ML20126E872
| ML20126E872 | |
| Person / Time | |
|---|---|
| Site: | Perry, Catawba, Harris, Grand Gulf, River Bend, Vogtle, San Onofre, Comanche Peak, Rancho Seco, Midland, Bellefonte, 05000000, Washington Public Power Supply System, Shoreham |
| Issue date: | 05/24/1985 |
| From: | Laity W Battelle Memorial Institute, PACIFIC NORTHWEST NATION |
| To: | Berlinger C Office of Nuclear Reactor Regulation |
| References | |
| CON-FIN-B-2963 NUDOCS 8506170246 | |
| Download: ML20126E872 (1) | |
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Pacific Northwest Labcratories P.O. Bos 999 Rx hiand, \\\\ashineron (1.5A 99352 May 24, 1985 1,;,pnon,,309, 375-2780 l
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Mr. Carllerlinger Division of Licensing U.S. Nuclear Regulatory Commission 7920 Norfolk Avenue Bethesda, Maryland 20014
Dear Mr. Berlinger:
SUBJECT:
TDI DIESEL ENGINE PROJECT (FIN B2963)--TRANSMITTAL OF TECHNICAL EVALUATION REPORT " REVIEW 0F EMERGENCY DIESEL GENERATOR ENGINE AND AUXILIARY MODULE WIRING AND TERMINATIONS" DATED MAY 1985 (PNL-5200-3)
Enclosed for your use are 10 copies of the subject PNL technical evaluation report and two additional copies for the NRC public document reading room.
Other copieMo have been distributied as noted on'the last page of the report.
The principal PNL consultants and PNL staff engineers who participated in this evaluation are J. E. Horner, E. Loftus, P. J. Louzecky, W. R. McSpadden, J. F. Nesbitt, N. M. Rivera and F. R. Zaloudek.
Sincerely, 6.
W. W. Laity PNL Project Manager WWL:ri
Enclosures:
cc:
As noted on distribution for report.
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PNL-5200-3 Technical Evaluation Report 1
Review of Emergency Diesel Generator Engine and Auxiliary Module Wiring and Terminations
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May 1985 Prepared for the U.S. Nuclear Regulatory Commission Division of Licensing Office of Nuclear Reactor Regulation under Contract DE-AC06-76RLO 1830 NRC FIN B2952 Pacific Northwest Laboratory Operated for the U.S. Department of Energy by Battelle Memorial Institute g
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2 DISCLAIMER
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This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government not any agency thereof. nor any of their employees, makes any warranty, express or
. implied, or assumes any legal liability or responsibility for the accuracy, com-
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pleteness, or usefulness of any information, apparatus, product, or process disclosed,or represents that its use would not infringe privately owned rights.
Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily
-constitute or imply its endorsement, recommendation, or favoring by the Umted States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.
PACIFIC NORTHWEST LABORATORY operated by BATTELLE for the UNITED STATES DEPARTMENT OF ENERGY under Contract DE-AC06-76RLO 1830 4
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PNL-5200-3 Technical Evaluation Report REVIEW 0F EMERGENCY DIESEL GENERATOR ENGINE AND AUXILIARY MODULE WIRING AND TERMINATIONS May 1985 Prepared for the U.S. Nuclear Regulatory Commission Division of Licensing Office of Nuclear Reactor Regulation under Contract DE-AC06-76RLO 1830 NRC FIN B2952 Project
Title:
Assessment of Diesel Engine Reliability / Operability NRC Lead Engineer:
C. H. Berlinger i
Pacific Northwest Laboratory Richland, Washington 99352
FOREWORD This report is supplied as part of the Technical Assistance Project, Assessment of Diesel Engine Reliability / Operability, being conducted for the U.S. Nuclear Regulatory Commission, Office of Nuclear Reactor Regulation, Division of Licensing,-by the Pacific Northwest Laboratory. The U.S. Nuclear Regulatory Commission funded this work under authorization B&R 20-19-40-42-1 FIN Ho. B2952.
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PACIFIC NORTHWEST LABORATORY PROJECT APPROVALS hw 7
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Date W. W. Laity, Project Manager
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Pacific Northwest Laboratory
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Date D O' W W. D. Richmond, Chairman Senior Review Panel Pacific Northwest Laboratory 9
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ACKNOWLEDGMENTS This report was compiled by PNL project team members J. F. Nesbitt and F. R. Zaloudek based on technical contributions provided by PNL staff member C. L. Wilson and consultants E. Loftus, P. J. Louzecky, W. R. McSpadden, J. E. Horner, and N. M. Rivera.
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ABSTRACT This report documents the review cerformed by the Pacific Northwest Laboratory (PNL) of action taken by the Transamerica Delaval, Inc. (TDI) Diesel Generator Owners' Group to evaluate wiring and terminations for TDI engines at 10 nuclear power plants.
In response to TDI Service Information Memo (SIM) 361, Rev.1, concerning potentially defective engine-mounted cables for the Woodward governor / actuator and the Air-Pax magnetic pickup, the Owners' Group authorized Stone & Webster Engineering Corporation (SWEC) to evaluate all class IE auxiliary module wiring and terminations installed on the engines.
The evaluations are described in five SWEC reports.
In field surveys of the engine installations, SWEC investigated the compatibility of the wiring and terminations on the diesel engines with the electrical and environmental service characteristics of the applications. SWEC conclusions and recommendations are as follows:
The existing wiring and terminations are acceptable for service at e
the following installations:
Comanche Peak Grand Gulf Perry Rancho Seco River Bend San Onofre Engine No. 2 Shearon Harris The following recommendations should be implemented at the e
installations noted:
Catawba:
TDI SIM 361 should be implemented, the period of manufacture of the States-type sliding link terminal blocks should be verified, and certain Kyner-insulated wire should be replaced.
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Midland: TDI SIM 361 should be implemented, and the period of manufacture.of the. States-type sliding link terminal blocks should be verified.
(Construction of this power plant was subsequently suspended.)
San Onofre Engine No. 1: TDI SIM 361 should be implemented.
Shoreham: Wiring with type MTW insulation should be replaced in the circuits for the crankcase vacuum fans and the starting air supply solenoid valves.
PNL concurs with the conclusions and recommendations described in the SWEC reports.
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CONTENTS FOREWORD.................................................................
11 PACIFIC NORTHWEST LABORATORY PROJ ECT APPROVALS...........................
iii ACKNOWLEDGMENTS..........................................................
iv ABSTRACT.................................................................
v
1.0 INTRODUCTION
1 1.1 ISSUE ADDRESSED BY 0WNERS' GROUP...............................
2
1.2 DESCRIPTION
OF INSTALLATIONS...................................
2 2.0 OWNERS' GROUP STUDY.................................................
2 2.1 SCOPE OF INVESTIGATION.........................................
3 2.2
SUMMARY
OF RESULTS.............................................
3 2.2.1 Shoreham Nucl ea r Power Station..........................
3 2.2.2 Comanche Peak Steam Electric Station Unit 1.............
4 2.2.3 Grand Gul f Nuclear Station Uni t 1.......................
4 2.2.4 Catawba Nucl ear Stati on U ni t 1..........................
4 2.2.5 Other Nucl ear Power Stati ons............................
5 2.3 REVIEWS DEFERRED TO PHASE II 0F OWNERS' GROUP PROGRAM..........
6 3.0 PNL'S EVALUATION....................................................
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4.0 CONCLUSION
S AND RECOMMENDATIONS.....................................
7 4.1 INSTALLATIONS FOR WHICH NO FURTHER ACTION IS NECESSARY.........
7 4.2 INSTALLATIONS RECOMMENDED FOR FURTHER ACTION...................
8 4.2.1 Ac t i o n Com pl e te d........................................
8 4.2.2 Action Pending..........................................
8 4.2.3 Ac t i o n D e f e r re d.........................................
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4.3 REVIEWS DEFERRED TO PHASE II 0F OWNERS' GROUP PROGRAM..........
9 REFERENCES...............................................................
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REVIEW OF EMERGENCY DIESEL GENERATOR ENGINE AND AUXILIARY MODULE WIRING AND TERMINATIONS
1.0 INTRODUCTION
The Pacific Northwest Laboratory (PNL) is supporting the U.S. Nuclear Regulatory Commission (NRC) staff in addressing questions of the reliability, operability, and quality assurance of Transamerica Delaval, Inc. (TDI) diesel engines used to provide standby power in some nuclear power plants. These ouestions were raised because of a major failure in one TDI diesel at the Shoreham Nuclear Power Station in August 1983 and other problems encountered with TDI diesels. One of the principal tasks in PNL's effort is to evaluate the resolution by the TDI Owners' Group of known problems with potential generic applicability.
This report documents PNL's evaluation of the Owners' Group review of the electrical wiring and terminations supplied with the TDI emergency diesel generators at the Catawba, Comanche Peak, Grand Gulf, Midland, Perry, Rancho Seco, River Bend, San Onofre, Shearon Harris, and Shoreham nuclear power sta-tions. The details of the Owners' Group review were presented in five reports prepared by Stone & Webster Engineering Corporation (SWEC):
Emergency Diesel Generator Engine and Auxiliary Module Wiring and Termination Qualification to IEEE-383-1974, April 1984 Supolement To The Emergency Diesel Generator Auxiliary Module Control e
Wiring and Termination Qualification Review, DR4-210-013, May 4,1984 Supplement to the Emergency Diesel Generator Auxiliary Module Control Wiring and Termination Qualification Review, B2-1160060-2, June 1984 Supplement to the Emeraency Diesel Generator Auxiliary Module Control Wirina and Termination Qualification Review, 82-1160060-4, June 1984 Emeroency Diesel Generator Auxiliary Module Control Wiring and Termination Qualific1 tion Review TDIO287, July 1984.
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1.1 ISSUE ADDRESSED BY OWNERS' GROUP TDI's Service Information Memo (SIM) 361, Rev.1, notified the engine owners of potentially defective engine-mounted cables associated with the Woodward governor / actuator and the Air-Pax magnetic pickup. This memo led the Owners' Group to question the suitability of all class IE auxiliary module wiring and terminations currently installed on the diesel engines. Of special interest was the suitability of this wiring with respect to flame-retardancy of
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the insulation, qualification to industry standards, routing of conduit, compatibility with circuit requirements, and the need for special requirements such as shielding.
1.2 DESCRIPTION
OF INSTALLATIONS All cable / wire associated with the engines is generally routed in either electrical metallic tubing (EMT), rigid galvanized steel conduit, or flexible conduit. A variety of wire and insulation types is used, depending on the characteristics of the circuit. These include types SIS, MTW, XLPE, and XHHW.
The conduits installed on the skid and supported away from the engine are potentially subject to the maximum room temperature (120*F to 140*F). The junction boxes, conduits, and cables attached to the engine block are poten-tially subject to at least engine cooling jacket / lubricating oil temperature (180*F).
2.0 OWNERS' GROUP STUDY This issue was addressed by SWEC, a consultant to the Owners' Group. The objectives of the SWEC effort were to examine the functional attributr
"' the electrical wiring and teminations supplied with the diesel engines ano to determine their suitability for the intended purpose.
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2.1 SCOPE OF INVESTIGATION The scope of SWEC's investigation encompassed the following activities:
Identify all wiring and terminations supplied with the diesel engines from TDI manuals (or, in the case of Shoreham, from the SWEC design documents).
Review the wiring insulation for compatibility with circuit e
requirements.
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Determine if the insulating material is known to have generic fire-e retardant characteristics and is qualified to selected industry standards, Review the wiring installation routing to determine the physical e
environment for each cable.
Evaluate circuit requirements to 'etermine if special cable is e
required.
Compare the termination types, materials, sizes, and insulation e
ratings as given in the manufacturer's specifications with the characteristics required for the particular circuit and environment.
2.2
SUMMARY
OF RESULTS 2.2.1 Shoreham Nucinar Power Station SWEC surveyed the class IE auxiliary module wiring and terminations currently installed on the TDI diesel engines at Shoreham. Each circuit's service characteristics were identified and compared to the service ratings of the cable and termination types used.
IEEE-383-1974 was used as the basis for this review.
As reported in Emergency Diesel Generator Engine and Auxiliary Module Wiring and Termination Qualification to IEEE-383-1974 (April 1984), SWEC reached the following conclusions for the Shoreham engines:
Qualified replacement cable was provided by TDI and installed on the e
diesel engines in accordance with SIM 361, Rev.1.
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e The module wirino, cable, and terminations are compatible with the circuit characteristics and the operating environment, except for the wiring with type MTW insulation used in the circuits for the crank-case vacuum fans and the starting air supply solenoid valves. Type MTW insulation is not compatible with expected ambient temperatures in these circuits. The selected replacement cable, Okonite 1/C#12-19X Black Okozel (Tefzel insulation), type ZW, rated at 125'C, is acceptable for the expected operating temperature (87.2*C). When this replacement is accomplished, all functional attributes established for the design review of the wiring and terminations will be satisfied.
2.2.2 Comanche Peak Steam Electric Station Unit 1 Taking into consideration the same attributes and qualifications as those applied at Shoreham, SWEC conducted a field survey of the class IE auxiliary module wiring and terminations currently installed on the TDI diesel engines at Comanche Peak. SWEC reported in the Supplement to the Emergency Diesel Generator Auxiliary Module Wiring and Termination Qualification Review (May 1984) that all wiring and tenninations are acceptable for their intended service.
2.2.3 Grand Gulf Huclear Station Unit 1 In the Supplement to the Emergency Diesel Generator Auxiliary Module Control Wiring and Termination Qualification Review (B2-1160060-2, June 1984),
SWEC concluded from a field survey of the TDI diesel engines at Grand Gulf that qualified replacement cable had been installed in accordance with SIM 361, Rev.1, and that all wiring and terminations are acceptable for their intended service.
2.2.4 Catawba Nuclear Station Unit 1 The results of the field survey conducted by SWEC on the TDI engines at Catawba are reported in the Supplement to the Emergency Diesel Generator Auxiliary Module Control Wirino and Termination Qualification Review 4
(B2-1160060-4, June 1984). SWEC found the wiring and terminations accept-able for their intended service, subject to implementation of the following recommendations:
- TDI SIM 361 should be implemented.
In accordance with NRC IE Information Notice No. 80-08 of March 7, 1980, the period of manufacture of States-type NT sliding link terminal blocks (item 5 in Table A of the SWEC report) should be checked to verify that the blocks were penduced in a time perind other than 1974 through 1976.
The Kyner-insulated,14 AWG wire identified as item 2 in Table A of e
the SWEC report should be replaced with wire qualified to IEEE-383-1974.
2.2.5 Other Nuclear Power Stations The results of the field surveys conducted on class IE auxiliary module wiring and terminations installed on TDI diesel engines at six other nuclear power stations were reported by SWEC in Emergency Diesel Generator Auxiliary Module Control Wiring and Termination Qualification Review (July 1984).
SWEC found the existing wiring, cable, and terminations acceptable for their intended service on the TDI engines at the following installations:
Perry Nuclear Power Plant Unit i o
e Rancho Seco Nuclear Power Station Unit 1 River Bend Nuclear Power Station Unit i e
San Onofre Nuclear Generating Station Unit 1, Engine No. 2 e
Shearon Harris Nuclear Power Plant Unit 1.
e SWEC also found the wiring and terminations acceptable for the intended service at the following installations, subject to implementation of certain recommendations:
Midland Nuclear Power Plant - TDI SIM 361 should be implemented, and e
the period of manufacture of the States-type sliding link terminal blocks should be verified.
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San Onofre Nuclear Generating Station Unit 1, Engine No.1 - TDI e
SIM 361 should be implemented.
2.3 REVIEWS DEFERRED TO PHASE II 0F OWNERS' GROUP PROGRAM SWEC commented in the above-mentioned report of July 1984 that wiring and terminations on engines not reviewed during Phase I of the Owners' Group Program will be reviewed as part of the Phase II Design Review / Quality
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Revalidation Program.
3.0 PNL'S EVALUATION The following PNL staff and consultants participated in the reviews of the reports prepared by Stone & Webster Engineering Corporation on engine and auxiliary module wiring and tenninations:
J. F. Nesbitt, PNL project team e
E. Loftus, electrical engineer, Kaiser Engineers Hanford Co.
o P. J. Louzecky, consultant, Engineered Applications Corporation W. R. McSpadden, Ph.D., engineering consultant e
J. E. Horner, consultant, Seaworthy Systems, Inc.
e N. M. Rivera, consultant, Designers and Planners, Inc. (TRACOR e
Hydronautics, Inc.)
C. L. Wilson, PNL staff.
e PNL's reviews focused on the following areas:
Were the methods of analysis and approaches taken in the studies e
satisfactory?
Are the infonnation and data collected in the studies adequate for e
proper evaluation?
Are the conclusions and recommendations supportable?
e Have the objectives of the study been met?
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PHL's reviews focused on the SWEC reports.
Some use was made of specific references and written and oral infonnation requested from and provided by the Owners' Group.
4.0 CONCLUSION
S AND RECOMMENDATIONS PNL concurs with the approach used to evaluate the class IE auxiliary module wiring and termiriottoris curreritly Iristalled on TDI diesel generators at 10 nuclear power plants owned by the TDI Diesel Generator Owners' Group. PNL also concurs with the conclusions and recommendations in the five SWEC reports on the field surveys of the wiring and terminations. SWEC's conclusions and recommendations, and the references for them, are discussed in Section 2.2 of this report. They are categorized under the two subheadings that follow according to those found to be satisfactory during the field surveys and those for which SWEC recommended that certain actions by taken.
4.1 INSTALLATIONS FOR WHICH NO FURTHER ACTION IS NECESSARY SWEC concluded that the existing class IE auxiliary module wiring and terminations are acceptable for service on TDI diesel engines at the instal-lations listed below. On the basis of the field surveys reported by SWEC, PNL concurs that no further action to upgrade th engine-mounted wiring and terminations at these installations is necessary:
o Comanche Peak Steam Electric Station Unit 1 e Grand Gulf Nuclear Station Unit i e Perry Nuclear Power Plant Unit 1 e Rancho Seco Nuclear Power Station Unit i e River Bend Nuclear Power Station Unit 1
- San Onofre Nuclear Generating Station Unit 1, Engine No. 2 e Shearon Harris Nuclear Power Plant Unit 1.
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4.2 INSTALLATIONS RECOMMENDED FOR FURTHER ACTION SWEC concluded that the wiring and terminations on TDI diesel engines are acceptable for service at three other installations, subject to implementation of certain recommendations. These recommendations, and the status of action on each at the time this PNL report was written, are as follows.
4.2.1 Action Completed San Onofre Nuclear Generating Station Unit 1, Engine No.1 SWEC Recommendation: TDI SIM 361 should be implemented.
Status:
In a letter to NRC (C. H. Berlinger) dated April 3, 1985, the Owners' Group ( A. M. Segrest) confirmed that SIM 361 has been implemented on this engine.
(TOI SIM 361 had pre-viously been implemented on Engine No. 2.)
e Shoreham Nuclear Power Station SWEC Recommendation: Wiring with type MTW insulation should be replaced in three circuits for the crankcase vacuum fans and the starting air supply solenoid valves. The selected replacement cable, Okonite 1/C#12-19X Black Okozel (Tefzel insulation), is acceptable for the expected operating temperature.
Status:
In a letter to NRC (C. H. Berlinger) dated May 7,1985, Duke Power Company ( A. M. Segrest) confirmed on behalf of the Owners' Group that this recommendation has been implemented.
4.2.2 Action Pending Catawba Nuclear Station Unit 1 e
SWEC Recommendations:
a.
TDI SIM 361 should be implemented.
b.
The period of manufacture of States-type NT sliding link terminal blocks should be verified in accordance with NRC IE Information Notice No. 80-08 of March 7,1980.
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c.
Certain Kyner-insulated,14 AWG wire should be replaced with wire qualified to IEEE-383-1974.
Status:
In a letter to NRC (C. H. Berlinger) dated April 3, 1985, Duke Power Company ( A. M. Segrest) confimed on behalf of the Owners' Group that SIM 361 has been implemented (recommen-dation a., above), but that the verification of the sliding link teminal blocks has not been performed to date (recommendation b.).
Duke Power ( A. M. Segrest) stated in a letter to NRC (C.
H. Berlinger) dated May 7,1985 that the Kyner-insulated wire has not yet been replaced (recomendation c.)
PNL Recommendation:
SWEC recommendations b. and c., above, should be implemented by Duke Power Company in a timely manner and no later than the first outage for power plant refueling.
4.2.3 Action Deferred e Midland Nuclear Power Plant SWEC Recommendations: TDI SIM 361 should be implemented, and the period of manufacture of States-type link terminal blocks should be verified.
Status: Construction of the Midland plant was suspended, and the owner, Consumers Power Company, withdrew from the TDI Diesel Generator Owners' Group.
PNL Recommendation: The SWEC recommendations should be implemented if construction of the Midland plant is resumed.
4.3 REVIEWS DEFERRED TO PHASE II 0F OWNERS' GROUP PROGRAM As noted in Section 2.2.6 of this report, SWEC observed that wiring and teminations on engines not reviewed during Phase I of the Owners' Group Program will be reviewed as part of Phase II, the Design Review / Quality Revalidation Program. PNL recomends that these later reviews be conducted using the same approach and with the same thoroughness as was used in the reviews already completed.
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REFERENCES ANSI /IEEE STD 383-1974.
IEEE Standard for Type Test of Class IE Electric Cables, Field Splices, and Connections for Nuclear Power Generating Stations.
The Institute of Electrical and Electronics Engineers, Inc., New York, New York.
Ray, C. L., Jr. August 13, 1984. Letter to NRC (C. H. Berlinger, "TDI Diesel Generator Owners' Group Response to PNL and NRC Questions."
Segrest, A. M.
April 3, 1985. Letter to NRC (C. H. Berlinger) re Response of TDI Owners' Group to Questions on Engine Wiring and Terminations.
Segrest, A. M.
May 7, 1985. Letter to NRC (C. H. Berlinger) re Response of TDI Owners' Group to Questions on Engine Wiring and Terminations.
Stone & Webster Engineering Corporation. April 1984. Emergency Diesel Generator Engine and Auxiliary Module Wiring and Termination Qualification to IEEE-383-1974. Boston, Massachusetts.
Stone & Webster Engineering Corporation. May 1984.
Supplement To The Emergency Diesel Generator Auxiliary Module Control Wiring and Tennination Qualification Review. DR4-210-013 Boston, Massachusetts.
Stone & Webster Engineering Corporation. June 1984.
Supplement to the Emergency Diesel Generator Auxiliary Module Control Wiring and Termination Qualification Review. B2-1160060-2, Boston, Massachusetts.
Stone & Webster Engineering Corporation. June 1984.
Supplement to the Emergency Diesel Generator Auxiliary Module Control Wiring and Tennination Qualification Review. B2-1160060-4, Boston, Massachusetts.
Stone & Webster Engineering Corporation. July 1984.
Emergency Diesel Generator Auxiliary Module Control Wiring and Termination Qualification Review.
TDIO287, Boston, Massachusetts.
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PNL-5200-3 l
DISTRIBUTION l
No. of No. of Copies Copies 0FFSITE P. Lang, NE-14 U.S. Department of Energy 16 Division of Licensing Office of Nuclear Energy l
Office of Nuclear Reactor Washington, DC 20555 Regulation U.S. Nuclear Regulatory ONSITF Commission Washington, DC 20555 00E Richland Operations Office ATTN:
C. Berlinger (10)
M. Carrington (2)
H. Ransom /M. Plahuta D. Corley F. Miraglia Pacific Northwest Laboratory l
H. Thompson l
M. Williams 5 Consul tants 12 NRC Plant Project Managers J. Horner Division of Licensing E. Loftus U.S. Nuclear Regulatory P. Louzecky Commission W. McSpadden Washington, DC 20555 N. Rivera ATTN:
B. Buckley S. Burwell 5 Senior Review Panel l
D. Hood l
D. Houston F. Albaugh l
K. Jabbour S. Bush T. Kenyon C. Hill l
E. McKenna W. Richmond M. Miller L. Williams S. Miner C. Stahle 27 Project Team l
J. Stefano E. Weinkam J. Alzheimer A. Currie l'
2 U.S. Nuclear Regulatory D. Dingee l
Connission R. Dodge Public Document Room W. Gintner l
Division of Technical W. Laity (20)
Information and Document J. Nesbitt Control F. Zaloudek Washington, DC 20555 Technical Information (5)
Publishing Coordination (2) l l
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