ML20094A866
| ML20094A866 | |
| Person / Time | |
|---|---|
| Site: | Shoreham File:Long Island Lighting Company icon.png |
| Issue date: | 10/24/1984 |
| From: | Fohnson D, Dante Johnson, Dante Johnson, Swanger L FAILURE ANALYSIS ASSOCIATES, INC., LONG ISLAND LIGHTING CO. |
| To: | |
| Shared Package | |
| ML20094A854 | List: |
| References | |
| OL, NUDOCS 8411060585 | |
| Download: ML20094A866 (11) | |
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.._., LILCO, Octobar 24, 1984 27,M.E. ee.C UNITED STATES OF AMERICA NUCLEAR REGULATORY. COMMISSION 00T 26 /10 :0 2 Before the Atomic Safety and Licensing Bo'a'rd. : u,
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In the Matter of
)
)
LONG ISLAND LIGHTING COMPANY
)
Docket No. 50-322 (OL)
)
(Shoreham Nuclear Power Station,
)
Unit 1)
)
1 SUPPLEMENTAL TESTIMONY OF DONALD O. JOHNSON, DUANE P.
JOHNSON AND LEE A. SWANGER ON BEHALF OF LONG ISLAND LIGHTING COMPANY REGARDING AE PISTON SKIRTS AT SHOREH 1.
Please state your names, employers and business addresses.
A.
(Donald Johnson)
My name is Donald O.
Johnson.
(Duane Johnson)
My name is Dr. Duane P. Johnson.
(Lee Swanger)
My name is Dr. Lee A.
Swanger.
(Donald Johnson, Duane Johnson, Lee Swanger)
We are employed by Failure Analysis Associates (FaAA), 2225 East Bayshore Road, Palo Alto, California 94303.
2.
Have you previously testified in this proceeding?
A.
(Duane Johnson, Lee Swanger)
Yes, as members of the LILCO panel on the AE piston skirts.
See Attachments 2 and 6, respectively, of the AE piston testimony for our professional qualifications.
(Donald Johnson)
I have not testified previously in 8411060585 841024 PDR ADOCK 05000322 g
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-2 this proceeding, but am the author of the memoranda dated February 17, 1984 and February 3, 1984 in Exhibit P-29.
3.
Mr. Johnson, describe your responsibilities relevant to the AE'pistone.
A.
(Donald Johnson)
I am an FaAA. nondestructive testing technician and a certified Level II Testing Technician in eddy current,. liquid dye penetrant, magnetic particle, n
radiographic and ultrasonic testing.
In November 1983, I witnessed the pre-service finishing and inspection at
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Transamerica Delaval, Inc. (TDI) of the AE piston skirts for the Shoreham Nuclear Power Station.
I also performed eddy cur-rent examination on some of these skirts after their 100 hour0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> i
test run.
In addition, as a part of the TDI Owners Group pro-gram,-I performed or witnessed the liquid dye penetrant and eddy c'urrent inspections on two AE pistons from the Kodiak en-gine and the two AE pistons from the R-5 engine.
4.
What have you been asked to address in this testimony?
A.
(Donald Johnson, Duane Johnson, Lee Swanger)
Based
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on our inspections, we have been asked to clarify the fact that the stud boss regions, particularly the highly stressed area, in the R-5 and Shoreham AE piston skirts are essentially iden-tical and that the highly stressed areas are not polished.
I (Donald Johnson) also address the meaning of the following description frok my February 3, 1984 memorandum.
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During the inspection I observed that-there was a layer of plating on the 'inside
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of the skirt and that the casting wasivery smooth, different from general produ'ction runs of cast material.
The inside~ofithe skirt was cleaned, and all the flash lwas removed.
The boss area was very smooth, a
as if polished by cratex, and all.the.
ground areas were very carefully polished, with smooth racius into boss.
5.
Dr. Johnson and Dr. Swanger, have you inspected the two R-5 AE piston skirts referenced in Donald Johnson's February 3, 1984 memorandum and, if so, what'did you observe?
A.
[DuaneJohnson, Lee Swanger)
Yes.
Recently, for the first time, we inspected the two R-5 AE piston skirts at TDI.
We also recently inspected one of those skirtsHat FaAA in Palo Alto.
The surface conditions we observed in the two R-5 AE pisten skirts are essentially the same as the AE piston skirts in the Shoreham emergency diesel generators that we have inspected.
The highly stressed areas of the stud boss region in both the Shoreham and R-5 piston skirts are as-cast surfaces that show no evidence of any grinding or polishing.
The washer landing areas of all AE piston skirts, including the Shoreham, i
R-5 piston and Kodiak AE piston skirts, are machined surfaces and, therefore, appear smoother in contrast to the as-cast sur-faces.
These areas on the AE piston skirts are machined as a I
part of the manufacturing process to form a flat, circular area
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for. seating of the Bellville washers.
On both the R-5 and 4
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Shore, ham pistons, some of the lip areas formed by.the machining
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had also been ground.
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. 7.
Did you see any evidence to suggest that the fatigue resistance in the stud boss region of the R-5 AE piston skirts would be any different from the fatigue resistance of the stud boss region in the Shoreham AE piston skirts?
A.
(Lee Swanger)
No.
I would agree with the testimony given by Dr. Harris on Monday, October 1, 1984 (Tr. at 23784),
that there is no evidence of any difference in the fatigue re-sistance in these areas.
Under any given, imposed state of stress, the local stresses would be essentially identical.
8.
Mr. Johnson, are the observations of Dr. Johnson and Dr. Swanger consistent with your observations of the R-5 AE piston skirts and the Shoreham piston skirts?
A.
(Donald Johnson)
Yes.
The surface conditions, particularly in the highly stressed areas in the R-5 and Shoreham AE piston skirts, are substantially the same.
The highly stressed areas in both are as-cast surfaces that have not been polished.
The only as-cast surface in the stud boss region in both the Shoreham and R-5 piston skirts that had been ground or smoothed was the machined washer landing and lip areas.
In November 1983, I witnessed the grinding of the lip and the smoothing of the lip and radius area with cratex on the Shoreham AE piston skirts.
As a fo:.er machinist, I describe the smoothing by cratex as polishing, but it does not produce the same highly polished surface that is normally associated
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with metallurgical polishing.
Cratex is used'to level off the surface created by machining.
9.
Mr. Johnson, have you had an opportunity to inspect the AE piston skirts from the R-5 engines since your inspections in January 1984?
A.
(Donald Johnson)
Yes.
On September 29, 1984, I inspected both.R-5 piston skirts at TDI.
On October 12, 1984, I inspected one of the R-5 skirts at FaAA in Palo Alto.
With the exception of the absence of the red dye and developer, the condition of'the inside of the skirts was the same as when I inspected them in January 1984.
The skirts did not appear to have been run or altered since January 1984.
10.
Mr. Johnson, does your testimony today differ from the statements in your February 3, 1984 memorandum?
A.
(Donald Johnson)
No.
The language quoted above in the February 3, 1984 memorandum that I wrote about the R-5 piston skirta was not meant to suggest or imply that the sur-face condition of the R-5 piston skirts was significantly bet-ter than the Shoreham skirts.
When I first saw the inside of the R-5 skirt it did appear smooth in comparison to the earlier production AH, AN'ar.d AF pistons I had seen.
At first glance, the R-5 interior cast surfaces also appeared smooth because of the uniformity id color created by the very thin coat of tin on the inside of the skirt which I had not seen on any other e
pistons prior to my inspection of the R-5 skirts in January 1984.
The R-5 skirt also appeared generally smoother than the Shoreham pistons as they came directly from the production runs because,,at that point, the Shoreham pistons still had some flash on the inside surfaces.
Flash-is a rough metal edge that is created when the molten cast iron runs into a small imper-fection in a core and subsequently solidifies.
The Shoreham pistons had flash on the ribs and wrist pin boss areas, but not on the highly stressed boss area.
Steps were taken to remove the flash bEfgre shipment.
And, as I have stated, in the highly stressed areas of the boss, the Shoreham pistons are es-sentially the same in terms of smoothness as the R-5 pistons.
In my February 3, 1984 memorandum where I indicated that the " boss area was very smooth, as if polished by cratex,"
I was referring only to the machined surface of the stud boss region which is the washer landing area.
In the last sentence from my February 3 memorandum quoted above, I made the observation that the washer landing area and the ground areas in the R-S skirts were smooth and had been carefully polished.
These statements reflect a condition that differs in no way fr'om the overall condition that I observed in the AE skirts that were finally shipped to Shoreham.
11.
Mr. Johnson, do you know where the highly stressed 4
area in the stud boss region is?
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A.
(Donald Johnson)
Yes.
My choice of words -
describing the washer landing area in my February 3, 1984 memorandum should have been more specific.
I am a' ware of the difference between the washer landing area and the highly stressed area in the stud boss region.
I wir.essed or 4
performed eddy current and liquid dye penetrant examinations of the entire stud boss region, including the highly stressed area, in the AE piston skirts from the Shoreham, Kodiak and R-5 engines.
12 '.
Dr. Johnson, please elaborate on your testimony in this proceeding on September 12, 1984 about the comparative smoothness of the surface of the R-5 and Shoreham AE piston skirts.
A.
(Duane Johnson)
Based on my understanding of the February 3 memorandum and several. conversations with Donald 1
Johnson, I commented in my testimony in this proceeding on September 12, 1984 (Tr. at 22312) that the casting surface on the R-5 AE pistons "was' smoother than the surfaces which were j
generally observed an the Shoreham pistons on the inside."
I went on to speculate in response to a specific question regarding polishing that the difference in smoothness "could have resulted from polfshing" but that "we didn't know that it was the result of polishing."
In any event, I did not consider i.
l '-
the supposed differences in the surfaces of the R-5 and i
. -. = _ _. _ _ _ _,, - _.
. 4 Shoreham AE piston skirts to be significant.
My recent inspec-L tion of the two R-5 AE piston skirts confirms this and further-more clarifies that the as-cast surface in the highly stressed areas of the R-5 AE skirts have not been polished, and the highly stressed areas in the R-5 and Shoreham AE skirts are es-sentially the same.
13.
Dr.~Swanger, please elaborate on the testimony you gave earlier in this proceeding regarding the polishing of the R-5 AE piston skirts in light of your recent personal observations.
A.
(Lee Swanger)
On September 12 and 13, 1984, I testified regarding the polishing on the R-5 AE piston skirts based on my reading of the February 3, 1984 memorandum written by Donald Johnson.
Although my subsequent personal inspection of the R-5 piston skirts has revealed that there is no polishing in the highly stressed ~ area of the stud boss region,.
my testimony about the practice of polishing an area of interest for a prototype engine is still valid in general, but is not applicable here.
14.
Please summarize your conclusionc regarding a comparison of the R-5 and Shoreham AE piston skirts.
A.
(Donald Johnson, Duane Johnson, Lee Swanger)
Based observations and a clarification of the language in r.
on recent the. February 3 memorandum, we conclude that the highly stressed
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g-g areas in both the R-5 and Shoreham AE piston skirts are very similar as-cast surfaces that have not been polished.
I (Lee Swanger) observed nothing that would indicate that the highly stressed areas in the R-5 and Shoreham AE piston skirts differ in their resistance to fatigue cracking.
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L3:.hc CERTIFICATE OF SERVICE In the Matter of LONG ISLAND LIGHTING COMPANY OFFic 7 c:
(Shoreham Nuclear Power Station, Uni @i')NjNG'sM/,I Docket No. 50-322 (OL)
CRANCH I hereby certify that copies of LILCO's Motion To Admit Supplemental Testimony Of Donald O.
Johnson, Duane P.
Johnson And Lee A.Swanger On Behalf Of Long Island Lighting Company Regarding AE Piston Skirts At Shoreham were served this date upon the following by first-class mail, postage prepaid, or by hand'aslindicated by an asterisk:
Lawrence Brenner, Esq.*
Secretary of the Commission Administrative Judge U.S. Nuclear Regulatory Atomic Safety and Licensing Commission Board Panel Washington, D.C.
20555 U.S. Nuclear Regulatory Commiscion Atomic Safety ahd Licensing 4350 East-West Highway Appeal Board Panel Fourth Floor (North Tower)
U.S. Nuclear Regulatory Bethesda, Maryland 20814 Commission Washington, D.C.
20555 Dr. Peter A. Morris
- Administrative Judge Atomic Safety and Licensing Atomic Safety and Licensing Board Panel l
Board Panel U.S. Nuclear Regulatory U.S. Nuclear Regulatory Commission Commission Washington, D.C.
20555 4350 East-West Highway Fourth Floor (North Tower)
Robert E.
Smith, Esq.*
Bethesda, Maryland 20814 Guggenheimer & Untermyer 80 Pine Street Dr. George A.
Ferguson New York, New York 10005 Administrative Judge School' of Engineering Herbert H. Brown, Esq.*
Howard University Lawrence Coe Lanpher, Esq.
Room 1114 Alan R. Dynner, Esq.
2300 - 6th Street, N.W.
Joseph J.
Brigati, Esq.
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Washington, D.C.
20059 Kirkpatrick, Lockhart, Hill, Christopher & Phillips 1900 M Street, N.W.
8th Floor Washington, D.C.
20036
v-f- -
Bernard M. Bordenick, Esq.*
Stephen B. Latha', Esq.
m David A. Repka, Esq.
Twomey, Latham & Shea Richard J. Goddard, Esq.
33 West Second.~ Street U.S.' Nuclear Regulatory Post Office Box 398 Commission Riverhead, New York 11901 Maryland' National-Eank Bldg.
7735 Old Georgetown Road Ralph Shapiro, Esq.
Bethesda, Maryland 20814 Cammer and Shapiro, P.C.
9 East 40th Street Martin Bradley Ashare, Esq.
New York, New York 10016 Attn: Patricia A. Dempsey, Esq.
County Attorney.
James Dougherty, Esq.
Suffolk County Department 3045 Porter Street of Law Washington, D.C.
20008 Veterans Memorial Highway Hauppauge, New York 11787 Jonathan D.
Feinberg, Esq.
New York State Mr. Marc W.'Coldsmith Department of Public Service Energy Research Group Three Empire State Plaza 4001 Totten Pond Road Albany, New York 12223 Waltham, Massachusetts 02154 Howard L. Blau MHB Technical Associates 217 Newbridge Road 1723 Hamilton Avenue Hicksville, New York 11801 Suite K San Jose, California 95125 Fabian G. Palomino, Esq.
Special Counsel to the Mr. -Jay Dunkleberger Governor New York State Energy Office Executive Chamber, Room 229 Agency Building 2 State Capitol Empire State Plaza Albany, New York 12224 Albany, New York 12223 f.s i J.s. EAxl, Hunton &~ Williams 707 East Main Street Post Office Box 1535 Richmond, VA 23225 DATED:
Octo,ber 24:, 1984 r
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