ML20112D295
| ML20112D295 | |
| Person / Time | |
|---|---|
| Site: | Shoreham File:Long Island Lighting Company icon.png |
| Issue date: | 08/03/1984 |
| From: | Terry D AFFILIATION NOT ASSIGNED |
| To: | Taylor J AFFILIATION NOT ASSIGNED |
| References | |
| I-SC-LP-029, I-SC-LP-29, OL-4, NUDOCS 8501140178 | |
| Download: ML20112D295 (9) | |
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S G2.7_- Q4L OiO January 15, 1981 J.H. Taylor Emergency Diesel Generator 102 Problems Encountered To Date i
Shoreham Nuclear Power Station - Unit No. 1 l
W.O. 44430/48923 1
i The attached report, prepared by T. Brown, J. Higgins and
'W. Cook accurately state the problems we have had to date.
An attempt to resolve many of the items was tried on December i
18, 1980 when Startup arranged a meeting between ourselves, S&W and Delaval.
Regretfully, Delaval could not attend and no i
real progress on eroblem solutions were made.
Another meeting is scheduled for January 20, 1981 at Shoreham and. hopefully resolution to many problems will be achieved.
Many of the problems encountered by Startup to date have been the result of the " Skid Mounted Equipment", as with this type, the Construction organization has very minimal involvement other than " hooking up" to it.
Along these lines, alignment deficiencies have been identified, storage problems have been corrected etc.,
all of which adds to Startup's scope of work as related to placing the equipment into service.
A rescheduling effort of the Diesel generators must be conducted
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due to the recent Proposed Site policy to primarily support the Integrated Flush.. At the present time, we can not project a preep start date glue to many unresolved problems and no projected i
l turnover date for Engines 101 and 103.
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D.D. Ter COMP 6/C DOC Lead Sta up Engineer ntF DDT:be cc: T. Brown J.
Higgins W. Cook L.W. Lewin j
W.M. Matejek SR2-R43.010 j
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Il PROBLEM REPORT R43-EMERGENCY DIESEL GENERATORS 1-Procedure that had been JTG approved for subsystam flushes were not adequate.
Specifically, the lube oil flush did not provide sufficient flow to clean the system. (this test procedure used B&A pump (40GPM.) which has a normal flow of about 250GPM.
Also, the JW system flush procedure uses the J.W. heater circulating pump (50GPM) for a sys-tem with a normal flow of 800 GPM.
This procedure will be revised to incorporate a temporary flush pump, 2-Excessive amounts of time were required to review component lists since (a) initial list missed many items (b) isome-tries are continually changing resulting in added and/or deleted' sections, and (c) hanger listings change as isos are revised and the designation changes (E&DCR F.29376).
Changes in component lists are no longer to be reviewed -
only marked noted by test engineer.
3-Excessive amounts o'f time was required to review punchlist itams.
This was campounded by (a) reorganization of lists by ranumbering all items, (b) excessive number of items, (c) failure to perform verification of completion by turnover and (d) non-informative responsiblity assignment.
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Responsibility is not discussed with the individual i
resulting frequently in the wrong discipline being assigned, the individual being unaware of his responsi-bility, and the wrong completion code being assigned.
The issuing of the complete. list each month instead of a list of changes results in an impossible review I
task.
4-F.xcessive amounts of time are required for review of preliminaries.
New preliminary release packages are submitted for review with little or no change in the punchlists.
Meetings are called to discuss package updates with the only change being requests for further concessions on number of items required for turnover.
R43A has had six preliminaries and the punchlist is still some 46 pages long.
5-
'Constru2iti'6n*s'tatuis fi:if"fil'e5NaNas~ poor-T-we'recei-vedG a minimum of requested storage history information.
Final engine alignment was not performed.
There was l
no record of foundation bolt torquing.
Megger readings of generator stator were not up to date.
Megger reading of generator field and bearing pillow block were non-existant.
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6-Numerous decrgn_cnA construction _ errors necessitated ini-
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tiation of E&DCR's
( 65 to date.
This has resulted in an exorbitant amount of time being expended reviewing drawings and documents.
Many of the original problem solutions were incorrect which resulted in rewriting the E&DCR or calling SEO to request the next issue.
We have attempted to get the drawings updated to reflect the system as it was designed and to get the drawings that the diesels were built to, but
. usually we are requested to mark up prints reflecting as built conditions.
Problem solutiens are at a standstill at present, only one has been answered since the end of October - nineteen are unanswered.
7-Numerous repair-reworks (.3 8 ) have been written because
_ - _ _ _ _ _ -7 of many incomplete _.or_. defective items.' Some of these are a result of E&DCR's,some are a Y sult..ofc. poor.. factory assembly'pradtices,somee_rearesultofaforcedturnover 7
with incomplete / deficient components, and some are a re-sult of poor construction practices.
A great amount of time was expended in obtaining documentations Tior.. rework
~~m oCTfactory-wiring.
This has also been expended on attempts to expedite parts and tools for reworks.
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8-Extra time has been expended because of numerous techni-cian changes with no overlap.
This has resulted in some rework, additional time locating equipment, and additional time locating documents.
9-Many hours have been expended attempting to get infor=a-tion for C&Io work (especially the tach-relay, the fuel oi3 Booster Pu=p'D.C. motor loss of field relay)with incomplete results.
Many hours have been expended attempting to set up for testing D.C. Circuit breakers i
since there is no regulated DC power supply of 30 amp capacity on site.
Pcior... storage conditions and2w'cir~klarea conXrply.%,du ing 10-constructronTphase,s had to be compensated by cleaning of the 102 generator by Startup support.
11-Poor design of panel cable support and poor housekeeping during construction resulted in a prolonged cleaning effort to achieve error free operation of relays.
12-original schedules did not allow time for rewritting
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procedures, reperforming C&IO work because of design changes, performing design and construction review.
13-original C&IO schedule by previous test engineer allowed six weeks.
A recalculation including all equipment with the same allowed time for devices, indicates that fif teen weeks should be allowed.
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n 14-Modification of diesel generators to upgrade design are being incorporated.
This was not allowed for this in the assigned schedule.
15-Additional time and manpower was required to clean crank cases of diesel since preservative of wrong type was sus-pected to have been used on engine during storage.
16-Additional Test Engineer time was expended clearing construction red tags after system release.
17 -
Failure to be able to control access to the Diesel room because construction activities were in progress slowed Startup activities.
Construction work on rewiring MCC, installing scaffolds (for X60 actuators, service water line walk, and conduit resupporq, and reworks assigned to construction.
Temporary doors were unlocked, knocked down and holes were cut in them.
18-Power feed (120VAC) Repair / Rework (R35-6) prevented com-plate testing of accessories.
19-ASME piping was not turned over at original "B"
release.
There has been confusion in this area concerning who owns which components.
We are still unable to use Startup Support to break flanges on these systems - this results in poor control of activities by Startup.
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20-Lack of personnel continuity has impacted progress -
three turnover engineers have been responsible for R43 since May 1980.
21-Many hours have been spent listing problems with design, drawings, construction, and documentation.
Many hours
..have been~ spent attending meetings - the only result thus far has been requests for more paperwork, (lists & copies of specific E&DCR's) and more meetings.
We need to have the diesel generators Placed on a higher priority-if we are to meet a date required to support other plant activities.
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