ML18037A447

Emd Owners Group Procedure EMD9314, Recommended Maint Program.

ML18037A447
Person / Time
Site:	Browns Ferry
Issue date:	04/16/1993
From:	DUKE ENGINEERING & SERVICES
To:
Shared Package
ML18037A445	List: ML18037A444 ML18037A446 ML18037A447
References
EMD9314, NUDOCS 9309080153
Download: ML18037A447 (63)

Text

~ i EMD6"k. RC3I. 0 NO. EMD9314 DATE 04I1 6I93 DVKE ENGINEERING ck SERV1CES, INC.

EMD - PS OWNERS GROVP INI6 ORNA TION 8 VI.LETIN INFORMATION ONLY RESPONSE REQUESTED (if checked see below)

.,)vP

SUBJECT:

EMD-PS Owners Group "Recommended Maintenance Program - Final Version dated February, 1993.

EI Enclosed is the final version of the "Recommended Maintenance Program" for the EMD-PS Owners Group. Refer to EMD9309 for a copy of MKW-PS letter of endorsement of this program.

l9 Enclosure (20 pages).

Submit Response to: R.C. (Dick) Day Duke Engineering & Services, Inc.

230 South Tryon Street P.O. Box 1004 Charlotte, NC 28201-1004

~ Telecopy No. (704)382-8770 IF YOU IIAVEANY QUESTIONS, PLEASE CONTACT R.C. DAY AT (704)382-2763.

9309080153 930902 PDR ADOCK 05000259' EMD9314.wP PDR

C

~ I 4

~

1l t

~ ~

EMD OWNERS GROUP RECO1QKENDED MAINTENANCE PROGRAM FEBRUARY 1993 The following represents the tasks reviewed and considered applicable for Nuclear Standby Service for EMD Diesel Generators. This information was compiled from the EMD Maintenance Instructions MI-1723, MI-1728 and MI-1742.

This maintenance program is based on experience generated by the EMD Owner's Group nuclear utility members and is. intended to address maj or engine components and support systems. Instrumentation and electrical components have been purposely excluded from these instructions.

This maintenance program is based on the following conditions:

Fuel oil used in the engines will meet the specifications of EMD Maintenance Instruction 1750.

2. Lubricating oil used in the engines will meet the specifications of EMD Maintenance Instructions 1760 and 1764, and will be changed at the intervals specified in this RECOMMENDED MAINTENANCE PROGRAM.

'Engine coolant used in the engines will meet the specifications of EMD Maintenance Instruction 1748.

. Lubricating this oil filters will be'hanged at RECOMMENDED MAINTENANCE PROGRAM.

the intervals specified in Operating load limitations will be adhered to.

6. Torquing procedures contained= in this RECOMMENDED MAINTENANCE PROGRAM will be followed for new engines and for newly installed replacement parts. 'I 1 of 20

~ ~

4 TABLE OR CONTENTS Section Description Page(s)

Non-Operating Engine Log (Daily/Weekly)

2. Engine Pre-Start Checks 4-5

3. Monthly Engine Operating Checks 6-7

-4 Quarterly Engine Checks

5. Refuel Cycle Engine Checks 9-14

6. Alternate Refuel Cycle Engine Checks 15-16 1

6 Year Engine Checks 17-18 12 Year Engine Checks 19-20 2 of 20

~~

~ ~

NON-OPERATING ENGINE LOG (DAILY/WEEKLY)

Com onent Task Comments Cooling Check for leaks Ops shift'Daily or Weekly)

Cooling Check coolant level Fuel Check for leaks ~ B Fuel Check Fuel supply Lube Check for leaks Lube Check oil level Start Check for leaks Start Drain Condensate Gov Check oil level engine Keep warm system Check for proper operation.

'3 of 20

t

~ ~

ENGINE PRESTART CHECKS Com onent Task Comments Gov Check oil level See Manufacturer Spec.

Fuel Check fuel supply initiate engine prime Cooling Check coolant level Expansion tank Engine Manual Bar over Unless run within last 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> period.

Engine Prelube thru main pump Only if installed.

MI (2) 9644 not Engine Check no oil 8 cams Top deck inspection (1).

Lube Check oil level in pan ube Check strainer oil level Not required (2) .

Lube Check lube oil'irc. Insure proper standby system operation. (3) oil pump(s) operation Start Drain condensate Unless installed air start dryers (4).

Start Check Air Pressure Prior to start. (3)

Start Visual inspection Should be prestart check.

leaks/degradation Most engine runs are performed on a monthly frequency.

4 of 20

~ ~

l

l AR-16" 1993 16: 11 FROIR TVA t lUCLEAR I'AI HT. ro 917297952'.86

~

~

ENGINE PRESTART CHECKS (continued)

MSTrPXCaTXOm:

(1) This check is to verify that the turbo filter check valves are not leaking by opening the top deck,and verifying that thex'e is no oil pumping down on th5 cams.

(2) Pre-lube not required if LO mod installed. Xf prelube mod is installed, check prelube mod pax'ametex's (LO level gauges, pump pressures, etc. ) .

This assures strainer is full. , Otherwise, >30psi at circ. pump dischaxge. Still no need to open strainer.

(3) Most engine runs are done on a monthly basis. For those cases where the engine xuns are more frequent,'his type of check is considered good.

practice. The pumping components are necessary for reliable engine performance. The objective being to assure that engine tux'bocharger has oil during starting for proper lubrication.

(4) This a good practice regax'dless. However', the use of air dryexs will eliminate most all condensate concerns which would require this task.

gof 20

~ ~

f

MONTHLY ENGINE OPERATING CHECKS Com 6nent Task Comments Intake Check air box drains For excess fluids bef ore start, for blockage while engine running.

Intake Inspect handhole covers ~

While engine running for leaks Intake Inspect cylinder test While engine running valves for leaks Intake Visual inspection for While engine running leaks/degradation Lube Check for leaks While engine running Lube Idle-check LO level Not required if pres tart check is performed. 24hr runs will however require periodic checks.

Lube Check Oil Pressure At Load Lube Filter press DP (=25psi Filter clogging check.

Cooling Visual inspection for While engine running.

leaks/degradation Fuel Visual inspection for While engine running.

leaks/degradation Exhaust Check for leaks While engine running.

Ops Run min 1 HR )= 7S ~ Yes Not if a

at all possible.

firm requirement .

but considered <<'a good practice. ',Reduces exhaust system fouling and cylinder glazing.

Starter Check air line lubr. Prior to each start. (1) oil level or verify proper operation tarter Check air compressor V 6 of 20

~

~

MONTHLY ENGINE OPERATING CHECKS continued JUSTIFICATION:

(1) The vendor recommends that the oil level be checked monthly. It is unlikely that the oil lubricator will consume the entire contents within the normal periodic testing frequencies done between refueling cycles.

Normal lube oil consumption is approximately 1 tablespoon with each start. At this rate, the lubricator reservoir contains sufficient oil to properly operate for a full fuel cycle unless in accelerated testing.

Therefore, it is recommended that proper operation be checked with each start (ie. oil residue or some other appropriate means).

(2) PM for Station batteries should not be governed by engine maintenance.

Most plants have air start motors and battery power is required for engine controls or field flashing.. This is normally part of the plant station battery systems and checked accordingly. If using electric start motors, then this parameter is not to be omitted.

7 of 20

QUARTERLY ENGINE CHECKS Com onent Task Comments Cooling Check engine coolant Quarterly analysis Reference MI-1748 Fuel Drain condensate from Monthly (1) day tank Lube Take LO sample for analysis Lube Oil Analysis serves as the basis for many tasks R frequencies (3)

Intake Check air filter oil Where applicable level (oil bath type)

Engine Check LO drain e turbo Check quarterly (2)

JUSTIFICATION:

1) The vend or does not recommend this task. However, based on the type of service, it is considered good practice to assure that there is not a buildup of condensate in the day'ank. This also be considered as an engine prestart check.

(2) The vendor recommends a quarterly check. It is considered very unlikely that the soak back system would not be draining properly. With the prestart check of the circulating pump operation, that the engine oil would not be draining from it the is very unlikely turbocharger gear train. Trending of the pumping system pressures will give indications that there may be a blockage in the turbocharger.

(3) Lube oil analysis should be a part of every utility maintenance program in the EMD Owners Group. The basis for many of the frequencies of tasks requires a lube oil analysis program be in place. The minimum recommendation is for quarterly analysis, however, the preferred frequency would be monthly (or following every loaded engine run). The analysis program selected should evaluate the oil qualities, (wear metals, etc) and take into consideration the oil additive package.

8 of 20

~

~

A

REFUEL CYCLE (18 - 2 4 MONTHS )

Com onent Task Comments Starter Test operation of sep. Refuel interval inspection. (1) bank of starter motors Starter (grease/lube) starters Omit for air start motors w/air line lubricators, otherwise perform 8 refuel intervals (2).

Starter Remove/Clean/Inspect Applies to electric starter starter motors motors only.

Exhaust Manifold bolt toigue Refuel interval inspection. (1) check Exhaust inspect turbo screen Refuel interval inspection. (1)

Exhaust Visually inspect f'ex Refuel interval inspection. (1) connectors 0-Fuel Fuel Clean line leak FO pump check, suction

.Refuel interval inspection.

Refuel interval inspection.

(3) strainers Fuel Clean FO transfer pump Refuel interval inspection.

strainers/filters Fuel Replace fuel xfer filt. Or on high filter DP.

Fuel Replace fuel filters Or on high filter DP.

intake Check Aftercooler DP For oil bath filters only.

Intake Xnsp oil bath filter Clean/change as required (4)

Cooling Cooling system 'eak Refuel interval inspection. (3) check Cooling Rebuild/Repl AMOT vlv Leave at 3 years. Perform 8 refuel intervals for 24 month refuel cycl'es only.

Check cooling fan/motor Check belts, tension, blade clearances/pitch, lubricate bearings R,motor Quarterly (9).

9 of 20

REFUEL CYCLE (18 - 24 MONTHS) continued Com onent Task Comments Cooling Check shutter linkage Check and adjust as req. (9) and blades Lube Replace lube oil Use LO analysis a'nd change based on analysis (S).

Lube Clean strainer box Refuel interval inspection Lube Change main filters To include cutout and full il inspection of f ter media (6) .

Lube Change aux turbo filter See Main filter changeout (6) .

Lube Check DC pump operation Refuel interval inspection (7).

Replace DC circulating Refuel intervals only for pump brushes continuous duty service. For standby service, inspection PM recommended.

Lube Check Turbo-filter check Refuel interval inspection valves Lube Replace Turbo filter Refuel interval inspection element Lube Clean Main oil filter Perform with f ilter change housing Lube Clean/Inspect circ alignment, seal, pump and motor grease/lube.

Engine Check lash adjusters Refuel interval inspection (8) ~

Engine Check auto start sequ. Refuel interval inspection (8);

Engine Inspect upper deck area Refuel interval inspection (8) .

Engine Adjust injector timing.rings'heck Refuel interval inspection (8) .

and rack settings Engine Perform overspeed tr'ip Refuel interval inspection (8).

ngine Inspect pistons 8 Refuel interval inspection (8).

10 of 10

REFUEL CYCLE (18 - 24. MONTHS) continued Com onent Task Comments Engine Inspect cylinder liners Refuel interval inspection (8) .

Engine Check torq on crab bolts, Refuel interval inspection.

Engine Perform lead wire readings Refuel interval inspection.

Engine Perform visual ckcs insp Includes connecting rod &

crankshaft inspection as well as P pipe alignment check (11)

Gov Lube gov. linkage. Refuel interva'l inspection (8).

Gov Replace oil Check 8 refuel intervals change as per governor manufacturer guidelines Chk brush'condition Refuel interval inspection (8).

- Gen Inspect/replace brushes Clean/Inspect collector Refuel interval inspection (8).

Refuel interval inspection (8) rings Elec Perform alarm test Refuel interval test (8).

Elec Megger LO circ pump mtr Not required unless incorporated in predictive maintenance.

Elec. Calibrate all TDR relays See (10)

Elec. Check voltage regulator See (10) operation "

Elec. Clean/inspect voltage See (10) regulator Elec. Check operation of See (10) relays/controls/br'eakers 11 of 20

0 REFUEL CYCLE (18 - 24 MONTHS) continued JUSTIFICATION:

The vendor recommended frequency would require an engine outage to perform the task. This is undesirable'n nuclear standby service, there is approximately 50 hours5.787037e-4 days <br />0.0139 hours <br />8.267196e-5 weeks <br />1.9025e-5 months <br /> (or less) run time placed on the engine.

With so few operating hours,- it is very unlikely that any significant wear has been accumulated. The components inspected have no degradation as a result of the installation (ie. heat, oil, water, corrosion, etc.

attack causing degradation).

(2) All air start installations have in line lubricators, There is no need to provide additional lubrication. For greased motors, it is feasible

'e to extend the maintenance interval to refuel cycles based on the fact that the grease will not consumed, lubricating properties within this time period.

evaporate, or loose its (3) Each monthly engine'perating check will inspect engine systems for leaks. The task can be. considered redundant. However, at refuel, the engine is operated for maintenance activities which include a open top deck inspection. Fuel or coolant leaks in this area can be located visually. Similar leaks can be detected with oil analysis.

O. The oil does not evaporate (appreciably) and is not consumed with the low engine run time. The condition of the filter can be inspected and if necessary, cleaned at regular scheduled outag'es. This inspection frequency applies to all filter types.

(5) Most all signs of engine distress are detected early via lube oil analysis. MI-1760 provides detailed basis for lube oil analysis and likewise. recommends such a program. Lube oil analysis is strongly recommended. It should be. noted that lube oil analysis is the basis for much of the owners group recommendations. Without implementation of oil analysis, much of the justification presented herewith cannot be substantiated and therefore extension of vendor recommended maintenance practices cannot be supported by the owners group. Maximum calendar time between lube oil changes should not exceed 6 .years. Lube oil analysis programs should include means for analyzing current condition of oil additive materials.

(6) Vendor recommendations for annual filter replacement are based upon experiences where engine lube oil has caused deterioration fo the filter media. MI-1760 qualifies this . recommendation based on the* type of lubricating oil used and pro'nged high temperature service. Nuclear

~

standby service experiences does not appear to cause severe deterioration of the filter media. Additionally, there is not sufficient engine run time. to'ause filter fouling.

12 of 20

I REFUEL CYCLE (18 - 24 MONTHS) continued JUSTIFICATION:

(6) (cont) Lube oil keep warm system temperature is not considered high. It has not been determined filter media degradation.

if 'any .one type of oil will cause accelerated While maintaining lube oil quality in accordance with MI-1760, it is further recommended that the filters be replaced at each refuel cycle and that every filter be cut open and the media inspected for signs of degradation.

(7) For continuous duty service,= the DC brushes will wear considerably faster than that for standby applications. 1f the engine uses DC circulating pumps in continuous operation, it is recommended that they be first inspected new, then at .the recommended annual interval measuring the accumulated wear and finally at the refueling interval to quantify the wear.

service intervals At are this point sufficient.

it can Most be determined nuclear if standby refueling service applications use DC circulating pumps as a backup to AC pumps which are normally in continuous operation. For this application, there is very few actual hours of operation. over the life of the motor such that this PM may be deleted entirely.

These engine checks are basic maintenance items done on. either a "calendar" periodic basis or every 8000 hours0.0926 days <br />2.222 hours <br />0.0132 weeks <br />0.00304 months <br /> of operation.

diesel will It notis acknowledged that nuclear standby emergency engines accrue major maintenance overhaul operational hours.

. However, the annual recommendation likewise, does not account for the considerable idle time associated with nuclear standby service. Between refuel cycle, actual engine operating hours will be less that 1% of the 8000 hours0.0926 days <br />2.222 hours <br />0.0132 weeks <br />0.00304 months <br /> recommended for the same inspections. Actual experience has shown that inspections performed at refuel intervals yields negligible variance from vendor specified operating limits.

The engines are in stand by service and the cooling fans do not see more that 20 hours2.314815e-4 days <br />0.00556 hours <br />3.306878e-5 weeks <br />7.61e-6 months <br /> of operation monthly during normal operation.

(10) These components vary in manufacturer and model. The exact operation can likewise vary based upon the vendor of the Diesel-Generator package.

Maintenance is to be performed in accordance with the specific manufacturers recommendations consistent with site specific requirements which may inclued generic applications.

13 of 20

REPUEL CYCLE (18 - 24 MONTHS) continued JUSTIFICATION:

(11) Engine crankcase, ,crankshaft and connecting rod inspections are primarily visual inspections which attempt to locate obvious signs of engine distress. The use. of oil analysis will indicate any abnormal signs of engine wear long before they become visible in the crankcase.

With the engine full of oil, there is a greater potential for oil contamination with the opening of the lower covers for such an inspection. A visual inspection is virtually useless without some breakdown of various components such that bearing surfaces can be properly inspected and service limits measured. If the oil is to be it

~

changed, then is advisable to inspect the engine crankcase, crankshaft and connecting r'ods. Likewise, if oil analysis indicates that significant problems are'ocated in these areas, proper attention should be given to determination of cause and problem resolution regardless of this recommendation.

14 of 20

ALTERNATE REFUEL CYCLE (3 6 - 48 MONTHS)

Task Comments Engine Check wtr jumper torque Note Power Pointer 2P-78 (1).

Cooling Repl Coolant Fill Cap 2nd refuel inspection. (1).

Cooling inspect filler neck for 2nd refuel inspection. (1) damage Cooling Rebuild/Repl AMOT vlv 3 year replacement. Perform every other refuel interval for 18 month refuel cycles only.

Starter Dissas. Clean/insp/repl. Every 4 years with air Sol.vlv. 6 Starters, dryers. Otherwise. every 50 starts (2).

Lube LO circ system check 2nd refuel inspection to valves (30]j 8 755) clean and inspect valves.

Lube Repl 6QPM circ pump/mtr Replace as required per per f ormance monitoring otherwise every 4 years (3) .

Lube Replace 6 gpm Circ Pump Replace as required if DC backup coupling spider Otherwise every 4 years (3) .

Turbo Replace 3 gpm circ pump Replace as required if DC back up otherwise every 4 yrs. (3)

Engine Engine Engine Check Check torque on duct to aftercooler torque on head frame to crankcase Check torque on turbo

'nd 2nd refuel inspection.

2nd refuel inspection.

refuel inspection.

(1)

(1)

(1) to duct bolts Engine Check vibration damper 2nd refuel inspection. (1) for freedom of movement Engine Replace crankcase See engine protector pressure detector recommendation below. (4)

Engine Check Engine protector Replace every 2nd refuel and for proper operation delete this requirement. (4) 15 of 20

r ALTERNATE REPUEL CYCLE (3 6 - 4 8 MONTHS )

JUSTIFICATION:

The owners group recommendation affects only those utilities which have 2 year refuel cycles (18 month refuel cycles meet the vendor recommendations). Based on actual operating hours, the engine does not accumulate sufficient wear to require; a) replacement of fuel oil coupling spider, b) replacement of coolant fill cap and inspection, c) vibration damper check - especially when vibration filler pump neck analysis/trending is also performed. Bolt 'orque checks on various engine components are primarily utilized to assure leak tightness.

Complete engine .inspections are recommended to be performed by the owners group of the associated systems at each refuel cycle whereby leaks are to be detected and,corrected. With the exception of the water inlet jumpers, all other potential leak paths can and are recommended by the owners group to be inspected prior to or during monthly engine runs.

Oil analysis will identify . any internal water leaks which are not readily visible.

(2) The vendor recommends annual maintenance on the air start motors. This component may see more activity in nuclear standby service than in other forms of stationary power application. However, it is recognized that the quality of air is considered the governing factor affecting degradation. With clean, dry, lubricated air, the wear associated in starting the engine is significantly reduced. Water and other corrosion induced contaminants are not present with a'ir dryer installations and therefore, extending the qualified life of the air start motor is justified.

The 6GPM soak back (circulating) pump operates continuously. However,m most nuclear applications utilize a DC backup. The performance of the main soak back pump can be trended and replaced upon failure or near failure with no impact on engine operability status.

Check not recommended. The engine protector (Low water, Crankcase pressure) must be removed to check. Calibration testing involves actual trip of the component. Each trip can, and in most cases, induces some degradation. It is considered more detrimental to the reliability of it rather that mere replacement. There are no the component to test consumable or time dated components within the detector assembly. The elastomer materials used (O-rings, diaphragms, gaskets, screws) are not in corrosive, harmful, or high wear environments. The engine maintenance manual recommends periodic testing but not replacement.

Experience has shown that calibration testing is harmful to the component. Replacement as recommended meets the intent of the vendor recommendations.

16 of 20

6 YEAR ENGINE CHECKS Com onent Task Comments Fuel Replace eng drvn fuel 6 yrs or 3rd refuel. (2) pump coupling spider Fuel Replace DC Fuel pump 6 yrs or 3rd refuel.

coupling spider Fuel Qualify injectors 6 yrs or 3rd refuel.

Lube Inspect and .clean lube 6 yrs or 3rd refuel. (1) oil separator Lube Clean/inspect eductor . 6 yrs or 3rd refuel. (1) tubes Governor inspect booster motor 6 yrs or 3rd refuel.

seals and brushes enerator Reverse collector ring 6 yrs or 3rd refuel.

polarity latches'nsp.

Generator & grease, bearing Also suggest grease sample analysis at this time Engine Replace power assembly 6 yrs or 3rd refuel.

head gasket Engine Replace power assembly 6 yrs or 3rd refuel.

head to liner (grommets) water'eals Engine Replace wtr jumper seals 6 yrs or 3rd refuel.

17 of 20

6 YEAR ENGINE CHECKS (cont)

JUSTIFICATION:

(1) The fouling associated withe this component is primarily related to engine run time. In nuclear standby service, the engine run time is minimal (( 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br />)'. Both engine operation at light load (idle and (

75: power) and lube oil/fuel oil add some fouling since low load operation induces higher lube oil consumption and poor lube oil/fuel oil quality yields higher carbon fouling. However, fouling of any type can only be induced while the engine is operating regardless of load. Xn nuclear standby service, the fuel oil and lube oil quality strictly adheres to manufacturers specifications (Ref. MI-1750 and MI-1760).

Assuming 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br /> of actual engine operation, the extension of this maintenance interval is justified.

(2) Based on actual operating hours,, the engine does not accumulate sufficient wear to require the replacement of the fuel oil pump coupling spider. The engine, will accumulate approximately 600 run hour during this period. This component does not degrade over time such that replacement at the extended interval meets the vendor recommendation.

18of 20

12 YEAR, ENGINE CHECKS Com onent Task Comments Cooling Replace rubber seals on Leave at 12 years cooling system Cooling Clean/inspect heat 'ex. Leave at 12 years Cooling Repl/rebuild wtr Perform every 12 years. (1) pumps'eplace Fuel eng drvn fuel Replace every 12 years. (1) pump Lube Clean/insp LO cooler Leave at 12 years Lube Replace lube oil filter Perform every 12 years. (1) bypass valve Engine Replace top deck seals Replace every 12 years (2) and latches engine Replace power assembly Perform every 12 years lower liner seals (already EMD approved).

Engine Check exh valve timing Perform every 12 years (3).

Engine Replace crankshaft damper Applies to viscous type damper only. Gear type damper does not require replacement.

JUSTIFICATION:

(1) In nuclear standby service, there is approximately 1000 hours0.0116 days <br />0.278 hours <br />0.00165 weeks <br />3.805e-4 months <br /> (or less) run time placed on the engine. With so few operating hours, it is very unlikely that any significant wear has been accumulated. These components have. no degradation as a result of the installation, (ie.

heat, oil, water, corrosion, 'etc. 'attack causing degradation). The primary failure mode associated with the pumping components will be mechanical seal failure which will be detected during either prestart or operating engine checks.

(2) There is no major consequence .with the failure of either. of these components. Leakage will be the main concern which will either become a housekeeping concern or prompt a corrective maintenance job to replace these components. These compone'nts have no degradation as a result of the installation (ie. heat, oil, water, corrosion, etc. attack causing 0 degradation).

19 of 20

12 YEAR ENGINE CHECKS (cont)

JVSTIPICATIOH:

(3) This inspection is primarily used to check engine gear train wear.

Engines used for nuclear standby service do not accumulate sufficient operating hours to require this inspection over the life of the plant.

Unless there has been engine operation with severe oil contamination or other forms of catastrophic engine failure, it is very unlikely that there has been sufficient gear train wear to require this check at the six (6) year interval.

20 .of 20

ENCLOSURE 3 MKW-PS OWNERS GROUP PROPOSED MAINTENANCE PROGRAM LETTERS DATED MAY 25, 1993

4 0

NO. EMlUQK3 DATE DDEEZ<NrlNziERdvrz SERFICES /PC ZiMS PS 0/AYERS GROUP lPFORiNXSNBD~TIiY INFORMATION ONLY H RESPONSE RE(UESTED

~

(if checked see below)

SUBJECT:

MKW-PS/Owners Group Proposed Maintenance Pro ram

.Letter dated 5-25-93 from Larry Deans, VP MKT Sales

.Letter dated 5-25-93 from David Strickland, Prod. Sup. Engr.

nclosed are two letters from MKW-PS related to the Proposed Maint. Program. Please use as appropriate to support your. Diesel's.-

.No response to DEdmlS required. Contact two correspondents if any questions

.Enclosures (4 pages)

Submit Response to: R.C. (Dick) Day Duke Engineering & Services, Inc.

230 South Tryon Street P.O. Box 1004 Charlotte. NC 28201-1004 Telecopy No. (704)382-8770 IF YOU HAVE ANY QUESTIONS. PLEASE CONTACT R.C. DAY AT (704)382-2763.

ONE Ei(G(1)hr.i.:Q.'0 S."..~!C~cS, P)C.

MKW. o SVÃi%K4)no, BFC" P7F0 h)AY 2 7 1993 I C

AIAlsO ~

F()8 ALT<- 2.2.~ 2 Mav 25, 1993 Ccp) ",o '"; t t;r)/err'o EMD-PS Owners Group Duke Engineering and Services, Inc. vP,re~q I 'VI,~~()p~

230 Tryon Street /;.~.4a. (

P. 0; Box 1004 Charlotte, NC 28201.

Attention: R. C. Day

Subject:

Proposed Maintenance Program

Reference:

(1) Meeting 'on January 19, 1993 with the Owners Group, h(KN Power Systems and Electro-Motive Division of General h(otors (2) EMD Owners Group Recommended Maintenance Program Do'cument Dated I'ebruary, 1993 (3) EMD Maintenance Instruction (MI) 1723, 1728 and 1742I

Dear Mr. Day:

The Owners Group recommended Maintenance Program, as defined in Reference (2), ha's been reviewed bv MKW Power Systems as the Authorized Distributor for EMD servicing .the nuclear industry." Ne support and encourage all of our customers in efforts made to increase the overall operati'ng efficiency of the equipment. Increased operating efficiencv provides overall cost reductions.. while maintaining or increasing reliability.

This program has been developed to coincide with the scheduled outages, which has altered scheduled maintenance periods defined in EMD's maintenance Instructions (MIs) shown in Reference (3). These 'Maintenance Instructions are not written specifically for, the nuclear industry and are only intended to serve as a guide to establish a maintenance schedule. Noting that these maintenance Instructions are provided as a guide only and are not necessarily addt essing the nuclear power industry, the history which the industry has experienced becomes very important information when defining its scheduled maintenanc'e. Based on this historical information, and the experience MKN Power Systems has gained through working for 20 years in every domestic nuclear power plant operating EMD engines, we approve of PAGE 1 of 4 Post Oltice Box 1928 ~ Rocky Mount, North Caro!ina 27802-1928 ~ Phone: (919) 977-2720 TWX: (510) 929-0725 ~ fAX: (919) 446-3830

1 arnaO~

t EMD-PS Owners Group May 25, 1993 Page 2 this program (Reference 3) with the following three modifications:

Reference 3 states that the following tasks are to be performed during the 18 24 month. refueling 'cycle.

Refuel Cycle (18 24 months)

Com onent Task Comments Fuel Change 1'uel f i 1 ter or on high filter DP Lube Change aux,turbo filter or on high filter DP l.ub e Change main filters, or on high filter DP It is necessary to have the ability to monitor the differential pressure (DP) on the above filters if the usage cycle is to be increased to 18 24 months. Nithout the ability to monitor DP, the condition of these filters is not clearly def.ined.

Nith the implementation of this program, we stress the impor"tance of monitoring and trending. Any new information should be considered for action. This action will continually improve operation. efficiency and the reliability of the industries emergency diesel generators.

If you have any questions or comments. please do not hesitate to call.

Sincerely, MKN PO'WER~ SYSTEMS, INC.

g,g,/

Larry I. cans Vice Pr si ent Marketin nd Sales lid/bhp st5-19 PAGE 2 of 4

DNE NG!i(ffni')GA'(OS,pg, Advanced thclr-f P:o8r~s RECDilED MKW

~ May 25, 1993 Fi!e MAY 2 7 1995 Hl7 s- z2. /2.

QICTIKI 40'OpY 70 4:tit:r>(tt!r'0 EMD-PS Owners Group Duke Engineering and Services, Inc.

230 South Tryon Street.

P.O. Box 1004 XC'r~r',- ( fiP f({ ~

Charlotte, NC 28201 >

I t".(..J.F;!.~ (~j - RW Attention: R.C. Day

Reference:

Proposed Maintenance Program Gentlemen:

MKW Power Systems, Inc. has completed our review of the Owners Group Proposed Maintenance Program. As we have indicated in our previous letter we find the Proposed Maintenance Program acceptable with the stipulation that monitoring of differential pressures across the main lube oil filter, auxiliary turbo filter and fuel filters should be included before extending the change out interval of the filter elements.

The pricing for each of the modifications listed b'elow includes all necessary materials, drawings and installation i'nstructions for installation of the differential pressure gauges in a safety related application.

Installation of each modification is available through MKW Power System, Inc. under our standard rates for field service at nuclear facilities. The estimated installation time required is listed with each modification.

MAIN LUBE OIL FILTER $ 3, 311. 00 DIFFERENTIAL PRESSURE Installation 1 Day AUXILIARY TURBO 4,457.00 DIFFERENTIAL PRESSURE

~

Installation 1 Day PAGE 3, of 4 Post Ofiico Box 1928 ~ Rocky Mount. North Carolina 27802-1928 ~ Phono: (919) 977-2720 TWX: (510) 929-0725 ~ FAX: (919) 446-3830

EMD-PS Owners Group May 25, 1993 Page 2 FUEL OIL FILTER 3,311.00 DIFFERENTIAL PRESSURE Installation 1 'Day Additionally, all 16 cylinder engines without the water manifold support bracket as described in Power Pointer 2P-78 will require this modification.*

PARTS KIT 9326240 62.30 WATER MANIFOLD SUPPORT KIT Two required per engine Installation 1 day Please do not have questions hesitate to contact us at 1-800-759-2720 or require clarification for any of the if you above modifications.

Sincerely, MKW o r s, Inc.

David A. Strickland Product Support Engineer PAGE 4 of 4

ENCLOSURE 4 ADDITIONAL INFORMATION CONCERNING EDG TECHNICAL SPECIFICATION CHANGE

ENCLOSURE 4 ADDITIONAL INFORMATION CONCERNING EDG TECHNICAL SPECIFICATION CHANGE BFN has eight Emergency Diesel Generators (EDGs). Since accurate records concerning start and valid test data have been kept (beginning in 1987), BFN has had a total of 586 valid tests (as defined in USNRC Reg Guide 1.108), and only three valid failures (two load run failures and one start failure). This corresponds to an estimated reliability of approximately 99.5 percent.

BFN currently has a performance monitoring program in use for the EDGs. This program consists of recording diesel operating parameters at 15 minute intervals for the first hour of operation, and then 30 minute intervals thereafter.

This data is then compiled and analyzed to determine adverse trend is developing. This trend may be done by if any manual comparison, or by computerized database manipulation.

The data has been recorded and maintained since 1987. The data points monitored and trended are: priming fuel oil pressure, normal fuel oil, engine lube oil pressure, lube oil filter pressure, engine cooling water outlet temperature, lube oil cooler cooling water outlet temperature, and lube oil cooler lube oil outlet temperature. The engine oil level, governor oil level, and expansion tank level are also monitored. Due to the vintage EDGs in use at BFN, no additional trending points are available to monitor.

BFN also has a program in place to monitor the condition of the lubricating oil used in the EDGs. This program takes a sample of the lubricating oil and analyzes it for contaminants, viscosity, total base number, etc., as required by Electomotive Division (EMD) Maintenance Instruction (MI) 1760. This sample is taken every other month. Upon final implementation of the EMD Owners Group maintenance program, this interval will be increased to a monthly check.

The Morrison Knudsen Wartsila Power System (MKW-PS) concurrence letter dated May 25, 1993, stipulated that in order to extend the changeout interval of the lube oil filters and the fuel oil transfer filters, differential pressure indication must be available and monitored. BFN currently has no dP indicators for these filters, so the current yearly changeout will continue. The engine driven and motor driven fuel oil filters each have filter input pressure gauges which are recorded and trended on a monthly basis. The original EMD Maintenance Instructions (MI 1728 and 1742) set the replacement interval for these filters at two years. The replacement interval will be two years for these filters based on the MI's and the trending.

The endorsement of the EMD Owners Group maintenance program by MKW-PS in the letter to the EMD Owners Group dated May 25, 1993, contained three exceptions to the standard as written in the February 1993 revision. These three exceptions required differential pressure monitoring of the main, auxiliary turbocharger, and fuel filters in order to increase the replacement interval to once every two years. BFN does not have this type monitoring installed, so the changeout interval for these filters will remain at once every year.

The technical specifications currently require annual maintenance based on vendor recommendations. The vendor (EMD) recommendations give specific tasks to perform once per year and make no mention of allowable deviances. BFN currently allows a 25 percent deviation in surveillance intervals. This revision will perform vendor maintenance at two year intervals based on the EMD Owners Group maintenance program. A 25 percent surveillance extension will be allowed in accordance with BFN current technical specifications. As with the current one year requirement, the proposed two year interval does not represent an absolute maximum interval.

The per engine reliability breakdown is as follows:

Diesel Generator Number of valid Number of Reliabil tests valid ity failures 76 100 78 100 69 100 D 77 100 3A 98.6 3B 65 100 3C 73 98. 6 3D 74 98. 6 Total for site 586 99 '

~ ~

The EMD Owners Group recommends that fuel oil, lube oil, and coolant be maintained in accordance with the applicable EMD Maintenance Instruction (MI). BFN maintains and analyzes its diesel fuel oil in accordance with ASTM D975-89. MI 1750 (Diesel Fuel Recommendations) is consistent with BFN's program. BFN's lube oil analysis program is consistent with the requirements of EMD MI 1760, Lubricating Oil for EMD Engines. The engine coolant used in the BFN diesels is water with an EMD approved corrosion inhibitor. The inhibitor is checked monthly to ensure the proper concentration is in use. This is in accordance with EMD MI 1748, Engine Coolant.

ENCLOSURE 5 BFNiS PROPOSED EDG 18-24 MONTHS INSPECTIONS AND CHECKS

1 ENCLOSURE 5 BFNiS PROPOSED EDG 18-24 MONTHS INSPECTION AND CHECKS The following is a item by item discussion of the Electromotive Division (EMD) Owners Group Maintenance Program, revision dated February 1993 (ref. EMD9314, EMD9309, and EMD9323). This discussion will cover only the 18 24 month checks. The 18 24 month checks are 'comprised of the 12 month checks currently used at BFN as required by the existing annual maintenance technical specification. All checks are currently performed at BFN on an annual maintenance basis unless noted.

1) Test operation of separate bank of starter motors.

This item is currently performed every six months by performing a fast start using starter bank 1 in December and starter bank 2 in July of each year. This will not change.

2) Grease/lube starters.

t 3)

BFN uses starters with air line lubricators. If the existing starters have grease/lube fittings, then perform recommended by EMD Remove/clean/inspect Owners Group maintenance star'ter motors.

This item applies only to electric starters.

starters.

program.

BFN uses air as

4) Exhaust manifold bolt torque check.

This check is currently performed every 18 months. Perform as recommended by EMD Owners Group maintenance program.

5) Inspect. turbocharger screen.

Perform as recommended by EMD Owners Group maintenance program.

6) Visually inspect exhaust flex connectors.

Perform as recommended by EMD Owners Group maintenance program.

7) Fuel line leak check.

Fuel leaks checks are performed every month during the monthly surveillance. Perform additional leak checks under the top deck as recommended by EMD Owners Group maintenance program.

Clean fuel oil pump suction strainers.

Perform as recommended by EMD Owners Group maintenance program.

Clean fuel oil transfer pump strainers.

Perform as recommended by EMD Owners Group maintenance program.

Replace fuel transfer filters.

This task will continue to be performed on a yearly basis.

As Morrison Knudsen Wartsila Power System (MKW-PS) stated in their letter dated May 25, 1993, these filters may be changed every 24 months if pressure drop (dP) across these filters is monitored. BFN does not have dP indication across these filters, so the changeout frequency will remain once every 12 months.

Replace fuel filters.

Perform as recommended by EMD Owners Group maintenance program. These filters are currently replaced every 12 months to correspond with the existing annual maintenance requirement. The original EMD Maintenance Instructions on which the EMD Owners Group document and BFN's diesel maintenance is based requires changeout of these filters every two years. Fuel oil filter inlet pressure is monitored and trended and replacements may be required based on increasing filter pressure.

Check aftercooler differential pressure.

BFN does not check aftercooler dP because our diesels do not have the instrumentation installed to perform this check.

Inspect oil bath air filter.

Perform as recommended by EMD Owners Group maintenance program.

Cooling system leak check.

Cooling system leak checks are performed every month during the monthly surveillance. Perform additional leak checks under the top deck and in the air box as recommended by EMD Owners Group maintenance program. Lube oil analysis will also identify any coolant leaks.

fp 4

~ I

Rebuild/replace AMOT valve.

This item is currently performed once every three years. Zf BFN implements a two year diesel outage schedule, the AMOT valve will be replaced/rebuilt once every two years.

16) Check cooling fan/motor.

This item is not applicable to BFN.

17) Check shutter linkage and blades.

This item is not applicable to BFN.

18) Replace lube oil.

BFN currently replaces the engine lube oil once every three years. The interval will be changed to once every four years, or when lube oil analysis recommends changeout. BFN currently performs lube oil analysis and may base the frequency of changeout only on this analysis in the future.

This is in accordance with the proposed maintenance program.

19) Clean strainer box.

Perform as recommended by EMD Owners Group maintenance program.

20) Change main lube oil filters.

This task will continue to be performed on a yearly basis.

As MKW-PS stated in their letter dated May 25, 1993, these if filters may be changed every 24 months pressure drop (dP) across these filters is monitored. BFN does not have dP indication across these filters, so the changeout frequency will remain once every 12 months.

21) Change auxiliary turbocharger lube oil filter.

This task will continue to be performed on a yearly basis.

As MKW-PS stated in their letter dated May 25, 1993, these filters may be changed every 24 months if pressure drop (dP) across these filters is monitored. BFN does not have dP indication across these filters, so the changeout frequency will remain once every 12 months.

22) Check DC pump operation (lube oil).

Not applicable to BFN.

V A

0,

23) Replace DC circulating pump brushes (lube oil).

Not applicable to BFN.

24) Check turbocharger filter check valve.

Perform as recommended by EMD Owners Group maintenance program.

25) Replace turbocharger filter element.

Perform as recommended by EMD Owners Group maintenance program.

26) Clean main oil filter housing.

This task will be performed with the main oil filter change.

27) Clean/inspect lube oil circulating pump and motor.

Perform as recommended by EMD Owners Group maintenance program.

Perform as recommended by EMD Owners Group maintenance program.

29) Check autostart sequence.

This task is performed every six months during the redundant start test. The six month test schedule will not be changed.

30) Inspect upper deck area.

Perform as recommended by EMD Owners Group maintenance program.

31) Adjust injector timing and rack settings.

Perform as recommended by EMD Owners Group maintenance program.

32) Perform overspeed trip test.

Perform as recommended by EMD Owners Group maintenance program.

ri u

33) Inspect pistons and rings.

Perform as recommended by EMD Owners Group maintenance program.

34) Inspect cylinder liners.

Perform as recommended by EMD Owners Group maintenance program.

35) Check torque on crab bolts.

Perform as recommended by EMD Owners Group maintenance program.

36) Perform lead wire readings Perform as recommended by EMD Owners Group maintenance program.

37) Perform visual crankcase inspection Perform as recommended by EMD Owners Group maintenance program.

38) Lubricate governor linkages.

Perform as recommended by EMD Owners Group maintenance program.

39) Replace governor oil.

Perform as'recommended by EMD Owners Group maintenance program.

40) Check generator brush condition.

Perform as recommended by EMD Owners Group maintenance program. The brushes are also checked each month during the two hour load run.

41) Inspect/replace generator brushes.

Perform as recommended by EMD Owners Group maintenance program.

42) Clean/inspect collector rings.

Perform as recommended by EMD Owners Group maintenance program.

43) Perform alarm tests.

Perform as recommended by EMD Owners Group maintenance program.

44) Megger lube oil circulating pump motor.

This item will be done every two years. BFN determines the need for motor replacement based on these periodic megger readings.

45) Calibrate all time delay relays.

The timers will be checked every two yea'rs. The critical timers which involve the proper operation of the starting circuits will continue to be checked every six months during performance of the redundant start tests.

46) Check voltage regulator operation.

The regulator setpoints will be checked every two years.

Operation of the regulator is checked during every run of the diesel (typically once a month).

~ 47) Clean/inspect voltage regulator.

This item will be performed every two years. Any regulator performance problems will be noted during the monthly runs.

48) Check operation of relays/controls/breakers.

This check will be done once every two years. Any operational problems will be detected during the monthly runs or the six month redundant start tests.

s ~'t'