ML20211E828

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Forwards Addl Info Re Issues on Reliability of Tdi Diesel Generators,Including Plant Position on SER Recommendations, Phase II Component Insp Status & Justification for Design Review/Quality Revalidation Rept Deviation
ML20211E828
Person / Time
Site: Vogtle  Southern Nuclear icon.png
Issue date: 10/17/1986
From: Bailey J
GEORGIA POWER CO.
To: Youngblood B
Office of Nuclear Reactor Regulation
Shared Package
ML20211E834 List:
References
GN-1121, NUDOCS 8610230217
Download: ML20211E828 (13)
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' Georgia Fbwer Company Fbst Offics Box 282 Wayrtisboro, Georgia 30830 Telephone 404 554-9961 404 724-8114 Southern Company Services,Inc.

Fbst Office Box 2625 Birmingham, Alabama 35202 Telephone 205 870-6011 VOgtie Project October 17, 1986 Director of Nuclear Reactor Regulation File: X4AK01 B. J. Youngblood X4BA17 Attention:

Licensing Branch #4 Log: GN-1121 Division of Licensing U. S. Nuclear Regulatory Commission Washington, D.C. 20555 REF: (1) LETTER GN-1072 DATED SEPTEMBER 5, 1986 (2) LETTER GN-1080 DATED SEPTEMBER 19, 1986 NRC DOCKET NUMBERS 50-424 AND 50-425 CONSTRUCTION FERMIT NUMBERS CPPR-108 AND CPPR-109 V0GTLE ELECTRIC GENERATING PIANT - UNITS 1 AND 2 DESIGN REVIEW / QUALITY REVALIDATION REPORT l TDI DIESEL GENERATORS i

Dear Mr. Denton:

As requested by your staff we have reviewed the issues concerning reliability of TDI Diesel Generators at VEGP. In response to these issues Georgia Power Company provides the following attachments:

Attachment 1: VEGP Position on SER Recommendations Attachment 2: _ Phase II Component Inspection Status Attachment 3: Justification for DR/QR Report Deviation Should you require additional information, please do not hesitate to call.

l Sincerely, i

. ' 4. [

J. A. Bailey Project Licensing Manager JAB /sm xc: List attached.

8610230217 861017 PDR ADOCK 05000424 E pm i

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Director of Nuclear Reactor Regulation File: X4AK01 October 17, 1986 X4BA17 Page 2 Log: GN-1121 xc: .R. E. Conway R. A. Thomas l B. W. Churchill, Esquire J. E. Joiner, Esquire M. A. Miller L. T. Gucwa G. Bockhold, Jr.

B. Jones, Esquire O. Batum D. Feig NRC Regional Administrator NRC Resident Inspector 0793V

ATTACHMENT 1 VEGP Position SER Recommendations (NUReg-1216)

A. S4 ction 2.1.2 - Components that Warrant Special Emphasis The following table (Table 2.I' of Section 2.1.2 reproduced) shows applicability to VEGP. Specific applicability and implementation is discussed in Section 2.1.3.

Table 2.1 Components requiring engine load limits and/or special routine maintenance and surveillance Special maintenance Engine and load surveillance Applicability Component limited required to VEGP Crankshaft DSR-48 Yes Yes No DSRV-20 Yes* Yes No Cylinder block DSR-48 (Shoreham) No Yes No DSRV-16 (Comanche Peak) No Yes Yes Cylinder heads No Yes Yes Connecting rods DSRV engines, 1-7/8 in, bolts Yes Yes No DSRV engines,1-1/2-in. bolts No Yes Yes Piston skirts Type AF Yes Yes No Turbocharger No Yes Yes

  • Limitations on engine testing have been established to minimize crankshaft torsional stresses during startup transients.

B. Section 2.1.3 Clarifications, Exceptions and Licensing Considerations Pertaining to PNL Reconsnendations in PNL-5600.

1. Section 2.1.3.1 Engine Overhaul Frequency VEGP concurs with Revision 2 of the DR/QP. and will perform engine overhaul at approximate 10-year intervals, for. the two engines, and the one-time 5 year inspection on a sample basis.
2. Section 2.1.3.2 Air Start Capscrews VEGP has verified all airstart capscrews are 2-3/4 inches in length.

.The capscrews were torqued to.150 ft-lbs initially and retorqued to 150 ft-lbs every 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> of engine operation until no change in torque was noted. Permanent plant procedures are in place to ensure.this practice is continued. No outstanding items remain.

3. Section 2.1.3.3 Auxiliary Module Wiring and Terminations VEGP has implemented TDI SIM 361 and verified period of manufacture of states-type sliding link terminal blocks. No outstanding items remain.
4. Section 2.1.3.4 Connecting Rod Bearing Shells VEGP concurs with Revision 2 of the DR/QR and will inspect all connecting rod bearings at 10-year intervals, and the one-time 5 year inspection of a sample of the bearings. VEGP engine oil analysis will be performed monthly for the first three months of operation, then quarterly. Oil analysis will include a " wear analysis" looking at cooper, chromium, iron, aluminum, tin and silicon content. VEGP has inspected all connecting rod bearings radiographically to the acceptance criteria adpoted by the Owners Group. Permanent plant procedures are in place that require all new connecting rod bearings shells be radiogrphically examined prior to use.
5. Section 2.1.3.5 DSR-48 Connecting Rods Not applicable to VEGP.
6. Section 2.1.3.6 DSRV Connecting Rods The VEGP connecting rods (with 1-1/2 inch connecting rod bolts) have been subjected to at least the following inspections:
a. Link pin to link rod clearance
b. Connecting rod centerline bow
c. Eddy current inspection of all connecting rod threaded bolt holes.
d. Magnetic particle inspection of connecting rod bolts.
e. Liquid penetrant inspection of the rod eye bushing.
f. Adequate contact between the rack joints of connecting rod box.
g. Visual inspection of bolts and washers for galling.
h. Connecting rod. bolts torqued to 1700 ft-lbs using a mixture of graphite and oil for lubrication.

VEGP will perform the connecting rod bolt baseline ultrasonic elongation measurements on a 25% sample at the 5-year inspection and all the connecting rods at the 10-year inspection. VEGP will also incorporate the recommendation of the staff, to include in the M/S program provisions to take corrective actions if bolt preload is found to be less than 93% of its initial valve during any connecting rod disassembly. VEGP will also require ultrasonic measurements of connecting rod bolts following assembly and prior to disassembly.

VEGP will include in its N/S program the requirement to reinspect the contact at the serrated joint of the rod box if inspections reveal a loss of preload on the rod bolts, fretting of the serrated surfaces or evidence of other connecting rod distress.

VEGP will also follow the DR/QR recommendations to MT the connecting rod bolts and inspect the connecting rod bolt holes using an appropriate NDE method each time a connecting rod is disassembled and at 10-year intervals.

7. Section 2.1.3.7 Crankshaft VEGP has performed the required NDE examination of the crankshaft oil holes. and fillers. The material certification reports for the crankshafts have been reviewed and it has been verified that the mechanical properties of the crankshafts are within design specifications. The torsiograph test is scheduled to be performed during ESFAS testing (ie, prior to fuel load) VEGP has incorporated into its M/S program provisions to monitor cylinder balance (exhaust temperatures) on at least an hourly basis and to monitor maximum cylinder exhaust temperatures.
8. Section 2.1.3.8 DSR-48 Crankshaft - Shoreham and River Bend Not applicable to VEGP.
9. Section 2.1.3.9 Other DSR-48 Crankshafts Not applicable to VEGP.
10. Section 2.1.3.10 DSRV-16 Crankshafts See item 7 above
11. Section 2.1.3.11 DSRV-20 Crankshafts Not applicable to VEGP
12. Section 2.1.3.12 Engine Block VEGP has performed the inspections recommended by the Owners Group and has found all blocks to be free of ligament cracks, stud-to-stud cracks and circumferential cracks in the liner bore (camshaft gallery cracks not applicable to VEGP).

All of the blocks at VEGP have been metallurgically examined and

. verified to be characteristic of typical grey cast iron (ie., no degraded microstructure was found). VEGP has incorporated into its M/S program procedures to require inspection of the cylinder blocks per Oweners Group recommended techniques at a frequency based on the cumulative damage index model.

13. Section 2.1.3.13 Cylinder Heads Vogtle has installed all Group III Cylinder Heads and performed all required preservice inspections including PT of valve seating surfaces and MT and UT of the firing deck.

Verified none of the cylinder heads have through wall weld repair.

Plant procedures include requirements to Air Roll Engine at least 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> but not more than 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> after eng. shutdown, with cylinder l cocks open. Second air roll to be performed after 24 hrs. Also, air rolls are performed shortly before any planned start.

14. Section 2.1.3.14 Cylinder Head Studs Vogtle has cylinder head studs with necked down shanks. The modification referred to in the September 24, 1984 Owners Group letter (C. Ray) which requires the bottom two threads of the ' stud to be removed, has been performed.

Vogtle will update the TDI Parts Manual to incorporate the new

! TDI part no. 03-315-01-0A Rev. G which reflects the new design change. Plant procedures already include instructions for proper installation and torquing.

15. Section 2.1.3.15 Engine Base Vogtle will perform a visual inspection of the engine base at each 10 year overhaul and each of the first three refueling outages.

Samples from each engine base will be taken and checked for degenerate widmanstaetten graphite. Samples will be submitted for analysis prior to fuel load.

16. Section 2.1.3.16 Fuel Oil Injection Tubing Vogtle has performed eddy current testing on all fuel injection tubing for each engine. Eddy current testing was performed by FaAA.

Vogtle has installed shrouded fuel oil lines.

Fuel injection lines were inspected for leakage after engine operation.

Manufacturer's instructions on installing fitting for the injection tubing.

17. Section 2.1.3.17 Jacket Water Pump Vogtle has visually inspected the jacket water pump gear for chipped or broken teeth, excessive wear, pitting or other abnormal conditions.

Checked key to keyway interface for tight fit.

Checked torque on castle nut that drives the external spline on its taper.

18. Section 2.1.3.18 Piston Skirts - Type AE Vogtle has replaced all of the originally supplied AN piston skirts with AE skirts.

Performed visual inspection of rib area near wristpin and rib at intersection of wrist pin boss.

19. Section 2.1.3.19 Piston Skirts - Type AF Does not apply to Vogtle
20. Section 2.1.3.20 Piston Skirts - Type AH and AN Does not apply to Vogtle
21. Section 2.1.3.21 Push Rods Vogtle has installed all friction welded push rods and performed liquid penetrant testing on them.
22. Section 2.1.3.22 Rocker Ann Capscrews Vogtle has performed a magnetic particle test on the thread root area of all capscrews for linear indications.

Verified proper torque.

23. Section 2.1.3.23 Turbochargers VEGP has installed the drip lubrication system, with a flow between 0.10 gph and 0.35 gph, and the full-flow prelubrication system for each of the turbochargers. VEGP has incorporated into its M/S program provisions to monitor individual cylinder exhaust

temperature. Should any cylinder exhaust temperature exceed 1050 F appropriate instrumentation will be required to be installed to ensure turbocharger inlet temperature does not exceed 1200 F.

As discussed in item 4, oil analysis will be performed on a quarterly basis, including a " wear analysis". The nozzle ring inspection for all four turbochargers will be performed following ESFAS testing (ie, prior to Fuel Load), at which time a total turbocharger inspection will be performed.

VEGP concurs with the Owners Group (DR/QR) recommended inspections and recommended frequencies and will incorporate these into the M/S program. Additionally VEGP will reinspect any turbocharger in which any nozzle ring anomalies were found at the next E0C inspection. Even if nozzle rings of an appropriate redesign are installed in the VEGP turbochargers, the 5-year inspections will be continued.

C. Section 2.2 Technical Resolution of Phase II VEGP has completed the vast majority of the DR/QR recommendations for Phase II components. Attachment 2 of this letter delineates those items which are open at this time.

D. Section 2.3 Maintenance / Surveillance Program VEGP commits to the M/S program as given in Appendix II of the VEGP DR/QR, with corrections as listed in Table 1 (these were previously transmitted to the staff in a September 19, 1986 letter as Attachment 2), and as discussed throughout Attachment 1. This commitment is made with the understanding that changes may be made to the program as necessary and as additional operating experience is gained, under the provisions of 10 CFR50.59.

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i. PAGE 1 0F 3 ,

TABLE 1

, CORRECTIONS TO APPENDIX II 0F VEGP DR/QR i

! COMPONENT ITEM PM PAGE NUMBER DESCRIPTION NO. RECOMMENDATION FREQUENCY COMMENTS II-B-9 02-425A 3. Castle nut minimum and *

  • Torque valves will be checked l

j Jacket Water torque valves, each time pump is disassembled.

3 Pump Gear i

II-C-2 CP-102 5. Check meter calibrations. E0C Generator Control Panel

} II-C-12 02-371A Check and lubricate. Monthly j Fuel Pump j Control Shaft II-C-15 02-413A 1. Install locking hardware *

  • Frequency will be based on the l Governor to the lever arm clamp results of the monthly inspec-j Linkage bolt heads and shaft roll tion for loose parts on the j pins. linkage assembly.

l 3. Lubricate cross shaft Monthly j bearings.

i 3

II-C-17 02-475A, C 1. Inspect bracket bolting. E0C

Turbocharger l

Bracket Bolting II-C-19 02-500C 3. Trip check circuit breakers. 5 Yr.

l Circuit

] Breakers II-C-20 02-525B 1. Replace control valve "0" 5 Yr.

Barring Device rings and lube shaft. , ,

2. Replace press regulator N/A VEGP has no press regulator.

j elastomeric parts.

1 I II-C-20 02-525C 1. Replace filter element. E0C ,

Barring Device I

Air Filter

! 2. Drain barrring device air Monthly l filter.

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PAGE 2 0F 3

  • TABLE 1 CORRECT 10N TO APPENDIX If 0F VEGP DR/QR ,

COMPONENT # ITEM PM PAGE NUMBER DESCRIPTION NO. -REQUIREMENT FREQUENCY COMMENTS II-C-21 02-540A 3. Visually inspect sump tank level E0C Lube Oil switch floats. Check switch set Sump Tank points.

II-C-22 02-695C 1. Check switch setpoints. E0C Engine Control Pneumatic Trip Switches 2. Replace elastomeric parts. 5 Yr.

II-C-22 02-7008 1. Replace elastomeric parts in 5 Yr.

Jacket Water valves.

Stand Pipe II-C-24 02-810E 1. Check calibration and inspect Alt. E0C Jacket Water thermostat.

Heaters II-C-25 02-820A 2. Check calibration and inspect Alt. E0C Lube Oil Sump condition of thermostat.

Tank Heaters II-C-26 02-820F 3. Lube oil filter gauge - calibration Alt. E0C Full Flow Lube check. '

Oil Filters II-C-26 02-820H 3. Lube oil strainer pressure gauge - Alt. E0C Full Press Lube calibration check.

Oil Strainer II-C-28 02-835J 2. Starting air tank pressure gauges - Alt. E0C Starting Air calibration check.

Storage Tank

3. Starting air tank pressure switches - Alt. E0C calibration check.

II-D-V3 02-315A Perform inspections per DR/QR E0C* *A review will be performed of Cylinder Block Report 02-315A. the hours logged on the engine since the last inspection.

Inspection will be performed '

at the E0C following 490 hours0.00567 days <br />0.136 hours <br />8.101852e-4 weeks <br />1.86445e-4 months <br /> from the previous inspection.

PAGE 3 0F 3 TABLE 1 CORRECTION T0 APPENDIX II 0F VEGP DR/QR V0GTLE PAGE NUMBER COMPONENT DESCRIPTION COMPONENT NUMBER COMMENTS I I-E-2 Barring Device Air Filter 02-525B II-E-2 Barring Device Control 02-525B Valve and Press Regulator II-E-3 Crankcase Vacuum Fan 02-387A II-E-6 Flywheel Bolting N/A Matrix does not require maintenance on Vogtle engine II-E-6 Gear Train N/A Matrix does not require maintenance on Vogtle engine II-E-7 Hydraulic Valve Lifters N/A Vogtle does not have hydraulic valve lifters II-3-8 Lube Oil Keep-Warm Strainer SE-031

1 1

ATTACHMENT II PHASE II COMP 0NENT INSPECTION STATUS The vast majority of Phase II inspections has been completed. Most cf these

. inspections were documented in the VEGP DR/QR. At the time the DR/QR was finalized for VEGP several items were pending or incomplete. Our letter to the staff dated September 19, 1986, contained in Attachment I, information concerning questions the staff had concerning the VEGP DR/QR. The. following is a comprehensive list of all known outstanding inspections within .the scope of the DR/QR.

1. Component - MP-022/23 - Turbochargers (a) Inspect thrust bearings following 100 starts -

Will be performed prior to fuel load following ESFAS testing.

(b) Perform liquid penetrant test on the stationary nozzle ring following 100 starts -

Will be performed prior to fuel load following ESFAS testing.

2. Component 02-310A - Crankshaft (a) Perform torsiograph testing - Will be performed during ESFAS testing prior to fuel load.
3. Component 02-442A - Starting Air Distributors (a) Verify installation _of folicwer lobe on camshaft -

Will be performed prior to fuel load following ESFAS testing.

(b) Evaluate wear of air distributors cam lobes and valve spools - Will be performed prior to fuel load following ESFAS testing.

4. Component 02-455C - Fuel Oil Filters and Strainers (a) Visually inspect the as-installed condition of mounting handware - Will be performed prior to fuel load following ESFAS testing.

ATTACHMENT III Plant Vogtle will take exception to the following two items of the DR/QR with justifications provided.

1. The Owner's Group recommends per task description No.

Dr-11-02-420-1 that a dresser coupling be added on the pump suction line to mitigate the thermal expansion loading and stresses on the pump inlet nozzle.

Bechtel Power Corporation performed an analysis on this line to determine the pump loads on the pump nozzle (Ref. Calc. X4C2403G0309 Rev. 1). TDI engineer, T. Bridge, Wds contacted to verify the design assumptions used were in agreement with TDI design.

The result of the analysis showed that no revision to the piping is required as all loads are within allowable limits.

2. The Owner's Group recommends per task description No.

DR-11-02-380A-0 to replace one slip joint at the end of each of the sliding spans on the exhaust manafold, with a slip-on flange.

Duke Power has analyzed the original design and the Owner's Group proposed modification per Supplement Report No. 1 Rev. 1 for component 02-380A (Attached).

The result of the analysis showed that the exhaust manifold piping as designed and installed by TDI is adequate to perform its intended design function.

h V DUKE POWER COMPANY e, s. e e s a s e s e GENERAL OFFICES """'s'll.',!!!

4:s seets snescu steest l CHARLOTTE. N. C. 28242 November 5,1985 Mr 0 Batur:, General Manager Engineering Department Georfia Power Company Route 2, Box 299A Waynesboro, GA 30830 5e: Management and Technical f ervices  !

T0! wiesel Gercator Owners Group I Vogtle Electric G*nerating Plant - Unit 1 Exhaust Manifcid Piping Supplemental Report, Revistan 1 File: MTS-4086

Dear Mr Batum:

Attached please find one copy of Supplemental Report No.1. Rev.1 for Component 02-380A. This revision adds References 3 and 4 If you have any questions or require additional information, please contact S E Eckert at 704-373-3818.

Very truly yours, A P Cobb, Jr. Manager -

Project Management Olvision y: AM st Sen r Engineer AMS/SEE/gla/E10-22/2 cc: C L Ray (w/o attach)

DUKE I MANAGEMENT AND POWER I TECHNICAL SERVICES

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