Text

Rev 1 Tdi Diesel Generator Design Review & Quality Revalidation Rept
	ML20112F047
Person / Time
Site:	Vogtle
Issue date:	02/28/1985
From:	Rick Deese, Ray C; TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP
To:	;
Shared Package
ML20112F034	List: ML20112F030; ML20112F047;
References
	NUDOCS 8503270321
	Download: ML20112F047 (77)
	v • d • e

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V0GTLE ELECTRIC GENERATING PLANT

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-v REVISION 1 TO DR/QR REPORT Enclosed is Revision 1 to the DR/QR Report. Please revise your copy (ies) per the instructions below.

NOTE: Revise by component number. and unique file identifier which is found in bottom left corner of revised page.

Delete Insert VOLUME 1 Title Page (V03569) Title Page Title Page Section~2.0(V03569) Page 2-6 Page 2-6 Section 3.0 (V03477) Pages 3-2 Pages 3-2 3-3 3-3 3-4 3-4 3-5 3-5 3-9 3-9 VOLUME 2 6 F-068(V03393) Page 1 of 2 Page 1 of 2 02-475A (V03484) Pages 2 of 4 Pages 2 of 4 3 of 4 3 of 4 4 of 4 4 of 4 02-475C (V03484) Pages 2 of 4 Pages 2 of 4 3 of 4 3 of 4 4 of 4 4 of 4 02-420(V03426) Page 1 of 2 Page 1 of 2 02-7170(V03428) Pages 1 of 2 Pages 1 of 2 2 of 2 2 of 2 02-315A (V03239) Pages 1 of 3 Pages 1 of 4 2 of 3 2 of 4 3 of 3 3 of 4 4 of 4 02-385B (V03190) Page 1 of 2 Page 1 of 2 VOLUME 3 02-341A (V03214) Page 1 of 2 Page 1 of 2 VOLUME 4 b 02-425 (V03394) Page 1 of 2 Page 1 of 2 02-371A(V03384) Page 1 of 2 Page 1 of 2 02-371B (V03384) Page 1 of 2 Page 1 of 2 8

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' VOLUME 4 (continued) 02-650A (V03478) Pages 1 of 3 Pages 1 of 3 2 of 3 2 of 3 3 of 3 3 of 3

, 02-650A(V02979) Page B2 of 3 Page B2 of 3 02-6500(V03479) Pages-1 of 14 thru Pages 1 of 14 thru 14 of 14 14 of 14 Appendix II (V03171) Pages 2, 3, 4, 6, Pages 2, 3, 4, 6, 10, 76, 27, 32, 10, 26, 27, 32

33, ~>8 thru 57 33, 38 thru 59 i

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l 5 TDI DIESEL GENERATOR 4

DESIGN REVIEW AND QUALITY REVALIDATION REPORT prepared for 4

GEORGIA POWER COMPANY V0GTLE ELECTRIC GENERATING PLANT by i

TDI DIESEL GENERATOR OWNERS GROUP Revision 1 i

February 1985 Reviewed by: kTJ. Deese R.

hh Licensing Coordinator TDI Diesel Generator Owners Group Approved by: - - . -

C. L. Ray TFchnical Program Director TDI Diesel Generator Owners Group 4

O V03569

t l~ 2.6 FINAL DOCUMENTATION The DR/QR program has. been completed for Georgia Power Company. A summary of the results of this effort are contained in Section 3.0.

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

Appendix II contains a comprehensive set of maintenance and surveillance recomme7dations for each component. These recommendations were derived from existing vendor recommendations and the individual component DR/QR Summary reports. The purpose of this Appendix is to provide the utility a basis for its maintenance and surveillance program which will maintain the qualificat h 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 Vogtle TDI diesel generators.

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V03569 2-6 REV. 1 L_

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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 40) that covered the 16 generic components. The results of these reviews are summarized below.

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

Revision of operating procedures.

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

03-305C, 03-3050)

Crankshaft Unlimited Life None (03-310A)

Cylinder Block Unlimited Life Additional maintenance and I and Liner inspection requirements.

V (03-315A, 03-315C)

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

Connecting Rods: Unlimited Life Additional inspection Connecting Rods requirements, and Bushings 1 (03-340A) l Connecting Rod Unlimited Life Additional maintenance

-Bearing Shells requirements. Additional l (03-3408) inspections recommended.

i Pistons (03-341A) Unlimited Life AN piston skirt should be replaced with AE piston s ki rt.

Air Start Valve Unlimited Life Additional maintenance (03-359) requirements. Verification of dimensions recommended.

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

! V03477 3-2 REV 1

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p 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 requirement. Additional (03-390C,03-3900) inspections recommended.

Random nestructive test.ng recommended.

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

Wiring and Unlimited Life None Terminations (03-6888)

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O V03477 3-3 REV 1

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3.2 ~ Summary Resolution of Phase II Components Component Acceptability Recommended Action TUR80, INTAKE, INTERCOOLER & EXHAUST Intercooler Unlimited Life

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Additional maintenance recommend-(F-068) ations.

Turbocharger' Modifications Additional modifications /

(MP-022/023) inspections to assure turbocharger reliability and performance.

Refer to Component Design Review Checklist for details. Additional Quality inspections recommended.

Intake Manifold Modifications Ensure proper installation of

& Piping U-bolts on the crossover piping.

(Large Bore Additional maintenance recommend-Scope Only) ations. Additional Quality (02-375) inspections recommended.

Exhaust Manifold Modifications Modify slip joints. Inspect

'(02-380A) capscrews. Refer to Component O Design Review Checklist 02-380A for details. Additional maintenance recommendations.

Exhaust Msnifold: Unlimited Life Additional Quality inspections Gasket & Bolting recommended.'

(02-3808)

Intercooler Piping- Unlimited Life None Pipe (Large Bore Scope Only)

(02-436A&B)

Turbocharger-Bracket: Unlimited Life Implementation of proper torque Bolting and Gaskets on bracket bolting. Additional (02-475A+C) Quality Revalidation tasks 1 recommended. Additional inspections recommended.

Air Butterfly Modifications Addition of grease fittings.

Valve Assembly Reperform hardness testing (02-4758) on Engine 1. Additional Quality inspections recommended.

Turbo Splash Unlimited Life Verify the proper installation /

O Shield-Supports (02-4750) support for the splash shield.

REV 1 V03477 3-4

Component Acceptability Recommended Action

('v) Intake Air Unlimited Life Inspect intake air filter oil Filter distribution plate and change (02-805A) oil in filter at each outage.

Intake Air Unlimited Life None Silencer (02-8058)

Flex Connections Unlimited Life None (02-8050)

LUBE OIL Lube Oil Full Unlimited Life Additional maintenance Pressure Strainer recommendations.

(SE-025)

Lube Oil System: Unlimited Life Additional maintenance recommend-Lube Oil Keepwarm ations.

Strainer (SE-031)

Lube Oil Pressure Unlimited Life Additional maintenance recommend-Regulating Valve ations.

(00-420)

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

(02-307A-LB)

Lube Oil Fittings- Modifications Modify supports. Refer to Internal: . Headers Component Design Review Checklist (Small Bore 02-3070 for details.

Scope Only)

(02-307A-SB)

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

(02-3078)

Lube Oil Fittings Modifications Modify U-bolts. Refer to Internal-Supports Component Design Review Checklist (Small Bore 02-3070 for details.

Scope Only)

(02-3070)

Engine Driven liodifications Addition of a Dresser coupling on the Lube Oil Pump pump suction line to mitigate the 1 (02-420) thermal expansion loading and stresses V03477 3-5 on the pump inlet nozzle.

REV. 1

Component Acceptability Recommended Action V Main Bearings Unlimited Life At first refueling outage, inspect (02-3108) bearings for misalignment.

Crankshaft & Unlimited Life Additional maintenance recommend-Bearings: Thrust ations.

Bearing Ring (02-310C)

Crankcase: Unlimited Life Additional maintenance recommend-Crankcase Assembly ations.

(02-311A)

Crankcase: Unlimited Life None Crankcase Mounting Hardware (02-3110)

Crankcase: Unlimited Life Additional Quality inspections Crankcase Gaskets recommended.

and Mounting Hardware (02-3868)

CYLINDER BLOCK, LINERS, & WATER MANIFOLD Cylinder Block Unlimited Life Implement routine inspections.

(02-315A) 1 Cylinder Block Unlimited Life Additional maintenance recommend-Liners & Water ations.

Manifold-Cylinder Liner (02-315C)

Jacket Water Unlimited Life None Manifold Piping (Large Bore Scope Only)

(02-3150)

Cylinder Block Unlimited Life Change installation torque to Liners & Water lower the stresses in the cylinder Manifold: Studs block.

(02-315E)

Cylinder Block Unlimited Life Additional Quality inspections Liner & Water recommended.

Manifold-Cylinder Head Nuts v (02-315F)

V03477 3-9 REV. 1

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COMPONENT DESIGN REVIEW CHECKLIST V0GTLE ELECTRIC GENERATING PLANT - UNIT 1

e COMPONENT Intercooler UTILITY Georgia Power Company GROUP PARTS LIST NO. F-068 TASK DESCRIPTION NO: DR-11-F-068-1 SNPS GPL NO. F-068 CLASSIFICATION TYPE B TASK OESCRIPTIONS

-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 experience, except that

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already addressed in the lead engine report. There was no site experience. Nuclear and non-nuclear industry experience shows a number of intercooler problems mainly due to engine vibration. TDI has issued SIM No. 365, which contains suggested modifications to p prevent intercooler problems such as these, and it is recommended g that this SIM be implemented at Vogtle.

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

Both Vogtle and Comanche Peak intercoolers were manufactured by Young g Radiator and are Mode! No. 0264836.

There are no modification recommendations from the lead engine DR/QR reports.

The following maintenance recoiquendations from the lead engine DR/QR report should be implemented:

The intercooler should be inspected for external leaks every month.

The intercooler should be disassembled as necessary and cleaned every refueling outage.

The drain connection en the intake air system low point should be verified open and cleaned daily.

Quality revalidation is not required for this component.

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Rev. I V03393/1

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k COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 4 (n) v OR-11-02-475A&C-1 The Comanche Peak lead engine DR/QR report indicates that the pipe thermal loads, along with the engine vibration loads are the most significant loads experienced by the brackets and the mounting bolts. The design of the water jacketed, multi pipe, exhaust manifold connecting the cylinders to each turbocharger is identical for both stations. The adapter piece (transitional piece) at the turbocharger exhaust connection and its expansion joint is also similar. The thermal loads experienced by the turbocharger brackets and the associated mounting hardware for both stations should therefore remain similar.

Review of the amplified response acceleration spectra curves for Vogtle Station (Ref. 6) indicates that the seismic loadings are much more favorable than those at the Comanche Peak Station.

Based on the above review the turbocharger brackets at Vogtle Power Station are adequate to resist the seismic inertia loads, deadweight, thermal loads, and engine vibration loads. Similarly, the 3/4 in. capscrews (12 screws for each bracket) attaching the bracket to the engine block are satisfactory; however, based on the OR/QR report for Comanche Peak Station, the review of the turbochager bracket and bolting finds that in the worst case load condition, vibration and manifold nozzle loads could potentially produce bolt loads in excess of preloads. Therefore, the bracket to engine and bracket to turbo base screws (P.N. GB-001-143 and GB-001-120) are recommended to be inspected on a regular basis as discussed below:

Each month for the first three months of commercial operation these screws should be inspected to assure that no screw has loosened because of engine operating loads. If during these inspections none of the screws are found loosened or damaged, from then on 1 inspections are to be conducted on a yearly basis (or during plant shutdown). But if any time during inspection any screw is found loosened or damaged, it must then be replaced (if damaged) and all screws retorqued as follows; 125 ft-lbs for the bracket to engine screws and 75 ft-lbs for the bracket to turbo base screws.

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

There are no modification recommendations for these components.

Quality revalidation for the turbocharger bracket (Component No. 02-475A) is not required.

i The Quality inspection results contained in TER 11-086 were reviewed and found l satisfactory. However, inspections performed to date only address the screws l attaching the turbo to bracket and not the screws that attach the bracket to the engine block. It is recommended that these screws (P/N 6B-001-143) be O

l reviewcd.

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! V03484/2 REV. 1 i

,o COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 4

(] DR-11-02-475A&C-1 The various tasks as described in the Component Quality Revalidation Checklist for Component No. 02-475C should be performed on both engines:

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

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

PRIMARY FUNCTION The primary function of the turbocharger brackets and bolting is to support the two turbochargers, the two intercoolers, as well as the inlet and adapters at each intercooler and to secure the assembly to the engine block by 3/4 in.

capscrews.

ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES

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

2. TDI Manual Volume II, for Model DSRV-16-4 Diesel Engine / Generator, Vogtle Units 1, Parts List No. 02-475-10-1 and Drawing 02-475-30.

3. TDI Manual Volume II for Model DSRV-16-4 Diesel Engine / Generator, Comanche Peak Steasi Electric Station -

Unit 1, Parts List No.

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

REV. 1 CARRY OVER FROM PREVIOUS PAGE VC3484/3

n COMPONENT DESIGN REVIEW CHECKLIST Page 4 of 4 1,] ' -

DR-11-02-475A&C-1

4. TDI Drawings Drawing No. Description 02-475-22-AL Bar Support Outer 02-475-30-AA Bar Support Inner 02-475-21-AD Adapter, Intercooler Inlet - Right Bank 02-475-21-AE Adapter, Intercooler Inlet - Left Bank 02-475-21-AF Bracket, Turbo G Right Bank 02-475-21-AG Bracket, Turbo G Left Bank 02-475-22-AA Adapter, Intercooler OutleL - Right Bank 02-475-22-AB Adapter, Intercooler Outlet - Left Bank

5. Bechtel Power Corp. Specification No. X4AK01 Rev. 6, issued August 19, 1983 for Standby Diesel Generator for the Alvin W. Vogtle Nuclear Plant, Georgia. Appendix H, January 31, 1974.

DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON _ [1 [>la x PROGRAM MANAGER d C 6 - A O

REV. 1 CARRY OVER FROM V03484/4 PREVIOUS PAGE

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COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 4 l

DR-11-02-475A&C-1 The Comanche Peak lead engine DR/QR report indicates that the pipe thermal loads, along with the engine vibration loads are the most significant loads experienced by the brackets and the mounting bolts. The design of the water jacketed, multi pipe, exhaust manifold connecting the cylinders to each turbocharger is identical for both stations. The adapter piece -(transitional piece) at the turbocharger exhaust connection and its expansion -joint is also similar. The thermal loads experienced by the turbocharger brackets and the associated mounting hardware for both stations should therefore remain

-similar.

Review of the amplified response acceleration spectra curves for Vogtle Station (Ref. 6) indicates that the seismic loadings are much more favorable than those at the Comanche Peak Station.

- Based on the above review the turbocharger brackets at Vogtle Power Station are adequate to resist the seismic inertia loads, deadweight, thermal loads,

-and engine vibration loads. Similarly, the 3/4 in. capscrews (12 screws for each bracket) attaching the bracket to the engine block are satisfactory; however, based on the DR/QR report for Comanche Peak Station, the review of the turbochager bracket and bolting finds that in the worst case load condition, vibration and manifold nozzle loads could potentially produce bolt loads in excess of preloads. Therefore, the bracket to engine and bracket to turbo base screws (P.N. GB-001-143 and G8-001-120) are recommended to be O inspected on a regular basis as discussed below:

Each month for the first three months of commercial operation these screws should be inspected to assure that no screw has loosened because of engine operating loads. If during these inspections none of the screws are found loosened or damaged, from then on 1 inspections are to be conducted on a yearly basis (or during plant shutdown). But if any time during inspection any screw is found loosened or damaged, it must then be replaced (if damaged) and all screws retorqued as follows; 125 ft-lbs for the bracket to engine screws and 75 ft-lbs for the bracket to turbo base screws.

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

There are no modification recommendations for these components.

Quality revalidation for the turbocharger bracket (Component No. 02-475A) is not required.

The Quality inspection results contained in TER 11-086 were reviewed and found satisfactory. However, inspections performed to date only address the screws attaching the turbo to bracket and not the screws that attach the bracket to the engine block. It is recommended that these screws (P/N 68-001-143) be O reviewed.

V03484/2 REV. 1

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COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 4 (m) v DR-11-02-475A&C-1 The various tasks as described in the Component Quality Revalidation Checklist for Component No. 02-475C should be performed on both engines:

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

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

PRIMARY FUNCTION The primary function of the turbocharger brackets and bolting is to support the two turbochargers, the two intercoolers, as well as the inlet and adapters at each intercooler and to secure the assembly to the engine block by 3/4 in.

capscrews.

ATTRIBUTE TO BE VERIFIED Not required

(

v SPECIFIED STANDARDS Not required REFERENCES

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

2. TDI Manual Volume II, for Model DSRV-16-4 Diesel Engine / Generator, Vogtle Units 1, Parts List No. 02-475-10-1 and Drawing 02-475-30.

3. TDI Manual Volume II for Model DSRV-16-4 Diesel Engine / Generator, Comanche Peak Steam Electric Station -

Unit 1, Parts List No.

?

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

O REV. 1 CARRY OVER FROM PREVIOUS PAGE V03484/3

(T COMPONENT DESIGN REVIEW CHECKLIST Page 4 of 4 y) OR-11-02-475A&C-1

4. TDI Drawings Drawing No. Description 02-475-22-AL Bar Support Outer 02-475-30-AA Bar Support Inner 02-475-21-AD Adapter, Intercooler Inlet - Right Bank 02-475-21-AE Adapter, Intercooler Inlet - Left Bank 02-475-21-AF Bracket, Turbo G Right Bank 02-475-21-AG Bracket, Turbo G Left Bank 02-475-22-AA Adapter, Intercooler Outlet - Right Bank 02-475-22-AB Adapter, Intercooler Outlet - Left Bank

5. Bechtel Power Corp. Specification No. X4AK01 Rev. 6, issued August 19, 1983 for Standby Diesel Generator for the Alvin W. Vogtle Nuclear Plant, Georgia. Appendix H, January 31, 1974.

DOCUMENTATION REQUIRED Not required (w

GROUP CHAIRPERSON 1'l bla x PROGRAM MANAGER M \4c %

0 REV. 1 CARRY OVER FROM V03484/4 PREVIOUS PAGE i

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Page 1 of 2 l t

^ ~ COMPONENT DESIGN REVIEW CHECKLIST V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 COMPONENT Engine Driven Lube Oil Pump UTILITY Georgia Power Company GROUP PARTS LIST NO.02-420 TASK DESCRIPTION NO. DR-11-02-420-1 SNPS GPL NO.03-420 CLASSIFICATION TYPE A TASK OESCRIPTIONS Design review for this component is not required based on the following: i

. . A review of the EDG Component Tracking System indicated that there !

was no 'significant applicable industry experience, except that previously addressed 'in the lead engine report. There was no site experience in the Component Tracking System.

"* Similarity of Vogtle cornonent to lead engine component. Both are IMO Model 3JK-4370.

There are no maintenance recommendations for this component.

It is recommended that a Dresser coupling be added on the pump suction line to mitigate the thermal expansion loading and stresses on the pump inlet nozzle. 1 The coupling should be located between the relief valve branch connection and the pump inlet nozzle.

Quality revalidation is not required for this component.

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PRIMARY FUNCTION Not required i

ATTRIBUTE TO BE VERIFIED

.Not required SPECIFIED STANDARDS Not required

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, V03426/1 !

REV. 1

n Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 Before & After Lube COMPONENT Oil Pump UTILITY Georgia Power Company GROUP PARTS LIST NO. 02-717U TASK DESCRIPTION NO. DR-11-02-717U-1 SNPS GPL NO.10-113 CLASSIFICATION TYPE A

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

-

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

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

/

The before & after lube oil pump at Vogtle and Comanche Peak are

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both IMO Series 30.

A review of pump nozzle loads indicates that the applied piping loads are above the manufacturer's recommended allowables. There has however been no experience of pump leakage due to these loads at Comanche Peak or other V-16 installations. As such, the following inspection should be performed as part 1 of the daily engine walkdown:

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

There are no modification recommendations based on the lead engine DR/QR report.

Quality revalidation is not required for this component.

PRIMARY FUNCTION Not required v

REV. 1 V03428/l

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 h

v OR-11-02-717U-1 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON H PROGRAM MANAGER -SC \4%sa-um WO ~

o REV. 1 CARRY OVER FROM PREVIOUS PAGE V03428/2

7N TDI OWNERS GROUP for V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 CYLINDER BLOCK COMPONENT PART NO. 02-315A I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Vogtle Electric Generating Plant requires Design and Quality Revalidation re-views of the cylinder blocks to determine the adequacy of design for their intended use at Vogtle. The blocks are manufactured by TDI and are supplied under their part number 02-315-03-AE. The cylinder block forms the framework of the liquid cooled engine and provides passage for coolant and support for the cylinder liners and cylinder heads.

II 08JECTIVE The objective of this review was to evaluate the structural adequacy of p) g the cylinder block for its intended use at Vogtle Electric Generating Plant.

III METH000 LOGY In order to meet the stated objective, the following methods were used:

Review of liquid penetrant inspections of Vogtle DSRV-16-4 Engine 1 and 2 engine blocks.

Review of operating history. 1

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

Performance of dimensional check and evaluation of liner / block interaction.

Evaluation of steady state stresses, alternating stresses and stiffness in key portions of the cylinder block.

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

Review of metallurgical / microstructural analysis of cylinder block O

material.

Review of Vogtle site, nuclear and non-nuclear experience (see Appendix C).

REV. 1 V03239/1

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Page 2 of 4

!ol V e Review of Quality Revalidation Checklist results for acceptability.

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. 1 Evaluation of steady state stresses, alternating stresses and stiffness in key portions of the cylinder block was accomplished as part of the strain gauge 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 1 and 2 have had limited operational experience.

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

The engine operating conditions at Vogtle were compared to those at Comanche Peak and Shoreham. No significant differences were found that would affect the structural integrity assessment of the Vogtle blocks.

O Results of dimensional inspection of the cylinder liner bore and mating block surfaces were used to evaluate the interaction of the block and cylinder liner in the analysis of steady state and alternating stresses.

These results were utilized in the cumulative damage analysis. 1 The power output for this engine is 7000 kW at 100 percent load. Maximum output required for LOOP /LOCA is 6032 kW. The duration of a LOOP /LOCA used in this analysis is 168 hours0.00194 days 0.0467 hours 2.777778e-4 weeks 6.3924e-5 months .

Strain gauge testing of the original Shoreham EDG 103 block, inspection data from before and af ter extensive test operation and materials testing were used as a basis to predict adequate life for cylinder blocks. The rate of propagation of cracks between stud holes during operation in the 1 original Shoreham EDG 103 block, when compared with the LOOP /LOCA requirements at Vogtle, indicates that even if the Vogtle blocks had Ifgament cracks they are predicted to withstand with sufficient margin a LOOP /LOCA event.

Block tops have been inspected and no detectable ligament, stud-to-stud or stud-to end cracks have been reported. In addition, a material microstructure evaluation has been performed on all engine blocks at Vogtle verifying that the block material is characteristic of typical Class 40 grey cast iron.

O REV. 1 V03239/2

Page 3 of 4 O Application of the cumulative damage analysis (Figure 5-1 of Reference 1)

.shows that the Vogtle engines can perform for 490 hours0.00567 days 0.136 hours 8.101852e-4 weeks 1.86445e-4 months at 100 percent load (or operation resulting in equivalent cumulative 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 1 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.

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 sufficient 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.

One block of Unit 2 Engine No.1 has been found to contain a weld repair region in cylinder No. 1. Vogtle is planning to replace this block with a new RV-5 design. Based on review of dimensional changes made in this O design, and test engine experience in excess of 5000 hours0.0579 days 1.389 hours 0.00827 weeks 0.0019 months , block top stresses are reduced from the R-4 levels thereby descreasing the possibi-lity of block top crack formation. Assuming satisfactory inspection results from all Appendix B inspections, application of the cumulative damage algorithm as described above shows that engine operation, without subsequent inspections for 490 hours0.00567 days 0.136 hours 8.101852e-4 weeks 1.86445e-4 months at 100 percent power level (or operation resulting in equivalent cumulative damage) would be possible with sufficient margin remaining for a LOOP /LOCA event (Reference 2).

Therefore, the RV-5 block is acceptable for emergency standby service provided that all Appendix B inspections are completed satisfactorily and the cumulative damage algorithm as outlined in Reference 1 is applied to determine future inspection frequency period.

The information provided on the following TERs has been reviewed and is consistent with the final conclusions of this report: 11-049, 11-010 and 11-050.

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 Vogtle.

REV. 1 V03239/3

Page 4 of 4 V.. R.gfERENCES

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

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

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PREVIOUS PAGE l V03239/4

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COMPONENT DESIGN REVIEW CHECKLIST V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 Cylinder Block COMPONENT Covers: Gaskets & Bolts UTILITY Georgia Power Company GROUP PARTS LIST NO. 02-3858 TASK DESCRIPTION NO. DR-11-02-3858-1 SNPS GPL NO. 03-3858 CLASSIFICATION TYPE C TASK DESCRIPTIONS Design review for this component is not required based on a review of the lead engine DR/QR report (Comanche Peak) and the applicable site and industry experience listed in the EDG Component Tracking System.

There have been cases of fastener failures on the cylinder block covers; however, these failures are not attributed to design deficiencies of this component. Based on the lead engine DR/QR report, the recommended torque value of 30 ft-lbs is appropriate and the specified bolting and stud materials (SAE GR 5 and SAE GR 1120 respectively) are acceptable for their intended function (o'] of holding the covers onto, the cylinder block. Isolated failures can occur when the torque is not applied properly or a lesser grade material is substi-tuted. Barring any deviations as mentioned above the bolting is acceptable for use on the diesel engines.

There are no modification or maintenance recommendations for this component.

The following Quality inspections are recommended to be performod on one engine:

Verify that the proper torque is applied and the specified material is installed, plant personnel should review site documentation or perform the necessary inspection to make these determinations.

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

1 PRIMARY FUNCTION Not required O

i 0 Rev. 1 l V03190/1 i

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COMPONENT DESIGN REVIEW CHECKLIST V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 COMPONENT Pistons UTILITY Georgia Power Company GROUP PARTS LIST NO. 02-341A TASK DESCRIPTION NO. DR-11-02-341A-2 SNPS GPL NO. 03-341A CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review is not required for this component based on review of the Phase I reports, the lead engine DR/QR reports (Shoreham/ Comanche Peak) and the applicable industry experience. There is no significant site experience in the EDG Component Tracking System.

Georgia Power has replaced the originally supplied AN piston skirts with the product improvement AE skirts. The liquid penetrant examination at the rib area near the wrist pin, and the rib at the intersection of the wrist pin boss, as described in the attached CQRC is not required. Tin plating in these areas 1 make this examination impossible. It is recommended that a visual inspection

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be performed instead on the aforementioned areas for any indications in the casting at this time.

Quality inspections conducted to date on the AE skirts have been reviewed and are considered satisfactory.

There are no maintenance or modification recommendations for this component.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required-O _ -

V03214/1 REV. 1

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 Engine Driven COMPONENT Jacket Water Pump UTILITY Georgia Power Company GROUP PARTS LIST NO.02-425 TASK DESCRIPTION NO. DR-11-02-425-1 SNPS GPL NO. 03-425A CLASSIFICATION TYPE A J

. 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 site experience. Significant applicable industry experience was previously addressed in the lead engine DR/QR report (Comanche Peak). ,

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

O The engine driven jacket water pumps at Vogtle and Comanche Peak are

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of the same design, but the impellers on the Vogtle pump are cut to smaller diameters for lower design flows with a corresponding decrease in torque, and consequently lower stress levels.

The following maintenance recommendations from the lead engine DR/QR should be implemented:

It is recommended that the key to keyway interface be checked for a tight fit on both the pump shaft and the impeller during pump reassembly. This, along with the drive fit of the impeller onto the shaft, will preclude past problems where relative motion between shaft and impeller caused fretting and upset of the keyway sides.

It is also recommended that the key to keyway interface be checked for a tight fit on both the spline and the pump shaft during pump 1 reassembly. This, along with the drd.ve fit of the spline onto the shaft, will preclude past problems where relative motion between spline and pump shaft caused fretting and upset of the keyway sides.

The castle nut that drives the external spline on its taper does not have a maximum specified torque "not to be exceeded." It is recommended that the minimum and maximum torque values of 120 ft-lb and 660 ft-lb, respectively, be included in the Vogtle maintenance procedures.

There are no modifications required for the pump, based on the lead engine DR/QR report.

REV 1 V03394/1

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COMPONENT DESIGN REVIEW CHECKLIST V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 Fuel Pump Linkage:

Fuel Pump Control Shaft; COMPONENT Linkage Assembly & Bearings UTILITY Georgia Power Company GROUP PARTS LIST NO. 02-371A&B TASK DESCRIPTION NO. DR-11-02-371A&B-1 SNPS GPL NO. 03-371A&B CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry experience, except that al-ready addressed in the lead engine report. There was no site experience listed in the Component Tracking System.

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

The components are identical to the lead engine components.

The following maintenance recommendation from the lead engine DR/QR report should be implemented:

To maintain proper control shaft alignment, it is recommended that the oil cups be inspected and filled on a monthly basis.

No modifications are required for this component, based on the lead engine DR/QR report.

The following Quality inspections should be performed:

Inspect linkage and bearings for freedom of movement (Engines 1 & 2).

Determine the hardness of the shaft (Engine 1).

Ensure that site bearing lubrication procedures are in compliance with the TDI Instruction Manual. 1 PRIMARY FUNCTION Not required V03384/1 Rev. 1

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 Fuel Pump Linkage:

Fuel Pump Control Shaft; COMPONENT Linkage Assembly & Bearinas UTILITY Georgia Power Company GROUP PARTS LIST NO. 02-371A&B TASK OESCRIPTION NO. DR-11-02-371A&B-1 SNPS GPL NO. 03-371A&B CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry experience, except that al-ready addressed in the lead engine report. There was no site experience listed in the Component Tracking System.

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

The components are identical to the lead engine components.

The following maintenance recommendation from the lead engine DR/QR report should be implemented:

To maintain proper control shaft alignment, it is recommended that the oil cups be inspected and filled on a monthly basis.

No modifications are required for this component, based on the lead engine DR/QR report.

The following Quality inspections should be performed:

Inspect linkage and bearings for freedom of movement (Engines,1 & 2).

Determine the hardness of the shaft (Engine 1).

Ensure that site bearing lubrication procedures are in compliance with the TDI Instruction Manual. 1 PRIMARY FUNCTION Not required V03384/1 Rev. 1

t 4

TDI OWNERS GROUP for V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 EMERGENCY DIESEL GENERATOR f, COMPONENT PART NO. 02-650A I INTRODUCTION i

The TDI Emergency Diesel -Generator Owners Group Program for the Vogtle Electric Generating Plant requires Design and Quality Revalidation reviews of the generator to determine its adequacy for its intended use at Vogtle.

The primary function of the generator (AC Synchronous Generators, serial t

Nos. 17612170/173, manufactured by Electric Products Division, Portec, 4

Inc.) is to supply all safety related loads in the event of loss of offsite power during a LOCA and to supply the normal safe shutdown loads.

I- II OBJECTIVE The objective of this review was to verify the generator's ability to maintain emergency bus voltage under emergency loading conditions.

i III METHODOLOGY i-The maximum coincident demand on the diesel generators was compared with

the continuous and short-term ratings of the generator. NRC Safety Guide 9.0 (Ref. 1), Regulatory Guide 1.9 (Ref. 2), and IEEE Standard 387-1977 -

j (Ref. 3) were reviewed regarding the ratings. ,

The sequential loading of the generators as specified in VEGP-FSAR

l. (Ref. 4) was examined. Using the generator parameters provided by the vendor (Ref. 5), minimum generator voltage was computed for each step of

the sequential load. Calculations (Ref. 6) were performed to verify that j the minimum generator terminal voltage is in excess of 75 percent of the rated voltage.

4 Vogtle site experience, as reported in Component Tracking System printouts,.was reviewed. In addition, nuclear and non-nuclear industry

, experience was reviewed.

The design of the brush arrangement was reviewed for adequacy (Ref. 6). y

Comparison was made with the brush arrangement at Shoreham. .

The generator maintenance program was reviewed with regard to brushes and

{ ' slip rings (Ref. 5). ,

e l The procurement specification, X4AK01, Rev. 6 (Ref. 8), was reviewed in

, s the light of IEEE Std. 387-1977, NRC Regulatory Guide 1.9, and Safety Guide 9.0.

V03478/1 Rev. 1 j

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G Quality Revalidation Checklist results were reviewed for acceptability.

IV. RESULTS AND CONCLUSIONS ExaminaEion of the automatic sequential loading as specified in Reference

~ 4 shows that the maximum continuous load will not exceed 5517 kW at 0.91 power factor on each diesel generator in the event of loss of offsite power. Each generator has a continuous rating of 7000 kW and a short-term rating of 7700 kW. Therefore, it is concluded that the continuous and short-term ratings of each generator are adequate.

Calculations (Ref. 6) show that the minimum voltage of the generator during automatic sequencing in the event of a loss of offsite power during a LOCA will not drop below 80.0 percent of the rated voltage. Baseu upon the calculations, the performance of the generator is acceptable with regard to the specified minimum voltage (75 percent of the rated. voltage as per Reference 2). The ability of the generator and its excitation system to make' the voltage recover to 90 percent of its rated value after the initial dip as specified in Reference 2 needs to be verified by ~

preoperational tests.

Vogtle, nuclear and non-nuclear industry experience listed in the Component Tracking System was reviewed. The results of the review are given in Appendix C of this report. It was found that the incidents were 4

not of a generic nature and do not impact the conclusions of this report.

4 Evaluation of the design of the brushes and brush holders at Vogtle and comparison with those at Shoreham show that the brushes and brush I holders are selected and designed adequately for both generators (Ref. ,

4L 6).

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Maintenance procedures recommended by the manufacturer with regard to brushes and slip rings (Ref. 7) are adequate.

i The procurement specifications (Ref. 8) reflect the relevant standards (Ref. 1, 2, and 3).

The information provided on TER 11-088 has been reviewed and is consistent

_ with the final conclusions of this report.

t Quality Revalidation Inspection results identified in Appendix B have been reviewed and considered in the performance of this design review, and I

the results are consistent with the final conclusions of this report.

I Based on the above review, and satisfactory verification of generator

[ voltage recovery capabilities as specified in Reference 2, it is concluded t

that the emergency diesel generator is designed adequately for its intended use at Vogtle.

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I Rev. 1 V03478/2

(-' Page 3 of 3 V REFERENCES

1. NRC Safety Guide 9.0, " Selection of Diesel Generator Set Capability for Standby Power Supplies," dated 03/10/71.

2. NRC Regulatory Guide 1.9, " Selection, Design and Qualification of Diesel Generator Units Used as Standby (Onsite) Electrical Power Systems of Nuclear Power Plants," Rev. 2, December 1979.

3. IEEE Std. 387-1977, " Criteria for Diesel Generator Units Applied as Standby Power Supplies for Nuclear Power Generating Stations."

4. VEGP-FSAR-8 Table 8.3.1-2 Diesel Generator Loading Profile for LOCA

.and Loss of Offsite Power.

5. Generator Data Sheet, Serial No. 17612170/173, supplied by Portec.

6. Support Package FaAA-SP-84-6-45(j). I

7. Portec Instruction Manual, Operation and Maintenance of ac Synchronous Generator, Serial No. 17612170/173.

8. Spec. No. X4AK01, Rev. 6 Standby Diesel Generators, A. W. Vogtle Electric Generating Plant, Burke County, Georgia, dated August 19, O' 1983.

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O Rev. 1 V03478/3

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 3

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11-02-650A i REFERENCES Engine 1

1. QCI No.52 Engine 2 Same as Engine 1 DOCUMENTATION REQUIRE 0 Engine 1

1. Document Summary Sheet Engine 2 Same as Engine 1 GROUP CHAIRPERSON , PROGRAM MANAGE h 1 Adcuw w + o _

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COMPONENT REVIEW Engine 1

1. No EDGCTS site experience documents are in evidence.

Engine 2 Same as Engine 1 Note: A trip report was received for both engine generators. This 1 report was transmitted by TER# 11-088.

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RESULTS AND CONCLUSION Engine 1 The Quality Revalidation effort with respect to this component, as outlined above, is complete. The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of j the final report.

V02979/2 REV 1

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TDI OWNERS GROUP for

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V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 GENERATOR CONTROLS' COMPONENT PART NO. 02-650B I INTRODUCTION The, TDI Emergency Diesel Generator Owners Group Program for the Vogtle Electric Generating Plant requires. Design and Quality Revalidation reviews of the generator controls (manufactured by' Electric Products Division, Portec, Inc.), Part No. 72-12500-100, to determine the adequacy of the design for the intended use at Vogtle. The primary functions of the generator controls are to provide field current for the generator and to' regulate the voltage of the 4.16-kV emergency bus. This is accomp.

lished by the static exciter, which is the subject of this report.

The. static exciter consists of the following subcomponents:

O

(,)

+ The diode bridge rectifier assembly and diverter silicon controlled 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 bus voltage.

The field flashing circuit, which ensures self excitation of the generator.

L i

e The power potential transformer (PT), current transformers (cts) and linear reactors, which supply the required AC voltage to the j rectifier bridge and SCRs.

The min-max excitation limit circuit, which controls the minimum and

maximum reactive power output when the generator is synchronized to the plant electrical system.

The generator control cabinets, as discussed in this report, consist of a i ' double depth set of cabinets, three cabinats wide. Two bridge rectifier

, assemblies, two gate firing modules, and a manual transfer switch are located in the left-front cabinet. The center-front cabinet contains the

- automatic and manual voltage regulators, the automatic and manual motor driven potentiometers, the Min-Max excitation limiter and field flashing i

i V03479/1

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Page 2 of 14 circuit. The power PT is located in the bottom of the right-rear cabinet.

The power cts and linear reactors are mounted in the left-rear and center-rear cabinets. The cabinet behind the left-front is designated left-rear . for reference. The right-front cabinet contains overcurrent relays and governor controls, which are not addressed in this report.

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 Vogtle.

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.

4

, Detailed design review calculations (Ref. 2) were performed for the above subcomponents. Specifically, calculations were made to verify the adequ-acy 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.

l-l The design of the voltage regulator was evaluated qualitatively (Ref. 2).

l

l. The generator control cabinets were inspected at RTE Switchgear, l Stockton, California, on December 10,1984, (Ref. 3) prior to shipment to Vogtle. . 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.

V03479/2 1.

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[\ .Page 3 of 14

.Q:

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.

Applicable TERs were reviewed.

IV RESULTS AND CONCLUSIONS

, The Emergency. Diesel Generator Component Tracking System does not list any 4

incidents related to - the operation of the generator controls at Vogtle.

Notification of a potential design deficiency in the relay logic circuits associated with the exciter field flashing circuit was received (Ref.

4). The potential deficiency pertained to overheating of exciter

, electronic components resulting from prolonged energizing of the field flashing resistor. During normal _ operation the field flashing relay closes about one second after an. engine start signal and opens when the generator output builds up to about 60 percent of rated voltage. During the time the relay is closed, usually about 2 to 5 seconds, the field is g energized from the station battery through the field flashing resistor.

, This resistor, which dissipates 5000-7500 watts, is located adjacent to electronic components of the exciter and will generate excessive heat if

, energized for a prolonged period of time. In addition, the field L flashing resistor itself can be damaged if energized for a prolonged period of time. Damage to the field flashing resistor or the nearby electronic components under this condition could prevent the generator from performing its intended safety function, y l Although the specific problem that prompted this notification was later determined to be unrelated to equipment design, it was found that an attempted start concurrent with certain diesel generator fault conditions could cause a prolonged period of field flashing resistor energization.

Specifically, if the start sequence progresses to the point of closing

the field flashing relay and the output voltage of the generator does not i build up for any reason, the field flashing resistor will remain I . energized until the exciter is manually reset.

In order to prevent the occurrence of this condition ,at Vogtle, it is recommended that the design of these circuits be reviewed. If the potential for the subject overheating exists, all diesel generator starts (other than emergency starts) should be monitored to assure that an unsuccessful start does not result in a period of prolonged field l flashing resistor energization. A manual reset of the exciter should be initiated if the resistor is energized for more than 10 seconds.

Alternatively, a control logic modification could be implemented to produce the desired circuit operation.

Notification has been received regarding a potential problem with Multi-Amp, States Division terminal blocks manufactured between 1974 O. and 1976 (Ref. 5). It is recommended that Georgia Power Company inspect the generator control cabinets and if found, replace these terminal blocks with a suitable substitute.

V03479/3 REV 1 l

'Page 4 of 14 The following inadequacies have been discovered as a result of this design review:

.The bridge . rectifier diode current rating is inadequate for the application. Calculations (Ref. 2) show that the current rating and maximus junction temperature of the diode will be exceeded during a 30-second short circuit on the 4.16-kV. emergency bus. This condition has been used consistently throughout the DR/QR program for verifying the adequacy of the current rating and cooling of the dicde. In addition, the generator and exciter are . required to meet 4

this condition (without damage) by the- procurement specification (Ref. 6) for the Vogtle emergency diesel generators. Detailed recommendations for the replacement of the diodes are given in Attachment 1 of this report.

The coil voltage range of the field flashing relay is inadequate for the application. The present relay . is guaranteed for operation at coil voltages of 125 Vdc plus or minus 10 percent (Ref. 2, Item 8). However, the procurement specification (Ref. 6) requires operation from 100-140 V, which is a larger voitage range than guaranteed by the manufacturer. In addition, the housing of the relay is inadequate for the application. Several failures of this relay have been reported in industry experience (Ref.1) as a result O of dirty relay contacts. It is recommended that this relay be replaced by an enclosed relay with the proper coil voltage range.

Detailed recommendations are given in Attachment 1 of this report.

Qualitative evaluation of the design of the voltage regulator in-dicates 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 po-tentiometer spindles with Glyptol lacquer, using MIL style multi-turn sealed potentiometers, soldering ICs to the printed circuit (PC) board directly instead of mounting in sockets, using double sided PC boards, conformal coating of the PC boa'rds, and shielding signal leads. Detailed recommendations to incorporate these fea-tures are .made in Attachment 3 of this report. When the recommenda-tions 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 reet its intended functions, imple-mentation of the recommendations of Attachment 3 is left to the discretion of Georgia Power Company.

Inspection of the subcomponents reviewed in this report (Ref. 3) revealed the following construction and mounting inadequacies:

The diodes and the SCRs of the bridge rectifier assembly are mounted on the heat sinks with tapped holes, and no other mounting hardware.

Manufacturer's recommendations required drilled holes, nuts and O- lockwashers. Westinghouse, the manufacturer of the diodes and SCRs, specifically recommends against mounting with tapped holes.

V03479/4

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- The generator control cabinets are inadequately ventilated.

Diode and SCR _ connections are terminated with up to six lugs on one stud, contrary to good wiring practice.

To assure that the current = rating and cooling of the diodes.is adequate, the diodes .must be replaced in accordance with detailed recommendations in Attachment 1. The recommendations in Attachment 1 for replacing the diodes also address the diode mounting and constructon deficiences found in the-inspection of the diode and SCR heatsinks.

The construction and mounting deficiences listed above do not presently endanger the SCRs, but for continued safe operation, these deficiencies must be remedied to assure proper thermal and electrical contact with the heatsinks and to prevent . loosening of the SCRs from vibration.

Remedial measures in the form of maintenance procedures and codifications

address the mounting and wiring deficiencies of the SCRs without requiring significant modification to the equipment. The recommendations in Attachment 2 involve remounting of the SCRs and redesign of the cable terminations.

Recommendations to remedy the design ' and construction deficiencies are organized as follows:

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Attachment 1 -

The recommendations must be implemented prior to placing the engine in emergency standby service to provide adequate I diode rating and to enable monitoring of the SCRs. Recommendations are also made concerning the field flashing relay, linear reactors, heatsink wiring, and voltage regulator.

Attachment 2 - The recommendations must be implemented at the first refueling outage of the plant or earlier at the discretion of Georgia Power. When the recommendations are implemented the 1 maintenance procedures in Sections IB and IC of Attachment 1 are no longer necessary.

Attachment 3 -

The recommendations should be implemented at the discretion of Georgia Power to enhance the long-term reliability and

,, performance of the voltage regulator. These recommendations repre-h sent design changes to the equipment and would best be implemented

by the manufacturer at the request of Georgia Power.

Other incidents reported in the EDG Component Tracking System not involving the subcomponents considered in this report were reviewed.

l 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.

7 The information provided on TER 11-089 has been reviewed and is consistent with the final conclusions of this report.

i i

V03479/5 REV 1

V Page 6 of 14 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 Vogtle if all the recommenda-tions of Attachment 1 of this report are adopted. The recommendations of Attachment 2 of this report must be implemented at the first refueling outage or earlier, at the discretion of Georgia Power. When the '

recommendations of Attachment 2 are implemented, the recommendations of Attachment 1, Sections IB and IC will no longer be necessary.

Reco;amendations of Attachment 3 of this report may be implemented at the discretion of Georgia Power to improve the long-term reliability.

1 V REFERENCES

1. Component Tracking System printout for Vogtle Electric Generating Plant, Component Part. No. 02-6508, dated 12/03/84.

2. FaAA design review support package SP-84-6-46 (j).

3. Alexander Kusko, Inc. Trip Report, RTE Switchgear, 12/10/84. 1

4. Letter from Mr. R. W. Helmick of River Bend Nuclear Group to Mr. C.

L. Ray of Duke Power Company, dated 11/02/84.

5. Letter from Mr. R. D. Libbey of States Division to Mr. T. M. Jacob of SWEC, dated Augu'st 4, 1980.

6. Bechtel Specification No. X4AK01 Rev. 6, 08/19/83 for Standby Diesel Generators - Vogtle Electric Generating Plant.

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V03479/6 REV 1

Page 7 of 14 k-Attachment 1 Vogtle Electric Generatina Plant - Unit 1 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 To assure that adequately rated bridge rectifier diodes are employed in the exciter, the present diodes must be replaced following the guidelines

'below. These recommendations are intended to be used to aid the utility in requesting engineering assistance from the manufacturer of the exciter, Parsons Peebles Electric Products (formerly PORTEC), Cleveland, Ohio. The utility is advised not to attempt to implement this modification without assistance from PORTEC.

A. Diode Replacement

1. The present diodes should be replaced with diodes having the

-p following minimum ratings:

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a. Current rating - 300 A average (3 phase rectifier operation),

b. Voltage rating - 1000 V.

c. Surge current - 7000 A.

2. A suggested replacement is Westinghouse Model R7001204XXUA (for 5101015XXWA) and model R7011204XXUA (for 5111015XXWA) .

(Ref. 1).

3. These diodes should be mounted on new heatsinks following mounting procedures recommended by the manufacturer (Ref. 2).

4. The diodes should be mounted on 18-inch lengths of International Rectifier Type HE-63 heatsink (the same type as presently used) using the present spacing as a guide (Ref. 3). l S. Modification of the heatsink to accommodate the recommended hardware may be necessary.

6. In replacing the diodes, the diode heatsink wiring should be redesigned so that no more than two lugs are attached to any stud terminal.

l V03479/7 REV 1

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B. SCR Mounting

1. Monitor the SCR maximum temperature attained by the SCRs by r placing a temperature-sensitive label on the most visible face of the hexagonal body of the SCR.

2. The temperature-sensitive label should be of the type that permanently blackens when its temperature has been reached or g exceeded.

3. The temperature rating of the labels should be 210 degrees F.

Omega brand model BE-210 or equivalent (Ref. 4) is l 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 i temperature has . been exceeded, perform an electrical test on i the SCR (Ref. 5), and remove the SCR from the heatsink to inspect the mounting threads of the heatsink and SCR. Replace the SCR and the heatsink as required to assure that proper mounting tightness, _360 in-lbs (Ref. 6) and thread condition are maintained.

C. Heatsink

1. Coat the side of the lugs and mounting bolt for the lugs that

] attach to the bottom of the diode and SCR heatsinks with Glyptol

. lacquer (Ref. 7),

d

2. Apply the Glyptol on a readily visible side so that relative motion 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 j generator.

Retighten connections that appear to have loosened.' Remove old 4.

Glyptol and reapply if connections are retightened.

() . Cabinet Ventilation

1. The left-front generator control cabinet should be ventilated .

i so that the temperature in the cabinet does not exceed 50 l

degrees C (122 degrees F).

II. VOLTAGE REGULATOR PRINTED CIRCUIT BOARDS l

The recommendations below pertain to the automatic and manual voltage regulator, which is located in the center front cabinet. 1 V03479/8 REV 1 t

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A. Adjustment Potentiometers

1. Coat one side of the adjustment screw for each of the adjustment l

_ 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 con.plete.

B. Printed Circuit Board

1. At each refueling outage, remove the covers of the voltage regulator enclosures and inspect the components mounted on the printed circuit boards. 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 t the request of Georgia Power Company. 1 A. Relay Rating

1. Replace the FF relay (a de contactor, Class P10 Cat. No.

P102D12, made by Gould Distribution and Control Division, Ref.

8) by an equivalent de contactor rated as follows: coil voltage operating range, 100-140 V; contact voltage, 250 V dc; contact current, 110A dc (interrupting and continuous). It may be necessary to install .a voltage reduction circuit to permit the y use of a contactor with a conventional coil voltage range.

B. Relay Enclosure. ,

1. The relay' should be of the enclosed type to prevent particles of dirt from being deposited on the contacts.

C. Relay Logic

1. Review the design of the relay logic in the field flashing cir- I cuit to determine whether the overheating problem (discussed in the report) exists. If the problem exists, all diesel generator starts (other than emergency starts) should be monitored to assure that an unsuccessful start does not result in a period C of prolonged field flashing resistor energization. A manual

(, reset of the exciter should be initiated if the resistor is energized for more than 10 seconds. Alternatively, a control logic modification could be implemented to produce the desired circuit operation.

V03479/9 REV 1

i\ Page 10 of 14 U

IV. WIRING The recommendations below pertain to all generator control cabinets. 1 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. I V. REFERENCES

1. Westinghouse Power Semiconductor User's Manual, pp. R39-R42.

2. Westinghouse Power Semiconductor User's Manual, pp. G43-G46.

3. Portec Drawing No. 72-15 201-002.

4. 1983 Omega Temperature Measurement Handbook, Omega Engineering, Inc.,

p. Q-5.

p)

( 5. Portec Static Exciter Voltage Regulator Instruction Manual.

6. Westinghouse Power Semiconductor User's Manual pp S41-S44.

7. Gerber Electronics Catalog, p. 585 - General Cement Production Bulletin.

I

8. Portec Dwg. D72-12500-710.

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V03479/10 REV 1

Page II of 74 Attachment 2 Vogtle Electric Generating Plant - Unit 1 Recommendations for Design and Construction Modifications - Generator Controls I. BRIDGE RECTIFIER ASSEMBLY The recommendations below pertain to the bridge rectifier assembly, which y is located in the left front cabinet.

A. SCR Mounting

1. The SCRs must be mounted on the heatsinks with drilled holes, nuts, and lockwashers, and tightened to the proper torque (Refs. 1 and 2).

B. Heatsink Connections

1. The bolted-on lug arrangement must be redesigned so that there are not more than two lugs on each bolt.

O 2. Heatsink anodizing must be removed in the contact areas of all bolts and bus bar studs.

y

3. Current-carrying surfaces of lugs must not be separated by washers or nuts.

II. REFERENCES

1. Westinghouse Power Semiconductor Manual, pp S41-S44.

2. Westinghouse Power Semiconductor Manual, pp G43-G46.

O V03479/11 REV 1

N Page 12 of 14 Attachment 3 Vogtle Electric Generating Plant - Unit 1 Modifications Recommended to Improve Long-Term Reliability - Generator Controls (To be performed by manufacturer at the request of utility)

I. VOLTAGE REGULATOR The recommendations below pertain to the automatic and manual voltage regulator, which is located in the center 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. Inspec-tion of the PC board and the voltage regulator schematic shows g that power supply bypassing has been almost completely neglected 5 in the circuit design. The following modifications are recom-mended:

a. The power supply terminals of. each individual integrated 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. D72-13000-710 Rev. E, Schematic-SVS Regulator with paralleling) require bypassing capacitors of 0.1 micro-farad so that transients will not get back to the ICs (Ref. 2).

b. In addition to the high frequency bypass capacitors, a large value capacitor (approximately 10 microfarads) is recommended for voltage regulator op amp U1, Portec Drawing No. D72-13000-710, Schematic-SVS Regulator with paralleling. This is because of the presence of CR31 and R73.

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 leads. This is done by using shielded signal leads and by routing the leads so as to maximize Q the distance between the signal and high current leads. These h techniques have been neglected in the wiring of the voltage regulator.

V03479/12 REV 1

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s Page 13 of 14 The following modifications are recommended:

a. Shielded signal leads should be used for the connections between the motor-driven potentiometer and the voltage i regulator.

b. A high frequency bypass capacitor providing an in-circuit low frequency cutoff of no less than 1 kHz should be installed to reduce high frequency noise on the feedback signal without interfering with the feedback loop operation, t

.c. The leads for the SCR gate signals should be run in separ-ate bundles away from the current carrying leads.

3. Current Feedback Signal 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 three-phase current sensing circuit. This requires the use of a three phase sensing transformer and a three phase bridge rec-tifier circuit on the PC board. Additional stability is pro ,

vided by reducing the filtering requirements of the feedback signal, which are presently provided by a resistance-capacitance filter on the PC board.

B. Construction -

1. Vibration Protection Reliable mounting of components on the PC board and the proper selection of components is necessary to ensure that the voltage regulator can withstand the vibration encountered during seismic events, construction or maintenance. However, the design of the board does not appear to be adequate for these 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).

b. The voltage range and stability adjustment potentiometers (R4 and RS) are unsealed, one turn commercial grade de-O vices. 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.

V03479/13

Page 14 of 14

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 modifi-cations 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 side 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 should be provided to hold the components in the sockets. ,

II. REFERENCES O'~' 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 Trial-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 V03479/14

p 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.

~

S. Check fuel oil pump rack for freedom of movement through full limit of travel. Do not disconnect from governor.

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

7. Drain water from crankcase vent piping drip legs.

8. Verify all controls in proper position for standby mode.

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9. Visually inspect lube oil heat exchanger and jacket . water heat exchanger for signs of leakage from the lantern ring leakoff ports, l1 indicating leaking packing rings.

The following Preventive Maintenance Recommendation 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 Vogtle on a planned schedule basis. It should be followed closely and referred to often.

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V0GTLE MAINTENANCE MATRIX Component Component Alt.

Ember Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments F-068 Intercoolers 1. Evaluate heat exchanger X j performance by checking

engine operating parameters. 7 j 2. Clean / inspect shell and X Ref: Lead engine DR/QR 4 tube sides every outage ' Report #F-068

. or as necessary. (Items 2, 3, 4)

} 3. Visually inspect for X Ref: 7/26/84 IOC

! external leaks. from J. Cadogan to 1 M. McGerigle,

! Ref: 08/14/84 letter i to C. Ray from j M. Lowrey .

i 4. The drain connection on To be performed daily.

1 the air intake system

]I low point should be j verified open, and j cleaned daily.

I 1 MP-022/3 Turbocharger 1. Measure vibration and X To be accomplished during

j. check with base Ifne data. 24 hour2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months test run.

2. Clean impeller and diffuser. X

3. Measure rotor end play X Review thrust bearing (antal clearance) to axial clearances after identify trends of in- inspection to determine

, creasing clearance, i.e; if a trend exists. Any i thrust bearing degradation. trend toward increasing .

} axial clearance could 4 signify thrust bearing j degradation. Ref: Lead engine DR/QR Report

MP-022/3 i j V03171/4 Revision 1 l i l

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V0GTLE MAINTENANCE MATRIX Component Component Alt.

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

3. Lube oli strainer X pressure gauge - call-bration check. 't SE-031 Lube 011 Keepware Pump 1. Check strainer differential Clean and/or replace the If pressure DAILY. element when the manu-facturer's recommended maximum differential pressure is achieved.

Ref: Shearon Harris DR/QR Report #02-4650 Task Description.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.

Ref: Lead engine DR/QR Report #00-/20

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

regulating valve should be disasseebied and cleaned until abnormal L.O. pressure excursions subside.

V03171/6 Revision 1

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G J 0 V0GTLE MAINTENANCE MAT E Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments Complete TDI Inspection and Maintenance Record form Mo. 115-1-1. TDI Instruction Manual, Volume I, Section 6.

Ref: Lead engine DR/QR Report #02-3418-02-317A&B Water Discharge Manifold - 1. Visually inspect for leaks. X This recommendation is Jacket Water Discharge Note: In the event of a made on the basis that Piping, coupilngs a w seals leak developing in the the maximum suggested existing Dresser Style 65 operating temperature of coupilngs, these couplings 150*F for the Style 65

, should be replaced with coupilng may be exceeded.

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

I Ref: Letter dated 8

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

Report #02-317A&8

]

) 02-340A/B Connecting Pods Bushings 1. Inspect and measure con- To be performed in

. and Bearing shells necting rod bearing shells conjunction with piston j to verify lube oil mainte- pin inspection. Con-j nance which affects wear plete TDI Inspection

, rate. The visual and dimen- and Maintenarce Record j sional inspection of the Form No. 340-1-1, TDI bearing shells should be Instruction Manual,

conducted at the fuel Volume I, Section 6, i outage which precedes 500 Appendix III for

hours of operation by at clearance values.

least the sum of hours of Ref: Lead engine DR/QR V03171/10 Revision 1 i

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m-V0GTLE MAINTENANCE MATRIN Component Component Alt.

Number Identification PM Recommendation Monthly- Outage Outage S Year 10 Year Comments

2. , Visually inspect and Not to exceed 1300 measure exhaust rocker maximum hours of engine arm bushings, operation between inspections as described auove.

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

02-390G Rocker Arm Capscrews, 1. Verify capscrew torque X This inspection should Drive Studs (Pop Rivets) values. be performed at each outage if the rocker 1 disassencled for inspection. Use TDI Instruction Manual, Volume I, Section 8, Appendix IV for proper torque values.

2. Verify that rocker arm X Ref: Lead engine DR/QR drive studs are intact Report #02-390G and tight. (Items 1, 2) 02-410A Overspeed Trip Governor 1. Check trip set point X Modify the surveillance

- adjust as required. testing procedure to include verification that the overspeed trip is correctly set to an overspeed trip setting of $18 rps il % every outage.

V03171/26 Revision 1 1

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V0GTLE MAINTENANCE MATRIX a

Component Component Alt.

4 Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments Ensure that the electric governor and the mechanical backup governor setting are 1 properly returned to their normal settings following the overspeed test. The test is to be performed with no load on the engine-

by increasing the normal governor speed setting (s) until a trip occurs.

After several inspection

, periods, the history of the required adjustments

should be reviewed to evaluate and possibly 4 modify the testing j interval.

Ref: Lead engine DR/QR Report #02-41DA Note: After setting the over-speed governor, the ad-justment screw settings

, should be marked with l Torque Seal to reveal any unintended changes in the set positions.

02-4108 Overspeed Trip Governor 1. Remove plugs from housing X Ref: IOC dated 03/27/84 and Accessory Drive and check for magnetic from M. Weyneyer to ,

particles. N. Cooperrider. (Items 1, 2, 3)

2. Check shafts for excessive X radial and axial movement.

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m J V V0GTLE MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments governor response, 4

during an engine start ,,

to ensure agreement with the specification as detailed in Item #5 above.

{ 02-4158 Governor Booster Servosotor 1. Clean, inspect, and X 'Ref: 3/27/84 IOC from replace "0" rings M. Wehmeyer to i and gaskets. J. Kammeyer

! 02-415C Governor Heat Exchanger 1. Clean and inspect. X 02-425 Jacket Water Pump - Gear 1. Visually inspect jacket X Any abnormal situations 3 water pump gear for or indications of pro-

chipped or broken gressive pitting should 1

teeth, excessive wear, be reported for an

! or potential / progressive engineering evaluation.

pitting or other Ref: Lead engine DR/QR I abnormal conditions. Report #02-3558

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 shaft, will preclude shaft to impeller and past problems where

the spline to pump relative motion between 1 shaft during pump both the shaft and reassembly. Impeller, and the spline and pump shaft caused fretting and upset of the keyway sides. Ref: DR/QR Report #02-425A V03171/32 Revision 1 i

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I V0GTLE MAINTENANCE MATRIX l Component Component Alt.

7 Number Identification PM Recommendation Monthly- Outage Outane 5 Year 10 Year, Comments i

3. It is recommended that Ref: DR/QR Report the castle nut that #02-425A

!g drives the external To be performed i' spline on its upon reassembly.

taper, have minimum and maximum torque values of 120 i ft-lbs and 660

ft-lbs respectively.

i

02-435A Jacket Water Fittings - Pipe 1. Visually inspect for leaks. X This recommendation is '

j and Fittings (Small Bore Note: In the event of a made on the basis that i Scope Only) leak developing in the the maximum. suggested i existing Dresser Style 65 operating temperature couplings, these couplings of 150*F for the Style should be replaced with 65 coupling may be Dresser Style 90 couplings exceeded.' The maximum equiped with Viton gaskets. suggested operating temperature of the Style

90 is 212*F.

! Ref: Letter dated

] 12/13/84 from C. L. Ray to J. George.

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02-437 Turbo Water Piping - Pipe 1. Visually inspect for leaks. X This recommendation is j and Fittings Note: In the event of a made on the basis that

leak developing in the the maximum suggested

! existing Dresser Style 65 operating temperature ,

i couplings, these couplings of 150*F for the Style l should be replaced with 65 coupilng may be

' Dresser Style 90 couplings exceeded. The maximus j equiped with Viton gaskets. suggested operating .

temperature of the Style l

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V0GTLE MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments equiped with Viton gaskets. suggested operating temperature of the Style 90 is 212*F.

Ref: . Letter dated 12/11/84 from C. L. Ray to J. George.

02-475A.C Turbocharger: Bracket 1. Each month for the first Refr: DR/QR Reports Bolting and Gaskets three months of commercial #02-475A C operation these screws should be inspected to assure that no screw has loosened because of engine operating loads. If during these inspections none of the screws are found loosened or damaged, from then on inspections are to be conducted on a yearly g basis (or during plant shutdown). But if any time during inspection any screw is found loosened or damaged, it must then be replaced (if damaged) and all screws retorqued as follows; 125 ft-lbs for the bracket to engine screws and 75 ft-Ibs for the bracket to turbo base screws.

Note: To avoid damage to bracket to engine, and/or bracket to turbo, base screws, the proper torques V03171/38 Revision 1 s

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V0GTLE MAINTENANCE MATRIX Component Component Alt.

l Mumber Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments as delinated above should 1 be utilized for each ,

respective bracket bolting 's application.

02-4758 Air Butterfly Valve 1. Lube valve shaft X Ref: IOC dated 3/28/84 via grease fittings, from M. Wehmeyer to J. DiMare.' If all' cups i are used, this should

! be completed monthly.

2. Check valve disc for X Check by visually observ-j, freedom of movement. ing valve / actuator oper-ation. Ref: 04/16/84 j from R. Jaquinto to 1

R. Johnson i 3. Verify that associated X Ref: DR/QR Report locking devices (jas #02-4758 nuts and lock washers)

, are tight.

1 4

02-500A Engine Control Cabinet 1. Inspect interior of cabinet X Ref: 3/29/84 IOC for cleanliness and clean from M. Wehmeyer as required. to T. Jacobs for

Itees 1-5, Ref: 07/30/84 IOC from J. Cadogan to

) K. Hore11k for Items 1-6

, 2. Visually check wiring for X

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insulation degradation.

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

3. Visually check instrument X tubing for leaks.

o

4. Functionally check cabinet X heater and calibration of thermostat.

L. Test pneumatic $/D board X logic.

6. Replace "0" rings, gaskets X and filter in pressure regulator.

02-500C Circuit Breakers and Contact 1. Check all terminals X To be accomplished during Blocks clean / tighten. panel clean / inspection.

2. Visually check wiring X To be accomp11shed during insulation for degradation. panel clean / inspection.

3. Trip check circuit breakers. X 02-500G Control Panel Valves 1. Inspect and clean control X This recommendation i..-

panel valves, terval should be reas-sessed depending on the degree of system fouling.

Ref: Lead engine DR/QR Report #02-500G

2. Inspect and clean the X Ref: Lea'd engine DR/QR 200 mesh screen in the Report #02-190G check valve.

V03171/40 Rev. 1 Carryover from Previous Page

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O(g b V V0GTLE NAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outaae 5 Year 10 Year Comments 02-500J Control Panel Assembly: 1. Inspect contacts and clean X Ref: 08/10/84 IOC from Relays as required. K. Hore11k to J. Cadogan a

2. Visually check condition X of wiring and tightness of terminations.

02-500N 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.

02-525B Barring Device Control Valve 1. Drain filter daily while Ref: Lead engine DR/QR barring device is in Report #02/525B (Items operation. 1, 2)

2. Replace regulator X elastometric parts.02-550 Founaation Bolts 1. Visually inspect founda- X Ref: TDI Instruction tion for breaks in the Manual, Maintenance bond between the sole Schedule, Section 5 plates and grout.

2. Check foundation bolts X Use TDI Instruction ,

for correct torque. Manual, Volume I, V03171/41 Rev. 1 Carryover from Previous Page

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V0GTLE MAINTENANCE MATRIX Component Component -

Alt.

Number Identification PM Recommendatico Outage Outage Mor.thly 5 Year 10 Year Comments Retorque as necessary Section 8 Appendix then recheck crankshaft IV for proper torque web deflections, values.

3. Generator foundation bolts Ref: Lead engine DR/QR are to be retorqued after Report #02-550 a generator short circuit if the bolts were initia11y torqued to 480 ft-Ibs. If initial. bolt torque was 600 ft-lb no retorque is required.

02-6300 Thermocouples 1. Check that thermocouple X An inconsistant reading indicates ambient engine traced to thermocouple temperature when the trouble should result engine is cold. in rrplacement of the thermocouple.

2. Clean and irspect X Indications of fatigue thermocouples and thermo- should result in re-couple shields. placement of the thermo-couple and/or thermo-couple shield, Ref: 7/31/84 Memo from S. Riess to W. Littmann

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 IOC from J. Cadogan to S. Riess V03171/42 Rev. 1 l

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I V0GTLE MAINTENANCE MATRIX

! Component Component Alt.

Number Identif! cation PM Recommendation Monthly Outaes Outace. 5 Year -10 Year Comments l 02-650A Emergency Generator 1. Check operation of X Ref. IOC dated 03/30/84 l brushes and slip rings. M. Wehmeyer to D. Mercaid l (Items 1-5).

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2. Clean / inspect all. X

} accessible parts of

the generator.

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3. Megger rotor and stator. X ,

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! space heaters.

i 5. Measure vibration and .X i check against base line data, j 02-6508 Emergency Generator 1. Inspect panel for X Items 1-5; Ref: 3/30/84

Control Panel cleanliness and clean IOC from M. Wehmeyer

! as required. to D. Mercaldi i; 2. Check terminal boards X for loose wiring.

3. Visually check condition X i of wire insulation for degradation.

4. Clean and inspect relay X contacts.

5. Check meter calibrations. X 1

6. Bridge rectifier assembly Ref: DR/QR Report

]

0?-6508, Attach. 1

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and SCR mounting.

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V0GTLE MAINTENANCE MATRIM 4

Componeet Component Alt.

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

a. Inspect the temperature X If either of the labels <

sensitive label placed permanently blacken the

{ on the most visible maximum, temperature of the t ' face of.the hexagonal diode and/or SCR has been body of the diodes exceeded requiring an j and the SCR. These electrical inspection ,

labels shall be and an inspection of

inspected before and the mounting threads I

after each running of the heat sinks and

< of the engine. diode and/or SCP.

j Replace the diode and/or SCR and the heat sinks I as needed and assure that

proper mounting tightness j

of 300 in-lbs (diode) and 275 in-Ibs (SCR) and proper thread condi-tions are maintained.

b. Inspect glyptol applied X To be performed after to the side of the lugs each monthly test run.

, and mounting bolt for Retighten any loose j the lugs which attach connections, remove j .to the bottom of the old glyptol and reapply 4 diode and the SCR if connections are

} heatsinks for signs retightened.

j 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 glyptoi j of the five adjustment and reapply when the

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potentiometers on the adjustment procedure printed circuit board is complete.

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i V0GTLE MAINTENAIICE MATRIX Component Component Alt.

! Number Identification PM Roccamendation Nanthly Outace Outace 5 Year 10 Year Comments 1

i of the voltage regulator j- for signs of relative motion. ,

I i 8. Printed circuit boards - X To be performed after

! check for cleanliness each monthly test run, i and proper sounting of Report any abnormal i components. conditions to engineer-ing for evaluation.

l i 02-650C Emergency Generator Pedestal 1. Check ring oilers X To be accomplished during j 8 earing for proper operation every test run of the j and verify oil level, engine.

4 Ref: 3/30/84 IOC j from M. Weheeyer -

l to N. Cooperrider

(Itees 1-4) f 4

2. Drain flush refill X

bearing housing.

J

] 3. Measure bearing housing X 1 insulation resistance.

I 4. Disassemble and inspect X 1 bearing and check

} clearances.

02-6958 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 802-6958 (Items 1 & 2)

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V0GTLE MAINTENANCE MATRIX Component Component Alt.

Ihmeer Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments

2. Replace elastomeric parts X and gaskets in the pressure regulator. .,

02-695C Engine Control Pneuestic Trip 1. Check swiLJ. set points. X Pressure switches.

Switches Ref: 3/30/84 IOC from M. Wehmeyer to J. DiMare -

2. Replace elastomeric parts. X 02-7008 Jacket Water Standpipe: 1. Replace elastomeric parts X Ref: Lead engine DR/QR Valves in circle seal valves. Report #02-717B 02-700F Jacket Water Standpipe 1. Visually inspect jacket Any visible cracking and Miscellaneuous Bolting water standpipe, pump or minor jacket water suction and engine return leakage should result I nozzle welds during each in rework of nozzle routine engine run and welds.

every 100 hours0.00116 days 0.0278 hours 1.653439e-4 weeks 3.805e-5 months during Refr: DR/QR Report extended engine runs. #02-700F 02-7175 Auxiliary Sub-base & Gil & Water 1. Inspect the valves for X Replace as necessary.

Piping - Jacket Water: Valves packing leakage. Ref: Lead engine DR/QR Report #02-717B 02-717C Auxiliary Sub-Base & 011 & 1. Visually inspect for leaks. X This recommendation is Water Piping - Jacket Water: Note: In the event of a made on the basis that Pipe, Coupilngs, Fittings, leak developing in the the maximum suggested Orifices. Y-$ trainers existing Dresser Style 65 operating temperature (Small Bore Scope Only) couplings, these coupilngs of 150*F for the Style should be replaced with 65 coupilng may be Dresser Style 90 couplings exceeded. The maximum equiped with Viton gaskets. suggested operating s

V03171/46 Rev. I and Carryover from Previous Page

- =' e . - - ~ .-.A -.4 -- 7 m -. m ------ L O O O 4

V0GTLE MAINTENANCE MATRIX Component Component . Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments temperature of the Style 90 is 212*F.

! Ref: Le ter dated

! 12/13/84 from C. L. Ray to J. George.

l

! 02-717F Auxiliary Sub-Base Lube Oil 1. Visually inspect for leaks. X This recommendation is l

} Pipe and Fittings Mote: In the event of a made on the basis that leak developing in the the maxieue suggested ,

existing Dresser Style 65 operating temperature t

couplings, these couplings of 150*F for the Style i should be replaced with 65 coupling may t e i Dresser Style 90 couplings exceeded. The maximus -

equiped with Viton gaskets. suggested operating i temperature of the Style 90 is 212*F.

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

4 Ref: 4/2/84 IOC from M. Weheeyer to J. Freeman l

, 2. Clean and inspect L.O. X Complete when L.O. tank keep ware pump suction is drained.

! strainer. Ref: 04/16/84 letter from R. Jaquinto to R. Johnson j 02-717G Auxiliary Sub-Base Lube 011 1. Disassemble, lubricate, X Ref: IOC dated 4/6/84 Valves inspect and refurbish. from M. Weheeyer to J. DiMare.

Ref: Lead engine DR/QR Report #02-717G i

V03171/47 Rev. 1

} Carryover from Previous Page l

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m 7s V0GTLE MAINTENANCE MATRIX Component Component Alt.

Mumber Identification PM Recommendation Monthly Outace Outace S Year 10 Year Comments

2. Olssassemble, clean and X Ref: 07/31/84 IOC check relief valve to M. McGerigle from lift pressure. J. Cadogan, Ref: 08/16/84 IOC from M.' McGerigle to J. Cadogan, Ref: Lead engine DR/QR Report #02-717G/K (Items 1 & 2) 02-717N 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 thermostat.

02-717P Lube 011 Sump Tank 1. Measure heater X Replace heater if de-Heaters insulation resistance. gradation of insulation resistance is noted.

2. Inspect and clean X To be accomplished during heater elements. tank inspection.

3. Check calibration and X Ref: 05/10/84 IOC inspect condition of from M. McGerigle thermostat. to W. Brown for Items 1, 2, 3 02-717Q Jacket Water Heat 1. To avoid corrosion and Ref: Lead engine DR/QR Exchanger fouling the jacket water Report 802-810C, heat exchanger and Ref: 04/20/84 IOC V03171/48 Rev. 1 Carryover from Previous Page

n m s m

\

V0GTLE MAINTENANCE MATRIX Component Component- Alt.

Number Identification PM Recoseendation Monthly Outane Outane 5 Year 10 Year Comments associated service from M. Idehmeyer to water piping should be R. Kadlec flushed on a periodic **

basis (continuous service flow is sufficient).

Alternatively, service water chemistry control can be used to maintain heat exchanger performance and integrity.

2. Perform a daily visual To be performed daily, inspection for leakage Ref: 07/19/84 Telecon at packing whenever the D. Pasquale and engine is in the R. Ch11 emergency standby mode.

Verify that no leakage is present through the leak-off ports of the lantern ring.

3. Record heat X Use for trend data exchanger perfor-eence by checking engine operating parameters.

4. Evaluate heat exchanger X performance data.

5. Inspect tubes X Ref: TDI Instruction and tube sheet Manual, Volume I, for fouling and Maintenance Schedule errosion - remove entrance and exit channel covers.

V03171/49 Rev. 1 Carryover from Previous Page

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V0GTLE 9441mTEmamCE MATRIX Component Camponent Alt, thaber Identification Pet Recommendation stonthly Outage Outage 5 Year 10 Year Comments Replace packing rings Ref: Lead engine DR/QR at floating tube Report #02-810C sheet af ter tube '+

inspection.

6. Inspect and clean X Replace / rework lantern ring. Verify lantern ring as leak-off holes are necessary'to not plugged. ensure concentricity prior to reinstall-ation.

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 02-717R Liee Oil Heat 1. Perform a daily visual Ref: Shoreham DR/QR Exchanger inspection for leakage Report #10-104 at packing. Verify Ref: 06/12/84 IOC that no leakage is from R. Chit to present through the P. 84artia, leak-off ports of Ref: 04/02/84 IOC the lantern ring. from M. idehmeyer to R. Kadlec

2. Record heat X Use for trend data exchanger perfer-mance t'y checuing engi.M cperating parameters.

V03171/50 Rev. 1 Carryover from Previous Page

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40GTLE Ith!NTEleAseCE penTRIM Campenent Camponent Alt.

Iemmer Identificatten Pet neceamendation Itenthly Outage . Outage 5 Year 10 Year Comments

3. Evaluate heat enchanger X performance data.

n

4. Inspect tubes and X Ref: TDI Instruction tube sheet for Manual, Volume I, erosion and fouling - Maintenance Schedule, remove entrance and Ref: 07/19/84 Telecon exit channel covers. D. Pasquale and R. Chii

5. Inspect and clean X Replace /reuork lantern ring. lantern ring as Verify leak-off necessary to holes are not , ensure concentricity.

Plugged.

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 analysts approntaate quarterly of tf.e tube oil, intervals.

Particular attention Ref: Lead engine shall be given to DR/QR Report #02-820G percent moisture content.

02-7175 Full Flow Lube Oil 1. Record filter d/p. X Use for trend data, Filters Ref: 04/02/84 IOC from M. Wehmeyer to 1

V03171/51 g 3 Carryover from Previous Page s

C O O V0GTLE IIAIPTEtenseCE teATRIX cvwt Component Alt, thaber Identification P98 Recommendation Monthly Outaea Outage 5 Year 10 Year Comments J. OlMare, Ref: TDI Instruction Manual, Volume I.

Maintenance Schedule

2. Drain water and/or X sludge from lubri-cating 011 full flow filter.

3. Replace' filter To be performed before cartridges and the filter d/p reaches the perform a visual manufacturers recor wnded inspection to maximum differential determine the pressure. Ref: 05/30/84 nature of the IOC from M. McGerigle material caught to 8. Brown, in the filter. Ref: Lead engine DR/QR Report 802-820F, Ref: 07/31/84 IOC from J. Cadogan to M. McGerigle

4. Lube oil filter X gauge - calibra-tion check.

02-717U Lube 011 Keep-Wars Pump 1. Check operation of X Items 1-5; Ref:

pump / motor bearings. 04/05/84 IOC from M. Wehmeyer to T. Fritsch

2. Check eechanical seal X leakage.

V03171/52 Rev. 1 Carryover from Previous Page

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(~ .(~Y m./

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l 40GTLE MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outace Outaae. 5 Year' 10 Year Comments

3. Record pump X Use for trend data discharge pressure.

u

4. Measure unit vibra- X tion (pump / motor)

5. The pump should be To be performed daily-inspected for signs Refr: DR/QR Report of leakage and #02-820C corrective modifications 1

(addition of flexible piping connections) be implemented as required.

02-717V Lube 011 Keep-Wars F11ter 1. Record filter d/p. X Ref: 04/05/84 IOC froe' M. Wehmeyer to J. DiMare

2. Change filter To be performed before elements. the filter d/p reaches the manufacturers recom-mended maximum differen-tial pressure. Ref:

Lead engine DR/QR Report #02-820E 02-71N Thermostatic Valves 1. Replace thermal power X Ref: Lead engine DR/QR ,

Report #02-8100 (Items

~

elements at 3 to 5 year internals. 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.

v03171/53 Rev. 1 Carryover from Previous Page

f. [ _

V0GTLE MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outace Outace 5 Year 10 Year Comments 02-805A Intake Air Filters 1. Inspect air intake dis- X Ref: Perry Lead engine tribution plate and DR/QR Report #02-8050 change filter oil. 7 02-8050 Flex Connection 1. Visually inspect for X evidence of cuts, holes, or dents.

02-835A Diesel Starting Air 1. Check lubricating all X All items; Ref:

Compressors level. 04/02/B4 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.

4. Replace intake filter X element.

5. Change compressor oil. X C. Check belt tension. X

7. Check pulley clamp X bolts / set screws tight.

8. Inspect filter felts on X Replace as necessary.

unloader system.

V03171/54 Revision 1 Carryover from Previous Page

i o d t v V0GTLE MAINTENANCE MATRIX Component Component Alt.

Number Identification PM Recommendation Monthly Outage Outace S Year 10 Year Comments 02-835C Ste-t ng Air Float Trap 1. . Verify operability daily Ref: Rancho Seco DR/QR Report 903-835C Task Description (Items 1, 2) 3

2. Disassemble, c?ean and X inspect 02-8350 Starting Air Tank 1. Drain air receiver float If quantity of traps or drain valves moisture is DAILY and monitor the excessive correct .

quantity of moisture immediately. Check produced at the float air dryer operation.

traps or drain valves. Ref: Lead engine DR/QR Report #02-835J

2. Disassemble and clean X Ref: IOC dated the float trap. 05/08/84 from P. Titus to P. Martin (Items 1

& 2)

3. Starting air tank pressure X gauges - calibration check.

4. Starting air tank pressure X switches - calibration check.

02-835G Air Dryers and 1. Blow down trap X Ref: 04/05/84 IOC Moisture Traps sediment bowls. from H. Wehmeyer to J. Kammeyer,-

Ref: TDI Instruction Manual, Volume I, Maintenance Schedule

2. Inspect and service X moisture traps.

V03171/55 Revision 1 and Carryover from Previous Page

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l 1

j V0GTLE It41NTEllANCE It4TRIX Component Camponent Alt.

Ilumber Identification Pet Recommendation 14onthly Outano Outaae 5 Year 10 Year Comments J

3. Check proper operation X Replace desiccant charge of desiccant dryer. as required.

1 Ref: 04/16/44 letter

from R. Jaquinto to l R. Johnson ;

Jacket hter System 1. Check pH. factor X Ref: TDI Instruction ;

of Jacket water and planual, Volume I, plain-i correct as recom- tenance Schedule j mended by chemical

supplier, i

1 2. Replace elastomeric parts X j in jacket water valves.

l Lube 011 System 1. Check lubricating X Ref: TDI Instruction oil with a viscost- Manual, Volume I, Main-

)* meter for fuel oli tenance Schedu'e, Items dilution. Send a 1, 2

! sample of oli to laboratory for analysis.

] ,

! 2. Drain lubricating X Idhen replacing engine a oli system and oil use H.D. oli that clean sump tank. meets or exceeds series 3 Depending on tre standards. The base stock results of tube should be more resistant :

oil analysis, refill to thermal degradation ,

with new oil. and coke formation. The additive package should provide high detergent dispersant properties .

i with high alkalinity and j a high level of antiwear

}

t V03171/56 Rev. 1 Carryover from Previous Page 1

N

~

O WOGTLE IttlhTERAIKE STRIM Campenent Campenent Alt.

Ihaber Identification pel Recommendation stenthly Outaae Outane 5 Year le Veer Ceements addittwo such as zine eithlephosphate. Total Base Ihaber (TEII) should be 12 to 15 for use with p2 fuel ett and a sulfated ash centent of 1.5E to 2. 5 is preferred. An engine all with such properties.

Itob11 guard 412 or equivalent product may be used to insure leproved l erication.

3. Visually inspect lee x To be performed oli sump tanet level after lube oil-switch floats. has been drained ChecIt switch set from sump.

points.

.4. perform a spectro- To be perfereed at cheelcal analysis approxiestely quarterly of the tube oil.

Intervals. Ref: TDI Instruction knual, welume I, h intenance Schedule.

System Operation 1. Record all operating x To be performed parameters. Compare during monthly with base line data engine test run.

to ensure engine is operating properly.

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WOCTLE IthlmTEmamer gehTaII Campenant ry-g Ag g, Ihamer Identificaties pet Recommendation nanthly Outaae Outage 5 Year le Year Comments Piplag System 1. Conduct a detailed X Tighten, repair or visual and audible replace as required.

Inspection of all Ref: TDI, Instruction fuel, air, oil. Manual, Volume I, and water piping Maintenance Schedule and valves for leakage.

2. Inspect, clean and X as appitcable.

Id ricate manual valves on skid.

Engine Internels 1. Remove alternate left X If excessive side d ors and uater, sludge or examine the inside any indication of of the opgine for any bearing failure abnormal conditions. is present, drain ChoctL with a good crankcase, deter-light for evidence of eine cause, and take babbit flakes. necessary action.

Miscell- Engine gesunted 1. Replace elastomeric X anceous Pressure Switches parts.

Gear Train 1. Inspect gears for X general condition.

. 2. Measure gear bact X Replace uorn lash en all gears. gears exceeding maximum clearance.

Complete TDI Inspection and Maintenance Form No. 355-1-1 W31W54 Rev. I Carryover from Previous Page

40GTLE 8EnlWTEIIANCE IthTetz Cet Ceapeaset Alt, we jeontificetten Pet Secommensatten stenthly Outene Outeen 5 Year 10 Year Comments TOI Instruction flanuel, Vol. I, Section 5. Use Vol. I, Sectlen 8 Appendix III-I for clearence values.

Ref: 04/16/04 letter free R. Jaquinto to R. Johnsten WO3171/59 gy, g Carryover from Previous Page

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ML20112F047

Text

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