ML20093F352
| ML20093F352 | |
| Person / Time | |
|---|---|
| Site: | Shoreham File:Long Island Lighting Company icon.png |
| Issue date: | 07/16/1984 |
| From: | Iannuzzi T, Lewis K LONG ISLAND LIGHTING CO. |
| To: | |
| Shared Package | |
| ML20093F343 | List: |
| References | |
| OL-4, NUDOCS 8407190006 | |
| Download: ML20093F352 (52) | |
Text
, LILCO, July 16, 1984 A.
)-
UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION Before'the Atomic Safety and Licensing Board In the Matter of )
)
LONG ISLAND LIGHTING COMPANY ) Docket No. 50-322-OL-4
) (Low Power)
.(Shoreham Nuclear Power Station, )
Unit 1) ) ,
TESTIMONY OF THOMAS W. IANNUZZI AND KENNETH A. LEWIS
-ON BEHALF OF LONG ISLAND LIGHTING COMPANY Q.1. -Please state your names and business address.
() 'A. (Iannuzzi) My name is Thomas W. Iannuzzi. My business address is Morrison-Knudsen Company, 101 Gelo Road,
' Rocky Mount, North Carolina 27801.
(Lewis) My name is Kenneth A. Lewis. My business address is Morrison-Knudsen Company, 101 Gelo Road, Rocky Mount, North Carolina 27801.
g Q.2. Mr. Iannuzzi, what is your current position with Morrison-Knudsen?
A. (Iannuzzi) Manager of Engineering of Power Systems Di-
. vision (PSD) of Morrison-Knudsen Company, Inc. (M-K).
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Q.3. Mr.'Iannuzzi, does the resume designated as Attachment 1 to this~ testimony accurately reflect your education
-and professional experience?
A. (Iannuzzi) Yes it does in summary form.
Q.4. For purposes of convenience, please summarize your responsibilities in your current position as Manager of Engineering.
A. (Iannuzzi) I am responsible for direct supervision of project engineers, designers and document control per-sonnel required to design and build diesel and turbine
.i ,.h generator systems for utility, military and emergency
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applications. These include diesel generator systems used in nuclear plants. I also supervise PSD's engi-
.neering staff'in the review of test reports, equipment specifications, and vendor quotations and in the provi-sion of. production assistance to PSD's. shop. I write and certify design. specifications for ASME Code compo-nents and review and approve design reports for nuclear projects. . Additionally, I review nuclear owners' de-sign specifications and implement codes and standards related'to safety related equipment for nuclear power.
generating stations.
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Power-Systems, over the.past 12 years, has designed and f- fabricated 137 diesel generator sets for customers in commercial applications,-and 65 diesel generator sets for 21 utilities at 26 nuclear plants. In addition to
. lthese units we have provided parts, service, modifica-tion packages and consulting for 51 engines.at 18 nu-clear sites for which Power Systems had not provided the original units.
QS. Please summarize _your prior professional and education-al' experience.
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- A. (Iannuzzi) 'As stated in greater detail in my resume, I t
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( received a Bachelor of Science in Mechanical Engineer-ing from Pennsylvania State University in 1968 and a Master of Science in Industrial Administration from-L
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Union College in 1973. From 1968 to 1973, I worked for the Machinery Apparatus Operation of General Electric
! Company as engineer for a procurement organization re-
'sponsible.for~ design, manufacture and refueling of nu-clear pressure. vessels for Navy _ applications. From g -1973 to 1978, I was lead engineer for the Power. Systems L
Group of' Combustion Engineering,-Inc. and was responsi-ble for the specification and procurement of primary
, nuclear steam supply system components. In this capac-L. _ity, among other. things, I acted as liaison with O.
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~ (V customers and various in-house groups, provided techni-cal' expertise, prepared sections of safety analysis re-ports.and maintained familiarity with shop operations and status of components. From 1978-1982, I was Super-visor / Systems Engineering at Colt Industries, Fairbanks-Morse Engine Division. In that capacity, I supervised a group of eight engineers responsible for the engineering of diesel engines and diesel generator units for application in a variety of government, nu-clear and commercial installations. In 1982, I became manager of engineering for PSD'as described earlier.
,,- Q.6. Are you a member of any industry committees involved in L' nuclear work?
A. (Iannuzzi) I am a member of a committee working on 4
draft standard ANS 59.53, " Starting Air Systems for Standby Diesel Generators."
Q.7. Mr. Lewis, what is your current position with Morrison-Knudsen? -
A. (Lewis) Technical Services Manager of PSD.
Q.8. Does-the resume designated as Attachment 2 to this tes-timony accurately reflect your education and profes-sional experience?
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!j A. (Lewis)' It does, though without much detail.
Q.9. For purposes of convenience, what are your responsibilities as Technical Services Manager?
A. (Lewis) .As Technical Services Manager, I direct and administer PSD's field service activities. I act as liaison with. customers and interface ith responsible division departments in the resolution of any technical problems concerning PSD supplied equipment or equipment maintained by PSD under contract.
Q.10. Please summarize your prior professional and education-
- ~. al experience.
A. (Lewis)' I received an A.S. Degree in refrigeration from Wilson Technical College in Wilson, North Carolina. Following other jobs involving servicing of electrical and mechanical equipment, in 1972 I joined PSD, which was then a division of. Bruce GM Diesel, as an Electrician A. My duties involved the building and wiring of control panels, wiring engine electrical sys-tems and motor controls and general electrical work.
From 1974-1981, I was a Senior Test Technician at PSD and was responsible for performing complete testing of PSD-supplied diesel and turbine generator sets. Also, my duties included troubleshooting electrical and v s
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- - mechanical systemsf for gas turbine. and diesel powered generator sets. In 1981, I became Technical Services Manager.
Since~I have been Technical Services Manager, PSD has engaged in a great deal of service work at nuclear plants, all of which is'within my responsibility. A
. partial listing of such service work for the years 1982
- 1983 is-Attachment 3 to this testimony. As is shown there, in those two years, PSD did work on diesel gen-erators at'no less than eighteen nuclear plants, such as Nine(Mile' Point, St. Lucie Units I and II, Watt's y Bar, Surry, Robinson, Beaver Valley, LaSalle, Grand
, :, l c . Gulf,. Turkey Point and others. Attachment 4 lists ad-
- i. -ditional nuclear plants at which PSD has had experi-ence. Attachment 5 lists additional non-nuclear in-stallations at which PSD has had experience.
Q.11. Gentlemen, what is the purpose of your testimony?
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A. .
-(Iannuzzi and Lewis) Based on our experience with and f knowledge of EMD and other diesel generators in both y
nuclear and.non-nuclear applications, and the EMD die-sel generators:at Shoreham in particular, we will talk l- about the reliability of EMD diesel generators, and specifically - those at Shoreham.
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Q.12. ' Please describe-your familiarity with the use of diesel
. generators at nuclear power plants.
.e A. (Iannuzzi). I have been involved in the application of diesel generators at nuclear power plants since 1978.
-While at Fairbanks-Morse I was the project engineer for
. diesel generator sets being fabricated for the Marble Hill, and Hope' Creek plants, and as such was involved in.all aspects of the design and fabrication of those
- units. Also as previously stated,- I supervised engi-
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' neers working on units for Limerick, Seabrook,
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Washington Public Power Supply System (WPPSS), Callaway
. and Wolf Creek. Since coming to PSD I have been per-h*s sonally involved with diesel generator sets at Sequoya,
- Watt's Bar, Brown's Ferry, St. Lucie 1 & 2, Zorita and Cofrentes-(Spain), and-have worked on modifications to units at WPPSS and Davis-Besse. In that involvement, I have become familiar with the application of the vari-ous codes and standards used'in these installations at nuclear power plants, and'with the starting, test 1ng and operational needs in these' applications. I am fa-1 miliar with the safety-related aspects of emergency
. power.in carrying emergency loads to bring the plant to a-safe shutdown condition.
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-(Lewis) My experience is detailed in part in Attach-ments 3 and 4. I am responsible for overseeing all of the service work performed by PSD on the diesels at the listed nuclear plants. These lists are not complete, since PSD is continuing to engage in a great deal of nuclear diesel generator work, much of which involves retrofitting of older diesel generators.
Q.13. .Please describe your familiarity with EMD diesel gener-ators in the industry and, in particular, their appli-cation at nuclear plants.
A. (Iannuzzi) EMD diesel engines have been widely used in
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industry. They are used, for example, in locomotives ,
ships and drill rigs; however, PSD/M-K has not been in-volved with those applications. PSD's experience with EMD diesels includes tneir use in hospitals, military bases, utilities and nuclear plants. These include both skid mounted and housed units, such as those at
.Shoreham. I personally have been involved, at a mini-mum, with EMD diesels at the following nuclear plants:
Sequoya, Watt's Bar, Brown's Ferry, St. Lucie 1 & 2, 1
Zorita and Cofrentes (Spain). I have also been in- !
l volved with modifications to EMD diesels at WPPSS, '
i Davis-Besse and the Naval nuclear facilities at q Windsor, Connecticut, and West Milton, New York.
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. Additionally,.I have been. involved.with commercial units for the Norfolk, Virginia,_ Naval Station; King's
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Bay, Georgia, Naval Base; and Kotzebue,' Alaska.
' (Lewis) 'PSD has historically specialized in the nucle--
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ar application of:EMD diesels. Today, it is one of
[ eight. jobbing contractors for EMD, which is a division of General Motors, though PSD sells and services other-
. - brands of power-systems. PSD services many of the die-sel generator sets it sells and many that it did not sell. This service, done under my supervision, runs from complete inspections, installations and overhauls
_.- .to emergency repairs. PSD has recently been involved
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in the retrofitting and modification of diesel genera-
-tors in nuclear service to enhance their' reliability
[ and to upgrade-them. We have performed this service or are in the process'of contracting _for this service in l'
Lj -approximately 37 nuclear-plants. Finally, I have been
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E responsible for the installation and preoperational testing of 64 diesel generators at the PSD shop, and 30 units at nuclear plant sites including TVA, Florida
- Power & Light, Duquesne Light,.Zorita, Cofrentes
. (Spain),1MP&L,. Duke Power, Toledo Edison, Korea and the Phillippines.
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Q.14. AreLyou familiar with the EMD diesel generators at Shoreham?
A. (Iannuzzi and Lewis) Yes.
Q.15. How did you acquire that familiarity?
- A. (Iannuzzi) I have reviewed the manuals and maintenance records concerning those units, spoken with PSD service personnel responsible for their installation and main-tenance, and actually visited the site and looked at the units in detail.
(Lewis) I became familiar with the units now at b,~ ' Shoreham when I became Technical Services Manager for PSD in 1981 when they were still owned by New England Power-Company- (NEPCO). I had a crew of five men act-ing as a service organization in the New England area.
This crew serviced these machines at NEPCO. I visited the NEPCO site at least twice a year with them. I kept up a service: record and made sure that work was per-formed in accordance with the contract. I'was also in-
- volved in the engineering to connect these EMDs at Shoreham and-supervised their installation. Through field service representatives, I coordinated all
- changes during installation. In addition, I have vis-ited the Shoreham plant and have viewed the EMD diesels A/ -~
- in place.
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.~j Q.16. Based on your experience with diesel generators, what are the criteria by which their reliabity can be
' judged?
A.: (Iannuzzi'and Lewis) The EMD diesel generators do not strictly comply with all technical requirements for qualified nuclear grade diesels. Nevertheless, there are a number of factors to which one would normally look to esaluate the reliability of diesel generators-and an-assessment of these factors for the EMDs at
.Shoreham allows us to assess their reliability with some degree of confidence. These factors include the
- g3 following
V (a) whether the design has been proven through operating history; ,
(b) evidence of proper manufacturing pro-cesses; (c) whether the application of the unit is consistent with its design and intended purpose; (d) the-inspection and maintenance history of the specific unit; (e) the operating history of the specific unit; and (f) whether the manufacturer's recommenda-tions of replacement schedules have been followed.
Q.17. Are.you familiar with the operating history of EMD
() engines?
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A. (Iannuzzi) These units are EMD 645E4 engines. EMD 645E4 engines have been in service in applications on locomotives, shipboard and land based sites for many years. They are widely used and well accepted in the industry. In fact, this engine is in use in many nu-clear plants.
(Lewis) The engines and generators on the four EMDs at Shoreham are the same as those in nuclear service at
.several nuclear plants which PSD services. They in-clude Nine Mile Point I, Connecticut Yankee, Beaver Valley, Turkey Point, Surry, and others. Industry ex-
-~ perience with this design has been positive and indi-t cates their general reliability.
Q.18. Are you familiar with manufacturing processes for EMD engines?-
A. (Iannuzzi) I have visited the EMD manufacturing facil-ity at LaGrange, Illinois, and have seen the process by which.these engines are made. EMD engines are produced from standardized parts so that all engines are essen-tially identical. Parts are.not required to be indi-vidually hand fitted. The PSD Quality Assurance De-partment has performed audits of the EMD facility as far back as 1974 and qualified EMD as a supplier of
(') equipment to our nuclear program. In my experience we
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have seen no problem with parts provided by the manu-facturer that did not perform properly. Therefore, there is assurance.not only that the engines were manu-factured properly based on their history of reliability, but that replacement parts are and will be of high quality to maintain the past level of high reliability.
Q.19.- Is the' application of the EMD diesel generators at Shoreham consistent with the design and intended pur-pose of,the units?
A. (Iannuzzizand Lewis) Yes. These units were designed
(,) - for emergency duty and for use as peaking units. Orig-inally, these were peaking units with minimum dead load pickup capability. When LILCO purchased them, LILCO installed, through PSD, the maximum dead load pickup capability so that the units can function most effec-
-tively in. emergency situations. Again, as stated ear-lier, the same generator and engine is, in fact, in use at a number of nuclear plants as an emergency AC power source.
Q.20. 'Are you familiar with the inspection and maintenance history of the EMD diesels at Shoreham?
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.I f A. (Iannuzzi) Yes. I have reviewed the maintenance records from 1978 through 1983, and reports of work
_ performed back to 1974. PSD has had the service con-tract for these units since 1978.
(Lewis) Yes. I have been responsible for inspection and maintenance of these units since 1981 and have re-viewed the PSD and NEPCO maintenanco records before
~
that. From that review, it appears that the machines have been inspected and maintained in accordance with the manufacturer's recommendations.
Q.21. Describe the. maintenance history of the EMDs now at
.Shoreham.
A. (Iannuzzi and Lewis) Since 1978, these units have been maintained in accordance with the PSD maintenance ser-vice contract which meets or exceeds the mainte."ance schedule published by EMD. The maintenance program consisted of monthly service trips to perform the main-tenance program according to a set: service schedule.
The. maintenance contract by which this service schedule was established is Attachment 6 to this testimony. All I recommended maintenance has been performed and any con-ditions, which were discovered during these visits and which required additional service, were taken care of.- There is but one-exception. In 1981, EMD recommended
I 'uJ that the viscous dampers on this model be enanged to a different design which provides a longer service life. 13un viscous damper is a device which absorbs torsional vibration in. crankshafts. The viscous damper has not been changed on three of the four units at Shoreham. If necessary,'this change could be accomplished in two to three. weeks. Even a failure of the viscous damper would not lead to an immediate catastrophic failure of the unit. - In our opinion, the unit could run approxi-mately 150 hours after such a failure before the unit would develop' problems causing it to shut down. This is greater than the number of hours one would expect (n,j annually on such an emergency diesel generator at a nu-clear plant at full power. Importantly, based on PSD's inspection of these units at Shoreham, there is no evi-dence of any problem with the viscous dampers on the three units still having the original design. Additionally, the service records for the Shoreham EMD diesels show a number of instances of cracked cylinder heads. It has been our experience that early design heads produced by EMD were prone to cracking. These heads were commonly designated by EMD as " Circle 1 and 2" style heads. Later improved designs, designated as
" Circle 3," " Diamond 3," or " Diamond 4," have corrected this problem. All heads on the four EMD units at
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w-r m k_,sI Shoreham are of the new design, that is, Circle 3, Dia-mond 3, or Diamond 4. From the maintenance records of the EMDs at Shorehaa, it is evident that there have been no instances of cracking with the new heads. Unit 1 (NEPCO's Unit 5) received all new power packs, consisting primarily of'a cylinder liner, piston, con-necting rod, and head, at 12,932 hours; Unit 3 (NEPCO's Unit 7) at 13,153 hours. Inspection of the other two units shows the power packs to be recommended for con-tinued use and they have approximately 1,000 hours of use remaining before an overhaul is recommended by the 3-4) manufacturer. (
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Units 3 and 4 (NEPCO's Units 7 and 8) had new
-turbo-chargers installed at 13,153 hours for Unit 3 and 10,962 and 11,696 hours for Unit 4. Presently we know
, of.no reason the turbo-chargers on all four units should not continue to function properly. Q.22. What does their maintenance history tell you about the l- reliability of the four.EMD diesel generators at Shoreham?
-A. (Iannuzzi and Lewis) The maintenance records show that these units have'been properly maintained, and we
,_s therefore believe, based on our experience with EMD f }
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< ; t n' engines,-that'they-should continue.to operate reliably
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- for..the. foreseeable future.. This presumes that regular and proper maintenance continues.
a ' 4 LQ.23.' What should that maintenance consist of? A.- -(Iannuzzi and4 Lewis)- A' continuation of-the schedule s
-referenced earlier:and-in Attachment 6.
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Q.24. Are1you familiar with the industry experience concern-
-ing. starting. reliability of EMD diesels?
A. (Iannuzzi). Yes. In'the years 1968 through 1970, "fastu s tart" tests were' performed by EMD on'17 diesels e .-- () of.the 645E4-type'. A total of 1,720 successful-starts in-. ten' seconds'or less were completed, and three fail-ures were recorded for a total'of 1,723 attempts or
, 99.9% success. ,
In the years.1971 through 1973, a total of 632 " fast-starts" were performed on five model 20-645E4 (20 cyl-
~
inder) EMD engines by Bruce GM Diesel (the predecessor 1
' Lof Power Systems Division of Morrison-Knudsen). All sp - . starts were " successful" starts in ten seconds or less.
; The engines subjected to the above tests were the same ,
l type of engine (645E4) as those at Shoreham, with the exception that the starting motors on the tested units 1 3m
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7 k.) consisted of redundant air start motors rather than the single electric motor used on the Shoreham units. Ad-ditionally, the engines were fitted with a backup elec-tric fuel pump which would be used in the event of failure of the engine driven pump.
'Q.25. Are you familiar with starting reliability of electric start units of the type used on the Shoreham engines?
-A.. (Iannuzzi) In 1967, EMD reported a success rate of
~
29,136 starts in 29,362 attempts on electric start units, or 99.23%. 7_ (Lewis) PSD experience also shows that electric start t'^)' units are reliable. There are many such electric start units in commercial use and a few in nuclear use. PSD services many such units and has experienced very few problems with their starting reliability. ' Also, the log books for the four EMD diesels at Shoreham show that throughout their lifetime, there have been no failures to start. This is a reliability of 100% which is comparable to and better than the starting reliability found by EMD in its own tests dis-cussed previously. Q.26. What does this indicate about the starting reliability (~^i of these units? U
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A. (Iannuzzi and Lewis) It is evident that EMD 645E4 die-
'sel engines are extremely reliable in starting, regard-
-less'of the type of starting motors used.
Q.27. Are you familiar with the operating history of the four EMDs now at Shoreham?' A. > (Iannuzzi and Lewis) Yes. We have described above our familiarity with the engines and review of their opera-tional as well as maintenance records. Q.28. Describe their operating history and state what, if anything, can be deduced about their reliability from-
,, their operating history.
(-[ A. (Lewis) These units have been operated for periods of time between 12,833 and 13,277 hours. For the most part, they have been used as peaking units by NEPCO and were run at 2750 KW which is 110% of rated load. Dur-ing this time, they operated very. reliably. There were few problems and no-shutdowns for major repairs becausa of an operating condition. In contrast, at Shoreham they would only be subject to 100% rated load on an in-frequent basis which is a less severe load than the en-i gines have already proven themselves capable of carry-ing. (O
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Q.29. In assessing a diesel generator's reliabilty, do you , distinguish between its past unavailability because of l scheduled maintenance and its past unavailability be-cause of unscheduled outages and, if so, why? A. (Iannuzzi) Scheduled maintenance for a diesel genera-tor normally implies work which is to be done for the purpose of maintaining the longevity of or improving the unit. Such work is normally planned for a time , when the unit is not required to be available for ser-vice.and can be rescheduled if the unit becomes needed. For this reason, it is my opinion that in assessing
- , reliability, only unavailability due to unscheduled
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outages should be considered. That would be particu-larly appropriate here since low power testing presuma-bly could be suspended if the diesel generators were out of service for scheduled maintenance. Q.30. What is the historical availability of these units eliminating unavailability due to scheduled maintenance outages? A. (Iannuzzi and Lewis) We are aware of no instance in which the units shutdown for repairs during operation as peaking units at NEPCO. Therefore, the historic availability of these units has been very high. ,
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Q.31. - Whait abo'ut compliance wf h the manufacturer's suggested '
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,( Lewis) Except for the viscous dampers mentioned
- ,' ear 1 tier, all replacements have been made. It is fur-
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ther, assuring.td observe that NEPCO always replaced w parts with new. parts whan available. It only used UTEX parts, which are perts rebuilt by EMD, when new ones
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were not,avai1able. In my experience, the UTEX parts areperf'ectlybaliable.
.Q.32. Can you' compare the features of the EMD diesel genera-tors at Shor.eham with EMD diesel generators which have o
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.been qualified for use at nuclear power plants?
A./J (Iannuzzi and Lewis) The EMD model 645E4 diesel engine is a.ntandardized design which has been in continuous production since 1965. There have been 843 units pro-vided forDservice worldwide in the configuration simi-lar to the units at Shoreham and a total of 16,230 turbocharged 645E4-engines produced. M-K Power Systems a . Division has provided 65 generator sets, and 110 en-
, gines'for service in nuclear power plants; additional h :. units have been provided_to nuclear plants by GM-EMD s .
and other packagers. The 645E4 engines are the same regardless of the application. Similarly, the genera-f~l V tors on the units'at Shoreham are identical to those in U service.at some nuclear plants, t
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The difference between the Shoreham units and diesel generators which have been qualified for use at nuclear power plants is in the auxiliary equipment which sup-ports the operation of the engine. That equipment in-cludes such items as piping, valves, pumps, heat ex-changers, tanks, supports, and electrical equipment. The equipment qualified for use at a nuclear power plant is usually designed and manufactured to specific codes and standards, with consideration given for envi-ronmental and seismic qualification and quality assur-ance documentation. These requirements for the auxil-iary equipment are different from the standard A
!,_) commercial items otherwise used. Despite these differ-ent component items,,the systems and the design parameters-for them remain the same.
For example, the design requirements in ASME Section 3
---a major' design criterion -- are intended to ensure the integrity of the pressure boundary of the compo-nents and systems during operation under design condi-tions. Units of the Shoreham design, though not de-signed to ASME Section 3, have nevertheless withstood many thousands of hours of operation and we are aware of no catastrophic failures of the pressure boundary related to auxiliary equipment. By this, we mean that
({) there have been no failures causing the units to shut T;'
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- a a: ,y .c - . incurred'byDone of PSD's many customers or because it
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1-it;our' business'to keep abreast of such problems- - findustry-wide in order *to better perform our jobs. m , .
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\i :Similarly,~the'[iiesels.at-ShorehamdonothaveClass
- , I-Eiwiring and electriedl equipment which means that
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% th'nequiphent hasqnot been environmentally qualified r .' for.thess specific unl~ts. -Nevertheless, this same y' ' - <,
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- gradeN ffequipment is in-use in many of the EMDs with
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4 i -twhi,ch we- are familiar and .has suffered no major fail-w.. 4
'ures.of which we are aware. The equipment in the spe-f s(f*.{
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'cific units at'Shoreham is the original equipment and W ~ i. 1
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likewise has suffered no major failures. Similarly, es - [ l' ' "
.~;4 the. electrical ~ equipment in LILCO's EMD diesels at w.)?O P Montuuk is t'he.same and has functioned with no major
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g y .fai, lures in an;. r environinent simi-lar to Shoreham with re-
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-spect to temperature, humidity,. air quality and the
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. w N sone important, factor to note in comparing these diesels
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N No(those In nuclear. service is that these diesels do s eg X: not'have tol" fast start." Unlike qualified nuclear diesels necessary for full power operation which must ro'acht their rated speed in 'a matter of seconds, the fo -
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EMDs at Shoreham can idle for several minutes and still have power supplied in timely fashion. This reduces excessive wear on the engine and reduces stress on the auxiliary package. Additionally, the duration over which these EMDs will be used at Shoreham for emergency
.AC power is limited especially when compared to the 40
-year expected life of qualified diesels.
Q.33. Please address the fire protection available to the EMDs at Shoreham and how that might affect their 2 reliability. A. (Iannuzzi'and Lewis) Fire protection available at the
. X)~
i, EMD units at Shoreham consists of hand held-fire extin-guishers. Our experience with stationary diesel units of this type is that fires are very rare occurrences. In fact our servicemen have been called in to service only one stationary unit which had been involved in a
~
. fire. That fire'was caused by a component in the -
starting system overheating as a result of repetitive start attempts. The consequences of the fire were con-fined to limited electrical damage. We have not re-I ceived any other reports of stationary EMD units which l have been involved-in fires of any kind. p. t). e -
.h~T
-\_) ' '
'Q.34. Do you have any overall opinion as to the reliability of the four EMD diesel generators at Shoreham and as to whether one of the four can be expected to start and
_ operate when needed in an emergency situation?- A. (Iannuzzi and Lewis) Given the previous starting his-tory of'these units, their overall condition, their maintenance records and our experience with EMD en-gines, it is our opinion that the reliability of these four units will continue to be good for the foreseeable future. We would expect the likelihood that all four units will start and operate in an emergency situation is very high, and-that therefore the likelihood that
.O.
' ~'
-one of the four will start and operate'is virtually as-sured.
I. t L H l~ \ ()- u .i . l
POWER SYSTEMS ~ !
" " " " " " " " " * " Attachment 1 ,
1 POWER SYSTEMS DIVISION / MANAGER OF ENGINEERING MORRISON-KNUDSEN COMPANY, INC. JOB TITLE: MANAGER OF ENGINEERIN'G
= -NAME: .inomas W. Iannuzzi, P.E.
EDUCATION: -Pe'nnsylvania State University, 1968
'Bachalor of Science, Mechanical Engineering Union College, 1973 Master of Science, Industrial Administration j l
BUSINESS EXPERIENCE: 1982 - Present POWER SYSTEMS DIVISION OF MORRISON-KNUDSEN COMPANY, INC. Manager of Engineering - Responsible for direct supervision of project engineers designers and document control personnel required to design complete diesel and
.- l turbine generator systems for utility, military and emergency applications.
- iO l Participation in meetings with customers / vendors as a technical advisor. Super-vision of: engineering staff in review of test reports, equipment specifications, review of vendor and Power Systems' quotations and production assistance. Writes
~
and certifies Design Specifications for ASME Code components and reviews and approves design reports for Nuclea'r Projects. Reviews Nuclear Owner's Design
' Specifications, and implements Codes and Standards related to safety class
- equipment for Nuclear power generating stations.
- 1978 - 1982 COLT INDUSTRIES FAIRBANKS MORSE ENGINE DIVISION BELOIT, WISCONSIN Supervisor / Systems Engineering - Supervisor of a' group of eight engineers '
responsible for the engineering of diesel engines and diesel generator units for application in a variety of Government, nuclear and commercial installations. Responsible for projects involving the application of diesel generators for
, . standby power in nuclear power plants. Units were designed and built to ASME Section III Class 3, and this position required detailed knowledge and application of Code requirements. in all phases. Included working within the guidelines of the Nudlear Quality Assurance program in effect in the depart-ment and reviewing available nuclearLindustry reports for overall applica-
-bility to the equipment.
7 . ( +- g:
* " - ** * .. ,,,,....v.,-
' APOWER SYSTEMS geossidaue60LeeWEJhLfe 4Avebew88 l
Thomas W. I'annuzzi, P.E.
' BUSINESS EXPERIENCE: (Continued)
Earlier' position was as a Project Engineer, responsible for projects involving the application of diesel generators fcr standby power in nuclear power plants, J including all phases of the project, from specification review through design,
. drawing preparation, manufacturing, test and shipment. This included close coordination with the customer and many individuals within the company to assure F <
~ timely completion of the project.
' ~
1973.- 1978- COMBUSTION ENGINEERING, INC. POWER SYSTEMS GROUP WINDSOR, CONNECTICUT flead Engineer - Responsible _for the specification and procurement of major nuclear steam supply system components built to ASME Code Section III require-ments.. This involved translating contract requirements into technical speci-fications and providing technical follow of the order, inclu' ding liaison with the~ customer and various in-house groups. Specific duties as a Lead Engineer included: providing technical expertise and performing detailed review of all safety related work performed by three engineers in the procurement of the components; preparing sections of the Safety Analysis Reports which are used in obtaining the Operating License for the power plant; obtaining and evaluating
. quotations for equipment, and preparing cost estimates for changes to existing
< . n, contracts; and maintaining familiarity with shop operations and status of , . components. 1968-- 1973 ' GENERAL ELECTRIC COMPANY
. MACHINERY ~ APPARATUS OPERATION SCHENECTADY, NEW YORK Cognizant Engineer _ - Engineer for a procurement organization responsible for design, manufacture and refueling of nuclear pressure vessels for Navy applica-tions. Specific duties included: writing specifications for new procurements; reviewing vendor drawings, procedures and schedules for conformance to contract and military. specifications; rendering technical assistance in vendor production problems; evaluating manufacturing discrepancies and proposed changes to
. design for operational suitability; making and substantiating technical recommen-dations for design improvements to the government; resolving problems arising
. during installation, and coordinating activity and planning concerning pressure vessels during refueling; and establishing a computer system for maintaining control of shipping and storage equipment.
-PROFESSIONAL REGISTRATION:
Professional Engineer, State of Connecticut LO . 4 e - - - - .-,e..-enm. -m,.n- .. - - . r.,-. ---
l n gg S Attachment 2 POWER SYSTEMS DIVISION / TECHNICAL SERVICES MANAGER MORRISON-KNUDSEN CO., INC. TITLE:
- Technical Services Manager NAME: ..' Kenneth A. Lewis-EDilCATION: Wilson Technical College, Wilson, North Caroliaa A. S. - Electronics t BtlSINESS EXPERIENCE:
June 1981 - Power Systems Division /Morrison-Knudsen Company, Inc.
-Present Technical Services Manager
' Administers and directs Division field service 4
activities, acts as liaison with customers and interface with responsible Division department in the resolution of any technical problems concerning Power Systems , Division supplied equipment or equipment being maintained under contract. October 1974 - Power Systems Division /Morrison-Knudsen Company Inc. June 1981 Senior Test Technician Responsible for performing complete testing of Power Systems Division supplied diesel and turbine generator L sets. Additional' duties included troubleshooting electrical and mechanical systems on generator sets, design of mechanical-and electrical' systems for gas turbine and diesel powered generator sets. . March 1972 - Power Sytems Division / Bruce GM Diesel October 1974 Electrician A. Job duties required the building and wiring of control panels, wiring engine electrical systems and motor controls, general electrical work. l. February 1970 ~- Pullen Refrigeration w March-1972 Service Mechanic Responsible for job estimates, servicing all types of refrigeration equipment,. control wiring and general e electrical duties. i: September 1969 - Bedgood Heating and Air Conditioning February 1970 Installation Mechanic Duties were the installation and servicing of residential heating and air conditioning systems. L l '},
-, - , . - - , -------,,-,,.-,.,,n-- --,,,--,,,,e..,,,,.w.,,.,,,.---,n-n-,--n.-n,--,anm,,,-ern, ,,,e,,,.-,-w
.. powen sysTzus civisioN Attachment 3
%"s5M
.I L PARTIAL LISTING OF SERVICE WORK 1982/1903
'(A) NUCLEAR UURETTC CUSTWER LOCATION WORK PERFORMED
. 1.- Niagara Mohawk Corp. Oswego, N.Y. Supervised Annual Inspection
'9 Mile Point Upgrade EMD Engines
- 2. Florida P&L Co. Hutchinson Is., FL Furnishea Material and St. Lucie I&II Supervised Total EMD Retrofit Package. Held 5 day Training School.
- 3. Tennessee Valley Spring City, TN Inspect Retrofits and Authority Installation Watts Bar
( b ht
- 4. Sacramento Municipal Utility District Sacramento, CA Perfomed Annual Inspection and Minor Repairs i . Ranch Seco
- 5. Virginia Electric Power s h ,-VA '
Emergency Repair Speed Sensing Co. Surry and Control Panel
- 6. Carolina Power & Light Hartsville, SC Supervised Annual Inspection Robinson l 7. Portland G.E. Co. Ranier, Oregon Supervised Installation of Tro,jan Retrofit Equipment
( 8. Duquesne Light Co. Pittsburgh, PA . (a) Supervise Annual Inspection Seaver Valley EMD 999 Units i (b) Start-up New PSD-M-K ! 2500 KW Unit
- 9. ' Newport News Ship- Newport News, VA Supervise Repair of Four (4)
(
- building Engines l Nuclear Aircraft
? Carrier
'10. Consonwealth Edison Co. Marseilles, Ill. Perfomed Turn-Key Modification La Salle On 6 Engines
g ET4AvM Page 2 of 3 PARTIAL LISTING-(A) NUCLEAR / DOMESTIC (contd.)
- 11. Jersey Central Power. Toms River, NJ Inspection and
& Light maintenance on EMD Oyster Creek MP45 Units
- 12. - Duke Power Co. Clemson, S.C. Training School and Oconee startup of PSD-MK Furnishe Gen Set
~
- 13. Ebasco-TVA Knoxville, TN Supervise removal and Phipps Bend -
loading for transfer to another N:. clear Plant
- 14. Mississippi Power & Light Port Gibson, Miss. Held three (3) consecutive Grand Gulf Training Schools
- 1f. - Northeast Utilities Hartford, Conn. Perfonned Annual Inspectic Connecticut Yankee -
on TW (2) EMD 999 Units
- 16. Florida Power & Light Miami, FL Perfonned Inspection &
Turkey Point Services
- 17. Wasington Public Power Washington Install Engine Modificatio i 18. Main Yankee Atomic Wiscasset, ME Supervise Installation of G(3 ; Power Co. Modification To EMD Engine (B) COPMERCIAL-
- l. AT&T (Fonnerly Western Electric) Work perfonned all parts of U.S.-Startup Retrofit-Emergency. Schools and Training held semi-annuall
.2. Panama Pipeline -
Start-up, maintenance and personnel training of 20 M PSD-M-K provides power pla
- 3. Abbott Labs Check-out and start-up Rocky Mount 00AD Unit.
- 4. Florida Power & Light Emergency Electrical Repai Flagler Street Station l' 5.- Detyens Shipyard Performed Engine Overhaul Mt. Pleasant, SC ~
on USS Mohawk [ j_ ., l t
POWER SYSTEMS OlVISION Page 3 of 3 g gagn _ v,") . PARTIAL LISTING-(B) COMMERCIAL (contd.)
- 6. -Military Sealift Connand Inspection of Main Propulsion Little Creek, VA Engine
- 7. Kotzebue Electric Startup on two Diesel Gen Sets Alaska
- 8. New England Telephone Co. Emergency Repair Essen Junction, Mass. and Modifications
- 9. West Indies Oil Emergency Repair St. Johns, Antiquia
- 10. Horne Bros. Assist in Sea Trials on LST
- 11. Camentios Nationales Install and Start up Dominican Republic Two 2500 KW Units
- 12. VA Hospital Perfonn Inspection Vennont and Repairs to standby Gen Set O
u 9 I l l t l
~'s
-(O L__ _
ru, van .... === uiviosum "J* epm"O Page 1 of I a -. Aj FOREIGN CUSTOMER LOCATION WORK PERFORMED gniona Spain Supervise start-up 2000 KW orita Electrica PSD/M-K Diesel Gen Set Almaraz Spain Supervise Modifications to Engine Gen Sets
. Cofrentes Spain Supervise Total Retrofit of Engine - Start-up and Comissi 9-ing Westinghouse Philippines Start-up two PSD/M-K Tandem Philippines Units Westinghouse Korea Start-up two PSD/M-K Tandem Korea Units Taiwan Utility Taiwan Supervise Start-up 4400 KW Taiwan Tandem Diesel Gen Sets
[ v, l l o b v l
Attachment 4
@ Powen Y=AM sysTas omsson April II, 1984 3 - SECTION 9100.00 Page One EXPERIENCE Nuclear Plants Sacramento Municipal Utility District Rancho Seco. Nuclear Generating Station 8echtel Corporation, Vernon, California, Engineers 2 - 2750 106 units Single Engine
! Power AuthoMty of the. State of New York James A. Fitzpatrick Nuclear Power Plant Stone & Webster Engineering Corporation ' Eng1neers 4 - 260010d units - Single Engine Forced Synchronized Tennessee Valley Autho M ty Sequoyah Nuclear Plant TVA - Engineer 4 - 4000 loi units - Tanden Engine Portland General Electric Company : Trojan Nuclear Plant 8echtel Corporation, San Francisco, California - Engineers l 2 - 4416 loi units - Tanden Engine ~ General Electric Company l Atomic Power Equipment Division 1 - 260010d - Standby for HPCS Pump - Single Engine Taiwan Power Company Chin-Shan Nuclear Power Ebasco Services, Inc. - Engineers 4 - 3650 loi units - Tandem Engine l l Toledo Edison Company
.' Davis 8essee Nuclear Plant Bechtel Corporatioin, Gaithersburg, Maryland, Engineers 2 - 2600 loi units - Single Engine Tennessee Valley Authority Browns Ferry Nuclear Plant:
TVA - Engineer i 4 - 260010f units - Single Engine GEAPED - Atoute Power Equipment Division Laguna Verde - Mexico 2 - 2200 KW - Standby for HPSC Pump - Single Engine I 4 _ , , . - . ~ , _.w- __,e--..s._y,y,.,, .,.y._ _ __, . , , , _ _ , , , , .. _ ,,m___ _ _ , , _ _ . .. _ _ _ _ _ _ _ _ _ ...,..,-w
l g POWERm SYSTWheS OlVISION SECTION 9100.00 Page Two O EXPSIDCE CONTINUED Nuclear Plants Continued GEAPED - Atomic Power Equipment Division , ! Grand Gulf Nuclear Plant L & II Mississippi Power and Light 2 - 3300 KW - Standby for HPSC - Tandem EmpresaMos Agrupados - Spain Central Nuclear de Almaraz Gibbs & Hill - Engineers
- 3. - 4406 KW, 50 Hz units - Tanden GEANG - General Electric Nuclear Energy Division Kuo Sheng Taiwan Power Authority 2 - 2400 XW Units - Standby for HPCS Pump - Single Engine Tennessee Valley Authority Watts Bar TVA Engineer .
4 '- 47$0 XW Units - Tandem I ElectMc Boat Division General Dynamics Corporation
-(~ West Nilton, New York Facility 2 -170010d Units - Single Engine . GDED - General Electric Nuclear Energy Division C0FRENTES - Spain 1 - 2400 KW, 50 Cycle Unit - Tandem Engine GDED - General Electric Nuclear Energy Division CNV l Val de Caballeros - Spain 2 - 2600 XW, 50 Cycle Unit - Tandem Engine HIORO ELECTRICA ESPAN0LA 2 - 4407 KW, 50 Hz. Tanden.
FLORIDA POWER & LIGHT ST. LUCIE II Nuclear Plant 2 - 3800 KW Tandem Units Westinghouse International KRSK0 Nuclear Plant Yugoslavia
.2 - 3920 KW, 50 Hz. Tandem l
m ,o. wev=eus "E SECTION 9100.00 Page Three EXPSIENCE CONTINUG Nuclear Plants Continued GDG Skagit Nuclear Plant 1 - 3300 XW Tanden Unit GDE TVA Hartsville & Phipps Bend 6 - 2500 XW Units Rental Unit - Housed Dresden Nuclear (1 Yr.) 1 - Housed 2500 XW GSG
' Black Fox Nuclear 1 ea.
2 - 2500 XW Units 1 ea. GSG Allens Creek Nuclear (1) 1 - 2500 XW Unit Westinghouse International PHPP - 1 Nuclear Power Plant
/ 2 - 4840 XW Tanden Units 1 m . Dasco Engineers CFE - Mexico Laguna Verde Nuclear 2 - 3676 XW Tanden Units Duke Power Oconee Nuclear 1 - 3500 XW Tanden Unit Westinghouse International Xori Nuclear - Xorea 2 - 4840 XW Tanden Units l Tennessee Valley Authority l
Sequoyah Nuclear Watts Sar Nuclear 2 - 4750 XW Tanden - -- Union Electrica, S.A. Zorita Nuclear Plant 1 - 2600 XW Unit . _ _ _ Pennsylvania Power & Light Susquehanna Nuclear 1 - 5000 XW Unit O -
powen sysTsus osvislCN a==== .ar= Attachment 5
' SECTION 9100.00 Page One ,
O
.ik ] NON-NUCLEAR ?NSTALLATIONS U.S. Health, Education and Weifare Dept.
Research Triangle, Raleigh, NC 1 - 1150 W Unit Western Electric Company Long Line Communication Center - Via satellita 323 Broadway, New York 4 - 2500 G Units Southern Bell Telephone Company Orlando, Florida L - 1200 G Unit Southern Bell Telephone Company Miami, Florida 1 - 1200 G Unit Orange Hospitai Orange, New Jersey 1 - 1575 G Unit Guan Power Authority 2 - 2500 W Units e V7 Meadowbrook Hospital i East Meadow, Long Island, NY . l 2 - 1575 W Units l U.S. Navy Guantanamo Bay, Cuba 2 - 2100 G Housed Units i Southern Bell Telephone Company Jacksonville, Florida 1 - 2500 W Unit i PANAMER ! Departamento del Distrito Federal (City of Mexico) Mexico 2 - 2100 W Units, 50 Hz. and 1 - 1750 W Units, 50 Hz. l Departamento del Distrito Federal (City of Mexico) Mexico . 2 - 1350 W Units, 50 Hz. U.S. Navy 12 - 2000 W Trailer Mounted Gas Turbine Units l l i O' i
...,__,_.,,__...m__---, , . _ _ _ _ _ _ . . _ __ _ _ _ . . _ _ _ _ _ . _ _ . _ _ _ _ _ _ _ , _ . _ _ _
, POWER SYSTBAS OfVISION SECTION Q100.00 Page two p-NON-NUCLEAR INSTALLATIONS CONTINUED -
Xansas City Power & Light La Cyp Power Station 1 - zz00 m Housed Unit Eureka Stone- Quarry, Inc. 1 - 2100 W Unit 1 - 2500 W Unit i Brooklyn V.A. Hospital New York 1 - 2000 W Housed Unit City of Petersburg, Alaska 1 - 2500 W Unit Spanish Air Ministry Madrid, Spain 8 - 3100 W, 50 Hz. - Housed Units - Forced Synchronized Instituto EcuatoMano de klectMficacion , Manta. Ecuador- ' 1 - 2500 W Unit National Electric Power AuthoMty O- y Lagos, NigeMa 3 - 2100 KW, 50 Hz., Housed Units l New York & Honduras RosaMo Mining Co. Hondurrs, Cantral Amedca 1 - 2500 XW Unit i Allis Chalmers Corporation , City of Winston Sales, NC i 1 - 2350 8.H.P. Pump Unit for Raw Water International Manufacturing and Equipment Comoany l Impergilio ! Salto Grande, Argentina ' 1 - 2100 m, 50 Ha. Unit Instituto Ecuatoriana de Electrification Esser:1 des, Ecudor 2 - 2500 XW Unit 1 i Flintkota Company , Calavaras Cement Calavaras, California 1 - 750 XW Unit O
Powen sysTams onnsson SECTION 9100.00 Page Three f3 - NON-NUCLEAN INSTALLATIONS CONTINUED Western ElectHc A. T. & T. Cambridge, Mass. 2 - 2500 XW Units INECEL - Ecuador 1 - 1575 XW Unit Mark Sharpa & Dohne 1 - 2500 XW Unit 3 Spanish Air Ministry Madrid, Spain 2 - 2100 XW, 50. Hz. , Housed Units - Forced Synchronized Electricity Board of Isaffordur Iceland 1 - 2100 XW, 50 Hz. Unit County of Fairfax Lower Potomac Pollution Control Plant Fairfax, Virginia 2 - 2500 XW Housed Units I Power Equipment Company, Inc.
"' City of Euclid, Ohio 7
L - 1575 XW Unit Rosario Resources Corporation Puerto Cortez, Honduras 1 - 2500 XW Unit Western ElectMc A.1. & T. Rego Park, New York 2 - 2500 XW Units
' City of Norton Xansas Housed 2500 XW Unit U.S. Naval Facilities Command 12 - 2500 XW Housed Portable Sets Potashnik Contractors Barge - Operating Arabian 5 - 2500 Skid Mounted Pecon Oept. of Water & Electricity A8U OHA8I p 7 - 2100 KW, 50 Hz. Housed Units
M'SY37EnfS OMSION 1 lllr4" M SECTION 9100.00 Page Four
. NON-NUCi. EAR ~ INSTALLATIONS CONTINUED Deputy Ministry of War -
For Annament tran 1 - 2500 XW Skid. Mounted Miles Laboratory Elkhart, Indiana 2 - 2500 KW Skid Mounted PEMEX 011 Oriti Gulf of Mexico 3 - 2500 KW Skid Mounted Sistama Electrica Regional Manabi City of Manta Ecuador 1 - 2500 XW Skid Mourited Jeddah Hospital Saudi Arabia 2 - 2500 KW Skid Mounted ! PEMEX "h, 011 Orill
~
Gulf of Mexico 3 - 2500 W Skid Mounted Williams Export Paper Plant - Ecuador 1 - 2500 XW Skid Mounted City of Malagro Ecuador 2 - 2500 G Housed Units Rosario Resources Puerto Corter, Honduras 1 - 2500 XW Skid Mounted Carolina Power & Light ._ . H.S. Robinson Nuclear Plant 1 - 2500 KW Housed Unit City of Iola Kansas 1 - 2500 KW - Housed - MP C"
Powen sysTeus onnsson
, illllllr."A"#L^
SECTION 9100.00 Page Five NON-NUCLEAR INSTALLATIONS CONTINUED l City of Russell i Kansas ! 1 - 2300 W - Housed - MP L General ElectMc International r Saudi Arabia l 1 - 1600 XW Skid Mounted l AmeH ean Samoa 1 - 2500 XW Skid, Mounted Amed can Samoa 1 - 2500 XM Skid Mounted l Hinkook Tire Company Pusan, Korea 2 - 2000 XW Skid Mounted Georgia Power Company l Wansley 1 - 2200 XW Housed O General Public utilities Three Mile Island (,1" 1 - 2500 XW Housed , General Public Utilities Three Mile Island l 1 - 2500 XW Housed Cementos Nationale Dominican Republic l 2 - Housed 2550 XW Units Xansas Fower & Light Co. Hutchinson Energy Center
. 1 - 2750 XW Peeking Housed Unit - MP N.Y. State ElectMc & Gas Corp.
l Somerset Station 1 - 2200 XW Skid Mounted 1 - 1600 XW Skid Mounted Duquesne Light Company Beaver Valley Nuclear Plant 1 - 2500 XW Skid Mountad
. Powan SYSTEMS OlV;SION
. SECTION 9100.00 Page Six
-- \
- NON-NUCLEAR INSTALLATIONS CONTINUEQ Balbina Project Brazil 1 - 2150 KW Housed Unit l St. John River Project Jacksonville Electric Co.
4 1 - Tanden - 1400 KW Housed Unit , 4 Jefferson Parish New Orleans, LA l 3-2305 BHP Pump Drives l Kotzebue, Alaska 1 645E4 Engine For Existing Gen.
'l - 1750 KW, 720 RPM Unit '
l U.S. Government - USN Kings Bay, GA 3-2500 KW Housed Units U.S. Government - USN O , Norfolk, VA 1 - 2000 KW, 11.5 KV Unit
'v(
U.S. Government - USN Norfolk Naval Shipyard 1 - 2500 KW Unit Martinr Marietta Alumina St. Croix - Virgin Islands 1 - 2600 KW Unit Perulack Compressor Station Texas Eastern - Dresser Clark DC - Turbine (Replaces Obsolete Turbine) Antrak New Haven Maintenance Dresser Clark 1 - DC-990 Gas Turbine Unit, 4580 KW o
POWER $YSTES OM3!On Attachment 6 Service Agreement No. 78914 l APPENDIX "B" N Power Systems Division will provide the folics-ing services: PART I i Periods of Inspections: (a) Monthly, Every 3 Months, Every 6 Months, Annually, After 3 Years, After 6 Years.
- i. *(b) After First 350 Hours of Operation, Every 350 Hours Thereafter, After 700 Hours, After 1400 Hours, After 2000 Hours, After 4000 Houis, After
, 8000 Hours, After 12,000 Hours, After 16,000 Hours, After 24,000 Hours, and After 72,000 Hours. Everv Month: A. VISUALLY INSPECT FOR 1EAKS
- 1. Cooling system at following locations:
- a. Radiators and headers
- b. Marmon flexible-couplings JO c. Thermostatic valves V d.
e. Immersion heaters, pump and piping Engine water pumps .
- f. Water expansion tank, gauge glass and piping
; 3 Water connections, valves and plugs on engine
- 2. Fuel System at following locations:
- a. Fuel tranafer pumps and piping b .' Filters
- c. Engine driven pumps and piping
- d. Day tank connections
- a. Fuel tranafer system and piping
- f. External fuel manifolds and connections
- 3. Lube oil System at the following locations:
I
- a. Filters and piping
- b. Circulating. pump and strainer
- c. A=m=*y lube oil cank and piping connections
- d. Connections to the lube oil cooler
- a. Main bearing pressure switch and gauge connections
- f. Piping, valves, and plugs under the deck i
l 0 L I l'?dG L
POWER SYSTEMS DMS;ON SERVICF. AGREDfENT NO. 78914 v A i L) -
- g. Turbine filters and oil lines
- h. Engine pressure and scavenging oil pumps, oil separator
- 1. Engine gaskets J. Governor, priming 4 Exhaust system at the following locations:
- a. Exhaust mantfold base flanges
- b. Exhaust manifold to turbocharger
- c. Turbocharger to outlet pipin]
- d. Exhaust manifold section connections B. ENGINE AIR INTAEE FILTERS:
- 1. Check oil level in oil bath type filters i
- 2. Check indicator of disposable paper elements C.. VISUALLY CHECK THE FOLLOWING FLUID LEVELS
- 1. Governor 011 (running)(use 30 veight oil)
, 2. Engine 011 (idling) t -
- 3. Engine Coolant D. MAEE THE FOLLOWING VISUAL AND AUDIO INSPECTION WITH THE
.I , INGINE OPERATING AT IDLE SPEED 1.. Listen.for unususi engine and turbine noises
- 2. Fan and fan drive systek for normal operation
- 3. Check stack damper for proper opening (HP-36 only)
- E. CEECK BATTERY CONDITION L 1. Check electrolyte level - Add water if required
- 2. Check electrolyte specific gravity.of pilot cell
- 3. Check es11 voltage
- 4. Inspect connections for corrosion i.
- 5. Observe charger operation by manually starting charger
- 6. Initiate 24-hour equalizing charge F. CEECK PERFORMANCE OF STAND 8T BEATING SYSTEM
- 1. Note readings of oil and water temperature gauges
- 2. Check stack damper for proper closure with the engine stopped (NF-36 only)
P G. VISUALLY INSPECT ELECTRICAL CABINETS
- 1. MP Unic generator and engine cabinets for discolored c connections and fis1d relay appearance
- 2. MP Unit starting and solenoid contactors ,
(, J.7*.N l
rr
.~
power SYSTEMS CMS;CN Service Agreement 78914 H. GENERAL UNIT INSPECTION:
- 1. MC Unit (Control House)
- a. Check all positions of unit and bus metering
- b. Check circuit breaker indicator lights for proper indication
- c. Observe synchronizer of performance during automatic start
- d. Note that breaker trips open between 300 and 600 IG when stopping unit
- 2. 'MP Units (Power Unit)
- a. Observe exhaust for proper condition
- b. Note governor rack stop setting (check meter in MC) *
- c. Note engine temperature and pressure gauges for proper indication;
- d. Note that no unusual noise or vibration exists
- a. Give unit complete operating sequence check by initiating start and stop cycles, using all controls Every Three Months:
.A. Drain condensate from Tuel Tank B. Change auxiliary turbocharger oil filter element or clean metal (C auxiliary oil filter element as applicable.
C. Take sample of ensine lube oil for customers laboratory analysis D. Clean and lubricate starters E. Lubricate door hinges and inspect door seals and locks F. Lubricate ventilating fan actor bearing on MC unit or outdoor switchgear station G. Lubricate cooling fan bearings unless 700 hour lubrication occurred first E. Lubricate shutter linkage and motor Every Six Months: ' A. Check operation of protective devices and annunciators B. Check inhibitor and add treatment as required (Spring and Fall)
"in cooling systen".
O v .
- 1. 1743
l. POWER SYSTInts CMS!ON
. Service Agreement No. 78914 }
Everv Year: A. Lube oil system 1.- Clean scavenging oil screens
- 2. Change filters and clean filter housing
- 3. Remove and clean oil separator
- 4. Inspect and clean oil filter bypass valve
- 5. Remove and clean strainer in strainer housing B. Engine
- 1. Estorque engine nuts and bolts
- a. Head frame to crankcase bolts
- b. Turbocharger to aftercooler air duct bolts
- c. Turbocharger compressor scroll flange bolts
- d. Engine and generator hold down bolts
- e. Check top deck cover seals
- 2. Check settings
- a. Overspeed trip by intentionally overspeeding the engine O b. Lash adjusters by observation with engine idling
() c. - Governor rack setting, valve and injector timing
- 3. Ejector Eductor Tube Assembly
- a. Inspect for carbon deposits and clean
- 4. Governor oil - flush and change C. Generator
- 1. Visually inspect and clean i D. Electrical Cabinets and Compartments
- 1. Visually inspect and clean l a. Voltage regulators
- b. Synchronizer
- c. All relays, contactors, and circuit breakers I
O ' t l'.N 9 t i
POWER SYSTEMS DIVI 5!CN O' . Service Agreement No. 78914 Every Year (Cont'd.)
- 2. Remove Circuit Breakers from Compartments
- a. Clean insulators
- b. Lubricate linkage bearings
- c. Check operation manually and electrically in test position f E. Lube 011 Circulating Pump l 1. Remove and clean check valve
- 2. Replace spider F. Engine Air Intake Filters
! 1. Disposable paper elements
- a. Check for, deterioration
- 2. Oil Bath Type Filters
- a. Change oil and clean sump O b. Clean filter media G. Exhaust Systest ,.
- 1. Manifold connections
- a. Inspect for cracks and leaks
- b. Torque manifold base bolts Every Three Yearst A. Crankcase Pressure Detector .
- 1. ' Unie exchange *(See Note 1)
Everv Six Tears: A. Cylinder Head Groannets, Outlet and Inlet Seals, Lower Liner Seals
- 1. Replace if not already changed at 8000 Hours. *(See Note 1) v
- 1. 1'?b0
POWER SYSTWi3 C.".*15:0?! C\ i-V Service Agreement No. 78914 After First 350 Hours: After first 350 hours of operation, on a replacement engine or a newly installed service part: A. Engine nut and bolt retorquing
- 1. Cylinder liner water inlet line nuts and bolts
- 2. Exhaust manifold flange bolts
- 3. Cylinder head crab nuts 4 Head frame to crankcase bolts
- 5. Turbocharger to afcar cooler air duct bolts Everv 350 Hours of Operation:
A. General Examination
- 1. Inspect cooling fan belts for defects
- 2. Visually inspect cylinder head mechanism with engine at idle speed and at operating temperature
- 3. Add required amount of lube oil 7 4. Fill oil cups on engine water pumps j
p) 5 V
- 5. Check operation of crankcase pressure detector Every 700 Hours of Operation:
A. Engine c
- 1. Inspect by barring over and observing the following:
- a. Air box drain
- b. Pistons, piston rings and cylinder liners
- c. Piston to head clearance
[ d. Engine cooling system for leaks i e. Engine fuel system for leaks l j B. MP45 Units, Lube 011 Filters
- 1. Change the fallowing:
- a. Engine filter alaments l- b. Engine mounted turbocharger filter element c.
Auxiliary turbocharger filter element O I 1751 L
. POWER SYSTEMS DMSION Service Agreement No. 78914 Every 700 Hours (Cont'd.)
C. MP26, MP27, MP36 Units, Lube oil Filters
- 1. Change engine lube oil filters
- 2. Clean turbo oil supply filter D. Coolung System
- 1. Check fan belt tension
- 2. Lubricate cooling f an bearings unless the three months lubrication occurred first E. Fuel Filters
- 1. Clean fuel suction strainer
- 2. Change engine mounted fuel filter elements
- 3. . Change fuel transfer pump filter elements (where used)
Everv 1400 Hours of Operation: A. Engine
- 1. Check engine speed l-O 2.
3. Remove and clean oil separator element Inspect ejector tube for carbon deposits and clean if necessary
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B. Engine Air Intake Filter
- 1. Disposable paper element
- a. Change elements if required
- 2. 011 bath type filter
- a. Change oil, clean sump and filter media C. Engine Aftercoolers (Air bath filter equipped engines only)
(. 1. .Take menometer reading scross aftercoolers Clean air passages if required *(See Note 1) i \ 2. F Every 2000 Hours of Operation: I A. Lube Oil System
' 1. Change ensine lube oil unless yearly occurred first
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' ?CWER SYMTEMS DM$C:4
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4 i . V Service Agreement No. 78914
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E'.ery_2000 *! curs (Cont'd)
- 5. Engine
! 1. Remove r.nd clean strainers in strainer housing 2 .' Clean su.vengina oil screens
- 3. Clain oil pan 4 Clean f11ter hcusing
- 5. Check itijector timing utd injector rack length !
- 6. Check all external bolts - tighten if necessary C. Generator
- 1. Insp(ce slip rings and brushes
- 2. Check for hast, smise, or grease purging at *oearing 4
D. Fuel Syatem i
- 1. Check operation cf fuel transfer system controls, switches, and alar =
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, , D.'ery 4000 Ecurs 'of Operation:
p) Engine A. t -
- 1. 'Icapact top deck cover seal and latches
- 2. Jacorque cylinder head. crab nuts
- 3. Recorque main tube oil'and piston cooling oil pump shate nuts
. 4. Recorque rocker arm assemblies
- 5. Inspect harmonic balancer B. Exhaust System
- 1. Reeme manifold screen. Check for cracks and clean.
Clean the trap (if applies) '
- 2. Inspect manifold connectors for liner cracks and replace if necessary O. Lube 011 3ystem
- 1. Resce sed clean turbo oil filter check valve in the engine
mounted turbocharger filter head
- 2. Cican and inspect lube oil filter bypass valve e
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PoWSR SYSTEMS DMCCN Service Agreement No. 78914 Every 4000 Hours (Cont'd) D. Cooling System
- 1. Check operation and setting of engine water temperature controls
- 2. Check torque on flexible pipe coupling bolts Check for hardened or damaged gaskets
- 4. Clean and inspect radiators E. Inertial Filters (MF-45 units only) ,
- 1. Take monometer readings across inertial filters. Engine at full speed, no load Everv 8000 Hours of Operation:
A. Engine
- 1. Replace cylinder head groamats, outlet and inlet seals and lower liner seals. *(See Note 1)
- 2. Clean top deck, air box, and oil pan
- 3. Qualify injectors *(See Note 1)
- 4. Check lash adjusters 5.
O 6. 7. Check valve timing, reset injector timing and injector racks Unit exchange engine water pumpes *(See Note 1) Inspect engine driven fuel pump
- a. Replace if needed ,*(See Note 1)
- 5. Starting Motors
- 1. Inspect starting motors and renew parts if necessary *(See Note 1)
C. Lube 011 Soak Back System
- 1. Remove and clean
- a. Soak back check valve h
' b. Soak back oil pressure relief valve '
- c. Soak back filter bypass valve in soak back filter head l d. Soak back pump motor (clean with dry air)
- e. Replace coupling spider *(See Note 1) 6
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/N Service Agreement No. 78014 i . . .
, -! Every 8000 74ure :(C:nt'd)
D.- Cociing System
/ -1. Replace cooling system pressure cap LEvary.16000. Hours of Operation:
~A ' Engine] Overhaul *(See Nota 1)
.1.~ ~Inscall-new thruse collars
- 2. -Install naw lower main bearings
- , 3.. . Replace _ cylinder assemblies (power pack change-out)
, ./ A." t Inspect and qualify connecting rod bearings
- 5. . . Inspect and qualify piston cooling tubes u -
6t; Raplact w"ater pump seals,and all worn parts
, 3.. Turbocharger (Manufacetired prior to 71D serial number) j 'MQ 1. Unit exchange *(See Note 1) i, ,
C. Soak, Bach or Lube 011' Circulating Iump and Motor i - ,
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- 1. Unit exchange '*(See Note 1)
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-D. Cooling Sy: stem *(See Note 1.)
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- r; i.!; . ~? 1.- Mylac_e flexible coupling seals (MP26 and MP36 only) . Replace
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internal parts of camperature regulating valve.. n .; ~./v.- ,,
. .; . .';c :- y Every 16000 Hourb o'f Operatimt s
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Urdt! exchange *(See Ncta- 1)
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m 3. Flexible drive couplings - e j. 1. : Inspect flexible drive couplings for torn or splic rubber bushings i; l - r l
;Everr'24000 Hoursof Operat'on:i> i
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Lv'os Oil System *(See Note 1) l .fa: f : h- j . 1. . Rabuild. lube oil pumps
- 2. Clean anif test luhe oil cooler b
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I oCWER SYOTIMS CMSiOH Service Agreement No. 78914 Every 24000 Hours (Cont'd) I B. Fuel System
- 1. Rebuild or replace engine or motor driven fuel pump *(See Note 1)
C. - Engine *(See Note 1)
- 1. Replace crankshaft viscous damper
- 2. Replace oil pumps
- 3. Replace lower liner inserts .
- 4. Replace injector costrol linkage links, seals, and bearings
- 5. Check camshafe bearings
- 6. Check rocker level and roller bushings
- 7. Inspect crankcase
- 8. Replace crankshaft harmonic balancer (3 pack type, where used)
D. Governor
- 1. Unit exchange *(See Note 1)
E. Ger.oracor-Bearing l
- 1. Relubricate *(See Note 1)
F. Cooling Fan
- 1. Replace drive bearings ' *(See Note 1)
Fvery 72000 Hours of Operation: A. Unit exchange engine *(See Note 1) .
- 3. Unit exchange generator *(See Note 1)
'* NOTE 1: Performance of these items subject to additional billing not part of this Maintenance contract. Items unde
- 4000 Hours of Operation. 8000 Hours of Operation,
- l. 12000 Hours of Operation, 16000 Hours of Operation, 24000 Hours of Operation and l 72000 Hours of Operation are not' included as part of this agreement. They are recom ,
sendations only. Performance of any part of the aforementioned recommendations will be additional to the agreement and require prior approval to perform and additional billing to the customer. e W . 9
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