ML20117F489
| ML20117F489 | |
| Person / Time | |
|---|---|
| Site: | 05000000 |
| Issue date: | 05/25/1984 |
| From: | Ray C DUKE POWER CO., TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP |
| To: | |
| Shared Package | |
| ML20115A145 | List: |
| References | |
| FOIA-84-275 NUDOCS 8505130266 | |
| Download: ML20117F489 (12) | |
Text
.
1 TO! O!ESEL GENERATOR OY!NERS GROUP MONTHLY STATUS REPORT MAY 25,1984 1
TECHNICAL PROGRAM DIRECTOR d$02n.f-C.L. RAY, JR.
8!#52pgt6e42oao JMilMATS BELL 64-275 pgg
~
EXECUTIVE
SUMMARY
This report summarizes the status of the TDI Diesel Generator owners Group Technical Program as cf May 25, 1904.
Duke Pcwer Management and Technical Services began managing the-Owners Group-Technical Program May 7, 1984.
A Project Interface Document was issued May 10, 1984 defining Duke's responsibilities and interfaces between all parties involved.
Attachmen: 1 is an abbreviated organi:ational chart for the current Cwners Group Technical Program.
The Phase l reports for Shoreham are complete except for engine block and liner.
The completion date for this component is
- unknown at this ~ time.
.The problem is being able - to quantify stresses in.the block top where cracking has occurred.
A multifaceted approach to resolve the problem including a
qualitative analysis, mechanical tests, metalurgical examination and strain gage testing has been initiated.
Our goal is to have a-block report issued by June 15, 1984.
The Phase I reports for all other. plants are expected to be complete by June 15, 1984 except for. wiring and terminations.
See Attachment 2
for details.1 Results of the Phase I Program as of May 25, 1984 are
' listed in Attachment 3.
The final DR/QR Report for Shoreham (Phase I and II) will be complete - and : signed off by June 15, 1984.
The report will be assembled, bound and transmitted the following week.
Attachment.
4 indicates the current status of this work.
Plans are to complete final DR/QR reports (Phase I and II) for the initial 11 utilities no later than December 31, 1984.
The current priority order for utilities is reflected on Attachment 5.
A schedule'for all utilities Phase II work'will be issued with'the next monthly status report on June 20, 1984.
The component selection process is complete for all utilities except Southern California Edison, TVA and WPPS.
For details of the status of all inspection related activities see Attachment 6.
- Initial comments from PNL. have been received on all reports
- submitted to the NRC ' except for Turbocharger, Cylinder-Head, Wiring and ' Terminations, and supplemental reports on ' threaded fasteners.
Communication between the Owners Group and PNL is improving..The NRC assessment of the Owners Group Program Plan
. is in final draft at the NRC.
.The final NRC response is-expected
. the first week in June.
The results of this assessment ~are not known.
i The cost estimate for ccmpleting the Technical Program will be presented at the Executive Committee meeting on May 30, 1984.
4 4
~.
I 1
TECHNIC AL PROGRAM ORG ANIZ ATION A
i LECH PROGRAW DIRECT OR l'
t CL ARENCE L RAY EDI i
4 1
A55' 'ECH PROGRAW OftECTOR JW HAR1 IMINEl8D3 4
I I
t DR/OR H PO T E V'L PROJECT ENGINEER LICENSING COORDINATOR
[)R/OR PROGR AW WANAGER EH L ARRY G. 805T IDI WE COLEMAN IBIL LI 8Cl JOHN C M AWWEYEN (58 RW BON 5ALL #dlCki (D) t OUAL IT Y RE V AL ID A llON DESIGN REVIEW CH AIRW AN CH AIRM AN GARY W ROGERSIFl VA S AL E I A eviC1 ISI LEGEND C-CLEVEL AND ELEC TRIC a
D-DUME POWE R F -f AILUGE AN AL V515 ASSOC 5-5IONE & WE BST E R E NGINE ERING CORP N1I4(IIM'fil I i
j 9
i i
PHASE I FINAL REPORT ST ATUS I.
DATE EXPECTED REPORT COMPL E T E COMPLE TE DATE 1 CONNECTING ROD BE ARING SHELLS 3 -12 l
2.
PISTONS:
A.
AE/ AF PISTONS IlNITIAll 2-27 8 AE/AF PISTONS OFINALS S-24 C.
AN PISTON 4 -15 i
3.
A.
5HOREHAW ONLY 3-13 l
S.
ALL OTHER ENGINES 4-25 4.
CYLINDER HE AD STUDS.
l A.
SHOREHAM ONLY 3-30 B.
ALL OTHER ENGINES 4 -13 3.
AIR ST ART VALVE CAP 5 CREW 5:
t A.
5HOREHAW ONLY 3-23 i
B.
ALL OTHER ENGINES 4 -13 i
S.
PUSH RODS I ALL E NGINE SI 4 -19 7.
CRANKSHAFT 5 A.
05R-45 4-20 9.
054v-te S-24 C.
05mv-12 & 20 4 -15 S.
WIRING AND TERWINATIONS.
A.
SHOREHAM ONL Y 4-24 3.
CR ANO CULF ONLY 8-7 C.
COMANCHE PE Ak, C AT AWS A. SHE ARON H ARRIS 8 -82 D.
ALL REWAINING ENGINE S ENCEPT TVA AND WPP5 7 - 12 9.
CONNECTING ROD 5:
A.
DSR-es 4-27 3 05mv IALLI a-24
- 10. JACKE T W A T E R PUWP5:
A.
D5R-48 4 -16 9.
05NV 1 ALLS 4-t5 11.
FUEL OIL INJECTION TUBING I ALL ENGINE 51 4-27 12 B ASE AND BE ARING C APS.
A.
05R-48 4-27 9.
DSRV IALLI 4-IS
- 13. CYLINDE R HE ADS 8 AL L E NGINE58 S-IS 14 TURBOCHARGER A.
05R-48.0$RV-14 S-IS 0.
DSRy - 12. & 20 4 - 14
- 15. E NGINE BL OCM AND LINER UtlkNOWN 41IArsifil'Ili
I i
l PHASEIRESULTS i
TEST /
TION COMPONENT HISTORY ANALYSIS CONCLUSION I
j
- 1. PISTONS
- AF PISTON SNIRT
=AE NSPECTIONS OK
- ADEOUATE AE&AN DESIGNS l
+AN PISTON SMIRT OPERATNG HISTORY
- AH WRIS1 PN DOSS CRACMING
- = SIGetFICANT ALEOUATE -
i l
lMPROPER HEAT
= AN NSPECTIDNS OF AN ANALYSIS AfcEA UNIER REVEW TREATMENT STUD BOSS AREA UNDERWAY.
j OM AT CATAWBA.
CRACMING AT WRrST j
PIN 9055DISCOVERiD ADEOUATE IF O.G.
ADEOUAlE
- 2. COpeECTNG ROD CRACMED BEARNGS
- BEARINGS GENER-BEARNG SELLS AT Si4SS ALLY SERVICABLE ALLOWABLE FLAW lNSPECTIONS AND i
NO PATTERN OF WHEN INSPECTED SIZE NOT SOME REl* LACE-FAR.ED BEARNGS
=FL AW SIZES EXCEEDED MENTS REOulhED i
EXCEED O.G.
ALLOWABLE IN SOME CASES
- 3. ROCNER ARM lSOLATED FAllRES
= SIGNIFIC ANT
.ADEOUATE 061GINAL ADO i
CAPSCREWS POSITIVE MODF6ED DESIGNS OPERATING ADEOUATC HISTORY FALURES LEELY CAUSES isY INfUFFICifNT PRELOAD ILA4.EuENT TOHOUNG REQUIREMZNTS
- 4. AR START VALVE
- ORIGNAL CAPSCREWS
- SIGNIFIC ANT
. ADEOUA TE ADEOUATE WITH j
CAPSCREW BOTTOhED OUT N POSITIVE DIOENSIONAL l
CYLtOER TAD OPERATION VERIFICATION TAPPED HOLE HISTORY M 'LEl.EN I 10 CFR 21 REPORT TCROWJG REQUIREMENTS j
u ivonn, r
- ils
- Tl 4, l' *.
j
1 i
i l
I PHASEIRESULTS TEST /
TlON COMPONENT' HISTORY AN AL YSIS CONCLUSION
<j
- 5. CYLINDER HEAD NO FAttRES N
+SIGWICANT POSITIVE ADEOUATE BOTil DESICNS i
i STUDS NUCLEAR APPL 1-OPERATNG HSTORY ADEOUATE I
j CATION
- NECl,'ED DESIGN IS lSOLATED FALUPES MORE FATICUE N NON NUCLEAR RESISTANT ISTRAIGHT DESIGN)
+ FAILURES LIKELY CAUSED BY l
l lNSUeTICIENT j
PRELOAD
- 6. JACKET WATER PREVIOUS PUhF
+SIGWICANT POSITIVE + ADEOUATE FOR SHOfiEHAM F.EDESIGN PUMP SHAFT FALURES OPERATNG HSTORY INLINE ENGNES ADEGUATE
.TWO REDESIGNS BOTH M K ANALYZED RIVElf BEND &
BY TDI FOR SPFS APO VEE ENGlES ANALYSIS RANLHO SECO CONTINUING FOR CHAtiGE luPLLLER RV ENGINES MATERIAL ElnaNATE j
MPELLER KEYWAY j
7.PUStRODS FORGED EAD
+ORIGNAL DESIGN
.SOME FALURES-NOT +ADEOUATE ADEOUATE V.lTH i
DESIGN AFFECTING ENGINE NSPECTIONS CALLED 4
OPERATION FOR BALL EPO DESIGN
- FRST TDI REDESIGN
+CRACKNG N
+UNSAT
+ REPL ACE Wi1 H FOR COST REDUCTION NTERMEDIATE FORCED HEAD OR PtRPOSES PUSH RODS FRICilON WELD FRICTION WELD SECOND REDESIGN POSITIVE EXPERENCE ADEOUATE
.MOST RELIABLE DESIGN DUE TO CRACKING AT CATAWBA &
DESICri
)
OF BALL END GRAPO GLLF
- NSPECTIONS DESIGN FATIGLE TESTS REOU.ED S ATISFACTORILY
. RAP (k)M DES 1RUCTIVE 3
cot #'LETED TESTS 1
d l
A l l' Afillll'Il f 1 I
q r,pi:t 'I.'
.I
- j E
S C
E N N
A O
ME I
O N
L VDTC D EM S P
T RE E
Y D T
R E
I I
E T
O RRW O S
R N ELO N F8 O FWPL S)
SR U
O AN 4OFMCERONO O EE OT W
L ET E
AS t T P
I TtES
]T26 : F ED T t.
I l
E i
I i.S t t C
ASAC UoN C
l O/eE
't BA tI A A GA U D L A*
4T N
uR YeER U2 P
, i 4
l O
Oi:b OfLT J 5l a. L O
Ef ASLP EECS& EGfE WTRP i
t DDEu DNER 1
C DONEL WWIE I
AI l
i A L 'l A l
ACATA1
=
l iL
(
=
4 B
1; 4
RE S
D E
A R
RV I
S ET O
O LE FE F D N
Y E
E EA L
EM E G T
T T N A
AS A
ASS E
N UE U
UEE O#A OD OINN I
S A
=
L N
S T
T U
O S
D E
A G
S T
E E
DS h
R D
I M
T T
GD W G
E E
C NAE N
P E E
C O
1 S
D E A
L
.EE O N N
EC U
2E 5
ELPS W( O N B R
E TE8) -
tE BS T
STTGC T
PDOO D NR4 SD 0P t
S NFNCN NS CN N D DR)
S CP EESENEPI E N
O E
AE T
T I
ASSFCTE Y LF RO T
F T F GCCE LET E AR pE A OOE X
I T
5 ETA S
T RCJ D/RE V H L
V EED NEEE DSC N T
h AEP FV E
TCA eEP LR0 NLHR GG 5E MOR)E 1
I l S
SU OGPX LL L
EO U
E S
E NS4NSOE ASITDFWS SNL(3ND2.UNWNO 1
I I
T
=
A R
H 3A D
S
)
1 E
E2 E
P 1
L EF R
Y S C NT R R U&
R EU TNF A L S
R N CEC E AEE O
U T
LN ED0 LF D. IN S
F 1
CJEMG AO S
FN R DEDR E
ES T
N AC I
I DI E
H S6 U LTO VH P1L OB P NRTE
- A WAYE OEOE DSVF TCBR NSBV
- =
SDO T
S S
R N
T N
F DO G
E N
A N T I
N H
AA T
O S
N C
K GI P
N NM E
R N
M A
R I
E O
O R
I C
WT C
C 0
8 9
1
- i.
t i
j ; "
i
.,i
!iji!l;I
!j:
ljii
<l!
ilil ill
- l
i S
E N
PR Y
(
f NE T
S O O
Y
D S
F ET D W O
LE A EN P
d 3 COA T t.
E A Ar 3 O t
U I
C N
MLNITL A P C
Ut iS I
O AO F E 8
V EK SO RH DDT N
I E
E L
TI A ANl DT T t, B R
TCS GVDAEA
't f
TENT AiO EE D A EE LETL C
ATTI O CREC UK T f
4 U SE UD NNEOHCL
'I 4
N UCPRI I
OC O C O KTl EA i
OEEE T E J t. E f
I t
t l
O EPClDFORT EAERNU EECS RWPT l
1 I
I I
SS i
l i
I C
DS CHD S EUE DRUOOD DRHAOOE 4 -
Al ACAt CD ACDTNI AFTCTFtIN4 l
t
- I I
l' t
t I
I 1
.W C. A S
OL I
F S
F I
Y E
EL D
E E
L TDT T
T E
A AAOD A
A N
UWNE U
U OO E O
O S
A ELEC E
E X
D D
DLIZ T
AASE A
A L
N U
O S
E G R T
I S
T N U A
G E
T TO DD N Y
I A SH E R O
R R
R A D F LSSN E
TI PN TG T
C T
TEDE E
NNN SNRCU AE C P
A TEOAOES I
O Y A
TE I
F R K C A R CIDOFNH I
/
DO A I
E FRE E P UH EIS T
R S
OS GPX ERSA EEAA S
E G H"B SOE DAAMTNHS I
I T
A S
S M
H SS W G
G T
N E A
H N
E@R C TF L
T.O ES AOS BR R
K K
P Y
U AKP R
R LS(D C
C FD T
C A E AETAS OA N A A
DN R D RE E
DNEDPL O R H
A AT L1 KFESA EFA 0 N CEC C AA C O
C I
L G
C V O M OTEWS)
T L
.A ND U d CDS N P
S U EEPO E AEEEP C B TLKAV O E
N TRM ERSTN S
.W SOCE LDRNC T
I A ARAL I
H AU M A
CNLTVOKOVNR LE AS WSA F NLLDA LCPNL O O ANE O UXOET A@TLAtl U
E L
1 NISFAS SNENRA FSCGA 8 NNS l
G S
T N
D N
B A
U EG K
E T
SN N
AI R
R N
B A E
O LO P
OI EB O
E T
P M
LC e S I
EE GDP L
J NNA Y
O UFN EAC C
c l
2 3
I 1
1 y
I!
i i!
!I'
- i' ' '
l
.l l'
l'
- I
- l l
1
i I
PHASEIRESULTS COMPONENT HISTORY AN AL Y SIS
. CONCLUSION TEST INS TION l
l_
H. TURBOCHARGER
=FALURES AT SFS,
- NSPECTION AT StPS
.Tt@UST BEAREM
=ADEOUATE CATAWBA, GRAM)
& CATAWBA-ThaOST ADEOUATEif 14tELUBE -
GlLF ENG FALLAIC DUE TO PROPERLY HOLFICATION NON MJCLEAR LACK OF LLAEhCATION LUBRICATED llEOURt.D ON FALURES DURWG FAST START
- NOZ2LE VAIES SOLI t,MTS j
=GOOO OPERATIOi4AL (M)ER REVEW EXPERENCE $NCE PRELUBE j
MODFICATION i
B. CYLN)ER ELOCK
- BLOCK CRACKNG aCRAO(S AT
.AVGD FJGH CYLDMR i
.NON MJCLEAR Al REPAGATED N FROM OPERATION IMSS/ IEW BLOCK CRACNNG Of ENCtE AT HCH LOADS lELAX I DER ON ttDE AM)
S NO CRAOC GROWTH A>0 STUD PRELOAD L4TERFEMNCE VEE ENGDES N 2 ENCDES
- CRACKS CAUSED BY. LOW.ER Stim
= CATAWBA-LINER TENuAL YtE2A05 NO CRACMS EXPANSON AM)
NWOMIDO-STUD LOADuG V-WS,EOUATE NO CRACMS LOW CYCLE FOR HT2RN USE
=COWNCM PEAM-FAllGUE uECHAMSM.STR2SS EDLCTION NO 14pMCt IELATED Itot,/ c.flON J M AY OtAO(S lE idC(naENDED
- LitiE M S LN)CR LVALUATION l
i
'1 1T ria I;!^"lT 1
SHOREHAM DR/QR PROGRAM ST ATUS
- 165 COMPONENTS REOUIRING DR AND/OR Qlt WILL BE ADDRESSED IN THE SHOREHAu Dit/QR REPORT
- 175 REPORTS ARE REOUIRED TO ADDRESS THESE 165 COMPONENTS
- 106 OF THE TOT AL OF 175 REPORTS HAVE BEEN 1
t REVIEWED BY THE DR/QR REVIEW CouulTTEE
- FINAL DR/QR REPORT WILL BE SIGNED OFF BY 6/15/84. REPORT WILL BE ISSUED NO L ATER THAN 6/22/84 il'l 4t'lI 1 Ell r 4
s, l
i TDI OWNERS GROUP i
OVERALL DR/OR SCHEDULE
SUMMARY
2 APS 30 APs 24 asAY 23 JUN 30 JUL 27 AUG 24 SEP 29 OCl 24 NOV 31 DEC LILCO-SHOREllAM 3 C 3
TU-COMMANCilE PEAK i
MP&L-GRAND GULF DUKE-CATAWBA l
CP&L-SHEARON IIARRIS j
SMUD-RANCHO SECO GULF STATES-RIVER BEND CEI-PERRY CONSUMERS-MIDIMD GEORGIA-VOGTLE l
TVA-BELLEFONTE WPPS-WNP-1 LEGENS A
O PSEP OF Da IASM O(SC.
C O asp. on I Asn oc5C.
C C fmeAL RtPoai NITACliMEN r ',
t t
=.
i l-i ENGINE INSPECTION ST ATUS RE VIE W ISSUE COMPLETE ISSUE ISSUE HECEIVE i
PARTS COMPONENT CGhePONEN T TASK INSPE C TION INSPE C T ION R-48 MANUAL DATA BASE SEl.E C T ION DESCRIPTIONS PLANS RESUL TS SHOREHAM RIVER BEND V
V V
V BY UTILITY 8/17 i
RANCHO SECO V
V V
V 6/8 10 / 19 V-16 W
W V
V BY UTlliTY UNSCtEDULED GRAND GULF COMANCHE PE AK W
V V
V V
6/22
O IIISI*S PERRY W
V V
V I
CATAW8A V
V V
V BY UTILITY 7/27
)
SHE ARON HARRIS V
V V
V S / 31 7 / 13 VOGTLE V
V V
V 6 /12 9 / 21 BELLEFONTE S / 31 S/4 8/7 6/18 6/29
- UNSCt(DulED WNP-1 S / 31 a/4 8/7 6/18 6/29
- UNSCtfDt(ED V-l2 i
MIDL A ND V
V V
5/30 6 /13 11 / 2 3 V-20 DUE TO SAN ONOFRE V
V START 5/30 6/15 6/29 UN'.Ctf DUL E ASSUMES UTILITY REPRESENT ATIVE BEGINS WORKING WlIH OWNEHS CR0tlP llY $/ 31/ M4 e
trucmesM A rtvilllEin e.
- -