05000346/LER-1980-071-03, /03L-0:on 800923,fire Discovered in Exhaust Chamber of Diesel Generator 1-2.Caused by Component Failure Resulting in Turbocharger Failing & Releasing Lubricating Oil Into Exhaust Chamber.Turbocharger Replaced

/03L-0:on 800923,fire Discovered in Exhaust Chamber of Diesel Generator 1-2.Caused by Component Failure Resulting in Turbocharger Failing & Releasing Lubricating Oil Into Exhaust Chamber.Turbocharger Replaced

ML19338F848
Person / Time
Site:	Davis Besse
Issue date:	10/21/1980
From:	Syslo J TOLEDO EDISON CO.
To:	NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML19338F847	List: 05000346/LER-1980-071, Forwards LER 80-071/03L-0 05000346/LER-1980-071-03, /03L-0:on 800923,fire Discovered in Exhaust Chamber of Diesel Generator 1-2.Caused by Component Failure Resulting in Turbocharger Failing & Releasing Lubricating Oil Into Exhaust Chamber.Turbocharger Replaced
References
LER-80-071-03L, LER-80-71-3L, NUDOCS 8010270388
Download: ML19338F848 (3)

LER-1980-071, /03L-0:on 800923,fire Discovered in Exhaust Chamber of Diesel Generator 1-2.Caused by Component Failure Resulting in Turbocharger Failing & Releasing Lubricating Oil Into Exhaust Chamber.Turbocharger Replaced

Event date:
Report date:
3461980071R03 - NRC Website

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60 61 DOCKET NUMBE R 68 b9 EVENT DATE 74 75 REPORT DATE 83 EVENT DESCRIPTION AND PROBABLE CONSEQUENCES h l3 l2l i (NP-33-80-88) On 9/23/80 at 2105 hours0.0244 days <br />0.585 hours <br />0.00348 weeks <br />8.009525e-4 months <br /> while performing surveillance testing on Diese]

Generator (DG) 1-2, the operator noted a " surging" in the engine. He then detected l

73,3, l smoke, and upon scanning the engine, discovered the turbocharger casing glowing red. i 13 l 41 l DG l-2 was immediately tripped, and the fire brigade was called. There was no danger l l3 ;3) l l3 is l l to the health and safety of the public or station personnel. The fire was contained l in the exhaust piping and was extinguished as soon as the diesel was stopped. DG l-1l l3l7ll

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31 40 41 42 43 44 47 33 CAUSE DESCRIPTION AND CORRECTIVE ACTIONS 1110 l l The cause was a component failure. The turbccharger failed and released lubricating l oil into the exhaust chamber of the unit.

Alv high exhaust temperature caused the g, li j l oil to ignite, thus causing a fire inside the exhaust pipe.

Under MWO 80-3300, the

,, l turbocharger and after-coolers were replaced. The lubricating oil and oil filters l

,,,3, j were changed. On 10/1/80 at 0415 hours0.0048 days <br />0.115 hours <br />6.861772e-4 weeks <br />1.579075e-4 months <br /> DG 1-2 was declared operabic.

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DG 80-167 NAME OF PREPARER

O TOLEDO EDISON COMPANY DAVIS-BESSE NUCLEAR POWER STATION UNIT ONE SUPPLEMENTAL INFORMATION FOR LER NP-33-80-88 DATE OF EVENT: September 23, 1980 FACILITY: Davis-Besse Unit 1 IDENTIFICATION OF OCCURRENCE:

Emergency Diesel Generator #2 turbocharger failure Conditions Prior to Occurrence: The unit was in Mode 5 with Power (MWT) = 0 and Load (Gross MWE) = 0.

Description of Occurrence: On September 23, 1980 at 2105 hours0.0244 days <br />0.585 hours <br />0.00348 weeks <br />8.009525e-4 months <br />, during the performance of ST 5081.01, T-4944 (Diesel Generator Monthly Test 24 Hour Run) on Diesel Generator (DG) 1-2, the operator noted a " surging" in the engine. This occurred during the last two hours of the test with the engine at 110% load. As the operator was scanning the control panel, he smelled smoke. Upon scanning the engine, he saw the turbocharger casing glowing red and immediately tripped the Diesel Generator. The fire brigade was called. The fire was contained in the exhaust stack and extinguished itself when the engine was stopped.

The diesel fuel was shut off at the day tank. The soak back pump was de-energized. The fuses were removed for AD 101 (#2 DG output breaker).

The Station Technical Advisor, Emergency Duty Officer and Station Superintendent were notified.

D. Brinkman of the NRC was also notified for information only.

The factory representative was immediately called in to be on hand as the number two DG was disassembled to determine the amount of damage. The results of this inspection are as follows:

1)

The vanes of the intake fan had contacted the turbocharger casing. This caused excessive heating (indicated by burnt spots) and also caused the vanes to break off from the hub.

2) The drive shaf t to the fan was apparently broken.

3) The exhaust turbine section of the turbocharger was badly charred and the inter-nal components were damaged by the fire in the exhaust chamber.

4) Metal particles carried through the air intake manifolds, causing severe imping-ment on the after oil coolers.

Metal particles were also found in the air i'n-takes to the cylinders.

5)' All of the gears in the diesel drive train were found to be damaged. There was severe marking and scoring evident on all gears.

6) The oil seals-in the turbocharger were found to have failed.

No power reduction was necessary as the plant was in Mode 5.

Being in Mode 5, the station did not enter the action statement of Technical Specification 3.8.1.2.

The technical specification requires only one diesel generator to be operable in this mode.

DG_1-1 was operable during this tLme.

This event is being reported to document a component. failure.

LER #80-071

L TOLEDO EDISON COMPANY-DAVIS-BESSE NUCLEAR POWER STATION UNIT ONE SUPPLEMENTAL INIORMATION'FOR LER NP-33-80-88_

PAGE 2 Designation of' Apparent Cause~of Occurrence: The apparent cause of this occurrence was a component failure.

It is apparent that the oil seal in the turbocharger fciled and released lubricating: oil into the diesel exhaust chamber of the unit.

The high exhaust temperature caused the oil.to ignite, and this caused a fire in the cxhaust chamber. The fire heated the casing to a glowing " cherry red" condition.

4 This apparently caused the casing to warp which may have caused the damage which re-ruited to the turbocharger shaft, fan, and diesel gearing.

Analysis of Occurrence: There was no danger to the health and. safety of the.public or to station personnel.

The emergency diesel generator electrical generation capa-city is a redundant system and number one diesel generator was operable. The fire wzs contained in the axhaust piping and was extinguished as soon as the diesel was 4

stopped.

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Corrective Action

The following maintenance was completed under Maintenance Work Order 80-3300.

The turbocharger and the diesel generator drive train gears were re-j placed with new components.

The oil coolers were also replaced with new components.

The intake manifolds were flushed and vacuumed. The lubricating oil and oil filters i;

j ware changed. After reassembly, the diesel generator.was successfully tested under

.ST 5081.01.(24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> run).

Diesel Generator 1-2 was declared operable at.0415 hours0.0048 days <br />0.115 hours <br />6.861772e-4 weeks <br />1.579075e-4 months <br /> on October 1, 1980. The failed turbocharger was returned to the vendor for a factory teardown analysis. -Toledo Edison is investigating vendor recommendations to improve turbocharger service life, p

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Failure Data: There have been two previous turbocharger failures; the first occurred on February-8, 1978, see Licensee Event Report NP-33-78-21 (78-018); the second 1

occurred on March 30, 1979, see Licensee Event Report NP-33-79-49 (79-046).

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