ML20203F891
| ML20203F891 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 04/30/1986 |
| From: | Segrest A TDI (TRANSAMERICA DELAVAL, INC.) OWNERS GROUP |
| To: | |
| Shared Package | |
| ML20203F871 | List: |
| References | |
| NUDOCS 8607310201 | |
| Download: ML20203F891 (85) | |
Text
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O TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT Prepared For TEXAS UTILITIES GENERATING COMPANY COMANCHE PEAK STEAM ELECTRIC STATION - UNIT 1 By i
TDI DIESEL GENERATOR OWNERS GROUP Revision 2 April 1986 l
AMdgrest Program Manager TDI Diesel Generator Owners Group
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O 8607310201 860725 DR ADOCK 0500 5
i TDI 4
OWNERS GROUP APPENDIX - II GENERIC MAINTENANCE MATRIX i
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GENERIC MAINTENANCE MATRIX 4
APPENDIX - II OVERVIEW AND DEFINITIONS
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OPERATING AND STANDBY SURVEILLANCE PARAMETERS PART A 4
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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 overall 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 TOI 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 l
750-hour endurance run and subsequent engine teardown) performed l
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 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.
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II-A-1 Revision 2 2
1 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 mocifications 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 TDI 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.
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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 EOC prior to 10 years and the other engine at the E0C following 10 years.
Alternately for PWR units, the inspection 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 with the third engine to be inspected at the second EOC following 10 years).
The 10 year interval will typically be taken from issuance of the Low Power Operating license ar from subsequent teardown and O
inspection for plants already in operation.
II-A-2 Revision 2
Gh b)
A one time inspection will be performed at the E0C closest to 5 years.
For a unit, one engine may be inspected at the E0C prior to 5 years and the other at the EOC 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 inspected 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.
EOC - (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 EOC occuring nearest to the end 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 inanner.
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.
O II-A-3 Revision 2
TABLE 1 Diesel Engine Operating Surveillance Parameters and Frequency Component Frequency 1)
Lube Oil Inlet Pressure to Engine Log hourly 2)
Lube Oil Filter Differential Pressure Log hourly 3)
Lube Oil 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.)
DSRV Engines)
- 15) Crankcase Vacuum Log hourly
- 16) Engine Speed Log hourly l
- 17) Hour Meter Log hourly I
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II-A-4 Revision 2
TABLE 1 (Cont'd)
Diesel Engine Operating Surveillance Parameters and Frequency Component Frequency
- 18) Kilowatt Load Log hourly i
- 19) Visual Inspection for Leaks, etc.
Check hourly O
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II-A-5 Revision 2
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 Temperature (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 l
- 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.
O II-A-6 Revision 2
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y TABLE 2 (Cont'd)
Diesel Engine Standby Surveillance Parameters and Frequency l
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.
i II-A-7 Revision 2
O TDI OWNERS GROUP APPENDIX - II GENERIC MAINTENANCE MATRIX PART B PHASE I COMPONENTS O
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GENERIC MAINTENANCE MATRIX - PHASE I Component Component AIL.
I Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments i
1 MP-022/23 Turbocharger 1.
Measure vibration and X
To be accomp115hed during check with baseline data.
24-hour test run, i
2.
Inspect impeller / diffuser X
and clean if necessary.
3.
Measure rotor end play X
Review thrust bearing l
(axial clearance) to axial clearances after l
identify trends of inspection to determine increasing clearance if a trend exists. Any 1.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 the thrust bearing.
be performed after experiencing each 40 non prelubed (automatic) fast starts. In addi-tion, a one time inspec-tion should be completed after the first 100 engine starts.
5.
Disassemble, inspect, X
Note: During reassembly and refurbish.
ensure that capscrews are properly installed with the recommended torque.
If QR inspection was performed prior to accu-mulating significant hours (ip., the number of hours accumulated during plant preopera-tional testing, approxi-mately 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br />), the turbochargers should be reinspected at the next i
EOC.
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II-B-1 Revision 2
4 GENERIC MA A NANCE MATRIX - PHASE I l
Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 6.
The nozzle ring com-X Also perform a visual l
ponents and inlet inspection on one turbo-guide vanes should be charger per nuclear unit j
visually inspected at each EOC.
j for missing parts or parts showing distress.
Note: Discontinue inspec-l If such conditions are tion with appropriate re-4 noted, the entire ring design.
I assembly should be re-
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placed.
j 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, or other suit-exhaust temperature for able means that has been any cylinder exceeds appropriately tested and 1050*F (Refr: Table 1).
calibrated per plant pro-cedures.
Note: Also perform non-itoring any time the engine operates in an
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unbalanced condition.
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02-305A Base Assembly 1.
Perform a visual inspec-X Note: Any cracks detected tion of the base. The must be investigated l
Inspection should include further before the engine the areas adjacent to the is allowed to return to i
r.ut pockets of each bear-service. The mating sur-ing saddle and be con-faces of the base and cap l
ducted after a thorough shall be thoroughly cleaned j
wipe down of the surfaces, with solvent before any j
using good lighting.
reassembly. Perform on EOC basis for 3 cycles, then j
overhaul provided there are 1
satisfactory results.
Note: 3 EOC inspections may be eliminated by per-forming a metal analysis to confirm consistent to class 40 grey iron requirements; perfoming analysis does not elimi-nate need for overhaul inspections.
i Il-B-2 Revision 2
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GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 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 i
the absence of sur-face imperfections that might prevent tight boltup.
1 Note: Upon removal of l
bearing caps, clean mating surfaces with a solvent prior to reassembly of
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the caps to the base.
02-310A Crankshaft See site specific recommendations 02-315A Cylinder Block See site specific i
recommendations 02-315C Cylinder Liners 1.
Perform a visual inspection To be performed for first of liners for progressive 2 EOCs following piston i
wear.
removal; then discon-tinue until next piston removal. Boroscopic inspection is acceptable if heads are not removed.
Complete TDI Inspection and Maintenance Record Form No. 315-1-1 as applicable. TDI In-struction Manual, Volume I, Section 6.
l 02-340A/B Connecting Rods, Bushings 1.
Inspect and measure all X
Complete TDI 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 I, Section 6, Appendix III for clearance values.
Perform inspection at 5 years, on items acces-sible, consistent with Item 2 of this compo-nent.
1 Il-B-3 Revision 2
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GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.
Number Identification PM Pecommendation Monthly EOC EOC 5 Year Overhaul Comments 2.
Inspect and measure X
Complete 101 Inspection the c.onnecting rods.
Maintenance Record Form No. 340-2-1, -2 as Note: Perform inspection applicable. TDI In-and measure four connecting struction Manual, rods for DSRVs and two for Volume I, Section 6.
DSRs at random 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 applied.
Il-B-4 Revision 2
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GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.
Number identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 7.
At the overhaul, visually X
inspect the rack teeth surfaces for signs of fretting and at one time 5 year inspection for rods disassembled.
8.
Inspect mating 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 ultrasonically 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-fcr 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 tte 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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GENERIC MA TENANCE MATRIX - PHASE I
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Component Component Alt.
Number Identification PM Recommendation Monthly f0C EOC 5 Year Overhaal 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/8-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, 101 boroscope is acceptable.
Instruction Manual, Volume 1, 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.
kecord 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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O G[NERIC MAINTENANCE MATRIX - PHASE I Component Component AI L.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 3.
Blow-over the engine at In the event water is least 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> but'not detected, the cylinder more than 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> 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 Ill the cylinders. A second heads after one cycle air roll should be with positive inspection performed in the same results.
manner approximately 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> 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 i
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.
Il-B-7 Revision 2
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GENERIC MAINI NANCE MATRIX - PHASE I
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Component Component Alt.
Number Identification PM RecommenJation Monthly EOC EOC 5 Year Overhaul Comments 02-390C Push Rods 1.
Each push rod of the X
Refr: PNL-5600 forged-head design I
should be inspected by liquid penetrant prior to installation or, if i
installed, at each overhaul.
This should be repeated, until it has been deter-mined by 750 hours0.00868 days <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br /> 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 exhibiting cracks larger than 0.25 inch should be l
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.
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tion welded design should be inspected initially by liquid penetrant. If this If initial inspection was initial inspection was not not performed, perform on performed prior to placing sampling basis at 5 year the push rods in service, inspection consistent it shculd be performed at with Component 340A/B -
l the first overhaul. If the Connecting Rods.
I friction-welded push rod has been previously in-spected by liquid pene-trant, then visual exami-nation will suffice for future inspections. All friction welded push ris with cracks should be replaced, preferably with push ruds of the same design.
II-B-8 Revision 2
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Component Component Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments use TDI Instruction 02-390G Rocker Arm Capscrews, 1.
Verify capscrew torque Drive Studs (Pop Rivets) values during QR inspec-Manual, Volume I, tion. If not performed Section 8, Appendix IV for proper torque at QR, verify at next 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 <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br />, also inspect by EOC2.
2.
Check the key to keyway X
This along with the drive interface for a tight fit of the impeller onto j
the shaft will preclude l
fit on both the pump shaft to impeller and past problems where l
relative motion between the spline to pump shaft during pump shaf t and impeller caused j
reassembly.
fretting and upset of
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the keyway sides.
l At next teardown, verify j
impe11er is one piece, (i.e., without a bore l
insert). If it is not a one piece impeller, l
replace.
3.
It is recommended that the castle nut that drives the external spline on its taper have minimum and max-inum torque values of 120 ft-Ibs and 660 ft-lbs respectively for DSRVs and a maximum torque value of 77 ft-Ibs for DSRs.
Revision 2 II-B-9 e__
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TDI OWNERS GROUP APPENDIX - II GENERIC MAINTENANCE MATRIX PART C PHASE II COMPONENTS
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o GENERIC MAINTENANCE MATRIX - PHASE 11 Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments F-068 Intercoolers 1.
Record the following X
temperatures during the monthly surveillance test 1
I of the erigine: exhaust from cylinders and jacket cooling water supply.
Compare these results with i
similar data from previous month to establish whether the trend is sufficient to warrant further action.
2.
Inspect sheII and Inspect at [0Cl and EOC3 tube sides, and clean to verify item 1 results as required.
are valid.
3.
Verify intake manifold X
Note: Refer to TDI SIM drain connection is to be issued subsequent open and clean.
to March 1966.
4.
Perform leakage test of X
water side boundary for gross degradation.
CP-101A Emergency Generator 1.
Check operation of X
brushes and slip rings by visual examination during operation.
l 2.
Inspect all accessible X
parts of the generator,
)
and clean as required.
3.
X 4.
Verify that space heaters X
are on with engine shutdown.
5.
Measure vibration and X
check against baseline data.
CP-101B Emergency Generator Pedestal 1.
Drain, flush, refill X
Bearing bearing housing.
2.
Measure bear ing hous.I y X
insulation resistance.
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II-C-1 Revision 2
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GENERIC MAINTENANCE MAIRIX - PHASE 11 Alt.
Component Component Number Identification PM kecommendation Monthly EOC EOC 5 Year overhaul Comments 3.
Disassemble and inspect X
l bearing and check clearances.
i CP-102 Emergency Generator I.
Inspect panel for X
Control Panel cleanliness and clean as required.
4 2.
Check terminal boards X
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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
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sensitive label placed blackens, the maximus l
on the most visible temperature of the j
diode has been exceeded, l
face of the hexagonal j
body of the diodes.
requiring an electrical The label shall be inspection of the diode inspected before and and an inspection of af ter 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 thread condition is maintained.
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Il-C-2 Revision 2 i
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GENERIC MAINTENANCE MA1RIX - PHASE 11 Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year overhaul Comments b.
Inspect glyptol applied X
Relighten 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 needed, remove glyptol, j
inspect glyptol applied l
to the the side of the and reapply when the adjustment screws for each adjustment procedure i
1 of the five adjustment is complete.
potentiometers on the printed circuit board of the voltage regulator for signs of relative motion.
4 1
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8.
Printed circuit boards -
X Report any abnormal check for cleanliness conditions to engineer-a l
and proper mounting of ing for evaluation.
I components, i
9.
Implement a procedure to lhls recommendation is monitor generator voltage required 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 logic in of a failed start.
the generator control.
1 i
00-420 Lube Oil Pressure Regulating 1.
Disassemble and clean.
X If valve sticks repeat-l Valve edly, more frequent f
cleaning may be necessary. If valve plugging becomes a prob-lem, the dimensions of the valves internal parts should be checked to ensure proper clearance.
l 2.
During initial startup after I
a major reassembly of f
tube oil piping, abnormal 1
lube oil pressure excursions should be investigated and I
remedial action taken until excursions subside, i
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l II-C-3 Revision 2
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GENERIC MAINIENANCE MATRIX - PHASE II Component Component Alt.
Number Identification PM Recommendation Monthly M
M 5 Year Overhaul Comments 00-442A Starting Air Distributor 1.
Visually inspect the X
Evaluate the degree of Assembly poppet valve spool ends wear to determine 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 E0Cl 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.
02-3078 Lube Oil Tubing and 1.
Check accessible tubing To be performed as Fittings - Internal for dents or crimps required.
after periorming main-tenance in that area.
02-3108 Main Bearings Shells 1.
Inspect and measure thickness X
Note: Perform inspec-of all main bearing shells.
tion on bearings 5 & 7 Inspection shall evaluate for DSRVs and mains bearing wear and evidence between 5 & 6, and of harmful crankshaf t 6 & 7 for DSAs on one misalignment. If results engine / station at EOC2.
show evidence of mis-At one time 5 year in-alignment, 101 recom-spection, inspect bearings mendations for crankshaf t 3 through 8 inclusive.
realignment should be Complete TDI Inspection implemented.
and Maintenance Record Form No. 310-2-1 as applicable. TDI Instruction Manual, 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 Coaoonent 02-310A.
L Il-C-4 Revision 2
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's GENERIC MAINIENANCE MATRIX - PHASE !!
Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-310C Thrust Bearing Ring 1.
Measure thrust bearing X
Complete applicable ring clearance by sections of 101
" bump check" method to be Inspection and Main-performed in conjunction tenance Record Form with crankshaft web No. 310-1-1 IDI Instruc-deflection measurements.
tion Manual, 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 TDI
- Hours of engine operation Instruction Manual,
- Hours of engine operation at least one bearing since last bearing re-must be replaced.
placement Bearings should also
' Bearing clearance be replaced if they are cracked or gouged.
2.
Visually inspect thrust X
10 be performed at bearing ring for signs 10 year interval only of wear or degradation.
(i.e., not at one time 5 year inspection).
02-311A Crankcase Assembly 1.
Perform a visual inspection X
The first inspection of the vertical portion of after 185 hours0.00214 days <br />0.0514 hours <br />3.058862e-4 weeks <br />7.03925e-5 months <br /> of at the crankcase arch wall to or near full load opera-the nut pocket area for Lion may be used to indications of cracking.
justify the discontinua-tion of such inspection untti an overhaul. For engines with less than 185 hours0.00214 days <br />0.0514 hours <br />3.058862e-4 weeks <br />7.03925e-5 months <br /> operation at or near full load, inspect at each EOC until exceeds 185 hours0.00214 days <br />0.0514 hours <br />3.058862e-4 weeks <br />7.03925e-5 months <br />.
2.
Remove alternate left X
If excessive water, sludge side doors and or any indication of examine the inside bearing failure is present, of the engine for any drain crankcase, deter-abnormal conditions.
eine cause, and take Check with a good necessary corrective light for evidence of action.
babbit flakes.
3.
Check internals of X
block and base for leaks.
Il-C-5 Revision 2
GE NE RIC MA'i ENANCE MATRIX - PHASE II j
Component Component Alt.
Number Identification PM Recommendation Monthly
[0C EOC 5 Year overhaul Comments 02-317A&B Water Discharge Manifold -
1.
Visually inspect for X
Jacket Water Discharge leaks.
Piping, Coupilngs and Seals 02-341B Piston Rings 1.
Inspect and measure piston Complete TDI Inspection replacement rings, ar.d Maintenance Record Form No. 341-2-1 as appIlcable, IDI Instruc-tion Manual, Volume I, Section 6.
Use Volume 1, Section 8 Appendix 111 for clearance values.
To be performed as required.
1 02-341C Piston Pin Assembly 1.
Visually inspect for X
Also to be performed one chrome plate damage.
time at the 5 year Replace pins which show inspection on sampling chipped or blistered basis consistent with chrome.
Component 340A/8 -
Connecting Rods.
Note: AII new or re-pla:ement pins should be Note: MT 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 Ruds.
02-345A Intake and Exhaust Tappet 1.
Visually inspect intake and X
Complete TDI Inspection Assembly exhaust tappet assembly and Maintenance Report condition, and verify that Form No. 345-1-1 as can rollers are free to applicable, IDI Instruc-rotate and that there is tion Manual, Volume I, no noticeable clearance be-Section 6.
Refr: IDI tween the can rollers and Instruction Manual, the roller pins. Do this volume 1, Maintenance by manually checking for Schedule. Perform an excessive motion and additional inspection visually observing for by EOC2 on exposed or abnormalities on the mat-accessible assemblies, ing surfaces.
Also perform one time at 5 years consistent with Component 02-340 A/B lien 2.
4 II-C-6 Revision 2 l!
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GENERIC MAINTENANCE MATRIX - PHASE 11 1
Component Component AI L.
l Number identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-3458 fuel Tappet Assembly 1.
Visually inspect fuel tappet X
Complete TDI 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-that there is no notice-tion Manual, Volume 1,
.i able clearance between Section 6.
Also perform the can rollers and the one time at 5 years roller pins. Do this consistent with Componcnt 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 the expected life based I
on the size and extent of surface distress.
Any corrective measures shall be implemented as indicated by this analysis. Signs of I
spalling shall result in immediate replacement of.
i the can. Perform an I
additional inspection by EOC2 on exposed or 4
j accessible assemblies.
l Refr: 101 Instruction Manual, Volume I, Maintenance Schedule.
j Also to be performed one time at 5 years consistent with Com-ponent 02-340 A/8.
02-3508 Can Shaft Bearings 1.
Inspect and measure cam X
Complete TOI Inspection shaft bearing shells, and Maintenance Record i
Form No. 350-1-1 as l
applicable, IDI instruc-i tion Manual, Volume I, Section 6.
Use Volume 1, l
Section 8, Appendix 111 for clearance values.
1 i
l Il-C-7 Revision 2 l
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GENERIC MAINTENANCE MATRIX - PHASE II Alt.
Component Component Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments Also at one time 5 year inspection for Component 02-340A/8 measure clear-ances per 101 on one bearing housing / camshaft.
02-350C Can G o r 1.
Visually inspect can gear X
For engines with less for chipped or broken than 750 hours0.00868 days <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br />, also teeth, pitting, excessive inspect at EOC2.
wear, or other abnormal conditions. At this in-spection, the gear is in immediate proximity to the spray nozzle which should also be visually inspected.
2.
Measure gear backlash.
X Complete applicable X
sections of TDI Inspec-Note: If can gear hub tion and Maintenance is removed, it is Record form No. 355-1-1, recommended that the nut TDI Instruction Manual, be relocked at the Volume 1, Section 8, position corresponding Appendix 111-1 for to the torque of 70120 clearance values.
ft-lbs.
Insertion of the cotter pin must be Note: Refer to TDI accomplished at a torque SIM to be issued sub-150 f t lbs and 190 sequent to March 1986.
ft -Ibs.
If this is Also to be performed not possible, another one time at 5 years bolt, nut or washer consistent with Con-should be used.
ponent 02-340 A/8.
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 broken teeth, excessive should be reported wear, or progressive for an engineering pitting or other abnormal evaluation. For engines conditions.
with less than 750 hours0.00868 days <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br />, also inspect by E0C2.
Il-C-8 Revision 2
GENERIC mal'NIENANCE MATRIX - PHASE 11 Component Component Alt.
Number Identificath PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 2.
Measure gear backlash.
X Complete applicable sections of IDI Inspection and Main-tenance Record Form No. 355-1-1, TDI Instruction Manual, Volume I, Section 6.
Use Volume 1, Section 8, Appendix 111-1 for clearance values.
1 j
02-3558 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 l
abnormal conditions.
than 750 hours0.00868 days <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br />, also
^
inspect at EOC2.
2.
Measure gear backlash.
X Complete applicable sections of TDI Inspec-Note: If idler gear hub tion and Maintenance is removed, it is recom-Record Form No. 355-1-1, mended that the nut be TDI Manual, Volume 1, relocked at the position Section 6.
Use Volume 1, 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-Ibs and < 90 f t-Tbs.
If
~
this is not possible, another bolt, nut, or washer should be used.
i 02-359 Air Start Valves 1.
Remove, cican, and inspect X
Ensure valve installation air start valves. (Re-includes retorque re-I place copper valve-to-quirements.
head gasket).
Refr..
TDI SIM 360.
j i
2.
Inspect the piston, cap, X
l 1
guide, and housing sliding i
surfaces to evaluate wear or corrosion.
02-360B 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-stems and seats for v. ire pling basis consistent drawing, pitting, d.>tur-with Component 340A/B.
Lion, concentricity, and i
any abnormal condition.
Il-C-9 Revision 2 i
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GENERIC MAINTENANCE MATRIX - PHASE 11 t
Component Component Alt.
Number Identification PM Recommendation Monthly EDC EOC 5 Year Overhaul Comments 2.
Visually inspect subcovers This is a one-time only for evidence of valve inspection, to be a
guide blowby (soot).
performed after 500 or l
600 hours0.00694 days <br />0.167 hours <br />9.920635e-4 weeks <br />2.283e-4 months <br /> of operation after rebuild of a l
cylinder head.
l l
3.
Measure intake and ex-X Complete applicable l
haust valves head sections of TDI r
l thickness.
Inspection and Main-I tenance Records Form i;
360-2-1 TDI Instruc-tion Manual, Volume I, Section 6-one sheet for i
each cylinder. Use Section 8, Appendix III for clearance values. (Items 2 & 3).
Also to be perfomed one
[
I time at 5 years on sampling basis consis-i tent with Component 340A/8.
i 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. TDI Instruction Manual, Volume I, Section 5-one sheet for each cylinder. Use 101 SIM 336, Rev. I for clear-ance values (acceptante criteria). Also to be performed one time at 5 years on sampling basis consistent with Cog,onent 340A/B.
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/B. Subcovers with rod side only).
pedestal cracks that j
extend through the i
counter bore web down to the threads should be replaced. Refr:
DR/QR Report #02-362A.
11-C-10 Revision 2
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N GENERIC MAINlENANCE MATRIX - PHASE II Component Component Alt.
Number identification PM Recommendation Monthly E0C 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 101 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.
02-365B Fuel Injection Nozzles 1.
Remove, inspect, and clean X
Ensure that a new copper 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 I, Section 6.
Note: 135* fuel oil tips may be used if inspection results indicate a need for additional action to improve lubricatior and reduce coke buildup.
2.
Check nozzle pop pressure.
X 3.
Check spray pattern.
X ll-C-11 Revision 2
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GENERIC MAINTENANCE MATRIX - PHASE 11
]
Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-365D Fuel Oil Injection Lines:
1.
Visually inspect support X
Any inserts found to be Supports elastomer inserts for unsatisfactory shall be deterioration or degrada-replaced with new inserts 1
tion.
prior to reassembly of i
fuel oil lines. This inspection can be per-formed prior to reassembly of the fuel oli lines in conjunction with the i
cyIfnder lir.er inspection.
02-371A Fuel Pump Control Shaft 1.
Check and lubricate as required.
j 02-371B Fuel Pump Linkage Assembly 1.
Grease swivel link or X
1 and Bearings otherwise Iubricate i
all fuel oil pump i
assemblies.
1 l
02-380A Exhaust Manifold 1.
Perform a visual examination X
To be performed at EOCl of accessible pipe welds and alternate EOCs
)
and corresponding heat-thereafter.
affected zones.
i 02-385A Crankcase Relief Valve 1.
Clean flame arrestors.
X 2.
Inspect seat and disc.
X j
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 are time at 5 years on bushings.
sampling basis con-51 stent with Component 340A/B.
2.
Visually inspect and X
Also to be performed one 1
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 arm bushings, sampling basis consist-ent with Component 340A/B.
I Il-C-12 Revision 2 l
s A
GENERIC MAINTENANCE MATRIX - PHASE II Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-390F Hydraulic Valve Lifters 1.
Check and adjust valve X
lash.
2.
Reinstall and adjust X
Also to be performed one Ilfters.
time at EOC2 and at 5 years on a sampling basis consistent with Component 340A/8.
Note: Ensure lifters are installed with the fill holes up.
Verify condi-tion of lifters by com-parison of lifter leak-down rate (actual) to specifications noted on IDI Maintenance Manual.
Refr: TOI Maintenance Manual, Section 6-B-5.
02-410A Overspeed Trip Governor 1.
Check trip set point -
X Modify the surveillance adjust as required.
testing procedure to include verification that the overspeed trip is correctly set to an overspeed trip setting of 517 1 5 rps. Ensure that the electric governor setting is properly re-turned to 450 rpe 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 EOC2.
?
l Il-C-13 Revision 2
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,j GENERIC MAIN 1ENANCE MATRIX - PHASE II Alt.
Component Component Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments Note: Af ter setting the overspeed governor, the adjustaent screw settings should be marked with Torque 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 shafts for excessive X
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 EOC nearest 5 years. For and Shaft of wear.
engine with less than 750 hours0.00868 days <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br />, also inspect at EOC2.
02-411B Governor Drive - Couplings, 1.
Check that coupling is X
If the coupling is found (excluding Pins and Keys tight on shaft.
to be loose, it should be removed, all nating San Onofre surfaces cleaned, and
- See Site the unit reassembled Specific for San using Loctite 609 on the Onofre) mating surfaces.
i l
l l
l Il-C-14 Revision 2
O O
O GENERIC MAINTENANCE MAIRIX - PHASE II Component Component AIL.
Number Identification PM Recommendation Monthly M
g 5 Year Overhaul Comments 2.
Replace the elastomeric X
insert in the Koppers coupling.
4 02-413A Governor Linkage 1.
Install positive locking Note: To be performed l
hardware to the lever as necessary after are clamp bolt heads and tightening governor shaft roll pins.
linkage hardware to design -
torque spectfications.
2.
Inspect for loose parts X
on the linkage assembly.
02-413A Governor Linkage 3.
Lubricate cross shaft (DSRVs caly) bearings as required.
4.
Grease the rod end X
fittings, or lubricate oil wicks, especially those at the ends of the cross shaft.
02-4138 fuel Pump Linkage:
1.
Check cylinder for, X
To be accomplished when Automatic Shutdown Cylinder extension and return.
placing unit in main-tenance modes.
2.
Check tallrod went X
To be accomplished during for air leakage, controls system check.
02-415A Woodward Governor 1.
Drain, flush, refill, and X
Note: Ensure the hy-vent actuator 011 system draulic actuator is pro-with new oil from a perly vented.
clean container ensuring the appropriate cleanliness procedures are followed.
1 If contaminated oil is noted, increase frequency.
2.
Disassemble, clean, and X
]
refurbish the actuator.
3.
Verify all governor X
Note: Mechanical
)
control knob settings governor setting to l
I are in appropriate be 470 rpm.
positions.
1 1
i Il-C-15 Revision 2
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V GENERIC MAINIENANCE MATRIX - PHASE 11 Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 4.
Evaluate electric X
An evaluation of the governor settings to governor settings is verify overshoot of to be performed during the 450 rps set speed surveillance testing once is within plant-specific under joint mechanical guidelines and to and electrical governor avoid critical speeds control.
during start or when unloaded.
02-4158 Governor Booster Servosotor 1.
Clean, inspect, and X
replace "3" rings and gaskets.
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
and Fittings leaks.
02-441B Air Filter to Starting Air 1.
Replace filter elements.
X This can be modified so Distributor if filter in a metal that the filter is to be screen, cleaning with changed at a maxineum solvent is acceptable pressure drop of 25 psi in lieu of replacement.
for engines equipped with pressure monitoring devices.
Air Start Admission Valve 2.
Clean and inspect strainer.
X If the strainer is Strainer excessively dirty, the frequency of cleaning and inspecting should 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 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
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GENERIC MAINIENANCE MATRIX - PHASE II i
Component ComponenL Al L.
j Number Identification PM kecommendation Monthly M
g 5 Year Overhaul Comments I
.l 02-455A Fuel Oil Filter 1.
Record filter differ-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 tne 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.
J 3.
Inspect tubing and me-X Refr: 101 Instruction i
chanical connections for Manual, Volume 1.
tightness and/or leaks.
02-455B Fuel Oil 5 trainers 1.
Record strainer dif fer-X If greater than 5 psid-ential pressure or monitor shift, clean element.
supervisory alars as Bolt torques of 120-150 applicable.
in-lbs should be uti-lized during reassembly.
l 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 j
Flexible Coupling I
(Small Bore Scope Only) 1 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 i
inspected to assure that no screw has loosened because a
of engine operating loads.
If during these inspections none of the screws are found loosened or damaged, future I
t II-C-17 Revision 2 I
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O GENERIC MINTENANCE MATRIM - PHASE II i
Component Component
- Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments inspections are to be con-ducted on a yearly basis 1
(or during plant shutdown).
But if any time during inspection any screw is found j
loosened or damaged, it must j
then be replaced (if damaged) and all screws retorqued as jl follows: 125 ft-lbs for the i
bracket-to-engine screws and i
75 f t-Ibs for the bracket-to-turbo base screws.
Note: To avoid damage to bracket to engine, and/or i
bracket to turbo, the pro-i per torques as delineated above should be utilized l
for each respective bracket bolting application..
j 02-4758 Air Butterfly Valve 1.
Lubricate valve shaft X
If oil cups are used, via grease fittings.
Iubricate shaft monthly.
I 2.
Check valve disc for X
Check by visually observ-l 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 (jan nuts and lock washers) l are Light.
i 02-500A Engine Control Cabinet 1.
Inspect interior of cabinet X
l for cleanliness, and clean as required.
l 2.
Visually check wiring for X
insulation degradation.
i 3.
Visually check instrument X
tubing for leaks.
1 4
Functionally check cabinet X
heater and calibration of thermostat.
1 i
Il-C-18 Revision 2 l
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GENERIC MO NTENANCE MATRIX - PHASE 11 Component Component AIt.
Number Identification PM Recommendation Monthly EOC g
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 may exist down-stream.
7.
Monitor control system air X
pressure or supervisory alarm as appilcable.
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.
panel 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.
II-C-19 Revision 2
.)
GENERIC MAINTENANCE MATRIM - PHASE 11 Alt.
Component Component Number Identification PM Recommendation Monthly M
g 5 Year Overhaul Comments 02-5258 Barring Device Control valve 1.
Replace control valve As required.
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.
af ter each reassembly.
Check lubricating X
Refr: IDI Instruction oil with a viscost-Manual, Volume 1 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 ea3-oli system and ine oil use HD oil that clean sump tank.
meets or exceeds series 3 Refill with new oil.
standards. The base stock To be performed should be more resistant based on sample to thermal degradation analysis.
and coke formation. The additive package should 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 f
- 2 fuel, oil and a sulfated ash content of 1.5% to 2.0%
i is preferred. An engine I
oil with such properties, Mobliguard 412 or equiv-1 I
alent product may be used to insure improved lubri-i cation. Do not six lube oil brands or types. When changing tube oli replace the entire charge.
Re-place as required.
t l
l 11-C-20 Revision 2 J
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,__-_m
-,e-A L.
-+-6.
s fV GENERIC MAliTENANCE MATRIM - PHASE Il Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 3.
Visually inspect lube To be performed per oil sump tank level appropriate site intervals switch floats. Check for siellar equipment.
switch set points.
4.
Perform a spectro-X Note: Sample to be chemical engine oil drawn upstream of analysis to assist lube oli filter.
the bearing monitoring items 1 and 4 can program. To further be performed using expand or clarify chemical the same sample, 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 TDI Instruction for correct torque.
Manual, Volume 1 Retorque as necessary, Section 8, Appendix then recheck crankshaf t IV for proper torque web deflections.
values.
3.
Generator foundation bolts are to be retorqued af ter a generator short circuit if the bolts were initially torqued to 480 ft-Ibs. If initial bolt torque was 600 ft-Ibs, no retorque is required.
02-6300 Thermocouples 1.
Check that thermocouple X
An inconsistent reading indicates ambient engine traced to thermocouple temperature when the trouble should result engine is cold.
in replacement of the thermocouple.
II-C-21 Revision 2
i
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i
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GENtRIC Mi%1[ NANCE MlRIX - PHASE 11 j
Component Component AIL.
Number identification PM Reconsendation Monthly EOC EOC 5 Year Overhaul Comments t
2.
Clean and inspect Indications of fatigue
~
l thereocouples and should result in re-i thermocouple shields placement of the thereo-
)
as required.
couple and/or thereo-couple shield.
3.
Pyrometer wiring - check To be accomplished dur-j that terminations are ing control panel check-i l
tight.
out and initial operation inspections.
02-6958 Engine Control Air 1.
Inspect and clean engine Note: This reconsenda-Pressure Regulator control air pressure tion should be reassessed regulator when pressure depending on the degree a'
gauge indicates abnormal of systee fouling, pressure reduction during normal engine shutdown.
i 2.
Replace elastomeric parts As required.
and gaskets in the pressure regulator.
02-695C Engine Control Pneumatic Trip 1.
Check switch set points Pressure switches and Switches per appropriate site temperature switches.
interval.
j 1
2.
Replace elastomeric parts.
As required.
02-7008 Jacket Water Standpipe:
1.
Replace elastomeric As required.
l Valves parts in valves.
4 j
02-700F Jacket Water Standpipe 1.
Visually check jacket Any visible cracking
)
and Miscellanenous Bolting water standpipe, pump or einer jacket water i
suction and engine return leakage should result i
nozzle welds during each in rework of cracked routine engine run and nozzle welds.
{
every 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> during 4
extended engine runs, 1
i 2.
Check treatment (ph, X
Also to be performed j
etc. as applicable) of alter adding makeup i
jacket water and correct water.
j as recommended by chee-l ical supplier.
i 02-7178 Auxiliary Sub-Base and 1.
Inspect the valves X
Replace packing as l
Oil & Water Piping -
for packing leakage.
necessary.
Jacket Water: Valves 4
i I
II-C-22 Revision 2 t
i GENERIC MAETENANCE MATRIX - PHASE II 1
Component Component Alt.
humber Identification PM Recommendation Monthly M
M 5 Year Overhaul Comments 02-717C Auxiliary Sub-Base and Oil &
1.
Visually inspect for leaks. X Water Piping - Jacket Water:
1 Pipe, Coupilngs, Fittings Orifices Y-$ trainers (Small Bore Scope Only) 1 l
02-717F Auxiliary Sub-Base Lube Oil 1.
Visually inspect pipe X
Pipe and Fittings and joints for leakage.
2.
Clean and inspect tube Complete when lube oil oil keep-warm pump suction tank is drained.
strainer as required.
I 02-717G/K Auxiliary Sub-Base Lube 011/
1.
Disassemble, inspect, Fuel 011 Valves and refurbish off i
engine lube oli and fuel oil valves as required.
2.
Check relief valve X
lift pressure. Ols-assemble and clean if i
necessary.
02-805B Intake Air Filters 1.
Inspect air intake /oit Replace with change oil bath filters every 3 to if necessary. If samp-i 6 months.
ling is utilized, change based on analysis re-I sults.
I l
02-805D Flex Connection (Exhaust) 1.
Visually inspect for X
I evidence of cuts, holes, or dents.
1 2.
Visually check for X
evidence of exhaust leakage.
02-810C Jacket Water 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 flow is sufficient).
Alternatively, servir Water Cheelstry contiol can be used to maintain heat exchanger performance and integrity.
II-C-23 Revision 2
i w
GENERIC MAINTENANCE MATRIX - PHASE II Alt.
l Component Component i
Number identification PM Recommendation Monthly IDC EOC 5 Year Overhaul Comments 2.
Record heat exchanger X
Use for trend data.
]
parameters.
1 l
3.
Evaluate heat exchanger X
j performance data.
4.
Inspect tubes and tube X
Refr: 101 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 I
plant heat exchangers utilizing similar water s
chemistry.
3 5.
Inspect and clean Replace or rework lantern l
lantern ring as required.
ring as necessary to Verify leak-off holes ensure concentricity are not plugged.
prior to reinstalla-i tion.
J 6.
Replace packing Replace packing when j
rings as required.
packing becomes hard or leakage at the packing is noted and cannot be stopped by tightening.
02-8100 Ihermostatic Valves 1.
Replace thermal power elements as required.
I 2.
Visually inspect valve X
To be accomplished 1
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 siellar equipment. Replace heater if degradation of insulation resistance is noted.
i 1
Il-C-24 Revision 2
C O
O" GENERIC MAINTENANCE MATRIX - PHASE 11 Component Component Alt.
Number Identification PM Recommendation Monthly M
Eg 5 Year overhaul Comments 02-820A Lube Oil Susp Tank 1.
Inspect and clean Replace heater if de-Heaters heater elements as gradation of insulation required by trend data.
resistance is noted.
I 2.
Check calibration and 10 be performed at inspect condition of appropriate site intervals thermostat.
for siellar equipment.
02-820C Lube Oil Keep-Wars Pump 1.
Check mechanical seal X
and piping connection for leakage.
j 2.
Verify pump discharge X
Use for trend data.
i pressure is within manufacturer's specifi-cation.
02-8200 Lube Oil Keep-Warm Strainer 1.
Clean or replace strainer element when the differential 1
pressure change at the tube oil keep ware strainer is j
20 psid or for those plants not having this capability, clean or re-place when differential pressure of keep ware filter is 20 psid.
02-820E tube Oil Keep-Warm Filter 1.
Record filter differential X
pressure.
2.
Change filter To be performed when l
elements as required.
the filter differential pressure reaches 20 l
psid. For sites not i
equipped with differ-ential pressure gauge, inspect monthly and clean as necessary.
l 02-820F Full Flow Lube Oil 1.
Record filter differential X
Use for tre d data.
Refr: IDI Instruction j
Filters pressure.
m nual, Volume I, I'
k intenance Schedule.
2.
Replace filter cartridges To be performed when the and perform a visual filter differential inspection to determine pressure reaches 20 psid.
nature of the material caught in the filter.
I 1
II-C-25 Revision 2
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i GENERIC MAINTENANCE MATRIX - PHASE 11 Alt.
Component Component i
Number identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments i
3.
To be performed at calibration check.
appropriate site I
intervals for similar equipment.
i 1
i 02-820G tube Oil Heat 1.
Record heat exchanger X
Use for trend data.
Exchanger parameters.
2.
Evaluate heat exchanger X
{
periormance data.
i l
3.
Inspect tubes and tube X
Refr: TDI Instruction l
sheet.
N nual, Volume 1, hintenance Schedule.
a 4.
Inspect and clean lantern Replace or rework lantern ring as required. Verify ring as necessary to i
leak-off holes are not ensure concentricity, plugged.
I 5.
Replace packing rings When packing becomes at the floating tube hard or leakage at the 4
sheet during reassembly.
packing is noted and cannot be stopped by tightening.
i 02-820H Full Pressure tube Oil Strainer 1.
Monitor differential X
Use for trend data.
pressure of strainer and/or filter.
i 2.
Clean or replace strainer To be performed when the element when the differ-differential pressure j
ential pressure change across the strainer is i
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.
l differential pressure of full pressure filter is 1
1 20 psid.
3.
Lube oil strainer lo be performed per appropriate site intervals '
i pressure gauge -
calibration check.
for similar equipment.
I l
II-C-26 Revision 2
C O
o GENERIC mal"TENANCE MAlRIX - PHASE 11 Alt.
Component Component Number Identification PM Recommendation Monthly 10C EOC 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 and replace as neces-sary.
5.
Change compressor oil X
at each EOC, or if monthly sampling is performed change as required based on results.
6.
Check belt tension.
X 7.
Check pulley clamp X
bolts and set screws l
tight.
8.
Inspect filter felts on X
Replace as required, if so equipped.
unloader system.
02-8351 Air Dryers and 1.
Inspect and service X
Moisture Traps moisture traps.
2.
Check proper operation X
Replace desiccant charge or refrigerant as re-1 of dryer.
quired.
02-835J Starting Air Storage 1.
Disassemble and clean X
Tank the float trap if installed.
Revision 2 11-C-27
P l
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J GENERIC mal TENANCE MATRIX - PHA'J 11 i
j Component Component Alt.
Number Identification PM Recommendation Monthly M
M 5 Yeg Overhaul Comments s
j 2.
Starting air tank pressure To be performed per
.i gauges - calibration appropriate site l
check.
Intervals for siellar equipment.
I l
3.
Starting air tank pressure To be performed per switches - calibration appropriate site check.
intervals for siellar equipment.
Piping System 1.
Conduct a detailed vis-X Tighten, repair, or (for itees not previously ual and audible inspec-replace as required.
covered) tion of all fuel, air, Refr: IDI Instruction oil, and water piping Manual, Volume I, and valves for leakage.
Maintenance Schedule.
l l
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t 4
E l
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4 i
ll-C-28 Revision 2 I
TDI OWNERS GROUP APPENDIX-II SITE SPECIFIC MAINTENANCE MATRIX PART D O
O
O
\\.
i SITE-SPECIFIC MAINTENANCE MATRIX l
Component Cumponent Alt.
I Number Identification PM Recommendation Monthly EOC_
g 5 Year Overhaul Comments l
02-310A Crankshaft 1.
Measure and record crank-X Complete 101 Inspection i
(Comanche shaft web deflections and Maintenance Record Peak)
(hot and cold).
Form No. 310-1-1 as applicable, 101 Instruc-i tion Manual, Volume I, Section 6.
Refr: 101 Instruction Manual, Volume 1. Maintenance Schedule.
2.
Examine the fillets and Also to be performed once oil holes of three main at 5 years.
bearing journals (4,6,& 8)
Refr: PNL-5600.
using LP.
If indications 1
are evident, a more thor-
)
ough examination should I
be made using appropriate NDE methods.
j 3.
Examine the fillets and Also to be performed once oil holes in three of the at 5 years.
crankpin journals (choose Refr: PNL-5600.
t 3 from Nos. 3 through 8 inclusive) using LP.
If indications are evident, a more thorough examina-tion should be made using 1
]
appropriate NDE methods.
l 4.
Measure diameter of crank-X Complete TDI Inspection pin journals, and Maintenance Record Form No. 310-3-1 as applicable, IDI Instruc-tion Manual, Volume 1 Section 6.
]
Also perform inspection at 5 years, on items l
accessible, consistent i
l with this component and Component 02-340A/S.
1 i
l I
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Il-D-CPI Revision 2
i
"'s J
i i
f SITE-SPECIFIC MAINTENANCE MATRIX 1
l Component Component Alt.
j kumber Identification PM Recommendation Monthly EOC EDC 5 Year Overhaul Comments
)
5.
Analyze the trends of X
If an engine operates cylinder pressure and in a severely unbalanced l
temperature measurements condition, reinspect the to detect imbalances.
oil holes for fatigue cracks within a time-l frame determined by the j
utility consioering the particular circumstances t
of the abnormal operation.
i Refr: PNL-5600.
j I
Note: To avoid the Refr: PNL-5600.
t effects of the 4th order resonance, steady normal-loaded operation at speeds more than a few rpm below the rated speed of 450 rpm should be avoided. Appropriate l
l precautions should be i
taken to prevent sus-l tained engine operation I
with significant cylinder imbalance. Lower speeds j
for testing and break-in i
j are permissible. Avoid resonance frequencies.
i 4
i i
1 1
1 r
I l
r I
Il-D-CP2 Revision 2 j
t O
O SITE-SPECIFIC MAINTENANCE MATRIX Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-315A Cylinder Block 1.
Perform a visual inspection X Perfore monthly during (Comanche Peak) of the block top under surveillance run. Also intense light to detect perfore during any period any obvious evidence of continuous operation of cracking. Areas on a daily basis.
between adjacent cylinder Refr: DR/QR Report heads should be included 02-315A.
in this inspection.
2.
For blocks with known or X
Also, this inspection assumed ligament cracks, must be performed perform a visual and after any period of boroscopic inspection of operation exceeding block tops for stud-to-50% load, stud cracks between Refr: DR/QR 02-315A cylinder heads and the and/or subsequent in-block edge and the block spections.
edge and studs at the block ends.
3.
Additional inspecticas To ensure engine to be performed per availability after DR/QR Report 02-315A.
operation above 50%
load, maintain the engine in standby service and perform the required surface inspection of the block top within 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br />.
l l
I I
II-D-CP3 Revision 2
l O
TDI OWNERS GROUP APPENDIX-II CROSS REFERENCE INDEX BY COMPONENT i
PART E i
l Legend 1.
Index sorted by component name.
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.
4.
Maintenance or surveillance requirements for a subcomponent should be disregarded for those engines not equipped with the subcomponent.
l l O
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 ON0FRE V0GTLE GULF BELLEFONTE HARRIS Air Butterfly Valve 02-475B/
03-475B/
02-475B/
03-4758/
02-475B/
02-475B/
03-4758 02-475B 02-475B 02-475B 02-475B 02-4758 Air Dryers and Moisture Traps 02-3351/
03-833H/
02-835A/
03-8351/
02-835A/
02-835G/
)j 03-835H 02-833F 02-835G GG-115 02-835C 02-835C Air Filter to Starting Air 02-441B/
03-4418/
02-441B/
03-441B/
02-441B/
02-4418/
Distributor 03-441B 02-441B 02-4418 02-441B 02-441B 02-4418 Air Start Block Valves NONUM/
N0NUM/
NONUM/
N0NUM/
N0NUM/
NONUM/
03-441B N0NUM NONUM NONUM NONUM NONUM Air Start Valves 02-359/
03-359/
02-359/
03-359/
02-359/
02-359/
03-359 02-353 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 &
02-7178/
03-717B/
02-717B/
03-7178/
02-717B/
02-7178/
Water Piping - Jacket 03-717B 02-7178 02-717B 02-7178 02-717B 02-7178 Water:
Valves Auxiliary Sub-Base Lube Oil 02-717F/
03-717H/
02-717F/
03-717H/
N0NUM/
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/
NONLH/
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
O O
O TDI COMPONENT NUMBER CROSS REFERENCE I
RANCHO RIVER 1
CDMANCHE SEC0/
BEND /
WNP-1/
PEAK /
SAN PERRY /
GRAND CATAWBA /
SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS i
Barring Device Air Filter 02-525C 03-525C
/
/
/
/
L i
j Barring Device Control Valve 02-525B/
03-525B/
02-525B/
03-5258/
/
02-5258/
1 and Press Regulator 03-525B 02-525B 02-525B j
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/
03-350C/
02-350C/
02-350C/
03-350C 02-350C 02-350C 02-350C 02-350C 02-350C Camshaft Assembly 02-350A/
03-350A/
02-350A/
03-350A/
02-350A/
02-350A/
03-350A 02-350A 02-350A 02-350A 02-350A 02-350A Camshaft Bearings 02-3508/
03-3508/
02-3508/
03-3508/
02-350B/
02-3508/
03-350B 02-3508 02-350B 02-350B 02-3508 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 02-500C 02-500C 02-500C Connecting Rods, Bushings 02-340A/B/
03-340A/B/
02-340A/B/
03-340A/B/
02-340A/B/
02-340A/B/
l and Bearing Shells 03-340A/B 02-340A/B 02-340A/B 02-340A/B 02-340A/B 02-340A/B l
Control Panel Assembly:
02-500J/
03-500J/
02-500I/
03-500J/
02-500J/
02-500J/
Relays 03-500J 02-500J 02-500J 02-500J 02-500J 02-500J Control Panel Switches 02-500N/
03-500N/
02-500M/
03-500N/
02-500N/
02-500N/
Terminal Boards and Wiring 03-500N 02-500N 02-500N 02-500N 02-500N 02-500N l
II-E-2
O O
O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COM/ NCHE SEC0/
BEND /
WNP-1/
PE AK/
SAN PERRY /
GRAND CATAWBA /
SHEARON COMPONENT DESCRIPTION SH0GEHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS 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/
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/
/
/
/
/
/
N0NUM 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/
02-360B/
03-3608/
02-360B/
02-3608/
and Exhaust Valves 03-3608 02-360B 02-3608 02-3608 02-3608 02-360B 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 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 ONOFRE 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 02-835B/
03-835G/
02-835D/
03-8350/
NONUM/
02-835B/
Compressors10-112 02-835A 02-835A GG-113/14 02-8358 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 84-1018/
Bearing (and shaft) 03-650C S0-103 02-650C GG-1018 BL-101C 02-650C 6
Engine Control Air 02-6958/
03-6958/
02-6958/
03-6958/
02-695B/
02-6958/
Pressure Regulator 03-6958 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 i
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 02-8050/
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 02-3658/
03-365B/
02-365B/
03-365B/
02-365B/
02-365B/
03-365B 02-3658 02-365B 02-3658 02-365B 02-3658 Fuel Injection Pumps 02-365A/
03-365A/
02-365A/
03-365A/
02-365A/
02-365A/
i 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 02-4SSA Fuel Oil Injection Lires:
02-365D/
03-365D/
02-365D/
03-3650/
02-3650/
02-3650/
Supports 03-365D 02-3650 02-3650 02-365D 02-3650 02-365D Fuel Oil Strainers 02-455B/
SC-042B/
02-455B/
03-455B/
02-455B/
02-455B/
03-455B 02-455B 02-4558 02-455B 02-4558 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 ONOFRE V0GTLE GULF BELLEFONTE HARRIS Fuel Pump Linkage Assembly 02-3718/
03-371B/
02-371B/
03-3718/
02/371B 02-371B/
and Bearings 03-371B 02-371B 02-371B 02-3718 02-371B 02-3718 Fuel Pump Linkage:
02-413B/
03-371C/
02-413B/
03-371C/
02-413B/
02-413B/
Automatic Shutdown Cylinder 03-371C 02-4138 02-4138 02-4138 02-4138 02-413B Fuel Tappet Assembly 02-345B/
03-345B/
02-345B/
03-345B/
02-345B/
02-3458/
03-3458 02-345B 02-3458 02-3458 02-3458 02-345B Full Flow Lube Oil Filter (s) 02-820F/
03-820E/
02-820F/
03-820B/
CN-110/
84-115/
10-106 02-820C 02-717S GG-820B 02-8200 02-820E Full Pressure LuSe 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
/
/
/
/
/
/
i NONUM r
i Governor Booster Servomotor 02-4158/
03-415B/
02-415B/
03-415B/
02-415B/
02-415B/
03-415B 02-415B 02-415B 02-4158 02-415B 02-4158 Governor Drive - Couplings, 02-4118/
03-402B/
02-411B/
03-4028/
02-411B/
02-411B/
Pins and Keys 03-4028 02-411B 02-4118 02-411B 02-4118 02-411B Governor Drive - Governor 02-411A/
03-402A/
02-411A/
03-402A/
02-411A/
02-411A/
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/
BEND /
WNP-1/
PEAK /
SAN PERRY /
GRAND CATAWBA /
SHEARON COMPONENT DESCRIPTION SHOREHAM ON0FRE 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/
02-3558/
03-355B/
02-355B/
02-355B/
03-355B 02-355B 02-355B 02-355B 02-3558 02-355B Intake Air Filters 02-805B/
03-805B/
02-805B/
03-805B/
CN-106/
84-111/
10-114 02-805B 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 02-819C/
/
02-810B/
03-810A/
CN-120/
02-717N/
10-103 02-717Q GG-103 02-810A 02-810C 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 t
II-E-7
O O
O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/
BEND /
WNP-1/
PEAK /
SAN PERRY /
GRAND CATAWBA /
SHEAR 0N COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS j
Jacket Water Pump - Gear 02-425A/
03-425A/
02-425A/
03-425A/
02-425A/
02-425A/
l 03-425A 02-425A 02-425 02-425A 02-425A 02-425A i
l Jacket Water Standpipe 02-700F/
03-700F/
/
/
/
02-700E/
l and Miscellaneous Bolting 02-700F 02-700F 00-700F 02-700F 02-700F i
l Jacket Water Standpipe:
02-700B/
03-717B/
02-700B/
00-700B/
02-700B/
02-7008/
Valves 00-700B 02-7006 02-700B 00-7006 02-7008 02-7008 Lube Oil Heat Exchanger 02-820G/
03-8200/
02-820G/
03-820A/
CN-111/
02-717D/
10-104 02-8208 02-717R GG-104 02-820A 02-8208 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/
02-8208/
03-820C/
CN-109/
02-717R/
03-820C 02-8200 02-717U GG-109 02-820G 02-820F Lube Oil Keep-Warm Strainer 02-8200/
03-820H/
02-8200/
/
/
02-717V/
02-4650 Lube Oil Pressure Regulating 00-420/
00-420/
00-420/
00-420/
00-420/
00-420/
l Valve 00-420 00-420 00-420 00-420 00-420 00-420 1
)
Lube Oil Sump Tank Heaters 02-820A/
03-820B/
02-820A/
03-800B/
02-5400/
02-820A/
03-800B 02-820 02-717P 02-820A 02-820C I
03-540A/
02-540A/
03-5408/
02-540A/
02-540A/
03-540A 02-540A 02-540A 02-540A 02-540A 02-540A i
I
-l I I-E-8 i
O O
O TDI COMP 0NENT NUMBER CROSS REFERENCE RANCHO RIVER COMANCHE SEC0/
BEND /
WNP-1/
PEAK /
SAN PERRY /
GRAND CATAWBA /
SHEARON COMPONENT DESCRIPTION SHOREHAM ON0FRE V0GTLE GULF BELLEFONTE HARRIS Lube Oil Tubing and 02-307B/
03-307B/
02-307B/
03-307B/
02-307B/
02-307B/
Fittings - Internal 03-307B 02-307B 02-3078 02-3078 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 l
Main Bearings Shells 02-310B/
03-3108/
02-3108/
03-310B/
02-310B/
02-310B/
i 03-3108 02-310B 02-310B 02-3108 02-310B 02-310B Overspeed Trip Drive Couplings 02-410C/
03-410C/
02-410C/
03-410C/
02-4100/
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/
02-410B/
02-410B/
and Accessory Drive 03-410B 02-410B 02-410B 02-410B 02-410B 02-410B Overspeed Trip Vent Valve 02-410D/
03-4100/
02-4100/
03-410D/
02-4100/
02-4100/
03-4100 02-4100 02-410D 02-4100 02-410D 02-4100 Piping System N0NUM/
N0NUM/
N0NUM/
N0NUM/
N0NUM/
NONUM/
N0NUM NONUM N0NUM N0NUM NONUM N0NUM 1
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 02-341B/
03-341B/
02-341B/
03-341B/
02-3400/
02-341B/
03-3418 02-341B 02-341B 02-340D 02-341B 02-341B II-E-9
O O
O TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER I
COMANCHE SEC0/
BEND /
WNP-1/
i PEAK /
SAN PERRY /
GRAND CATAWBA /
SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS l
Pistons 02-341A/
03-341A/
02-341A/
03-341A/
02-340C/
02-341A/
03-341A 02-341A 02-341A 02-340C 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 02-3900 02-3900 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 l
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 j
Starting Air Distributor 00-442A/
03-442A/
00-442A/
03-442A/
02-442A/
00-442A/
1 Assembly 03-442A 02-442A 02-442A 02-442A 00-442A 02-442A l
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 02-6300/
03-6300/
02-6300/
03-6300/
02-6300 02-6300/
03-6300 02-6300 02-6300 02-630D 02-6300 02-6300 ll Thermostatic Valves 02-8100/
03-799A/
02-810C/
03-515/
C136/40/
02-810A/
s i
03-515 02-515 02-717W 02-515 02-8100 02-810E i
Thrust Bearing Ring 02-310C/
03-310C/
02-3100/
03-310C/
02-310C/
02-310C/
03-310C 02-310C 02-310C 02-3100 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
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 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 furbocharger 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
_s
O i
TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT Prepared For TEXAS UTILITIES GENERATING COMPANY COMANCHE PEAK STEAM ELECTRIC STATION - UNIT 1 By TDI DIESEL GENERATOR OWNERS GROUP Revision 2 April 1986 l
AMdgrest j
Program Manager TDI Diesel Generator Owners Group l
l l O
O TDI OWNERS GROUP APPENDIX - II GENERIC MAINTENANCE MATRIX O
O
. _ - _ _ ~
O TDI OWNERS GROUP GENERIC MAINTENANCE MATRIX APPENDIX - II l
I OVERVIEW AND DEFINITIONS
\\
l I
OPERATING AND STANDBY SURVEILLANCE' PARAMETERS PART A l
O l
a I
1
- O I
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 overall 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 l
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 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 O
II-A-1 Revision 2
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 0 entitled " Site-Specific Maintenance Matrix" and the sources defined in Section II form the TDI 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 4
parameters and frequencies.
It is recommended that the utility address J
these tables in its operating and monitoring programs.
Table 1 addresses operating parameters and is not duplicated in the maintenance schedules; i
these parameters are to be recorded and/or checked during the monthly testing and any other period of operatien.
Table 2 addresses the standby I
parameters that occur on a daily frequency and are not duplicated in the maintenance schedules.
i IV.
DEFINITION OF TERMS 1.
Overhaul Frequency j
a)
A complete engine teardown and inspection will be performed every 10 l
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 E0C l
following 10 years.
Alternately for PWR units, the inspection
)
may be performed coincident with the 10 year reactor vessel in-i service inspection.
This will permit both engines for each unit to be disassembled in parallel since one engine will not have to remain 4
in service with the reactor vessel off loaded.
(For reactor units having three engines, the inspections are to be carried out as above 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 O
inspection for plants already in operation.
II-A-2 Revision 2 E
1 b)
A one time inspection will be performed at the E0C closest to 5 years.
For a unit, one engine may be inspected at the E0C prior to 5 years and the other at the EOC 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 inspected 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 E0C - To be performed once every other outage for refueling.
l 6.
Five Years - To be performed once at the E0C occuring nearest to the end 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.
1 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 l
that is most suitable to obtain the information sought by an individual inspection item; choice of NOE shall be made to assure that the technique will detect indications consistent with the acceptance criteria.
i O
l II-A-3 Revision 2
--s-wnr,n-
,,,rp w -e r--------,--,cw
-m- ------
,,------rve-,
~----e,
\\
TABLE 1 s./
Diesel Engine Operating Surveillance Parameters and Frequency Component Frequency 1)
Lube Oil Inlet Pressure to Engine Log hourly 2)
Lube Oil Filter Differential Pressure Log hourly 3)
Lube Oil 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.)
- 15) Crankcase Vacuum Log hourly
- 16) Engine Speed Log hourly
- 17) Hour Meter Log hourly O
II-A-4 Revision 2
TABLE 1 (Cont'd)
Diesel Engine Operating Surveillance Parameters and Frequency Component Frequency i
- 18) Kilowatt Load Log hourly
- 19) Visual Inspection for Leaks, etc.
Check hourly 4
I b
i I
i i
f E
l l
l t
I II-A-5 Revision 2
- i... - - - -. -.. - -
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 Temperature (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 Sterage Tank and monitor the quantity of moisture produced.
If quantity of moisture is excessive, correct immediately.
O II-A-6 Revision 2
)
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.
i O
II-A-7 Revision 2
O TDI OWNERS GROUP APPENDIX - II GENERIC MAINTENANCE MATRIX PART B PHASE I COMPONENTS O
O GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.
Number identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments MP-022/23 Turbocharger 1.
Measure vibration and X
To be accomplished during check with baseline data.
24-hour test run.
I 2.
Inspect impeller / diffuser X
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 j
degradation.
l 4.
Perform visual and blue X
Note: Thrust bearing l
check inspections of inspection should also I
the thrust bearing.
be performed after J
experiencing each 40 l
non prelubed (automatic)
I fast starts. In addi-I tion, a one time inspec-l tion should be completed after the first 100 l
engine starts.
5.
Disassemble, inspect, X
Note: During reassembly and refurbish.
ensure that capscrews are properly insta11ed with the recommended torque.
1 If QR inspection was performed prior to accu-mulating significant I
hours (ip., the number of hours accumulated 4
during plant preopera-1 tional testing, approxi-l mately 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br />), the l
turbochargers should be reinspected at the paxt EOC.
i l
II-B-1 Revision 2
N
(
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/
GENERIC ANCE MATRIX - PHASE I
\\,_,/
Component Component Alt.
Number identification PH Recommendation Monthly E0C EOC 5 Year Overhaul Comments 6.
The nozzle ring com-X Also perform a visual ponents and inlet inspection on one turbo-guide wanes 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 Lion with appropriate re-noted, the entire ring design.
assembly should be re-placed.
7.
Monitor inlet tempera-Monitoring may b+ per-ture to ensure gas tem-formed using permanent perature does not exceed in-line thermecouple, manufacturer's recom-strap-on thermocouple, mendation of 1200*F if heat gun, or other suit-exhaust temperature for able means that has been any cylinder exceeds appropriately tested and 1050*f (Refr: Table 1).
calibrated per plant pro-cedures.
Note: Also perform non-itoring any time the engine operates in an unbalanced condition.
02-30$A Base Assembly 1.
Perform a visual inspec-X Note: Any cracks detected tion 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 EOC 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
CI
)
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j t
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GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-305C Main Bearing Caps - Studs 1.
The mating surfaces at and Nuts the bearing cap / saddle interface should be
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inspected when dis-assembled to ensure i
the absence of sur-j face imperfections that might prevent tight boltup.
Note: Opon removal of i
bearing caps, clean mating surfaces with a solvent 4
)
prior to reassembly of the caps to the base.
02-310A Crankshaft See site specific 1
recommendations I
02-315A Cylinder Block See site specific recommendations 02-315C Cylinder Liners 1.
Perform a visual inspection To be performed for first of liners for progressive 2 EOC: following piston wear.
removal; then discon-tinue until next piston i
removal. Boroscopic inspection is acceptable if heads are not removed.
Complete TDI Inspection and Maintenance Record 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 TDI 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 appilcable TDI In.
wear rate.
struction Manual, Vol-une I, Section 6, Appendix III for clearance values.
Perform inspection at 5 years, on items acces-sible, consistent with Item 2 of this compo-nent.
i Il-B-3 Revision 2
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GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.
Number Identification PM Hecommendation 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 i
Note: Perform inspection applicable, TDI In-and measure four connecting struction Manual, rods for DSRVs and two for Volume I, Section 6.
DSRs at random at one time 5 year inspection.
1 3.
Perform an x ray examin-This is to be performed ation on all replacement prior to installation 4
bearing shells to acceptance of any replacement criteria developed by Owners bearing shells as required.
i Group Technical Staff.
4.
All connecting rod bolts, X
Perform inspection at nuts, and washers should 5 years, on items acces-
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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 i
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 surfacc 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 i.e., no measurable clearance when the specified bolt torque of 1,050 ft-lbs is applied.
i j
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O' GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 7.
At the overhaul, visually 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 ultrasonically 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 u:;e 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 (ga111ng) ing rod is disassembled.
and the two pairs of connect-Perform inspection at ing rod bolts above the 5 years, on items l
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 i
of galling or cracking and replaced if damaged.
11.
A visual inspection should X-Also to be perforn,ed be performed of all external at any time the connect-l 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 Ites 2 of this component.
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l l
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GINLRIC MA ENANCE MATRIX - PHASE I Component Component Al t.
N umber 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 (ths 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 indicatior.s 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.
Instructica Manual, Volume I, Section 6 -
one sSeet 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 cylinjer heads, grind firing pressures.
valves, and reseat.
Refr: TDI Instruction Manual, Volume I, Section 6.
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O GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.
Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 3.
Blow-over the engi,ne at in the event water is least 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> but nut detected, the cylinder more than 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> 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 Ill the cylinders. A second heads after one cycle air roll should be with positive inspection performed in the same results.
manner approximately 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> 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 an each cylinder head should be replaced.
durirg the normal monthly run for signs of leakage.
02-365C Fuel Injection Tubing 1.
Cneck 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 II-B-7 Revision 2 4
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GENERIC MAINTENANCE MATRIX - PHASE I 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-1 mined by 750 hours0.00868 days <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br /> of operation at the load level used for survell-l lance testing that the push rod will not develop j
service-induced cracks.
Push rods confirmed in this way need be examined only visually at subsequent overhauls. Push rods of i
I the forged-head design exhibiting cracks larger than 0.25 inch should be l
replaced, preferably with j
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 I
be inspected initially by liquid penetrant. If this if initial inspection was initial inspection was not not performed, 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, friction welded push rod has been previously in-spected by liquid pene-trant, then visual exami-nation will suffice for future inspections. A11 friction welded push u.is with cracks should be replaced, preferably with push rods of the same design.
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GENERIC MAktiMANCE MATRIX - PHASE I Component Component Alt.
l Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments l
02-390G Rocker Arm Capscrews, 1.
Verify capscrew torgue Use TDI Instruction Drive Studs (Pop Rivets) values during QR inspec-Manual, Volume I, d
tion. If not performed Section 8, Appendix l
at QR, verify at next IV for proper torque j.
EOC, then as required at values.
reassembly.
l 2.
Verify that rocker are drive studs are intact I
and tight during QR l
inspection or EOC1, then as required at reassembly.
02-425A Jacket Water Pump - Gear 1.
Visually inspect jacket M
f.ny abnormal situations water pump gear for or indications of pro-chipped or broken gressive pitting should teeth, excessive v ar, be reported for an s
pitting or other engineering evaluation.
abnormal condi'. ions.
For engines with less than 750 hours0.00868 days <br />0.208 hours <br />0.00124 weeks <br />2.85375e-4 months <br />, also
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inspect by EOC2.
2.
Check the key to keyway X
This along with the drive 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 impeIIer 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 i
the castle nut that i
drives the external l
spline on its taper have minimum and max-j 1
imum torque values of
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120 ft-lbs and 660 ft-1bs respectively 4
i for DSRVs and a maximum torque value of 77 ft-lbs for DSRs.
II-B-9 Revision 2
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