ML20093F792
| ML20093F792 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 10/09/1984 |
| From: | Tucker H DUKE POWER CO. |
| To: | Adensam E, Harold Denton Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 8410150226 | |
| Download: ML20093F792 (6) | |
Text
0 Dmm Powen GOMPANY P.O. HoJC 33180 cunurrre, x.c. coe4e IIAL H. TUCKER ay?!L%
~~~~
October 9, 1984 Mr. Harold R. Denton, Director Office of Nuclear Regulation U.S. Nuclear Regulatory Consission l
Washington, D.C.
20555 i
I Ms. E. G. Adensam, Chief I
Attention:
l Licensing Branch No. 4 Zegarding:
Catat a Nuclear Station, Unit 1 Docket No. 50-413, 50-414 Resciution of Outstanding Items on Diesel Generators
References:
1)
NBC letter to H.
B. Tucker, DPC from T.M. Novak of August 14, 1984.
2)
Safety Evaluation Peport Catawba Nuclear Station Unit 1-Reliability of Diesel Generators Manufactured by Transamerica Delaval, Inc.
'IDI Project Group Division of Licensing.
3)
- PNL Report PNL-5211," Review and Evaluation of Transamerica Delaval, Inc., Diesel Engine Reliability and Operabili'j -
Catawba Nuclear Station Unit 1", August 1984.-
4)
Duke Power Co. letter to H.
R.
Denton, NRC from H.
B.
Tucker of July 16, 1984.
l 5)
Duke Power Co. letter to H.. R.
Denton, NRC from H.
B.
Tucker of August 28, 1984.
6)
Duke Power Co. letter to H.
R.
Denton, NRC from H.
B.
Tucker of July 6, 1984.
l kur Mr. Denton:
Ihe pu cose of this letter is to reply to a verbal connitment to answer a question m&Se during the July 26, 1984 meeting with NRC, Battelle PNL and Duke and to answer outstanding items on the Catawba Unit 1 diesel generators men-l tioned in reference 2 which was forwarded to Duke Power Co. by reference 1.
1 Resolution of the catstanding items described in reference 2 are required
[
prior to operation abcve 5% power.
The following is Duke Power Company's L
response to the July 26 question and resolution of the items discussed in reference 2.
i 1.
IdJbe Qil Pressure agl 'Ibwwrahire l
During the July 26, 1984 NRC Duke meeting at Catawba Nuclear Station 8410150226 841009
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H. R. Denton October 9, 19E4 Paga 2 the staff expressed a desire that the lubricating oil pressure be increased to the highest maximum value allowed by 'IDI.
In an August 24, 1984 letter to the Owners Group, TDI advises that RV engines be operated at oil inlet pressures between 50 and 60 PSIG. We are currently changing the necessary station rh= ants and adjusting the necessary equipment to allow engine operation in the upper portion of this range (approxi:nately 57 PSIG).
'Ihe staff also suggested that the lubricating oil inlet tenperatures be reduced to the lowest value allowed by the manufacturer in an effort to reduce bearing babbitt fatigue. TDI warns that reducing the tenperature below that ramamanded in the operating manual (170 to 180 deg. F) allows water to build up in these systems, causing an adverse affect on the lube all additives.
Therefore they do not reconmend that lower tenpera-tures be used.
Because we have no contradicting information, we feel that we sixx11d follow their reconmendation.
2.
'rurwharaer Adapter Both Unit 1 diesels have had modifications made to the turbocharger
. adapters on the right bank of the engine. 'Ibese modifications include a flexible joint between the adapter and turbocharger to absorb relative displacements between the turbocharger and adapter and the addition of strongbacks to the adapter casing to reduce casing displacements.
3.
'Pnrhrv harge; Ranrign Both Unit 1 diesels have had modifications made to the turbocharger prelube system which will reduce wear on the turbocharger bearings during startup of the units.
Tb confirm this reduction in wear, Duke Power Co. will inspect at least two turbochargers for bearing wear at the first refueling.
4.
Diesel JA cviirvlar Iland fiL e
Duke Power Co. has replaced cylinder head 6L on diesel 1A as we believe that this head had a plug repair weld in the fuel injector nozzle cavity.
No heads on either Unit 1 diesels will be returned to service with plug repair welds, i
5.
JaclLet Mater Emp J=allar Rt.
Duke Power Co. will measure the torque of the jacket water pung inpeller nut on diesel 1B at the first refueling.
Reassenbly procedures indicate that the torque on the diesel IA inpeller nut was 120 ft-Ibs.
6.
Maintenance and snrvaillarv a program Reference 4 forwarded the Duke Power Co.
maintenance and surveillance progrhm for the Unit 1 diesels.
Reference 2 and 3 consnented-on the reference 4 program.
Duke Power Co. will incorporate the reference 3 coaments as modified and anplified by
H. R. Denton October 9,1984 Paga 3 reference 2.
We understand that this will involve the following changes to the reference 4 doci==nt:
a.
Barring over the engine 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> after shutdown and prior to any planned engine operation (this is in addition to barring over the engine within 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> of operation, as already planned).
b.
When operating, the cylinder block will be visually in-spected using portable lighting. 'Ihis inspection will be done at least once per month, c.
Inspect connecting rod bolts preload at first refueling or 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> whichever comes first.
d.
Check lubricating oil of the engine for chamical and particulate contamination on a monthly basis for the first three months.
Future testing will be determined by a review of the first three months results.
e.
Check 100% of air-start valve capscrew torques and 25% of cylinder head. stud and rocker arm capscrew torques at each refueling.
f.
Measure hot crankshaft deflections as soon as possible following engine shutdown at each refueling.
g.
Continuously monitor and record at one hour intervals pre-turbine exhaust inlet tenperatures during operation.
h.
Until DQ/DR resolution is obtained, inspect items on page 92 of reference 3 at first refueling except that a 25%
inspection of connecting rod bearings will be done.
At 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br /> or ten years whichever comes
- first, dimensionally, visually, and radiographically inspect all ccu ecting rod bearings shells.
i.
At the first refueling, penetrant test the subcover pedes-tals on the subcovers which are removed during cylinder head inspection. This will involve a 25% inspection.
j.
At 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br /> or 10 years, whichever comes first, penetrant inspect 100% of the subcover pedestals.
7.
Revised Technical RnacW eaH nna A revised tachnical specification limiting operation of the diesels to 5750 kw has been sent to the NBC by reference 5.
8.
Revised Elant Procedures Plant procedures have been changed to reflect the fact that the diesels are not to be loaded to more than 5750 kw.
9.
Euel Linea Fuel line fittings on both Unit 1 diesels have been installed using Duke Power procedures for torquing to minimize leakage.
Fuel line walkdowns of both Unit 1 diesels have been coupleted with satisfactory results. All fuel lines on both Unit 1 diesels have been eddy c:trrent tested with satisfactory results.
H. R.'Denten - October 9,1984 Paga 4 10.
EualInfanHnn Bag Yabst Holders All valve holders on both. Unit 1 diesels have, been cleaned, boroscope.
inspected, reamed
_ here. necessary to remove w
indications, and found to be satisfactory.
- 11.
'turbccharger Gaa Inlah Bolta All turbocharger. gas -inlet bolts on-the IB diesel have been replaced by SA 453, Grade 660, Condition A anterial. Due to achablar constraints,. the 1A diesel inlet bolts were replaced with i
'mI-spare bolts. Duke Power Co. will replace these bolts with SA 453, Grade 660, Candition A bolts at the first refueling when two
- turbochargers have to come off an engine for bearing inspection (see item 3).-
Our rationale for postponing this retrofit is that at the
'first refueling the engine will only have about 50 hours5.787037e-4 days <br />0.0139 hours <br />8.267196e-5 weeks <br />1.9025e-5 months <br /> on it.
We believe. that these hours will not create a creep rupture failure of the type seen on.the 1A engine after about 420 hours0.00486 days <br />0.117 hours <br />6.944444e-4 weeks <br />1.5981e-4 months <br /> of operation.
j 12.
Radug Sox subanaanbly Pedantals
- Failure analysis of the rocker box pedestals has confirmed that the cracks were due to overload and not due to fatigue.
This indicates that the cracks were emiaad by manufacturing and/or installation error, and not due to service. Thus, recurrence of these cracks is not expected.. However, as a preciutionary measure, 4 rocker boxes will be inspected at the first refueling, and all of them will be inspected 'as diacnamed in item 6.j.
about every 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br />.or 10 years, which ever comes first.
13.
Return-to-service Testing All return-to-service testing as indicated in reference 6, has been
.ccapleted for engine 1A at loads of 5750 kw or less in accordance
- with section 3.3 of reference 2..In addition, reference 6 indicated that the Fast Start. Test under blackout conditions would load a dfesel to 4100kW. However plant conditions did not allow this much load. Tbe automatic load sequencer placed a load of about 2950kW on each diesel during the blackout test. We believe that the Fast Start Test has fully duplicated the testing required by the Catawba tec--
hnical-specifications and assured that the diesel generator controls-are capable of stably controlling the unit for the actual load ranps found under blackout conditions. Return-to-service testing has been sucessfully completed on engine 1A diesel generator. Information on
- engine IB return-to-service testing will be forwarded as soon as testing.is couplete.
. 14.
Omar's ficcup naccamiendations Duke Power Co.. Will incorporate all owners group rarmnandations
' applicable to the Catawba diesels which are accepted by the NIC staff in conformance with Section 3.5 of reference 2.
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H. R. Denton October 9,1984 Page 5 l
i 15.
'nirbocharger M 'hnparatures Duke Power Co. has completed turbocharger inlet tenperature tests on engine.1B.
Results of these tests are summarized in the table below.
Shown are load,~ average right bank and left bank exhaust temperatures, and right and left bank turbocharger inlet tenpera-
- tures.
.L1Pr BAMC RIGTP BAMC IDAD Avg. Pmbumt
'Ibrbo Inlet Avg. Exhaust-Turbo Inlet M
2kup frian P) g (clan F) g trian P) g trian F) 1750 723-746 707 734 3500 859 933 821 913 5200 914 1727 886 1016 5750 929 1648 906 1038
. If you have any questions or conenents please do not hesitate to call Rnaaall P. Muschick at (704) 373-5875.
. Very truly yours,-
c4 w
H._ B. 'Ibcker, Vice President Nuclear Production Department HBT:WNG:wwg cc - IGC Resident Inspector Catawba Nucleer StatIOu Robert Guild, Esq.
Attorney-at-Law P.O. Box 12097' Charleston, South Carolina 29412 Mr. Jes:m L. Riley Carolina Environmental Study Group 854 Benly Place Charlotte, North Carolina 28207 Walt Laity Pacific Northwest Laboratories P.O. Box 999 c
Battelle Blvd.
Richland, Washington 99352 C. H. Berlinger GER, U. S. !bclear Regulatory Cr-niaaion Washington, D. O.
20555
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1 H. R. Denton October 9,1984 Paga 6 Melanie A. Miller Division of Licensing, U. S. Nuclear Regulatory ennuntasion 7920 Norfolk Avenue Bethesda, Maryland 20814 Mr. James P. O'Reilly, Regional M:ninistrator U. S. Nuclear Regulatory C - iaaion Region II-101 Marietta Street,IM, Suite 2900 Atlanta', Georgia 30323 Palmetto Alliare 2135 Devine Street Colunbia, South Carolina 2920S 3
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