Text

Addresses plant-specific Items Identified in 860702 Ser,To Achieve Final Resolution of Tdi Generator Issue.Requests That NRC Close Out Tdi Diesel Generator Issue.Fee Paid
	ML20212C052
Person / Time
Site:	Catawba
Issue date:	08/01/1986
From:	Tucker H; DUKE POWER CO.
To:	Harold Denton, Youngblood B; Office of Nuclear Reactor Regulation
References
	NUDOCS 8608070321
	Download: ML20212C052 (11)
	v • d • e

- - - _ - _ - _ . - . _ . _ _ _ _ - _ - _ - - - - - - - - - - .

DuxE POWER GOMPANY P.O. BOX 33189 CHAML0ft'rE, N.C. 28249 HAL H. TL*CKER TEI.EMME veos passement 200 LEAR PSUDUCTION (704) Om838 A~ gust 1, 1986 Mr. Harold R. Denton, Director Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Cosmaission W:shington, D.C. 20555 ATTENTION: Mr. B.J. Youngblood, Project Director PWR Project Directorate No. 4 Re: Catawba Nuclear Station Docket No. 50-413 and 50-414 Dear Sir On July 2,1986, the NRC transmitted to Duke Power Company the Safety Evaluation Report on Operability / Reliability of Emergency Diesel Generators Manufactured by Transamerica Delaval, Inc. This SER provided the Staff's final conclusions and r: commendations stemming from its evaluation of the TDI Owners Group program. The purpose of this letter is to address those plant specific items identified in the SER in order to achieve final resolution of the TDI diesel generator issue on Catawba Units 1 and 2.

[ solution of Phase I In Section 2.1 of the SER, the Staff noted that their consultant, Pacific 1orthwest Laboratory (PNL), generally endorsed all of the Owners Group recommendations pertaining to modifications and/or replacement, quality rcvalidation inspections and maintenance / surveillance of Phase I components. In cddition, however, PNL recossiended in PNL-5600 some additional actions for crecific components beyond what the Owners Group recommended. The PNL findings ctd recommendations were adopted by the Staff subject to the clarifications and exceptions discussed in Section 2.1.3 of the SER.

Dake Power Company's planned followup actions for the Phase I components is discussed in Attachment 1.

Status of DR/QR Program - Phase II The Owners Group Phase II recommendations were documented in the Design Review and Quality Revalidation (DR/QR) Report for Catawba Unit 1. This document was cubmitted to the NRC on November 4, 1985. The design review conducted on the Catawba Unit 1 engines is considered to be applicable to the Unit 2 engines.

8600070321 060001 PDR b \Y ADOCK 00000413 *1l S PDR j $

g (k .

~

Harold R. Denton -

l August 1, 1986 '

Page 2 1 ,

Results of the quality revalidation (QR) inspections were reported'to the NRC by.

i letters dated June 29, 1984 (D/G 1A); July 6, 1984 (D/G IB); October 2, 1985 (D/G 2A); December 23,1985 (D/G 2B); and May 28, 1986 (D/G 2A). As documented in' '

these reports, the Owners Group Phase II recommendations have largely been imple -

j mented at Catawba. However, some Owners Group recommended Phase II QR inspe'c_tions remain to be completed. The status of remaining Phase II items is discussed in ,

Attachment 2. Duke's proposed resolution of three design modifications proposed ,

by the Owners Group were discussed in a May 19, 1986 letter to the NRC. '

Maintenance / Surveillance Program In Section 2.3 of the final SER, the Staff concluded that an acceptable mainte- ;

nance / surveillance (M/S) program must incorporate the following elements:

(1) The recommendations concerning operation, testing, inspection, maintenance, j adjustment, overhaul and repair of the engine as incorporated in the TDI i'

Instruction Manual, Service Information Menos (SIMS), and TDI correspondence j on specific maintenance / surveillance issues.

(2) Additional items required by the staff as identified in Section 2.1.3 of the i

SER.

i i' (3) The maintenance and surveillance recommendations developed by the Owners Group in Appendix II, Revision 2, of the DR/QR reports. + e *

/..

The TDI recommendations noted in item (1) have been incorporated into the M/S at #

,. 0 l'

Catawba; additional items required by the NRC Staff as discussed in Attachment 11 '

and the M/S recommendations developed by the Owners Group in Appendix II, Revision '

2, of the DR/QR report for Catawba will be incorporated into the respective unit? -

M/S program as follows: '

(1) Daily, monthly, EOC and Alternate EOC Inspections prior to restart from the k

first refueling outage.

(2) 5 year and Overhaul inspections prior to the start of the fourth refueling outage. /

A copy of Revision 2 to the DR/QR report for Catawba is attached.

J l Proposed License Conditions s

Appendix A to the final SER contained a sample license condition that woulu 1 reflect key maintenance and surveillance actions. Proposed license amendmauts l will be submitted for Catawba Units I and 2 to incorporate the appropriate 'por-i tions of the sample license condition.

1 i

,n-l

i j

N?

v Harold R. Denton August 1, 1986

,Page 3 Conclusion Based on the above response to the Staff's final generic SER on the TDI diesel generator issue and subject to the satisfactory completion of QR inspections and update of the M/S progree at the first refueling outage for each unit, it is requested that the NRC close out the TDI diesel generator issue for Catawba.

In accordance with 10 CFR 170.21, a check for $150.00 is enclosed.

, Very truly yours,

Hal B. Tucker

^'

lh/

ROS/05/jgm xc: Dr. J. Nelson Grace, Regional Administrator U.S. Nuclear Regulatory Commission - Region II

, 101 Marietta St., NW, Suite 2900 Atlanta, Georgia 30323 NRC Resident Inspector Catawba Nuclear Station e

i E

s:

o

/

'4 f l-

Attachment 1 Duke Power Company Catawba Nuclear Station Resolution of Phase I Items Duke Power Company has reviewed the Safety Evaluation Report on Operabili-ty/ Reliability of Emergency Diesel Generators manufactured by Transamerica Delaval, Inc. and the PNL findings discussed in report PNL5600 for Phase I components. As a result of this review, planned follow up actions on Catawba Nuclear Station diesel engine Phase I components are given below.

Unless specifically noted DPCo's actions meet the requirements of the TDI Owners Group DR/QR Maintena' n ce and Surveillance Program, PNL 5600 and the TransAmerica Delaval Emergency Diesel Safety Evaluation Report.

A. Air Start Valve Cap Screws No further action is required. DPCo. quality revalidation inspection program results 'and the DPCo. maintenance and surveillance program assure that this component is fit for continued service.

B. Auxiliary Module Wiring and Terminations Both Unit 1 and Unit 2 diesel generators will be inspected by the end of the first refueling outage to assure that states sliding link terminal blocks were not manufactured between 1974 and 1976. Terminal blocks manufactured ~between 1974 and 1976 will be replaced.

RSW:07:24:86:B2.PG1

C. Connecting Rods: OSRV-4 Series Engines Catawba Nuclear Station maintenance matrix (DR/QR Appendix II M/S Program) will be revised in accordance with the SER as follows:

1. Item 7, page II-B-5 Add the following sentence after the existing PM text, "If fretting has occurred, it should be subject to an engineering evaluation for appropriate corrective action."

2. Item 4, page II-B-4 Add to the Comment section of this item, "All connecting-rod bolts should be lubricated in accordance with the engine manufacturer's instructions and torqued to the specifications of the manufacturer."

3. Item 9, page II-B-5 Change PM of item 9 to read, "The lengths of the two pairs of bolts above the crank pin should be measured ultrasonically prior to detensioning and disassembly of the bolts. If bolt tension is less than 93% of the value at installation, the cause should be determined, appropriate corrective action should be taken, and the interval between checks of bolt tension should be re-evaluated. Upon reassembly, the lengths of the two pairs of bolts above the crank pin should be measured ultrasonically pre and post-tensioning."

RSW:07:24:86:B2.PG2

e D. Connecting Rod Bearing Shells As a point of clarification, it should be noted that a periodic oil analy-sis will be accomplished on Catawba engines in accordance with the provi-sions of the DR/QR Appendix II M/S Program. Specifically this analysis will include the following:

1. A monthly check of viscosity per item 1, page II-C-20 of the M/S Program.

2. A monthly spectro chemical check per item 4, page II-C-21 of the M/S program.

3. A ferrographic analysis will be used if results of spectro chemical analysis show high levels of a contaminate.

E. Crankshaft: 16-Cylinder DSRV-4 Series Engine l

1. DPCo. will modify Catawba engine operating and emergency procedures in accordance with the SER to provide a caution against operating the engine at speeds less than 445 RPM for more than brief periods because of the fourth order critical speed.

2. Catawba Nuclear Station maintenance matrix (DR/QR Appendix II M/S Program) will be revised as follows:

. Add to PM of Item 5, Page II-D-CAT 2 the following:

i l

I "In addition, analyze recorded cylinder exhaust temperatures on an hourly basis while operating to detect unbalance. Individual cylinder exhaust temperatures shall not differ from the mean of all cylinder temperatures by more than 100*F."

i l

l RSW:07:24:86:B2.PG3 _ _ _ _

l

F. Cylinder Block Catawba Nuclear Station maintenance matrix (DR/QR Appendix II M/S Program) will be revised as follows:

Change Item 1, Page II-D-CAT 3 to read as follows:

" Cylinder blocks shall be dye penetrant inspected for " ligament" cracks, " stud-to-stud" cracks and " stud-to end" cracks as defined in a report by Failure Analysis Associates, Inc. (FaAA) entitled,

" Design Review of TDI R-4 and RV-4 Series Emergency Diesel Generator Cylinder Blocks" (FaAA raport no. FaAA-84-9-11.1) dated December 1984. The inspection intervals (i.e., frequency) shall not exceed the intervals calculated using the cumulative damage index model in the subject FaAA report for cylinder blocks with no assumed ligament cracks. If inspection reveals cracks in the cylinder blocks between stud holes of adjacent cylinders (" stud-to-stud" cracks) or " stud-to-end" cracks, this condition shall be reported promptly to the NRC staff and the affected engine shall be considered inoperable. The engine shall not be restored to

" operable" status until the proposed disposition and/or correc-tive actions have been approved by the NRC staff."

Change Item 2, Page II-D-CAT 3 to read as follows:

" Perform dye penetrant inspection for cracks."

G. Cylinder Heads l

Catawba Nuclear Station maintenance matrix (DR/QR Appendix II M/S Program) l will be revised in accordance with the SER as follows:

. Replace Comments section of Item 3, Page II-B-7 as follows:

l RSW:07:24:86:B2.PG4

" Air roll tests are not to be performed when the plant is in an Action Statement of Technical Specification 3/4.8.1. (i.e., if the other diesel or AC sources are inoperable). Further air roll tests are not to be accomplished if the engino is taken out of service for reasons other than performance of the air roll test.

In such cases, engine is to be air rolled prior to return to service. In the event that water is detected, the head should be removed and the cause of the leak assessed. Cylinder heads with leaks due to cracks shall be replaced."

H. Cylinder Head Studs The following clarification of the Catawba head stud installation proce-dures relative to those discussed in Section 2.1.3.15 of the SER should be noted. Section 2.1.3.15 references OG letter of September 24, 1984 for head stud installation. The clarifications are as follows:

All head studs at Catawba are of the straight shank design and accordingly did not have to be modified per the OG letter.

Catawba has not used the stud torque procedure of the OG letter of September 24, 1984. Rather Catawba has used the stud torque procedures approved by OG letter 0GTP-98-0-46 of July 3, 1985.

This procedure is explained in the DPCo. letter to the NRC of January 13, 1986.

I. Engine Base and Bearing Caps

1. DPCo. will take replicas of the base on Unit 1 engines by the end of the first refueling outage. Replicas should be that of normal grey cast iron without any degenerate Wiedmanstaetten microstructure.

2. The following work will be accomplished on Unit 2 engines by the end of the first refueling outage:

RSW:07:24:86:B2.PG5

e Engine 2A and 2B - Check the main bearing cap studs and nuts for proper material.

Engine 2A - Retorque main bearing studs not previously torqued by DPCo.

Engine 2B - No. 7 main bearing shall be disassembled and inspect-ed.

J. Fuel Oil Injection Tubing The following inspections have been accomplished on spare fuel oil injec-tion tubing. All spare tubing at Catawba was ordered from TDI. The TDI tubing was supplied all ready formed and bent. This tubing was then ECT inspected up to the first bend with FaAA NDT Procedure 11.10 prior to placing it in stores. As this tubing was bent, ECT inspection over the complete tubing length could not be accomplished. However, the spare tubing has been subjected to the same NDT inspections as that installed which has not leaked in service. Accordingly, DPCo. considers the spare tubing satisfactory for installation on the engine.

K. Jacket Water pump Engine 1B jacket water pump will be removed from the engine during the first refueling outage and the nut holding the external spline to the pump shaft checked to verify a torque of 120 foot pounds.

L. Piston Skirts No additional follow-up is required by DPCo. as all engines now have AE pistons installed which have passed quality revalidation inspections.

RSW:07:24:86:B2.PG6

M. Push Rods No additional follow-up is required by DPCo. as all engines have friction welded push rods installed which have passed quality revalidation inspec-tions.

, N. Rocker Arm Capscrews Engine 2B will have material and hardness tests accomplished on four rocker arm capscrews by the end of the first refueling outage.

O. Turbochargers

1. Engine 1A turbocharger bracket bolting will be replaced by the end of the first refueling outage.

2. Catawba Nuclear Station maintenance matrix (DR/QR Appendix II M/S Program) will be revised in accordance with the SER as follows:

Add to PM of Item 3, Page II-B-1 the following:

" Measurement should be within TDI/Elliot Specification."

. Add to PM Section of Item 6, Page II-B-2 the following:

"A turbocharger in which nozzle ring abnormalities are found shall be reinspected at the next refueling outage."

e Under Comments section of Item 6, Page II-B-2 change Note to read:

" Note: Discontinue inspection of one turbocharger per nuclear Unit per EOC with appropriate redesign."

RSW:07:24:86:B2.PG7

Attachment 2 Duke Power Company Catawba Nuclear Station Status of Phase II Items Duke Power Company has reviewed the Safety Evaluation Report on Operabili-ty/ Reliability of Emergency Diesel Generators manufactured by Transamerica Delaval, Inc. and the Owners Group Design Review and Quality Revalidation Report for Phase II components. As a result of this review, planned follow up action on Catawba Nuclear Station diesel engine Phase II component inspection's is as i' follows:

A. Accomplish material comparitor test on 16 intake / exhaust valves on engine 2B. This test is to be accomplished once when heads are removed for other maintenance or surveillance actions.

B. Replace starting air distributor capscrews on Unit 2 engines with SAE grade 8 capscrews by the end of the first refueling outage.

C. Inspect rocker arm adjusting screw swivel pad for signs of cracking on Unit 2 engines by end of first refueling outage.

All other components meet the requirements of the TDI Owners Group DR/QR Pro-gram, TDI SER, and PNL 5600.

4 i

t J

RSW:07:24:86:B2.PG8

O TDI DIESEL GENERATOR DESIGN REVIEW AND QUALITY REVALIDATION REPORT Prepared For DUKE POWER COMPANY CATAWBA NUCLEAR. STATION - UNIT 1 By TDI DIESEL GENERATOR OWNERS GROUP O Revision 2 April 1986 Y / d4/

~rugsr Program Manager TDI Diesel Generator Owners Group l

i i

t '

/

l l

/(D O

O TDI OWNERS GROUP APPENDIX - II i

GENERIC MAINTENANCE MATRIX O

l I

I O

i I

i l9 TOI OWNERS GROUP i

I i GENERIC MAINTENANCE MATRIX I APPENDIX - II 4

l

! OVERVIEW ANO DEFINITIONS l

i I

! OPERATING AND STANDBY SURVEILLANCE

PARAMETERS PART A f i i l

l 1

i l

i i

I t

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

i o TDI OWNERS GROUP GENERIC MAINTENANCE AND SURVEILLANCE PROGRAM t APPENDIX - II

)

1 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 e

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.

4 II METHODOLOGY 4

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 components. The basis of this matrix is formed by the following:

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

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

Additional maintenance recommendations identified during the DR/QR review.

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

l

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.

i l III RESULTS ANO CONCLUSIONS l- 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 J

i

! II-A-1 Revision 2 y -w,w e -m- .g-,-_ . . - , ,--.m m. m .~,m - . - - . -m.-, _,,.%,w-r,.--,_-~-n---,mwm._,_.,_,. ,,_,.__-,-,-w-,-

q V is for these reasons that a detailed schedule of maintenance service has been laid out by the Owners Group for the TDI Diesel Generators. This schedule should be followed as closely as the operating conditions will permit. This maintenance service as specified supersedes previous general maintenance requirements, but is separate and does not supersede Quality Revalidation and/or modifications previously recommended. The schedule details specific components requiring maintenance on a regular basis.

This schedule separates the maintenance activities into frequencies as set forth in the subsequent list of definitions.

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

This generic matrix, Parts A, B, C together with Part D entitled " Site-Specific Maintenance Matrix" and the sources defined in Section II form the 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 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 scnedules.

IV. DEFINITION OF TERMS

1. Overhaul Frequency a) A complete engine teardown and inspection will be performed every 10 years. The utility has the flexibility to inspect one engine / reactor unit at the E0C prior to 10 years and the other engine at the 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 or from subsequent teardown and inspection for plants already in operation.

O II-A-2 Revision 2

.]

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 EOC 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 EOC 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 E0C - To be performed once every other outage for refueling. f

6. Five Years - To be performed once at the EOC occuring nearest to the end O of a recurring 5 year period.

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

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

9. Accessible -

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

10. Appropriate NDE - Nondestructive examination selected by site personnel l 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.

l I

i l

O II-A-3 Revision 2 k

(o N- /

TABLE 1 Diesel Engine Operating Surveillance Parameters and Frequency I

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.)

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

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

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

15) Crankcase Vacuum Log hourly

16) Engine Speed Log hourly

17) Hour Meter Log hourly l

i

< O II-A-4 Revision 2 1

l TABLE 1 (Cont'd)

Diesel Engine Operating Surveillance Parameters and Frequency i

Component Frequency

18) Kilowatt Load Log hourly

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

i i

6 i

i i

II-A-5 Revision 2 i

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

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

2) Lube Oil Sump Level Log daily

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

4) Monitor Lube Oil Keep-Warm Daily Strainer and/or Filter Differential Pressure

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

6) Fuel Oil Day Tank Level Log daily O 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 Storage Tank and monitor the quantity of I moisture produced. If quantity I

of moisture is excessive, correct immediately.

II-A-6 Revision 2 1

TABLE 2 (Cont'd) !

Diesel Engine Standby Surveillance Parameters and Frequency Component Frequency i

13) Check Operation of Compressor Air Traps Daily

14) Test Annunciators Before Engine Operation i

15) Check Alarm Clear Before Engine Operation !

16) Inspect for Leaks Daily l

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

i l O

l

}

l t

t O

II-A-7 Revision 2 L.-_ - . _ . - - - . . - - _ - . . . . - . - . - _ - - - . . . _ _ - . . . . - . , - - - - , . - . - - . , . - -

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

l O

O

f ^ %

b i

CENERIC MAINIENANCE MATRIX - PHASE I I

9 Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments To be accomplished during MP-022/23 Turbocharger 1. Measure vibration and X check with baseline data. 24-hour test run.

2. Inspect impeller /dif fuser X and clean if necessary.

4 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 1,e., thrust bearing trend toward increasing degradation. axial clearance could signify thrust bearing degradation.

4. Perform wisual and blue X Note: Thrust bearing check inspections of inspection should also I 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 i properly installed with the recommended torque.

If QR inspection was performed prior to accu-i mulating signifIcant

]

hours (ip., the number

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

l l

Il-B-1 Revision 2

f -

k J V GENERIC MAINIENANCE MATRIX - PHASE I Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments

6. The nozzle ring com- X Also perform a visual ponents and inlet inspection on one turbo-guide vanes should be charger per nucient 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 stould be re-placed.

7. Monitor inlet tempera- Monitoring may be per-ture to ensure gas tem- formed using permanent perature does not exceed in-line thermocouple, manufacturer's recom- strap-on thermocouple, sendation of 1200*F if heat gun, or other suit-exhaust temperature for able means that has been

any cylinder exceeds appropriately tested and 1050*F (Ref r: Table 1). calibrated per plant pro-cedures.

Note: Also perform non-j ltoring any time the

' engine operates in an unbalanced condition.

02-305A 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

i m

GENERIC MAINTE NANCE HAIRIX - PHASE I Component Component Alt.

Number Identification PM Recommendation Monthly E0C IOC 5 Year Overhaul Comments l 02-305C Main Bearing Caps - Studs 1. The mating surfaces at and Nuts the bearing cap / saddle i interface should be j inspected when dis-i assembled to ensure-the absence of sur-face imperfections that might prevent tight boltup.

Note: Upon removal of

bearing caps, clean mating i surfaces with a solvent prior to reassembly of the caps to the base.

l 02-310A Crankshaft See site specific i recommendations 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 EOCs following piston wear. removad; then discon-tinue until next piston removal. Boroscopic inspection is acceptable if heads are not removed.

Complete TDI Inspection and Maintenance Record form Mo. 315-1-1 as applicable. IDI In-struction Manual, Volume I, Section 6.

i i 02-340A/B Connecting Rods, Bushings 1. Inspect and measure all X Complete IDI Inspection and Bearing Shells connecting rod bearing and Maintenance Record (Generic) shells to verify lube oil Form Mo. 340-1-1 as maintenance, which affects applicable, IDI 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.

l i Il-B-3 Revision 2 i

( C t'"

\-

V)

GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments

2. Inspect and measure X Complete 101 Inspection the connecting rods. Maintenance Record Form No. 340-2-1, -2 as Note: Perform inspection applicable, TDI In-and measure four ConneCling struction Manual, rods for DSRVs and two for Volume I, Section 6.-

D5Rs at random at one time 5 year inspection.

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

1 Group Technical Staff.

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

4 replaced. lhe bolts should be Mi 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 j 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.

j i ll-B-4 Revision 2 4

(%/ , ,b\,

N ,I l CENERIC MAINlENANCE 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 yeai 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-for thread damage (galling) ing rod is disassembled.

and the two pairs of connect- Perform inspection at ing rod bolts above the 5 years, on items crankpin should be MT inspec- accessible, consistent led to verify the absence of with Item 2 of this cracking. All washers used component, with the bolts should be examined visually for signs of galling or cracking and replaced if damaged.

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

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

, with Item 2 of this component.

Il-B-5 Revision 2

C m)

(mV) .s GINERIC MAIN 1ENANCE MAIRIX - PHA5E I Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year overhaul Comments

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

damage (galling) or other Perform inspection at signs of abr.ormalities. 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-de:,tructive method to verify the absence of cracking. Any indications should be recorded for evaluation and corrective action.

5 02-341A Pistons 1. Inspect and measure skirt X Complete IDI Inspection i

and piston pin. This and Maintenance Report 1 item assumes that AE skirts Form No. 341-1-1 as 1 are installed. For other applicable. TDI types, see site-specific Instruction Manual, l

recommendations. Volume I, Section 6.

Use Volume 1. Section 8 Appendix 111 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, 101 boroscope is acceptable. Instruction Manual, Volume I, Section 6 -

one sheet for each head.

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

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

Refr: IDI Instruction Manual, Volume 1, Section 6.

Il-B-6 Revision 2

f V d GENERIC MAINTENANCE MATRIX - PHASE I Component Component Alt.

Number Identification FM Recommendation Monthly EOC EOC 5 Year Overhaul Comuments

3. Blow-over the eso,ry e- at in the event water is least 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months but out detected, the cylinder more than 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months after head should be replaced engine shutdown. The or returned to the vendor cylinder cocks should for repair. Delete post-be open for detection run air roll requirements of water leakage into for engines with Group 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 0.00667 hours 3.968254e-5 weeks 9.132e-6 months after engine shutdown. In addition, the engine should be air rolled shortly before any planned start.

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

during the normal monthly run for signs of leakage.

02-365C Fuel Injection Tubing 1. Check tubing for leaks X All fuel oil leak in-at compression fittings, spections to be per-formed while the engine is running or whenever the compression fittings a 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 1 detected at the leak off to be performed period-

ports in the base nuts, ically as indicated.

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

l l

11-B-7 Revision 2 4

l'\

J O GINlRIC MAINTENANCE MATRIX - PHASE I Component Component Alt.

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

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

Push rods confirmed in this l way need be examined only

, visually at subsequent overhauls. Push rods of j the forged-head design i exhibiting cracks larger d

than 0.25 inch should be

, replaced, preferably with push rods of the friction-welded design. Each forged-head rod should also be visually inspec-ted one time to confirm that the head was fully Inserted in the tube prior to welding.

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

tion-welded design should. '

> be inspected initially by liquid penetrant, If this . If initial inspection was

/ initial inspection was not not perfors,ed, perform cn

.j performed prior.to placing sampling basis at 5 year .

l m- the push rods-to service. . Inspection consistent

'- it shouta De performed at with Component 340A/B -

3 , y the first overhaul. If the Connecting Rods.

~

friction welded pJih rod -

] has been previously in-

--- % .-spected by liquid pene- "

4 * - ~" trant, then visual exami-

~

l '\ %-

~

_ cation will suffice for future inspections. All friction-welded push ..Is .

e

' ~

with cracks should be '

, replaced, preferably with ic% -

e push rods of the same '

X _sdesign.

N II-B-8 Revision 2 s 4

So y, p g

(

% 1 '\

s -

U '

v

~

GfNERIC e4AINlENANCE MATRIX - PHASE I Component Component Alt.

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

reassembly.

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

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

abnormal conditions. For engines with less than 750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months , also inspect by 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 impeller caused reassembly. fretting and upset of the keyway sides.

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

3. It is recommended that the castle nut that drives the external spline on its taper have minimum and max--

imum torque values of 120 ft-lbs and 660 ft-lbs respectively for DSRVs and a maximum torque value of 77 ft-lbs for DSRs.

f II-B-9 Revision 2

O TD1 OWNERS GROUP APPENDIX - II GENERIC MAINTENANCE MATRIX PART C PHASE II COMPONENTS O

O

w m m C U n%e -

e GENERIC MAINIENANCE MATRIX - PHASE 11 d Component Component Alt.

q Number identification PM Recommendation Monthly g g 5 1 ear Overhaul Comments l F-068 Intercoolers 1. Record the following X 4

temperatures during the monthly surveillance test of the engine: 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 shell and Inspect at EOCl and EOC3 tube sides, and clean to verify item I results as required. are valid.

3. Verify intake manifold X Note: Refer to IDI SIM q

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

]

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

4

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

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

3. Hegger rotor and stator. X ,

4. Verify that space heaters X

are on with engine shutdewn.

5. Measure vibration and X

' check against baseline data.

CP-1018 Emergency Generator Pedestal 1. Drain, flush, refill X Bearing bearing housing.

2. Measurebearinghouui.y X insulation resistance.

11-C-1 Revision 2

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

I O

\ V )

' GENERIC MAINTENANCE MAIRIX - PHASE 11 Component Component Alt.

Number Identification PM Recommendation Monthly 10C EOC 5 Year Overhaul Comments

3. Disassemble and inspect X 4

bearing and check clearances.

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

2. Check terminal boards X i for loose wiring.

3. Visually check condition X of wire insulation for

' degradation.

1

4. Clean and inspect relay X contacts.

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

1

6. Bridge rectifier assembly. Note: Inspections may

be deleted after modifications as i prescribed in DR/QR Report.

l I

a. Inspect the temperature X If the label permanently j blackens, the maximum sensitive label placed on the most visible temperature of the 4

face of the hexagonal diode has been exceeded, 1

' body of the diodes. requiring an electrical The label shall be inspection of the diode inspected before and and an inspection of j the mounting threads after each running of the engine. of the heat sink and i diode.

l Replace the diode and the heat sink as needed and assure that proper mounting tightness of

' 300 in-lbs and proper thread condition is maintained.

i I Il-C-2 Revision 2 Ii

O i d' U s i GENERIC MAINIEhANCE MATHlX - PHASE 11 Com,ionent Component Alt.

Number identification FM Hecommendation Monthly EOC LOC 5 Year overhaul Comments

b. Inspect glyptol applied X Netighten any loose to the side of the lugs connections, remove i

and mounting bolt for old glyptol, and reapply j the lugs which attach if connections are i to the bottom of the relightened.

i diode and SCR 5eatsinks for signs of v lative

! motion.

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

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

I 8. Printed circuit boards - X Report any abnormal check for cleanliness conditions to engineer-l ing for evaluation.

and proper mounting of components.

9. Implement a procedure to lhls recommendation is i 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 l

00-420 Lube Oil Pressure Regulating 1. Disassemble and clean. X If valve sticks repeat-Valve edly, more frequent cleaning may be i

necessary. If valve j

plugging becomes a prob-lem, the dimensions of the valves internal parts should be checked to ensure proper clearance.

2. During initial startup after l a major reassembly of j

lube oil piping, abnormal i lobe oil pressure excursions i should be investigated and remedial action taken until excursions subside.

l Il-C-3 Revision 2

m l

(

[

\\ -

GENERIC MAINTENANCE MATRIX - PHASE 11 Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 00-442A Starting Air Distributor 1. Visually inspect the X Evaluate the degree of Assembly puppet 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 EOC1 air manifold went is for sites that did not 3

< open and unobstructed by perform QR inspection noting the escape of af ter plant pre-opera-air during engine startup, tional testing.

02-307B tube Oil Tubing and 1. Check accessible tubing To be performed as Fittings - Internal for dents or crimps required, after performing 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 & 1 Inspection shall evaluate for D5RVs and mains

, bearing wear and evidence between 5 & 6, and

of harmful crankshaft 6 & 7 for DSRs on one misalignment. If results engine / station at EOC2.

show evidence of mis- At one time 5 year in-

' alignment, TDI recom- spection, inspect bearings mendations for crankshaft 3 through 8 inclusive.

j realignment should be Complete 101 Inspection implemented. and Maintenance Record Form No. 310-2-1 as applicable, l0I instruction Manual, Volume I, Section 6 -

4 one sheet for each main

) bearing. Use Volume 1 Appendix 111 for clearance values. Also inspect when removed consistent with inspections required l for Component 02-310A.

i Il-C-4 Revision 2

GENERIC MAINIENANCE MATRIX - PHASE II Component Component Alt.

Number PM Recommendation Monthly EOC EOC 5 year Overhaul Comments identification 02-310C Thrust Bearing Ring 1. Measure thrust bearing X Complete applicable ring clearance by sections of IDI

" bump check" method to be Inspection and Main-performed in conjunction tenance Record f orm '

with crankshaft web No. 310-1-1 IDI Instruc-deflection measurements. tion N nual, 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.

i

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

02-311A Crankcase Assembly 1. Perform a visual inspection X Ihe first inspection i of the vertical portion of after 185 hours0.00214 days 0.0514 hours 3.058862e-4 weeks 7.03925e-5 months of at the crankcase arch wall to or near full load opera-the nut pocket area for tion may be used to indications of cracking. justify the discontinua-l tion of such inspection ,

until an overhaul. For engines with less than 185 hours0.00214 days 0.0514 hours 3.058862e-4 weeks 7.03925e-5 months operation at i or near full load, inspect at each EOC until exceeds 185 hours0.00214 days 0.0514 hours 3.058862e-4 weeks 7.03925e-5 months .

I

2. Remove alternate left X If excessive water, sludge j 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.

1

' 3. Check internals of X block and base for leaks.

Il-C-5 Revision 2 i

(

s'

% (

GINtRIC MAIN!! NANCE MA1RIX - PHASL ll Component Component Alt.

Number Identification PM Recommendation Monthly [0C E0C 5 Year overhaul Comments 02-317A&8 Water Discharge Manifold - 1. Visually inspect for X Jacket Water Discharge leaks.

Piping, Couplings and Seals 02-3418 Piston Rings 1. Inspect and measure piston Complete TOI Intpection replacement rings. and Maintenance Record Form No. 341-2-1 as applicable, TDI Instruc-tion knual, Volume .I.

Section 6. Use Volume I, Section 8, Appendix 111 for clearance values.

To be performed as required.

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/B -

Connecting Rods.

Note: All new or re-placement 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 Nute: this inspection is reroll or replace any also to be performed one that are loose. time at'5 year interval on sampling basis consistent with Component 340A/B -

Connecting Rods.

02-345A Intake and Exhaust 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, TDI Instruc-rotate and that there is tion Manual, Volume I, no noticeable clearance be- Section 6. Refr: TDI 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 Item 2.

Il-C-6 Revision 2

-_ _ - - - . - ~ .

M GENERIC MAINTENANCE MATRIX - PHASE 11 4

Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments 02-345B Fuel Tappet Assembly 1. Visually inspect fuel tappet X Complete IDI Inspection assembly condition, and and Maintenance Report verify that can rollers Form No. 345-1-1 as i

are free to rotate and applicable, 101 Instruc-

, that there is no notice- tion Manual, Volume I, able clearance between Section 6. Also perform j the can rollers and the one time at 5 years roller pins. Do this consistent with Component i

i by manually checking for 02-340 A/S Item 2. Pe r-excessive motion and form an additional in-visually observing for spection by EOC2 on i 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 on the size and extent l of surface distress.

Any corrective measures shall be implemented as indicated by this i

analysis. Signs of 1

spalling shall result in immediate replacement of j the can. Perform an 4

additional inspection by EOC2 on exposed or dCCessible assemblies.

Refr: IDI Instruction l

Manual, Volume I, Maintenance Schedule.

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

) 02-350B Can Shaft Bearings 1. Inspect and measure can X Complete 101 Inspection j shaft bearing shells. and Maintenance Record Form No. 350-1-1 as 1~

applicable,101 Instruc-tion Manual, Volume I, Section 6. Use Volume 1, Section 8, Appendix Ill for clearance values.

Il-C-7 Revision 2

. _ _ ___ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ . . __ - _ _ . _ _ _ _ . _ _ . . _ _ _ _ . . . _ . _ ._ _ . _ . m_ . . 1_, .

m 3

a J

i GENERIC MAINTENANCE MATRIX - PHA$E Il Component Component Alt.

j

, Number Identification PM Recommendation Monthly M EOC 5 Year Overhaul Comments j

Also at one time 5 year

! inspection for Component 02-340A/B measure clear-i ancas per TDI on one 1 bearing housing / camshaft. ,

02-350C Can Gear 1. Visually inspect can gear X For engines with less for chipped or broken than 750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months , also teeth, pitting, excessive inspect at EOC2.

wear, or other abnormal conditions. At this in-j spection, the gear is in immediate proximity to i the spray nozzle which I should also be visually inspected.

2. Measure ge r backlash. X Complete applicable X sections of 101 Inspec-Note: If can gear hub tion and Maintenance is removed, it is Record Form No. 355-1-1, recommended that the nut IDI instruction Manual, be relocked at the Volume I, Section 8, position corresponding Appendix 111-1 for to the torque of 70120 clearance values, i' ft-lbs. Insertion of the cotter pin must be Note: Refer to 101 accomplished at a torque SIM to be issued sub-i > 50 f t lbs and < 90 sequent to March 1986.

It -lbs. If this is Also to be performed not possible, another one time at 5 years l

bolt, nut or washer consistent with Com-should be used. ponent 02-340 A/8.

02-355A Crank to Lube Oil 1. Visually inspect crank- X Any abnormal situations l or indications of

Pump Gear shaft to lube oil pump gear for chipped or progressive pitting

,' broken teeth, excessive should be reported I wear, or progressive for an engineering pitting or other abnormal evaluation. For engines j with less than 750 conditions, i

l hours, also inspect by 1 EOC2.

j 1

l l

i i

II-C-8 Revision 2

o O O GENERIC MAINIENANCE MAIRIX - PHASE 11 4

i a Component Component Alt.

J Number identification PM Recommendation Monthly M g 5 year Overhaul Comments

2. Measure gear backlash. X Complete applicable sections of 101 Inspection and Main-i tenance Record form No. 355-1-1. TDI Instruction k nual, 1

Volume I, Section 6.

Use Volume 1, Section 8, Appendix 111-1 for

' clearance values.

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

?

brchen teeth, excessive engineering evaluation.

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

inspect at EOC2.

2. Measure gear backlash. X Complete applicable sections of 101 Inspec-i Note: If idler gear hub tion and Maintenance l

is removed, it is recom- Record Form No. 355-1-1, j

mended that the nut be TDI Manual, Volume I, Section 6. Use Volume I, i

relocked at the position l 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 f t-lbs i

and < 90 f t-lbs. If

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

head gasket). Refr.. 101 SIM 360.

j 2. Inspect the piston, cap, X i

guide, and housing sliding

! surfaces to evaluate wear or corrosion.

02-360B Cylinder Head - Intake and 1. Visually inspect intake X Also to be performed one i Exhaust Valves and exhaust valves, keepers, time at 5 years on sam-

' stems and seats for , ire pling basis consistent drawing, pitting, destur- with Component 340A/B.

i tion, concentricity, and any abnormal condition.

i II-C-9 Revision 2 i

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

f y

) c j l GENT RIC MAINTENANCE MAlRIX - PHASE 11 Component Alt, Component j Number Identification PM Recommendation Monthly EOC EOC $ Year Overhaul Comments

2. Visually inspect subcovers This is a one-time-only a

for evidence of valve inspection, to be l

{ performed after 500 or 9ulde blowby (soot).

600 hours0.00694 days 0.167 hours 9.920635e-4 weeks 2.283e-4 months of operation i after rebuild of a cylinder head.

l a

3. Measure intake and ex- X Complete applicable

! sections of TDI haust valves head thickness. Inspection and Main- ,

j tenance Records Form '

1

) 360-2-1. TDI Instruc-tion Manual, Volume I,

! Section 6-one sheet for l! each cylinder. Use Section 8, Appendix i

Ill for clearance values. (Items 2 & 3).

' Also to be perfomed one time at 5 years on

' sampling basis consis-tent with Component I 340A/B.

! 4. Measure intake and exhaust X Complete applicable valves - valve-to guide sections of 101 l Inspection and Main-l clearances.

tenance Record Form l

j 360-2-1 TDI Instruction Manual, Volume I, Section 5-one sheet for each f cylinder. Use IDI SIM 336, Rev. I for clear-ance values (acceptance l

i criteria). Also to be performed one time at 5 years on sampling l basis consistent with Component 340A/B.

f i

02-362A Cylinder Head Covers - 1. Perform a liquid penetrant X Also to be performed one l time at 5 years on a

Subcover Assembly examination of the rocker are pedestals top and sampling basis con-2 vertical machined sur- sistent with Component

}

faces (connector push- 340A/8. Subcovers with rod side only), pedestal cracks that 1 extend through the

] counter bore web down I' to the threads should be replaced. Refr:

OR/QR Report #02-362A.

I Il-C-10 Revision 2 l

]

G GENERIC MAINifMANCE MATRIX - PHASE II Component Component Alt.

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

Complete fuel injection pump inspection in accordance with TDI instruction and h in-tenance k nual, Volume I, Section 6. Based on inspection results and operating parameters.

Complete IDI Instruction and h intenance Record Form No. 365-1-1 as applicable, for the pump disassembled.

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

02-3658 f uel Injection Nozzles 1. Remove, inspect, and clean X insure that a new copper tips. gasket is used upon reinstallation of nozzle into head. Perform retorque requirement per 101. Complete IDI Inspec-tion and Nintenance Record Form 365-2-1 as applicable, instruction knual, Volume I, Section 6.

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

2. Check nozzle pop pressure. X

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

~ G ,

%./

1 GENERIC MAINIENANCE MATRIX - PHASE 11 i

Component Component Alt.

)' Number Identification PM Recommendation h:thly 'g M 5 Year Overhaul Comments 1

02-365D Fuel Oil Injection Lines: 1. Visually inspect support X Any inserts found to be l

Supports elastomer inserts for unsatisfactory shall be j

deterioration or degrada- replaced with new inserts i tion. prior to reassembly of 7

fuel oil lines. This inspection can be per-formed prior to reassembly 1

of the fuel oil lines in

}

conjunction with the 1

cylinder liner inspection.

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

l 1 02-3718 Fuel Pump Linkage Assembly 1. Grease swivel link or X and Bearings otherwise lubricate all fuel oil pump assemblies.

02-380A Exhaust Manifold 1. Perform a visual examination X To be performed at EOCl i of accessible pipe welds and alternate EOCs

< and corresponding heat- thereafter. .

[

l affected zones.

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

2. Inspect seat and disc. X j 02-381A Crankcase Vacuus Fan 1. Inspect fan and clean X as necessary, li

2. Check bearing for X roughness.

02-390E Rocker Arm Bushings 1. Visually inspect and X Also to be perfomed one measure intake rocker arm time at 5 years on

' bushings. sampling basis con-sistent with Component 1

340A/B.

l 2. Visually inspect and X Also to be performed one measure exhaust rocker time at 5 years on are bushings, sampling basis con-sistent with Component 340A/B.

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

!!-C-12 Revision 2

{

F J O

)

GENERIC MAINTENANCE MAIRIX - PHASE II l Component Component Alt.

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

'l lash.

1

2. Reinstall and adjust X Also to be performed one i lifters. time at EOC2 and at 5 l years on a sampling basis consistent with Component 340A/B.

1 Note: Ensure lifters are t; installed with the fill j holes up. Verify condi-1 tion of lifters by com-parison of lifter leak-j down rate (actual) to specifications noted on IDI mintenance knual.

Refr: TDI m intenance knual, Section 6-B-5.

1

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 1

is correctly set to an j overspeed trip setting

' of 517

5 rpm. Ensure I

that the electric governor setting is properly re-1 turned to 450 rpm and the mechanical backup governor returned to the manu-facturer's specified interval following the overspeed test. The test

is to be performed with no load on the engine by l increasing the normal l governor speed setting (s)

I

' until a trip occurs.

1 After several inspection 1'

periods, the history of the required adjustments 1

should be reviewed to f

evaluate and possibly

)

' modify the testing in-terval. Also perform

, at EOC2.

I 4

I l

l Il-C-13 Revision 2

r O

GENERIC MAINifNANCE MATRIX - PHASE II Component Component Alt.

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

02-410B 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.

Overspeed Trip Drive Couplings 1. Remove the present L-110 To be completed by 02-410C the first refueling Lovejoy couplings in 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 [0C nearest 5 years. For and Shaft of wear, engine with less than 750 hours0.00868 days 0.208 hours 0.00124 weeks 2.85375e-4 months , also inspect at LOC 2.

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 San Onofre be removed, all meting surfaces cleaned, and

- See Site the unit reassembled Specific using toctite 609 on ttw for San mating surfaces.

Onofre)

II-C-14 Revision 2

O GENERIC MAINIENANCE MAlHlX - PHASE il Alt.

EOC 5 Year Overhaul Comments Monthly EOC Component Component PM Recoaunendatio_n X

Ntanber _ Identification Replace the elastomeric 2.

insert in the Koppers coupling. Note: lo be performed as necessary after

1. Install positive locking tightening governor Governor Linkage hardware to the lever linkage hardware to design 02-413A are clamp bolt heads and torque specifications.

shaft roll pins, X

2. Inspect for loose parts on the linkage assembly.

3. Lubricate cross shaft 02-413A Governor Linkage bearings as required.

(DSRVs only) X

4. Grease the rod end fittings, or lubricate oil wicks, especially those at the ends of the cross shaft. 10 be accomplished when j X placing unit in main-j 1 Check cylinder for tenance modes.

I 02-4138 fuel Pump Linkage: extension and return.

l Automatic Shutdown Cylinder lo be accomplished during X controls system check.

i

2. Check tailrod vent I

for air leakage. Note: Ensure the by-X draulic actuator is pro-

1. Drain, flush, refill, and perly vented.

02-415A Woodward Governor vent actuator oil system with new oil from a clean container ensuring the appropriate cleanliness procedures are followed.

It contaminated oil is noted, increase frequency. X

2. Disassemble, clean, and refurbish the actuator. Note: Mechanical X

governor setting to

3. Verify all governor be 470 rpm.

control knob settings are in appropriate positions.

Revision 2 Il-C-15

[ %

l GENERIC MAINTENANCE MAlRIX - PHASE 11 Component Component Alt.

Number Identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments

4. Evaluate electric X An evaluation of the j governor settings to governor settings is verify overshoot of to be performed during I the 450 rpm set speed surveillance testing once is within plant-specific under joint mechanical

) and electrical governor guidelines and to avoid critical speeds control.

i during start or when i unloaded.

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

This can be modified so 02-441B Air Filter to Starting Air 1. Replace filter elements. X l If filter in a metal that the filter is to be Distributor screen, cleaning with changed at a maximum

solvent is acceptable pressure drop of 25 psi in lieu of replacement, for engines equipped with pressure monitoring devices.

Air Start Admission Valve 2. Clean and inspect strainer. X If the strainer is Strainer excessively dirty, the I frequency of cleaning i

and inspecting should be increased.

l l

1 Air Start Block Valves 3. Clean and refurbish valves - X i

replace "0" rings and l clean the screened fitting.

! Ensure leak tightness

after reassembly.

4. Inspect for tightness l of fittings and bolts i

! and apply locking com-j pound as required i during reassembly of I components.

I i 5. Replace "0" rings of the X 1 shuttle valve.

j ll-C-16 Revision 2

k I

\.

GENERIC MAINTENANCE MATRIX - PHASE 11 Component Component Alt.

Number Identification PM Recommendation Monthly 10C E0C 5 Year Overhaul Comments i

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 the newly replaced cartridge.

After air has been purged,

' close vent valve and return handle to pre-wious operating position.

l

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

3. Inspect tubing and me- X Refr: 101 Instruction chanical connections for Manual, Volume 1.

tightness and/or leaks.

Fuel Oil 5 trainers Record strainer dif fer- If greater than 5 psid-

) '

02-4558 1.

ential pressure or monitor X

shift, clean element.

supervisory alarm as Bolt torques of 120-150

' applicable. in-lbs should be utt-lized during reassembly.

! 2. Purge air from stand-by As required.

strainers.

1 02-467A Turbocharger Lube Oil Fitting: 1. Visually inspect for leaks. X l Pipe, Tubing, Fittings, and

! Flexible Coupling (Small Bore Scope Only)

! 02-475A,C Turbocharger: Bracket Bolting 1. At each engine shutdown for )

and Gaskets the first three engine shut-

downs of operation after i

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

If during these inspections none of the screws are found loosened or damaged, future II-C-li Revision 2 i

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

i

! -6 j GENERIC MAINTENANCE MATRIX - PHASE 11 i Component Component Alt.

Number identification PM Recommendation Monthly EOC EOC 5 Year Overhaul Comments inspections are to be con-ducted on a parly basis (or during plant shutdown).

But if any time during i inspection any screw is found i loosened or damaged, it must then be replaced (if damaged) 1 and all screws retorqued as i follows: 125 ft-lbs for the l j bracket-to-engine screws and 75 ft-Ibs for the bracket-to- !

turbo base screws.

Note: To avoid damage to bracket to engine, and/or bracket to turbo, the pro-

! per torques as delineated above should be utilized s i for each respective bracket bolting application.

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

I

2. Check valve disc for X Check by visually observ-9 freedom of movement. Ing valve / actuator oper-I atlan. If oil cups are used, this should be

! completed monthly.

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

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

2. Visually check wiring for X j insulation degradation.

3. Visually checit instrument X tubing for leaks.

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

II-C-18 Revision 2

_ _ . _ . . _ . . _ _ _ _ . . _ _ _ _ _ . . __ _ . _ _ _ _ _ .. _ _ . .__._..m. . . _ _. m _ _ .__ . _ . _ . _ . _

l k \

s J

GENERIC MAINTENANCE MA1RIX - PHASE II i

Component Component Alt.

l l Number Identification PM Recommendation Monthly _ g M $ Year Overhaul Comments 1

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

7

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

1 i i 7. Monitor control system air X j pressure or supervisory alarm as applicable.

l 4 02-500C Circuit Breakers and Contact 1. Check all terminals - X Accomplished during 4

Blocks clean and tighten. panel cleaning and 1

inspection.

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

3. Trip check circuit To be performed at j

breakers. appropriate site intervals for similar equipment.

02-500G Control Panel Valves 1. Inspect control panel X l

valves for leaks.

1 j 2. Replace or refurbish X l pneumatic logic board.

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

l 2. Visually check condition X j of wiring and tightness of 1 j terminations.

1

]

02-500N Control Panel Switches Terminal 1. Clean terminal boards and X j

Boards and Wiring switch contacts.

I l 2. Visually check wire insu- X 1 lation and terminals for tightness and degradation.

! 3. Inspect for arcing and X l overheating.

1 1

1 1[-C-19 Revision 2 1

GENERIC MAINTENANCE MATRIX - PHA$E 11 Component Component Alt.

Number Identification PM Recommendation Munthly @ $ 5 Year Overhaul Comments I 02-5258 Barring Device Control Valve 1. Replace control valve As required.

and Press Regulator "0" rings and tube shaft.

2. Replace press regulator As required, elastomeric parts.

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

2. Drain barring cevice air As required.

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

after each reassembly.

i 02-540A Lube 011 Sump Tank 1. Check lubricating X Refr: IDI Instruction oil with a viscost- Manual, Volume I, meter for fuel oil Maintenance Schedule, j dilution. Send a items 1, 2.

sample of-oil to laboratory for analysis.

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

. based on sample to thermal degradation analysis, and coke formation. The i

additive package should i

provide high datergent dispersant properties with high alkalinity and a high level of antiwear additive such as zinc dithiophosphate. Total Base Number (TBN) should

) be 12 to 15 for use with

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

is preferred. An engine

' oil with such properties, Mobilguard 412 or equiv-

' alent product may be used to insure improved lubri-cation. Do not six lube oil brands or types. When ,

changing lube oil replace I the entire charge. Re- ,

place as required.

I i

Il-C-20 Revision 2

[ )

W N/

l GENtRIC MAINifMANCE MATRIK - PHASE 11 1

Component Component Alt.

Number Identification PM Recommendation Monthly E0C EOC 5 Year Overhaul Comments

3. Visually inspect lube To be performed per i

oil sump tank level appropriate site intervals switch floats. Check for similar equipment.

switch set points.

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

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

analysis, ferrographic analysis may be utilized.

Particular attention shall be paid to copper level and particulate

size, which could 1 signify thrust bearing degradation. Particular f '

attention shall be j given to percent mois-ture content.

!02-550 Foundation Bolts 1. Visually inspect founda- X

! tion for breaks in the bond between the sole plates and grout.

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

web deflections. values.

I

3. Generator foundation bolts are to be retorqued after a generator short circuit if the bolts were initially torqued to 480 ft-lbs. If initial bolt torque was 600 ft-Ibs, no retorque is required.

02-6300 1hermocouples 1. Check that thermocouple X An inconsistent reading

) traced to thermocouple indicates ambient engine d

temperature when the trouble should result engine is cold. In replacement of the i

thermocouple.

11-C-21 Revision 2

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

\

CthtRIC MAINIf HANCE MAINIX - HlASE Il Component Component AIt.

bat,er Identification PM Recommendation Monthly g EOC 5 Year Overhaul Comments

2. Clean and inspect Indications of fatigue thermocouples and should result in re-thermocouple shields placement of the thermo-as required. .

couple and/or thermo-couple shield.

3. Pyrometer wiring - check To be accomplished dur-that terminations are ing control panel check-tight. .

out and initial operation inspections.

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

pressure reduction during normal engine shutdown.

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.

2. Replace elastomeric parts. As required.

02-7008 Jacket W ter Standpipe: 1. Replace elastomeric As required.

Valves parts in valves.

02-700F Jacket W ter Standpipe 1. Visually check jacket Any visible cracking and Miscellanenous Bolting water standpipe, pump or minor jacket water.

suction and engine return leakage should result nozzle welds during each in rework of cracked routine engine run and nozzle welds, every 100 hours0.00116 days 0.0278 hours 1.653439e-4 weeks 3.805e-5 months during extended engine runs.

2. Check treatment (ph, X Also to be performed etc.,as applicable) of after adding makeup jacket water and correct water.

as recommended by chee-ical supplier.

02-717B Auxiliary Sub-Base and - 1. Inspect the valves X Replace packing as Oil & W ter Piping - for packing leakage. necessary.

Jacket dater: Valves

!!-C-22 Revision 2

I

h i

4 l GENtRIC MAINIENANCE MAIRIK - PHASE 11

] Component Component Alt.

Number Identification PM Recommendation hnthly EOC EOC 5 Year Overhaul Comments 1

l 02-717C Auxiliary Sub-Base and Oil & 1. Visually inspect for leaks. X

, hter Piping - Jacket hter:

} Pipe. Couplings, Fittings Orifices V-Strainers

]

(Small Bore Scope Only) j 02-717F Auxiliary Sub-Sase Lube Oil 1. Visually inspect pipe X t

Pipe and fittings and joints for leakage.

3

2. Clean and inspect tube Complete when lube oil

' oil keep ware pump suction tank is drained.

strainer as required.

02-717G/K Auxiliary $ 4-Base tube Oil / 1. Disassemble, inspect, fuel Oil valves and refurbish off 4

engine lube oil and 1

fuel oil valves as i required.

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

{ necessary.

f I

i 02-8058 Intaba Air Filters 1. Inspect air intake / oil Replace with change oil bath filters every 3 to if necessary. If samp-6 months, ling is utilized, change I

based on analysis re-i sults.

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

2. Visually check for X evidence of exhaust leakage.

02-810C Jacket h ter 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, servie water chemistry centsol can be used to maintain heat exchanger performance and integrity.

Il-C-23 Revision 2

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

N t

1, GENERIC MAINTENANCE MAIRIX - PHASE 11 i

l Component Alt.

Component Ember Identification PM Recommendation Enthly g g 5 Year Overhaul Comments t

2. Record heat exchanger X Use for trend data.

parameters.

3. Evaluate heat exchanger M 3

performance data.

I

.4. Inspect tubes and tube X Refr: 101 Instruction i i

sheet for fouling and Manual, Volume I, i Maintenance Schedule.

i erosion - remove en-trance and exit channel covers as required by trend data or at over-haul. Also review consistent with in-spections of other plant heat exchangers !

utilizing similar water cheelstry.

l

5. Inspect and clean Replace or rework lantern !

lantern ring as required. ring as necessary to Verify leak-off holes ensure concentricity are not plugged. prior to reinstalla-tion.

6. Replace packing Replace packing when

- rings as required. packing becomes hard or f leakage at the packing -

is nuted and cannot be stopped by tightening. t 1

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

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

t 02-810E Jacket Wter Heaters 1. Check calibration and 10 be performed at !

inspect thermostat. appropriate plant ,

interval for similar equipment. Replace heater if degradation ;

of insulation resist 4 ace ;

is noted. t i

4 :

b

i I

11-C-24 Revision 2 j

1

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

j GEM RIC MAlhlfMANCE MA1RIX - PHASE 11 f

Component Comporwnt Alt.

I Number Identification PM Recummendation Monthly [0C EOC 5 Year Overhaul Comments

}

tube Oil Sump Tank 1. Inspect.ind clean Replace heater it de-02-820A

~

Heaters heater eiements as gradation of insulation required by trend data. resistance is noted.

i

2. Check calibration and To be performed at '

I it spect condition of appropriate site intervals thermostat. for stellar equipment.

02-820C Lube Oil Keep-Wars Pump 1. Cteck mechanical seal X and piping connection 5 for leakage.

1 E 2. Verify pump discharge X use for trend data.

pressure is within manufacturer's specifi-cation.

02-8200 tube Oil Keep-Wara Strainer 1. Clean or replace strainer element when the differential pressure change at the lube oil keep wara strainer is 4 20 psid or for those

! plants not having this e

CapabIIity, Clean or re*

! place when differential l

pressure of keep ware I

filter is 20 psid.

4 4 02-820E tube Oil Keep-Wars Filter 1. Record filter dif ferential X pressure.

4 i

2. Change filter To be performed when elements as required. the filter differential

] pressure reaches 20 4

psid. For sites not

' equipped with differ-ential pressure gauge, '

l inspect monthly and j

clean as necessary.

1 t

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

Filters pressure. Refr: 101 Instruction J

Manual, Volume I, Maintenance Schedule.

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

}

i nature of the material j caught in the filter.

i 1

1 Il-C-25 Revision 2

.K \

%)

\ %

GINERIC MAINTENANCE MATRIX - PHASE 11 Component Component Alt.

Number identification FM Recommendation Munthly E0C E OC, 5 Year Overhaul Comments

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

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

Enchanger parameters.

2. Evaluate heat exchangar X performance data.

3. Inspect tubes and tube X Refr: 101 Instruction sheet. k nual, Volume I, h intenance Schedule.

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

plugged.

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

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

pressure of strainer and/or filter.

2. Clean or replace strainer To be performed when the etee-nt when the dif fer- - differential pressure t

ential pressure change across the strainer is i at the tube oil strainer 20 psid. Refr. IDI is 20 psid. For those plants Instruction k nual, j

not having this capability, Volume 1, h intenance clean or replace when Schedule.

~ '

differential pressure of l ' full pressure filter is '

20 psid.

3. Lube oil strainer- +

To be performed per pressure gauge - appropriate site intervals i f or similar equipment.

4 calibration check.

]

. j. r %

.~

% ~ . .

? s

- x q ,

i - . , _

- % - . ~y n . , .

q

, , m

.~; _ y .-

! 11-C-26 Revision 2 Q '

l

... A f. Y2

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

-m

.r ~ ; -- ~ 4- t e % ;y - -- --

- * - - s

e

~~

~

g i s ,. _, ,- -

GENERIC MAINT[hANCf MATRIX - PHASE II

i

! Component Camponent Alt.

. Numiser Identification PM Recommendation Monthly IOC [0C 5 Year overhaul Comments i

02-8358 Diesel Starting Air 1. Check oil pressure and X t Compressors oil level if compressor A is so equipped.

I

2. Overall visual X inspection.

]

' r j 3. Clean fins on intercoolers X ;

d and aftercoolers.

4. Inspect intake filter X 3 element if equipped r and replace as neces-sary.

1 4 5. Change compressor oil X

at each EOC, or if monthly

} sampling is performed i change as required based l

on results.

I 1 6. Check belt tension. X

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

8. Inspect filter felts on X Replace as required,

) unloader system. if so equipped.

t I

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

i

2. Check proper operation X Replace desiccant charge

' or refrigerant as re-of dryer.

quired.

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

t i

I Il-C-27 Revision 2 l ;

i

i 4

GENERIC MAINTENANCE MAIRIX - PHASE 11 AIt.

l Component CortM7eA' Monthly EOC 5 Year Overhaul Comments Number PM Recommendation EOC l atn!if b:ation

2. Starting air tank pressure To be performed per i

' gauges - calibration appropriate site

> check. Intervals for steilar .

equipment.

] i

3. Starting air tank pressure To be performed per switches - calibration appropriate site Intervals for similar 4

check.

} equipment.

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

l covered) tion of all fuel, air, Refr: 101 Instruction Manual, Volume I, 4

1 oil, and water piping as d valves for leakage. Maintenance Schedule.

{

1 -

I l

a i J

1 l

4 i

1 4

a s

=

1 t

a I

}

11-C-28 Revision 2

- - a m-..1 m.ns -m--.-- -- -- - - - - - , . +---A--,----- -.a-- - -- a u- -

E an O TDI OWNERS GROUP APPENDIX-II SITE SPECIFIC MAINTENANCE MATRIX PART D l

m O

O

(

-.--.....m-. -.,rc-.. . - - - - . , _ -,.---.. .-- . . _ . . . --------w - , . . - - . - . . -, _ --,,,..,,- - ,w.- - - - - _ _ , - - , - - - , - . , . - - - -,.m,

] U SIIE-SPECIFIC MAINTENANCE MAIRIX Component Component Alt.

Number Identification PM Recommendation Monthly EOC {0C 5 Year Overhaul Comments 02-310A Crankshaft 1. Measure and record crank- X Complete IDI Inspection (Catawba) shaft web deflections and h intenance Record (hot and cold). Form No. 310-1-1 as applicable. TOI Instruc-tion knual, Volume 1 "

Section 6. Refr: IDI Instruction knual, Volume 1, hintenance Schedule.

i 2. Examine the fillets and Also to be performed once I oil holes of three main at 5 years.

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

using LP. If indications are evident, a more thor-i ough examination should be made using appropriate NDE methods. i

3. Examine the fillets and Also to be performed once oil holes in three of the at 5 years.

crankpin journals (choose Ref r: PNL-5600.

3 from Nos. 3 through 8 inclusive) using Lp. If indications are evident, ;

a more thorough examina- 4 tion should be made using

' appropriate NDE methods.

4. Measure diameter of crank- X Complete TDI Inspection ,

pin journals. and h intenance Record i

' form No. 310-3-1 as applicable, IDI Instruc-tion k nual, Volume I, Section 6.

1 4

Also perform inspection at 5 years, on items accessible, consistent with this component and Component 02-340A/B.

1 4

4 Il-D-Call Revision 2

J O O a

l i SilE-SPECIFIC MAINT[ NANCE MAIRIX Component Component Alt.

Number Identi fication PN Recommendation Monthly (DC EOC 5 Year Overhaul Comments

5. Analyze the trends of X If an engine operates cylinder pressure and in a severely unbalanced i

temperature measurements condition, reinspect the to detect imbalances. oil holes for fatigue cracks within a time-frame determined by the utility considering the i

4 particular circumstances j of the abnormal operation.

1 Refr: PNL-5600.

1 l Note: To avoid the Re f r: PNL-5600.

i effects of the 4th order resonance. steady normal-loaded operation at speeds more than a few I rpe below the rated speed of 450 rps should be j avoided. Appropriate j precautions should be taken to prevent sus-i tained engine operation with significant cylinder l imbalance. Lower speeds

! for testing and break-in

! are permissible. Avoid resonance frequencies.

i i

a l

ll-0-CA12 Revision 2

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

'i

! i

! t SIIE-SPECIFIC MAINltNANCE MAINIX i i,

t Alt. i j Component Component j Number Identification PM Recommendation Monthh g M 5 Year Overhaul Comments 1

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

(Catawba)

} 2. Perform visual inspection X for cracks.

j Note: Visual inspection j not required if an appro-priate NDE is performed.

I I 1 .

i I

I i

i i

i l

l 1

4 i

}

II-D-CAT 3 Nevision 2 f _ . . _ _ . _ _ _ _ ._ _ _ _ _ . _ . . _ . _ _ . . - . _. . _ . . _ . _ _ _ . _ . _

6 O

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

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.

O

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

PEAK / SAN PERRY / GRAND CATAWBA / SilEARON j COMPONENT DESCRIPTION Si10REHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS Air Butterfly Valve 02-475B/ 03-4758/ 02-475B/ 03-475B/ 02-475B/ 02-4758/

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

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

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

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

03-359 02-359 02-359 02-359 02-359 02-359

, Auxiliary Sub-Base & Oil & 02-717C/ 03-7170/ 02-717C/ 03-717D/ / 02-717C/

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

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

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

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

Fuel Oil Valves 03-717I/N 02-717G/K 02-717G 02-717G/K 02-717G/K 02-7171

+

II-E-1

~

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

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

and Press Regulator 03-5258 02-525B 02-525B Base Assembly 02-305A/ 03-305A/ 02-305A/ 03-305A/ 02-305A/ 02-305A/ t 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/

i 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/ 02-3508/ 02-3508/

i 03-3508 02-3508 02-3508 02-350B 02-3508 02-350B l

i 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/

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

j Terminal Boards and Wiring 03-500N 02-500N 02-500N 02-500N 02-500N 02-500N i

I II-E-2

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

1 PEAK /~ SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM 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 Dil Pump Gear 02-355A/ 03-355A/ 02-355A/ 03-355A/- 02-355A/ 02-355A/

j 03-355A 02-355A 02-355A 02-355A 02-355A 02-355A Crankcase Assembly 02-311A/ / 02-311A/ / 02-311A/ 02-311A/

4 02-311A 02-311A 02-311A 02-311A 02-311A i

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

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

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

03-310A 02-310A 02-310A 02-310A 02-310A 02-310A i 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 02-360B/ 03-3608/ 02-3608/ 03-3608/ 02-3608/ 02-3608/ ;

4 and Exhaust Valves 03-3608 02-360B 02-360B 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 1

i i

II-E-3

O O O TDI COMPONENT NUMBER CROSS REFERENCE e

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 02-835B Emergency Generator CP-101A/ 03-650A/ / 03-650A/ CN-119/ 84-101A/

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

Control Panel 03-650B 02-650B GG-119 BL-101B 02-6508 Emergency Generator Pedestal CP-101B/ 03-650C/ 02-650C/ 03-650C/ CN-119A 84-101B/ d Bearing (and shaft) 03-650C S0-103 02-650C GG-101B BL-101C 02-650C Engine Control Air 02-695B/ 03-695B/ 02-695B/ 03-695B/ 02-695B/ 02-695B/

Pressure Regulator 03-6958 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 II-E-4

O O O TDI COMPONENT NUMBER CROSS REFERENCE l

RANCHO RIVER

! COMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ON0FRE V0GTLE GULF BELLEFONTE HARRIS Flex Connection 02-805D/ 15-110/ 02-805D/ 03-8050/ 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 02-559 Fuel Injection Nozzles 02-365B/ 03-365B/ 02-365B/ 03-365B/ 02-365B/ 02-3658/

03-365B 02-365B 02-365B 02-365B 02-3658 02-365B fuel Injection Pumps 02-365A/ 03-365A/ 02-365A/ 03-365A/ 02-365A/ 02-365A/

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

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

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

Supports 03-3650 02-365D 02-365D 02-3650 02-3650 02-365D Fuel Oil Strainers 02-455B/ SC-042B/ 02-4558/ 03-455B/ 02-4558/ 02-455B/

03-455B 02-455B 02-455B 02-4558 02-455B 02-455B Fuel Pump Control Shaft 02-371A/ 03-371A/ 02-37]A/ 03-371A/ 02-371A 02-371A/

03-371A 02-371A 02-371A 02-371A 02-371A 02-371A l

II-E-5

O O O 1

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 02-371B/ 03-3718/ 02-371B/ 03-3718/ 02/3718 02-3718/ <

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

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

l 03-345B 02-3458 02-345B 02-345B 02-3458 02-3458 Full Flow Lube Oil Filter (s) 02-820F/ 03-820E/ 02-820F/ 03-820B/ CN-110/ 84-115/

10-106 02-820C 02-7175 GG-820B 02-8200 02-820E i

j Full Pressure Lube Oil 02-820H 03-820C/ 02-820C/ 03-460A/ SE-025/ SE-025/

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

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

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

03-415B 02-415B 02-415B 02-415B 02-4158 02-415B i Governor Drive - Couplings, 02-411B/ 03-4028/ 02-411B/ 03-402B/ 02-411B/ 02-411B/

Pins and Keys 03-402B 02-411B 02-411B 02-411B 02-411B 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 ,

j

O O O

TDI COMPONENT NUMBER CROSS REFERENCE RANCH 9 RIVER l 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 02-3558/ 03-355B/ 02-355B/ 03-355B/ 02-355B/ 02-355B/

03-355B 02-355B 02-355B 02-3558 02-3558 02-355B Intake Air Filters 02-8058/ 03-805B/ 02-805B/ 03-8058/ 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 i

! 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 l Jacket Water Fittings - 02-435A/ 03-435A/ 02-435A/ 03-435A/ / 02-435A/

Pipe and Fittings 03-435A 02-135A 02-435A 02-435A 02-435A (Small Bore Scope Only)

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

10-103 02-717Q GG-103 02-810A 02-810C Jacket Water Heaters 02-810E/ 03-810C/ 02-8100/ 03-800A/ CN-128/ 02-810B/

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

O O O

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

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ON0FRE V0GTLE GULF BELLEFONTE HARRIS Jacket Water Pump - Gear 02-425A/ 03-425A/ 02-425A/ 03-425A/ 02-425A/ 02-425A/

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

and Miscellaneous Bolting 02-700F 02-700F 00-700F 02-700F 02-700F i

Jacket Water Standpipe: 02-700B/ 03-7178/ 02-700B/ 00-700B/ 02-700B/ 02-700B/

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

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

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

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

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

00-420/ 00-420/

Valve 00-420 00-420 00-420 00-420 00-420 00-420 Lube Oil Sump Tank Heaters 02-820A/ 03-8208/ 02-820A/ 03-800B/ 02-5400/ 02-820A/

03-8008 02-820 02-717P 02-820A 02-820C

Lube Oil Sump Tank 02-540A/ 03-540A/ 02-540A/ 03-5408/ 02-540A/ 02-540A/

03-540A 02-540A 02-540A 02-540A 02-540A 02-540A l

II-E-8

f () f%

( V C)

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

PEAK / SAN PERRY / GRAND CATAWBA / SHEAR 0N COMPONENT DESCRIPTION SHOREHAM CN0FRE V0GTLE GULF BELLEFONTE HARRIS Lube Oil Tubing and 02-3078/ 03-3078/ 02-307B/ 03-307B/ 02-3078/ 02-3078/

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

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

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

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

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

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

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

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

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

03-3418 02-341B 02-341B 02-340D 02-341B 02-341B II-E-9

7 O O o TDI COMPONENT NUMBER CROSS REFERENCE RANCHO RIVER

, COMANCHE SEC0/ BEND / WNP-1/

PEAK / SAN PERRY / GRAND CATAWBA / SHEARON COMPONENT DESCRIPTION SHOREHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS 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/0/ 02-390C/ 03-390C/ 02-390C/ 02-390C/

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

03-390E 02-390E 02-390E 02-390E 02-390E 02-390E

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

Drive Studs (Pop Rivets) 03-390G 02-390G 02-390G 02-360G 02-390G 02-390F l

Starting Air Distributor 00-442A/ 03-442A/ 00-442A/ 03-442A/ 02-442A/ 00-442A/

Assembly 03-442A 02-442A 02-442A 02-442A 00-442A 02-442A i

Sta ting Air Storage Tank 03-835A/ 02-835F/

02-835J/ 03-835F/ 02-835B/ CN-112 10-111 02-835E 02-8350 02-835A 02-8350

rmocouples 02-630D/ 03-6300/ 02-630D/ 03-6300/ 02-6300 02-6300/

03-630D 02-630D 02-6300 02-6300 02-6300 02-6300 Thermostatic Valves 02-8100/ 03-799A/ 02-810C/ 03-515/ C136/40/ 02-810A/

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

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

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

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

PEAK / SAN PERRY / GRAND CATAWBA / SHEAR 0N COMPONENT DESCRIPTION SH0REHAM ONOFRE V0GTLE GULF BELLEFONTE HARRIS Turbocharger MP-022/23/ MP-020/ MP-022/3/ MP-017/ HP-022/3/ MP-022/3/

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

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

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

Bolting and Gaskets 02-475A,D 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 x 2

ML20212C052

Text

Navigation menu

Search