ML20111C550
| ML20111C550 | |
| Person / Time | |
|---|---|
| Site: | River Bend  |
| Issue date: | 02/28/1985 |
| From: | Rick Deese, Ray C TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP |
| To: | |
| Shared Package | |
| ML20111C548 | List: |
| References | |
| NUDOCS 8503150453 | |
| Download: ML20111C550 (140) | |
Text
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TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT prepared for GULF STATES UTILITIES
]
RIVER BEND STATION i
by 1
4 TDI DIESEL GENERATOR OWNERS GROUP Revision 1 j
February 1985 Reviewed by:
d l
R. J. Deese Licensing Coordinator i
TDI Diesel Generator Owners Group Approved by:
bi-C. L. Ray TeYhdical Program Director TDI t
Diesel Generator Owners Group B503150453 850307 l
PDR ADOCK 05000450 8
PDR l
RB2740 4
2.6 FINAL DOCUMENTATION g
('j The DR/QR program has been completed for Gulf States Utilities.
A summary of the results of this effort are contained in Section 3.0.
Appendix I contains component DR/QR Summary Reports which provide a detailed summary of the review and analysis performed on each component including references to supporting documentation and the recommendations and conclusions resulting from this effort.
Appendix II contains a comprehensive set of maintenance and surveillance recommendations for each component.
These recommendations were derived from existing vendor reconnendations and the individual component DR/QR Summary reports. The purpose of this Appendix is to provide the utility a basis for its maintenance and surveillance program which will maintain the qualification of its diesel generators for the life of the plant.
This entire report constitutes final documentation of the completion of the DR/QR Program on the River Bend TDI diesel generators.
1 0
1 O
i RB2740 2-6 Rev. 1 1
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.)
Cylinder Block Unlimited Life Additional maintenance and O,
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.
I and Bushings (03-340A)
Connecting Rod Unlimited Life Additional maintenance Bearing Shells requirements.
Additional (03-340B) inspections recommended.
Pistons (03-341A)
Unlimited Life AN piston skirt should be replaced with AE piston skirt.
l Air Start Valve Unlimited Life Additional maintenance (03-359) requirements.
Verification of dimensions recommended.
I Cylinder Heads Unlimited Life Additional maintenance (03-360A) requirements.
O l
l RB2827 3-2 REV 1 l
Component Acceptability Recommended Action Fuel Injection Unlimited Life Additional testing and Equipment: Tube maintenance requirements.
Assembly (03-365C)
Procurement specification requirement.
Main and Connector Unlimited Life Additional procurement Pushrods (03-390C, requirement.
Additional 03-3900) inspections recommended.
Random destructive testing recommended.
1 Rocker Arm Unlimited Life Additional maintenance Capscrews requirements.
(03-390F)
Jacket Water Unlimited Life Additional maintenance and Pump (03-425A) inspection requirements.
Wiring and Unlimited Life None Terminations (03-6888)
O O
RB2827 3-3 REV 1 4
IO V
3.2 Summary Resolution of Phase II Components Component Acceptability Recommended Action TURBO, INTAKE, INTERCOOLER & EXHAUST Turbocharger Modifications Additional Quality inspections (MP-020) recommended.
Additional modifica-tions and maintenance inspections recommended.
Turbocharger Modifications Adoition of two-directional Thrust Bearing restraints at the by pass shutoff Drip Lube System valve near the sight glass and (Small Bore Scope mid-span in the riser near the Only) lube oil header branch connection.
(03-CFR)
Verification that the final assembly of Engine B is similar to Engine A.
Intercooler Unlimited Life Additional maintenance recommend-(F-068) ations.
Intake Manifold Modifications Additional maintenance recommend-
& Piping ations.
Additional Quality (Large Bore Scope inspections recommended.
Addition Only) of seven ribs to flat plate on (03-375) bottom of intake manifold.
Verify torque of all bolts on the bottom rectangular flange.
Exhaust Manifold Unlimited Life Perform a visual inspection and (03-380A) a magnetic particle test on a sample of the circumferential pipe weld and corresponding heat affected zones.
Exhaust Manifold:
Unlimited Life Additional Quality inspections Gasket & Bolting recommended.
Strut temperature (03-3808) verification / modification 1
required to limit Bolt Stress.
Turbocharger Unlimited Life Additional Quality inspections Bracket and bolting recommended.
(03-475A&D)
Modifications Addition of grease fittings per Bracket:
Air TDI SIM 322.
Additional mainten-Butterfly Valve ance recommendations.
Additional Assembly Quality inspections recommended.
O (03-4758)
RB2827 3-4 REV. 1 l
l
1 Component Acceptability Recommended Action Engine Driven Unlimited Life None Lube Oil Pump (03-420)
Lube Oil Full Unlimited Life None Pressure Strainers (03-460A)
Lube Oil Lines Unlimited Life Additional maintenance recommend-External:
- Tubing, ations.
Utilization of a minimum Fittings, Couplings installation gap between the (Large Bore pipe ends of 0.132 inch.
Scope Only)
Lube Oil Lines Modifications Addition / modification of supports.
External: Tubing, Refer to DR/QR report 03-465B for Fittings, Couplings details.
(Small Bore Scope Only)
Lube Oil Lines -
Unlimited Life None External Supports O
(Large Bore Scope Only)
Lube Oil Lines Modifications Modification of tubing.
Addition /
External:
Supports modification of supports.
(Small Bore Verification that the final Scope Only) assembly of Engine B is similar (03-4658-SB) to Engine A.
Refer to DR/QR report 03-465B for details.
Lube Oil Lines Unlimited Life None External - Valves (03-465C)
Turbocharger:
Modifications Removal of the single tie-rod Lube Oil Fitting -
assembly surrounding the y
Pipe, Tubing, couplings.
Fittings, and Flexible Coupling (Large Bore Scope Only)
O RB2827 3-6 REV. 1
Component Acceptability Recommended Action ENGINE BASE & BEARING CAPS Base and Bearing Unlimited Life Additional maintenance Caps-Base Assembly, recommendations.
Additional Main Bearing Studs Quality inspections and Nuts, and Main recommended.
Bearing Cap J
(03-305A,C,D)
Base and Bearing Unlimited Life Additional Quality inspections Caps-Through recommended.
Bolting (03-305E)
CRANKSHAFT & BEARINGS Crankshaft Unlimited Life None 1
(03-310A)
(provided the engines are run at no greater than a 3130 kW load)
Main Bearings Unlimited Life Inspection of bearings to check O4 (03-310B) for evidence of misalignment.
Additional Quality inspections l
recommended.
Crankshaft and Unlimited Life Additional maintenance recommend-Bearing:
Thrust ations.
Bearing Rings (03-310C)
CYLINDER BLOCK, LINERS & WATER MANIFOLD Cylinder Block Unlimited Life Implementation of routine in'cections recommended.-
1 (03-315A) s Cylinder Block Unlimited Life Additional Quality inspections Liners & Water recommended.
Additional main-Manifold -
tenance recommendations.
Cylinder Liners (03-315C)
Cylinder Block -
Unlimited Life Additional maintenance recommend-Liners and Water ations.
Manifold: Jacket Water Manifold O
and Piping (Large Bore Scope Only)
(03-315D)
RB2827 3-9 REV. 1 l
l
Component Acceptability Recommended Action Foundation Bolts-Unlimited Life None Anchors, Bolts &
Miscellaneous Hareware (03-550)
Sub Base-Sub Base Unlimited Life None Engine - Engine and Generator (03-715A)
Sub Base - Bolting Unlimited Life Additional Maintenance 1
(03-715B) insnections required.
Auxiliary Sub Base & Unlimited Life None Oil & Water Piping-Auxiliary Skid
-(03-717A)
O i
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)
}
R82827 3-23
O Index (continued)
Component Component Volume Number Description Category No.
F-068 Intercooler Turbo, Intake, 2
Intercooler &
Exhaust MP-020 Turbocharger Turbo, Intake, 2
Intercooler &
Exhaust 00-420 Lube Oil Pressure Regulating Lube Oil 2
Valve 03-CFR Turbocharger Thrust Bearing Turbo, Intake, 2
Orip Lube System Intercooler &
Exhaust 03-305A Base and Bearing Caps: Base Engine Base 2
Assembly
& Bearing Caps 03-305C Base and Bearing Caps:
Engine Base 2
O Main Bearing Studs & Nuts
& Bearing Caps 03-305D Base and Bearing Caps:
Engine Base 2
Main Bearing Caps
& Bearing Caps 03-305E Base and Bearing Caps -
Engine Base 2
Through Bolting
& Bearing Caps 03-307A Lube Oil Fittings:
Lube Oil 2
Internal - Headers 03-3078 Lube Oil Fittings:
Lube Oil 2
Internal - Tubing &
Fittings 03-307D Lube Oil Fittings Internal:
Lube Oil 2
Supports 03-310A Crankshaft Crankshaft &
2 Bearings 03-3108 Main Bearings Crankshaft &
2 Bearing 03-310C Crankshaft & Bearings:
Crankshaft &
2 Thrust Bearing Rings.
Bearing 11 ENTIRE PAGE REVISED
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Index (continued)
Component Component Volume Number Description Category No.
03-315A Cylinder Block Cyl. Block &
2 Liners & Water Manifold 03-315C Cylinder Block Liners &
Cyl. Block &
2 Water Manifold -
Liners &
Cylinder Liner Water Manifold 03-315D Cylinder Block Liners &
Cyl. Block &
2 Water Manifold:
Jacket Liners &
Water Manifold & Piping Water Manifold 03-315E Cylinder Block Liners &
Cyl. Block &
2 Water Manifold: Studs Liners &
Water Manifold 03-315F Cylinder Block Liner Cyl. Block &
2
& Water Manifold:
Liner & Water Cylinder Head Nuts Manifold 03-315G Cylinder Block Liners &
Cyl. Block &
2 O
Water Manifold: Seals &
Liners &
Gaskets Water Manifold 03-317A Water Discharge Manifold:
Jacket Water 4
Jacket Water Discharge Manifold 03-3178 Water Dicharge Manifold:
Jacket Water 4
Coupling & Seals 03-317C Water Discharge Manifold:
Jacket Water 4
Supports 03-330A Flywheel Flywheel 3
03-330B Flywheel - Bolting Flywheel 3
03-335B Front Gear Case: Gaskets and Idler Gear As-3 Bolting sembly & Front Gear Case 03-340A Connecting Rods:
Connecting 3
Rods & Bushings Rods O
111 ENTIRE PAGE REVISED
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Index (continued)
Component Component Volume Number Description Category No.
03-3408 Connecting Rods: Bearing Connecting 3
Shells Rods 03-341A Pistons Pistons 3
03-341B Pistons: Rings Pistons 3
03-341C Piston: Pin Assembly Pistons 3
4 03-345A Tappets and Guides:
Intake Camshaft &
3
& Exhaust Tappet Assembly Valve Train 1
03-345B Tappets and Guides: Fuel Camshaft &
3 Tappet Assembly Valve Train i
03-345C Tappets and Guides: Fuel Camshaft &
3 Pump Base Assembly Valve Train 03-350A Camshaft:
Camshaft Camshaft &
3 Assembly Valve Train
()
03-350B Camshaft:
Camshaft Camshaft &
3 Bearing Valve Train 03-350C Camshaft: Supports, Bolting Camshaft &
3 and Gear Valve Train 03-355A Idler Gear Assembly: Crank Idler Gear As-3 To Pump Gear sembly & Front Gear Case l
03-355B Idler Gear Assembly Idler Gear As-3 sembly & Front Gear Case i
03-355C Idler Gear Assembly:
Idler Gear As-3 Gaskets & Bolting sembly & Front Gear Case 03-359 Air Start Valve Air Start &
3 Barring Device 03-360A Cylinder Heads Cylindar Heads 4
& Valves O
iv ENTIRE PAGE REVISED l
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Index (continued)
Component Component Volume Number Description Category No.
03-360B Cylinder Head Valves:
Cylinder Heads 4
Intake & Exhaust Valves
& Valves 03-360C Cylinder Head and Valves:
Cylinder Heads 4
Bolting and Gaskets
& Valves 1
03-360D Cylinder Head and Cylinder Heads 4
Values:
Springs
& Valves and Retainer 03-362A Subcovers Camshaft &
3 Valve Train 03-365A Fuel Injection Equipment Fuel Oil In-4 Fuel Injection Pump jection 03-3658 Fuel Injection Equipment Fuel Oil In-4 Fuel Injection Tips jection 03-365C Fuel Injection Equipment -
Fuel Oil In-4 Tube Assembly jection 03-365D Fuel Injection Equipment:
Fuel Oil In-4 Supports jection 03-371A Fuel Pump Control Shaft, Fuel Oil In-4 i
Linkage Assembly & Bearings jection 03-3718 Fuel Pump Linkage: Linkage Fuel Oil In-4 Assembly and Bearing jection l
03-371C Fuel Pump Linkage:
Fuel Oil In-4 Automatic Shutdown jection Cylinder 03-375 Air Intake Manifold and Turbo, Intake, 2
Piping Intrcir. & Ex-haust 03-380A Exhaust Manifold Turbo, Intake, 2
Intrcir. & Ex-l haust 03-380B Exhaust Manifold: Gasket Turbo, Intake, 2
and Bolting Intrcir. & Ex-haust O
v ENTIRE PAGE REVISED
. 1 3.,, J.
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Index (continued)
Component-Component Volume Number Description Category No.
03-3858 Cylinder Block Covers:
Cyl. Block &
2 Gaskets and Bolting Liners & Water Manifold 03-387A Crankcase Ventilator:
Crankshaft &
2 Crankcase Vacuum Fan Bearings 03-390A Intake & Intermediate and Camshaft &
3 Exhaust Rocker Shaft Assembly Valve Train 03-3908 Rocker Arms and Pushrods:
Camshaft &
3 Exhaust Rocker Shaft Valve Train Assembly 03-390C Main and Connector Camshaft &
3 Pushrods Valve Train 03-3900 Rocker Arms and Pushrods:
Camshaft &
3 Pushrods Connector.
Valve Train 03-390E Rocker Arms and Pushrods:
Camshaft &
3 0
Bushings Valve Train 1
03-390F Rocker Arms and Pushrods:
Camshaft &
3 Lifters Valve Train 03-390G Rocker Arms and Pushrods:
Camshaft &
3 Miscellaneous Bolts &
Valve Train Drive Studs 03-402A Governor Drive - Governor Overspeed Trip 3
& Tachometer Drive
& Governor Gear & Shaft
~
03-4028 Governor Drive - Couplings, Overspeed Trip 3
Pins & Keys
& Governor 03-410A Overspeed Trip:
Governor Overspeed Trip 3
& Governor 03-410B Overspeed Trip: Governor
-0verspeed Trip 3
and Accessory Drive Assembly
& Governor 03-410C Overspeed Trip: Coupling Overspeed Trip 3
(Flexible & Spider)
& Governor O
vi ENTIRE PAGE REVISED i
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Index (continued)
Component Component Volume Number Description Category No.
03-4100 Overspeed Trip Vent Valve Overspeed Trip 3
& Governor 03-413 Governor Linkage Overspeed Trip 3
& Governor 03-415A Governor Assembly: Woodward Overspeed Trip 3
Governor
& Governor 03-415B Governor Assembly Overspeed Trip 3
Booster Servomotor
& Governor 03-415C Governor Assembly Overspeed Trip 3
Heat Exchanger
& Governor 03-420 Engine Driven Lube Oil Pump Lube Oil 2
03-425A Engine Driven Jacket Water 4
Jacket Water Pump 03-435A Jacket Water Fittings:
Jacket Water 4
Pipe & Fittings 03-435B Jacket Water Fittings:
Jacket Water 4
Piping, Tubing & Supports 03-437A Turbo Water Piping:
Jacket Water 4
Pipe & Fittings 03-4378 Turbo Water Piping:
Supports Turbo Intake 2
Intercooler &
Exhaust 03-441A Starting Air Manifold:
Air Start &
3 Piping, Tubing and Fitting Barring Device 03-441B Starting Air Manifold Air Start &
3 Valves, Strainers, Filters Barring Device 03-441C Starting Air Manifold:
Air Start &
3 Supports Barring Device 03-442A Starting Air Distributor:
Air Start &
3 Distributor Assembly Barring Device 03-4428 Starting Air Distributor:
Air Start &
3 Tubing, Fittings & Gaskets Barring Device vii ENTIRE PAGE REVISED
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Index (continued)
Component Component Volume Number Description Category No.03-445 Engine Driven Fuel Oil Fuel Oil In-4 Booster Pump jection 03-4508 Fuel Oil Header:
Fuel Oil In-4 Piping & Tubing jection 03-4500 Fuel Oil Header:
Fuel Fuel Oil In-4 011 Supports jection 03-455A Fuel Oil Filters &
Fuel Oil In-4 Strainers: Fuel Oil Filters jection 03-455B Fuel Oil Filters &
Fuel Oil In-4 Strainers:
Strainers jection 03-455C Fuel Oil Filters &
Fuel Oil In-4 Strainer: Mounting Hardware jection 03-460A Lube Oil Full Pressure Lube Oil 2
Strainer 03-465A Lube Oil Lines External:
Lube Oil 2
Tubing, Fittings, Couplings 03-465B Lube Oil Lines - External Lube Oil 2
Supports 03-465C Lube Oil Lines - External:
Lube Oil 2
Valves 03-467A Turbocharger: Lube Oil Lube Oil 2
Fitting - Pipe, Tubing, Fittings & Flexible Coupling 03-467B Turbocharger: Lube Oil Lube Oil 2
Fittings - Supports 03-475A Turbocharger: Bracket Turbo, Intake, 2
Intrcir. & Ex-haust 03-475B Turbocharger - Bracket:
Turbo, Intake, 2
Air Butteri'ly Valve Intrcir. & Ex-Assembly haust O
viii ENTIRE PAGE REVISED
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("'s Index (continued)
Component Component Volume Number Description Category No.
03-475C Turbocharger: Bracket -
Turbo, Intake, 2
Air Intake Piping Intrc1r. & Ex-haust 03-475D Turbocharger Bracket Turbo, Intake, 2
Bolting & Gaskets Intercooler &
Exhaust 03-475E Turbocharger - Bracket -
Turbo, Intake, 2
Pipe Support Intercooler &
Exhaust 03-500A Control Panel Assembly:
Control Panel 4
Cabinet / System Assembly 03-500F Control Panel Assembly Control Panel 4
Accumulator Assembly 03-500G Control Panel Control Panel 4
Valves Assembly O'
03-500H Control Panel Assembly Control Panel 4
Pressure Switch Assembly 03-500J Control Panel Assembly:
Control Panel 4
Control Relays Assembly 03-500K Control Panel Assembly:
Control Panel 4
Solenoid Valves Assembly 03-500M Control Panel Components:
Control Panel 4
Piping, Tubing, Fittings Assembly 03-500N Control Panel Assembly:
Control Panel 4
Terminal Boards / Switches /
Assembly Wiring 03-515 Jacket Water Thermostatic Jacket Water 4
Valve 03-525B Barring Device - Pneumatic:
Air Start &
3 Regulator Valve Shut Off Barring Device Valve 03-525D Barring Device Support Air Start &
3 Bracket Barring Device ix ENTIRE PAGE REVISED A
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Index (continued)
Component Component Volume Number Description Category No.
03-540A Lube Oil Sump Tank - Tank Lube Oil 2
with Strainer Assembly 03-5408 Lube Oil Sump Tank: Misc.
Lube Oil 2
Fittings, Gaskets, Pipe &
Bolting Material, Valves 03-540C Lube Oil Sump Tank:
Lube Oil 2
Mounting Hardware 03-550 Foundation Bolts:
Engine & Aux.
4 Anchors, Bolts, Misc.
Sub Base &
Hardware Foundation Bolts 03-630A Pyrometer Conduit Assembly:
Engine Instru-3 Conduit mentation &
Wiring 03-630B Pyrometer Conduit Assembly:
Engine Instru-3 Conduit Fittings mentation &
Wiring 03-630C Pyrometer Conduit Assembly:
Engine Instru-3 Support mentation &
Wiring 03-6300 Pyrometer Conduit Assembly:
Engine Instu-3 Thermocouples mentation &
Wiring 03-650A Emergency Diesel Generator Generator 4
03-6508 Generator Generator 4
Control 03-650C Generator - Shaft Generator 4
& Bearings 03-688A Engine & Aux Module Wiring Engine Instru-3 Material-Conduit & Fittings; mentation &
Pyrometer Conduit Assembly-Wiring Conduit, Fitting, Supports O
x ENTIRE PAGE REVISED i
,' h ELY.
.y
l fl Index (continued)
V Component Component Volume Number Description Category No.
03-6888 Engine & Aux. Module Engine Instru-3 Wiring Material: Wiring mentation &
& Terminations Wiring 03-688C Engine & Aux. Module Wiring Engine Instru-3 Material: Boxes & Terminals mentation &
Wiring 03-689 Off Engine Safety Alarm Engine Instru-3 Sensors Wiring mentation &
Wiring 03-690 On Engine Alarm Sensors Engine Instru-3 mentation &
Wiring 03-691 Off Engine Alarm Sensors Engine Instru-3 Level & Pressure Switches mentation &'
Wiring 03-695A Engine Shutdown E'quipment:
Engine Shut-3 O
Tubing / Fittings & Supports down & Equip-ment 03-6958 Engine Shutdown Equipment:
Engine Shut-3 Valves, Regulator, Orifices down & Equip-ment 03-695C Engine Shutdown Trip Engine Shut-3 Switches down & Equip-ment 03-700A Jacket Water Standpipe:
Jacket Water 4
Pipe, Fittings, Gaskets 03-7008 Jacket Water Standpipe:
Jacket Water 4
Valves 03-700C Jacket Water Standpipe:
Jacket Water 4
Supports 03-700E Jacket Water Standpipe:
Jacket Water 4
Switches 03-700F Jacket Water Standpipe:
Jacket Water 4
Misc. Bolting Mat.
O xi ENTIRE PAGE REVISED 1
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Index (continued)
Component Component Volume Number Description Category No.
03-715A Sub Base - Sub Base Engine & Aux.
4 Engine & Generator Sub Base &
Foundation Bolts 03-715B Sub Base Engine & Aux.
4 Bolting Sub Base &
Foundation Bolts 03-717A Aux Sub Base & 011 & Water Jacket Water 4
Piping - Aux. Skid 03-717B Aux Sub Base & Oil & Water Jacket Water 4
Piping - Jacket Water:
Valves 03-717C Aux. Sub Base & 011 & Water Jacket Water 4
Piping - Jacket Water - Pipe Couplings, Fittings, Orifices and Strainers 03-717D Aux Sub Base & Oil & Water Jacket Water 4
0 i
Piping - Jacket Water:
Gaskets & Bolting 03-717F Aux. Sub Base & Oil & Water Jacket Water 4
Piping - Jacket Water:
Gaskets & Bolting 03-717G Aux. Sub Base & Oil & Water Jacket Water 4
Piping - Jacket Water:
Supports 03-717H Aux. Sub Base & 011 & Water Lube Oil 2
Piping - Lube Oil:
Pipe and Fittings 03-717I Aux Sub Base & 011 & Water Lube Oil 2
Piping - Lube Oil Valves 03-717J Aux. Sub Base & Oil & Water Lube Oil 2
l Piping - Lube Oil - Gaskets &
Bolting 03-717K Aux. Sub Base & 011 & Water Lube Oil 2
Water Piping - Lube 011:
Supports & Mounting Hardware xii ENTIRE PAGE REVISED
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Index (continued)
O Component Component Volume Number Description Category No.
03-717L Aux. Sub Base & 011 & Water Lube Oil 2
Piping - Lube Oil:
Automatic Switchover Assembly 03-717M Aux. Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel 011: Piping and Fittings 03-717N Aux. Sub Base & Oil & Water Fuel Oil 4
Piping - Fuel Oil: Valves 03-717P Aux Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel Oil - Gaskets
& Bolting 03-717Q Aux. Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel Oil:
Supports 03-800A Misc. Equipment - Heater, Jacket Water 4
l Jacket Water 03-800A Misc. Equipment - Heater, Lube Oil 4
{
Lube Oil Sump Tank 03-805B Intake Air Filter Turbo, Intake, 2
i Intercooler &
Exhaust 03-805D Flex Connections Turbo, Intake, 2
Intercooler &
Exhaust 03-810B Jacket Water Standby Heater Jacket Water 4
Pump 03-820A Lube Oil Heat Exchanger Lube Oil 2
03-8208 Full Flow Lube Oil Filter Lube Oil 2
03-820C Before-and-After Lube Oil Lube Oil 2
Pump ENTIRE PAGE REVISED O
xiii
. A. -
(
Index (continued)
Component Component Volume Number Description Category No.
03-820D Oil Prelube Filter Lube Oil 2
03-825A Fuel Oil Booster Pump Fuel Oil 2
03-825C Fuel Oil Fuel Oil 4
Filters & Strainers:
Strainers 03-835A Starting Air Tank Air Start &
3 Barring Device l
03-8350 Starting Air Compressor Air Start &
3 Barring Device 03-835F Air Start System -
Air Start &
3 l
Starting Air Float Trap Barring Device 02-835G Starting Air Tank Air Start &
3 Relief Valve Barring Device O
i 1
I l
e l
l l
l i
O xiv ENTIRE PAGE REVISED l
ym
-..-m.
Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST RIVER BEND STATION - UNIT 1 Turbocharger Bracket COMPONENT and Bolting UTILITY Gulf States Utilities GROUP PARTS LIST NO. 03-475A&D TASK DESCRIPTION NO. DR-06-03-475A&D-1 SNPS GPL NO. 03-475A&D CLASSIFICATION TYPE A
TA5K OESCRIPTIONS A design review report is not required for this component for the following reasons:
The bracket is identical to that used at Shoreham.
There is a vibration support strut, which is similar to that used at Shoreham but has jacket water circulated through it to provide a parallel heat-up of the engine and strut.
The River Bend configuration has been analyzed and has been found similar to Shoreham, Ref. 2.
For engine vibration loads and pipe loads that were assumed to be the same as those at Shoreham, bracket bolt loads and bracket stresses have been found acceptable.
One of Shoreham's engines has operated 1700 hours0.0197 days <br />0.472 hours <br />0.00281 weeks <br />6.4685e-4 months <br /> without major failures of bolting.
Bolt failures at Shoreham are attributable to thermal expansion problems with the Shoreham strut, which should not apply to the River Bend jacket water heated strut.
In the design review calculation, Ref. 2, it was concluded that bolt stresses are acceptable as long as temperature differences between the engine block and strut are not large (about 10*F). As such, the following inspection should be conducted:
Temperature measurements should be taken at several external y
locations along the strut during engine ~: standby and operating modes.
The temperature difference between the engine block (as indicated by jacket water inlet temp. as per Ref. 3) and the strut should be verified to be not significantly larger than 10*F.
If inspection indicates temperature differences significantly above 10*F, adequate jacket water flow through the strut should be ensured and/or insulation applied as required to raise the strut temp.
O REV.
1 R82862/1
/]
COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 (j
DR-06-03-475A&D-1 The following bracket bolting requirement should be implemented:
Bracket installation dowels should be left in place during engine operation to provide added resistance to shear loading.
There are no maintenance or modification requirements identified in the lead engine report (Shoreham).
The following quality inspection should be performed for both station engines:
Turbocharger bracket and strut bolt torques should be inspected for i
proper bolting material and bolt torque after initial engine runs.
PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES 1.
Stone & Webster Specification number 244.700, Addendum 2,
8/30/82
" Standby Diesel Generator Systems" River Bend Station - Unit 1 Gulf States Utilities Company, West Feliciana Parish, Lousiana.
2.
Stone & Webster Calculation No. 11600.60-NM(B)-006-CZC-39 3.
1/28/85 Telephone Memo between J.
Cadogan, SWEC, and M.
Lowery, TDI.
DOCUMENTATION REQUIRED Not required PROGRAM MANAGER /(.f Y b de/f_
GROUP CHAIRPERSON L-1 /
/
REV. 1 RB2862/2
/
\\
TDI OWNERS GROUP for RIVER BEND STATION - UNIT 1 TURBOCHARGER:
LUBE OIL FITTING - PIPE, TUBING, y
FITTINGS AND FLEXIBLE COUPLING (LARGE BORE SCOPE ONLY)
COMPONENT PART NO. 03-467A I
INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the River Bend Station requires Design and Quality Revalidation reviews of the structural adequacy of the turbocharger-lube oil piping for the effects of normal operating and earthquake loadings.
The primary function of the piping is to carry lube oil from the turbocharger to the sump tank.
The primary function of the flexible couplings is to seal lube oil and O
accommodate thermal expansion.
The scope of piping embraced by this report ircludes the large bore (greater than 2-inch diameter) piping components as noted on the as-built information transmitted to and obtained by Impell field during verifica-tion (Ref. 1).
Piping components are defined as piping spool pieces, elbows, tees, flanges, Dresser couplings and the interconnecting welds.
This scope is uniquely defined in terms of Transamerica Delaval, Inc. (TDI) part numbers in Reference 1.
II OBJECTIVE The objective of this review was to verify the adequacy of the subject piping components for normal operating and earthquake loading.
III METHODOLOGY The evaluation of the piping was performed in accordance with the philoso-phy and intent of the ASME Section III Code, for Class 3 Nuclear Piping.
Towards this end, a criteria document was developed, " Design Criteria for Diesel Generator Large Diameter Piping for River Bend," which describes the background and provides the techniques for evaluating the subject O
piping and supports.
This criteria is presented in its entirety in Reference 2.
Quality Revalidation Checklist results were reviewed for acceptability.
RB2486/1 Rev. 1
i TDI OWNERS GROUP for RIVER BEND STATION - UNIT 1 CYLINDER BLOCK COMPONENT PART NO. 03-315A I
INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the River Bend Station requires Design and Quality Revalidation reviews of the cylinder blocks to determine the adequacy of design for the intended use at River Bend.
The blocks are manufactured by TDI and are supplied under their part number 03-315-03-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 the review was to evaluate the structural adequacy of the cylinder block for its intended use at River Bend Station.
III METHODOLOGY In order to meet the stated objective the following methods were used:
Evaluation of steady state
- stresses, alternating stresses and stiffness in key portions of the cylinder block.
Review of engine operating experience.
Review of engine operating conditions at River Bend and identification of any differences from those at Shoreham.
Performance of dimensional check and evaluation of liner / block interaction.
Evaluation of crack growth rate for cylinder block landing and counterbore diameter by comparison with conservative Shoreham data and analysis.
Review of liquid penetrant inspections of River Bend R-41A and 1B 1
engine blocks.
Review of metallurgical / microstructural analysis of cylinder block
)
material.
Review of River Bend site, nuclear and non-nuclear experiences O
(see Appendix C).
Review of Quality Revalidation Checklist results for acceptability.
R82846/1-t REV~1 l
t n
Page 2 of 3 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 in nuclear power plants is summarized in Reference 1.
The investigation considers the cause, extent, and consequences of cylinder block cracking, and the inspections required to assure a sufficient margin of safety dur-ing continued operation under test and postulated accident conditions.
Evaluation of steady state stresses, alternating stresses and stiffness in key portions of the cylinder block was accomplished as part of the strain gage testing at Shoreham and the results were' included in the cumulative damage and crack growth analyses.
The cumulative damage analysis is explained in Reference 1.
Diesel generators 1A and 1B have been inspected for block top cracks in the region adjacent to and between the cylinders.
No cracked ligaments or stud-to-stud or stud-to-end cracks were found.
Engine 1A has completed 124 hours0.00144 days <br />0.0344 hours <br />2.050265e-4 weeks <br />4.7182e-5 months <br /> of operation as of October 31, 1984.
The load breakdown for this service is I hou.' at zero load; 14 hours1.62037e-4 days <br />0.00389 hours <br />2.314815e-5 weeks <br />5.327e-6 months <br /> at 25 percent; 21 hours2.430556e-4 days <br />0.00583 hours <br />3.472222e-5 weeks <br />7.9905e-6 months <br /> at 50 percent; 11 hours1.273148e-4 days <br />0.00306 hours <br />1.818783e-5 weeks <br />4.1855e-6 months <br /> at 75 percent; 76 hours8.796296e-4 days <br />0.0211 hours <br />1.256614e-4 weeks <br />2.8918e-5 months <br /> at 100 percent; and 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> at 110 percent load.
Engine 1B has completed 40 hours4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br /> of operation as of October 31, 1984, with a load breakdown of 5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br /> at 25 percent; 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> at 75 percent; 31 hours3.587963e-4 days <br />0.00861 hours <br />5.125661e-5 weeks <br />1.17955e-5 months <br /> at 100 percent; and 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> at 110 percent load.
The engine operating conditions at River Bend were compared to those at y
Shoreham.
No significant differences were found that would affect the structural integrity assessment of the River Bend blocks.
Results of dimensional inspection of the cylinder liners and of the mating block surfaces were used to evaluate the interaction of the block and liner in the analysis of steady state and alternating stresses.
These results were utilized in the cumulative damage analysis.
The power output for this engine is 3500 kW at 100 percent load.
Maximum output required for LOOP /LOCA is 3130 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 />.
Strain gage testing of the original Shoreham EDG 103 block, inspection data from before and after extensive test operation and materials testing l
were used as a basis to predict adequate life for cylinder blocks.
The rate of propagation of cracks between stud holes during operation of the original Shoreham EDG 103 block, when compared with the LOOP /LOCA require-ments at River Bend, indicates that even if the River Bend engine blocks had ligament cracks they are predicted to withstand with sufficient margin a LOOP /LOCA event.
Diesel generators 1A and IB have completed limited operational experience.
Both engines have been inspected and found to be without detectable block-top cracks.
Further, the microstructure of biccks 1A and 1B have 1
REV 1 RB2846/2
Page 3 of 3 been examined and found to be representative of typical grey cast iron, Class 40.
Application of the cumulative damage analysis (Figure 5-1 of Ref. 1) shows that the River Bend engine blocks can perform for 675 hours0.00781 days <br />0.188 hours <br />0.00112 weeks <br />2.568375e-4 months <br /> at 1
3130 kW (or operation resulting in equivalent damage), without inspection, with sufficient margin for a LOOP /LOCA event (Ref. 2).
Engine operation in excess of the above time period without repeated inspection is justified if the fatigue damage index since the last inspection does not exceed the allowable fatigue damage index based upon the last inspection.
In the future this process may be repeated, and additional engine operation without inspection may continue until the additional fatigue damage index equals the allowable fatigue damage index established by the last inspection which showed no cracking.
1 Optionally, in the future, after additional engine operation without repeated inspection has accumulated a fatigue damage index which exceeds the allowable fatigue damage index, continued engine operation can continue without removal of cylinder heads and maintain st.fficient margin to withstand a LOOP or LOOP /LOCA event provided periodic eddy current inspections described in Figure 5-1 of Reference 1 are performed between the heads.
O The information provided on TER's06-040 and 06-083 have been reviewed and are consistent with the final conclusions of this report.
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 routine inspections, it is concluded that the cylinder blocks are acceptable for their intended use at River Bend.
V.
REFERENCES 1.
Design Review of TOI-R4 and RV-4 Series Emergency Diesel Generator Cylinder Blocks. FaAA-84-9-11.1.
2.
FaAA Support Package Number SP-84-G-12(g).
1 REV 1 O
RB2846/3
Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST RIVER BEND STATION - UNIT 1 Cylinder Block COMPONENT Covers: Gaskets & Bolts UTILITY Gulf States Utilities GROUP PARTS LIST NO 03-385B TASK DESCRIPTION NO. :
DR-06-03-385B-1 SNPS GPL NO. 03-3858 CLASSIFICATION TYPE C
TASK OESCRIPTIONS Design review for this component is not required based on a review of the lead engine DR/qR report (Shoreham) and the applicable industry experience.
There is no site experience reported in the EDG Component Tracking System.
There have been cases of fastener failures on the cylinder block covers, how?ver these failures are not attributed to design deficiencies of this co ap:snent.
Based on the lead engine DR/QR report, the recommended torque value of 30 ft-lbs is appropriate and the specified bolting and stud materials (SAE GR 5 and SAE GR 1120 respectively) are acceptable for thair intended function O
of holding the covers onto the cylinder block.
Isolated Silures can occur when the torque is not applied properly or a lesser grade material is substi-tuted.
Barring any deviations as mentioned above the bolting is acceptable for use on the diesel engines.
There are no modification or maintenance recommendations for tSis component.
The following quality inspections are recommended to be performed on one engine:
To verify that the proper torque is applied and the specified material is installed, plant personnel should review site documentation or perform the necessary inspection to make these determinations.
Visually inspect gaskets for signs of elastomeric compound breakdown and cracking.
I j
PRIMARY FUNCTION Not required l
O RB2682/1 Rev. 1 1
i I
i
' O Index (continued)
Component Component Volume Number Description Category No.
F-068 Intercooler Turbo, Intake, 2
Intercooler &
Exhaust MP-020 Turbocharger Turbo, Intake, 2
Intercooler &
Exhaust 00-420 Lube Oil Pressure Regulating Lube Oil 2
Valve 1
03-CFR Turbocharger Thrust Bearing Turbo, Intake, 2
Drip Lube System Intercooler &
Exhaust 03-305A Base and Bearing Caps: Base Engine Base 2
Assembly
& Bearing Caps 03-305C Base and Bearing Caps:
Engine Base 2
Main Bearing Studs & Nuts
& Bearing Caps 03-305D Base and Bearing Caps:
Engine Base 2
Main Bearing Caps
& Bearing Caps 03-305E Base and Bearing Caps -
Engine Base 2
Through Bolting
& Bearing Caps 03-307A Lube Oil Fittings:
Lube Oil 2
Internal - Headers 03-3078 Lube Oil Fittings:
Lube Oil 2
Internal - Tubing &
Fittings 03-3070 Lube Oil Fittings Internal:
Lube Oil 2
l Supports 03-310A Crankshaft Crankshaft &
2 i
Bearings 03-3108 Main Bearings.
Crankshaft &
2 4
Bearing 03-310C Crankshaft & Bearings:
Crankshaft &
2 Thrust Bearing Rings.
Bearing 11 ENTIRE PAGE REVISED
~...
a.w.
Index (continued)
Component Component Volume Number Description Category No.
03-315A Cylinder Block Cyl. Block &
2 Liners & Water Manifold 03-315C Cylinder Block Liners &
Cyl. Block &
2 Water Manifold -
Liners &
Cylinder Liner Water Manifold 03-3150 Cylinder Block Liners &
Cyl. Block &
2 Water Manifold: Jacket Liners &
Water Manifold & Piping Water Manifold 03-315E Cylinder Block Liners &
Cyl. Block &
2 Water Manifold: Studs Liners &
Water Manifold 03-315F Cylinder Block Liner Cyl. Block &
2
& Water Manifold:
Liner & Water Cylinder Head Nuts Manifold 03-315G Cylinder Block Liners &
Cyl. Block &
2 O
Water Manifold: Seals &
Liners &
Gaskets Water Manifold 03-317A Water Discharge Manifold:
Jacket Water 4
Jacket Water Discharge Manifold 03-317B Water Dicharge Manifold:
Jacket Water 4
Coupling & Seals 03-317C Water Discharge Manifold:
Jacket Water 4
Supports 03-330A Flywheel Flywheel 3
03-3308 Flywheel - Bolting Flywheel 3
03-3358 Front Gear Case: Gaskets and Idler Gear As-3 Bolting sembly & Front Gear Case 03-340A Connecting Rods:
Connecting 3
Rods & Bushings Rods tii ENTIRE PAGE REVISED
. h.$ ;.
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- -s~
Index (continued)
Component Component Volume Number Description Category No.
03-340B Connecting Rods: Bearing Connecting 3
Shells Rods 03-341A Pistons Pistons 3
03-3418 Pistons: Rings Pistons 3
03-341C Piston: Pin Assembly Pistons 3
03-345A Tappets and Guides:
Intake Camshaft &
3
& Exhaust Tappet Assembly Valve Train 03-345B Tappets and Guides: Fuel Camshaft &
3 Tappet Assembly Valve Train 03-345C Tappets and Guides: Fuel Camshaft &
3 Pump Base Assembly Valve Train 03-350A Camshaft: Camshaft Camshaft &
3 Assembly Valve Train 0
03-350B Camshaft:
Camshaft Camshaft &
3 Bearing Valve Train 03-350C Camshaft: Supports, Bolting Camshaft &
3 and Gear Valve Train 03-355A Idler Gear Assembly: Crank Idler Gear As-3 To Pump Gear sembly & Front Gear Case 03-355B Idler Gear Assembly Idler Gear As-3 sembly & Front Gear Case 03-355C Idler Gear Assembly:
Idler Gear As-3 Gaskets & Boltin9 sembly & Front Gear Case 03-359 Air Start Valve Air Start &
3 Barring Device 03-360A Cylinder Heads Cylinder Heads 4
& Valves iv ENTIRE PAGE REVISED
.,7 s,s:
,22 s'. M$iS $LL, uw.
.uG-a I
' -O\\
Index (continued)
Component Component Volume Number Description Category No.
03-3608 Cylinder Head Valves:
Cylinder Heads 4
Intake & Exhaust Valves
& Valves 03-360C Cylinder Head and Valves:
Cylinder Heads 4
Bolting and Gaskets
& Valves 03-3600 Cylinder Head and Cylinder Heads 4
Values:
Springs
& Valves and Retainer 03-362A Subcovers Camshaft &
3 Valve Train 03-365A Fuel Injection Equipment Fuel Oil In-4 Fuel Injection Pump jection 03-365B Fuel Injection Equipment Fuel Oil In-4 Fuel Injecticn Tips jection 03-365C Fuel Injection Equipment -
Fuel Oil In-4 Tube Assembly jection
()
03-3650 Fuel Injection Equipment:
Fuel Oil In-4 Supports jection 03-371A Fuel Pump Control Shaft, Fuel Oil In-4 Linkage Assembly & Bearings jection 03-371B Fuel Pump Linkage: Linkage Fuel Oil In-4 Assembly and esaring jection 03-371C Fuel Pump Lt;r:n.9:
Fuel Oil In-4 Automatic She-Evn jection Cylinder 03-375 Air Intake Marifold and Turbo, Intake, 2
Piping Intrcir. & Ex-haust 03-380A Exhaust Manifoid Turbo, Intake, 2
Intrcir. & Ex-haust 03-380B Exhaust Manifold: Gasket Turbo, Intake, 2
and Bolting Intrcir. & Ex-haust
()
v ENTIRE PAGE REVISED
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e.
Index (continued)
Component Component Volume Number Description Category No.
03-385B Cylinder Block Covers:
Cyl. Block &
2 Gaskets and Bolting Linert & Water Manifold 03-387A Crankcase Ventilator:
Crankshaft &
2 Crankcase Vacuum Fan Bearings 03-390A Intake & Intermediate and Camshaft &
3 Exhaust Rocker Shaft Assembly Valve Train 03-390B Rocker Arms and Pushrods:
Camshaft &
3 Exhaust Rocker Shaft Valve Train Assembly 03-390C Main and Connector Camshaft &
3 Pushrods Valve Train 03-3900 Rocker Arms and Pushrods:
Camshaft &
3 Pushrods Connector.
Valve Train 03-390E Rocker Arms and Pushrods:
Camshaft &
3 Bushings Valve Train 03-390F Rocker Arms and Pushrods:
Camshaft &
3 Lifters Valve Train 03-390G Rocker Arms and Pushrods:
Camshaft &
3 Miscellaneous Bolts &
Valve Train
~
Drive Studs Governor Dri' e - Governor Overspeed Trip 3
03-402A v
& Tachometer Drive
& Governor Gear & Shaft 03-402B Governor Drive - Couplings, Overspeed Trip 3
Pins & Keys
& Governor 03-410A Overspeed Trip: Governor Overspeed Trip 3
& Governor 03-4108 Overspeed Trip: Governor Overspeed Trip 3
and Accessory Drive Assembly
& Governor l
03-410C Overspeed Trip: Coupling 0verspeed Trip 3
(Flexible & Spider)
& Governor l
vi ENTIRE PAGE REVISED l
l l
A. e. 6 M h~4u m.m
... m.m
.I
g Index (continued)
'J Component Component Volume Number Description Category No.
03-4100 Overspeed Trip Vent Valve Overspeed Trip 3
& Governor 03-413 Governor Linkage Overspeed Trip 3
& Governor 03-415A Governor Assembly: Woodward Overspeed Trip 3
Governor
& Governor 03-415B Governor Assembly Overspeed Trip 3
Booster Servomotor
& Governor 03-415C Governor Assembly Overspeed Trip 3
Heat Exchanger
& Governor 03-420 Engine Driven Lube Oil Pump Lube Oil 2
03-425A Engine Driven Jacket Water 4
Jacket Water Pump 03-435A Jacket Water Fittings:
Jacket Water 4
Pipe & Fittings
-l 03-435B Jacket Water Fittings:
Jacket Water 4
Piping, Tubing & Supports 03-437A Turbo Water Piping:
Jacket Water 4
Pipe & Fittings
~
03-4378 Turbo Water Piping: Supports Turbo Intake 2
Intercooler &
Exhaust 03-441A Starting Air Manifold:
Air Start &
3 Piping, Tubing and Fitting Barring Device 03-441B Starting Air Manifold Air Start &
3 Valves, Strainers, Filters Barring Device 03-441C Starting Air Manifold:
Air Start &
3 Supports Barring Device 03-442A Starting Air Distributor:
Air Start &
3 Distributor Assembly Barring Device 03-44?B Starting Air Distributor:
Air Start &
3 Tubing, Fittings & Gaskets Barring Device
()
vii ENTIRE PAGE REVISED
.n. A n
. + *dien,
..... -za c.
r
l Index (continued)
Component Component Volume Number Description Category No.03-445 Engine'Oriven Fuel Oil Fuel Oil In-4 Booster Pump jection 03-4508 Fuel Oil Header:
Fuel Oil In-4 Piping & Tubing jection 03-4500 Fuel Oil Header:
Fuel Fuel Oil In-4 011 Supports jection 03-455A Fuel Oil Filters &
Fuel Oil In-4 Strainers: Fuel Oil Filters jection 03-4558 Fuel Oil Filters &
Fuel Oil In-4 Strainers:
Strainers jection 03-455C Fuel Oil Filters &
Fuel Oil In-4 Strainer: Mounting Hardware jection 03-460A Lube Oil Full Pressure Lube Oil 2
Strainer O
03-465A Lube Oil Lines External:
Lube Oil 2
Tubing, Fittings, Couplings 03-465B Lube Oil Lines - External Lube Oil 2
Supports 03-465C Lube Oil Lines - External:
Lube Oil 2
Valves 03-467A Turbocharger: Lube Oil Lube Oil 2
Fitting - Pipe, Tubing, Fittings & Flexible Coupling 03-4678 Turbocharger: Lube Oil Lube Oil 2
Fittings - Supports 03-475A Turbocharger: Bracket Turbo, Intake, 2
Intrcir. & Ex-haust 03-4758 Turbocharger - Bracket:
Turbo, Intake, 2
Air Butterfly Valve Intrcir. & Ex-Assembly haust i
V I
I th.
e " DS$Pt ;,*
. r.,,.-. dw * + -
l
r
.Index (continued)
+
Component Component Volume Number Description Category No.
t 03-475C Turbocharger: Bracket -
Turbo, Intake, 2
l Air Intake Piping Intrcir. & Ex-i 4
haust 03-4750 Turbocharger Bracket Turbo, Intake, 2
Bolting & Gaskets Intercooler &
Exhaust l
l 03-475E Turbocharger - Bracket -
Turbo, Intake, 2
Pipe Support Intercooler &
4 Exhaust 03-500A Control Panel Assembly:
Control Panel 4
Cabinet / System Assembly 1
j 03-500F Control Panel Assembly Control Panel 4
l Accumulator Assembly l
i 03-500G Control Panel Control Panel 4
Valves Assembly I
i 03-500H Control Panel Assembly Control Panel 4
Pressure Switch Assembly 03-500J Control Panel Assembly:
Control Panel 4
i Control Relays Assembly 03-500K Control Panel Assembly:
Control Panel 4
I i
Solenoid Valves Assembly 03-500M Control Panel Components:
Control Panel 4
Piping, Tubing, Fittings Assembly 03-500N Control Panel Assembly:
Control Panel 4
)
Terminal Boards / Switches /
Assembly j
Wiring j
03-515 Jacket Water Thermostatic Jacket Water 4
Valve 03-525B Barring Device - Pneumatic:
Air Start &
3
)
Regulator Valve Shut Off Barring Device i
Valve 03-5250 Barring Device Support Air Start &
3 Bracket Barring Device ix ENTIRE PAGE REVISED a
f l
,.I;.N N 5 lN$'S+.:s m
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i
()
Index (continued)
Component Component Volume Number Description Category No.
03-540A-Lube Oil Sump Tank - Tank Lube Oil 2
with Strainer Assembly 03-5408 Lube Oil Sump Tank: Misc.
Lube Oil 2
Fittings, Gaskets, Pipe &
Bolting Material, Valves i
Lube Oil 2
Mounting Hardware 03-550 Foundation Bolts:
Engine & Aux.
4 Anchors, Bolts, Misc.
Sub Base &
J Hardware Foundation Bolts 03-630A Pyrometer Conduit Assembly:
Engine Instru-3 l
1-Conduit mentation &
h Wiring 1
j 03-6308 Pyrometer Conduit Assembly:
Engine Instru-3 Conduit Fittings mentation &
i
' "9 03-630C Pyrometer Conduit Assembly:
Engine Instru-3 i
Support mentation &
l Wiring i
j 03-6300 Pyrometer Conduit Assembly:
Engine Instu-3 i
Thermocouples mentation &
Wiring 03-650A Emergency Diesel Generator Generator 4
03-6508 Generator Generator 4
Control 4
03-650C Generator - Shaft Generator 4
& Bearings 03-688A Engine & Aux Module Wiring Engine Instru-3 1
I Material-Conduit & Fittings; mentation &
Pyrometer Conduit Assembly-Wiring Conduit, Fitting, Supports l
L
{O i
x ENTIRE PAGE REVISED 5fh h v..YY&&.t.)s w
.*se.
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O\\
Index (continued) s Component Component Volume Number Description Category No.
03-6888 Engine'& Aux. Module Engine Instru-3 Wiring Material: Wiring mentation &
& Terminations Wiring 03-688C Engine & Aux. Module Wiring Engine Instru-3 Material: Boxes & Terminals mentation &
Wiring 03-689 Off Engine Safety Alarm Engine Instru-3 Sensors Wiring mentation &
Wiring 03-690 On Engine Alarm Sensors Engine Instru-3 mentation &
j Wiring 03-691 Off Engine Alarm Sensors Engine Instru-3 Level & Pressure Switches mentation &
Wiring 03-695A Engine Shutdown Equipment:
Engine Shut-3 O
Tubing / Fittings & Supports down & Equip-ment 03-6958 Engine Shutdown Equipment:
Engine Shut-3 Valves, Regulator, Orifices down & Equip-ment 03-695C Engine Shutdown Trip Engine Shut-3 Switches down & Equip-ment 03-700A Jacket Water Standpipe:
Jacket Water 4
Pipe, Fittings, Gaskets 03-7008 Jacket Water Standpipe:
Jacket Water 4
Valves 03-700C Jacket Water Standpipe:
Jacket Water 4
Supports 03-700E Jacket Water Standpipe:
Jacket Water 4
Switches 03-700F Jacket Water Standpipe:
Jacket Water 4
4 Misc. Bolting Mat.
()
xi ENTIRE PAGE REVISED e +. h s. AE'lib?e.
_... w &
Index (continued)
Component Component Volume Number Description Category
'No.
03-715A Sub Base - Sub Base Engine & Aux.
4 Engine & Generator Sub Base &
Foundation Bolts 03-715B Sub Base Engine & Aux.
4 Bolting Sub Base &
Foundation Bolts 03-717A Aux Sub Base & Oil & Water Jacket Water 4
Piping - Aux. Skid 03-717B Aux Sub Base & 011 & Water Jacket Water 4
Piping - Jacket Water:
Valves 03-717C Aux. Sub Base & 011 & Water Jacket Water 4
Piping - Jacket Water - Pipe Couplings, Fittings, Orifices and Strainers 03-717D Aux Sub Base & Oil & Water Jacket Water 4
O Piping - Jacket Water:
Gaskets & Bolting 03-717F Aux. Sub Base & Oil & Water Jacket Water 4
Piping - Jacket Water:
Gaskets & Bolting 03-717G Aux. Sub Base & Oil & Water Jacket Water 4
Piping - Jacket Water:
Supports 03-717H Aux. Sub Base & Oil & Water Lube Oil 2
Piping - Lube Oil:
Pipe and Fittings 03-717I Aux Sub Base & 011 & Water Lube Oil 2
Piping - Lube Oil Valves 03-717J Aux. Sub Base & 011 & Water Lube Oil 2
Bolting 03-717K Aux. Sub Base & 011 & Water Lube Oil 2
Water Piping - Lube Oil-Supports & Mounting Hardware m
xit ENTIRE PAGE REVISED j
be (4m.
n ts.s.
.?s
Index (continued)
Component Component Volume Number Description Category No.
03-717L Aux. Sub Base & 011 & Water Lube Oil 2
Piping - Lube Oil:
Automatic Switchover Assembly 03-717M Aux. Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel 011: Piping and Fittings 03-717N Aux. Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel 011: Valves 03-717P Aux Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel Oil - Gaskets
& Bolting 03-717Q Aux. Sub Base & 011 & Water Fuel Oil 4
i Piping - Fuel 011:
Supports 03-800A Misc. Equipment - Heater, Jacket Water 4
Jacket Water 03-800A Misc. Equipment - Heater, Lube Oil 4
Lube Oil Sump Tank 03-805B Intake Air Filter Turbo, Intake, 2
Intercooler &
Exhaust 03-805D Flex Connections Turbo, Intake, 2
Intercooler &
Exhaust 03-810B Jacket Water Standby Heater Jacket Water 4
Pump 03-820A Lube Oil Heat Exchanger Lube Oil 2
03-820B Full Flow Lube Oil Filter Lube Oil 2
03-820C Before-and-After Lube Oil Lube Oil 2
Pump ENTIRE PAGE REVISED xiii
- +69.
4 f
Index (continued)
Component Component Volume Number Description Category No.
l 03-8200 Oil Prelube Filter Lube Oil 2
03-825A Fuel Oil Booster Pump Fuel Oil 2
03-825C Fuel Oil Fuel Oil 4
Filters & Strainers:
Strainers 03-835A Starting Air Tank Air Start &
3 j
Barring Device 03-8350 Starting Air Compressor Air Start &
3 Barring Device 03-835F Air Start System -
Air Start &
3 Starting Air Float Trap Barring Device 02-835G Starting Air Tank Air Start &
3 Relief Valve Barring Device
! O i
l O
. V xiv ENTIRE PAGE REVISED
.ws,,
.w.in e a.
..r-s.
COMPONENT DESIGN REVIEW CHECKLIST RIVER BEND STATION - UNIT 1 COMPONENT Starting Air Compressor UTILITY Gulf States Utilities GROUP PARTS LIST NO.
03-8350 TASK DESCRIPTION NO. DR-06-03-8350-1 SNPS GPL NO.10-112 CLASSIFICATION TYPE C
TASK DESCRIPTION Design review for this component is not required based on the lead engine DR/QR report (Shoreham) and the applicable industry and site experience listed in the EDG Component Tracking System.
A 10CFR21 notification written against this component, and listed in the Component Tracking System, deals with the possibility of the loss of starting air due to a seismic event.
This failure.could take place along the sensing line connecting the starting air receiving tank to the air compressor.
The receivers and sensing lines are seismic while the compressor is non-seismic.
1 The design at River Bend incorporates the recommended restriction orifice in the sensing line to allow sufficient time for valve closure prior to reaching i
the critical tank pressure of 150 psig, therefore, no corrective action is required by River Bend.
Site operating and maintenance procedures should be reviewed to verify that the manufacturer's maintenance recommendations are met.
There are no modification recommendations for this component.
Quality revalidation is not required for this component.
PRIMARY FUNCTION j
Not required l
ATTRIBUTE TO BE VERIFIED Not required O
RB2843/1 REV 1 i
n
,3 Page 1 of 2 (g
COMP 0NENT DESIGN REVIEW CHECKLIST RIVER BENO STATION - UNIT 1 COMPONENT Pistons UTILITY Gulf States Utilities GROUP PARTS LIST NO. 03-341A TASK DESCRIPTION NO.
DR-06-03-341A-1 SNPS GPL NO. 03-341A CLASSIFICATION TYPE A
TASK DESCRIPTIONS i
Design review for this component is not required based on a review of the lead engine OR/QR reports (Shoreham/ Comanche Peak), the Phase I report and the applicable site and industry experience in the EDG Component Tracking System.
River Bend has changed piston skirts from the originally supplied AN skirts to the product improvement AE piston skirts.
The AE piston skirt incorporates design changes such as thickening the stud boss region and blending the rib (which has also been thickened) more smoothly into the wrist pin bosses.
There are no maintenance or modification recommendations for this component.
' h Liquid penetrant tests performed by TDI on the stud and pin boss areas of all V
sixteen replacement AE skirts were satisfactory.
The following Quality inspections as delineated in the CQRC are recommended:
Perform a liquid penetrant test on the rib area near the wrist pin and on the rib at the intersection of the wrist pin boss to check for indications in the casting.
If no rejectable indications are found, inspections should be performed on one station engine only.
Visually inspect the piston crown outside diameter for scuffing, and the combustion bowl in the crown for pitting.
(Engine 18 Only).
Note:
The liquid penetrant test should be performed during the j
next major engine overhaul or the next time the pistons are 1
l removed, whichever comes first.
I PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required O
RB2687/1 REV 1 l
COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-06-03-341A-1 SPECIFIED STANDARDS Not required l
REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON I T d l m PROGRAM MANAGER M \\4 w um i
7 a'
{
)
!O I
o O
aEv. 1 CARRY OVER FROM PREVIOUS PAGE,
RB2687/2 I
Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST RIVER BEND STATION - UNIT 1 COMPONENT Piston: Rings UTILITY Gulf States Utilities GROUP PARTS LIST NO.
03-341B TASK DESCRIPTION NO. DR-06-03-3418-0 SNPS GPL NO.
03-3418 CLASSIFICATION TYPE A
i TASK DESCRIPTIONS Des.gn review for this component is not required based on the following:
A review of the Comanche Peak and Shoreham DR/QR Reports, which establish the acceptability of the piston rings for their intended purpose.
The applicable engine dimensions and operating parameters at River Bend are identical or very similar to those for the same component at Shoreham (Lead Engine).
A review of the EDG Component Tracking System applicable industry experience.
No site specific experience is listed in the Component Tracking System.
Maintenance recommendations based on the Comanche Peak DR/QR Report to ensure proper performance under normal operating conditions are as follows:
Inspect and measure replacement piston rings in accordance with TDI inspection and maintenance records.
l To assure freedom from harmful scuffing, the cylinder liners should be inspected at each refueling outage to evaluate liner wear and coke deposits.
Ring replacements and cylinder liner honing should be performed with TDI maintenance procedures.
When replacing engine oil use H.D. oil that exceeds series 3 standards.
The base stock should be more resistant to thermal degradation and coke formation.
The additive package should provide high detergent dispersant properties with high alkalinity and a high level of antiwear additive such as zinc dithiophosphate.
Total Base Number (TBN) should be 12 to 15 for use with #2 fuel oil and a sulfated ash content of 1.5% to 2.0% is preferred.
An engine oil with such properties, Mobilguard 412 or an equivalent product, may be used to insure improved lubrication.
A 135* fuel oil spray tips may be used if inspections results indicate a V
need for additional action to improve lubrication and reduce coke buildup.
(River Bend has installed 135' spray tips (Ref. 1) in their fuel injection nozzle assemblies) 1 RB2407/1 Rev. 1
/
COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-06-03-3418-0 TASK DESCRIPTIONS (continued)
The following Quality Revalidation inspection recommendations are made to ensure proper component quality and performance and should be performed on both diesel engines:
Verify that the piston ring installation is in compliance with the TDI assembly requirements.
Perform a visual inspection of the rings for signs of wear, pitting an flaking.
Perform a visual inspection of the rings and ring grooves for carbon build up.
There are no modification recommendations for this component.
PRIMARY FUNCTION Not required O
ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES River Bend E&DCR C-24,947 A,
" installation of 135* fuel injection tips",
1 l
9/24/84.
4 DOCUMENTATION REQUIRED Not required y '$
e GROUP CHAIRPERSON d d!b 1.
PROGRAM MANAGER 3 C\\4c - h m
v RB2407/2 Rev. 1
p COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 Q
DR-06-03-350C-1 DR-06-03-355A-1 DR-06-03-3558-1 03-355A and B, Idler Gear Assembly - Crank to Pump Gear & Idler Gear:
Perform a visual inspection on the idler gear teeth for signs of wea, pitting, or any other discontinuities, on Engine 1A.
)
Determine the material of the crank to pump gear, on Engine 1A.
Material to be C1040.
Perform a visual inspection on the crank to pump gear set teeth and idler gear teeth for signs of wear,
- pitting, or any other discontinuities on Engine 18.
PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON I T j
PROGRAM MANAGER M\\4%me Q
C RB2547/3 Rev.
1 l
f-COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 E
DR-06-03-350C-1 DR-06-03-355A-1 DR-06-03-3558-1 l
03-355A and B, Idler Gear Assembly - Crank to Pump Gear & Idler Gear:
Perform a visual inspection on the idler gear teeth for signs of wear, pitting, or any other discontinuities, on Engine 1A.
)
Determine the material of the crank to pump gear, on Engine 1A.
Material to be C1040.
Perform a visual inspection on the crank to pump gear set teeth and idler gear teeth for signs of wear,
- pitting, or any other discontinuities on Engine 18.
PRIMARY FUNCTION 1
Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required i
DOCUMENTATION REQUIRED Not required GROUP CHAIRPERS0h f_ T d.
PROGRAM MANAGER d\\4~ ae g
J RB2547/3 Rev.
l
Appendix B Page 1 of 4 06-03-355A & B COMPONENT QUALITY REVALIDATION CHECKLIST Idler Gear Assembly - Crank Gulf States Utilities, COMPONENT to Pump Gear & Idler Gears UTILITY River Bend Station GPL NO. 03-355A & B REV. NO.
2 SNPS GPL NO. 03-355A & B TASK OESCRIPTIONS Engine 1A 1.
Assemble and review existing documentation.
2.
Perform a visual inspection on the crank to pump gear set teeth and idler gear teeth for signs of wear,
- pitting, or any other discontinuities.
3.
Determine the hardness of the idler gears.
,)
4.
Determine the material of the crank to pump gear and idler gears.
Engine 10 1.
Assemble and review existing documentation.
2.
Perform a visual inspection on the crank to pump gear set teeth and idler gear teeth for signs of wear,
- pitting, or any other discontinuities.
ATTRIBUTES TO BE VERIFIED Engine 1A 1.
Quality status of Component Document Package 2.
Surface integrity of the crank to pump gear and idler gears 3.
Hardness of the gears 4.
Material of the gears RB2109/1 Rev. 1.
O Index (continued)
Component Component Volume Number Description Category No.
F-068 Intercooler Turbo, Intake, 2
Intercooler &
Exhaust MP-020 Turbocharger Turbo, Intake, 2
)
Intercooler &
Exhaust 00-420 Lube Oil Pressure Regulating Lube Oil 2
Valve 03-CFR Turbocharger Thrust Bearing Turbo, Intake, 2
Drip Lube System Intercooler &
Exhaust 03-305A Base and Bearing Caps: Base Engine Base 2
Assembly
& Bearing Caps O
03-305C Base and Bearing Caps:
Engine Base 2
Main Bearing Studs & Nuts
& Bearing Caps 03-3050 Base and Bearing Caps:
Engine Base 2
Main Bearing Caps
& Bearing Caps 03-305E Base and Bearing Caps -
Engine Base 2
Through Bolting
& Bearing Caps 03-307A Lube Oil Fittings:
Lube Oil 2
Internal - Headers 03-307B Lube Oil Fittings:
Lube Oil 2
Internal - Tubing &
Fittings 03-3070 Lube Oil Fittings Internal:
Lube Oil 2
Supports 03-310A Crankshaft Crankshaft &
2 Bearings 03-310B Main Bearings Crankshaft &
2 Bearing 03-310C Crankshaft & Bearings:
Crankshaft &
2 O
Thrust Bearing Rings.
Bearing 11 ENTIRE PAGE REVISED 4
.-c
~
Index (continued) s Component Component Volume Number Description Category No.
03-315A Cylinder Block Cyl. Block &
2 Liners & Water Manifold 03-315C Cylinder Block Liners &
Cyl. Block &
2 Water Manifold -
Liners &
Cylinder Liner Water Manifold 03-315D Cylinder Block Liners &
Cy1. Block &
2 Water Manifold:
Jacket Liners &
Water Manifold & Piping Water Manifold 03-315E Cylinder Block Liners &
Cyl. Block &
2 Water Manifold: Studs Liners &
Water Manifold 03-315F Cylinder Block Liner Cyl. Block &
2
& Water Manifold:
Liner & Water Cylinder Head Nuts Manifold 03-315G Cylinder Block Liners &
Cyl. Block &
2 O
Water Manifold: Seals &
Liners &
Gaskets Water Manifold 03-317A Water Discharge Manifold:
Jacket Water 4
Jacket Water Discharge Manifold 03-3178 Water Dicharge Manifold:
Jacket Water 4
Coupling & Seals 03-317C Water Discharge Manifold:
Jacket Water 4
Supports 03-330A Flywheel Flywheel 3
03-330B Flywheel - Bolting Flywheel 3
03-3358 Front Gear Case: Gaskets and Idler Gear As-3 Bolting sembly & Front Gear Case 03-340A Connecting Rods:
Connecting 3
Rods & Bushings Rods O
111 ENTIRE PAGE REVISED
Index (continued)
Component Component Volume Number Description Category No.
03-340B Connecting Rods: Bearing Connecting 3
Shells Rods 03-341A Pistons Pistons 3
03-341B Pistons: Rings Pistons 3
03-341C Piston: Pin Assembly Pistons 3
03-345A Tappets and Guides:
Intake Camshaft &
3
& Exhaust Tappet Assembly Valve Train f
03-345B Tappets and Guides: Fuel Camshaft &
3 Tappet Assembly Valve Train 03-345C Tappets and Guides: Fuel Camshaft &
3 Pump Base Assembly Valve Train 2
03-350A Camshaft:
Camshaft Camshaft &
3 Assembly Valve Train 0
03-3508 Camshaft:
Camshaft Camshaft &
3 Bearing Valve Train 1
03-350C Camshaft: Supports, Bolting Camshaft &
3
)
and Gear Valve Train 03-355A Idler Gear Assembly: Crank Idler Gear As-3 To Pump Gear sembly & Front Gear Case 03-355B Idler Gear Assembly Idler Gear As-3 sembly & Front Gear Case i
03-355C Idler Gear Assembly:
Idler Gear As-3 Gaskets & Bolting sembly & Front Gear Case 03-359 Air Start Valve Air Start &
3 l
Barring Device i
03-360A Cylinder Heads Cylinder Heads 4
& Valves O
l iv ENTIRE PAGE REVISED i
Index (continued)
Component Component Volume Number Description Category No.
03-3608 Cylinder Head Valves:
Cylinder Heads 4
Intake & Exhaust Valves
& Valves 03-360C Cylinder Head and Valves:
Cylinder Heads 4
Bolting and Gaskets
& Valves 03-360D Cylinder Head and Cylinder Heads 4
Values:
Springs
& Valves and Retainer 03-362A Subcovers Camshaft &
3 Valve Train 03-365A Fuel Injection Equipment Fuel Oil In-4 Fuel Injection Pump jection 03-365B Fuel Injection Equipment Fuel Oil In-4 Fuel Injection Tips jection 03-365C Fuel Injection Equipment -
Fuel Oil In-4 Tube Assembly jection 03-365D Fuel Injection Equipment:
Fuel Oil In-4 Supports jection 03-371A Fuel Pump Control Shaft, Fuel Oil In-4 Linkage Assembly & Bearings jection 03-371B Fuel Pump Linkage: Linkage Fuel Oil In-4 Assembly and Bearing jection 03-371C Fuel Pump Linkage:
Fuel Oil In-4 Automatic Shutdown jection Cylinder 03-375 Air Intake Manifold and Turbo, Intake, 2
)
Piping Intrcir. & Ex-haust 03-380A Exhaust Manifold Turbo, Intake, 2
Intrcir. & Ex-haust 03-3808 Exhaust Manifold: Gasket Turbo, Intake, 2
and Bolting Intrcir. & Ex-haust 4
l 0U v
ENTIRE PAGE REVISED i
Index (continued)
Component Component Volume Number Description Category No.
03-385B Cylinder Block Covers:
Cyl. Block &
2 Gaskets and Bolting Liners & Water Manifold 03-387A Crankcase Ventilator:
Crankshaft &
2 Crankcase Vacuum Fan Bearings 03-390A Intake & Intermediate and Camshaft &
3 Exhaust Rocker Shaft Assembly Valve Train 03-3908 Rocker Arms and Pushrods:
Camshaft &
3 Exhaust Rocker Shaft Valve Train Assembly 03-390C Main and Connector Camshaft &
3 Pushrods Valve Train J
03-3900 Rocker Arms and Pushrods:
Camshaft &
3 Pushrods Connector.
Valve Train i
03-390E Rocker Arms and Pushrods:
Camshaft &
3 8
Bushings Valve Train 03-390F Rocker Arms and Pushrods:
Camshaft &
3 Lifters Valve Train 03-390G Rocker Arms and Pushrods:
Camshaft &
3 Miscellaneous Bolts &
Valve Train Drive Studs 03-402A Governor Drive - Governor Overspeed Trip 3
& Tachometer Drive
& Governor Gear & Shaft 03-402B Governor Drive - Couplings, Overspeed Trip 3
Pins & Keys
& Governor 03-410A Overspeed Trip:
Governor Overspeed Trip 3
& Governor 03-410B Overspeed Trip: Governor Overspeed Trip 3
and Accessory Drive Assembly
& Governor 03-410C Overspeed Trip: Coupling Overspeed Trip 3
(Flexible & Spider)
& Governor O
vi ENTIRE PAGE REVISED t
Index (continued)
Component Comporent Volume Number Description Category No.
03-410D Overspeed Trip Vent Valve Overspeed Trip 3
& Governor 03-413 Governor Linkage Overspeed Trip 3
& Governor 03-415A Governor Assembly: Woodward Overspeed Trip 3
Governor
& Governor 03-4158 Governor Assembly Overspeed Trip 3
Booster Servomotor
& Governor 03-415C Governor Assembly Overspeed Trip 3
Heat Exchanger
& Governor 03-420 Engine Driven Lube Oil Pump Lube Oil 2
03-425A Engine Driven Jacket Water 4
Jacket Water Pump 03-435A Jacket Water Fittings:
Jacket Water 4
O Pipe & Fittings 1
03-4358 Jacket Water Fittings:
Jacket Water 4
Piping, Tubing & Supports 03-437A Turbo Water Piping:
Jacket Water 4
Pipe & Fittings 03-437B Turbo Water' Piping:
Supports Turbo Intake 2
Intercooler &
Exhaust 03-441A Starting Air Manifold:
Air Start &
3 Piping, Tubing and Fitting Barring Device 03-441B Starting Air Manifold Air Start &
3 Valves, Strainers, Filters Barring Device 03-441C Starting Air Manifold:
Air Start &
3 Supports Barring Device 03-442A Starting Air Distributor:
Air Start &
3 Distributor Assembly Barring Device 03-442B Starting Air Distrioutor:
Air Stitrt &
3 Tubing, Fittings & Gaskets Barring Device vii ENTIRE PAGE. REVISED l
l
bi Index (continued)
V Component Component Volume Number Description Category No.03-445 Engine Driven Fuel Oil Fuel Oil In-4 Booster Pump jection 03-4508 Fuel Oil Header:
Fuel Oil In-4 Piping & Tubing jection 03-4500 Fuel Oil Header:
Fuel Fuel Oil In-4 Oil Supports jection 03-455A Fuel Oil Filters &
Fuel Oil In-4 Strainers: Fuel Oil Filters jection 03-4558 Fuel Oil Filters &
Fuel Oil In-4 Strainers:
Strainers jection 03-455C Fuel Oil Filters &
Fuel Oil In-4 Strainer: Mounting Hardware jection 03-460A Lube Oil Full Pressure Lube Oil 2
Strainer 03-465A
-Lube Oil Lines External:
Lube Oil 2
Tubing, Fittings, Couplings 03-465B Lube Oil Lines - External Lube Oil 2
Supports 03-465C Lube Oil Lines - External:
Lube Oil 2
4 Valves 03-467A Turbocharger: Lube Oil Lube Oil 2
j Fitting - Pipe, Tubing,
)
Fittings & Flexible Coupling 03-467B Turbocharger: Lube Oil Lube Oil 2
Fittings - Supports 03-475A Turbocharger: Bracket Turbo, Intake, 2
Intrcir. & Ex-haust 03-475B Turbocharger - Bracket:
Turbo, Intake, 2
Air Butterfly Valve Intrcir. & Ex-As.mmbly haust l
i i
l viii ENTIRE PAGE REVISED I
Index (continued)
J Component Component Volume Number Description Category No.
03-475C Turbocharger: Bracket -
Turbo, Intake, 2
Air Intake Piping Intrcir. & Ex-haust 03-4750 Turbocharger Bracket Turbo, Intake, 2
Bolting & Gaskets Intercooler &
Exhaust s
03-475E Turbocharger - Bracket -
Turbo, Intake, 2
Pipe Support Intercooler &
Exhaust 03-500A Control Panel Assembly:
Control Panel 4
Cabinet / System Assembly 03-500F Control Panel Assembly Control Panel 4
Accumulator Assembly 03-500G Control Panel Control Panel 4
Valves Assembly 03-500H Control Panel Assembly Control Panel 4
I Pressure Switch Assembly 03-500J Control Panel Assembly:
Control Panel 4
Control Relays Assembly 03-500K Control Panel Assembly:
Control Panel 4
j Solenoid Valves Assembly 03-500M Control Panel Components:
Control Panel 4
i Piping, Tubing, Fittings Assembly 03-500N Control Panel Assembly:
Control Panel 4
Terminal Boards / Switches /
Assembly Wiring l
03-515 Jacket Water Thermostatic Jacket Water 4
Valve 03-5258 Barring Device - Pneumatic:
Air Start &
3 Regulator Valve Shut Off Barring Device Valve 03-5250 Barring Device Support Air Start &
3 Bracket Barring Device ix ENTIRE PAGE REVISED a
,y-.
.c-.
c.
Index (continued)
Component Component Volume Number Description Category No.
03-540A Lube Oil Sump Tank - Tank Lube Oil 2
with Strainer Assembly 03-5408 Lube Oil Sump Tank: Misc.
Lube Oil 2
Fittings, Gaskets, Pipe &
Bolting Material, Valves 03-540C Lube Oil Sump Tank:
Lube Oil 2
Mounting Hardware 03-550 Foundation Bolts:
Engine & Aux, 4
Anchors, Bolts, Misc.
Sub Base &
Hardware Foundation Bolts 03-630A Pyrometer Conduit Assembly:
Engine Instru-3 Conduit mentation &
Wiring 03-630B Pyrometer Conduit Assembly:
Engine Instru-3 O
Conduit Fittings mentation &
Wiring 03-630C Pyrometer Conduit Assembly:
Engine Instru-3 Support mentation &
Wiring 03-630D Pyrometer Conduit Assembly:
Engine Instu-3 Thermocouples mentation &
Wiring l
03-650A Emergency Diesel Generator Generator 4
03-650B Generator Generator 4
Control 03-650C Generator - Shaft Generator 4
& Bearings 03-688A Engine & Aux Module Wiring Engine Instru-3 Material-Conduit & Fittings; mentation &
Pyrometer Conduit Assembly-Wiring Conduit, Fitting, Supports l
x ENTIRE PAGE REVISED 5
Index (continued)
Component Component Volume Number Description Category No.
03-688B Engine & Aux. Module Engine Instru-3 Wiring Material: Wiring mentation &
& Terminations Wiring 03-688C Engine & Aux. Module Wiring Engine Instru-3 l
Material: Boxes & Terminals mentation &
Wiring 03-689 Off Engine Safety Alarm Engine Instru-3 Sensors Wiring mentation &
Wiring 03-690 On Engine Alarm Sensors Engine Instru-3 mentation &
Wiring 03-691 Off Engine Alarm Sensors Engine Instru-3 Level & Passure Switches mentation &
Wiring l
l 0:< e95A Engine Shutdown Equipment:
Engine Shut-3 O
Tubing / Fittings & Supports down & Equip-ment 03-6958 Engine Shutdown Equipment:
Engine Shut-3 Valves, Regulator, Orifices down & Equip-ment 03-695C Engine Shutdown Trip Engine Shut-3 Switches down & Equip-ment 03-700A Jacket Water Standpipe:
Jacket Water 4
Pipe, Fittings, Gaskets 03-7008 Jacket Water Standpipe:
Jacket Water 4
Valves 03-700C Jacket Water Standpipe:
Jacket Water 4
Supports 03-700E Jacket Water Standpipe:
Jacket Water 4
Switches 03-700F Jacket Water Standpipe:
Jacket Water 4
Misc. Bolting Mat.
xi ENTIRE PAGE REVISED
Index (continued)
Component Component Volume Number Description Category No.
03-715A Sub Base - Sub Base Engine & Aux.
4 Engine & Generator Sub Base &
Foundation Bolts 03-715B Sub Base Engine & Aux.
4 Bolting Sub Base &
Foundation Bolts 03-717A Aux Sub Base & 011 & Water Jacket Water 4
Piping - Aux. Skid 03-717B Aux Sub Base & Oil & Water Jacket Water 4
Piping - Jacket Water:
Valves 03-717C Aux. Sub Base & 011 & Water Jacket Water 4
Piping - Jacket Water - Pipe Couplings, Fittings, Orifices and Strainers 03-717D Aux Sub Base & 011 & Water Jacket Water 4
O Piping - Jacket. Water:
Gaskets & Bolting 03-717F Aux. Sub Base & Oil & Water Jacket Water 4
Piping - Jacket Water:
Gaskets & Bolting 03-717G Aux. Sub Base & Oil & Water Jacket Water 4
Piping - Ja'cket Water:
Supports 03-717H Aux. Sub Base & Oil & Water Lube Oil 2
Piping - Lube Oil:
Pipe and Fittings 03-717I Aux Sub Base & 011 & Water Lube Oil 2
Piping - Lube Oil Valves 03-717J Aux. Sub Base & Oil & Water Lube Oil 2
Bolting 03-717K Aux. Sub Base & Oil & Water Lube Oil 2
Water Piping - Lube Oil:
Supports & Mounting Hardware xii ENTIRE PAGE REVISED
1 Index (continued)
O Component Component Volume Number Description Category No.
03-717L Aux. Sub Base & 011 & Water Lube Oil 2
Piping - Lube Oil:
Automatic Switchover Assembly 03-717M Aux. Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel 011: Piping and Fittings 03-717N Aux. Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel 011: Valves 03-717P Aux Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel Oil - Gaskets
& Bolting 03-717Q Aux. Sub Base & 011 & Water Fuel Oil 4
Piping - Fuel 011:
Supports 03-800A Misc. Equipment - Heater, Jacket Water 4
Jacket Water 03-800A Misc. Equipment - Heater, Lube Oil 4
Lube Oil Sump Tank 03-805B Intake Air Filter Turbo, Intake, 2
Intercooler &
Exhaust 03-805D Flex Connections Turbo, Intake, 2
Intercooler &
Exhaust 03-810B Jacket Water Standby Heater Jacket Water 4
Pump 03-820A Lube Oil Heat Exchanger Lube Oil 2
03-820B Full Flow Lube Oil Filter Lube 011 2
03-820C Before-and-After Lube Oil Lube Oil 2
Pump ENTIRE PAGE REVISED O
xiii l
l
=
Index (continued)
Component Component Volume Number Description Category No.
03-8200 Oil Prelube Filter Lube Oil 2
03-825A Fuel Oil Booster Pump Fuel Oil 2
03-825C Fuel Oil Fuel Oil 4
Filters & Strainers:
Strainers 03-835A Starting Air Tank Air Start &
3 Barring Device 03-835D Starting Air Compressor Air Start &
3 Barring Device 03-835F Air Start System -
Air Start &
3 j
Starting Air Float Trap Barring Device 02-835G Starting Air Tank Air Start &
3 Relief Valve Barring Device
- O O
xiv ENTIRE PAGE REVISED
Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST RIVER BEND STATION - UNIT 1 Jacket Water Standpipe:
COMPONENT Valves UTILITY Gulf States Utilities GROUP PARTS LIST NO. 03-700B TASK DESCRIPTION NO. DR-06-02-700B-1 SNPS GPL NO. 00-7008 CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following:
A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR report (Shoreham)
The following maintenance recommendations from the lead engine DR/QR should be implemented:
Inspect the valves for packing leakage monthly Replace elastomeric parts every 5 years There are no modifications recommended for this component.
The following Quality inspections are recommended:
Verify the proper Jacket Water Valve is intalled (2 in. Globe valve P/N 74039-1301 Note:
This valve is used to drain the jacket water standpipe and is listed under GPL No.03-717.
I Verify the proper installation of the Jacket Water Valve in accordance with the manufacturers bulletin.
PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED by Not required RB2932/1 Rev. 1
I i
Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST RIVER BEND STATION - UNIT 1 Fuel Injection Equipment:
COMPONENT Fuel In.iection Tips UTILITY Gulf States Utilities GROUP PARTS LIST NO.
03-365B TASK DESCRIPTION NO. DR-06-03-3658-0 SNPS GPL NO. 03-365B CLASSIFICATION TYPE B
TASK DESCRIPTIONS Design review for this component is not required based on the following:
A review of the EDG Component Tracking System indicated that there was no significant applicable industry and site experience, except
{
for that which was previously addressed in the lead engine -reports.
A review of the lead engine DR/QR reports (Shoreham and Comanche Peak)
The fuel injection nozzle assembly used at River Bend is of the same manufacturer and type as that used at Shoreham (i.e, Bendix, type H4L-400, Holder No. 10-328850-5, Tip No. 10-84802-30).
1 The following maintenance from the lead engine DR/QR report should be I
implemented:
At each refueling outage each assembly should be disassembled, cleaned, inspected and reassembled.
At this time each assembly
]
should be pop tested and the spray pattern should be checked.
TDI SIM 107 (cleaning spray tips) and SIM 108 (Tightening of Delivery Valve Holders) should be incorporated into the site maintenance procedures.
l There are no modifications required for this component,. based on the lead j
engine reports.
I There is no Quality Revalidation required for this component.
PRIMARY FUNCTION Not required l
t i
RB2721/1 Rev. 1
' O TDI OWNERS GROUP for RIVER BENO STATION - UNIT 1 GENERATOR CONTROLS COMPONENT PART NO. 03-650B I
INTRODUCTION I
The TDI Emergency Diesel Generator Owners Group Program for the River Bend Station requires Design and Quality Revalidation reviews of the generator-controls (manufactured by Electric Products Divir, ion, Portec, Inc.), Part No. 72-10300-100 to determine the adequacy of the design for the ~ intended use at River Bend.
The primary function of the generator 1
controls is to provide field current for the generator and to regulate the voltage of the 4.16-kV emergency bus.
This is accomplished by the static exciter, which is the subject of this report.
j The static exciter consists of the following subcomponents:
The diode bridge rectifier assembly and diverter silicon controlled O
rectifiers (SCRs), which together supply the field current.
The voltage regulator, which controls the SCR firing circuits such that generator output voltage is maintained constant.
The SCR firing circuits, which supply firing pulses to the diverter SCRs.
The motor driven potentiometer which is used to adjust the emergency 1
bus voltage.
The field flashing circuit, which ensures self excitation of the generator.
The power potential transformer (PT), current transformers'(cts) and linear reactors, which supply the required AC voltage to the rectifier bridge and SCRs.
The generator control cabinets as discussed in this report consist of a j
double depth set of cabinets, three cabinets wide.
The bridge rectifier assembly, the voltage regulator, the SCR firing circuits, and the field i
flashing circuit are contained in the left-front cabinet.
The power PT l1 is in the bottom of the right cabinet and is mounted on the floor halfway-between the front and rear panels.
The power cts and linear reactors are 3
mounted in the left-rear and center-rear cabinets.
For reference the l1 i
cabinet behind the left front is designated left rear.
The governor controls and motor driven potentiometer are mounted in the center-front i
cabinet.
j i
R82828/1 1
O Page 2 of 15 II. OBJECTIVE The objective of this review is to verify the adequacy of the design and construction of the static exciter for its intended use at River Bend.
III METHODOLOGY The Emergency Diesel Generator Component Tracking System (Ref. 1) was reviewed for industry experience and the following subcomponents were identified for a detailed design review:
The diode bridge rectifier assembly and the diverter SCRs.
The voltage regulator.
The motor-driven potentiometer.
The field flashing circuit.
The linear reactors in the power circuit.
Octailed design review calculations (Ref. 2) were performed for the above subcomponents.
Specifically, calculations were made to verify the adequacy of the following:
The continuous and surge current ratings of the diodes and the SCRs.
The ratings of the components of the motor-driven potentiometer circuit.
The ratings of the components of the field flashing circuit.
The thermal design of the linear reactors.
The design of the voltage regulator was evaluated qualitatively (Ref. 2).
The diesel generators at River Bend were inspected on October 8, 1984 (Ref. 3).
Construction details, arrangement and mounting of the sub-components of the static exciter were studied.
Recommendations for maintenance procedures or modifications were made to address the various design and construction deficiencies found in the above subcomponents of the static exciter.
Other failure incidents reported in the EDG Component Tracking System printouts not involving the above subcomponents were reviewed and the results are given in Appendix C of this report.
Quality Revalidation Checklist results were reviewed for acceptability.
7 Applicable TERs were reviewed.
RB2828/2
Page 3 of 15 IV RESULTS AND CONCLUSIONS The Emergency Diesel Generator Component Tracking System does not list any incidents related to the operation of the generator controls at River Bend.
One incident listed is a report from the exciter cabinet assembler (RTE Switchgear), which identifies a potential problem in a panel similar to those at River Bend. The problem involves apparent damage to a high voltage knife switch disconnect for one of the sensing potential trans-formers in the exciter system.
This problem has apparently been resolved (Ref. 4) by replacing the switch connection with one of a new design.
This problem has not been reported in any other site experience or industry experience listing and is not considered a generic design inadequacy.
Through correspondence with Portec (Ref. 5) notification of a potential problem with a Westinghouse current transformer (CT) has been received.
This CT is used only for paralleling and is not rated for the proper l1 temperature range of operation and a substitute transformer has been selected by Portec.
The Portec part number for the CT is A-01616-4 and although Reference 5 does not list River Bend as one of the sites having this CT, the Portec assembly list for the exciter (Ref. 6) does show that it was used in assembling the River Bend exciter.
It is recommended that GSU identify the CT that is installed and make arrangements with Portec for replacement if necessary.
Notification of a potential design deficiency in the relay logic circuits associated with the exciter field flashing circuit was received (Ref.
7).
The potential deficiency pertained to overheating of exciter electronic components resulting from prolonged energizing of the field flashing resistor.
A review of the River Bend exciter field flashing relay logic circuits determined that the condition reported represents no unacceptable impact on operation of the generator under emergency conditions.
Under normal starting conditions, failure of certain exciter circuit components could cause a prolonged period of field flashing resistor energization.
In order to prevent overheating of the resistor and the possible resulting component damage, it is recommended that all 1
normal engine starts be monitored to assure that an unsuccessful start does not result in a prolonged period of field flashing resistor energization.
A manual reset of the exciter should be initiated if the resistor is energized for more than 10 seconds.
Notification has been received regarding a potential problem with Multi-Amp, States Division terminal blocks manufactured between 1974 and 1976 (Ref. 9).
It is recommended that River Bend inspect the generator control cabinets and if found, replace these terminal blocks with a suitable substitute.
The following inadequacies have been discovered as a result of this design review.
O Rev. 1 RB2828/3
Page 4 of 15 The housing of the field flashing relay is inadequate for the 1
I application.
This is a relay operated from the 125-V (nominal) battery source and it closes its contacts to supply the field flashing current.
Failure of the relay to close would make the diesel generator unavailable to supply the safety related loads within the 10-second time requirement.
Several failures of this relay have been reported in industry experience as a result of dirty relay contacts.
It is recommended that this relay be replaced by an enclosed relay.
Detailed recommendations are given in Attachment 1 of this report.
Thermal calculations for the linear reactors that supply current to the exciter show that the temperature rating of the coil insulation will be exceeded if additional cabinet ventilation is not provided.
The reactor coils are built with Class B insulation, which is rated for 130 degrees C (266 degrees F).
Procurement specifications (Ref. 8) require that the generator controls operate with a maximum ambient air temperature in the diesel room of 122 -
degrees F or 50 degrees C. Calculations (Ref. 2) show that at rated current and a surrounding air temperature of 50 degrees C the internal temperature of the coils is 125 degrees C.
However, the reactors are =cunted inside the left-rear and center-rear generator control cabinets, which are vented but not force ventilated.
The heat generated by the reactors themselves will cause a temperature O
rise of at least 10 degrees C.
The coils, therefore, will operate slightly higher than the temperature rating of the insulation if ventilation is not provided.
Detailed recommendations for ventilation of the cabinets are discussed in Attachment 1.
Qualitative evaluation of the design of the voltage regulator indi-cates that although this subcomponent can perform its intended functions, several desirable features that ensure high reliability and performance have not been incorporated in the design.
These features are power supply bypassing, coating of all adjustable potentiometer spindles with Glyptol lacquer, using MIL style multi-turn sealed potentiometers, soldering integrated circuits (ICs) to the printed circuit board (PC) directly instead of mounting in sockets, using double sided PCs, conformal coating of the PC boards, and shielding signal leads.
Detailed recommendations to incorporate these features are made in Attachment 3 of this report.
When the recommendations are implemented, the long-term reliability and performance of the voltage regulator will be enhanced.
As the voltage regulator in its _ present state is adequate to meet its intended functions, implementation of the recommendations of Attach-1 ment 3 is left to the discretion of GSU.
Inspection of the subcomponents reviewed in this report (Ref. 3) revealed the following construction and mounting inadequacies:
O i
RB2828/4 Rev. 1
Page 5 of 15 The diodes and the SCRs of the bridge rectifier assembly are mounted on the heat sink by tapped holes, and no other mounting hardware.
Manufacturer's recommendations reouired drilled holes, nuts and lockwashers.
Westinghouse, the manufacturer of the diodes and SCRs, specifically recommends against mounting using tapped holes.
The generator control cabinets are inadequately ventilated.
Diode and SCR connections are terminated with up to five lugs on one stud, contrary to good wiring practice.
The construction and mounting deficiencies listed above do not presently endanger the diodes and SCR's, but for continued safe operation, these deficiencies must be remedied to ensure proper thermal and electrical contact with the heatsinks and to prevent loosening of the diodes and SCR's from vibration.
Remedial measures are recommended in the form of maintenance and modification procedures as detailed in Attachment 1 of this report, and design and construction modifications as detailed in 1 of this report.
With the exception of installing cooling fans in the exciter cabinets, the recommendations of Attachment 1 may be implemented without significant modification of the existing equipment.
These recommendations will allow monitoring of the temperature of the diodes and the SCRs.
The recommendations of Attachment 2 involve remounting of the diodes and SCRs, and redesign of the cable terminations.
O These recommendations must be implemented at the first refueling outage of the plant or earlier at the discretion of GSU.
Recommandations to remedy the design and construction deficiencies are orgs.iized as follows:
l l
- - the recommendations must be implemented prior to i
placing the engine in emergency standby service to enable monitoring of the diodes and SCR's.
Recommendations are also made concerning l1 the field flashing relay, linear reactors, heatsink wiring, and voltage regulator.
the recommendations must be implemented at the first refueling outage of the plant or earlier at the discretion of i
GSU.
When the recommendations are implemented the maintenance pro-cedures in Sections IA, IB, and IC of Attachment 1 will no longer be necessary.
t
- - the recommendations should be implemented at the discretion of GSU to enhance the long-term reliability and performance of the voltage regulator.
These recommendations represent design changes to the equipment and would best be 1
implemented by the manufacturer at the request of GSU.
O RB2828/5
n Page 6 of 15 V
Other incidents reported in the EDG Component Tracking System not involving the subcomponents considered in this report were reviewed.
The results are given in Appendix C of this report.
It was found that the failures were not of generic nature and do not impact the conclusions of this report.
The information provided on TER 06-077 dated November 1,1984, has been reviewed and is consistent with the final conclusions of this report.
The results of the Quality Revalidation Inspections performed to date and identified in Appendix B of this report have been reviewed and considered in the performance of this design review and are consistent with the final conclusions of this report.
Based upon the above review, it is concluded that the generator controls are adequate for their intended use at River Bend if all the recommenda-I tions of Attachment 1 of this report are adopted. of this report must be implemented at the first refueling outage or earlier at the discretion of GSU.
When the recommendations of are implemented the recommendations in Section IA, IB, and IC of Attachment 1 will no longer be necessary.
Recommendations of Attach-ment 3 of this report may be implemented at the discretion of GSU to improve the long-term reliability.
V REFERENCE 1.
Component Tracking System printout for River Bend Station, Component Part. No. 03-6508, dated 10/10/84.
2.
FaAA design review support package SP-84-6-46 (g).
3.
Alexander Kusko, Inc. Trip Report, River Bend Station, 10/08/84.
I 4.
Letter from Mr.
B.
G.
Schultz of Stone and Webster to Mr.
W.
J.
Cahill, Jr., of GSU dated March 7,1984.
5.
Letter from H. A. Ashby of Portec dated 08/02/84.
6.
Portec assembly list No. 72-10300-100.
l 7.
Letter from Mr. R. W. Helmick of River Bend Nuclear Group to Mr. C.
l L. Ray of Duke Power Company dated 11/02/84.
l 8.
Stone and Webster Procurement Specification 244-700 dated May 5, 1980, Rev. 2.
9.
Letter from Mr. R. D. Libbey of States Division to Mr. T. M. Jacob i
of SWEC dated August 4, 1980.
O Rev. 1 RB2828/6
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Page 7 of 15 i
River Bend Station Maintenance and Modification Procedures - Generator Controls I.
BRIDGE RECTIFIER ASSEMBLY The recommendations below pertain to the bridge rectifier assembly, which is located in the left front cabinet.
1 A.
Diode Mounting 1.
Monitor the maximum temperature attained by the diodes by placing a temperature-sensitive label on the most visible face of the hexagonal body of the diode.
2.
The temperature sensitive label should be of the type that permanently blackens when its temperature has been reached or exceeded.
3.
The temperature rating of the labels should be 275 degrees F.
O Omega brand model BE-275 or equivalent (Ref.
1) is recommended.
4.
The label should be inspected before and after each running of the emergency generator.
5.
If the temperature label indicates that the specified temperature has been exceeded, perform an electrical test of the diode (Ref. 2), remove the diode from the heatsink and inspect the mounting threads of the heatsink and the diode.
1 Replace the diode and the heatsink as required to assure that proper mounting tightness, 360 in-lbs (Ref. 3) and thread condition is maintained.
B.
SCR Mounting i
i 1.
Monitor the SCR maximum temperature as in I.A above.
2.
Use Omega brand model BE-210 or equivalent (Ref. 1) for 210 degrees F.
3.
Tighten to 300 in-lbs (Ref. 4).
l C.
Heatsink 1.
Coat the side of the lugs and mounting bolt for the lugs that O
attach to the bottom of the diode and SCR heatsinks with Glyptol lacquer (Ref. 5).
RB2828/7
Page 8 of 15 2.
Apply the Glyptol on a readily visible side so that relative notion of the lugs with respect to one another or with respect to the mounting bolt can be detected.
3.
Inspect the connections after each monthly test of the emergency generator.
4.
Retighten' connections that appear to have loosened.
Remove old Glyptal and reapply if connections are retightened.
D.
Cabinet Ventilation 1.
The left-front generator control cabinet must be ventilated so that the temperature in the cabinet does not exceed 50 degrees C (122 degrees F).
II.
VOLTAGE REGULATOR PRINTED CIRCUIT BOARDS The recommendations below pertain to the voltage regulator, which is located in the left front cabinet.
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.
2.
If adjustments are needed, remove the Glyptol and reapply when the adjustment procedure is complete.
B.
Printed Circuit Board 1.
At each refueling outage, remove the cover of the voltage i
regulator enclosure and 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.
C.
Spare Parts 1.
It is recommended that an adequate supply of spare parts be maintained.
III. FIELD FLASHING RELAY These recommendations would best be implemented by the manufacturer at 1
the request of Gulf States Utilities.
A.
Relay Rating i
RB2828/8 Rev. I
b(%
Page 9 of 15 1.
Replace the FF relay (a DC contactor, Class P10 Cat No. P102D12 made by Gou;1d Distribution and Control Division, Ref. 6) by an equivalent DC contactor rated as follows:
Coil voltage operating ringe, 100-140 V;de necessary to contact voltage, 140 V DC; contact current, 13 0A DC.
'It install a voltage may reduction circuit to permit the use of a contactor with a conventional coil voltage range.
B.
Relay Enclosure 1.
The relay must be of the enclosed type to prevent particles of dirt from being deposited on the contacts.
IV.
FIELD FLASHING RESISTOR A.
Monitor all non emergency engine starts to assure that an unsuccessful start does not result in a prolonged period of field flashing resistor energization.
Initiate a manual reset of the exciter if the resistor is energized for more than 10 seconds.
Alternatively, a control logic modification could be implemented to produce the desired circuit operation.
V.
POWER CIRCUIT LINEAR REACTORS The recommendation below pertains to the three reactors which are mounted 1
on the floor of the left rear and center rear cabinets.
A.
The left rear and center rear cabinets must be ventilated or cooled so that the air temperature in the cabinet does not exceed 50 degrees C (122 degrees F).
VI.
WIRING The recommendations below pertain to all the generator control cabinets.
A.
Terminal Blocks 1.
Verify that no Multi-Amp, States Division terminal blocks manufactured between 1974 and 1976 are installed in the generator controls cabinets.
2.
Replace the terminal blocks as needed with a substitute suitable for Class 1E use.
VII. REFERENCES 1.
1983 Omega Temperature Measurement Handbook, Omega Engineering, Inc., Q05.
Os 2.
Portec Static Exciter Voltage Regulator Model 72-10300-100 Instruction Manual.
RB2828/9 Rev. I
Page 10 of 15 3.
Westinghouse Power Semiconductor Manual pp R35-R38.
4.
Westinghouse Power Semiconductor Manual pp S35-S38.
1 l
l S.
Gerber Electronics Catalog, p.
585 General Cement Production Bulletin.
1 6.
Portec Dwg. D72-10300-710.
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OV Page 11 of 15 River Bend Station Recommendations for Design and Construction Modifications - Generator Controls l
I.
BRIDGE RECTIFIER ASSEMBLY The recommendations below pertain to the bridge rectifier assembly, which is located in the left front cabinet.
1 A.
Diode Mounting 1.
The diodes must be mounted on the heatsinks with drilled holes, nuts, and lockwashers, and tightened to the proper torque (Ref. 1).
B.
SCR Mounting i
1.
The SCRs must be mounted on the heatsinks with drilled holes, nuts, and lockwashers, and tightened to the proper torque (Ref.
2).
O C.
Heatsink Connections y
1.
The bolted-on lug arrangement must be redesigned so that there are not more than two lugs on each bolt.
2.
Heatsink anodizing must be removed in the contact areas of all bolts and bus bar studs.
3.
Current-carrying surfaces of lugs must not be separated by washers or nuts.
II.
POWER CIRCUIT REACTORS A.
Wiring The recommendation below pertains to the three reactors which are y
mounted on the floor of the left rear and conter rear cabinets.
One terminal of the reactors has five lugged wires attached to it.
The lug arrangement must be modified so that there are no more than two lugs on any one bolt.
O RB2828/11
i i
i' Page 12 of 15 III. REFERENCES l
1.
Westinghouse Power Semiconductor Manual pp R35-R38.
2.
Westinghouse Power Semiconductor Manual pp S35-S38.
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RB2828/12 I
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Page 13 of 15 River Bend Station Modifications Recommended to Improve Long-Term Reliability - Generator Controls (to be performed by manufacturer at the request of utility) 1 I.
VOLTAGE REGULATOR The recommendations below pertain to the voltage regulator, which is y
located in the left front cabinet.
A.
Circuit Design 1.
Power Supply Bypassing The purpose of power supply bypassing is to prevent AC noise voltages generated outside the voltage regulator circuit from interfering with its operation and to prevent voltages generated by the circuit itself from propagating in the circuit.
Inspection of the PC board and the voltage regulator schematic shows that -power supply bypassing has been almost O
completely neglected in the circuit design.
The following modifications are recommended:
4 j
a.
The power supply terminals of each individual integrated I
circuit (IC) should be bypassed with a 0.01 - 0.1 micro-farad ceramic capacitor from its supply terminals to ground (Ref.1 ).
The high current buffers (U3, US, U7, Portec Drawing No. 072-13000-710 Rev.
B, Schematic-SVS Regulator with paralleling) require bypassing capacitors of 0.1 F so that transients will not get back to the ICs (Ref. 2).
l b.
In addition to the high frequency bypass capacitor, a large value capacitor (approximately 10 microfarads) is required for voltage regulator op amp Ul, Portec Drawing No. D72-13000-710, Schematic-SVS. Regulator with parallel-ing.
This is because of the presence of CR31 and R70 2.
Shielding and Routing of External Signal Leads Shielding and proper routing of signal leads external to the PC board is intended to prevent electromagnetically induced noise voltages from entering the signal loads.
This is done by using shielded signal leads and by routing the leads so as to maximize the distance between the signal and high current l
These techniques have been neglected in the wiring of the voltage regulator.
The following modifications are recommended.
RB2828/13 Rev. 1
Page 14 of 15 a.
Shielded signal leads should be used for the connections between the motor-driven potentiometer and the voltage regulator.
4 b.
A high frequency bypass capacitor providing an in-circuit low frequency cutoff of no less than 1 kHz be installed to-reduce high frequency noise on the feedback signal without interfering with the feedback loop cperation.
4
^
c.
The leads for the SCR gate signals should be run in separate bundles away from the current carrying leads.
3.
Current Feedback Signal i
The -purpose of the current feedback signal is to improve the closed loop response of the voltage regulator.
The current feedback signal is derived from a sensing transformer that measures one of the diode currents in the - bridge rectifier.
The following modification should be made to improve the stability of the voltage regulator while providing the same performance.
Replace the single phase current sensing circuit with a O
three phase current sensing circuit.
This requires the use of a three phase sensing transformer and a three phase bridge rectifier circuit on the PC board.
Additional stability is provided by reducing the filtering requirements of the feedback signal, which are presently provided by a resistance-capacitance filter on the PC board.
B.
Construction j
1.
Vibration Protection Reliable mounting of components on the PC board and the proper selection of components is necessary to assure that the valtage regulator can withstand the vibration encountered during seismic events, construction or maintenance.
However, the l
design of the board does not appear tc, be adequate for these j
conditions.
At a minimum, the following modifications should be made:
a.
The nine integrated circuits on the PC board that are presently mounted in sockets should be soldered directly to the PC board (Ref. 3).
i b.
The voltage range and stability adjustment potentiometer (R4 and RS) are unsealed, one turn commercial grade O
devices.
General recommendations in Reference 4 suggest that MIL style components should be used in such ' Class 1E applications.
These potentiometers should be replaced with MIL style,
- sealed, multi-turn potentiometers to improve the reliability and stability of these components.
RB2828/14 a.
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Page 15 of 15 2.
Printed Circuit Board Construction It is essential that the PC board construction be suitable for
~the reliability, mechanical, environmental and electromagnetic requirements of the Class 1E application.
The following modifications should be made to assure adequacy of the design.
a.
The present PC board is a single-sided board (i.e., copper circuit on one tide and components on the other).
Double-sided PC boards are commonly used in noise sensitive applications and where high reliability is necessary.
The extra copper layer provides additional bypassing of high frequency AC noise.
)
b.
The PC board should be conformally coated as a final step in manufacturing.
Conformal coating prevents humidity and airborne particles from affecting the operation of the circuitry.
c.
Components should be soldered directly to the PC board.
If sockets are used, retaining mechanisms must be provided to hold the components in the sockets.
II.
REFERENCES 1.
Roberge, J. K., " Operational Amplifiers - Theory and Practice," p.
444, John Wiley & Sons, Inc., New York 1975.
2.
Stout D., and M. Kaufman, " Handbook of Operational Amplifier Circuit Design," p. 3-27, McGraw-Hill Book Co., New York 1976.
3.
"IEEE Trail-Use Guide for Class 1E Control Switchboards for Nuclear Power Generating Stations," IEEE Std. 420-1973, p.
8, Sec.
4.1.2.
4.
"IEEE Standard:
Criteria for Protecting Systems for Nuclear Power Generating Stations," IEEE Std. 279-1971, p. 8, Sec. 7.3.
O R82828/15
Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST RIVER BEND STATION - UNIT 1 COMPONENT Sub Base - Bolting UTILITY Gulf States Utilities GROUP PARTS LIST NO.
03-715B TASK DESCRIPTION NO. DR-06-03-7158-1 SNPS GPL NO.
03-715B CLASSIFICATION TYPE C
TASK DESCRIPTIONS Design review for this component is not required based on the following:
A review of the EDG Component Tracking System indicated no significant applicable industry and site experience.
A review of the lead engine report (Shoreham) indicated acceptable bolt
- behavior, but identified engine thermal expansion as a potential concern.
A 20 degree F difference in engine and skid temperature was calculated to be sufficient to plastically deform the bolts, thus relaxing O
the bolt torque.
If this does occur, it would occur at the bolts near the auxiliary skid end, farthest away from the pinned generator end.
At Shoreham this relaxation was not observed.
At River Bend a sub-base bolt (GB-139-003) is used to anchor the turbocharger support strut.
The f
turbocharger is at the auxiliary skid end of the engine, thus the
/
turbocharger support strut bolt would be susceptible to torque relaxation
(
due to engine expansion.
At Shoreham, minor relaxation of bolt torque
~%
was considered acceptable for a few bolts near the auxiliary skid end. At River Bend the turbocharger support strut sub-base bolt should not be loose as this could potentially effect the ability of the strut to sup-press turbocharger vibration.
Maintenance operations in which the engine is cooled to room temperature and subsequent heat-up when the engine is put into standby service or started, cause the greatest temperature difference between the engine and skid.
It is recommended that either the torque of the turbocharger support strut bolt be checked after each such occurrence or the turbocharger vibration be monitored during subsequent engine operation.
If the vibration is found to be excessive 1
and/or if the torque has relaxed the bolt should be replaced and torqued with the-engine at standby temperature.
Generator sub-base bolts have been found to be adequate by analysis, Ref 4.
There are no maintenance or modification recommendations from the lead engine DR/QR report.
Quality revalidation is not required for this component.
REV 1 RB2892/1
l O
TDI OWNERS GROUP for RIVER BEND STATION MAINTENANCE REVIEW APPENDIX - II I
INTRODUCTION The purpose of this Appendix is to provide River Bend with a set of maintenance and surveillance recommendations for diesel generator compo-nents which have been developed by TDI and/or the Owners Group as a result of the overall Owners Group Program.
This Appendix is intended to supplement the existing TDI Instruction Manual, Volume I and Volume III, which will maintain the qualification of the diesel generators for the life of the plant.
II METHODOLOGY During the implementation of the Owners Group Program Plan, the Owners Group Technical Staff reviewed many sources of information regarding the maintenance and surveillance for the diesel generator. components identi-fied in this Appendix.
These sources included TDI Instruction Manuals, Service Information Memos (SIMS), and TDI correspondence on specific components.
This review along with Technical Staff input regarding the adequacy of the recommendations found in the sources mentioned above, and additional maintenance recommendations identified during the DR/QR review, forms the basis for the content of this matrix.
III RESULTS AND CONCLUSIONS 1
Proper maintenance is important in ensuring long, reliable and satisfacto-ry service of the emergency diesel generators.
Maintenance work, in order to be effective, must be carried out thoroughly and regularly.
It is for these reasons that a detailed schedule of maintenance service has been laid out by the Owners Group for the TDI Diesel Generators at River Bend Station.
The schedule details specific components requiring maintenance on a regular basis.
This schedule separates the maintenance activities into a daily, monthly, outage, alternate outage (every other), 5 year and 10 year frequencies.
It should be noted here that the duration time between outages at River Bend is assumed to be 18 months.
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O RB2610/1 f
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Page 2 of 3 Those less significant diesel generator system components with which standard engineering practice and maintenance will ensure continued operation, are not specifically addressed in the matrix.
Standard mainte-nance practices are briefly discussed below, The engine and generator should be kept clean and dry at all times.
Oil and water leakage should be wiped off the unit as quickly as possible in order to assist in locating the source of leakage, prevent potential equipment damage and maintain a safe working environment.
Leaking pipes, gaskets and packing glands should be attended to promptly. so as not to impair the reliability and/or operation of the system.
Flanged gasketed connections may be retightened to stop leaks and any abnormal engine noises or vibrations.
Actions required to correct any abnormal conditions should be carried out in a timely manner.
Loose bolts and electrical terminals should be attended to in a safe, practical manner.
Specific items to be maintained on a DAILY basis consist of the following:
1.
Observe and record lubricating oil and jacket water temperatures (keep warm pump running).
2.
Drain all low point water collectors, barring device air filter and air receiver tank float traps in the air start system.
3.
Check engine and auxiliary equipment and piping connections for oil, water, and fuel oil leaks.
4.
Check level of lubricating oil in the governor and pedestal bearing.
Add oil as needed.
i 5.
Check fuel oil pump rack for freedom of movement through full limit j
of travel.
Do not disconnect from governor.
E 6.
Check turbocharger bearing lubricating oil system sight glass for oil flow.
7.
Drain water from crankcase vent piping drip legs.
t 8.
Verify all controls in proper position for. standby mode.
i 9.
Check all governor knob settings.
Load Maximum Droop Zero Speed To provide mechanical governor control at 460 rpm.
O l
l RB2610/2 Revision 1 l
Page 3 of 3 10.
Visually inspect lube oil heat exchanger and jacket water heat exchanger for signs of leakage from the lantern ring leakoff ports, indicating leaking packing rings.
The following Preventive Maintenance Recomendation Matrix was designed to assist the Maintenance Department in determining the scope of work re-
' quired to maintain the intended design function of the diesel generators at River Bend on a planned schedule
' asis.
It should be fcilowed i
closely and referred to often.
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s l O RB2610/3
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t RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outaae Outane 5 Year 10 Year Comments F-068 Intercoolers 1.
Evaluate heat exchanger X
performance by checking engine operating parameters.
2.
Clean / inspect shell and X
Ref: Lead engine DR/QR tube sides every outage Report #F-068 or as necessary.
(Items 2, 3, 4) 3.
Visually inspect for X
Ref: 7/26/84 10C external leaks.
from J. Cadogan to M. McGerigle, Ref: 08/14/84 letter to C. Ray from M. Lowrey 4.
The drain connection on To be performed daily.
the air intake system 3
low point should be verified open, and cleaned daily.
Measure vibration and X
To be accomplished during check with base line data.
24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> test run.
2.
Clean impeller and diffuser.
X 3.
Measure rotor end play X
Review thrust bearing (axial clearance) to axial clearances after identify trends of in-inspection to determine creasing clearance, i.e; if a trend exists. Any thrust bearing degradation.
trend toward increasing axial clearance could signify thrust bearing degradation. Ref: Lead engine DR/QR Report FMP-017 RB2610/4 Revision 1
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1 RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outaae Outaae 5 Year 10 Year Comments 4.
Perform visual and blue X
NOTE: Thrust bearing check inspections of inspection should also the thrust bearing.
be performed after 40 non prelubed (automatic) fast starts. Ref: Lead engine DR/QR Report fMP-017 5.
Disassemble inspect X
and refurbish.
6.
Perform a spectro-X To be performed during chemical engine oil the last monthly analysis to assist the test run prior to oil bearing monitoring change. NOTE: Sample program. To further to be drawn up stream of expand / clarify chemical lube oil filter, analysis, ferrographic Ref: Lead engine DR/QR analysis may be utilized.
Report fMP-017 Particular attention shall be paid to copper level, and g, articulate size, which could signify thrust bearing degradation.00-420 Lube Oil Pressure Regulating 1.
Disassemble and clean.
X If valve sticks repeated-Valve ly, more frequent cleaning may be necessary. If valve plugging becomes a problem, the dimensions of the valves' internal parts should be checked to ensure proper clearance.
RS2610/5 Revision 1 l
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RIVER BEND MAINTENAHCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments 2.
During initial startup after Ref: Lead engine a major reassembly of DR/QR Report #00-420 Lube Oil piping, the L.O.
(Items 1 & 2) regulating valve should be disassembled and cleaned until abnormal L.O. pressure excursions subside.
00-7008 Jacket Water Standpipe:
1.
Replace elastomeric parts X
Ref: Comanche Peak DR/QR Valves in circle seal valves.
Report #02-717B r
03-305A Base Assembly 1.
Perform a visual inspection X
NOTE: Any cracks detected of the base. The inspection must be investigated further should include the ar*as before the engine is adjacent to the nut pockets allowed to return to of each bearing saddle and to service. The mating be conducted after a thorough surfaces of the base and wipe down of the surfaces, cap shall be throughly using good lighting.
cleaned with solvent before any reassembly.
Ref: Lead Engine DR/QR Report #03-3058 (Items 1, 2) 1 2.
The mating surfaces of the base and cap shall be throughly cleaned with solvent before any reassembly.
03-305C Main Bearing Caps - Studs 1.
Upon removal of bearing Ref: Lead engine and Nuts g
caps, clean mating DR/QR Report #03-305C R82610/6 Revision 1 i
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RIVER 8END MAINTENANCE MATRIN Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments surfaces with a solvent prior to reassembly of the caps to the base.
03-3078 Lube 011 Tubing and Fittings -
1.
Check tubing for dents X
Items 1, 2; Ref: TDI Internal or crimps.
Instruction Manual, Vol. I, Maintenance Schedule 2.
Perform gear-train X
spray check.
03-310A Crankshaft 1.
Measure crankshaft web X
Complete TDI Inspection deflection.
and Maintenance Record Form No. 310-1-1. TDI Instruction Manual, Volume I, Section 6.
Ref: TDI Instruction i
Manual, Vol. I, Mainten-l ance Schedule l
2.
Measure diameter of This inspection is to be i
crankjournals.
performed during major l
engine overhauls.
l Complete TDI Inspection and Maintenance Record Form No. 310-3-1. TDI Instruction Manual, Volume I, Section 6.
03-3108 Main Bearings Shells 1.
Inspect and measure main X
The first inspection bearing shell thickness.
should be performed at Inspection shall evaluate the first fuel outage bearing wear and evidence and at alternate outages of harmful crankshaft thereafter, j
R82610/7 Revision 1 - entire page revised l
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Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments misalignment. If results complete TDI Inspection show evidence of mis-and Maintenance Record alignment TDI recom-Form Mo. 310-2-1. TDI mendations for crankshaft Instruction Manual, realignment should be Volume I, Section 6 -
implemented.
one sheet for each main bearing. Use Volume I, Appendix III for clearance values.
Ref: TDI Instruction Manual, Vol. 1, Maintenance Schedule. Ref: Lead engine DR/QR Report
- 03-3108 03-310C shrust Bearing Ring 1.
Measure thrus; 5e-aring X
Complete applicable ring clearance vis sections of TDI
" bump check" method to be Inspection and Main-performed in conjJnction tenance Record Form with crankshaft web No. 310-1-1 TDI Instruc-deflection measurements.
tion Manual, Volume I, The following information Section 6.
NOTE: If should be recorded:
the clearance is
- Date of inspection greater than the maximum
- Hours of engine operation allowed in the TOI
- Hours of engine operation Instruction Manual, since last bearing re-then at least one bearing placement (Last bearing must be replaced.
replaced:
forward Bearings should also back) be replaced if they
- Bearing clearance are cracked or gouged.
Ref: Lead engine DR/QR Report #03-310C Ref: 8/13/84 memo R82610/8 Revision 1 - entire page revised
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outaae 5 Year 10 Year Comments from G. McCarthy to D. Pasquale 2.
Visually inspect thrust X
To be performed simult-bearing ring for signs aneously with main of cracks, gouges, wear bearing shell inspec-or degradation.
tion. Ref: Lead engine DR/QR Report #03-310C 03-315A Cylinder Block 1.
Perform an inspection of X
Ref: DR/QR Report the cylinder block per
- 03-315A DR/QR Report #02-315A.
03-315C Cylinder Liners 1.
Perform a visual inspection X
Borescopic inspection of liners for potential is acceptable if heads progressive wear.
are not removed.
Complete TDI Inspection and Maintenance Record form No. 315-1-1, TDI Instruction Manual, Volume I, Section 6.
Ref: Lead engine DR/QR Report #03-341B 03-317A&B Water Discharge Manifold -
1.
Visually inspect for leaks. X This recommendation is made Jacket Water Discharge NOTE: In the event of a on the basis that the maxi-Piping, couplings and seals leak developing in the num suggested operating existing Dresser Style 65 temperatures of 150*F for couplings, these couplings the Style 65 coupling may be should be replaced with exceeded. The maximum Dresser Style 90 couplings suggested operating equipped with Viton gaskets.
temperature of the Style 90 is 212'F.
Ref: Letter dated 12/13/84 from C.L. Ray RB2610/9 Revision 1 - entite page revised a
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments to J. George. Ref: DR/QR Report #02-317A&B 03-340A/8 Connecting Rods, Bushings 1.
Inspect and measure To be performed in con-and Bearing Shells connecting rod bearing junction with piston pin shells to verify tube inpsection. Complete TDI oil maintenance which Inspection Maintenance affects wear rate.
Record Form No. 340-1-1 The visual and dimen-TDI Instruction Manual, sional inspection of the Volume I, Section 6, bearing shells should be Appendix III for conducted at the fuel clearnance Values, outage which precedes Ref: Comanche Peak, 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br /> of operation Lead engine DR/QR by at least the sum of Report #02-3408 hours of operation 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 x-ray examin-This is to be performed ation on all replacment prior to installation of bearing shells to any replacement bearing acceptance criteria shells.
developed by Dwners Ref: Lead engine Group Technical Staff.
DR/QR Report #03-3408 R82610/10 Revision 1 - entire page revised
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Number Identification PM Recommendatinn Monthly Outage Outage 5 Year 10 Year Comments 03-341A Pistons 1.
Inspect and measure skirt X
Complete TDI Inspection and piston pin, and Maintenance Report Form No. 341-1-1. TDI Instruction Manual, volume I, Section 6.
Use Volume 1 Section 8 Appendix III for clear-ance values. To be performed in conjunc-tion wlth piston pin inspection.
03-341B Piston Rings 1.
Inspect and measure X
Complete TDI Inspection replacement piston rings.
and Maintenance Record Form No. 341-2-1. TDI Instruction Manual, Volume I, Section 6.
Use Volume I, Section 8, Appendix III for clearance values. To be perform-ed in conjunction with piston pin inspection.
2.
Visually inspect liners X
Borescopic inspection for wear.
is acceptible if heads NOTE: Ring replacement are not removed. Com-and cylinder liner plete TDI Inspection honing should te performed and Maintenance Record in accordance with TDI Form No. 315-1-1, TDI maintenance precedures.
Instruction Manual, Volume I, Section 6.
Use Volume I, Section 8. Appendix III for clearance values.
Ref: Lead engine DR/QR Report #03-3418 (Items 2, 3, 4)
RB2610/11 Revision 1 - entire page revised i
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outaos 5 Year 10 Year Comments 3.
135* fuel oil spray X
Ref: 07/31/84 meno i
tips may be used if from L. Swanger to inspection results D. Pasquale 4
Indicate e ceed for additional action to improve lubrication and reduce coke buildup.
4.
When replacing engine X
NOTE: Do not six oil use H.D. oil that L.O. brands or types.
exceeds series 3 When changing L.O.
standards. The base replace the entire stock should be L.O. charge. Ref:
more resistant to 08/14/84 letter to thermal degradation C. Ray from M. Lowrey and coke formation.
The additive package should provide high i
detergent dispersant properties with high
. alkalinity and a high 4
level of antiwear additive such as zinc dithiophosphate.
Total Base Number (TBN) should be 12 to 15 for use with
- 2 fuel oil and a i
sulfated ash content of 1.5% to 2.0% is preferred. An engine of) with such properties, Mobilguard 412 or equivalent product may l
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RB2610/12 Revision 1 - entire page revised i
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RIVER BEND MAINTENANCE MATRIX 4
Component Component Alt.
Number Identification PM Recommendation Monthly Outaae Outaae 5 Year 10 Year Comments be used to ensure improved lubrication.
03-341C Piston Pin Assembly 1.
Visually inspect for X
Also to be performed chrome plate damege.
whenever pistons are Replace pins which show removed and disassembled chipped or blistered to an extent that such chrome.
Inspection is possible.
NOTE: All new or re-Ref: Lead engine placement pins will be DR/QR Report #03-341C L.P. or M.P. inspected (Items 112), for details on before installation in acceptance criteria, Ref:
Dwners Group engines.
08/22/84 meno from W.
Littmann to D. Pasquale 2.
Inspect end plugs and 6%te: This inspection is reroll or replace any to La performed whenever that are loose.
the engine is sufficiently dismantled to allow this inspection.
Ref: Comanche Peak DR/QR Report #02-341C 03-345A Intake and Exhaust Tappet 1.
Inspect intake and exhaust X
r.omplete TDI Inspection Assembly tappet assembly condition.
and Maintenance Report Form No. 345-1-1. TDI Instruction Manual, Volume I, Section 6.
Ref: Lead engine DR/QR Report #03-345A 2.
Verify ths+ can rollers X
Complete TDI Inspection are free to rotate, and and Maintenance Record that there is no measurable Form No. 345-1-1 TDI R82610/13 Revision 1 - entire page revised t
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments clearance between the can Instruction Manual, Vol.
rollers and the roller pins.
I, Section 6.
Ref Lead engine DR/QR Report #03-345A 03-3458 Fuel Tappet Assembly 1.
Inspect fuel tappet assembly X
Complete TDI Inspection condition and Maintenance Report Form No. 345-1-1 TDI Instruction Manual, Volume I, Section 6.
Ref: Lead engine DR/QR Report #03-345B 4
2.
Verify that can rollers X
Complete TDI Inspection are free to rotate, and and Maintenance Record that there is no measurable Form No. 345-1-1 TDI clearance between the cas Manual, Vol. I, Section 6.
rollers and the roller pins.
Ref: Lead engine DR/QR Repoit #03-345B 03-350A Can Shaft Assembly 1.
Perform a visual inspection X
Any signs of cracking, of all cam lobe surfaces pitting or spalling shall for signs of cracking, be followed by a detailed pitting or spa 111ng, 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 spalling shall result in immediate replacement of the can.
R8?610/14 Revision 1 - entire page revised l
U,-w RIVER BEND MAINTENANCE NATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments Ref: Lead engine DR/QR Report #03-350A 03-3508 Can Shaft Bearings 1.
Inspect and measure can X
Complete TDI Inspection and shaft bearing shells.
Maintenance Record Form No. 350-1-1. TDI Instruc-tion Manual, Volume I, Sec-tion 6.
Use Volume I, Section 8 Appendix III for clearance values.
03-350C Can Gear 1.
Visually inspect can gear X
Ref: Memo from B.
for chipped or broken Bickford to E. Montgomery teeth, pitting, excessive dated 6/23/84, wear, or other abnormal Ref: Lead engine conditions.
DR/QR Report #03-350C i
2.
Measure gear back lash.
X Complete applicable NOTE - if can gear hub is sections of TDI Inspec-removed, it is ESSENTIAL tion and Maintenance that the nut be relocked Record, Form No. 355-1-1, at the position corres-TOI Instruction Manual, ponding to the pro-Volume I, Section 8, Appen-scribed torque range of dix III-1 for clearance 70120 ft-Ibs.
Inser-val ues. Ref: Lead tion of the cotter pin engine DR/QR Report must be accomplished
- 03-350C at a torque > 50 ft-1bs force and < 90 ft-lbs force. If this is not i
possible another bolt, put or washer should be used.
R82610/15 Revision 1 - entire page revised
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Namber Identification PM Recommendation Monthly Outaae Outaae 5 Year 10 Year Comments 03-355A Crank to Pump Gear 1.
Visually inspect crankshaft X
Any abnormal situations to lube oli pump gear or indications of for chippea or broken teeth, progressive pitting excessive wear, or should be reported progressive pitting for an engineering or other abnormal evaluation.
conditions.
Ref: Lead engine DR/QR Report #03-355A 2.
Measure gear backlash.
X Complete applicable sections of TDI Inspection and Main-tenance Record Form' No. 355-1-1 TDI Instruc-tion Manual, Volume I, Section 6.
Use Volume
- 1. Section 8. Appendix III-1 from clearance values.
Ref: TDI Instruction Manual, Vol. I, Main-tenance Schedule 03-3558 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 cther Ref: Lead engine DR/QR abnormal conditiors.
Report #03-355B 2.
Measure gear backlash.
X Complete applicable NOTE: If idler gear hub sections of TDI Inspec-is removed, it is tion and Maintenance recommended that the nut Record Form No. 355-1-1, be relocked at the post-TDI Instruction Manual, RB2610/16 Revisicn 1 - entire page revised l
O RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments tion corresponding to the Volume I, Sections 6 Use torque of 70 120 ft-Ibs.
Vol. I, Section 8, Insertion of the cotter Appendix III-1 for values.
pin must be accomplished Ref: TDI Instruction at a torque > 50 ft-lb Manual, Vol. I, Main-and 5,90 ft-Ib.
If this tenance Schedule, is not possible, another Ref: Lead engine bolt nut, or washer DR/QR Report #03-3558 should be used.03-359 Air Start Valves 1.
Remove, clean and inspect X
Ensure valve installation air start valves.
includes retorque (Replace copper valve-requirements.
to-head gasket)
Ref: DR/QR Report j
- 03-359 (Items 1 l
2, 3) 2.
Inspect the piston, cap, X
guide and housing sliding surfaces to evaluate wear or corrosicn.
3.
Ensure that the dryer To be performed daily.
between the air com-Ref: DR/QR Report pressor after cooler
- 03-359 and the air receivers is working properly by blowing down the air receivers daily and monitoring the moisture content.
03-360A Cylinder Head 1.
Visually inspect cylinder X
Complete TDI Inspection heads (all cylinkrs),
and Maintenance Record Form No. 360-1-1 TDI RS2610/17 Revision 1 - entire page revised
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.i RIVER BEND MAINTENANCE MATRIX Component Component Alt.
h enber Identification PM Necommendation Monthly Outage Outage 5 Yea r 10 Year Comments Instruction Manual, Volume I,Section 6.
One sheet for each head.
2.
Record cold compression X
If so indicated remove pressures and maximum cylinder heads, grind firing pressures.
valves and reseat.
Re f: TDI Instruction Manual, Volume I, Section 6 3.
Blow-over the engine per In the event water is TDI maintenance require-detected, the cylinder ments, Volume I or at head should be replaced i
appropriate intervals or returned to the after shutdown of vendor for repair.
the engine to ensure Ref: Lead engine DR/QR against harmful effects Report #03-360A of water leaks.
4 Visually inspect the X
If water leak.ge is fuel injection port on detected, the head (s) each cylinder head si.ould be replaced.
"during" the normal Ref: Lead engine monthly engine sun DR/QR Report #C1-360A for water leaks.
03-3608 Cylinder Head - Intake and 1.
Visually inspect intake X
Complete the applicable Exhaust valves and exhaust valve, discs, sections of TDI Inspection stems and seats for wire and Maintenance Record drawing, pitting, distortion, Form 360-2-1.
concentricity, or any abnormal condition.
2.
Visually inspect subcovers This is a one time only for evidence of valve inspection to be per-RS2610/18 Revision 1 - entire page revised i
1
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m s-s RIVER BEND MAINTENANCE MATRIX Component Component
- Alt, humber identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments guide blowby (Scot).
formed after 500-600 hrs. of engine operation after rebuild of the cylinder head. Ref:
Lead engine DR/QR Report 903-3608 l
3.
Measura intake and exhaust X
Complete appilcable i
valves head thickness.
sections of TDI Inspection and Main-tenance Records Form 360-2-1 TDI Instruction Manual, Volume I, Section 6.
One sheet for each cylinder. Use Section 8. Appendix III for clearanca values. (Items 3, 4) 4.
Measure intake and exhaust X
Complete appilcable valves - valve-to guide sections of TOI clearances.
Inspection and Main-tenance Record Form 360-2-1. TDI Instruction Manual, Volume I, Section 5.
One sheet for each cylinder. Use Section 8, Appendix III for clearance values.
j 03-362A Cylinder Head Covers -
1.
Perform a liquid pene-X This inspection is to Subcover Assembly trant examination of be performed in conjunc-the rocker are pecestals tion with the rocker top and vertical s.achined are bushing inspections RS2610/19 Revisicn 1 - entire page revised i
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u RIVER BEND MAINTENANCE MATRIX Component Component Alt.
l Nimber Identification PM Recommendation Monthly Outage Outaae 5 Year 10 Year Comments surfaces (connector when the rocker are pushrod side only),
shafts are removed from the subcovers (Ref:
l Lead engine DR/QR Report #03-390E) or when the rocker arm i
shaft assembly is removed. Subcovers with pedestal cracks that extend through the counter bore web down to the threads should be replaced.
Ref: Lead engine DR/QR Report #03-362A 03-365A Fuel Injection Pumps 1.
Visually check pressure X
To be performed on all bleed screws for erosion.
eight pumps.
2.
Tear down one pump for X
Use representative pump inspection.
to determine need to overhaul other pumps.
Ref: TOI Instruction Manual, Volume I, Maintenance Schedule 3.
Complete fuel injection X
Based on inspection re-pump inspection in suits and operating accordance with TDI parameters. NOTE -
i Instruction and Main-Disassembly of fuel tenance Manual, Volume I.
injection pumps should be performed by a Bendix Corp. representative.
Complete TDI Instruction and Maintenance Record RB2610/20 Revision 1 - entire page revised 1
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RIVER BEND MAINTENANCE MATRIX Component Component Al t, humber Identification PM Reccamendation Monthly Outage Outrae 5 Year 10 Year Comments Form Mo. 365-1-1, Section 6 (Itees 1, 2).
Ref: TUI Instruction Mansil Volume I Maintenance Schedule i
for It.s 3. Ref: Lead engine t9/QR Report i
- 03-365A 'Itees 2 & 3) 1 03-3658 Fuel Injection Mozzles 1.
Remove, inspect and clean X
Ensure that a new copper tips.
gasket is used upon reinstallation of nozzle into head.
Complete TDI Inspection j
and Maintenance Record Form 365-2-1 Instruction Manual, Volume I, Section 6.
Ref: TDI Instruction Manual, vol. I, Section 5 1
Maintenance Schedule Ref: Lead engine DR/QR Report #03-3658 (Items 1-4) 2.
Check nozzle pop pressure.
X 3.
Check spray pattern.
X 4.
Check assembly for X
To be performed with the j
leakage.
running during the mounthly test run.
l I
03-365C Fuel Injection Tubing 1.
Check tubing for leaks X
All fuel oil leak inspec-at compression fittings.
tions to be performed i
i RR2610/21 Revision 1 - entire page revised 1
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Mumber Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments J
while the engine is running or whenever the compression fittings have been disturbed.
I Ref: Lead engine DR/QR Report #03-365C 2.
Visually inspect tubing X
Fitting inspection for lengths for F.O. leaks leaks to be performed or cracks, at first engine opera-tion following the installation of tubing.
t Subsequent inspections to be performed period-ically as indicated.
Fuel oil leakage from shrouded fuel oil lines can be detected at the leakoff ports in the base nuts, which are provided for this 4
purpose. Ref: Letter from C. A. Malourh to V. A. Saleta dated 8/30/84.
03-3650 Fuel 011 Injection 1.
Visually inspect support X
Any inserts found to be Lines: Supports elastomer inserts for unsatisfactory shall be
]
deterioration or degreda-replaced with new inserts tion.
' prior to reassembly of F.O lines. This inspection can be per-formed prior to reassembly of the F.0. lines in RB2610/22 Revision 1 - entire page revised
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l RIVER BEND MAINTENANCE MATRIX Component Component Al t.
Number Identification PM Recommendation Monthly Outage Outaoe 5 Year 10 Year Comments conjunction with the cylinder if ner inspection.
Ref: Lead engine DR/QR Report #03-315C Cylinder Liners. Ref: San Onofre DR/QR Report #02-3650 l
Task Description.
03-371A Fuel Pump control Shaft 1.
Check lube all cups X
Ref: Lead engine and fill as necessary.
DR/QR Report #03-371A 03-3718 Fuel Pump Linkage Assembly 1.
Grease swivel link on, X
and Bearings F.0. pump assemblies all cylinders.
l 03-371C Fuel Pump Linkoge:
1.
Check cylinder for X
To be accomplished during Automatic Shutdown Cylinder extension and return.
control system check.
2.
Check tailrod went X
To be accomplished during for air leakage.
control system check.
Items 1, 2; Ref: IOC dated 3/26/84 from M. Wehmeyer to R. Kaklec.03-375 Intake Manifold 1.
Care should be exercised If required, other castings in assembly of cylinders may be tried to achieve heads on to the eigine, to an acceptable fit, or bolt avoid cracking of the hole diameters may be j
ir.take manifold elbows.
increased to 1/8" oversize.
Component should under no circumstances be jacked to fit. Ref: Lead engine DR/QR Report
- 03-375 RB2610/23 Revision 1 - entire page revised 1
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 03-380A Exhaust Manifold 1.
Visually and MT examine X
To be performed during a sampling of circum-the first refueling forential pipe welds and outage and alternate corresponding heat outages thereafter.
affected zones. This However, diesel examination is to operation should not be performed in exceed 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> be-accordance with Impe11 tween inspections, meno from G. Shears Ref: Lead engiae DR/QR to J. Kammeyer dated Report #03-380A j
08/13/84.
03-385A Crankcase Relief Valve 1.
Clean flame arrestors.
X Ref: 3/26/84 IDC f rom A. Wehmeyer to J. Kammeyer 4
2.
Inspect seat and disc.
X 03-390E Rocker Arm Bushings 1.
Visually inspect and The visual and dimensional measure intake rocker arm inspection of the rocker bushings.
are bushings should be conducted at the fuel outage which precedes r
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 l
operation in a LOOP /LOCA event plus the expected hours of operation between outages. This l
Inspection schedule may be revised after the first or subsequent inspections if the inspection results justify a longer period of RS2610/24 Revision 1 - entire page revised i
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments engine operation between l
Inspections. Ref: Lead engine DR/QR Report 1
- 03-390E (Items 1, 2, & 3)
]
2.
Visually inspect and Not to exceed 1300 measure exhaust rocker maximum hours of engine I
are bushings.
operation between I
inspections as described above.
3.
Visually inspect and Not to exceed 730 measure intermediate maximum hours of engine rocker arm bushings.
operation between inspection as described above.
03-390G Rocker Arm Capscrews, 1.
Verify capscrew torque X
This inspection shculd be Drive Studs (Pop Rivets) values.
performed at each outage if the rocker arms are disassembled for inspection.
Use TDI Instruction Manual, Volume I, Section 8, Appendix IV for proper torque values.
2.
Verify that rocker ara X
Ref: Lead engine DR/QR drive studs are intact Report #03-390G and tight.
(Items 1, 2) 03-402A Governor Drive - Governor 1.
Visually inspect drive X
Ref: TDI Instruction and Tachometer Drive Gear gear and shaft for signs Manual, Vol. I, Section 5, and Shaft of wear.
Maintenance Schedule.
RB2610/25 Revision 1 - entire page revised 4
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I RIVER BEND MAINTENANCE MATRIM Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments 03-4028 Governor Drive - Couplings, 1.
Check that coupling is X
If the coupling is found 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 mating surfaces.
Ref: Lead engine DR/QR Report 803-4028 4
(Items 1, 2) 2.
Replace the neoprene To be perfoemed prior to l
insert in the Koppers placing the engine in the f
coupilng.
emergency standby mode.
1 3.
Replace the elastomeric X
insert at each refueling j
outage.
i I
03-41DA Overspeed Trip Governor 1.
Check trip set point X
Modify the surveillance
- adjust as required.
testing procedure to 4
include verification i
that the overspeed trip is correctly set to an overspeed trip setting of 518 rpe 21 % every outage.
Ensure that the electric governor and the mechanical backup governor setting are properly returned to their j
normal settings following j
the overspeed test. The test is to be performed with no load on the engine
]
RB2610/26 Revision 1 - entire page revised 1
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RIVER BENO MAINTENANCE MATRIX Component Component Al t.
Number Identification FM Recommendation Monthly Outage Outaae 5 Year 10 Year Comments by increasing the normal governor speed setting (s) untti a trip occurs.
After several inspection periods, the history of the required adjustaents should be reviewed to evaluate and possibly modify the testing interval.
Ref: Lead engine DR/QR Report #03-410A Note: Af ter setting the over-speed govern 3r, the ad-justment screw settings should be marked with Torque Seal to reveal any unintended changes in the set positions.
03-4108 Overspeed Trip Governor 1.
Remove plugs from housing X
Ref: 10C dated 03/27/84 l
and Accessory Drive and check for magnetic from M. Weymeyer to particles.
N. Cooperrider. (Items 1, 2, and 3) 2.
Check shafts for excessive X
radial and axial movement.
3.
Visually inspect accessory X
drive gear for excessive wear.
^*
RS2610/27 Revision 1 - entire page revised
RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outaae 5 Ye.nr 10 Year Comments 1
03-410C Overspeed Trip Drive Couplings 1.
Remove the present L-110 To be completed at Lovejoy couplings and the first refueling replace them with new outage.
units in accordance with SIM 363 and DR/QR Report recommendations.
4 2.
Verify that coupling is X
Ref: 6/24/84 meno tight on shaft.
from D. Liebert to l
E. Montgomery j
3.
Replace the Lovejoy coupling X
Replace elastomer if spiders or test coupling hardness is grester elastomer for hardness.
than 90 Shore A.
Ref: Lead engine 1
DR/QR Report #03-410C (Items 1, 2, 3)
^
03-4100 Overspeed Trip Vent Valve 1.
Disassemble and replace X
Ref: Lead engine "0"
rings.
DR/QR Report #03-4100 1
03-413 Governor Linkage 1.
Inspect for loose parts X
on the linkage assembly, i
2.
Install positive locking hardware to the lever are clamp bolt heads and shaft g
I roll pins. NOTE: To j
be performed as necessary after tightening gow-ernor linkage hardware i
to design torrue specifi-cations.
i.
RB2610/28 Revision 1 - entire page revised l
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments l
03-4154 Woodward Governor 1.
Drain, flush, refill and X
NOTE: Venting the vent actuator oil system hydraulle 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 i
procedures are followed.
oil is added. Ref: Lead engine DR/QR Report i
- 03-415A 2.
Disassemble, clean and X
Items 1, 2, 3: Ref:
refurbish the actuator.
03/27/84 IOC from M. Wehmeyer to N. Cooperrider, Ref: TDI Instruction 1
Manual, Volume I, Section 5, Maintenance Schedule 3.
Replace flex element X
Ref: Lead engine DR/QR j
for governor drive Report 903-4028 Governor J-coupling.
Drive Couplings 4.
Verify all governor X
All knob settings should control knob settings be secured with a are in appropriate commercially available positions:,
product such as LDAD - Maximum Torque-Seal.
DROOP - Zero Speed - To provide mechan-leal governor con-trol at 450 rpm.
5.
Modify the surveillance Note: These tests shall testing procedures to include examinations of include an evaluation of the engine speed transient RB2610/29 Revision 1 - entire page revised
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
]
humber Identification PM Recommendation Monthly Outage Outage 5 Year 10 Yaar Comments the governor settings by loading conditions.
means of the two tests Included as part of the below; above tests is the veri-l fication that the engine (a) Perform a test of set speed of 45-rps is the governor settings not exceeded by more than while under mechanical /
11.2 percent (500 rps max.)
electrical governor either during an engine control, with the diesel start or during the generator off the grid largest single load in the isochronous mode.
reduction. Ref: Lead engine DR/QR Report (b) Perform a test of the
- 03-415A 4
governor settings while under mechanical (Only) governor control, with the diesel generator l
1 off the grid in the i
isochronous mode.
L 6.
Augment the setting Ref: Lead engine adjustment procedures DR/QR Report #03-415A as described in the Woodward manuals, to I
include a test of the governor response, i
during an engine start to ensure agreement with the specification as detailed in Item #5 above.
RS2610/30 Revision 1 - entire page revised 1
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outane 5 Year 10 Year Comments 03-4158 Governor Booster Servosotor 1.
Clean, inspect, and X
Ref: 3/27/84 IOC from replace "0" rings M. Wehmeyer to and gaskets.
J. Kamseyer 03-415C Governor Heat Exchanger 1.
Clean and inspect.
X 03-425A 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 potentfal/ progressive engineering evaluation.
pitting or other Ref: Lead engine DR/QR abnormal conditions.
Report #03-3558 2.
Check the key to keyway X
This along with the drive interface for a tight fit of the impeller on to fit on both the pump the pump shaft will shaft to impeller and preclude past problems the spline to pump where relative motion shaft during pump between both the shaf t reassembly.
and impeller, and the i
spline and pump shaft caused fretting and upset of the keyway sides. Ref:
DR/QR Report #03-425A 3.
It is recommended that Ref: DR/QR Report the castle nut that
- 03-425A j
drives the external To be performed spline on its taper, upon reassembly.
have a maxie w torque value of 77 ft-lbs.
i RS2610/31 Revision 1 - entire page revised j
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s RIVER BEND MAINTENANCE MATRIX Camponent Component Alt.
Number Identification PM Recommendation konthly Outage Outage 5 Year 10 Year Comments 03-435A Jacket Water Fittings-Pipe 1.
Visually inspect for leaks. X This recommendation is made and Fittings (Small Bore NOTE: In the event of a on the basis that the maxi-Scope Only) leak developing in the num suggested operating existing Dresser Style 65 temperatures of 150*F for couplings, these couplings the Style 65 coupling may be should be replaced with exceeded. The maximum Dresser Style 90 couplings suggested operating i
equipped with Viton gaskets.
temperature of the Style 90 is 212*F.
Ref: Letter t
dated 12/13/84 from C.L. Ray to J. George.
03-437A Turbo Water Piping-Pipe -
1.
Visually inspect for leaks. X This recommendation is made and Fittings NOTE: In the event of a on the basis that the maxi-leak developing in the sua suggested operating existing Dresser Style 65 temperatures of 150*F for coupilngs, these couplings the Style 65 coupling may be should be replaced with exceeded. The maximum Dresser Style 90 couplings suggested operating equipped with Viton gaskets.
temperature of the Style 90 is 212*F.
Ref: Letter dated 12/13/84 from C.L. Ray to J. George.
03-441A Starting Air Manifold:
1.
Ensure that the starting X
Ref: 08/27/84 Memo from Air Vent air manifold went is W. Littmann to J. Cadogan, open and effective.
Ref: Lead engine DR/QR Report #03-442A (STAD) 03-4418 Air Filter to Starting Air 1.
Inspect filter elements.
X Ref: TDI Instruction Distributor Manual, Vol. I, Maintenance Schedule RB2610/32 Revision 1 - entire page revised
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I RIVER BEND MAINTENANCE MATRIX Camponent Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 2.
Replace filter elements.
X It is also recommended that the filter be changed whenever the manufacturers recom-mended maximum dif-a forential pressure is achieved. Ref: Lead
}
engine DR/QR Report
- 03-4418 (Items 1&2)
Strainer - Starting Air System 3.
Blow down strainer DAILY.
Ref: Lead engine DR/QR Report #03-4418 (Items 3&4) 4.
Clean and inspect strainer X If the strainer is monthly.
excessively dirty, the J.
frequency of cleaning and inspecting should be increased.
I Air Start Block Valves 5.
Clean, refurbish valves X
Ref: Lead engine DR/QR
-replace "0" rings and Report #03-441B (Items 5, clean the screened 6, 7)
I 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.
RP2410/33 Revision 1 - entire page revised 4
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Museer Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments
]
Starting Air Valves 7.
Disassemble, clean, inspect X
Ref: Lead engine DR/QR and lubricate valves to Report #02-4418.
to prevent fou11rg. Test to assure leak tightness upon reassembly.
03-442A Starting Air Distributor 1.
Visually inspect the X
Evaluate the degree of Assembly poppet valve spool ends twear to determine J
and timing can of the whether existing l
starting air distributor.
condition would have l
an adverse effect on timing and the specified ability to start the I
engine.
I 2.
Ensure that the starting X
Ref: Lead engine DR/QR air manifold vent is Report #03-442A (STAD),
open and unobstructed.
Items 1 & 2 03-455A Fuel Oil Filter 1.
Record filter d/p.
X Change filter elements at or before the filter i
d/p reaches the manufac-j turers recommended
]
maximum differential pressure. Purge entrapped air from the filter canister using the vent valve provided, and divert some fuel oil into the newly replaced cartridge. After air has been purged close l
vent valve and return 2
RS2610/34 Revision 1 - entire page revised 4
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O RIVER BENO AAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outane 5 Year 10 Year Comments handle to previous operating position.
Ref: Lead engine DR/QR Report #03-455A 2.
Inspect canister gaskets To be performed during and replace as necessary.
change out of filter elements.
Ref: 3/27/84 IOC from M. Wehmeyer to J. DiMare 3.
Inspect tubing and mech-X Ref: TDI Instruction anical connections for Manual, Volume I tightness and/or leaks.
03-4558 Fuel 011 Strainers 1.
Record strainer d/p.
X Shift / clean element if manufacturers recom-mended maximum dif-ferential pressure is achieved. Bolt torques of 120-150 in-lbs should be uttilzed during reassembly.
Ref: Lead engine DR/QR Report #03-4558 (Items 1. 2) 2.
Purge air from stand-by As required.
strainers 03-460A Full Pressure Lube 011 1.
Record strainer d/p.
X use for trend data Strainer R82610/35 Revision 1 - entire page revised t
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RIVER BEND MAINTENANCE MATRIM Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 2.
Inspect and clean elements.
To be performed when strainer differential pressure rises signi-ficantly.
Ref: Lead engine DR/QR Report #04-000, Ref: TDI Instruction Manual, Vo'lume I, Main-tenance Schedule 3.
Lube oli strainer X
pressure gauge - call-bration check.
03-465A Lube 011 Lines External:
1.
Ensure that a minimum To be performed whenever Tubing, Fittings and Couplings insta11ation gap of 0.132 piping is installed or inches is maintained between reinstalled. Ref: DR/QR pipe ends at the 8-inch Report 803-465A Dresser coupling.
03-467A Turbocharger Lube Oil Fittings 1.
Visually inspect for leaks. X This recommendation is made Pipe, Tubing, Fittings, and NOTE: In the event of a on the basis that the maxi-Flexible Coupilng (Small Bore leak developing in the num suggested operating Scope Only) existing Dresser Style 65 temperatures of 150*F for couplings, these coupilngs the Style 65 coupling may be should be replaced with exceeded. The maximum Dresser Style 90 couplings suggested operating equipped with Viton gaskets.
temperature of the Style 90 is 212*F.
Ref: Letter dated 12/13/84 from C.L. Ray to J. George.
l R82610/36 Revision 1 - entire page revised i
RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 03-4758 Air Butterfly Valve 1.
Lube valve shaft X
Ref: IOC dated 3/28/84 via grease fittings.
from M. Wehmeyer to J. DiMare. If all 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. Ref: 04/16/84 from R. Jaquinto to R. Johnson 3.
Verify that associated X
Ref: DR/QR Report locking devices (jam
- 03-4758 nuts and lock washers) are tight.
03-500A.
Engine Control Cabinet 1.
Inspect interior of cabinet X
Ref: J/29/84 IOC for cleanliness and clean from M. Wehmeyer as required.
to T. Jacobs for Items 1-5 Ref: 07/30/84 IOC from J. Cadogan to K. Horelik for Items 1-6 2.
Visually check wiring for X
insulation degradation.
3.
Visually check instrument X
tubing for Jeaks.
4.
Functionally check cabinet X
heater and calibration of thermostat.
RS2610/37 Revision 1 - entire page revised I
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j RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outane 5 Year 10 Year Comments 5.
Test pneumatic 5/D board X
logic.
6.
Replace "0" rings, gaskets X
and filter in pressure regulator.
03-500C Circuit Breakers and Contact 1.
Check all terminals X
To be accomplished during Blocks clean / tighten.
panel clean / inspection.
2.
Visuall'y check wiring X
To be accomplished during insulation for degradation.
panel clean / inspection.
3.
Trip check circuit breaker'.
X s
03-500G Control Panel Valves 1.
Inspect and clean control X
This recommendation in-panel valves.
terval should be reas-sessed depending on the degree of system fouling.
Ref: Lead engine DR/QR Report #03-500G 2.
Inspect and clean the X
Ref: Lead engine DR/QR 200 mesh screen in the Report #03-50DG check valve.
03-500J Control Panel Assembly:
1.
Inspect contacts and clean X
Ref: 08/10/84 IOC from Relays as required.
K. Horelik to J. Ca1ogan 2.
Visuall) check condition X
of wiring and tightness of terminations.
l l
R82610/38 Revision 1 - entire page revised
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Montnly Outane Outage 5 Year 10 Year Comments 03-500N Control Panel Switches Terminal 1.
Clean terminal boards and X
Ref: IOC dated 3/29/84 Boards and Wiring switch contacts.
to J. Kammeyer from M. Wehmeyer for Items 1, 2, 3.
2.
Visually check wire insul-X ation and terminals for tightness and degradation.
3.
Inspect for arcing and X
overheating.03-515 Thermostatic Valves 1.
Replace thermal power x
Ref: Lead engine DR/QR elements.
Report #03-515 (Items 1, 2) 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.03-550 Foundation Bolts 1.
Visually inspect founda-X Ref: TDI Instruction tion for breaks in the Manual Section 5, bond between the sole Maintenance Schedule plates and grout.3 2.
Check foundation bcits X
Use TDI Instruction for correct tprque..
Manual, Volume I, Retorque as necessary Section 8, Appendix then recheck crankshaft IV for proper torque web deflections.
values.
RS2610/39 Revision 1 - entire page revised
N t RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments 03-6300 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.
2.
Clean and inspect thermo-X-
Indications of fatigue couples and thermocouple should result in re-shields.
placement of the thermo-couple and/or thermo-couple shield.
Ref: 7/31/84 Memo from S. Riess to W. Littmar.n 3.
Pyrometer wiring-check To be accomplished during that terminations are control panel check-out tight.
and initial operation inspection. Items 1, 2, 3; Ref: 07-30-84 IDC from J. Cadogan to S. Riess 03-650A Emergency Generator 1.
Check operation of X
Ref. IOC dated 03/30/84 brushes and slip rings.
M. Wehmeyer to D. Mercaid (Items 1-5) 2.
Clean / inspect all X
accessible parts of the generator.
3.
X 4.
Verify operation of.
X i
space heaters.
4 R82610/40 Revision 1 - entire page revised
RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outana Outaoe 5 Year 10 Year Comments 5.
Measure vibration and X
check against base line data.
03-6508
[mergency Generator 1.
Inspect panel for X
Items 1-5; Ref: 3/30/84 Control Panel cleanliness and clean IOC from M. Wehmeyer as required.
to D. Mercaldt 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 6.
Bridge rectifier assembly Ref: DR/QR Report and SCR mounting.
- 03-6508, Attach. I r
a.
Inspect the temperature X
If either of the labels sensitive label placed permanently blacken the on the most visible maximum temperature of the face of the hexagonal diode and/or SCR has been body of the diodes exceeded requiring an and the SCR. These electrical inspection labels shall be and an inspection of inspected before and the mounting threads after each running of the heat sinks and of the engine.
diode and/or SCR.
RB2610/41 Revision 1 - entire page revised
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RIVER BEND MAINTENANCE MATRIX Component C y nent Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments b.
Inspect glyptol applied X
To be performed aftar to the side of the lugs each monthly test run.
and mounting bolt for Retighten any loose the lugs which attach connections, remove to the bottom of the old glyptol and reapply diode and the SCR if connections are heatsinks for signs retightened, of relative motion.
7.
Adjustment potentiometers - X To be performed after inspect glyptol applied each monthly test run.
to the the side of the If adjustments are adjustment screws for each needed, remove glyptol of the five adjustment and reapply when the potentiometers on the adjustment procedure printed circuit board of is complete.
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.
R82610/42 Revision 1 - entire page revised t
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 03-650C Emergency Generator Pedestal 1.
Check ring oilers X
To be accomplished during Bearing for proper operation every test run of the and verify oil level.
engine.
Ref: 3/30/84 IDC from M. Wehmeyer to N. Cooperrider (Items 1-4) 2.
Drain flush refill X
bearing housing.
3.
Measure bearing housing X
insulation resistance.
4.
Disassemble and inspect X
bearing and check clearances, i
03-6958 Engine Control Air 1.
Inspect and clean engine X
NOTE: This recommenda-Pressure Regulator shutdown equipment.
tion should be assessed depending on the degree of system fouling Ref: Lead engine DR/QR Report #03-6958 (Items 1 & 2) 2.
Replace elastomeric parts X
and gaskets in the pressure regulator.
03-695C Engine Control Pneumatic Trip 1.
Check switch s'et points.
X Pressure switches.
Switches Ref: 3/30/84 IOC from M. Wehmeyer to J. DiMare RB2610/43 Revision 1 - entire page revised 1
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O RIVER BEND MAINTENANCE MATRIX Component Component Alt.
' Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 2.
Replace elastomeric parts.
X 03-7178 Auxiliary Sub-base & 011 & Water 1.
Inspect the valves for X
Replace as necessary.
Piping - Jacket Water: Valves packing leakage.
Ref: Lead engine DR/QR Report #03-7178 03-7170 Aux 111ary Sub-base & 011 &
1.
Visually inspect for leaks. X This recommendation is made Water Piping-Jacket Water NOTE: In the event of a on the basis that the maxi-Pipe Couplings, Fittings, leak developing in the num suggested operating Orifices. Y-Strainers existing Dresser Style 65 temperatures of 150*F for (Small Bore Scope Only) couplings, these couplings the Style 65 coupling may be should be replaced with exceeded.
it.? maximus Dresser Style 90 couplings suggested operating equipped with Viton gaskets.
temperature of the Style 90 is 212*F.
Ref: Letter dated 12/13/84 from C.L.
Ray to J. George.
03-717H Auxiliary Sub-Base Lube Oil 1.
Visually inspect pipe and X
This recommendation is made and Fuel Oil Valves joints for leaks.
on the basis that the maxi-NOTE: In the event of a num suggested operating leak developing in the temperatures of 150*F for existing Dresser Style 65 the Style 65 coupilng may coapilngs, these couplings be exceeded. The maximum should be replaced with suggested operating Dresser Style 90 couplings temperature of the Style 90 equipped with Viton is 212*F.
Ref: Letter gaskets.
dated 12/13/84 from C.L. Ray to J. George. Ref: 4/2/84 IOC from M. Wehmeyer to J. Freeman.
R82610/44 Revision 1 - entire page revised 1
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments 2.
Clean and inspect L.O.
X Complete when L.0. tank keep-warm pump suction is drained.
strainer.
Ref: 04/16/84 letter from R. Jaquinto to R. Johnson 03-7171/N Auxiliary Sub-Base Lube 011 1.
Disassemble, lubricate, X
Ref: IDC dated 4/6/84 and Fuel Oil Valves inspect and refurbish.
from M. Wehmeyer to J. DiMare.
i Ref: Lead engine DR/QR Reports #03-7171/N 2.
Dissassemble, clean and X
Ref: 07/31/84 IOC check relief valve to M. McGerigle from lift pressure.
J. Cadogan, Ref: 08/16/84 IOC from M. McGerigle to J. Cadogan, Ref: Lead engine DR/QR Report #03-7171/N (Items 1 & 2) 03-800A 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.
Ref: 5/10/84 IOC from M. McGerigle to W. Brown 3.
Check calibration and X
for Items 1, 2, 3 inspect therngstat.
Measure heater X
Replace heater if de-Heaters insulation resistance.
gradation of insulation resistance is noted.
RB2610/45 Revision 1 - entire page revised
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outane Outage 5 Year 10 Year Comments 2.
Inspect and clean X
To be accomplished during heatee elements.
tank inspection.
3.
Check calibration and X
Ref: 05/10/84 IOC inspect condition of from M. McGerigle thermostat.
to W. Brown for items 1, 2, 3 03-8058 Intake Air Filters 1.
Inspect air intake Replace if necessary.
filters every 3 to Ref: Lead engine DR/QR 6 months.
Report #10-114 03-805D Flex Connection 1.
Visually inspect for X
evidence of cuts, holes, or dents.
03-810A Jacket Water Heat 1.
Jacket water heat To be performed daily.
Exchanger exchanger and Ref: Lead engine DR/QR associated service Report #10-103, water piping must Ref: 04/20/84 IOC be flushed periodi-from M. Wehmeyer to cally to prevent R. Kadlec fouling and corrosion.
+
2.
Perform a daily visual To be performed daily.
Inspection for leakage Ref: 07/19/84 Telecon at packing whenever the D. Pasquale and R. Chill engine is in the emergency STANDBY mode.
Verify that no leakage is present through the leak-off ports of the lantern ring, t
R82610/46 Revision 1 - entire page revised
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
l Number Identification PM Recommendation Monthly Outage Outane 5 Year 10 Year Comments i
^
3.
Record beat X
Use for trend data exchanger perfor-mance by checking engine operating parameters.
4.
Evaluate heat exchanger X
performance data, i
S.
Inspect tubes X
Ref: TDI Instruction and tube sheet Manual, Volume I, for fouling and Maintenance Schedule errosion - remove entrance and exit channel covers.
Replace packing rings Ref: Lead engine DR/QR l
at floating tube Report #10-103 sheet after tube inspection.
6.
Inspect and clean X
Replace / rework lantern ring. Verify lantern ring as leak-off holes are necessary to i
not plugged.
ensure concentricity prior to reinstall-ation.
7.
Replace packing Replace packing when rings.
packing becomes hard or leakage at the packing is noted and cannot be stopped by tightening.
Ref: Lead engine DR/QR Report #02-810C R82610/47 Revision 1 - entire page revised q
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RIVER BEND MAINTENANCE MATRIX Component Component Al t.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 03-820A Lube 011 Heat 1.
Perform a daily visual Ref: Lead engine DR/QR i
Exchanger inspection for leakage Report #10-104, at packing. Verify Ref: 06/12/84 IOC that no leakage is from R. Chii to present through the P. Martia leak-off ports of Ref: 04/02/84 IOC i
the lantern ring.
from M. Wehmeyer to R. Kadlec 2.
Record heat X
Use for trend data exchanger perfor-mance by checking engine operating parameters.
3.
Evaluate heat exchanger X
performance data.
4.
Inspect tubes and X
Ref: TDI Instruction tube sheet for Manual, Volume I, erosion and fouling -
Maintenance Schedule, remove entrance and Ref: 07/19/84 Telecon exit channel covers.
D. Pasquale and R. Chil 5.
Inspect and clean X
Replace / rework lantern ring.
Iantern ring as Verify leak-off necessary to holes are not ensure concentricity.
plugged.
4 R82610/48 Revision 1 - entire page revised
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Gutage Outa2e 5 Year 10 Year Comments 6.
Replace packing X
When 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 spectro To be performed at chemical analysis approximate quarterly of the lube oli.
intervals.
Particular attention Ref: Lead engine shall be given to percent DR/QR Report #10-104 moisture content.
03-8208 Full Flow Lube 011 1.
Record filter d/p.
X Use for trend data.
Filters Ref: 04/02/84 IOC from M. Wehmeyer to J. DiMare, Ref: TDI Instruction Manual, Volume I, Maintenance Schedule 2.
Drain water and/or X
sludge from lubri-cating oil full i
flow filter.
3.
Replace filter To be performed before cartridges and the filter d/p reaches the perform a visual manufacturers recommended inspection to maximum differential determine the pressure. Re f: 05/30/84 nature of the IOC from M. McGerigle
]
material caught to B. Brown, in the filter.
Ref: Lead engine DR/QR Report #10-106, RB2610/49 Revision 1 - entire page revised i
I RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 4
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4.
Lube oil filter X
gauge - calibra-tion check.
03-820C Lube 011 Keep-Warm Pump 1.
Check operation of X
Items 1-5; Ref:
pump / motor bearings.
04/05/84 IDC from M. Wehmeyer to T. Fritsch 2.
Check mechanic t) seal X
leakage.
3.
Record pump X
Use for trend data discharge pressu e.
l 4.
Measure unit vibr a-X tion (pump / motor) f
'03-8200 Lube Oil Keep-Warm Filter 1.
Record fliter d/p.
X Ref: 04/05/84 IOC from M. Wehmeyer to J. DiMare i
i R82610/50 Revision 1 - entire page revised 4
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outaae Outaae 5 Year 10 Year Comments 2.
Change filter X
To be performed before elements.
the filter d/p reaches the manufacturers recom-mended maximum differen-tial pressure. Ref:
Lead engine DR/QR Report #10-117 03-825C Fuel 011 Filters & Strair,ers:
1.
Change over, strainer Ref: River Bend DR/QR
~
Strainers element at 15 psid.
Report #03-825C Task Description.
03-835A Starting Air Storage Tank 1.
Drain air receiver float If quantity of traps DAILY and monitor the moisture is quantity of moisture excessive corrcet produced at the immediately. Check float traps, air dryer operation.
Ref: Lead engine DR/QR Report #10-111 2.
Disassemble and clean X
Ref: IDC dated the float trap.
05/08/84 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.
RB2610/51 Revision 1 entire page revised
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RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identif cation PM Recommendation Monthly Outage Outage S Year 10 Year Comments 03-8350 startini Air Compressors 1.
Check lubicating oil X
All items; Ref:
1evel.
04/02/84 IOC with attached Maintenance Chart from M. Wehmeyer to J. Kammeyer.
2.
Overall visual X
inspection.
3.
Clean fins on inter X
and after coolers.
Ni.
Replace intake filter X
element.
S.
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.
03-8351 Air Dryers and 1.
Blow down trap X
Ref: 04/05/e4 IOC Motsture Traps sediment bowls.
from M. Wehmeyer to J. Kammeyer, Ref: TDI Instruction Manual, Volume I, Maintenance Schedule 2.
Inspect and service X
moisture traps.
RS2610/52 Revision 1 - entire page revised
O RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Mumber Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments 3.
Check proper operation X
Replace desiccant charge of desiccant dryer.
as required.
Ref: 04/16/84 letter from R. Jaquinto to R. Johnson Jacket Water System 1.
Check pH. factor X
Ref: TDI Instruction of jacket water and Manual, Volume I, Main-correct as recom-tenance Schedule mended by chemical suppIfer.,
t 2.
Replace elastomeric parts X
in jacket water valves.
Lube 011 System 1.
Check lubricating X
Ref: TDI Instruction oil with a viscost-Manual, Volume I, Main-meter for fuel oil tenance Schedule Items dilution. Send a 1, 2 sample of oli to laboratory for analysis.
2.
Drain lubricating X
When replacing engine oil system and oil use H.D. oil that clean sump tank.
meets or exceeds series 3 Depending on the standards. The base stock results of lobe should be more resistant oli analysis, refill to thermal degradation with new oil.
and coke formation. The additive package should provide high detergent dispersant properties with high alkalinity and a high level of antiwear R82610/53 Revision 1 - entire page revised
i RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments l
l I
l 4
3.
Visually inspect lube X
To be performed oli sump tank level after lube oil i
switch floats.
has been drained Check switch set from sump.
j points.
I 4.
Perform a spectro-To be performed at chemical analysis approximately quarterly of the lube oil, intervals. Re f: TDI Instruction Manual, Volume I, Maintenance Schedule l
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 j
operating properly.
R82610/54 Revision 1 - entire page revised
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\\v RIVER BEND MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly Outage Outaae 5 Year 10 Year Comments Piping System 1.
Conduct a detailed X
Tighten, repair or visual and audible replace as required.
inspection of all Ref: TOI Instruction fuel, air, oil, Manual, Volume I, and water piping Maintenance Schedule and valves for leakage.
2.
Inspect, clean and X
as applicable, lubricate manual valves on skid.
Engine Internals 1.
Remove alternate left X
If excessive water, side doors and sludge or any indica-examine the inside tion of bearing of the engine for any failure is present, abnormal conditicns.
drain crankcase, Check with a good determine cause, and light for evidence of take necessary babbit flakes.
corrective e-tions.
i Miscell-Engine Mounted 1.
Replace elastomeric X
cnceous Pressure Switches parts.
Gear Train 1.
Inspect gears for X
general condition.
2.
Measure gear back X
Replace worn lash on all gears, gears exceeding maximum clearai.ce.
Complete TDI Inspection and Maintenance Form No. 355-1-1 R82610/55 Revision 1 - entire page revised 4
O Page 2 If, after completing the review, the engineer deter: nines 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.
4.2 Review of Small Bore Piping for Acceptsbility 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 l
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 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 funct* Jn, as Well as a review for the following:
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 acceptcbility 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.
O I
TDI1154/2 Rev. I