ML20079P615

Addendum to Motion to Admit Supplemental Diesel Generator Contentions.Certificate of Svc Encl

ML20079P615
Person / Time
Site:	Shoreham File:Long Island Lighting Company icon.png
Issue date:	01/27/1984
From:	Dynner A KIRKPATRICK & LOCKHART, SUFFOLK COUNTY, NY
To:	Atomic Safety and Licensing Board Panel
Shared Package
ML20079P612	List: ML20079P610 ML20079P615
References
ISSUANCES-OL, NUDOCS 8401310285
Download: ML20079P615 (91)

Text

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UNITED STATES OF AMERICA' .I'o1/ "

NUCLEAR REGULATORY COMMISSION Before the Atomic Safety and Licensing Board

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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) )

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ADDENDUM to SUFFOLK COUNTY'S MOTION TO ADMIT SUPPLEMENTAL DIESEL GENERATOR CONTENTIONS This Addendum presents to the Board information disclosed at a public eeting on January 26, 1984, between the NRC Staff and an organization comprised of eleven utilities, including LILCO, owning emergency diesel generators ("EDGs") manufactured by,Transamerica Delaval, Inc. ("TDI").1/ That information has a significant impact upon Suffolk County's Motion to Admit Sup-plemental Diesel Generator Contentions, dated the date hereof and of which this Addendum forms a part. The NRC Staff had a 11 /

The Staff's notice of the meeting and agenda are attached as Exhibit 1. The meeting began at 3:00 p.m. and ended at approximately 6:15 p.m.

6401310285 840127 PDR ADOCK 05000322 G PM

f r, formal transcript taken of the meeting, which is not yet available. Suffolk County respectfully urges this Board to read that, transcript before reaching conclusions regarding the County's Motion.

Mr. Denton of the Staff began the meeting by stating that the difficulties with TDi diesels is a "very serious problem" for the nuclear industry. The Staff reviewed significant operating problems with TDI diesels at three nuclear plants --

San Onofre 1, Grand Gulf, and Shoreham -- and on the ships M.V.

Columbia, M.V. Pride of Texas, and M.V. E.H. Gott. The Staff's

, written summary of these problems, distributed at the meeting, is attached as Exhibit 2. It appears that many of the EDG problems cited by the Staff in Exhibit 2 are identical to EDG design deficiencies and manufacturing defects included in and forming the bases for Suffolk County's supplemental EDG'conten-tions. Some of the information provided by the Staff has not

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previously been seen by the County, such as the problems at San Onofre; that information will be reviewed to determine wl. ether it should be added to the proposed EDG contentions.

Mr. Collins of NRC Region IV reviewed the results of seven NRC vendor inspections of TDI carried out since 1979.2/ There

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-2/ No NRC vendor inspections of TDI were performed prior to 1979. Two additional recent vendor inspection reports are expected to be available on January 27, 1984.

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r were 62 nonconformances/ violations identified in the summary of l

l the NRC's seven inspections distributed at the meeting, a copy of which is attached as Exhibit 3. The Staff noted that it has very serious concerns about the effectiveness of TDI's OA pro-gram, and that the QA programs of the utilities (including LILCO) were called into question by their failure to identify the many discrepancies in TDI's Oh program. The staff appeared particularly concerned that important TDI records concerning QA inspection were unavailable, making it impossible to assess whether inspections and other QA requirements were ever accoraplished. The areas of OA concern to the Staff are addressed in Contention IV of the County's supplemental EDG contentions. The summary by the Staff in Exhibit 3 covers the identical material summarize.d in Attachment 3 to the County's contentions. Suffolk County will review the two latest Region IV reports when they become available to determine whether the additional nonconformances they identify should be added to the proposed EDG contentions.

The.TDI Owner's Group then made a lengthy presentation, focused on the program it is implementing to attempt to prove to the Staff that EDGs manufcctured by TDI are reliable. A handout summary of that presentation, obtained by the County from the Staff, is attached as Exhibit 4. In the context of

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t the County's Motion, the following are the most important I

factors disclosed in the owner's Group presentation:

1. Mr. Museler of LILCO acknowledged the existence of 16 "significant known problems" with the Shoreham EDGs. See Exhibit 4 at IV-10. These problems are included in those iden-tified as design or manufacturing defecte in the County's sup-plemental EDG contentior.s.

2.

Dr. Wells of FaAA stated that the examination of the model "AE" piston was still continuing. He identified two areas of potential concern with piston design being investi-gated -- an outer edge gap and an inner ring contact area. See Exhibit 4 at pages following V-3. A West German firm has been retained to perform stress analyses of the "AE" piston, starting in about six weeks. This information gives support to the County's Contentions I and II regarding the design of the-

"AE" piston. Moreover, it suggests that litigation of the County's contentions would be premature before the results of the "AE" piston studies are reported and analyzed.

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3. Mr. Museler, in response to a question from the Staff, acknowledged the importance of crankshaft design standards other than those of DEMA. He stated that LILCO in-tended to apply the American Bureau of Shipping standt da o

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$ the replacement crankshafts at Shoreham , but has not yet done so. This supports the County's contention I regarding the im-portance of using crankshaft design standards of inter-nationally-recognized organizations such as ABS and Lloyd's Register of Shipping. See Affidavit of Professor Christensen (Attachment 1 to the supplemental EDG contentions) at para. 6&

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7. Later in the meeting Mr. Eisenhut of the Staff stated that '

the Staff does not believe that LILCO has addressed the " root cause" of why the original crankshaf ts failed, including the relationship of other components with the crankshaft. The County agrees. See proposed Contention I and Affidavit of Professor Christensen at para. 13.

4. The Owner's Group program will include obtaining l

experience data, including records of maintenance, failures, operating losses, and design changes, from all nuclear and non-nuclear owner /cperators of TDI diesels. Exhibit 4 at VI-5. In addition, the design of many components of the Shoreham EDGs l will be reviewed, and the quality of selected components is to be revalidated by inspections. Exhibit 4 at VI-6 & 7. The data generated by this program will be relevant and material to the County's supplemental EDG contentions, and the conclusions of the program will be germane. Litigation of the County's contentions clearly should not commence until this material has

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& been reviewed by all parties. Mr. E.4.senhut stated that all data and interim reports should be given to the Staff as developed, and will be made available by the Staff to the public and to Boards and parties in proceedings concerning TDI diesels.

In summary, Suffolk County submits that the information disclosed at yesterday's meeting strongly supports the County's supplemental EDG contentions, as well as the County's position that those integrated contentions should not be litigated until after LILCO and the NRC Staff have completed their evaluations.

Respectfully submitted, Martin Bradley Ashare, Esq.

Suffolk County Attorney Suffolk County Department of Law Veterans Memorial Highway Hauppauge, New York 11788 est vW Herbert H. Bfownf Lawrence Co/ Lanpher Alan Roy Dynner KIRKPATRICK, LOC KHART, HILL, CHRISTOPHER & PHILLIPS 1900 M Street, N.W., Suite 800 Washington, D. C. 20036 Attorneys for Suffolk County l January 27, 1984

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[o y'o,, UNITED STATES EXHIBIT 1

- E' o NUCLEAR REGULATORY COMMISSION

,; WASHING TON, C. C. 20665 Janua ry 17, 1984 S,y*...+,/

Docket Nos.: 50-322 l 50-416/417 50-206 50-312 50-458/459 50-400/401 50-413/414 50-440/441 50-438/439 50-445/446 50-424/425 50-329/330 l MEMORANDUM FOR: A. Schwencer, Chief Licensing Branch No. 2 Division of Licensing FROM: R. Caruso, Project Manager Licensing Branch No. 2 Division of Licensing

SUBJECT:

FORTHCOMING MEETING WITH OWNERS OF TRANSAMERICA DELAVAL, INC.

(TDI) DIESEL GENERATORS j DATE & TIME: Thursday, January 26, 1984 3:00 PM - 5:00 PM LOCATION: Room P-118 Phillips Building Bethesda, Maryland PURPOSE: To discuss actions required to address inspection results and operating experience related to Emergency Diesel Generators renufactured by TDI. (Agenda attached)

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A. Schwencer .

o PARTICIPANTS *: NRC APPLICANTS IE: G. Zech Consumers Power - S. Howell NRR: H. R. Denton J. Cook D. G. Eisenhut CP&L - A. Cutter R. Mattson M. McDuffie R. Vollmer Georgia Power - D. Foster T. Speis SCE - K. Baskin F. Miraglia LILCo - W. Uhl T. M. Novak M. Pollock L. Rubenstein MP&L - D. Lutken J. P. Knight J. McGaughy C. Berlinger Duke - W. Owen H. Tucker Gulf States - W. Cahill TUGCo - R. Gary J. George CEI - M. Edelman SMl!D - R. Rodriguez TVA - L. Mills J. Raulston TDI D. Bixby C.fatthews kd.QL-R. Caruso, Project Manager Licensing Branch No. 2 Division of Licensing ,

Attachment:

Agenda cc w/ attachment:

See next page

• Meetings between NPC technical staff and applicants for licenses Pre open for interested members of the public, petitioners, intervenors, or other parties to attend as observers pursuant to "Open Meeting Statement of NRC Staff Policy", 43 Federal Register 28058, 6/28/78.

MEETING AGENDA

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. TDI DIESEL GENERATORS

1. NRC Presentation A. Operating Experience C. Inspection History and Results C. Discussion (Break)

II. TDI Diesel Engine Owners Group Presentation 4

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EXHIBIT 2 Delaval Diesel Generator Operation Experience

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s U. S. Nuclear Experience In 1974, the Long Island Lighting Company (LILCo) contracted with TDI to purchase three emergency diesel generators for the Shoreham Nuclear Power Station. This was the first order received by TDI to provide an EDG for a comercial nuclear power station. In the next seven years, engines for 14 other plants were ordered from TDI.

San Onofre 1 Two TDI Diesel Encines Installed in 1976 - DSRV-20 Serial No. 75041/42, Rated at 6000KW (nominal) 8800KW(peak)

Engine Run Time to Date - 450 hours0.00521 days <br />0.125 hours <br />7.440476e-4 weeks <br />1.71225e-4 months <br /> par engine 1

The first plant to actually place a TDI engine into nuclear service was San Onofre Unit 1 (SONGS 1), which purchased two V-20 units to provide emergency power for its feed pumps, which also serve as Emergency Core Cooling System pumps.

The engines at SONGS 1 were installed in 1976, and declared operational in April 1977. Since then, SONGS has experienced some problems with the operation of the engine turbochargers, a lube oil pressure sensing line failure which resulted in a fire, and several other minor problems. Because l SONGS did not comit to meet the guidelines of Regulatory Guide 1.108, but rather Regulatory Guide 1.9, the program it used to test the engines before ,

they were placed in service was more abbreviated than for a new plant. A l detailed list of problems to date follows.

Date Problem Cause/ Solution 12/80 Excessive Turbocharger No lube oil during standby.

thrust bearing wear. Lube oil system modified.

10 CFR Part 21 report issued because problem generic.

7/81 Lube oil leak and fire. Excessive vibration of l a lube oil test line which had inadvertently been left .

installed by the lice ~nsee.

Line re:noved.

12/81 Piston modification to Pistons reworked by TDI to prevent crown separation. respond to Part 21 report.

Problem identified at Grand Gulf.

9/83 Unqualified instrument Replaced in accordance with cable. Part 21 report.

c' Grand Gulf Two TDI engines installed - Model DSRV-16 Serial No. 74033/34, Rated at 7000KW {'

Operating Hours to Date - Division I = 1100 hours0.0127 days <br />0.306 hours <br />0.00182 weeks <br />4.1855e-4 months <br />; Division II = 700 hours0.0081 days <br />0.194 hours <br />0.00116 weeks <br />2.6635e-4 months <br /> In 1981, Mississippi Power & Light (MP&L) commenced pre-operational testing of two V-16 engines installed at Grand Gulf Unit 1. They represent the first V-16 units ordered from TDI, and in fact, one of the Grand Gulf engines was used to qualify the entire TDI V-16 line of machines for nuclear applications.

The Grand Gulf engines have experienced significant problems in completing the pre-operational test program, have had several major failures, including a fuel line break which caused a fire, and many minor failures. A detailed list of problems at Grand Gulf follows.

Date Problem Cause/ Solution 11/81 Piston crown separation during Holddown studs failed.

operation. Pistons returned to TDI for rework. Generic problem.

3/81 Excessive turbocharger thrust No lube oil during standby.

bearing wear. Lube oil system modified.

5/11/82 Air starting valve capscrews Response to Part 21 report.

replaced. Too long for holes.

8/23/82 Flexible drive coupling material Replaced with different incompatible with operating material.

en'ironment. v 8/82 Latching relay failed during Relay replaced.

testing.

3/8/82 Air start sensing line not Sensing line relocated and seismically supported. properly supported.

1/29/82 Governor lube oil cooler ' Lube oil cooler relocated to located too high. Possibility lower elevation, of trapping air in system.

3/23/82 Engine pneumatic logic Pneumatic logic design improperly design. Could corrected.

result in premature engine shutdown.

2 Date Problem Cause/ Solution 4/29/81 Non-Class 1E motors supplied Motors replaced with Class 1E with EDG auxiliary system qualified motors.

pumps.

3/15/82 Crankcase cover capscrew Capscrews replaced with failed. Head lodged in higher strength screws.

generator and shorted it out. Lock tab washers installed.

Generator screens installed.

8/2/83 High pressure fuel injection Manufacturing defect in line failed. tubing. Tubing replaced.

9/4/83 Fuel oil line failed. Caused High cycle fatigia of major fire. Swagelock fitting. Additional tubing supports to be installed.

8/11/83 Cracks in connecting push All push rods replaced.

rod welds, 1983 -

Turbocharger vibration. Turbocharger replaced.

1983 Cracked jacket water welds. Excessive turbocharger

vibration. Cracks re-welded.

1983 Turbocharger mounting bolt Excessive turbocharger failures. vibration. Bolts replaced.

7/83 Air 3 tart valve failures. Cause unknown. System cleaned and several valves replaced.

More frequent maintenance scheduled.

10/28/83 Fuel oil leak. Tubing replaced.

Cracked push rod weld. Push rod replaced.

During EDG Cylinder head cracks. Head replaced.

Installation 12/83 Cylinder head cracks. Two heads replaced.

12/83 Cracks in piston skirts All Division II pistons on Division II EDG. replaced. Divis' ion I pistons to be inspected.

t 9/83 Unqualified instrument cable. Replaced in response to Part 21 report.

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4-1 Shoreham Three TDI Diesel Engines installed, Model DSR-48 Serial No. 74010-12, Rated at 3500KW Operating hours at time of crankshaft failure (8/83)

1. 101 = 646 (cracked crankshaft)

1. 102 = 718 (failed crankshaft)

1. 103 = 818 (cracked crankshaft)

The engines at Shoreham are the first straight-8 units to be placed in nuclear service in the U. S. One of the Shoreham engines (#101) was used to qualify the straight-8 series (R48) diesel engine for nuclear sarvice.

Pre-operational testing of the engines at Shoreham started in late 1981 and continued until the major failure of the #102 crankshaft on August 12, 1983.

After the perforinance of extensive tests in late September and early October, which were observed by staff members from NRR and Region I, as well as an NRC consultant, LILCo presented the results of its crankshaft failure investigation in a meeting on November 3, 1983. It reported that the crankshaft had been improperly designed, and had failed because the loading function used in the original design calculations was too small. LILCo also reported that it was investigating four failed connecting rod bearings which were discovered when the EDGs were disassembled. Their preliminary finding was that the failures occurred because the bearing material did not meet specifications, and the bearing loads had not been properly accounted for.

A detailed list of the EDG problems at Shoreham follows.

Date Problem Cause/ Solution 3/81 Excessive turbocharger thrust No lube oil during standby.

bearing wear. Lube oil system modified.

12/81 Piston mo'ifications to prevent Pistens reworked by TDI to crown separation, respond to Part 21 report.

Problem identified at Grand Gulf.

9/82 Engine jacket water pump Water pumps reworked by TDI.

modifications. -

6/82 Air starting valve capscrews Response to Part 21 report.

replaced. Too long for holes.

9/82 Engine jacket water pump shaft Pump shafts redesigned and failed by fatigue. replaced.

Spring /1983 Cracks in engine cylinder heads. Fabrication flaws. All heads replaced. -

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Date Problem Cause/ Solution 3/83 Two fuel oil injection lines Manufacturing defect in ruptured. tubing. Tubing replaced with shielded design.

3/83 Engine rocker arm shaft bolt High stress cycle fatigue.

failure. Bolts replaced with new design.

8/12/83 Broken crankshaft. Cracks in Inadequate design. Replaced remaining crankshafts. with larger diameter crankshafts.

9/03 Cracked connecting rod bearings. Inadequate design and substandard material.

Replaced with new design.

10/83 Cracked piston skirts. Replaced all piston skirts with new design. Generic problem.

11/83 Broken cylinder head stud nuts. Replaced all head stud nuts.

9/83 Cracked bedplates in area of Cracks evaluated by LILCo and main journal bearings. . determined to not be significant.

9/83 Unqualified instrument cable. Replaced in response to Part 21 report.

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Operating Experience - Non-Nuclear Marine Applications '

Besides being used for stationary electric power generation, TDI diesel engines have been placed in service as propulsion units on commercial cargo vessels. As part of the Shoreham operating license hearing, an intervenor, Suffolk County, requested and was granted by the Licensing Board, subpoenas for the State of Alaska, U. S. Steel, and Titan Navigation, Inc. These three organizations operate vessels which use TDI V-16 diesel engines which are very similar to most of the TDI units installed in nuclear power plants. The responses which were received indicate that the TDI engines in marine service for these organizations have experienced severe reliability problems, Most have related to faulty cylinder heads, but they have also included problems with pistons, cylinder liners, turbochargers, cylinder blocks, connecting rods, connecting rod bearings, main journal bearings, and camshafts. A detailed experience list follows. The staff is reviewing this material to see how much of it is applicable to engines in nuclear service.

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. Marine Experience with TDI Diesel Generators State of Alaska, M. V. Columbia Vessel fitted with two DMRV-16-4 Engines - Serial No. 72033/34 Rated at 9200 HP (6900 KW) at 450 RPM Vessel and engines placed in service in Jene 1974.

Each engine has approximately 30,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br /> of operating time to date.

Document Date Prob 1gg, Der:ription 12/76 - All cylinder liner seals replaced. All cylinder heads have been removed, reinstalled, or renewed at least three times.

All pistons have been removed and reinstalled at least once.

Turbochargers have been removed, repaired and reinstalled, or renewed 16 times due to leaking oil seals, vibration, rotor damage, or defective bearing seal housing.

Exhaust manifolds have been removed and reinstalled because of frozen expansion joints and resulting cylinder head flange face damage.

Lube oil consumption is excessi.ve.

6/15/78 Rapid deteriorations of fire seal rings causing blowby across gasket surface of cylinder heads.

Very low lube oil filter life (40 hours4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br />).

Caused by blowby of pistons and valve guides.

Stainless steel exhaust bellows burn out rapidly. Installed backwards by TDI.

11/28/78 (Letter to Alaska from TDI).

Recommends timing changes to improve turbocharger performance.

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. Document Cate _ Problem Description 1/31/79 Valve seats and valve guides not concentric. Results in bad valve contact.

Defective piston rings shipped as replacement parts.

Reworked cylinder head received from TDI without all required modifications and with damaged gasket face.

Newly furnished cylinder liners received with incorrect surface finish (twice).

. Connecting rod bearings furnished as spare parts were wrong size - 13" vice 12".

Turbocharger exhaust flex section incorrectly furnished by TDI. '

2/2/79 Chrome plating failure of piston rings.

Caused heavy scoring of cylinder liner, Associated cylinder head found cracked.

Seven cylinder heads replaced during 15 weeks of operation.

Excessive lube oil filter change out rate. Due to piston blowby.

Fuel injector spray tips changed at TDI recomendation to reduce carbon buildup and eliminate washing of liner walls with fuel oil.

Three major overhauls of engines in 6 years of operation.

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Carbon accumulations in rocker box areas. ,

Excessive oil vapor discharge from engine crankcases.  !

Heavy carbon deposits on valve springs.

Suspect valve blowby. j When exhaust valve guides were modifieti by TDI, they did not follow the procedure -

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outlined in their SIM (Service Information Memo).

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c Document Date Problem Description.

Loose piston pin end caps.

Incorrect piston crown to skirt bolt torque.

Bad connecting rod beariags. Excessive l wear, cracks.

Damaged connecting rod bolts.

Valve push rods cracked at weld of ball to

, pipe. QC problem.

Crankshaft size changed after engines for ship ins + ailed. No notice to owners of '

reason for change.

Excessive main bearing wear.

Camshaft lobe hard facing worn.

TDI recommended the installation of a new flexible exhaust duct which was too short (new design). Installation attempted at insistence of TDI. Unit damaged by attempt and returned to TDI for repair.

3/19/79 QC or material problems with respect to non-concentricity /out-of-round valve seats, push rods, rod bolts, bearing shells, valve stem plating.

6/14/79 Thermal growth and cracking of exhaust manifold.

12/26/79 Failure of new connecting bearings.

Cracks of 25% of connecting rods.

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Document Date Problem Description 1/16/80 Ten (10) new cylinder heads have cracks.

This includes 8 that were previously ,

repaired. 1 Fifteen (15) valves are defective with chrome flaking off the valve stems.

Valve stems are being deformed.

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Five additional push rods have cracks. l Turbocharger air cooler inlet housing is cracked for fourth time. I Internal bracing in engine intercoolers is cracked.

2/S/80 Piston rings installed improperly because mistake by TDI in the drawing used by TDI shop.

2/29/80 Piston crown-to-skirt nut torque inconsistent among nuts on various pistons.

Excessive link rod bushing bail wear caused by improperly relieved, drilled oil l passages on the matching link rod pins.

3/24/80 Abnorral carbon deposits and formations noted on pistons and cylinder head assemblies.

Fretting of jaw areas of connecting rods.

Insufficient turbo (manifold) air except at near full speed operation.

Cracked exhaust manifold end plates.

Cracking of connecting rod boxes.

Cracking of newly installed connecting rod bearing shells at 4500/ hours.

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, b Document Date Problem Description Frettug of link rod and link rod pins at their attachment together.

Fretting between link rod bushings and link rod bushing bore.

Gelling of link rod bushings in way of link rod pin outer drilled oil passages.

l Improper wear / contact pattera on newly l installed connecting rod bearings at l 4500/ hours. Four-point loading.

Insufficient connecting rod bearing wear / contact area to journal wherein it is less than 15% of the total bearing area.

Upsetting of stems in valve keeper area, Damage to number four piston ring and ring groove on all pistons modified during the '

1978-79 engine teardown and rebuilt after 4500/ hours operation.

Fretting between piston crown and skirts at 4500/ hours since piston modifications.

Variations in piston bolt torque, beyond specified limits, at 4500/ hours since piston modifications.

Damage to rod bolts, including cracking, tnd damage to threads on both the bolt and in the rod boxes.

4/18/80 Exhaust manifold conversion kits received with cuts and grooves in finished surface. Required rework by owner before installation.

5/12/80 rods received without New connecting required code (American Bureau of Shipping) approval. TDI did not have record of which rods were shipped with approval,or without approval.

Some new connecting rods shipped with -

oversize bearings but no note to customer informing of difference.

l or l

S Document Date Problem Description j l

5/14/80 Cylinder head returned to TDI has been lost by TDI. Cannot be located.

5/15/80 Custerer received new connecting rod bolt in rusty condition with damaged threads.

5/27/80 Customer received reworked cylinder heads with lip left on exhaust seats which prevents valves from seating.

Customer noted that it now was in possession of two cylinder heads with the same serial number.

Could not install lockwire in new connecting rod cap screw. Hole drilled partway through with drill broken off in center of hole. Also noted that edges of lockwire holes on other screws had not been rounded to. prevent damage to lockwire.

5/29/80 Discovered leaks in newly installed exhaust manifold head plates.

9/4/80 (Meeting Summary)

TDI says that all cylinder head prcblems should be corrected by ney! design.

TDI reports that connecting rod bearing cracks could have resulted from bad bearing alloy makeup by vendors. TDI looking at different bearing materials.

TDI stated that they had erred on piston modifications. Effected others besides COLUM8IA.

9/30/80 Eleven remaining master connecting rods to be sent to TDI to have oversize bearings and other modifications installed.

Many of the or'ginal cylinder heads that were returned to TDI for rework were exchanged for other used heads.

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er Document Date Problem Description 11/6/80 Cylinder head changed due to heavy external water leakage.

Severe smoke causing excessive lube oil '

contamination and engine room atmosphere p roblems. Engine secured to prevent possible crankcase explosion.

12/10/80 All connecting rods removed. New rod cap screws and washers to be installed because increased torque specified by TDI caused galling.

New connecting rod bearing shell found cracked.

Heavy wear noted on piston side thrust areas. Heavy hard carbon buildup noted in area of compression rings. Fourth ring groove area to be reworked by TDI due to design / machine error by TDI during previous modifications.

Nineteen (19) of 32 cylinder liners exceed spec for out-oferound. TDI to modify limits to permit continued usage.

Twenty-one (21) of 32 liners lost crush.

New phenomena. Repairs require machining i

of engine block.

Fuel injectors removed and to be changed  ;

from 140* spray pattern to 135* pattern. i Original noz-les had 150* pattern.

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1/16/S1 Cylinder block bores found to be distorted.  !

Four new engine camshafts installed.

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( Document Date Problem Description 3/13/81 Reworked cylinder heads were returned to the customer without removing the grinding compound from the valves and valve seats.

Two reworked pistons returned to customer without roll pins, which lock the securing nuts in place.

Cylinder liner delivered with wrong surface finish.

Cracks found in cylinder blocks. All replaced.

Main engine blocks found to be cracked and warped. The main block-to-base through bolts appear to have been improperly torqued during initial assembly.

One "new" camshaft found to be a rebuilt unit containing several damaged bearing journal areas.

The threaded head stud holes in the new cylinder blocks were not countekored deeper, as TDI had indicated they currently do. This was to' eliminate cracking of the block near the stud holes. The customer re-machined each of the 256 head studs to accomplish the same intent.

4/9/81 Several reworked pistons were returned without groove pins.

In response to a request for 20 li" capscrews and washers, TDI supplied 1 7/8" capscrews.

Drawings furnished by TDI for head stud modifications were not applicable to the studs in question.

50% of the fuel pump bases would not fit onto the new cylinder blocks be~cause of slight changes in the design of the blocks.

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Document Date Problem Description Two new cylinder liners provided with incorrect surface finish.

One new cylinder liner provided with flange thickness larger than manufacturer's maximum tolerance.

New connecting rod capscrews were found to be galled and unfit for use.

4/29/81 Service manual showed incorrect installation of engine camshafts.

2/3 of fuel cam tappet assemblies on one engine could not be installed on one engine because the new cylinder blocks had not been properly counterbored.

Cylinder liner counterbore depths were off to such an extent that difficulty experienced in establishing proper liner crush.

Weld spatter noted on many seating surfaces.

Dirt, sand, and metal showings found in passages and holes which should have been clean.

Cylinder h'ead water port outlet locations varied considerably, causing a water flow restriction.

Air start distributor not properly assembled at factory.

6/1/81 Exhaust manifold head plate developed a leak. Cracks found around 2 of 3 tie rods due to poor initial welding.

11/19/S1 Defective valve springs found on one engine.

7/29/82 Valve rotator failed.

Cracks discovered in the intercooler.

1 Document Date Problem Description l 7/29/82 "In nine years of operation every basic engine component has been modified or replaced with an improved item, at least once, with the exception of the crankshaft (which is obsolete and has not been used for years), the engine base, the fuel pumps and the governor. The last two items are not manufactured by TDI."

10/15/82 Turbochargers replaced.

Exhaust valve lubricating system to be installed.

3/9/83 Cracks discovered in three cylinder heads.

Reworked cylinder returned to customer with tap broken off in' threaded hole.

Others returned with internal cracks and damaged flange faces.

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O-Titan Navigation, M. V. Pride of Texas Vessel fitted with two DMRV-12-4 engines, Serial No. unknown Rated at 7800 HP at 450 RPM Engines installed 1981 - no information on total engine hours to date.

Document Date Problem Description 7/16/82 Catastrophic piston failure. Due to crack in piston skirt. Engine had 5791 hours0.067 days <br />1.609 hours <br />0.00958 weeks <br />0.0022 months <br /> of operation.

4/1/82 Cylinder block broken and cracked.

Cylinder head cracked.

Cylinder liner cracked.

Piston skirt fractured.

Suspect that all of above problems caused by water leaking into cylinder from air intake manifold. Leaking tubes found in j air intercooler.

8/19/82 Cracks discovered in six piston skirts.

7/22/82 tracked exhaust valve seats in cylinder heads. Engine had 3000 hours0.0347 days <br />0.833 hours <br />0.00496 weeks <br />0.00114 months <br /> service.

Camshaft lobe design appears to be deficient. Causes excessive stress on l fuel cam lobe and roller.

Tappet assembly rollers severely galled.

Believed to be due to camshaft and lobe 7 placement and inadequate heat treatment.

l Fuel cam lobes have failed twice due to improper heat treatment. -

Chrome plating lost from one piston wrist pin.

All four intercoolers have failed because of erosion due to high fluid velocity.

Air start valves have suddenly ceased to function, for no apparent reason. -

o Document Date Problem Description

, Plugs in crankshaft oil ways may be cracking because improper material used.

Under investigation.

Fuel oil return lines have failed. To be replaced with heavier wall tubing.

4/1/83 Exhaust valves fail after about 2000 hours0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br /> of use. Serious problems with cylinder head cracks.

Turbochargers experiencing difficulty supplying sufficient air.

s e

- - - - - m-. e,e .- g.,-,- Hw. -.,g-, . , , -we c- , ---: <.t r- *- -v+-C=*-v- 7*- Y "Y'r ' -'M' Y

e U. S. Steel, MV E. H. Gott Vessel fitted with two DMRV engines (model unknown)

Engine Serial No. 75039-40 No information on engine hours to date.

Document Date Problem Description 11/13/80 Cracked cylinder head. Replaced. l 11/1/79 Cracked cylinder head. Replaced.

6/1/80 Cracked cylinder head. Replaced.

10/8/81 Cracked cylinder head. Replaced.

Note: This information was summarized from documents provided by U. S. Steel in response to a subpoena which asked specifically for information about cyliner head failures. Many other portions of the documents were deleted by U. S. Steel, and it appears that the deleted portions referred to problems with other engine parts.

b O

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20 -

Other Applications The staff understands that other TOI engines are in service as stationary electric power-generators. The operating history of these engines will be taken into consideration during the staff assessment of TDI engines.

i l

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, ..r,-r,arr, ,7,y-, - - - g.,---r-- w~, > , , , -- - -e ., - -pn -- , ew- --g-a--er ,e-

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Reference List Shoreham .

Letter dated 1/6/84 from B. McCaffrey (LILCo) to H. Denton (NRC) ,

Board Notification 83-160 dated 10/21/83 Board Notification 83-160 dated 11/17/83 Letter dated 12/9/83 from J. Smith (LILCo) to T. Muley (NRC)

Letter dated 12/9/83 from A. Schwencer (NRC) to M. Pollock (LILCo)

Letter dated 12/29/83 from A. Schedncer (NRC) to M. Pollock (LILCo)

Letter dated 12/16/83 from C. Matthews (TDI) to T. Novak (NRC)

Letter dated 12/16/83 from J. Smith (LILCo) to T. Murley (NRC)

Letter dated 12/16/83 from A. Dynner (Suffolk County) to A. Earley (LILCo)

Letter dated 10/20/83 from A. Earley (LILCo) to L. Brenner (NRC)

Letter dated 10/16/83 from R. Boyer (TDI) to NRC Letter dated 11/17/83 from A. Earlt; (LILCo) to L. Brenner (NRC)

IE Information Notice 83-51, dated 8/5/83 IE Inspection Report 99900334/83-01, dated 10/3/83 IE Information Notice 83-58, dated 8/30/83 Grand Gulf Letter dated 11/15/83 from L. Dale (MP&L) to H. Denton (NRC) l Letter dated 10/19/83 from L. Dale (MP&L) to H. Denton (NRC)

LER 50-416/83-171/03L-0 dated 11/28/83 Letter dated 10/26/83 from L. Dale (MP&L) to H. Denton (NRC)

LER 50-416/83-082/01T-0 LER 50-416/83-126/01T-0 e

.~

San Onofre Unit 1 LER 50-206/81-017 dated 8/12/81 Letter dated 9/15/81 from H. Ray (SCE) to R. Engelken (NRC)

LER 50-206/80-039 dated 12/23/80 Letter dated 6/8/81 from J. Haynes (SCE) to R. Engelken (NRC)

Marine Applications Letter dated 12/21/83 from A. Dynner (Suffolk County) to A. Earley (LILCo)

Includes many other individual documents.

e

E)GIIBIT 3

~

Vendor Inspection History To date, the Region IV Vendor Inspection program has inspected the TDI facility in Oakland, California, nine times. The following inspection reports have been published in the PDR regarding these inspections:

1. Docket No. 99900334/79-1, dated 3/20/79

2. Docket No. 99900334/80-01, dated 1/22/81

3. Docket No. 99900334/81-01, dated 5/27/81 .-

4. Docket No. 99900334/81-02, dated 9/18/81

5. Docket No. 99900334/82-01, dated 4/15/82

6. Docket No. 99900334/82-02, dated 12/8/82

7. Docket No. 99900334/83-01, dated 10/3/83 Attached is a summary by' the Vendor Inspection Branch of the TDI inspection hi sto ry. The history includes some results from the last two inspections, which are being reviewed for proprietary information, and which will be published when that review is complete.

G e

D e

y ATTACHtiENT

[ TRANSAMERICA DELAVAL INSPECTION HISTORY VENDOR PROGRAM BRANCH FINDINGS 1979-1983 MANUFACTURING PROCESS CONTROL:

1. Performance of required inspections for completed operations on Shop Engine No. 2931 Tank Lube Oif Sump Inlet Compartment could not be verified, in that neither inspection acceptance stamps were present on the route sheets for the completed operations nor were inspection reports available to indicate rejectable conditions had been found upon ,

inspection.

, 2. Route sheets were not available to confirm required inspection acceptance of assembly operations for the emergency diesel generator (EDG) jacket water pump reflected on Drawing No. 101973, Revision C.

3. Absence of evidence of inspection acceptance for components manufactured l during. jacket water pump modifications performed in September and October 1982.

4 a. Acceptance signoff by QC inspectors was made on route sheets in-l-

regard to installation of rocker arm hold down bolts. These bolts k

were subsequently found to be missing on' inspection at the Shoreham

. Nuclear Power Station (SNPS).

-b. ShipmentofreworkedpistonstoSanbnofre, Unit 1,priortodates indicated on route ' sheets by QC inspectors that various manufacturing operations were accepted.

5. a. Route sheets not issued for rework of 92' pistons from SNPS and Grand.

Gulf EDGs' and there is, thus, no evidence of inspection acceptance of the various manufacturing operations,

b. No records of quality actiyities for rework activities on Grand Gulf EDG pistons which was a specific requirement of the procurement specification.

6. Absence of required NDE reports for SNPS replacement cylinder head castings.

7. Apparent use of unqualified personnel for performance of NDE operations on SNPS replacement cylinder head assemblies. .

13 . Improper signoffs and dates for acceptance of SNPS replacement cylinder heads with respect to personnel identity.and use of a surrendered .

, inspection stamp prior to expiration of the minimum 6-month period.

9. Use of a different hard facing welaing. procedure specification to that specified on the route sheets for valve seats in SNPS replacement cylinder head assemblies.

10. Requirements not provided for welding of and acceptance of Shearon Harris EDG fuel oil line clamps.

2 -2 .

11. Prior to October 1981, manufacture of piston skirt castings did not comply with engineering component drawing instructions with respect to performanc of specified stress relief heat treatment.

12. Route shee s for Job No. 02933 did not provide instructions in regard to swaging operations performed on crankshaft oil plugs.

13. No assembly route sheets available for SNPS replacement cylinder head .

assemblies.

. CONTROL OF SPECIAL PROCESSES:

1. Absence of procedures for examination of Level III NDE personnel and failure to qualify personnel performing visual examinations in accordance with ASME Code requirements.

2. a. Performance of vertical up position welding on ASME Section III piping (Shop Engine No. 2931, Shop Order No. 94302) by welder qualified- only fcr flat position weldin'g.

b. Welding of a 2'-inch ASME Section III piping assembly by unqualified welder. -

3. Observations during three different inspections of failure to return unused welding electrodes in required 4-hour issuance period.

4. Identification of welders used for certain operations on Shop Engine Nos. 2931 and 2959 could not be verified.

5. Unacceptable fillet weld size in Shop Engine No. 2931 Tank Lube Oil Sump Inlet Compartment due to bad fitup of tank roof and sidewall resulting in ,

almost flush condition.

6. Use of welding electrode sizes that were not permitted by appl;.able welding procedure specifications on Job Nos. 94922 and 96632.

7. Use of Job No. 95395 of welding amperage and voltage in excess of welding procedure specification requirements.

E. Performance of welding on Job Order No. 97-4'85-3085 without specified revision of welding procedure specification being in welder's possession.

9. Certification records for nondestructive examination perser.r.cl did r.ot -

indicate the use of ten checkpoints by the examiner durihg the practical examination as required by SNT-TC-1A and internal procedures.

PROCUREMENT CONTROL:

1. Failure of Quality Engineering to both update Qualified Suppliers List every 3 months and to provide a monthly summary of vendor quality ratings to QC and Purchasing.

iU ~ .

I

! 2. Evidence not available to assure that the seller of auxil'iary lube oil and jacket water pump motors complied with the requirements of the purchase order.

3. Betts Spring Company, a supplier of critical valve springs, had not been surveyed every 3 years. The,available evidence showed it was approximately 5 years since a survey had been made.

4 '

Associated Spring Company (Barnes Group) was placed on the Approved Suppliers List and used for procurement without completion of a survey or audit.

5. Kobe Steel Ltd. , a supplier of -crankshaft, was not surveyed every 3 years as required by the quality assurance program. The only available record -

was a self' evaluation survey form completed by Kobe Steel's American representative. .

6. Fuel oil tubing for Purchase Order No. 45333 was acceptea'by receiving inspection without issue of a nonconformance report, although required mill test reports had not been received.

7. Purchased Material Specification No. RL 019000 dated October 6, 1982, was not approved as required by Engineering Operating Procedure 7.

8. A 0A program was not imposed on the manufacturer of exhaust silencees for EDGs furnished to Perry, Units 1 and 2, as required by Perry Specification Nos. SP-750-4549-00 and SP-706-4549-00.

9. Purchased material specifications for engine mounted electrical control cables required only commercial grades of cable and did not invoke applicable customer specification requirements.

10. a. No available evidence to indicate that materials which were used to fabricate EDG ASME Section III Code Class 3 component supports (Midland),a,nd fuel oil systems (Midland and Grand Gulf) were procured from vendors who were either identified on the Approved Suppliers List or had been subject to audits.

b. Prior to 1982, ASME Section III Code fasteners were procured from

~ vendors who had neither been audited nor were identified on the Approved Suppliers List as being approved' for supply of this product.

11. Acceptance by receiving inspection of ASME Section III Ccde fastener certifications which did not comply with purchase order requirements with respect to: (a) conformance of chemical composition to material specification requirements, (b) completeness of mechanical test data, and (c) compliance with ASME Section III Code requirements for reporting of material heet treatment.

P i

j  ; .

12. Failure'to comply with testing requirements of paragraph NCA-3867.4(e) in the ASME Section III Code when purchasing stock materials from unsurveyed vendors.

MATERIAL IDENTITY AND CONTROL:

i j Eleven discrepancies in material identity observed in a-sample of 45 between the identity of material issued and that recorded as being used for Midland EDG S/N 77002 piping system component supports. '

DESIGN AND DOCUMENT CONTROL:

-1. Failure to comply with Division Standard Practice Nos. 4.101 and 4.201 requirements with respect to:

J

a. Release of a drawing revision to the shop without receiving approval of the applicable Engineering Change Notice from Industrial 3 Engineering.

1,

b. Maintenance of the Engineering Change Log, classification of changes as major or minor, and initiation of required forms, i 2. Parts list and component drawings released by Engineering did not define acceptance criteria for installation of crankshaft oil plugs.

3. Arsence of any . instructions' in regard to installation location of governor '

-lube oil cooler to engine. - -

4. 74.ilure to comply with Drafting Room Practice during 1982 redesign of the i EDG jacket water pump in regard to certain layout drawings not being j either drawn on tracing paper or signed and dated.

5. Dynamic analysis or testing not performed in accord,ance with Stone &  ;

l' Webster Specification No. SHI-89 after redesign of the SNPS EDG jacket water pumps. -

l

6. Failure to comply with Engineering Operating Procedure 4 and Drafting Room Practice requirements with respect to signing and dating of calculations by the designer for the SNPS jacket water pump redesign.

7. No evidence of required approval cf "D Sheets" by the applicable

-Engineering manager. Examples noted were D-4986 and D-4956 which were ertitled, " Assembly Instru;tions," and pertained tc the EDG jacket water pump.

8. Jacket water pump analyses dated September 24 and October 4, 1982, and July 15, 1983, for SNPS had not received required certification from the staff Registered Professional Engineer.

s-E l NONCONFORMANCES AND CORRECTIVE ACTION:

1. No evidence to indicate that required quarterly submittal of completed corrective action activity to the Division General Manager had ever been accomplished. -

2. Failure of Quality Engineering to process a required Corrective Action Request Form after customer identification of TOI failure to meet weld ,

quality requirements in ASME Section III Code Class 3 diesel generator '

piping.

i

3. a. Removal ano replacement of a defective weld in Shop Enginer No. 2931, Part No. 02-717-02YR, without required rejection and documentation on an Inspection Report. ,

b. Disposition of a dimensional nonconformance on Shop Engine No. 2931, Part No. 02-540-07-87, ma'de by QC supervision without required submission of the Inspection Report to the Material Review Board for review.

4. Failure to comply with ASME QA Manual requirements with respect to immediate identification of nonconforming items, on Inspection Reports and

• segregation of the items.

5. Weld shop audit not performed in the fall oY 1981'in accordar.ce with corrective action commitments made to the NRC.

EQUIPMENT CALIBRATION:

1. Actual calibration measurements for micrometers and a pressure gage were not recorded as required by Quality Control Procedure No. IP-100.

2. Gage used to measure, accept / reject the diameter and depth of the link rod dowel counterbore had not been identified in accordance with QA program requirements for calibration equipment.

3. Measures were not established to assure that tools used in crankshaft oil plug installation were properly controlled and adjusted at specified periods to maintain accuracy within necessary limits.

4. a. A welding machine in Weld Area No. 3 (Foundry) was observed in September 1983 to have calibration stickers showing a calibration due date of August 30, 1980. The OA program calibration frea.uer.:y ,

requirement for this equipment is 12 months.

b. A heat treat furnace was observed in September 1983 to have calibration stickers on the meters and temperature recorder showing a calibratten due date of March 13, 1983. ,

j. -

4 INTERNAL AUDITS:

Failure to perform required semiannual audits of the Foundry, Manufacturing and support activities.

10 CFR PART 21 PRACTICES:

1. . Records were not ava.iiable with respect to fractured thermostatic control ,

valves in Grand Gulf, Unit 1, EDGs to indicate either that an evaluation '

had been conducted in accordance with 10 CFR Part 21 requirements or that actions had been taken to determine whether the product deviation contributing to the valve fractures *

(i.e., improper use of raised face flanges in connecting piping) was present in equipment supplied to other customers.

2. Notification to affected parties in regard to.a potential problem with isoprene flexible elements of drive couplings was made after the committed date in the 10 CFR Part 21 report.

3. Failure to notify the NRC in regard to:

a. Jacket water pump shaft failures at SNPS. .

b. Potential defect in fuel injection line tubing that was used on~EDGs furnished to Grand Guld and San Onofre, Unit 1. -

OA RECORDS:

1. Recordsnotavailabletodemonstrateenvironphntalqualificationof auxiliary lube oil and jacket water pump motors with respect to Bechtel Specification Nos. 9645-M-018.0 and 9645-G-QA-1.

2. Failure to protect reccrds against fire in accordance with QA Manual raquirements noted during two separate inspections.

MISCELLANEOUS:

Failure to have Certificate of Compliance for SNPS replacement cylinder head assemblies notarized in accordance with customer. specification requirements.

E

_____-______;_;____w.

I .

s A

l l TRANSAMERICA DELAVAL, INCORPORATED VENDOR PROGRAM BRANCH. INSPECTION HISTORY

SUMMARY

OF NINE INSPECTIONS DURING 1979-1983 Number of Subject Nonconformances/ Violations ,.

Manufacturing Proce'ss Control 13 Control of Special Processes 11 Procurement Control 12 Material Identity and Control 1 Design and Document Control 8 Nonconformances and Corrective Action 5 Equipment Calibration 4 ,

Internal Audits 1 10 CFR Part.21 Practices ,

, 3 (Violations)

QA Records '3 Miscellaneous 1

/

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1- -

. , - , . , , . . ~ . . - . . . . . . .. .- - . - . - . . . , . .. . ... ,

e W EXHIBIT 4 0WNNRSAGENDA TDI'0WNER'S GROUP MEETING WITH NRC DATE: 01/26/84 TIME: 3:00 P.'M.

LOCATION: PHILLIPS BUILDING - BETHESDA I. 0WNER'S GROUP FORMATION AND CHARTER J.P. McGAUGHY II. 0WNER'S GROUP PROGRAM DESCRIPTION' W.J. MUSELER III. CURRENT STATUS OF MAJOR GENERIC FAILURE ANALYSIS ACTIVITIES -

FAAA IV. DESIGN REVIEW / QUALITY REVALIDATION PROGRAM C.K. SEAMAN (DRQR) .

V. TRANSAMERICA/DELAVAL ACTIVITIES -

TDI C. MATTHEWS VI. INTEGRATED PROGRAM APPROACH W.J. MUSELER SCHEDULE VII.

SUMMARY

J.P. McGAUGHY

SUMMARY

'0FOWNERSGROUPACTIVITIES

1. TIE MEETING NEED FOR A UTILITY IECHNICAL INFORMATION EXCHANGE ON D/G RELIABILITY EXPERIENCES PROMPTED MP&L TO SPONSOR 1ST D/G TIE MEETING IN ATLANTA ON 10/25/83, 0 26 UTILITIES REPRESENTED 0 59 INDUSTRY REPRESENTATIVES INCLUDING INPO, NRC, AND NSAC/EPRI O PRESENTATIONS GIVEN BY SEVERAL D/G OWNERS 0 REVIEWED MUTUAL PROBLEMS AT. BREAKOUT SESSIONS 0 ATTENDEES MADE 2 RECOMMENDATIONS (1) HOLD WORKSHOP OF D/G OWNERS (2) ORGANIZE D/G OWNERS's GROUP O STEERING COMMITTEE FORMED

messes 9

& $/ O k@ IMAGE EVALUATION //gj d'4j 2 x; / (4 #,

4)f,7 gy,,, ++

TEST TARGET (MT-3) t$' y,,,, p 4

+  %

l.0 'd m 12 5 9 LE 1 i,i [!- He1.8 l

I.25 1.4 1.6 4 150mm >

< 6" >

• '+kSp%*% /+A 4E>po -$d%+3 *k s_

+ t+ k'2 F

IMAGE EVALUATION /

((j%j bg,

<l pjj+\v 4/ TEST TARGET (MT-3) 4 gy, y,'*

+ N,l[ */f[

/// , .

l.0 lf 2 M tim Mm RE -

M lf{}!b l,j

, 1.8 I.25 1.4 1.6

< 150mm #

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6" #

%  %//

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1

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3

SUMMARY

OF DWNER'S GROUP ACTIVITIES (CONTINUED)

2. STEERING COMMITTEE MEETING STEERING COMMITTEE MEETING HELD NOVEMBER 30, 1983 AT OAKLAND, CALIFORNIA.

0 12 STEERING COMMITTEE MEMBERS AND 23 OTHER REPRESENTATIVES FROM UTILITIES, TDI, EPRI/NSAC, FAA REPRESENTED 0 PRESENTATIONS ON SHOREHAM TECHNICAL PROBLEMS GIVEN BY FAA 0 LIST OF D/G PROBLEMS WERE DEVELOPED FOR DISCUSSION WITH IDI

'O -

DRAFT CHARTER PREPARED BY AN OG SUBCOMMITTEE O IDI CONDUCTED TOUR AND PRESENTED INFORMATION ON CRANKSHAFTS, PISTONS, CONNECTOR ROD BEARINGS, PUSH RODS, GA PROGRAM 0 STEERING COMMITTEE RECOMMENDED IMPROVEMENTS IN TDI'S DA AND PRODUCT IMPROVEMENT PROGRAM AND COMMUNICATIONS 0 STEERING COMMITTEE RECOMMENDED IDI RESPOND WITH WRITTEN REPORT 0 COMPREHENSIVE REPORT WAS PREPARED BY IDI AND DISTRIBUTED To OWNER'S GROUP MEMBERS D e-T P W W W

. . _ . . _ . . _ . . _ . . _ _ . ..._....__.._......_._._.._.......e.

5UMMARY'0FOWNER'SGROUPACTIVITIES 3

(CONTINUED)

3. EXECUTIVE MEETING DELAVAL D/G OWNER'S EXECUTIVE MEETING HELD DECEMBER 21, 1983,

! ATLANTA, GEORGIA.

O MP&L AND LILC0 VP'S SPONSOR EXECUTIVE'S MEETING:

PURPOSE OF MEETING:

0 UTILITIES TO MANAGE EFFORT 0 DEVELOP COORDINATED EFFORT - BACK TO BASICS

~

O ADDRESS NRC AND UTILITY TDI ENGINE RELIABILITY ISSUES O DESIGN, MANUFACTURE, IESTING 0 MUST HAVE TDI INVOLVEMENT

, O ALL UTILITIES TO SUPPLY ACTIVE TECHNICAL PARTICIPATION O BUILD ON LILC0 EFFORT - HIT THE GROUND RUNNING l

0 LILC0 APPOINTED AS TECHNICAL PROGRAM MANAGER 0 MP&L V.P. WAS APPOINTED TO CHAIR COMMITTEE i

(

I - _- -

SUMMARY

'0F OWNER'S' GROUP ACTIVITIES 2

(CONTINUED)

4. TDI OG TECHNICAL MEETING TDI - OWNER'S GROUP IECHNICAL PROGRAM MEETING HELD JANUARY 6, 1984, AT LILC0/SHOREHAM SITE, N.Y.

O LILCO, TUGCO, DUKE, MP8L REPRESEhiED 0 Ph0 POSED TDI-0G PROGRAM OUTLINED 0 MAJOR ELEMENTS DEFINED 0 COSTS ESTIMATED 0 AGENDA FOR OG AND NRC PRESENTATION APPROVED 0 RECOMMENDATIONS MADE FOR UTILITIES TO IMMEDIATELY IMPLEMENT COMPONENTS SELECTION PHASE OF PROGRAM 0 SCHEDULED PRESENTATION TO OG EXECUTIVES FOR APPROVAL 0 UTILITY PERSONNEL ASSIGNED TO IECHNICAL REVIEWS

.__c

e. . . ,

suMMARYOFOWNER'SGROUPACTIVITIES I

(CONTINUED)

5. PROGRAMNPrit0 VAL-ALLTDIOWNERS 0 EXECUTIVE COMMITTEE MET JANUARY 16 0 FINAL PROGRAM PRESENTED TO OWNERS 0 PROGRAM WAS APPROVED BY ALL PARTICIPATING UTILITIES O IDI COMMITTED TO EFFORT 1

s

~ _ _

i SUMMARV 0F OWNER'S GROUP ACTIVITIES (CONTINUED)

6. DS UTILITY PARTICIPANTS GULF STATES UTILITIES (GSU)

SOUTHERN CALIFORNIA EDISON (SCE)

~

CAROLINA POWER AND LIGHT (CP&L)

DUKE POWER SACRAMENTO MUNICIPAL UTILITY DISTRICT (SMUD) ,

TEXAS UTILITIES GENERATING CO. (TUGCO)

CONSUMERS POWER MISSISSIPPI POWER AND LIGHT (MPL)

CLEVELAND ELECTRIC ILLUMINATING CO. (CEICO)

LONG ISLAND' POWER AND LIGHT CO (LILCO)

GEORGIA POWER i

, , .- - .- m ..... . - ,. .,... -, . - . ., - - -- - - - - . .. - , _ .. - - .--.

Attr.chment 2 .

TDI DIESEL GENERATOR OWNERS' GROUP ,

Chairman -

J. McGaughy (MP&L)

Vice Chairman J. George '

(TU)

Executive' Committee Program Administration

, 11 Utilities W. Angle (MP&L) i Technical Program Director W. Muscler (LILCO)

. Design Review and Quality Generic Problem Revalidation Program Testing Program Resolution (FaAA, S&W, Consultants, Definition (FaAA Lead) TDI, Utilities) (FaAA, Utilities)

I .

i .

_ m .

A .

i j D.G. DESIGN REVIEW QUALITY REVALIDATION PROGRAM YE-2 .

PROGRAM MANAGER

C.K. SE AM AN (0)

~

I l I 1 -

DESIGN GROUP COMPONENT SELECTION 'OUALITY GROUP CHAIRMAN CHAIRMAN CHAIRMAN G W. ROGERS (F) J.C. K AMMEYER (S) R.J. N AJUCH (S) 1 Y

4 l- l l l l TASK LE ADERS DIESEL l OWNERS CONSULTANTS r FoAA LEAD SCW LEAD OWNER LEAD i

REPRESEN TATIVES (S)

.C N u YER 1.FEV 1. SITE ENGl.*!EERS

2. VALV ES

r. s ""I p, RU ER I 2. DESIGN SPEC.

J. dim AM ($1 4

P. T HOL E N (c) 3. T DI R E P.

3' 'P

, , , , cg g, 2. M ARL SCHMIOT

• '"E"8 l 4. E M D j J. F H EE M AN/ (S) i

0. ESit tiONiS (S) j 5. I E C _  !

T.M. JACOB (Si lE l DOCUMENTATION RVW QUALITY ENGR'G FIELD INSPECTION l 6. T UH OO -_ I TASK LEADER TASK LE ADER TASK LEADER l R. x AotrC (Fl COMPONENT I OWNERS

• o. ASOUINO (St J.REILLY (S) J. ERR A NT E (31 i 7. BE AHitJGS -RODS-N OR REPRESENTAMES

! GEARS 1.FaAA 1.R48 g

I l

E E N. N. COOP E R H ID E R (F) 2 SEW 2.RV M

8. H DS J. P HILL 8P S (S) R. A. CHIN ($1 E.HESS ($1 9 _co; CASTINGS,3 3. DIESEL COLSULT. 3. RV 12 c. JERRSEY ($1 K.JACO8 SON (S) E.KUHNS (S)

4. OWN ERS' REP. 4. R V 20 P. N EI ER (S) R. WHITE (S)

9. STRUCT UR AL/

MECllANICAL 5. T DI R E P.

P. R. jot

• N S T O N (FI TOTAL ESTIMATE 14 i E NGINE E R'S

' STAFF SO F - FAILURE ANALYSIS #SSOCIATES j S- STONE C WE8STE.1 s20-TOTAL PERSONNEL 0- OWNER REPRESENTATIVE j- C- CONSULTANTS d

! 4

r

! TDI DIESEL GENERATOR OWNERS GROUP H -1 i

l'

! CHAIRMAN J. McGaugby

! . ( MP G L)

' VICE CHAIRMAN J. George (TU) l l

EXECUTIVE COMMITTEE PROGRAM ADMINISTRATION II UTILITIES W. Angle (M P S L) j_

)

4 TECHNICAL PROGRAM DIRECTOR W. Museler (LILCO) 4

l. .

I c I I GENERIC PROBLEM TESTING PROGRAM

' DEFINITION RESOLUTION ^

^'

' (FAAA, UTILITlE S)

(FAAA LEAD)

TDI, UTILITIES) j i

1 N-2 l PROGRAM PARTICIPANTS l-

1. OWNERS' GROUP UTILITIES (11)

2. FAAA l,

3.TDI

, 4. SWEC I

i

5. D.G. CONSULTANTS

{

! s ..

i j .

I 1

N-3 DR. FRANZ F. PISCHINGER

• CURRENT POSITION

' - DIRECTOR, INSTITUTE FOR APPLIED THERMODYNAMICS, AACHEN TECHNICAL UNIVERSITY, AND f - VICE PRESIDENT, FORSCHUNGSGESELL SCHAFT FUR

] ENERGIETECHNIK UND VERBRENNUNGSMOTOREN (FEV) i - 30 YEARS EXPERIENCE IN ALL ENGINEERING ANALYSIS AND '

) DESIGN ASPECTS OF DIESEL ENGINES i.

! e FORMER POSITION

- DIRECTOR, RESEARCH AND DEVELOPMENT, K.H.D. AG, i DIESEL ENGINE MANUFACTURER, WEST GERMANY

- RESEARCH DEPARTMENT HEAD, INSTITUTE FOR INTERNAL COMBUSTION ENGINES GRAZ l

• PUBLICATIONS l - AUTHORED TEXTBOOKS AND TECHNICAL PAPERS ON l DIESEL ENGINE DESIGN AND ENGINEERING ANALYSIS i

\

f i

E4 l PAUL THOLEN I

! e CURRENT POSITION

- CONSULTANT TO DR. F. F. PISCHINGER, FEV j e FORMER POSITION

- DIRECTOR OF RESEARCH AND DEVELOPMENT, K.H.D. AG, DIESEL ENGINE MANUFACTURER, WEST GERMANY i - RESPONSIBLE FOR:

[, - DIESEL ENGINE DEVELOPMENT i - TESTING AND MEASUREMENT

- THERMODYNAMICS i - DESIGN ANALYSIS

- DEVELOPED HIGHLY-TURBOCHARGED DIESEL ENGINES l

• PUBLICATIONS -

- " WEAR AND FUEL CONSUMPTION IN DIESEL ENGINES", S.A.E.

! MILWAUKEE CONFERENCE, SEPTEMBER 1983

~

- "TURBOCHARGING OF DIESEL ENGINES", PRESENTED IN TOKYO, f JAPAN 1977 l

- "NEW PROCEDURES IN TURBO CHARGING OF ENGINES", SIEMAG CONFERENCE, WASHINGTON, D.C.1973 5

I N-5

.DR. CLIFFORD H. WELLS (FAAA) l l e CURRENT POSITION

- VICE PRESIDENT, RESEARCH AND DEVELOPMENT

- RESPONSIBLE FOR:

j - FATIGUE AND RELIABILITY ANALYSIS l: - NONDESTRUCTIVE EVALUATION l'

l e FORMER POSITIONS

- DIRECTOR OF ENGINEERING MECHANICS, SOUTHWEST RESEARCH INSTITUTE j - ASSISTANT MANAGER, MATERIALS ENGINEERING AND RESEARCH, PRATT & WHITNEY AIRCRAFT CORP.

- CHAIRMAN, EXECUTIVE COMMITTEE, MATERIALS DIVISION, ASME i

l

• PUBLICATIONS -

l

- EDITOR," FATIGUE OF ENGINEERING MATERIALS AND ,

j STRUCTURES" l

1

l i

i l E6

! GARY W. ROGERS, P.E. (FAAA)

I

! e CURRENT POSITION

! - DIRECTOR, FAAA, PHOENIX OFFICE

! - RESPONSIBLE FOR:

- RECIPROCATING AND TURBO MACHINERY DESIGN

- VIBRATIONS ANALYSIS AND FIELD TESTING

- CONDUCTED:

- DIESEL MAIN BEARING AND GENERATOR SHAFT FAILURE ANALYSIS, ARKANSAS NUCLEAR - 1 l-

- MOTOR BEARING FAILURE ANALYSIS, SAN ONOFRE- 2

- RCP SEAL FAILURE ANALYSIS, INDIAN POINT - 2 l

i l

l e FORMER POSITION

- GARRETT CORPORATION i - RESPONSIBLE FOR:

- G-T ENGINE DESIGN AND DEVELOPMENT

- DESIGN ANALYSIS OF DRIVESHAFT TORSIONAL INSTABILITY '

i - MEMBER MATERIAL REVIEW BOARD (DESIGNIQUALITY

~

. REVIEW)

I:

l 3 '

l

DR. LEE A. SWANGER, P.E. (F A AA) .

11-7 e CURRENT POSITION l

- MANAGING ENGINEER

- RESPONSIBLE FOR:

- PALO ALTO EXPERIMENTAL LABORATORIES

- METALLURGICAL ANALYSIS i e FORMER POSITION DIRECTOR, RESEARCH AND DEVELOPMENT, IMPERIAL CLEVITE INC.

i - RESPONSIBLE FOR:

I

- COMPONENT DEVELOPMENT

- BEARING FAILURE ANALYSIS l - COMPONENT MANUFACTURE PROCESS DEVELOPMENT l

e PUBLICATIONS

" SELECTION OF CRANKSHAFT MATERIALS FOR OPTIMUM BEARING r PERFOR M ANCE",

SOCIETY OF MANUFACTURING ENGINEERS CM80-392

- "DE.VELOPMENT IN BEARINGS AND PISTONS", PRESENTED AT O MOTOR NO FUTURO, SAO PAULO, BRAZIL, SEPTEh.' R 1980

. U.S. PATENT NO. 4333215 " BEARING MATERIAL AND METHOD OF MAKING" s ..

c. , ,e nen

l t

i N-8 PROGRAM CONCEPTS

1. FOCUS ON SPECIFIC COMPONENTS i

2. CONSIDER ALL ENGINE COMPONENTS FOR POTENTIAL REVIEW

3. NUCLEAR AND INDUSTRY EXPERIENCE FACTORED IN

4. HIGH QUALITY RESOURCES

5. UNIFIED ~ TEAM APPROACH

6. ADDRESS SUBSTANTIVE ATTRIBUTES

! (SMALL "q" VS. CAPITAL "O" FOR QUALITY)

~

l 7. ADDITIONAL TESTING WHERE REQUIRED l

I 8. ADDITIONAL INSPECTIONS WHERE REQUIRED l-l.

i .

15E*8 l

OWNERS' GROUP . PROGRAM i

ELEMENTS .

I i e KNOWN PROBLEM RESOLUTION (GENERIC AND ENGINE UNIQUE) e DESIGN REVIEW AND QUALITY REVALIDATION (DRQR)

L e ADDITIONAL TESTING AND INSPECTION (WHERE REQUIRED) .

l e RESPONSES TO NRC QUESTIONS

l j H-10 l SIGNIFICANT KNOWN PROBLEMS ,

i

1. CRANKSHAFT j 2. CONNECTING ROD BEARINGS

! 3. PISTONS

4. CYLINDER HEADS ,

j 5. CYLINDER LINERS ,

6. CYLINDER BLOCK

7. ENGINE BASE

8. HEAD STUDS

9. PUSH RODS

10. ROCKER ARM CAPSCREWS

11. CONNECTING RODS l 12. ELECTRICAL CABLE

13. FUEL INJECTION LINES i 14. TURBOCHARGER

15. JACKET WATER PUMPS

' 16. AIR START VALVE CAPSCREWS I g ..

4 - .

l s 44

! DOCUMENT PACKAGES FOR

! NRC REVIEW j, (FOR EACH OWNER) l 1. SPECIFIC REPORTS ON EACH KNOWN j PROBLEM

• GENERIC i

i

• ENGINE SPECIFIC .

)

i

2. ENGINE SPECIFIC DRQR REPORT l 3. PREOPERATIONAL TEST REPORTS (VIA I&E)

4. SPECIAL TEST REPORTS (IF APPLICABLE)

5. RESPONSES TO NRC QUESTIONS I

• GENERIC

• ENGINE SPECIFIC ,

i s .-

3E-1 l CRANKSHAFT FAILURE RESOLUTION

! 1. CAUSE IDENTIFIED VIA MULTIPLE METHODOLOGIES

{

• HOLZER ANALYSIS j

• MODAL SUPERPOSITION 4

i

• FINITE ELEMENT ANALYSIS j

2. TEST OF 13 X 11" SNPS CRANKSHAFT CONFIRMED ANALYSIS i

3. ADEQUACY OF NEW 13 X 12" CRANKSHAFT CONFIRMED

)

• ANALYTICALLY t

• TESTING c

4. PROBLEM WAS SHOREHAM UNIQUE '

5. OTHER CRANKSHAFT TYPES BEING CONFIRMED f

i

~

l i s .-

0 0 2 -

. 2 -

- - 7 ~ - 7 f

) )

s s e e e e r

r g D g e E e D

(

d T d E

(

R 0 E LA 05 U g l 6 L U i I 6 L S

- 3 G C 3 G A N L N E A AC A M K K N N A A R R C C AW L

- - - - ~ - -

0 0 0 0 0 0 0 0 0 0 0 0 2 2 2 2 29.x10WD0EOFng<xa 29.xL0 woOgOF Fu.<Im me> T I t 1Im \

,h' oij :i : ; ' ,l

.I i111i

, :l i < 'Iij

' . L ;!!j!i ) I j!

~

i CRANK PIN, JOURNAL BEARING -

4 11 INCH 12 INCH ~

PIN DI AMETER PIN DI AMETER i

l Peak Oil Film Pressure ,

2 9,745 psi 2 6,7 80 psi Max. Predicted Yaw 0.0 0 7 9 inch O.0052 inch i

Max. Calculated Stress 10,931 psi 5,412 psi l Crack Growth Life from 250 hour0.00289 days <br />0.0694 hours <br />4.133598e-4 weeks <br />9.5125e-5 months <br /> 38,000 hour0 days <br />0 hours <br />0 weeks <br />0 months <br />

) From O.7mm Diameter Defect

\

- FaAA-M-84-1-6 l ,

) Y-2 .

i BEARING FAILURE RESOLUTION ~

i

) 1. CAUSE IDENTIFIED

2. PROBLEM WAS SHOREHAM UNIQUE I 3. 'NEW SHOREHAM DESIGN FOUND l ADEQUATE VIA

= ANALYSIS l

• INSPECTION

• MATERIAL TESTING l 4. BEARINGS ON OTHER ENGINES TO BE CONFIRMED VIA

• ANALYSIS

• INSPECTION a MATERIAL TESTING

)

1

/. / /

cham r: ~

, [ / '

cha fe a s / - /;

1/16*! connecting rod bearing iconnecting rod bearing chamforj .

Inner surface'

_, _- F' N

UNSUPPORTED END COMPLETELY SUPPORTED END Bearing: Connecting rod configuration. Bearing: Connecting rod configuration with original 11-inch Journals.. with replacement 12-inch Journals.

i l

FaAA-M-84-1-6 e, ..

m

l V-g I; i

'i' l STATUS OF PISTON ANALYSIS  ;

i 1

1. Three piston skirt types involved

! ( AF, AN, AE) .

l i

) 2. Analytical model still under development by FaAA i

i .

l 3. Strain gage rig test planned i  !

l i I

l 4. German piston consultant engaged for i,,

j additional analysis 4

5. AE piston operating experience good

• TDI test engine (2)

{

• Kodiak utility engine (16)

~

FaA A-M-84-1-9

, 3 l

I ___

s .

i P

T- 2 62 V , 3 _

r u __ y

- / s AE AF AE t

y

~ AF..

' '... ' r._. u). ,u :a:-%

. y ;7;': . ;-

..  ; Ap

,"",y-i ....;,..

. . :.-.. , v 3 '

Cavity AE i l

1 i

I I 1

FaAA-M-84-1-6

. . _ __. . . _ . . . . _ _ _ _ . . _ , __._..._. _.__.._..._.___. _ . _ __. ..._...._.__.__..._ ..._.. .__ .__ .___. __ ____.__.,., _ _ _ _ .~

.. g Crown

/

C

/

/j $0 f h- 5  ! -h hy( /! .

Al(hftW-**$dh\' s Dgf,,

inner ring outer odge gap I '

contact area l Figure 3-2. Cross section of crown and skirt indicating the two areas of load transfer j .,, from the crown to the skirt.

)$>

J b

• I 4

3 f

sN 1 N T N

N r N'

N N N

N N \

N \

N

)i \ '

k NN

\

N N/\

\

s \

s \

Region of peakx s streso selected O' '

s iiM, =

for local refined model i \ \ .1 ' s ,, _ ,

(

--- j : - -

'i 1 ! ' , . k ",n (see Figure 3-11)lll!l~:J' "

z 4

///ff-5:6 s _- '

a gy '

s__-

{

=x s\ \\ \ lili l Figure 3-10. . Global model of AE piston skirt.

• FaAA-83-11-13

l I E1 -

l DESIGN REVIEW / QUALITY .

REVALIDATION PROGRAM l

e ORGANIZATION 1 e. PROGRAM DESCRIPTION l

e SCHEDULE AND STATUS e SAMPLE TASK DESCRIPTIONS

! ~

I s ..

i . _ _ . _

D.G. DESIGN REVIEW QUALITY REVALIDATl'ON PROGRAM 3ZI-2 5

1 -

,t

, [ PROGRAM MANAGER C.K. SE AM AN (01 f .i 1 I _

I

, DESIGN GROUP COMPONENT SELECTION QUALITY GROUP CHAIRMAN CHAIRMAN CHAIRMAN e w.Ro6ERS (F) J.C.N AMMEVER (S) R.J. N AJUCH (S) l I I I

/' TASK LEADERS DIESEL OWNERS' FoAA LEAD SEW LEAD OWNER LEAD CONSULTANTS REPRESENTATIVES

1. SITE fHGINEER L. A. SwANoE R (FI w.ORR ($3 u.H.SCHuStr.A (On J.c. s s uuE V ER ISI 1.FEV 1. SITE ENGINEERS

2. VALV E S i 'jp ' ,*u g"'"E R 2. DESIGN SPEC.

' J.Dlu ARE (S) P. T HOL E N (Cl 3.TDI REP.

3'

, ,,$c, g33 2. M ARL SCHMIOT

4. E MD J. F R E E W 4 N/ (S) s o.ESIEL ONIS (S)

5. l E. C  !

T.u JAcos (St DOCUMENTATION RVW QUALITY ENGR *G FIELD INSPECTION TASK LEADER TASK LEADER TASK LEADER

6. TUR BO R. M ADL EC lFl COMPONENT OWNERS

• O. ASQUINO (St J.REILLY (Si J. E R R A N TE ISl

7. BE ARINGS RODS-GEAHS 1. Fa A A 1.R48 l

E

[E l E

N N.COOPEHRIDER (F)

2. S E W 2. RV 16 J. PHIL LIPS IS D R. A. CHIN (S) E. NESS ISI i'

j 8. HE ADS-CAST INJS 3. DIESEL CONSULT. 3. R V 12 0.JERRSEY ($3 K.JACOBSON (Si E.NUHNS (SB

"*""I" I "'""I

4. OWN E RS' REP. 4. R V 20 4

9. ST RUCT UR AL /

l MECHANICAL 5. TDI REP.

) -

P.H.JOHNSTON (Fl 1

j TOTAL ESTIMATE 14 PERSONNEL l5 PERSONNEL l 11 EST. PERSONNEL l 8 EST. PERSONNEL l 5 EST. PER3ONNEL l 8 4

ENGINEER'S 50

STAFF -

F- FAILURE ANALYSIS ASSOCIATES

~

820- TOTAL PERSONNEL O- OWNER REPRESENTATIVE

. C- CONSULTANTS s ..

3&3 PROGRAM DESCRIPTION PROGRAM IS CONDUCTED IN FIVE PHASES:

I. ASSEMBLE EXPERIENCE DATA II. COMPONENT SELECTION IIL PREPARATION OF TASK DESCRIPTIONS

]Y. IMPLEMENT TASK DESCRIPTIONS .

~

Y. PREPARE FINAL REPORT

+ ..

i DR/QR PROGRAM FLOW CHART 3ZE-4 N

IDENTIFY ENGINE COMPONENTS

) I 4 4

! ASSEMBLE SITE ASSEMBLE INDUSTRY j

EXPERIENCE DATA: > PHASE y

j EXPERIENCE DATA:

1.R-48 1. NUCLEAR

! 2.TDI MARINE I 2. RV-t6 3.TDI STATIONARY J

3. R V-12 j 4. R V-20

i I /

4 PHASE SELECT COMPONENTS FOR REVIEW QUALITY REVALIDATION DESIGN REVIEW l

+ +

PdEPARE TASM PREPARE TASK DESCRIPTIONS DESCRIPTIONS

~

I I PHASE PERFORM CALCULATIONS, PERFORM INSPECTIONS TESTS, REVIEWS EVALUATIONS, REVIEWS I I PHASE PREPARE AND ISSUE y

FINAL REPORT 4

\ ..

i 3(l5 L ASSEMBLE EXPERIENCE DATA A. SITE EXPERIENCE MAINTENANCE RECORDS OPERATING LOSS DESIGN CHANGES &.lMPROVEMENTS FAILURES B. INDUSTRY EXPERIENCE NUCLEAR -

ALL MANUFACTURERS NON-NUCLEAR -

TRANSAMERICA DELAVAL ONLY C. COMPUTER

SUMMARY

REPORT e

b

i 3K-6

! H. COMPONENT SELECTION j A. TRANSAMERICA DELAVAL PARTS LIST h

• BASE DOCUMENT

[

• IDENTIFY COMMON PARTS B. SELECTION COMMITTEE

• OWNERS REPRESENTATIVE

= SWEC -

• FAAA

~

• TDI

• DIESEL GENERATOR SPECIALIST C. SELECTION BY CONSENSUS

• COMPONENT FUNCTION (CLASSIFICATION)

• REVIEW EXPERIENCE DATA D. OUTLINE MINIMUM REVIEW REQUIREMENTS

• IDENTIFY IMPORTANT QUALITY ATTRIBUTES

• OUTLINEE DESIGN REVIEW REQUIREMENTS E. SHOREHAM R-48 COMPONENT SELECTION

• TOTAL COMPONENTS -

217 152

• DESIGN REVIEW -

• QUALITY REVALIDATION -

133

• TOTAL COMPONENTS HEVIEW OR REVALIDATED -

166 s- .,

i l

YI-7 i -

i i

IIL PREPARATION OF TASK DESCRIPTIONS A. TASK LEADER ASSIGNED .

• ENGINEERING OR QUALITY SPECIALISTS

• RESPONSIBILITIES I B. QUALITY REVALIDATION

• NDE

= DESTRUCTIVE EXAMINATIONS 1

• IDENTIFY SAMPLE SIZE l

• PROCEDURES SPECIFIED ,

j C. DESIGN REVIEW i = INDUSTRY STANDARDS

• DETAll METHODOLOGY & REQUIRED INFORMATION

• UNIQUE ANALYSIS (FEM) j- = EVALUATIONS l D. TASK DESCRIPTION REVIEWS

• OWNER'S REPRESENTATIVES l

!

• TDI

• GROUP CHAIRPERSON & PROGRAM MANAGER

![

~

i- -

j i ..

L -. - - . .. . _ _ _ _ _ _ _ _ _

l l

l YI-8 l IV. IMPLEMENT TASK DESCRIPTION A. REVIEW / REVALIDATION IMPLEMENTED BY TASK j LEADER B. QUALITY REVALIDATIONS l

• USE OF SPARE OR REPLACEMENT PARTS l

• ENGINE INSPECTIONS & TESTS -

!

• DOCUMENT RESULTS

!

• ANALYZE RESULTS (USE DESIGN GROUP IF NECESSARY) .

i C. DESIGN REVIEWS

!

• REVIEW EXPERIENCE DATA  !

I e CALCULATIONS PERFORMED

{

• EVALUATIONS BY CONSULTANTS

• FEEDBACK TO QUALITY GROUP

D. IDENTIFY RESULTS AND RECOMMENDATIONS i' '

e REVIEWED BY OWNER'S REPRESENTATIVES, TDI, GROUP CHAIRPERSON AND PROGRAM MANAGER  ;

• COMPONENT ACCEPTABLE

• INCREASE INSPECTION I MAINTENANCE FREQUENCY

!

• UPGRADEIREPLACEMENT ,

i i e'

{

l l 119 i Y. PREPARE FINAL REPORT l

! EXECUTIVE

SUMMARY

) PROGRAM DESCRIPTION

! METHODOLOGY FOR SELECTING COMPONENTS

SUMMARY

LIST OF COMPONENTS AND CLASSIFICATION

)

J METHODOLOGY AND RESULTS OF COMPONENT DESIGN REVIEW l

! METHODOLOGY AND RESULTS OF COMPONENT QUALITY

! REVALIDATION I

TABULATION AND DISCUSSION ON ANY DEVIATIONS THAT WERE FOUND CORRECTIVE ACTIONS AND RECOMMENDATIONS f

i ,.

-- ____m _

i SCHEDULE / STATUS H -10 R48 LEAD ENGINE (SHOREHAM)

I ll/l 12 /l l/l 2/l 3/l 4/l ASSEMBLE EXPERIENCE I.

f I H. COMPONENT SELECTION i

l l III. PREPARATION OF TASK l l DESCRIPTION I l

N. IMPLEMENT TASK

! DESCRIPTION i

Y. PREPARE FINAL REPORT l l O

j i ge l

L SCHEDULE / STATUS M - 18 LEAD V-ENGINE (GRAND GULF, V-16) 1/1 2/1 3/l 4/l 5/l 6/l 1

I. ASSEMBLE EXPERIENCE DATA /

IL. COMPONENT SELECTION l

III . PREPARATION OF TASK DESCRIPTION l l ,

. 1:

]E . IMPLEMENT TASK DESCRIPTION l l 3E PREPARE FINAL REPORT t ..

PRELIMINARY DRQR SCHEDULE 3ZI- 12 (ALL PLANTS)  ;

i i

2/1 3/l 4/5 5/l 6/l 7/l i 1/1 I. ASSEMBLE EXPERIENCE l DATA [////((d

2. COMPONENT SELECTION R - 4 8's ]

V- 16's V-12's  ! l' V-20 III. PREPARATION OF TASK DEScalTIONS ( ALL UNITS) f///M l 4

N.lMPLEMENT TASK  ;

DESCRIPTION ! ALL UNITS)

DESIGN f//////

//////r l

QUALITY

• Y.lSSUF FIN AL REPORTS R-4S's 8 b b V 16*s O

V- 12 's y . 20's

• INSPECTIONS, NDE, ETC.WILL bE PERFORMED IN ACCORDANCE WITH EXISTING SITE CONSTRUCTION AND S/U TESTING SCHEDULES t :e

l llIK-1 '!

INTEGRATED PROGRAM APPROACH L e . GENERIC CONCERNS RESOLVED ON i LEAD ENGINES [

i 9

l e DESIGN REVIEWS OF LATER ENGINES ';

l BUILT ON EARLY UNITS j

! e SAMPLE INSPECTIONS ON ALL UNITS

INCREASE SAMPLE UNIVERSE

} e CONFIDENCE BUILDS AS PROGRAM

!~

I.

PROGRESSES

i GENERIC PROBLEM RESOLUTION p 1 P400L E W. 54sOHLHAM CH ANh5HAf f F AILURES 14 .k E 50t u l 60N. .

UNIT ANALYTICAL WORK N5 HARDWARE CHANGES INSPECT RE E H- 4 8 E NClkE i. I

'1 e 100 64R$ AT 100A POWER-3 ENGiHE5

• Hm 2E R A 64 Al v 5:5 e Nul tNSPECisON OF 3 CRAllE5HAf15 e REPL ACE 13" Ell" CRANM5HAf f 5440sLHAW e WODAL SUPEhPOS1140M Wil!l 13"Ml2*

e 10R540 GRAPH TEST-l ENGINE e flNITE EEEWENI ANAL 1545 e SIRAIN GAUCE TEST-l ENGINE -

i i e 500 HRS. Al SOOm POWER-1 ENGINE g,ygg DE ND eHa2ER ANAM585It e NDI tid 5PECilON Of I CRAN #5N AT T e NONE e-Dif 6 ENENT FGOW AbOWE) e TO8tSaOGWAPH TEST-1 ENGR 4E kANCHO 5ACHO e ltm ZE H L ' e TOR 540GR APH 1[51-8 ENGINC e NONE p y gpE N1 ucu ABOv0 i

j V-M El4GtHES: j-

- i e 100 llRS. Al 100s POWER-1 ENGINE i G14 A NO CUL F e 460L ZE R AN AL Y SIS

• t801 INSPECI60N Of 8 CRANK 5HAfI e NOkE e TOR 580 GRAPH 1EST-3 ENGINE e TORS 60GR APH IESI-l ENGINE

• 'i0L 2L e NOT INSPECilON Af1ER PREOP eNONE j C AI AWdA O fE AN I AL 1515,tt g yg 1

1E SIlNG-1 [NG4NE

! e TORSIOGRAPH IEST-1 ENCANE PE kid y * ** L $' '" e N01 eNSPECisON AfIER PREOP e NOteE O ILHENI R W ABOv0 TE51BNG-1 ENG4NE f,

• I" ' e NONE COWWANCHE PE Ak e 10N540 GRAPH IEST-l ENGINE fEkENI OW ABOVU i

aAaR 5 * #d','i 'i" nn#0,n as=Aea iEsi-i EaG= aoNE l5 e TORSIOGRAPH TEST-1 ENGiteE eNONE I VOG1LE * 'n'f,f,"g,8 N 3 Al g g, og V-12 ENGudE S:

W4DLANO e HOL2ER ANAL 15t5

• TORS 60 GRAPH TEST-l ENGINE

• NOkE

~

V-20 E HGlHL5;

• S AN Ot40f RE e 6tOL2ER ANAL V515 e 10R510CRAPN 1[51-l ENGINE eNONE l

l IL GACteteNOut

GENERIC PROBLEM RESOLUTION [

t PHOut EW CONNt'C11Nb HOD SE Akil4GS at RE SOL UllON.

unu awatvucat wonu ,[sgcl5s"?!?iEU?s. HARDWARE CHANGES H-48 ENCINES:

e JOURNAL ONBli ANALYSIS e 100 HRS AT 100m POWER-3 ENGIN($

e L CE WIDE CHAW 8ER COWCimG SNONEHAW e FINIIE ELEWCHI ANAL YSIS

• NOT INSPECi60N OF BE ARNM-

" ' C"

• L C Ci OD e F AllCUE/f RACTURE WECHAN4CS SAMPLE SASIS- ALL ENGINES g,gpLggg gg. SE ARINGS WiiH ll* BE AR4NGS >

l

• CH e 100 HRS AT 100e POWER-1 ENGINES R4Vt R Ut 440 g g Igpog ANAL,V5S g gg e NO1 INSPECilON OF BE ARINGS- o NONE SAMPLE SASIS- ALL ENGudES e NOI INSPECilON OF BE ARINGS-NANCNO SACNO e JOURNAL OHall ANALYSf5 AFTER PREOP IESilNG-

• ff DeFTENENT P ROM ABOVER S AMPL E B A SIS- ALL ENGINE S IF REOUIRE06 ,

V- to E NGINE $;

i e 100 HRS. At loos POWER-l ENGINE CHAND Gulf ELEWE I A 4AL YSIS e F AllGUE /T R ACTUHE WECHANICS ofy gg "_ ypg[ 0I

$$ _AfiER eNONE ALL ENG4NES 4

e JOUkriAL ORGli ANALYSIS e NOI INSFECitON OF BE ARlNGS-

' LA1AWUA AFIER PREOP TESTNG* *NONE dif 0.Ff ENENT FROW ABOVE) SAMPLE GAhlS- ALL ENGINES e NDi INSPECilON OF BE ARINGS-IINNY

• JOURNAL OH91T ANALYSIS Ar1[R PREOP TESilNC- *" i tir Onf f ERENT F ROM ABOVE) SAMPL E B ASIS- ALL ENGINES at REObwt[D) e NOI INSPE C100N Of BE ARINGS-CouMAf4Catt PE Ak e JOURNAL OWhil ANALYSIS AFIER PREOP TESiiNG-

• I!F Dif f EPENT FROW ABOv[I S AMPL E B ASIS- AL L E NG4NE S

• W REQUIREDI e NDI INSPECllON OF BE AN4NGS-H A"N'b

• JOUNNAL ON8ti AN AL YSIS AFIE R PREOP IESinNG- * }

tiF DFFEHENT FROW ABOVEB SAMPLE BASIS- ALL ENGINES I

, 81F REQUsRLDI s  !

e N01 INSPECilON OF BE AR6NGS-I e JOURNAL OH8ti ANAL YSIS AFI! R PREOP TESilNG- *"

lif OtFIENENT FROM A00 vel S AMPL E B ASIS- ALL ENGINE S sir REOutREDI NOll.

int' Sit ECilON Of Of ARMS FON NOT & DESINUCIIVE 1ESTING WILL ENSURE COVEWAGE OF INE ENilNE PERIOD OURedG WH6Cli

. IllE 6HSI AI L ED & SPANE WE ARINGS #4 IHE OWHENS* GHOUP ENGINE S WE RE MANUF ACIURED THE OVERALL SAWPL E WIL L INE RE F OWE

• 4 BE PROPERL Y HEPe<EEENil alive & iltE S AMPLE SilE W6t L WE SOFFUCUEN1L T L ARGE TO PROVl0E ADEOUATE CONFIDENCE IN ALL 184E SE ARANGS.

l-e-

i i

t I

GENERIC PROBLEM RESOLUTION (CON'T.)

I PROBL E M. CONNEC14NG ROD BE ARINGS

41. RE SCL UllON:

CO C UNii ANALYTICAL WORK gg ,

HARDWARE CHANGES V-12 E NGINE S:

• IJDT INSPECTION OF BE ARINGS-

• JOUNNAL OHBli ANALYSIS AFIER PREOP IESilNG- l MOLAND tif DIFTERENI IROM ABOVEB SAMPL E BASIS- ALL ENG6NES

+ OM lif REOUlklDI _

V - 20 E NGlHL 5.

• NDI INSP[CilON OF BE ARINCS- .

SAN ONOT HE

. JOUNNAL ON0il ANALYSIS AF TER PREOP TES11NG- *NONE lif Dif f ERENT FROM ABOVO S A MPL E B ASIS- AL L E NGINE S Ilf REQUIREDI NOT E:

THE SilECiloH Of HE AHiteCS FOR NDI & DESIRUCIIVE IESitNG WILL ENSb2E COVERACE OF THE EHilRE PERIOD DURING Wit!CH illE INST AL L ED & SP ARE BE ARINCS IN ll4E OWNERS

• GROUP (NGINES WER MANUF ACTURED. INE OVERALL SAMPL E WIL L IHE REFORE .

DE PROPt HL Y fiEPetL SLNil AllVE & Tit [ S AMPL E Silf WILL DE SUFFUCUENILY L ARGE TO PNOVIDE ADEOUATE CONFIDirNCE IN ALL Tite BE ARINGS.

\

. l i

e i t c Auwwuut

1 s

GENERIC DESIGN REVIEW AND ""'-*

OUALITY REV ALID ATION (DROR) PROGRAM MATRIX COMPONENT  ! HARDWARE INSPECTIONS "

UNIT SELECTION DESIGN /0UALITY REVIEW ISAMPLE OR 100m BASISI R-48 ENGINE S:

SitOHEll A M FULL FULL l fkU,"f" UNIO PARIS RIVER Uf N9 FULL FULL IMINtJS COWWON PARTSI lfy0W N UN!OUE P RT R ANCit0 S ACllO FULL F ULL IMINUS COWWON PARTSI

"" $ IREDI

• fh"tN 10 0 P RT V-16 E NGit4L S.

GRAND GULF FULL f uLL IWINUS R-48 COWWON PARTSI V-IN-4 8 - If REOUlHEDI [

e COWWON P ARTS EV-16)  ;

• ENGINE UNIOUE PARTS ,

CA1AWUA FULL FULL iMINUS COMMON PARISI " " ~

['fh[lN U 000 P R T S W

PEHHY FULL FULL lWINUS COWWON PARTSI lfk[i fNUNIOUE P RI COWWANCitE Pf Ak FULL FULL iMINUS COWWON PARTSI "

fN I U IOUL P RTS NARRIS FULL -

FULL IMINUS COWWON PARTSB [f ,W NU IOUE P R15 VOGit E FULL FULL IMINUS COWWON PARTS) fl IN UNIQUE P RIS ,

V

_ - 12 Et4Gitif S:

FULL FULL e COMMON PARIS NIDL AND IMINUS H-4 8/V-16 COMMON PART S) IV-12/ V-16/ R- 4 8 - IF RE QUIREDI e ENGINE AND V-12 UNIQUE PARTS V- 20 E 14 Git 4E S: _

FULL e COWWON paris S AN UNOF HE FULL tulNUS R-4 8, V-16, V-12 COWWON PARISl IV-20/V-12 /V-16/R-4 8 - if REOutHED)

• ENGINE AND V-20 UtalOUE PARIS t 4 ,

I L _G AUf NPHOU3

_ t

TDI OWNERS' GROUP TESTING PROGR AM

SUMMARY

UNIT PRE-OP TESTS INSPEC TIONS R-4 8 ENGINE S:  ;

.NRC PREOPS

• NDE CR ANKSil AFI I Atl. ENGINESI '

SilOREHAM . 300 llHS. AI TULL* POWER .NDE CONNECIING ROD BE ARINGS tSAMPLE6 01 L 1Esil 3 HRS. .NDE PISTONS ISAMPLE)

RIVER HEND

• NRC PREOPS .NDE CONNECilNG ROD BE ARINGS ISAMPLEl

• 130 HRS. AT FULL POWER 81 ENGINEl + NDE CR ANKSilAFI 11 ENGINE - S AMPLEI

+ SIMUL A TE D L OC A RUN ll EhCINE) .NDE PiSIONS ISAMPLEl H AlicilO S ACHO *NRC PREOPS

• NDE CONNECIING ROD BE ARINGS ISAMPLEl V-16 El4GINES:

GH AND GULF a NRC PREOPS .NDE CRAt4kSH AF T ll ENGINED

• l00 HRS. Al FUL L POWER II ENGINEl

• NDE (#0hNECithG ROD BE ARINGS ISAMPLEI

• ENDURANCE RUN ll ENGINE) e NDE PISIONS tl ENGINE - SAMPLES CA1AWUA

• NHC PREOPS

• NDE CRA14KSH AF1 II ENGINE - S AMPL E)

.NDE CONNECTING ROD BE ARINGS ISAMPLE! ,

e NDE PISIONS El ENGINE - SAMPLEl _

PEkRY

• HRC PHEOPS

• NDE CRANKSHAFT tl ENGINE - SAMPLE. IF REQUIRED)

• NDE CONNECilNG ROD BE ARINGS ISAasPLE AS REQUIRED)

• NDE PISIONS IS AMPLE - IF REQUIRE DI COMWANCilE PE AK

• NHC PREOPS .NDE CRANKSHAFT 11 ENGINE - SAWPLE. IF REOutREDI l

• NDE CONNECilNG ROD BE ARINGS ISAMPLE, AS HEOUIRED [

• NDE PISTONS IS AMPLE - IF REQUIRED) i llAHRIS

• NRC PREOPS

• NDE CRANkSHAF T 8 4 ENGINE - S AMPL E. IF REQUIREDI

+ NDE CONNECllNG ROD BE ARINGS iSAMPLE. AS REQUIREDI

• NDE PISTONS ISAMPLE - IF REQUIRED)

% OG I L f.

• NRC PREOPS 'llDE CR ANKSH AFl li ENGINE - S AMPL E. IF REOutREDI i

+ NDE CONNECTING ROD BE ARINGS (SAMPLE. AS hEOUIRED) l

• NDE PISIONS IS AMPLE - if REQUIRED) )'

. V-12 E NGINE S-uiDL A140

• NRC PREOPS e NDE CRANKSHAF T tl ENGINE - S AMPLEl

.NDE CONNECilNG ROD BE ARINGS iSAMPLEI V-?O ENGINES:

SAN ONOFHE

• NRC PHEOPS . NDE CRANkSH AF T 41 ENGINE - S AMPL E)

.NDE CONNECTING ROD BE ARINGS ISAMPLEl i 9

9 G A(.T hPHOil4 L---..----._. -- 1

TDI OWNERS GROUP

SUMMARY

SCHEDULE II-I

( PRELIMIN ARY )  !

ACTIV4TY JANI FEBI MAR I APR I MAYI JUNEl JULYl AUGl SEPTl GCTI NOVI DECl JANI I. KNOWN PROBLEMS (LEAD UNIT INSPECTIONS) .

vS S

1. CRANKSHAFT $^u'pg g l l '

1 (LEAD UNIT INSPECTIONS)

YS S 2

2. BE ARINGS ^$'pgEg

3. PISTONS A N ALYSIS l (INDUSTRIAL }

l j { INSPECTION UNIT (LEAD UNIT INSPECTIONS)

[SI l l 4.OTHERS l' AN ALYSIS l INSPECTION 1. TESTING AS REQUIRED i

H. DESIGN f. QUALITY REVIEW (DROR)

l. COMPONENT SELECTION Nd ,

2. TASK DESCRIPTIONS '////J l , ,

l

3. DRQR IMPLEMENTATION W//J l

, 4. FINAL REPORTS l R - 4 8's A n d I V- 16's a n oosia i.

V-12 O V-20 Q

. m. TESTING / MAJOR INSPECTIONS l

l l.R-48 '////J LEAD R-48 (OTHERS TBD)  ;

i I l

2. V - 16 ILES.DV-16(TENill (OTHERS TBD) {

3. V - 12 TBD

4. V - 20 TBD

i l

i i

II-2

> REQUIREMENTS FOR LICENSING ,

1. RESOLUTION OF SIGNIFICANT KNOWN PROBLEMS h

• GENERIC (IF APPLICABLE)

• ENGINE UNIQUE  !

l u l 2. COMMITMENT TO DROR PROGRAM L

3. COMPONENT SELECTION (DROR) AND PRELIMINARY .

REVIEW OF SELECTED COMPONENTS FOR SIGNIFICANT [

i ITEMS

4. COMPLETION OF PREOP TESTING AND ANY ADDITIONAL

.' TESTING (100 HRS. @ FULL POWER FOR SOME UNITS) o

5. COMPLETION OF ANY MAJOR INSPECTIONS (CRANKSHAFTS, BEARINGS, AND PISTONS)

l. .

o -,

l

9 1

UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION Before the Atomic Safety and Licensing Board

)

In the Matter of )

)

LONG ISLAND LIGHTING COMPANY ) Docket No. 50-322 0.L.

)

(Shoreham Nuclear Power Station, )

Unit 1) )

)

CERTIFICATE OF SERVICE I hereby certify that copies of SUFFOLK COUNTY'S MOTION TO ADMIT SUPPLEMENTAL DIESEL GENERATOR CONTENTIONS and the ADDENDUM to such motion, dated January 27, 1984, have been served to the following this 27th day of January 1984 by U.S. mail, first class, except as otherwise indicated.

Lawrence J. Brenner, Esq.* Ralph Shapiro, Esq.

Administrativc: Judge Cammer and Shapiro Atomic Safety and Licensing Board 9 East 40th Street U.S. Nuclear Regulatory Commission New York, New York 10016 Washington, D.C. 20555 Dr. George A. Ferguson* Howard L. Blau, Esq.

Administrative Judge 217 Newbridge Road Atomic Safety and Licensing Board Hicksville, New York 11801 School of Engineering Howard University W. Taylor Reveley, III, Esq.*

2300 6th Street, N.W. Hunton &' Williams Washington, D.C. 20059 P.O. Box 1535 707 East Main Street Dr. Peter A. Morris

• Richmond, Virginia 23212 Administrative Judge Atomic Safety and Licensing Board Mr. Jay Dunkleberger U.S. Nuclear Regulatory Commission New York State Energy Office Washington, D.C. 20555 Agency Building 2 Empire State Plaza Edward M. Barrett, Esq. Albany, New York 12223 General Counsel Long Island Lighting Company James B. Dougherty, Esq.

250 Old Country Road 3045 Porter Street, N.W.

Mineola, New York 11501 Washington, D.C. 20008

--m_m%.

r~~~ /

in 1 Mr. Brian McCaffrey Stephen B. Latham, Esq.

Long Island Lighting Company Twomey, Latham & Shea 175 East Old Country Road P.O. Box 398 Hicksville, New York 11801 33 West Second Street Riverhead, New York 11901 Jeff Smith Marc W. Goldsmith Shoreham Nuclear Power Station Energy Research Group, Inc.

P.O. Box 618 400-1 Totten Pond Road North Country Road Waltham, Massachusetts 02154 Wading River, New York 11792 Joel Blau, Esq. MHB Technical Associates New York Public Service Commission 1723 Hamilton Avenue The Governor Nelson A. Rockefeller Suite K Building San Jose, California 95125 Empire State Plaza Albany, New York 12223 Hon. Peter F. Cohalan Suffolk County Executive Martin Bradley Ashare, Esq. H. Lee Dennison Building Suffolk County Attorney Veterans Memorial Highway H. Lee Dennison Building Hauppauge, New York 11788 Veterans Memorial Highway Hauppauge, New York 11788 Atomic Safety and Licensing Board Ezra I. Bialik, Esq.

Panel Assistant Attorney General U.S. Nuclear Regulatory Commission Environmental Protection Washington, D.C. 20555 Bureau New York State Department Docketing and Service Section of Law Office of the Secretary 2 World Trade Center U.S. Nuclear Regulatory Commission New York, New York 10047 1717 H Street, N.W.

Washington, D.C. 20555 Atomic Safety and Licensing Appeal Board Richard J. Goddard, Esq.* U.S. Nuclear Regulatory Ralph Caruso Commission U.S. Nuclear Regulatory Commission Washington, D.C. 20555 Washington, D.C. 20555 Jonathan D. Feinberg, Esq.#

Stuart Diamond Staff Counsel Environment / Energy Writer New York State Public NEWSDAY Service Commission Long Island, New York 11747 3 Rockefeller Plaza Albany, New York 12223

.y .,

k

- Stewart M. Glass, Esq. Fabian Palomino, Esq.#

Regional Counsel Special Counsel to the Federal Emergency Management Governor Agency Executive Chamber

26 Federal Plaza Room 229 New York, New York 10278 State Capitol Albany, New York 12224 Gerald C. Crotty, Esq.

Counsel to the Governor Executive Chamber State Capitol '

Albany, New York 12224 Ben Wiles, Esq.

Assistant Counsel to the Governor Executive Chamber State Capitol Albany, New York 12224 Robert E. Smith, Esq.

Guggenheimer & Untermyer 80 Pine Street New York, New York 10005

- _ _ ~ .

Alan Roy Dynp r JF KIRKPATRICK( LOCKHART, HILL, CHRISIGPHER & PHILLIPS 1900 M Street, N.W., Suite 800 Washington, D.C. 20036 DATE: January 27, 1984

1. By Federal Express

• By Hand Delivery

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