ML20093M480
| ML20093M480 | |
| Person / Time | |
|---|---|
| Site: | Shoreham File:Long Island Lighting Company icon.png |
| Issue date: | 10/18/1984 |
| From: | Richard Anderson, Christensen S, Eley G, Hubbard R LONG ISLAND LIGHTING CO. |
| To: | |
| References | |
| CON-#484-607 OL, NUDOCS 8410220164 | |
| Download: ML20093M480 (83) | |
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UNITED STATES OF AMERICA '84 00T 22 A11:12 NUCLEAR REGULATORY COMMISSION.-
J Before the Atomic Safety and' Licensing Board
)
In the Matter of- ) . .
)
'LONG ISLAND LIGHTING COMPANY
) Docket No. 50-322-OL
) _
(Shoreham Nuclear Power Station, ) -
Unit 1) )
)
SUPPLEMENTAL TESTIMONY OF DR. ROBERT N. ANDERSON, PROFESSOR STANLEY CHRISTENSEN,' G. DENNIS ELEY, AND RICHARD B. HUBBARD REGARDING SUFFOLK COUNTY'S EMERGENCY DIESEL GENERATOR CONTENTION CONCERNING CYLINDER BLOCKS i
l SUFFOLK COUNTY October 18, 1984.
l 8410220164 841018 l PDR ADOCK 05000322 T
PDR D
l l
l
. TABLE OF CONTENTS l 1
PAGE )
l I. INTRODUCTION . . . . . . . . . .. . . . . . . 1 l
II.- CAM GALLERY CRACKS . . . . . . . . . . . . . . 3 l
l l III. CIRCUMFERENTIAL CRACKS . . . . . . . . . . . . 10 I
IV. CRACK INSPECTIONS . . . . . . . . . . . . . . '13 EXHIBITS S-1 FaAA Liquid Penetrant Examination Report
.(8/24/84)
S-2 FaAA Crack Depth Measurements (9/21/84)
S-3 Pnotographs of Cam Gallery Bearing Saddles Nos. 5, 7 and 8, Original Block, EDG 103 S-4 Photographs (Magnified) of Section of Cam Saddle No. 7, Original Block, EDG 103 S-5 LILCO Magnetic Particle Examination Report, EDG 101 (9/20/84)
S-6 LILCO Liquid Penetrant Examination Report, EDG 101 (9/21/84)
S-7 LILCO Deficiency Report 2507 and Attachments S-8 Inspection Report of C. R. Islieb S-9 Drawing of Location of Cracks S-10 LILCO Magnetic Particle Examination Report (9/19/84)
(i)
,74 SUFFOLK COUNTY'10/18/84 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
) -
(Shoreham Nuclear. Power Station, )
Unit 1) )
)_ ,
SUPPLEMENTAL TESTIMONY OF DR. ROBERT N. ANDERSON,
- PROFESSOR STANLEY CHRISTENSEN, G. DENNIS ELEY, AND RICHARD B. HUBBARD.
REGARDING SUFFOLK COUNTY'S EMERGENCY DIESEL GENERATOR CONTENTION CONCERNING CYLINDER BLOCKS I.' INTRODUCTION 1.0 What is the purpose of this testimony?
A. (All). This testimony addresses new information on cylinder blocks disclosed by Supplemental Testimony filed on September 20, 1984, on behalf of LILCO's witness panel and by subsequent discovery. That information concerns: (1) cracks in the cam gallery area of all EDG cylinder blocks, including the replacement block for EDG 103; (2) circumferential cracks around the cylinder counterbore landing; and (3) changes in LILCO's maasurements of cracks in the blocks.
2.Q. What conclusions have you reached as,to these matters?
A. (All). Our conclusions may be summarized as follows:
I
(1)(a) Cracks in the camshaft gallery area of the original EDG 103 cylinder block have been found to be far more I
cxtensive and more than twice as deep than-first represented by l LILCO and FaAA. Analysis of fractography and metallography of crack samples shows that' these cracks were originally formed as hot tears during-the casting process, were unsuccessfully at-
- tempted to be repaired with welding, and have since propagated.
i (b) Similar cracks are in the cam gallery areas of the blocks of EDGs 101 and 102. These cracks will continue to propagate, and those blocks are'therefore unsuitable for nuclear ,
earvice. .
[ (c) Cam gallery cracks have been found in the replacement block for EDG 103 after operation of that engine during testing. Inspection records show that no such cracks were present before the replacement block was placed into operation.
Accordingly, these cracks occurred due to operating stresses.
(2) Circumferential cracks were recently discovered during destructive examination of the original EDG 103 block.
LILCO and FaAA did not thereafter reinspect EDGs 101 and 102 for circumferential cracks, but assume they are present extending continuously 360 degrees around the circumference of the liner landing,of each cylinder. Examination of sections of the original EDG 103 block shows the circumferential crack to be relatively deep and propagating. Circumferential cracks in EDGs 101 and 102 may cause EDG failure, i
l 1
(3) Sectioning of the original EDG 103 block disclosed i that the large-stud-to-stud crack between cylinder numbers 4 and 5, which LILCO and FaAA had represented to.be 5-1/2 inches deep,
.wns really 3 inches' deep. The erroneous measurement of this crack suggests other crack measurements may be wrong., Further, the inability of LILCO, FaAA, rand TDI Owners Group inspections to
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discover the circumferential cracks or the nature and extent of the cam gallery cracks casts considerable doubton the reliability-t' of those inspections.
II. CAM GALLERY CRACKS 30 What cracks were found by FaAA and/or LILCO in the camshaft gallery area of the original EDG 103 block?
A. (Hubbard, Anderson). The FaAA Block Report issued in June 1984 and LILCO's cylinder block testimony stated that there ware " crack indications" in the cam galleries of all three EDGs, with the longest measuring 4-1/2 inches long and 0.375 inch deep in EDG 103.1! This information proved to be erroneous when, in late August, FaAA sectioned portions of the original EDG 103 block. Inspections showe'd cracks in all nine camshaft gallery saddle areas; there was a single 3-inch long crack, while the other eight cracks ranged in length from 4-1/4 inches to 5-3/8 1/ See Exhibit 7 to Suffolk County EDG testimony at 4-6; see also Testimony of Roger.L. McCarthy, et al., August 14, 1984, at 62-63, and Exhibit B-52 (since deleted by LILCO).
inches.2/ Some of these cracks were measured by FaAA after
'ccctioning and found to be from 0.5 inch to 0.906 inch deep in a block wall only 1.25 inches thick.d! FaAA found that all of these cracks had-been ground and welded. Some representative photo-graphs of these cracks areEshown in Exhibit S-3.
4.Q. What do you believe initially caused the cam gallery cracks in the original EDG 103 block to form?
A. (Anderson). Based upon my examination of the sections removed by FaAA from the block and of numerous photographs.of these cracks, they appear to be hot tears formed initially during .
fabrication of the block. This theory is supported by the fact that the cracks were filled with welding material in an apparent effort to repair them.
5.Q. Do you agree with FaAA's conclusion that these cam gallery cracks did not propagate after their formation during the casting process?
A. (Anderson). No. That conclusion is based upon FaAA's I
erroneous interpretations of a " dark oxide" on the surface of a I
crack sectioned from cam gallery No. 7, the presence of high con-centrations of calcium on the surface of that crack, the absence of a " rust-colored oxide," and the appearance of the crack' -
surface.
6.Q. Was the sectioned crack surface covered with a thick dark oxide?
2/ FaAA Liquid Penetrant Examination Report, 8/24/84 (Exhibit S-1). .
3/ _ Exhibit S-2.
T A.- (Anderson)'. FaAA did not analyze the crack surface to.
l datermine the presence of oxygen, so the substance is not neces-sarily an oxide.- Although.it is possible that'all or.part of the coating is an-oxide, I believe the darkness of its color is attributable to graphite from "graphitization" or graphitic corrosion of the surface of the crack, and not to oxidation at.
extremely high' temperatures as. hypothesized by FaAA. Graphitic-
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corrosion occurs-in gray cast iron in relatively mild.(low ,
temperature) environments.A! Thergraphite would have the effect of darkening a rust-colored oxide on'the' crack surface. The .
presence of minute particles of dirt and the oil to which the crack would'be exposed could contribute to the darkness of the surface. The EDX chemical analysis of the surface performed by 1
FaAA would not detect the presence of carbon (and hence, graphite). -
! 7.Q. If most of the substance covering the crack surface is an oxide, is FaAA correct that the oxide could only have formed in l high temperatures and in the presence of air during cooling at the l
time of the casting process?
l A. (Anderson). No. First, I believe FaAA's conclusion is
! based in part on their misinterpretation of the cause of the
" dark" color of the surface substance. As indicated above, I believe that the darkness of the color is attributable to the
-surface presence of carbon due to graphitization, and does not-indicate that the substance was the product of oxidation at ex-4/ Fontana and Greene, Corrosion Engineering (McGraw-Hill, 1978) at 70-71.
Ltremely-high temperatures. Red or rust-colored oxides, unlike derk oxides, are formed in_ low and moderate temperature environ-m;nts and would have the dark appearance of the surfaces I cxamined if graphitization had taken place.
Second, the block casting is formed under strong reducing conditions where air cannot enter. Initially, the block casting mold is literally burning. If air did enter the cam gallery area, it could do so only by diffusion in small amounts over a short period before the surface metal cools to the. point where any hot tears present would not form oxides. If this had .
occurred, there would only be a small amount of oxide with uneven distribution over the crack surface. Thicker layers of oxide would occur at the mouth of the crack than lower down, because the mouth would have been exposed to more oxygen during the cooling period than the bottom of the crack. However, the substance covering the crack appeared fairly uniform in thickness.
Third, the cracks in the sections I examined appear to have been ground and widened in preparation for the welding repairs, because they narrow abruptly below the weld material; a normal hot tear config.1 ration would have a more uniformly V-shaped configuration. Thus, in the ordinary course of events, an oxide formed during the cooling process would have been removed in the upper area of the crack where the grinding took place; but the crack surface from which the weld had separated had a uniform layer of the dark substance from the top to the bottom of the crack. .
Alternatively, if the oxide layer postulated by FaAA formed at the time of the casting process was not all removed by.
the-pre-welding grinding, then the oxide should have been present on the side of the crack to which the weld material was still adhered. I examined cross sections of the crack under a micro-scope and observed no sign of'the so-called dark oxide in the area of the crack to which weld material was still adhering.
8.Q. Does the presence of high concentrations of calcium on.
the crack surface support FaAA's conclusion that the " oxide" covering that surface was introduced -during casting whi'le the .
crack was exposed to high temperatures? ,
A. (Anderson). No. FaAA's chemical analysis disclosed the presence of calcium in some, but not all, areas which were tested. In all. samples where calcium was detected, sulfur was also detected in proportionate amounts. Therefore, I believe that the presence of concentrations of calcium resulted from exposure of the crack surfaces to calcium sulfide, which is often present in diesel oil lubricants and dye penetrants. Thus, the calcium was introduced after the block had been cast and cooled complete-ly.
9.Q. Do you agree with FaAA's conclusion that the relative uniformity of the " oxide" layer on the entire crack surface shows that no crack propagation has occurred?
A. (Anderson). No. A relatively uniform layer throughout the crack's surface is consistent with graphitic corrosion. While the ferritic material corrodes or rusts at different points in i
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time asfthe crack propagates, the-graphitic corrosion-leaves a-curface-layer of graphite. This1 graphite forms a protective layer co that the corrosion stops and the-surface becomes relatively uniform over time.
- 10.Q. .Does the absence of any beach' marks in the-crack
.suggest-that.there was no propagation of the crack after it was initially formed?
A. (Anderson). No. Because of its brittle na6ure, c'ast
. iron does not form beach marks during the process of crack.propa -
gation. -
11.Q. Is there additional evidence.that the cam gallery .
cracks are. propagating?
A. (Anderson). Yes. Exhibit S '4 is two photographs showing the magnified surface of a portion of a cam gallery crack that was sectioned by FaAA. The photographs show that the weld material.(the white area in the upper left) has pulled loose from the cast iron surface of the crack, but that some cast iron was still adhering to the weld material. This shows that the weld material pulled free from the crack surface due to operating stresses, as opposed to heat shrinkage.
12.Q. Are there cracks in the cam gallery areas of the blocks of'EDG 101 and 1027 A. (Hubbard, Anderson). Yes. LILCO has reported the presence of these cracks in all of the EDG blocks.
The cam gallery area of the EDG 101 block was subjected to magnetic particle ("MP") examination on September 20, 1984 and to liquid p2netrant ("LP") examination the following day.- The inspection
.rcports:(attached respectively as Exhibits S-5 and S-6) disclosed cracks'in the cam gallery areas of all eight cylinders, ranging up to 2-3/4 inches long. Mr._Rau of FaAA examined the cam gallery baaring saddles Nos. 8 and'9 on the block of EDG 102 and found wslded crack indications-about'2-1/2 inches long in both areas.
! (Anderson). Based upon photographs of the cracks in the camshaft' gallery ~ areas of t'he blocks of'EDGs 101 and 102, the descriptions of those cracks by.FaAA personnel, and LILCO inspec-tion reports, I believe these cracks are similar to those found.in ,
, the original block of-EDG 103. While the lengths of the cracks in the EDG 101 block may be somewhat shorter than those i'n the original EDG 103 block, they are, like those in the latter block, propagating cracks. Hence, I believe-the blocks of EDGs 101 and 102 are unsuitable for nuclear service.
14.Q. Were cracks found in the cam gallery area of the replacement block for EDG 103?
A. (Hubbard, Anderson). Yes. The areas of cam bearing saddles numbers 2 and 8 were inspected by LILCO both before and after grinding (on September 30 and October 1, 1984) while prepar-ing EDG 103 for additional testing. The test reports show cracks in both of these areas, ranging up to 2 inches long.E!
15.Q. Were these cracks present in the block before it was used during operation of EDG.103?
5/ Exhibit S-7.
i.
I A. (Hubbard, Anderson). No. LILCO has supplied us with- i copies of reports of all inspections of the replacement block by i or on behalf of TDI, LILCO, Stone & Webster, FaAA, and the TDI Owners Group, or any agent of LILCO, pertaining to the cam gallery crea. None of these reports disclosed any indications in that area . - Moreover, LILCO retained an expert, Mr. C. R. Isleib, to observe the casting of the replacement block and conduct a datailed inspection of it after cleaning and before it was painAed. The Isleib inspection. report concluded:
Careful inspection revealed no cold or .
- hot cracks or tears, nor any cold shuts visible to my naked eye, nor.under the 5x glass I used. Special attention was paid to internal fillets such as in camshaftbearingsaddleareas.6phe Wa therefore conclude that the cracks in_the camshaft gallery area of the replacement block initiated, or propagated from sub-surface defects, during and as a result of the operation'of EDG 103.
, III. CIRCUMFERENTIAL CRACKS 16.Q. Are there circumferential cracks in the original block of EDG 103?
A. (Hubbard, Anderson). Yes. The FaAA Block Report erroneously stated that none of the EDG blocks had circumferential cracks. Circumferential cracks are cracks at the corner formed by thn cylinder liner counterbore and the cylinder liner landing; a representational drawing of a circumferential crack is shown in 6/ The Isleib report is attached as Exhibit S-8.
Exhibit S-9.2/ After August 14, FaAA found "some"'circumferential cr cks.when it sectioned portions of two cylinders of the original EDG 103 block, according to'LILCO's Supplemental' Testimony.
4 Actually, the LILCO report of magnetic particle inspections conducted on September 19, 19848/ shows circumferential cracks extending 100 percent around the circumference of all eight cylinders.
17.Q. Are there circumferential cracks in t'he blocks of.EDGs 101 and 1027 A. (Hubbard, Anderson). .Apparently LILCO and its agents -
have conducted no inspections since September to determine this.
They claim that it is difficult to inspect for circumferential cracks, and simply assume that they are present in the EDG 101 and 102 blocks, running continuously 360 degrees around the circumfer-ence of each cylinder.S!
18.Q. Do you agree with FaAA's testimony that circumferential cracks in the EDG blocks are " shallow"?
A. (Anderson). No. FaAA's statement that the cracks are
" shallow" is based upon examination of sections of portions of only two cylinders from EDG 103, with a maximum depth which FaAA says is 3/8 inch. There is no data to determine whether circum-forential cracks in other cylinders may be deeper. I have made an 7,/ Exhibit S-9 is Figure 1-1 of the FaAA Block Report.
8/ The Magnetic Particle Examination Report is attached as 5'xhibit S-10.
9/ Deposition of Charles 4. Rau, Harry F. Wachob, and Robert K.
Taylor, October 11, 1984, at 20.
- examination oficircumferential cracks in the sections analyzed by
~
riFcAA', and'I observed that below the tip of the 3/8-inch crack are.
multiple small disconnected cracks branching out into the cast
, iron: material. .The linking'up.of the main crack with the branch
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cracks would in my' estimation extend the crack to over one inch in dapth.- This would extend-about 2/3 completely through the block l~ material thickness running at a 45 degree angle from the corner of' the counterbore landing to the cylinder.between'the-stud boss-- ,
.es 10/ ]
FaAA-speculates that circumferential cracks in the. . ,
- blocks of EDGs 101 and 102 would'be smaller than those in the ,
- l. original 103 block, because of the allegedly inferior. mechanical-properties of that block. I conducted a microscopic examination
. of a specimen of the liner landing ledge from the original EDG 103 l block, and observed that it contained appreciably less amounts of I
j Widmanstaetton graphite than appeared in other portions of the block as shown by LILCO's block exhibit B-33. Therefore, I do not-believe one can validly predict that circumferential cracks are smaller in the blocks of EDGs 101 and 102.
19.Q.- Do you agree with FaAA's conclusion that circumferen-tial cracks will " grow slowly, arrest, and will not cause any
-operational problems"?
l l A. (Anderson). No. The fact that the original EDG 103~
block did not fail due to the circumferential cracks by'the time ,
it failed and was scrapped for other reasons, does not support 10/. FaAA estimates that the thickness is 1-1/2 inches at that point. Deposition of Rau, et al., at 14.
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l FcAA's conclusion that the circumferential cracks will not propa-gnte to the point of impairing EDG operation. As described above, the circumferential crack I examined had numerous branches below ,
i its.tip and appeared to be propagating. The operating history of EDG 103 is therefore cause for concern with EDGs 101 and 102 rather than evidence of their reliability.
20.Q. Can circumferential cracks cause operation of an EDG to fail?-
A. (Christensen, Eley). Yes. A circumferential crack could permit some up and down movement of the cylinder liner .
relative to its position against the gasket sealing the liner to the cylinder head. Such movement could cause leakage of combus-tion gases, requiring premature shutdown of the engine. In the event the crack propagates through the counterbore, the cylinder liner landing would separate from the block, causing the cylinder
, liner to fall into the crankcase. This would cause serious damage to the EDG and probable catastrophic failure.
IV. CRACK INSPECTIONS 21.Q. What changes in crack depth measurements has LILCO made as a result of'FaAA's sectioning of portions of the original block of EDG 103?
A. (Hubbard). LILCO sectioned the large stud-to-stud crack between cylinder numbers 4 and 5 of the original block of EDG 103 and found it had a' depth.of 3 inches, rather than 5-1/2
~ inches.as previously reported in the FaAA Block Report and LILCO's
- written testimony.
22.Q. Is there any basis for LILCO's Supplemental Testimony ,
that "the actual depth of the cracks in the original EDG block are challower than previously thought"?
A. (Hubbard). No. Tlze depth of only one single crack was revised by the Supplemental Testimony. The Supplemental Testimony
~
does, however, cast considerable doubt upon the' reliability of inspections for cracks in the EDG cylinder blocks carried'out by LILCO, FaAA and the TDI Owners' Group. First, the erroneous ,
maasurement of the crack in the original EDG 103 block suggests that other crack measurements may also be wrong, whether over-stating or under-stating crack depths. Second, before last month naither LILCO, FaAA nor the TDI Owners' Group had discovered the existence of circumferential cracks in the EDGs, dor 31 ;c numerous inspections. Third, before last month none of those organizations had discovered that the camshaft gallery cracks were twice the assumed depth and had been welded. The final DR/QR Report for Storeham was issued and LILCO's testimony was filed in this case in reliance upon faulty inspection data.
9
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j DEFICIENCY M. Herlihv REPORT LSU DATE O CLASS SYSTEM DESIGNATOR MARK NO. 2 SYSTE9/ COMPONENT Emergency Diesel Gen. IR43 1R43*ENG-103 10/1/84 EIOnOm MATEb8AL LOCATION REJECT TAG O YES P.O. NO-M F G./ CON TR A CT OR control Blde.EDG-10] CI NO 3 TDI 310552 PROCEDURE VIOLATED CODE!$TAND ARD VIOLATED SPEC. VIOLATE D OR AWING VIOLATED 4 N/A N/A NDE 6.2 para. 4.2.2 CONDITION DETAILS Per results of NDE Inspections performed on IR43*ENG 103 (Cam Galley area) rejectable indications were noted. This is in violation of the LILCO NDE Manual NDE 6.2 (Liquid Penetrant) paragraph 4.2.2 (See attached LILCO 00A 5 Inspection Reports for Condition details) A' kV 2, w ^ // 6 . ' SIGN A Tu n e cATE sign Aru nE c ATW A f I r [/ 7 RESPONSIBILITY S & W ENG. is ]( b SIGN ATU AE.LE AC SU EiyG h C REWORK C MANUAL O FSAR C ACCEPT AS IS O REPAIR O PROCEDURE C OTHER 8 ACTION C SCRAP DISPCSITION DETAILS 9 APPROVALS 10 OATE PROJECT ENGINEEn S & W LE AD ENG3LSU TEST ENG./D ATE REPAIR /REWCRK REQUEST NO. 11 DATE LILCo SITE oOA DATE LILCo SU ENG. ARR COMPLETE REWORK INSPECTION ENG. COMPLETE /DATE OSAT. 12 O UNSAT. LILCo SU/DATE LILCO SITE OoA/D ATE Co NST. SUPT./D AT E REMARKS LOR CLOSED NEW LDR REPORT NO. ISSUED 13 LILCo SITE oQ AIDATE _ FC-9350
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-w J.. Kelly r7 L 7f W - av /C Diesel Engine 1013 - Cam Galley. Strain
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9/20/84, and have received their concurrence that it is accept-able to perform the tiP test (i.e., one test with magnetic flux applied in one direction). e If you have any further questions, please cal'.pT.e en ext. 334
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- 9 M3 Diesel Engine 101A - Cam Galley Strain Gauge NDE Testing SHOREII.25. NUCLEAR POWER STATION - UNIT 1 W.O. 44430/48923 DR/OR has been requested by FaAA to perform .NiPI of all Cam Galley saddles on DG-101. This e::am would be a repeat of infor tional MP performed by CQA, LDR 1224, RR 869, 870, 371 and 880. In addition to MP inspections, LP baselir.c -
.:.nsp:ctions will also be completed.
':P I can not be comuleted in ecmpliance with TILCO '!DE Pro-cedura 7.1 and 7.2, due to access limitations (i.e., Para-graph 4.1.3 NDE 7.1). I have reviewed this deviation with C. .: ells, F-2.u , Telecon 9/19/84 and R. Kascsak, ::ED , Telecon S/20/8', and havc received their concurrence that it is accept-able to perfcrm the tiP test (i.e., one test with magnetic flu:. applied in one direction).
If you have any further questions, please call v.e on ext. 334 cr 335. f-W *?, .y; W The informational MPI ar.d napping described acove will be required 'il, to assist ir. placement of strairc gauces. - NDE 7.1 acce.nt/ reject a - criteria does not apply. /
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N May 17o 1984 Mr. Robert M. Kascseko Manager Ecclear systens Engineering Division Long Zsland Lightlag Company Post Office Box 614 Berth Country Road Wading Rivero Eew York 11792 Dear Mr. Kascsakt
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Attached is my report of the Delaval foundry heat nade on - _ poured f1984 May to or LZLCC. and my essainatica of the gray iron block which was-i
, Zn summaryo Z observed the farance charge o meltlago and casting procedurest they were representacLve of very good L,
current. practice which would result La an excellent casciago netallurgically. from which the block was pouredoChemical analysts of the ladle of noiten iron i showed satisfactory composition. af ter additions had been nade r
- Photonicrographs will be provided the test bars. by Dalavslo as will results of nochanical testing of on May I Laspected 12.
the block af ter clesalag (but before palating) - castlag appears With to the exception of one gate break-Lao the be excellent. It is well fornedo without
= holes, cracks o
= cleased and niaos flan o relas shrinkage or Laciunloas: it has been thoroughly ground off. o and hurat on sand carefully -
- The gate break =La on the lower flange o between 12 and 84 cy1 Laders canshaft side o
o appeared to have no cracks radiat
lag from notch Ltp and effects. can be ground smooth to e1Lainste possible The Lacegrity of the flat seallag surface of
~
a ? between flange boltviolated the flange is not hol es andby the breako in frent of a anc its location nafor reinf orcing E e M 1 r
m L membero flange plus the nachining stock which will be removed from the in my opinion. its effect on the casting probably insignificanto make o A review of design stresses in this area should be made to ascertain this. Some defectso sack as microporosity, ca rbon flotationo and slag inclusions, are often not visible on as-cast surfaces but can we seen after nachining. I will inspect the casting for o those detects at that tine if you so desire. Please give se o as many days
- notice as possible if you want se to do this. I will be out of town for 9 daye r June 1-10o but can be reached at 919-986-2$03 during that time.
Very truly yours, 1 C. R. Isleibo P.E.
.1. J . Reg. No. 1))S6 CRZeEMW ~
Eac. l . O v O m ha e
- E0d L2:!O S I /* * '9 0
m i entraer
- ZLCC con =Lssionet the writet to observe and review Delaval heat 615 x a nd se Laspect the 8-cy1 Lader diesel eatLae block poured fros that beat. This Laciudad a review of the f u rna ce charger obeetwation of the heat la progress o melt sad ladle additionso t a pptato and castlaga discussions eith foundry and qualit v aneu ranee assageneat regarding guelity control and inspection proceduress and visual Laspection of the cleased castlag. The Leoa wee to contorn to Astm Standard specifLca-tion A 48, class 4l, s-co.vc:.us:oss - ms:.r:na suo cast:sc -
. :. t . ?
~
neleins and caaeing . $.?.$.'-(-
. . .: - ~ ; :- ~ 1. The furnace ch a rge *^*
- ma . . . . .._ de'.s p of goed quality virgia asterials and seta9. 'ef..?,f.,,5eifs aospositLon. .
- saw ,no purchased .wotor bioek3* 931Y.eWo
- kends or other sotap which might contata 2 ,ed, stad,[,,4bt.or alusians Las e rt s which could be deleteriens to ' tin'o;Wraphite or sa cris s tructu res
. *. .=: ~. :
or cantahilsty et the tren f. '.*,'*; ,
*. ~... = ~...;
, . .-i.MC.
- 3. The meltdova of the 23*t_}0 fat.beganat 4s00 A. n.o'May 2o sted: sappt ag ti** ** *l* *.A* ' A.*
** NEEinen temperature reached in the termace was['abent 17507 tapping ge,y,,s.
tute was about 2 60*!I : b*.th'g.a, , , . . ea,s e red by Laeeragea gg,,,a_ couple. This praattee and should resu18 in .Lai... in******.*$W*.0044c=1 g<?l=..eAGCa..
==* a ..u-defined, complete casting. .
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2 The heat was tapped Lato one 30-ton kotton= pour Ladie which had been preheated to red heat. Ladie additione of Graphidos and z:20 were ande during the tag for graphitis= Lag purposes. so delays were encountereds tapping was clean and completely satisfactory. 4 Castlag was begun promptly at about 160071 no s toppe r tecuble was encountereds and the noid was tLiled la onder 2=1/2 minutes, a very good time for this sEse castlag. An La=nold gesphtCLstag block is normal practice at Dela valo to alnialze Anacciation fade.
- 5. All mold venes were Ltc offs ao gas explosions occurreds and the risers all fedo judslas f rom ersaination of the hold inter 12 the mornias.
-), 4. Zt was reported by.Superlatendent Dobrec that one=o two o and .1= tach test bars were cast Latogrelly la the noida off the same gating sestaa, and cooled La the acid alcar with the casting. separately cast specimens were also poured. 7 Saaples for spectrographic analysis were poured as the heat approached finishing and just before tapplag. The fLaal ladie analysis is shown below. CONMENTSt the furnace used was a 30-ton capacity three-phase direct arc furnace, acid =11nede rated at 10 tons per bout settlag rate. The charge for heat 61SK was as fo110wes I
- y
- 90d L2:10 */ I / 6 0 * */ 9
- - m=
1 . l I n Charge Lbs. Delaval gtsy Lton returns (all shop accep) ............ 18.400 St ructural steel plate r etc. .......................... 12o800 Sorel setal pig (4.2 Co 0.2 Sto 0.01 Ma. 0.02 9 0.02 S)
.................................. Go900 Etss Allan Foundry pig (0.063 ?) .............e......... Ga900 Righ Carbon Ferrosanganese ............................ 170 Graphite
.............................................. 460 Nolybdeaua oxide briquettee (50% No) .....e............ 175 Ferranolybdenun (S2n Mo) ................. ~............ 37 total ................. 46,842 Ladle Additions EL80 Craphistser (80% eLLLcon) ........................ 124-Graphidos (50% etilcoa) ...........'.................... 46
~ Casting Congosition
/
Actual Ladie . Ansluels (t) total carboa
......................................... 2.0$
Namganese
............................................ 0.78 Stitcon ..............................................
!bosphores 1.82
........................................... 0.067 Sullut
............................................... 0.055 Chronius .....,........................................ 0.02 Elckel
............................................... 0.21 nolybdenen ....p......................................
0.28 Copper .............................................. 0.849 y-- a py 7 . *a & * /^* *L -
. -e g -
t Exasination of Cleaned Casting I esamined the casting on May 14o 1984, Lanedtateig after , shothiast cleaning but before painting (and before shop inspec- ~ cloa by Delaval) with the objective of locating and identifying . any defecte o especially those vbich would be harmful to the
.astL.,.s L.C.,rit, and Lat.nd.d s.r,,c. as an .n,Ln. h1och.
%A Jt y essataation was visuale aided by a Est, Ss hand eagnity=
Lag glass o nasauring tape and scale o supplementary lights o and a Newage pin brinell portable metal hardness tester. (the '
- purpose of the hardness ~ tester was not to dete
- sine definitive
- hardness levels o but staply to compare ha rdoes s invels at
[ several points on the casting and to help detect posalhte-porosity or other casting inhonagenettles.) .. 2 the casting was set up on rails and blocks in a we11~ lighted area no that 2 was a bl e to essaine every surface, _ E Laterior and esterior, cope and drag sides, as well as core cavities. It was blown free of netal blastiaq ehot for my Laspection. Particular attention was given to the head sur-faces and each cylinder bore area. e }?,L ,'.f . [.3 E:: :'
- the casting was examiand from the viewpoints and the
- ~
,.ll* *k,
'c systea of organisation described in The internettonal Atlas of
,; y, N CWkting Defects o publ. 1974 by the American Foundrymen's Q _. ;
e y Society, Des Plaines o 1111acist and the Annivsis of casting Nl)C
,e.
,T ,
Defecte o 4th ed.o ist revision o publ. 1974 by the American jy '.' F t Foundrynen*e Societyr Des Plaines, 2111acis. .T:. . oa - - M :;l _y. .
.9 .
p h%,< yg.>' ey_.3 E. "- A*C. .' . ^ .. : h ': P 0
- L0d 'L?:10 ft/60'73
l CONC:.US:0.45 - CrAv:NAT:CX or stir CAST:xc
- 1. Metallic Prosectrone Z saw no evidence of thick fine or veine o swells o not any significant washes, crusbes o drops o raises or scabs. Thin tLas '
and thin velas La fillet areas had been carefully ground clean. Cae ainer reland a rea (1-lach 1sngo thin vela) was noticed la a , acted slot on the vnter jacket side o and some einer seining La an entside flange-sidewall fillet.
- 2. Cavitsee Z saw no evidence of surface or corner blowholes or_
pinholes o not any shrinks or draws. The castlag appears sonad.
- 3. Discontinuities Careful Laspection revealed no col d or bot cracks or tears o not any cold abuts visible to ey naked eveo not under the Su glass ! used. Special attention was paid to internal fillets such as La the cansbate bearing saddle areas.
- d. surf ace Xtresula rities there are ao folds e seansa roughness o buckles o cat-tails o orange peelo slag inclusionso slaks or drawso o r cla np*of f defectso and no significant cruebes o bura~ ens or bura=1ns, netal penetration or scabs were visible. Very minor burn = ens or netal penetration had been carefully ground clean. Cae small surface irregula rity, 2 inchen long by 1/2 inch wide and
}
- _ _ a- .,.-- w-
T s M i, W . m 1/2 inch deepo in a cope side pocket tillet area near the it 5 cylinder liner support ring, water jacket side j o ? judge ins ig niti ca nt . _Hiii
- 5. Enconcleteness -A
?
there is no sign of mistan o short pouco or runout in this _i castinto aor should there he r based on og observation of the x noiten iron c ompe ra tu re and casting sequence on May :r to the icwor block flange (cope side of the casting as poured)
- 2. Cates
'-]
nessure approxiantely 3=L/2 inches wide by 2-1/2 Laches high. -N One of these gates o between the 13 and 04 cglinders e aanshaft side o suffered a break-in when the gating and risering systee &_ was renoved. This break ~in in between the flange bolt hole ~ locations and in front of a major reinforcing aanhet. 15 does & act estead to the flat sealing surface of the flanges nachin- ' 1 ing stock to be removed will help ainisine the significance of .- - this break ~1n. 20 cracks or incipient cracks were visible in or radiating from this break =La area. _?$
=
A second snail (2 inches long by 1/2 inch deep) gate _ S break-in exists in the flange below to cylinders this will 2 probably be removed during machining, and I judge it to be _ insignifica nt . No break =in or porosity was visible at the test ba r ingate areas, which are located inside the cores in the approx 1 sata f_ center of the casting.
~
[' 6 Encorrect Disensions . _q z saw no evidence of casting deformationo sold or core _'h' M niS E
=
- 6_0daZ_H M -
- l l .
shif** or ras-off defects in chts castsag.
- 7. Inclusions Z saw ac metallic laciusions o cold shoto slago dross.
sendo refractoryo oxide or graphite flotation defects. Hardness Tests Za a test for any asfor unsoundness or Lahonogenettles in the castlago 2 ande several hardness nessurements o si ng a '_ Newege pin brinell kardness tenter. Because the surfaces r casted were shot-blasted but not groundo the lagression zead-Laga are act saant to be a eensure of actual brinell ha rdness - level. A properly prepared surface would gleid higher valaes. The pin indentat. Loa discesers that were nessured indicat-ed good homogeneity. The heaviest sections o which cooled slowest, showed saaewhat greater indeatation-diameters than the flanger which cooled f aster and would be espected to be harder. There was no indication of sicro= or gross shrinkage free these ' observations. O t+ A _f m
@ s Oid L2:10 7t/5C'7G_ y
D Location Zndentation Diameter (a ve ra ge reading) in el11Leeters Flange ~0 reg side ~near Lngace break =in ersa 2>90
- Test 1 2.75 =
Test 2 Read cylinders surface ~ between 14 and 15 3.20 Read surface o beyond di cylinder 1.10 Head outface s outside 15 cylinder 2.90 - Test 1 1.00 - Test 2 Head surface, between 87 and de cylinders 3.00 Exceptas the castlag forjudged the 11ange by nybreak-in mentioned la Conclusion So quality. visual Laspectica is of excellent .. d
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24 9 2 7' MAGNETIC PARTICLE IIAMINATION REPORT
- MI FABRICATED e A. MATERIAL TYPE ( </ I,' q ED g CAST Q WOR m PROCESS nn GB3 METRY PIPE O PLATE O ROD -
OTHER: f 7 5 O MACHIsED D CROSS l. MAI lPYPE DIA. SURFACE O cR0uND . SECTION N/A
/u /4 CONDITION % 5
', / s AS FABRICATED 0 OTHER m H THIC1CfESS ! MIN '
B. NDE PROCEDJRE MWR/RR 6 5 - L c' 7 3 EQUIPMENT I.D. S/II / 6 I ' /- I> b NO. ~1. t / " . . 2- NO. /bA ~I ~ 10!/ MEsTE NO. C IL - >**'? )' a,.., = > s- - - - 1 TECHNIQUE PRODS N YOKE . COIL OTHER ' 2
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0 10 lb SLATE x CURRENT
' AC
\ DC HW/DC D L3 lb PLATE 1- e, . s . , .
. <,,o2,... ,-
' AMPS s + /, ' 1 PROD SPACI:;G C.
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PRODS E ',- O,' i e t % l~ ~
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MATERIAIE l _ DRY ','_ WET BRAND / DESIGNATION '; ,,. f- , ,; os
, G SKITCH OR OTHEh SEIAIIa OTHER SIDE IF NECESSARY h
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% sj r .= vJ REPORT'BELOW THOSE INDICATIONS OBSERVED AND THE PERTINENT INFORMATION REQUIRED. WHERE ADDITIONAL SPACE IS REQUIRED
. ATION USE OTHER SIDE ,
l SIZE ACTION .,, j LOCATION (INCHES) DECRIPTION (ACCEPI/ REJECT, AND COMMENT AS NECESSARY) l s lCC* 1 Cys.i i o<- 2 g ,_'e;,,, CL,,,f eG.a,.es L w 1s) JMc , Qje ct/'a o scw' m-
- 3 sica g 2 a/A 4/A dlA &l& ;'I "$
m 3 M/a N/,t alt dl,5 n k N/& 4/n sin nlA 00 OPEATOR M 'V / r'% k
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& 3 D. ACCEPIANCE CRITERIA l UO r_. 7, 3., p% 4. 2. L LEVEL ~~5 - DATE <i// J/#/
r.! fit)a , itm e J_ aESPONSIstr,CatTmED PEAS 0x3EI. LEvEI. 'DATE i
L . RELATED CORRESPONDENCE,, UNITED STATES OF AMERICA c ',E,'E' NUCLEAR REGULATORY COMMISSION Mh" Before the Atomic Safety and Licensing Board gg g7
) - - ; = Ji
- In the Matter of ) (0 d5Nhu% SEWl'-
) SaANCH LONG ISLAND LIGHTING COMPANY ) Docket No. 50-322-OL
)
(Shoreham Nuclear Power Station, ) Unit 1) )
)
CERTIFICATE OF SERVICE I hereby certify that copies of the SUPPLEMENTAL TESTIMONY OF DR. ROBERT N. ANDERSON, PROFESSOR STANLEY CHRISTENSEN, G. DENNIS ELEY, AND RICHARD B. HUBBARD REGARDING SUFFOLK COUNTY'S EMERGENCY DIESEL GENERATOR CONTENTION CONCERNING CYLINDER BLOCKS, dated October 18, 1984, have been served on the following this 18th day of October 1984 by U.S. mail, first class, except as otherwise noted. Lawrence J. Brenner, Esq.* MHB Technical Associates Administrative Judge 1723 Hamilton Avenue Atomic Safety and Licensing Board Suite K U.S. Nuclear Regulatory Commission San Jose, California 95125 Washington, D.C. 20555 E. Milton Farley, III, Esq.* Dr. George A. Ferguson* Hunton & Williams Administrative Judge P.O. Box 19230 Atomic Safety and Licensing Board 2000 Pennsylvania Ave., N.W. School of Engineering Washington, D.C. 20036 Howard University 2300 6th Street, N.W. Odes L. Stroupe, Jr., Esq. Washington, D.C. 20059 Hunton & Williams 333 Fayetteville Street Dr. Peter A. Morris
- Raleigh, North Carolina 27602 Administrative Judge Atomic Safety and Licensing Board Mr. Jay Dunkleberger U.S. Nuclear Regulatory Commission New York State Energy Office Washington, D.C. 20555 Agency B.111 ding 2 Empire State Plaza Edward M. Barrett, Esq. Albany, New York 12223 General Counsel Long Island Lighting Company James B. Dougherty, Esq.
250 Old Country Road 3045 Porter Street, N.W. Mineola, New York 11501 Washington, D.C. 20008
- l i
l - l i E Robert E. Smith, Esq. Stephen B. Latham, Esq. Guggenheimer & Untermyer Twomey, Latham & Shea L 80 Pine Street P.O. Box 398 ' New York, New York 10005 33 West Second Street - Riverhead, New York 11901 i Mr. Brian R. McCaffrey L Long Island Lighting Company Mr. Frank R. Jones Shoreham Nuclear Power Station Leputy County Executive I P.O. Box 618 H. Lee Dennison Building North Country Road Veterans Memorial Highway Wading River, New York 11792 Hauppauge, New York 11788 [ [ Joel Blau, Esq. Mr. Stuart Diamond New York Public Service Commission Business / Financial NEW YORK TIMES The Governor Nelson A. Rockefeller Building New York, New York 10036 :
- Empire State Plaza 12223 Hon. Peter F. Cohalan Albany, New York Suffolk County Executive
- Martin Bradley Ashare, Esq. H. Lee Dennison Building Suffolk County Attorney Veterans Memorial Highway 7 H. Lee Dennison Building Hauppauge, New York 11788 ? Veterans Memorial Highway i Hauppauge, New York 11788 Fabian Palomino, Esq.9 Special Counsel to the r Atomic Safety and Licensing Board Governor Panel Executive Chamber U.S. Nuclear Regulatory Commission Room 229 Washington, D.C. 20555 State Capitol Albany, New York 12224 r Docketing and Service Section F Office of the Secretary Atomic Safety and Licensing ( U.S. Nuclear Regulatory Commission Appeal Board f - 1717 H Street, N.W. Washington, D.C. 20555 U.S. Nuclear Regulatory Commission
- Washington, D.C. 20555 Edwin J. Reis, Esq.*
Bernard M. Bordenick, Esq. Jonathan D. Feinberg, Esq. Richard J. Goddard, Esq. Staff Counsel Office of Exec. Legal Director New York State Public U.S. Nuclear Regulatory Commission Service Commission Washington, D.C. 20555 3 Rockefeller Plaza Albany, New York 12223
l - Stewart M. Glass, Esq. Regional Counsel Federal Emergency Management Agency 26 Federal Plaza New York, New York 10278
^
Alan Roy Dynpr j/ KIRKPATRICK / LOCKH ART, HILL, CHRISTOPHER & PHILLIPS 1900 M Street, N.W., Suite 800 Washington, D.C. 20036 DATE: October 18, 1984
# By Federal Express
- By Hand Delivery
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