Text

Rev 2 to Tdi Diesel Generator Design Review & Quality Revalidation Rept
	ML20198S400
Person / Time
Site:	Washington Public Power Supply System
Issue date:	04/30/1986
From:	Segrest A; TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP
To:	;
Shared Package
ML20198S391	List: ML20198S388; ML20198S400;
References
	NUDOCS 8606100414
	Download: ML20198S400 (66)
	v • d • e

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TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT Prepared For WASHINGTON PUBLIC POWER SUPPLY SYSTEM WASHINGTON PUBLIC POWER SUPPLY SYSTEM - NUCLEAR PROJECT 1 N By ,

TDI DIESEL GENERATOR OWNERS GROUP Revision 2 April 1986

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A M6egrest

' ' Program Manager TDI Diesel Generator Owners Group 1

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O TDI OWNERS GROUP APPENDIX - II GENERIC MAINTENANCE MATRIX l

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i TDI OWNERS GROUP GENERIC MAINTENANCE MATRIX l APPENDIX - II i

OVERVIEW ANO DEFINITIONS OPERATING AND STAND 8Y SURVEILLANCE PARAMETERS i

PART A

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TDI OWNERS GROUP GENERIC MAINTENANCE AND SURVEILLANCE PROGRAM APPENDIX - II I INTRODUCTION The purpose of this appendix is to provide the TDI Owners with a set of maintenance and surveillance recommendations for diesel generator com-ponents which have been developed by TDI and/or the Owners Group as a result of the cverall Owners Group Program and including subsequent testing and inspections performed following the review conducted by the original program. This appendix is intended to enhance the existing TDI Instruction Manual, Volume I and Volume III, which will maintain the qualification of the diesel generators for the life of the plant.

II METHODOLOGY During the implementation of the Owners Group Program Plan, the Owners Group Technical Staff reviewed many sources of information regarding the maintenance and surveillance for the diesel generator components iden-tified in this appendix. These sources included TDI Instruction Manuals, Service Information Memos (SIMS), and TDI correspondence on specific O+' components. The basis of this matrix is formed by the following:

Owners Group Technical Staff review of TDI Instruction Manuals, SIMs, and TDI correspondence on specific components.

Technical Staff input regarding the adequacy of recommendations found in sources mentioned above.

Additional maintenance recommendations identified during the DR/QR review.

Results of subsequent testing and surveillance (i.e. , Shoreham EDG103 750-hour endurance run and subsequent engine teardown) performed following the review conducted during the original program.

Additional review by the Owners Group representatives.

It should be noted that this revision in some cases modifies the original program results based on this additional information and review.

III RESULTS AND CONCLUSIONS l

1 Proper maintenance is important in ensuring long, reliable and satis-factory service of the emergency diesel generators. Maintenance work, in order to be effective, must be carried out thoroughly and regularly. It II-A-1 Revision 2

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l is for these reasons that a detailed schedule of maintenance service has been laid out by the Owners Group for the TDI Diesel Generators. This schedule should be followed as closely as the operating conditions will permit. This maintenance service as specified supersedes previous general

, maintenance requirements, but is separate and does not supersede Quality Revalidation and/or modifications previously recommended. The schedule details specific components requiring maintenance on a regular basis.

This schedule separates the maintenance activities into frequencies as set

forth in the subsequent list of definitions.

Inspections, as outlined in this maintenance schedule, are to be performed and parts refurbished or replaced as required by the program or deemed necessary by the inspection. Any adverse findings shall be investigated and corrective action, including amended inspection frequencies, shall be implemented unless sufficient justification is present to do otherwise.

This generic matrix, Parts A, B, C together with Part D entitled " Site-Specific Maintenance Matrix" and the sources defined in Section II form the T.DI Maintenance Program. Note that component numbers used in the generic matrix are for Texas Utilities' Comanche Peak Steam Electric Station - Unit 1. Part E provides a cross reference to identify corre-

, sponding components for other engines. Also note that a blank in the cross reference signifies that a component is not on a particular engine and thus that Owner would not perform that maintenance item.

Tables 1 and 2 of Part A provide engine operating and standby surveillance parameters and frequencies. It is recommended that the utility address these tables in its operating and monitoring programs. Table 1 addresses operating parameters and is not duplicated in the maintenance schedules; these parameters are to be recorded and/or checked during the monthly testing and any other period of operation. Table 2 addresses the standby

. parameters that occur on a daily frequency and are not duplicated in the maintenance schedules.

IV. DEFINITION OF TERMS

1. Overhaul Frequency a) A complete engine teardown and inspection will be performed every 10 years. The utility has the flexibility to inspect one engine / reactor unit at the E0C prior to 10 years and the other engine at the EOC following 10 years. Alternately for PWR units, the inspection l may be performed coincident with the 10 year reactor vessel in-service inspection. This will permit both engines for each unit to be disassembled in parallel since one engine will not have to remain in service with the reactor vessel off loaded. (For reactor units having three engines, the inspections are to be carried out as above a with the third engine to be inspected at the second E0C following 10

. years). The 10 year interval will typically be taken from issuance

- of the Low Power Operating license or from subsequent teardown and 4

inspection for plants already in operation.

LI-A-2 Revision 2

l b) A one time inspection will be performed at the EOC closest to 5 years. For a unit, one engine may be inspected at the EOC prior ta 5 years and the other at the E0C after 5 years to minimize plant outage length. (For reactor units having three engines, the inspections are to be carried out as above with the third engine to be inspec'.ed at the second E0C following 5 years). This inspection will generally involve the same components as the 10 year teardown; however, only a sample of items for some components will be inspected as set forth in the maintenance schedule. During this 5 year inspection any signifi-cant adverse findings of a particular component will result in an inspection of all such components of that engine to determine any adverse trends. Favorable findings will result in reassembly of the engine for service.

2. Daily Frequency - To be performed once per day.

3. Monthly Frequency - To be performed once in a month; normally during,-

before, or after test run per plant Technical Specifications.

4. E0C - (End of Cycle) - To be performed once during outage for refueling.

5. Alternate EOC - To be performed once every other outage for refueling.

6. Five Years - To be performed once at the E0C occuring nearest to the end O

V of a recurring 5 year period.

7. As Required - To be performed as often as good maintenance, site proce-dures, manufacturer's recommendations, or experience dictate as determined by site personnel.

8. Maintenance - Monitoring and/or surveillance on a periodic frequency to assure the component will perform its intended function in a safe reliable manner.

9. Accessible -

Any item on which the required function can be performed without disassembly of an engine component. Removal of defined access cover is not considered disassembly.

10. Appropriate NDE - Nondestructive examination selected by site personnel that is most suitable to obtain the information sought by an individual inspection item; choice of NDE shall be made to assure that the technique will detect indications consistent with the acceptance criteria.

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II-A-3 Revision 2

TABLE 1 Diesel Engine Operating Surveillance Parameters and Frequency l

Component Frequency

1) Lube Oil Inlet Pressure to Engine Log hourly

2) Lube Oil Filter Differential Pressure Log hourly

3) Lube'011 Temperature (engine inlet and Log hourly outlet)

4) Lube Oil Sump Level Log hourly

5) Turbocharger Oil Pressure Log hourly

6) Fuel Oil Filter Differential Pressure Log hourly

7) Fuel Oil to Engine Pressure Log hourly

8) Fuel Oil Day Tank Level Check hourly

9) Jacket Water Pressure (engine inlet) Log hourly

10) Jacket Water Temperature (in, out) Log hourly

11) Engine Cylinder Temperature Exhaust - Log hourly All (If temperature in any one cylinder exceeds 1050 , refer to MP-022/023 Item 7.)

12) Manifold Air Temperature (RB, LB for Log hourly DSRV Engines)

13) Manifold Air Pressure (RB, LB for Log hourly DSRV Engines)

14) Starting Air Pressure (RB, LB for Check hourly DSRV Engines)

15) Crankcase Vacuum Log hourly

16) Engine Speed Log hourly

17) Hour Meter Log hourly O

II-A-4 Revision 2 1

l TABLE 1 (Cont'd)

Diesel Engine Operating Surveillance Parameters and Frequency Component Frequency

18) Kilowatt Load Log hourly

19) Visual Inspection for Leaks, etc. Check hourly O

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(d TABLE 2 Diesel Engine Standby Surveillance Parameters and Frequency Component Frequency

,1) Lube Oil Temperature (in, out) Log daily

2) Lube Oil Sump Level Log daily

3) Check Operation of Lube Oil Daily Keep-Warm Pump Motor

4) Monitor Lube Oil Keep-Warm .

Daily Strainer and/or Filter Differential Pressure

5) Perform a visual inspection for Daily leakage of the Lube Oil Heat Exchanger. Verify that no leakage through the leak-off ports of the lantern ring is present.

6) Fuel Oil Day Tank Level Log daily

7) Jacket Water Tempera *ure (in, out) Log daily

8) Perform a visual inspection for Daily leakage at packing for Jacket Water Heat Exchanger whenever the engine is in the emergency STANDBY mode. Verify that no leakage through the leak-off ports of the lantern ring is present.

9) Governor Oil Level Daily

10) Verify proper oil level of Daily generator pedestal bearing

11) Starting Air Pressure Log daily

12) Drain air receiver float traps Daily and/or drain Starting Air Storage Tank and monitor the quantity of moisture produced. If quantity of moisture is excessive, correct immediately.

II-A-6 Revision 2

i TABLE 2 (Cont'd)

Diesel Engine Standby Surveillance Parameters and Frequency Component Frequency

13) Check Operation of Compressor Air Traps Daily

14) Test Annunciators Before Engine Operation

15) Check Alarm Clear Before Engine Operation

16) Inspect for Leaks Daily

, 17) Visually inspect intercooler for Daily external leaks including intake manifold drain connection.

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TDI OWNERS GROUP APPENDIX - II GENERIC MAINTENANCE MATRIX PART B PHASE I COMPONENTS O

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I l GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.

Number Identification PM Recommendation Monthly E0C EOC 5 Year Overhaul Comments i MP-022/23 Turbocharger 1. Measure vibration and X To be accomplished during

. check with baseline data. 24-hour test run.

2. Inspcct impeller /dlffuser X i

and clean if necessary.

3. Measure rotor end play X Review thrust bearing

, (axial clearance) to axial clearances after identify trends of inspection to determine increasing clearance if a trend exists. Any i.e., thrust bearing trend toward increasing degradation. axial clearance could signify thrust bearing degradation.

4. Perform visual and blue X Note: Thrust bearing check inspections of inspection should also

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the thrust bearing. be performed after experiencing each 40

non prelubed (automatic) fast starts. In addi-i tion, a one time inspec-i tion should be completed I after the first 100 engine starts.

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5. Disassemble, inspect, X Note: During reassembly l and refurbish, ensure that capscrews are -

- properly installed with the recommended torque.

l If QR inspection was l performed prior to accu-

' mulating significant

- hours (ip., the number of hours accumulated i during plant preopera-l tional testing, approxi-mately 100 hours0.00116 days 0.0278 hours 1.653439e-4 weeks 3.805e-5 months ), the turbochargers should be reinspected at the next EOC.

II-B-1 Revision 2

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\' / GENERIC MAI ANCE MATRIX - PHASE I s_ /

Component Component Alt.

Number Identification PM Recommendation Mor.thly EOC EOC 5 Year Overhaul Comments

6. The nozzle ring com- X Also perform a visual ponents and inlet inspection on one turbo-guide vanes should be charger per nuclear unit visually inspected at each EOC.

for missing parts or parts showing distress. Note: Discontinue inspec-If such conditions are tion with appropriate re-noted, the entire ring design.

assembly should be re-placed.

7. Monitor inlet tempera- Monitoring may be per-ture to ensure gas tem- formed using permanent perature does not exceed in-line thermocouple, manufacturer's recom- strap-on thermocouple, sendation of 1200*F if heat gun, er other suit-exhaust temperature for able means that has been any cylinder exceeds appropriately tested and 1050*F (Ref r: Table 1). calibrated per plant pro-cedures.

Note: Also perform non-itoring any time the engine operates in an unbalanced condition.

02-305A Base Assembly 1. Perform a visual inspec- h Note: Any cracks detected Lion of the base. The must be investigated inspection should include further before the engine the areas adjacent to the is allowed to return to nut pockets of each bear- service. The mating sur-ing saddle and be con- faces of the base and cap ducted after a thorough shall be thoroughly cleaned wipe down of the surfaces, with solvent before any using good lighting. reassembly. Perform on EOC basis for 3 cycles, then overhaul provided there are satisfactory results.

Note: 3 E0C inspections may be eliminated by per-forming a metal analysis to confirm consistent to class 40 grey iron requirements; performing analysis does not elimi-nate need for overhaul inspections.

Il-B-2 Revision 2

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U GENERIC MAINTENANCE MATRIX - PHASE I J

1 l Component Component Alt.

Number Identification PM Recommendation Monthly M M 5 Year Overhaul Comments

{ 02-305C Main Bearing Caps - Studs 1. The mating surfaces at and Nuts the bearing cap / saddle interface should be inspected when dis-

, assembled to ensure the absence of sur-

! face imperfections' l . that might prevent j tight boltup.

l l Note: Upon removal of i bearing caps, clean mating j surfaces with a solvent j prior to reassembly of the caps to the base.

02-310A Crankshaft See site specific

! recommendations i

02-315A Cylinder Block See site specific l recommendations 02-315C Cylinder Liners 1. Perform a visual inspection To be performed for first of liners for progressive 2 EOCs following piston wear. removal; then discon-

tinue until next piston removal. Boroscopic inspection is acceptable if heads are not removed.

Complete TDI Inspection and Maintenance Record d

Form No. 315-1-1 as applicable TDI In-struction Manual, Volume I, Section 6.

, 02-340A/B Connecting Rods, Bushings 1. Inspect and measure all X Complete 101 Inspection-and Bearing Shells connecting rod bearing and Maintenance Record (Generic) shells to verify lube oil Form No. 340-1-1 as maintenance, which affects applicable. TDI In-wear rate. struction Manual, Vol-une 1, Section 6, Appendix Ill for clearance values.

Perform inspection at 5 years, on items acces-sible, consistent with item 2 of this compo-nent.

Il-B-3 Revision 2

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GENERIC r i iENANCE MATRIX - PHASE I Component Component Alt.

L Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments

2. Inspect and measure X Complete TDI Inspection the connecting rods. Maintenance Record Form No. 340-2-1, -2 as Note: Perform inspection appitcable. TDI In-and measure four connecting struction Manual, rods for DSRVs and two for Volume I, Section 6.

DSRs at randon at one time 5 year inspection.

3. Perform an x-ray examin- This is to be performed ation on all replacement prior to installation bearing shells to acceptance of any replacement criteria developed by Owners bearing shells as required.

Group Technical Staff.

4. All connecting rod bolts, X Perform inspection at nuts, and washers should 5 years, on items acces-be visually inspected, and sible, consistent with damaged parts should be item 2 of this component.

replaced. The bolts should be MT inspected to verify the continued absence of cracking.

No detectable cracks should be allowed at the root of the threads.

5. During any disassembly that Perform inspection, as exposes the inside diameter required and on items of a rod-eye (piston pin) accessible, consistent bushing, the surface of with Item 2 of this the bushing should be LP component.

inspected to verify the continued absence of linear indications in the heavily-loaded zone width 115 degrees of the bottom dead-center position.02-340 A/B Connecting Rods, Bushings 6. Measure the clearance between To be performed once for DSRV's and Bearing Shells the link pin and link rod. each connecting rod.

only This clearance should be zero 1.e., no measurable clearance when the specified bolt torque of 1,050 ft-Ibs is I applied.

Il-B-4 Revision 2 L_ __ __ _

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GENERIC MAIN 1ENANCE MATRIX - PHASE I Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments

7. At the overhaul, visua11y X inspect the rack teeth surfaces for signs of fretting and at one time 5 year inspection for rods disassembled.

8. Inspect nating surfaces To be performed once to verify that the minimum for new and/or re-manufacturers' recommended placement parts.

percent contact surface is available.

9. If connecting rod bolt stretch X Also to be performed was measured ultrasonica11y at any time the connect-during reassembly following ing rod is disassembled.

the preservice inspection, Perform inspection at the lengths of the two pairs 5 years, on items of bolts above the connecting accessible, consistent rod should be remeasured with item 2 of this ultrasonically before the component.

link rod box is disassembled.

If ultrasonic measurement was not previously used, begin use at next inspection that accesses the connecting rods. Measure bolt stretch before disassembly.

10. All connecting rod bolts X Also to be performed should be visually inspected at any time the connect-for thread damage (galling) ing rod is disassembled.

and the two pairs of connect- Perform inspection at ing rod bolts above the 5 years, on items crankpin should be MT inspec- accessible, consistent ted to verify the absence of with item 2 of this cracking. All washers used component.

with the bolts should be examined visually for signs of galling or cracking and replaced if damaged.

11. A visual inspection should X Also to be performed be performed of all external at any time the connect-surfaces of the link rod ing rod is disassembled.

box to verify the absence Perform inspection at of any signs of service- 5 years, on items included distress. accessible, consistent with item 2 of this component.

II-B-5 Revision 2

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\ r i j GENERIC MAI ENANCE MATRIX - PitASE I Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments

12. All of the bolt holes in X Also to be performed the link rod box should at any time the connect-be inspected for thread ing rod is disassembled.

damage (galling) or other Perform inspection at signs of abnormalities. 5 years, on items Bolt holes subject to the accessible, consistent highest stresses (the with item 2 of this pair immediately above the component.

crankpin) should be examined with an appropriate non-destructive method to verify the absence of cracking. Any indications should be recorded for evaluation and corrective action.

02-341A Pistons 1. Inspect and measure skirt X Complete TDI Inspection and piston pin. This and Maintenance Report item assumes that AE skirts form No. 341-1-1 as are installed. For other applicable TDI types, see site-specific Instruction Manual, recommendations. Volume I, Section 6.

Use Volume 1, Section 8 Appendix III for clear-ance values. To be performed at 5 year interval on sampling basis consistent with Component 02-340A/B-Connecting Rods.

02-360A Cylinder Head 1. Visually inspect cylinder X Complete TDI Inspection heads (all cylinders). and Maintenance Record Form No. 360-1-1 as Note: Inspection by applicable, TDI boroscope is acceptable. Instruction Manual, Volume I, Section 6 -

one sheet for each head.

To be performed at 5-year interval on sam-pling basis consistent with Component 02-340 A/B - Connecting Rods.

2. Record cold compression X If so indicated - remove pressures and maximum cylinder heads, grind firing pressures. valves, and reseat.

Refr: TDI Instruction Manual, Volume I, Section 6.

Il-B-6 Revision 2

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(/ (\.3/ 'j GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments

3. Biow-over the engine at in the event water is least 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months but not detected, the cylinder more than 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months after head should be replaced engine shutdown. The or returned to the vendor cylinder cocks should for repair. Delete post-be open for detection run air roll requirements of water leakage into for engines with Group III the cylinders. A second heads after one cycle air roll should be with positive inspection performed.in the same results.

manner ap' proximately 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months after engine shutdown. In addition, the engine should be air rolled shortly before any planned start.

4. Visually inspect the area X If water leakage is around the fuel injection detected, the head (s) port on each cylinder head should be replaced.

during the normal monthly run for signs of leakage.

02-365C Fuel Injection Tubing 1. Check tubing for leaks X All fuel oil leak in-at compression fittings. spections to be per-formed while the engine is running or whenever the compression fittings have been disturbed.

2. Visually inspect tubing X Fitting inspection for lengths for fuel oil leaks leaks to be performed or cracks if tubing is at engine operation unshrouded. If shrouded, following shutdown.

fuel oil leakage can be Subsequent inspections detected at the leak-off to be performed period-ports in the base nuts, ically as indicated.

which are provided for Unshrouded tubing, used this purpose. as replacement, should be fully inspected con-sistent with FaAA NDE Procedure 11.10 prior to bending.

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O O GENIRIC MAINTENANCE MATRIX - PHASE I O

Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-390C Push Rods 1. Each push rod of the X Refr: PNL-5600 forged-head design should be inspected by liquid penetrant prior to installation or, if installed, at each overhaul.

This should be repeated, until it has been deter-mined by 750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months of operation at the load level used for survell-lance testing that the push rod will not develop service-induced cracks.

' Push rods confirmed in this way need be examined only visually at subsequent overhauls. Push rods of

the forged-head design

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exhibiting cracks larger l than 0.25 inch should be replaced, preferably with push rods of the friction-welded design. Each forged-head rod should also be visually inspec-ted one time to confirm that the head was fully inserted in the tube prior to welding.

2. Each push rod of the fric- X Refr: PNL-5600.

tion welded design should be inspected initially by liquid penetrant. If this If initial inspection was initial inspection was not not perfomed, perform on performed prior to placing sampling basis at 5 year the push rods in service, inspection consistent it should be performed at with Component 340A/B -

the first overhaul. If the Connecting Rods.

i friction welded push rod j has been previously in-

spected by liquid pene-

, trant, then visual exami-nation will suffice for future inspections. All friction-welded push i.ts with cracks should be replaced, preferably with *

! push rods of the same l design.

II-B-8 Revision 2

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GENERIC MAINH NANCE MATRIX - PHASE I /

Component Component Alt.

Number Identification PM Recommendation Monthly 10C EOC 5 Year Overhaul Comments 02-390G Rocker Arm Capscrews, 1. Verify capscrew togque Use TDI Instruction Drive Studs (Pop Rivets) values during QR u. spec- Manual, Volume 1, Lion. If not performed Section 8 Appendix at QR, verify at next IV for proper torque EOC, then as required at values.

reassembly.

2. Verify that rocker are drive studs are intact and tight during QR inspection or EOC1, then as required at reassembly.

02-425A Jacket Water Pump - Gear 1. Visually inspect jacket X Any abnormal situations water pump gear for or indications of pro-chipped or broken gressive pitting should teeth, excessive wear, be reported for an pitting or other engineering evaluation.

abnormal conditions. For engines with less than 750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months , also inspect by E002.

2. Check the key to keyway X This along with the dHve interface for a tight fit of the impeller onto fit on both the pump the shaft will preclude shaft to impeller and past problems where the spline to pump relative motion between shaft during pump shaft and impeller caused reassembly. fretting and upset of the keyway sides.

At next teardown, verify impeller is one piece, (i.e., without a bore insert). If it is not a one piece impeller, replace.

3. It is recommended that the castle nut that drives the external spline on its taper have minimum and max-imum torque values of 120 ft-lbs and 660 ft-Ibs respectively for DSRVs and a maximum torque value of 77 f t-Ibs for D5Rs.

11-8-9 Revision 2

O TDI OWNERS GROUP APPENDIX - II GENERIC MAINTENANCE MATRIX PART C PHASE II COMPONENTS O

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J O O GENERIC MAINTENANCE MATRIX - PHASE 11 Component Component Alt.

Number Identification PM Recommendation Monthly M EOC 5 Year Overhaul Comments F-068 Intercoolers 1. Record the following X temperatures during the monthly surveillance test of the engine: exhaust from cylinders and jacket cooling water supply.

Compare these results with similar data from previous month to establish whether the trend is sufficient to warrant further action.

2. Inspect shell and Inspect at E0Cl and EOC3 tube sides, and clean to verify iten I results as required. are valid.

3. Verify intake manifold X Note: Refer to 101 SIM i

drain connection is to be issued subsequent open and clean. to March 1986.

4. Perform leakage test of X water side boundary for gross degradattan.

CP-101A Emergency Generator 1. Check operation of X brushes and slip rings by visual examination during operation.

I 2. Inspect all accessible X parts of the generator, and clean as required.

3. Megger rotor and stator. X

4. Verify that space heaters X

are on with engine shutdown.

5. Measure vibration and X check against baseline data.

CP-101B Entrgency Generator Pedestal 1. Drain, flush, refill X 8 ear mg bearing housing.

2. Measure bearing housd.y X insulation resistance.

Il-C-1 Revision 2

GENERIC MAINTENANCE MATRIX - PHASE II Alt.

Component Component 4 Number Identification PM Recommendation Monthly g g 5 Year Overhaul Comments

3. Disassemble and inspect X bearing and check clearances.

CP-102 Emergency Generator 1. Inspect panel for X Control Panel cleanliness and clean as required.

2. Check terminal boards X for loose wiring.

3. Visually check condition X of wire insulation for degradation.

4. Clean and inspect relay X contacts.

5. Check meter calibrations. To be performed per appropriate site intervals for similar equipment.

6. Bridge rectifier assembly. Note: Inspections may be deleted after modifications as prescribed in DR/QR Report.

a. Inspect the temperature X If the label permanently sensitive label placed blackens, the maximum on the most visible temperature of the face of the hexagonal diode has been exceeded, body of the diodes, requiring an electrical The label shall be inspection of the diode inspected before and and an inspection of after each running the mounting threads of the engine. of the heat sink and diode.

Replace ~the diode and the heat sink as needed and assure that proper mounting tightness of 300 in-Ibs and proper tleread condition is maintained.

Il-C-2 Revision 2

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GENERIC MAINTENANCE MATRIX - PHA5E II Component Component Alt.

Number Identification PM Recommendation Monthly M EOC 5 Year Overhaul Comments

b. Inspect glyptol applied X Retighten any loose to the side of the lugs connections, remove and mounting bolt for old glyptol, and reapply the lugs which attach if connections are to the bottom of the retightened.

diode and SCR heatsinks for signs of relative motion.

7. Adustment potentiometers - X If adjustments are inspect glyptol applied needed, remove glyptol, to the the side of the and reapply when the adjustment screws for each adjustment procedure of the five adjustment is complete.

potentiometers on the printed circuit board of the voltage regulator for signs of relative motion.

8. Printed circuit boards - X Report any bnormal 4

check for cleanliness condition', to engineer-l and proper mounting of ing for evaluation.

) components.

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9. Implement a procedure to Ib'.s recommendation is monitor generator voltage sequired until such time at start. A manual that modifications are reset of the exciter must made to the time delay be performed in the event relay latching lugic in of a failed start. the generator control.

1 00-420 Lube Oil Pressure Regulating 1. Disassemble and clean. X If valve sticks repeat-Valve edly, more frequent cleaning may be necessary. If valve plugging becomes a prob-lem, the dimensions of the valves internal parts I should be checked to I ensure proper clearance.

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2. During initial startup after a major reassembly of tube oil piping, abnormal lube oil pressure excursions should be investigated and remedial action taken until excursions subside.

Il-C-3 Revision 2

i C O GENERIC MAINTENANCE MATRIX - PHASE 11 o

Component Component Alt.

Number Identification PM Recommendation Monthly EOC g 5 Year Overhaul Comments Visually inspect the X Evaluate the degree of 00-442A Starting Air Distributor 1.

wear to determine Assembly poppet valve spool ends and timing can of the whether existing starting air distributor. condition would have an adverse effect on timing and the specified ability to start the engine.

2. Ensure that the starting X Note: Inspect at EOC1 air manifold went is for sites that did not

-open and unobstructed by perform QR Inspection noting the escape of after plant pre-opera-air during engine startup, tional testing.

Lube Oil Tubing and 1. Check accessible tubing To be performed as 02-307B required.

Fittings - Internal for dents or crimps after performing main-tenance in that area.

Main Bearings Shells 1. Inspect and measure thickness X Note: Perform inspec-02-310B tion on bearings 5 & 7 of all main bearing shells, Inspection shall evaluate for DSRVs and mains bearing wear and evidence between 5 & 6, and of harmful crankshaft 6 & 7 for DSRs on one misalignment. If results engine / station at E0C2.

show evidence of mis- At one time 5 year in-alignment, IDI recom- spection, inspect bearings mendations for crankshaft 3 through 8 inclusive.

realignment should be Complete IDI Inspection implemented. and Maintenance Record Fom No. 310-2-1 as applicable, 101 Instruction Manual, l

Volume I, Section 6 -

one sheet for each main

' bearing. Use Volume I, Appendix 111 for clearance values. Also inspect when removed consistent with inspections required for Component 02-310A.

Il-C-4 Revision 2

0 GENERIC MAINTENANCE MATRIX - PHASE 11 C

Component Component Alt.

Number Identification PM Recommendation Monthly M [0C 5 Year Overhaul Comments 02-310C Thrust Searing Ring 1. Measure thrust bearing X Complete applicable ring clearance by sections of TDI

" bump check" method to be Inspection and Main-performed in conjunction tenance Record Form with crankshaft web No. 310-1-1 TDI Instruc-t deflection measurements. tion knual, Volume 1, The following information Section 6.

should be recorded:

Note: If the clearance is greater than the maximum

Date of inspection allowed in the 101

Hours of engine operation Instruction knual,

Hours of engine operation at least one bearing must be replaced.

since last bearing re-l placement Bearings should also i

'

Bearing clearance be replaced if they are cracked or gouged.

2. Visually inspect thrust X To be performed at bearing ring for signs 10 year interval only of wear or degradation. (i.e., not at one time l 5 year inspection).

i 02-311A Crankcase Assembly 1. Perform a visual inspection X The first inspection of the vertical portion of after 185 hours0.00214 days 0.0514 hours 3.058862e-4 weeks 7.03925e-5 months of at ,

the crankcase arch wall to or near full load opera- !

the nut pocket area for tion may be used to r indications of cracking. justify the discontinua-tion of such inspection until an overhaul. For engines with less than j

185 hours0.00214 days 0.0514 hours 3.058862e-4 weeks 7.03925e-5 months operation at or near full load, inspect at each EOC until exceeds

! 185 hours0.00214 days 0.0514 hours 3.058862e-4 weeks 7.03925e-5 months .

i I

2. Remove alternate left X If excessive water, sludge l or any indication of '

i side doors and j examine the inside bearing failure is present, of the engine for any drain crankcase, deter-

eine cause, and take abnormal conditions.

Check with a good necessary corrective action, i light for evidence of babbit flakes.

3. Check internals of X i

block and base for leaks, i

I il-C-b Revision 2

N i

GENERIC MAlk'IEhnhCE MATRIX - PHASE 11 Component Alt.

Component Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-317A&B Water Discharge Manifold - 1. Visually inspect for X Jacket Water Discharge leaks.

Piping, Coupilngs and Seals Piston Rings 1. Inspect and measure piston Complete 101 Inspection 02-3418 replacement rings, and Maintenance Record Form No. 341-2-1 as applicable, IDI Instruc-tion Manual, Volume I, Section 6. Use Volume I, Section 8, Appendix III for clearance values.

To be performed as required.

Piston Pin Assembly 1. Visually inspect for X Also to be performed one 02-341C time at the 5 year chrome plate damage.

Replace pins which show inspection on sampling chipped or blistered basis consistent with chrome. Component 340A/8 -

Connecting Rods.

Note: All new or re-placement pins should be Note: Mi may cause FE LP or MP inspected particulate accumulation, before installation in Owners Group engines.

2. Inspect end plugs and X Note: This inspection is reroll or replace any also to be performed one that are loose. time at 5 year interval on sampling basis consistent with Component 340A/B -

Connecting Rods.

02-345A Intake and Exhaust lappet 1. Visually inspect intake and w, X Complete TDI Inspection Assembly exhaust tappet assembly and Maintenance Report condition, and verify that Form No. 345-1-1 as 1, cam rollers are free to appIlcable, 101 Instruc-rotate and that there is Lion Manual, Volume 1 no noticeable clearance be- Section 6. Refr: TDI Instruction Manual, tween the can rollers and the roller pins. Do this Volume 1, Maintenance by manually checking for Schedule. Perform an R. excessive motion and ,

additional inspection by EOC2 on exposed or

~

visually observing for abnormalities on the mat- accessible assemblies.

ing surfaces. Also perform one time at 5 years consistent with Component 02-340 A/B Item 2.

Il-C-6 Revision 2

n U O GENERIC MAINTENANCE MATRIX - PHASE 11 O

Component Component Alt.

Number Identification PM Recommendation Anthly EOC EOC 5 Year overhaul Comments 02-3458 Fuel Tappet Assembly 1. Visually inspect fuel tappet X Complete IDI inspection assembly condition, and and Maintenance Report verify that can rollers Form No. 345-1-1 as are free to rotate and applicable 101 Instruc-l that there is no notice- tion Manual, Volume 1, able clearance between Section 6. Also perform the can rollers and the one time at 5 years roller pins. Do this consistent with Component by manually checking for 02-340 A/8 Item 2. Per-excessive motion and form an additional in-visually observing for spection by EOC2 on abnormalities on the exposed or accessible mating surfaces, assemblies.

02-350A Can Shaft Assembly 1. Perform a visual inspection x Any signs of cracking, of all can lobe surfaces pitting, or spalling shall

for signs of cracking, be followed by a detailed pitting, or spalling, analysis to evaluate i the expected life based on the size and extent of surface distress.

i Any corrective measures shall be implemented as indicated by this analysis. Signs of spalling shall result in i

immediate replacement of the can. Perform an additional inspection by EOC2 on exposed or 4CCe'ssible assemblies.

Ref r: TDI Instruction Manual, Volume I, Maintenance Schedule.

Also to be performed one time at 5 years consistent with Com-ponent 02-340 A/8.

02-3508 Can Shaf'. Bearings 1. Inspect and measure cam X Complete TDI Inspection shaft bearing shells, and Maintenance Record Form No. 350-1-1 as applicable, 101 Instruc-tion Manual, Volume I, Section 6. Use Volume I, Section 8, Appendix 111 i

for clearance values.

Il-C-7 Revision 2

b GiNERIC MAINTENANCE MATRlx - PHASE 11 Component Component i Alt.

M 5 Year Overhaul Comments Number Idertification PM Recommendation %nthly EOC Also at one time 5 year inspection for Cooponent 02-340A/B e,easure clear-

- ances per 101 on one bearing housing / camshaft.

02-330C Can Gear 1. Visually inspect can gear 1 For engines with less for chipped or broken than 750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months , also inspect at EOC2.

teeth, pitting, excessive wear, or other abnormal conditions. At this in-spection, the gear is in immediate proximity to th& spray nozzle which s

should also be visually inspected. .

2. Measure gear backlash. X Complete applicable X sections of TDI Inspec-Note: If cas gear hub tion and Maintecance is removed, it is Record Form No. 355-1-1, recommended that the nut TDI instruction Manual, be relocked at the Volume I, Section 8, position corresponding Appendix 111-1 for to the torque of 10120 clearance values.

ft-lbs. Insertion of the cotter pin must be Note: Refer to TDI accomplished :it a torque SIM to be issued sub-

> 50 f t lbs and 190 sequent to March 1986.

ft -lbs. If this is Also to be performed not possible, another one time at 5 years bolt, nut or washer consistent with Com-should be used. ponent 02-_340 A/B.

02-355A Crank to Lube Oil 1. Visually inspect crank-

~

X Any abnormal situations Pump Gear , shaft to lube oil pump or indications of gear for chipped or progressive pitting should be reported broken teeth, excessive wear, or progressive for an engineering pitting or other abnormal evaluation. For engines conditions. _

with less than 750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months , also inspect by E0C2.

k f

Il-C-8 Revision 2

d b GENERIC MAINTENANCE MAIRIX - PHASE 11 b)

Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments

2. Measure gear backlash. X Complete applicable sections of IDI Inspection and m in-tenance Record Form No. 355-1-1 TDI Instruction k nual, Volume I, Section 6.

Use Volume 1. Section 8 Appendix 111-1 for clearance values.

02-355B Idler Gear Assembly 1. Visually inspect idler X Any abnormal indications gears for chipped or should be reported for an broken teeth, excessive engineering evaluation.

wear pitting, or other For engines with less abnormal conditions. than 750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months , also inspect at EOC2.

2. Measure gear backlash. X Complete applicable sections of 101 Inspec-Note: If idler gear hub tion and h intenance is removed, it is recom- Record Form No. 355-1-1, sended that the nut be TDI knual, Volume I, relocked at the position Section 6. Use Volume I, corresponding to the Section 8 Appendix 111-1 torque of 70120 ft-lbs. for clearance values.

Insertion of the cotter pin must be accomplished at a torque > 50 ft-lbs and < 90 f t-Tbs.

If this is not possible, another bolt, nut, or washer should be used.02-359 Air Start Valves 1. Remove, clean, and inspect X Ensure valve installation air start valves. (Re- includes retorque re-place copper valve-to- quirements.

head gasket). Ref r. : TDI SIM 360.

2. Inspect the piston, cap. X guide, and housing sliding surfaces to evaluate l wear or corrosion.

l 02-3608 Cylinder Head - Intake and 1. Visually inspect. intake X Also to be performed one Exhaust Valves and exhaust valves, keepers, time at 5 years on sam-l stems and seats for , ire pling basis consistent drawing, pitting, d,stur- with Component 340A/B.

Lion, concentricity, and any abnormal condition.

II-C-9 Revision 2

O O GENERIC MAINTENANCE MATRIX - PHASE 11 O

Component Component AlL.

Number Identification PM Recommendation Monthly M M S Year Overhaul Comments

2. Visually inspect subcovers lhis is a one-time-only for evidence of valve inspection, to be guide blowby (soot). performed after 500 or 600 hours0.00694 days 0.167 hours 9.920635e-4 weeks 2.283e-4 months of operation after rebuild of a cylinder head.

3. Measure intake and ex- X Complete applicable haust valves head sections of TDI thickness. Inspection and Main-tenance Records Form 360-2-1, TDI Instruc-tion Manual, Volume 1, Section 6-one sheet for each cylinder. Use Section 8, Appendix 111 for clearance values. (Items 2 & 3).

Also to be perfomed one time at 5 years on sampling basis consis-tent with Component 340A/8.

4. Measure intake and exhaust X Complete applicable valves valve-to guide sections of IDI clearances, inspection and Main-tenance Record Form 360-2-1. IDI Instruction Manual, Volume I, Section 5-one sheet for each cylinder. Use IDI SIM 336. Rev. I for clear-ance values (acceptance criteria). Also to be performed one time at 5 years on sampling basis consistent with Component 340A/8.

02-362A Cylinder Head Covers - 1. Perform a liquid penetrant X Also to be performed one Subcover Assembly examination of the rocker time at 5 years on a arm pedestals top and sampling basis con-vertical machined sur- sistent with Component faces (connector push- 340A/8. Subcovers with rod side only), pedestal cracks that extend through the counter bore web down to the threads should be replaced. Refr:

DR/QR Report #02-362A.

11-C-10 Revision 2

D GENERIC MAINTENANCE MATRIX - PHASE II U

Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-365A Fuel Injection Pumps 1. Tear down one pump for X Use representative pump inspection. to determine need to overhaul other pumps.

Complete fuel injection pump inspection in accordance with TDI Instruction and Main-tenance Manual, Volume I, Section 6. Based on inspection results and operating parameters.

Complete TDI Instruction and Maintenance Record Form No. 365-1-1 as applicable, for the pump disassembled.

2. Visually check pressure X bleed screw for erosion on disassembled pump.

Fuel Injection Nozzles 1. Remove, inspect, and clean X - Ensure that a new copper 02-365B tips. gasket is used upon reinstallation of nozzle into head. Perform retorque requirement per 101. Complete TDI Inspec-tion and Maintenance Record form 365-2-1 as applicable,.

Instruction Manual, Volume 1, Section 6.

Note: 135* fuel oil tips may be used if inspection results indicate a need for additional action to improve lubrication and reduce coke buildup.

2. Check nozzle pop pressure. X

3. Check spray pattern. X II-C-11 Revision 2 ,

a--- - - a , ,

t'~ s-(% \-

(

GENERIC MAINTENANCE MATRIX - PHASE 11 Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-3650 Fuel Oil Injection Lines: 1. Visually inspect support X Any inserts found to be i Supports elastomer inserts for unsatisfactory shall be deterioration or degrada- replaced with new inserts tion. prior to reassembly of

fuel oli lines. This inspection can be per-formed prior to reassembly of the fuel oil lines in conjunction with the cylinder liner inspection.

02-371A Fuel Pump Control Shaft 1. Check and lubricate as required.

02-371B Fuel Pump Linkage Assembly 1. Grease swivel link or X and Bearings otherwise lubricate all fuel oil pump assemblies.

02-380A Exhaust Manifold 1. Perform a visual examination X To be performed at EOC1 of accessible pipe welds a, and alternate EOCs and corresponding heat- thereafter.

affected zones.

02-385A Crankcase Relief Valve 1. Clean flame arrestors. X

2. Inspect seat and disc. X 02-387A Crankcase Vacuum Fan 1. Inspect fan and clean X as necessary.

2. Check bearing for X roughness.

02-390E Rocker Arm Bushings 1. Visually inspect and X Also to be performed one measure intake rocker arm time at 5 years on bushings, sampling basis con-sistent with Component

' 340A/B.

2. Visually inspect and X Also to be performed one measure exhaust rocker time at 5 years on arm bushings. sampling basis con-

)

sistent with Component 340A/B.

3. Visually inspect and X Also to be performed one measure intermediate time at 5 years on rocker are bushings, sampling basis consist-i ent with Component 340A/B.

11-C-12 Revision 2

N J s GENERIC MAINTENANCE MATRIX - PHASE 11 J

Alt.

Component Component PM Recommendation Monthly g EOC, 5 Year Overhaul Comments Number Identification 02-390F Hydraulic Valve Lifters 1. Check and adjust valve X lash.

Reinstall and adjust X Also to be performed one 2.

Ilfters.

time at EOC2 and at 5 years on a sampling basis consistent with Component 340A/S.

Note: Ensure lifters are installed with the fill holes up. Verify condi-tion of Ilfters by com-l parison of lifter leak-

[ down rate (actual) to specifications noted on TDI k intenance k nual.

Refr: IDI Maintenance Manual, Section 6-B-5.

Check trip set point - X Modify the surveillance 02-410A Overspeed Trip Governor 1.

testing procedure to adjust as required.

include verification that the overspeed trip is correctly set to an overspeed trip setting of 517 1 5 rpm. Ensure that the electric governor setting is properly re-turned to 450 rpm and the mechanical backup governor returned to the manu-facturer's specified interval following the overspeed test. The test is to be performed with no load on the engine by increasing the normal governor speed setting (s) until a trip occurs.

After several inspection periods, the history of the required adjustments should be reviewed to evaluate and possibly modify the testing in-terval. Also perform at E0C2.

Il-C-13 Hevision 2

F O D GENERIC MAINTENANCE MATRIX - PHASE 11 Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments Note: After setting the overspeed governor, the adjustment screw settings should be marked with forque Seal or other positive means to reveal any unintended changes in the set positions.

02-4108 Overspeed Trip Governor 1. Remove plugs from housing X and Accessory Drive and check for magnetic particles.

2. Check shaf ts for excessive 1(

radial and axial movement.

3. Visually inspect accessory X drive gear for excessive wear.

02-410C Overspeed Trip Drive Couplings 1. Remove the present L-110 To be completed by Lovejoy couplings in the first refueling compliance with SIM 363. outage.

2. Verify that coupling is X tight on shaft.

3. Replace the Lovejoy coup- X Replace elastomer if ling spiders or test coup- hardness is greater ling elastomer for hardness. than 90 Shore A.

02-4100 Overspeed Trip Vent Valve 1. Disassemble and replace X "0" rings or replace valve.

02-411A Governor Drive - Governor 1. Visually inspect drive X Also inspect one time at and Tachometer Drive Gear gear and shaft for signs E0C nearest 5 years. For

and Shaft of wear. engine with less than 750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months , also inspect at FOC2.

t 02-411B Governor Drive - Couplings, 1. Check that coupling is X If the coupling is found (excluding Pins and Keys Light on shaft. to be loose, it should

, San Onofre be removed, all nating

- See Site surfaces cleaned, and Specific the unit reassembled i

for San using Loctite 609 on the Onofre) mating surfaces.

Il-C-14 Revision 2

~ ()) (

GENERIC MAINTENANCE MATRIX - PHASE II Alt.

Component Component 5 Year Overhaul Comments Monthly E0C EOC Numbe r Identification PM Recommendation

2. Replace the elastomeric X insert in the Koppers coupling.

Note: To be performed 02-413A Governor Linkage 1. Install positive locking as necessary after hardware to the lever tightening governor are clamp bolt heads and linkage harcheare to design shaft roll pins.

torque specifications.

2. Inspect for loose parts X on the linkage assembly.

02-413A Governor Linkage 3. Lubricate cross shaft l (DSRVs only) bearings as required. l l

4. Grease the rod end X fittings, or lubricate oil wicks, especially j those at the ends of the cross shaft.

To be accomplished when 02-4138 Fuel Pump Linkage: 1. Check cylinder for X placing unit in main-Automatic Shutdown Cylinder extension and return. tenance modes.

l 10 be accomplished during

2. Check tallrod went X controls system check.

for air leakage, X Note: Ensure the hy-02-415A Woodward Governor 1. Drain, flush, refill, and draulic actuator is pro-vent actuator oil system with new oil from a perly vented.

clean container ensuring the appropriate cleanliness procedures are followed.

If contaminated oil is noted, increase frequency.

X

2. Disassemble, clean, and refurbish the actuator.

3. Verify all governor X Note: Mechanical control knob settings governor setting to are in appropriate be 470 rpm.

positions.

11-C-15 Revision 2

O O GENERIC MAINTENANCE MATRIX - PHASE II O

Component Component Alt.

, Number Identification PM Recommendation Monthly g M 5 Year Overhaul Comments I

4. Evaluate electric X An evaluation of the l governor settings is governor settings to verify overshoot of to be performed during

! the 450 rpm set speed surveillance testing once i is within plant specific under joint mechanical guidelines and to and electrical governor l avoid critical speeds control.

i during start or when unloaded.

02-4158 Governor Booster Servosotor 1. Clean, inspect, and X replace "0" rings and gaskets.

i 02-415C Governor Heat Exchanger 1. Clean and inspect. X 02-435A Jacket Water Fittings - Pipe 1. Visually inspect for X and Fittings (Small Bore leaks.

Scope Only)02-437 Turbo Water Piping-Pipe 1. Visually inspect for X j and Fittings leaks.

02-4418 Air Filter to Starting Air 1. Replace filter elements. X This can be modified so l that the filter is to be Distributor if filter in a metal screen, cleaning with changed at a maximum solvent is acceptable pressure drop of 25 psi in lieu of replacement. for engines equipped with

! pressure monitoring

! devices.

I Air Start Admission Valve 2. Clean and inspect strainer. X If the strainer is Strainer excessively dirty, the frequency of : leaning i and inspecting should l

be increased.

Air Start Block Valves 3. Clean and refurbish valves - X replace "0" rings and clean the screened fitting.

Ensure leak tightness after reassembly.

4. Inspect for tightness l of fittings and bolts and apply locking com-pound as required during reassembly of components.

5. Replace "0" rings of the X shuttle valve.

II-C-16 Revision 2

s GENERIC MAINTENANCE MATRIX - PHASE 11 Component Component Alt.

Number Identification PM Recommendation Monthly IOC EOC 5 Year Overhaul Comments 02-455A Fuel Oil Filter 1. Record filter dif fer- X Change filter elements ential pressure. when filter differential pressure reaches 20 psid rise above the clean differential pressure.

Purge entrapped air from the filter canister using the vent valve provided, and divert some fuel oil into the newly replaced cartridge.

After air has been purged, close vent valve and return handle to pre-vious operating position.

2. Inspect canister gaskets To be performed during and replace as required, change out of filter elements.

3. Inspect tubing and me- X Re f r: TDI Instruction chanical connections for Manual, Volume 1.

tightness and/or leaks.

02-4558 Fuel Oil 5 trainers 1. Record strainer differ- X lt greater than 5 psid-ential pressure or monitor shift, clean element.

supervisory alarm as Bolt torques of 120-150 applicable. in-Ibs should be uti-lized during reassembly.

2. Purge air from stand-by As required.

strainers.

02-467A Turbocharger Lube Oil Fitting: 1. Visually inspect for leaks. X Pipe Tubing, Fittings, and Flexible Coupling (Small Bore Scopt only) 02-475A,C Turbocharger: Bracket Bolting 1. At each engine shutdown for and Gaskets the first three engine shut-downs of operation after -

turbo installation, these screws should be visually inspected to assure that no screw has loosened because of engine operating loads.

If during these inspections none of the screws are found loosened or damaged, future Il-C-17 Revision 2

O (

GENERIC M41NTENANCE MATRIM - PHASE 11 o

Component Component Alt.

Number Identification PM Recommendation Monthly M EOC 5 Year overhaul Comments inspections are to be con-ducted on a yearly basis (or during plant shutdown).

But if any time during inspection any screw is found loosened or damaged, it must then be replaced (if damaged) and all screws retorqued as follows: 125 ft-Ibs for the bracket-to-engine screws and 75 ft-lbs for the bracket-to-turbo base screws.

Note: To avoid damage to bracket to engine, and/or bracket to turbo, the pro-per torques as delineated above should be utilized for each respective bracket bolting application.

Air Butterfly Valve 1. Lubricate valve shaft X If oil cups are used, 02-4758 lubricate shaft monthly.

via grease fittings.

2. Check valve disc for X Check by visually observ-freedom of movement. ing valve / actuator oper-ation. If oil cups are used, this should be completed monthly.

3. Verify that associated X locking devices (jam nuts and lock washers) are tight.

02-500A Engine Control Cabinet 1. Inspect interior of cabinet X for cleanliness, and clean as required.

2. Visually check wiring for X insulation degradation.

3. Visually check instrument X tubing for leaks.

4. Functionally check cabinet X heater and calibration of thermostat.

Il-C-18 Revision 2

O GENERIC MAINTENANCE MATRIX - PHASE II O

Component Component Alt.

humber Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments

5. Replace "0" rings, gaskets, and filter in pressure regulator as required.

6. Inspect filter surface for X matter to determine if problems say exist down-stream.

7. Monitor control systes air X pressure or supervisory alarm as applicable.

02-500C Circuit Breakers and Contact 1. Check all terminals - X Accomplished during Blocks clean and tighten. panel cleaning and inspection.

2. Visually check wiring X Accomplished during insulation for degradation. paael cleaning and inspection.

3. Trip check circuit To be performed at breakers. appropriate site intervals for similar equipment.

02-500G Control Panel Valves 1. Inspect control panel X valves for leaks.

2. Replace or refurbish X pneumatic logic board.

02-500J Control Panel Assembly: 1. Inspect contacts and clean X Relays as required.

2. Visually check condition X of wiring and tightness of terminations.

02-500N Control Panel Switches Terminal 1. Clean terminal boards and X Boards and Wiring switch contacts.

2. Visually check wire insu- X lation and terminals for tightness and degradation.

3. Inspect for arcing and X overheating.

1 Revision 2 II-C-19

% m AENERIC MAINTENANCE MATRIX - PHALE 11 Component Component Alt.

Number Identification PM Recommendation Monthly EOC M 5 Year overhaul Comments 02-5258 Barring Device Control Valve 1. Replace control valve As required.

i and Press Regulator "0" rings and lube shaft.

2. Replace press regulator As required.

elastomeric parts.

02-525C Barring Device Air Filter 1. Replace filter element. As required.

2. Drain barring device air As required.

filter.

02-5250 Barring Device - Mounting 1. Replace old cotter pin To be performed after Bracket / Supports with new cotter pin each reassembly, after each reassembly.

02-540A Lube Oil Sump Tank 1. Check lubricating x Refr: IDI Instruction oil with a viscosi- Manual, Volume I, meter for fuel oil Maintenance Schedule, dilution. Send a items 1, 2.

sample of oil to laboratory for analysis.

! 2. Drain lubricating Note: When replacing eng-oil system and ine oil use HD oil that clean sump tank, meets or exceeds series 3 Refill with new oil. standards. 1he base stock i

To be performed should be more resistant based on sample to thermal degradation

) analysis. and coke formation. The I additive package snould provide high detergent dispersant properties with high alkalinity and a high level of antiwear additive such as zinc dithiophosphate. Total Base Number (TBN) should be 12 to 15 for use with

2 fuel, oil and a sulfated ash content of 1.5% to 2.0%

is preferred. An engine oil with such properties, Mobilguard 412 or equiv-alent product may be UGed to insure improved lubri-cation. Do not six lube oil brands or types. When changing lube oil replace the entire charge. Re-place as required.

II-C-20 Revision 2

?

O O GENERIC MAINTENANCE MATRIX - PHASE 11 O

Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC $ Year Overhaul Comments

3. Visually inspect lube To be performed per oil sump tank level appropriate site intervals switch floats. Check for stellar equipment.

switch set points.

4. Perform a spectro- X Note: Sample to be chemical engine oil drawn upstream of analysis to assist tube oil filter.

the bearing monitoring items 1 and 4 can program. To further be performed using expand or clarify chemical the same sample.

i l

analysis, ferrographic analysis may be utilized.

Particular attention shall be paid to copper level and particulate size, which could signify thrust bearing degradation. Particular attention shall be given to percent mois-ture content.02-550 Foundation Bolts 1. Visually inspect founda- X tion for breaks in the bond between the sole plates and grout.

2. Check foundation bolts X Use 101 Instruction for correct torque. Manual, Volume I, Retorque as necessary, Section 8, Appendix then recheck crankshaft IV for proper torque web deflections. values.

3. Generator foundation bolts are to be retorqued l

l after a generator short circuit if the bolts were initially torqued i to 480 ft-Ibs. If initial bolt torque was 600 ft-lbs, no retorque is required.

Thermocouples 1. Check that thermocouple X An inconsistent reading 02-6300 traced to thermocouple indicates ambient engine temperature when the trouble should result engine is cold. in replacement of the thermocouple.

l II-C-21 Revision 2

[ r

' t On CthtRIC MA15fENANCE MAIRIX - PHA5E II A1L.

Component ComponenL 5 Year Overhaul Comments PM Recommendation Monthly EOC EOC Number Identification Indications of fatigue

2. Clean and inspect thermocouples and should result in re-thermocouple shields placement of the thereo-as required. couple and/or thenno-couple shield.

To be accomplished dur-

3. Pyrometer wiring - check ing control panel check-that terminations are out and initial operation Light. inspections. I 1

I Inspect and clean engine Note: 1his recommenda-02-6958 Engine Control Air 1. tion should be reassessed Pressure Regulator control air pressure depending on the degree regulator when pressure of system fouling.

gauge indicates abnormal pressure reduction during normal engine shutdown.

Replace elastomeric parts As required.

2.

and gaskets in the pressure regulator.

Check switch set points Pressure switches and 02-695C Engine Control Pneumatic Trip 1. temperature switches.

Switches per appropriate site interval.

As required.

2. Replace elastomeric parts.

As required.

02-7008 Jacket Water Standpipe: 1. Replace elastomeric Valves parts in valves.

Visually check jacket Any visible crackin) 02-700F Jacket Water Standpipe 1. or minor jacket water and Miscellanenous Bolting water standpipe, pump leakage should result suction and engine return nozzle welds during each in rework of cracked routine engine run and nozzle welds.

every 100 hours0.00116 days 0.0278 hours 1.653439e-4 weeks 3.805e-5 months during extended engine runs.

Also to be performed

2. Check treatment (ph, X after adding makeup etc. as applicable) of water, jacket water and correct as recommended by chem-ical supplier.

Replace packing as 02-7178 Auxiliary Sub-Base and 1. Inspect the valves X necessary.

Oil & Water Piping - for packing leakage.

Jacket Water: Valves 11-C-22 Revision 2

D

\ sj' GENERIC MAINlENANCE MATRIX - PHASE 11 Component Component Alt.

Number Identification PM Reconnendation Monthly EOC EOC 5 Year Overhaul Comments 02-717C Auxiliary Sub-Sase and Oil & 1. Visually inspect for leaks. X hter Piping - Jacket Water:

Pipe, Couplings, Fittings Orifices. Y-Strainers (Small Bore Scope Only) 02-717F Auxiliary Sub-Base Lube Oil 1. Visually inspect pipe X Pipe and Fittings and joints for leakage.

2. Clean and inspect lube Complete when tube oil oil keep ware pump suction tank is drained.

strainer as required.

S2-717G/K Auxiliary Sub-Base Lube 011/ 1. Disassemble, inspect, Fuel Oil Valves and refurbish off engine lube oil and fuel oil valves as required.

2. Check relief valve X lift pressure. Dis-assemble and clean if necessary.

02-8058 Intake Air Filters 1. Inspect air intake / oil Replace with change oil bath filters every 3 to if necessary. If samp- i 6 months. ling is utilized, change based on analysis re-suits.

1. Visually inspect for X 02-805D Flex Connection (Exhaust) evidence of cuts, holes, or dents.

2. Visually check for X evidence of exhaust leakage.

02-810C Jacket hter Heat 1. To avoid corrosion and Exchanger fouling, jacket water heat exchanger and associated service water piping should be flushed on a periodic basis (continuous service i I flow is sufficient).

Alternatively, servic water chemistry control can be used to maintain heat enhanger performance and integrity.

I II-C-23 Revision 2

p G

CENERIC MAINTENANCE MAIRIX - PHASE Il Cg) v Component Component A1t.

Number Identification PM Recommendation Monthly EOC g 5 Year Overhaul Comments Record heat exchanger Use for trend data,

2. X parameters.

3. Evaluate heat exchanger X performance data.

4. Inspect tubes and tube X Refr: IDI instruction sheet for fouling and Manual, Volume I, erosion - remove en- Maintenance Schedule.

trance and exit channel covers as required by trend data or at over-haul. Also review consistent with in-spections of other plant heat exchangers utilizing siellar water chemistry.

5. Inspect and clean Replace or rework lantern lantern ring as required. ring as necessary to Verify leak-off holes ensure concentricity are not plugged. prior to reinstalla-tion.

6. Replace packing Replace packing when rings as required. packing becomes hard or leakage at the packing is noted and cannot be stopped by tightening.

02-8100 Thermostatic Valves 1. Replace thermal power elements as required.

2. Visually inspect valve X To be accomplished bonnet for evidence of during monthly test leakage, run. Ensure that any replacement valves have cast steel valve bodies.

02-810E Jacket Water Heaters 1. Check calibration and To be performed at inspect thermostat. appropriate plant interval for similar equipment. Replace heater if degradation of insulation resistance is noted.

11-C-24 Revision 2

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GENERIC MAINTENANCE MATRIX - PHASE 11 i

Component Component A1t.

Number Identification PM Recommendation Monthly g EOC 5 Year Overhaul Comments A 02-820A Lube Oil Sump Tank 1. Inspect and clean Replace heater if de-Heaters heater elements as gradation of insulation required by trend data. resistance is noted.

2. Check calibration and To be performed at inspect condition of appropriate site intervals thermostat. for similar equipment.

4, 02-820C Lube Oil Keep-Wars Pump 1. Check mechanical seal X and piping connection for leakage.

2. Verify pump discharge X Use for trend data, pressure is within

! manufacturer's specift-I cation.

i' 02-8200 Lube Oil Keep-Warm Strainer 1. Clean or replace strainer element when the differential pressure change at the lube oil keep-ware strainer is 20 psid or for those plants not having this capability, clean or re-t place when differential i pressure of keep ware filter is 20 psid.

02-820E Lube Oil Keep-Wars Filter 1. Record filter dif ferential X l pressure.

2. Change filter To be performed when elements as required. the filter differential pressure reaches 20 psid. For sites not equipped with differ-

' ential pressure gauge,

j. inspect monthly and clean as necessary.

1 02-820F Full Flow Lube Oil 1. Record filter differential X Use for trend data.

4 Filters pressure. Refr: TDI Instruction I Manual, Volume I, Maintenance Schedule.

f!

2. Replace filter cartridges To be performed when the and perform a visual filter dif ferential inspection to determine pressure reaches 20 psid.

nature of the material caught in the filter.

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l II-C-25 Revision 2 l

' t GENERIC MAINTENANCE MATRIX - PHASE 11 (v

Component Component Alt.

Number Identification PM Recommendation Monthly EOC_ g 5 Year Overhaul Comments

3. Lube oil filter gauge - To be performed at calibration check. appropriate site intervals for siellar equipment.

02-820G Lube Oil Heat 1. Record heat exchanger X Use for trend data.

Exchanger parameters.

2. Evaluate heat exchanger X periorsance data.

3. Inspect tubes and tube X Re f r: TDI Instruction sheet. Manual, Volume 1 Maintenance Schedule.

4. Inspect and clean lantern Replace or rework lantern ring as required. Verify ring as necessary to leak-off holes are not ensure concentricity.

plugged.

5. Replace packing rings When packing becomes at the floating tube hard or leakage at the sheet during reassembly. packing is noted and cannot be stopped by tightening.

02-820H full Pressure Lube Oil Strainer 1. Monitor differential X Use for trend data.

pressure of strainer and/or filter.

2. Clean or replace strainer To be performed when the element when the differ- differential pressure ential pressure change across the strainer is at the lube oil strainer 20 psid. Refr. 101 is 20 psid. For those plants Instruction Manual, not having this capability, Volume I, Maintenance clean or replace when Schedule.

differential pressure of full pressure filter is 20 psid.

3. Lube oil strainer 10 be performed per pressure gauge - appropriate site intervals calibration check. for similar equipment.

11-C-26 Revision 2

O GENERIC MAINTEhAhlE MATRIK - PHASE II O

Component Component Alt.

Ember Identification PM Recommendation Monthly g g 5 Year Overhaul Comments 02-8358 Diesel Starting Air 1. Check oil pressure and X Compressors oil level if compressor is so equipped.

2. Overall visual X inspection.

3. Clean fins on intercoolers X and aftercoolers.

4. Inspect intake filter X element if equipped ard replace as neces-sary.

5. Change compressor oil X at each EOC, or if monthly samp1tng is performed change as required based on results.

6. Check belt tension. X

7. Check pulley clamp X bolts and set screws tight.

8. Inspect filter felts on X Replace as required, unloader system. if so equipped.

02-8351 Air Dryers and 1. Inspect and service X Moisture Traps moisture traps.

2. Check proper operation X Replace desiccant charge of d yer. or refrigerant as re-quired.

02-835J 5 tarting Air Storage 1. Disassemble and clean X Tank the float trap if installed.

Il-C-27 Revision 2

C GENERIC MAINTENANCE MATRIM - PHASE 11 O

Component Alt.

Component Number Identification PM Reconsendation Monthly M M 5 Year Overhaul Comments

2. Starting air tank pressure To be performed per gauges - calibration appropriate site check. Intervals for siellar equipment.

3. Starting air tank pressure To be performed per switches - calibration appropriate site check. Intervals for similar equipment.

Piping System 1. Conduct a detailed vis- X Tighten, repair, or (For items not previously ual and audible inspec- replace as required.

covered) tion of all fuel, air, Refr: 101 Instruction oil, and water piping Manual, Volume I, and valves for leakage. Maintenance Schedule.

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II-C-28 Revision 2

TDI OWNERS GROUP APPENDIX-II' SITE SPECIFIC MAINTENANCE MATRIX PART D i

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-n.,-,-,,--------.~~,,-------,------..-a---..nn-

- - , -,---n--,n, - - - . , - _ . _ . _ _ - , - - , - - - - - . , - - . - -- -- - - - -

SITE-SPECIFIC MAINTENANCE MATRIM 1

Component Component Alt.

l 5 Year Overhaul Comments i Number identification PM Recommendation Monthly M EOC,

1. Measure and record crank- X Complete 101 Inspection i 02-310A Crankshaft and Maintenance Record 1 (WNP-1) shaft web deflections (hot and cold). Forn No. 310-1-1 as applicable, TDI instruc-1 I

tion Manual, Volume 1, Section 6. Ref r: 101 l' Instruction knual, Volume 1, h intenance Schedule.

2. Examine the fillets and Also to be performed once

) oil holes of three main at 5 years, f

j bearing journals (4,6,& 8) Refr: PNL-5600.

j using LP. If indications i

are evident, a more thorough examination should be made using appropriate NDE methods.

3. Examine the fillets and Also to be performed once 1

oil holes in three of the at 5 years.

crankpin journals (choose Refr: PNL-5600.

- 3 from Nos. 3 through 8 inclusive) using LP. If indications are evident, i

a more thorough examina-tion should be made using .

{ appropriate NDE methods.

i I 4. Measure diameter of crank- X Complete 101 Inspection pin journals. and Maintenance Record Form No. 310-3-1 as applicable TDI Instruc- ;

sion Manual, Volume 1, Section 6.

Also perform inspection

! at 5 years, on items accessible, consistent

, with this component and Component 02-340A/B.

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i II-D-W1 Revision 2

SITE-SPECIFIC MINTEIWueCE MIRIX Component Component Alt.

her Identification PH Recommendation knthly EOC EOC 5 Year Overhaul Comments

5. Analyze the trends of X If an engine operates cylinder pressure and in a severely unbalanced temperature measurements condition, reinspect the to detect imbalances. oil holes for fatigue cracks within a tica-frame determined by the utility considering the particular circumstances of the abnormal operation.

Refr: PNL-5600.

Note: To avoid the effects Refr: PNL-5600.

of the 4th order resonance, steady normal-loaded opera-tion at speeds more than a few rps below the rated speed of 450 rps should be avoided. Appropriate precautions should be taken to prevent sus-tained engine operation with significant cylinder imbalance. Lower speeds for testing and break-in are permissible. Avoid resonance frequencies.

Il-D-W2 Revision 2

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SITE-SPECIFIC MAINTENANCE MATRIM l

j Component Component Alt.

] Number Identification PM Recommendation Monthly M g 5 Year Overhaul Comments 1

02-315A Cylinder Block 1. Perform inspections per l DR/QR Report 02-315L

! (WMP-1) j 2. Perform visual inspection X for cracks.

Note: Visual inspection i

not required if an appro-priate NDE is performed.

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SITE-SPECIFIC MAINTENANCE MA1RIX Component Component A1t.

Nuateer Identification PM Recommendation Monthly EDC g 5 Year overhaul Comments

1. Inspect the stud boss X Satisfactory performance 02-3341A Pistons of type AH piston skirts (WP-1) (Type AH) attachments of all shall be demonstrated by piston skirts by LP and/or eddy current an engine run (750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months as appropriate. at 450 rps) before placing the skirts in nuclear stane y service. The run should be performed at a load that bounds the max-laun emergency service load to which the pistons will be exposed. Pre run and post-run inspections of the crown to skirt stud attachment bosses and the rib ends to be performed.

Refr: PNL-5600.

II-D-W4 Revision 2

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(

O TOI OWNERS GROUP APPENDIX-II CROSS REFERENCE INDEX BY COMPONENT PART E lO

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/

1

! Legend ,

! 1. Index sorted by component name.

I

! 2. Component number listed or "nonum" indicates that the utility engine should perform the maintenance as described.

3. Blank indicates that utility is not required to perform maintenance indicated. ,

I

4. Maintenance or surveillan~e c requirements for a subcomponent s'hould be i

j disregarded for those engines not equipped with the subcomponent.

l O

O O O TOI COMPONENT NUMBER CROSS REFERENCE ,

RANCHO ~

RIVER COMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ON0FRE V0GTLE GULF BELLEFONTE HARRIS Air Butterfly Valve 02-475B/ 03-4758/ 02-4758/ 03-475B/ 02-475B/ 02-4758/

03-4758 02-475B 02-475B 02-475B 02-475B 02-475B Air Dryers and Moisture Traps 02-8351/ 03-835H/ 02-835A/ 03-835I/ 02-835A/ 02-835G/

03-835H 02-835F 02-835G GG-115 02-835C 02-835C Air Filter to Starting Air 02-4418/ 03-4418/ 02-441B/ 03-4418/ 02-441B/ 02-441B/

Distributor 03-441B 02-441B 02-441B 02-441B 02-4418 02-441B Air Start Block Valves NONUM/ NONUM/ N0NUM/ N0NUM/ N0NUM/ N0NUM/

03-441B NONUM N0NUM NONUM N0NUM N0NUM Air Start Valves 02-359/ 03-359/ 02-359/ 03-359/ 02-359/ 02-359/

03-359 02-359 02-359 02-359 02-359 02-359 Auxiliary Sub-Base & Oil & 02-717C/ 03-717D/ 02-717C/ 03-717D/ / 02-717C/

Water Piping - Jacket 03-717C 02-717C 02-717C 02-717C / 02-7170 Water: Pipe, Couplings, Fit-tings, Orifices, Y-Strainers (Small Bore Scope Only)

Auxiliary Sub-Base & Oil & 02-717B/ 03-7178/ 02-7178/ ~

03-7178/ 02-717B/ 02-7178/

Water Piping - Jacket 03-7178 02-717B 02-7178 02-717B 02-7178 02-7178 Water: Valves Auxiliary Sub-Base Lube Oil 02-717F/ 03-717H/ 02-717F/ 03-717H/ NONUM/ 02-717F/

Pipe and Fittings 03-717H 02-717F 02-717F 02-717F 02-717F 02-717H Auxiliary Sub-Base Lube Oil / 02-717G/K/ 03-7171/N/ 02-717G/K/ 03-717H/N/ N0NUM/ 02-717G/K/

Fuel Oil Valves 03-717I/N 02-717G/K 02-717G 02-717G/K 02-717G/K 02-717I II-E-1 m

O O O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/ BEN 0/ WNP-1/

PEAK / SAN PERRY / GRAND -

CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF __

BELLEFONTE HARRIS Barring Device Air Filter 02-525C 03-525C / / / /

Barring Device Control Valve 02-525B/ 03-525B/ 02-525B/ 03-5258/ / 02-525B/

and Press Regulator 03-525B 02-525B 02-525B Base Assembly 02-305A/ 03-305A/ 02-305A/ 03-305A/ 02-305A/ 02-305A/

03-305A 02-305A 02-305A 02-305A 02-305A - <02-305A Cam Gear 02-350C/ 03-350C/ 02-350C/ 03-3500/ 02-350C/ 02-350C/

03-350C 02-350C 02-350C 02-350C 02-350C 02-350C Camshaft Assembly 02-350A/ 03-350A/ 02-350A/ 03-3'50A/ 02-350A/ 02-350A/

03-350A 02-350A 02-350A 02-350A 02-350A 02-350A CamshafteBearings 02-350B/ 03-3508/ 02-3503/ 03-3508/ 02-3508/ 02-3508/

03-3508 02-3508 02-3508 02-350B 02-3506' 02-3508 Circuit Breakers and Contact 02-500C/ 03-500C/ 02-500C/ 03-500C/ 02-500C/ 02-500C/

' Blocks 03-500C 02-500C 02-500C 02-5000 02-500C 02-500C 1

Connecting Rods, Bushings 02-340A/B/ 03-340A/B/ 02-340A/B/ 03-340A/B/ 02-340A/B/ 02-340A/B/

and Bearing Shells 03-340A/B 02-340A/B 02-340A/B 02-340A/B 02-340A/B 02-340A/B Control Panel Assembly: 02-500W '03-500J/ 1.02-5001/ 03-500J/ 02-500J/ 02-500J/

Relays , 03-500J 02-500J C02-500J 02-500.) 02-500J 02-500J ControlPanel: bitches ~02-500N/ 03-50GN/ 02-500M/ 03-500N/ 02-500N/ 02-500N/

Terminal Boards _.and Wiring 03-500N 02-500N 02-500N 02-500N 02-500N 02-500N w

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II-E-2 , -

O O

TDI COMPONENT NUMBER CROSS REFERENCE O '

RANCHO RIVER CDMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS i

Control Panel Valves 02-500G/ 03-500G/ 02-500G/ 03-500G/ 02-500G/ 02-500G/

03-500G 02-500G 02-500G 02-500G 02-500G 02-500G Crank to Lube Oil Pump Gear 02-355A/ 03-355A/ 02-355A/ 03-355A/ 02-355A/ 02-355A/

03-355A 02-355A 02-355A 02-355A 02-355A 02-355A

, Crankcase Assembly 02-311A/ / 02-311A/ / 02-311A/ 02-311A/

l 02-311A 02-311A 02-311A 02-311A 02-311A

! Crankcase Relief Valve 02-385A/ 03-385A/ 02-385A/ 03-385A/ 02-385A/ 02-385A/

(and covers) 03-385A 02-385A 02-385A 02-385A 02-385A 02-386A Crankcase Vacuum Fan 02-387A/ / / / / /

NONUM 02-387A Crankshaft 02-310A/ 03-310A/ 02-310A/ 03-310A/ 02-310A 02-310A/

03-310A 02-310A 02-310A 02-310A 02-310A 02-310A Cylinder Block 02-315A/ 03-315A/ 02-315A/ 03-315A/ 02-315A/ 02-315A/

! 03-315A 02-315A 02-315A 02-315A 02-315A 02-315A Cylinder Head 02-360A/ 03-360A/ 02-360A/ 03-360A/ 02-360A/ 02-360A/

03-360A 02-360A 02-360A 02-360A 02-360A 02-360A Cylinder Head - Intake 02-3608/ 03-3608/ 02-3608/ 03-3608/ 02-360B/ 02-3608/

and Exhaust Valves 03-360B 02-3608 02-360B 02-3608 02-360B 02-360B i Cylinder Head Covers - 02-362A/ 03-362A/ 02-362A/ 03-362A/ 02-362A/ 02-362A/

Subcover Assembly 03-362A 02-362A 02-362A 02-362A 02-362A 02-362A l i

II-E-3

O O O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ONCFRE V0GTLE GULF BELLEFONTE HARRIS Cylinder Liners 02-315C/ 03-315C/ 02-315C/ 03-315C/ 02-315C 02-315C/

03-315C 02-315C 02-315C 02-315C 02-315C 02-315C Diesel Starting Air 02-8358/ 03-835G/ 02-835D/ 03-835D/ NONUM/ 02-835B/

Compressors10-112 02-835A 02-835A GG-113/14 02-835B Emergency Generator CP-101A/ 03-650A/ / 03-650A/ CN-119/ 84-101A/

03-650A S0-101 02-650A GG-101A BL-101A 02-650A Emergency Generator CP-102/ 03-6508/ / 03-6508/ / 84-121/

Control Panel 03-6508 02-6508 GG-119 BL-101B 02-650B Emergency Generator Pedestal CP-101B/ 03-650C/ 02-650C/ 03-650C/ CN-119A 84-101B/

Bearing (and shaft) 03-650C S0-103 02-650C GG-101B BL-101C 02-650C Engine Control Air 02-695B/ 03-695B/ 02-695B/ 03-695B/ 02-695B/ 02-695B/

Pressure Regulator 03-695B 02-6958 02-6958 02-6958 02-6958 02-6958 (Valves, Orifices)

Engine Control Cabinet 02-500A/ 03-500A/ 02-500A/ 03-500A/ 02-500A/ 02-500A/

03-500A 02-500A 02-500A 02-500A 02-500A 02-500A Engine Control Pneumatic 02-695C/ 03-695C 02-695C/ 03-695C/ 02-695C/ 02-695C/

Switches 03-695C 02-695C 02-695C 02-695C 02-695C 02-695C Exhaust Manifold 02-380A/ 03-380A/ 02-380A/ 03-380A/ 02-380A/ 02-380A/

03-380A 02-380A 02-380A 02-380A 02-380A 02-380A II-E-4

O O O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ON0FRE V0GTLE GULF BELLEFONTE HARRIS Flex Connection 02-805D/ 15-110/ 02-805D/ 03-805D/ CN-121/ 84-114/

10-109 02-805C 02-805D GG-111 02-805A 02-805D Foundation Bolts 02-550/ 03-550/ 02-500/ 03-500/ 02-500/ 02-500/

03-550 02-550 02-550 02-550 02-550 02-550 Fuel Injection Nozzles 02-365B/ 03-365B/ 02-365B/ 03-365B/ 02-365B/ 02-3658/

03-365B 02-365B 02-3658 02-365B 02-365B 02-365B

Fuel Injection Pumps 02-365A/ 03-365A/ 02-365A/ 03-365A/ 0% 365A/ 02-365A/

03-365A 02-365A 02-365A 02-365A 02-365A 02-365A Fuel Injection Tubing 02-365C/ 03-365C/ 02-365C/ 03-365C/ 02-365C/ 02-365C/

03-365C 02-365C 02-365C 02-365C 02-365C 02-365C Fuel Oil Filter 02-455A/ SC-014A 02-455A/ 03-455A/ 02-455A/ 02-455A/

03-455A 02-455A 02-455A 02-455A 02-455A 02-455A Fuel Oil Injection Lines: 02-365D/ 03-365D/ 02-365D/ 03-3650/ 02-365D/ 02-365D/

Supports 03-3650 02-3650 02-3650 02-365D 02-3650 02-365D

Fuel Oil Strainers 02-455B/ SC-0428/ 02-455B/ 03-455B/ 02-455B/ 02-455B/

03-455B 02-455B 02-455B 02-455B 02-455B 02-455B Fuel Pump Control Shaft 02-371A/ 03-371A/ 02-371A/ 03-371A/ 02-371A 02-371A/

03-371A 02-371A 02-371A 02-371A 02-371A 02-371A II-E-5

O O ,

O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM GNOFRE V0GTLE GULF BELLEFONTE HARRIS Fuel Pump Linkage Assembly 02-371B/ 03-371B/ 02-3718/ 03-371B/ 02/371B 02-371B/

and Bearings 03-3718 02-371B 02-371B 02-371B 02-371B 02-371B Fuel Pump Linkage: 02-4138/ 03-371C/ 02-413B/ 03-371C/ 02-413B/ 02-413B/

Automatic Shutdown Cylinder 03-371C 02-413B 02-4138 02-4138 02-4138 02-413B Fuel Tappet Assembly 02-345B/ 03-345B/ 02-345B/ 03-345B/ 02-345B/ 02-345B/

03-345B 02-345B 02-345B 02-345B 02-345B 02-345B Full Flow Lube Oil Filter (s) 02-820F/ 03-820E/ 02-820F/ 03-8208/ CN-110/ 84-115/

10-106 02-820C 02-717S GG-8208 02-820D 02-820E Full Pressure Lube Oil 02-820H 03-820C/ 02-820C/ 03-460A/ SE-025/ SE-025/

Strainer 03-820C SE-014 SE-025 SE-025 02-820C 02-820A Flywheel Bolting / / / / / /

03-3308 02-330B Gear Train / / / / / /

NONUM Governor Booster Servomotor 02-415B/ 03-415B/ 02-415B/ 03-415B/ 02-415B/ 02-415B/

03-415B 02-415B 02-415B 02-415B 02-415u 02-4158 Governor Drive - Couplings, 02-4118/ 03-402B/ 02-411B/ 03-402B/ 02-411B/ 02-411B/

Pins and Keys 03-402B 02-411B 02-411B 02-411B 02-4118 02-411B Governor Drive - Governor 02-411A/ 03-402A/ 02-411A/ 03-402A/ 02-411A/ 02-411A/

q and Tachometer Drive Gear 03-402A 02-411A 02-411A 02-411A 02-411A 02-411A and Shaft II-E-6

O O O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/ ~ BEN 0/ WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS Governor Heat Exchanger 02-415C/ 03-415C/ 02-415C/ 03-415C/ 02-415C/ 02-415C/

03-415C N0NUM 02-415C 02-415C 02-415C 02-415C Governor Linkage 02-413A/ 03-413/ 02-413A/ 03-413/ 02-413A/ 02-413A/

03-413 02-413A 02-413A 02-413A 02-413A 02-413A Hydraulic Valve Lifters 02-390F/ / 02-390F/ / / 02-390F/

03-390F 02-390F 02-390F 02-390F Idler Gear Assembly 02-355B/ 03-355B/ 02-355B/ 03-355B/ 02-355B/ 02-355B/

03-355B 02-355B 02-355B 02-355B 02-3559 02-355B Intake Air Filters 02-8058/ 03-8058/ 02-805B/ 03-805B/ CN-106/ 84-111/

10-114 02-8058 02-805A GG-118 02-805C 02-805B Intake and Exhaust Tappet 02-345A/ 03-345A/ 02-345A/ 03-345A/ 02-345A/ 02-345A/

Assembly 03-345A 02-345A 02-345A 02-345A 02-345A 02-345A Intercoolers F-068/ NB-002/ F-068/ F-068/ F-068/ F-068/

F-068 41-127A F-068 F-068 F-068 F-068 Jacket Water Fittings - 02-435A/ 03-435A/ 02-435A/ 03-435A/ / 02-435A/

Pipe and Fittings 03-435A 02-435A 02-435A 02-435A 02-435A -

(Small Bore Scope Only)

! Jacket Water Heat Exchanger 02-810C/ / 02-8108/ 03-810A/ CN-120/ 02-717N/

10-103 02-717Q GG-103 02-810A 02-810C i Jacket Water Heaters 02-810E/ 03-810C/ 02-810D/ 03-800A/ CN-128/ 02-810B/

03-800A 02-810 02-717N 02-810A 02-8100 02-810A II-E-7

O O O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS Jacket Water Pump - Gear 02-425A/ 03-425A/ 02-425A/ 03-425A/ 02-425A/ 02-425A/

03-425A 02-425A 02-425 02-425A 02-425A 02-425A Jacket Water Standpipe 02-700F/ 03-700F/ / / / 02-700E/

and Miscellaneous Bolting 02-700F 02-700F 00-700F 02-700F 02-700F Jacket Water Standpipe: 02-700B/ 03-717B/ 02-700B/ 00-700B/ 02-700B/ 02-700B/

Valves 00-700B 02-700B 02-7008 00-700B 02-700B 02-700B Lube Oil Heat Exchanger 02-820G/ 03-8200/ 02-820G/ 03-820A/ CN-111/ 02-7170/

10-104 02-8208 02-717R GG-104 02-820A 02-820B Lube Oil Keep-Warm Filter 02-820E/ 03-820G/ 02-820E/ 03-8200/ CN-122/ 02-7175/

10-117 02-820E 02-717V GG-121 02-820E 02-820G Lube Oil Keep-Warm Pump 02-820C/ 03-820F/ 02-820B/ 03-820C/ CN-109/ 02-717R/

03-820C 02-8200 02-717U GG-109 02-820G 02-820F Lube Oil Keep-Warm Strainer 02-820D/ 03-820H/ 02-8200/ / / 02-717V/

02-4650 Lube Oil Pressure Regulating 00-420/ 00-420/ 00-420/ 00-420/ 00-420/ 00-420/

Valve 00-420 00-420 00-420 00-420 00-420 00-420 Lube Oil Sump Tank Heaters 02-820A/ 03-8208/ 02-820A/ 03-8008/ 02-5400/ 02-820A/

03-800B 02-820 02-717P 02-820A 02-820C Lube Oil Sump Tank 02-540A/ 03-540A/ 02-540A/ 03-5408/ 02-540A/ 02-540A/

03-540A 02-540A 02-540A 02-540A 02-540A 02-540A II-E-8

O O O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS Lube Oil Tubing and 02-307B/ 03-307B/ 02-307B/ 03-307B/ 02-307B/ 02-307B/

Fittings ,- Internal 03-3078 02-3078 02-3078 02-307B 02-3078 02-3078 Main Bearing Caps - Studs 02-305C/ 03-305C/ 02-305C/ 03-305C/ 02-305C/ 02-305C/

and Nuts 03-305C 02-305C 02-305C 02-305C 02-305C 02-305C Main Bearings Shells 02-310B/ 03-3108/ 02-310B/ 03-310B/ 02-310B/ 02-3108/

03-310B 02-310B 02-3108 02-310B 02-310B 02-310B Overspeed Trip Drive Couplings 02-410C/ 03-410C/ 02-410C/ 03-410C/ 02-410C/ 02-410C/

03-410C 02-410C 02-410C 02-410C 02-410C 02-410C Overspeed Trip Governor 02-410A/ 03-410A/ 02-410A/ 03-410A/ 02-410A/ 02-410A/

03-410A 02-410A 02-410A 02-410A 02-410A 02-410A Overspeed Trip Governor 02-410B/ 03-410B/ 02-410B/ 03-410B/ 02-4108/ 02-410B/

and Accessory Drive 03-4108 02-410B 02-410B 02-4108 02-4108 02-410B Overspeed Trip Vent Valve 02-410D/ 03-410D/ 02-4100/ 03-410D/ 02-4100/ 02-4100/

03-4100 02-4100 02-410D 02-410D 02-4100 02-410D Piping System N0NUM/ N0NUM/ N0NUM/ N0NUM/ NONUM/ N0NUM/

N0NUM NONUM N0NUM N0NUM NONUM N0NUM Piston Pin Assembly 02-341C/ 03-341C/ 02-341C/ 03-341C/ 02-341C/ 02-341C/

03-341C 02-341C 02-341C 02-340E 02-341C 02-341C Piston Rings 02-3418/ 03-341B/ 02-341B/ 03-341B/ 02-3400/ 02-341B/

03-3418 02-341B 02-3418 02-3400 02-341B 02-3418 Il-E-9

O O O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS Pistons 02-341A/ 03-341A/ 02-341A/ 03-341A/ 02-340C/ 02-341A/

03-341A 02-341A 02-341A 9?-340C 02-341A 02-341A Push Rods 02-390C/ 03-390C/D/ 02-390C/ 03-390C/ 02-390C/ 02-390C/

03-390C 02-390C 02-390C 02-390C 02-390C 02-390C Rocker Arm Bushings 02-390E/ 03-390E/ 02-390E/ 03-390E/ 02-390E/ 02-390E/

03-390E 02-390E 02-390E 02-390E 02-390E 02-390E Rocker Arm Capscrews, 02-390G/ 03-390G/ 02-390G/ 03-390G/ 02-390G/ 02-390G/

Drive Studs (Pop Rivets) 03-390G 02-390G 02-390G 02-360G 02-390G 02-390F Starting Air Distributor 00-442A/ 03-442A/ 00-442A/ 03-442A/ 02-442A/ 00-442A/

Assembly 03-442A 02-442A 02-442A 02-442A 00-442A 02-442A Starting Air Storage Tank 02-835J/ 03-835F/ 02-835B/ 03-835A/ CN-112 02-835F/

10-111 02-835E 02-8350 02-835A 02-8350 Thermocouples 02-630D/ 03-630D/ 02-6300/ 03-6300/ 02-6300 02-6300/

03-6300 02-6300 02-6300 02-630D 02-6300 02-6300 Therm'ostatic Valves 02-810D/ 03-799A/ 02-810C/ 03-515/ C136/40/ 02-810A/

03-515 02-515 02-717W 02-515 02-810C 02-810E Thrust Bearing Ring 02-310C/ 03-310C/ 02-310C/ 03-310C/ 02-310C/ 02-310C/

03-310C 02-310C 02-310C 02-310C 02-310C 02-310C Turbo / water Piping - 02-437/ 03-437A/ 02-437/ 03-437A/ 02-437/ 02-437/

Pipe and Fittings 03-437A 02-437A 02-437A 02-437 02-437 02-437 II-E-10 a

O O TDI COMPONENT NUMBER CROSS REFERENCE O

i

! RANCHO RIVER i COMANCHE SEC0/ BEN 0/ WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS Turbocharger MP-022/23/ MP-020/ MP-022/3/ MP-017/ MP-022/3/ MP-022/3/

MP-017 MM-19/20 MP-022/3 MP-022/3 MP-022/3 MP-022/3 Turbocharger Lube Oil Fit- 02-467A/ 03-467A/ 02-467A/ 03-467A/ 02-467A/ 02-467A/

tings: Pipe, Tubing, Fittings 03-467A 02-467A 02-467A 02-467A 02-467A 02-467A and Flexible Coupling (Small Bore Scope Only)

Turbocharger: Bracket 02-475A,C/ 03-475A,C/ 02-475A,C/ 02-475A,C/ 02-475A,C/ 02-475A,C/

Bolting and Gaskets 02-475A,0 02-475A,C 02-475A,C 02-475A,C 02-475A,C 02-475A,C Water Discharge Manifold - 02-317A&B/ 03-317A&B/ 02-317A&B/ 03-317A&B/ 02-317A&B/ 02-317A&B/

Jacket Water Discharge 03-317A&B 02-317A&B 02-317A&B 02-317A&B 02-317A&B 02-317A&B Piping, Couplings and Seals Woodward Governor 02-415A/ 03-415A/ 02-415A/ 03-415A/ 02-415A/ 02-415A/

03-415A 02-415A 02-415A 02-415A 02-415A 02-415A II-E-11

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ML20198S400

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