ML20042C977
Text
{{#Wiki_filter:c 01 - M S O o s. pm Rigg e A i(ifj \\,..vQ May 29, 1986 POLICY ISSUE secv-86-164 (Notation Vote) For: The Commissioners From: Victor Stello, Jr. Executive Director for Operations
Subject:
PROPOSED RULE ON THE IMPORTANT-TO-SAFETY ISSUE
Purpose:
To obtain Commission approval of proposed definitions of safety-related, important-to-safety, facility licensing documents, and normal industry practice and obtain additional Commission direction on the rulemaking option to be followed. Category: This paper covers a significant policy issue. Issue: This paper is the first step in implementing the Commission's decision to initiate rulemaking In the Matter of Long Island Lighting Company (Shoreham Nuclear Power Station, Unit 1) CL1-84-9, 19 NRC 1325 (June 5, 1984).
Background:
In the Shoreham licensing decision (CLI-84-9, 19 NRC 1323, June 5, 1984) the Commission directed the staff to prepare a rulemaking package to resolve the issue concernine the definitionandusageoftheterms" safety-related"(SR)and "important-to-safety" (ITS). Subsequent to this Commission direction, the Utility Safety Classification Group petitioned (October 30,1984) the NRC to define these terms in its regulations. In response to the Commission direction, on December 20, 1984, the staff provided an information paper, SECY-84-476, to the Commission concerning the steps the staff was taking to implenent the Commission's directives in the area of equipment "important-to-safety." At that time, the staff informed the Commission that, after further discussion with interested industry groups, the staff was planning to go forward with a Notice of Proposed Rulemaking to the Commissicn for its decision in early 1985. as held between representatives On January 31, 1985, a meeting w(AIF), the Utility Safety of the Atomic Industrial Forum Classification Group (USCG) and the NRC staff concerning the important-to-safety issue. The staff and the industry repre:entatives agreed that the interpretation of the term CONTACT: e' yk 3 Brian K. Grimes, IE 49-29696 i o 00U J ~ -_ J
~ 4 1 important-to-safety" in General Design Criterion-1 to 10 CFR 50, Appendix A, and elsewhere in Part 50, only needed to be clarified to reflect the statement of past practice adopted by the Commission in the Shoreham decision. On April 5,1985 the staff presented'the Commission with a proposed rulemaking package (SECY-85-119) which embodied the agreed upon interpretation, i.e., normal industry practice is acceptable for important-to-safety items that are not safety-related unless otherwise specified in licensing documents. On December 31, 1985, the Office of the Secretary issued a Staff Requirements Memoranoum which stated that the Commission had disapproved SECY-85-119, and that the proposed rule did not adequately differentiate nor clarify the terms important-to-safety and safety-related. Additionally, in the SRM the Commission requested the sta'f to address or clarify particular aspects of the issue, with Commissioner Asselstine requesting that two additional concerns be addressed. Discussion: The December 31, 1985 Staff Requirements Memorandum (SRM) directed the staff to resubmit a revised preposed rule. based on the guidance provided by the Commission. The staff is providing a revised Commission Paper for the Commissien's consideration. This paper provides revised definitions of important-to-safety and safety-related, defines normal industry practice and facility licensing documents, and requests Commission approval of these definitions prior to developing the preposed rulemaking package. ~ As the staff understands the SRM, there are two basic issues. involved: (1) what equipment should be classified as ITS, and l (2) what requirements are imposed on this class of equipment. The staff has grouped the Commission's requests, guidance, c-d questions that appeared in the SRM into five general recuests as listed below. The staff believes that the two basic issues have been addressed within the responses that follow. 1. Clarify the definitions of "important-to-safety" and " safety-related." 2. Define " normal industry practice." 3. Develop criteria for determining what equipment is ITS on a plant-specific basis. a. Review the usage of the terms ITS and SR in 10 CFR for consistency and prcpose appropriate mcdifications if the usage is not consistent. v
~ =. k 5. If any new requirements are imposed, the appropriate backfitting procedures will be used. i A discussion of the staff's response to and recommendation on each of these requests follows: 1. Clarify definitions of Important-to-Safety and Safety-Related The Commission's guidance contained in the SRM concerring clarifying the definitions of " safety-related"'and "important-to-safety" keyed on clarifying that " safety-related" is a subset of "important-to-safety" and the i concept that the staff had required some " specialized treatrient" in the plant's licensing _ documents for equipment "important-to-safety." ~ To stress the fact that " safety-related" is a subset of "important-to-safety," the staff has revised the definition of " safety-related" to specifically state "... safety-related is a subset of important-to-safety...." This action divides the general' category of important-to-safety into two subsets, important-to-safety / safety-related (ITS/SR) and important-to-safety /non-safety-related (ITS/NSR). A literal interpretation of the SRM would result in the following definition of important-to-safety: "Important-to-safety" when referring to structures, systems, and components means those structures, systems, and components for which the flRC staff has required the application of some specialized treatment in the facility licensing documents or generic regulatory requirements. Requirements imposed on imp'ortant-to-safety items are only those which were specifically required by inclusion in the facility licensing documents or in generic regulatory requirements. In order to assess the SRM guidance concerning the use of " specialized treatment," the staff reviewed the Final Safety Analysis Reports (FSARs) and selec.ted portions of the cther licensing documents for two' nuclear power plants, Rancho Seco and River Bend. The purpose of the review was to determine what items that the staff traditionally consir'ered "important-to-safety" would not be encompassed as such using the " specialized treatment" criteria. For this review the 1 i
l s-3, staff considered specialized treatment to include references in the licensing documents to codes, standards, seisnic design or qualification provisions, missile hazard prevention provisions, fire protection provisions, special calibration, testing, maintenance or inspection provisions, and any quality control or quality assurance provisions. Documents submitted by the licensee in support of the application for an operating license were considered the facili ty licensing documents, i.e., documents submi tted after the license was issued were not considered unless they were a condition of the license. For Rancho Seco, the integrated control systen, and the main turbine trip and control systems are examples of systems that are described in the FSAR but for which no " specialized treatment" is specified in the FSAR or the other licensing documents reviewed. The staff believes these systems are clearly important-to-safety as their failure would cause transients that would challenge the plant's safety-related systems. For River Bend, the feedwater control system and the red control and information system ere examples of systems or components described in the FSAR but for which no " specialized treatment" exists in the FSAP or the other licensing dccuments reviewed and which the staff believes are important-to-safety. Based on this review the staff believes the guidance in the SPF, if strictly followed, would not include systems that the staff considers "inportant-to-safety" nor would it make clear that the Commission expects that normal industry practice would be followed for these systems The when " specialized treatment" has not been specified. staff, with its limited resources, does not review every detail of an application and assure that the appropriate treatment is given to each ITS/NSR item. The staff review presumes that a body of good practice exists for plant structures, systems and components whether or not explicit specialized treatment is specified in the facility licensing documents. Under this narrow definition of ITS proposed by the SRM, the systems listed above could be excluded from the category of ITS and therefore be beyond the requirements of the ceneral design criteria (10 CFR 50, Appendix A). This could weaken the basis for taking action on safety concerns for ary eauipment for which specialized treatment is not required in facility licensing documents. E
{ 6 , As an alternative to the SRP definiticn, the staff propcses the following definition of."inportant-to-safety:" "Important-to-safety" when referring to structures, systems, and components means those structures, systems, and components that are described in the facility licensing documents and that provide reasonable assurance that the facility can be operated without undue risk to the health and safety of the public. The staff further would define facility licensing documents for the staff definition as follows: " Facility licensing documents" are those documents that comprise the application and associated proceedings; NRC regulations; Final Safety Analysis Report; NRC orders; license conditions; and written licensee l commitments to the NRC. The staff's approach encompasses all the equipment, 4 information, and commitments that served as a basis for issuing an operating license or a construction permit and for allowing continued operation or construction. There is, however, the possibility that for some-plants not all equipment that the staff presently-considers ITS is described in the. facility licensing documents. Under. the NRC's current regulatory requirements, a requirerent by the staff to add a description to the FSAR for this equipment would be subject to a backfit analysis. The Commission should note that although increased emphasis is being placed on ITS/NSR equipment because'of recent operational events, the NRC inspection program has been and continues to be primarily focused on ITS/SR equipment ~due to resource limitations and the presumption that a body of good practice exists for plant structures, systems and components. The staff does not foresee a change in the level of inspection effort expended on ITS/NSR equipment solely as a result of this rulemaking. 2. Define Nornal Industry Practice The staff considered two options in responding to the Commission's request to define " normal industry practice:" fa) using the ATWS CA guidance previously developed for "important-to-safety but not safety-related" equipment or (b) develop new guidance which generally describes the
s staff's interpretation. The staf# considered the STWS'CA guidance as it is reasonably specific and already applies to scme eouipment falling in the ITS/MSR category.
- Hcwever, the staff determined that the application of the ATWS guidance to the entire ITS/NSR category may constitute a backfit for some equipment at some plants. The staff believes that a substantial effort would be reouired te develop a suitable backfit analysis and considers it doubtful that such an analysis would support the imposition of the guidance.
Therefore, the staff concluded ~that such an imposition of the ATWS QA cuidance on all ITS/NSP items would be inappropriate. As an alternative, the staff proposes the following' defi-nition cf " normal industry practice:" " Normal Industry Practice" when referring to structures, systems, and components impcrtant-to-safety but not safety-related (ITE/NSR), means that these items are: (1) designed, constructed, operated, inspected, tested, and maintained in accordance with applicable nuclear or non-nuclear codes and standards, and vendor-or manufacturer-supplied information or recom-mendations; (2) replaced with parts assured to be of at least the same cuality as the original parts through inspections, tests, evaluation, or audits; and (3) evaluated to establish root causes and necessary corrective actinns for any nonconforming items'or operational perform-1 ance problems that occur. Based on the information gathering visits that have been made concerning licensees' handling of ITS/NSR structures, systems, and components, the staff considers that this description of normal industry practice describes the intent, if not in every case the practice, at operating plants. to this paper provides examples of the main-tenance, operation, and inspection aspects of normal industry practice for emergency power diesel generators and valve motor operators. This information is provided to show the level of detail that the staff considers acceptable in describing " normal industry practice" for ITS/NSR equipment. Althcugh emergency power diesel gener-ators are classified as safety-related by licensees, General Motors provides the diesels as commercial grade to a customer who assembles the diesel generator unit. The enclosed diesel vendor information is illustrative of the level of detail specified by vendors for complex equipment and is illustrative' of " normal industry practice."
The Comnission should ncte that neither current regulations nor the proposed rule, as presently perceived, would requ. ire licensees to comply with this definition cf normal industry practice, although as stated above it is the opinion of the staf f that most licensees already comply. If the Commission determines that compliance with this definition should be explorea, the staff will make appropriate modifications to the proposed rule anc prepare the requisite backfit analysis. 3. Develop Criteria for Determininn what Equipment is ITS en e Plant Specific Basis On the issue of guidance 'or determining what ecuipment is irportant-to-safety, the SRM stated that a list of eouipment ITS/MSR is not required; that for NT0Ls, equipment ITS/NSR could, in general, be determined during the normal licensing process; that it is not the intention of the rule to add new requirements: and that criteria for determining what equipment is ITS/NSR on a plant-specific basis should be developed. To date neither the licensees nor the staff has compiled a list of ITS/NSR equipment. The licensee's FSARs centain descriptiens of both ITS/SR and ITS/NSR structures systems, and components. The descriptions usually clearly state which equipment is ITS/SR but licensees have not specificelly identified eouipment which is ITS/NSR. The staff in their review of licensee's FSARs have, to date, including NTOLS, concentrated on structures, systems, and components which are ITS/SR. The Safety Evaluatien Reports (SERs) issued by the staff specifically cover ITS/SR equipment.
- However, issuance of an SER does indicate general acceptance of the Safety Analysis Report. Therefore, although ITS/NSR equip-ment has not been specifically identified as such, equipment contained in the category ITS/NSR can generally be determined by using the staff's definitions of ITS and facility licensing documents. To do so would be a major undertaking for an individual licensee.
The staff also reviewed the deckets for those plants that have not received an operating license but are actively pursuing completion of the plants. For all plants except Bellefonte 1 & 2 and WNP 1 & 3, the staff has issued a Safety Evaluation Report thereby establishing what structures, systems, and components are ITS. Therefore, due to the small number of plants that would be affected by the proposed definitions, the staff proposes that for all currently docketec plants that ITS equipment be that which is or will be de-scribed in the facility licensing documents, as per the previously cited definition. - - - =
.e-4. Review Usage of Terms ITS and SR The staff has reviewed the use of the terms " safety-related" and "important-to-safety" in 10 CFP and concluded that the use of the terms is r.ct interna 11v consistent nor is it [ consistent with the proposed definitions. " Safety-related" appears 39 times and "important-to-safety" appears 126 times. t A clear example of a use inconsistent with the proposed definition of "important-to-safety" appears in General Cesign Criterion 2; " Structures, systems, and components important-to-safety shall be designed to withstand the effects of natural phenomena such as earthouakes...without loss of capability to perform their safety functions...." In general, the staff has recuired that ITS/SR ecuipment meet this recuirement, but most cf the ITS/CER equipment does not. As such, the proposed definition of ITS would i tend to imply that all ITS equipment must be designed to operate after a design basis earthquake which is not intended by the staff. Powever, a direct substitution of " safety-related" for "important-to-safety" would not encompass certain aspects such as non-Category I seismic design requirements. Similarly, the adequacy and relia-bility of effsite power would not be encompassed by changing "important-to-safety" to " safety-related" in other General Design Criteria. Due to the magnitude of the problem and the difficulties involved in developing acceptable alternatives, the staff has not pursued the issue of consistent usage of these There are four options available to the Commissicn te rms. in implementing the definitions of important-to-safety and safety-related: 1. Withhold issuing a notice of proposed rulemaking on the proposed definitions until the rest of 10 CFR can be appropriately modified to be consistent with the proposed definitions. These usage changes would then be published with the proposed definitions in the same proposed rule. 2. Withhold issuing a notice of proposed rulemaking on the proposed definitions until 10 CFR Part 50 can be appropriately modified to be consistent with the new definitions. These usage changes would then be published with the proposed definitions in the same proposed rule, w Mi w
~ -9 3. Issue a notice of proposed rulemaking on the proposed definitions, review the public comrents, finalize the definitior.s, receive Commission erdersement of the definitions and then prepare a second notice of l proposed rulemaking on the appropriate changes to 10 CFR or 10 CFP. 50 based on the final definitions. I \\ 4 Issue a policy statement announcing the Cennission's f adoption of the definitions and forego rulemaking. The first eption would attempt to achieve consistency in t the usage of the terms safety-related and important-to-sefety throughout the regulations. However, this effort would entail revising portions of Parts 2, 21, 34, 50; General Cesign Criteria 2, 3, A, 5,16,17,18, '44, 54 }~ and 61 contained in Appendix A to Part 50; Appendix R to Part 50; and portions of Parts 60, 71, 72 and Appendix A to Part 100. It is the opinion of the staff that the two areas where the usage problem would be most difficult to resolve are the General Design Criteria and the inconsis-tencies between the parts of the regulations concerning l production and utilization facilities versus the parts of l the regulations concerning waste repositories, independent scent fuel storage facilities, and packaging and transpor-tation of radioactive ma: tal. Additinnally, the safety concerns and equipment involved are sufficiently differer.t between production and utilization facilities and the waste repository, independent spent fuel storage, and transportation areas that different definitions and use of terminology between these areas will not create any significant loss of clarity. Moreover, the term safety-related is not used in regulations applicable to waste repositories, independent spent fuel storage, and transpor-tation areas. The term important-to-safety, as it applies to these areas, is specifically defined in each of the relevant subparts of 10 CFR. Therefore, there is no l l uncertainty over the present usage of these terms in these portions of the regulations. For these reasons, the staff considers it unnecessary and inappropriate to attempt 'a naking the definitions and usage of the terms important-to-safety and safety-related consistent throughout 10 CFP..- Additionally, any attempt to de so would take an effort substantially in excess of the other options and.would not j be the most appropriate use of staff resources. If l extensive public comments are received that necessitate revision of the definitions, the effort would, in effect, { have to be undertaken a second time. I } l The staff does not recommend the Commission approve this option. J i
The second option would resolve the issue of safety-related versus important-to-safety for the regulations concerning production and utilization facilities (principally power reactors). This is the area where the issue was originally raised and where the lack of definitions and consistent usage have created uncertainty. Additionally, the equipment involved and the r61es governing that eouipment are suffi-ciently different between prcduction and utilization facil-ities and the waste repository, independent spent fuel storage, and transportation areas that different definitions and use of terminology between these areas will not adversely affect the regulatory environment. Restricting the rule-making to those portions of 10 CFR concerning production and utilization facilities would reduce the areas considered difficult to resolve by the staff to General Design Criteria (GDC) 2, 3, 4, 5, 16, 17, 18, 44, 54 and 61. To fully resolve the usage problem it may be necessary to take the guidarce currently contained in the Standard peview Plan and appli-cable Regulatory Guides and place that information in the GDC. The staff currently estimates that this option would take two to three years and involve approximately two FTE per year just to issue the proposed rule. If extensive public comments are received that necessitate revision of the definitions, the effort would have to be repeated. The staff recommends that any rulemaking be restricted to those parts of 10 CFR that concern production and utilization facilities. Option three would postpone any action on resolution of the usage problem until the staff has had the benefit of public comments on the proposed definitions and the final definitions had received Commission approval. This option would have the advantage of early public comments on the proposed definitions with a very limited impact on staff resources and would also avoid the possible situation of having to attain staff agree-ment on the necessary modifications to the regulations twice. The disadvantage of this option is that the public would not have the benefit of reviewing the proposed definitions and the proposed revisions in the use of the definitiens at the same time. The staff believes that adopting this option would eliminate the possibility of having to revise the regulations twice, once to issue a proposed rule and the second time to address any changes to the definitions and their use resulting frem public comments. ,r
4 . I The Cctmissior should note that -his option can be pursued regardless of whether the Comnission elects to restrict the 3 rulemaking to those secticos of the regulations that concern prcduction and utilizaticn facilities or elects to have the rulemaking cover all o' 10 CFR. The fourth opticn would forege rulemaking cn this subject. The Commission would issue a policy statement arnouncing the adoption of the proposed definitions withcut any changes to the existing regulations. The advantages of this approach are the relatively shcrt time span required, the very limited impact on staf# resources, the clear establishment of a class of equipment that is important-to-safety but not safety-related, and a statement of the Commission's expectation that a standard of normal industry practice will be followed for such equipment. The disadvantages of this option are the lack of public comment and the possible continuing uncertainty among licensees resulting from the mixed usage of terms in the 10 CFP 50, Appendix A Gcneral Design Criteria. 5. Imposition of Backfit Procedures for New Requirements In response to Commissicner Asselstine's reauest that the staff consider a rulemaking which would allow additions to or deletions from the scope of ITS eouipment based on new information or analyses without applying the backfit rule, the staff considers a backfit analysis appropriate prior to recuiring any additional equipment be classified important-to-safety for currently licensed plants. However, licensees may voluntarily amend their FSARs (after an appropriate 50.59 review) or make changes to the scope of ITS equipment as a result of operational events or other factors. s With respect to Commissioner Asselstine's request that the staff consider a rulemaking for future plants so that confusion and uncertainty do not persist and so that standardization can be enhanced, the staff prefers to wait to accumulate experience with the proposed definitions before considering further rulemaking. The i staff anticipates that any existing confusion or uncertainty will be taken care of by the definitions proposed by this paper and the fact that current treatment of existing plant equipment will not change. The importance of increased attention to ITS/NSR plant eouipment was recently emphasized in an ED0 memo dated November 26, 19E5 on NRC lessons learned in the Davis Besse event: 1 v-e--
' l "The paramount importance of proper reintenance in maintaining levels of reliability assumed in the safety analyses that form the licensing basis for operating plants has been accorded greater recognition and increased emphasis and attention by both NRC and utility management in the af termath of the TMI accident. However, it appears frem the circumstances noteo in the review of the June 9 Davis-Besse event that an inappropriate, artificial distinction between the impnrtance of safety-related i vs nonsafety-related plant features may have led some licensees to place inadequate emphasis on proper maintenance of all equipment necessary to assure proper facility cperations. Some balance-of-plant systens may actually have ecual or perhaps greater safety importance (cumulatively) than equipment classi-fied as safety-related because their too #requent failure can needlessly challenge the safety-related systems, and their f ailure can alsn aggravate conditions under which the safety-related systems must respond. We need to give increased attention to assuring that the attention of licensee management is focused properly en this important aspect of plant cperations and that important balance-of-plant systems and equipment receive adequate attention in the overall maintenance picture...." The staff believes that the proposed definitions, while not in themselves imposing any new requirements, will bring to the attention of the industry the Commission's concern that a proper level of attention be paid to items which are not " safety-related" but which play a large role in assuring safe plant operation. ~ Recommendation: That the Commission: 1. Aporove the staff's proposed definitions of important-to-safety, safety-related, facility licensing documents, and normal industry practice. 2. Approve and direct the staff to proceed, on a long term basis, with option 2 while, in the short term, direct the staff to develop as discussed in option 4, a Policy Statement announcing the Commission's adoption of the definitions and intent to codify them. 3. Provide additional guidance to the staff as to whether licensee ccapliance with the proposed definition of nnrmal industry practice should be required. 4 Note: The staff dces not recommend that the Commission a. pursue Option 1.
.,1 . b. That a Backfit Analysis has not been perforred for this paper since it only requests Corrmissign approval of proposed definitions and additional guidance. The staff will perform an appropriate Backfit Analysis if the Commission chooses the rulemaking option, That because this paper only requests Cerrission c. approval of proposed definitions and additional guidance, a Regulatory Analysis is nct necessary. The staff will perform an appropriate Pegulatory Analysis if the Commission chooses the rulemaking option. Scheduling: If scheduled on the Commission agenda, I reccmmend this paper be censidered at an open meeting. -ft- , f u, Victor Stello, Jr. Executive Director for Operations
Enclosure:
Examples of Normal Industry Practice Commissioners' comments or consent should be provided directly to the Office of the Secretary by c.o.b. Monday, June 16, 1986. Commissioner Staff office comments, if any, should be submitted to the Commissioners NLT Monday, June 9, 1986, with an'infor. mation copy to the Office of the Secretary. If the paper is ~ of such a nature that it requires additional time for analytical review and comment, the Commissioners and the Secretariat should. be apprised of when comments may be expected. ~ DISTRIBUTION: Commissioners OGC ~ OPE OI OCA OIA OPA REGIONAL OFFICES EDO .i ELD ACRS j ASLBP ASLAP SECY e
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INSTALLATIONTIPS oi
- 16. Do check volve stem travel before
- 7. Don't plug motor -by c.remete'v s -
mounnn, stem protection cover on ns,ng irg cne sreoorg me.:,.o :0, e, c-cse . Do st:re croted units under shelter. Your s'em volves All stems should have pro. o volve too ngnt for normc6 coe'rc-mitercue is not wecmerproof unni prep. tecnon cover 3, pon t use oversize motor overlood lv installed. 17.Do check for proper direction of roto-heoters-ins'ecc look for c use Of osen 'D) cut power off before opening or tion of motor. lf volve cioses when open looding iocing limit switen comocrtment cover buffon is pushed the motor may hcve to
- 9. Don't reset torque switch scoring heov.
C D3 check limit switch operonon en con. ier thon moximum recommenced oy crion wim morcr rotenon if motor is iS. Do distinguish between _normolly
- factory, rning in wrong direenen interchenge open ond normolly closed" terminois gro7 ;eods en geored limit switch micro switches
- 10. Don't run " plug" type volve ogoinst stop os demcge rnov *esult to vcae C
Do mount motors on honzonrol pione. .19. Do keep ormeture cleon ond pened-
- 11. Don't ottempt to remove eitner sonng
- possib'?. itis ore erred to keep motor or r
pit switch comportment from henging ecolly check brushes for proper contoct cartridge cop or housing cover from Limitorque whde volve is torque sected. ~ -wn.This prevents t eod of g'eose oeing and weer when DC. motors are em-Alwcys bcck volve cM sect sevetcl ncrc - boinst motor or switch Sects pDW wheel turns be'ere dismcrsr!mg wrut Do connect spoce heoters if unit is to be
- 20. Do remember ther D.C. motor speed
- 12. Don't ettempt to ser limit switches led in o CCmp plCte pnor to insrClio.
is not Constont out wol fluCruc'e wiceY without first disconrechng ccF"Ol C"c wim the food coplied power orcuits ' De keep volve stem cleon and prop-21 Do cleon limit switch cover thoroughly
- 13. Don't motor operote volve withhout Iy luencottd.
cod copy min coct of greose on beenn9 first checking limit switch setting. lD3 set up periodic operoting schedule surfoces Defore mounteg on exclcsson proof bmecroue 22.Do check and repbce demoged limi, Trouble-Shooting: L mito ve control if volve is infre. ,Do lubricote dnve sleeve top beonng switch cover gosket before sec;,,neg on if geored limit switch foils to stop volve l wee.ng, proof br9dorQue travel check the following: 9 ef
- 23. Do refer to ports list when ordering A Control witcg ced mo*Cr eve's rg ss r fenng o s ng c Do kup geared limit and torque replocement or spore ports.
c0ntccror i G've nomepicte doto D Gected bene sw'rtn semag irch contocts cleon. Use cercen terrc~ fonda er erner selve-r en hnt. free c'em UrNt Type Orde' No C 5emng red to see mer r res oee-Una Size Serici No DCckec oH cf er ecca sCe Of sw'*c" "Cs (jn and dry, Do kcop limit switch comportment
- 24. Do check to be sure stem out is se-C"' 58' g-L Do be sure creo is cleon before dis-cured nghtly by locking nut cod met too O WC# h"# 5*"C' 9'C' UC
- CCd' mreod of lock nur is cnmped or stoked in FC #5P'C' IC' CCf~C9'C T WCP ymbimg Limitorque. Cecn 011 ports two pieces 9'C'
5 nowng be' ore re.cssembly if unoble to operate Limitorque by mo. h Do opply fresh cleon lubricont offer Dodt: 'C': - ssembly. A Cneck bCT "c!ct oCwer Cod COr"Of h Da reser gecred limit swetch beforei. D n't force declutch lever int mt r c.rc,.nts for s.:cly enc connn: ry
- -tsr operation if umeercue hcs been pee n posh erre v s T M D
pce s.m ccge wm moc her dismontted or removea from volve. pcsaion automoricolly when motor is cnd controber ncmepicte reting.f C K I. Do r;ploce whole limit switch gear energtZed. me" check mo'or cr'"Dercce locd )x remer men of empt repoirs in field
- 2. Don't try to foece declufch lever from C if s'c!!ed motor is edicciec stNt c f e
. Do reploce moulded plostic conduit motor operotion position to hond oper. OC*e'end coero e utmecroue by nc c. otion position.
- ""l 'C Ove VC!v'
- prLtectors ;cstCUed for shippeg ond rCg2 coly) wim pipe plug 5 when in.
- 3. Don't use obrosive cloth or paper to Excessive hond wheel effort con indicore lilonon wireg is cometered Cleon silver Contoets of geored limit switch the following:
and torque switch. Contacts should be A Imoroperly (cncered or cc cgec bumished. VCiv' 5 "
- 4. Don't depress declutch lever dunng O De Deckeg gicod 'oo ngnt motor oper'otion to stop volve trovel.
C'C O'N CC*'O *
- ce in emergency on 5M0000 cnd f
.y [C0 ',5{.3 c7 c
- 5. Don't torque sect plug volves or but-ted'y volves unless volve mcnufcc'v eris r
Consulted
- 6. Don't use cheoter on hondwheel.
\\. ... ~... .. ~ n. ..-w.
0,e TYPICALOPERATION ~ SMB UblTS Descrintion of ~ ^"oom =5 'e *o'~= 9eo"'95 e 9=se Ge ^e'= " v =* ='=
- 5 ~":" s ~~ e= - =
F e dnve Steeve teeg 50knec in'e'ncey me mOfOr cOrtrOf ercun 0 5 toc te ::e 0 MOfOr Operation: we x =2c me rent =Seim em e e esed OO5mCn e 0, v0 n ;., t 'O TO?O!e Cnc COen Cr C'05e me re", */pe Of CoarOnon Cnd '*e geO'eO IFe mO*0'5 v5ed O' *e Um *OfOee VO!ve "reCOed re" Of Pe VO've Ibe 5'em AU! hmit SWRCN 95 wi'ec in 0 me mO O cO-O
- Ort'O!! C*e *999 5*0" ng 'Of0.e *O*O9v is *.feOOeC *O ':? *e *'eOd Of Cry n5mg PCe? !O 5*00 *e Coe?O!Or CT *e '.l OOe"
~ e*C'0$eO 90'O'5 re y Cte f.,r* 5"ed P 5*e9 v0:<e i^ *e CO$e Of ^O4n5fg 5'em OOS:*-Cr in ine CC$e Cf MOS* GO; '.*" weO'* e 'O' O Of e AD 05 0" O'OOf O' 5.O
- v0've5 Or wre e te e ec't!C Coe*0for !$
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- OCM OeO*-ags OnO OrO cceO geOr 0,ive *e 5 een af DC 20 5 mere!y cui! ?O YOO fne Coe'CBOR O' OC' *e f.!
w." g'eC5e SeC'S NO,,0*.*0nOn O' **eie OC'eO O'd 4ev eC *O f't *e SPC'* Ope 9 COC full C:C5e 005+!.00 O *e VCive f f*.OrO*5 'S re'*e55C'V SoCe "ey O'e bO"' .a re *Pv5? 'Jeve.O OeO by C bmaOTCue +e OeOreO $mn swe -) c OO n Ore:pers Ibe f0f 0Ve Swi'Ch.5 wee:1.n 5e'45 *P CO'ec O* *e ';;*0'y *07 tieWe OOe'OnOn A3 3 CnO5e A : *O*O's C'e O' 'Fe 50Jtrei v0 ve CCn!!Of 5 OO50roeO Oy me "eOVy 50 6Cf in te event O me0*C^4CO! Ove'
- Oe Oe5 0" O O DC mO!O'5 O'e Or-'.
Ov'y *PN5! OeO*mg5 O** Pe ?OO Cnd dor * ~ IOCO OC;yr5 me !OrOve Swi c= wd! OOen ',nc WO "O tor * -d *e TO+ Or>ve 5:eeve AS Te bm. Cnd Cou5e Te mC?Of TO 5*C0 Cf'e$ *e JOf 0Le VCive OafrC: deveiCOS greOfer win"9 CC**Cm Of Te C"?vC: f5?' P'** ,. e m.e ,.9 7. - r 4.np *..~..-, 9 y
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70'C A W"e" WO**g *e VC!ve me WCr* .- c eree m m e y e --r er-wer- - qrer. e5 O Wy Ng 7 SMe5 d M WC7 ![Ca5 f0 De mCOe fOr e OfCLe SW ?;"Ck ..- D e. 5. e s OW' , e.-e' Sncff Or0 C O *" O'e55e5 fPe Oe!levo, e y ,f. 3 **iO*'0" Of *e "O*Of O Oe'C00F 5 O OOb ger eM nme Swif"* ~ ~ . COOe A ny O' *"e OC"5 O'Owmg5 ""O y Oe 50'.n 5 OC :$C 20" '5 e ?OrOW Sonrg pese Ore ;OZ'O'ed SCh*C5 OSC for ever/
- e'e"ec 'O F 80?Oweg ""5 OeScrOSC*
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- 0 sg*) *e v0'.0 ;.,5 OCr* *.v*noe'5 wdl I
- p. O Cer*Oe DreCe'e** rec O 'nM* d
- fe' 'Of eO ' S Ze OOe O'Cr 'O' *e O s 'O'O.re 15 deve OOed I*e 'O'Ove SwPC" 5 f O O Se O e w O'C aO' O R we w H re+e 'O e meC*Cni Ohy C0%O'eO Oy r'e Worm OC'*5 45' O'O # 9 we..*e wor
- F* C ve$ OOCk O "re5e*
j '"e e e:" "O'O' nOS O "eLCO 0:nCn O'5'Once OnO Ce ve OO5 **e Oe'e**%neO ~ 0.,**eO O* *5 5"O'* e r'e"$ 0F h5 0diO-C **O ur! O' 'O' Owe OL*0 6* 'eO steO e O 24C Onves *e *0rT 5n0 0 v?Cm !O*0.,e 5WP"n Coe*5 O*C 0 DCe O e'eC - 8 f OeO* OC =d' w* ;" 5 e^gOOed WJn PC
- CO' con?CC'$ w%Ch C'e weed ir.r0 *e 5:5 3 *e *0'~ !*O" ::./cn Ihis O ece !5 MC*Of COR*TOi CifC#f in~e'r ot5 *e t ' cyst w
50 rec *O " e wO*m 5FC'! OC 43 P ete Onc 5?0p5 Se M C'Or O' *i5 po c;
- $3 ?e w0'.'".5 50#ed f 0 *ne WOf m
,re geCrec we Sween DC 105 5 On SnO'* Oc =43 O ece 53 me uCrm 15 i 50n eO tO te w0's SnOf OnC when e 5 * 'Y9'CC * ** *0'mSnOhOneise +0*O*eO ? N'*5 00 :*. 0 *e wo'n geOr 5?ep O' Cil fime5 wm *ne rf'Ovement Of ' " e 4 Orm OeO-C5 "wO ;vg5 COST Onto *nmaOrOve vC ve COrrOI F :OnrOr 5;iC
- e CO OO4 n wmCn enOOges me wO 5*:S ** C 'O De*5 C' 0 *" "#0' 0
Lg5 Cr **e Cnve 5:eeve DC = 9 i Tnese Ce5 v$ed a c5 OpeCW h me UOS Ore 5,,cteO 50 Or wren-ewO"n gMW W 5WC $ FO N M OW PC$itiCn Of VCive ffCve' it wdl *rc Of te Z" eof Oe]**5 ?C 'grr c,,,nng motor OOee-Sc-e OOef eve'y we W c5nuCROn5 On ^* ' 'C 5t ,e,5 -,'EOY ea--+ C EgOge 0n0 ~ ~ g5 e "O*
- 5*' ** 9'C'*d ## 5 *#
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- h!,.
= .. ~ n: m_ = y m%m;p ., p, ;, m~c s m O.u r ,J .j cw p QJ, j_ n.i. g . (N a r P.Mu ' gg% A l ( w~ M' s 1 y ' ~.. f. /..%.*J t.. CUTAWAY VIEW OF 4 SMD 0 LIMITORQUE VALVE CONTROL ~ g 7"'S C55e"* Of y 15 "e'C " **'5 00510
- Oy A5 50CF C5 f*e e eC"'c -"C'Os eae'g ZeO
- r OOt'5 w"'0" O'e :i 5"O*eO O^ Te OC'*5
- e r"COer Oc5
- 0* O *e 00 Of *e Q
- e r"COer Oc5
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- O Oe reteOSec OHOwi*g ~'e WO** 5"O'-
In '*e eve *' O OCwe' *Ow'e O FO*C w"ee' e e0*fic *0rOf.5 e^ erg 290 0"C
- e " 00t' VC". 'O De 'etCied f'O* "O*C O De*O*0 8 f
15 OrOvicec fOr emae'geacy no O OOe'O-00*5 mOu^ rec OS *e WC'* 5'Of* 0.Se OnC engOge o morO' OperOr.On j rion of *e km0' ole VC've COf trci ine tre inOOe'$ !O 'e eO59 *e CV:* ' n9 0"C ( in C:I CC5e5 w'ft' **e 5MD CDe'O*"r **e* 5,An 'yDe Of ode #C*0r PC5 On OL'Or*O*'C C'wr;h dey5 from Te,r rc 0 OOS.* On IF 5
- eFam%*r @ 15 *> T* ' "' *N *' ** *~ * *' * *e
- CC W*ee' Oe;%'0"-.FO O*rOFOe*e*r In 15 Cn CuromCr+C feO'ure Of *e 'irTY0rO,,e me "nc'*r 51*-..lc rf y wee'm *e ~'*r^' 5 '
Cr0er 'O "O*d Coe'O*e *e ype'5MD Oce'- vCive contrei i va ^w coe*cecn te mondweee OOe5 O' *. - c*ar *e e-'h c k'aOh' >5 +~ ~ve ^h *n-This cedurc*mg cctOn 'S StWer a cu ~e wOrc ind Ee 05cO-e e e ec'r.c mO o 3'O* e -0.+c w eel ictger 5ce 5MD oce'Oro*5 Re4rnag 'O *e rnrOugn *e :wr: 055e-O!y tr *e cO5e ocn3 crOweg fenne SMD C 4 5nOW te of the SMD COO Ond SMD CC 're+e' to "O *d *0' *"'O " d 'C MC" ** ' ' 5 pcge 'S Te -'**m c9 oc =28 crd deOT55ed me dectr h' eve'5'Of*:OuSes c.'..., ; e y5 Oc '. ; re me ceclutch fork r0 Ov5r te worm Sref' ~ve, .,werc w M- - r wi e --r- * .;nnl~e c v c* sev5 erOOce wi*- *e v5 r 5 v I 0 *e O O Ora Of me ac-hw eei W e e ^' C O' 9 'O"9 0 "U #'O '"9 0 9 F,'"" a
- e BCFCw*ee-5 5 0e
- 0.f'ed Of' * 'e
~ SMS 00 ~ e'er O ocge tO' te ev:- kav5 w rm Shch durcn 5 le:4ec in ns oc5.* On en9O9e'*.eIv C 5 ** n *r e "*' ^* "* O r" "*'
- e deve! geO' oc :,,.00 wheel 15 f 0'Cred tre nonCw eel **eO' rutn5 ne nondwnee, suren ocion 0 0 m turn me worm Snch ovinng Te im3OrOue Ope *0rOr into monOn
M 0 ;e 3 j 0 1 FOURTRAINGEARED LIMITSWITCH-ROTORTYPE )(oC& dure for Settinn'. C C5e e eC*hC C'rC#5 ;ue^e*O'iy Cre 'OfOr ~=~ ~=~c*===
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- be fOur 'rO:n gec ec hr93 SwC' 3C'Of v0Ne Ord 0"e f 0*O' 5 Se' 'O 'nO Cf fs.
YOe ' e r?' O.OV5 'O wr *O *O f y O P'.'" S w'?C" e5 C 05e OC5MO^ O e v0!ve 're OPer ^O .C Sc' ] SWFC"?5 O.,O.'
- 0 a : ;.., g f
f POCD hOveC; 'OL' C Orf0C's Ve* e 'Of Or ,,= ? 01 5 O*Ocef'y Set *O ff O O' *e Oes,'eO 005 - d'
- /,)
Iwi'C*, I* e,,00er se** ng Oc Oc q'i O 'Ows OO,,.5? ert Of Te 40 00 0 3:. A .OCe' "O*O'S OFC Owe' 5e*ag ;c ;f Ows 045 pen d e uO 00 el h-p og' DESCRIPTION M 5[b Cen'.Cw errO!Or5 J, U 21 1 CAPTAiDGE P 22 2 OfLITE BUSHING h_d.Q[ - h .1. '. [ [' ~ ~ ' ~ ' ~ ,,," ~"' ~ ' ~ ' ' '. (;2 ' - 23 1 CAIVE SHAFT 24 1 DRIVE PtNION tlNTE ANAL)
- ~ --.
._2b \\, ~ 25 1 HELICAL PINICN u 26 2 GROC%T PIN 4 0 x 1* LG Q r ,s \\ d~ $[ 27 2 C AlvE SLEEVE & GEAA 4 i:ZH-7 28 2 DECLUTCH SPRING w*m -X_pt. -T. 29 2 CALVE A'NION SPUR \\w 30 2 P1N '4 0 u "/.s LG p, g b v' g b, 31 1 CAATAIDGE GASKET 31 1 CAATRIDGE MTG PLATE f m, s v y
- n 33 4.
sv20 x % LG SOC HO C S 34 1 0" AING sC22711 3f' ,6" "' t 33 1 0.aiNG se227 21 Y Nfk, (-
- *.6++c e 36 4
s'e 18 % " FlLL HD CAP Q ff,sn - = - ;; yr ---- - p-.4,,p- .e, SC AEW & L W ~ g 41 2 GEAA FAAME N \\..i ""C ~ k, p - .m -,,y a
- 'y l
/ [ { jp" ]a_ _,h t.2 4 INTER GEAA SHAFT N a,. ' W ? W 'zOe I84h du! W 43 4 iNTE A PINION SHAFT I, 1 I" [ 44 4 G L F AAME COVER i j s g 4S 16 iNTE R MIT'ENT GEAR / [ M% - r b, I 46 12 INTE AMITTENT PtN10N / (. $"' "; M~"* - i ~ ,v / 47 4 STEM SPUA piNtON i ji' \\ 48 2 SET ADO 50 4 G AOCVE P5N %r O n %" LG / / 49 4 AOTCA / ,Q '7) g g@ 51 4 COVE A GASKET p u 52 16 e6-32 '4* LG FILL. HD. M S 53 2 0 -AING s1820 3 S4 2 SETTING AOD BUSHING 4 ~ y ~ r 55 2 GASKET GEAR F AAME ,,MO 4 56 16 INSERT f AOTOR) ((f $1-3, " ' g 57 2 0 AING s1820 5 T' e3 '4 [ $8 2 G ADOVE P'N '4 0 a 1* LG f rp"' ki 61 2 8tNGE A BASE 5 T j 62 10 A *4 FINGER ASSY ' d*' (4, Ij .,r' N s w $3 to LM FINGE A ASSY { {. ~ p I, p (f 64 32 s10 32 m 1* LG hex HD CS T - )vd
- i, i
,a. 6S 32 s t o LOCKWAS>*E A ~. ', 86 64 s10 32 HEX NUT ' '- ;, [ i r; i ~ q' 67 64 stO SWL ~ AASME A K q y 3., sw.20 a '{ FILL HD C S l es a
SMB-00 THRU SMB-5 0-DOUBLE TORQUE SWITCH
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- sav.NAust:cs
, i N %: 4*a ~? 2 2 CONTACT BLOCK 4 2 AAv .Tje tve 4 5 1 C'AL . hf-7.ny N.h' ~ h.h.;ii-ofm!C " ' 9 ~ N 6 1 ACTU AT.NG NK 7 2 PO.NTEA C *~ ?.$k;'". l i ["?MGT i e i S-aft l l= I .~ 9 1 SGACEA L' :/ 10 2 CONT AC' Sce; ORT f*> .s, i r $;.[hP l i it 1 TC A O V E LIV 6TE A 12 1 w -w tNG P TlbPNON 1 "D 5 '3 1 1" @EAA,WG e '4 ? 15 2 CGNTACT ANGE A 1 t-16 .2
- E ev:NAL ST,;:
h g 17 2 COMPA SPRING 6 O l,' / 'e 2 ~CG 5 C N SPG+NG [ I
- 14 1
iN S,;t AT C A I 1 0 A!NG A ,/'
- . AT i A S.< E A 20 b
D ' "~~ w-7 22 2 5CCEW ACUND -O ,~ C -s h ' * ' ~ LG u 23 i A^ c N: O = 25 3 THAU$TAASMER ~e .,= 24 1 tccmAA5-Ea., _d[g. /m,,,%.6- .. Cc,..- - o 27 12 LOCEWASME A 310 \\,r\\ 26 1 AOtt P N : : CIA eJ4LG Y~ f ,b
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- LG
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- v. A.x AS REQUIRED 39 2
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4
- 7*
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1.UBRICANTS i STANDAD SU35TITUTES AEQU3EMEN75 Standard Lubricoats: LubricantSubstitutes: Do not cdd o dif ,c, e ope,o,,'erent lubricent to o Limi. vnies, it,, c, me, cme A M:in Unit: : x x.~- : -O ' an ' s zes bc :t : -*me'C:C"Y eve !:: e 'sc: !s socp bcse es the existing kericent vNess .,, ~t yg.4 Sea ~I+e *e r ~ r Y " h0 "' "'d 'h'
- '0 " '
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- lubricent mcnufocturer.
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- 37. g y y
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- e The minimum lubricent Quolities retvirec 3 3 39 3.
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S ], !0* 'C'995 0' VOLUME WElGHT 4 0 '..' *: UNIT SIZE G A LLONS POUNDS SMS SB 58D 000 50 35 lSM B /S B 'SBD-00 .50 40 SMB;SB ~SBD 0 1 00 95 j SMB/SBiSBD 1 1.50 15.0 SMB/SE -SBD-2 1 75 14 5 SMB SB/SBD 3 5.50 50.0 SMB SB SBD-4 8 50 75 0 SMB 4T 8 00 71 0 SMB-ST 7 50 65 0 SMB5 8.50 72.0 UNIT SIZE TYPE MANUFACTURER COLOR BASE STANDARD SMB /SB /SBD NEBULA EPO EXXON DARK TAN CALClUM -20:F TO 1504 LUBRIC ANTS 000 00 COMPLEX oSMB /SB /SBD/WB NEBULA EPO EXXON DARK TAN CALCIUM O TO 4 COMPLEX 'S M B -5 50 EP ixC 42139) SUN OIL CO BLACK LITHlUM LEAD 'FOA NUCLE AR CONTAINMENT UNITS. NEBULA EP-0 AND EP 1 A AE THE ONLY APPAOVED 1 .UBRICANTS PO A SMB.000 TO 5. MANUFACTURER TYPE TEMPERATURE RANGE BASE LUBRICANT 4XxON " BEACON P29D ~40F TO 120*F LITHlUM LINE SUBSTITUTES ! ARCO LITHOLINE HEP 1 -10*F TO 220 F LITHlUM GULF OIL GULFCROWN EPO -20 F TO 220:F LITHlUM CITIES SERVICE CITY AP -O'F TO 220'F LITHlUM MOBIL OIL CO MOBILUX EPO -10CF TO 220:F LITHlUM 12 SHELL OIL DARINA 0 -10 F TO 250 F HYDROXYSTEARATE NO SOAP Y FISKE LUBRIPLATE LOW TEMP -40'F TO 150*F LITHlUM TEXACO MARFAK O +20SF TO 200'F SODIUM LOW TEMP. EP -40*F TO 200*F LITHlUM flDEWATER OIL VEEDOL ALITHO 10 -10F TO 1502F LITHlUM
- ESTES ANO,SEO ev uwCoOv5 cO: ApoL1 CATIONS AT LOW TEVPE 4 A?vAES -5S#TO-58, 0?.5 A" UviTOEO.E i: T-E TEv:E AATV4E RANGE iS BEv0ND T-*E Liv ?AitONS S*C..N ABOVE
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a a SMB-56 5MB-5T DISASSEMBLYO? VALVE OPEMTOR General: SMB-5T m.sn re ew :r.e rc- :- =n n (Tor ueUnit): ." c e'= ~'= = T. J. '. " 2..e ; 1 ; w eceevew :sa:5.: m ese .. = -. 3 333e -,"s' ~ p-c - 1 ; .: chscssemtie ciecse ::ser,e te w,a ".c,* s,*4*-~ 3.--- g r-e Sv3 5 se s wec: c : cce 4:.:c.,cq cece e 00e2 C^re : 3:. es i -r,--(vD ST -r-- - e we A t n m :se w its u en c:n ocrtm e - 3 %~ ~- a a~r ~ = 0 * - e r .: : : -r.s' tec c :sse ov t e v -
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- CAUTION. Ensure that unit is not under
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- cer oress'Ortue 3
- g before proceeding, if so. the volve must 0;e' 0'C =3 0'",9 s'e?$e DC =1' be in the full open position.
^-w-- C- - Crd 3 n move iceve,. oc =;3 e '2 CAUTION! Declutch Housing is un~-e- "e'Ove crc #ee' wesre oc =c0 A 7e e.e rwe t eese : car t oc =i30 --u--r,~,*e"_.,3,C _m*,r* u spnng iood. WARNING'. SMD 5 dnye sI.eeve locknut u
- " ^
- A Remove cef -
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~
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ee:r g :: ~.ege s.e c =:5 NOTE: f c.s:sse 'o:v :f -.3 co:: e-CLTh l eve Ce:VCh sref e^c 000 c.c. ,t.,e.s.e,_.-.....-.,....--....~.. _y Orc sace de:Vc' sref' oc _3v s s
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- e Q
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a .e., - u.^ - e " - 3 .e,. oc = v.,4' e is oc bb oC =.,., DC = t* : C CC - - ' = - - -Cm =
- n,,3 f roan u it n
D ::se-se' screw c e ese -.sf D Remew *cndeee srch Orc crice
- 4 Ae ~'es e m :*:- Oc =**5
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e~mo -- ~ c e ~v = * ^ 5 ' ~-- - ~ 3~ oc =40 00:0'e' oc =5 ~e'~e0 0 9 : $ccre '~cOse"g ' q'5 = ~ '~ C Rer ese utee ce: rg e :sse. 'e eve enve socfr oc =43 sec '.em 5e ~,,*g,se J v *f =.'.,._=.., s. s = ; f - -, -.3, ,.,,~ ~ ~,a,,,g ~4'.';.c = ~J; - "
- 3 oc =
- 3 *
>e.cw r cr oc =50 es e eg ciesse - .7 980 d 50
- DC *# 7 5"d' 9 D et t ss enve s eese ec =* 20 v :t 9ser ge'er *o"c _51 cae :st-r :: meres-
'~ - oc = 1, =, r st
- C ~ ^ *e
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s.Cn 50ffg oc. 66 t a,e-' eve cwe te:*rg Or r sse-e civ x = 3' 7 Remove solceo esert oc =54 useg JCc'< sC ews $ciroicx nrg DC =* C :*C "'CFCwree+ Qect oc =b $ A Remove gect r Cur'hng CrO"ker oc =6 uscq;::sscrews cecreg oc =c3 C C Decrfg ecCC'et oc =b5 0 Pu!i hollow enve sheff oc = 55 *o. werd ceCIutCo end cod emove $Csrt- 'ox nng oc =106 O Remove dedLtCh housirg oc =2
SMB-5 & SMB-5T l0 REA55EMBLYOFVALVE O?ERATOR ) D Checs cre*me:C'e D:nc^ Cnc $*C't NOTE: De:vC" SmC* m.5 Oe 5 0 e0 f 0' Cf 0De' 5B'm1 wi'm key 5eO* 40: ag
- ga 5.ce Of Of Ue ni :
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- =0 e
.>C :44 C^C C'OD OF DeO*'"g *rO9 E Re rStOli decutCn nov$eng f:gn'e* 5e' 5C'ew wO' e*C ta$w'e *Cf CO*"iCge COO DeOn"; mOv*?inc b'CChe' C5-( gerere deri b P'5?O4 m,% ,'#',,-,'*5' Se"~,*5 ^~ ^' "f*"* c "* ~ 5e - O'y DCS = $ = $ 5 C e C': 0 3 "C '" OCI"C' OO #50" CEC # ' u ?'eOO
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$@ OC = OC :,,, r w a C' 45' wO5Fe' *1 OgOrSt 50tegs t*C' geO' Dwt;* SDOte* DC :47 '5 C"O QCM5 X 43 O Tr'eOO CO'*tCOe 5'e~ n t DC 46 DCCe A 5Dhee5 C". Onve 5"C Cac NOTE: E 1, re *O' SC e a-te' O' ~ u O**O OeO*'*g CO'".0ge s'e* DC :4 5 Chve ShC ' geO' 09C' OwS" Chve 5"Of! gO5ke'$ C'e r5*0de0 05 *e'.y e intO u it fro Cepg*:n eac n 3.e g, 7pm eye; g,neg g;3733g, g C'Soce Oeco O :0 "cOe wO'm C5 6 Mou'!bec'egs D:5:C4 Cnc :C7 on DC*55 0' 90 5"'*5 ~ "5' D' 5e-04 yin'OrO[5nc h09Cw"ee' SSC't Cf'O pcCS DC 240 CSC I*"C E^I 'O OVE** **U CO O ~ tr5'Cd C55e'*O'y ir!O v*if ,4" DeCong O* On e 5"O A l*SO" "OllOw Onve 5"Cf' DC ~55 4-CA ir$f0!! cec L C*' 5"C ' DC 23~' C *~'"
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t a 4 4 SMB-5 & SMB-5T REASSEMBLYOF VALVE OPERATOR I
- ~
3 3, f*,,,*,'0**? 05+CeOOwe Crc "5?OJ WARNING!$MO $ cnve 5 eeve oCur f rC5 u " OL 5.* g ?'"L,5' O C C O *e ' C 55e" D!y OC lef t hCnd thre0d5 OnC must De 'O*O?ec L (ThrustUnitOnlyh =jy^='6'J5c'J;ge "" 0 c 3
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- Res. G ELECTRO mom E M
ABTENANCE x { NSTRUCTION w A SCHEDULED MAINTENANCE PROGRAM DOMESTIC STATIONARY POWER UNITS WITH TURBOCHARGED ENGINES INTRODUCTION
- 5. Operating load limitations will be adhered to.
This Maintenance Instruction provides average
- 6. Torquing procedures contained in this M.I. will recommendations which should ensure satisfactory be followed for new engines and newly installed engine operation and economical maintenance cost replacement assemblies.
where average load factors and average climatic conditions are encountered. It is intended to serve as a guide when establishing maintenance schedules This Maintenance Instruction is disided into three that will meet the particular requirements of sections. The first section is maintenance performed individual operations, and planned economic life of before and after each start, the second section is the engine and associated equipment. performed on a " calendar period" basis. and the third section is performed on a" running time" basis. These recommendations are based on the following Because operating requirements for this equipment conditions: can sary from standby. to periodic, to continuous usage the maintenance procedures must be
- 1. Ettel oil used will meet the specifications of modified to suit individual requirements.
Maintenance Instruction 1750. REFERENCES l 2. Lubricating oil used willmeet the specifications of Maintenance Instructions 1760 and 1764 and will be changed at the intervals specified in this Abbreviations are used in this instruction to M.I. reference publications that contain information related to maintenance. The following examples are
- 3. Engine coolant used will meet the specifications provided to aid in understanding the abbreviations in Maintenance Instruction 1748.
used. ~4. Lubncating oil filters will be of a quality equal EMM means Engine Maintenance Manual to original equipment and will be changed at the OM means Operating Manual intervals specified in this M.I. M.I. means Maintenance instruction l This bulletin is revised and supersedes previous issues of this number. Areas of change are indicated by vertical bars. c.u w n
M.I.1720 CAUTION ~ if the only available diesel fuel does not meet the sulfur content. distillation recosery. or sediment and ash specifi-cations contained in M.I.1750, observe the schedules and cautions given in M.I.1725. Scheduled Maintenance Program - Export Stationary Power Units With Turbo. charged Engines. The use of good quality, high alkaline reserve lubricating oils is strongly recommended where only high sulfur fuels are available for use. NOTE The following recommendations are applicable to stationary power units used for emergency power
- 1. Unit should be operated at least once a week.
- 2. Operate unit at idle for a sufficient period of time to allow coolant temperature to stabilize at 49 C(120 Fj or
- higher, 11 minimum temperature cannot be obtained at idle speed gradually apply load until temperature stabihzes.
- 3. Operate unit at full speed, fullload for a minimum of one hour.
BEFOWE!EACKSTART (NON-AUTOMATIC START UNITS) LUBE OIL SYSTEM Check for lube oil in pan and strainer housing. EM M. M.I.1760 l Add oilif required. I If engine requires prelube.rechecklube oil NOTE levelin pan as a quantity will transfer to external system (cooler, filter, strainer and piping). Add oilif required. COOLING SYSTEM Check coolant level. Add coolant if OM, M.I.1748 i necessary. NOTE Do not continue to operate engine requiring periodic addition of coolant. Check for possible coolant leak and repair if required. FUEL SYSTEM Check fuel supply and open fuel supply valves. OM Prime system. OM 2
4 M.l.I'2s ~ BEFORG EACH STARK (CONT'B) (NON AUTOMATIC START UNITS) AIR SYSTEM Drain condensate. ~ OM ~ Check system pressure. OM Check oil suppiy in air line lubricator. EMM ENGINE I the running " latched" position. Check os erspeed trip les er OST to ensure it is in EMM Open cylinder test vah es and manually bar over if fluid discharge is obsersed from any cylinder. find engine one complete revolution, check for the cause and make necessary repairs prior to liquid ejected from s alves, and close test valves, starting the engine. Prelube engine it unit has been shut down for EMM. Unless equipped with immersion heater oser 48 hours. system. Check racks. EMM. Move injector control lever to check for l Ensure exhaust stack is open. GOVERNOR Check oil lesel. Add oil if necessary. EM M. M.I.1764 NND'M (NON AUTOMATIC START UNITS) INSPEdT FOR LEAKS Cooling system Fuel oil system Lube oil system .i Exhaust system Air system LUBE OIL SYSTEM Check lube oil level in pan with engine at idle. EMM i Check lube oil pressure at engine. OM COOLING SYSTEM l Check operation of external cooling system. OM FUEL SYSTEM i Check for proper fuel pressure. OM j -3
M.I.1728
- ISO 4EDIATELY AETER EACH START (CONTDP:
(NON AUTOMATIC START UNITS) ENGlWE Check cylinder test valves for leakage. Tighten EMM if required. Check handhole cosers for leakage. Tighten if EMM veguired. Check air box drains for proper operation and EM M. If drains are kept closed. drain es ery 4 hours. stean. if necessary. j Check for unusual noises or sounds. or any I fault indications (lights or alarm), as provided. PERFORM THE FOLLOWING ITEMS ON CALENDAR TIME BASIS DAILY (NON-AUTOMATIC START UNITS) INSPECT FOR LEAKS Cooling system Fuel oil system Lube oil system Exhaust system Air system LUBE OIL SYSTEM Check lube oillevelin pan. Add oilif required. EM M, hi.l.1760 I COOLING SYSTEM Check coolant lesel. Add coolant if necessary. OM. M.I.1748 NOTE Do not continue to operate engine requiring periodic addition of coolant. Check for possible coolant leak and repair as required.. FUEL SYSTEM Check fuel supply. OM AIR SYSTEM Drain condensate from lines and tanks. GOVERNOR Check oil level. Add oil if required. EM M. M.I.1764 4
l 7 N1.1. IG iffEEKLY (AUTOMATIC STARTS UNITS) ENGINE SHUT DOWN LUBE OIL SYSTEM Check for lube oilin pan and strainer housing, E M M. M.J.1760 l Add oilif required. I external sy stem (cooier, filter. strainer and NOTE If engine requires prelube. recheck lube oil les el in pan as a quantity will transfer to piping). Add oilif required. COOLING SYSTEM Check coolant level. Add coolant if necessary. OM. M.I.1748 ~ NOTE Do not continue to operate engine requiring periodic addition of coolant. Check for possible coolant leak and repair if required. FUEL SYSTEM Check fuel supply. OM P AIR SYSTEM Drain condensate. OM Check system pressure. OM Ch'eck oil supply in air line lubricator. EMM ENGINE Prior to maintenance start. check overspeed EMM trip leser OST to ensure it is in the running " latched" position. Prior to maintenance start open cylinder test if fluid discharge is observed from any cylinder. find salves and manually bar over engine one the cause and make the necessary repairs prior to complete resolution. check for liquid ejected starting the engine. from vakes and close test valves. Prelube engine if unit has been shut down for EMM. Unless equipped with immersion heater over 48 hours. system. Check racks. EMM. Mose injector control lever to check for freedom of moument with no binding ofinjectors. I " stack is open. Prior to maintenance start, ensure that exhaust 5-
s ' M.I.1728 WQEKLi((CONTD) ENGINE Sl!UT DOWN GOVERNOR Check oillevel. Add oilif necessary. EM M, M.I.1764 ENGINE RUNNING ' 'NSPECT FOR LEAKS Cooling system Fuel oil system Lube oil system Exhaust system Air system LUBE OlL SYSTEM Check lube oil level in pan with engine at idle. EMM Check lube oil pressure at engine. OM ICOOLING SYSTEM Check operation of external cooling system. OM FUEL SYSTEM Check for proper fuel pressure. OM ENGINE Check cylinder test vah es for leakage. Tighten EMM if required. Check handhole covers for leakage. Tighten if EMM required. Check air box drains for proper operation and EMM. If drains are kept closed, drain es ery 4 hours. clean,if necessary. I Check for unusual noises or sounds, or any fault indications (lights or alarm), as provided. n-e LUBE OIL SYS1 EM Take sample for analysis. The services of a competent laboratory should be used to monitor the suitability of the oil for continued use accordine to M.I. I'760. I LUBE OIL CIRCULATING PUMP AND MOTOR (Where Used) Check for proper operation. OM -
i l ? l N1.1.1 3 < curmr_ asnerst enmarrn IMMERSION HEATER (Where Used) Check for proper operation. O NI ,w AUXILIARY TURBOCHARGER FILTER (Where Used) Replace elements. ON! IN-LINE LUBE OIL STRAINER (Where Used) Clean strainer screen. LUBE OIL CIRCULATING PUMP AND MOTOR (Where Used) Inspect and clean with dry air. Replace brushes. If equipped with DC motor. Remose and clean check vahe. LUBE OIL FILTERS Change filter elements. EN1N1. Unless the 1400 hour filter change has occurred first. Clean tube oil strainer. E NIN1. Fill strainer housing with oil before starting engme. TURBOCHARGER OIL FILTER Replace filter elements. ENiht. Unless 1400 hour filter change has occurred first. SOAK BACK OIL FILTER (Where Used) Replace filter element. EN151. Unless 1400 hour filter change has occurred first.
M.I.1728 l 'nVEindfEARICONT*D% ELECTRICAL CONTROL CABINET AND ASSOCIATED EQUIPMENT (Where Used) Check operation of protective devices. Protective switches relays. and alarm mdicators. Visually inspect and clean: Voltage regulator. M.I. 4523 or appropriate manufacturer's voltage regulator manual. All relays, contactors, and circuit breakers. OM Remose circuit breakers from compartments. Clean insulators. Lubricate linkage bearings. Check operation. COOLING SYSTEM Check operation and setting of engine water temperature control (s). Check torque on flexible pipe coupling bolts. Take cooling water sample for lab analysis and M.I.1748. Unless 2000 hour sampling has occurred corrosion test. first. LUBE OIL COOLER 1 Check temperature differential between tube oil OM and M.I. 927. Clean cooler. if necessary. and cooling water into engine. M. YEARS FUEL FILTERS Change engine mounted filter elements. EM M. Unless 2000 hour filter change has occurred first. . Clean or replace suction strainer element. OM. Unless 2000 hour maintenance has occurred first. ENGINE PROTECTOR l Replace or recondition and requalify. M.I. 259 or M.I. 260. Qualify on test stand after renewing springs,"O" rings, and diaphragms. LUBE OIL CIRCULATING PUMP AND MOTOR (Where Used) Replace. Replacement can be EMD Unit Exchange. O .g.
M.I.17$ EVERY.THREEifVEARE COOLING SYSTEM THERMOSTATIC VALVE Replace -O" rings and thermostatic elements. EM M. M.I. 581 COOLING SYSTEM PRESSURE CAP Replace. Unless 16,000 hour replacement has occurred first. E FREQUENCY GENERATOR COUPLING SPIDER (Where Used) Replace. Unless 16.000 hour replacement has occurred first. ENGINE Replace top deck cover seals and check latches. EMM. Unless 8000 hour replacement has occurred first. Replace c.s linder head grommets, inlet and EM M. Unless 16.000 hour cylinder assembly outlet seals. and lower liner seals. replacement has occurred first. MAIN GENERATOR Remove bearing coser and inspect for grease Unless 48.000 hour lubrication has occurred first. contamination, excessive wear, and over-M.I. 3327 or M.I. 3328 for EMD generators if heating. Apply new grease. generator is other than E M D. refer to manu-facturer's manual. i M,1.-1728 PERFORM THE FOLLOWING ITEMS ON RUNNING TIME BASIS AFTERDIE FIRsE 350480UR$OFOPERATION 1 ENGINE NUT AND BOLT TIGHTNESS CHECK Check that the following nuts and bolts are tightened to the corect values specified in the E M M. Cylinder head crab nuts. All except those equipped with plate type crabs. Exhaust manifold flange bolts. Cylinder liner water inlet line nuts and bolts. l Head frame to crankcase bolts. Turbocharger to air duct bolts, aftercooler to I and turbine inlet link bolts. air duct bolts, and air duct to crankcase bolts. 1 Engine mounting bolts. 1 Miscellaneous nuts and bolts. and all piping connections. l ENGINE Inspect air box. EMM - Inspect crankcase. EMM i inspect crankshaft and connecting rods. EMM Inspect pistons and piston rings. EMM Inspect cylinder liners. EMM inspect cylinder head mechanism with engine EMM idling and at operating temperature, inspect engine fuel lines and connection for EMM leaks. 1 Inspect engine water system for leaks. EMM t FUEL FILTER Check fuel pressure gauge with engine at rated On units where gauge is connected to filter input RPM. side, change filter elements if pressure is greater than 345 kPa (50 psi). On units uhere gauge is connected on filter output I side. change filter elements if pressure is less than 83 kPa (12 psi). _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. ..........a
4 + r ~ f Nt.l.I'25 LUBE OIL FILTER Check lube oil pressure at filter input with ' ChanFe filter elements if input pre <sure a gre.ner engine at rated RPM. than 172 kPa (25 psil.- e s ENGINE PROTECTOR Check operation. E M M. M.I. 259 or M.I. 260 SOAK BACK PUMP AND MOTOR Check operation. With the engine shut down and 30ak back pump motor running. remose left rear handhoie cos er and check oil flow through gear train. Observe camshaft bearings. If tube oli tious from camshaft bearings with soak back pump running and engine shut down. inspect turbo filter outlet check valve for proper operation. ENGINE AIR FILTER - CYCOIL T.YPE (Where Used) Check oillevel. OM. M.I. 442 ENGINE AIR FILTER - PANEL TYPE O!L BATH (Where Used) Check oillesel. OM. M.I. 440 ENGINE AIR FILTER - PAPER OR FIBERGLASS TYPE (Where Used) Check indicator. If tripped, take manometer OM readings and replace elements if necessary. HEAT EXCHANGER Inspect corrosion zine electrodes. EMM g. w.w.,. SD WUkN ' LUBE OlL FILTERS Change filter elements. OM Clean lube oil strainers. EMM. Fill strainer housing with oil before starting engine.
c M.I.1728 - e, IA'L2104.il'i'lil'181dif(?i'ld.191 TURBOCHARGER OIL FILTER Replace filter element. Filter elements must be of a quality equal to original equipment.The interval of change for turbocharger and soak back filter elements is influenced by load factor, kind of lubricating oil, type of operation. climatic conditions. and maintenance of main lube oil filters. SOAK B ACK OIL FILTER (Where Used) Replace filter element. Same as abose. AUXlLIARY TURBOCHARGER FILTER (Where Used) Replace elements. EMM PROTECTIVE DEVICES Check operation. OM, EMM n-se e e FUEL FILTERS Clean or replace suction strainer element. OM Change engine mounted filter elements. EMM. Use only elements equal to original equipment. COOLING SYSTEM Take cooling water sample for lab analysis and M.I.1748. Unless the yearly sampling has occurred corrosion test. first. ENGINE AIR FILTERS - CYCOIL TYPE (Where Used) Change oil. Drain and fill only. OM, M.I. 442 ENGINE AIR FILTER - PANEL TYPE i Olt BATH (Where Used) - Change oil. Drain and fill only. OM, M.I. 440 ENGINE AIR FILTERS - PAPER TYPE (Where Used) Take manometer readings. Replace elements if necessary. NOTE Take manometer readings whenever the annunciator light indicates a plugged filter. 1
9 .? \\1.1. 17 3 pdhelgh3gygg3)) ENGINE AIR FILTERS - FIBERGLASS TYPE Replace eiements. OM STARTING MOTORS (Electric) Blow out with dry air. EMM ENGINE Inspect air box. EMM Inspect crankcase. EMM Inspect crankshaft and connecting rods. EMM inspect pistans and piston rings. EMM Inspect cylinder liners. EMM Inspect cylinder head mechanism with engine EMM idling and at operating temperature. Inspect engine fuel lines and connections for EMM leaks. Inspect engine water system for leaks. EMM EVERY,4000 HOURS EXHAUST SYSTEM Remove exhaust manifold-to turbocharger E M M. Clean screen and trap box. Obsen e recommen-adapter assembly. dations found in EMM concerning checking for cracks. TURBOCHARGER EXHAUST DIFFUSER Visually inspect for evidence of warpage or EMM damage. EDUCTOR TUBE (Exhaust Stack Mounted) Inspect for carbon deposits and clean, if EMM necessary. a M.I.172S' T EVERY4000 HOURS (CONT'01 l LUBE Oll. SYSTEM Change engine oil. E M M. Evaluation of engine and oil condition - should dictate the frequency of this item. Type of service. type of oil, quality of filter elements, and condition of engine willinfluence the frequency of oil change. Clean oil pan. EMM Clean filter housing. EMM Clean oil suction screens. EMM Clean seasenging oil screens. EM M. Fill strainer housing with oil before starting engine. ENGINE Check pressure drop across af tercoolers; oil EM M. Clean air passages if necessary. bath filter equipped engines only. Check exhaust manifold base flange bolts for EMM proper tightness. MAIN GENERATOR If equipped. inspect brushes and collector rings. M.l. 3327 or M.I. 3328 for EMD generator. If Replace brushes if required. generator is other than EMD, refer to manu-facturer's manual. If equipped. reserse polarity of collector rings. GOVERNOR Change oil. EM M. M.I.1764 Lubricate linkage mosing parts. EMM Lubricate gosernor synchronizing motor, EMM motor bearings. IWhere used.) 7-M.l.178 - ~ lVi41h'di'M*IHell]IM ENGINE NUT AND BOLT RETOROUING C.slinder head crab nuts. Follow retorquing procedures if called for in the EMM. Main tube oil and piston cooling oil pump shaft EMM nut. Head frame to crankcase bolts. EMM Turbocharger to air duct bolts. aftercooler to EMM air duct bolts, air duct to crankcase bolts, and turbine inlet Imk bolts. Engine mounting bolts. Miscellaneous nuts and bolts. and all piping connections. ENGINE Replace top deck cover seals and check latches. EMM Qualify injectors. EMM Check injector timing and injector rack length. EMM Check engine speed. EMM Check overspeed trip. EMM Remove and clean oil separator element. EMM Check pressure drop across aftercooler: paper EMM. Clean air passages if necessary, and fiberglass filter equipped engines only. Inspect crankshaft damping device. EMM Remove. clean, and inspect replace if EMM necessary: Soak back check valve in the turbo filter inlet. Soak back oil pressure relief vahe in the soak back filter head. Soak back filter bypass valve in the soak back filter head. Turbo oil filter check valve in the turbo filter head..
m. ~ M.I.1728 EXHAUST SYSTEM Inspect manifold sections for possible cracked EMM leg baffles or expansion joints and replace. if necessary. mal [ GENERATOR AND BRUSHLESS ' EXCITER (If Equipped) Clean and usually inspect. M.I. 3327 or M.I. 3325 If equipped. replace collector ring brushes. M.I.3327 EXTERNAL EXCITEP Clean and sisually inspect. M.I.3706 Inspect and replace brushes when required. Rep. ace brushes in sets only. ENGINE AIR FILTER - CYCOIL TYPE (Where Used) Change oil and clean sump. OM. M.J. 442 Check operation of vartflow vahes. Check condition of hoses. ENGINE AIR FILTERS - PANEL TYPE OIL BATH (Where Used) Change oil. Clean sump and filter media. OM. M.I. 440 SOAK BACK PU,MP MOTOR (Where Used) Inspect and clean with dry air. M.I.4101 Replace brushes. M.I.4101 COOLING SYSTEM Inspect and perform pressure test. OM Replace pressure cap if defective. OM LUBE Ott FILTER Remose internal oil filter bypass valve; clean, M.I.926 inspect. and test. (Where used.) LUBE OIL FILTER AND OIL COOLER + BYPASS VALVES (Where Used) Remove; clean, inspect, and test. EMM O f e ? A M.I.1 3 [NL%IifQidn191 STARTING MOTORS (Air) Disassemble. clean, inspect and lubricate. EMM STARTING MOTORS (Electric) Disassemble.~ clean, inspect and lubricate. EMM Inspect brushes and replace if necessary. EMM EVERY,.TE,000 ffOURS FUEL PUMP Replace coupling spider. SOAK BACK PUMP (Where Used) Replace coupling spider. FREQUENCY GENERATOR (Where Used) Replace coupling spider. COOLING SYSTEM Replace pressu e cap. (Where used.) OM Inspect filler neck for damage. Replace if OM damaged. (Where used.) ENGINE Replace cylinder assemblies. EMM Replace injectors. EM M. Replacement should be E M D l' nit l Exchange or equivalent. l Inspect and qualify connecting rod bearings. EMM Inspect and qualify piston cooling tubes. EMM Check rocker arms. rocker arm bushings, and EMM cam followers. Check lash adjusters. EMM Check exhaust valse timing. EMM Inspect lower liner inserts, and replace if EMM required. t I - 17
9-4 ENGINE Install new thrust collars. EMM install new lower main bearings. EMM Replace water pump seals and all worn parts. EMM TURBOCHARGER Unit Exchange. EM M. Average individual operating conditions will determine frequency. TURBOCHARGER-TO-FlLTER AIR DUCT (Where Used) Replace. COOLING SYSTEM Replace flexible coupling seals. LUBE OIL COOLER i Inspect. clean, and test. M.I.927 l HEAT EXCHANGER Inspect. clean and test. EMM I Cl u t tWN*M*1 Hellu fd GOVERNOR 1 Replace. Replacement should be EMD Unit Exchange or -l equivalent. j GOVERNOR BOOSTER SERVO (Whero Used) Disassemble, clean, inspect. and replace O-ring EMM seals. FUEL PUMP l Replacc or recondition. M.I. 4110. Replacement can be EMD Unit .l Exchange. SOAK BACK PUMP AND MOTOR (Where Used) I-Replace or recondition. M.I. 4101 M.I. 4110. Replacement can be EMD Unit Exchange. ;
,t + e +- a. ENGINE Replace vibration damper or harmonic EM M. Replace with gear type damper. balancer. (Where used.) l Replace or recondition oil pumps. EMM. Replacement can be EMD Unit Exchange. l. Remove oil pressure relief valve; clean, inspect. EMM and test. Replace lower liner insens. EMM Inspect injector control linkage. Replace links. seals. and bearings,if required. MAIN GENERATOR Remove bearing coser and inspect for grease M.I. 3327 or M.I. 3328 for EMD generators. If' contamination. excessive wear and overheating. generator is other than EMD. refer to manu-Apply new grease. facturer's manual. ENGINE Replace crankshaft damping device. EM M. Replace with new or reconditioned gear type i damper. If already equipped with gear type damper. recondition and requalify. EVERY 98,000 HOURS i ENGINE l' nit Exchange. GENERATOR Unit Exchange. j A Service Department Publication E ec c#ot ve D es on Of Geaera *.terors La Gra ge. i vo i 605:5 i Litho in U.S A - 19
o 'p 4ePP-9 \\ l ACTION - Taylor, IE o cag'o UNITED STATES Cys: Dircks NUCLEAR REGULATORY COMMISSION e E WASHINGTON D.C.20555 ehm l'/ Ste'lo M ogue o December 31, 1985 k * ***
- p
'rdJ Denton GCunningham orrictorTHz p/# Ankrum, IE stensTAny Goldberg, IE Philips MEMOPANDUM FOR: William J. Dircks, Executive Director for Operations FROM: amuel J. Chilk Secretary
SUBJECT:
STAFF REQUIREMENTS -- SECY-85-119 - " ISSUANCE OF PROPOSED RULE ON THE IMPORTANT-TO-SAFETY ISSUE" The Commission, by a vote of 5-0 has disapproved SECY-85-119. The Commission agrees that the proposed rule does not adequate-ly differentiate nor clarify the terms "Important-to-Safety" (ITS) and " Safety Related" (SR). The Commission continues to believe that it is necessary to resolve the apparent confusion surrounding usage of the term "Important-to-Safety". The Commission directs you to resubmit a proposed rule concerning ITS. The Commission believes the following guidelines should be followed in redrafting the proposed rule. (A]Concerning the ITS definition: 1. If a term such as " normal industry practice" is to be V applied in the definition, that term also needs clarifica-p tion. For example, how is normal industry practice de-termined? l ,h 2. Safety-related is a subset of ITS. .m ~ wW T M 3. ITS refers to those systems, structures, and components at M '* 'W da# a specific plant for which the staff has explicitly (4 required the application of some specialized treatment in d4 i Sg/\\ that plant's licensing documents or to which certain r generic regulatory requirements have been added. Further-W- is// Mg more, the requirements imposed on those systems, struc-tures, and components determined to be ITS are only those y f which were specifically required in the plants' cufrent g licensing documents or in the generic regulatory ':equire-g ments. 4. Specialized treatment is not restricted just to'OA/0C pa requirements. It includes, among other things, codes, standards, missile hazard prevention requirements, fire r protection requirements, etc. revdCM.CDO D a to... l.~...~.E.b.... / M-4g n =.... 3 B......... s
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A specific listing of safety-related equipment is required.f e'j to be maintained. A specific listing of ITS equipment is not required to be maintained. [ Concerning the process for making changes to the commitments associated with items ITS or for new determinations of items ITS: 1. It is not the intention of the rule to add new require-ments, to modify existing requirements, or to broaden the existing scope of the Commission's requirements. 2. As with all systems, structures, and components, appropri-ate backfitting procedures will be used in all instances y where new requirements are proposed by the NRC staff. 3. Systems, structures, and components that will be called ITS for NTOLs will be determined during the normal licens-y ing process. 4. Formal guidance should be included on how determinations Q( g'4,pd of items ITS will be made, including criteria to be used '\\ 8, to determine ~on a plant-specific basis what equipment is ITS. g pf-it) Concerning the review and amendment of existing regulations and V other regulatory documents: f 1. It is expected that 10 CFR will be reviewed to determine if use of the terms " safety-related" and "impor-V tant-to-safety" is appropriate and consistent with the new definition. If not consistent, staff should propose o appropriate modifications to 10 CFR. 4*/c4*f m M b
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s g'. .k addition of a formal definition to Part 50 of 10 CFR. 2. The Commission suspects this will require more than the 3. The staff should inform the Commission of the results of g its review. In addition to the above guidelines, Commissioner Asselstine gwouldappreciatestaffconsiderationofthefollowing: 1. A rulemaking defining "important to safety" that would allow additions to or deletions from that set based on new y information or analyses without going through the full% 6 I f ; M q F %l }*'* ' N gamut of the backfit rule. g ;u & f,cc
',.. ?.. . $+ f I Cdf hd} 2. A rulemakina defining "ITS" for fut_ure.ylants so that CebnWion and uncertainty do Ho'T~ persist) and so that stan3ardization can be enhanced. ~ (EDO) (SECY SUSPENSE: 3/21/86) Copies: Chairman Palladino Commissioner Roberts Commissioner Asselstine Commissioner Bernthal Commissioner Zech Commission Staff offices S
r_.m;t ~ it Q f"'%,, nay 22, :sse POLICY ISSUE srcr-se-164 (Notation Vote) The Commissioners ror: From: Victor Stello, Jr. Executive Director for Operations Subiect: PT!0 POSED RULE ON THE D'.PORTANT-TO-SAFETY ISSUE To obtain Ccmission approval of proposed definitions of Purcose: safety-related, important-to-safety, facility licensing documents, and normal industry practice and cbtain additional Commission direction on the rulemaking option to be followed. This paper covers a significant policy issue. Cateaory: This paper is the first step in implerentina the Co mission's' Issue: decision to initiate rulemaking In the Matter of Lona Ishne d Lichtina Company (Shoreham Nuclear Power Station, Unit 1) CLI-64-9, 19 NRC 1325 (June 5, 1984). In the Shoreham licensing decision (CLI-84-9, 19 NRC 1323, Backaround: June 5, 1984) the Commission directed the staff to prepare a rulemaking package to resolve the issue concerning the definition and usage of the terms " safety-related" (SR) and "important-to-safety" (ITS). Subsecuent to this Commission direction, the Utility Safety Classification Group petitioned (October 30,1984) the NRC to define these terms in its regulations. In response to the Comission direction, on 20, 1984, the staff provided an information paper, December SECY-84-476, to the Comission concerning the steps the staff was taking to implenent the Comission's directives in the area of equipment "important-to-safety." At that time, the staff informed the Commission that, af ter further discussion with interested industry groups, the staff was planning to go forward with a Notice of Proposed Rulemaking to the Commissien i for its decision in early 1985. On January 31, 1985, a meeting was held between representatives of the Atomic Industrial Forum (AIF), the Utility Safety Classification Group (USCG) and the NRC staff concerning the important-to-safety issue. The staff and the industry representatives agreed that the interpretation of the term n CONTACT: Brian K. Grimes IE ~D D 0 f @ 49-29696
1 .a v., s e-C \\ "important-to-safety" in General Design Criterion-1 tc 10 CFR S0, Appendix A, and elsewhere ir Part 50, coly needed to be clarified to reflect the statement of past practice adopted by the Commission in the Shoreham decision. On April 5, 1985 the staff presented the Commissien with a proposed rulemaking pachace (SECY-E5-119) which eroodied the agreed upon interpretation, i.e., normal industry cractice is acceptable for important-to-safety items that are not safety-related unless otherwise specified in licensing documents. On December 31, 1985, the Office of the Secretary issued a Staff Requirements Memoranoum which stated that the Conmission had disapproved SECY-85-119, and that the preposed rule did not adequately-differentiate nor_ clarify the terms important- + to-safety and safety-related. Additionally, in~ the SRM the 4 Commission requested the sta#f to address or clarify particular aspects of the issue, with Commissioner Asselstine reauesting. that two additional concerns be addresseo. Discussion: The December 31, 1985_ Staff Requirements Memorancum (SRM) directed the staff to resubmit a revised preposed rule based The staff is on the guidance provided by the Commission. providing a revised Commission Paper for the Commissien's consideration. This paper provides revised definitiens of important-to-safety and safety-related, defines rormal industry practice and facility licensing documents, and renuests Commissien. approval of these definitions _ prior to developing tne proposed rulemaking package. As the staff understands the SRM, there are two basic issues involved: (1) what equipment should be classified as ITS,'end (2) what requirements are imposed on-this class of equipment. The staff has grouped the Commission's recuests, cuidance, and l questions that appeared in the SRM into five general recuests as listed below. The staff believes that the two basic issues-have been addressed within the responses that follow. 1. Clarify the definitions of "important-to-safety" and " safety-related." 2. Define " normal industry practice." 3. Develop criteria for determining what equipment is ITS on a plant-specific basis. A. Review the usage of the terms ITS and SR in 10 CFR for consistency and prcpose appropriate mcdifications if the usage is not consistent.
^ 5. If any new reouirements are imecsed, the appropriate. backfitting procedures will be used. A discussion of the staff's response to and recommendation on each of these recuetts follows: 1. Clarify definitions of Important-to-Safety ano Safety ; elated The Ccmmission's guidance contained in the SRM concerring clarifying the definitions of " safety-related" and "important-to-safety" keyed on clarifying that " safety. related" is a subset of "important-to-safety" and the-concept that the staff had recuired some " specialized treatment" in the plant's licensing documents for eouipment "important-to-safety." ~ To stress the fact that " safety-related" is a subset of "important-to-safety," the staff has revised the definitien of " safety-related" to specifically state "... safety-related is a subset of important-to-safety...." This action divides the general category of important-to-safety into two subsets, fs important-to-safety / safety-related (ITS/SR) ano important-( to-safety /non-sefety-related (ITS/NSR). x A literal interpretation of the SRM would result in the following definition of important-to-safety: "Important-to-safety" when referring to structures, systems, and components means those structures, systems, and components for which the NRC staff has reouired the application of some specialized treatment in the facility licensing documents or generic regulatory requirements. Requirements imposed on important-to-safety items are only those which were specifically required by inclusion in the facility licensing documents or in generic regulatory requirements. In order to assess the SRM guidance concerning the use of " specialized treatment," the staff reviewed the Final Sa'ety Analysis Reports (FSARs) and selec.ted portions of the cther licensing documents for two' nuclear power plants, Rancho Seco and River Bend. The purpose of the review was to determine what items that the staff traditionally consifered "important-to-safety" would not be encompassed as such using the " specialized treatment" criteria. For this review the \\
B staff considered specialized treatment to include references in the licensing documents to codes, standards, seismic design or cualification provisions, missile hazard ;reventicn provisions, fire protecticn provisions, special calibration, testing, maintenar.ce or inspection provisions, and any quality control or quality assurance crevisiens. Documents submitted by the licensee in succort of the applicatien for an operating license were considered the facili ty licensing documents, i.e., documents submi tted after the license was issued were not considerec unless l they were a condition of the license. For Rancho Seco, the integrated centrol systen, and the rain turbine trip and control systems are examples cf systems that are described in the FSAR but for which no "specializec treatment" is specified in the FSAR or the cther licensing documents reviewed. The staff believes these systems are clearly important-to-safety as their f ailure would cause transients that would challenge the plant's safety-related systems. For River Bend, the feedwater centrol system and the red control and information system ere examples of systems or components described in the FSAR but for which no " specialized treatment" exists in the FIAP or the other licensing dccuments reviewed and which the staff believes are important-to-safety. Based on this review the staff believes the guidance in the SPV, if strictly followed, would not include systems that the staff considers "important-to-safety" nor would it make clear that the Ccomission expects that normal industry practice would be followed for these systems The when " specialized treatment" has not been specified. staff, with its limited resources, does not review every detail of an application and assure that the appropriate treatment is given to each ITS/NSR item. The staff review presumes that a body of good practice exists for plant structures, systems and components whether or not explicit specialized treatment is specified in the facility licensing documents. Under this narrow definition of ITS proposed by the SRM, the systems listed above could be excluded frem the category of ITS and therefore be beyond the requirements of the ceneral design criteria (10 CFR 50, Appendix A). This could weaken \\ the basis for taking action on safety cencerns for cry eouipment for which specialized treatment is not required in facility licensing documents.
y . p ,( As an alternative to the SRM definitien, the staf# preccses the following definition of "inportant-to-safety:" x ,(_"Importart-to-safety"jWhen referring to structures, systems, and components means those structures, systems, and components that are described in the facility licensing documents and that provide reasonable assurance that the facility can be operated without undue risk to the health and safety of the puolic. The staff further would define facility licensing documents for the staff definition as follows: L'ffacility licensino documents"Jare those documents that comprise the apolication and associated proceedings; NRC regulations; Final Safety Analysis Report; NRC orders; license conditions; and written licensee commitments to the NRC. The staff's approach encompasses all the eouicment, information, and commitments that served as a basis for issuing an operating license or a construction permit and for allowing continued operation or construction. There is, however, the possibility that for scme plants not all equipment that the staff presently considers ITS Uncer is described in the facility licensing documents. the NRC's current regulatory requirements, a recuirerent by the staff to add a descriptien to the FSAR for this equipment would be subject to a backfit analysis. The Commission should note that although increased emphasis is being placed on ITS/NSR eouipment because of recent operational events, the NRC inspection program has been and centinues to be primarily focused on ITS/SR equipment due tc resource limitations and the presumption that a body of good practice exists for plant structures, systems and The staff does not foresee a change in the components. level of inspection effort expended on ITS/NSR ecuipment solely as a result of this rulemaking. 2. Define Nornal Industry Practice The staff considered two options in responding to the Commission's reauest to define " normal industry practice:" fai using the ATWS CA guidance previously developed for f ~'g "important-to-safety but not safety-related" equipment or -( ) (b) develop new guidance which generally describes the 's
. io staff's interpretation. The staf# censidered tre ATWS CA guidance as it is reasonably specific and already applies F wever, to scme eouipment falling in the ITS/MSR category. } the staff determined that the application of the AT',iS guidance to the entire ITS/NSR category may constitute a l The staff backfit for some equipment at some plants. believes that a substantial effort would be reouirec t develop a suitable backfit analysis and corsicers it doubtful that such an analysis would support the imcosi*icn of the guidance. Therefore, the staff concluced that such an imposition of the ATWS QA guidance on all :TS/NSP 'ters would be inappropriate. As an alternative, the staff proposes the following cefi-nition of " normal incustry practice:" 1 -\\" Normal Industry Pract_ ira"! when referring to structures, systems, and components impcrtant-to-safety but not safety-related (ITS/NSR), means that these items are: (1) designec, constructed, operated, inspected, testec, and maintained in accordance witb applicable nuclear O or non-nuclear codes and standaros, and vendor-or manufacturer-supplied information or recem- .V mendations; (2) replaced with parts assured to be of at least the same cuality as the original parts through inspections, tests, evaluation. or audits; and (3) evaluated to establish root causes and necessary corrective actinns for any nonconforming items or operational cerform-ance problems that occur. Based on the information gathering visits that have been made concerning licensees' handling of ITS/NSR structures, systems, and components, the staff considers that this description of normal industry practice describes the intent, if not in every case the practice, at operating plants. to this paper provides examples of the main-tenance, operation, and inspection aspects of normal industry practice for emergency power diesel generators and valve motor operators. This information is provided to show the level of detail that the staff considers acceptable in describing " normal industry practice" for ITS/NSR eouipment. Althcugh emergency power diesel gener-ators are classified as safety-related by licensees, Generai-p Motors provides the diesels as commercial grade to a customer who assembles the diesel generator unit. The enc:osed r( diesel vendor information is illustrative of the level of detail specified by vendors for complex eouipment and is illustrative of " normal industry practice."
) l t a The Comnission should ncte that neither current regulaticns ner the proposec rule, as presently perceived, would recu. ire licensees to comply with this definition cf normal incustry practice, although-as stated above it is the opinier c# ite staff that most licensees already comply. If the Cc missicn determines that ccmpliance with this definition shoulc be expicred, the staff will make appropriate modificaticns tc the proposed rule anc pre;:are the recuisite backfit analysis. 3. Develoo Criteria for Cetermininn what Ecui; ment is ITS cn a Plant Specific Basis Cn the issue of guidance #or determining what ecuipment is iroortant-to-safety, the SRM stated that a list of eouipment ITS/NSR is not required; that for MTOLs, ecuicment ITS/NSR could, in general, be deternined during the normal licensing process; that it is net the intention of the rule to add i new requirements; and that criteria for determining what equipment is ITS/NSR on a plant-specific basis should be ceveloped. To date reither the licensees ner the staff has ccmciled a list of ITS/NSR equipment. The licensee's FSARs ccntain descriptiens of both ITS/SR and ITS/NSR structures sys ems, and ccmponents. The cescriptions usually clearly state which ecuipment is ITS/SR but licensees have not specifics 11y identified ecuipment which is ITS/NSR. The staff in their review of licensee's FSARs have, to date,'includinc NTCLS. concentrated on structures, systems, and components which are ITS/SR. The Safety Evaluaticn Reports (SERs) issced by the staff specifically cover ITS/SR eauipment.
- However, issuance of an SER does indicate general acceptance of the I
l Safety Analysis Report. Therefore, although ITS/NSR eauip-ment has not been specifically identified as such, ecuictent contained in the categcry ITS/NSR can generally be determined by using the staff's definitions of ITS and facility licensing documents. To de so would be a major undertaking l for an individual licensee. The staff also reviewed the deckets for those plants that have not received an operating license but are actively pursuing completion of the plants. For all plants except Bellefonte 1 & 2 and WNP 1~L 3, the staff has issued a Safety Evaluation Report thereby establishing what' structures, systems, and components are ITS. Therefore, due to the small number of plants that would be affected by the preposed definitions, the staff proposes that for all currently decketec plants that ITS eauioment be that which is or will be de-scribed in the facility licensing documents, as per the previously cited definition. I
.e-O 4. Review Usage of Terms ITS and SR The staff bas reviewed the use of the terms " safety-relatec" and "inportant-to-safety" in 10 CFR and concluoed that the use of the terms is not internally consistent nor is it censistent with the proposed definitions. Safety-relatec" accears 39 tires and "important-tn-safety" accears 1:6 times. A clear example of a use incensistent with-the propesec definition of "important-to-safety" appears in General resign Criterion 2; " Structures, systems, and components important-to-safety shall be cesigned te withstand the effects of natural phenomena such as earthouakes...without less of capability to perform their safety functions...." In general, the staff has recuired that ITS/SR ecuiprent meet this recuirenent, but most of the ITSA;SR eouipment dces not. As such, the croocsed definition of ITS would tend to imply that all ITS ecuipment must be designed to cperate after a design basis earthquake which is not intended by the staff. However, a direct substitution of " safety-related" for "important-to-safety" would not encompass certain aspects such as non-Category I seismic desion requirements. Similarly, the adequacy and relia-bility of effsite power would not be encompassed by changing "important-to-safety" to " safety-related" in other General Design Criteria. Due to the magnitude of the problem and the difficulties involved in developing acceptable alternatives, the start I has not pursued the issue of consistent usage of these There are four options available to the Commissicn terms. in implementing the definitions of impcrtant-to-safety anc safety-related: 1. Withhold issuing a notice of proposed rulemaking en the proposed definitions until the rest of 10 CFR can be appropriately modified to be consistent with the proposed definitions. These usage changes would then ~ be published with the proposed definitions in the same proposed rule. 2. ' Withhold issuing a notice of proposed rulemaking en the proposed definitions until 10 CFR Part 50 can be appropriately modified to be consistent with the new definitions. These usage changes would then be /'~~ published with the proposed definitions in the sane (s proposed rule. wr --=m w-n r-- s 3 -,-m'-'+-ete-v'
. p) \\v Issue a notice of proposed rulemaking on the prcpesed 3. definitions, review the public comments, finalize the cefiniticr.s, receive Ccmission erdersement of the definitions and then prepare a second notice of proposed rulemaking on the appropriate changes to 10 CFR or 10 CFR 50 based en the final definitions. Issue a policy statement announcing the Ccrnission's 4 adcotion of the definitions and forego rulemaking. The first ertion would attempt to achieve cer.sistency in the usage of the terms safety-related and important-to-However, this effort safety thrcugnout the regulations. would entail revising portions of Parts 2, 21, 34, 50; General Cesign Criteria 2, 3, a, 5, 16, 17, 18, 44, 54 and 61 contained in Apoendix A to Part 50; Accendix R to Part 50; and portions of Parts 60, 71, 72 and Acpendix A to Part 100. It is the opinion of the staff that the two areas where the usage problem would be most difficult to resolve are the General Design Criteria and the inconsis-tencies between the parts of the regulations concerning-production and utilization facilities versus the parts of \\ the regulations cencerning waste repositories, independent scent fuel storage facilities, and packaging and transper-tation of radioactive material. Additinnally, the safety concerns and equipment involved are sufficiently differert between production and utilizaticn facilities and the-waste repository, independent spent fuel storage, and transportation areas that different definitions and use of terminology between these areas will not create any significant loss of clarity. Moreover, the term safety-related is not used in regulations applicable to waste repositories, independent spent fuel stcrage, and transoor-The term important-to-safety, as it applies tation areas. to these areas, is specifically defined in each of the relevant subparts of 10 CFR. Therefore, there is no uncertainty over the present usage of these terms in these portions of the regulations. For these reasons, the staff considers it unnecessary and inappropriate to attempt naking the definitions and usage of the terms impcrtant-to-safety and safety-related consistent throughout 10 CFR. Additionally, any attempt to de so would take an effort substantially in excess of the other options and would not If be the most appropriate use of staff resources. extensive public comments are received that necessitate revision of the definitions, the effort would, in effect, have to be undertaken a second time. The staff does not recommend the Commission approve this option.
w' l The secord cotion would resolve the issue of safety-relatec versus important-to-safety for_ the regulations concernirg production and utilization facilities (principally power reactors). This is the area where the issue was originally raised and where the lack of definitions and consistent. Additionally, the eouipment usage have created uncertainty. involved and the rules governing that eouipment are suffi-ciently different between prcduction and utilization facil-ities and the waste repository, independent spent fuel storage, and transportation areas that different definitiens and use cf terminology between these areas will not adversely affect the regulatory environment. Restricting the rule-making to those portions of 10 CFR concerning production and utilization facilities woulo reduce the areas considered difficult to resolve by the staff to General Design Criteria (GDC) 2, 3, 4, 5, 16, 17, 18, 44, 54 and 61. To fully resolve-the usage problem it may be necessary to take the guidance currently contained in the Standard Review Plan and appli-cable Regulatory Guides and place that information in the GCC, i The staff currently estimates that this option would take two to three years and involve approximately two FTE per i year just to issue the proposed rule. If extensive public comments are received that necessitate revision of.the definitions, the effort would have to be-repeated. The staff reccomends that any rulemaking be restricted to those parts of 10 CFR that concern production and utilization facilities. Option three would postpone any action on resolution cf tne usage proolem until the staff has had the benefit of public comments on the proposed definitions and the final definitions had received Commission approval. This option wculd have the advantage of early public comments on the proposed definitiens with a very limited impact on staff rescurces and would also avoid the possible situation of having to attain staff agree-ment on the necessary modifications to the regulations twice. The disadvantage of this option is that the public would not have the benefit of reviewing the proposed definitions and the proposed revisions in the use of the definitions at the -l same time. The staff believes that adopting this option would eliminate the possibility of having to revise the regulations twice, once to issue a proposed rule and the second time to address p any changes to the definitions and their use resulting frem (' public comments.
i a The Ccmmissier should note that this oction can be pursueo recardless of whether the Commission elects to restrict the ruiemaking to those secticts of the regulations that concern prcduction and utili:atier facilities er elects to have the rulemaking cover all o' 10 CF:. The fourth cotien would fore;c rulemaking cc this subject. The Commission would issue a colicy statement arnouncing the adoption of the proposed definitiens withcut any changes to the existing regulations. The advantages of this accroacn are the relatively shcrt time span recuired, the very_ limited impact en staff re!curces, the clear establishment of a class-of equipment that is important-to-safety but no: safety-related, and a staterent of the Commission's expectation that a standard of normal industry practice The disadvantages of will be followed for such eouipment. this option are the lack of puolic comment and the possible continuing uncertainty among licensees resulting frcm the mixed usage of terms in the 10 CFP 50, Appencix A General Design Criteria. 5. Imposition of Backfit Procedures for New Recuirements In response to Commissicner Asselstine's.recuest that the staff consider a rulemaking which would allow additions to or deletions from the scope of ITS eouipment based on new infermation or analyses without applying the backfit rule, i the staff considers a backfit analysis approcriate prior to recuiring any additional eouioment be classi'ied important-to-safety for currently licensed plants. However, licensees may voluntarily amend their FSARs (af ter an appropriate 50.59 review) or make changes to the scope of ITS eouipment as a result of operational events or other factors. With respect to Commissioner Asselstine's reouest that the staff consider a rulemaking for future plants so that confusion and uncertainty do not persist.and so that standardization can be enhanced, the staff prefers to wait to accumulate experience with the proposed The i definitions before considering further rulemaking. staff anticipates that any existing confusion or uncertainty will be taken care of by the definitions proposed by this paper and the fact that current treatment of existing plant equipment will not change. s\\ < The importance of increased attention to IT5/NSR plant ecuf pment '} ')}s was recently emphasized in an ECO meno dated November 26,19E4 -l on NRC lessons learned in the Davis Besse event: s \\ i 4, i i i
a f \\ "The paramcunt importance of prcper reintenance in mainteiring levels of reliability assumed in the safety analyses that f:r-the licensing basis for operating clants has been accorded greater reccgnition and increased emchasis and attentien by both NRC and utility management in the aftermath of the TPI accident. However, it appears frem the circumstances notec in the review of the June 9 Davis-Sessa event that an inapprecriate, artificial distinction oetween the impnrtance of safety-relatec vs nonsafety-related plant features may have led some licensees to place inadeouate emchasis en prc er maintenance of all ecuipment necessary to assure prcper facility cperations. Some balance-of-plant systems may actually have ecual or perhaps greater safety importance (cumulatively) than ecuipment classi-fied as safety-related because their too #recuent failure can needlessly challenge the safety-related systems, and their 'ailure can also aggravate conditions under which the safety-related systems must respond. We need to give increased attentien y' to assuring that the attention of licensee management is focusec j l properly en this important aspect of plant cperations anc that. important balance-of-plant systems and ecuicment receive acecuate ,121 attention in the overall maintenance picture...." The staff believes that the proposeo definitiens, while not in i' \\ themselves imposing any new recuirements, will bring tc the attention of the incustry the Commission's concern that a procer level of attentien be paid to items which are not " safety-relatec" but which play a large role in assuring safe plant operation. Fecommendation: That the Commission: 1. Accreve the staff's proposed definitions of important-to-safety, safety-related, f acility licensing documents, and normal industry practice. 2. Accrove and direct the staff to proceed, on a long tern-basis, with option 2 while, in the shcrt term, direct the staff to develop as discussed in option 4, a Policy Statement announcing the Commission's adoptien of the definitions and intent to codify them. 3. Provide additional guidance to the staff as to whether licensee compliance with the proposed definition of normal industry practice should be required. 4. Note: The staff dces not recccmend that the Commission a. \\ pursue Option 1.
_n. ~ .\\v) That a Backfit Analysis has not been perforred b. for this paper since it only' requests Cerrrissic.n approval of proposed definitions and addit.icnal guidance. The staff will perform an appropriate Backfit Analysis if the Ccmmission chooses-the rulemaking option. That because this pacer only requests Corrission c. approval o# proposed definiticns and additional guidance, a Regulatory Analysis is net necessary. The staff will perform an appropriate Regulatory Analysis if the Commission chooses the rulemaking option. If scheduled on the Commission agenda, ! reccmmend this paper Scheduling: be censidered at an open meeting. - Sk * .,a,;, Victor Stello, Jr. Executive Director for Operatiens
Enclosure:
Examples of Normal Industry Practice Commissioners' comments or consent should be provided directly June 16, 1986. to the Office of the Secretary by c.o.b. Monday, Commissioner Staff Office comments, if any, should be submitted to the Commissioners NLT Mondav, June 9, 1986, with an infor-If the paper'is mation copy to the Office of the Secretary. of such a nature that it requires additional time for analytical the Commissioners and the Secretariat should review and comment, be apprised of when comments may be expected. DISTRIBUTION: Commissioners OGC ' OPE OI OCA OIA CPA REGIONAL OFFICES EDO ELD ACRS ASLBP ASLAP SECY
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ELECTRO MOTI\\ E M AINTENANCE J NSTRUCTION SCHEDULED MAINTENANCE PROGRAM. DOMESTIC STATIONARY POWER UNITS WITH TURBOCHARGED ENGINES INTRODUCTION
- 5. Operating load limitations will be adhered to.
This Maintenance Instruction provides average
- 6. Torquing procedures contained in this M.1; will recommendations w hich should ensure satisfactory be followed for new engines and newly mstalled engine operation and economical maintenance cost replacement assemblies.
(- where aserage load factors and aserage climatic f conditions are encountered. It is intended to serve as g a guide when establishing maintenance schedules This Maintenance Instruction is divided into three that will meet the particular requirements of sections. The first section is maintenance performed individual operations. and planned economie life of before and after each start, the second section is I the engine and associated equipment. performed on a " calendar period" basis. and the third section is performed on a" running time" basis. These recommendations are based on the following Because operating requirements for this equipment -- ~ conditions: can sary from standby. to periodic, to continuous usage. the maintenance procedures must be
- 1. Fttel oil used will meet the specifications of modified to suit individual requirements.
Maintenance Instruction 1750. REFERENCES l 2. Lubricating oil used will meet the specifications of Maintenance Instructions 1760 and 1764 and will be changed at the intervals specified in this Abbreviations are used in this instruction to M.I. reference pu blications that contain information related to maintenance. The following examples are
- 3. Engine coolant used will meet the specifications provided to aid in understanding the abbreviations in Maintenance instruction 1748.
used. '4. Lubricating oil filters will be of a quality equal EMM means Engine Maintenance Manual to original equipment and will be changed at the OM means Operating Manual intervals specified in this M.I. M.l. means Maintenance Instruction O "This bulletin is revised and supersedes previous issues of this number. I: A ren, a e8.n.,.. ;oair...a w..,,,,nr.1 h.c.
M1.l > f ~ BEFORE EACH START (CONG) d (NON-AUTOMATIC START UNITS) AIR SYSTEM Drain condensate. ~ OM Check 5.sstem pressure. OM Check vil supply :n air line lubricator. EMM ENGINE I the running " latched" position. Check overspeed trip les er OST to ensure it is in EMM Open cylinder test vals es and manually bar over If fluid discharge is obsersed from any cylinder tind engine one complete revolution check for the cause and make necessary repairs prior to liquid ejected from s alves, and close test valves. starting the engine. Prelube engine it umt has been shut down for EMM. Unless equipped with immersion heater oser 48 hours. system. Check racks. EM M. Move injector control lever to check for l Ensure exhaust stack is open. GOVERNOR Check oil lesel. Add oil if necessary. EM M. M.I.1764 IMMEDIA1] Eld $Af:IEITEACNSTART (NON AUTOMATIC START UNITS) INSPECT FOR LEAKS Cooling system Fuel oil system Lube oil system Exhaust system Air system LUBE OIL SYSTEM Check lube oil level in pan with engine at idle. EMM Check lube oil pressure at engine. OM COOLING SYSTEM Check operation of external cooling system. OM FUEL SYSTEM Check for proper fuel pressure. OM
t- \\1.1.1 "3 - /~} WEEKLY (AUTOM ATIC STARTS UNITS) ENGINE SHUT DOWN LUBE OIL SYSTEM Check for lube oilin pan and strainer housing. EN151. N1.1.1760 l Add oilif required. NOTE If engine requires prelube. recheck tube oil level in pan as a quantity will transfer to e xternal system Icooier, filter. st rainer and piping). Add oilif required. COOLING SYSTEM Check coolant level. Add coolant if necessary. 0 51. 51.1. 1748 NOTE Do not continue to operate engine requiring periodic addition of coolant. Check for possible coolant leak and repair if required. FUEL SYSTEM Check fuel supply. ON1 AIR SYSTEM Drain condensate. ON1 Check system pressure. ON1 I Check oil supply in air line lubricator. EN1N1 i ENGINE Prior to maintenance start. check overspeed ENihi I trip leser OST to ensure it is in the running -latched" position. Prior to maintenance start. open cylinder test if fluid discharge is observed from any cylinder. find - valves and manually bar over engine one the cause and make the necessary repairs prior to I complete-revolution, check for liquid ejected starting the engine. from valses, and close test valves. Prelube engine if unit has been shut down for EMN1. L'nless equipped with immersion heater over 48 hours. system. .O' Check racks. EMN1. Niose injector conu ol lever to check for-freedom of moyment with no binding ofinjectors. 1
- stack is open.
Prior to maintenance start, ensure that exhaust j 1 'I
r. \\t.!. F:'i O '. N E M atW W E C M M g IMMERSION HEATER (Where Used) Check for proper operation. ONI EMERWTTRIIa01ETHE AUXILfARY TURBOCHARGER FILTER (Where Used) Replace elements. ONt IN.LINE LUBE OIL STRAINER (Where Used) Clean strainer screen. 2 3 LUBE OIL CIRCULATING PUMP AND MOTOR (Where Used) Inspect and clean with dry air. Replace brushes. If equipped with DC motor. Remose and clean check vahe. LUBE OlL FILTERS Change filter elements. ENiN1. Unless the 1400 hour filter enange has occurred first. Clean lube oil strainer. Eht N1. Fill strainer housing with oil before starting engine. TURBOCHARGER OlL FILTER Replace filter elements. Ehiht. Unless 1400 hour filter enange has occurred first. SOAK BACK OIL FILTER (Where Used) Replace filter element. ENiSt. Unless 1400 hour filter change has occurred first.
/ f' " N1.1.1 Th EVERY THREEYEARS COOLING SYSTEM THERMOSTATIC VALVE Replace -O" rings and thermostatic elements. ENIN1. 51.1. 581 EVERY FOUEYEARS COOLING SYSTEM PRESSURE CAP Replace. Unless 16.000 hour replacement nas occurred !:rst. EVERY F3VEEYEDpRS FREQUENCY GENERATOR COUPLING SPIDER (Where Used) Replace. Unless 16.000 hour replacement has occurred first. EVER1(SIMYEARS ENGINE Replace top deck cover seals and check latches. Ehiht. Unless 8000 hour replacement has occurred first. Replace cy linder head grommets. inlet and ENt St. Unless 16.000 hour cylinder assembly outlet seals. and lower liner seals. replacement has occurred first. MAIN GENERATOR Remove bearing coser and inspect for grease Unless 18.000 hour lubrication has occurred first. contamination, excessive wear, and oser-N1.1. 3327 or N1.1. 3328 for EN1D generators. If heating. Apply new grease. generator is other than EN1D. refer to manu-facturer's manual. t -.--_-------------s.-,---.----___.__ w w'
.p. m, ,gT k# . EVERY350 HOURS (CONTDL LUBE OIL FILTER Check lube oil pressure at filter input with Change filter elements if input pressure reater engine at rated RPM. than 172 kPa (25 psis. ? 5. ENGINE PROTECTOR Check operation. EM M. M.I. 259 or M.l. 260 SOAK BACK PUMP AND MOTOR Check operation. With the engine shut down and 30ai cack pump motor running. remove left rear hanchose cos er and check oil flow through gear tra:n. Observe camshaft bearings. If tube oii tiows f rom camshaft bearings with soak back pump running and engine shut down inspect turbo filter outlet check valve for proper operation. ENGINE AIR FILTER - CYCOIL T.YPE (Where Used) Check oillevel. OM. M.1, 442 ENGINE AIR FILTER - PANEL TYPE OIL BATH (Where Used) Check oil lesel. OM. M.I. 440 ENGINE AIR FILTER - PAPER OR FIBERGLASS TYPE (Where Used) Check indicator. If tripped, take manometer OM readings and replace elements,if necessary. HEAT EXCHANGER Inspect corrosion zine electrodes. EMM (EVER.W/T409)H..U. UNE e.. .u " LUBE Olt FILTERS Change filter elements. OM i Clean lube oil strainers. EMM. Fill strainer housing with oil before starting D engine.
n +.,m.wwy,;c a. e, t._, - \\1.1. l *:.3 '. ,m EVERY2000 HOURS (CONT *D) ENGINE AIR FILTERS - FIBERGLASS TYPE Replace elements. ON! STARTING MOTORS (Electric) - Blou out with dry air. ENIN1 ENGINE inspect air box. ENIN1 Inspect crankcase. EN151 Inspect crankshaft and connecting rods. EN1Ni Inspect pistans and piston rings. ENINi Inspect cylinder liners. ENINi inspect cylinder head mechanism with engine ENt N1 i idling and at operating temperature. eO Inspect engine fuel lines and connections for ENiht leaks. Inspect engine water system for leaks. ENIN1 EXHAUST SYSTEM Removeexhaust manifold to turbocharger E N151. Clean screen and trap box. Obsen e recommen-adapter assembly. dations found in Ehihi concerning checking for cracks. TURBOCHARGER EXHAUST DlFFUSER Visually inspect for evidence of warpage or EN1Ni damage. EDUCTOR TUBE (Exhaust Stack Mounted) Inspect for carbon deposits and clean. if ENiN1 necessary. k
.n y m, r ~ '<4 A-gg,g, j 3 /O EVERY8000 HOURS d ENGINE NUT AND BOLT RETORQUING C 1inder head crab nuts. Follow retorquing procedures if called for in tr.: i 3 ENIN1. Niain lube oil and piston cooling oil pump shaft EN1N1 nut. Head frame to crankcase bolts. EN1N1 Turbocharger to air duct bolts. aftercooler to ENiM air duct bolts, air duct to crankcase bolts. and turbine inlet link bolts. Engine mounting bolts. Miscellaneous nuts and bolts, and all piping connections. ENGINE Replace top deck cover seals and check latches. EMM e Qualify injectors. EN1N1 Check injector timing and injector rack length. EN1N1 Check engine speed. EMM Check overspeed trip. EMM Remove and clean oil separator element. EMM Check pressure drop across aftercooler; paper EMM. Clean air passages if necessary. and fiberglass filter equipped engines only. Inspect crankshaft damping device. EMM Remove. clean, and inspect; replace if EMM necessary: Soak back check valve in the turbo filter inlet. Soak back oil pressure relief valve in the soak b.ck filter head. Soak back filter bypass valve in the soak n back filter head. / Turbo oil filter check valve in the turbo filter head.
) M.I.'l 3 m. g STARTING MOTORS (Air) Disassemble. clean, inspect and lubricate. EMM STARTING MOTORS (Electric) Disassemble. clean. inspect and lubricate. EMM Inspect brushes and replace if necessary. EMM EVERY TE OOOHOURS FUEL PUMP Replace coupling spider. SOAK BACK PUMP (Where Used) Replace coupling spider. FREQUENCY GENERATOR (Where Used) Replace coupling spider. COOLING SYSTEM O-Replace pressu*e cap. (Where used.) OM inspect filler neck for damage. Replace if OM damaged.1Where used.) ENGINE Replace cylinder assemblies. EM M Replace injectors. EMM. Replacement should be EM D Unit l Exchange or equivalent. I Inspect and qualify connecting rod bearings. EMM Inspect and qualify piston cooling tubes. EMM Check rocker arms. rocker arm bushings, and EMM cam followers. Check lash adjusters. EMM Check exhaust valve timing. -EMM Inspect lower liner inserts, and replace if EMM required. w w =
, e' C PW=liLIFX'.UDIU1M k ENGINE Replace vioration damper or harmonic EMM. Replace with gear type damper. balancer. (Where used.) l Replace or recondition oil pumps. EMM. Replacement can be EMD Unit Esenange. l ' l Remove oil pressure relief valve: clean, inspect. EMM and test. Replace lower liner insens. EMM Inspect injector control linkage. Replace links. seals, and beanngs,if required. MAIN GENERATOR Remove bearing coser and inspect for grease M.I. 3327 or M.I. 33:S for EMD generators. If contamination. excessive wear and overheating, generator is other than EMD. refer to manu-Apply new grease. facturer's manual. m-e C ENGINE i Replace crankshaft damping device. EM M. Replace with new or reconditioned gear 13 pe i damper. If already equipped with gear 13 pe damper. recondition and requalify. m-e e ENGINE l' nit Exchange. GENERATOR Unit Exchange. / \\ A Service Department Publication i l E ectrottot we Des,on Of Geaera. *.totors La Gra ge i oao n 605:5
y oTy qq q) ACTION - Taylor, IE [one%e UNITED STATES Cys: Dircks f ~,, NUCLEAR REGULATORY COMMISSION Roe s ,i WASHINGTON, D.C. 20555 Rehm Stello o \\, y/ December 31, 1985 Minogue Denton orrect or THE GCunningham SECRETARY Ankrum, IE Goldberg, IE Philips MEMORANDUM FOR: William J. Dircks, Executive Director for Operations FROM: amuel J. Chilk Secretary
SUBJECT:
STAFF REQUIREMENTS -- SECY-85-119 - "IdJUANCE OF PROPOSED RULE ON THE IMPORTANT-TO-SAFETY ISSUE" The' Commission, by a vote of 5-0 has disapproved SECY-85-119. The Commission agrees that the proposed rule does not adequate-ly differentiate nor clarify the terms "Important-to-Safety" (ITS) and " Safety Related" (SR). The Commission continues to believe that it is necessary to resolve the apparent confusion surrounding usage of the term "Important-to-Safety". The Commission directs you to resubmit a proposed rule concerning ITS. The Commission believes the following guidelines should be followed in redrafting the proposed rule. Concerning the ITS definition: 1. If a term such as " normal industry practice" is to be applied in the definition, that term also needs clarifica-tion. For example, how is normal industry practice de-termined? 2. Safety-related is a subset of ITS. 3. ITS refers to those systems, structures, and components at a specific plant for which the staff has explicitly required the application of some specialized treatment in that plant's licensing documents or to which certain generic regulatory requirements have been added. Further-more, the requirements imposed on those systems, struc-tures, and components determined to be ITS are only those which were specifically required in the plants' current licensing documents or in the generic regulatory require-ments. 4. Specialized treatment is not restricted just to'0A/0C requirements. It includes, among other things, codes, standards, missile hazard prevention requirements, fire protection requirements, e c. irsi CA. COO Dats...l.~...l.E.h....... g(o&l} nm.....eh.......,.. L
, 5. A specific listing of safety-related equipment is required to be maintained. A specific listing of ITS equipment is not required to be maintained. Concerning the process for making changes to the commitments associated with items ITS or for new determinations of items ITS: 1. It is not the intention of the rule to add new require-ments, to modify existing requirements, or to broaden the existing scope of the Commission's requirements. 2. As with all systems, structures, and components, appropri-ate backfitting procedures will be used in all instances where new requirements are proposed by the NRC staff. 3.- Systems, structures, and components that will ba called ITS for NTOLs will be determined during the normal licens-ing process. 4. Formal guidance should be included on how determinations of items ITS will be made, including criteria to be used to determine on a plant-specific basis what equipment is ITS. Concerning the review and amendment of existing regulations and other regulatory documents: 1. It is expected that 10 CFR will be reviewed to determine if use of the terms " safety-related" and "impor-tant-to-safety" is appropriate and consistent with the new definition. If not consistent, staff should propose appropriate modifications to 10 CFR. 2. The Commission suspects this will require more than the addition of a formal definition to Part 50 of 10 CFR. 3. The staff should inform the Commission of the results of its review. In addition to the above guidelines, Commissioner Asselstine would appreciate staff consideration of the following: 1. A rulemaking defining "important to safety" that would allow additions to or deletions from that set based on new information or analyses without going through the full gamut of the backfit rule.
r r. . 2. A rulemaking defining "ITS" for future plants so that confusion and uncertainty do not persist and so that standardization can be enhanced. (EDO) (SECY SUSPENSE: 3/21/86) Copies: Chairman Palladino Commissioner Roberts Commissioner Asselstine Commissioner Bernthal Commissioner Zech Commission Staff offices Oe [ I}}