ML20108D562

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

ML20108D562
Person / Time
Site:	Comanche Peak
Issue date:	01/31/1985
From:	Rick Deese, Ray C TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP
To:
Shared Package
ML20108D551	List: ML20108D562 TXX-4430, Forwards Rev 1 to Tdi Diesel Generator Design Review & Quality Revalidation Rept
References
NUDOCS 8503080409
Download: ML20108D562 (171)

Text

____________

O TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT prepared for TEXAS UTILITIES GENERATING COMPANY COMANCHE PEAK STEAM ELECTRIC STATION - UNIT 1 by TDI DIESEL GENERATOR OWNERS GROUP REVISION 1 January, 1985 Reviewed by:

A R. J. Deese Licensing Coordinator TDI Diesel Generator Owners Group Approved by:

b, C. L. Ray Technical Program Director TDI Diesel Generator Owners Group 8503080409 850301 PDR ADOCK 05000445

(]

S PDR TDIO888

.. ~. :v.

2.6 FINAL DOCUMENTATION The DR/QR program has been completed for texas Uti.lities.

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

Appendix I contains component DR/QR Sumary Reports which provide a detailed sumary of the review and analysis performed on each component including references to supporting documentation and the recomendations j

and conclusions resulting from this effort.

j i

I 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 Sumary 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 1

the DR/QR Program on the Comanche Peak TDI diesel generators.

O O

TDIO888 2-7 Rev. I

b 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 34) which 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, 03-3050)

Crankshaft Unlimited Life None (03-310A)

(provided the engines are run at no greater than a 3130 kW load.)

O Cylinder Block Unlimited Life Additional maintenance and V

and Liner inspection requirements.

(03-315A, 03-315C)

Cylinder Head Unlimited Life None Studs (03-315E)

Connecting Rods:

Unlimited Life Additional inspection Connecting Rods requirements.

and Bushings (03-340A)

Connecting Rod Unlimited Life Additional maintenance Bearing Shells requirements. Additional (03-3408) inspections recommended.

Pistons (03-341A)

Unlimited Life AN piston skirts 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.

l (( )

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

Assembly (03-365C)

Procurement specification l

requirement.

TDI1191 3-2 REV 1 t.

($)

Component Acceptability Recommended Action Main and Connector Unlimited Life Additional procurement Pushrods (03-390C, requirement.

Additional 03-3900) inspections recommended.

Random destructive testing recommended.

Rocker Arm Unlimited Life Additional maintenance Capscrews requirements.

1 (03-390F) l Jacket Water Unlimited Life Additional maintenance Pump (03-425A) requirements.

Wiring and Unlimited Life None Terminations (03-6888)

O i

a 1

O TDI1191 3-3 REV 1

._~

O 3.2 Summary Resolution of Phase II Components Component Acceptability Recommended Action t

TURBO, INTAKE, INTERCOOLER & EXHAUST Intercooler Unlimited Life Additional maintenance (F-068) requirements.

Turbocharger Unlimited Life See section 3.1 (MP-022/023)

Turbocharger Modifications Addition of supports-Thrust Bearing Drip Lube System j

(02-CFR)

~

~ Air-Intake Modifications Installation of missing Manifold U-bolt nuts. Additional (02-375) installation requirements.

Exhaust Modifications Replace slip joints with Manifold Piping slip on flanges. Additional

~

(02-380A) maintenance requirements.

Exhaust Manifold Unlimited Life None Bolting and Gaskets j.,

(02-3808)

.Intercooler Piping - Unlimited Life None Pipe (02-436A)

Intercooler Piping - Unlimited Life None l

Gaskets, Bolting (02-4368) l

-Turbocharger Bracket Unlimited Life Additional inspections Bolting and Giskets (pending con-of the. bracket to engine (02-475A&C) firmation of and bracket to turbo base I

acceptable screws recommended.

engine vibration levels) l Air Butterfly Modifications Addition.of grease fittings Valve to valve shaft. Additicnal (02-4758) maintenance requirements.

O TDI1191 3-4 REV. 1

-,r,"v...-w

-~

-,,- e

4 Component Acceptability Recommended Action Intake Air Unlimited Life None Silencer (02-805A)

Intake Air Unlimited Life-Additional maintenance Filters requirements.

i (02-805B)

Flex Connections Unlimited Life None (02-8050)

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

(00-420)

Lube Oil Fittings -

Modifications Modification of several Internal - Headers supports.

(02-307A)

Lube Oil Fittings -

Unlimited Life None Internal ~- Tube and Fittings (02-3078) 4 Lube Oil Fitting -

Modifications Modification of several Internal - Supports supports.

-(02-3070)

Engine Driven Unlimited Life None Lube Oil Pump (02-420)

Lube Oil Lines Modifications Addition of supports.

External - Tubing, Additional installation Fittings, Couplings requirement.

l-(02-465A)

Lube Oil Lines Modifications Modification of a support.

External - Supports (02-465B)

O TDI1191 3-5 REY. 1

(v)

Component Acceptability Recommended Action Auxiliary Sub-Base Modifications Addition, replacement and and Oil and Water modification of supports.

Piping Lube Oil:

Supports and Mounting Hardware (02-717I)

Lube Oil Sump Unlimited Life None Tank Heater (02-820A)

Miscellaneous Unlimited Life None Equipment -

Auxiliary Lube Oil Pump (02-8208)

Prelube Oil Unlimited Life Additional inspections recommended 1

820C)

^

Lube Oil Keep-warm Unlimited Life Additional maintenance Strainer (02-8200) requirements.

Oil Prelube Filter Unlimited Life Additional maintenance (02-820E) requirements.

Full Flow Lube Oil Unlimited Life Additional maintenance Filters requirements.

(02-820F)

Lube Oil Heat Unlimited Life Additional maintenance Exchanger requirements.

(02-820G)

Lube Oil Full Unlimited Life Additional maintenance Pressure Strainer requirements.

(02-820H) l ENGINE BASE & BEARING CAPS Base and Bearing Valimited Life See section 3.1 l

Caps Base l

Assembly (02-305A)

O TOI1191 3-7 REV. 1

-fi V

Component Acceptability Recommended Action Connector Pushrods Unlimited Life See Section 3.1 (02-3900)

Rocker Arms and Unlimited Life Additional maintenance Pushrods:

Bushings requirementti.

(02-390E)

Rocker Arms and Unlimited Life At each refueling outage, Pushrods - Lifters replace worn lifters.

1 (02-390F)

Rocker Arms and Unlimited Life See Section 3.1 Pushrods - Bolts, Drive Studs (02-390G)

IDLER GEAR ASSEMBLY & FRONT-GEAR CASE Front Gearcase -

Unlimited Life None Gasket and Bolting (02-3358)

D)-

Idler Gear Unlimited Life None Assembly - Crank to Pump Gear (02-355A)

Idler Gear Assembly Unlimited. Life -

Implement nut locking

-(02-3558) procedure and additional maintenance requirements.

CYLINDER HEADS & VALVES Cylinder Heads Unlimited Life See Section 3.1 (02-360A)

Intake & Exhaust Unlimited Life Additional maintenance Valves-requirements.

(02-3608)

-Cylinder Head Unlimited Life None and Valves - Bolting and Gaskets (02-360C)

Cylinder Head Unlimited Life None Valvos:

Springs and Retainers O

(02-3600)

V TDI1191 3-11 REV. 1

(3 U

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 Comanche Peak specific component numbers.

A given component report can be found by:

a)

If the component number is known - use the alpha - numeric index which identifies the volume number and category in which the component 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.

I v

j Rev. 1 TDIO907

INDEX(continued)

Component Component Vol.

Number Description Category No.

CP-101A Generator:

Generator Generator 8

CP-101B Generator: Shaft and Generator 8

Bearings CP-102 Generator Controls Generator 8

F-068 Intercooler Turbo, Intake, 2

Intrcir. & Ex-haust MP022/3 Turbocharger Turbo, Intake, 2

Intrcir. & Ex-haust 00-420 Lube Oil Pressure Lube Oil 2

Regulating Valve 00-442A Starting Air Distributor:

Air Start 4

Distributor Assembly

& Barring Device 00-442B Starting Air Distributor:

Air Start &

4 Tubing, Fittings, Gaskets Barring Device 621A Fuel-Oil Drop Tank Fuel Oil In-8 jection 02-CFR Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrcir. & Ex-haust t

02-305A.

Base and Bearing Caps: Base Engine Base 3

Assembly

& Bearing Caps 02-305C.

Base and Bearing Caps:

Engine Base 3

Main Bearing Studs & Nuts

& Bearing Caps 02-3050 Base and Bearing Caps:

Engine Base 3

Main Bearing Caps

& Bearing Caps 02-307A Lube Oil Fittings:

Lube Oil 2

Internal - Headers

.02-3078 Lube Oil Fittings:

Lube Oil 2

Internal - Tube & Fittings

' O Rev. 1 11 Entire Page Revised

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-307D Lube Oil Fitting Internal-Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

3 Bearings 02-310B Crankshaft and Bearings:

Crankshaft &

3 Bearing Shells Bearing 02-310C Crankshaft Crankshaft &

3 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy Crankshaft &

-3 Bearing 02-311D Crankcase: Crankcase Crankshaft &

3 Mounting Hardware Bearings 02-315A Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Cylinder.

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

4 Liners &

Water Manifold 02-315D Water Manifold: Jacket Cyl. Block &

4 Water Manifold & Piping Liners &

Water Manifold 02-315E Cylinder Block Liners' &

Cyl. Block &

4 Water Manifold: Studs Liners &

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

4

& Water Manifold: Nuts Liner & Water Manifold l

02-315G Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Seals and Liners &

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

Jacket Water 7

l Manifold Assembly W/ Hardware i

and Coupling and Gaskets l

Rev. 1 Entire Page Revised 949 TDIO907 i.

L

t INDEX(continued)

Component Component Vol.

Number Description Category No.

02-316B Jacket Water Inlet Manifold:

Jacket Water 7

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

Jacket Water 7

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

Jacket Water 7

Jacket Water Discharge Manifold, Coupling and Seals 02-317B Water Dicharge Manifold:

Jacket Water 7

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Water 7

Supports 02-330A Flywheel: Flywheel Flywheel 6

02-3308 Flywheel Bolting Flywheel 6

02-335B Front Gear Case-Gasket and Idler Gear As-5 Bolting sembly & Front Gear Case 02-340A Connecting Rods: Connecting Connecting 4

Rods'& Bushings Rods 02-340B Connecting Rods: Bear ^ing Connecting 4

Shells Rods 02-341A Pistons: Pistons Pistons 5

02-341B Pistons: Rings Pistons 5

02-341C Piston: Pin Assembly Pistons 5

02-345A Intake / Exhaust and Fuel Camshaft &

5 Tappet Assembly Valve Train i

02-345B Tappets and Guides: Fuel Cr.mshaft &

5 Tappet Assembly Valve Train i,

02-345C Tappets and Guides: Fuel Camshaft &

5 Pump Base Assembly Valve Train

- b

.g 4

Rev. 1 iv Entire Page Revised TOIO907

---~.---,,.r,,---

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-n.-,-e,,-.

f

' [

INDEX(continued)

Component

'Compor.ent Vol.

Number Description Category No.

02-350A Camshaft Camshaft &.

5 Valve Train l~

02-3508-Camshaft Bearing Camshaft &

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

5 and Gear Valve Train 02-355A Idler Gear Assemble: Crank Idler Gear As-5 To Pump Gear sembly & Front Gear Case

02-355B Idler Gear Assembly:

Idler Gear As-5 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valves: Air Start Air Start &-

4 Valve Barring Device 02-360A Cylindt.- Head Cylinder Heads 8

& Valves 02-360B Intake & Ext.sust Valves Cylinder Heads 8

& Valves 02-360C Cylinder Head and Valves -

Cylinder Heads 8

Bolting and Gaskets

& Valves 02-3600

- Valve Springs Cylinder Heads 8

& Retainers

& Valves 02-362A Subcover.

Camshaft &

5 Valve Train

.02-365A Fuel Injection Pump Fuel Oil In-8 jection 02-3658 Fuel Injection Nozzle Fuel Oil In-8 Assembly jection

'02-365C Fuel Oil Injection Tubing Fuel Oil In-8 jection 02-365D Fuel Injection Equipment:

Fuel Oil In-8 Supports jection

'g 02-371A Fuel Pump Linkage: Fuel Fuel Oil In-8 Pump Control Shaft jection V

Rev. 1 TDIO907.

Entire Page Revised l

l i

INDEX(continued)

Component Component Vol.

Number Description Category No.

I 02-371B Fuel Pump Linkage: Linkage Fuel Oil In-8 Assembly and Bearing jection 02-375 Air Intake Manifold Turbo, Intake, 2

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

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

Bolting and Gaskets Intrcir. & Ex-haust 02-385B Cylinder Block and Cyl. Block &

4 Crankcase Covers:

Liners & Water Gaskets and Bolts Manifold 386B Crankcase Covers: Crankcase Cranshaft &

3 Gaskets and Mounting Bearings

/

Hardware

+

V 02-390A Intake / Intermediate Camshaft &

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

Camshaft &

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

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

Camshaft &

5 Pushrods Connector.

Valve Train 02-390E Rocker Arms and Pushrods:

Camshaft &

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

Camshaft &

5 Lifters Valve Train 02-390G.

Rocker Arms and Pushrods-Camshaft &

5 Miscellaneous Bolts &

Valve Train Drive Studs

!V Rev. 1 TDIO907

1

.v y.

~ INDEX(continued)

. Component Component Vol.

Number' Description Category ~

No.

02-41'0A Overspeed Trip: Governor Overspeed Trip 6

& Governor 02-410B Overspeed Trip: Governor Overspeed Trip 6

and Accessory Drive

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 6

& Governor 02-4100'

'Overspeed Trip Vent Valve Overspeed Trip 6

& Governor 02-411A Governor Drive: Governor Overspeed Trip 6

-and Tachometer Drive Gear

& Governor

& Shaf't 02-411B Governor Drive: Couplings, Overspeed Trip 6

Pins & Keys:

& Governor 02-413A Governor. Linkage

'Overspeed Trip 6-

& Governor 02-413B Fuel Pump Linkage Fuel Oil In-8 jection 02-415A' Governor ~ Assembly: Woodward Overspeed Trip 6

Governor

& Governor 02-415B Governor Assembly - Booster Overspeed Trip 6

'Servometer

& Governor 02-415C Governor Assembly Heat Overspeed Trip 6

Exchanger

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425A Engine Driven Jacket Water 7

j-Jacket Water Pump

' 02-435A Jacket Water Fittings:

Jacket Water 7

i Piping 02-435B Jacket Water Fittings:

Jacket Water 7

Supports 02-435C Jacket Water Inlet Fittings:

Jacket Water 7

Valves Rev. 1 y99 TDIO907 Entire Page Revised

-.., 2.

. -.. ~

INDEX(continued)

Component Component.

Vol.

-Number-Description Category No.

02-436A Intercooler Piping Turbo Intake, 2

and Piping Couplings, Intrcir. & Ex-Gaskets and Bolting haust 02-436B Intercooler Piping: Coupling, Turbo Intake, 2

Gaskets, Bolting Intrcir. & Ex-haust 02-437 Turbo Water Piping:

Jacket Water 7

Pipe & Fittings T 441A Starting Air Manifold:

Air Start &

4 Piping, Tubing and Fitting Barring Device 02-441B Starting Air hnifold Air Start &

4 Valves. Strainer & Filters Barring Device

. 02-441C Starting Air Manifold:

Air. Start &

4 Supports

-Barring Device 02-445 Fuel Oil Booster Pump Fuel Oil In-8 jection 02-450A Fuel Oil Headers Piping /

Fuel Oil In-8 Tubing jection 02-450B Fuel Oil Header: Fuel Oil Fuel Oil In-8 Tubing Supports jection 02-455A Fuel Oil Filters &

Fuel Oil In-8 Strainers: Fuel Oil Filters jection 02-4558 Fuel Oil Fuel Oil In-8

[

Strainers jection i

02-455C Fuel Oil. Filters and Fuel Oil In-8 l

Strainer Mounting Hardware jection i

02-465A Lube Oil Lines External:

Lube Oil 2

l- -

Tubing, Fitting, Ccuplings l-

'02-465B Lube Oil Liners External Lube Oil 2

Supports l

02-465C Lube Oil Lines External:

Lube Oil 2

Valves viii Rev. 1 TDIO907 Entire Page Revised

e

(]s INDEX(continued)

Component Component Vol.

Number Description Category No.

02-467A Turbocharger: Lube Oil Lube Oil 2

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

Fittings - Supports 02-475A Turbocharger:. Bracket Turbo, Intake, 2

Intrc1r. & Ex-haust

.02-475B Air Butterfly Valve Turbo, Intake, 2

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

Turbo, Intake, 2

Bolting & Gaskets Intrcir. & Ex-haust

.02-500A Control Panel Assembly:

Control Panel 9

Cabinet / System Assembly L

02-500F Control Panel Assembly:

Control Panel 9

Accumulator Assembly 02-500G Control Panel Control Panel 9

Valves Assembly 02-500H Control Panel Assembly:

Control Panel 9

Pressure Switch Assembly 02-500J Control Panel Assembly:

Control Panel 9

Relays Assembly 02-500K Control Panel Assembly:

Control Panel 9

Solenoid Valves Assembly r

02-500M Control Panel Assembly-Control Panel 9

Piping, Tubing, and Assembly Fittings 02-500N Miscellaneous Equipment Control Panel 9

Terminal Boards /Switchs/

Assemoly i

Wiring 02-540A Lube Oil Sump Lube Oil 3

Tank with Strainer Assembly and Mounting j

Hardware I

ix Rev. 1 TOIO907 Entire Page Revised i

INDEX(continued)

Component Component Vol.

Number Description Category No.

i 02-540B Lube Oil Sump Tank: Misc.

Lube Oil 3

Fittings, Gaskets, Pipe

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

Lube Oil 3

i Mounting Hardware t

02-550 Foundation Bolts:

Engine & Aux.

9 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly:

Engine Instru-6 Conduit mentation &

Wiring 02-6308 Pyrometer Conduit Assembly:

Engine Instru-6 Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly:

Engine Instru-6

/~

Support mentation &

'(

Wiring 02-6300 Pyrometer Conduit Assembly:

Engine Instu-6 Thermocouples mentation &

Wiring 02-688A Engine & Aux Module Wiring Engine Instru-6 Material: Conduit & Fittings; mentation &

Pyrometer conduit assembly -

Wiring conduit, Fittings, Supports 02-6888 Engine & Aux. Module Engine Instru-6 Wiring Material: Wiring mentation &

& Terminations Wiring 02-688C Engine & Aux. Module Wiring Engine Instu-6 Material: Boxes & Terminals mentation &

Wiring 02-689 Off Engine Alarm Engine Instru-6 Sensors: Wiring mentaticn &

Wiring 02-693 On Engine Alarm Sensors Engine Instru-6 i

mentation &

Wiring x

Rev..l TDIO907 Entire Page Revised

. p.c)

INDEX(continued) t Component Component Vol.

Number Description Category No.02-691 Off Engine Alarm Engine Instru-6 Sensors:

mentation &

Wiring 02-695A Engine Shut Down Equipment Engine Shut-6 Tubing / Fittings & Supports down & Equip-ment 02-695B Engine Shut Down Equipment:

Engine Shut-6 Valves, Regulator, Orifice down & Equip-ment 02-695C Engine Shutdown: Trip Engine Shut-6 Switches down & Equip-ment 02-700A Jacket Water Stand Pipe-Jacket Water 7

Pipe, Fittings, Gaskets 02-700B

' Jacket Water Stand Pipe:

Jacket Water 7

Valves 02-700C Jacket Water Stand Pipe-Jacket Water 7

s Supports 02-700E Jacket Water Stand Pipe-Jacket Water 7

Switches 02-700F Jacket Water Stand Pipe Jacket Water 7

and Misc. Bolting Material 02-717A Aux Sub Base and Oil and Engine Aux.

9 Water Piping-Aux Sub Base Sub-8ase &

Foundation Bolts 02-717B Aux Sub Base and Oil and Jacket Water 7

Water Piping-Jacket Water Valves 02-717C Aux Sub Base & Oil Water Jacket Water 7

Piping-Jacket Water: Pipe, Couplings, Fittings, Orifices, Y Strainers 02-7170 Aux Sub Base & Oil & Water Jacket Water 7

Piping: Jacket Water Gaskets

& Bolting Rev. 1

1. 9*

• TDIO907

(O v )-

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-717E Aux Base & Oil & Water Jacket Water 7

Piping: Jacket Water Supports 02-717F Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping and Tub-ing - Lube Oil - Pipe, Tubing, Fittings 02-717G Aux Sub Base & 011 & Water Lube Oil 3

Piping: Lube Oil-Valves 02-717H Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping-Lube Oil-Gaskets and Bolting 02-717I Aux Sub Base and Oil and Lube Oil 3

Water Piping: Lube Oil-Supports & Mounting Hardware 02-717J Aux Sub Base & Oil & Water Fuel Oil In-8

('_/')

Piping: Fuel Oil-Piping jection s

N_

and Fittings 02-717K Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Valves jection 02-717L Aux Sub Base and Oil and Fuel Oil In-8 Water Piping-Fuel jection Oil-Gaskets and Bolting 02-717M Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Supports jection 02-805A Intake Air Silencer Turbo, Intake, 2

Intrcir &

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

Intrcir &

Exhaust 02-8050 Flex Connections Turbo, Intake, 2

1 Intrcir &

Exhaust 02-810A Auxiliary Jacket Water Jacket Water 7

/\\

Pump V

xii Rev. 1 TOIO907 Entire Page Revised

f)

V INDEX(continued)

Component Component Vol.

Number Description Category No.

02-810B Jacket Water Standby Jacket Water 7

Heater Pump 02-810C Jacket Water Heat.

Jacket Water 7

Exchanger 02-8100 Jacket Water Thermostatic Jacket Water 7

Valve 02-810E Misc. Equipment:

Jacket Water 7

Jacket Water Standpipe Heater 02-820A Misc. Equipment:

Lube Oil 3

Lube Oil Sump Tank Heater 02-820B Auxiliary Lube Lube Oil 3

Oil Pump 02-820C Pre-Lube Oil Lube Oil 3

[

Pump 02-8200 Lube Oil Lube Oil 3

Keepwarm Strainer 02-820E Oil Prelube Filter Lube Oil 3

02-820F Full Flow Lube Oil Filter Lube Oil 3

02-820G Lube Oil Heat Exchanger Lube Oil 3

02-820H-Lube Oil Full Pressure Lube Oil 3

Strainer 02-825A Fuel Oil Fuel Oil 8

Day Tank Injection l

02-825B Miscellaneous Equipment Fuel Oil 8

Fuel Oil Transfer Pump Injection 02-825E Fuel Oil System: Fuel Oil Fuel Oil 8

Duplex Strainer Injection 02-935A Air Start System: Starting Air Start &

4 Air Skid Base Barring Device r

Rev. 1 i

TDIO907 Entire Page Revised i

L

INDEX(continued)

Component Component Vol.

Number Description Category No. 8350 Starting Air Tank Air Start &

4 Relief Valve Barring Device 02-835F Starting Air Float Trap Air Start &

4 Barring Device 02-835J

. Starting Air Tank Air Start 4

Barring Device Appendix II 9

Appendix III 9

O O

Rev. 1 TDIO907 Entire Page Revised

V)

Page 2 of 3

(

The evaluation of the exhaust water jacket was performed in accordance with the philosophy, and intent of the ASME Code,Section III " Nuclear Power Plant Components"; Subsection ND for Class 3 Components.

. Quality Revalidation Checklist results were reviewed for acceptability.

The TDI Emergency Diesel Generator Component Tracking System was reviewed for the Comanche Peak site, nuclear, and non-nuclear industry experience.

IV RESULTS ANu CONCLUSIONS The maximum deadweight stress for the subject component is 2,260 psi.

The piping load controlled seismic stresses were acceptable, never exceeding 7,060 psi.

Thermal expansion stresses were somewhat higher, with stresses always less than 16,500 psi and the stresses caused by axial discontinuity at the in-line slip joints were less than 4,320 psi.

All piping stresses are acceptable.

Consistent with intent and philosophy of the ASME Code, the adoption of an inspection program which provides a means for identifying the possible degradation of the exhaust manifold piping components, particularly the welded joints is recommended (Ref.3).

[

Because of the flexibility of the slip joints, especially with respect to seismic considerations, modifications are recommended for the present configuration.

Four of the twelve slip joints for this component require removal and replacement with 150 lb. slip-on flanges.

The remaining eight slip joints were found to be acceptable and will perform their intended design function at Comanche Peak.

The exhaust water jacket was evaluated for normal operating loads, earthquake (OBE and SSE), thermal effect, and the effects of all applicable load combinations described in Reference 1.

The intent and philosophy of ASME Code Section III, Subsection ND for Class 3 components was used as the acceptace criteria.

Based on this review it is concluded that the exhaust ' water jacket is acceptable for its intended design function at Comanche Peak.

In the event of a SSE, it is recommended that the cap screws which hold the water jacket to the exhaust manifold assembly support be inspected at some time subsequent to the SSE event and replaced if the inspection warrants, but the equipment will continue to operate safely after a SSE event.

The following maintenance recommendation is required to be performed on the exhaust manifold:

Perform a visual inspection and a Magnetic Particle test for a sampling of the circumferential pipe welds and corresponding I

heat affected zones.

This is to be performed during the first refueling outage and alternate t -

outages thereafter.

However, diesel operation should not exceed 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> betw'aen inspections.

TDI1168/2 Rev. I r

r-

4 l

g] -

(

Page 3 of 3 All pipe loads on the engine block and turbocharger have been tabulated and issued for evaluation.

The information provided on the following TERs has been reviewed and is consistent with the final conclusions of this report: 10-115 and 10-134.

Quality Revalidation Checklist 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 conclusion of this report.

Based-on the above review, it -is concluded that the subject ping components, with the recommended modifications and inspection (Ref.4). are adequate for their intended design function at Comanche Peak.

V REFERENCES 1.

" Supporting Calculations for the Evaluation of Comanche Peak Diesel Generator Large Diameter Piping and Supports, "

Impell Report No.

02-0630-1230, Rev. O, August 1984.

2.

" Design Criteria for Diesel Generator Large Diameter Piping," Impell Report No. 02-0630-1231, Rev.

O, August 1984, This is included in Appendix III of the final DR/QR report.

3.

Memorandum form G. Shears (Impell) to J. Kammeyer (SWEC), " Inspection program for Exhaust Manifold, " August 13, 1984.

4.

Memorandum from R.

Markovich/G. Shears (Impell) to J.

Kammeyer (SWEC), " Required Modifications for Validations of Impell's Design Review for Impell Report No. 02-0630-1215, Rev. A," dated August 13, 1984.

t Rev. 1 Carryover From TDI1168/3 Previous Page

'V Page 2 of 3 the background and provides the technique for evaluating the subject pip-ing components and supports.

This criteria is presented in its entirety in Reference 2.

Quality Revalidation Checklist results were reviewed for acceptability.

The TDI Emergency Diesel Generator Component Tracking System was reviewed for the Comanche Peak site, nuclear, and non-nuclear industry experience.

The Dresser couplings were evaluated by comparing the coupling against the manufacturer's selection and service requirements.

These included the design service conditions, relative end displacements -- both translation-al and rotational of the joined pipe, and shelf and service life.

IV RESULTS AND CONCLUSIONS The maximum. deadweight stress for the intercooler piping. is 2,200 psi.

The piping load-controlled seismic stresses were acceptable, never exceed-ing 9,500 psi.

Thermal expansion stresses were lower, with stresses less than 800 psi, and the stresses caused by the axial discontinuity at the in-line Dresser couplings were less than 2200 psi.

All piping stresses were within the design allowables specified by the ASME Section III Code.

'v) t The total movements at two of the Dresser couplings (Style 38, 7 inches long) are within the manufacturer's allowables, Reference 3.

The move-ments due to thermal, deadweight, and pressure on the intercooler inlet pipe coupling are within the manufacturers allowables.

However, the increment due to seismic loading exceeds allowables by less.than 20 percent.

Since the seismic loading is occasional, this is acceptable.

TERs 10-60 and 10-108 have been reviewed.

These TERs indicate that the Dresser couplings are Style 450 and not Style 38, as listed in the Comanche Peak TDI Parts Manual.

However, per Reference 5, the Dresser l)

Manufacturing Co.

does not manufacture a Style 450 coupling.

An Impell field walkdown has confirmed that a Style 38 is installed and is accept-able.

The information provided on the following TERs has been reviewed and is consistent with the final conclusions of this report: 10-115 and 10-134.

There are no service life constraints (Ref. 4) because these couplings have no significant history of failure.

Shelf life (Ref. 4) is unlimited as long as the' gaskets remained packed and protected from the elements:

light, water, etc.

The coupling is adequate with respect to manufactur-er's service condition limits.

v TDI1225/2 Rev. 1

Page 3 of 3 All pipe loads on the intercooler were tabulated and issued for evaluation.

Quality Revalidation Inspection results identified in Appendix 8 have been reviewed and considered in the performance of this design review and the results are consistent with the final conclusion of this report except for information on TERs10-060 and 10-108 which was superseded by Impell's field walkdown.

Based on the above review, it is concluded that the subject piping compo-nents are adequate for the intended design function at Comanche Peak.

V REFERENCES 1.

" Supporting Calculations for the Evaluation of Comanche Peak Diesel Generator Large Diameter Piping and Supports," Impell Report No.

02-0630-1230, Rev. O, August 1984.

2.

" Design Criteria for Diesel Generator Large Diameter Piping for Comanche Peak," Impell Report No. 02-0630-1231, Rev. O, August 1984.

This is included in Appendix III of the final DR/QR report.

3.

Dresser Pipe Couplings, Pipe Fittings, and Pipe Repair Products Catalog, No. 63.

.[3\\

V 4.

Telephone - Conservation A. Palumbo and M. Riley, of Dresser Manufac-turing Co., June 5, 1984.

5.

Telephone Conversation A. Palumbo and B. Steck, of Dresser Manufac-

)

turing Co., July 25, 1984.

TDI1225/3 Rev. 1

7 Page 2 of 3 l

IV RESULTS AND CONCLUSIONS The SDRC seismic analysis report adequately modeled the turbocharger bracket; _however, loads were only based upon seismic inertia loads and dead weight.

Analyses of the Shoreham bracket (Ref. 2) indicated that pipe thermal loads and engine vibration loads may be the most significant loads. experienced by the bracket and bolts.

By comparison to the Shoreham bracket which was stress analysed, it can be concluded that the bracket is designed to have a high stiffness and would not be a weak point.

Stresses in the Shoreham bracket were found to be insignificant.

The Comanche Peak bracket is similar in that it is of substantial cross section and uses full penetration welds for major structural connections.

The SDRC analysis reported stresses for 1 inch diameter bracket bolts, while 3/4 inch bolts are specified in the parts listing.

In TER 10-122 it was determined that 3/4 inch bolts were used.

The 3/4 inch bolts have been analyzed and found to have adequate strength (Ref. 3).

However, the review of the turbocharger 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 o

screws - (P.N. GB-001-143 and GB-001-120) are recommended to be inspected on a regular basis as discussed below:

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

If during these inspection none of the screws are found I

loosened or damaged, from then on inspections are to be conducted on a yearly basis (or during plant shutdown).

But if at any time during 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.

To avoid damage to the bracket to engine, and/or bracket to turbo base screws, the proper torques as deliniated above should be utilized for each respective bracket bolting application.

The information provided on the following TERs has been reviewed and is consistent with the final conclusions of this report: 10-035,10-110, and 10-122.

The bolts ~ as currently installed have been torqued correctly, are of the correct material, have adequate thread engagement, and have been installed properly.

Quality Revalidation 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 conclusion of this ' report.

~

Based on the above review, the turbocharger bracket and bolting have been found adequate for their intended service at Comanche Peak pending confirmation of acceptable engine vibration levels.

TDI1183/2 REV 1

.n

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,.,,,,-.m,

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

y i

Page 3 of 3 V

REFERENCES 1.

SORC Seismic Report No. 7663 on DSRV-16-4 Diesel Gen. Units.

2.

Stone Webster Calculation No.

11600.02 NM(B)

-437-CIC-039,

" Design Review of the Turbocharger Bracket and Bolting."- (Shoreham) 3.

Stone & Webster Calculation No. 11600.60-NM(B)-001-CZC-039, " Design 1

Review of the Turbocharger Bracket and Bolting."

(Comanche Peak) j O

r l

4 L

?.l TDI1183/3 Rev. 1 j

1 1

Appendix C Page C2 of 2 1

REFERENCE COMANCHE PEAK EXPERIENCE DOCUMENTS STATUS NON-NUCLEAR Breakage of holddown City of Homestead Nozzle loads for Comanche capscrews of turbocharger Florida Peak have been reviewed due to high stress in Letter from J. Smith and were found acceptable, manifold-turbo-jumper (Homestead) to pipe area.

G. Trussell (TOI) 05/14/77.

Due to high vibration, Rafha Electricity Co.

The means to resolve vibra many. bracket-to-engine and Suburbs, Saudi tion concerns mounting bolts failed.

Arabia dated are provided in the OR Bolts were replaced 07/12/81 (File #T-57).

report.

See text for further details.

• s O

5 O

TDI1183/2 REV 1

Appendix B~

Page 81 of 3 10-02-465B COMPONENT QUALITY REVALIDATION CHECKLIST i

Lube Oil Lines Texas Utilities Generating Co.,

COMPONENT External - Supports UTILITY Comanche Peak Station GPL NO.

02-465B REV. NO.

2

' SNPS GPL NO.

03-465B TASK DESCRIPTIONS-D.G. CP1-MEDGEE-01 1.

Assemble and review existing documentation.

2 2.

Verify the proper installation of the supports by a line walkdown.

3.

Perform a material comparator test on the supports. required by TER#

10-115.

D.G. CP1-MEDGEE-02 Same as D.G. CP1-MEDGEE-01 ATTRIBUTES TO BE VERIFIED D.G. CP1-MEDGEE-01 1.

Quality status of Component Document Package 2.

All supports are installed in accordance with the issued as-built i

isometric drawings.

~

3.

Material of supports required by TER# 10-115.

.D.G.

CP1-MEDGEE-02 Same as D.G. CP1-MEDGEE-01 O

REV. 1 TDIO571/1 NEW PAGE

u-()

COMPONENT QUALITY REVALIDATION CHECKLIST-Page B2 of 3 10-02-465B ACCEPTANCE CRITERIA D.G. CP1-MEDGEE-01 1.

Satisfactory Document Package 2.

Review of detailed information by the Design Group 3.

Review of inspection report by Design Group D.G. CP1-MEDGEE-02 Same as D.G. CP1-MEDGEE-01 4 '

-REFERENCES D.G. CP1-MEDGEE-01 1.

QCI-FSI-F11.1-020 2.

Procedure DG-7 3.

TER# 10-115 D.G.' CP1-MEDGEE-02 Same as D.G. CP1-MEDGEE-01 DOCUMENTATION REQUIRED D.G. CP1-MEDGEE-01 1.

. Document Summary Sneet 2.

Quality verified as-built isometric drawing for supports.

3.

Inspection Report D.G. CP1-MEDGEE-02 Same es D.G. CP1-MEDGEE-01 '/' /

.i J '/..

y,'

7'L;E~

PROGRAM MANAGER -'

T. L.

GROUP CHAIRPERSON REV. 1 TDIO571/2 NEW PAGE x..

COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 3

- d~

10-02-465B COMPONENT REVIEW D.G. CP1-MEDGEE-01 1.

.No EDGCTS site experience documents are in evidence.

2.

The Design Group will be responsible for closing out the as-built

. drawings as per Procedure DG-7.

The as-built drawings will be Quality verified by the appropriate site Quality organization.

-3.

A material comparator test was performed on a lube oil support as required by TER# 10-115.

Results were reported by TER# 10-134.

D.G. CP1-MEDGEE-02 Same as D.G. CP1-MEDGEE-01 RESULTS AND CONCLUSION D.G. CP1-MEDGEE-01

-The-Quality Revalidation effort with respect to this component,- as outlined above, is complete.

The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of the final report.

^

D.G. CP1-MEDGEE-02 Same as D.G. CP1-MEDGEE-01

'y

/

o GROUP CHAIRPERSON sroht // hih/4 PROGRAM MANAGER-f

~. -/~

i 1

1 4

REV. 1 NEW PAGE TDIO571/3

O HOW TO USE THIS REPORT Tabs in this report identify the following categories:

Turbo, Intake, Intercooler & Exhaust j

4 -

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 Bolt <,

These categories have been defined to allow the re:. der to review a complete diesel generator subsystem in a convenient manner.

Within each category tabs identify Comanche Peak specific component numbers.

i A given component report can be found by:

a)

If the component number is known - use the alpha - numeric index which identifies the volume number and category in which the component 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.

I O

i j

Rev. 1

-TDIO907

~...+,..y-.

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

.-.,,,...--_.,,r,.-.-,-~,.,,,.-,--,m,.,

....,m,__-.,-..--,,m_-,,,,,.,-.--m.---.,-,,--,.,,.-,,..r-

INDEX(continued)

Component Component Vol.

Number Description Category No.

CP-101A Generator: Generator Generator 8

CP-101B Generator: Shaft and Generator 8

Bearings CP-102

~

Generator Controls Generator 8

F-068 Intercooler Turbo, Intake, 2

Intrcir. & Ex-haust MP022/3 Turbocharger Turbo, Intake, 2

Intrcir. & Ex-haust 00-420' Lube Oil Pressure Lube Oil 2

Regulating. Valve 00-442A Starting ' Air Distributor:

Air Start 4

Distributor Assembly

& Barring Device 00-442B Starting Air Distributor:

Air Start &

4 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drop Tank Fuel Oil In-8 jection 02-CFR

. Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrcir. & Ex-haust 02-305A Base and Bearing Caps: Base Engine Base 3

Assembly

& Bearing Caps 1

02-305C Base and Bearing Caps:

Engine Base 3

Main ~ Bearing Studs & Nuts

& Bearing Caps 02-3050 Base and Bearing Caps:

Engine Base 3

Main Bearing Caps

& Bearing Caps 02-307A Lube Oil Fittings:

Lube Oil 2

Internal - Headers 02-3078

. Lube Oil Fittings:

Lube Oil 2

s Internal - Tube & Fittings l

i s-Rev. 1 ii Entire Page Revised TDIO907

/

"^

v--~c-

.,, w we,e-.,r,.

.-#~

,,+<.-,ww-e.~,<m,.-.-m,--r-

+ - -,vve4e

't INDEX(continued)

• Component Component Vol.

Number Description Category No.

i 02-307D Lube Oil Fitting Internal.-

Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

3 Bearings 02-310B_

Crankshaft and. Bearings:

Crankshaft &

3 Bearing Shells Bearing 02-310C Crankshaft Crankshaft &

3 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy Crankshaft &

3 Bearing i

02-3110 Crankcase: Crankcase Crankshaft &

3 4

Mounting Hardware Bearings 02-315A Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Cylinder.

Liners & Water Block Manifold 4

02-315C Cylinder Block Liners Cyl. Block &

4 Liners &

Water Manifold 02-3150 Water Manifold: Jacket Cyl. Block &

4 Water Manifold & Piping Liners &

4 Water Manifold 02-315E Cylinder Block Liners ~ &

Cyl. Block &

4 Water Manifold: Studs Liners &

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

4

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

Cyl. Block &

4 Water Manifold: Seals and Liners &

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

Jacket Water 7

Manifold Assembly W/ Hardware and Coupling and Gaskets O

Rev. 1 Entire Page Revised 9$$

TDIO907

i 9[V INDEX(continued)

Component Component Vol.

Number Description Category No.

02-316B Jacket Water Inlet Manifold:

Jacket Water 7

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

Jacket Water 7

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

Jacket Water 7

Jacket Water Discharge Manifold, Coupling and Seals 02-317B Water Dicharge Manifold:

Jacket Water 7

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Water 7

Supports 02-330A Flywheel: Flywheel Flywheel 6

02-3308 Flywheel Bolting Flywheel 6

v 02-335B Front Gear Case-Gasket and Idler Gear As-5 Bolting sembly & Front Gear Case.

02-340A Connecting Rods:

Connecting Connecting 4

Rods & Bushings Rods 02-340B Connecting Rods: Bearing Connecting 4

~

Shells Rods 02-341A Pistons: Pistons Pistons 5

02-3418 Pistons: Rings Pistons 5

02-341C Piston: Pin Assembly Pistons 5

02-345A Intake / Exhaust and Fuel Camshaft &

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

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

5 Pump Base Assembly Valve Train

/~5 Rev. 1 iv Entire Page Revised

-TDIO907

q INDEX(continued)

Component Component Vol.

Number Description Category No.

02-350A Camshaft Camshaft &

5 Valve Train 02-3508 Camshaft Bearing Camshaft &

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

5 and Gear Valve Train 02-355A Idler Gear Assemble: Crank Idler Gear As-5 To Pump Gear sembly & Front Gear Case 02-3558 Idler Gear Assembly:

Idler Gear As-5 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valves: Air Start Air Start &

4 Valve Barring Device 02-360A Cylinder Head Cylinder Heads 8

& Valves 02-360B Intake & Exhaust Valves Cylinder Heads 8

& Valves 02-260C Cylinder Head and Valves -

Cylinder Heads 8

Bolting and Gaskets

& Valves 02-360D Valve Springs Cylinder Heads 8

& Retainers

& Valves 02-362A Subcover Camshaft &

5 Valve Train 02-365A Fuel Injection Pump Fuel Oil In-8 jection 02-3658 Fuel Injection Nozzle Fuel Oil In-8 Assembly jection 02-365C Fuel Oil Injection Tubing Fuel Oil In-8 jection 02-365D Fuel Injection Equipment:

Fuel Oil In-8 Supports jection 02-371A Fuel Pump Linkage: Fuel Fuel Oil In-8 Pump Control Shaft jection Rev. 1 TDIO907 Entire Page Revised e

~ - -

,m.-

.g..--.

-,--me,y-

..--w c,-y,r-

,-,-mm---m.-

y.

+ry--

-+-9

--+,-y.-.--m,,.

+

.-yr

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-371B Fuel Pump Linkage: Linkage Fuel Oil In-8 Assembly and Bearing jection 02-375 Air Intake Manifold Turbo, Intake, 2

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

Intrc1r. & Ex-haust 02-380B Exhaust Manifold-Turbo, Intake, 2

Bolting and Gaskets Intrcir. & Ex-haust 02-385B Cylinder Block and Cyl. Block &

4 Crankcase Covers:

Liners & Water Gaskets and Bolts Manifold 02-3868 Crankcase Covers: Crankcase Cranshaft &

3 Gaskets and Mounting Bearings p

Hardware 02-390A Intake /latermediate Camshaft &

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

Camshaft &

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

5 Pushrods Valve Train 02-3900 Rocker Arms and Pushreds:

Camshaft &

5 Pushrods Connector.

Valve Train 02-390E Rocker Arms and Pushrods:

Camshaft &

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

Camshaft &

5 Lifters Valve Train 02-390G Rocker Arms and Pushrods-Camshaft &

5 Miscellaneous Bolts &

Valve Train Drive Studs O

V Rev. 1 V

Entire Page Revised TDIO907

(~s)

INDEX(continued)

Component Component Vol.

' Number Description Cateaorv No.

02-410A Overspeed Trip: Governor Overspeed Trip 6

& Governor 02-410B Overspeed Trip: Governor Overspeed Trip 6

and Accessory Drive

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 6

& Governor 02-4100 Overspeed Trip Vent Valve Overspeed Trip 6

& Governor 02-411A Governor Drive: Governor Overspeed Trip 6

and Tachometer.Orive Gear

& Governor

& Shaft 02-411B Governor Drive: Couplings, Overspeed Trip 6

Pins & Keys

& Governor 02-413A Governor Linkage Overspeed Trip 6

& Governor 413B Fuel Pump Linkage.

Fuel Oil In-8 jection 02-415A Governor Assembly: Woodward Overspeed Trip 6

Governor.

& Governor 02-4158 Governor Assembly - Booster Overspeed Trip 6

Servometer

& Governor 02-415C Governor Assembly Heat Overspeed Trip 6

Exchanger

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425A Engine Driven Jacket Water 7

Jacket Water Pump 02-435A Jacket Water Fittings:

Jacket Water 7

Piping 02-435B Jacket Water Fittings:

Jacket Water 7

Supports i

02-435C Jacket Water Inlet Fittings:

Jacket Water 7

Valves Rev. 1 V

TOIO907 Entire Page Revised

4

[

')

INDEX(continued)

%.J Component Component Vol.

Number Description Category No.

02-436A Intercooler Piping Turbo Intake, 2

and Piping Couplings, Intrcir. & Ex-Gaskets and Bolting haust 02-436B Intercooler Piping: Coupling, Turbo Intake, 2

Gaskets, Bolting Intrcir. & Ex-haust 02-437 Turbo Water Piping:

Jacket Water 7

Pipe & Fittings 02-441A Starting Air Manifold.

Air Start &

4.

Piping, Tubing and Fit Ung Barring Device 02-441B Starting Air Manifold Air Start &

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

Air Start &

- 4 er 4

Supports Barring Device 02-445 Fuel.011 Booster Pump Fuel Oil In-8

(

)

jection 02-450A Fuel Oil Headers Piping /

Fuel Oil In-8 Tubing jection 02-450B Fuel Oil Header: Fuel Oil Fuel Oil In-A Tubing Supports jection 02-455A Fuel Oil Filters &

Fuel Oil In-8 Strainers: Fuel Oil Filters jection 02-455B Fuel Oil Fuel Oil In-8 Strainers jection 02-455C Fuel Oil Filters and Fuel Oil In-8 Strainer Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fitting, Couplings 02-465B Lube Oil Liners - External Lube Oil 2

Supports 4

02-465C Lube Oil Lines External:

Lube Oil 2

Valves J

viii Rev. 1 TDIO907 Entire Page Revised i

. im (O)

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-467A Turbocharger: Lube Oil Lube Oil 2

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

Fittings Supports 02-475A Turbocharger:

Bracket Turbo, Intake, 2

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

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

Turbo, Intake, 2

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

Control Panel 9

Cabinet / System Assembly 02-500F.

Control Panel Assembly:

Control Panel 9

Accumulator Assembly 02-500G Control Panel Control Panel 9

Valves Assembly 02-500H Control Panel Assembly:

Control Panel 9

Pressure Switch Assembly 02-500J Control Panel Assembly:

Control Panel 9

Relays Assembly 02-500K Control Panel Assembly:

Control Panel 9

Solenoid Valves Assembly 02-500M Control Panel Assembly-Control Panel 9

Piping, Tubing, and Assembly Fittings 02-500N Miscellaneous Equipment Control Panel 9

Terminal Boards /Switchs/

Assembly Wiring 02-540A Lube Oil Sump Lube Oil 3

Tank with Strainer O

Assembly and Mounting Hardware ix Rev. 1 TDIO907 Entire Page Revised

O INDEX(continued)

V Component Component Vol.

Number Description Category No.

02-5408 Lube Oil Sump Tank: Misc.

Lube Oil 3

Fittings, Gaskets, Pipe

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

Lube Oil 3

Mounting Hardware 02-550 Foundation Bolts:

Engine & Aux.

9 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly:

Engine Instru-6 Conduit mentation &

Wiring 02-630B Pyrometer Conduit Assembly:

Engine Instru-6 Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly:

Engine Instru-6 Support mentation &

V Wiring 02-6300 Pyrometer Conduit Assembly:

Engine Instu-6 Thermocouples mentation &

Wiring

'02-688A Engine & Aux Module Wiring Engine Instru-6 Material: Conduit & Fittings; mentation &

Pyrometer conduit assembly -

Wiring conduit, Fittings, Supports 02-6888 Engine & Aux. Module Engine Instru-6 i

Wiring Material: Wiring mentation &

I

& Terminations Wiring 02-688C Engine & Aux. Module Wiring Engine Instu-6 Material: Boxes & Terminals mentation &

Wiring 02-689 Off Engine Alarm Engine Instru-6 Sensors: Wiring mentation &

Wiring 02-690 On Engine Alarm Sensors Engine Instru-6 mentation &

Wiring x

Rev. 1 TDIO907 Entire Page Revised

n

(

INDEX(continued)

Component ComponIent Vol.

' Number Description Cateoory No.02-691 Off Engine Alarm Engine Instru-6 Sensors:

mentation &

Wiring 02-695A Engine Shut Down Equipment Engine Shut-6 Tubing / Fittings & Supports down & Equip-ment 02-695B' Engine Shut Down Equipment:

Engine Shut-6 Valves, Regulator, Orifice down & Equip-ment 02-695C Engine Shutdown: Trip Engine Shut-6 Switches down & Equip-ment 02-700A Jacket Water Stand Pipe-Jacket Water 7

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

Jacket Water 7

Valves b

V 02-700C Jacket Water Stand Pipe-Jacket Water 7

Supports 02-700E Jacket Water Stand Pipe-Jacket Water 7

Switches 02-700F Jacket Water Stand Pipe Jacket Water 7

and Misc. Bolting Material 02-717A Aux Sub Base and Oil and Engine Aux.

9 Water Piping-Aux Sub Base Sub-Base &

Foundation Bolts 02-717B Aux Sub Base and Oil and Jacket Water 7

Water Piping-Jacket Water Valves 02-717C Aux Sub Base & Oil Water Jacket Water 7

Piping-Jacket Water: Pipe, Couplings, Fittings', Orifices, Y Strainers 02-717D Aux Sub Base & Oil & Water Jacket Water 7

Piping: Jacket Water Gaskets h

& Bolting

%./

Rev. 1 xi Entire Page Revised

1 INDEX(continued)

Component Component Vol.

Number Description Category No.

02-717E Aux Base & Oil & Water Jacket Water 7

Piping: Jacket Water Supports 02-717F Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping and Tub-ing - Lube Oil - Pipe, 1

Tubing, Fittings 02-717G Aux Sub Base & 011 & Water Lube Oil 3

Piping: Lube Oil-Valves 02-717H Auxiliary ~Sub Base and Oil Lube Oil 3

and Water Piping-Lube Oil-Gaskets and Bolting 02-717I Aux Sub Base and Oil and Lube Oil 3

Water Piping: Lube Oil-Supports & Mounting Hardware 02-717J Aux Sub Base & 011 & Water Fuel Oil In-8 h

Piping: Fuel Oil-Piping jection C

and Fittings 02-717K Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Valves jection 02-717L Aux Sub Base and Oil and Fuel Oil In-8 Water Piping-Fuel jection Oil-Gaskets and Bolting 02-717M Aux Sub Base & 011 & Water Fuel Oil In-8 Piping: Fuel Oil-Supports jection 02-805A Intake Air Silencer Turbo, Intake, 2

Intrcir &

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

Intrcir &

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

Intrcir &

Exhaust 02-810A Auxiliary Jacket Water Jacket Water 7

Pump xii Rev. 1 TDIO907 Entire Page Revised

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-8108 Jacket Water Standby Jacket Water 7

Heater Pump 02-810C Jacket Water Heat Jacket Water 7

Exchanger 02-8100 Jacket Water Thermostatic Jacket Water 7

Valve 02-810E Misc. Equipment:

Jacket Water 7

Jacket Water Standpipe Heater 02-820A Misc. Equipment:

Lube Oil 3

Lube Oil Sump Tank Heater 02-8208 Auxiliary Lube Lube Oil 3

011 Pump 02-820C Pre-Lube Oil Lube Oil 3

Pump 02-8200 Lube Oil Lube Oil 3

Keepwarm Strainer 02-820E Oil Prelube Filter Lube Oil 3

02-820F Full Flow Lube Oil Filter Lube Oil 3

02-820G Lube Oil Heat Exchanger Lube Oil 3

02-820H Lube Oil Full Pressure Lube Oil 3

Strainer 02-825A Fuel Oil Fuel Oil 8

Day Tank Injection 02-825B Miscellaneous Equipment Fuel Oil 8

Fuel Oil Transfer Pump Injection 02-825E Fuel Oil System: Fuel Oil Fuel Oil 8

Duplex Strainer Injection 02-835A Air Start System: Starting Air Start &

4 Air Skid Base Barring Device Rev. 1 TDIO907 Entire Page Revised

J t

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-8350 Starting Air Tank Air Start &

4 Relief Valve Barring Device 02-835F Starting Air Float Trap Air Start &

4 Barring Device l'

i 02-835J Starting Air Tank Air Start 4

Barring Device 4

Appendix II 9

i Appendix III 9

l i

i O

i i

i 1

4 l

e i O l

Rev. 1 TDIO907 Entire Page Revised 1.

Y e

,,v,--r,.v,~,v..,,,-,,.

-,,-,--,-.----,v..-.

_,,,n,,n.,

,_-,n_

.n-._-,

G~Q Page 2 of 3 background and provides technique for evaluating the subject piping and supports..This criteria is presented in its entirety in Reference 2.

Quality Revalidation Checklist results were reviewed for acceptability.

The TDI Emergency Diesel Generator Component Tracking System was reviewed for the Comanche Peak site, nuclear and non-nuclear-industry experience.

-IV RESULTS AND CONCLUSIONS The maximum deadweight stress for the subject component is 3,885 psi. The piping -load controlled seismic stresses were acceptable, never exceeding 11,680 psi.

Thermal expansion stresses were higher, with stresses always less than 22,550 psi. and the stresses caused by the axial discontinuity at the in-line Dresser couplings were less than 9,130 psi.

All piping stresses were within the design allowables specified by the ASME Section III Code.

With respect to the Dresser couplings, Impell evaluated the couplings against the manufacturer's selection and service requirements.

These include the design service conditions, relative end displacements from both translation and -rotation of the joined pipes, and shelf and service life.

It is recommended that two of the five Dresser couplings for this compo-nent be modified.

To take credit for the mutual stiffening effects of the joined pipes, extra nuts. are required on the tie-rod assemblies surround-ing the two 6 inch Dresser Couplings.

Also, a 1 inch diameter rod is recommended to accommodate the compression loading.

I In addition, it is recommended that a 6 inch Style 38, 6 7/8 inch long Dresser coupling be added on the piping between the lube oil sump tank and the engine pump ' inlet to mitigate the thermal expansion loading and stresses on these nozzles.

There are no service life constraints (Ref. 4) because this style coupling has no significant ' history of failure.

Shelf life (Ref. 4) is unlimited as long. as the gaskets ~ remained packaged and protected from the elements:

light, water, etc.

The coupling is adequate with respect to manufactur-er's service condition limits.

In order ' to provide adequate load transfer capability, the 3 inch x 2h inch ' - 150# reducing flanges at supports LO-PSA-10204 and LO-PSA-10205 have specific requirements for-bolt torquing; specified in Appendix IV of l

the DeLaval Instruction Manual Vol. 1 for Model DSRV-16-4.

All pipe loads on the engine were tabulated and issued for evaluation.

t l0 i

TDI1169/2 Rev. 1 i

m

E l

i l f]

Page 3 of 4 V'

i Mechanical Design This pump's design has been used by the IMO Division of TDI for many years.

The following summarizes the major pump design parameters and the l

operating requirements (Ref. 1 and 2):

Parameter Design Operating Design Pressure 500 psig 25 psig Speed 4400 rpm 1800 rpm Brake Horsepower 57 hp 15 hp Suction Pressure 75 psig 1 psig No stresses were calculated since the operating conditions are so far below the design conditions and the AC induction motor imposes no unusual torque fluctuations on the pump.

The coupling is a Falk Model 40T10 with a maximum speed rating of 4500 rpm vs. an operating speed of 1800 rpm; the horsepower rating is 1.90 hp per 100 rpm.

At 1750 rpm this 33.25 'hp vs. the 15 hp operating; this is a safety factor of 9.5.

The coupling is satisfactory.

The mechanical design is satisfactory.

Material Suitability v

The pressure boundary parts are carbon steel.

The internal wetted parts are cast iron and carbon steel. The mechanical seal is a John Crane Type

-9 with 18-8 stainless steel metal parts and Teflon secondary seals.

All are satisfactory for lubricating oil service.

Vendor Qualification The Comanche Peak pumps are not, nor are they required to be, N-stamped components.

However, the IMO Division of TOI has been a supplier of ASME Section III N-stamp pumps for well over 10 years.

B.

Conclusions The applied piping loads on the prelube oil pump inlet and outlet nozzles are above the manufacturer's allowables.

There has, however, been no experience of pump leakage due to these loads at Comanche Peak or other V-16 engines using the same model prelube pump.

It is recommended 1

therefore that as part of daily engine walkdown, the pump be inspected for signs of leakage and corrective modifications (addition of flexible piping connections) be implemented as required.

l p

TDIO584/3 REV.

1 L

ha Page 4 of 4 Quality Revalidation 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.

There are no TERs associated with this component.

Based on the-above, it is concluded that the lube oil keepwann pump is acceptable for its intended design function at Comanche Peak.

-V References 1.

IMO Pump Division " Process, Transfer and Burner Pump Data Book,"

PT-80.

2.

IMO Pump Division, "IMO Lube Oil and Seal Oil Pump Data Book," LS-80.

1 O

O TDIOS84/4 REV. 1

f 4

m Page 2 of 3 A modal superposition' analysis of the crankshaft was performed.

The L.

pressure loading was obtained from the dynamic test at Shoreham Nuclear L

Power Plant (Ref.

2).

This analysis calculates the nominal shear

. stresses at each crank pin and main journal locatien.

The TDI Holzer calculations were reviewed by comparing the results with results obtained '

from the torsiograph test and the modal superposition analysis (Ref.1).

The stress levels in the main journal oil holes were compared with the endurance limit.

IV RESULTS AND CONCLUSIONS The - TDI Holzer - calculations were found to be in agreement with modal superposition analysis..The torsiograph test has not been conducted.to date.

A comparison of the TDI Holzer calculations with the torsiograph I

test results will need to be performed upon completion of the test.

The ' modal superposition analysis determined the maximum amplitude of' I

nominal stress to be 5326 psi between cylinder numbers 5 and 6 for a load at 7000 kW.

This value is slightly lower than the value of 5367 psi, which was determined for the OSRV-16-4 crankshafts at Grand Gulf Nuclear Power Station.

The difference is due to the slightly lower inertia at the j

flywheel and ' generator at Comanche Peak. The nominal stresses were found to satisfy ~ the requirements of DEMA, and are less than 5000 psi for a single order and less than 7000 psi for combined orders.

. The material certification reports. for the crankshaf ts at Comanche Peak L

indicate that-the tensile strengths for the crankshaft material in.

engines Serial No. '76001 and Serial No. 76002 are within the original L

. design specifications (Ref. 3).

The material for engine Serial No. 76003 has a tensile strength -of 79.5 ksi or 3.5. ksi below the original design specifications (Refs. 3 and 4).

The factor of safety against - fatigue failure in the main journal oil ~ holes was found to be 1.3 based on a minimum ultimate tensile strength of 83 ksi for engine Serial No. 76002.

l Eddy Current tests were performed on selected main journal oil holes on engine 76001 and 76002.

At various locations, background readings were i

recorded that exceed the allowable threshold limit.

The affected oil holes were polished out and reinspected by Eddy Current methods.

As a result of the reinspection, no relevant indications were noted.

Non nuclear experience (M/V Pride

'-Texas) disclosed cracking of oilway plugs which resulted from improper installation of the thinner plug material used in those crankshaft oilway plugs.

Reference 5 identifies the interval. from March-1980 to June 1982 when the thinner gage material was used.in the plugs for easier installation.

Reference 6 confirms that y

the Comanche Peak engines were delivered before the change to thinner i

plug material occurred.

No problems have been encountered with the plugs made from the ' thicker material.

Therefore, the oilway plugs at Comanche j

Peak are acceptable.

O TDIO969/2 REV. 1 i

p)

Page 3 of 3

!V The information provided on the following-TERs has been reviewed and is I

consistent with the final conclusions of this report, TER #10-002, TER #10-069 and TER #10-137, Quality Revalidation 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 conclusion of this report.

Based on the above review, it is concluded that the crankshafts in engine Serial Nos. 76001 and 76002 are acceptable for their intended function at Comanche Peak, provided the torsiograph test is completed satisfactorily.

V REFERENCES 1.

Yang, Roland,

" Torsional and Lateral Critical Speed Analysis:

Engine Numbers 76001/04 Delaval Enterprise Engine Model DSRV-16-4 7000 kW, 9737 BHP at 450 RPM," Transamerica Delaval Inc., Engine and Comoressor Division, Oakland, California, October 5,1976.

2.

" Evaluation of Emergency Diesel Generator Crankshafts at Shoreham and Grand Gulf Nuclear Power Stations," Report No. FaAA-84-3-16, Failure Ar% lysis Associates, Palo Alto, California, May 22, 1984.

3.

Material Certification Reports, Numbers 0-06751, 0-07042, 0-07019

(

and 0-12850, National Forge Company, Quality Control Department, V

Irvine, Warren County, Pennsylvania.

'4.

National Forge Company, Quality Control, Request for Waiver, Request Number E-2767, 2/8/79.

5.

Letter from C.S. Matthews (TDI) to C. Seaman (LILCO), dated 7/12/84 on Crankshaft Oil Hole Plug P/N R3149.

6.

IOC M. Lange (TUGCO) to W. Littman (FaAA), dated 8/15/84.

l I

n v

TDIO969/3 REV. 1 i

i HOW TO USE THIS REPORT Tabs in this report identify th~e following categories:

Turbo, Intake, Intercooler & Exhaust Lube Oil Engine Base & Bearing Caps Crankshaft & Bearings i

. Cylinder Block, Liners & Water Manifold Air Start & Barring Device i

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 O

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 Comanche Peak specific component numbers.

A given component report can be found by:

a)

If the. component number is known -.use the alpha - numeric index which identifies the volume number and category in which the component 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.

I O

j Rev. 1 TDIO907

'k INDEX(continued)

- Component

-Component Vol.

Number Description Category No.

CP-101A Generator: Generator Generator 8

CP-1018 Generator: Shaft and Generator 8

' Bearings CP-102 Generator Controls Generator 8

- F-068 Intercooler Turbo, Intake, 2

Intrc1r. & Ex-haust MP022/3 Turbocharger Turbo, Intake, 2

Intrcir. & Ex-haust 00-420 Lube Oil Pressure Lube Oil 2

Regulating Valve 00-442A Starting Air Distributor:

Air Start 4

Distributor Assembly

& Barring Device 00-442B Starting Air Distributor:

Air Start &

4 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drop Tank Fuel Oil In-8 jection 02-CFR Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrc1r. & Ex-haust 02-305A Base and Bearing Caps: Base Engine Base 3

Assembly

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

Engine Base 3

Main Bearing Studs & Nuts

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

Engine Base 3

Main Bearing Caps

& Bearing Caps 02-307A Lube Oil Fittings:

Lube Oil 2

Internal - Headers 02-307B Lube Oil Fittings:

Lube Oil 2

Internal - Tube & Fittings O

~

Rev. 1 11 Entire Page Revised TDIO907

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-3070 Lube Oil Fitting Internal-Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

3 Bearings 02-310B Crankshaft and Bearings:

Crankshaft &

3 Bearing Shells Bearing 02-310C Crankshaft Crankshaft &

3 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy Crankshaft &

3 Bearing 02-3110 Crankcase: Crankcase Crankshaft &

3 Mounting Hardware Bearings 02-315A Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Cylinder.

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

4 Liners &

Water Manifold 02-3150 Water Manifold: Jacket Cyl. Block &

4 Water Manifold & Piping Liners &

Water Manifold 02-315E' Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Studs Liners &

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

4

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

Cyl. Block &

4 Water Manifold: Seals and Liners &

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

Jacket Water 7

Manifold Assembly W/ Hardware and Coupling and Gaskets Rev. 1 Entire Page Revised 443 TDIO907

^\\

INDEX(continued)

,( Y Component Component Vol.

Number Description Category No.

02-316B Jacket Water Inlet Manifold:

Jacket Water 7

Coupling and Gaskets 02-316C Ja:ket Water Inlet Manifold:

Jacket Water 7

W.nt Line to Discharge Manifold 02-317A Water Discharge Manifold:

Jacket Water 7

Jacket Water Discharge Manifold, Coupling and Seals 02-317B Water Dicharge Manifold:

Jacket Water 7

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Water 7

Supports 02-330A Flywheel: Flywheel Flywheel 6

02-3308 Flywheel Bolting Flywheel 6

(O y

02-335B Front Gear Case-Gasket and Idler Gear As-5 Bolting sembly & Front Gear Case 02-340A Connecting Rods:

Connecting Connecting 4

Rods & Bushings Rods 02-3408 Connecting Rods: Bearing Connecting 4

Shells Rods 02-341A Pistons: Pistons Pistons 5

02-341B Pistons: Rings Pistons 5

02-341C Piston: Pin Assembly Pistons 5

02-345A Intaxe/ Exhaust and Fuel Camshaft &

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

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

5 Pump Base Assembly Valve Train O

l Rev. 1 iv Entire Page Revised TDIO907 i

e.

-~

g-

!PQ l

f t

l

(

INDEX(continued)

Component Component Vol.

Number Description Category No.

t 02-350A Camshaft Camshaft &

5

,j Valve Train 02-3508 Camshaft Bearing Camshaft &

5 Valve Tr-in 02-350C Camshaft: Supports, Bolting Camshaft &

5 and Gear Valve Train i

02-355A Idler Gear Assemble: Crank Idler Gear As-5 l

To Pump Gear sembly & Front Gear Case 02-355B_

Idler Gear Assembly:

Idler Gear As-5 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valves: Air Start Air Start &

4 Valve Barring Device 02-360A~

Cylinder Head Cylinder Heads 8

& Valves 02-360B Intake & Exhaust Valves Cylinder Heads 8

& Valves Cylinder Head and Valves -

Cylinder Heads-8 02-360C Bolting and Gaskets

& Valves 02-3600 Valve Sorings Cylinder Heads 8

& P.e.n..ars

& Valves s

?02-362A Subcover Camshaft &

5 Valve Train 02-365A Fuel Injection Pump Fuel Oil In-8 jection 02-365B Fuel Injection Nozzle Fuel Oil In-8 Assembly jection 02-365C Fuel Oil Injection Tubing Fuel Oil In-8 jection 02-365D.

~

Fuel Injection Equipment:

Fuel Oil In-8

. Supports jection

-[

'02-371A Fuel Pump Linkage: Fuel Fuel Oil In-8 Pump Control Shaft jection TOIO907

• • • I Entire Page Revised S

[

')

INDEX(continued)

\\s /

Component Component Vol.

Number Description Category No.

02-3718 Fuel Pump Linkage: Linkage Fuel Oil In-8 Assembly and Bearing jection 02-375 Air Intake Manifold Turbo, Intake, 2

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

Intrcir. & Ex-haust 02-3808 Exhaust Msnifold-Turbo, Intake, 2

Bolting and Gaskets Intrcir. & Ex-haust 02-385B Cylinder Block and Cyl. Block &

4 Crankcase Covers:

Liners & Water Gaskets and Bolts Manifold

.02-386B Crankcase Covers: Crankcase Cranshaft &

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

5 and Exhaust Rocker Valve Train Shaft Assembly 02-390B Rocker Arms and Pushrods:

Camshaft &

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

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

Camshaft &

5 Pushrods Connector.

Valve Train i

02-390E Rocker Arms and Pushrods:

Camshaft &

5 Bushings Valve Train

.02-390F Rocker Arms and Pushrods:

Camshaft &

5 Lifters Valve Train 02-390G Rocker Arms and Pushrods-Camshaft &

5 Miscellaneous Bolts &

Valve Train Drive Studs

/

\\

C#

Rev. 1 V

Entire Page Revised TDIO907

r

/~'s I

i INDEX(continued)

V Component Component Vol.

Numbg Description Category No.

02-410A Overspeed Trip: Governor Overspeed Trip 6

& Governor 02-410B Overspeed Trip: Governor Overspeed Trip 6

and Accessory Drive

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 6

& Governor 02-410D Overspeed Trip Vent Valve Overspeed Trip 6

& Governor 02-411A Governor Drive: Governor Overspeed Trip 6

and Tachometer Onive Gear

& Governor

& Shaft 02-4118 Governor Drive: Couplings, Overspeed Trip 6

Pins & Keys

& Governor 02-413A Governor Linkage Overspeed Trip 6

& Governor 02-4138 Fuel Pump Linkage Fuei Oil In-8 jection 02-415A Governor Assembly: Woodward Overspeed Trip 6

Governor

& Governor 02-4158 Governor Assembly - Booster Overspeed Trip 6

Servometer-

& Governor 02-415C Governor Assembly Heat Overspeed Trip 6

Exchanger

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425A Engine Driven Jacket Water 7

Jacket Water Pump 02-435A Jacket Water Fittings:

Jacket Water 7

Piping 02-435B Jacket Water Fittings:

Jacket Water 7

Supports 02-435C Jacket Water Inlet Fittings:

Jacket Water 7

,C't Valves

'G Rev. 1 TDIO907 Entire Page Revised

INDEX(continued)

L~J Component Component Vol.

Number Description Category No.

02-436A Intercooler Piping Turbo Intake, 2

and Piping Couplings, Intrcir. & Ex-Gaskets and Bolting haust 02-4368 Intercooler Piping: Coupling, Turbo Intake, 2

Gaskets, Bolting Intrcir. & Ex-haust 02-437 Turbo Water Piping:

Jacket Water 7

Pipe & Fittings 02-441A Starting Air Manifold:

Air Start &

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

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

Air Start &

4 Supports Barring Device 02-445 Fuel Oil Booster Pump Fuel Oil In-8 O

jection 02-450A Fuel Oil Headers Piping /

Fuel Oil In-8 Tubing jection 02-4508 Fuel Oil Header: Fuel Oil Fuel Oil In-8 Tubing Supports jection 02-455A Fuel Oil Filters &

Fuel Oil In-8 Strainers: Fuel Oil Filters jection 02-455B Fuel Oil Fuel Oil In-8 Strainers jection 02-455C Fuel Oil Filters and Fuel Oil In-8 Strainer Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fitting, Couplings 02-465B Lube Oil Liners - External Lube Oil 2

Supports 02-465C Lube Oil Lines External:

Lube Oil 2

Valves fG )-

viii Rev. 1 TDIO907 Entire Page Revised

~[

INDEX(continued)

(

Component Component Vol.

Number Description Category No.

02-467A Turbocharger: Lube Oil Lube Oil 2

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

Fittings - Supports l

02-475A Turbocharger:

Bracket Turbo, Intake, 2

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

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

Turbo, Intake, 2

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

Control Panel 9

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

Control Panel 9

Accumulator Assembly 02-500G Control Panel Control Panel 9

Valves Assembly 02-500H Control Panel Assembly:

Control Panel 9

Pressure Switch Assembly 02-500J Control Panel Assembly:

Control Panel 9

Relays Assembly 02-500K Control Panel Assembly:

Control Panel 9

Solenoid Valves Assembly 02-500M Control Panel Assembly-Control Panel 9

Piping, Tubing, and Assembly Fittings 02-500N Miscellaneous Equipment Control Panel 9

Terminal Boards /Switchs/

Assembly Wiring 02-540A Lube Oil Sump Lube Oil 3

Tank with Strainer Assembly and Mounting m..

Hardware ix Rev. 1 TDIO907 Entire Page Revised

i-7"N INDEX(continued)

Component Component Vol.

Number-Description Category No.

02-540B Lube Oil Sump Tank: Misc.

Lube Oil 3

Fittings, Gaskets, Pipe

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

Lube Oil 3

Mounting Hardware 02-550 Foundation Bolts:

Engine & Aux.

9 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts l

02-630A Pyrometer Conduit Assembly:

Engine Instru-6 Conduit mentation &

Wiring 02-630B Pyrometer Conduit Assembly:

Engine Instru-E Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly':

Engine Instru-6 n

Support mentation &

Q Wiring 02-6300 Pyrometer Conduit Assembly:

Engine Instu-6 Thermocouples mentation &

Wiring 02-668A Engine & Aux Module Wiring Engine Instru-6 Material: Conduit & Fittings; mentation &

Pyrometer conduit assembly -

Wiring conduit, Fittings, Supports 02-688B Engine & Aux. Module Engine Instru-6 Wiring Material: Wiring mentation &

& Terminations Wiring 02-688C Engine & Aux. Module Wiring Engine Instu-6 Material: Boxes & Terminals mentation &

Wiring 02-689 Off Engine Alarm Engine Instru-6 Sensors: Wiring mentation &

Wiring 02-690 On Engine Alarm Sensors Engine Instru-6 mentation &

Wiring x

Rev. 1 TDIO907 Entire Page Revised

INDEX(continued)

Component Component

• Vol.

Number Description Category No.02-691 Off Engine Alarm Engine Instru-6 Sensors:

mentation &

Wiring 02-695A Engine Shut Down Equipment Engine Shut-6 Tubing / Fittings & Supports down & Equip-ment 02-6958 Engine Shut Down Equipment:

Engine Shut-6 Valves, Regulator, Orifice down & Equip-ment 02-695C.

Engine Shutdown: _ Trip Engine Shut-6 Switches down & Equip-ment 02-700A Jacket Water Stand Pipe-Jacket Water 7

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

Jacket Water 7

Valves 02-700C Jacket Water Stand Pipe-Jacket Water 7

Supports 02-700E Jacket Water Stand Pipe-Jacket Water 7

Switches 02-700F Jacket Water Stand Pipe

' Jacket Water 7

and Misc. Bolting Material 02-717A Aux Sub Base and Oil and Engine Aux.

9 Water Piping-Aux Sub Base Sub-Base &

Foundation Bolts 02-717B Aux Sub Base and Oil and Jacket Water 7

Water Piping-Jacket Water Valves 02-717C Aux Sub Base & Oil Water Jacket Water 7

Piping-Jacket Water: Pipe, Couplings, Fittings, Orifices, Y Strainers 02-7170 Aux Sub Base & Oil & Water Jacket Water 7

Piping: Jacket Water Gaskets

'& Bolting Rev. 1

" #9" TDIO907 O

(

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-717E Aux Base & 011 & Water Jacket Water 7

Piping: Jacket Water Supports 02-717F Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping and Tub-ing - Lube Oil - Pipe, Tubing, Fittings 02-717G Aux Sub Base & Oil & Water Lube Oil 3

Piping: Lube Oil-Valves 02-717H Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping-Lube Oil-I Gaskets and Bolting 02-717I Aux Sub Base and Oil and Lube Oil 3

Water Piping: Lube Oil-Supports & Mounting Hardware 02-717J Aux Sub Base & Oil & Water Fuel Oil In-8

['

Piping: Fuel Oil-Piping jection and Fittings 02-717K Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Valves jection 02-717L Aux Sub Base and Oil and Fuel Oil In-8 Water Piping-Fuel jection Oil-Gaskets and Bolting 02-717M Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Supports jection 02-805A Intake Air Silencer Turbo, Intake, 2

Intrcir &

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

Intrc1r &

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

Intrc1r &

Exhaust 02-810A Auxiliary Jacket Water Jacket Water 7

Pump xii Rev. 1 TDIO907 Entire Page Revised

Q INDEX(continued)

V Component.

Component Vol.

Number Description Category No.

02-8108 Jacket Water Standby Jacket Water 7

Heater Pump 02-810C Jacket Water Heat Jacket Water 7

Exchanger 02-8100 Jacket Water Thermostatic Jacket Water 7

Valve 02-810E Misc. Equipment:

Jacket Water 7

Jacket Water Standpipe Heater 02-820A Misc. Equipment:

Lube Oil 3

Lube Oil Sump Tank Heater 02-8208 Auxiliary Lube Lube Oil 3

Oil Pump 02-820C Pre-Lube Oil Lube Oil 3

O Pump 02-820D Lube Oil Lube Oil 3

Keepwarm Strainer 02-820E Oil Prelube Filter Lube Oil 3

02-820F Full Flow Lube Oil Filter Lube Oil 3 820G Lube 041 Heat Exchanger Lube Oil 3

02-820H Lube Oil Full Pressure Lube Oil 3

Strainer 02-825A-Fuel Oil Fuel Oil 8

Day Tank Injection 02-825B Miscellaneous Equipment Fuel Oil 8

Fuel Oil Transfer Pump Injection l

02-825E Fuel Oil System: Fuel Oil Fuel Oil 8

i Duplex Strainer Injection 02-835A Air Start System: Starting Air Start &

4 l

Air Skid Base Barring Device

O i

Rev. 1 TDIO907 Entire Page Revised w-m.,,

m

,w,,

,-,,n

INDEX(continued)

Component Component Vol.

Number-Description Category No.

02-8350 Starting Air Tank Air Start &

4 Relief Valve Barring Device 02-835F Starting Air Float Trap Air Start &

4 Barring Device 02-835J Starting Air Tank Air Start 4

Barring Device Appendix II 9

Appendix III 9

l

O f -

t

{-

4 J

' O Rev. 1 xiv TDIO907 Entire Page Revised i

4

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_,,,_-a,._,__,._

/m (J) l 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 l

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 Comanche Peak specific component numbers.

A given component report can be found by:

a)

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

l b)

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

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.

I v

g Rev. 1 TDIO907

'O (d

INDEX(continued)

Component Component Vol.

Number Description Category No.

CP-101A Generator: Generator Generator 8

CP-101B Generator: Shaft and Generator 8

Bearings CP-102 Generator Controls Generator 8

F-068 Intercooler Turbo, Intake, 2

Intrcir. & Ex-haust MP022/3 Turbocharger Turbo, Intake, 2

Intrcir. & Ex-haust 00-420 Lube Oil Pressure Lube Oil 2

Regulating Valve 00-442A Starting Air Distributor:

Air Start 4

Distributor Assembly

& Barring Device (9

^t

/.

00-442B Starting Air Distributor:

Air Start &

4 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drop Tank Fuel Oil In-8 jection 02-CFR Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrcir. & Ex-haust 02-305A Base and Bearing Caps: Base Engine Base 3

Assembly

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

Engine Base 3

Main Bearing Studs & Nuts

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

Engine Base 3

Main Bearing Caps

& Bearing Caps 02-307A Lube Oil Fittings:

Lube Oil 2

Internal - Headers 02-307B Lube Oil Fittings:

Lube Oil 2

Internal - Tube & Fittings t0 V

Rev. 1 11 Entire Page Revised TOIO907

~

b

(')N INDEX(continued)

\\.

Component Component Vol.

Number Description Category No.

02-307D Lube Oil Fitting Internal-Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

3 Bearings 02-310B Crankshaft and Bearings:

Crankshaft &

3 Bearing Shells Bearing 02-310C Crankshaft Crankshaft &

3 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy Crankshaft &

3 Bearing 02-311D Crankcase: Crankcase Crankshaft &

3 Mounting Hardware Bearings 02-315A Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Cylinder.

Liners & Water Block Manifold s,/

02-315C Cylinder Block Liners Cyl. Block &

4 m

Liners &

Water Manifold 02-3150 Water Manifold: Jacket Cyl. Block &

4 Water Manifold & Piping Liners &

Water Manifold 02-315E Cylinder Block Liners ~ &

Cy1. Block &

4 Water Manifold: Studs Liners &

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

4

& Water Manifold: Nuts Liner & Water 4

Manifold 02-315G Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Seals and Liners &

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

Jacket Water 7

Maaifold Assembly W/ Hardware and Coupling and Gaskets Rev. 1 Entire Page Revised TDIO907

[

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-316B Jacket Water Inlet Manifold:

Jacket Water 7

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

Jacket Water 7

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

Jacket Water 7

Jacket Water Discharge Manifold, Coupling and Seals 02-317B Water Dicharge Manifold:

Jacket Water 7

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Water 7

Supports 02-330A Flywheel: Flywheel Flywheel 6

02-3308 Flywheel Bolting Flywheel 6

f s

02-335B Front Gear Case-Gasket and Idler Gear As-5 Bolting sembly & Front Gear Case 02-340A Connecting Rods:

Connecting Connecting 4

Rods & Bushings Rods 02-3408 Connecting Rods: Bearing Connecting 4

Shells Rods 02-341A Pistons: Pistons Pistons 5

02-341B Pistons: Rings Pistons 5

02-341C Piston: Pin Assembly Pistons 5

.02-345A Intake / Exhaust and Fuel Camshaft &

5 L

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

5 Tappet Assembly Valve Train

(

'02-345C Tappets and Guides: Fuel Camshaft &

5 l

Pump Base Assembly Valve Train O

j Rev. 1 iv Entire Page Revised TOIO907

Q INDEX(continued)

Component Component Vol.

Number Description Category No.

02-350A Camshaft Camshaft &

5 Valve Train 02-350B Camshaft Bearing Camshaft &

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

5 and Gear Valve Train 02-355A Idler Gear Assemble: Crank Idler Gear As-5 To Pump Gear-sembly & Front Gear Case 02-355B Idler Gear Assembly:

Idler Gear As-5 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valves: Air Start Air Start &

4 Valve Barring Device 02-360A Cylinder Head Cylinder Heads 8

x

& Valves 02-3608 Intake & Exhaust Valves Cylinder Heads 8

& Valves 02-360C Cylinder Head and Valves -

Cylinder Heads 8

Bolting and Gaskets

& Valves 02-3600 Valve Springs Cylinder Heads 8

& Retainers

& Valves 02-362A Subcover Camshaft &

5 Valve Train 02-365A Fuel Injection Pump Fuel Oil In-8 jection 02-365B Fuel Injection Nozzle Fuel Oil In-8 Assembly jection 02-365C Fuel Oil Injection Tubing Fuel Oil In-8-

jection 02-365D Fuel Injection Equipment:

Fuel Oil In-8 Supports jection 02-371A Fuel Pump Linkage: Fuel Fuel Oil In-8

\\

l Pump Control Shaft jection l

l TDIO907 Rev. 1 Entire Page Revised I

. /- 1

(}

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-371B Fuel Pump Linkage: Linkage Fuel Oil In-8 Assembly and Bearing jection 02-375 Air Intake Manifold Turbo, Intake, 2

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

Intrcir. & Ex-haust 02-3808 Exhaust Manifold-Turbo, Intake, 2

Bolting and Gaskets Intrcir. & Ex-haust 02-385B Cylinder Block and Cyl. Block &

4 Crankcase Covers:

Liners & Water Gaskets and Bolts Manifold 02-386B Crankcase Covers: Crankcase Cranshaft &

3 Gaskets and Mounting Bearings C.)

Hardware

\\s/

02-390A Intake / Intermediate Camshaft &

5 and Exhaust Rocker Valve Train Shaft Assembly 02-390B Rocker Arms and Pushrods:

Camshaft &

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

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

Camshaft &

5 Pushrods Connector.

Valve Train

.02-390E Rocker Arms and Pushrods:

Camshaft &

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

Camshaft &

5

+

Lifters Valve Train 02-390G Rocker Arms and Pushrods-Camshaft &

5 Miscellaneous Bolts &

Valve Train Drive Studs U)

Rev. 1 V

Entire Page Revised TDIO907 l

, _. ~ - -,

INDEX(continued)

Component Component.

Vol.

Number Description Category No.

02-410A Overspeed Trip: Governor Overspeed Trip 6

& Governor 02-410B Overspeed Trip: Governor Overspeed Trip 6

and Accessory Drive

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 6

& Governor 02-4100 Overspeed-Trip Vent Valve Overspeed Trip 6

& Governor 02-411A Governor Drive: Governor Overspeed Trip 6

and Tachometer Drive Gear

& Governor

& Shaf't 02-411B Governor Drive: Couplings, Overspeed Trip 6

Pins & Keys

& Governor 02-413A Governor Linkage Overspeed Trip 6

& Governor 02-4138 Fuel Pump Linkage Fuel Oil In-8 jection 02-415A Governor Assembly: Woodward Overspeed Trip 6

Governor

& Governor 02-4158 Governor Assembly - Booster Overspeed Trip 6

Servometer

& Governor 3

02-415C Governor Assembly Heat' Overspeed Trip 6

i Exchanger

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump I

02-425A Engine Driven Jacket Water 7

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

Jacket Water 7

Piping 02-435B Jacket Water _ Fittings:

Jacket Water 7

Supports-02-435C Jacket Water Inlet Fittings:

Jacket Water 7

.O Valves

l. V Rev. 1

.TDIO907 Entire Page Revised

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-436A Intercooler Piping Turbo Intake, 2

l and Piping Couplings, Intrcir. & Ex-

' Gaskets and Bolting haust 02-436B'

'Intercooler Piping: Coupling, Turbo Intake, 2

i Gaskets, Bolting Intrcir. & Ex-haust 02-437 Turbo Water Piping:

Jacket Water 7

Pipe & Fittings 02-441A Starting Air Manifold:

Air Start &

4 Piping, Tubing and Fitting Barring Device I

02-441B Starting Air Manifold Air Start &

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

Air Start &

4 Supports Barring Device

~

02-445 Fuel Oil Booster Pump Fue1 Oil In-8 jection 02-450A Fuel Oil Headers Piping /

Fuel Oil In-8 f.

Tubing jection 02-450B Fuel Oil Header: Fuel Oil Fuel Oil In-8 Tubing Supports jection 02-455A Fuel Oil Filters &

Fuel Oil In-8 Strainers: Fuel Oil Filters jection 02-455B Fuel Oil Fuel Oil In-8 Strainers jection 02-455C Fuel Oil Filters and Fuel Oil In-8 Strainer Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fitting, Couplings 02-465B Lube Oil Liners - External Lube Oil 2

Supports 02-465C Lube Oil Lines External:

Lube Oil 2

Valves O

viii ReV-I TDIO907 Entire Page Revised

-[

INDEX(continued) s.

Component Component Vol.

Number Description Category No.

02-467A Turbocharger: Lube Oil Lube Oil 2

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

Fittings - Supports 02-475A Turbocharger:

Bracket Turbo, Intake, 2

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

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

Turbo, Intake, 2

Bolting & Gaskets Intrcir. & Ex-haust 02-500A Control Panel Assemb'":

Control Panel 9

Cabinet / System Assembly

,s (s

02-500F Control Panel Assembly:

Control Panel 9

Accumulator Assembly 1

02-500G Control Panei Control Panel 9

Valves Assembly 02-500H Control Panel Assembly:

Control Panel 9

Pressure Switch Assembly 02-500J Control Panel Assembly:

Control Panel 9

Relays Assembly 02-500K Control Panel Assembly:

Control Panel 9

Solenoid Valves Assembly 02-500M Control Panel Assembly-Control Panel 9

Piping, Tubing, and Assembly Fittings 02-500N Miscellaneous Equipment Control Panel 9

Terminal Boards /Switchs/

Assembly Wiring 02-540A Lube Oil Sump Lube Oil 3

Tank with Strainer

/

Assembly and Mounting N,T)

Hardware u

i ix Rev. 1 TOIO907 Entire Page Revised l

3 INDEX(continued)

Component Component Vol.

e Number Description Category No.

02-5408 Lube Oil Sump Tank: Misc.

Lube 011' 3

Fittings, Gaskets, Pipe

& Bolting Material, Valve i

02-540C' Lube Oil Sump Tank:

Lube Oil 3

Mounting Hardware 02-550 Foun'dation Bolts:

Engine & Aux.

9 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 02-630A

' Pyrometer Conduit Assembly:

Engine Instru-6 Conduit mentation &

Wiring 02-630B Pyrometer Conduit Assembly:

Engine Instru-6 Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly:

Engine Instru-6 C)

Support mentation &

V Wiring 02-6300 Pyrometer Conduit Assembly:

Engine Instu-6 Thermocouples mentation &

Wiring 02-688A Engine & Aux Module Wiring Engine Instru-6 Material: Conduit & Fittings; mentation &

Pyrometer conduit assembly -

Wiring conduit, Fittings, Supports 02-6888 Engine & Aux. Module Engine Instru-6 Wiring Material: Wiring mentation &

4

& Terminations Wiring i

02-688C Engine & Aux. Module Wiring Engine Instu-6 Material: Boxes & Terminals mentation &

Wiring 02-689 Off Engine Alarm Engine Instru-6 Sensors: Wiring mentation &

Wiring l

02-690 On Engine Alarm Sensors Engine Instru-6 mentation &

Wiring x

Rev. 1

- TDIO907 Entire Page Revised 2-y

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INDEX(continued)

Component Component Vol.

Number-Description Category No.02-691 Off Engine Alarm Engine Instru-6 Sensors:

mentation &

Wiring 02-695A Engine Shut Down Equipment Engine Shut-6 Tubing / Fittings & Supports down & Equip'-

ment 02-695B Engine Shut Down Equipment:

Engine Shut-6 Valves, Regulator, Orifice down & Equip-ment 02-695C Engine Shutdown: Trip Engine Shut-6 Switches down & Equip-ment 02-700A Jacket Water Stand Pipe-Jacket Water 7

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

Jacket Water 7

Valves 02-700C.

Jacket Water Stand Pipe-Jacket Water 7

Supports 02-700E Jacket Water Stand Pipe-Jacket Water 7

Switches 02-700F Jacket Water Stand Pipe Jacket Water 7

and Misc. Bolting Material 02-717A Aux Sub Base and Oil and Engine Aux.

'9 Water Piping-Aux Sub Base Sub-Base &

Foundation Bolts 02-717B Aux Sub Base and Oil and Jacket Water 7

Water Piping-Jacket Water Valves 02-717C Aux Sub Base & 011 Water Jacket Water 7

Piping-Jacket Water: Pipe, Couplings, Fittings, Orifices, Y Strainers 02-7170 Aux Sub Base & Oil & Water Jacket Water 7

g-Piping: Jacket Water Gaskets IV;

& Bolting Rev. 1

" #9 TDIO907 p

i

/

(

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-717E Aux Base & 011 & Water Jacket Water 7

Piping: Jacket Water Supports 02-717F Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping and Tub-ing - Lube Oil - Pipe, Tubing, Fittings 02-717G Aux Sub Base & Oil & Water Lube Oil 3

Piping: Lube Oil-Valves 02-717H Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping-Lube Oil-Gaskets and Bolting 02-717I' Aux Sub Base and Oil and Lube Oil 3

Water Piping: Lube Oil-Supports & Mounting Hardware

~

m 02-717J Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Piping jection and Fittings 02-717K Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Valves jection 02-717L Aux Sub Base and Oil and Fuel Oil In-8 Water Piping-Fuel jection Oil-Gaskets and Bolting 02-717M Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel'0il-Supports jection 02-805A Intake Air Silencer Turbo, Intake, 2

Intrcir &

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

Intrcir &

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

Intrcir &

Exhaust 02-810A Auxiliary Jacket Water Jacket Water 7

Pump i

xii Rev. 1 TDIO907 Entire Page Revised

INDEX(continued)

Component Component.

Vol.

Number Description Category No.

02-810B Jacket Water Standby Jacket Water 7

Heater Pump 02-810C Jacket Water Heat Jacket Water 7

Exchanger 02-810D Jacket Water Thermostatic Jacket Water 7

Valve 02-810E Misc. Equipment:

Jacket Water 7

Jacket Water Standpipe Heater 02-820A Misc. Equipment:.

Lube Oil 3

Lube Oil Sump Tank Heater 02-8208 Auxiliary Lube Lube Oil 3

011 Pump 02-820C Pre-Lube Oil Lube Oil 3

Pump 02-8200-Lube Oil Lube Oil 3

Keepwarm Strainer "02-820E Oil.Prelube Filter Lube Oil 3

02-820F Full Flow Lube Oil Filter Lube Oil 3

02-820G Lube Oil Heat Exchanger Lube Oil 3

b2-820H Lube 011 Full Pressure Lube Oil 3

Strainer 825A Fuel Oil Fuel Oil 8

Day Tank Injection

'02-825B Miscellaneous Equipment Fuel Oil 8

Fuel Oil Transfer Pump Injection 02-82SE

. Fuel Oil System: Fuel Oil Fuel Oil 8

Duplex Strainer Injection 02-835A Air Start System: Starting Air Start &

4 Air Skid Base Barring Device Rev. 1 TDIO907 Entire Page Revised

t y;

i i

s INDEX(continued)

Component Component Vol.

Number Description Category No.

02-8350 Starting Air Tank Air Start.&

4 Relief Valve Barring Device 02-835F Starting Air Float Trap Air Start &

4 Barring Device 02-835J Starting Air Tank Air Start 4

Barring Device 4

g

].

Appendix II 9

Appendix III 9

4 I

1 I

O i

i l

i 4

J r

0 4

Rev. 1 xiv TDIO907 Entire Page Revised i

t i.

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I r

(-

TDI OWNERS GROUP i

for COMANCHE PEAK STEAM ELECTRIC STATION - UNIT 1 CYLINDER BLOCK COMPONENT PART NO. 02-315A i

l I

INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Comanche Peak Steam Electric Station requires Design and Quality Revalidation reviews of cylinder blocks to detemine the adequacy of their design for the intended use at Comanche Peak.

The blocks are manufactured by TDI and are supplied under their part numbers 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 adequacy of the cylinder block for intended service at Comanche Peak Steam Electric Station;

[sv) specifically to perform:

A review of liquid penetrant, and 100 hour0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> inspections of Comanche Peak RV-16 engines.

Evaluate steady state stresses, alternating stresses, and stiffness in key portions of this component.

Evaluate critical flaw sizes for cylinder block landing and 1

counterbore diameter.

A review of Comanche Peak Site, nuclear, and non-nuclear industry experience.

A review of Quality Revalidation Checklist results for acceptability.

III METHODOLOGY The TDI Emergency Diesel Generator Component Tracking System results were reviewed for the Comanche Peak, nuclear, and non-nuclear industry experi-ences with the cylinder block.

Iv TDI1179/1 Rev. 1

.=.

Page 2 of.4 G

The structural adequacy of the cylinder block for the intended service was evaluated by ~ strain gauge testing combined with two and three-dimensional 4

' analytical models of the block top and liner.

The ability of the cylinder blocks to perform adequately.during emergency service was established based on:

1) comparison of block microstructure between Comanche Peak i

cylinder blocks with Shoreham EDG 103 cylinder block, and 2) comparison of cumulative damage incurred during testing of Shoreham EDG 103 from March 11, 1984 through April 14, 1984, with the predicted cumulative damage

'during a LOOP /LOCA event (Refs. 1 and 2).

All Quality Revalidation documents were analyzed for pertinent data (Ref.

2).

IV RESULTS AND CONCLUSIONS A generic investigation of the structural adequacy of the TDI R-4 and RV-4 series diesel engine cylinder blocks for. emergency standby service t.

in nuclear power plants is summarized in Reference ~1.

The investigation considers the cause, extent, and consequences of cylinder block cracking, 1

and the inspections required to assure sufficient margin of safety during continued operation'under test and postulated accident conditions.

Diesel generators DG CP1-MEDGEE-01 and DG CP1-MEDGEE-02 have been inspect-ed for block cracks.

Cracks were indicated by liquid penetrant inspection

.O of DG cpl-MEDGEE-01 in cylinders 4 and 5 right bank and 6 left bank.

Additional inspection with eddy current confirmed the presence of indica-tions in the right bank but did not substantiate indications in the left bank.

The cracks in the right bank extend adjacent to the cylinder head t

stud boss from just below the bottom of the block top diagonally upwards across the cylinder liner landing and then up. through the upper cylinder liner counterbore towards the surface of the block top.

The cracks lie in.

the vicinity of the between cylinder studs on the exhaust side of the l1 engine.

Acetate replicas for metallurgical evaluation of the cracks. in the right bank were made.

Results of this evaluation show the cracks to -

i'~

be casting induced.

In engine DG CP1-MEDGEE-02 several linear indications were found in the lower pilot diameter in cylinders 4 and 5 right bank.

The length of.these

[

indications are 3/8-inch or less and the depth appears to be less than l-0.050-inch as measured.by ultrasonic examinatio~n.

The indications are located near the longitudinal centerline of the engine.

I For the purpose of further analysis and determining inspection criteria, i'

'these cracks in the right banks of both engines are considered to be treated conservatively as ligament cracks.

In addition, other acetate. replicas have been made of each block top in a thick-section region to evaluate the microstructure and to determine whether Widmanstaetten graphite was present. Widmanstaetten graphite is a i

degenerate microstructure that reduces fatigue resistance.

All four block tops at Comanche Peak were found to be free of Widmanstaetten graphite.

Rev. 1 TDIll79/q

wmw,

+-w,r-,

.mu.w

.----t-b-------~

= - - - - - * = - - * - - - - -

.,,%O, Page 3 of 4 i,/

l

~

b Therefore, for the purpose of the cumulative damage computations, the cylinder blocks are considered to have typical material properties for

^

gray cast iron, Class 40.

The power. o'utput for. these engines is 7000 kW at 100 percent load.

Maximum output required for LOOP /LOCA is 7000 kW.

The duration of a -

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 />.

Evaluation of steady state stresses, alternating stresses and stiffness 1

in < key.' portions of.the cylinder block ~was accomplished as part of the strain gauge testing and the results were included in the cumulative damage and crack growth analysis.

The cumulative damage algorithm is l

explained in Reference 1.

-Strain gauge testing of the original Shoreham EDG 103 block, inspection 3

data from before and after testing, and material _ testing were used to predict adequate. life for, cylinder blocks. The apparent rate of propaga--

tion of cracks-.between studs. holes in' the original EDG 103 block at Shoreham, when compared with the Comanche Peak LOOP /LOCA requirements, i

indicates that blocks with -ligament cracks (i.e., the right cylinder bank

[

of DG CP1-MEDGEE-01.and 02) are. predicted _ to withstand with sufficient stud-to-studcracksbetweencylinderheadsandnodetectablestud-to-edge ly margin a -LOOP /LOCA event provided that inspection.shows no detectable

=

i 1.

cracks adjacent to the number 1 and 8 cylinder heads at the ends of the

~

-engines ~ whenever the engines are returned to emergency standby service i

i. -

after any period of operation in excess of 50 percent load.

_ Application of the cumulative _ damage algorithm (Figure 5-1 of Reference

1). shows that the left cylinder. banks (those without cracks at the last inspection) for engines DG CP1-MEDGEE-01 and 02 can perform for 437 hours0.00506 days <br />0.121 hours <br />7.225529e-4 weeks <br />1.662785e-4 months <br /> at 100 percent load (or operation resulting in equivalent damage),

without inspection, with sufficient margin -for a LOOP /LOCA ' event (Reference 2).

.Engineooperation in excess of the time periods -listed - above without

' inspection could be justified if the fatigue damage-index.since the last inspection has not exceeded the allowable fatigue damage index.before -

the last inspection.

In the future, after additional-engine operation without inspection has _ been. accumulated, additional engine operation may-

.be performed after removal of the cylinder heads and inspection of the i

block top !for detectable ligament, stud-to-stud or stud-to end cracks.

i If ' none are, found, then - additional engine operation without inspection t'

may be performed until the future fatigue damage index equals the allowable._ fatigue damage index accrued to the last. inspection. -This.

processimay be repeated indefinitely throughout the life of the engine.

Optionally, in the-future,- after additional engine operation without inspection has been accumulated and the fatigue damage index for

' future : operations, exceeds the allowable ' fatigue damage index, continued

' engine operation without-removal of cylinder heads and inspection of the

[s/s].

J blockR top will allow sufficient margin to withstand a LOOP /LOCA event provided periodic eddy current inspections are performed.

The periodic eddy current '. inspections are described in Figure 5-1 of Reference 1.

TDI1179/3

_REV 1

m Page 4 of 4 The information provided on the following TERs has been reviewed and is consistent with the final conclusions of this report:

10-012,10-013, 10-066.

Quality Revalidation 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 and implementation of the recommended inspec-tions, it is concluded that the cylinder blocks are acceptable for their intended use at Comanche Peak Steam Electric Station.

V REFERENCES 1.

" Design Review of TDI-R4 and RV-4 Series Emergency Diesel Generator l1 Cylinder Blocks," FaAA-84-9-11.

2.

FaAA Support Package Number SP-84-9-11(b).

OU O

TDI1173/4 REV 1

p)

N,_

Page 3 of 3 b'

The manufacturing process used to create' the interference fit between the r

roller pin and bushing is acceptable based on analysis and service history.

The pin material is yielded by the hydraulic press and shortens enough to capture the bushing while remaining secure in the tappet.

If j

the pin-bushing interference was not adequately achieved during

)

manufacture, the pin would fail soon afi.er initial start-up.

Overall industry experience, shop testing and field endurance testing show that the manufacturing process is acceptable As part of the routine maintenance for this component, at the refueling 3

outage, the tappet assemblies should be inspected with the TDI inspection and maintenance record form 345-1-1.

The information provided on the following TERs has been reviewed and is consistent with the final conclusions of this report:

TERs10-044, 10-062,10-085.

Quality Revalidation Checklist results identified in Appendix B have been reviewed and considered with the performance of this design review.

The

^

results are consistent with the final conclusions in this report.

Based on the above review, it is concluded that the intake, exhaust and fuel tappet assemblies are acceptable for their intended use at Comanche Peak.

V REFERENCES 1.

FaAA memorandum, J.

Zimmerman (FaAA) to J.

Kammeyer (TDI) Owners Group, Program Manager).

SUBJECT:

Intake, Exhaust and Fuel Tappet Reivew. 8/17/84.

2.

TDI Memo from M. Lowrey (TDI) to J. Zimmerman, (FaAA) 5/29/84.

3.

Telecon; J.

Carbonaro (SWEC) to M.

Lowrey (TDI)

Subject:

Approximate Number of Existing Tappet Assemblies, 8/20/84.

l.

I hw;'

W

'v TDI1106/3 Rev. 1

(*

/)

Page 2 of 3 Static and linear dynamic models of-the gear system (Ref.1) were used to determine the steady state and' transient loads which must be transmitted through the gear interfaces.

These loads were then used in calculations to evaluate resistance of the gears to pitting and bending in conformance with AGMA standards (Ref. 2).

The adequacy of the support structure, outboard support bushing, and the bolts which connect the hub to the gear was also investigated.

A journal orbit analysis of the bushing was completed.

IV RESULTS AND CONCLUSIONS The results _of the linear dynamic analysis and AGMA evaluation of the gear are presented below in tabular form for pitting and bending resistance.

Backlash was considered through the choice of the AGMA applications and dynamic factors.

CAMSHAFT GEAR FACTOR OF SAFETY

. Pitting Stresses 1.56 Bending Stresses 1.91 The calculated factors of safety indicate that this gear is acceptable for-its intended use.

However, due to the pitting that has been observed on the Shoreham gears, it is recommended that:

4U 1

The surveillance maintenance / inspection procedures be modified to inspect the cam gear at every refueling outage.

The four bolts which connect the cam hub to the cam gear are adequate (factor of safety of 3.1) with respect to the preload generated by the initial 70120 ft-lbf torque (Ref. 3).

They do not, however, provide a clamping force which is sufficient to prevent slipping between the gear and hub.

It is recommended that either:

The number of No. 9167 bolts, torqued at 70120 ft-lbf, be increased from 4 to 6.

This is more consistent with the 6 bolts which connect

.the idler gear and hub, particularly in view with the fact that the torque imbalance on the cam gear (4 bolts) is larger than on the idler gear (6 bolts). The resulting factor of safety with respect to slipping is 1.31.

OR The initial torque in the No. 9167 bol+ which connect the cam gear to the cam hub be increased to 80(-0,+10) ft-lbf providing a unit factor of safety with respect to slipping and a factor of safety of 3.1 with respect to the preload in the bolt.

The first s o'. "ti o n is preferred in that it results in factors of safety larger than one for both slipping and bolt preload.

x-TDIO960/2 Rev. 1

i Page 2 of 3

'[

The suitability of solid lifters was established by comparing valve train forces with the zero lash imposed by hydraulic lifters and the specified lash of solid lifters (Ref. 4).

The conversion from hydraulic lifters to solid lifters is analyzed from the viewpoint of the suitability of the existing hydraulic lifters for service. That is, if hydraulic lifters are found suitable, the conversion is deemed unnecessary (Ref. 4).

The manufacturer of the hydraulic lifters (Eaton Corporation) was contacted to determine what application specification might apply to this component.

Quality Revalidation Inspection results were analyzed to determine whether or not they confirm the other findings of this report.

IV.

RESULTS AND CONCLUSIONS Other similar TDI engines have experienced collapsed lifters.

The problem only occurred at the time of the first start following an extended period of inactivity and is diagnosed as resulting from the oil within the lifter draining out in response to gravitational forces.

In fact, at the time this problem arose, the hydraulic lifters were wrongly specified by TDI to be installed upside down.

A modification has been reade at the instruction of TDI (Ref. 1) to reinstall the lifters right side up; and indeed, the collapsed lifter problem has not reoccurred.

IQ The operational forces imposed upon the valve train using solid lifters are essentially indentical to those found with hydraulic lifters (Ref. 3).

No reliability improvement is forecast by converting from one to the other.

The hydraulic lifter arrangement has ' proven its reliability at Comanche Peak by successfully operating through extended engine testing.

This history of demonstrated reliability proves that the conversion to a solid lifter system is unnecessary and hence, the suitability of solid lifters is irrelevant to Comanche Peak.

Inspection results do indicate a high wear rate of the hydraulic lifters.

Although this wear is undesirable, operating experience at C.P.

1 links no failures to it.

Therefore, it is concluded that the degree of wear seen thus far is benign and it is recommended that worn lifters be replaced with new lifters at each refueling outage.

l l LI TDIO217/2 REV. 1

~_-

l n)

Page 2 of 2

'(%J Crank To Pump Gear

)

Factor Of Safety Pitting Stresses 1.14 Bending Stresses-2.89 l1 Due to the low factor of safety with respect to pitting, as well as the pitting observed at Shoreham, it is recommended that the crank to pump gear be inspected during each refueling outage.

The inspection should be 1

directed at potential pitting and any, abnormal indications or progressive pitting should be reported for an engineering evaluation.

The capscrews which connect the " crank to pump gear" to the crankshaf t are adequate with a factor of safety of 4.6 with respect to the tensile preload in the bolt under the prescribed torque of 70 ft-lbs (Ref. 3).

Quality Revalidation Checklist results have been reviewed and considered in the performance of this design review, and the results are consistent with the final conclusion of this report.

The information provided on the following TER's has been reviewed and is consistent with the final conclusions of this report:

10-045,10-083.

,_s (V)

Based on the above review, it is concluded that the idler gear assembly -

crank to pump gear and capscrew are acceptable for their intended service at Comanche Peak.

V REFERENCES 1.

" Gear Train Analysis," FaAA 84-6-69(b).

2.

AGMA Standard Publication 218.01, " Rating the Pitting Resistance and Bending Strength of Spur and Helical Gear Teeth."

3.

TDI Instruction Manual, Appendix IV, p. 8-5-A.

1 4

l TDIO396/2 I

Rev. 1 L

-,10 V

TDI OWNERS GROUP for COMANCHE PEAK STEAM ELECTRIC STATION - UNIT 1 IDLER GEAR ASSEMBLY COMPONENT PART NO. 02-355B I

INTRODUCTION The TDI' Emergency Diesel Generator Owners Group Program for the Comanche Peak Steam Electric Station requires Design and Quality Revalidation reviews of the idler gear assembly. This assembly consists of:

Part Name TDI Part No.

Manufacturer Idler hub 02-355-03-AC TDI 1

1 Idler gear 02-355-01-0 E TDI Bolt idler gear to hub 9167 TDI

' Washer Flat 5/8 std GA-001-027 Various vendors 1

Nut 5/8 slotted GB-061-006 Various vendors Cotter pin 1/8 x 1 & 3/4 GC-002-024 Various vendors

. Idler gear hub bushing 03-355-01-0B TDI The primary function of the idler gear assembly is to transmit torque from the crankshaft to the camshaft.

The idler gear bushings interface between the idler hub and the supports.

II OBJECTIVE I

l The objective of this design review was to evaluate the ability of the l

idler gear assembly to provide adequate service life, specifically to perform:

An evaluation of the structural integrity of the gear interfaces and the bolts under steady state and dynamic loads.

An evaluation of the bushing to provide adequate support for the idler gear assembly during normal operation.

A review of Comanche Peak site, nuclear, and non-nuclear industry experience.

O s

TDIO959/1 pey, 1

F 2

A-U HOW TO USE THIS REPORT

)'

Tabs in this report identify the following categories:

Turbo, Intake, Intercooler & Exhaust 4

Lube Oil Engine Base & Bearing Caps d-Crankshaft & Bearings Cylinder Block, Liners & Water Manifold 4

Air Start & Barring Device

?

Connecting Rods

[

Pistons l

Camshaft & Valve Train Idler Gear Assembly & Front Gear Case Flywheel 1

Engine Instrumentation & Wiring i

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 Comanche Peak specific component numbers.

A give'n component report can be found by:

a)

If the component number is known - use the alpha - numeric index I

which identifies the volume number and category in which the component report is located.

b)

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

I 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.

I i

5

O-j Rev. 1 TDIO907

+

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

....._..-.-__-.,_.___,_,,,_,,,--,.-_,m.,-.-r,m-_,

,__,,,,..,,,..~._,._,_.,,,,mm-,y,..m,---.

s O

INDEX(continued)

'N Component Component Vol.

Number Description Category No.

j CP-101A Generator: Generator Generator 8

CP-101B Generator: Shaft and Generat.or 8

Bearings CP-102 Generator Controls Generator 8

F-068 Intercooler Turbo, Intake, 2

Intrcir. & Ex-haust MP022/3 Turbocharger Turbo, Intake, 2

Intrcir. & Ex-haust 00-420 Lube Oil Pressure Lube Oil 2

Regulating Valve 00-442A Starting Air Distributor:

Air Start 4

Distributor Assembly

& Barring Device v

00-442B Starting Air Distributor:

Air Start &

4 Tui,ing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drop Tank Fuel Oil In-8 jection 02-CFR Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrcir. & Ex-haust 02-305A Base and Bearing Caps: Base Engine Base 3

Assembly

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

Engine Base 3

Main Bearing Studs & Huts

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

Engine Base 3

Main Bearing Caps

& Bearing Caps 02-307A Lube Oil Fittings:

Lube Oil 2

Internal - Headers 02-3078 Lube Oil Fittings:

Lube Oil 2

Internal - Tube & Fittings O

V Rev. 1 11 Entire Page Revised TDIO907

<m INDEX(continued)

Component Component Vol.

Number Description Category No.

02-3070 Lube Oil Fitting Internal-Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

3 Bearings 02-310B Crankshaft and Bearings:

Crankshaft &

3 Bearing Shells Bearing 02-310C Crankshaft Crankshaft &

3 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy_

Crankshaft &

-3 Bearing 02-311D Crankcase: Crankcase Crankshaft &

3 Mounting Hardware Bearings 02-315A Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Cylinder Liners & Water Block Manifold 02-315C Cylinder Block Liners Cyl. Block &

4 Liners &

Water Manifold 02-3150 Water Manifold: Jacket Cyl Block &

4 Water Manifold & Piping Liners &

Water Manifold 02-315E Cylinder Block Liners' &

Cyl. Block &

4 Water Manifold: Studs Liners &

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

4

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

Cyl. Block &

4 Water Manifold: Seals and Liners &

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

Jacket Water 7

Manifold Assembly W/ Hardware and Coupling and Gaskets O

Rev. 1 Entire Page Revised 99$

TDIO907

INDEX(continued)

Component Component, Vol.

Number Description Category No.

02-316B Jacket Water Inlet Manifold:

Jacket Water 7

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

Jacket Water 7

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

Jacket Water 7

Jacket Water Discharge Manifold, Coupling and Seals 02-317B Water Dicharge Manifold:

Jacket Water 7

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Water 7

Supports 02-330A Flywheel: Flywheel Flywheel 6

02-3308 Flywheel B.olting Flywheel 6

O

.y/

02-335B Front Gear Case-Gasket and Idler Gear As-5 Bolting sembly & Front Gear Case 02-340A Connecting Rods: Connecting Connecting 4

Rods & Bushings Rods 02-3408 Connecting Rods: Bearing Connecting 4

Shells Rods 02-341A Pistons: Pistons Pistons 5

02-341B Pistens: Rings Pistons 5

02-341C Piston: Pin Assembly Pistons 5

02-345A Intake / Exhaust and Fuel Camshaft &

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

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

5 Pump Base Assembly Valve Train Rev. 1 iv Entire Page Revised TDIO907

1 m.

)

INDEX(continued)

/.

Component Component.

Vol.

Number Description Category No.

02-350A Camshaft Camshaft &

5 Valve Train 1

02-3508 Camshaft Bearing Camshaft &

5 Valve Train 5

02-350C Camshaft: Supports, Bolting Camshaft &

5 and Gear Valve Train t

02-355A Idler Gear Assemble: Crank Idler Gear As-5 To Pump Gear sembly & Front Gear Case 02-355B Idler Gear Assembly:

Idler Gear As-5 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valves: Air Start Air Start &

4 Valve Barring Device 02-360A Cylinder Head Cylinder Heads 8

& Valves 02-360B Intake & Exhaust Valves Cylinder Heads 8

& Valves 02-360C

. Cylinder Head and Valves -

Cylinder Heads 8

Bolting and Gaskets

& Valves 02-3600 Valve Springs Cylinder Heads 8

& Retainers

& Valves 02-362A Subcover Camshaft &

5 Valve Train 02-365A Fuel Injection Pump Fuel Oil In-8 jection 02-365B Fuel Injection Nozzle Fuel Oil In-8 Assembly jection 02-365C Fuel Oil Injection Tubing Fuel Oil In-8 jection 02-3650 Fuel Injection Equipment:

Fuel Oil In-8 Supports jection

.02-371A Fuel Pump Linkage: Fuel Fuel Oil In-8

(

Pump Control Shaft jection Rev. 1 TDIO907 Entire Page Revised

~'h

[d INDEX(continued)

Component Component Vol.

Number Description Category No.

02-371B Fuel Pump Linkage: Linkage Fuel Oil In-8 Assembly and Bearing jection 02-375 Air Intake Manifold Turbo, Intake, 2

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

Intrcir. & Ex-haust 02-3808 Exhaust Manifold -

Turbo, Intake, 2

Bolting and Gaskets Intrcir. & Ex-haust 02-385B Cylinder Block and Cyl. Block &

4 Crankcase Covers:

Liners & Water Gaskets and Bolts Manifold 02-386B Crankcase Covers: Crankcase Cranshaft &

3 Gaskets and Mounting Bearings Hardware 02-390A

' Intake / Intermediate Camshaft &

5 and Exhaust Rocker Valve Train Shaft Assembly 02-390B Rocker Arms and Pushrods:

Camshaft &

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

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

Camshaft &

5 Pushrods Connector.

Valve Train 02-390E Rocker Arms and Pushrods:

Camshaft &

5 Bushings Valve Train 1

02-390F Rocker Arms and Pushrods:

Camshaft &

5 Lifters Valve Train 02-390G Rocker Arms and Pushrods-Camshaft &

5 Miscellaneous Bolts &

Valve Train Drive Studs O

Rev. 1 TDIO907

INDEX(continued)

%d Component Component Vol.

Number-Descripticn Category No.

02-410A-Overspeed Trip:. Governor Overspeed Trip 6

& Governor 02-4108 Overspeed Trip: Governor Overspeed Trip 6

and Accessory Drive-

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 6

& Governor 02-4100 Overspeed Trip Vent Valve Overspeed Trip 6

& Governor 02-411A Governor Drive: Governor Overspeed Trip 6

and Tachometer Drive Gear

& Governor

& Shaft 02-4118 Governor Drive: Couplings, Overspeed Trip 6

Pins & Keys

& Governor 02-413A Governor Linkage Overspeed. Trip 6

& Governor O(

02-413B Fuel Pump Linkage Fuel Oil In-8 jection 02-415A Governor Assembly: Woodward Overspeed Trip 6

Governor

& Governor 02-415B Governor Assembly - Booster Overspeed Trip 6

Servometer

& Governor 02-415C Governor Assembly Heat Overspeed Trip 6

Exchanger

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425A Engine Driven Jacket Water 7

Jacket Water Pump 02-435A Jacket Water Fittings:

Jacket Water 7

Piping 02-435B Jacket Water Fittings:

Jacket Water 7

Supports t

02-435C Jacket Water Inlet Fittings:

Jacket Water 7

Valves Rev. I I

vii l

TOIO907 Entire Page Revised

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

INDEX(continued)

L Component Component Vol.

Number Description Category No.

02-436A Intercooler Piping Turbo Intake, 2

and Piping Couplings, Intrcir. & Ex-Gaskets and Bolting haust 02-436B Intercooler Piping: Coupling, Turbo Intake, 2

Gaskets, Bolting Intrcir. & Ex-haust 02-437 Turbo Water Piping:

Jacket Water 7

Pipe & Fittings 02-441A Starting Air Manifold:

Air Start &

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

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

Air Start &

4 Supports Barring Device

~

02-445 Fuel Oil Booster Pump Fuel Oil In-8 jection 02-450A Fuel Oil Headers Piping /

Fuel Oil In-8 Tubing jection 02-4508 Fuel Oil Header: Fuel Oil Fuel Oil In-8 Tubing Supports jection 02-455A Fuel Oil Filters &

Fuel Oil In-8 Strainers: Fuel Oil Filters jection 02-4558 Fuel Oil Fuel Oil In-8 Strainers jection 02-455C Fuel Oil Filters and Fuel Oil In-8 Strainer Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fitting, Couplings 02-465B Lube Oil Liners - External Lube Oil 2

Supports 02-465C Lube Oil Lines External:

Lube Oil 2

Valves O

'O viii Rev. 1 TDIO907 Entirc Page Revised I

Eh

_ (

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-467A Turbocharger: Lube Oil Lube Oil

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

Fittings - Supports 02-475A Turbocharger:

Bracket Turbo, Intake, 2

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

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

Turbo, Intake, 2

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

Control Panel 9

Cabinet / System Assembly V

02-500F Control Panel Assembly:

Control Panel 9

Accumulator Assembly 02-500G Control Panel Control Panel 9

Valves Assembly 02-500H Control Panel Assembly:

Control Panel 9

Pressure Switch Assembly 02-500J Control Panel Assembly:

Control Panel 9

Relays Assembly 02-500K Control Panel Assembly:

Control Panel 9

Solenoid Valves Assembly 02-500M Control Panel Assembly-Control Panel 9

Piping, Tubing, and Assembly Fittings 02-500N Miscellaneous Equipment Control Panel 9

Terminal Boards /Switchs/

Assembly Wiring i

j 02-540A Lube Oil Sump Lube Oil 3

l Tank with Strainer l

i Assembly and Mounting i

C Hardware l

ix Rev. 1 TDIO907 Entire Page Revised

[N INDEX(continued)

Component Component Vol.

Number Description Category No.

02-5408 Lube Oil Sump Tank: Misc.

Lube Oil 3

Fittings, Gaskets, Pipe

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

Lube Oil 3

Mounting Hardware 02-550 Foundation Bolts:

Engine & Aux.

9 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly:

Engine Instru-6 Conduit mentation &

Wiring 02-6308 Pyrometer Conduit Assembly:

Engine Instru-6 Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly':

Engine Instru-6 O,

Support mentation &

Wiring 02-6300 Pyrometer Conduit Assembly:

Engine Instu-G Thermocouples mentation &

Wiring 02-688A Engine & Aux Module Wiring Engine Instru-6 Material: Conduit & Fittings; mentation &

Pyrometer conduit assembly -

Wiring conduit, Fittings, Supports 02-688B Engine & Aux. Module Engine Instru-6 Wiring Material: Wiring mentation &

& Terminations Wiring 02-688C Engine & Aux. Module Wiring Engirie Instu-6 Material: Boxes & Terminals mentation &

Wiring 02-689 Off Engine Alarm Engine Instru-6 Sensors: Wiring mentation &

Wiring 02-690 On Engine Alarm Sensors Engine Instru-6 mentation &

Wiring x

Rev. 1 TDIO907 Entire Page Revised

k

[/)

INDEX(continued)

A_

s Componer.t Component Vo.l.

l Number Description Category No.02-691 Off Engine Alarm Engine Instru-6 Sensors:

mentation &

Wiring 02-695A Engine Shut Down Equipment Engine Shut-6 Tubing / Fittings & Supports down & Equip-ment 02-6958 Engine Shut Down Equipment:

Engine Shut--

6 Valves, Regulator, Orifice down & Equip-ment 02-695C Engine Shutdown: Trip Engine Shut-6 Switches down & Equip-ment 02-700A Jacket Water Stand Pipe-Jacket Water 7

Pipe, Fittings, Gaskets e

02-700B Jacket Water Stand Pipe:

Jacket Water 7

Valves f-s i

\\

\\~ l 02-700C Jacket Water Stand Pipe-Jacket Water 7

Supports 02-700E Jacket Water Stand Pipe-Jacket Water 7

Switches 02-700F Jacket Water Stand Pipe Jacket Water 7

and Misc. Bolting Material 02-717A Aux Sub Base and Oil and Engine Aux.

9 Water Piping-Aux Sub Base Sub-Base &

Foundation Bolts 02-717B Aux Sub Base and Oil and Jacket Water 7

Water Piping-Jacket Water Valves 02-717C Aux Sub Base & Oil Water Jacket Water 7

Piping-Jacket Water: Pipe, Couplings, Fittings, Orifices, Y Strainers 02-7170 Aux Sub Base & Oil & Water Jacket Water 7

Piping: Jacket Water Gaskets

(

& Bolting Rev. 1

• #9*

TDIO907

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-717E Aux Base & 011 & Water Jacket Water 7

Piping: Jacket Water Supports 02-717F Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping and Tub-ing - Lube Oil - Pipe, Tubing, Fittings 02-717G Aux Sub Base & Oil & Water Lube Oil 3

Piping: Lube Oil-Valves 02-717H Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping-Lube Oil-Gaskets and Bolting 02-717I Aux Sub Base and Oil and Lube Oil 3

Water Piping: Lube Oil-Supports & Mounting Hardware 02-717J Aux Sub Base & 011 & Water Fuel Oil In-8 Piping: Fuel Oil-Piping jection b

and Fittings 02-717K Aux Sub Base & 011 & Water Fuel Oil In-8 Piping: Fuel Oil-Valves jection 02-717L Aux Sub Base and Oil and Fuel Oil In-8 Water Piping-Fuel jection Oil-Gaskets and Bolting 02-717M Aux Sub Base & 011 & Water Fuel Oil In-8 Piping: Fuel Oil-Supports jection 02-805A Intake Air Silencer Turbo, Intake, 2

Intrcir &

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

Intrcir &

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

Intrcir &

Exhaust 02-810A Auxiliary Jacket Water Jacket Water 7

O Pump

-L]

. TDIO907 -

xii Rev. 1 Entire Page Revised

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-810B Jacket Water Standby Jacket Water 7

Heater Pump 02-810C Jacket Water Heat Jacket Water 7

Exchanger 02-8100 Jacket Water Thermostatic Jacket Water 7

Valve 02-810E Misc. Equipment:

Jacket Water 7

Jacket Water Standpipe Heater 02-820A Misc. Equipment:

Lube Oil 3

Lube Oil Sump Tank Heater 02-820B Auxiliary Lube Lube Oil 3

011 Pump 02-820C Pre-Lube Oil Lube Oil 3

Pump 02-8200-Lube Oil Lube Oil 3

Keepwarm Strainer 02-820E Oil Prelube Filter Lube Oil 3

02-820F Full Flow Lube Oil Filter Lube Oil 3

02-820G Lube Oil Heat Exchanger Lube Oil 3

02-820H Lube Oil Full Pressure Lube Oil 3

Strainer 02-825A Fuel Oil Fuel Oil 8

Day Tank Injection 02-825B Miscellaneous Equipment Fuel Oil 8

Fuel Oil Transfer Pump Injection 02-825E Fuel Oil System: Fuel Oil Fuel Oil 8

Duplex Strainer Injection 02-835A Air Start System: Starting Air Start &

4 Air Skid Base Barring Device O

Rev. 1 TDIO907 Entire Page Revised

_J

l INDEX(continued) i Component Component Vol.

Number Description Category No.

4 02-8350 Starting Air Tank Air Start &

4 Relief Valve Barring Device 02-835F Starting Air Float Trap Air Start &

4 Barring Device l

02-835J Starting Air Tank Air Start 4

i Barring Device j

Appendix II 9

Appendix III 9

I

)

1 1.

i j

j Rev. 1 TDIO907 Entire Page Revised

p_

Page 3 of.4 adjustment affects the reset speed as well.

An additional screw setting is basically used to hold the speed adjusting lever (within the governor) in a-_ fixed position, in conjunction with the trip speed adjusting screw.

The TDI Instruction Manual has a section on adjustment of the overspeed trip which essentially duplicates the material from the Woodward manual.

These adjustment procedures are-acceptable.

While the Woodward manual does not specify the trip speed, the TDI in-structions specify _a setting 15 percent above normal (corresponding to a governor speed of 3381 - rpm), which agrees with the diesel generator purchased material specification for the overspeed trip (Rev. 4).

Since it is a bistable device, the overspeed trip is less susceptible to torsional vibrations from an operational point of view, in comparison with a continuous acting device like the governor.

There may be concern over the material integrity of the governor's parts, especially. since the manufacturer has_ no specification for an allowable level of vibration.

However, neither the industry and Comanche Peak experiences nor that of the manufacturer. indicate that there is any problem with the overspeed trip failing due to torsional vibrations.

Industry experience indicates that a potential problem exists with incor-rect. settings causing trips when they are not warranted.

Since the adjustments are screw settings, there is no easy way to visually check the governor's trip ' speed.

Thus, the trip speed setting should be tested as e

part of the normal surveillance testing.

Based on the overspeed trip's history and the manufacturer's suggested practices, the following recommendations are made to improve the system's reliability (Ref. 5):

Modify the surveillance testing procedures to include verifica-tion that the overspeed trip is correctly set to an overspeed trip setting of 518 +/- 1% at every refueling outage, ensuring that both the electric governor and the mechanical ' backup-governor are' properly returned to their normal settings following the overspeed test.

The test is to be performed with

)

no load on the engine by increasing the normal governor's speed setting (s) until a trip occurs.

After_ several inspection periods, the history of the required adjustments should be reviewed to evaluate and possibly modify the testing interval.

O TDI1187/3 Rev. 1

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 Comanche Peak specific component numbers.

A given component report can be found by:

a)

If the component number is known - use the alpha - numeric index which identifies the volume number and category in which the 3

component 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 coeponent.

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.

I O

j Rev. 1 TDIO907

..[

INDEX(continued)

Component Component Vol.

Number Description Category No.

' CP-101A Generator: Generator Generator 8

CP-101B Generator: Shaft and Generator 8

Bearings CP-102 Generator Controls Generator 8

F-068 Intercooler Turbo, Intake, 2

Intrcir. & Ex-haust MP022/3 Turbocharger Turbo, Intake, 2

Intrcir. & Ex-haust 00-420.

Lube Oil Pressure Lube Oil 2

Regulating Valve 00-442A Starting Air Distributor:

Air Start 4

Distributor Assembly

& Barring Device 00-442B Starting Air Distributor:

Air Start &

4 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drop Tank Fuel Oil In-8 jection 1

02-CFR Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrcir. & Ex-haust 02-305A Base and Bearing Caps: Base Engine Base 3

Assembly

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

Engine Base 3

Main Bearing Studs & Nuts

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

Engine Base 3

Main Bearing Caps

& Bearing Caps 02-307A Lube Oil Fittings:

Lube Oil 2

Internal - Headers 02-307B Lube Oil Fittings:

Lube Oil 2

Internal - Tube & Fittings O

Rev. 1 11 Entire Page Revised TDIO907 i

-r-

,-,,-.,-,,-,---,----..e.,,m-,_

,..gmg

,w,_.y-

-w,em,-_,,

-_,,,-.-,,_,m->.,n,-,,y-r,,,-

re,r

r(,).

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-307D Lube Oil Fitting Internal-Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

3 Bearings 02-310B Crankshaft and Bearings:

Crankshaft &

3 Bearing Shells Bearing 02-310C Crankshaft Crankshaft &

3 Thrust Bearing Rings.

Bearing 02-311A

. Crankcase: Crankcase Assy Crankshaft &

3 Bearing 02-3110 Crankcase: Crankcase Crankshaft &

3 Mounting Hardware Bearings 02-315A Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Cylinder Liners & Water Block

'O, Manifold 02-315C Cylinder Block Liners Cyl. Block &

4 Liners &

Water Manifold 02-3150 Water Manifold: Jacket Cyl. Block &

4 Water Manifold & Piping Liners &

Water Manifold 02-315E Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Studs Liners &

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

4

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

Cyl. Block &

4 Water Manifold: Seals and Liners &

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

Jacket Water 7

Manifold Assembly W/ Hardware and Coupling and Gaskets O

Rev. I Entire Page Revised 934 TDIO907

.[]

INDEX(continued)

V Component Component Vol.

Number Description Category No.

02-3168 Jacket Water Inlet Manifold:

Jacket Water 7

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

Jacket Water 7

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

Jacket Water 7

Jacket Water Discharge Manifold, Coupling and Seals 02-3178 Water Dicharge Manifold:

Jacket Water 7

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Watn 7

Supports 02-330A Flywheel: Flywheel Flywheel 6

02-3308 Flywheel Bolting Flywheel 6

02-335B Front Gear Case-Gasket and Idler Gear As-5 Bolting sembly & Front Gear Case 02-340A Connecting Rods:

Connecting Connecting 4

Rods & Bushings Rods 02-3408 Connecting Rods: Bearing Connecting 4

Shells Rods 02-341A Pistons: Pistons Pistons 5

02-341B Pistons: Rings Pistons 5

02-341C Piston: Pin Assembly Pistons-5 02-345A Intake / Exhaust and Fuel Camshaft &

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

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

5 Pump Base Assembly Valve Train Rev. 1 iv Entire Page Revised TOIO907

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-350A Camshaft Camshaft &

5 Valve Train 02-350B' Camshaft Bearing Camshaft &

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

5 and Gear Valve Train 02-355A Idler Gear Assemble: Crank Idler Gear As-5 To Pump Gear sembly & Front Gear Case 02-355B Idler Gear Assembly:

Idler Gear As-5 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valves: Air Start Air Start &

4 Valve Barring Device 02-360A Cylinder Head Cylinder Heads 8

p

& Valves 02-360B Intake & Exhaust Valves Cylinder Heads 8

& Valves 02-360C Cylinder Head and Valves -

Cylinder Heads 8

Bolting and Gaskets

& Valves 02-360D Valve Springs Cylinder Heads 8

& Retainers

& Valves 02-362A Subcover Camshaft &

5 Valve Train 02-365A Fuel Injection Pump Fuel Oil In-8 jection 02-3658 Fuel Injection Nozzle Fuel Oil In-8 Assembly jection 02-365C Fuel Oil Injection Tubing Fuel Oil In-8 jection 02-3650 Fuel Injection Equipment:

Fuel Oil In-8 Supports jection 02-371A Fuel Pump Linkage: Fuel Fuel Oil In-8 d

Pump Control Shaft jection

"*** I TDIO907 Entire Page Revised

A

)

INDEX(continued) v Component Component Vol.

Number Description Category No.

02-371B_

Fuel Pump Linkage: Linkage Fuel Oil In-8 Assembly and Bearing jection 02-375 Air Intake Manifold Turbo, Intake, 2

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

Intrcir. & Ex-haust 02-3808 Exhaust Manifold-Turbo, Intake, 2

Bolting and Gaskets Intrcir. & Ex-haust 02-385B Cylinder Block and Cyl. Block &

4 Crankcase Covers:

Liners & Water Gaskets and Bolts Manifold 02-386B Crankcase Covers: Crankcase Cranshaft &

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

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

Camshaft &

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

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

Camshaft &

5 Pushrods Connector.

Valve Train 02-390E Rocker Arms and Pushrods:

Camshaft &

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

Camshaft &

5 Lifters Valve Train 02-390G Rocker Arms and Pushrods-Camshaft &

5 Miscellaneous Bolts &

Valve Train l

Drive Studs

!O r

Rev. 1

• #9" TDIO907 l

{G-INDEX(continued)

Component Component Vol.

Number Description Category No.

02-410A Overspeed Trip: Governor Overspeed Trip 6

& Governor 02-410B Overspeed Trip: Governor Overspeed Trip 6

and Accessory Drive

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 6

& Governor 02-4100 Overspeed Tr!p Vent Valve Overspeed Trip 6

& Governor 02-411A.

Governor Drive: Governor Overspeed Trip 6

and Tachometer Drive Gear

& Governor

& Shaft 02-411B Governor Drive: Couplings, Overspeed Trip 6

Pins & Keys

& Governor 02-413A Governor Linkage Overspeed Trip 6

& Governor 02-413B Fuel Pump Linkage Fuel Oil In-8 jection 02-415A Governor Assembly: Woodward Overspeed Trip 6

Governor

& Governor 02-415B Governor Assembly - Booster Overspeed. Trip 6

Servometer

& Governor 02-415C Governor Assembly Heat Overspeed Trip 6

Exchanger

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425A Engine Driven Jacket Water 7

Jacket Water Pump 02-435A Jacket Water Fittings:

Jacket Water 7

Piping 02-435B Jacket Water Fittings:

Jacket Water 7

Supports 02-435C Jacket Water Inlet Fittings:

Jacket Water 7

Valves V

Rev. 1 V

TDIO907 Entire Page Revised

i

/7 INDEX(continued)

Component Component Vol.

Number Description Category No.

02-435A Intercooler Piping Turbo Intake, 2

and Piping Couplings, Intrcir. & Ex-Gaskets and Bolting haust 02-4368 Intercooler Piping: Coupling, Turbo Intake, 2

Gaskets, Bolting Intrcir. & Ex-haust 02-437 Turbo Water Piping:

Jacket Water 7

Pipe & Fittings 02-441A Starting Air Manifold:

Air Start &

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

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

Air Start &

4 Supports Barring Device 02-445-Fuel Oil Booster Pump Fuel Oil In-8 jection 02-450A Fuel Oil Headers Piping /

Fuel Oil In-8 Tubing jection 02-4508 Fuel Oil Header: Fuel Oil Fuel Oil In-8 Tubing Supports jection 02-a55A Fuel Oil Filters &

Fuel Oil In-8 Strainers: Fuel Oil Filters jection 02-455B Fuel Oil Fuel Oil In-8 Strainers jection 02-455C Fuel Oil Filters and Fuel Oil In-8 Strainer Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fitting, Couplings 02-465B Lube Oil Liners - External Lube Oil 2

Supports 02-465C Lube Oil Lines External:

Lube Oil 2

Valves

)

t viii Rev. 1 TDIO907 Entire Page Revised L.

(

INDEX(continued)

Com;:onent Component Vol.

Number Description Category No.

02-467A Turbocharger: Lube Oil Lube Oil 2

Fitting - Pipe, Tubing, Fittings & Flexible Coupling -

02-467B Turbocharger: Lube Oil Lube Oil 2

Fittings - Supports 02-475A Turbocharger:

Bracket Turbo, Intake, 2

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

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

Turbo, Intake, 2

Bolting & Gaskets Intrcir. & Ex-haust

-7 k

02 500A Control Panel Assembly:

Control Panel 9

Cabinet / System Assembly l'

N 02-500F Control Panel Assembly:

Control Panel 9

Accumulator Assembly 02-500G Control Panel Control Panel 9

Valves Assembly l

02-500H Control Panel Assembly:

Control Panel 9

Pressure Switch Assembly i

02-500J Control Panel Assembly:

Contrcl Panel 3

-Relays Assembly 02-500K Control Panel Assembly:

Control Panel 9

Solenoid Valves Assembly.

02-500M Control Panel Assembly-Control Panel 9

Piping, Tubing, and Assembly Fittings 02-500N.

Miscellaneous Equipment Control Panel 9

Terminal Boards /Switchs/

Assembly Wiring 02-540A Lube Oil Sump Lube Oil 3

Tank with Strainer

.(

Assembly and Mounting Hardware ix Rev. 1

J TDIO907 Entire Page Revised

(

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-5408 Lube Oil Sump Tank: Misc.

Lube Oil 3

Fittings, Gaskets, Pipe

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

Lube Oil 3

Mounting Hardware 02-550 Foundation Bolts:

Engine & Aux.

9 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly:

Engine Instru-6 Conduit mentation &

Wi ring 02-630B Pyrometer Conduit Assembly:

Engine Instru-6 Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly:

Engine Instru-6

[7 Support mentation &

(

Wiring 02-630D Pyrometer Conduit Assembly:

Engine Instu-6 Thermocouples mentation &

Wiring 02-688A Engine & Aux Module Wiring Engine Instru-6 Material: Conduit & Fittings; mentation &

Pyrometer conduit assembly -

Wiring conduit, Fittings, Supports 02-688B Engine & Aux. Module Engine Instru-6 Wiring Material: Wiring mentation &

& Terminations Wiring 02-688C Engine & Aux. Module Wiring Engine Instu-6 Material: Boxes & Terminals mentation &

Wiring

'02-689 Off Engine Alarm Engine Instru-6 Sensors: Wiring mentation &

Wiring 02-690 On Engine Alarm Sensors Engine Instru-6 mentation &

(

Wiring x

Rev. 1 TDIO907 Entire Page Revised

INDEX(continued)

V Component Component Vol.

4 Number Description Category No.

l 02-691 Off Engine Alarm Engine Instru-6 Sensors:

mentation &

Wiring 02-695A Engine Shut Down Equipment Engine Shut-6 Tubing / Fittings & Supports down & Equip-ment 02-6958 Engine Shut Down Equipment:

Engine Shut-6 Valves, Regulator, Orifice down & Equip-ment 02-695C Engine Shutdown: Trip Engine Shut-6 Switches down & Equip-ment 02-700A Jacket Water Stand Pipe-Jacket Water 7

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

Jacket Water 7

Valves 02-700C Jacket Water Stand Pipe-Jacket Water 7

Supports 02-700E Jacket Water Stand Pipe-Jacket Water 7

Switches 02-700F Jacket Water Stand Pipe Jacket Water 7

and Misc. Bolting Material i-02-717A Aux Sub Base and Oil and Engine Aux.

9 Water Piping-Aux Sub Base Sub-Base &

Foundation Bolts 02-717B Aux Sub Base and Oil and Jacket Water 7

Water Piping-Jacket Water Valves 02-717C Aux Sub Base & Oil Water Jacket Water 7

Piping-Jacket Water: Pipe, Couplings, Fittings, Orifices, Y Strainers 02-717D Aux Sub Base & Oil & Water Jacket Water 7

Piping: Jacket Water Gaskets O

& Bolting b

Rev. 1 "9'

TDIO907

(

INDEX(continued)

Component Component Vol.

Number-Description Category No.

02-717E Aux Base & 011 & Water Jacket Water 7

Piping:. Jacket Water Supports 02-717F Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping and Tub-ing - Lube Oil - Pipe, Tubing, Fittings 02-717G Aux Sub Base & 011 & Water Lube Oil 3

Piping: Lube Oil-Valves 02-717H Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping-Lube Oil-Gaskets and Bolting

'02-717I Aux Sub Base and Oil and Lube Oil 3

Water Piping: Lube Oil-Supports & Mounting Hardware 02-717J Aux Sub Base & Oil & Water Fuel Oil In-8

.s Piping: Fuel Oil-Piping jection and Fittings 02-717K Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Valves jection 02-717L Aux Sub Base and Oil and Fuel Oil In-8 Water Piping-Fuel jection Oil-Gaskets and Bolting 02-717M Aux Sub Base & 011 & Water Fuel Oil In-8 Piping: Fuel Oil-Supports jection 02-805A Intake Air Silencer Turbo, Intake, 2

Iatrcir &

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

Intrcir &

Exhaust l

02-805D Flex Connections Turbo, Intake, 2

Intrcir &

Exhaust 02-810A Auxiliary Jacket Water Jacket Water 7

[~T Pump U

xii Rev. 1 TDIO907 Entire Page Revised L

1 INDEX(continued)

Component Component Vol.

Number Description Category No.

02-810B Jacket Water Standby Jacket Water 7

Heater Pump 02-810C Jacket Water Heat Jacket Water 7

Exchanger 02-810D Jacket Water Thermostatic Jacket Water 7

Valve 02-810E Misc. Equipment:

Jacket Water 7

Jacket Water Standpipe Heater 02-820A Misc. Equipment:

Lube Oil 3

Lube Oil Sump Tank Heater 02-820B Auxiliary Lube Lube Oil 3

Oil Pump

~

02-820C Pre-Lube Oil Lube Oil 3

Pump 02-8200 Lube Oil Lube Oil 3

Keepwarm Strainer 02-820E Oil Prelube Filter Lube Oil 3

02-820F Full Flow Lube Oil Filter Lube Oil 3

02-820G Lube Oil Heat Exchanger Lube Oil 3

02-820H Lube Oil Full Pressure Lube Oil 3

Strainer 02-825A Fuel Oil Fuel Oil 8

Day Tank Injection 02-825B Miscellaneous Equipment Fuel Oil 8

Fuel Oil Transfer Pump Injection 02-825E Fuel Oil System: Fuel Oil Fuel Oil 8

Ouplex Strainer Injection 02-835A Air Start System: Starting Air Start &

4 Air Skid Base Barring Device O

Rev. 1 TDIO907 Entire Page Revised

i

' O INDEX(continued)

V Component Component

.Vol.

Number Description Category No.

02-8350 ftarting Air Tank Air Start &

4 Relief Valve Barring Device i

02-835F Starting Air Float Trap Air Start &

4 i

Barring Device 02-835J Starting Air Tank Air Start 4

i i

Barring Device l

l l

Appendix II 9

Appendix III 9

O O

Rev. 1 TDIO907 Entire Page Revised

b Page 2 of 2 IV RESULTS AND CONCLUSIONS In order to mitigate pipe support and in-line equipment loadings, pipe support JW-PSVER-10265 should be modified.

It is a single directional support, providing restraint against downward movement only.

In order to validate the analysis of the associated pipe, restraint against upward movement is required.

This suggested modification is provided in Reference 3.

All pipe support loads were tabulated and issued for evaluation.

Quality Revalidation 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 conclusion of this report.

The information provided on the following TERs has been reviewed and is consistent with the final conclusions of this report:

10-115 and 10-134.

With respect to the Design Review Attribute regarding support evaluation with the piping stress analysis, this is not applicable since the supports are evaluated in this report.

Based on the above review, it is concluded that the subject piping f-support, nodified as noted above, is adequate for its intended design

(

function at Comanche Peak.

N V

REFERENCES 1.

" Supporting Calculations for the Evaluation of Comanche Peak Diesel Generator Large Diameter Piping and Supports," Impell Report No.

02-0630-1230, Rev. O, August 1984.

2.

" Design Criteria for Diesel Generator Large Diameter Piping for Comanche Peak,"

Impell Report No. 02-0630-1231, Rev.

O, August 1984.

This is included in Appendix III of the final DR/QR report.

3.

Memorandum from R.

Markovich/G. Shears (Impell) to J.

Kammeyer (SWEC) " Required Modification for Validation of Impell's Design Review for Impell Report No. 02-0630-1217, Rev. A" dated August 1, 1

1984.

l Ch l Q TDI1160/2 Rev. 1

f

, (Vo)

Page 2 of 3 The TDI Emergency Diesel Generator Component Tracking System was reviewed for the Comanche Peak site, nuclear, and non-nuclear industry experience.

IV RESULTS AND CONCLUSIONS The maximum deadweight stress for the subject component is 2,675 psi.

The piping load controlled seismic stresses were acceptable, never exceeding 14,600 psi.

Thermal expansion stresses were lower, with stresses always less than 7,300 psi and the stresses caused by the axial discontinuity at the in-line Dresser couplings were less than 2,375 psi.

All piping stresses were within the design allowables specified by the ASME Section III Code.

With respect to the' design review attributes regarding the Dresser couplings, Impell evaluated the couplings against the manufacturer's selection and service requirements.

These include the design service conditions, relative end displacement, both rotational and translational, of the joined pipes, and shelf and service life.

The movements at five of the ten Dresser couplings in the subject component exceed the manufacturer's end movement requirements (Ref. 3).

This requires modifications to be made to these five couplings.

Because of excessive relative pipe end movements at three of these couplings,

_[

even when additional supports were postulated, these three couplings must V) be removed and replaced with flanges.

Also, in order to mitigate the excessive movements at the Dresser coupling located above the jacket I

water inlet manifold, it is recommended that a support be added.

In additions, extra nuts are required on the tie-rod assemblies of the other two couplings.

Further details on these modificaitons are provided in Reference 4.

Specifically the following modifications are recommended:

Remove 3 Dresser couplings and replace with flanges.

- Remove the 8 inch coupling on the jacket water cooler piping and replace with an 8 inch-150# S.O. flange.

- Remove tha 6 inch coupling on the jacket water cooler piping and replace with a 6 inch-150# S.O. flange.

Remove the 6 inch coupling at the jacket water auxiliary pump discharge and replace with a 6 inch-150# S. O. flange.

Double-nut the tie-rod assemblies, surrounding two of the Dresser couplings, to prevent excessive relative inward axial movement of the adjoining piping spool pieces.

Also, a 1-inch diameter rod is

{l recommended to accommodate the compression loading.

These two couplings are:

I,b)

- the 6 inch coupling joining the jack at water skid piping, and the intercooler inlet piping TDI1164/2 Rev. 1

h)

Page 3 of 3 N_./

- the 8 inch couplinh south of the 8 inch three-way thermostatic valve In order to provide adequate - load transfer capability, the 6"-150# S.0.

flange at support JW-PSA-10251 has specific requirements for bolt l1 torquing as specified in Appendix IV of the Delaval Instruction Manual Vol. I for Model DSRV-16-4.

It is recommended that these bolts be torqued per the requirements (Ref. 4).

There are no service life constraints (Ref. 5) because.these style couplings have no significant history of failure.

Shelf life (Ref. 5) is unlimited as long as the gaskets remain packaged and protected from the I

elements: light, water, etc.

The coupling is adequate with respect to manufacturer's service condition limits.

To ensure adequate restraint of the piping system, modifications of some supports are recommended.

Details on support modifications are summarized in Impell Report No. 02-0630-1227, Rev. A, August 1984, for Component No.

02-717E and described in more detail in Reference 1.

All pipe. loads on the pump, coolers and intercooler were tabulated and issued for evaluation.

Quality Revalidation Inspection results identified in Appendix B have

[s')

been reviewed and considered in the performance of this design review and V

the results are consistent with the final conclusion of this report.

Based on.the above review, it is concluded that the subject piping components with the recommended modifications, are adequate for their intended design function at Comanche Peak.

V REFERENCES 1.

" Supporting Calculations for the Evaluation of Comanche Peak-Diesel Generator Large Diameter Piping and Supports,".Impell Report No.

02-0630-1230, Rev. O, August 1984.

2.

" Design Criteria for Diesel Generator Large Diameter Piping for Comanche Peak," Impell Report No. 02-0630-1231, Rev.

O, August 1984.

This is included in Appendix III of the final DR/QR Report.

3.

Dresser Pipe Couplings, Pipe Fittings, and Pipe Repair Products Catalog No. 63.

4.

Memorandum from R.

Markovich/G. Shears (Impell) to J.

Kammeyer (SWEC), " Required Modificaitons for Validation of Impell's Design Review for Impell Report No. 02-0630-1226, Rev. A," dated August 6, 1984.

5.

Telephone conversation between A.

Palumbo and M. Riley, of Dresser

,,}

Manufacturing Company, June 5, 1984.

TDI1164/3 Rev. 1

l I

i l -

HOW TO USE THIS REPORT l

l Tabs in this report identify the following categories:

l-Turbo, Intake, Intercooler & Exhaust Lube Oil l

Engine Base & Bearing Caps l

Crankshaft & Bearings Cylinder Block, Liners & Water Manifold Air Start & Barring Device Connecting Rods Pistons Camshaft & Valve Train Idler Gear Assembly & Front Gear Case l

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 h

.Q 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 Comanche Peak specific component numbers.

A given component report can be found by:

a)

If the component number is known - use the alpha - numeric index which identifies the volume number and category in which the component 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.

I j

Rev. 1 TDIO907

k INDEX(continued)

!k i

I Component.

Component Vol.

Number Description Category No.

I CP-101A Generator: Generator Generator 8

CP-1018 Generator: Shaft and Generator 8

Bearings CP-102 Generator Controls Generator 8

F-068 Intercooler Turbo, Intake, 2

Intrcir. & Ex-haust MP022/3 Turbocharger Turbo, Intake, 2

Intrcir. & Ex-

~

haust j

00-420 Lube Oil Pressure Lube Oil 2

Regulating Valve 00-442A Starting Air Distributor:

Air Start 4

Distributor Assembly

& Barring Device 00-4428 Starting Air Distributor:

Air Start &

4 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drop Tank Fuel Oil In-8 jection 02-CFR Turbocharger Thrust Bearing Turbo, Intake, 2

Lubricant System Intrcir. & Ex-haust 02-305A ~

Base and Bearing Caps: Base Engine Base 3

Assembly

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

Engine Base 3

Main Bearing Studs & Nuts

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

Engine Base 3

Main Bearing Caps

& Bearing Caps 02-307A Lube Oil Fittings:

Lube Oil 2

Internal - Headers 02-307B Lube Oil Fittings:

Lube Oil 2

Internal - Tube & Fittings OV Rev. 1 ii Entire Page Revised TDIO907 t

u

[]

INDEX(continued)

V Component Component Vol.

Number Description Category No.

02-307D Lube 011 Fitting Internal-Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

3 Bearings 02-310B Crankshaft and Bearings:

Crankshaft &

3 Bearing Shells Bearing 02-310C Crankshaft Crankshaft &

3 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy Crankshaft &

-3 Bearing 02-3110 Crankcase: Crankcase Crankshaft &

3 Mounting Hardware Bearings 02-315A Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Cylinder Liners & Water Block Manifold 02-315C Cylinder Block Liners Cyl. Block &

4 Liners &

Water Manifold 02-315D Water Manifold: Jacket Cyl. Block &

4 Water Manifold & Piping Liners &

Water Manifold l

02-315E Cylinder Block Liners'&

Cyl. Block &

4 Water Manifold: Studs Liners &

Water Manifold 02-315F Cylinder Block Liners Cy1. Block &

4-

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

Cyl. Block &

4 Water Manifold: Seals and Liners &

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

Jacket Water 7

Manifold Assembly W/ Hardware and Coupling and Gaskets

)

c l

%d Rev. 1 Entire Page Revised gg TDIO907

[Q')

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-3168 Jacket Water Inlet Manifold:

Jacket Water 7

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

Jacket Water 7

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

Jacket Water 7

Jacket Water Discharge Manifold, Coupling and Seals 1

02-317B Water Dicharge Manifold:

Jacket Water 7

Coupling & Seals

'02-317C Water Discharge Manifold:

Jacket Water 7

Supports 02-330A Flywheel: Flywheel Flywheel 6

02-3308 Flywheel Bolting Flywheel 6

02-3358' Front Gear Case-Gasket and Idler Gear As-5 Bolting sembly &_ Front Gear Case 02-340A Connecting Rods:

Connecting Connecting 4

Rods & Bushings Rods 02-340B Connecting Rods: Bearing Connecting 4

Shells Rods 02-341A Pistons: Pistons Pistons 5

02-3418 Pistons: Rings

' Pistons 5

02-341C Piston: Pin Assembly Pistons 5

02-345A Intake / Exhaust and Fuel Cam: haft &

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

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

5 Pump Base Assembly Valve Train (h

Rev. 1 iv Entire Page Revised TOIO907

INDEX(continued)

Component Component Vol.

Number Description Category No.

]

02-350A Camshaft Camshaft &

5 Valve Train 02-3508 Camshaft Bearing Camshaft &

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

5 and Gear Valve Train 02-355A Idler Gear Assemble: Crank Idler Gear As-5 To Pump Gear sembly & Front Gear Case 02-355B Idler Gear Assembly:

Idler Gear As-5 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valves: Air Start Air Start &

4 Valve Barring Device 02-360A Cylinder Head Cylinder Heads 8

]

& Valves 02-360B Intake & Exhaust Valves Cylinder Heads 8

& Valves 02-360C Cylinder Head and Valves -

Cylinder Heads 8

Bolting and Gaskets

& Valves 02-360D Valve Springs Cylinder Heads 8

& Retainers

& Valves 02-362A Subcover Camshaft &

5 Valve Train 02-365A Fuel Injection Pump Fuel Oil In-8 jection 02-3658 Fuel Injection Nozzle Fuel Oil In-8 Assembly jection 02-365C Fuel Oil Injection Tubing Fuel Oil In-8 jection 02-365D Fuel Injection Equipment:

Fuel-011 In-8 Supports jection 02-371A Fuel Pump Linkage: Fuel Fuel Oil In-8 Pump Control Shaft jection Rev. 1 TDIO907 Entire Page Revised

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-371B Fuel Pump Linkage: Linkage Fuel Oil In-8 Assembly and Bearing jection 02-375 Air Intake Manifold Turbo, Intake, 2

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

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

Bolting and Gaskets Intrcir. & Ex-haust 02-385B Cylinder Block and Cyl. Block &

4 Crankcase Covers:

Liners & Water Gaskets and Bolts

' Manifold 02-386B Crankcase Covers: Crankcase Cranshaft &

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

5 and Exhaust Rocker Valve Train Shaft Assembly 2-390B Rocker Arms and Pushrods:

Camshaft &

5 0

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

5 Pushrcds Valve Train s

02-3900 Rocker Arms and Pushrods:

Camshaft &

5 Pushrods Connector.

Valve Train 02-390E Rocker Arms and Pushrods:

Camshaft &

5 4

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

Camshaft &

5 Lifters Valve Train-02-390G Rocker Arms and Pushrods-Camshaft &

5 Miscellaneous Bolts &

Valve Train Drive Studs

- s./

Rev. 1

• #9 TOIO907

/m\\

INDEX(continued)

(_).

Component Component Vol.

Number Description Category No.

02-410A Overspeed Trip: Governor Overspeed Trip 6

& Governor 02-4108 Overspeed Trip: Governor Overspeed Trip 6'

and Accessory Drive

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 6

& Governor 02-410D Overspeed Trip Vent Valve Overspeed Trip 6

& Governor 02-411A Governor Drive: Governor Overspeed Trip 6

and Tachometer Drive Gear

& Governor

& Shaft 02-4118 Governor Drive: Couplings, Overspeed Trip 6

Pins & Keys

& Governor 02-413A Governor Linkage Overspeed Trip 6

& Governor 02-4138 Fuel Pump Linkage Fuel Oil In-8 jection 02-415A Governor Assembly: Woodward Overspeed Trip 6

Governor

& Governor 02-415B Governor Assembly - Booster Overspeed Trip 6

Servometer

& Governor 02-415C Governor Assembly Heat Overspeed Trip 6

Exchanger

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425 Engine Driven Jacket Water 7

Jacket Water Pump 02-435A Jacket Water Fittings:

Jacket Water 7

Piping 02-435B Jacket Water Fittings:

Jacket Water 7

Supports 02-435C Jacket Water Inlet Fittings:

Jacket Water 7

Valves Rev. 1 TDIO907 Entire Page Revised

[)

INDEX(continued)

N Component Component Vol.

Number Description Category No.

02-436A Intercooler Piping Turbo Intake, 2

and Piping Couplings, Intrcir. & Ex-Gaskets and Bolting haust 02-436B Intercooler Piping: Coupling, Turbo Intake, 2

Gaskets, Bolting Intrcir. & Ex-haust 02-437 Turbo Water Piping:

Jacket Water 7

Pipe & Fittings 02-441A Starting Air Manifold:

Air Start &

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

4 F

Valves, Strainer & Filters Barring Device i

j 02-441C Starting Air Manifold:

Air Start &

4 Supports

.Barring Device

~

02-445 Fuel Oil Booster Pump Fuel Oil In-8 jection 02-450A Fuel Oil Headers Piping /

Fuel Oil In-8 L

Tubing jection 02-450B Fuel Oil Header: Fuel Oil Fuel Oil In-8 Tubing Supports jection 02-455A Fuel Oil Filters &

Fuel Oil In-8 Strainers: Fuel Oil Filters jection 02-455B Fuel Oil Fuel Oil In-8 Strainers jection 02-455C Fuel Oil Filters and Fuel Oil In-0 St;ainer Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fitting, Couplings 02-465B Lube Oil Liners - External Lube Oil 2

Supports 02-465C Lube Oil Lines External:

Lube Oil 2

Valves

{b N

viii Rev. 1 TDIO907 Entire Page Revised

i INDEX(continued)

Component Component Vol.

Number Description Category No.

02-467A Turbocharger: Lube Oil Lube Oil 2

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

Fittings - Supports 02-475A Turbocharger:

Bracket Turbo, Intake, 2

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

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

Turbo, Intake, 2

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

Control Panel 9

Cabinet / System Assembly

\\

02-500F Control Panel Assembly:

Control Panel 9

Accumulator Assembly 02-500G Control Panel Control Panel 9

Valves Assembly 02-500H Control Panel Assembly:

Control Panel 9

Pressure Switch Assembly 02-500J

. Control Panel Assembly:

Control Panel 9

Relays Assembly 02-500K Control Panel Assembly:

Control Panel 9

Solenoid Valves Assembly 02-500M Control Panel Assembly-Control Panel 9

Piping, Tubing, and Assembly Fittings 02-500N Miscellaneous Equipment Control Panel 9

Terminal Boards /Switchs/

Assembly

' Wiring 02-540A Lube Oil Sump Lube Oil 3

Tank with Strainer O

Assembly and Mounting Hardware ix Rev. 1 TDIO907 Entire Page Revised

[D INDEX(continued)

N)

Component Component Number Description Category Vol.

No.

02-5408 Lube Oil Sump Tank: Misc.

Lube Oil 3

Fittings, Gaskets, Pipe

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

Lube Oil 3

Mounting Hardware 02-550 Foundation Bolts:

Engine & Aux.

9 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 1

02-630A Pyrometer Conduit Assembly:

Engine Instru-6 Conduit mentation &

Wiring 02-630B Pyrometer Conduit Assembly:

Engine Instru-6 Conduit Fittings mentation &

Wiring 02-630C Pyrometer Conduit Assembly:

Engine Instru-6 Support mentation &

v Wiring 02-6300 Pyrometer Conduit Assembly:

. Engine Instu-6 Thermocouples mentation &

Wiring 02-688A Engine & Aux Module Wiring Engine Instru-6 Material: Conduit & Fittings; mentation &

Pyrometer conduit assembly -

Wiring conduit, Fittings, Supports 02-688B

~ Engine & Aux. Module Engine Instru-6 Wiring Material: Wiring mentation &

& Terminations Wiring 02-688C Engine & Aux. Module Wiring Engine Instu-6 Material: Boxes & Terminals mentation &

Wiring 02-689 Off Engins Alarm Engine Instru-6 Sensors: Wiring mentation &

Wiring 02-690 On Engine Alarm Sensors Engine Instru-6 mentation &

Wiring

\\

x Rev. 1 TDIO907 Entire Page Revised

~

INDEX(continued)

Component Component Vol.

Number Description Category No.02-691 Off Engine Alarm Engine Instru-6 Sensors:

mentation &

Wiring 02-695A Engine Shut Down Equipment Engine Shut-6 Tubing / Fittings & Supports down & Equip-ment 02-6958 Engine Shut Down Equipment:

Engine Shut-6 Valves, Regulator, Orifice down & Equip-ment 02-695C Engine Shutdown: Trip Engine Shut-6 Switches down & Equip-ment 02-700A Je.cket Water Stand Pipe-Jacket Water 7

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

Jacket Water 7

Valves 02-700C Jacket Water Stand Pipe-Jacket Water 7

Supports 02-700E Jacket Water Stand Pipe-Jacket Water 7

Switches 02-700F Jacket Water Stand Pipe Jacket Water 7

and Misc. Bolting Material 02-717A Aux Sub Base and Oil and Engine Aux.

9 Water Piping-Aux Sub Base Sub-Base &

Foundation Bolts 02-717B Aux Sub Base and Oil.and Jacket Water 7

Water Piping-Jacket Water Valves 02-717C Aux Sub Base & Oil Water Jacket Water 7

Piping-Jacket Water: Pipe,

[.

Couplings, Fittings, Orifices, Y Strainers t

02-7170 Aux Sub Base & Oil & Water Jacket Water 7

Piping: Jacket Water Gaskets

'~[_}

& Bolting

%J Rev. 1 n

e Page Re s ed TOIO907

INDEX(continued)

Component Component Vol.

Number Description Category No.

2-717E Aux Base & Oil & Water Jacket Water 7

Piping: Jacket Water Supports 02-717F Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping and Tub-ing - Lube Oil - Pipe, Tubing, Fittings 02-717G Aux Sub Base & 011 & Water Lube Oil 3

Piping: Lube Oil-Valves 02-717H Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping-Lube Oil-Gaskets and Bolting 02-717I Aux Sub Base and Oil and Lube Oil 3

Water Piping: Lube Oil-Supports & Mounting Hardware 02-717J Aux Sub Base & Oil & Water Fuel Oil In-8

)

Piping: Fuel Oil-Piping jection l

V and Fittings j.

02-717K Aux Sub Base & Oil & Water Fuel Oil In-8 j

Piping: Fuel Oil-Valves jection 02-717L Aux Sub Base and Oil and Fuel Oil In-8 Water Piping-Fuel jection Oil-Gaskets and Bolting 02-717M Aux Sub Base & Oi_1 & Water Fuel Oil In-8 Piping: Fuel Oil-Supports jection 02-805A Intake Air Silencer Turbo, Intake, 2

Intrcir &

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

Intrcir &

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

Intrcir &

Exhaust 02-810A Auxiliary Jacket Water Jacket Water 7

Pump xii Rev. 1

.TDIO907 Entire Page Revised

INDEX(continued)

Compo.nent Component Vol.

Number' Description Category No.

02-810B Jacket Water Standby Jacket Water 7

Heater Pump 02-810C Jacket Water Heat Jacket Water 7

Exchanger 02-8100 Jacket Water. Thermostatic Jacket Water 7

Valve 02-810E Misc. Equipment:

Jacket Water 7

Jacket Water Standpipe Heater L

02-820A Misc. Equipment:

Lube Oil 3

Lube Oil Sump Tank Heater 8208 Auxiliary Lube Lube Oil 3

011 Pump

~

02-820C Pre-Lube Oil Lube Oil 3

l Pump 02-8200 Lube Oil Lube Oil 3

Keepwarm Strainer 02-820E Oil Prelobe Filter Lube Oil 3

02-820F Full Flow Lube Oil Filter Lube Oil 3

02-820G Lube Oil Heat Exchanger Lube Oil 3

02-820H Lube Oil Full Pressure Lube Oil 3

Strainer 02-825A Fuel Oil Fuel Oil 8

Day Tank Injection 02-825B Miscellaneous Equipment Fuel Oil 8

Fuel Oil Transfer Pump Injection 02-825E Fuel Oil System: Fuel Oil Fuel Oil 8

Duplex Strainer Injection 02-835A Air Start System: Starting Air Start &

4 Air Skid Base Barring Device OV Rev. 1 TDIO907 Entire Page Revised i

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-835D Starting Air Tank Air Start &

4 Relief Valve Barring Device 02-835F Starting Air Float Trap Air Start &

4 Barring Device 02-835J Starting Air Tank Air Start 4

Barring Device Appendix II g

Appendix III g

O i

I O

xiv Rev. 1 TDIO907 Entire Page Revised

Page 3 of 4 One significant failure occurred in 1984 at the Catawba. Nuclear Plant (Duke Power).

A delivery valve holder, which experiences full discharge

. pressure, fractured.

Duke Power had the part examined at the Babcock &

Wilcox Alliance Research Center.

It concluded that the fracture initiated at-~a casting defect in the part and was not a design

. deficiency.

Perfu.1 nance Each pump is shop-tested and calibrated at 225 rpm and the eouivalent operating pressure of 12,800 psig at three rack setting (Ref. 2).

At Comanche Peak and other nuclear power plants, the engines have run at

-full load and speed for sufficient time to prove the sufficiency of properly assembled and adjusted pumps to deliver the required fuel.

There is *lso no reported history of failure of the Bendix pumps to supply sufticient fuel to their engines.

Material Suitability The materials of the pressure boundary and high stress members of. the pump are various grades' of steel, heat - treated as required for service.

The pump housing is.an automotive grade cast iron which is suitable for O-its non pressure boundary duty.

There is no history at Comanche Peak or other nuclear power plants of a material problem on this pump except for

,the one instance at ' the Catawba Nuclear Plant mentioned ab_ove, which resulted from a casting defect. The pump materials are suitable for corrosion

. resistance to No. 2 fuel oil.

Vendor Qualifications The Electrical Components Division of Bendix is r.

supplier of fuel injection pumps and nozzles to the nuclear industry on engines manufactured by TDI, Cooper Industries, Worthington, and Nordberg.

B.

Conclusion End reactions on small bore components (2 in. and smaller) are considered acceptable since the relative strength of small bore is much greater than that of the attached'small bore piping / tubing components.

There are no TERs associated with this component.

To augment the maintenance procedures, it is recommended that the utility inspect this component for leaks during the routine engine walk-around 8

and that one pump be disassembled, inspected and tested during altemte refueling outages.

Based on the results, a decision can be made rega:,

3 the remainder of the pumps.

Based on the above, it is concluded that the pump is acceptable for its intended design function at Comanche Peak.

TDIO892/3 REV. 1

Page 8 of 14 II. VOLTAGE REGULATOR BOARDS A.

Adjustment Potentiometers 1.

Coat one side of the adjustment screw for each of the five adjustment potentiometers on the printed circuit board of the voltage regulator with Glyptol lacquer.

After each monthly test, inspect the potentiometers to ensure that no motion of the adjustment screws has occurred.

2.

If adjustments are needed, remove the Glyptol and reapply when the adjustment procedure is complete.

B.

Printed Circuit Board 1.

After each monthly test, inspect the components mounted on the printed circuit board.

Check for cleanliness and proper mounting of components.

Report any abnormal conditions to engineering for evaluation.

2.

Any integrated circuits which are in the T0-5 (metal can) package should be replaced with those of the Mini DIP (Dual Inline Package) package.

C.

Spare Parts 1.

It is recommended that an adequate supply of spare parts be maintained.

III. FIELD FLASHING RELAY A.

Relay Rating 1.

Replace FF relay (a DC contactor, class P10 Cat. No. 102012 made by Gould Distribution and Control Division, Ref. 5) by an equivalent Gould DC contactor rated as follows:

Coil voltage 90-140 V, contact voltage 140 V DC contact 90A DC.

It may be necessary to install a voltage reduction circuit to permit the use of a contactor with a conventional coil voltage range.

B.

Enclosure 1.

The relay should be of the enclosed type to prevent particles of dirt from beir,g deposited on the contacts.

REV.1 O

TDI1151/8

I Page 8a of 14 IV.

REFERENCES 1.

1983 Omega Temperature Measurement Handbook, Omega Engineering, Inc. p. Q05.

2.

Portec Static Exciter Voltage Regulator Model 72 11800 10 Instruction Manual.

3.

GE Semiconductor Data Handbook 3rd Edition, p. 255-256.

4.

Gerber Electronics Catalog p.

585 - General Cement Production Bulletin.

5.

Portec Dwg. D7211801710.

0 1

' O TDI1151/9

m :.

O T

^

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 2

Cylinder Block, Liners & Water Manifold Air Start & Barring Device Connecting Rods m

Pistons Camsiaft & Valve Train

- ^

Idler Gear Assembly & Front Gear Case Flywheel Engine Instrumentation & Wiring Overspeed Trip & Governor Engine Shutdown & Equiprr.ent vdf Jacket Water Cylinder Heads & Valves Fuel Oil Injection w

Generator D

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.

i Within each category tabs identify Comanche Peak specific component numbers.

"L A given component report can be found by:

a)

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

b)

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

Some repcrts 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 E

abbreviation LB-Large Bore, and SB-Small Bore on the component number tabs.

I s

O g

Rev. 1 TDIO907 l

L h-

v.

' +

t' INDEX(continued)

Component Component Vol.

p r 3r Number-Description Category No.

CP-101A Generator:

Generator Generator 8

CP-1018' Generator: Shaft and Generator 8

l Bearings l-CP-102 Generator Controls Generator 8

1 F-068 Intercooler-Turbo, Intake,.

2

.g Intrcir. & Ex-haust

'E MP022/3 Turbocharger Turbo, Intake, 2

Intrcir. & Ex-j haust

'b 00;420 Lube Oil Pressure Lube Oil 2

Regulating Valve

( '00-442A Starting Air Distributor:

Air Start 4

c'.

Distributor Assembly

& Barring Device 00-442B Starting Air Distributor:

Air Start &

4 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drop Tank Fuel Oil In-8 7,

jection 02-CFR Turbocharger Thrust Bearing.

Turbo, Intake, 2

Lubricant System Intrcir. & Ex-haust 305A Base and Bearing Caps: Base Engine Base 3

~

Assembly

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

Engine Base 3

.f'~.

Main Bearing Studs & Nuts

& Bearing Caps t,< r L

z/

02-3050 Base and Bearing Caps:

Engine Base 3

Main Bearing Caps

& Bearing Caps p02'-307A L ube,0il Fittings:

Lube Oil 2

1 Internal - Headers t

02-307B' Lube' Oil Fittings:

Lube Oil 2

Internal - Tube & Fittings

-h i"

Rev. 1 ii Entire Page Revised 7

INDEX(continued)

Component Component Vol.

Number Description Category

'No.

02-3070 Lube Oil Fitting Internal-Lube Oil 2

Supports 02-310A Crankshaft Crankshaft &

3 l

Bearings 02-310B Crankshaft and Bearings:

Crankshaft &

3 Bearing Shells Bearing 02-310C Crankshaft Crankshaft &

3 Thrust Bearing Rings.

Bearing 02-311A Crankcase: Crankcase Assy Crankshaft &

3 Bearing 02-311D Crankcase: Crankcase Crankshaft &

3 Mounting Hardware Bearings 02-315A Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Cylinder Liners & Water Block Manifold

(

02-315C Cylinder Block Liners Cyl. Block &

4 Liners &

Water Manifold 02-315D

-Water Manifold: Jacket Cyl. Block &

4 Water Manifold & Piping Liners &

Water Manifold 02-315E Cylinder Block Liners &

Cyl. Block &

4 Water Manifold: Studs Liners &

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

4

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

Cyl. Block &

4 Water Manifold: Seals and Liners &

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

Jacket Water 7

Manifold Assembly W/ Hardware and Coupling and Gaskets O)

\\v Rev. 1 Entire Page Revised TDIO907

INDEX(continued)

. Component Component Vol.

Number-Description Category No.

02-316B Jacket Water Inlet Manifold:

Jacket Wa 7

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

Jacket Water 7

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

Jacket Water 7

Jacket Water Discharge Manifold, Coupling and l

Seals 02-3178 Water Dicharge Manifold:

Jacket Water 7

Coupling & Seals 02-317C Water Discharge Manifold:

Jacket Water 7

Supports 02-330A Flywheel: Flywheel Flywheel 6

02-330B Flywheel Bolting Flywheel 6

02-335B Front Gear Case-Gasket and Idler Gear As-5 Bolting sembly & Front Gear Case 02-340A Connecting Rods: Connecting Connecting 4

Rods & Bushings Rods 02-3408 Connecting _ Rods: Bearing Connecting 4

Shells Rods

~

02-341A Pistons: Pistons Pistons 5

02-341B Pistons: Rings Pistons 5

02-341C Piston: Pin Assembly Pistons 5

02-345A Intake / Exhaust and Fuel Camshaft &

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

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

5 Pump Base Assembly Valve Train N

Rev. 1 iv Entire Page Revised TOIO907

INDEX(continued)

Component Component Vol.

Number Description Category No.

02-350A Camshaft Camshaft &

5 Valve Train 02-3508 Camshaft Bearirg Camshaft &

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

5 and Gear Valve Train 02-355A Idler Gear Assemble: Crank Idler Gear As-5 To Pump Gear sembly & Front Gear Case 02-355B Idler Gear Assembly:

Idler Gear As-5 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valves: Air Start Air Start &

4 Valve Barring Device 02-360A Cylinder Head Cylinder Heads 8

- bs)

& Valves

(/

02-3608 Intake & Exhaust Valves Cylinder Heads.

8

& Valves 02-360C Cylinder Head and Valves -

Cylinder Heads 8

Bolting and Gaskets

& Valves 02-360D Valve Springs Cylinder Heads 8

& Retainers

& Valves 02-362A Subcover Camshaft &

5 Valve Train 02-365A Fuel Injection Pump Fuel Oil In-8 jection 02-365B Fuel Injection Nozzle Fuel Oil In-8 Assembly jection 02-365C' Fuel Oil Injection Tubing Fuel Oil In-8 jection 02-3650-Fuel Injection Equipment:

Fuel Oil In-8 Supports jection 02-371A Fuel Pump Linkage: Fuel Fuel Oil In-8

'-E Pump Control Shaft jection Rev. 1 TDIO907 Entire Page Revised

O INDEX(continued)

J

.Gomponent Component Vol.

Number Description Category No.

02-3718 Fuel Pump Linkage: Linkage '

jection Fuel Oil In-8 Assembly and Bearing 02-375 Air Intake Manifold Turbo, Intake, 2

Intrc1r. & Ex-haust 02-380A Exhaust' Manifold Piping Turbo, Intake, 2

Intrcir. & Ex-haust 02-3808 Exhaust Manifold-Turbo, Int =ke, 2

Bolting and Gaskets Intrcir. & Ex-haust 02-385B Cylinder Block and Cyl. Block &

4 Crankcase Covers:

Liners & Water Gaskets an. Bolts' Manifold 02-3868 Crankcase Covers: Crankcase Cranshaft &

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

5 and Exhaust Rocker Valve Train Shaft Assembly 02-3908

. Rocker Arms and Pushrods:

Camshaft &

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

5 I~

Pushrods

' Valve Train f

02-3900 Rocker Arms and Pushrods:

Camshaft &

5 l

Pushrods Connector.

Valve Train 02-390E Rocker Arns and Pushrods:

Camshaft &

5 Bushings Valve Train 02-390F Rocker Ares and Pushrods:

Camshaft &

5 Lifters Valve Train 02-390G Rocker Arms and Pushrods-Camshaft &

5 Miscellaneous Bolts &

Valve Train Drive Studs O

b Rev. 1 TDIO907 9

v)

INDEX(continued)

Component Component Vol.

Number Descriotion Category No.

02-410A Overspeed Trip: Governor Overspeed Trip 6

& Governor l

02-410B Overspeed Trip: Governor Overspeed Trip 6

and Accessory Drive

& Governor 02-410C Overspeed Trip: Coupling Overspeed Trip 6

& Governor 02-4100 Overspeed Trip Vent Valve Overspeed Trip 6

& Governor l

02-411A Governor Drive: Governor Overspeed Trip 6

and Tachometer Drive Gear

& Governor

& Shaft 02-411B Governor Drive: Couplings, Overspeed Trip 6

Fins & Keys

& Governor 02-413A Governor Linkage Overspeed Trip 6

n

& Governor 413B Fuel Pump Linkage Fuel Oil In-8 jection 02-415A Governor Assembly: Woodward Overspeed Trip 6

Governor

& Governor 02-415B Governor Assembly - Booster Overspeed Trip 6

Servometer

& Governor 02-415C Governor Assembly Heat Overspeed Trip 6

Exchanger

& Governor 02-420 Engine Driven Lube Oil 2

Lube Oil Pump 02-425A Engine Driven Jacket Water 7

Jacket Water Pump 02-435A Jacket Water Fittings:

Jacket Water 7

Piping 02-435B Jacket Water Fittings:

Jacket Water 7

Supports 02-435C Jacket Water Inlet Fittings:

. Jacket Water 7

Valves Rev. 1 TDIO907 Entire Page Revised

r

[~')

INDEX(continued)

\\_,/.

Component Component-Vol.

Number

' Description Category No.

02-436A Intercooler Piping Turbo Intake, 2

and Piping Couplings, Intrcir. & Ex-Gaskets and Bolting haust 02-436B Intercooler Piping: Coupling, Turbo Intake, 2

Gaskets, Bolting Intrcir. & Ex-haust 02-437 Turbo Water Piping:

Jacket Water 7

Pipe & Fittings 02-441A Starting Air Manifold:

Air Start &

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

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

Air Start &

4 Supports Barring Device 02-445 Fuel Oil Booster Pump Fuel Oil In-8

(

jection

(.

02-450A Fuel Oil Headers Piping /

Fuel Oil In-8 Tubing jection 02-4508 Fuel Oil Header: Fuel Oil Fuel Oil In-8 Tubing Supports jection 02-455A Fuel Oil Filters &

Fuel Oil In-8 Strainers: Fuel Oil Filters jection 02-455B Fuel Oil Fuel Oil In-8 Strainers jection 02-455C Fuel Oil Filters and Fuel Oil In-8 Strainer Mounting Hardware jection 02-465A Lube Oil Lines External:

Lube Oil 2

Tubing, Fitting, Couplings 02-465B Lube Oil Liners - External Lube Oil 2

Supports 02-465C Lube Oil Lines External:

Lube Oil 2

Valves viii Rev. 1

.TDIO907 Entire Page Revised

(

INDEX(continued)

%d Component.

Component Vol.

Number Description Category No.

02-467A Turbocharger: Lube Oil Lube Oil 2

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

Fittings - Supports 02-475A Turbocharger:

Bracket Turbo, Intake, 2

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

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

Turbo, Intake, 2

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

Control Panel 4

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

Control Panel 9

Accumulator Assembly l-02-500G Control Panel Control Panel 9

Valves Assembly 02-500H Control Panel Assembly:

Control Panel 9

Pressure Switch Assembly 02-500J Control Panel Assembiy:

Control Panel-9 i

l Relays Assembly 02-500K Control Panel Assembly:

Control Panel 9

i Solenoid Valves Assembly l

02-500M Control Panel Assembly-Control Panel 9

Piping, Tubing, and Assembly Fittings 02-500N Miscellaneous Equipment Control Panel 9

Terminal Boards /Switchs/

Assembly Wiring 02-540A Lube Oil Sump Lube 011 3

Tank with Strainer h3 Assembly and Mounting

(/

Hardware ix Rev. 1 TDIO907 Entire Page Revised

l im'

-t i

INDEX(continued)

\\_)'

Component Component Vol.

Number Description Category No.

02-5408 Lube Oil Sump Tank: Misc.

Lube Oil 3

Fittings, Gaskets, Pipe

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

Lube Oil 3

Mounting Hardware 02-550 Foundation Bolts:

Engine & Aux.

9 Anchors, Bolts, Misc.

Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly:

Engine Instru-6 Conduit mentation &

Wiring 6308 Pyrometer Conduit Assembly:

Engine Instru-6 Conduit Fittings centation &

Wiring 02-630C Pyrometer Conduit Assembly:

Engine Instru-6 Support mentation &

. N_,

Wiring 02-6300 Pyrometer Conduit Assembly:

Engine Instu-6 Thermocouples mentation &

Wiring 02-688A Engine & Aux Module Wiring Engine Instru-6 Material: Conduit & Fittings; mentation &

Pyrometer conduit assembly -

Wiring conduit, Fittings, Supports 02-688B Engine &' Aux. Module Engine Instru-6 Wiring Material: Wiring mentation &

& Terminations Wiring 02-688C Engine & Aux Module Wiring Engine Instu-6 i

Material: Boxes & Terminals mentation &

Wiring 02-689 Off Engine Alarm Engine Instru-6 Sensors: Wiring mentation &

Wiring 02-690 On Engine Alarm Sensors Engine Instru-6 mentation &

.(}

Wiring wJ x

Rev. 1 TDIO907 Entire Page Revised

.p INDEX(continued)

'\\J' Component Component Vol.

Number Description Category No.02-691 Off Engine Alarm Engine Instru-6 Sensors:

mentation &-

Wiring 02-695A Engine Shut Down Equipment Engine Shut-6 Tubing / Fittings & Supports down & Equip-ment 02-695B Engine Shut Down Equipment:

Engine Shut-6 Valves, Regulator, Orifice down & Equip-ment 02-695C Engine Shutdown: Trip Engine Shut-6 Switches down & Equip.

ment 02-700A Jacket Water Stand Pipe-Jacket Water 7

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

Jacket Water 7

Valves 02-700C Jacket Water Stand Pipe-Jacket Water 7

Supports 02-700E Jacket Water Stand Pipe-Jacket Water 7

Switches 02-700F Jacket Water Stand Pipe Jacket Water 7

and Misc. Bolting Material 02-717A Aux Sub Base and Oil and Engine Aux.-

9 Water Piping-Aux Sub Base Sub-Base &

Foundation Bolts 02-717B Aux Sub Base and Oil and Jacket Water 7

Water Piping-Jacket Water Valves 02-717C Aux Sub Base & Gil Water Jacket Water 7

Piping-Jacket Water: Pipe, Couplings, Fittings, Orifices, Y Strainers 02-7170 Aux Sub Base & Oil & Water Jacket Water 7

Piping: Jacket Water Gaskets

& Bolting Rev. 1 "9"

TDIO907

I)

INDEX(continued)

Component' Component Vol.

Number Description Category No.

.02-717E Aux Base & 011 & Water Jacket Water 7-Piping: Jacket Water.

Supports 717F Auxiliary Sub Base and Oil Lube Oil 3

and Water Piping and Tub-ing - Lube Oil - dipe, Tubing, Fittings 02-717G Aux Sub Base & 011 & Water Lube Oil 3

Piping: Lube Oil-Valves r -

02-717H Auxiliary Sub Base and Oil Lube Oil 3

l and Water Piping-Lube Oil-i Gaskets and Bolting 02-717I Aux Sub Base and Oil and Lube Oil 3

Water Piping: Lube Oil-Supports & Mounting Hardware 02-717J Aux Sub 3ase & 011 & Water Fuel Oil In-8 C_s\\

Piping: Fuel Oil-Piping jection

/

and Fittings s

02-717K Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Valves jection 02-717L Aux Sub Base and Oil and Fuel Oil In-8 Water Piping-Fuel jection Oil-Gaskets and Bolting 02-717M Aux Sub Base & Oil & Water Fuel Oil In-8 Piping: Fuel Oil-Supports jection 02-805A Intake Air Silencer Turbo, Intake, 2

Intrcir &

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

Intrcir &

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

Intrcir &

Exhaust u

02-810A Auxiliary Jacket Water Jacket Water 7

Pump wJ xii Rev. 1 T0f0907 Entire Page Revised

[ h INDEX(continued)

XJ' Component Component Vol.

Number Description Category No.

02-810B Jacket Water Standby Jacket Water 7

Heater Pump 02-810C Jacket Water Heat Jacket Water 7

Exchanger 810D Jacket Water Ther ostatic Jacket Water 7

Valve 02-810E Misc. Equipment:

Jacket Water 7

Jacket Water Standpipe Heater 02-820A Misc. Equipment:

Lube Oil 3

Lube Oil Sump Tank Heater 02-8208 Auxiliary Lube Lube Oil 3

Oil Pump 02-820C Pre-Lube Oil Lube Oil 3

[' '/l Pump 02-8200 Lube Oil Lube Oil 3

Keepwarm Strainer 02-820E Oil Prelube Filter Lube Oil 3

02-820F Full Flow Lube Oil Filter Lube Oil 3

02-820G Lube Oil Heat Exchanger Lube Oil 3

02-820H Lube Oil Full Pressure Lube Oil 3

Strainer 1

02-825A Fuel Oil Fuel Oil 8

Day Tank Injection 02-825B Miscellaneous Equipment Fuel Oil 8

Fuel Oil Transfer Pump Injection 02-825E Fuel Oil System: Fuel Oil Fuel Oil 8

Duplex Strainer Injection 02-835A Air Start System: Starting Air Start &

4 Air Skid Base Barring Device O

Rev. 1 Entire Page Revised TDIO907

i INDEX(continued)

Component Component Vol.

Number Description Category No.

02-835D' Starting Air Tank Air Start &

4 Relief Valve Barring Device i

02 335F Starting Air Float Trap Air Start &

4 r-Barring Device 02-835J Starting Air Tank Air Start 4

Barring Device Appendix II 9

i-Appendix III g

i h

j 4

O i

f d

P O

xiv Rev. 1 TDIO907 Entire Page Ravised

jg

/"N

. [h

\\

c i

COMANCHE PEAK MAINTENANCE MATRIX

(

Component Component ^

Alt.

l N_ umber Identification PM Recommendation Monthly Outage Outaae 5 Year 10 Year Comments t

F-068 Intercoolers 1.

Evaluate heat exchanger X

performance by checking engine cperating parameters.

2.

Clean / inspect shell and X

Refr: DR/QR Report tube sides.

1. F-068. (Items 2, 3 4) 3.

Visually inspect for X

Refr: 7/26/84 IOC i

external leaks.

from J. Cadogan to M. McGerigle.

Refr: 08/14/84 letter to C. Ray from M. Lowrey, 4.

Verify intake manifold To be performed daily, drain connection is open and clean daily.

MP-022/23 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, f.e; if a trend exists. Any thrust bearing degradation.

trend toward increasing axial clearance could signify thrust bearing degradation. Refr:

DR/QR Report #MP-022/23.

4.

Perform visual and blue X

NOTE: Thrust bearing check inspections of inspection should also the thrust bearing.

be performed prior to 40 non prelubed (automatic) fast starts. Refr:

DR/QR Report #MP-022/23.

5.

Disassemble inspect X

For Items 1-6; Refr:

and refurbish.

IOC dated 3/23/84 from M. Wehmeyer to R. Kadlec.

l TDIO405/4 Revision 1 - entire page revised

v

/

y.

. /m\\

/" %

k

/

k b-V COMANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 6.

Perforin 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 Refr: DR/QR Report analysis may be uttitzed.

MP-022/3.

.Particular attention shall be paid to copper level and particulate size, which could signify thrust bearing degradation.

CP-101A Emergency Generator 1.

Check operation of X

Refr: IOC 3/30/84 brushes and slip rings.

M. Wehmeyer to D. Mercaldi (Items 1-5).

2.

Clean / inspect all X

accessible parts of the generator.

3.

Megger rotor and stator.

X 4.

Verify oper. lion of X

space heaters.

5.

Measure vibration and X

check against base line data.

CP-101B Emergency Generator Pedestal 1.

Check ring oilers X

To be accomplished during i

Bearing for proper operation every test run of the

.and verify oil level, engine.

Refr: 2/30/84 IOC from M. Wehmeyer to N. Cooperrider.

I 2.

Drain flush refill X

bearing housing, j

3.

. Measure bearing housing X

insulation resistance.

4.

Disassemble and inspect X

bearing and check clearances.

CP-102 Emergency Generator 1.

Inspect panel for X

Items 1-5; Refr: 3/30/84 i

Control Panel cleanliness and clean IOC from M. Wehmeyer j

as required, to D. Mercaldi.

i TDIO405/5 Revision 1 - entire page revised

]

'(

D-

'()

COMANCHE PEAK MAINTENANCE MATRIX Component' Component Alt.

Number Identification PM Recommendation Monthly Ou,tay Outage 5 Year 10 Year Comments' f

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 F.

Bridge rectifier assembly.

Refr: DR/QR Report

1. CP-102, Attach. 1.

a.

Inspect the temperature X If the label permanently sensitive label placed blackens, the maximum on the most visible temperature of the face of the hexagonal diode has been exceeded-body of the diodes.

requiring an electrical The label shall be inspection of the diode inspected before and and an inspection of af ter each running the mounting threads of the engine.

of the heat sink and diode.

Replace the diode and the heat sink as needed and assure that proper mounting tightness of 300 in-lbs and proper thread condition is l

maintained.

i b.

Inspect glyptol applied To be performed after to the side of the lugs each monthly test run.

and mounting bolt for Retighten any loose i

the lugs which attach connections, remove to the bottom of the old glyptol and reapply diode and SCR heatsinks if connections are for signs of relative retightened.

motion.

7.

Adustment potentiometers - X To be performed after inspect glyptol applied each monthly test run.

I to the the side of the If adjustments are adjustment screws for each needed, remove glyptol of the five adjustment and reapply when the l

TDIO405/6.

Revision 1 - entire page revised

g g

)

(

(J i

-rG COMANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

Number Identification, PM Recommendatio_n Monthly Outage Outage 5 Year 10 Year Comments potentiometers on the adjustment procedure printed circuit board is complete.

of the voltage regulator for signs of relative motion.

8.

Printed circuit boards -

X

. To be performed after check for cleanliness each monthly test run.

and proper mounting of

- Report any abnormal components.

conditions to engineer-ing for evaluation.00-420 Luba 011 Pressure Regulating 1.

Disassemble and clean.

X If valve sticks repeated-Valve

-ly, more frequent cleaning may be necessary. If valve

{

plugging becomes a pro-blem, the dimensions of the valves internal parts should be checked to ensure proper clearance.

2.

During initial startup after Refr: DR/QR Report a major reassembly of

1. 00-420.

Lube 011. piping, the L.O.

regulating valve should be disassembled -

j and cleaned until i

abnormal L.O. 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

Refr: DR/QR Report air manifold vent is 00-442A (STAD). Items open and on obstructed.

1 & 2.

TDIO405/7 Revision 1 - entire page revised

~

U U

t

. COMANCHE PEAK MAINTENANCE MATRIX Alt.

Component Component.

Number Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments 02-305A Base Assembly 1.

Perform a visumi inspec-X Note: Any cracks detected tion of the base. - The must be investigated inspection should include further before the engine -

the areas adjacent to the is allowed to return to nut pockets of each service. The mating sur-i bearing saddle and be con-faces of the base and cap 1

ducted after a thorough shall be throughly cleaned wipe down of the surfaces, with solvent before any using good lighting.

reassembly. Refr: DR/QR Report #02-305A.

02-305C Main Bearing Caps - Studs 1.

Upon removal of bearing Refr: DR/QR Report

1. 02-305C and Nuts caps, clean mating surfaces with a solvent prior to reassembly of the caps to the base.

02-3078 Lube Oil Tubir;.nd 1.

Check tubing for dents X

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

Instruction Manual, Vol. I, Maintenance Schedule.

f 2.

Perform gear-train X

[

spray check.

I 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.

Refr: TDI Instruction Manual, Vol. I, Main-l tenance Schedule.

2.

Measure diameter of X

Complete TDI Inspection and Maintenance Record crank journals.

Form No. 310-3-1. TDI l

Instruction Manual, I

Volume I, Section 6.

Revision 1 - entire page revised TDIO405/8 i

u

I COMANCHE PEAK MAINTENANCE MATRIK -

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 should be performed at

-bearing shell thickness.

Inspection shall evaluate the first fuel outage bearing wear.and evidence and at alternate outages of harmful crankshaft thereafter.

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.

' Refr: TDI Instruction Manual, Vol. I, Maintenance Schedule. Ref: DR/QR Report #02-3108.

02-310C Thrust 8 earing Ring 1.

Measure thrust bearing X

Complete applicable ring clearance via of sections TDI

" bump check" method to be

. Inspection and Main-performed in conjunction tenance Record Form with crankshaft web Mo. 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

• 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

• Eng clearance are cracked or gouged.

Refr: DR/QR Report

1. 02-310C.

Refr: 8/13/84 memo from G. McCarthy to D. Pasquale.

2.

-Visually inspect thrust X

To be performed simult-bearing ring for signs aneously with main of wear or degradation.

bearing shell inspec-tion.

TDIO405/9 Revision 1 - entire page revised

(

f

(,,

Nj COMANCHE PEAK MAINTENANCE MATRIX

{

Compcnent Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-311A Crankcase Assembly 1.

Perform a visual inspection X

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

justify the discontinuattor.

of such inspection.

Refr: DR/QR Report #

02-311A.

02-315A Cylinder Block 1.

Perform a visual inspection This inspection must be of the cys ender block. Per-performed prior to form an eddy current inspec-returning the engine to tion of block tops for emergency STAND 8Y service stud-to-stud cracks after any period of between cylinder heads operation exceeding 50%

and for cracks between the load.

block edge and studs at Refr: 08/24/84 Memo the block ends.

from C. Vogler to

0. Pasquale.

02-315C Cylinder Liners 1.

Perform a visual inspection Boroscopic inspection of liners for potential is acceptable if heads progressive wear, are not removed.

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

Refr: OR/QR Report 802-3418.

02-317A&B Water Olscharge Manifold -

1.

Visually inspect for leaks. X This recommendation is Jacket Water Discharge Note: 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 couplings, these couplings of 150*F for the Style should be replaced with 65 coupling may be Dresser Style 90 couplings exceeded. The maximum equipped with Viton gaskets.

suggested operating temperature of the Style 90 is 212*F.

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

Ref: OR/QR Report 802-317A&8 TDIO405/10 Revision 1 - entire page revised I

p)

(w'

(m-)

(

Q COMANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

. 10 Year Comments.

Number Identification PN Recommendation Monthly.

Outane Outage 5 Year 02-340A/B Connecting Rods, Bushings 1.

Inspect and measure To be performed in and Bearing Shells conn. rod bearing shells conjuction with piston j

to verify tube oil main-pin inspection. Complete tenance, which affects TDI Inspection and wear rate. The visual Maintenance Record and dimensional inspec-Form No. 340-1-1, TDI tion of the bearing shells Instruction Manual, should be conducted at Volume I, Section,',

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 ? east the Refr: DR/QR Report sum of hours of operation

1. 02-3408 (Item 1)

.in a LOOP /LOCA event

. plus the expected hours of operation between outages.

2.

Inspect and measure X

Complete TDI Inspection the connecting rods.

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

3.

Perform an m-ray examin-This is to be performed ation on all replacement prior to installation bearing shells to acceptance of any replacement criteria developed by bearing shells.

Owners Group Technical Refr: DR/QR Report I

Staff.

1. 02-3408.

4.

Measure the clearar'ce between X

Ref: DR/QR Report j

the link pin and link rod.

1. 02-340A This clearance should be zero, le; no measurable clearance when the specified bolt torque of 1050 ft-lbs is applied. This examination may be performed with the engine assembled after a major engine disassembly.

5.

At the first 5 yr overhaul X

Refr: DR/QR Report visually inspect the rack

1. 02-340A (Items 4, 5).

teeth surfaces for signs of fretting and prior to reassembly inspect nating surfaces to verify that the minimum manufacturers recommended percent contact surface is available.

TDID405/11 Revision 1 - entf e page revised l

L__

_m im

.m 1

' COMANCHE PEAK MAINTENANCE MATRIN Alt.

Component Component luy Comments

-Number Identification-PM Recommendation Monthly Outaae Outaae 5 Year 02-341A Pistons 1.

Inspect and measure skirt M

Complete TDI Inspection and Maintenance Report and piston pin.

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

Use Volume 1. Section 8, 1

Appendix III for clear-ance values. To be performed in conjunc-tion with piston pin inspection.

02-341B Piston Rings 1.

Inspect and measure piston Complete TDI Inspection and Maintenance Record replacement rings.

Form No. 341-2-1. TDI Instruction Manual, Volume 1, Section 6.

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

2.

Visually inspect liners X

Complete TDI Inspection and Maintenance Record for wear.

NOIE: Ring replacement Form No. 315-1-1, TDI and cylinder liner -

Instruction Manual, Volume honing should be performed I, Section 6.

Use Volume I

in accordance with TDI

1. Section 8, Appendix III for clearance values.

maintenance procedures.

Refr: DR/QR Report

1. 02-341B (Items 2, 3, 4).

3.

135* fuel oil spray X

Refr: 07/31/84 Memo tips may be used if frem L. Swanger to inspection -esults D. Pasquale, indicate a need for additional action to improve lubrication and l

reduce coke buildup.

i l

4.

When replacing engine X

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

meets or exceeds series When changing L.O.

3 standards, the base replace the entire stock should be L.O. charge. Refr:

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

and coke formation.

The additive package Revision 1 - entire page revised TDIO405/12

j V

U U

COMANCHE PEAK MAINTENANCE MATRIX

. Alt.

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

-should provide high detergent dispersant properties with high alkalinity and a high level of antiwear additive such as zinc dithiophosphatw.

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

1. 2 fuel all 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.

02-341C Piston Pin Assembly 1.

Visually inspect for X

Also to be performed chrome plate damage, whenever pistons are Replace pins which show removed and disassembled to an extent that such chipped or bilstered Inspection is possible.

chrome.

NOTE: All new or re-Refr: DR/QR Report placement pins should be

1. 02-341C (Items 1, 2).

L.P. or M.P. Inspected For details on acceptance before installation in criteria, Refr: 08/22/84 Owners Group engines, meno from W. Littmann to-D. Pasquala and DR/QR Report #02-341C.

2.

Inspect,end plugs and X

Note: This inspection 13 reroll cr replace any to be performed whenever that are loose.

the engine is sufficantly dismantled to allow this inspection Ref: DR/QR Report #02-341C.

I 02-345A Intake and Exhaust Tappet 1.

Inspect intake and exhaust x

Complete TDI Inspection Assembly and tappet assembly and Maintenance Report condition.

Form No. 345-1-1. TDI I.'struction Manual, volume I, Section 6.

Refr: TDI Instruction Manual, Vol. 1 Main-tenance Schedule Refr:

TDI Letter dated 2/16/84 from D. Schmitz to J.

1 kammeyer, Ref. IOC 9/14/84 from J. Carbonaro to D. Pasquale.

Revision 1 - entire page revised T0I0405/13 I

J

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-COMANCHE PEAK MAINTENANCE MATRIM

\\

Component Component Alt.

Number Identification PM Recommendation-Monthly

Outaa, Outane 5 Year 10 year Comments 2.

Verify that can rollers X

Complete TOI inspection are free to rotate ar.d maintenance Record-and that there is no Form b. 345-1-1 TDI measurable clearr. ace Instrc tion Manual, Vol. I, between the can rollers Section 6.

Refr: DR/QR '

and the roller pins.

Report #02-345A.

02-3458 Fuel Tappet Assembly 1.

Inspect fuel assembly X

Complete TL Inspection condition.

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

j Refr: DR/QR Report

1. 02-3458.

2.

Verify that can rollers N

Complete TDI Inspection are free to rotate and Maintenance Record and that there is no Form No. 345-1-1 TDI l

measurable clearnace Instruction Manual, Vol. I, between the can rollers Section 6.

Refr: DR/QR' I

and the roller pins.

Report #02-3458.

02-350A Can Shaft Asses 41y 1.

Perform a visual inspection X

Any signs of cracking, of all can 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 i

spalling shall result in tenediate replacement of the can Refr: sDI Instruction Manual, Vol. I, hintenance Schedule.

Refr: DR/QR Report

1. 02-350A.

U2-3508 Can Shaft Bearings 1.

inspect and measure can X

Complete TOI Inspection l

shaft bearing shells, and Maintenance Record For No. 350-1-1. TDI Instruction k nual, Volume I, Section 6.

use Volume I, Section 8 I

Appendix III for clear-ance values, l

l Revision 1 - entire page revised TDIO405/19

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's COMANCHE PEAK MAINTENANCE MATRIX t

Component Component Alt.

Number Identification PM Rucommendation Monthly Outage Outane 5 Year 10 Year Commerts

. 350C Cam Gear 1.

Visually inspect can gear X

Refr: Memo from B.

for chipped or broken Bickford to E. Montgomery teeth, pitting, excessive dated 6/23'84, wear, or other abnormal Refr: DR/QR Report

]

conditions.

1. 02-350C.

2.

Measure gspr back lash.

X Complete applicable NOTE - if saa 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 4

80 (-0+10) ft-lbs.

clearance values.

Insertion of the cotter Refr: DR/QR i

pin must be accomplished Report #02-350C.

i at a torque > 80 ft-Ibs force and < 30 ft-1bs

~

force. If this is not possible another bolt, r

nut or washer should be used.

I The above is applicable to 4-bolt arrangments only.

The torque range i

for 6-bolt arrangements j

is 70 2 20 ft-1bs with the same restrictions as described above for in-T sertion of the cotter

pins, j

02-355A Crank to tube 011 1.

Visually inspect crank-X Any abnormal situations Pump Gear.

shaft to lube oil pump or indications of.

.j gear for chipped or progressive pitting

]

broken teeth, excessive should be reported wear, or progressive for an engineering i

pitting or other abnormal evaluation.

]

conditions.

, Refr: DR/QR Report l

i

1. 02-355A.

1 2.

Measure gear backlash.

X Complete applicable f

sections of TOI i

Inspection and Main-(

tenance Record Form j

No. 155-1-1, TOI j

Instruction Manual, j

Volume I, Section 6.

Use Volume 1, Section 8 j

Appendix 111-1 from i

clearance values.

l TDIO405/15 Revision 1 - entire page revised i

.J J

f D

a COMANCHE PEAK MAINTENANCE MATRIX Alt.

Component Component

_PM Recommendation Monthly Outane Ou_ tem 5 Year 10 Year Comments t'

Number Identification Refra TOI Instruction Manual, Vol. I, Maintenance Schedule.

02-3558 Idler Gear Assembly 1.

Visually inspect idler-X Any abnormal indications-

. gears for chipped or should be reported for an broken teeth, excessive engineering evaluation.

wear pitting, or other Refr: DR/QR Report abnormal conditions.

1. 02-3558.

2.

Measure gear backlash.

M Complete applicable NOTE: If idler gear hub sections of TDI Inspec-is removed, it is recom-tion and Maintenance mended that the not be Record Form Mo. 355-1-1.

relocked at the position TDI Manual, Volume I, corresponding to the Section 6 use Volume I, torque of 70220 ft-lbs.

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

pin must be accomplished Refr: TDI Instruction at a torque > 50 ft-lb Manual, Vol. 1, and < 90 ft-lb.

If ~

Maintenance Schedule.

~

this is not possible, Refr: DR/QR Report another bolt, nut or

1. 02-3558.

washer should be used.02-359 Air Start Valves 1.

Remove, clean and inspect X

Ensure valve installation air start valves, includes retorque (Replace copper valve-requirements.

l to head gasket).

Refr: 5/3/84 IDC from P. Ziminsky to P. Martin Refr: DR/QR Report

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

f 2.

Inspect'the piston, cap.

X guide and housing sliding I

surfaces to evaluate j

wear or corrosion.

3.

Ensure that the desiccant To be performed daily.

dryer between the air Refr: DR/QR Report compressor af ter cooler

1. 02-359.

and the air receivers is working properly

.by blowing down the air receivers daily and monitoring the moisture content.

T010405/16 Revision 1 - entire page revised

gg s

J COMANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

Number identification PM Recommendation Monthly Ogtam Outage 5 Year 10 Year Comments 02-360A Cylinder Head 1.

Visually inspect cylinder X

Complete TOI 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 cola compression X

If so indicated remove pressures and maximum cylinder heads, grind valves and reseat. - Ref:

firing pressu ~*

TDI Instruction Manual, Volume I, Section 6.

3.

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

the engine to ensure DR/QR Report #02-360A.

against harmful effects 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 Refr: DR/QR Report monthly engine run

1. 02-360A.

l for water leaks.

02-3608 Cylinder Head - Intake and 1.

Visually inspect intake X

Exhaust Valves and exhaust valve, discs, stems and seats for wire drawing, pitting, distor-tion, concentricity, or any abnormal condition.

2.

Visually inspect subcovers This is a one-time-only for evidence of valve inspection, to be guide blowby (soot).

performed af ter 500 or 600 hours0.00694 days <br />0.167 hours <br />9.920635e-4 weeks <br />2.283e-4 months <br /> of operation after rebuild of a cylinder head.

Refr: DR/QR Report

1. 02-3608, 3.

Measura intake and ex-X Complete applicable haust valves head sections of TDI thickness.

Inspection and Main-tenance Records Form I

360-2-1. TDI, Instruc-tion Manual.

Revision 1 - entire page revised TDIO405/17 l

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COMANCHE PEAK MAINTENANCE MATRIX Component Component Outage SJar. 10 Year Comments Alt.

Number Identificatio_n PM Recommendation Monthly

.Og gge, Volume I, Section 6.

One sheet for each cylinder. Use

'Section 8. Appendix III for clearance values. (Items 2, 3).

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 !!! for clearance values.

02-362A Cylinder Head Covers -

1.

Perform a liquid penetrant X

This inspection is to be Subcover Assembly examination of the rocker performed in conjunction are pedestals top and with the rocker arm vertical machined bushing inspection when surfaces. (connector the rocker are shafts pushrod side only),

are removed from the subcovers (Refr: DR/QR Report #02-390E] or whenever 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. Refr:

OR/QR Report 802-362A.

02-365A Fuel Injection Pumps 1.

Visually check pressure X

To k performed on all bleed screws for erosion.

sixteen pumps.

2.

Tear down one pump for X

Use representative pump inspection.

to determine need to overhaul other pumps.

3.

Complete fuel injection X

Based on inspection re-pump inspection in sults and operating accordance with TOI parameters. NOTE -

Instruction and Main-Disassembly of fuel tenance Manual, Volume I.

injection pumps should be performed by a Bendix Corp. representative.

TDIO405/18 Revision 1 - entire page revised

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COMANCHE PEAK MAINTENANCE MATRIX Component component Alt.

Number Identification PM Recommendation Monthly Ogge Outage 5 Year 10 Year Comments Complete TDI Instruction i

and Maintenance Record rorm No. 365-1-1. Section

6. Items 1, 2 Refr: 3/26/84 IOC from M. Wehmeyer to l

T. Fritsch; Refr: 4/27/84 Letter from R. Johnston to R. Jaquinto.

Refr: TDI Instruction Manual, Volume I, Main-l tenance Schedule for Item 3.

Refr: DR/QR 1

Report #02-365A (Items 2&3).

02-365B Fuel Injaction Nozzles 1.

Remove, inspect and clean X

Ensure that a new copper I

tips.

gasket is used upon reinsta11ation of nozzle into head. Complete TDI Inspection and Maintenance Record Form 365-2-1 Instruction Manual, Volume 1. Section 6.

1 Refr: TDI Instruction Manual, Vol. I, Section 5

]

Maintenance Schedule.

Refr: DR/QR Report

1. 02-3658. (Items 1-4) 2.

Check nozzle pop pressure.

X 3.

Check spray pattern.

X 4.

Check assembly for X

leakage'.

02-365C Fuel Injection Tubing 1.

Check tubing for leaks X

All fuel oli leak in-at compression fittings.

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

l 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 4

installation of tubing, j

Subsequent inspections to be performed period-4 ically as indicated.

Fuel oil leakage from TDIO405/19 Revision 1 - entire page revised i

m V

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COMANCHE _ PEAK MAINTENANCE MATRIX Component Component Alt.

0 Outage

$ Year lo Year Comments Number

&ntification PM Recommendation Monthly 3ge shrouded fuel oli lines can be detected at the leakoff ports in the base nuts, which are l

provided for this purpose.

02-371A Fuel Pump Control Shaft 1.

Check lube oil :ups -

X Refr: 5/17/84 IOC from 4

and fill as necessary.

T. Fritsch to Paul Martin.

02-3718 Fuel Pump Linkage Assembly 1.

Grease swivel link, X

and Bearings all sixteen F.O. pump assemblies.

i 1

02-375 Intake Manifold 1.

Care should be exercised If required, other castings in assembly of cylinder may be tried to achieve heads to the engines, to an acceptable fit, or bolt j

avoid cracking of the hole diameters may be 4

intake manifold elbows.

increased to 1/8" oversize.

Comporent should under no circumstances be jacked i

to fit. Refr: DR/QR Report #02-375.

02-380A Exhaust Manifold 1.

Perform an MP examination X

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

.affected zones. This However, diesel operation i

examination is to be should not exceed 200 performed in accordance hours between inspections.

with Impe11 memo from.

Refr: DR/QR Report G. Shears to J. Kammeyer

1. 02-360A.

dated 08/13/84.

02-385A Crankcase Relief Valve 1.

Clean flame arrestors.

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

2.

Inspect seat and disc.

X i

02-387A Crankcase Vacuum Fan 1.

Clean and inspect fan.

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

2.

Check bearing for X

roughness.

i 1

5 TDIO405/20 Revision 1 - entire page revised

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COMANCHE PEAK MAINTENANCE MATRE Component Component Alt.

Number Id.ntification PM Recommendation Monthly Outage 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, arm bushings should be conducted at the fuel outage which precedes 2300 hours0.0266 days <br />0.639 hours <br />0.0038 weeks <br />8.7515e-4 months <br /> of operation by at least the sum of expected hours'of operation in a LOOP /LOCA event plus the expected hours of operation between outages. Refr:

DR/QR Report #03-390E (Items 1, 2, 3).

2.

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

operation between inspections as described above.

3.

Visually inspect and Not to exceed 730 measure intermediate.

maximum bours of engine rocker arm bushings.

operation between inspection as desgribed above.

02-390F Hydraulic Valve Lifters 1.

Check valve lash.

X 2.

Reinstall and adjust X

Ensure lifters are lifters perform installed with the f111 leak down test.

holes up.

Verify condition of lifters via comparison of lifter leak down rate (actual) to specifications noted on TDI Maintenance Manual.

Refr: TDI Maintenance Manual, Section 6-8-5.

Refr: 04/16/84 letter to R. Johnson from R.

Jaquinto.

02-390G Rocker Arm Capscrews, 1.

Verify capscrew torque X

Use TDI Instruction Drive Studs (Pop Rivets) values.

Manual, Volpme I, Section 8 Appendix 2.

Verify that rocker arm X

IV for proper torque drive studs are intact

values, and tight.

Refr: DR/QR Report

1. 02-390G (Items 1, 2).

TDIO405/21 Revision 1 - entire page revised

7-7x v)'

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(J COMANCHE PEAK MAINTINANCE MATRIM Component Component Alt.

Number Identification PM Recommendation Monthly OutaDe

'Outene

5. Year 10 Year Comments 02-410A Overspeed Trip Governor 1.

Check trip set point X

Modify the surveillance

- adjust as required.

testing procedure to include verification that the overspeed trip is correctly set to an overspeed trip setting of 518 rpa every outage.

Ensure that the electric governor setting ts pro-perly returned to 450 rpm and the mechanical backup governor returned to 460 rps following the overspeed test. The test is to be performed with no load on the engine by increasing the normal governor speed setting (s) until a trip occurs.

After several inspection periods, the history of the required adjustments should be reviewed to evaluate and possibly modify the testing interval. Ref r:

DR/QR Report 802-410A (Items 1, 2).

2.

NOTE: After setting the overspeed governor, the adjustment screw settings should be marked with Torque Seal to reveal any unihtended changcs in the set positions.

02-4108 Overspeed Trip Governor 1.

Remove plugs from housing X

Refr: IOC dated and Accessory Drive and check for magnetic 03/27/84.from particles.

M. Weyneyer to N. Cooperrider.

(Items 1, 2, 3) 2.

Check shaf ts for excessive X

radial and axial movement.

3.

Visually inspect accessory X

drive gear for excessive wear.

T010405/22 Revision 1 - entire page revised

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CDMANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-410C overspeed Trip Drive Couplings 1.

Remove the present L-110 To be completed at Lovejoy coupilngs and the first refueling replace them with new outage-units in accordance with SIM 363 and DR/QR Report recommendations.

2.

Verify that coupilng is X

Refr: 06/24/84 memo tight on shaft.

from D. Liebert to E. Montgomery.

3.

Replace the Lovejoy coupi-X Replace elastomer if ing spiders or test coup 1-hardness is areater ing elastomer for hardness.

than 90 Shore A.

Refr: OR/QR Report

1. 02-410C (Items 1, 2, 3).

02-4100 Oveispeed Trip Vent Valve 1.

Disassemble and replace X

Refr: 3/27/84 IOC from "0" rings.

M. Wehmeyer to J. Dinare.

02-411A Governor Drive - Governor 1.

Visually inspect drive X

Ref:. TDI Instruction and Tachometer Drive Gear

. gear and shaf t for signs Manual, Vol. I, Section 5, and Shaft of wear.

Maintenahce Schedules.

02-411B Governor Drive - Coupilngs, 1.

Check that coupling is X

If the coupling is found i

Pins and Keys tight on shaft.

to be loose, it should be removed, all mating surfaces cleaned and the unit reassembled using Loctite 609 on the j

mating surfaces.

Ref: DR/QR Report 1

1. 02-4118.

Refr: 6/19/84 Memo j

to E. Montgomery from D. Limbert.

2.

Replace the present X

Refr: DR/QR Report elastomeric insert in

1. 02-4118.

the Koppers coupling before placing the engine in emergency l

STANDBY service.

02-413A Governor Linkage 1.

Install positive locking Refr: DR/QR Report hardware to the lever

1. 02-413A (Item 1-4).

are clamp bolt heads and shaft roll pins.

NOTE: To be performed as necessary after l

tightening governor j

linkage hardware to design torque specifications.

TDIOl05/23 Revision 1 - entire page revised

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COMANCHE PEAK MAINTENANCE MATRIX e

Component component Alt.

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

Inspect for loose parts X

on the linkage assembly.

3.

Lubricate cross shaft X

Refr: DR/QR Report bearings.

802-413A. (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.

Controls system check.

2.

Check tallrod vent X

To be accomplished during for air leakage, controls system check.

Items 1, 2; Refr: IOC dated 3/26/B4 from M. Wehmeyer to R. Kaklec.

02-415A 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.

2.

Disassemble, clean and X

Items 1, 2, 3; Refr:

refurbish the actuator 03/27/84 IOC from M. Wehmeyer to N. Cooperrider.

Refr: TDI Instruction Manual, Volume I, Section 5 Maintenance Schedule.

3.

Replace flex element X

Refr: DP/QR Report for governor drive 802-411B.

coupilng.

Governor 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 LOA 0 - Maximum Torque-Seal.

DROOP - Zero Speed - To provide mechanical governor control at 460 rpm.

TDIO405/24 Revision 1 - entire page revised

1 g

V C/

V COMANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5,,Jeg 10A Comments 5.

Evaluate electric X

An evaluation of the governor settings to governor settings is verify overshoot of to be performed during the 450 rpm set speed surveillance testing once is no more than under joint mechanical 7.5% or a max.

and electrical governor speed of 484 rps control and once under during start or only mechanical governor when unloaded by control, off the grid 1400 kW.

in the isochronous mode for both start and transient loading conditions.

Refr: DR/QR Report

1. 02-415A.

6.

Augment the setting Refr: DR/QR Report adjustment procedures,

1. 02-415A.

as described in the Woodward manuals to include tests of the governor response during an engine start to ensure agreement with the specifications as detailed in Item

1. 5.

02-4158 Governor Booster Servomotor 1.

Clean, inspect, and X

Refr: 3/27/84 IOC from replace "0" rings M. Wehmeyer to and gaskets.

J. Kammeyer.'

02-415C Governor Heat Exchanger 1.

Clean a,nd inspect.

X 02-425A Jacket Water Pump - 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 Refr: DR/QR Report abnormal conditions.

1. 02-3558.

2.

Check the key to keyway X

This along with the drive interface for a tight fit of the impeller onto fit on both the pump the shaft will preclude shaft to impeller and past problems where the spline to pump relative motion between shaft during pump shaft and impeller caused reassembly.

fretting and upset of 1D10405/25 Revision 1 - entire page revised

C

(

V' CONANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outege Outaee 5 Year 10 Year Comments i

the keyway sides.

Refr: DR/QR Report

1. 02-425A.

3.

It is recommended that Refr: DR/QR Report the castle nut that

1. 02-425A.

drives the external spline on its taper, have minimum and maximum torque values of 120 ft-Ibs and 660 ft-lbs respectively.

02-435A Jacket Water Fittings - Pipe 1.

Visually inspect for leaks. X This recommendation is and Fittings (Small Sore Note; In the event of a made on the basis that Scope only) leak developing in the the maximum suggested existing Dresser Style 65 operating temperature coupilngs, these coupilngs of 150*F for the Style should be replaced with 65 coupling may be Dresser Style 90 couplings exceeded. The maximum equipped with Viton gaskets.

suggested operating temperature of the Style 90 is 212*F.

Ref: Letter dated 12/13/84 from C. L. Ray to J. George.02-437 Turbo Water Piping-Pipe 1.

Visually inspect for leaks. X This recommendation is 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 couplings, these couplings of 150*F for the Style should be replaced with 65 coupling may be Dresser' Style 90 couplings exceeded. The maximum equipped with Viton gaskets.

suggested 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

Refr: DR/QR Report Air Vent air manifold vent-is

1. 00-442 (STAD).

open and unobstructed.

02-441B Air Fliter to Starting Air 1.

Inspect filter elements.

X Replace as necessary.

Distributor Refr: TDI Instruction Manual. Vol. I. Mainte-nance Schedule. Ref:

DR/QR Report #02-441B (Items 1, 2).

TDIO405/26 Revision 1 - entire page revised

9

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N COMANCHE PEAK MAINTENANCE MATRIM Component Component Alt.

Number Identification PN Recommendation Monthly Outage Oh 5 Year 10 Year Comments 2.

Replace filter elements.

X' It is also recommended that the filter be changed at a maximum pressure drop of 25 psi. Refr:

DR/QR Report #02-4418.

3.

Blowdown strainer DAILY.

Refr. DR/QR Report

1. 02-4418.

4.

Clean and inspect strainer X If the strainer is monthly.

excessively dirty, the frequency cf cleaning and inspCCting should be increased. Refr.

DR/QR Report #02-4418.

Air Start Block Valves 5.

Clean and refurbish valves X

Refr: DR/QR Report

-replace "0" rings and

1. 02-441B (Items 5, 6, 7).

clean the screened 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.

7.

Replace "0" rings of the X

shuttle valve.

02-455A Fuel Oil Filter 1.

Record filter d/p.

X Change filter elements n, hen filter d/p reaches 20 psid rise above the clean d/p - Purge entrapped air from the filter canister using the vent valve provided, and divert some fuel oil into the newly replaced cartridge. Af ter air has been purged close vent valve and return handle to previous operating position.

Refr: DR/QR Report

1. 02-455A.

TDIO405/27 Revision 1 - entire page revised

y-COMANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

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

- Inspect canister gaskets X

Refra 3/27/84 IOC and replace as necessary, from M. Wehmeyer to J. DiMare.

To be performed during change out of filter elements.

3.

Inspect tubing and mech-X Refr: TDI Instruction l

anical connections for Manual, Volume I.

tightness and/or leaks.

02-4558 Fuel Oil Strataers 1.

Recore strainer d/p.

X If greater than 5 psid shift / clean element.

Bolt torques of 120-150 in-lbs should be utilized during re-assembly. Refr: DR/QR Report #02-4558, 2.

Purge air from stand-by As required.

j strainers.

02-465A Lube Oil Lines External:

1.

Ensure that a minimum To be performed Tubing Fitting and Couplings installation gap of 0.171 whenever piping 4

in. is maintained between is installed or

]

pipe ends at the 12-inch reinstalled.

j Dresser coup 11pg.

Refr: DR/QR Report

1. 02-465A.

02-467A Turbocharger tube oil Fitting:

1.

Visually inspect leaks.

X This recommendation is Pipe Tubing, Fittings, and Note: In the event made on the basis that Flexible Coupilng of a leak developing the maximum suggested (Small Bore Scope Only) in the existing Dresser operating temperature Style 65 couplings, these of 150*F for the Style couplin's should be replaced 65 coupling may be g

with Dresser Style 90 exceeded. The maximum couplings equipped with suggested operating Viton gaskets.

temperature of the Style

)

90 is 212*F.

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

02-475A.C Turbocharger: Bracket Bolting 1.

Each month for the first Refr: DR/QR Reports and Gaskets three months of commerical

1. 02-475A,C operation, these screws should be inspected to assure that no screw has loosened because 4

i of engine operating loads.

If during these inspections

)

TDIO405/28 Revision 1 - entire page revised

. f-N k

CONANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendetion Monthly

%ge Qutage M aj.JO Year Caseents none of the screws are found loosened or damaged, from then on inspections are to be i

conducted on a yearly basis l

(or during plant shutdown).

l But if any time during Inspection any screw is found 1

loosened or damaged, it must l

then be replaced (if damaged) l and all screws retorqued as follows; 125 ft-lbs for the 4

bracket to engine screws and 75 ft-Ibs for the bracket to turbo base screws.

Note: To avoid damage to bracket to engine, and/or bracket to turbo, base i

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

02-4758 Air Butterfly Valve 1.

Lube valve shaft X

Refr: 10C 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 valve / actuator oper-

)

ation.

Refr: 04/16/84 letter from R. Jaquinto to j

R. Johnson, i

3.

Verify that associated X

Refr: DR/QR Report

]

locking devices (jan

1. 02-4758.

nuts and lock washers)

{

are tight.

l 02-500A Engine Control Cabinet 1.

Inspect interior of cabinet X

Refr: 3/29/84 IOC i

j for cleanliness and clean from M. Wehmeyer as required.

to T. Jacobs for 3

Items 1-5.

1 Refr: 07/30/84 IOC from J. Cadogan to j

R. Horelik for Items 1-6.

}

2.

Visually check wiring for X

i insulation degradation.

l TDIO405/29 Revision 1 - entire page revised

pu f%

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,k COMANCHE PEAK MAINTEIIANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outaos Outane

$ Year 10 Year Comments 3.

Check instrument tubing X

for leaks.

4.

runctionally check cabinet X

heater and calibration of thermostat.

5.

Test pneuoatic 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

Accomplished during Blocks clean / tighten, panel clean / inspection.

2.

Visually check wiring X

Accomplished during insulation for degradation.

panel clean / inspection.

3.

Trip check circuit breakers.

X 02-500G Control Panel Valves 1.

Inspect and clean control X

This recommendation panel valves interval should be reassessed depending on the degree of of system fouling.

Refr: DR/QR Report

1. 02-500G.

2.

Inspect and clean the X

Refr: DR/QR Report 200 mesh screen in the 802-500G.

check valve.

02-500J Control Panel Assembly:

1.

Inspect

• contacts and clean X

Refr: 08/10/84 IOC from Relays as required.

K. Horelik to J. Cadogan.

2.

Visually check condition X

of wiring and tightness of terminations.

02-500N Control Panel Switches Terminal 1.

Clean terminal boards and X

Refr: 10C dated 3/29/84 Boards and Wiring switch contacts, to J. Kasseyer from M. Wehmeyer for Items 1, 2, 3.

2.

Visually check wire insul-X atton and terminals for tightness and degrada-tion.

TDIO405/30 Revision 1 entire page revised

k.

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w COMANCHE PEAK MAINTENANCE MATRIN Component Component Al t.

Ember Identification PM a.,-- - - -ttion Monthly Outaae Outene 5 Veer,10 A. Coseents 3.

In6pect for arcing and M

overheating.

02-5258 Barring Device Control Valve 1.

Replace control valve X

and Press Regulator "0" *Ings/ lube shaft.

2.

Replace press regulator M

elastomeric parts.

02-525C Barring Device Air Filter 1.

Replace filter element.

X hefr: IOC dated 3/30/84 from M. Wehmeyer to J. Freeman.

2.

Drain barring device air This should be performed filter. *See Comments

• on a DAILY basis when barring device is in use. Refr: 5/10/84 IOC from M. McGerigle-

'to W. Brown.

02-5250 8arring Device - Mounting 1.

Replace old cotter pin To be performed after Bracket / Supports with new cotter pin each reassembly.

after each reassembly.

Refr: 5/8/84 IOC to P. Martin from P. Titus.02-550 Foundation Bolts 1.

Visually inspect founda-M ltees 1, 2; Refr: TDI,

tion for breaks in the Instruction Manual, Main-bond between the sole tenance Schedule plates and grout.

Section 5.

2.

Check foundation bolts X

Use TDI Instruction for correct torque.

Manual, Volume I, Retorque as necessary Section 8, Appendix then recheck crankshaft IV for proper torque web deflections.

values.

3.

Generator foundation bolts-Refr: DR/QR Report are to be retorqued

1. 02-550.

after a generator short circuit if the bolts were initially torqued to 480 ft-Ibs.

If initial bolt torque

. was 600 ft-Ib 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.

TDIO405/31 Revision 1 - entire page revised

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U COMNCHE PEAK MINTENANCE MTRIM Component Component Alt.

Number Identification PM Recommendation 140nthly Outaae Outege 5_Vear 10 Year Comments

?

2.

Clean and inspect M

Indications of fatigue thermocouples and thermo-should result in re-couple shleids.

placement of the thermo-couple and/or thermo-couple shleid.

Refr: 7/31/84 Memo from

5. Riess to W. Littmann.

3.

Pyrometer wiring-check -

To be accomplished during that terminations are control panel check-out and tight.

Initial operation inspections. Items 1, 2, 3; Refr; 07/30/84 IOC from J. Cadogan to S. Riess.

02-6958 Engine Control Air 1.

Inspect and clean engine X

NOTE: This recommendation Pressure Regulator shutdown equipment, should be reassessed depending on the degree of system fouling.

Refr: DR/QR Report

1. 02-6958 (Items 1&2).

2.

Replace elastomeric parts X

and gaskets in the pressure regulator.

02-695C Engine control Pneumatic Trip 1.

Check switch set points.

X Pressure switches.

Switches Refr: 3/30/84 IOC from M. Wehmeyer to J. DiMare.

2.

Replace elastomeric parts.

X 02-695C Engine Control Pneumatic 1.

Check switch set points.

X Temperature switches.

Trip Swtichef 02-7008 Jacktet Water Standpipe:

1.

Replace elastomeric X

Refr: DR/QR Report Valves parts in circle seal

1. 02-7178.

valves.

02-700F Jacket Water Standpipe 1.

Visually inspect jacket Any visible cracking and Miscellanenous Bolting water standpipe, pump or minor jacket water suction and engine return leakage should result nozzle welds during each in rework of nozzle routine engine run and welds.

every 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> during Refr: DR/QR Report extended engine runs.

1. 02-700F 02-7178 Aust11ary Sub 8ase & 011 &

1.

Inspect the valves X

Replace packing as Water Piping - Jacket for packing leakage.

necessary. 'Refr: DR/QR Water: Valves Report #02-7178.

1DIO405/32 Revision 1 - entire page revised

f ry w

'( y ).

e m aar6*E PEAK MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outaae h

5 Year 10 Year Comments

?

02-717C Auxiliary Sub-Base & Gil &

1.

Visually inspect for leaks. X This recommendation is Water Piping - Jacket Water:

Note: In the event of a made on the basis that Pipe. Couplings. Fittings leait developing in the

,the maximum Suggested Orifices. Y-Strainers existing Dresser Style 65 operating temperature (Small 8 ore Scope Only) couplings, these couplings of 150*F for the Style should be replaced with 65 coupilng may be Dresser Style 90 couplings exceeded. The maximum equipped with Viton gaskets, suggested operating temperature of the Style 90 is 212*F.

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

02-717F

%xiliary Sub-Base tube 011 1.

Visually inspect pipe X

This recommendations Pipe and Fittings and joints for leakage, made on the basis that Note: In the event the maximum suggested of a leak developing operating temperature in the existing Cresser of 150*F for the Style Style 65 coupling, these 65 coupling may be couplings should be replaced exceeded. The maximum with Dresser Style 90 suggested operating coupilngs equipped with Viton temperature of the style gaskets.

90 is 212*F.

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

Ref: 4/2/84 IOC from M. Wehmeyer to J. Freeman 2.

Clean and inspect L.O.

X Complete when L.O. tank keep-ware pump suction is drained. Refr:

strainer.

04/16/84 letter from R. Jaquinto to R. Johnson.

02-717G/K Auxiliary Sub-Base tube 011/

1.

Disassemble, inspect X

Refr: IOC dated 4/6/84 Fuel Oil valves and refurbish.

from M. Wehmeyer to J. OlMare. Ref: DR/QR Report #02-717G/K.

TOIO405/33 Revision 1.- entire page revised

s--

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COMANCHE PEAK MAINTENANCE MATRIX Component Camponent

Alt, Number Identification PM Reconnendation-Monthly Outage Outage 5 Year 10 Year Comments 2.

Dissassemble, clean and X

Refr: 07/31/84 IOC check relief valve to M. McGerigle from lift pressure.

J Cadogan.

Refr: 08/16/84 IOC from M. McGerigle to J. Cadogan.

Refr: DR/QR Report

1. 02-717G/K.

02-8058 Intake Air Filters 1.

Inspect air intake Aeplace if necessary.

filters every 3 to Refr: DR/QR Report 6 months.

1. 02/9058.

02-8050 Fles Connection 1.

Visually inspect for X

Check for exhaust evidence of cuts, holes,

leakage, or dents.

02-810C Jacket Water Heat 1.

To avoid corrosion and Refr: DR/QR Report Exchanger fouling, jacket water 802-810C, heat exchanger and Refr: 04/20/84 IOC associated service from M. Wehmeyer to water piping should R. Kadlec.

be flushed on a periodic basis (continuous service flow is sufficient.)

Alternatively, service water chemistry control can be used to maintain heat exchanger performance and integrity.

2.

Perform a daily visual To be performed daily, inspection for leakage Refr: 07/19/84 Telecon at packing whenever the D. Pasquale and engine is in the R. Chil.

emergency STAN08Y mode.

Verify that no leakage is present through the leak-off ports of the lantern ring.

3.

Record heat X

Use for trend data.

exchanger perfor-mance by checking engine operating parameters.

4.

Evaluate heat exchanger x

performance data.

T010405/34 Revision 1 - entire page revised

m ym m

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U COMANCHE PEAM MAINTENANCE MATRIN Component Component Alt.

Number plentif kation PM Recommendation Monthly Outaae Outage 5 Year 10 Year Comments 5.

Inspect tubes X

Refr: Tot Instruction and tube sheet Manual, Volume 1, for fouling and Maintenance Schedule.

errosion - remove entrance and exit Ch4anel covers.

Replace packing rings Reft: DR/QR Report at floating tube

1. 02-810C.

sheet after 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.

7.

Replace packing X

Replace packing when rings.

packing becomes hard or leakage at the packing is noted and cannot be stopped by tightening.

Refr: DR/QR Report

1. 02-810C, 02-8100 Thermostatic valves 1.

Replace thermal power X

Refr: DR/QR Report elements.

1. 02-8100.

2.

Visually inspect valve X

To be accomplished body for evidence of during monthly test leakage.

run. Ensure that any replacement valves have cast steel. valve bodies.

Refr: DR/QR Report

1. 02-8100.

02-810E Jacket Water Heaters 1.

Measure heater X

Replace heater if insulation resistance.

degradation of insulation resis-2.

Clean and inspect X

tance is noted.

heater elements.

Refr: 5/10/84 IOC from M. McGerigle to W. Brown 3.

Check calibration and X

for Items 1, 2, 3.

Inspect thermostat.

02-820A Lube Oil Sump Tank 1.

Measure heater 4

Replace heater if de-Heaters insulation resistance.

gradation of insulation resistance is noted.

TOIO405/35 Revision 1 - entire page revised

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4

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s COMANCHEPEAEMdINTENANCEMATRIX j

Component Component Alt.

Number gentification PM Recommendat M Monthly O

Qutage 5 Yeae 10 Year Comments

?

h 2.

Inspect and clean X

To be accomplished during heater elements.

tank inspection.

i 3.

Check calibration and N

Refr: 05/10/84 IOC Inspe:t condition of from M. McGerigle j

thermostat.

to W. Brown for Items i

1, 2, 3.

02-820C Lube 011 Keep-Wars Pump 1.

Check operation of X

Items 1-6; Refr:

i pump /cotor bearings.

04/05/84 IOC from j

. M. Wehmeyers to T. Fritsch.

l 2.

Check mechanical seal X

leakage.

3.

Clean, inspect and X

megger motor.

j 4.

Check coupling X

3 alignment, i

5.

Record pump X

Use for trend data.

discharge pressure.

l 6.

Measure unit vibra-X tion (pump / motor).

I 7.

The pump should be To be performed daily inspected for signs

.~

Refr: DR/QR Report of leakage and

1. 02-820C corrective modifications j

(addition of flexible piping connections) 4 l

be implemented as required.

j 02-8200 tube Oil Keep-Warm Strainer 1.

Check strainer dif ferential Refr: DR/QR Report pressure daily.

1. 02-8200.

1 4

2.

Clean / replace strainer l

element at 20 psid.

l 02-820E Lube oil Keep-Wars Filter 1.

Record filter d/p.

X Refr: 04/05/84 IOC from M. Wehmeyer to J. DiMare.

1 8

2.

Change filter To be performed before elements.

the filter d/p reaches 20 psid.

Refr: DR/QR Report

1. 02-820E, t

i TD10405/36 Revision 1 - entire page revised

p 3

k 5

(

COMANCHE PEAK MAINTENANCE MATRIX Component Component

Alt, Number Identification PM Recommendation Monthly

. Outage Outage 5 Year 10 Year Comments 02-820F Full Flow Lube 011 1.

Record filter d/p.

X Use for trend data.

Filters Refr: 04/02/84 IOC from M. Wehmeyer to J. DiMare.

Refr: TDI Instruction-Manual, Volume I, Maintenance Schedule.

2.

Drain water and/or X

sludge from lubri-cating oil full flow filter.

3.

Replace filter To be performed before the cartridges and filter d/p reaches 20 psid perform a visual Refr: 05/30/84 IOC inspection to from M. McGerigle determine the to B. 8rown.

nature of the Refr: DR/QR Report material caught 802-820F.

in the filter.

Refr: 07/31/84 IOC from J. Cadogan to M. McGerigle.

4.

Lube oil filter X

gauge - calibra-tion check.

02-820G Lube Oil Heat 1.

Perform a daily visual Refr: DR/QR Report Exchanger inspection for leakage

1. 02-820G.

at packing. Verify Refr: 06/12/84 IOC that no leakage is from R. Chlj to present through the P. Martia.

leak-off ports of Refr: 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

Refr: TDI Instruction tube sheet for Manual, Volume I, erosion and fouling -

Maintenance Schedule.

remove entrance and Refr: 07/19/84 Telecon exit channel covers.

D. Pasquale and R. Chil.

TDIO405/37 Revision 1 - entire page revised

O f

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COMANCHE PEAM MAINTENANCE MATRIM Component Component Alt.

Ent,er Ident6fication PM Recommendation Monthly 03 ge Outaae 5 Year

_10 Year Comments

?

5.

Inspect and clean X

Replace / rework lantern ring.

Iantern ring as Verify leak-off necessary to holes are not ensure concentricity.

plugged.

6.

Replace packing X

idhen packing becomes rings at the floating hard or leakage at the tube sheet during packing is noted and reassembly after each cannot be stopped by inspection.

tightening.

7.

Perform a spectrocheetcal To be performed at analysis of the lube oil.

approximately quarterly Particular attention shall intervals.

be given to percent noisture content.

02-82OH Full Pressure Lube oil Strainer 1.

Record strainer d/p.

X Use for trend data.

2.

Inspect and clean X

To be performed when the

elements, differential pressure across the strainer rises significantly.

Refr: DR/QR Report

1. 02-820H.

Refr: TDI Instruction Manual, Volume I, Maintenance Schedule.

3.

Lube oli strainer X

pressure gauge -

calibration check.

02-8358 Diesel Starting Air 1.

Check operating oil X

All itees, Refr:

Compressors pressure.

04/02/84 IOC with attached Maintenance Chart from M. Wehmeyer to J. Kamseyer.

2.

Overall visual X

inspection.

3.

Clean fins on inter X

and af ter coolers.

4.

Replace intake filter M

element.

TDIG405/38 Revision 1 - entire page revised

J N

\\J l

COMANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

Ember Identification PM Recommendation 14onthly Outage 0u, tag 5 Year 10 Year Comments

,t 5.

Change compressor oil.

X 6.

Check belt tension.

X 7.

Check pulley clamp X

bolts / set screws tight.

8.

Inspect filter felts on X

Replace as necessary.

unloader system.

02-835I Air Dryers and 1.

Riow down trap X

Refr: 04/05/84 IOC Motsture Traps sediment bowls.

from M. Wehmeyer to J. Kammeyer Refr: 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.

02-835J Starting Air Storage 1.

Drain air receiver float If quantity of Tank traps DAILY and monitor the moisture is quantity of moisture excessive correct produced at the immediately. Check float traps.

air dryer operation Refr: DR/QR Report 802-835J.

2.

Disassemble and clean X

Refr: 05/08/84 the float trap.

IOC from P. Titus to P. Martin (Items 2 & 3).

3.

Starting air tank pressure X

gauges - calibration check.

4.

Starting air tank pressure X

switches - calibration check.

Jacket Water System 1.

Check pH factor X

Refr: TDI Instruction cf Jacket water and Manual, Volume I, correct as recom-Maintenance Schedule.

mended by chemical supplier.

2.

Replace elastomeric X

Refr: DR/QR Report parts in jacket water

1. 02-717B.

valves.

TDIO405/39 Revision 1 - entire page revised

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t COMANCHE PEAK MAINTENANCE MATRIX Component Component Alt.

Number Identification PN Secommendation Monthly Outace Outage 5 Year 10 Veer Comments Lube Oil System 1.

Check lubricating.

X Refra TDI Instruction oil with a viscost-Manual, Volume 1, meter for fuel oil Maintenance Schedule, dilution. Send a items 1, 2.

sample of oli to laboratory for analysis.

2.

Drain lubricating X

When replacing engine oli system and oli use H.D. oli that clean sump tank.

meets or exceeds series 3 Depending on the standards. The base stock results of lube should be more resistant oil analysis, reffli 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 2inc 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%

is preferred. An engine all with such properties, Mobliguard 412 or equivalent product may be used to insure improved lubrication.

3.

Visually inspect tube X

To be performed oli sump tank level after lube oli switch floats, has been drained Check switch set from sump.

points.

4.

Perform a spectro-To be performed at chemical analysis approximately quarterly of the lube oil.

Intervals. Refr: TDI Instruction Manual, Volume I, Maintenance Schedule.

System Operation 1.

Record all operating X

To be performed parameters. Compare during monthly with base line data engine test run, to ensure engine is operating properly.

TDID405/40 Revision 1 - entire page revised

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COMANCHE PEAK'MAINTEtuueCE MATRIX Component Component Alt.

Number Identification pH Recommendetion Monthly

.Outagg Outane 5 Year 10 Year. Comments Piping System 1.

Conduct a detalled X

Tighten, repair or visual and audible replace as required.

inspection of all Refr: TDI Instruction fuel, air, oli, Manual, Volume I, and water piping Maintenance Schedule.

and valves for leakage.

2.

Inspect, clean and X

lubricate manual valves on skid as applicable.

3.

Bolted flanges which are utilized as connecting points for pipe supports and should be torqued in accordance with TDI Instruction Manual Appendix IV.

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 mi.e cause, and take babbit flakes.

necessary corrective action.

Miscell-Engine Mounted 1.

Replace elastomeric X

anceous

. Pressure Switches parts.

Gear Train 1.

Inspect gears for x

general condition.

2.

Measure gear back X

Replace worn Iash 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.

Refr: 04/16/84 letter from R. Jaquinto to R. Johnson.

TDIO405/41 Revision 1 - entire page revised

V Page 2 If, after completing the review, the engineer determines that the component is acceptable, based on the existing documentation, the Component Design Report will.be issued stating the conclusion of acceptability.

If TDI documentation is not available, or if it is determined that the available documentation does not readily lead to a conclusion of accpetability

-the engineer will alternatively continue the review as outlined in the following paragraphs.

v.2 Review of Small Bore Piping for Acceotability In cases where the review of TDI documentation does not lead to component acceptability, the engineer will -judge if the component will perform its intended function under all normal and earthquake loadings.

This judgment will be based on a review of the following information:

Quality approved as built piping isometrics System operating parameters Physical piping data Site specific amplified response spectra Oh System function In addition to reviewing the above information, a physical walkdown of the engine and skid piping may be required.

The walkdown would include a review of the piping to determine pipe support type and function, as well as a review for the fol',owing:

Thermal flexibility:

The engineer will determine if sufficient flexibility exists for each between support section of small bore piping.

The thermal movement imparted by the supports onto the piping will also be considered.

Deadweight spans:

The deadweight spans between supports will be reviewed by the engineer and acceptability will be based on judgment.

Seismic spans:

The seismic spans between supports will be reviewed by the engineer and acceptability will be based on judgment.

The engineer's judgment will consider the site specific amplified response spectra and all components, fittings and branch connections.

Engine induced vibration will also be considered in determining acceptability of seismic spans and is further discussed in paragraph 4.5.

The engineer will document the reviews of the individual components by a written trip report.

The trip report will serve as a summarization of 1

the engineering walkdown.

V Rev. 1 TDI1154/2

_ _ _ _ -.