ML20077G088

Affidavit of Ej Youngling Responding to Questions in ASLB 830720 Memorandum & Order Re Diesel Generators.Util Will Replace All Remaining Original Cylinder Heads W/Improved Heads Prior to Fuel Load

ML20077G088
Person / Time
Site:	Shoreham File:Long Island Lighting Company icon.png
Issue date:	07/28/1983
From:	Youngling E LONG ISLAND LIGHTING CO.
To:
References
ISSUANCES-OL, NUDOCS 8308030362
Download: ML20077G088 (7)

Text

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I LILCO, July 22, 1983 a

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UNITED STATES OF AMERICA  ; 30 NUCLEAR REGULATORY COMMISSION / --

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Before the Atomic Safety and Licensing _ U y *.

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In the Matter of )

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LONG ISLAND LIGHTING COMPANY ) Docket No. 50-322 (OL)

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(Shoreham Nuclear Power Station, )

Unit 1) )

- - AFFIDAVIT OF EDWARD J. YOUNGLING Edward J. Youngling, being duly sworn, deposes and says as follows:

1. My name is Edward J. Youngling and I am employed by the Long Island Lighting Company (LILCO) as Startup Manager for the Shoreham Nuclear Power Station. My professional qualifica-tions have been previously submitted to the Board. As Startup Manager, I am responsible for all preoperational test activi- ')

ties. I also coordinate, Checkout and Initial Operation (C&IO)

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testing and preoperational testing. In this role I have been t

directly involved in the testing of Shoreham's diesel genera-tors and in resolving related issues that developed during t

, testing. Specifically, I am familiar with the County's conten-l tion regarding Shoreham's diesel generators.

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2. I. testified previously in this proceeding as a mem- _

ber of the LILCO panel on the Quality Assurance / Quality Control '

issues. I have also submitted three previous affidavits to the. .

Board regarding Shoreham's diesel generators dated May 16, 1983, June 3, 1983 and July 7, 1983. On June 10, 1983, I ap- ,

peared before the Board to answer questions regarding Shoreham's diesel generators.

3. The purpose of this affidavit is to respond to ths two questions raised by the Board in its July 20 memorandum and -

- order concerning diesel generators. Before doing so, however, I should report to the Board that L1LCO has decided to complete.

prior to fuel load the planned replacement of the remaining s original cylinder heads with the improved, current production model cylinder heads. As my July 7 affidavit demonstrated, the rigorous preoperational testing of the diesel generators'has '

confirmed the reliability of the remaining original cylinder heads. Nonetheless, LILCO has elected to. install the improved, .

current production model cylinder heads to further enhance the 4

reliability of the diesel generators. Although LILCO is concerned over the potential impact of this on fuel load, steps will be taken to minimize any such impact.

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, 4. As noted, this affidavit addresses the two ques-e '

tions raised by the Board in its July 20 memorandum. First, l .

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the Board note.d tha my April 6 memo'randum referred to-

" difficulties with five of the twenty-four cylinder heads"

~ whpreas pievious information presented to the Board discussed

'three cracked cylinder heads. Second, the Board indicated that c my memorandum made it. aware of the possibility of lubecoil con-

amination due to water leakage from the cylinder chamber into s.

thelubeoil[ystem. 'This affidavit _shows that ,

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, (a) there have only been three, instances -

of cylinder head cracks wh1'ch could

. - result in leakage of water into the

' cylinder,

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(b) the other cylinder head occurrence $

-t referred to~in the memorandum did I

not involve cylinder head crackss h t, which could result in leakage into i the cylinder, chamber, and

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(c) the possible lube oil contamination does not affect the reliable operation of the diesele, but may require more frequent replacement of

~ .- - engine oil to avoid excessive engine wear.

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,,5 . My July 7 affidavit dis 6ussed the.three cylinder head cracks founch in the original c'ylinder heads which resulted

, ti in leakage of watersfrom the jacket water system into the cyl-

'inder chmbe'r. These three cracked heads were the subject of SNRC-873. These three affecte.d cylinder heads were also ,

discussed in my prior affidavits an'd at the June 10, 1983 con-ference of the Board and parties. They are the subject of the E '*

contention admitted by the Board. .

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6. My April 6 memorandum to Mr. Rivello states that LILCO experienced difficulties with five cylinder heads. Three of these five were the cylinder heads that were the subject'of SNRC-873. The other two cylinder heads were occurrences not involving leakage into the cylinder chamber. In fact, at the present time there have been a total of six such occurrences Ali of these not involving leakage into the cylinder chamber.

involved the original heads. Even though all of the original heads will be replaced before fuel load, for the Board's infor-mation, I will discuss each of these other occurrences below.

7. Two of these occurrences were the result of mechan-ical damage incurred during the removal and reinstallation of the cylinder heads for other maintenance activities. The first was a scrape on the cylinder head gasket mating surface which  ;

E we believe was caused by the impact of a tool or other device.

This scrape was detected by LILCO personnel and the head was f

replaced. The second instance involved bolt hole thread damage i encountered during the removal of exhaust flange bolts. This problem was identified and the head was replaced.

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8. Two other occurrences resulted in very minor water '

leakage external to the cylinder chamber. The first was the ,

result of a pinhole size sand hole on a non-machined, external surface which resulted in a very small water leakage onto I .

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external portions of the diesel engi,ne. The second occurrence involved leakage at a subcover assembly bolt hole which also resulted in a very,small amount of external water leakage '

detectable only upon removal of the bolt. The water leakage in both of these instances was external to the cylinder chamber and thus had no impact on the ability of the diesels to perform

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their function. The a' mount of leakage in both cases was very small and well within the make-up capability of the jacket water system. Although these occurrences did not affect operation, both were corrected by replacing the.. cylinder heads.

9. The final two cylinder head occurrences related to components contained in the cylinder head assembly. In one in-stance, a noisy valve was detected by LILCO personnel. The second instance occurred when the rocker arm shaft bolt failed

and damaged a valve stem. Both situations were remedied by replacing the entire head assembly,

10. The second question raised by the Board concerns the possibility of lube oil contamination due to water leakage past the piston rings. When the engines are not in operation, if th'ere is a large amount of cylinder head leakage, water would overflow the dished piston head and would likely flow ,

past the piston rings into the lube oil sump. This increases our confidence that a leak in a cylinder head, should one p..

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occur, would not affect the rapid start capability of.the diesels. The concern expressed in my April 6, 1983 memorandum regarding the possible contamination of the lube oil was not a concern with the reliable operation of the diesel; rather, it was a concern relating to maintenance because water contamina-tion of the lube oil system could increase maintenance require-ments. Under LILCO's preventive maintenance program, diesel generator lube oil quality is sampled on a periodic basis.

Water contamination would require replacement of the oil. In addition, substantial amounts of water leakage into the lube oil could result in excessive wearing of components over the long term if undetected and uncorrected. It is unlikely, how-ever, that large amounts of water leakage into the lube oil system via a cracked cylinder head would go undetected. The level of the jacket water system is monitored during operation and standby of the diesels and substantial dec_ eases in water inventory would be detected. The barring over procedure, which is no longer necessary because the new heads will be installed, also would have detected any leakage. Thus, although lube oil contamination was a concern to me, that concern did not compro-mise the ability of the diesels to perform their safety func-tions. ,

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11. Finally, I would like to correct a statement made in my July 7 affidavit. Footnote 2 of paragraph 9 of that af-fidavit mistakenly states that "during low power testing, o'nly two diesel generators are required to be operable under Shoreham Technical Specification 5 3.8.1.2." While only two diesel generators are required to be operable under the

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Shoreham Technical Specifications for loading of fuel, low power testing requires operability of all three diesel genera-tors.

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Edward [%oUngli fr T VL Subscribed and sworn to before me this 28"da of July, 1983.

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