ML20080E224
| ML20080E224 | |
| Person / Time | |
|---|---|
| Site: | Perry, Catawba, Grand Gulf, Comanche Peak, Midland, 05000000, Shoreham, Clinch River |
| Issue date: | 10/14/1983 |
| From: | Eisenhut D Office of Nuclear Reactor Regulation |
| To: | Gilinsky V, Palladino N, Roberts T NRC COMMISSION (OCM) |
| Shared Package | |
| ML20080E228 | List: |
| References | |
| TASK-AS, TASK-BN83-160 BN-83-160, NUDOCS 8308310050 | |
| Download: ML20080E224 (15) | |
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,,-i UtilTaD STATES y/].. J' j NUCLE AR REGULATCRY COMMISSION.
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October 21, 1983
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Docket No. 50-416
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MEMORANDUM FOR:
Chairman Palladino' Commissioner Gilinsky Commissioner Roberts Com.issioner Asselstine
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Cc =.issioner Eernthal FR7:
Carreli G. Eisenhut, Directer Division cf Licensing SUEJECT:
NEW INFORMATION CONCERNING TRANSAMERICA DELAVAL (TDI) EMERGENCY DIESEL GENERATORS, EGARD NOTIFICATION 83160 In accordance with NRC procedures for board notifications, the folicwing information is being provided directly to the Commission. The appropriate i -
boards ar.d parties 'are being provided with a copy of this memorandum.' The-
. information is aoslicable to Grand Gulf (an uncontested case), which will. be before the Ccr.ission fer full power authorization in November, 1983.
On August 12, 1923, during post-modification testing, the main crankshaft on one of the three emercency diesel generators (EDG) at the Shcreham Nuclear c
Fower Station failed and broke into two pieces.
The applicant subsecuently inspected the remaining two ciesel generators at Shoreham ar.d identified additicnal flaws in the crankshafts of these machines in locations similar to tha failure of the first machine.
A more detailed description of the failure is contained in Enclosure 1 (IE Information Notice No. 83-58).
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The EDGs at Shoreham were manufactured by Transamerica DeLaval Incorporated
~(TDI). TDI has' also' provided EDGs to several other nuclear power' plants (see ). The only; currently operating reactor with TDI diesels Lis Grand Gulf. The TDI diesel at San Onofre is used by Unit 1, which is shutcown for seismic modifications, and the diesels at Rancho Seco are not yet installed.
Eesides'the failure of the crankshaft at Shoreham, the staff has noted~the
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occurrence 6f many minor problems with TDI EDGs, which are sum.arized in.
The staff would expect minor problems to occur duringi he-t startup testing of any large piece of machinery, such as a diesel cenerator, but the number,of minor problems experienced by the TDI machines in nuclear service appears to be abnormally high (also See Encicsure 4).
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- Adci-icr. ally, during vendc-ins;ect'nns rf TDI which were pe-ferred recentiy
- t. Eecicr I'!, in resronse to allecaticrs. 'hc :taff identified ccnditiens which' imply that portiens cf the IDI Guelity Assurance (CA) Procram have net been carried cut in accordance with the provisiers c# 10 CFR 50, Appendix 3.
Regicn IV has referred the CA problems to the Office cf investigations, which has rec,uested that details nct be revealed to avoid cerrrcr.isinc the in-vestigation. As e result of an inspection performed in July 1983, the staff -
identified a potential violation and several potential nonconformences which are described in IE Inspection Report No. 99900334/83-01, dated October 3, 1983 (Enclosure 5).
The Shoreham applicant is investigating the crerksheft failure, but does nct excect te publish a reper until later in October. The staff has asked the app'.ican: to accress a series of-cuestiers cencerninc the Shoreham E03 desicn, fabrica:icn, cperation, and naintenance in its #ailure report (see Enclosure 3).
A similar list of cuestiers is being developed for other applicants.
The identifica icn cf OA problems at TDI, taken together with the nutber of operational problens and the Shcreham crankshaft failure, has reduced the staff's level of confidence in the reliability of all TDI diesel cenerators.
,.The staff will recuire, on a case.by case basis, a demonstration that these '
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concerns are not applicable to specific diessi generators because efisub-
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secuert inspections or testing performed specifically to addres's the chrve matters.
Further cevelopments and additional information on'this sub.iect will be reported to the apprcpriate Scards.
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-Da'i re 1 : 'G. Eis'enhu'., Director Division of Licensing l
-ncicsures:
(1)
IE Information Motice 83-58 l
.'i(2) Summary of DeLaval DG Problems (12/80-8/83)
>J (3)
Summary of September 2, 1983
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EDG Meeting on Shoreham l
(a)
(5)
IE Inspection Resort No. 99900334/83-01 4
With October 3,1983 Transmittal Letter '
l to Transknerica DeLaval, Inc.
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cc:
See next page I
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9 cc:
Shorenam 50-322 (Brenner, Ferguson; Morris, Laurenson, Kline, Shon) 4 Perry 50-440/441 (Bloch, Bright, Kline) -
Comanche Peak 50-445/446 (Bloch, Jordan, McCollan)
Midland 50-329/330 (Bechhoefer, Cowan, Harbour)
Catawba 50-413/414 (Kelley, Callihan, Foster)
Clinch River 50-537 (Miller, Hand, Linenberger)
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ASLAB FOR:
Snorenam 50-322 (Rosenthal, Edles, Wilber)
Clinch River 50-537 (Edles, Johnson, Wilber)
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DISTRIEUTION LIST FOR SCARD NOTIFICATION i
Cata.ca Ur.its 152, Docke Nos. 50-413/a14 Howard A. Wilber, Esq.
Clinen River Breecer Reactor, Docket No. 50-537 Mr. Donald R. Willard l
Comanche Peak Units 1&2, Docket Nos. 50 445/446 Frederick C. Williams, Esc.
Grand Gulf Units 1&2, Docket Nos. 50-416/417 Richard P. Wilson, Esc.
1 Midland Units 1&2, Docket Nos. 50-329/330 Daniel D. Wilt, Esq.
Perry Units 1&2, Docket Nos. 50-440/441 Shoreham Unit 1, Docket No. 50-322 Director, Clinch River Breeder Reactor Plant Lawson McGhee Public Edward M. Barrett, Esq.
Dr. Walter H. Jordan Library i
l Charles Bechhoefer, Esq.
Carole F. Kagan, Esq.
MHB Technical Associates Ms. Lynne Bernabei Mr. James R. Kates Manacer of Power
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Lee L". Bishop, Esq.
Frank J. Kelley, Esq.
Mississippi Power & Light Howard L. Elau, Esq.
James L. Kelley, Esq.
Palmetto Alliance De:er E. Sloch, Esq.
Dr. Jerry R. Kline Project Mgmt Corp.
Ms. Nora Bredes Christine N. Kohl, Esq.
Lawrence Brenner, Esq.
William E. Lantrip, Esq.
Atomic Safety and Licensing Mr. Glenn 0. Bright Stephen 3. Latham, Esq.
Board Panel Herbert H. Brown, Esq.
James A. Laurenson, Esq.
Atomic Safety and Licensinc James E. Brunner, Esq.
William M. Leech, Jr.,.Esq.
Appeal Panel Dr. John H. Buck Mr. Howard A. Levin Docketing & Service Section John G. Cardinal, Esq.
Mr. Gustave A. Linenberger Document Management Branch Terry 'J. Lodge, Esq. s - Wp c-i. Myron M. Cherry, p.c.
Dr. Thomas S. Cechran Karen E. Long, Esq.
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ACRS Members
-Hon. Peter Cohalan Mr. Wendell H. Marshall Dr. Rooert C. Axtmann Mr. John T. Collins Mr. Brian McCaffrey Mr. Myer Bender i
Troy 3. Conner, esq.
Dr. Kenneth A. McCollom Dr. Max W. Carbon i
Dr. Frederick P. Cowan J. Michael McGarry III,Esq. Mr. Jesse C. Ebersole Mr. T. J. Creswell Robert S. McGeree, Esq.
Mr. Harold Etherington James B. Dougherty, Esq.
Marshall I. Miller, Esq.
Dr. William Kerr Mr. Jay Dunklebercer Michael Miller, Esq.
Dr. Harold W. Lewis George L. Edgar, Esq.
Thomas S. Moore, Esq.
Dr. J. Carson Mark Gary J. Edles, Esq.
Dr. Peter A. Morris Mr William M. Mathis i
Mrs. Juanita Ellis Spence W. Perry, Esq.
Dr. Dade W. Moeller.
Donald T. Ezzone, Esq.
William L. Porter, Esq.
Dr. David Okrent
. ( Mr. Jonathan D. Feinberg.
David J.- Preister,.Es.q.
.Mr. Jeremiah J. Ray
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Dr. Milton S. Plesset
'Dr. George Ac Ferguson
.Dr. Paul W. Purdom',,
l Dr. Richard F. Foster Mr. Paul Rau Dr. Paul C. Shemon l
Leon Friedman, Esq.
W. Taylor Reveley.III,Esq.
Dr. Chester P. Siess l
Eleanor L. Frucci, Esq.
Nicholas S. Reynolds, Esq.
Mr. David A. Ward Steve J. Gadler, P.E.
Mr. Jesse L. Riley j
Mr. R. J. Gary Alan S. Rosenthal, Esq.-
j David H. Gilmartin, Esq.
Cherif Sedkey, Esq.
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Stewart M. Glass, Esq.
Ralph Shapiro, Esq.
Mr. Marc W. Goldsmith Mr. Frederick J. Shon Rcbert Guild, Esq.-
Jay Silberg, Esq.
Mr. William J. Guste, Jr.
Ms. Mary Sinclair Dr. Ca#et H. Hand, Jr.
Mr. Lanny Alan Sinkin v
Dr..' Jerry Harbour Mr. Jeff Smith
_Mr. Wayne Hearn' Ms. Barbara Stamiris !
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Ms. Susan Hiatt Lucinda low Swartz, Esq.
.Dr. W. Reed Johnson Mr.. Robert G. Taylor g.
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Clir.cr. River Marshall E. Miller, Esq., Chairman Raymond L. Ccpeland Atomic Safety and Licensing Board Project Management Corp..
U. S. Nuclear Regulatcry Commission P.O. Box U Washington, D.C.*
20555 Oak Ridge, TN 27530 Mr. Gustave A. Linenberger.
Barbara A. Finamore Atomic Safety and Licensing Board S. Jacob Scherr U. S. Nuclear Regulatory Commission Dr. Thomas 5. Cc:kran Washingten, D.C.
20555 Natural Resources Defense Council, Inc.
Dr. Cadet H. Hand, Jr., Director 1725 I Street, N.W. Suite 500 Bodega Marine Laboratory Washington, D.C.
20006 University.of California P. O. Sox 247:
L. Rib Bodega Bay, California 94923 LNR Associates Nuclear Power Safety Consultants Counsel for NRC Staff 3505 Grimsby Ccurt-U. S. Nuclear Regulatory Commission Potomac, MD 20E54 Washington, D.C.
20555 Theodore J. Garrish William 5. Hubbard, Esq.
Leon Silverstrca Deputy Attorney General William Luck
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State of Tennessee U. S. Department of-Energy Office of the Attorndy General 1000, Independence Ave., S.W.
a50 James Robertson Parkway' Rocm 5-B-255 Nashville, TN 37219 Washington, D. C.
20585 William E. Lantrip, Esq.
Ci.ty Attorney Municipal Building P.O. Box 1 Oak Ridge, TN 37830 George L. Edgar, Esq.
Morgan, Lewis & Sockius 1800 M. Street, N.W.
Washington, D.C.
20036 Herbert S. Sanger, Jr., Esq.
General Counsel Tennessee Valley Authority 400 West Summit Hill Drive Knoxville, TN 37902 Scott Stuckey, Chief Occketing and Service Section Office of the Secretary
'U. S. Nuclear Regulatory Commission Washington, D.C.
20555 l
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C::ancr.e Peak Mr. R. J. Gary Exe:utive Vice President and General Manager Texas Utilities Generating Comoany 2001 Bryan Tower Dallas, Texas 75201 cc:
Nicholas S.Reynolds, Esq.
Mr. Robert G. Taylor Debevoise & Liberman Resident Inspector / Comanche Peak 1200 Seventeenth Street, N.
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Nuclear Power Station
~ Washington, D. C. 20036 r/o:U. S. Nuclear' Regulatory Commission-
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Spencer C. Relyea, Esq.
P. O. Box 38 Worsham, Forsythe & Sampels Glen Rose, Texas 75043 2001 Bryan Tcwer Dallas, Texas 75201 Mr. John T. Collins U. S. NRC, Region IV Mr. Mcmer C. Schmidt 511 Ryan Plaza Drive Manager - Nuclear Services Suite 1000 Texas Utilities Services, Inc.
Arlington, Texas 73011 2001 Bryan Tower Dallas, Texas 75201 Mr. Larry Alan Sinkin 838 East Magnolia Avenue Mr. H. R. Rock 114 W.~7th, Suite 220 Gibbs and Hill, Inc._.
__s Austin, Texas. 787,01 MM, 393 Seventh Avenue
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Mr. A. T. Parker -
Westinghouse Electric Corporation P. O. Box 355 Pittsburgh, Pennsylvania 15230~
9 David J. Preister Assistant Attorney General Environmental Protection Division-P. 0. Box 12548, Capitol Station Austin, Texas.78711 a..9 g.: =w. u.
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- Mrs. Juanita" Ellis," President i
Citizens Association for Sound Energy 1426 South Polk Dallas, Texas 75224
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l Mr. H. 3. Tucker, Vice President i
Nuclear Production Dept.
j Duke Power Company 422 South Cnurch Street Charlotte, North Carolina 28242 cc: William L. Porter, Esq.
North Carolina Electric Membership Duke Power Company Co rp.
i P.O. Box 33189 3333 North Boulevard Charlotte, North Carolina 28242 P.O. Box 27306-Raleigh, North Carolina 27611
'J. Michael McGarry,' III, Esq.
Debevoise & Libeman Saluda River Electric Cooperative, 1200 Seventeenth Street, N.W.
Inc.
Washington, D. C.
20036 207 Sherwood Drive Laurens, South Carolina 29350 North Carolina MPA-1 P.O. Bor. 95162 Mr. Peter M. YanDoorn Raleigh, North Carolina 27525 Route 2, Box 179N York, South Carolina 29745 Mr. F. J. Twogood Power Systems Division _ _ _
% estinghouse' Electric Corp"..
James P. O'Reilly, Regional: Administrator W
U.S. Nuclear Regulatory Commission, P.O. Sex 35.5 Region II Pittsburgh, Pennsylvania 15230 101 Marietta Street, Suite 3100 At1 anta,. Georgia 30303 Mr. J. C. Plunkett, Jr.
NUS Corporation Robert Guil d, Esq.
2536 Countryside Soulevard P.O. Box 12097 ~
Clearsater, Florida 33515 Charleston, South Carolina 29412 Mr. Jesse L. Riley, President Palmetto Alliance Carolina Env-ironmental Study Group 2135 1/2 Devine Street E54 Henley ? lace Columbia, South Carolina 29205 Charlotte, North Carolina 28208 J'
Carol F. Kagan, Attorney -
Richard P. Wilson, Esq.
Atomic Safety and Licensing Board Panel Assistant Attorney General U.S. Nuclear Regula tory Commission S.C. Attorney General's Office Washington, D. - C.
20555 P.O. Box 11549 Columbia, South Carolina 29211 Karen E. Long Assistant -Attorney General-Mr. Pierce X. ' Skinner.
N.C. Depart:reent of Justice Route 2, Box 179N P.O. Box 629 York, South Carolina 29745 Raleigh,-North Carolina 27602 e
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3 rand Gulf M*. J. P. McGauchy Vice Presicent Nuclear Production Mississippi Power & Light Company P.' O. Box 1640 -
Jackson, Mississippi 39205 cc: P.obert B. McGehee, Esquire Wise, Carter, Child, Steen and Caraway
?. O. Box 651 Jackson, Mississippi 39205 Troy B. Conner, Jr., Esquire Conner and Wetterhahn 1747 Pennsylvania Avenue, N. W.
Washington, D. C. 20006 Dr. D. C. Gibbs, Vice President Middle South Energy, Inc.
225 Saronne Street P. O. Box 6100 New Orleans, Louisiana-70161 ag.
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Mr. Larrv' Dale
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Mississippi Power & Light Company P. O. Box 1540 Jackson, Mississippi 39205 Mr. R. Trickovic, Project Engineer Grand Gulf fluclear Station Bechtel Power Corporation Gaithersburg, Maryland 20760 Mr. Alan G. Wagner Resicent inspector 7.:;ts Route 2,. Box,150 3,g,
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~, fyfiPortGibsonT: Mississipp.ijh9150 V
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j iUDLASD (For BNs)
/ Mr. J. W. Cook
' Vice President
~ Consumers Poaer Company 1945 West Parnall Road
/ Jackson, Michigan 49201 '
cc:
Stewart H. Freeman,
Ja:res G. Keppler, Regional Administrator t
Assistant Attorney General U.S. Nuclear Regulatory Commission, i
State of Michigan Enviornmental 799 Roosevelt Road Rephn III Protection Division 720 Law Building Lansing, Michigan 48913
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Glen Ellyn, Illinois 60137
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Pr. Ron Callen Mr. Paul Rau Michigan Public Service Commission Midland Daily News.
6545 Mercantile Way 124 Mcdonald Street P.O. Box 30221 Midland, Michigan 48540 Lansing, Michigan 48909 Mr. R. B. Borsum Geotechnical. Engineers, Inc.
Nuclear Power Generation Division ATTN: Dr. Steven J. Poulos Babcock & Wilcox 1017 Main Street 7910 Woodmont Avenue, suite 220 Winchester, Massachusetts 01890 Bethesda, Maryland 20814 Billie Pirner Garde Mr. Don van Farrowe, Chief Director,, Citizens Clinic Division of Radiological Health-for Accountable Government Department of Public Health Government Accountability Project P.O. Box 33035 Institute for Policy Studies Lansing, Michigan 48909 1901 Que Street, N.W.
U.S. Nuclear Regulatory Commission Resident Inspectors Office Commander, Naval Surface' Weapons Center Route 7 ATIN: P._C. Huang Midland, Michigan 48640
'n' nite Oak Silver Spring, Maryland 20910 Mr. Paul A. Perry, Secretary Censumers Power Company Mr. L: J. Auge, Manager 212 W. Michigan Avenue Facility Design Engineering-
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Jackson, Michigan-49201:~
Energy Technology Engineering ~ Center c
P.O. Box ' 1449 '
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Mr. Walt Apley Canoga Park, California 91304 c/o Mr. Max Clausen Battelle Pacific North West Labs (Ph"n't)
Mr. Neil Gehring Battelle Blvd.
U.S. Corps of' Engineers SIGMA IV Building NCEED - T-Richland, Washington 99352 7th Floor 477 Michigan. Avenue" Mr. I. Charak, Manager
-Detroit, Michigan 48226 NRC Assistance Project Argonne National Laboratory,
9700 South Cass Avenue Argonne, Illinois 60439
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Perry i
Mr. Murray R. Edelf.an Vice Fresifent, Nucisar Group The Cisveland Elec:ric Illuminating Company P. O. Box 5000 Cleveland, Ohio 44101 cc:
Jay Silberg, Esq.
Shaw, Pittman, Potts & Trowbridge 1200 M Street, N. W.
Washington, D. C.
20006
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Donald H. Hauser, Esq.___.
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The Cleveland Electric Illuminating Company P. O. Box 5000 Cleveland, Ohio 441d1
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Resident Inspector's Office U. S. Nuclear Regulatory Commission Farmly at Center Road Ferry, Ohio 44081 U. S. Nuclear Regulatory Cc= mission Mr. James G. Keppler, Regional Administrator, Region III 759 Roosevelt Road Glen Ellyn, 111inois1-60137.,q 7
..j D nald T. Ezz:ne, Esq.
Assistant Prosecuting Attorney 105 Main Street Lake County Administration Center Painesville, Ohio 44077 Ms. Sue Hiatt OCRE Interim Representative 8275 Munson Mentor, Ohio 44060
_. Terry _J. Lodge, Esq.
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618 N. Michigan Street.
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Suite 105 1
Toledo, Ohio 43624 i
i John G. Cardinal, Esq.
Prosecuting Attorney _
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Asntabula County Courthouse Jefferson, Ohio 44047 5
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' Sacramento Municipal Uti5ity 1-Rancho Seco, Docket No.' 50-312 District cc w/ enclosure (s):
David S. Kaplan, Secretary and Christopher Ellison, Es.q.
General Counsel Dian Grueuich, Esq.
Sacramento Municipal; Utility California Energy Corraission District 1111 Howe Avenue 6201 S Street Sacramento, California 95825 P. O. Box 15830 e
Sacramento, California 95813 Ms. Eleanor Schwartz California State Office Sacramento County 600 Pennsylvania Avenue, S.E., Rm. 201 Board of. Supervisors Washington, D. C.
20003 827 7th Street, Room 424 Sacramento, California 95814 Docketing and Service Section Office of the Secretary Mr. John B. Martin, Regional U.S. Nuclear Regulatory Commission Administrator Washington, D. C.
20555 U.S' Nuclear Regulatory Commission Residlnt Inspector / Rancho Seco Region Y c/o U. S. N. R. C.
i 1450' Maria. Lane, Suite 210 14410 Twin Cities Road-Walnut Creek, California 94596 Herald, CA 95638 g
Atomic Safety and Licenlsing Appeal Board Panel U.S. Nuclear Regulatory Commission Washington, D. C.
20555 Regional Radiation Eepresentative EPA Reaion IX Alan S. Rosenthal, Chairman 215 Fremont Street Atomic Safety and Licensing San Francisco, California 94111 Appeal Board U. S. Nuclear Regulatory Commission Mr. Robert B. Borsum Washington, D. C.
20555 Babcock & Wilcox Nuclear Power Generation. Division Dr. John H. Buck Suite 220, 7910 Woodmont Avenue Atonic Safety and Licensing' Bethesda, Maryland 20814 Appeal Board U. S. Nuclear Regulatory Commission Thomas Baxter, Esq.
Washington, D. C.
20555 Shaw, Pittman, Potts & Trowbridge 1800 M Street, N.W.
Christine N. Kohl
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Washington, D. C.
20036 Atomic Safety and Licensing Appeal Board U. S. Nuclear Regulatory Commission Washington, D. C.
20555 Joseph 0. Ward, Chief l
Radiological Health Branch Ste te Department of Health Services Helen Hubbard 714 P Street, Office Building #8 l
P. O. Box 63 Sacramento, California, 95814 Sunol, California 94586 I
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b Shoreham l
Mr. M. S. Pollock Vice Presicen - Nuclear Long :sland Lighting Company 175 East Old Country Road l
Hicksviile, New York 11801 cc:
Howard L. Blau, Esquire MHB Technical Associates Blau and.Cohn, PC.
1723 Hamilton. Avenue, Suite K 217 Newbridge Road San Jose,' California 95125 Hicksville, New York 11801 Stephen Latham, Esquire Mr. Jay Dunkleberger Twomey, Latham & Shea New York State Energy Office Post Office Box 398 Agency Building 2 33 West-Second Street Empire State Plaza Riverhead, New York 11901 Albany, New York 12223 Jonathan D. Feinberg, Esquire Energy Research ' Group, Inc.
New York State 400-1 Totten Pond Road Dept. of Public Service Waltham, Massachusetts 02154 Three Empire State Plaza Albany, New York 12223 Mr. Jeff Smith Shoreham Nuclear Power Station Ezra I. Bialik, Esquirc Post Office ' Box 618 m.
Assistant Attorney General
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Wading River, New York._ 11792 C,,
Environmental Protection Bureau New York State Department of Law W. Taylor Reveley, III, Esquire 2 World Trade' Center Hunton & Williams New York', New York 10047-Post Office Box 1535 Richmond, Virginia 23212 Resident Inspector.
Shoreham NPS, U.S. NRC Ralph Shapiro, Esquire Post Office Box B Cammer & Shapiro
. Rocky Point, New York 11778 9 East 40th Street New York, New York 10016 Herbert H. Brown, Esquire Kirkpatrick, Lockhart, Hill, Mr. Brian McCaffrey
. ' Christopher & Phillips l
M@- Long Island lighting Company; ~..
' 1900 M Street, N.W.
175 E. Old Country Road
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" Washington, D.C.
20036
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Hicksville, New York 11801
- Lawrence Coe Lanpher, Esquire Honorable Peter Cohalan Kirkpatrick, Lockhart, Hill, Suffolk County Executive Christopher. & Phillips County Executive / Legislative Bldg.
1900 M Street,1N.W..
Yeteran's Memorial Highway
-Washington, D.C.
20036 Hauppauge, New York 11788 l
Karla J. Letsche, Esquire i
David Gilmartin, Esquire Kirkpatrick, Lockhart, ' Hill, i
suffolk County Attorney
. Christopher & Phillips County Executive / Legislative Bldg.
-1900 M Street, N.W.
.c ii Veteran's : Memorial _ Highway Washington, D.C.'
20036' i
l Hauppauge, New York 11788 1
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ENCLOSURE'l
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UNITED STATES NUCLEAR REGULATORY COMMISSION t
0FFICE OF INSPECTION A:C ENFORCEMENT
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.r-Auoust 30, 15E3 i
t IE INFOR5. TION NOTICE NO. 83-55:
TRANSAMERICA DELAVAL DIESEL GENERATOR CRANKSHAFT FAILURE Adcressees:
All nuclear power facilities holding an operating license (OL) or a construction -
oermit I, CP ).
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This information' notice is provided to brino to the J.ttention c' licensees and f
ccnstruction permit holders a.recent event at.the Lhoreham Nuclear Station in which a ciesel generator crankshaft failed during post-modification full loac-
-;es ti n g.
The Nuclear Regulatory Cc= mission staff is reviewing the problem and its effects.
If the evaluation so indicates, the NRC.may recues explicit licensee or CF holder action._ In the ; interim, 'we expect' the addressees of this ir.ftraation notice to review the information herein for applicability to their -
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f,acilities. No specific action cr response is recuired at this time.
.Sescrio ion of Circumstances:
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Af er instaliation of eight new cylinder heads, emercency diesel cenerator' i
(E G) No.102 failed during post-modification testing when its crankshaft assembly ~ fractured at the crankpin and crankana (web) cn ths' generator ' side.cf '
the Cylinder No. 7 crank.
This failure occurred during the last 15 minutes of estine at the two-hour overload rating.
EDG-102 had a total oof 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> and -
4 25 minutes of two-hour overload testing when failure occurred.
Its. installed:
- ransshaf: assembly has a crankshaft diameter of 12" and La-crankpin diameter'of 11".
Replacement crankshafy ass,emblies with'12" diameter trankpins are.being
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procured.
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Subsec.uent to'this ' failure of EDG-102, the licensee examined the crankshafts :of -
the two other' diesel generator units at the.Shoreham site,lEDG-101 and EDG-103, i
by opening the crankshaft area. The examination of-the EDG-101 crankshaft
.assembiy showed cracking on the ~ Cylinder No._7 crankweb' (generato.r side) and cye penetrant indications.on the cranks at ' Cylinder Nos. 3 and 5. '
Examination of the EDG-103 crankshaft assembly identified a crack about-2"'
lor.c and 3/8" deep on the-Cylinder No. 6 crankweb ;(covernor side)' and'a.cen-r,ecting rod to crankpin bearing failure.on' Cylinder No. 5.
The bearingcfailure^
'recived breaking off of approximately a 1" x 3" piece and overheating of
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i Trar.samerica Delaval reported that the following nuclear sites have Transamerica DElaval diesel generators:
Shoreham Perry
-.f Mid1 aid.
Grand Gulf Bellefonte Ha n-tsville Catawba
-WPPS Phipps Eend San Cnofre Comanche Peak River Bend Voctie Rancho Seco Shearon Harris.
o n ncr. x1ver The reli=# nary'.informatien from the manufacturer is that the. diesels at ar.0 e..am,..iver zenc, anw, mancno.z,eco" are eight cyllncer in-line engines.
Ecs:sver, the crankpin diameter is 11" in the Shcreham units and 12" in the ur.i s at the c:her two sites.
The diesel engines at the remainder of the sites iisted above are of a "V" design and have 12,15, or 20 cylinders.
.ns sr.a t material Tor all the engines is the same, wit.n t.ne possi.g..ie excep lon c'
he 20 cylinder encines.
All the encines are designed to have approximatelv the same bra,ne mean er:Tective pressure.
_.ine torsional systems or. the engines differ.
At this time it is.not clear to.what extent other diesel canerators manufactured by Transamerica Delaval are vul'nerable tofthe same or'similar
~
failures as these experienced by the Shoreham engines.
If you have an.v. c.uestions rec.ardinc this matter, please contact the Recionai
'd--ir.istra cr of the apprcpriate NRC F.ecional Office, or this office..
t
...... i.
!. o.<.: :
Edward L. Jordan, Director Division oT
.tmergency.,reparedness anc engineering r.esponse
.. L,_L.
= ~w Office of Inso. ection and Enforcement' y
- 6. 9
.a Technical
Contact:
W. Laudan, IE
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(w:0.) Le2.c7.c.e
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...:s: c r,ecently a.ssuec n InTormation Notices -
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M:s..ancr.: 5eco units are not installed; they will bejusec to replace the ex'. stir.c diesel cenera tors.
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ENCLCSURE 2
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a Cranks har.t Tailure e
s seing it.vestigated e Cause unknown, as yet e Shorenam :De.-l v:-
b3/30/E3 e holdcown capscrews, rocker arm assy.
e reDiated wi n new desien e Sho renam.D.,.10e-e iv,l says isoiate: Taiiure e-replaced wi:n new T:,1 desigr 3/ 5/E3 e crz:ked cylinder heacs e
a water in cylincers D, says n: a:Te:;-on e i operabili y e Shoreham -
101,-1n2,.r.:.
t v e-s i
replaced with r sw design -
hi-press fuel line 3/03/33 e
e e canufa :uring defects fusi line i.-/s sei shr:vd am - u,,- s us,- 10-s e Shoren.
c
^
e Also failed at Grand Gulf'on 8/2/83 12 /i3/52 e encualified cor. rci cabies e reper:ed by 3 rand Gulf cniy e :a < i e. s i :: = :,,.,
., s.
c-.
0.0/17/52 e jacket water pump shaft failur.es new' design af er f reigr. f ailur@
e
. ours vwi.;-
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ner v-a.ci.-
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k e.
e e
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e S ho r e h am.,.. D.,
( :. 0 n.
- 10 e-e oro cesign inciuces: new s e-i, (1/0 n.ours) 1 pel.i er cat,i., removin g shaft key, size of hub washer, new assently instructicns 1
.a v
design deficiency-07/22/S2 e hi water jacket te=p. trip e
e closed cooling outlet valve e incorrect valve pos. indication e. Grand Guif Div. 2 05/23/52 e gove rner flex. drive coupiing replaced w/ neoprene a
e misapplication of caterials
. iseprena intended fer atmospheric
.appiica lon e being used at hi-te=:., cil.
environment inside gear case e Grand Gulf '.
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e J
and pitted; wris: pin cisco2crec.
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e ENCLOSUP.E 3
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f, UNITED STATES ib e gc ;
NUCLE AR REGULATORY COMMISSION 3.pqJ/.=. &S/ lj wi=SMNO*CN, O. C. 20555
.e
,4...'.i n SE? 2 i 1533 Decket No.:
50-322 APPLICANT:
Lcng Island Lighting Compcny
' FACILITY:
Shoreham Nu'elear Power Station SUEJECT:
SUMMARY
OF SEPTEMBER 2, 1983 EMERGENCY DIESEL GENERATOR MEETING f
On Se:tember 2,1953., a team ;cmposed of NRC staff mem:ers frcm the Office of Nucisar Reactor Regulation and from the Region I office, and NRC centractors, met with representatives cf the Long island Lighting Company (LILCO) to discuss LILCO's plans to investigate the cause of the failure of the #102 Emergency Diesel Generator at Shoreham.
A list of attendees is enciesed (Enclosure 1).
On August 12, 1983, during a load test,.the main crankshaft of the #102 EDG failed.
Subsecuent inspection of the !101 and !103 EDG crankshafts revenled
~
cracks in locations similar to that of the break in the #102 crankshaft.
An investigaticn of the cause of causes cf the failure is underway and will be conducted in accorcance with a master plan (Enciosure 2) which generally describes the steps to be taken.
LILCO intends to'use the resources of apprecriate LILCO crganizations, Transamerica Dela~ val (TDI), Stone &.
Webster Engineering Corporation, and appropriate contrtctors to carry cut the s eps outlined in the master plan.
Failure Analysis Asscciates (FAA) will conduct the investigatien to determine the.'cause of the crankshaft failure and the cracks.
Mr. Ycungling describec the various phases of the program, which include c~ an' independent review of the crankshaft : torsional,. design by FAA, an ov.erall
~ C des'icn. review of the entire.EDG, and:a review'of other crankshaft failures.
He reported that FAA's. torsional analysis results,ito date, agreed very clcsely with both the TDI torsional analysis and w'ith'the values measured.
by TOI in a torsional test run on the !101 EDG at the TDI factory.
LILCO has decided to use the #101 EDG as a test-bed to gather additional torsional test information and was in the process of instrume,nting th~e machine at the time of this meeting. The test data will be used to verify analytical models and to try to correiate the observed problems with the effects of previous EDG qualificatien testing.
i 4
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2-l Mer.bers of the NRC staff discussed some of the philese;hy behind the EDG test j
recuirecer.ts centainec in the Regulatcry Guides, ar.d explained the need to l
understood the pctential generic implications of tnese failures. ine staff i
i's cencerned that the failures may indicate a dificiency in the TDI desien
}
process which may shew up in other TDI ciesel c;neraters.in other nuclear j
power plants.
The staff then presented LILCO with a list of questiens and concerns which cust be addressed before the staff can have confidence in the i
ability of the diesel generators (Enclosure 3).
LILCO was requested to respend to these items as quickly as possible, as the necessary information becomes available, and Mr. Youngling and Mr. Museler assured that that could be done.
]
Mr. Museler reported 'that TDI had committed to prcvide LILCO with all the gucpert necessary te solve this prcblem. He also exclained that FAA would e the tsam leacer and that it had been' instructed te :ensider all possible ailure mechanisims and root causes, and not arbitrarily dismiss unlikely causes.
Mr. Dynner and Mr. Christensen, representing Suffolk Ccunty, as'.ad several' questiens concerning the design of the machine which LILCO premised to answer, and were assured that they would be promptly notified of the results of y e inspections.
she s.taff concluded that LILCO's plan appeared to be h
basically scund and proceeding in the right direction.
.il l
N sil c&
j Ralph aruso, Project Manager -
j Licen ing Eranch No. 2 Division of L.icensing
Enclosures:
As stated cc:
See next page
=
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. - -. ~. -
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J Shorenam M r. v.. S. Pollock Vice President - Nuclear-Long Island Lighting Ccapany 175 Eas Olo Country Road Hicksville, New York 11801 cc:
Howard L. Blau, Esquire MHB Technical Associates Blau and Cohn, PC.
1723 Hamilton. Avenue, Suite X 217 Newbridge Road
. San Jcse, California 95125 Hicksville, New York 11801 Stephen Latham, Esquire Mr. Jay Dunkleberger Twomey, Latham & Shea New York State. Energy Office Post Office Box 398 Agency Builoing 2 33 West Second Street Ecoire State Plaza Riverhead, New York 11901 Albany, New York 12223 Jonathan D. Feinsers, Esquire Energy Research Group, Inc.
New York State 400-1 Totten Pond Road Dept. of Public Service Waltham, Massachusetts 02154 Three Empire State Plaza Albany, New York 12223 Mr. Jeff Smith Shoreham Nuclear Power Station Ezra I. Bialik, Esquire Post Office Box 618 -
~ Assistant Attorney General Wading River, New York 11792 Envi ronment.al Protection ' Bureau New York State Department of Law W. Taylor Reveley, III, Esqui e 2 World Trade Center r
Hunton & Williams New York, ' thew. York 10047 Post Office Box 1535 Richmond, Virginia 23212 Resident Inspector Shoreham NPS, U.S. NRC Ralph Shapiro, Esquire Post Office Box B Cammer & Shapiro Rocky Point,cNew York 11778 9 East 40th Street New York, New York 10016 Herbert H.' Brown, Esquire Kirkpatrick, Lockhart,. Hill, Chris.topher. & Phillips.
Mr. Brian.McCaffrey.
';?CZ~Cf :
Long Island Lighting Company
'.;1900 M Street; N.W..
~175 E.~ Old Country Road
' Washington, D.C.
20036 Hicksville,.New York 11801 r
Lawrence Coe Lanpher, Esquire Honorable Peter Cohalan Kirkpatrick,; Lockhart, Hill,
Suffolk. County; Executive.
Christopher;& Phillips County Executive / Legislative Bldg.
~1900 M Street', N.W.
Yeteran's.Mecorial Highway Washington, -D.C.
20036 Hauppauge,' New York 11788
.Kar,la J. Letsche, Esquire David Gilmartin, Escuire
. Kirkpatrick,' Lockhart, Hill,
Suffolk. County Attorney
. Christopher & Phillips
. County Executive /L'egislative Bldg.
1900 M Street, N.W.
a Veteran's Memorial Highway
-Washington, D.C.
20036 '
Haucpauge, New York 11788 1
.i
\\
i Shoreham 2-James B. Ocugherty,, Esc.
is 2045 Porter Street Washington, D. C.
20005
+
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.Mr. James Rivello Plant 11anager Shoreham Nuclear Power Station P, O. Box 623 Wading River,,New York 11792 Lawrence Brenner, Esq.
- cministrative Judge Atcaic Safety & Licensing Board Ua S.. Nuclear Regulatery Cc= mission Washington, D. C.
20555 Dr. George A. Ferguson 1
School of Engineering l
Ecward University i
2300 - 6th Street, NW 4
Washington, D. C.
20059 Dr. Peter. A.~ P. orris i
Acministrative Judge Atcaic Safety & Licensing Board U. 5. Nuclear Regulatory Cc=sission 3
Washington, D. C.
20555 1
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L Sectember 2. 1983 i
I NRC R. Caruso Robert J. Giardina J,
Charles Petrone x
.J. C. Higgins J. T. Beard D. J. Vito
- t. T. i.r 0 Ivan Os rewski E. J. Ycungling W. J. Museler Kenneth Simes Franklin Research Center R. Cly'e Herrick d
Harry W. Raines
~
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ec" Shalid Ahmed-Newsday i
Stuart Diamond KLHCP - Counsel fer Sufick Ccunty 9
Alan Rey Dynner Stanley Christensen Hunten & Williams
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The curecse cf this = aster plan is to describe the crea.1.iza icn and organizarienal responsibilities for i.plementing the investigation into and recovery frca the crankshaft failure en the Imergency Diesel Generator 102 e '.. c. N. u c ' e = - O. cw a_ - S a '-' c...
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- .:,.Energency Diesel Generatcr'102., an organization has
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.=cen put in place consisting o, t.ne necessary s:
exc.ertise.to assess the cause cr:causes of the crankshaft failure; te recover:frem that failure and
=erform suitable retestinc folicwine recovery and to w e._ -.~,. e. n._ -.. 3., 4 c a 'w _4 a.. s' o #
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attachment, suppert from the LILCO Office of Nuclear a
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urance Maintenance c Departments.
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.ccm by c..isconnecting 202 r. rem t.ne Diese3 t n.e =1=anc, e _3ectricaa anc ot.ner acorc=riate cennections to tne engine anc generator in accercance C. e..._. _.,
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Gercsa Inc., a ric.c.inc. and hauling contractor,t..will
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engineering support and is respensible fer the failure analysis.
T acccmplish these tasks LFO will use its own resources supplemented by Stone & Webster Engineering Ccrporatica, TD:,.=ailure Analysis n _ s w- _ _ _, __._ _. a ; c u..
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Qualiev Assurance Opera 1cna. Quality nssurance w 3_1 provice t,ne
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engine disassenbly and reasse=bly bv. the'T?I work force.
The LILCO Quality Assurance Department will c.
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During enis investigatien and the cubsequent recovery
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. - -. f Engineerinc, Re:resentative TDI Representative
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The Test Engineer will be the'Sh,ft Direc'tcr and is
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to be accc=plished during that shift.
A pre shift meetine wl,1 u.e held to insure ::ccer coverace is availa.,e anc. to review.:nese act v t es w :n'ene c-g..4.e. c - ~..~,1.'.n. e '.. '..
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Failure Analvsis Conc.uc an nvestigation.o,, and develop a c.e:a:Aec failure analvsis fer the Diesel Generator 102 4-C _ a..,. s..a.:.
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App cpriate analysis cf the failed crankshaf.
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Review maintenance and operational history.
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Cencuct an insr.ection and assessment of the acec.uaev.
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Generaters 101, 102 and 103.: This effort consists of-the folicwing:
1)
Review of the TDI design calculatiens.
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Inspections & Tests ~- Diesel Generater~102
-The inspections and tests on cresel generator'102 incidde but may net be limited to the:following:
-1.)
The cennectinc. rod for evlinder no. 7-will be cualec. to allow :or insc.ection/examinat on :::
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2.)
Main bearings #E,-9, 10 &~11'-adjacent to the.
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An overall ene.ine insc.ectica durinc. dstailed
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100% v sua_ inspecticn or cranxsna wees anc cye ar c--ic-*=-.
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The connectine reds en cylinder 6,
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Diesel Generator 102 Reverk B4
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Gerosa r.ersonnel will ric. anc.3acx :ne engine, s r.ic. it A
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an existinc C,ean room vial be set up and access Control ceCh.
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the 'ac..crec. riate ins =. ections to.l take e. lace'.. The *Di
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Service Representative will be the resc.onsible.
suo.erviser for the TDI woikman'. ITF.e c.ene'rator will also be inspected for damage while on the. turbine i
insoecticns wl,_, be performed
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Once re=cved, the damaged shaft will be sent eff' site
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During the i..vestigation cf the Diesel Generater 102 failure the duly authorized. Failure Analysis Associate Recresentative-w en snt:t.u.as :ne autneraty to stop,erk as 1cng as the s:cp
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Upon issuing a s cp work order the Failure Analysis Associate Representative shall notify the undersigned of this action
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l Infer.r.atier Recuests en Diesel Ger.erators (D/Gs)
I. General 1.
Provide a written su=cary of the approach to be usad on the Failure analysis for DG 102 on an expedited basis.
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2.
Provide the preoperational NDE records of the three DG crankshafts.
3.
Provide the number of crankshaft failures and pooulation size for al.1 Delaval D/Gs, all nuclear service Delaval D/Gs, and all R-4 D/Gs.
Provide ~the failure analysis, if any, for the above crankshaft failures.
5.
?'rovide the total number of operating hours en each D/G and the tetal 4
numoer of hours at 39CD KW or greater.
6.
Provide copies of all LILCO/S&W audits of Delaval and responses.
7.1 What is the maximum load to which these D/Gs could be upgraded?
7.2 What modifications wculd be required to make the upgrade?
7.3 What are'the limiting components?
' 7.4 Provide an eirly reply as to whether_ these three cuestions can be a swered and an estimate as to when.
8.
Prov.ide an explanation of the claim in the June 10,1983 letter of :
Delaval to LILC0 that the LILCO DGs are " state of the art" with no other-product improvements which cculd positively affect reliability in' light of the subcover cracks and crankshaft failure and the fact that mocified
' parts were available but not identified. Also provide a commitment to review all product improvements available for the Shoreham D/Gs,-if these D/Gs are to be repaired and used.
19.
Does.Delaval have a program where parts / components etc. are modifisd (such as design margins reduced).in order to. improve okes. i i sf?.
Does this app 1y to any D/G parts for Shoreham?
0 10.
Provide responses to all NRC open. items on D/Gs.
11.
Provide responses to all itemsLin NRC consultants's report.
12.
Provide all vendor documentation on crankshafts, certificatien's of cenformance,. specs, NDE records, etc. _ Include statements of how'and where frem each crank shaft or.igi.nated.
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Frovide jus.tifica:icr:.fcr ;rincing cracks ou: cf 101 DG cranksr,af: w/o s
is dcne.
T a,. i Ure ar.a l.v5 7 5 e T O re a r.V C. ri n C i r.C.
14 Provide a cc=it: ment for tes-ing to demonstrate adequate vibra-icn i
aT:er reinsta.la:1cn.
15.
Rescense to 5/12/82 Delaval Part 21 report on starting air valve assembly.
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1 II. Precuremer.t l
1.
Provide precuremen,t specifications to which the diesel generators were ordered.
In addition, previde the performance specification, and the-inspecticns perfer ed upon rectiving the diesels to shew that the procurement specifications were met..
2.
Discuss all tests performed en the DG's that were observed by LILCo at the manufacturing facilities. Describe all the tests performed at the manufacturing facilities that were not observed by LILCo. The description should include test procedures, pertinent instrumentation diagrams, and test data and results.
3.
I'n ac'dition to the cualification tests pefernec in accordance with the guidelines RG's 1.9 and 1.108 and IEEE Stancard 887, descrite all ensite tests that were performed on the DGs.
Provide test procedures for these tests and also the data and tests results.
4 In adcition to the deficiency reports alreacy provided to the NRC',
describe any installaticn prcblems encountered during the installation and operatien of the DGs.
Provide complete operating histories of.the DGs.
5.
Provide a description cf the original design basis of the straight eight DGs used at Shoreham and a cceplete and detailed list of all product improvements made in this product line of DGs.
Include in the description the reccmmended continucus and maximum loads and the~ operating hours for each rating for each modification.
5.
Provide a latest ccpy of the technical ~ instruction manual for these DGs.
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,hg -i g of :ng
. #-'/ ice ; e tes; p'r0cecures. hit wer e ::ei,; used 3:
Tillure.
. e : s cenci:1cas in the test arsa prior to, during, and after ne ve s c r1.s 4.
allure.
ine cescription should include all pertinent tes; infermaticn' si al signs, and tes ccndi-icns such as tes: grid condition, all
,instrument reading prior := failure and post-failure, dither, all traces, vibraticns noticed and recorded, and noises.
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IV. Failure Investigation 1.
Provic'e a copy of the failure Analysis Associates (FAA) charter.
2.
Provide the manufacturer's design calculations fer the tersional analysis of the DGs.
In additicn, provide the models used, metnods of arrivine at the lumped parameters, justifications of any correlating fsctors used, calculations of all the natural frequencies, their mode ' shapes including the mode locations.
3.
Describe all the torsional testing that was performed by the manufact-urers on the straight-eight DGs. The description should include the test -
procedure, test data, test results, configurations and ccmponents of the DGs and loacing devices curing _ the test, and the instrumentation used e
and their iccations.
a.
Ccmpare the DGs presently at Shorenam' with all either TDI emergency DGs models now in use or to be used in other nuclear generating stations to show that the cenditions and/or failure modes present at Shoreham will not occur at these other nuclear plants.
5.
Describe the analytical investigations that FAA is or will be performinc on the DGs. The description shall include the torsional vibration analysis, the stress analysis and the evaluation or the TDI torsional vibration and stress analysis.
6.
Describe all the testing that will be performed by FAA on the emergency DGs at Shoreham. The description shall include test procedures and objectives, instrumentation and location, test data, test results, test loadings, test configuration, power factors, a'nd methods of evaluation icad interacticn.
7.
Based on the results of the analytical investigations and the test results, describe the effects, if any, that' fast starts had on the failure.
8.
Describe all the metallurgical and failure analysis of the crankshaft
- .m;b that will be' performed by FAA.
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i cc:ur as a resui: cf :ne installa.icn of the IEx.'2 crankshaf.
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c.
-escribe and justiry the requal...71ca:1on testinc crceram that will be j
perfcrmed on the modified DGs.
The description'snali in:iude crsior$al viera:1on and stress testing, any t.esting in addition to the testino.
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required in RGs 1.9 and 1.108 and IEEE Standard 357.
3.
Describe the impact of the previous multiplicity of failures on the modified DGs.
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s E:::LOSURI' 4 55 INS No.:
5835 i.
IN E3-51 UNITED STATES NUCLEAR REGULATORY COMMISSION OFFICE OF INSFECTION AND ENFORCEMENT WASHINGTON, D.C.
.20555 August 5, 1983 IE INFORMATION NOTICE NO. 83-51:
DIESEL GENERATOR EVENTS Addressees:-
All nuclear power facil,ities holding an o'erating license (OL) or a construction p
- emit (CP).
Pur:cse:
This information notice is provided to bring to the attention of licensees ano construction permit holders some events and experience of generic diesel cenerator problems and corrective action taken.
It is expected that.
recipients will review the information for applicability to their facilities.
No cther action or response is required.
Description of Circumstance's:
(
In its continuing review of licensee event reports (LERs), NRC has identified during the past five cenths more than 100 LERs pertaining to diesel generator prebiems. -Most of these appear to be material, equipment, or component failures.
No single co.mmon trend can be ide.stified.
j NRC is cencerned about the large number of diesel generator events.
During ciscussicns with diesel manu/acturers. and license'es, it appears that many' of i
these events could have been eliminated or prevented by. implementation of a
~
i conscientious maintenance and inspection program as well. as monitnring. equip-ment.through a plant's trend program.
Some 1.icensees have instituted such a program to detemine the underlying cause of the failures (see IE Information
!!otice 82-10) and to prevent their recurrence.: Components or materials that
^
have experienced failures are' monitored or inspected more frequently.. Many affected items are repaired or replaced before actual breakdown.
For example, l
cooling water heat exchangers that were found to be. ineffective after a certain l
period of time because of tube fculing.were replaced.
Cooling jacket circulating L
water puma bearings are inspected for wear and replaced. in.certain -intervals.
I Pressure switches and timers have been found with drifting setpoints and were' l
recalibrated or' replaced frequently.
l Escause cf the larce number of diesel generator events it is not feasible to
- escribe all the events reported.
However, Attachrent 1 to this infcrmation.
~
notice gives several representative examples and corrective acticns daken.
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... c - n August 5, 19E3 Page 2 cf E
- tr.e-e are any questiens regardir.; this matter, please centac: the Regional Acmir.is rncr of the apprcpriate !?RC Recional Office, or this of# ice, j
-[a e
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g-Edward L. Jorda, Director.
4 Division of Emergency Preparedness and Engineering Response Office of Inspection and Enforcement Technical
Contact:
Wolfgang Laudan, IE 301 492-975g A :acr.mencs:
1.
Selected Examples of Licensee Event Reports Related to Emergency Diesel Generators 2.
List cf Recently Issued IE Information ilotices
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IN 63-E1 August 5, 19E3 Page 1 of 4 SELECTED EXAMFLES 0F LICENSEE EVENT rep 0RTS AND VENDOR REPORTS RELATED TO EMERGENCY DIES $L GENERATORS OUAO-CITIES 2. OCTOBER 5. 19S2 During the monthly preventive maintenance testing of Unit 2 diesel generator,
~
the diesel tripped on high temperature 10 minutes after loading.
The cause was determined to be fouling in the cooling water heat exchanger.
The heat exchanger was replaced.and the diesel testing was satisfactorily completed.
The licensee placed the heat exchanger on a preventive maintenance schedule for ciencing.
SEOJOYAM 2, OCTOEER 20, 1952 During a performance test of diesel generator 23-B, the ecoling jacket circulating water pumo en the diesel generator was found to be inoperable as a result of a bail bearing failure in the pump.
The bearing was replaced and the diesel generater was returned to service.
SUSCUEHANNA, OCT05ER.27, 19_82 I
During a ;erformance test of a diesel generator, the diesel centrator tripped cn high vibraticn.
It was postulated that a ' vibration switch and a pressure regulator were both involved in the trip.
Both were repaired and the diesel generater was returned to service.
The equipment will be monitored through the plant's trend pregram.
ERUNSWICK 1. NOVEMBER 5, 1982 During a cuick start testing program of diesel generator No. 4, the diesel cenerater tripped on "1cw lube oil pressure."
The same problem occurred 2 cays later on the same unit.
Both events resulted from intermittent failures of the." low lube oil pressure start time relay" (STR).
The relay timed out before actual pressure was above the icw trip setpoint.
The relay was replaced and the diesel testing was satisfactorily completed.
DRESDEN 3, NOVEMBER 9, 19S2 During a Unit 3 diesel generator surveillance test, the diesel generator tripped en icw cooling water pressure.
A defective low cooling. water pressure switch caused this event.
The switch was replaced and the testing was satisfactorily Completed.
RASCHO SECO, MAY 25, 19S3 During startup testing, the diesel generator would not reach. full cperating
~
speed.
The Woodward governor speed adjustment on the unit stcpped at ~,about 650 rpm.
It was found~that the pointer disk was hanging up behind the dial plate.
The_ manufacturer reccmmended. filing about 1/16-inch eff-the pointer \\
disk to allow free-movement.
After that the diesel' achieved proper speed.
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At:achman-1 IN 83-51 Aucust 5, 1933 Page 2 cf 4
.ri. ". :.:.. s e., - ::c,.:.p e. n. t,.es-
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During a routine inspection of the in ake air check valve of No.11 diessi
- enera
- cr, the licensee found a check valve holding pin sheared and the check valve locse.
The same valve on two other diesel genera:crs.at Calvert Cliffs had been found to be cracked when inscected during 1982.
The disk of one of tr.ese.alves was found broken in two pieces. The engines in question are Fairbanks Morse Medei 387D81/8.
Because these failures did not render the diesel generators inoperable, as evidenced by successful ccr.;1stien of weekiy cperational tests, ne LER was issuec.
The licensee pointed out that there were internal baffles between the check valves and the diesei turbochar;er which made it unlikely to have a ciece cf the cneck valve enter the diesel's turcocharger.
The eneck valve in questicn diverts air be: ween the diesel turbocharger and integral air-blower.
Failure of the check valve wculd result in air being available through the turbocharcer at icw 1 cads and would affect the load centrol.
SHOR5 HAM. OCT055R 15. 1982: A?RIL 15, 1983: APRIL 20, 1983: MAY 4, 1983 During preoperaticnal testing of Shoreham's three Transa' erica Delayal, Inc.
m emergency diesel genera crs, the felicwing mechanical problems'were identified in the past g mon ns and reported by the licensee under 10 CFR 50.55 (e):
October 15, 1952 - The jacket waterpump shaft failed.
April 15,1983
- The engine head cracked.
April 20, 1983
- The fuel injecticn line failed.
May a, 1953
- The rocker arm bolt failed.
Approximately 2 years before these problems occurred, the licensee discovered the following:
' 1.
Loose hardware in cam gears during initial.onsite inspection.
2.
P.ultiple broken cylinder head exhaust bolts resulting from insufficient pipe guide clearances in' the exhaust manifo'id.
3.
Cracks in the fuel' oil ejector that connects (to the fuel oil drip line.
4 Absence of a drilled passageway for the relief valve on one lube oil pump line as required by design.
'5.
Leaky lube oil cooler tubes resulting from improper rolling in the tube sheet.
6.
Cracks in rocker arm push rod sccket (or cup)..
l l
7.
Cam gear fitted bolts not installed at the ~ factory as required.
l The crcbiens were corrected under the' surveillance of vendor representatives.
Nuclear. sites with Transamerica Delavai diesel generators are. l'sted on i
.page 4 of tnis attachment.
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Attachment i
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r August 5, 1923 raQe
- CT.,
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(Lcuis Aliis is the succe'ssor to Selouit Power Systems, Inc., and to Coit-
- airbanks Engine Division) 1.
At the diesel generator in the Clinton Nuclear Plant, a three-chase rectifier assembly in the exciter was not connected in parallel, which could cause field winding insulation to deteriorate.
Louis Allis field service took corrective action by making the necessary connections.
2.
Detrtit Ediscn experienced high vibration en its diesel generator.
The cause was loose pole wedges.
Louis Allis perferred a detailed engineering evaivatien of this problem and fcuno that in 1975 a caterial change 'rca HRS 1020 steel to 1045 steel was made.
This means that diesel cenerat:rs manufactured before this change may experience the same loose pole wedge problem.
The affected plants are Fermi, Millstone Unit 2, and Hatch.
These plants were notified by copy of the Part 21 report dated May 20, 1983.
TRA"SAMERICA DELAVAL - 1981 TO 1983 e
1\\.
he manufacturer reported the f'ollowing turbocharger thrust bearing lubrication
^,
problem:
The design of the lubricating oil system permits the oil flew to the turbo-charger tearing only when the diesel generator is running.
When the_ diesel generator is in the stancby mode, the turbccharger bearing lube oil system is by;assed to prevent a possible fire hazard should oressurized oil leak around the cearing seals ento hot impellers. _Therefore, during startup, a sufficient amount of oil would not be available to adecuately lubricate the turbocharger bearing.
Because diesels are started once a month and run for a short length -
cf time, premature bearing wear was experienced because of insufficient
~
lubrication.
At San Onofre, the wear rate for this condit, ion after 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of operation was ecuivaTent to 15,c > to 20,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br /> of continuous operatien.
To ensure proper lubrication during startup, a design modification.in the form cf a lubrication oil drip system causing the lubricating oil. to drip on the bearings thruugh an orifice at a given rate was proposed, installed, and tested.
An alternate method to this design modification is a change in the cperating procedure.
Before a monthly start, an cperator would manually' run the auxiiiary lube. cil pump for 20 to 60 sec:nds anc confirm lube oil :ressure.
I. the event of an emergency start, the bearings will functicn untii. oil pressure is deveicped.
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Page 4 of 4
' Iran! america Delaval TE0erted that thE foll0 Wing nuclear Sites were affECtEd:
Shoreham Ferry WPFSS 4 Grand Gulf Bellefonte Midland 1 & 2 Catawba WPPSS 1 Hartsville San Onofre Comanche Psak 1_& 2 Phipps Bend The licensees of th.e above plants were notified by ; copy of Transamerica Delaval Part 21 report dated Septe.T.ber 19, 1980.
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IN 83-51 August 5, 1953 l
LIST OF :.ECENTLY ISSUED IE INFORMATION NOTICES i
Info mation Date of Notice No.
Suoject Issue Issued to l
83-50 Failure of Class 1E Safety 8/1/83 All power reactor Related Switchgear Circuit.
facilities holding Breakers.to Close on. Demand,
'an 0L or CP-83-49 Sampling and Prevention of 07/25/83 All power reactor, Intrusien of Organic Chemi-facilities holding cals-Into Reactor. Coolant an OL or CP Systems 82-48 Gaseous. Effluent Releases 07/14/83 NRC licensed bypro-of Radioactive Iodine-1?5 and product material Iodine-131 in Excess of NRC licensees, including Limits medical and academic institutions, radio-pharmaceutical sup-pliers, and indus-trial research j;c f,...c - y
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i 83-47 Failure of Hydraulic Snubbers 07/12/83
'A1.1 pcwer reactor-as a Result of Contaminated facilities holding Hydraulic Fluid an OL or CP 83-46 Cor=on-Mode Valve Failures 07/11/83 All power reactor Degrade Surry's Recirculation.
facilities holding Spray Subsystem an OL or.CP 83 45 Environmental Qualification 07/01/83 All power reactor Test Of General Electric facilities holding Company "CR-2940" Position an OL or CP
-Sel'ector Control Switch'
- d.,.
- c m.
3
.vu y 83-44 Potential Damage to Redundant 0.7/01/83.
.All power reactor
~
Safety Equipment as a Result facilities holding of Backflow Through the an OL or CP Equipment 83-43 Improper Settings of Inter.-
06/24/83 All power reactor mediate Range (lR) High facilities holding Flux Trip Setpoints an OL or CP 83 42 Reactor Mode Switch Modi-06/23/83 All SWR. facilities fications-holding an OL-or.CP y
y
~
.L OL =:0;eratjng License N
CP = Construction Permit:
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OCT 0 3 i333 3
- /
/ Docket No. 99900334/E3-01 '
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Transamerica Dels<al, Incorporated Engine t.nd Compr.essor Division ATTN:
Mr. C.-Mathews General Manager 550 85th Avenue Oakland, California 94251 Gentlemen:
This refers to the inspection conducted by Mr. J. W. Sutton of this office on July 11-15,1953, of your facility at Oakland, California, associated with the manufacture of em,ergency diesel generators and to the discussions.of our findings with you and members of your staff at the conclusion of the inspection.
This inspection was made as a result of the issuance of several 10 CFR Parts 21 and 50.55(e) reports.
The reports pertained'to:
(1) incorrectly identified bolt material, (2) f ailure of high pressure fuel oil injection lines, (3) failure of jacket water pump shafts, (3) failure of a crankcase cover bolt, (4) unqualified isoprene material, and..(5) ceficient piston skirts.
These 'conditicas were cbserved singly or in combination at one or more nuclear generating stations..
Areas examined and our findings are discussed in the enclosed report..Within these areas, the inspection consisted of an examinatien of procedures and representative records, interviews with personnel, and observations by.the inspector.
During the inspection it was found that the implementation of your DA program failed to meet certain NRC requirements.
The specific findings.and eeferences to the pertinent requirements are identified in the enclosures to-thi:. letter.
This Notice of Violation is sent to you pursuant to the provisions of Section 206 of the Energy Reorganization Act of 1974.
You are required to submit to this office within 30 days from the date of this letter, a written statement i.ontaining: '(1) a description of steps that have been or will be taken to correct these items; (2) a description of steps that have been or will be taken to prevent recurrence; and (3) the dates your corrective' a'ctions-and preventive measures were or will be completed.
Consideration may be given to ex.ending you'r response time f or goed cause shc n.
~
You are alsc requested to St.bmit a similar written statement for ceach' item which appears in the enclosed Notice of Noaconformance.
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Transamerica Delaval, Incorpora*ed
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Engine and Compresscr Division C a**
The responses requested by this letter are not subject to the clearance procedures of the Of fice of Management and Eudget as required by the Paperwerk Reduction Act of 1930, PL 96-511.
In accordance with 10 CFR 2.790 of the Commission's regulations, a copy of this letter and the enclosed inspection report will be placed in~ the !?RC's Public Docunc.it Room.
If this report contains any information that.you believe to be exempt from disclosure under 10 CFR 9.5(a)(4), it is necessary that you (a) notify this office by telephone within 10 days from the date of this letter of your intention to file a request f'or withholding; and (b) submit within 25 days frca the dat'e of this. letter a written application to this office to withhold such information.
If your receipt of this letter has been delayed such that'less than 7 days are available for your review, please notify this office promptiy so that a new cue date may be established.
Consistent with Section 2.790(b)(1), any such application must be acccmpanied by an affidavit executed by~the owner of the information which identifies the document or part soucht to be withheld, and which contains a full statement of the reasons on the basis which it is claimed that the information should be withheld from public disclosure.
This section further requires the statement to address with' specificity the considerations listed in 10 CFR 2.790(b)(4).
The information sought to be withheld shall be incorporated as far as possible into a, separate part of the affidavit.
If we do not hear from you in this regard within the specified periods noted abcVe, the report will be' placed in.the Public Document Ecom.
~
Should you have any questions concerning this inspection, we will be pleased to discuss them with you.
Sincerely,
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Ob..- eAP L 4 e.- 2 :.;:c. m Uldis:Potapovs, cnie Vend'or. Program Sranch
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Enclosures:
1.
Appendix A - tiotice of Violation l
2.
Appendix B - tiotice of Nonconformance 3.
Appendix C - Inspection Report tio. 9990033US3-01 4
Appendix D - Inspection Data Sheets (11 pages) l
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6 APPENDIX A j
e Transamerica Delaval, Incorporated Engine anc Compressor Division
~
Decket No. 99900334/S3-01 NOTICE OF VIOLATION As a r,esult of the inspection conducted on July 11-15, 1983, and in accordance witn Secticn 205 of the Energy Recrganization Act of 197' and its implenenting regulatica 10 CFR Part 21, the following violation was identified and has been categorized in accordance with the NRC Enforcement Policy (10 CFR Part 2, Appendix C), 47 FR 9987 (March 9, 1982):
Section 21.21(b)(1) of 10 CFR Part 21, dated December 30, 1982, states, in part:
A director or responsible of ficer subject to.the regulations of this part or_ a designated person shall notify' the Ccmmission when he obtains information reasonably indicating-a failure to ccmply or a defect affecting... a basic-component that is within his organization's responsibility and is supplied for a facility or activity within the United States that is subject to the licensing requirements under Parts 30, 40, 50, 60, 61,'70, 71, cr.72 of this chapter.
The above notification is not required if such individual has actual knowledge that the Ccamission has been adequately informed of such defect or such failure to comply.
Centrary to the above, a director, responsible officer, or designated person
~
had not notified the Commission in regard to:
1.
Jacket water' pump shaft-failures 'on the emergency diesel gene'rators (EDG)
~
tha.t had been furnished to the Shoreham Nuclear Power Station.
2.
A pctential d'efect in _the fuel injection line tubing that~ uas used on EDGs furnished to Grand Gulf and San Onofre.
This is a Severity Level IV violation -(Supplement VII).
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APPENDIX 3 t
Transamerica Delaval, Incorporated Engine and Compressor Division Decket No. 99900324/83-01
- y NOTICE OF NONCONFORMANCE Based on t,he results of an NRC inspection conducted on July 11-15, 1983, it appears that certain cf ycur activities were not conducted in accordance with NRC recuirements as. indicated below:
Criterien V of Appendix B to 10 CFR Part 50 states:
" Activities affecting cuclity shall be prescribed by documented instructions, procedures, or drawings, of a type apprcpriate to the circumstances and shall be acccmplis.hed in accordance with these instructions, procedures, or drawings.
Instructions, procedures, or drawings.shall include appropriate quantitative or qualitative
. acceptance criteria for determining that important activities'have been satisfactorily accomplished."
~ "
~
Nonconfermances with these requirements are as follows:'
A.
Paragraph 4.6.2 of Section 4 of the Quality. Assurance Manual (QAM) dated April 30, 1951, states, in part, "when recuired by, Purchase 'Orcer material received destined to beccme a part of the manufactured item m'ust be acccmpanied by a Certificate of Vender inspection.
The material is then inspected to all applicable specifications utili-ing Vender Certifications.
In addition, paragraph 4.1.1 of Quality Control Precedure I.P.200, states, in part, "when it is determined that product devi'ates from specification, an Inspection Report, Form.P-249, will be gy
. initiated by the Receiving Inspector describing-the. nature of..the d e f e ct. *' -
1 Contrary to the above, the Transamerica.Delaval Incorporated (TOI) receiving inspector accepted material on Purchase Order.No. 45333, for which required mill test reports had not been receiv.ed, 'without issuing a nonconformance form P-249.
3.
Subparagraphs of II.A and II.S dated January 29, 1976, and November 10, IEc9, respectively, of the Drafting Rccm Practice (DRP) requires:
(1) drawing cf layouts on tracing paper;' and (2) a special title block on layout drawings with ample, space for signatures in full of the designer and witnesses along with dates.
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J C.
Paragraphs 2.2 and 2.3 of the Engineering Operating Procedure (EOP).4, dated April 19, 1979, states, respectively, '"The designer shall perform the necessary calculations, if required, and prepare the required design layouts.
"The designer shall sign, date, and submit the calculations which he has checked for ccepleteness and accuracy, along with the design layout as required, and his signed and dated form E-213, to the P.anager of Design."
Paragraph II. A.6 dated January 29, 1975, of the Drafting Room Practice, states, "Icportant calculations should.be written in the proper notebook, maintained ir,the department files."
Contrary to the above, regarding calculations for redesign of defective EDG jacket water pumps located at Shoreham Nuclear Power Station:
1.
Ca1'culations for the first occurrence (1979) which are written in
~
~
the proper notebook had not been signed and dated in the spaces provided.
2.
Calculations for the second occurrence (1982) had not been (a) signed, and (b) written in the proper notebook.
D.
Section 6 dated February 27, 1981, of the QAM, contains the foilcwing recuirements:
1.
Paragraph 6.1.1 states, " Documents establishing and defining processes and procedures pertaining to the quality of the product shall be controlled by the subdivision that has the initial responsibility of issue."
2.
Paragraph 6.2.1 states, in part, "All documents relating to the quality of the product shall be reviewed by the manager of the issuing section or his representative."
3.
Paragraph 6.3.1 states, in part, "All documents such as'. Engineering drawings.
.. rust have a mechanism for irantification~ au,thority of issuance and revision."
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Contrary to the abcve, "O Sheets" which pertain to quality of the crocuct are issued by the Engineering Department; however, they are not eviewed by the manager as evidenced by the lack of provisions to identify the date, preparer, reviewer, approver, or revision.
Examples e
are D-4986 and D-4955, which are entitled, " Assembly Instructions," and pertain to the EDG jacket water pu=p.
It was noted that the latter document reflected the release' date, four revision levels 'and dates in the lower margin of the affected sheets'.
E.
Paragraphs 5.3.2 and 5.3.3 of Section 5 dated February 27, 1991, of the QAM, require tt.at Manuf acturing Engineering provide written instructions in the form of route sheets, tooling sheets, or special written instructions, etc., to Manufacturing and Assembly Departments.
Paragraph 15.2.1 of Section 15 cat.d February 27, 1982, of the QAM states, in part, "Manuf acturing and assembly Route Sheets are used as records of in process inspection of parts, components, and assemblies.
All Route Sheets are retained by Quality Control as objective evidence of inspection acceptance."
Contrary to the above, route sheets for the assembly of the EDG jacket water pump reflected on Drawing No. 101973,, Revision C, had'not been retained by Quality Control as objective evidence'of inspection acceptance.
F.
Paragraphs 2.4.1 and 9.1.1 of Quality Control Inspection Procedure No.'300 dated April 1, 19S1, requires that the area inspector (1) inspect, (2) stamp and date the Production Routing Sheet (PRS) in the' space provided, and (3) stamp and date and enter quantity accepted in the final acceptance block of the PRS.
Contrary to the above, regarding EDG jacket, water pump parts that were anufactured during the time period when defective jacket water pumps were being modified:
,k 1.
Stamp and date had not been entered <at Operation No. 90 and final accept block of PRS No. 03-426-08-AE Water Pump Shaft which was processed in October 1982.
Further, the quantity accepted had not been entered in the quantity accepted block.
2.
Stamp had not been entered in'the final accept block of. PRS No. 101969 Seal Retainer which was processed in September 19S2.
G.
Stone and Webster Engineering Corporation Specification No. SH1-S9 dated June 24, IcS1, provides the bidder with the option of testing or dynamic ar.alysis of mechanical equ.ipment.for seismic qualification.
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state tnat tne engine driven jacket water pump will be shake tested.
The
" Qualification Statement for 03-425-04 Jacket Water Cooling Pump Revision" dated October 18, 1982, states, in part, "We submit that tnese.
changes do not have any negative effect on the seismic qualification of the subject pump.
Contrary to the above, dynamic analysis or testing had not been. conducted on the. redesigned EDG jacket water pumps to assure that the seismic qualification had not been compromised.
H.
Paragraph A.1 of E0P 7 dated April 20, 1981, states, in part, "This procedure outlines those steps taken in accceplishing release or revision of..
purchase specifications."
Purchase specifications ccntain a space for approval.
Contrary to the above, Purchased Material Specification No. RL 019000 dated October 6, 1952, had not.been approved as evidenced by the lack of a signature in the approval block.
I.
TDI's 10 CFR Part 21 report letter dated June 23, 1953, concerning a potential problem with the isoprene flexible elements of drive couplings, states, in part, "a copy of this letter will be sent to each of the cognizant parties as listed in paragraph 2, no later than July 15, 1982."
Contrary to the above, the TOI. notification letters to 10 affected custcmer cognizant parties were dated August 18, 1982.
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TRANSAMERICA DELAVAL, INCORPORAT-D s, i. r -
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~.--,rs, EN31NE AND CCM?RESSCR DIVIS:0N 1
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ss AU vTh-REPORT INSPECTION SM, J. ;._, MI. figs l
ND.:
99900334/83-01 OATE(S) 7/11-15/83 ON-SITE CURS:
El CORRESP:NDENCE ADDRESS: 'Transamerica Delaval, Incorporated Engine and Compressor Divisien ATTH:
Mr. C. Mathews, General Manager 550 E5th Avenue Oakland, California 94261 ORGANIZATIONAL CONTACT:
Mr. R. E.'Boyer, Manager, Quality Assurance TELEP'30NE NUMSEU (4151 577-7422 PRINCIPAL PRODUCT:
NUCLEAR INDUSTRY ACTIVITY:
Transamerica Delaval, Incorporated (TDI) has no current contracts for domestic nuclear emergency diesel generators (EDGs).
I) 1 v g ASSIGNED INSPECTOR:
._ 44 W iM-W\\ j f/3 /p 3 J(\\W. Sutton, Reactive and Cc:ponent Program Dhte /
section (R& CPS)
OTHER INSPECTOR (S):
W.
E. Foster, R& CPS R. E. Oiler, R& CPS b
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- h ; /? 3 APPROVED BY
s I. Barnes, Chief, R& CPS Date INSPECTICN EASES AND SCOPE:
i A w-BASES: 210 CFR Part 50, Appendix-B and 10 EC,FR Part 21.
B.
SCOPE:
This inspection was made as.a result Ef the issuance of several j
(
10 CFR Part 21 and 50.55(e) reports.
The reports pertained to:
(1) incorrectly identified bolt material, (2) failure of high pressure fuel
^
oil injection lines, (3) failure of jacket wat'er pump shafts, (4) failure of a crankcase cover bolt, (5) unqualified isoprene material,~and.(6) deficient piston skirts.
These conditions yere observed singly or in cc bination at l
one or more' nuclear generating stations.
?LANT S:TE APPLICAEILITY:
~
Incorre: 1y identified bolt material:
50-400.
Fa'ilure of.high pressure fuel oil injection lines:
30-322, 50-206, 50-361, 50-362, 50-416, and 50-417.
(cont, en next page)'
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EN3INE ;O C0!'. PRE 550E ::v:5 ON c,......,
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"" U F E PCF.T INSPECTION 2%T!Ti v "
NO.-
59900334/53-01l RESULTS:
PAGE 2 of II i
PLANT SITE APPLICAEILITY:
(cont.)-
Failure of jacket water pump shafts:
50-322.
Failure of a crankcase cover coit:
50-416.
Unqualified isoprene material:
50-416, 50-417, 50-400,.50-413, 50-414, 50-424, and 50-425.
Deficient piston skirt:
50-413, 50-414, 50-518, i
50-519, 50-553, 50-554, 50-400, 50-401.
A.
VIOLATIONS:
Contrary to Section 21.21(b)(1) of 10 CFR Part 21 dated December 30,19S2, a cirector, responsible officer, or designated person had not notified t..a Commission in regard to:
1.
Jacket water pucp shaft failures on EDGs that had been furnished to the Shoreham Nuclear Power Station.
2.
A potential' defect in the fuel injection line tubing that was used on EDGs furnished to Grand Gulf and San Onofre.
This is a Severity Level IV violat_ ion (Supplement VII).
3.
NONCONFORMANCES:
1.
Contrary to Criterion V of Appendix B to 10 tFR Part 50, paragraph 4.6.2 of Section 4 of the Quality Assurance Manual (QAM) and paragraph 4.1.1 of Quality Control Procedure I.P.200, the receiving inspector accepted caterial on Purchase Order (PO) 45333,,
for which required mill test report's had not been received, withcut issuing a nonconformance form P-249.
2.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and the commitment date of July 15, JSE2, in TDI's 10 CFR Part 21 report dated June 23, 1982, concerning unqualified material in flex,ible drive couplings of EDGs, the' notification letters were rot:sent until August 18, 1982.
3.
Contrary to Criterion V of. Appendix B to 10 CFR Part 50 and subparagraphs II.A and II.B. dated January 29, 1976, and November 10, 1969, respectively, of the Drafting Room Practice, the following layout drawings for the late 1982 redesign of the.EDG jacket water pucp had not been (1) drawn on-tracing paper and,
(2) signed and dated:
(a) 101973,-(b) 03-425-08-AA, and (c) 03 425-10-AE (lined thrcugh).
4.
Contrary to Criterion V 'of Appe.6 dix.S to 10 CFR Part_50,. paragraphs.
2N2 and 2.3 of Engineering Operating Procedure (EOP)l; dated April 19,
.]
1979, and paragraph'II.A.6 dated January 29, 1976, of.the-1
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a TEANSAMERICA DELAVAL, INCORPORATEC
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e-EhGINE AND COMPRESSDR C:' VISION
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PAGE 3 cf 14 lNO.-
99900334/S3-01 ',
RESULTS:
Drafting Rcom Practice, regarding calculations for the redesign of defective EDG jacket water pumps located at Shoreham Nuclear Power Station:
s; Calculations for the first occurrence (1979), which are a.
written in the proper notebook, had not been signed and dated in the spaces provided.,
-v b.
Calculat' ions for the second occurr'ence (1982) had not been (a) signed, and (b) written in the proper notebook.
5.
Centrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraphs 6.1.1, 6.2.1, and 6.3.1 of Section 6 dated February 27, 1981, of the QAM, "O Sheets" which pertain to quality of the product are issued by the Enginee' ring Department; hcwever, they are not reviewed by the manager as evidenced by the lack of provisions to identify the date, preparer, reviewer, approver, or revision.
Exacples are D-4986 and D-4956 which are entitled, " Assembly Instructions," and pertain to the EDG jacket water pump.
It~was
~
noted that the latter document reflected t'he rel' ease _ date, four revisior levels, and dates in the lower margin of the affected sheets.
~
6.
Contrary to Criterien V of Appendix B to 10 CFR Part'50 and paragraphs 5.3.2, 5.3.3, and 16.2.1 of Sections 5 and 16, respectively, i
dated.r bruary 27, 1951, of the QAM, rcute sheets.for the assembly of e
the EDG jacket water pump reflected.on Drawing No. 101973, Revision C, had not been retained by Quality Cor, trol as objective evidence of inspection acceptance.
7.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraphs 2.4.1 and 9.1.1 of Quality Centrol Inspection Procedure t; ' J.
No. 300 dated April 1,.1981,. regarding jEDG jacket water pump parts
~^
'i'
.that were manufactured during the time period when defective jacket water pumps were being modified:
^
Stamp and date had not been entered at Operation No. oO and a.
final accept block of PRS No., 03-426-0,8-AE water pump shaft which was processed in October 1982.
Further, the 'cuantity accepted had not been entered in the= quantity accepted block.
b.
Stamp. had not been entered in the final accept bicck of PRS No. 101969 seal retair.er which was prccessed in September-1982.
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TRANSAMERICA. DELAVAL, INCORPORATiirg n n
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OAKLAND, CALIFORNIA
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ND.:
99900334/53-01 ~
RESULT S:
PAGE 4 cf 14-t 8.
' Contrary to Cri.terion V of Appendix B to 10 CFR Part 50, Stone and Webster Engineering Corporation Specification No. SHI-89 dated June 24, 1981, paragraph 15.3.1 and its subparagraph 5 of EOP 1 dated April 20, 1981, and the " Qualification Statement for 03-425-04 Jacket ' dater Cooling Pump Revision" datec October 18, 1982, dynamic analysis or testing had not been conducted en the redesigned EDG jacket water pumps to assure that the seismic qualification had not been compromised.
9.
Centrary to Criterion V of Appendix B to 10 CFR Part 50, and paf agraph A.1 of EOP 7 dated April 20,19El, Purchased Material Specification No. EL 019000 cated October 6, 1982, had not been approved as evidenced by the lack of a signature in the approval block.
C.
UNRESOLVED ITEMS:
None D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Clesed) Ncnconformance A (Report No. S2-02).:.
The Quality Assurance / Quality Control organizational chart had not been updatec to reflect. changes in the QA/QC crganization since January 1, 1982.
The NRC inscector reviewed the current QA/QC crear.izational chart which was revised en January 15, 1933, shesing that the Ncndestructive Examination (NDE) Level III examiner is no. longer the Manager of Quality Engineering.
- 2.
(Closed) Nonconformance B (Report No. 82-02):
Kobe Steel Ltd. had
. not been surveyed at a minimum of once every three years 'as.
required by paragraph 4.4.3 of Section 4 of the QAM.
The NRC inspector reviewed a revision to the QAM, subparagraph 4.4.5, issued April 22, 1983, which indicates that vendors who hold current ASME certificates of authorization or Quality Systems Certificates need not be surveyed or audited.
Chemical ar.alysis of subject crankshaft materials were performed and the materials found to, be acceptable.
The NRC inspecter was informed by TOI that they' intend to perf'orm a physical inspecticn at Kcte Steel Ltd. within.the next three months.
CF.Gl&.:ATIN:
TRANS:.'4ERIC A DELAVAL, IN:O;.?; RATE 7. b
_",,,v.T'M
..s. eC v _._ J, i
ENSINE, AND COMPRESSOR D; VISION
~ - - ~~ :- -
. " - - ~ '
DAKLAND, CALIFORNIA.
"..'.'...'.".,"***.'n"''"'
RE?DRT INS?ECTION c rot'"" ^ ~ ^ ^ -
l "O.:
99900334/S3-01 ~
RESULTS:
? AGE 5 of 14 3.
(Ciosed) Nonconformance C (Report No. 82-02): (a) Component drawings released by engineering did not constitute the final instructions to assembly for definition of acceptance criteria for the governor lebe oil cooler, and (b) instructions for assembly of the governor lobe oil cooler had not been provided in writing from manufacturing engineering to assembly.
The NRC inspe.ctor reviewed the lube oil governor assembly drawing and verifie~ 'that the location of the cooler was not identified.
In d
addition, the parts list for this drawing was reviewed for content.
The route sheet now indicates the assembly drawing.
TDI's corrective action commitments contained in the January 5,1953, letter to the NRC have been complied with.
E.
OTHER FINDINGS AND COMMENTS:
1.
Carolina Power and Light Company's (CPL) 10 CFR Part 50.55(e) notification report, dated January 18, 1983, identified that bolting material for the CPL Shearon Harr,is, Unit 1, EDG was not properly identified in accordance with design requirements.
The NRC inspector reviewed documents and correspondence between TDI, Ebasco, and CPL pertaining to this subject.
It appeared to the NRC inspecto. that a misunderstanding existed as to whether the bolts and nuts were requested to be fabricated to AISI 4140 or ASTM specifications.
The nuts and boits. were bought to the AISI 4140 specification which conforms to ASTM A193 Grade 37 chemical and mechanical property requirements.
Specification CAR-SH-E-11, Revision 6, did not require ASTM materials to be purchased.
TDI's letter of June 22, 1983, to Ebasco outlines this finding.
This is not considered a generic problem.
e.
' I, ~. Tennessee Valley Authority (TVA) 10 CFR Part 50.55(e) report to the
'~
2.
NRC dated February 10, 1982,- addressedgthe failure of TDI to take corrective action on TVA audit findings described ~in TVA audit S1V-47, conducted December 1-3, 1981.
Documentation and correspondence between TVA and TDI to date was reyiewed.
Reaudits havs been performed by TVA to determine compliance t'o their findings.
TDI had taken action to make sure that pr'oposed corrective actions were implemented before signing off on the corrective action form.
Documentation for compliance to thi,s requirement was reviewed.
All outstanding items wdre closed out by TVA during a TVA reaudit.
~-
TVA's lett'er to TDI dated August 24, 1982, indicated no findings.
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ENGINE AND ccsp.:.ESSun. DIVISION
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REPOPT INSPECT 10H a--*.-
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NO.:
99900334/83 RESULTS:
PAGE'6 cf 14 3.
Len; Island Lighting Company (LILCO)' filed a 10 CFR Part 50.55(e)
' report on April-20, 1983, with the NRC, Region I.
The report stated that failures had occurred in fuel oil injection lines to the EDGs that had been furnished to Shoreham Buclear Power Station, Unit 1.
As a result of the documentation review by the NRC inspector, the following conditions were found to exist:
a.
Three diesel generators were supplied to the Shoreham Nuclear Station for emergency power.
A failure occurred to the high pressure fuel oil injector line b.
during routine testing of Generator No. 102 on March 3, 1983.
The tubing was replaced and on March 5, 1983, a fuel injection line failed on Generator No. 103.
Both lines were sent to an independent laboratory for failure c.
- analysis, d.
A failure analysis issued by TDI dated Jun.e 24, 1983, concluded that the failure was attributable to the presence of _ a discontinuity on the inside diameter (I.D.) of the injection tube.
This discontinuity acted as a stress riser and combined with the line operating pressures resulted in the. fatigue endurance limit of the caterial being exceeded.
The report indicated that the discontinuity was a draw seam that had been created during manufacture of the tubing.
e.
TDI conducted a 10 CFR Part 21 meeting on June 27, 1953, as required by the Division 10 CFR Policy Procedure, to evaluate the findings and to determine reportability to the NRC.
The committee determined that this problem was an isolated case.
and was not reportable.
On July 5, 1983, another meeting was held which still determined the condition to be nonreportable due to'the fact that many' engines had oeen and are running with the same type of tubing that had been installed at Shoreham.
f.
The NRC inspector requested a search be made as to when the tubing used in the Shoreham Units was purchased and if other nuclear sites could have injection lines installed that had been manufactured from the same lot of tubing.
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PAGE 7 cf M INSPECTION
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55500334/S2-01 g.
TDI searched their records and found that the tubing was r
purchased in 1975.
Purchase lots are made in 2000 ft.
increments with approximately' 200 f t. being us'ed per diesel unit.
The reccrd checks indicated that besides the Shoreham nuclear site, EDGs had been furnished to Grand Gulf and San Onofre nuclear sites which had utilized tubing from the
.same purchase. lot.
h.
TDI Desi~gn Specification D-255 dated October 2,1972,' and Revisions A anc 5 cated August 18, 1978, and August 15, 1980, contain the applicacie recuirements required to be folicwed in regard to tubir.; manuf acturing operations.
The supplier was required to furnish material certificates of conformance and test reports with each order.
Purchase documentation for this period of time (1975) was not retained by TDI in that the QA program only requires retention for 5 years.
The NRC inspector reviesed a recer.t PD for tubing, No. 45333 dated October -1,1981, fer conformance to purchase requ.irements.
The PO required that mill test' reports be furnished.
A nonconformance was identified as a result of the acceptance of the material by the receiving inspector, 'although mill test reports had not been received (see paragraph B.1).
i.
The action to preclude recurrence wa's contained in the failure analysis report, June 24, 19S3, and indicated "more rigid QA procedures were called for.
Sections from each length of tubing should be cut off, sawed lengthwise at,90 intervais, and inspected to ensure there are-no draw marks on the tubing ID.
Since draw seams would run the entire length cf the tubing, this inspection measure will ensure that no draw seams are present in any line manufactured from that length of tubing
.$' jh.w
- ':(200.ft.).
Such' a QA requirement should be cal. led for 'on any high pressure fuel injection lineidestined for use on a nuclear stand-by emergency diesel generator.!'
j.
As a result of the NRC inspector's -review of documentation,
. consistency of drawings, procedures,lP0s, letters, in-house memos, and repcrts, it was. concluded {that this f ailure ~ may not be an isolated occurrence and that a potential existed.for:
draw seams to be present in fuel injection lines of dies'e.1 generators supplied to Grand Gulf. and San Onofre.
In addition, reviea of 10 CFR Part 21 evaluation activities
.concerning the fuel oil line fail _ure consisted of side notes
. on letters and records, etc., produced by TDI personnel during i
Deliured Product Trouble (DPT) meetings.
These were considered s
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OR3ANIZATION:
TR ANS AMERI C A. DEL A'.'AL. INCORPCR.tT r.n.
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t as inadequate by the NRC inspector to establish the reason ~for classifying this occurrence as one of a kind.
The violation t
i detailed in paragraph A was identified as a result of. this review.
k.
Subsequent to the inspection, TDI filed a 10 CFR Part 21 report with NRC, Headqu~arters.
The report is dated July 20, 1983, and identifies the following nuclear generating stations with the potential defect:
(1) Shoreham, (2) Grand Gulf, and (3) San Onofre.
4.
LILCD filed a 10 CFR Part 50.55(e) report on Octcber 15, 1982, with the NRC, Region I.
The report stated that jacket water pump shaf ts had failed on EDGs that had been furnished to Shoreham Nuclear Power Station, Unit 1.
Further, the repcrt stated that the failures occurred on jacket water pumps that had been modified to preclude failures that had been experienced in similar units operating cverseas.
The following conditions were observed during the course of the inspection:
The Engine and Compressor Division of TDI filed a 10 CFR Part 21 a.
report on September 20, 1979, regarding~"a potential failure of the drive shaft for the engine driven jacket water pump which would result in engine nonavailability." The' report stated that jacket water pumps of the same design as those that failed had been-installed on the three EDGs that had been furnished to Shoreham Nuclear Power Station.
The NRC inspector was informed that the jacket water pumps had been modified.
b.
A TDI ceco dated October 18, 1982, states, in part, "In the
.e
~
past five months, Lilco [Long Island Lighting Company],has
.,r experienced three jacket water pump failures."
Information presented as a record of evaluation was included in open areas of a form entitled, " Authorization For No. Charge Billings" dated October 7,1982, and identified LILCO as the. customer.
The following hand written / printed information was. exhibited in.the open areas:
"Re' view 10 CFR 21 no only site. conditions at LILCO diff OK other plants not a 20 CFR 21 LILCO. unique only site with this problem attendees [ list of names dated 10-11-82] LILCO is aware of. prcblem.TDI & LlLCO will solv'e
)
[ signed, dated 11/11/82]."
The :information is not suf ficiently i
detailed to enable an adequate evaluatien of the decision I
regarding reportability. ' The failure of the jacket water
~
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pumps had not been reported.to the Commission.
As a result of
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the foregoing, the violation detailed in paragraph A was ~
identified.
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9EE00334/S3-01
- RESULTS.:
PAGE 9 of la i
Layouts are created by redlining ev.isting drawir;s rather than
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by initiating new drawings.
The redlined drawings (layouts) had not been subjected to the.recuired signature /date. cycle.
Calculations had not been controlled in the manner specified.
There was no indication that assembly instructions had been reviewed / approved.
Route sheets for assembly of the jacket water pu=p had not been retained; also, some route sheets for manufacturing activity had not been completed as required.
The fore' going, along with other observations, resulted in the nonconformances detailed in paragraph B.3 through B.9.
d.
A TDI memo dated July 16, 1979, which acdresses jacke't water pumps, identifies Gulf States alcng with LILCO and a foreign customer.
Requested documents were not presented regarding Gulf States; as a result, this issue will remain open in order to determine whether or not Gulf States received suspect jacket water pumps.
TDI identifies the cause as engineering and assembly induced.
e.
The NRC inspector concurs; however, 'in his ' judgement, the quality organi:ation cannot-be excluded.
Based.upon the observations of this area of the inspection, it is not apparent that acequate corrective actions and preventive measures have been taken.
However, the NRC inspector was informed that the pumps.at Shoreham Nuclear Power Station have cperated past the times of the previous fail'ures.
f.
In an ef fort to assess the effectiveness of the corrective actions and preventive measures, the following areas were evaluated:
(a) change control, (b) manufacturing process control, and (c) records.
This area of the inspection was accomplished by evaluating the following documents for,
rif 4. n-l' '
requirements and/or imp'lementation of requirements:
12 drawings,.3 specifications, 6 procedures, 3 sections of the QA Manual, 5 memoranda, 7 letters, and 24 other documents identified as:
analysis / calculations, packaging / shipping notifications, production routing sheets, qualification statement, material requisitions, authorization'for no charoe billing, failure analysis report, ass'embly instructions, and requests for drafting room action.
The findings are indi,cated at other locations of this report.
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Subsequent to the inspection, TDI filed a 10 CFR Part 21 report dated July 20, 1983, with NRC, Headquarters.
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NO.
99900224/83-01 :
RESULTS:
PAGE 10 of 14 5.
Two 10 CFR Part'50.55(e) reports by Mississippi Power and Light (MPEL) Company to the NRC were' filed on March 22, 1982, and April 21, 1982.
These reports concerned,the' shorting of the generator by a sheared crankcase capscrew hea.d of a, Unit I, Division II, diesel generator furnished by TDI; This matter was reported in several interim reports by MP&L with the most recent one being Interim Report No. 6.
a.
During a 24-hour perforcance test, the unit tripped on a
" Generator Differential" which was accompanied by electrical arcing inside the generator.
Later inspection verified that the stator insulation had been camaged and the head from a 5/S x 11 threads x 1 3/4" long capscrew was embedded in the stator.
It was determined that the capscrew head was from the diesel engine's rear crankcase cover.
All of the capscrews were replaced by the utility, and an analysis of the failed capscrew indicated the head broke off due to low-stress fatigue cracking during service.
This cracking appeared to have been initiated by over or under torqueing of the capscrews.
b.
Fincines:
Review of the problem with TDI's Grand Gulf site service personnel provided the followinc information:
The source of the capccrew hcad found in the generator stator was from a top capscrew in the vertical crankcase cover.
The screw shank was still in the. cover hole.
The screws are classed as noncritical service and recuire torcueing of 60 foot pounds (Ft. Lb.).
Since the metallurgical analysis indicated a fatigue failure mechanism, the cause appears to h' ave been over or undertorqueing coupled with operating stresses.
No information was available to indicate when ghis incorrect torcueing may have occurred.
TDI service personnel indicated
~
that the site Bechtel craftsman would have.had a minimum of two occasions when they would have removed and replaced the crankcase cover for bearing checks af ter the diesel generator was delivered to the, site.
In addition, they would have had a TDI instruction manual which showed the required torque value of 60 Ft. Lb. for this size bolt while using a special lubricant.
.The TDI service personnel also indicated that this incident of a sheared screw head shorting the generator was a first time occurrence for the TDI diesel generators.
The matter was discussed between.TDI and MP&L perscnnel, but no meeting notes were cade available to the NRC inspector by TDI.
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NO.:
99900234/83-01 ~
RESULTS:
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PAGE 11 of 14 i
6.
In 10 CFR Part 50.55(e) reports to the NRC by four electric utility ccmpanies, a misapplication of unqualified isoprene material in the flexible element of the. couplings for diesel generators supplied by TDI was identified.
This material was not suitable for use in the high temperature oil atmosphere of the diesel generator and would deteriorate rapidly in service.
The couplings were manufactured by.
Koppers Company.
The utilities reporting were:
(1) MP&L for Grand Gulf Nuclear' Station, Units 1 and 2; (2) CP&L for Shearon Harris U'it 1, (3) Duke Power for Catawba Nuclear Nuclear Power Plant, n
Statien, Units 1 and 2, and (4) Georgia Power for Vogtle Nuclear Plant, Units 1 and 2.
This matter was also reported by TDI in 10 CFR Part 21 reports to the NRC on June 23 and July 13, 1982.
The action necessary to correct this deficiency was to change a.
out the existing flexible element in the coupling with one made of neoprene which was suitable material for service.
- TDI, in their report, identified 10 nuclear power' plants which have affected diesel generators, and indicated'these cognizant parties would be notified no later than July 15,1982.
7 b.
Findines:
The NRC inspector verified the following information through observations, discussions, and review of cocuments:
(1)
The incident which prompted TDI.to report on June 23, 1982, was a failure of a coupling flexible element made of isoprene in a nonnuclear diesel generator.
The utilities reported' subsequent to the above date.
The suspect couplings were manufactured by Koppers Company starting in 1977 and purchased as stock items by TDI g.;
based on TDI's purchased material specification for 4
4
~
" Couplings-Elastomeric, Part;.No. AK-007-000," dated November 11, 1976.
The original version of this specification did not specify,the type ma'terial of the flexible element.
After the above failure, TDI issued Revisions A, B, and C to the specification'in 1981, 1982, and 1983, respectively.
Change.A specifis'd.that the flexible element should be neoprene which is a suitable material.
Change B specified service in a 175 F oil' atmosphere, and Change C specified that the flexible element must have a 1/2 " wide red band on it to distinguish it as neoprene.
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2n:Dsnuns L.I DU EAUE 12 of 14 (2)
Review of TDI notification letters verified that all nuclear order customers with affected diesel generators were notified of the deficiency.
However,10 of. the TDI notification letters were dated August 18, 1982.
This date was contrary to the TD1 commitment date of July 15, 1982, in their 10 CFR Part 21 report and resulted in the nonconformance identified in paragraph B.2.
(3) Observation of a coupling flexible element in the stores department verified that it did not have a red band on it as required by Revision _ C of the purchase specification.
Hcwever, this flexible element was identified only by part number and it could not be traced to specific P0s placed with Koppers Company after April 25, 1983.
(4) heview of receiving inspection cards, " Vendor Inspection Report," for Koppers Company, indicated that the bases for -receiving inspection of the couplings was Mil-Std 105 D.
(5)
Review of 10 CFR Part 21 evaluation records cencerning the iseprene flexible element established that records were inadequate to establish the cause of the misapplication and the basis for the determination that the item was reportable under 10 CFR Part 21.
The only records available were entries dated June 15 and June 22, 1982, in the DPT ccmmittee week.ly log.
The June 15, 1982, entry indicated Product Engineering was to compile a list of engines using Kopper's Elastemer GDV drive couplings, and the June 22, 1982, entry indicated that it was determined that the Kcpper's Elastomsric coupling was a 10 CFR Part 21 reportable item and the responsible individuals were to issue the appropriate notification.
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~
~
These DPT committee meeting notes did not provide sufficient information to show the bases for the
' evaluation (and do not appear to meet the requirements 10 CFR Part 21, paragraph 21.51(a) and-(b)).
7.
In five -10 CFR Fert 50.55(e) reports to the NRC by.three electric utility ccmpanies, a deficiency in the piston skirt castings of diesel generators was icentified.
This matter concerned the*
potential failure of the engine piston skirt castings cf diese'l generat' ors supplied by TDI.
Such failures would result in.the unavailability of the diesel generators,.
The castings were-manufactured by TDI between December 1978 and October 1981.
The, utilities reporting were:
(1) Duke Power for the {atawba Nuclear Station, Units-1 and 2;;(2) TVA for Hartsville e
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- R;AN::AT::s:
TRANSAMERICA DELAVAL, INCORPORATED
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OAKLAND, CALIFORNIA hs wy r.E ?DRi INSPECTION NO.:
559:~234/53-01 '
RESULTS:
PAGE 13 of 14 i
Nuclear Plant, Units 1 and 2, and Phipps Bend Nuclear Plant, Units 1 and 2; and (3) CP&L for the Shearon Harris Nuclear Power Plant, Units 1 and 2.
This matter was also reported by TDI in a 10 CFR Part 21' report to the NRC on October 28, 19S2.
The NRC inspector ascertained the following information by discussions and review of' documents:
The inc[ dent which prompted TDI to report was a f ailure of a a.
type "-AN" piston skirt casting in early 1980.
The utilities subsecuently made their reports to NRC.
Subsequently, TDI produced a report entitled, " Failure Analysis No. 152, Piston S ki rt, P/N 03-041-02-AN," cated June 20, 1933.
This report included a description of events leading up to a change in foundry heat treating practice to include f an cooling of the castings.
This cooling method was determined to have resulted in high residual stresses in the cas t'ings which, when combined with cperating stresses, could result in failure of the castings.
The report also provided recommended c'orrective measures including NDE, stress relieving at 1050 F, and selective grinding of the affected castings.
b.
Review of six TDI notification letters verified that all utility nuclear units with affected diesel generators were accounted for.
The letters included a list,of foundry shop order numbers and serial numbers of ~ the affected castings to aid the utilities in identifying the suspect castings.
The letters also recommended that the castings be returned to TDI for NDE and. stress relieving if possible, or' replacement with suitable castings, and return for reinstallation.
As of this inspection date, only Duke Power Company and Gulf States
- E,7
_ Utilities have returned: skirt castings to TDI.
m-
,f.
c.
Review of a current process routing:for Job No 69501 covering reprocessing of returned castings ve'rified that corrective action was being performed under controlled conditions using
. process travelers, qualified personnel, and procedures.
Other records reviewed for Job No. 69501 consisted of:
(a).special instruction specification No. 750R; (b) a certificate of compliance; (c) la packaging and shipping notification; (d)' a magnetic particle inspection report;,(e) an NDE technician's cualification record; and (f) heat treatment records for
. Iron ASTM A-536, Grade 100/70/03 castings.
The review also
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55900334/S3-01 '
RESULTS:
PAGE 14 of 14 1
included the original master engine book of records for diesel generator 5.N. 75018-2752.
Within this area cf the inspection, no nonconformances or unresolved items were
' identified.
F.
EXIT INTERVIEW:
i During the exit interview, at which time the inspection findings were discussed, the NRC inspectors were informed by TDI's management that they wei:ld take exception to all of th'e violations that had been icentified during the inspection.
The NRC inspector incicated that.this position would be identified in the inspection report.
It.was determined by staff review subsequent to the inspection to defer issue of one violation which had been identified to TDI management unti1 after performance of further inspectio~n.
This violation subject pertained to inadequate evaluation records.
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