ML20092K712
| ML20092K712 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 06/25/1984 |
| From: | Carr A DUKE POWER CO. |
| To: | CAROLINA ENVIRONMENTAL STUDY GROUP, PALMETTO ALLIANCE |
| References | |
| OL, NUDOCS 8406290024 | |
| Download: ML20092K712 (28) | |
Text
- -. Q9/J RELATFD CCi:ZCFONDENCK 4.
UNITED STATES OF AMERICA 00g.TED NUCLEAR REGULATORY COMMISSION c
BEFORE THE ATOMIC SAFETY AND LICENSING BOARD i
d4 JIJf! 28 N0 3 In the Matter of
)
)
DUKE POWER COMPANY, et al.
)
Docket No. 50-413 0L
)
50-414 O L (Catawba Nuclear Station
)
Units 1 and 2)
)
APPLICANTS' SUPPLEMENTAL RESPONSE TO
" PALMETTO ALLIANCE AND CAROLINA ENVIRONMENTAL STUDY GROUP'S INTERR0GATORIES AND REQUESTS TO PRODUCE DOCUMENTS ON DIESEL GENERATORS CONTENTIONS TO APPLICANTS AND NRC STAFF" AND "CESG'S INTERROGATORIES TO DUKE POWER REGARDING EMERGENCY DIESEL CONTENTIONS ADMITTED BY ATOMIC SAFETY AND LICENSING BOARD."
t Pursuant to the discovery schedule established in the Board's conference call helc! May 21, 1984 and in accordance with their duty to update answers to interrogatories, Applicants hereby file supplemental responses to the interrogatories identified in the caption.
Applicants' original responses were filed April 2, 1984.
I.
Applicants' original responses addressed both the Intervenors' contention on the Catawba crankshaft design and the contention admitted by the Board on its own motion dealing with certain Catawba - specific problems (Memorandum and Order (Referring Certain Diesel Generator Issues to the Appeal Board), February 23,
- 1984, pp.
4-6; Memorandum and Order (Admitting a Board Contention Concerning Certain Diesel Generator Problems), February 27, 1984, pp. 2-3).
Subsequent to the filing of these responses, Intervenors defaulted on a condition imposed by the Board in admitting the crankshaft design contention 8406290024 840625 gDRADOCK 05000413 PDR i
'DSO3
e 4
that Intervenors provide the name and expected testimony of a crankshaft expert.
As a result, the Board dismissed the crankshaft contention.
(Order, April 13,1984, pp. 1-2).
As a consequence of this action, the sole remaining contention on diesel generators is the former Board contention which is now Palmetto Alliance /CESG contention, which as amended in the May 21, 1984 conference call (Tr. 12634), states:
a,-
Whether there is reasonable assurance that the TDI emergency diesel generators at the Catawba Station can perform their function and provide reliable service because of the problems that have arisen in the course of testing and inspections of the Catawba diesel generators such as the problems reported in the Applicants' letter to the Board of February 17, 1984.
Applicants, in providing supplemental responses to Intervenors' interrogatories, therefore address only those interrogatories which are directed to that contention.
Applicants objected to many of the Intervenors' interrogatories as beyond the scope of the admitted contentions.
Applicants hereby preserve their objections to interrogatories which are beyond the scope of the admitted contention.
II.
Requests to Produce Applicants have made documents not subject to privilege available for t
inspection and copying by Palmetto Alliance and CESG.
These documents concerned both the Intervenors' contention and the Board contention. As a result of the Board orders dismissing the Intervenors' contention, Applicants have withdrawn documents which relate to the crankshaft design issue.
Only documents relevant to the admitted contention will be available for inspection '~
i 6
and copying. / The documents identified in Applicant's April 2,1984 response are, and have been, available to Palmetto Alliance and CESG since that date.
The documents identified with this supplemental response will be available to Intervenors for inspection and copying on, and for a reasonable period of time after, June 26 at Duke Power Company's offices at 422 South Church Street, Charlotte, North Carolina.
l i
III.
Responses to Palmetto Alliance Interrogatories A.
General Interrogatories 1.
Please state the full name, address, occupation and employer of each person answering the interrogatories and designate the interrogatory or the part thereof he or she answered.
The initials of the person or persons providing the primary information I
used in the answers to interrogatories is indicated in parentheses following
[
each answer.
The business address, occupation and employer of each such person is provided in the attachment to these responses that contains each such person's affidavit.
2.
Please identify each and every person whom you are considering to call as a witness at the hearing in this matter on this contention, and with respect to each such person, please a.
State the substance of the facts and opinions to which the witness is expected to testify;
- /
- Applicants have also agreed, as an accommodation to Intervenors, to provide for their inspection copies of documents generated by the TOI Owners Group for the NRC Staff and are available to applicants by virtue of their membership in the Owners Group. t
k o
b.
Give a summary of the grounds for each opinion; and c.
Describe the witness' educational and professional background.
(a) Applicants are in the process of developing their direct case on the admitted contention, so that the information necessary to respond completely to this interrogatory does not yet exist.
However, Applicants have tentatively identified four witnesses to address that contention:
G.
Wayne Hallman, Nuclear Maintenance Manager for Duke Power Company, Russell P.
- Muschick, Maintenance Engineer for Duke Power Company, William R. McCollum, Jr., Schedule Engineer for Duke Power Company, and C. H. Wells, Vice President, Research and l
Development, for Failure Analysis Associates.
Applicants anticipate calling these witnesses to testify as to the testing, disassembly, inspection, component repair / replacement, reassembly, and post-inspection testing aspects of their program to assure the reliability of the Catawba diesel generators.
Further information with respect to this interrogatory, including identification of additional witnesses, if any, will be provided as that information becomes available.
3.
Is your position, claim or defense regarding the contention based on one or more calculations? If so:
a.
Describe each calculation and identify any document setting forth such calculation.
b.
Who performed each calculation?
c.
When was each calculation performed?
i d.
Describe each parameter used in such calculation and each value assigned to the parameter, and describe the source of your data, e.
What are the results of each calculation?
f.
Explain in detail how each calculation provides a basis for the contention.
l l t
9 4
Any of Applicants' positions, claims or defenses relevant to the Board contention, which is based on one or more calculations, is explained in detail in the documents already provided to Intervenors or made available for inspection and copying, such as the results of Applicants' test and inspection program, the results of which have been made available to Intervenors.
4.
Is your position, claim or defense regarding the contention based on one or more experiments or tests? If so:
a.
Describe each experiment or test and identify any document setting forth such experiment or test.
b.
Who performed each experiment or test?
c.
When was such experiment or test performed?
d.
Describe each parameter cr variable measured in such experiment or test.
e.
.What are the results of each experiment or test?
f.
Explain in detail how each experiment or test provides a basis for your position, claim or defense regarding the contention.
Applicants' position, claim or defense with respect to why the ability of the Catawba. diesel generators to provide reliable backup power is not compromised by the problems set out in the contention is based upon Applicants' test and inspection program, the results of which have already been made available to Intervenors.
Applicants' testing program is described in the attachment to the February 22, 1984 response to NRC Staff questions, as well as in handouts (previously provided to Palmetto Alliance and CESG) accompanying a presentation made to the NRC Staff in Bethesda on March 21.
Applicants provided to the NRC Staff on April 5,1984 a more detailed description of the test and inspection program.
A copy of that document was served upon Palmetto Alliance and CESG.
The program of the Owner's Group is described in several Board Notifications sent out by the NRC Staff.
Copies of all those documents have been served on Palmetto Alliance and CESG. The information sought in parts c, d and e of this Interrogatory is and will be contained in the described documents.
The results of Applicants' test program demonstrate that the Catawba diesel generators are capable of providing a reliable source of backup power, as indicated in tne June 1,1984 " Catawba Nuclear Station Diesel Engine 1A r
Component Revalidation Inspection Report", a copy of which was provided to Intervenors.
(GWH) 5.
Is your position, claim or defense regarding the contention based upon conversations, consultations, correspondence or any other type of communication with one or more individuals?
If so, a.
Identify by name and address each such individual.
b.
State the educational and professional background of each such individual, including occupation and institutional affiliations.
c.
Describe the nature of each communication with such individual, when it occurred, and identify all other individuals involved.
d.
Describe the information received from such individuals and explain how it provides a basis for the issues.
e.
Identify each letter, memorandum, tape, note or other record related to each conversation, consultation, correspondence, or i'
other communication with such individual.
Applicants preserve their objection to this Interrogatory.
In Applicants' view it is directed either to the position which Applicants have taken with respect to the Board contention before the Licensing Board in this proceeding, or the manner in which Applicants have interpreted the PA/CESG Interrogatories and furnished these responses thereto.
In either event, any conversations, correspondence or any other type of communications are privileged, and thus not subject to discovery.
4 With respect to the positions Applicants have taken on contention before the Board, such are guided by legal strategy developed in anticipation of litigation after extensive consultation among counsel for Applicants, and between and among Applicants' counsel and members of Applicants' staff, to ascertain the factual matters necessary to formulate that strategy.
The positions Applicants have taken with respect to answering the PA/CESG Interrogatories were formulated on the basis of discussions among counsel for I
the Applicants.
Such positions were then communicated, during telephone conference calls and conferences, to members of Applicants' staff to guide and l
aid those persons in preparing initial drafts of responses to the Interrogatories.
In short, these positions, and thus the communications between and among Applicants' counsel and staff underlying those positions, are a direct result of Applicants'
- counsel, while preparing the case for litigation,
~
"[A]ssembl[ing] information, sift [ing] what [they] consider [ ] to be relevant I
from the irrelevant facts, prepar[ing] [their] legal theories and plan [ning]
[their] strategy.
Such preparation includes " interviews, statements, memoranda, correspondence, briefs, mental impressions, personal beliefs, and countless other tangible and intangible [ actions]."
Hickman vs. Taylor, 329 U. S. 495, 511-512 (1945).
Applicants' counsel are entitled to conduct this process "without undue and needless interference" and any communications and/or conversations conducted during that process are subject to protection under the i
attorney work product privilege.
M. at 511; see Consumers Power Company (Midland Plant, Units 1 and 2) ALAB-691, NRC (September 9, 1982) l slip op. at 33-35.
Thus, Applicants object to this Interrogatory in that it calls for i
information which is privileged under the attorney work product doctrine.
l
Applicants would note, however, that to the extent members of Applicants' staff have communicateo with one another, and with other organizations or
- persons, regarding the subject matter of these contentions, and those communications are reflected in documents, such documents have been made available in accordance with Part II, above, and have been addressed in some Interrogatory responses.
Those documents are indexed and a copy of the index has been provided to Intervenors.
They range from notes of conversations to final reports of consultants.
Therefore Applicants believe that whatever obligation exists under this Interrogatory has been discharged, and object to providing further information in response to it.
For Applicants to provide any further information in what could be a myriad of conversations with various individuals would be to impose a substantial and unnecessary burden upon them, which.is unwarranted in light of the voluminous information made available to Intervenors.
Therefore, for the reasons set forth above, Applicants object to providing further information in response to this Interrogatory.
To respond further would cause Applicants annoyance, oppression, undue burden and expense.
Further, such information is not relevant to the subject matter of the t
contention, nor would its disclosure be reasonably calculated to lead to the discovery of admissible evidence.
6.
Is your position, claim or defense regarding the contention based upon one or more NRC Staff documents?
If so, please identify such documents and make them available for inspection and copying.
Applicants have no change to their prior response. Applicants continue to believe that this interrogatory is addressed to the NRC Staff; Applicants would note that NRC Regulatory Guides 1.108, 1.137, 1.41, 1.68 and 1.9 are generally. _ _ -.
i
+
applicable to diesel generators.
These Regulatory Guides will be available for inspection and copying in accordance with Part II.
(RPM) i B.
Specific Interrogatories 3
i Intervenors filed two sets of interrogatories.
The set filed jointly is j
i referred to by the designation PA/CESG.
The set filed by CESG uses that designation.
PA/CESG Interrogatories 1-12, and 30A, and CESG Interrogatories 1-2 were based upon Intervenors' crankshaft design contention which has been dismissed by the Board.
Therefore, Applicants are under no obligation to
{
update these interrogatories.
t i
PA/CESG 13, 14, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 27, 28, 29, 30, 31, 32, 35A, 36, 39, 41, 42, 44A, 50, 51, 52; CESG 10, 11, 12, 18.
Applicants i
objected to these Interrogatories in whole or in part.
Applicants have reviewed their prior objections and hereby preserve their objections.
l i
PA/CESG 19, 31, 33A, 34, 35A, 36, 37, 39A, 40, 43, 44, 45, 45A, 46, 47, 48, 48A, 51, 52; CESG 4, 5, 7, 9,13,14,15,16,17,19, 20, 21, 22, 23, 24, 25, 27, 28, 29.
Applicants have reviewed their prior answers to these interrogatories and believe such answers provide a full and complete response to the interrogatories, without further updating.
i Upon review Applicants have concluded that the following interrogatories require updating:
PA/CESG 14, 26, 33, 35, 38, 49, 49A, 50; CESG 3, 6, 8, 26.
t -- - -
.--.----.----..--l
~
e*
PA/CESG Interrogatories 14.
How long will it take for TDI to properly manufacture diesel generators or components? How will this point be identified?
The fabrication of the diesel generators at Catawba began in November of t'
1976 and the last engine was shipped in December of 1979.
In Applicants' view these diesels were " properly manufactured."
That view has been confirmed by Applicants' test and incpection program, which is documented in Applicants' June 1, 1984 report to the NRC.
(GWH)
Applicants object to providing further information in response to this Interrogatory.
Though it is unclear on its face, it appears to seek information related solely to TSI's QA Program, and Applicants object on the ground that it seeks information outside the scope of the contention admitted by the Board.
Therefore for the reasons given in Applicants' original response I
to Interrogatory 13, Applicants object to responding to this Interrogatory.
For Applicants to respond would be to cause them annoyance, oppression, undue l
burden, and expense.
Further, the information sought is not relevant to the subject matter of the contention, nor would its disclosure be reasonably calculated to lead to the discovery of admissible evidence.
26.
The following statement was made in the Owners Group 1/26/84, presentation to the NRC:
. we had decided that as part of the design review quality revalidation effort, the quality engineers and indeed the specialists are evaluating the need to perform either inspections or evaluations of components on the basis of their function and their real t
requirements as opposed to just doing quality assurance program review.
(Tr. 27).
Describe in detail, such inspections and evaluations and identify the components and their " function" and "real requirements" t
as applied to the Catawba diesel generators.,
l lE.
c.
The information sought is contained in updated ' Attachments 1 and new l
attachment 5.'
(RPM) h 33.
Provide a listing of each 10 C.F.R. Part 21 report with respect to i
The 10 CFR Part 21 Report information of which Applicants are aware for f
TDI diesel generators is provided as a part of Applicants' Response 4-1 to the NRC Staff, dated February 22, 1984.
Additional 10 CFR Part 21 reports which j
t have been filed.since the February 22 response are:
(1) Overspeed Governor and Fuel Transfer Pump Drive (Hubs); (2) Turbocharger Thrust Bearing Lubrication.
j t
These should be added to the list in Applicants' Response 4-1.
j Applicants object to providing any further information in response to thi.,
Interrogatory.
Information with respect to 10 CFR Part 21 Reports for diesel f
generators other than those manufactured by TDI is clearly outside the scope of the contention admitted by the Board.
In addition, such information is not readily available to Applicants and to collect it would impose an undue burden.
Therefore, for reasons set forth abcVe, Applicants object to providing further information in response to this Interrogatory.
To respond further would -cause Applicants annoyance, oppression, undue burden and expense.
Further, such information is not relevant to the subject matter of the l
contention, nor would its disclosure be reasonably calculated to lead to the f
i discovery of admissible evidence.
r 35.
List results/ recommendations put forth by Owners Group task force.
How many would be changed on review?
What were the changes?
By l
which reviewer were they suggested?
How many reviews left the results/ recommendations unchanged?
How many recommendations were made less stringent?
More stringent?
Who made what changes?
i Identify and describe in detail each.
i i
l t l
J *
?
The TDI Owners' Group has provided Duke Power Company with recommendations for inspections of diesel engine parts on the DRSV-16 engine.
To the extent that these recommendations are applicable to the specific engines at Catawba Nuclear Station, they have been incorporated into our inspection program.
A list of these parts, and a brief description of the inspection to be performed on each part, is contained in updated Attachment 2.
(RPM)
- 38. Three AE pistons are to be inspected at Shoreham after run.
With respect to later model engines what test / inspection results would call for a reduced level of inspection?
See, 1/26/84 Meeting (Tr.
84).
A reduced level of inspection would be warranted on later model engines whose owners have elected to install AE pistons if inspection results from lead R48 & V-16 engines, following accumulation of 100 hrs at full load, confirm the absence of linear indications in the piston-crown stud boss region and the wrist pin boss region for all pistons examined.
(RPM)
- 49. With respect to the testing of the Catawba Unit 1 diesel generators described in response to item 7 in Applicants' 2/22/84 submittal explain in detail the results of each of the start-up and pre-operational functional testing.
Identify documents reflecting circumstances and conditions of each test as well as the test results.
If any test was omitted or modified explain fully the basis for such action.
The information sought in the Interrogatory is contained in Attachment 3, which has been updated.
(WRM)*
The results of the Catawba diesel generator lA inspection will be used to determine the appropriate tests and inspections for the other diesel units at Catawba.
(RPM)
- This attachment is being prepared and is being transmitted forthwith. t-
--w-
a*
t 49A. Identify in detail any and all documents reflecting the Catawba diesel generators operating history and any problems, deficiencies or unusual or abnormal operations observed.
Include each item and event reflected in response No. 8 and Applicants' 2/22/84 submittal. Please update your response to include any subsequent developments.
The information sought in response to this Interrogatory is contained in, which has been updated.
(WRM)*
50.
Identify fully the documentary basis for responses No.11 and 12 in I
Applicants' 2/22/84 submittal to the NRC Staff.
Please make these documents available for inspection and copying.
i The documentary bases for response No.11 are identified in the response itself.
Intervenors have been served with copies of the response.
The
{
documentary basis for the response to No.11 is available for inspection and l
copying.
A further documentary basis is the June 1,1984 inspection result i
report which has been provided to intervenors.
t The documentary bases for responses 12(3), 12(4), 12(5) and 12(6) are identified in the responses themselves.
Intervenors have been served with copies of the responses.
The documentary bases for these responses is available for inspection and copying.
To the extent that specific TDI Owner's Group documents are not identified in the response and are relevant to the admitted contention, such documents are available for inspection and copying.
(JDH)
Applicants object to providing any documentary basis or other information related to responses 12(1) and 12(2) because these relate to Applicants' and/or TDI's QA programs.
Therefore, Applicants object to this Interrogatory on the grounds that it seeks information outside the scope of the contention admitted by the Board.
- This attachment is being prepared and is being transmitted forthwith.
1 : -
a Therefore, for the reasons given in the Applicants' original responses to Interrogatories 13 ar.d 15, Applicants object to responding to this Interrogatory.
For Applicants to respond would be to cause them annoyance, L
oppression, undue burden and expense.
Further, the information sought is not relevant to the subject matter of these contentions nor would its disclosure be reasonably calculated to lead to the discovery of admissible evidence.
CESG Interrogatories 3.
In regard to the NRC staff's questions of December 30, 1983, specifically Duke Power Company's response to 8, describe fully and completely the failure of the turbo bearing both physically and functionally.
The turbocharger bearing did not fail in the sense that it would have prevented the diesel generator from providing backup power.
a.
Physically, the face of the turbine end thrust bearing exhibited excessive wear due to insufficient lubrication during repetitive cold fast starts of the diesel generator, b.
Functionally, the turbocharger bearings performed their intended function with no adverse affect on diesel generator operation during the extended operational test.
The diesel control circuits are designed such that during maintenance and test runs, when the turbocharger oil pressure drops below 15 psi, the diesel is automatically shut down.
- However, during an actual emergency condition, this protective circuit is bypassed and low turbocharger oil pressure would not shut the diesel engine down.
Therefore, the diesels would continue to perform during an emergency.
(JEC) s
e 6.
Would a significantly failed turbocharger bearing make a Catawba DG inoperable?
What would the consequence be of a seized turbocharger shaft?
What effect would an inoperative turbocharger have on the power output of a Catawba DG--in quantitative terms?
I A failed turbocharger would not make the diesel inoperative.
A seized turbocharger shaft would stop the turbocharger from rotating. The diesel could i
l then be operated as a normally aspirated engine.
An inoperative turbocharger would reduce the load carrying capability of the diesel generator to 70 to 75%
of the rated load.
(JEC) 8.
Regarding response 9, what additional tests and inspections will be l
performed on DGs 1B, 2A, and 2B.
Applicants do not understand the reference to " response 9."
However, the Catawba Nuclear Station 18 DG will be operated for a total of least 750 hours0.00868 days <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br />.
It will then be inspected.
The extent of the IB inspection will be based on i
the results of the previous inspection of the IA DG, and/or completed previous DSRV 16-4 inspections.
The extent of the Catawba DG 1B inspection is covered in the June 1,1984 inspection report, copies of which have been provided to l
Intervenors.
(RPM) 26.
Did DPC require preventive maintenance programs of TDI at the time of procurement?
Was such a requirement absent from the purchase requisitions?
Yes.
This requirement was included in the purchase specification.
The preventive maintenance program is still under development.
(RPM)
Respectfully Submitted, Klbert V. Carr, Jr. T
// (#
DUKE POWER COMPANY P. O. Box 33189 Charlotte, North Carolina 28242 (704) 373-2570 i
~
.~
O UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD In the Matter of
)
)
DUKE POWER COMPANY, et al.
)
Docket Nos. 50-413
)
50-414 (Catawba Nuclear Station
)
Units 1 and 2)
)
CERTIFICATE OF SERVICE I hereby certify that copies of " Applicants' Supplemental Response To
" Palmetto Alliance and Carolina Environmental Study Group's Interrogatories and Requests To Produce Documents On Diesel Generators Contentions To Applicants and NRC Staff" And "CESG's Interrogatories To Duke Power Regarding Emergency Diesel Contentions Admitted By Atomic Safety and Licensing Board" in the above captioned matter have been served upon the following by deposit in the United States mati this 25th day of June,1984.
James L. Kelley, Chairman Richard P. Wilson, Esq.
Atomic Safety and Licensing Board Assistant Attorney General i
Panel State of South Carolina U. S. Nuclear Regulatory Commission P. O. Box 11549 Washington, D. C. 20555 Columbia, South Carolina 29211 Dr. Paul W. Purdom Robert Guild, Esq.
235 Columbia Drive Attorney-at-Law Decatur, Georgia 30030 P. O. Box 12097 Charleston, South Carolina 29412 Dr. Richard F. Foster Palmetto Alliance P. O. Box 4263 2135 1/2 Devine Street Sunriver, Oregon 97702 Columbia, South Carolina 29205 Chairman Jesse L. Riley Atomic Saf ety and Licensing 854 Henley Place Board Panel Charlotte, North Carolina 28207 U. S. Nuclear Regulatory Commission Washington, D.C. 20555 Chairman John Clewett, Esq.
Atomic Safety and Licensing
~236 Tenth Street, S.E.
Appeal Board Washington, D.C. 20003 U. S. Nuclear Regulatory Commission Washington, D.C. 20555 A
George E. Johnson, Esq.
Karen E. Long Office of the Executive Legal Assistant Attorney General Director N. C. Department of Justice U. S. Nuclear Regulatory Commission P. O. Box 629 Washington, D.C. 20555 Raleigh, North Carolina 27602 J. Michael McGarry, III, Esq.
William L. Clements l
Anne W. Cottingham, Esq.
Docketing and Service Section l
Bishop, Liberman, Cook, Purcell & Reynolds U. S. Nuclear Regulatory 1200 Seventeenth Street, N.W.
Commission i
Washington, D.C. 20036 Washington, D.C. 20555 Don R. Willard Spence Perry, Esq.
Mecklenburg County Associate General Counsel Department of Environmental Federal Emergency Management Health Agency 1200 Blythe Boulevard Room 840 Charlotte, North Carolina 28203 500 C Street, S.W.
Washington, D.C. 20472 N
Albert V. Carr 7
(Nw 4
i
)
e f
ATTACHMENT 1 f
RESPONSE TO PALMETTO ALLIANCE /
CESG INTERROGATORY 26 t
i The purpose of this Attachment is to describe such inspections and
[
evaluations and identif y the components and their " function" and "real requirements" as a result of Catawba diesel generator operation.
t t
t 1.
Cylinder Heads Functional Reauirements: Provide pressure tight cap for engine cylinder, and provide passages and sealing for cooling water, lube oil, starting air, intake and exhaust gases.
Insoections:
The following inspections will be done to evaluate the 1
Catawba cylinder heads.
A.
Visual inspection of intake and exhaust valve seats, and intake and i
exhaust valves, starting air valves, and fuel injectior nozzle I
holder studs.
B.
Liquid penetrant examination of:
e Intake and exhaust valve seats e Fire deck area between exhaust valves l
C.
Ultrasonic thickness measurements of:
i e Fire deck ares r
6 o Injector cavity area i
D.
Magnetic particle examination of fuel injector nozzle holder studs.
i l
2.
Subcover Assembly l
Functional Requiresent: Provide structural mounting on top of the t
l cylinder head for rocker arm assembly.
t 1
f Inspec tion:
The following inspections will be done to evaluate the Catawba subcover assembly.
l A.
Visual inspection.
i l
B.
Liquid penetrant inspection of rocker arm mounting surfaces.
i l
J
?
(
-.. ~ - -. - -. - - -. -
3.
Ym.nl Inleetion Lua Func t ional Reauirement :
To convert low pressure f'uel delivered by the fuel oil transfer pump to high pressure fuel suitable for injector
. operation.
Insoection:
The following inspections will be done to evaluate the Catawba fuel injection pumps.
A.
Material hardness measurements.
B.
Ultrasonic inspection to test casting integrity.
4.
Crankcase Covers I
Functional Recuirements: Provide access to crankcase for inspection and maintenance.
Insoec t ion: The following inspections will be done to evaluate the Catawba crankcase covers:
A.
Bolt torque readings.
i B.
Visual inspection of bolt holes for cracks.
t i
5.
Pushrods Functional Reauirements: The pushrods form a portion of the linkage that transmits camshaft lobe motion to the cylinder intake and exhaust valve, thereby controlling the valve opening and closing cyc-le.
Insoec t ion:
The following inspections will be done to evaluate the Catawba pushrods:
i A.
Visual inspection to assure that pushrod of friction welded design.
B.
Visual inspection of spherical surfaces.
C.
Liquid penetrant examination of friction welds.
6.
Rocker Arm Assembly Functional Reauirement:
The rocker arm assembly forms a portion of the valve operating linkage taking rectilinear motion from the pushrod to opening the exhaust and intake valves.
Insnec t ion:
The following inspections will be done to evaluate the Catawba rocker arm assemblies:
A.
Visually inspect for signs of distress.
B.
Material tests.
2
.. - _ - = - _
t l
t C.
Hardness tests.
D.
Liquid penetrant inspection of adjusting screw swivel pads.
E.
Magnetic particle test of rocker are capocrews.
7.
Fgg1 pil Pin 4== 31 Tubinn Func tional Reauirements: To cransfer fuel oil from one component to l
another.
i Inspect ion:
The following inspections will be done to evaluate the i
Catawba fuel oil piping and tubing:
t l
A.
Walk down of piping system to confirm that it is in accordance with l
TDI drawings.
[
i B.
Visual examination of supports to confirm that they are in j
accordance with TDI drawings.
C.
Eddy-current testing of high pressure tubing to eliminate l
possibility of cracks.
l r
8.
Turhns.harter Lub.191L Finine l
Functional Recuirement:
Provide means for supplying lubrication to the i
l f
Insnec tion:
The following inspections will be done to evaluate the
[
Catawba turbocharger lube oil piping:
l l
A.
Walkdown of piping system to confirm that is is in accordance with TDI drawing.
t B.
Visual examination of supports to confirm that they are in f
accordance with TDI drawings.
9.
Turbocharaer 331 Intercooler i
I Functional Reauirements: Provide means of increasing air volume to cylinder.
Insnec tion:
The following inspection will be done to evaluate the Catawba turbocharger and intercooler.
A.
Visual inspection of turbine parts, bearing, butterfly valves, and l
intercooler, and mounting hardware.
I I
B.
Visual and dimensional inspection of bearings.
)
C.
Hardness and material tests of mounting fasteners.
3 l
t i
D.
Torque reading on fasteners.
i E.
Liquif p'enetrant inspections of intercooler adapters.
s
- 10. Crankshaft Functional Requirement:
The crankshaft converts reciprocating motion.
l component ninertial forc'es and gas pressure piston forces to rotary motion and' torque at the output flange.
,j Inspec tion:
-The isllowing inspections will be done to evaluate the m
Catawba crankshaft:
h A.
Thrust clearance and web deflection measurements.
4 B.
Visual inspections of main bearings and journals.
j i
~ C.
Liquid penetrant inspection of bearing caps and base.
D.
Dimension measuerment of main bearing shells.
E.
Eddy-current inspection of fillets between crankpins and webs.
l
- T F.:
Liquid ' penetrant inspection of main bearing oil holes.
f i
G.Torsiograph tests.
m
- 11. Ccn'necting Egit l
i
' Functional Reauirements:
The connecting s.'d transmits engine firing i'
force from the pistons and piston pins 'throuh'a the rod to the crankshaft such that the reciprocating motion of the pistons induces rotation and output, torque of the crankshaft.
{
.m m
I.napections:
The following inspections will be done to evaluate the Catawba connecting rods:
A.
Visual inspection of connecting rods, connecting rod bushings and shells, piston pins, and bolts.
B.
Dimensional measurement of connecting rods, connecting rod bushings and shells, piston pin and link rod pin.
C.
Eddy-current inspection of female thread' le rod box and crank pin bearing shells.
D.
Liquid penetrant inspection of rod svx saa.= and crankpin bearing shells.
t I
i.
E.
Magnetic particle inspection of connecting rod bolts.
F.
I-ray inspectioc'of crank pin she,11s.
i
~
4 t
t G.
Material and hardness test of connecting rod piston pin bushing, l
piston pins, rods, linkrod pin and rod box bushings.
- 12. Pistons Func t ional Reauirement :
The pistons react to the cylinder firing i
pressure and provide a reciprocating mechanism for converting combined t
inertia and combustion pressure forces into mechanical torque through l
the connecting rod piston pin, connecting rod and crankshaft.
l Inanec t ion:
The following inspection will be done to evaluate the Catawba pistons:
l r
A.
Visual inspection of pistons and piston rings.
l B.
Dimensional measurements of piston ring axial clearance in piston and piston ring butt gap in cylinder.
C.
Liquid penetrant inspection of stud bosses in piston and external l
surfaces on skirt portion of piston.
l t
D.
Torque measurement of piston believue studs.
E.
Magnetic particle inspection of piston skirt internal surfaces.
t i
- 13. Cylinder }l9.Gk And.LiRRI Functional Reauirements:
The cylinder block comprises the framework of i
a liquid cooled engine and provides passages and support for the cylinder liner and camshaft.
The cylinder block reacts to the dynamic l
loads from the cylinder firing pressure and the valve assemblies.
The liner forms the walls of the combustion chamber and must provide the l
l guide for the piston motion while reacting to high temperature gas i
forces and piston skirt side forces without excessive wear or scuffing.
Inspec tion:
The following inspection will be done to evaluate the Catawba cylinder blocks and liners:
r A.
Visual inspection of cylinder block liner and cylinder head studs.
i B.
Dimensional inspection of cylinder liner and cylinder liner seating i
area in cylinder block.
C.
Liquid penetrant inspection of top of cylinder block and liner seating area in cylinder block.
D.
Eddy-current examination of stud boles in block.
l E.
Materials and hardness tests on cylinder liners.
F.
Material test on cylinder head studs.
l 5
[
l
o
- 14. Air Start Valye Caoscrews i
Func t ional Requirement :
The air start valve capscrews provide a clamping force to hold air start valves in place on cylinder heads.
5 Inspection:
A dimensional inspection of air start valve capscrews will be accomplished to evaluate their use in the Catawba diesels.
i
- 15. Jacket Water.ZEEP.
Func t ional Reavirement:
The jacket water pump takes suction from the l
jacket water standpipe and delivers the required pressure and flow to i
the jacket water header. The jacket water circulates through the engine l
cylinder jackets, exhaust manifold, the turbocharger water cooler, the j
turbocharger oil cooler and jacke.t water cooler.
l Insoec t ion:
The following will be done to evaluate the Catawba jacket water pumps:
A.
Visual inspection of jacket water pump gearing, jacket water pump wear ring and face seals, and all bolted parts for looseness.
l B.
Liquid penetrant of gearing, keyways and impeller.
C.
Material and hardness tests of jackets water pump shaft.
- 16. Wirina and Termination:
Func t ional Reauirements The wiring and terminations interconnect instrument, control and power circuits on the diesel generator and at t
the control panels.
Inso ec t ion:
Walkdown of system to determine if cabbing components meet technical standards.
l l
- 17. Instrumentation Thermocouples:
Func t ional Reauirement:
Provides temperature signals for control and I
monitoring of the diesel engine.
Inso ec t ion :
Engineering evaluation of thermocouples and their application.
h 6
6 i
l l
ATTACHMENT 2 RESPONSE TO PAIJfETTO ALLIANCE /
CESG INTERROGATORY 35 Catawba IA Diesel Inspection Plan i
Part Name Comments Main Bearing Cap Base Assembly Visual. PT, Main Bearing Caps Visual, PT Lube Oil Internal Headers Yerify As Built With Walkdown to Drawing Lube Oil Tubing and Fittings Verify As Built With Walkdown to Drawing Lube Oil Line Supports Verify As Built With Walkdown to Drawing Crankshaft and Turning Gear
- ECT, PT, Visual Crankshaft Bearing Shell Visual, Dimensions Crankcase Assembly Visual Cylinder Block PT, ECT, Dimensions i
Cylinder Liner Visual, Dimensions, Material, Hardness
[
Cylinder Block Jacket Water-As Built System Walkdown per Drawings l
Manifold l
Cylinder Head Studs Visual, Materials Hardness Cyl. Block Jacket Wtr. Man. Nuts Visual Flywheel Bolting Verify Torques Meet TDI Requirements, Visual
[
Front Gear Case Bolting Visual Connecting Rods and Bushings Visual. Dimen., Materials, Hardness, PT, e
ECT, MT Connecting Rod Bearing Shells Visual, Dimensions, RT, ECT, PT Piston MT, PT, Visual, Dimensions Piston Rings Visual Piston Pin Assembly Visual. Dimensional, Material, Hardness Intake Tappets Visual Fuel Tappets Visual l
Camshaft Assembly Visual Camshaft Supports, Bolting &
As Found Torques, Visual, Material, Hardness Gear Idler Gear Assembly (Crank to Visual, Materials, Hardness j
Pump)
Idler Gear Assembly Visual, Materials, Hardness Air Start Yalve Visual. Dimensions Cylinder Head
Valve Springs Visual Subcover Assembly Visual. PT Fuel Pump Linkage and Control Visual, Material, Hardness i
Shaft Fuel Pump, Linkage, Bearings &
Visual Shaft i
Intake Manifolds Visual
~ Exhaust Manifold Bolting Visual Cylinder Block Cover, Gekts. &
Visual Bolts Crankcase Covers Verify Torque, Visual 1
?
o I
Rocker Arm Assembly Visual Materials, Hardness, PT, Dimen.
Exhaust Rocker Arm Assembly Visual, Dimensions, PT, Materials l
Pushrods Verify Friction Welded Pushrods Installed, i
PT f
Connector Pushrod Verify Friction Welded Pushrods Installed, l
PT Rocker Arm Bolting Verify Torque, MT, Materials, Hardness l
Governor Drive Gear and Shaft Vis., PT, Material, Hardness i'
Governor Drive Coupling Verify Condition of Coupling Material Gov. Ove speed Trip & Acc. Drive
- Visual, PT, Materials, Hardness Overspeed Trip Couplings 7isual Governor Linkage Visual Governor Heat Exchanger Assemb.
Visual 8
Jacket Water Pump Materials, Hardness, Visual l
Intercooler Piping-Coupling, -
Visual l
Bolting, Gasket
' Starting Air Distributor Assemb.
Dimensional, Hardness Turbo Air Butterfly Valve Visual Turbocharger Bracket Bolting Verify Torque, Materials, Visual l
Lube Oil Sump Tank Bolting Verify Bolted Connections are Tight.
Verify Tank Mounting Hardware Tightened.
Hardware Turbocharger Visual Rocker Arm Bushings Visual Crankshaft Thrust Bearing Measure Thrust Clearance i'
Main Bearing Studs & Nuts Visual. Dimensional Gear Case Covers Bolting Visual Fuel Injection Pump Hardness, UT l
Fuel Filter Mtg. Hardware Visual, Verify Torque External Lube Oil Lines Verify As Built with Walkdown to Drawing i
External Lube Oil Supports Verify As Built with Walkdown to Drawing l
Lube oil Sump Tank Verify As Built with Walkdown to Drawing l
Jacket Water Discharge Manifold Visual, Verify As Built with Walkdown Camshaft Bearing Visual l
Exhaust Manifold Visual, Verify As Built with Walkdown i
Fuel Pump Linkage Visual
[
i Turbo. Bracket Visual Intercooler Visual, PT, MT Fuel Inj. Tubing ECT, Verify As Built with halkdown Jacket Water Stdpipe Fittings &
Verify As Built with Walkdown to Drawing Gasket Jacket Water Standpipe Supports Verify As Built with Walkdown to Drawing Jacket Water Standpipe Bolting Verify As Built with Walkdown to Drawing Jacket Water Manifold Assembly Verify As Built with Walkdown to Drawing t
Jacket Water Inlet Manifold Verify As Built with Walkdown to Drawing l
Jacket Water Manifold Coupling Verify As Built with Walkdown to Drawing Jacket Water Discharge Manifold Verify As Built with Walkdown to Drawing Turbo Cooling Water Piping Verify As Built with Walkdown to Drawing l
Turbo Cooling Water Supports Verify As Built with Walkdown to Drawing Start Air Manifold Tubing Verify As Built with Walkdown to Drawing Start Air Manifold Supports Verify As Built with Walkdown to Drawing Start Air Dist. Tubing & Fttags.
Verify As Built with Walkdown to Drawing Fuel Oil Piping and Tubing Verify As Built with Walkdown to Drawing l
Fuel Oil Piping Supports Verify As Built with Walkdown to Drawing Turbo Lube Oil Piping Verify As Built with Walkdown to Drawing 2
i
- -. ~ - -. -
l 4
o Turbo Lube Oil Supports Verify As Built with Walkdown to Drawing Pyrometor Conduit Verify As Built with Walkdown to Drawing Pyroueter Conduit Fittings Verify As Built with Walkdown to Drawing Pyrometer Conduit Supports Verify As Built with Walkdown to Drawing Engine and Aux. Mod. Wiring -
Verify As Built with Walkdown to Drawing Conduit Engine Shutdown Tubing & Fttngs.
Verify As Built with Walkdown to Drawing Turbo Thrust Bearing Tubing &
Verify Aa Built with Walkdown to Drawing Fittings Notes:
PT = Liquid Penetrant Test NT = Magnetic Particle Test ECT = Eddy-Current Test RT = I-ray Test UT = Ultrasonic Test Visual = Visual inspection of part to prescribed acceptance standards.
Dimen., Dimensions = Dimensional inspection of part.
Material = Material tests to determine parts material composition.
Hardness = Hardness tests to determine parts hardness or tensile strength.
I i
l 1
i 3
l l
l
i d
{
ATTACHMENT 5 i
RESPONSE TO PAIJfETTO ALLIANCE /
CESG INTERROGATORY 35 I
I Catawba IB Diesel Inspection Plan f
Part Name Comments j
i Lube 011 Internal Headers Yerify As Built With Walkdown to Drawing Lube Oil Tubing and Fittings Verify As Built With Walkdown to Drawing l
Lube Oil Line Supports Verify As Built With Walkdown to Drawing l
Crankshaft and Turning Gear ECT, Visual
}
Cylinder Block PT, ECT, Dimensions l
Cylinder Liner Visual l
Cylinder Block Jacket Water-As Built System Walkdown per Drawings Manifold Cylinder Head Studs Visual l
Cyl. Block Jacket Wtr. Man. Nuts Visual i
Plywheel Bolting Verify Torques Meet TDI Requirements, Visual Front Gear Case Bolting Visual Connecting Rods and Bushings Visual.
PT, ECT, MT Connecting Rod Bearing Shells Visual, Dimensions, RT, ECT, PT
[
- Visual, i
Piston Rings Visual Piston Pin Assembly Visual Intake Tappets Visual I
Fuel Tappets Visual Camshaft Assembly Visual i
Camshaft Supports Bolting &
As Found Torques, Visual, Material, i
Gear Idler Gear Assembly (Crank to Visual Pump)
Idler Gear Assembly Visual Air Start Valve Visual, Dimensions I
Cylinder Head
- Visual, PT, UT, Intake and Exhaust Valves Visual Valve Springs Visual Subcover Assembly Visual. PT l
Intake Manifolds Visual Exhaust Manifold Bolting Visual
[
Cylinder Block Cover, Gekts. &
Visual i
Bolts Crankcase Covers Visual i
Rocker Arm Assembly Visual, PT
[
Exhaust Rocker Arm Assembly Visual,PT Pushrods Yerify Friction Welded Pushrods Installed, PT l
Connector Pushrod Verify Friction Welded Pushrods Installed, l
PT j
Rocker Arm Bolting Verify Torque, MT, Materials, Hardness Governor Drive Coupling Verify Condition of Coupling Material j
Overspeed Trip Couplings Visual Starting Air Distributor Assemb.
Dimensional, Hardness 1
L
I D Turbocharger Bracket Bolting Verify Torque, Visual i
Lube Oil Sump Tank Bolting Verify Bolted Connections are Tight.
Verify Tank Mounting Hardware Tightened.
l Hardware Turbocharger Visual Rocker Arm Bushings Visual 1
Crankshaft Thrust Bearing Measure Thruat Clesrance j
Fuel Injection Pump Hardness, UT External Lube Oil Lines Verify As Built with Walkdown to Drawing l
External Lube Oil Supports Verify As Built with Walkdown to Drawing Lube Oil Sump Tank Verify As Built with Walkdown to Drawing Jacket Water Discharge Manifold Viwual, Verify As Built with Walkdown Camshaft Bearing Visual Exhaust Manifold Visual, Verify As Built with Walkdown Fuel Pump Linkage Visual
~
Turbo. Bracket Visual l
Intercooler Visual, PT, MT Fuel Inj, Tubing ECT, Verify As Built with Walkdown Jacket Water Stdpipe Fittings &
Verify As Built with Walkdown to Drawing Gasket i
Jacket Water Standpipe Supports Verify As Built with Walkdown to Drawing 4
Jacket Water Standpipe Bolting Verify As Built with Walkdown to Drawing Jackgt Water Manifold Assembly Verify As Built with Walkdown to Drawing Jacket Water Inlet Manifold Verify As Built with Walkdown to Drawing Jacket Water Manifold Coupling Verify As Built with Walkdown to Drawing Jacket Water Discharge Manifold Verify As Built with Walkdown to Drawing Turbo Cooling Water Piping Verify As Built with Walkdown to Drawing Turbo Cooling Water Supports Verify As Built with Walkdown to Drawing Start Air Manifold Tubing Verify As Built with Walkdown to Dravig Start Air Manifold Supports Verify As Built with Walkdown to Drawing r
Start Air Dist. Tubing & Fttags.
Verify As Built with Walkdown to Drawir.g
~
Fuel Oil Piping and Tubing Verify As Built with Walkdown to Drawing Fuel Oil Piping Supports Yerify As Built with Walkdown to Drawing Turbo Lube Oil Piping Verify As Built with Walkdown to Prawing 1
Turbo Lube Oil Supports Verify As Built with Walkdown to Drawing Pyrometor Conduit Verify As Built with Walkdown to Drawing Pyrometer Conduit Fittings Verify As Built with Walkdown to Drawing Pyrometer Conduit Supports Verify As Built with Walkdown to Drawing
[
Engine and Aux. Mod. Wiring -
Verify As Built with Walkdown to Drawing Conduit Engine Shutdown Tubing & Ftap.
Verify As Built with Walkdown to Drawing Turbo Thrust Bearing Tubing &
Verify As Built with Walkdown to Drawing l
Fittings j
i Notes:
l PT = Liquid Penetrant Test NT = Magnetic Particle Test ECT = Eddy-Current Test RT = I-ray Test UT = Ultrasonic Test l
Visual = Visual inspection of part to prescribed acceptaa.ce standards.
i Dimen.. Dimensions = Dimensional inspection of part.
[
Material = Material tests to determine parts material composition.
l-Hardness = Hardness tests to determine parts hardness or tensile strength.
j i
l 2
l
...