ML20090A244
| ML20090A244 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 07/06/1984 |
| From: | Tucker H DUKE POWER CO. |
| To: | Adensam E, Harold Denton Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 8407110316 | |
| Download: ML20090A244 (8) | |
Text
d Dune POWER GOMPANY P.O. nox 03180 CHARLOTTE, N.C. 28242 IIAL H. TI!CKER TELEPHONE YN2 PERhlDENT (704) 373-4531 NWLEAll PRODUCTHW July 6, 1984 Mr. Harold R. Denton, Director Office of Nuclear Reactor Regulation U. S. Nuclear Regulatory Commission Washington, D. C. 20555 Attention: Ms. E. G. Adensam, Chief Licensing Branch No. 4 Re: Catawba Nuclear Station Docket Nos. 50-413 and 50-414
Dear Mr. Denton:
The purpose of this letter is to submit Duke Power Company plans for the inspection of the Catawba 18 diesel engine and the return to service testing of the Catawba lA engine following reassembly after inspection. The Duke Power Company plans for these two items appear below:
A.
Catawba 1B Diesel Engine Inspections 0'ar letter of April 5,1984 forwarded a report entitled " Catawba Nuclear Station Extended Operation Tests and Inspections of Diesel Generators."
Section 6 of this report noted that the extent of inspections to be carried out of the Catawba 1B diesel would be based upon the results of the Catawba 1A diesel inspections and other TDI emergency diesels. The Catawba lA diesel inspections are now complete. The Catawba lA diesel inspection results as well as the Owners Group inspection requirements for the second diesel at a nuclear station have been reviewed and an inspection plan matrix for the Catawba 1B diesel has been developed from this review. The Catawba 1B inspection plan matrix is shown in a revised Table 5-1 to the above mentioned report and is included as an enclosure to this letter. Referring to the revised Table 5-1, sample size of components to be inspected on the Catawba 13 diesel will be the same as the Catawba lA diesel except as noted by parentheses. Where parentheses are included, sample size of inspection for the Catawba 18 diesel appears in the parentheses.
B.
Catawba Diesel lA Return to Service Testing In accordance with a commitment made in " Catawba Nuclear Station Diesel Engine 1A Component Revalidation Inspection, Final Report," of June 29, 1984, the following is the Duke Power Company plan for return to service testing of the Catawba lA diesel.
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8407110316 840706 PDR ADOCK 05000413 PDR G
i 1
Mr. Harold R. Denton, Director
-July 6, 1984 Page 2 1.
Run-In Operation:
This will be in accordance with TDI Instruction Manual, Chapter 6, Part C (page 6-C-18). The runs are mainly for seating new rings in the cylinder liner and consist of ranning the engine at various speeds and loads, inspections of the engine following various runs, hot crankshaft web deflection checks, and cold compression checks.
In addition, during these runs, control systems, vital engine parameters, and auxiliary services will be monitored to assure proper operation.
2.
Modified Load Tests:
Ten modified load tests will be run at a load of at least 3500 KW.
Pertinent parameters that will be adhered to are as follow:
a.
A test will be of one hour minimum duration followed by at least one and a half hours with the engine secured prior to the next modified load test, b.
All test starts will be performed with a pre-lube of the engine.
c.
During a test, the load will be increased to a minimum of 3500 KV in a period less than five minutes.
d.
Vital engine parameters will be monitored on a fifteen minute basis during the one hour run at power to assure proper operation.
3.
24-Hour Run:
A twenty-four hour run test will be conducted. This test will consist of twenty-two hours at 7000 KW and two hours at 7700 KW. Pertinent parameters that will be adhered to are as follow:
The engine test starts will be perfo"med after the engine has a.
I been pre-lubed.
l l
b.
During the test, all load changes will be accomplished in five minutes or less.
l l
c.
Vital engine parameters will be monitored on a one-hour basis to
[
assure proper operation.
4.
Fast Start Test:
l Two fast start tests will be conducted. Pertinent parameters that will be adhered to are as follow:
l l
- 1 p-
Mr. Harold R. Denton, Director July 6, 1984 Page 3 a.
Diesel engine will come up to speed and voltage within eleven
- seconds, b.
Diesel engine will be loaded with accelerated blackout loads in the period of eleven seconds to thirty seconds.
Peak load will be about 4100 KW. This is the highest load obtainable with the load sequencer under ESF or blackout conditions.
c.
After the engine has achieved 4100 KW, each test will last for a period of one hour followed by a shutdown of at least one and a half hours. The one hour duration at load is set so that auxiliary cooling devices will not have to be cut in for some of the respective loads which would place an undue burden on the plant for the performance of these tests.
d.
One of these tests will be conducted under pre-lube conditions.
The other of these tests will be performed with the engine in ready standby status without pre-lube.
e.
Vital engine parameters will be monitored on a 15-minute basis.
Further, visacorder tracings of diesel generator voltage and frequency will be made during starting and loading transients.
5.
Trip Device Verification:
There are ten trips which cause the engine to shut down under normal operation and three trips which cause shutdown under emergency operation.
To verify proper operation of these trip devices, shutdown from the tests outlined in B-2 through B-4 above will be accomplished by sequentially introducing these trips for each of the thirteen tests.
6.
Load Reject' ion:
To assure that the diesel generator does not go over five hundred RPM on a load rejection of 7000 KW, visacorder tracings of frequency will be made during the trip from 7000 KW outlined in B-3 above.
Criteria used to judge the tests outlined above as to what is a successful test, as opposed to a failed test, will be according to the following plan:
c o The operation runs outlined in B-1 above are for break-in and grooming.
As such, there are not any pass / fail criteria applied to them.
In addition to break-in, this run will be to assure that the diesel generator is ready for tests B-2 through B-6.
o Tests outlined in B-2 through B-6 will be conducted in accordance with the pass / fail criteria of NRC Regulatory Guide 1.108.
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Mr. Harold R. Denton, Director July 6, 1984 Page 4 i
We trust the above information is keeping you fully informed of the status of the Catawba Unit 1 diesels.
Please call me if I can be of any further service.
Very truly yours, d4 k r <<
^~
t Hal B. Tucker NAR/php cc: Mr. James P. O'Reilly, Regional Administrator U. S. Nuclear Regulatory Commission Region II r'
101 Marietta Street, NW, Suite 2900 Atlanta, Georgia 30323 i
NRC Resident Inspector Catawba Nuclear Station Robert Guild, Esq.
Attorney-at-Law P.O. Box 12097 l
Charleston, South Carolina 29412 Palmetto Alliance 21351 vevine Street Columbia, South Carolina 29205 Mr. Jesse L. Riley i
Carolina Environmental Study Group 854 Henley Place Charlotte, North Carolina 28207 I
i n
4 t
Table 5-1.
Catsuba Unit 1 Diesels Inspection Plan Matrix Sanple Siae, P;rcent of Engine Parts Inspected Pagie1 Surf. Vol.
Part Name Part No. Class Disen. Visual EE EE Material Hardness Fbg Ev Notes Inbe Oil Pressure Ragulating Valve 00-420 A
X 9
Jacket Water Standpipe, Ptzgs, Gasket 04-700A B
100 Jacket Water Standpipe Valves 00-700B B
X 9
Jacket Eter Standpipe Supports 00-7000 5
100 l
Jacket Water Standpipe Switches 00-700E B
X 9
Jacket Water Standpipe Boltirs Materials 00-700F B
100 Main Bearing Cap Base Aa===hly 02-30 %
A 50(0) 50(0)
Main Bearing Studs and Nuts 02-305C A
10(0) 30(0) 50(0) 50(0)
Main Bearing Caps
/
02-305D A
Imbe Oil Internal Earters 02-307A A
100 Imbe Oil'Ibbirg and Fittirgs-Internal 02-307B A
100 Imbe Oil Line Supporte-Inremal 02-307D B
100 Crackshaft 02-310A A 100 100 38(0) 3,4 Crankshalt Bearirg Shell 02-310B A
50(0) 50(0) 4 Crakshaft 1hrust Bearirg Rirg 02-310C A 100-Crankcase Assembly 02-311A A
100 X
9 Cum Bearing Cgs and Dowels 02-311B B
Cramkcase Mounting Hanhare 02-311D B
X(0) 9 Cylinder Block 02-315A A 40(25) 100(25) 20(0) 20(0)
Cylinrier Liner 02-315C A 100 100 Cyliruler Block Jacket Water Manifold 02-315D B
100 3(0)
Cylinder Head Studs 02-315E B
25 Cyl. Block Jacket Wtr. Manifold M2ts 02-315F B
100 X(0) 9 Cylinder Block Seals and Gaskets 02-315G B
Jacket Water Inlet Manifold Assenbly
'02-316A B
100 Jacket Water Inlet Manifold coupling 02-316B B
100 Jacket Water Discharge Manifold 02-317A B
100 Jacket Water Disch. Manifnid coupling 02-317B.
B 100 Jacket Water Disch. Manifold Supports 02-317C B
100 X(0) 9 Flyuheel 02-330A A
100 Flywheel Bolting 02-330B A
Front Gear Case Bolting 02-335B C
100 25(0) 25(0)
Connectirg Rods and Bushings 02-340A
.A 100(0)100 100 Connecting Rod Bearing Shells 02-3405 A 100 100 100 100 Piston 02-341A A
100(0)100 100(0) 5,10 Piston Rings 02-341B A
25(0)100(0) 25(0) 11 Piston Pin Assembly 02-341C A
25(0)100 25(0) 25(0)
Intake Tappets 02-345A A
25 1%el Tappets.
02-345B A
25 X(0) 9 INel Ptup Base Assembly 02-345C B
100 r===h=ft Assembly 02-350A A
c-ahaft Bearing 02-350B B
100 7
100(0) 100(0) 100(0) c===h=ft Supports, Boltirs and Gear 02-350C A
Crankshaft Gear 02-355A A
100 1
Idler Gear Assembly 02-355B A
100 100(0)
Air Start Valve '02-359 A
100 100 l
Cylinder Head 02-360A B
100 100 100 100 X
2,9 Intake and Exhaast Valves 02-360B B
25(0)100 25(0)
Cylinder Head Bolting and Gaskets-02-360C B
X(0)
Valve Springs 02-360D B
100 1
100 100 Sdcover Assembly 02-362A B
100(0)
X 9
Fuel Injection Pimp 02-36 %
B 100 100(0)
X(0) 9 1%el Injection Tips 02-365B B
Table 5-1.
Catawba Unit 1 Diessla Inspection Plan Matrix Sanple Size, Percent of Engine Parts Inspected P
2 Surf. Vol.
Part Name Part No. Class Dimen. Visual 10E
!OE Material Hardness Erg Ev Notes N1 Injection Ming 02-365C B
100 100 8
h1 Injection hbiog Supports 02-365D B
100 i
N1 Puup Linkage arr! Control Shaft 02-371A A
100(0) 100(0)
N1 Puup, Linkage, Bearings aral Shaft 02-371B A
100 Exhaust 14anifnid 02-380A B
100 100 100(0) 100(0)
Exhaust Manifold Bolting 02-380B B
9 9
8 t
Cyliruler Block cover, Caskets and Bolts 02-385B C
X(0) 9 Crankcase Cover Caskets armi Bolting 02-386B C
100 Intake & Intermediate Rocker Arm Asnbly. 02-390A B
100 100(0) 100(0) 100(0)
Exhaust Rocker Arm Assembly 02-390B B
100 100(0) 100(0) 100(0) l Intake and h at h hrods 02-390C B
100 100 Connector PLahrod 02-393)
B 100 100 Rocker Arm Bcahings 02-390E B
100 Rocker Arm Bolting 02-390G B
100 100 100(0) 100(0)
Overspeed hip Covernor 02-410A A
X(0) 9 t
Overspeed Trip & Accessory Drive 02-410B A
100(0)100(0) 100(0) 100(0)
Overspeed hip Couplirgs 02-410C A
100 Overspeed Trip ht Valves 02-410D A
X(0) 9 Speed Regulatizg Covernor Drive 02-411A A
100(0)100(0) 100(0) 100(0)
Covernor Drive Couplings 02-411B A
100 100 Covernor Linkage 02-413 A
100 N1 Purp Linkage-Auto Slutdout Cylinder 02-413B B
100 Speed Regulating Governor 02-415A A
X(0) 9 Covernor Booster Servonotor 02-415B B
X 9
Governor Heat Excharger Assenbly 02-415C A
X(0) 9 Inbe Oil Ptsp 02-420 A
1 X(0) 9 Jacket %ter Punp 02-425A A
100(0) 100(0) 100(0) 1 Intercooler Piping-Coupling, Bolt, Gskt. 02-436B A
100 hrbo Cooling Eter Pipe and Fittings 02-437A B
100 Wrbo Cooling Eter Pipe Supports 02-437B A
100 l
Start Air Manifold Pipe, Abing & Fttug. 02-441A A
100 Start Air Manifold Vivs, Strners, F1trs. 02-441B A
X(0) 9 I
Start Air Manifold Pipe Supports 02-441C A
100 Starting Air Distributor Asserbly 02-442A A
100(0) 100(0) 100(0) 6 Start Air Distributor 7bg., Ftg., Gskts. 02-442B A
100 h 1 Oil Booster Ptmp 02-445 A
X(0) 9 h1 Oil Piping and Abing 02-450B A
100 h1 Oil Piping Supports 02-450D A
100 h1 Oil Filters 02-455A B
X(0) 9 h1 Oil Strainers 02-455B B
X(0) 9 h1 Oil Filter hunting Hardware 02-455C A
100 External Imbe Oil Lines 02-465A A
100 External Inbe Oil Line Supports 02-465B A
100 External Inbe Oil Valves 02-465C A
X 9
hrbocharger Imbe Oil Pipizg 02-467A B
100 Wrbocharger Imbe Oil Piping Supports 02-467B B
100 hrbocharger Bracket 02-475A B
100 hrbocharger Air Butterfly Valve 02-475B A
100(0) 100(0) 100(0) hrbocharger Bracket Bolting 02-475D B
8(0) 8(0) 12 Control Panel Cabinet 02-500A A
X 9
Control Air Acetmulator 02-500F A
X 9
Control Air Systen Valves 02-500G A
X 9
l
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I 8818 In8Pecth Plan Ntrh Table 5-1.
Scaple Siza, Parcant of Engins Parts Inspscted Pag 2 3 Surf. Vol.
i Part No. Class Dimen. Visus 1 NDE NDE Material Hardness Rg Ev Notes Part hua I
9 Control Air Systen Pressure ihr3*eh==
02-50Gt B
I 9
l Control System Belays 02-500J A
I 9
Control Systan Solomoid Enives02-50K A
100 Cetrol Air Systen Piping,1hbias, Ptags 02-50st B
I 9
Cetrol Panel Wiring 02-505 A
100 Imbe Oil Susp Tank 02-540A B
100 Imbe oil Sg Tam Bolting 02-540s B
100 Imbe Oil Sisy 11mdt Mantizg Entduare 02-540C B
l I(0) 9 6
Fondation Bolts and Anchors02-550 B
I 9
Instrimmitatica 1hermocamples 0243(B B
l 100 mgine & '-41(*=y Edule Wirfag Conduit 02-688k A
I 9
l Rgine and Aimiliary Ituksia Wiring 02-68 8 A
I 9
kgine sad '-ili= y Modula Wiring Bones 02488C A
I 9
l l
R eine Alarm Sensors02-690 A
I 9
l Off Reise Safety Alana Sensor -evitches 02491A B
100
(
[
Beine Statdann 12ias ami Fittings 02495a B
I 9
l Rigine Stutdoen Valves, Eags. & Orifice 02495s A
I 9
m ine Stutdoin 1 rip Switches 02495C A
a I
I 9
I hel 011Ihplar Strainer 02-823)
A l
100 f-- ?='=---- 1hrust Bearing Imbe Systen 02-Q1 C
I 9
hr= static Valw C 136-40 5 I
9 l
Int &e Air Filter 05-106 B
I 9
i l
Int &e Air Sit.nr.e CN-107 B
I 9
Enfore and After Imbe oil Pump m-109 A
I 9
i hil Flow Imbe Oil Filter 3-110 A
I 9
i l
Imbe Oil Best Ekchanger 05-111 B
I 9
Generator Shaft and Bearings 05-119A A
I 9
i Jacket Water Emet Brchager 3-120 B
I 9
011 Prelube Filter G-122 A
I 9
I Imbe Oil Keepesta Strainer 05-131 A
Intercooler F-068 A
100 100 Nt+ F----r
)EKn2/3 A 100 100 I
9 i
Imbe Oil N11 Pressure Strainer SE-025 A
i i
l
?
f i
L I
F I
I t
Notes to Table 5-1 1.
Intake and exhaust valve springs have proper color code.
2.
Ultrasonic wall thickness measurement of fire deck area and fuel nozzle area.
3.
A torsiograph will be developed of the crankshaft.
4.
Crankshaft web deflections and thrust clearance will be measured with the diesel both hot and cold.
5.
Measure torque on believille spring loaded bolts.
6.
Hardness of the spools will be measured only if excessive wear is measured on one or more of the spools.
7.
If inspection of camshaft lobes shows no abnormal wear, then no inspections of the camshaft bearings will be performed.
8.
Eddy current test to determine if there are cracks.
9.
Engineering validation (Eng Ev) of diesel 1A part including visual inspection to determine that part is per bill of materials and review of unscheduled maintenance reports associated with part.
For diesel 1B, engineering validation consists of reviewing unscheduled maintenance reports.
10.
Piston skirts will be replaced on the 1B diesel. Surface NDE and hardness wene performed in receipt inspection.
- 11. New piston rings will be installed on the new skirts.
- 12. All bolting will be replaced.
- 13. Catawba 1B frequency of inspections same as Catawba 1A except as noted by parentheses. Where parentheses are included, frequency of inspection for Catawba 18 appears in the parentheses.
.-