Text

Vols 1-4 to Tdi Diesel Generator Design Review & Quality Revalidation Rept
	ML20113H632
Person / Time
Site:	Perry
Issue date:	12/31/1984
From:	Rick Deese, Ray C; TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP
To:	;
Shared Package
ML20113H577	List: ML20113H575; ML20113H606; ML20113H632;
References
	NUDOCS 8501250240
	Download: ML20113H632 (550)
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{{#Wiki_filter:- O TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT - mu-- CONTROL # g. . - . . - DATE /-//-ff O Prepared For THE CLEVELAND ELECTRIC ILLUMINATING COMPANY PERRY NUCLEAR POWER PLANT l By

TDI DIESEL GENERATOR OWNERS GROUP VOLUME 1

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O , l l l i i TDI DIESEL GENERATOR DESIGN REVIEW

AND . l QUALITY REVALIDATION REPORT l l prepared for THE CLEVELAND ELECTRIC ILLUMINATING COMPANY PERRY NUCLEAR POWER PLANT i by TDI DIESEL GENERATOR OWNERS GROUP December, 1984 Roviewed by: 84=e R. J. Deese Licensing Coordinator TDI Diesel Generator Owners Group

Approved by:

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C. L. Ray 1Vchpical Program Director TDI Diesel Generator Owners Group O PE3333

TABLE OF CONTENTS O . EXECUTIVE

SUMMARY

1.0 INTRODUCTION

2.0 PROGRAM PLAN OVERVIEW 2.1 GENERIC PROBLEM RESOLUTION - PHASE I 2.2 COMPONENT SELECTION 2.3 TASK DESCRIPTION PREPARATION 2.4 DESIGN REVIEW 2.5 QUALITY REVALIDATION 2.6 FINAL DOCUMENTATION

3. 0 RESULTS OF DESIGN REVIEW AND QUALITY REVALIDATION 3.1

SUMMARY

RESOLUTION OF SIXTEEN GENERIC COMPONENTS (PHASE I) 3.2

SUMMARY

RESOLUTION OF PHASE II COMPONENTS 4.0 SUPNARY/ CONCLUSIONS 5.0 RECOMMENDATION 3

6.0 REFERENCES

APPENDICES I. DR/QR

SUMMARY

REPORTS II. MAINTENANCE & SURVEILLANCE RECC MENDATIONS III. INCLUDED REFERENCES O - PE3333

EXECUTIVE

SUMMARY

Thirteen U.S.-nuclear utilities have formed the Transamerica Delaval, Inc (TDI) 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 TDI Diesel Generator Owners Group established a. comprehensive program, through a combination of design

reviews, quality revalidations, engine tests and component inspections, to provide an in-depth assessment of the adequacy of the respective utilities' TDI diesel generators to perform their intended safety related functions.

The first major program element was characterized as Phase I and involved the resolution of generic known problems. A review of the accumulated operational experience resulted in the conclusion by the Owners Group Technical Staff that a limited number of components warranted priority attention and consideration as significant known problems with potentially generic applicability. Final i reports for each of these components were submitted by the Owners Group to the NRC for review. The purpose of this accelerated review was to establish a basis for licensing plants with TDI diesel generators prior to completion of the follow up effort described below. This review has shown that with imple-mentation of the Phase I report recommendations, TDI diesel get *stors can reliably perform their intended function. The second major program element involved design reviews and quality revalida-l tions of selected engine components. The Owners Group Design Review and Quality Revalidation Program (DR/QR) was established to perform these exami-O- nations for each owner's engine in order to assess each engine's ability to reliably perform its intended design function. The effort was conducted by a centralized team of engineering personnel with specialized skills in appropriate fields including diesel generator design, operation, and manufacture. The first portion of the DR/QR Program involved reviewing the Engine Parts List and selecting the components of each engine that warranted a detailed design review and/or quality revalidation. Following component selection these components were subjected to either a design review, a quality revalidation, or both. Upon completion of _ these reviews, the inspection results, document packages, . design review findings and calculation results were reviewed and approved by the Owners Group Technical Staff. The third major program element involved specific component tests and inspec-tions. The Owners Group Technical Staff, in evaluating specific engine compo-nents, provided technical recommendations to each Owner regarding special component inspections, preventive maintenance, and surveillance recommendations which will give added assurance that the engines and components perform their intended operational functions over the life of the plant. The implementation of these recommendations is a plant-specific function. This final report for The Cleveland Electric Illuminating Company (CEIC) pro-vides the results of this extensive investigation of 171 components of the TDI DSRV-16 diesel generators at Perry Nuclear Power Plant Unit 1. It forms the O basis for .the conclusion that the TDI diesel generators presently installed are fully capable of reliably performing their intended safety function. PE3333 i

,N

1.0 INTRODUCTION

This report has been prepared for The Cleveland Electric Illuminating O- Company by the TDI Diesel Generator Owners Group. The results of the Design Review and Quality Revalidation Program are specifically appli-cable to Perry and are based on the generic program methodology briefly discussed in Section 2.0. The purpose of this report is to pravide the results of an extensive investigation of the design and manu'.cture of 171 components of the TDI DSRV-16 diesel generators at Perry. This report forms the basis for the conclusion that the TDI diesel generators presently installed are fully capable of performing their safety function as described in the Perry Final Safety Analysis Report. l l l l l O ! PE3333 1-1 L

2.0 PROGRAM PLAN OVERVIEW A The TDI Owners Group Program Plan (the Plan) has been previously provided V by reference (1). This overview of the Plan is provided to assist the reader in understanding the generic methodology by which the plant-specific results of Section 3.0 were obtained. The Plan consists of two phases comprised of the following major elements: Phase I Generic Problem Resolution Phase II Component Selection Task Description Preparation Design Review Quality Revalidation Final Documentation Each element is briefly discussed in the following sections. O i PE3333 2-1

v. 2.1 GENERIC PROBLEM RESOLUTION - PHASE I Using- input from various nuclear data sources (INPO, SOERs, LERs, O 10CFR50.55e reports & 10CFR21 reports, etc) as well as non-nuclear sources (marine and stationary TDI engine applications), a substantial data base of TDI engine / component operational experience has been accumulated. A review of this data by the TDI Diesel Generator Owners Group Techni-

                 ' cal Staff resulted in the conclusion that a limited number of TDI engine components had evidenced sufficient adverse operating experience in one or

, more applications, such that they warranted priority attention and consid-

eration as significant known problems with potentially generic applicabil-: ity. Therefore, the Owners Group technical resources were heavily applied; to these problem areas in order to expedite the reviews, tests and/or
analyses necessary to resolve them. The purpose of this accelerated: review was to establish a basis for licensing those plants with near term licensing needs prior to the completion of the Phase II effort.

! Resolution of these problems has been pursued on a priority basis and was termed the Phase I effort. The generic known problem listing is generic only to the' extent that a body of experience exists to suggest that a l design type (or several design types) of a particular component in service in one or more TDI engine applications has not performed acceptably or may not have been designed adequately. A listing of the identified generic components is included as Table 2.1. Reports on these components have been previously submitted to the NRC for '. N review._ Summary Phase II reports for the generic problems (Phase I components) as they apply to Perry are included in Appendix I of this i report. The results of the reviews of these components are summarized in Section

                  -3.0.

e A f O PE3333 2-2

m 2.2 COMPONENT SELECTION The diesel generator components to be subjected to the DR/QR Program were O determined by a Component Selection Committee. Selection was 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 Commit-tee's engineering judgement. The selection process included a review of available operating information on TDI diesels and TDI recommended product improvements to ensure that relevant experience was considered. As part of the component selection process, components were 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 operation of the diesel generator are classified as Type C. Following classification, the Comittee established appropriate design review and quality revalidation requirements. These requirements were then forwarded to the Design Review Group and Quality Revalidation Group for preparation of task descriptions. Table 2.2 . lists those components of the Perry diesel generators which c were reviewed by the Component Selection Committee. The Table identifies ! the results of the Component Selection process by showing which compon-( ents required a design review (DR) and/or a quality revalidation (QR), t and those components requiring no review. The Category identified in Table 2.2 refers ' to the Appendix I heading under which that component's

         ,               .DR/QR Summary Report is found.

t l i l l

           .      PE3333                                       2-3
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2.3 TASK DESCRIPTION PREPARATION

   .A        The Design Review Group and the- Quality Revalidation Group prepared task V         descriptions to define the tasks (reviews, inspections, calculations, etc.) to be performed to' determine the adequacy of each component. The task descriptions included recommendations identified in the selection process as well as Design Review Group and/or Quality Revalidation Group recommended component inspections.          These task descriptions provide, as applicable:

A. DR Task Descriptions

1. Primary component function and required attributes,

2. Applicable codes and standards,

3. Alternative codes, standards, or analytical techniques,

4. Analysis or evaluation to be performed to assure satisfactory design,

5. Available verifications of TDI analysis (if any), and

6. Final documentation requirements.

B. QR Task Descriptions (Component Revalidation Checklist) . 1. Component to be validated

2. Attributes to be verified
3. Methodology to be used (documentation review, NDE techniques, etc.): 4. Acceptance criteria; 5. Final documentation requirements In some cases the Design Review Group and the Quality Revalidation Group l, (O/

i prepared task descriptions which required no additional Design Review or Quality Revalidation for certain components. The individual task descrip-l tions in Appendix I contain the justification for this reduction in scope. I In general, the basis for not requiring a Design Review and/or Quality l Revalidation Report is the following: i l Leac; Engine Component Reviews - This component wat reviewed on a [ 1ead engine. Any recommendations which supported the conclu-l sions in the lead engine report are evaluated for applicability i .to the follow on engine component and included in the task l description. Experience - Either no adverse site or industry experience j exists or if it does exist, the task description addresses its resolution. Task descriptions for all components are included with each component's DR/QR Summary Report in Appendix I. Figure 2.1 graphically depicts the process followed in the DR/QR Program. l l 'O L PE3333 2-4 I

2.4 DESIGN REVIEW N The Design Review Group completed the design review in accordance with the

. task descriptions. Due to the number and diversity of the components and standards involved, the design review was tailored to each component. The actual design review was accomplished by using any one or more of the following methods, including: a) an independent calculation performed by the Design Review Group; b) an independent review of the adequacy, appro-priateness or correctness of existing vendor and/or subvendor calcula-tions; c) testing specified by the Design Review Group; or, d) other methods specified and approved in the task descriptions.
' During implementation of the task descriptions, the Design Review Group specified quality attributes (in addition to those identified during the component selection process) for incorporation into the quality revalida-tion process. The Design Review Croup also identified any components which may require corrective action to improve reliability of the diesel generators. This included recommendations such as increased frequency of component replacement and/or maintenance, or additional in-service inspection.
' 2. 5 QUALITY REVALIDATION The Component Quality Revalidation Group was provided with the quality attributes required to be revalidated. QR Task Descriptions were devel-oped to identify methodology for verification of attributes. These task descriptions include applicable component descriptions, attributes to be verified, methodology, acceptance criteria, and type of documentation to 2

( be provided. Each component required to undergo Quality Revalidation was subjected to a documentation review. This process identified and catalogued all appro-priate documentation (e.g. material test reports, NDE, vendor /subvendor records, site records, etc) associated with the component. With assis-tance from Quality Engineering, each document was reviewed for acceptabil-ity. These document packages were then made available to the Design Review Group to assist in the engineering review. Important attributes identified by the Design Review Group, for which acceptable documentation did not exist in the component file, were verified by tests and/or inspec-tions performed by the Quality Group. Tests or inspections required to be performed on components were then forwarded to Quality Engineering to develop detailed methodology and procedures to be followed. These instructions were issued to Quality Inspection via the task description. Field inspections and tests were performed by qualified personnel. Depending upon the specified test or inspection, spare parts or surplus parts in lieu of installed parts were used as the test / inspection article. Results of inspections and tests were summarized by the - Quality Revalidation Group and reviewed by the Design Review Group as necessary. , t 8 PE3333 2-5

p. 2.6 FINAL DOCUMENTATION i The DR/QR program has been completed for The Cleveland Electric Illuminating 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 i including references to supporting documentation and the recommendations , and conclusions resulting from this effort. Appendix II contains a comprehensive set of maintenance and surveillance i recommendations 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

L qualification of its diesel generators for the life of the plant. This entire . report constitutes final documentation of the completion of the DR/QR Program on the Perry TDI diesel generators pending final completion of a limited number of calculation packages involving nozzle loads, pipe support / restraints, and mechanical reports. i h t b .l 1 1 , O PE3333 2-6

TABLE 2-1 O PHASE I COMPONENTS (GENERIC PHASE I) COMPONENT NUMBER COMPONENT MP-017 Turbocharger [ 03-305A,C,D,E Base & Bearing Caps 03-310A Crankshaft 03-315A&C Cylinder Block & Liners l' 03-315E Cylinder Head Studs , 03-340A- Cylinder Rods 03-340B Connecting Rod Bearing Shells 03-341A Pistons 03-359 Airstart Valve Capscrews 03-360A Cylinder Heads i 03-365C Fuel Oil Injection Tubing 03-390C&D Main and Connecting Pushrods 03-390G Rocker Arm Capscrews 03-425A Jacket Water Pump 03-6888 Wiring & Termination 4 O PE3333 2-7

TABLE 2-2

  ,q                          PERRY COMPONENT SELECTION RESULTS V  Component Component                       DR             No QR Number    Description                  Rea'd   Rea'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 00-4428 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 O PE3333 2-8

TABLE 2-2 A PERRY COMPONENT SELECTION RESULTS U Component Component DR QR No Number Description Reo'd Reg'd Review Categors 02-CFR Turbocharger Thrust Bearing X X Turbo, Intake, Drip Lube System Intrcir. & Ex-haust 02-305A 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 02-305D 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 02-3078 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 l 02-310A Crankshaft X X Crankshaft & Bearings 1 02-310B Main Bearings X X Crankshaft & Bearing 02-310C Crankshaft & Bearings: X X Crankshaft & l Thrust Bearing Rings. Bearing 02-311A Crankcase: Crankcase Assy X X Crankshaft & ! Bearing f-l l PE3333 2-9 f

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS

      \O'    Component Component                        DR            No QR Number    Description                   Reo'd  Rea'd   Review Category 02-311B   Cylinder Block Liners & Water                   X Manifold: Cam Bearing Caps &

Dowels 02-311C Crankcase: Crankcase Seal X 02-3110 Crankcase: Crankcase X X Crankshaft & Mounting Hardware Bearings 02-315A Cylinder Block X X Cyl. Block & Liners & Water Manifold 02-315B Cylinder Block: Block To X Crankcase Dowel 02-315C Cylinder Block Liners & X X Cyl. Block & Water Manifold - Liners & Cylinder Liner Water Manifold 02-315D Jacket Water Manifold X X Cyl. Block & k'__)T Piping Liners & Water Manifold 02-315E Cylinder Block Liners & X X Cyl. Block & i Water Manifold: Studs Liners & ! Water Manifold 02-315F Cylinder Block Liners X X Cyl. Block &

                       & Water Manifold:                                   Liner & Water Cylinder Head Nuts                                  Manifold l             02-315G   Cylinder Block Liners &         X      X            Cyl. Block &

Water Manifold: Seals & Liners & i Gaskets Water Manifold t 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 l Coupling and Gaskets l l , o l PE3333 2-10

n. TABLE 2-2 O PERRY COMPONENT SELECTION RESULTS , Component Component DR QR No ) Number Description Reg'd Reg'd Review Category 02-316C Jacket Water Inlet Manifold: X X Jacket Water Vent line to Discharge Manifold 02-317A Water Discharge Manifold: X X Jacket Water Jacket Water Discharge Manifold, Coupling and Seals 02-3178 Water Dicharge Manifold: X X Jacket Water Coupling & Seals 02-317C Water Discharge Manifold: X X Jacket Water Supports 02-330A Flywheel X Flywheel 02-330B Flywheel Bolting X X Flywheel 02-331A Guards: Flywheel Guard X Assembly (,,/ 02-335A Front Gear Case: Gear Case X 02-3358 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 Sheils Rods 02-341A Pistons X X Pistons 02-341B 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 O

PE3333 2-11

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component . DR QR No Number Description Reo'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-O 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 Retainers 02-361    Indicating Cocks                                                          X O

v PE3333 2-12

TABLE 2-2 q PERRY COMPONENT SELECTION RESULTS V Component Component DR QR No Number Description Reo'd Reg'd Review Cateocry 02-362A Subcover X X Camshaft & Valve Train 02-3628 Cylinder Head Covers: X Gaskets and Bolting 02-365A Fuel Injection Equipment: X Fuel Oil In-Fuel Injection Pump jection 02-565B Fuel Injection Equipment - X Fuel Oil In-Fuel Injection Tips jection 02-365C 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 02-371B 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 Manifolo 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 O PE3333- 2-13

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Rea'd Rea'd Review Category 02-385B Cylinder Block Covers: X X Cyl. Block & Gaskets and Bolting Liners & Water Manifold 02-386A Crankcase: Crankcase X Cover Assy 02-3868 Crankcase: Crankcase X X Crankshaft & Gaskets and Mounting Bearings Hardware 02-387A Crankcase Ventilator: X Crankcase Vacuum Fan 02-387B Crankcase Ventilator - Oil X Separator 02-387C Crankcase Ventilator- X Crankcase Vacuum Fan (N 02-387D Crankcase Ventilator- X

 \m)            Crankcase & Fluid Manometer 02-390A   Intake & Intermediate and      X       X             Camshaft &

Exhaust Rocker Shaft Assembly Valve Train 02-390B Rocker Arms and Pushrods: X X Camshaft & Exhaust Rocker Shaft Valve Train Assembly 02-390C Main and Connector X X Camshaft & Pushrods Valve Train 02-3900 Rocker Arms and Pushrods: X X Camshaft & Pushrods Connector. Valve Train 02-390E Rocker Arms and Pushrods: X Camshaft & Bushings Valve Train 02-390F Rocker Arms and Pushrods: X X Camshaft & Lifters Valve Train 02-390G Rocker Arms and Pushrods X X Camshaft & Misc. Bolts & Drive Studs Valve Train 0) (_- PE3333 2-14

m TABLE 2-2 PERRY COMPONENT SELECTION RESULTS d Component Component DR QR No Number Description Rea'd Reg'd Review Category 02-395A Gear Case Covers: Cover X 02-395B' Gear Case Covers: Gaskets X and Bolting 02-410A Overspeed Trip Governor X X Overspeed Trip

                                                                         & Governor 02-4108   Overspeed Trip: Governor              X       X             Overspeed Trip and Accessory Drive Assembly                                & Governor 02-410C   Overspeed Trip: Couplings             X       X             Overspeed Trip (Flexible and Spider)                                       & Governor 02-4100   Overspeed Trip Vent Valve             X       X             Overspeed Trip
                                                                         & Governor 02-411A   Governor Drive: Governor &            X       X             Overspeed Trip Tachometer Drive Gear and                                   & Governor Shaft 02-411B   Governor Drive: Couplings,            X       X             Overspeed Trip Pins & Keys                                                 & Governor 02-413A   Governor Linkage                     X        X             Overspeed Trip
                                                                         & 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 Se comotor                                          & Governor 02-415C   Governor Assembly -                  X        X             Overspeed Trip Heat Exchangers                                             & Governor 02-420    Engine Driven                        X        X             Lube Oil Lube Oil Pump PE3333                                       2-15

TABLE 2-2 es PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Reg'd Reg'd Review Category 02-425A Engine Driven X X Jacket Water Jacket Water Pump 02-425B Jacket Water Pump: X Cover Plate 02-435A Jacket Water Fittings: X X Jacket Water Pipe & 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 O                Coupling, Gaskets, Bolting Intercooler &

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 Barring 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 i f , v l l PE3333 2-16 l L

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS ( Component Component DR QR No Number Description Rea'd Rea'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 Valves 02-465C Lube Oil Lines X X Lube Oil External-Supports 02-467A Turbocharger: Lube Oil X X Lube Oil Fitting - Piping A (s) 02-4678 Turbocharger: Lube Oil X X Lube Oil Fittings - Supports 02-475A Turbocharger: Bracket X X Turbo, Intake, Intrcir. & Ex-haust 02-475B Air Butterfly Valve X X Turbo, Intake, Assembly Intrcir. & Ex-haust 02-475C Turbocharger: Bracket - X X Turbo, Intake, Bolting & Gaskets Intrcir. & Ex-haust 02-500A Control Panel Assembly X X Control Panel Cabinet / System Assembly 02-5008 Control Panel Assembly: X Annunciators O V PE3333 2-17

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Rea'd Rea'd Review Category 02-500C Control Panel Assembly: X Circuit Breaker / Contact Blocks 02-5000 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 02-500N Control Panel Assembly: X r Pyrometers 02-520 Instruction Plate: X i Nameplate 02-525A Barring Device - Pneumatic: X Barring Device Assembly r P V PE3333 2-18

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS O, Component Creponent DR QR No Number _ Ducription Reg'd Reo'd Review Category 02-525B Barring Device - Pneumatic: X X Air Start & Regulator Valve / Shutoff Barring Device Valve 02-525C Barring Device - Pneumatic: X Misc. Fitting, Hose, Filters Tubing 02-525D Barring Device - Pneumatic: X Air Start & Mounting Bracket / Supports Barring Device 02-530A Platform - Front & Side: X Side Platform Assembly 02-530B Platform - Front & Side: X Front Platform Assembly 02-530C Platform, Ladders, X Stairs - Stair Assembly 0 - U 02-5300 Platform, Ladders, X Stairs - Supports 02-540A Lube Oil Sump X Lube Oil with Strainer Assembly and Mounting Hardware 02-540B Lube Oil Sump Tank: Misc. X X Lube Oil Fittings, Gaskets, Pipe

                 & Bolting Material, Valves 02-540C    Lube Oil Sump Tank:              X         X                  Lube Oil Mounting Hardware 02-550     Foundation Bolts:                X         X                  Engine & Aux.

Anchor Bolts, Misc. Sub Base & Hardware Foundation Bolts 02-590 Special Tools: Asst. X Engine Assembly Tools O PE3333 2-19

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Reg'd Rea'd Review Category 02-630A Pyrometer Conduit Assembly: X X Engine Instru-ronduit ' 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 02-6300 Pyrometer Conduit Assembly: X Engine Instu-Thermocouples mentation & Wiring 02-630E Pyrometer Conduit Assembly: X Gaskets . 02-650A Generator X X Generator 02-650B Generator Control X X Generator 0 02-650C Generator-Shaft & Bearings X X Generator 02-688A Engine & Aux Module X X Engine Instru-Wiring Material- Conduit mentation &

                & Fittings; Pyrometer                                   Wiring Assembly - Conduit, Fitting, Supports 02-688B   Engine & Aux.                    X       X              Engine Instru-Module Wiring Material:                                 mentation &

Wiring & Terminations Wiring l 02-688C Engine & Aux. Module Wiring X Engine Instu-l Material: Boxes & Terminals mentation & Wiring 02-689 Off-Engine Alarm Sensor X X Engine Instru-Wiring mentation & Wiring l PE3333 2-20

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS O

     \ ,/        Component   Component                       DR               No QR Number      Description                   Reo'd      Reg'd Review Category 02-690      On-Engine Alarm Sensors         X          X          Engine Instru-mentation &

Wiring 02-691- 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-i Regulator, Orifices ment 02-695C Engine Shutdown Trip X X Engine Shut-Switches down & Equip-ment 02-700A Jacket Water Standpipe: X X Jacket Water Os_, Pipe, Fittings, Gaskets 02-700B Jacket Water Standpipe: X X Jacket Water Valves 02-700C Jacket Water Standpipe: X X Jacket Water Pipe Supports 02-7000 Jacket Water Standpipe: X Gauges 02-700E 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 C
     \~ >i PE3333                                   2-21

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS

   ) 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 02-717D Aux Sub Base & 011 & 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 & 011 & Water X X Lube Oil Piping - Lube Oil: Pipe and Fittings 02-717G Aux Sub Base & 011 & Water X X Lube Oil Piping - Lube Oil: 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 011: Supports & Mounting Hardware l 02-717J Aux Sub Base & 011 & Water X X Fuel Oil Piping - Fuel Oil - Piping

               & Fittings 02-717K   Aux Sub Base & 011 & Water             X        X              Fuel Oil Piping - Fuel Oil Valves                                       Injection i

O PE3333 2-22

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

TABLE 2-2 PERRY COMPONENT SELECTION RESULTS I Component Component DR QR No Number Description Reg'd Rea'd Review Category 02-717L Aux Sub Base & Oil & Water X X Fuel Oil Piping - Fuel Oil - Injection Gaskets & Bolting 02-717M Aux Sub Base & 011 & Water X X Fuel Oil Piping - Fuel Oil: Injection Supports 02-805A Intake Air Silencer X Turbo, Intake, Irtercooler & Exhaust 02-805B Intake Air Filter X X Turbo, Intake, Intercooler & Exhaust 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 02-8208 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 - Lut,e Oil X X Lube Oil Keepwarm Strainer O U PE3333 2-23

e TABLE 2-2 PERRY COMPONENT SELECTION RESULTS Component Component DR QR No Number Description Reg'd Reg'd Review Category 02-820E 011 Prelube Filter X X Lube Oil 02-820F Full Flow Lube Oil Filter X X Lube Oil 02-820G Lube Oil Heat Exchanger X X Lube Oil 02-825A Fuel Oil Day Tank X X Fuel Oil Injection 02-825B Fuel Oil System- X Fuel Oil Drip Waste Pump 02-825C Fuel Oil Booster Pump - X D.C. Motor Driven 02-8250 Fuel Oil System - Fuel X Fuel Oil Oil Duplex Strainer Injection 02-825E Fuel Oil System - Fuel X 011 Valves, Bolting O V 02-835A Air Dryer X 02-835B Starting Air Tank X X Air Start & Barring Device 02-835C Misc. Equipment: After X Cooler 02-835D 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, Fittings, Tubing 02-835G Misc. Equipment - After X Cooler Bolting 02-835H Misc. Equipment - After X Cooler Bolting PE3333 2-24

r. O . FIGURE 2.1 Component Selection DR Task Description QR Task Description 4 0 Design Analysis and ----------- Quality Documentation Technical Backup and Inspection Data 4 u DR Results and QR Results and Conclusions Conclusions

      .I component DR/QR Summary Report o

Engine DR/QR Report O 4 PE3333 2-25

3.0 Results of Design Review and Quality Revalidation The DR/QR Program implemented for the Perry Nuclear Power Plant - Unit 1 TDI diesels was consistently performed with the generic methodology described in Section 2.0. The results of these reviews are summarized in this section. More detailed component sumary reports are contained in Appendix I of this report. Sections 3.1 and 3.2 list the components of the Perry diesel generators have been reviewed under Phase I and Phase II, respectively. The majority of these components are assessed to be acceptable for their intended service with unlimited life provided that the recomendations

identified are followed. These recomendations deal mainly with addi-tional inspection requirements, and installation, operating and mainten-ance procedure improvements. In some cases, procurement specification recommendations are identified to aid the utility in its spare parts program.

Some of the components required modifications as identified in the recomended actions. The implementation of these recomended actions by ! the utility will result in a component that is acceptable for its intended service with unlimited life. O i l l PE3294 3-1

r 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 44) 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 (02-305A, inspection requirements. 02-305C, 02-3050) Crankshaft Unlimited Life Additional inspection and

               .(02-310A)                                 testing requirements.

Cylinder Block Unlimited Life Additional maintenance and and Liner inspection requirements. (02-315A,02-315C)

(

Cylinder Head Unlimited Life None g Studs (02-315E)

. Connecting Rods: Unlimited Life Additional inspection

! Connecting Rods requirements. ! -and Bushings

(02-340A) l Connecting Rod Unlimited Life Additional maintenance Bearing Shells requirements.

(02-3408) l '~ Pistons (02-341A) Unlimited Life None-Air Start Valve Unlimited Life Additional maintenance (02-359) requirements. l- . Cylinder Heads Unlimited Life Additional maintenance l (02-360A) requirements. l Fuel Injection Unlimited Life Additional testing and l Equipment: Tube maintenance requirements. Assembly (02-365C) Procurement specification requirement. e ! PE3294 3-2 t I-

Component Acceptability Recommended Action Main and Connector Unlimited Life Additional procurement Pushrods requirement. (02-390C, 02-390D) Rocker Arm Capscrews Unlimited Life Additional maintenance (02-390G) requirements. Jacket Water Pump Unlimited Life Additional maintenance

(02-425A) requirements.

l Wiring and Unlimited Life None Terminations (02-6888) O 1 il r i i l i i t t i O L

             ~PE3294                                   3-3

m 3.2 Summary Resolution of Phase II Components Component 1 Acceptability Recommended Action TURBO, INTAKE, INTERCOOLER & EXHAUST Intercooler Unlimited Life Additional maintenance (F-068) recommendations. Turbocharger Modifications Additional Quality inspections (MP-022/023) recommended. Modifications and inspections recommended to ensure the reliability and performance of the turbocharger. Refer to Component Design Review Checklist MP-022/023 for details. Turbocharger Thrust Modifications Addition of supports / restraints. Bearing Drip Lube Refer to DR/QR report 02-CFR for System details. (Small Bore Scope , Only) (02-CFR) Intake Manifold and Modifications Ensure U-bolts on the crossover I piping piping are properly installed. 5 3 (Large Bore Scope Additional maintenance recom-Only) mendations. Additional Quality (02-375) inspections recommended. Exhaust Manifold Modifications Additional maintenance recommend-(02-380A) ations. Modify slip joints. Refer to Component Design Review Checklist 02-380A for details.

            , Exhaust Manifold:    Unlimited Life       Additional Quality inspections

l. Gaskets & Bolting recommended.

I (02-3808) Intercooler Piping- Unlimited Life Additional Quality inspections l Pipe (Large Bore recommended. Scope Only) (02-436A&B) i O V i l PE3294 3-4

Component Acceptability Recommended Action Turbocharger - Unlimited Life Additional Quality Revalidation C' Bracket: Bolting inspections recommended. and Gaskets (02-475A&C) Air Butterfly Unlimited Life Additional maintenance Valve Assembly recommendations. Additional (02-4758) Quality inspections recommended. 1 Intake Air Unlimited Life None Silencer (02-805A) Intake Air Filter Unlimited Life Additional maintenance (02-805B) recommendations. Flex Connections Unlimited Life None (02-8050) LUBE OIL , Lube Oil Pressure Unlimited Life Additional maintenance Regulating Valve O (00-420) recommendations. Lube Oil Fittings Unlimited Life None Internal Headers I (Large Bore I Scope Only) (02-307A-LB) Lube Oil Fittings- Unlimited Life Verify as-built conditions Internal: headers are as indicated in Component

                    ' (Small Bore Scope                                                                                Design Review Checklist 02-3070.

Only) (02-307A-SB) r I Lube 011 Fittings- Unlimited Life None

Internal-Tubing i and Fittings (Small Bore
Scope Only) !

i (02-3078) ' O PE3294 3-5 l

      -,-re,.    ,m   --

e .r,-e. - - , . - ,,.,.,..-.n._.e,-, ,,v. , ... ,... , ~. .,- ,. ,-- _ _ - ,_ _ _ ,-- _

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

Component Acceptability Recommended Action

    ^
             -Lube 00 Fittings      Modifications                   Replace all 1/4-inch U-bolts with internal-Sapports                                    3/8-inch U-bolts. U-bolts should (Small Bore                                          be torqued sufficiently to Scope Only)                                          prevent the header from moving (02-3070)                                            axially without overstressing the header. Nuts should have           ,

suitable locking devices installed. Engine Driven Lube Unlimited Life None Oil Pump (02-420) Lube Oil Lines - Modifications Replace 12-inch Dresser coupling External Tubings, gasket with VITON gaskets. Ensure Fittings, Couplings a minimum installation gap of (Large Bore Scope 0.171 inches, between pipe ends, Only) exists at the 12-inch Dresser

              -(02-465A-LB)                                         coupling.

Lube Oil Lines - Modifications Addition / modification of supports. External-Tubing, Refer to DR/QR report 02-465C Fittings, Coupling for details. (Small Bore Scope Only) (02-465A-SB) Lube Oil Lines Unlimited Life None U External - Valves . (02-4658) Lube Oil Lines .. There are no supports for this component. No design External-Supports review is required.

             '(Large Bore Scope'Only)
             -(02-465C-LB)

.. Lube Oil' Lines Modifications Addition / modification of supports. l' External-Supports Refer to DR/QR report 02-465C-SB ! (Small Bore for details. Scope Only) l-(02-465C-SB) i- -Turbocharger - Modifications Replace 2 -inch Dresser couplings Lube Oil Fitting- -(located between the turbocharger Piping-(Large and lube oil sump tank for both Bore Scope Only)' drain lines) with 2 -inch 150 (02-467A-LB) lb. S.O. flanges with A307 bolts. r ( _- .PE3294 3-6

Component Acceptability Recommended Action Turbocharger - (f'~,g) Modifications Addition of supports. Refer to Lube Oil Fitting- DR/QR report 02-467B for details. Pipe,. Tubing, Fittings and Flexible Couplings (Small Bore Scope Only) (02-467A-SB) Turbocharger - Modifications The multiple support (attached to j Lube Oil Fittings- both 2 -inch drain lines) l Supports (Large located between the lube oil Bore Scope Only) sump tank and the Dresser coupling (02-4678-LB) requires reinforcement of support

members and increases in the welds.

Turbocharger - Modifications Addition / modification of supports. Lube Oil Fittings: Refer to DR/QR report 02-4678-LB Supports (Small for details. Bore Scope Only) (02-467B-SB) Lube Oil Sump Unlimited Life Additional Quality Revalidation Tank-Tank with tasks recommended. Strainer Assembly (N _/} s and Mounting Hardware (02-540A&C) Lube Oil Sump Unlimited Life None Tank-Misc. Fittings, Gaskets, Pipe, and Bolting Material, Valve (Small Bore Scope Only) (02-5408) 9 O PE3294 3-7

r Component Acceptability Recommended Action

Auxiliary Sub-Base Unlimited Life None

          & 011 & Water Piping-Lube Oil:

Pipe and Fittings (Small Bore Scope Only) (02-717F-LB) Auxiliary Sub-Base Modifications Addition / modification of supports.

          & Oil & Water                                                                 Refer to DR/QR report 02-717I Piping-Lube 011:                                                               for details.

Pipe and Fittings (Small Bore Scope Only) (02-717F-SB) Auxiliary Sub-Base & Unlimited Life Additional maintenance Oil & Water Piping- recommendations. Lube 011: Valves Additional field inspections (02-717G) recommended. Auxiliary Sub-Base Unlimited Life None

          & 011 & Water Piping - Lube Oil:

Gaskets and Bolting (02-717H) Auxiliary Sub-Base Unlimited Life None

          & 011 & Water Piping-Lube Oil:

Supports and Mounting Hardware (Large Bore Scope Only) (02-7171-LB) Auxiliary Sub-Base Modifications Addition of two-directional

          & Oil & Water                                                                 restraints on the lube oil l          Piping - Lube Oil:                                                            cooler drain lines (shell side)

Supports and Mounting near the drain valves to prevent Hardware loosening of threaded connections (Small Bore Scope to vessel during a seismic event. Only) (02-717I-SB) Miscellaneous Unlimited Life Additional maintenance recommend-Equipment - Heater, ations. Lube Oil Sump Tank (02-820A) O PE3294. 3-8

Component Acceptability Recommended Action Before & After Unlimited Life O Lube Oil Pump (02-8208) None Lube Oil Full Unlimited Life Additional maintenance Pressure Strainer recommendations. 2 (02-820C) Lube Oil System: Unlimited Life None Lube Oil Keepwarm Strainer i (02-8200) Oil Prelube Filter Unlimited Life Additional maintenance (02-820E) recommendations. ! Full Flow Lube Oil Unlimited Life Additional maintenance Filter recommendations. (02-820F) Lube Oil. Heat Unlimited Life Additional maintenance Exchanger recommendations. (02-820G) ENGINE BASE & BEARING CAPS ,O l ! \s / Base and Bearing Unlimited Life Additional maintenance recommend-Caps - Base Assembly, ations. Additional Quality Main Bearing Studs inspections recommended. and Nuts, and Main Bearing Caps (02-305A,C,D)

, CRANKSHAFT & BEARINGS l - ! Crankshaft Unlimited Life Additional Quality Revalidation l (02-310A) (pending satis- inspections recommended. factory completion of the torsiograph test) Main Bearings Unlimited Life Additional Quality inspections (02-310B) recommended. At the first refueling outage, the main l bearings should be inspected for evidence of misalignment. e I l PE3294 3-9

Component Acceptability Recommended Action Crankshaft & Unlimited Life Additional maintenance recommend-Cg Bearings: Thrust ations. Bearing Ring (02-310C) Crankcase: Unlimited Life Additional maintenance recommend-Crankcase Assembly ations. Additional Quality (02-311A) inspections recommended. Crankcase: Unlimited Life None Crankcase Mounting Hardware (02-311D) Crankcase: Crank- Unlimited Life Additional Quality inspections case Gaskets and recommended. Mounting Hardware (02-386B) CYLINDER BLOCK, LINERS & WATER MANIFOLD Cylinder Block Unlimited Life Perform a material microstructure (02-315A) evaluation on all engine blocks. A dimensional check of the cylinder liner bore and mating block i should be performed. Implement-s_- / ation of routine inspections recommended. Cylinder Block Unlimited Life Additional maintenance recommend-Liners & Water ations. Additional Quality Manifold - inspections recommended. Cylinder Liner (02-315C) Jacket Water Unlimited Life None

              -Manifold Piping (Large Bore Scope Only)

(02-315D) ! Cylinder Block Unlimited Life The installation torque should i Liners & Water be changed to lower the stresses Manifold: Studs in the cylinder block. Additional (02-315E) Quality inspections recommended.

l~

L) PE3294 3-10 t

Component Acceptability Recommended Action Cylinder Block Unlimited Life Additional Quality Revalidation Os Liner & Water Manifold - inspections recommended. Cylinder Head Nuts (02-315F) Cylinder Block - Unlimited Life Perform a review of applicable Liners & Water site documentation to verify Manifold: Seals that the proper cylinder liner and Gaskets seals (TDI P/N JF-019-00) have (02-315G) been installed. Cylinder Block Unlimited Life Additional Quality inspections Covers: Gaskets recommended.

        & Bolts (02-385B)

AIRSTART & BARRING DEVICE Starting Air Unlimited Life Additional maintenance recommend-Distributor: ations. Additional Quality Distributor inspections recommended. Assembly (00-442A) - Starting Air This component review has been deleted. O' Distributor - Tubing, Fittings, distributor tubing is addressed under component numbers 02-441A&C and 02-3078. All air and Gaskets (00-4428) Air Start Valves Modifications Implementation of TDI SIMs 329 Valves and 360. Additional maintenance (02-359) recommendations. Additional Quality inspections recommended. Starting Air Modifications Modify supports in_ order to Manifold: Piping, provide stiffer load paths and Tubing, and Fittings to relieve thermal restraint. (Large Bore Scope Only) (02-441A-LB) Starting Air Modifications Addition / modification of supports. Manifold: Piping, Refer to DR/QR report 02-441C Tubing, and for details. Fittings (Small Bore Scope Only) (02-441A-SB) - y . PE3294 3-11

F Component Acceptability Recommended Action N Starting Air Modifications Additional maintenance (Q Manifold: Valves, Strainers, & Filters recommendations. Addition of free flowing drains to the (02-441B) air distributor filter. Starting Air Unlimited Life None Manifold - Supports (Large Bore Scope Only) (02-441C-LB) Starting Air Modifications Addition / modification of supports. Manifold - Supports Refer to DR/QR report 02-441C-SB (Small Bore for details. Scope Only) (02-441C-SB) Barring Device- Unlimited Life Additional maintenance Pneumatic Regulator recommendations. Valve / Shutoff Valve (02-525B) Starting Air Tank Unlimited Life Additional maintenance (02-835B) recommendations. [] Air Start Tank Unlimited Life None V Relief Valves s (02-835E) CONNECTING RODS Connecting Rods: Unlimited Life Additional maintenance recommend-Rods and Bushings ations. Additional Quality (02-340A) inspections recommended. Connecting Rods: Unlimited Life Additional maintenance recommend-Bearing Shells ations. Additional Quality l (02-3408) Revalidation inspections ! recommended. PISTONS Unlimited Life Pistons Perform a liquid penetrant test (02-341A) on the piston skirts. Pistons: Rings Unlimited Life Additional maintenance recommend-(02-341B) ations. Additional Quality Revalidation inspections re-commended. O PE3294 3-12 l- --

Component Acceptability Recommended Action

       '~x       Piston:    Pin        Modifications        Replace the spiral ring retainers Assembly                                   with Waldes snap ring retainers (02-341C)                                   (P/N GE-003-067). Additional ~

Quality inspections recommended. Additional maintenance recommend-ations. CAMSHAFT & VALVE TRAIN Tappets and Guides: Unlimited Life Additional maintenance recommend-Intake & Exhaust ations. Additional Quality Tappet Assembly inspections recommended.

                -(02-345A)

Tappets and Guides: Unlimited Life Additional maintenance recommend-Fuel Tappet ations. Additional Quality Assembly inspections recommended. (02-345B) a Tappets and Guides- Unlimited Life None Fuel Pump Base

Assembly (02-345C) .

Camshaft: Unlimited Life Additional maintenance recommend-Camshaft Assembly ations. Additional Quality x (02-350A) Revalidation inspections recommended. Camshaft: Unlimited Life None Camshaft Bearing (02-350B) Subcover Unlimited Life Additional inspections recommended. (02-362A) Additional Quality Revalidation inspections recommended. Rocker Shaft Unlimited Life Additional Quality Revalidation Assemblies: inspections recommended. Intake / Intermediate

                & Exhaust (02-390A&B)

O PE3294 3-13

Component Acceptability Recommended Action

       'S       Main and                Unlimited Life     Additional Quality Revalidation Cy       Connector Pushrods                          inspections recommended. Pur-(02-390C&D)                                chase order of pushrods should specify destructive verification of weld quality.

Rocker Arms Unlimited Life Additional maintenance recommend-and Pushrods: ations. Bushings (02-390E) Rocker Arms Unlimited Life Additional Quality Revalidation and Pushrods: inspections recommended. Lifters (02-390F) Rocker Arms and Unlimited Life Additional maintenance recom-Pushrods - Miscel- mendations. Additional Quality laneous Bolts and inspections recommended. Drive Studs (02-390G) IDLER GEAR ASSEMBLY & FRONT GEAR CASE Front Gear Case- Unlimited Life Additional maintenance

   -(N          Gasket and Bolting                         recommendations. Additional
    \s          (02-335B)                                  Quality inspections recommended.

Camshaft - Supports, Unlimited Life Additional maintenance recom-Bolting and Gear; mendations. Additional Quality Idler Gear Assembly - inspections recommended. Crank to Pump Gear;

               -Idler Gear Assembly (02-350C, 02-355A&B)

FLYWHEEL Flywheel Unlimited Life None (02-330A) Flywheel Bolting Unlimited Life None - (02-330B) O PE3294 3-14

Component Acceptability Recommended Action f-'s ENGINE INSTRUMENTATION & WIRING

   . \g, Pyrometer             Unlimited Life       Additional maintenance re' commend-Conduit Assembly:                          ations.

Thermocouples (02-6300) Engine and Auxiliary Unlimited Life Perform an upgrade to tighten / Module Wiring fix, replace or add missing Material and conduit supports as required. Fittings: Pyrometer Conduit Assembly - Conduit,~ Fittings and Supports (02-688A, 02-630A,B,C) Engine & Auxiliary Unlimited Life None Module Wiring Materials: Wiring

              & Termination (02-6888)

Engine & Auxiliary- Unlimited Life None

             -Module Wiring

(~') Materials: Boxes (/ & Terminals (02-688C) i Off-Engine Alarm Unlimited Life None Sensor Wiring (02-689) On-Engine Alarm Unlimited Life None Sensors

(02-690)
Off-Engine Alarm Unlimited Life None l Sensors l (02-691)

OVERSPEED TRIP & GOVERNOR Overspeed Trip - Unlimited Life Additional maintenance recommend-Governor ations. Additional Quality (02-410A) inspections recommended. t i l PE3294 3-15

Component Acceptability Recommended Action

Overspeed Trip: Unlimited Life Additional Quality Revalidation Governor and inspections recommended. Accessory Drive Assembly (02-4108) Overspeed Trip: Unlimited Life Additional maintenance recommend-Couplings ations. Additional Quality

                      '(Flexible _and                      Revalidation inspections recommended.

Spider) (')2-410C) Overspeed Trip Unlimited Life Replace valve 0-ring every 5 years. Vent Valve (02-4100) Governor Drive: Unlimited Life Additional Quality inspections Governor and recommended. Tachometer Drive Gear and Shaft (02-411A) Governor Drive: Unlimited Life Additional maintenance recommend-Couplings, Pins ations. Additional Quality

                      & Keys                               inspections recommended.

(02-411B) Governor Linkage . Unlimited Life Additional maintenance / (02-413A) modification recommendations. Additional-_ Quality Revalidation inspections recommended. Governor Assembly: IInlimited Life Additional maintenance Woodward Governor recommendations. (02-415A) Governor Assembly Unlimited Life Additional Quality inspections Booster Servosotor recommended. j (02-4158)- Governor Assealby - Unlimited Life Additional Quality inspections Heat Exchanger recommended.

_ (02-415C) 5 5
O l

l

                -PE3294                               3-16 l

_ ~ , . _ .

_ r Component Acceptability Recommended Action ENGINE SHUTDOWN & EQUIPMENT Engine Shutdown Modifications Addition of supports / restraints. Equipment'- Tubing / Refer to DR/QR report 02-695A for Fittings & Supports details. (Small Bore Scope Only) * (02-695A) Engine Shutdown Unlimited Life Additional maintenance recommend-Equipment - ations. Valves, Regulators, Orifices (02-695B) Engine Shutdown Unlimited Life None Trip Switches (02-695C) JACKET WATER Jacket Water Modifications The tie rod assembly surrounding Manifold - Manifold the 6-inch Dresser coupling Assembly with requires double-nutting to prevent Hardware, Coupling inward axial movement. A 1-inch and Gaskets diameter rod is required to O4. (Large Bore accommodate the compression load. Scope Only) The second support west of the (02-316A&B) 6-inch TDI custom flanges requires stiffening in the lateral direction to accommodate total support loads. Additional Quality inspections recommended. Jacket Water Modifications Verify and/or modify supports to Inlet Manifold- ensure that they have sufficient Vent Line to moment connection at the support Discharge Manifold to structural steel interface. (02-316C) Jacket Water Modifications Replace the Style 65 Dresser Discharge Manifold / couplings with Style 90 or Style Piping (Large 165 Dresser couplings. Addi-Bore Scope Only) tional Quality inspections (02-317A&B) recommended. PE3294 3-17

-- 3 Component Acceptability Recennended Action [V] Water Discharge Manifold-Supports (Large Bore Modifications Ensure that the supports (attached to the water jacket shroud) on the two 5-inch headers have a Scope Only) minimum weld of 3-inches long (02-317C) on both sides of the longer end of the plate. Ensure that the welds between the existing 3/4-inch plate and engine block have a minimum weld of

                                                                   %-inch along the total width of the plate.

Engine Driven Unlimited Life Additional maintenance Jacket Water recommendations. Additional Pump Quality inspections recommended. (02-425A) Jacket Water Unlimited Life None Fittings-Pipe and Fittings (Large Bore Scope Only) (02-435A-LB) Jacket Water Unlimited Life Additional maintenance recommend-Fittings - Pipe ations. O- and Fittings (Small Bore Scope Only) (02-435A-SB) Jacket Water Modifications Modify the support on the 8-inch Fittings: Supports x 8-inch tee located after the (Large Bore pump discharge. Scope Only) (02-4358-LB) Jacket Water Unlimited Life None Fittings - Supports (Small Bore Scope Only) (02-4358-58) Jacket Water Inlet Unlimited Life None Fittings and Valves - (02-435C) O

       -PE3294                                              3-18

Component Acceptability Recommended Action Turbo Water Unlimited Life Additional maintenance recommend-

   -(         Piping - Pipe                           ations.

and Fittings (Small Bore Scope Only) (02-437) Jacket Water Unlimited Life Ensure that the installation of Standpipe-Pipe, the jacket water vent lines of Fittings, Gaskets the air bubble removal system (Small Bore are in accordance with TDI Scope Only) drawing No. 09-810-75051. (02-700A) Jacket Water Unlimited Life Additional maintenance Standpipe: Valves recommendations. (02-7008) Jacket Water Modifications The jacket water vent lines of Standpipe: the air bubble removal system Supports (Small should utilize two-directional Bore Scope Only) restraints at maximum spacing (02-700C) of 4 ft. 6 in, for %-inch diameter tubing and 5 ft. - 0-inch for 3/8-inch diameter tubing. Jacket Water Unlimited Life None Standpipe Switches (02-700E) Jacket Water Unlimited Life None Standpipe and Miscellaneous Bolting Material (02-700F) Auxiliary Sub-Base Unlimited Life Inspect the valves for packing l & Oil & Water Piping - leakage monthly. Jacket Water: Valves (02-7178) . Auxiliary Sub-Base Unlimited Life None

              & 011 & Water Piping - Jacket Water:

Pipe, Couplings, [ Fittings, Orifices, Y-Strainers (Large Bore-Scope Only) - l /N (02-717C-LB) i V PE3294 3-19 l

Component Acceptability Recommended Action O Auxiliary Sub-Base Unlimited Life None V & Oil & Water Piping: Jacket Water Pipe, Couplings,-Fittings, Orifices, (Small Bore Scope Only) (02-717C-SB) Auxiliary Sub-Base Unlimited Life None

                     & 011 & Water Piping-Jacket Water:    Gaskets and Bolting (02-717D)

Auxiliary Sub-Base Unlimited Life None

                     & 011 & Water Piping-Jacket Water: Supports

_(Large Bore Scope Only) (02-717E-LB) Auxiliary Sub-Base Unlimited Life None O & 011 & Water Piping-Jacket Water: Supports (Smal1~ Bore Scope Only) (02-717E-SB) Jacket Water Unlimited Life None Standby Heater-Pump (02-810A) Jacket Water Heat Unlimited Life Additional maintenance Exchanger recommendations. (02-8108) Thermostatic Valves Unlimited Life Additional maintenance

(02-810C) recommendations.

O

               .PE3294                               3-20

r-

           . Component            Acceptability        Recommended Action Miscellaneous         Unlimited Life O        Equpiment-Heater, Jacket Water Additional maintenance recommend-ations.

Standpipe (02-8100) CYLINDER HEADS & VALVES - Cylinder Heads Unlimited Life Additional maintenance recommend-(02-360A) ations. Additional Quality inspections recommended.

           -Cylinder Head         Unlimited Life      Additional Quality Revalidation Valves: Intake                             inspections recommended.

and Exhaust Valves (02-3608) Cylinder Head Unlimited Life Additional Quality Revalidation and Valves: . inspections recommended. Bolting and

Gaskets (02-360C)

Cylinder Head Unlimited Life Visually inspect and document and Valves: Springs the color code of the valve , O and Retainers (02-360D) springs. There should be no grey springs with brown-stripes. , FUEL OIL INJECTION Fuel Oil Drip Unlimited Life None Tank Assembly (00-621A) Fuel Injection Unlimited Life Additional maintenance Equipment: Fuel recommendations. Injection Pump l (02-365A) j Fuel Injection Unlimited Life Additional maintenance i Equipment: Fuel recommendations. l Injection Tips I (02-3658) Fuel Injection Unlimited Life Perform monthly inspections of Equipment: Tube compresion fittings at both ends i Assembly of each fuel injection line. (02-365C) O PE3294 3-21 l r

Component- Acceptability Recommended Action Unlimited Life Fuel Injection Perform a visual inspection of the Equipment: Supports support elastomer for signs of (Small Bore deterioration or degradation at Scope Only) each refueling outage. (02-365D) Fuel Pump Linkage: Unlimited life Additional maintenance Fuel Pump Control recommendations. Additional Shaft - Linkage Assembly Quality inspections recommended. and Bearings (02-371A&B) Fuel Pump Unlimited Life None Linkage: Automatic Shutdown Cylinder (02-413B) Fuel Oil Booster Unlimited Life None , Pump (02-445)

                           . Fuel Oil' Header:     Modifications   Addition / modification of supports.

Piping / Tubing Refer to DR/QR report 02-4508 for (Small Bore details. Scope Only) (02-450A) Fuel Oil Header- Modificatons Addition / modification of supports. Fuel Oil Tubing Refer to DR/QR report 02-4508-SB

Supports for details.

(Small Bore Scope Only) (02-4508) Fuel Oil Filters & Unlimited Life Additional maintenance Strainers: Filters recommendations. (02-455A)- Fuel Oil Filters & Unlimited Life Additional maintenance Strainers: Strainers recommendations. Modification (02-455B) to enchance operation recommended, but not required for system operation.

                           ' Fuel Oil Filters      Unlimited Life  None         -

and Strainers: . _ Mounting Hardware

                           '(02-455C)

() ' i PE3294 3-22

Component Acceptability Recommended Action Auxiliary Sub-Base Modifications Addition / modification of supports. O' & 011 & Water Piping-Fuel 011: Refer to DR/QR report 02-717M for details. Piping and Fittings (Small Bore Scope Only) (02-717J) - Auxiliary Sub-Base Unlimited Life Additional maintenance recom-

              & 011 & Water. Piping:                               mendations. Additional Quality Fuel Oil Valves                                      inspections recommended.

(02-717K) Auxiliary Sub-Base Unlimited Life None

              & 011 & Water Piping-Fuel 011:

Bolting and Gaskets (02-717L) Auxiliary Sub-Base Modifications Addition / modification of supports,

             .& 011 & Water Piping -                               U-bolts and locking devices.

Fuel Oil: Supports (Smal_1 Bore Scope - , Only) [ (02-717M) Fuel Oil Day Unlimited Life None Pump (02-825A) Fuel Oil System- Unlimited Life None , Fuel Oil Duplex

Strainer (02-825D)

GENERATOR L Emergency Diesel Unlimited Life None , Generator j (02-650A) Generator Controls Modifications Replace field flashing relay (02-6508) with an enclosed relay. Generator: Shaft Unlimited Life' None

              & Bearing l              (02-650C) 1 PE3294 -                                       3-23 4

4

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

Component Acceotability Recommended Action CONTROL PANEL ASSEMBLY

     /-^3 q_,)                                                                                           -

Control Panel Unlimited Life None Cabinet / System (02-500A) Control Panel Unlimited Life None Accumulator (02-500F) Control Panel Unlimited Life Additional maintenance recommend-Valves ations. (02-500G) Control Panel Unlimited Life None Assembly-Pressure Switches (02-500H) Control Panel Unlimited Life None Assembly Control Relays (02-5001) Control Panel Unlimited Life None Assembly Solenoid fNh Valves (02-500J) Control Panel Unlimited Life None Assembly-Piping, Tubing & Fittings i- (02-500L) L Control Panel Unlimited Life None Assembly-Terminal , Boards / Switches, l Wiring l (02-500M) ENGINE & AUXILIARY SUB BASE & FOUNDATION BOLT Foundation Unlimited Life Additional maintenance Bolte-Anchors recommen.ations. l Bolts & - l Miscellaneous Hardware (02-550) Auxiliary Sub-Base Unlimited Life None L & Oil & Water Piping-l (s Auxiliary Skid

    'y)        (02-717A) l PE3294                                      3-24

r

  /S 4.0

SUMMARY

/ CONCLUSIONS The TDI Diesel Generator Owners Group has completed its review of the TDI diesel generators installed at Perry.

The scope and depth of this review as outlined in this report represents a significant effort by the TDI Diesel Generator Owners Group Technical Staff and Cleveland Electric Illuminating Company. Nuclear standby diesel generator reliability has been a major concern of the industry and the NRC. Although ;revious programs have been sponsored by the NRC, EPRI, and other industry groups to quantify and improve this reliability, the Design Review and Quality Revalidation effort summarized in this report is unprecedented in its approach and analytical detail. This effort has produced a detailed assessment of 171 TDI diesel generator components. Many of these components have been analyzed using analytical techniques which exceed the detailed engineering effort of the original i design. Extensive component inspections are an integral part of the DR/QR program. The performance of these inspections leaves no doubt as to the quality of these critical diesel generator components. Thus, the TDI Diesel Generator Owners Group effort has gone a long way toward quantifying the reliability of the TDI Diesel Generator by estab-p) g U lishing the acceptability of these critical engine components. In many cases, recommendations are made to improve component reliability and therefore improve overall diesel generator reliability. The TDI Diesel Generator Owners Group believes that this extensive effort verifies the acceptability of the TDI diesel generators for nuclear service. The results of this review, as outlined in Section 3.0 of this report, show that the important components of the TDI diesel generator have been assessed to be adequate for their intended function. In cases where component adequacy has been judged to be marginal, corrective action is recommended which will ensure the adequacy of the component. This report supports the conclusion that the TDI diesel generators in-stalled at Perry are acceptable for their intended safety related function and, in addition, the incorporation of the maintenance and surveillance recommendations into the plant's existing program provides added assurance that these diesel generators will continue to perform their intended function for the life of the plant. A PE3333 4-2

5.0 RECOMMENDATIONS IV The purpose of the TDI Diesel Generator Owners Group Program was to assess the acceptability of the TDI Emergency Diesel Generator at Perry and to make recommendations as required to improve the reliability of given components. These recommendations are summarized in section 3.0 and given in detail in Appendix I. Additionally, the TDI Diesel Generator Owners Group Program has made recommendations concerning component maintenance and surveillance. These recommendations have been assembled from manufacturers manuals and the component DR/QR summary reports. These maintenance and surveillance recommendations are outlined in Appendix II. Although the recommendations of this report are not requirements, their adoption by The Cleveland Electric Illuminating Company will give added assurance that the TDI Emergency Diesel Generators installed at Perry will perform their. intended function for the life of the plant. These recommendations represent a conservative approach to insuring diesel generator reliability. In some cases, the utility may propose alternate means of insuring the reliability of their emergency diesel engines. Justification of these alternate means is the responsibility of the utility. O O PE3333 5-1

6.0 REFERENCES

  't         Component DR/QR Summary Reports list references directly related to that component.

Ref. # 1 TDI-3 3- 2-84 TDI Owners Group Program Plan 2 TDI-2 2-27-84 Investigation of Types AF and AE Piston Skirts 3 TDI-4 3-12-84 D.R. of Connecting Rod Bearing Shells 4 TDI-5 3-13-84 TDI D.G. Rocker Arm Capscrew Stress Analysis Report 5 TDI-6 3-23-84 TDI D.G. Air Start Valve Capscrew Dimensional and Stress Analysis Report 6 TDI-8 3-30-84 TDI D.G. Cylinder Head Stud Stress Analysis 7 TDI-14 4-13-84 TDI D.G. Supplement to the Cylinder Head Stud Stress Analysis and Supplement to the Air Start Valve Capscrew Dimension and Stress Analysis O 8 TDI-15 4-16-84 TDI D.G. Report on Engine Driven Jacket Water Pump Design Review 9 TDI-16 4-19-84 TDI D.G. Report on Push Rods 10 TDI-17 4-20-84 TDI D.G. Report on the Evaluation of Emergency D.G. Crankshafts at Shoreham 11 TDI-18 4-24-84 TDI D.G. Report on the Evaluation of Emergency D.G. Wiring and Terminations of Shoreham 12 TDI-19 4-24-84 TDI D.G. Supplement to the Rocker Arm Capscrew Stress Analysis 4-27-84 TDI D.G. Report on Fuel Injection Tubing 13 OGTP-8 Qualification Analysis ' 14 OGTP-9 5-14-84 TDI D.G. Report on D.R. of Connecting Rods of Inline DSR-48 Emergency D.G. 15 OGTP-10 4-27-84 TDI D.G. Report on D.R. of Engine Base and Bearing Caps 16 OGTP-25 5-14-84 TDI D.G. Cylinder Head Report PE3333 6-1 v- -. , - ~ . v - - - --e. - - -- - --- - - --- , --,-%---- .

Ref. #

   /G    17    OGTP-26   5-14-84 TDI D.G. Turbocharger Report O     18    OGTP-39   5-24-84 Evaluation of Emergency D.G. Crankshafts at Shoreham and Grand Gulf Nuclear Power Station 19    OGTP-40   5-24-84 D.R. of Connecting Rods for TDI DSRV-4 Series Diesel Generators 20    OGTP-41   5-24-84 Investigation of Types AF & AE Piston Skirts 21    OGTP-57   6-05-84 Emergency D.G. Aux. Module Control Wiring and Termination Qualification Report for G.G.N.S.

22 OGTP-70 6-13-84 Emergency D.G. Aux. Module Control Wiring and Termination Qualification Report for C.P.S.E.S. 23 OGTP-72 6-14-84 The Infulence of Thermal Distortion on the Performance of AF and AE Piston Skirts 24 OGTP-74 6-15-84 EDG Aux. Module Control Wiring and Termination Qualification Report for Shearon Harris Nucleai Power Station Unit I 25 OGTP-76 6-15-84 Evaluation of E.D.G. Crankshafts at Midland and Shearon Harris Nuclear Generating Stations v 26

OGTP-77 6-15-84 DR of Elliott Model 656 Turbocharger used on TDI DSRV-12-4 and DSRV-20-4 EDG sets 27 OGTP-79 6-18-84 DR of Connecting Rods of TDI Inline DSR-48 EDG 28 OGTP-80 6-18-84 DR of Engine Base and Bearing Caps for TDI DSRV-16 Diesel Engines 29 OGTP-90 6-25-84 DR cf TDI R-4 and RV-4 series EDG Cylinder Blocks and Liners 30 OGTP-89 6-22-84 DR of Connecting Rod Bearing Shells for Transamerica Delavel Enterprise Engines 31 OGTP-111 7-6-84 Supplement to the Emergency Diesel Generator Engine Driven Jacket Water Pump Design Review ! 32 OGTP-129 7-24-84 Emergency D.G. Rocker Arm Capscrews Stress Analysis 33 OGTP-140 7-27-84 Report on Emergency D.G. Auxiliary Control Module Control Wiring & Termination Review 34 OGTP-147 8-1-84 Design Review of Elliott Model 65G Turbocharger

V p '

used on TDI DSP.V-12-4 & DSRV-20-4 Emergency D.G. Sets PE3333 6-2 l

Ref. # OGTP-181 8-10-84 O 35 _ Design Review of Engine Base and Bearing Caps

                                                . for TDI DSRV-16 Diesel Engines 36       OGTP-190 8-14-84     Design Review of Elliott Model 90G Turbo-l                                                    charger used on TDI DSR-48 and DSRV-16 Emergency Diesel Generator Sets 37       OGTP-260 9-7-84      Design Review of Connecting Rods for TDI DSRV-4 Series Diesel Generators 38       OGTP-261 9-7-84      Design Review of Engine Base and Bearing Caps for TDI Diesel Engines 39       OGTP-263 9-7-84      Evaluation of Cylinder Heads of TDI Series R-4 Diesel Engines 40       OGTP-306 9-28-84     Survey of Start 5xperiences and Cause of

Unscheduled Shutdowns of TOI Diesel Engines 41 OGTP-403 10-17-84 Baseline Vibration Survey for Shoreham Nuclear Power Station DG 101 i

42 OGTP-485 11-6-84 Design Review of Connecting Rod Bearing Shells

- for TDI Engines, March 12, .384 l O 43 OGTP-591 11-27-84 Phase I Report - Turbocharger - Nozzle Ring Supplement for DSR-48 and DSRV-16-4 Engines i 44 OGTP-593 11-27-84 Investigation of Types AN and AH Piston Skirts b

f b 1 i !0!

 !                 PE3333                                      6-3

O TDI DIESEL GENERATOR DESIGN REVIEW ! AND ' i QUALITY REVALIDATION i e REPORT PHPP D.uuc.. iu cum R L i CONTEG' # ; uswa f _ O propor a ,or au 2=a=a-l l THE CLEVELAND ELECTRIC ILLUMINATING COMPANY l l PERRY NUCLEAR POWER PLANT j 1 l By

             ,.                                                TDI DIESEL GENERATOR OWNERS GROUP VOLUME 2 i
                             --,,,-,-,...,---_,,n.                 ~~,-.-._,.w~__,,,,,_,-..,_.,_~n-

4 d

How To Use This Report Tabs in this report identify the following categories:

                 -Turbo, Intake, Intercooler & Exhaust Lube 011.

Engine Base & Bearing Caps L Crankshaft & Bearings t Cylinder Block, Liners & Water Manifold Air Start & Barring Device Connecting rods Pistons , Camshaft & Valve Train , Idler Gear Assembly & Front Gear Case i. Flywheel Engine Instrumentation & Wiring Overspeed Trip & Governor Engine Shutdown & Equipment

                 ' Jacket Water Cylinder Heads & Valves Fuel Oil Injection Generator d         Control Panel Assembly

!- Engine & Auxiliary Sub-Base & Foundation Bolts p i These categories have been defined to allow the reader to review a complete. diesel generator subsystem in a convenient manner. > l . Within each category tabs identify Perry specific component numbers.

t. A given component report can be found by:

l l a) If the component number is known use the alpha - numberic index-l which identifies the volume number and category in which the compon-ent report is located. b) If only the component name is known - Section 3.2 may be used as a cross-reference to find the volume number where the component report may be found. Some reports address more than one component. a tab is provided for each component. However,' some components are combined under one report. Slip - sheets are provided where required to reference back _to the appropriate tab. .

i. Some components required more than one report. These are identified by the E

abbreviation LB-Large Bore and SB-Small Bore on ' the component number tabs. f O l-i I 53375

l l

            ,                            INDEX (continued) s Component  Component                       DR      QR                     Volume Number      Description                  Reg'd    Reg'd Category             No.

F-068 Intercooler X X Turbo, Intake 2 Intrcir. & Exhaust MP022/23 Turbocharger X X Turbo, Intake, 2 Intrcir. & Exhaust 00-420 Lube Oil Pressure X X Lube Oil 2 Regulating Valve 00-442A Starting Air Distributor: X X Air Start & 3 Distributor Assembly Barring Device 00-4428 Starting Air Distributor: X X Air Start & 3 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drip Tank X X Fuel Oil 4 Assembly Injection 02-CFR Turbocharger Thrust Bearing X X Turbo, Intake, 2 Lubricant System Intrc1r. & Ex-haust 02-305A Base and Bearing Caps: Base X X Engine Base 2 Assembly & Bearing Caps 02-305C Base and Bearing Caps: X X Engine Base 2 Main Bearing Studs & Nuts & Bearing Caps 02-305D -Base and Bearing Caps: X X Engine Base 2 Main Bearing Caps & Bearing Caps 02-307A Lube Oil Fittings: X X Lube Oil 2 Internal - Headers 02-3078 Lube Oil Fittings: X X Lube Oil 2 Internal - Tube & Fittings 02-307D~ Lube Oil Fittings Internal: X X Lube Oil 2 Supports 02-310A Cranksh, aft X X Crankshaft & 2 Bearings 02-310B Main Bearings X X Crankshaft & 2 Bearing , 11 PE337S

INDEX (continued) Component Component DR QR Volume Number Description" Reg'd Reg'd Category No. 02-310C Crankshaft & Bearings: X X Crankshaft & 2 Thrust Bearing Rings. Bearing 02-311A Crankcase: Crankcase Assy X X Crankshaft & 2 Bearing 02-311D Crankcase: Crankcase X X Crankshaft & 2 Mounting Hardware Bearings 02-315A Cylinder Block X X Cyl. Block & 2 Liners & Water Manifold 02-315C Cylinder Block Liners & X X Cyl. Block & 2 Water Manifold - Liners & Cylinder Liner Water Manifold 02-315D Cylinder Block Liners & X X Cyl. Block & 2 Jacket Water Manifold Liners & 3 & Piping Water Manifold 2-315E Cylinder Block Liners & X X Cyl. Block & 2 Water Manifold: Studs Liners & Water Manifold 02-315F Cylinder Block Liners X X Cyl. Block & 2

                 & Water Manifold:                                                           Liner & Water Cylinder Head Nuts                                                          Manifold j      02-315G    Cylinder Block Liners &           X        X                                Cyl. Block &     2

!' Water Manifold: Seals & Liners & j Gaskets Water Manifold l 02-316A Jacket Water Inlet Manifold: X X Jacket Water 4 Manifold Assembly W/ Hardware and Coupling and Gaskets l 02-316B Jacket Water Inlet Manifold: X X Jacket Water 4 Coupling and Gaskets 02-316C Jacket Water Inlet Manifold: X X Jacket Water 4 l Vent line to Discharge L Manifold ! Water Discharge Manifold: X X Jacket Water 4

   /)02-317A     Jacket Water Discharge i   V             Manifold / Piping I                                                111 L

PE3375

F nv

Component Component INDEX (continued)

DR Volume QR Number Description Reo'd Reg'd Category No. 02-317B Water Dicharge Manifold: X X Jacket Water 4

 ,                   Coupling & Seals 02-317C    Water Discharge Manifold:         X       X   Jacket Water      4 Supports 02-330A     Flywheel                         X           Flywheel          3 02-330B     Flywheel - Bolting               X      X    Flywheel          3 02-335B      Front Gearcase - Gaskets         X      X    Idler Gear As-    3 and Bolting                                  sembly & Front Gear Case

, 02-340A Connecting Rods: Connecting X X Connecting 3

 ;.                  Rods & Bushings                              Rods

, 02-340B Connecting Rod Bearing X X Connecting 3 Shells Rods

- 02-341A Pistons X X Pistons 3 02-341B Pistons: Rings X X Pistons 3 02-341C Piston Pin Assembly X X Pistons 3

       '02-345A     Tappets and Guides: Intake       X       X    Camshaft &        3
                    & Exhaust Tappet Assembly                     Valve Train 02-345B     Tappets and Guides: Fuel         X       X    Camshaft &        3 Tappet Assembly                               Valve Train j        02-345C    . Tappets and Guides: Fuel        X       X    Camshaft &        3 Pump Base Assembly                            Valve Train 02-350A     Camshaft:    Camshaft            X       X    Camshaft &        3 Assembly                                      Valve Train 02-350B     Camshaft:    Camshaft            X            Camshaft &        3 Bearing                                       Valve Train 02-350C     Camshaft: . Supports, Bolting    X       X    Camshaft &        3 and Gear                                      Valve Train l        02-355A     Idler Gear. Assembly Crank       X       X    Idler Gear As-    3

l. A To Pump Gear sembly & Front i b Gear Case

,1 IV l l PE3375

   ,O                                   INDEX (continued)
   \j                                     _

Component Component DR QR Volume Number Description Req'd Reg'd Category No. 02-355B Idler Gear Assembly: X X Idler Gear As- 3 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valve X X Air Start & 3 Barring Device 02-360A Cylinder Heads X X Cylinder Heads 4

                                                                & Valves 02-3608    Cylinder Head Valves:           X       X    Cylinder Heads    4 Intake & Exhaust Valves                     & Valves 02-360C    Cylinder Head and Valves:       X       X    Cylinder Heads    4 Bolting and Gaskets                          & Valves 02-3600    Cylinder Head                  X        X    Cylinder Heads    4
                   & Valves: Springs                            & Valves 02-362A    Subcover-                      X        X    Camshaft &        3 Valve Train 02-365A    Fuel Injection Pump            X             Fuel Oil In-      4 jection 02-365B    Fuel Injection Equipment -     X             Fuel Oil In-      4 Fuel Injection Tips                          jection l        02-365C    Fuel Injection Equipment -     X        X    Fuel Oil In-     4 Tube Assembly                                jection 02-3650    Fuel Injection Equipment:      X        X    Fuel Oil In-     4 Supports                                     jection 02-371A    Fuel Pump Linkage: Fuel        X        X    Fuel Oil In-     4

. Pump Control Shaft jection l 02-3718 Fuel Pump Linkage: Linkage X X Fuel Oil In- 4 Assembly and Bearing jection 02-375 Intake Manifold and X X Turbo, Intake, 2 Piping Intrcir. & Ex-haust 02-380A Exhaust Manifold X X Turbo, Intake, 2 O ! , Intrcir. & Ex-d haust v l PE3375

r-INDEX (continued) Component Component DR QR Volume Number Description Rea'd Reg'd Category No. 02-3808 Exhaust Manifold: Gasket X X Turbo, Intake, 2 and Bolting Intrcir. & Ex-haust 02-385B Cylinder Block Covers: X X Cyl. Block & 2 Gaskets and Bolting Liners & Water Manifold 02-3868- Crankcase: Crankcase X X Crankshaft & 2 Gaskets and Mounting Bearings Hardware l 02-390A Intake & Intermediate and X X Camshaft & 3 Exhau=t Rocker Shaft Assembly Valve Train 02-3908 Rocker Arms and Pushrods: X X Camshaft & 3 Exhaust Rocker Shaft Valve Train Assembly 02-390C Main and Connector X X Camshaft & 3 Pushrods Valve Train 02-390D Rocker Arms and Pushrods: X X Camshaft & 3 Pushrods Connector. Valve Train 02-390E Rocker Arms and Pushrods: X Camshaft & 3 Bushings Valve Train 02-390F Rocker Arms and Pushrods: X X Camshaf+ *a 3 Lifters Valve Train 02-390G Rocker Arms and Pushrods: X X Camshaft & 3 Misc. Bolts & Drive Studs Valve Train 02-410A Overspeed Trip Governor X X Overspeed Trip 3 1

                                                             & Governor-02-410B   Overspeed Trip: Governor      X        X    Overspeed Trip  3 and Accessory Drive Assembly                & Governor 02-410C   Overspeed Trip: Coupling      X        X    Overspeed Trip  3
                                                             & Governor 02-4100   Overspeed Trip Vent Valve     X        X    Overspeed Trip  3
                                                             & Governor vi PE3375

_( 7 INDEX (continued) O Component Component DR QR Volume Number Description Req'd Reg'd Category No. 02-411A ' Governor Drive: Governor & X X Overspeed Trip 3 , Tachometer Drive Gear and & Governor Shaft 02-411B Governor Drive: Couplings, X X Overspeed Trip 3 Pins & Keys & Governor 02-413A Governor Linkage X X Overspeed Trip 3

                                                                   & Governor 02-413B      Fuel Pump Linkage:             X            Fuel Oil Injection   4 Automatic Shutdown                                 -

Cylinder 02-415A Governor Assembly: Woodward X X Overspeed Trip 3 Governor & Governor 02-415B Governor Assembly - X Overspeed Trip 3 Booster Servomotor & Governor 02-415C Governor Assembly - . O' Heat Exchanger X X Overspeed Trip

                                                                   & Governor 3

02-420 Engine Driven X X Lube Oil 2 Lube Oil Pump 02-425A Engine Driven X X Jacket Water 4 Jacket Water Pump 02-435A Jacket Water Fittings: X X Jacket Water 4 Pipe & Fittings 02-435B Jacket Water Fittings - X X Jacket Water 4 Supports 02-435C Jacket Water Inlet X X Jacket Water 4 Fittings - Valves 02-436A Intercooler_ Piping X X Turbo, Intake 2 Intercooler

        ,                                                          & Exhaust 02-4368      Intercooler Piping            X        X    Turbo, Intake        2 Coupling, Gaskets,                          Intercooler &

Bolting Exhaust bs_ / vii PE3375

e INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-437 Turbo Water Piping: X X Jacket Water 4

                    ' Pipe & Fittings 02-441A    Starting Air Manifold:           X        X   Air Start &      3 Piping, Tubing an:1 Fitting                  Barring Device
         *02-441B    Starting Air Manifold            X        X   Air Start &      3 Valves, Filters & Strainer                    Barring Device 02-441C    Starting Air Manifold:           X        X   Air Start &      3 Supports                                      Barring Device 02-445     Fuel Oil Booster Pump            X        X   Fuel Oil In-     4 jection 02-450A    Fuel Oil Header:                X         X   Fuel Oil In-     4 Piping / Tubing                               jection 02-450B    Fuel Oil Header:    Fuel        X         X   Fuel Oil In-     4 Oil Supports                                  jection 02-455A    Fuel Oil Filters &              X             Fuel Oil In-     4 Strainers: Filters                            jection 02-455B    Fuel Oil Filters &              X             Fuel Oil In-     4 Strainers:    Strainers                       jection 02-455C    Fuel Oil Filters &              X         X   Fuel Oil In-     4 Strainer: Mounting Hardware                   jection l

l 02-465A Lube Oil Lines External: X X Lube Oil 2 i Tubing, Fittings, Couplings 02-465B Lube Oil Lines - External X X Lube Oil 2 Valves 02-465C Lube Oil Lines X X Lube Oil 2 External Supports 02-467A Turbocharger: Lube Oil X X Lube Oil 2 Fitting - Pipe, Tubing, Fittings & Flexible Coupling ! 02-4678 Turbocharger: Lube Oil X X Lube Oil 2 l Fittings - Supports O m viii PE3375 l a.

INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reo'd Category No. 02-475A Turbocharger: Bracket X X- Turbo, Intake, 2 Bolting and Gaskets Intrcir. & Ex-haust 02-4758 Air Butterfly Valve X X Turbo, Intake, 2 Assembly Intrcir. & Ex-haust 02-475C Turbocharger: Bracket - X X Turbo, Intake, 2 Bolting & Gaskets Intrcir. & Ex-l haust 02-500A Control Panel Assembly X X Control Panel 4

1. Cabinet / System Assembly i

02-500F Control Panel Assembly X X Control Panel 4 Accumulator Assembly

i. 02-500G Control Panel X X Control Panel 4 Valves Assembly 02-500H Control Panel Assembly X X Control Panel 4'

, Pressure Switch Assembly l 02-500I Control Panel Assembly: X X Control Panel 4 L Control Relays Assembly 02-500J Control Panel Assembly: X X Control Panel 4 Solenoid Valves Assembly 02-500L Control Panel Assembly - X Control Panel 4 Piping, Tubing, Fittings Assembly 02-500M Control Panel Assembly: X Control Panel 4 Terminal Boards / Switches / Assembly Wiring 02-525B Barring Device - Pneumatic: X X Air Start & 3 Regulator Valve / Shut Off Barring Device Valve 02-525D Barring Device - Pneumatic: X Air Start & 3

l. Mounting Bracket / Supports Barring Device 02-540A Lube Oil Sump X Lube Oil 2 O with Strainer Assembly and Mounting Hardware ix

j. PE3375

r-INDEX (continued) Component Component DR QR Volume Number Description Reo'd Reg'd Category No. 02-5408 Lube Oil Sump Tank: Misc. X X Lube Oil 2 Fittings, Gaskets, Pipe

                 & Bolting Material, Valves 02-540C   - Lube Oil Sump Tank:            X        X               Lube Oil         2 Mounting Hardware 02-550     Foundation Bolts:               X        X               Engine & Aux. 4 Anchors, Bolts, Misc.                                    Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly: X X Engine Instru- 3 Conduit mentation & Wiring 02-630B Pyrometer Conduit Assembly: X X Engine Instru- 3 Conduit Fittings mentation & Wiring

  )   02-630C    Pyrometer Conduit Assembly:    X        X                Engine Instru-   3 Support                                                  mentation &

Wiring 02-6300 Pyrometer Conduit Assembly X Engine Instu- 3 Thermocouple mentation & Wiring 02-650A Emergency Diesel Generator X X Generator 4 02-650B Generator X X Generator .4 Control 02-650C Generator-Shaft & Bearing X X Generator 4 02-688A Engine & Aux Module X X- Engine Instru- 3 Wiring Material- Conduit mentation &

                & Fittings; Pyrometer                                     Wiring Assembly - Conduit, Fitting, Supports 02-6888    Engine & Aux.                  X        X                Engine Instru-   3 Module Wiring Material:                                   mentation &

Wiring & Terminations Wiring O x PE3375

(} INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-688C Engine & Aux. Module Wiring X Engine Instu- 3 Material: Boxes & Terminals mentation & Wiring 02-689 Off-Engine Alarm Sensors X X Engine Instru- 3 mentation & Wiring 02-690 Engine Alarm Sensors - X X Engine Instru- 3 Temperature & Level mentation & Switches Wiring 02-691 Off Engine Safety Alarm X X Engine Instru- 3 Sensors - Level & mentation & Pressure Switches Wiring 02-695A Engine Shutdown X X Engine Shut- 3 Equipment: down & Equip-Tubing / Fittings & ment Supports

        02-6958    Engine Shutdown                 X      X    Engine Shut-      3 Equipment: Valves,                          down & Equip-Regulator, Orifices                         ment 02-695C    Engine Shutdown Trip            X      X    Engine Shut-      3 Switches                                    down & Fquip-ment 02-700A    Jacket Water Standpipe:         X      X    Jacket Water      4 i                     Pipe, Fittings, Gaskets l          02-700B    Jacket Water Standpipe:         X      X    Jacket Water      4 i                     Valves 02-700C    Jacket Water Standpipe:         X      X    Jacket Water     4 Pipe Supports l          02-700E    Jacket Water Standpipe:         X      X    Jacket Water     4 Switches l

j 02-700F Jacket Water Standpipe X X Jacket Water 4

                     & Misc. Bolting 02-717A    Auxiliary Skid                  X      X    Jacket Water     4 l      \

l'(\~) xi PE3375

INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-717B Aux Sub Base & Oil & X X Jacket Water 4 Water Piping - Jacket Water: Valves 02-717C Aux Sub Base & Oil & Water X X Engine & Aux. 4 Water Piping - Jacket Sub Base & Water: Pipe, Couplings, Foundation Bolts Fittings, Orifices, Y-Strainers 02-7170 Aux Sub Base & 011 & Water X Jacket Water 4 Piping - Jacket Water: Gaskets & Bolting 02-717E Aux Sub Base & Oil & Water X X Jacket Water 4 Pipi:1g - Jacket Water: Supports 02-717F Aux. Sub Base & Oil & Water X X Lube Oil 2 Piping - Lube Oil: Pipe and p Fittings 02-717G Aux Sub Base & Oil & Water X X Lube Oil 2 Piping - Lube Oil: Valves 02-717H Aux. Sub-Base & 011 & Water X X Lube Oil 2 Piping - Lube Oil: Gaskets & Bolting 02-717I Aux Sub Base & 011 & Water X X Lube Oil 2 Piping - Lube 011: Supports & Mounting Hardware 02-717J Aux Sub Base & Oil & Water X X Fuel Oil 2 Piping - Fuel Oil - Piping

             & Fittings 02-717K   Aux Sub Base & 011 & Water    X        X    Fuel Oil          4 Piping - Fuel 011: Valves                   Injection 02-717L   Aux Sub Base & 011 & Water    X        X    Fuel Oil          4 Piping - Fuel Oil -                         Injection Gaskets & Bolting o

xii PE3375

N l INDEX (continued) Component Component DR QR Volume Number Description Reo'd Reg'd Category No. 02-717M Aux Sub Base & Oil & Water X X Fuel Oil 4 Piping - Fuel Oil: Injection Supports 02-805A Intake Air Silencer X Turbo, Intake, 2 Intercooler & Exhaust 02-805B Intake Air Filter X X Turbo, Intake, 2 Intercooler & Exhaust 02-805D Flex Connections X X Turbo, Intake, 2 Intercooler & Exhaust 02-810A Jacket Water Standby X Jacket Water 4 Heater Pump f-~s 02-810B Jacket Water Heat Exchanger X X Jacket Water 4

    '-    02-810C    Thermostatic Valve             X       X      Jacket Water     4 02-8100    Misc. Equipment - Heater,              X      Jacket Water     4 Jacket Water 1

02-820A Misc. Equipment - Heater, X Lube Oil 2 Lube Oil Sump Tank , 02-820B Before & After Lube Oil X X Lube Oil 2 Pump l 02-820C Lube Oil Full Pressure X X Lube Oil 2 i Strainer l

l. 02-820D Lube Oil System - Lube Oil X X Lube Oil 2 l Keepwarm Strainer 1

02-820E 011 Prelube Filter X X Lube Oil 2 02-820F Full Flow Lube Oil Filter X X Lube Oil 2 02-820G Lube Oil Heat Exchanger X X Lube Oil 2 l l 02-825A Fuel Oil Day Tank X X Fuel Oil 4 I I~' ' Injection ! (_ /N i

xiii l

< PE3375 L

l INDEX (continued)

     . Component Component                        DR     QR                 Volume Number     Description                  Reg'd    Reg'd Category         No.

02-8250 Fuel Oil. System - Fuel X Fuel Oil 4 Oil Duplex Strainer Injection 02-8358 Starting Air Tank X X Air Start & 3 Barring Device 02-835E Misc. Equipment - Starting X X Air Start & 3 Air Tank Relief Valve Barring Device O i

l. .

l l \ I' l i l O xiv PE3375 l

    ,                                                                           Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Intercooler                      UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. F-068                 TASK DESCRIPTION NO: DR-03-F-068-0 SNPS GPL NO. F-068                         CLASSIFICATION TYPE               B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry experience, except that 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 prevent intercooler problems such as these, and it is recommended that this SIM be implemented at Perry.

C

A review of the lead engine DR/QR report (Comanche Peak).
Both Perry and Comanche Peak intercoolers were manufactured by Young Radiator and are Model No. 0264836.

There are no modification recommendations from the lead engine DR/QR reports. l The following maintenance recommendations from the lead engine DR/QR report should be implemented: 4

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 on the intake air system low point should be

. verified open and cleaned daily. Quality revalidation is not deemed necessary for this component. O PE3251/1

( COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-F-068-0 , k PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required ACCEPTANCE CRITERIA Not required REFERENCES Not required GROUP CHAIRPERSON - PROGRAM MANAGER SC \4A% 1 O VV' l 1 , 1 i O PE3251/2

     . - -  . - - - . _ . - - . - - - . = - - - - - - - - - - - - - - -.                          - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Page 1 of 3 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Turbocharger UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. MP-022/23 TASK DESCRIPTION NO: DR-03-MP-022/23-0 SNPS GPL NO. MP-017 CLASSIFICATION TYPE A TASK DESCRIPTIONS A design review for this component is not required, based on the following:

Design reviews for the lead engines, Shoreham and Comanche Peak, as well as Grand Gulf and Catawba, establish the acceptability of the Elliott Model BCO-90G turbocharger. This model turbocharger is used on all Owners Group DSRV-16 and DSR-48 diesel engines.
The turbocharger operating conditions at Perry are approximately equal to those at Comanche Peak and other Owners Group OSRV-16 and DSR-48 diesel engines with full load ratings of 225 BMEP.
These engines use the before and after lube oil pump and piping

 \            modifications to provide sufficient oil to the turbocharger prior to startup. The   effectiveness of this raodification on reducing turbocharger thrust bearing wear has been demonstrated at Shoreham.

The EDG Component Tracking System was reviewed for any applicable experience. The primary adverse experience associated with the turbocharger was rapid thrust bearing wear and broken nozzle ring capscrews and vanes. The thrust bearing wear was attributed to insufficient lubrication prior to engine start. Nozzle ring vane failures were due to high cycle fatigue arising either from diesel engine exhaust gas pulsations or vibration during operation. The capscrews failed by means of intergranular cracking as the result of improper heat treatment during manufacturing, or in another case, due to high cycle fatigue, probably from improper torquing during assembly. Vane failures have not affected engine operability in the past and capscrew failures are rare events and' are not expected to recur provided that the installation torque is to specification and that manufacturing defects are not present. Thus, the current nozzle ring and attachment design is adequate for nuclear standby service. The drip lubrication system was modified to allow full oil flow to the turbocharger bearings prior to engine starts. The modification consists of a manually operated valve that allows the drip system orifice to be by passed. This greatly increases the amount of oil supplied to the turbocharger by the before and after pump, and should significantly reduce bearing wear. PE3061/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 3 TASK DESCRIPTIONS (continued) The following Quality inspections, as outlined by the site CQRC, should be performed on both station engines to verify proper turbocharger operating condition:

Perform a visual inspection on the bearings for signs of scoring or pitting.

Determine the end clearances (Rotor Float).

Verify that the proper number of bolts on the turbine inlet casing

are installed.

I

Verify that the proper torque loads are applied to the bolts of the turbine inlet casing.

4

Perform a liquid penetrant test on the stationary nozzle ring for I signs of adverse wear and cracking.

i e Verify that SIM 300 was implemented and perform a liquid penetrant test on the welds retaining the core plug (hub nut). In addition, verify that the core plug is staked. i The following modifications and inspections . were recommended in the lead

. engine DR/QR reports and apply to the turbochargers at Perry as well. These modifications / inspections will help ensure turbocharger reliability and

. performance:

Revise appropriate operating procedures to use the bypass valve to

! prelube the turbocharger bearings. The valve should be opened 1 to ' 2 minutes prior to engine start and closed approximately 30 seconds after the engine reaches full speed.

The TDI recommended drip system should be retained for minimizing L thrust bearing wear associated with automatic fast starts. The

. quantity of oil passing through the turbocharger should be measured and be at least 0.1 gph. Increased flow rates up to 0.35 gph are

recommended to improve effectiveness of the drip system.

l

For improved confidence in the reliability of the turbocharger, i inspection of a thrust bearing for signs of excessive wear should be performed to verify the adequacy of the full flow prelube system.

! This inspection should be performed on a thrust bearing installed during or after implementation of the full flow prelube system and following an initial 100 engine starts or at the closest plant refueling outage but not to exceed 130 starts.

The rotor axial clearance should be routinely checked in accordance with the TDI Instruction Manual. In addition, since trends of O increasing clearance could signify thrust bearing degradation (even if the total displacement is .within specification), any such trends should be reviewed.

PE3061/2 i

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

COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 DR-03-MP-022/23-0 0\ TASK DESCRIPTIONS (continued)

Since the nuclear standby diesel gen'erator sets may undergo non prelubed automatic fast starts not associated with a potential LOOP /LOCA event, the turbocharger thrust bearing of any Perry engine should be inspected for excessive wear and, if necessary, replaced after experiencing no more than 40 such starts. This recommendation is applicable to all thrust bearings installed.
Spectrochemical engine oil analysis should be incorporated into the TDI Instruction Manual. In addition, to further expand the preven-tive monitoring of the turbocharger thrust bearing, ferrographic engine oil analysis may be utilized. Particular attention should be paid to copper level and particulate size, which could signify thrust bearing degradation.
At any turbocharger disassembly there should be a visual inspection of nozzle ring components for any apparent damage, failure or apparent mispositioning of vanes. Replace all affected nozzle ring components. During reassembly ensure that capscrews are properly installed with recommended pretorque.
Monitor engine operation to ensure exhaust gas temperatures do not exceed those specified.

O U PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required , ACCEPTANCE CRITERIA Not required REFERENCES Not required GROUP CHAIRMAN s - PROGRAM MANAGER d Wew w w w A (j Y a o O I PE3061/3 i L

O TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 TURBOCHARGER THRUST BEARING DRIP LUBE SYSTEM (SMALL BORE SCOPE ONLY) COMPONENT PART NO. 02-CFR I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of

             -the structural adequacy of the turbocharger thrust bearing drip lube system components and supports to withstand the effects of normal operating and earthquake loadings.      The primary function of this tubing is to provide lube oil to the turbocharger thrust bearing prior to engine startup.

II OBJECTIVE The objective of this review was to perform an engineering evaluation of the tubing and supports to assure that the component will perform its

   ;O         intended design function during normal operating and earthquake loadings.

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

The TDI Emergency Diesel Generator Component Tracking System was reviewed for the Perry site, nuclear, and non-nuclear industry experience. See Appendix C for results.

'

The Quality Revalidation Checklist results were reviewed for acceptability.

( Refer to the review procedures as described in Reference 1 for a detailed I methodology of this evaluation. IV , RESULTS AND CONCLUSIONS i The tubing and supports, as defined by this Component Design Review I have been evaluated in accordance with Reference 1 and have been found l acceptable with modification. l There are no TERs' associated with this component. I 1 O PE3202/1 L

Page 2 of 3 The Quality Revalidation Inspection results identified in Appendix B have been reviewed and considered in the performance of this design review, and the results are consistent with'the final conclusion of this report. Based on the above review, it is concluded from Reference 2 that the tubing and supports will perform their intended design function at Perry under all normal operating and earthquake loadings with the provision that the following recommended modifications, as detailed in Reference 3, be implemented: Engines 1A and IB Drip Lube Supply Tubing Two directional restraints should be added to the risers at the 90 degree fittings near the sight glass, typical at both turbochargers.

The routing of the tubing from the left side sight glass to the -

cross fitting should include lateral offsets. Offsets similar to the right side or 90 degrees and are acceptable to allow for thermal expansion and equipment movements.

The one-bolt tubing clips should be replaced using two-bolt straps to prevent lateral slippage throughout the system.

Engine 1B Tubing to Pressure Switches left Bank Turbocharger A two-directional restraint should be added between the cross connection and the first restraint at approximately mid-span. A two-directional restraint should be added in the horizontal run perpendicular to the crank shaft approximately 18 inches from the bulkhead under the left bank turbo. Right Bank Turbocharger A two-directional restraint should be added in the horizontal run adjacent to the riser from the cross connection. Engine 1A Tubing to Pressure Switches Left Bank Turbocharger

A two-directional restraint should be added approximately mid-span between the cross connection and the pressure switch.

PE3202/2

e-i l Page 3 of 3 Right Bank Turbocharger

Two-directional restraints should be added.at 3 feet - 0 inch maximum span. intervals between the cross connection and the pressure switch.

V. REFERENCES

1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," Report No. 11600.60-DC-02, Revision 0.

2. Stone & Webster Calculation number 11600.60-NP(B)-0301-XH.

3. Memo 6548 from C. Malovrh (SWEC) to J. Kammeyer (SWEC) dated 11/29/84.

4 O l i~ s ! PE3202/3

APPENDIX A Page Al of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Turbocharger Thrust COMPONENT Bearing Lubricant System UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-CFR TASK DESCRIPTION NO.: DR-03-02-CFR-0 SNPS GPL NO. 03-CFR CLASSIFICATION TYPE B TASK DESC'tIPTIONS Perform an engineering review of the tubing and supports to provide additional assurances that the component will perform its intended design function during normal operating and earthquake loading. PRIMARY FUNCTION To- provide lube oil to the turbocharger thrust bearing prior to engine startup. ATTRIBUTES TO BE VERIFIED Structural adequacy of the tubing and ~ supports due to the effects of normal operating and earthquake loadings. SPECIFIED STANDARDS IEEE 387 REFERENCES

     " Engineering Review Criteria Report for the Design Review of TDI Diesel Small

, Bore Piping, Tubing, and Supports for the TDI Owners' Group" Report No. 11600.60-DC-02, Revision 0.

O PE3024/1

COMPONENT DESIGN REVIEW CHECKLIST Page A2 of 2 DR-03-02-CFR-0 DOCUMENTATION REQUIRED Delaval design documentation (specifications, calculations, drawings, etc.). In lieu of information from Delaval, the following information is required: verified support sketches and piping isometrics, material specifications, pipe size and schedule, and operating parameters (pressure, temperature, load combinations) GROUP CHAIRPERSON PROGRAM MANAGER \<uwww L/V u O 1 l 1 I O PE3024/2

Appendix B Page B1 of 3 f_ b} COMPONENT QUALITY REVALIDATION CHECKLIST 03-02-CFR Turbochargar Thrust Cleveland Electric Illuminating Co. COMPONENT Bearing Lubricant System UTILITY Perry Nuclear Station - Unit 1 GPL NO. 02-CFR REV. NO. 1 SNPS GPL NO. 03-CFR TASK DESCRIPTIONS Enaine 1A

1. Assemble and review existing documentation.

2. Obtain sufficient data to support the design review effort. This may be accomplished by developing quality verified as-builts in accor-dance with Procedure DG-7, or by the Design Group performing a field walkdown.

Engine IB Same as Engine 1A ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package

2. Information necessary for the design review effort Engine 18 Same as Engine 1A ACCEPTANCE CRITERIA Engine 1A

1. Satisfactory Document Package

2. Review of detailed information by the Design Group PE3213/1

c COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 3 p 03-02-CFR v ACCEPTANCE CRITERIA (continued) Engine 18 Same as Engine 1A REFERENCES Engine 1A

1. QCI No. 52

2. Procedure DG-7 Engine 1B Same as Engine 1A DOCUMENTATION REfiUIRED Engine 1A v

1. Document Summary Sheet

2. Quality verified as-built isometric drawing for the lubricant system if available from the Owner.

Enaine IB Same as Engine 1A / GROUP CHAIRPERSON J PROGRAM MANAGER M W w w g . 4

                                           %h                                       J COMPONENT REVIEW Engine 1A

1. No EDGCTS site experience documents are in evidence.

O PE3213/2

   ;g v;

COMPONENT QUALITY REVALIDATION CHECKLIST Page 83 of 3 03-02-CFR COMPONENT REVIEW (continued)

2. The Design Group will be responsible for closing out the as-built drawings as per Procedure DG-7. The as-built drawings will be Quality verified by the appropriate site Quality organization. The performance of an engineering walkdown by the Design Group, precludes the issuance of a quality verified as-built drawing or sketch.

Engine 1B Same as Engine 1A RESULTS AND CONCLUSION Engine IA The R.:ality Revalidation effort with respect to this component, as out-lined above, is complete. The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of the final report. Engine 1B Same as Engine 1A GROUP CHAIRPERSON [M - - h0N PROGRAM MANAGER M u w % g l PE3213/3 m

                              -,.--,c-..-,,-+.-
                                                  - - - - - - ,,,--,-- ---.--- . ~ _,            -._,.-,,..-..-a        . . - - . - -     - , . . . . - .

Appendix C Page C1 of 4 EDG COMPONENT TRACKING SYSTEM: PERRY SITE, NUCLEAR AND NON-NUCLEAR INDUSTRY EXPERIENCE SUPNARY COMPONENT NO. 02-CFR Effective Printout Date: 11/05/84 COMPONENT TYPE: Turbocharger Thrust Bearino Lubricant System REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS PERRY None NUCLEAR Report concerning possible St. Lucie 1 Perry has installed the thrust bearing damage LER: 335-79021 lube oil drip system in under hot start conditions 790625 accordance with TDI's while lube oil is above recommendations. This 160*F. system allows the turbo-O charger thrust bearing to be lubricated during tb engine shutdown, thereby eliminating insufficient oil to the bearing during startup. See turbocharger Design Report. Potential problem with Pt. Beach 1 Perry has installed the turbo hearing lubrication / LER: 256-79007 lube oil drip system in i bearing smear if engines 790424 accordance with TDI's receive a repeat rapid recommendations. This start coincident with a system allows the turbo-loss of AC power. , charger thrust bearing to be lubricated during engine shutdown, thereby eliminating insufficient oil to the bearing during startup. See turbocharger Design Report. O LJ PE3202/1

Appendix C Page C2 of 4 A G EXPERIENCE REFERENCE DOCUMENTS PERRY STATUS GM notified VEPC0 of Surry 1 Perry has installed the potential thrust bearing LER: 280-79017 lube oil drip system in problems under certain 790502 accordance with TDI's repeat start operating recommendations. This modes. system allows the turbo-charger thrust bearing to ' be lubricated during engine shutdown, thereby eliminating insufficient oil to the bearing during startup. See turbocharger Design Report. During normal operation Monticello Perry has installed the the engine may reach LER: 263-79010 lube oil drip system in operating speed prior 790426 accordance with TDI's to oil pressure being recommendations. This established at thrust. system allows the turbo-charger thrust bearing to be lubricated during engine shutdown, thereby eliminating insufficient oil to the bearing during j startup. See turbocharger Design Report. Distress on the turbine Taiwan Power Perry has installed the end bearing thrust face So. Calif. Edison lube oil drip system in and shaft thrust face letter from E.S. accordance with TDI's because of dry start. Ncilhattan recommendations. This Require instant oil flow (Elliot Co.) to system allows the turbo- , at start signal. A. Fleischer (TDI) charger thrust bearing to 04/06/81 T-33 be lubricated during engine shutdown, thereby eliminating insufficient , oil to the bearing during startup. See turbocharger [ Design Report. l Thrust bearing totally Kuosheng 2 Perry has installed the

burned, possibly from TPC Nuc. Plant No.2 lube oil drip system in lack of lubricant prior 06/03/83 accordance with TDI's to engine start. File No. T-45 recommendations. This system allows the turbo-charger thrust bearing to be lubricated during engine shutdown, thereby i

eliminating insufficient l Q- oil to the bearing during

 'Q                                                 startup. See turbocharger Design Report.

PE3202/2 l

y. __

Appendix C_ Page C3 of 4 (V EXPERIENCE REFERENCE DOCUMENTS PERRY STATUS Turbocharger thrust Catawba Perry has installed the bearings experienced 04/05/84 lube oil drip system in excessive wear from File no. T-53 accordance with TDI's lack of prelube oil Pg. 7-2 recommendations. This during multiple fast system allows the turbo-starts of the diesel. charger thrust bearing to be lubricated during engine shutdown, thereby eliminating insufficient oil to the bearing during startup. See turbocharger Design Report. Lube oil is not supplied Grand Gulf Perry has installed the to the turbocharger thrust No. 83-024 lube oil drip system in bearing until lube oil 10/22/83 accordance with TDI's pump initiates upon recommendations. This upon engine start, system allows the turbo-charger thrust bearing to be lubricated during engine shutdown, thereby eliminating insufficient oil to the bearing during startup. See turbocharger Design Report. Fast repeat starts Kewaunee Perry has installed the of diesels may result LER 305-79024, lube oil drip system in in engine-reaching 790922 accordance with TDI's operating speed before I & E 79-12 recommendations. This required oil pressure is system allows the turbo-reached at turbocharger charger thrust bearing to hoist bearing. Cumulative be lubricated during damage from similar starts engine shutdown, thereby would result in turbocharger eliminating insufficient failure. oil to the bearing during startup. See turbocharger Design Report. Turbocharger thrust 10CFR 50.55E LILCO Perry has installed the bearings experienced Letter SNRC-549, lube oil drip system in excessive wear from 10CFR21 TDI Letter accordance with TDI's lack of prelube oil to 0.I.& E. recommendations. This during multiple fast system allows the turbo-starts of the diesel. charger thrust bearing to be lubricated during engine shutdown, thereby ' eliminating insufficient oil to the bearing during ( startup. See turbocharger Design Report. PE3202/3

Appendix C Page C4 of 4

REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS Potential problem with TDI letter to 0.I.&E. Perry has installed the lubrication thrust US NRC dated 12/16/80 lube oil drip system in bearings from accordance with TDI's lack of oil at startup. recommendations. This system allows the turbo-charger thrust bearing to be lubricated during engine shutdown, thereby eliminating insufficient oil to the bearing during startup. See turbocharger Design Report. Diesel tripped because of Zion 1 EPRI 121574 Perry has installed the low turbocharger oil lube oil drip system in pressure. accordance with TDI's recommendations. This

system allows the turbo-charger thrust bearing to be lubricated during

engine shutdown, thereby eliminating insufficient: oil to the bearing during

, ~ startup. See turbocharger Design Report. NON-NUCLEAR p None 0 l i l O PE3202/4 i t

    --w,*   .-.-,*,.,.<r-..-..-e.-

F Page 1 of 2 O Q- COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Intake Manifold and Piping

    . COMPONENT (Larae Bore Scope Only)      UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-375             TASK DESCRIPTION NO. DR-03-02-375-0 SNPS GPL NO. 03-375                    CLASSIFICATION TYPE                   B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak).
A comparison of the intake manifold and piping spool pieces and fittings and supports for Perry with Comanche Peak.

The following modification recommendations made on the lead engine DR/QR CI report should be implemented:

Ensure U-bolts on the crossover piping are properly installed.

The following maintenance recommendations are made to avoid cracking from misalignment:

Other castings may be tried in an attempt at a better fit.
Bolt hole diameter on the intake manifold elbows may be increased from 1/16-inch oversize to 1/8-inch oversize. However, under no circumstances shall any component be jacked to fit.

The following quality inspection should be- performed on all station engines:

Visually inspect all intake manifolds for cracks at both flange faces.
Upon reinsta11ation, ensure that the manifold installation does not cause excessive stress on flange bolt holes due to misalignment.

O PE3103/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES l Not required DOCUMENTATION REQUIRED Not required l GROUP CHAIRPERSON - PROGRAM MANAGER ACMt.mwh j[ U \ l O PE3103/2

Page 1 of 2 b COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Exhaust Manifold UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-380A TASK DESCRIPTION NO. DR-03-02-380A-0 SNPS GPL NO. 03-380A CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shorehag/ Comanche Peak).
A comparison of the exhaust manifold and piping spool pieces and fittings for Perry with Comanche Peak.

The diesel generators at Perry have not yet been operational, therefore no operating hours or temperatures can be projected. The following modification recommendations made on the lead engine DR/QR report should be implemented:

1. The second 6" slip joint from the No. 8 cylinder head, on both right and left banks is to be removed and replaced with 6" 150 lb. S.O. Flanges with A449 bolts.

2. The first 6" slip joint from the No. 2 cylinder head (second from the No.

7 cylinder head), on both the right and left banks, is to be removed and replaced with 6" - 150 lb. 50.0. Flanges with A449 bolts.

3. The first 6" slip joint from the No. 3 cylinder head (second from the No.

6 cylinder head), on both the right and left banks, is to be removed and replaced with 6" - 150 lb. S.0. Flanges with A449 bolts.

4. The first slip joint from the No. 4 cylinder head (second from the No. 5 cylinder head), on both the right and left banks, is to be removed and replaced with 6" - 150 lb. S.O. Flanges with A449 bolts.

5. In the event of an SSE, the capscrews, which hold the water jacket to the exhaust manifold assembly support, will require inspection at some time subsequent to the SSE event and replaced if the inspection warrants.

O

   -PE3104/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 OR-03-02-380A-0 TASK DESCRIPTIONS (continued) The following maintenance recommendation is required to be performed on the exhaust aanifold:

Perform a visual inspection and a magnetic particle test on a sample of the circumferential pipe . welds and corresponding heat affected zones. This is to be performed during the first refueling outage and alternate outages thereafter. However, diesel operation should not exceed 200 hours between inspections.

Quality Revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required , DOCUMENTATION REQUIRED l' Not required GROUP CHAIRPERSON PROGRAM MANAGER ,)C\<ch (jr - O PE3104/2

y COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Exhaust Manifold: COMPONENT Gasket & Boltina UTILITY Cleveland Electric Illuminatino Company GROUP. PARTS LIST NO. 02-380B TASK DESCRIPTION NO. DR-03-02-3808-0 SNPS GPL NO. 03-380B CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak) and the applicable industry experience. There is no site experience reported in the EDG Component Tracking System. There are no maintenance or modification recommendations for this component. The following Quality inspections should be performed on all station engines:

Verify that the proper torque was applied to the exhaust pipe flange capscrews; ,
Verify that the proper gasket material and bolting are installed at the manifold and flange connections;
Verify at reinstallation that no binding exists on the exhaust manifold and no cracks exist at the manifold flange fillets by a visual l

inspection. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O PE3064/1 1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 O . REFERENCES DR-03-02-3808-0 Not required DOCUMENTATION REQUIRED Not required

GROUP CHAIRPERSON - PROGRAM MANAGER d C W e u V U O ri PE3064/2 L _ -

[T - COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Intercooler Piping - Pipe COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-436A&B TASK DESCRIPTION NO. DR-03-02-436A&B-0 SNPS GPL NO. 99-436A&B CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak).
A comparison of the intercooler piping spool pieces and fittings for Perry with Comanche Peak.

There are no maintenance or modification recommendations made based on the lead engine DR/QR report. The following Quality Inspection should be performed on all station engines:

Verify that the type of Dresser coupling installed is in accordance with the TDI manual.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not requried i PE3159/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-436A&B-0 REFERENCES Not required DOCUMENTATION REQUIRED Not required

GROUP LHAIRPERSON PROGRAM MANAGER 1 4 % k./ V () ? O O PE3159/2 l

1 i-TDI OWNERS GROUP FOR ' PERRY NUCLEAR POWER PLANT . Intercooler Piping Coupling, Gaskets, Bolting I COMPONENT PART NO.: 02-436B l ' ? See Component Part No.: 02-436A 4 < l r e o

M: I f i

                                                                                        . _ _              u               -

w y , , ~w-, &,em-r--w----y -,-e.w - wy n . e v er -,e~w~-ne - -

COMPONENT DhSIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Turbocharger-Bracket: COMPONENT Bolting and Gaskets UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-475A.C TASK DESCRIPTION NO. DR-03-02-475A,C-0 SNPS GPL NO. 03-475A.D CLASSIFICATION T.YPE 8 TASK DESCRIPTIONS Design review for these components is not required based on a review of the following: '

The Comanche Peak lead engine DR/QR report (Ref.1).
TDI Parts Manuals, Volume II for Perry and Comanche Peak Power Stations-(Refs. 2 and 3).
TDI drawings (Ref. 4).
The EDG Component Tracking System for applicable industry and site experience (Refs. 5 and 6). Nuclear and non-nuclear experience identifies a few incidents of broken welds on fabricated items or piping supported by the turbocharger bracket; such events were caused by loosened or broken turbocharger hold-down bolts, all resulting from engine vibration. To prevent recurrence of similar events, verification of the torque values applied to the . turbocharger hold-down bolts and the bracket mounting bolts during installation is

required.

l i - 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 l' experienced by the brackets and the mounting bolts. The design of the water l jacketed, multi pipe, exhaust manifold connecting the cylinders to each l turbocharger is identical for both stations. The adapter piece (transitional'

piece) at the turbocharger exhaust connection and its expansion joint is l similarily designed, though the dimensions are different. The thermal loads i

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 Perry Station

. (Ref. 7) indicates that the seismic loadings are more favorable than those at l the Comanche Peak Station.

l O PE3234/1

   .....  . . . . . - . - - . - + . . . . . - .         -

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 3 (_. s DR-03-02-475A,C-0 TASK DESCRIPTIONS (continued) Based on the -above review the turbocharger brackets at Perry should be 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 should be satisfactory; however, based on the DR/QR report for Comanche Peak Station, the pretension from bolt torque has been found to have a relatively small margin to accommodate' the engine vibration loads. Any changes to the preload of the mounting bracket bolts, as a result of vibration testing at Comanche Peak, should also be implemented at Perry Station. There are no maintenance or modification recommendations for these components. The following inspections 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.
Visual inspection to verify proper installation of the bracket bolting.
Verification of the material of the bracket-to-engine bolting.

PRIMARY FUNCTION Not required l l ATTRIBUTE TO BE VERIFIED Not required l SPECIFIED STANDARDS Not required 1 O PE3234/2 L_

l l l COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 l DR-03-02-475A,C-0 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, Perry Nuclear Power Plant, Units 1 and 2, Parts List No. 02-475-22-02, Rev. 3, dated October 22, 1979, and Drawing 02-475-22, Rev. B, dated February 9, 1978.

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.

4. TDI Drawings Drawing No. Description 02-475-22-AL Bar Support Outer 02-475-22-AK 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. Emergency Diesel Generator Component Tracking System -

Nuclear and Non-nuclear Industry Experience dated November 5,1984.

6. Emergency Diesel Generator Component Tracking System -

Perry Nuclear t Power Station dated November 5, 1984.

7. Gilbert Associates, Inc., Specification SP-562-4549-00 for Class 1E Diesel Generator- Units, Rev. II dated January 11, 1977, Attachment Specification for Seismic Analysis, Testing, and Documentation, Perry Nuclear Power Station -

Units 1 and 2, SP-750-4549-00, dated August 30, 1973. l ! DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON w - PROGRAM MANAGER M \<c % w u . V' O O . PE3234/3

l l 1 Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 l COMP 0NENT Air Butterfly Valve Assembly UTILITY Cleveland Electric Illuminating Company 4 GROUP PARTS LIST NO. 02-475B TASK DESCRIPTION NO. DR-03-02-4758-0 SNPS GPL NO. 03-475B 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 or site experience. *
A review of the lead engine DR/QR reports (Shoreham and Comanche Peak)
Similarities between Perry components and' the lead engine components.

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

Locking devices on the valve linkages should be verified to be snug on a monthly basis.

, TDI Manual Volume II Dwg. 03-475-6491 indicates that a modification has been made to add grease fittings as per TDI SIM 322. No other modifications are required for this component. The following Quality inspections are recommended in order to ensure that the valve is capable of operating satisfactorily: !

Inspect butterfly to shaft attachment pins for signs of wear and distress.
Perform visual inspection of shaft condition, lubrication, wear and distress, document with photographs.

                               *.            Verify installation and alignment of butterfly valve (cold spring of piping on valve reinstallation to be noted), for freedom of movement.

Determine the microhardness of the shaft (TDI/PN 02-475-15AS). NOTE: Inspection to be performed on one engine only, if condition of valve is acceptable. PE3288/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-4758-0 PRIMARY FUNCTION Not required. ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION RE0VIRED O Not required GROUP CHAIRPERSON E PROGRAM MANAGEf} X W m s u m. u . G V V' l l l l O . PE3288/2

   --   -em +--+    _        _ _ .        . - - - - -     ,            ,,9, _- -_ __

l

                                                                                                                                                        ,                                                                        t TDI OWNERS GROUP FOR PERRY NUCLEAR POWER PLANT Turbocharger: Bracket-Bolting & Gaskets COMP 0NENT PART NO.: 02-475C                                                                                 ,

See Component Part No.: 02-475A 4 i I e

                                                                                                                                                                                                                 .2 w

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Page 1 of 1 0 COMPONENT QUALITY REVALIDATION CHECKLIST 03-02-805A Cleveland Electric Illuminating Co. . COMPONENT Intake Air Silencer UTILITY Perry Nuclear Power Plant - Unit 1 s GPL NO. 02-805A _ REV. NO. 2

               -SNPS GPL NO.                  99-805 TASK DESCRIPTIONS No further review of coinponent 02-805A is required for the following reasons:

i a) There is no site or industry experience-in evidence. b) The Intake Air Silencer was manufactured by American Air Filter, a subsidiary of Allis Chalmers. Their products including the Intake Air-Silencer are widely used in the nuclear and non nuclear industry. Their products are designed to AFI standards. A review of their air filters was performed at Shoreham with satisfactory results. O GROUP CHAIRPERSON MM PROGRAM MANAGER S C_ M PE2615/1

l l s Page 1 of 2

    ' s_-)                                     COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Intake Air Filter                          UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-805B                         TASK DESCRIPTION NO. DR-03-02-8058-0 SNPS GPL NO. 10-114                                  CLASSIFICATION TYPE                    B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry experience. Perry experience was related to filter installation, and not filter design /perfor-mance.
A review of the lead engine DR/QR report (Comanche Peak)
The lead engine and Perry intake air filters are manufactured by American Air Filter Co.. However, unlike the lead engine, Perry uses

. an oil-bath type intake air filter. This type of . filter has been used successfully throughout industry. The following maintenance should be performed:

Inspect intake air filter distribution plate and change oil in filter at each outage.

l No modifications are' recommended for this component. Quality Revalidation is not required for this component. PRIMARY FUNCTION Not required l l ATTRIBUTE TO BE VERIFIED Not required l r O PE3290/1 L w.

          *           -- --      -----e,m p, --m---- w . e,- ,, - ym - -i--~ ,e-        -  -

7--

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-8058-0

   'SPECIFIED STANDARDS Not required.

REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -- PROGRAM MANAGER X \< % , _ () V' Q O O PE3290/2 l l

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Flex Connections UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-8050 TASK DESCRIPTION NO. DR-03-02-805D-0 SNPS GPL NO. 10-109 CLASSIFICATION TYPE C TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak).

         . The exhaust flex connection resides downstream of the turbocharger. A failure of the exhaust flex connection would result in exhaust gases penetrating the boundary and escaping into the diesel room. This would not impair the diesels operability.

There are no maintenance or modification recommendations made based on the lead engine DR/QR report. Quality revalidation is not required for this component. PRIMARY FUNCTION

         .. Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required PE3160/1.
                                                                       ..-.w ,        --       e,,g- x -,--.re----

r COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 O REFERENCES DR-03-02-8050-0 Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - PROGRAM MANAGER 1 \<a % c/(f a O , S l PE3160/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Lube Oil Pressure COMPONENT Regulatina Valve UTILITY Cleveland Electric Illuminatino Co: pany GROUP PARTS LIST NO. 00-420 TASK DESCRIPTION NO: DR-03-00-420-0 , SNPS GPL NO. 00-420 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 industry or site experience.
A review of the lead engine DR/QR report (Comanche Peak).
Lube oil regulator valves at Comanche Peak and Perry are identical.

(TDI Part No. 00-420-01-0C). l The following maintenance from the engine DR/QR report should be implemented:

Disassemble and clean valve at each refueling outage.
If valve plugging becomes a problem, measure the dimensions of the valve internals for proper clearance and increase frequency of. valve cleaning.

There are no modifications recommended for this component. Quality revalidation is not required for this component. PRIMARY FUNCTION p

j. -Not required i

l ATTRIBUTE TO BE VERIFIED Not required O PE3250/1 Y, - - - . - . , - , . - -

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ( , DR-03-00-420-0 SPECIFIED STANDARDS Not required - ACCEPTANCE CRITERIA Not required REFERENCES Not required GROUP CHAIRPERSON PROGRAM MANAGER.~ Y h ; _ Lj y' o - O 4 i e O PE3250/2 l l i

      -s s Page 1 of 2
       ~]                                     COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Lube Oil Fittings Internal Headers COMPONENT (Large Bore Scope Only)          UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-307A               TASK DESCRIPTION NO. DR-03-02-307A-0 SNPS GPL NO. 03-307A                       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 or site experience.
A review of the - lead engine DR/QR reports (Shoreham/ Comanche Peak)

A comparison of the lube oil fittings - internal headers and piping

    's                         spool pieces and fittings for Perry with Comanche Peak.

There are no maintenance or modification recommendations made based on the lead engine DR/QR report. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O PE3100/1

c. COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 OR-03-02-307A-0 REFERENCES Not required

      ' DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON                    PROGRAM MANAGER 2 C % t e w m ..

(/ ' O O O : I PE3100/2 i

Page 1 of 2 , COMPONENT DESIGN REVIEW CHECKLIST + PERRY NUCLEAR POWER PLANT - UNIT 1 Lube 011 Fittings-Internal: Headers COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminating Company GROUP PART LIST NO. 02-307A TIGK DESCRIPTION NO: DR-03-02-307A-0 SNPS GPL NO. 03-307A CLASSIFICATION TYPE A

                    . TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR Report (Comanche Peak) and the applicable . industry experience.                                   There. is no     site experience for this component in the EDG Component Tracking System.

There are no maintenance recommendations for : this component. However, the lead engine report does address site specific modifications to supports. The necessity for similar modifications on Perry is addressed below. 7 A field walkdown was not possible because of component inaccessibility. However, this component will perform its intended function for all normal and earthquake loadings provided the as-built condition of supports is verified to be installed as indicated in Component Design Review Checklist 02-3070. It should be noted that these verification recommendations are based on the review

                   - of the DR/QR reports for Comanche Peak and Grand Gulf.

Quality revalidation for this component is not required. PRIMARY FUNCTION l' Not required ATTRIBUTE TO BE VERIFIED !~ Not required i - SPECIFIED STANDARDS Not required O PE3005/1

      -%   ,,s....      ...,.-_,..-...--,,-,..--.--..---.-.--w.,                         ~~-...-r,y_r   - _ . - , - , , , _ . - ,     y,ve,   erw-----------,--,.._rm       .     - - - -

r I l 1 l g COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-307A-0 l REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON / PROGRAM MANAGER _dC_\4-w uv o bo 4 3 4 O PE3005/2

e-

 ;.   .s                                                                    Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 L'ube Oil Fittings-Internal- Tubing and Fittings COMPONENT (Small Bore Scope Only)        UTILITY Cleveland Electric Illuminating Company GROUP PART LIST NO. 02-307B              TASK DESCRIPTION NO: DR-03-02-3078-0 SNPS GPL NO. 03-3078                     CLASSIFICATION TYPE                 A TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak) and the applicable industry experience. There is no   site experience for this component in the EDG Component Tracking System.

There are no maintenance recommendations or support modifications for this component. A field walkdown was not performed due to component inaccessibility. However,

    \    it should be noted that because of spatial restrictions, all sections of unsupported tubing will meet acceptable span lengths. Therefore this component will perform its intended function for all normal and earthquake loading.

Quality revalidation for this component is not required. PRIMARY FUNCTION Not required , ATTRIBUTE TO BE VERIFIED Not required i SPECIFIED STANDARDS Not required O PE3004/1

                                                                     .                                                     --                  __                -         - ..                         .. _ _ - _ = .                           ~ = .

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-3078-0 Not required , I DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -- PROGRAM MANAGER S C \<c- = = 1m _

                     .                                                                            g y-                                                                                                      v                 -

4 O l L L O PE3004/2 i

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Page 1 of 2 COMPONENT Drc.fcN REVIEW CHECKLIST PERRY NUCLEsn <oWER PLANT - UNIT 1 Lube Oil Fittings Internal - Supports.

                     . COMPONENT (Small Bore Scope Only)                                         UTILITY Cleveland Electric Illuminatina Company
                     - GROUP PARTS LIST NO.                     02-3070                          TASK DESCRIPTION NO. DR-03-02-3070-0
          ,5             SNPS GPL-NO.             03-3070                                        CLASSIFICATION TYPE                    B TASK DESCRIPTIONS                                                                                                            :

Design review for this component is not required based on the review of, the lead engine DR/QR reports (Comanche Peak and Grand Gulf). There is no site or industry experience for this component in the EDG Component Tracking System. There are no maintenance recommendations for this component. The lead engine reports do address the following recommended modifications to supports:

Replace all 1/4-inch U-bolts with 3/8-inch U-bolts.

     .n
     'Q.'

The U-bolts should be torqued sufficiently to prevent the header from moving axially without overstressing the header. Nuts should have suitable locking devices installed.

A. field walkdown was not possible because of component naccessibility.

However, this component will perform its intended function for normal and i earthquake loading provided that the -3/8-inch U-bolts are verified to be installed as per the TOI-parts manual (Vol. II) and the other aforementioned lead engine recommendations are verified to be implemented.

Quality revalidation for this component is not required.

m. PRIMARY FUNCTION I Not. required r ATTRIBUTE TO BE VERIFIED Not required LO PE3003/1-l.

                 -b
                           ;t

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - u PROGRAM MANAGER X \< N (jv' G O O PE3003/2

Page 1 of 2 s j COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Engine Driven COMPONENT Lube Oil Pump UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-420 TASK DESCRIPTION NO. DR-03-02-420-0 l SNPS GPL NO. 03-420 CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the following: j l

A review of the EDG Component Tracking System indicated that there was no significant applicable industry experience, except that l

previously 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 for Comanche Peak.
Similarity of the Perry component to the lead engine component. Both

[\ are IMO Model SJK-4370. l 1 There are no maintenance recommendations for this component as a result of lead engine design review. There are no required modifications for this component. Quality revalidation is not deemed necessary for this component. PRIMARY FUNCTION Not required I ATTRIBUTE TO BE VERIFIED i Not required 1 l PE3230/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-420-0 O . SPECIFIED STANDARDS Not required REFERENCES Not required i DOCUMENTATION REQUIRED i- Not required GROUP CHAIRPERSON PROGRAM MANAGER d C M % V! O 4

                                                 -.    ,-   - , , . .,-~.,--,..--.,,--.--,.-,-r.,,-_,7    -

 .                                                                                     Page 1 of 2
    \_/                                    COMPONENT DESIGN REVIEW CHECKLIST PEPRY NUCLEAR POWER PLANT - UNIT 1 Lube Oil Lines - External Tubings, Fittings, Couplings COMPONENT (Large Bore Scope Only)                  UTILITY Cleveland Electric Illuminating Company
   . GROUP PARTS LIST NO. 02-465A                       TASK DESCRIPTION NO. DR-03-02-465A-0 SNPS GPL NO. 03-465A                               CLASSIFICATION TYPE               A TASK DESCRIPTIONS Design review for the subject component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A . review of the lead engine DR/QR reports (Shoreham/ Comanche Peak).

('N

A comparison of the lube oil lines - external piping spool pieces,

   \j                       fittings and couplings for Perry with Comanche Peak.

The following maintenance and modification '. commendations made on the lead engine DR/QR report should be implemented:

The 12-inch Dresser coupling gasket is to be replaced with VITON gasket should leaks develop.
Ensure a minimum installation gap of 0.171 inches, between pipe ends, exists at the 12-inch Dresser coupling.

Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not reguired O PE3157/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-465A-0 SPECIFIED STANDARDS

Not requried REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER M h > U (./// O O PE3157/2

l l COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Lube Oil Lines-External-tubing, Fittings, Coupling COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatina Co. GROUP PART LIST NO. 02-465A TASK DESCRIPTION N0: DR-03-02-465A-1 SNPS GPL NO. 03-465A CLASSIFICATION TYPE A TASK DESCRIPTIONS A design review for this component is not required based on the review of the lead engine DR/QR ' reports (Comanche Peak, Grand Gulf and Catawba) and the applicable industry and site experience listed .in the EDG Component Tracking i System. ' A field walkdown was performed at Perry in accordance with the small bore piping criteria document (Ref. 1). However, a review of this component in its entirety was not possible since portions of piping and tubing were not installed at the time of the walkdown. Therefore, component acceptability and O any ' subsequent recommendations shall be based upon the lead engine reports (Comanche Peak, Grand Gulf and Catawba). L Should' a leak develop in a Style 65 Dresser coupling, replace with a Style j 90 coupling equipped with Viton gasket (Ref. 2). I- The lead engine reports address the need for site specific support additions I and modifications. The necessity for similar additions / modifications for Perry are addressed in DR/QR report 02-465C. Therefore, based on the above review, it is concluded ttit this component will perform its intended function at Perry under all normal operating and earthquake loadings provided that supports are_added/ modified as indicated in DR/QR report 02-465C. Quality Revalidation for this component is not required. PRIMARY FUNCTION Not required

                 - ATTRIBUTE TO BE VERIFIED l

I~

               . Not required O               PE2995/1
  ~

v-- ' o gg*tW9 +g=pp m-gwww-w-m-

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-465A-1 SPECIFIED STANDARDS Not required REFERENCES

1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TOI Owners' Group," report No.

11600.60-DC-02, Revision 0.

2. December 5, 1984 Letter from J. DiMare to J. Kammeyer " Recommended Maintenance-Small Bore Dresser Couplings".

DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -

                                                 - PROGRAM MANAGER , Y \( m w

(/ F G O O PE2995/2

i COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Lisbe Oil Lines External - COMPONENT Valves UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-465B TASK DESCRIPTION NO: DR-03-02-4658-0 I SNPS GPL NO. 99-465A CLASSIFICATION TYPE A 1 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 industry or site experience.
A review of the lead engine DR/QR report (Comanche Peak).
Similarity of Perry and the lead engine component.

p

The Clow and Williams-Hager check valves (2, 2 and 6 in.) as well as

' g'y the Tufline 3-way valve are used at both Perry and Comanche Peak. The Whitey %" shutoff valve was used at Comanche Peak in other systems (i.e. , jacket water) and there is no r.dverse experience with this valve. There are no maintenance or modification recommendations from the lead engine DR/QR report. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required PE3247/1

r 1 l' i. COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 SPECIFIED STANDARDS Not required ACCEPTANCE CRITERIA Not required REFERENCES Not required GROUP CHAIRPERSON e- = PROGRAM MANAGER 1 4 - A VV G i i O 1 9 4 4 4 O PE3247/2 i

n. Page 1 of 1 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Lube Oil Lines - COMPONENT External Supports UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-465C TASK DESCRIPTION NO. DR-03-02-465C-0 SNPS GPL NO. 03-465B CLASSIFICATION TYPE B TASK DESCRIPTIONS There are no supports for this component. No design review is required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -- - PROGRAM MANAGER 2 C_ M a w h J (JF (] U PE3163/1

(M '

 'D)                                     TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 LUBE OIL LINES EXTERNAL: SUPPORTS (SMALL BORE SCOPE ONLY)

COMPONENT PART NO. 02-465C I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of the structural adequacy o f- the lube oil line external supports to withstand the effects of normal operating and earthquake loadings. The primary function of these supports is to provide adequate restraint to the external lube oil small bore piping / tubing. II OBJECTIVE The objective of this review was to perform an engineering evaluation of the small bore piping / tubing supports to assure that the component will perform its intended design function during normal operating and earthquake loadings. III METHODOLOGY In order to meet the stated objective, the following methods were used:

The TDI Emergency Diesel Generator Component Tracking System was reviewed for the Perry site, nuclear, and non-nuclear industry experience. See Appendix C for results.
The Quality Revalidation Checklist results were reviewed for acceptability.
Engines 1A and 18, both partially disassembled, were evaluated using actual walkdown- information and by comparison to the Comanche Peak lead engine report.

Refer to the review procedures as described in Reference 1 for a detailed methodology for this evaluation. IV RESULTS AND CONCLUSIONS The supports, as defined by this Component Design Review have been evaluated in accordance with Reference 1 and have been found acceptable with modifications. O v PE3109/1

l l There are no TERs associated with this component. The 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 information contained in Reference 2, it is concluded that the -small bore piping / tubing supports will perform their intended design function at Perry unfer all normal operating and earthquake loadings with the provision that the following recommended modifications be implemented as detailed in Reference 3. Engines 1A and 1B Lube 011 Supply from Filters to Crossover Header The three-directional restraint in the 1 inch pipe riser at the turbocharger support bracket should be installed as shown on TDI Drawing 02-465-21 (Items 48 and 79). Lube Oil Headers and Rocker Arm Branches Lubt oil headers and rocker are branches were not installed during the field walkdown because of the disassembled state of the engines. Installation of the headers, branch tubing and restraints should be per O manufacturer drawings and include the following modification:

One of the eight required two-directional restraints on each engine bank should be revised to a three-directional restraint and located approximately mid-engine. The remaining two-directional restraints should be modified or shimmed as required to provide proper sliding fit.

In order to support the piping / tubing of component 02-465A it is recommended that the following supports be added: Lube Oil Gearcase Header and Branches L

A three-directional restraint should be added in the r'ser of the l 1\-inch gearcase heades' near the top to provide axial and lateral

support of the cantilever configuration.

l l

A two-directional restraint should be added in the riser of the 3/8-inch tubing to the right camshaft bearing approximately 6 inches down from the horizontal run.
A two-directional restraint should be added in the lower horizontal

! run of the 3/8-inch tubing to the fuel oil pump bearing at approxi-mately 2 feet - 6 inches from the 1 -inch pipe header. l l PE3109/2-1

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

Page 3 of 3 b e A two-directional restraint should be added in the horizontal run of 3/8-inch tubing to the left camshaft bearing at approximately mid-span. Lube oil lines to the jacket water pump bearings were not installed at the time of the field walkdown. Installation of this tubing and restraints should be similar to the lead engine. V REFERENCES

1. " Engineering Review Criteria Document for - the Design Review of TOI Diesel Small Bore Piping, Tubing, and Supports for tha TDI Owners Group," Report No. 11600.60-DC-02 Revision 0.

2. Stone & Webster Calculation number 11600.60-NP(B)-0301-XH.

3. Memo No. 6548 from C. Malovrh/SWEC to J. Kammeyer/SWEC dated 11/29/84.

O . e E w' l PE3109/3 _ . . , . . , . - - - - . , - , . ._ . , - . . , _ , . - . _ , , _ , , , . _ . . ., .,,,,,a._ ,.,.,,,.-n , . , _ - , . . , _ . , , , . , , , - , , . _ , _ . - - , , , , , . , , , _ . -

APPENDIX A . Page Al of 2 COMPONENT DESIGN REVIEW CHECKLI!T PERRY NUCLEAR POWER PLANT - UNIT 1 Lube 011 Lines - External: -Supports CONPONENT ISmall Bore Scope Only) UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-465C TASK DESCRIPTION NO.: DR-03-02-465C-0

i. - SNPS GPL'NO. 03-4658 CLASSIFICATION TYPE A I -

TASK DESCRIPTIONS i Perform an engineering review of the small bore piping / tubing supports to provide additional assurances that the component will perform its intended design function during normal operating and earthquake loading. t i- PRIMARY FUNCTION

Provide adequate restraint of the small bore piping / tubing system, in the intended support load direction.

z . ATTRIBUTES TO BE VERIFIED i-' Structural adequacy of the pipe / tube supports due to the effects of normal operating and earthquake loadings. SPECIFIED STANDARDS s i IEEE 387 i j' REFERENCES i " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group" Report No. 11600.60-DC-02, Revision 0 l PE3023/1 i I

I COMPONENT DESIGN REVIEW CHECKLIST Page A2 of 2 5 DR-03-02-465C-0

V DOCUMENTATION REQUIRED Delaval design documentation (specifications, calculations, drawings, etc.).

In lieu of information from Delaval, the following information is required: verified support sketches and piping isometrics, material specifications, pipe size and schedule, and operating parameters (pressure, temperature, . load i combinations)

                             -       A GROUP CHAIRPERSON        )        --
                                            --PROGRAM MANAGER S C W N V (/                                                 G t

O O PE3023/2

(- Appendix B Page B1 of 3 O 03-02-465C COMPONENT QUALITY REVALIDATION CHECKLIST Lube Oil Lines Cleveland Electric Illuminating Co. COMPONENT External - Supports UTILITY Perry Nuclear Power Plant - Uint 1 GPL NO. 02-465C REV. NO. 2 SNPS GPL NO. 03-465B TASK DESCRIPTIONS Engine 1A

1. Assemble and review existing documentation.

2. Obtain sufficient data to support the design review effort. This may be accomplished by developing quality verified as-builts in accordance with procedure DG-7, or by the Design Group performing a field walkdown.

Engine 18 Same as Engine 1A ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package

2. Information necessary for the design review effort.

Enaine 1B Same as Engine 1A

O PE2623/1

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 3 03-02-465C ACCEPTANCE CRITERIA Enaine 1A

1. Satisfactory Document Package

2. Review of detailed information by the Design Group Encine 1B Same as Engine 1A REFERENCES Engine 1A

1. QCI No. 52

2. Procedure DG-7 Engine IB Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A

1. Document Summary Sheet

     . 2. Quality verified as-built isometric drawings for the supports if available from the Owner.

l l Engine IB - Same as Engine PROGRAM MANAGER e)CWu ,4.---- GROUP CHAIRPERSON , L l PE2623/2

COMPONENT QUALITY REVALIDATION CHECKLIST Page 83 of 3 p 03-02-465C COMPONENT REVIEW Engine 1A

1. No EDGCTS site experience documents are in evidence.

2. The Design Group will be responsible for closing out the as-built drawings as per Procedure DG-7. The as-built drawings will be Quality verified by the appropriate site Quality organization. The performance of an engineering walkdown- by the Design Group, precludes the issuance of a Quality verified as-built drawing or sketch.

Engine 18 Same as Engine 1A RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as p) (U outlined above, is complete. The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of the final report. Engine 18 Same as Engine 1A GROUP CHAIRPERSON [Y* h m PROGRAM MANAGER,3C \<c .~ssa h-o I i l i O PE2623/3

                    -. _.-.e_,         . - . _ . . . . _ _ . ,     ,  _    ,_

f Appendix C Page C1 of 1 i EDG COMPONENT TRACKING SYSTEM: PERRY SITE, NUCLEAR A!40 NON-NUCLEAR INDUSTRY EXPERIENCE SUmiARY , COMPONENT NO. 02-465C Effective Printout Date: 11/05/84 COMPONENT TYPE: Lube Oil Lines External: Supports REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS PERRY ! None NUCLEAR None . NON-NUCLEAR l None

I

! f l i l I PE3109/1 i

  --.-n -,- - . - _ .       , _ . _ _ - - , . _ . . _        . . - - . . . . - . _ . . _                                            _ , _ . . _ , _ . . , -             ,

l Page 1 of 2 V COMPONENT DESIGN REVIEW CHfCKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Turbocharger-Lube 011 Fitting Piping COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-467A TASK DESCRIPTION NO. DR-03-02-467A-0 SNPS GPL NO. 03-467A CLASSIFICATION TYPE B TASK DESCRIPTIONS Design Review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak).
A comparison of the turbocharger-lube oil fittings piping spool pieces and fittings for Perry with Comanche Peak.

O The following modification recommendations made on the lesd engine DR/QR V report should be implemented:

The 2 -inch Dresser couplings (located between the turbocharger and lube oil sump tank for both drain lines) should be removed and replaced with 2 4- inch 150 lb. S.O. flanges with A307 bolts.

There are no maintenance recommendations from the lead engine DR/QR report for this component. Quality revalidation is not required for this component. PRINARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O 0] PE3162/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2

                                                 .          DR-03-02-467A-0 Not required DOCUMENTATION REQUIRED

, Not required j GROUP CHAIRPERSON '

                                      -- _ PROGRAM MANAGER )C %

L/(/' G i O I i O PE3162/2

l l Page 1 of 2 O ('j COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Turbocharger-Lube Oil Fitting-Pipe, Tubing, Fittings and Flexible Coupling COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminating Co. GROUP PART LIST NO. 02-467A TASK DESCRIPTION N0: DR-03-02-467A-0 SNPS GPL NO. 03-467A CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak) and the applicable industry experience. There is no site experience for this component in the EDG Component Tracking System. There are no maintenance recommendations for this component. However, the lead engine report does address site specific additions of supports. The necessity for similar additions on Perry has been assessed by a field walkdown. (b The field walkdown was performed in accordance with the small bore piping criteria document (Ref.1) and concluded that this component will perform its intended function for normal and earthquake loading provided that the supports are added as indicated in DR/QR Report 02-467B. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O i V PE2994/1 b _ _ _ _ _ - _ _ . _ . . _ _ _ _ . . . _ _ _ _ ._ - --- -- -

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-467A-0 O V REFERENCES

      " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," report No.

11600.60-DC-02, Revision 0. DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGERMC__We u VV' 0 O I i PE2994/2

Page 1 of 2 O Q COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR P0t1ER PLANT - UNIT 1 Turbocharger - Lt.be Oil Fittings: Supports COMPONENT (Larae Bore Scope Only) UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-4678 TASK DESCRIPTION NO. DR-03-02-467B-0 SNPS GPL NO. 03-4678 CLASSIFICATION TYPE- B TASK DESCRIPTIONS Design Review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak)
A comparison of the turbocharger-lube oil fittings supports for Perry with Comanche Peak.

The following modification recommendations made on the lead engine DR/QR report should be implemented:

The multiple support (attached to both 2 -inch drain lines) located between the lube oil sump tank and the Dresser coupling requires reinforcement of support members and increases in the welds.

There are no maintenance recommendations from the lead engine DR/QR report for this component. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O PE3161/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 OR-03-02-4678-0 RFFFRENCFS Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON , PROGRAM MANAGER Z \< % uv v i

'O 1

i-r k f PE3161/2 e------, ,, e-,,..v--,,-,,,,,,,, , -_, ,n__,.,,--_,,_,.,,,,,__.,,,,,_--_,m,-w,n ,,m_ ,_ ,,_w ,,,,--e ,,,.n.,_cve.

m O-TDI OWNERS GROUP for' i PERRY NUCLEAR POWER PLANT - UNIT 1 i TURBOCHARGER - LUBE OIL FITTINGS: SUPPORTS (SMALL BORE SCOPE ONLY) , COMPONENT PART NO. 02-4678 l I -INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation review:s of i the structural adequacy of the turbocharger lube oil tubing suoports, to withstand the effect of normal operating and earthquake loadings. The primary function of these supports is to provide adequate restraint of the !p._ tubing system in the intended support load direction. II OBJECTIVE . The objective of this review was to perfcra an engineering evaluation of i the tubing supports to assure that the component will perform its intended design function during normal ' operating and earthquake loadings. i III NETH000 LOGY In order to meet the stated objective, the following methods were used:

The TDI Emergency Diesel Generator Component Tracking System was reviewed for the Perry site, nuclear, and non-nuclear industry i experience, See Appendix C for results.

i

The _ Quality Revalidation Checklist results were reviewed for acceptability.

Refer to the review procedures as described in Reference 1 for a detailed j methodology for this evaluation. IV RESULTS AND CONCLUSIONS L l The tubing supports, as defined by this Component Design Review, have [' been evaluated in accordance with Reference 1 and have been found acceptable with modifications. There are no TERs associated with this component. r I The Quality' Revalidation Inspection results identified in Appendix B have l- been reviewed and considered in the performance of this design review, and' the results are consistent with the final conclusions of this report. O FE3u2/1 l t

r m' Page 2 of 3 O Aj Based on the above review and information contained in Reference 2, it is concluded that the tubing supports will perform their intended design function at Perry under all normal operating a.nd earthquake loadings with the provision that the following recommended modifications be i'mplemented as detailed in Reference 3. Engine 1A Left Bank Turbocharger

The support located between the lube oil header and the turbocharger lube oil cross should be redesignsd to increase vertical and lateral capacity. The use of "UMPC0" clip pipe attachments at this location is not advised.

Right Bank Turbocharger

The support located between the lube oil header and the turbocharger lube oil cross should be modified to provide a more positive fastening for the unistrut. Single bolts may loosen under dynamic

loading.

Engine IB Right Bank Turbocharger

The structural cross section of the existing h-inch thick flat bar restraint in the horizontal run that is perpendicular to the crankshaft should be increased to provide added lateral stiffness.

In order to support the tubing of component 02-467A, it is recommended that the following supports be added: Engine 1A Left Bank Turbocharger

             *    - A two-directional restraint should be added in the 3/ 4-inch tubing horizontal run parallel to the crankshaft near the lube oil beader t

(02-465A).

Right Bank Turbocharger

A two-directional restraint should be added in the horizontal run l perpendicular to the crankshaft adjacent to the riser near the lube oil header (02-465A) similar to Engine 18.

r l lO [ -PE3112/2 l l l ta

rr Page 3 of 3 Engine 18 Left Bank Turbocharger

A two-directional restraint should be added in the tube riser near the cross fitting, similar to Engine 1A.
A two-directional restraint should be added in the horizontal tube run parallel to the crankshaft near the lube oil crossover header.

Right Bank Turbocharger

A two-directional restraint mounted to the turbocharger casing should be added in the horizontal tubing run parallel to the crankshaft similar to the Engine 1A.

, >

A two-directional restraint near the top and of the 180-degree " hair pin" loop above the lube oil header (02-465A) should be added. .

V REFERENCES

1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," Report No. 11600.60-DC-02, Revision 0. 1

2. Stone & Webster Calculation number 11600.60 NP(B)-0301-XH.

O

3. Memo No. 6548 from C. Malovrh/SWEC to J. Kammeyer/SWEC dated +

11/29/84. O PE3112/3 E

                                                                     - . .__ _     _ . _- -                _-  . -._ - ~         -. _-

APPENDIX A Page Al of 2 COMPONENT DESIGN REVIEW CHECKLIST ; PERRY NUCLEAR POWER PLANT - UNIT 1 Turbocharger - Lube 011 , Fittings: Supports I COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatina Company , i GROUP PARTS LIST NO. _ 02-4678 TASK DESCRIPTION NO. DR-03-02-4678-0 SNPS GPL NO. 03-4678 CLASSIFICATION TYPE B t TASK DESCRIPTIONS ! Perform an engineering review of the small bore piping and tubing supports to provide additional assurances that the component will perform its intended design function during normal operating and earthquake loading. PRIMARY FUNCTION , t' Provide adequate restraint of the small bore piping / tubing system, in the O intended support load directions. ATTRIBUTES TO BE VERIFIED Structural adequacy of the small bore piping and tubing supports due to the effetts of normal operating and earthquake loadings. SPECIFIED STANDARDS IEEE-387 ^ ' REFERENCES

             " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group" Report . No.

14 11600.60-DC-02, Revision O. i O PE3022/1- - i

     , - _ -              .w. . _ _ . _ . _ .    . . _ , . _ . . _ _ _           .___:.______.___..____._.-.             . . , _  _~

 ~
                                                                                       \

COMPONENT REVIEW DESIGN CHECKLIST Page A2 of 2 DR-03-02-4678-0 DOCUMENTATION REQUIRED , l Delaval design documentation (specifications, calculations, drawings, etc.). In lieu of information from Delaval, the following information is required: verified support sketches and piping isometrics, material specifications, pipe size and schedule, and operating parameters (pressure, temperature, load combinations). GROUP CHAIRPERSON ' _ PROGRAM MANAGER ACAhw o L/r t 1 1 I I l

PE3022/2

Appendix B Page B1 of 3 03-02-4678 COMPONENT QUALITY REVALIDATION CHECKLIST Turbocharger-Lube Oil Cleveland Electric Illuminating Co. COMPONENT Fittings: Supports UTILITY Perry Nuclear Power Plant - Unit 1 , GPL NO. 02-467B REV. NO. 2 SNPS GPL NO. 03-4678 . l TASK OESCRIPTIONS l Engine 1A

1. Assemble and review existing documentation.

2. Obtain sufficient data to support the design review effort. This may be accomplished by developing quality verified as-builts in

! accordance with Procedure DG-7, or by tha Design Group performing a field walkdown. Engine IB Same as Engine 1A ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package

2. Information necessary for the design review effort l Engine 1B Same as Engine 1A ACCEPTANCE CRITERIA i

Engine 1A

1. Satisfactory Document Package l 2. Review of detailed information by the Design Group l PE2628/1 l

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 3 ACCEPTANCE CRITERIA (continued) Enaine IB Same as Engine 1A REFERENCES Engine 1A

1. QCI No. 52

2. Procedure DG-7 Enaine 1B i

Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A l i

1. Document Summary Sheet

2. Quality verified as-built isometric drawings for the supports if l available from the Owner.

Engine IB Same as Engine GROUP CHAIRPERSON a/j PROGRAM MANAGER h C_ CAMPONENT REVIEW w ne 1A

1. No 3GCTS site ekperience documents are in evdience.

2. The 01 sign Group will be responsible for closing out the as-built drawia.gs as per Procedure DG-7. The as-built drawings will be j Quality verified by the appropriate site Quality organization. The i performance of an engineering walkdown by the Design Group, precludes the issuance of a Quality verified as-built drawing or sketch.

l PE2628/2

COMPONENT QUALITY REVALIDATION CHECKLIST Page 83 of 3 d COMPONENT REVIEW (continued) Engine 18 Same as Engine 1A RESULTS A"O CONCLUSION 1 Engine 1A l The Quality Revalidation effort with respect to this component, as l outlined above, is complete. The results have been forwarded to the ; Design Review Group for their evaluation and conclusions in support of the final report. Enaine 18 Same as Engine 1A GROUP CHAIRPERSON d5L A- hf PROGRAM MANAGERUC.MwA U O I-I I l O PE2628/3 _ . _ _ _ _ . . _ - _ . , _ _ _ ~ _ _ . - _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . - _ _ _ _ _ _ _

Appendix C Page C1 of 1 O EDG COMPONENT TRACKING SYSTEM: PERRY SITE, NUCLEAR AND NON-NUCLEAR INDUSTRY EXPERIENCE SUte4ARY COMPONENT NO. 02-4678 Effective Printout Date 11/05/84 COMPONENT TYPE: Turbocharger - Lube Oil Fittings: Supports REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS PERRY None NUCLEAR None NON-NUCLEAR i None

O O PE3112/4 l

l

     ~ - - -           -

l l l l Page 1 of 3 , COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Lube Oil Sump Tank with Strainer Assembly and . COMPONENT Mountina Hardware UTILITY Cleveland Electric Illuminatina Company ,

               - GROUP PARTS' LIST NO. 02-540A&C                                 TASK DESCRIPTION NO. DR-03-02-540A&C-0 SNPS GPL NO. 03-540A&C                                          CLASSIFICATION TYPE                       B TASK DESCRIPTIONS Design review of these components is not required based on the review of the 1                 Comanche Peak lead engine DR/QR report, TDI Parts Manuals for Perry and                                          '
               . Comanche Peak Power Stations (Refs. 2 and 3), Seismic Qualification Report for lube oil sump tank - (Ref. 4), and the EDG Component Tracking System for                                         t applicable industry and site experience (Refs. 6 and 7).                                         The Component Tracking System for Perry Station identified problems with incomplete date on the form N-6, " Manufacturers' Data for Storage Tanks," for the lube oil sump tanks (component. 03-540A). According to Mr. E. ' Root of Cleveland Electric Illuminating Company, TDI has resubmitted the corrected data report and the j            Non-Conformance Report has been closed out as of April 2, 1984.

i' The lube oil sump tank assembly for Perry Station consists of two vertical , cylindrical steel vessels (inlet and outlet compartments) interconnected by a

16 in, flanged connection. These vessels are qualified to the requirements of l ASME Section III, Code Class 3 component. The inlet compartment serves not i only as the receiver tank for the engine lube oil drain, the turbocharger lube oil drain, and the recirculation flow from the pressure-regulating valves, but also accommodates an internal strainer assembly.

The lube oil ~ sump tanks for Perry and Comanche Peak Stations have different parts lists and drawing numbers (Refs. - 2 and 3). ' A close scrutiny, however, reveals that they are identical with the only exception that the 6 in, connection intended for the auxiliary lube oil. pump suction piping of the Comanche Peak installation is not needed for the Perry site and is blanked off with a blind flange. The associated foot valve fitted internally to the ! outlet compartments . is likewise not installed. Same strainer assembly and ' mounting hardware are provided. The mounting hardware consists of four 1 in. 8 UNC by 2 in. long, hexagonal-head cap screws securing the baseplate of each compartment to the auxiliary subbase; the same bolt torque value of 245 ft-lb applies to both installations (Refs. I and 5).

               - Review of the _ amplified response acceleration spectra curves for Perry Station (Ref. 8) indicates that the seismic loadings are more favorable than those at the Comanche -Peak Station. The seismic analyses for Comanche Peak, therefore, were used without modifications for the seismic qualification report of the lube oil sump tank for Perry Station noting such differences (Refs.1 and 4).

PE3281/1 l

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 3 s, DR-03-02-540A&C-0 Based on the DR/QR report of this component for Comanche Peak Station, the design of the lube oil sump tank and mounting hardware is structurally adequate for the intended use at Perry Station. There are no maintenance or modification recommendations for these components. Quality Revalidation for Component No. 02-540A is not required. The various tasks described in the Component Quality Revalidation Checklist for Component No. 02-540C should be performed on both er.gines:

Verification of compliance to the TDI Instruction Manual for torque loads applied to the hold-down bolts through review of existing documentation.
Visual inspection to verify proper installation of the lube oil sump tank bolting.

FRIMARY FUNCTION . Not required O ATTRIBUTE TO BE VERIFIED Not required

SPECIFIED STANDARDS l

Not required t l l REFERENCES

1. Comanche Peak Stea:n Electric Station - Unit 1, DR/QR Report for Group Parts List Nos. 02-540A and 02-540C.

2. TDI Manual Volume II, for Model DSRV-16-4 Diesel Engine / Generator, Perry Nuclear Power Plant, Units 1 and 2, Parts List No. 02-540-07-04 and l

Drawings 02-540-6275 and R-3562. l i PE3281/2 l l

COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 DR-03-02-540A&C-0 d 3. TDI Manual Volume II for Model DSRV-16-4 Diesel Engina/Gener6 tor, Comanche Peak Steam Electric Station - Unit 1, Parts List No. 02-540-07-03 and Drawings 02-540-6260 and R-3562. ,

4. Final Report Volume I, Seismic Qualification of Transamerica Delaval Diesel Generator Sets, Serial Nos. 75051-75054 for Cleveland Electric Illuminating Company, Perry Nuclear Power Plant, Units 1 and 2 - Appendix II, ASME Qualification Report on Delaval Lube Oil Sump Tank.

5. TDI Manual Volume I, for Model DSR-16 Diesel Engine / Generator, Perry Nuclear Power Plant, Units 1 and 2.

6. Emergency Diesel Generator Component Tracking System -

Nuclear and Non-Nuclear Industry Experience dated November 5, 1984.

7. Emergency Diesel Generator Component Tracking System - Perry Nuclear Power Station experience dated November 5, 1984.

8. Gilbert Associates, Inc., Specification SR-562-4549-00 for Class 1E Diesel Generator Units, Rev. II dated January 11, 1977, Attachment Specification for Seismic Analysis, Testing, and Documentation, Perry Nuclear Power Plant - Units 1 and 2, SP-750-4549-00 dated August 30, 1973.

!~

[

   \    DOCUNENTATION REQUIRED Not required l

GROUP CHAIRPERSON -

                                                                       - PROGRAM MANAGER d N e 4 %

(/ V' C I l O PE3281/3 -

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Lube Oil Sump Tank - Misc. Fittings, Gaskets, Pipe and Bolting Material, Vaive COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminating Co. GROUP PART LIST NO. 02-540B TASK DESCRIPTION NO: DR-03-02-5408-0 SNPS GPL NO. 03-5408- CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak). There is no site or industry experience for this component in the EDG Component Tracking System. There are no - maintenance or modification recommendations for this component. A field walkdown was performed in accordance with the small bore piping criteria document (Ref.1) and concluded that this component will perform its

intended function for normal and earthquake loadings.

i Quality revalidation for this component is not required. ! PRINARY FUNCTION l Not. required

ATTRIBUTE-TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O PE2993/1 i

     #.--a-,..,-,og-m--a           e y -g-     g----

1 COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-5408-0

     " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," report No.

11600.60-DC-02, Revision 0. DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER 3C \<a.- 2. - i(y u . I3 0 O PE2993/2

r-TDI OWNERS GROUP , FOR PERRY NUCLEAR POWER PLANT Lube Oil Sump Tank: Mounting Hardware j COPP0NENT PART NO.: 02-540C 4 See Component Part No.: 02-540A 2-t f. ( ' l 5 i t ' I e I- , i e DP l . G I' -- - -- _ . , - . _ t __ -

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

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR PCWER PLANT - UNIT 1 Aux. Sub Base & 011 & Water Piping-Lube Oil: Pipe and Fittings COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-717F TASK DESCRIPTION NO. DR-03-02-717F-0 SNPS GPL NO.~ 03-717H CLASSIFICATION TYPE B u TASK DESCRIPTIONS Design review for this component is not required based on a review of the , applicable industry and site experience in the EDG Component Tracking System and the lead engine DR/QR report (Comanche Peak). There 'are no maintenance recommendations for this component. However, the lead engine report does address site specific modifications to the skid piping L and/or supports. Generic application of these modifications is not required for Perry since the Comanche Peak modifications were not required- for , piping operability. .The lead engine modifications were recommended in order to

meet the intent and philosophy of the ASME Code for the boundary conditions
and assumptions used in the Owners Group analysis. These boundary conditions j and assumptions may be somewhat different from those used in the original l manufacturer's analysis. Lead engine skid mounted large bore pipe modifica-i tions, as they apply to equipment nozzle loads, are addressed, if necessary, in
the. individual equipment design reviews.

I j Quality revalidation for this component is not required. PRINARY FUNCTION Nct required ATTRIBUTE TO BE VERIFIED Not required

      'SPECIFIED STANDARDS Not required O  PE3176/1 l.

l

r i-COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-717F-0 REFERENCES Not required i DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -= PROGRAM MANAGER M% % vr u E O f 4 C b h 'l f e O PE3176/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Auxiliary Sub Base and Oil and Water Piping - Lube Oil: Pipe and Fittings COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-717F TASK DESCRIPTION NO. DR-03-02-717F-0 SNPS GPL NO. 03-717H CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR Report (Comanche Peak) and the applicable industry and site experience. There are - no maintenance recommendations for this component. However, the lead engine report does address site specific modifications to supports. The necessity for similar modifications on Perry has been assessed by a field walkdown. The field walkdown was performed in accordance with the small bore piping O' criteria document (Ref.1) and concluded that this component will perform its intended function for normal and earthquake loading provided that the supports are added/ modified as indicated in DR/QR report 02-7171. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not requried

                     . REFERENCES Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore -Piping,-Tubing, and Supports for the TDI Owners' Group" Report No.

11600.60-DC-02, Revision 0. PE3028/1 f

   -.r=e , , ..c-,.-   y--~%m ,,v.

m & .-- --, ....- --.-. -- xa- . - - . -x.- . .- ...aa .--- - COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-717F-0 DOCUMENTATION REQUIRED Not required i GROUP CHAIRPERSON . PROGRAM MANAGER M O M VV U O r l l O PE3028/2

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Auxiliary Sub Base & 011 & Water Piping - Lube 011: .

             -COMPONENT Valves                                                                    UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO.                                            02-717G             TASK CESCRIPTION NO. DR-03-02-717G-0                            +

SNPS GPL NO. 03-717I CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review of this component is not required based on the following:

A review of the EDG Component Tracking System indicated no significant applicable industry or site experience.
A review of the lead engine DR/QR report (Comanche Peak).

The lobe oil valves at Perry are very similar to those in the lead engine lube oil system. Both engines have the following valves: Powell Globe Valves - Fig. 2475 (1" and 2") Crosby Relief Valves - Style J0-25 (2" inlet) Cros'by Relief Valves - Style Jie (li" s inlet)' , Tufline Valves: 3-way - Fig. 037AX (6") i

j. Tufline Valves: plug - Fig. OS7EG (4")

Perry ' also has an additional Tufline plug valve - Fig. 067. This type of valve is identical to Fig. 067EG valves, except there is no enclosed gear operator. l_ l The following maintenance recommendation from the lead engine DR/QR report j should be implemented: i

Check the relief valve lift pressure every 5 years.

Proper orientation of the relief valves should be verified by field inspection

             '(i.e.,             vertical installation).                                      Pending satisfactory completion of this inspection, there are no modifications required for this component based on the lead engine report.

i Quality Revalidation is not required for this component. (O l PE3283/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED 9 Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON ^ PROGRAM MANAGER e M \< w w st m (j r a 9 O PE3283/2

Page 1 of 1 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Auxiliary Sub-Base & 011 and Water Piping COMPONENT Lube Oil-Gaskets & Boltina UTILITY Cleveland Electric I11uminatina Company GROUP PARTS LIST NO. 02-717H TASK DESCRIPTION NO. DR-03-02-717H-0 SNPS GPL NO. 03-717J CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of applicable industry experience and the lead engine DR/QR reports (Shoreham/ Comanche Peak). There is no site experience for this component. There are no maintenance or modification recommendations for this component. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON N PROGRAM MANAGER NC\<u.wveWN O PE3147/1 (JV G

Page 1 of 2

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Aux. Sub Base & 011 & Water Piping-Lube 011: , Supports & Mounting , Hardware l COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminating Co.

                             ' GROUP PARTS LIST NO. 02-717I                                                                      TASK DESCRIPTION NO. DR-03-02-717I-0 SNPS GPL NO. 03-717K                                                                              CLASSIFICATION TYPE                             B l

li TASK DESCRIPTIONS Design review for this component is not required based on a review of the , applicable industry and site experience in the EDG Component Tracking System and the lead engine DR/QR report (Comanche Peak).

                             - There are no maintenance recommendations for this component. However, the lead engine report does address site specific modific, ations to the skid piping

and/or. supports. Generic application of these modifications is not required

( for Perry since the Comanche Peak modifications were not required for piping operability. The lead engine modifications were recommended in order to meet the intent and philosophy of the ASME Code for the boundary conditions and assumptions used in the Owners Group analysis. These boundary conditions

                             . and assumptions may be somewhat different from those used in the original manufacturer's analysis. Lead engine skid mounted large bore pipe modifica-tions, as they apply to equipment nozzle loads, are addressed, if necessary, in the individual equipment design reviews.

Quality revalidation for this component is not required. PRINARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required f 4 i PE3175/1 r--.,s.-3 ,v -,e-, .,~.~..-.w-.~ - . . - , - - , - - . - , - - - - - - - - - - , . - - - . - , - - - . - - - . - m,--.- 4, - . w- - - - . . -..., n , e- * - ,

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-7171-0 O' SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - PROGRAM MANAGER 2GW k O i O PE3175/2 k _._ __. ____ _ ______ ._ . _ _ _ _ _ . . _ _ _ _

O TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 AUXZLIARY SUB-BASE AND OIL AND WATER PIPING-LUBE OIL: SUPPORTS AND G NTING HARDWARE (SMALL BORE SCOPE ONLY) COMPONENT PART NO. 02-717I I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of-the structural adequacy of the auxiliary sub-base and oil and water piping lube oil supports and mounting hardware to withstand the effects of normal operating and earthquake loadings. The primary function of these supports is to provide adequate restraint of the small bore piping / tubing system in the intended support load direction. II OBJECTIVE The objective of this review was to perform an engineering evaluation of the small = bore piping / tubing supports to assure that the component will O perform its intended design function during normal operating and earthquake loadings. III METHODOLOGY In order to meet the stated objective, the following methods were .used:

The TDI Emergency Diesel Generator Component Tracking System was reviewed for the Perry site, nuclear, and non-nuclear industry experience. See Appendix C for results.
The - Quality Revalidation Checklist results were reviewed for acceptability.
Engines 1A and 1B, both partially disassembled, were evaluated using actual walkdown information and by comparison to the Comanche Peak lead engine report.

Refer to the review procedures as described in Reference 1 for a detailed methodology for this evaluation. IV RESULTS AND CONCLUSIONS The small bore piping / tubing supports, as defined by this Component Design Review and as shown in Reference 2, have been evaluated in accordance with Reference 1 and have been found acceptable with O modification. NI PE3110/1

Page 2 of 2 D (V There are no TERs associated with this component. The 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 information contained in Reference 2, it is concluded from References 1 and 2 that the small bore piping / tubing sup-ports will perform their intended design function at Perry under all normal operating and earthquake loadings with the provision that the following recommended modification be implemented as detailed in Refer-ence 3. Engines 1A and 1B In order to support the piping / tubing of component 02-717F, two-directional restraints should be added on the lube oil cooler drain lines (shell side) near the drain valves to prevent loosening of threaded connections to vessel during a seismic event. V REFERENCES

1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners Group," Report No. 11600.60-DC-02 Revision 0.

2. Stone & Webster Calculation number 11600.60-NP(B)-0301-XH.

3. Memo No. 6548 from C. Malovrh SWEC to J. Kammeyer/SWEC dated 11/29/84.

O PE3110/2

APPENDIX A Page Al of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Auxiliary Sub-Base and Oil and Water Piping - Lube Oil Supports and Mounting Hardware COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-717I TASK DESCRIPTION NO: DR-03-02-7171-1 SNPS GPL NO. 03-717K CLASSIFICATION TYPE s TASK DESCRIPTIONS Perform an engineering review of the small bo're piping / tubing supports to provide additional assurances that the component will perform its intended design function during normal operating and earthquake loading. PRIMARY FUNCTION Provide adequate restraint of the small bore piping / tubing system in the intended support load direction. ' ATTRIBUTE TO BE VERIFIED ) Structural adequacy of the small bore pipe / tube supports due to the effects of ) normal operating and earthquake loadings. ; l l SPECIFIED STANDARDS ASME Boiler and Pressure Vessel Code, Section III, 1971 Edition with all addenda. REFERENCES

   " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners Group," Report No.

1160.60-DC-02, Revision O. PE3020/1 1

                               -                                           COMPONENT DESIGN REVIEW CHECKLIST    Page A2 of 2 DR-03-02-7171-1 O              DOCUMENTATION REQUIRED
                 'Delaval design documentation (specificitions, calculations, drawings, etc.).

In lieu of information from Delaval, the following information is requirud: verified support sketches and piping isometrics, material specifications, pipe size and schedule, and operating parameters (pressure, temperature, load combinations). GROUP CHAIRPERSON w PROGRAM MANAGER SC\4%u VV % O 4 O PE3020/2 1 I

l l I Appendix B Page 81 of 3 03-02-717I 0 " COMPONENT QUALITY REVALIDATION CHECKLIST Aux. Sub. Base & 011 & Water Piping - Lube 011: Supports Cleveland Electric Illuminating Co. COMPONENT & Mounting Hardware UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-717I REV. NO. 3 SNPS GPL NO. 03-717K TASK DESCRIPTIONS Engine 1A ! 1. Assemble and review existing documentation. ,

2. Obtain sufficient data to support the design review effort. This may be accomplished by developing quality verified as-builts in dCCordance with Procedure DG-7, or by the Design Group performing a field walkdown.

Engine 1B i Same as Engine 1A ~ ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package

2. Information necessary for the design review effort Engine 18 Same as Engine 1A

F. COMPONENT QUALITY REVALIDATION CHECKLIST Page 82 of 3 ACCEPTANCE CRITERIA Engine 1A

1. Satisfactory Document Package

2. Review of detailed information by the Design Group Engine 18 Same as Engine 1A REFERENCES Engine 1A .

1. QCI No. 52

2. Procedure DG-7 Engine '.B Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A ,

1. Document Summary Sheet

2. Quality verified as-built isometric drawings for the supports and mounting hardware if available from the Owner.

Engine IB - Same as Engine 1 GROUP CHAIRPERSON , _. PROGRAM MANAGER MC \4ci.e-w O PE2783/2 l l I

COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 3 COMPONENT REVIEW Engine.1A

1. All EDGCTS site experience documents were assembled and reviewed with satisfactory results.

2. The Design Group will be responsible for closing out the as-built drawings as . per Procedure DG-7. The as-built drawings will be Quality verified by the appropriate site Quality organization. The performance of an engineering walkdown by the Design Group, precludes the issuance of a quality verified as-built drawing or sketch.

Engine 1B l Same as Engine 1A RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as O outlined above, is complete. The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of the final report. Engine 18 Same as Engine 1A i a n A/

l. GROUP CHAIRPERSON PROGRAM MANAGER X W o u.u '

l O l PE2783/3

                           ,_                                            ..      =

Appendix C Page C1 of 1 O V EDG COMPONENT TRACKING SYSTEM: PERRY SITE, NUCLEAR AND NON-NUCLEAR INDUSTRY EXPERIENCE SU W RY COMPONENT NO. 02-717I Effective Printout Date: 11/05/84 Auxiliary Sub-Base and Oil and Water Piping COMPONENT TYPE: Lube 011: Supports and Mountina Hardware REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS PERRY Reworked skid mounted NCR P039-1530 DR/QR reviews provide pipe supports to meet assurance that components ASME III Class 3 will perform their intended requirements. design functions during normal operating and earthquake loadings. Perry resolved this deficiency by reworking the supports. See NCR P039-1530. NUCLEAR 10CFR50.55E filed after Cleveland Electric DR/QR reviews provide inspection revealed 10CFR50.55E assurance that components ASME III Class NF DAR No. 117 will perform their intended code requirements design functions during were violated. normal operating and earthquake loadings. Perry resolved this deficiency by reworking the supports. See NCR P039-1530. NON-NUCLEAR None PE3110/1 4

     -- e

   .                         -                               -                   -  _=    _ .._

4 Page 1 of 1 COMPONENT QUALITY REVALIDATION CHECKLIST Misc.-Equipment-Heater, Cleveland Electric Illuminating Co. COMPONENT Lube 011 Sump Tank UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-820A REV. NO. 2 SNPS GPL NO. ~03-8008 1 TASK DESCRIPTIONS No further review of component 02-820A is required for the following-reasons: a) There is no pertinent industry experience in evidence, b) Component was reviewed on lead engine (Shoreham). The following recommendations, made in the Shoreham DR/QR report should be followed i by Cleveland Electric Illuminating Co. Preventive maintenance included in the TDI manual should be accom-O p11shed during the lube oil sump cleaning. Inspections scheduled at 18-month intervals should consist of the following. Measure heater insulation resistance and replace heater if degradation of insulation resistance is noted. Thoroughly clean heater element of coking and other depos-its and inspect for signs of deterioration. Check calibration and inspect condition of thermostat and recalibrate or replace thermostat when necessary. l GROUP CHAIRPERSON [4I4 - PROGRAM MANAGER M N O PE2617/1

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

t COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Before & After COMPONENT Lu5e 011 Pump UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-820B TASK DESCRIPTION NO. DR-03-02-8208-0 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 and site experience, except that already addressed in the lead engine report.
A review of the lead engine DR/QR report (Comanche Peak).
The before and after lube oil pump at Perry is the same a.s the component in the lead engine.

There re no maintenance items or modifications required based on the lead engine report. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required

                                   . SPECIFIED STANDARDS                                                                                                                                             .
                                   ' Not required PE3227/1
   ,-~           ww,,--, .,r. ,,n.--      y ,- , , - . , , , , , , . , , , , , , , . , , , , , , , , , , , , _ . , _ , , , ,,,..,.,,.,,,..w.,m                                               ,.,,,mw

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-8208-0 O REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CNAIRPERSON ) - PROGRAM MANAGER , M M , 7 l j ) l l l O PE3227/2 !' 'Ws'

__

Page 1 of 2 O

     \s_s/ .                                  COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Lube Oil Full Pressure COMPONENT Strainer                         UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-820C                TASK DESCRIPTION NO: DR-03-02-820C-0 SNPS GPL NO. 04-000                         CLASSIFICATION TYPE                 A TASK DESCRIPTIONS Design review for this cocponent 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 which was previously addressed in the lead reports. There was no site experience listed in the Component Tracking System.
A review of the lead engine DR/QR report (Comanche Peak).
Similarity of Perry anJ 1ead engine components. Both plants use Air

    'C                         Maze simplex strainers with 100% at 80 micron filtration.

The following maintenance recommendation from the lead engine DR/QR report should be implemented: The differential pressure should be checked during each engine operation and the strainer element should be cleaned / replaced at 15 psi, per TDI Manual, or at any significant increase in AP.

               -There are no modifications required for te.is component.

Quality revalidation-is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required

~ -)

PE3243/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-820C-0 SPECIFIED STANDARDS Not required ACCEPTANCE CRITERIA Not required REFERENCES Not required GROUP CHAIRPERSON e- - PROGRAM MANAGER 2CWw m Vr ca 4 0 4 O PE3243/2

Page 1 of 2 U COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Lube Oil System: Lube Oil COMPONENT Keepwarm Strainer UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-8200 TASK DESCRIPTION NO: DR-03-02-8200-0 SNPS GPL NO. 99-820B CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on review of the lead engine DR/QR report (Comanche Peak). There is no reported site or industry experience in the EDG Component Tracking System for this component. Keepwarm strainers at Comanche Peak and Perry are Air Maze Model No. 07EM23L which provide 80 micron filtration. Maintenance from the lead engine report is to check the strainer differential pressure daily and clean / replace the strainer element at 15 psid (per TDI Manual for Perry), which is acceptable from the viewpoint of strainer design. There are no modification recommendations for this component. , Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required i b PE3241/1

      }                                                                                  COMPONENT DESIGN REVIEW CHECKLIST                                                                     Page 2 of 2                     t DR-03-02-8200-0 ACCEPTANCE CRITERIA Not required l

REFERENCES Not required i GROUP CHAIRPERSON w- - PROGRAM MANAGER 2 C h - % o Uf { i 4 1 p 1 t O . l PE3241/2 ,i

m- - Page 1 of 2

J COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 l COMPONENT Oil Prelube Filter UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-820E TASK DESCRIPTION NO. DR-03-02-820E-1 ! SNPS GPL NO. 10-117 CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the following:

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

            .*     A review of the EDG Component Tracking System indicated that there was no significant applicable industry and site experience. Industry experience was addressed in the lead engine report. Site experience was limited to documentation problems.

Both plant's prelube filters are Commercial Filter Model p 18-494-P3-2-2.5-FG2K1, providing 10 micron filtration.

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

Filter should be replaced before manufacturer's recommended maximum of 30 psid. Perry's TDI maintenance manual specifies 15 psid, which is acceptable from viewpoint of filter design.

There are no modifications for this component based on the lead engine report. Quality Revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required O PE3291/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-820E-1 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER 2\4mh Q V' C.) O l l O PE3291/2

r Page 1 of 2 O V COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Full Flow Lube Oil Filte:- UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-820F TASK DESCRIPTION NO: DR-03-02-820F-0 SNPS GPL NO. 10-106 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 previously addressed in the lead engine DR/QR report. Site experience is limited to ASME documentation problems.
A review of the lead engine DR/QR report (Comanche Peak).
The Comanche Peak and Perry full flow lube oil filters are manufactured by Commercial Filter, Model No.18433-P9-3-6FG2K2 Os (10-micron) and are ASME III.

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

The TDI Instruction Manual specifies that the filter differential pressure will be checked monthly and the filter elemen6 cleaned or replaced at 15 psid. This is acceptable from the viewpoint of filter design.

There are no modification recommendations from the lead engine DR/QR report. Quality revalidation is not deemed necessary for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required O PE3242/1

j COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-820F-0 SPECIFIED STANDARDS Not required ACCEPTANCE CRITERIA Not required REFERENCES Not required

      -GROUP CHAIRPERSON            -
                                         - PROGRAM MANAGER 1\4a.e VH                                            U O

l l I i i lO PE3242/2

Page 1 of 2 d COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Lube Oil Heat Exchanger UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-820G TASK DESCRIPTION NO. DR-03-02-820G-0 SNPS GPL NO. 10-104 CLASSIFICATION TYPE B TASK OESCRIPTIONS Design review for this component is not required b .ed on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry experience, except that which was addressed in the lead engine report. Site experience was limited to documentation problems.
A review of the lead engine DR/QR report (Comanche Peak)

Both plants have lube oil coolers manufactured by Thermxchanger and p O are Model 1820, Type NSP, 1 Pass. The following preventive maintenance should be implemented: Remove exchanger channel covers and inspect tube sirie , during refueling outages, to assess the condition of the tubes and tube sheet for fouling corrosion and other symptoms of deterioration. + Replace gaskets and packing during reassembly at each outage.

Spectrochemical analysis of lube oil sanples should be performed approximately every three months to monitor the condition of the diesel engine.

No modifit ... to this component are required, based on the lead engine report. Quality Revalidation is not required for this component. bd PE3285/1

        . ~ . .        _-                    _

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-820G-0 PRIMARY FUNCTION Not required , E RIBUTE TO BE VERIFIED Not .equired SPEC'.FIEC STANDAF S Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON 1 _ PROGRAM MANAGEF. J R -2 _ G I' G i .i , I 1 9 PE3285/2

  ,             .              .                                         ..    -   -       -    =                                     . -                  . --

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Base and Bearing Caps - Base Assembly, Main Bearing Studs and Nuts, and COMPONENT Main Bearina Caps UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-305A.C.D TASK DESCRIPTION NO. DR-03-02-305A.C,0-0 i SNPS GPL NO. 03-305A.C.D CLA'SSIFICATION TYPE A TASK DESCRIPTIONS . Cesign review is not required for these components based on a review of the

                                  . applicable industry and site experience listed in the EDG Component Tracking System, and the lead engine DR/QR report -(Comanche Peak). The component parts at Perry are the same as those at Comanche Peak.

, The following maintenance items are recommended to ensure reliability of this component: 4

At each refueling outage, a visual inspection of the area adjacent to the

( - main bearing stud nut pockets of each bearing saddle should be conducted. 1 The inspection should be done several minutes after a thorough wipe down l of the surfaces. Good lighting should be used for this inspection. Any crack thus detected must be investigated further before the engine is allowed to return to service.

The mating surfaces of the base and cap should be thoroughly cleaned with solvent before any reassembly.

There are no modification recommendations for these components. The Quality inspections listed below are recommended to be performed:

Verify preload torque applied to the bearing cap stud nuts during engine

installation / maintenance. Torque values of nuts to be in compliance with j' TDI manual, engines IA and 18.

Perform a visual inspection of the No. 5 main bearing cap mating surface for

. evidence of fretting. Record all. evidence. of excessive wear (fretting, erosion, or corrosion) for engineering review. Perform this inspection on a single engine per station; if inspections are unsatisfactory,

;-                                                   increase inspection plan in accordance with TER.

PE2952/1

F 1 COMPONLNT DESIGN REVIEW CHECKLIST Page 2 of 2 TASK DESCRIPTIONS (continued)

Perform an LP inspection of base, No. 5 main bearing saddle area, as indicated on Perry Component Revalidation Checklist, Task Description No.

QR-03-02-305A. Perform this inspection on a single engine per station; if inspections are unsatisfactory, increase inspection plan in accordance i with TER. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED

   .Not required SPECIFIED STANDARDS Not required REFERENCES I

Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER 2C W~ G fr U O PE2952/2

t TDI OWNERS GROUP FOR f PERRY NUCLEAR POWER PLANT Base and Bearing Caps: Main Bearing Studs & Nuts COMPONENT PART NO.: 02-305C See Component Part No.: 02-305A I e e e O F e

                                                                                                                      ~9 J .m a - ..                        -

_ or _A

i i TDI OWNERS GROUP FOR PERRY NUCLEAR POWER PLANT l i Base and Bearing Caps: Main Bearing Caps COMPONENT PART NO.: 02-305D See Component Part No.: 02-305A I k i e I . 4 e i w , e 5 0 L j-b r l . l t l. l. l I f 4 a -h - -- A -h , , h. , { . __

TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 CRANKSWAFT COMPONENT PART NO. 02-310A I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for Perry Nuclear Power Plant requires Design and Quality Revalidation reviews to determine the adequacy of the crankshafts for their intended service at Perry. The primary function of the crankshaft is to convert reciprocating motion of the piston to rotary motion, and to transfer the resulting torque to the generator rotor. The manufacturer's part humber for the crankshafts at Perry is 02-310-08-AE. The forging and machining of the crankshaft for engine No. 75051 was performed by Ellwood City Forge Company, and the forging and machining of the crankshaft for engine No. 75052 was done

.               by National Forge Company.

II OBJECTIVE s The objective of this review was to evaluate the adequacy of the crankshafts for their intended use at Perry. i-III METHODOLOGY i ! The Emergency Diesel Generator Component Tracking System records were i- reviewed to determine the nuclear, non-nuclear, and Perry site experience i of the crankshafts. Perry pertinent literature specified on the Component Tracking System records was examined for information on the performance of the crankshafts (see Appendix C). The TDI Holzer calculations were reviewed by comparing the results with results obtained from the modal superposition analysis (Ref 1, 3). A modal superposition analysis of the crankshaft was performed. The pressure loading was obtained from the dynamic test at Shoreham Nuclear Power Station (Ref. 2). This analysis calculates the nominal shear stresses at each crank pin and main journal location. The stress levels in the main journal oil holes were compared with the ! endurance limit. L The Component Quality .Ravalidation Checklist was reviewed for acceptability. lO PE3236/1 l L

Page 2 'of 3 IV RESULTS AND CONCLUSIONS The TDI Holzer calculations were found to be accurate. The torsiograph test has not been conducted to date. The results of the torsiograph test need to be compared with the TDI Holzer calculations and the vibrational analysis when avaiable. The modal superposition analysis determined the maximum amplitude of nominal stress to be 5335 psi between cylinder numbers 5 and 6 for a load at 7000 kW (Ref 3). The nominal stresses were found to satisfy the requirements of DEMA, and are less than 5000 psi for a single order, and less than 7000 psi for combined orders (Ref. 4). The material certification reports for the crankshafts at Perry indicate that the tensile strengths for the crankshaft material in Engine Serial Nos. 75051, 75052, 75053, and 75054 are within the original design specifications (Refs. 5, 6 and 7). The factor of safety against fatigue failure in the main journal oil holes was found to be 1,42 based on a minimum ultimate tensile streogth of 90 ksi for Engine Serial No. 75052 (Ref. 3). There are no TERs associated with this component. The Perry Component Quality Revalidation Checklist has been reviewed in preparation of this report. Since no documents are in evidence that fulfill these requirements, is recommended that the Quality O it Revalidation Inspections listed in Appendix B be performed. Based on the above review, it is concluded that the crankshafts in Engine Serial Nos. 75051 and 75052 are acceptable for their intended function at Perry provided that a torsiograph test verifies that the actual level of stress does not exceed that calculated and that crankshaft inspections j verify that the vital areas are free of unacceptable flaws. ! V REFERENCES i ! 1. Yang, Roland, "The Cleveland Electric Illuminating Co., Perry Nuclear Power Plant No. 1 & 2, 7000 kW, 9734 HP 9 450 RPM, Delaval Enterprise DSRV 16-4, 225 BMEP, Engine No. 75051/54," Transamerica Delaval Inc. , Engine and Compressor Division, ' Oakland, California.

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

3. FAA support package SP-84-6-10(1).

4. Standard Practices for Low and Medium Speed Stationary Diesel and Gas Engines, Diesel Engine Manufacturers Association, 6th ed., 1972.

5. " Report on Castings or Forgings," Report No. 77-PH36072-646 for engine S/N 75051 and Report No. 77-PH36140-646 for engine S/N 75053, American Bureau of Shipping, Pittsburgh, Pennsylvania.

PE3236/2 t

Page 3 of 3 l

                                                            - 6. Material Certification Reports 0-07413' of heat number 12-6309 for engine S/N 75052, National Forge Company.

7. Test Report dated 10/6/77 of heat number 73605-3 for engine S/N 75054, Ellwood City Forge Corporation, Ellwood City, Pennsylvanis.

i b I O O ,,,,,,,, l i

    - e ,. . . , , . ~ . - , . ,__.... __. ,._ ,, ___. . , ,                       _ _ _ _ _ , . . - . _ _ . . . . . _ . . . . . _ _ . _ _ _ , . - _ _ _ _ . . - - . . . _ . .       . _ . _ . _ _ _ . _

l APPENDIX A Page Al of 2

   /
   'g                                                      COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT      Crankshaft                                                UTILITY Cleveland Electric Illuminating Co.

GROUP PARTS LIST NO. 02-310A TASK DESCRIPTION NO. DR-03-02-310A-0 SNPS GPL NO. 03-310A CLASSIFICATION TYPE A TASK DESCRIPTIONS Review of Perry site, nuclear and non-nuclear experience. Review of TDI Holzer calculations and torstograph tests. Perform modal superposition of the crankshaft. Compare stress levels at the oil holes with the endurance limit. Review Quality Reva11dation Checklist for acceptability. Review information provided on TERs. PRIMARY FUNCTION The crankshaft converts reciprocating motion, component inertial forces, and gas pressure piston forces to rotary motion and torque at the output flange. ATTRIB'JTE TO BE VERIFIED Sufficient strength, stiffness, frequency characteristics: material properties, surface finish, and bearing characteristics for EDG service. SPECIFIED STANDARDS Standard Practices for Low and Medium Speed Stationary Diesel and Gas Engines, Diesel Engine Manufacturer's Association; 6th ed. ,1972. l l l REFERENCES None ! PE2780/1

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

COMPONENT DESIGN REVIEW CHECKLIST Page A2 of 2 DOCUMENTATION REQUIRED TDI drawings, test reports, experimental pressure vs. tire curves, Holzer calculations for OSRV-16-4 engine. GROUP CHAIRPERSON _oROGRAM MANAGER M \4 w , _ () (/ O O l O PE2780/2

       -ow--,-oww -- - -w-ww- - , _ . , - , . , _ . _

Appendix B Page 81 of 4 COMP 0NENT QUALITY REVALIDATION CHECKLIST Crankshaft & Bearings - Cleveland Electric Illuminating Co. COMPONENT Crankshaft & Turning Gear UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-310A REV. NO. 2 SNPS GPL NO. 03-310A TASK DESCRIPTIONS Engine 1A

1. Assemble and review existing documentation.

2. Perform a visual inspection of all cran ~kpin and main journal surfaces for signs of scoring, wear or damage. Document with photographs.

3. Perform an Eddy Current test on the main journal oil holes Nos. 4, 6 and 8. If inspection is unsatisfactory perform an Eddy Current test on the remaining main journal oil holes and'on all crankpin journal oil holes.

4. Perform'a torsiograph on the crankshaft.

Engine IB

1. Assemble and review existing documentation.

2. Perform a visual inspection of all crankpin and main journal surfaces for signs of scoring, waar or damage. Document with photographs.

3. Perform an Eddy Current test on the main journal oil holes Nos. 4, 6 and 8. If inspection is unsatisfactory perform an Eddy Current test on the remaining main journal oil holes and on all crankpin journal oil holes.

ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package 2-3. Surface integrity of crankpin journals . i

4. Stress on the crankshaft.

O PE2665/1

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 4 ATTRIBUTES TO BE VERIFIED (continued)

       'Enaine IB

1. Quality status of. Component Document Package

2. Surface integrity of crankpin journals.

3. Surface integrity of main journals.

ACCEPTANCE CRITERIA Engine 1A

1. Satisfactory Document Package

2. Review of inspection report by the Design Group

3. See Attachment A

4. Review of inspection report by the Design Group Enaine IB

1. Satisfactory Document Package

2. Review of inspection report by the Design Group

3. See Attachment A REFERENCES Enaine 1A

1. QCI No. 52

2. Approved Site NDE Procedures

3. Approved Site NOE Procedures, TER# 99-015

4. Approved Site NDE Procedures Enaine IB

1. QCI No. 52

2. Approved Site hDE Procedures I 3. Approved Site NDE Procedures,.TER# 99-015 PE2665/2

COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 o'f 4 03-02-310A DOCUMENTATION REQUIRED Engine 1A

1. Document Summary Sheet 2-4. Inspection Report Engine 18 Same as Engine GROUP CHAIRPERSON -

PROGRAM MANAGER M W u. - w h A O COMPONENT REVIEW Engine 1A

1. No EDGCTS site experience documents are in evidence.

2-4. No inspection reports have been received which fulfills these requirements. Engine 18

1. No EDGCTS site experience documents are in evidence.

2-3. No inspection reports have been received which fulfill these requirements. RESULTS AND CONCLUSION Engine 1A

 ,       The Quality Revalidation effort with respect to this component, as out-lined above, is complete. The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of the final report.                                               .

Engine 18 Same as Engine 1A GROUP CHAIRPERSON / d[k N

PROGRAM MANAGER g Ka...x.- t %

PE2665/3

Attachment A- COMPONENT QUALITY REVALIDATION CHECKLIST Page B4 of 4 03-02-310A Main Journal Oil Hole Inspections for DSRV-16-4 Crankshafts Depth of Notch" (units) Journal Location 0" to 1" from 1" to 2" from 2" to 3" from Journal Surface Journal Surface Journal Surface Front End No inspection No inspection No inspection i Between Cylinders 1 and 2 40 No inspection No inspection Between Cylinders 2 and 3 30 40 No inspection Between Cylinders 3 and 4+ 10 15 20 Between cylinders 4 and 5 10 15 30 Between Cylinders 5 and 6+ 10 15 20 -

         'Between Cylinders 6 and 7                                 10                                        15                                     30 Between Cylinders 7 and 8+                                10                                        15                                     20 Flywheel End                                15                                        20                                     40 TA8LE 2

! Crankpin Oil Hole Inspections for DSRV-16-4 Crankshafts L Depth of Notch" (mils) Crankpin Location 0" to 1" from 1" to 2" from 2" to 3" from Journal Surface Journal Surface Journal Surface Cylinder 1 No inspection No inspection No inspection

Cylinder 2 No inspection No inspection No inspection Cylinder 3 -

20 30 40 Cylinder 4 20 30 40

Cylinder 5 20 30 40 l Cylinder 6 20 30 40

                       . Cylinder 7                                 20                                        30                                    40 Cylinder 8                                  20                                        30                                    40
          " Width of notch is twice the depth.
          + Initial inspection'- only inspect remaining locations if initial inspection is unsatisfactory.

O PE2665/4 i i

    ,.~_    -,     .._              , _ . _ . _ . _ _ .                ......_..___,._..__.--m_,_,.                     - . , . _ , _ , , _ , , - _ , - _ . . . . . , _ . . . _ _ . .

! Page C1 of 4 EDG COMPONENT TRACKING SYSTEM: PERRY SITE NUCLEAR 2 AND NON-NUCLEAR INDUSTRY EXPERIENCE SUP94ARY COMP 0NENT N0. 02-310A l Effective Printout Date: 11/30/84 COMPONENT TYPE: Crankshaft REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS PERRY

                .           None NUCLEAR While feeding steam                        LER, Trojan;                                   Failure of a different generators with the                        344-7700, 770324                               design crankshaft.

diesel driven auxiliary Crankshaft at Perry feed pump, the diesel is adequately designed. tripped on low lube oil pressure. Steam generator l 1evel was maintained by b d using the steam driven auxiliary feed pump. The diesel failure was due to a broken crankshaft. Inspection-of the engine did not reveal a cause for the failure. A metallurgi-cal analysis of the crank-shaft is being conducted. , Manufacturer: Electro-Motive i Div. of GM. During performance of EPRI TMI 2, Not a crankshaft failure. surveillance procedures, 052078, DG-28 2303-N16 " Emergency Diesel Generator and Cooling Water Valve Operability Test," the "B" diesel generator failed to start. The redt... dant emergency diesel generator was oper-able. Cause was attributed to improper material-in vertical shaft between upper and lower crankshaft. Manufacturer: Fairbanks-Morse PE3236/1

1 l l Page C2 of 4 , REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS A Delaval diesel generator I&E Shoreham Problem associated with at Shoreham fractured its notice 83-58, inadequate design. crankshaft at the crankpin 08/30/83 Perry crankpins

 .. and crankarm. Examination                             are adequately designed.

of 2 other diesels showed cracks on the crankshaft and crankpin bearing failure. Manufacturer: TDI Cylinder No. 4 had exces- 10CFR50.55E MP&L Problem not related to sive threading (grooved Grand Gulf 12/10/81, design. radially) on the crank- 04/15/82. shaft bearing. The crank-pin was discolored and the cylinder liner was grooved in 3 places: 10 inches long by 1/16 inch deep. ' Manufacturer: TDI. Info procedure to measure TDI SIM 283 No impact on adequacy of crankshaft thrust clear- crankshafts. ance. ~ Manufacturer: TDI. O' Crankshaft overall lengths TDI Letter to LILCO No impact on adequacy of have increased and there- 01/10/84 S/N 74010/12 crankshafts, fore require a modified to Mike Herlihy (LILCO) inspection cover. Instal-lation is prevented be-caused of interference with the lube oil strainer. Interference may be eliminated by effecting reduction in the length of the cover by reducing the flange thickness and facing the end plate from 11/16-inch to %-inch thickness. Info-instructions for TDI SIM 141 No impact on adequacy of flushing lube oil header. crankshafts. O PE3236/2 s

n Page C3 of 4 O EXPERIENCE REFERENCE DOCUMENTS PERRY STATUS NON-NUCLEAR Crankshaft oil way plugs Titan Navigation, Per phone conversation cracking from the use Inc., Letter dated with site personnel, oil of improper gauge of July 22, 1982 hole plugs at Perry material issued for use thicker gauge material. plugs. (M/V Pride of Texas) Experienced engine vibra- Hunton & Williams Not applicable since tion at crankshaft due to (12/29/83) to C. engines at Perry do vibration damper coupling Seaman. Letter from not have vibration dampers. failure. M. Zbinden (M/V Columbia) (State of Alaska) to D. Martini (TDI) dated 03/19/79. Letter from M. Zbinden to W. Hudson dated 02/02/79. Currently checking the Hunton & Williams Insufficient information cause of excessive main (12/29/83) to C. Seaman. in reference document for engine crankshaft dis- Memo from M. Zbinden evaluation. tortion. (State of Alaska) (M/V Columbia) to R. Ward dated 12/10/80. l During normal operation Failure Analysis Report Resulted from inadequate l , engine experienced a low No. 0135 12/10/80 repair following failure of i lube oil pressure alarm. (File T-39). Memo TDI another component. l Engine was shut down for H. Schilling 12/15/80 to inspection and two cracks G.E. Trussell (File T-1). were found at the No. 5 Memo TDI H. Schilling crank pin. 12/14/80 to G.E. Trussell (File T-1). Crankshaft failed at No. Failure Analysis Report 0otapplicablesincethis 6 main bearing journal. No. 0124 dated 12/11/79 engine had a 4th order Indications started at (File T-16). critical at operating speed, discontinuity that is and Perry does not. located about 3/4-inch l from oil hole opening. Failure was caused by fatigue. i O PE3236/3

Page C4 of 4 REFERENCE - PERRY EXPERIENCE DOCUMENTS STATUS A bend is suspected on Telex from Bailey No indication of a bent I the crankshaft and the (TDI) to Delaval crankshaft at Perry. shaft consequently does HQ. (File T-33). not have the r9 quired Enclosure 2 to support from each bear- SWEC letter dated ing, the risk of cracking 04/29/81 by G. is prevalent because of Sandstrom (File T-36). fatigue stressing during ; operation and load vari-ations. Broken crankshaft and Letter from Village of Resulted from failure of ; further extensive damage Rockville Centre to another component, to the engine. City of Smith & Gillespie St. Cloud, Fla. Eng. Inc. 11/09/81 Eng. DG-SRV-16-4 ,~ Unit No. 7 City of St. Cloud - (File T-63). The' original crankshaft Sales order No. W-25354 No indication of a bent was bent during the 07/13/81. Rafha Electric crankshaft at Perry , overspeed. Co. Eng. No. 79003.

O Model DSR-r48 l- (File T-57) i Repaired crankshaft No. 2 Telex from C. Just Not relevant to design ' crankpin journal was to Pratt (TDI) considerations at Perry. reduced in diameter by 07/27/83 i 0.273 thousandths of an ; inch. i l l 1

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

r l Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Main Bearinas UTILITY Cleveland Electric Illuminatina Company CROUP PARTS LIST NO. 02-3108 TASK DESCRIPTION NO. DR-03-02-3108-0 SNPS GPL NO. 03-3108 CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is noi required based on the following:

The DR/QR report for the lead engine at Comanche Peak included analysis of the main bearing shells and determined that they were acceptable for their intended application with a margin of safety suitable for small variations in loading and oil film pressures.
The diesel engines at Perry and Comanche Peak use identical bearing shells (TDI Part Numbers R-3313, R-3315 and R-3317). The engine operating parameters, main engine components, and Icads at Perry are similar to those at Comanche Peak.

A review of the nuclear and non-nuclear experiences listed in the EDG Component Tracking System reports several diesels were found with overheated and scored bearirgs. These problems were caused by abnormal operating conditions involving contaminated oil or loss of lubrication, and not because of the bearing design. Because of the low operating hours on the engines, it is recommended that at the first refueling outage the main bearings be irspected for evidence of misalignment. If harmful misalignment is discovered, corrective procedures should be implemented. There are no modification recommendations for this component. The following quality inspections should be performed to assure component quality:

Perform a dimensional check of the bearing shell to verify thickness is within TDI specifications.
After 100 hours run or preoperation testing, perform a visual or liquid penetrant inspection of the main bearing shells for signs of scoring, galling or cracking. Minimum sample to be the #5 main bearing shell.

O PE2918/1 l L

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-3108-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required . SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON

                                      - - PROGRAM MANAGER ,MMa.M ur                                      u O PE2918/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Crankshaft & Bearings: COMPONENT Thrust Bearina Rino UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-310C TASK OESCRIPTION NO. DR-03-02-310C-0 SNPS GPL NO. 03-310C CLASSIFICATION TYPE A l TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the Comanche Peak and Shoreham DR/QR reports which establish the acceptability of the thrust bearing ring assembly for its intended purpose.
The applicable engine dimensions and operating parameters at Perry are identical or very similar to those for the same component at Comanche Peak (lead engine).
A review of the EDG Component Tracking System indicated that there '

was no site experience and no significant applicable nuclear or non-nuclear industry experience. Maintenance recommendations based on the Comanche Peak DR/QR report to ensure proper performance under normal operating conditions are as follows:

Measure thrust bearing ring clearance via " bump check" method to be performed in conjunction with crankshaft web deflection measuraments at every outage. If the clearance is greater than the maximum allowed in the TDI Instruction Manual, then at least one bearing must be replaced. Bearings should also be replaced if. they are cracked or gouged.
Visually inspect thrust bearing ring for signs of cracks, gouges, wear or degradation at alternate outages.

There are no modification recommendations for this component. , No Quality Revalidation is required for this component. O PE2920/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-310C-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON e PROGRAM MANAGER M Ko., w h (./(/ U O PE2920/2

m Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Crankcase: Crankcase Assembly UTILITY C_]p eland Electric Illuminating GROUP PARTS LIST NO. 02-311A TASK DESCRIPTION NO: DR-03-02-311A-0 SNPS GPL NO. 99-311A CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review of this component is not required based on the review of the lead engine DR/QR report (Cor::anche Peak) and the applicable industry experience. There is no reported site experience in the EDG Component Tracking System for this component. The crankcase at Perry is the same part number as the one used at Comanche Peak (TDI P/N 02-311-03-AL), which is considered acceptable for its intended service. The maintenance recommendation for this component is as follows: f-

Perform a visual examination of the vertical crankcase arch wall d and the crankcase-to-base nut pocket area. This inspection dould be performed during each .efueling outage. The first inspection which occurs after 185 hours, at or near full load, can be used to justify the discontinuation of future inspections.

There are no modification recommendations for this component. The following Quality inspection should be performed on all station engines:

Perform a visual examination of the vertical crankcase arch wall and crankcase-to-base nut pocket area for machined surfaces with sharp corners. Crankcase vertical arch wall should be as-cast surface.

Nut pocket shall be free of cracks. \- PRIMARY FUNCTION Not re' quired , ATTRIBUTE TO BE VERIFIED l l Not required PE3018/1 i

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 O SPECIFIED STANDARDS DR-03-02-311A-0 Not required REFERENCES Not required GROUP CHAIRPERSON -- PRG0 RAM MANAGER 2C Ma,ws , yr o _, O O PE3018/2

Page 1 of 1 l COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 l Crankcase: Crankcase COMPONENT Mountina Hardware UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-311D TASK DESCRIPTION NO. DR-03-02-3110-0 SNPS GPL NO. 99-311C CLASSIFICATION TYPE A_ TASK DESCRIPTIONS . Design review is not required for this component based on review of the Cossache Peak DR/QR report (the crankcase mounting hardware used at Perry is identical to that used at Comanche Peak), and the fact that there is no applicable site or industry experience in the EDG Component Tracking System. There are no maintenance or modification recommendations for this component. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required . GROUP CHAIRPERSON = 9ROGRAM MANAGER ,3CWe%mm PE2954/1 ~_

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Crankcase: Crankcase Gaskets COMPONENT and Mountina Hardware UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-386B TASK DESCRIPTION NO. DR-03-02-3868-0 SNPS GPL NO. 99-3868 CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak) and the applicable site and industry experience. A review of site and industry experience indicates that there have been some instances of bolting failures caused by undertorquing, which resulted in fatigue failures, or overtorquing, which resulted in shear failures. These failures are not attributed to design deficiencies of this component. The recommended torque. values are appropriate, and the specified bolting and stud materials (SAE GR 5 and SAE GR 1120, respectively) are acceptable for their intended function of holding the covers onto the crankcase. Isolated failures can occur when the O torque is not applied properly or a lesser grade material is substituted. Barring any deviations as mentioned above, the bolting is acceptable for use on the diesel engines. There are no modification or maintenance reccomendations for this component. The following Quality inspection should be performed on all engines:

Review the existing documentation or physically verify that the bolt torques are in accordance with the 1DI manual.
Verify that no cracking exists, at the bolt holes of covers.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required Pf3148/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON e- % PROGRAM MANAGER d MN V j V' O d PE31'48/2

TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 CYLINDER BLOCK COMPONENT PART NO. 02-315A l I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of the cylinder blocks to determine the adequacy of design for the intended i use at Perry. 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 OBJECTIVE The objective of this review was to evaluate the structural adequacy of the cylinder block for its intended use at Perry Nuclear Power Plant. III METHODOLOGY In order to meet the stated objective, the following methods were used:

Review of engine operating conditions at Perry and identification of l 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 stiff-ness'in key portions for the cylinder block.

l s Evaluation of crack growth rate for cylinder block landing and counterbore diameter by comparison with conservative Shoreham data and analysis.

Review of liquid penetrant inspections of Perry DSRV-16-41A and IB engine blocks.
Review of metallurgical / microstructure analysis of cylinder block material.
Review of Perry site, nuclear and non-nuclear experiences (see Appendix C).
Review of Quality Revalidation Checklist results for acceptability.

PE3237/1 t

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

Page 2 of 3 IV RESULTS AND CONCLUSIONS Diesel generators 1A and IB have had limited operational experience. Engine hours of operation accumulated to date consist of factory test hours performed by TDI. The engine operating conditions at Perry were compared to those at Comanche Peak and Shoreham. No significant differences were found that would affect the structural integrity assessment of the Perry blocks. It is recommended that cylinder liner bore and mating block dimensions be checked in order to evaluate the interaction of the block and cylinder liner. For the purpose of analyzing the steady state and alternating stresses present, the cylinder liner / bore interaction is assumed to be similar to that present at Shoreham. This assumption must be ver*fied for Engines 1A and 18. These results were utilized in the cumulative damage analysis. The cumulative damage algorithm is explained in Reference 2. Evaluation of steady state stresses, alternating stresses and stiffness in key portions of the cylinder block was accomplished as part of the strain gage testing at Shoreham and the results were included in the cumulative damage and crack growth analyses (Ref. 2). The power output for this engine is 7000 kW at 100 percent load. Maximum output required for LOOP /LOCA is 4460 kW (Ref. 3). The duration of a LOOP /LOCA used in this analysis is 168 hours. Strain gage testing of the original Shoreham' EDG 103 block, inspection data from before and after testing, and materials testing were used as a basis to predict adequate life for cylinder blocks. The apparent rate of , propagation of cracks between stud holes in the original Shoreham EDG 103

when compared with the Perry LOOP /LOCA requirements, indicates
that even if the Perry blocks had ligament cracks they are predicted to withstand with sufficient margin a LOOP /LOCA event (Ref. 2) provided that block material is shown to be characteristic of typical Class 40 grey cast iron.

To .date, no inspection results for Engine 1A and IB block- tops have been reported. It is required that, prior to placing the engines in emergency standby service, the visual and NDE examinations consistent with those identified in Appendix B be performed on Engines 1A and 1B to determine whether or not block top cracks are present. Further, it is recommended that a material microstructure evaluation be performed on all engine blocks at Perry, to verify that the block material is characteristic of typical Class 40 grey iron. Without satisfactory material verification, there is no analytical basis for continued engine operation. Increased operational time between inspections can be justified with demonstration of block material f characteristics as typical Class 40 grey cast iron. PE3237/2

F Page 3 of 3 0'

 ,       Application of the cumulative damage algorithm (Ref. 2) shows that the Perry engines, with Class 40 grey cast iron. material blocks, cauld perform 260 hours at 100 percent load (or operation resulting in equivalent cumulative damage), without inspection, with sufficient margin for a LOOP /LOCA event. Subsequent time periods of operation can be justified after reinspection of the block top for detectable ligament, stud-to-stud and stud-to-end cracks. If none are found, then engine operation may be performed until the future cumulative damage equals the total cumulative damage accrued to the last inspection, minus 3 times the damage postulated during a LOOP /LOCA. This process may be repeated indefinitely throughout the life of the engines.

, The above recommendations are a direct application of the cumulative damage algorithm and are described in Reference 1, Figure 5-1. There are no TERs associated with this component. 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, subsequent completion and review of block top inspections, block material evaluations and cylinder liner / block bore dimensional check as identified in Appendix B for Engines 1A and 18, and implementation of routine inspections, it is concluded that the cylinder blocks are acceptable for their intended use at Perry. IV REFERENCES

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

2. FaAA Support Package Number SP-84-6-12(1).

3. Latter from E. C. Christiansen (Perry Nuclear Power Plant) to C. L.

Ray, Jr. (TDI Owners Group), dated 7/23/84. e e O' PE3237/3

i APPENDIX A Page Al of 2 COMPONENT DESIGN REVIEW CHECKLIST N PERRY NUCLEAR POWER PLANT - UNIT 1 Cylinder Block-Liners and Water Manifold: COMPONENT Cylinder Block UTILITY Cleveland Electric Illuminatina Co. GROUP PARTS LIST NO. 02-315A TASK DESCRIPTION NO. DR-03-02-315A-0 SNPS GPL NO. 03-315A CLASSIFICATION TYPE A TASK DESCRIPTIONS Review liquid penetrant inspections of Perry DSRV-16-4 engine block tnps and review engine operating experience. Review engine operating conditions of Perry and identify any differences from those at Comanche Peak. Perform dimensional check on cylinder block and cylinder liners and evaluate liner / block interaction. j Evaluate steady state stresses, alternating stresses and stiffness in key l portions of the cylinder block. l Evaluate crack growth rate for cylinder block landing and counterbore diameter by comparison with conservative Shoreham data and analysis. Review metallurgical / microstructural analysis of cylinder block top material. ! Review of Perry site, nuclear and non-nuclear experiences (see Appendix C). Review of Quality Revalidation Checklist results for acceptability. Review information provided on TERs. PRIMARY FUNCTION l To provide framework for engine components and to provide cooling water passages. A PE2781/1 l l l

COMPONENT DESIGN REVIEW CHECKLIST Page A2 of 2 ATTRIBUTE TO BE VERIFIED That components have sufficient strength and stiffness to react major loads. SPECIFIED STANDARDS None, l REFERENCES None. DOCUMENTATION REQUIRED Manufacturer's drawings for DSR-48 and RV bic ks, liners and studs, including all specifications for material, torques, valve train loads and gas cycles. Engine operating history (time vs. load) for operation prior to block top inspection, and for total engine hours. Anticipated engine operating profile (time vs. load) for fuel cycle, including pre-operational, qualification, and surveillance testing. Engine factory test logs that report firing pressures and exhaust temperatures for each cylinder. i GROUP CHAIRPERSON -- PROGRAM MANAGER MC__Wmw-me_ U ' O l l , O' PE2781/2 i . . _ .-. _

Appendix B Page B1 of 6 03-02-315A 0 COMPONENT QUALITY REVALIDATION CHECKLIST Cleveland Electric Illuminating Co. COMPONENT Cylinder Block UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-315A REV. NO. 2 SNPS GPL NO. 03-315A TASK DESCRIPTIONS Engine 1A

1. Assemble and review existing documentation.

2. Perform a dimensional check on the area around the cylinder liner for all cylinder block liner landings.

3. Perform a Liquid Penetrant test or Magnetic Particle test on the cylinder block liner landing along the top landing surface, fillet radius, and vertical face adjacent to the landing surface. Liner 1andings 3L, 4L, SL, 6L and 3R, 4R, SR, ER should be inspected with the liners removed. If linear indications are found, increase inspection plan to all liner landings.

4 Perform a Liquid Penetrant test or Magnetic Particle test on the cylinder head mating surface on top of the cylinder block. The area netween stud . hole and liner, and between adjacent cylinder stud hole should be inspected.- The inspection plan should include cylinders : 3L, 4L, SL, 6L . and 3R, 4R, SR and 6R. If linear indications are found, increase inspection plan to all cylinders. i

5. Perform an Eddy Current test on the cylinder head stud holes if ,

required (i.e. linear indications found at stud hole extending into ' threads).

6. Remove a sample from each cylinder block by drilling and cutting. i The samples shall be tetrahedral in shape with a one inch square base and a height of 5/8 inch. Attachment B shows the locations where the samples should be taken.

O PE2634/1'

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 6 TASK DESCRIPTIONS (continued) Engine IB Same as Engine 1A ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package

2. Dimensions of the cylinder block liner landing area 3-5. Surface integrity of the cylinder block liner ~ landing

6. Samples are taken from the cylinder . block in accordance with TER

                #99-016.

Engine 1B Same as Engine 1A O ACCEPTANCE CRITERIA Engine 1A

1. Satisfaccory Document Package

, 2. Review of inspection report by Design Group , 3-4. See Attachment A 5-6. Review of inspection report by the Design Group i Engine 18 i Same as Engine 1A 4 1 O PE2634/2

COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 6 l REFERENCES , I Engine 1A ;

1. QCI No. 52

2. Anc~cved Site NDE Procedures 3-4. TER#s 99-004, 99-018, 99-036

5. FaAA Procedure NDE 11.8

6. TER #99-016, 99-031 Enaine 18 Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A g 1. Document Su. mary Sheet .

2-6. Inspection Report l Engine IB Same as Engine 1A GR0!!P CHAIRPERSON A _ PROGRAM MANAGER 1 W w u % A w U COMPONENT REVIEW Engine 1A

1. No EDGCTS site experie..ce documents are in evidence.

O PE2634/3

COMPONENT QUALITY REVALIDATION CHECKLIST Page B4 of 6 m 03-02-315A l COMPONENT REVIEW (continued) Engine 1A (continued) 2-6. No inspection reports have been received which fulfill these require ments. Engine IB Same as Engine 1A RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as out-lined above, is complete. The results have been fnrwarded to the Design Review Group for their evaluation and conclusions in suppcrt of the final report. Enaine 1B Same as Engine 1A GROUP CHAIRPERSON d M. St/t/C PROGRAM MANAGER . 1 W e d A y l l l a O PE2634/4

Attachment A Page B5 of,6 03-02-315A ( COMPONENT QUALITY REVALIDATION CHECKLIST ACCEPTABLE CRITERIA A) Area to be inspected

1. Top of Block

2. Liner counterbore B) Reference Standard ASTM E125 C) Evaluation of indications

1. Relevant indications are:

a) Hot tears and cracks, linear indications that exceed ASTM E125 Class I-2 b) Shrink that exceeds ASTM E125 Class II-3 c) Inclusions that exceed ASTM E125 Class III-3 d) Porosity that exceeds ASTM E125 Class V-1

2. All indications exceeding the specification listed above shall be' documented and submitted to the Design Group.

3. Indications that do not exceed the ASTM E125 reference regardless of size and quantity are acceptable.

D) Non Relevant Indication

1. The indications referenced below shall be considered non relevant.

a) Magnetic writing b) Linear grain boundaries (carbon, ferrite, or graphite induced) c) Rounded grain boundaries (carbon, ferrite, or graphite induced) C ( G PE2634/5 L

m t Attachment B COMPONENT OUALITY REVALIDATION CHECKLIST p\. . z page B6 of 6 03-02-315A

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Appendix C Page C1 of 7 EDG COMPONENT TRACKING SYSTEM: PERRY SITE, NUCLEAR AND NON-NUCLEAR INDUSTRY EXPERIENCE SumARY COMPONENT NO. 02-315A Effective Printout Date 10/15/84 COMPONENT TYPE: Cylinder Block REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS PERRY None NUCLEAR Cylinder block repair SIM 247 Inspection of block tops for corrosion. . at intervals governed by inspection results and accumulated operation will confirm block reli-ability at Perry. s Gasket groove of 7R Service Report TPC Inspection of blo d cylinder was cracked. Nuclear Plant No. 3 tops at intervals [v} Maanshan Dec. 9, 1983 governed by inspection (File No. T-45) results and accumulated operation will confirm block reliability at Perry. NON-NUCLEAR The forward outboard Letter 04/21/83 No impact on Perry. cylinder block of the J. Blain to W. Busch; Reference intercooler report. starboard main engine Complaint C.A. No. of the vessel cracked H-83-2420 filed l from the entry of U.S. District Ct. l water from the cooling 52, p.4.; U.S. 1 system into the air Salv. Assoc. Rpt. intake system of 52-15573, 07/01/82; the engine. Amer. Bur. Ship. Rpt. HA-81-2539, 12/16/31; Salv. Assoc. Rpt. CH0830, 04/01/82. PE3237/1

Appendix C Page C2 of 7

REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS Block cylinder bores Hunton & Williams to Inspection of block tops were found egg shaped. C. Seaman 12/29/83; at intervals governed by Memo M. Zbinden to inspection results and R. Ward 01/16/81 accumulated operation will confirm block reliability at Perry. Extensive cracking of Hunton & Williams to Inspection of block tops cylinder block. C. Seaman 12/29/83; at intervals governed by Memo M. Zbinden to inspection results and R. Ward 03/13/81 accumulated operation will confirm block reliability at Perry. Final cam tappet Hunton & Williams to No impact on Perry. could not be placed C. Seaman 12/29/83; Isolated initial assembly into position because of M. Zbinden to File problem. deficient cylinder 04/29/81 block. Cylinder blocks ordered Hunton & Williams to Inspection of block tops because previous ones C. Seaman 12/29/83; at intervals governed by fretted, distorted, M. Zbinden to File inspection results and O and cracked. Head 04/09/81; M. Zbinden accumulated operation b stud holes not machined to R. Ward 03/13/81 will confirm block + properly per TDI's spec. reliability at Perry. TDI blocks on mala- Hunton & Williams to No impact on Perry. spiner class vessels C. Seaman 12/29/83; are structurally M. Zbinden to R. stronger although Lind 06/17/81 rated less than half of Columbia's HP. Allegations made that Hunton & Williams to Inspection of block tops at cylinder block has C. Seaman 12/29/S3; intervals governed by experienced creep and G. Trussell to D. inspection results and cylinder block is Thompson 10/27/81 accumulated operation heated during operation will confirm block in the center and room reliability at Perry, temperature at the ends. Engine derating will SES Report 123-01, Inspeck.ionofblocktopsat lessen thermal stresses pp. 4-6, 4-7 intervals governed by of cylinder block. inspection results and accumulated operation will confirm block reliability at Perry. O PE3237/2

Appendix C Page C3 of 7 REFERENCE - PERRY EXPERIENCE DOCUMENTS STATUS Observed deformation of SES Report 123-01, Inspection of block tops at cylinder liner block. 04/83, pp. 3-14, intervals governed by Counterbore lip of 3-28, 6-3 inspection results and cylinder block observed accumulated operation to have circumferential will confirm block cracking. reliability at Parry. Deformation of counter- Engine Rebuild Inspection of block tops at bore lip of cylinder Report for Alaska intervals governed by liner block caused 03/31/81, pp. I, inspection results and by metallic fatigue. I-10 accumulated operation will confirm block reliability at Perry. Block deformation caused Engine Rebuild Report Inspection of block tops at by cracks, metallic for Alaska 03/31/81, intervals governed by fatigue creep, overload pp. I-9, V, V-10, inspection results and of counterbore lip, VI, VIII and Summary accumulated operation close proximity of cooling pp. 26, 27 will confirm block water holes, close reliability at Perry, proximity of head retaining studs, and 7 , thread termination for studs level with counterbore depth is causing high stress concentration area. Engine crankshaft out Engine Rebuild Report Reference crankshaft report of alignment; possibly for Alaska 03/31/81, for Perry. No impact on Perry. from engine block pp. V-10, V-12, VI misalignment. l Reported cracks between Memo from E. Sigrist Inspection of block tops at heads and liner bores. (TDI) to G.E. Trussell intervals governed by (TDI) dated 11/08/82 inspection results and (File No. T-10) City accumulated operation of Homestead, Fla. will confirm block reliability at Perry. Reported cracks between Letter from R. Pratt Inspection of block tops at the head stud holes and (TOI) to John Smith, intervals governed by liner bores. City of Homestead, inspection results and l Fla. dated 06/17/82 accumulated operation (File No. T-2) City will confirm block of Homestead, Fla. reliability at Perry. ( L.)) PE3237/3 i

Appendix C Page C4 of 7 REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS

                     . Engine block cracked                      Memo from E. Sigrist                           Inspection of block tops at from improper placing                     (TDI) to G.E. Trussell                         intervals governed by and tightening of head                     (TDI) dated 11/08/82                           inspection results and gaskets (April 1979).                      (File No. T-10) City                           accumulated operation of Homestead, Fla.                             will confirm block reliability at Perry.

Several cracks were Letter from R.C. Inspection of block tops at discovered running from Grindeland (BIEHL) intervals governed by the cylinder cover to C. Mathews (TDI) inspection results and bolt holes into liner. 03/16/81 accumulated operation Cause of cracks not (File No. T-14) will confirm block determined. reliability at Perry. Distortion in upper Report by George Inspection of block tops at deck and small cracks in G. Sharp, Inc. intervals governed by cylinder block. New " Overview of Reports, inspection results and blocks have heavier Analysis and Re- accumulated operation external walls and commendations Re- will confirm block interior bulkheads. Propulsion Engines reliability at Perry. M/V Columbia" July 26, 1983 Cylinder block fractures. Letter from M. Lowrey Inspection of block tops at Caused by the combination (TDI) to H. Blanding intervals governed by l of diametral and vertical (American Bureau of inspection results and thermal expansion of the Shipping) dated accumulated operation r liner, cyclic stress from 12/30/83 (File No. will confirm block l combustion pressure both T-30). reliability at Perry. j radially from the liner Letter from M. Lowrey ' and vertically through (TDI) to H. Taylor l the head studs, and (American Bureau of torque down stress of Shipping) dated the studs themselves. 10/28/83 (File No. Recommendations: cylinder T-30). head, studs machined to Minutes of meeting remove stud load stress, . between TDI and USS-GLF cracks repaired by Metalok on 12/20, 21, 1983 technique and diameter (File No. T-30). of the upper liner collar Letter from R. Gertz was reduced by 0.005 (USS-GLF) to A. Barich inches. (TDI) dated 04/07/83 (File No. T-30). Letter from R. Bertz (USS-GLF) to M. Lowrey (TDI) dated 07/14/83 (File No. T-30). , Minutes of meeting between TDI and l O PE3237/4 USS-GLF dated 06/17/83 (File No. T-30).

Appendix C Page C5 of 7 REFERENCE PERRY

EXPERIENCE DOCUMENTS STATUS Cracks in the engine Letter from A. Muxo Inspection of block tops at block at a point between (City of Homestead) intervals governed by the cylinder head hold- to C.S. Mathews and inspection results and down studs and the R. J. Bazzini accumulated operation cylinder liner bore. (TDI) dated 05/31/82 will confirm block These cracks were (File No. T-10). reliability at Perry. repaired in Unit 18 Letter from A. Huxo but the same type of (City of Homestead) 1 block cracks have to C. S. Mathews reappeared in both dated 12/13/82 (File Units 18 and 19 in several No. T-10). - stud locations on each. Letter from J. A. Smith (City of Homestead to G.E. Trussell (TDI) 06/14/77 (File No. T-10).

     .                                                     Comments by City of Homestead, Fla., on the observations of R.A.

Pratt and G.E. Trussell tested in the Transamerica

                                                          -Delaval Survey Report, 08/10/82 (File T-10)

Cylinder block cracking. Minutes of meeting Inspection of block tops at between USS Great intervals governed by Lakes Fleet Service inspection results and Inc. and TDI dated accumulated operation 04/13/84 (File No. will confirm block T-46). . reliability at Perry. Telex from G. Trussell (TDI) to R. Bertz (USS-GLF) dated 04/08/83 (File No. T-46). Letter from R. Bertz (USS-GLF) to A. Barich (TDI) dated 04/07/83 (File No. T-46). Agenda TDI and USS-GLF dated 04/13/83 (File No. T-46) American Bureau of Shipping Report by D.W.

                                                         ' Johnson Report No.

DL4702 dated 03/22/83. (File No. T-46) O PE3237/5 - 1 4

                                                                                    .-          .-        -.__,m   .   . , , _.. .m.

Appendix C Page C6 of 7 REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS Cracks in engine block. Letter 05/13/82 from Inspection of block tops at Florida City of Homestead, intervals governed by Fla. , to TDI (Oakland inspection results and and New York) Units accumulated operation 18 and 19 (File T-64) will confirm block reliability at Perry. Piston failed and hit TDI letter to Isolated incident. Not a b

ausing crack. Metalok International design related problem.

Drt' ^ top each 05/12/81 (File No. No impact on Perry. leg of crack, then T-50), Greg Beshouri stitch up holes with (TDI), D. Venning a few supporting stitches (Metalok Int. Assn. along length of crack. Ltd). Enterprise Oak (Geoff King) to Beshouri 05/28/81-2 (File T-50). Photocopy of preliminary report on crack on left cylinder (4th) by G.K. Rao (Bhel). Memo dated 05/11/81 Bob Bailey (Riyadh) to G. King (Oakland) (File T-50) Cracked block on Unit Letter from John A. Inspection of block tops at i No. 19. Smith (City of intervals governed by inspection results and Homestead) to G.E. i Trussell (TDI) accumulated operation

           .                      06/17/77.                 will confirm block (File No. T-55)           reliability at Perry.

Eng. S/N 79002 exploded. Rafha Electricty Co. Fracture attributed to Cylinder block damaged. and Suburbs, Saudi Co. installation of three Attributed to multiple Ltd., Saudi Arabia rather than 2 head I- ;.huad gaskets (2). dated 07/12/81. gaskets. No impact on No addressee or Perry. transmittal letter l available. No. 3 gen. (File No. T-57) l O PE3237/6 i

l. <

i l t

r Appendix C Page C7 of 7 O V EXPERIENCE REFERENCE DOCUMENTS PERRY STATUS Cylinder block fracture Engine Rebuild Report Inspection of block tops at caused by high compressive State of Alaska intervals governed by stresses on the counter- dated 03/31/81 inspection results and bore lip. Localized p. iv. accumulated operation stress condition from the will confirm block combinations of sharp reliability at Perry. internal corner for lip (1/32 inch radius), nearby drilling for water jacket or stud. Termination of stud threading at the same level, creep deformation, and fatigue. (M/V Columbia) Cylinder block repaired Telex 05/28/81 G. Inspection of block tops at by Metalok. King (TDI) to intervals governed by Desrumeax/ Wilder / inspection results and Beshouri-Jizan accumulated operation 77036 TDI will confirm block File No. T-50 reliability at Perry. O PE3237/7

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Cylinder Block Liners

              & Water Manifold -

COMPONENT Cylinder Liner UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-315C TASK DESCRIPTION NO. OR-03-02-315C-0 SNPS GPL NO. 03-315C CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review is not required for this component based on review of the lead engine DR/QR reports (Shoreham/ Comanche Peak) and the reported applicable industry experience. There is no site experience in the EDG Component Tracking System. There are no modification recommendations for this component, however, the following is recommended as a maintenance ites: .Q

Inspect the cylinder liners borescopically (visually if the cylinder Q heads are off) at every refueling outage for signs of progressive wear.

The following Quality inspections as delineated in the CQRC are recommended:

Verify liner dimensions including bore, length, height, 0.D. and shoulder height for all cylinder liners.
Visually inspect the outside pilot diameter whee it contacts the cylinder block on all cylinders.
Visually inspect all cylinder liners over the zone of piston travel.
Determine the material of a spare liner.

PRIMARY FUNCTION Not required O PE2955/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED . Not required GROUP CHAIRPERSON -

                                       - PROGRAM MANAGER 1%tws;m m 0                   VV                                        C7 l

i I

   ' PE2955/2 l

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Manifold Piping COMPONENT (Large Bore Scope only) UTILITY Cleveland Electric-Illuminatina Company GROUP PARTS LIST NO. 02-3150 TASK DESCRIPTION NO. DR-03-02-315D-0 SNPS GPL NO. 03-315D CLASSIFICATION TYPE B TASK DESCRIPTIONS , Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak)
A comparison of the jacket water manifold for Perry with Comanche Peak. .

v There are no maintenance or modification recommendations made based on the lead engine DR/QR report. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required' i ATTRIBUTS TO BE VERIFIED Not required SPECIFIED STANDARDS Not required PE3107/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-3150-0 Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - -- PROGRAM MANAGER UC\4% ,m V V' O O O PE3107/2 W

I Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Cylinder Block Liners & COMPONENT Water Manifold: Studs UTILITY Cleveland Electric Illuminatino Co. GROUP PARTS LIST NO. 02-315E TASK DESCRIPTION NO. DR-03-02-315E-0 _ SNPS GPL NO. 03-315E CLASSIFICATION TYPE B _ TASK DESCRIPTIONS Design review of -this component is not required based on the review of the lead engine DR/QR report (Comanche Peak) and the applicable industry experience. There is no site experience for this component in the EDG Component Tracking System. There are no maintenance recommendations for this component; however, the following change to the installation torque is recommended to lower the stresses in the cylinder block (Ref.1): f,-.

Lubricate the cylinder head stud blockside threads with engine oil.
Torque the studs into the block to 80-120 ft-lbs. Use the necessary lockwashers (shims) to obtain a stud free length. of 15" i 1/16".

(Caution: Do not use impact type tools to tighten the studs). The free length is measured from the block top to the end of the cylinder head stud. Care should be taken not to further tighten the headstuds during installation of the heads and torquing of the head stud nuts to 3600 ft-lbs. Per a conversation with CEI personnel (Ref. 1), Perry is in the process of replacing their straight shank with the latest necked down design (either 03-315-01-0A Rev. f or Rev, g) if TDI can guarantee shipment by December 5. Both stud designs are acceptable for use on the engines. The following Quality inspections should be performed regardless of the design

that is implemented:

            *-    Psrform a visual inspection of the head studs for-signs of distress (four heads; per engine) 1

Determine the material of four studs (material to be AISI 4140/4142) on one engine;

     'L)    PE3039/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 TASK DESCRIPTION (continued)

Determine the hardness of one stud (hardness to be 25-30 Rc) on.one engine;
Verify that the studs are installed with a torque cf 80-120 ft-lbs into the block per the above recommendations, all engines.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES

1. TDI Diesel Generator Owners Group letter (OGTP-296-0-156) cylinder head stud modification and revised installation procedure. File: MTS-4086 (Dated 9/24/84).

2. Telecon between J. Carbonaro (SWEC) and T. Pusateri (CEI) 11/21/84.

DOCUMENTATION REQUIRED' i Not required GROUP CHAIRPERSON = 4 R0 GRAM MANAGER edC We%h GV U PE3039/2

Page 1 of 2 O CCMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT.1 Cylinder Block Liner & Water Manifold - Cylinder COMPONENT Head Nuts UTILITY Cleveland Electric Illuminatina Co. GROUP PARTS LIST NO. 02-315F TASK DESCRIPTION NO. DR-03-02-315F-0 SNPS GPL N0. 03-315F CLASSIFICATION TYPE _ B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the Comanche Peak and Shoreham DR/QR reports, which estaolish _ the acceptability of the cylinder head nuts for their intended purpose.
A review of. site, nuclear and non-nuclear industry ' experience indicated there had been no design related failures associated with this component. The cylinder head nuts are identical on all the Owner's Group TDI Diesel Engines (TDI Part No. F-090-021).

The only adverse experience occurred at Shoreham and involved a cracked nut attributed to a forging lap during manufacturing, and did not impair engine operation. There are~ no maintenance or modification recommendations for this component. The following Quality Revalidation inspections should be performed on both engines to ensure component quality:

Visually examine all nuts for identification markings.
Verify the proper installation and torquing of the nuts. ]
Perform a visual inspection of the nuts for signs of forging laps.. j l

I

        ' PRIMARY FUNCTION Not required O'       PE2877/1 l

l l l COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 l DR-03-02-315F-0 ! ATTRIBUTE TO BE VERIFIED ! Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON

                                        - PROGRAM MANAGER T\4

,0 V l/ ' G I i PE2877/2

Page 1 of 2 O v COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Cylinder Block-Liners and Water Manifold: COMPONENT Seals and Gaskets UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-315G TASK DESCRIPTION NO: DR-03-02-315G-0 SNPS GPL NO. 03-315G CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of the applicable industry experience and the lead engine DR/QR reports (Shoreham/ Comanches Peak). There is no reported site experience for this component in the EDG Component Tracking System. A review of the applicable site documentation should be performed to verify that the proper cylinder liner seals (TDI P/N JF-019-000) have been installed in the diesel generators. There are no maintenance or modification recommendations for this component. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED 4 Not required SPECIFIED STANDARDS Not required PE3040/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-315G-0 O REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER Xh.% V l/ G O i PE3040/2

Page 1 of 2

        -/                                                                             COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 4

i Cylinder Block COMPONENT Covers: Gaskets & Bolts UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO 02-3858 TASK DESCRIPTION NO. DR-03-02-3858-0 SNPS GPL N0. 03-3858 CLASSIFICATION TYPE C TASK OESCRIPTIONS Design review for this component is not required based on a review of the lead engine DR/QR report (Comanche Peak) and the applicable site and industry experience. 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 S and SAE GR 1120 respectively) are acceptable for their intended function 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- ,

x tuted. Barring any deviations as mentioned above the bolting is acceptable for '

l use on the diesel engines. There are no modification or maintenance recommendations for this component. l The 'following quality inspections are recommended to be . performed 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.

                   ~*         Perform a visual inspection to verify that the gaskets are suitable for the environment.

PRIMARY FUNCTION Not required i A PE3065/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-385B-0 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS , Not required REFERENCES Not required DOCUMENTATION REQUIRED - Not required PROGRAM MANAGER 3CW GROUP CHAIRPERSON

                                                                                                                                                                       %a (j v lO 4

l i l l PE3065/2 l

O TDI DIESEL GENERATOR i DESIGN REVIEW AND

QUALITY REVALIDATION REPORT l PNPP DOCUMENT CONTROL l CONTROL #g ISSULD

,O propo,.a Eo, oare__aecc a THE CLEVELAND ELECTRIC ILLUMINATING COMPANY . PERRY NUCLEAR POWER PLANT [ By , TDI DIESEL GENERATOR OWNERS GROUP VOLUME 3 l l

r a How To Use This Report

                 -Tabs in.this report identify the following categories:
                                                          ~

Turbo, Intake, Intercooler & Exhaust Lube Oil Engine Base & Bearing Caps Crankshaft & Bearings Cylinder Block, Liners & Water Manifold

Air Start & Barring Device 4

Connecting rods j- Pistons Camshaft & Valve Train Idler Gear Assembly & Front Gear Case Flywheel - i - Engine Instrumentation & Wiring L~

                      - Overspeed Trip & Governor                                                  .

Engine Shutdown & Equipment Jacket Water Cylinder Heads & Valves Fuel Oil Injection ,n

                      . Generator Control Panel Assembly Engine & Auxiliary Sub-Base & Foundation Bolts i

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

                .Within each category tabs identify Perry specific component numbers.
                .A given component report can be found by:

, a) If the component number is known - use the alpha - numberic index
which identifies the volume number and category in which the compon-i ont report is located.

b) If only the component name is known - Section 3.2 may be used as a cross-reference to find the volume number where the component report

may.be found.

i Some reports address more than one component. a tab is provided for each component. -However, some components are combined .under one report. Slip. sheets are provided where required to reference back to the appropriate tab.

              , Some ~ components required more than one report. These are identified by the abbreviation LB-Large Bore ~and SB-Small Bore on the component number tabs, t

4 i i PE3375

INDEX (continued) Component Component DR QR Volume Number Description Reo'd Rea'd Category No. F-068 Intercooler X X Turbo, Intake 2 Intrcir. & Exhaust MP022/23 Turbocharger X X Turbo, Intake, 2 Intrcir. & Exhaust 00-420 Lube Oil Pressure X X Lube Oil 2 Regulating Valve 00-442A Starting Air Distributor: X X Air Start & 3 Distributor Assembly Barring Device 1 00-442B Starting Air Distributor: X X Air Sta'; & 3 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drip Tank X X Fuel Oil 4 Assembly Injection 02-CFR. Turbocharger Thrust Bearing X X Turbo, Intake, 2 Lubricant System Intrcir. &-Ex-haust 02-305A Base and Bearing Caps: Base X X Engine Base 2 Assembly & Bearing Caps 02-305C Base and Bearing Caps: X X Engine Base 2 Main Bearing Studs & Nuts & Bearing Caps 02-3050 Base and Bearing Caps: X X Engine Base 2 Main Bearing Caps & Bearing Caps 02-307A Lube Oil Fittings: X X Lube Oil 2 Internal - Headers 02-307B Lube Oil Fittings: X X Lube 011 2 i Internal - Tube & Fittings 02-3070 Lube Oil Fittings Internal: X X Lube Oil 2 . Supports 310A Crankshaft X X Crankshaft & 2

_ Bearings 02-310B Main Bearings X X Crankshaft & 2 Bearing

( 11 PE3375

(~T INDEX (continued) i

     %)                                                                                     l Component     Component                      DR      QR                  Volume Number        Description                  Rea'd    Reg'd Category          No.   ;

02-310C Crankshaft & Bearings: X X Crankshaft & 2 Thrust Bearing Rings. Bearing 02-311A Crankcase: Crankcase Assy X X Crankshaft & 2 Bearing 02-3110 Crankcase: Crankcase X X Crankshaft & 2 Mounting Hardware Bearings 02-315A Cylinder Block X X Cyl. Block & 2 Liners & Water Manifold 02-315C Cylinder Block Liners & X X Cyl. Block & 2 Water Manifold - Liners & Cylinder Liner Water Manifold 02-3150 Cylinder Block Liners & X X Cyl. Block & 2 Jacket Water Manifold Liners &

                       & Piping                                     Water Manifold v   02-315E       Cylinder Block Liners &        X        X    Cyl. Block &      2 Water Manifold: Studs                        Liners &

Water Manifold 02-315F Cylinder Block Liners X X Cyl. Block & 2

                       & Water Manifold:                            Liner & Water Cylinder Head Nuts.                          Manifold 02-315G       Cylinder Block Liners &        X        X    Cyl. Block &      2 Water Manifold: Seals &                      Liners &        '

Gaskets Water Manifold 02-316A Jacket Water Inlet Manifold: X X Jacket Water 4 , Manifold Assembly W/ Hardware and Coupling and Gaskets 02-316B Jacket Water Inlet Manifold: X X Jacket Water 4 Coupling and Gaskets 02-316C Jacket Water Inlet Manifold: X X Jacket Water 4 Vent line to Discharge Manifold ' i 02-317A Water Discharge Manifold: X X Jacket Water 4 ( Jacket Water Discharge C Manifold / Piping iii I l PE3375

n

 /'"s INDEX (continued)

L-) Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-317B Water Dicharge Manifold: X X Jacket Water 4 Coupling & Seals 02-317C Water Discharge Mani fold: X X Jacket Water 4 Supports 02-330A Flywheel X Flywheel 3 02-3308 Flywheel - Bolting X X Flywheel 3 02-3358 FrontGearcase-baskets X X Idler Gear As- 3 and Bolting sembly & Front Gear Case 02-340A Connecting Rods: Connecting X X Connecting 3 Rods & Bushings Rods 02-340B Connecting Rod Bearing X X Connecting 3 Shells Rods

 /'~'\ 02-341A    Pistons                                X   X            Pistons                  3

() 02-3418 Pistons: Rings X X Pistons 3 02-341C Piston Pin Assembly X X Pistons 3 02-345A Tappets and Guides: Intake X X Camshaft & 3

                  & Exhaust Tappet Assembly                               Valve Train 02-345B    Tappets and Guides: Fuel               X   X            Camshaft &               3 Tappet Assembly                                         Valve Train 02-345C    Tappets and Guides: Fuel              X    X            Camshaft &             3 Pump Base Assembly                                      Valve Train 02-350A    Camshaft:   Camshaft                  X    X            Camshaft &             3 Assembly                                                Valve Train 02-3508    Camshaft:   Camshaft                  X                 Camshaft a             3 Bearing                                                 Valve Train 02-350C    Camshaft: Supports, Bolting           X    X            Camshaft &             3 and Gear                                                Valve Train 02-355A    Idler Gear Assembly Crank             X    X            Idler Gear As-         3 g                To Pump Gear                                            sembly & Front s_-                                                                     Gear Case iv PE3375

INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-355B Idler Gear Assembly: X X Idler Gear As- 3 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valve X X Air Start & 3 Barring Device 02-360A Cylinder Heads X X Cylinder Heads 4

                                                                         & Valves 02-3608   Cylinder Head Valves:           X         X              Cylinder Heads    4 Intake & Exhaust Valves                                  & Valves 02-360C   Cylinder Head and Valves:       X         X              Cylinder Heads    4 Bolting and Gaskets                                      & Valves 02-3600   Cylinder Head                   X         X              Cylinder Heads    4
                & Valves: Springs                                        & Valves 02-362A   Subcover                        X         X              Camshaft &        3 Valve Train 02-365A   Fuel Injaction Pump             X                        Fuel Oil In-      4 jection 02-365B   Fuel Injection Equipment -      X                        Fuel Oil In-      4 Fuel Injection Tips                                      jection 02-365C   Fuel Injection Equipment -      X         X              Fuel Oil In-      4 Tube Assembly                                            jection 02-3650   Fuel Injection Equipment:       X         X              Fuel Oil In-      4              >

Supports jection 02-371A Fuel Pump Linkage: Fuel X X Fuel Oil In- 4 Pump Control Shaft jection 02-371B Fuel Pump Linkage: Linkage X X Fuel Oil In- 4 Assembly and Bearing jection 02-375 Intake Manifold and X X Turbo, Intake, 2 Piping - Intrc1r. & Ex-haust 02-380A Exhaust Manifold X X Turbo, Intake, 2

  /')                                                                    Intrcir. & Ex-V                                                                      haust v

PE3375

n-INDEX (continued) Component- Component DR QR Volume Number Description Reg'd Req ' Category No. 02-380B Exhaust Manifold: Gasket X X Turbo, Intake, 2 and Bolting Intrcir. & Ex-haust 02-3858 Cylinder Block Covers: X X Cyl. Block & 2 Gaskets and Bolting Liners & Water Manifold 02-3868 Crankcase: Cra'nkcase - X X Crankshaft & 2 Gaskets and Mounting Bearings Hardware 02-390A Intake & Intermediate and X X Camshaft & 3 Exhaust Rocker Shaft Assembly Valve Train 02-3908 Rocker Arms and Pushrods: X X Camshaft & 3 Exhaust Rocker Shaft Valve Train Assembly 02-390C Main and Connector X X Camshaft & 3 Pushrods Valve Train O '02-3900Rocker Arms and Pushrods: X X Camshaft & 3 Pushrods Connector. Valve Train 02-390E Rocker Arms and Pushrods: X Camshaft & 3 Bushings Valve Train 02-390F Rocker Arms and Pushrods: X- X Camshaft & 3 Lifters Valve Train 02-390G Rocker Arms and Pushrods: X X Camshaft & 3 Misc. Bolts & Drive Studs Valve Train 02-410A Overspeed Trip Governor X X Overspeed Trip 3

                                                                    & Governor 02-410B     Overspeed Trip: Governor        X         X    Overspeed Trip   3 and Accessory Drive Assembly
                                                                    & Governor i

02-410C Overspeed Trip: Coupling X X Overspeed Trip 3

                                                                    & Governor

02-4100 Overspeed Trip Vent Valve X X Overspeed Trip 3

                                                                    & Governor i                                                    vi j-      -PE3375 e     -

O

    >                                  INDEX (continued)

Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-411A Governor Drive: Governor & X X Overspeed Trip 3 Tachometer Drive Gear and & Governor Shat't 02-411B Governor Drive: Couplings, X X Overspeed Trip 3 Pins & Keys & Governor 02-413A _ Governor Linkage X X Overspeed Trip 3

                                                               & Governor 02-4138     Fuel Pump Linkage:            X            Fuel Oil Injection   4 Automatic Shutdown Cylinder 02-415A    Governor Assembly: Woodward   X        X    Overspeed Trip       3 Governor                                    & Governor 02-4158    Governor Assembly -           X             Overspeed Trip       3 Booster Servomotor                          & Governor 02-415C    Governor Assembly -           X        X    Overspeed Trip       3 l            Heat Exchanger                              & Governor 02-420     Engine Driven                 X        X    Lube Oil             2 Lube Oil Pump 02-425A    Engine Driven                 X        X    Jacket Water         4 Jacket Water Pump 02-435A    Jacket Water Fittings:        X        X    Jacket Water         4

! Pipe & Fittings 02-435B Jacket Water Fittings - X X Jacket Water 4 j Supports 02-435C Jacket Water Inlet X X Jacket Water 4 Fittings - Valves 02-436A Intercooler Piping X X Turbo, Intake 2 Intercooler

& Exhaust l'

02-436B Intercooler Piping X X Turbo, Intake 2

Coupling, Gaskets, Intercooler &

l Bolting Exhaust l vi, j Pe3 m

A INDEX (continued) V Component Component DR QR Volume Number Description- Reg'd Rea'd Category No. 02-437 Turbo Water Piping: X X Jacket Water 4 Pipe & Fittings 02-441A Starting Air Manifold: X X Air Start & 3 Piping, Tubing and Fitting Barring Device 02-441B Starting Air Manifold X X Air Start & 3 Valves, Filters & Strainer Barring Device 02-441C Starting Air Manifold: X X Air Start & 3 Supports Barring Device 02-445 Fuel Oil Booster Pump X X Fuel Oil In- 4 jection 02-450A Fuel Oil Header: X- X Fuel Oil In- 4 Piping / Tubing jection 02-4508 Fuel Oil Header: Fuel X X Fuel Oil In- 4 011 Supports jection 02-455A Fuel Oil Filters & X Fuel Oil In- 4 Strainers: Filters jection 02-4558 Fuel Oil Filters & X Fuel Oil In- 4 Strainers: Strainers jection 02-455C Fuel Oil Filters & X X Fuel Oil In- 4 Strainer: Mounting Hardware jection 02-465A Lube Oil Lines External: X X Lube Oil 2 Tubing, Fittings, Couplings 02-4658 Lube Oil Lines - External X X Lube Oil 2 Valves 02-465C Lube Oil Lines X X Lube Oil 2 External Supports 02-467A Turbocharger: Lube Oil X X Lube Oil 2 Fitting - Pipe, Tubing, Fittings & Flexible Coupling 02-4678 Turbocharger: Luba Oil X X Lube Oil 2 Fittings - Supports O viii PE3375

() G' ' INDEX (continued)

          "omponent            Component                         DR     QR                 Volume Number               Description                   Reg'd    Reg'd Category         No.

02-475A Turbocharger: Bracket X X Turbo, Intake, 2 Bolting and Gaskets Intrcir. & Ex-haust 02-475B Air Butterfly Valve X X Turbo, Intake, 2 Assembly Intrcir. & Ex-haust 02-475C Turbocharger: Bracket - X X Turbo, Intake, 2 Bolting & Gaskets Intrcir. & Ex-haust 02-500A Control Panel Assembly X X Control Panel 4 Cabinet / System Assembly 02-500F Control Panel Assembly X X Control Panel 4 Accumulator Assembly 02-500G Control Panel X X Control Panel 4 Valves Assembly x- - 02-500H Control Panel Assembly X X Control Panel 4 Pressure Switch Assembly 02-500I Control Panel Assembly: X X Control Panel 4 Control Relays Assembly 02-500J Control Panel Assembly: X X Control Panel 4 Solenoid Valves Assembly 02-500L Control Panel Assembly - X Control Panel 4 Piping, Tubing, Fittings Assembly 02-500M Control Panel Assembly: X Control Panel 4 Terminal Boards / Switches / Assembly Wiring 02-5258 Barring Device - Pneumatic: X X Air Start & 3 Regulator Valve / Shut Off Barring Device Valve 02-5250 Barring Device - Pneumatic: X Air Start & 3 Mounting Bracket / Supports Barring Device 02-540A Lube Oil Sump X Lube Oil 2 with Strainer Assembly

   \-                         and Mounting Hardware fx PE3375

INDEX (continued) Component Component DR Volume QR Number Description Reg'd Reg'd Category No. 02-5408 Lube Oil Sump Tank: Misc. X X Lube Oil 2 Fittings, Gaskets, Pipe

                 & Bolting Material, Valves 02-540C   Lube Oil Sump Tank:            X        X   Lube Oil         2 Mounting Hardware 02-550    Foundation Bolts:              X       X    Engine & Aux. 4 Anchors, Bolts, Misc.                       Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly: X X Engine Instru- 3 Conduit mentation & Wiring 02-6308 Pyrometer Conduit Assembly: X X Engine Instru- 3 Conduit Fittings mentation & Wiring 02-630C Pyrometer Conduit Assembly: X X Engine Instru- 3 Os Support mentation & Wiring 02-6300 Pyrometer Conduit Assembly X Engine Instu- 3 Thermocouple mentation & Wiring 02-650A Emergency Diesel Generator X X Generator 4 02-650B Generator X X Generator 4 Control 02-650C Generator-Shaft & Bearing X X Generator 4 02-668A Engine & Aux Module X X Engine Instru- 3 Wiring Material- Conduit mentation &

                 & Fittings; Pyrometer                       Wiring Assembly - Conduit, Fitting, Supports 02-6888    Engine & Aux.   .

X X Engine Instru- 3 Module Wiring Material: mentation & Wiring & Terminations Wiring PE3375 l

INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-686C- Engine & Aux. Module Wiring X Engine Instu- 3 Material: Boxes & Terminals mentation & Wiring 02-689 Off-Engine Alarm Sensors X X Engine Instru- 3 mentation & Wiring 02-690 Engine Alarm Sensors - X X Engine Instru- 3

                  . Temperature & Level                         mentation &

Switches Wiring 02-691 'Off Engine Safety Alarm X X Engine Instru- 3 Sensors - Level & mentation & Pressure Switches Wiring 02-695A Engine Shutdown X X Engine Shut- 3 Equipment: down & Equip-Tubing / Fittings & ment Supports 02-6958 Engine Shutdown X X Engine Shut- 3 Equipment: Valves, down & Equip-Regulator, Orifices ment ! 02-695C Engine Shutdown Trip X X Engine Shut- 3 i Switches down & Equip-ment 02-700A Jacket Water Standpipe: X X Jacket Water. 4 i Pipe, Fittings, Gaskets

i. 02-7008 Jacket Water Standpipe: X X Jacket Water 4 Valves 02-700C Jacket Water Standpipe: X X Jacket Water 4 Pipe Supports' 02-700E Jacket Water Standpipe: X X Jacket Water 4 Switches 02-700F Jacket Water Standpipe X X Jacket Water 4'

                  & Misc. Bolting 02-717A     Auxiliary Skid                  X             Jacket Water     4

!O X xi PE3375 o

INDEX (continued) Component Component DR Volume QR Number Description Reg'd Reg'd Category No. 02-717B Aux Sub Base & Oil & X X Jacket Water 4 Water Piping - Jacket Water: Valves 02-717C Aux Sub Base & 011 & Water X X Engine & Aux. 4 Water Piping - Jacket Sub Base & Water: Pipe, Couplings, Foundation Bolts Fittings, Orifices, Y-Strainers 02-717D Aux Sub Base & 011 & Water X Jacket Water 4 Piping - Jacket Water: Gaskets & Bolting 02-717E Aux Sub Base & 011 & Water X X Jacket Water 4 Piping - Jacket Water: Supports 02-717F Aux. Sub Base & Oil & Water X X Lube 011 2 a Piping - Lube Oil: Pipe and Fittings 02-717G Aux Sub Base & 011 & Water X X Lube Oil 2 Piping - Lube Oil: Valves 02-717H Aux. Sub-Base & 011 & Water X X Lube Oil 2 Piping - Lube Oil: Gaskets & Bolting 02-717I Aux Sub Base & 011 & Water X X Lube Oil 2 Piping - Lube Cil: Supports & Mounting Hardware 02-717J Aux Sub Base & Oil & Water X X Fuel Oil 2 Piping - Fuel Oil - Piping

               & Fittings
   .02-717K    Aux Sub Base & 011 & Water     X       X    Fuel Oil           4 Piping - Fuel Oil: Valves                   Injection 02-717L    Aux Sub Base & 011 & Water     X       X    Fuel Oil           4 Piping - Fuel Oil -                         Injection Gaskets & Bolting xii PE3375

     T                                  INDEX (continued)

(G Component Component DR QR Volume Number Description Rea'd Reg'd Category No.

O2-717M Aux Sub Base & 011 & Water X X Fuel Oil 4 Piping - Fuel Oil: Injection Supports 02-805A Intake Air Silencer X Turbo, Intake, 2 Intercooler & Exhaust 02-8058 Intake Air Filter X X Turbo, Intake, 2 Intercooler & Exhaust 02-805D Flex Connections X X Turbo, Intake, 2 Intercooler & Exhaust 02-810A Jacket Water Standby X Jacket Water 4 Heater Pump 02-810B Jacket Water Heat Exchanger X X Jacket Water 4 b)

    \m. 02-810C     Thermostatic Valve              X       X    Jacket Water     4 02-810D     Misc. Equipment - Heater,               X    Jacket Water     4 Jacket Water 02-820A     Misc. Equipment - Heater,               X    Lube Oil         2
                    ' Lube Oil Sump Tank 02-820B     Before & After Lube Oil        X        X    Lube Oil         2 Pump 02-823C     Lube Oil Full Pressure         X        X    Lube Oil         2 Strainer 02-8200     Lube Oil System - Lube Oil     X        X    Lube Oil         2 l                     Keepwarm Strainer 02-820E     011 Prelube Filter             X        X    Lube Oil        2 02-820F     Full Flow Lube Oil Filter      X        X    Lube Oil        2 02-820G     Lube Oil Heat Exchanger        X        X    Lube Oil        2 02-825A     Fuel Oil Day Tank              X        X    Fuel Oil        4 Injection xiii PE3375

INDEX (continued) Component Ccaponent DR QR Volume Number Description Reg'd Reg'd Category No. 02-8250 Fuel Oil System - Fuel X Fuel Oil 4 Oil Duplex Strainer Injection l j, , t 02-8358 Starting Air Tank X X Air Start & 3 Barring Device

!         02-835E                                Misc. Equipment - Starting                            X    X               Air Start &                                3 Air Tank Relief Valve                                                      Barring Device l

r O L l l i LO I XiV PE3375

u .a .. Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST ['T PERRY NUCLEAR POWER PLANT - UNIT 1 V Starting Air Distributor: COMPONENT Distributor Assembly UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 00-442A TASK DESCRIPTION NO. DR-03-00-442A-0 SNPS GPL NO. 03-442A CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review is not required for this component, based on the Comanche Peak lead engine DR/QR report which establishes the acceptability of the distributor assembly. The parts under review are the same as those of the lead engine. ' A review of the EDG Component Tracking System indicates no new significant applicable industry or site experience. . In addition to the normal maintenance tasks of water removal and filter replacement for the starting air system, the following maintenance recommendation from the lead engine DR/QR report should be implementcd: Perform an inspection of the poppet valves and cams on all engines during refueling outages, to assess the degree of wear. Based on a recent Grand Gulf site experience in which the starting air manifold vent became obstructed, the additional m'aintenance item listed below is recommended:

Maintain surveillance inspections to assure that the starting air manifold vent remains open and effective.

There are no modification recommendations for this component. The following Quality inspections are recommended to be performed on engines 1A and 1B:

Verify the proper timing of the air start distributor as described in the TDI Manual.
After verifying the correct timing of each starting air distributor, as described in the TDI Manual, evaluation of wear on the cam and valve contacts should be performed as follows:

a. Remove the distributor from the engine.

b. Visually inspect the wear marks on the cam lobes.

PE2965/1

l l l COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-00-442A-0 N Note the position and orientation of the lube o.11 jet. Oil flow from the jet should cover the wear mark region on the cam lobe. I

c. Visually inspect the wear marks on the end of each valve spool where it slides on the cam. Measure the average diameter of the " flat" worn area on the end of each spool to the nearest 1/64-inch. If the largest of these measurements is more than 1.5 times the smallest, an engineering evaluation of the observed wear should be performed and a superficial hardness measurement should be made on the end " wear flat" of each valve spool. If the hardness of any spool end is significantly below 30 Rc, it should be replaced.

Verify the installation of the follower lobe on the camshaft (one engine only).

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES l Not required DOCUMENTATION RFQUIRED Not required GROUP CHAIRPERSON C = PROGRAM MANAGER 2C W-%w O vv' " PE2965/2

TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 !

, Startina tiir Distributor - Tubina, Fittinas and Gaskets Component Part No.: 00-442B 1 This component number has been deleted. All air d'stributor tubing is addressed under component numbers 02-441A and C and 02-3078. i' 4 5 O o S 4 O PE1

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Air Start Valves UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-359 TASK DESCRIPTION NO. DR-03-02-359-0 SNPS GPL NO. 03-359 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 or site experience, other than that already addressed in the lead engine report. *

A review of the lead engine DR/QR report (Cc.nanche Peat)
Similarities between Perry components and the lead engine components.

The following maintenance recommendations from the lead engines DR/QR reports ( should be implemented:

Remove, inspect and, if necessary, clean the air start valves during every refueling outage. The inspecti;n should include inspection of the piston / cap and guide / housing sliding surfaces to evaluate severity of wear and corrosion present.
Ensure that the dryer between the compressor after cooler and air receiver is functioning properly by blowing down the air receivers daily and noting any moisture content. Appropriate action should be taken if moisture is noted.

The following TDI SIMS should be implemented:

SIM 329, copper gasket between valve and head
SIM 360, capscrew length and torque /retorque requirements The following Quality inspections should be performed:
Verify adequate seating of valve and valve ring.
Verification of hold down capscrew initial torque and hot torque.

!O PE3284/1-

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-359-0 O

Dimensional check, sample basis, of hold down capscrew (two per bank).
Perform material comparator check on capscrews (two per bank).
Verify gasket type.

Note: To be performed on all station engines. PRIMARY FUNCTION Not required I ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES r Not required t ( DOCUMENTATION REQUIRED l Not required i GROUP CHAIRPERSON ' _ - PROGRAM MANAGER d \ dcv % w l (j r u l r O PE3284/2

TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 STARTING AIR MANIFOLD: PIPING, TUBING, AND FITTINGS (LARGE BORE SCOPE ONLY) COMPONENT PART NO. 02-441A I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of the structural adequacy of the starting air, manifold piping for the effects of normal operating and earthquake loadings. The primary function of the starting air manifold piping is to provide adequate starting air from the 'off-skid supply piping to each engine cylinder.

           'The scope of the piping embraced by this report includes the large bore (greater than 2-inch diameter) piping components as noted on the as-built information obtained during Impell field verification (Ref. 1), plus small bore piping, which was included because of the configuration.

O Piping components are defined as piping spool pieces, elbows, tees, flanges, Dresser couplings and the interconnecting welds. This scope is uniquely defined .in terms of Transamerica Delaval, Inc. (TDI) part numbers in Reference 1. II OBJECTIVE The objective of this. review was to verify the adequacy of the subject piping components for normal operating and earthquake loadings. III METHODOLOGY The evaluation of the piping is performed in accordance with the philosophy and intent of the ASME Code' Section III, for Class 3 Nuclear Piping. Towards this end, a criteria document was developed, " Design Criteria for Diesel Generator Large Diameter Piping for Perry," which describes the background and provides the -techniques for evaluating the subject-piping. These - criteria are presented in .their entirety in Reference 2. Quality- Revalidation Checklist results were reviewed for -acceptability. The TDI Emergency Diesel Generator Component Tracking System was reviewed

   ..       for the Perry site, nuclear, and non-.cclear industry experience.

PE3012/1

Page 2 of 3 IV RESULTS AND CONCLUSIONS w All piping stresses were within the desigri allowables specified by the ASME Section III Code. With respect to the Dresser couplings, Impell evaluated the couplings against the manufacturer's selection and service requirements. These include the design service conditions, relative end displacements from both translation and rotation of the joined pipes, and shelf and service life. The movements at the Dresser couplings are within the manufac-turer's end movement requirements (Ref. 3). There are no service life constraints (Ref. 4) because this style of coupling has no significant history of failure. Shelf life (Ref. 4) is unlimf ted as long as the gaskets remain packaged and protected from the eierents (light, water, etc.). The couplings are adequate with respect to the manufacturer's service condition limits. It is recommended that support modifications be effected in order to provide stiffer load paths and to' relieve thermal restraint in certain directions by partial support removal through bolt hole elongations. The support modifications are summarized in Reference 5. Historical corrosion data for carbon steel starting air systems was not available. However, the subject starting air piping and interconnecting welds have a limiting wall thickness of 5.15 times that required (Ref. n 2), which should be sufficient margin against corrosion. All pipe loads on the engine were tabulated and issued for evaluation. There are no TERs associated with this component. The 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. l -Based on the above review, it is concluded that the subject piping components, with the above recommended modifications, are adequate for their intended design function at Perry. i V REFERENCES

1. " Support Calculations for the Evaluation of Perry Diesel Generator Large Diameter Piping and Support," Impell Report No. 02-0630-1296,

, Rev. O, November 1984. l 2. " Design Criteria for Diesel Generator Large Diame'ter Piping for i Perry," Impell Report No. 02-0630-1295, Rev. O, November 1984. This , is included in Appendix III of the final DR/QR Report. O PE3012/2 i

Page 3 of 3

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

4. Telephone Conversation between A. Palumbo (Impell) and M. Riley (Dresser Manufacturing Co.), dated June 5, 1984.

5. Letter from R. Markovich/G. Shears (Impell) to J. Kammeyer (SWEC),

              " Required Modification for Validation of Impell's Design Review for Component No. 02-441A-Perry," dated November 21, 1984.

O l l l l I O' PE3012/3 I-

Page 1 of 1 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Starting Air Manifold Piping COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-441A TASK DESCRIPTION NO. DR-03-02-441A-0 SNPS GPL NO. 03-441A CLASSIFICATION TYPE B TASK DESCRIPTIONS Evaluate structural integrity of the starting air manifold piping spool pieces and fittings, for the effects of normal operating and earthquake loadings by (a) comparison to previous analyses, (b) review of previous qualification documentation, and/or (c) actual performance of stress evaluation in accordance with the intent and philosophy of ASME III Class 3 and Impe11 Design Criteria. Review information provided on TERs. PRIMARY FUNCTION Provide adequate starting air from of f-skid supply piping to each engine cylinder. ATTRIBUTE TO BE VERIFIED I Structural integrity of large bore (greater than 2-inch diameter) piping spool pieces and fittings to withstand the effects of normal operating and earthquake loadings. SPECIFIED STANDARDS l None l DOCUMENTATION REQUIRED Verify piping isometric, material specification, size and schedule, design parameters (temp., pressure), contents, and insulation. A GROUP CHAIRPERSON s v PROGRAM MANAGER M O M % O U "' " PE3165/1 l l

l l Appendix B Page B1 of 3 03-02-441A ('"') COMPONENT QUALITY REVALIDATION CHECKLIST

\>

Starting Air Mainfold: I Piping, Tubing and Cleveland Electric Illuminating Co.

          ' COMPONENT Fittings                      UTILITY Perry Nuclear Station - Unit 1 GPL NO.       02-441A                    REV. NO.           1 SNPS GPL NO.       03-441A TASK DESCRIPTIONS Engine 1A

1. Assemble and review existing documentation.

2. Obtain sufficient data to support the design review effort. This may be accomplished by developing quality verified as-builts in accordance with Procedure DG-7, or by the Design Group performing a field walkdown.

Engine 1B Same as Engine 1A ATTRIBUTES TO BE VERIFIED Engine IB

1. Quality status of Component Document Package

2. Information necessary for the design review effort.

Engine 1A Ssme as Engine IB V PE3238/1

 -                                                                                     i l

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 3 03-02-441A ACCEPTANCE CRITERIA Engine 1A

1. Satisfactory Document Package

2. Review of detailed information by the Design Group Engine 1B '

Same as Engine 1A REFERENCES Engine 1A

1. QCI No. 52

2. Procedure DG-7 Engine IB Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A

1. Document Summary Sheet

2. Quality verified as-built isometric drawings for the piping, tubing and fittings if available from the Owner.

j Engine 18 Same as Engine 1 GROUP CHAIRPERSON _ PRGGRAM MANAGER 2 4 \-< % g u l d 1-1 PE3238/2

a COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 3 03-02-441A COMPONENT REVIEW C]

Engine 1A

1. No EDGCTS site experience documents are in evidence.

2. The Design Group will be responsible for closing out the as-built drawings as per Procedure DG-7. The as-built drawings will be Quality verified by the appropriate site Quality organization. The performance of an engineering walkdown by the Design Group, precludes the issuance of a quality verified as-built drawing or sketch.

Engine 1B Same as Engine 1A RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as outlined above, is complete. The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of the final report. Engine IB l Same as Engine 1A GROUP CHAIRPERSON , Hk M- PROGRAM MANAGER 3 C \4a _ l v l l PE3238/3

Appendix C Page C1 of 1 EDG COMPONENT TRACKING SYSTEM: PERRY SITE, NUCLEAR AND NON-NUCLEAR INDUSTRY EXPERIENCE

SUMMARY

(} COMPONENT NO. 02-441A Effective Printout Date: 11/20/84 COMPONENT TYPE: Starting Air Manifold: Piping, Tubing and Fittings REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS PERRY None NUCLEAR Manifold purge from air TDI SIM 323 TDI SIM #323 is concerned intake manifold to with purgi.ig moisture prevent moisture / from the starting air corrosion. manifold. Historical data on corrosion in carbon steel starting 7- air lines was not available. However, Impell evaluation of subject piping determined that the nominal available pipe wall thickness was 5.15 times the minimum required. Therefore, there is adequate pipe margin against l corrosion in the subject

lines. TDI SIM #323 l 1s concerned mainly with fouling of starting air valves from corrosion.

l

NON-NUCLEAR None O

G PE3012/4

N Page 1 of 2 ~ COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Starting Air Manifold: Piping, Tubing and Fittings COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatino Co. GROUP PART LIST NO. 02-441A TASK DESCRIPTION NO. DR-03-02-441A-0 SNPS GPL NO. 03-441A CLASSIFICATION TYPE A i TASK DESCRIPTIONS l Design review for this component is not required based on the review of the 4 lead engine . DR/QR report (Comanche Peak) and the applicable industry experience. There is no site experience for this component in the EDG

    ' Component Tracking System.

There are no maintenance recommendations for this component. A field waskdown was performed at Perry in accordance with the small bore piping criteria document (Ref. 1). However, a review of this component in its ' entirety was not possible since portions of piping and tubing were not

    -installed at the time of the walkdown.                Therefore, component acceptability and

, . any subsequent -recommendations shall .be based upon the lead engine reports 1 (Comanche Peak, Grand Gulf and Catawba). l The lead engine reports address the need for site specific modification, specifically, support additions and modifications. The necessity for similar additions / modifications for Perry are addressed in DR/QR report 02-441C. Therefore,. based on the above review, it is concluded that this component will perform its intended function at Perry under all normal operating and earthquake loadings provided that supports are added/ modified as indicated in

' DR/QR report 02-441C.

   . Quality Revalidation for this component is not required.

t l PRIMARY FUNCTION

   - Not required l

ATTRIBUTE TO BE VERIFIED

   - Not. required      -

L PE2998/1

t

i l COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-441A-0 SPECIFIED STANDARDS Not required REFERENCES

            " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," report No.                          i 11600.60-DC-02, Revision 0.                                                                             '

DOCUMENTATION REQUIRED Not required r GROUP CHAIRPERSON -

                                                                - PROGRAM MANAGER     3 C Kcow m - 2 _

Lj v- o O 1 O PE2998/2

i Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Starting Air Manifold: COMPONENT Valves, Strainers & Filters UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-441B TASK DES'CRIPTION NO. DR-03-02-4418-0 SNPS GPL NO. 03-441B __ 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 app'licable industry and site experience, other than that previously addressed in the lead engine reports.
A review of the lead engine DR/QR reports (Shoreham and Comanche Peak)
The components ust:d at Perry have been used on the lead engines with the exception of the Airmatic valve and the Nupro check valve.

There has been no adverse experience with these valves.

In addition, review of TDI Instruction Manual Volume II, Group Parts List for 02-441 indicates Perry's engines have a starting air-manifold purge line from intake manifold (TDI SIM 323) installed.

The following maintenance from the applicab?e lead engine reports should be implemented at Perry:

The starting air admission valve has an 0-ring and a screened fit-ting, susceptible to wear and fouling. The 0-ring should be replaced and the screened fitting cleaned at each refueling outage.
The starting air valves should be disassembled, cleaned, inspected, lubricated, reassembled to prevent fouling and tested to assure leak tightness at each refueling outage.
Inspect for tightness of fittings and bolts and apply locking com-pound, as required, during reassembly of components at each refueling outage.

         *   .The shuttle valve has an 0-ring susceptible to wear. The 0 ring will be replaced at each refueling outage.
        .*    The filter. element should be inspected and clean / replaced, on a O            monthly basis.                     .

V PE3292/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-441B-0 m d TASK DESCRIPTIONS (continued)

In accordance with the manufacturer's recommendation, the filter should be changed before the maximum pressure drop of 25 psi. The strainer is recommended to be blown down daily and cleaned and inspected monthly. If the strainer is excessively dirty, the frequency of cleaning and inspecting should be increased.

The following modification is applicable:

In accordance with TDI recommendation, free flowing drains should be added to the air distributor filter. This is a design improvement that will help maintain a cleaner supply of starting air.

Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES I l Not required l DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON e- - PROGRAM MANAGER 2 C. K m e f -

( G V' C I i PE3292/2 1

Page 1 of 2 (' COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Starting Air Manifold Supports COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-441C TASK DESCRIPTION NO. DR-03-02-441C-0 SNPS GPL H0. 03-441C CLASSIFICATION TYPE B TASK DESCRIPTIONS i Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/Comenche Peak).

Based on previous experience, the supports appear to be adequate provided that the analysis of the corresponding piping Component No. 02-441A does not mandate modifications. If the piping analysis warrants modifications to the supports, (h

        \_,/

these modifications will be addressed in the DR/QR report for Component No. 02-441A. There are no maintenance requirements from the lead engine DR/QR report for this component. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required l l ATTRIBUTE TO BE VERIFIED l Not required l l SPECIFIED STANDARDS l l Not required 1

      . g- g                                                                                       .

k/ PE3158/1 i

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-441C-0 REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON [ - PROGRAM MANAGER d ,\ 4 m u u % V(/' o i l l l O , 1 O - PE3158/2 l __-__ _ - - - . , _ _ _ . - , _ . , . - . - . _ . . . _ - . _ . . . - - - , - . - . - . . . , . - - - - - , . - - . . - , , . , . - .

O TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1

                  .                     STARTING AIR MANIFOLD - SUPPORTS (SMALL BORE SCOPE ONLY)

COMPONENT PART NO. 02-441C I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of the structural adequacy of the starting air manifold tubing supports to withstand the effects of normal operating and earthquake loadings. The primary function of these supports is to provide adequate restraint to the starting air manifold tubing components. II OBJECTIVE The objective of this review was to perform an engineering evaluation of the tubing supports to assure that the component will perform its intend-ed design function during normal operating and earthquake loadings. III METHODOLOGY In order to meet the stated objective, the following methods were used:

The TDI Emergency Diesel Generator Component Tracking System was reviewed for the Perry site, nuclear, and non-r.uclear industry experience. See Appendix C for results.

The Quality Revalidation Checklist results were reviewed for acceptability.
Engines 1A and 1B, both partially disassembled, were evaluated using actual walkdown information and by comparison with the Comanche Peak lead engine report.

Refer to the review procedures as described in Reference 1 for a detailed methodology for this evaluation. IV RESULTS AND CONCLUSIONS The tubing supports, as defined by this component design review have been evaluated in accordance with Reference 1 and have been found acceptable with modifications. PE3111/1

Page 2 of 3 There are no TERs associated with this component. The 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 information contained in Reference 2, it is concluded that the tubing supports will perform their intended design function at Perry under all normal operating and earthquake loadings with the provision that the following recommended modifications be implemented as detailed in Refenence 3. Engines 1A and 1B Line-Distributors to Start Valves in Cylinder Heads The %-inch tubing from the distributors to the cylinder heads is only partially installed because of the dissassembled state of the engines. Upon installation of the air start distributors, the existing tube supports should be reinstalled. Tubing spacers should be modified by the addition of cover plates and secured to the engine blocks. In order to support the tubing of component 02-441A it is recommended that the following supports be added: ( Engines 1A and IB Line-Manifold to Governor Oil Booster Servo A two-directional restraint should be added on the 3/8-inch tubing located in the riser at the govern ir base plate elevation, typical on bcth engines. Line-Air Supply from Manifolds to Filters to Air Start Distributors A two-directional restraint should be added on the 3/4-inch tubing at approximately mid-span between the air supply manifold and the air filter inlet, typical on left bank and right bank on both engines. The body of each filter should be secured with a U-bolt to prevent torsion on fittings during a seismic event. Air start dinributors and the 3/4-inch tubing from the filters to the distributors were not installed during the field walkdown. Intermediate seismic restraints should be added if the lirear length of tubing exceeds 4 feet - 9 inches. . PE3111/2

Page 3 of 3 p Line-Distributors to Start Valves in Cylinder Heads b Two-directional restraints should be added as required to ensure 3 feet - 6 inch maximum span lengths are not exceeded. Engine IB Air Purge Lines A two-directional restraint in the %-inch tubing from the air start manifolds to the combustion air headers should be added at approximately mid-span to meet 3 feet - 6 inch maximum span length requirements, typical on both sides of the engine. Engine 1A Air Purge Lines k The k-inch tubing from the air start manifold to the combustion air headers was not installed during the field walkdown. Installation of this tubing should be similar to Engine 1B, including modifications. V REFERENCES

1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners O- Group," Report No. 11600.60-DC-02 Revision 0.

2. Stone & Webster Calculation number 11600.60-NP(B)-0301-XH.

3. Memo No. 6548 from C. Malovrh/SWEC to J. Kammeyer/SWEC dated 11/29/84.

PE3111/3

I APPENDIX A Page Al of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT I Starting Air Manifold - Tubing Supports COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-441C TASK DESCRIPTION NO.: DR-03-02-441C-0 SNPS GPL NO 03-441C CLASSIFICATION TYPE A TASK DESCRIPTIONS Perform an engineering review of the tubing supports to provide additional assurances that the component will perform its intended design function during normal operating and earthquake loading. PRIMARY FUNCTION Provide adequate restraint to the starting air manifold tubing components. ATTRIBUTES TO BE VERIFIED Structural adequacy of the tubing supports due to the effects of normal operating and earthquake loadings. SPECIFIED STANDARD 3 IEEE 387 REFERENCES

   " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group" Report No.

11600.60-DC-02, Revision 0. PE3025/1

COMPONENT DESIGN REVIEW CHECKLIST . Page A2 of 2 l DP.-03-02-441C-0 DOCUMENTATION REQUIRED Delaval design documentation (specifications, calculations, drawings, etc.). In lieu of information from Delaval, the following information is required: verified support sketches and piping isometrics, material specifications, pipe

                       . size and schedule, and operating parameters (pressure, temperature, load combinations).

GROUP CHAIRPERSON "- - PROGRAM MANAGER NC.Abm%, ^ U

                                            } {/ ~

4 A O e I t 0 . l PE3025/2

   .m.., , . . . . . ~ _       .

l

     . Appendix B                                                                           Page B1 of 3 03-02-441C COMPONENT QUALITY REVALIDATION CHECKLIST Starting Air Manifold:                      Cleveland Electric Illuminating Co.

COMPONENT Supports UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-441C REV. NO. 2 SNPS GPL NO. 03-441C TASK DESCRIPTIONS Engine 1A

1. Assemble and review existing documentation.

2. Obtain sufficient data to support the design review effort. This may be accomplished by developing quality verified as-builts in accordance with Procedure DG-7, or by the Design Group performing a field walkdown.

Engine 1B Same as Engine 1A ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package-

2. Information necessary for the design review effort.

Engine 18 Same,as Engine 1A O PE2626/1

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 3 03-02-441C ACCEPTANCE CRITERIA Engine 1A

1. Satisfactory Document Package

2. Review of detailed information by the Design Group Engine IB Same as Engine 1A REFERENCES Engine 1A

1. QCI No. 52

2. Procedure DG-7 Engine IB Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A

1. Document Summary Sheet

2. Quality verified as-built isometric drawings for the supports if available from the Owner.

Engine 1B Same as Engine , GROUP CHAIRPERSON ,d( L s PROGRAM MANAGER 1 \<cuw - e o . PE2626/2 . - . _ - - . _ _ _- A

COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 3 03-02-441C COMPONENT REVIEW Engine 1A

1. No EDGCTS site experience documents are in evidence.

2. The Design Group will be responsible for closing out the as-built drawings as per Procedure DG-7. The as-built drawings will be Quality verified by the appropriate site Quality organization. The performance of an engineering walkdown by the Design Group, precludes the issuance of a quality verified as-built drawing or sketch.

Engine IB Same as Engine 1A RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as f') s-utlined ab ve, is c mplete. The results have been f rwarded to the Design Review Group for their evaluation and conclusions in support of the final report. Engine IB Same as Engine 1A GROUP CHAIRPERSON /4 A E dd PROGRAM MANAGER M\<a ew o - PE2626/3

Appendix C Page C1 of 1 PERRY SITE, NUCLEAR O EDG COMPONENT TRACKING SYSTEM: AND NON-NUCLEAR INDUSTRY EXPERIENCE

SUMMARY

COMPONENT NO. 02-441C Effective Printout Date: 11/05/84 , COMPONENT TYPE: Starting Air Manifold: Supports REFERENCE PERRY ! EXPERIENCE DOCUMENTS STATUS PERRY None NUCLEAR None NON-NUCLEAR None O PE3111/1

l l Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST

 *O -                          PERRY NUCLEAR POWER PLANT - UNIT 1 Barring Device-Pneumatic COMPONENT Regulator Valve / Shutoff Valve UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO.      02-525B             TASK DESCRIPTION NO. DR-03-02-5258-0 SNPS GPL NO.      03-525B                     CLASSIFICATION TYPE       C TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry and site experience, except that which was previously addressed in the lead engine report.
A review of the lead engine DR/QR report (Shoreham).
The barring device is used during maintenance operation only and is O' supplied by customer service air rather than. starting air as in the lead engine.

Maintenance from the lead engine report calls for replacing regulator elasto-metric parts every 5 years and draining filter daily while barring device is in operation. There are no modification recommendations from the lead engine DR/QR report. Quality revalidation is not required for this component. PRIMARY FUNCTI0rj Not required ATYRIBUTE TO BE VERIFIED Not required .

%J

PE3228/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-525B-0 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -

                                                         -PROGRAM MANAGER-SC \4ce-h Gf                                                 U O

t O .' PE3228/2 i

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 i

                 -COMPONENT Startino Air Tank                UTILITY Cleveland Electric Illuminatina Company l GROUP PARTS LIST NO.       02-8358         TASK DESCRIPTION NO. DR-03-02-835B-0
                'SNPS GDL NO.        10-111                  CLASSIFICATION TYPE                     A TASK DESCRIPTIONS Design review of this component for Perry Nuclear Power Plant is not required based on the following:

A review of the lead engine DR/QR report (Comanche Peak and Shoreham).
A review of the EDG Component Tracking System indicated no signifi-cant applicable industry or site experience. ;
The tank is similar in configuration to the Comanche Peak tank. It

.                            has the same diameter, length and wall thickness as the Comanche Peak Os                     tank, which has been reviewed and found acceptable (Ref. 3).

The final report done by TDI qualifies this tank by comparison with'the Comanche Peak Tank (Ref. 2).

I' - Special maintenance requirements identified in the lead engine design reviews (Comanche Peak and Shoreham), apply to Perry. The drain valve or float trap n should be monitored daily and excessive amounts of moisture should be reported to determine its cause. There are no modification requirements from the lead engine DR/QR reports for this component. Quality Revalidation is not required for this component. l- PRIMARY FUNCTION i . Not required

               ' ATTRIBUTE TO BE VERIFIED

Not required PE3280/1 i

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

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 SPECIFIED STANDARDS Not required REFERENCES

1. Spec. no. SP-562-4549-00, " Specification of Class 1E Diesel Generators Units, Perry Nuclear Power Plant - Units 1 and 2," through Rev. IV, dated 7-17-78.

2. Final Report Volume I, Part I, " Seismic Qualification of Delaval Turbine Inc. Diesel Generator Sets Serial Nos. 75051 - 75054, for Cleveland Electric Illuminating C3., Perry Nuclear Stations No. I and 2," Project No. 3816, Section III.4, Starting Air Tank, dated May 3, 1978.

3. Stone & Webster Calculation No. 11600.60-NM(B)-001-CZC-007, " Review Calculations for the Starting Air Tank," for Comanche Peak, Rev. O, dated 11/01/84.

DOCUMENTATION REQUIRED / (_)) Not required GROUP CHAIRPERSON w- - - PROGRAM MANAGER 1 % m e _~ yv a O v . PE3280/2

1 Page 1 of 2 l [ , COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 l Air Start Tank Relief COMPONENT Valves UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-835E TASK DESCRIPTION NO: DR-03-02-835E-0 l SNPS GPL NO. 03-800C 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 or site experience.
A review of the lead engine DR/QR report (Comanche Peak).
Both Perry and Comanche Peak air start tank relief valves are Crosoy Model JMBU.

No mainter.'nce or modifications are required based on the lead engine DR/QR report. Quality revalidation is not required for this component. l PRIMARY FUNCTION l Not required ! ATTRIBUTE TO BE VERIFIED Not required i SPECIFIED STANDARDS Not required ( PE3246/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ACCEPTANCE CRITERIA Not required REFERENCES Not required 4 GROUP CHAIRPERSON - PROGRAM MANAGER 3C_\<cv%, _ ~

y/ O l

l l O 1 O PE3246/2

, Page 1 of 2 '" COMPONENT DESIGN REVIEW CHECKLIST

                         .                                                PERRY NUCLEAR POWER PLANT - UNIT 1 Connecting Rods:

COMPONENT Rods and Bushings UTILITY Cleveland Electric Illuminatina Company l GROUP PARTS LIST NO. 02-340A TASK DESCRIPTION NO. DR-03-02-340A-0 , SNPS GPL NO. 03-340A CLASSIFICATION TYPE A p TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System for site, nuclear and non-nuclear industry experience.
A review of the Comanche Peak and Shoreham DR/QR reports, which establish the acceptability of the connecting rod assembly for its intended purpose.

Maintenance recommendations based on the Comanche Peak DR/QR report to ensure O proper performance under normal = operating conditions are as follows:

                                          *-   Measure the clearance between the link pin and link rod.-                         This clearance should be zero,                  i.e.,  no measurable clearance when the specified bolt torque of 1050 ft-lbs is applied.                     This examination may be performed with the engine assembled.

At the first 5 year overhaul visually inspect the rack , teeth surfaces for signs of fretting.

There are no modification recommendations for this component. 2 The following Quality Re'r.lidation inspection recommendations are made to ensure proper component quality and performance, and should be performed on both diesel engines:

Perform a material comparator test on the connecting rods (sample of 4). Use spares if available. Engine 1A only. '
Perform a hardness test on the connecting rods (sample of 4). Use p spares if available. Engine 1A only.
Perform eddy current test on all rod box female threads.
Perform a magnetic particle test on all connecting rod bolts.
Perform a visual inspection of all connecting rod bolt washers and I'

contact surfaces for signs of galling. I

                                  - PE2946/1 w     . . --- - - - - - - --               . . - - -...-,n-~-.-

4 COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 g DR-03-02-340A-0 TASK DESCRIPTIONS (continued)

Verify that the torque loads on all connecting r'od bolts are in accordance with the latest TDI recommended values.
Perform a liquid penetrant test on the surface of the internal diameter of all the wrist pin bushings.
Perform a visual inspection of the rack teeth connection for signs of fretting and prior to reassembly inspect mating surfaces to verify that the minimum manufacturers recommended precent contact surface is available.
Perform a clearance check of the link rods and link pins for proper alignmant.
Verify the proper fit-up for the serrated edge of the connecting rods.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required

          , SPECIFIED STANDARDS Not required REFER 8ENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON
                                                =

PROGRAM MANAGER ) C.\ b % (J V' P J PE2949/2

Page 1 of 2 O U COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 l Connecting Rod: COMPONENT Bearing Shells UTILITY Cleveland Electric Illuminating Co. , l GROUP PARTS LIST NO. 02-340B TASK DESCRIPTION NO. DR-03-02-340B-0 ! SNPS GPL NO. 03-340B CLASSIFICATION TYPE A f l TASK DESCRIPTIONS

Design review for this component is not required based on the following: A review of the Comanche Peak and Shoreha,n DR/QR reports, which establish the acceptability of the bearing shells for their intend- I ed purpose. The applicable engine dimensions and operating parameters at Perry are identical or very similar to those for the same component at q Comanche Peak (Lead Engine). A review of the EDG Component Tracking System indicated that there was no site experience and no significant applicable nuclear or non-nuclear industry experience. Maintenance recommendations based on the Comanche Peak DR/QR report to ensure proper performance under normal operating conditions are as follows: Inspect and measure connecting rod bearing shalls to verify lube oil maintenance, which affects wear rate. The visual and dimensional inspection of the bearing shells should be conducted at the fuel outage that precedes 500 hours of operation by at least the sum of hours of operation in a LOOP /LOCA event plus the expected hours of operation between outages. Perform an X ray examination on all bearing shells using a procedure ~ with sufficient resolution to implement recommendations for acceptance criteria developed by Owners Group connecting rod bearing shells Phase I Report. (A) v PE2873/1

COMPCNENT DESIGN REVIEW CHECKLIST Page 2 of 2 There are no modification recommendations for this component. The following Quality Revalidation inspection recommendations are made to ensure proper component quality and performance, and should be performed on both diesel engines:

Perform a visual inspection of the connecting rod bearing shells.
Perform a liquid penetrant test of the connecting rod bearing shells.
Perform a dimensional check of the connecting rod bearing shells.
Perform a radiographic inspection of the connecting rod bearing shells.
Perform an eddy current test as required to identify surface discontinuities.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON = ~ PROGRAM MANAGER N C \ b % VY PE2873/2

Page 1 of 2 O COMPONENT DESIGN. REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT : UNIT 1 COMPONENT Pistons UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-341A TASK DESCRIPTION NO. DR-03-02-341A-0 SNPS GPL NO. 03-341A CLASSIFICATION TYPE A l TASK DESCRIPTIONS A design review is not required for this component based on the November 1984 Phase I report titled, " Investigation of Types AN and AH Piston Skirts". This Phase I report is applicable to Perry since engines 1A and 1B both have AH skirts. The Phase I report includes a review of the service history of the AH piston skirt. Two separate approaches were undertaken in this review. One approach relied on information supplied by. TDI and showed a positive operating experience for engines with AH skirts. The other approach used the EDG Component Tracking System and showed no reported negative experience due to AH piston skirt initiated events. There is no reported site experience in the w ' Component Tracking System. The Phase I report concludes that based on the combination of experiments, analysis, and field observations, there is no reason to expect that the AH piston skirt is not suitable for service. , There are no maintenance or modification recommendations for this component. The following Quality inspection as delineated in the CQRC is recommended:

Perform a liquid penetrant test on the piston skirts. Map all linear indications in the stud boss area and document with photographs.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required u , PE3038/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER 2CA4a u-, s _ UV 0 0 9 O PE3038/2

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST I PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Piston: Rings UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-341B TASK DESCRIPTION NO. DR-03-02-341B-0 SNPS GPL NO. 03-341B CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the Comanche Peak and Shoreham DR/QR reports, which establish the acceptability of the piston rings for their intended purpose.

The applicable engine dimensions and operating parameters at Perry are identical or very similar to those for the same component at Comanche Peak (lead engine).

A review of the EDG Component Tracking System indicated that there O- was no site specific experience, and no new applicable nuclear or non-nuclear experience.

Maintenance recommendations based on the Comanche Peak DR/QR report to ensure proper performance under normal operating conditions are as follows:

Inspect and measure replacement piston rings in accordance with TDI inspection and maintenance records.
To assure freedom from harmful scuffing, the cylinder liners should be inspected at each fuel outage to evaluate liner wear and coke deposits. Ring replacements and cylinder liner honing should be performed in accordance with TDI maintenance procedures.
When replacing engine oil use H.D. oil that exceeds series 3 standards. The base stock should be more resistant to thermal degradation and coke formation. The additive package should provide high detergent dispersant properties with high alkalinity and a high level of antiwear additive such as zinc dithiophosphate. Total Base Number (TBN) should be 12 to 15 for use with #2 fuel oil and a sulfated ash content of 1.5% to 2.0% is preferred. An engine oil with such properties, Mobilguard 412 or equivalent product may be used to ensure improved lubrication.

./

k. PE2921/1

F COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-341B-0

135* fuel oil spray tips may be used if inspections results indicate a need for additional action to improve lubrication and reduce coke

               . buildup.

There are no modification recommendations for this component. The following Quality Revalidation inspection is recommended to ensure component quality:

Verify piston ring installation is in compliance with TDI assembly requirements for all station engines.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required O SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not req'uired GROUP CHAIRPERSON PROGRAM MANAGER M W e yr u O . PE2921/2 1

Page 1 of 2

   /                                      COMPONENT DESIGN REVIEW CHECKLIST
   's                                    PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Piston Pin Assembly                        UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-341C                         TASK DESCRIPTION NO. DR-03-02-341C-0 SNPS GPL NO. 03-341C                                 CLASSIFICATION TYPE                A TASK DESCRIPTIONS Design review is not required for this component based on review of the lead engine DR/0R reports (Shoreham/ Comanche Peak) and the reported applicable industry experience. There is no site experience listed in the EDG Component Tracking System.

Presently, Perry uses spiral ring retainers (P/N F-108-030) to prevent lateral movement of the wrist pins. For increased engine reliability (as stated in the Shoreham DR/QR report) the following modification is recommended: Replace the spiral ring retainers with Waldes snap ring retainers O, (P/N GE-003-067). No inspection results have been received for this component, therefore, the following Quality inspections as delineated in the CRC are recommended: Perform a material comparator and hardness test on one wrist pin and one spare.

Visually inspect the rolled-end oil plug installations.
Visually inspect the wrist pins for signs of distress.
Perform a dimensional check of one spare wrist pin.

Note: Inspections to be performed on four wrist pins except where noted (Engine 1A and 1B). The following maintenance items are recommended:

Visually inspect all pins for chrome plate da:.iage. ,
Inspect end plugs and reroll or replace any that are loose.

Note: The above inspections should be performed during major engine overhauls and also whenever the pistons are removed and disassembled to an extent that such inspections are possible. J PE2964/1

r COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-341C-0

Perform a liquid penetrant test or a magnetic particle test on all new or replacement pins before installation in engines.

PRIMARY FUNCTION - Not required l ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required S DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER 1. \4t UT o) u PE2964/2

c l , Page 1 of 2 4 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Tappets and Guides: Intake COMPONENT & Exhaust Tappet Assembly UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-345A TASK DESCRIPTION NO: DR-03-02-345A-0 SNPS GPL NO. 03-345A CLASSIFICATION 'YPE A TASK DESCRIPTIONS Design review for this component is not required based on the review of appli-cable industry experience and the lead engine DR/QR report (Comanche Peak). , There' is no reported site experience for this component in the EDG Component Tracking System. ' The following routine maintenance is recommended fo 'is

                                                                              . component:

Verify that the intake and exhaust tappet rollers are free to rotate, and that there is no measurable clearance between the cam rollers and roller pins. This inspection should take place at each outage using TDI -

inspection and maintenance record form 345-1-1.

        -There are no modification recommendations for this component.

The following Quality inspection is recommended to be performed on all engines: e Verify that the intake and exhaust rollers are free to rotate and that no m3asurable clearance exists between the pin and roller. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required

O , PE3062/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-345A-0 O- SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP C:lAIRPERSON

                                                                        - - PROGRAM MANAGER M W %

a V (/ ' 4

O r

i 1 1 4 PE3062/2

Page 1 of 2 O V COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Tappets and Guides: COMPONENT Fuel Tappet Assembly UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-345B TASK DESCRIPTION NO. DR-03-02-345B-0 SNPS GPL NO. 03-345B CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the review of appli-cable industry experience a .d the lead engine DR/QR report (Comanche Peak). There is no reported site operience for this ccmponent in the EDG Component Tracking System. The following routine maintenance is recommended for this component:

Verify that the fuel tappet rollers are free to rotate and that there is no measurable clearance between the cam roller and roller pin. This

   ,-       inspection should take place at each outage.

The are no modification recommendations for this component. The following Quality inspection is recommended to be performed on all engines:

Verify that the fuel tappet rollers are free to rotate and that no measurable clearance exists between the pin and roller.

PRIMARY FUNCTION Not required j ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS l Not required PE3067/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-3458-0 Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON --

                                              - PROGRAM MANAGER 2 C \4a_%
                            }V                                      G O

O PE3067/2

Page 1 of 2 i O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 i

                   -Tappets and Guides - Fuel COMPONENT Pump Base Assembly                        UTILITY Cleveland Electric Illuminatina Company:

i , GROUP PARTS LIST NO. 02-345C TASK DESCRIPTION NO. DR-03-02-345C-0 4 SNPS GPL NO. 03-345C CLASSIFICATION TYPE B I' TASK DESCRIPTIONS Design review of this component for Perry is not required based on the review of applicable industry and site experience listed in the EDG Component Tracking

System, and the lead engine DR/QR reports (Comanche Peak /Shoreham). No r experience items have been reported. The fuel pump base assembly (assembly #

IA-6167), is similar to that used at Comanche Peak, Grand Gulf and San Onofre, (assembly IA-3443), with the only difference being the diameters of the center push rod hole and surrounding boss. The Catawba engines use the same pump base. The Catawba engines have each operated for approximately 800 hours with

no reported difficulties with the fuel pump base.

i No special maintenance or modification requirements were identified in the lead engine design reviews. Initial bolt torque should'be as specified in the

       -TDI Manual.

Quality revalidation is not required for this component. PRIMARY FUNCTION Not required l l t-

ATTRIBUTE TO BE VERIFIED l'

Not required-SPECIFIED STANDARDS Not required O PE3282/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-345C-0 REFERENCES TDI Drawing No. 02-345-05-AF, " Base, Fuel Pump" (listed in the Perry Parts list as the base for the fuel pump base assembly # IA-6167).

DOCUMENTATION REQUIRED Not required

, GROUP CHAIRPERSON PROGRAM MANAGER X W - u. h UV G L 1 i I I i. PE3282/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST O PERRY NUCLEAR POWER PLANT - UNIT 1 Camshaft:

                              - COMPONENT Camshaft Assembly                                                             UTILITY Cleveland Electric Illuminating Company 1                                 GROUP PARTS LIST NO. 02-350A                                                           TASK DESCRIPTION NO. DR-03-02-350A-0 SNPS GPL NO. 03-350A                                                                   CLASSIFICATION TYPE                        A

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

A review of the Comanche Peak and Shoreham DR/QR reports, which l establish the acceptability of the camshaft assembly for its i

intended purpose.

The applicable engine dimensions and operating parameters at Perry are identical or very similar to those for the same component at Comanche Peak (lead engine).
A review of the EDG Component Tracking System indicated that there

was no significant applicable industry or site experience.

! ' Maintenance recommendations based on the Comanche Peak DR/Qf. report to ensure

                             . proper performance under normal operating conditions are as follows:
                                      *-     Perform a visual inspection of all cam lobe surfaces for signs of cracking, pitting or spalling, at each outage.                                                                 Any signs of cracking, pitting or spalling shall be followed by a detailed analysis to evaluate the expected life based on the size and extent of surface distress, and any corrective measures shall be implemented

as indicated by this analysis. Signs of .spalling shall result in .

. immediate replacement of the cam. i There are no modification recommendations for this component.

- The following Quality Revalidation inspection recommendations are made to ensure proper component quality and performance and should be performed on both diesel engines

Visually inspect the cam lobes for indications of premature wear.
No scoring or galling should be found on the camshaft lobes. ,

O

                             ' PE2919/1'
       +w~.r-w.,-,s-..-,.,,ec.-,          ~.  ==m.-- ..e--.r.-.,..---.--,m-_.w.,....w,-.-,,,-.w--.c,ye.-,,g_,,--,---rww-,---mypw,e----                              -,,-,w.ww --,,.n.%, w-,,,-

e-COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-350A-0 f3

    .Q PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required I

l DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON ~- - PROGRAM MANAGER , CCWetwax U' O 4

l l

O -

PE2919/2

Page 1 of 1 COMPONENT DESIGN REVIEW CHECKLIST ( , PERRY NUCLEAR POWER PLANT - UNIT 1 Camshaft: COMPONENT Camshaft Bearing UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-350B TASK DESCRIPTION NO. OR-03-02-3508-0 SNPS GPL NO. 03-3508 CLASSIFICATION TYPE A TASK DESCRIPTIONS__ Design review is not required for this component based on the Comanche Peak lead engine DR/QR report, which establishes the acceptability of the camshaft bearings. A review of the EDG Component Tracking System indicates no significant applicable site or industry experience. There are no maintenance or modification recommendations for this component. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS . Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON 1 - PROGRAM MANAGER NC_Mevu mueg Lp u PE2947/1-

Page 1 of 3 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Camshaft - Supports, Bolting and Gear; Idler Gear Assembly - Crank to Pump Gear; Idler Gear Assembly Cleveland Electric. COMPONENT - Idler Gear Assembly UTILITY Illuminating Co. GROUP PARTS LIST NO. 02-350C,02-355A,02-355B TASK DESCRIPTION NO: DP.-03-02-350C-0

                                                                                                             -355A
                                                                                                             -355B SNPS GPL NO. 03-350C, 03-355A, 03-355B                    CLASSIFICATION TYPE                          A TASK DESCRIPTIONS Design review is not required for these components based on the lead engine DR/QR report (Comanche Peak) which establishes the acceptability of the gear train assembly.            Calculations performed in the analyses of the Comanche Peak and Grand Gulf gear trains demonstrate the acceptability of the gear at Perry.                                      -

O A review of the EDG Component Tracking System indicates no significant ( applicable industry or site experience. The following maintenance recommendations are made to ensure reliability of the components: 02-350C, Camshaft - Supports, Bolting and Gears:

It is recommended that the cam gear be inspected during scheduled refueling outages. The inspection should be directed at pitting.

Any abnomal situations or indications of progressive pitting should reported for an engineering evaluation. A photographic

! record of tooth surfaces should be maintained at the site to aid l in the evaluation of the surface durability. , t If the cam gear and hub are disassembled and reassembled for any reason, it is essential that the nut be re-locked at the position l' corresponding to the prescribed torque range. Insertion of the cotter pin must be accomplished at a torque greater than 50 ft-lbf and less than 90 ft-lbf. If this is not possible, another bolt l and/or nut and/or washer should be used. l O PE3017/1 l

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 3 DR-03-02-350C-0 (q V) DR-03-02-355A-0 DR.03-02-3558-0 02-355A, Idler Gear Assembly - Crank to Pump Gear:

It is recommended that the crank to pump gear and especially' the jacket water pump drive and driven gear be inspected during scheduled refueling outages. The inspection should be directed at pitting. Any abnormal situations or indications of progressive pitting should be reported for an engineering evaluation. A photo- ,

graphic record of tooth surfaces should be maintained at the site to aid in the evaluation of the surface durability. l 02-3558, Idler Gear Assembly - Idler Gear Assembly:

It is recommended that the idler gear be inspected during scheduled refueling outages. The inspection should be directed at pitting.

Any abnormal situations or indications of progressive pitting should be reported for an engineering evaluation. A photographic record of tooth surfaces should be maintained at the site to aid in the evaluation of the surface durability.

The mating surfaces between the idler gear and hub should be thoroughly cleaned with solvent prior to assembly to ensure that there is an adequate friction coefficient between the parts.

If the idler gear and hub are disassembled and reassembled for any

( reason, it is essential that the nut be relocked at precisely the position corresponding to the prescribed torque range. The idler gear-to-hub bolt torque specification should be 80120 ft-lbf. If the cotter pin cannot be inserted at a torque greater than 60 ft-lbf and less than 100 ft-lbf, another bolt, washer, and/or nut should be used. There are no modification recommendations for these components. It is recommended that the Quality inspections listed below be performed and submitted for engineering evaluation. 02-350C, Camshaft - Supports, Bolting and Gears:

Verify that the proper torque values are applied to the bolts (cam to cam gear) on Engines 1A and IB.
Perform a visual inspection of the cam gear for signs of wear, pitting or any other discontinuities, on Engines 1A and 1B.
Determine the hardness of the cam gears, Engine 1A.
Determine the material of the cam gears, Engine 1A. Material to be AISI 4340.

O - PE3017/2

COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 DR-03-02-350C-0 DR-03-02-355A-0 O 02-355A, Idler Gear Assembly - Crank to Pump Gear: DR-03-02-355B-0

Perform a visual inspection of the crank to pump gear for wear, pitting, or any other discontinuities on gear teeth, where accessible, on all station engines. *
Perform a hardness test and material comparator test on crank to pump gear, one station engine only.

02-355B, Idler Gea- Assembly - Idler Gear Assembly:

Perform a visual inspection of the idler ger.rs (photograph gear teeth) for pitting, wear, or chips / nicks on all station engines, where eccessible.
Perform hardness test and material comparator test on gears (P/N 02-355-01-0E), on one station engine only. Hardness to be 380-405 Brinell. Material to be AISI 4340.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS l l Not required REFERENCES Not required GROUP CHAIRPERSON -

                                                            - _    PROGRAM MANAGER,CC \&mei             s (JV'                                                        o O

PE3017/3 i l

Page 1 of 2

     .'                                                        COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Subcover                                              UTILITY Cleveland Electric Illuminating Co.

GROUP PARTS LIST NO. 02-362A TASK D2SCRIPTION NO. DR-03-02-362A-0 SNPS GPL NO. 03-362A CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of applicable industry and site experience and the lead engine DR/QR reports (Shoreham and Comanche Peak). There are no modification recommendations for this component. The following Quality Revalidation inspections are recommended to assure component quality and apply to both engines:

Perform a visual inspection on the web area of the subcover assembly and examine for indications of cracking (four per engine).
Perform a liquid penetrant test of the subcovers on the machined surfaces of the rocker shaft assembly bolt boss (pedestal) for evidence of linear indications.

I-i _ Quality inspections conducted at Catawba and Comanche Peak ~ identified several cracked subcover pedestals. The majority were located near the intermediate rocker arm assembly. The pedestals here are counterbored 1/2 inch deep to accept hollow dowels (bushings) that keep the rocker arm shafts from moving

laterally under the loads generated by the connector pushrods. The reported: i. pedestals each had a tight crack running down through the web between the -

l counterbore and the machined surface. This type of cracking could- be l initiated by improper disassembly / assembly of the rocker shaft or an excessive interference fit between the rocker shaft dowel and the subcover pedestal counterbore (TDI drawings specify a clearance of .000 to .0015 inch). Metallurgical examination indicates that the crack, once ' initiated, may propagate by fatigue. Although there is no documentatiois of engine failure directly attributed to cracked subcover pedestals, cracks that extend into the threaded portion of I the hole for the rocker arm capscrews could cause a decrease in bolt torque. To prevent this possibility, the following inspection is recommended: Perform a liquid penetrant test on the top and vertical machined surfaces of the subcover pedestals -(conriector pushrod side only) for signs of cracking at the counterbores. PE2876/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-362A-0 O (Q NOTE: This inspection is to be performed in conjunction with the rocker arm bushing inspections when the rocker arm shafts are removed from the subcovers. Sub: overs with pedestal cracks that extend through the counterbore web down to the threads should be replaced. This inspection is to be performed at major engine overhauls (5 years). PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required n

GROUP CHAIRPERSON ,

                                                     - + PROGRAM MANAGER M N t, - %

U l U V' I e PE2876/2. l

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST ( PERRY NUCLEAR POWER PLANT - UNIT 1 Rocker Shaft Assemblies: Intake / Intermediate & COMPONENT Exhaust UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-390A&B TASK DESCRIPTION NO. DR-03-02-390A&B-0 SNPS GPL NO. 03-390A&B CLASSIFICATION TYPE B TASK DESCr.IPTIONS Design review for this component is not required based on the following:

A review of the Comanche Peak and Shoreham DR/QR reports, which establish the acceptability of the rocker shaft assemblies for their intended purpose.
A review of nuclear and non nuclear industry experience listed in the EDG Component Tracking System indicated there had been no design related failures associated with this component. There is no site O. experience listed in the Component Tracking System.

There are no maintenance or modification recommendations for this component. The following Quality Revalidation inspection ' recommendations are made to ensure proper component quality and performance:

Perform a visual inspection (both engines) of the intake, intermedi-ate and exhaust rocker arm assemblies for signs of distress, linear indications and chipped pieces in the swivel pads and outer lips of the pushrod cups. The lips should be flush in the assembly.

l

Perform a material comparator test on one intake / intermediate rocker aru shaft and one exhaust rocker arm shaft (one engine only).

PRIMARY FUNCTION Not required PE2875/1 t w--, g-,w- -w -wr ---*r --- +n--r+= - -------i--- ---e--+--y- - -

                  -e     %     w         *--t

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-390A&B-0 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required

                                    % PROGRAM MANAGER Mh%h O GROUP CHAIRPERSON vr                                             a~

O PE2875/2

TDI OWNERS GROUP FOR PERRY NUCLEAR POWER PLANT Rocker Ams and Pushrods: Exhaust Rocker Shaft Assembly , COMPONENT PART NO.: 02-390B ! See Component Part No.: 02-390A e i I k r 6 ? i I e h i I -

                                                                                                                               ...um ... .-- .        .       .

i

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

Page 1 of 2 (O 'd COMPONENT DESIG;4 REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 - COMPONENT Main and Connector Pushrods UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-390C&D TASK DE"CRIPTION NO. LR-03-02-390C&D-0 SNPS GPL NO. 03-390C&D CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the Comanche Peak and Shoreham DR/QR Reports, which establish the acceptability of the friction welded and forged head pushrods for their intended purpose.
A review of the nuclear and non-nuclear industry experience listed in the EDG Component Tracking System indicated there had been no design related failures associated with friction welded or forged head pushrods. There is no site experience listed in the Component Tracking System.

There are no maintenance or modification recommendations for this component. The following Quality Revalidation inspections are recommended to assure proper component quality and performance and should be performed on all pushrods (both engines):

Verify that the main and connector pushrods are friction welded.
Perform a liquid penetrant test on all friction welded main and connector pushrods. As an alternative, visual inspection may be used if a thorough wipedown of the surface is done to remove any coatings or deposits on the surface. No surface cracks should be allowed along the bond line between the rod end and the tube.

For future purchases of pushrods, it is recommended that the purchase order specify destructive verification of weld quality by sectioning random samples from each manufacturing lot. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required v PE2881/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ts DR-03-02-390C&D-U SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - PROGRAM MANAGER M C W w w e m (j e- a. o V O\ . v PE2881/2

m O TDI OWNERS GROUP FOR PERRY NUCLEAR POWER PLANT Rocker Anns and Pushrods: Pushrods Connector COMP 0NENT PART NO.: 02-390D See Ccmponent Part No.: 02-390C O O 4 p_m.-.are---e-we-wa-m**---'*'m - *- * " ' * " ~ " ' " * * -

Page 1 of 2 N 1 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Rocker Arms and Pushrods: COMPONENT Bushings UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-390E TASK DESCRIPTION NO. DR-03-02-390E-0 SNPS GPL NO. 03-390E CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following: A review of the Comanche Peak and Shoreham DR/QR reports, which establish the acceptability of the bushings for their intended purpose. The applicable engine dimensions and operating parameters at Perry are identical or very similar to those for the same component at Conianche Peak (lead engine). [ t v

A review of the EDG Component Tracking System indicated that there was no site experience and no significant applicable nuclear or non-nuclear industry experience.

Maintenance recommendatiors based on the Comanche Peak DR/QR report to ensure proper performance under normal conditions are as follows: ,

Visually inspect and measure the intake, intermediate, and exhaust rocker arm bushings. The periods of engine operation to wear the bushings from an initial clearance of 0.0045 inch (diametral) to 0.010 inch (value at which bushings should be replaced were calculated to be: 2300 hours - Intake, 730 hours - Intermediate, and 1300 hours - Exhaust. It is recommended that an inspection be conducted at the fuel outage which precedes the applicable number of engine hours of operation in LOOP /LOCA event plus the expected hours of operation between outages.

No modifications are recommended for this component. No Quality Revalidation is required for this component. PRIMARY FUNCTION Not required PE2874/1 l

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-390E-0

  .A ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON             -

PROGRAM MANAGER ,9 C.\ 4 t w e Vf/ O PE2874/2

Page 1 of 2 O (Q COMPONENT DESIGN REVIEW CHECKLIST-PERRY NUCLEAR POWER PLANT - UNIT 1 Rocker Arms and Pushrods: COMPONENT Lifters UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-390F TASK DESCRIPTION NO. DR-03-02-390F-0 SNPS GPL NO. 03-390F CLASSIFICATION TYPE B 6 TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the Comanche Peak and Shoreham DR/QR reports, which establish the acceptability of the hydraulic lifter for its intend-ed purpose.
A review of nuclear and non-nuclear industry experience listed in the EDG Component Tracking System indicated that there had been no design related failures associated with this component. There is no site experience listed in the Component Tracking System.

The only adverse experience with this component involves collapsed lifters which occurred when the lifters were installed upside down. Quality inspections have not been conducted to date at Perry to verify correct lifter installation. There is no maintenance or modification recommendations for this component. The following Quality Revalidation inspection recommendations are made to ensure proper component quality and performance and should be performed on both diesel engines:

Verify tnat the hydraulic lifters are installed with the plunger l

(hole side up) at the top of the lifter assembly, and the barrel at I

the bottom.

Perform a leak down rate test on the lifters.

PRIMARY FUNCTION Not required i l lO PE2880/1 l ( i-

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-390F-0 , ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON v r- a PROGRAM MANAGER SC Mc-%

                                                                                    -a i

O . P22880/2 i

COMPONENT DESIGN REVIEW CHECKLIST

                                                          . PERRY NUCLEAR POWER PLANT - UNIT 1 Rocker Arms and Pushrods -

COMPONENT Misc. Bolts and Drive Studs UTILITY Cleveland Electric Illuminatina Company

            . GROUP PARTS LIST NO. 02-390G                                        TASK DESCRIPTION NO DR-03-02-390G-0 SNPS GPL NO. 03-390G                                               CLASSIFICATION TYPE                B TASK DESCRIPTIONS Design review for this component is not required based on applicable industry
            . experience, the Phase I report, and the lead engine DR/QR report (Comanche Peak). There is no site experience in the EDG Component Tracking System for this-component. The industry experience of rocker arm bolt failures has been attributed to insufficient preloading.

The following maintenance recommendation is made for this component to improve reliability:

Verify that the proper torque is applied to the rocker arm bolts O (365 f t-lbs). This inspection should take place at each refueling outage if the rocker arms are disassembled for inspection.
Verify that the rocker are drive studs are intact and tight. This inspection should also be performed at each outage.

There are no modification recommendations for this component. The following Quality inspections are recommended to be performed on all station engines:

Verify that the proper , torque loads are applied to the rocker are capscrews. !
Perform a magnetic particle test on the thread root area of all capscrews for linear indications.

i e Perform a material comparator test on four capscrews.

Perform a hardness test on four capscrews.

!:

Perform a visual inspection on the drive studs for signs of irregu-j larjty.
Verify that there is no movement of the drive studs in the rocker arm.

O

PE3149/1 i

t t

    , _ _ . _ , - - - ~ , . , , - ,_
                                  , - . . , _             _ _ . - - _ , . - _ - -                                             ___-I

LOMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-390G-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON =

                                         ' PROGRAM MANAGER 3 C u m w u 4 % _

y V' V i O - PE3149/2

l COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Front Gear Case'- , COMPONENT Gaskets and Bolting UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-335B TASK DESCRIPTION NO: DR-03-02-3358-0 SNPS GPL NO. 03-3358 CLASSIFICATION TYPE A TASK DESCRIPTIONS

  . Design review of this component is not required based on the review of Comanche Peak lead engine DR/QR report (Ref. 1), TDI Parts Manual Volume II for - Perry and Comanche Peak Power Stations (Refs. 2 and 3), manufacturer's drawings for the front gear case assembly (Ref. 5), and the amplified response acceleration- spectra curves for Perry Station (Ref. 6).         The EDG Component Tracking System identifies no industry or site experience for this component.

The front gear case assembly for Perry Station (Parts List 02-335-03-06),with the exception of the cover for the crankshaft opening, is identical with that for Comanche Peak Station (Parts List 02-335-03-07). The bolting (Part No. GB-011-069) associated with the cover for the crankshaft opening for both O stations remains the same and consists of six socket-head capscrews 1/2 in.-13 NC by 1 in. long. This cover is a nonstructural member and has, therefore, no effect on the design integrity of the front gear case and its associated bolting.

  ~The front gear case serves as a lubricant seal and support for the engine driven lube oil pump, engine driven jacket water pump, governor, the overspeed trip / engine driven fuel oil pump assembly, and the outboard bearings of the two camshafts and the two idler gears. The primary function of the bolts and gaskets is to support the gear case cover and resist pipe loads and gear train loads imposed by the attached components while maintaining an adequate oil seal. The front gear case consists of the gear case right bank (Part No.

02-335-03-ON) and the gear case left bank (Part No. 02-335-03-0M). The left bank and right bank halves are joined by seven hexagon-head capscrews (Part No. GB-002-125, S/8 in. 18 NF x 3 1/4 in. long) and three studs (Part No. 98915, 5/81n. 18 NF x 3 1/4 in. long) and the associated nuts. The gear case

,  as.sembly is bolted to the engine by 34 hexagon-head capscrews (Part No.

G8-001-120, 5/8 in. 11 ' NC x 2 in. long). The . gasket set (Part No. 97555) consists of bottom section gasket (Part No. 97438), vertical section lower gasket (Part No. 97441), center section top gasket (Part No. 97442), and outer section top gasket (Part No. 97443).

O - PE3305/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 3 3 DR-03-02-335B-0 x ,) At Comanche Peak, all forces and moments due to the deadweight seismic inertia, and engine vibration loads from the attached components, as pell as piping loads and bearing reactions transmitted to the gear case, were evaluated for the determination of the bolt loads and stresses at the gear case bolting (Part No. GB-001-120). The bo'lts were torqued to 60 ft-lb (Ref.

1) at assembly, and the calculated bolt forces were less than the pretension resulting from the bolt torque.

Review of the amplified response acceleration spectra curves for Perry (Ref.

6) indicates that the seismic loadings are move favorable than those at the Comanche Psak Station. The TDI Instruction Manual (Ref. 4) also indicates that the bolt torque value is identical and would result in identical bolt pretension as Comanche Peak Station. Piping loads on the components supported by the gear case cover are similar to those at Comanche Peak Station because of the similarity of design of the auxiliary sub-base and the sub-base mounted lube oil sump tank and jacket water standpipe.

Similarity of design between the Comanche Peak and the Perry emergency diesel. generator units suggests that the findings of the DR/QR Report for Comanche Peak lead engine are equally applicable to the Perry engine, and that the front gear case bolting and gaskets are adequate for their intended use.

There are no special maintenance requirements identified in the lead engine report, however, a QC inspection of the bolts at Shearon Harris (CP&L NCR h V 84-1777) showed two bolts internal to the gearcase that were not evident on the parts manual drawing. These two bolts are part of the perimeter bolt pattern that attaches the cover to the block, but are internal and must be accessed by removing a cover plate or the governor supporting assembly. These bolts must be torqued the same as the other bolts. The CP&L inspection found that no positive means of locking was provided. Considering the damage these bolts could cause if they loosen, it is recommended that these bolts be inspected at Perry and positive locking features (bent tab or lockwire) be added, and bolts be properly torqued in accordance with the TDI manual. The following Quality inspection should be performed on each engine:

Verify that the proper grade colting and bolt torque values are used for the gear case.

PRIMARY FUNCTION Not required l O PE3305/2 1

COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 O DR-03-02-335B-0 V 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. 02-335B.

2. TDI Manual Volume II, for Model DSRV-16-4 Diesel Engine / Generator, Perry Nuclear Power Plant, Units 1 and 2, Parts List No. 02-335-03-06.

3. TDI Manual Volume II for Model DRSV-16-4 Diesel Engine / Generator, Comanche Peak Steam Electric Station - Unit 1, Parts List No.

02-335-03-07. h,'L/ 4. TDI Manual Volume I for Model DSRV-16-4 Diesel Engine / Generator, Perry Nuclear Power Plant, Units 1 and 2.

5. TDI Drawings 02-335-03 and 02-335-2436.

6. Gilbert Associates, Inc., Specification SP-562-4549-00 for Class 1E Diesel Generator Units, Rev. II dated January 11, 1977, Attachment Specification for Seismic Analysis, Testing, and Documentation, Perry Nuclear Power Plant -

Units 1 and 2, SP-750-4549-00 dated August 30, 1973. DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON = -- PROGRAM MANAGER 3 C % m - w s (f f ' d PE3305/3

TDI OWNERS GROUP FOR PERRY NUCLEAR POWER PLANT , i

        ' Idler Gear Assembly: Crank to Pump Gear COMPONENT PART NO.: 02-355A See Component Part No.: 02-350C
                                                                                   '     s e

h r e f I i e a I

                                     .~          -

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O TDI OWNERS GROUP FOR PERRY NUCLEAR POWER PLANT Idler Gear Assembly: Idler Gear Assembly COMP 0NENT FART NO.: 02- 355B See Component Part No.: 02-350C O . b p* S O

l Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST U' PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Flywheel UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-330A TASK DESCRIPTION NO: DR-03-02-330A-0 SNPS GPL NO. 03-330A CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the following:

There is no relevant site or applicable industry experience listed in the EDG Component Tracking System.
The DR/QR report for Comanche Peak indicated a sufficiently large factor of safety for the flywheel to cover the larger diameter flywheel used at Perry (90 inch versus 68 inch).

There are no maintenance or modification recommendations for this component. Quality Revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required

 .I o

PE3068/1

i COMPONENT DESIGN REVIEW CHFCKLIST Page 2 of 2

                                                                                                            ^'          i DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON                =
                                                      - PROGRAM MANAGER .MMa%

V V' o O t J l i l l l PE3068/2 l l

Page 1 of 2 (' COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Flywheel Bolting UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-330B TASK DESCRIPTION N0. DR-03-02-330B-0 SNPS GPL NO. 03-3308 CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the review of the following:

The Comanche Peak lead engine DR/QR report.
The EDG Component Tracking System for applicable industry and site experience (Refs. 3 and 4). The Component Tracking Syster. cited the TDI Service Information Memo No. 64H for an increase in torque load for the in-line engine flywheel bolts; this memo, however, does not apply to the V-16 engines and therefore has no impact on the Perry Nuclear Power Plant.

Design information furnished in TDI Parts Manual Vol. II (Ref. 2).

The flywheel assembly for Perry Nuclear Power Plant has the identical quantity (12) and part numbers (97253 and F-090-038 for bolts and nuts, respectively), as well as bolt torque requirements (4,500 ft-lb) for the flywheel bolting components as those for the Comanche Peak Station (Ref. 5). The design of the flywheels is different with the engine flywheels for the Perry site being considerably larger. This, however, has insignificant effect on the maximum and minimum torque transmitted by the flywheel (Ref. 6). At both Comanche Peak and Perry sites, the flywheel is assembled to the engine crankshaft flange and the generator flange with the mating surfaces lubricated with anti-seize lubricant; the flywheel bolts are lubricated and fitted to the bolt-holes. This assembly procedure results in a favorable ratio of the torque transmission capability over the peak torque transient. Design calculation performed on the flywheel bolting for the V-16 engines (Ref. 6) indicates that a large design margin exists, and that two bolts would be adequate to carry the applied shear load from the peak transient torque. The flywheel bolting at Perry Nuclear Power Plant is therefore adequate for its intended application. There are no modification or maintenance recommendations for this component. Quality revalidation is not required for this component. O PE3233/1

r COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-3308-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES

     .1. Comanche Peak Stea,a Electric Station - Unit 1, DR/QR Report for Group Parts List No. 02-330B.

2. TDI Parts Manual, Volume II, for Model DSRV-16-4 Diesel Engine / Generator, Perry Nuclear Power Plant, Units 1 and 2, Parts List No. 02-33-0-01-10 and Drawing No. 02-330-01.

f (

3. Emergency Diesel Generator Component Tracking System Non-nuclear Industry Experience dated November 5,1984.

Nuclear and

4. Emergency Diesel Generator Component Tracking System -

Perry Nuclear Power Plant dated November 5, 1984.

5. TDI Parts Manual, Volume II, for Model DSRV-16-4 Diesel Engine / Generator, Comanche Peak Power Station, Parts List 02-330-02-05 and Drawing No.

101505.

6. SWEC Calculation No. 11600.60-NM(B)-001-CZC-004, " Flywheel Mounting Bolts, Design Review and Seismic Qualification".

7. Flywheel torque excursions. Memorandum to P. Titus from Lisa Shusto dated l October 16, November 5, November 20, 1984. Attachment B included in i Reference 6.

l DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON d - PROGRAM MANAGER, DC WmwMLA lO . yr o PE3233/2

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

s Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Engine and Auxiliary Module Wiring Material and Fittings; ' Pyrometer Conduit Assembly - Conduit,. Fittings and COMPONENT Supports UTILITY Cleveland Electric Illuminating Company ' 02-688A DR-03-02-688A-0 GROUP PARTS LIST NO. 02-630A B.C TASK DESCRIPTION NO. DR-03-02-630A B.C-0 03-688A SNPS GPL NO.-03-630A B.C CLASSIFICATION TYPE A

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

A review of the EDG Component Tracking. System indicated that there was no significant applicable industry and site experience.
A review of the lead engine DR/QR report (Comanche Peak)
A walkdown and inspection of the engines.

The detailed modifications listed in the lead engine DR/QR report (Comanche

Peak) are not applicable to Perry because of the differences in the conduit l layout and conduit supports.

! Based on the walkdown and an inspection of conduit 'and conduit supports, a

review of as-t,uilt drawings, and the results ' of analysis - (Calculation No.

f. 11600.60/CS-11) using input from the specification (SP-750-4549-00), it is recommended to perform an upgrade to tighten /fix, replace or add missing

conduit supports as required. Additional supports are recommended at '8

locations for both engines (Ref. Memo from A.Y.C. Wong to J.C. Kammeyer, dated i 11/30/84).

t There are no maintenance recommendations for this component. b Quality revalidation is not required for this component. ? { I j PE3131/1 i

    ,-,-m-           -            .w,.. _ _ . . . . , -         _,,w..,.,_.,_.,m,_...,m,.__,_...vm-.--,.~.            .,,~.m. __..v.,_m_ ...

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 O DR-03-02-688A-0 DR-03-02-630A,B,C-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required i REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -= PROG' LAM MANAGER 2 C \4c% G (/ ' G l l l O PE3131/2

                                                                                                                   -3 l

TDI OWNERS GROUP FOR , PERPY NUCLEAR POWER PLANT l Pyrometer Conduit Assembly: Conduit Fittings ; COMPONENT PART NO.: 02-630B

                                                        .                                                           r See Component Part No.: 02-630A                                         !

i 4 B 6 r P

                                                                         **                                         l 6

e l L. l l i -- f f. r L - l: s 4

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

l-

 ._.. m _ _ _ _._. _ _ . _ . _ _ _ _ .            _- ._....__.______._____.;.___.___.-...,__.

TDI OWNERS GROUP FOR PERRY NUCLEAR POWER PLANT Pyrometer Conduit Assembly: Support COMPONENT PART NO.: 02-630C See Component Part No.: 02-630A k I ? L l l i 4 j.

                                 -._.-,_.m_,...,;..,.       ._ ,   _ , , , . . . _ , , _ , ,
    .4_,.___.___

Page 1 of 2 (O.j COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Pyrometer Conduit Assembly: COMPONENT Thermocouples UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-630D TASK DESCRIPTION NO. DR-03-02-6300-0 SNPS GPL NO. 03-630D CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the lead eagine (Comanche Peak) DR/QR report which establishes the acceptability of the thermocouples for their intended purpose.
A review of the EDG Component Tracking System indicated that there was no site experience, and no significant applicable nuclear and non-nuclear industry experience.

[] (,)

The applicable engine dimensions and operating parameters at Perry are identical or similar to those for the same component at Comanche Peak.

Maintenance recommendations, based on the Comanche Peak DR/QR report, to ensure proper performance of the thermocouples during normal operation are as follows: l

Check that each thermoccuple's indicated temperature is consistent with the engine's ambient temperature when the engine is cold. _Any inconsistent reading traced to the thermocouple should result in replacement of the thermocouple. This is to be conducted during l every refueling cutage.
Remove, clean and inspect each thermocouple and thermocouple shield for indications of fatigue. Any indications of fatigue should result .i n replacement of the thermocouple and/or thermocouple shield. This will be performed during every other refueling outage.

There is no modification recommendations for this component. No Quality Revalidation is required for this component.

    . PRIMARY FUNCTION h    Not required PE2882/1

e COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ATTRIBUTE:TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not-required () GROUP CHAIRPERSON _ v PROGRAM MANAGER MCW %

   %)                   V V'                                       G

\ PE2882/2

          ..                     .-   -  ..         _ . _ - - - - . _ . - - -                  . . .                    _ - _ = .
 .                                                                                                                                                                                     l
 !                                                                                                                                                                                     l I

TDI OWNERS GROUP n FOR PERRY NUCLEAR POWER PLANT , Engine & Aux Module Wiring Material- Conduit & Fittings; Pyrometer Assembly- l Conduit, Fitting, Supports l COMPONENT PART NO.: 02-688A I { See Component Part No.: 02-630A i i l 4 I e i i e. I l l 4 i i 2 l 4 l

4 , -._n-----w-. _ _..- _-., - ~ , . . ~ L_., ..._.-....~..,_,,-_m.____ - - - . . . - - - , - . . _ - - - - . - - - - - - - - - - . - - -

Page 1 of 2 ! COMPONENT DESIGN REVIEW CHECKLIST ('~ PERRY NUCLEAR POWER PLANT - UNIT 1 Engine & Auxiliary Module Wiring Materials: . COMPONENT Wiring and Terminations UTILITY Cleveland Electric Illuminating Co. GROUP PART LIST NO. 02-688B TASK DESCRIPTION NO: DR-03-02-688B-0 SNPS GPL NO. 03-688B CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the fo' lowing:

A review of the lead engine DR/QR report for Shoreham and Comanche Peak.
A review of the Phase I Report for this component (see References).
A review of the EDG Component Tracking System indicated that there was no significant applicable industry and site experience that had not been addressed in the Phase I report.

b("'N There are no maintenance or modification recommendations from the lead engine DR/QR reports for this component. The Phase I report details all material used in this component and evaluates acceptability of functional attributes. The visual inspection called for on the CQRC has been previously performed as part of the Phase I effort and has been documented in the Phase I report (see References). No further Quality Revalidation is required for this component.

PRIMARY FUNCTION i

Not required l-ATTRIBUTE TO BE VERIFIED Not required

SPECIFIED STANDARDS l l p Not required l V 1 I PE2841/1 i F

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-6888-0 REFERENCES

         " Emergency Diesel Generator Auxiliary Module Control Wiring and Termination Qualification Review," Stone & Webster Engineering Corporation for TDI Emergency Diesel Generator Owners Group, July 1984.

DOCUMENTATION REQUIRED

        -Not required GROUP CHAIRPERSON                     "
                                                      - PROGRAM MANAGER 2 C K - r O

Q(/ O l i l Q v PE2841/2

Page 1 of 1 03-02-688C ,

 /                             COMPONENT QUALITY REVALIDATION CHECKLIST                                  l Eng. & Aux-Module Wiring            Cleveland Electric Illuminating Co.            !

COMPONENT Mat'l- Boxes & Terminals UTILITY Perry Nuclear Power Plant - Unit 1 i a GPL NO. 02-688C REV. NO. 2 SNPS GPL NO. 03-628C TASK DESCRIPTIONS No further review of component 02-688C is required for. the following reasons: a) Boxes and terminals were reviewed on the lead engine (Shoreham) and inspection results were satisfactory. In addition, terminals were reviewed as part of component 02-6888. b) There is no site or industry experience reported for this component. GROUP CHAIRPERSON [esA M C PROGRAM MANAGER N U o U PE2620/1

Page 1 of 2

 /N                                                                   COMPONENT DESIGN REVIEW CHECKLIST U                                                                 PERRY NUCLEAR POWER PLANT - UNIT 1 j

Off-Engine COMPONENT Alarm Sensor Wiring UTILITY Cleveland Electric Illuminating Co. GROUP PART LIST NO. 02-689 TASK DESCRIPTION NO: DR-03-02-689-0 SNPS GPL NO. 03-691B 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 and site experience.
A review of the lead engine lead engine DR/QR report for Comanche Peak.

              *    'The wiring used for this component is similar to that used on the lead engine (Comanche Peak).

There are no maintenance or modification recommendations from the lead engine DR/QR reports for this component. No Quality Revalidation is required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required PE2842/1

f- ' COMPONENT DESIGN' REVIEW CHECKLIST Page 2 of 2 DR-03-02-689-0 DOCUMENTATION REQUIRED Not required

    . GROUP CHAIRPERSON                    w PROGRAM MANAGER d u w d, w jf                                         G O

9 O PE2842/2

Page 1 of 2 7, COMPONENT DESIGN REVIEW CHECKLIST (Q PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT On-Engine Alarm Sensors UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-690 TASK DESCRIPTION NO. DR-03-02-690-0 SNPS GPL NO. 03-690 CLASSIFICATION TYPE B TASK DESCRIPTIONS A design review for the on-engine alarm sensors is not required for Perry based on the following:

A review of the lead engine DR/QR report (Comanche Peak).
The application and manufacturer of the on engine alarm sensors used en Perry is identical to Comanche Peak. A review of vendor information shows that these components are of adequate design to '

perform their intended function. O

There is no Perry site, or non-nuclear industry experience listed in V the EDG Component Tracking System. Nuclear industry experience listed showed no significant experience items.

There are no maintenance or modification recommendations required for the on-engine alarm sensors. Quality revalidation of the on-engine alarm sensors is not deemed necessary.

       -PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not_ required PF.2906/1

COMPONENT 2 SIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-690-0 REFERENCES Not required DOCUMENTATION REQUIRED Not required I GROUP CHAIRPERSON %~ PROGRAM MANAGER M W _ .., ~ m C/ " "

O i

J e 4 9: i l PE2906/2 i 4

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMP 0NENT Off Engine Alarm Sensors UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-691 TASK DESCRIPTION NO. DR-03-02-691-0 SNPS GPL NO. 99-691A CLASSIFICATION TYPE B TASK DESCRIPTIONS A design review for the off-engine alarm sensors is not required for Perry based on the following:

A review of the lead engine DR/QR report (Comanche Peak).
The application of the off-engine alarm sensors used on Perry is similar to Comanche Peak with the exception of Sensilevel level

'               switches (TDI Part Nos. F-528-027 and F-528-029).        These switches are used to sense lube oil level (providing a low level signal to the annunciator) and to sense fuel oil level (providing a high/ low 1             leiel output signal to the annunciator). A review of vendor infor-
  \             mation shows that these components are of adequate design to perform their intended function.

i

There is no Perry site, nuclear or non-nuclear industry experience listed in the EDG Component Tracking System for the off-engine alarm sensors. ,

There 'are no maintenance or modification recommendations required for the off engine alarm sensors. L Quality revalidation of the off-engine alarm sensors is not deemed necessary. l l . I PRIMARY FUNCTION l Not required ! ATTRIBUTE TO BE VERIFIED l Not required O PE2907/1 I

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-691-0 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON % PROGRAM MANAGER M \4ctww. mum L/ r a O O PE2907/2

I Page 1 of 2

    /'~]                                      COMPONENT DESIGN REVIEW CHECKLIST Q                                      , PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Overspeed Trip-Governor UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO.                02-410A     TASK DESCRIPTION NO. DR-03-02-410A-0 SNPS GPL NO.              03-410A               CLASSIFICATION TYPE              A TASK DESCRIPTIONS Design review is not required for this component, based on the Shoreham and Comanche Peak lead engine DR/QR reports, which establish the acceptability of the overspeed trip governor.

A review of the EDG Component Tracking System indicates no significant applicable industry or site experience. The following maintenance items, from the lead engine DR/QR report (Shoreham), are recommended for the Perry Plas ; to ensure reliability of the overspeed trip governor:

Modify the surveillance testing procedures to include verification that the overspeed trip is correctly set to an overspeed trip setting of 518 +/- 1% rpm at every refueling outage, ensuring that

! both the electric governor and the mechanical backup governor are properly returned to their normal settings following the overspeed test. The test is to be performed with no load on the engine by increasing the normal governor's- speed setting (s) until a trip occurs. After several inspection periods, the history of the required adjustments should be reviewed to evaluate and possibly modify the testing interval.

After setting the overspeed governor, the aajustment screw positions

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

There are no modification recommendations for this component. The following quality inspections are recommended for all engines to ensure component quality and performance:

Verify proper installation and calibration of the governor overspeed trip in accordance with the Installation and Oil Supply Topic of Woodward Documentation, TDI Manual.

Verify that proper operational procedures are used on the overspeed l p trip governor, in accordance with Woodward Documentation, TDI Manual.

l PE2948/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-410A-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required

SPECIFIED STANDARDS Not required i

REFERENCES Not requ. ired DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER 2CW-2 > y y- m 4 4

                -PE2948/2

Page 1 of 2 (-)j N./ COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Overspeed Trip: Governor and Accessory COMPONENT Drive Assembly UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-410B TASK DESCRIPTION NO. DR-03-02-410B-0 SNPS GPL NO. 03-410B CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review is not required for this component, based on the Comanche Peak lead engine DR/QR report, which establishes the acceptability of the overspeed trip and accessory drive gear and shafting. The component parts under review are identical. A review of the EDG Component Tracking System indicates no significant applicable industry or site experience. There are no maintenance or modification recommendations for this component. (O

  ' ,j   The following Quality Revalidation inspection recommendations, to be performed on one station engine only, are made to ensure component quality and performance:

Confirm that the material of the accessory drive gear, P/N 02-410-01-0A, is AISI 4340. Use material comparator test.
Perform visual inspection of assembled accessory drive gear for wear.
Measure accessory drive gear shaft-to-bearing clearance. This clearance can be measured by placing a dial indicator on the gear and manually moving the gear in all directions.
Perform a visual and LP inspection of the' governor shaft.
Perform a dimensional check of the governor shaft in the bearing area.
Perform superficial hardness tests on outer gear tooth flat (top land) of overspeed governor drive gear, TDI P/N 02-410-01-0A.

PRIMARY FUNCTION

 /~
 'g)
 \       Not required PE2950/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-410B-0

      'TTRIBUTE TO BE VERIFIED A

Not required SPECIFIED STANDARDS Not_ required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON _

                                          - PROGRAM MANAGER 2CMcc e w

()(l' 0 1 i I. l LO

    'PE2950/2 I

Page 1 of 2 ( COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Overspeed Trip: Couplings COMPONENT (Flexible and Spider) UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-410C TASK DESCRIPTION NO. DR-03-02-410C-0 SNPS GPL NO. 03-410C CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the review of'the Comanche Peak lead engine DR/QR report, which establishes the acceptability of the overspeed trip couplings. The parts under review are the same as those of the lead engine.

       -A   review of the EDG Component Tracking System indicates no significant applicable industry or site experience.

The following maintenance recommendations should be implemented to improve the reliability of the Perry design:

Either modify the maintenance specifications to replace the Lovejoy coupling spiders at every refueling outage, or, during the refueling outages, test the coupling elastomer for hardness and replace it, if it has exceeded the coupling manufacturer's specification.
Discontinue use of Loctite 680 on heavy interference fits, but use Loctite 609 in a manner prescribed by TDI SIM 363 during assembly.
Modify the maintenance specifications to check for coupling shaft looseness during refueling outages.
At 'the next refueling outage, remove the present Lovejoy couplings and replace with new units. The shafts upon which each half are to be mounted should be measured and machining modifications made to the coupling halves to keep the interference fit below 0.0005 inch. Other procedures outlined in SIM 363 should be followed, except with using Loctite 609 in place of 680 when reassembled.

3 There are no modification recommendations for this component. The following Quality inspection is recommended to be performed:

Perform a visual examination of the coupling for signs of wear,

             . deterioration or any other discontinuities on Engines 1A and 1B.

O V PE2949/1-

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-410C-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER ) C_ h s e m x - - yll' d i O PE2949/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Overspeed Trip Vent Valve UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-4100 TASK DESCRIP' TION NO. DR-03-02-410D-0 SNPS GPL NO. 03-410D 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. There was no site experience listed in the Component Tracking System.
A review of the lead engine DR/QR reports (Shoreham and Comanche Peak).
Similarity between Perry and lead engine components (AMOT Model 40958).

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

Replace valve o-rings every 5 years There are no modifications required for this component.

Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O PE3232/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-410D-0 REFERENCES Not required DOCUMENTATION REQUIRED , Not required GROUP CHAIRPERSON _ F- PROGRAM MANAGER 2C \<e== h yp- a ' O i m O PE3232/2 1....._-.___..-------...-.-.._--_---. ..,. - --_-_- - .- -. _ - --_.

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Governor Drive: Governor and Tachometer Drive COMPONENT Gear and Shaft UTILITY Cleveland Electric 111uminatina Company

GROUP PARTS LIST NO. 02-411A TASK DESCRIPTION NO. DR-03-02-411A-0 SNPS GPL NO. 03-402A CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review is not required for this component, based on the Comanche Peak lead engine DR/QR report, which establishes the acceptability of the governor drive gears and shafts.

A. review of the EDG Component Tracking System indicates no significant applicable industry or site experience. There are no modification or maintenance recommendations for this component. O The . following Quality inspections are recommended to be performed on one station engine:

Determine' the material of the governor drive gear (P/N 02-411-01-08) and governor driven gear (P/N 02-411-02-AB) by use of comparator. Material to be AISI 4142.

       *     . Perform LP inspections of governor drive for fatigue cracks (after pre-operational testing' or 100 hours running) in the following areas:

(a) Gear / shaft contact surfaces and surfaces immediately adjacent; (b) Gear pins and bores; I (c) Vertical shaft / gear keyway; - (d) Reduced shaft diameter at coupling. n l

PE2951/1 t

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 i DR-03-02-411A-0 f-

     \      PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED

< Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required I GROUP CHAIRPERSON u PROGRAM MANAGER 3CKcwah cp - 1 O PE2951/2

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Page 1 of 2 (~' COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Governor Drive: COMPONENT Couplings, Pins & Keys UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-411B TASK DESCRIPTION NO. DR-03-02-4118-0 SNPS GPL NO. 03-402B CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review is not required for this component, based on the Comanche Peak lead engine DR/QR report which establishes the acceptability of the governor drive coupling, pins, and keys. A review of the EDG Component Tracking System indicates no significant applicable industry or site experience. The following maintenance items are recommended to ensure reliability of this component:

Replace the present neoprene inserts in the Koppers couplings before (v~ ') placing the engines in emergency standby service.
Modify the maintenance schedule to include checking the coupling tightness at refueling outages. If the coupling is found loose, it should be removed, all mating surfaces cleaned, and the unit reassembled using Loctite 609 on the mating surfaces.
Replace the elastomeric insert at refueling outages.

There are no modification recommendations for this component. The following Quality inspections are recommended to be performed on Engines 1A and 1B:

Verify that the elastomeric insert of the Koppers coupling is made of neoprene, by reviewing existing documentation.
Verify that the set screw and drive pins are locked in place in accordance with installation instructions.

t PE2953/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 PRIMARY FUNCTION Not required 1 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS

;        Not required REFERENCES Not required 1
        -DOCUMENTATION REQUIRED
        'Not required l

1 - GROUP CHAIRPERSON M = PROGRAM MANAGER NC.K0 %%% G(/' G I i .i l . I LO t PE2953/2

I 1 Page 1 of 3

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Governor Linkage UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-413A TASK DESCRIPTION NO. DR-03-02-413A-0 SNPS GPL NO. 03-413 CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the review of the following:

A review of the Comanche Peak lead engine DR/QR report. i
A review of the EDG Component Tracking System, which indicates no significant applicable industry and site experience. The Component Tracking System industry experience, however, reported two incidents of loosening governor _ linkage components - a valid concern in the absence of positive locking devices at the lever clamp screws.

Another incident cited binding at the governor linkage components. O. To alleviate such concerns, the required preventive measures. are addressed under maintenance / modification recommendations below. I j

The governor linkage and cross-shaft assemblies are identical for-

                                                            - both Perry and Comanche Peak Power Stations and, based on the review I                                                              for Comanche Peak Station, are sat,isfactory for the seismic and the operational loads.

The cross-shaft assembly includes the fuel control shaft, bearings, and the actuating levers which consist of the cross-shaft lever 102-413-11-AG, , connecting to the extensive link assembly, the fuel control levers 02-413-11AB, and the shutdown lever 02-413-09-AF. The cross-shaft bearings are oil lubricated, sleeve-type, bronze bearings as for Comanche Peak. However, there are some differences in the design details for maintaining oil supply to the ' wicking felt. The arrangement at Perry Station (Ref. 3) is a later design apparently having a large lubricant holding volume but without the washer immediately above the felt. The following maintenance and modification recommendations stated in the Comanche Peak lead engine DR/QR report should be implemented: i LO PE3235/1 _ t

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 3 DR-03-02-413A-0 TASK DESCRIPTIONS (continued)

The cross-shaft bearings should be lubricated monthly, and all rod-end fittings should be greased at each outage to maintain proper service.
To prevent loosening of governor linkage components, a periodic inspection for loose parts should be performed and suitable locking hardware should be added to the lever bolts and roll pins experiencing such problems.

The following inspections, as described in the Component Quality Revalidation Checklist and the Task Evaluation Report TER No. 99-021, shuuld be performed on all the station engines:

Visual inspection on the governor linkage to detect signs of corrosion, wear, pitting, and discoloration.
Verification of the installation of roll pins to hold the fuel control levers to the cross-shaft.

PRIMARY FUNCTION f3 Not required d ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES

1. Comanche Peak Steam Electric Station - Unit 1, DR/QR Report for Component Part No. 02-413A.

2. TDI Parts Manual, Volume II, for Model DSRV-16-4 Diesel Engine / Generator, Perry Nuclear Power Plant, Units 1 and 2. '

3. TDI Parts Drawings 02-413-12, 02-413-3693, 02-413-3841, anc 02-413-4933.

4. Emergency Diesel Generator Component Tracking System -

Nuclear and Non-Nuclear Industry experience dated November 5, 1984.

5. Emergency Diesel Generator Component Tracking System -

Perry Nuclear Power Station dated November 5, 1984. PE3235/2

l l COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 DR-03-02-413A-0 DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - - PROGRAM MANAGER M C \(cu m m (,J V ~ G O 1 O PE3235/3

                                                                                      -- ,- - - ,-,-             - -       . ,  n
             ~           - - - - -        -       -.,w-,,-w---w-   , - , ~ , - , - ,,
                                                                                                         ,7,,        --

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Governor Assembly: COMPONENT Woodward Governor UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-415A TASK DESCRIPTION NO. DR-03-02-415A-0 SNPS GPL NO. 03-415A CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review is not required for this component, based on review of the lead engine DR/QR report for Comanche Peak, which establishes the acceptability of the Woodward governor. A review of the EDG Component Tracking System indicates no significant applicable industry or site experience. The TDI suggested maintenance schedules, outlined in their instruction manual, should be carefully followed, including daily checks of the oil level, governor tings and mechanical connections, and annual replacement of the hydraulic The following maintenance recommendations should be implemented to improve component reliability:

Modify the surveillance testing procedures to include an evaluation of the governor settings, by means of the two tests given below:

(a) Perform a test of the governor settings, under joint electrical and mechanical governor control, off the. grid in the isochronous mode. (b) Perform a test of the governor settings, under only mechanical governor control, off the grid in the isochronous mode. These tests are to include examination of the engine speed transients under both start and -transient loading conditions. They are to regularly ensure that- the governor' settings are appropriate to avoid the critical speed resonance at '496 rpm, specifically, that the overshoot of the 450 rpm set speed is: no more than 7.5 percent or a maximum speed of 484 rpm, either during a start or when unloaded by the largest single load.

Augment the setting adjustment procedures, as described in the Woodward manuals, to include tests of the governor response during an engine ensure O, indicated above.

start to agreement with the specifications PE2963/1

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

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-415A-0

   .O Q     ,

Modify the maintenance schedules to ensure that the hydraulic actuator is vented per the Woodward Instructions whtin more than a half quart of oil is added to the unit.
Modify the cleanliness control specification to ensure that appropriate procedures are followed when adding or changing the governor oil so as not to contaminate fresh oil and the interior of the governor.

There are no modification recommendations for this component. Quality Revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required l DOCUMENTATION' REQUIRED l 1- ! Not required l' I GROUP CHAIRPERSON PROGRAM MANAGER 2 & wm. %. . O (_/V 1 O J ~ l PE2963/2 i

        ~ . .   .  . __      .,           _ . _ _ _ _         . . _ ~       _       ,    _ _ _ .      ___ ,_.___.,      . __.

Page 1 of 2 A COMPONENT DESIGN REVIEW CHECKLIST U PERRY NUCLEAR POWER PLANT - UNIT 1 Governor Assembly COMPONENT Booster Servomotor UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-415B TASK DESCRIPTION NO. DR-03-02-4158-0 SNPS GPL NO. 03-415B CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the applicable industry experience in the EDG Component Tracking System and the lead engine DR/QR reports (Shoreham/ Comanche Peak). There is no reported site experience in the EDG Component Tracking System. There are no maintenance or modification recommendations for this component. The following Quality inspections are recommend.ed to be performed on all 4 engines:

Booster servomotor should be mounted on the engine at a lower level than the governor to prevent air infiltration into the booster oil lines;
The inlet and outlet lines for the booster should be 3/8-inch and 1/4-inch (or larger) tubing, respectively;
Oil lines should slope upward from the booster to the governor and should have a minimum number of loops or bends. .

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required e

.    (

PE3146/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-415B-0 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON , PROGRAM MANAGERNC \<a.-h ()V G O i !O h PE3146/2 1

Page 1 of 2 i ( ( COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLAllT - UNIT 1 Governor Assembly - COMPONENT Heat Exchanger UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-415C TASK DESCRIPTION NO. DR-03-02-415C-0 SNPS GPL NO. 03-415C CLASSIf! CATION 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 ne significant applicable industry and site experience, with the exception of cooler location.
A review of the Lead Engine DR/QR report (Comanche Peak).
This component was found to be similar to that used on Comanche Peak.

No special maintenance or modifications are recommended for this component based on the lead engine report. The following Quality inspection is recommended to be performed:

Verify that the cooler is mounted below the oil level in the governor, on each station engine.

PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required o-PE3231/1

i COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-415C-0 SPECIFIED STANDARDS Not required REFERENCES t Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - ; PROGRAM MANAGER X.Meu e m UV O O 'T I ( 4 i 4 !O

,                          PE3231/2

_ . , _--_--_--,,.y,,- -.-- , . . _ _ _ . , , , _ _ . _ . _ _ _ _ _ , . , , - , . . . . _ . _ _ - - - _ - . _ _ . . , _ _ _ , _ _ , , _ - , . , , . _ _ . _ , - . -

TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 ENGINE SHUTDOWN EQUIPMENT - TUBING / FITTINGS & SUPPORTS (SMALL BORE SCOPE ONLY) COMPONENT PART NO. 02-695A I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of the structural adequacy of the engine shutdown equipment - tubing / fittings and supports to withstand the effects of normal operating and i earthquake loadings. The primary function is to maintain the capability to effect engine shutdown. II OBJECTIVE The objective of this review was to perform an engineering evaluation of the tubing and supports to assure that the component will perform its intended design function during normal operating and earthquake loadings. O l III METHODOLOGY In order to meet the stated objective, the following methods were used: l

The TDI Emergency Diesel Generator Component Tracking System was

reviewed for the Perry site, nuclear, and non-nuclear industry experience. See Appendix C for results.

The Quality Revalidation Checklist results were reviewed for acceptability.
Engines IA and IB, both partially disassembled, were evaluated using actual walkdown information and comparison to the Comanche - Peak

                    -lead engine report.

Refer to the review procedures as described in Reference 1 for a detailed methodology of this evaluation. IV RESULTS AND CONCLUSIONS-The engine external tubing and supports, as defined by this Component L Design Review, have been evaluated in accordance with Reference 1 and have been found acceptable with modifications. O o PE3211/1 l

Page 2 of 3 O The engine internal tubing and supports (line E19, high temperature

   \d         bearing trip) as defined by this Component Design Review, have been found to be acceptable based upon the results obtained from the review of the comparable components on the DSR-48 engines at Shoreham, and in the fact that a review of all nuclear and non-nuclear industry experiences indicate that there are no design problems that affect the structural integrity of this componenf..              In addition, it should be noted that because of spacial restrictions, all sections of unsupported tubing will meet acceptable span lengths.

There are no TERs associated with this component. The 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 information contained in Reference 2, it is concluded that the tubing and supports will perform their intended design function at Perry under all normal operating and earthquake loadings with the provision that the following recommended ' modifications be implemented as detailed in Reference 3. Engines 1A and 1B Lines E31R, E90, E20 and E89: 1/4-inch tubing to manual stop-run valve from the bulkhead mounted on the governor support casing to the bulkhead w at the engine base should have two-directional restraints added at approximately mid-span to meet 3 foot-6 inch maximum span requirements. Line E19: High temperature bearing trip line should have two-directional restraints added midway between the engine block connections (8 locations). Lines E23H, E24: Turbo and engine vibroswitches should have 'two-direction-al restraints added within 12-inches of the vibroswitch connections to

minimize vibrations at the tubing connections. Tubing supports (poly spacers) should utilize metal cover plates at all locations and should be rigidly attached to the mounting surface. Two screws per support is considered the minimum for proper restraint. I Engine 1A Line E16: High temperature jacket water trip should have a two-directional restraint added in the riser near the governor and between the engine bulkhead and the first existing restraint. Line E34, E92: Right bank turbo oil pressure tubing should have a two-directional restraint located near the riser at the face of the engine between the pressure sensor and the first existing restraint on the engine block. TDI1122/2

Page 3 of 3 g Line E31L: Left bank starting air pressure tubing should have ( 1 two-directional restraints at 4 foot-0 inch maximum span inte.rvals between ' the branch connection on the air start header and the first exist'ing - restraint on the engine block. Restraints should be located near major

,            directional changes to provide lateral stability.

Line E31R: Right bank starting air pressure line should have a two-directiont.1 restraint added in the 16-inch long riser near the air start header branch connection to provide lateral stability. Engine 1B Lines E28, E59: Right bank and left bank combustion air pressure lines should have a two-directional restraint added at the top of the combustion air manifold flange similar to Engine 1A. Lines E21R, E31L: Right and left bank starting air pressure lines should have two-directional restraints added at the bottom of the riser from the starting air header branch connecticas. Line E53: Air supply tubing from the left bank starting air header should have a two-directional restraint added at the end of the platform support bracket. V REFERENCES G 1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," Report No. 11600.60-DC-02, Revision 0.

2. Stone & Webster Calculation number 11600.60-NP(B)-0301-XH.

3. Memo No. 6548 from C. Malovrh/SWEC to J. Kammeyer/SWEC dated 11/29/84.

l l l TDI1122/3

APPENDIX A Page Al of 1 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Engine Shutdown Equipment-Tubing / Fittings , COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatina Co. GROUP PARTS LIST NO. 02-695A TASK DESCRIPTION NO. DR-03-02-695A-0 SNPS GPL NO. 03-695A CLASSIFICATION TYPE B TASK DESCRIPTIONS Perform an engineering review of the tubing and supports to provide additional assurances that the component will perform its intended design function during normal operating and earthquake loading. PRIMARY FUNCTION Maintain capability to effect engine shutdown. ATTRIBUTES TO BE VERIFIED Structural adequacy of the tubing and supports due to the effects of normal operating and earthquake loadings. SPECIFIED STANDARDS IEEE 387 REFERENCES

     " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group" Report No.

11600.60-DC-02, Revision O. DOCUMENTATION REQUIRED Delaval design documentation (specifications, calculations, drawings, etc.). In lieu of information from Delaval, the following information is required: verified support sketches and piping isometrics, material specifi, cations, pipe size and schedule, and operating parameters (pressure, temperature, load h wJ combinations). GROUP CHAIRPERSON PE3021/1 PROGRAM MANAGER M\<n.%-v%

                                  /'                                                           Q

Appendix B Page B1 of 3 03-02-695A

      .M COMPONENT QUALITY REVALIDATION CHECKLIST Engine Shutdown Equipment:             Cleveland Electric Illuminating Co.

COMPONENT Tubing and Fittings UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-695A REV. NO. 2 SNPS GPL NO. 03-695A TASK DESCRIPTIONS Engine 1A

1. Assemble and review existing documentation.

2. Obtain sufficient data to support the design review effort. This may be accomplished by developing quality verified as-builts in accordance with procedure DG-7, or by the Design Group performing a field walkdown.

O Engine 18 b Same as Engine 1A ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package

2. Information necessary for the design review effort Engine IB Same as Engine 1A

( 9 PE2624/1

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 3 03-02-695A ACCEPTANCE CRITERIA Engine 1A

1. Satisfactory D,ocument Package

2. Review of detailed information by the Design Group Engine 1B Same as Engine 1A REFERENCES Engine 1A

1. QCI No. 52

2. Procedure DG-7 Engine 18 Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A

1. Documer.t Summary Sheet

2. Quality verified as-built isometric drawings for the tubing and fittings if available from the Owner.

Engine IB . Same as Engine 1A - GROUP CHAIR.SERSON u_ ,Mb 7 PROGRAM MANAGER M \4es ~ <a am u i-u n v l PE2624/2 i f

                                                                                                      .            _.<_.-,~4   -

e COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 3 09-02-695A COMPONENT REVIEW Engine 1A

1. No EDGCTS site experience documents are in evidence.

2. The Design Group will be responsible for closing out the as-built drawings as per Procedure DG-7. The as-built drawings will be Quality verified by the appropriate site Quality organization. The performance of an engineering walkdown by the Design Group, precludes the issuance of a Quality verified as-built drawing or sketch.

Engine IB Same as Engine 1 RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as O outlined above, is complete. The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of the final report. Engine IB Same as Engine 1A GROUP CHAIRPERSON M9M A <bf PROGRAM MANAGER 1 h - : G 501557/3

Appendix C Page C1 of 2 EDG COMPONENT TRACKING SYSTEM: PERRY SITE, NUCLEAR p(j AND NON-NUCLEAR INDUSTRY EXPERIENCE

SUMMARY

COMP 0NENT NO. 02-695A Effective Printout Date: 11/05/84 COMPONENT TYPE: Engine Shutdown Equipment - Tubing / Fittings REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS PERRY None NUCLEAR Diesel tripped because North Anna 2 Shutdown system worked of high jacket water LER 339-83054 properly. Does not temperature caused by low affect component design lube oil level. or integrity. Engine ran successfully after oil was added. O Instrument line to cooling Palisades jacket water line was Pipe nipples used at Perry are schedule 80, which C/ leaking. Cause found to LER 255-77000 will prevent this problem. be a crack in 1/4-inch Design report for this nipple. component concludes that lines are adequately supported. Air leak found on pressure Zion 2 This event is probably gauge sensing line. LER 304-75000 caused by improper Fittings were tightened tightening of fittings and diesel operated during installation and properly. has not occurred at Perry. Does not affect component design or integrity. Engine tripped because Zion 1 This event is probably of air leak on line to LER 295-80028 caused by improper fuel shutoff pistons. tightening of fittings during installation and has not occurred at Perry. Does not affect component design or integrity, v PE3211/4

Appendix C Page C2 of 2

     /O                              REFERENCE        PERRY V     EXPERIENCE                DOCUMENTS        STATUS Diesel tripped because    Zion 2           This was probably caused of a leak in a line       LER 304-77000    by inadequately supported to the master shutdown                     piping. The design report cylinder. Pipe nipple                      for this component concludes was replaced.                              that the Perry lines are adequately supported. Also, pipe nipples used at Perry are schedule 80, which will prevent this problem.

Diesel tripped because Zion 2 Pipe nipples u' sed at of split pipe nipple LER 304-770691-1 Perry are schedule 80, in control air system. which will prevent this Pipe nipple was replaced. problem. The Design Report for this component concludes that the lines are adequately supported. Dirt particles clogged Monticello 1 The valves, regulators small bleed-off orifice NPRDS 770411 and orifices are recommended in air relay air start to be cleaned on a routine system. basis (see Design Report () NON-NUCLEAR for 02-695B. None l 4 s-PE3211/5 l l t

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST C) PERRY NUCLEAR POWER PLANT - UNIT 1 Engine Shutdown Equipment - Va10es, Regulators, COMPONENT Orifices UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-6958 TASK DESCRIPTION NO. DR-03-02-695B-0 SNPS GPL NO. 03-6958 CLASSIFICATION TYPE A TASK DESCRIPTIONS A design review for the engine shutdown equipment - valves, regulators and orifices is not required for Perry based on the following:

A' review of the DR/QR lead engine report (Comanche Peak).
The engine shutdown equipment valves, regulators, and orifices used on Perry are identical to Comanche Peak, with regard to manufacturer and application. In addition, the configuration of this equipment on Perry in the pneumatic shutdown system to trip on engine e overspeed and to propagate the shutdown signal is also identical to Comanche Peak.
There is no Perry site or non-nuclear industry experience listed in the EDG Component Tracking System for this component. The nuclear industry experience listed does not show any significant problems applicable to Perry design.

To minimize fouling of the engine shutdown equipment valves, regulators and orifices, it is recommended that the equipment be inspected and cleaned and the elastomeric parts be replaced during each refueling outage. This recommended maintenance interval should be reassessed depending on the degree of system fouling. There are no recommended modifications for the engine shutdown equipment valves,~ regulators and orifices.

      -Quality revalidation for the engine shutdown equipment valves, regulators and orifices is not deemed necessary.

PRIMARY FUNCT:0N Not required PE2901/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-695B-0 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required O GROUP CHAIRPERSON yt/ . PROGRAM MANAGER d C l< % 4 O 1 _ 1 i l l LO l l PE2901/2

Page 1 of 2 p3- COMPONENT DESIGN REVIEW CHECKLIST

   \s,,)                         PERRY NUCLEAR POWER PLANT - UNIT 1 Engine Shutdown COMPONENT Trip Switches                UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-695C           TASK DESCRIPTION NO. DR-03-02-695C-0 SNPS GPL NO. 03-695C                   CLASSIFICATION TYPE                 A TASK DESCRIPTIONS A design review for the engine shutdown trip switches is not required for Perry based on the following:

A review of the DR/QR lead engine report (Comanche Peak).
The application and manufacturer of the engine shutdown trip switches used on Perry are identical to those on Comancho Peak.
There is no Perry site experience listed in EDG Component Tracking

(~') System for the engine shutdown trip switches. The applicable

   '\-_/            nuclear and non-nuclear industry experiences listed do not indicate any generic or significant problems with the trip switches.

There are no maintenance or modification recommendations for the engine shutdown trip switches. Quality revalidation of the engine shutdown trip switches is not deemed neces-sary. PRIMARY FUNCTION Not required i i l l ATTRIBUTE TO BE VERIFIED Not required O PE2908/1 L

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-695C-0

SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - PROGRAM MANAGER M C_.\<o.w v - m UV O O . f f 9

O PE2908/2

O TDI DIESEL GENERATOR
DESIGN REVIEW AND
QUALITY REVALIDATION l REPORT 1 PNPP DCCU: .:ENT CONTRCL; CONT.;CL# ~~g lQ uu _g Prepared For uTc .__2.yg

~~

l l l THE CLEVELAND ELECTRIC ILLUMINATING COMPANY I PERRY NUCLEAR POWER PLANT l f l By 4 TDI DIESEL GENERATOR OWNERS GROUP , l l lO 4 VOLUME 4 : i

O How To Use This Report Tabs in this report identify the following categories: Turbo, Intake, Intercooler & Exhaust Lube Oil Engine Base & Bearing Caps Crankshaft & Bearings Cylinder Block, Liners & Water Manifold Air Start & Barring Device Connecting rods Pistons Camshaft & Valve Train Idler Gear Assembly & Front Gear Case Flywheel Engine Instrumentation & Wiring Overspeed Trip & Governor Engine Shutdown & Equipment Jacket Water Cylinder Heads & Valves Fuel Oil Injection O Generator Control Panel Assembly Engine & Auxiliary Sub-Base & Foundation Bolts - These categories have been defined to allow the reader to review a complete diesel generator subsystem in a convenient manner. Within each category tabs identify Perry specific component numbers. A given component report can be found by: a) If the component number is ynown - use the alpha - numberic index which identifies the volume number and category in which the compon-ent report is located. b) If only the component name is known - Section 3.2 may be used as a 3 cross-reference to find the volume number where the component report may be found. Some reports address more than one component. a tab is provided for each

component. However, some components are combined under one report. Slip sheets are provided where required to reference back to the appropriate tab. ,

Some components required more than one report. These are identified by the ! i abbreviation LB-Large Bore and S8-Small 8 ore on the component number tabs. F ! i I ; i

)

! PE3375 j

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

r INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reo'd Category No. F-068 Intercooler X X Turbo, Intake 2 Intrcir. & Exhaust MP022/23 Turbocharger X X Turbo, Intake, 2 Intrcir. & Exhaust 00-420 Lube Oil Pressure X X Lube Oil 2 Regulating Valve 00-442A Starting Air Distributor: X X Air Start & 3 Distributor Assembly Barring Device 00-442B Starting Air Distributor: X X Air Start & 3 Tubing, Fittings, Gaskets Barring Device 00-621A Fuel Oil Drip Tank X X Fuel Oil 4 Assembly Injection 02-CFR Turbocharger Thrust Bearing X X Turbo, Intake, 2 Lubricant System Intrcir. & Ex-h u haust 02-305A Base and Bearing Caps: Base X X Engine Base 2 Assembly & Bearing Caps 02-305C Base and Bearing Caps: X X Engine Base 2 Main Bearing Studs & Nuts & Bearing Caps 02-305D Base and Bearing Caps: X X Engine Base 2 Main Bearing Caps & Bearing Caps 02-307A Lube Oil Fittings: X X Lube Oil 2 Internal - Headers 02-3078 Lube Oil Fittings: X X Lube Oil 2 Internal - Tube & Fittings 02-3070 Lube Oil Fittings Internal: X X Lube 011 2 Supports 02-310A Crankshaft X X Crankshaft & 2 Bearings 02-3108 Main Bearings X X Crankshaft & 2 Bearing 11 PE3375

INDEX (cont.inued) Component Component OR QR Volume Number Description Reg'd Reg'd Category No. 02-310C Crankshaft & Bearings: X X Crankshaft & 2 l Thrust Bearing Rings. Bearing 02-311A Crankcase: Crankcase Assy X X Crankshaft & 2 Bearing 02-3110 Crankcase: Crankcase X X Crankshaft & 2 Mounting Hardware tearings t 02-315A Cylinder Block X X Cyl. Block & 2 Liners & Water Per.1 fold 02-315C Cylinder Block Liners & X X Cyl. Block & 2 Water Manifold - Liners & Cylinder Liner Water Manifold 02-3150 Cylinder Block Liners & X X Cyl. Elock & 2 Jacket Water Manifold Liner, &

               & Piping                                        Water rbnifold 02-315E   Cylinder Block Liners &         X        X      Cy1. Block &     2 Water Manifold: Studs                           Liners &

Water Manifold 02-315F Cylinder Block Liners X X Cyl. Block & 2

               & Water Manifold:                               Liner & Water Cylinder Head Nuts                              Manifold 02-315G   Cylinder Block Liners &         X        X      Cyl. Block &     2 Water Manifold: Seals &                         Liners &

Gaskets Water Manifold 02-316A Jacket Water Inlet Manifold: X X Jacket Water 4 Manifold Assembly W/ Hardware and Coupling and Gaskets 02-3168 Jacket Water Inlet Manifold: X X Jacket Water 4 Coupling and Gaskets 02-316C Jacket Water Inlet Manifold: X X . Jacket Water 4 Vent ifne to Discharge Manifold 02-317A Water Discharge Manifold: X X Jacket Water 4 O Jacket Water Discharge Manifold / Piping 111 PE3375

-- i INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-317B Water Dicharge Manifold: X X Jacket Water 4 Coupling & Seals 02-317C Water Discharge Manifold: X X Jacket Water 4 Supports 02-330A Flywheel X Flywheel 3 02-3308 Flywheel - Bolting X X Flywheel 3 02-335B Front Gearcase - Gaskets X X Idler Gear As- 3 and Bolting sembly & Front Gear Case 02-340A Connecting Rods: Connecting X X Connecting 3 Rods & Bushings Rods 02-3408 Connecting Rod Bearing X X Connecting 3 Shells Rods O 02-341A Pistons X X Pistons 3 V 02-3418 Pistons: Rings X X Pistons 3 02-341C Piston Pin Assembly

X X Pistons 3 02-345A Tappets and Guides: Intake X X Camshaft & 3

              & Exhaust Tappet Assembly                      Valve Train 02-345B   Tappets and Guides: Fuel       X        X      Camshaft &        3 Tappet Assembly                                Valve Train 02-345C   Tappets and Guides: Fuel       X        X      Camshaft &        3 Pump Base Assembly                             Valve Train 02-350A   Camshaft:   Camshaft           X        X      Camshaft &        3 Assembly                                       Valve Train 02-3508   Camshaft:   Camshaft           X               Camshaft &       3 Bearing                                        Valve Train 02-350C   Camshaft: Supports, Bolting    X        X      Camshaft &       3 and Gear                                       Valve Train 02-355A   Idler Gear Assembly Crank      X        X      Idler Gear As-   3 O

V To Pump Gear sembly & Front Gear Case tv PE3375

l i l INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-3558 Idler Gear Assembly: X X Idler' Gear As- 3 Idler Gear Assembly sembly & Front Gear Case 02-359 Air Start Valve X X Air Start & 3 Barring Device 02-360A Cylinder Heads X X Cylinder Heads 4

                                                                 & Valves 02-3608    Cylinder Head Valves:          X         X     Cylinder Heads         4 Intake & Exhaust Valves                       & Valves 02-360C    Cylinder Head and Valves:      X        X      Cylinder Heads         4 Bolting and Gaskets                            & Valves 02-3600    Cylinder Head                  X        X      Cylinder Heads         4
                  & Valves: Springs                              & Valves 02-362A    Subcover                                       Camshaft &

O X X 3 Valve Train b 02-365A Fuel Injection Pump X Fuel Oil In- 4 jection 02-3658 Fuel Injection Equipment - X Fuel Oil In- 4 Fuel Injection Tips , jection 02-365C Fuel Injection Equipment - X X Fuel Oil In- 4 Tube Assembly jection 02-3650 Fuel Injection Equipment: X X Fuel Oil In- 4 Supports jection , 02-371A Fuel Pump Linkage: Fuel X X Fuel Oil In- ' 4 Pump Control Shaft jection 02-3718 Fuel Pump Linkage: Linkage X X Fuel Oil In- 4 Assembly and Bearing jection 02-375 Intake Manifold and X X Turbo, Intake. 2 Piping Intrcir & Ex-haust 02-380A Exhaust Manifold X X Turbo, Intake, 2

     ,                                                           Intrcir. & Ex-J                                                             haust v

PE3375

INDEX (continued) O Component Component DR QR Volume Number Description Rea'd Rea'd Category No. 02-380B Exhaust Manifold: Gasket X X Turbo, Intake, 2 and Bolting Intrcir. & Ex-haust 02-3858 Cylinder Block Covers: X X Cyl. Block & 2 Gaskets and Bolting Liners & Water Manifold 02-386B Crankcase: Crankcase X X Crankshaft & 2 Gaskets and Mounting Bearings Hardware 02-390A Intake & Intermediate and X X Camshaft & 3 Exhaust Rocker Shaft Assembly Valve Train 02-3908 Rocker Arms and Pushrods: X X Camshaft & 3 Exhaust Rocker Shaft Valve Train Assembly 02-390C Main and Connector X X Camshaft & 3 Pushrods Valve Train 02-3900 Rocker Arms and Pushrods: X X Camshaft & 3 Pushrods Connector. Valve Train 02-390E Rocker Arms and Pushrods: X Camshaft & 3 Bushings Valve Train 02-390F Rocker Arms and Pushrods: X X Camshaft & 3 Lifters Valve Train 02-390G Rocker Arms and Pushrods: X X Camshaft & 3 Misc. Bolts & Drive Studs Valve Train 02-410A Overspeed Trip Governor X X Overspeed Trip 3

                                                                     & Governor 02-410B    Overspeed Trip: Governor              X     X         Overspeed Trip               3 and Accessory Drive Assembly                          & Governor 02-410C    Overspeed Trip: Coupling              X     X         Overspeed Trip               3
                                                                     & Governor 02-4100    Overspeed Trip Vent Valve             X     X         Overspeed Trip               3
                                                                     & Governor

[) v . vi PE3375

4 i INDEX (continued) Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-411A Governor Drive: Governor & X X Overspeed Trip 3 Tachometer Drive Gear and & Governor Shaft 02-411B Governor Drive: Couplings, X X Overspeed Trip 3 Pins & Keys & Governor 02-413A Governor Linkage X X Overspeed Trip 3

                                                          & Governor 02-413B   Fuel Pump Linkage:            X             Fuel Oil Injection   4 Automatic Shutdown Cylinder 02-415A   Governor Assembly: Woodward   X        X    Overspeed Trip       3 Governor                                    & Governor 02-415B   Governor Assembly -           X             Overspeed Trip       3 Booster Servomotor                          & Governor 02-415C   Governor Assembly -           X             Overspeed Trip C1           Heat Exchanger X
                                                          & Governor 3

02-420 Engine Driven X X Lube Oil 2 Lube Oil Pump 02-425A Engine Driven X X Jacket Water 4 Jacket Water Pump 02-435A Jacket Water Fittings: X X Jacket Water 4 Pipe & Fittings 02-435B Jacket Water Fittings - X X Jacket Water 4 Supports 02-435C Jacket Water Inlet X X Jacket Water 4 Fittings - Valves 02-436A Intercooler Piping X X Turbo, Intake 2 Intercooler

                                                          & Exhaust 02-4368   Intercooler Piping            X        X    Turbo, Intake       2 Coupling, Gaskets,                          Intercooler &

Bolting Exhaust vii PE3375

r

                              ,         INDEX (continued)

Component Conr,.anent DR QR Volume Number Description Reg'd Reg'd Category No. 1 437 Turbo Water Piping: X X Jacket Water 4 Pipe & Fittings 02-441A Starting Air Manifold: X X Air Start & 3 Piping, Tubing and Fitting Barring Device 02-441B Starting Air Manifold X X Air Start & 3 Valves, Filters & Strainer Barring Device 02-441C Starting Air Manifold: X X Air Start & 3 Supports Barring Device 02-445 Fuel Oil Booster Pump X X Fuel Oil In- 4 jection 02-450A Fuel Oil Header: X X Fuel Oil In- 4 Piping / Tubing jection 02-450B Fuel Oil Header: Fuel X X Fuel Oil In- 4

   ,.             Oil Supports                                              jection 02-455A    Fuel Oil Filters &                  X                     Fuel Oil In-     4 Strainers: Filters                                        jection 02-4558    Fuel Oil Filters &                  X                     Fuel Oil In-    4 Strainers:    Strainers                                   jection 02-455C    Fuel Oil Filters &                  X                X    Fuel Oil In-    4 Strainer: Mounting Hardware                               jection 02-465A    Lube Oil Lines External:           X                 X    Lube Oil        2 Tubing, Fittings, Couplings 02-4658    Lube Oil Lines - External          X                 X    Lube Oil        2 Valves 02-465C    Lube Oil Lines                     X                 X    Lube Oil        2 External Supports 02-467A    Turbocharger: Lube Oil             X                 X    Lube Oil        2 Fitting - Pipe, Tubing, Fittings & Flexible Coupling 02-4678     Turbocharger: Lube Oil-            X                 X    LJbe Oil        2 Fittings - Supports viii PE3375

INDEX (continued) s./ Component Component DR QR Volume Number Descriptien Reg'd Reg'd Category No. 02-475A Turbocharger: Bracket X X Turbo, Intake, 2 Bolting and Gaskets Intrcir. & Ex-haust 02-475B Air Butterfly Valve X X Turbo, Intake, 2 Assembly Intrcir. & Ex-haust 02-475C Turbocharger: Bracket - X X Turbo, Intake, 2 Bolting & Gaskets Intrcir. & Ex-haust 02-500A Control Panel Assembly X X Control Panel 4 Cabinet / System Assembly 02-500F Control Panel Assembly X X Control Panel 4 Accumulator Assembly 02-500G Control Panel X X Control Panel 4 Valves Assembly 02-500H Control Panel Assembly X X Control Panel 4 Pressure Switch Assembly 02-500I Control Panel Assembly: X X Control Panel 4 Control Relays Assembly 02-500J Control Panel Assembly: X X Control Panel 4 Solenoid Valves Assembly 02-500L Control Panel Assembly - X Control P'anel 4 l Piping, Tubing, Fittings Assembly 02-500M Control Panel Assembly: X Control Panel 4 Terminal Boards / Switches / Assembly Wiring 02-5258 Barring Device - Pneumatic: X X Air Start & 3 Regulator Valve / Shut Off Barring Device Valve 02-5250 Barring Device - Pneumatic: X Air Start & 3 Mounting Bracket / Supports Barring Device

    ,   02-540A   Lube Oil Sump                            X    Lube Oil         2 l                  with Strainer Assembly

~

and Mounting Hardware ix PE3375

INDEX (continued) Component Component DR QR Volume Number Description Reg'd Rog'd Category No. 02-5408 Lube Oil Sump Tank: Misc. 1 X Lube Oil 2 Fittings, Gaskets, Pipe

               & Bolting Material, Valves 02-540C    Lube Oil Sump Tank:            X       X         Lube Gil            2 Mounting Hardware 02-550     Foundation Bolts:             X        X         Engine & Aux.       4 Anchors, Bolts, Misc.                            Sub Base &

Hardware Foundation Bolts 02-630A Pyrometer Conduit Assembly: X X Engine Instru- 3 Conduit mentation & Wiring 02-6308 Pyrometer Conduit Assembly: X X Engine Instru- 3 Conduit Fittings mentation & Wiring [ 02-630C Pyrometer Conduit Assembly: X X Engine Instru- 3 ( Support mentation & Wiring 02-630D Pyrometer Conduit Assembly X Engine Instu- 3 Thermocouple mentation & Wiring 02-650A Emergency Diesel Generator X X Generator 4 i 02-650B Generator X X Generator 4 i Control 02-650C Generator-Shaft & Bearing X X Generator 4 02-688A Engine & Aux Module X X Engine Instru- 3 l Wiring Material- Conduit mentation &

j. & Fittings; Pyrometer Wiring i Assembly - Conduit, Fitting, Supports 02-688B Engine & Aux. X X Engine Instru- 3 l Module Wiring Material: mentation &

Wiring & Terminations Wiring O l x i. i l PE3375

INDEX (continued) Component Component DR QR Volume Number Description Reg'd Rea'd Category No. 02-688C Engine & Aux. Module Wiring X Engine Instu- 3 Material: Boxes & Terminals mentation & Wiring 02-689 Off-Engine Alarm Sensors X X Engine Instru- 3 mentation & Wiring 02-690 Engine Alarm Sensors - X X Engine Instru- 3 Temperature & Level mentation & Switches Wiring 02-691 Off Engine Safety Alarm X X Engine Instru- 3 Sensors - Level & mentation & Pressure Switches Wiring 02-695A Engine Shutdown X X Engine Shut- 3 Equipment: down & Equip-Tubing / Fittings & ment s Supports

    ' . 02-695B   Engine Shutdown                X       X    Engine Shut-     3 Equipment: Valves,                          down & Equip-Regulator, Orifices                         ment 02-695C   Engine Shutdown Trip           X       X    Engine Shut-     3 Switches                                    down & Equip-ment i

02-700A Jacket Water Standpipe: X X Jacket Water 4 Pipe, Fittings, Gaskets 02-700B Jacket Water Standpipe: X X Jacket Water 4 Valves 02-700C Jacket Water Standpipe: X X Jacket Water 4 l Pipe Supports l' 02-700E Jacket Water Standpipe: X X Jacket Water 4 Switches 02-700F Jacket Water Standpipe X X Jacket Water 4

                    & Misc. Bolting 02-717A   Auxiliary Skid                X        X    Jacket Water    4
                                    ,            xi PE3375

(~N INDEX (continued) (h Component Component DR QR Volume Number Description Reg'd Reg'd Category No. 02-7178 Aux Sub Base & Oil & X X Jacket Water 4 Water Piping - Jacket Water: Valves 02-717C Aux Sub Base & 011 & Water X X Engine & Aux. 4 Water Piping - Jacket Sub Base & Water: Pipe, Couplings, Foundation Bolts Fittings, Orifices, Y-Strainers 02-717D Aux Sub Base & 011 & Water X Jacket Water 4 Piping - Jacket Water: Gaskets & Bolting 02-717E Aux Sub Base & 011 & Water X X Jacket Water 4 Piping - Jacket Water: Supports 02-717F Aux. Sub Base & 011 & Water X X Lube Oil 2 Piping - Lube Oil: Pipe and Fittings 02-717G Aux Sub Base & Oil & Water X X Lube Oil 2 Piping - Lube Oil: Valves 02-717H Aux. Sub-Base & Oil & Water X X Lube Oil 2 Piping - Lube Oil: Gaskets & Bolting 02-717I Aux Sub Base & Oil & Water X X Lube Oil 2 Piping - Lube Oil: Supports & Mounting Hardware

       '02-717J   Aux Sub Base & Oil & Water    X        X    Fuel Oil            2 Piping - Fuel Oil - Piping
                  & Fittings 02-717K   Aux Sub Base & Oil & Water    X        X    Fuel Oil            4 Piping - Fuel 011:   Valves                 Injection 02-717L   Aux Sub Base & 011 & Water-   X        X    Fuel Oil        -

4 Piping - Fuel Oil - Injection Gaskets & Bolting O xii PE3375

(~'T INDEX (continued)

    \s-) ~                                                                                !

Component Component DR QR Volume i Number Description Reg'd Reg'd Category No. 02-717M Aux Sub Base & 011 & Water X X Fuel Oil 4 Piping - Fuel Oil: Injection Supports 02-805A Intake Air Silencer X Turbo, Intake, 2 Intercooler & Exhaust 02-805B Intake Air Filter X X Turbo, Intake, 2 Intercooler & Exhaust 02-8050 Flex Connections X X Turbo, Intake, 2 Intercooler & Exhaust 02-810A Jacket Water Standby X Jacket Water 4 Heater Pump 02-810B Jacket Water Heat Exchanger X X Jacket Water 4 O's 02-810C Thermostatic Valve X X Jacket Water 4 02-810D Misc. Equipment - Heater, X Jacket Water 4 Jacket Water 02-820A Misc. Equipment - Heater, X Lube Oil 2 Lube Oil Sump Tank 02-8208 Before & After Lube Oil X X Lube Oil 2 Pump 02-820C Lube Oil Full Pressure X X Lube Oil 2 Strainer 02-8200 Lube Oil System - Lube Oil X X Lube Oil 2 i Keepwarm Strainer 1 02-820E Oil Prelube Filter X X Lube Oil 2 02-820F , Full Flow Lube Oil Filter X X Lube Oil 2 02-820G Lube Oil Heat Exchanger X X Lube Oil 2 02-825A Fuel Oil Day Tank X X Fuel Oil 4 Injection L xiii l l -PE3375

INDEX (continued) Component Component DR QR Volume Number Description Req'd Reg'd Category No. , 02-825D Fuel Oil System - Fuel X Fuel Oil 4 011 Duplex Strainer Injection 02-835B Starting Air Tank X X Air Start & 3 Barring Device , 02-835E Misc. Equipment - Starting X X Air Start & 3 Air Tank Relief Valve Barring Device i s 4 i O e f 4 O j XiV PE3375

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Manifold Manifold Assembly With Hardware, Coupling And Gaskets COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-316A&B TASK DESCRIPTION NO. ,DR-03-02-316A&B-0 SNPS GPL NO. 03-316A&B CLASSIFICATION TYPE B l

     -TASK DESCRIPTIONS                                                              -

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

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.

I

A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak)

O

A comparison of the jacket water manifold - menifold essembly with hardware for Perry with Comanche Peak.

The following modification recommendations made on the lead engine DR/QR report should be implemented: l

The tie rod assembly surrounding the 6-inch Dresser coupling requires double-nutting to prevent inward axial movement. Also, a 1-inch diameter rod is required to accommodate the compression load.
The second support west of the 6-inch TDI custom flanges requires stiffening in the lateral direction to accommodate total support loads.

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

     -The following Quality inspection is recommended:

Verify the type of- Dresser coupling installed is in accordance with the TDI Instruction Manual.

O PE3106/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-316A&B-0 O PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required , DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON o PROGRAM MANAGER \4wA () v' a O PE3106/2

                                                                                                                                                                                        ~                                                     t t

P 4 - I I I TDI OWNERS GROUP , FOR PERRY NUCLEAR POWER PLANT Jacket Water Inlet Manifold: Coupling and Gaskets l COPP0NENT PART NO.: 02-316B See Component Part No.: 02-316A i e p 4 e 0 f e-1 i i i I d 4 Y 4 3 e e

                                                                                                                                                                                            b  $S    &O-O           O%-Mg Q%

ag

  ,uw..
        - - - w w- -r-ggyeymwy       m---- g-   s  -geg- - - + ,y,     ,,,-.my,.,--,,w.www,                *-w--w---w-,yr-%w--, - - - , --m-                        - -                --w                     --          - - - + ' -

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Inlet Manifold - Vent Line To COMPONENT Discharge Manifold UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-316C TASK DESCRIPTION NO. DR-03-02-316C-0 SNPS GPL NO. 99-316C CLASSIFICATION TYPE B TASK DESCRIPTIONS A design review is not required for this component based on a review of applicable industry and site experience and a comparison with the lead en' ine g DR/QR report (Comanche Peak).

      -There is no site or industry experience for this component in the EDG                                                                  ~

Component Tracking System. A field walkdown was performed in accordance with Ref. I at Perry Nuclear , Power Plant. However, a review of this component was not possible becaut.e of its uninstalled condition at the time of the walkdown. Therefore, component acceptability and any subsequent recommendations shall be based upon the lead engine DR/QR report. This component is considered essentially the same based on a comparison of assembly drawings No. 02-316-04 from each of the TDI parts manuals Refs. 2 and 3. The lead engine DR/QR report for this component contains no maintenance recommendations. However, the lead engine report does address a support modification. Specifically, the report recommended the provision of a more suitable type of moment connection at the support to structural steel

        -interface.

Therefore, based on .the above review, it is concluded that this component will perform its intended design function at Perry Nuclear Power Plant under i all normal operating and earthquake loadings with the provision that the !~ supports are verified or modified to have sufficient moment connection at the support to structural steel interface. l

Quality Revalidation for this component is not deemed necessary.

l l O PE3037/1 ,

  , _         _ __. . _ _ _ _ _ _ .                 ~ . _ _ _ _ . _ _ _ , . _ _ . _ _ _ . , _ _ . _ _ _ , _ , . _ , _ .

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-316C-0 PRIMARY FUNCTION Not applicable ATTRIBUTE TO BE VERIFIED Not applicable SPECIFIED STANDARDS I None REFERENCES

1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing and Supports for the TDI Owners Group" Report No. 11600.60-DC-02, Revision 0.

2. "Transamerica Delaval Parts Manual Volume II for Model DSRV-16-4" for Texas Utilities Services Inc., Comanche Peak Steam Electric Station, dated 3/6/81.

3. "Transamerica Delaval Parts Manual Volume II for Model DSRV-16-4" for Cleveland Electric Illuminating Co., Perry Nuclear Power Plant, dated 3/31/83.

DOCUMENTATION REQUIRED i Not applicable l l n GROUP CHAIRPERSON WR0 GRAM MANAGER 3C_ %%%~ % V y' O r l 0% U , PE3037/2 l , l c -

l 1 l i l Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Discharge Manifold / Piping COMPONENT (Laroe Bore Scope Only) UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-317A&B TASK DESCRIPTION NO. DR-03-02-317A&B-0 SNPS GPL NO. 03-317A&B CLASSIFICATION TYPE B 1 TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak)

A comparison of the jacket water discharge manifold and piping spool pieces and fittings for Perry with Comanche Peak. There are no maintenance requirements for this component from the lead engine DR/QR report. The following modification recommendations made on the lead engine DR/QR report should be implemented:

The style 65 Dresser couplings are to be replaced with style 90 or style 165 Dresser couplings should leaks develop.

The following Quality inspection is recommended:

Verify the type of Dresser coupling installed is in accordance with the TDI Instruction Manual.

PRIMARY FUNCTION Not required l O PE3101/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required ,

                                        --- PROGRAM MANAGER M C N %

0 GROUP CHAIRPERSON V(/'

u' 1 1 9 l O PE3101/2 9

TDI OWNERS GROUP FOR PERRY NUCLEAR POWER PLANT Water Discharge Manifold: Coupling & Seals COMPONENT PART NO.: 02-317B See Component Part No.: 02-317A 4 i 1

i I ~ i l i t 9

                                     -.-.--...--_m.                         ....m.. . . .

Page l'of 2 f,

     -                                    COMPONENT DESIGN PEVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Water Discharge Manifold -

Supports COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminatina Company

               . GROUP PARTS LIST NO. 02-317C              TASK DESCRIPTION NO. DR-03-02-317C-0 SNPS GPL NO. 03-317C                       CLASSIFICATION TYPE                              B U SK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak)'.
A comparison of the water discharge manifold supports for Perry with Comanche Peak.

There are no maintenance requirements frc,e - the lead engine DR/QR report for this component. I The following modification recommendations made on the lead engine DR/QR j report should be implemented:

Ensure that the supports (attached to the water jacket shroud) on l the two 5-inch headers have a minimum weld of 3-inches long on both sides of the longer end of the plate. Also, ensure that the welds between the existing 3/4-inch plate and engine block have a minimum weld of 1/4-inch along the total width of the plate.

Quality revalidation is not required for this component. PRIMARY FUNCTION Not required i i l PE3102/1 l

4 4 COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 s DR-03-02-317C-0 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required l i REFERENCES i Not. required DOCUMENTATION REQUIRED Not required , GROUP CHAIRPERSON -PROGRAM MANAGER QCN.<c %

O UV- a f

l O PE3102/2 -

w Page 1 of 3 i COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Engine Driven COMPONENT Jacket Water Pump UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-425A ' TASK DESCRIPTION NO. DR-03-02-425A-0 j SNPS GPL NO. 03-425A 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 site experience. Significant applicable industry experi'ence was previously addressed in the lead engine report.
A review of the lead engine DR/QR report (Comanche Peak). ,

The engine driven jacket water pumps at Perry and Comanche Peak are of the same design, but the impellers on the Perry pump are cut to smaller diameters for lower design flows so that the torques, and consequently the stress levels, are lower.

The following maintenance recommendations from the lead engine DR/QR report j should be implemented: i -

It is recommended that the key to keyway interface be checked for a l tight fit on both the pump shaft and the impeller during pump i 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 reassembly. This, along with the drive 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 maxium specified torque; "not to be exceeded." It is l recommended that the minimum and maximum torque values of 120 ft-lb

j. and 660 ft-lb, respectively, be included in - the Perry maintenance procedures.

There are no modifications required for- the pump, based on the lead engine ( DR/QR report. lO PE3293/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 3 DR-33-02-425A-0 0- TASK DESCRIPTIONS (continued) The following quality inspections have not been performed to date and are recommended:

Verify material of shaft with superficial hardness and material comparator test.
Disassemble jacket water pump and visually inspect gears to shaft for signs of excessive scoring wear on shaft and pitting or galling on gear teeth.
Document any questionable items via photograph and submit to design group.
LP roots of gear teeth and transition area (gear to shaft).
Visually inspect clearance ring for evidence of galling or excessive wear. Document, via photograph, any questionable items and submit y

to design group. peroformed on one station

NOTE: To be engine only, provided no unsatisfactory generic conditions are noted. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required j REFERENCES - Not required i i O PE3293/2 l

      ,                     COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON             = m PROGRAM MANAGER ,3 C M %

(_./(/' U O l l . l O PE3293/3

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST - PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Fittings - Pipe and Fittings . COMPONENT (Laroe Bore Scope Only) UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-435A TASK DESCRIPTION NO. DR-03-02-435A-0 SNPS GPL NO. 03-435A CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following: ,

A review of the EDG Component Tracking System indicated that there -

was no significant applicable industry or site experience.

A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak)
The items listed in the letter referenced below are incorporated.

There are no maintenance recommendations made on the lead engine DR/QR report. Quality revalidation is not required for this component. i PRIMARY FUNCTION i Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O PE3105/1 l

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-435A-0 Letter from R. Markovich/G. Shears (Impe11) to J. Kammeyer (SWEC),

                 "Recommende'd Design of Piping Components 02-435A and 02-435B for Perry,"

dated 11/26/84. DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER ) C.\< m V W- u O i O PE3105/2 ll v + < . , ,-

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Fittings-Pipe and Fittings COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminating Co. GROUP PART LIST NO. 02-435A TASK DESCRIPTION N0: DR-03-02-435A-0 SNPS GPL NO. 03-435A CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of the l 1ead engine DR/QR report (Comanche Peak) and the applicable industry experience. There is no site experience for this component in the EDG Component Tracking System. There are no modification recommendations for this component. As a maintenance recommendation, in the event of a leak developing in the existing Dresser style 65 couplings, these couplings should be replaced with uresser , style 90 couplings. This recommendation is made on the basis that the maximum suggested operating temperature of 150* F for the style 65 coupling may be , exceeded. The maximum suggested operating temperature of the style 90 is 212' A field walkdown was performed in accordance with the small bore piping criteria document (Ref.1) and concluded that this component will perform its intended function for normal and earthquake loadings.

Quality revalidation for this component is not required.

i PRINARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED. Not required SPECIFIED STANDARDS Not required O PE3001/1 _ _ _ . _ _ . - , , . _ _ . _ . _ _ _ _ _ _ _ _ . _ . _ _ _ _ - _______..____i

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-435A-0 O's REFERENCES

       " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," report No.

11600.60-DC-02, Revision 0. DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - PROGRAM MANAGER 1 \ b - m .- U[l O I I e f 4 O i O PE3001/2

4 4 Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Fittings:

                ,                                                     Supports COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-4358                                                                    TASK DESCRIPTION NO. OR-03-02-4358-0 SNPS GPL NO. 03-4358                                                                            CLASSIFICATION TYPE                  B TASK DESCRIPTIONS                                                                                              -

Design Review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience.
A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak)
The items listed in the letter referenced below are incorporated.

The following modification recommendation made on the lead engine DR/QR report O should be implemented:

The support on the 8-inch x 8-inch tee located after the pump discharge (Component No. 02-435A) requires modification to restrain in the upward (+y) direction (Ref. 1).

There are no maintenance recommendations from the lead engine DR/QR report for this component. , Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED j Not required i SPECIFIED STANDARDS i Not required

t

!O

PE3164/1 1

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COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-435B-0

1. Letter from R. Markovich/G. Shears (Impell) to J. Kammeyer (SWEC),

         " Recommended Design of Piping Components 02-435A and 02-4358 for Perry,"

dated 11/26/84. DOCUMENTATION REQUIRED Not required. GROUP CHAIRPERSON e PROGRAM MANAGER MC \ () I o O PE3164/2

e Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Fittings-Supports COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminating Co. GROUP PART LIST NO. 02-435B TASK DESCRIPTION NO: DR-03-02-435B-0 SNPS GPL NO. 03-4358 CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak). There is no site or industry experience for this component in the EDG Component Tracking System. There are no maintenance or modification recommendations for this component. A field walkdown was performed in accordance with the small bore piping and tubing criteria document (Ref. 1) and concluded that this component will perform its intended function for normal and earthquake loading. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required l SPECIFIED STANDARDS l l Not required REFERENCES I f

             " Engineering Review Criteria Document for the Design Review of TDI Diesel i             Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," Report No.

11600.60-DC-02, Revision 0. ( O PE3000/1

COMPCh2NT DESIGN REVIEW CHECKLIST Page 2 of 2 OR-03-02-4358-0 DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER Z \<c % W V V' i < l l O !O . PE3000/2

  ~
                                                                                      --~

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Inlet COMPONENT Fittinas: Valves UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-435C TASK OESCRIPTION NO: DR-03-02-435C-0 SNPS GPL NO. 99-435A CLASSIFICATION TYPE B

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

A review of the EDG Component Tracking System indicated that there was no significant applicable industry 'cr site experience.
A review of the lead engine DR/QR report (Comanche Peak). .
Components at both plants are Durabia check valve Model LC2 and Whitey shutoff valve Model Ne. IVM4-54-CS.

There are no maintenance items or modifications for this component from the lead engine report. Quality revalidation is not required for this component. I PRIMARY FUNCTION l l Not required l ATTRIBUTE TO BE VERIFIED l l Not required l l SPECIFIED STANDARDS Not required O PE3248/1

                .                                _J_

                                  ,         COMPONENT DESIGN REVIEW CHECKLIST      Page 2 of 2 DR-03-02-435C-0 ACCEPTANCE CRITERIA Not required REFERENCES Not required GROUP CHAIRPERSON                 - PROGRAM MANAGER 2 C \<

y I' G k l O l l l O PE3248/2

Page 1 of 2 COMP 0NENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Turbo Water Piping-Pipe and Fittings COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminating Co. GROUP PART LIST NO. 02-437 TASK DESCRIPTION NO: DR-03-02-437-0 SNPS GPL-NO. 03-437A CLASSIFICATION TYPE B' TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak) and the applicable industry experience. There is no site experience for this component in the EDG Component Tracking System.

                                     .There are no modification recommendations for this component.
                                                                                                                      ~

As a maintenance recommendation, in the event of a leak developing in the existing Dresser style 65 couplings, these couplings should be replaced with Dresser style 90 couplings. This recommendation is made on the basis that the maximum suggested operating temperature of 150' F for the style 65 coupling may be O exceeded. F. The maximum suggested operating temperature of the style 90 is 212* A field ~ walkdown was performed in accordance with the small bore piping criteria document (Ref.1) and concluded that this component will perform its intended function for normal and earthquake loadings. Quality revalidation for this component is not required. PRIMARY-FUNCTION Not required ATTRIBUTE TO BE VERIFIED !- Not required SPECIFIED STANDARDS Not required 1-l O i PE2999/1 J

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 O REFERENCES - DR-03-02-437-0

                  " Engineering Review Criteria Document for the Design Review of TOI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," report No.

11600.60-DC-02, Revision 0. DOCUMENTATION REQUIRED Not required i GROUP CHAIRPERSON PROGRAM MANAGER 1 \< w VV . 4 4 O , d 1 O PE2999/2

l 1 Page 1 of 2 ' COMPONENT DESIGN Ri: VIEW CHECKLIST PERRY NUCLEAR POWER PLANT 'JNIT 1 Jacket Water Standpige - Pipe, Fittings, Gaskets COMPONENT (Small Bore Scope Or.ly) UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-7004 TASK DESCRIPTION NO DR-03-02-700A-1 SNPS GPL NO. 00-700A CLASSIFICATION TYPE- B , TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR Report (Comanche Peak) and the applicable industry and site experience. , There are no maintenance recommendations for this component. However, the lead ~ engine report does address site specific additions of supports. The necessity for similar additions on Perry is assessed below. . A field walkdown was performed in accordance with the small bore piping and tubing criteria document (Ref. 1) at Perry. However, a review of this component in its entirety was not possible since portions of the tubing on the O air, bubble removal system were not installed at the time of the walkdown. Component acceptability and recommendations shall be based on the walkdown and a review of the lead engine reports (Comanche Peak,-Grand Gulf). It is concluded that this component will perform its intended function for normal and earthquake loading provided the jacket water vent lines of the air

 , bubble removal system are installed in accordance with TDI drawing No.

09-810-75051. Tubing supports should be as indicated in Task Description No. 02-700C. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not_ required SPECIFIED STANDARDS Not required O PE3031/1

                                       . . _ ~                 __             __   _   __       _

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-700A-1 REFERENCES

1. Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," report No. 11600.60-DC-02, Revision O.

DOCUMENTATION REQUIRED Not required

                                                           "      '=

GROUP CHAIRPERSON - PROGRAM MANAGER M V m _ 1 Ljv- e 1 I l O b l O PE3031/2

F Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Standpipe: COMPONENT Valves UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-7008 TASK DESCRIPTION NO. OR-03-02-700B-0 SNPS GPL NO. 00-7008 CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the followingi

A review of the EDG Component Tracking System indicated that there was no industry or site experience.
A review of the lead engine DR/QR report (Comanche Peak). .
Similarity between Perry and Comanche Peak components; both are Circle Seal %" shutoff valves (ASME III).

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

Inspect the valves for packing leakage monthly.
Replace elastomeric parts every 5 years.

There are no modifications recommended for this component. l ! Quality revalidation is not required for this component. I I l PRIMARY FUNCTION Not required

     , ATTRIBUTE TO BE VERIFIED Not required i

!O PE3223/1 i

      . , - , -   , , ,       . - , . . _ , . , - , -     ,,,,,,,,,.,v, ,,-----r-,-     - . - - , , - < -                           - , -

i t COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 O SPECIFIED STANDARDS DR-03-02-700B-0 Not required , l REFERENCES l Not required i DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON = PROGRAM MANAGER,2 C_ W % m Q V' C - l O l

O PE3223/2

f 4 Page 1 of 2 n COMPONENT DESIGN REVIEW CHECKLIST V PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Stand Pipe: Supports COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatina Company l GROUP PARTS LIST NO. 02-700C TASK DESCRIPTION NO. DR-03-02-700C-0

                                       - SNPS GPL NO. 00-700C                                           CLASSIFICATION TYPE                                                                              B TASK DESCRIPTIONS Design review for this component is not required cased on the review of the lead engine DR/QR report (Comanche Peak).                                There is no site or industry experience for this component in the EDG Component Tracking System.

There are no maintenance or modification recommendations for this component. A field walkdown was performed in accordance with the small bore piping anii tubing criteria document (Ref. 1) at Perry. However, a review of this i component in its entirety was not possible since portions of the tubing supports on the air bubble removal system were not installed at the time of the O

,                                       walkdown.           Component acceptability and recommendations shall be based on the walkdown and a review of the lead engine reports (Comanche Peak, Grand Gulf).

It is concluded that this component will perform its intended -function for normal and earthquake loading provided the jacket water vent lines of the air bubble removal system are installed utilizing two-directional restraints at a maximum spacing of 4 ft-6 in for k inch diameter tubing and 5 ft-0 inch for 3/8 inch diameter tubing. A minimum offset of 6 inches around bends is required to accommodate thermal expansion. i-Quality Revalidation for this component is not required. PRINARY FUNCTION Not required I ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O PE3030/1 2

  - . , - - . . , . , - ,,-,-,,..:,-,--,-,---,--,,,,-,,,--.--,-,~,..c-               -----,,,----,,-n--            - - - - - - - , - - - - - - - - - , - - - - - - - - - - - - - - - + - . - ~ - - - - -

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-700C-0 REFERENCES

1. " Engineering Review Criteria Document for the' Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," report No. 11600.60-DC-02, Revision 0.

DOCUMENTATION REQUIRED Not required 1 - GROUP CHAIRPERSON

                                                                                             -- - PROGRAM MANAGER M h w e l                                                                             (. / v '                                                                                   o I

1 J e O PE3030/2

                                                              -_                               - - _ _ , , - . , , . . - _ , _ _ _ . , , . -     ._.._w,,.,,,,._,.----__-...._._,_..-.r   .,

                          .                                                    Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 I

Jacket Water COMPONENT Standpipe Switches UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-700E TASK DESCRIPTION NO. DR-03-02-700E-0 SNPS GPL NO. 00-700E CLASSIFICATION TYPE 8 ; TASK DESCRIPTIONS i A design review of the jacket water standpipe switch is not required for Perry based on the following: !-

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

!

The jacket water standpipe switch use'd at Perry is similar to that used at Comanche. Peak with regard to manufacturer and application,

and both are identified as TDI Part No. F-577-066. .

l' l

The Perry site switch differs from Comanche Peak in the model l number and operating range of the Dwyer Instruments, low l differential pressure switch, used for low level alarming on the i jacket water standpipe. Perry uses a Dwyer D/P switch, Model 1823-80, with operating range of 9 to 85 in. W.C. (low level alarm set point is at 21h in. W.C. below normal operation). Comanche Peak has a Dwyer D/P switch, Model 1823-40, with operating range of 5 to 44 in. W.C. (set point is at 37 in. W.C. - falling).
The sensor tap located below the centerline of the inlet flange on the jacket water standpipe is piped to the differential pressure switch identically for both Perry and Comanche Peak sites.
The Dwyer Instruments low differential pressure switch is compatible with the treated cooling water contained in - the jacket water standpipe and the environment at the Perry site location. The.

design function of the jacket water standpipe switch is adequate for intended service at Perry.

There is no Perry site experience, nuclear or non nuclear industry experience, listed in the EDG Component Tracking System for this component.

There are no maintenance or modification recommendations required for the jacket water standpipe switches. Quality revalidation for the jacket water standpipe switch is not deemed ! necessary. l t' O PE2909/1-

             -                                                           w-m,,,-,,,-,,e-,,,------~~~w,,-w,,      -,e~v

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-700E-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required . DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON 1 _ PROGRAM MANAGER _ M W % m VV O t 4 5 O PE2909/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST . PERRY NUCLEAR POWER PLANT - UNIT 1 Jacketwater Standpipe and COMPONENT Misc. Bolting UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-700F TASK DESCRIPTION NO. DR-03-02-700F-0 SNPS GPL NO. 00-700F CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review of this component for Perry is not required based on the following:

A review of the applicable industry and site experience from the EDG Component Tracking System indicated that no experience items have been reported.
The standpipe and installation at Perry is very similar to that at Comanche Peak which was previously reviewed and found acceptable.

There are no maintenance or modification recommendatioris for this component. Quality revalidation is not required for this component. l PRIMARY FUNCTION ! Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O PE3304/1 l , i l l i _ _ _ . , _ _ _ _ _

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-700F-0 O REFERENCES TDI drawings nos. 102448, 1012081 Gilbert Associates, Inc. Specification SF-562-4549-00; Class 1E Diesel Genera-tor Units, Rev. II, Jan 11, 1977, Perry Nuclear Power Plant Units 1 and 2, Cleveland Electric Illuminating Co., Cleveland, Ohio Final Report Volume 1 Part I Seismic Qualification of TDI Diesel Generator Sets, Serial Numbers 75051/75054 for Cleveland Electric 1110minating Co. , Perry Nuclear Stations No. I and 2. Appx. 1, Jacketwater Standpipe. DOCUMENTATION REQUIRED Not required GRO:JP CHAIRPERSON - PROGRAM MANAGER NC \4a.,wh y vr U O LJ O PE3304/2 I

l l Page 1 of 2 () COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Auxiliary Sub Base & 011

             & Water Piping - Jacket COMPONENT Water: Valves                     UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-717B                TASK DESCRIPTION NO: DR-03-02-7178-0 SNPS GPL NO. 03-717B                        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 and site experience, except that which are previously addressed in the lead engine report,
A review of the lead engine DR/QR report (Comanche Peak).
Similarity between Perry and Comanche Peak components. Both have O Powell valves; 2342 - Check valve, 2491 - Gate valve and 2475-Globe valves.

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

Inspect the valves for packing leakage monthly.

There are no modifications recommended for this component. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required b v PE3249/1

e 4 COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-7178-0 O SPECIFIED STANDARDS Not required ACCEPTANCE CRITERIA Not required i REFERENCES i Not required GROUP CHAIRPERSON e- ~ PROGRAM MANAGER A C \ h U {l'

O i

I 4 O O PE3249/2 4

1 1 Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Aux. Sub Base & 011 & Water Piping-Jacket Water: Pipe Couplings, Fittings Orifices, Y-Strainers COMPONENT (Laroe Bore Scope Only) UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-717C TASK DESCRIPTION NO. DR-03-02-717C-0 SNPS GPL NO. 03-7170 CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on a review of the applicable industry and site experience in the EDG Component Tracking System and the lead engine DR/QR report (Comanche Peck). There are no maintenance recommendations for this component. However, the lead engine report does address site specific modifications to the skid piping and/or supports. Generic application of these modifications is not required for Perry since the Comanche Peak modifications were not required for O piping operability. The lead engine modifications were recommended in order to meet the intent and philosophy of the ASME Code for the boundary conditions and assumptions used in the Owners Group analysis. These boundary conditions and assumptions may be somewhat different from those used in the original manufacturer's analysis. Lead engine skid mounted large bore pipe modifica-tions, as they apply to equipment nozzle loads, are addressed, if necessary, in the individual equipment design reviews. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required PE3177/1

f~ l l COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-717C-0 l 1 REFERENCES Not required r DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON V V'

                                                                ?ROGRAM MANAGER DC_.\4t.%o i

l P f O 1 I I e O PE3177/2

                 .                                                         Page 1 of 2

( COMPONENT. DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Aux. Sub-Base and Oil and Water Piping: Jacket Water - Pipe, Couplings, Fittings, Orifices, and Y-Strainers COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-717C TASK DESCRIPTION NO. DR-03-02-717C-0 SNPS GPL NO. 03-717D CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR Report (Comanche Peak) and the applicable industry experience listed in the EDG Component Tracking System. . There are no maintenance recommendations for this component. However, the lead engine report does address site specific additions of supports. The p necessity for similar additions on Perry has been assessed by a field Q wal kdown. The field walkdown was performed in accordance with the small bore piping criteria document (Ref. 1) and indicates that this component will maintain its functional capability for normal and earthquake loading. Quality revalidation for this component is not required. PRIMARY FUNCTION Nat required ! ATTRIBUTES TO BE VERIFIED Not required SPECIFIED STANDARDS Not required i i 'n v S01971/1 4

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-717C-0

      " Engineering Review Criteria Document for the De' sign Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," Report No.

11600.60-DC-02, Revision O. DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - PROGRAM MANAGER S C. W % V (/' u l F i 1 O i i I O PE3029/2

Page 1 of 1 I 03-02-7170 COMPONENT QUALITY REVALIDATION CHECKLIST Aux. Sub Base & 011 & Water Piping - Cleveland Electric Illuminating Co. COMPONENT J. W. : Gaskets & Bolting UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-7170 REV. NO. 2 SNPS GPL NO. 03-717F TASK DESCRIPTIONS No further review of component 02-7170 is required for the following reasons: a) Component was reviewed on two lead engi,nes with satisfactory results, b) There is no significant industry experience and no site experience reported for this component. . O GROUP CHAIRPERSON /ldt 4 M PROGRAM MANAGER 2 C \<ct-m_ G f O PE2619/1

     .                                                                      Page 1 of 2 O

h . COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Aux. Sub Base & 011 & Water Piping-Jacket Water: Supports COMPONENT (Large Bore Scope Only) UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-717E TASK DESCRIPTION NO. DR-03-02-717E-0 SNPS GPL NO. 03-717G CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on a review of the applicable industry and site experience in the EDG Component Tracking System and the lead engine DR/QR report (Comanche Peak). There are no maintenance recommendations for this component. However, the lead engine report does address site specific modifications to the skid piping and/or supports. Generic application of these modifications is not required for Perry since the Comanche Peak modifications were not required for piping operability. The lead engine modifications were recommended in order to meet the intent and philosophy of the ASME Code for the boundary conditions O. and assumptions used in the Owners Group analysis. These boundary conditions and assumptions may be somewhat different from those used in the original manufacturer's analysis. Lead engine skid mounted large bore pipe modifica-tions, as they apply to equipment nozzle loads, are addressed, if necessary, in the individual equipment design reviews. Quality revalidation for this component is not required. PRIMARY FUNCTION l Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS ! Not required O PE3178/1 l

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-717E-0 REFERENCES Not required DOCUMENTATION REQUIRED Not required l - GROUP CHAIRPERSON

                                                                                                     -PROGRAM MANAGER MW %

(_ J V G a t i a i 4 6 4 0

O PE3178/2 ;

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Auxiliary Sub Base 011 and Water Piping - Jacket Water Supports COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatina Company

GROUP PARTS LIST NO. 02-717E TASK DESCRIPTION NO. DR-03-02-717E-0 SNPS GPL NO. 03-717G CLASSIFICATION TYPE 8 TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak) and the applicable industry and site experience listed in the EDG Component Tracking System.

There are no maintenance recommendations for this component. However, tN 1ead engine report does address site specific modifications to supports. The necessity for similar modifications on Perry has been assessed by a field walkdown. The field walkdown was performed in accordance with the small bore piping criteria document (Ref.1) and concluded that this component will perform its intended function for normal and earthquake loading. Quality revalidation for this component is not required. PRINARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED - Not required SPECIFIED STANDARDS Not requried O PE3027/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ; DR-03-02-717E-0 REFERENCES - Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group" Report No. 11600.60-DC-02, Revision 0. DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON / - PROGRAM MANAGER 1 6 % V (/ ' G _ [ 0 l I PE3027/2

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

Page 1 of 1 COMPONENT QUALITY REVALIDATION CHECKLIST Jacket Water' Standby Cleveland Electric Illuminating Co. COMPONENT Heater Pump UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-810A REV. NO. 2 SNPS GPL NO. 10-107 TASK DESCRIPTIONS No further review of component 02-810A is required for the following reasons: a) Component was reviewed on two lead engines with satisfactory results. b) There is no industry experience for this component. c) Type C component - Failure has little bearing on the effective use or operation of D.G. GROUP CHAIRPERSON c65 /f- PROGRAM MANAGER MC \4a e2% G O PE2616/1

Page 1 of 2 j COMP 0NENT DESIGN REVIEW CHECKLIST O PERRY NUCLEAR POWER PLANT - UNIT 1 Jacket Water Heat COMPONENT Excharner UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST N0. 02-8108 TASK DESCRIPTION NO. DR-03-02-8108-0 SNPS GPL FO. 10-103 CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry experience except that already addressed in the lead engine report. The site experience, in which the code data reports contained insufficient and/o.r inaccurate information as required by ASME III, has been resolved via Perry document NCR P039-326. Also, Perry experience involving the retorquing of the jacket water flange bolts is a maintenance item and is addressed by Perry document NCR P039-211.
A review of the lead engine DR/QR report (Comanche Peak).
The jacket water heat exchanger used at Comanche Peak and Perry are

{' both manufactured by Therexchanger, No. 2422, Type NSP. The Comanche Peak heat exchanger is a ' single pass, and the heat ) exchanger at Perry is a double pass. These heat exchangers are ASME III, Code Class 3. The following maintenance recommendation from the lead engine DR/QR report should be implemented. I

Periodic flushing of the heat exchanger to prevent fouling and corrosion.
Leakage through the packing that is visible can be eliminated by careful adjustment to compress the neoprene packing. It is recommended that the packing rings be replaced and not reused if head removal is required, because of work hardening of the packing.

I There are no modifications based on the lead engine DR/QR report. , i Quality revalidation is not. required for this component. i O PE3224/1

F e ); COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2

DR-03-02-8108-0 PRIMARY FUNCTION .

Not required-ATTRIBUTE TO BE VERIFIED ! Not required I . SPECIFIED STANDARDS i Not required REFERENCES Not required . i i DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON I ---

                                                            - PROGRAM MANAGER S C V h s .

VV o O e

l (l,; -: O PE3224/2 m+ --

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4 Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Thermostatic Valves UTILITY Cleveland Electric Illuminatina Company

GROUP PARTS LIST NO. 02-810C TASK DESCRIPTION NO: DR-03-02-810C-0 4

SNPS GPL NO. 03-515 CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following:

                                 *-               A review of the EDG Component Tracking System indicated that there was no significant applicable industry experience, except that previously 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).
Both Comanche Peak and f'erry have AMOT Control Corp. Model 8DAS valves.

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

Replace the thermal power element at 3 to 5 year intervals.

!

Proper orientation of the valve should be- verified by ' field inspection (i.e. , exhaust ports should be centerline horizontal, if not, adequate vent lines must be installed).

No modifications are required pending results of above inspection. Quality revalidation is not required for this component. PRIMARY FUNCTION-Not required i. ATTRIBUTE TO BE VERIFIED Not required PE3244/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-810C-0 SPECIFIED STANDARDS Not required

 .                         ACCEPTANCE CRITERIA Not required 4

REFERENCES l Not required 4 GROUP CHAIRPERSON

                                                                   -  PROGRAM MANAGER ,) C K (jf                                            U      .

lO 1 l l-. 1 PE3244/2

     , _ - - - -, .-w-+,-. e,-    ,   - . ---m,,

Page 1 of 1 03-02-8100 COMPONENT QUALITY REVALIDATION' CHECKLIST Misc. Equipment-Heater, Cleveland Electric Illuminating Co. COMPONENT Jacket Water Standpipe UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-8100 REV. NO. 2 SNPS GPL N3. 03-800A TASK DESCRIPTIONS No further review of component 02-8100 is required for the following , reasons: a) There is no pertinent industry experience in evidence. l b) Component was reviewed on lead engines (Shoreham). The following recommendations, made in the Shoreham DR/QR report should be followed by Cleveland Electric Illuminating Co. Preventive maintenance included in the TDI manual should be per-formed. Inspections scheduled at 18-month intervals should consist of the following. Measure heater insulation resistance and replace heater if degradation of insulation resistance is noted. Thoroughly clean heater element of deposits and inspect for j signs of deterioration. l Check calibration and inspect condition of thermostat and recalibrate or replace thermostat when necessary. GROUP CHAIRPERSON JM PROGRAM MANAGER S C W w m m C O PE2618/1 l I

l Page 1 of 2 O, , COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Cylinder Heads UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST N0. 02-360A TASK DESCRIPTION NO. DR-03-02-360A-0 SNPS GPL NO. 03-360A CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review is not required for this component based on review of the August 1984 Phase I cylinder head report and the reported applicable industry experi-ence. There is no site experience in the EDG Component Tracking System. A review of TDI casting certificates revealed that all of the cylinder heads presently intended for use at Perry were cast prior to October 1978. These cylinder heads are termed Group I as defined in the Phase I report. All of , these cylinder heads have been sent back to TDI for reconditioning. The reconditioning includes manufacturing improvements such as repair of the valve seats and fuel injection port,' and additional heat treatment. After the reconditioning is ~ complete, the cylinder heads will be inspected by TDI O (witnessed by representatives of CEI). For increased reliability of the cylinder heads, the following maintenance items are recommended:

Blow-over the engine after each operation of the engine to ensure against harmful effects of water leaks. In the event water is detected as a result of a cylinder head leak,- the cylinder head should be replaced.
Visually inspect the fuel injection port on each cylinder head for water leaks during the normal monthly engine run. If water leakage is. detected, the cylinder head should be replaced.

There are no modification recommendations for this component, however,'the following Quality inspections as delineated in the CQRC are recommended:

Perform a liquid penetrant test of the valve seating surfaces.
Perform a magnetic particle test on the fire deck area excluding the valve seating area.

l .~

Determine the thickness of the fire deck area by ultrasonic testing.

Note: These inspections should be performed on a 100% sample plan for O both engines. i PE2966/1 i

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              -- - - - _ _ _ . -_       ----y  ,y-   -,,,.,w ---,-,,weiv-----w----         v--1,--~   -- ve-r e ve-e       r,e-*-     -=-*==**-e*     ' - * - * " - * ' ' " * * ~ * - - * * * ' * ~ - - * ' - " * ~ ' - - " " " - ~ ' ' " '

                        ,                   COMPONENT DESIGN REVIEW CHECKLIST   Page 2 of 2 DR-03-02-360A-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required                                                                             .

DOCUMENTATION REQUIRED Not required - GROUP CHAIRPERSON [ PROGRAM MANAGER 2 C W - w u y v-O PE2966/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Cylinder Head Valves: Intake COMPONENT and Exhaust Valves UTILITY Cleveland Electric Illuminatina Co. GROUP PARTS LIST NO. 02-3608 TASK DESCRIPTION NO. DR-03-02-3608-1 SNPS GPL NO. 03-3608 CLASSIFICATION TYPE B TASK DESCRIPTIONS D. sign review for this component is not required based on the following:

A review of the Comanche Peak and Shoreham .DR/QR repcrts, which establish the acceptability of the cylinder head valves for their intended purpose.
A review of site, nuclear and non-nuclear industry experienc'e indicated that there had been no design related failures associated with this component. The cylinder head valves are identical on all the Ovner's Group TDI diesel engines (TDI Part No. 03-360-02-0D).

j The primary nuclear and non-nuclear industry experiences associated with this component have been chrome plate flaking, scuffing, and scoring, and exhaust gas blowby due to lack of concentricity of the valve and seat. Because of the small number of hours nuclear service diesels are expected to operate between inspections, this will not noticeably affect 2ngine performance.

There are no modifications recommended for this component.

The following Quality Revalidation inspection recommendations are made to ensure proper component performance and ' quality and should be performed on both engines:

Perform a ' visual inspection to verify adequate valve seating. There should be a uniform linear metallic ring on valve ring.
Perform a visual examination of the valve and valve ring for scuffing and erosion on valve ring or valve seat area.
Perform a dimensional check of the valve to valve guide clearance.

l

Perform a visual examination of the valve stems and the top of the valves at the rocker arm contact area for scuffing or scoring.
Perform a liquid penetrant test on the blended radius of the stem l- head for cracking. ,

PE2879/1 -

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-3608-1

      .The valve inspections outlined in the lead engine DR/QR reports also apply to the engines at Perry.                       The inspection should be performed for all new or reworked cylinder heads after an initial 500-600 hours of operation:

Remove the subcover bonnet an inspect the interior for soot, which indicates valve blowby. Corrective action should be taken if this condition is found to exist.

t PRIMARY FUNCTION I l Not required ATTRIBUTE TO BE VERIFIED i Not required SPECIFIED STANDARDS i Not required O REFERENCES l Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - - PROGRAM MANAGER SC. Krawwa-h yV U O PE2879/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Cylinder Head and Valves: COMPONENT Bolting And Gaskets UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-360C TASK DESCRIPTION NO. OR-03-02-360C-0 SNPS GPL NO. 03-360C CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak) and the applicable industry experience. There is no site experience in the EDG Component Tracking System for this component. There are no modification or maintenance recommendations for this component. The following Quality Revalidation inspections should be performed on al.1 station engines:

Verify that the proper gaskets are installed in accordance with specification requirements; k
Perform a visual inspection of the gaskets for signs of distress.

PRIMARY FUNCTION Not required - ATTRIBUTE TO BE VERIFIED Not required l l SPECIFIED STANDARDS i Not required REFERENCES Not required c t)

PE3066/1 -

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-360C-0 DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -

                                            - PROGRAM MANAGER 3CW%  -

u

                         } f' O

O PE3066/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Cylinder Head and Valves: COMPONENT Springs And Retainers UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-360D TASK DESCRIPTION NO.- DR-03-02-3600-0 SNPS GPL NO. 03-3600 CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the Comanche Peak and Shoreham DR/QR reports, which establish the acceptability of the valve spring and retainer for their intended purpose.
A review of site, nuclear and non-nuclear industry experience liste'd in the EDG Component Tracking System indicates there has been no design related failures associated with this component. The valve springs are identical on all the Owners Group TDI diesel engines (TDI O Part No. 03-360-02-0M).

There have been several non-nuclear experiences where improperly shot peened springs were installed on some TDI engines. These springs failed during service and in some cases caused engine damage. The inspection recommendation below will verify that correct springs are installed in the engines at Perry. There are no maintenance or modification recommendations for this component. The following Quality Revalidation inspection recommendation is made to ensure component qualify and performance and should be performed on both engines:

Visually inspect and document the color code of the valve springs.

l There should be no grey springs with brown stripes. l f l PRIMARY FUNCTION Not required i

l O PE2878/1 - L o

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-3600-0 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required . GROUP CHAIRPERSCN -

                                         - PROGRAM MANAGER MC\<a wu (j{/                                                  O l

l \ PE2878/2

Page 1 of 2 O CONPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Fuel Oil Drip Tank UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 00-621A TASK DESCRIPTION N0: DR-03-00-621A-0 SNPS GPL NO. 99-621A CLASSIFICATION TYPE C TASK DESCRIPTIONS . Design review of this component is not required based on the following:

There is no significant industry experience reported for the fuel oil drip tank in the EDG Component Tracking System. There has baen no adverse experience with this component at Perry.

                                         *.            The fuel oil drip. tank used at Perry is identical ta that used at Comanche Peak. The Comanche Peak tanks were reviewed in detail (Ref.                                                    '

2) and were found to have a relatively large margin of safety.

There are no maintenanca or modification recommendations for this component. Quality revalidation for this component is not required. PRINARY FUNCTION Not required i ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS ! Not required l' O PE3311/1 - l r

       ...~,.__,..,._...m._.. __._,,..m_,_,,,m-_,_           , _ _ _ , _ _ , , , . , , _ . , , , _ . , _ . _ , , ,    ____%__  , _ , - _-,%,_   %,m__._,_,,,,,%m.u,m.,,y     3, . . - , . -

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-00-621A-0

1. TDI Drawing number 00-621-01-AP, Fuel Oil Drip' Tank

2. Stone & Webster Calculation No. 11600.60-NM(B)-001-CZC-041 " Fuel Oil Drip Tank Assembly Structural Integrity Review and Seismic Qualification" (for Comanche Peak)

DOCLNENTATION REQUIRED Not required GROUP CHAIRPERSON _ s PROGRAM MANAGER N C14a_m.m % o s Ljv o P O l O PE3311/2 I- .- . - . _. . _ - . - . .- . . - - - . - - _.

i Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST - PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Injection Equipment: COMPONENT Fuel In.iection Pump UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-365A TASK DESCRIPTION NO. DR-03-02-365A-0 SNPS GPL NO. 03-365A CLASSIFICATION TYPE B TASK DESCRIPTIONS , Design review for this component is not required based on the following: .

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

t e A review of the lead engine DR/QR reports (Shoreham/ Comanche Peak).

The fuel injection pump used at Perry is of the same manufacturer

, and type as that used at Shoreham and Comanche Peak (i.e. , Bendix, Type FDXE-26, No. 10-375636-5). 2 The following maintenance recommendation from the lead engine DR/QR report should be implemented. This is in addition to those maintenance items speci-fied in the TDI Manual:

Disassemble, inspect, test and reassemble one pump at alternate refueling outages. Based on the results, a decision can be made regarding the necessity to examine the remainder of the pumps.

No - modifications ' are required for this component, based on the lead engine reports. ~ Quality revalidation is not required for this component. O PE3225/1 - 1:

l l l

                               .              COMPONENT DESIGN REVIEW CHECKLIST   Page 2 of 2 DR-03-02-365A-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required                                                                           ,

DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON / I) 5 ---

                                                                  - ROGRAM MANAGER U C W e 9e                                             a O                   PE3225/2 i
                                          -_-._.,_.._-_.---_.__.--.----.n,--._...         _, - . - - - - - - - - -

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Injection Equipment: COMPONENT Fuel Injection Tips UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-365B TASK DESCRIPTION NO. DR-03-02-3658-0 SNPS GPL NO. 03-3658 CLASSIFICATION TYPE B , TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry or site experience, except that previously addressed in the lead engine report.
A review of the lead engine DR/QR reports (Shoreham and Comanche Peak)'.
The fuel injection nozzle asstably used at Perry is identical to that used at Shoreham and Comanche Peak (i.e. , Bendix, Type H4L-400, Holder No. 10-328850-5 Tip No. 10-84802-29).

The following maintenance recommendations from the lead engine DR/QR report should be implemented. (This is in addition to the maintenance items specified in the TDI Manual):

TDI SIM Nos.107 and 108 should be incorporated in the Perry maintenance procedures.
At each refueling outage, it is recommended that each assembly be dis-assembled, inspected, cleaned, and reassembled. At this time, each as-sembly should be pop tested and have the spray pattern checked.

No modifications are racommended for this component, based on the lead engine l report. i l Quality revalidation is not required for this component. PRIMARY FUNCTION Not required i ! O PE3226/1 I

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-3658-0 ATTRIBUTE TO DE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required , i GROUP CHAIRPERSON = PROGRAM MANAGER 2 C W o w a - h J GF u l l O PE3226/2

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Injection Equipment COMPONENT Tube Assembly UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-365C TASK DESCRIPTION NO. DR-03-02-365C-0 SNPS GPL NO. 03-365C CLASSIFICATION TYPE B TASK DESCRIPTIONS Design re' view for this component is not required based on the review of the EDG Component Tracking System for applicable industry and site experience (Refs. 2 , 'and 3) and the lead engine DR/QR Reports (Shoreham/ Comanche Peak). The fuel oil injection lines transfer fuel from the high pressure fuel injection pumps to the fuel injectors for the engine cylinders. The injection lines experience the extreme pulsating pressure of the plunger operated injection pumps. For TDI nuclear standby diesel generators, the pressure pulses are 3 ksi minimum pressure to 14. 5 ksi maximum pressure. It was determined from fracture mechanics and fatigue analyses that flaws on the j inner surface of the tubing potentially cause fatigue failure of the tubing from pulsating fuel pressure (Ref. 1). Industry experience (Rev. 2) indicates a number of fuel leakage incidents ( involving the high pressure fuel oil tube assemblies. Such incidents are related to either failures or loosening of attachment fittings during engine operation or tube failures because of manufacturing flaws on the inner su'rface exceeding the critical limit. I All TDI fuel injection tubing is 1/2 in. SAE 1008 or SAE 1010 steel manufactured to identical specification and is found -to be suitable fer l nuclear standby diesel generator service (Ref.1) when manufacturing flaws on the inner surfaces are below the critical limit. The following maintenance recommendations for this component from the lead engine DR/QR Report for Shoreham site should be performed monthly while the engine is operating:

Inspect compression fittings at both ends of each fuel injection line.

l There are no modification recommendations for this component. p PE3060/1

r COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 T DR-03-02-365C O [G TASK OESCRIPTIONS (continued) The following quality inspections as described on the Component Quality Review Checklist should be performed on all station engines:

Perform a visual inspection on the fuel injection equipment for signs of leakage.
All high pressure fuel lines are to be examined by an Eddy Current test (Ref. 4).

PRIMARY FUNCTION l Not required i ATTRIBUTE TO BE VERIFIED Not requ. red , SPECIFIED STANDARDS Not required REFERENCES

1. Emergency Diesel Generator Fuel Oil Injection Tubing Qualification Analysis prepared for TDI Emergency Diesel Generator Owners Group April 1, 1984.

2. Emergency Diesel Generator Computer Tracking System - Industry Experience dated October 15, 1984.

i 3. Emergency Diesel Generator Computer Tracking System - Perry Nt. clear Power Plant dated October 10, 1984.

4. Failure Analysis Assoc. NDE Procedures 11.10 " Eddy Current Inspection Procedure - High Pressure Fuel Lines - Carbon Steel."

i DOCUMENTATION REQUIRED Not required \ ^ GROUP CHAIRPERSON -

                                                                     - PROGRAM MANAGERM\<

(/V U PE3060/2 l l i

CONPONENT DESIGN REVIEW CHECKLIST

                                                         . PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Injection Equipment:

Supports COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-3650 TASK DESCRIPTION NO. DR-03-02-3650-0 SNPS GPL NO. 03-3650 CLASSIFICATION TYPE 8

                              ' TASK DESCRIPTIONS Design review for this component is not required based on the review of the lead engine DR/QR report (Comanche Peak).             There is no site or industry experience for this component in the EDG Component Tracking System.

A field walkdown of this component could not be performed at Perry becaus,e the component had been removed. However, this component is considered acceptable based on the following: A comparison of the lead engines (Comanche Peak) and Perry's TDI O parts manuals (Vol. II).

A walkdown of Comanche Peak, Grand Gulf, Catawba and Shearon Harris which were performed in accordance with Reference 1.

There are no modification recommendations for this component. 4 Based on the above review it is concluded that this component will perform its intended function at Perry under all normal operating and earthquake loadings with the provision that upon installation the following recommendation be implemented:

A visual inspection of the support elastomer for signs of I deterioration or degradation should be performed at each refueling <

outage. Any inserts found unsatisfactory should be replaced. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required O PE3002/1

t COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-3650-0 ATTRIBUTE TO BE VERIFIED Not required-l SPECIFIED STANDARDS Not required REFERENCES

                           " Engineering Review Criteria Document for the Design Review of TDI Diesel Small                                               l Bore Piping, Tubing, and Supports for the TDI Owners' Group," report No.

11600.60-DC-02, Revision 0. . t DOCUMENTATION REQUIRED , Not required O GROUP CHAIRPERSON ..

                                                                      -- = PROGRAM MANAGER M \<a,-+w yy                                                -

i O PE3002/2 i I

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Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Pump Linkage: ' Fuel Pump Control Shaft; COMPONENT Linkage Assembly & Bearings UTILITY Cleveland Electric Illuminatina-Company GROUP PARTS LIST NO. 02-371A&B TASK DESCRIPTIO.N NO. DR-03-02-371A&B-0

                     - 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 already addressed in the lead engine report. There was no site g experience listed in the EDG Component Tracking System.

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

This component is identical to lead engine componsnt.

The following maintenance recommendations from the lead engine DR/QR report O 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

report.

The following Quality inspections should be performed: l

Inspect linkage and bearings for freedom of movement (to be l performed on all station engines) i
Determine the hardness of the shaf t (to be performed on one station engine only).

PRIMARY FUNCTION Not required l L ATTRIBUTE TO BE VERIFIED Not required O PE3289/1 l' l

  ,- .   ,.__._,...___-.._-.___..._,.--,_.,--.m..-,                                                ,_.-.m. _.~....--m.-,___-_                   , _ _ _

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-371A&B-0 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER SCW (j r a J l PE3289/2 y-.. - . ,

              , ,        -   ---.---,y --- .-  -.---,.-------w---       ----r---   ----+----e     - - - -- - - - - - - - * - - - -           " - " ' '

F

1 .

TDI OWNERS GROUP FOR PERRY NUCLEAR POWER PLANT . Fuel Pump Linkage: Linkage Assembly and Bearing

               .                                                                                        COPPONENT PART NO.: 02-371B See Component Part No.: 02-371A
                                                                                                                                                                                                                .4 S

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                                                                                                                                                    - u .                    ,              ,          ,,              , , , ,

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e Page 1 of 2 [,s~)

     's                               COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Pump Linkage:

Automatic Shutdown COMPONENT Cylinder UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-413B TASK DESCRIPTION NO. DR-03-02-4138-0 SNPS GPL NO. 03-371C CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following: .

A review of the Comanche Peak and Shoreham DR/QR reports, which establish the acceptability of the piston rings for their intended purpose. .
A review of the EDG Component Tracking System . indicated that there

 ,                    was no significant applicable industry and site experience.

The applicable engine dimensions and operating parameters at Perry are identical or very similar to those for the same component at Comanche Peak (lead engine).

No maintenance recommendations, modification recommendations or Quality Revalidation are required for this component. , PRIMARY FUNCTION Not required i ( ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required l PE2883/1 l I

e COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-4138-0 REFERENCES Not required , DOCUMENTATION REQUIRED Not regaired GROUP CHAIRPERSON =, PROGRAM MANAGER M \ h

(j r a l

l l i O O PE2883/2

l Page 1 of 2 b h COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Fuel Oil Booster Pump UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-445 TASK DESCRIPTION NO. DR-03-02-445-0 SNPS GPL NO. 03-445 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. There was no site experience listed in the Component Tracking System.
A review of the lead engine DR/QR report (Comanche Peak).
Both Comanche Peak and Perry fuel oil booster pumps are Roper Model 18-AM-27, Type 1.

There are no maintenance items or modifications recommended based on the lead i engine report. Quality revalidation is not deemed necessary for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required 1 O PE3229/1

COMPONENT DESIGN REVIEW' CHECKLIST Page 2 of 2 DR-03-02-445-0 REFERENCES Not required DOClMENTATION REQUIRED Not required PROGRAM MANAGER 3 C M e v e GROUP CHAIRPERSON (Jr o O t e O PE3229/2

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Oil Header: Piping / Tubing COMPONENT (Snall Bore Scope Only) UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-450A TASK DESCRIPTION NO. DR-03-02-450A-0 SNPS GPL NO. 03-4508 CLASSIFICATION TYPE A TASK DESCRIPTIONS A design review for this component is not required based on the review of the lead engine DR/QR reports (Comanche Peak, Grand Gulf and Catawba). There is no site experience for this component in the EDG Component Tracking System. . The review of the applicable industry experience indicates that fuel oil line failures' have occurred at Grand Gulf and Catawba. These failures were located at a tee connection on the fuel oil header. Cause of failure has been O attributed to vibration. A field walkdown was performed at Perry in accordance with the small bore piping criteria document (Ref.1). The walkdown indicated that a 1-inch threadolet was used as the method of connecting the 1-inch fuel i oil supply tubing (branch side) to the 1-inch NPS front crossover header. This could result in stress concentration at the fitting-to-run pipe juncture, because of the abrupt change in wall thickness. (Fitting 0.D. exceeds run pipe ( 0.D.) Therefore, it is recommended that the 1-inch threadolet be changed to a l socket welded tee to preclude the possibility of fatigue failure from long-term vibration stresses. There are no maintenance recommendations for this component. A review by walkdown of this component in its entirety was not possible since portions of the piping and tubing were not- installed. Therefore, component

acceptability and any subsequent recommendations shall be based upon the lead

(- engine reports (Comanche Peak, Grand Gulf and Catawba). I' The lead engine reports address the need for site specific modifications, ! specifically, support additions and modifications. The necessity for similar additions / modifications for Perry are addressed in DR/QR report 02-4508. 1 PE2997/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-450A-0 TASK DESCRIPTIONS (continued) Based on the above review, it is concluded that this' component will perform its intended design function at Perry under all normal operating and earthquake loadings provided that supports are added/ modified as indicated in DR/QR report 02-4508, and provided that the threadolet mentioned above is replaced with a socket welded tee. Quality Revalidation for this component is not required. PRIMARY FUNCTION

   . Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS

( Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON --

                                               - PROGRAM MANAGER ,)C_.\<%      %

V V' O O PE2997/2

l i TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 FUEL OIL HEADER -FUEL OIL TUBING SUPPORTS ; (SMALL BORE SCOPE ONLY) COMPONENT PART NO. 02-4508 i I INTRODUCTION

                   ' The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of the structural adequacy of the fuel oil header small bore piping / tubing supports to withstand the effects of normal operating and earthquake loadings. The primary function of these. supports is to provide adequate i

restraint of the small bore piping / tubing system in the intended support load direction. , II OBJECTIVE , The objective of this review was to perform an engineering evaluation of

                   ' the small bore piping / tubing supports to assure that. the component will perform its intended design function during normal operating and O              earthquake loadings.

III METHODOLOGY In order to meet the stated objective, the following methods were Uset

                   .*     The TDI Emergency Diesel Generator Component Tracking Systee, was reviewed for Perry site, nuclear,                                             and      non-nuclear industry
                         -experience. See Appendix C for results.

The Quality Revalidation Checklist results were reviewed for acceptability.
Engines 1A and IB, both partially disassembled, were evaluated using actual walkdown information and comparison to the Comanche Peak lead engine report.

Refer to the review procedures as described in Reference 1 for a detailed methodology of this evaluation. IV RESULTS AND CONCLUSIONS The .small bore piping / tubing _ supports, as defined by this Component Design Review, have been evaluated in accordance with Reference 1 and have been found acceptable with modification. O PE3200/1 e- -

       , - -                          -.-e  , - - - , , - - - - -      +   ,--.     .r-.-.4.--- - - , -   , , -       3 - - - . . , - - - -   ... --r- ,

                    .                               .                                                                         .._=.                  .         .. .--

Page 2 of 3 The : 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, it is concluded from Reference 2 that the small bore piping / tubing supports will perform their intended design function at Perry under all normal operating and earthquake loadings with the provision that the following recommended modifications as detailed in Neference 3 be implemented: ENGINES 1A and 18 Fuel Filter to Front Crossover Header

The support between the fuel filter and the header requires stiffening in the lateral and vertical tubing directions to limit load transfer at the filter and header connections.

Check Valve to Fuel Filter

The support located on the horizontal tubing run at the base of the riser to the inlet of the fuel filter should be modified to

, eliminate the attachment of the 1/4-inch tube to the bolt on the "

"unistrut" clamp. The thickness of the 1 1/2 x 1 1/2 x 1/8 inch angle should be increased. Reattachment of a support for the l

1/4-inch tube to the unistrut is acceptable. Fuel Oil Pump Inlet, Outlet

The bent "flatbar" supports directly below the fuel oil pump inlet and outlet and attached to the lube oil pump flange should be I

modified to increase the stiffness /section properties lateral to the tubing run. The use of multiple bolts when attaching to the lube oil pump flange is advised.

The 6 x 3/8-inch plate restraint located on the horizontal tubing run approximately two feet from the fuel oil pump inlet. riser should be stiffened in the lateral tubing direction.

Fuel Oil Drip Return

The first restraint on the right and left bank fuel c,il drip return i

headers at the governor end of the engine should be modified to a l three-directional restraint to provide axial restraint of the headers. j

The existing U-bolts on the drip-header crossover piping should be replaced with 3/8-inch U-bolts and suitable locking devices.

Installation should not restrict axial line movement while providing lateral restraint. !O PE3200/2 { I i

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

E.sge 3 of 3

The twisted " flat bar" supports located in the horizontal offset in the riser of the tubing from the right and left side drip header to the return tank should be modified to provide an increase in section properties in the vertical and horizontal directions. The use of multiple bolts when attaching to the engine is advised.
The support located on the horizontal drip return tubing between the engine and the drip tank and attached to the engine base under the lube oil strainer brackets should have vertical stiffening added to existing assembly. -

Recirculation and Supply Headers, Left and Right Bank Engine headers and branch lines including injector return tubing and supports were not installed because of the disassembly status of the engines during the walkdown. Installation of the headers, branch lines and associated supports should be per manufacturers' drawings and ' include the following modifications:

One of the eight required two-directional restraints on each engine bank should be revised to be-a three-directional restraint and should be located approximately mid-engine. The remaining two-directiongl restraints should be modified or shimmed as required to provide a proper sliding fit.

In order to support the tubing of Component 02-450A, it is recommended

J that the following supports be added

For the fuel drip return, a two-directional restraint should be

. added within twelve inches of the tee at the base of the right bank tubing riser running from the header to the drip tank (near the crossover piping). This is to provide axial restraint of the crossover piping.

For the fuel recirculation lines, the 1/4-inch tubes from the t injector nozzle to the header should have clip type restraints added to the header near. the top of riser. Clip type restraints should also be installed approximately midspan ors the horizontal portion immediately after the riser from the injector no ule.

V. REFERENCES i- 1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and STpports fc? the TDI Owners Group," Report No. 11600.60-0C-02. Revision OT

2. Stone & Webster Calculation number 11600.60-NP(B)-0301-XH.

3. Memo no. 6548 from C. Malovrh/SWEC to J. Kammayer/SWEC, dated

                                           -11/29/84.'

i O PE3200/3 - e.- - . , - , . - . - . .. - , - --..------n--,, .,,,---....w- - ,a- . - - - , _ . . ----.-.-.,--,a- - - , . m- - w -, -

APPENDIX A . Page Al of 2 0 b COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Oil Header - Fuel Oil Supports COMPONENT (Small Sore Scope Only) UTILITY Cleveland Electric Illuminatino Company GROUP PARTS LIST NO. 02-450B TASK DESCRIPTION NO: DR-03-02-450B-0 SNPS GPL NO. 03-4500 CLASSIFICATION TYPE A TASK DESCRIPTIONS Perform an engineering review of the small bore piping / tubing supports to provide additional assurances that the component will perform its intended design function during normal operating and earthquake loading. PRIMARY FUNCTION Provide adequate restraint of the small bore piping / tubing system in the intended support load directions. ATTRIBUTES TO BE VERIFIED Structural adequacy of the pipe / tube supports due to the effects of normal operating and earthquake loadings. SPECIFIED STANDARDS IEEE 387 - l REFERENCES l

      " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group" Report No.

11600.60-DC-02, Revision 0 O U PE2996/1 l

COMPONENT DESIGN REVIEW CHECKLIS Page A2 of 2 O DOCUMENTATION REQUIRED DR-03-02-4508-0 Delaval design documentation (specifications, calculations, drawings, etc.). In lieu of 'information from Delaval, the following information is required: verified support sketches and piping isometrics, material specifications, pipe size and schedule, and operating parameters (pressure, temperature, load combinations) GROUP CHAIRPERSON = PROGRAM MANAGER M \<cu w h vs J e e O o PE2996/2 . _ _ . . - ~_ _ _ __ ._. . . _ , - .- , .._ -

Appendix B Page B1 of 3 03-02-450B COMPONENT QUALITY REVALIDATION CHECKLIST Cleveland Electric Illuminating Co. COMPONENT Fuel Oil Header - Supports UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-4508 REV. NO. 2 SNPS GPL NO. 03-4500 TASK DESCRIPTIONS Engine 1A

1. Assemble and review existing documentation.

2. Obtain sufficient data to support the design review effort. This may be accomplished by developing quality verified as-builts in accordance with Procedure DG-7, or by the Design Group performing a field walkdown.

Enaine 1B Same as Engine 1A l ATTRIBUTES TO BE VERIFIED l Engine IB

1. Quality status of Component Document Package

2. Information necessary for the design review effort.

Engine 1A Same as Engine IB l l ACCEPTANCE CRITERIA Engine 1A

1. Satisfactory Document Package

2. Review of detailed information by the Design Group i

l PE2629/1

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 3 ACCEPTANCE CRITERIA (continued) Engine 18 Same as Engine 1A REFERENCES Engine 1A

1. QCI No. 52

2. Procedure DG-7 Engine 18 Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A

1. Document Summary Sheet

2. Quality verified as-built isometric drawings for the supports if i available from the Owner.

l r Enaine IB i Same as Engine 1A GROUP CHAIRPERSON _ A M/ .p PROGRAM MANAGER 2<- C M u %) COMPONENT REVIEW Engine 1A

1. No EDGCTS site experience documents are in evidence.

2. The Design Group will be responsible for closing out the as-built drawings as per Procedure DG-7. The as-built drawings will be Quality verified by the appropriate site Quality organization. The performance of an engineering walkdown by the Design Group, precludes the issuance of a quality verified as-built drawing or sketch.

O PE2629/2 l

COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 3 03-02-450B COMPONENT REVIEW (continued) Engine 18 Same as Engine 1A i RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as outlined above, is complete. The results have been forwarded to the ! Design Review Group for their evaluation and conclusions in support of the final report. Engine IB Same as Engine 1A GROUP CHAIRPERSON / MM PROGRAM MANAGER M W . m O o l l t O PE2629/3

 -                                            .                                            e Appendix C                                                         Page C1 of 1 EDG COMPONENT TRACKING SYSTEM:   PERRY SITE. NUCLEAR AND NON-NUCLEAR INDUSTRY EXPERIENCE

SUMMARY

COMPONENT NO. 02-4508 Effective Printout Dates: Perry: 11/05/84 - Industry: 11/05/84 COMPONENT TYPE: Fuel Oil Headers: Supports REFERENCE PERRY EXPERIENCE DOCUMENTS STATUS

     ' PERRY None NUCLEAR None                                                                            ,

NON-NUCLEAR None I O O PE3200/4 I i

                   .                                                                          Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST            -

PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Oil Filters & COMPONENT Strainers: Filters UTILITY Cleveland Electric Illuminating Co. GROUP PARTS LIST NO. 02-455A TASK DESCRIPTION NO: DR-03-02-455A-0 SNPS GPL NO. 03-455A CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the following:

A review of the EDG Component Tracking System indicated that there was no significant applicable industry and site experience, except that previously addressed in the lead engine report.
A review of the lead engine DR/QR report (Comanche Peak).
The fuel oil filters at Perry are the same model and from the same manufacturer O 511-150-1.

as those used at Comanche Peak, Hilliard Model The following maintenance recommendations from the lead engine DR/QR report

      , should be implemented:

The filter differential pressure should be checked monthly and procedures should be established for replacing the filter cartridges at or before the manufacturers specified maximum of 25 psid.

i

Air should be purged from the filters after maintenance.

There are no modifications required for this component. Quality Revalidation is not required this component. PRIMARY FUNCTION Not required 4 l l l PE3286/1 l t _ __. ___ _ _ . . . _ , _ . _ _ . . _ . . . . . _ , _ , _ _ . , . . ~ . _

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-455A-0 ATTRIBUTE TO BE VERIFIED Not required ACCEPTANCE CRITERIA Not required REFERENCES Not required GROUP CHAIRPERSON 1 - PROGRAM MANAGERM\<w% ()(.r G , 6 O PE3286/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Fuel Oil Filters & COMPONENT Strainers: Strainers UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST N0. 02-4558 TASK DESCRIPTION NO. DR-03-02-4558-0 SNPS GPL NO. 03-4558 CLASSIFICATION TYPE 8 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. Perry experience was restricted to documentation.
A review of the lead engine DR/QR report (Comanche Peak).
Both Perry and Comanche Peak use Air Maze Model 03J24XDL, which ,

provides 46 micron (300 mesh) filtration. ' O The following maintenance recommendations from the lead engine DR/QR report should be implemented:

The strainer elements should be cleaned or replaced at 5 psid maximum.
Air should be purged from the strainer after maintenance.
Bolt torques of 120-150 in-lbs should be utilized during reassembly.

The following modification from the lead engine DR/QR report should be considered: l l l

The strainer can be replaced with a coarser design that would require less maintenance, but would still satisfy the filtration requirement for the booster pump, which is 100-200 mesh. This

, recommendation is made to enhance operation but is not required for system operation. l Quality revalidation is not required for this component. l ( PRINARY FUNCTION Not required PE3287/1 i . 1 i

     .-__.--,-,.-m~,,,-_.-.,-_.___                         -,~.rmm.m..~.-                         - , - , - . . . ~ . _ _ _ . . . . , , _ . - . - - _ _ . , . . - - . - - . <

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required , GROUP CHAIRPERSON -

                                                                                                         -               PROGRAM MANAGER M C W s A%

C> v v- o .I PE3287/2 1

7 - _. Page'l of 2 O f V COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1

Fuel Oil Filters and l COMPONENT Strainers Mounting Hardware UTILITY Cleveland Electric Illuminatino Company i GROUP PARTS LIST NO. 02-455C TASK DESCRIPTION NO. DR-03-02-455C-0 SNPS GPL NO. 03-455C 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 and site experience.
A review of the lead engine DR/QR reports for Comanche Peak and Shoreham indicated substantial design margins.

There are no maintenance or modification recommendations for this component. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required O PE3310/1

COMPONENT DESIGN REVIEW CHECKLIST 9 f O REFERENCES Not required 4 DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -

                                                                                                                                                                      = PROGRAM MANAGER 3 C \4a* > s y I'                                                                                                                                  G O

l l l l l [ I l !O { PE3310/2

l l l Page 1 of 2 O' COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 i Auxiliary Sub-Base Aad Oil l' And Water Piping - Fuel 011: Piping And Fittings COMPONENT (Small Bore Scope Only) UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-717J TASK DESCRIPTION NO. DR-03-02-717J-0 SNPS GPL NO. 03-717M CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the review of'the i lead engine DR/QR report (Comanche Peak) and the applicable industry and sita experience. There are no maintenance recommendations for this component. A field walkdown was performed in accordance with the small bore piping criteria document (Ref.1) and concluded that this component will perform its intended function for normal and- earthquake loading providing that the O supports are added/ modified as indicated in DR/QR report 02-717M. Quality Revalidation for this component is not required. PRINARY FUNCTION Not required l ) ATTRIBUTE TO BE VERIFIED

 .                Nat required I                  SPECIFIED STANDARDS Not required 1

PE3026/1 f

   ,~ m - - - - -
                  +- -   ,
                            --s-en-._   . . ~ . . .,, . , ,-,..,_,,,m.,,,,-        ,-,n- ,,. ann  ~.w,-_,,, .-,.,n.__,__-a__,,_-_,ve,_,.,.           .,,_,,,._,_m.,,n,,-,

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-717J-0 REFERENCES

1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners Group," Report No. 11600.60-DC-02, Revision O.

DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON / PROGRAM MANAGER _Y\bm---2 - 1 VV U O O PE3026/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Auxiliary Sub Base and Oil and Water Piping: Fuel COMPONENT 011 Valves UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST N0. 02-717K TASK DESCRIPTION NO: DR-03-02-717K-0 SNPS GPL NO. 03-717N CLASSIFICATION TYPE A t TASK DESCRIPTIONS l 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 other than that previously addressed in the lead engine DR/QR report. There was no, site experience listed in the Component Tracking System. ~
A .aeview of the lead engine DR/QR report (Comanche Peak).
The valves used at both the lead engine plant and Perry are Crosby relief valves Models J0 and JR-25.

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

Inspect and clean valves at each plant refueling outage.

There are no modifications required for this component. The following Quality inspection should be performed: *

An inspection should be performed to verify the relief valves have l been installed in a vertical position per the manufacturer's recommendations.

! i PRIMARY FUNCTION , Not required

       ,                                                                                                                                i a

!O

PE3245/1 ,

i

   ,,c       ,,-,c,--.n~-,,,m-,.,-n,m---_n-m.---na,                                   ,,n,_._                                 __,__n,,a

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required ACCEPTANCE CRITERIA Not required REFERENCES Not required , GROUP CHAIRPERSON PROGRAM MANAGER M \ 4 % . _ O t/ r a l ( . O O PE3245/2 '

E Page 1 of 1 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Auxiliary Sub Base - 011 & Water Piping - Fuel COMPONENT 011: Bolting and Gaskets UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-717L TASK DESCRIPTION N0. DR-03-02-717L-0 SNPS GPL NO. 03-717P CLASSIFICATION TYPE B TASK DESCRIPTIONS Design review for this component is not required based on the review of applicable industry experience and the lead engine DR/QR reports (Shoreham/ Comanche Peak). There is no site experience for this component. There are no maintenance or modification recommendations for this component. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON -- N PROGRAM MANAGER MCW- u _ PE3145/1 l l

D TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT - UNIT 1 AUXILIARY SUB-BAFE AND OIL AND WATER PIPING - FUEL OIL: SUPPORTS (SMALL BORE SCOPE ONLY COMPONENT PART NO. I INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program for the Perry Nuclear Power Plant requires Design and Quality Revalidation reviews of the structural adequacy of the auxiliary sub-base fuel oil supports to withstand the effects of normal operating and earthquake loadings. The primary function of these supports is to provide adequate restraint of the small bore piping / tubing system in the intended support load direction. II OBJECTIVE The objective of this review was to perform an engineering evaluation of the small bore piping / tubing supports to assure that the components will perform their intended design function during normal operating and earthquake loadings. III METHODOLOGY In order to meet the stated objective, the. following methods were used:

The TOI Emergency Diesel Generator Component Tracking System was reviewed for the Perry site, nuclear, and non-nuclear industry experience. See Appendix C for results.
The Quality Revalidation Checklist results were reviewed for acceptability.
Engines IA and IB, both partially disassembled, were evaluated usino actual walkdown information and comparison to the Comanche Peak lead engine report.

Refer to the review procedures as described in Reference 1 for a detailed methodology of this evaluation. IV RESULTS AND CONCLUSIONS The piping / tubing supports, as defined by this component design review, and as shown in Reference 2, have been -evaluated in accordance with Reference 1 and have been found acceptable with modifications. O PE3201/1

e Page 2 of 3 A Q There are no TERs associated with this component. The Quality Revalidation Inspection results identified in Appendix B have been reviewed and considered in the performance of this design review, and the results are consistent with the final conclusion of this report. Based on the above review, it is concluded from Reference 2 that the supports will perform their intended design function at Perry under 'all normal operating and earthquake loadings with the provision that the following recommended modifications as detailed in Reference 3 be implemented. ENGINES 1A AND 18 Fuel Oil Booster Pump

The vertical support on the riser before the booster pump on the line from the day tank should be redesigned to bring the lug in contact with the support structure. ,

ENGINE 1A Fuel Oil Booster Pump f

A 1 1/2-NPS U-bolt is installed on the line fro:o the booster pump to the check valve. This U-bolt should be replaced with one of proper h

D pipe diameter and should be of 3/8-inch diameter stock. locking devices are recommended. Suitable ENGINE IB Fuel Oil Drip Pump

On the drip pump to strainer piping, the existing " washer" type spacer on the first support downstream of the pump should be replaced with the proper assembly.
On the drip pump to strainer piping, the existing U-bolts should be replaced with 3/8-inch diameter. Suitable locking devices should be installed.

In order to support the piping / tubing of component 02-717J it is recommended that the following supports be added: Fuel 011 Orip Tank Pipina (Engines 1A and 18) l

The 1-inch IPS overflow lines should have a two-directional restraint added at the top of the risers between the drip tank nozzle and the first existing restraint to meet span requirements.
The 1 1/4-inch tube header to the drip tanks should have a two-directional restraint added in the horizontal run at the bottom G of the riser at the drip tank to provide lateral stability, i s PE3201/2

~ I Page 3 of 3 V REFERENCES

1. " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping, Tubing, and Supports for the TDI Owners' Group," Report No. 11600.60-DC-02, Revision 0.

2. Stone & Webster Calculation number 11600.60 NP(B)-0301-XH

3. Memo No. 6548 from C. Malovrh/SWEC to J. Kammeyer/SWEC dated 11/29/84. ,

I O O PE3201/3

e APPENDIX A Page Al of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT ' UNIT 1 Auxiliary Sub-Base & 011 & Water Piping - Fuel 011: Supports COMPONENT (Small Bore Scope only) UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-717M TASK DESCRIPTION NO. DR-03-02-717M-0 SNPS GPL NO. 03-7170 CLASSIFICATION TYPE B TASK DISCRIPTIONS Perform an engineering review of the small bore piping / tubing supports to assure that the component will perform its intended design function during normal operating and operating loadings.

PRIMARY FUNCTION Provide adequate restraint of the small bore piping / tubing system, in the intended support load directions. , ATTRIBUTE TO BE VERIFIED Structural adequacy of sr.?all bore pipe / tube supports to withstand the effects of normal operating and earthquake loadings. SPECIFIED STANDARDS ASME Boiler and Pressure Vessel Code, Section III, 1971 Edition with all addenda. REFERENCES

    " Engineering Review Criteria Document for the Design Review of TDI Diesel Small Bore Piping. Tubing, and Supports for the TDI Owners' Group," report No. 11600.60-DC-02, Revision O.

O PE3019/1

n COMPONENT DESIGN REVIEW CHECKLIST Page A2 of 2 DOCUMENTATION REQUIRED Delaval design documentation (specifications, calculations, drawings, etc.). In lieu of information from Delaval, the following information is required: verified support sketches and piping isometrics, material specifications, pipe size and schedule, and operating parameters (pressure, temperature, load combinations). l\ n_ b GROUP CHAIRPERSON M Lf M : -1 - PROGRAM MANAGER XWeu-w f O O O PE3019/2 \

Appendix B Page B1 of 3 [ 03-02-717M COMPONENT QUALITY REVALIDATION CHECKLIST A'ux. Sub-Base & 011 & Water Piping - Cleveland Electric Illuminating Co. COMPONENT Fuel 011: Supports UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-717M _ REV. NO. 3 I SNPS GPL NO. 03-7170 l TASK DESCRIPTIONS Engine 1A

1. Assemble and review existing documentation,

2. Obtain sufficient data to support the design review effort. This may be acc mplished by developing quality verified as-builts in accordance with Procedure DG-7, or by the Design Group performing a field walkdown.

O V Engine 18 Same as Engine 1A ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package

2. Information necessary for the design review effort Engine 1B Same as Engine 1A F

[ t PE2782/1

i l COMPONENT QUALITY REVALIDATION CHECKLIST Page 82 of 3

   ,                                                                            03-02-717M

( ACCEPTANCE CRITERIA Engine 1A

1. Satisfactory Document Package

2. Review of detailed information by the Design Group Engine IB Same as Engine 1A REFERENCES Engine 1A

1. QCI No. 52

2. Procedure DG-7 Engine IB Same as Engine 1A DOCUMENTATION REQUIRED Engine 1A

1. Document Sunnary Sheet

2. Quality verified as-built isometric drawings for the supports if available from the Owner.

Engine 18 Same as Engine 1 GROUP CHAIRPERSON d PROGRAM MANAGER e k kcs. O PE2782/2

COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 3 03-02-717M COMPONENT REVIEW Engine 1A

1. All EDGCTS site experience documents were assembled and reviewed with satisfactory results.

2. The Design Group will be responsible for closing out the as-built drawings as per Procedure DG-7. The as-built drawings will be Quality verified by the appropriate site Quality organization. The performance of an engineering walkdown by the Design Group, precludes the issuance of a quality verified as-built drawing or sketch.

Engine IB Same as Engine 1A RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as ON outlined above, is complete. The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of the final report. Engine 1B Same as Engine 1A s // f) GROUP CHAIRPERSON PROGRAM MANAGER 1 \ & m e va

a PE2782/3

Appendix C Page C1 of 1 O Q EDG COMPONENT TRACKING SYSTEM: PERRY SITE, NUCLEAR AND NON-NUCLEAR INDUSTRY EXPERIENCE SLM4ARY COMPONENT NO. 02-717M Effective Printout Dates Perry: 11/05/84 Industry: 11/05/84 Auxiliary Sub-Base Oil & Water COMPONENT TYPE: Piping-Fuel 011: Suppo.-ts REFERENCE PERPY EXPERIENCE DOCUMENTS STATUS PERRY Reworked skid mounted NCR P039-1530 This OR/QR review provides pipe supports to meet ASME assurance that the Section III Class 3 components will perform requirements. All engines. their intended design functions during normal operating and earthquake loadings. This incident has been resolved via p Perry document NCR P039-1530 I NUCLEAR Supports omitteci San Onofre 1 As-built review during assembly of LER 206-77000, indicates that all fuel oil bypass 770510 fuel oil supports have lines. been installed at l Perry. 10 CFR 50.55E filed, 10 CFR 50.55E This DR/QR provides support not built Cleveland Electric assurance that components

to ASME III Class NF DAR No. 117 will perform their intended as required. dated 02/17/83 design function during normal operating and earthquake loadings. This incident has been resolved via Perry document NCR t

P039-1530. NON-NUCLEAR None PE3201/4

l COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Fuel Oil Day Tank __ UTILITY Cleveland Electric Illuminatina Co. GROUP PARTS LIST NO. 02-825A TASK DESCRIPTION NO: DR-03-02-825A-1 SNPS GPL NO. 99-825A CLASSIFICATION TYPE A TASK DESCRIPTIONS

                          - A detailed design review of the fuel oil day tank is not necessary at Perry.

No inherent design flaws have been identified in TDI supplied fuel oil day tanks. The tank is designed and con:;t.ructed in accordance with ASME Section . III. The results of the ASME III. qualification program for the Comanche Peak fuel oil day tank were reviewed, and no deficiencies were found. There . is one experience item reported for this tank at Perry in the EDG t Component Tracking System. Nonconforming welds were reworked. There are no , other nuclear or non-nuclear industry experience items reported. There are no maintenance or modification recommendations for this component. j= Quality revalidation is not required for this component. PRIMARY FUNCTION

                          'Not required i

i ATTRIBUTE TO BE VERIFIED Not required 1 SPECIFIED STANDARDS Not required t_ i O i PE3308/1

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

r (' COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-825A-1 REFERENCES Specification SP-582-4549-00, Class 1E Diesel Generator Units, Perry Nuclear Power Plant - Units 1 and 2, Cleveland Electric Illuminating Co. , by Gilbert Associates, Inc. Rev IV, July 17, 1978, Section 2:06.6. DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON ,

                                          -  PROGRAM MANAGER 1 \<c. sa...a -z em Gl'                                                       .:)

4 O f O PE3308/2

Page 1 of 1 [..

COMPONENT QUALITY REVALIDATION CHECKLIST 03-02-825D F'el u Oil System - Fuel Cleveland Electric Illuminating Co. COMPONENT 011 Duplex Strainer UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-8250 REV. NO. 2 SNPS GPL NO. 99-825E TASK DESCRIPTIONS No further review of component 02-8250 is required for the following reasons a) There is no site or industry experience reported for this component. b) Component was reviewed on the lead engines (Shoreham - under Component 03-455B/ Comanche Peak) with satisfactory results. GROUP CHAIRPERSON / 4 +M A- M PROGRAM MANAGER N C M u ~ ~ l O PE2614/1 1

t Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Generator UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-650A TASK DESCRIPTION NO. DR-03-02-650A-1 SNPS GPL NO. 03-650A CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on review of the Perry

      . FSAR Table 8.3-1, the procuremer.t specification, and the reported applicable industry experience. A review of nuclear and non-nuclear industry experience and Perry site experience revealed no incidents of generic nature that would prevent the generator from performing its intended function.

During a plant incident requiring diesel generator operation, the sequential loading as specified in the FSAR shows that the maximum continuous load will be on the Division 2 diesel generator (1R435001B) and will not exceed 5824 kW. Each generator has a continuous rating of 7000 kW. Therefore, the continuous and short-term rating of each generator is adequate. The minimum voltage and O voltage recovery during sequential loading (Regulatory Guide 1.9) is addressed in the procurement specification and adequately reflects the relevant stan-dards. l. No cases of failure of the brushes or slip rings has been reported at Perry. l l Maintenance procedures recommended by the manufacturer in the GE instruction I manual "Large AC Horizontal Synchronous Motor and Generator GEH 3178" are adequate to identify and prevent any potential problems. There are no maintenance or modification recommendations for this component. Quality revalidation is not required for this component. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required O PE3307/1 l

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED , Not required GROUP CHAIRPERSON - PROGRAM MANAGER X M % j (f ' O O

     .PE3307/2

Dage 1 of 2 O' COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT'1 COMPONENT Generator controls UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-6508 TASK DESCRIPTION NO. DR-03-02-6508-0 SNPS GPL NO. 03-650B CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on a review of applicable industry and site experience, the lead engine DR/QR report (Comanche Peak), and a field walkdown. There is no significant Perry site experience or non-nuclear industry experience listed in the EDG Component Tracking System for this component. The nuclear industry experiences have been reviewed with regard to Perry, and no generic or significant problems exist which could affect the integrity of this component other than an apparent pattern of failures involving field flashing relays. O The lead engine DR/QR report addresses modifications for the generator controls. site specific maintenance and The necessity for similar maintenance and modifications on Perry has been assessed by a field walkdown. The field walkdown revealed that the generator controls for Perry are built by a different manufacturer than those for all other engines being evaluated by the TDI Owners Group. Examination of the Perry controls verified that all maintenance and modification recommendations that were made in the lead engine DR/QR report to ensure adequate operation have been implemented in this design with one exception. This exception is a recommendation involving replacement of the field flashing relay due to problems experienced with dirty contacts and underrated coils. Due to problems experienced with field flashing relays in the nuclear industry, it is recommended that these relays be replaced at Perry by an equivalent type with supplemental ratings as follows: Coil voltage,100-140 Vdc; contact voltage, 140 Vdc. The relay should be of the enclosed type to prevent particles of dirt from being deposited on the contacts. This relay replacement should be made prior to placing the engines into emergency standby service. O PE3306/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2

-~

DR-03-02-6508-0 (' TASK DESCRIPTIONS (continued) There are no maintenance recommendations for this component. Quality revalidation inspection results for this component have been reviewed. This review indicates that the majority of inspections have not been completed. However, only one of those inspections is required to substantiate this design review. Therefore, prior to placing the engines into emergency standby service, it is recommended that the controls be inspected to verify that no Multi-Amp, States Division terminal blocks which were manufac-tured between 1974 and 1976 are installed. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required [ l SPECIFIED STANDARDS l Not required REFERENCES Memorandum' from D. Galler (Alexander Kusko, Inc.) to J. Kammeyer (SWEC) dated j December 6, 1984. l l DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON 21 = PROGRAM MANAGER 2CA<a. VV ' U I PE3306/2

APPENDIX B Page B1 of 3 COMPONENT QUALITY REVALIDATION CHECKLIST Generator - Cleveland Electric Illuminating Co. COMPONENT Generator Control UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-6508 REV. NO. 2 SNPS GPL NO. 03-650B TASK DESCRIPTIONS Engine 1A

1. Assemble and review existing documentation.

2. Visually inspect the three phase voltage regulator to identify the specific components.

3. Visually inspect the voltage regulator bridge rectifier to check the method of bonding the diodes to the heat sinks.

4. Visually inspect the exciter to determine the wiring and construction method used.

5. Verify that no Multi-Amp, States Division terminal blocks which were manufactured between 1974 and 1976 are installed.

Engine 18

1. Assemble ard review existing documentation.

2. Verify that no Multi-Amp, States Division terminal blocks which were manufactured between 1974 and 1976 are installed.

ATTRIBUTES TO BE VERIFIED Engine 1A

1. Quality status of Component Document Package

2. Specific components of three phase voltage regulator

3. Method by which diodes were bonded to the heat sinks

4. Wiring and construction method used on exciter.

5. Type of terminal blocks-installed.

PE2632/1

COMPONENT QUALITY REVALIDATION CHECKLIST Page B2 of 3 03-02-650B b

     \--
 ,       ATTRIBUTES TO BE VERIFIED (continued)

Engine IB

1. Quality status of Component Document Package

2. Type of terminal blocks installed ACCEPTANCE CRITERIA Engine 1A

1. Satisfactory Document Package 2-4. Review of inspection report by the Design Group

5. No Multi-Amp, States Division terminal blocks (1974-1976) are installed.

Engine 18

1. Satisfactory Document Package O 2. No Multi-Amp, installed.

States Division terminal blocks (1974-1976) are REFERENCES ! Engine 1A i

1. QCI No. 52 l 2-4. Approved Site NDE Procedures, TER# 99-014

5. Approved Site NDE Procedures, TER# 99-037 l

Engine IB

1. QCI No. 52 l

2. Approved Site NDE Procedures, TER# 99-037 1

O PE2632/2 w - - - ~ < ~ - - - - - - .-- -

I I l ! COMPONENT QUALITY REVALIDATION CHECKLIST Page B3 of 3 03-02-6508 V DOCUMENTATION REQUIRED Enaine 1A

1. Document Summary Sheet 2-5. Inspection Report Engine 1E,

1. Document Summary Sheet l 2. Inspection Report GROUP CHAIRPERSON 4/afo ,4 PROGRAM MANAGER M C W -

COMPONENT REVIEW Enaine 1A

1. All EDGCTS site experience documents were assembled and reviewed

, with satisfactory results.

   /     2-5. No inspection reports have been received which fulfill these
   's           requirements.

Engine IB

1. All EDGCTS site experience documents were assembled and raviewed with satisfactory results.

2. No inspection report has been received which fulfills this requirement.

RESULTS AND CONCLUSION Engine 1A The Quality Revalidation effort with respect to this component, as outlined above, is complete. The results have been forwarded to the Design Review Group for their evaluation and conclusions in support of the final report. Engine IB Same as Engine 1A GROUP CHAIRPERSON / id PROGRAM MANAGER 2C_\<=% V

                                            's
    \

PE2632/3

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST PERRY FUCLEAR POWER PLANT - UNIT 1 Generator: COMPONENT Shaft & Bearinas UTILITY Cleveland Electric Illuminatina Co. GROUP PARTS LIST NO. 02-650C TASK DESCRIPTION NO: DR-03-02-650C-0 SNPS GPL NO. 03-650C CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review for this component is not required based on the following:

The generator shaft dimensicas, torque inputs, and bearing reactions are comparable to other Owner's Group generators with V-16 engines. The DR/QR report for Comanche Peak indicated an adequate margin of safety against shaft yielding and fatique.
A review of the EDG Component Tracking System applicable industry experience indicates that there have been no design related problems associated with this component.

Perry site experience indicated that on one occasion the journal and bearing v were found with minor scratches from foreign particles imbedded in the bearing babbitt. Both were cleaned and polished and should have no effect on the operational performance. Ther are no maintenance or modification recommendations for this component other than those specified by the vendor.

Quality revalidation for this component is not required.

PRIMARY FUNCTION . Not required ATTRIBUTE TO BE VERIFIED Not required

    -PE3192/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-6500-0 ACCEPTANCE CRITERIA Not required l REFERENCES Not required GROUP CHAIRMAN -

                                          -        PROGRAM MANAGER MC_.\4a we VV                                                 O
                                                                                 ~

O 't 6

Page 1 of 2 O COMPONENT DESIGN REVIEW CHECKLIST V0GTLE ELECTRIC GENERATING PLANT - UNIT 1 Control Panel Assembly COMPONENT Cabinet / System UTILITY Georgia Power Company GROUP PARTS LIST NO. 02-500A TASK DESCRIPTION NO. DR-11-02-500A-1 SNPS GPL NO. 03-500A CLASSIFICATION TYPE A TASK DESCRIPTIONS Design review of the control panel assembly cabinet / system is not required for Vogtle based on the following:

A review of the Rancho Seco DR/QR report.
The application of the electropneumatic control system used on Vogtle to start, stop, operate, protect, and monitor the diesel is more extensive and complex than Comanche Peak design, but is similar to Rancho Seco.
The logic design used on Vogtle to disable the Group II trip f's functions during initial diesel startup, lockout the diesel for maintenance, provide test bypass and reset from LOCA features is identical to Rancho Seco design.
Vogtle differs from Rancho Seco in that two, two-out-of-three logic boards are used on Vogtle providing both a low lube oil pressure trip and high jacket water temperature trip. The redundant overspeed trip signal is transmitted through both these boards to the mother board. These trips remain et tive during an emergency

. condition.

There is no Vogtle site experience . listed in the EDG Component Tracking system. Nuclear and non-nuclear industry experience listed does not show any significant or generic problems associated with the type of electropneumatic-system used on Vogtle.

There are no maintenance or modification recommendations required for the control panel assembly cabinet / system. Quality revalidation of the control panel assembly cabinet / system is not deemed necessary. PRIMARY FUNCTION Not required O V03011/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON += PROGRAM MANAGER UC_\h a - O o v <' ' l I ' t i O V03011/2

I - )- Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST , PERRY NUCLEAR POWER PLANT - UNIT 1 Control Panel Assembly -

COMPONENT Accumulator UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-500F TASK DESCRIPTION NO. DR-03-02-500F-0 i

SNPS GPL NO. 03-500F CLASSIFICATION TYPE A TASK DESCRIPTIONS

,                        A design review for the accumulators is not required for Perry based on the following:

A review of the DR/QR lead engine report (Comanche Peak). -
The accumulators used at Perry are identical .to those used on Comanche Peak with regard to manufacturer and application.
There is no Perry site, nuclear or non-nuclear industry experience listed in EDG Component Tracking System for this component.

O There are no maintenance or modification recommendations for the accumulators. Quality revalidation of the accumulators is not deemed necessary. PRIMARY FUNCTION Not required 1 F ATTRIBUTE TO BE VERIFIED

                      - Not required SPECIFIED STANDARDS Not required O                    PE2902/1
    *.-e- r - , - -pww.-.m,..--   e.-9v,   + - . . ,

f, - , . ,--+ - - - , - - , - , - - - - ..p ,,---,,,--,v,c.-w-.r-e,------ . , . ,,-,--,-.-.---**,v-,e

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-500F-0 REFERENCES Not required 1 DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON PROGRAM MANAGER 1 W % O hI i-l O 4 d h. t I 4 PE2902/2

                                      ,.,-m   , _ ,- _ , _ _ _ _ _ , - _ , , __,,,   __w_-,,,-,, ,  . - - . _ _ _ , _ , , - ,   9,

r i Page 1 of 2

   'j                              COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 COMPONENT Control Panel Valves          UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-500G            TASK DESCRIPTION NO. DR-03-02-500G-0 SNPS GPL NO. 03-500G                    CLASSIFICATION TYPE                A TASK DESCRIPTIONS A design review for the control panel valves at Perry is not required based on the following:

A review of the DR/QR lead engine report (Comanche Peak).
The control panel valves used on Perry are identical to those on Comanche Peak with regard to valve application and manufacturer, with the exception of Valvair 3-way valve F-160-002. This valve is manually actuated at Perry to provide local manual start capability and is of adequate design for this function.

b

There is no Perry site experience listed in the EDG Component Tracking System for the control panel valves. The nuclear and non-nuclear industry experience listed does not show any significant experience relating to the control panel valves.

To minimize fouling of the control panel valves, the valves should be inspected and cleaned during each refueling outage. This recommended maintenance inter-val should be reassessed depending upon the degree of system fouling. There are no recommended modifications for the control panel valves. Quality revalidation for the control panel valves is not deemed necessary. PRIMARY FUNCTION l l Not required l ATTRIBUTE TO BE VERIFIED Not required O PE2903/1 l

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 SPECIFIED STANDARDS Not required REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - PROGRAM MANAGER 3C_\<< (/V G O O PE2903/2

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1

Control Panel Assembly - COMPONENT Pressure Switches UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-500H TASK DESCRIPTION NO. DR-03-02-500H-0 SNPS GPL NO. 03-500H CLASSIFICATION TYPE B TASK DESCRIPTIONS A design review for the pressure switches is not required for Perry based on the following:

A review of the lead engine DR/QR report (Comanche Peak).
The pressure switches used at Perry are identical to those used on Comanche Peak with regard to manufacturer and application.
There i.; no Perry site, nuclear or non-nuclear industry experience listed in EDG Component Tracking System for this component. The nuclear industry experience listed does not show any generic or significant problems with the pressure switches.

l [ There are no maintenance or modification recommendations for the pressure switches. Qualit" revalidation of the pressure switches is not deemed necessary. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required l SPECIFIED STANDARDS Not required O PE2904/1

F i. ll COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 DR-03-02-500H-0 REFERENCES Not required DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - PROGRAM MANAGER MW% L/v o l l l l O 4 1 4 i f P O PE2904/2 i

Page 1 of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 ; Control Panel Assembly COMPONENT Control Relays UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-500I TASK DESCRIPTION NO. DR-03-02-500I-0 SNPS GPL NO. 03-500J CLASSIFICATION TYPE A i TASK DESCRIPTIONS A design review of the control panel assembly is not required for Perry based

                     .on the following:

A review of the lead engine DR/QR report (Grand Gulf).
The application of the control relays used on Perry to start /stop the diesel generator and to monitor its integrity is similar to s

Grand Gulf except for the use of_ Agastat time delay relays (TDI Part no. F-590-206, 220, 221). Perry uses these relays to energize the field flash solenoid valves and also to arm various alarms after I timing out upon energization. A review of the vendor's information for this relay shows that it meets design requirements.

There is no Perry site or non-nuclear industry experience identified in the EDG Component Tracking System. Nuclear industry experience

listed identified a problem with Agastat GP & EGP relays. Perry uses a different model Agastat relay in their design, therefore, 4

this problem is not applicable to Perry. A review of the remainder of the nuclear industry experience indicated that most of the experience items are not applicable to relay type, service condition, or are otherwise unrelated to TDI design, and therefore are not

applicable to this component, i There are no maintenance or modification recommendations required for the control panel assembly control relays.

Quality revalidation of the control panel assembly control relays is not deemed necessary, s

'    O                 PE2905/1 t
      . .-, .- , . . . ....,_.. _ ,, - -..__ - ~.. _. . .~ - _ _ _.... _ ,                                  _ _ _ - - ,                 . _ ~ _ _ _ _ _ . - - . _ -

COMPONENT DESIGN REVIEW CHECKt.IST Page 2 of 2 OR-03-02-500I-0 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED i Not required SPECIFIED STANDARDS Not required l REFERENCES Not required l l DOCUMENTATION REQUIRED Not required GROUP CHAI'RPERSON

                                                                                                   - PROGRAM MANAGER d % - wt e V (l'                                                                       C O         PE2905/2 l

Page l'of 2 COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Control Panel Assembly COMPONENT Solenoid Valves UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-500J TASK DESCRIPTION NO. DR-03-02-500J-0 SNPS GPL NO. 03-500K CLASSIFICATION TYPE A TASK DESCRIPTIONS A design review of the solenoid valves is not required for Perry based on the following: !

A review of the DR/QR lead engine report (Comanche Peak).
The control panel assembly solenoid valves used at Perry are similar to those used at Comanche Peak with regard to manufacturer and application. The soienoid valves are identified for both ' plant 4 sites as Humphrey Products, Model T062El-3-10-35-125VDC. TDI part numbers . differ on Perry from those assigned to control panel i

O

assembly solenoid valves for Comanche Peak site.

The Perry site control panel assembly solenoid valves are employed l for control of mode (inop and normal), shutdown system activate, stop, shutdown system deactivate, field flash, d.c. power, up to l speed, and running at 200 rps functions. At Perry, - the solenoid c valves are located on a Humphrey, seven-station manifold assembly (part no. 75051-128) and a Humphrey eight-station, manifold assembly (part no. 75051-129) for the above functions.

The Circle Seal Controls solenoid valves, used as pilot valves for the California Controls Company " Start Air Admission Valves", (TDI Part No. KR-001-000) in the starting air system at Perry are identical to Comanche Peak design.

j

There is no Perry site experience or non-nuclear industry experience listed in the EDG Component Tracking System for this component. The nuclear industry experiences have been reviewed with regard to Perry, and no generic or significant problems are apparent.

There are no maintenance or modification recommendations for the control panel assembly solenoid valves. Quality revalidation of the control panel assembly solenoid valves is not

                      . deemed necessary.

O PE2910/1 i

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required SPECIFIED STANDARDS Not required REFERENCES Not required . DOCUMENTATION REQUIRED v O Not required

GROUP CHAIRPERSON -- - PROGRAM MANAGER m I W m w w- 2_ %~ .- U/ G ' L O PE2910/2 i _i._. -

E Page 1 of 2 O' COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 l Control Panel Components-COMPONENT Piping, Tubing, Fittings UTILITY Cleveland Electric Illuminating Company GROUP PARTS LIST NO. 02-500L TASK DESCRIPTION NO. OR-03-02-500L-0 SNPS GPL NO. 03-500M CLASSIFICATION TYPE B TASK OESCRIPTIONS Detailed design review of control panel piping, tubing and fittings is not required for Perry. Review of the two lead TDI engines has revealed no inherent design flaws in these components. Typically the engine control panel is seismically qualified by shake table tests, and these tests have 'provided adequate qualification for all service conditions. The control panel used at Perry was shake table tested at Wyle labs. Experience items reported in the EDG Component Tracking System usually relate to minor raintenance problems. No experience items are reported for Perry in the Component Tracking Systera. There are no maintenance or modification recommendations for this component. No quality revalidation is required for this component. PRIMARY FUNCTION Not required L ATTRIBUTE TO BE VERIFIED Net required , l SPECIFIED STANDARDS Not required t v PE3309/1

COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 OR-03-02-500L-0 v REFERENCES Gilbert Associates, Inc. Specification No. SP-562-4549-00, Class 1E Diesel Generator Units, Rev. II, Jan 11, 1977. Final Report, Volume II, Seismic Qualification of Delaval Turbine Inc. Diesel Generator Sets, Serial Numbers 75051-75054, for Cleveland Electric Illuminating Company, Perry Nuclear Stations No. 1 and 2, Seismic Testing of one Engine Control Panel, Part Number 1A-7007. DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON " _ = PROGRAM MANAGER ,)C_ \4% ()

G l' O O' PE3309/2 l

Page 1 of 1 O COMPONENT QUALITY REVALIDATION CHECKLIST 03-02-500M Control Panel Assembly Terminal Boards / Cleveland Electric Illuminating Co. COMPONENT Switches, Wiring UTILITY Perry Nuclear Power Plant - Unit 1 GPL NO. 02-500M REV. NO. 2 SNPS GPL NO. 03-500N TASK DESCRIPTIONS Recommend that the following inspection for component 02-500M be performed:

Verify that no ' Multi-Amp, States. Division terminal blocks, manufactured between 1974 and 1976, are installed.

Any terminal blocks failing the above criteria should be replaced. Upon completion of the above verification, no further review of component 02-500M is required based on the following reasons. a) Component was received the lead engines O satisfactory results. on (Shoreham) with b) There is no site experience or significant industry experience reported for this component. GROUP CHAIRPERSON 8d/N M PROGRAM MANAGER M C_ M ct e M b i l l l PE2621/1 L _-

9 Page 1 of 3

COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 Foundation Bolts - Anchor Bolts, Miscellaneous COMPONENT Hardware UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-550 TASK DESCRIPTION NO. DR-03-02-550-0 SNPS GPL NO. 03-550 CLASSIFICATION TYPE B TASK DESCRIPTIONS t A design review report for this component is not required based on review of the Comanche Peak lead engine DR/QR report (Ref. 1), the TDI Parts Manual Volume II for Perry and Comanche Peak Power Stations (Refs. 2 and 3), the 4 amplified response acceleration spectra curves for Perry Station (Ref. 5), and i the EDG Component Tracking System for applicable industry experience. There is no reported site experience in the EDG Component Tracking System for this component. Items included in this cosponent consist of the foundation bolts and associated

 'O       hardware for the engine base, jacket water standpipe, lube oil cooler, jacket water cooler, auxiliary base, barring device, and the generator base. All bolting hardware for the engine base (Parts List 02-550-03-04) is identical to that for Comanche P,ak Station. Likewise* the various items listed for Perry
    ,     in the Parts List 02-550 (for 75051) are the same as those provided for Comanche Peak under Parts List 02-550 (for 76001).

Review of the TDI Instruction Manual (Ref. 4) indicates that-.all bolt torque

values of corresponding foundation bolts are identical for Perry and Comanche i Peak Power Stations with the exception of the heat treated engine . foundation bolts, which have a torque value of 3,000 ft-lb for Perry versus 3,800 ft-lb,

! as specified for Comanche Peak and other V-16 engines. l l Review of the amplified response acceleration spectra curves for Perry (Ref.

5) indicates that the seismic loadings are more favorable than those at the
Comanche Peak Station, and thus the lower foundation bolt preload torque is

! judged adequate. Similarity of design between the Comanche Peak and the ( Perry emergency diesel generator units suggests that the findings of the DR/QR report for . Comanche Peak lead engine are equally applicable to the . Perry Nuclear Power Station, and that the foundation bolts are structurally adequate for their intended use. i PE3334/1

                .                COMPONENT DESIGN REVIEW CHECKLIST       Page 2 of 3 DR-03-02-550-0 The following maintenance recommendation is made for this component.

T.he generator foundation bolts should be retorqued to 480 ft-lb and alignment should be checked after each generator short circuit occurrence if the bolts have not previously been torqued to 600 ft-lb. This assumes that the GE generator has a comparable short circuit torque as the Portec unit used at Comanche Peak.

There are no modification recommendations for this component. Quality revalidation for this component is not required. PRIMARY FUNCTION Not required ATTRIBUTE TO BE VERIFIED Not required O SPECIFIED STANDARDS , Not required REFERENCES

1. Comanche Peak Steam Electric Station - Unit 1, DR/QR report for Group Parts List No. 02-550.

2. TDI Manual Volume II, for Model DSRV-16-4 Diesel Engine / Generator, Perry Nuclear Power Plant, Units 1 and 2, Parts List Nos. 02-550 (for 75051) and 02-550-03-04, and Drawing No. R-3952.

3. TDI Manual Volume II for Model DRSV-16-4 Diesel Engine / Generator, Comanche Peak Steam Electric Station - Unit 1, Parts List Nos. 02-550 (for 76001), and 02-550-03-04, and Drawing No. R-3943.

j 4. TDI Manual Volume I for Model DSRV-16-4 Diesel Engine / Generator, Perry l Nuclear Power Plant, Units 1 and 2. iO PE3334/2 l

(~ COMPONENT DESIGN REVIEW CHECKLIST Page 3 of 3 DR-03-02-550-0

5. Gilbert Associates, Inc., Specification SP-562-4549-00 for Class 1E Diesel Generator Units, Rev. II dated January 11, 1977, Attachment Specification for Seismic Analysis, Testing, and Documentation, Perry Nuclear Power Plant Units 1 and 2, SP-750-4549-00 dated August 30, 1973.

DOCUMENTATION REQUIRED l Not required GROUP CHAIRPERSON "

                                       - _ PROGRAM MANAGER 2C \(-

U (/ ' G' O O PE3334/3

      .                                -                                                                                     .   .    =. -.            -.

4 i COMPONENT DESIGN REVIEW CHECKLIST PERRY NUCLEAR POWER PLANT - UNIT 1 l COMPONENT Auxiliary Sub Base UTILITY Cleveland Electric Illuminatina Company GROUP PARTS LIST NO. 02-717A TASK DESCRIPTION NO. OR-03-02-717A-0 SNPS GPL NO. 03-717A CLASSIFICATION TYPE B i TASK DESCRIPTIONS Design review for this component is not required based on the following: L , !

A review of the EDG Component Tracking System indicated, no l significant applicable industry experience. There is no experience reported for the Perry site for this component.
A detailed dynamic analysis was performed to seismically qualify the skid (Ref. 2).

The Ref. 2 seismic report references ASME III stress .allowables but it is not clear if the seismic report is intended as an ASME III stress report. The O seismic model, report format, and stress allowables are identical for Comanche Peak and Perry. However, compliance with ASME III NF requirements was found deficient at Comanche Peak. ASME III components are supported off the auxiliary skid but subsection NF jurisdiction is not as clearly called out in the parts manual for Perry as for some other Owners Group plants where skid NF supports subassembly drawings are listed. It is recommended that skid design and fabrication details be reviewed at Perry for ASME III - NF applicability , and compliance. There are no maintenance or modification recommendations from the lead _ engine report. Quality revalidation is not required for this component. PRIMARY FUNCTION , Not required i. ? I i ATTRIBUTE TO BE VERIFIED L ! Not required I

O 'PE3335/1 l

n. COMPONENT DESIGN REVIEW CHECKLIST Page 2 of 2 SPECIFIED STANDARDS Not required REFERENCES

1. Gilbert Associates, Inc. , Specification SP-562-4549-00, Class 1E Diesel Generator Units, Perry Nuclear Power Plant - Units 1 and 2, Cleveland

Electric Illuminating Co., Rev. IV, July 17, 1978.

l t

2. Final Report Volume I, Part I, Seismic Qualification of Delaval Turbine Inc., Diesel Generator Sets, Serial Numbers 75051-75054 for Cleveland Electric Illuminating Co., Perry Nuclear Stations No. I and 2, SDRC Report Number 3816, Section 111.7, Auxiliary Skid.

i DOCUMENTATION REQUIRED Not required GROUP CHAIRPERSON - PROGRAM i4ANAGER 3C \<% t/ r G O PE3335/2

                           -r --

O TDI OWNERS GROUP for PERRY NUCLEAR POWER PLANT MAINTENANCE REVIEW APPENDIX - II I INTRODUCTION The purpose of this Appendix is to provide Perry with a set of maintenance r and surveillance recommendations for diesel generator components which have been developed by TDI and/or the Owners Group as a result of the overall Owners Group Program. This Appendix is intended to supplement the existing TDI Instruction Manual, Volume I- and Volume III, which will maintain the qualification of the diesel generators for the life of the plant. II METHODOLOGY During the implementation of the Owners Group Program Plan, the Owners Group Technical Staff reviewed many sources of information regarding the maintenance and surveillance for the diesel generator components identi-v fied in this Appendix. These sources included TDI Instruction Manuals, Service Information Memos (SIMS), and TDI correspondence on specific components. This review along with . Technical Staff input regarding the adequacy of the recommendations found in the sources mentioned above, and additional maintenance recommendations identified during the DR/QR review, forms the basis for the content of this matrix. III RESULTS AND CONCLUSIONS Proper maintenance is important in ensuring long, reliable and satisfacto-ry service of the emergency diesel generators. Maintenance work, in order to be effective, must be carried out thoroughly and regularly. It is for these reasons that a detailed schedule of maintenance service has been laid out - by the Owners Group for the TDI Diesel Generators at Perry Nuclear Power Plant. The schedule details specific components requiring

maintenance on a regular basis. This schedule separates the maintenance activities into a daily, monthly, outage, alternate outage (every other), 5 year and 10 year frequencies. It should be noted here that the dura-cion time between outages at Perry is assumed to be 18 months. (Q) PE3041/1

Page 2 of 3 Those less significant diesel generator system components with which standard enginee:ing 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 c,.' 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.

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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.

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

i 6. Ch:ck 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.

9. Check all governor knob settings.

L Load Maximum Droop Zero Speed To provide mechanical governor control at 450 rpm. PE3041/2 l l -. L -

Page 3 of 3 ! .10. Visually inspect lube oil heat exchanger and jacket water heat

                                                   . exchanger for signs of leakage from the lantern ring leakoff ports, indicating leaking packing rings.

. The following Preventive Maintenance 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 Perry on a planned schedule basis. It should be followed closely and referred to often. i i O 1 e t d i e O PE3041/3 4

        ,-_.... _ ~ , _ , . . . , _ . . _ ,   .,m_ ..,.m. , , _ , , , _ . . . . , . , , , . , , . _ , ,              _ . . . .

p x d (- PERRY MAINTENANCE MATRIX Component ' Component Al t. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments F-068 Intercoolers 1. Evaluate heat exchanger X

 }                                                                                   performance by checking engine operating parameters.

2. Clean / inspect shell and X Ref: Lead engine DR/QR tube sides every outage Report fF-068 or as necessary. (Items 2, 3, 4)

                                                                               '3. Visually inspect for             X                                       Ref: 7/26/84 IOC external leaks.                                                          from J. Cadogan to M. McGerigle, Ref: 08/14/84 letter to C. Ray from M. Lowrey

4. Verify intercooler inlet To be performed daily.

plenum drain connection-is open and clean daily. MP-022/3 Turbocharger 1. Measure vibration and X To be accomplished during check with base line data. 24 hour test run.

2. Clean impeller and diffuser. X

3. Measure rotor end play X Review thrust bearing (axial clearance) to axial clearances after identify trends of in- Inspection to determine creasing clearance, f.e; s if a trend exists. Any thrust bearing degradation. trend toward increasing axial clearance could signify thrust bearing degradation. Ref: Lead engine DR/QR Report fMP-022/3 PE3041/4

PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments

4. Perform visual and blue X NOTE: . Thrust bearing check inspections of inspection should also the thrust bearing, be performed after 40 non-prelubed (automatic) fast starts. Ref: Lead engine DR/QR Report

                                                                                                                  #MP-022/3

5. Disassemble inspect X and refurbish.

6. Perform a spectro- X To be performed during chemical engine oli the last monthly analysis to assist the test run prior to oil bearing monitoring change. NOTE: Sample program. To further to be drawn up stream of ,

expand / clarify chemical lube oli filter. analysis, ferrographic Ref: Lead engine DR/QR analysis may be utilized. Report MP-022/3 Particular attention shall be paid to copper level, and particulate size, which could signify thrust bearing degradation. 00-420 Lube 011 Pressure Regulating 1. Disassemble and clean. X If valve sticks repeated-Valve ly, more frequent cleaning may be necessary. If valve plugging becomes a problem, the dimensions of the valves' internal parts should be checked to ensure proper clearance. PE3041/5

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b V PERRY MINTENANCE MATRIX Component Component Alt. , Number Identifica'. ton PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments I Ref: Lead engine DR/QR Report #00-420

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

regulating valve should be disassembled and cleaned untti abnormal L.0. pressure excursions subside. 00-442A Starting Air Distributor 1. Visually inspect the X Evaluate the degree of Assembly peppet valve spool ends wear to determine and timing can of the whether existing starting air distributor. condition would have an adverse effect on timing and the specified ability to start the engine.

2. Ensure that the starting X Ref: Lead engine DR/QR air manifold went is Report #00-442A (STAD),

open and unobstructed. Itees 1 & 2 02-305A Base Assembly 1. Perform a visual inspection X MOTE: Any cracks detected of the base. The inspection must be investigated further should include the areas before the engine is adjacent to the put pockets allowed to return of each bearing saddle and to service. The mating be conducted after a thorough surfaces of the base and wipe down of the surfaces, cap shall be throughly using good lighting. cleaned with solvent before PE3041/6

PERRY MAINTENANCE MTRIX Component Component . Alt. Number Identification PM Recommendation Monthly Outaea Outage 5 Year 10 Year Comments iny reassembly. Ref: Lead engine DR/QR Report #02-3058 02-305C Main Bearing Caps - Studs 1. Upon removal of bearing Ref: Lead engine DR/QR and Nuts caps, clean mating Report #02-305C surfaces with a solvent prior to reassembly of the caps to the base. 02-3078 Lube 011 Tubing and 1. Check tubing for dents X Items 1, 2; Ref: TDI Fittings - Internal or crimps. Instruction Manual, Vol. I Maintenance Schedule

2. Perform gear-train X spray check.

02-310A Crankshaft 1. Measure crankshaft web X Complete TDI Inspection deflection. and Maintenance Record Form No. 310-1-1, TDI Instruction Manual, Volume I, Section 6. Ref: TDI Instruction Manual, Vol. I, Mainten-ance Schedule

2. Measure diameter of M Complete TDI Inspection crank journals, and Maintenance Record Form No. 310-3-1, TDI Instruction Manual, Volume I, Section 6.

PE3041/7

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PERRY MAINTENANCE MATRIX Component -Component Alt. l l Number Identification PM Recommendation Monthly Outane Outage 5 Year 10 Year Comments 02-3108 Main Bearings Shells 1. Inspect and measure main X ~The first inspection bearing shell thickness. should be performed at Inspection shall evaluate the first fuel outsom bearing wear and evidence and at alternate outages of harmful crankshaft thereafter. v misalignment. If results Complete TDI Inspection i show evidence of mis- and Maintenance Record alignment. TDI recom- Form No. 310-2-1. TDI

  ;                                                                                 mandations for crankshaf t                                            Instruction Manual, i                                                                                   realignment should be                                                 Volume I, Section 6 -

J implemented, one sheet for each main bearing. Use volume 1 Appendix III for clearance

 ;                                                                                                                                                        values.

Ref: TDI Instruction i Manual, Vol. 1, Maintenance

!                                                                                                                                                         Schedule, Ref: Lead engine DR/QR Report 4                                                                                                                                                          #02-3108 02-310C                          Thrust Bearing Ring  1.       Measure thrust bearing                    X                           Complete applicable i                                                                                    ring clearance via                                                    sections of TDI
                                                                                    " bump check" method to be                                            Inspection and Main-i                                                                                    performed in conjunction                                              tenance Record Fore
;                                                                                   with crankshaft web                                                   No. 310-1-1 TDI Instruc-deflection measurements.                                              tion Manual, Volume I, I

The fo11owing information Section 6. NOTE: If should be recorded: the clearance is l

Date of inspection greater than the maximum

Mours of engine operation allowed in the TDI 4

i PE3041/8 1 ) l l l .i

r_ _ _ - _ _ - - - - - _ - - - PERRY MAINTENANCE MTRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outaae 5 Year 10 Year Comments

Hours of engine operation Instruction Manual, since last bearing re- then at least one bearing placement (Last bearing must be replaced.

replaced: forward Bearings should also back) be replaced if they

E ng clearance are cracked or gouged.

Ref: Lead engine DR/QR Report #02-310C, Ref: 8/13/84 meno from G. McCarthy to D. Pasquale

2. Visually inspect thrust X To be performed simult-bearing ring for signs aneously with main of cracks, gouges, wear bearing shell inspec-or degradation, tion. Ref: Lead engine DR/QR Report #02-310C 02-311A Crankcase Assembly 1. Perform a visual inspection X The first inspection to be of the vertical portion performed after 185 hours of the crankcase arch wall of at or near full load to the nut pocket area operation, may be used to for indications of justify the discontinua-cracking. tion of further inspect-tions. Ref: Lead engine DR/QR Report #02-311A 02-315A Cylinder Block 1. Perform an inspection of Ref: DR/QR Report the cylinder block per #02-315A DR/QR Report #02-315A.

PE3041/9

l PERRY MAINTENANCE MATRIX

   !      Component         Component.                                                                        Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-315C . Cylinder Liners - 1. Perform a visual inspection X Borescopic inspection of liners for potential is acceptable if heads progressive wear. are not removed. Complete TDI Inspection and Maintenance Record

}                                                                                                                                    form No. 315-1-1. TDI Instruction Manual,
;                                                                                                                                    Volume I, Section 6.

Ref: Lead engine DR/QR Report #02-3418 02-317A&B Water Discharge Manifold - 1, Visually inspect for leaks. X This recommednation is Jacket Water Discharge - Note: In the event of a made on the basis that Piping, couplings and seals leak developing in the the maximum suggested existing Dresser Style 65 operating temperature of l couplings, these couplings 150*F for the Style 65 should be replaced with coupling may be exceeded. i Dresser Style 90 coupilngs The maximum suggested j equipped with Viton gaskets. operating temperature of the Style 90 is 212*F. Ref: Letter dated i 12/13/84 from C L Ray j to J George. Ref:

DR/QR Report #02-317A&B 02-340A/B Connecting Rods, Bushings 1. Inspect and measure To be performed in 1

and Bearing Shells connecting rod bearing conjunction with piston

!                                                             . shell to verify lube oli                                             pin inspection. Coe-t                                                               maintenance which affects                                             plate TDI Inspection wear rate.                                                            and Maintenance Record l                                                               The visual and dimensional                                            Form No. 340-1-1. TDI
;                                                              inspection of the bearing                                             Instruction Manual, i                                                              shells should be conducted                                            Volume I, Section 6,
                                                              .at the fuel outage which                                              Appendix Ill for precedes 500 hours of                                                 clearance values.

l operation by at least the Ref: Lead engine DR/QR , PE3041/10 4 i i i I

O J PERRY MAINTEWNCE MATRIX Component Component Alt. Number Identification' PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments sum of hours of operation Report #02-3408 in a LOOP /LOCA event plus the expected hours of operation between outages.

2. Inspect and measure the X Complete TDI Inspection connecting rods. Maintenance Record Form No. 340-2-1, 2 TDI Instruction Manual, Volume I, Section 6.

i

3. Perform an x-ray examina- This is to be performed tion on all replacement prior to installation of bearing shells to accep- any replacement bearing tance criteria developed shells. Ref: Lead engine by owners Group Technical DR/QR Report #02-3408 i

Staff.

4. Measure the clearance This recommendation is between the Ifnk pin and required one time only.

Ifnk rod in accordance Ref: Lead engine DR/QR with TDI-SIM #349. This Report #02-340A 4 clarance should be zero, l 1.e.; no measurable clearance when the spect- ! fled bolt torque of 1050 ! ft-Ibs is applied. This should be performed with the engine assembled after a major disassembly.

5. At major engine overhauls X If fretting has occured visually inspect the rack a further engineering teeth surfaces for signs evaluation will be

' of fretting. necessary. Ref: DR/QR Report #02-340A PE3041/11 i i i I i

I 3 ( ~ l PERRY MAINTENANCE MATRIM Co.aponent Component Alt. Number Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments 02-341A Pistons 1. Inspect and measure skirt X Complete TDI Inspection and piston pin. and Maintenance Report Form No. 341-1-1, TDI Instruction Manual, Volume I, Section 6. Use Volume 1 Section 8 Appendix III for clearance values. To be performed in con-junction with piston pin inspection. 02-341B Piston Rings 1. Inspect'and measure Complete TDI Inspection replacement piston rings. and Maintenance Record Form No. 341-2-1. TDI Instruction Manual, volume I, Section 6. Use Volume I, Section 8, Appendix III for clearance values. To be perform-ed in conjunction with piston pin inspection.

2. Visually inspect liners X Borescopic inspection for wear. is acceptible if heads NOTE: Ring replacement are not removed. Com-and cylinder liner plete TDI Inspection honing should be performed and Maintenance Record in accordance with TDI Form No. 315-1-1. TDI maintenance procedures. Instruction Manual, Volume I, Section 6. Use Volume I, Section 8, Appendix III for clearance values.

Ref: Lead engine DR/QR Report #02-341B (Items 2, 3, 4) PE3041/12

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PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments

3. 135* fuel oli spray Ref: 07/31/84 memo tips may be used if from L. Swanger tt, inspection results D. Pasquale indicate a need for additional action to improve lubrication and reduce coke buildup.

4. M en replacing engine MOTE: Do not six oil use H.D. oli that L.0. brands or types.

exceeds series 3 Wen changing L.O. standards. The base replace the entire stock should be L.O. charge. Ref: more resistant to 08/14/84 letter to thermal degradation C. Ray from M. Lowrey and coke fornation. The additive package should provide high detergent dispersant properties with high alkalinity and a high level of antiwear additive such as zine dithiophosphate. Total Base Mus6er (TOM) should be 12 to 15 for use with

                                #2 fuel oil and a sulfated ash content of 1.SE to 2.05 is preferred. An engine oil with such properties, Mobilguard 412 or equivalent product may be used to ensure improved lubrication.

PE3041/13

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    'l PERRY MAINTENANCE MATRIX Component  Component                                                                                 Alt.

Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-341C Piston Pin Assembly 1. Visually inspect all pins X Also to be performed for chrome plate damage, whenever pistons are Replace pins which show removed and disassembled chipped or blistered to an extent that such chrome. inspection is possible. NOTE: All new or re- Ref: Lead engine DR/QR placement pins will be Report #02-341C (Items L.P. or M.P. inspected 1&2), For details on 4 before installation in acceptance criteria, Ref: Owners Group engines. 08/22/84 meno from W. Littmann to D. Pasquale NOTE: This inspection

is to be performed whenever the engine is 1 sufficantly dismantled to allow this inspection.

Ref: Lead engine DR/Q9 Report 802-341C I

2. Inspect end plugs and X NOTE: This inspection is i reroll or replace any to be performed whenever

 ,                                                                         that are loose.                                                       the engine is sufficantly

" dismantled to allow this inspection. 02-345A Intake and Exhaust Tappet 1. Inspect intake and exhaust X Complete TDI Inspection Assembly tappet assembly condition, and Maintenance Report i Form No. 345-1-1 TDI Instruction Manual, Volume I, Section 6. Ref: Lead engine DR/QR Report #02-345A i 1 PE3041/14 f a 5 i i

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PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recomm'ndation Monthly Outage Outaae 5 Year 10 Year Comments

2. Verify that can rollers X Complete TDI Inspection are free to rotate, and and Maintenance Record that there is no measurable Form No. 345-1-1 TDI clearance between the can Instruction Manual, Vol, rollers and the roller pins. I, Section 6. Ref: Lead engine DR/QR Report 802-345A 02-3458 Fuel Tappet Assembly 1. _ Inspect fuel assembly X Complete TDI Inspection

!                                              condition.                                                                and Maintenance Report

] Form No. 345-1-1. TDI l Instruction Manual, Volume i I, Section 6. Ref; Lesd engine DR/QR Report F02-3458

2. Verify that cas rollers X Complete TDI Inspection are fr*e to rotate, and and Maintenance Record

                                              'that there is no measurable                                               Form No. 345-1-1 TDI clearance between the can                                                Instruction Manual, Vol.

rollers and the roller pins. I, Section 6. Ref: Lead l

                               .                                                                                         engine DR/QR Report
                                                                                                                         #02-3458 1

1 02-350A Can Shaft Assembly 1. Perform a visual inspection X Any signs of cracking, of all can lobe surf aces pitting or spalling shall for signs of cracking, be followed by a detailed pitting or spelling, analysis to evaluate 4 the expected life based on the size and extent of surface distress and any corrective measures shall be implemented as ' indicated by this analysis. Signs of PE3041/15 i i i I s l i i i

i PERRY MAINTENANCE MATRIM Component Component Alt. Mumber Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments spalling shall result in immediate replacement of the can. Ref: Lead engine DR/QR Report #02-350A 02-3508 Can Shaft Bearings 1. Inspect and measure cam X Complete TDI Inspection and shaft bearing shells. Maintenance Record Form Mo. 350-1-1 TDI Instruc-tion Manual, Volume I, Sec-tion 6. Use Volume I, Section 8. Appendir III for clearance values. 02-350C Can Gear 1. Visually inspect can gear X Ref: Memo from B. for chipped or broken Bickford to E. Montgomery teeth, pitting, excessive dated 6/23/84, wear, or other abnormal Ref: Lead engine conditions. DR/QR Report #02-350C

2. Measure gear back lash. X Complete applicable MOTE - if can gear hub is sections of TDI Inspec-removed, it is ESSENTIAL tion and Maintenance that the nut be relocked Record, Form Mo. 355-1-1, at the position corres- TDI Instruction Manual, ponding to the pre- Volume I, Section 8, scribed torque range of Appendix III-1 for 70210 ft-lbs. clearnance values. Ref:

Insertion of the cotter Lead engine DR/QR pin must be accomplished Report #02-350C at a torque > 50 ft-1bs force and < 30 ft-Ibs force. If this is not possible another bolt, PE3041/16

).

PERRY MAINTENAstCE MATRIX Component Component Alt. Ilumber Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments nut or washer should be used. 02-3554 Crank to Pump Gear 1. Visually inspect crankshaf t X Any abnormal situations to lube of) pump gear or indications of for chipped or broken teeth, progressive pitting excessive wear, or should be reported progressive pitting for an engineering or cther abnormal evaluation. conditions. Ref: Perry DR/OR Report #02-355A Task Description.

2. Measure gear backlash. X Complete appilcable sections of TDI Inspection and Main-tenance Record Form No. 355-1-1 TDI Manual, Volume I, Section 6.

Use Volume 1, Section 8 Appendix III-1 from clearance values. Ref: TDI Instruction Manual, Vol. I, Main-tenance Schedule 02-3558 Idler Gear Assesely 1. Visually inspect idler X Any abnormal indications gears for chipped or should be reported for an broken teeth, excessive engineering evaluation, wear pitting, or other Ref: Lead engine DR/QR abnormal conditions. Report #02-1558 PE3041/17

l n U ( p o PERRY MAINTENANCE MATRIX Component Component Al t. Number Identification FM Recommendation Monthly Outage Outage 5 Year 10 Year Comments

2. Measure gear backlash X Complete appItcable NDTE: If idler gear hub sections of TDI Inspec-is removed, it is tion and Maintenance recommended that the not Record Fore No. 355-1-1, be relocked at the post- TDI Manual, Volume I, tion corresponding to the Section 6. Use Volume I, torque of 80 220 f t-Ibs. Section 8, Appendix III-1 Insertion of the cotter for values.

pin must be accomplished Ref: TDI Instruction at a torque 1 60 ft-1b Manual, Vol. I, Main-and 100 ft-1bs. If this tenance Schedule, is not possible, another Ref: Perry bolts, nut, or washer DR/QR Report #02-3558 should be used. Task Description

3. The eating surfaces between Ref: Perry DR/QR Report the idler gear and hub #02-3558 Task Description.

should be throughly cleaned with solvent prior to assembly to ensure that there is an adequate friction coefficient between the parts. 02-359 Air Start Valves 1. Remove, clean and inspect X Ensure valve installation air start valves. Includes retorque (Replace copper valve- requirements. to-head gasket) Ref: DR/QR Report

                                                                                                         #02-359 (! tees 1, 2, 3)

PE3041/18

PERRY MAINTENANCE MATRIN Component Component Alt. Number Identification PM Recommendation Monthly Outage Outaae 5 Year 10 Year Comments

2. Inspect the piston, cap, X guide and housing s11 ding surfaces to evaluate wear or corrosion.

3. Ensure that the dryer To be performed daily.

between the air compressor Ref: DR/QR Report after cooler and the air #02-359 receivers is working properly by blowing down the air receivers daily and monitoring the moisture content. 02-3604 Cylinder Head 1. Visually inspect cylinder X Complete TDI Inspection heads (all cylinders). and Maintenance Record Form No. 360-1-I, TDI Instruction Manual, Volume I, Section 6. One sheet for each head.

2. Record cold compression X If so indicated remove pressures and maximam cylinder heads, grind firing pressures. valves and reseat, i Ref: TDI Instruction Manual, Volume I, Sec-tion 6

3. Slow-over the engine per In the event water is TDI maintenance require- detected, the cylinder ments, Volume I or at head should be replaced >

appropriate intervals or returned to the af ter shutdown of vendor for repair, the engine to ensure Ref: Lead engine DR/QR PE3041/19 4 i j i l

D \ PERRY MAINTENANCE MATRIX

Component Component Alt, humber Identification PM Recommendation Monthly Outace Outage 5 Year. 10 Year Comments-against harmful effects Report #02-360A of water leaks.

4. Visually inspect the X If water leakage is fuel injection port on detected, the head (s) each cylinder head should be replaced.

                                           'during" the normal                                                    Ref: Lead engine monthly engine run                                                     DR/QR Report #02-360A for water leaks.

02-3600 Cylinder Head - Intake and 1. Visually inspect intake X Complete the applicable Exhaust Valves and exhaust valve, discs, sections of TDI Inspection stems and seats for wire and Maintenance Record drawing, pitting, distortion. Form 360-2-1. concentricity, or any abnormal condition.

2. Visually inspect subcovers This is a one time only for evidence of valve inspection to be performed guide blo.6y (Scot) after 500-600 hrs. of engine operation on new or reworked cylinder heads.

Ref: Lead engine DR/QR Report 902-3608

3. Measure intake and exhaust X Complete appilcable valves head thickness, sections of TDI Inspection and Main-tenance Records Form 360-2-1, TDI Instruction Manual, Volume I, Section

6. One sheet for each cylinder. Use Section 8. Appendix III for clearance PE3041/20

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PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outace 5 Year- 10 Year Commnts valves. (Items 3.4)

4. Measure intake and exhaust X Complete appilcable valves valve-to guide sections of TDI clearances. Inspection and Main-tenance Record Form 360-2-1. TDI Instruction Manual, Volume I, Section

5. One sheet for each cylinder. Use Section 8 Appendix III for clearance values.

02-362A Cylinder Head Covers - 1. Perform a 11guld pene- X This inspection is to Subcover Assembly trant examination of be performed in conjunc-the rocker are pedestals tion with the rocker top and vertical machined are bushing inspections surfaces (connector when the rocker are pushrod side only) for shafts are removed from signs of cracking at the the subcovers (Ref: counter bores. Lead engine DR/QR Report 902-390E) or when the rocker are shaft assembly is removed. Subeovers tith pedestal cracks that extend through the counter bore web down to the threads should be replaced. Ref. Lead engine DR/QR Peport 802-3E2A l PE3041/21

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PERRY MAINTEMAMCE MATRIX Component Component Alt. Mumber Identification ,PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-365A Fuel Injection Pumps 1. Visua11y check pressure M To be performed on all

                                                                    . bleed screws for erosion.                                             sixteen pumps.

2. Tear down one pump for X Use repm sentative pump inspection. to determine need to overhaul other pumps.

Ref: TDI Instruction Manual, Volume I, Maintenance Schedule

3. Complete fuel injection X Based on inspection re-pump inspection in suits and operating

accordance with TDI parameters. Complete Instruction and Main- TDI Instruction and

! tenance Manual, Volume I. Maintneance Record Form No. 365-1-1, Section 6 (Items 1, 2). ! Ref: TDI Instruction Manual, Volume I, l Maintenance Schedule for item 3. Ref: Lead engine DR/QR Report

                                                                                                                                            #02-365A (Items 2&3) 02-365B    Fuel Injection Mozzles                              1. Remove, inspect and clean                 X                           Ensure that a new copper tips.                                                                 gasket is used upon reinstallation of nozzle into head.

Complete TDI Inspection and Maintenance Record Form 365-2-1 Instruction Manual, Volume I, Section 6. PE3041/22

PERRY MAINTENANCE MATRIX Component Component Alt. Nimber Identification PM Recommendation Monthly Outage Outage S vear 10 Year Comments Ref: TOI Instruction Manual, Vol. I Section 5 Maintenance Schedule. Ref: Lead engine DR/QR Report 802-3658 (Items 1-4)

2. Check nozzle pop pressure. X

3. Check spray pattern. X

4. Check assembly for X To be performed with the leakage, engine running during the monthly test run.

02-365C Fuel Injection Tubing 1. Check tubing for leaks X All fuel oli leak in-i at compression fittings. spections to be perforn-ed while the engine is running or whenever the compression fittings have been disturbed. Ref: Lead engine DR/QR Report 802-365C

2. Visually inspect tubing X Fitting inspection for i lengths for F.0. leaks leaks to be performed or cracks. at first engine opera-tion following the installation of tubing.

Subsequent inspections to be performed period-ically as indicated. Fuel oil leakage from shrouded fuel oil lines PE3041/23 i

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W J PERRY MAINTENANCE MATRIX Component Component Alt. Number- Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comments can be detected at the leakoff ports in the base nuts, which are provided for this purpose.. Ref: Letter from C.A. Malourh to V.A. Saleta dated 08/30/84. 02-3650 Fuel 011 Injection 1. Visually inspect support X Any itserts found to be Lines: Sepports elastomer inserts for unsatisfactory shall be deterioration or replaced with new inserts degredation. prior to reassembly of F.O. lines. This inspection can be per-formed prior to reassembly of the F.O. lines in conjunction with the cylinder liner inspection.

                                                                                                                   '!ef: Lead engine DR/QR Report #02-315C Cylinder Liners, Ref: San Onofre DR/QR Report #02-365D Task Description.

02-371A Fuel Pump Control Shaft 1. Check lube oil cups X Ref: Lead engine DR/QR and fill as necessary. Report #C2-371A 02-371B Fuel Pump Linkage Assembly 1. Grease swivel link on X and Bearings F.O. pump assemblies, all cylinders. 1 PE3041/24 4 l 1

fm n PERRY MAINTENANCE ETRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-375 Intake Manifold 1. Care should be exercised If required, other castings in assembly of cylinder may be tried to achieve heads onto the engine, an acceptable fit, or bolt to avoid cracking hole diameters may be of the intake manifold increased to 1/8" oversize, elbows. Component should under no circumstances be jacked to fit. Ref: Lead engine DR/QR Report

                                                                                                                       #02-375 02-380A     Exhaust Manifold           1.  . Visually and MT examine                         X                    To be performed during a sampilng of circum-                                                the first refueling forential pipe welds and                                             outage and alternate corresponding heat                                                   outages thereafter, affected zones. This                                                 However, diesel examination is to                                                    operation should not be performed in                                                      exceed 200 hours be-accordance with Impe11                                               tween inspections.

memo from G. Shears Ref: Lead engine DR/QR to J. Kammeyer dated Report #02-3e0A 08/13/84. 02-385A Crankcase Relief Valve 1. Clean flame arrestors. X Ref: 3/26/84 IOC from M. Wehmeyer to J. Kammeyer

2. Inspect seat and disc. X PE3041/25 i

I. i i l l l

I

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v d PERRY MAINTENANCE MYRIN Component Component' Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-390E Rocker Arm Bushings 3 Visually inspect and T1.e visual and dimensional measure intake rocker are inspection of the rocker bushings. are bushings should be conducted at the fuel outage which precedes 2300 hours of operation by at least the sum of expected hours of operation in a LOOP /LOCA event plus the expected hours of operation between outages.- This inspection schedule may be revised after the first or subsequent inspections if the inspection results justify a longer period of engine operation between inspections. Ref: Lead engine DR/QR Report

                                                                                                             #02-390E (Items 1, 2, 3)

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

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

PE3041/26 i f l

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PERRY MAINTENANCE MATRIX Component Component- Alt. Number Identification PM Recommendatfor. Monthly Outage Outage 5 Year 10 Year Comments 02-390F Hydraulic Valve Lifters 1. Check valve lash. X

2. Reinstall and adjust X Ensure lifters are lifters perform leak installed with the fill down test. holes up. Verify condition of Ilfters via comparison of lifter leak down rate (actual) to specifications noted on TDI Maintenance Manual Ref: TDI Maintenance Manual Section 6-8-5, Ref: 04/16/84 letter to R. Johnson from R. Jaquinto 02-390G Rocker Are Capscrews, 1. Verify capscrew torque X This inspection should be Drive Studs (Pop Rivets) values. performed at each outage if the rocker arms are disassembled for inspec-tion. Use TDI Instruction Manual, Volume I, Section 8, Appendix IV for proper torque values.

2. Verify that rocker ara X Ref: Lead engine DR/QR drive studs are intact Report #02-390G and tight. (Itees 1, 2)

PE3041/27 l r 1

O O O 4 PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification- PM Recommendation Monthly Outane Outane 5 Year 10 Year Comments 02-410A Overspeed Trip Governor 1. Check trip set point X Modify the survelliance

                                                                                                                        - adjust as required.                                                testing procedure to include verification that the overspeed trip I

is correctly set to an overspeed trip setting of 518 rpe 21 % every outage.

;                                                                                                                                                                                            Ensure that the electric governor and the mechanical backup governor setting are properly returned to their 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) l                                                                                                                                                                                             until a trip occurs.

After several inspection periods, the history of . the required adjustments should be re>1ewed to evaluate and possibly modify the testing interval. Ref: Lead engine DR/QR Report 802-410A PE3041/28 I s u

 ,                                                                                                                                             .\

[_ _ ( D) v PERRY MAINTENANCE MATRIX' Component Component Alt. Number Identification PM Recommendation Monthly Outage Outaae 5 Year 10 Year Comments Note: After setting the over-speed governor, the ad-justment screw settings should be marked with 1 Torque Seal to reveal

 !                                                  any unintended changes 1                                                    in the set positions.

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

2. Check shafts for eacessive X 2. Same as above radial and axial movement.

3. Visually inspect accessory X 3. Same as above drive gear for excessive wear.

I 02-410C Overspeed Trip Drive Couplings 1. Replace the Lovejoy coupling X Replace elastomer if spiders or test coupling hardness is greater d elastomer for hardness. than 90 Shore A. Ref: Lead engine DR/QR Report #02-410C (Items 1,2,3)

2. Verify that coupling is X Ref: 6/24/84 como tight on shaft. from D. Liebert to '

E. Montgomery i i PE3041/29

n. v P PERRY MAINTENANCE MATRIX Component Component . Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 1

3. Remove t h present L-110 To be completed at Lovejoy cw glings and the first refueling

, replace them with new outage. i units in accordance with SIM 363 and DR/QR-3 Report recossendations. l 02-4100 Overspeed Trip Vent Valve 1. Disassemble and replace X Ref: Lead engine j "0" rings. DR/QR Report #02-4100 ! 02-411A Governor Drive - Governor 1. Visually inspect drive X Ref: TDI Instruction and Tachometer Drive (and (and driven) gears and shaft Manual, Vol. I, Section 5 driven) Gears and Shaft for signs of wear. Maintenance Schedule l 02-4118 Governor Drive - Coupilngs, 1. Check that coupilng is X If the coup 1tng is found Pins and Keys tight on shaft. to be loose, it should

!                                                                                                                                                              be removed, all nating surfaces cleaned, and

the unit reassembled using Loctite 609 or equivalent on the mating surfaces.

Ref: Lead engine DR/QR Report #02-411B (Items 1, 2, 3)

2. Replace present neo- To performed prior to 4'

prone insert in the Koppers placing the engine in coupilng. the emergency standby j mode. l 3. Replace elastomeric insert X i each refueling outage. PE3041/30 4 a

T PERRY MAINTENANCE MATRIX Component Component . Alt. Number Ider,tification PM Recommendation- Monthly Outage Outage 5 Year 10 Year Comments 02-413A Governor Linkage 1. Install positive locking hardware to the lever are clamp bolt heads and shaft roll pins. NOTE: . To be performed as necessary after tightening gov-ernor linkage hardware to design torque specifi-cations. , 2. Inspect for loose parts X on the linkage assembly.

3. Lubricate cross shaft X Ref: Lead engine DR/QR l bearings cups. Report #02-413A (Items

+ 3&4) 1

4. Grease the rod end X fittings, especially those at the ends of the cross shaft.

i 02-4138 Fuel Pump Linkage: 1. Check cy11nder for X To be accomplished during l Autoestic Shutdown Cylinder extension and return. control system check.

2. Check tallrod went X To be accomplished during I for air leakage, control system check.

! Items 1, 2; Ref: IOC i dated 3/26/84 from M. Wehmeyer to R. Kaklec. i . , PE3041/31 i i I 4 E

- . . . . _ - ~- . - . . m - 3 s PERRY MAINTENANCE MATRIX Component Component. Alt. Mumber Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-415A Woodward Governor 1. Drain, flush, refill and X NOTE: Venting the vent actuator oli system hydraulic actuator shall with new oil from a be performed per the clean container ensuring Woodward manual if more the appropriate cleanliness than a half quart of procedures are followed. oli is added. Ref: Lead engine DR/QR Report 02-415A

2. Disassemble, clean and X liens 1, 2. 3; Ref:

refurbish the actuator. 03/27/84 IOC from M. Wehmeyer to N. Cooperrider Ref: TDI Instruction Manual, Volume I, Section 5 Maintenance Schedule

3. Replace flex element X Ref: Lead engine DR/QR for governor drive Report 802-411B Governor coupling. Drive Couplings

4. Verify all governor X All knob eettings should control knob settings be secured with a are in appropriate commercially available positions: product such as LOAD - Maximum Torque-Seal.

DROOP - Zero Speed - To provide mechan-ical governor con-trol at 46C .p . PE3041/32

b'j ' b O, U J G PERRY MAINTENANCE MATRIX Component Component . Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments

5. Modify the sure111ance X NOTE: These tests shall testing procedures to include examinations of include an evaluation the engine speed transi--

of the governor settings ents during start and be means of the two transient loading condi-test below: tic's. Included as , part of the above tests (a) Perfrom a test of is the verification that the governor settings the engine set speed of while under mechanical 450 rpm is not exceeded

                                                                                            / electrical governor                                               by more than 7.5 percent control, with the                                                   (484 rpm max.) either diesel generator off                                                during an engine start or the grid in the                                                     during the largest single 4                                                                                            isochronous mode.                                                   load reduction.

Ref: Lead engine DR/QR ! (b) Perform a test of Report #02-415A l the governor settings t while under mechanical (only) governor

control, with the diesel generator off the grid in the a isochronous mode.: 6. Augment the setting Ref: Lead engine adjustment procedures DR/QR Report #02-415A as described in the Woodward manuals, to ,

include a test of the governor response, j- during an engine start to ensure agreement with l the specification as detailed in Item #5 above. PE3041/33 I

O > PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-4158 Governor Booster Servosotor 1. Clean, inspect, and X Ref: 3/27/84 IOC from replace "0" rings M. Wehmeyer to and gaskets. J. Kammeyer 02-415C Governor Heat Exchanger 1. Clean and inspect. X 02-425A Jacket Water Pump - Gear 1. Visually inspect jacket X Any abnormal situations water pump gear for or indications of pro-chipped or broken gressive pitting should teeth, excessive wear, be reported for aa or potential / progressive engineering evaluation. pitting or other Ref: Lead engine DR/QR abnormal conditions. Report #02-3558

2. Check the key to keyway 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 shaft during pump both the shaft and spline, reassembly. and the spline and pump shaft caused fretting and upset of the keyway sides.

Ref: DR/QR Report #02-425A

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

                                                                                                         ' drives the external spline on its taper, have minimum and maximum torque values of 120 ft-lbs and 660 ft-1bs respectively.

PE3041/34

O O O PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outaae Outage .5 Year 10 Year Comments 02-435A Jacket Water Fittings- 1. Visually inspect for leaks. X This recommendation is Pipe and Fittings Note: In the event of a made on the basis that (Small Bore Scope Only) leak developing in the the maximum suggested existing Dresser Style 65 operting temperature of couplings, these couplings 150*F for the Style 65 should be replaced with coupling may be exceeded. Dresser Style 90 coup 11pgs The m ximum suggested equipped with Viton gaskets. operating temperature of the Style 90 is 212*F. Ref: tetter dated 12/13/84 from C L Ray to J George. 02-437 Turbo Water Piping- 1. Visua11y inspect for leaks. X This recommendation is Pipe 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 of coupilngs, these couplings 150*F for the Style 65 should be replaced with coupling may be exceeded. Dresser Style 90 couplings The maximum suggested equipped with Viton gaskets. operating temperature of the Style 90 is 212*F. Ref: Letter dated 12/13/84 from C L Ray to J George. 02-441A Starting Air Manifold: 1. Ensure that the starting X Ref: 08/27/84 Memo from Air Vent air manifold vent is W. Littmann to J. Cadogan, open and effective. Ref: Lead engine DR/QR Report #02-442A (STAD) 02-441B Air Filter to Starting Air 1. Inspect filter elements. X Ref: TDI Instruction Distributor Manual, Vol. I, Main-tenance Schedule PE3041/35

I: 1 J O v PERRY MAINTENANCE MATRIX Component Component . Al L. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments

2. Replace filter elements.

It is recommended that the filter be changed whenever the manufacturers recom-mended maximum dif-forential pressure is achieved. Ref: Lead engine DR/QR Report 902-4418 (Items 1&2) Strainer - Starting Air System 3. Blow down strainer DAILY. Ref: Lead engine DR/QR Report #02-4418 (Items 3&4)

4. Clean and inspect strainer X If the strainer is monthly. excessively dirty, the frequency of cleaning and inspecting should be increased.

Air Start Block Valves 5. Clean, refurbish valves X Ref: Lead engine DR/QR

                                                  -replace "0" rings and                                                 Report #02-4418 (Items 5, clean the screened                                                     6, 7) fitting. Ensure leak tightness after reassembly.

6. Inspect for tightness X of fittings and bolts and apply locking com-pound, as required during reassembly of components.

PE3041/36 4 i P l l O ._.

PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification. PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments f 7. Replace "0" rings of. X j the shuttle valve. l Starting Air Valves 8. Disassemble, clean, X Ref: Lead engine DR/QR inspect and lubricate Report #02-4418. valves to prevent fouling. Test to assure leak tight-ness upon reasonably. l 02-455A Fuel 011 Filter 1. Record filter d/p. X Change filter elements i at or before the filter !- d/p reaches the manu-

facturers recosamnded maximum differential pressure. Purge entrapped air from the i filter canister using i the vent valve provided,

! and divert some fuel oli into the newly replaced cartridge. After air has been purged close vent valve and return handle to previous operating position. Ref: Lead engine DR/QR Report 802-455A

2. Inspect canister gaskets X To be performed during and replace as necessary. change out of filter elements.

Ref: 3/27/84 IOC from M. Wehmeyer to J. DiMare, PE3041/37

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PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments

3. Inspect tubing and mech- X Ref: TDI Instruction anical connections for Manual, Volume I tightness and/or leaks.

02-4558 Fuel 011 Strainers 1. Record strainer d/p. X Shift / clean element if i manufacturers recom-i mended maximum dif-ferential pressure is achieved. Bolt torques of 120-150 in-1bs should be utt11 red during reassembly. , Ref: Lead engir.e DR/QR 4 Report #02-4558 1 (Items 1 & 2)

2. Purge air from stand-by As required.

strainers 02-465A Lube Oil Lines External: 1. Ensure that a minimum To be performed whenever Tubing, Fitting and Couplings installatloa gap of 0.171 piping is installed or inches is maintained between reinstalled. Ref: DR/QR pipe ends at the 12-inch Report #02-465A j Dresser coupling.

2. Replace the 12-inch Ref: Shearon Harris Dresser coupilng gasket DR/QR Report #02-465A with a VITON gasket Task Description.

should leaks develop. PE3041/38 l l i I

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S O J b-- ' PERRY MAINTENANCE MATRIX

     ' Component    Component                                                                      Alt.

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

3. Should a leak develop Ref: Perry DR/QR Report in a Style 90 small 802-465A (seaII bore).

bore coupling, replace it with a style 90 coupling equipped with a viton gasket. 02-4758 Air Butterfly Valve 1. Lube valve shaft X Ref: IOC dated 3/28/84 via grease fittings. from M. Wehas r to J. DiMare. If oil cups are used, this should be completed monthly. Check by visua11y observ-i 2. Check valve 'isc for X freedom of n.ovement. ing valve / actuator oper-l atton. Ref: 04/16/84 1 4 from R. Jaquinto to R. Johnson

3. Verify that associated X Ref: DR/QR Report locking devices (jam #02-4758 nuts and lock washers) are tight.

02-500A Engine Control Cabinet 1. Inspect interior of cabinet X Ref: 3/29/84 IOC for cleanliness and clean from M. Wenmeyer as required. to T. Jacobs for Items 1-5, Ref: 07/30/84 IOC from J. Cadogan to l i K. Horelik for Items 1-6 1 l PE3041/39

m p

                                 )                                                                                                                                                 /

PERRY MAINTENANCF MATRIX Component Component Al t. Number Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments

2. Visually check wiring for X insulation degradation.

3. Visually check instrument X tubing for leaks.

4 Functionally check cabinet X heater and calibration of ] thermostat. S. Test pneumatic S/D board X logic.

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

02-467A Turbocharger Lube 011 Fitting: 1. Visually inspect for leaks. X This recommendation is Pipe Tubing, Fittings, and Note: In the event of a made on the basis that Flexible Coupling leak developing in the the maximum suggested (Small Bore Scope Only) existing Dresser Style 65 operting temperature of coupilngs, these coupilngs 150*F for the Style 65 should oe replaced with coupling may be exceeded. Dresser Style 90 couplings The maximum suggested equipped with Viton gaskets, operating temperature of the style 90 is 212*F. Ref: Letter dated 12/13/84 from C L Ray to J George. 02-500C Circuit Breakers and Contact 1. Check all terminals X To be accomp11shed during Blocks clean / tighten. panti clean / inspection.

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

PE3041/40 i

- 1 D O f ( PERRY-MAINTENANCE MATRIX-

Component Component .

Alt. i Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments

3. Trip check circuit breakers. X

   '02-500G    Control Panel Valves            1. Inspect and clean control                  X                           This recommendation in-panel valves.                                                          terval should be reas-sessed depending on the degree of system fouling.

Ref: Lead engine DR/QR-Report #02-500G l 2. Inspect and clean the X Ref: Lead engine DR/QR a 200 mesh screen in the Report #02-500G check valve. 02-5001 Control Panel Assembly: 1. Inspect contacts and clean X Ref: 08/10/84 IOC from Relays as required. K. Horelik to J. Cadogan j 2. Visually check condition X of wiring and tightness

;                                                   of terminations.

1 02-500M Control Panel Switches Terminal 1. Clean terminal boards and X Ref: IOC dated 3/29/84 i 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.

l 02-5258 Barring Device Control Valve 1. Drain filter daily while Ref: Lead engine DR/QR 1 barring device is in Report #02-5258 ) operation. (Items 1 & 2) PE3041/41 5 r l t i I i

m -

n O (h) tv r PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-467A Turbocharger tube 011 Fitting: 1. Visually inspect for leaks. X This recommendation is Pipe. Tubing, Fittings, and Note: In the event of a made on the basis that Flexible Coupling leak developing in the the maximum suggested (Small Bore Scope Only) existing Dresser Style 65 operting temperature of coupilngs, these coupilngs 150*F for the Style 65 should be replaced with coupling may be exceeded. Dresser Style 90 coupilngs ~.ae maximum suggested equipped with Viton gaskets. operating temperature of the Style 90 is 212*F. Ref: Letter dated 12/13/84 from C L Ray to J George.

3. Generator fouidation bolts Ref: Lead engine DR/QR are to be retorqued Report #02-550 after a generator short circuit if the bolts were initially torqued to 480 ft-lbs. 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 replacement of the thermocouple.

2. Clean and inspect 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 PE3041/42 I

L 3

PERRY MAINTENANCE MATRIX Component Component Alt. Mumber Identification PM Recommendation Monthly Outage -Outage 5 Year 10 Year Comments 02-467A Turbocharger Lube 011 Fitting: 1. Visually inspect for leaks. X This recommendation is Pipe. Tubing. Fittings, and Mote: In the event of a made on the basis that Flexible Coupling . leak develtping in the the maximum suggested (Small Bore Scope Only) existing Dresser Style 65 operting temperature of coupilngs, these couplings 150*F for the Style 65 should be replaced with - coupling may be exceeded. Dresser Style 90 coupilngs The maximum suggested equipped with Viton gaskets, operating temperature of the Style 90 is 212'F. Ref: Letter dated 12/13/84 from C L Ray to J George. 02-650A Emergency Generator 1. Check operation of X Ref. IOC dated 03/30/84 brushes and slip rings. M. Wehmeyer to D. Mercald (Items 1-5).

2. Clean / inspect all X accessible parts of the generator.

3. Megger rotor and stator. X

4. Verify operation of X space heaters.

5. Measure vibration and X check against base line data.

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. Mercaldt

2. Check terminal boards X for loose wiring.

PE3041/43 l {

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\'

e O% i PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outace 5 Year 10 Year Comumeng 02-467A Turbocharger Lube Oil Fitting: 1. Visually inspect for leaks. X This recommendation is Pipe, Tubing, Fittings, and Note: In the event of a made on the basis that Flexible Coupling leak developing in the the maximum suggested (Small Bore Scope Or,1y) existing Dresser Style 65 operting temperature of couplings, these coupilngs 150*F for the Style 65 should be replaced with coupilog may be exceeded. Dresser Style 90 coupilngs The maximum suggested equipped with Viton gaskets. operating temperature of the Style 90 is 212*F. Ref: Letter dated 12/13/84 from C L Ray to J George. 4 02-650A Emergency Generator 1. Check operation of X Ref. IOC dated 03/30/84 brushes and slip rings. M. Wehmeyer to D. Mercaid (Items 1-5). ' 2. Clean / inspect all X accessible parts of the generator.

3. Megger rotor and stator. X i

4. Verify operation of X i space heaters.

5. Measure vibration and X check against base line data.

!. 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. Mercaldt

2. Check terminal boerds X l

for loose wiring.

PE3041/43 1

1 _ 2 a i

PERRY MAINTENANCE MATRIlt Component Component , Alt. Number Identification PM Roccamendation Monthly Outage Outage 5 Year 10 Year Comments 02-467A Turbocharger Lube Oil Fitting: 1. Visually inspect for leaks. X This recommendation is Pipe. Tubing, Fittings, and Note: In the event of a made on the basis that Flexible Coupling leak developing in the the maximum suggested (Small Bore Scope Only) existing Dresser Style 65 operting temperature of couplings, these couplings 150*F for the Style 65 should be replaced with coupling may be exceeded. Dresser Style 90 couplings The maxima suggested equipped with Viton gaskets. operating temperature of the Style 90 is 212*F. Ref: Letter dated 12/13/84 from C L Ray to J George. . 02-650C Emergency Generator Pedestal 1. Check ring oilers X To be accomplished during Bearing for proper operation every test run of the

!                                                                                    and verify all level.                                                   engine.

Ref: 3/30/84 IOC { from M. Wehmeyer i to N. Cooperrider (Items 1-4)

2. Drain flush refill X bearing housing.

l

3. Measure bearing housing X 3

insulation resistance.

4. Disassemble and inspect X i bearing and check i clearances.

f PE3041/44 i I I i i 9

l PERRY HAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comunents 02-6958 Engine Control Air 1. Inspect and clean engine X NOTE: This recommenda-Pressure Regulator shutdown equipment. tion should be assessed a depending on the degree of system fouling Re f: Lead engine DR/QR Report 802-6958 (Items 1 & 2)

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

02-695C Engine Control Pneumatic Trip 1. Check switch set points. X Pressure switches. Switches 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 ns.717B Auxiliary Sub-base & Oli & Water 1. Inspect the valves for X Replace as necessary.

Piping - Jacket Water: Valves packing leakage. Ref: Lead engine DR/QR Report 802-717B , 2. Inspect, clean and lube valves. 4 PE3041/45 I

O O PERRY MAINTENANCE MATRIX 1 Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 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-Strainers existing Dresser Style 65- operting temperature of (Small Bore Scope Only) couplings, these couplings 150*F for the Style 65 should be replaced with coupilng may be exceeded. Dresser Style 90 couplings The maximum suggested equipped with Viton gaskets. operating temperature of the Style 90 is 212*F. Ref: Letter dated 12/13/84 from C L Ray to J George. 02-717F Auxiliary Sub-Base Lube Oil 1. Visually inspect for leaks. X This recommendation is Pipe and Fittings Note; In the event of a made on the basis that leak developing in the the maximum suggested existing Dresser Style 65 operting temperature of couplings, these couplings 150*F for the Style 65 should be replaced with coupilng may be exceeded. Dresser Style 90 couplings The maximum suggested equipped with Viton gaskets, operating temperature of the Style 90 is 212*F. Ref: Letter dated 12/13/84 from C L Ray to J George.

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 PE3041/46

PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-717G Auxiliary Sub-Base Lube 011 1. Dissassemble, clean and X Ref: 07/31/84 IOC check relief valve to M. McGerigle from lift pressure. J. Cadogan, Ref: 08/16/84 IOC from M. McGerigle to J. Cadogan, Ref: Lead engine DR/QR Report #02-717G 02-717K Auxiliary Sub-Base and 011 1. Dissassemble, lubricate, X Ref: IOC dated 4/6/84 and Water Piping: Fuel inspect and refurbish, from M. Wehmeyer to 011 Valves J. OlMare. Ref: Lead engine DR/QR Report #02-717K 02-8058 Intake Air Filter.s 1. Inspect intake air X Ref: Perry DR/QR Report distribution plate #02-8058 and change f11ter oil. 02-8050 Flex Connection 1. Visually inspect for X evidence of cuts, holes, or dents. 02-8108 Jacket Water Heat 1. To avoid corrosion and Ref: Lead engine DR/QR Exchanger fouling the jacket water Report #02-810C, heat exchanger and Ref: 04/20/84 IOC associated service from M. Weheeyer to water piping should be R. Kadlec flushed on a periodic basis (continuous service flow is sufficient). Alternatively, service water cheelstry control can be used to maintain heat exchanger performance and integrity. PE3041/47

                                                                    ..        s, -
                                                                                                                                              .T
                                                                 ]                 1, V

i '

            \                                                  'd./      u PERRY MAINTENANCE MATRIX w                                                                -

, . Component Component Alt. Number Identification PH Reconnendation Monthly Outage Outane 5 Year 10 Year Comments

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 emer- R. Chit gency standby mode. Verify that no leakage is pre-sent through the leak-off ports of the lantern ring.

3. Record heat exchanger X Use for trend data performance by checking

. engine operating parameters.

4. Evaluate heat excharger e X performance data.

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

!                                          Replace packing rings                                                      Ref: Lead engir.e DR/QR at floating tube                                                           Report #02-810C sheet after tube inspection.

j . 6. Inspect and clean X Replace / rework lantern ring. Verify tantern ring as leak-off holes are necessary to not plugged. ensure concentricity prior to reinstall-ation. i PE3041/48 1 i

q O O O PERRY MAINTENANCE MATRIX Component Component . Alt. Numbe= _ .. Identification PM Recommendation Monthly Outage Outage 5 Year 10 Yeg Comments

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 02-810C Thermostatic Valves 1. Replace thermal power X Ref: Lead engine DR/QR elements. Report #02-8100 (Items 1, 2)

2. Visually inspect valve X To be accomplished body for evidence of during monthly test leakage. run. Ensure that any replacement valves have cast steel valee bodies.

02-8100 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.

02-820A Lube Oil Sump Tank 1. Measure heater X Replace heater if de-Heaters insulation resistance. gradation of insulation resistance is noted. PE3041/49 1 I l t

')

PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year J'sYear Comments

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 02-8208 Oil Prelube 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 mechanical seal X leakage.

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

4. Measure unit vibra- X tion (pump / motor) 02-820C Full Pressure Lube Oil Strainer 1. Record strainer d/p. X Use for trend data

2. Inspect and clean elements. Inspect / clean when strainer differential pressure rises signi-ficantly.

Ref: Lead engine OR/QR Report #02-820H, Ref: TDI Instruction Manual, Volume I, Main-tenance Schedule PE3041/50 1 l. l I 5 1

O O

                                                                                  ' PERRY MAINTENANCE MATRIX O

Component Component . Alt, Number Identification PM Recommendation Monthly Outage Outage S Year 10 Year Comments

3. Lube oil strainer X pressure gauge - call-bration check.

02-8200 Prelube 011 Pump Strainer 1. Check strainer differntial Clean and/or replace the pressure DAILY. element when the manu-facturer's recommended maximum differential pressure is achieved. Ref: Shearon Harris DR/QR Report #02-a650 Task Description. 02-820E 011 Prelube Filter 1. Record fli er d/p. X Ref: 04/05/84 IOC from 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 802-820E 02-820F Full Flow Lube 011 1. Record filter d/p. X Use for trend data, Filters Ref: 04/02/84 IOC from M. Wehmeyer to J. DiMare, Ref: TDI Instruction Manual, Volume I, Maintenance Schedule PE3041/51

                                                      ~
                                                                                                                                                                                           )

O O O PERRY MAINTENANCE MATRIX Component Component Alt. Number IJentification 'PM Recommendation' Monthly Outane ~ Outage 5 Year 10 Year Comments

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

1 Replace filter To be performed before

'l                                                                                      cartridges and                                                          tne filter d/p reaches the perform a visual                                                        manufacturers recommended 1                                                                                       inspection to                                                           maximum differential 1

determine the pressure. Ref: 05/30/84 a nature of the IOC from M. McGerigle a material caught to B. Brown, J in the filter. Ref: Lead engine DR/QR j Report #02-820F, Ref: 07/31/84 IOC from J. Cadogan to M. McGerigle i 4. Lube oil filter X

                                                                                .       gauge - calibra-tion check.

1 02-820G Lube 011 Heat 1. Perform a daily visual Ref: Shoreham DR/QR Exchanger inspection for leakage Report #10-109, at packing. Verify Ref: 06/12/84 IOC i that no leakage is from R. Chit to present through the P. Martia, leak-off ports of Ref: 04/02/84 IOC l the lantern ring, from M. Wehmeyer to R. Kadlec l PE3041/52 i r l l

A w/ PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outaae Outage 5 Year 10 Year Comments f

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

3. Evaluate heat exchanger X performance data.

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

5. Inspect and clean X Replace / rework

, tantern' ring. lantern ring as Verify leak-off necessary to holes are not ensure concentricity. plugged.

6. Replace packing X And/or packing becomes rings at the floating hard or leakege 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 cheetcal analysis approximate quarterly of the lube oil. intervals.

Particular attention Ref: Lead engine shall be given to DR/QR Report #02-82DG percent moisture content. PE3041/53

O O O PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments 02-835A Air Dryers and 1. Blow down trap X Ref: 04/05/84 IOC Moisture Traps sediment bowls. from M. Wehmeyer to J. Kammeyer, Ref: TDI Instruction Manual, Volume I, Maintenance Schedule

2. Inspect and service X moisture traps.

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

Ref: 04/16/84 letter from R. Jaquinto to R. Johnson 02-8358 Starting Air Tank 1. Drain air rece'ver 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 S 2)

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

PE3041/54 i 1 i

N

                                             )                                                                         .
                                                                                                                                                                                        )

PERRY MAINTENANCE MTRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments

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

02-83!D Starting Air Ccapressors 1. Check lubricating oil X All items; Ref: level. 04/02/84 IOC with attached Maintenance Chart from M. Wehmeyer to J. Kammeyer.

2. Overall visual X inspection.

3. Clean fins on inter X and after coolers.

4. Replace intake filter X element.

5. Change compressor oil. X

6. Check belt tension. X

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

8. Inspect filter felts on X Replace as necessary.

unloader system. PE3041/55

_\

                                                                                                . m                                                               -
                            ~
                                                                                                 \

PERRY MAINTENANCE MATRIX

                         -Component Component                                                                       .      Alt.

Mumber' Identification PM Recommendation Monthly Outage Outaae S Year 10 Year Comments Jacket Water System - 1. . Check pH. factor X Ref: TOI Instruction of jacket water and Manual, Volume I, Main-correct as recom- tenance Schedule mended by chemical supplier.

2. Replace elastomeric parts X in jacket water valves.

Lube Oil System 1. Check lubricating X Ref: TDI Instruction all with a viscost- Manual, Volume I, Main-meter for fuel oli tenance Schedule, Items dilution. Ser.d a 1, 2 sample of oli to laboratory for analysis.

2. Drain lubricating X When replacing engine oli system and oil use H.D. oli that clean sump tank. meets or exceeds series 3 Depending on the standards. The base stock results of lube should be more resistant oil analyris, refill to thermal degradation with new oil. and coke formation. The additive package should provide high detergent dispersant properties with high alkalinity and a high level of antiwear additive such as zinc 1

dithiophosphate. Total Base Number (TBN) should be 12 to 15 for use with ' #2 fuel oli and a sulfated ash content of 1.5% to 2.0% l PE3041/56 l l

                                                                                                                                \
   . f' fM r
                                                                                                                   \

PERRY MAINTENANCE MATRIX Component Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5 Year 10 Year Comments is preferred. An engine oil with such properties, Mobliguard 412 or equivalent product may be used to insure improved lubricatio1. e

,                            3. Visually inspect lube                    X                          To be performed oli sump tank level                                                 after lube oil switch floats,                                                      has been drained Check switch set                                                    from sump.

points.

4. Perform a spectro- To be performed at chemical analysis approximately quarterly of the lube oil. Intervals. Ref: TDI Instruction Manual, Volume I, Maintenance Schedule.

System Operation 1. Record all operating X To be performed parameters. Compare during monthly with base line data engine test run. to ensure engine is operating properly. Piping System 1. Conduct a detailed X Tighten, repair or visual and audible replace as required. Inspection of all Ref: TDI Instruction fuel, sir, oil. Manual, Volume I, and water piping Maintenance Schedule and valves for leakage. j PE3041/57

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PERRY MAINTENANCE MATRIX' Component- . Component Alt. Number Identification PM Recommendation Monthly Outage Outage 5_ Year 10 Year Ccaments

2. Inspect, clean and X as applicable, lubricate manual valves on skid.

Engine Internals 1. Remove alternate left X If excessive side doors and water, sludge or examine the inside any indication of of the engine for any bearing failure . abnormal conditions. is present, drain Check with a good crankcase, deter-light for evidence of mine cause, and take babbit flakes. necessary action. Miscell- Engine Mounted 1. Replace elastomeric X anceous Pressure Switches parts. Gear Train 1. Inspect gears for X general condition.

2. Measure gear back X Replace worn '

lash on all gears. gears exceeding . maximum clearance. ' Complete TDI Inspection and Maintenance Form No. 355-1-1 ! TDI Instruction Manual, Vol. I, Section 5. Use Vol. I, Section 8 Appendix III-I for clearance values. Ref: 04/16/84 letter from R. Jaquinto to R. Johnston PE3041/58 l . s I l-I L-

l O - ENGINEERING REVIEW CRITERIA DOCUMENT FOR THE DESIGN REVIEW OF THE TDI DIESEL SMALL BORE PIPING, TUBING AND SUPPORTS FOR THE TDI OWNERS GROUP Report No. 11600.60-00-02 Revision 1 Prepared by Stone & Webster Engineerina Corporation Boston, Massachusetts December 1984 l l . O TDI1154 l I

TABLE OF CONTENTS Section Title Pm

1. 0 INTRODUCTION 1 2.0 APPLICABILITY , 1 3.0 OBJECTIVE 1 4.0 REVIEW METHODS 1 4.1 REVIEW OF EXISTING TDI DOCUMENTATION 1 .

4.2 REVIEW OF SMALL BORE PIPING 2 4.3 REVIEW OF TUBING 3 4.4 REVIEW OF SMALL BORE PIPING AND 3 TUBING SUPPORTS 4.5 REVIEW OF ENGINE INDUCED VIBRATION 4 5.0 SPECIAL CONPONENTS 4 5.1 DRESSER COMPRESSION COUPLINGS 4 i 5.2 PIPING FLANGES 4 l i l l i lO TDI1154

TDI OWNERS GROUP ENGINEERING REVIEW CRITERIA DOCUMENT FOR THE DESIGN REVIEW OF THE TDI DIESEL SMALL BORE PIPING, TUBING AND SUPPORTS FOR THE TDI OWNERS GROUP 1.0 ~ INTRODUCTION The TDI Emergency Diesel Generator Owners Group Program requires Design and Quality Revalidation reviews to independently verify the structural adequacy of the small bore piping, tubing and associated supports to withstand the effects of normal operating and earthquake loadings. This report provides the criteria to be used to perform the review. 2.0 APPLICABILITY The requirements of the review contained in this report are applicable to all TDI supplied small bore piping and tubing systems including associated supports contained in the diesel engine and its skid, unless specifically excluded by an approved Task Description in accordance with TDI Diesel Generator Owners Group Procedure DG-3. O v 3.0 OBJECTIVE The objective of this report is to provide the criteria to be utilized to verify that the small bore piping, tubing and supports will perform their intended function under all normal and earthquake ' loadings. 4.0 REVIEW METHODS 4.1 Review of Existing TDI Documentation The initial method to be utilized in determining a component's acceptability l. is to perform a review of all existing small bore pipe stress and support documentation provided by TDI. l The documentation will be re'tiewed to determine if it provides an adequate l design basis in accordance with the appropriate codes as delineated by the l individual utilities design specification for the diesel engine, The review shall also compare the as built piping and support condition to the existing design basis to determine compatability. l(' l( TDI1154/1 l l

Page 2 O d If, after completing the review, the engineer determines that the component is acceptable, based on the existing documentation, the Component Design Report will be issued stating the conclusion of acceptability. If TDI documentation is not available, or if it is determined that the available documentation does not readily lead to a conclusion of accpetability the engineer will alternatively continue the review as outlined in the following paragraphs. 4.2 Review of Small Bore Piping for Acceptability In cases where the review of TDI documentation does not lead to component acceptability, the engineer will judge if the component will perform its intended function under all normal and earthquake loadings. This judgment will be based on a review of the following infomation: Quality approved as built piping isometrics System operating parameters Physical piping data Site specific amplified response spectra System function In addition to reviewing the above information, a physical walkdown of the engine and skid piping may be required. The walkdown would include a review of the- piping to determine pipe support type and function, as well as a review for the following: Thermal flexibility: The engineer will determine if sufficient flexibility exists for each between support section of small bore piping. The thermal movement imparted by the supports onto the piping will also be considered. Deadweight spans: The deadweight spans between supports will be reviewed by the engineer and acceptability will be based on judgment. Seismic spans: The seismic spans between supports will be reviewed by the engineer and acceptability will be based on judgment. The engineer's judgment will consider the site specific amplified response spectra and all components, fittings and branch connections. Engine induced vibration will also be considered in determining acceptability of seismic spans and is further discussed in paragraph 4.5. The engineer will document the reviews of the individual component by a written trip report. The trip report will serve as a summarization of A l the engineering walkdown. !O TDI1154/2 l l l

Page 3 V) In cases where the engineer judges that the component will perform its intended design function the Component Design Report will be issued stat-ing the conclusion of acceptability. In cases where the engineer judges that a modification may be required to assure functional capability, a recommendation for the modification will be stated in the conclusions of the Component Design Review. The analyst may perform calculations to support the judgment in cases where it is not apparent that a modification is required. The object of these calculations is not to provide code compliance, but specific codes may be referenced for guidance. 4.3 Review of Tubina for Acceptability A field walkdown of all critical tubing components will be required. The same methods as outline in paragraph 4.2 for small bore piping review will be employed for tubing. 4.4 Review of Small Bore Pipina and Tubina Support In cases where the review of TDI documentation, as outlined in paragraph 4.1, does not lead to component acceptability the engineer must continue the review based on the following:

1) Quality approved as built support sketches, if available.

2) Physical support data

3) Anticipated support loads In addition to, or in conjunction with, reviewing the above information, a physical walkdown of the engine ad skid supports may be required. The walk-down would consist of a review of the following support components so that the engineer may judge if the support will perform its intended function:

1) Structural members

2) Structural bolts and base plates

3) Welds

! The engineer will document the review and recommend modifications as outlined in paragraph 4.2. 4.5 Engine Induced Vibration The effects of engine induced vibration will be considered in determing the adequacy of the piping spans for dynamic loading. Specifically, the engineer TDI1154/3

,~-

Page 4 will determine if the existing piping spans may cause the piping to respond at the resonant frequency of the engine. This determination may be based on calculation or review of the vibration test results obtained at Shoreham and Comanche Peak. Another acceptable method of considering engine induced vibra-tion is to compare the specific engine small bore piping or tubing with proven

                   - acceptable design experience.

The documentation of acceptability or recommendation of modifications will be in accordance with paragraph 4.2. 5.0 SPECIAL COMPONENTS 5.1 Dresser Compression Coupling , Based on review of the small bore Dresser couplings at Shoreham, it is not required to perform qualifying calculations for the coupling on the remaining engines. The couplings are inherently qualified based on acceptability' of the attached piping. 5.2 Pipe F1ances Based on review of the small bore pipe flanges at Shoreham, it is not required to perform qualifying calculations for the flanges on the remaining engines. The flanges are inherently qualified based on acceptability of the attached piping. O I' l l. I

O TDI1154/4 i

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O bESIGNCRITERIAFOR DIESEL GENERATOR LARGE DIAMETER PIPING FOR PERRY Submitted to TDI Owners Group Charlotte, North Carolina Prepared by O Impell Carporation 225 Broad Hollow Road Melville, New York 11747 Report No. 02-0630-1295 Rev. A Job No. 0630-037-1641 November, 1984 l v . l l 8 O PE3353 f

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y-TABLE OF CONTENTS Title Page Table of Contents 1.0 PURPOSE 2.0 APPLICABLE CODES 2.1 Diesel Generator Specification Requirements 2.2 Code Requirements 2.2.1 DEMA Standards 2.2.2

American Bureau of Ships Building Codes 2.2.3 ANSI B31.1 and 831.3 2.2.4 ANSI B31.7 2.2.5 ASME Code Section III 2.3 Applicable Code Acceptance Criteria 2.4 Conclusion 3.0 ACCEPTANCE PHILOSOPHY 4.0 LOADING CONSIDERATION 5.0 SPECIAL COMPONENT CONSIDERATIONS 5.1 Mitered Joints 5.2 Unreinforced Branches 5.3 Pressure Retaining Buttwelds 5.3.1 Weld Penetration Considerations 5.3.2 Weld Joint Capacity 5.3.3 Stress Intensification Factor O PE3353

TABLE OF CONTENTS (continued) 5.4 Dresser and Compression Couplings 5.4.1 Code Acceptability of Dresser and Compression Couplings 5.4.2 Coupling Validation 5.4.3 Effects of Couplings on Pipe Stress Analysis 5.5 Pipe and Equipment Supports

5. 6 Pipe Flanges' 5.G.1 Standard Flanges 5.6.2 Non-Standard Flanges 5.6.3 Flange Bolt Pipe Support Attachments

6.0 REFERENCES

O l l l l l r I l PE3353 l I L

l 1.0 PURPOSE The purpose of this document is to provide structural acceptance criteria for evaluation of the Transamerica Delaval, Inc. (TDI), large diameter, diesel generator skid mounted piping at the Perry Nuclear Power Plant Unit No. 1, (PNPP). This criteria was based primarily upon the philosophy embodied in

     . industry accepted Codes and Standards for design of nuclear power station piping.

2.0 APPLICABLE CODES 2.1 Diesel Generator Specification Requirements The PNPP Diesel Generator Specification, Ref. 1, invokes ASME III - Class 3 (Ref. 2) for the subject piping. 2.2 Code Requirements 2.2.1 Diesel Engine Manufacturers Association (DEMA) Standards t The DEMA Standard (Ref. 3) extensively covers the detailed performance

requirements of systems and subsystems for diesel engine. driven electric power generating units, but does~ not cover analytical requiraments or allowable stresses for piping systems. It relies on other codes for these requirements but does not specifically reference any.

2.2.2 American Bureau of Ships Buildina Code . Section 36 of the American Bureau of Ships Building Code (Ref.4) discusses requirements for pumps and piping systems. This code presents very few design requirements, providing specific analytical formulas only for pipe wall thick-ness versus piping design pressure. The code makes no specific provisions for analysis for deadweight, thermal expansion, or dynamic effects. Piping materi-als and allowable membrane stresses are addressed in this ' de. For example, ASTM A53 Grade B and A106 Grade B are approved materials. It is noted that this code provides tabulated membrane stress allowables which are the same as for B31.1 (Ref. 5) and ASME III Class 3 and 2 (Refs. 2 and 6). I l 2.2.3 ANSI B31.1 and 831.3 The general philosophy of ANSI B31.1 (Ref. 5) and 831.3 (Ref. 7) is to parallel those provisions of Section I " Power Boilers" of the ASME Boiler and Pressure Vessel Code, _ as they can be applied to piping systems functioning at elevated pressures and temperatures. These codes are conservative, reflecting the general naed for long service life and maximum reliability in power, chemical, and petroleum refinery installations. O PE3353/1 l

Page 2 O Q B31.1 and B31.3 are quite similar, except that 831.3 allowable stresses are somewhat more permissive than B31.1 values. Both are all inclusit codes which set forth engineering requirements for design and construction of piping systems. These codes contain basic reference data'and formulas deemed neces-sary for design, including the following: (1) Material specifications and component standards which have been accepted for code usage; (2) The designation of proper dimensional standards for the elements compris-ing piping systems; (3) Requirements for the design of component parts and assembled units, including necessary pipe supporting elements; (4) Requirements for the evaluation and limitation of stresses, reactions, and movements associated with pressure, temperature, and external ' forces; (5) Requirements for the fabrication, assembly, and erection of piping systems. (6) Requirements for testing and inspection of elements before assembly or erection and of the completed systems after erection. 2.2.4 ANSI B31.7 ANSI B31.7 " Nuclear Power Piping" (Ref. 8) was the precursor of ASME III-Class 1 Subartiue NB-3600, which covers ASME Code Class 1 piping design, and embrac-es the same design philosophy as ASME III-Class 1 (Ref. 9). 2.2.5 ASME Code, Section III The ASME Boiler and Pressure Vessel Code provides rules for the construction of boilers, pressure vessels, and nuclear components. Section III of this Code addresses nuclear power plant components, and consists of two (2) divisions. Division 2 covers concrete reactor vessels and containments and is not perti-nent here. Division 1 consists of the following subsections: l NCA General Requirements NB Class 1 Components NC Class 2 Components ND Class 3 Components NE Class MC Components NF Components Supports NG Core Support Structures Appendices l l l l v ( PE3353/2 l L

Page 3 Each subsection is divided into articles as follows: Article 1000 Introduction and Scope Article 2000 Material Article 3000 Design Article 4000 Fabrication and Installation Article 5000 Examination Article 6000 Testing Article 7000 Overpressure Protection Article 8000 Nameplates, Stamping and Reports The code recognizes that various components have different levels of importance associated with the components' function, as related to the safe. operation of , the nuclear power plant. The code classes thus permit a choice of rules that provide assurance of structural integrity and quality commensurate with the , relative importance assigned to the individual items. Class 1 components are assigned the highest level of importance. Reactor coolant pressure boundary components are examples of what is normally assigned as ASME III-Class 1. Class 2 components are assigned the next lower level of importance. NucTear safety related components other than reactor coolant pressure boundary compo-nents are examples of what is normally assigned to ASME III-Class 2. Class 3 components are usually of the same level of importance as Class 2 components, but are assigned to ASME III-Class 3 by virtue of their moderate normal operat-ing temperatures and pressures. ? ASME Code Section III does not provide guidance in the selection of component p] classification and places the responsibility of such component classification on the owner of the nuclear power plant. 'i~

2. 3 Applicable Code Acceptance Criteria Those portions of the applicable building codes and ' standards which refer to structural integrity of the subject piping are addresced herein. The portions of these codes which provide requirements for documentation and other quality assurance related requirements, as well as adequa<;y of system design requirements such as overpressure protection adequacy, are not part of this scope.

l The PNPP Diesel Generator Specification, Ref. 1, invokes ASME III - Class 3

      .(1971 edition, with all addenda). This classification is consistent with the moderate service temperatures and pressures associated with the subject piping.

ASME III - Class 3 applies specifically to nuclear safety related piping, having rigorous analytical requirements that are acceptable to the nuclear industry and the U.S. Nuclear Regulatory Commission. ANSI 831.1 and ANSI l B31.3, by virtue of their similarity to ASME III - Class 3, are also applicable. O PE3353/3 l

Page 4 Since ASME III-Class 3 permits qualification to more stringent code .subsec-

         'tions, it is permissible to provide ASME III-Class 2 (Ref. 6) or ASME III-Class 1 (Ref.9) analysis for this purpose. ANSI B31.7 (Ref. 8) is the predecessor to ASME III-Class 1 and is, therefore, similarly applicable.

ASME III-Class I has considerably higher allowable stresses for material such as ASTM A106 Grade B. However, this is applicable only if ASME III-Class 1 stress analysis is performed. Note that ASME III-Class 1 analysis provides design rules for rigorous evaluation of fatigue life and must be used if the piping is justified on that basis. 2.4 Conclusion It was concluded that the PNPP diesel generator piping design utilize the

;         philosophy and intent of ASME III - Class 3 design (Ref. 2) to provide analyti-cal justification of piping design acceptability.       The other above referenced l          codes (References 5, 6, 7, 8 & 9) were also judiciously considered where
        . applicable, as described in Section 3.0.

3.0 ACCEPTANCE PHILOSOPHY The intent and philosophy of ASME III - Subsection N0 design rules for Class 3 , components (Ref. 2) was utilized as the basis of acc tance. The requirements of other codes and standards (Refs. 5, 6, 7, 8 and 9) were also considered for applicability. The analysis was performed in steps, as follows:

,         1. Pipe stress analysis was first performed in accordance with the design -

rules of ASME III - Class 3 (Ref. 2), using conservative assumptions for i modeling and stress intensification described in detail in 5.0 (below).

2. If this analysis indicated excessive stresses, then the results were

! evaluated to determine if relaxing some of the conservatisms could be l justified for the particular piping systems being considered. ! For example, it was, at times beneficial to consider the more rigorous, l ASME III-Class 1 analysis in an attempt to justify thermal expansion i stresses on the basis of adequate thermal fatigue life.

3. If pipe stress was still excessive after relaxing conservatises, support removal and/or modification was then considered.

4. The applicable piping system was then reanalyzed to reflect the above referenced analytical modification. Or, as an alternative, hand calcula-tions were performed to account for a highly localized effect.

4.0 LOADING CONSIDERATIONS The pipe stress analysis accounts for all loads due to deadweight, thermal expansion, and earthquake. O PE3353/4 i

Page 5 The effects of earthquake were determined by dynamic pipe stress analysis utilizing .ppropriate seismic response spectrum envelopes. As noted in the Diesel Generator Seismic Criteria (Ref.10), Operating Basis Earthquake (OBE) and Safe Shutdown Earthquake (SSE or DBE) were considered. Consistent with Reference 10, a three-directional earthquake was assumed. The effects of each of the vertical and two horizontal earthquakes was first determined by combin-ing across modes by square root sum of squares (SRSS) with closely spaced modes considered by the ten percent method. The three directions of earthquake were then combined by SRSS to determine the seismic results. Seismic spectra as well as the appropriate damping values, were also based on Reference 10. Based upon data provided in Reference 11, the diesel, its supporting skid and the auxiliary skid have all first mode natural frequencies in the rigid range of the applicable response spectrum. Therefore, consideration of the dynamic amplification of those components was not necessary and the floor spectra was used for all analyses. The analytical piping model for both thermal and seismic analyses included the pipe supports, which were modeled as springs whose spring constants were based on the as-built pipe support configuration of the Lead Diesel (Comanche Peak), where applicable. When the Perry supports could not utilize spring constants from Comanche Peak, either spring constants were developed upon available information, or computer program default spring constants were used. In addition, to more accurately represent both the flexibility of equipment and its dynamic effect on the piping, the equipment was included in the analytical O piping model using cross-sectional properties and component weights derived from the applicable equipment details. However, if a particular piece of equipment was apparently rigid, based on engineering judgement, then that equipment was not included in the analytical model. 5.0 SPECIAL COMPONENT CONSIDERATIONS This section provides discussions relating the analytical considerations of special configurations and components. These include specialty items such as Dresser and Compression Couplings, and pipe flanges, and also includes special configurations such as mitered joints, unreinforced branches and circumferential buttwelds. 5.1 Mitered Joints Mitered joints are permitted by ASME III-Class 1, 2 and 3 (Refs. 2, 6, and 9), as well as B31.1 (Ref. 5) and B31.3 (Ref. 7). Flexibility characteristic (h), flexibility factor (k), and stress intensification factor (1), as tabulated in Figure NC-3673.2(b)-1 and Figure ND-3673-2(b)-1 in Ref. 2 and 6, were utilized for ASME III-Class 2 and 3 analyses, respectively. Furthermore, to assure that the miter joint induced discontinuity stresses were acceptably low, equation 4(c), paragraph 304.2.3 of B31.3 (Ref 7) was evaluated to determine the pressure capacity of the joint as compared with the normal operating pressure of the pipe in question. O~ PE3353/5 l

5.2 Unreinforced Branches The use of unreinforced branch connections, including unreinforced lateral connections as used in the PNPP diesel generator skid mounted piping, is permitted by ASME III-Class 1, 2 and 3, as well as by 831.1 and B31.3.

Flexibility characteristic (h), flexibility factor (k) and stress intensifica-

! tion factor (i), as tabulated in Figure NC-3673.2(b)-1 and Figure ! ND-3673.2(b)-1 were utilized for ASME III-Class 2 and 3 respectively. e Additional analysis was performed to confirm that the pipe is "self-j reinforcing" and that the rules for metal reinforcement requirements set forth l in the codes (e.g. , ASME III-NC-3643.3, et. al.) were satisfied. It is noted that .since the design pressure was small in relation to the actually furnished pipe wall thickness, there was considerable excess wall thickness available for-l self-reinforcing of the branch penetrations. 5.3 Pressure Retaining Buttwelds 5.3.1 Weld Penetration Considerations For the seamless on-engine piping, weld only in the bevel region was assumed. No . weld penetration in the land region (assumed as 1/16 inch) was assumed.

5.3.2 Weld Joint Capacity Minimum wall thickness requirements dictated by design pressure (e.g. ASME III-NC-3641.1, Equation (3), et. al. ) must be maintained at the circumferen-l tial buttwelds, which join adjacent spool pieces.

For the PNPP diese1 ~ generator piping, it was conservatively assumed that the I material available for design pressure requirements was equal to the pipe wall thickness minus 3/32 inch, to account for the worst possible minimum weld thickness. Minimum weld thickness to minimum required pipe wall thickness , ratios were determined for all ' of the subject pipe sections. The smallest ratio of (tw/tain) was found to be 2.0 (or 200 percent of minimum required wall thickness). Thus, these welds always met minimum Code requirements for pres-sure dependent pipe wall thickness. This excess wall provides adequate generic margin against corrosion. More specific data regarding corrosion is provided

      -in the specific component reports where applicable.

All pipe stress calculations, 'other than design pressure vs. . wall thickness calculations,- utilized the nominal pipe wall thickness, since a local thinning of the pipe affects its pressure capacity but has a negligible effect on gross bending stresses. This is consistent with the philosophy of ASME III and ANSI codes. Applying this philosophy to the circumferential welds, it was thus assumed that

      . for deadweight, thermal expansion and seismic . loading stress analysis, the available' wall thickness was the nominal wall thickness minus the nominal flat landing of' 1/16 inch.       The evaluation of stresses at the circumferential 1      buttwelds considered this reduction in section.

O PE3353/6 1 1

Page 7 If the stresses thus derived were adequately low,'then strength capacity of the circumferential weld joints furnished for the subject piping was considered to be adequate. 5.3.3 Stress Intensification Factor

     - The initial analysis utilized a stress intensification factor (SIF) of 1.8, which was the upper limit specified in ASME III-NO (1974 version including

! addenda through Summer 1974) Figure ND-3673.2(b)-1 for a mismatch of an as welded buttweld (which is in excess of 0.1., i.e, having a ratio of mismatch to l pipe wall thickness [ delta /t 3)* n { This approach was a conservative necessity. If it could easily be determined that the ratio (delta /t ) is 0.1 or less, then the code permits an SIF of 1.0 for as welded or flusS buttweld. However, since the pipe had independent I.D. ,0.0. , and out of round tolerances, it was not possible to determine the actual pipe wall mismatch (delta) between two adjacent spools by visual'inspec-tion of the outside of the piping. Thus the conservative value of 1.8 was utilized. 5.4 Dresser and Compression Couplings Dresser Couplings (see Figure 1) and Compression Couplings (see Figure 2) were utilized throughout the PNPP diesel generator skid mounted piping. These couplings provide a flexible, leak proof seal at the pipe spool piece inter-face, without pipe threading, or welding, and do not require precise spool O piece end preparation or precise piping alignment. These couplings have an 80 year record of successful service on all kinds of piping such as water mains, sewage treatment, and water filtration piping, and in all branches of the oil industry, and have been used extensively by TDI for , other diesel generator installations. 5.4.1 Ccde Acceptability of Dresser and Compression Couplinas ASME III-NC-3649 (for Class 2 components) and ASME III-ND-3649 (for Class 3 components) permit the use of pressure retaining products not specifically

covered in the code, which are shaped, proportioned, and sized similar to components that have been proven satisfactory by successful performance under comparable service conditions.

By virtue of their long record of satisfactory service for nioderate pressure / temperature systems of this type of application, the Dresser Couplings and the Compression Couplings meet the intent of ASME-III Class 2 and Class 3 (Refs. 2 and 6) and were therefore acceptable components. 5.4.2 Coupling Validation PE3353/7

Page 8 0 1. Selection

     .The Dresser catalog specifies limiting pressures and temperatures for the various couplings. The subject service conditions were evaluated against these requirements and some couplings, because of the gaskets supplied, were slightly marginal with respect to the temperature requirements. For these couplings, replacement with an upgraded model was specified if leaks developed.

2. Displacement Verification When acceptable piping / pipe support results are obtained, the relative transla-

      'tions and rotations of the joined pipes were compared to the vendor allowables
     .for the coupling to validate the analysis.

5.4.3 Effects of Couplings on Pipe Stress Analysis

1. Pressure Effects Pressure integrity of the piping is achieved by wedging the coupling gasket against the outside of the pipe and into the mating fitting (Reference Figures 1 and 2). However, this configuration permits axial pipe movements of the adjacent pipe spool pieces. Thus, when the pipe is pressurized, it would tend to slip out of the coupling and separate, if some external axial anchorage were not also furnished. Pipe supports and terminal end connections were relied upon to prevent slipping. The pipe stress analysis included the effects of these resulting unbalanced pressure forces.

O 2. Constraint of Thermal Expansion As shown in Figures 1 and 2, a gap is intended to be maintained between the two pipe spool pieces' during installation. This would accommodate a modest amount of thermal pipe expansion. However, if this gap is not maintained during the installation of the piping, then the thermal expansion relief is partially negated. Pipes joined by couplings have only the gasket and its frictional capacity to provide any mutual stiffening across the joint. Since this is very low, the coupling connection was analyzed as completely free to rotate and translate relatively. .

3. Seismic Interaction at the Couplinas Examination of Figures 1 and 2 indicates that modest translations and rotations between the two adjacent piping spool pieces are possible, by virtue -of the soft gaskets, and the gaps within the couplings. For seismic analysis, it is not conservative to neglect this flexibility.

In order to account for this, seismic pipe stress analysis first conservatively assumed the piping systems to be completely separated at the coupling, thus

     'taking no credit for any mutual stiffening across the coupling. If the seismic stresses were acceptable, then no further evaluation was performed.

O PE3353/8

Page 9 5.5 Pipe and' Equipment Supports Pipe and equipnent supports were qualified on the basis of plant specific

   ,                         operating history as well as Impell's experience with the Shoreham and Comanche Peak Diesel Generators.                         Engineering judgement was used in the qualification of supports.                       Since as-built details for supports were not provided, it' was assumed that supports were installed 'as originally designed by TOI. Where previous support problems existed, either on the Comanche Peak engine or on similar engines, generic-type recommendations for modifications were made. Where piping analysis deessed support modifications (e.g. , addition or removal of supports) necessary, recommendations to incorporate such changes were included in the final reports,.                      Where there was no history of problems with a support nor any analytical basis for nodification, that support was judged adequate for its intended purpose.

5.6 Pipe Flances 5.6.1 Standard Fla_ngess Flanges fabricated to standards listed in ASME III-NC-3132-1 (for Class 2) and NO-3132-1 (for Class 3) are acceptable for ASME III Class 2 and 3. For these flanges the established pressure / temperature rating was first compared with operating pressure / temperature to evaluate the flange selection. Since the operating pressures for the subject piping systems were modest, the flange had excess capacity to carry mechanical loads imposed on the flange. This was confirmed by conservative hand calculations using techniques outlined in ASME III . Subsection N0 3658. 5.6.2 Non-Standard F1ances At a number of locations within the RBS Diesel Generator skid mounted piping, , square or rectangular, flat plate flanges were utilized. These flanges were analyzed as flat plates, using conservative assumptions. 5.6.3 Flance Bolt Pipe' Support Attachments At a numberJof locations pipe support straps were connected to piping at pipe l flanges by means of two or more flange bolts. Since these bolts have the i multiple duty of providing pressure closure and flange continuity, as well as serving as a pipe support attachment, they required special evaluation for adequacy. These flange bolts were evaluated on the following basis: l If the flange bolts are properly torqued, providing ample precompression at the flange / pipe support strap, then there is frictional resistance to transmit load. If this frictional resistance capacity is greater than the actual l applied force, tMn the bolt is loaded only in tension. It does not therefore realize any _of the transverse load, or accompanying bending which is transmitted to the flange assemiby by the pipe support strap plate. PE3353/9 i

Page 10

     .The bolt frictional capacity, based on Transamerica Delaval bolt torque recommendations, (Ref.16), was compared to the strap load, and the connection was adequate to transfer shear without bolt bending provided the frictional capacity is at least 1.5 times the support load.        If this criteria was not met, then higher strength bolts were specified, such that an increased bolt torque could be applied, yielding higher pretension and thus ensuring a greater frictional capacity.

6.0 REFERENCES

1. Specification No. SP-562-4549-00, Revision IV, July 17,1978 " Class IE Diesel Generator Units, Perry Nuclear Power Plant-Units 1 and 2."

2. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, " Rules for Construction of Nuclear Power Plant Compo-nents" (ASME III) Subsection ND Class 3 Components (ASME III-Class 3).

3. Diesel Engine Manufacturers Association (DEMA), " Standards and Practices for Low and Medium Speed Stationary Diesel and Gas Engines," 1972.

4. American Bureau of Ships, " Rules for Buiding and Classing Steel Vessels,"

1976.

5. American National Standards Institute (ANSI) Document ANSI /ASME B31.1,

            " Power Piping" (B31.1).

6. ASME III, Subsection NC, Class 2 Components (ASME III-Class 2).

7. ANSI document ANSI /ASME B31.3, " Chemical Plant and Petroleum Refinery Piping" (831.3).

8. ANSI B31.7, " Nuclear Power Piping" (B31.7).

9. ASME III Subsection NB, Class 1 Components (ASME III-Class 1). ~

, 10. Attachment Specification SP-750-4549-00, Revision 1, March 11, 1974 l " Seismic Analysis, Testing, and Documentation - Perry Nuclear Power Plant-Units 1 and 2".

11. TDI Final Report, Volume I, Part 1 - Seismic " Qualification of Delaval Turbine Inc. Diesel Generator Sets - Serial Nos. 75051 and 75054 for j Perry Nuclear Stations No. 1 and 2".

12. TDI Instruction Manual, Volume I, Appendix IV "MODEL DSRV-16-4 Diesel Engine / Generator".

l l ( PE3353/10

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Text

SUMMARY

1.0 INTRODUCTION

SUMMARY

SUMMARY

6.0 REFERENCES

SUMMARY

SUMMARY

1.0 INTRODUCTION

SUMMARY

6.0 REFERENCES

SUMMARY

SUMMARY

SUMMARY

SUMMARY

6.0 REFERENCES

6.0 REFERENCES

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