Text

Summary of 840127 Meeting W/Util Re Delaval Diesel Issue. Meeting Agenda,Handouts & Supporting Documentation Encl
	ML20117F369
Person / Time
Site:	05000000, Grand Gulf
Issue date:	02/02/1984
From:	Olshinski J; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:	James O'Reilly; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
Shared Package
ML20115A145	List: ML20115A141; ML20117F369; ML20117F386; ML20117F397; ML20117F482; ML20117F489;
References
	FOIA-84-275 NUDOCS 8505130214
	Download: ML20117F369 (165)
	v • d • e

.-

16 Ol*b"

Ne.

~'

u sire o sT,. n s j[...w c

NUCLEAR REGULATORY COMMisslON r'

aEGiou ii

,e g

g 101 M ARIETTA STREET, N W.

c;

[

ATL ANTA. GEORGIA 30303

+.'.... /

FEB 2 1954 J-MEMORANDUM FOR:

James P. O'Reilly Regional Administrator FROM:

John A. Olshinski, Director Division of Engineering and Operational Programs

SUBJECT:

NRC/MP&L MEETING ON JANUARY 27, 1984 On January 27, 1984, I attended a meeting with the NRC staff and Mississippi Power and Light Company (MP&L) concerning the Delaval diesel issue as it pertains to Grand Gulf. The meeting was held at the request of MP&L in order to present the staff with a summary of their ongoing efforts concerning DeLaval. The enclosure was provided by MP&L surmiarizing their efforts. The next to the last-page of the enclosure indicates MP&L's views of what is required prior to proceeding with licensing for Grand Gulf. The senior NRC member in attendance was Tom Novak. The staff did not give any significant reaction to the presenta-tion, but did express the desire to have the pertinent material docketed.

There

.was some disagreement between MP&L and NRR on what has been docketed to date.

NRR teok' the opportunity to introduce Carl Berlinger who is the NRR project group i,

manager on the DeLaval issue.

It was not clear to me that NRR intended to address the Delaval issue on a plant specific basis, and I do not believe that NRR has assigned resources to address the issue on that basis.

b

/ hn A. Olshinski

Enclosure:

NRC/MP&L Meeting Agenda and Handouts-2 cc w/ encl:

R. Martin R. Lewis A. Herdt 95051M14 B41030 i

PDR FOIA BELL 84-275 PDR

~.

?

s

. NRC/MP8L MEETING - TDI D/G REllABILITY JANL'ARY 27, 1984 - BETHESDA AGENDA 1.

INTRODUCTION NRC 11.

MPal OBJECTIVES /0VERVIEW MPEL - J. P. MCGAUGHY 1

IESl'E HISTORY GGNS SCHEDULE 4

SIGN:FICANT INSPECTION /

MAINTENANCE PROGFESS 111. TOPICS FOR DISCUSSION MPEL - J. P. MCG A'.'

HY l

QUALITY ASSURANCE AND l

INSPECTION ACTIVITIES CODES AND STANDARDS USED DESIGN SPECIFICATIONS MAJOR PROBLEMS / CORRECTIVE ACTIONS TESTING AND SURVEILLANCE OPERATING DATA RELIABILITYENHiNCEMENTDROR PROGRAM IV.

MP&L CONCLUSIONS MPal - J. P. MCGAUGHY

^

V.

NRC/MP&L DISCUSSION NRC/MPEL VI.

IDENTIFICATION OF ACTIONS REQUIRED FOR FULL POWER LICENSING

s i

w k

i QUALITY SURVEILLANCE t

l THE SELECTIVE REVIEW, OESERVATION AND EVALUATION OF :

PROCESSES, PROCUREPENTS, MANUFACTURING OPERATIONS, QUALITY CONTROL SYSTEMS, AND PROGRAMS, TO Ik.iaditE SUPPLIER COP.PLI ANCE WITH CONTRACTURAL REQUIREMEf'TS.

f

. c l

b 6

1

t 6

e

.s s

1 l

l C

2" C

C=

V3 V3 Lt W

.d g

C nW C

W C5 IL v3 c=

W Z

E C

~

C C

V3 t-.

~

L.J Z

U c:

g m

=

C c=

Z E

v3 C.

v3 C

W W

Z C=

C=

c

=

C C

W Z

W C

Z W

m Z

W c

C C

E E

V3 C

O C,.

W Z

M G

V3 M

C

'C C'

U

=

Z C

Zi C

C V3

~

W W

3 "E

V E

C C

=

c=

m N

E C

C C

C 4

W Z

v Z

C Lu C

C Z

m C

c 2

Z C.

W

~

E acll LLJ U

C C

J W

auc Z

Z w

Z t.L eil:

=

3 C

W

~

C Z

J M

V)

Z W

L.J Z

W E

3 e

e e

L

s u, i t.........g. a.....

4'

....... o i i e o RTE-DELTA TDI PORTEC (CONTROL J.D_lE_ Sell HENE. RAT 0ll!

_ PANELS) 10JAL_

REPORTS 112 8

2 84 1 181 DAYS IN Sil0P 279 lli 19 312 SillPMENTS 17 3

2 52 1

DEFICIENCIES 33 1

ln 7 11 i

WITNESS AND ll0LD POINTS 128 81 6

138 IN-PROCESS INSPECTIONS 53 11 3

62 9

e

)

t

(

//

ELD SHIP RESTRICTION FAB LNIT 1 LNIT 2

~ START SHIP SHIP -

1 AAm

=

7. OF o

~

MISC.

8 EDUI E T 7

.(

6 5

P!S~;4 tC:F:';. TIS'i 4

3 2

'/ /

x M

1 10/75 7/76 9/77 9//8 9//9 9/80 9/El 9/82

/4DITS b

w

--,e

w-g.-.N O-t e

Q C

=

k

+

b E

wx,

x s.

G Et N

u a

sk\\

E~.k a

y a

m y

x w

.(

5

~

=

5 5

e g

_s a

e 5

S l

M 5

e m

h Waue

$E$

sE!

m

,.7

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

,.m-

0*.EP.GENCY DIESEL GENE?ATOR DESIGN CODES AN: STA' CAP:S s

~

ESSENTIAL COMPONENTS.0F FUEL OIL SYSTEM:

ASME BOILER AND PRESSURE VESSEL CODE (1974 EDITION), SECTION lli NONESSENTIAL COMPONENTS OF FUEL OIL SYSTEM AND ALL CCMPCNENTS CF AUXILIARY SYSTEMS (LUBE OIL, STARTING AIR AND JACKET WATER SYSTEMS) UP TO ENGINE IPTERFACE:

ANSI B31.1 POWER PIPING (1973 EDIT 10t: AND SuMME; 7t*

ADDENDut')

DIESEL ENGINE AND ON ENGINE MOUSTED PIPING AND COMPCt!Et'TS:

DEMA STANDARD PRACTICES 21[

ASTM - A106 ASTM - A5?

ANSI - B16.5 ANSI - B16.25 ANSI - B16.10 ANSI - B16.11 PRESSURE VESSELS (LUEE OLL COOLER, JACKET WATER COOLE:, AfC STARTING AIR TANK):

i ASME SECTION Vill, Div!SION I TEMA CLASS R FOR LUBE O!L AND JACKET WATER COCLERS PUMPS:

HYDRAULIC INSTITUTE STANDARDS s

s 6

GENERATORS:

m NEMA-MG-1-1972, MOTORS AND GENERATORS

'~

ANSI-C-50.10-19E5, GENERAL P.ECUIREMENTS FCR SYNCHRONOUS MACHINES ANSI-C-50.12-1965, RECUIREMENTS FOR SALIENT POLE GENERATCRS

~

AND CONDENSERS MOTORS:

NEMA-MG-1-1972. MOTORS AND GENERATORS DIESEL GENERAT' ORS:

IEEE STD 308 - CRITERIA FOR CLASS IE P0wER SYSTEMS.:0R NUCLEAR GENERATING STATIONS IEEE STD 323 - STANDARDS FOR CUALIFYIMG CLASS lE ECU!FMENT

.I FOR NUCLEAR POWER GEt'ERATING STATIONS lEEE STD 344 - RECCMMENDED PRACT!CES FOR SE!SMIC QUALIFICATION OF CLASS IE ECU;FMENT FOR NUCLEAR PCwSR I

GENERATING STAT!ONS IEEE STD 387 - CRITERIA F0F DIESEL GENERATCF U!!TS AP: LIE" AS STANDEY POWER SUFFLIER FOR NUCLEAR POWER GF!'EP.ATING STAT!cNS DIESEL GENEFATOR TESTS:

IEEE STD 115 - 1965 - TEST PROCEDURES FC: SYNCHRCNCU5 MACHINES ASME PERFORMANCE TEST CODES, PTC-17-1957 AND PTC-25-195^

' (,

- E I

k4

O.

4 EMERGENCY DIESEL GENERAL SPEC!FICITION ulSTORY SPECIFICATION REcUIREMENTS DEFINED IN REVIS!CN 2 AND ISSUED FOR PURCHASE IN JULY, 1974, e

DESIGN RATING:

7000 KW, 450 RPM, 4160 V e

NO ExCEPT!Ch5 TO PROTOTYPE TESTING RECUIREMENT OF 300 STARTS w!TH ONE FAILURE PER 100 STARTS PERMISs!s'.E SUBSECUENT hlNOR REVISIONS INCLUDE:

e UPGRADED FUEL OIL SYSTEM TO ASME SECTICN lli e

EXPANDED hDE SCOPE o

REVISED AND AEDED TECHNICAL DETAILS:

!(

1)

LUEE O!L TRIP LOGIC 2)

TEMP. MON!TORING e

CLARIFIED AND DEFINED:

1)

VEhDOR SCOPE l

2) lhTEkFACE WITH MP&L 3)

SEISMIC REQUIREMENTS 4)

TESTING REQUIREMENTS l

5)

WELDING REQUIREMENTS l

(-

SINCE JULY, 1974, N2 MAJOR DESIGN CHANGES A

e

(

9 e

C

- 1. ~ ' l

_.^

s

~

s.

m NN l

/l

, b:y o.,

\\

/

f

'1 4

-1 wY f

J x$W ',

, g-

.\\

.t

,. p 3

. \\

eG )p,.0 0 1 s ' i k/

1 t

1 Mp 4,>

gl/ /

w, g

7' ^m C

^

3 w =,

1

'Q i

s' u n n l.. $

'a:.

- ' 7 m.

4.-l g

c, -~,.m 1

x l

(

DSkV ENGINE

-~-- -

r--

,, - - - - - - ~ _

DIESEL ENGINE SPECIFICATIONS

(

MODEL DSRV-15-4 l

L ENGINE SERIAL NUMBER 74033-2524 8 74034-2525 SERVICE Stational generator for o

nuclear service FUEL MODE DIESEL CONFIGURATION 45' "V" Typr.

l No, cf Cylinders 16 Bore (in.)

17 Stroke (in.)

21 lC-l Cycle Mode 4 stroke I

Totcl Displacement (cu.in.)

76,265

^

l I

Crankshaft Rotation CW (from crcnkshaft er.d.'

l l

Firing Order IL-5R-4L-2R-7L-6R-3L-1R l

8L-4R-5L-7R-2L-3R-6L-8R Continuous Rating (kw) 7000 i

Overload Rating (kw) 7700 I

Quantity 2

i Crankshaf t Diameter (in.)

13 lb Crank Pin Diameter (in.)

13 i

L

[.

i OllALIFIC ATION TESTINC-L L

TEST SPECIFIED P ::~' '*ED i' ' *. " : 3 3 I

2 j.

1)

FUNCTIONAL X

X X

L (COMPONENTS' L

1). OPERAT10NAL X

X X

l (SYSTEf:)

3)

ELECTRICAL X

X X

c)

STARTING AIR TDi X

X l

l COMPRESSOR CAPACITY 51 3Cf START X

X X

l El SE0i'Ef'TI AL LOAD X

X X

L 7)

LOAD REJECT!0f.'

X X

Y 8)

MARGiff X

X X

l 9)

ENDURANCE X

X X

N 10)

ACOL'STICAL TDI X

X 4

11)

CRANV.SPAFT TDl X

)

TORSION (TORS 10 GRAPH) 12)

STARTING AIR TDl" X

)

BOTTLE CAPACITY 13)

LOAD CAPABILITY TDl" X

Y l

OUAllFICATION 10)

IDLE ENDURANCE TDl4 y

g.

NOTES:

1)

TEST NOMENCLATURE TAKEN FROM TDI TEST REPORT, 2)

AS REQUIRED FY SPECIFICATION 9645-M-018,0, REV. 22.

l 3)

AS WITNESSED EY BECHTEL, ACTING AS MPal'S l

REPRESENTATIVE, 4)

ADDITIONAL TESTS PERFORMED BY TD1 TO ALIGMENT THOSE REQUIRED EY MP8L AND DEMA, I

l

PRESENT D/G LOADINGS

(

DivistoN I D!vis!os !!

PROC SPEC ESTIMATED LOAD 5730 KW 6100 KW SPECIFIED DG RATING 7000 KW 7000 KW LOSP loads 3627 KW (51.8) 4745 Kh (67.8)

Post LOCA loads 4711 KW (67.3) 3914 KW (55.9)

TOTAL CONNECTED ESF Bus LOAD 5963 KW (85.2) 6397 KW (91.4) i e

r i

I

(-'

j j

c:

1 i

I fGJOR PROBLEMS / CORRECTIVE ACTIONS t (

e CRANKSHAFT e

CONNECTING R0D BEARINGS I

e PISTON SKIRTS I

L e

CONNECTOR PUSH RODS l

e CYLINDER HEADS e

LOW PhESSURE FUEL OIL LINE e

ENGINE h00NTED COMPONENTS e

HIGH PRESSURE FUEL OIL LINE fb e

REAR CRANKCASE CAPSCREWS l

L l

l l

l C

G t

)ESIGN C0t M.R150A g

.)tlk%AL O/O Usik

\\,.

SHOREH/#.

GMND GULF HORSE POWER 4889 9970 7000KW ELEC. OUTPUT 3500Kw BORE, IN.

17" 17" STROKE, IN.

21" 21" CRANKSHAFT LENGTH, FT.

19-1/2 FT.

20' - 7" CRANK PIN DIAMETER, IN, 11" 13" NUMBER OF BEARifiGS 11 MAIN 10 hA!..

(LAST 2 IN OfiE JOURNA'.)

CRANKSHAFT DIAMETER, IN.

13" 13" 1

COMPRESSION RATIO 12:1 11.6:1 i

r RPM 450 450 f

s NOTES:

1.

DATA ON SHOREHAM WAS OBTAINED IN TELEPHONE COMMUNICATIONS WITH LILC0 PERSONNEL AND DELAVAL.

i l

l l

I i

O

(

im.WC

?-

L lN b

1 ]\\ (

If 2

Q:

1 O,=a. idu s

r-

[

(

A

/.

[

)

8L

)

.i (e.

l u_

-d

/

i ICl

\\'

pi

/, I M

' I d.7 i

-4, c

_G d'

'I k (1,

(

DSR ENGitiE w.

\\.

.%.b

F 9

CRANKSHAFT

(

1.

SHOREHAM FAltuRE PRCMPTED CONCERN 12.

VIERATION MEASUREMENTS TAKEN ON BOTH DIV i AND DIV 11 ENGINES - VIBRATION LEVELS TYPICAL OF LARGE' INTERNAL COMBUSTION ENGINES 3.

DIV I AND 11 D/G CRANKSHAFTS INSPECTED UTILIZING VISU -. A *.:

LIOUID FLUORESCENT DYE PENETRANT METHODS 4.

NO REJECTABLE DEFECTS FOUND 5.

DIFFERENCES IN GGNS AND SHOREHAM DESIGN EVALUATED - GGNS SUPERIOR DESIGN 6.

COMPARISON INDICATES THAT GGNS STRESSES AhE WELL BELOW

{

SHOREHAM STF. ESSES AND DEMA STANDARDS 7.

TDl'S ANALYTICAL hETHODS IN ACCORD WITH lfDUSTRi STAN AR:

PRACTICES i

L l

\\

i.

l GC-NS TDI D/G CRANKSPAFT DESIP' VERI:lCATION 1.

AFTER SHOREHAP CRANKSHAFT FAILURE, EECHTE PERFORMED CRANKSHAFT DESIGN ANALYSIS REVIEW FOR GGNS 2,

BECHTEL PEVIEWED METHOD 0LOCY A O TEST USED FY TDI 3.

Nt"'.EPOUS SPOT CHECKS TO EPSURE ACCURACY OF TDI PESl'LTS 4.

BECHTEL CONDL'CTING INDEPEt1 DENT STRESS ANALYSIS FINDINGS 1,

METHODS USED BY TD! IU ACCORD WITH INDL'STFY PRACT!CE AND PROPERLY APPLIED 2.

ACCEPTAELE ACCURACY 3.

REVIEW 0F TDI'S ANAL;YTICAL, OUALITATIVE, A!'D EXPEP!ECL DATA IMPLIES A LIFE CONSISTENT WITH EXPECTED GGNF PLANT LIFE 4.

PRELIMINARY RESULTS OF THE INDEPENDENT STRESS ANALYS'S INDICATE THAT STRESSES ARE WITHIN DEMA REC 0f',tiENDED' ALLOWAELES

,,.-,,r, mm.

. ~__,._...... _ _. _., _,_, _. _, __%.1

_,.r

__.y~,..,

m.._,

SHOREHAP AND GGNS CRANKSHA.T DATA

-(..

Ss:REHAM R SERIES GRAND Gulf RV SEc:ES

-WEB WIDTH 21 IN.

25 IN.

. WEB THICKNESS 4-1/2 IN.

5-1/8 IN.

l-WEB SHAPE FLAT SIDED Rout:t CRANK PIN DIA.

11 IN.

13 IN.

FILLET RADluS 1/2 IN.

3/4 IN.

FILLET FINISH tc SHOT PEENED SHOT PEENED FIRST MODE NATURAL FREQUENCY 2323 VPM 1730 VPM

~

i l

l i

L

g b,,

FC^CTURE Pt.C N E I

13, CRANI f[

il, CRANiti IN If SIIAFT e

l[ SilAF T

-s I

s

-e-

)-

N

- ', - ')

-l I"

COUNTERwDGHT g

g y

- ) - 4.-

l-(

&)

J m

'SHOREH AM - REPORTED a

No muMTERwEir.His SECTION "AA HOT ATED 90' GGNS CONFlGURATION

_SHOREHAM CONFIGURATION l

et a3 l

44

'j es s

es f r^

.. " 5 A.

/r

\\

g,s u

e

/

I

-4 3-f

(~~ ~l f 3 l

d'

'. _ _. -.g'l

.d iE 1

16 CYL I.N. DER F

- =

i N m_ '.

M - 56__3G _a.M...-1 l

[e l

g t

p i- -

1

_.p_

I

-- _ _ _..m %3. ID-5 lnmEmm,kmqc.nts!.

n4n g

i h--A 7

l

SilAFT COEFFICIENTS X

LOAD COIFFICIENTS X

ENGINE C0FFFICIENTS X

AMPLIFICATION FACTOP SHAFT

=

\\

/

\\

/

\\

/

\\

/

V V

. SHAFT PROPERTIES

. CYL. GAS PRESSURE

. NO. OF CYLINDERS

. RATIO OF EXCITING g

N (MATERIAL E GEOMETRY IPIERTIA EFFECTS OF FIRING ORM R FREQUENCY (LOAD pE

. NATURAL FREQUENCIES RECIPROCATING PARTS. ENGitlE CONFIGURATION HARMONIC COEFFI-E{

R F10DE SHAPES (IN TERMS OF, LOAD CIFNTS) TO SHAFT IIARMONIC COEFF1-NATURAL FREQUENCY 5

CIENTS) j

l e

SMAFT COECFICIEriTS CONVEFTSAL"i:TTORCUETdASHAFTSTFEf5 GENERALLY 15 EEDUCED k'liF LAPGEP SHAFT DI AMETEF It!FLUENCED SY SHAFT t'0DE SHAPES s

1 l

LOAD COEFFICIENTS COMSINATION:

CYLINDER GAS PRESSURE CURVE 1

0 b

~

SHAFT ANGLE INERTIA EFFECTS OF RECIPROCATING PAFTS (P!STON

CON'ECTINC PO REPFESENTED EY SERIES'0F HAP.MONIC FU.'.; TIC'i!

U nf V

U B

V V

V

1 O

LEGEND:

1983 TDI ANALYSIS 160 -

0F M al DIESEL AVERAGE VALUES FOR 14e0 -

DIESFL ENGINES SIMILAR TO 120 -

MPat DIESEL (DOES NOT

~

INCLUDE INERTIA EFFECTS)

I 100 -

i

=

l S

M-I C

I I

E I

l e

I 60 -

8 I

I r

I a-l l

l l

i i

I i

l i

i l

l l

20 -

i l

l l'

1:

d i: d<

a 0

1 2

3 4

5 6

7 8

IIARMONIC COEFFICIENTS TYPICAL LOAD HARMONIC COEFFICIENTS FOR EMERGENCY STANDRY DIESELS

l ENGINE CCEFFICIENTS COM?: NATION OF LARGE NUMPEe OF CYLINDERS (IC) AfD F!:!f;G CDE:

PLU VEE COM: 10VPAT10N RESL'LTS IN DES!RAELE PFAS!?'O tlHlCF FECUCES OVERALL YlEPATORY TCrCUE EFFECT PARTICL'LARLY IN THE Tr0l'FLESOf'E LOVE: HARMONICS

12 -

i l

n-

~

\\

10 -

9-8-

7-r i

=

w 6-

\\

I u.

I u-5-

4 wou l

w 4-i z

l o

l 2

l 3-w 2-1-

1 l

Iiii 0

i 0

1 2

3 4

5 6

7 8

9 10 i

l EEINE HARMONIC l

F EINF C0FFilCIENTS FOR MPAL STANDP.Y DIESFLS (IsT MDDE) i

l e

1 l

1 12 t ac l 2 ly 10

, u.

8" 45' 6"

lE ii' lQ 4

2 lill li........

0 0

1 2

3 4

5 6

7 8

9 10 HARMDMIC ORDER AMPLIFICT.IION FACTORS FOR MPal EMERGENCY DIESEL (1sT MODE NO DAMPING)

r t

WEF APEI ENHAtlCE? EY CPEATEP WIDTH AND THICKNESS CIPCL' LAP SHAPE GPEATER FlLLET RADIUS E IPPROVED FILLET Fit'ISH

s CONCLUSION:

COMBlf'ATION OF

- REDi' CEC SFAFT COEFFICIENTS (13" DIA. SHAFT)

- REDUCED ENGINE COEFFICIENTS IN LOWER 41RPON!CS (WHERE LOAD COEFFICIENTS ARE HIGH)

AfID AT SHAFT fiATilRAL FRE0llENCIES (WHERE AMPLIFICAT!0t' FACT 0PS ARE HIGP) g RESL'LT IN ACCEPTABLE TORSIONAL V!ERATOR SFLcT STRESSES WITHIN DEMA Sl'GGESTED ALLOMAELES s qu y, e

IMPP.0VED GEOMETRY OF WEB AREA FURTHEP REDL'CES STRESS LEVELS IN THOSE AREAS k

\\

%iI&uerd!iSi f&ng!E ?!

sis E

.[...F v. m u....... e _ _ -........

=g p;

i l at i t ui ' : ii i l 1

l rn-s

11E?~

=maa.=

- wlll w

t 3

n fy'"

js --

a c~ b:.u m:= <-

2. :

A e

a stems Mgf!

I 8

s;C$difii[Ed lli e

~

a::vp

i

_.-_ _ ' mfg-i 5 lif.i.

f

)

/

i 1-

.. ' _ _..a.n t

-/

p.

....n i 1

i f:--

.________.....i

/

.\\M R.1-. m.a.n s

.\\;;.,

7*'g 9;.

I ;.

,. s. _p 7

9

.u

/

v is t".

E

~N. l $

t f

'h l

I j

/

g.

ni s

,4

\\

Is

%.~.~.

?

u x g'%'y

'==e n

a

~

l NN'N ee =...?

g -

g*

)

/ _,*,*

\\

\\ \\

J.og':;

yf

., g,//

E

~

. 68.O $.

.... - ; j

'56 *_' _._

'~- ~~ ~ T

CONNECTING ROD SEarlNGF 1.

LILCO REPORTED CRACKS IP FOUF BEARINC SHELLS 2.

POSSIBLE CAUSE:

SURFACE POROSITY AND "0\\'EPHANG APPANGEMENT" 0F EEARINC/ CONNECTING ROD ASSEMPLY 3.

GGNS DIV !! D/G ROD PEARINGS INSPECTED NO CPACKS ESSENTIALLY FREE OF POROSITY NO APPRECIABLE WEAP.

NC "0VERHANG APRANGEMENT" INTEGP.lTY C-00D:

NOT AFFECTED FY PREVIOUS SERVICF 4.

OLD EEARINGS WEP.E PEPLACED WITH NEW EEARINGS TO EXPEDITE RETURN TO SERVICE AND EXTEND REPLACEMENT PERIOD 5.

INTEGPITY OF REPLACEMENT BEAFINGS BASED ON: ;

REPLACEMENT BEARINGS WEPE EXACT PART NUMBER EXCHANGE FAV0PABLE RESULTS ON EXTENSIVE INSPECT!ONF/ ANALYSES CONDUCTED ON ORIGIPAL BEARINGS INSPECTION PERFORMED PT,10R TO INSTALLATION L

6.

ADDED ASSURANCE REGARDING INTEGRITY OF REPLACEMENT EEARINGS TO EE PROVIDED BY CONFIRMATORY ANALYSES i

d

n n

Anin:lar grccve

'N Oil n

w ol pin

)

,?~l l.

C~

\\

/

S crea t er a

~

'./

grcove

,e

. -f C:we

.1 SathitV '

N ne,,

\\

arting line overlay on suMace s

S 4 Lc wsiw or C2.Act.

[

\\-

l

(

Insie' dia m e t er

/

! L en e:.-

/

I CONNECTlhG ROD BEARING DESIGN AND NOMENCLATUhE (SCHEMATIC)

SHOREHAh 4

L

COMMEC TING ROO 0 3 -3 40 - 0 3 - O C

%\\\\

A I' 'NE

...+ ;.,..,;,;.

6 RG. 3MFCL a

03*340-03%0A q

L~

A= F = s: r >> e 2 i n. a.

R (""casaxrin)

SCHEMATIC OF SHOREHAM "0VERHANG ARRANGEMENT" INDICATING UNSUPPORTED BEARING MATERIAL CONNECTING ROD 02-340 - t I - A.s

,kx 45

CHEN N

,L s 4S* CHF.

~

A g

BRG. S HEL L h

0 2-34 0 - o4. AG I

~

^

%A = 78. 2 7 IN5 13*CI A.

gy ( 13"CR ANKPIN)

L SCHEMATIC OF GGNS BEARING AhRANGEhENT WITH BEARIhG MATERIAL SUPPORTED

%.u a mas.

PISTON SKIRTS

(

l.

INSPECTION OF SHOREHAM MODIFIED IYPE "AF" PISTON SKIRTS INDICATED CRACKS.

PART 21 NOTIFICATION FILED BY IDI 2.

GGNS'ALSO HAD MODIFIED AF SKIRTS AS A RESULT OF A PISTON CROWN-SKIRT SEPARATION ON GGNS Div II D/G IN OCTOBER OF 1981 3.

TDI RECOMMENDED INSFECTION OF 257. OF M ::. iED ' A?" rIST;.

SKIRTS, 100% IF LINEAR INDICATIONS FOUND ON 25% }NSPECTICT:

4.

LINEAR INDICATIONS WERE FOUND ON SEVERAL DIVISION 11 PISTCN SKIRTS 5.

ALL DIV I AND 11 D/G PISTON SKIRTS REPLACED WITH NEw TYPE "AE" PISTON SKIRTS 6.

LINEAR INDICATIONS DID NOT IMFAIR THE OPERATION OF TEE GGNS DIESEL GENERATORS i

L l

i

l PISTON COMPARISQNS

(

\\

W 7, '.

r i

V// / /// /INNN l

b

-- n-

</ /// /

,. h,k. -

l 48 SKIRT gnga..

w<-

03-3 s o-0 A-A C

\\

l. 4

~

..........-..,ep.

i i

i 4

Y

(

N-Y J

J FULL STA C K

$XlRT BELL f!LL E STTLE hh0D \\ C tG D kW l

r. 4

2. 4 l

l f

r/

. [,.

~... -.............

[f s'..

- i

'g l

N wx - -

t 7

a L'

i--

t

?rsex S WIMT S EL W/'l L E STYL E C3-34 !- C A - A E R

& N. M

CONNECT 0k PUSH RODS

(

1.

DURING MAINTENANCE ACTIVITIES CONNECTOR PUSH ROD FOUND WITH DEFECTIVE EALL-TO-TUBE WELD ON AUGUST 11, 1983 2.

REPLACED DEFECTIVE CONNECTOR PUSH ROD AND ESTABLISHED-INSPECTION SCHEDULE

~

3.

SUBSEQUENT' INSPECTIONS FOUND.'- Cr l#

7-~~'

D7G AND 13 cF 16 DEFECTIVE Oh DIV I.,S PUSHRODSWEREREDESIGNEDBYTDI&MPELUSINGikFROVED 4.

FABRICATION TECHNIQUES 5.

ALL PUSH RODS SCHEDULED TO BE REPLACED

(

6..

PUSHRODDEF5CTSDIDNOTIMPAIROPERATIONOFTHEGGh5TDI DIESEL GENERATORS b

,.s.

n'

\\

P F - 0 05 - 074 FILLET WELD EACH END p______9 7 9 7

q>_ _ _. _ _y 4

+

1 _ _7

(+ _ A s s s j - - - - 4)

L- - -

- - L,.A y I

II

'lk WELDED BALL CONNECTr"?

?:

b[

03-390 -o4 - Aa

I

.i

,I P

n' n;

e i

- OC-3 9 O-Q7-AE O2-39O-07 Ar F RICTION WELQ EACM EMD 3 4 S

- _,7

- __ [

y i

t PUSHR..OD, IhJTAKE AidD EX'HAd57 l

.oa-39o - 07MH..

m

,?.@

(I\\

e-

.)

I

CYLINJEF HEADS 1.

DURING DISASSEMBLY OF DIV II D/G FOR PISTON INSPECTIONS, RED RUST WAS FOUND IN AREA 0F EXHAUST VALVE SEATS #5EE HEAD

~

2.

ALL HEADS INSPECTED VISIBLY AND WITH LDP 3.

SIx HEADS ON Div I D/G AND TWO HEADS ON Div II HAD REJECTAELE INDICATIONS ON EXHAUST VALVE SEATS II SUSFECTED.F HAVING WATER JACKET LEAK 14.

ONE HEAD ON DIV 0

5.

HEADS WERE REPLACED WITH DEFECT-FREE HEADS FROM UNIT 2 TDI D/G'S 6.

INVESTIGATION CONTINUING 7.

HEADS WITH REJECTABLE INDICATIONS DID NOT IMPAIR OPERATION OF THE DIESEL ENGINES

(

~. n ~-

2

.~

c :qL,.+..,..==_

C

.i-

'Md';_

'.4,

-e_%

i ts_..

_- c

$&kW Q a ' '"- M.. ? ] !

,,y.-

6 4.ERL2. : =-

_e

\\

m m

g. e.. r_-- @-

\\

+

r+_=- M - -

11.,

9. 3 M

'?.. :

-rr.2 s % f

m. t s., r

,=. -25

\\,. ;.<->

m ;__

m

a.

,:::=4

. ~+ Y - ~ ~- -s...F ~ T LC f i,.

...-. A.n 7 r._ :.. e ~ m ' q :. r s.- 4.s-

.... g.- w -~

-~~--

.'..?..- V T T.f -'j

' O '*OY.

"* l. 1 p, _-- --- _ -..._'_t-k-%S.

r.

., Pg DIVISION 11 D/G NO. SRB EXHAUST VALVE SEAT C

O~o

-n o

30 O

o

/r

/@ O o

t O) ' o o

@y

/A Oo_. r50

(

COMSUSTION SIDE OF CYLINDER HEAD s.

LOW PRESSURE FUEL OIL LINE 1.

LOW PRESSURE, FUEL OIL LINE FAILED SPRAYING FUEL OIL ON EXHAUST PIPING CAUSING A FIRE AND MAJOR REWORK ON Div i D/G 2.

1 INCH IUBE INSTALLED BETWEEN ENGINE MOUNTED FUEL FILTERS AND ENGINE SUPPLY-HEADERS FAILED 3.

METALLURGICAL EVALUATION PERFORMED 4.

L::,E i,.1-D AT SWAGELOK FITTING DUE TO hlGn CYCLE FATIGU5 5.

CAUSE WAS DUE TO VIBRATION FROM IURB0 CHARGER THAT HAD EEEN

~

REPLACED PR10R TO THE FAILURE OF THE LINE COMPOUNDED BY MISSING IUBING SUPPORT 6.

A SUPPORT WAS DESIGNED AND INSTALLED ON FUEL Olt LINE ON DIV C-I AND 11 D/GS TO PRECLUDE SIMILAR FAILURES 7.

ENHANCED VIERATORY EVALUATIONS PERFORMED DURING SPECIAL TEST RUNS 8.

PROELEM SULVED BY ELIMINATION OF UNUSUAL VIBRATION SOURCE AND INSTALLATION OF SUPPORT BRACKET 9.

VlBRATION VALUES WERE TYPICAL OF THOSE EXPECTED FOR LARGE INTERNAL COMBUSTION. ENGINES k.

.~ ----

/ \\

fN PIPE CROSSOVER HE ADER y..

)

i ENGINE

/CVL.LS.

(J)

CLAMP PIPE CVL.A.g4T Ia

/

'J)

PIPE CROSSOVER - FRONT

\\)-

N * * """ '"' "

if,

una0-1 N T.

~

SwA4fL0tt Tutt - I" O.D. SML.

MAutT-FRONT PW (TUSING FAILUr"

' w* --b*

('

POINT l SetACNEY - FRONT PIPE

__,'g'*_':--,...-g*

CLAMP PIPE F

7 f

(6 00SHING, REOUCING i

g g'

h...a.

,U

, j f0

<g

~j L

CONNECTOR. MALE l

6

=

I' g

j Il

{

'4

/

10 N. P.

FUEL INJECTION PUMP

_... _. 5 4

.I--..

.i FILTE R

,..ll.f

)%,

y

)t iu f

- Q'k.'b

._..]!'T

\\

' s' y + - r. N.. p v..)<,,, i

.m.

r.~

l I..

~,,, P i

,.~

5 u.-

y-

.y w m

.7 4, 1

-k hy\\

p.p

. UL N:t.___

.;9 q,,.b/> / g tm

%r p

m I'

I

,j)

[

.. o t*

g' l

STR AIN E'R is

}

i DELAVAL D I V. 1 FUEL OIL-HEADER AS.

iJ:_

l

O fue i C.~1 Cross Ac< (, d

(

}'? 4,'

pg.(Q

_ I.....

~

flatteninJ _ k[ free f7f E

?

~>

t NA

~ fticNiq uf N f

.. 5% -

/

3+

,..: t.;

C.hemo d j ' ""f l-

.. d. "

(

.:.. Inadass E etng Ltdat

,7,..;-

..'yl....

.Qilbii Rlta Ud

'. ' ~

LOW PPESSUPE FUEL OIL LINE THE FAILURE OCCURRED AT THE SWAGELOK AT THE END OF THE LO STRAIGHT RUN (UPPER MIDDLE ON THE PHOTOGRAPH),

THE FUEL Olt LINE CONNECTS THE FUEL FILTER MOUNTED ON ENGINE BLOCK (SWAGELOK, LOWER RIGHT HAND ON PHOTOGF.APH) TO A FUEL DISTRIBUTION LINE ANCHORED TO THE TURBOCHARGER SUPPORT STRUCTURE.

FAILURE OCCURRED AT THE SWAGELOK FITTING CONNECTil?G THE FUEL Olt LINE TO THE FUEL OIL CROSSOVER LINE.

{

e

i

(

i 1

cou.eh X anmh %

g,.u lari-caue<<U" 4

g e

'd.

Dd 5,..

.a r.

1 o

1

. Y"--

.~

h)

C

6 '

l;..

~

'.ne:.;,h ;3a g.1,;n38, :--~. $

Esd femh g

. 4c'*gc_. ftmis-. '.. o f :' ~

.s s-

_... m _ _..w a..

+>

. r, ;- u

~.

i EXPLODED VIEW 0F THE SWAGELOV. FITTING WHERE FAllVRE OCCURRED THIS FIGURE SHOWS HOW A SWAGELOK FITTING IS ASSEMBLED, ALSO OBSERVABLE ON THis FIGURE IS A WEAR MARK ON THE BULGED STUB 0F THE TUBE.

L i

l

lD D

q f

ENGI.NE l0lNTED af0ENTS PROBLEMS ITEM DESCRIPTION OF PROBLEM CAlEE CORRECTION A.CTION

]

CRACKED WELDS AND BASE NTAL FATIGUE COMPOUNDED BY lllG1 REAPAIRED WELDS AND BASE NTAL CRACKS ON INTERCOOLERS.

VIBRATION FROM IURBOCIIARGER.

CRACKS.

RESEATED TURB0CitARGER To ELIMINATE UNDUE STRESSES-CAUSED B.Y MISAL'GtNENT.

2 CRACKED WELDS ON JACKET WATER FATIGUE COMPOUNDED BY ll!GH RI. PAIRED WELDS.

REFABRICATION FLANGES AND PIPING HEADERS.

VIBRATION FROM TURBOGIARGER.

IlEADER To ASPE 111 CLASS 3.

RESEATED TURBOGIARGER.

3 loN PRESSURE FUEL OIL llEADER FATIGlE COMPOUNDED BY lllGH REPLACED FUEL liflE AtlD FITTirnS FAlltRE RESULTING IN Div i VIBRATION FROM TURBOCHARGER.

RESEATED TURBOGIARGER.

i FIRE.

Il IllGil PRESSURE FUEL INJECTION FATIGUE CAUSED BY CYCLIC REPLACED ONE litlE ON EACli FtmlNr.

LINE FAILtRE.

LOADING OF FUEL IPUECTION PUMP EVALUATED REST AS OK, POTrNTI Al.1 y Ill CorelNATION WITH INTERNAL REPORTABLY DEFICIENCY BY IIll.

SEAM (DRAW MARK).

HIGH PRESSURE-FUEL OIL LINE 1.

Two HIGH PRESSURE FUEL OIL LINES FAILED AT SHOREHAM 2.

TDI IDENTIFIED DRAW SEAM IN HIGH FRESSURE-FUEL OIL LINE DUE To MANUFACTURING DEFECT IN A LIMITED NUMBER OF TUBING PARTS 3.

ONE LINE FAILED ON DIV I D/G AT GGNS AFTER 1,000,000 CYCLES 4.

CONFi.~.;cT'.', I T;...Li3.C*L E

.S SH0wS SIMILAR DRAW SEAM DEFECT IN GGNS FAILED LINE.

ANALYSIS VERIFIES Low CYCLE FATIGUE 5.

ONE LINE ON EACH D/G CONSIDERED SUSPECT BECAUSE OF Low NUMBER OF CYCLES AND BcTH WERE REPLACED 6.

REMAINING. LINES HAD 10,000,000 (HIGH) CYCLES AND WERE (c

CONSIDERED FREE OF DEFECTS OF THIS TYPE i

-m,

e.

sn _ a r.

DIV 11 D/G REAR CRANKCASE COVER CAPSCREWS 1.

REAR CRANKCASE COVER CAPSCREW ON DIV 11 D/G BROKE HEAD ENTERED GENERATOR AIR GAP, DAMAGING THE GENERATOR AND REQUIRING REPLACEMENT OF THE GENERATOR D'URING PRE-OP TESTS

~

2.

FAILURE DUE TO L0w STRESS FATIGUE J.

COMFRE.-ENSIVE TESTING PROGRAM INDICATED PROBLEM UNIQUE TO.DIV 11 D/G 4.

TEST RESULTS INCONCLUSIVE AS ROOT CAUSES OF VIBRATION SOURCES 5.

SCREENS INSTALLED ON GENERATOR AIR GAPS

(

6.

HIGH STRENGTH CAPSCREWS AND TAB WASHERS INSTALLED 7.

CONTINUING 'lNVESTIGATION - CAPSCREw PERIODICALLY REMOVED

-FROM Div II AND SUBJECTED TO DESTRUCTIVE ANALYSIS FOR FURTHER INFORMATION 8.

SURVEILLANCE MONITORING AND PROTECTIVE MEASURES PREVENT RECURRENCE l

(s.

~ ~. wu

FT ~

RETEST AFTER PISTON /EEARINI, REPLACEMENT 1.

BREAKIN RUN 2.

INTERNAL AND EXTERNAL INSPECTIONS 3.

100Z LOAD REJECTION 4,

2h HOUR. RUN - 2 HOUR AT 11^" AtT 22 HOUP AT 100%

5.

MONTHLY SURVEILLANCE - RATED SPEED AND VOLTAGE 10 SEC f

e i

SdKMARYOFQUAllFICATIONANDVAllDATIONTESTING RE0 ADDITION:L QUALIFICATION TESTING X

PREOP TESTING X

TECH SPEC TESTING X

7-DAY EQUIVALENT TEST X

VIBRATION TEST RUNS X

PISTON INSPECTION X

CRANKSHAFT INSPECTION X

ROD BEARING INSPECTION X

BREAK-IN RUN X

LOAD REJECT X

("

24-HOUR RUN - 2 HR a 110%, 22 HR a 100%

X MONTHLY SURVEILLANCE X

(1)

INCLUDES STARTING, LOAD ACCEPTANCE, OVERLOAD, DESIGN LOAD, i

REJECTION, RELIABILITY, ELECTRICAL AND SUBSYSTEM TESTS.

(2)

INCLUDES MONTHLY SURVEILLANCE AND 18 MONTH FUNCTIONAL TESTS F

r GGNS TDI D/G OPERATING DATA h

DIVISION 1 DIVISION !!

SHOP AND PRE-OPER. RUN TIME (HRS) 535 252 SINCE DATE OF OL Run TIME (HRS)

N j.Q.h (3)

~

TOTAL RUN TIME (HRS) 1127 756 TOTAL NO. OF STARTS DELAVAL SHOF RUNS

?!f -

5 PRE-OPERATIONAL RUNS 60 60 SINCE DATE OF OL RUNS j.EQ 1Q1 TOTAL STARTS 510 166 NOTES:

1.

SOURCE OF INFORMATION - DELAVAL TECHNICAL MANUAL

(

2.

DIVISION I ENGINE HAD 300 PROTOTYPE RUNS FOR RELIABILITY TESTING 3.

DATA AS OF JANUARY 16, 1984 4.

VALID STARTS:

DIV. I

- 69 D iv. I I - 4.L8 TOTAL 117 VALID FAILURES:

1 (DIV. I)

START RELIABILITY:

99.1%

L

\\

\\\\

'k-b\\.6e

<**L 6

Off E'

1,,o y-7 4

W- --CD F"

(

h) m m.

r..,

M e, m f_^ L1A-pa--a)

M a' n r

G e ne ra+=<

G Q^=

[-

oo a ano aa O No n

ESF A

ESF S

ESF C

C C3

(

's

l Dias. l y ;,,, \\

m..u m A

t GRAND GULF, NUCLEAR STATION UNIT I o,

ONE LINE DI A38 TAW 5

II d

I s,

g g

~

I A

A A

l I ""

u O

6 6

6 I

O O

O i

I O

O O

O I

I l

soo av l

wtST SUS 1

dt. 8..

4 JL, C

'YTV

'Y T

~

g 41 41

'T T

'T T g, fh) gt av 34.s av 34.s av WasIT E Y etn WJLe 4

JLi W4 F7 F7 F7 r7 F7 r7 4.16 KV 4JG Ky dje av i

N.tlL m.0.

kA D

Den n.

Unt? I uuse? I unsif I EF 17 AC EW 16 AS E5p SUSISAA l*nPCS PU.P 3.ews puurs I.L CS Puur P

...P..

O, rg,;, _,y

........,,.v.

c3 g

-T=

~ '

G O

t?

t'fa

~.!!A..

on*

..w C\\

L.

A A. it

UNDERV0LTAGE INCIDENTS ON DIV i AND 11

(

h.16 KV ESF BUSSES 1.

14 INCIDENTS IDENTIFIED FROM INCIDENT REPORTS 2.

IN ALL INCIDENTS 1 OR MORE SOURCES OF 0FFSITE POWER REMA:NED AVAILABLE 3.

D:v 1 AND 11 D/Gs STARTED AND I!ED TO.EESFL;TIVE SUSIES WHE!.

IN STANDBY AND CALLED UPON

(

i L

i k

l I

OTHEP CONSIDERATIONS LOSS OF 0FFSITE POWER IS RARE IN USA GGNS HAS STRONG, RELIAELE SYSTEM PLANT HAS ADV;"CE.3.'!:T :..L'Ti" E:::::

PLANT HAS RCIC AND HPCS CAPAEILITY e

REI.IABILITY ENHANCE.U.ENT PROGFM.

l I:OROCC::TS I

SURVEILLANCE I

[

N ENHANCED RELIABILITY j

~

DESIGN REVALIDATION I

h O

I

-.e----,-,__,n_,

_.--g-

,,,-,,.r-

TDI PRODUCT IMPROVEMENT PROGRAM

(

l.

OBJECTIVES:

e ENSURE D/G OPERABILITY /REL!' ABILITY e

EXTENDING COMPdNENT LIFE

~

e ALLOW EASTER MAINTENANCE 2.

IMPLEMENTATION:

e ISSUANCE OF SERVICE INFORMATION MEMOS (SIMS) ADvlSING TDI OWNERS ON:

A.

IMPROVED DESIGNS DEVELOPED BY IDI B.

DESIGN CHANGES C.

ADDITIONAL MAINTENANCE GUIDELINES e

MODIFICATIONS REQUIRED TO CORRECT DEFICIENCIES REPORTED BY TDI OR TDI D/G OWNERS UNDER 10CFR21 e

DESIGN CHANGES RESULTING FROM OPERATING EXPERIENCE SY TDI D/G OWNERS 3.

GGNS INTERFACE a

0 IMPLEMENT MODIFICATIONS RECOMMENDED IN SIMS AND 10CFR21 REPORTINGS, AS APPROPRIATE e

REVISE MAINTENANCE PROCEDURES e

INSTALL OR REPLACE EXISTING D/G COMPONENTS WITH COMPONENTS OF IMPROVED DESIGN

(

t l

l DESIG'N REVIEW /0UAllTY REVAllDATION (DPCR) PROGRAM i

PROGRAM OBJECTIVE:

e DROR PROGRAM IS BEING DEVELOPED TO CONDUCT A DETAILED REVIEW OF THE TDI T/G DESIGN AND TO PERFORM A RIGOROUS QUALITY REVALIDATION OF EACH D/G COMPONENT IN ORDER TO PROVIDE REASONABLE ASSURANCE THAT THE TDI D/GS WILL PERFORM THEIR INTENDED SAFETY FUNCTION f

(

L t

i

.A 7 5 3

y DESIGN REVIEW /00ALITY REVAllDr. TION (DPOR)

\\'

SHORT TEPM 8 LONG TERM PROGRAM

~

l TOBEPERFORMED.UNDERTDID/GOWNERS'UROUPCHARTER LILC0 DESIGNATED AS THE TDI D/G 0WNERS' GROUP PROGRAM MANAGER GGNS ENGINEEPS HAVE JOINED THE OWNERS' GPOUP TECHNICAL TEAM OWNERS' GROUP INCLUDES GENERIC Af'D SPECIFIC COMPONENTS OF V-16 ENGINES AT GGNS h

8

,f s )'

s DROR PROGRAM OUTLINE THE DROR PROGRAM IS DIVIDED INTO FIVE (5) MAJOR STEPS:

A.

COMPONENT SELECTION

~-

B.

TASK DESCRIPTION C.

DESIGN REVIEW D.

QUALITY REVALIDATION E.

FINAL REPORT e

3

~

TASK DESCRIPTIONS g-(

THE TASK DESCRIPTION WILL PROVIDE:

1..

COMPONENT FUNCTION AND DESIGN SPECIFICATIONS 2.

APPLICABLE CODES AND STANDARDS 3.

ALTERNATE CODES, STANDARDS, OR ANALYTICAL TECHNIQUES 4,

ANALYSIS OR EVALUATIONS TO BE PERFORMED TC ASEURE SATISFACTORY DESIGN 5.

AVAILABLE VERIFICATIONS OF TDI ANALYSIS 6.

DOCUMENTATION REQUIEMENTS

(

7.

SCHEDULE FOR COMPLETION L

I

-m.

,3 COMPONENT SELECT 10t' COMPONENTSELECTIONISEASEDONC0t?0NENT'SFUNCTION/

IMPORTANCE TO OPERAT10N'0F THE ENGINE _

COMPONENTS ARE CLASSIFIED INTO THREE (3) CATEGORIES:

A.

THOSE COMPC#ENTS luiOSE FAl' "~. ' :' ! RESULT I t' D/G SHUTDOWN B.

THOSE COMPONENTS WHOSE FAILURE WILL RESULT IN REDUCED D/G CAPACITY OR EVENTUAL FAILUPE OF TYPE A COMPONENTS C.

COMPONENTS WHOSE FAILURE WILL FAVE LITTLE EFFECT ON D/G OPERATION MP8L TEAM IS ACTIVELY WORKINE ON PROGRAF a

-~--m--

DESIGN REVIEW DESIGN REVIEW WILL BE PERFORMED FOR EACH COMPONENT BY ANY OF THE FoLLOWING METHODS:

1.

INDEPENDENT CALCULATIONS 2.

INDEPENDENT REVIEW OF THE ADECL't ?',

f rir-ce '

r*:E 5 ?

I :..C -

CORRECTNESS OF EXISTING VENDOR AND/,

i:. T..

e LATIONS 3.

TESTING 4.

OTHER APPROVED METHODS k

t

00ALITY REVAllDATION THIS PROGRAM WILL BE PERFORMED ON EACH COMPONENT IN ACCORDANCE

~

WITH THE FOLLOWING:

1.

LIST QUALITY ATTRIBUTES TO BE EVALUATED 2.

D?CUMENTATION IDENTIFICATION (MATERIAL TEST PEPcRTS, NEE, VENr0R/5;;,Er.DcR QA RECORDS, ETC.)

3.

DOCUMENT REVIEW FOR ACCEPTABILITY 4.

IF ACCEPTfBLE DOCUMENTS DO NOT EXIST, DEFINE IESTS

~

AND/OR INSPECTIONS TO BE PERFORMED 5.

DEVELOP METHODOLOGY AND PROCEDURES FOR TEST AND/OR C

INSPECTION 6.

PERFORM INSPECTION AND/OR TESTS ON THE ACTUAL COMPONENT OR PROTOTYPE COMPONENT 7.

PREPARE A REPORT OF FINDINGS AND RECOMMENDATIONS FOR CORRECTIVE ACTION L

+

REQUIREMENTS F0F LICENSING t.

1.

RESOLUTION OF SIGNIFICANT KNOWN PROBLEMS GENERIC (IF APPLICABLE)

ENGINE UNIOL'E 2.

COMMITMENT TO DROR PROGRAM 3.

COMPONENT SELECTION (DROR) AND PRELIMINAPY PE\\'!EW 0F SELECTED COMPONENTS FOR SIGNIFICANT ITEMS 4.

COMPLETION OF PREOP TESTING AND ANY ADDITIONAL TESTINC (100 HOURS AT FULL POWER FOR SOME UNITS) 5.

COMPLETION OF ANY MAJOR INSPECTIONS (CRANKSHAFT, BEARINGS, AND PISTONS)

e a'

CONCLUSIONS 1.

DESIGNED, PROCURED, MANUFACTURED, INSPECTED, AND TESTED TO INDUSTRY STANDARDS 2.

OPERATING HISTORY SHOWS HIGH STARTING RELIABILITY:

GREATER THAN 98% (IN ACCORDANCE WITH R.G. 1.108) 3.

PROBLEMS ENC 0UNTERED HAVE BEEN STUDIED AND CORRECTED 4.

MPal INITIATED AGRESSIVE PROGRAM FOR FURTHER STUDY SRC RECOMMENDATIONS OWNERS' GROUP FOR D/G RELIABILITY DROR PROGRAM 5.

MPal ELECTRICAL SYSTEM:

RELIABLE DESIGN AND PERFORMANCE OVERALL:

GGNS D/G PROVIDES RELIABLE SOURCE OF EMERGENCY POWER O

e

.n

85N,Erm mcr.osos 1

" W #i TRANSAMERICA DELAVAL HAS SUPPLIED THE DSR FOI. LOWING SITES:

IITTLTTY SITF SFotAI. NO, MonEL LONG ISLAND LIGHTING SHOPEHAM 70n10/p DSo up

.viDDLE SOUTP ENERGY GPAND GULF

un?? /3R DSpV in GULF STATES UTILITIES RIVER BEND 70nyn/np pgp gg CAROLINA POWER A LIGHT SHEARON HARDTS 70006/40 DSpV 16 DUKE POWER COMPANY CATAWBA 75017/20 DSPV '6 SOUTHERN CALIF 0PMIA EDISON SAN ONOFRE 75041/u7 nsnV 99 CLEVELAND ELECTRIC TLLUM, DERPY 75051/50 DSRV 18 T1/A BELLEFONTE 75090/83 DSPV 16 WASHINGTON PilBLIC POWER WPPSS 1 7508u/85 DSOV 16 WASHINGTON PUBLIC POWER

WPPSS u 76031/39 DSRV JR l

TEXAS UTILITIES SERVICFS COMANCHC PEAK 7A001/0h PSPV ]6 GE0AGIA POWER V0GTLE 76071/20 DS9V 16 CONSUMEDS POWER MIDLAND 77001/ou nSpV I?

TVA*

HARTSVfLI.E/

770?u/39 DSAV 1R PHTPPS REMD SMllD QANCHO SECO P 1.015/16 PSD 49

' PROJECT DELAYED OR CANCELLED 9

n._.

U S, NUCLEAP EXPERIENCE WITH

~

TDI DIESEL GENERA W S SAN ONOFRE 1 GRAND GilLF SHOREHEAM 1

CAN ONOFRE 1 TWO TDI DIESEL ENGINES INSTALLED IN 1976 - MODFL OSPV-?n DECLAPED GPERATIONAL IN APPIL 1977 FNGINE OPERATING TIME TO DATE - 450 H0llRS/ENGINF SEPT AL N0,' 790h.1/h?, PATc0 AT 6n00 Kw (NnMINAL) 9800 VW (PE.AK)

FIPST TDI ENGINES TO ACTUALLY ENTEP NUCLEAP SERVICE ONLY V-20 JN NUCLEAP SEPVICE S!GNIFICANT PROBl. EMS TO DATE EXCESSIVE TUPB0CHARGEP THRUST BEARING WEAR LUBE OIL LEAK AND FTPE P!STON MODIFICATION TO PPEVENT CPOWN SEPARATTON UNOUALIFIED INSTRUMEf!T CABLE P0TENTIALLY DEFECTIVE GOVERNOR COUPLING MATEPIAL S

e

GRAND GULF TWO TDI EPGINES INSTALLED - MODEL DSRV-16 SERIAL NO. 70033/34, PATED AT 7000 KW OPERATING HOURS TO DATE - DIVISION i = 1100 HOURS; DIVISION II = 700 PollPS FIRST V-!R UNITS IN NUCLEAR SEPVICF SIGNIFICANT PROBLEMS TO DATE PISTON CROWN SEPARATION PISTON SKIPT CRACKS FUEL LINE FAILURES - FIRE CYLINDER HEAD CPACKS TURBOCHARGER PROBLEMS PUSH ROD CRACKS GENERATOR SHORT DUE TO ENGINE FASTENER FAILUPE AIR STARTING VALVE PROBLEMS e

a j

l l

SHOREHAM THREE TDI DIESEL ENGINES INSTALLED, MODEI. DSR-48 SEPIAL NO, 7a010-12, PATED AT 3500 KW OPERATING HOURS AT TIME OF CRANKSHAFT Fall.URE (8/83)

101 = 606 (CPACKED CRANKSHAFT) 8102 = 718 (FAII.ED CRANKSHAFT)

)03 = FIF (CRACKED CRANKSHAFT)

FIRST STRAIGHT-8 ENGINES IN U. S. NUCl. EAR SEpyrrE SirJj!FICANTPROBLEMSTODATE JACVET WATER PUMP PROBLEMS FUEL Oil I.INES RUPTUPED CYL~INDER HEAD CRACKS CRANKSHAFT FAILURES CONNECTING POD BEARING FAILURES PISTON SKIRT CPACKS FAILURES OF SEVEPAL DIFFERENT TYPE FASTENERS

MARINE EXPERIENCE TNFORMATION FROM THREE DiFFERENT OPERATOPS OF MARINE ENGINES -

V-16 AND V-12 ENGINES ENGINFS OPERATING HOURS TO DATE PANGE FROM 3000 TO 30,000 SIGNIFICANT PROPLEMS TO DATE CYLINDER HEAD CRACKS (ALL OPERATORS)

PISTnN CRACKS AND COPPLETE FAILURES EXCFSSIVE BEARING WEAR TURBOCHARGER PROBLEMS CRACKS IN PUSH POD WELDS CDACKS IN CONNECTING RODS CYLINDER BLOCKS l

l l

l l.

i e

1.

r-ll 0 l

ENCTLSURE 2 l

l Delaval Diesel Generator Operation Experience U. S. Nuclear Experience In 1974, the Lono Island Lighting Company (LILCo) contracted with TOI to purchase three emergency diesel generators for the Shoreham Nucipar Power l

Station. This was the first order received by TOI to provide an EDG for a j

commercial nuclear power station.

In the neyt seven years, engineF for la other plants were ordered from TOI.

San Onofre 1 Two TOI. Diesel Enoines Installed in 1976 - OSRV-20 Serial No. 75041/42, Rated at 6000KW (nomina 11 8800KW Ipeak)

Engine Run Time to Date - 450 hours0.00521 days 0.125 hours 7.440476e-4 weeks 1.71225e-4 months per enaine The #irst plant to actually place a TOI engine into nuclear service was San Ono*re Unit 1 (SONGS 1), which purchased two V-20 units to provide emeroency cower for its feed pumps, which also serve as Emergency Core Coolina System cumps.

The enoines at SONGS 1 were installed in 1976, and declared operational in April 1977 Since thee, SONGS has experienced some problems with the operation of the engine.turbochargers, a luhe oil pressure sensino line failure which resulted in a fire, and several other minor problens. Recause SONGS did not commit to meet the guidelines of Reculatory Guide 1.10R, but rather Regulatory Guide 1.9, the program it used to test the engines before they were placed in service was more abbreviated than for a new plant. A detailed list of problems to date follows.

Date problem Cause/ Solution 12/80 Excessive Turbocharger No tube oil durino standby.

thrust bearing wear.

Lube oil system modified.

10 CFP Part 21 report issued because eroblem ceneric.

7/81 Lube oil leak and fire.

Excessive vibration n' a lube oil test ifne which had inadvertent 1v been lef t instelled by the licensee.

Line removed.

12/81 Piston modification to Pistons reworked by TOI to orevent crown separation.

respond to Part 21 recort.

Problem identifiad at Grand Gulf.

9/83 Unc ualified instrurent Replaced in accordece with cah1e.

Part 11 r*00rt.

-2 Grind Gulf

.Two TDI engines installed - Model DSRV-16 Serial No. 74033/34, Rated at 7000KW Operating Hours to Date - Division I = 1100 hours0.0127 days 0.306 hours 0.00182 weeks 4.1855e-4 months ; Division !T = 700 hours0.0081 days 0.194 hours 0.00116 weeks 2.6635e-4 months In 1981 Mississippi Power & Light (MP&L) commenced pre-operational testing of two V-16 engines installed at Grand Gulf Unit 1.

They represent the first V-16 units ordered from TDI, and in fact, one of the Grand Gulf engines was used to qualify the entire TDI V-16 line of machines for nuclear applications.

The Grand Gulf engines have experienced significant problems in completing the pre-operational test program, have had several major failures, including a fuel line break which caused a fire, ano many minor fa11ures. A cetailed list of problems at Grand Gulf follows.

Date Problem Cause/ Solution 11/81 Piston crown separation during Holddown studs failed.

operation.

Pistons returned to TDI for rework. Generic.

problem.

3/81 Excessive turbocharger thrust No lube oil during standby.

bearing wear.

Lube oil systen modified.

6/11/82 Air starting valve capscrews Pospense to Part 21 report, replaced. Too long for holes.

8/23/82 Flexible drive coupling material Replaced with different incompatible with operating

material, environment.

8/82 Latching relay failed during Relay replaced.

testing.

3/8/82 Air start sensing line not Sensing line relocated ard seismically supported.

properly supported.

1/29/82 Governor lube oil ccoler Lube oil cooler relocated to located too high. Possibility lower elevation, of trapping air in system.

3/23/82 Engine pneumatic logic Pneumatic logic design improperly design. Could corrected.

result in premature engine shutdown.

. Date problem

, Cause/ Solution 4/29/81 Non-Class 1E motors supplied Motors replaced with Class 1E with EDG auxiliary system qualified coters.

pumps.

3/15/82 Crankcase cover capscrew Capscrews replaced with failed. Head lodged in higher strength screws, generator and shorted it out.

Lock tab washers installed.

Generator screens installed.

8/2/83 High pressure fuel injection Manufacturing defect in line failed.

tubing. Tubing replaced.

9/4/83 Fuel oil line failed. Caused High cycle fatigue of eaior fire.

Swagelock fitting. Additional tubing supports to be installed.

8/11/83 Cracks in connecting p0sh All push rods replaced.

rod welds.

1983 Turbocharger vibration.

Turbocharger replaced.

' 1983 Cracked jacket water welds.

Excessive turbocharger vibration. Cracks re-welded.

1983 Turbocharger mounting bolt Excessive turbocharger failures.

vibration. Bolts replaced.

7/83 Air start valve failures.

Cause unknown. System cleaned and several valves replaced.

More frequent maintenance scheduled.

10/28/83 Fuel ofi. leak.

Tubing replaced.

Cracked push rod weld.

Push rod replaced.

Durina EDG Cylinder head cracks.

Head replaced.

Installation 12/83 Cylinder head cracks.

Two heads replaced.

12/83 Cracks in piston skirts All Division II pistons on Division II EDG.

replaced. Division I pistons to be inspected.

9/83 Uncualified instrument cable.

Replaced in response te Part 21 repert.

6

Shoreham Three TDI Diesel Engines installed, Model DSR 48 Serial.No. 74010-12, Rated at 3500KW Operating hours at time of crankshaft failure (8/83)

101 = 646 (cracked crankshaft) 4102 = 718 (failed crankshaft)

103 = 818 (cracked crankshaft)

The engines at Shoreham are the first straight-8 units to be placed in nuclear service in the U. S.

One of the Shoreham ergines (*101) was used te cualify -

the straight-8 series (R48) diesel engine for nuclear service.

Pre-operational testing of the enoines at'Shoreham started in late 1981 and continued until the major failure of the #102 crankshaft en August 12, 1983.

After the performance of extensive tests in late September and early October, which were observed by staff members from NRF. and Region I, as well as an NRC consultant, LILCo presented the results of its crankshaft failure investigation in a meeting on November 3, 1983.

It reported that the crankshaft had been improperly designed, and had failed because the loading function used in the criginal design calculations was too small. LILCo also reported that it was investigating fcur failed connecting red bearings which were disco 0ered when the EDGs were disassembled. Their prelfininary finding was that the failures occurred because the bearing material did not meet specifications, and the bearing loads had not been properly accounted for.

A detailed list of the EDG problems at Shoreham fo_11ows.

Date Problem Cause/ Solution 3/81 Excessive turbocharger thrust No lube oil during standby.

bearing wear.

Lube oil system modified.

12/81 Piston modifications to prevent Pistons reworked by TOI to crown separation.

respond to Part 21 report.

Problen identified at Grand Gulf.

9/82 Engine jacket water pump Water pumps reworked by TOI.

modifications.

6/82 Air starting valve capscrews Response to Part 21 repert.

replaced. 'Too long for holes.

9/82 Engine jacket water pump shaft Pump shafts redesigned and failed by fatigue.

replaced.

Spring /1983 Cracks in engine cylinder heads.

Fabrication flaws. All heads replaced.

Date Problem Cause/ Solution 3/83 Two fuel oil injection lines Manufacturing defect in ruptured.

tubing. Tubing replaced with shielded design.

3/83 Engine rocker arm shaft bolt High stress cycle fatigue.

failure.

Bolts replaced with new design.

8/12/83 Broken crankshaft. Cracks in Iradequate design. Replaced remaining crankshafts, with larger diameter crankshafts.

9/83 Cracked connecting rod bearings.

Inadeouate design and substandard material.

Replaced with new design.

10/83 Cracked piston skirts.

Replaced all piston skirts with new design. Generic problem.

11/83 Broken cylinder head stud nuts.

Replaced all head stud cuts.

9/83 Cracked bedplates in area of Cracks evaluated by LILCo and main journal bearings.

determined t; not be significant.

9/83 Unoualified instrument cable.

Replaced in response to Part 21 report.

J e

a.e.

,,-,,..m

.y.m--

,-,w-

-m

P--

O 4.

o BLANK 6

9 e

Operating Experience - Non-Nuclear Marine Applications Besides being used for stationary electric power generation. TDI diesel engines have been placed in service as propulsion units on commercial cargo vessels. As part of the Shoreham operating license hearing, an intervenor, Suffolk County, requested and was granted by the Licensing Board, subcoenas for the State of Alaska. U. S. Steel, and Titan Navigation, Inc. These three organizations operate vessels which use TDI V-16 diesel engines which are very similar to most of the TDI units installed in nuclear power plants. The responses which were received indicate that the TDI engines in marine service for these organizations have experienced severe reliability problems. Most have related to faulty cylinder heads, but they have also included problems with pistons, cylinder liners, turbochargers, cylinder blocks, connecting rods, connecting rod bearings, nain jourral bearings, and camshafts. A detailed experience list follows. The staff is reviewing this material to see how much of it is applicable to en nes in nuclear service.

~

a 4

r.-

,m--... -, -

Marine Experience with TDI Diesel Generators State of Alaska, M. V. Columbia Vessel fitted with two DMitV-16-4 Engines - Serial No. 72033/34 Rated at 9200 HP (69C0 KW) at 450 RPM Vessel and engines placed in service in June 1974 Each engine has approximately 30,000 hours0 days 0 hours 0 weeks 0 months of operating time to date.

Document Date Problem Description 12/76 All cylinder liner seals replaced. All cylinder heads have been removed, reinstalled, or renewed at least three times.

All pistons have been removed and reinstalled at least once.

Turbochargers have been removed, repaired and reinstalled, or renewed 16 times due to leaking oil seals, vibration, rotor damage, or defective bearing seal hcusing.

~

Exhaust manifolds have been removed and reinstalled because of frozen expansion joints and resulting cylinder head flange face damage.

Lube oil consumption is excessive.

6/15/78 Rapid deteriorations of fire seal rings causing blowby across gasket surface of cylinder heads.

Very low lube oil filter life (40 hours4.62963e-4 days 0.0111 hours 6.613757e-5 weeks 1.522e-5 months ).

Caused by blowby of pistons and valve guides.

Stainless steel exhaust bellows burn cut rapidly.

Installed backwards by TDI.

11/28/78 (Letter to Alaska frem TOI).

Recomends timing changes to improve turbocharger performance.

l-l

\\

E

.g.

Document Date Problem Description 1/31/79 Valve seats acd valve guides not concentric. lesults in bad valve contact.

Defective piston rings shipped as replacement parts.

Reworked cylinder head received frem TDI without all required modifications and with damaged gasket face.

Newly furnished cylinder liners received with incorrect surface finish (twice).

Connec~ ting rod bearings furnished as soare parts were wrong size - 13" vice 12".

Turbocharger exhaust flex section incorrectly furnished by TDI.

2/2/79 Chrome plating failure of piston rings.

Caused heavy scoring of cylinder liner.

Associated cylinder head found cracked.

Seven cylinder heads replaced during 15 weeks of operation.

Excessive lube oil filter change out rate. Due to piston blowby.

Fuel injector spray tips changed at TDI recommendation to reduce carbon buildup and eliminate washing of liner walls with fuel oil.

Three major overhauls of engines in 5 years of operation.

Carbon accuculations in rccker box areas.

Excessive of t vapor discharge from engine crankcases.'

Heavy carbon deposits on valve springs.

Suspect valve blowby.

When exhaust valve guides were redified by TDI, they did not follow the procedure outlined in their SIM (Service Information Memo).

1 1

.-~

Document Date Problem Description Loose piston pin end caps.

Incorrect piston crown to skirt bolt torque.

Bad connecting rod bearings. Excessive wear, cracks.

Damaged connecting rod bolts.

Valve push rods cracked at weld of ball to pipe. OC problem.

Crankshaft size changed after engines for ship installed. No notice to' owners of reason for change.

Excessive main bearing wear.

Camshaft lobe hard facing worn.

TDI recommended the installation of a new -

flexible exhaust duct which was too short (n.ewdesign).

Installation attempted at insistence of TDI. Unit damaged by attempt and returned to TDI for repair.

3/19/79 OC or material problems with respect to non-concentricity /out-of-round. valve seats, push rods, rod bolts, bearing shells, valve stem plating.

6/14/79 Thermal growth and cracking of exhaust manitpid.

12/26/79 Failure of new connecting bearings.

Cracks of 25% of connecting rods.

. Document Date Problem Description 1/'6/80 Ten (10) new cylinder heads have cracks.

This incluces 8 that were previously repaired.

Fifteen (15) valves are defective with chrone flaking off the valve stems.

Valve stems are being deformed.

Five additional push rods have cracks.

Turbocharger air cooler inlet housing is cracked for fourth time.

Internal bracing in engine intercoolers is cracked.

2/5/80 Piston rings installed improperly because mistake by TOI in the drawing used by TDI shop.

2/29/80 Piston crown-to-skirt nut torque inconsistent among nuts on various pistons.

Excessive link rod bushing bail wear caused by improperly relieved, drilled oil passages on the matching link rod pins.

3/24/80 Abnomal carbon deposits and famations noted on pistons and cylinder head assembifes.

Fretting of jaw areas of connecting rods.

Insufficient turbo (manifold) air except at near full speed operation.

Cracked exhaust manifold end plates.

Cracking of connecting rod boxes.

Cracking of newly installed connecting rod bearing shells at 4500/ hours.

Document Date Problem Description Fretting of link red and link rod pins at their attachment together.

Fretting between link rod bushings and link rod bushing bore.

Gallica of link roc bushings in way of link rod pin outer drilled oil passages.

Improper wear / contact pattern on newly installed connecting rod bearings at 4500/ hours. Four-point loading.

Insufficient connecting rod bearing wear / contact area to journal wherein it is less than 15% of the total bearing area.

Upsetting of stems in valve keeper area.

Damage to number four piston ring and ring groove on all pistens modified during the 1978-79 engine teardewn and rebuilt after 4500/ hours operation.

Fretting between piston crown and skirts at 4500/ hours since piston modifications.

Variations in piston bolt torque, beyond specified limits, at 4500/ hours since piston modifications.

Damage to rod bolts, including cracking, and damage to threads on both the bolt and in the rod boxes.

4/18/80 Exhaust manifold conversion kits received with cuts and grooves in finished surface.

Required rework by owner before installation.

-5/12/80 New connectirg(American Bureau of Shipping) rods received without reauired code approval. TOI did not have record of which rods were shipped with approval or without approval.

Some new connecting rods shipped with oversize bearings but no note to customer l

infaming of difference.

i L

i Document Date Problem Description 5/14/80 Cylinder head returned te TDI has been*

lost by TDI. Cannot be located.

5/15/80 Custoner received new connecting rod bolt

,e in rusty condition with damaged threads.

5/27/80 Customer received. reworked cylinder heads with lip left on exhaust seats which prevents valves from seating.

Customer noted that it now was in possession of two cylinder heads with the same serial number.

Could not install lockwire in new connecting rod cap screw. Hole

drilled partway through with drill broken off in center of hole. Also noted that edges of lockwire holes on other screws had not-been rounded to prevent damage to lockwire.

5/29/8b Discovered leaks in newly installed c

exhaust ne'nifold head plates.

9/4/80 (Meeting Summary)

TDI says that all cylinder head problems should be corrected by new design.

TDI reports that connecting rod bearing cracks could have resulted # rom bad bearing alloy makeup by vendors. TDI looking at different bearing materials.

TDI stated that they had erred on piston modifications. Effected others besides COLUMBIA.

9/30/80 Eleven remaining master cornecting rods to be sent to TDI to have oversize bearings and other modifications installed.

Many of the original cylinder heads that '

were returned to TDI for rework were exchanged for other used heads.

?

9 8

4

,,r-----m- - -,

e--

v w,

e-- e s J

---vm w

---r

- ' ~ ~

= *'

. Problem Description' Document Date 11/6/80 Cylinder head changed due to heavy external water leakage.

Severe snoke causing excessive lube oil contamination and engine room atmosphere problems. Engine secured to prevent possible crankcase explosion.

12/10/80 All connecting rods removed. New rod cap screws and washers to be installed because increased torque specified by TDI caused galling.

New connecting rod bearing she'll found cracked.

Heavy wear noted on piston side thrust areas. Heavy hard carbon buildup noted in area of compression rings. Fourth ring groove area te be reworked by TDI due to~

design / machine error by TDI during

' previous modifications.

Nineteen (19) of 32 cylinder liners exceed '

spec for out-of-round. TDI to modify limits to pennit continued usage.

Twenty-one (21) of 32 liners lost crush.

New phenomena. Repairs require machining of engine block.

Fuel injectors removed and to be changed from 140' spray pattern to 135' pattern.

Original nozzles had 150' pattern.

1/16/81 Cylinder block bores fcund to be distorted.

Four new engine camshafts installeo.

- - - - + - -

3-.-

,.,,.,,.-_,,_7

-__.m

.. Document Date Problem Description 3/13/81 Reworked cylinder heads were returned to the customer without removing the grinding compound from the valves and valve seats.

Two reworked pistens. returned to customer without roll pins, which lock the securing nuts in place.

o Cylinder liner delivered with wrong surface finish.

Cracks found in cylinder blocks. All replaced.

Main engine blocks found to be cracked end warped. The main block-to-base through bolts appear to have been improperly

{

torqued during initial assembly.

One "new" camshaft found to be a rebuilt unit centaining several damaged bearing journal areas.

The threaded head stud holes in the new cylinder blocks were not counterbored r/

deeper, as TDI had indicated they J

currently do. This was to eliminate cracking of the block near the stud holes. The customer re-machined each of the 256 head studs to accomplish the same intent.

4/9/81 Several reworked pistons were returned without groove pins.

In response to a reauest for 20 li" capscrews and washers, TDI supplied 1 7/8" capscrews.

Drawings furnished by TDI for head stud modifications were not applicable to the studs in question.

50% of the fuel pump bases would not fit onto the new cylinder blocks because of slight changes in the design of the blocks.

l

. Document Date Problem Description Two new cylinder liners provided with incorrect surface finish.

One new cylinder liner provided with flange thickness larger than manufacturer's maximum tolerance.

New connecting rod capscrews were found to be galled and unfit for use.

4/29/81 Service manual showed incorrect installation of engine camshafts.

I 2/3 of fuel can tappet assemblies on ore t

engine could not be installed on one engine because the new cylinder blocks had not been properly counterbored.

Cylinder liner counterbore depths were off

.to such an extent that difficulty experienced in establishing proper liner c rush.

Weld spatter noted on many seating surfaces.

Dirt, sand, and metal showings found in passages and holes which should have been clean.

Cylinder head water port outlet locations varied considerably, causing a water flow restriction.

I Air start distributor not properly assembled at factory.

6/1/81 Exhaust nanifold head plate developed a l

leak. Cracks found around 2 of 3 tie rods due to poor initial welding.

11/19/81 Defective valve springs found on one i

engine.

7/29/82 Valve rotator failed.

Cracks discovered in the intercooler.

I

Document Date Problem Description 7/29/82 "In nine years of operation every basic engine ccmponent has been modified or replaced with an improved item, at least once, with the exception of the crankshaft (which is obsolete and has not been used for years), the engine base, the fuel pumps and the governor. The last two items are not manufactured by TDI."

10/15/82 Turbochargers replaced.

Exhaust valve lubricating system to be installed.

3/9/83 Cracks discovered in three cylinder heads.

Reworked cylinder returned to customer with tap broken off in threaded hole.

Others returned with internal cracks and damaged flange faces.

Titan Navigation, M.,V. Pride of Texas Vessel fitted with two DMRV-12-4 engines, Serial No. unknown Rated at 7800 HP at 450 RPM Engines installed 1981 - no information on total ergine hours to date.

^

Document Date Problem Description 7/16/82 Catastrophic piston failure. Due to crack in piston skirt. Engine had 5791 hours0.067 days 1.609 hours 0.00958 weeks 0.0022 months of opera tion.

4/1/82 Cylind.er block broken and cracked.

Cylinder head cracked.

Cylinder liner cracked.

Piston skirt fractured.

Suspect that ail of above problems caused by water leaking into cylinder from air

~

intake manifold. Leaking tubes found in air intercooler.

8/19/82 Cracks discovered in six piston skirts.

7/22/82 Cracked exhaust valve seats in cylinder heads. Engine had 3000 hours0.0347 days 0.833 hours 0.00496 weeks 0.00114 months service.

Camshaft lobe design appears to be deficient. Causes excessive stress on

' fuel cam lobe and roller.

Tappet assembly rollers severely galled.

Believed to be due to camshaft and lobe placement and inadequate beat treatment.

Fuel can lobes have failed twice cue to improper heat treatment.

Chrome plating lost from one piston wrist pin.'

All four intercoolers have failed because of erosion due to high fluid velocity.

Air start valves have suddenly ceased to function, for no apparent reason.

. Document Date Problem Description Plugs in crankshaft oil ways may be cracking because improper material used.

Under investiga, tion.

Fuel oil return lines have failed. To be replaced with heavier wall tubing.

4/1/83 Exhaust valves fail after about 2000 hours0.0231 days 0.556 hours 0.00331 weeks 7.61e-4 months of use. Serious problems with cylinder head cracks.

Turbochargers experiencing difficulty supplying sufficient air.

O e

-w

^

. U. S. Steel, MV E. H. Gott Vessel fitted w'ith two DMRV engines (model unknown)

Engine Serial No. 75039-40 No information on engine hours to date.

Document Date Problem Description 11/13/80 Cracked cylinder head. Replaced.

11/1/79 Cracked cylinder head. Replaced.

6/1/80 Cracked cylinder head. Replaced.

10/8/81 Cracked cylinder head. Replaced.

Note: This information was summarized from documents provided by U. S. Steel in response to a subpoena which asked specifically for information about cyliner head failures. fiany other portions of the documents were deleted by U. S. Steel, and it appears that the deleted portions referred to problems with other engine parts.

i

. ' Other Appl 1. cations The staff understands that other TDI engines are in service as stationary electric power generators. The operating history of these engines will be taken into consideration during the staff assessment of TDI engines.

O e

e 4

e-22 -

Reference List Shoreham Letter dated 1/6/84 from B. McCaffrey (LILCo) to H. Denton (NRC)

Board Notificatien 83-160 dated 10/21/83 Board Notification 83-160 dated 11/17/83 Letter dated 12/9/83 from J. Smith (LILCo) to T. Muley (NRC)

Letter dated 12/9/83 from A. Schwencer (NRC) to M. Pollock (LILCo)

Letter dated 12/29/83 from A. Schewncer (NRC) to M. Pollock (LILCo)

Letter dated 12/16/83 from C; Matthews (TDI) to T. Novak (NRC)

Letter dated 12/16/83 from J. Smith (LILCo) to T. Murley (NRC)

Letter dated 12/16/83 frem A. Dynner (Suffolk County) to A. Earley (LILCo)

Letter dated 10/20/83 from A. Earley (LILCo) to' L. Brenner (NRC)

Letter dated 10/16/83 from R. Boyer (TDI) to NRC Letter dated 11/17/83 from A. Earley (LILCo) to L. Brenner (NRC)

IE Information Notice 83.51, dated 8/5/83 IE Inspection Report 99900334/83-01, dated 10/3/83 IE Information Notice.83-58, dated 8/30/83 Grand Gulf Letter dated 11/15/83 from L. Dale (MP&L) to H. Denton (NRC)

Letter dated 10/19/83 from L. Dele (bP&L) to H. Denton (NRC)

LER 50-416/83-171/03L-0 dated 11/28/83 L'etter dated'1C/26/83 from L'. Dale (MP&L) to H. Denton (NRC)

LER 50-416/83-082/01T-0 LER 50 416/83-126/01T-0 e

~

23 -

San Onofre Unit 1 LER $0-206/81-017 dated 8/12/81 Letter dated 9/15/81 from H. Ray (SCE) to R. Engelken (NRC)

LER 50-206/80-039 dated 12/23/80 Letter dated 6/8/81 from J. Haynes (SCE) to R. Engelken (NRC)

Marine Applications Letter dated 12/21/83 from A. Dynner (Suffolk County) to A. Earley (LILCo)

Includes many other individual documents.

O e

s n

/S...fod *!L-8 ENCIDSURE 3, IRANSAMERICA DELAVAL', INCORPORATED VENDOR PROGRAM BRANCH INSPECTION HISIORY SUMARY Of NINE INSPECIl0NS 00 RING 1979-1983 NUMBER OF SUBJECT NONCONf0RMANCES/V10LATIONS 13 MANUFACTURING PROCESS CONTROL CONIROL Of SPECIAL PROCESSES 11 PROCUREMENT CONIROL 12 1

MATERIAL IDENTITY AND CONTROL 1

DESIGN AND DOCUMENT CONTROL 8

NONCONf0RMANCES AND CORRECTIVE ACTION 5

EQUIPMENT CAllBRATION 4

INTERNAL AUDITS 1

10 CFR PART 21 PRACIICES 3 (VIOLATIONS)

QA RECORDS 3

q MISCELLANE0US 1

~

MANUFAC1URING PROCESS CONTROL ROUTE SilEEiS WERE NOT AVAILABLE 10 CONFIRM REQUIRED INSPECTION ACCEPTANCE OF ASSEMBLY OPERATIONS FOR THE EMERGENCY DIESEL GENERATOR'(EDG) JACKET WATER PUMP REFLECTED ON DRAWING NO. 101973, REVISION C.

ABSENCE OF EVIDENCE OF INSPECTION ACCEPTANCE FOR COMPONENTS MANUFACTURED DURING JACKET WATER PUMP MODIFICATIONS PERFORMED IN SEPTEMBER AND OCTOBER 1982.

ACCEPTANCE SIGNOFF BY QC INSPECTORS WAS MADE ON ROUTE SHEETS IN REGARD 10 INSTALLATION OF ROCKER ARM HOLD DOWN BOLTS.

THESE BOLTS WERE SUBSEQUENTLY FOUND TO BE MISSING ON INSPECTION AT THE SHOREHAM HUCLEAR POWER STATION (SNPS).

SHIPMENT OF REWORKED PISIONS 10 SAN ONOFRE, UNIT 1, PRIOR TO DATES INDICATED ON ROUTE SHEETS BY QC INSPECTORS THAT VARIOUS MANUFACTURING OPERATIONS WERE ACCEPTED.

ROUTE SilEETS NOT ISSUED FOR REWORK OF 92 PISTONS FROM SNPS AND GRAND GULF EDGs AND THERE IS, THUS, NO EVIDENCE OF INSPECTION ACCEPTANCE OF THE VARIOUS MANUFACTURING OPERATIONS.

NO RECORDS OF QUALITY AC11VITIES FOR REWORK ACTIVITIES ON GRAND GULF EDG PISTONS WHICH WAS A SPECIFIC REQUIREMENT OF Tile PROCUREMENT SPECIFICATION.

APPARENT USE Of UNQUALIFIED PERSONNEL FOR PERFORMANCE OF NDE OPERATIONS ON.SNPS REPLACEMENT CYLINDER llEAD ASSEH0 LIES.

REQUIREMENTS NOT PROVIDED FOR WELDING OF AND ACCEPTANCE OF SHEARON HARRIS EDG FUEL OIL LINE CLAMPS.

PRIOR TO OCTOBER 1981, MANUFACTURE OF PISTON SKIRT CASTINGS DID NOT COMPLY WITH ENGINEERING COMPONENT DRAWING INSTRUCTIONS WITil RESPECT TO PERFORMANCE OF SPECIFIED STRESS RELIEF HEAT TREATMENT.

bHO ASSEMBLY ROUIE SilEE15 AVAILABLE FOR SNPS REPLACEMENT CYLINDER llEAD ASSEMBLIES.

y v

,... u, ~ ~ g s J + u - -

3 y 4 ~

Il

~

S F

T O

N 3

E NE S

E R

OM l

E SR E

I E i

D SE W

TTR I AI A

AW R

L R

WCUQ G

C0 O

I L

EWi N

YFE l

LI R A

D D

PC I

OS E

MEE C

CR T

OPD' R

O I

CSO E

I D D

C M

I N U

TL M

I E A

OAI O

V NI I C

N N

RI OM E

DE Y

I O E

1 TN L

TR B

0AO N

CF MI l

O E

R T

i SD E

COC l

D E

l I TE E

ER lT H

S R

MU lC WN I

SC EU OE U

AO ND SI M Q

R O

NTS E

GP DR OIA R

D AP I S H

TOH EE S

R5 S

APT CMI E

EE1

) I Kl L

TW1 IOW 4i B

A D

bT FC A

C)U I

E FA SF TLC C

I RL RO RAN LS BU0 O

ECA OT AG1 DY CI I L

RN F

NL ML O

TE DT EP REP R

NM ONC VP EHM T

OE TAE U

NCO N

CR RJ MS E

C DGB O

TF O

I C

LU E

U RR SO)

AQ SDS FO A

C T

CE UN F

FE(

N I R AN D

C E

R E

E ED END M

TN RDE RE DAN E

CO ENB UV OMA R

EI WA CO CR U

LT LD OR O

C EA HDA RP I FA O

C CI l PP I NT l

l M A

I OA R

DI l

P EF i(R E

CD TI W

O RG N

NC S

EN O)T UE SMT WI AS I

OP

LES, E

T(E MS ATI SB C

T I SL R

E ER RY ES S

L NE ESS NA 0A M

T R

E E1C I

GO ALE TT M

I NT MI I

SS STNT ES OL AI ACAN U

T P

FL EiE l

RC ALP FPCM O

HEU ES OSET FE TUS DR EMA L

F OE NR E

SB E

D

'CI O

FR NA TDE L

I liOT OC ANV l P TT I I CAO l P CI ST TL I

R I U EWSA AP D)P S

P EE l

CP NDP N

SSNl A

NA OD NTE I

I F

A I E I NTL I E OLE TV EEA CK TDH CO GMLI E0 I T ER NEPR PV EM SP I

RME SN C(N P

VI OT UCA N

O EA I

I L

ES M

EQ M

AT DT D SE CE)

O I RE Al ERBF l

I RN VOI I

R (O

R E

EPF TD PI 2N YE

,G AI EUT 8O BDSN MD LSN 9

RTI B

E 1D EONT DD ATD E

C ER EN LNI OI NEMO SA I E TF ASEP A

ANR I

TARE HE VOE RT PHI R CL APH ON ECU RB MT I E CRQR UA OOI RD CUEO PC NCE PI APRF l

.h h

8 9<

cw3m W

m.e 4

4

"=w>

f A

C

>=

h.e e

W@

ZW wE CC

-A A LiJ 3 ZW ZZ ww

-J LaJ Z o

3 m

==

W Z

S C

U U

MvE o

w Z

w >=

Om wW W

-J

==

W Z

=

w AA Q

=

==

<A J

ZN

=C

=

C E

CN w

w rs

>=

MZ Z

wN MW

@ 8

>w

>=

"'* O WZ Z<

wJ O O.=

E J

<M

=C Ew wWQ

<w Zm3 Z

=

m-Ww

= Ql3 UZW 44 AwQ zw UQ WM

C CUw ZK w> >

WI a.

W >==

i NONCONIORMANCES AND CORRECTIVE ACTION I

I i

NO EVIDENCE 10 INDICATE THAT REQUIRED QUARTERLY SU8MITTAL OF COMPLETED CORRECTIVE ACTION ACTIVITY TO THE DIVISION GENERAL MANAGER HAD EVER BEEN ACCOMPLISHED.

I FAILURE OF QUALITY ENGINEERING TO PROCESS A REQUIRED CORRECTIVE ACTION REQUEST FORM AFTER CUSTOMER IDENTIFICATION OF 101 FAILURE TO MEET WELD QUALITY REQUIREMENTS IN ASME SECTION III CODE CLASS 3 DIESEL GENERATOR PIPING.

WELD SHOP AU0ll NOT PERFORNED IN'THE FALL OF 1981 IN ACCORDANCE WITH CORRECTIVE ACTION ComITMENTS MADE TO THE NRC.

4 l

i j

j

e 9

d S

W e=e W

==>

W W

4 W

E

=3m v

E3 G4 m

w

==

8<

J g

=

aw E

6

==

wO m

W

==o m

i Ew Qw 2

==

ClY w

E E

O 6

w L

g W

33a m

w

10 CFR PARI 21 PRACTICES RECORDS WERE NOT AVAILABLE WITil RESPECT TO FRACTURED TilERM0 STATIC CONTROL VALVES IN GRAND GULF, UNIT 1, EDGs TO INDICATE EllHER TilA1 AN EVALUATION HAD BEEN CON 00CIED IN ACCORDANCE WITH 10 CFR PART 21 REQUIREMENTS OR TilAT ACTIONS IIAD BEEN TAKEN 10 DETERMINE WHElllER 1HE PRODUCT DEVIATION CONTRIBUTING TO THE VALVE FRACTURES (1.E.,

IMPROPER USE OF RAISED FACE FLANGES IN CONNECTING PIPING) WAS PRESENT IN EQUIPMENT SUPPLIED TO OTHER CUSTOMERS.

)

FAILURE TO NOTIFY Tile NRC IN REGARD 10:

JACKET WATER PUMP SilAFT FAILURES AT SNPS.

POTENTIAL DEFECT IN FU'EL INJECTION LINE TUBING TilAT WAS USED IN EDGs FURNISHED TO GRAND GULF AND SAN ONOFRE, UNIT 1.

j

F.NCU)SURE 4 y 'ti Vendor Insoection History a

To date, the Region IV Vendor Inspection program has inspected the TDI facility in Oakland, California, nine times..The following inspection reports have been published in the PDR regarding these inspections:

1.* Docket No. 99900334/79-1, dated 3/20/79 2.

Docket No. 99900334/80-01, dated 1/22/81 3.

Docket No. 99900334/81-01, dated 5/27/81 4.

Docket No. 99900334/81-02, dated 9/18/81 5.

Docket No. 99900334/82-01, dated 4/15/82 6.

Docket No. 99900334/82-02, dated 12/8/82 7.

D.ocket No. 99900334/83-01, dated 10/3/83 Attached is a summary by the Vendor Inspection Branch of the TDI inspection history. The history includes some results from the last two inspections, which are being reviewed for proprietary information, and which will-be published when that review is complete.

ATTACHMENT TRANSAMERICA DELAVAL INSPECTION HISTORY VENDOR PROGRAM BRANCH FINDINGS 1979-1983 MANUFACTURING PROCESS CONTROL:

1.

Performance of required inspections for completed operations on Shop Engine No. 2931 Tank Lube Oil Sump Inlet Compartment could not be verified, in that neither inspection acceptance stamps were present on the route sheets for the completed operations nor were inspection reports available to indicate rejectable conditions had been found upon inspection.

2.

Route sheets were not available to confirm required inspection acceptance of assembly operations for the emergency diesel generator (EDG) jacket water pump reflected on Drawing No. 101973, Revision C.

3.

Absence of evicence of insoection acceotance for components manufacturec during jacket water pump modifications performed in September and Octocer 1982..

4 a.

Acceptance signoff by QC inspectors was made on route sneets in regard to installation of rocker arm hold down bolts. These bolts were subsequently found to be missing on inspection at the Shoreham Nuclear Power Station (SNPS).

b.

Shipment of reworked pistons to San Onofre, Unit 1, prior to dates indicated on route sheets by OC inspectors that various manufacturing operations were accepted.

5.

a.

Route sheets not issued for rework of 92 pistons from SNPS and Grand Gulf EDGs and there is, thus, no evidence of inspection acceptance of the various manufacturing oper'ations.

b.

No records of quality activities for rework activities on Grand Gulf EDG pistons which wa.s a specific requirement of the procurement speci fi cati on.

6.

Absence of required NDE reports for SNPS replacement cylinder head castings.

7.

Aoparent use of unqualified personnel for performance of NCE coerations on SNPS replacement cylinder head assemblies.

-3.

Improper signoffs and dates for acceotance of SNPS replacement cylincer teads w'th e:cect to reasonnel identity and use of a sur ente sc inscection stamp prior to expiration of the minimum 6-month period.

9.

Use of a different hard facing welcing procedure soecif' cation to that specified on tne route sheets for valve seats in SNPS replacement cylinder head assemblies.

10.

Requirements not provided for welding of and acceptance of Snearon Harr s ECG fuel oil line clamps.

. 11. Prior' to October 1981, manufacture of piston skirt castings did not comply with engineering comoonent drawing instructions with respect to performance of specified stress relief heat treatment.

12. Route sheets for Job No. 02933 did not provide instructions in regard to swaging operations performed on crankshaft oil plugs.

- 13. No assembly route sheets available for SNPS replacement cylinder head

-assemblies.

CONTROL OF SPECIAL PROCESSES:

- 1.

Absence of procedures'for examination of Level III NDE personnel and fail,ure to qualify personnel performing visual examinations in accordance 1

witn ASME Code req'uirements.

2.

a.

Performance of vertical up position welding on ASME Section III piping (Shop Engine No. 2931, Shop Order No. 94302) by welder qualified only for flat position welding.

b.

Welding of a 2-inch ASME Section III piping assembly by unqualified welder.

3.

Observations duri,ng three different inspections of failure to return unused welding electrodes in reautred 4-hour issuance period.

4 Identification of welders used for certain operations on Shop Engine Nos. 2931 and 2959 could not be verified.

5.

Unacceptable fillet weld size in Shop Engine No. 2931 Tank Lube Oil Sump Inlet Compartment due to bad fitup of tank roof and sidewall resulting in almost flush condition.

6.

Use of welding electrode sizes that were not permittec by applicable welding precedure specifications on Job Nos. 94922 anc 96632.

7.

Use of Job No. 95395 of welding amperage and voltage in excess of welding procecure specification requirements.

3.

Performance of welding on Job Order No. 97-435-3085 without specified revision of welding procedure specification being in welder's possession.

3

-e s -4e4->*fon re: -c; s ~, enda ru:ttv= 9vy 4rs:f:

73-s.:- a t :ie :t o

indicate the use of t2n checkpoints by tne examiner during :ne practical examination as requirec cy SNT-TC-1A anc faterna! pro:acures.

PRCCUREMENT CONTROL:

1.

Failur'e of Quality Engineering to both u3date Qualifiec Supoliers List every 3 months and to provide a montnly summary of vencor quality ratings to QC and Purchasing.

,. 2.

Evidence not available to assure that the seller of auxiliary lube oil and Jacket water pump motors complied with the requirements of the purchase order.

3.

'Betts Spring Company, a supplier of critical valve springs, had not been surveyed every 3 years.

The available evidence showed it was approximately 5 years since a survey had been made.

4.

Associated Spring Company (Barnes Group) was placed on the Approved Suppliers List and used for procurement without completion of a survey.or audit.

5.

'Kobe Steel Ltd., a supplier of crankshaft, was not surveyed every 3 years as. required by the quality assurance program.

The only available rec:rc was a self evaluation survey form completed by Kobe Steel's American representative.

6.

Fuel oil tubing for Purchase Order No. 45333 was accepted by receiving inspection without issue of a nonconformance report, although required mill test reports had not been received.

7.

Purchased Material Specif' cation No. RL 019000 dated October 6,1982, was -

not approved as required by Engineering Operating Procedure 7.

8.

A OA program was not imoosed on*the manufacturer of exhaust silencers for EDGs furnisneo to Ferry, Units 1 and 2, as requirec oy Perry Specification.

Nos. SP-750-4549-00 and SP-706-4549-00.

9.

Purchased material dpecifications for engine mounted electrical control cables required only commercial. grades of cable and did not invoke applicable customer specification requirements.

10.

a.

No available evidence to indicate that materials which were used to fabricate EDG ASME Section III Code Class 3 component supports (Midland) and fuel oil systems (Midland and Grand Gulf) were procured-from vendors who were either identified on the Approved Suppliers List or had been subject to audits, b.

Prior to 1982. ASME Section III Code fasteners were procured frcm vendors who had neither been audited nor were identified on the

- Approved Suppliers List as being approved for supply of this product.

1.:dertande 5.y reci ving f dspe: tion Of ASME Se tion !!! C:de "astece-11.

d certifications wnich did not comply with purchase. order recuirements witn' respect to:

(a) conformance of chemical composition :: :ateria!

specification requirements (b) completeness of mechanical test data and (c) compliance with ASME Section III Code requirements for reporting of material' heat treatment.

)

T

12. Failure to comply with testing requirements of paragraph NCA-3867.4('e) in the ASME Section III Code wnen purchasing stock materials from unsurveyed vendors.

MATERIAL IDENTITY AND CONTROL:

Eleven discrepancies in material identity observed in a sample of 45 between the identity of material issued and that recorded as being used for Midland EDG S/N 77002 piping system component supports.

DESIGN AND DOCUMENT CONTROL:

1.

Failure to comply with Division Standard Practice Nos. 4.101 and 4.201 recuirements with respect to:

a.

Release of a drawing revision to the shop without receiving approval of the applicable Engineering Change Notice from Industrial Engineering.

b.

Maintenance of the Engineering Change Log, classification of changes as major or minor, and initiation of required forms.

2.

Parts list and component drawings released by En'gineering did not define acceptance criteria for installation of crankshaft oil plugs.

3.

Aasence of any instructions in regard to i'nstallation location of governor lube oil cooler to engine.

4 Failure to comply with Drafting Room Practice during 1982 redesign of :ne EDG jacket water pump in regard to certain layout drawings not being either drawn on tracing paper or signed and dated.

5.

Dynamic analysis or testing not performed in accordance with Stone &

Webster Specification No. SHI-89 after redesign of the SNPS ECG Jacket water pumps.

6.

Failure to comply with Engineering Operating Procedure 4 and Oraf ting Recm Practice requirements with respect to signing and dating of calculations by the designer for the SNPS jacket water pumo redesign.

7.

No evidence of required approval of "O Sheets" by the applicable Engineer 1.ng manager. Examples noted were 0-4986 and 0-4956 -wnich were ent'tled. "as sa?.bly Instruttic. s," and ce-tained te t e E00.'a:t et wate-pump.

S.

Jacket water pump analyses dated Septemoer 24 and Octooer 4.1952. and July 15, 1983, for SNPS had not received required certification from tne staff Registered Professional Engineer.

w

. NONCONFORMANCES AND CORRECTIVE ACTION:

1.

No evidence to indicate that required quarterly submittal of completed corrective action activity to the Division General 'ianager had ever been accomplished.

2.

Failure of Quality Engineering to process a required Corrective Action

-Request Form after customer identification of TOI failure to meet weld quality requirements in ASME Section III Code Class 3 diesel generator piping.

3.

a.

Removal and replacement of a defective weld in Shop Enginer No. 2931, Part No. 02-717-02YR. without required rejection and documentation on an Inspection. Report, b.

Disposition of a dimensional nonconformance on Shop Engine No. 2931 Part No. 02-540-07-87, made by QC suoervision without recuired submission of the Inspection Report to the Material Review Board for review.

4 Failure to comply with ASME QA Manual requirements with respect to immediate identification of nonconforming items on Inspection Reports and segregation of.the items.

5.

Weld shop audit not performed in the fall of 1981 in accordance with corrective action commitments' mace to tne NRC.

ECUIPMENT CALIBRATION:

1.

Actual calibration measurements for micrometers and a pressure gage were not recorded as required by Quality Control Procedure No. IP-100.

2.

Gage used to measure, accept / reject the diameter and depth of the link rod dowel counteroore had not been identified in accordance with QA program requirements for calibration equipment.

3.

Measures were not established to assure that tools used in crankshaft oil plug installation were properly controlled and adjusted at specified periods to maintain accuracy withic necessary limits.

4 a.

A welding machine in Weld Area No. 3 (Foundry) was observed in September 1983 to have calibration stickers showing a calibration cue.

date of Au;ust' 30. 1980.

The OA c-og ar :a bra-' r # er;s :y requirement for this equipment is 12 months, b.

A heat treat furnace was observed in September 1933 to have calibration stickers on the meters and temoerature recorder snowing a calibration due date of March 13. 1983.

o INTERNAL AUDITS:

Failure to perform required semiannual audits of the Foundry, Manufacturing and support activities.

10 CFR PART 21 PRACTICES:

1.

Records were not available with respect to fractured thermostatic control valves in Grand Gulf, Unit 1, EDGs to indicate either that an evaluation had been conducted in accordance with 10 CFR Part 21 recuirements or that actions had been taken to determine whether the product deviation contributing to the valve fractur'es (i.e., improper use of raised face flanges in connecting piping) was present in ecufpment suoplied to other cust0mers.

2.

Notification to affected parties in regard to a potential problem with isoprene flexible elements of drive couplings was mace after the committed date in the 10 CFR Part 21 report.

3.

Failure to notify the NRC in regard to:

a.

Jacket water pump shaft failures at SNPS.

~

Potential defect in fuel injection line tubing that was used on EDGs b.

furnished to Grand Guld and San Onofre Unit 1.

CA RECCROS:

1.

Records not available to demonstrate environmental qualification of auxiliary lube oil and jacket water pump motors with respect to Eechtel Specification Nos. 9645-M-018.0 and 9645-G-QA-1.

2.

Failure to protect records against fire in accordance with QA Manual requirements noted during two separate inspections.

MISCELLANEOUS:

Failure to have Certificate of Comoliance for SNPS replacement cylinder head assemblies notari:ed in accordance with customer specification requirements.

a..

TRANSAMERICA DELAVAL, INCORPORATED VENDOR PROGRAM BRANCH INSPECTION HISTORY

SUMMARY

OF NINE INSPECTIONS CURING 1979-1983 Number of Subject Nonconformances/ Violations Manufacturing Process Control 13 Control of Special Processes 11 Procurement Control 12 Material Identity and Control 1

Cesign and Document Control 8

Nonconformances and Corrective Action 5

Equirment Calibration, 4

Internal Audits 1-10 CFR Fart 21 Practices 3 (Violations)

OA Records 3

Miscellaneous 1

i t

-s

naam s j

l OWNER'S AGENDA TDI OWNER'S GROUP MEETING WITH NRC DATE:

01/26/84 TIME:

3:00 P.M.

"~

LOCATION:

PHILLIPS BUILDING - BETHESDA I.

0WNER'S GROUP FORMATION AND CHARTER J.P. McGAUGHY II.

0WNER'S GROUP PROGRAM DESCRIPTION W.J. MUSELER III.

CURRENT STATUS OF MAJOR GENERIC FAILURE C. WELLS ANALYSIS' ACTIVITIES FAAA IV.

DESIGN REVIEW / QUALITY REVALIDATION PROGRAM C.K. SEAMAN (DRGR)

TDI C. MATTHEWS V.

-TRANSAMERICA/DELAVAL ACTIVITIES VI.

INTEGRATED PROGRAM APPROACH W.J. MUSELER SCHEDULE VII.

SUMMARY

J.P. McGAUGHY

r O.

r

'4

SUMMARY

OF OWNER'S GROUP ACTIVITIES 1.

TIE MEETING NEED FOR A UTILITY IECHNICAL INFORMATION EXCHANGE O RELIABILITY EXPERIENCES PROMPTED MP&L TO SPONSOR IST D/G TIE MEETING IN ATLANTA On 10/25/83.

0 26 UTILITIES REPRESENTED 59 INDUSTRY REPRESENTATIVES INCLUDING INPO, NRC, AND 0

NSAC/EPRI PRESENTATIONS GIVEN BY SEVERAL D/G OWNERS 0-REVIEWED MUTUAL PROBLEMS AT. BREAKOUT SESSIONS 0

ATTENDEES MADE 2 RECOMMENDATIONS O

(1)

HOLD WORKSHOP OF D/G OWNERS (2)

ORGANIZE D/G OWNERS'S GROUP O

STEERING COMMITTEE FORMED

SUMMARY

OF 0WNER'S GROUP ACTIVITIES (CONTINUED) 2.

STEERING COMMITTEE MEETING STEERING COMMITTEE MEETING HELn NOVEMBER 30, 1983 AT 0AKLAND, CALIFORNIA.

O 12 STEERING COMMITTEE MEMBERS AND 23 OTHER REPRESENTATIVES FROM UTILITIES, TDI, EPRI/NSAC, FAA REPRESENTED

~

0 PRESENTATIONS ON SHOREHAM TECHNICAL PROBLEMS GIVEN BY FAA O

LIST OF D/G PROBLEMS WERE DEVELOPED FOR DISCUSSION WITH IDI O

DRAFT CHARTER PREPARED BY AN OG SUBCOMMITTEE O

IDI CONDUCTED TOUR AND PRESENTED INFORMATION ON CRANKSHAFTS, PISTONS, CONNECTOR ROD BEARINGS, PUSH RODS, QA PROGRAM 0

STEERING COMMITTEE RECOMMENDED IMPROVEMENTS IN IDl'S QA AND PRODUCT IMPROVEMENT PROGRAM AND COMMUNICATIONS O

STEERING COMMITTEE RECOMMENDED IDI RESPOND WITH WRITTEN REPORT 0

COMPREHENSIVE REPORT WAS PREPARED BY IDI AND DISTRIBUTED TO OWNER'S GROUP MEMBERS

~

g ow y

,w-

e

SUMMARY

OF OWNER'S GROUP ACTIVITIES (CONTINUED) 3.

EXECUTIVE MEETING DELAVAL D/G OWNER'S EXECUTIVE MEETING HELD DECEMBER 21, 1983, ATLANTA, GEORGIA.

O MP8L AND LILC0 VP'S SPONSOR EXECUTIVE'S MEETING:

PURPOSE OF MEETING:

0 UTILITIES TO MANAGE EFFORT 0

DEVELOP COORDINATED EFFORT - BACK TO BASICS 0

ADDRESS NRC AND UTILITY TDI ENGINE RELIABILITY ISSUES 0

DE IGN, MANUFACTURE, IESTING 0

MUST HAVE IDI INVOLVEMENT 0

ALL UTILITIES TO SUPPLY ACTIVE TECHNICAL PARTICIPATION O

BUILD ON LILC0 EFFORT - HIT THE GROUND RUNNING O

LILC0 APPOINTED AS IECHNICAL PROGRAM MANAGER O

MP&L V.P. WAS APPOINTED TO CHAIR COMMITTEE

O e *

SUMMARY

OF OWNER'S GROUP ACTIVITIES (CONTINUED) 4.

TDI OG TECHNICAL MEETING TDI - OWNER'S GROUP IECHNICAL PROGRAM MEETING HELD JANUARY 6, 1984, AT LILC0/SHOREHAM SITE, N.Y.

O LILCO, TUGCO, Duxe, MP&L REPRESENTED 0

PROPOSED IDI-0G PROGRAM OUTLINED 0

MAJOR ELEMENTS DEFINED 0

COSTS ESTIMATED 0

AGENDA FOR OG AND NRC PRESENTATION APPROVED 0

RECOMMENDATIONS MADE FOR UTILITIES TO IMMEDIATELY IMPLEMENT COMPONENTS SELECTION PHASE OF PROGRAM 0

SCHEDULED PRESENTATION TO OG EXECUTIVES FOR APPROVAL 0

UTILITY PERSONNEL ASSIGNED TO IECHNICAL REVIEWS i

l

4

SUMMARY

OF OWNER'S GROUP ACTIVITIES (CONTINUED) 5.

PROGRAM APPROVAL - ALL TDI OWNERS O

EXECUTIVE COMMITTEE MET JANUARY 16 O

FINAL PROGRAM PRESENTED TO OWNERS ~

O PROGRAM WAS APPROVED BY ALL PARTICIPATING UTILITIES 0

TDI COMMITTED TO EFFORT l

E Y

SUMMARY

-0F OWNER'S GROUP ACTIVITIES (CONTINUED) 6.

OG UTILITY PARTICIPANTS GULF STATES UTILITIES (GSU)

SOUTHERN. CALIFORNIA EDISON (SCE)

CAROLINA POWER AND LIGHT (CP&L)

DUKE POWER SACRAMENTO MUNICIPAL UTILITY DISTRICT (SMUD)

TEXAS UTILITIES GENERATING CO. (TUGCO)

CONSUMERS POWER MISSISSIPPI POWER AND LIGHT (MPL)

CLEVELAND ELECTRIC ILLUMINATING CO. (CEICO)

LONG ISLAND POWER AND LIGHT CO. (LILCO)

GEORGIA POWER y--

.<-n,-,,---g_-.w,,,

,-,_,,7 g y ggnn-,e r

,,,e,y---,n.

.g,,gern.wg-,,

.,,_g,-

Attaciunent 2 TDI DIESEL GENERATOR OWNERS' GROUP s

Chairman J. McGaughy (MP&L)

Vice Chairman J. George (TU)

Executive Committee Program Administration 11 Utilities W. Angle (MP&L) l 4

Technical Program Director W. Muscler (LILCO)

Design Review and Quality Generic Problem Revalidation Program Testing Program Resolution

( Pa AA, S&W, Consultants, Definition (FaAA Lead)

TDI, Utilities)

(FaAA, Utilities)

o D.G. DESIGN REVIEW QUALITY REVALIDATION PROGRAM 3ZI-2 PROGRAM MANAGER C.K.SE AW AN (On I

l I

DESIGN GROUP COMPONENT SELECTION QUALITY GROUP CilAIRMAN CilAIRMAN CHAIRMAN G w. ROGERS (F)

J.C. N AMMEVER ($1 R.J. N AJUCH (S) l I

I I

TASK LEADERS DIESEL OWNERS Fo A A LE AD SSW LEAD OWNER LEAD CONSULTANTS REPRESENTATIVES

1. SITE ENGINEER L. A. swANCE R (F )

w.oRR (Si u.u.sChusTER (os J.C. m AuuEvER (sl 1.FEV

1. SITE ENGINEERS

l ( " " " ' I

2. DESIGN SPEC.

2. VALV ES P NUE ER (CI J.DluaRE

($)

P. T HOL E N (Cl

3. T Di R E P.

,,$c,

~

2. u ARL sCHusor g3g

, oTHEas

4. E MD J. F HE E u AN/

($1

0. EbaE L 40NIS

($1

5. I E. C l

l T.M.JAC08

($1 DOCUMENTATION RVW QUALITY ENGR *G FIELD INSPECTION

6. T URBO TASK LEADER TASK LE ADER TASK LEADER R. W AOL EC (Fl COMPONENT OWNERS *

o. ASOUINO (St J.REBLLY ($1 J. ER R A NTE (3)

SELECTION COMM.

REPRESENTATIVES

7. BEARINGS-RODS-g GEARS 1.foAA

l. R 48 I

E I

N E.COOPERM10ER (FI 3

J. PHILL 8P S (Si R. A. CHIN

($1 E.HESS (5)

8. itE ADS-CAST INGS

3. DIESEL CONSULT.

3. R V 12 D.JERRSEV (S)

K.JAC0050N (S)

E.NUHNS ($1 g,y sn HER (si R. w H TE lst

4. OWNERS

REP.

4. R V 2 O

9. STRUC T UR AL /

MECilANICAL

5. T DI RE P.

P. R. JOHN S T ON (F )

PERSONNEL l5 PERSONNEL l 11 EST. PERSONNEL l 8 EST. PERSONNEL l 5 EST. PERSONNEL l 8 TOTAL ESTIMATE 14 E NGlHE E R'S 50 STAFF F - FAILURE ANALV$1S ASSOCIATES 420 - TOTAL PERSONNEL O-OwhER REPRESENTAT8vE C-CONSULTANTS

TDI DIESEL GENERATOR OWNERS GROUP E -l

'l CH AIRMAN J. McGougby (MP GL)

VICE CH AIRMAN j

J. George i

(TU)

PROGR AM ADMINISTR ATION EXECUTIVE COMMITTEE W. Angle (M P a L) 11 UTILITIES i

l TECHNICAL PROGRAM DIRE CTOR W. Museler (LILCO) 4 I

I TESTING PROGRAM GENERIC PROBLEM DEFINITION 1

RESOLUTION (FAAA, UTILITIE S)

(FAAA LEAD)

TDI, UTILITIES) e I-36.278

H-2 1

PROGRAM PARTICIPANTS i

1. OWNERS' GROUP UTILITIES (11) l l

2. FAAA

~

l 3.TDI 4.SWEC

5. D.G. CONSULTANTS O

l i

i N-3 DR. FRANZ F. PISCHINGER I

e CURRENT POSITION

- DIRECTOR, INSTITUTE FOR APPLIED THERMODYNAMICS, AACHEN TECHNICAL UNIVERSITY, AND

- VICE PRESIDENT, FORSCHUNGSGESELL - SCHAFT FUR ENERGIETECHNIK UND VERBRENNUNGSMOTOREN (FEV)

- 30 YEARS EXPERIENCE IN ALL ENGINEERING ANALYSIS AND DESIGN ASPECTS OF DIESEL ENGINES e

FORMER POSITION

- DIRECTOR, RESEARCH AND DEVELOPMENT, K.H.D. AG,

[

DIESEL ENGINE MANUFACTURER, WEST GERMANY

- RESEARCH DEPARTMENT HEAD, INSTITUTE FOR INTERNAL COMBUSTION ENGINES GRAZ e

PUBLICATIONS

- AUTHORED TEXTBOOKS AND TECHNICAL PAPERS ON DIESEL ENGINE DESIGN AND ENGINEERING ANALYSIS j

~

l

l K-4 i

PAUL THOLEN

l e

CURRENT POSITION

- CONSULTANT TO DR. F. F. PISCHINGER, FEV i

e FORMER POSITION i

- DIRECTOR OF RESEARCH AND DEVELOPMENT, K.H.D. AG, DIESEL ENGINE MANUFACTURER, WEST GERMANY l

- RESPONSIBLE FOR:

)

- DIESEL ENGINE DEVELOPMENT

- TESTING AND MEASUREMENT 4

- THERMODYNAMICS

- DESIGN ANALYSIS

- DEVELOPED HIGHLY-TURBOCHARGED DIESEL ENGINES e

PUBLICATIONS

" WEAR AND FUEL CONSUMPTION IN DIESEL ENGINES", S.A.E.

l i

MILWAUKEE CONFERENCE, SEPTEMBER 1983 "TURBOCHARGING OF DIESEL ENGINES", PRESENTED IN TOKYO, i

JAPAN 1977 "NEW PROCEDURES IN TURBO CHARGING OF ENGINES", SIEMAG CONFERENCE, WASHINGTON, D.C.1973 i

~

t I

l

I i

E5 DR. CLIFFORD H. WELLS (FAAA) e CURRENT POSITION I

- VICE PRESIDENT, RESEARCH AND DEVELOPMENT i

- RESPONSIBLE FOR:

i

- FATIGUE AND RELIABILITY ANALYSIS l

- NONDESTRUCTIVE EVALUATION e

FORMER POSITIONS

- DIRECTOR OF ENGINEERING MECHANICS, SOUTHWEST RESEARCH INSTITUTE

- ASSISTANT MANAGER, MATERIALS ENGINEERING AND RESEARCH, PRATT & WHITNEY AIRCRAFT CORP.

- CHAIRMAN, EXECUTIVE COMMITTEE, MATERIALS DIVISION, ASME i

e PUBLICATIONS

- EDITOR," FATIGUE OF ENGINEERING MATERIALS AND STRUCTURES"

\\

j l

l_

4 i

I N-6

~

GARY W. ROGERS, P.E. (FAAA) e CURRENT POSITION

- DIRECTOR, FAAA, PHOENIX OFFICE

- RESPONSIBLE FOR:

- RECIPROCATING AND TURBO MACHINERY DESIGN

- VIBRATIONS ANALYSIS AND FIELD TESTING I

l

- CONDUCTED:

- DIESEL MAIN BEARING AND GENERATOR SHAFT FAILURE i

ANALYSIS, ARKANSAS NUCLEAR - 1

- MOTOR BEARING FAILURE ANALYSIS, SAN ONOFRE - 2

- RCP SEAL FAILURE ANALYSIS, INDIAN POINT-2 4

i l

l FORMER POSITION l

- GARRETT CORPORATION l

- RESPONSIBLE FOR:

j

- G-T ENGINE DESIGN AND DEVELOPMENT l

- DESIGN ANALYSIS OF DRIVESHAFT TORSIONAL INSTABILITY

- MEMBER MATERIAL REVIEW BOARD (DESIGNIQUALITY l

REVIEW)

)

i l

1 i

DR. LEE A. SWANGER, P.E. (F A AA) m-7

.I e CURRENT POSITION I

- MANAGING ENGINEER

- RESPONSIBLE FOR:

- PALO ALTO EXPERIMENTAL LABORATORIES

- METALLURGICAL ANALYSIS i

e FORMER POSITION

- DIRECTOR, RESEARCH AND DEVELOPMENT, IMPERIAL CLEVITE INC.

- RESPONSIBLE FOR:

l

- COMPONENT DEVELOPMENT

- BEARING FAILURE ANALYSIS

- COMPONENT MANUFACTURE PROCESS DEVELOPMENT i

e PUBLICATIONS

" SELECTION OF CRANKSHAFT MATERIALS FOR OPTIMUM BEARING l

PERFOR MANCE",

i SOCIETY OF MANUFACTURING ENGINEERS CM80-392 l

" DEVELOPMENT IN BEARINGS AND PISTONS", PRESENTED AT O MOTOR NO FUTURO, SAO PAULO, BRAZIL, SEPTEMBER 1980 i

e U.S. PATENT NO. 4333215 " BEARING. MATERIAL AND METHOD OF MAKING" 1

ll liisI-36,268 l

E8 PROGRAM CONCEPTS

1. FOCUS ON SPECIFIC COMPONENTS

~

2. CONSIDER ALL ENGINE COMPONENTS FOR POTENTIAL REVIEW

3. NUCLEAR AND INDUSTRY EXPERIENCE FACTORED IN

4. HIGH QUALITY RESOURCES t

5. UNIFIED TEAM APPROACH

6. ADDRESS SUBSTANTIVE ATTRIBUTES I

(SMALL "q" VS. CAPITAL "Q" FOR QUALITY)

7. ADDITIONAL TESTING WHERE REQUIRED i

8. ADDITIONAL INSPECTIONS WHERE REQUIRED l

l

II'8

(

l.

i OWNERS' GROUP PROGRAM i

ELEMENTS e

KNOWN PROBLEM RESOLUTION i

(GENERIC AND ENGINE UNIQUE) i DESIGN REVIEW AND QUALITY j

REVALIDATION (DRQR) e ADDITIONAL TESTING AND INSPECTION (WHERE REQUIRED) e RESPONSES TO NRC QUESTIONS e

e

X-10 l

SIGNIFICANT KNOWN PROBLEMS l

' ^ '

1. CRANKSHAFT

2. CONNECTING ROD BEARINGS A f

3. PISTONS

l

4. CYLINDER HEADS

i l

5. CYLINDER LINERS <>

i

6. CYLINDER BLOCK o 4

7. ENGINE BASE ci

8. HEAD STUDS o l

9. PUSH RODS R

10. ROCKER ARM CAPSCREWS O i

11. CONNECTING RODS O

12. ELECTRICAL CABLE K

~

13. FUEL INJECTION LINES '"

~

14. TURBOCHARGER 0 l

15. JACKET WATER PUMPS "'

1

16. AIR START VALVE CAPSCREWS k 1

' ba "M g: g w.n,.3 r i G v (n-3 l" '

o :Oth tl

?

l

)

Br-11 DOCUMENT PACKAGES FOR NRC REVIEW (FOR EACH OWNER)

1. SPECIFIC REPORTS ON EACH KNOWN PROBLEM

~

GENERIC

ENGINE SPECIFIC

2. ENGINE SPECIFIC DRQR REPORT

3. PREOPERATIONAL TEST REPORTS (VIA l

I&E)

4. SPECIAL TEST REPORTS (IF APPLICABLE)

5. RESPONSES TO NRC QUESTIONS

GENERIC

ENGINE SPECIFIC

[

Y-1 CRANKSHAFT FAILURE RESOLUTION

~

1. CAUSE IDENTIFIED VIA MULTIPLE METHODOLOGIES l

HOLZER ANALYSIS l

MODAL SUPERPOSITION

FINITE ELEMENT ANALYSIS

2. TEST OF 13 X 11" SNPS CRANKSHAFT CONFIRMED ANALYSIS

3. ADEQUACY OF NEW 13 X 12" CRANKSHAFT CONFIRMED i

j

ANALYTICALLY

= TESTING

~

4. PROBLEM WAS SHOREHAM UNIQUE

5. OTHER CRANKSHAFT TYPES BEING CONFIRMED i

i l

o O

N N

t L

i C

\\

b y

J V

ee 7

o e

e o

5g b

o m o O m

y e W w

4 15 o

J Cw 3

$g$$

~

e

~

s e 0 0 A Z J Z W 4 d 4 E O

g 2

Z Z

4 CC O

C r

I g

I t

i O

O o

O O

O 0

O O

N T

g i

(SdlM Ig) anoWOi idVHS bgdgM-ll) 30

\\

FaAA-M-84-1-6

l 4

1/4 Connecting rod

//

Connecting rod

[////

[/

1/ 6' chamfer _.

[

chamferag

//

/ / / / /

1/16*

chamfer

_ Connecting rod bearing EConnecting rod bearing Inner surface

~

>r y

l i

UNSUPPORTED END COMPLETELY SUPPORTED END i

Bearing: Connecting rod configuration Bearing: Connecting rod configuration with original 11-inch journals.,

with replacement 12-inch Journals.

i Fa A A-M-84-1-6

1 i

i CRANK PIN, JOURNAL BEARING L

11 INCH 12 INCH PIN DI AMETER PIN DIAMETER i

l Peak Oil Film Pressure 2 9,745 psi 26,7 80 psi l

Max. Predicted Yaw 0.00 7 9 inch O.0052 inch Max. Calculated Stress 10,931 psi 5,412 psi i

t Crack Growth Life from 250 hour0.00289 days 0.0694 hours 4.133598e-4 weeks 9.5125e-5 months 3 8,000 hour0 days 0 hours 0 weeks 0 months From 0.7mm Diameter Defect i

Fa A A-M-84-1-6

+

,i 4

jl Y2 BEARING FAILURE RESOLUTION i

1. CAUSE IDENTIFIED

2. PROBLEM WAS SHOREHAM UNIQUE

3. NEW SHOREHAM DESIGN FOUND ADEQUATE VIA

ANALYSIS j

INSPECTION l

MATERIAL TESTING

4. BEARINGS ON OTHER ENGINES TO BE CONFIRMED VIA

)

ANALYSIS l

INSPECTION l

MATERIAL TESTING l

i

!+-

+

m

\\

i h

~

^

2.62 Y

A i

y l

AE AF AE I

l AF AF

~

l F a A A-M-84-1-6

\\ '{

s,.

e e

o

0 E

R

~

=

r E

3 E

3

+N3 s

=

o tr" O

e y

l B

e f

sw A oy

,m, ce I

$E O

5~

m$$

6eu NoI 4j y

.;"1 A~

.....I e

.T c5 w

s. n F a A A-83-11-13

r. -

I (1

1

' N N

\\

N N

s

\\

a N

\\tN N

ew

\\

x(

\\

3

\\h Region of peaks

. s\\s s

stress selected i i MI

\\

for local refined model

\\ \\ \\ \\

N (see Figure 3-11) i i i i

e iII l-

///

.. /

/////

g:-:-5 l

z

/

/,////

lllill f

1 1 sts t

\\

=,

Figure 3-10.

Global model of AE piston skirt.

e f

i l

I Fa A A-83 13

i v-a l

I STATUS OF PISTON ANALYSIS

,l 1.

Three piston skirt types involved l

(AF, AN, AE) 2.

Analytical model still under development by FaAA i

}

l 3.

Strain gage rig test planned l

1 1

4. German piston consultant engaged for i

additional analysis i

l 5.

AE piston operating experience good

TDI test engine (2) l

Kodiak utility engine (16)

FeA A-M-84 9

i YL-1 DESIGN REVIEW / QUALITY REVALIDATION PROGRAM o

ORGANIZATION l

e. PROGRAM DESCRIPTION

SCHEDULE AND STATUS l

e SAMPLE TASK DESCRIPTIONS

~

i - -

l

)

D.G. DESIGN REVIEW QUALITY REVAllDATION PROGRAM 32I-2 PROGRAM MANAGER C.s.stauam toe i

l I

I l

DESIGN GROUP COMPONENT SELECTION QUALITY GROUP CHAIRMAN CHAIRMAN CHAIRWAN I

e w. mostas trl J C.saastatvEn tai S.J MaJuCH tel l

1 l

I I

l TASK LEADERS DIESEL OWNERS

FeAA LEAD SEW LEAD OWNER LEAD CONSULTANTS REPRESENTATIVES Cse a

est t.FEV

t. SITE ENGINEERS

'" I

.,[,,,,,,,

2. VALV E S

2. DESIGN SPEC.

Josuaat est P. T seot t u tcI

3. T DI R E P.

I

",ua;,5

2. sa.L

..e,o,

3.., E..

Jrnetunut est l

o esstLeones est

5. I E C i

as Jacos tel OOCUMENTATION RVW OUALITY ENGR'S FIELD INSPECTION TASK LEADER

' TASK LE ADER TASK LEADER

6. T UR BO a anotsC trl COMPONENT OWNERS

o.asouwee est J.steLLv tel J. tam a nit tsi T. BE ARINGS-ROOS-TI m g

l GEARS LFeAA I.R48 E

I E

a n.cooPenneta Irl

2. S E W

2. RV 16 J. PHILLIPs tel R. A.CHim Isl E.Hess tel

-l D S -CAST INGS,,,

8.

3. DIESEL CONSULT.

3. R V 12 s Jeanser ist u.Jacosson tel E.sunus est l

l 4 OWNERS

REP.

4. R V 2 O

9. STRUCTUR AL /

l MECHAMICAL

5. TDI REP.

P R. Jo*80ssioes trl

}

PERSONNEL l5 PERSONNEL l Il EST. PERSONNEL l 8 EST. PERSONNEL l 5 EST. PERSONNEL l 8 i

TOTAL ESTIMATE 14 ENGINE E R*S 50 STAFF t - Fastung amatysis associates I

s-stoms cwtosite 1

sao-Totat Ptasonesto o-owestR REPRESENiaTave

)

C CoelsuLTassis

,I i

3fL3 PROGRAM DESCRIPTION t

PROGRAM IS CONDUCTED IN FIVE PHASES:

L ASSEMBLE EXPERIENCE DATA IL COMPONENT SELECTION i

IIL PREPARATION OF TASK DESCRIPTIONS

]Y. IMPLEMENT TASK DESCRIPTIONS Y. PREPARE FINAL REPORT l

DR/QR PROGRAM FLOW CHART 3ZI-4 IDENTIFY ENGINE COMPONENTS i

I 4

4 ASSEMBLE SITE ASSEMBLE INDUSTRY EXPERIENCE DATA:

EXPERIENCE DATA:

. > PHASE I

l 1.R-48

1. NUCLEAR 2.TDi MARINE

2. RV-88 3.TDI STATIONARY

3. R V-12

4. RV-20 I

i PHASE SELECT COMPONENTS FOR REVIEW OUALITY REVALIDATION DESIGN REVIEW l

+

PREPARE TASK PREPARE TASK DESCRIPTIONS DESCRIP TiONS I

I PHASE PERFORM INSPECTIONS PERFORM CALCULATIONS, EVALUATIONS, REVIEWS TEST 3. REVIEWS I

I A

PHASE PREPARE AND ISSUE Y

FINAL REPORT G

9 O

I

Es L ASSEMBLE EXPERIENCE DATA A. SITE EXPERIENCE i

MAINTENANCE RECORDS OPERATING LOSS DESIGN CHANGES & IMPROVEMENTS FAILURES B. INDUSTRY EXPERIENCE l

NUCLEAR ALL MANUFACTURERS NON NUCLEAR - TRANSAMERICA DELAVAL ONLY I

C. COMPUTER

SUMMARY

REPORT e

9 O

3EI6 II. COMPONENT SELECTION A. TRANSAMERICA DELAVAL PARTS LIST

BASE DOCUMENT

= IDENTIFY COMMON PARTS B. SELECTION COMMITTEE

OWNERS REPRESENTATIVE

SWEC

FAAA

TDI

DIESEL GENERATOR SPECIALIST C. SELECTION BY CONSENSUS

COMPONENT FUNCTION (CLASSIFICATION)

REVIEW EXPERIENCE DATA D. OUTLINE MINIMUM REVIEW REQUIREMENTS

IDENTIFY IMPORTANT QUALITY ATTRIBUTES

OUTLINE DESIGN REVIEW REQUIREMENTS E. SHOREHAM R-48 COMPONENT SELECTION

TOTAL COMPONENTS 217 152

DESIGN REVIEW

QUALITY REVALIDATION 133 166

TOTAL COMPONENTS REVIEW OR REVALIDATED O

L YI-7 l

III. PREPARATION OF TASK DESCRIPTIONS l

A. TASK LEADER ASSIGNED

ENGINEERING OR QUALITY. SPECIALISTS 4

l

RESPONSIBILITIES B. QUALITY REVALIDATION i

NDE

DESTRUCTIVE EXAMINATIONS

IDENTIFY SAMPLE SIZE

PROCEDURES SPECIFIED C. DESIGN REVIEW

INDUSTRY STANDARDS

DETAIL METHODOLOGY & REQUIRED INFORMATION

UNIQUE ANALYSIS (FEM)

EVALUATIONS D. TASK DESCRIPTION REVIEWS

OWNER'S REPRESENTATIVES

TDI

GROUP CHAIRPERSON & PROGRAM MANAGER e

O O

O

N. IMPLEMENT TASK DESCRIPTION l

A. REVIEW / REVALIDATION IMPLEMENTED BY TASK LEADER l

B. QUALITY REVALIDATIONS

USE OF SPARE OR REPLACEMENT PARTS

ENGINE INSPECTIONS & TESTS

DOCUMENT RESULTS

ANALYZE RESULTS (USE DESIGN GROUP IF NECESSARY)

C. DESIGN REVIEWS

REVIEW EXPERIENCE DATA

-CALCULATIONS PERFORMED

EVALUATIONS BY CONSULTANTS

FEEDBACK TO QUALITY GROUP D. IDENTIFY RESULTS AND RECOMMENDATIONS

REVIEWED BY OWNER'S REPRESENTATIVES, TDI, GROUP CHAIRPERSON AND PROGRAM MANAGER

COMPONENT ACCEPTABLE

INCREASE INSPECTION I MAINTENANCE FREQUENCY

UPGRADEI REPLACEMENT 1

l 1

TI9 Y. PREPARE FINAL REPORT EXECUTIVE

SUMMARY

PROGRAM DESCRIPTION METHODOLOGY FOR SELECTING COMPONENTS l

SUMMARY

LIST OF COMPONENTS AND CLASSIFICATION l

METHODOLOGY AND RESULTS OF COMPONENT DESIGN REVIEW METHODOLOGY AND.RESULTS OF COMPONENT QUALITY REVALIDATION l

TABULATION AND DISCUSSION ON ANY DEVIATIONS THAT WERE FOUND l

CORRECTIVE ACTIONS AND RECOMMENDATIONS i

e

i l

SCHEDULE / STATUS E -10 l

R48 LEAD ENGINE (SHOREHAM) l l

11/ 1 12 /l 1/1 2/1 3/1 4/l I.

ASSEMBLE EXPERIENCE l

H.

COMPONENT SELECTION I

IE.

PREPARATION OF TASK r

DESCRIPTION a

i IE.

IMPLEMENT TASK l

l DESCRIPTION I

Y.

PREPARE FINAL REPORT no, e

l SCHEDULE / STATUS E - il LEAD V-ENGINE (GRAND GULF, V-16) 1/1 2/1 3/l 4/l 5/l 6/1 l

l I.

ASSEMBLE EXPERIENCE l

DATA 4

E.

COMPONENT SELECTION 1

i III.

PREPARATION OF TASK l

l j

DESCRIPTION i

E.

IMPLEMENT TASK l

l DESCRIPTION 3E PREPARE FINAL REPORT 1

ee et *W db

PRELIMINARY DRQR SCHEDULE YI-12 (ALL PLANTS) y/l 2/1 3/3 4/I 5/1 6/I 7/I

1. ASSEMBLE EXPERIENCE b/((((d DATA R. COMPONENT SELECTION R 4 8's

]

V-16's V-12*s d

v-20 IE. PREPARATION OF TASK DESCRITIONS ( ALL UNITS) f//[M l

lY.lMPLEMENT TASK DESCRIPTION ( ALL UNITS)

DESIGN

'//////

I ouAtliy *

//////

I Y.lSSUE FIN AL REPORTS R - 4 8's O

O O

D OOOOO y i g.,

O V-12 's D

V - 2 0's

lNSPECTIONS, NDE.CTC.WILL BE PERFORMED IN ACCORDANCE WITH EXISTING SITE CONSTRUCT!ON AND S/U TESTING SCHEDULES q

I s

i i

HIII-1 j

l INTEGRATED PROGRAM APPROACH e

GENERIC CONCERNS RESOLVED ON l

LEAD ENGINES e

DESIGN REVIEWS OF LATER ENGINES BUILT ON EARLY UNITS e SAMPLE INSPECTIONS ON ALL UNITS INCREASE SAMPLE UNIVERSE e

CONFIDENCE BUILDS AS PROGRAM PROGRESSES i

"~'

GENERIC PROBLEM RESOLUTION O. PROS 8 (M: SHON(H AM Cit ANk SHAf i f AIL UR(5 A bi sot ullON.

UNIT At!ALYTICAL WORK HARDWARE CHANGES INSPE 1 RE E

N$

R - 4 8 L taGINE 5 e 100 Hft5 AT 100s Post R-5 ENGAM 5 e NUI WSPECllON OF 3 CRANILSHAf15 e RE PL ACE l)", Mil" CRANW 5HAf I SHORtHAM e MODAL 5 R SIIION eflHilE EL(hfENI ANAttsl5 l

A GA E ESI-l E GINE o 100 HII5. AI 800m POeg w.g (NGm[

II #

RIVLR B(teo e 9003 INSPE CllON Of I CR Alek 5 HAT I e 18088E DefI(AtNI fROM ADOvtl e TOR 580 GRAPH TE5I-l (NGlHC

I "L

R A NCHO 5 A CHO

TOR 540GR APH IEST-t ENGINC

NONE D f ER Del ROM ABOVED V-16 (NGINE 5:

e 900 HRS. At 800m POttR-1 INCINC GR AND Cuti e HOLZER ANALV5t5 e 8801 tee 5PECilON OF 1 CRANGL5HAI T e NOle[

e 10R5eOGRAPH IE5I-I ENGleet e 1081540GR APH IEST-l EleGINE gfI,"

e NOT W5PECIBON AF If R PREOP e 84000E CAIAesA EN1 R A vil Tt5f mG-t ENGaNE e 10RSIOGR APH TESI-I E90GRE II" #"#I T $'$

PtWRY e NOI StsPECTION AfitR PREOP e NOesE G L R(N 3 ROW ASOVE)

Il51WG-1 ENGINE

' ' u ABOV(l e TOR 540GR APH 11SI-t f NGINE e NONC CowedANCHE PF Ak fER I RO

i'4 ",";t,A%,..

5=R A a u si-"=

=Nc

-R=

"i'",, ";tu,A%,c)

^

> =s=R A ra a s i -"==

'a"=

vOGiu V-17 tNG94(5:

MtOtANO e HOL liR A N AL T SIS e IOR$40 GRAPH IEST-I fl4Cledt e NONE V-2 0 ( NGINL 5.

S AN ONOI R(

e HOL2(R ANAL v585 e TORSIOGRAPH IESI-I (NGIIt[

NONE o

G A Gt Ht'Ruus

GENERIC PROBLEM RESOLUTION I PHOUL L I4 (;ONNt C 56Ns, ROD 9( AR44G5 N R L 50t illlOM C

C IN UNIT ANALYTICAL WORK HARDWARE CHANCES g

g R - 4 8 ( NCR4( 5:

I OMef C1MG

JOURNAL 0R911 ANAL YSIS e 100 HR$ Al 100s pow (R-3 ENC 445 g,y 3g,, ggggg p SHON( HA W e f lhill (L L W(Ifl AN AL 1515 e NOT WSPECIBON Of Bf ARNGS-CONN (CIWG RODS e i AllGU6 /t RACIURE WLCHANICS SAWPL E G A515-ALL E NGINE S R(PLAC[ ll" Bf ARING5 WIIH 12" Of ARINGS e 100 HIIS A t 100e POWE R-l (NGINE S

+ JOl#1NAL 09911 ANAL YSl5

{

RIVl R DI ND e NOI INSPf CllON Of IN ARMGS-e NONE lt OW f ER(141 F ROM ABOVil 54WPL [ R A515-AL L ( HClNf 5 e NO B INSPf C T40N OF BE ARING5-

JOURN AL 0RS11 AN AL YSIS At lLR PREOP ILS11NG-RANCHO SACilO I?F OWFER(NT FROW A80Vf B S AWPL E B ASIS-ALL E NGINE S SW REOUIRf 06 i

V - 16 ( NGNet 5:

~

e 100 HRS. Al SOOs pot [R-1 (NCIN[

JOURlial OR918 AN AL V 585 GRAND GULF e flNill EL(MENI ANAL YSIS (O I 551 G-5A LE 55-e f AllGUEif RACIURE W(CllANICS gg g g,,gg,g g e NOT INSPF CllON Ul* 8( AltlNG5-e JOURNAL OilGIT ANAL V585 LAIAnUA

III E

II $I

~

fit OlfftRENI fROM ADOVEl S AMPL E B ASIS-AL L (NGINES I

e NDI INSPECIION OF Bf ARING5-e J00RNAL 09911 ANAL YSIS AF IE R PREOP I[5]Il4G-PE *

]

Ilf Diti! RENT f ROW AUOVEI SAMPL L B A515-AL L E NS INE 5 IIF RtOUIR(OS e NDI M5PL CllON Of BE ARING5-

. JOURNAL ORell ANAL YSIS AF itR PRE OP f(51R4G-COMWAl4016L PE AIL "I

IT Dif f ERLNI F ROW ABOVil S AWPL E BA515-All L NGlHE S lif RLQUNilD)

I e ND1 INSPEC flON OF BE ARINGS-

JOURN AL ORB 11 AN AS V585 At lill PREOP IE51 RIG-

" # ""'b

'T Ott IE RE N E I ROW ABOVil 5 AMPL E B A SIS-All E NGlH( 5 J

lif RE OUIRE Of e NOI INSP!CllON OF Of ARINGS-o JOUNN AL 05811 ANAL Y SIS Af IL R PRLOP It SIN 4G-WOG il E e NONE lif DIFf[l#ENI IROM A80VES S AMPLE B ASIS-At L (NGINE S IIF RI OUIRE DI NOll.

THE SilECilON Of DE AkMGS FOR NDI & OESIRUCIlvt IESTING WILL EN511Rt COVER AGE OF IHE ENIINE Pf RIOO DURW4G WHifl1 o

litt R4SI Atl(D A SPAes Bl aRWG5 R4 IH( OWNER 5* GROUP INGINis WE RE MANUT ACIURE D IHf OVf R AL L S AMPi t all t IHEREf0NE St PRUP(RLD HEPl#I $1 Nil AllVE & 181[ S AMPL E Silt wa t W[ 5t# f UCU(NIL Y L ANGE 10 PROV6DE ADEOUAIE CONIIDE NCE 184 All llM 9( ARINGS, D

G AGI NPROtf 7

GENERIC PROBLEM RESOLUTION (CON'T.)

I PROBttad CONNt C11NG ROO BE ARINGS W Rt 50t Ulk)N:

C C

EA UNIT ANALYTICAL WORK HARDWARE CHANGES TE pg V-12 E NGBd 5:

~

NOT INSPECilON OF BE ARINGS-e JOURNAL 08011 ANAL Y5IS AFItp PREOP It511HG-MIDL AW l

tt DeFTERENI f ROM AHOVEI SAMPt [ B ASIS-At t i NGINE S It REOUIN1DI V-20 t NGlHE 5:

NO3 MSPt CIIOes OF DE ARMGS-

'I SAN ON0fRt

NONE It DtiERtNT FROM ABOVEI 5 AWPt E B ASIS-AL1 E NGWE 5 ft ptOUIRE Di Nolit flat. Sit f C lklN 06 Bt ARWG5 FOR NOI & OtSIRUCIIVE It51mG wat (N50Rt COVER AGE Of list E NIlpt PERIOO OtsRING WittCil Ilt IN$1 At t ED & SPAet 9t ARWG5 M litt OWNE R5* GROUP E NGINE S WE RE MANtN ACitlRf D IHL OVE Ratt SAMPit Dit t litt REI ORE DE PROl'IRL T REPitt%tNII AllVE & THE SAWett 58f t att Bt SUFf UCUt Nit y L ARGt 10 PROVIDE ADEOUAlt CONFIDE NCE N AL L Iltt BE ARINGS.

k G A t,l HPH Otll

GENERIC DESIGN REVIEW AND OUALITY REVALIDATION (DROR) PROGR AM MATRIX COMPONENT HARDWARE INSPECTIONS UNIT DEstGN/0UALITY REVIEW SELEC TION ISAMPLE OR 100s B ASISI R - 4 6 [ NGINE 5:

fNG 5110R[ tl A M FULL F UI.L PARTS fMGIN RIVE R Bf ND F UL L FUL L IMINUS COMMON PART SI I O P R N A OlllR E DI fOMM RANCllO 5AClio FUL L FULL EM;NUS COMMON PARISi OUE P RI V-16 [NGif4L S.

/N IF RE QUINEDI GRAND GULF FULL IULL IMINUS R-45 COWuoN PARISI V -- I

COMMON PARIS IV-16)

E NCINE UNI,Out P A R I S

['fNGlN

~

CA1AWBA F UL L FULL EMs NUS COMMON PARTSI t OUE P R OUIRE DI

fkG N PLRRV F UL L FULL IMINUS COMMON PARTSI O

PR l fNGlN C OMM ant.Il[ P[Ak FULL FULL IMINUS COMMON PARTSI UNIOt t P RIS

'E '

f0 HARRIS F UL L F UL L IMINUS COMMON P ARTSI P RI G1 f IN 0]EPR VOGIL E F UL L FULL IMINUS COMMON PAR T SI I

V-12 NGINE 5:

F UL L

COMMON PARIS Ml0LAHD F UL L EMINUS R-4 8/V-16 COMMON P ARIS)

IV-12/ V-16 /R-4 0 - II RE OUIREDI

E NGINE ANO V-12 UNIOUE PARIS V-20 (I4GilJE 5:

FIA L

COMMON PARIS SAN ONCtRL FULL IMINUS R-48. V-16, V-12 COMMON PARIS)

IV-20/V-12/V-16/R-4 8 - II R[OUIRE D)

ENGINE AND V-20 UtilOUL PARIS d

GAGENPROH3

.L

4m yew.

re ei.ru--ey nyg go.gug e w. am i

TDI OWNERS' GROUP TESTING PROGR AM

SUMMARY

"'"~'

UNii PRE-OP TESTS INSPEC TIONS R-4 8, E NGINE S:

"00 Np{0

+ NDE CR ANkSilAF T I ALL [NGINE Sl PR Spoutnau F ut t POWER e SIMUL A TED I OCA RUN

= NDE CONNECIING ROD B[ ARINGS ISAMPLE)

IOIAL 1[SilNG J00 NRS.

NDE PISIONS ISAMPt El RivlR Ril1D

NRC PREOPS

NDE CONNECilNG ROD BE ARINGS IS AMPI ES

100 NRS. A T F UL L POWE R 11 E NGINEl

NDE CRANkSNAF T tl E NGINE - S AMPLEI

+ SlWUS. ATE D L OCA RUN 11 ENCINEI

NDE PISTONS 45AWPL[l RANCilO SACilO e NRC PRLOPS e NDE CONNECilNG ROD BE ARINGS ISAMPL[l V-16 [liClNE S:

NRC PREOPS

NDE CR ANkSNAF I el ENGINES GRAND Gutf

+ 100 NRS. Al FUL L POWER tl ENGINES

HDE CONNECilNG ROD BE ARINGS ESAMPLEl e ENOURANCE RUN II ENGINEl e NDE PBSIONS II ENGINE - 5 AWPLEI l

CAIAWDA

.NRC PREOPS

+ NDE CRANMSNAF T ll ENGlHE - S AWPI E l

NDE CONNECilNG ROD BE ARINGS IS AMPLEI

NDE PISIONS II ENGINE - S AMPL El PERRY

NRC PR[ OPS

NDE CRANMSN AFI II ENGINE - SAMPl[. IF R[OUIR[D3

NDE CONIKCilNG ROO BE ARINGS iS AMPLE, AS R[OutREDI

NDE PISIONS 8 SAMPLE - IF REOUIRE DI COuadANCl;L PE Ak

NRC PRIOPS

NDE CR ANKSNAF1 el ENCINE - S AMPL[. IF REOUIR[DB

NDE CONNE C ilNG ROD BE ARINGS IS AMPLE; AS REOUIRE DI

HDE PiSIONS ISAMPt [ - IF REOUIRE DI HARRIS

. NRC PREOPS

NDE CR ANkSil AF T ll [NGINC - S AMPl[ OF RE OUIRED)

NDE CONNE C18NG ROD BE ARINGS iS AMPLE, AS REQUIRE DI

NDE P1SIONS ISAMPL E - IF REOUIREDI VOG il E

NRC PREOPS ellDE CR AllhSNAFI II E NGINE - S AMPi t. II REOutREDI

NDE CONNECIING HOD BE ARINGS ISAWPLE, AS h[OUIREDI e ND[ PISIONS ISAWPt E - IF RE OUIRE Di V-12 E NGINE S:

WIDIAND

. NRC PREOPS

NDI CHANMSil AF I El [NGINE - SAMPLES

NDE CONNE CilNG ROD BL ARINGS IS AMPLEI V- ?O E NGINE S:

SAN ONOFRE

NRC PR[ OPS

+NDE CR ANk SN AF I il [NGINE - S AMPL E )

e NDE CONiet CIING ROD DE ARINGS ISAWPLEI, e

G AGE laPRO U 4 1

TDI OWNERS GROUP

SUMMARY

SCHEDULE

.DC-1 l

( PRELIMIN ARY )

i l

ACTIVITY JANI FESI MARI APRI MAYI JUNEI JULYl AUGI SEPTl OCT1 NOVI DECl JANI

[

l f

1 KNOWN PROBLEMS (LEAD UNIT INSPECTIONS) i

1. CRANKSHAFT

$"g'p*t yg l

l SS l

(LEAD UNIT INSPECTIONS)

}

2.BE ARINGS

"$'pg VS S g i

3. PISTONS ANALYSIS l

(INDUSTRIAL j

[

UNIT

[

(LEAD UNIT INSPECTIONS) j INSPECTIONTS l

l l

j 4.OTHERS ANALYSIS l INSPECTION & TESTING AS REOUIRED i

i H. DESIGN L QUALITY REVIEW (DROR)

1. COMPONENT SELECTION Eg-J 4

2. TASK DESCRIPTIONS 7///J l

3.DROR IMPLEMENTATION 7///J l

j i

4. FINAL REPORTS i

R - 4 8's O

h 8

i V-16's o

n oosa n V-12 O

l V-20 Q

l

15. TESTING / MAJOR INSPECTIONS l

1.R-48 7///J LEAD R-44 (OTHERS T8D) l l

I 1

2. V - 16 LEADV-E(TENT)

(OTHERS T8D)

3. V - 12 TBD

4. V - 20 Ta0 9

f

/<

3L2 l

REQUIREMENTS FOR LICENSING

1. RESOLUTION OF SIGNIFICANT KNOWN PROBLEMS

GENERIC (IF APPLICABLE)

ENGINE UNIQUE

2. COMMITMENT TO DROR PROGRAM

3. COMPONENT SELECTION (DRQR) AND PRELIMINARY REVIEW OF SELECTED COMPONENTS FOR SIGNIFICANT i

ITEMS i

4. COMPLETION OF PREOPTESTING AND ANY ADDITIONAL TESTING (100 HRS. @ FULL POWER FOR SOME UNITS)

5. COMPLETION OF ANY MAJOR INSPECTIONS

?

(CRANKSHAFTS, BEARINGS, AND PISTONS) 4 t

_

ML20117F369

Contents

Text

SUBJECT:

Enclosure:

C CUw ZK w> >

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

5=R A a u si-"=

SUMMARY

SUMMARY

Navigation menu

ML20117F369

Text

SUBJECT:

Enclosure:

C CUw ZK w> >

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

SUMMARY

5=R A a u si-"=

SUMMARY

SUMMARY

Navigation menu

Search