ML20133B914
| ML20133B914 | |
| Person / Time | |
|---|---|
| Site: | Vogtle  |
| Issue date: | 07/24/1985 |
| From: | Phillips S GEORGIA POWER CO. |
| To: | |
| Shared Package | |
| ML20133B788 | List: |
| References | |
| OL, NUDOCS 8508060288 | |
| Download: ML20133B914 (35) | |
Text
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July 24gg3pg50 USNRC UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD OFFIE OF SECRETAH-In the Matter of
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00MThkCH
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Docket Nos. 50-424
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50-425
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(Vogtle Electric Generating
)
Plant, Units 1 and 2)
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AFFIDAVIT OF STEVE A.
PHILLIPS
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STATE OF GEORGIA
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ss.
COUNTY OF BURKE
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I, Steve A.
Phillips, being duly sworn, state as follows:
1.
Since July of 1984, I have been employed by Georgia Power Corporation ("GPC"), as Maintenance ~5Epervisor of Nuclear Operations.
My business address is Vogtle Electric Generating Plant, Route 2, Box 299A, Waynesboro, Georgia 30830.
As Main-i l
tenance Supervisor I am responsible for the planning, coordination, and execution of all on-site activities associ-l ated with the Transamerica Delaval, Inc. ("TDI") Emergency l
jM* &aa gg l
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Diesel Generator Resolution Program ("EDG Resolution Program")
at the Vogtle Electric Generating Plant ("VEGP").
This in-cludes the disassembly and inspection'of the Unit 1 and 2 die-sel generators.
I have personal knowledge of each of the mat-ters set forth herein, and believe them to be true and correct.
2.
Immediately prior to taking my current position, I was employed by VEGP as a Maintenance Foreman.
As such, I was responsible for the development of a " Planned Maintenance Pro-gram" for the plant.
I hold a Bachelor of Science degree in mechanical engineering.
A statement of my professional quali-fications is attached hereto as Exhibit 1.
I.
THE VEGP EMERGENCY DIESEL
' GENERATOR RESOLUTION PROGRAM 3.
Problems encountered during the preoperational testing of the engines at Grand Gulf Nuclear Power Plant
(" Grand Gulf") led Applicants, working with TDI representa-tives, to identify potential engine problems for inspection and technical evaluation at VEGP.
To address concerns raised as to the adequacy of the TDI diesel generators at VEGP, the EDG Res-olution Program was established at the plant in November of 1983.
The EDG Resolution Program at VEGP was established prior to formation of the TDI Diesel Generator Owners Group.1/ The 1/
The Owners Group and Owners Group Program Plan are addressed in the accompanying " Affidavit of John C. Kammeyer"
("Kammeyer Affidavit").
l l l l
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VEGP EDG Resolution Program is managed by a Program Manager who reports to the Vice President and General Manager of the Vogtle Project.
Reporting to the Program Manager is an implementation task force which includes representatives from Nuclear Opera-tions, Construction, Project Licensing, Procurement, and Bechtel Power Corporation ("Bechtel"), including persons from Bechtel Project Engineering, Field Engineering and a Bechtel diesel generator engineer.2/
4.
On March 15, 1984, the VEGP Nuclear Operations De-partment began the complete disassembly of the Unit 1 diesels as the first step in the EDG Resolution Program.
This work was performed under the surveillance of the VEGP Site Quality Con-trol and Quality Assurance Groups.
VEGP contacted personnel at Grand Gulf, the Shoreham Nuclear Power Station ("Shoreham"),
and Comanche Peak Steam Electric Station (" Comanche Peak"), to obtain information on their engines' operating experience and any problems encountered in order to identify the testing, inspection, modification and/or repair of components necessary to assure the VEGP engine 5* reliable performance.
Components on the VEGP engines were visually inspected for signs of damage or wear.
Proper installation and preloading were verified, as necessary.
Nondestructive examinations of components were 2/
Bechtel is the architect / engineer for VEGP..
7 performed.
In some cases, testing of component material and/or hardness was conducted.
Certain components were' modified and/or replaced.
5.
In May of 1984, the Owners Group issued VEGP-specific Component Revalidation Checklists ("CRCs").3/
In many in-stances, the number of Owners Group recommended inspections and tests had been exceeded by VEGP's own engine revalidation ef-fort.
In some cases, however, it was apparent that additional testing or inspections were going to be necessary to meet the Owners Group's revalidation requirements for what became the Phase I and Phase II components.4/
6.
The Unit 1 engines were reassembled by August, 1984.
On October 17, 1984, VEGP forwarded a 12-volume report to the Owners Group documenting its inspection effort for the Unit 1 diesels.
The report included documentation of inspections, nondestructive examinations, testing, repairs, and modifica-tions made on the emergency diesel generators to assure their capability to provide reliable emergency power.
These items were subsequently included in the Owners Group Design Review /
Quality Revalidation ("DR/QR") Report for VEGP Unit 1 which was 3/
The CRCs developed by the Owners Group are discussed in the Kammeyer Affidavit at 1 82.
4/
The Phase I and Phase II Programs are discussed, in de-tail, in the Kammeyer Affidavit.
1 d
issued in December of 1984.
The VEGP DR/QR Report was sub-mitted to the NRC Staff and its consultant, Pacific Northwest Laboratory ("PNL") on January 18, 1985.
A summary description of the work done under the EDG Resolution Program for Unit 1 through June of 1985 is provided in Exhibit 2.
7.
The Unit 1 diesels will be disassembled again, for the purpose of completing the work required by the VEGP CRCs.
During the months of July and August of this year, VEGP Nuclear Operations will be performing the Owners Group recommended com-ponent inspection and testing requirements which were not con-ducted during VEGP's original revalidation effort for these en-gines.
These additional tests and inspections have been listed on a computer-generated punchlist for tracking and completion prior to engine preoperational testing.
Included are a number of visual and dimensional checks, as well as nondestructive ex-amination of certain components, such as the fuel oil injection tubing.1/ At the end of this effort, all applicable Owners Group recommended inspections will have been performed.p/
E/
Shrouded tubing will also be installed on the engines at this time.
Shrouded tubing will be installed on the Unit 2 diesels prior to operation of the engines.
s/
As discussed below, certain components are scheduled to be inspected after 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of operation.
r-6 8.
The tear-down and revalidation of the Unit 2 diesels began in the summer of 1984.
From the beginning, the VEGP-D specific CRCs dictated the nature of the testing, inspection, modification and/or repair of components necessary to support the revalidation effort for these engines.
Visual inspections, non-destructive and destructive examination of components, etc.
was conducted, just as for Unit 1.
Engine reassembly was com-pleted in March of 1985 for both engines.
The results of this effort are compiled in a 15-volume report which was finalized in May of 1985.
The majority of the Owners Group recommended component tests and inspections have been completed for Unit 2, as documented in this report.
Owners Group recommended inspec-tions which remain to be performed on the Unit 2 diesels in-clude items such as material comparator testing of the airstart valve capscrews, nondestructive examination of the jacket water pump shaft, miscellaneous torque verifications, and'certain visual inspections of components.
II.
VEGP ENGINE MAINTENANCE AND SURVEILLANCE PROGRAM 9.
Appendix II of the VEGP DR/QR Report lists the Owners Group's maintenance and surveillance recommendations for VEGP.
The maintenance and surveillance recommendations were developed J
by the Owners Group following its review of TDI maintenance recommendations and its review of the individual diesel generator components.
Recommendations are based on standard maintenance practices, analysis of k'own problems for which regular maintenance could reduce occurrence, and analysis of specific findings made during the VEGP inspection program.
The recommendations contained in the DR/QR Report also include inspections beyond the normal maintenance program ~.
These inspections are designed to provide early detection of condi-tions which have created problems at other plants.
10.
An example of Owners Group recommended maintenance and surveillance (taken from Appendix II of the VEGP DR/QR Re-port) is provided below for the turbocharger:
Owners Group M/S Alt.
Recommendation Outage Outage 5 Year Comments 1.
Measure vibration X
To be accom-and check with plished during baseline data.
24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> test run.
2.
Clean impeller X
and diffuser.
3.
Measure rotor X
Review thrust end play (axial bearing axial clearance) to clearances after identify trends inspection to of increasing determine if a clearance (i.e.,
trend exists.
thrust bearing Any trend toward degradation).
increasing axial clearance could signify thrust bearing degrada-tion.
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Owners Group M/S Alt.
Recommendation Outage Outage 5 Year Comments 4.
Perform visual X
Thrust bearing and blue check inspection should inspections of also be performed the thrust after 40 non-pre-
- bearing, lubed (automatic) fast starts.
1 5.
Disassemble, X
inspect and refurbish.
6.
Perform a spectro-X To be performed chemical engine during the last oil analysis to monthly test assist the bear-run prior to ing monitoring oil change.
program.
To Sample to be further expand /
drawn upstream clarify chemical of lube oil analysis, ferro-filter.
graphic analysis may be utilized.
Particular atten-tion shall be paid to copper level, and par-ticulate size, which could sig-nify thrust bear-ing degradation.
11.
The following is a summary of the items contained in the VEGP Maintenance Matrix of Appendix II, based on frequency, of performance:
7
+
23 Daily inspections 49 Monthly inspections 2
Quarterly inspections
-- 127 Inspections at every refueling I
outage 15 Inspections at alternate refueling outages (in addition to outage inspections) 27 5-year outage inspections (in addition to outage and alter-nate outage inspections) 28 Inspections on an as-needed basis (normally based on engine hours) 3 One-time inspections VEGP is committed to implementing each of the owners Group maintenance and surveillance recommendations.
It is estimated that nearly 3800 man hours per year will be expended performing the required maintenance and surveillance on each diesel gener-ator.
These maintenance and surveillance procedures, together with standard VEGP procedures and TDI maintenance recommenda-tions, will be incorporated into a single comprehensive ongoing maintenance and surveillance program.
This program will ensure that the initial performance capability and reliability of the diesel generator system equipment is maintained throughout the operating life of the plant.
12.
VEGP will continue to monitor TDI's Service Informa-tion Memos ("SIMs").
Under this program, TDI notifies owners of product and procedure improvements gained through operating exp*srience.
In many instances, these improvements are in the fcrm of revised operating, maintenance, and installation
_g_
m procedures.
In some cases, equipment modifications are recom-mended by TDI.
To date, TDI has issued at least twenty-eight SIMs applicable to the VEGP diesel generators.
13.
Deviation Reports are written at VEGP for any type of equipment hardware deviation from specifications.
Thece re-ports are then forwarded to Bechtel Field Engineering for re-view and an engineering evaluation, where necessary.
They are
- then returned to Nuclear Operations or Construction for review I and corrective action, as appropriate.
Deviation Reports writ-ten against TDI equipment are routinely reviewed for report-ability to the NRC pursuant to 10 C.F.R. Part 21 and 5 50.55(e).
When Vogtle becomes operational, any significant item will be reported pursuant to the requirements of 10 C.F.R.
$ 50.73 which governs Licensee Event Reports ("LERs").
14.
VEGP regularly monitors 10 C.F.R. Part 21 reports re-ceived on TDI equipment and determines their applicability to the VEGP diesels.7/ The following table summarizes the Part 21 7/
The origin of some of Joint Intervenors', references to en-gine problems is unclear, and may be Part 21 reports.
Joint Intervenors noted that a latching relay failed during testing at Grand Gulf.
See " CPG /GANE's Response to Applicants' First Set of Interrogatories and Request for Production of Docu-ments," December 5, 1984, Answer to Interrogatories 14-1, 14-2.
l Presumably, this item refers to the relay for the voltage regu-lator.
VEGP will be performing an engineering evaluation to determine the applicability of this incident to its engines.
Joint Intervenors cited a problem with improperly designed en-(Continued next page) reports received by VEGP on TDI components / equipment and the disposition of those items determined to be applicable to VEGP:
(Continued) gine pneumatic logic at Grand Gulf.
See id.
This item is in-applicable to VEOP because VEGP has a different type of logic board from the one used at Grand Gulf.
Similarly, the fact that non-class 1E motors were supplied at Grand Gulf is irrele-vant to VEGP.
See id.
Non-class 1E motors supplied to VEGP are not used in safety-related applications and, therefore, are not required to be class 1E.
Finally, the crankcase cover capscrew failure at Grand Gulf, see id.,
(which caused a gener-ator fault when the bolt entered the generator), is inapplica-ble to VEGP's engines.
Screens on the VEGP generators would prohibit entry of any such object.
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Description of 10 C.F.R.
Applicability /Nonapplicability Date Part 21 Report to VECP VECP Disposition Sept. '79 R-Engine Jacket Water Pump N.A.
Assembly Drive Shaf t Sept. '80 RV-Engine Link Rod Assembly N.A.
Dowel Counterbore Dec. '80 R&RV-Engine Turbocha rger Thrust N.A.
Bearing Lubrication June '81
' RV-Engine Cranksha rt Oil Plug -
N.A.
improper Installation Tool July '81 R&RV-Engine Valve Spring -
N.A.
Defective Material Nov. '81 R&RV-Engine - Spherical Washer N.A.
Pisten Assembly Nov. '81 R&RV-Engine - Sta rting Ai r Chech N.A.
Valve Dec. '81 Covernor tube Oil Cooler Assembly A
If the governor tube oil coolers Visual inspections at VECP verified a re located above the governor lube that the three installed governor oil level, air could be trapped in lube oil coolers were located below the system when the tube oil level the tube oil level shown on the gov-in the governor is low, e rno r o i l level sight gauge, preclud-I ng the poss i b i l i ty or a i r be i ng t ra pped, i
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Description of 10 C.F.R.
Applicability /Nonapplicability Date Part 21 Report
.to VEGP VEGP Disposition i
Ma r. '82 Startine Air Sensine Line A
TDI postulated that during a sels-Although noted by TDI as applicable mic event, the air start pressure to VEGP, this issue was specifically sensing line could fall, causing evaluated and found not to be appil-the starting air receivers to bleed cable to the VEGP diesel generator down to a point where the engines a i r sta rt sys tem.
Subsequent to this i.
could not start.
determination, the airstart sensing line was relocated to a pressure tap on the a i r rece ive r.
A restriction orifice has been provided at the air-s ta rt receiver to maximize the time of depressurization of the airstart receiver should fa i lstres in upstream piping, including the sensing line, occur.
May '82 Sta rt ine Ai r Va lve As semb ly A
Fasteners TDI reported a potential defect This defect was resolved by replac-related to the length of capscrews ing the original 3"-long cap-that could prevcnt proper torquing, screws with 2-3/4" long capscrews.
June '82 Gove rno r Drive Coup l i ne Ma te ria l A
TDI reported that the governor New couplings of neoprene i
drive coupling made of isoprene construction were installed, is not suitable for use for the high temperature oil atmosphere of the engine gea rcase.. The rubbe r.
deteriorates rapidly and could cause i
the engine to trip.
TDI recommended that the couplings be - replaced with couplings made f rom neoprene.
. 4 Oct. '82 Piston Skirt Cast ne. I mo rone r A
i Heat Treatment TDI repo rted tha t the hea t t rea t ing The type AN skirts were replaced method used in fabrication of the with new design type AE skirts type AN skirts could cause residual which were properly heat-treated stress leading to cracking in service, and are not susceptible to the
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Description of 10 C.F.R.
Apolicability/Nonapplicability Date Part 21 Report to VEGP VEGP Disposition problems reported for the AN skirts.
Jan. '83 R-Engine - Jacket Water Pump N.A.
Assembly Failure July '83 R&RV-Engine - High, Pressure fuel N.A.
Line Material Aug. '83 R&RV-Engine - Woodwa rd Governor N.A.
Assembly Condition Sept. '83 R&RV-Engine - Engine Mounted Fuel N.A.
Oil Line Sept. '83 Enoine-Mounted Electrical Cables A
TDI reported a potontial deficiency The cables in question ( rated -
concerning the qualification or for 75* and 80*C) will be re-certain classes of 1E electrical placed with 90*C IEEE-qualirled cables. The insulation temperature
- cable, rating of some of these electrical cables may be exceeded during engine operation, causing the diesel to have a slightly slower response to load pickup.
Nov. '83 R&RV-Engine - Engine Piston Skirt N.A.
Jan. '84 overspeed Governor and Fuel A
Booster Pumo Flexible Couplina l
Drive Overspeed governor and fuel TDI recommended installation booster pump flexible drive hubs and inspection procedure were discovered to be loose on No. 363 was incorporated the sha f ts on a non-nuclea r com-into the VECP diesel gene ra to r me rc ia l installation due to maintenance program.
excessive alignment tolerances
)
in the insta llation and ma in-tenance process, 1 f
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Description of 10 C.F.R.
Applicability /Nonapplicability Da te Part 21 Report to VEGP VEGP Disposition Feb. '84 Turbocha raer Th rust Bea rino A
Lubrication l
Turbocha rger failures occurred at TDI has developed a revised Shoreham and Catawba due to in-lube oil system that provides sufficient lubrication of thrust for the manual addition of tube bearings in the standby mode.
oli on starting. This revised Insufficient lubrication is system is being installed at l
experienced on quick starts VEGP and operation of this sys-l af ter prolonged standby periods, ten will be inco rpo ra ted into l
plant operating procedures.
l Ma r. '84 R&RV-Engine - Westinghouse Relay N.A.
July '84 Valve Sprina Failure A
l A valve spring failure was exper-This incident was reviewed lenced in a non-nuclea r ma rine and it was concluded that no l
engine application af ter 4,500 corrective action was required, hours operation.
Quality revalidation of the intake and exhaust valves was included in the VEGP revall-dation prog ram.
Sept. '84 R&RV-Engine Generator Voltage N.A.
Regulators.
Oct. '84 Engine Fuel Control Shaft -
N.A.
I Pinninq l
Retaining pins on the fuel con-Although noted by TDI as appil-t ro l levers were not installed, cable to VEGP, this item was per instructions, on some levers evaluated and found to be inap-at the San Onofre #1 nuclea r plant.
plicable to the VEGP diesel gene ra to rs.
The fuel control i
levers for the VEGP diesel i
generators were inspected and it was found that the retain-ing pins were i n s ta l l ed'.
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l Description of 10 C.r.R.
Applicability /Nonapplicability Date Pa rt 21 Report to VECP VECP Disposition Jan. '85 Air Filter Bowl N.A.
TDI reported a potential defect Although noted by TDI as appil-with polycarbonate bowls used on cable to VECP, this item was some engine control panel air evaluated and round to be inap-(
ri t ters, where the bowl manufac-plicable to the VECP diesel turer had revised the pressure gene ra to rs.
The a i r f i l te rs ra t i ng.
at VECP were inspected and verified as having metal bowls i
j rated at 250 psig.
~
I Ma r. '85 R&RV-Engine - Sta rting Ai r System N.A.
I Check Valve Ma r. '85 Cranksha f t Oil Plues Wall Thickness A
TDI reported a potential defect The 22-gauge oil plugs utilized with engines manufactured prior to at VEGP will be replaced with Ma rch 10, 1980 and af ter JLne 23, 16-gauge oil plugs before pre-1982 and using 22-guage crankshaf t ope ra t iona l testing of the oil plugs.
engines.
May '85 Gene ra to r Cont ro l Pa ne l Ove rhea t i ng A
TDI reported a potential defect Ventilation air has been provided wherein the generator control panel to the voltage regulator and may overheat leading to failure or exciter sections or the control some components. TDI has orrered panel as part of VEGP's DR/QR a design revision that involves errort to reduce the heat rise in adding three exhaust rans to the the panel.
This modification is control panel if overheating is being reviewed, if inadequate, experienced, exhaust fans for the diesel generators will be procured. l 1
III.
TDI DIESEL GENERATOR TESTING 15.
A major element of the TDI Diesel Generator Owners Group Program involves an enhanced engine testing program, cou-pied with specific component inspections.
The Owners Group technical staff, in evaluating specific engine components, pro-vided recommendations to the owners regarding special tests and component inspections which would provide additional assurance of the adequacy of both the engines and the components to per-form their, safety-related functions.
This testing will be con-ducted at VEGP in addition to the required regulatory testing.
A.
The " Lead" Engine Concept 16.
The Owners Group's recommendations for the VEGP en-gine testing program were based on the results of the analyti-cal studies performed by the Owners Group and a recognition that tests conducted on the " lead" DSRV-16-4 engines have been successfully performed.
The " lead" engines for the model DSRV-16-4 engines at VEGP are the DSRV-16-4 engines located at Comanche Peak.
A full preoperational test program has been conducted on the Comanche Peak engines in accordance with the utility's program based on NRC Regulatory Guide 1.108, " Period-ic Testing of Diesel Generator Units Used as Onsite Electrical Power Systems at Nuclear Power Plants" (Revision 1, August 1977) and Institute of Electrical and Electronic Engineers I
("IEEE") Standard 387-1977, "IEEE Standard Criteria for Diesel Generator Units Applied as Standby Power Supplies for Nuclear Power Generating Stations."
In excess of 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of opera-tion have been logged on these engines.
The Comanche Peak test program included starting and load acceptance tests, auxiliary system tests, load capability tests, and control
- circuit tests.
In addition to those tests described in Comanche Peak's FSAR, Owners Group recommended testing, including a torsiograph test (which confirms the adequacy of the crankshaft), and engine vi-bration tests were performed.
17.
In addition to the Comanche Peak testing, more than 1600 hours0.0185 days <br />0.444 hours <br />0.00265 weeks <br />6.088e-4 months <br /> of operation have been accumulated on the DSRV-16-4 engines at the Catawba Plant.
This has further substantiated the Comanche Peak test results.
The results of the Comanche and Catawba engine tests have provided additional assuranco of the capabilities of the DSRV-16-4 engine design.
B.
VEGP Engine Testing Program i
18.
The VEGP diesel generators will be subjected to a multi-phase test program prior to plant licensing and opera-tion.
This test program will demonstrate the diesel generator systems' operability, reliability, and capability to provide emergency power.
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19.
The first phase of the test program will consist of construction acceptance testing to be conducted by the VEGP Nuclear Operations Department.
These tests will ensure that the individual electrical and mechanical components of the die-sel generator systems are properly installed and functioning correctly.
20.
Following construction acceptance testing, the diesel generator systems will be checked by a TDI service representa-tive.
This supplier check-out program includes steps to ensure proper operation of the control system, initial startup of the diesel generators, break-in operation at varying loads, opti-mizing governor operation, operation in both the isolated and paralleled modes, and 100%, and 110% load-carrying capability tests.
21.
Following this, preoperational testing will be initi-ated.
The preoperational test program for VEGP will be con-ducted in accordance with Regulatory Guides 1.9,
" Selection, Design, and Qualification of Diesel-Generator Units Used as Standby (Onsite) Electric Power Systems at Nuclear Power Plants," 1.108, cited previously, and IEEE Standard 387-19*,7, cited previously, as committed to in the VEGP FSAR.
The five categories of preoperational testing to be conducted on each engine are outlined below:
e Operation of'the fuel oil transfer system, storage tank to day tank, and its associated alarms and interlocks will be demonstrated.
The starting air system will be evalu-ated by testing the operation of the air compressors and associated alarms and interlocks.
Control logic and auxiliaries testing will test the operation of:
-- Lube oil and jacket water keepwarm systems
-- Miscellaneous alarms
-- Start circuitry
-- Stop circuitry
-- Pneumatic logfc 7
-- Excitation circuit
-- Governor and regulator logic
-- Protective relaying
-- Breaker control logic
-- Integrated logic Diesel generator operation testing will demonstrate the engines' ability l
to start five times on each air stor-age tank.
The overspeed trip setpoint will be tested.
The engines' ability to synchronize with offsite power will be demonstrated.
Diesel operation in the isolated mode will be checked.
Integrated testing of the diesels will consist of the following individual tests:
-- Response to a Loss of Offsite Power (LOOP)
-- Response to a Loss of Coolant Accident (LOCA)
-- Response to a LOOP and LOCA
-- 24-hour rated load test
-- Response to 100% load rejection
-- Response to loss of the largest single load
-- A 35 consecutive start test
-- Response to LOCA while in the l
test mode s l
}
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22.
A seven-day continuous run of each of the diesel gen-f I
erators is tentatively planned to demonstrate engine oper-ability.
Additional testing recommended by the Owners Group, includ.ing a torsiograph test of both Unit 1 engines (to confirm l
the adequacy of the crankshaft to withstand operating torsional t
stresses), and an engine vibration survey at full load will also be conducted.
Cylinder imbalance testing will also be conducted on the engines.
Equipment inspections recommended in the VEGP Owners Group DR/QR Report will also be performed at this time, as applicable.
For example, the engines' turbo-chargers will be inspected after 100 starts.
Components sched-uled for inspection after 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of operation include the airstart valves, main bearings, crankshaft, and cylinder block covers.
Seven components are scheduled for special inspections at various intervals beyond 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of engine operation.g/
IV.
CONCLUSION t
23.
The VEGP TDI diesel generators have been thoroughly reviewed from both a design and quality standpoint by the TDI Diesel Generator Owners Group and VEGP's engineering and quali-ty assurance personnel.
Based on recommendations generated in Phase I of the Owners Group Program, the components with g/
The same types of inspections will b'e performed on the Unit 2 engines..
f potentially generic problems are being inspected, replaced, and/or modified prior to fuel load.
24.
The Phase II DR/QR effort, and the final elements cf the Owners Group effort, implementation of a maintenance and surveillance program and additional testing and inspection of components, provide additional assurance that_the VEGP TDI die-sel generators will reliably perform their intended safety-related functions for the life of the plant.
VEGP is committed to implementing each of the applicable Owners Group recommenda-tions (with the possible exception of two design modifica-tions), and testing to verify the reliability of the TDI diesel generators.9/
i 25.
As described above, the VEGP test program meets both the testing described in IEEE Std. 387-1977 and the testing de-scribed in the VEGP FSAR pertaining to Regulatory Guides 1.108 and 1.9, and implements the Owners Group recommendations.
Ful-fillment of the testing program will provide assurance that the TDI diesel generators meet their design requirements and will perform with a high degree of reliability.
This comprehensive testing program, other DSRV-16-4 successful test programs, the 9/
As discussed in the Eppler Affidavit at 7, 8, VEGP presently does not plan to implement two component modifica-tions.
A walkdown indicated that the piping configuration on the VEGP diesels prohibited the installation of a Dresser cou-pling at the location recommendecl by the Owners Group.
Id.,
1 7.
An analysis by Bechtel determined that the addition of a l
Dresser coupling on the engine-driven lube oil pump suction l
line was unnecessary.
See id.
VEGP will replace certain slip l
joints on the exhaust manifolds, as needed, following a l
walkdown to verify the piping configuration.
Id.,
1 8.
1 O.
VEGP engine revalidation effort, and the Owners Group results, all provide an unprecedented level of assurance regarding the reliability of the TDI diesel generator units at VEGP.
i A G;ffsi
.se Steve A. Phillips Subscribed and sworn to before me this ~3c" day of July, 1985.
En n Q. 0.', [.-
N #ary Public
~T My commission expires on:
M::$.y rebte, ^:.3~ n. 0 ' ' 9 L~'23 hiy Cem.wwcn 6Pa'W I' DOI I
i l, - - _ _ _ _ _ -
EXHIBIT 1 4
RESUME NAME:
Steve A.
Phillips
Title:
Maintenance Supervisor DECREE:
Mechanical Engineering (Bachelor of Science)
DATE OF BIRTH: Uuly 15, 1957 DATE EMPLOYED: June 22, 1981 WORK EXPERIENCE:
NUCLEAR (CPC)
Position:
Maintenance Supervisor Dates:
July 21, 1984 to Present Location Plant Vogtle, Waynesboro, Ca.
Plant Status:
Under Construction Job
Description:
Responsible for planning, coordinating and executing all on-site activities associated with the Transamerica Delaval Diesel Generator Resolution Program.
Position:
Maintenance Foreman Dates:
June 25, 1983 to July 20, 1984 Location:
Plant Vogtle, Waynesboro, CA.
Plant Status:
Under Construction Job
Description:
Responsible for the development af a Planned Maintenance Program. Program will encompass all licensing require-ments (i.e., Technical Specifications, Equipment Qualifications, FSAR commit-ments, etc.), scheduled maintenance and predictive maintenance (i.e.,
lube oil analysis, vibration analysis, trent analysis, etc.)
Position:
Foreman-In-Training Dates:
Jan.
8, 1983 to June 24, 1983 Location:
333 Piedmont Bldg., Atlanta / Plant Hatc[
Baxley, CA.
Plant Status:
Plant Hatch Unit #1-on'line Plant Hatch Unit #2-refueling outage Job
Description:
Participant in a six-month training program for maintenance foreman that included supervisory and management, safety, fire protection and labor rela, tions training in Atlanta and on-the-j training in the Maintenance Department at Plant Hatch (see Training for detailed description of courses).
I
' Resume Page 2 Position:
Assoc. Plant Engineer /Jr. Plant Engineer Dates:
January 1982 to January 1983 Location:
Plant Vogtle, Waynesboro, CA.
Plant Status:
Under Constr'uction Job
Description:
Responsible for the development of a procedure index and schedule for writing maintenance procedures.
Responsible for the development and implementation of maintenance procedure-that meet all criteria associated with a nuclear plant maintenance program. Wrote maintenance administrative procedures.
to support and implement required programs and establish philosophy.
WORK EXPERIENCE (Continued)
NUCLEAR (CPC)
Position:
Jr. Plant Engineer Dates:
June, 1981 to January 1982 tocation:
Plant Vogtle, Waynesboro, CA.
Plant Status:
Under Construction Job
Description:
Coordinate and monitor ISI/IST Prograd Conduct reviews of RSPL/ASPL's to de:e mine correct type and quantity of spa:
parts to be purchased for plant stari and operation. Investigate specific potentist p; ant design and maintenance problems.
Position:
Jr. Plant Engineer Dates:
July 8, 1981 to July 27, 1981 Location:
Plant Hatch, Baxley, CA.
Plant Status:
Both units on line.
u Job
Description:
Assistant electrician. Also worked as; plant equipment operator in Radwaste.
Position:
Engineering Co-Op Student Dates:
September, 1977 to September, 1978 Location:
Plant Hatch, Baxley, GA.
Plant Status:
Pre-operational and Power Ascention Testing of Unit #2.
Job
Description:
Aided plant engineers and instrument technicians performing pre-operationa.
and surveillance testing. Duties included (1) calibration and installa; t
RESUME PACE 3 tion of instruments, (2) monitoring the eclibration of test equipment used as standards.
NUCLEAR (OTHER)
N/A NON-NUCLEAR (CPC)
N/A F
NON-NUCLEAR (OTHER)
Position:
Engineering Co-Op Student Dates:
June, 1979 to June, 1980 Location:
Photo Products Division of E.
I. DuPon de Nessurs & Co.,
Brevard, NC Plant Status:
Commercial Operation Job
Description:
Monitored quality of polyester film products. Conducted a study of core related defects created during baserol windup and storage. Started the develo sent of a new method to measure subcoa thickness, which resulted in an improv and substantial reduction in the cost manufacturing polyester base.
TRAINING NUCLEAR Course
Title:
Boiling Water Reactor Training Dates:
January 24 to February 11, 1983 Total Course Hrs.:
120 Hours Vendor:
Plant Hatch Training Dept.
==
Description:==
General overview of plant operation and system functions (System operations / interface, system logic and reactor theory). Consisted of 40 hours4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br /> on NSSS, 40 hour4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br />; on BOP and 40 hours4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br /> on the simulator.
Course
Title:
Pressurized Water Reactor Training Dates:
August 17-21, 1981 Total Course Hrs.:
40 hours4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br /> Vendor General Physics
==
Description:==
General overview of plant operation and system functions (system operation system logic, and reactor theory).
OTHER (Applicable to Power Plant or Related Industry) i
c:
RESUME PAGE 4 Course
Title:
Fire Brigade Course Dates:
May 16-20, 1983 Total Course Hrs.:
40 Hrs.
Vendor:
Georgia Fire Academy Descriptions.
Basic instruction on industrial fire fighting techniques.
Course
Title:
Labor Relations Course Dates:
May 9-13, 1983 Total Course Hrs.:
40 Hours Vendor:
CPC Labor Relations Dept.
==
Description:==
Included instruction on administering the contract between GPC and Local Union No. 84 of the.IBEW, contract interpretation, labor law and grievance procedure and arbitration.
Course
Title:
Supervisory & Management Training Dates:
January 12 to June 24, 1983 Total Course Hrs.:
Approximately 200 hrs.
Vendor:
CPC Manpower Development
==
Description:==
Courses included the following (1) Communication Skills
-How to give and receive useful feedback
-Communication Barriers
-Nonverbal Connunication
-Effective Listening
-Effective Writing
-Techniques.for conducting an effective meeting (2)
Basic Principles of Supervision
-How To Establish Goals
-Setting Priorities
-Giving Instructions
-Monitoring Work
-Performance Management (3)
-Middle Management Development
-Interpersonal Relationships
-Social Style
-Social Values
-Anticipating style and planning actic3s
- (4)' Stress Management (5) Management Style u ^
(6) Project Management i
-Critical Path Method
-PERT (7) Basic Principles of Probles Solving Course
Title:
Safety & Health Training Dates:
March 7-11, 1983 Total Course Mrs.:
40 Hours Vendor:
CPC Safety Dept.
==
Description:==
Included instruction on recognizing safety hazards an-unsafe acts, performing accident investigations, establishing safe practices and instruction in first aid and CPR.
.~. -.
RESUME PAGE 5 Course
Title:
New Supervisor Basic Electrical Skills Orientation Dates:
February 21-25, 1983 Total Course Hrs.:
40 Hours Vendor:
CPC Skills Development Center, Milledgeville, CA.
Description:
Included instruction on plant clearances, system operation, basic electrical theory, reading electrica*
prints, batteries, transformers, circuit breakers, motors, precipitators and control devices.
Course
Title:
Technical Communications Workshop Dates:
May 11-14, 1982 Total Course Hrs.:
32 Hours Vendor:
Nilsson Professional Consulting, Inc.
==
Description:==
Course included the followings (1) Technical Writing
- Letters Procedures (2)
Briefings (3)
Improving Meeting Effectiveness Course
Title:
Problem Solving / Decision Making Workshop Dates:
February 1-3, 1982 Total Course Hrs.:
24 Hours Vendor:
Consultant Bob Leech, LaJolla, CA.
==
Description:==
Course included the following:
(1) Casual Analysis (management of the past)
(2) Decision Making (management of the present)
(3)
Planning (management of the future)
(4). Situational Review (getting started)
Exhibit 2 Summary of EDG Resolution Program Work Performed on Unit 1 Through June, 1985 Turbocharcer, MP022/23 Visual inspections for damage and wear, dimensional checks of clearances, and torque setting checks were performed to verify I
conformance with the manufacturerb specifications.
The thrust journal bearing was replaced in one turbocharger on engine 1A and the rotating assembly, nossle ring, capscrews, and thrust journal bearing were replaced in one turbocharger on engine 15.
- Enoine Base, 02-305A Visual inspections and liquid penetrant tests warm performed on all bearing pedestal mating surfaces.
Based on the penetrant tests, an eddy current examination was performed on one bearing pedestal mating surface.
All were found acceptable for use.
Main Bearina Studs and Nuts, 02-305C Visual inspections were performed to verify that the main bearing studs and nuts were properly installed and preloading was applied in accordance with the manuf acturer's specifications.
Main Bearine Caps, 02-305D Visual inspections were performed on all main bearing cap mating surf aces and all were found acceptable for use.** Two alignment pins were replaced on engine 1A.
Crankshaft, 02-310A Visual inspections were performed on all crankpin and main journal surfaces and all surface indications found were stoned smooth.
Eddy current examinations were performed on the crankpin fillet.
The engine 1A crankshaft oil holes were polished and examined by addy cu: rent and determined to be acceptable.
The engine IB crankshaft oil holes will be polished and examined prior to engine testing.
The turbochargers drip pre-lubrication systens are being modified so that lube oil can be manually-added. Instrumentation is in place to tronitor exhaust temperatures.
- 'Ihe mating surfaces of the base and cap were cleaned with solvent, before asserbly, per Owners Group recrmnendations.
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Cylinder Head Gaskets, 02-360C New gaskets were' installed on reassembly.
Valve Sprinas, 02-360D Visual inspection of the valve springs found that the correct type of spring was installed and that the springs showed no sign of cracking.
Subcover Assemblies, 02-362A Visual inspections and liquid penetrant tests were performed on all subcovers.
Based on the liquid penetrant test results, two subcovers were replaced.
Fuel Iniection Nozzles, 02-365B All fuel nozzles were tested for opening pressure (pop-test),
cleaned, and adjusted as required to assure correct operation.
One nozzle damaged during adjustment was replaced.
Shrouded fuel oil tubing will be installad.
Fuel Pump Control Shaft, 02-371A Material comparator tests and hardness tests were performed.
Intake Manifolds,02-375 A visual inspection was performed on all intake elbows.
One elbow was replaced.
Crankcase Covers, 02-3868 Visual inspection of crankcase cover bolt holes was performed to ensure that there were no cracks.
The covers were found acceptable for use.
Intake and Intermediate Rocker Shafts, 02-390A Visual inspections, material comparator tests, and hardness tests were performed on all intake and intermediate rocker shafts.
The visual inspections were satisfactory, the material i
comparator tests verified proper material, and the hardness was acceptable.
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d Exhaust Rocker Shafts, 02-390B Visual inspection's, material comparator tests and hardness tests were performed on all exhaust rocker shafts with satisfactory results.
The proper material was verified and the hardness was acceptable.
Intake and Exhaust Pushrods, 02-390C All intake and exhaust pushrods were replaced with friction welded type pushrods which are not susceptible to cracking.
All pushrods for engine 1A were liquid penetrant tested with satisfactory results prior to engine testing.
The engine IB pushrods will be liquid penetrant tested prior to engine testing.
- Connector Pushrods, 02-390D All connector pushrods were replaced with friction welded type pushrods which are not susceptible to cracking.
All pushrods for engine 1A were liquid penetrant tested with satisfactory results.
Engine IB pushrods will be liquid penetrant tested prior to engine testing.
- Rocker Arm Capscrews, 02-390G Magnetic particle tests, material comparat6r tests, and hardness tests were performed on all capscrews with satisfactory results.
All capscrews were torqued to TDI specifications.
The engine 1A rocker arm drive studs (rivets) were visually inspected to ensure that there is no movement of the drive stud in the rocker arm area.
The engine IB drive studs will be inspected prior to engine testing. **
Overspeed Trio - Governor, 02-410A A visual inspection was performed during disassembly and reassembly of the overspeed trip governor and accessory drive.
The overspeed trip adapter plate on engine 1A was redoweled to correct alignment.
Overspeed Trio - Governor Drive, 02-410B
' Visual inspections, material comparator tests, and hardness tests were performed on the drives.
The material comparator tests will be repeat'ed on engine 1A prior to engine testing.
Further dimensional checks and a liquid penetrant test on the governor shaft as recommended in the DR/QR will be performed prior to testing.
- The Unit 2 pushrods have all been liquid-penetrant tested, with acceptable results.
- iVEGP's rockerarm capscrews are of the " necked" shank design.
s i
d Overspeed Trio - Governor Couplino, 02-410C The original isoprene construction couplings were r'.placed with neoprene construction couplings which are more st'scable for the operating conditions.
Governor Drive, 02-411A Material comparator tests and hardness tests we re performed.
.Thd results of the Owners Group review is give1 in the DR/QR Soport.
The material comparator test results were satisfactory.
The hardness test results indicate that periodic inspection for wear will be required.
This inspection is called for in the preventive maintenance schedule.
Governor Heat Exchangers, 02-415C The heat exchanger was visually inspected to ensure correct location below the governor oil level.
J_acket Water Pump,02-425 Material comparator tests, hardness tests, liquid penetrant tests, dimensional checks, and visual inspections were performed.
The impeller and backing plate wear ring were replaced on both pumps.
Turbocharger Air Butterfly Valve, 02-475B A hardness test was performed on the valve shaft.
These tests will be repeated prior to engine testing to confirm shift hardness.
Turbocharger Bracket - Bolting and Gasket, 02-475C Material comparator tests were performed on the turbocharger bolts.
One bolt with signs of thread damage was replaced on engine lA.
All bolts were torqued to TDI specifications.
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Fuel Tappet Assemblies, 02-3458 Visual inspection and dimensional checks were performed on all fuel tappets with satisfactory results.
~
Camshaft, OE-350A Visual inspections were made of all cam lobes and dimensional checks were made of camshaft thrust clearance.
All were
. acceptable.
Camaear 02-350C Visual inspections, superficial hardness tests, and material comparator tests were performed on the cam gears with satisfacto y results.
Crank to Ptno Gear, 02-355A Visual inspections, superficial hardness tests,'and material comparator tests were performed on the crank-to-pump gear with satisfactory results.
Idler Gears, 02-355B Visual inspections, superficial hardness tests, and material comparator tests were performed on the idler gears with satisfactory results.
Air Start Valves,02-359 Original 3" long capscrews were replaced with 2-3/4" long capscrews and copper gaskets were installed.
The shorter capscrews permit proper torquing of the valve assembly to the cylinder head.
- Cylinder Heads, 02-360A Visual inspections, liquid penetrant tests, magnetic particle tests, and ultrasonic tests were performed on all cylinder heads.
As a result of these examinations, one cylinder head was rejected. The cylinder heads are Group III heads, manufactured after September,1980. *
- Intake and Exhaust Valves, 02-3608 Visual inspections, liquid penetrant tests, and dimensional checks were performed on all valves.
One valve on engine B exhibited chrome plate flaking and was replaced.
VEGP will retorque the capscrews at eight-hour intervals during initial engine operation, as reconmended by the Owners Group.
- The Unit 2 cylinder heads have all been inspected. One head from a
each of the engines was rejected and replaced.
Connecting Rods and Bushing, 02-340A Material comparator, hardness tests, and visual inspections were performed on all connecting rods and bushings with satisfactory results.
Eddy current examinations were performed on all connecting rod bolt holes with satisfactory results.
Magnetic particle, visual inspection, dimensional check, and torque settings checkswere performed on all connecting rod bolts with satisfactory results.
Liquid penetrant tests were
, performed on all wrist pin bushings.-
The connecting rod bolts and nuts that exhibited signs of galling were machined to TDI specifications and all washers with signs of galling were replaced.
- Connecting Rod Bearing Shells, 02-340B Visual inspections, liquid penetrant tests, eddy current examinations, dimensional checks, and radiographic examinations were performed on all connecting rod bearing shells.
Based on the results of these.tes.ts, one bearing shell on engine 1A and three shells..on. engine 1B will be replaced prior to engine testing.
In addition two of the original bearing shells were rejected from engine 1A and one of.the original bearing shells was rejected from engine 1B.
Pistons, 02-341A The original AN type skirts were replaced with new design AE type skirts which have been heat treated and are not susceptible to cracking.
Visual inspections, liquid penetrant tests, and dimensional checks were performed on all replacement piston skirts.
Piston Rings, 02-3418 Visual inspections and dimensional checks were performed on all l
piston rings with satisfactory results.
Piston Pin, 02-341C Visual inspections, dimensional checks, material comparator tests and hardness tests were performed on all piston pins with satisfactory results.
Intake and Exhaust Tappet Assemblies, 02-345A visual inspection and dimensional checks were performed on all intake tappets with satisfactory results.
- The VEGP connecting rods have 1-1/2" diameter bolts.
i 4
I E
Main Bearing Shells, 02-310B visual, dimensional and radiographic examinations were performed on all main bearing shells.
Liquid penetrant tests were performed on engine 1A main bearing shells and will be performed on engine 18 prior to preoperational testing.
All 4
main bearing shells were acceptable but one on engine 1A which was replaced.
~
' Crankshaft Thrust Bearing, 02-310C The' crankshaft thrust clearance was measured and adjusted as required to conform with the manufacturer's specifications.
Crankcase, 02-311A The crankcase arch walls were examined for sharp discontinuities between machine surfaces and casting and all surfaces were satisfactory.
Cylinder Block, 02-315A visual inspections, dimensional checks, liquid penetrant tests, and oddy current examinations were performed on the cylinder blocks with satisfactory results.
Material samples from each block,were analyzed with satisfactory results.
Cylinder Liners, 02-315C i
The liners were machined to current TDI specifications. Liner crush was maintained.
Cylinder Block Studs, 02-315E Torque setting checks and visual inspections were performed on all studs.
All studs were machined to latest TDI specifications to reduce stress in the upper cylinder block area.
Material comparator and hardness tests were performed on four studs on each engine with satisfactory results.
Cylinder Head Stud Nuts, 02-315F Torque setting cht ks and visual inspections were performed on all nuts.
All f'at washers were replaced with new washers that were examined by liquid penetrant tests prior to installation.*
- VEGP's cylinder head studs are of the " necked" shank design.
Materials verification of the cylinder haad studs indicated that they met AISI 4140 requirements.
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