ML20149D631

Forwards Engineering Summary Repts for 16 Tdi Phase I Diesel Generator Components,Containing Detailed Info on Design Review/Quality Revalidation Program.Vibration Problems W/Turbocharger Support Bracket Resolved

ML20149D631
Person / Time
Site:	Rancho Seco
Issue date:	01/04/1988
From:	Coward G SACRAMENTO MUNICIPAL UTILITY DISTRICT
To:	Miraglia F Office of Nuclear Reactor Regulation
References
AGM-TA-87-297, TAC-63030, NUDOCS 8801130066
Download: ML20149D631 (97)

Text

esuu.SACRAMENTO MUNICIPAL UTILITY DISTRICT C P. O. Box 15830, Sacramento CA 95852-1830,(916) 452 3211 AN ELECTRIC SYSTEM SERVING THE HEART OF cal.lFORNIA January 4, 1988 >

AGM/TA 87-297 U. S. Nuclear Regulatory Commission Attention: Frank J. Miraglia, Jr.

Associate Director for Projects Philips Building 7920 Norfolk Avenue Bethesda, MD 20014 DOCKET 50-312 RANCHO SECO NUCLEAR GENEP.ATING STATION UNIT #1 DR/QR INFORMATION ON TDI DIESEL GENERATORS

Dear Mr. Miraglia:

l The District's July 8,1987 letter (GCA 87-330) provided Engineering Sumary Reports for the sixteen Phase I diesel generator components. These reports '

contained detailed information on the Design Review / Quality Revalidation ,

(DR/QR) Program for the Rancho Seco TDI Diesel Generators. All of these Engineering Sumary Reports were final except for the turbocharger report.

This report had been marked "preliminary" due to vibration problems with the turbocharger support bracket. These problems have been resolved and the finai Engineering Sumary Report for the turbocharger is attached.

Engineering Sumary Reports have also been included for those components which have 10CFR Part 21 notifications or NRC IE Notices associated with them.

The attached Engineering Sumary Reports replace the corresponding reports in '

the District's June 12, 1985 submittal (RJR 85-260). Each sumary report addresses line item by line item each DR/QR issue. The sumary report also provides the District's resolution to concerns identified in NUREG 1216 and in 10CFR Part 21 notifications.

This submittal completes documentation of the actions for Phase I diesel generator components in NUREG-1216 for qualification of the Rancho Seco TDI Diesel Generators. This submittal also includes and completes the District's response to the remaining questions in the NRC's January 31, 1984 request for additional information.

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RANCHO SECO NUCLEAR GENERATING STATION O 14440 Twin Cities Road, Herald, CA 95638-9799;(2o9) 333 2935

)

Frank Miraglia, Jr January 4, 1988 Please contact me if you have any questions. Members of your staff requiring additional information or clarification may contact Mr. Jerry Delezenski at (209) 333-2935, extension 4919. ,

Sincerely, dM eorge Coward Assistant General Manager Technical and Administrative Services Attachments cc: A. D'Angelo, NRC, Rancho Seco G. Kalman, NRC, Bethesda (2)

J. B. Martin, Walnut Creek I

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NUC. REG

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Sheet 1. of 5 Attachment 1, pg. 1 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING SUtHARY REPORT Diesel Engine Serial Number 81015 Engine Train A part

Description:

TURBOCHARGER j part Number: MP-020

REFERENCES:

CIOR MC172-002 NDE Report Number: UST-PT-118-85 Associated Reports: NCRs S-4224, 4326, 4332, 6106, 6133; IMs QC-19-20-85, 19-19-85, 19-4-85, 19-3-84, 19-2-84, 19-1-84,86-009; FPR 7, 17, 32, 279; SFR 153-86 Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED

a. Perform visual inspection of the bearings and nozzle ring. Additionally the maintenance matrix specifies inspection of nozzle ring components (stationary ring and capscrews) after 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of run time or at first refueling outage,

b. Determine the end clearancos (rotor float). .

! c. Verify that the proper number of bolts on th'e ' turbine inlet easing are installed. .

! d. Verify that the proper torque loads are applied to the bolts of the turbine inlet casing, i

e. Perform LP test on stationary nozzle ring (on one engine only, unless results j are unsatisfactory). -

f. Verify that SIM 300 has been implemented and perform an LP test on welds. '

retaining the core (hub nut). Also verify that the co.'e plug is staked.

g. Verify that nozzle ring capscrews are properly torq0ed.

h. Verify adequacy of full flow pre-lube system by inspecting a' thrust bearing.

l This inspection should be performed on a thrust bearing during or after {

implementation of the full flow pre-lube system modification and following an  :

, initial 100 engine starts or at the closest plant refueling outage but not to exceed 130 starts. (Refer to subsection V for discussion of the modification). 1 Evaluated By: -&a - Date: /2 !MI/'7 1

Reviewed By: '77Requalification U Project Engineer Date: A9-/'i 32

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Sheet 2 of 5 Attachment 1, pg. 2 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT CONTINUATION Diesel Engine Serial Number 81015 -

Part No. MP-020 Engineering Evaluation and Recommendation (Continued):

II. ACCEPTANCE CRITERIA

~

a. Absence of excessive wear on the bearings. Nozzle ring components have no -

damage, mispositioned vanes, or missing nozzle ring capscrews.

b. Rotor float clearance criteria 0.008" - 0.020".

c. There should be 12 bolts installed in turbine inlet easing,

d. Torque tur!.ine inlet casing bolts.to 55-60 ft.-lbs.

e. Absence of adverse wear and relevant indications as defined in procedure No.

UST-PT-2.

f. Implementation of SIM 300; LP acceptance criteria - absence of adverse wear and relevant indications as defined in procedure No. QCI 101; Also, the hub nut shall be staked,

g. Torque nozzle ring capscrews to 18-22 ft.-lbs.

h. Absence of excessive wear.

III. INSPECTION FINDINGS

a. Following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing, both turbocharger bearings exhibited j excessive wear. Nozzle ring components (stationary ring and capscrews) were j all found satisfactory. '

l

b. Preservice inspection indicated rotor end float to be .005". Evaluation by the Elliott service representative indicated that although the clearance was not within specifications it was acceptable. Following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing, reinspection revealed a clearance of .0065". Re-evaluation by the Elliott factory indicated this time that the clearance dimension was unacceptable,

c. Turbine inlet casing bolts (piece #57 in vendot manual) were installed and 4 -- lockwired after reassemb.ly of the turbocharger. (Ref: Quality Surveillance Report, Form PSQ 221, dated 12/19/86) l l

1 l

Sheet 3 of 5 Attachment. 1, pg. 3 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT CONTINVATIgj Diesel Engine Serial Number 81015 Part No, MP-020 Engineering Evaluation and Recommendation (Continued):

d. Torque of turbine inlet casing bolts (piece #57) was verified upon reassembly of turbocharger. (Ref: Quality Surveillance Report, Form PSQ 221, dated 12/19/86)

e. LP examination of nozzle ring performed during preservice inspection _ revealed seven minor casting blemishes on the outer edge of nozzle ring hub. These were evaluated as acceptable. Following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> or startup testing, the nozzle ring was once again satisfactorily LP examined.

f. SIM 300 has been implemented. The as-found condition of the turbocharger revealed that a thick steel plate was welded in place in lieu of a hub nut. LP examination of the weld performed during preservice inspection revealed indications which were evaluated to be acceptable. The stsel plate was found welded all around its perimeter, firmly securing it to the nose piece (#51, in vendor manual).

g. Torquing and lockwiring of all eight capscrews (piece #62 in vendor manual) was verified. (Ref: Quality Surveillance Report, Form PSQ 221, dated 12/19/87)

h. Visual inspection of thrust bearings was performed following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing. Results are included with item a, above.

i. The following additional finding was reported by Q.C. during removal of the turbocharger:

o Turbocharger intake and exhaust transition bolting was found to be without any grade markings on the heads.

IV. CORRECTIVE ACTIONS  !

a. The bearing wear was attributed to high vibration of the turbocharger during startup testing. The turbocharger was sent to the Elliott factory for a '

complete checkout and rework as necessary. The following summarizes the l problems revealed during disassembly:

o Rotor was found to be out of balance - (determined at factory) o Both bearings exhibited excessive wear: Blower end bearing indicated smooth but excessive wear on thrust and journal surfaces. Turbine end bearing i revealed smooth but excessive wear pattern on journal surface only.

(determined at Rancho Seco)

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Sheet 4 of 5 Attachment 1, pg. 4 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part .No. 'iP-020 Engineering Evaluation and Recommendation (Continued):

c .Rotcr end float dimension too tight - (determined at Rancho Seco and confirmed at factory).

Corractive Actions taken were as follows:

1 o Rotor shaft was rebalanced.

o New bearings and new oil seals were installed.

o Intermediate casing was lightly machined at factory to achieve proper rotot clearance. Final "as-left" clearance measurements was .011".

o Additional supports were designed and installed to bring turbocharger vibration within acceptable levels. Subsequent vibration testing and turbocharger bearing inspections have demonstrated the adequacy of these supports.

b. Rotor end float - see Corrective Action under a, above.

c. None required.

d. None required,

e. None required,

f. None required.  ;

I

g. None required. l

h. Bearing inspection - see Corrective Action under a, above. i

i. Bolts were replaced with higher strengt;i material. .

V. MODIFICATIONS The TDI Owners Group has recommended modifications to the turbochargers and their operational procedures. The elements of these recommendations are:

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Sheet 5 of 5 Attachment 1, pg. 5 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. MP-020 Engineering Evaluation and Recommendation (Continued):

o The temperature of exhaust gas entering the turbine shall be monitored to ensure that it does not exceed 1200 degrees F. An acceptable method of determining this is to ensure that cylinder exhaust temperatures do not exceed 1050 degrees F. (Cylinder exhaust temperatures during pre-operational testing were below 1050 degrees F.)

o TOI's recommended bypass valve addition to the exi' sting drip system should be implemented to provide full flow to the turbocharger prior to non-emergency starts. Increased flow rates of the drip system up to 0.35 gph are also re' commended by the Owners Group. Rancho Seco implemented this modification prior to running the diesel generator. ,

o Once the ful, flow system is installed, operating orocedures should be revised to use the bypass valve. Rancho Seco has included steps and precautionary statement: in startup test procedures. Although the maintenance and surveillance p*ocedures for this equipment have not yet been issued, they will address the use ef the bypass valve for turbocharger bearing lubrication.

VI. ADDITIONAL CONCERNS The District was also made a.9re of similar concerns with this component from a 10CFR Part 21 notification on *.urbocharger bearing lubrication and NRC NUREG-1216.

The DR/QR inspections and the c)rrective actions described above have resolved the concerns of the 100FR Part i'l notification and those in NUREG-1216.

NRC NUREG-1216 has also indicates that spectrochemical and ferrographic oil analyses should be performed quarterly to provide evidence of bearing degradation.

Although the maintenance and surveillance procedures for this cauipment have not been issued, they will include the above analyses on at laast a quarterly basis.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Grotp in this OR/QR report, the inspection ~s made, corrective actions taken, and the actions taken to address the above additional concerns, the turbocharger is acceptable for its intended usr; at Rancho Seco.

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f Sheet 1 of 5 Attachment 1,pg. 6 of 90 RANCHO SECO DIESEL GC.NERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Die. sal Engina Serial Number 81016 Engine Train B Part

Description:

TURBOCHARGER Brt Number: MP-020

REFERENCES:

CIDR MC172-00?

fi6E Report Number: NONE Associated Reports: NCR S-6152; FPRs 23, 27, 29, 32, 279; SFR 137-86, 153-86 dngineering Evaluation and Recommendation:

1. ATTRIBUTES TO BE VERIFIED

a. Perform visual inspection of the bearings and nozzle ring. Additionally the maintenance matrix specifies inspectica of nozzle ring components (stationary ring and capscrews) after 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of run time or at first refueling outage.

b. Determine the end clearances (rotor float).

c. Verify that the proper number of bolts on the turbine inlet casing are installed.

d. Verify that the proper toro 2e loads are applied to the bolts of the turbine inlet casing.

e. Perform LP test on stationary nozzle ring (on one engine only, unless results are unsatisfactory).

Verify that SIM 300 has been implemented and perform an LP test on welds f.

retaining the core (hub nut). Also verify that the core plug is staked.

g. Verify that nozzle ring capscrews are properly torqued.

h. Verify adequacy of full flow pre-lube system by inspecting a thrust bearing.

This inspection should be performed on a thrust bearing during or after implementation of the full flow pre-lube system modification and fo', lowing an initial 100 engine starts or at the closest plant refueling outage but not to exceed 130 starts. (Refer to subsection V for discussion of the modificatien).

Evaluated By: c4w~ <. .c N Date: A f7 (j

l Reviewed By: Y b. . s ., I ' -

Datd: h /9 N l

/ Requalification Project. Engineer "

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Sheet 2 of 5 Attachment 1, pg.'7 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT CONTINUATION Diesel Engine Serial Number 81016 Part No. MP-020 Engineering Evaluation and Recommendation (Continued):

II. ACCEPTANCE CRITERIA

a. Absence of excessive wear on the bearir.gs. Nozzle ring components have no damage, mispositioned vanes, or missing' nozzle ring capscrews.

b. Rotor float clearance criteria 0.008" - 0.020".

c. There should be 12 bolts installed in turbine inlet ccting.

d. Torque turbine inlet casing bolts to 55-60 ft.-lbs.

e. Absence of adverse wear and relevant indications as defined in procedure No.

UST-PT-2.

l

f. Implementation of SIM 300; LP acceptance criteria - absence of adverse wear and l clevant indications as defined in procedure No. QCI 101; Also, the hub nut

$11 be staked. '

g. Torque nozzle ring capscr'ews to 18-22 f.t. Ibs.

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h. Absence of excessive wear.

III. INSPECTION FINDINGS

a. Following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing both turbocharger bearings exhibited excessive wear. Nozzle ring components (stationary ring and capscrews) were l all found to be satisfactory.

1

b. Rotor end float was measured to be .010" which is within specifications and therefore satisfactory.

c. Turbine inlet casing bolts (piece' #57 in vendor manual) were . installed and lockwired after reassembly of.the turbocharger. (Ref: Quality Surveillance Report, Fo.rm PSQ 221, dated 12/24/86) -

d. Torque of turbine inlet casing bolts (piece #57) was verified upon reassembly of turbocharger. (Ref: ~ Quality Surveillance Report, Form PSQ 221, dated 12/24/86)

Sheet 3 of 5 Attachment 1, pg. f of 9D RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No MP-020 Engineering Evaluation and Recommendation (Continued):

e. Following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing, the nozzle ring was LP examined with satisfactory results.

f. SIM 300 has been implemented. The as-found condition of the turbocharger revealed that a thick steel plate was welded in place in lieu of a hub nut. LP inspection of the weld revealed one rounded indication which'was evaluated to be acceptable. The steel plate was found welded all around its perimeter, firmly securing it to the nose piece (piece #51 in the vendor manual).

g. Torquing and lockwiring of all eight capscrews (piece no. 62 in the vendor manual) was verified. (Ref. Quality Surveillance Report, Form PSQ 221, dated 12/24/86)

h. Visual inspection of thrust bearings was performed following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of

, startup testing. Results are included with a, above.

IV. CORRECTIVE ACTIONS

. I

a. The bearing wear was attributed to high vibration experienced during startup '

testing, and foreign material within the turbocharger. The turbocharger was sent to Elliott factory for a complete checkout and rework as necessary. The follcwing summarizes the problems reveeled during disatsembly:

o Rotor was found to be out of balance - (determined at factory),

o Both bearings exhibited excessive wear: Blower end bearing revealed scoring.on thrust and journal surfaces. Also thrust collar had scoring:

The turbine-end bearing revealed scoring and pitting - (determined at Rancho Seco_and factory).

o Rotor shaft exhibited scoring at areas of bearing contact - (determined at Rancho Seco and factory),

o Oil seals revealed signs of wear.

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Sheet 4 of 5 Attachment 1, pg. 9 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATI0t{_

Diesel Engine 3erial Number 81016 Part No. MP-020 Engineering Evaluation and Recommendation (Continued):

Corrective Actions taken were as follows:

o New rotor shaft was installed and rotor assembly was balanced.

o New bearings, thrust collar, and oil seals were installed to replace damaged parts. Also as a precaution, eight new nozzle ring capscrews were installed.

o Additional supports were designed and installed to bring turbocharger vibration within acceptable levels. Subsequent vibration testing and turbocharger bearing inspections have demonstrated the adequacy of these supports,

b. None required.

c. None required.

d. None required.

e. None required.

f. None' required.

g. None required. ,

I

h. Visual inspection of thrust bearings was performed following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing. Results are included with a, above.

V. MODIFICATIONS .

The TDI Owners Group has recommended modifications to the turbochargers and their operational procedures. The elements of these recommendations are:

o The temperature of exhaust gas entering the turbine shall be monitored to ensure that it does not exceed 1200 degrees F. An acceptable method of determining this is to ensure that cylinder exhaust temperatures do not exceed 1050 degrees F. (Cylinder exhaust temperatures during pre-operational testing ,

were below 1050 degrees F.) I l

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Sheet 5 of 5 Attachment 1, pg. 10 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT CONTINUATION Diesel Engine Serial Number 81016 Part No. MP-020 Engineering Evaluation and Recommendation (Continued):

o TDI's recommended bypass valve addition to the existing drip system should be implemented to provide full flow to the turbocharger prior to non-emergency starts. Increased flow rates of the drip system up'to 0.35 gph are also recommended b~y the Owners Group. Rancho Seco implemented this modification prior to running the diesel generator.

o Once the full flow system is installed, operating procedures should be revised to use the bypass valve. Rancho Seco has included steps and precautionary statements in startup test procedures. Although the maintenance and surveillance procedures for this equipment have not yet been issued, they will address the use of the bypass valve for turbocharger bearing lubrication.

VI. ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component from a 10CFR Part 21 notification on turbocharger bearing lubrication and NRC NUREG-1216.

The OR/QR inspections and the corrective actions described above have resolved the concerns of the 10CFR Part 21 notification and those in NUREG-1216.

NRC NUREG-1216 has also indicated that spectrochemical and ferrographic oil analyses should be performed quarterly to provide evidence of bearing degradation.

Although the maintenance and surveillance procedures for this equipment have act been issued, they will include the above analyses on at least a quarterly basis.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the inspections made, corrective actions taken, and the actions taken to address the above additional concerns, the turbocharger is acceptable for.its intendest use at Rancho Seco.

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Sheet 1 of 2 Attachment 1, pg.'ll of 90 '1 RANCHO SECO DIESEL GENERATOR RE0UALIFICATION ENGINEERING

SUMMARY

REPORT l

Diesel-Engine Serial Number 81015 Engine Train A Part~0escription: VALVE SPRINGS & RETAINERS Part Number: 03-3600 I

REFERENCES:

CIOR MC172-042 NDE Report Number: NONE Associated Raports: IM-QC-16-7-84 Engineering Evaluation and Recommendation:

I. ATTRIBuidS TO BE VERIFIED Valve spring color code.

• II. ACCEPTANCE CRITERIA Absence of grey springs with brown stripe.

III. INSPECTION FINDINGS All sorings had white stripe.

IV. CORRECTIVE ACTIONS Nc.ie required.

V. MODIFICATIONS None required.

l N Date: M # F7 Evaluated By c &* W Reviewed By: h 7 M w .'.w.h Date: M / 9-F 2

/ Requalification Project Engineer l i

Sheet 2 of 2 Attachment 1, pg. 12 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION.

ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Part No. 03-360D Engineering Evaluation and Recommendation (Continued):

VI. ADDITIONAL CONCERNS The District was also made aware of similar concerns from 10CFR Part 21 Notifications of July 13, 1984 and of November 6, 1985. The DR/QR inspections above revealed that the springs had a white stripe indicating they were manufactured by Betts Spring Company. These springs are the subject of the 10CFR Part 21 Notifications above in that there is a possibility that they may be improperly shot penned. IMO Delaval recommends changing all Setts valve springs to ensure their maximum possible integrity. The District will replace these springs prior to the end of the next refueling outage. The currently installed springs are suitable until that time because of the isolated incidence of failure of springs by this manufacturer plus the fact that the District has logged in excess of 300 hours0.00347 days <br />0.0833 hours <br />4.960317e-4 weeks <br />1.1415e-4 months <br /> of run time on each engine with n'o failure to date.

VII. RESULT 5_AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Group in this DR/QR report, the inspections performed, and the actions taken to address the above additional concerns, the valve springs and retainers are acceptable for their intended use at Rancho Seco.

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Sheet 1 of.2

-Attachment 1, pg. 13 of 90 RANCHO SECO DIESEL GENERATO: REQUALIFICATION  :

ENGINEERING

SUMMARY

REPORT 1

Diesel Engine Serial Number 81016 Engine Train B -

Part

Description:

VALVE SPRINGS & RETAINERS '

Part Number: 03-3600

REFERENCES:

CIDR MC172-042 NDE Repo'rt Number: NONE Associated Reports: IM-QC-16-7-84 Engineering Evaluation and Recommendation-l I. ATTRIBUTES TO BE VERIFIED Valve spring color code. l l

II. ACCEPTANCE CRITERIA

~

Absence of grey springs with brown stripe.

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i III. INSPECTION FINDINGS ,

j All springs had white stripe. )

- 1 IV. CORRECTIVE ACTIONS None required.

V. MODIFICATIONS None required. l 1

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Evaluated By: d-

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d' Date: ///Mh 7 Reviewid'By:

YY ....b '

Requalification Project Engineer Date: /J /b5 7 (s

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Sheet 2 of 2 Attachment 1, pg'. 14 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT l

Oiesel Engine Serial Number 81016 Part No. 03-3600 Engineering Evaluation and Recommendation (Continued):

VI. ADDITIONAL CONCERNS ,

1 The District was also made aware of similar concerns from 10CFR Part 21 Notifications of July 13, 1984 and of November 6, 1985. The OR/QR inspections-above revealed that the springs had a white stripe indicating they were manufactured by Betts Spring Company. These springs are the subject of the 10CFR Part 21 Notifications above in that there-is a possibility that they may be  ;

improperly shot penned. IMO Delaval recommends changing all Betts valve springs to '

ensure their maximum possible integrity. The District will replace these springs ,

prior to the end of the next refueling outage. The currently installed springs are i suitable until that time because of the isolated incidence of fai'ure of springs by i this manufacturer plus the fact that the District has logged in ex ess of 300 hours0.00347 days <br />0.0833 hours <br />4.960317e-4 weeks <br />1.1415e-4 months <br /> I of run time on e'ach engine with no failure to date. l.

l VII. RESULTS AND CONCLUSIONS , l

)

Based upon the evaluation made by the TDI Owners Group in this DR/QR r'e' port, the inspections performed, and the actions taken to address the above additional concerns,.the valve springs and retainers are acceptable for their intended use at l Rancho Seco.

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Sheet 1_ of 2 Attachment 1, pg. 15 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT' Diesel Engine Serial Number 81015 Engine Train A Part

Description:

FUEL INJECTION PUMP Part Number: 03-365A

REFERENCES:

CIDR MC172-107, MC172-210; TDI SIM-345 -

NDE Report Number: NONE Associated Reports: NCR S-6001, NCR S-6145; IM QC-16-85, QC-17-12-84 Engineering Evaluation and Recorxnendation:

1. ATTRIBUTES TO BE VERIFIED' Quality revalidation is not required. l II. ACCEPTANCE CRITERIA None required.

1 III. INSPECTION FINDINGS Not applicable.

1 IV. CORRECTIVE ACTIONS 1

None required. I V. MODIFICATIONS In response to a product improvement rec)mmendation from TDI, Rancho Seco has replaced the orifice and fitting in each fuel oil pump bypass return line to ensure l that the orifice can not work i ose and enter the pump body.

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Evaluated By:

U Lt,t v ~ . > Date: /2-[d/f2 Reviewed By: b h /d.,bd Oate: A b/9-4 7

/. Requalification Project Engineer I

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Sheet 2 of 2 Attachment 1, pg. 16 of 90 ,

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT Diesel-Engine Serial Number 81015 Part No. 03-365A Engineering Evaluation and Recommendation (Continued):

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from a 10CFR Part 21 notification on a defect in the bore of the fuel injection pump delivery valve holder. The District performed a boroscopic inspection on each pump's delivery valve holder, including spares, and found a notch in the pump for the #3 cylinder. The defective pumps were returned to manufacturer and replaced with spares.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the modifications implemented, and the actions taken to address the above additional concerns, the fuel injection pumps are acceptable for their intended use at Rancho Seco, i

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Sheet 1 of 2 Attachment 1, pg. 17 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORJ Diesel Engine Serial Number 81016 Engine Train 8 part

Description:

FUEL INJECTION PUMP Part Number: 03-365A

REFERENCES:

CIDR MC172-107, MC172-210; TDI SIM-345 NDE Report Number: NONE Associated Reports: NCR S-6001, NCR S-6145, NCR S-6050 Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Quali.ty revalidation is not required.

II. ACCEPTANCE CRITERIA, None required.

III. INSPECTION FINDINGS Not applicable.

IV. CORRECTIVE ACTIONS None required. .

V. MODIFICATIONS In response to a product improvement recommendation from TDI, Rancho Seco has replaced the orifice and fitting in each fuel oil pump bypass return line to ensure that the orifice can not work loose and enter the pump body.

Evaluated By: ) h>, -  % .Jate : / &

h '

i Reviewed By: h -

Date: /-)-/ 9 -D

/ Requalification Project Engineer

n. ? -

.=_. - - . .. . - . . .

Sheet 2 of 2 Attachment 1, pg. 18 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Part No. 03-365A Engineering Evaluation and Recommendation continued):

VI. ADDITIONAL CONCERNS The District was slso made aware cf other concerns with this component from a 10CFR Part 21 notification on a defect in the bore of the fuel injection pump delivery valve holder. The District performed a boroscopic inspection on each pump's delivery valve holder, including spares, and found a notch in the pump for the #3 cylinder. The defective pumps were returned to manufacturer and replaced with-spares.

Vll. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the modifications implemented, and the actions taken to address the above additional concerns, the fuel injection pumps are acceptable for their intended use at Rancho seco.,

9 4

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' Sheet i of 2 Attachment 1, pg. 19 of 9'O RANCHO SECO DIESEL,.GENERATvR RE00ALIFICATION E_N_GINEERING

SUMMARY

REPORT Oissel Engine Serial Number 81015 Engine Train A Part

Description:

FUEL PUMP LINKAGE - CONTROL SHAFT, LINKAGE ASSY, & BEARINGS Part Number: 03-371A/B

REFERENCES:

C. J MC172-045, CIDR MC172-046, CIDR MC172-061 NLE Report Numbei. NONE '

Associated Reports: NCR S-4221; IM QC-15-23-85, QC-16-3-84 Engineering Evaluation pnd Recomendation:

ATTRIBUTES TO BE VERIF?ED

a. Hardness of the shaft (one engina only).

b. Visual inspection of linkage and bearings to evaluate freedom of movement.

II. ACCEPTANCE CRITERIA

-a. Hardness to be 190-230 Brinnell.  !

b. All linkage moves freely and the bearings show evidence of lubrication. i III. INSPECTION FINDINGS  !

a. Hardness was found to be acceptable. .

b. The linkage"and bearings are acceptable. l

'1 I

IV. CORRRECTIVE ACTIONS I l

None required.  !

l V. MODIFICATIONS None required.

Evaluated By: a_g -

, i.e Date. ' /& /P7 f/

L./

/

h eb d Reviewed By: - Date:, # / D d N ' ,. --

- -r-

/ Requalification Project Engineer,,,' ,

y .. : r. " '* " J ,

l Sheet 2 of 2 I Attachment 1, pg. 20 of 90 l I

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT l

CONTINUATION l Diesel Engine Serial '! amber 81015 Part No. 03-371A/B Engineering Evaluation and Recommendation (Continued):

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from a 10CFR Part 21 notification dated 10-2-84 where the fuel pump linkage levers could rotate about the shaf t if not properly torauad and pinned. The District found that the fuel levers had not been pinned, so the needed holes were drilled and pins were lockwired in place. Furthermore, the District torqued the lever capscrews to 12 ft.-lbs. These actions have resolved this concern.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the inspections made and the actions taken to address the above additional concerns, the fuel pump control shaft, linkage and bearings are acceptable for their intended use at Rancho Seco.

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Sheet 1_ of 2 Attachment 1, pg. 21 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT r

Diesel Engine Serial Number 81016 Engine Train B Part

Description:

FUEL PUMP LI'NKAGE - CONTROL SHAFT, LINKAGE ASSY, & BEARINGS Part Number:

03-371A/B E

RE_FERENCES: CIDR MC172-045, CIDR MC172-046, CIDR MC172-061 ,

NDE Report Number: NONE Associated Reports: NCR S-4220; IM QC-15-23-85, QC-15-3-84 Enoir.eering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED

a. Hardness of the shaft (one engine only).

b. V',sual inspection of linkage and bearings to evaluate freedom of movement.

II. ACCEPTANCE CRITERIA ,

a. Hardness to be 190-230 Brinnell.

b. All linkage moves freely and the bearings show evidence of lubrication.

III. INSPECTION FINDINGS

a. Engine "A" tested.

b. The linkage and beari.ngs are acceptable.

IV. CORRRECTIVE ACTIONS None required.

V. MODIFICATIONS None required. -

Evaluated By L+ a . .- _

Date: / 7 7

[/ ,

/

Reviewed By: /hRequalification ~I Date: M -/ '}-D

/ Project Engineer

, n,

l l

i Sheet 2 of 2 '

Attachment 1, pg. 22 of 90 l

. RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT ,

l CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-371A/B Engineering Evaluation and Recommendation (Continued):

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from a 10CFR Part 21 notification dated 10-2-84 where the fuel pump linkage levers could rotate .

about the shaft if not properly torqued and pinned. The District found that the I fuel levers had not been pinned, so the needed holes were drilled and pins were

. lockwired in place. Furthermore, the District torqued the lever capscrews to 12 ft.-lbs. These actions have resolved this concern.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the inspections made and the actions taken to address the above additional concerns the fuel pump control shaft, linkage and bearings are acceptable for their intended use at Rancho Seco.

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Sheet .1_ of 2 Attachment 1, pg. 23 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015_

Engine Train A Part

Description:

GOVERNOR DRIVE COUPLINGS, PINS & KEYS Part Number: 03-402B

REFERENCES:

CIDR MC172-057 NDE Report Number: NONE Associated Reports: NCR S-6140 Engineering Evaluation and Recommendation:

L ATTRIBUTES TO BE VERIFIED

a. Documentation of coupling elastomeric insert (spider) material.

b. Set screw and drive pin installation.

II. ACCEPTANCE CRITERIA

a. Neoprene,

b. Set screws have loctite and one spot stake. Drive pins are installed and appear tight.

III. INSPECTION FINDINGS

a. Material was labeled neoprene. ,

l

b. The setscrews were not installed with loctite and were not staked.

1 IV. CORRECTIVE ACTIONS l

a. None required.

b. The District reinstalled the setscrews with loctite and spot staked them to maintain their tightness.

Evalaated By: h# <. A Date: /2[/f!17 i Reviewed By:

oh_ Y_. b h Date: M-/ 7-U

/ Requalification Project Engineer

Sheet 2 of 2 Attachment.1, pg. 24 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-402B Engineering Evaluation and Recommendation (Continued):

V. MODIFICATIONS None, however this DR/QR required replacement of the neoprene elastomeric insert prior to placing the engines in emergency standby service. Although revision 2 to the maintenance matrix has deleted this requirement, the District has replaced the insert to ensure its maximum available life.

VI. ADDITIONAL CONCERNS The District was also made aware of similar concerns ~with this component from a 10CFR Part 21 notification which identified a material problem with the elastomeric insert (spider) of the governor coupling. The DR/QR inspections above have resolved this concern. .

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this OR/QR report, the inspections made, and corrective actions taken, the governor drive couplings, pins and keys are acceptable for their intended use at Rancho Seco'. ,

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Sheet 1 of 2 Attachment 1, pg. 25 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT

- Diesel Engine Serial Number 81016 Engine Train B Part

Description:

GOVERNOR DRIVE COUPLINGS, PINS & KEYS ,

Part Number: 03-402B

REFERENCES:

CIDR MC172-057 NDE Report Number: NONE Associated Reports: NCR/IM NONE ,

Engineering Evaluation and Recommendation:

1. ATTRIBUTES TO BE VERIFIED

a. Documentation of coup 1,ing elastomeric in' sert (spider) material,

b. Set screw and drive pin installation.

II. ACCEPTANCE CRITERIA

a. Neoprene.

4

b. Set screws have loctite and one spot stake. Drive pins'are installed and appear tight.

III. INSPECTION FINDINGS *

a. Material was labeled neoprene.

b. The coupling tightness was satisfactory. .

IV. CORRECTIVE ACTIONS i

None required.

Evaluated By:

• g., ., w s Date: /2/eJ[F 7 u

Reviewed By: Y d. . ~. b ~

Date: /J / *> 'T >

/ Requalification Project Engineer

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2 Sheet 2 of 2 Attachment 1, pg. 26 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION .

1 ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Dart No. 03-402B Engineering Evaluation and Recommendation (Continued):

1 V. MODIFICATIONS None, however this DR/QR required replacement of the neoprene elastomeric insert prior to placing the engines in emergency standby service. Although revision 2 to the maintenance matrix has deleted this requirement, the District has replaced the insert to ensure its maximum available life. ,

1 l

VI. ADDITIONAL CONCERNS '

The District was also made aware of similar concerns with this component from a l 10CFR Part 21 notification which identified a material problem with the elastomeric insert (spider) of the governor coupling. The DR/QR inspections above have resolved this concern. ,

l VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report and

~

the inspections made, the governor drive couplings, pins and* keys are acceptable ,

fer their ir. tended use at Rancho Seco.  ;

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Sheet 1 of 2 Attachment 1, p8 27 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

OVERSPEED TRIP COUPLING Part Number: 03-4100

REFERENCES:

CIDR MC172-060; CIDR MC172-204 NDE Report Number: NONE Associated Recor'ts: NCRs S-6149, S-6155; FPRs 18, 21, 22, 44 Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Visual inspection of coupling.

II. ACCEP"ANCE CRITERIA Absence of wear, deterioration, and other discontinuities.  ;

III. INSPECTION FINDINGS Two minor go'uges were found on one coupling half (attached to the accessory drive gear shaft).

IV. CORRECTIVE ACTIONS The gouges were smoothed by light hand polishing since the elastomeric insert .

(spider) was found in excellent condition. However, the District also replaced the elastomeric insert to ensure the maximum available life for the spider insert.

Furthermore, the other coupling halves were replaced as a result of damage to them during the performance of other OR/QR inspections.

• 4 Evaluated By: h .w -

Date: / J/9 2 U .

. N Reviewed By: h bE Date: M -/ 9- O Requalification Project Engirieer

/

_ . _ _ . _ - ~ . _ - - - - - - _ ___ _ _ .

Sheet 2 of 2 Attachment 1, pg. 28 of 90 Rancho Seco Diesel Generator Requalification Engineering Summary Reoort Continuation Diesel Engine Serial Number 81015 Part No. 03-410C Engineering Evaluation and Recommendation (Continued):

V. MODIFICATIONS None required.

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this compon'ent from a 10CFR Part 21 notification, which indicated that due to coupling looseness the fuel transfer pump may stop turning and render the engine inoperable. The recommended corrective action was to perform TDI SIM-363. During the implementation of this SIM the District observed that the coupling setscrews were missing. It was determined that they had never been put in, so setscrews were installed per the guidance in SIM-363.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owne'rs Group in this DR/QR report the inspections made, the corrective actions taken, and the actions taken to address the above additional concerns, the overspeed trip coupling is acceptable for its intended use at Rancho Seco.

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Sheet ,1,of 2_

Attachment 1, pg. 29 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING SUf91ARY REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

OVERSPEED TRIP COUPLING Part Number: 03-410C

REFERENCES:

CIOR MC172-60; CIDR MC172-204 NDE Report Number: NONE Associated Reports: NCR S-6228; FPR 50 Engineering Evaluation and Recommendation:

1. ATTRIBUTES TO BE VERIFIED Visual inspection of coupling.

l II. ACCEPTANCE CRITERIA 1

Absence of wear, deterioration, and other discontinuities.

III. 1NSPECTION FINDINGS l

The coupling was satisfactory.

IV. CORRECTIVE ACTIONS None required. However, although the elastomer 4c insert (spider) was found in excellent condition, the District replaced it to ensure th,e maximum available life  !

for the spider insert.

V. MODIFICATIONS ,

i Nonc required.

Evaluated By: - c <-, ' -

Date: / J 7 f

v/ /

Reviewed By: hh Requalification Project Engineer Date: M '/4- D

/

. _ _ . _ . . _ ,,.._, . , .i

Sheet 2 of 2 Attachment 1, P8 30 of 90 Rancho Seco Ciesel Generator Requalification Engineering Summary Report Continuation Diesel Engine Serial Number 81016 Part No. 03-410C Engineering Evaluation and Recommendation (Continued): '

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from a 10CFR Part 21 notification, which indicated that due to the coupling looseness the fuel transfer pump may stop turning and render the engine inoperable. The recommended corrective action was to perform TDI SIM-363. During the implementation of this SIM the District observed that the separation between the coupling hub faces was 3/32. inches greater than the specified 7/8 inches, and that the total indicated runout (TIR) for angular alignment of the coupling was .0015 inches greater than the specified .006 inches. These conditions were evaluated by TOI and accepted as is because of the excellent condition of the elastomeric insert 'after more than 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of pre-operational testing, Nevertheless, the District will replace the coupling hub faces with new parts to obtain the correct component separation measurements. j i

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the  ;

inspections made, the corrective actions taken, and the actions taken to address ,

the above additional concerns, the overspeed trip coupling is acceptable for its  !

intended use at Rancho Seco. j 1

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Sheet 1 of 1 Attachment 1, pg. 31 of 90 RANCHO SECO DIESEL GENERATOR REQUAl.IFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A_

Part

Description:

GOVERNOR LINKAGE Part Number: 03-413

REFERENCES:

CIDR MC172-061 NDE Report Number: NONE Associated Reports: IM QC-19-34-85, M-024-86 Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Visual inspection of linkage assembly for signs of corrosion or wear.

II. ACCEPTANCE CRITERIA Lack of pitting and discoloration.

^

III. INSPECTION. FINDINGS The linkage assembly is acceptable. '

IV. CORRECTIVE ACTIONS None required. "

I

^ ' '

V. MODIFICATIONS Nona required, although the TDI Owners Group recommended the addition of lockwire ,

to the linkage bolts and roll pins as a maintenance item. The District has '

implemented this recommendation as described in the engineering summary for part no. 03-371A/B.

~

\

VI. ADDITIONAL CONCERNS l

The District was also made aware of similar concerns with this component from a 10CFR Part 21 notification dated 10/2/84. These concerns and the District's response to them are addressed in the engineering summary for part no. 03-371A/B.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Group in this OR/QR report, the governor linkage s suitable for its intended use at Rancho Seco.

Evaluated By: _

w.u e '------ ' Da'te : /2 th7 i Reviewed By: 7 D~  : Date: /J -/ 9-F ?

/ Requalification Project Engineer I

t. J

Attachment 1, 3h k b R_ANCHO SECO DIEstL GENERATOR REQUALIFICATION ENGINF.ERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

GOVERNOR LINKAGE Part Number: 03-413

REFERENCES:

CIDR MC172-061 NDE Reoort Number: NONE Associated Reports: IM QC-19-34-85, M-024-86 Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Visual inspection of linkage assembly for signs of corrosion or wear.

II. ACCEPTANCE CRITERIA Lack of pitting and discoloration.

III. INSPECTION FINDIN_GS_

The linkage assembly is acceptable.

IV. CORRECTIVE ACTIONS None required.

V. MODIFICATIONS None required, although the TDI Owners Group recommended the adaiti1n of lockwire to the linkage bolts and roll pins as a mTintenance item. The Dist ict has irtplemented this recommendation as described in the enginea ing sumary for part no. 03-371A/B.

VI. ADDITIONAL' CONCERNS The District was also made aware of simi lar concerns with this component from a 10CFR Part 21 notification dated 10/2/84. These concerns and the District's response to the:n are addressed in the engineering summary for part no. 03-371A/B.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Ow.wrs Group in this OR/QR report, the governor linkage is suitable for its intended use at Rancho Seco. 1 Evaluated By- <m 4.I Date: /2[s[g 7 Reviewed By: 0 7 O,.u M Date: /u ' 0 4 7'

/ Requalification Project Engineer ,' '

Sheet 1 of 2_

Attachment 1, pg. 33 of 90 RANCHO SECO DIESEL GENERATOR REQUALITICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015_

Engine Train A Part Descriotion: GOVERNOR ASSEMBLY: WOODWARD GOVERNOR Part Number: 03-415A I

REFERENCES:

NO CIDR NDE Report Number: NONE Associated Reports: NCR/IM NONE

~

I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

II ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS Not applicable.

IV. ' CORRECTIVE ACTIONS None required.

l V. MODIFICATIONS None required.

Evaluated By: 7 d e u - '- k Date: /3dr 7

'V Y Ab--- I'

P$viewedBy:

'Date: /J -/ 9 - 2 7

/ Requalification Project Engineer- j l

l

Sheet 2 of 2 Attachment 1, pg. 34 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Ergine Serial Number 81015 Part No. 03-415A Engineering Evaluation and Recommendation (' Continued):

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from a 10CFR Part 21 notification, and an IE Information Notice. The 10CFR Part 21 notification, dated August 10, 1983, informed the U. S. Nuclear Regulatory Commission that the governor had been assembled incorrectly at the factory. The governor was rebuilt correctly by the manufacturer, prior to preoperational testing. IE Information Notice No. 86-07 stated that an inadequate inventory of oil in the governor following preventive maintenance activities had allowed an engine to overspeed. The TDI Instruction Manual, Volume I, Section 6, has been revised to provide detailed procedures to vent air from a newly filled governing system, thereby ensuring that the qua.itity of oil in the governor is correct.

These revised procedures were followed during the preoperational testing. Al though the maintenance and surveillance procedures for this equipment have not yet been issued, they will address the proper venting technique.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Group in this DR/QR report and the actions taken to address the above additional concerns, the Woodward governor is acceptable for its intended use at Rancho Seco.

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Sheet 1 of 2 Attachment 1, p3, 35 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

GOVERNOR ASSEMBLY: WOODWra0 GOVERNOR vart Number: 03-415A

REFERENCES:

NO CIOR NDE Report Number: NONE Associated Reoorts: NCR/IM NONE I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

II. ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS Not applicable.

IV. CORRECTIVE ACTIONS None required, V. MODIFICATIONS None required.

l l

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t Evaluated By: und - -

Date: / / 2 y

, /

Reviewed By: '

3 ,d Date: /J -/ ? -77

/ Requalification Project Engineer

Sheet 2 of 2 Attachment 1, pg. 36 or 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGIFEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-415A Engineering Evaluation and Recommendation (Continued):

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from a 10CFR Part 21 notification, and an IE Information Notice. The 10CFR Part 21 notification, dated August 10, 1983, informed the U. S. Nuclear Regulatory Commission that the governor had been assembled incorrectly at the fac' tory. The governor was rebuilt correctly by the manufacturer, prior to preoperational testing. IE Information Notice No. 86-07 stated that an inadequate inventory of oil in the governor following preventive maintenance activities had allowed an engine to overspeed. The TOI Instruction Manual, Volume I, Section 6, has been revised to provide detailed procedures to vent air from a newly filled governing system, thereby ensuring that the quantity of oil in the governor is correct. -

These revised procedures were followea during the preoperational testing. Although the maintenance and surveillance procedures for this equipment have not been issued, they will address the proper venting technique.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Group in this DR/QR report and the actions taken to address the above additional concerns, the Woodward governor is  ;

acceptable for its ' intended use at Rancho Seco. 1 1

l l

E.2et 1 of 1_

Attachment 1, pg. 37 o f 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

GOVERNOR ASSEMBLY HEAT EXCHANGER Part Number: 03-415C

REFERENCES:

CIDR MC172-111 NDE Report Number: NONE Associated Reports: NCR/IM NONE I. ATTRIBUTES TO BE VERIFIED Visually inspect the governor cooler mounting configuration.

II. ACCEPTANCE CRITERIA Cooler is mounted below the governor oil level.

III. INSPECTION FINDINGS

~

The cooler location is acceptable.

IV. CORRECTIVE ACTIONS None required.

V. MODIFICATIONS None required.

VI. ADDITIONAL CONCERNS The District was also made aware of sim lar concerns with this component from a 10CFR Part 21 notification on cooler elevation. The DR/QR inspections described ,

above have resolved this concern. l l

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report and l the inspections made, the governor assembly heat exchanger is acceptable for its I intended use at Rancho Seco. l

_ Eva.l uated By: dm -

- Date: / 2[r/h 7 Reviewed By: h/ Requalification 7 did Project Engineer ,

Date: / /T ? ?

Sheet 1 of 1 Attachment 1, pg. 38 of 90 RANCHO SECO DIESEL GENERATOR REQuiLIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

GOVERN 0R ASSEMBLY HEAT EXCHANGER Part Number: 03-415C

REFERENCES:

CIDR MC172-111 NDE Report Number: NONE '

Associated _ Reports: NCR/IM NONE I. ATTRIBUTES TO BE VERIFIED Visually inspect the governor cooler mounting configuration.

II. ACCEPTANCE CRITERIA Cooler is mounted below the governor oil level.

III. INSPECTION FINDINGS The cooler location is acceptable.

IV. CORRECTIVE ACTIONS None required.

V. MODIFICATIONS None required.

VI. ADDITIONAL CONCERNS The District was also made aware of rinilar cancerns with this component from a 10CFR Part 21 notification on cooler elevation. The DR/QR inspections described above have resolved this concern.

VII. RESULTS AND CONCLUS'03 Based upon the evaluation made by the TOI Owners Group in this DR/QR report and the inspections made, the governor assembly heat exchanger is acceptable for its intended use at Rancho Seco

)

Evaluated By: hw se -

Date': / /d/f7 l Reviewed By: Q7 Date: A -/ 9 -FP

/ Requalification Project Engineer

/ -Sheet 1 of 1 ..

. . Attachment 1, page 39 of 90 l RANCHO SECO OTESEL GENERATOR REQUALIFICATION  ;

l ENGINEERING

SUMMARY

REPORT Diesel Engine Se ial Number 81015 Engine Train A Part

Description:

ENGINE ORIVEN FUEL OIL B0OSTER PUMP ~ l part Number: 03-445

REFERENCES:

NO CIOR NDE Report Number: NONE Associated Reports: NCR/IM NONE Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Qualify revalidation is not required.

II. ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS Not applicable IV. CORRECTIVE ACTIONS None required.

V. MODIFICATIONS None required.

VI. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this 'OR/QR report, this component is acceptable for its i ended use at Rancho Seco.

Evaluated By: o_w . M -

Date: / 8 7 i Reviewed By: OY/b Requalification Project Engineer Date: N -/9-7 7

/

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Sheet 1 of 1 Attachment 1,-pg. 10 of~90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING _,SUMt%RY REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

ENGINE ORIVEN FUEL OIL B0OSTER PUMP Part Number: 03-445

REFERENCES:

NO CIOR .

NDE Renort Number: NONE Associated Reports: FPR 52 Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Qualify revalidation is not required.

II. ACCEPTANCE CRITERIA None required. '

III. INSPECTION FINDINGS Not applicable IV. CORRECTIVE ACTIONS None required. However, during the performance of other DR/QR inspections, the District observed that the shaft of the pump did not turn freely. Foreign material had entered the pump resulting in impeller / casing binding. The District replaced the pump and verified the cleanliness of the associated components during reassembly.

V. MODIFICATIONS None required.

VI.t RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Group in this DR/QR report, and the corrective actions'taken, this component is acceptable for its intended use at i Rancho Seco. .  !

Evaluated By: zw< < . -

Date: / Y Y7 Reviewed By: U'Q7 /

/d d.I Requalifit:ation Project Engineer Date: AN9- 7 ?

l

~ _ - _ _ - - - - - -

Sheet 1 of 3' l Attachment 1, pg. 41 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT I

Diesel Engine Serial Number 81015 Engine Train A Part

Description:

FUEL OIL HEADER PIPING & TUBING Part Number: 03-450B d

REFERENCES:

CIDR MC172-073 NDE Report Number: NONE Associated Reports: IM QC-17-49-85 I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required. .

II. ACCEPTANCE CRITERIA None required. ,

III. INSPECTION FINDINGS Not applicable.

IV. CORRECTIVE ACTIONS None required.

4 V. MODIFICATIONS None required.

Evaluated By: x/aw#

C ,/

A

,. /

Date: /V /# U U

, Reviewed By: h Y Mr- l d Date: d-/1 7 )

/ Requalification.Rroject Engineer

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Sheet 2 of 3 Attachment 1, pg. 42 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Part No. 03-450B Engineering Evaluation and Recommendation (Continued):

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from a 10CFR Part 21 notification dated 9/21/83, and from IE Bulletin 86-73.

The IE Bulletin identified a fuel system relief valve induced vibration problem which caused fa c iure of a fuel line by its rubbing of another process line on a Cooper-Bessemer . esel. The Rancho Seco TD1 engines have a different configuration which avoids this particular problen..

The 10CFR Part 21 notification indicated that excessive fuel header supply line vibration may resuit in its failure. A subsequent letter (TDI to SMUD dated 10/27/87) provided the following site specific recommendations:

1. Compare the as-built configuration of fuel oil lines with the TDI design

'for compliance.

2. Monitor the fuel lines for excessive vibration, adding additional clamps where necessary.

3. Maintain proper engine balance. j

4. Add a means of preventing spray from a broken fuel oil line from reaching the turbocharger exhaust gas inlet area.

The District has reviewed these 10CFR Part 21 concerns and has addressed them as follows:

1. The as-built configuration was reviewed and accepted by the TDI Owners Group after a field walkdown was performed.

2. The District has obtained vibration measurements of the fuel oil piping, has replaced the plastic inserts of the supports with an elastomeric compound, and has added two supports to this line.

3. Although the maintenance and surveillance procedures for the diesel have not yet been issued, they will address the concern of maintaining proper engine balance, as required by the TDI Owners Group haintenance Matrix (Rev. 2) and by NRC NUREG-1216.

4. The District has added a spray shield to the fuel oil header supply line.

Furthermore, in response to a product improvement recommendation from TDI, Rancho Seco has installed flexible fuel lines for the "supply header to injection pump" ana "injection pump to circulating header." This modification reduces vibration, reduces fuel oil leaks at the connections, and incorporates a flame resistant firesleeve to shield fuel oil spray in the event of a failure.

Sheet 3 of 3 Attachment 1, pg. 43 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Part No. 03-450B Engineering Evaluation and Recommendation (Continued):

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this OR/QR report and the actions taken to address the above additional concerns, the fuel oil header piping and tubing is acceptable fo,r its intended use at Rancho Seco durhig testing and interim operations.

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Sneet 1 of 3_

Attachment 1, an 44 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

FUEL OIL HEADER PIPING & TUBING Part Number: 03-450B

REFERENCES:

CIDR MC172-073 NDE Report Number: NONE Associated Reports: IM QC-16-40-85 i

I. ATTRIBUTES TO BE VERIFIED  !

Quality revalidation is not required.

1 II. ACCEDTANCE CRITERIA l

None required. ,

l III. INSPECTION FINDINGS l l

Not applicable. 1 l

IV. CORRECTIVE ACTIONS None required,

u. MODIFICATIONS I None required.

Evaluated By: -m- o Date: / 7 D

?/

Reviewed By: ') f Ad>E~I' Date: />-/ f -2 7

/ Requalification Project Engineer

Sheet 2 of 3 Attachment 1, pg. 45 of 90 -

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Part No. 03-4508 P

Engineering Evaluation and Recommendation (Continued):

1 VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from a 10CFR Part 21 notification , dated 9/21/83, and from IE Bulletin 86-73.

The IE Bulletin identified a fuel system relief valve induced vibration problem which caused failure of a fuel line by its rubbing of another process line on a Cooper-Bessemer diesel. The Rancho Seco TOI engines have a different configuration which avoids this particular problem. ,

The 10CFR Part 21 notification indicated that excessive fuel header supply line vibration may result in its failure. A subsequent letter (TDI to SMUD dated 10/27/87) provided the following site specific recommendations:

Compare the as-built configuration of fuel oil lines with the TDI design

1. i for compliance. '

l

2. Monitor the fuel lines for excessive vibration, adding additional clamps where necessary. l

3. Maintain proper engine balance.

4 Add a means of preventing spray from a broken fuel oil line 'from reaching the turbocharger exhaust gas inlet area.

The District has reviewed these 10CFR Part 21 concerns and has addressed them as follows:

1. The as-built configuration was reviewed and accepted by the TDI Owners Group af ter a field walkdown wds performed. {

2. The District has obta'ined vibration measurements of the fuel oil piping, has replaced the plastic inserts of the supports with an elastomeric compound, and has added two supports to this line. I

3. Although the maintenance and surveillance procedures for the diesel have not yet been issued, they will address the concern of maintaining proper  !

engine balance, as required by the TDI Owners Group Maintenance Matrix  !

(Rev. 2) and by NRC NUREG-1216.  !

4. The District has added a spray shield to the fuei oil header supply line.

Furthermore, in response to a product improvement recommendation from TDI, Rancho Seco has installed flexible fuel lines for the "supply header to injection pump" i and "injection pump to circulating header." This modificati~on' reduces vibration,  ;

reduces fuel oil. leaks at the connections, and incorporates a flame resistant firesleeve to shield fuel oil spray in the event of a failure, ,

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Sheet 3_ of 3_

' Attachment 1, pg. 46 of 90 '

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT ,

Diesel Engine Serial Number 81016 part No. 03-450B-Engineering Evaluation and Recommendation (Continued):

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Group in this DR/QR report and the actions taken to address the above additional concerns, the fuel oil header piping and tubing is acceptable for its intended use at Rancho Seco during testing and interim operations. .

. 0 1 .

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Sheet 1 of 2 Attachment 1, pg. 47 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

FUEL OIL HEADER SUPPORTS Part Number: 03-4500

REFERENCES:

CIOR MC172-074 NDE Report Number: NONE Associated Reports: IM QC-17-49-85; ERPT-M0024 Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

II. ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS Not applicable.

l IV. '

CORRECTIVE ACTIONS l None required.

]

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Evaluated By: ne w - N Date: / 5/37 cf5'

~

Reviewed By: b4Mb Date: /.d -/ 9 -2 7 -

/ Requalification Project Engineer e

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i Sheet 2 of 2  ;

Attachment 1, pg. 48 of 90 l RANCHO SECO DIESEL GENERATOR REQUALIFICATION l ENGINEERING

SUMMARY

REPORT l CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-4500 Engineering Evaluation and Recommendation (Continued):

V. MODIFICATIONS The TDI Dwners Group recommends:

a. One drain header U-bolt type restraint be modified to three-directional type.

b. The other drain header 3/16-inch U-bolts be changed to 3/8-inch with locking devices.

c. Add a'two-directional lateral restraint on each 1+inen ejector tube,

c. For both fuel oil to day tank return lines, a two-directional lateral restraint should be added.

The District has reviewed these recommended modifications and takes exception to their implementation at Rancho Seco. The District has calculations which demonstrate that the associated generic evaluations performed.by the Dwners Grcup are extremely conservative with respect to the as-built condition and plant-specific seismic spectra for the TDI diesels at Rancho Seco. These calculations also provide justification that the existing configuration is acceptable without modification.

VI. ADDITIONAL CONCERNS '

The District was also made aware of other concerns with this component from a 10CFR Part 21 notification dtted 9/21/83. These concerns and the District's response to '

them are addressed in the engineering summary for P/N 03-4508.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the justifications concerning the proposed modificationa, and the actions taken to address the above additional concerns, the fuel oil header supports are acceptable for their intended use at Rancho Seco, i

• 1 J

Sheet 1 of 2_

Attachment 1, pg. 49 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING Suf41ARY REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

FUEL OIL HEADER S'JPPORTS Part Number: 03-4500

REFERENCES:

CIDR MC172-074 NDE Repoet Number: NONE _

g.iatedReports: IM QC-16-40-85; ERPT-M0024 Engineering Evaluation and Recommendation:

1. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

_I I . ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS Not applicable.

. IV. CORRECTIVE ACTIONS None required.

Evaluated By: cww- <. - Date: / I/f7 u

Reviewe.d By: b/ k Requalification

/d -

~

Project Engineer -

Date: M"6- N

/ '

<J 9

-s

Sheet 2 of 2 Attachment 1, pg. 50 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-4500 Engineering Evaluation and Recommendation (Continued):

V. MODIFICATIONS The TDI Owners Group recommends:

a. One drain header U-bolt type restraint be modified to three-directional type.

b. The other drain header 3/16-inch U-bolts be changed to 3/8-inch with locking devices.

c. Modify the 1-inch ejector tubing restraint located between the ejector assembly and the fuel oil header.

d. For both fuel oil to day tank return lines, a two-directional lateral restraint should be added.

The District has reviewed these recommended modifications and takes exception to their implementation at Rancho Seco. The District has calculations which demonstrate that the associated generic evaluations performed by the Owners Group are extremely conservative with' respect to the as-built condition and plant-specific seismic spectra for the TDI diesels a't Rancno Seco. These calculations  ;

also provide justification that the existing configuration is acceptable without j modification.

VI. ADDITIONAL CONCERNS The District was also made aware of other ccacerns with this component from a 10CFR Part 21 notification dated 9/21/83. These concerns and the District's response to them are addressed in the engineering summary for P/N 03-450B. ,

l VII. RESULTS AND CONCLUSIONS Based upon the evalu; tion made by the TDI Owners Group in this DR/QR, report, the justificatic.is concerning the proposed modifications, and the actions taken to address the above additional concerns, the fuel oil heacer supports are acceptable for their intended use at Rancho Seco.

Sheet 1 of 1

' ' Attachment 1, pg. 51 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINE 2 RING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A part

Description:

CONTROL PANEL ASSEMBLY Part Number: 03-500A

REFERENCES:

NO CICR NDE Report Number: NONE I

Tssociated Reports: NCR/IM NONE I

1. ATTRIBUTES TO BE VERIFIED ,

Quality revalidation is not required.

II. ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS i

. Not applicable, j IV.

CORRECTIVE ACTIONS 1 None required. .

J V. MODIFICATIONS None required.

V_I . ADDITIONAL CONCERNS

~

The District was diso made aware of other concerns with this component from NRC IE l Bulletin 83-17 concerning the loss of starting air during a shutdown time delay l perio'd on GMC type diesels. Rancho Seco TOI engine have a different design of '

control logic which avoids the problem of wasted air identified in this bulletin.

^

VII. 'RESULTS AND CONCLUSIONS

^

Based upon the evaluation made by the TOI Owners Group in this DR/QR report, the ,

u control panel assembly is acceptable for its intended use at Rancho Seco. I Evaluated By: we t c ~ Date: /2[y/f7 Reviewed By: hY NO -

Date: # -/ 9-F 7

. . . / Requalification Project Engineer 9

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g

Shoot-1 of 1 RANCHO SECO DIESEL GENERATOR REQUALIFfbIT50g nt 1. P8 52 of 90 ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 4 .

Engine Train B Part

Description:

CONTROL PANEL ASSEMBLY  ;

Part Number: 03-500A RE#ERENCES: NO CIOR NDE Report Number: NONE Associated Reports: NCR/IM NONE i I. ATTRIBUTES TO BE VERIFIED ,

Quality revalidation is not required.

II. ACCEPTANCE CRITERIA  !

None required. .

III. INSPECTION FINDINGS

Not applicable. '

IV. CORRECTIVE ACTIOris l

None required.

V. MODIFICATIONS None required.

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from NRC IE Bulletin 83-17 concerning the loss of starting air during a shutdown time delay l i- period on GMC type diesels. Rancho Seco TOI engine have a different design of l control logic which avoids the problem of wasted air identified in this bulletin.

VII. RESULTS AND CONCLUSIONS

, Based upon the evaluation made by the TOI Owners Group in this OR/QR report, the control panel assembly is acceptable for its intended use at Rancho Seco.

Evaluated By: as.  %. Date: / r/$7 Reviewed By: h/ 7 Requalification Mc d d" Project Engineer Date: /a -/1 - # 7 I

1

Sh;st 1 of 2 Attachment 1, pg. 53 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINE _ERING

SUMMARY

rep 0RT Diesel Engine Serial Number 81015 Engine Train A part

Description:

CONTROL PANEL RELAYS Part Number: 03-500J

REFERENCES:

NO CIDR NDE Reoort Number: NONE Associated Reports: NCR S-5020

1. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

II. ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS Not applicable.

IV. CORRECTIVE ACTIONS None required. However, during the performance of startup testing, the  !

District observed erratic operation of two time delay relays. Investigation revealed several areas of poor internal design:

I the bottom of an internal lamp hits the relay l the internal wiring is large with bulky insulation  ;

the flat spot for the adjustment potentiometer is subject to .

excessive wearing one internal solder joint had no solder )

The District inspected the other relays for similar problems. All problems were repaired to support the diesel test program, and the affected relays have been replaced prior to release to operations. Both the District and TDI '

have initiated 10CFR Part 21 investigations on these components, c . ,-,.,

Evaluated By: A. ' II'0 4 4 Datc:' !' U '/

/

Reviewed By:_ .) Y N. ,, J . d ' Date: Ai -/1 -2 7 f

/ Requalification Project Engineer ,

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Shoet 2 of 2 Attachment 1, pg. 54 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Part No. 03-500J Engineering Evaluation and Recommendation (Continued)

V. MODIFICATIONS None required.

VI. ADDITIONAL CONCERNS The District was also made aware of another concern with this component from NRC Information Notice IE 82-04 on Agastat E-7000 time delay relays. This problem does not apply to Rancho Seco because the panel design does nat use these relays.

• VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI OwneYs Group in this DR/QR report and the corrective actions taken, the control panel relays'are acceptable for their intended use at Rancho Seco, i

l l

ShQet 1 of 2 Attachment 1, pg. 55 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

CONTROL PANEL RELAYS Part Number: 03'500J ,

REFERENCES:

NO CIOR NDE Report Number: NONE Associated Reoorts: NCR S-5020

1. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

II. ACCEPTANCE CRITERIA None re. quired.

III. INSPECTION FINDINGS Not applicable.

IV. CORRECTIVE ACTIONS ,

None required. However, during the performance of startup testing, the District observed erratic operation of two time delay relays. Investigation revealed several areas of poor internal design: ,

the bottom of an internal lamp hits the relay the internal wiring is large with bulky insulation the flat spot for the adjustment potentiometer is subject to excessive wearing one internal solder joint hart no solder The District inspected the other relays for similar problems. All problems were repaired to support the diesel test program, and the affected relays have been replaced prior to release to operations. Both the District and TOI have initiated 10CFR Part 21 investigations on these components

^

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//, 7/ _ -r : : J- IN7/ '

I Evaluated By: -

' . . Date:

Reviewed By: 9 / U d I ." , Date: A9 -/1 -2 '/

/ Requalification project Engiiie~er

-w e

1 Sheet 2 of 2 .

Attachment 1, pg. 56 of 90 !

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT 4 Diesel Engine Serial Number 81016 Part No. 03-500J Engineering Evaluation and Recommendation (Continued)

V. MODIFICATIONS None required.

VI. ADDITIONAL CONCERNS The District was also made aware of another concern with this component from NRC Information Notice IE 82-04 on Agastat E-7000 time delay relays. This problem does not apply to Rancho Seco because the panel design does not use these relays'.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report and the corrective actions taken, the control panel relays are acceptable for their intended use at Rancho Seco.

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• Sheet 3,of 2_

Attachment 1, pg. 57 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

CONTROL PANEL PIPING, TUBING & FITTINGS Part Number: 03-500M

REFERENCES:

MC172-209, -214 NDE Reoort Number: NONE Associated Reports: NCR/IM NONE Engineering Evaluation and Recommendation: l I. ATTRIBUTES TO BE VERIFIED Quality reva'lidation is not required.

II. ACCEPTANCE CRITERIA <

l None required.

I i

III. INSPECTION FINDINGS i None required.

l IV. CORRECTIVE ACTIONS None required. )

V. MODIFICATIONS None required.

Evaluated By: s e mu , ~ S ~ Oate: /2 3/ 7 u '

Reviewed By: M 7 ' A'-r. d' Date: 4-/ f T7

/ Requolification Project Engineer , , . .

e M

Sheet 2 of 2 RANCHOSECODIESELGENERATORREQU.i_IFkANh["

ENGI"EERING SUMMAR'Y REPORT Diesel Engine Serial Number 81015 Part No 03-500M Engineering Evaluation and Recommen(ation (Continued)

VI. ADDITIONAL CONCERNS The District was made aware of other concerns with this component from 10CFR Part 21 notificatiens, of 1/22/85 and 5/28/87, which indicated material problems with the bow; of the Engine Control Panel air filter. The District determined the bowl to be made of metal, not plastic, which resolves one concern, and the date code to be correct, which resolved the concern of an improper gasket seating surface, >

VII. RESULTS AND CONCUJSIONS .

Based upon the evaluation made by the TOI Owners Group in this 'OR/QR report and the actions taken to address the above additional concerns, the control panel piping, tubi si and fittings are acceptable for their intended use at Rancho Seco, i

l 4

. l

Sheot 1 of 2 Attachment 1, pg. 59 nf 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

CONTROL PANEL PIPING, TUBING & FITTINGS Part Number: 03-500M

REFERENCES:

MC172-209, -214 NDE Report Number: NONE Associated Reports: NrR/IM NONE Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

II. ACCEPTANCE CRITERIA None required. ,

III. IRSPECTION FINDINGS None required.

IV. CORRECTIVE ACTIONS None required.

V. MODIFICATIONS None required.

Evaluated By: - n tee <.  % Oate: r' d //3 7

'V Reviewed By:

/

7[ I' Requalification Project Engineer Date: 4 -/ 'l- <7

-4

. . . . . - - . - . -- .__. . ~ . - - - -. . . . . .. . - . -

Sheet 2 '

f2 Attachment 1, ra. 60 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT Diesel Engine Serial. Number 81016 oart No. 03-500M Eng'rieering Evaluation and Recommendation (Continued)

VI. ADDITIONAL CONCERNS The District was made aware of other concerns with this component from 10CFR Part 21 notifications, of 1/22/85 and 5/28/87, which indicated material problems with the bowl of the E..gine Concrol Panel air filter. The. District determined the bowl to be made of metal, not plastic, which resolves one concern, and the date code to be correct, which resolved the concern of an improper gasket seating surface.

VII. RESULTS AND CONCLUSIONS 4

Based up~on the esaluation made by the TDI Owners Group in this DR/QR report and the actions taker, to address the above additional concerns, the control panel piping, tubing anc fittings are acceptable for their intended use at Rancho Seco.

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Sheet 1 of 1 Attachment 1, P8 61 of 90 RANCP0 SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REFORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

EMERGENCY DIESEL GENERATOR Par t Number: 03-650A REFEDENCES: NO CIOR NDE Report Number: NONE

,Asscciated .'.eports: NCR/IM NONE I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required, II. ACCEPTANCE CRITERIA None required. '

III. INSPECTION FINDINGS Not applicable. .

IV. COP.RECTIVE ACTIONS Nons required.

V. MODIFICATIONS None required.

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from NRC IE Notice 85-68 concerning cracked ntorpolar connecting bars. This problem does not apply to Rancho Seco, which is of a different design.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Group in this OR/QR report, the emo<gency diesel generator is acceptable for its inter.ded use at Rancho Seco.

Evaluated By: n >o t eu& Dase:

(2[{/87 Reviewed By:

/

YRequalification

/d-$d Project Engineer Date: 4 - / 'l -D

Sheet 1 of 1 Attachment 1, pg. 62 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

EMERGENCY DIESEL GENERATOR Part Numbtz: 03-650A

REFERENCES:

NO CIDR NDE Report Number: NONE Associated Reports: NCR/IM NONE I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

II. ACCEPTANCE CRITERIA None required.

III. INSPECTIOh FINDINGS Not applicable.

IV. CORRECTIVE ACTIONS i

None required.

V. MODIcICATIONS -

None required.

VI. ADDITIONAL CONCERNS -

The District was also made aware of other concerns with this component from l NRC IE Notice 85-68 concerning cracked interpolar connecting bars. This .

problem does not apply to Rancho Seco, which is of a different design.

~

VII. RESULTS AND CONCLUSIONS l

i Based upon the evaluation made by.the T01 Owners Group in this OR/QR report, the s emergency diesel generator is acceptable for its intended use at Rancho Seco. ./

~

Evaluated By: nuskhfhews :Date: 12/6f9 . " '

7 N- . .is Reviewed By: e ' - ' 4 ^ Oate: / 2 R.equalif.idat' ion'Proj ect Engineer -

I

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Sheet ,1 of 7 Attachment 1, pg. 63 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATIO" ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

GENERATOR CONTROLS Part Number: 03-650B

REFERENCES:

CIDR MC172-108 NDE Report Number: NONE Associated Reports: NCR/IM NONE Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED

a. Type of current transformer installed.

b. Terminal block manufacturer and manufacture date.

c. Temperature range of IC's installed.

d. Field flashing circuit design.

II. ACCEPTANCE CRITERIA

a. Absence of Westinghouse type ECT-5 current transformer.

b. Absence of Fulti-Amp States Division terminal blocks manufactured between 1974 and 1976.

c. Military temperature range (-55 to 125 C).

d. No potential for overheating of field flashing resistor or nearby components.  !

III. INSPECTION FINDINGS

a. Current transformers are acceptable (Westinghouse type KIN).

b. Terminal blocks are a cceptable (General Electric type EB).

Evaluated By: o NW uw Date: < ? /2 i N 7

/

Reviewed By: b'A Date: V '> 2 O

/ ,,Regaalification Project Engineer i

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- -. ._. . _ _ ._. =. _ __ __

Sheet 2 of 7 Attachment 1, pg. 64 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATISN Diesel Engine Serial Number 81u15 Part No. 03-650B Engineering Evaluation and Recommendation (Continued):

c. IC's are acceptable (qualified to MIL-M-38510).

d. The District has reviewed the relay logic of the FF circuit on the resistors.

For the original circuit, under all generator starts (other than emergency start) in which an unsuccessful start develops due to an abnormal condition, the field flash circuit is only closed for 4 secoi:os. No proloncad field flashing resistor energization exists. A logic modi.'ication is na. required.

However, the District has modified this circuit to oee.'ergize the field flash about ten seconds following any start.

IV. CORRECTIVE ACTIONS .

None required.

V. MODIFICATIONS The TDI Owners Group has recommended tha the following modifications be implemented prior to placing the engines in standby nuclear service.

a. The installation on each. diode of a temperature sensitive label which permanently blackens whc., 300 deg. F is reached or exceeded in order to monitor the maximum temperature attained.

b. The installation on each SCR of a temperature sensitive label which permanently blackens when 220 deg. F is reached or exceeded in order to monitor the maxirum temperature attained.

c. The coating of the side of the lugs and mounting bolt of each diode and SCR with a Glyptol-typa lacquer to detect any relative motion.

d. Ventilation of the left-front control cabinet so that the cabinet internal temperature.does not exceed 104 deg. F.

e. The coating of the adjustment screw of the five potentiometers on the voltage regulator circuit board with a Glyptol-type lacquer to detect any relative motion.

f. Replacement of the field flashing. relay with one which meets the required -

electrical ratings.

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Sheet 3 of 7 Attachment 1, pg. 65 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-650B Engineering Evaluation and Recommendation (Continued):

g. Ventilation of the left-rear and center-rear control cabinets so that the cabinet internal temperature does not exceed 104 deg. F.

h. Remounting of the linea reactor so that the cooling slots are vertical or supply cold air to the linear reactors so that the internal temperature of the left-rear and center-rear control cabinets does not exceed 104 deg. F.

The District has reviewed these modifications and has addressed them as follows:

a. The temperature labels have been installed.

b. The temperature labels have been installed.

c. The Glyptol-type lacquer has been applied.

d. The District has added a.660 CFM fan to tDe left-front control cabinet to reduce internal temperatures as recommended by a 10CFR Part 21 notification (described below in the "Additional Concerns" section). The District has performed preoperational tests to assure that the cabinet internal air temperature does not exceed 61.70C under any operating conditions, as required by the TDI Owners Group. Tests for the "A" panel have been successful, with the "B" panel to be retested because of instrumentation errors during the test.

e. The Glyptol-type lacquer has been applied.

f. The District takes exception to the relay replacement because a justification has been developed to demonstrate that the existing relay is acceptable with tLa installation of'a timer circuit. The timer will isolate the relay during an emergency start (ESFAS or LOOPS) to prevent exceeding the contact rating shouTd the engine fail to start. This ,

modification has been installed and tested satisfactorily, and submitted to j the TDI Owners Group for concurrence. ,

i

g. The District has added a 660 CFM fan to both the left-rear and center-rear control cabinets to reduce internal temperatures as recommended by a 10CFR Part 21 notification (described below in the "Additional Concerns" section). District's position on internal cabinet temperature is described in paragraph d. above. ,

[+

s~ a jm -k'

, as l .

Sheet 4 of 7 Attachment 1, pg. 66 of 90 RANCHO SECO DIESEL GENERATOR RE0VALIFICATION ENGINEEi,1NG

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 01015 Part No. 03-650B Engineering Evaluation and Recomme-dation (Continued):

h. The District takes exception to remounting the linear reactors because of the site specific conditions at Rancho Seco. The linear reactors utilized at Rancho Seco, P/N CD-1257, have Class F insulation as verified by the manufacturer. This insulation class is rated for a maximum temperature of 1550 C (total), with an ambient temperature not exceeding 65 0C. After the installation of fans (2 on left/right rear doors, where the linear reactors are located, as described in paragraph ' above) for panel cooling, preoperational tests at Rancho Seco have shown that the panel internal temperature does not exceed 61.70C under any opsrating conditions Remounting of the linear reactors is therefore not required.

The TDI Owners Group has recommended that the fdllowing modifications be implemented at the firsc refueling outage (or earlier) to eliminate several maintenance inspections.

i. Mount the diodes to the heatsinks usirg drilled holes, lockwashers, nuts, and the proper torque.

j. Mount the SCRs to the heatsinks ~using drilled holes, lockwashers, nuts, and the proper torque.

k. Redesign the bolted-on lug arrangement so there are not more than two lugs on each bolt.

1. Remove the heatsink anodizing in the contact areas of all bolts and bus bar studs.

The District has reviewed these mocifications and has addressed them as follows:

i. The diodes will be remounted at the first refueling outage following tie-in of the TDI diesel generators. <

l

j. The SCRs will be remounted at the fir's t ' refueling Gutage following tje-in )

of the TDI diesel generators.

J

k. The bolted-on lug ~ arrangement will be redesigned by NEl Peebles Electric Products and will be reworked during the first refueling outage following 1 tie-in of the TDI diesel generators. I l

4

. . . . , ,. .s.*~ , . _ . - ogi . , . . . . _ , _ , - , . . -

Sheet 5 of 7 Attachment 1, pg. 67 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-6508

~

Engineering Evaluation and Recommendation (Continued):

1. The District takes exception to the removal of heatsink anodizing because the anodizing is 100% conductive and prevents longterm oxidation and degradation of the thermal interface. The manufacturer concurs with not removing the anodizing and December 10, 1987 correspondence from the TDI Owners Group also indicates agreement. A new, separate recommendation of applying electrical joint compound has been provided by the TDI Owners Group in this letter, which is presently being reviewed by the District.

The TDI Owners Group has recommended that the following modifications be implemented at the discretion of the District to enhance the longterm reliability and performance of the voltage regulator.

m. The addition of power supply bypass capacitors to the integrated circuits

.(ICs) of the voltage regulator.

n. The use of shielded signal leads for connections between the motor-driven potentiometer and the voltage regulator.

o. The addition of a high frecuency byoass capacitor to the feedback loop of the voltage regulator.

p. The rerouting of SCR gate signal leads in bundles separate from the current carrying leads. '

O. The use of a three-phase current sensing circuit instead of a single-phase circuit and reduction of feedback signal filtering.

r. The d'irect soldering of ICs to the printed circuit board to replace sockets,

s. The replacement of the potentiometers with MIL style, sealed, multi-turn potentiometers.

t. The use of double sided printed circuit boards instead of single sided boards. -

u. The addition of a conformal coating to the printed circuit boards,

v. Thedirectsolderingofcomponentstotheprintedcircuithoard.andthe'use "

. . nf retaining mechanisms on all remaining sockets. ,

The Olstrict will evaluate the usefdinets and practicality of these long term improv9 ment madifications after the first refueling outage following tie-in of the

- TDI diesel generators. -

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Sheet 6 of 7 Attachment 1, pg. 68 or 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engirie Serial Number 81015 Part No. 03-650B Engineering Evaluation and Recommendation (Continued):

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component frem several sources which include 10CFR Part 21 notifications and IE notices. The concerns and the District's response to then, are addressed individurilly below. ,

NRC Information Notice 62-54-indicated that Westinghouse type NBFD relays require special inspection and test procedures. Rancho Seco's TDI diesels do not use this component.

NRC Information Not::a 82-55 indicated that Westinghouse type AR relays with ARMLA latch mechanisms are not qualified for use in Seismic I systems. Rancho Seco's TDI TDI diesels do not use this component. ,

A letter form General Electric Co. dated 7/12/82 advised that Century Series relays (12HFA17.3K-A) manufactured between 10/77 and 2/81 may be defective. Rancho Seco's TDI diesels do not use this component.

A 10CFR Part 21 notification dated 8/9/82 identified a failure of a Magnecraft '

W88LCPX-12 switching relay on a TDI diesel generator. Rancho Seco's TDI diesels do not use this component. -

A 10CCR Pa*t 21 notification dated 8/18/83 indicated that some multiple conductor cable from Champlain Cable Corporation may contain unauthorized cable splices.

Rancho Seco's TDI diesels do not use Champlain cable. ,

A 10CFR Part 50.55(e) notification dated 12/17/82 indicated that the silver plated contacts of a starting circuit relay from Potter Brumfield stuck due to oxidation.

Rancho Seco's TDI diesel use Allen Bradley relays with solid silver contacts, which is a superior design not prone to sticking.

A letter from General Electr c Co. dated 12/21/82 indicated that type SB!i switches i

l with date codes of HU, JU, or KU could be defective. An inspection at Rancho Seco has verified acceptable date codes for the SBM switches on the TDI diesel generators.

A 10CFR.Part 21 notification dated 5/17/85 identified a potential overheating problem with this component. The DR/QR actions described above have resolved this concern.

Sheet 1 of 1 Attachment 1, pg. 69 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-650B Engineering Evaluation and Recommendation (Continued):

A General Electric Advice Bulletin 721-PSM-167.1 irdicated that certain protective relays may fail because they contain a defective telephone relay from the Liberty Control Company. The date. codes on the relays at Rancho Seco ind.icate chat this problem is not applicable.

A 10CFR Part-21 notification dated 8/7/85 identified a cracking insulation problem in some multi-conductor wire when petroleum fumes are present. Rricho Seco's TDI engines do not have this problem because the control room is separate from the engine room, hence there are no fumes which could cause insulation cracring.

NRC Information Notice 85-82 stated that a differential protection relay (GE model 12CFD) was not seismically qualified for its intended service in an emergency diesel generator. Rancho Seco's TDI diesals do not use this component and its differential relays (Westinghouse model.CA) are seis'mically qualified.

During pre-operational testing at Rancho Seco (8/85), several relays manufactured by Syracuse Electronics were found to be defective in various ways. The District has replaced the defective relays and inspected the other relays to ensure their acceptability. A 10CFR Part 21 notification was also initiated by the District.

A 10CFR Part 21 notification dated 4/24/36 indicated that GE type NGA15AG3 relays may be damaged by a wiring error. The District has corrected the wiring error.

Relays with burnt resistors were replaced with new ones, others were repaired, retested and re-installed in the control panels.

A 10CFR Part 21 notification dated 3/11/87 described a design problem with the reset circuitry of the static exciter voltage regulator. The District has revised the

. static exciter voltage regulator reset circuitry and performed preoperational testing successfully.

l A 10CFR Part 21 notification dated 3/31/87 described a design problem with the engine shutdown circuitry which prevented restarting until manually reset. The District has modified the circuit to eliminate this problem.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Group in this OR/QR report, the

, inspections performed, the modifications made, and the c.ctions taken to address the additional conctens, the generator controls are acceptable for their intended use at Rancho Seco during testing and interim operations.

1 v4

Sheet ,1_ of 2 Attachment 1, pg. 70 of 90 RANCHO-SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016-Engine Train B Part

Description:

GENERATOR CONTROLS Part Number: 03-6508

REFERENCES:

CIDR MC172-108 NDE Report Number: NONE Associated Reports: NCR/IM NONE i

Engineering Evaluation and Recomme'ndation:

l 1

I. ATTRIBUTES TO BE VERIFIED ,

1 i

a. Type of current transformer installed. l

b. Terminal block manufacturer and manufacture date. ,

c. Temperature range of IC's installed. l l

d. Field flashing circuit design.

II. ACCEPTANCE CRITERIA i

a. Aesence of Westinghouse type ECT-5 current transformer. ,

b. Absence of Multi-Amp States Division to.minal blocks manufactured between 1974 and 1976.

c. Military temperature range (-55 to 125 C).

i

d. No potential for overheating of field flashing resistor or nearby components. ,

1 III. INSPECTION FINDINGS

a. Current transformers are acceptable (Westinghouse type KIN).

Terminal blocks are acceptable (General Electric type EB).

b. l n

Evaluated By: -- / y/b m L Date: /2[22[57 Reviewed By:

• U Date: O 'C ' ? '

j' Requalification Project Engineer

- . _ ~ -- - . - . _ - - . - - - . . . - - _ - - - .. .- - - . . . - _ . _

h i

Sheet 2 of 2 Attachment 1, pg. 71 of 90 RANCHO SECO DIESEL GENERATOR RE0VALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-6508 Engineering Evaluation and Recommendation (Continued):

c. IC's are acceptable (qualified to MIL-M-38510).

d. The C '.stri;t %as reviewed the relay logic of the FF circuit on the resis, tors.

For the or- 1 circuit, under all. generator starts (other than emergency i

start) in i an unsuccessful star, develops due to an abnormal condition, the field flash circuit is only closed for 4 seconds. No prolonged field flashing resistor energization exists. A logic modification is not required.

However, the District has modified this circuit to deenergize the field flash about ten seconds following any start.

IV. CORRECTIVE ACTIONS None required.

V. MODIFICATIONS d

A discussion of the modifications recommended by the TDI Owners Group for this component can be found in the Engine "A" summary. .

VI. ADDITIONAL CONCERNS

. A discussion of other concerns with this component can be found in,the Engine "A" summary. -

VII. RESULTS AND CONCLUSIONS '!

Based upon the evaluation made by the TDI'0wners Group in this DR/QR report, the l inspections performed, the modifications made, and the actions taken to address i the additional concerns, the generator controls are acceptable for their intended i use at Rancho Seco during testing and interim operations. j d

I

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• L

Sheet 3,of 2,

' Pg.12 of %

RANCHO SECO DIESEL GENERATOR REQUALIFNkiSb5""'

ENGINEERING

SUMMARY

REPORT Diesel Engine Serial ' lumber 81015 Engine Train A Part

Description:

AUX. SUB BASE LUBE OIL: VALVES Part Number: 03-7171

REFERENCES:

CIDR MC172-109 NDE Repart Number: NONE Associated Reports: ASME Section'III, ( - 3, Paragraph ND-7141; SMUD-TDI 9/23/85, TDI Memo 11/7/85 f.ngineering Evaluation and Recommendation:

~

L ATTRIBUTES TO Bi VERIFIED  ;

Verify proper in'stallation of relief valves.

l II. ACCEPTANCE CRITERIA I I

Installed in accordance with manufacturer's recommendations (i.e. vertical 1 installation). l I

III. INSPECTION FINDINGS The District takes exception to this requirement based on generally accepted industry standards which allow these valves to be installed in the horizontal position and a TDI memo (dated'11/7/85). According to TD.I the PCV is the primary '

controller of pressure in the lube oil system; the relief valves are backups to the.

PCV (as a carryover from an earlier design) and therefore are not actually 1 required. Furthermore, the reliefs are Crosby guided poppet type valves which keep I themselves in alignment regardless of their orientation. This, plus the fact that I they are continually lubricated by oil, makes them suitable for orientation in the horizontal position. The TDI Owners Group has agreed that the Rancho Seco configuration is acceptable as is, i i

I IV. CORRECTIVE ACTIONS None required. ,

V. MODIFICATIONS None required.

Evaluated By: - Ge' c -

Date: / 2 U h7Requalificatiqn bM' N' Project Engineer Reviewed By: Date: 4 -N -U

/

- ___ . . ~ _ _ . . . - . . . . . . . _ , _ . . , . .-. ._. _ -

_.. _ . - . _ _ _ ~ . _ .. - ._ _ ... _ _. ._ __ _

Sheet 2 of 2 Attachment 1 pg. 73 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT I

Diesel Engine Serial Number 81015 Part No. 03-7171 Engineering Evaluation and Recommendation (Centinued)

VI. ADDITIONAL CONCERNS The District was made aware of another concern by a 10CFR Part 21 notification '

where the lube oil check valve liner and' seat material deteriorated. The District replaced these valves with new valves with the proper seat material-(Buna N).

Another concern regarding the Lube Oil Sump Tank Foot Valve was brought to the  ;

District's attention in 10CFR Part 21 notification of March 10, 1986. This concern does not apply to Rancho Seco based on subsequent information supplied in TDI letters of May 8, 1986 and May 12, 1986.

l VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DP/QR report and the l actions ta. ken to address the above additional concerns, this component is I acceptable for its intended use at Rancho Seco.  !

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T Sheet 1 of 2 RANCHO SECO DIESEL GENERATOR REQUALIFNtNfnt A 1. Pg. 74 of 90 ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B part

Description:

- AUX. SUB BASE LUBE OIL: VALVES

'PTrt Number: 03-7171

REFERENCES:

CIDR MC172-109 NDE Report Number: NONE Associated Reports: ASME Section III, Class 3, Paragraph ND-7141; SMUD-TDI 9/23/85, TOI Memo 11/7/85 Engineering Evaluation and Recornmendation:

. I. ATTRIBUTES TO BE VERIFIED Verify proper installation of relief valves.

II. ACCEPTANCE CRITERIA Installed in accordance with manufacturer's recommendations (i.e. vertical installation).

III. INSPECTION FINDINGS The District takes exception to this requirement based on generally accepted industry standards which allow these valves to be installed in the horizontal position and a TDI memo (dated 11/7/85). According to TDI the PCV is the primary controller of pressure in the lobe oil system; the relief valves are backups to the PCV (as a carryover from an earlier design) and therefore are not actually required. Furthermore, the reliefs are Crosby guided poppet type valves which keep themselves in alignment regardless of their orientation. This, plus the fact that they are continually lubricated by oil, makes them suitable for' orientation in the horizontal position. The TDI Owners Group has agreed that the Rancho Seco i configuration is acceptable as is.

IV. CORRECTIVE ACTIONS None required, i j

V. MODIFICATIONS i

None required.

Evaluated By: e  % c- -

Date: 87 l

Reviewed By: YMM Date: / 2-/ ?*> (

/ Requalification Project Engineer j

Sheet 2 of.2 Attachment 1, pg. 75 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

rep 0RT Diesel Engine Serial Number 81016 Part No. 03-7171 Engineering Evaluation and Recommendation (Continued)

VI. ADDITIONAL CONCERNS The District was made aware of another concern by a 10CFR Part 21 notification where the lube oil check valve liner and seat material deteriorated. The District replaced these valves with new v.alves with the proper seat material,(Buna N).

Another concern regarding the Lube Oil Sump Tank Foot Valve was brought to the ,

District's attention in 10CFR Part E_ notification of March 10, 1936. This concern does not apply to Rancho Seco based on subsequent information supplied in TDI letters of May 8, 1986 and May 12, 1986.

VII. RESULTS AND CONCLUSIONS .

Based upon the evaluation made by the TDI Owners Group in this DR/QR report and the actions taken to address the above additional concerns, this component is acceptable for its intended use at Rancho Seco. i i

l 1

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. =. .. . . - - - _ - - . - - . .-

Sheet 1 of 2

' Pg. M og 90 RANCHO SCCO DIESEL GENERATOR REQUALIFbkffh"'

ENGINt' RING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

JACKET WATER THERM 0 STATIC VALVE Part Number: 03-799A

REFERENCES:

CIDR MC172-113 NDE Report Number: NONE Associated Reports: NCR/IM NONE I. ATTRIBUTES TO BE VERIFIED Valve body material.

II. ACCEPTANCE CRITERIA l

Cast steel, not bronze.

i l

III. INSPECTION FINDINGS Valve body material is acceptable. *

, j i

IV. CORRECTIVE ACTIONS j None to date.

V. MODIFICATIONS None requireo.

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from IE l Notice 82-56 which identified possible setpoint changes due.to nut movement and possible sticking operation due to the 0-ring problems. The District disassembled the valve and confirmed the temperature operation of the power pills, the use of a castellated nut and cotter pin, and the absence of an 0-ring for bypass leakage.

These inspections fully address the concerns of the IE Notice. However, during these inspections the District also observed that a long (11-1/4 inch) spring was installed instead of a short one (7-1/8 inch) which the TDI Manual (Robertshaw section) recommended for inverted operation. The District has replaced the spring with a short one Evaluated By: am< -

Date: /J/f 7__

Reviewed By:

7Ud Date: 7 2

/ Re, qualification Project Engineer

Shaet 2 of 2 Attachment 1, pg. 77 of 90 '

RANCHO SECO DIESEL GENERATOR REQUALIFICATION

-ENGINEERING

SUMMARY

rep 0RT.

CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-799A Engineering Evaluation and Recommendation (Continued):

VII. RESULTS AND CONCLUSIONS  :

' Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the inspections made, and the actions taken.to address the above additional concerns, this valve is acceptable for its intended use at Rancho Seco. -

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- - . .. .- . . -~ .

Sheet 1 of 2 RANCHO SECO DIESEL GENERATOR REQUALIFbilg at 1, pg. 78 of 90 ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B part

Description:

JACKET WATER THERM 0 STATIC VALVE Part Number: 03-799A  ;

REFERENCES:

CIDR MC172-113 NDE Repart Number: il0NE Associated Reports: NCR/IM NONE l

I. ATTRIBUTES TO BE VERIFIED Valve body material. I II. ACCEPTANCE CRITERIA Cast steel, not bronze. l III. INSPECTION FINDINGS  ;

1 Valve body material is acceptable.

IV. CORRECTIVE ACTIONS' None to date. I V. MODIFICATIONS None required. -

VI. ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from IE )

Notice 82-56 which identified possible setpoint changes due to nut movement and possible sticking operation due to the 0-ring problems. The District dirassembled

. the valve and confirmed the temperature operation.of the power pills, the use of a castellated nut and cotter pin, and.the absence of an 0-ring for bypass leakage.

These inspections fully address.the concerns of,the IE Notice. However, during these inspections the District also observed that a long (11-1/4 inch) spring was installed instead of a short one (7-1/8 inch) which the.TDI Manual (Robertshaw

.section) recommended for inverted operation. The District has replaced the spring

~

with a short one. ...e '

Evaluated.By: M Date: J

'l; ,Rev.iewed By: d@Requalification Project Engineer Date:- - / 1 - 7 7_

/. i 1

.c , . -, -..

Sheet 2 of 2 Attachment 1, pg. 79 of 90 RANCHO SECO OIESEL GENERATOR REQUALIFICATION ENGINEERING SUft1ARY REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-799A Engineering Evaluation and Recommendation (Continued):

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the inspections made, and the actions taken to address the above additional concerns, this. valve is acceptable for its intended use at Rancho Seco.

R 1

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Sheet }_ of 2 Attachment 1, pg. 80 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

INTAKE AIR SILENCER Part Number: 03-805C

REFERENCES:

CIOR MC172-211 -

NDE Report Number: NONE Associated Reports: NCR/IM NONE I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required. I i

II. ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS None required.

IV. CORRECTIVE ACTIOj{S, .

None required. l V. M0DiFICATIONS None required.

VI. ADDITIONQL CONCERNS The District was made aware of a concsrn with this component in a 10CFR Part 21 notification, which indicated a possibility that the intake silencer had an internal part not welded in place. The District verified that the end caps were elded in piace (not friction fitted).

- Evaluated Cy: _ ,% e d Date: '

d 87 rj i

~

Reviewed By: OT ka-. . .r C Date: W < '; - b 7

/ Requalification Project Engineer

-v.,

.. . . . = ~ .

Sheet 2 of 2 Attachment 1, pg. 81 of 90 RANCHO SECO DIESEL' GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTIMUATION Diesel Engine Serial Number 81015 Part No. 03-805C ,

i Engineering Evaluation and Recommendation (Continued):

l VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this OR/QR report and the actions taken to address the above additional concern, the intake air silencer )

is acceptable for its intended use at Rancho Seco.  ;

1 1

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-r-- ++,r-- -e -,=v rm- w v v a==

Sheet 1 of 2 Attachment 1, pg. 82 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

INTAKE AIR SILENCER Part Number: 03-805C

REFERENCES:

CtDR MC172-211 NDE Report Number: NONE Associated Reoorts: NCR/IM NONE I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

II. ACCEPTANCE CRIYERIA None required.

III. INSPECTION FINDING _S, None required.

IV. CORRECTIVE ACTIONS None required. )

V. MODI _FICATIONS

~

None required.

l VI. ADDITIONAL CONCERNS The District was made aware of a concern with this component ';n a 10CFR Part 21 '

l notification, which indicated a possibility that the intake silencer had an internal part not welded in place. The District verified that the end caps were welded in place (not friction fitted).

Evaluated By: _ - (w/

c > -- - - Date: / el[ 7 r/ /

Reviewed By: h 7- [eM~d _ Date: A> -/ 'I- J )

/ Requalificationdrojet Enytneer

._. ._ _ . _ _ _ . . _ _. _. ___ ~ - . _ __ . _ _ _ _ _

t 4

Sheet 2 of 2 Attachment 1, pg. 83 of 90 RANCHO SECO DIESEL GENERATOR PEQUALIFICATION ENGINEERING

SUMMARY

REPORJ CONTINUATION ,

Diesel Engine Serial Number 81016 Part No. 03-805C Engineering Evaluation and Recommendation (Continued):

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the T01 Owners Group in this OR/QR report and~ ,

the actions taken to address the above additional concern, the intake air silencer 1s acceptable for its intended use at Rancho Seco.

)

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. . - . . . . . -- .. . _ . . - . . _... _ ~_ . - . - _ _

Sheet 1 of 1 Attachment 1, pg. 84 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

LUBE OIL HEAT EXCHANGER Part Number: 03-8200

REFERENCES:

NO CIDR NDE lleport Number: NONE Associated Reoorts: NCR/IM NONE I. ATTRIBUTES TO BE VERIFIED Quality revalidation is no't required.

II. ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS Not applicable.

H. CORRECTIVE ACTIONS None required.

V. MODIFICATIONS ,

None required.

• VI.

ADDITIONAL CONCERNS The District was also mado aware of other concerns witn this component from IE Notice.79-23, however it pertained to an inadequate desigh of ant'.her manufacturer and another type of diesel. The DR/QR review of the TDI Owners grc.!p has established the adequacy of the heat exchanger at Rancho Seco.

VII. RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the lube oil heat exchanger is acceptable for ;ts intended use at Rancho-Seco; Evaluated Byi << __ Date:

/3 A -

Reviewed By: N [6 d' -

Date': /d M *7-T > <

/ Requalification Project Engine.er

Sheet 1 of 2 Attachment 1, pg. 85 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING SufMARY REPORT Diesel Engine Serial Number 8101),

Engine Train B Part

Description:

LUBE OIL HEAT EXCHANGER Part Number: 03-820D

REFERENCES:

CIDR MC172-208 NDE Report Number: NONE Associated Reports: NCR S-5022 I. ATTRIBUTES TO BE VERIFIED Quality revalidation is not required.

II. ACCEPTANCE CRITERIA None required.

III. INSPECTION FINDINGS Not applicable, however, an excessive amount of loose metal particles were found in

. the heat exchanger during startup inspections.

IV. CORRECTIVE ACTIONS, The heat exchanger was disassembled, steam cleaned, and reinspected for cleanliness,

y. MODIFICATION _S None required.

VI. ADDITIONAL CONCERNS The District m s also made. aware of other concerns with.this component from IE Notice 79-23, however it pertained to ail inadequate design of another manufacturer and another type of diesel. The DR/QR review of the TOI owners group has ,

established the adequacy of the heat exchanger at Rancho Seco.

Evaluated By: -

or >

Oate: / 1 97 Reviewed By: 7b s. e Date: N f ? -P 3

/ Requalification Project Engineer

i Sheet 2 of 2 Attachment 1, pg 86 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ,

i ENGINEERING

SUMMARY

REPORT l

CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-8200 Engineering Evaluation and Recommendation (Continued): _

l l

VII. .RESULTS AND CONCLUSIONS Based upon the evaluation made by the TOI Owners Group in this DR/QR report, the lube oil heat exchanger is acceptable for its intended use at Rancho Seco, i

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Sheet 1 of 2 Attachment 1, pg. 87 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

FUEL OIL DUPLEX STRAINER Part Number: SC-042B / 03-825E

REFERENCES:

CIDR MC172-004 NDE Report Number: NONE Associated Reports: NGR/IM NONE Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Strainer mesh size.

II. ACCEPTANCE CRITERIA Mesh size of 0.055 inches.

III. INSPECTION FINDINGS Mesh size is 0.055 inches. i i

IV. CORRECTIVE ACTIONS j l

None required.

V. MODIFICATIONS ,

l None required. l VI. ADDITIONAL CONCERNS l

The District was also made aware of another concern from IE Information Notice No. l 87-04 where the strainer could become fouled by contaminated fuel oil. At Rancho i Seco this strainer is a duplex style with a differential pressure gauge mounted across it with an alarm set point of 5 PSID. The strainer can be switched from one side to the other when the Delta P reaches 5 PSID. One basket can be cleaned while the other is in use during engine operations. The maintenance matrix requires monitoring of the Delta P during monthly surveillance testing and requires cleaning of the element if the Delta P exceeds 5 PSID. Further, the District has undertaken a rigorous fuel oil testing program which will preclude the possibility of fuel oil i contamination.

~ Evaluated By: a4 C - Date: _,

7 Reviewed By: / M.,..I..I- _

Oate: &/74 /

/ Requalification Project Enginaer

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Sheet 2 of 2 Attachment 1. pg. 88 of 90 RANCHO seq 0 DIESEL GENERATOR REQUALIFICA110N ENGINEERING

SUMMARY

REP;RT CONTINUATION Diesel Engine Serial Number 81015 Part No. SC-042B/03-825E Engineering Evaluatior. and Recommendation (Continued):

VI. REL 1TS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR repnrt, the inspections performed, and the actions taken'to address the above aaditional concerns, the fuel oil strainer is acceptable for its intended use at Rancho Seco.

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Sheet 1 of 2 Attachment 1, pg. 89 of 90 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesei Engine Serial Number 81015 ingine Train B Part Desctiption: FUEL OIL DUPLEX STRAINER Part Numbgr: SC-042B / 03-825E PEFERENCES: CIDR MC172-004 NDE Report Number: NONE Associated Reports: NCR/IM NONE Engineering Evaluation and Recommendation:

I. ATTRIBUTES TO BE VERIFIED Strainer mesh size.

II. ACCEPTANCE CRITERIA i

Mesh size of 0.055 incnes.

III. INSPECTION FINDINGS Mesh size is 0.055 inches.

IV. CORRECTIVE ACTIONS None required. ,

V. MODIFICATIONS Non required.

VI. ADDITIONAL CONCERNS l l

The District was also made aware of another concern f-om IE 7.iformation Notice No. I 87-04 where the strainer could become fouled by contaminated fuel oil. At Rancho Seco this strainer is a duplex style with a differential pressure gauge mountea across it with an alarm set puint of 5 PSID. The atrainer c a be switched from one side to the other when the Delta P reaches 5 PSID. Ona Lasket can be cleaned 'ihile the other is in use during engine operations. The maintenance matrix requires monitor $ng of the Delta P during monthly surveillance testing and requiras cleaning of the element if the Delta P exceeds 5 PSID. Further, the District has undertaken a rigorou fuel oil testing program which will preclude the possibility of fuel oil contamination, p Y ,

l Evaluated By: _ Va u . < - 'o =

~ Date: /'i// Y/C 2

/

C

-Reviewed By: ,, O 7 d .,.[,o I '

Date: / 7-/ 7 -Tr /

/ R9qualificatioi) Project Engineer

Sheet 2 of 2 Attachment 1, pg. 90 of 90 RANCHO SECO DIESEL GENERATOR REQLALIFICATION ENGINEERING $U,'AM,ARY REPORT CONTINUATION Diefe'. Engine Serial Number 81015 Part No. SC-0428/03-825E Engineering Evaluation and Recommendation (Continued): .

VI. RESULTS AND CONCL'JSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR ieport, the inspections performed, and the actions taken to 'ddress the above additional concerns, the fuel oil strainer is acceotable for its intended use at Rancho Seco.

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Attachment 2, pg. 1 of 5 RANCHO SECO NUCLEAR GENERATING STATION DELAVAL DIESEL GENERATOR TESTING /0PERATING HISTORY In response to an NRL request for TDI diesel testing information (ref. NRC istter dated January 31, 1984; Enclosure #2, questions 7 and 8) the District is providing the following response as a synopsis of diesel testing.

The following pages provide a detailed summary of the testing and operating history of Rancho Seco's 3500 KW Transamerica Delaval diesel generators.

These generators were installeo in 1984 when it became evident that, due to plant safety upgrades, more energency power was needed to operate additional safety related equipment and systems. The subject engines are 8 cylinder, model DSR-48 diesels with serial numbers of 81015-3057 and 81016-3058. These diesels drive 3500 KW (nameplate) N.E.I. Parsons-Peebles synchronous generators at a rated speea of 450 RPM.

As a result of a Transamerica Delaval diesel generator crankshaft failure at the Shoreham Nuclear Power Station and other subsequent engine quality problems, the utility industry organized a TDI Owners Group to address TDI diesel reliability. This group, after extensive review, developed a corrective action program *.o be implemented prior to and after plaring the TDI diesels into nuclear service. A site implementation plan was neveloped to implement this program at Rancho Seco in three basic phases. Piase "A" involved a pre-run engine tear dowr.. Phase "I" involved prelimina/ diesel engine runs and tests (prior to Phasa "B") and later, preoperati.y al testing (after Phase "B"). The third phase w. Phase "B" which involver. additional engine teardowns for wear and clearance inspections, etc., aftur preliminary engine runs.

Phase "A" engine inspections and part replacements were performed prior to initial engine runs to ensure that conditions and materials were satisfactory to prevent possible engine damage. This phase of the test program cddressed the 16 known generic problem areas identified by the Owners Group program along with various other areas of concern. These areas were addressed using the District's Construction Inspection Data Report (CIDP.) format. Do Phase "A" teardown occurred from November 1984 to February 1985. As a result of these Phase "A" inspections, all engine piston skirts were rephetd along with various bolting hardware on the turbocharger, flywheel and engine.

Several engine bearing shells were replaced due to their not meeting minimum radiographic acceptance criteria. Rust and dirt were removed from the turbocharger during a disassembly inspection. Full details of the Phase "A" engine work are contained in the partial Rancho Seco final Design Review /

Quality Revalidation (DR/QR) report submitted to the NRC on July 8,1987.

Following the completion of Phase "A" teardown work, testing of the individua'. diesel support systems (Jacket water, fuel o'1, starting air) was per#ormed on piping, mechanical, electrical and instrumentation components.

Initial electrical checks were performed on MCC's and distribution panels, along with tut'ng of componar.t motors and the diesel contro'. panels.

Mechanical testing cs performed on individual components, ard all diesei piping systems were cleaned and tiushed. Instrumentation and control logic checks and calibrations were also done during this time period (March 1985 through July 1986).

Attachment 2, pg. 2 of 5 This testing was all a prerequisite to initial engine runs under Special Test ,

Proceduc e (STP) 195A & B. The main purposes of STP 195A & B were as follows:

1) Demonstrate automatic operation of the diesel generator system pumps, fans and heaters.

2) Demonstrate the automatic operation of the diesel starting air system and satisfactory engine and component operating temperatures and pressures.

3) Varify all cystem alarms and diesel trips and verify the capability of each air receiver tank to provide enough air for 5 consecutive cold starts.

4) Demonstrate that the generator can be manually synchronized and paralled with a temporary load transformer and that rated voltage is maintained during load shedding with no engine overspeeds.

5) Obtain a minimum of 100 hrs run time at >50% load (>1750KW) and demonstrata satisfactory operation of the diesels at 110% nameplate load (3850 KW) for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> and 100% load (3500 KW) for 22 hours2.546296e-4 days <br />0.00611 hours <br />3.637566e-5 weeks <br />8.371e-6 months <br /> during a continuous 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> run.

6) Perform torsiograph and vibration testing of the diesel generators-and associated piping and components for baseline information.

These test objectives were met as documented with the final STP 195A/B test results. Testing was performed from October 1986 through December 1986.

After initial engine operations, the TDI Owners Group Maintenance Matrix (from the DR/QR report) was placed into effect. Alto, pt.* iodic luce oil testing was begur, which included ferrographic analysis.

. The following major problems were discovered and addressed as a result of STP ,

195A/B testing: '

1) Slow response time on the Woodward Governor allowed overspeed trips when switching between electrical control and mechanical governor controi.

This was resolved by changing the governor oil from Mobilgard 412 +.o Delvac Special 20-40 which has a broader temperature range for optration.

2) Lube oil pump noise and vibration on the "A" engine was initially thought to be caused by out of specification lubricating oil. Oil samples were tested by TDI Delaval, Herguth Laboratories, and Mobil Oil Corporation, and found to meet all specification requirenients. During inve:tigation a nut was found lodged in the engine driven L. O. pump suction foot valve which did not allow the valve to be fully open during operation. Tnis was removed, resulting in a reduceJ 1evel of noise and vibration, and engine testing continued.

3) During testing the engine vibration baseline and tors:ograph test were performed, as required by the TDI Owners Group. The torsiograph testing results were analyzed, resulting in a pre osed qualified load of 3300 KW.

HcMever, various piping vibration problems and turbocharger vibration problems were uncovered. How these problems were addressed is detailed l in a separate report entitled "Report of the Resolutions to Vibration <

Relateu Concerns on the TDI Emergency Diesel Generators." This report will be submitted to the NRC when all vibration concerns have bee,1 l resolved.  ;

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--w n w , =y - -+ e

. --. . . . -_ .- ~ . - -.

Attachment 2, pg. 3 of 5 After completion of initial diesel testing under STP 195A/B, the Phase "B" engine teardown was performed. The purpose of this teardown was to verify proper engine part clearances and to inspect for adverse wear after 100 plus hours of loaded operation. This teardown occurred from December 1986 through- ,

~ February 1987. The highlights are listed below.

1) Due to excessive vibration, the turbochargers were disassembled to inspect for bearing wear, etc. Inspection revealed unsatisfactory bearing wear and the units were returned to Elliot for rework. It was discovered that the rotdrs were out of balance, which was corrected prior to reinstallation. Additional details are contained in the District's final OR/QR report submittal for this component (MP-020).

2) Several fuel injection pumps were replaced due to internal discontinuities and stuck rack extension arms.

3) The engine driven fuel oil pump was replaced Jue to excessive casing wear caused by an' internal alignment problem. ,

4) Several rocker arm assemblies were replaced due to push rod cup holder bores being out of tolerance.

5) Major design improvements were added to tne fuel oil system by installing double walled high press .re injection tubing with a visible leak and detection system from the pump outlets to the injectors. Also, i-'gh temperature / pressure flex lines were installed from the fuel oil header to the injection pump inlet and from the pump excess flow port to the by-pass return line. These modifications improved system pressure boundary integrity.

Full details of Phase "B" teerdown results are documented in the Rancho Seco final DR/QR report submitted to the NRC.

In pacallel with the Phase "B" teardown, numerous piping and component vibration problems were addressed by support redesign and installation.

These concerns are addressed in detail in the "Report of the Resolution to Vibration Related Concerns on the TDI Emergency Dicsel Generators". As required in NUREG-1216, an alarm circuit designed to notify Control Room operators when the diesel generators exceed "qualified load" was designed and installed during this time period. Also, engine base metal samples were analyzed for graphite and found to meet TDI Owners Group recommendations.

Following phase "B" teardown and new support installations for vibration

- attenuation, final preoperational testing was performed under STP 1009A/B.

The main purposes of these tests were as follows:

1) Demorstrate diesel generator reliability by successfully completing 35 valid test starts per engine.

2) Demonstrate that diesel generator maintains rated voltage after rejection-of 3000 KW and that no engine overspeed trip occurs. ,

3) Perform a 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> diesel generator run at 3000 KW,  ;

4) Verify that diesel generator control panel internal temperatures do not exceed design parameters while Lt 3000 KW for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />.

3 j

, . . . . . .m Attachment 2, pg, 4 of 5

5) Demonstrate 6iesel operation, incTuding voltage end frequency control, from the remote controls in t5e Main Control Room.

6) Demonstrate that the diese) autamatic6tly starts &fter the receipt of a sin ~,ulated Engineered Safety Features ActuRtion System (ESFAS) signal, generates rated voltage and freqvancy, and is re&6y to accept load, within 10 seconds.

7) Demonstrate the diesel capability to 6perate for a period of time with no load, and then assume full load without shutdown or adverse effects.

8) Demonstrate that diesel ger.erators chn be manually synchroniied and paralleled with the associated preferred offsite power supply through the associated Class IE 4160 V bas, and can ba loaded.

These test objectivet were met as documented with the final STP 1009A/B test results. Testing was performed from April 1987 through August 1987. The following major problems were discovered and addressed as a result of this testing.

1) Woodward governor response time and stability continued to be a problem.

Governor hydraulic oil was switched to Automatic Transmissica Fluid (ATF) to alleviate this problem. During this changeou.t excessive metal '

filings and dirt were found in the governor internals. The units were removed anu shipped to the governor ve,idor (Woodward Governor Co.) for cleaning, inspection, and repair as cequired. Also, <.de servoboosters were inspected and cleaned alors with the governor heat exchangers.

Upon their re' urn from the vendar, the governor components were verified by the District to be clean prior to installation and ATF was used as hydraulic oil. The governors performed satisfa'torily c during centinued testing both in response time and sensitivity.

2) Af ter a 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> loaded diesel run, a simu'eated ESFAS signal was generated, but the diesel did not start f4r approximately 90 to 120 seconds. This was due to the inherent design of the TDI pneumatic i controls, which required an approximate 2 minute air bleed off time prior to restarting the engine. It was initially concluded th&t 90 seconds would be considered as "immediate" for a fast restart from an ESFAS signal, but the, District later decided to implement a TOI (vendor supplied) design change to the controls. This design change allows for an immediate restart instead of waiting 90 seconds, and it was installed and tested satisfactorily.

3) The retest of various piping and ccmponents indicated that some modifications to resolve vibration concerns were successful while others were inadequate. Or,co again, these are detailed in "Report of the Resolutions to Vibration Re?ated Concern 2 on the TDI Emergency Diesel Generators" which will be submitted separately'. ,

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Attachment 2, pg. S of 5 Automatic starts and load sequencing testing will be documented in the integrated ?_oss of Offsite Power Test (STP-961). A number of test '.tems previously performed in STP 1009A/B n'll be retested in STP 1134A/B. This test will also document starting air system air loss rates during diesel operations and Ivbe oil consumption rates. The intent of this testing is to address all open test items from previous testing and bring the TDI diesel test progr.'n to a satisf actory completion.

Continued diesel generater reliability will be improved due to the adherence to the TOI Owners Group cnhanced Maintenance Matrix Program and a detailed Surveillance T6st Program. These programs, coupled with the extensive requalification test effort, will ensure reliable TDI diesel generator operations at Rancho Seco in support of plant power operations.

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