ML20100A974

Rev 1 to Tdi Diesel Generator Design Review & Quality Revalidation Rept

ML20100A974
Person / Time
Site:	Perry
Issue date:	02/28/1985
From:	Rick Deese, Ray C TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP
To:
Shared Package
ML20100A956	List: ML20100A952 ML20100A974
References
PE3333, NUDOCS 8503260332
Download: ML20100A974 (129)

Text

!

't TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT prepared for THE CLEVELAND ELECTRIC ILLUMINATING COMPANY PERRY NUCLEAR POWER PLANT by TDI DIESEL GENERATOR OWNERS GROUP Revision 1 February,1985 Reviewed by:

A R.

J.

Deese Licensing Coordinator TDI Diesel Generator Owners Group b,

Approved by:

C.

L.

Ray Tethnical Program Director TDI Diesel Generator Owners Group o

PE3333 o

2. 6 FINAL DOCUMENTATION The DR/QR program has been completed for The Cleveland Electric Illuminating Company.

A summary of the results of this effort are contained in Section 3.0.

Appendix I contains component DR/QR Summary Reports which provide a detailed summary of the review and analysis performed on each component including references to supporting documentation and the recommendations and conclusions resulting from this effort.

Appendix II contains a comprehensive set of maintenance and surveillance recommendations for each component.

These recommendations were derived from existing vendor recommendations and the individual component DR/QR Summary reports. The purpose of this Appendix is to provide the utility a basis for its maintenance and surveillance program which will maintain the qualification of its diesel generators for the life of the plant.

This entire report constitutes final documentation of the completion of the DR/QR Program on the Perry TDI diesel generators.

1 O

O PE3333 2-6 REV. 1

O 3.1 Summary Resolution of Sixteen Generic Components (Phase I)

The results of the Phase I program have been submitted to the NRC in a series of reports and supplements (Refs. 2 through 44) that covered the 16 generic components. The results of these reviews are summarized below.

Component Acceptability Recommended Action Turbocharger Unlimited Life Additional testing and (MP-022/3) maintenance requirements.

Revision of operating procedures.

Base and Bearing Unlimited Life Additional maintenance and Caps (03-305A, inspection requirements.

03-305C, 03-305D)

Crankshaft Unlimited Life None (03-310A)

Cylinder Block Unlimited Life Additional maintenance and

\\

and Liner inspection requirements.

(03-315A, 03-315C)

Cylinder Head Unlimited Life None j

Studs (03-315E) l Connecting Rods:

Unlimited Life Additional inspection Connecting Rods requirements.

and Bushings t

(03-340A) l Connecting Rod Unlimited Life Additional maintenance l

Bearing Shells requirements.

Additional l

(03-3408) inspections recommended.

Pistons (03-341A)

Unlimited Life AN piston skirt should be replaced with AE piston skirt.

Air Start Valve Unlimited Life Additional maintenance (03-359) requirements.

Verification of dimensions recommended.

Cylinder Heads Unlimited Life Additional maintenance (03-360A) requirements.

Fuel Injection Unlimited Life Additional testing and Equipment: Tube maintenance requirements.

Assembly (03-365C)

Procurement specification requirement.

PE3294 3-2 REV 1 l

L

l Component Acceptability Recommended Action Main and Connector Unlimited Life Additional procurement Pushrods requirement.

Additional (03-390C, 03-390D) inspections recommended.

Random destructive testing recommended.

Rocker Arm Capscrews Unlimited Life Additional maintenance 1

(03-390F) requirements.

Jacket Water Pump Unlimited Life Additional maintenance (03-425A) requirements.

Wiring and Unlimited Life None Terminations (03-6688)

O I

l l

O I

PE3294 3-3 REV 1 t

/~N Component Acceptability Recommended Action Turbocharger -

Unlimited Life Implementation of proper torque Bracket:

Bolting on bracket bolting.

Additional y

and Gaskets Quality Revalidation inspections (02-475A&C) recommended.

Additional inspections recommended.

Air Butterfly Unlimited Life Additional maintenance Valve Assembly re'. Artndations.

Additional (02-4758)

Quality inspections recommended.

Intake Air Unlimited Life None Silencer (02-805A)

Intake Air Filter Unlimited Life Additional maintenance (02-805B) recommendations.

Flex Connections Unlimited Life None (02-8050)

LUBE OIL Lube Oil Pressure Unlimited Life Additional maintenance Regulating Valve recommendations.

(00-420)

Lube Oil Fittings Unlimited Life None Internal Headers (Large Bore Scope Only)

(02-307A-LB)

Lube Oil Fittings-Unlimited Life Verify as-built conditions Internal: headers are as indicated in Component (Small Bore Scope Design Review Checklist 02-3070.

Only)

(02-307A-SB)

Lube Oil Fittings-Unlimited Life None Internal-Tubing and Fittings (Small Bore Scope Only)

(02-3078)

O PE3294 3-5 REV 1

p Component Acceptability Recommended Action Lube Oil Fittings Modifications Replace all 1/4-inch U-bolts with Internal-Supports 3/8-inch U-bolts.

U-bolts should (Small Bore be torqued sufficiently to Scope Only) prevent the header from moving (02-307D) axially without overstressing the header.

Nuts should have suitable locking devices installed.

Engine Driven Lube Modifications Addition of a Dresser coupling 011 Pump on the pump suction line to (02-420) mitigate the thermal expansion 1

loading and stresses on the pump inlet nozzle.

Lube Oil Lines -

Modifications Replace 12-inch Dresser coupling External Tubings, gasket with VIT0N gaskets.

Ensure Fittings, Couplings a minimum installation gap of (Large Bore Scope 0.171 inches, between pipe ends, Only) exists at the 12-inch Dresser (02-465A-LB) coupling.

Lube Oil Lines -

Modifications Addition / modification of supports.

External-Tubing, Refer to DR/QR report 02-465C Fittings, Coupling for details.

O' (Small Bore Scope Only)

(02-465A-SB)

Lube Oil Lines Unlimited Life None External - Valves (02-4658)

Lube Oil Lines There are no supports for this component.

No design External-Supports review is required.

l (Large Bore Scope Only)

(02-465C-LB)

Lube Oil Lines Modifications Addition / modification of supports.

External-Supports Refer to DR/QR report 02-465C-SB l

(Small Bore for details.

Scope Only)

(02-465C-SB)

Turbocharger -

Modifications Replace 2 -inch Dresser couplings Lube Oil Fitting-(located between the turbocharger Piping (Large and lube oil sump tank for both l

Bore Scope Only) drain lines) with 2 -inch 150 (02-467A-LB) lb. S.O. flanges with A307 bolts.

O PE3294 3-6 REV. 1

~ - - - -

Component

&ceptability Recommended Action Crankshaft &

Unlimited Life Additional maintenance recommend-Bearings:

Thrust ations.

Bearing Ring (02-310C)

Crankcase:

Unlimited Life Additional maintenance recommend-Crankcase Assembly ations.

Additional Quality (02-311A) inspections recommended.

Crankcase:

Unlimited Life None Crankcase Mounting Hardware (02-3110)

Crankcase:

Crank-Unlimited Life Additional Quality inspections case Gaskets and recommended.

Mounting Hardware (02-3868)

CYLINDER BLOCK, LINERS & WATER MANIFOLD Cylinder Block Unlimited Life Implementation of routine inspections (02-315A) recommended. Perform cylinder liner /

I w

block bore dimensional check. Addi-tioral Quality inspections reconnenderi.

Cylinder Block Unlimited Life Additional maintenance recommend-Liners & Water ations.

Additional Quality Manifold -

inspections recommended.

Cylinder Liner (02-315C)

Jacket Water Unlimited Life None Manifold Piping l

(Large Bore l

Scope Only)

(02-3150)

Cylinder Block Unlimited Life The installation torque should Liners & Water be changed to lower the stresses Manifold:

Studs in the cylinder block.

Additional (02-315E)

Quality inspections recommended.

PE3294 3-10 REV. 1

eg Component Acceptability Recommended Action

(

)

Starting Air Modifications Additional maintenance Manifold: Valves, recommendations.

Addition Strainers, & Filters of free flowing drains to the (02-441B) air distributor filter.

Starting Air Unlimited Life None Manifold -

Supports (Large Bore Scope Only)

(02-441C-LB)

Starting Air Modifications Addition / modification of supports.

Manifold - Supports Refer to DR/QR report 02-441C-SB (Small Bore for details.

Scope Only)

(02-441C-SB)

Barring Device-Unlimited Life Additional maintenance Pneumatic Regulator recommendations.

Valve / Shutoff Valve (02-5258)

Starting Air Tank Unlimited Life Additional maintenance (02-8358) recommendations.

7_

Air Start Tank Unlimited Life None Relief Valves (02-835E)

CONNECTING RODS Connecting Rods:

Unlimited Life Additional maintenance recommend-Rods and Bushings ations.

Additional Quality (02-340A) inspections recommended.

Connecting Rods:

Unlimited Life Additional maintenance recommend-Bearing Shells ations.

Additional Quality (02-3408)

Revalidation inspections recommended.

l l

PISTONS Pistons Unlimited Life Additional Quality inspections (02-341A) rect uended.

1 Pistons:

Rings Unlimited Life Additional maintenance recommend-(02-3418) ations.

Additional Quality Revalidation inspections re-commended.

O PE3294 3-12 REV 1

h How To Use This Report Tabs in this report identify the following categories:

Turbo, Intake, Intercooler & Exhaust Lube Oil i

Engine Base & Bearing Caps Crankshaft & Bearings Cylinder Block, Liners & Water Manifold Air Start & Barring Device i

Connecting rods Pistons Camshaft & Valve Train i

Idler Gear Assembly & Front Gear Case.

Flywheel 4

f Engine Instrumentation & Wiring i

Overspeed Trip & Governor Engine Shutdown & Equipment Jacket Water i

Cylinder Heads & Valves Fuel Oil Injection

+

Generator Control Panel Assembly Engine & Auxiliary Sub-Base & Foundation Bolts 4

These categories have been defined to allow the reader to review a complete i

diesel generator subsystem in a cor.venient manner.

i j

Within each category tabs identify Perry specific component numbers.

4 A given component report can be found by:

a)

If the component number is known - use the alpha - numberic index which identifies the volume number and category in which the compon-ent report is located.

b)

If only the component name is known - Section 3.2 may be used as a i

cross reference to find the volume number where the component report may be found.

Some reports address more than one component.

a tat' is provided for each component.

However, some components are combined under one report.

Slip sheets are provided where required to reference back to the appropriate tab.

j Some components required more than one report.

These are identified by the abbreviation LB-Large Bore and SB-Small Bore on the component number tabs.

i PE3375

- - ~.

INDEX (continued)

Component Component Volume Number Description Category No.

F-068 Intercooler Turbo, Intake 2

Intrcir. & Exhaust MP022/23 Turbocharger Turbo, Intake, 2

Intrcir. & Exhaust 00-420 Lube Oil Pressure Lube Oil 2

Regulating Valve 00-442A Starting Air Distributor:

Air Start &

3 Distributor Assembly Barring Device 00-442B Starting Air Distributor:

Air Start &

3 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drip Tank Fuel Oil 4

Assembly Injection 02-CFR Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrc1r. & Ex-haust 02-305A Base and Bearing Caps: Base Engine Base 2

Assembly

& Bearing Caps 02-305C Base and Bearing Caps:

Engine Base 2

Main Bearing Studs & Nuts

& Bearing Caps 02-305D Base and Bearing Caps:

Engine Base 2

Main Bearirig Caps

& Bearing Caps 02-307A Lube Oil Fittings:

Lube Oil 2

Internal - Headers 02-3078 Lube Oil Fittings:

Lube Oil 2

Internal - Tube & Fittings 02-307D Lube Oil Fittings Internal:

Lube Oil 2

Supports 4

02-310A Crankshaft Crankshaft &

2 Bearings 02-3108 Main Bearings Crankshaft &

2 l

Bearing O

Rev. 1 4

II Entire page revised PE3375

l INDEX (continued)

Component Component Volume Number Description Category No.

02-310C Crankshaft & Bearings:

Crankshaft &

2 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy Crankshaft &

2 Bearing 02-311D Crankcase: Crankcase Crankshaft &

2 Mounting Hardware Bearings 02-315A Cylinder Block Cyl. Block &

2 Liners & Water Manifold 02-315C Cylinder Block Liners &

Cyl. Block &

2 Water Manifold -

Liners &

Cylinder Liner Water Manifold 02-315D Cylinder Block Liners &

Cyl. Block &

2 Jacket Water Manifold Liners &

& Piping Water Manifold O

02-315E Cylinder Block Liners &

Cyl. Block &

2 Water Manifold: Studs Liners &

Water Manifold 02-315F Cylinder Block Liners Cyl. Block &

2

& Water Manifold:

Liner & Water Cylinder Head Nuts Manifold 02-315G Cylinder Block Liners &

Cyl. Block &

2 Water Manifold: Seals &

Liners &

Gaskets Water Manifold 02-316A Jacket Water Inlet Manifold:

Jacket Water 4

Manifold Assembly W/ Hardware and Coupling and Gaskets 02-316B Jacket Water Inlet Manifold:

Jacket Water 4

Coupling and Gaskets 02-316C Jacket Water Inlet Manifold:

Jacket Water 4

Vent line to Discharge Manifold 02-317A Water Discharge Manifold:

Jacket Water 4

Jacket Water Discharge Manifold / Piping 999 Rev. 1 Entire page revised PE3375

[ f;y INDEX (continued) b Component Component Volume Number Description Category No.

02-317B Water Dicharge Manifold:

Jacket Water 4

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Water 4

Supports 02-330A Flywheel Flywheel 3

02-3308 Flywheel - Bolting Flywheel 3

02-335B Front Gearcase - Gaskets Idler Gear As-3 and Bolting sembly & Front Gear Case 02-340A Cor.aecting Rods:

Connecting Connecting 3

Rods & Bushings Rods 02-340B Connecting Rod Bearing Connecting 3

Shells Rods 02-341A Pistons Pistons 3

02-341B Pistons: Rings Pistons 3

02-341C Piston Pin Ass 2..y Pistons 3

02-345A Tappet's and Guides:

Intake Camshaft &

3

& Exhaust Tappet Assembly Valve Train 02-345B Tappets and Guides: Fuel Camshaft &

3 Tappet Assembly Valve Train 02-345C Tappets and Guides: Fuel Camshaft &

3 Pump Base Assembly Valve Train 02-350A Camshaft:

Camshaft Camshaft &

3 Assembly Valve Train 02-350B Camshaft:

Camshaft Camshaft &

3 Bearing Valve Train 02-350C Camshaft: Supports, Bolting Camshaft &

3 and Gear Valve Train 02-355A Idler Gear Assembly Crank Idler Gear As-3 To Pump Gear sembly & Front

)

Gear Case (d

$y Rev. 1 Entire page revised PE3375

p INDEX (continued)

V Component Component Volume Number Description Category No.

02-355B Idler Gear Assembly:

Idler Gear As-3

!dler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valve Air Start &

3 Barring Device 02-360A Cylinder Heads Cylinder Heads 4

& Valves 02-3608 Cylinder Head Valves:

Cylinder Heads 4

Intake & Exhaust Valves

& Valves 02-360C Cylinder Head and Valves:

Cylinder Heads 4

Bolting and Gaskets

& Valves 02-3600 Cylinder Head Cylinder Heads 4

& Valves:

Springs

& Valves 02-362A Subcover Camshaft &

3 Valve Train 02-365A Fuel Injection Pump Fuel Oil In-4 jection 02-365B Fuel Injection Equipment -

Fuel Oil In-4 Fuel Injection Tips jection 02-365C Fuel Injection Equipment -

Fuel Oil In-4 Tube Assembly jection 02-365D Fuel Injection Equipment:

Fuel Oil In-4 Supports jection 02-371A Fuel Pump Linkage: Fuel Fuel Oil In-4 Pump Control Shaft jection 02-371B Fuel Pump Linkage: Linkage Fuel Oil In-4 Assembly and Bearing jection 02-375 Intake Manifold and Turbo, Intake, 2

Piping Intrcir. & Ex-haust 02-380A Exhaust Manifold Turbo, Intake, 2

Intrcir. & Ex-haust Rev. 1 V

Entire page revised PE3375

INDEX (continued)

Component Component Volume Number Description Category No.

02-380B Exhaust Manifold:

Gasket Turbo, Intake.

2 and Bolting Intrcir. & Ex-haust 02-3858 Cylinder Block Covers:

Cyl. Block &

2 Gaskets and Bolting Liners & Water Manifold 02-3868 Crankcase:

Crankcase Crankshaft &

2 Gaskets and Mounting Bearings Hardware 02-390A Intake & Intermediate and Camshaft &

3 Exhaust Rocker Shaft Assembly Valve Train 02-3908 Rocker Arms and Pushrods:

Camshaft &

3 Exhaust Rocker Shaft Valve Train Assembly 02-390C Main and Connector Camshaft &

3 Pushrods Valve Train 02-3900 Rocker Arms and Pushrods:

Camshaft &

3 Pushrods Connector.

Valve Train 02-390E Rocker Arms and Pushrods:

Camshaft &

3 Bushings Valve Train 02-390F Rocker Arms and Pushrods:

Camshaft &

3 Lifters Valve Train i

02-390G

' Rocker Arms and Pushrods:

Camshaft &

3 Misc. Bolts & Drive Studs Valve Train i

~

02-410A Overspeed Trip Governor Overspeed Trip 3

& Governor 02-410B Overspeed Trip: Governor Overspeed Trip 3

and Accessory Drive Assembly

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 3

& Governor 02-410D Overspeed Trip Vent Valve Overspeed Trip 3

& Governor O

Rev. 1 Entire page revised PE3375 m._

INDEX (continued)

Component Component Volume Number Description Category No.

02-411A Governor Drive:

Governor &

Overspeed Trip 3

Tachometer Drive Gear and

& Governor Shaft 02-411B Governor Drive: Couplings, Overspeed Trip 3

Pins & Keys

& Governor 02-413A Governor Linkage Overspeed Trip 3

& Governor 02-4138 Fuel Pump Linkage:

Fuel Oil Injection 4

Automatic Shutdown Cylinder 02-415A Governor Assembly: Woodward Overspeed Trip 3

Governor

& Governor 02-415B Governor Assembly -

Overspeed Trip 3

Booster Servomotor

& Governor 02-415C Governor Assembly -

Overspeed Trip 3

O i

Heat Exchancer

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425A Engine Driven Jacket Water 4

Jacket Water Pump 02-435A-Jacket Water Fittings:

Jacket Water 4

Pipe & Fittings 02-435B Jacket Water Fittings -

Jacket Water 4

Supports 02-435C Jacket Water Inlet Jacket Water 4

Fittings - Valves 02-436A Intercooler Piping Turbo, Intake 2

Intercooler

& Exhaust 02-4368 Intercooler Piping Turbo, Intake 2

Coupling, Gaskets, Intercooler &

Bolting Exhaust

~

{s~ 'l\\

4 1

Rev. 1 vii Entire page revised PE3375

9 OQ INDEX (continued)

Component Component Volume Number Description Category No.02-437 Turbo Water Piping:

Jacket Water 4

Pipe & Fittings 02-441A Starting Air Manifold:

Air Start &

3 Piping, Tubing and Fitting Barring Device 02-441B Starting Air Manifold Air Start &

3 Valves, Filters & Strainer Barring Device 02-441C Starting Air Manifold:

Air Start &

3 Supports Barring Device 02-445 Fuel Oil Booster Pump Fuel Oil In-4 jection 02-450A Fuel Oil Header:

Fuel Oil In-4 Piping / Tubing jection 02-450B Fuel Oil Header:

Fuel Fuel Oil In-4 011 Supports jection 02-455A Fuel Oil Filters &

Fuel Oil In-4 Strainers: Filters jection 02-455B Fuel Oil Filters &

Fuel Oil In-4 Strainers:

Strainers jection 02-455C Fuel Oil Filters &

Fuel Oil In-4 Strainer: Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fittings, Couplings 02-465B Lube Oil Lines - External Lube Oil 2

Valves 02-465C Lube Oil Lines Lube Oil 2

External Supports 02-467A Turbocharger: Lube Oil Lube Oil 2

Fitting - Pipe, Tubing, Fittings & Flexible Coupling 02-467B Turbocharger: Lube Oil Lube Oil 2

Fittings - Supports O

viii Rev. 1 Entire page revised PE3375

(]

INDEX (continued)

V Component Component-Volume Number Description Category No.

02-475A Turbocharger: Bracket Turbo, Intake, 2

Bolting and Gaskets Intrcir. & Ex-haust 02-475B Air Butterfly Valve Turbo, Intake.

2 Assembly Intrcir. & Ex-haust 02-475C Turbocharger: Bracket -

Turbo, Intake, 2

Bolting & Gaskets Intrcir. & Ex-haust 02-500A Control Panel Assembly Control Panel 4

Cabinet / System Assembly 02-500F Control Panel Assembly Control Panel 4

Accuraulator Assembly i

02-500G Control Panel Control Panel 4

Valves Assembly b

02-500H Control Panel Assembly Control Panel 4

V Pressure Switch Assembly 02-500I Control Panel Assembly:

Control Panel 4

Control Relays Assembly 02-500J Control Panel Assembly:

Control Panel 4

Solennid Valves Assembly 02-500L Control Panel Assembly -

Control Panel 4

Piping, Tubing, Fittings Assembly 02-500M Control Panel Assembly:

Control Panel 4

Terminal Boards / Switches /

Assembly Wiring 02-525B Barring Device - Pneumatic:

Air Start &

3 Regulator Valve / Shut Off Barring Device Valve 02-525D Barring Device - Pneumatic:

Air Start &

3 Mounting Bracket / Supports Barring Device 02-540A Lube Oil Sump Lube Oil 2

with Strainer Assembly O

and Mounting Hardware ix Rev. 1 PE3375 n

e page re h

(S INDEX (continued)

N -]

Component Component Volume Number Description Category No.

02-5408 Lube Oil Sump Tank: Misc.

Lube Oil 2

Fittings, Gaskets, Pipe

& Bolting Material, Valves 02-540C Lube Oil Sump Tank:

Lube Oil 2

Mounting liardware 02-550 Foundation Bolts:

Engine & Aux.

4 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly:

Engine Instru-3 Conduit mentation &

Wiring 02-630B Pyrometer Cor.duit Assembly:

Engine Instru-3 Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly:

Engine Instru-3

,7-~gj Support mentation &

\\s Wiring 02-6300 Pyrometer Conduit Assembly Engine Instu-3 Thermocouple mentation &

Wiring 02-650A Emergency Diesel Generator Generator 4

02-650B Generator Generator 4

Control 02-650C Generator-Shaft & Bearing Generator 4

02-688A Engine & Aux Module Engine Instru-3 Wiring Material-Conduit mentation &

& Fittings; Pyrometer Wiring Assembly - Conduit, Fitting, Supports 02-6888 Engine & Aux.

Engine Instru-3 Module Wiring Material:

mentation &

Wiring & Terminations Wiring O

x Rev. 1 Entire page revised PE3375

,.--.-w,

p INDEX (continued)

~V Component Component Volume Number Description Category No.

02-688C Engine & Aux. Module Wiring Engine Instu-3 Material: Boxes & Terminals mentation &

Wiring

.02-689 Off-Engine Alarm Sensors Engine Instru-3 mentation &

Wiring 02-690 Engine Alarm Sensors -

Engine Instru-3 Temperature & Level mentation &

Switches Wiring 02-691 Off Engine Safety Alarm Engine Instru-3 Sensors - Level &

mentation &

Pressure Switches Wiring 02-695A Engine Shutdown Engine Shut-3 Equipment:

down & Equip-Tubing / Fittings &

ment Supports Os 02-695B Engine Shutdown Engine Shut-3 Equipment:

Valves, down & Equip-Regulator, Orifices ment 02-695C Engine Shutdown Trip Engine Shut-3 Switches down & Equip-ment 02-700A Jacket Water Standpipe:

Jacket Water 4

Pipe, Fittings, Gaskets 02-700B Jacket Water Standpipe:

Jacket Water 4

Valves 02-700C Jacket Water Standpipe:

Jacket Water 4

Pipe Supports 02-700E Jacket Water Standpipe:

Jacket Water 4

Switches 02-700F Jacket Water Standpipe Jacket Water 4

l

& Misc. Bolting 02-717A Auxiliary Skid Jacket Water 4

(D

'w)

Rev. 1 xi Entire page revised PE3375

p INDEX (continued)

V Component Component Volume Number Description Category No.

02-717B Aux Sub Base & 011 &

Jacket Water 4

Water Piping - Jacket Water:

Valves 02-717C Aux Sub Base & 011 & Water Engine & Aux.

4 Water Piping - Jacket Sub Base &

Water:

Pipe, Couplings, Foundation Bolts Fittings, Orifices, Y-Strainers 02-7170 Aux Sub Base & Oil & Water Jacket Water 4

Piping - Jacket Water:

Gaskets & Bolting 02-717E Aux Sub Base & 011 & Water Jacket Water 4

Piping - Jacket Water:

Supports 02-717F Aux. Sub Base & 011 & Water Lube Oil 2

Piping - Lube Oil:

Pipe and Fittings 02-717G Aux Sub Base & 011 & Water Lube Oil 2

Piping - Lube Oil:

Valves 02-717H Aux. Sub-Base & 011 & Water Lube Oil 2

Piping - Lube 011:

Gaskets & Bolting 02-717I Aux Sub Base & Oil & Water Lube Oil 2

Piping - Lube Oil:

Supports & Mounting Hardware 02-717J Aux Sub Base & 011 & Water Fuel Oil 2

Piping - Fuel Oil - Piping

& Fittings 02-717K Aux Sub Base & 011 & Water Fuel Oil 4

Piping - Fuel 011:

Valves Injection 02-717L Aux Sub Base & Oil & Water Fuel Oil 4

Piping - Fuel Oil -

Injection Gaskets & Bolting xii Rev. 1 Entire page revised PE3375

-)

p INDEX (continued)

V Compenent Component Volume Number Description Category No.

02-717M Aux Sub Base & 011 & Water Fuel Oil 4

Piping - Fuel Oil:

Injection Supports 02-805A Intake Air Silencer Turbo, Intake, 2

Intercooler &

Exhaust 02-805B Intake Air Filter Turbo, Intake, 2

Intercooler &

Exhaust 02-805D Flex Connections Turbo, Intake, 2

Intercooler &

Exhaust 02-810A Jacket Water Standby Jacket Water 4

Heater Pump 02-810B Jacket Water Heat Exchanger Jacket Water 4

02-810C Thermostatic Valve Jacket Water 4

02-8100 Misc. Equipment - Heater, Jacket Water 4

Jacket Water 02-820A Misc. Equipment - Heater, Lube Oil 2

Lube Oil Sump Tank 02-820B Before & After Lube Oil Lube Oil 2

Pump 02-820C Lube Oil Full Pressure Lube Oil 2

Strainer 02-8200 Lube Oil System - Lube Oil Lube Oil 2

Keepwarm Strainer 02-820E 011 Prelube Filter Lube Oil 2

02-820F Full Flow Lube Oil Filter Lube Oil 2

02-820G Lube Oil Heat Exchanger Lube Oil 2

02-825A Fuel Oil Day Tank Fuel Oil 4

Injection O

xiii Rev. 1 PE3375

1 INDEX (continued)

Component ' Component Volume Number Description Category No.

02-825D Fuel Oil System - Fuel Fuel Oil 4

1 011 Duplex Strainer Injection 02-8358 Starting Air Tank Air Start &

3 Barring Device 02-835E Misc. Equipment - Starting Air Start &

3 Air Tank Relief Valve Barring Device i -

i i

O i

i a

L 3

8

O Rev. 1 PE3375

fN Page 1 of 4 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Turbocharger-Bracket:

COMPONENT Bolting and Gaskets UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO.

02-475A,C TASK DESCRIPTION NO. DR-03-02-475A,C-1 SNPS GPL NO.

03-475A,0 CLASSIFICATION TYPE B

TASK OESCRIPTIONS Design review for these components is not required based on a review of the following:

The Comanche Peak lead engine DR/QR report (Ref.1).

TDI Parts Manuals, Volume II for Perry and Comanche Peak Power Stations (Refs. 2 and 3).

L TDI drawings (Ref. 4).

G The EDG Component Tracking System for applicable industry and site experience (Refs. 5 and 6).

Nuclear and non-nuclear experience identifies a few incidents of broken welds on fabricated items or piping supported by the turbocharger bracket; such events were caused by loosened or broken turbocharger hold-down bolts, all resulting from engine vibration.

To prevent recurrence of similar events, verification of the torque values applied to the turbocharger hold-aown bolts and the bracket mounting bolts during installation is required.

The Comanche Peak lead engine DR/QR report indicates that the pipe thermal loads, along with the engine vibration loads, are the most significant loads experienced by the brackets and the mounting bolts.

The design of the water jacketed,. multi pipe, exhaust manifold connecting the cylinders to each turbocharger is identical for botn stations.

The adapter piece (transitional piece) at the turbocharger exhaust connection and its expansion joint is similarily designed, though the dimensions are different.

The thermal loads experienced by the turbocharger brackets and the associated mounting hardware for both stations should therefore remain similar.

Review of the amplified response acceleration spectra curves for Perry Station (Ref. 7) indicates that the seismic loadings are more favorable than those at the Comanche Peak Station.

O PE3234/1

q COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 4

/

DR-03-02-475A,C-1 TASK DESCRIPTIONS (continued)

Based on the above review the turbocharger brackets at Perry should be adequate to resist the seismic.nertia loads, deadweight, thermal loads, and engine vibration loads.

Similarly, the 3/4 in. capscrews (12 screws for each bracket) attaching the bracket to the engine block should be satisfactory; however, based on the DR/QR report for Comanche Peak Station, the review of the turbochager bracket and bolting finds that in the worst case load condition, vibration and manifold nozzle loads could potentially produce bolt loads in excess of preloads.

Therefore, the bracket to engine and bracket to turbo base screws (P.N. GB-001-143 and GB-001-120) are recommended to be inspected on a regular basis as discussed below:

Each month for the first three months of commercial operation these screws should be inspected to assure that no screw has loosened because of engine operating loads.

If during these inspections none of the screws are found loosened or damaged, from then on-1 inspections are to be conducted on a yearly basis (or during plant shutdown).

But if any time durir.g inspection any screw is found loosened or damaged, it must then be replaced (if damaged) and all screws retorqued as follows; 125 ft-lbs for the bracket to engine screws and 75 ft-lbs for the bracket to turbo base screws.

h To avoid damage to bracket to engine, and/or bracket to turbo, base screws, V

the proper torques as delinated above should be utilized for each respective bracket bolting application.

There are no modification recommendations for these components.

The following inspections as described in the Component Quality Revalidation Checklist for Component No. 02-475C should be performed on both engines:

Verification of compliance to the TDI Instruction Manual for bolt torque loads applied to the bolted connections through review of existing documentation.

Visual inspection to verify proper installation of the bracket bolting.

Verification of the material of the bracket-to-engine bolting.

PRIMARY FUNCTION Not required OV PE3234/2 REV. 1 j

N COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 4 (A.

DR-03-02-475A,C-1 ATTRIBUTE TO BE VERIFIED Not required i

I 4-i SPECIFIED STANDARDS I

Not required 1-

-REFERENCES 1.

Comanche Peak Steam Electric Station - Unit 1, DR/QR Report for Group Parts List No. 02-475A and C.

l 2.

TDI Manual Volume II, for Model DSRV-16-4 Diesel Engine / Generator, Perry Nuclear Power Plant, Units 1 and 2, Parts List No. 02-475-22-02, Rev. 3, dated October 22,

1979, and Drawing 02-475-22, Rev.

B, dated February 9, 1978.

3.

TDI Manual Volume II for Model DSRV-16-4 Diesel Engine / Generator, O.

Comanche Peak Steam Electric ' Station Unit 1,

Parts List No.

02-475-22-02, Rev. C.

4.

TDI Drawings Drawing No.

Description 02-475 22-AL Bar Support Outer 02-475-22-AK Bar Support Inner 02-475-21-AD Adapter, Intercooler Inlet - Right Bank 02-475-21-AE Adapter, Intercooler Inlet Left Bank 02-475-21-AF Bracket, Turbo G Rig 5t Bank 02-475-21-AG Bracket, Turbo G Left Bank 02-475-22-AA Adapter, Intercooler Outlet - Right Bank 02-475-22-AB Adapter, Intercooler Outlet - Left Bank 5.

Emergency Diesel Generator Component Tracking System Nuclear and Non-nuclear Industry Experience dated November 5, 19d4.

6.

Emergency Diesel Generator Component Tracking System Perry Nuclear Power Station dated November 5, 1984.

7.

Gilbert Associates, Inc.,

Specification SP-562-4549-00 for Class 1E Diesel Generator Units, Rev.

II dated January 11, 1977, Attachment Specification for Seismic Analysis, Testing, and Documentation, Perry O

Nuclear-Pcwer Station Units 1

and 2,

SP-750-4549-00, dated August 30, 1973.

REV. 1

-PE3234/3 CARRY 0VER FROM PREVIOUS PAGE

COMPONENT DESIGN REVIEW CHECKLIST Page 4 of 4 DR-03-02-475A,C-1 DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON b be PROGRAM MANAGER M mm

[JC /.

O i

i i

O REV. 1 CARRY 0VER FROM PE3234/4 PREVIOUS PAGE l'

=_

e Page 1 of 2 j

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Engine Driven COMPONENT Lube Oil Pump UTILITY Cleveland Electric Illuminating Company i

GROUP PARTS LIST NO.02-420 TASK DESCRIPTION NO. DR-03-02-420-1 i

SNPS GPL NO.03-420 CLASSIFICATION TYPE A

i 1-TASK DESCRIPTIONS I

Design review far this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there i

was no.significant applicable industry experience, except that previously addressed in the lead engine report.

There was no site experience listed in the Component Tracking System.

A review of the lead engine DR/QR report for Comanche Peak.

Similarity of the Perry component to the lead engine component.

Both are IMO Model 8JK-4570.

l There are no maintenance recommendations for this component as a result of lead I

engine design review.

f It is recommended that 'a Dresser coupling be added on the pump suction line to mitigate the thermal ' expansion loading and stresses on the pump inlet nozzle.

The coupling. should be located between the relief valve branch connection and i

the pump inlet nozzle.

Quality revalidation is not deemed necessary for this component.

i-

' PRIMARY FUNCTION

'Not required ATTRIBUTE TO BE VERIFIED Not required PE3230/1 REV. I

.~. -

A Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Before & After COMPONENT Lube Oil Pump UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO.

02-8208 TASK DESCRIPTION NO. DR-03-02-820B-1 SNPS GPL NO.10-113 CLASSIFICATION TYPE A

TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that'there was no significant applicable industry and site experience, except that already addressed in the lead engine report.

A review of the lead engine DR/QR report (Comanche Peak).

The before and after lube oil pump at Perry is the same as the w.)

component in the lead engine.

A review of pump nozzle loads indicates that the applied piping loads are above the manufacturer's recommended allowables.

There has however been no experience of pump leakage due to these loads at Comanche Peak or other V-16 1

installations.

As such, the following inspection should be performed as part of the daily engine walkdown:

The pump should be inspected for signs of leakage and corrective modifications (addition of flexible piping connections) be implemented as required.

There are no modifications required based on the lead engine report.

Quality revalidation is not required for this component.

PRIMARY FUNCTION Not required 4

O v

PE3227/1 REV. 1

p COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 V

DR-03-02-8208-1 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS I

Not required REFERENCES Not required 4

DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON

./ j

- PROGRAM MANAGER c) C \\4 m - w.

h[h O

i 1

5 O

REV. 1 CARRYOVER FROM PE3227/2 PREVIOUS PAGE

(V)

TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 CYLINDER BLOCK COMPONENT PART NO. 02-315A I

INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of the cylinder blocks to determine the adequacy of design for the intended use at Perry.

The blocks are manufactured by TDI and are supplied under their part number 02-315-03-AE.

The cylinder block forms the framework of the liquid cooled engine and provides passage for coolant and support for the cylinder liners and cylinder heads.

II OBJECTIVE The objective of this review was to evaluate the structural adequacy of the cylinder block for its intended use at Perry Nuclear Power Plant.

III METHODOLOGY In order to meet the stated objective, the following methods were used:

Evaluation of steady state stresses, alternating stresses and stiff-ness in key portions for the cylinder block.

Review of engine operating experience.

Review of engine operating conditions at Perry and identification of any differences from those at Comanche Peak.

Review of metallurgical / microstructure analysis of cylinder block material.

1 Performance of dimensional check and evaluation of liner / block l

interaction.

Evaluation of crack growth rate for cylinder block landing and counterbore diameter by comparison with conservative Shoreham data and analysis.

Review of liquid penetrant inspections of Perry OSRV-16-41A and 18 engine blocks.

Review of Perry site, nuclear and non-nuclear experiences (see Appendix C).

\\-

Review of Quality Revalidation Checklist results for acceptability.

PE3237/1 REV. 1

. ~ -..

A IV

-RESULTS AND CONCLUSIONS l

A generic investigation of the structural adequacy of the TDI R-4 and

{

RV-4 series diesel engine cylinder blocks for emergency standby service in nuclear power plants is summarized in Reference 1.

The investigation 1

i considers the cause, extent, and consequences of cylinder block cracking, and the inspections required to assure a sufficient margin of safety i

during continued operation under test and postulated accident l

conditions.

Evaluation of !.t.nady state stresses, alternating stresses and stiffness in j

key portions of the cylinder block was accomplished as part of the strain gage testing at Shoreham and the results were included in the cumulative

?

damage and crack growth analyses (Ref. 1).

1 1

Diesel generators 1A and 1B have had limited operational experience.

Engine hours of operation accumulated to date consist of factory test hours performed by TDI.

l The engine operating conditions at Perry were compared to those at f

Comanche Peak and Shoreham.

No significant differences were found that would affect the structural integrity assessment of the Perry blocks.

{

It is recommended that liner bore and mating block dimensions be checked in order to evaluate the interaction of the block and liner.

These i

results are utilized in applying the cumulative damage methodology outlined in Figure 5-1 of Reference 1.

For the purpose of analyzing the 1

steady state and alternating stresses present, cylinder liner / block bore interaction "is assumed similar to that present at Shoreham.

This assumption must be verified prior to the next emergency standby for engines 1A and 18.

l The power output for this engine is 7000 kW at 100 percent load. Maximum output required for LOOP /LOCA is 4460 kW (Ref. 2).

The duration of a 1

LOOP /LOCA used in this analysis is 168 hours0.00194 days <br />0.0467 hours <br />2.777778e-4 weeks <br />6.3924e-5 months <br />.

Strain gage testing of the original Shoreham EDG 103 block, inspecticn data from before and after extensive test operation, and materials testing were used as a basis to predict adequate life for cylinder blocks.

The rate of propagation of cracks between stud holes during operation 1

of the original Shoreham EDG 103 block, when compared with the Perry LOOP /

LOCA requirements, indicates that even if the Perry blocks had ligament 1

cracks they are predicted to withstand with sufficient margin a LOOP /LOCA 1

event.

To date, no inspection results for Engine 1A and 18 block tops have been reported.

With no block top inspection results, application of the cumulative damage analysis, Figures 5-1 and 5-3 of Reference 1, shows that continued operation is acceptable provided that:

O PE3237/2 REV. 1

O Page 3 of 4 O

a.

Cylinder liner / block bore dimensions are satisfactory.

b.

Inspections show that no stud-to-stud or stud-to-end cracks are present either between the cylinder heads or at the end of the block whenever the engine is placed into emergency standby service af ter any operation greater than 50 percent nameplate load.

If cracks are found, further inspection must demonstrate that tne cracks are less than 1.5 inches deep before returning the engine to standby status.

Alternatively, it is recommended that when the engines are disassembled for the cylinder liner / block bore dimensional inspection, the block tops be inspected for cracks.

Then, application of the cumulative damage analysis, Figure 5-1 of Reference 1, shows that continued engine operation without inspection is justified for 572 hours0.00662 days <br />0.159 hours <br />9.457672e-4 weeks <br />2.17646e-4 months <br /> at 100 percent power level (or variable power operation resulting in equivalent cumulative damage) with sufficient margin remaining for LOOP /LOCA event (Reference 2) a provided that:

a.

Inspections show that block tops are without detectable block top cracks.

b.

Cylinder liner / block bore dimensions are satisfactory.

1 Engine operation in excess of the above listed time periods without

. (m) repeated inspection is justified so long as the fatigue damage index 4

d since the last complete block top inspection does not exceed the allowable fatigue damage index based upon the last complete inspection.

In the future this process may be repeated, and additional engine operation without repeated inspection may continue until the additional fatigue damage index equals the allowable fatigue damage index establish-ed by the last complete inspection which showed no cracking.

Optionally, in the future after additional engine operation without repeated inspection has accumulated fatigue damage index which exceeds the allowable fatigue damage index, engine operation can continue without removal of cylinder heads and maintain sufficient margin' to withstand a LOOP /LOCA event provided repeated eddy current inspections described in Figure 5-1 of Reference 1 are performed between the cylinder heads and adjacent to the cylinder heads at the ends of the blocks.

The information provided on TER 03-004 has been reviewed and is consistent with the final conclusions of this report.

O PE3237/3 REV. 1

A Page 4 of 4 U

Quality havalidation Inspection results identified in Appendix B have been reviewed and considered in the performance of this design review, and the results are consistent with the final conclusions of this report.

Based on the above review, subsequent completion and review of block top inspections, and cylinder liner / block bore dimensional check as identified i

in Appendix B for Engines lA and 1B, and implementation of inspections, it is concluded that the cylinder blocks are acceptable for their intended use at Perry.

IV REFERENCES 1.

Design Review of TDI-R4 and RV-4 Series Emergency Diesel Generator Cylinder Blocks FaAA-84-9-11.1.

2.

Letter from E. C. Christiansen (Perry Nuclear Power Plant) to C. L.

I Ray, Jr. (TOI Owners Group), dated 7/23/84.

3.

FaAA Support Package Number SP-84-6-12(i).

O A

O PE3237/4 REV. 1

O Appendix B Page B1 of 6 (j

03-02-315A COMPONENT QUALITY REVALIDATION CHECKLIST Cleveland Electric Illuminating Co.

COMPONENT Cylinder Block UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO.

02-315A REV. NO.

1 SNPS GPL NO.

03-315A TASK DESCRIPTIONS Engine 1A 1.

Assemble and review existing documentation.

2.

Perform a dimensional check on the area arcund the cylinder liner for all cylinder block liner landings.

3.

Perform a Liquid Penetrant test or Magnetic Particle test on the

,\\

cylinder block liner landing along the top landing surface, fillet radius, and vertical face adjacent to the landing surface.

Liner s

landings 3L, 4L, SL, 6L and 3R, 4R, SR, 6R should be inspected with the liners removed.

If linear indications are found, increase inspection plan to all liner landings.

4.

Perform a Liquid Penetrant test or Magnetic Particle test on the cylinder head mating surface on top of the cylinder block.

The area between stud hole and liner, and between adjacent cylinder stud hole should be inspected.

The inspection plan should include cylinders 3L, 4L, SL, 6L and 3R, 4R, SR and 6R.

If linear indications are found, increase inspection plan to all cylinders.

5.

Perform an Eddy Current test on the cylinder head stud holes if required (i.e. linear indications found at stud hole extending into threads).

6.

Remove a sample from each cylinder block by drilling and cutting.

The samples shall be tetrahedral in shape with a one inch square base and a height of 5/8 inch.

a tachment B shows the locations where the samples should be taken.

O PE2634/1

/)

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 6

(,/

03-02-315A TASK DESCRIPTIONS (continued)

Engine 18 Same as Engine 1A ATTRIBUTES TO BE VERIFIED Enaine 1A 1.

Quality status of Component Document Package 2.

Dimensions of the cylinder block liner landing area 5.

Surface integrity of the cylinder block liner landing 6.

Samples are taken from the cylinder block in accordance with TER

1. 99-016.

Engine IB

()

Same as Engine 1A 4

ACCEPTANCE CRITERIA Engine 1A 1.

Satisfactory Document Package 2.

Review of inspection report by Design Group 3-4.

See Attachment A 5-6.

Review of inspection report by the Design Group Engine 18 Same as Engine 1A i

O PE2634/2

(j3 COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 6

\\

03-02-315A REFERENCES Engine 1A 1.

QCI No. 52 2.

Approved Site NDE Procedures 3-4.

TER#s99-004, 99-018,99-036 5.

FaAA Procedure NDE 11.8 6.

TER #99-016,99-031 Engine 18 Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A 1.

Document Summary Sheet 2-6.

Inspection Report Engine IB Same as Engine 1A GROUP CHAIRPERSON # I' /w 7'

PROGRAM MANAGER, d % w m

~

/

f COMPONENT REVI Q Engine 1A 1.

No EDGCTS site experience documents are in evica. e.

O PE2634/3

/^

COMPONENT QUALITY REVALIDATION CHECKLIST Page B4 of 6 03-02-315A COMPONENT REVIEW (continued)

Engine 1A (continued) 2-5.

No inspection reparts have been received which fulfill these require ments.

6.

The block sample was forwarded to design for analysis.

The block was found to be typical Class 40 grey cast iron.

These results were reported by TER# 03-004.

Engine 1B Same as Engine 1A RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as out-lined above, is complete.

The results have been forwarded to the Design O

Review Group for their evaluation and conclusions in support of the final report.

Engine IB Same as Engine 1A GROUP CHAIRPERSON Mu7iE 8 bitII PROGRAM MANAGER,2 C W w su 1

O PE2634/4

Attachment A Page B5 of 6 COMPONENT QUALITY REVALIDATION CHECKLIST ACCEPTABLE CRITERIA A)

Area to be inspected 1.

Top of Block 2.

Liner counterbore B)

Reference Standard ASTM E125 C)

Evaluation of indications 1.

Relevant indications are:

a)

Hot tears and cracks, linear indications that exceed ASTM E125 Class I-2 b)

Shrink that exceeds ASTM E125 Class II-3 c)

Inclusions that exceed ASTM E125 Class III-3 d)

Porosity that exceeds ASTM E125 Class V-1 2.

All indications exceeding the specification listed above shall be documented and submitted to the Design Group.

3.

Indications that do not exceed the ASTM E125 reference regardless of size and quantity are acceptable.

D)

Non Relevant Indication 1.

The indications referenced below shall be considered non relevant.

a)

Magnetic writing b)

Linear grain boundaries (carbon, ferrite, or graphite induced) c)

Rounded grain boundaries (carbon, ferrite, or graphite induced)

O PE2634/5

t 5)

COMPONENT OUALITY REVALIDATION CHECKLIST l

i Page B6 of 6

,H 03-02-315A

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p Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Cylinder Block COMPONENT Covers: Gaskets & Bolts UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO 02-385B TASK DESCRIPTION NO.

DR-03-02-3858-1 SNPS GPL NO. 03-385B CLASSIFICATION TYPE C

TASK DESCRIPTIONS Design review for this component is not required based on a review of the lead engine DR/QR report (Comanche Peak) and the applicable site and industry experience.

There have been cases of fastener failures on the cylinder block covers, however these failures are not attributed to design deficiencies of this component.

Based on the lead engine DR/QR report, the recommended torque value of 30 ft-lbs is appropriate and the specified bolting and stud materials (SAE

/

GR 5 and SAE GR 1120 respectively) are acceptable for their intended function V) of holding the covers onto the cylinder block.

Isolated failures can occur when the torque is not applied properly or a lesser grade material is substi-tuted.

Barring any deviations as mentioned above the bolting is acceptable for use on the diesel engines.

There are no modification or maintenance recommendations for this component.

The following quality inspections are recommended to be performed on one engine:

Verify that the proper torque is applied and the specified material is installed.

Plant personnel should review site documentation or perform the necessary inspection to make these determinations.

Visually inspect gaskets for signs of elastomeric compound breakdown and cracking.

1 PRIMARY FUNCTION Not required

(/

PE3065/1 Rev. 1

h O

How To Use This Report Tabs in this report identify the following categories:

Turbo, Intake,.Intercooler & Exhaust Lube Oil Engine Base & Bearing Caps Crankshaft & Bearings-Cylinder Block, Liners & Water Manifold Air Start & Barring Device Connecting rods Pistons Camshaft & Valve Train Idler Gear Assembly & Front Gear Case Flywheel Engine Instrumentation & Wiring Overspeed Trip & Governor Engine Shutdown & Equipment Jacket Water Cylinder Heads & Valves Fuel Oil Injection Generator

)

Control Panel Assembly Engine & Auxiliary Sub-Base & Foundation Bolts These categories have been defined to allow the reader to review a complete diesel generator subsystem in a convenient manner.

Within each category tabs identify Perry specific component numbers.

A given component report can be found by:

a)

If the component number is known - use the alpha - numberic index which identifies the volume number and category in which the compon-ent report is located.

b)

If only the component name is known - Section 3.2 may be used as a cross-reference to find the volume number where the component report may be found.

Some reports address more than one component.

,a tab is provided for each component.

However, some components are combined under one report.

Slip sheets are provided where required to reference back to the appropriate tab.

Some components required more than one report.

These are identified by the abbreviation LB-Large Bore and SB-Small Bore on the component number tabs.

O i

PE3375

INDEX (continued)

Component Component Volume Number Description Category No.

F-068 Intercooler Turbo, Intake 2

?

Intrcir. & Exhaust MP022/23 Turbocharger

~

Turbo, Intake, 2

Intrcir. & Exhaust 00-420 Lube Oil Pressure Lube Oil 2

Regulating Valve 00-442A Starting Air Distributor:

Air Start &

3 Distributor Assembly Barring Device 00-442B Starting Air Distributor:

Air Start &

3 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drip Tank Fuel Oil 4

Assembly Injection 02-CFR Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrcir. & Ex-haust 02-305A Base and Bearing Caps: Base Engine Base 2

Assembly

& Bearing Caps 02-305C Base and Bearing Caps:

Engine Base 2

Main Bearing Studs & Nuts

& Bearing Caps 02-305D Base and Bearing Caps:

Engine Base 2

Main Bearing Caps

& Bearing Caps 02-307A Lube Oil Fittings:

Lube Oil 2

Internal - Headers 02-307B Lube Oil Fittings:

Lube 011 2

Internal - Tube & Fittings 02-307D Lube Oil Fittings Internal:

Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

2 Bearings 02-310B Main Bearings Crankshaft &

2 Bearing O

Rev. 1 II Entire page revised PE3375

O('~S INDEX (continued)

Component Component Volume Number Description Category No.

02-310C Crankshaft & Bearings:

Crankshaft &

2 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy Cranks' aft &

2 h

Bearing 02-311D Crankcase: Crankcase Crankshaft &

2 Mounting Hardware Bearings 02-315A Cylinder Block Cyl. Block &

2 Liners & Water Manifold 04-315C Cylinder Block Liners &

Cyl. Block &

2 Water Manifold -

Liners &

Cylinder Liner Water Manifold 02-315D Cylinder Block Liners &

Cyl. Block &

2 Jacket Water Manifold Liners &

& Piping Water Manifold 02-315E Cylinder Block Liners &

Cyl. Block &

2 Water Manifold: Studs Liners &

i Water Manifold 02-315F Cylinder Block Liners Cyl. Block &

2

& Water Manifold:

Liner & Water Cylinder Head Nuts Manifold 02-315G Cylinder Block Liners &

Cyl. Block &

2 Water Manifold: Seals &

Liners &

Gaskets Water Manifold 02-316A Jacket Water Inlet Manifold:

Jacket Water 4

Manifold Assembly W/ Hardware and Coupling and Gaskets 02-316B Jacket Water Inlet Manifold:

Jacket Water 4

Coupling and Gaskets 02-316C Jacket Water Inlet Manifold:

Jacket Water 4

Vent line to Discharge Manifold 02-317A Water Discharge Manifold:

Jacket Water 4

Jacket Water Discharge Manifold / Piping Rev. 1 gjj Entire page revised PE3375

INDEX (continued)

Component Component Volume Number Description Category No.

02-3178 Weter Dicharge Manifold:

Jacket Water 4

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Water 4

Supports 02-330A Flywheel Flywheel 3

02-3308 Flywheel - Bolting Flywheel 3

02-335B Front Gearcase - Gaskets Idler Gear As-3 and Bolting sembly & Front Gear Case 02-340A Connecting Rods:

Connecting Connecting 3

Rods & Bushings Rods 02-3408 Connecting Rod Bearing Connecting 3

Shells Rods 02-341A Pistons Pistons 3

02-341B Pistons: Rings Pistons 3

02-341C Piston Pin Assembly Pistons 3

02-345A Tappets and Guides:

Intake Camshaft &

3

& Exhaust Tappet Assembly Valve Train 02-345B Tappets and Guides: Fuel Camshaft &

3 Tappet Assembly Valve Train 02-345C Tappets and Guides: Fuel Camshaft &

3 Pump Base Assembly Valve Train 02-350A Camshaft:

Camshaft Camshaft &

3 Assembly Valve Train 02-3508 Camshaft:

Camshaft Camshaft &

3 Bearing Valve Train 02-350C Camshaft: Supports, Bolting Camshaft &

3 and Gear Valve Train 02-355A Idler Gear Assembly Crank Idler Gear As-3 To Pump Gear sembly & Front Gear Case Rev. 1 jy Entire page revised PE3375

INDCX (continued)

Component Component Volume Number Description Category No.

02-3558 Idler Gear Assembly:

Idler Gear As-3 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valve Air Start &

3 Barring Device 02-360A Cylinder Heads Cylinder Heads 4

& Valves 02-3608 Cylinder Head Valves:

Cylinder Heads 4

Intake & Exhaust Valves

& Valves 02-360C Cylinder Head and Valves:

Cylinder Heads 4

Bolting and Gaskets

& Valves 02-3600 Cylinder Head Cylinder Heads 4

& Valves:

Springs

& Valves 02-362A Subcover Camshaft &

3 Valve Train Os 02-365A Fuel Injection Pump Fuel Oil In-4 jection 02-3658 Fuel Injection Equipment -

Fuel Oil In-4 Fuel Injection Tips jection 02-365C Fuel Injection Equipment -

Fuel Oil In-4 Tube Assembly jection 02-365D Fuel Injection Equipment:

Fuel Oil In-4 Supports jection 02-371A Fuel Pump Linkage: Fuel Fuel Oil In-4 Pump Control Shaft jection i

02-371B Fuel Pump Linkage: Linkage Fuel Oil In-4 Assembly and Bearing jection 02-375 Intake Manifold and Turbo, Intake, 2

Piping Intrcir. & Ex-f haust 02-380A Exhaust Manifold Turbo, Intake, 2

4 i

Intrcir. & Ex-t haust Rev. 1 l

Entire page revised V

PE3375 i

i

..--4._-

.-,-.-,,.,,,,m_.-.

_..~,,,---.._d,_--.

INDEX (continued) i Component Component Volume Number Description Category No.

02-3808 Exhaust Manifold: Gasket Turbo, Intake, 2

j and Bolting Intrcir. & Ex-haust 02-385B Cylinder Block Covers:

Cyl. Block &

2 Gaskets and Bolting Liners & Water Manifold 02-3868 Crankcase:

Crankcase Crankshaft &

2 Gaskets and Mounting Bearings Hardware 02-390A Intake & Intermediate and Camshaft &

3 Exhaust Rocker Shaf t Assembly Valve Train 02-3908 Rocker Arms and Pushrods:

Camshaft &

3 Exhaust Rocker Shaft Valve Train Assembly 02-390C Main and Connector Camshaft &

3 Pushrods Valve Train 02-3900 Rocker Arms and Pushrods:

Camshaft &

3 Pushrods Connector.

Valve Train 02-390E Rocker Arms and Pushrods:

Camshaft &

3 Bushings Valve Train 02-390F Rocker Arms and Pushrods:

Camshaft &

3 Lifters Valve Train 02-390G Rocker Arms and Pushrods:

Camshaft &

3 Misc. Bolts & Drive Studs Valve Train 02-410A Overspeed Trip Governor Overspeed Trip 3

& Governor 02-4108 Overspeed Trip: Governor Overspeed Trip 3

and Accessory Drive Assembly

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 3

& Governor 02-4100 Overspeed Trip Vent Valve Overspeed Trip 3

& Governor Rev. I "I

Entire page revised PE3375

_.-,.an,_..~_--__.-_

- (]

V INDEX (continued)

Component Component Volume Number Description Category No.

02-411A Governor Drive: Governor &

Overspeed Trip 3

Tachometer Drive Gear and

& Governor Shaft 02-4118 Governor Drive: Couplings, Overspeed Trip 3

Pins & Keys

& Governor 02-413A Governor Linkage Overspeed Trip 3

& Governor 02-4138 Fuel Pump Linkage:

Fuel Oil Injection 4

Automatic Shutdown Cylinder 02-415A Governor Assembly: Woodward Overspeed Trip 3

Governor

& Governor 02-4158 Governor Assembly -

Overspeed Trip 3

Booster Servomotor

& Governor O.

02-415C Governor Assembly -

Overspeed Trip 3

Heat Exchanger'

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425A Engine Driven Jacket Water 4

Jacket Water Pump 02-435A Jacket Water Fittings:

Jacket Water 4

Pipe & Fittings 02-4358 Jacket Water Fittings -

Jacket Water 4

Supports 02-435C Jacket Water Inlet Jacket Water 4

Fittings - Valves 02-436A Intercooler Piping Turbo, Intake 2

Intercooler

& Exhaust 02-436,8 Intercooler Piping Turbo, Intake 2

Coupling, Gaskets, Intercooler &

Bolting Exhaust O

"Ii Rev. 1 Entire page revised PE3375

INDEX (continued)

Component Component Volume Humber Description Category No.02-437 Turbo Water Piping:

Jacket Water 4

Pipe & Fittings 02-441A Starting Air Manifold:

Air Start &

3 Piping, Tubing and Fitting Barring Device 02-441B Starting Air Manifold Air Start &

3 Valves, Filters & Strainer Barring Device 02-441C Starting Air Manifold:

Air Start &

3 Supports Barring Device 02-445 Fuel Oil Booster Pump Fuel Oil In-4 jection 02-450A Fuel Oil Header:

Fuel Oil In-4 Piping / Tubing jection 02-450B Fuel Oil Header:

Fuel Fuel Oil In-4 011 Supports jection OV 02-455A Fuel Oil Filters &

Fuel Oil In-4 Strainers: Filters jection 02-455B Fuel Oil Filters &

Fuel Oil In-4 Strainers:

Strainers jection 02-455C Fuel Oil Filters &

Fuel Oil In-4 Strainer: Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fittings, Couplings 02-4658 Lube Oil Lines - External Lube Oil 2

Valves 02-465C Lube Oil Lines Lube Oil 2

External Supports 02-467A Turbocharger: Lube Oil Lube Oil 2

Fitting - Pipe, Tubing, Fittings & Flexible Coupling 02-467B Turbocharger: Lube Oil Lube Oil 2

Fittings - Supports viii Rev. 1 Entire page revised PE3375

INDEX (continue.0

% J Component Component Volume Number Description Category No.

5 02-475A Turbocharger: Bracket Turbo, Intake, 2

Bolting and Gaskets Intrcir. u Ex-haust 02-475B Air Butterfly Valve Tuao, Intake, 2

Assembly Intrcir. & Ex-haust 02-475C Turbocharger: Bracket -

Turbo, Intake, 2

Bolting & Gaskets Intrcir. & Ex-haust 02-500A Control Panel Assembly Control Panel 4

Cabinet / System Assembly 02-500F Control Panel Assembly Control Panel 4

Accumulator Assembly 02-500G Control Panel Control Panel 4

Valves Assembly 02-500H Control Panel Assembly Control Panel 4

Pressure Switch Assembly 02-500I Control Panel Assembly:

Control Panel 4

Control Relays Assembly 02-500J Control Panel Assembly:

Control Panel 4

Solenoid Valves Assembly 02-500L Control Panel Assembly -

Control Panel 4

Piping, Tubing, Fittings Assembly 02-500M Control Panel Assembly:

Control Panel 4

Terminal Boards / Switches /

Assembly Wiring 02-525B Barring Device - Pneumatic:

Air Start &

3 Regulator Valve / Shut Off Barring Device Valve 02-5250 Barring Device - Pneumatic:

Air Start &

3 Mounting Bracket / Supports Barring Device 02-540A Lube Oil Sump Lube Oil 2

with Strainer Assembly and Mounting Hardware i*

Rev. 1 PE3375 Entire page revised

(~3 INDEX (continued)

V Component Component Volume Number Description Category No.

02-540B Lube Oil Sump Tank: Misc.

Lube Oil 2

Fittings, Gaskets, Pipe

&~ Bolting Material, Valves 02-540C Lube 911 Sump Tank:

Lube Oil 2

Mounting Hardware 02-550 Foundation Bolts:

Engine & Aux.

4 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly:

Engine Instru-3 Conduit mentation &

Wiring 02-630B Pyrometer Conduit Assembly:

Engine Instru-3 Conduit Fittings mentation &

Wiring n

02-630C Pyrometer Conduit Assembly:

Engine Instru-3

(

Support mentation &

Wiring 02-6300 Pyrometer Conduit Assembly Engine Instu-3 Thermocouple mentation &

Wiring 02-650A Emergency Diesel Generator Generator 4

02-650B Generator Generator 4

Control 02-650C Generator-Shaft & Bearing Generator 4

02-688A Engine & Aux Module Engine Instru-3 Wiring Material-Conduit mentation &

& Fittings; Pyrometer Wiring Assembly - Conduit, Fitting, Supports 02-688B Engine & Aux.

Engine Instru-3 Module Wiring Material:

mentation &

Wiring & Terminations Wiring O

x Rev. 1 Entire page revised PE3375

INDEX (continued)

Component Component Volume Number Description Category No.

.02-688C Engine & Aux. Module Wiring Engine Instu-3 Material: Boxes & Terminals mentation &

Wiring 02-689 Off-Engine Alarm Sensors Engine Instru-3 1

mentation &

Wiring 02-690 Engine Alarm Sensors -

Engine Instru-3 Temperature & Level mentation &

Switches Wiring 02-691 Off Engine Safety Alarm Engine Instru-3 Sensors - Level &

mentation &

Pressure Switches Wiring 02-695A Engine Shutdown Engine Shut-3 Equipment:

down & Equip-Tubing / Fittings &

ment Supports 0

02-695B Engine Shutdown Engine Shut-3 Equipment:

Valves, down & Equip-Regulator, Orifices ment 02-695C Engine Shutdown Trip Engine Shut-3 Switches down & Equip-ment 02-700A Jacket Water Standpipe:

Jacket Water 4

Pipe, Fittings, Gaskets l

02-7008 Jacket Water Standpipe:

Jacket Water 4

Valves

(

l 02-700C Jacket Water Standpipe:

Jacket Water 4

i Pipe Supports 02-700E Jacket Water Standpipe:

Jacket Water 4

Switches 02-700F Jacket Water Standpipe Jacket Water 4

j

& Misc. Bolting 02-717A Auxiliary Skid Jacket Water 4

O Rev. 1

• I Entire page revised PE3375 l

e""

INDEX (continued) v Component Component Volume Number Description Category No.

02-717B Aux Sub Base & 011 &

Jacket Water 4

Water Piping - Jacket Water:

Valves 02-717C Aux Sub Base & 011 & Water Engine & Aux.

4 Water Piping - Jacket Sub Base &

Water:

Pipe, Couplings, Foundation Bolts Fittings, Orifices, Y-Strainers 02-7170 Aux Sub Base & 011 & Water Jacket Water 4

Piping - Jacket Water:

Gaskets & Bolting 02-717E Aux Sub Base & 011 & Water Jacket Water 4

Piping - Jacket Water:

Supports 02-717F Aux. Sub Base & 011 & Water Lube Oil 2

Piping - Lube Oil:

Pipe and Fittings O'

02-717G Aux Sub Base & 011 & Water Lube Oil 2

Piping - Lube Oil:

Valves 02-717H Aux. Sub-Base & 011 & Water Lube Oil 2

Piping - Lube Oil:

Gaskets & Bolting 02-717I Aux Sub Base & 011 & Water Lube Oil 2

Piping - Lube Oil:

Supports & Mounting Hardware 02-717J Aux Sub Base & 011 & Water Fuel Oil 2

Piping - Fuel Oil - Piping

& Fittings 02-717K Aux Sub Base & 011 & Water Fuel Oil 4

Piping - Fuel 011: Valves Injection 02-717L Aux sub Base & 011 & Water Fuel Oil 4

Piping - Fuel Oil -

Injection Gaskets & Bolting O

Rev. 1

• I Entire page revised PE3375

p INDEX (continued)

O Component Component Volume Number Description Category No.

02-717M Aux Sub Base & 011 & Water Fuel Oil 4

Piping - Fuel 011:

Injection Supports 02-805A Intake Air Silencer Turbo, Intake, 2

Intercooler &

Exhaust 02-805B Intake Air Filter Turbo, Intake, 2

Intercooler &

Exhaust 02-8050 Flex Connections Turbo, Intake, 2

Intercooler &

Exhaust 02-810A Jacket Water Standby Jacket Water 4

Heater Pump 02-8108 Jacket Water Heat Exchanger Jacket Water 4

02-810C Thermostatic Valve Jacket Water 4

02-8100 Misc. Equipment - Heater, Jacket Water 4

Jacket Water 02-820A Misc. Equipment - Heater, Lube Oil 2

Lube Oil Sump Tank 02-820B Before & After Lube Oil Lube Oil 2

Pump 02-820C Lube Oil Full Pressure Lube Oil 2

Strainer 02-8200 Lube Oil System - Lube Oil Lube Oil 2

Keepwarm Strainer 02-820E 011 Prelube Filter Lube Oil 2

02-820F Full Flow Lube Oil Filter Lube Oil 2

02-820G Lube Oil Heat Exchanger Lube Oil 2

02-825A Fuel Oil Day Tank Fuel Oil 4

Injection O

xiii Rev. 1 Entire page revised 3

. _ =. - -. - -.-

l 1

1

(

INDEX (continued)

Component Component Volume Number Description Category No.

l l

02-8250 Fuel Oil System - Fuel Fuel Oil 4

Oil Duplex Strainer Injection I

02-8358 Starting Air Tank Air Start &

3 Barring Device 4

02-835E Misc. Equipment - Starting Air Start &

3 Air Tank Relief Valve Barring Device 1

I

O 1

i i

4 O

Rev. 1 PE3375 Entire page revised

m Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Pistons UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-341A TASK DESCRIPTION NO. DR-03-02-341A-1 SNPS GPL NO. 03-341A CLASSIFICATI0h TYPE A

TASK DESCRIPTIONS Design review is not required for this component based on review of the lead engine DR/QR reports (Shoreham/ Comanche Peak), the Phase I report and the applicable site and industry experience in the EDG Component Tracking System.

CEI has replaced the originally supplied AH piston skirts with the product improvement AE piston skirts at Perry Nuclear Power Plant.

The AE piston skirt incorporates design changes and has not been observed to crack in service.

O The following Quality inspections as delineated in the CQRC are recommended for the replacement AE pistons:

Prior to installation, perform a liquid penetrant test on the piston skirts.

Map all linear indications in the stud boss area and 1

document with photographs.

(Note:

If the results of the above inspections reveal indications greater than 1/32 inch length, either remove the indications by surface conditioning, or perform an eddy current test to determine if the indications must be removed.)

Perform a liquid penetrant test on the rib area near the wrist pin and on the rib at the intersection of the wrist pin boss to check for indications in the casting.

Visually inspect all piston skirt and crown outside diameters for scuffing, and the combustion bowls in the crowns for pitting.

There are no maintenance or modification recommendations for this component.

PRIMARY FUNCTION Not required n

v REY. 1 PE3038/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 s

DR-03-02-341A-1 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDAROS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON b "T*

d '

PROGRAM MANAGER SC \\4(twwa~h

<c, O

REV. 1 CARRYOVER FROM PE3038/2 PREVIOUS PAGE

O How To Use This Report Tabs in this report identify the following categories:

Turbo, Intake, Intercooler & Exhaust Lube Oil Engine Base & Bearing Caps Crankshaft & Bearings Cylinder Block, Liners & Water Manifold Air Start & Barring Device Connecting rods Pistons Camshaft & Valve Train Idler Gear Assembly & Front Gear Case Flywheel Engine Instrumentation & Wiring Overspeed Trip & Governor Engine Shutdown & Equipment Jacket Water Cylinder Heads & Valves Fuel Oil Injection Generator Ob)

Control Panel Assembly Engine & Auxiliary Sub-Base & Foundation Bolts These categories have been defined to allow the reader to review a complete diesel generator subsystem in a convenient manner.

Within each category tabs identify Perry specific component numbers.

A given component report can be found by:

a)

If the component number is known - use the alpha - numberic index which identifies the volume number and category in which the compon-ent report is located.

b)

If only the component name is known - Section 3.2 may be used as a cross-reference to find the volume number where the component report may be found.

Some reports address more than one component.

a tab is provided for each component.

However, some components are combined under one report.

Slip sheets are provided where required to reference back to the appropriate tab.

Some components required more than one report.

These are identified by the abbreviation LB-Large Bore and SB-Small Bore on the component number tabs.

lo

.v i

PE3375

INDEX (continued)

Component Component Volume Number Description Category No.

F-068 Intercooler Turbo, Intake 2

Intrcir. & Exhaust MP022/23 Turbocharger Turbo, Intake, 2

Intrcir. & Exhaust 00-420 Lube 011 Pressure Lube Oil 2

Regulating Valve 00-442A Starting Air Distributor:

Air Start &

3 Distributor Assembly Barring Device 00-4428 Starting Air Distributor:

Air Start &

3 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drip Tank Fuel Oil 4

Assembly Injection 02-CFR Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrcir. & Ex-haust 02-305A Base and Bearing Caps: Base Engine Base 2

Assembly

& Bearing Caps 02-305C Base and Bearing Caps:

Engine Base 2

Main Bearing Studs & Nuts

& Bearing Caps 02-3050 Base and Bearing Caps:

Engine Base 2

Main Bearing Caps

& Bearing Caps 02-307A Lube 011 Fittings:

Lube 011 2

Internal - Headers 02-3078 Lube Oil Fittings:

Lube Oil 2

Internal - Tube & Fittings 02-307D Lube 011 Fittings Internal:

Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

2 Bearings 02-3108 Main Bearings Crankshaft &

2 Bearing O

Rev. 1 II Entire page revised PE3375

g INDEX (continued)

U Component Component Volume Number Description Category No.

02-310C Crankshaft & Bearings:

Crankshaft &

2 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy Crankshaft &

2 Bearing 02-311D Crankcase: Crankcase Crankshaft &

2 Mounting Hardware Bearings 02-315A Cylinder Block Cyl. Block &

2 Liners & Water Manifold 02-315C Cylinder Block Liners &

Cyl. Block &

2 Water Manifold -

Liners &

Cylinder Liner Water Manifold 02-3150 Cylinder Block Liners &

Cyl. Block &

2 Jacket Water Manifold Liners &

& Piping Water Manifold

(

02-315E Cylinder Block Liners &

Cyl. Block &

2 L

Water Manifold: Studs Liners &

Water Manifold 02-315F Cylinder Block Liners Cyl. Block &

2

& Water Manifold:

Liner & Water Cylinder Head Nuts Manifold 02-315G Cylinder Block Liners &

Cyl. Block &

2 Water Manifold: Seals &

Liners &

Gaskets Water Manifold 02-316A Jacket Water Inlet Manifold:

Jacket Water 4

Manifold Assembly W/ Hardware and Coupling and Gaskets 02-316B Jacket Water Inlet Manifold:

Jacket Water 4

Coupling and Gaskets 02-316C Jacket Water Inlet Manifold:

Jacket Water 4

Vent line to Discharge Manifold 02-317A Water Discharge Manifold:

Jacket Water 4

Jacket Water Discharge

, Q Manifold / Piping D

Rev. 1 444 Entire page revised PE3375

I

(

INDEX (continued)

Component Component Volume Number Description Category No.

02-317B Water Dicharge Manifold:

Jacket Water 4

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Water 4

Supports 02-330A Flywheel Flywheel 3

02-330B Flywheel - Bolting Flywheel 3

02-335B Front Gearcase - Gaskets Idler Gear As-3 and Bolting sembly & Front Gear Case 02-340A Connecting Rods:

Connecting Connecting 3

Rods & Bushings Rods 02-3408 Connecting Rod Bearing Connecting 3

Shells Rods 02-341A Pistons Pistons 3

i 02-3418 Pistons: Rings Pistons 3

02-341C 4 Piston Pin Assembly Pistons 3

02-345A Tappets and Guides:

Intake Camshaft &

3

& Exhaust Tappet Assembly Valve Train 02-3458 Tappets and Guides: Fuel Camshaft &

3 Tappet Assembly Valve Train 02-345C Tappets and Guides: Fuel Camshaft &

3 Pump Base Assembly Valve Train 02-350A Camshaft:

Camshaft Camshaft &

3 Assembly Valve Train 02-3508 Camshaft:

Camshaft Camshaft &

3 Bearing Valve Train 02-350C Camshaft: Supports, Bolting Camshaft &

3 and Gear Valve Train 02-355A Idler Gear Assembly Crank Idler Gear As-3 To Pump Gear sembly & Front Q

Gear Case V

Rev. 1 gy Entire page revised PE3375

,Q INDEX (continued) b Component Component Volume Number Description Category No.

02-355B Idler Gear Assembly:

Idler Gear As-3 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valve Air Start &

3 Barring Device 02-360A Cylinder Heads Cylinder Heads 4

& Valves 02-360B Cylinder Head Valves:

Cylinder Heads 4

Intake & Exhaust Valves

& Valves 02-360C Cylinder Head and Valves:

Cylinder Heads 4

Bolting and Gaskets

& Valves 02-3600 Cylinder Head Cylinder Heads 4

& Valves:

Springs

& Valves 02-362A Subcover Camshaft &

3 Valve Train U

02-365A Fuel Injection Pump Fuel Oil In-4 jection 02-3658 Fuel Injection Equipment -

Fuel Oil In-4 Fuel Injection Tips jection 02-365C Fuel Injection Equipment -

Fuel Oil In-4 Tube Assembly jection 02-365D Fuel Injection Equipment:

Fuel Oil In-4 Supports jection 02-371A Fuel Pump Linkage: Fuel Fuel Oil In-4 Pump Control Shaft jection 02-371B Fuel Pump Linkage: Linkage Fuel Oil In-4 Assembly and Bearing jection 02-375 Intake Manifold and Turbo, Intake, 2

Piping Intrcir. & Ex-haust 02-380A Exhaust Manifold Turbo, Intake, 2

IntrcIr. & Ex-haust Rev. I v

Entire page revised PE3375

CT INDEX (continued)

V Component Component Volume Number Description Category No.

02-380B Exhaust Manifold:

Gasket Turbo, Intake, 2

and Bolting Intrcir. & Ex-haust 02-385B Cylinder Block Covers:

Cyl. Block &

2 Gaskets and Bolting Liners & Water Manifold 02-3868 Crankcase:

Crankcase Crankshaft &

2 Gaskets and Mounting Bearings Hardware 02-390A Intake & Intermediate and Camshaft &

3 Exhaust Rocker Shaft Assembly Valve Train 02-3908 Rocker Arms and Pushrods:

Camshaft &

3 Exhaust Rocker Shaft Valve Train Assembly 02-390C Main and Connector Camshaft &

3 Pushrods Valve Train U

02-3900 Rocker Arms and Pushrods:

Camshaft &

3 Pushrods Connector.

Valve Train 02-390E Rocker Arms and Pushrods:

Camshaft &

3 Bushings Valve Train 02-390F Rocker Arms and Pushrods:

Camshaft &

3 Lifters Valve Train 02-390G Rocker Arms and Pushrods:

Camshaft &

3 Misc. Bolts & Drive Studs Valve Train 02-410A Overspeed Trip Governor Overspeed Trip 3

& Governor 02-410B Overspeed Trip: Governor Overspeed Trip 3

and Accessory Drive Assembly

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 3

& Governor 02-4100 Overspeed Trip Vent Valve Overspeed Trip 3

& Governor Rev, 1 Entire page revised PE3375

INDEX (continued)

Component Component Volume Number Description Category No.

02-411A Governor Drive:

Governor &

Overspeed Trip 3

Tachometer Drive Gear and

& Governor Shaft 02-411B Governor Drive: Couplings, Overspeed Trip 3

Pins & Keys

& Governor 02-413A Governor Linkage Overspeed Trip 3

& Governor 02-413B Fuel Pump Linkage:

Fuel Oil Injection 4

Automatic Shutdown Cylinder 02-415A Governor Assembly: Woodward Overspeed Trip 3

Governor

& Governor 02-4158 Governor Assembly -

Overspeed Trip 3

Booster Servomotor

& Governor

+

02-415C Governor Assembly -

Overspeed Trip 3

Heat Exchanger

& Governor J

02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425A Engine Driven Jacket Water 4

Jacket Water Pump 02-435A' Jacket Water Fittings:

Jacket Water 4

Pipe & Fittings 02-4358 Jacket Water Fittings -

Jacket Water 4

Supports 02-435C Jacket Water Inlet Jacket Water 4

l.

Fittings - Valves 02-436A Intercooler Piping Turbo, Intake 2

i Intercooler

& Exhaust 3

02-4368 Intercooler Piping furbo, Intake 2

Coupling, Gaskets, Intercooler &

Bolting Exhaust O

Rev. 1

1. 'I Entire page revised PE3375

O INDEX (continued)

O Component Component Volume Number Description Category No.02-437 Turbo Water Piping:

Jacket Water 4

Pipe & Fittings 02-441A Starting Air Manifold:

Air Start &

3 Piping, Tubing and Fitting Barring Device 02-4418 Starting Air Manifold Air Start &

3 Valves, Filters & Strainer Barring Device 02-441C Starting Air Manifold:

Air Start &

3 Supports Barring Device 02-445 Fuel Oil Booster Pump Fuel Oil In-4 jection 02-450A Fuel Oil Header:

Fuel Oil In-4 Piping / Tubing jection 02-4508 Fuel Oil Header:

Fuel Fuel Oil In-4 011 Supports jection 02-455A Fuel Oil Filters &

Fuel Oil In-4 D

Strainers: Filters jection 02-455B Fuel Oil Filters &

Fuel Oil In-4 Strainers:

Strainers jection 02-455C Fuel Oil Filters &

Fuel Oil In-4 Strainer: Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fittings, Couplings 02-4658 Lube Oil Lines - External Lube Oil 2

Valves 02-465C Lube Oil Lines Lube Oil 2

External Supports 02-467A Turbocharger: Lube 011 Lube Oil 2

Fitting - Pipe, Tubing, Fittings & Flexible Coupling 02-4678 Turbocharger: Lube Oil Lube Oil 2

Fittings - Supports O

viii Rev. 1 Entire page revised PE3375

' /]

INDEX (continued)

()

Component Component Volume Number Description Category No.

02-475A Turbocharger: Bracket Turbo, Intake, 2

Bolting and Gaskets Intrcir. & Ex-haust 02-475B Air Butterfly Valve Turbo, Intake, 2

Assembly Intrcir. & Ex-haust 02-475C Turbocharger: Bracket -

Turbo, Intake, 2

Bolting & Gaskets Intrcir. & Ex-haust 02-500A Control Panel Assembly Control Panel 4

Cabinet / System Assembly 02-500F Control Panel Assembly Control Panel 4

Accumulator Assembly 02-500G Control Panel Control Panel 4

Valves Assembly 4

(

02-500H Control Panel Assembly Control Panel 4

N Pressure Switch Assembly 02-500I Control Panel Assembly:

Control Panel 4

Control Relays Assembly 02-500J Control Panel Assembly:

Control Panel 4

Solenoid Valves Assembly 02-500L Control Panel Assembly -

Control Panel 4

Piping, Tubing, Fittings Assembly 02-500M Control Panel Assembly:

Control Panel 4

Terminal Boards / Switches /

Assembly Wiring 02-5258 Barring Device - Pneumatic:

Air Start &

3 Regulator Valve / Shut Off Barring Device Valve 02-525D Barring Device - Pneumatic:

Air Start &

3 Mounting Bracket / Supports Barring Device 02-540A Lube Oil Sump Lube Oil 2

with Strainer Assembly and Mounting Hardware k

3 l

I*

Rev. 1 PE3375 Entire page revised

[v#}

INDEX (continued)

Component Component Volume Number Description Category No.

02-540B Lube Oil Sump Tank: Misc.

Lube Oil 2

Fittings, Gaskets, Pipe

& Bolting Material, Valves 02-540C Lube Oil Sump Tank:

Lube Oil 2

Mounting Hardware 02-550 Foundation Bolts:

Engine & Aux.

4 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly:

Engine Instru-3 Conduit mentation &

Wiring 02-630B Pyrometer Conouit Assembly:

Engine Instru-3 Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly:

Engine Instru-3

(/)

Support mentation &

Wiring

~-

02-6300 Pyrometer Conduit Assembly Engine Instu-3 Thermocouple mentation &

Wiring 02-650A Emergency Diesel Generator Generator 4

02-650B Generator Generator 4

Control 02-650C Generator-Shaft & Bearing Generator 4

02-688A Engine & Aux Module Engine Instru-3 Wiring Material-Conduit mentation &

& Fittings; Pyrometer Wiring Assembly - Conduit, Fitting, Supports 02-688B Engine & Aux.

Engine Instru-3 Module Wiring Material:

mentation &

Wiring & Terminations Wiring 4

.C x

Rev. 1 Entire page revised PE3375

INDEX (continued)

Component Component Volume Number Description Category No.

02-688C Engine & Aux. Module Wiring Engine Instu-3 Material: Boxes & Terminals mentation &

Wiring 02-689 Off-Engine Alarm Sensors Engine Instru-3 mentation &

Wiring 690 Engine Alarm Sensors Engine Instru-3 Temperature & Level mentation &

Switches Wiring 02-691 Off Engine Safety Alarm Engine Instru-3 Sensors - Level &

mentation &

Pressure Switches Wiring

'02-695A Engine Shutdown Engine Shut-3 Equipment:

down & Equip-Tubing / Fittings &

ment Supports O

02-6958 Engine Shutdown Engine Shut-3 Equipment: Valves, down & Equip-Regulator, Orifices ment 02-695C Engine Shutdown Trip Engine Shut-3 Switches down & Equip-ment 02-700A Jacket Water Standpipe:

Jacket Water 4

Pipe, Fittings, Gaskets 02-7008 Jacket Water Standpipe:

Jacket Water 4

Valves 02-700C Jacket Water Standpipe:

Jacket Water 4

Pipe Supports 02-700E Jacket Water Standpipe:

Jacket Water 4

Switches 02-700F Jacket Water Standpipe Jacket Water 4

& Misc. Bolting 02-717A Auxiliary Skid Jacket Water

- 4

.O Rev. 1

• I Entire page revised PE3375

~-_

p INDEX (continued)

V Component Component Volume Number Description Category No.

02-717B Aux Sub Base & 011 &

Jacket Water 4

Water Piping - Jacket Water:

Valves 02-717C Atx Sub Base & 011 & Water Engine & Aux.

4 Water Piping - Jacket Sub Base &

Water:

Pipe, Couplings, Foundation Bolts Fittings, Orifices, Y-Strainers 02-7170 Aux Sub Base & Oil & Water Jacket Water 4

Piping - Jacket Water:

Gaskets & Bolting 02-717E Aux Sub Base & 011 & Water Jacket Water 4

Piping - Jacket Water:

Supports 02-717F Aux. Sub Base & 011 & Water Lube Oil 2

Piping - Lube 011:

Pipe and Fittings 02-717G Aux Sub Base & Oil & Water Lube Oil 2

Piping - Lube Oil:

Valves 02-717H Aux. Sub-Base & Oil & Water Lube Oil 2

Piping - Lube Oil:

Gaskets & Bolting 02-717I Aux Sub Base & 011 & Water Lube Oil 2

Piping - Lube Oil:

Supports & Mounting Hardware 02-717J Aux Sub Base & Oil & Water Fuel Oil 2

l Piping - Fuel Oil - Piping l

& Fittings 02-717K Aux Sub Base & 011 & Water Fuel Oil 4

Piping - Fuel 011:

Valves Injection I

02-717L Aux Sub Base & 011 & Water Fuel Oil 4

Piping - Fuel Oil -

Injection Gaskets & Bolting Rev. 1 xii Entire page revised PE3375 l-

p INDEX (continued) g Component Component Volume Number Description Category No.

02-717M Aux Sub Base & 011 & Water Fuel Oil 4

Piping - Fuel Oil:

Injection Supports 02-805A Intake Air Silencer Turbo, Intake, 2

Intercooler &

Exhaust 02-805B Intake Air Filter Turbo, Intake, 2

Intercooler &

Exhaust 02-805D Flex Connections Turbo, Intake, 2

Intercooler &

Exhaust 02-810A Jacket Water Standby Jacket Water 4

Heater Pump 02-810B Jacket Water Heat Exchanger Jacket Water 4

O 02-810C Thermostatic Valve Jacket Water 4

d 02-8100 Misc. Equipment - Heater, Jacket Water 4

Jacket Water 02-820A Misc. Equipment - Heater, Lube Oil 2

Lube Oil Sump Tank 02-8208 Before & After Lube Oil Lube Oil 2

Pump 02-820C Lube Oil Full Pressure Lube Oil 2

Strainer 02-8200 Lube Oil System - Lube Oil Lube Oil 2

Keepwarm Strainer 02-820E Oil Prelube Filter Lube Oil 2

02-820F Full Flow Lube Oil Filter Lube Oil 2

02-820G Lube Oil Heat Exchanger Lube Oil 2

02-825A Fuel Oil Day Tank Fuel Oil 4

Injection O.

• iii Rev. 1 Entire page revised PE3375

I INDEX (continued)

Component Component Volume Number Description Category No.

02-825D Fuel Oil System - Fuel Fuel Oil 4

Oil Duplex Strainer Injection 02-8358 Starting Air Tank Air Start &

3 Barring Device 02-835E Misc. Equipment - Starting Air Start &

3 Air Tank Relief Valve Barring Device i

O Rev. 1 xiv Entire page revised PE3375

6

[Vl.

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Control Panel Assembly COMPONENT Cabinet / System UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-500A TASK DESCRIPTION NO. DR-03-02-500A-1 i

SNPS GPL NO. 03-500A CLASSIFICATION TYPE A

TASK OESCRIPTIONS A design review of the control panel assembly cabinet / system is not required for Perry based on the following:

l A review of the DR/QR lead engine report (Comanche Peak).

The application of the electropneumatic control system used on Perry to

start, stop,

operate, protect, and monitor the diesel is identical to Comanche Peak design.

The logic design used on Perry to disable the Group II trip functions during initial diesel startup and bypass all the Group I and Group II trips during an emergency condition is identical to Comanche Peak design.

In addition, the controls to lock out the diesel for maintenance on Perry are also identical to those on Comanche Peak.

The applicable industry experience listed in the EDG Component Tracking System showed non-1E interlocks were used to initiate the diesel generator building ventilation system at Perry.

Contacts from non-1E relays, supplied by TDI for customer use, were used incorrectly by Perry for this purpose.

Corrective action has been taken at Perry to rewire those relays with Class 1E safety related power.

The remaining industry experience listed does not show any significant or generic problems associated with the type of electropneumatic system used on Perry.

There are no maintenance or modification recommendations for the control panel assembly cabinet / system.

Quality revalidation of the control panel assembly cabinet / system is not deemed 4

necessary.

O U

Rev. 1 PE2911/1 Entire Page Revised

C COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-500A-1 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required

(

DOCUMENTATION REQUIRED Not required PROGRAM MANAGE d \\(m %

GROUP CHAIRPERSON ff G

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O Rev. 1 Entire Page Revised pggg

I TDI OWNERS GROUP for l

PERRY NUCLEAR POWER PLANT MAINTENANCE REVIEW APPENDIX - II i

I INTRODUCTION 1

The purpose of this Appendix is to provide Perry with a set of maintenance and surveillance recommendations for diesel generator components which have been developed by TDI and/or the Owners Group as a result of the overall Owners Group Program.

This Appendix is intended to supplement the existing TDI Instruction Manual, Volume I and Volume III, which will maintain the qualification of the diesel generators for the life of the i-plant.

II METHODOLOGY During the implementation of the Owners Group Program Plan, the Owners I

i Group Technical Staff reviewed many sources of information regarding the

\\

maintenance and surveillance for the diesel generator components identi-fied in this Appendix.

These sources included TDI Instruction Manuals, Service Information Memos (SIMS), and TDI correspondence on specific components.

This review along with Technical Staff input regarding the adequacy of the recommendations found in the sources mentioned above, and additional maintenance recommendations identified during the DR/QR review, forms the basis for the content of this matrix.

III RESULTS AND CONCLUSIONS i

Proper maintenance is important in ensuring long, reliable and satisfacto-ry service of the emergency diesel generators. Maintenance work, in order to be effective, must be carried out thoroughly and regularly.

It is for these reasons that a detailed schedule of maintenance service has been laid out by the Owners Group for the TDI Diesel Generators at Perry Nuclear Power Plant.

The schedule details specific components requiring maintenance on a regular basis.

This schedule separates the maintenance activities into a daily, monthly, outage, alternate outage (every other),

5 year and 10 year frequencies.

It should be noted here that the dura-tion time between outages at Perry is assumed to be 18 months.

.O 1

PE3041/1 45

O Page 2 of 3 Those less significant diesel generator system components with which standard engineering practice and maintenance will ensure continued operation, are not specifically addressed in the matrix.

Standard mainte-nance practices are briefly discussed below.

The engine and generator should be kept clean and dry at all times. Oil and water leakage should be wiped off the unit as quickly as possible in order to assist in locating the source of leakage, prevent potential equipment damage and maintain a safe working environment.

Leaking pipes, gaskets and packing glands should be attended to promptly so as not to impair the reliability and/or operation of the system.

Flanged gasketed connections may be retightened to stop leaks and any abnormal engine noises or vibrations. Actions required to correct any abnormal conditions should be carried out in a timely manner.

Loose bolts and electrical terminals should be attended to in a safe, practical manner.

Specific items to be maintained on a DAILY basis consist of the following:

1.

Observe and record lubricating oil and jacket water temperatures (keep warm pump running).

2.

Drain all low point water collectors, barring device air filter and air receiver tank float traps in the air start system.

h 3.

Check engine and auxiliary equipment and piping connections for oil, k/

water, and fuel oil leaks.

4.

Check level of lubricating oil in the governor and pedestal bearing.

Add oil as needed.

5.

Check fuel oil pump rack for freedom of movement through full limit of travel.

Do not disconnect from governor.

6.

Check turbocharger bearing lubricating oil system sight glass for oil flow.

l 7.

Drain water from crankcase vent piping drip legs, i

8.

Verify all controls in proper position for standby mode.

9.

Check all governor knob settings.

Load Maximum Droop Zero Speed To provide mechanical governor control at 460 rpm.

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PE3041/2 i

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l Page 3 of 3

10. Visually inspect lube oil heat exchanger and jacket water heat 3

exchanger for signs of leakage from the lantern ring leakoff ports, i

l indicating leaking packing rings.

The following Preventive Maintenance Recomendation Matrix was designed to assist the Maintenance Department in determining.the scope of work re-quired to maintain the intended design function of the diesel generators at Perry on a planned schedule basis.

It should be followed closely and referred to often.

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U PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outane 5 Year 10 Year Comments F-068 Intercoolers 1.

Evaluate heat exchanger X

performance by checking engine operating parameters.

2.

Clean / inspect shell and X

Ref: Lead engine DR/QR tube sides every outage Report #F-068 or as necessary.

(Items 2, 3, 4) 3.

Visually inspect for X

Ref: 7/26/84 IOC external leaks.

from J. Cadogan to M. McGerigle, Ref: 08/14/84 letter to C. Ray from M. Lowrey 4.

The drain connection To be performed daily.

on the air intake system I

low point should be verified open, and cleaned daily MP-022/3 Turbocharger 1.

Measure vibration and X

To be accomplished during check with base line data.

24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> test run.

2.

Clean impeller and diffuser.

X 3.

Measure rotor end play X

Review thrust bearing (axial clearance) to axial clearances after identify trends of in-inspection to determine creasing clearance, i.e; if a trend exists. Any thrust bearing degradation.

trend toward increasing axial clearance could signify thrust bearing degradation. Ref: Lead engine DR/QR Report

1. MP-022/3 PE3041/4 Revision 1

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O PERRY MAINTENANCE MATRIX Component Component Al t.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 4.

Perform visual and blue X

NOTE: Thrust bearing

' check inspections of inspection should also the thrust bearing.

be performed af ter 40 non prelubed (automatic) fast starts. Ref: Lead engine DR/QR Report

1. MP-022/3 5.

Disassemble inspect X

and refurbish.

6.

Perform a spectro-X To be performed during chemical engine oil the last monthly analysis to assist the test run prior to oil bearing monitoring change. NOTE: Sample program. To further to be drawn up stream of expand / clarify chemical lube oil filter.

analysis, ferrographic Ref: Lead engine DR/QR analysis may be utilfred.

Report MP-022/3 Particular attention shall be paid to copper level, and particulate size, which could signify thrust bearing degradation.00-420 Lube Oil Pressure Regulating 1.

Disassemble and clean.

X If valve sticks repeated-Valve ly, more frequent cleaning may be necessary. If valve plugging becomes a problem, the dimensions of the valves' internal parts should be checked to ensure proper clearance.

PE3041/5

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v PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outane Outaoe 5 Year 10 Year Comments Refd Lead engine DR/QR Report #00-420 2.

During initial startup after a major reassembly of-Lube Oil piping, the L.O.

regulating valve should be disassembled and cleaned untti abnormal L.0. pressure excursions subside.

00-442A Starting Air Distributor 1.

Visually inspect the X

Evaluate the degree of Assembly poppet valve spool ends wear to determine and timing can of the whether existing starting air distributor.

condition would have an adverse effect on timing and the specified ability to start the engine.

2.

Ensure that the starting X

Ref: Lead engine DR/QR air manifold vent is Report #00-442A (STAD),

open and unobstructed.

Items 1 & 2 02-305A Base Assembly 1.

Perform a visual inspection' X

WOTE: Any cracks detected of the base. The inspection must be investigated further should include the areas before the engine is adjacent to the nut pockets allowed to return of each bearing saddle and to service. The mating be conducted after a thorough surfaces of the base and wipe down of the surfaces, cap shall be throughly using good lighting.

cleaned with solvent before PE3041/6 m.._.

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Number Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments any reassembly.

Ref: Lead engine DR/QR Report #02-3058 02-305C Main Bearing Caps - Studs 1.

Upon removal of bearing Ref: Lead engine DR/QR and Muts caps, clean mating Report #02-305C surfaces with a solvent prior to reassembly of the caps to the base.

02-3078 Lube 011 Tubing and 1.

Check tubing fer dents X

Items 1, 2; Ref: TDI Fittings - Internal or crimps.

Instruction Manual, Vol. I, Maintenance Schedule 2.

Perform gear-train X

spray check.

02-310A Crankshaft 1.

Measure crankshaft web X

Complete TDI Inspection deflection.

and Maintenance Record Form No. 310-1-1 TDI Instruction Manual, Volume I, Section 6.

Ref: TDI Instruction Manual, Vol. I, Mainten-ance Schedule 2.

Measure diameter of X

Complete TDI Inspection crank journals, and Maintenance Record Form No. 310-3-1. TDI Instruction Manual, Volume I, Section 6.

PE3041/7 2

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PERRY MAINTENANCE MATRIX Component Component

Alt, Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-3108 Main Bearings Shells 1.

Inspect and measure main X-The first inspection bearing shell thickness.

should be performed at Inspection shall evaluate the first fuel outage bearing wear and evidence and at alternate outages of harmful crankshaf t thereaf ter.

misalignment. If results Complete TDI Inspection show evidence of mis-and Maintenance Record alignment, TDI recom-Form No. 310-2-1. TDI mendations for crankshaft Instruction Manual, realignment should be volume I, Section 6 -

implemented.

one sheet for each main bearing. Use Volume I, Appendix III for clearance values.

Ref: TDI Instruction Manual, Vol.1, Maintenance Schedule, Ref: Lead engine DR/QR Report

1. 02-3108 02-310C Thrust Bearing Ring 1.

Measure thrust bearing X

Complete applicable ring clearance via sections of TDI

" bump check" method to be Inspection and Main-performed in conjunction tenance Record Form with crankshaft web No. 310-1-1 TDI Instruc-deflection measurements.

tion Manual, Volume I, The following information Section 6.

NOTE: If should be recorded:

the clearance is

• Date of inspection greater than the maximum

• Hours of engine operation allowed in the TDI I

PE3041/8 t

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PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outane Outaoe 5 Year 10 Year Comments

• Hours of engine operation Instruction Manual, since last bearing re-then at least one bearing placement (Last bearing must be replaced.

replaced:

forward Bearings should also back) be replaced if they

• Bearing clearance are cracked or gouged.

Ref: Lead engine DR/QR Report #02-310C, Ref: 8/13/84 meno from G. McCarthy to D. Pasquale 2.

Visually inspect thrust X

To be performed simult-bearing ring for signs aneously with main of cracks, gouges, wear bearing shell inspec-or degradation.

tion. Ref: Lead engine DR/QR Report #02-310C 02-31LA Crankcase Assembly 1.

Perform a visual inspection X

The first inspection to be of the vertical portion performed after 185 hours0.00214 days <br />0.0514 hours <br />3.058862e-4 weeks <br />7.03925e-5 months <br /> of the crankcase arch wall of at or near full load to the nut pocket area operation, may be used to for indications of justify the discontinua-cracking.

tion of further inspect-tions. Ref: Lead engine DR/QR Report #02-311A 02-315A Cylinder Block 1.

Perform an inspection of Ref: DR/QR Report the cylinder block per

1. 02-315A DR/QR Report #02-315A.

PE3041/9

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PERRY MAINTENANCE MATRIM Component Component Alt.

Number Identification

. PW Recommendation Monthly Dutage Outaos 5 Year 10 Year Comments 02-315C Cylinder Liners 1.

Perform a visual inspection X

Borescopic inspection of liners for potential is acceptable if heads progressive wear, are not removed.

Complete TDI Inspection and Maintenance Record form No. 315-1-1, TDI Instruction Manual, Volume I, Section 6.

Ref: Lead engine DR/0R Report #02-3418 02-317A&B Water Discharge Manifold -

1.

Visually inspect for leaks. X This recommednation is Jacket Water Discharge Mote: In the event of a made on the basis that Piping, couplings and seals leak developing in the the maximum suggested existing Dresser Style 65 operating temperature of couplings, these couplie.gs 150*F for the Style 65 should be replaced with coupling may be exceeded.

1 Dresser Style 90 couplings The maximum suggested equipped with Viton gaskets, operating temperature of the Style 90 is 212*F.

Ref: Letter dated 12/13/84 from C L Ray to J George. Ref:

DR/QR Report #02-317A&B 02-340A/B Connecting Rods, Bushings 1.

Inspect and measure To be performed in and Bearing Shells connecting rod bearing conjunction with piston shell to verify lube oil pin inspection. Com-maintenance which affects plete TDI Inspection wear rate, and Maintenance Record The visual and dimensional Form No. 340-1-1 TDI inspection of the bearing Instruction Manual, shells should be conducted Volume I, Section 6, at the fuel outage which Appendix III for precedes 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br /> of clearance values.

operation by at least the Ref: Lead engine DR/QR PE3041/10 Revision 1

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NJ PERRY MAINTENANCE MATRIX Component Component Al t.

Number Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments sum of hours of operation Report #02-3408 in a LOOP /LDCA event plus the expected hours of operation between outages.

2.

Inspect and measure the X

Complete TDI Inspection connecting rods.

Maintenance Record Form No. 340-2-1, 2. TDI Instruction Manual, Volume I, Section 6.

3.

Perform an x-ray examina-This is to be performed tion on all replacement prior to installation of bearing shells to accep-any replacement bearing tance criteria developed shells. Ref: Lead engine by Dwners Group Technical DR/QR Report #02-3408 Staff.

4.

Measure the clearance This recommendation is between the link pin and required one time only.

link rod in accordance Ref: Lead engine DR/QR with TDI-SIM #349. This Report #02-340A clarance should be zero, i.e.; no measurable clearance when the spect-fled bolt torque of 1050 ft-Ibs is applied. This should be performed with the engine assembled after a major disassembly.

5.

At major engine overhauls X

If fretting has occured visually inspect the rack a further engineering teeth surfaces for signs evaluation will be of fretting.

necessary. Ref: DR/QR Report #02-340A PE3041/11 Revision 1 - entire page revised

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PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments 02-341A Pistons 1.

Inspect and measure skirt X

Complete TDI Inspection and piston pin.

and Maintenance Report Form No. 341-1-1 TDI Instruction Manual, Volume I, Section 6.

Use Volume 1 Section 8, Appendix III for clearance values.

To be performed in con-junction with piston pin inspection.

02-3418 Piston Rings 1.

Inspect and measure X

Complete TDI Inspection replacement piston rings.

and Maintenance Record Form No. 341-2-1. TDI Instruction Manual, Volume I, Section 6.

Use Volume I Section 8 Appendia III for clearance values. To be perform-ed in conjunction with piston pin inspection.

2.

Visually inspect liners X

Borescopic inspection for wear.

is acceptible if heads NOTE: Ring replacement are not removed. Com-and cylinder 11ner plete TDI Inspection honing should be performed and Maintenance Record in accordance with TDI Form No. 315-1-1. TDI maintenance procedures.

Instruction Manual, Volume I Section 6.

Use Volume I, Section 8, Appendix III for clearance values.

Ref: Lead engine DR/QR Report #02-341B (Items 2, 3, 4)

PE3041/12 Revision 1 - entire page revised l

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O PERRY MAINTENANCE MATRIX Component Component Alt.

Number identification PN Recommendation Monthly Outage Outage S Year 10 Year Comments 3.

135* fuel oil spray X

Ref: 07/31/84 meno tips may be used if from L. Swanger to inspection results D. Pasquale indicate a need for additional action to improve lubrication and reduce coke buildup.

4.

When replacing engine X

NOTE: Do not six oil use.H.D. oil that L.O. brands or types.

exceeds series 3 When changing L.O.

standards. The base replace the entire stock should be L.O. charge. Ref:

more resistant to 08/14/84 letter to thermal degradation C. Ray from M. Lowrey and coke formation.

The additive package should provide high detergent dispersant properties with high alkalinity and a high level of antiwear additive such as zinc dithiophosphate.

Total Base Number (TBN) should be 12 to 15 for use with

1. 2 fuel oli and a sulfated ash content of 1.5% to 2.0% is preferred. An engine oil with such properties, Mobilguard 412 or equivalent product may be used to ensure improved lubrication.

PE3041/13 Revision 1 - entire page revised

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PERRY MAINTENANCE MATRIX-Component Component Alt.

Number Identification PM Recommendation Monthly Outaae Outane 5 Year 10 Year Comments 02-341C Piston Pin Assembly 1.

Visually inspect all pins X

Also to be performed for chrome plate damage.

whenever pistons are Replace pins which show removed and disassembled chipped or blistered to an extent that such chrome.

Inspection is possible.

NOTE: All new or re-Ref: Lead engine DR/QR placement pins will be Report #02-341C (Items L.P. or M.P. inspected 1&2), For details on before installation in acceptance criteria, Ref:

Owners Group engines.

08/22/84 memo from W.

Littmann to D. Pasquale NOTE: This inspection is to be performed whenever the engine is sufficantly dismantled to allow this inspection.

Ref: Lead engine DR/QR Report #02-341C i

2.

Inspect end plugs and X

NOTE: This inspection is reroll or replace any to be performed whenever that are loose.

the engine is sufficantly dismantled to allow this inspection.

02-345A Intake and Exhaust Tappet 1.

Inspect intake and exhaust X

Complete TDI Inspection Assembly tappet assembly condition.

and Maintenance Report Fore No. 345-1-1 TDI Instruction Manual, Volume I, Section 6.

Ref: Lead engine DR/QR Report #02-345A t

PE3041/14 Revision 1 - entire page revised i

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PERRY MAINTENANCE MATRIM Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 2.

Verify that can rollers X

Complete TDI Inspection are free to rotate, and and Maintenance Record that there is no measurable Form No. 345-1-1 TDI clearance between the can Instruction Manual, Vol.

rollers and the roller pins.

I, Section 6.

Ref Lead engine DR/QR Report

1. 02-345A 02-3458 Fuel Tappet Assembly 1.

Inspect fuel assembly X

Complete TDI Inspection condition.

and Maintenance Report Form No. 345-1-1, TDI Instruction Manual, Volume I, Section 6.

Ref: Lead engine DR/QR Report #02-345B 2.

Verify that can rollers X

Complete TDI Inspection are free to rotate, and and Maintenance Record that there is no measurable Form No. 345-1-1 TDI clearance between the can Instruction Manual, Vol.

rollers and the roller pins.

I, Section 6.

Ref; Lead engine DR/QR Report

1. 02-3458 02-350A Can Shaft Assembly 1.

Perform a visual inspection X

Any signs of cracking, of all cam lobe surfaces pitting or spalling shall for signs of cracking, be followed by a detailed pitting or spalling, analysis to evaluate the expected life based on the size and extent of surface distress and any corrective measures shall be implemented as indicated by this analysis. Signs of PE3041/15 Revision 1 - entire page revised

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U PERRY MAINTENANCE MATRIX Component Component

Alt, Number Identification PM Recommendation Monthly Outaae Outaae 5 Year 10 Year Comments spalling shall result in immediate replacement of the can.

Ref: Lead engine DR/QR Report #02-350A 02-3508 Can Shaft Bearings 1.

Inspect and measure cam X

Complete TDI Inspection and shaft bearing shells.

Maintenance Record Form No. 350-1-1 TDI Instruc-tion Manual, Volume I, Sec-tion 6.

Use Volume I.

Section 8 Appendix III for clearance values.

02-350C Can Gear 1.

Visually inspect can gear X

Ref: Memo from 8.

for chipped or broken Bickford to E. Montgomery teeth, pitting, excessive dated 6/23/84, wear, or other abnormal Ref: Lead engine conditions.

DR/QR Report #02-350C 2.

Measure gear back lash.

X Complete applicable NOTE - if can gear hub is sections of TDI Inspec-

- removed, it is ESSENTIAL tion and Maintenance that the nut be relocked Record, Form No. 355-1-1, at the position corres-TDI Instruction Manual, ponding to the pre-Volume I, Section 8, scribed torque range of Appendix III-1 for 70210 ft-lbs.

clearnance values. Ref:

Insertion of the cotter Lead engine DR/QR pin must be accomplished Report #02-350C at a torque > 50 ft-lbs force and < 90 ft-Ibs force. If this is not possible another bolt, PE3041/16 Revision 1 - entire page revised

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V PERRY MAINTENANCE MATRIX 1

Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments l

nut or washer should be used.

02-355A Crank to Pump Geer 1.

Visually inspect crankshaft X

Any abnormal situations to lube oil pump gear or indications of for chipped or broken teeth, progressive pitting excessive wear, or should be reported progressive pitting for an engineering or other abnormal evaluation.

conditions.

Ref: Perry i

DR/QR Report #02-355A Task Description.

1 2.

Measure gear backlash.

X Complete applicable

]

sections of TDI 1

Inspection and Main-l tenance Record Form l

No. 355-1-1 TDI Manual, Vclume I, Section 6.

3 Use Volume 1 Section 8 Appendix III-1 from j

clearance values, j

Ref: TDI Instruction Manual, Vol. I, Main-tenance Schedule 02-3558 Idler Gear Assembly 1.

Visually inspect idler X

Any abnormal indications gears for chipped or should be reported for an j

broken teeth, excessive engineering evaluation.

wear pitting, or other Ref: Lead engine DR/QR l

abnormal conditions.

Report #02-355B I

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Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 2.

Measure gear backlash X

Complete appilcable NOTE: If idler gear hub sections of TDI Inspec-is removed, it is tion and Maintenance recommended that the nut Record Form No. 355-1-1, be relocked at the post-TDI Manual, Volume I, tion corresponding to the Section 6.

Use Volume I, torque of 80 120 ft-lbs.

Section 8, Appendix III-1 Insertion of the cotter for values.

pin must be accomplished Ref: TDI Instruction at a torque > 60 ft-Ib Manual, Vol. I, Main-and 100 ft-lbs.

If this tenance Schedule, is not possible, another Ref: Perry bolts, nut, or washer DR/QR Report #02-3558 should be used.

Task Description 3.

The mating surfaces between Ref: Perry DR/QR Report the idler gear and hub

1. 02-3558 Task Description.

should be throughly cleaned with solvent prior to assembly to ensure that there is an adequate friction coefficient between the parts.02-359 Air Start valves 1.

Remove, clean and inspect X

Ensure valve installation air start valves.

Includes retorque (Replace cooper valve-requirements.

to-head gasket)

Ref: DR/QR Report

1. 02-359 (Items 1, 2, 3)

PE3041/18 Revision 1 - entire page revised f

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D PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outane 5 Year 10 Year Comments 2.

Inspect the piston, cap, x

guide and housing sliding surfaces to evaluate wear or corrosion.

3.

Ensure that the dryer To be performed daily between the air compressor Ref: DR/QR Report after cooler and the air

1. 02-359 receivers is working properly by blowing down the air receivers daily and monitoring the moisture content.

02-360A Cylinder Head 1.

Visually inspect cylinder X

Complete TDI Inspection heads (all cylinders),

and Maintenance Record Form No. 360-1-1 TDI Instruction Manual, Volume I, Section 6.

One sheet for each head.

2.

Record cold compression X

If so indicated remove pressures and maximum cylinder heads, grind firing pressures.

valves and rescat.

Ref: TDI Instruction Manual, Volume I, Sec-tion 6 3.

Blow over the engine per In the event water is TDI maintenance require-detected, the cylinder ments, Volume I or at head should be replaced appropriate intervals or returned to the after shutdown of vendor for repair.

the engine to ensure Ref: Lead engine DR/QR PE3041/19 Revision 1 - entire page revised i

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PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthiv Cutage Outane 5 Year 10 Year Comments against harmful effects Report #02-360A of water leaks.

4.

Visually inspect the X

If water leakage is fuel injection port on detected, the head (s) each cylinder head should be replaced.

"during" the normal Ref: Lead engine monthly engine run DR/QR Report #02-360A for water leaks.

02-3608 Cylinder Head - Intake and 1.

Visually inspect intake X

Complete the appilcable Exhaust Valves and exhaust valve, discs, sections of TDI Inspection stems and seats for wire end Maintenance Record drawing, pitting, distortion, Form 360-2-1.

concentricity, or any abnormal condition.

2.

Visually inspect subcovers This is a one time only for evidence of valve inspection to be performed guide blowby (Soot) after 500-600 hrs. of engine operation on new or reworked cylinder heads.

Ref: Lead engine DR/QR Report #02-3608 3.

Measure intake and exhaust X

Complete appilcable valves head thickness.

sections of TDI Inspection and Main-tenance Records Form 360-2-1. TDI Instruction Manual, Volume I, Section 6.

One sheet for each cylinder. Use Section 8, Appendix III for clearance PE3041/20 Revision 1 - entire page revised

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PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outaoe Outage 5 Year 10 Year Comments val ues. (Items 3,4) 4.

Measure intake and exhaust X

Complete applicable valves - valve-to guide sections of TDI clearances.

Inspection and Main-tenance Record Form 360-2-1. TDI Instruction Manual, Volume I, Section 5.

One sheet for each cylinder. Use Section 8 Appendix III for clearance values.

02-362A Cylinder Head Covers -

1.

Perform a 11guld pene-X This inspection is to Subcover Assembly trant examination of be performed in conjunc-the rocker are pedestals tion with the rocker top and vertical machined are bushing inspections surfaces (connector when the rocker are pushrod side only) for shafts are removed from signs of cracking at the the subcovers (Ref:

counter bores.

Lead engine DR/QR Report #02-390E) or when the rocker are shaft assembly is removed. Subcovers with pedestal cracks that extend through the counter bore web down to the threads should be replaced.

Ref: Lead engine DR/QR Report #02-362A PE3041/21 Revision 1 - entire page revised

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PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-365A Fuel Injection Pumps 1.

Visually check pressure X

To be performed on all bleed screws for erosion.

sixteen pumps, i

2.

Tear down one pump for X

Use representative pump inspection.

to determine need to l

overhaul other pumps.

Ref: TDI Instruction Manual, Volume I.

Maintenance Schedule 3.

Complete fuel injection X

Based on inspection re-pump inspection in suits and operating 4

accordance with TDI parameters. Complete Irstruction and Main-TDI Instruction and tenance Manual, Volume I.

Maintneance Record Form No. 365-1-1, j

Section 6 (Items 1, 2).

Ref: TDI Instruction 4

Manual, Volume I, Maintenance Schedule for Item 3 Ref: Lead engine DR/QR Report

1. 02-365A (Items 2&3) 02-3658 Fuel Injection Nozzles 1.

Remove, inspect and clean X

Ensure that a new copper tips.

gasket is used upon reinsta11ation of j

nozzle into head.

Complete TDI Inspection j

and Maintenance Record Form 365-2-1 Instruction Manual, Volume I, 1

Section 6.

I s

PE3041/22 Revision 1 - entire page revised j

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PERRY MAINTENANCE MATRIX Component Component Alt.

Number

. Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments Ref: TDI Instruction Manual, Vol. I Section 5 Maintenance Schedule, Ref: Lead engine DR/QR Report #02-3658 (Items 1-4) 2.

Check nozzle pop pressure.

X 3.

Check spray pattern.

X 4.

Check assembly for X

To be performed with the

leakage, engine running during the monthly test run.

02-365C Fuel Injection Tubing 1.

Check tubing for leaks X

All fuel oil leak in-at compression fittings.

spections to be perform-ed while the engine is running or whenever the compression fittings have been disturbed.

Ref: Lead engine DR/QR Report #02-365C 2.

Visually inspect tubing X

Fitting inspection for lengths for F.O. leaks leaks to be performed or cracks.

at first engine opera-tion following the installation of tubing.

Subsequent inspections to be performed period-ically as indicated.

Fuel oil leakage from shrouded fuel oil lines PE3041/23 Revision 1 - entire page revised 1

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%.J PERRY MAINTENANCE MATRIX Component Component Al t, Number Identification PM Recommendation

-Monthly Outage Outage 5 Year 10 Year Comments l

can be detected at the leakoff ports in the base nuts, which are provided for this purpose. Ref: Letter i

from C.A. Malourh to V.A. Saleta dated 08/30/84.

02-3650 Fuel Oil Injection 1.

Visually inspect support X

Any inserts found to be Lines: Supports elastomer inserts for unsatisfactory shall be.

deterioration or replaced with new inserts degredation.

prior to reassembly of F.0. lines. This inspection can be per-formed prior to reassembly of the F.O. lines in conjunction with the 4

cylinder ilner inspection.

I Ref: Lead engine DR/QR Report #02-315C Cylinder Liners, Ref: San Onofre DR/QR Report #02-3650 Task Description.

02-371A Fuel Pump Control Shaft 1.

Check lube oil cups X

Ref: Lead engine DR/QR and fill as necessary.

Report #02-371A 02-3718 Fuel Pump Linkage Assembly 1.

Grease swivel link on X

and Bearings F.0. pump assemblies, all cylinders.

PE3041/24 Revisjon 1 - entire page revised i

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10 Year Comments Number Identification PM Recommendation Monthly Outage Outage 5 Year 02-375 Intake Manifold 1.

Care should be exercised If required, other castings in assembly of cylinder may be tried to achieve heads onto the engine, an acceptable fit, or bolt to avoid cracking hole diameters may be of the intake manifold increased to 1/8" oversize.

elbows.

Component should under no circumstances be jacked to fit. Ref: Lead engine DR/QR Report

1. 02-375 02-380A Exhaust Manifold 1.

Visually and MT examine X

To be performed during a sampling of circum-the first refueling ferential pipe welds and outage and alternate corresponding heat outages thereafter.

affected zones. This However, diesel examination is to operation should not be performed in exceed 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> be-accordance with Impe11 tween inspections.

meno from G. Shears Ref: Lead engine DR/QR to J. Kammeyer dated Report #02-380A 08/13/84.

02-385A Crankcase Relief Valve 1.

Clean flame arrestors.

X Ref: 3/26/84 IOC from M. Wehmeyer to J. Kammeyer 2.

Inspect seat and disc.

X PE3041/25 Revision 1 - entire page revised

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Number Identification PM Recommendation Monthiv Dutage Outage 5 Year 10 Year Comments 02-390E Rocker Arm Bushings 1.

Visually inspect and The visual and dimensional measure intake rocker are inspection of the rocker

bushings, are bushings should be conducted at the fuel ostage which precedes 2303 hours0.0267 days <br />0.64 hours <br />0.00381 weeks <br />8.762915e-4 months <br /> of operation by at least the sum of expected hours of operatfor. In a LOOP /LOCA event plus the expected hours of operation between outages. This inspection schedule may be revised after the first or subsequent inspections if the inspection results justify a longer period of engine operation between irispections. Ref:

Lead engine DR/QR Report

1. 02-390E (Items 1, 2, 3) 2.

Visually inspect and Not to exceed 1300 measure exhaust rocker maximum hours of engine are bushings.

operation between inspections as described above.

3.

Visually inspect and Not to exceed 730 measure intermediate maximum hours of engine rocker arm bushings, operation between inspection as described above.

PE3041/26 Revision 1 - entire page revised

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PERRY MAINTENANCE MTRIX Component Component Alt Number Identification PM Recommendation Monthly Outage ' Outage 5 Year 10 Year Comments 02-390F Hydraulic Valve Lifters 1.

Check valve lash.

X 2.

Reinstall and adjust X

Ensure lifters are lifters perform leak installed with the fill down test.

. holes up.

Verify condition of lifters via comparison of lif ter leak down rate (actual) to specifications noted on TDI Maintenance Manual Ref: TDI Maintenance Manual Section 6-B-5, Ref: 04/16/84 letter to R. Johnson from R. Jaquinto 02-390G Rocker Arm Capscrews, 1.

Verify capscrew torque X

This inspection should be Drive Studs (Pop Rivets)

values, performed at each outage if the rocker arms are disassembled for inspec-tion. Use TDI Instruction Manual, Volume I, Section 8, Appendix IV for proper torque values.

2.

Verify that rocker ara X

Ref: Lead engine DR/QR drive studs are intact Report #02-390G and tight.

(Items 1, 2)

PE3041/27 Revision 1 - entire page revised

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Number Identification PM Recommendation Monthly Outaae O m 5 Year 10 Year comments ga 02-410A Overspeed Trip Governor 1.

Check trip set point X

Modify the surveillance

- adjust as required.

testing procedure to include verification i

that the overspeed trip is correctly set to an overspeed trip setting of 518 rpe 21 % every l

outage, Ensure that the electric t

governor and the mechanical 3

backup governor setting are i

properly returned to their normal settings following the overspeed test. The test is to be performed

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with no load on the engine j

by increasing the normal governor speed setting (s) i untti a trip occurs.

After several inspection 1

j periods, the history of the required adjustments should be reviewed to I

evaluate and possibly modify the testing 4

interval.

Ref: Lead engine j

DR/QR Report #02-410A i

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PE3041/28 Revision 1 - entire page revised i

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as PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outace Outane h 10 Year Comments Note: After setting the over-

• C speed governor, the ad-justment screw settings should be marked with Torque Seal to reveal any unintended changes in the set positions.

02-4108 overspeed Trip Governor 1.

Remove plugs from housing X

Ref: IOC dated and Accessory Drive and check for magnetic 03/27/84 from particles.

M. Weyneyer to N. Cooperrider.

2.

Check shafts for excessive X

radial and axial movement.

3.

Visually inspect accessory X

drive gear for excessive wear.

02-410C Overspeed Trip Drive Coupilngs 1.

Remove the present L-110 To be completed at Lovejoy couplings and the first refueling replace them with new

outage, units in accordance with SIM 363 and DR/QR Report recommendations.

2.

Verify that coupling is X

Ref: 6/24/84 memo tight on shaft.

from D. Limbert to E. Montgomery PE3041/29 Revision 1 - entire page revised

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Number Identification PM Recommendation Monthly Outaae Outaae 5 Year 10 Year Comments 02-413A Governor Linkage-1.

Install positive locking hardware to the lever are clamp bolt heads and shaft roll pins. NOTE: To be performed as necessary after tightening gov-ernor linkage hardware to design torque specifi-cations.

2.

Inspect for loose parts X

on the linkage assembly.

3.

Lubricate cross shaft X

Ref: Lead engine DR/QR bearings cups.

Report #02-413A (Items 3&4) 4.

Grease the rod end X

fittings, especially those at the ends of the cross shaft.

02-4138 Fuel Pump Linkage:

1.

Check cylinder for X

To be accomplished during Automatic Shutdown Cylinder extension and return.

control system check.

2.

Check ta11 rod went X

To be accomplished during for air leakage, control system check.

Items 1, 2; Ref: IOC dated 3/26/84 from M. Wehmeyer to R. Kaklec.

PE3041/31 Revision 1 - entire page revised

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PERRY MAINTENANCE MATRIX Component Cmunt Alt.

Nnmber Identification PM Recommendation Monthly Outace Outaae 5 Year 10 Year Comments 02-4154 Woodward Governor 1.

Drain, flush, refill and X

NOTE: Venting the vent actuator oil system hydraulic actuator shall with new oil from a be performed per the

. clean container ensuring Woodward manual if more the appropriate cleanliness than a half quart of procedures are followed.

oil is added. Ref:

Lead engine DR/QR Report 02-415A 2.

Disasses le, clean and X

Items 1, 2, 3; Ref:

refurbish the actuator.

03/27/84 IOC from M. Wehmeyer to M. Cooperrider Ref: TDI Instruction Manual, Volume I, Section 5 Maintenance Schedule 3.

Replace flex element X

Ref: Lead engine DR/QR for governor drive Report 802-411B Governor coupling.

Drive Couplings 4.

Verify all governor X

All knob settings should control knob settings be secured with a are in appropriate commercially available positions:

product such as LOAD - Maximum Torque-Seal.

DROOP - Zero Speed - To provide mechan-ical governor con-trol at 460 rpm.

PE3041/32 Revision 1 - entire page revised

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PERRY MAINTENANCE MATRIN Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage

$ Year 10 Year Comments 5.

Modify the surveillance X

NOTE: These tests shall testing procedures to include examinations of include an evaluation the engine speed transi-of the governor settings ents during start and be means of the two transient loading condi-test below; tions. Included as part of the above tests (a) Perfrom a test of is the verification that the governor settings the engine set speed of while under mechanical 450 rpe is not exceeded

/ electrical governor by more than 7.5 percent control, with the (484 rps max.) either diesel generator off during an engine start or the grid in the during the largest single isochronous mode.

load reduction.

Ref: Lead engine DR/QR (b) Perform a test of Report #02-415A the governor settings while under mechanical (only) governor control, with the diesel generator off the grid in the isochronous mode.

6.

Augment the setting Ref: Lead enoine adjustment procedures DR/QR Report #02-415A as described in the Woodward manuals, to include a test of the governor response, during an engine start to ensure agreement with the specification as detailed in Itee #5 above.

PE3041/33 Revision 1 - entire page revised

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O PERRY MINTENANCE MATRIX Camponent Camponent Alt.

haber Identification PM Recommendation Monthly Outage Outane 5 Year 10 Year Comments 02-4158 Governor Booster Servosotor 1.

Clean, inspect, and X

Ref: 3/27/84 IOC from replace "0" rings M. idehmeyer to and gaskets.

J. Kamseyer 02-415C Governor Heat Exchanger 1.

Clean and inspect.

X 02-425A Jacket Water Pup - Gear 1.

Visually inspect jacket X

Any abnormal situations water pump gear for or indications of pro-chipped or broken gressive pitting should teeth, excessive wear, be reported for an or potential / progressive engineering evaluation.

pitting or other Ref:. Lead engine GR/QR abnormal conditions.

Report #02-3558 2.

Checit the key to keyway X

This along with the drive interface for a tight fit of the impeller on to fit on both the pump the pump shaft, will pre-shaft to impeller and clude past problems where the spline to pump relative motion between shaft during pump both the shaft and spline, reassed ly, and the spline and pump shaft caused fretting and upset of the keyway sides.

Ref: DR/QR Report #02-425A 3.

It is recommended that To be performed upon the castle nut that reassembly drives the external Ref: DR/QR Report spline on its

1. 02-425A taper, have minimum and maximum torque values of 120 ft-Ibs and 660 ft-Ibs respectively.

PE3041/34 Revision 1 - entire page revised

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U PERRY M INTENANCE M TRIX C asponent P- ;: lt Alt.

Number Identification PM Recommendation Monthly Outage Ou+g 5 Year 10 Year Comments 02-435A Jacket Water Fittings-1.

Visually inspect for leaks. X This recommendation is Pipe and Fittings Note: In the event of a made on the basis that (Small Sore Scope Only) leak developing in the the maximum suggested existing Dresser Style 65 oporting temperature of couplings, these coupilngs 150*F for the style 65 should be replaced with coupling may be exceeded.

Dresser Style 90 coupilngs The maximum suggested equipped with Viton gaskets.

operating temperature of the Style 90 is 212*F.

Ref: Letter dated 12/13/64 from C L Ray to J George.02-437 Turbe Water Piping-1.

Visually inspect for leaks. X This recommendation is Pipe and Fittings Note: In the event of a made on the basis that leak developing in the the maximum suggested existing Dresser Style 65 operating temperature of couplings, these couplings 150*F for the Style 65 should be replaced with coupilng may be exceeded.

Dresser Style 90 couplings The maximum suggested equipped with Viton gaskets.

operating temperature of the Style 90 is 212*F.

Ref: Letter dated 12/13/84 from C L Ray to J George.

02-441A Starting Air Manifold:

1.

Ensure that the starting X

Ref: 08/27/84 Memo from Air Vent air manifold went is W. Littmann to J. Cadogan, open and effective.

Ref: Lead engine DR/QR Report #02-442A (STAD) 02-4418 Air Filter to Starting Air 1.

Inspect filter elements.

X Ref: TDI Instruction Distributor Manual, vol. I, Main-tenance Schedule PE3041/35 Revision 1 - entire page revised

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PERRY MAINTENANCE MATRIM Campement P-----

-t Alt.

Number Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments j

1 2.

Replace filter elements.

It is recommended that the filter be changed whenever the 1

manufacturers recom-mended maximum dif-ferential pressure is achieved. Ref; Lead engine DR/QR Report

1. 02-4418 (Items 1&2)

Strainer - Starting Air System 3.

Slow down strainer DAILY.

Ref: Lead engine DR/QR Report #02-4418 (Items 3&4) 4.

Clean and inspect strainer X If the strainer is sonthly.

excessively dirty, the frequency of cleaning and inspecting should be increased.

Air Start Block Valves 5.

Clean, refurbish valves X

Ref: Lead enoine DR/QR

-replace "O" rings and Report #02-4418 (Items 5, clean the-Acreened 6, 7) fitting. Ensure leak tightness after reassembly.

6.

Inspect for tightness X

of fittings and bolts and apply locking com-pound, as required during reassembly of components.

PE3041/36 Revision 1 - entire page revised

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PERRY MAINTENANCE MATRIX ret e77 s gi g, thamber Identification FM Recommendation E nthly Outage Outace 5 Year 10 Year Comments 7.

Replace *0" rings of X

the shuttle valve.

Starting Air Valves 8.

Disassemble, clean, X

Ref: Lead engine DR/QR inspect and lubricate Report 802-4418.

valves te prevent fouling.

Test to assure lealt tight-ness upon reasonably.

02-455A Fuel Oil Filter 1.

Record fliter d/p.

X Change filter elements at or before the filter d/p reaches the manu-facturers recommended maximum differential pressure. Purge entrapped air from the filter canister using the vent valve provided, and divert some fuel oil into the newly replaced cartridge.

After air has been purged close went valve and return handle to previous operating position. Ref: Lead engine DR/QR Report 802-455A 2.

Inspect canister gaskets X

To be performed during and replace as necessary.

change out of filter elements.

Ref: 3/27/84 IOC from M. Wehmeyer to J. DiMare.

PE3041/37 Revision 1 - entire page revised

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stumber Identification PM Recommendation Monthly Outaae 0

5 Year g Comments 3

3.

Inspect tubing and mech-X Ref: TDI Instruction anical connections for Manual, Volume I tightness and/or leaks.

02-4558 Fuel Oil 5 trainers 1.

Record strainer d/p.

X Shift / clean element if manufacturers recom-mended maximum dif-forential pressure is achieved. Solt torques of 120-150 in-Ibs should be utfilzed during reassembly.

Ref: Lead engine DR/QR Report #02-4558 (Items 1 & 2) 2.

h.rge air from stand-by As required.

strainers 02-465A Lube Oil Lines External:

1.

Ensure that a minimum To be performed whenever Tubing, Fitting and Coupilngs installation gap of 0.171 piping is installed or inches is maintained between reinstalled. Ref: DR/QR pipe ends at the 12-inch Report #02-465A Dresser coupling.

2.

Replace the 12-inch Ref: $hearon Harris Dresser coupilng gasket DR/QR Report #02-465A with a VITON gasket Task Description.

should leaks develop.

PE3041/38 Revision 1 - entire page revised

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pet #Y tenINTEmaseCE ItATRIX ret Camponent Ai t.

hr Identification Pet Recommendation peonthly Outage Outaea 5 Year 10 Year Comments 3.

Should a leak develop Ref: Perry DR/QR Report in a Style 90 small 802-465A (small bore).

bore coupilng, replace it with a style 90 coupilng equipped with a viton gasket.

02-467A Turbocharger Lute Oil Fitting:

1.

Visually inspect for leaks. X This recommendation is Pipe T elag Fittings, and slote: In the event of a made on the basis that Flexible Coeoling leak developing in the the maximum suggested (Small Bure Scope Only) existing Dresser Style 65 operting temperature of cotelings, these coupilngs 150*F for the Style 65 should be replaced with coupling may be exceeded.

Dresser Style 90 couplings The maximum suggested equipped with Viton gaskets, operating temperature of the Style 90 is 212*F.

1 Ref: Letter dated 12/13/84 from C L Ray to J George.

02-475A.C Turbocharger: Bracket 1.

Each month for the first Refr: DR/QR Reports Bolting and Gaskets months of commercial 802-475A,C operation these screws should be inspected to assure that no screw has f

loosened because of engine operating loads. If during 1

these inspections none of the screws are found j

loosened or damaged, from i

then on inspections are to be conducted on a yearly basis (or during plant shutdown). But if any time PE3041/39 Revision 1 - entire page revised S

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PERRY M INTENANCE ETRIX P- ;:-- 2 PT - - _. t

Alt, humber Identification M Recommendation Monthly Outage Outace Hear 10 Year Comments during inspection any screw is found loosened or damaged, it must then be replaced (if damaged) and all screws retorqued as follows; 125 ft-1bs for the bracket to engine screws and 75 ft-1bs for the bracket to turbo base screws.

Note: To avoid damage to bracket to engine, and/or bracket to turbo, base screws, the proper torques as delinated aw we should be uttilzed for each respective bracket bolting appilcation.

02-4758 Air Butterfly Valve 1.

Lube valve shaft X

Ref: IOC dated 3/28/84 via grease fittings.

from M. Wehmeyer to J. DiMare. If oil cups are used, this should be completed monthly.

2.

Check valve disc for X

Check by visually observ-freedom of movement.

ing valwe/ actuator oper-ation. Ref: 04/16/84 from R. Jaquinto to R. Johnson 3.

Verify that associated X

Ref: DR/QR Report locking devices (jas

1. 02-4758 nuts and lock washers) are tight.

PE3041/40 Revision 1 - entire page revised

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x PERRY IIAINTEnAleCE MATRIX Ceapenent P-

- ---t Alt.

Ituater Identification PII Receemendation Monthly Outaae Outage 5 Year 10 Year Comments 02-50GA Engine Control Cabinet 1.

Inspect interior of cabinet X

Ref: 3/29/84 IOC for cleanliness and clean from M. tiehneyer as required.

to T. Jacobs for Itees 1-5 Ref: 07/30/84 IOC from J. Cadogan to K. Morelik for items 1-6 2.

Visually check wiring for X

insulation degradation.

3.

Visually check instrument X

tubing for leaks.

4.

Functionally check cabinet X

heater and calibration of thermostat.

5.

Test pneuentic S/D board X

logic.

6.

Replace "0" rings, gaskets X

and filter in pressure regulator.

02-500C Circuit Breakers and Contact 1.

Check all terminals X

To be accomplished during Blocks clean / tighten.

panel clean / inspection.

2.

Visually check wiring X

To be accomplished during insulation for degradation.

panel clean /inspectior..

3.

Trip check circuit breakers.

X PE3041/41 Revision 1 - entire page revised

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PERRY DIAINTFIIAIICE IIATRIX Campenent r- ; -. t Alt.

Iteher Identification pet Recommendetton leonthly Outage Outage 5 Year 10 Yeer Comments 02-500G Centrol Panel Valves 1.

Inspect and clean control X

This recommendation in-panel valves.

terval should be reas-sessed depending on the degree of system fouling.

Ref: Lead engine DR/QR Report 802-500G 2.

Inspect and clean the X

Ref: Lead engine DR/QR 200 mesh screen in the Report 802-500G check valve.

02-5001 Control Panel Assembly:

1.

Inspect contacts and clean X

Ref: 08/10/84 IOC from Relays as required.

K. Morelik to J. Cadogan 2.

Visually check condition X

of wiring and tightness of terminations.

02-500M Control Panel Switches Terminal 1.

Clean terminal boards and X

Ref: IOC dated 3/29/84 Roares and Wiring switch contacts, to J. Kamseyer from M. Wehmeyer for Items 1, 2, 3.

2.

Visually check wire insul-X atton and terminals for tightness and degradation.

3.

Inspect for arcing and X

overheating.

02-5258 Barring Device Control Valve 1.

Drain filter daily while Ref: Lead engine DR/QR barring device is in Report 802-5258 operation.

(Items 1 & 2)

PE3041/42 Revision 1 - entire page revised

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PERRY IIAINTEleNICE seTRIX Campenent C: C ^^ t Alt.

thamber Identification Pee Recommendation peonthly Outaae Outaee 5 Year 10 Year Comments 2.

Replace regulator X

elastometric parts.02-550 Foundation Bolts 1.

Visually inspect found-X Ref: TDI Instruction ation for breaks in flanual, Maintenance the bond between the Schedule, Section 5 sole plates and grout.

2.

Check foundation bolts X

Use TDI Instruction for correct torque.

flanual, Volume I, Retorque as necessary Section 8. Appendia IV then recheck crankshaft for proper torque valves.

web deflection.

3.

Generator foundation bolts Ref: Lead engine DR/QR are to be retorqued Report #02-550 after a generator short circuit if the bolts were initially torqued to 480 ft-lbs. If initial bolt torque was 600 ft-lb no retorque is required.

02-6300 Thermocouples 1.

Check that thermocouple X

An inconsistant reading indicates ambient engine traced to thermocouple temperature when the trouble should result engine is cold.

in replacement of the thermocouple.

PE3041/43 Revision 1 - entire page revised

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PERRY MAINTENANCE ImTRIX Camponent P-t Alt.

Ituoher Identification POI Recommendation peonthiv Ou_ta_ge Outace 5 Year 10 Year Comments 2.

Clean and inspect X

Indications of fatigue thermocowles and thereo-should result in re-cogle shleids.

placement of the thermo-couple and/or therse-couple shield.

Ref: 7/31/84 femmo from

5. Riess to W. Littmann 3.

Pyremeter wiring - check To be accomp11shed during that terminations are control panel check-out tight.

and initial operation inspection. Itees 1,

2. 3: Ref: 07-30-84 IOC from J Cadogan to 5. Riess 02-650A Emergency Generator 1.

Check operation of X

Ref. IOC dated 03/30/84 brushes and slip rings.

M. Wehmeyer to D. Mercaid (Itees 1-5).

2.

Clean / inspect all X

accessible parts of the generator.

3.

Megger rotor and stator.

X 4.

Verify operation of M

c.

space heaters.

5.

Measure vibration and X

check against base line data.

02-6508 Emergency Generator 1.

Inspect panel for X

Items 1-5; Ref: 3/30/84 Control Panel cleanliness and clean IOC from M. Wehmeyer i

as required.

to D. Mercaldi PE3041/44 Revistor. 1 - entire page revised

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PERRY stAINTEleAletE IthTRIN Camponent P- ; _ _. _t Alt.

m.shee Identificetten pee ascemoondation etenthly outaas Outeen i Year 10 Year Cemente 2.

Check terminal boards X

for loose wiring.

3.

Visually check condition X

of wire insulation for degradation.

4.

Clean and inspect relay X

contacts.

5.

Check meter calibrations.

X 02-650C Energency Generator Pedestal 1.

Check ring ellers X

To be accompilshed during Bearing for proper operation every test run of the and verify 011 level, engine.

Ref; 3/30/84 IOC from M. Wehmeyer to N. Cooperrider (Items 1-4) 2.

Drain flush refill X

bearing housing.

3.

s,e w : beartM nousing X

insulation resistance.

4.

Disassemble and inspect X

bearing and check clearances.

PE3041/45 Revision 1 - entire page revised

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O PERRY teh!NTfteRNCE IIATRIN Ceepenent P 7._-_^.

Alt.

Ihaber Identification POS Recommendation Dionthly Outage Outaan 5 Year 10 Veer Comeents 02-6958 Engine Control Air 1.

Inspect and clean enSine MOTE: This recommenda-Pressure Regulater shutdown equipment.

tion should be assessed depending en the degree of system fouling Ref: Lead engine DR/QR Report 802-6958 (Itses 1 & 2) 2.

Replace elastomeric parts X

and gaskets in the pressure regulator.

02-695C Engine Centrol Pnematic Trip 1.

Check switch set points.

I Pressure switches.

Switches Ref: 3/30/84 IOC from M. Wehmeyer to J. DiMare 2.

Replace elastomeric parts.

M 02-7006 Jacket Water Standpipe:

1.

Replace elastomeric parts X

Ref: Lead engine DR/QR Valves in circle seal valves.

Report #02-7178 02-7178 Auxiliary Sub-base & Gil & Water 1.

Inspect the valves for X

Replace as necessary.

Piplag - Jacket Water: Valves packing leakage.

Ref: Lead engine DR/QR Report 802-7178 PE3041/ M Revision 1 - entire page revised

V PEMY IIRINTENANCE MTRIE re-pam.-t r==ra===*

Alt.

Ihamber Identificatten pe8 Secommendation monthly Outaes Outage S Year 10 Year Caseents 82-717C Aust15ery See-Sase & Oil &

1.

Visually inspect for leeks. X This recommendation is Water Piping - Jechet Water:

mete: In the event of a made on the basis that Pipe. Couplings, Fittings.

leak developing in the the maximum suggested Orifices. Y-5 trainers existing Dresser Style 65 oporting temperature of (Small tore Scepe Only) coeglings, these cowlings 150*F for the Style 65 should be replaced with coupling may be exceeded.

Dresser Style 90 coupilngs The samtaum suggested equipped with Viten gaskets.

operating temperature of the Style 90 is 212*F.

Ref: Letter dated 12/13/84 from C L Ray to J George.

02-717F Aimalliary See-Base Laee Oil 1.

Visually inspect for leaks. X This recommendation is Pipe and Fittings mete: In the event of a made on the basis that leak developing in the the maximum suggested existing Dresser Style 65 oporting temperature of couplings these coupilngs 150*F for the Style 65 should be replaced with coupilng may be exceeded.

Dresser Style 90 couplings The maximum suggested equipped with Viton gaskets.

operating temperature of the Style 90 is 212*F.

Ref: Letter dated 12/13/84 from C L Ray to J George.

2.

Clean and inspect L.O.

X Complete when L.O. tank keepmsare pump suction is drained.

strainer.

Ref: 04/16/84 letter from R. Jaquinto to R. Johnson Revision 1 - entire page revised PE3041/47

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i PERRY MAINTEleANCE MATRIX Camponent F-;rzt Alt.

mueber Identification Pee Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-71?G Aemillary Sub-Sase Liee 011 1.

Olssassemble, clean and X

Ref: 07/31/84 IOC check relief valve to M. McGerigle from lift pressure.

J. Cadogan, Ref: 08/16/84 IOC from M. McGerigle to J. Cadogan, i

Ref: Lead engine DR/QR Report #02-717G l

02-717E Aemillary Sub-Sase and 011 1.

Dissassamble Iubricate, X

Ref: IOC dated 4/6/84 j

and Water Piping: Fuel inspect and refurbish.

from M. Wehmeyer to i

Oil Valves J. DiMare.

j Ref: Lead engine DR/QR Report #02-717K 4

l 02-8058 Ir.take Air Filters 1.

Inspect intake air X

Ref: Perry DR/QR Report distribution plate

1. 02-8058 and change filter oli.

I

^

02-8050 Flex Connection 1.

Visually inspect for X

evidence of cuts, holes, 2

or dents.

02-8108 Jacket Water Heat 1.

To avoid corrosion and Ref; Lead engine DR/QR

]

Exchanger fouling the jacket water Report #02-810C, heat exchanger and Ref: 04/20/84 IOC 1

associated service from M. Wehmeyer to 1

water piping should be R. Kadlec flushed on a periodic basis (continuous service I

flow is sufficient).

Alternatively, service water chemistry control i

can be used to maintain l

heat exchanger performance and integrity.

PE3041/48 1

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s PERRY MAINTENANCE MTRIX Caeronent Component Alt.

. Number Identification PM Recommendation Monthly Outaae Outaae 5 Year 10 Year Comments 2.

Perform a daily visual To be performed daily, inspection for leakage Ref: 07/19/84 Telecon at packing whenever the D. Pasquale and engine is in the emer-R. Chij gency standby mode. Verify that no leakage is pre-sent through the leak-off ports of the lantern ring.

3.

Record heat exchanger X

Use for trend data performance by checking engine operating parameters.

4.

Evaluate heat exchanger X

performance data.

5.

Inspect tubes X

Ref: TDI Instruction and tube sheet Manual, Volume I, for fouling and Maintenance Schedule errosion - remove entrance and exit channel covers.

Replace packing rings Ref: Lead engine DR/QR at floating tube Report #02-810C sheet af ter tube inspection.

6.

Inspect and clean X

Replace / rework lantern ring. Verify lantern ring as leak-off holes are necessary to not plugged.

ensure concentricity prior to reinstall-ation.

PE3041/49 Revision 1 - entire page revised

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PERRY MAINTENANCE MATRIX Component Cm : _.t Al t.

Mumber Identification PM Recommendation Monthly Outage Dutage 5 Year 10 Year Comments l

7.

Replace packing Replace packing when rings.

packing becomes hard or i

I leakage at the packing i

is noted and cannot be stopped by tightening.

Ref: Lead engine DR/QR Report #02-810C i

02-810C Thermostatic valves 1.

Replace thermal power X

Ref: Lead engine DR/QR

?

elements.

Report #02-8100 (Items 1, 2) 1

{

2.

Visually inspect valve X

To be accomplished 1

body for evidence of during monthly test

leakage, run. Ensure that any replacement valves have cast steel valve 4

j bodies.

02-8100 Jacket Water Heaters 1.

Measure heater X

Replace heater if insulation resistance, degradation of insulation resis-l 2.

Clean and inspect X

tance is noted.

j heater elements.

Ref: 5/10/84 IOC from M. McGerigle to W. Brown 3.

Check calibration and X

for Items 1, 2, 3 inspect thermostat.

02-820A tube 011 Sump Tank 1.

Measure heater X

Replace heater if de-l Heaters insulation resistance.

gradation of insulation resistance is noted.

1 i

i PE3041/50 Revision 1 - entire page revised i

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O PERRY MAINTENANCE MATRIX.

Component Component' Alt.

Number Identification PM Recommendation' Monthly Outaae Outene 5 Year 10 Year Comments 2.

Inspect and clean X

To be accomplished during heater elements.

tank inspection.

3.

Check calibration and X

Ref: 05/10/84 IOC inspect condition of from M. McGerigle thermostat.

to W. Brown for Items

1. 2. 3 02-8208 Lube 011 Keep-Wars Pump 1.

Check operation of X

Items 1-5; Ref:

pump / motor bearings.

04/05/84 IOC from M. Wehmeyer to T. Fritsch 2.

Check mechanical seal X

1eakage.

3.

Record pump X

Use for trend data discharge pressure.

4.

Measure unit vibra-X tion (pump / motor) 5.

The pump should be To be performed daily inspected for signs Ref: DR/QR Report of leakage and

1. 02-820C corrective s;odifications (addition of flexible piping connections) be implemented as required 0.2-820C Full Pressure Lube Oil Strainer 1.

Record strainer d/p.

X use for trend data j

PE3041/51 Revision 1 - entire page revised f

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PERRY MAINTEMANCE MATRIX Component Cseponent Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 2.

Inspect and clean elements.

Inspect / clean when strainer difforential pressure rises signi-ficantly.

Ref: Lead engine DR/QR Report #02-8 M,

Ref: TDI Instruction Manual, Volume I, Main-tenance Schedule 3.

Lube oli strainer X

pressure gauge - cali-bration check.

02-8200 Prelube Oil Pump Strainer 1.

Check strainer differential Clean and/or replace the pressure DAILY.

element when the manu-facturer's recommended maximum differential pressure is achieved.

Ref: Shearon Harris DR/QR Report #02-465D Task Description.

02-820E 011 Prelube Filter 1.

Record filter d/p.

X Ref: 04/05/84 IOC from M. Wehmeyer to J. DiMare 2.

Change filter To be performed before elements.

the filter d/p reaches the manufacturers recom-mended maximum differen-tial pressure. Ref:

Lead engine DR/QR Report #02-820E PE3041/52 Revision 1 - entire page revised

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O PERRY MAINTENANCE MATRIM Component Component Alt.

Number Identification PM Recommendation Monthly Outane Outage 5 Year 10 Year Comments 02-820F Full Flow Lube 011 1.

Record filter d/p.

X Use for trend data, Filters Ref: 04/02/84 IOC from M. Wehmeyer to J. DiMare, Ref: TDI Instruction Manual, Volume I, Maintenance Schedule 2.

Drain water end/or k

sludge from ;ubri-cating oil full flow filter.

3.

Replace filter 10 Le perfa % d before cartridges and the f t1ter e/p reaches tne perform a visual manufacturers recommended inspection to maximum differential determine the pressure. Ref: 05/30/84 nature of the IOC from M. McGerigle material caught to B. Brown, in the filter.

Ref: Lead engine DR/QR Report #02-820F, Ref: 07/31/84 IOC from J. Cadogan to M. McGerigle 4.

Lube oil filter X

gauge - calibra-tion check.

l PE3041/S3 Revision 1 - entire page revised l

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PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments 02-820G Lube Oil Heat 1.

Perform a daily visual Ref: Shoreham DR/QR Exchanger inspection for leakage Report #10-109, at packing. Verify Ref: 06/12/84 IOC that no leakage is from R. Chit to present through the P. Martia, leak-off ports of Ref: 04/02/84 IOC the lantern ring.

from M. Wehmeyer to R. Kadlec 2.

Record heat X

Use for trend data exchanger perfor-mance by checking engine operating parameters.

3.

Evaluate heat exchanger X

performance data.

4.

Inspect tubes and X

Ref: TDI Instruction tube sheet for Manual, Volume I, erosion and fouling -

Maintenance Schedule, remove entrance and Ref: 07/19/84 Telecon exit channel covers.

D. Pasquale and R. Chii 5.

Inspect and clean X

Replace / rework lantern ring.

lantern ring as Verify leak-off necessary to holes are not ensure concentricity.

plugged.

6.

Replace packing X

And/or packing becomes rings at the floating hard or leakage at the i

l tube sheet during packing is noted and reassembly after each cannot be stopped by inspection.

tightening.

Revision 1 - entire page revised i

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PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 7.

Perform a spectro To be performed at chemical analysis approximate quarterly of the lube oli.

Intervals.

Particular attention Ref: Lead engine shall be given to DR/QR Report #02-820G percent moisture content.

02-835A Air Dryers and 1.

Blow down trap X

Ref: 04/05/84 IOC Moisture Traps sediment bowls, from M. Wehmeyer to J. Kammeyer, Ref: TDI Instruction Manual, Volume I, Maintenance Schedule 2.

Inspect and service X

moisture traps.

3.

Check proper operation X

Replace desiccant charge of desiccant dryer.

as required.

Ref: 04/16/84 letter from R. Jaquinto to R. Johnson 02-8358 Starting Air Tank 1.

Drain air receiver float If quantity of traps or drain valves moisture is DAILY and monitor the excessive correct quantity of moisture immediately. Check produced at the float air dryer operation.

traps or drain valves.

Ref: Lead engine DR/QR Report #02-835J 2.

Disassemble and clean X

Ref: IOC dated the float trap.

05/08/84 from P. Titus to P. Martin (Items 1

& 2)

Revision 1 - entire page revised l

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s PERRY MAINTENANCE MATRIX Component Component Alt.

I humber Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments i

3.

Starting air tank pressure X

gauges - calibration l

check.

)

4.

Starting air tank pressure X

switches - calibration check.

02-835D Starting Air Compressors 1.

Check lubricating oil X

All items; Ref:

level.

04/02/84 IOC with attached Maintenance i

Chart from M. Wehmeyer to J. Kammeyer.

l 2.

Overall visual X

l inspection.

3.

Clean fins on inter X

j and after coolers.

I 4.

Replace intake filter X

element.

5.

Change compressor oil.

X 4

6.

Check belt tension.

X l

7.

Check pulley clamp X

]

. bolts / set screws tight.

l 8.

Inspect filter felts on X

Replace as necessary.

3 unloader system.

i PE3041/56 Revision 1 - entire page revised r

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J PERRY MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage outene 5 year 10 Year Comments Jacket Water System 1.

Check pH. factor X

Ref: TOI Instruction of Jacket water and Manual, Volume I, Main-correct as recom-tenance Schedule mended by chemical supplier.

2.

Replace elastomeric parts X

in jacket water valves.

Lube Oil System 1.

Check lubricating X

Ref: TDI Instruction all with a viscost-Manual, Volume I, Main-meter for fuel oli tenance Schedule, Items dilution. Send a 1, 2 sample of oil to laboratory for analysis.

2.

Drain lubricating X

When replacing engine oli system and oil use H.D. oli that clean sump tank.

meets or exceeds series 3 Depending on the s tandards. The base stock results of lube should be more resistant oli analysis, refill to thermal degradation with new oil.

and coke formation. The additive package should provide high detergent dispersant properties with high alkalinity and a high level of antiwear additive such as Zinc dithiophosphate. Total Base Number (TBN) should be 12 to 15 for use with

1. 2 fuel oil and a sulfated ash content of 1.5% to 2.0%

Revision 1 - entire page revised c

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PERRY MAINTENANCE MATRIN Component Component Alt.

Number Identification PM Recommendation Monthly Outage Qutane 6 Year 10 Year Comments is preferred. An engine oil with such properties.

Mobilguard 412 or a

equivalent product may be used to insure improved lubrication.

]-

3.

Visually inspect lube X

To be performed i

oil sump tank level after lube oil switch floats, has been drained j

i Check switch set from sump.

points.

4.

Perform a spectro-To be performed at chemical analysis approximately quarterly

,i of the lube oil.

intervals. Ref: TDI l

Instruction Manual, Volume I, Maintenance

Schedule, i

System Operation 1.

Record all operating X

To be performed j

parameters. Compare during monthly with base line data engine test run.

to ensure engine is operating properly.

Piping System 1.

Conduct a detailed X

Tighten, repair or 1

visual and audible replace as required.

l inspection of all Ref: TDI Instruction fuel, air, oli, Manual, Volume I, and water piping Maintenance Schedule and valves for leakage.

1 i

PE3041/58 j

Revision 1 - entire page revised 4

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PERRY MAINTENANCE MATRIX Component component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 2.

Inspect, clean and X

as applicable, lubricate manual valves on skid.

Engine Internals 1.

Remove alternate left X

If excessive side doors and water, sludge or examine the inside any indication of of the engine for any bearing failure abnormal. conditions.

is present, drain Check with a good.

crankcase, deter-light for evidence of mine cause, and take babbit flakes.

necessary action.

Miscell-Engine Mounted 1.

Replace elastomeric X

Enceous Pressure Switches parts.

Gear Train 1.

Inspect gears for X

general condition.

2.

Measure gear back X

Replace worn lash on all gears.

gears exceeding maximum clearance.

Complete TDI Inspection and Maintenance Form No. 355-1-1 TDI Instruction Manual, Vol. I, Section 5.

Use Vol. I, Section 8 Appendix III-I

]

for clearance values.

Ref: 04/16/84 letter j

from R. Jaquinto to i

R. Johnston PE3041/59 Revision 1 - entire page revised l

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