ML18019B008
| ML18019B008 | |
| Person / Time | |
|---|---|
| Site: | Harris  |
| Issue date: | 04/30/1986 |
| From: | Segrest A TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP |
| To: | |
| Shared Package | |
| ML18019B006 | List: |
| References | |
| NUDOCS 8606110622 | |
| Download: ML18019B008 (73) | |
Text
TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT Prepared For CAROLINA POWER & LIGHT COMPANY SHEARON HARRIS NUCLEAR POWER PLANT - UNIT 1 By TDI DIESEL GENERATOR OWNERS GROUP Revision 2
April 1986 A
Segrest Program Manager TDI Diesel Generator Owners Group
~ 'I
$606110622
$60605 PDR ADOCK 05000400 so~ Q.
TABLE OF CONTENTS EXECUTIVE
SUMMARY
- 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 UALITY 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.'R/QR
SUMMARY
REPORTS II.
MAINTENANCE 8( SURVEILLANCE RECOMMENDATIONS III.
INCLUDED REFERENCES SH2605
4l
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 powei 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'DI 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 guality Revalidation Program (DR/gR) 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/gR 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 Carolina Power 8
Light (CP8 L) provides the results of this extensive investigation of 164 components of the TDI DSRV-16 diesel gener-ators at Shearon Harris Nuclear Power Plant Unit l. It forms the basis for the conclusion that the TDI diesel generators presently installed are fully capable of reliably performing their intended safety function.
SH2605 REV I
- 1. 0 INTRODUCTION This report has been prepared for Carolina Power 8 Light by the TDI Diesel Generator Owners Group.
The results of the Design Review and guality Revalidation Program are specifically applicable to Shearon Harris 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 164 components of the TDI DSRV-16 diesel generators at Shearon Harris.
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 Shearon Harris Final Safety Analysis Report.
SH2605 REV 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 equality Revalidation Final Documentation Each element is briefly discussed in the following sections.
SH2605 2-1
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2.1 GENERIC PROBLEM RESOLUTION -
PHASE I Using input from various nuclear data sources (INPO,
- SOERs, LERs, 10CFR50.55e reports 8
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 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 Shearon Harris are included in Appendix I of this report;
'he results of the reviews of these components are summarized in Section 3.0.
SH2605 2-2
W4 Cl)
2.2 COMPONENT SELECTION
~
~
The diesel generat or components to 'be subjected to the DR/gR 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 includeg 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 guality Revalidation Group for preparation of task descriptions.
Table 2.2 lists those components of the Shearon Harris 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 (gR),
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/gR Summary Report is found.
SH2605 2"3
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Ii)
2.3 TASK DESCRIPTION PREPARATION The Design Review Group and the guality 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 guality 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.
gR 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 guality Revalidation Group prepared task descriptions which required no additional Design Review or
.guality 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 guality 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/gR Summary Report in Appendix I.
Figure
- 2. 1 graphically depicts the process followed in the DR/gR Program.
SH2605
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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.
2.5 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.
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, NOE, 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.
SH2605 2-'5
h CS
- 2. 6 FINAL DOCUMENTATION The OR/gR program has been completed for Carolina Power 5 Light.
A summary of the results of this effort are contained in Section 3.0.
Appendix I
contains component DR/gR 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
'rom existing vendor recommendations and the individual component OR/gR 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 completi'on of the OR/gR Program on the Shearon Harris TDI diesel generators.
SH260f) 2"6
TABLE 2-1 PHASE I COMPONENTS (GENERIC PHASE I)
COMPONENT NUMBER MP-017 03-305A,C,D,E 03-310A 03-315A&C 03-315E 03-340A 03-340B COMPONENT Turbocharger Base 8 Bearing Caps Crankshaft Cylinder Block 8 Liners Cylinder Head Studs Connecting Rods Connecting Rod Bearing Shells 03-341A 03-359 03-360A 03-365C 03-390C8 D Pistons Airstart Valve Capscrews Cylinder Heads Fuel Oil Injection Tubing Main and Connecting Pushrods 03-390G 03-425A 03-688B Rocker Arm Capscrews Jacket Water Pump Wiring 8 Termination SH2605 2-7 REV I
TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Number F"068 Component Descri tion Intercool,er DR QR No Re 'd Re 'd Review Cate or Turbo, Intake Intrclr.
8 Exhaust F-139 Tools Turbo F-161 Pyrometer Wire MP022/23 Turbocharger Turbo, Intake, Intrclr.
8 Exhaust 00-420 Lube Oil Pressure Regulating Valve Lube Oil 00-491A Turbocharger
- Air Inlet Adapter:
Adapter 00-491B Turbocharger
- Air Inlet Adapter:
Mounting Hardware W/Flexible Connector 00-495A Turbocharger - Air Outlet Adapter 00-495B Turbocharger Air Outlet Adapter:
Mounting Hardware 00-520 02-CFR 02-305A 02-305B 02-305C 02-305D 02-305F Instruction Plate - Warning Plate Turbocharger Thrust Bearing X
Lubricant System Base and Bearing Caps:
Base X
Assembly Base and Bearing Caps:
Dowels Base and Bearing Caps:
Main Bearing Studs
& Nuts Base and Bearing Caps:
Main Bearing Caps Base and Bearing Caps:
- Seals, Gaskets 8 Covers Turbo, Intake, Intrclr.
8 Ex-haust Engine Base 8 Bearing Caps Engine Base 8 Bearing Caps Engine Base 8 Bearing Caps SH2605 2-8 REV 1
TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Number 02"307A 02-307B 02-307C Component Descri tion Lube Oil Fittings:
Internal - Headers Lube Oil Fittings:
Internal Tube & Fittings Lube Oil Fittings Internal:
Seals DR QR No Re 'd Re 'd Review X
X Cate or Lube Oil Lube Oil 02-307D 02-310A Lube Oil Fittings Internal:
X Supports Crankshaft Lube Oil Crankshaft 8
Bearings 02-310B Main Bearings Crankshaft Bearing 02-310C 02-311A 02-311B 02"311C 02-311D 02-315A 02-315B 02"315C 02-315 D Cr ankshaft
& Bearings:
Thrust Bearing Rings.
Crankcase:
Crankcase Assy Cylinder Block Liners 8 Water Manifold:
Cam Bearing Caps Dowels Crankcase:
Crankcase Seal Crankcase:
Crankcase Mounting Hardware Cylinder Block Cylinder Block: Block To Crankcase Dowel Cylinder Block Liners Water Manifold-Cylinder Liner Cylinder Block Liners &
Jacket Water Manifold
& Piping Crankshaft Bearing Crankshaft 8
Bearing Crankshaft 8
Bearings Cyl. Block &
Liners & Water Manifold Cyl. Block 8 Liners Water Manifold Cyl. Block &
Liners &
Water Manifold SH2605 2"9
TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Number 02-315 E 02-315F 02"315G Component Descri tion Cylinder Block Liners &
Water Manifold: Studs Cylinder Block Liners 8 Water Manifold:
Cylinder Head Nuts Cylinder Block Liners 8
Water Manifold: Seals Gaskets DR gR No Re 'd Re 'd Review Cate or Cyl. Block &
Liners Water Manifold Cyl. Block &:
Liner & Water Manifold'yl.
Block &
Liners Water Manifo'ld 02-316A 02" 316B 02-316C 02-317A 02-317B 02-317C 02-330A 02-3308 02-331A 02-335A 02-3358 02-340A Jacket Water Inlet Manifold:
X Manifold Assembly W/Hardware and Coupling and Gaskets Jacket Water Inlet Manifold:
X Coupling and Gaskets Jacket Water Inlet Manifold:
X
. Vent line to Discharge Manifold Water Discharge Manifold:
X Jacket Water Discharge Manifold, Coupling and Seals Water Dicharge Manifold:
Coupling & Seals Water Discharge Manifold:
Supports Flywheel Flywheel - Bolting Guards:
Flywheel Guard Assembly Front Gear Case:
Gear Case Front Gearcase Bolting Connecting Rods:
Connecting X
Rods 8 Bushings X
Jacket Water Jacket Water Jacket Water Jacket Water Jacket Water Jacket Water Flywheel Flywheel Idler Gear As-sembly
& Front Gear Case Connecting Rods SH2605 2"10
TABLE 2"2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Component Number Descri tion 02-340B Connecting Rod Bearing Shells DR QR No Re 'd Re 'd Review Cate or Connecting Rods 02-341A Pistons 02-341B Pistons:
Rings 02-341C Piston Pin Assembly 02-345A Tappets and Guides:
Intake X
& Exhaust Tappet Assembly 02-3458 Tappets and Guides:
Fuel Tappet Assembly 02-345C Tappets and Guides:
Fuel Pump Base Assembly Pistons Pistons Pistons Camshaft Valve Train Camshaft Valve Train Camshaft Valve Train 02-350A Camshaft:
Camshaft Assembly Camshaft:
Camshaft Bearing Camshaft Valve Train Camshaft Valve Train 02-355B Idler Gear Assembly:
Idler Gear Assembly 02-355C Idler Gear Assembly:
& Bolting Air Start Valve 02-359 02-360A Cylinder Heads 02-360B Cylinder Head Valves:
Intake & Exhaust Valves 02-350C Camshaft:
- Supports, Bolting X
and Gear 02-355A Idler Gear Assemble:
Crank X
To Pump Gear Camshaft Valve Train Idler Gear As-sembly
& Front Gear Case Idler Gear As-sembly
& Front Gear Case Air Start Barring Device Cylinder Heads
& Valves Cylinder Heads
& Valves SH2605 2-11
TABLE 2"2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Component Number Descri tion DR gR No Re 'd Re 'd Review Cate or 02"360C 02"360D 02-361 02-362A Cylinder Head and Valves:
Bolting and Gaskets Cylinder Head
& Valves:
Springs Indicating Cocks Subcover X
X Cylinder Heads 8 Valves Cylinder Heads
& Valves Camshaft Valve Train 02-362B Cylinder Head Covers:
Gaskets and Bolting 02-365A Fuel Injection Pump 02-365B Fuel Injection Equipment -
X Fuel Injection Tips 02-365C Fuel Injection Equipment
X Tube Assembly 02-365D Fuel Injection Equipment:
X Supports Fuel Oil In-jection Fuel Oil In-jection Fuel Oil In-jection Fuel Oil In-jection 02-371A 02-371B 02-373A 02"373B 02-375 02"380A Fuel Pump Linkage:
Fuel Pump Control'haft Fuel Pump Linkage:
Linkage X
Assembly and Bearing Gear Case Opening - Cover Gear Case Opening Cover-Gaskets
& Bolting Intake Manifold and Piping Exhaust Manifold Fuel Oil In-jection Fuel Oil In-jection Turbo, Intake, Intrclr. & Ex-haust Turbo, Intake, Intrclr. & Ex-haust SH2605 2-12
TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Number Component DR QR No Descri tion Re 'd Re 'd Review Cate or 02"380B Exhaust Manifold:
Gasket X
X Turbo, Intake, and Bolting Intrclr. & Ex-haust 02-385A 02-385B Cylinder Block Covers:
Covers Cylinder Block Covers:
Gaskets and Bolting Cyl. Block 8 Liners 8 Water Manifold 02-386A Crankcase Covers:
Crankcase Cover Assy and Relief Valves 02-386B Crankcase:
Crankcase Gaskets and Mounting Hardware Crankshaft 8
Bearings 02-387A Crankcase Ventilator:
Crankcase Vacuum Fan 02-3878 02-390A Crankcase Ventilator - Oil Separator Intake 8 Intermediate and X
Exhaust Rocker Shaft Assembly Camshaft 8
Valve Train 02-3908 02-390C Rocker Arms and Pushrods:
X Exhaust Rocker Shaft Assembly Main and Connector Pushrods Camshaft 8
Valve Train Camshaft 8
Valve Train 02-390D Rocker Arms and. Pushrods:
Pushrods Connector.
Camshaft 8
Valve Train 02-390E 02-390F Rocker Arms and Pushrods:
Bushings Rocker Arms and Pushrods:
Misc. Bolts 8 Drive Studs Camshaft 8
Valve Train Camshaft 8
Valve Train 02-395A 02-395B Gear Case Covers:
Cover Gear Case Covers:
Gaskets and Bolting SH2605 2-13 REV I
TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Component Number Descri tion DR QR No Re 'd Re 'd Review Cate or 02-410A Overspeed Trip Governor Overspeed Trip 8 Governor 02-410B Overspeed Trip: Governor and Accessory Drive Assembly Overspeed Trip 8 Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 8 Governor 02-410D Overspeed Trip Vent Valve X
Overspeed Trip 8 Governor 02-411A Governor Drive:
Governor 8
X Tachometer Drive Gear and Shaft Overspeed Trip 8
Governor 02-411B Governor Drive: Couplings, X
Pins 8
Keys Overspeed Trip 8 Governor 02-413A Governor Linkage Overspeed Trip 8 Governor 02-413B Fuel Pump Linkage:
Automatic Shutdown Cyl inder Fuel Oil Injection 02-415A Governor Assembly:
Moodward X
Governor Overspeed Trip 8 Governor 02-415B Governor Assembly-Booster Servomotor Overspeed Trip L Governor 02-415C 02-420 Governor Assembly Heat Exchangers Engine Driven Lube Oil Pump Overspeed Trip
& Governor Lube Oil 02-425A Engine,Dr iven Jacket Mater Pump Jacket Water 02-435A Jacket Water Fittings:
Pipe 8 Fittings Jacket Water 02-435B Jacket Water Fittings-Supports Jacket Water SH2605 2-14
C'omponent Number TABLE 2"2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component'R QR No Descri tion Re 'd Re 'd Review Cate or 02-435C 02"436A 02"436B 02-437 02-441A 02-441B 02-441C'2-442A 02-442B 02-445 02-450A 02-450B 02-455A 02-455B 02-455C Jacket Water Inlet Fittings - Valves Intercool er Piping Intercool er Piping Coupling, Gaskets, Bolting Turbo Water Piping:
Pipe
& Fittings Starting Air Manifold:
Piping, Tubing and Fitting Starting Air Manifold Valves, Filters & Strainer Starting Air Manifold:
Supports Starting Air Distributor:
Distributor Assembly Starting Air Distributor:
- Tubing, Fittings, Gaskets Fuel Oil Booster Pump Fuel Oil Header:
Piping/Tubing Fuel Oil Header:
Fuel Oil Supports Fuel Oil Filters Strainers:
Filters Fuel Oil Filters Strainers:
Strainers Fuel Oil Filters Strainer:
Mounting Hardware X
X X
X Jacket Water Turbo, Intake Intercooler
& Exhaust Turbo, Intake Intercooler Exhaust Jacket Water Air Start 8
Barring Device Air Start Barring Device Air Start Barring Device Air Star t 8 Barring Device Air Start Barring Device Fuel Oil In-jection Fuel Oil In-jection Fuel Oil In-jection Fuel Oil In-jection Fuel Oi 1 In-jection Fuel Oil In-jection SH2605 2-15
'I
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TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Number 02-465A 02-465B 02-465C 02"465D 02-467A Component Descri tion Lube Oil Lines External:
Tubing, Fittings, Couplings Lube Oil Lines - External Suppor ts Lube Oil Lines External-Valves Lube Oil Keepwarm Strainer Turbocharger:
Lube Oil Fitting - Pipe, Tubing, Fittings 8 Flexible Coupling DR QR Re 'd Re 'd X
~
X No Review Cate or Lube Oil Lube Oil Lube Oil Lube Oil Lube Oil 02-467B 02-475A 02"475B 02-475C 02"500A 02"500B Turbocharger:
Lube Oil Fittings - Supports Turbocharge:
Bracket Air Butterfly Valve Assembly Turbocharger:
Bracket-Bolting 8 Gaskets Control Panel Assembly Cabinet/System Control Panel Assembly:
Annunciators Lube Oil Turbo, Intake, Intrclr.
8 Ex-haust Turbo, Intake, Intrclr. L Ex-haust Turbo, Intake, Intrclr.
8 Ex-haust Control Panel Assembly 02-500C Control Panel Assembly:
Circuit Breaker/Contact Blocks 02-500D 02"500E Control Panel Assembly:
Pressure Gauges Control Panel Assembly:
Hourmeter SH2605 2-16
t %
TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Number 02"500F 02-500G 02-500H 02-500I 02"500J 02-500K 02-500L 02-500M 02-500N 02-503 02-520 02-525A Component Descri tion Control Panel Assembly Accumulator Control Panel Valves Control Panel Assembly Pressure Switch Control Panel Assembly:
Pyrometers Control Panel Assembly:
Control Relays, Control Panel Assembly:
Solenoid Valves Control Panel Assembly:
Tachometer Control Panel Assembly-Piping, Tubing, Fittings Control Panel Assembly:
Terminal Boards/Switchs/
Wiring Thermometer Instruction Plate:
Nameplate Barring Device - Pneumatic:
Barring Device Assembly DR gR No Re 'd Re 'd Review Cate or Control Panel Assembly Control Panel Assembly Control Panel Assembly Control Panel Assembly Control Panel Assembly Control Panel Assembly Control Panel Assembly 02-525C 02-525D Barring Device - Pneumatic:
Misc. Fitting, Hose, Filters Tubing Barring Device - Pneumatic:
Mounting Bracket/Supports X
Air Start 8
Barring Device SH2605 2"17 REV I
Component Number 02-530A TABLE 2"2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component DR QR No Oescri tion Re 'd Re 'd Review Cate or Platform - Front & Side:
Side Platform Assembly 02"530B 02-531A 02-531B 02-540A 02-540B 02-540C 02-550 02"590 02-630A 02-630B 02-630C Platform - Front 8 Side:
Front Platform Assembly Platform, Ladders, Stairs - Stair Assembly
- Platform, Ladders, Stairs - Supports
. Lube Oil Sump with Strainer Assembly and Mounting Hardward Lube Oil Sump Tank: Misc.
Fittings, Gaskets, Pipe 8 Bolting Material, Valves Lube Oil Sump Tank:
Mounting Hardware Foundation Bolts:
Anchors, Bolts, Misc.
Hardware Special Tools: Asst.
Engine Assembly Tools Pyrometer Conduit Assembly:
X Conduit Pyrometer Conduit Assembly:
X Conduit Fittings Pyrometer Conduit Assembly:
X Support X
Lube Oil Lube Oil Lube Oil Engine 8 Aux.
Sub Base 8
Foundation Bolts Engine Instru-mentation 8
Wiring Engine Instru-mentation 8
Wiring Engine Instru-mentation 8
Wiring 02"630D Pyrometer Conduit Assembly X
Thermocouple Engine Instu-mentation 8
Wiring SH2605 2"18
Component Number 02-630E TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component DR gR No Descri tion Re 'd Re 'd Review Cate or Pyrometer Conduit Assembly:
Gaskets 02-650A 02.-650B 02"650C 02-688A 02-688B 02-688C 02-688D 02-689 02-695A 02-6958 02"695C Emergency Diesel Generator X
Generator Control Generator-Shaft
& Bearing X
Engine
& Aux Module X
Wiring Material-Conduit
& Fittings; Pyrometer Assembly - Conduit, Fitting, Supports Engine
& Aux.
Module Wiring Material:
Wiring & Terminations Engine
'& Aux. Module Wiring Material:
Boxes
& Terminals On-Engine Alarm Sensors Off-Engine Alarm Sensors Engine Shutdown Equipment:
Tubing/Fittings Supports Engine Shutdown Equipment:
- Valves, Regulator, Orifices Engine Shutdown Trip Switches Generator Generator Generator Engine Instru-mentation Wiring Engine Instru-mentation Wiring Engine Instu-mentation Wiring Engine Instru-mentation
.'iring Engine Instr u-mentation Wiring Engine Shut-down & Equip-ment Engine Shut-down & Equip-ment Engine Shut-down &
Equip-'ent 02-700A Jacket Water Standpipe:
Pipe, Fittings, Gaskets Jacket Water SH2605 2-19
Component Number TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component DR QR No Descri tion Re 'd Re 'd Review Cate or 02"700B 02-700C 02-700D 02-700E 02-700F 02-717A 02-717B 02-717D 02-717E 02-717F 02-717H 02-717I 02-717J Jacket Water Standpipe:
Valves Jacket Mater Standpipe:
Pipe Supports Jacket Water Standpipe:
Gauges Jacket Mater Standpipe:
Switches Jacket Mater Standpipe
& Misc. Bolting Auxiliary Skid Aux Sub Base 8 Oil 8 Mater Piping - Jacket Water:
Valves Aux Sub Base
& Oil 8 Mater Piping - Jacket Water:
Pipe Couplings, Fittings, Orifices, Y-Strainers Aux Sub Base 8 Oil & Water Piping - Jacket Water:
Gaskets 8 Bolting Aux.
Sub Base 8 Oil 8 Water Piping - Jacket Water:
Supports Aux. Sub-Base
& Oil & Water Piping - Lube Os 1:
Piping and Fittings Aux Sub Base
& Oil 8 Water Piping - Lube Oil:
Valves Aux Sub Base 8 Oil 8 Water Piping - Lube Oil:
Gaskets 8 Bolting X
X X
Jacket Water Jacket Water Jacket Mater Jacket Water Jacket Mater Jacket Water Jacket Mater Jacket Water Jacket Water Lube Oil Lube Oil Lube Oil SH2605 2-20 REV I
TABLE 2"2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Component DR gR No Number Descri tion Re 'd Re 'd Review Cate or 02-717K 02-717M 02" 717P 02-805A 02-805B Aux Sub Base
& Oil & Water X
X Piping - Lube Oil:
Supports
& Mounting Hardware Aux Sub Base
& Oil & Water X
Piping - Fuel Oil - Piping
& Fittings Aux Sub Base
& Oi 1
& Water X
Piping Fuel Oil-Gaskets
& Bolting Exhaust Silencer Intake Air Filter Lube Oil Fuel Oil Fuel Oil Turbo, Intake, Intercooler Exhaust 02-805C Intake Air Silencer 02-805D Flex Connections Turbo, Intake, Intercooler Exhaust Turbo, Intake, Intercooler Exhaust 02-810A 02-810C 02-810D 02-810 E 02-820A 02-820B 02-820C 02-820D Misc. Equipment Heater, Jacket Water Jacket Water Heat Exchanger X
Jacket Water Standby Heater Pump Thermostatic Valve Lube Oil Full Pressure Strainer Lube Oil Heat Exchanger Misc. Equipment Heater, Lube Oil Sump Tank Lube Oil System - Aux Lube Oil Pump Jacket Water Jacket Water Jacket Water Jacket Water Lube Oil Lube Oil Lube Oil Lube Oil SH2605 2-21
TABLE 2-2 SHEARON HARRIS COMPONENT SELECTION RESULTS Component Number Component Descri tion DR QR No Re 'd Re 'd Review Cate or 02-820E 02-820F 02-820G 02-825A 02-835A 02-835B 02-835C 02-835D Full Flow Lube Oil Filter X
Lube Oil Keep Warm Pump X
Lube Oil Keep Warm Filter X
Fuel Oil Day Tank Starting Air Compressor Misc Equipment:
After Cooler Air Dryer Starting Air Tank X
Lube Oil Lube Oil Lube Oil Fuel Oil Air Start 8 Barring Device SH2605 2-22 REV 1
FIGURE 2.1 Component Selection
.DR.Task Description QR Task Description Design Analysis and Technical Backup Quality Documentation and Inspection Data OR Results and Conclusions QR Results and Conclusions Component DR/QR Summary Report Engine DR/QR Report SH2605 2-23
3.0 Results of Desi n Review and ualit Revalidation The DR/gR Program implemented for the Shearon Harris Nuclear Power Plant-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.
Sections
- 3. 1 and 3.2 list the components of the Shearon Harris 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 that 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 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 1
with unlimited life.
SH2592 3-1 REV I
3.1 Summar Resolution of Sixteen Generic Com onents 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.
~corn onent Turbocharger (MP-022/3)
Base and Bearing Caps (03-305A, 03-305C, 03-305D)
Unlimited Life Unlimited Life Recommended Acti'on Additional test i ng and maintenance requirements.
Revision of operating procedures.
Additional maintenance and inspection requirements.
Crankshaft (03-310A)
Unlimited Life None Cylinder Block and Liner (03-315A, 03-315C)
Cylinder Head Studs (03-315E)
Unlimited Life Unlimited Life Additional maintenance and inspection requirements.
None Connecting Rods:
Connecting Rods and Bushings (03-340A)
Unlimited Life Additional inspecti on requirements.
Connecting Rod Bearing Shells (03-340B)
Pi stons (03-341A)
Unlimited Life Unlimited Life Additional maintenance requirements.
Additional inspections recommended.
An piston skirt should be replaced with AE piston skirt Air Start Valve (03-359)
Unlimited Life Additional maintenance requirements.
Verification of dimensions recommended.
Cylinder Heads (03-360A)
Fuel Injection Equipment:
Tube Assembly (03-365C)
SH2592 Unlimited Life Unlimited Life 3-2 Additional maintenance requirements.
Additional testing and maintenance requirements.
Procurement specification requirement.
Rev.
1
~Com anent Acce tabi lit Recommended Action Main and Connector Unlimited Life Pushrods (03-390C, 03-3900)
Additional procurement requi rement.
Additional inspections recommended.
Random destructive testing recommended.
Rocker Arm Capscrews (03-390F)
Jacket Water Pump (03-425A)
Wiring and Terminations (03-688B)
Unlimited Life Unlimited Life Un 1 imi ted Life Additional maintenance Requirements.
Additional maintenance and inspection requirements'one SH2592 3-3
3.2 Summar Resolution of Phase II Com onents
~Com onent Acce tabi lit Recommended Action
.TURBO INTAKE INTERCOOLER & EXHAUST Intercooler (F-068)
Turbocharger Thrust Bearing Lubricant System (02-CFR)
Intake Manifold
& Piping (Large Bore Scope Only)
(02-375)
Exhaust Manifold (02-380A)
Exhaust Manifold:
& Bolting (02-380B)
Intercooler Piping:
Pipe (Large Bore Scope Only)
(02-436A&B)
Turbocharger Bracket:
Bolting and Gaskets (02-475A&C)
Air Butterfly Valve Assembly (02-475B)
SH2592 Modification Modifications Modifications Modifications Modifications Unlimited Life Unlimited Life Unlimited Life Modifications 3-4 Addition of a low point drain in the intake air downstream of the intercool er.
Additional maintenance recommendations.
Additional guality inspections recommended.
Additional maintenance and modification recommendations.
Addition of supports in order to reduce the unsupported span lengths and to minimize vibration.
Check installation of U-bolts on the crossover piping.
Additional maintenance require-ments.
Additional quality inspections recommended.
Modifications concerning slip joints.
Refer to Component Oesign Review Checklist for details.
Additional maintenance requirement.
Additional qual ity inspections recommended.
None Implementation of proper torque on bracket bolting.
Additional equality Revalidation inspections recommended.
Additional inspections recommended.
Addition of grease fittings as per TDI SIM 322.
Additional maintenance recommendations.
Additional quality inspections recommended.
REV I
~Com onent Intake Air Filters (02"805B)
Intake Air Silencer (02-805C)
Flex Connections (02-805D)
Lube Oil Pressure Regulating Valve (00-420)
Lube Oil Fittings:
Internal Headers (Large Bore Scope Only)
Lube Oil Fittings:
Internal - Headers (Small Bore Scope Only)
Lube Oil Fittings:
Internal - Tubing and Fittings (Small Bore Scope Only)
(02-307B)
Lube Oil Fittings:
Internal - Supports (Small Bore Scope Only)
(02-307D)
Engine Driven Lube Oil Pump (02-420)
Lube Oil Liner-External Tubings, Fittings, Couplings (Large Bore Scope Only)
Acce tabilit Unlimited Life Unl imited Life Unlimited Life LUBE OIL Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Recommended Action Additional maintenance requirements.
None None Additional maintenance requirements.
None None None None None Additional maintenance require-ments.
SH2592 3-5 Rev.
1
~Com onent Lube Oil Lines-External - Tubing, Fittings, Coupling (Small Bore Scope Only)
(02-465A"SB)
Acce tabi lit Modifications Recommended Action Addition and/or modification of suppor ts.
Refer to DR/gR Report 02-465B for details.
Lube Oil Lines-External Supports (Large Bore Scope Only)
There are no supports for this component.
Lube Oil Lines External:
Supports (Small Bore Scope Only)
(02-465B"SB)
Lube Oil Lines-External - Valves (02-465C)
Lube Oil Keepwarm Strainer (02-465D)
Turbocharger-Lube Oil Fittings and Piping (Large Bove Scope Only)
Turbocharger - Lube Oil Fittings and Piping (Small Bore Scope Only)
Turbocharger - Lube Oil Fittings:
Piping (Large Bove Scope Only)
(02-4678-LB)
Modifications Unlimited Life Unlimited Life Modifications Modifications Modifications Replace two-direction lateral restraint located on the lube oil supply line between the front crossover header and stvainers for Engine 1B with three-direction restraints.
Addition of a two-direction lateral restraint to the riser of the 1<-inch diameter gear case lube oil line of Engine 1B.
None Additional maintenance recommendations.
Replace 24-inch Dresser couplings with 24-inch 150 lb.
S.O.
flanges with A307 bolts.
Modify supports.
Refer to DR/QR Report 02-467B for details.
The multiple support located between the lube oil sump tank and Dresser coupling requires reinforcement of its support members and increases in their welds.
SH2592 3-6 Rev.
1
~Com onent Turbochavger-Lube Oil Fittings:
Supports (Small Bore Scope Only)
(02-467B"SB)
Lube Oil Sump Tank, with Strainer Assembly and Mounting Hardware (02-540A&C)
Acce tabilit Modifications Unlimited Life Recommended Action Addition of a three-directional restraint to each turbocharger lube oil line to reduce the unsupported span length.
Additional equality Revali dation requirements.
Fittings, Gaskets, Pipe 8 Bolting (02-540B)
There is no small bore piping associated with this component.
Auxiliary Sub Base 8
Oil 8 Water Piping-Lube Oil:
Pipe and Fittings (Large Bore Scope Only)
Auxiliary Sub Base 8 Oil 8 Water Piping - Lube Oil:
Piping and Fittings (Small Bove Scope Only)
(02"717H-SB)
Auxiliary Sub Base
& Oil & Water Piping - Lube Oil:
Valves (02"717I)
Auxiliary Sub Base
& Oil & Water Piping - Lube Oil-Gaskets and Bolting (02-717J)
Auxiliary Sub Base 8 Oil 8 Water Piping-Lube Oil:
Supports and Mounting Hardware (Large Bore Scope Only)
(02-717K)
SH2592 Unlimited Life Modifications Unlimited Life Unlimited Life Unlimited Life 3-7 None Addition of supports in order to reduce the unsupported tubing span lengths of the lube oil system.
Additional maintenance recommend-ations.
None None Rev.
1
~Coo anent Auxiliary Sub Base 8
Oil 8 Water Piping-Lube Oil:
Supports and Mounting Hardware (Small Bore Scope Only)
(02-717K)
Lube Oil Full Pressure Strainer (02-820A)
Lube Oil Heat Exchanger (02-820A)
Misc. Equipment-
Lube Oil System-Aux.
Lube Oil Pump (02-8200)
Full Flow Lube Oil Filter (02-820E)
Lube Oil Keep Warm Pump (02-820F)
Lube Oil Keep Warm Filter (02-820G)
Lube Oil Keep Warm Filter (02-820G)
Acce tabilit Modifications Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Recommended Action Modification of tubing supports to provide two-direction lateral restraints.
Additional maintenance requirements'dditional maintenance requirements.
Additional maintenance requirements.
None Additional maintenance None None Additional maintenance requirements.
ENGINE BASE & BEARING CAPS Base and Bearing Caps - Base
- Assembly, Main Bearing Studs, and Main Bearing Caps (02-305A,C,O)
Unlimited Life Additional maintenance recommend-ations.
Addi.tional equality inspection recommendation.
SH2592 3-8 Rev.
1
~Com onent Acce tabilit Recommended Action CRANKSHAFT & BEARINGS Cr ankshaft (02-310A)
Main Bearings (02-310B)
Camshaft Bearing:
Thrust Bearing Ring (02-310C)
Crankcase:
Crankcase Assembly (02-311A)
Crankcase:
Crankcase Mounting Hardware (02-311D)
Crankcase:
Crankcase Gaskets and Mounting Hardware (02-386B)
Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Perform torsiograph test and compare results with TDI Holzer calculations and vibrational analysis.
Polish and inspect oil holes to verify a satis-factory condition.
Inspection for evidence of misalignment.
Additional guality inspections recommended.
Additional maintenance recommend-ations.
Additional maintenance recommendations.
None Additional guality inspections recommended.
CYLINDER BLOCK LINERS 8 WATER MANIFOLD Cylinder Block (02-315A)
Unlimited Life Implementation of routine insPection Procedures.Verify liner bore and mating block dimensions.
Cylinder Block Liners & Water Manifold-Cylinder Liner (02"315C)
Unlimited Life Additional maintenance recommenda-tions.
Additional guality inspections recommended.
SH2592 3-9 Rev.
1
~corn onent Cylinder Block Liners and Jacket Water Manifold and Piping (Large Bore Scope Only)
(02-315D)
Cyl inder Block Liners and Water Manifold:
Studs (02-315 E)
Cylinder Block Liners and Water Manifold:
Cylinder Head Nuts (02-315F )
Cylinder Block Liners and Water Manifold:
Seals and Gaskets (02-315G)
Cylinder Block Covers:
Gaskets Bolts (02-385B)
Acce tabilit Unlimited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Recommended Action None Change in installation torque recommended.
Additional equality Revalidation inspections recommended.
Additional guality inspections recommended.
Verify that the proper cylinder liner seals have been installed.
Additional guality inspections recommended.
AIRSTART 8( BARRING DEVICE Air Start Valves (02-359)
Starting Air Manifold: Piping,
- Tubing, 8 Fittings (Large Bore Scope Only)
Starting Air Manifold:
- Piping, Tubing, and Fittings (Small Bore Scope Only)
(02-441A"SB)
Unlimited Life Unlimited Life Modifications Additional maintenance recommend-ations.
Implementation of TDI SIMs 329 and 360.
Additional equality inspections recommended.
None Modify supports as indicated in DR/gR report 02-441C.
SH2592 3-10 Rev.
1
~Con onent Starting Air Manifold:
- Valves, Strainers, 8
Filters (02-4418)
Starting Air Manifold: Supports (Large Bore Scope Only)
Star ting Air Mani fold:
Suppor ts (Small Bore Scope Only)
Starting Air Distributor:
Distributor Assembly (02-442A)
Acce tabilit Modifications Modifications Modificati ons Unlimited Life Recommended Action Additional maintenance recommendations.
Addition of free flowing drains to the air distributor filter.
Reinforcement of supports.
Refer to Component Design Review Checklist 02-441C-LB for details Replace existing two-direction lateral support on the air supply to distributor tubing located adjacent to the right bank filter.
Addition of a two-direction lateral restraint to the distributor air supply tubing on the right bank lines between the header filter and distributor.
Additional maintenance requirements.
Additional equality inspections recommended.
Starting Air Distributor:
Tubing, Fittings, Gaskets (02-442B)
The tubing, fittings, and gaskets for this component are considered under component Nos.
02-441A8C and 02-3078.
Starting Air Tank (02-835D)
Unl imited Life Daily checks for moisture at the drain valve or float trap recom-mended.
CONNECTING RODS Connecting Rods:
Rods and Bushings (02-340A)
Connecting Rod Bearing Shells (02-340B)
Modifications Unlimited Life Additional inspection recommend-ations.
Additional guality inspections recommended.
Replacement of two wrist pins and one connecting rod bolt.
Additional maintenance recommend-ations.
Outstanding NCR's should be closed during reassembly of the engines.
SH2592 3-11 Rev.
1
~Com anent Acce tabilit Recommended Action PISTONS Pistons (02-341A)
Unlimited Life None Pistons:
Rings (02-341B)
Pi ston:
Pin Assembly (02-341C)
Modifications Additional maintenance require-ments.
Evaluate the need to upgrade present engine oil.
Replace spiral r ing retainers with Waldes snap ring retainers (P/N GE-003-067).
Return wrist pin R-2 and R-5 from engine 1A-SA to TDI for reworking or replace with acceptable wrist pins.
Retest by material comparator method wrist pin L-4 from engine lA-SA.
Additional maintenance inspections recommended.
Additional guality inspections recommended.
CAMSHAFT 8( VALVE TRAIN Tappets and Guides:
Intake 8 Exhaust Tappet Assembly (02-345A)
Unlimited Life Additional maintenance recommend-ations.
Additional guality inspections recommended.
Tappets and Guides:
Fuel Tappet Assembly (02-345B)
Unlimited Life Additional maintenance recommend-ations.
Additional quality inspection recommended.
Tappets and Guides-Fuel Pump Base Assembly (02-345C)
Unlimited Life None Camshaft:
Camshaft Assembly (02"350A)
Camshaft:
Camshaft Bearing (02"350B)
Unlimited Life Unlimited Life Additional maintenance recommend-ations.
Additional guality inspection recommendation.
None Subcover (02-362A)
Unlimited Life Additional inspections and equality Revalidation inspections recommended.
SH2592 3-12 Rev.
1
~Com onent Rocker Shaft Assemblies:
Intake/
Intermediate Exhaust (02-390A&B)
Main and Connector Pushrods (02-390C&D)
Rocker Arms and Pushrods:
Bushings (02-390E)
Unlimited Life Unlimited Life Unlimited Life Recommended Action Hardness tests on the rocker arm shafts recommended for Engine 1B.
Recommendation for purchase orders to specify destructive verification of weld quality.
Additional maintenance requirements.
Rocker Arms and Unlimited Life Pushrod - Misc.
Bolts and Drive Studs (02-390F)
Additional maintenance requirements.
Additional equal ity inspections recommended.
IDLER GEAR ASSEMBLY & FRONT GEAR CASE Front Gearcase-Gasket and Bolting (02-335B)
Unlimited Life Additional inspections of bolts.
Addition of positive locking features (bent tab or lockwire).
Gear Train Assembly Unlimited Life (02-350C 02-355A & B)
FLYWHEEL Additional maintenance recommend-ations.
Additional equality inspections recommended.
Flywheel (02-330A)
Flywheel-Bolting (02-330B)
Unlimited Life Unlimited Life None None Pyrometer Conduit Assembly-Thermocouples (02"630D)
ENGINE INSTRUMENTATION & WIRING Unimited Life Additional maintenance requirements.
SH2592 3-13 Rev.
1
~Com onent Engine and Aux.
Module Wiring Material and Fittings:.
Pyrometer condui.t, Fittings and Supports (02-688A, 02-630A,B,C)
Engine 8 Auxiliary Module Wiring Material:
Wiring
& Terminations (02-6888)
Engine
& Aux.
Module Wiring Material - Boxes
& Terminals (02"688C)
On Engine Alarm Sensors (02"688D)
Off Engine Alarm Sensors (02-689)
Acce tabilit Unl.imited Life Unlimited Life Unlimited Life Unlimited Life Unlimited Life Recommended Action Upgrade conduit supports.
None None None 1
None OVERSPEED TRIP & GOVERNOR Overspeed Trip:
Governor (02-410A)
Overspeed Trip:
Governor and Accessory Drive Assembly (02-410B)
Overspeed Trip:
Couplings (02-410C)
Overspeed Trip:
Vent Valve (02-410D)
Unlimited Life Unlimited Life Unlimited Life Unlimited Life Additional maintenance requirements.
Additional guality inspections recommended.
Additional guality inspections recommended.
Additional maintenance requirements.
Additional equality inspections recommended.
Additional maintenance recommendations.
SH2592 3-14 Rev.
1
~Com onent Governor Drive:
Governor Tachometer Drive Gear and Shaft (02-411A)
Acce tabilit Unlimited Life Recommended Action Additional qual ity inspecti ons recommended.
Governor Drive:
- Pins, and Keys (02"411B)
Unlimited Life Additional maintenance recommend-ations.
Additional equality inspections recommended.
Governor Linkage (02-413A)
Unlimited Life Additional maintenance and modi ficati on recommendati ons.
Additiona1 qua 1 ity inspecti ons recommended.
Governor Assembly-Woodward Governor (02"415A)
Unlimited Life Additional maintenance requirements.
Governor Assembly-Booster Servomotor (02-415B)
Governor Assembly-Heat Exchanger (02-415C)
Unlimited Life Unlimited Life Additional guality inspections recommended.
Additional guality inspections recommended.
ENGINE SHUTDOWN & E UIPMENT Engine Shutdown Equipment-Tubing/Fittings Supports (Small Bore Scope Only)
(02-695A)
Modifications Addition of two-way supports.
Modify supports on tubing lines that run along the right bank to provide two-direction lateral restraint (Engine 1B only).
Engine Shutdown Equipment-Valves, Regulators, Orifices (02"695B)
Engine Shutdown Trip Switches (02-695C)
Unlimited Life Unlimited Life Additional maintenance inspections recommended.
None SH2592 3-15 Rev.
1
~Com onent Acce tabilit JACKET WATER Recommended Action Jacket'ater Inlet Manifold-(Manifold Assembly with Hardware and Coupling and Gaskets (Large Bore Scope Only)
(02-316A&B)
'acket Water Inlet Manifold-Vent Line to Discharge Manifold (02-316C)
Jacket Water Discharge Manifold/
Piping (Large Bore Scope Only)
(02-317A&B)
Water Discharge Manifold:
Supports (Large Bore Scope Only)
(02-317C)
Modificati ons Modifications Modifications Modifications The second support west of the 6" TDI Custom Flanges requires stiffening in the lateral direction to accommodate the total support loads.
Modify supports to have sufficient moment connection at the support to structural steel interface.
Replace Style 65 Dresser couplings with Style 90 or Style 165 Dresser couplings.
Verify proper installation of all jacket water manifold supports.
Ensure that the supports pads for the supports on each of the 5-inch jacket water discharge
- headers, have a minimum weld of 1/4-inch (3 inches long) between the engine block and the longer sides of the support pad.
Also ensure that the welds between the engine block and the shorter sides of the support are 1/4-inch.
Engine Driven Unlimited Life Jacket Water Pump (02-425A)
Additional maintenance recommendations.
Additional guality inspections recommended.
Jacket Water Fitting - Pipe and Fittings (Large Bove Scope Only)
(02-435A)
Jacket Water Fittings - Pipe and Fittings (Small Bore Scope Only)
(02-435A)
SH2592 Modifications Unlimited Life 3-16 Reinforcement of supports.
Refer to DR/gR report 02-435A fov details.
None Rev. I
~Com onent Jacket Water Fittings:
Supports (Large Bore Scope Only)
(02-435B)
Jacket Water Inlet Fittings:
Valves (02-435C)
Turbo Water Piping:
Pipe and Fittings (Large Bore Scope Only)
(02-437)
Turbo Water Piping:
Pipe and Fittings (Small Bore Scope Only)
(02-437)
Jacket Water Standpipe:
- Pipe, Fittings, Gaskets (02-700A)
Jacket Water Standpipe:
Valves (02-7008)
Jacket Water Standpipe:
Pipe Supports (02-700C)
Jacket Water Standpipe:
Switches (02-700E)
Jacket Water Stand-pipe and Misc. Bolt-ing (02-700F)
Acce tabilit Unlimited Life Unlimited Life Unlimited Life Unlimited Life Modificati ons Unlimited Life Modificati ons Unlimited Life Unlimited Life Recommended Action None None None None Addition of three-directional restraint on the standpipe overflow line.
Addition of an anchor on the standpipe fill line.
Verification of installation of jacket water vent lines.
Additional maintenance requirements.
Modify tubing supports to have two-directions of restraint and sufficient moment connection.
U-bolts should have a minimum diameter of 3/8-inch.
Suitable locking devices should be installed.
None Additional guality inspections recommended.
SH2592 3-17 Rev.
1
~Coe onent Acce tabilit Recommended Action Auxiliary Sub Base 8
Unlimited Life Oil 8 Water Piping-Jacket Water:
Valves (02-717B)
Auxiliary Sub Base 8
Unlimited Life Oil & Water Piping-Jacket Mater: Pipe, Couplings, Fittings, Orifices, Y-Strainers (Large Bore Scope Only)
(02-7170" LB)
Auxiliary Sub Base 8
Unlimited Life Oil 8 Mater Piping-Jacket Water:
Auxiliary Sub Base 8
Unlimited Life Oil 8 Water Piping-Jacket Water:
& Bolting (02-717E)
Auxiliary Sub Base Unlimited Life
& Oil 8 Water Piping-Jacket Water:
Suppbrts (Large Bore Scope Only)
(02-717F)
Auxiliary Sub Base
& Modifications Oil & Water Piping-Jacket Mater Supports (Small Bore Scope Only)
(02-717F)
Additional maintenance recommendations.
None Installation of two and/or three-directional restrai nts such that the unsupported tubing spans do not exceed a maximum of 4 ft - 6 in.
Installation of restraints to allow for thermal expansion.
None None Verification or modification of sufficient stiffness and weld of the jacket water cooler drain line supports.
Miscellaneous Equipment - Heater, Jacket Water (02-810A)
Unlimited Life Additional maintenance requirements.
SH2592 3-18 Rev. I
~Coe anent Jacket Water Heat Exchanger (02-810C)
Jacket Water Standby Heater Pump (02-810D)
Acce tabi lit Unlimited Life Unlimited Life Recommended Action Additional maintenance requirements.
None Thermostatic Valves Unlimited Life (02-810 E)
Additional maintenance recommendations.
Additional inspections recommended.
Cylinder Heads (02-360A)
CYLINDER HEADS 8 VALVES Additional guality inspections recommended.
Additional maintenance recommendations.
Cylinder Head Valves:
Intake and Exhaust Valves (02"360B)
Cylinder Head and Valves:
Bolting and Gaskets (02-360C)
Cy1 i nder Head and Valves:
Springs (02-360D)
Unlimited Life Unlimited Life Unlimited Life Additional inspections recommended.
Additional guality Revalidation inspections recommended.
Additional guality Revalidation inspections recommended.
Additional guality Revalidation inspections recommended.
Fuel Injection Pump (02-365A)
FUEL OIL INJECTION Unl imited Life Additiona1 maintenance recommendations.
Fuel Injection Equip-Unlimited Life ment:
Fuel Injec-tion Tips (02-365B)
Additional maintenance recom-mendations.
Fuel Injection Equipment Tube Assembly (02-365C)
Unlimited Life Additional maintenance recommendations.
Additional guality inspections recommended.
SH2592 3-19 Rev. I
~con onent Fuel Injection Equipment:
Supports (Small Bore Scope Only)
(02-365D)
Fuel Control Rod Linkage 8 Bearings (02-371A8B)
Acce tabilit Unlimited Life Unlimited Life Recommended Action Inspections of the support elastomer for signs of deter-ioration or degradation recommended.
Additional maintenance recommendations.
Additional guality inspections recommended.
Fuel Pump Linkage:
Unlimited Life Automatic Shutdown Cylinder (02-413B)
None Fuel Oil Booster Pump (02-445)
Fuel Oil Header:
Piping/Tubing (02-450A)
Fuel Oil Header-Fuel Oil Supports (Small Bore Scope Only)
(02-450B)
Unlimited Life Modifications Modifications None Addition and/or modification of supports.
Refer to DR/gR report 02-450A for details.
Replacement of threadolet with a socket welded tee.
Addition/Modification of supports and restraints.
Refer to DR/gR report 02-450B for details.
Fuel Oil Filters Unlimited Life 8 Strainers:
Filters (02-455A)
Fuel Oil Filters 8
Unlimited Life Strainers:
Strainers (02-455B)
Additional maintenance recommendations.
Additional maintenance recommendations.
Recommendation to replace strainer with a coarser design.
Fuel Oil Filters
& Strainers Mounting Hardware (02-455C)
Auxiliary Sub Base 8 Oil 8 Water Piping - Fuel Oil:
Piping and Fittings (Small Bore Scope Only)
(02-717M)
SH2592 Unlimited Life Unlimited Life 3-20 None None Rev. I
~Com onent Auxiliary Sub Base 6 Oil & Water Piping - Fuel Oil:
Bolting and Gaskets (02"717P)
Fuel Oil Day Tank (02-825A)
Emergency Diesel Generator (02-650A)
Unlimited Life Unlimited Life GENERATOR Unlimited Life Recommended Action None None None Generator Controls Unlimited Life (02-650B)
Recommendations for temperature monitoring in exciter cabinets.
Replace field flashing relay with appropriately rated relay.
Provide additional cabinet venti-lation.
Additional maintenance recommendations to increase long-term reliablity.
Generator:
Shaft and Bearings (02-650C)
Unlimited Life None CONTROL PANEL ASSEMBLY Control Panel Assembly-Cabinet/System (02-500A)
Control Panel Assembly-Accumulator (02-500F)
Control Panel Assembly-Valves (02-500G)
Control Panel Assembly - Pressure Switches (02-500H)
Unlimited Life Unlimited Life Unlimited Life Unlimited Life None None Additional maintenance require-ments None SH2592 3-21 Rev.
1
~Con anent Control Panel Assembly - Control Relays (02"500J)
Control Panel Assembly - Solenoid Valves (02-500K)
Control Panel Assembly-Piping, Tubing, Fittings (02-500M)
Control Panel Assembly - Terminal Boards/Switches, Wiring (02-500N)
Acce tabi lit Unlimited Life Unlimited Life Unlimited Life Unlimited Life Recommended Action None None None None ENGINE & AUXILIARYSUB BASE 8c FOUNDATION BOLTS Foundation Bolts-Anchor Bolts, Miscellaneous Hardware (02-550)
Auxiliary Skid (02-717A)
Unlimited Life Unlimited Life Additional mainenance requirements.
Investigation of the adequacy of the ASME III qualifications as they apply to the auxiliary skid.
SH2592 3-22 Rev. I
4.0
SUMMARY
/CONCLUSIONS The TDI Diesel Generator Owners Group has completed its review of the TDI diesel generators installed at Shearon Harris.
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 Carolina Power 8 Light Co.
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 guality Revalidation effort summarized in this report is unprecedented in its approach and analytical detail.
This effort has produced a detailed assessment of 164 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/gR 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 wi 11 ensure the adequacy of the component.
This report supports the conclusion that the TDI diesel generators in-stalled at Shearon Harris 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.
SH2605 REV I
I
- 5. 0 RECOMMENDATIONS The ur ose of p
p the TDI Diesel Generator Owners Group Program was to assess the acceptability of the TDI Emergency Diesel Generator at Shearon Harris 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/gR summary reports.
These maintenance and surveillance recommendations are outlined in Appendix II.
Although the recommendations of this report are not requirements, their adoption by Carolina Power 8
Light will give added assurance that the TDI Emergency Diesel Generators installed at Shearon Harris will perform their intended function for the life of the plant.
These recommendations represent a
conservative approach to insuring diesel generator relia-bility.
In some
- cases, the utility may propose alternate means of insur-ing the reliability of their emergency diesel engines.
Justification of these alternate means is the responsibility of the utility.
SH2605 5-1
6.0 REFERENCES
Component DR/gR Summary component.
Ref.
8 Reports list references directly related to that TDI"3 TDI-2 3-2"84 2-27-84 TDI Owners Group Program Plan Investigation of Types AF and AE Piston Skirts TDI-4 TDI"5 3"13-84 TDI D.G.
Rocker Arm Capscrew Stress Analysis Report 3-12-84 D.R. of Connecting Rod Bearing Shells TDI-6 3-23-84 TDI D.G. Air Start Valve Capscrew Dimensional and Stress Analysis Report TDI-8 3-30-84 TDI D.G. Cylinder Head Stud Stress Analysis 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 TDI-15 4-16-84 TDI D.G. Report on Engine Driven Jacket Mater Pump Design Review TDI-16 4-19-84 TDI D.G. Report on Push Rods 10 12 13 TDI"17 4"20"84 TDI"18 4-24-84 TDI-19 4-24" 84 OGTP-8 4-27-84 TDI D.G. Report on the Evaluation of Emergency D.G. Crankshafts at Shoreham TDI D.G. Report on the Evaluation of Emergency D.G. Wiring and Terminations of Shoreham TDI D.G.
Supplement to the Rocker Arm Capscrew Stress Analysis TDI D.G. Report on Fuel Injection Tubing qualification Analysis OGTP-9 5-14-84 TDI D.G. Report on D.R. of Connecting Rods of Inline DSR-48 Emergency D.G.
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 D.G. Cylinder Head Report SH2605 6-1
Ref. ¹ OGTP-26 5-14-84 TDI D.G.
Tur bocharger Report 18 19 20 21 22 23 24 25 26
~
27 28 29 30 31 32 33 34 OGTP-39 5"24-84 OGTP-40 5"24-84 OGTP"41 5-24-84 OGTP-57 6"05"84 OGTP-70 6"13-84 OGTP"72 6-14-84 OGTP-74 6"15" 84 OGTP-76 6-15-84 OGTP" 77 6-15-84 OGTP-79 6-18-84 OGTP"80 6-18-84 OGTP-90 6-25-84 OGTP-89 6-22-84 OGTP-111 7"6"84 OGTP-129 7-24-84 OGTP-140 7-27" 84 OGTP-147 8-1-84 Evaluation of Emergency D.G. Crankshafts at Shoreham and Grand Gulf Nuclear Power Station D.R. of Connecting Rods for TDI DSRV-4 Series Diesel Generators Investigation of Types AF & AE Piston Skirts Emergency D.G. Aux. Module Control Wiring and Termination gualification Report for G.G.N.S.
Emergency D.G.
Aux. Module Control Wiring and Termination gualification Report for C.P.S.E.S.
The Infulence of Thermal Distortion on the Performance of AF and AE Piston Skirts EDG Aux. Module Control Wiring and Termination gualification Report for Shearon Harris Nuclear Power Station Unit I Evaluation of E.D.G. Crankshafts at Midland and Shearon Harris Nuclear Generating Stations.
DR of Elliott Model 656 Turbocharger used on TDI DSRV-12-4 and DSRV-20-4 EDG sets DR of Connecting Rods of TDI Inline DSR-48 EDG DR of Engine Base and Bearing Caps for TDI DSRV-16 Diesel Engines DR of TDI R-4 and RV-4 series EDG Cylinder Blocks and Liners DR of Connecting Rod Bearing Shells for Transamerica Delavel Enterprise Engines Supplement to the Emergency Diesel Generator Engine Driven Jacket Water Pump Design Review Emergency D.G.
Rocker Arm Capscrews Stress Analysis Report on Emergency D.G. Auxiliary Control Module Control Wiring 8 Termination Review Design Review of Elliott Model 65G Turbocharger used on TDI DSRV-12-4 8 DSRV-20-4 Emergency D.G.
Sets SH2605 6"2
35 OGTP-181 8-10-84 36 OGTP"190 8-14-84 37 OGTP-260 9"7"84 Design Review of Engine Base and Bearing Caps for TDI DSRV-16 Diesel Engines Design Review of Elliott Model 90G Turbo-charger used on TDI DSR-48 and DSRV-16 Emergency Diesel Generator Sets 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 40 OGTP-263 9-7-84 Evaluation of Cylinder Heads of TDI Series R-4 Diesel Engines OGTP-306 9-28-84 Survey of Start Experiences and Cause of Unscheduled Shutdowns of TDI Diesel Engines SH2605 6-3