ML20033C223

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Summary of 811029 Meeting W/Util in Bethesda,Md Re Util Presentation of Diesel Generator Reliability Improvements Program.Agenda Encl
ML20033C223
Person / Time
Site: Farley  Southern Nuclear icon.png
Issue date: 11/09/1981
From: Reeves E
Office of Nuclear Reactor Regulation
To:
Office of Nuclear Reactor Regulation
References
NUDOCS 8112020889
Download: ML20033C223 (8)


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DISTRIBUTION Docket IE-3 0 9 1981 NRC PDR CParrish L PDR ACRS-10 Docket Nos. 50-348 TERA NRC 50-354 NSIC Participant ORB #1 Rdg J01shinski JHeltemes LICENSEE: Alabama Power Company BGrimes Joseph M. Farley Nuclear Plant Units Nos.1 and 2 Svarga OELD

SUBJECT:

SUMMARY

OF MEETING HELD ON CCTOBER 29, 1981 RELATING TO DIESEL GENERATOR RELIABILITY AT FARLEY SITE I.

Introduction A meeting was held in Bethesda, Maryland on October 29, 1981 between representatives of Alabama Power Company (APCo) and the NRC Staff.

A list of attendees is enclosed.

The meeting was requested by the NRC staff to allow APCo representatives to present a discussion of the Diesel Generator (DG) Reliability Improvements Program at Farley Nuclear Plant. A copy of the meeting agenda is enclosed.

II.

Discussion of Recent DG Failures, Causes and Actions Taken Mr. R. P. Mcdonald, Vice President Nuclea-Generation, APCo reviewed the DG operating history since formation e 7 a corporate Task Force established on May 10, 1981. A docketed report by APCo, issued on October 14, 1981 addresses the action itens of NUREG/CR-0660

" Enhancement of On-Site Emergency Diesel Generator Reliability."

Details of the Task ihree Report were not discussed at this meeting.

However, twenty-five design changes and nine operational changes have been initiated as the result of this effort.

The DG failures which occurred to DG 1C on May 8. July 30 and September 18, i

1 1981 were discussed in detail. A followup detail failure report was docketed on October 23, 1981 by APCo. Primary reasons for the first two failures appeared to be water in one or more cylinders resulting a in either a partial or complete " hydraulic lock" found during attempts to start the DG, These failures resulted in extensive repairs including replacing cylinder liners, piston assemblies and other components. Then, extensive vendor supervised retests were acco shed.

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. However, during these retests operator inattention resulted in operating the generator at overloaded conditions (observed as high as 114%). The time period of overloading was not definitely estab-lished. This overloaded condition probably resulted in the failure on DG IC which occurred on September 18, 1981, after about 60 hours6.944444e-4 days <br />0.0167 hours <br />9.920635e-5 weeks <br />2.283e-5 months <br /> of running time. This failure appeared as piston pin bushing fLilures and damaging high cylinder temperatures. Two corrective measures were taken at this time:

(1) Operational changes were made to assure close operator attention during overload tests and to preclude themal stresses during tests.

(2) The operating temperature of the bearing lube oil system was reduced from 205'F to 185*F to improve hearing perfomance.

DG-lC has been fully operational since October 2,1981.

APCo (Mcdonald) next reviewed the failure of DG-2C on September 22, 1981 which was similar, but less extensive than the failures previously noted on DG-lC. Both DG-lC and DG-2C are the same design, opposed piston type 81/8 x 10 OP, designed by Fairbanks Morse Engine Division.

To summarize, Mr. Mcdonald noted that these four failures in the same type of DG at Farley Nuclear Plant appeared to result from the following causes:

1.

Overpowering of engines due to a Technical Specification requirement to perfom an overpower test at 18 month intervals.

2.

Overpowering of engines during tests due to operator inattention.

3.

Too frequent starts resulting in extreme themal stresses. APCo estimates about 110 tests in 210 days on each of tne five DG's (Total over 500 starts in seven months).

4.

Inadequate loading and unloading DG's during operation (see 3 above).

Mr. Mcdonald reviewed another DG failure which occurred to DG 1-2A on October 9,1981 during preventive maintenance checks. A cooling water pump bearing failed due to a high spot on shaft spline gear causing abnomal bearing wear. This was considered an isolated failure found during preventive maintenance.

Mr. John Tangye of Colt Industries, the DG vendor, discussed the problems in perfoming DG repairs, DG overhauls and tests at the field sites as compared to the factory lccation. Specifically, he

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perform such work at the site was considered a negative factor.

Also, Mr. Tangye noted that frequent DG starting and acceleration to 100% loaded conditions followed by immediately stopping the engines created excessive thermal stresses. He has recommended operation, periodic tests and overhaul run-in checks to improve the DG reliability.

He stated Colt Industries fully endorsed APCo's proposed Technical Specification changes (discussed later).

IV.

Discussion of DG Reliability 1

APCo (Mcdonald) provided an analysis (see enclosures) of DG reliability at Farley Nuclear Plant since Unit No. I was licensed in June 1977 4

until October 17, 1981. Also cumulative reliability was presented for the period since Unit No. 2 was licensed in March 1981. The range of reliability figures are between 93% (DG IC) and 98% (DG 2C) for the entire period and between 94% (DG 28) and 99% (DG 1B) for the last seven months.

Farley Nuclear Plant has five DG's for the two unit site. Three DG's are currently considered " swing" diesels capable of providing power for either or both units.

V.

Summary APCo considers that the Emergency Power System at Farley Nuclear Plant is reliable. It is ready to support two-unit operation when Unit No.1 completes the present refueling outage. However APCo considers

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significant Technical Specification revisions are needed to ensure that improved DG reliability continues. A license amendment request was provided to the NRC by letter dated October 28, 1981. The requested changes, in the opinion of APCo and Colt Industries (manufacturer of the dhsel generators at Farley Nuclear Plant), would provide for improud assurance of diesel generator reliability.

The NRC staff agreed to review the proposals. We agreed to advise APCo of any further information needed to complete the review prior I

to the scheduled Unit No.1 startup (about January 30, 1982),

pgionIAL SIGlE f

Edward A. Reeves, Project Manager Operating Reactors Branch #1 l

Division of Licensing i

Enclosurbs:

As stated omcc>.DL D,L:

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! tmoronu m om emeu ono OFFICIAL RECORD COPY usa m e - a m L_

Mr. F. L. Clayton, Jr.

Alabama Power Company cc: fir. W. O. Whitt-Mr. R. P. Mcdonald Executive Vice President Vice President - Nuclear Generation Alabama Power Company

- Alabama Power Company Post Office Box 2641 P.O. Box 2641-Birmingham, Alabama 35291

' Birmingham AL 35291 Ruble A. Thonas, Vice President Southern Company Services, Inc.

Post Office Box 2625

. Bi rmiccham, Alabama 35202 George F. Trowbridge, E~ squire Shaw, Pittman, Potts and Trowbridge 1800 M Street, N.W.

Washington, D. C.

20036 Mr. Robert A. Buettner, Esquire Balch, Bingham, Baker, Hawthorne, Williams and Ward Post Office Box 306 4

' Birmincham, Alabama 35201 George S. Houston Memorial Library 212 W. B0rdeshaw Street Dothan, Alabama 36303 Resident Inspector U,. S. Nuclear Regulatory Commission Post Office Box 21-Route 2 Columbia, Alabama 36319 j

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ATTENDANCE APC0 MEETING 10/29/81 - MNBB 6110 - 1 :00 P.M.

RELIABILITY OF DIESEL GENERATORS AT FARLEY SITE Alabama Power Co.

NRC Name/ Organization Name/Organiza**on R. L. George E. Reeves, ORB #1, DL R. P. Mcdonald W. H. Bradford, IE/ SRI O. D. Kingsley D. Rubinstein, RRAB/NRR R. O. Montenero, Colt Ind.

E. J. Brown, AEOD J. W. Tangye, Colt Ind.

Doug Pickett, ORAB/DL D. W. Kennamer B. Milstead, SPEB/ DST M. Srinivasan, PSB/DSI A. R. Ungaro, PSB/DSI M. Chiramal, AEOD T. M. Novak, DL/NRR

5. Varga, DL/ ORB #1 b

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AGENDA, MEETING BETWEEN ALABAMA POWER COMPANY AND NUCLEAR REGULATORY COMMISSION CONCERNING RELIABILIfY OF FARLEY NUCLEAR PLANT ~ DIESEL GENERATORS f

I.

Introduction II. Summary of Recent D.G. Failures and Repairs III.

Items Contributing to D.G. Failures A.

Design B.

Operation C.

Maintenance D.

Technical Specification Restrictions IV. Actions Taken to Alleviate These Items A.

Design Changes and Enhancements B.

Operation Changes C.

Maintenance Training and Improved Direction j

D.

Revised Technical Specification V.

Diesel Generator Reliability at Farley Site y

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ATTACHMENT RELIABILITY STATISTICS FOR D.G.s Although the recent D.G. problems have been major, potentially raising concerns about Farley D.G. reliability, the overall D.G. reliability has been quite good.

1.

Cumulative Reliability from 6/01/77 to 10/17/81 (Figure 0-1)

Cumulative Reliability since D.G. testing began is between 93% (D.G. IC) and 98% (0.G. 2C).

2.

Cumulative Reliability Since 3/16/81 (Figure 0-2) a.

Cuiulative Reliability since 3/16/81 is between 94%

(D.G.2B) and 99% (D.G. 1B) in accordance with existing Technical Specification criteria (including 10 second start requirement).

b.

Assuming a 12-second start is considered successful, based on APCo recent Safety Evaluation, cumulative reliability since 3/16/81 would be between 96% (D.G. E) and 99% (D.G. 1B and 28).

3.

Cumulative Reliability Since The Last Major Repair On The

" Swing" D.G.s The reliability on tha " Swing" D.G.s has been 100% since the last major repair.

D.G. 1C 7/7 (Pass / Total Tests)

D.G. 2C 4/4 (Pass / Total Tests)

D.G.1-2A 1/1 (Pass / Total Tests e

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