ML20081K001

Forwards 831103 Diesel Generator Status Rept,Per 830912 Commitment.Related Correspondence

ML20081K001
Person / Time
Site:	Shoreham File:Long Island Lighting Company icon.png
Issue date:	11/03/1983
From:	Earley A HUNTON & WILLIAMS, LONG ISLAND LIGHTING CO.
To:	Brenner L Atomic Safety and Licensing Board Panel
References
ISSUANCES-OL, NUDOCS 8311090229
Download: ML20081K001 (6)

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.czrom v ... . a s..' November 3, 1983 ao -===-s sos o,.Ec, o,.4 o. .o. ,..- 8 3 61 BY HAND Lawrence Brenner, Esq.

Administrative Judge Atomic Safety and Licensing Board Panel U.S. Nuclear Regulatory Commission

. Washington, D.C. 20555 Long Island Lighting Company Docket No. 50-322 (OL)

Dear Judge Brenner:

Enclosed is LILCO's Diesel Generator Status Report dated November 3, 1983. This Status Report, which LILCO committed to provide in its Response to Suffolk County's Motion to Compel dated September 12, 1983, is the fourth of a series of periodic status reports on the progress of the diesel generator effort that will be provided to the Board and parties.

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Anthony F. Earle'y, Jr.

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Enclosure cc: Dr. Peter A. Morris Dr. George A. Ferguson All Parties 8311090229 031103 PDR ADOCK 05000 G

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November 3, 1983 DIESEL GENERATOR STATUS REPORT I. Diesel Generator 101 Reassembly of diesel generator 101 is underway. The new crankshaft was received on October 24, 1983. Thereafter, it was inspected and shot peened and the drive gear and oil plugs installed. It has now been installed in the engine.

The lube oil and jacket water flushes of the diesel generator 101 auxiliary systems remaining in the diesel generator room have been completed satisfactorily.

As noted in the previous status report, surface distress was observed on a number of camshaft lobes and LILCO made the decision to ship the camshaft to TDI for repairs. The rebuilt camshaft has been received back on site and is being reinstalled in the engine.

II. Diesel Generator 102 As noted in the previous status report, the reassembly of diesel generator 102 was completed and the engine rein-stalled in the diesel generator room. Final alignment of the engine has been completed. Engine flywheel reaming and final generator positioning is in progress. Reconnection of all service systems is also in progress.

As noted in the previous status report, indications of shaf t wear were found on the jacket water pump impeller shaf t.

4 The entire jacket water pump for diesel generator 102 has been received and is being evaluated by FaAA. Preliminary indications are that the shaft wear observed was the result of the crankshaft failure. A spare jacket water pump has been installed on diesel generator 102.

As noted in previous status reports, FaAA is continuing its investigation with respect to the connecting rod bearings.

An interim report is expected to be published on November 3.

FaAA found that four of the original 24 connecting rod bearinga exhibited cracks. A fifth connecting rod bearing (102-number 7) was destroyed in the course of the crankshaft failure. Tests by TDI on one failed bearing from diesel generator 103 indicated tensile strength below specified values and voids in the grain structure. FaAA tests on a second cracked bearing disclosed tensile strengths that met TDI's currently specified values but not the originally specified values. FaAA has received the cracked bearing tested by TDI

and will conduct tests to ascertain the tensile strength properties of that bearing. Both bearings, the bearing tested

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by TDI and the one tested by FaAA, exhibited voids in the microstructure. FaAA will also perform tests on the remaining cracked bearings and will issue a second, final report on the bearing matter in approximately one month or sooner if possible.

The previous status report indicated that LILCO intended to install new main bearings in all three diesel generators. In light of the absence of any damaged main bearings and in light

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of the FaAA tests that indicate that tensile strengths of that i

material met the current specification, LILCO will delay a decision whether to install new main bearings until further testing is completed by FaAA on both connecting rod and main 9 bearings. I As noted in the previous status report, the 102 generator rotor was returned to Parsons Peebles-Electric Products, Inc.

for analysis. As previously noted, the mechanical damage was caused by a sharp corner located close to the winding. This corner was rounded off and the rotor pole repaired. The generator rotor has been reinstalled. TDI and LILCO have not P completed their review of the report, but a copy will be pro- @

vided this week to the Staff and the County. I; The governor for diesel genera' tor 102 has been sent to 3 1

the manufacturer for inspection and the preliminary results d of that inspection indicate that the governor was damaged as g a result of the crankshaft failure. The manufacturer's report will be provided this week to the Staff and the County. ,

III. Diesel Generator 103 l

l The 103 diesel engine flywheel is being reamed, to be followed by final positioning of the generator. Reconnection p of service systems is also in progress. All of the preinstalla- E tion system flushes have been completed.  !

I As a result of information obtained concerning a piston [

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, failure in a marine application, LILCO undertook to inspect a a

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. 1 piston that had been originally installed in diesel generator ,

103. An indication was observed in the skirt in the vicinity of the boss machined for the installation of Belleville washers. Cya penetrant examination showed an indication and ,

the piston was sent to FaAA for further examination. At FaAA, destructive testing confirmed the existence of a fatigue crack 1/8" X 5/16". This matter was reported to the NRC as potentially reportable under 10 CFR S 50.55(e). LILCO currently intends to conduct further investigation regarding the piston indication and further information concerning this matter will be included in a subsequent FaAA report expected to be completed in approximately one month.

IV. New Crankshafts The three new crankshafts have now been received, in-spected, shot peened and installed.

.l V. Schedule The FaAA report setting forth FaAA's conclusions con-cerning the cause or causes of the diesel generator 102 crank-shaf t failure will be completed and published on November 3, 1983. An NRC noticed meeting for November 3 has been scheduled to distribute and explain FaAA's report on the cause or causes of the crankshaft failure. At this time, FaAA will also distribute and explain its interim report concerning the connecting rod bearing matter. Finally, it is also ex-pected that FaAA will distribute a report and present the

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results of its evaluation of the structural integrity of the 13" X 12" crankshaft.

As a result of FaAA's preliminary evaluations and LILCO management concerns, LILCO decided to develop and implement a program to review and assess the design and fabrication of the Shoreham diesel generators and their components to verify and ensure that the engines will perform their intended func-tion.

This program will be generally described at the November 3 public meeting. In essence, the program will identify the components to be reviewed, develop appropriate design and quality verification checklists and then review these checklists against appropriate documentation, inspection results and testing.

Where necessary or appropriate, independent verifica-tions, tests or analyses will be performed.

LILCO's counsel has proposed a litigation schedule to counsel for the County. The Board will be advised of the re-sults of the parties' consultations in this regard.