ML20128H993

Interim Deficiency Rept Re Defect in Replacement EDG Fuel Oil Pumps Supplied by Colt Industries (Fairbanks Morse Engine Div).Initially Reported on 930111.Plugs & O-rings Repositioned.Vendor Requested to Perform Evaluation

ML20128H993
Person / Time
Site:	Hope Creek
Issue date:	02/09/1993
From:	Miltenberger S Public Service Enterprise Group
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-93 NLR-N93009, NUDOCS 9302170275
Download: ML20128H993 (6)

Text

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Putiac Service Dectsit and G&s Company Steven E. Miltenberger Pubhc Servic" Electric and Gas Company P C . % 236, Hancocks Bndge, NJ 08038 609-339-1i00 vaeese edcuth erom FEB 0 91993 NLR-N93009 United States Nuclear Regulatory Commission Document Control Desk Washington, DC 20555 Gentlemen:

10CFR21 NOTIFICATION, COLT INDUSTRIES EMERGENCY DIESEL GENERATOR FUEL OIL PUMP HOPE CREEK GENERATING STATION FACILITY OPERATING LICENSE NO. NPF-57 DOCKET NO. 50-354 Pursuant to the notification requirements of 10CFR21, Public Service Electric and Gas Company (PSE&G) hereby provides the attached report concerning a deficiency in replacement Emergency Diesel Generator Fuel Oil Pumps supplied by Colt Industries (Fairbanks Morse Engine Division) of Beloit, WI.. This deficiency was reported to the NRC Operations Center on January 11, 1993.

Attachment 1 fully describes the identified deficiency and corrective actions implemented.

Please do not hesitate to contact us if there are any questions regarding this submittal.

Sincerely, Y

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- . - . 1 Document l Control Desk 2 NLR-N93009 FEB 0 9.1993; 1 J

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-C Mr. T. T. Martin, Administrator - Region I-U. S. Nuclear Regulatory Commission 475 Allendale Road .

King of Prussia, PA 19406 i

Mr. S. Dembek - Licensing Project Manager U. S. Nuclear Regulatory Commission One White Flint North 11555 Rockville Pike Rockville, MD 20852 Hr. T. P. Johnson (SOS)

USNRC Senior Resident Inspector

-Mr. K. Tosch, Chief NJ Department of Environmental Protection Division of Environmental Quality Bureau of Nuclear Engineering CN 415 -

Trenton, NJ 08625 a

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.. , -, , . ,,,...,t NLR-N93009 ATTACHMENT 1 Backaround On January 11, 1993, PSE&G notified the NRC of a 10CFR21 reportable condition concerning the engine driven fuel oil pump associated with the "B" Emergency Diesel Generator which was During replaced during the recent Hope Creek Outage.

post-installation testing of the Diesel1992, Generator prior to low fuel oil turnover to operations on November 1, discharge pressure was observed. The Hope, Creek EDGs are provided with an engine driven fuel oil pump and a motor driven fuel oil pump which is provided as a backup should the engine driven pump fail or if low pump discharge pressure is sensed.

During post-installation testing of the EDG, the fuel oil discharge pressure was observed to be approximately 11-12 psi under no load condition with the standby motor driven pump running constantly in parallel with the engine driven pump.

U.; der 100% loaded condition, the fuel oil discharge pressure was observed to be less than 5 psi with the standby motor and engine driven pump in operation. The discharge pressure for the replaced engine driven pump without the backup-pump in operation was expected to be approxiniately 28 psi under 100% loaded condition. The EDG was operated in the loaded condition for approximately 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br />. The exhauot temperature and firing pressure were monitored and found to be normal.

The replacement engine driven fuel oil pump (Part No. P12605391) was supplied by Colt Industries (Fairbanks Morse Engine Division, Beloit, WI.).- Investigation into the cause of the low pump discharge pressure determined that the plugs and associated "O" ring gaskets (Piece Nos. 40, 41 and 42) shown on the attached Colt Industries Renewal Parts List were installed in a configuration to support the operation of a fuel oil pump with a clockwise engine rotation (Part No. P12605390). However, the plugs should have been installed to support a counter-clockwise engine rotation (Part No. P12605391) which is the correct configuration for Hope Creek, and which was ordered by PSE&G from Colt Industries. Procurement documentation and labelinq on the pump indicates that the correct Part No. P12605391 was supplied when, in fact, the equivalent to Part No. P12605390 was supplied.

The plugs and associated "O" rings were repositioned to support tae counter-clockwise engine rotation. Based on the length of-the run with. low fuel pressure and the normal-exhaust temperature and firing pressure' observed during the initial run, an intrusive inspection of the EDG was not performed. The EDG was satisfactorily retested in both the 100% load and no-load condition a. the exhaust temperature and firing pressure were again found to be normal. The engine driven fuel oil pump discharge pressure was observed to be 28 psi under 100% load and 40 psi in the no loi' condition.

Page 1 of 3

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NLR-N93009 ATTACHMENT 1 Evaluation Engineering evaluation has determined that operation of the EDGs

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with the engine driven fuel oil pump configured to support a clockwise engine rotation instead of the counter-clockwise engine rotction, and operating in parallel with the standby motor driven fuel oil pump resulted in the abnormally low discharge pressure of 5 psi in the 100% loaded condition. Effectively, the engine driven fuel oil pump under this configuration was drawing suction from the fuel oil being supplied to the EDG from the standby motor driven pump thereby starving the EDG of fuel oil. The fuel oil also provides a cooling and lubrication function to the fuel injection system to support the long term cperation of the EDGs should offsite power be lost. There are many variables that nced to be considered to accurately predict how long the EDG could run with low fuel pressure prior to failure. Low fuel oil pressure provided to the unit injector pumps can cause cavitation resulting in erosion in the plunger and barrel assembly of the injector pumps. Degradation of the injector pumps would be reflected by low firing pressures and changes in injector timing.

It is PSE&G's position that operation of the EDG in this condition for a period of time greater than 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> could not be assured. Engineering evaluation concluded that the low discharge pressure could result in reduced lubrication and cooling, and as such, it .is PSE&G's opinion that the EDG would have failed if left running in this manner.

Each of the four (4) 4.16 kV Class lE busses are electrically independent and supplied by a deticated EDG. A combination of any three out of four EDGs are required to assure one division of safe shutdown equipment is available to safely shutdown the plant. The EDGs are required to function upon a Loss of Offsite Power (LOP) or sustained ilndervoltage to a 4.16 kV bus, and/or receipt of an Emergency Core Cooling System (ECCS) actuation signal. Since the EDGs long term operation (> 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />) cannot be assured in response to these design basis events, it is concluded that this deviation could create a substantial safety hazard and is reportable in accordance with 10CFR21.

Corrective Action The engine driven fuel oil pump installed on the "B" EDG has been corrected to support the counter-clockwise engine rc'ation, and was satisfactorily retested during the Hope Creek outage, l

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NLR-N93009- I ATTACHMENT 1 Corrective Action (Cont'd)

Two (2) additional replacement engine-driven pumps were in spare  !

parts in the warehouse. These pumps have been. inspected and were also supplied with plugs in the incorrect orientation. These pumps were also purchased and labeled as Part No. P12605391 but- =i the equivalent to Part No. P12605390 was provided. The plugs and j "O" rings on one (1) pump have-been repositioned by PSE&G to j support a counter-clockwise engine rotation. Damage was ,

identified on a plugLand "O" ring on the second pump. This pump l has been ret arned to Colt Industries for evaluation and correction.

PSE&G has also requested Colt Industries to. perform.an evaluation of this deficiency and address root cause and~any corrective actions which they plan to take to prevent recurrence. Colt Indestries was requested to notify other utilities / purchasers that may affected.

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