ML19345B903
| ML19345B903 | |
| Person / Time | |
|---|---|
| Issue date: | 10/14/1980 |
| From: | Barnes I, Foster W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19345B883 | List: |
| References | |
| REF-QA-99900300 NUDOCS 8012020702 | |
| Download: ML19345B903 (11) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900300/80-02 Program No. 51300/
51400 Company:
Colt Industries Fairbanks Morse Engine Division 701 Lawton Avenue Beloit, Wisconsin z53511 Inspection Conducted:
September 15-18, 1980 d[4.E.F6 ster,-ContractorInspector I
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Inspector:
/ Kate ComponentsSection II Vendor Inspection Branch 0
Approved b
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? FI. Barnes,-Chief D' te a
ComponentsSection II Vendor Inspection Branch Summary Inspection September 15-18, 1980 (99900300/80-02)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B, criteria, and appli-cable codes and standards, including follow-up on Part 21 reports; and follow-up on inspector identified problems. The inspection involvec twenty-six inspector-hours on site and three inspector-hours at the mota.
Results:
In the two areas inspected, the following two deviations and one unresolved item were identified:
Deviations:
10 CFR Part 21 Reports Follow-up - practices were not consistent with Criterion V of Appendix B to 10 CFR 50, and paragraphs 5.1, 7.2.2, and 7.2.4 of Standard Practice No. 350.60, dated May, November 1978 and February 1980 (See Notice of Deviation, Item A).
Follow-up.on Inspector Identified Problems practices were not consistent with Criterion V of Appendix B to 10 CFR.50, and the customer agreed to dis-position of Bechtel's Supplier. Deviation Disposition Request No. M71-35 (See Notice of. Deviation,-Item B).
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2 Unresolved Items: Part 21 reports follow-up-External thrust bearings,~with rectangular oilireservoirs,l-lhave been purchased, received, accepted and installed;--however, no engineering.. drawing depicts this configuration (Details Section,Jparagraph B.4.c).
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DETAILS TECTION 4
A.
Persons Contacted
- C. A. Ankrum, Manager - Quality Assurance
- R.
H. Beadle, Vice President ~--Engineering D. P. Beck, Senior Engineer
- E.
L.. Fay, Vice President - Contracts
- W. T. Hailey, Vice President - Sales T. W. Iannuzzi, Special Projects
- G. E. Lanzendorfer, Manager - Contract Administration
- J.
F. Morgan, President
- J. M. Moriarty, Manager - Utility Sales
- G. W. Olson, Supervisor - Contract Administration
- W. A. Schlagenhaf t, Manager - Quality Assurance Engineering (Nuclear)
- Attended Exit Interview.
B.
Part 21 Reports Follow-ug
===1.
Background===
a.
The crankshaft external thrust bearing failed during shop tests of the Colt-Pielstick, Type PC-2 Diesel Generator Set for Wolf Creek Generating Station, Unit 2.
Colt's investigation of fail-ure revealed that clearance between the thrust bearing halves did not provide for thermal expansion of the thrust bearings.
b.
Emergency Diesel Generator Battery Racks supplied by Colt' Industries, Fairbanks MoFse Engine Division, for the North Anna Nuclear Power Station; Unit 2 contained a defect. As reported by Stone and Webster Engineering Corporation, Boston, Massachusetts, "A review of the manufacturer's seismic calcu-lations revealed that the designs of the battery rack vall -
attachment bracket and the side rail support system utilized in the calculations were different from the system which was supplied and installed. Analysis indicated that the installed battery rack support system could not sustain the forces imposed by the design seismic event..This represented a departure from the technical requirements of the specification which required the system to withstand ~such forces."
c.
The rocker arms pre-lubrication pumps of the two Colt-Pielstick, Type PC-2 Diesel Generator Sets installed at Summer Station, could operate continuously while the engine is shutdown.
Such operation could lead to a failure of the' diesel generator to start.
This less than desirable operation of the pump is con-trolled by an on/ auto /off switch.
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4 2.
Objectives The objectives of this area of-the inspection were to verify that:
(1) -the reports accurately' described the problems and satisfied the reporting requirements; (2) the problems had been evaluated as required; (3) the generic implication-had been assessed; and (4) the stated corrective' actions are appropriate, adequate and imple-mented or planned.
3.
Methods of Accomplishment The preceding objectives were accomplished by:
a.
Reviewing the -following documents - and observing the available hardware to verify that:
(1) the problems had been accurately described; (2) Lthe problems had been evaluated; (3) generic implication had been assessed; and-(4) corrective actions had been appropriate, adequate, implemented or planned:
(1) Fairbanks Morse Engine Division's Manual, entitled - Investi-gation Into Thrust Bearing Failure, SNUPPS Contract, dated May 22, 1980.
(2) Engineering Report, File Number 700001, 5.67-210.9, dated May 27, 1980, entitled - Investigation Into Thrust Bearing Failure (SNUPPS No. 4).
(3) Operation Sheet for Part Numbers -
(a) P04-700001/18, Engine Index - 14 Cylinder PC 2.5, D/P date, September 4, 1980, and (b)- P12612642, Collar, Ext. Thrust - PC 2.5, D/P date, June 9, 1980.
1 (4) Colt Pielstick PC 2.5 Quality Control Records, Assembly-and Test, No. 2309QC.
(5) Procedure For Checking Thrust Bearing Clearances, No.
P12612227, Revision 2, dated June 19, 1980.
(6) Engineering-Drawings, Numbers -
(a) - P09594, Revision 5, dated August 18, 1980, entitled -
Collar, External Thrust - PC-2.5.
(b) P209751, Revision 2, dated Augusc 31, 1976, entitled Lower Half Bearing, m
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5 (c) P209752, Revision 2, dated August 21, 1976,. entitled -
-Upper Half Bearing, (d) P12612640, Revision 1, dated June 20, 1980, entitled -
Bearing, Upper Half, and (e) P12612641, Revision 1, dated June 20, 1980, entitled -
Bearing, Lower Half.
(7)
Inspection Rejection - Purchased Material,'No. FM-30823, dated May 13, 1980 and its associated Variation Request,
. dated May 19, 1980, on Upper and Lower Bearings, Part Numbers P209751 and P209752.
(8) Engineering Report, File Number 700001, 5.67 - 210.9, dated November 1, 1979, entitled - Failure of External Thrust Bearing (SNUPPS No. 2 Engine).
(9) Standard Practices, Numbers -
(a) 350.40,-dated March 1978, entitled - Engineering Change Orders, (b) -350.60, dated May, November 1978, and February 1980, entitled - Engineering Design Control Procedure For Nuclear Contracts, (c) 660.20, dated June 1974, entitled - Receipt and Acceptance of Purchased Material, and (d) 660.25, dated April 1976, entitled - Defective Purchase Material Procedure.
(10) Procedure No. P12612942, dated July 14, 1980, entitled -
Procedure For Checking Exterior Thrust Bearing Clearance, No. 700001 SNUPPS.
(11) Quality Control Instructions No. 2313 QC, dated June 5, 1980, entitled - Charting of Thrust Bearings - PC Engines.
(12) Thrust Bearings, Part Numbers P209751 and P209752 at the Receiving and Engine Erection Areas.
(13). Seismic Analysis of Battery Racks for the Emergency Diesel-Generating Systems at North Anna Nuclear Power Plant, Units 1 and 2... dated December 19, 1978-(second analysis) and Revision 1, dated December 22, 1978.
A' y-6 (14) Stone:and:WebsterIEngineering-Corporation letter, dated January 2, 1979, J. 0.-No. 13075.01, to Colt Industries Operating Corporation', Atta:
Mr. G. W. Olson,
Subject:
' Battery Racks - Seismic Analysis.
. North Anna Power Station.
b.
Reviewing the following customer Purchase Orders (P.O.),' selected changes, and attendant specifications to verify that Design Control and 10 CFR Parte 21 had been invoked:
(1) Stone and Webster Engineering. Corporation P.O. No. 2447.300 -
241, dated June 24, 1974, and-(2). Bechtel Power-Corporation P.O. No. 10466-M-018-1, Revision 0, dated October 5, 1976.
4.
Findings a.
Comments (1) Design Control and 10 CFR Part 21 had been invoked.
1 (2) The external thrust bearings art purchased items. There are'two designs of the1 bearing; one contains a triangular depression, while the other contains a pronounced rectangular-area, these. serve as oil reservors. A previous failure of the external thrust bearing occurred during the initial run of the SNUPPS No. 2 engine (Callaway, Unit 2). LThe bearings were badly damaged and clearances could not be measured; however, it was determined that the probable cause of fail-ure was inadequate clearance.
Corrective and preventive measures include:
(1)' Disassembl-ing,. inspecting, correcting, and recording clearances of the thrust bearings on the diesel generators at the sites an'd in storage at thef manufacturer's. facility;. and (2) revising i
drawings and operation sheets, initiating Quality Control Instructions and data sheets.
(3) Fairbanks Morse Engine Division has supplied diesel generator battery racks once and that was to the North Anna Nuclear Power Station.
Battery racks are not an item of the. current purchase orders. The battery' racks were manufactured by Exide and shipped _directly to North Anna;-apparently, with-out source inspection by Fairbanks Morse.
Also,_there are indications that Exide was modifying battery racks to the extent that material size differed from rack to rack.
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.- 7 (4)' Fairbanks Morse Engine Division proposes to replace the on/ auto /off. switch, of the pre-lubrication pump, with an-on/off switch.
Discussions with~the customer had taken place but the authority-to proceed with the proposed correction; had not been given.
The instruction manuals.
would'also be revised to indicate the length of time and
-frequency of operating.the pump, b.
Deviation From Commitmen_ts See Notice of Deviation, Item A.
1 Thermal expansion calculations of the external thrust bearing, after.its failure on SNUPPS No. 4-(Wolf Creek, Unit 2) resulted in increasing clearances between:
(1) bearing and keeper plate, and (2) butt. faces.
The.second seismic analysis for the battery rack occurred subsequent to the May and November 1978 dates of Standard Practice No. 350.60; of course, this is also true of
, Revision 1 to the second analysis.
t-c.
Unresolved Item-External thrust bearings, Part Nos. P209751 and P209752, have been purchased, received, accepted by Receiving Inspection,
'and installed on diesel generators for an indeterminate period of time. There are two designs of this bearing; one contains a triangle depression, while the other contains a pronounced rectangular area.
A shipment of bearings, with the rectangular configuration, was received about May 1980.
An Inspection Rejection, No. PM-30823 was initiated on May 13, 1980 and a Variation Request (VR) was
-initiated on May 19, 1980.
The recommended (and approved) dis-position in the 35t was, "Use AS Is."
There is no engineering drawing'that depicts the rectangular configuration; therefore, no engineering dimensions are apparent.
Due to'the lack of an engineering drawing, the NRC inspector was unable to determine how the parts: (1) had been accepted for an indeterminate period of time, and-(2)~were deemed usable.
l-The. NRC inspector was informed that a Change Order would be i
initiated to depict the rectangular configuration on an Engineer-ing drawing.
d.
. Follow-up Items I
During a future. inspection, the NRC inspector will verify that:
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e 8-(1) LThe. external thrust bearings have been corrected on Millstone III;'Seabrook 1 and 2; and SNUPP5 1. 2, 3; and (2). Corrective actions and preventive measures, related to the
. pre-lubrication pump, are adequate and appropriate.
C.
-Follow-up on Inspector Identified'Probimes 1.
-Objectives The objectives of this area of the inspection were to. verify that
-inspector identified problems during previous inspections, had been corrected and resolved-satisfactorily.
2.
Methods of Accomplishment l
The preceding objectives were accomplished by:
Reviewing the following_ records to verify that previously identified problems had been corrected and resolved satisfactorily:
Assembly'and Inspection Records for the Duquesne Light Company a.
diesel generators, b.
Procedure No. P12610998, Revision 1, dated March 22, 1979, entitled - Flushing of Lube Oil Header Before Fitting to Engine for Duquesne Light Company diesel generators.
c.
Summer Station Work Request Nos. 50728 and 50729 and Colt Procedure No. P12610590, dated October 18,-1978, entitled -
Fuel Pipe Inspection.
d.
Procedure No.-P12610998, Revision 1, dated March 21, 1979, entitled - Flushing of Lube Oil Header.
. for Northeast-Utilities (Millstone No. 2).
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Welding-Proceoures Specification, Numbers (1) 16:05:03, dated December 10, 1976, (2) 16:42:00, dated October 30, 1978, and (3) 16:23:02, dated April 13,_1978.
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Procedure-No._P12611620, Revision 1, dated February 4,-1980, entitled
-Procedure for Checking Oil Plugs in Thrust Bearing.
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Verification Forms that oil diversion plugs were installed in-the external thrust bearings at Callaway and Summer Stations.
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Engineering Drawings, Numbers -
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(1) 11908186, Revision 8, dated March 21,- 1979, 2ntitled -
Heat Exchangers Jacket Water..., and (2) -11908187, Revision 11,. dated June 28, 1979, entitled -
Heat Exchanger Intercooler Water.
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Design Review Documentation, page 3/3 for Limerick, Change Order 11702, entries dated January 25, 1980.
J.
Inspection Rejection No. B39951, dated January 16, 1980, for Part Nos. 11908186 and 11908187.
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Interoffice Memo, dated September 18,.1980, To:
Mr. George Olson, From:
J..D. Swanna.ek,
Subject:
Limerick.
. Heat Exchanger Stock Uneven Fit of Heat Exchanger Feet Connections.
1.
Inspection Rejection - Purchased Material No. PM-26963, dated October 11, 1979,- for Part Nos. 11908186 and 11908187.
Colt'.s Purchase Order No.-B-403773-0, dated January 10, 1980, m.
to American Standard, Inc.
Bechtel's Supplier Deviation Disposition Request No. M71-35, n.
dated January 28, 1980, on Part Nos. 11908186 and 11908187.
o.
Inspectio'n Verification Check Sheets that attest to inscallation of the oil diversion plugs in the external thrust bearings of the diesel' generators for Duquesne Light Company.
p.
Operation Sheet, D/P Date, September 4, 1980, for Part Number P04-700001/18, Engine Index-14 Cylinder PC 2.5.
3.
Findings a.
Comments
'(1) The inspector verified that documentation had been completed for:
(1): installation of Fuel Injection Pumps Barrel and Plunger (manufactured by L' Orange) on the diesel generators for Duquesne Light Company; (2) non-destructive examina-tion of rocker arms and valve clearance adjustments on the diesel generators for Duquesne Light Company; (3) testing and: flushing'of the_ redesigned lube oil headers on the diesel
. generators for' Duquesne Light Company and Northeast Utili-ties; and (4) pressure test'of the one and one quarter fuel'
' lines on the units at Summer Station.
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10 (2) Corrective and preventive measures-include:
(1) inspecting
.all diesel generators and installing external thrust bearing oil diversion plugs, as required, and (2) initiating and completing _ verification sheets that specifically_ require inspection for the plugs.
Preventive measures, for the heat exchanger mounting pad problem, have not been documented.
(3) The first five heat exchanger assemblies are in~ storage at the sites and will be corrected before the units are placed in service. Units six and seven were repaired at Colt and unit eight was returned to the vendor for repair. All units have been shipped.
b.
Deviation From Commitment See Notice of Deviation, Item B.
c.
Unresolved Item None.
d.
Follow-up Items During a future inspection, the NRC inspector will verify that inspections / corrections have been made on:
(1) The thrust bearing 0:1' plugs for the Seabrook and Millstone III-diesel generators; two each.
(2) The installation of L' Orange Fuel Injection Pumps Barrel and Plunger Assembly; also, initial timing adjustments of the two diesel generators for Millstone III.
(3) The exhaust rocker arms (non-destructive examination) for the two' diesel generators for Millstone III.
D.
Exit Interview 1.
The inspector met with management representatives denoted in para -
graph A. at the conclusion of the inspection on September 18, 1980.
2.
The following subjects were discussed:
.a.
Areas inspected.
b.
-Deviations. identified.
ic.
Unresolved Item-identified.
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. Contractor response to the report.
The contractor was requested to structure-his1reponse under headings-of corrective action,-~ preventive measures, and dates:for each deviation.
Additionally,l management representatives were requested to notify the Commission in writing if dates' require adjustment, commitments require modification, etc.
3.
Management' representatives' acknowledged the comments of the' inspector.
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