ML20127B542

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Forwards Listing of Unresolved Issues Re Tdi Diesels,To Be Discussed at 840413 Meeting.Issues Include Cylinder Heads, Engine Block,Wrist Pin Bushings,Connecting Rods & Rod Bearings,Turbocharger & Testing/Maint Plans
ML20127B542
Person / Time
Site: Grand Gulf, 05000000
Issue date: 04/11/1984
From: Adensam E
Office of Nuclear Reactor Regulation
To: Mcgaughy J
MISSISSIPPI POWER & LIGHT CO.
Shared Package
ML19263A614 List:
References
FOIA-84-459 NUDOCS 8404270314
Download: ML20127B542 (6)
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, / o UNITED STATES l E * *t NUCLEAR REGULATORY COMMISSION

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April 11, 1984

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Docket No.'50-416 Mr. J. P. McGaughy .

Vice President Nuclear Production Mississippi Power and Light Company P.O. Box 1640 Jackson, Mississippi 39205

Dear Mr. McGaughy:

Sub,iect: Major Unresolved issues Relating to TDI Diesel Generators at Grand Gulf Nuclear Station As we dicussed last week, the staff and its consultants have identified a number of unresolved issues pertaining to the TDI diesels at Grand Gulf Nuclear Station and which we would like to discuss at next Friday's meeting (4/13/84). Considerations pertinent to these issues are enclosed. The unresolved issues include the following:

Cylinder Heads Engine Block Wrist Pin Bushings Connecting Rods Connecting Rod Bearings Turbocharger Testing / Maintenance Plans E/go* .

Elinor G. Adensam, Chief Licensing Branch No. 4 Division of Licensing

Enclosure:

As stated cc: See next page 6W/147//$/fM  !

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GRAND gut.F Mr. J. P. McGaughy Vice President Nuclear Production Mississippi Power & Light Company P.O. Box 1640 Jackson, Mississippi 39205 cc: Robert B. McGehee, Esquire Wise, Carter, Child, Steen and Caraway P.O. Box 651 Jackson, Mississippi 39205 Troy B. Conner, Jr., Esquire Conner and Wetterhahn 1747 Pennsylvania Avenue, N.W.

Washington, D. C. 20006 Mr. Ralph T. Lally Manager of Quality Middle South Energy, Inc.

225 Baronne Street P.O. Box 61000 New Orleans, Louisiana 70161 Mr. Larry Dale Mississippi Power A Light Company P.O. Box 1640 Jackson, Mississippi 39205 Mr. R. W. Jackson, Project Engineer Grand Gulf Nuclear Station Bechtel Power Corporation Gaithersburg, Maryland 20760 Mr. Alan G. Wagner Senior Resident Inspector Route 2, Box 399 Port Gibson, Mississippi 39150 James P. O'Reilly, Regional Administrator U.S. Nuclear Regulatory Comission, Peq1on !!

101 Marietta Street, Suite 3100 Atlanta, Georgia 30303

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2 4 Connecting Rods o Evidence presented suggests that a reduction in frequency of failures may have been achieved but not necessarily a solution to the problem. Please address.

o Because of the potentially serious consequences of connecting rod failure, a conservative approach to establishing connecting rod adequacy is called for. This approach should take into consideration such factors as the root cause of connecting rod cracking, appro-priate tests to verify corrective action, probable minimum time l failure under worst-case conditions that may be imposed on Grand i Gulf engines, and appropriate enhanced ongoing surveillance to j onsure that the connecting rods remain sound in service.  !

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5. Connecting Rod Bearings The evidence available to the reviewers is insufficient to conclude whether the problems identified at Shoreham are applicable to Grand Gulf. Pertinent information which should be addressed by MP&L for establishing bearing suitability includes the following:

o Radiographic inspection of all bearings to acceptance critoria established by the Owners Group in a recently issued bearing shell report.

o Inspection and documentation of wear patterns of all bearings at Grand Gulf to verify absence of normal conditions, suen as end loading.

6. Turbncharger o The MP&L statements on misalignment as the cause does not provide a convincing argument, o It is considered unlikely based on the information available that vibration generated internal to the tubocharger could be the cause since such imbalance could rapidly lead to destruction of the bearings and rotor, i o It is considered more likely that vibration is caused by engine vibration transmitted inappropriately through turbocharger supports and/or piping.

l 0 MP&L should verify that appropriate consideration has been given to exhaust pipe residual loads on the turbocharger. These loads contribute to the loads on the turbocharger mounting bolts, and may contribute to excitation of turbocharger mounting vibration.

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7. Testing / Maintenance Plans 1

o The test program to demonstrate the adequacy of the TDI engines should be related to the demands that may be placed on the engines under emergency conditions as described in the Grand i

Gulf FSAR. I o Plans for post-test verification inspections should be provided, including what components are to be inspected and sampling plans ,

to be implemented. Results should be documented to the NRC. l Where MPL is relying upon post-test verification inspections '

from other plants in lieu of such inspections at GGNS, this should be identified and justification provided.

o The staff's preliminary thoughts are that such component verifi-cation inspections should include inspections performed after 1000 hours0.0116 days <br />0.278 hours <br />0.00165 weeks <br />3.805e-4 months <br /> of component service at or above the maximum power IcVels which can be experienced during emergency engine service (which we understand to be 68% for GGNS).

o The sumary of testing presented in Table 11-1 suggests that the AE piston skirts at GGNS were not subjected to " Tech. Spec. Testing".

It is not clear from Section 11.3 of the report which tests normally included as part of the 18 month functional testing were not included in the requalification testing following piston replace-ment. For example, Section 11.3.3 does not indicate whether 69 consecutive " valid" startup tests were performed. Please clarify whether an "18 month test" was performed subsequent to piston replacement, and if not, which tests were omitted.

o The brief description provided in the MP&L submittal of the maintenance program and reliability enhancement testing is not convincing to the reviewers that there will be adequate sur-veillance of physical conditions and monitoring of operating parameters to assure continuous availability and operability of the engines. An appropriate maintenance and surveillance program should be defined and comitted to, giving due consideration to the incomplete status of the Owners Group program. It should include appropriate maintenance and survelliance intervals for key components and justification / bases for proposed intervals.

8 Pistons o MPL should confirm with TDI that the AE piston skirts at GGNS are the same as those used in the R-5 tests, o Adequacy of the pistors should be verified by inspection to establish no rejectable indications following conclusion of the engine test program.

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9. Push Rods o A push rod failure may ultimately lead to shutdown of a cylinder and may in turn require early shutdown of the engines.

o The MP&L submittal addresses corrective action for the connector push rods but does not address the 2% failure of the main rods, o There is no evidence based on information available that the new design has been proven to be reliable.

o Adequacy of the modifications should be verified through 100%

inspection of the push rods to establish that no cracks have developed following conclusion of the engine test program.

10. Crankshaft o Incipient problems could be indicated by the finding of wear patterns on bearings.

o Hot and cold shaft deflection readings should be taken to reveal potential alignment problems that could lead to difficulties with shaft, bearings, bearing supports and base. (Hot deflection readings should be completed within 15 minutes of engine shutdown to be valid.)

o MPL should verify that crankshafts of this design (any service) i have not failed due to design deficiencies.

11. L.P. Fuel Line l o MPL should establish that no new vibration response problems have been introduced as a result of the corrective actions taken.
12. M.P. Fuel Line o MPL should verify that _new lines are not defective (i.e., do not contain the draw seam).
13. Engine Base o MPL should verify through TDI, that historical engine base problems do not involve other than maintenance considerations in installations similar to Grand Gulf.
14. Rocker Arm Capscrew o A recent report issued by the Owners Group on this topic addresses:

(1) design, (2) materiais, and (3) retorquing.

o MP&L should implement the Owners Group recommendations.

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