'49106 U.S. Environmental Protection Agency Region Y Office ATTN:

E IS COORDINATOR 230 South Dearborn Street

Chicago, IL 60604 Maurice S. Reizen, M.D.

Director Department of Public Health.

Post Office Box 30035

Lansing, Michigan 48109 The Honorable Tom Corcoran United States House of Representatives Washington, DC 20515 James G. Keppler Regional Administrator - Region III U.S. Nuclear Regulatory Commission 799 Roosevelt Road Glen El lyn, IL 60137