ML20128E097

Notification of 850701 & 02 Meetings W/Util in Glen Rose,Tx to Audit Design Review/Quality Revalidation Program for Facility Diesel Generators Mfg by Tdi.Agenda Consists of Encl Questions

ML20128E097
Person / Time
Site:	Comanche Peak
Issue date:	06/25/1985
From:	Burwell S Office of Nuclear Reactor Regulation
To:	Noonan V NRC - COMANCHE PEAK PROJECT (TECHNICAL REVIEW TEAM)
References
NUDOCS 8507050256
Download: ML20128E097 (9)

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Docket Nos.: 50-445 and 50-446 JUN 2 51985 MEMORANDUM FOR: Vincent S. Noonan, Director for Comanche Peak Project. DL FROM: S. B. Burwell, Project Manager Licensing Branch No. 1, DL

SUBJECT:

FORTHCOMING MEETING WITH TEXAS UTILITIES TO AUDIT THE COMANCHE PEAK DIESEL GENERATOR RELIABILITY PROGRAM DATE & TIME: Monday, July 1, 1985 Tuesday, July 2, 1985 1:00 p.m. - 5:00 p.m. 8:30 a.m. - 4:00 p.m.

LOCATION: Visitors Center / Nuclear Operations Support Facility Comanche Peak Steam Electric Station, F. M. 201 Glen Rose, Texas PURPOSE: Audit the design review / quality revalidation (DR/QR) program for the Comanche Peak diesel generators manufactured by Trans-america Delaval, Inc. (TDI), a part of Phase 2 of the TDI Owners Group Prgram. The enclosed questions will be used as an agenda. Open issues identified in SSER No. 6 Section 9.5.9 I may be discussed.

PARTICIPANTS: NRC APPLICANT S. Burwell D. Woodlan C. Berlinger R. Haskovec D. Persinko C. Ray, et. al.

NRC Consultants D. Dir. gee H. Hardy P. Louzecky A. Wendell ORIGINAL SIrJED BYa S. B. ,9urwell, Project Manager Licensing Branch No. 1 Division of Licensing

Enclosure:

As stated DISTRIBUTION:

See attached page cc: See next page LB#1:DL - LB . P :DL CP:TRT.

SBurwell:kab BJYbTnqblood C ammell VNoon 06/$/85 06 85 6/f /85 06 /8'5 8507050256 850625 gDR ADOCK 050 9

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1. COMANCHE PEAK JUN 2 5 B65 Mr. M. D. Spence President Texas Utilities Generating Company 400 N. Olive St., L.B. 81 Dallas, Texas 75201 cc: Nicholas S. Reynolds, Esq. Mr. H. Snannon Phillips Bishop, Liberman, Cook, Resident Inspector / Comanche Peak Purcell & Reynolds Nuclear Power Station 1200 Seventeenth Street, N. W. c/o U. S. Nuclear Regulatory Washington, D. C. 20036 Commission 4

P. O. Box 38 Robert A. Wooldridge, Esq. Glen Rose, Texas 76043 Worsham, Forsythe, Sampels &

Wooldridge Regional Administrator 2001 Bryan Tower, Suite 2500 U. S. NRC, Region IV Dallas, Texas 75201 611 Ryan Plaza Drive Suite 1000 Mr. Homer C. Schmidt Arlington, Texas 76011 Manager - Nuclear Services Texas Utilities Generating Company Lanny A. Sinkin Skyway Tower 3022 Porter Street, N. W. #304 400 North Olive Street Washington, D. C. 20008 L. B. 81 Dallas, Texas 75201 B. R. Clements Vice President Nuclear Mr. Robert E. Ballard, Jr. Texas Utilities Generating Company Director of Projects Skyway Tower Gibbs and Hill, Inc. 400 North Olive Street, LB#81 11 Penn Plaza Dallas, Texas 75201 New York, New York 10001 Ms. Billie Pirner Garde Mr. A. T. Parker Citizens Clinic Director Westinghouse Electric Corporation Government Accountability Project P. O. Box 355 1901 Que Street, N. W.

Pittsburgh, Pennsylvania 15230 Washington, D. C. 20009 Renea Hicks, Esq. David R. Pigott, Esq.

Assistant Attorney General Orrick, Herrington & Sutcliffe Environmental Protection Division 600 Montgomery Street P. O. Box 12548, Capitol Station San Francisco, California 94111 Austin, Texas 78711 Anthony Z. Roisman, Esq.

Mrs. Juanita Ellis, President Trial Lawyers for Public Justice Citizens Association for Sound 2000 P. Street, N. W. Suite 611 Energy Washington, D. C. 20036 1426 South Polk Dallas, Texas 75224

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f COMANCHE PEAK JUN 2 5 E85 cc: Ms. Nancy H. Williams CYGNA 101 California Street San Francisco, California 94111 Mr. Dennis Kelley Resident Inspector - Comanche Peak c/o U. S. NRC P. O. Box 1029 Granbury. Texas 76048 Mr. John W. Beck Manager - Licensing Texas Utilities Electric Company Skyway Tower 400 N. Olive Street L. B. 81 Dallas, Texas 75201 Mr. Jack Redding Licensing Texas Utilities Generating Company i

4901 Fairmont Avenue Bethesda, Maryland 20814 -

! William A. Burchette, Esq.

[ .4eron, Burchette, Ruckert & Rothwell

! Suite 700 1025 Thomas Jefferson St., N. W.

Washington, D. C. 20007 i

Mr. James McGaughy Southern Engineering Company of Georgia 1800 Peachtree Street. H. W.

Atlanta, Georgia 30367-8301 1

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, ENCLOSURE o

OUEST10NS RAIS1'O lid.CpSES OR/QR AU0lf REVIEW CP102 - Generator Controla _

In the opinion of the Pfit. Mviewers, the analysis Nported for the generator controls does not meet the objective of the OR/QR effort, priserily because i the methodology followed was too Itaited in scope, It addresses only four of

[ the se'nerators control' components and leaves many out that are critical to system reliability. -

Desien/Qualit.v Concerns Generally most voltage regulator and exciter fatfure modes are considered crittcal to the overall reliability of the diesel generator, especfally those

. tavolving common mode effects. Ceanents pertinent to the results and r

eenclusions of the Comanche Peak OR/QR report acet

! e Diedes and SCRs - States that current ratings are odequate . subject to ,

proper eeoling. Does not address voltage ratings. At least four failuro i l incidents Itsted in the 800 CTS are unexplained as to probable failure l bedes. One failure related to out-of-phase paralleling, it may have been caused by the sustained overvoltage conditions privalent in such events.

The temperature sonitoring provisions of Attachment 4 would not preclude

the occurmnee of a failure during en emergency operatine condition. It is recommended that tests be implemented to positively ideni.ify over- .

temperature conditions and permanent corrective actions taken as required.

This effort should be oocamplished by TUGC0 as soon se practical.

o Field fleshing relay. voltage specifications in Attachment 1 may not be adequate. A nominal voltage rating equal to or lower then' the lowest '

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. dropping resistor by-passed by a normally closed relay contact should use battery voltage should be Speojfied to insure relay pick-up. be to prevent coil demate when eneroiand at higher volta This is standard practice and is needed to insure relay pick ge levels.up under conditions and to preclude relay coil overheating under maximum voltage -

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conditions.

o Rather than relying only on a device such as Glyptol lacquer to monitor festener tightness, positive actions should be taken to insure such tightness. Fostener lockine devices'such as the use of double nuts or e bonding agent such as 40CTI1E U 1 (Lectite Corporation, Newington, j

connecticut 06111) are more positive. -

i o . Substitution of lockable pignttonmeters may be preferred to monitoring by use of Glyptol lacquer.

o f.abinet ventilation -- forced ventilation can creste new reliability problems by sucking-in large quantities of Ifnt and dirt if the cabinet is en the suetion side of the fan (s), .The presence of vent filters would not help if other openings such as enclosure joints.. enused fastener holes, or openings eroved sable penetrations bypass the filters. These problems require much attention to detail and can be avoided by instellino the fans '

so they discharge into the sabinet through filters or with filters en the

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suction cabinet through filters or with filters on the suction side. Or perhaps forced ventilation could be avoided by relocatiing temperature-critical components to the bottom of the enclosure where air temperatures ~

are 1 ewer.

o Power supply Sypassing -- The resoenendations for power supply bypassing

were made without an apparent knowledge of the energy levels of transient overvoltages to be suppressed. The EDGCTS shows incidents involving large voltage levels tospikes, An investigation insum edequate should be semiconductor made toTUGC0 protection, assessshov1d such energy give t his e high prferity for resolution.

o Current Feedback Signal - The need for this recommendation is not apparent from available performance date. -

o The status remarks of the EDGCT3 designated fifteen t'ncidents ss random i

failures havine no relevance to Comenche Peak reltability. These random failures include four fuseholder fativres and seven relay or relay contact l

failures representing discernible feiture patterns which should be l investigated. No effort appears to have been made to identify and document ell probable failure. modes on other listed incidents. Most of these l

l incidents caused outape of the emerpency generator, therefore their impact

.should have been cons <dered critice to reliability.

F-068 - Intercooler The report dfd not confirm that the heat rejection ca ncity of the cooler is ,ie adequate for the application. In the case of the tur >ocharger thte was done v test leg's. A related concern id whether the cooler will function adequately if

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it were 102 (example) fouled. .00-420 - Lube 011 Pressure Reeuiator.v Valve The QR inspectfon reports apparently were not available to the Owners' Group Review Team. Does the conclusion regarding edequacy of the component still remain on*open guestion? ,

00-6_21h-Fue)011OrtoTank Can TUGC0 (tre that fuel return entry is not by means of an open funnel which also can e it dirt?

02-3108 - Crankshaft Bearina She1Ts The etnimum oil film thickness of'147 microtnches is about 10% below the u pected minious velve for W 1evel of filtration pertaining to CP5E3. .Noreover, if a 10 micron filter is used it will pass dirt ht is twice the size of the of T f f1m thickness.

bearing shell crush (radial interfarence) and side location, and Normally,f details o the design of oil holes and grooves are considered in a design review because h oe are fundamental to strength. Inbefcation and cooling e.f the bearing. Why was this not done?

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t Was anything The QR makes no direct reference to hardware cheeks (inspections).

done in this regard?

02-310C - Crankshaft Thrust learine Rinet

! The DR did not address emiel vibretton as a source of thrust bearing feeding.

This can be e significent force. Please explain. ,

The QR makes no reference to inspections. Were any done?

02-336B - Front Geor' Basket /Soltina Was this l The QR does not confirm %et bolts were toreved to 60 ft-lbs.

confirmed?

l 02-341C - piston Pin Assembly The Qlt indicates a complete inspection of pisten pins on E00-01 win l

50G-42 was inspected on all right bank pins with -

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' unsatisfactory satisfactory results. results.In vfew of the ensatisfactory(o.ndings s.. River Send)T Canen 100-0 siefler unsettsfeetory results on other 101 engines 500-007 TUSCO., explain why s11 pins were not inspected on The application of chrome p1 sting con reduce the fetigue strength of steels.

Wes this cons (dered in % e DR7 i

02-3803 - tahaust Manifold Soltine and Saskets There het engine parts, have been e number of instances of ffres savsed by fapin It is considered head to e point inside of Ge exhaust senifold shield.imprtent tha en uust elbows. In particular all piping Jefnts shov1d be shocked to insureuse Possible that sprey could not tap noe on hot surfaces if a lenk developed.

of shrouded Joints shout 6e considered. .02-420 lEnotneDrivenLubs011 Puma It is noted that the piasp body end nor:1e Did are tho DR made of cast canfire theseiront presumably ports can Me sounting fienges are also of cast iron.

withstand seismic loed?

02-5404.8.C - Lube 011 Sumo Tank - Strainer MASAO 2 The OR did not address acceesibility for seir.tenance to v Can TU0C0 comment en thief meintaining systes cleanliness end. tightness. ,

02 689 - Off-Eneine Alers Sensors - W(rinn The QR did not confirm thet wirlng (items 2. Si and 4) seet IEEE 383 i requirements.

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4-02-7174.H.! - Ausiliarv Subbese Gaskets. Bottino, Fittinas_

The QR did not include a walkdown to confirm the absence of -low spots thet could trap sludge or foretgn setter. Can TUGC0 confirm this?

02-410A - Misc. teutoment - Aux. Jacket Water Puno The OR makes no mention of the capacit oftheauxiliary(orenginedriven)

Jacket water pumps. Are they edequate .

02-810C - Jacket Water Meat Exchancer Wee 'is no indication that the heet exchenger performance will be adequete under the estremes of teeperature Wt might prevetl et TU0Co. % review does not correlate the performance of the various components of he system such as

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the jacket water pump, strainers and thensostats. Are W y all compatiblef 02-410E . Jacket Water Standoise Heater P/oblems with W component were encountered at Shorehen. Can TUGC0 sonfirm that there is no similert.y between t the shorehen sad Cp5ES installations?02-820s - Aust1farv tube 011 puse The OR does not state est the capacity and pressure of'this pump is equal to that of Oc engine driven pump. TUGC0 should verify dis.

02-8200,E - Lube 011 Yeanware Strainer / Filter The OR did not verify Wt the stratner or filter. flew esosoity is equal te or

• greater than that of the prelvbe off pump (90 GPM). 100C0 should confirm this.

Note also that a plot of filter dp versus time would be a useful maintenance tools g.820F 6 Fuel Flow Lube 011 Filters 100C0 should verify that the filter capacity is sufficient for the engine delven -

lube oil pump (600 GPM). Also. %ere is no indication as to whether a relief valve and bypass around the filter is provided. If it is, the valve should be installed at. the top of the' filter to prevent the passage.ef dirt and sludge into the eAgine if the valve lifts. If %e engine is required to start when %e lobe oil heater 1s inoperative. it mey be necessary to have a bypass in order to -

insure that the engine will be Ivbefeated adequately under this cold start condition. In any case, the pressure drop should be checked and recorded at

' regular intervals so es to enticipate de necessity for a filter change. -

Appendix C tadteates a number of instances of excessive pressure drop serost s

filters which indleates Wt filter elements are not always changed when they j should be. ,

02-8206 - Lube 011 Heat (scheneer-f If We cooling water is too cold, eludse in W oil will deposit en the fins and i

reduce W heet exehanger espectty. Was this considered in the OR/047

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3-820H - Lube 011 Fuel hessure Strainer l

. TUSCO should confirm that the capacity is greater than or equel to that of the

' - engine driven tube oil pump (600 GPM). .

02-825A - fuel 011 Day Tank 4

There is no indication in the OR/QR that there.ts adequate means of removing water fra ne fuel oil to insure that W fuel injection pumps are protected.

A drein line at the bottee ei the day tank wovid be useful in view of the intermittent operation of the engine. Howevers even if the engine runs sentinuously for several hours at fulf lead, there will be insufficient stee for, water to settle in the de;r tank; TUGC0 should verify Wt there is means for stripping or filtering va",er from the fuel ott.

! M-83SA - Startina Air Skid Base. Tank Relief Valve. Float Tras and Tank TU0C0 should verify W4 there is adequate eccessibility to: the air valves and fToat traps.for saintenance. In addition..it is noted thet the starging air relief velve capacity is slightly greeter then the compressor espasity. TUGC0 should verify that it is not possible to connect more then one sempressor to

each air tank.

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