ML20133C026
| ML20133C026 | |
| Person / Time | |
|---|---|
| Issue date: | 07/03/1985 |
| From: | Aidu K, Merschoff E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20133C013 | List: |
| References | |
| REF-QA-99900702 NUDOCS 8508060327 | |
| Download: ML20133C026 (7) | |
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ORGANIZATION: MORRISON-KNUDSEN COMPANY, INC.
ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION INSPECTION NO.: 99900702/85-01 DATE(S)-
R/14 16/R4 nN_RTTF unHDR-1M CORRESPONDENCE ADDRESS: Morrison-Knudsen Company, Inc.
ATTN: Mr. W. Frank Jones Vice President and General Manager Post Office Box 1928, 101 Gelo Road Rocky Mount, North Carolina 27802 ORGANIZATIONAL CONTACT: Mr. Harry W. Falter, Division Engineer TFl FPHONF NINRFR.
(410) Q77 979n PRINCIPAL PRODUCT: Emergency diesel driven power systems.
NUCLEAR INDUSTRY ACTIVITY: Currently the company is involved in providing modifications and maintenance services to diesel engines installed in nuclear power plants and developing training and service instructions for personnel in the nuclear power plants.
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I ASSIGNED INSPECTOR:
of -
K. R. Naidu, Reactive Inspection Section (RIS)
Date OTHER INSPECTOR (S):
E. L. Burns, Consultant 7!3!P3-~
APPROVED BY:
E. W. Merschoff/Ehief. RIS. Vendor Proaram Branch Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR 50 Appendix B.
B.
SCOPE:
Reviewed corrective action taken on previously identified items, reviewed the status of Part 21 reports.
PLANT SITE APPLICABILITY:
Browns Ferry 2/3, Davis Besse, Grand Gulf (HPCS) 1/2, St. Lucie 2. Sequoyah 1/2, Watts Bar 1/2, Susquehanna, Oconee, Three Mile Island, Trojan 1, Fitzpatrick, Rancho Seco.
8508060327 850 g K OOho f EEC p
ORGANIZATION: MORRISON-KNUDSEN COMPANY, INC.
ROCKY MOUNT, NORTH CAROLINA l
REPORT INSPECTION NO.-
99900702/85-01 RESULTS:
PAGE 2 of 7 A.
INSPECTION ISSUES:
The Power Systems Division of Morrison-Knudsen Company, Inc. (MKC) packages emergency electric power systems with diesel engines manufactured by other companies. Two 10 CFR Part 21 items were reported on the diesel engines procured by MKC related to a lube oil modification problem and an electrical generator failure.
B.
BACKGROUND INFORMATION:
The Power Systems Division of Morrison-Knudsen Company (MKC) is an-engineering company which packages emergency power systems. MKC purchased diesel engines manufactured by the Electromotive Division (EMD) of General Motors, and Cooper Bessemer Company. MKC used electrical generators manufactured by Electric Products, Beloit Power Systems (currently known as Louis-Allis), Westinghouse, Electric Machining Manufacturing and General Electric.
Excitation cubicles for the electrical generators were either supplied by the manufacturer of the electrical generator or by Basler Company. MKC has submitted bids for emergency power systems for Nuclear application with quotations from diesel engines manufactured by Motoren and Turbinen Union (Friedrichshafen, West Germany); Sulzer Brothers (Switzerland) and Grandimatori (Italy). MKC employes 100 persons at Rocky Mount. Currently, the company is involved in providing modifications and maintenance services to diesel engines installed in nuclear power plants and developing training and service instructions for personnel at nuclear power plants.
C.
FOLLOWUP DN PREVIOUSLY IDENTIFIED ITEMS:
1.
(Closed) Violation (83-01): This item related to the corrective action taken to resolve excessive engine room ambient temperature presumed to be the result of under-designed heating, ventilation and cooling (HVAC) equipment. MKC developed a generic procedure for licensees to test the installed engines.
It was realized that the ambient temperature is dependent on the velocity and quantity of air moved over the diesel engine and will vary with the size of the room and location of the HVAC ducts'. Tennessee Valley Authority (TVA) conducted tests at the Watts Bar Nuclear Power Plant based on the MKC procedure. The results at Watts Bar indicate that the revised heatload is conservative. The results of a test conducted at the I
Trojan Nuclear Power Plant indicates that the revised heatload was acceptable. Other nuclear plants notified of this problem by MKC have not yet responded with their results.
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ORGANIZATION: MORRISON-KNUDSEN COMPANY, INC.
ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION NO.-
44400702/85-01 RESULTS:
PAGE 3 of 7 '
2.
(Closed) Nonconformance 83-01: This item related to the omission of imposing the requirements of 10 CFR-Part 21 and 10 CFR 50 Appendix B on Purchase Order 50206-6036/379 for the supply of level indicators and adapters. As indicated in the MKC letter dated October 17, 1983, to the NRC, the applicable MKC procedure (PCP 201) was revised. The revised procedure requires the originator to impose the 10 CFR Part 21 and 10 CFR 50 Appendix B requirements on safety related items. The current Revision 5 of PCP 201 dated April 25, 1984, contains these requirements in paragraphs 6.1.8, 6.1.9 and 6.1.10.
The level indicators and the adapters referenced were not safety related.
3.
(Closed) Violation Item A 84-01: This violation identified that measures adopted by MKC did not provide for review, evaluation, and escalation into a Part 21 system for all deviations. MKC developed procedure EP-205 titled " Reporting of Defects and Noncompliance."
This procedure provides for review, evaluation and escalation.
Records indicate that all cognizant personnel were trained in the use of this procedure.
4.
(Closed) Violation Item B 84-01: The violation identified that MKC did not notify the NRC of the existence of a defect relative to the "A.C. Generator roller bearing" and the " Lube oil cooler leak" within the required time limit in section 21.21(b)(2) o,f 10 CFR Part 21.
The MKC Quality Assurance Instruction QAI 15-1 was revised and paragraph 6.3.2 states in part " Notification shall be made within 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br />.
If this notification is by means other than written communication, a written report shall be submitted to the appropriate office within five (5) days after the information is obtained."
5.
(Closed) Nonconformance Item 184-01: This item identified lack of source evaluation records on four companies.
Records were available to indicate that evaluations were performed on Starret on August 27, 1984; Anglo Repair Service on August 20, 1984; TRW-J.W. Williams Division on August 23, 1984; and Dresser Industries on September 29, 1984. The current MKC Approved Suppliers List reflects source evaluations.
1 6.
(Closed) Nonconformance Item 2 84-01:
This item identified inadequate implementation of procedure QCP-7 relative to the placement on and 1
maintenance of the MKC Approved Suppliers List (ASL). MKC developed j
QA Procedure QAP to control placement and on-going status of vendors j
listed on the ASL. Corborundum and Machine Welding Supply were_
deleted from the ASL.
Faster Supply and System Service Corporation were audited on March 30, 1984 and March 31, 1984, respectively.
F ORGANIZATION: MORRISON-KNUDSEN COMPANY, INC.
ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION NO.-
99900702/85-01 RESULTS:
PAGE 4 of 7 7.
(Closed) Nonconformance Item 3 84-01: This item related to failure to follow procedures to include Quality Levels (QL) on Purchase Requisitions (prs) and Purchase Orders (P0s) and failure of QA to review and approve P0s. As stated in MKC's response dated October 12, 1984, Change Orders were issued to prs and P0s to include the QLs.
8.
(Closed) Nonconformance Item 4 84-01: This item related to failure to follow procedures relative to certification of NDE personnel. All currently employed inspectors were administered the appropriate examinations, including visual acuity. The certifications were examined and determined to be acceptable.
9.
(Closed) Nonconformance Item 5 84-01: This item related to nonavail-ability of welder qualification records for several welders. The welder qualification records were examined and determined to be adequate. The records identified the welder, the Weld Procedure Specification (WPS) used and ihe month welded. The Level III inspector assures that the welders maintain their qualification by welding to each WPS within three months.
10.
(Closed) Noncompliance Item 6 84-01: This item identified that a procedure was not developed to perform heatload tests on an installed diesel generator. MKC developed a procedure dated May 5, 1982, to determine the heat rejected by an EMD Model 645E4 diesel engine manufactured by General Motors. This test has been completed at Watts Bar and Trojan Stations.
D.
INSPECTION FINDINGS AND OTHER COMMENTS:
1.
Processing of NRC Information Notices The Division Engineer distributes copies of NRC Information Notices (IN) to his staff alerting them of events reported relative to Diesel Engine problems experienced at nuclear plants so they can review these events for applicability to their machines.
Records indicate that NRC ins 85-08 (Corrosion Lining in Tanks), 85-27 (Defects Reporting),
and 85-25 (Consideration of Thermal Conditions in the Design and Installation of Supports for Diesel Generator Exhaust Silencers) were distributed to the engineering staff.
1 ORGANIZATION: MORRISON-KNUDSEN COMPANY, INC.
ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION NO.-
99900702/85-01 RESULTS:
PAGE 5 of 7 2.
Part 21 Report by Hub, Inc.
MKC evaluated a Part 21 report from Hub, Inc. to ascertain whether any SA-106 pipe manufactured by Phoenix Steel Corporation and supplied by Hub, Inc. was used in their installations. The Part 21 report stated that the SA-106 pipe may have a wall thickness problem due to the inspection method used by Phoenix. MKC determined that SA-106 pipe manufactured by Phoenix had not been used.
3.
Westinghouse AC Generator Failure (MKC Serial # 0023)
MKC reported on April 19, 1985 that an AC generator bearing seal,
failed during a test at the Napot Point Nuclear Plant (Napot) in the i
Phillipines. The electrical generator was manufactured by Westinghouse at their Round Rock plant located in Texas. Records indicate that Westinghouse manufactured only four of these AC generators of which two were supplied to Napot in the Phillipines and
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two to Kori Nuclear Power Plant in South Korea. During a routine full load surveillance test performed at Napot, the generator bearing experienced a problem. Subsequent investigation revealed that the oil thrower lockwasher had been omitted from the assembly which, in time, allowed the outboard oil thrower / slinger to back off the thread such that it contacted the bearing cap and the thread forced the two pieces together. Extreme heat developed due to friction and the bearing lube oil was lost because the slinger no longer performed the lubrication function.
Inspection revealed that the insulation had deteriorated and allowed the bearing to drop slightly causing contact with both inboard and outboard seals. MKC stated that prior to this incident, two generators were returned to Westinghouse Round Rock plant for slip ring replacement because the slip rings had rusted during storage. MKC stated that during the replacement of the slip rings, the oil thrower lockwasher was inadvertantly omitted during the reassembly. This failure is restricted to one of the two generators supplied to Napot. MKC notified the NRC that the Part 21 notification is being withdrawn because the failure is not reportable.
s.
ORGANIZATION: MORRISON-KNUDSEN COMPANY, INC.
ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION NG_*
99900702/RS-01 RESULTS:
PAGE 6 of 7 '
4.
Lube Oil Modification on 6 GPM Circulating System MKC (serial # 0020) reported a 10 CFR Part 21 relative to the low standby lube oil pressure alarm switch. MKC modified the lube oil systems in certain models of diesel engines manufactured by the Electro Motive Division (EMD) of General Motors. Specifically, the lube oil modification divides the standby lube oil flow into two channels.
Channel one consists of a motor driven pump that draws lube oil from the sump and pumps through a filter to the engine turbocharger. The other draws lube oil from the sump and pumps to the engine scavenging pump piping system. The latter furnishes lube oil to the piping between the lube oil scavenging pump discharge and the strainer mounted on the engine. The oil flow in this channel is monitored by a pressure switch located in the piping between the motor driven pump discharge and the 30 psi spring loaded relief check valve discharging into the piping system. The spring loaded check valve allows the pressure to be monitored since the pressure in the scavenging piping system is too low to unseat the check valve.
(The report did not apply to installations where a single motor driven pump is used to furnish the lube oil scavenging pump with oil.) The modification required the installation of a check valve on the discharge side of each pump to prevent one pump from pumping back i
through the other pump. The pressure alarm switch is attached to a section of piping which has a check valve at each end. These check valves will close when the pumps are off and will trap pressure between them, which, in effect defeats the function of the alarm switch. The control switches which start and stop the motor driven pumps are not located in this piping section. Therefore, the function of the motor driven pumps is not affected. Corrective action recommended was to drill a 1/16" diameter hole in the disc of the 30 psi spring loaded relief check valve to allow the pressure to bleed into the scavenging pump piping. MKC reviewed the applicability of 10 CFR Part 21 and determined that the oil pressure switch will indicate a high pressure condition, but will not cause the diesel engine to fail to start or fail to perform its safety function. The MKC evaluation is considered acceptable.
5.
High Capactty Turbo Charger Problems MKC (serial # 0021) informed the NRC of High Capacity Turbo Charger failures identified in diesel engines manufactured by Electro Motive Division (EMD) of General Motors. These failures were experienced in diesel engines used in freight locomotives.
EMD's preliminary evaluation is that this problem is confined to locomotive operation.
a-ORGANIZATION: MORRISON-KNUDSEN COMPANY, INC.
ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION NO.*
14400707/85-01 RESULTS:
PAGE 7 of 7 EMD has not forwarded to MKC a detailed report.
EMD recommended a precautionary inspection program for high capacity planetary gear trains of 17.9:1 ratio turbo chargers. EMD informed MKC that they found grinding notches in high capacity style sun gears at or below the optimum radius at the root of the gear tooth.
EMD contends that the gear tooth stress levels are altered as a function of gear tooth notch radius and unequal loading of the planet gears due to eccentricities of the gearshaft. To date no problems have been identified in standby emergency diesel generators. MKC is awaiting further information from EMD.
E.
The inspectors met with MKC personnel identified in paragraph F at the conclusion of the inspection and discussed the scope and results of the inspection.
F.
Morrison-Knudsen Company, Inc.
- H. W. Falter, Division Engineer
- M. Vann Mitchel, Manager Quality Assurance H. E. Loewe, Senior Quality Assurance Engineer D. S. Odom, Associate Engineer, Special Projects K. Lewis, Supervisor, Technical Services and Maintenance S. Cramton, Field Engineer
=_
- Denotes those individuals who attended the exit interview on 5/16/85.
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