ML20133B925
| ML20133B925 | |
| Person / Time | |
|---|---|
| Site: | Vogtle  |
| Issue date: | 07/24/1985 |
| From: | Eppler L BECHTEL GROUP, INC. |
| To: | |
| Shared Package | |
| ML20133B788 | List: |
| References | |
| OL, NUDOCS 8508060291 | |
| Download: ML20133B925 (28) | |
Text
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o 4
July 24, 1985 UNITED STATES OF AMERICA 00thETED USNRC NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD 15 AUG -5 A10 :46 GFFICE OF SECRtTAli-In the Matter of
)
00CKETING & SERVICI BRANCH
)
)
Docket Nos. 50-424
)
50-425
)
(Vogtle Electric Generating
)
Plant, Units 1 and 2)
)
AFFIDAVIT OF LARRY L.
EPPLER
)
STATE OF GEORGIA
)
)
ss.
COUNTY OF BURKE
)
)
I, Larry L. Eppler, being duly sworn, state as follows:
f 1.
Since 1984, I have been employed by Bechtel Power 4
Corporation ("Bechtel"), as a Mechanical Engineer.1/
My business address is Bechtel Power Corporation, 12440 East Imperial Highway, Norwalk, California 90650.
I am currently working with VEGP's Construction Department on the installation of-the Transamerica Delaval, Inc. ("TDI") diesel generators.
Over the last year I have been involved in the preparation of the reports detailing VEGP's inspection effort for the Unit 1 and Unit 2 1/
Bechtel is the architect / engineer for the Vogtle Electric Generating Plant ("VEGP").
c.
DR j
O r
m diesels. 'See " Affidavit of Steve A.-Phillips" ("Phillips Affidavit"), 11 6,-8.
I have also been responsible for the disposition of Deviation Reports at the plant (see id.,
T 13),
and the preparation of engineering evaluations addressing the results of non-destructive testing of diesel engine components.
I have personal knowledge of each of the matters' set forth herein, and believe them to be true and correct.
2.
Prior to taking my current position, I was employed by Bechtel as a Plant Design Engineer.
I have a B.S. degree in advanced mathematics and chemistry.
I received a B.S. degree in mechanical engineering from Oregon State University in 1982.
A statement of my professional qualifications is attached hereto as Exhibit 1.
I.
DESCRIPTION OF THE VEGP TDI DIESEL GENERATORS 3.
Two TDI model DSRV-16-4 diesel generators are provided for each Unit at VEGP.
This model is a 16-cylinder, four-cycle, V-type diesel engine.2/
Each diesel generator is rated at 7,000 kw for continuous operation and 7,700 kw for a short-term (2 hour2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />) period every 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />.
As indicated in the VEGP Final Safety-Analysis Report (FSAR), in the event ~that loss of offsite power causes a forced plant shutdown, the calculated maximum load j2 /
This model differs from the DSR-48 model at Shoreham Nuclear Power Station.
The TDI model DSR-48 is an in-line, 8-cylinder engine.
The DSRV-16-4 model also differs from the DSRV-20 engines, such as those installed at San Onofre, which are 20-cylinder models.. - - - -
l' automatically sequenced onto the VEGP engines is 5,517 kw.
This is only 79% of the engines' continuous operation rating.
The VEGP engines, therefore, have more thaIn adequate capacity to handle the most severe design basis sequenced loading.
1 4.
The diesel generators are electrically isolated from each other.
Physical separation (for fire and missile protection) is also provided since they are housed in separate rooms of the seismic category 1 diesel generator building.
Class 1E power and control cables for the diesel generators and associated switchgear are routed to maintain physical separation.
5.
The diesel generators are monitored and alarmed in the control room.
Alarms are also provided in the diesel generator room.
Protective devices which function to shut down the diesels during accident (safety injection) conditions are actuated by the following signals:
o Engine overspeed o
Generator differential o
Low lube oil pressure o
High jacket water temperature Should one diesel generator be tripped by a' protective device, the redundant diesel generator will provide the power required to maintain the plant in a safe condition. Repairs can be performed while the redundant diesel is in operation.
II.
VEGP DIESEL GENERATOR COMPONENT MODI-FICATIONS RECOMMENDED BY OWNERS GROUP 6.
As discussed in the " Affidavit of John C.
Kammeyer"
("Kammeyer Affidavit"), and the Phillips Affidavit, VEGP was an active participant in the TDI Diesel Generator. Owners Group Program.
The VEGP Design Review / Quality Revalida' tion ("DR/QR")
Report includes Owners Group recommendations for design modifica-tions to the VEGP Unit 1 diesel generator systems' piping, piping supports, and control panel assemblies.
Each of these modifica-tions were reviewed by Bechtel for application at VEGP.
A priority implementation effort has been undertaken to incorporate the recommended modifications.
With two exceptions, VEGP currently plans to perform each of the recommended design modifi-cations, as outlined in Exhibit 2, "DR/QR Report Implementation."
7.
The first exception concerns the recommended addition of a Dresser coupling on the engine-driven lube oil pump suction line.
The results of a walkdown indicated that due to the piping configuration on the VEGP diesels, it was not physically possible to install a Dresser coupling as recommended.
Therefore, Bechtel performed a stress analysis for piping between the pressure regulating valves and the pump and calculated the nozzle loads.
These loads have been reviewed and found to be within TDI maximum allowable loads for the nozzles.
See Ex.
2, Sec. 3.3.10.
Addition of a Dresser coupling is, therefore, not required.._
8.
Based on the lead engine repart, the Owners Group also recommended that certain slip joints on the exhaust manifolds be removed and replaced ~with 6"-150 alip-on flanges with A449 bolts.
Discussions with the Owners Group consultant indicated that the change is intended to modify pipe spools that are unrestrained in the axial direction. Bechtel reviewed the engine drawings to determine the VEGP-specific modification necessary.
Bechtel concluded that only some of the slip joints needed to be replaced to assure that all pipe spools are restrained in the axial direction and to meet the intent of the Owners Group modification.
See id.,
Sec.
3.5.1.1.
A walP.down will be performed to confirm that the as-built piping configuration corresponds with TDI drawings.
Modifications will be performed only after this has been verified.
Applicants will formally submit these explanations to the NRC Staff.
9.
Each of the Unit 1 modifications will be implemented prior to fuel load.
The analysis and design modifications made for Unit 1 will be applied, as appropriate, to the Unit 2 diesel generator systems.
III.
CONCLUSION 10.
All of the modifications recommended by the Owners Group have been reviewed by Bechtel.
The majority of the applicable modifications have already been implemented.
The remainder will be implemented prior to fuel load. Implementation of all applicable Owners Group recommendations at VEGP provides.--
r reasonable assurance that the VEGP diesel generators will
. reliably perform their intended. safety-related function.
d/W h/ U Ldrry L. Eppler Subscribed and sworn to before me this30 day of July, 1985.
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k N5t ' y Public -
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My commission expires on g;: n p _.:, : :c: -
. _ ' ar, M CU' 3;' C'. L.s
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j
EXHZBIT 1 L
LARRY L. EPPLER MECHANICAL ENGINEER BECHTEL POWER CORPORATION, WESTERN POWER DIVISION 2
EDUCATION Bachelors of Science, Mechanical Engineering
- Oregon State University, 1982 Masters of Arts in Teaching (Advanced Mathematics)
Oregon College of Education, 1973 B.S.
(Advanced Mathematics and Chemistry)
Oregon College of Education, 1969 EMPLOYMENT HISTORY 1982 to Present:
Bechtel Power Corporation o
One year as Mechanical Engineer working as diesel system engineer in the construction phase and working as diesel engineer on the task force implementing the Owners Group recommendations.
o Two years as a Plant Design Engineer doing pipe stress analysis, pipe support design and miscella-neous steel calculations.
1 1970 to 1981:
Mathematics Teacher at high school and college levels.
-1
EXIIIBIT 2 DR/QR REPORT IMPLEMENTATION
1.0 INTRODUCTION
This report addresses implementation of the TDI Owner's Group DR/QR report recommended equipment modifications at VEGP Unit 1.
Each of the recommendations was technically evaluated to determine the method by which compliance will be met.
Details of the design changes performed to comply with specific recommendations are also summarized.
All of the requiced design changes will be implemented prior to fuel load.
The analysis and design modifications mode for Unit 1 will be applied as applicable to the Unit 2 diesel generator systems.
2.0 ANALYTICAL APPROACH 2.1 Applicable Codes for Piping Analysis The specification for the Standby Diesel Generators (Bechtel Specification X4AK01, Revision 6) states that all auxiliary module piping is to be analyzed per ASME III Class 3 requirements.
Piping and equipment mounted on the engine itself is designed per Diesel Engine Manufacturers' Association which does not provide unique requ.irements for piping analysis.
Owner's Group recommendations for additional or modified supports for the on-engine piping were analyzed to ensure the pipe stress did not exceed ASME III Class 3 allowables.
This conservative approach was implemented because it provides analytical consistency.
2.2 Isometric Drawings and Sketches To utilize existing documents to the greatest extent practical, the TDI-generated seismic report was used.
A small portion of that report which contains isometrics of the auxiliary module piping served as the basis for the preparation of isometric drawings.
The majority of required isometric drawings were, however, originated as a result of piping walkdowns because these drawings did not previously exist in the TDI report.
2.3 Pipe Stress Analysis A new pipe stress analysis was generated for those lines where new supports were added or where existing supports were modified to change the directions of a restraint.
If the modification was to provide a stiffer restraint and stress loads were provided by Impell a new stress analysis was not required since the pipe stresses were not affected.
2656t/32
r 2.4 Support Analysis Pipe support calculations and support drawings were prepared for all new and modified supports.
Unless specified otherwise, supports were designed to be rigid with movement less than 0.04 inches in the direction of the restraint.
3.0
SUMMARY
OF OWNER'S GROUP RECOMMENDATIONS AND COMPLETED IMPLEMENTATION EVALUATION / ANALYSIS The following is a qualitative discussion of each of the Owner's Group recommendations for each piping run, tubing run, or component in individual subsystems including the results of the completed implementation evaluation / analysis.
North-South and East-West orientation in the Owner's Group recommendations were revised to reflect the true orientation of equipment and piping on the engines installed in Plant Vogtle.
3.1 Starting Air Subsystem 3.1.1 Starting Air Manifold:
Valves, Strainers and Filters; Group Parts List No. 02-441B Owner's Group Recommendation:
In accordance with TDI recommendation, free flowing drains should be added to the air distributor filter.
This is a design improvement which will help maintain a cleaner supply of starting air.
Completed Evaluation / Analysis:
An engineering walkdown indicated the drains were added at the factory.
Supports have also been furnished.
No further engineering analysis is required and this item is considered complete.
3.1.2 Component Parts No. 02-441A 3.1.2.1 U-bolt Supports Owner's Group Recommendation:
The two U-bolt supports adjacent to the strainers require stiffening of their support members in the lateral direction.
Completed r aluation/ Analysis:
A stress analysis was performed on the en i<a engine-mounted starting air subsystem.
An additional support adjacent to the original U-bolt supports was added in each starting air line to provide support in the lateral direction based on actual loads.
I 2656t/33
3.1.2.2 Support Members for Starting Air Headers Owner's Group Recommendation:
The ten support members on the two headers running parallel to the length of the engine require reinforcement and bolt hole elongations in the north-south direction.
Completed Evaluation / Analysis:
Holes will be slotted.
A l
thermal analysis has been performed to determine the size of the slots.
Because the supports are welded to the pipe, a stiffness was calculated in each restrained direction and restrained moment and subsequently modeled.
Supports were stiffened based on the results of a stress analysis.
A new support design was required to accommodate the resulting loads.
3.1.2.3 Supports and Hole Elongations for the Risers Owner's Group Recommendation:
The support located on the riser west of the valves (left bank) and the support located on the riser east of the valves (right bank) require reinforcement; bolt hole elongations in the east-west direction are also required.
Completed Evaluation / Analysis:
Holes will be slotted.
Stiffening was not required due to the support added per item 3.1.2.1.
3.1.2.4 Supports for the Riser Owner's Group Recommendation:
The support located on the riser east of the valves (left bank) and the support located on the riser west of the valves (right bank) require reinforcement of support members.
Completed Evaluation / Analysis:
Supports will be stiffened (one on each starting air line) resulting in a new support design to accommodate the loads.
3.1.2.5 Material for Retaining Bolts on Strainer Flange Owner's Group Recommendation:
Ensure that the bolts, for the flanged connection on the west side of the strainers for the right bank on both diesels, are A449 or better (based on ASME III allowable stress).
Completed Evaluation / Analysis:
Bolts were inspected and verified to be A449.
a 2656t/34
F 3.2 Fuel Oil Subsystem 3.2.1 Fuel Oil Valves; Group Parts List No.02-825 Owner's Group Recommendation:
The following modification should be considered based on system operation:
If frequent bypassing of oil is required, the valve outlet should be piped below the oil level in the fuel oil day tank to prevent air entrainment and erratic operation.
Completed Evaluation / Analysis:
The return line back to the. day tank will be extended to terminate below the minimum level of the fuel oil.
3.2.2 Fuel Oil Header - Fuel Oil Supports (Small Bore Scope Only); Group Parts List No. 02-450C 3.2.2.1 Fuel Oil Drip Header Owner's Group Recommendation:
For each fuel oil drip header (two per engine), one of the existing two-directional restraints per header should be modified to a three-directional restraint in order to provide axial restraint of the header and to minimize the effects on all associated tubing.
Completed Evaluation / Analysis:
One of the two-directional restraints per header will be modified to a three-directional restraint and a new support design has been completed.
3.2.2.2
,Eiector Assembly Owner's Group Recommendation:
The ejector assembly and adjacent 1-inch diameter tubing need to be resupported/ anchored in order to minimize the imposed loading and stresses on the ejector assembly nozzles.
Completed Evaluation / Analysis:
Two additional three-directional restraints were added and a new support design was completed.
3.2.2.3 Fuel-Oil-to-Day Tank Return Piping Owner's Group Recommendation:
Upon installation, an anchor (six-way restraint) should be added on the fuel-oil-to-day tank return piping (two lines per engine) in order to reduce the unsupported span length and to minimize the effect from the off-engine piping.
2656t/35
.p.,--.y
,m rF--
Completed Evaluation / Analysis:
The Owner's Group did not identify the specific location for this anchor.
To avoid the transmission of loads to the on-engine TDI piping, a short (approximately 12 inches in length) ASME III flexible hose will be furnished downstream of the TDI-furnished flange.
Bechtel will procure the necessary hoses for all four trains.
Piping drawings will be revised and supports will be designed.
Supports have been added to the off-engine piping to reduce the effect on the on-engine piping.
3.2.2.4 1-inch Eiector Tubing Owner's Group Recommendation:
A two-direction lateral restraint should be added on the 1-inch ejector tubing (2 lines) approximately 2 feet-6 inches below the supply and circulation rear crossover headers in order to reduce the unsupported span lengths.
Completed Evaluation / Analysis:
An engineering walkdown confirmed that the two-directional lateral restraint currently exists on Engine 1A.
A new support design was completed so that this restraint will be added in a similar location on Engine 1B.
3.2.2.5 Riser on the 1/4-inch Fuel Oil Line Owner's Group Recommendation:
A two direction lateral restraint needs to be added on the riser of the 1/4-inch fuel oil line, nozzle holder to drain header (Engine 1A), in order to reduce ta unsupported span length and to maintain consistency with Engine 1B.
Completed Evaluation / Analysis:
A calculation was done to document placement of clamps providing two-directional restraint and an isometric sketch has been developed to physically locate these clamps.
3.2.2.6 Engine lA Left Bank Fuel Oil Suction Ltne' Owner's Group Recommendation:
Upon installation of the Engine 1A left bank fuel oil suction 'ine (1/2-inch tube from the ejector assembly to the drain header), restraints should be added or verified for consistency with the installed tubing of Engine 18.
Completed Evaluation / Analysis:
The engine IB configuration will be duplicated on engine lA.
No additional analysis or supports are required.
I 2656t/36
F.
3.2.3 Fuel Oil Header:
Piping / Tubing (Small Bore Scope Only); Group Parts List No. 02-450B Owner's Group Recommendation:
It is recommended.that the 1-inch threadolet be changed to a socket welded tee to preclude the possibility of fatigue failure from long term vibration stresses.
Completed Evaluation / Analysis:
A threaded tee will be installed.
A calculation was performed to verify maximum allowable stresses have not been exceeded.
3.2.4 Fuel Oil Filters and-Strainers:
Strainers; Group' Parts List No. 02-455B Owner's Group Recommendation:
The following modification from the lead engine DR/QR report should be considered:
The strainer can be replaced with a coarser design that would require less maintenance, but would still satisfy the filtration requirement for the booster pump, which is 100-200 mesh.
This recommendation is made to enhance operation but is not required for system operation.
Completed Evaluation / Analysis:
TDI has agreed that the fuel oil pump strainer may be reduced to 200 mesh from.the present 300 mesh size size but not to anything smaller without jeopardizing pump integrity.
The 300, mesh strainer will be replaced with a 200 mesh strainer.
3.3 Lube Oil Subsystem 3.3.1 Auxiliary Sub Base and Oil Water Piping Lube Oil:
Pipe and Fittings (Large Bore Scope Only); Group Parts List No.
02-717F.
Owner's Group Recommendation:
In order to mitigate thermal expansion loading at the nozzles, it is recommended that the support located between the duplex filter outlet and duplex strainer inlet be modified to a U-bolt.
Completed Evaluation / Analysis:
The support was modified to a one directional restraint consistent with the Impell results recommending use of a lateral support only.
3.3.2 Auxiliary Sub-Base and Oil.and Water Piping Lube Oil:
Piping and Fittings (Small Bore Scope Only); Component Parr No. 02-717F Owner's Group Recommendation:
The location of two and/or three directional restraints should be such that the unsupported 2656t/37
tubing span does not exceed a maximum of 4 feet 6 inches.
The location of restraints should allow for thermal expansion by providing a minimum of 6-inch offset around elbows.
Completed Evaluation / Analysis:
A walkdown was performed on the J-presently installed small bore piping and tubing.
An additional walkdown will be performed to verify compliance with span lengths subsequent to installation of remaining tubing.
Restraints are to be added, as necessary, to comply with the maximum allowable span length between restraints.
3.3.3 Auxiliary Sub-Base and Oil and Water Piping Lube Oil:
Supports and Mounting Hardware (Small Bore Scope Only); Group Parts List No. 02-717I Owner's Group Recommendation:
Upon installation, the tubing supports should be verified or modified to have, as a minimum, two directions of restraint.
j Completed Evaluation Analysis:
As of the date of this report, the subject tubing has not been installed.
Compliance with this requirement will be verified subsequent to installation.
3.3.4 Lube Oil Lines External:
(Small Bore Scope Only);
Component Part No. 02-465B Owner's Group Recommendation:
In order to support the piping / tubing of Component 02-465A, it is recommended that a two-directional lateral restraint be added on the riser of the 1-1/2-inch diameter gear case lube oil line of Engine 1A to provide support of the cantilevered configuration and to maintain consistency with Engine 1B.
Completed Evaluation / Analysis:
The Engine 1B configuration will be duplicated on Engine 1A; the location of supports are currently shown on TDI drawings.
No additional analysis or supports are required.
1 3.3.5 Turbocharger-Lube Oil Fitting:
piping, Tubing, and Flexible Coupling (Large Bore Scope Only); Group Parts List i
No. 02-467A Owner's Group Recommendation:
The 2-1/2 inch Dresser couplings (located between the turbocharger and lube oil sump tank for both drain lines) are to be removed and replaced with 2-1/2 inch 150 lb flanges with A307 bolts.
Completed Evaluation / Analysis:
Dresser couplings will be
' replaced with 2-1/2 inch 150 lb weld neck flanges with A307 bolts.
2656t/38
3.3.6 Turbocharger-Lube Oil Fitting:
Supports (Large Bore Only); Group Parts List No. 02-467B Owner's Group Recommendation:
The multiple support (attached to both 2-1/2 inch drain lines) located between the lube oil sump tank and the Dresser coupling requires reinforcement of its support members and increases in their welds.
Completed Evaluation / Analysis:
A calculation was performed incorporating 3.3.5 above.
A new stiffened support design based upon the calculated' loads was developed.
3.3.7 Turbocharger-Lube Oil Fittings:
Supports (Small Bore Scope Only); Component Part No. 02-467B Owner's Group Recommendation:
In order to support the tubing of component 02-467A, it is recommended that a three-directional restraint be added on each turbocharger lube oil line to reduce the unsupported span length.
Completed Evaluation / Analysis:
Three two-directional restraints are to be added to each lube oil line per TDI drawing 02-467-22.
A calculation was done based on the presence of these supports and the results show that an additional three-directional restraint is not necessary.
3.3.8 Turbocharger Thrust Bearing Drip Lube System (Small Bore Scope Only); Component Part No. 02-467C 3.3.8.1 Two-way Supports for the Right Bank Lube Oil Line Owner's Group Recommendation:
It is recommended that two-way supports be added to the right bank lube oil line (Engine 1B) and/near the turbocharger connection such that the spans between supports are limited to a maximum of 3 feet.
Locations of supports should allow for thermal expansion by providing a minimum 6-inch offset around elbows.
l Completed Evaluation / Analysis:
See 3.3.8,3 l
l 3.3.8.2 1A Installation of Drip Lube System Owner's Group Recommendation:
Upon installation of this I
component for Engine lA, it is recommended that the installation be consistent with Engine 18.
Completed Evaluation / Analysis:
See 3.3.8.3 2656t/39
3.3.8.3 Full Flow prelubrication Modification Owner's Group Recommendation:
Based on the review of indus,try experience and subsequent walkdown of this component, it is recommended that a full flow prelubrication modification be installed to preclude the possibility of turbocharger thrust bearing failures.
Completed Evaluation / Analysis:
TDI has issued drawing 102675 Revision B,
" Schematic - Elliott Turbo Thrust Bearing Drip Lubrication System," that provides for a manual full flow bypass valve around the drip system flow control orifice.
This modification will be made with the manually operated valve located in an a-cessible area to permit safe operation by plant personnel.
Lines will be shown on isometric drawings and subsequently analyzed; required supports will be installed.
3.3.9 Lube Oil Fittings Internal - Supports (Small Bore Scope Only); Group parts List No. 02-307D Owner's Group Recommendation:
The lead engine reports do address the following recommended modifications to supports:
(1) Replace all 1/4-inch U-bolts with 1/8-inch U-bolts, (2)
U-bolts should be torqued sufficiently to prevent the header from moving axially without overstressing the header; nuts should have suitable locking devices installed, and (3) The U-bolts radius should be coincident with the radius of the header to provide a snug fit.
Completed Evaluation / Analysis:
Review of the TDI parts manual indicated that ten 3/8 inch U-bolts are furnished on the internal lube oil system per engine.
Double-nutting or a locking clip will be installed to satisfy maintenance of torquing requirements.
Verification of installation will be made to ensure the U-bolt radius is consistent with the radius of the header.
3.3.10 Engi$e Driven Lube Oil pump; Gtoup parts List l
No.02-420 Owner's Group Recommendation:
It is recommended that a Dresser coupling be added on the pump suction line to mitigate the thermal expansion loading and stresses on the pump inlet nozzle.
The coupling should be located between the relief valve branch connection and the pump inlet nozzle.
Completed Evaluation / Analysis:
The results of a walkdown indicated that due to the piping configuration on the VEGp diesels, it was not physically possible to install a Dresser coupling as recommended.
Therefore, a stress analysis was performed for the piping between the pressure regulating valves ona the pump and calculated the loads for the pump nozzle.
These l
2656t/40
loads were subsequently reviewed and found to be within TDI maximum allowable loads for the nozzles.
Addition of a Dresser coupling is, therefore, not required.
3.4 Jacket Water Subsystem 3.4.1 Jacket Water Standpipe:
Pipe Supports; Group Parts List No. 02-700C I
Owner's Group Recommendation:
Upon installation, the (vent line) tubing supports are verified or modified to have, as a minimum, two directions of restraint and sufficient moment connection.
Also, the U-bolts used in the support of the standpipe overflow line should be a minimum of 3/8-inch in diameter and suitable locking devices should be installed.
Completed Evaluation / Analysis:
Installed U-bolts are correct.
Tubing for the vent lines will be shown on an isometric drawing and will subsequently be analyzed and supported as recommended.
j 3.4.2 Auxiliary Sub-Base and Oil and Water Piping-Jacket Water:
Pipe, Couplings, Fittings, Orifices, Y-Strainers, (Small Bore Scope Only); Group Parts List No. 02-717C Owner's Group Recommendation:
Upon installation the following criteria must be met:
(1) The location of two and/or three directional restraints is such that the unsupported tubing spans do not exceed a maximum of 4 feet 6 inches and (2) The location of restraints should allow for thermal expansion by providing a minimum of 6 inch offset around elbows.
Completed Evaluation / Analysis:
A walkdown was performed on the presently installed small bore piping and tubing.
An additional walkdown will be performed to verify compliance with span lengths subsequent to installation of remaining tubing.
Clamps will be added, as necessary, to comply with the maximum allowable span lengths.
3.4.3 Auxiliary Sub-Base and Oil and Water Piping - Jacket Water Supports (Small Bore Scope Only); Component Part No. 02-717E Owner's Group Recommendation:
Upon installation, the jacket water cooler drain line supports are verified or modified to have sufficient stiffness and weld.
Completed Evaluation / Analysis:
Action co be taken on this iteht is identified in paragraph 3.4.2.
3.4.4 Jacket Water Standpipe:
Pipe, Fittings, Gaskets; Group Parts List No. 02-700A 2056t/41
3.4.4.1 Restraint on the Standpipe Overflow Line Owner's Group Recommendation:
A three-directional restraint on the standpipe overflow line needs to be installed to ensure vertical support of the riser.
Completed Evaluation / Analysis:
A walkdown confirmed that the subject restraint has been installed.
3.4.4.2 Anchor on the Standpipe Fill Line Owner's Group Recommendation:
Upon installation, verify or modify an anchor on the standpipe fill line to isolate seismic skid piping from the nonseismic off-skid piping.
If the off-skid piping is seismically designed then the nozzle loading at the TDI (skid) to off-skid interface should be verified to be within the allowable nozzle loading as specified in the TDI piping analysis reported, dated May 4, 1984.
Completed Evaluation / Analysis:
The off-skid piping will be analyzed to verify nozzle loads hrce not been exceeded.
3.4.4.3 Jacket Water Vent Lines Owner's Group Recommendation:
Jacket water vent lines (air bubble removal system) should be installed in accordance with TDI drawing No. 09-810-76021.
Completed Evaluation / Analysis:
The subject vent lines will be installed per TDI requirements.
3.4.5 Jacket Water Fittings-pipe and Fittings (Large Bore Scope Only); Component Part No. 02-435A 3.4.5.1 Lateral supports at the U-Bolts
..__. Owner's Group Recommendation:
Add lateral support at each of the two U-bolts below the check valve (on both sides of the tee) to strengthen side load capability.
Bechtel's Completed Evaluation / Analysis:
The Impell loads (Ref. 4) furnished by the Owner's Group were used as the basis for support redesign.
The existing supports were stiffened in the lateral direction.
3.4.5.2 Bolt Torque at the Check Valve Flange Owner's Group Recommendation:
Increase bolt torque at the theck valve flanges to 130ft lb.
Completed Evaluation / Analysis:
Bolt torque will be checked and adjusted as required.
2656t/42
3.4.6 Jacket Water Manifold:
Manifold Assembly with Hardware, Coupling and Gaskets (Large Bore Scope Only); Group Parts List No. 02-316A&B 3.4.6.1 Tie Rod Assembly Owner's Group Recommendation:
The tie rod assembly surrounding the 6-inch Dresser coupling requires double-nutting to prevent inward axial movement.
Also, a 1-inch diameter rod is required to accommodate the compression load.
Completed Evaluation / Analysis:
The 1-inch diameter tie rod assembly with double nutting will be installed.
i 4
3.4.6.2 Stiffening of Selected Support Owner's Group Recommendation:
The second support south of the 6-inch TDI custom flanges requires stiffening in the lateral direction to accommodate total support loads.
Completed Evaluation / Analysis:
The support was stiffened, as necessary, based on the Impell loads and a new support design has been developed.
3.4.7 Jacket Water Inlet Manifold-Vent Line to Discharge Manifold; Group Parts List No. 02-316C Owner's Group Recommendation:
The report recommended the l
provision of a more suitable type of moment connection at the
(,
support to structural steel interface.
Completed Evaluation / Analysis:
The line will be shown on an isometric drawing for subsequent analysis and support design.
3.4.8 Jacket Water Discharge Manifold Piping (Large Bore Scope Only); Group Parts List No. 02-317A&B Owner's Group Recommendation:
The style 65 Dresser couplings are to be replaced with a new Dresser Style 90 or Style 165 coupling equipped with Viton gaskets, should leaks develop.
Completed Evaluation / Analysis:
The new style couplings will be procured as spare parts and will be installed if leaks develop, i
3.4.9 Water Discharge Manifold / Supports (Large Bore Scope Only); Group Parts List No. 02-317C Owner's Group Recommendation:
Ensure that the supports
- (attached to the water jacket shroud) on the two 5-inch headers have a minimum weld of 3-inches long on both sides of the longer end of the plate.
Also, ensure that the welds between the existing 3/4" plate and the engine block have a minimum weld of 1/4-inch along the total width of the plate.
2656t/43 l
y Completed Evaluation / Analysis:
Existing configuration shows a full weld around the bottom plate attached to the engine shroud (not the engine block as indicated).
The top plate is bolted to the bottom plate and the jacket water piping is securely attached to the top plate via gusset plates which are welded along their entire length.
An as-built sketch is furnished.
This configuration provides maximum welds at all locations.
3.5 Miscellaneous Components 3.5.1 Exhaust Manifold; Group Parts List No. 02-380A 3.5.1.1 Slip Joints Owner's Group Recommendation:
The following recommendations made on the lead engine DR/QR report should be implemented:
1.
The second 6"
' lip joint from the No. 8 cylinder head, on both right and left banks is to be removed and replaced with 6"-150 lb. S.O. Flanges with A449 bolts.
2.
The first 6" slip-joint from the No. 2 cylinder head (second from the No. 7 cylinder head) on both the right and left banks, is to.be removed and replaced with 6"-150 lb. S.O. Flanges with A449 bolts.
3.
The first 6" slip joint from the No. 3 cylinder head (second from the No. 6 cylinder head), on both the right and left banks, is to be removed and replaced with 6"-150 lb.
S.O.
Flanges with A449 bolts.
4.
The first 6" slip joint from the No. 4 cylinder head (second from the No. 5 cylinder head) on both the right and left banks is to be removed and replaced with 6"-150 lb. S.O. Flanges with A449 bolts.
Completed Evaluation / Analysis:
Based on the lead engine report, the Owners Group also recommended that certain slip joints on the exhaust manifolds be removed and replaced with 6"-150 slip-on flanges with A449 bolts.
Discussions with the Owners Group consultant indicated that the change is intented to modify pipe spools that are unrestrained in the axial direction.
The engine drawings were reviewed to determine the VEGP-specific modification necessary.
It was concluded that only some of the slip joints needed to be i
replaced to assure that all pipe spools are restrained in the Dzial direction and to meet the intent of the Owners Group modification.
A walkdown will be performed to confirm that the as-built piping configuration corresponds with TDI drawings.
Modifications will be performed only after this has been l
verified.
l 2656t/44 J
p 3.5.1.2 Circumferential Pipe Welds Owner's Group Recommendation:
Perform a visual inspection and a magnetic particle test on a sample of the circumferential pipe welds and corresponding heat affected zones.
This is to be performed during the first refueling outage and alternate outages thereafter.
However, diesel operation should not exceed 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> between inspections.
Completed Evaluation / Analysis:
This surveillance has been incorporated into the GPC maintenance program.
3.5.2 Engine Shutdown Equipment - Tubing / Fittings and Supports (Small Bore Scope Only); Component Part No. 02-695A 3.5.2.1 Supports for Line E16 Owner's Group Recommendation:
It is recommended that two-way supports be added to line E16 (upon installation), high temperature jacket water between the water discharge manifold (governor end) and the gearcase area below, to ensure the between-support spans are limited to a maximum of 4 feet 6 inches.
Completed Evaluation / Analysis:
A sketch will be prepared subsequent to installation to show physical location of any required supports to satisfy maximum span lengths and the supports will be provided.
3.5.2.2 Supports for Lines-E31R, E31L, E23H, and E24 Owner's Group Recommendation:
It is recommended that two way supports for lines E31R and E31L, starting air pressure indication, midway between the air start header connection and cylinder No. 8 (right and left banks) as well as lines E23H and E24, trip excess vibration, at/near the left bank turbocharger trip mechanism on Engine IB need to be added.
Locations of supports should accommodate thermal expansion by providing a minimum of 6-inch tubing offset around elbows.
Completed Evaluation / Analysis:
A calculation was done to determine the physical location of intermediate supports to ensure maximum allowable span lengths are not exceeded.
A sketeb is provided showing location of required clamps to satisfy maximum span lengths for Engine 1B.
When Engine 1A tubing is installed, it will be supported in a similar fashion to the configuration of Engine 18.
2656t/45 i
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r r---ww-p.w m.------w-m-,..p
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3.5.2.3 Modification of One Bulkhead Type Support Owner's Group Recommendation:
It is recommended that the first bulkhead type support at the interface between the TD1 on-engine tubing and Vogtle's off-engine tubing (right bank, gearcase end) be modified at the lower connection in order to increase the stiffness and moment connection.
Completed Evaluation / Analysis:
A calculation was performed to determine the actual loads at the support.
The lower connection was stiffened and a new support design was furnished.
3.5.2.4 Intercooler; Group Parts List No. F-068 Owner's Group Recommendation:
TDI issued service information 1
memo (SIM) No. 365 for this component recommending that stiffeners be added to the intercooler adapters to prevent
[
distortion that can result from turbocharger blower discharge pressure.
Completed Evaluation / Analysis:
This modification will be incorporated per the design details given in SIM 365.
3.5.2.5 Turbocharger; Group Parts List No. MP-022/23 Owner's Group Recommendation:
Verify that SIM 300 was implemented and perform a liquid penetrant test on the welds 4
retaining the core plug (hub nut).
In addition, verify that the core plug is staked.
Completed Evaluation / Analysis:
Per TDI SIM 300 is not applicable to Vogtle.
i 3.5.2.6 Air Butterfly Valve Assembly; Group Parts List No. 02-475B m
Owner's Group Recommendation:
Modification should be made to add grease fittings as per TDI SIM 322.
Completed Evaluation / Analysis:
Per TDI SIM 322 is not applicable to Vogtle.
A walkdown was perfocmed, however, and verified that grease fittings have already been installed.
3.5.2.7 Governor Linkage and Cross Shaft Assembly; Group Parts List No. 02-413A l
Owner's Group Recommendation:
Verification of the integrity of
- the mechanical fasteners should be addressed by implementation 1
bf the following maintenance procedure:
Monthly inspections j
for loose parts should be' performed, and future tightening of j
this hardware to prevent loose parts should include the addition of lockwire to the lever arm clamp bolts and shaft j
roll pins.
2656t/46 1
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n,,n-n wn n,
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e Completed Evaluation / Analysis:
This surveillance action has been incorporated into the GPC maintenance program.
3.5.2.8 Control Panel Assembly; 02-500N Owner's Group Recommendation:
Verify that no Multi-Amp States Division terminal blocks, manufactured between 1974 and 1976, are installed.
Completed Evaluation / Analysis:
Per TDI Multi-Amp States Division terminal blocks manufactured between 1974 and 1976 are not used in either the generator control panels or engine control panels.
3.5.2.9 Conduit Supports Owner's Group Recommendation:
(1) Provide support for the 3-1/2" conduits, going to " MAG Pickups" and "L.O.
Temp.
In.,"
at the governor end, at about l'-6" from the center line of the first terminal box from the right bank, for both engines; (2) Provide a support for 1/2" conduit going to "EJBG" box at right bank, at about l'-6" from the existing support, for Room "A",
similar to Room "B",
and (3) Replace the existing plates for supports for 1-1/2" conduit, going to pyrometer harness, at flywheel end, by 1/4" plates, for both engines.
Completed Evaluation / Analysis:
A walkdown was performed and recommended locations for additional supports can be accommodated.
Furthermore, the existing 1/8" plates on the engine will be replaced with 1/4" plates.
3.5.2.10 Generator Control Panel 3.5.2.10.1 Mandatory Modification Owner's Group Recommendation:
Recommended panel modifications are to replace specific diodes in the bridge rectifier assembly with higher rated diodes; to replace the field flashing relay with an enclosed higher rated relay; to add ventilation to the left front generator control cabinet; to revise the SCR mounting to use drilled holes, nuts, and lockwashers; to revise the heatsink connections so that there are not more than two lugs on each bolt; to remove anodizing in contact areas of bus bar bolts and bus bar studs; and to eliminate any separations of current carrying surfaces by washers or nuts.
Completed Evaluation / Analysis:
The electrical modifications described above including qualification will be done by Parsons Teebles - Electric Products, Inc. (manufacturer of the affected assemblies).
2656t/47
i The existing NEMA size 2 field flashing relay (dc contactor) will be replaced with a NEMA size 3 contactor with 100 amp DC i
continuous current rating.
The NEMA, size 3 contactor will be enclosed by a dust tight hood.
Although the DR/QR recommended
)
a 110 amp rating, the maximum current experienced by the field flashing contactors is 101 amp DC.
This maximum occurs only during an incomplete start due to an equipment failure.
The NEMA size 3 contactor has been tested over the entire voltage I
range from 100 to 140 VDC and meets the intent of the DR/QR recommendation, which is to minimize the potential for damage to this contactor during abnormal incomplete starting sequence events.
All other electrical modifications will be completed as recommended in the DR/QR.
To minimize the potential for Unit 1 schedule impact, the Unit 2 panel assemblies will be modified first for substitution into the Unit 1 panels.
The Unit 1 panel assemblies will then be modified for use in the Unit 2 panel.
The Unit 2 panel assemblies are currently being removed for return t'o the manufacturer in time to support preoperational testing and fuel load schedules.
The modifications to the Unit 1 panel assemblies will be completed and the panel returned to the jobsite in sufficient time for use in Unit 2.
The cabinet ventilation will be provided from the diesel generator building ventilation system which adds outside ambient air to the building when the engines are in service.
The additional ventilation duct will provide 1200 scfm of outside air to the generator cabinet.
3.5.2.10.2 Optional Modifications Owner's Group Recommendation:
Optional recommendations dealing with the voltage regulator circuit design, vibration protection, and printed circuit board construction should be made as possible improvements to enhance the panel reliability.
The recommended modifications are discretionary.
The Owners Group DR/QR concluded that the voltage regulator as presently designed is adequate for its intended functions.
The voltage regulator as currently designed and assembled has undergone extensive testing for seismic and environmental qualification that has demonstrated the ability to withstand vibration.
The discretionary modification pertaining to separation of the external signal leads from high current leads will be accomplished at this time by splitting the wiring harness to separate the leads to the clamping diodes from the other voltage regulator leads.
The remaining discretionary modifications will not be incorporated unless future testing end operating experience indicates that further improvement in this equipment is necessary.
2656t/48
3.5.2.10.3 Excitor Field Flashing Circuit Owners Group Recommendation:
An attempted start concurrent with certain diesel generator fault conditions could cause a prolonged period of field flashing resistor energization.
Specifically, if the start sequence progresses to the point of closing the field flashing relay and the output voltage of the generator does not build up for any reason, the field flashing resistor will remain energized until the exciter is manually reset.
In order to prevent the occurrence of this condition at Vogtle, it is recommended that the design of these circuits be reviewed.
If the potential for the subject overheating exists, all diesel generator starts (other than emergency starts) should be monitored to assure that an unsuccessful start does not result in a period of prolonged field flashing resistor energization.
A manual reset of the exciter should be initiated if the resistor is energized for more than 10 seconds.
Alternatively, a control logic modification could be implemented to produce the desired circuit operation.
Completed Evaluation / Analysis:
During normal operating condition on a diesel engine start, the field flashing relay is energized one second after an engine start signal, and de-energizes when the generator output voltage builds up to about 60 percent of rated voltage within 2 to 5 seconds.
The
. voltage relays VR1 and VR2 pickup and corresponding contact opens the field flashing circuit, thereby de-energizing the field flashing relay (FF).
Once the relay FF is de-energized, its contact opens and cuts off power to the field flashing resistor.
There is however a condition wherein the field flashing resistor will remain energized and may overheat.
This condition occurs when the generator output voltage does not build up to about 60 percent rated voltage within 2 to 5 seconds due to the following condition:
e Excitation system malfunction e
Generator field malfunction e
Generator fault (3-phase fault).
When 3 phase fault occurs, the diesel generator trips under any condition and cannot be started again unless the fault is cleared.
i s
2656t/49 1
e 9
The above conditions would result in a failure-to-start event requiring field flashing resistor system shutdown.
The potential failure is a secondary effect.
However, all diesel generator starts (other than emergency starts) will be -
monitored to assure that an unsuccessful start does not result in prolonged field flashing resistor energization.
3.5.2.11 Engine Wiring Owner's Group Recommendation:
SIM 361 (lE Nuclear Qualified cable) is applicable to Vogtle and needs to be implemented.
Completed Evaluation / Analysis:
SIM 361 will be implemented.
I 2656t/50
.,-,,-.-r.
b C
DGCYETED SNRC UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOA { AM -5 N0 :46 0FFICE OF SEcstin In the Matter of
)
00CXETING & SEPylef
)
BRANCH GEORGIA POWER COMPANY, --ET AL.
)
Docket Nos. 50-424d l-
)
50-425
)
(Vogtle Electric Generating
)
Plant, Units 1 and 2)
)
CERTIFICATE OF SERVICE This is to certify that copies of the foregoing APPLICANTS' MOTION FOR
SUMMARY
DISPOSITION OF CONTENTION 14, APPLICANTS' STATEMENT OF MATERIAL FACTS AS TO WHICH THERE IS NO GENUINE ISSUE TO BE HEARD ON CONTENTION 14, AFFIDAVIT OF JOHN C. KAMMEYER, AND A'FIDAVIT OF LARRY L.
- EPPLER, AFFIDAVIT OF STEVE A.
- PHILLIPS, E
were served this 1st day of August, 1985, by deposit in the United States Mail, postage prepaid, on the individuals listed on the attached Service List.
t OO _em h
w Rose Ann Sullivan
UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION Before the Atomic Safety and Licensing Board In the Matter of
)
)
GEORGIA POWER COMPANY, et al.
)
Docket Nos. 50-424
)30-425 (Vogtle Electric Generating Plant,
)
Units 1 and 2)
)
SERVICE LIST
- n B. Margulies, Chairman Douglas C. Teper Aic Safety and Licensing Board 1253 Lenox Circle U.S.
Nuclear Regulatory Commission Atlanta, GA 30306 Washington, D.C.
20555 Laurie Fowler Mr. Gustave A.
Linenberger, Jr.
Legal Environmental ArJistance Atomic Safety and Licensing Board Foundation U.S. Nuclear Regulatory Commission 218 Flora Avenue, N.E.
Washington, D.C.
20555 Atlanta, GA 30307 Dr. Oscar H.
Paris Tim Johnson Atomic Safety and Licensing Board Campaign for a Prosperous U.S. Nuclear Regulatory Commission Georgia Washington, D.C.
20555 175 Trinity Avenue, S.W.
Atlanta, GA 30303 Bernard M.
Bordenick, Esq.
Office of Executive Legal Director Docketing and Service Section U.S. Nuclear Regulatory Commission Office of the Cacretary Washington, D.C.
20555 U.S. Nuclear Regulatory Commission Atomic Safety and Licensing Washington, D.C.
20555 Board Panel U.S. Nuclear Regulatory Commission Bradley Jones, Esquire Washington, D.C.
20555 Regional Counsel U.S. Nuclear Regulatory Atomic Safety and Licensing Commission Appeal Beard Panel Suite 3100 U.S. Nuclear Regulatory Commission 101 Marietta Street Washington, D.C.
20555 Atlanta, GA 30303