ML20113H606
| ML20113H606 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 01/17/1985 |
| From: | CLEVELAND ELECTRIC ILLUMINATING CO. |
| To: | |
| Shared Package | |
| ML20113H577 | List: |
| References | |
| PROC-850117, NUDOCS 8501250229 | |
| Download: ML20113H606 (48) | |
Text
m TABLE OF CONTENTS Perry Nuclear Power Plant TDI Diesel Generator Program Plan I.
Program Plan Summary A.
Introduction
-B.
T.D.I. Owners Group Program Plan C.
PNPP Diesel Engine General Description D.
Phase I - Known Problem Resolution E.
Phase II-Design Review and Quality Revalidation (DR/QR)
P.
Diesel Generator Disassembly, Inspection, Repair and Reassembly G.
Diesel Generator Testing and Inspection H..
Maintenance & Surveillance Program I.;
-Quality Assurance II.
' Program Plan Schedule III.
Conclusions-IV.-
Appendixes
-A.
Ferry Component Selection Result.s B.
Service Information-Memo's C.
Chronological Test Log Attachment - PNPP DR/QR Package.
V..
850125h9G5011705000440 pDR AD PDR S
Perry:Nuclezr Power Plant TDI Diesel Generator Program Plan I.
Program Plan Suorary A.
Introduction The issue of the reliability of diesel generators manufactured by TransAmerica Delaval, Inc. (T.D.I.) was prompted by a fracture of the crankshaft in one of the three TDI diesel engines furnish-ed to the Shoreham Nuclear Power Station during preoperational testing, and the subsequent discovery of cracks in the crank--
shafts of the other two Shoreham engines. These events were reported to the NRC and then publicized in NRC Information Notice 83-58. Other failures of TPI engine components have also been noted.
These noted problems with TDI diesel-generators (DG's) led to concern both within the utility commmunity and the NRC. This concern subsequently led to formation of the TDI 0wners Group which has created a program to resolve these concesas (see Section B for a description of the Owners Group Program).
Perry raclear Power Plant (PNPP) is presently involved in implementing the -Owners Group Program Plan, as it directly relates to the PNPP DSRV-16 diesel-generators. This comprehensive, detailed effort is designed to apply the Owners Group recommendations on inspection, testing, maintenance'and surveillance to the PNPP diesels in order to ensure they will reliably perform their intended safety functions and to support issuance of a full power license on schedule in mid-1985.
This Program Plan outlines the approach being taken at PNPP.for the resolution of known generic concerns (the original 16.
components), design review and/or quality. revalidation (DR/QR) of other selected engine components, expanded engine testing and inspection and a maintenance and surveillance program. Each'of these is explained in detail in the following sections..Also included is a schedule of PNPP milestones showing when specific aspects of the program are expected to be completed and when submittals to the NRC will be filed.
B.
T.D.I.~Owntra Group Progrem Plan
.Th2 Clevalend Electric.Illurinsting Compzny (CEI) and elevan other U.S. nuclear utilities formed the T.D.I. Diesel Generator Owners Group in~ order to address operational and regulatory issues relative to TransAmerica Delaval diesel generator sets used for backup power supplies in U.S. nuclear power plants, The T.D.I. Diesel Generator Owners Group established a comprehensive program which, through a combination of design reviews, quality revalidations, engine tests and component inspections, provides an in-depth assessment of the adequacy of the respective utilities' T.D.I. engines to perform their intended safety related functions.
The present structure of the T.D.I. Owners Group was formalized
.and approved at an executive meeting held in Atlanta, Georgia on December 21, 1983. Twelve utilities owning T.D.I. engines agreed to participate in a common effort to assess the adequacy of the respective utilities T.D.I. engines. After discussion of the concepts required to adequately address the TDI engines, it was agreed that a common program methodology would be utilized by all; owners. The program embodies four major efforts:
1)
Resolution.of known generic problems-2)
Design Review of important engine components and Quality Revalidation of important attributes' for selected engine components 3)
Expanded engine testing and inspection 4)
Maintenance and surveillance program The implementation of these major elements of the program will 1
provide assurance of the ability of the T.D.I. engines to provide reliable backup power supplies for nuclear power plant service.
The T.D.I. Owners Group has employed high quality technical resources and has provided close supervision of_the effort. The
^
1 use of organizations and individuals with expert knowledge in the various areas requiring investigation, inspections and analysis ensure that the evaluations of the individual T.D.I. engines are thorough and meaningful.
1-i 2
n Ths first eliment'of tha TDI Diesel Gennrator Ownars Group Progren (Phmae I) is tha resolution of generic known probisas.
The initial stages of 'the TDI Diesel Generator'0wners Group
'i' Program. included the assembly of experience data regarding diesels.. In particular, nuclear industry data was gathered for all engine manufacturers, and non-nuclear industry data (stationary diesel generator and marine diesels) was gathered for TDI engines.. Additional data is entered into this component data
~
file based on the Owner's inspection and testing results conducted as a part of the Owners Group program. A review of the accumulated data by the TDI Diesel Generator Owners Group Technical Staff has resulted in the conclusion that a limited number of engine components have had sufficient adverse operating experiences to warrant consideration as significant known problems. 'These components, which exhibited possible generic concern either for a specific engine type or among all TDI engine types, were subjected to a priority review.'and reporting program.
t.nother important element of the Phase I component selection.
. process involved' analysis of component design. As progress was-made in this' area, considerable information was exchanged among selection committee members, including the diesel engine consultants, regarding the design.o2.the TDI engine components.
This information exchange resulted in the identification of a I^
limited number of components for which specific design and/or manufacturing concerns were identified.
The result of the review' processes described above led to the
~
identification of the sixteen (16) significant known problems.
It was determined that resolution.of=these significant known
. problems would provide substantial increased confidence in 'the
-reliability of the TDI engines.
(These components have been
' addressed in 15 reports,'since two components (block and liner)
~
_ ere combined into one report). These reports were submitted to w
the NRC from March 1984 through' December-1984 as shown in Section D, Phase 1 - Known Problem Resolution.
3
e
-Tha.dssign review of thm significant known problem corpontnto addresses several key factors in accordance with the Owners Group Program. A detailed design review of each of these components was conducted to establish the adequacy of the design. An
~
. evaluation of site and industry experience, establishment of maintenance requirements, and the preparation of inspection plans also formed part of the Phase I effort. The component designs in place in the lead plant engines (Comanche Peak and Shoreham) provided the basis for the design reviews. Reports are issued
.after completion of the lead plant engine review, which formed the basis for reviews conducted for "following" engine owners
~
such as PNPP. Follow-up reports include an evaluation of different loading considerations, modified parts and other differences which should be considered as part of the design review of the PNPP engines.-
The second phase of the program (Phase II) consists of the Design
-Review / Quality Revalidation Program (DR/QR). The DR/QR has been organized to provide a detailed review of TDI engines supplied to nuclear power plants for emergency diesel generator service.
This portion of the Owner's Group Program addressed components of the engines supplied to each owner by review of the Parts Manuals supplied by TDI, design drawings, applicable industry experience, and engine teardown inspections excluding the Significant Known Problems which are addressed separately in Phase I.
Engine components were individually reviewed based on their significance to engine operation and past performance (experience data). Considering these factors, components were selected for design reviews and/or quality revalidations to assure that they have been adequately designed and fabricated.
' Design reviews consider maintenance and inspection programs, where appropriate, in addition to the component design adequacy, and in all cases examine experience data associated with each component..
Components selected for quality revalidation were subjected to inspections specified during the selection process and additional inspection which may be identified by the Design Group.
4
r In psetions w ra parformed by qualified personnel in accordcnca with approved procedures. Where required, inspection results were forwarded to the Design Group for evaluation.
Upon completion of the DR/QR Program on the lead engines, the results of the DR/QR Program for the lead engines were factored into the follow-on engines such as PNPP. A separate design review was not required, for example, on a common component for follow-on engines. However, an inspection may be required to verify that the component is actually the same as the one reviewed for the lead engine. Likewise, quality revalidation inspections completed on a component in a lead engine would serve as a basis for either in:reasing or decreasing inspections for a follow-on engine, depending on the lead engine inapection results.
Phase II DR/QR reports have been issued for PNPP, and are included as an attachment to this Program Plan. Components which are acceptable, require replacement, require increased maintenance and/or require follow-up inspection are clearly identified in the final report. In addition, the final report identifies recommendations regarding improvements for possible future implementation and recommendations regarding future testing.
In the process of evaluating specific engine components, the Owners Group technical staff provides recommendations to the owners regarding special or expanded engine or component tests or inspections which may be appropriate to insure the adequacy of the engines and components to perform their intended operational functions. Depending on the circumstances associated with the specific component, for example, prior industry operating experiences, criticality of the known failure modes to continued engine ~ operation, appropriateness of the test / inspection results with respect to accumulated operating engine hours, etc., these tests or inspections may be recommended for implementation anytime during preoperational testing, af ter a certain number of accumulated engine hours at power during preoperational testing, or as a post operational test.
5
F-ExpInd d tssting or inspacticas will gansrally be focumsd on thm
" lead". engine, with less stringent requirements for following
- engines of the same type if warranted by preceding results. (For
.PNPP the lead engine is a V-16 diesel at TUGCO's Comanche Peak).
However, if feedback from the " lead" engine inspections or testing programs result in unfavorable conclusions which have applicability to other engines, appropriate expanded testieg and/or inspection would be recommended for "following" engines (eg. PNPP).
The TDI Owners Group Program Plan (OGPP) has been reviewed by the NRC and a Safety Evaluation Report (SER) on the overall program was published on August 13, 1984. The Staff found that the OGPP incorporates the essential elements needed to resolve the outstanding concerns relating to the reliability of the TDI diesel generators for nuclear service, and to ensure that the TDI diesel engines comply with GDC 1 and GDC 17. They noted that these essential elements include (1) resolution of known generic problems (Phase I), (2) systematic design review and quality revalidation of all components important to reliability and' operability of the engines (Phase II), (3) appropriate engine inspections and testing as identified by the results of Phase I and II, and (4) appropriate maintenance and surveillance programs as indicated by the results of Phase I and II.
The Cleveland Electric Illuminating Company plans to address each of the areas in the overall Program Plan described herein in order to obtain a full power license on schedule in mid-1985.
Section 11 provides the PNPP schedule for achieving this goal.
1 6
C..
PNPP Dismal Engina Gensral Dercription Tha ettndby diszsl-ganerators supplied by TDI for ura at Parry Nuclear Power Plant Units 1 and 2 are model DSRV-16-4 engines eith General Electric generators. These engine - generator sets are rated 7000 kw and 8750 kva at a 0.8 power factor continuous with a short term overload rating of 7700 Lw and 9625 kva. Listed below is pertinent engine data:
M0DCL........................
DSRV-16-4 SERIAL NUMBERS...............
75051-2814, 75052-2815 75053-28l6, 75054-2817 FUEL.........................
DIESEL TYPE INSTALLATION............
STATIONARY - NUCLEAR STANDBY CONFIGURATION................
45 VEE NUMBER OF CYLINDERS..........
16 BORE.........................
17 IN.
STROKE.......................
21 IN.
CYCLES.......................
FOUR BMEP.........................
224 PSI HORSEPOWER...................
9717 RATED SPEED..................
450 RPM ROTATION.....................
CLOCKWISE (VIEWED FROM FLYWHEEL END)
STARTING SYSTEM..............
PILOT AIR - GEAR DRIVEN DISTRIBUTORS FIRING ORDER.................
IL-8R-4L-5R-7L-2R-3L-6R-8L-IR-5L-4R-2L-7R-6L-3R TOTAL DISPLACEMENT...........
76,266 CU-IN.
FLYWHEEL DIAMETER............
70 IN.
FUEL INJECTION TIMING........
LEFT BANK 22 (13.439 IN.)
RIGHT BANK 2l (12.828 IN.)
BEFORE TOP DEAD CENTER FUEL INJECTION PUMP RACK.....
SEE ENGINE NAMEPLATES 37.0 MM (7505l & 75052) 38.0 MM (75353 & 75054)
VALVE CLEARANCE..............
N/A (HYDRAULIC VALVE LIFTERS) 7
_~_.-.
D.
Plant I - Known Problen Rerolutien As ctstid in Secticn B, ths Ownsrs Group ilantifisd tha known generic problems associated with the TDI engines. These problems were analyzed by technical experts hired by the Owners Group to determine the possible modes of failure and to recommend scorrective actions if appropriate. Sixteen problems were evaluated as generic.and are addressed in fifteen separate reports (and supplements); two of the originally identified problems, block and liners, were combined into one Owners Group report. Where applicable, PNPP has incorporated the requirements of each of these documents into our TDI engine program. The final Phase I reports and supplements are listed below.
Applicability of each report or supplement to PNPP is also denoted.
PHASE I FINAL REPORTS WITH SUPPLEMENTS APPLICABILITY REPORT REPORT DATE TO PERRY (Y/N) 1.
CONNECTING R0D BEARING SHELLS March 1984 Y
2.
ROCKER ARM CAPSCREWS:
A. SHOREHAM ONLY March 1984 N
B. ALL OTHER ENGINES July 1984 Y
3.
CYLINDER HEAD STUDS A. SHOREHAM ONLY April 1984 N
B. ALL OTHER ENGINES May 1984 Y
4.
AIR START VALVE CAPSCREWS:
A. SHOREHAM ONLY March 1984 N
B. ALL OTHER ENGINES April 1984 Y
5.
PUSH RODS (ALL ENGINES)
April 1984 Y
6.
CRANKSHAFTS:
A. DSR-48 April 1984 N
- 4. DSRV-16 May 1984 Y
C. DSRV-12 & 20 June 1984 N
.g.
7.
JACKET WATER PUMPS:
A. DSR-48 April 1984 N
B..DSRV-12 & 16 June 1984 Y
C. DSRV-20 July 1984 N
8.
FUEL OIL INJECTION TUBING April 1984 Y
(ALL ENGINES) 8
f:
BASE AND BEARING CAPS:
A. DSR-48 July 1984 N
B. DSRV (ALL)
August 1984 Y
10.
CYLINDER 11EADS (ALL ENGINES)
August 1984 Y
11.
PISTONS:
A. AE/AF PISTONS (INITIAL)
February 1984 Y
B. AE/AF PISTONS (FINAL)
May 1984 Y
C. AN/AH PISTONS November 1984 N
12.
WIRING AND TERMINATIONS:
A. SHORERAM ONLY April 1984 N
B. GRAND GULF ONLY June 1984 N
C. COMANCHE PEAK, CATAWBA May 1984 N
D. RIVER BEND, RANCHO SECO, July 1984 Y
MIDLAND, PERRY, SHEARON HARRIS, AND SAN ONOFRE 13.
CONNECTING RODS:
A. DSR-48 April 1984 N
B. DSRV - (ALL), PRELIMINARY May 1984 Y
C. DSRV - (ALL), FINAL August 1984 Y
14.
TURBOCHARGER:
A. DSR-48, DSRV-16 May 1984 Y
B. DSRV-12 & 20 August 1984 N
C. SUPPLEMENTAL REPORT November 1984 Y
1 (VANES AND CAPSCREWS) 15.
ENGINE BLOCK AND LINER A. INITIAL REPORT June 1984 Y
B. ADDITIONAL METALLURGICAL December 1984 Y
TESTING AND REFINEMENT ANALYSIS Detailed results of the inspections performed on the Phase I items summarized below will be submitted as noted in Section II, on the Program Plan schedule.
1.
Connecting Rod Bearing Shells on the PNPP engines were inspected by visual checks, as well as by radiography, eddy current and liquid penetrant (PT) examinations. Dimensional checks were also performed. Some bearing shells were replaced, and all bearing shells presently installed in the engines meet the acceptance criteria of the Owners Group.
9
2.
Rocktr Arn Cap;crrwa en tha PNPP anginas are of ths origin 21 1
.etrcight dasign. These capterswa wera inspreted for initial torque settings as specified by the Owners Group. Magnetic particle (MT) examinations in the thread root area were performed, and were acceptable. Hardness and comparitor tests on two cylinders, four capscrews per cylinder on both engines were found to be acceptable.
3.
Cylinder Head Studs supplied on the PNPP engines were of the original straight design. A necked down head stud has been installed in place of the original design. Although both designs of studs have been determined to be adequate for TD1 engines, PNPP decided to utilize the necked down stud. This decision was made because the newer design is more fatigue resistant due to its increased flexibility. A dimensional check was performed at TDI by a PNPP representative on the new cylinder head studs and they were found to be acceptable. Visual examinations noted no signs of distress. Hardness anil comparitor tests on both engines were performed and proved acceptable.
4.
Air Start Valve Capscrews at PNPP have been dimensionally checked in accordance with the Owners Group requirements. Since the existing design for the capscrews.has been evaluated as adequate and dimensional checks and material comparitor tests were acceptable, no changes were made to the capscrews on the PNPP engines. A torque verification was also performed.
5.
Main and Intermediate Push Rods originally supplied with the PNPP engines were of the ball-end design. All the originally supplied pushrods have been replaced by the friction-welded plug end design.- Each of the new pushrods were inspected to verify that they are of the friction weld design.
6.
Crankshafts in the PNPP engines have a 13 inch by 13 inch diameter design. This design differs significantly from the 11 inch by 11 inch crankshaft that failed at the Shoreham Nuclear Power Station in 1983. Calculations and torsiograph testing of the lead engine has shown that the 13 inch by 13 inch crankshaft meets DEMA requirements. A torstograph test will be performed on one PNPP engine to' verify that it meets the DEMA requirements.
Because the oil holes on the crankshaf t have been determined to be critical in torsion, they were inspected for cracks. An eddy current test was performed on main journal oil holes number 4, 6 10
e cnd 8 cf.th3 PNPP_crcnkIh2fta by a ecntultKnt cf tha Ownsrs Group, Failure Analysis Associates (FaAA), and found to have excessive machine marks. These machine marks were polished away on all the main journal and crank pin oil holes. The test was repeated for all the crankshafft oil holes and revealed no recordable indications in the oil holes.
7.
Jacket Water Pumps were included on the generic list of failed
. equipment because of pump shaf t failures. The jacket water pump model used on the engines at PNPP differs from the pump with the failure history. An Owners Group mechanical design review of the pumps has found pumps of the PNPP design acceptable. Per the Owners Group recommendation, hardness and comparitor tests, visual checks for wear or pitting, and PT examinations were performed and were acceptable.
8.
Fuel Oil Injection Tubing was examined by eddy current for inner surface fabrication flaws similar to those found at the Grand Gulf Nuclear Station. No such flaws were found on the fuel lines on the PNPP engines. PNPP will install shroud lines around the fuel oil injection tubing as an added precaution.
9.
Engine Base and Bearing Caps on the PNPP engines were thoroughly cleaned prior to engine reassembly. It was determined by the Owners Group that engine base assembly for Vee-16 engines were adequately designed for the loading encountered. Thorough cleaning of the bearing cap / saddle interface during reassembly was a recommended action suggested by the Owners Group. Dye penetrant (PT) examination of the #5 main bearing cap land was performed, which showed minor surface indications away from the studs on the Division 2 engine. The results of this examination are being evaluated by the Owners Group. The results will be provided as part of the detailed engine inspection results as noted-in Section II, Program Plan Schedule. PNPP will implement any recommendations which result from this review.
10.
Cylinder Heads on the PNPP engines were shipped back to the TDI factory for rework. With a CEI representative observing, the heads were inspected by TDI at the factory, per the requirements specified by the Owners Group. In some cases, the heads had to be reworked to meet those requirements, or be replaced with heads of the latest TDI design. In addition, each head was heat created and pickled for additional stress relieving.
11 l
e 11.
-Platens criginnily cupplied with ths PNPP enginas htd modal AH-
'typa skirtei Sinen theca piston skirts h d licitad cparating history, all such skirts were replaced by the model AE type.
Each AE type skirt purchased was inspected at the factory by magnetic particle testing. Twelve AE skirts which had been-intended for use at another plant were purchased thru TDI for.use at PNPP. Each of these skirts was liquid penetrant tested onsite before installation. Two of these skirts were rejected for use at PNPP. Critical dimension checks were also made on all new piston skirts. The results of the factory and the onsite inspections for the skirts used in the engines at PNPP were found to be acceptable per the Owners Group criteria.
12.
Diesel Generator Auxiliary Module Control Wiring and Terminations supplied by TDI as part of the diesel generator package were 7..f evaluated for conformance to the functional attributes noted by the Owners Group. An Owners Group team performed the evaluation r
at the site and determined that all functional attributes of the b
wiring and terminations were acceptable.
13.
Connecting Rod assemblies at PNPP are of the articulated design with a link rod box containing the pin bearing bolted to the
. master rod.
I 1/2 inch bolts are used for the connection. The.
bolts at PNPP were examined by magnetic particle testing. Visual checks looked at the bolt washers and contact surfaces. Bolt.
torque was verified. The link rod box threads were inspected for i
cracks by an eddy current test. The connecting rods were hardness and comparitor tested. Wrist pin bushings received PT exams. Visual checks looked for wear. The results of the testing and inspections were acceptable.
14.
Turbochargers installed on the Perry engines are Elliott model 90G's.
The lubrication system to the turbocharger bearings has 2.
been modified to allow for manual prelubrication one to two minutes prior to engine test starts. The modification also allows for a continuous drip ~1ubrication system to provide for automatic emergency fast starts. This modification was previously reported as PNPP Deviation Analysis Report (DAR) number 44.
In addition, a clearance inspection between the impeller and the blower inlet was performed and assorted mounting,
bolts were torque verified.
12
15.
Engina Blecks and Linare for thn PNPP angins3 wara ingpactsd for structural adequacy. Each liner was removed from the block.
Liners were honed to provide for seating of new rings and to remove possible carbon and corrosion build up.
The honing also etched a cross hatch pattern on the inside of the liners per the Owners Group requirements. The liners were also machined to assure that the maximum extension of the liner above the block land met the Owners Group criteria. This modification was performed to minimize " loop" stresses on the cylinder head due to expansion.of the liner. Liners were reinstalled following honing and were dimensionally checked. On the block, the top head mating surfaces and liner landing surfaces received PT examinations. The liner landing was dimensionally checked.
Samples of the engine block material were taken and sent to the Owners Group for material analysis. Results of the material analysis are not available at the time of this report. They will be provided to the NRC as part of the detailed engine inspection results noted in Section II, Program Plan Schedule. PNPP will implement any recommendations which result from this review.
'13
e
=
E.
Phsee II - Design'R:vizw sud Qu111ty Revalidttion
. Phase IIaof the Owners Group effort was established to show that
-these engines are capable.of performing their safety related function throughout theirlintended life. This effort was called
^
the' Design Review and Quality Revalidation (DR/QR) Program. It was developed to examine the critical components in the engine
~~
~ not covered under' Phase 1.
The PNPP diesel generator components subjected to the Design Review / Quality Revalidation Program were determined by a Component Selection Committee. Each critical component identified by the Owners Group and a PNPP representative was reviewed from a design and a quality standpoint. Selection was L
based on the component's function and role in the overall
) -
. operation of the engine, the component's nuclear and non-nuclear industry experience, and the Committee's engineering judgement.
The selection process included a review of available operating s
{
information on TDI diesels and TDI recommended product improvements to ensure relevant experience was considered. The
-PNPP selection was also based-on the selections previously conducted for the Shoreham, Comanche Peak and Grand Gulf diesel engines.
As part of the component selection process, components were i
classified as either. Type A,'B or C.
These classifications are based on the effect of the component's. failure on the diesel generator performance. Type A components are those whose failure would result in diesel generator shutdown or failure to start in~
an accident mode. Type B components include those whose failure would result in reduced capacity of the diesel generator:or the eventual failure of a Type A component if not detected.
Components whose failure have little or.no bearing on the effective use or operatioa of the diesel generator are classified as Type C..
4 Following' classification, the Cocoonent Selection Committee established appropriate design review or quality revalidation requirements. These requirements were then forwarded.to the 14
e r..
Ownero Grcup Design Revisw Grcup and tha Quality Revalidation
. Group for preparation of the required task descriptions.
Appendix A lists all the identified components and ir.dicates the DR and/or QR requirements for. each.
+ >
'1 Each DR/QR report has been prepared by a DR/QR task committee.
1These reports are identified by component name and part number.
In each report is a description of the component, objective of the review, methodology used,'and results and conclusions. One hundred and seventy-one components have been identified for a
-design review and/or quality revalidation on the PNPP engines.
Of the one-hundred and seventy-one reports, one hundred fifty-three are the same as the lead engine. A justification report is included in the PNPP DR/QR package to show the applicability of the previously prepared lead engine reports to' Perry. A total of eleven reports haie been prepared for unique components associated with the PNPP engines. Some of the 11 reports address multiple components to account for the total of 171 components reviewed.
A PNPP representative was involved in the review of the DR/QR reports. His signature, along with appropriate Owners Group DR/QR leaders, appears on the coversheet of each Perry unique
- report.
Component Revalidation Checklists (CRC) were prepared for each QR component. These checklists formed a basis for the field inspections during the engine revalidation effort (see Section F) and have been-included in the DR/QR reports. These reports are incorporated in-the DR/QR package which is being provided to the NRC as an attachment to this Program Plan.
a e
n 15
F. - Initial Dinral Gentriter Dioc Strbly, Insp;ction, Rnpnir, rnd Rernexcbly Inspection requirements for the diesel components are contained in Component Revalidation Checklists (CRC) which have been prepared for each Quality Revalidation component (see Section E).
Each CRC has been incorporated in a PNPP Inspection Checklist which have been implemented in accordance with established PNPP procedures. During the teardown and inspection, PNPP personnel also performed routine inspections and maintenance in accordance with the manufacturer's instruction manuals and incorporated changes recommended in TDI Service Information Memos (SIM) as shown in Appendix B.
To coordinate and implement the disassembly, inspection, repair and reassembly program, CEI has established a Diesel Generator Task Force with full-time representatives from the following PNPP organizations:
Nuclear Construction Engineering Section Nuclear Test Section Perry Plant Operations Department Nuclear Quality Assurance Scheduling TDI representatives also participate as full-time Task Force members. They observe the inspection activities end help in the interpretation of TDI documentation.
Unfavorable inspection results are evaluated by routine established PNPP procedures, or in some cases, by the Owners Group.
Nonconformance Reporta document hardware-related problems and Action Requests document programmatic concerns. All results of the inspection are maintained. Results of the site revalidation effort will become the field inspection portion of the DR/QR Program. To date only two notable concerns have been encountered. During the inspection it was discovered that.four rocker arms on the Division I engine and eight rocker arms on the Division II engine had come in contact with the swivel pad, indenting the rocker arm forging. This indention, or lip, 16
p ractrictid the moviment cf the hydraulic liftsrs. It is assumed tha prchl n cccursd during tha fcetory run tsat and was ecutsd by improper adjustment of the lifter adjusting screw. The rocker arms have been restored to an operating condition using methods recommended by the Owners Group and the manufacturer.
Eddy current inspection of the oil holes on the crankshaft, by the Owners Group's consultant, indicated excessive machining marks in the unpolished surface at a depth greater than one inch.
These holes were then polished to a depth of three inches. The eddy current test was repeated on the polished oil holes. The tests indicated that the oil holes were free of defects.
Detailed results of the inspection effort will be provided to the NRC as detailed in Section II, Program Plan Schedule.
17
' G.. Di7nal Gensrcter-Tanting rnd Intpecticn The purpons of ths PNPP dietsi gintrator tseting progrco is to provide a confirmatory demonstration of the. reliability of the PNPP Unit i TDI diesel generators, prior to plant licensing and operation. This program will consist of a full preoperational engine test program for the Ucit I diesel engines, in accordance with NRC Regulatory Guide 1.108, " Periodic Testing of Diesel Generator Units Used As Onsite Electrical Power Systems at Nuclear Power Plants" (Revision 1, August, 1977), as clarified in Table 1.8 of the PNPP FSAR and IEEE-387-1977, " Criteria for Diesel Generator Units Applied as Standby Power Supplies for Nuclear Power Generating Stations."
Additional tests have been recommended by the Owners Group. A torsiograph test to confirm the adequacy of the crankshaft to withstand operating torsional stresses will be performed by Owners Group representatives on one Unit i engine as recommended by the Owners Group. This test will be performed at 0%, 25%,
50%, 75% and 100% of engine nameplate loading, prior to preoperational testing.
In addition, an engine baseline vibration survey will be taken to determine the initial vibration
' characteristics of both engines.. A visual survey will also be performed to identify any individual component with unusually
'high vibration levels. This will be performed while the engines are running at full load. TDI recommended hot and cold crankshaf t deflection measurements will also be performed prior to preoperational testing..
Other preoperational tests to be performed include diesel generator auxiliary systems tests for electrical and pneumatic control, diesel generator control circuit functional and start tests, diesel generator load tests, diesel generator sequencing and operational stability tests, and diesel generator reliability tests..These will be performed on both Unit 1 engines, with the exception of'the torsiograph test as noted above. Throughout preoperational testing, cylinder exhaust temperature sensor readings will be logged and checked to assure they do not exceed the manufacturers recommended maximum.
18
c.
The discal gansrater auxilicry cyctres tests will dtmonstrata tha proper functioning of the electrical and pneumatic controls for the diesel generator auxiliary systems. The auxiliary sytems include the. Starting A.t r, Jacket Water, Lube Oil and Fuel Oil systems.
~ Thedieselgeneratorcontrolcircufhfunctionalandstarttests wi11' demonstrate electrical and pneumatic control circuit operability in the " Manual" mode of operation for both Unit I diesel generators. For this test, each Diesel Generator shall be capable of starting, achieving rated voltage, speed, frequency and loading, and stopping in the " Local Normal Manual", " Remote Normal Manual", and the "Energency Manual" mod ( S of operation.
The diesel generator load tests will demonstrate the capability of both Unit I diesel generators to start, load to 100 percent of nameplate, and achieve steady state temperature and pressure.
Each diesel generator shall demonstrate operation at 100 percent load for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> within design and operational parameters.- Each diesel generator shall be capable of accepting 100 percent load rejection without tripping due to overspeed.
The diesel generator sequencing and operational stability testa s
will demonstrate the capability of both Unit I diesel generators to start upon receipt of an " Emergency-Start" signal (e.g.,
Safety Injection) and/or. a " Normal Start" signal (e.g.,' Loss of
.0ff-site Power). An " Emergency Start" signal shall be capable.of-overriding test mode' operation and the diesel generator shall
' continue to be operated'in " Standby". After starting, each unit' shall be capable of independently accepting design loads without exceeding manufacturer specifications land design criteria.
The diesel generator reliability tests will demonstrate the reliability of both Unit-t diesel generators by performing 35 consecutive valid tests on one diesel generator and 34 on the other, with no failures, in accordance with the criteria specified in Regulatory Guide 1.108, Rev. 1 Section C.2.a(9) and C.2.e, PNPP will perform 20 total additional tests, 10 each on both Unit I diesel generators.
Including the 69 tests required 19 o
rt-by Regulctory Guida 1.108, this would be a total of 89 ctert-nd-locd tarts (dividad 45 on ona and 44 on thn other standby diesel generator). Diesel start reliability will be demonstrated as part of *.he Regulatory Guide 1.108 testing. Each start, successful or otherwise, will be documented on a chronological test log (see Appendix C).
The 20 additional start-and-load tests will be conducted in accordance with Regulatory Guide 1.9 and IEEE-387-1977, Section 6.3.2 with one exception. Since a single step load of 50% of the generator nameplate continuous kW rating is not available, the generator will be loaded with the available bus loads once it has attained the necessary speed and voltage.- The bus will then be synchronized with offsite power and loaded as quickly as possible to 50% of rating. This exception is necessary due to field configuration versus factory testing capability.
One test per diesel will be performed with the engine initially at normal operating temperature equilibrium. The remaining start-and-loads will be done with the diesel generator initially at warm standby. Each diesel generator will successfully complete the ten tests without failure as identified in Regulatory Guide 1.9.
After completion of these tests, the results will.be available for NRC review.
PNPP FSAR Amendment 15 Table 8.3-1 details the loading on each' of '
the Unit I diesels. The Table shows that the maximum load on the diesels would be 5634 KW for simultaneous loss of offsite power (LOOP) and forced shutdown. The maximum accident load will be 4668 KW for simultaneous LOOP and a loss of coolant accident (LOCA). Following. completion of pre-operational tests, a verification of maximum load that each engine will experience during emergency service conditions will be performed. This verification is performed by measuring the actual load required to operate each of the components linked to each diesel. The results of this verification will be provided to the NRC as noted
'in Section II,' Program Plan Schedule.
i et 20
m i
Some Component Revalidation Checklists recommend inspection of selected components following the initial 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> (approximately) of cperations for each engine. Inspections will be conducted following procedures similiar to those described above in Section F.
Results will be included in the test program final report, which will be submitted to NRC as detailed in Section -11 on the Program Plan Schedule.
9 1
4 21
,b.
H.. Maintsn nca cnd Survaillenet Progran Appendix II of the PNPP DR/QR final report contains maintenance and surveillance recommendations prepared by the Owners Group based on the results of the Owners Group Program. These recommendations are intended to supplement the existing TDI Instruction Manuals. The Owners Group maintenance recommendations are a compilation of information gathered from many sources.
These sources included TDI Instruction Manuals, Service Inforsation Menos (SIM's), and TDI correspondence on specific components. The Owners Group technical staff reviewed these sources for adequacy and added additional maintenance recommendations identified during the DR/QR review.
The maintenance and surveillance recommendations of the Owners Group and the TDI Instruction Manuals together with standard CEI maintenance practices for heavy rotating machinery will provide the basis for maintenance and surveillance procedures for the TDI diesel generators. CEI is committed to incorporating all the Owners Group recommendations on maintenance and surveillance from the DR/QR reports into these procedures. The procedures are being prepared by the Maintenance Section and will be available for NRC review at PNPP.
4 6
4
n.
I.
Qunlity Askuranca
'As netsd in thn~NP.C Safety Evalustien Rsport on ths TransAmerica
^
Delaval, Inc. (TDI) Owners Group Program Plan, the Phase II design review / quality revalidation reviewed the important engine
' components to assure that their design and manufacture, including specifications, quslity control and quality assurance, and operational surveillance and maintenance, are adequate. PNPP has worked within the Owners Group guidelines to ensure that these aspects are, and will continue to be, adequate and implemented throughout the lifetime of the PNPP diesels.
Since formation of the Owners Group and the PNPP Diesel-Generator task force, PNPP has supplemented-its QA review of TDI. A PNPP.
representative was assigned to witness actions performed by TDI undertaken to satisfy both Owners Group and PNPP requirements, ~as noted in the PNPP procurement documents. These actions included heat treatments, non-destructive examinations and inspections of~
individual components, such as reworked cylinder heads and new "AE" piston skirts. The representative also performed dimensional and visual checks, documentation package reviews, and verifications of cleaning, coating, painting and tagging prior to final acceptance.
The inspection program undertaken at the PNPP site on the Unit I diesel generators during the recent revalidation disassembly was conducted as described below:
All engine teardown / reassembly activities _were conducted in-accordance with approved Test Work Procedures and Work ~
Authorizations.
Component inspections were planned, performed, documented and reported.in accordance with PNPP procedure 1-1004 (Operational Quality Section Inspection-Program), by the Operational' Quality Section.
3 Hardware deficiencies were documented and evaluated on Nonconformance Reports.
Programmatic concerns were documented on Action Requests.
I~
Inspection results were indicated as satisfactory or unsatisfactory when acceptance criteria was specific.
When information was requested by the CRC's, it was obtained during inspections for evaluation by site engineering or the Owners Group.
23
e Phstogrrph3 wers taken in some inattnces to supplcment or document "co-fcund" ccnditions.
Replacement engine components (other than those inspected by the PNPP representative at TDI) were inspected on site per the CRC's.
Final closure of inspection results were handled per procedure 1-1004, as noted above.
All documentation (i.e. Nonconformance Reports, Inspection Reports, Component Conditicn Reports, Photographs, etc.)
generated as a result of the Diesel Generator Inspection Program will be provided to the Owners Group in copy form for their review.
Any replacement parts for the TDI diesels that have associated CRC's from the Owners Group, will be revalidated per the requirements of their CRC.
d 0
24 e
II.
Prtgrca Plcn_Scheduls Milestone Goal Actual
- Join owners Group 12-21-83
- Component selection for Phase II 3-6-84
- Submit PNPP-specific responses to 10-26-84 NRC questions
- Receive Lead Engine Phase I Reports Various
- Begin work on Initial Engine 9-24-84 Teardown and Inspection
- Receive completed DR/QR reports 1-4-85 (Phase II) from Owners Group
- Complete work on Initial Engine 1-11-85 teardown and inspection
- Submit PNPP Diesel-Generator 1-17-85
. Program Plao
- Submit DR/QR Reports to NRC 1-17-85
- Submit results of Initial Inspection 2-15-85 to NRC
- Begin Engine Pre-Operational Testing 3-19-85
-' Complete Engine Testing 5-9-85
- Begin Supplemental Engine Inspections 5-10-85
- Submit Engine Load Verification to NRC 5-21-85
- Finish Supplemental Engine Inspections 5-24-85
- Submit Supplemental Engine Inspection 6-1-85 l
results to NRC 25
LIII.
'Concluniens
'The Phase I effort, generic component problems, has been completed by the Owners Group. Each of the Phase I reports has been submitted to the NRC for review. Purpose of the Phase I Program was to establish a basis for licensing plants with TDI diesel generators prior to completion of the Design Review and Quality Revalidation (DR/QR) program (Phase II). Based on the results from these reports, the Owners Group has concluded that provided the Phase I recommendations have been implemented the TDI diesel generators can reliably perform their intended function.
The Phase II DR/QR review has also been completed by the Owners Group for PNPP. This review was performed to show that critical components, other than those examined in Phase I, were adequately designed and. fabricated.. Implementation of the DR/QR field inspection provided further assurance of the reliability of the TDI engines as qualified safety related devices.
The.chird function of the Owners Group was to establish specific component tests and inspections. The Owners Group technical staff, during their review of the engine components established special inspections, preventive maintenance, and surveillance recom-mendations..These recommendations, when implemented, will give added assurance that the' engines will-perform their intended function over the' life of-'the plant.
FNPP has committed to' implement'the' requirements of the Owners Group.
All up-grades required by Phase I and inspections required by Phase
.II will be completed prior to fuel load. Any additioaal tests required by the Owners Group will be completed and evaluated in the same. time-frame. A maintenance program that will assure the TDI engines will perform their intended function for the life of the plant will also be in place.
Based on the above, it'can be concluded that the TDI engines will
-perform their safety related function throughout the life of PNPP.
With the implementation of all the Owners Group's requirements and with the establishment of c comprehensive maintenance program, the
'TDI diesel generators _ installed at the Perry Nuclear Power Plant will meet the requirements for a. full power license.
26
[
e-APPENDIX A TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Osscription Reo'd Reo'd Review Category
)
F-068 Intercooler X
X Turbo, Intake Intrcir. & Exhaust F-139 Tools Turbo X
F-509 Pyrometer Wire X
MP022/23 Turbocharger X
X Turbo, Intake, Intrcir & Exhaust 00-420 Lube Oil Pressure X
X Lube Oil Regulating Valve 00-442A Starting Air Distributor:
X X
Air Start &
Distributor Assembly Barring Device 00-442B Starting Air Distributor:
X X
Air Start &
Tubing, Fittings, Gaskets Barring Device 00-491A Turbocharger - Air Inlet X
Adapter:
Adapter 00-4918 Turbocharger - Air Inlet X
Adapter: Mounting Hardware W/ Flexible Connector 00-495A Turbocharger - Air Outlet X
Adapter 00-495B Turbocharger Air Outlet X
Adapter: Mounting Hardware 00-520 Instruction Plate - Warning X
-Plate 00-621A Fuel Oil Drip Tank X
X Fuel Oil Injection 00-621B Fuel Oil Drip Tank X
Assembly-Misc. Hardware, Gasket, Switch s
PE3333 -
2-8
1 l
TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component
. DR QR No
(
Number Description Reo'd Reg'd Review Category 02-CFR Turbocharger Thrust Bearing X
X Turbo, Intake, Drip Lube System Intrcir. & Ex-haust 02-3'05A Base and Bearing Caps: Base X-X Engine Base Assembly
& Bearing Caps 02-305B Base and Bearing Caps:
X Dowels 02-305C Base and Bearing Caps:
X X
Engine Base Main Bearing Studs & Nuts
& Bearing Caps 02-3050 Base and Bearing Caps:
X X
Engine Base Main Bearing Caps
& Bearing Caps 02-305E Base and Bearing Caps:
X Seals, Gaskets & Covers 02-307A Lube Oil Fittings:
X X
Lube Oil Internal - Headers 02-307B Lube Oil Fittings:
X X
Lube Oil Internal - Tube & Fittings 02-307C Lube Oil Fittings Internal:
X Seals 02-307D Lube Oil Fittings Internal:
X X
Lube Oil Supports 02-310A Crankshaft X
X Crankshaft &
Bearings 02-310B Main Bearings X
X Crankshaft &
Bearing 02-310C Crankshaft & Bearings:
X X
Crankshaft &
Thrust Bearing Rings.
Bearing 02-311A Crankcase: Crankcase Assy X
X Crankshaft &
Bearing PE3333 2-9
4 TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No t
)
Number Description Reg'd Rea'd Review Category i
02-311B Cylinder Block Liners & Water X
3 Manifold: Cam Bearing Caps &
Dowels 02-311C Crankcase: Crankcase Seal X
02-311D Crankcase: Crankcase X
X Crankshaft &
Mounting Hardware Bearings l
l 02-315A Cylinder Block X
X Cyl. Block &
Liners & Water i
Manifold i
02-3158 Cylinder Block: Block To X
Crankcase Dowel 02-315C Cylinder Block Liners &
X X
Cyl. Block &
Water Manifold -
Liners &
Cylinder Liner Water Manifold 02-3150 Jacket Water Manifold X
X Cyl. Block &
Piping Liners &
Water Manifold 02-315E Cylinder Block Liners &
X X
Cyl. Block &
Water Manifold: Studs Liners &
Water Manifold 02-315F Cylinder Block Liners X
X Cyl. Block &
& Water Manifold:
Liner & Water Cylinder Head Nuts Manifold 02-315G Cylinder Block Liners &
X X
Cyl. Block &
Water Manifold: Seals &
Liners &
Gaskets Water Manifold 02-316A Jacket Water Inlet Manifold:
X~
X Jacket Water Manifold Assembly W/ Hardware and Coupling and Gaskets 02-316B Jacket Water Inlet Manifold:
X X
Jacket Water Coupling and Gaskets PE3333 2-10
TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No c
Number Description Reg'd Reg'd Review Category 02-316C Jacket Water Inlet Manifold:
X X
Jacket Water Vent line to Discharge Manifold 02-3'17A Water Discharge Manifold:
X' X
Jacket Water Jacket Water Discharge Manifold, Coupling and Seals 02-317B Water Dicharge Manifold:
X X
Jacket Water Coupling & Seals 02-317C Water Discharge Manifold:
X X
Jacket Water Supports 02-330A Flywheel X
Flywheel 02-3308 Flywheel Bolting X
X Flywheel 02-331A Guards: Flywheel Guard X
Assembly 02-335A Front Gear Case: Gear Case X
02-335B Front Gearcase - Gaskets &
X X
Idler Gear As-Bolting sembly & Front Gear Case 02-340A Connecting Rods:
X
,X Connecting Rods & Bushings Rods 02-340B Connecting Rod Bearing X
X Connecting Shells
-Rods 02-341A Pistons X
X Pistons D2-341B Pistons: Rings X
X Pistons 02-341C Piston Pin Assembly X
X Pistons
'02-345A Tappets and Guides:
Intake X
X Camshaft &
& Exhaust Tappet Assembly Valve Train
.PE3333 2-11
F i
TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No
(
Number Description Reg'd Reg'd Review Category 02-345B Tappets and Guides: Fuel X
X Camshaft &
Tappet Assembly Valve Train 02-345C Tappets and Guides: Fuel
_X X
Camshaft &
Pump Base Assembly Valve Train 02-350A Camshaft:
Camshaft X
X Camshaft &
Assembly Valve Train 02-350B Camshaft:
Camshaft X
Camshaft &
Bearing Valve Train 02,350C Camshaft: Supports, Bolting X
X Camshaft &
and Gear Valve Train
~!
02-355A Idler Gear Assembly: Crank X
X Idler Gear As-To Pump Gear sembly & Front Gear Case 02-355B Idler Gear Assembly:
X X
Idler Gear As-Idler Gear Assembly sembly & Front Gear Case 02-355C Idler Gear Assembly:
X Gaskets & Bolting 02-359 Air Start Valve X
X Air Start &
Barring Device 02-360A Cylinder Heads X
X Cylinder Heads
& Valves 02-360B Cylinder Head Valves:
X X
Cylinder Heads Intake & Exhaust Valves
& Valves
' 02-360C Cylinder Head and Valves:
X X
Cylinder Heads Bolting and Gaskets
& Valves 02-3600 Cylinder Head X
X Cylinder Heads
& Valves:
Springs and
& Valves Retainers02-361 Indicating Cocks X
PE3333 2-12 L
F TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No
(
Number Description Reo'd Reg'd Review Category 02-362A Subcover X
X Camshaft &
Valve Train 02-36EB Cylinder Head Covers:
X Gaskets and Bolting 02-365A Fuel Injection Equipment:
X Fuel Oil In-Fuel Injection Pump jection 02-365B Fuel Injection Equipment -
X Fuel Oil In-Fuel Injection Tips jection 02-3,65C Fuel. Injection Equipment -
X X
Fuel Oil In-Tube Assembly jection 02-365D Fuel Injection Equipment:
X X
Fuel Oil In-Supports jection 02-371A Fuel Pump Linkage: Fuel X
X Fuel Oil In-Pump Control Shaft jection 02'3718 Fuel Pump Linkage: Linkage X
X Fuel Oil In-Assembly and Bearing jection 02-373A Gear Case Opening - Cover X
02-3738 Gear Case Opening Cover -
X Gaskets & Bolting 02-375 Intake Manifold and X
X Turbo, Intake, Piping Intrcir. & Ex-haust 02-380A Exhaust Manifold X
X Turbo, Intake, Intrcir. & Ex-haust 02-3808 Exhaust Manifold:
Gasket X
X Turbo, Intake, and Bolting Intrcir. & Ex-haust 02-385A Cylinder Block Covers:
X Covers and Relief Valves PE3333 2-13
(-.
i i
}'
's
-l TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Reg'd Reg'd Review Category S
b1 02-385B Cylinder Block Covers:
X X
Cyl. Block &
- ]
Gaskets and Bolting Liners & Water
~
.?
1 02-386A Crankcase:
Crankcase
~
X Cover Assy
" 386B Crankcase:
Crar.kcase X
X Crankshaft &
~
Gaskets and Mounting Bearings Hardware 4
ij 02-387A Crankcase Ventilstor:
X 1
Crankcase Vacuum Fan Q
r 1
02-387B Crankcase Ventilator - Oil X
4 Separator
- l.
M 02-387C Crankcase Ventilator-X Crankcase Vacuum Fan.
02-387D Crankcase Ventilator-X Crankcase & Fluid a
}
Manometer 02-390A Intake & Intermediate and X
.X Camshaft &
Exhaust Rocker Shaft Assembly Valve Train
-l 02-390B Rocker Arms and Pushrods:
X X
Camshaft &
l Exhaust Rocker Shaft Valve Train l
Assembly 02-390C Main and Connector X
X Camshaft &
Pushrods Valve Train
,02-3900-Rocker Arms and Pushrods:
X X
Camshaft &
l,
Pushrods-Connector.
Valve Train 02-390E Rocker Arms and Pushrods:
X Camshaft &
Bushings Valve Train l
02-390F Rocker Arms and Pushrods:
X X
Camshaft &
Lifters Vaive Train 02-390G Rocker Arms and Pushrods X
X Camshaft &
Misc. Bolts & Drive Studs Valve Train h
PE3333 2-14 r
w
TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Reg'd Reg'd Review Category 02-395A Gear Case Covers: Cover X
02-3958 Gear Case Covers: Gaskets X
~
and Bolting 02-410A Overspeed Trip Governor X
& Governor 02-4108 Overspeed Trip: Governor X
X Overspeed Trip and Accessory Drive Assembly
& Governor 02-410C-Overspeed Trip: Couplings X
/".
(Flexible and Spider)
& Governor 02-410D Overspeed Trip Vent Valve X
& Governor 02-411A
' Governor Drive:
Governor &
X X
. Tachometer Drive Gear and
& Governor Shaft 02-411B Governor Drive: Couplings, X
X Overspeed Trip Pins & Keys
& Governor 02-413A Governor Linkage X
& Governor 02-413B Fuel Pump Linkage:
X Fuel Oil Injection Automatic Shutdown Cylinder 02-415A Governor Assembly: Woodward X
X Overspeed Trip Governor
& Governor 02-415B Governor Assembly -
X Overspeed Trip Booster Servomotor
& Governor 02-415C Governor Assembly -
X X
~
Heat Exchangers
& Governor 02-420 Engine Driven X
X Lube Oil tube Oil Pump 9
PE3333 2-15
TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No.
t
' Number-Description Reg'd Reo'd Review Category 02-425A Engine Driven X
X Jacket Water Jacket Water Pump
~
02-425B Jacket Water Pump:
X Cover Plate 02-435A Jackat Water Fittings:
X X
Jacket Water Pipt a Fittings 02-4358
. Jacket Water Fittings -
X X
Jacket Water Supports 02-435C Jacket Water Inlet X
X Jacket Water Fittings - Valves 02-436A Intercooler Piping -
X X
Turbo, Intake Pipe Intercooler
& Exhaust 02-436B Intercooler Piping X
X Turbo, Intake Coupling, Gaskets, Intercooler &
-Bolting Exhaust 02-437 Turbo Water Piping:
X X
Jacket Water Pipe & Fittings 02-441A Starting Air Manifold:
X X
Air Start &
Piping, Tubing and Fitting Bacring Device 02-441B Starting Air Manifold X
X Air Start &
Valves, Filters & Strainer Barring Device 02-441C Starting Air Manifold:
X X
Air Start &
Supports Barring Device
'02-445 Fuel Oil Booster Pump X
X Fuel Oil In-jection 02-450A Fuel Oil Header:
X X
Fuel Oil In-Piping / Tubing jection 02-450B Fuel Oil Header:
Fuel X
X Fuel Oil In-Oil Tubing Supports jection PE3333 2-16
,---y.-,-m
r TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Reg'd Reg'd Review Category 02-455A Fuel Oil Filters &
X Fuel Oil In-Strainers: Filters jection 02-455B Fuel Oil Filters &
X Fuel Oil In-Strainers:
Strainers jection 02-455C Fuel Oil Filters &
X X
Fuel Oil In-Strainer: Mounting Hardware jection 02-465A Lube Oil Lines External:
X X
Lube Oil Tubing, Fittings, Couplings 02-465B Lube Oil Lines External X
X Lube Oil e
Valves 02-465C Lube Oil Lines X
X Lube Oil External-Supports 02-467A...
Turbocharger: Lube Oil X
X Lube Oil Fitting - Piping 02-467B Turbocharger: Lube Oil X
X Lube Oil Fittings - Supports 02-475A Turbocharger: Bracket X
X Turbo, Intake, l
Intrcir. & Ex-haust 02-475B Air Butterfly Valve X
X Turbo, Intake, Assembly Intrcir. & Ex-l haust l
02-475C Turbocharger: Bracket -
X X
Turbo, Intake, i
Bolting & Gaskets Intrcir. & Ex-haust 02-500A Control Panel Assembly X
X Control Panel-l Cabinet / System Assembly l
l 02-500B.
Control Panel Assembly:
X Annunciators l
l PE3333 2-17 l
A
.e,,,..._..---n...
..--n-.,,,
l TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No a
Number Description Reg'd Req'd Reviev Category 02-500C Control Panel Assembly:
X Circuit Breaker / Contact Blocks 02-500D Control Panel Assembly:
~
X Pressure Gauges 02-500E Control Panel Assembly:
X Hourmeter 02-500F Control Panel Assembly X
X Control Panel Accumulator Assembly 02-500G Control Panel X
X Control Panel Valves Assembly 02-500H Control Panel Assembly X
X Control Panel Pressure Switch Assembly.
02-500I Control Panel Assembly:
X X
Control Panel Control Relays Assembly 02-500J Control Panel Assembly:
X X
Control Panel Solenoid Valves Assembly 02-500K Control Panel Assembly:
X Tachometer 02-500L Control Panel Components -
X Control Panel Piping, Tubing, Fittings Assembly 02-500M Control Panel Assembly:
X Control Panel Terminal Boards / Switches /
Assembly Wiring d2-500N Control Panel Assembly:
X Pyrometers02-520 Instruction Plate:
X Nameplate 02-525A Barring Device - Pneumatic:
X Barring Device Assembly PE3333 2-18
A TABLE 2-2
~
PERRY COMPONENT SELECTION RESULTS Component Component DR QR No
(
Number Descripti'on Rea'd Reg'd Review Category l
02-5258 Barring Device - Pneumatic:
X X
Air Start &
Regulator Valve / Shutoff Barring Device Valve 02-b25C Barring Device - Pneumatic:
~
X
~
1 t
Misc. Fitting, Hose, Filters
)
Tubing 02-5250 Barring Device'- Pneumatic:
X Air Start &
Mounting Bracket / Supports Barring Device 02-530A Platform - Front & Side:
X i
e.
Side Platform Assembly
'02-5308 Platform - Front & Side:
X Front Platform Assembly 02-530C Platform, Ladders, X
~
Stairs - Stair Assembly l
02-5300 Platform, L' adders, X
Stairs - Supports l
02-540A
'L'ube Oil Sump X
Lube Oil with Strainer Assembly and Mounting Hardware 02-540B Lube Oil Sump Tank: Misc.
X X
Lube Oil l
Fittings, Gaskets, Pipe
& Bolting Material, Valves i
X X
Lube Oil i
j Mounting Hardware
'02-550
. Foundation Bolts:
X X
Engine & Aux.
l Anchor Bolts, Misc.
Sub Base &
l Hardware Foundation
(
Bolts02-590 Special Tools: Asst.
X Engine Assembly Tools L
I PE3333 2-19
-- l
l TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Reg'd Reg'd Review Category h) 02-630A Pyrometer Conduit Assembly:
X X
Engine Instru-
~~
Conduit mentation &
Wiring 02-630B Pyrometer Conduit Assembly:
-X X
Engine Instru-Conduit Fittings mentation &
Wiring 02-630C Pyrometer Conduit Assembly:
X X
Engine Instru-Support mentation &
Wiring 02-630D Pyrometer Conduit Assembly:
X Engine Instu-l
,.s Thermocouples mentation &
Wiring
.i 02-630E Pyrometer Conduit Assembly:
X Gaskets 02-650A Gen'erator X
X Generator 02-650B-Generator Control X
X Generator 02-650C Generator-Shaft & Bearings X
X Generator 688A Engine & Aux Module X
X Engine Instru-Wiring Material-Conduit mentation &
& Fittings; Pyrometer Wiring Assembly - Conduit, Fitting, Supports 02-6888 Engine & Aux.
X X
Engine Instru-Module Wiring Material:
mentation &
Wiring & Terminations Wiring 02-688C Engine & Aux. Module Wiring X
Engine Instu-Material: Boxes & Terminals mentation &
Wiring 02-689 Off-Engine Alarm Sensor X
X Engine Instru-Wiring mentation &
Wiring PE3333 2-20
5 TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Rea'd Reg'd Review Category 02-690 On-Engine Alarm Sensors X
X Engine Instru-mentation &
Wiring
- 691 Off Engine Alarm Sensors X~
X Engine Instru-mentation &
Wiring 02-695A Engine Shutdown X
X Engine Shut-Equipment:
down & Equip-Tubing / Fittings &
ment Supports 02-6958 Engine Shutdown X
X Engine Shut-
+
Equipment:
- Valves, down & Equip-
~
Regulator, Orifices ment d
02-695C
. Engine Shutdown Trip X
X Engine Shut-Switches down & Equip-ment 02-700A Jacket Water Standpipe:
X X
Jacket Water Pipe, Fittings, Gaskets y>
02-7008 Jacket Water Standpipe:
X X
Jacket Water Valves o
02-700C Jacket Water Standpipe:
X X
Jacket Water Pipe Supports 02-7000 Jacket Water Standpipe:
X Gauges 02-70CE Jacket Water Standpipe:
X X
Jacket Water Switches
'02 700F Jacket Water Standpipe X
X Jacket Water
- & Misc. Bolting 02-717A Auxiliary Sub-Base X
X Jacket Water i
I
~
PE3333 2-21 d
5 y-c,,
.,-.v.,,.-._,y.m,
.,v.,,.,__,,,,.,.-.mm,
,..m,
-., _ ~
_,,_.,,-,.,,m-,-._...,__,_.,_.
m.
m r
5 1
TABLE 2-2 PERRY COMPONENT SELECTION RESULTS i
Component Component DR
. QR No Number Description Reg'd Reg'd Review Category 02-717B Aux Sub Base & Oil &
X X
Jacket Water Water Piping - Jacket Water:
Valves 02-717C Aux Sub Base & Oil & Water X.
X Engine & Aux.
Water Piping - Jacket Sub Base &
Water:
Pipe, Couplings, Foundation Bolts Fittings, Orifices, Y-Strainers
~
02-7170 Aux Sub Base & Oil & Water X
Jacket Water Piping - Jacket Water:
Gaskets & Bolting 02-717E Aux Sub Base & Oil & Water X
X Jacket Water Piping - Jacket Water:
Supports 02-717F Aux. Sub Base & Oil & Water X
X Lube Oil Piping - Lube Oil:
Pipe and Fittings 02-717G Aux Sub Base & 011 & Water X
X Lube Oil Piping - Lube 011:
Valves 02-717H Aux. Sub-Base & 011 & Water X
X Lube Oil Piping - Lube Oil:
Gaskets & Bolting 02-717I Aux Sub Base & 011 & Water X
X Lube Oil Piping - Lube Oil:
Supports & Mounting Hardware 02-717J Aux Sub Base & 011 & Water X
X Fuel Oil Piping - Fuel Oil - Piping
& Fittings 02-717K Aux Sub Base & Oil & Water X
X Fuel Oil Piping - Fuel Oil Valves Injection PE3333 2-22
'1 TABLE 2-2 PERRY COMPONENT SELECTION RESULTS i
Component Component DR QR No Number Description Reg'd Reg'd Review Category 1
02-717L Aux Sub Base & 011 & Water X
X Fuel Oil 1
Piping - Fuel Oil -
Injection-i Gaskets & Bolting-a 02-717M Aux Sub Base & Oil & Water X_
X Fuel Oil Piping - Fuel Oil:
Injection Supports 02-805A Intake Air Silencer X
Turbo, Intake, Intercooler &
Exhaust j
02-805B Intake Air Filter X
X Turbo, Intake, i
Intercooler &
Exhaust 3
02-805C Exhaust Silencer X
02-805D Flex Connections X
X Turbo, Intake, Intercooler &
Exhaust 02-810A Jacket Water Standby X
Jacket Water Heater Pump 02-810B Jacket Water Heat Exchanger X
X Jacket Water 02-810C Thermostatic Valve X
X Jacket Water 02-8100 Misc. Equipment - Heater, X
. Jacket Water Jacket Water Standpipe 02-820A Misc. Equipment - Heater, X
Lube Oil Lube Oil Sump Tank 02-820B Before & After Lube Oil X
X Lube Oil Pump 02-820C Lube Oil Full Pressure X
X Lube Oil Strainer 02-8200 Lube Oil System - Lube Oil X
X Lube Oil Keepwarm Strainer PE3333 2-23
).
1 TABLE 2-2 j
PERRY COMPONENT SELECTION RESULTS Component Component DR.
QR No Number Description Rea'd Reg'd Review Category i
02-820E 011 Prelube Filter X
X Lube Oil 02-820F Full Flow Lube Oil Filter X
X Lube Oil t
d 02-820G Lube Oil Heat Exchanger X,
X Lube Oil ij 02-825A Fuel Oil Day Tank X
X Fuel Oil 4
Injection 02-825B Fuel Oil System-X
..'l Fuel Oil Drip 4
Waste Pump j
h 02-825C Fuel Oil Booster Pump -
X D.C. Motor Driven N
.02-825D Fuel Oil System - Fuel X
Fuel Oil 1
.011 Duplex Strainer Injection 02-825E Fuel Oil System - Fuel X
011 Valves, Bolting 02-835A Air Dryer
_X b
02-835B Starting Air Tank X
X Air Start &
Barring Device 02-835C Misc. Equipment:
After X
Cooler 02-8350 Starting Air Tank X
Compressor 02-835E Air Start Tank Relief X
X Air Start &
Valve Barring Device
'02-835F Air Start System:
-X Starting Air Piping, l
' Fittings, Tubing 02-835G~
Misc. Equipment - After X
l Cooler Bolting l
02-835H Misc.-Equipment - After X
Cooler Bolting l-PE3333 2-24 r
APPENDIX B
't TDI Service Information Memo's E
,?
E O
(
Incorporated o
u SIM #
Subject at Perry U
E Remarks 64 R-1 Torque Valves yes X
In work procedures X
99 '
Piston Ring Replacement yes 107 Cleaning Spray Tips yes X
108 Tightening Delivery yes X
Valve Holder & Assembly Nuts 133 L. O. Piping Fab.
yes I
133-A Cleaning & preservation yes X
L. O. Pipe was Pickled at TDI. At Perry, pipe has been hydrolazed, dried and corrosion in-
~
hibitors applied to meet
~
cleanliness require =ents.
139 Piston Rings yes X
Will be used in Main-tenance procedure.
1 i
141 L. O. Flushing yes X'
164 Safety Wiring yes X
174 Piping Systas Cleaning yes X
Same methods or equal 190 Crankshaft Rotation and yes'
'X Cyl. Bank Designation 191 Cooling Water System yes X
-Treatment J -
233 Nozzle ' Assembly Puller N/A I
Maintenance Tools 240-A Lubricat'ing 011 yes X
243 Indicator Cock N/A X
Maintenance Tools 249 R-2 Cyl. Head Valve Seat yes X
'TDI is inspecting and 1-Repair will repair heads if necessary. TDI repair will be incorporatedfin-to future CEI repair procedure.
283
_ Crankshaft Thrust Clear-yes X
ance 286 Hydraulic Pre-Stresser yes X
X Maintenance Tools (Main Bearing Caps)
APPENDIX B
. /:
TDI Service Information Memo's, O
U Incorporated o
SIM i-Subject at Perry U
E Remarks C
64 R-1
-Torque Valves yes X
In work procedures Piston Ring Replacement yes X
9 9 *"
m 107 Cleaning Spray Tips yes X
108 Tightening Delivery yes X
Valve Holder & Assembly
+
Nuts
.L. O. Piping Fab.
yes X
- 133 ',
o e
s.
Cleaning & preservation yes X
L. O. Pipe was-Pickled 4133-A at TDI. At Perry, pipe
[
has been hydrola:ed, l_
dried and corrosion in-
'~
4 hibitors applied to meet
~ ~ ~ '
' cleanliness require =ents..
~139 Piston Rings.
yes X
Will.be used in Main-tenance procedure.
1 yes X
141
.L. O. Flushing 164'
. Safety Wiring yes X
4.-
'174 Piping System Cleaning yes X'
Same methods or equal fl90
-Crankshaft Rotation and yes X
3Cyl. Bank Designation i
191L
-Cooling Water System.
yes X
Treatment i
233 Nozzle Assembly Puller N/A.
X Maintenance Tools'
. 240-A
. Lubricating 011 yes X
~
243 Indicator Cock N/A X
Maintenance Tools 249 R-2 Cyl. Head Valve Seat yes 1
TDI is inspecting and
~
Repair will repair heads ify necessary. TDI repair will be incorporated in-to. future CEI repair procedure.,
283 Crankshaft Thrust Clear-yes X
ance
'286l Hydraulic Pre-Stresser yes X-X Maintenance Tools.
(Main Bearing Caps) n-
Test Program Instruction - 28 APPENDIX C Rav. _ 1_,
- ~
Paga 21 of 25
- t..1 Rev. 1/82 E-CHRONOLOGICAL TEST LOG Sheet of TITLE TEST NO,.
SYSTEM TEST ENGINEER -
DATE TIME LOG OF SEQUENCE OF EVENTS WITH COMMENTS INITIAL 9
4 9
9 t
4 9
(-
422/AA/2/kf m.