ML20094E483

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Forwards Affidavit of C Matthews Attesting to Accuracy of Info Contained in Re Crankshaft Oil Passage Plug Issue.Related Correspondence
ML20094E483
Person / Time
Site: Shoreham File:Long Island Lighting Company icon.png
Issue date: 08/01/1984
From: Dreifus D
HUNTON & WILLIAMS, LONG ISLAND LIGHTING CO.
To: Brenner L, Ferguson G, Morris P
Atomic Safety and Licensing Board Panel
Shared Package
ML20094E476 List:
References
OL, OL-1, NUDOCS 8408090223
Download: ML20094E483 (21)
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==onv.u.c t. o. no., o=.o........ o. =,....... In the Matter of -ga Er,ac - 24566.3 a LONG ISLAND LIGHTING COMPANY (Shoreham Nuclear Power Station, Unit 1) Docket No. 50-322-1 (OL) Hon. Lawrence Brenner, Esq. Hon. Dr. Peter A. Morris .. Administrative Judge Administrative Judge s Atomic. Safety and' Licensing Atomic Safety and Licensing Board Eoard 'U.S. Nuclear Regulatory U.S. Nuclear Regulatory Commission Commission . Washington, D.C. 20555 Washington, D.C. 20555 Hon. Dr. George A. Ferguson Administrative Judge -School'of Engineering Howard University 2300 - 56 Street, N.W. Washington, D.C.- 20059

Dear. Administrative Judges:

In accordance with the Board's Order of July 25, 1984 ' dismissing-the crankshaft oil passage plug issue, enclosed for . filing is the Affidavit of Clinton Mathews attesting to the ccc.iracy of the information contained in his letter of July 12, '1984 to Craig Secman of LILCO. I am sending the original Affidavit -to Judge Brenner with copies to all other parties. Very truly yours, David Dreifus 300/918 Enclosure cc: Alan Roy Dynner, Esq. (w/ encl) (By Federal Express) Richard J. Goddard, Esq. (w/ encl) (By Federal Express) Fabian G. Palamino, Esq. (w/ encl) (By Federal Express) Entire Service List (w/o encl) 8408090223 840806 PDR ADOCK 05000322 g PDR

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~, ", UNITED STATES OF AMERICA +% w, NUCLEAR REGULATORY COMMISSION Before the Atomic Safety and Licensing Board Docxr- ) US!;[- In the Matter of ) ) Docket No. 50-322-OL .N /gg g LONG ISLAND' LIGHTING COMPANY ) ) c f.,,- -(Shoreham Nuclear Power- ) C;6,"jf.h SE:.h, Station, Unit 1) ) pj.;f C' ) AFFIDAVIT OF CLINTON S. MATHEWS STATE OF CALIFORNIA)) ss.:. COUNTY OF ALAMEDA -) CLINTON S. MATHEWS, being duly sworn, deposes and says: 'l. I am Vice President and General Manager of the Engine and Compressor Division of Transamerica Delaval Inc. ? ( TDI"). ,2. On July 12, 1984, I wrote to Craig Seaman of The g !Long; Island Lighting Company comparing the design of the crank-L T cshaft oil-hole plugs used in the TDI engines at Rafha, Saudi ~~ aArabia and those used at Shoreham. The information contained in .that letter'and its attachments (copies of which are annexed as Exhibit:A)-is accurate. / / s (*,- Clinton S. Mathews Sworn to'before me this N day of July, 1984 OFFICIAL SEAL

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' a e es sousse us sums. (- _Engin2 t.nd Csimptssse { /n 'l ,t g g' 550 85th Avenua \\ P.O. Box 2161 j* 3lt g 0 klind. California 95621 (415) 577 7400 s ' July li,1984 [ i. Mr. Craig Seaman Long Isl.andjlighting Company Shoreham4 Nuclear Power Station P.O.' Bow 618 North (Country Road WadinpRiver, New York 11792

Subject:

Crankshaft Oil Hole Plug l P/N R-3149

Dear,

Craig: t 7 .In re' to your inquiry regarding the design of the oil hole plugs

  • Nused']ponsen (the crankshaft at Rafha Electricity Corp., enclosed are drawing R-hl rele,49, the drawini release and change notice form showing the original ase, an:)-the ' change notices for change A (3/10/80) and change B

>a - (6/23/82) i:Mch tiescribe the oil hole plug and its changes over the years. ( As seti.forch below, Ahe oil hole plugs in place at Shoreham use signifi-cantlygAick'er stesi than used at Rafha,and TDI has no knowledge of any j .c failurd of the 2oreham design plug which is in usc in more than 300 "R" series' engine crankshafts. Nqs The origi,nal' design of the crankshaft oi,1 hole plug was released in December,,1965 and called for the plug tc, be stamped from 16 gauge sheet steel which is approximately 1/16" in thickness. Over the years this plug was completely successful, liowever, our manufacturing people suggested changing to a lighter gaugq magwial which would reduce the time required for installation. Please note that the plug installation consists of inserting the plug into its location and then mechanically deforming the plug by rolling it into a premachined groove in the crantrhaft, thereby locking the plug in place. In March of 1980, the plug material was changed from 16 gauge sheet steel to 22 gauge sheet steel, for " ease of assembly" (change symbol A). Twenty-two (22) gauge sheet metal is approximately 1/32" in thickness, or approximately nne-hal f the thickness of the previously-used 16 gagge material. \\ 3 i ss

~ irans:mziiua ( ~ ( ,.; Delaval F 'lii ~ Mr. Craig Seamn Long Island Lighting Company July 12,1984 Page 2 While almost all of the 22 gauge plugs worked perfectly, field experience and shop experience showed.us that the crankshaft oil hole plugs made from the thinner 22 gauge material were more likely to be damaged during the installation process where they were set into the crankshaft hole with a plug punch. Such installation damage is believed to have resulted in failures at Rafha in Saudi Arabia. As a result of these failures, where the center of the 22 gauge plug partially sheared out, we returned to the original 16 gauge material design in June of 1982 (change symbol B), which design remains unchanged from that time to the present. In the 300 R4 and RV-4 series engines s-hipped in the last 20 years, this 16 gauge plug has been used approxiamtely 6000 times with no -reported failures. Both the original Shoreham enankshafts and the replacement crankshafts use the heavier 16 gauge plugs. We trust the foregoing satisfies your needs. If not, please let me hear from you. Best regards, ll C. S. Mathews Vice President and General Manager i. CSM/pn - L cc: Mr. Clarence Ray, TDI Owners Group w/att. /_

A 'PUJG - CRA1XSH. [ IL HOLE l...,,,, g, R 'Prcors m e. ENGc m a,,,,,, p-3 woe z. ~ o*Tr ? 7 8 - 6 f. _ d ? 5 E NEW DRAWIN^., RELEASED FOR PRODUCTION c RECEIVED s E PRODUCT 10N 2 M r. pe em.rE N-E MAR 031966 il C.ods ' t % *' /A AM PV E 7.RAE11ilhli2 3,4xr /1 /-2c RELEASED FOR PRODUCTION 2$ FILE G RECORO % EX~A.r l C::T r; C - CTHCP ' MEManKS I PARTE AFFECTEC NEW *M-D.5 PO SITioN FINISHi3 ; ROUGH IN QN AS S E M B L E DI FE R CHANGT o f N C T I C --- CF STOCK STOCR STOCK PR OG R ESS ORDER NOTSHpPC PARTo-PER PA RTS LIST h'f) [O[W ENY'OE _~ RWORY t L'SC W/C CH ANGE l ] l Cs4ANGED BY PHECK APPROVm DA.RTS LIFT a c Rr t, a c. Of L.AW AL TURSIME 'M:. ENTEMMteSE DevistoN ' * * " ~ ' DRAWING = NOTICE R-3149 J i EFFECTIVE JOB 'h CHANGE PLUG-CRANKSHAFT OIL HO M csa~ct svusou __ 'I A NAME MODEL M 'E. 3/10/o0 oasc D. PRATT REQUESTED BY M MATERIAL WAS 16 CU AGE (,0595) STEEL SHEET S'I AMPING. t E e HEASON: EASE OF ASSEMBLY O g i 5 3 NOTE: EFFECTIVE ON NEXT MADE I ,, / /3 o/" M# ) d( b /c o j acLeasce 9 on,aooucvio~ X oraca aawTs araccToo aat Tca~ c-a~ct 'I enoG acss / issuc To oiseosJio'~ w oa,~ NO o~-a~o Asstueuv or sTocx Tv c Y / NEW PATTEaN ^ S h e, Ust A5 USE AS No V waso a r\\ua~oaToav NOTE IS Ts Pcwoax T'.:., " "'c" ' ' 5c ~ ' '~^' EC O atw at'resc -.if'i oATED ,, c g

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( DR AWING. RELEA"A NOTICE ""*" co " CHANGE EFFECTIVE JOB R-3149 PLUG. CRANKSHAFT OIL HOLE NAME 8 MODEL CwANcE Svuect 6/23/82 REQUESTED BY D-RTPPFr CHG. RFOf frST Or 6-14-8? OATE ' C AM (qt/ 7/4[l/ E-MATERIAL WAS 22 GA. (.N?f) COLD ROLLED STL. ( 8 O REASON: TO LESSEN CHANCE OF DAMAGE TO PLUG AT INSTALLATION i. 5 REMARKS: NEXT PART MADE MUST BE PER THIS REVISION O y MISC. 82-135 O RELE ASEO FOR PRODUCTsON % FILE O 015PossTION WORKIN 855UE TO OTHER PARTS AFFECTED PATTERN CHANGE TYPE OF STOCK PR OG R ESS ON MAND ASSEuBLY X X X

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.a,}'- 1 N $69 -g $70.'30 In the Matter of ) 50-322-OL,Q crc, ) Docket No. LONG ISLAND LIGHTING COMPANY ) ) " ' TE-l9. s_ (Shoreham Nuclear Power ) I'/['yO - Station, Unit 1) ) ) AFFIDAVIT OF CLINTON S. MATHEWS STATE OF CALIFORNIA)) ss.: COUNTY OF ALAMEDA ) CLINTON S. MATHEWS, being duly sworn, deposes and says: 1. I am Vice President and General Manager of the Engine and Compressor Division of Transamerica Delaval Inc. ("TDI"). 2. On July 12, 1984, I wrote to Craig Seaman of The Long Island Lighting Company comparing the design of the crank-shaft oil hole plugs used in the TDI engines at Rafha, Saudi Arabia and those used at Shoreham. The information contained in that letter and its attachments (copies of which are annexed as Exhibit A) is accurate. f.' _l '{I.' Clinton S. Mathews Sworn to before me this day of July, 1984 fg OFFICIAL SEAL 'S_ -f ' \\ B J DOWD ' N OTARv CU3L'C - C AUFORNIA 5.1985f

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Oaklanc. cahtornia 94621 E (415) 577J400 ' July 12,1984 rir. Crai g Seaman Long Island Lighting Company Snoreham Nuclear Power Station P.O. Box 618 North Country Road Wading River, New York 11792

Subject:

Crankshaft Oil Hole Plug P/N R-3149

Dear Craig:

In response to your inquiry regarding the design of the oil hole plugs used in the cranksha ft at Ra fha Electricity Corp., enclosed are drawing R-3149, the drawing release and change notice form showing the ori ginal elease, and the change notices for change A (3/10/80) and change S (6/23/82) which describe the oil hole plug and its changes over the years. As set forth below, the oil hole plugs in place at Shoreham use signifi-cantly thicker steel than used at Ra fha,and TDI has no knowledge of any failures of the Shoreham desigii plug which is in use in more than 300 "R" series engine crankshafts. The original design of the crankshaft oil hole plug was released in December,1965 and called for the plug to be stamped from 16 gauge sheet steel which is approximately 1/16" in thickness. Over the years this plue was complietely success ful. However, our manu facturing people suggested changing to a lighter gauge material which would reduce the time required for installation. Please note that the plug installation consists of inserting the plug into its location and then mechanically deforming the plug by rolling it into a premachined groove in the crankshaft, thereby locking the plug in place. In March of 1980, the olug material was changed from-16 gauge sheet steel to 22 gauge sheet steel, for " ease of assembly" (change symbol A). Twenty-two (22) gauge sheet metal is approximately 1/32" in thickness, or 6pproximately one-Pal f the thickness of the previously-used 16 gauge material.

~ ' ' Transamence Delaval Mr. Craig Seamn Long Island Lighting Company Page 2 July 12,- 1984 While almost all of the 22 gauge plugs worked perfectly, field experience and shop experience showed.us that the crankshaft oil hole plugs made from the thinner 22 gauge material were more likely to be damaged during the installation process where they were set into the crankshaft hole with a plug punch. Such installation damage is believed to have resulted in failures at Rafha in Saudi Arabia. As a result of these failures, where the center of the 22 gauge plug partially sheared out, we returned to the original 16 gauge material design in June of 1982 (change symbol B), which design remains unchanged from that time to the present. In the 300 R4 and RV-4 series engines s-hipped in the last 20 years, this 16 gauge plug has been used approxiamtely 6000 times with no reported failures. Both the original Shoreham crankshafts and the replacement crankshafts use the heavier 16 gauge plugs. .We trust the foregoing satisfies your needs. If not, please let me hear from you. Best.regards, )/ / C. 5..Mathews-Vice President and General Manager CSM/pn cc: Mr. - Clarence Ray, -TDI Owners Group w/att. 9 e ---a

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6-s ~ 1 c.n? :: :: ', '_TO::09;CE flU UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION Before~the Atomic Safety and Licensing Board '84 ) .In the Matter of ) C e., : ) Docket No. 50-322-OL r LONG ISLAND-LIGHTING COMPANY ) CCdif- ) -(Shoreham Nuclear Power ) Station, Unit 1) ) ) AFFIDAVIT OF CLINTON S. MATHEWS STATE OF CALIFORNIA)) ss.: COUNTY OF ALAMEDA. )- CLINTON S. MATHEWS, being duly sworn, deposes and says: 1. I am Vice President and General Manager of the Engine and Compressor Division of Transamerica Delaval Inc. -("TDI"). 2. On July 12, 1984, I wrote to Craig Seaman of The Long Island Lighting Company comparing the design of the crank-shaft oil hole plugs used in the. TDI engines at Rafha, Saudi . Arabia a3d those used at Shoreham. The information contained in that letter and its attachments (copies of which are annexed as Exhibit A) is accurate. ,. x' /Ig h.., Clinton S. Mathews Sworn to before me this Y day of July, 1984 OFFICIAL SEkL &i5_:l

  • B J DOWD

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c ~ Trtnsamenca Detvil Inc. s Transamenca. en#n m ecom,,;,,c { ce Delaval 55 5;j;;"" v a EXHIBIT A Caktanc. Cahfornia 94621 (415) 577 7400 ' July 12,1984 Mr. Craig Seaman Long Island Lighting Company Shoreham Nuclear Power Station -P.O. Box 618 North Country Road ' Wading River, New York 11792

Subject:

Crankshaft Oil Hole Plug P/N R-3149

Dear Craig:

In response to your inquiry regarding the design of the oil hole plugs used in the crankshaft at Rafha Electricity Corp., enclosed are drawing R-3149, the drawing release and change notice form showing the original release, and the change notices for change A (3/10/80) and change B (6/23/82) which describe the oil hole plug and its changes over the years. As set forth below, the oil hole plugs in place at Shoreham use signifi-cantly thicker steel than used at Rafha,and TDI has no knowledge of any failures of the Shoreham design plug which is in use in more than 300 "R" series engine crankshafts. The original design of the crankshaft oil hole plug was released in December,1965 and called for the plug to be stamped from 16 gauge sheet steel which is approximately 1/16" in thickness. Over the years this plug r was compietely success ful. However, our manufacturing people suggested changing to a lighter gauge material which would reduce the time required for installation. Please note that the plug installation consists of inserting the plug into its location and then mechanically deforming the plug by rolling it into a premachined groove in the crankshaft, thereby L locking the plug in place. In March of 1980, the plug material was changed from*16 gauge sheet steel to 22 gauge sheet steel, for " ease of assembly" (change symbol A). Twenty-two (22) gauge sheet metal is approximately 1/32" in. thickness, or approximately one-half the thickness of the previodsly-used 16 gauge material. 1

~ ' Transamence 1 Delaval Mr. Craig Seamn Long Island Lighting Company July 12,1984 Page 2 While almost all of the 22 gauge plugs worked perfectly, field experience and shop experience showed.us that the crankshaft oil hole plugs made from the thinner 22 gauge material were more likely to be damaged during the installation process where they were set into the crankshaft hole with a plug punch. Such installation damage is believed to have resulted in failures at Rafha in Saudi Arabia. As a result of these failures, where the center of the 22 gauge plug partially sheared out, we returned to the original 16 gauge material design in June of 1982 (change symbol B), which design remains unchanged from that time to the present. In the 300 R4 and-RV-4 series engines s-hipped in the last 20 years, this 16 gauge plug has been used approxiamtely 6000 times with no reported failures. Both the original Shoreham crankshafts and the replacement crankshafts use the heavier 16 gauge plugs. We trust the foregoing satisfies your needs. If not, please let me hear from you. Best regards, f/ C. S. Mathews Vice Pres,ident and General Manager CSM/pn ec: Mr. Clarence Ray, TDI Owners Group w/att.

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