ML20235M565

Forwards Design Review/Quality Revalidation (Dr/Qr) Program for Rancho Seco Tdi Diesel Generators, Final Engineering Summary Rept.Preliminary Turbocharger Final Rept Will Be Submitted by 871001

ML20235M565
Person / Time
Site:	Rancho Seco
Issue date:	07/08/1987
From:	Andognini G SACRAMENTO MUNICIPAL UTILITY DISTRICT
To:	Miraglia F NRC
References
GCA-87-330, TAC-63030, NUDOCS 8707170239
Download: ML20235M565 (96)

Text

-

i g# SMUD 1

SACRAMENTO MUNICIPAL UTILITY DISTRICT D P; O. Box 15830, Sacramento CA 95852-1830,'(916) 452,3211

=

g; AN ELECTRIC SYSTEM SERVING THE HEART OF CALIFORNIA' l

J

% 6 8 1987 GCA 87-330 i

U. S. Nuclear Regulatory Commission 3

Attn:

Frank J. Miraglia,-Jr.

Associate Director for Projects j

~Philips Bldg..

7920 Norfolk Avenue Bethesda, MD 20014 DOCKET 50-312 RANCHO SEC0 NUCLEAR GENERATING STATION UNIT #1 DR/QR INFORMATION ON TDI DIESEL GENERATORS l

Dear Mr. Miraglia:

1 The District's February 20, 1987 (JEH 87-232) and May 18, 1987 (GCA 87-048) correspondence committed to provide Engineering Summary Reports for the sixteen Phase I diesel generator components.

These' reports contain detailed information on the Design Review / Quality Revalidation (DR/QR) Program for the 1

Rancho Seco TDI Diesel Generators. Attached are the sixteen Phase I Engineering Summary Reports.

All of the Engineering Summary Reports are final except for the turbocharger report.

This report has been marked " preliminary" due to vibration problems with the turbocharger support bracket.

The District will submit the final Engineering Summary Report for the turbocharger by October 1, 1987..The submittal will also include the District's response to the remaining' questions I

in the NRCs' January 31, 1984 request for additional information.

The attached Engineering Summary Reports replace the Phase I reports in the District's June 12, 1985 submittal (RJR 85-260).

Each summary report

,1 addresses line item by line item each DR/QR issue.

The summary reports also l

provide the District's resolution to NUREG 1216 identified concerns and 10 CFR l

Part 21 notifications.

Except for the turbocharger Engineering Summary Report, this submittal along with the District's June 12, 1985 (RJR 85-260) and February 20, 1987 (JEW 87-232) submittals complete the actions for Phase I diesel generator components in NUREG 1216 for qualification of the Rancho Seco TDI Diesel Generators.

8707170239 870700 PDR ADOCK 05000312 S

PDR po r

I, i RANCHO SECO NUCLEAR GENERATING STATION O 1444o Twin Cities Road. Herald, CA 95638-9799;(209)'333-2935

]

GCA 87-330 Frank J. Miraglia, Jr. -

(M 0 81987 1

I The District committed in the February 20, 1987 submittal (JEW 87-232) to implement the maintenance and surveillance program described in NUREG-1216.

All maintenance and surveillance procedures will be issued prior to restart, j

except for procedures designated "End of Cycle" or longer.

These post restart procedures will be completed prior to the next refueling outage.

I If you have any questions, please contact John Vinquist of my staff.

1 Sincerely,

'h

/

~

G. Carl Andognini I

Chief Executive Officer, J

Nuclear Attachment cc:

A. D'Angelo, NRC, Rancho Seco i

l l

G. Kalman, NRC, Bethesda (2) l l

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1 1

Sh;st i of 5

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RANCHO SECO DIESEL GENERATOR REQUALIFICATION I

ENGINEERING

SUMMARY

REPORT l

Diesel Engine Serial Number 81015 l

Engine Train A l

Part

Description:

TURBOCHARGER Part Number: MP-020

REFERENCES:

CIDR MC172-002 NDE Report Number: UST-PT-118-85 1

Associated Reports:

NCRs S-4224, 4326, 4332, 6106, 6133; IMs QC-19-20-85, 19-19-85, 19-4-85, 19-3-84, 19-2-84, 19-1-84,26-009; FPR 7, 17, 32, 279; SFR 153-86 l

Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.

Perform visual inspection of the bearings and nozzle ring.

Additionally the l

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

b.

Determine the end clearances (rotor float).

c.

Verify that the proper number of bolts on the turbine inlet casing are j

installed.

)

I d.

Verify that the proper torque loads are applied to the bolts of the turbine l

inlet casing.

i e.

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

j i

f.

Verify that SIM 300 has been implemented and perform an LP test on velds retaining the core (hub nut).

Also verify that the core plug is staked.

g.

Verify that nozzle ring capscrews are properly torqued.

l l

l l

h.

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

This inspection should be performed on a thrust bearing during or after implementation of the full flow pre-lube system modification and following an i

initial 100 engine starts or at the closest plant refueling outage but not to exceed 130 starts.

(Refer to subsection V for discussion of the modification).

I Evaluated By:

Date:

Reviewed By: _

Date:

Requalification Project Engineer

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1 1

Shrst 2 of 5 1

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT 1

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

II.

ACCEPTANCE CRITERIA l

l a.

Absence of excessive wear.on the bearings.

Nozzle ring components have no damage, mi,spositioned vanes, or missing nozzle ring capscrews.

1 b.

Rotor float clearance criteria 0.008" - 0.020".

l c.

There should be 12 bolts installed in turbine inlet casing.

i l

d.

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

1 e.

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

UST-PT-2.

f.

Implementation of SIM 3001 LP acceptance criteria - absence of adverse wear and relevant indications as defined in procedure No. QCI 1013 Also, the hub nut shall be staked.

g.

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

h.

Absence of excessive wear.

III.

INSPECTION FINDINGS a.

Following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing, both turbocharger bearings exhibited excessive wear.

Nozzle ring components (stationary ring and capscrews) were all found satisfactory.

b.

Preservice inspection indicated rotor end float to be.005".

Evaluation by the l

Elliott service representative indicated that although the clearance was not within specifications it was acceptable.

Following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing, reinspection revealed a clearance of.0065".

Re-evaluation by the Elliott factory indicated this time that the clearance dimension was unacceptable.

c.

Turbine inlet easing bolts (piece #57 in vendor manual) were installed and lockwired after reassembly of the turbocharger.

(Ref: Quality Surveillance l

Report, Form PSQ 221, dated 12/19/86) l

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Sheet 3 of 5 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

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

d.

Torque of turbine inlet casing bolts (piece #57) was verified upon reassembly of turbocharger.

(Ref: Quality Surveillance Report, Form PSQ 221, dated 12/19/86) e.

LP examination of nozzle ring performed during preservice inspection revealed seven minor casting blemishes on the outer edge of nozzle ring hub.

These were evaluated as acceptable.

Following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing, the nozzle j

ring was once again satisfactorily LP examined.

l f.

SIM 300 has been implemented.

The as-found condition of the turbocharger revealed that a thick steel plate was velded in place in lieu of a hub nut.

LP examination of the veld performed during preservice inspection revealed indications which were evaluated to be acceptable.

The steel plate was found welded all around its perimeter, firmly securing it to the nose piece (#51, in vendor manual).

l g.

Torquing and lockwiring of all eight capscrews (piece #62 in vendor manual) was verified.

(Ref: Quality Surveillance Report, Form PSQ 221, dated 12/19/87) g^

l h.

Visual inspection of thrust bearings was performed follov$ng 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing.

Results are included with item a, above.

l l

1.

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

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

IV.

CORRECTIVE ACTIONS l

a.

The bearing wear was attributed to high vibration of the turbocharger during startup testing.

The turbocharger was sent to the Elliott factory for a complete checkout and rework as necessary.

The following summarizes the problems revealed during disassembly:

o Rotor was found to be out of balance - (determined at factory) o Both bearings exhibited excessive wear: Blower end bearing indichted smooth but excessive wear on thrust and Journal surfaces.

Turbine end bearing revealed smooth but excessive wear pattern on journal surface only.

(determined at Rancho Seco)

Sh90t i of Q RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number ct013, Part No. MP-020 Engineering Evaluation and Reco.iendation (Continued):

]

l

)

o Rotor end float dimension too tight - (determined at Rancho Seco and I

confirmed at factory)

Corrective Actions taken were as follows:

o Rotor shaft was rebalanced o

New bearings and new oil seals were installed o

Intermediate casing was lightly machined at factory to achieve proper rotor clearance.

Final 'as-left" clearance measurements was.011' o,

An additional support is being designed and installed to bring turbocharger vibration within acceptable levels.

Vibration monitoring of the turbocharger \\will centinue until acsurance is gained that satisfactory I

performance has been achieved.

I b.

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

c.

None required.

d.

None required.

e.

None required.

f.

None required.

g.

None required.

h.

Bearing inspection - see Corrective Action under a, above.

1.

Bolts were replaced with higher strength material.

V.

MODIFICATIONS The TDI Owners Group has recommended modifications to the turbocharger and their operational procedures.

The elements of these recommendations are:

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Sh:2t 1 of 5 RANCHO SECO DIESEL GENERATOR REQUALIF3 CATION 1

ENGINEERING

SUMMARY

REPORT CONTINUATION l

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

The temperature of exhaust gas entering the turbine shall be monitored to o

ensure that it does not exceed 1200 degrees F.

An acceptable method of determining this is to ensure that cylinder exhaust temperatures do not exceed 1050 degrees F.

(Cylinder exhaust temperatures during pre-operational testing were below 1050 degrees F.)

TDI's recommended bypass valve addition to the existing drip system should be o

implemented to provide full flow to the turbocharger prior to non-emergency starts.

Increased flow rates of the drip system up to 0.35 gph are also recommended by the Owners Group.

Rancho Seco implemented this modification prior to running the diesel generator.

1 o

Once the full flow system is installed, operating procedures should be revised

)

to use the bypass valve.

Rancho Seco has included steps and precautionary statements in startup test procedures.

Although the maintenance and surveillance procedures for this equipment have not yet~been issued, they will address the use of the bypass valve for turbocharger bearing lubrication.

VI.

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

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

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

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

VII.

RESULTS AND CONCLUSIONS Based upon.the evaluation made by the TDI Owners Group in this DR/QR report, the inspections made, corrective actions taken, and the actions taken to address the above additional concerns, the turbocharger is acceptable for its intended use at Rancho Seco during testing. Upon completion of final turbocharger support modifications and satisfactory vibration monitoring, the turbocharger will be considered acceptable for its intended use at Rancho Seco.

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Sheet'l of E RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

TURBOCHARGER Part Number: MP-020

REFERENCES:

CIDR MC172-002 NDE Report Number:

NONE Associated Reports: NCR S-61523 FPRs 23, 27, 29, 32, 279; SFR 137-86, 153-86 Engineering Evaluation and Recommendation:

l I.

ATTRIBUTES TO BE VERIFIED a.

Perform visual inspection of the bearings and nozzle ring.

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

b.

Determine the end clearances (rotor float).

Verifythattheprohernumberofboltsontheturbineinletcasingare c.

installed.

d.

Verify that the proper torque loads are applied to the bolts of the turbine inlet casing.

e.

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

f.

Verify that SIM 300 has been implemented and perform an LP test on velds retaining the core (hub nut).

Also verify that the core plug is staked.

g.

Verify that nozzle ring capscrews are properly torqueds h.

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

This inspection should be performed on a thrust bearing during or after implementation of the full flow pre-lube system modification and following an initial 100 engine starts or at the closest plant refueling outage but not to exceed 130 starts.

(Refer to subsection V for discussion of the modification).

Evaluated By:

Date:

Reviewed By:

Date:

Requalification Project Engineer n, p. *.,s

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Sheet 1 of 5 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

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

II.

ACCEPTANCE CRITERIA a.

Absence of excessive wear on the bearings.

Nozzle ring components have no damage, mispositioned vanes, or missing nozzle ring capscrews.

b.

Rotor float clearance criteria 0.008" - 0.020'.

c.

There should be 12 bolts installed in turbine inlet casing, d.

Torque turbine inlet casing bolts to Sb-60 ft.-Ibs.

e.

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

UST-PT-2.

f.

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

g.

Torque nozzle ring capscrews to 18'-22 f t. Ibs.

)

h.

Absence of excessive wear.

i III.

INSPECTION FINDINGS l

l

, e.

Following 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of startup testing both turbocharger bearings exhibited j

excessive wear.

Nozzle ring components (stationary ring and capscrews) were j

all found to be satisfactory.

i l

b.

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

c.

Turbine inlet casing bolts (piece f57 in vendor manual) were installed and lockwired after reassembly of the turbocharger.

(Ref: Quality Surveillance Report, Form PSQ 221, dated 12/24/86) d.

Torque of turbine inlet casing bolts (piece #57) was verified upon reassembly of turbocharger.

(Reft Quality Surveillance Report, Form PSQ 221, dated 12/24/86) m v m~.

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Shest 1 of 1 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No, MP-020

)

Engineering Evaluation and Recommendation (Continued):

e.

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

i f.

SIM 300 has been implemented.

The as-found condition of the turbocharger revealed that a thick steel plate was welded in place in lieu of a hub nut.

LP inspection of the veld revealed one rounded indication which was evaluated to be acceptable.

The steel plite was found welded all around its perimeter, firmly securing it to the nose piece (piece #51 in the vendor manual).

g.

Torquing and lockwiring of all eight capscrews (plece no. 62 in the vendor manual) was verified.

(Ref Quality Surveillance Report, Form PSQ 221, dated j

12/24/86)

J h.

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

Results are included with a, above.

IV.

CORRECTIVE ACTIONS a.

The bearing wear was attributed to high vibration experienced during startup j

testing, and foreign material within the turbocharger.

The turbocharger was j

sent to Elliott factory for a complete checkout and rework as necessary.

The following sumatarizes the problems revealed during disassembly:

o Rotor was found to be out of balance - (determined at factory) o Both bearings exhibited excessive wear:

Blower end bearing revealed scoring on thrust and journal surfaces.

Also thrust collar had scoring:

The turbine-end bearing revealed scoring and pitting - (determined at Rancho Seco and factory) o Rotor shait exhibited scoring at areas of bearing contact - (determined at Rancho Seco and factory) o 011 seals revealed signs of wear

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Sheet 4 of 5 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

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

Corrective Actions taken were as follows:

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

o New bearings, thrust collar, and oil seals were installed to replace damaged parts.

Also as a precaution, eight new nozzle ring capscrews were installed.

An additional support is being designed and insta]1ed'to bring o

turbocharger vibration within acceptable levels.

Vibration moaitoring of the turbocharger vill continue until assurance is gained that satisfactory performance has been achieved.

b.

None required.

c.

None required.

d.

None required.

I e.

None required.

f.

None required.

g.

None required.

h.

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

Results are included with a, above.

V.

MODIFICATIONS The TDI Owners Group has recommended modifications to the turbocharger and their operational procedures.

The elements of these recommendations are:

o The temperature of exhaust gas entering the turbine shall be monitored to ensure that it does not exceed 1200 degrees F.

An acceptable method'of determining this is to ensure that cylinder' exhaust temperatures do not exceed 1050 degrees F.

(Cylinder exhaust temperatures during pre-operational testing.

were below 1050 degrees F.)

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Sheet 5 of 5

~

RANCHO SECO DIESEL GENERATOR REQUALIFICATION

~

ENGINEERING

SUMMARY

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

TDI's recommended bypass valve addition to the existing drip system should be o

implemented to provide full flow to the turbocharger prior to non-emergency starts.

Increased flow rates of the drip system up to 0.35 gph are also recommended by the Owners Group.

Rancho Seco implemented this modification prior to running the diesel generator.

Once the full flow system is installed, operating procedures should be revised o

to use the bypass valve.

Rancho Seco has included steps and precautionary statements in startup test procedures.

Although the maintenance and surveillance procedures for this equipment have not yet been $ssued, they will address the use of the bypass valve for turbocharger bearing lubrication.

VI.

ADDITIONAL CONCERNS The District was also made, aware of similar concerns with this component from a

{

10CFR Part 21 notification'on turbocharger bearing lubrication and NRC NUREG-1216.

The DR/QR inspections and the corrective actions described stove have resolved I

j the concerns of the 10CFR Part 21 notification and those in NURE?-1216.

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

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

]

l VII.

RESULTS AND CONCLUSIONS 1

Based upon the evaluation made by the TDI Owners Group in this DR/QR repart, the l

inspections made, corrective actions taken, and the actions taken to address the above additional concerns, the turbocharger is acceptable for its intended use at i

Rancho Seco-during testing.

Upon completion.of final turbocharger support modifications and satisfactory vibration monitoring, the turbocharger will be considered acceptable for its intended use at Rancho Seco.

2 PRE E NARY

Sheat 1 of 3_

RANCHO SECO' DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A, 1

Part

Description:

ENGINE BASE ASSEMBLY Part Number: 03-305A, C, D

REFERENCES:

CIDR MC172-005,.MC172-006, MC172-007 NDE Report Ntimber: ERPT-M0027 Associated Reports: NCRS S-4292, S-4293; IM QC-18-13-84, QC-19-7-85,.M-025-86 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.

Visual inspection of the #5 main bearing cap mating surface.

(one engine only) b.

Liquid penetrant inspection of the #5 main bearing saddle area in the base.

(one engine only) l 1

y c.

Torque check of the #5 mair, bearing cap stud nuts prior to engine operation.

d.

Metallurgical properties of the engine base.

II.

ACCEPTANCE CRITERIA.

a.

No signs of fretting, erosion, corrosion, or other indications per criteria in SMUD Procedure QCI-112.

b.

No indications per criteria in SMUD procedure QCI-101.

1 c.

. Torque in a criss-cross pattern to 2150 ft-lbs per criteria in TDI Manual, j

Appendix IV.

d.-

The metal shall be typical Class 40 grey cast iron without evidence of degenerate Widmanstaetten graphite per criteria in Engine Base Supplement i to the DR/QR Report.

Evaluated By:

Date: S ~O' N U

6/29 7

Reviewed By:

i7 Date:

l

,//

Requalification Project Engineer l

Sheet 2 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICAT(ON ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-305A Engineering Evaluation and Recommendation (Continued):

III.

INSPECTION FINDINGS a.

The main bearing cap mating surfaces +are acceptable.

(Both engines examined.)

b.

Saddle area is acceptable.

c.

Dt ring the retorquing, four main bearing cap studs were found to be frozen to the stud nuts.

d.

Engine base metal is acceptable.

NOTE: During a startup inspection by a vendor representative Just after the initial engine 15 minute run test, a mismatch was observed between the #4 main bearing halves.

Disassembly revealed that the retaining pin was loose.

NOTE: Additional inspections performed after initial engine testing included visual inspection of the #7 & 8 main bearing base / cap mating surfaces and visual inspection of saddle mating surface cleanliness for bearings #5, 7, & 8 prior g

to reassembly. (Both engines examined.) Inspection results were acceptable.

IV.

CORRECTIVE ACTIONS a.

None required.

b.

None required.

c.

All studs with frozer. nuts were replaced, lubricated with a 50/50 mixture of

. lube oil and graphite, and properly torqued.

3 d.

Nene required.

' MOTE: The devel retaining setscrev was properly retorqued after inspection of the

1. 4 main bearing surface.

Visual inspection of the main bearing shells revealed no abnormalities.

V.

MODIFICATIONS None required.

VI.

ADDITIONAL CONCERNS Tae District was e:1so made aware of similiar concerns with this component from NRC ll0 REG-1216.

The IR/QR inspections described above and their results have resolved these con; erns.

l

' ]

1 Sheet ;Lof 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part Ko. 03-305A Engineering Evaluation and Recommendation (Continued):

i VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI.0wners Group in this DR/QR report, the inspections performed, and the corrective actions taken, this component is acceptable for its intended use at Rancho Seco.

l

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l Sheet 1,of 2 RANCHO SECO DIESEL GENERATOR REQUA,LIFICATION j

i I

ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81011 Engine Train B Part

Description:

ENGINE BASE ASSEMBLY Part Number:

03-305A, C, D

REFERENCES:

CIDR MC172-005, MC172-006, MC172-007 l

NDE Report Number: ERPT-M0027 j

Associated Reports:

I.1 QC-16-8-84, QC-18-30-85, QC-19-9-85, QC-19-16-85, QC-19-18-85, MC-025-86

' Engineering Evaluation and Recommendation:

i I.

ATTRIBUTES TO BE VERIFIED 1

1 a.

Visual inspection of the #5 main bearing cap mating surface.

j (one engine only) j b.

Liquid penetrant inspection of the #5 mLin bearing saddle area in the base.

tone engine only)

I c.

Torque check the main bearing cap stud r.uts prior to engine operstion.

4 d.

Metallurgical properties of the engine base.

II.

ACCEPTANCE CRITERIA I

a.

No signs of fretting, erosion, corrosion, or other indications noted in SMUD l

Procedure QCI-112.

I b.

No indications per criteria in SMUD Procedure QCI-101.

c.

Torque in a criss-cross pattern to 2150 ft-lbs per criteria in TDI Manual, Appendix IV.

d.

The metal shall be typical Class 40 grey cast iron without evidence of I

degenerate Widmanstaetten graphite per criteria in Engine Base Supplement 1 to the DR/OR Report.

6-/9-37 Evaluated By:

Date:

Date: '+'

E 5'/

Reviewed By:

[/'RequalificationProjectEngineer

Sheet 2 of 2 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016, Part No. 03-305A Engineering Evaluation and Recommendation.(Continued):

l III.

INSPECTION FINDINGS a.

The main bearing cap mating surfaces are acceptable.

(Both eagines examined.)

b.

(Er.gine ' A' examined. )

c.

Torquing was satisfactorily performed.

d.

Engine base metal is acceptable.

NOTE: Additional inspections performed after initial engine testing. include visual inspections of the #7 & 8 main bearing base /ca7 mating surfaces and visual inspection of saddle mating surface cleanliness for bearings #5, 7, &8 prior to reassembly. (Both engines examined.) Inspection results were acceptable.

I V.

CORRECTIVE ACTIONS None required.

V.

MODIFICATIONS None required.

VI.

ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component frcm NRC NUREG-1216.

The DD/QR inspections described above and their results have resolved these concerns.

VII.

RESULTS AND CONCLUSIONS _

Based upon the evaluation made by the TDI Owners Group in this DR/QR report and the inspections performed, this component is acceptable for its intended use at Rancho Seco.

Shiat }_ of 2, l

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT-1 i

Diesel Engine Serial Number 81015 j

Engine Train A Part

Description:

THROUGH BOLTS (BASE TO CYLINDER BLOCK)

Part Number: 03-305E

REFERENCES:

CIDR MC172-008 NDE Report Number: NONE Associated Reoorts:

IM QC-16-9-84 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED Perform a dimensional verification of uniform washer thickness on accessible washers.

\\

4 II.

ACCEPTANCE CRITERIA Washers are approximately 1/2 inch thick and do not show signs of tapering.

III.

INSPECTION FINDINGS All washers are acceptable.

IV.

CORRECTIVE ACTIONS None required.

V.

MODIFICATIONS None required.

I i

d Date: 0-O~E 7 j

Evaluated By:

!b7

~

Date:t' Reviewed By:

f'/

Requalification Project Engineer I

Sheet 1 of 2 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-305E Engineering Evaluation and Recommendation (Continued):

l VI.

ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component from NRC NUREG-1216.

The Dh/QR inspections described above have resolved this concern.

VII.

RESULTS AND CONCLUSIONS Eased upon the evaluation made by the TDI Owners Group in this DR/QR report and the inspections made, the through bolt assemblies (base to cylinder block) are acceptable for their intended use at Rancho Seco.

e

1

\\

I Sheet 1 of 2, RANCHO SECO DIESEL GENERATOR REQUALIF) CAT 3ON ENGINEERING

SUMMARY

REPORT i

Diesel Engine Serial Number 81016 Engine Train @.

l Part

Description:

THROUGH BOLTS (BASE TO CYLINDER BLOCK)

Part Number: 03-305E

)

l

REFERENCES:

CIDR MC172-008 NDE Report Number: NONE Associated Reports:

IM QC-16-9-84 I

Engineering Evaluation and Recommendation:

l I.

ATTRIBUTES TO BE VERIFIED l

Perform a dimensional verification of uniform washer thickness on accessible j

washers.

\\

II.

ACCEPTANCE CRITERIA l

Washers are approximately 1/2 inch thick and do not shew signs of tapering.

III.

INSPECTION FINDINGS i

All washers are acceptable.

IV.

CORRECTIVE ACTIONS l

l None required.

V.

M0t3IFICAT10NS Ncne required.

0'O~E 7 Evaluated By:

Date:

/

li g~ Al ' mgf Date:clggjg7 Reviewed By:

[-

Requalification Project Engineer

s Sheet 2 of 2 RANCHO SECO DICSEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-305E Engineering Evaluation and Recommendation (Continued):

VI.

ADDITIONAL CONCERNS The~ District war also made aware of similar concerns with this component from NRC NUREG-1216.

The DR/QR inspections described above have resolved this concern.

VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report and the inspections made, the through bolt assemblies (base to cylinder block) are acceptable for their intended use at Rancho Seco.

l i

O l

l l

t Sheet 1 of G.

RANCHO SECO DIESEL GEllERATOR REQUALIF3 CAT 10N ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81011 Engine Train A Part

Description:

CRANKSHAFT Part Number: 03-310A

REFERENCES:

CIDR MC172-012, CIDR MC172-213; ERPT-M0021 NDE Reoort Number: ERPT-M0020 Associated Reports: FaAA 85-1-6; NCR S-5017; IMs QC-15-11-84, QC-15-07-85, QC-15-10-85. QC-15-18-85, QC-19-4-85; QC-19-6-85; FPR-33 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.

Visual inspections ar.d a photographic record of the crankpin and main journal

surfaces, b.

Eddy current inspections of the main Journal oil holes et the flywheel end of the engine and at cylinders #6, 7, and 8 (for ma$n bearings #7 through #11).

c.

Eddy current inspections of the crankpin Journal oil holes at cylinders #5 and 6 (for conn rod bearings #5 and 6).

[

d.

Eddy current inspections of the fillet welds on the. governor end (toward front of engine) for the crankpin Journals at cylinders #5, 7, and 8.

(one engine only) e.

Torsiograph testing of the crankshaft. (one engine only)

II.

ACCEPTANCE CRITERIA a.

No evidence of abnormal scoring, wear, or damage per criteria in SMUD procedure QCI-112.

b.

No indications of notches in excess of the allowable limits stated in Attachment A, Table 1 in the DR/QR report.

c.

No indications of notches in excess of the allowable limits stated in Attachment A, Table 2 in the DR/QR Report.

d.

No indications per criteria in FaAA procedure 11.3.

e.

Torsiograph analysis reveals actual crankshaft stresses are in compliance with the DEMA recommendations for allowable stress levels, specifically:

1.

No harmful torsional vibratory stresses occur within five percent above and below rated speed (450 +/-22.5 rpm).

Q Date:

b~d N Evaluated By:

b' b

7 Date:

l Reviewed By:

(,/'

Requalification Project Engineer i

4

'l Sheet'2 of 6 RANCHO SECO DIESEL GENERATOR REQUALIFICATION I

ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-310A-Engineering Evaluation and Recommendation (Continued):

II.

ACCEPTANCE CRITERIA (cont'd) 2.

A superimposed stress of less than 5000 psi (if created by a. single order i

j of vibration), or i

3.

A superimposed stress of less than 7000 psi (if created by a summation of the major orders of vibration which might come into phase periodically).

III.

INSPECTION FINDINGS

']

I a.

Journal surfaces are acceptable, but no photographs were taken.

l b.

Main journal oil holes are acceptable; no indications were found.

c.

Crankpin journal oil holes are acceptable) no indications vere found.

0 d.

Crankpin journal fillet velds (governor end) are acceptable; no indications were found.

e.

Torsiograph analysis revealed the following:

1.

Nearest significant harmonic is satisfactory (421 rpm).

2.

Stress of single crders is satisfactory (3023 psi).

3.

Stress of combined orders is satisfactory (5769 psi).

NOTE: Additional inspections performed include eddy current testing of crankpin journal fillet velds (generator end) of cylinders #5, 7, 8 and liquid

)

penetrant testing of the main journal oil holes at the flywheel end of the engine (for main bearings #10 and 11).

No indications were found during these additional inspections.

IV.

CORRECTIVE ACTIONS I

a.

A minor scratch-like indication was found on the entire circumference of the,

j journal for main bearing #7.

It was removed by light polishing with crecus -

cloth.

-l 1

j

i 1

Sheet 3 of 6 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-310A Engineering Evaluation and Recommendation (Continued):

I V.

CORRECTIVE ACTIONS (cont'd)

NOTE: The District takes exception to the requirement of a photographic record of the journal surfaces.

Instead, the District has chosen to clearly identify.

each minor indication separately in writing, with a. corresponding l

engineering evaluation.

The TDI Owners Group has agreed that the District's position is acceptable and that the photographic record is useful, but that L

complete disassembly for the sole purpose of photography is unnecessary.

l b.

None required.

c.

None required.

d.

None required.

e.

Nond required.

i V.

MODIFICATIONS _

None required.

VI.

ADDITIONAL CONCERNS The Distr $ct was also made aware of other concerns with this component from a 10CFR Part 21 notification on crankshaft oil plugs, a NRC information notice IE 83-58 on the crankshaft failure at the Shoreham Nuclear' Power Station, and NRC NUREG-1216.

The Owners Group DR/QR inspections above have resolved the concerns of IE 83-58.

The 10CFR Part 21 notification indicated that some engines may have 22 gauge oil plugs which could potentially fail.

The District inspected all crankshaft oil plugs and found them to be 22 gauge.

The District replaced them with 16 gauge plugs under TDI direction.

NRC NUREG-1216 has identified the following additional considerations regarding this component:

~

1.

Plant specific procedures should clarify that the hourly cylinder exhaust i

temperatures should also be monitored for engine imbalance (para 2.1.3.7).

2.

The recommendations of report PNL-5600 (section 4.6.8) should be followed to show that conclusions reached for Shoreham and Riverber.d are applicable to Rancho Seco.

This includes preservice fluorescent liquid penetrant examination (and, as appropriate, eddy current examinatioal of the oil holes and fillets of crankpin aournals #5, 6, and 7 (the most heavily loaded) and two main Journals in between (for main bearings #7 and 8).

I (para 2.1.3.9)

Sheet 4 of 6 RANCH 0 SECO DIEEEl. GENERATOR REQUALIFICATION

~

ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-310A Engineering Evaluation and Recommendation (Continued):

V I.

ADDITIONAL CONCERNS (cont'd) 3.

Torsional stresses calculated from torsiograph testing and material certification reports should be compared with Shoreham and Riverbend data to establish a ' qualified" load capacity.

4.

Plant Technical Specifications must incorporate load restrictions during surveillance testing.

5.

Operating procedures and training should preclude operators from overloading the diesels above the qualified load.

6.

Distinctive and unique instrumentation and clarms should be installed to warn operators when the engines are loaded above the qualified load.

7.

Contingency inspection requirements after exceeding the qualified load for unspecified reasons shall be included as a condition of licensing.

The inspections shall\\ include liquid penetrant inspections of crankpin journals #5, 6, and 7 (the most heavily loaded) and the two main 3curnals in between (for main bearings #7 and 8).

Any indications should be evaluated with eddy current testing as appropriate.

8.

Key inspection items of the DR/QR Appendix II maintenance and surveillance program shall be included as a condition of licensing.

9.

Additional operating and maintenance practices (per section 4.6.6.4.1 of report PNL-5600) may be necessary depending on how close the harmonic speeds are to the nominal engine speed of 450 rpm.

The District has reviewed these concerns of NUREG-1216 and has addressed them as follows:

1.

Although the operating procedures for this equipment have not yet been issued, they vill indicate that hourly cylinder temperatures vill be monitored for engine imbalance per the TDI Manual, Appendix II.

2.

The District takes exception to the requirement of fluorescent liquid penetrant examination of the crankshaft surfaces.

Instead, the District performed liquid penetrant examination, which is consistent with the initial testing performed at Shoreham and Riverbend for FaAA approval of the

Sheet 5 of 6 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REP'3RT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-310A Engineering Evaluation and Recommendation (Continued):

VI.

ADDITIONAL CONCERNS (cont'd) l crankshaft quality.

Furthermore, the use of liquid penetrant testing is consistent with the conditions of license imposed upon Riverbend and in NUREG-1216 for the testing required when the qualified load is exceeded, and it is also consistent with the testing recommended by the Owner's Group in the DR/QR Appendix II Maintenance Matrix (Rev 2) for Rancho Seco.

The report PNL-5600 also refers to fluorescent liquid pecetrant testing and liquid penetrant testing interchangeably.

For these reasons the District did not perform fluorescent liquid penetrant testing during its recent, second inspection of the crankshaft surfaces, using liquid penetrant testing instead.

However, no l

adverse findings were observed during inspections of this component.

Moreover, the TDI Owners Group has accepted the District's use of liquid penetrant testing to comply with this requirement.

3.

The following information is provided to establish the qualified load for the Rancho Seco diesels:

Requirement Plant Value Item Shoreham Riverbend Rancho Seco

+/-5%

Nearest Significant 430 rpm 455 rpm 421 rpm Ilarmonic to 450 rpm (5.5th order)

(5th order)

(5.5th order) 5000 psi Max Torsiograph 3108 psi 3348 psi 3023 psi stress (single (4th order)

(4th order)

(4th order) l order) 0 3500 KW 7000 psi Max Torsiograph 6626 psi 6546 psi 5769 psi l

Stress (combined) l 0 3500 KW 83 kei Min Ultimate 100.8 kai 94 kal 93.3.ksi Tensile Strength Qualified Load 3300 KW 3130 KW 3300 kw (proposed)

Factor of Sofety 1.51 1.39 1.39 (03311 kw)

F

~

I

' Sheet cf. E,

~

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-310A i

Engineering Evaluation and Recommendation (Continued):

VI.

ADDITIONAL CONCERNS (cont'd) 4.

The District has submitted proposed ammendment no. 147 to the Technical Specifications which includes load restrictions to less than 3300 kw during surveillance testing.

5.

Although the operating and training procedures for this equipment have not yet been issued, they will address the limitations of the qualified load rating.

6.

The District is currently adding instrumentation and an alarm to alert operators when the engines are loaded above the qualified load.

7.

Conditions of licensing will be established by the NRC, however, the District has a,nticipated these conditions in several ways.

Although initial testing of the diesels used.a full lead rating of 3500 kw and included 110% overload testing, appropriate inspections were subsequently g

performed on both engines to address the issue of exceeding the qualified load rating.

Specifically, liquid penetrant inspections were performed on crankpin Journals #5, 6, and 7, and on the main Journals inbetween.

• No indications were found on either engine.

Furthermore, additional startup testing performed after these inspections has been procedurally limited to 3000 kw, which is below the qualified load rating.

8.

Conditions of licensing will be established by the NRC, however, the District has anticipated these conditions by ensuring that the requirements of Appendix II to this DR/QR will be included in the operating and surveillance procedures for this equipment.

9.

Torsiograph testing has indicated that additional operJting restrictions are unnecessary because the normal engine speed is not in the vicinity of a harmonic resonance.

VII. RESULTS AND CONCLUSIONS 1

Based upon the evaluation made by the TDI Owners group in this DR/QR report, the modifications made, the inspections performed and corrective actions taken, and the l

actions taken to address the above additional concerns, the crankshaft is acceptable for its intended use at Rancho Seco.

4

Sheet 1 of 3 i

RANCHO SECO DIESEI, GENERATOR REQU AL.IFICATION -

ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 8101E j

Engine Train B I

Part

Description:

CRANKSHAFT Part Number: 03-310A

REFERENCES:

CIDR-MC-172-012, CIDR MC172-213; ERPT-M0021 NDE Report Number: None Associated Reoorts: FaAA 85-1-6; NCRs S-4280, S-4287, S-4302, S-4303, S-4945; IMs QC-15-11-84, QC-15-03-85, QC-19-04-85.

QC-19-05-85, QC-19-15-85; SFR 280-86; FPR-i 33 i

Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED i

a.

Visual inspections and a photographic record of the crankpin and main Journal surfaces.

i l

b.

Eddy current inspec,tions of the main Journal oil holes at the flywheel end of 1

the engine and at cylinders #6, 7, and 8 (for main bearings #7 through #11).

g c.

Eddy current inspections of the crankpin journal oil holes at cylinders #5 and 6 (for conn rod bearings #5 and 6).

d.

Eddy current inspections of the fillet welds on the governor end (toward front of engine) for the crankpin Journals at cylinders #5, 7, and 8.

(One engine l

only)

)

l e.

Torsiograph testing of the crankshaft.

(One engine only) l i

II.

ACCEPTANCE CRITERIA a.

No evidence of abnormal scoring, wear, or damage per criteria in SMUD procedure QCI-112.

i b.

No indications of notches in excess of the allowable limits stated in Attachment A, Table 1 in the DR/QR Report.

1 i

c.

No indications of notches in excess of the allowable limits stated in Attachment A, Table 2, in the DR/QR Report.

d.

No indications per criteria in FaAA procedure 11.3.

fb M

... [,}~ I 9 Date:

Evaluated By:

/

25 !I9 E'

Date:

Reviewed By:

/'

Requalification Project Engineer

'l t

Sheet 2 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 8101E Part No. 03-310A Engineering Evaluation and Recommendation (Continued):

II.

ACCEPTANCE CRITERIA (cont'd) e.

Torsiograph analysis reveals actual crankshaft stresses are in compliance with the DEMA recommendations for allowable stress levels, specifically:

1.

No harmful torsional vibratory stresses occur within five percent above and below rated speed (450 +/- 22.5 rpm).

2.

A superimposed stress of less than 5000 pai (if created by a single order of vibration), or 3.

A superimposed stress of less than 7000 psi (if created by a summation of the major orders of vibration which might come into phase periodically).

III.

INSPECTION FINDINGS Journal eurfaces are, acceptable, but no photographs were taken.

a.

b.

Main journal oil holes are acceptablei no indications were found.

I c.

Crankpin acurnal oil holes are acceptable; no indications were found.

d.

(Engine "A" examined.)

e.

(Engine

• A" examined.)

NOTE:

Additional inspections performed include liquid penetrant testing of the main journal oil holes at the flywheel end of the engine (for main bearings #10 and 11).

h'o indications vere found during these additional inspections.

IV.

CORRECTIVE ACTIONS a.

Prior to initial engine running, minor scratch-like indications were found on the Journals for main beraings #1, 2, 5, 7 and 9.

They all were removed by light polishing.

It was also noted that the journal for main bearing #11 had a minor scratch that was polished in the factory before the engine was shipped to Rancho Seco.

After engine operations, a short, scratch-like indication was found near the oil hole of the Journal for main bearing #5.

It too was removed by light polishing.

NOTE: The District takes exception to the requirement of a photographic record of the Journal surfaces.

Instead, the District has chosen to clearly identify each minor indication separately in writing, with a corresponding engineering evaluation.

The TDI Owners Group has agreed that the District's position is acceptable and that the photographic record is useful but that complete disassembly for the sole purpose of photography is unnecessary.

I Sheet 1 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-310A 1

Engineering Evaluation and Recommendation (Continued):

I V.

CORRECTIVE ACTIONS (cont'd) b.

None required.

c.

None required.

d.

None required.

e.

None required.

V.

MODIFICATIONS Ncne required.

VI.

ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from a 10CFR Part 21 notification on crankshaft oil plugs, a NRC information notice IE 83-58 on the crankshaft failure at the Shoreham Nuclear Power Station, and NRC NUREG-1216.

The Owners Group DR/QR inspections above have. resolved the concerns of IE 83-58.

The 10CFR Part 21 notification indicated that some engines may have 22 gauge oil plugs which could potentially fail.

The District inspected all crankshaft oil plugs and found them to be 22 gauge.

The District replaced them with 16 gauge plugs under TDI direction.

The concerns within NRC NUREG-1216'and the District's response to them are addressed in the Engine "A" summary.

VII.

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

l Sheet 1 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION 1

ENGINEERING

SUMMARY

REPORT D.esel Engine Serial Number 81015 Engine Train &

Part

Description:

CYLINDER BLOCK Eart Number: 03-315A

REFERENCES:

CIDR MC172-014 1

NDE Report Number:

UST-PT-013-84, 014-84, 015-84, 019-84, 020-84, 021-84, 022-84, 023-84, 024-84, 025-84, 026-84, 027-84, 028-84 Associated Reports: NCR/IM NONE 1

1 Engineering Evaluation and Recommendation:

I, ATTRIBUTES TO BE VERIFIED a.

Dimensions of the cylinder block liner landing area.

b.

Liquid penetrant inspection of the cylinder block liner landing area (for cylinders #5, 7 & 8) along ther i

l 1.

top landing surface 1

2.

fillet radius

)

3.

vertical face adjacent to the landing surface c.

Liquid penetrant inspection'of the top cylinder block mating surface, especially between the stud holes and liner and between adjacent stud holes (for cylinders #5, 7 & 8).

d.

Eddy current inspection of the cylinder block stud holes if the liquid penetrant inspections revealed indications at a stud hole extending into the,

threads, e.

Metallurgical properties of the cylinder block.

Evaluated By:

Dater d'/ 7'E 7

/

1 Reviewed By:

Date:

6/ Requalification Project Engineer i

Sheet 2.of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION t

l ENGINEERING

SUMMARY

REPORT I

CONTINUATION-

.]

1 I

Diesel Engine Serial Number 8101l[

Part No. 03-315A Engineering Evaluation and Recommendation (Continued):

l l

II.

ACCEPTANCE CRITERIA a.

No significant variations in the dimensions among the cylinders, b.* No indications per criteria in SMUD procedure QCI-101.

c.

No indications per criteria in SMUD procedure QCI-101 d.

No crack-like signals on the CRT per criteria in FaAA procedure 11.8.

e.

The metal shall be typical class 40 gray cast iron without evidence of

-)

degenerate Widmanst,aetten graphite.

l s

i III.

INSPECTION FINDINGS 4

a.

All dimensional checks are acceptable.

b.

The cylinder block liner landing areas are acceptable.

No linear indications were found.

c.

The top cylinder block mating surfaces are acceptable.

No linear indications were found.

d.

Eddy current inspections were not required.

e.

Cylinder block metal is acceptable.

IV.

CORRECTIVE ACTIONS None required.

Sheet Q cf 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-315A Engineering Evaluation and Recommendation (Continued):

)

V.

MODIFICATIONS None required.

VI.

ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component frcm HRC NUREG-1216.

The DR/QR inspections described above have resolved these concerns.

VII.

RESULTS AND CONCLUSIONS Based upon the eva'luation made by the TDI Owners Group in this DR/QR report, and the inspections made, the cylinder block is acceptable for its intended use at Rancho Seco.

1 l

l

1 4

i 1

Sheet 1 of 3 i

RANCHO SECO DIESEL GENERATOR REQUAL)FICATION ENGINEERING

SUMMARY

REPORT l

i Diesel Engine Serial Number 81016 Engine Train B l

1 Part

Description:

CYLINDER BLOCK

]

Part Number: 03-315A j

i

REFERENCES:

CIDR MC172-014 j

NDE Report Number:

UST-PT-020-84, 061-84, 062-84, 065-84, 068-84, 069-84, 071-84, 072-84, 073-84, 074-84 Associated Reports:

IM QC-19-11-85 l

l l

Engineering Evaluation and Recommendation:

l I.

ATTRIBUTES TO BE VERIFIED l

a.

Dimensions of the cylinder block liner landing area.

b.

Liquid penetrant inhpection of the cylinder block liner landing area (for cylinders #5, 7 &.8) along the:

1.

top landing surface l

l 2.

fillet radius l

l 3.

vertical face adjacent to the landing surface c.

Liquid penetrant inspection of the top cylinder block mating surface, especially between the stud holes and liner and between adjacent stud holes i

I (for cylinders #5, 7 & 8).

d.

Eddy current inspection of the cylinder block stud holes if the liquid penetrant inspections revealed indications at a stud hole extending into the threads.

e.

Metallurgical properties of the cylinder block.

l Evaluated By:

__Da t e : b~

7 l

/

'!3 ! 7 Reviewed By:

Date:

(,/

Requalification Project Engineer l

l

___.m__

Sheet 2 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT

~

CONTINUATION Diesel Engine Serial Number 8101@,

Part No. 03-315A Engineering Evaluation and Recommendation (Continued):

II.

ACCEPTANCE CRITERIA a.

No significant variations in the dimensions among the cylinders.

b.

No indications per criteria in SMUD procedure QCI-101.

c.

No indications per criteria in SMUD procedure QCI-101 d.

No crack-like signals on the CRT per criteria in FaAA procedure 11.8.

e.

The metal shall be typical class 40 gray cast iron without evidence of degenerate Widmanstaetten graphite.

III.

INSPECTION FINDINGS All dimensional checks are acceptable.

a.

b.

The cylinder block liner landing areas are acceptable.

No linear indications were found.

c.

The top cylinder block mating surfaces are acceptable.

No linear indications were found.

d.

Eddy current inspections were not required.

e.

Cylinder block metal is acceptable.

IV.

CORRECTIVE ACTIONS None required.

Sheet 2 of 3 RANCHO SECO D%ESEL GENERATOR REQUALIFICATION ENGINEF: RING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 8101@,

Part No. 03-315A Engineering Evaluatico and Recommendation (Continued):

V.

MODIFICATIONS None required.

VI.

ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component from NRC NUREG-1216.

The DR/QR inspections described above have resolved these concerns.

VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, and the inspections made, the cylinder block is acceptable for its intended use at Rancho Seco.

i i

-l

~

Sheet L of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGTHEERING

SUMMARY

REPURT j

i Diesel Engine Serial Number 81015

]

l Engine Train &

J Part

Description:

CYLINDER LINERS Part Number: 03-315C l

REFERENCES:

CIDRs MC172-015, MC172-114, MC172-200

]

NDE Reoort Number:

121586SCM 1

Associated Reports: NCR-S-4226, 43303 IMs-QC-19-9-84, 19-10-84, 19-11-84, 19-8-85, 19-10-85, 19-13-85, 19-14-85, 19-17-85 Engineering Evaluation and Recommendation:

l I.

ATTRIBUTES TO BE VERIFIED i

a.

Verify liner dimensions including bore, length, height, 0.D. and shoulder I

height.

l s

b.

Visual inspection of the outside pilot diameter where it contacts the cylinder block.

c.

Visual inspection of cylinder liner inside diameter over the zone of piston travel.

d.

Determine.the material of a spare liner.

(One engine only)

II.

ACCEPTANCE CRITERIA l

l e.

Liner dimensions shall meet the TDI standards.

b.

Absence of excessive contact spalling.

c.

Absence of excessive scuffing and scoring.

d.

Nodular (ductile) cast iron per TDI specifications.

l l

1 o

Evaluated By:

Y b = ^^

Date: 0 ~ / 2 ~E 7

/

Reviewed By:

b Date:

~

[/

Requalification Project Engineer

j Sheet 1 cf 1 RANCHO SECO DIESEL GENERATOR REQUALIFICATIQN ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Er.gine Serial Number 81015

. Part No. 03-315C i

Engineering Evaluation and Recommendation (Continued):

III.

INSPECTION FINDINGS a.

The outside pilot diameter for all cylinders was too large and the proudness i

l I

for all liners was excessive when compared with current TDI Specifications.

The bore dimension for cylinders #2, 3, 4, 5, 7 and 8 is slightly undersize.

1 b.

The outside pilot diameters of the liners are acceptable.

j c.

The District performed this visual inspection prier to initial engine run and repeated it with a boroscope after about 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of operation.

All liner inside surfaces are acceptable.

]

d.

Rancho Seco does nog have a spare liner.

A material comparator test was performed on cylinder #3 which demonstrated that the 11rier material was comparable to a liner sample which met TDI specifications.

)

l IV.

CORRECTIVE ACTIONS a.

The oversize liner dimensions were corrected by the product improvement modifications described below.

The undersize bore dimensions were accepted as is since they were within a.005 inches machining tolerance accepted by TDI.

b.

None required.

c.

None required.

d.

None required.

l NOTE: Nonconforming Report S-4330 describes the minor liner damage that occurred i

during engine reassembly when the connecting rod of a piston assembly struck j

the top inner edge of the #5 cylinder liner during engine reassembly.

The I

liner was measured to verify there was no deformation, the minor dent was filed and stoned smooth, and the surfacce were liquid penetrant tested to verify that the absence of cracks and indications.

l V.

MODIFICATIONS In response to a product improvement recommendation from TDI, Rancho Seco has remachined the upper part of all liners to reduce the stress levels in.the upper block area.

The outer diameters of the upper liner ledge and the water seal ledge I

have been reduced by about.005 inches, and the liner proudness has been reduced by about.003 inches.

1 l

1

Sheet 3 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICAT10N ENGINEERING

SUMMARY

REPORT CONTINUATION 1

l Diesel Engine Serial Number 81015 Part No. 03-315C Engineering Evaluation and Recommendation (Continued):

VI.

ADDITIONAL CONCERNS.

The concerns in NRC NUREG-1216 for this component have also been resolved by 'the DR/QR inspections described above.

VII.

RESULTS AND CONCLUSIONS'

-Eased upon the evaluation made by the TDI Owners Group in tnic DR/QR report, the inspections made, the corrective actions taken, and the modifications implemented, the cylinder liners are acceptable for their intended use at Rancho Seco.

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1 i

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4 Sheet 1 of 1 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

CYLINDER LINERS Part Number: 03-315C

REFERENCES:

CIDR MC172-015, MC172-200 NDE Report Number: NONE Associated Reports: IM QC-15-6-85, 16-12-85, 19-11-84; FPR-28 Engineering Evaluation and Recommendation:

^

I.

ATTRIBUTES TO BE VERIFIED a.

Verify liner dimensions including bore, length, height, 0.D. ahd shoulder height.

b.

Visual inspection of the outside pilot diameter where it contacts the. cylinder block.

1 c.

Visual inspection of cylinder liner inside diameter over the zone of piston travel.

~

d.

Determine the material of a spare liner.

(One engine on1y) s II.

ACCEPTAMCE CRITERIA a.

Liner dimensions shall meet the TDI standards.

b.

Absence of excessive contact spalling.

c.

Absence of excessive scuffing and scoring, d.

Nodular (ductile) cast iron per TDI specifications.

III.

INSPECTION FINDINGS a.

The outside pilot diameter for all cylinders was too large and the proudness for all liners was excessive when compared with current TDI Specifications.

The bore dimension for cylinders #1, 2, 3, 4 and 8 is siightly undersize.

0W~ E 7 Evaluated By:

Date:

/

4'! 5/b7 Reviewed By:

/

Date:

[/

Requalification Project Engineer 4

I l

1 Sheet 1 of 1 PANCHO SECO DIESEL GENERATOR REQUALIFICATION

.i ENGINEERING

SUMMARY

REPORT i

I CONTINUATION Diesel Engine Serial Number 81016, Part No. 03-315C i

l Engineering Evaluation and Recommendation (Continued):

b.

The outside pilot diameters of the liners are acceptable.

c.

The District performed this visual inspection prior to initial engine run and repeated it v:.th a boroscope after about 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of operation.

During the boroscopic inspection nine rings of silver lines were observed on the #7 cylinder liner.

d.

(Engine

'A' tested.)

IV.

CORRECTIVE ACTIONS a.

The oversize liner dimensions were corrected by the product improvement modifications described below.

The undersize bore dimensions were accepted as is since they were within a.005 inches machining tolerance accepted by TDI.

b.

None required.

l l

c.

The rings were evaluated by TDI to be a result of discoloration caused by the Tectyl preservative.

Because the other cylinder parameters were satisfactory, J

no actions were deemed necessary.

d.

None required.

V.

MODIFICATIONS In response to a product improvement recommendation frcm TDI, Rancho Seco has I

remachined the upper part of all liners to reduce the stress levels in the upper block area.

The outer diameters of the upper liner ledge and the water seal ledge have been reduced by about.005 inches, and the liner proudness has been reduced by about.003 inches.

l VI.

ADDITIONAL CONCERNS l

The concerns in NRC NUREG-1216 for this component have also been resolved by the DR/QR inspections described above.

VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report the inspections made, the corrective actions taken, and the modifications implemented, the cylinder liners are acceptable for their intended use at Rancho Seco.

e Sheet }_of 3 I

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine _ Serial Number 81015 i

Engine Train A Part

Description:

CYLINDER HEAD STUDS Part Numbey_: 03-315E

REFERENCES:

CIDR MC172-0173 MC172-114 NDE Report Number: HONE Associated Reports:

IM-QC-16-20-85, 17-30-85, 17-28-85, 18-25-85, 16-14-85, 15-6-84, 15-5-84, 17-05-84.

1 Engineerin,g Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED

]

a.

Perform visual inspection of head studs, any 4 cylinders.

Record all visible ID numbers (all station engines).

I b.

Perform material comparator on 4 studs (two each end) per engine (one station

]

engine).

j l

c.

Verify installation torque with existing documentation (all station engines).

I d.

Upon reinstallation of cylinder head studs into block, verify that stud j

block-side threads are lubricated with a 50-50 miuture (by volume) of powdered i

graphite and engine lubricating oil.

]

l l

e.

Verify upon reassembly that studs are properly torqued.

Care should be taken I

not to further tighten the head studs during installation of the heads and torquing of the head stud nuts to 3600 ft-lbs.

CAUTION: Do not use impact-type tools to tighten studs.

~

i.

Use the necessary lock washers (shims) to obtain a stud free length of 15 +/-

I l

1/16*.

The free length is measured from the block top to the end of the l

l cylinder head stud.

l II.

ACCEPTANCE CRITERIA a.

Absence of signs of distress.

b.

Material is comparable to AISI 4140/4142.

l c.

Torque Values: 80 to 120 ft-lbs.

d.

Visusi evidence of lubrication.

k3W'[

Evaluatec Ey:

e Date:

Reviewed By:

k

~u Date:

e O

Requalification Project Engineer E

Sheet 1 of l' RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81011 Part No. 03-315E Engineering Evaluation and Recommendation (Continued):

II.

ACCEPTANCE CRITERIA (Cont.)

e.

Torque Values: 80 to 120 ft-lbs.

f.

Stud Free Length: '15 +/- 1/16' III.

INSPECTION FINDINGS a.

Visual inspection results of new studs were satisfactory.

Studs were marked

'03-315-01-0A-H" for cylinder 1, 5, 7 and 8.

b.

A spectrographic teet was performed in lieu of a material comparator test.

Results confirmed AISI 4140/4142' material.

c.

Initial installation torque values were acceptable.

d.

Stude are properly lubricated.

e.

Torquing was satisfactorily performed.- Impact-type tdols were not used.

Precautions were taken to prevent over tightening head studs during torquing of head stud nuts.

f.

Stud free lengths are satisfactory.

IV.

CORRECTIVE ACTIONS None required.

V.

MODIFICATIONS In response to to a product improvement recommendation from TDI, Rancho Seco has replaced all head stude with the latest design (Part No. 23-315-01-0A-H) and the above inspection findings apply to the replacement studs (except for item c).

VI.

ADDITIONAL CONCERNS The District was also made aware of another concern with this component from NUREG-1216.

NUREG-1216, Section 2.1.3.14 requires that plant specific programs address cylinder head stud installation procedures identified in Owners Group letter of 09/24/84.

This requirement will be included in maintenance procedures at Rancho Seco.

l

Sheet l 'f 1 o

RANCHO SECO DIESEL' GENERATOR REQUALIFICATJgN, ENGINEERING

SUMMARY

REPORT CONTINUATION l

Diesel Engine Serial Number 81015 Part No. 03-315E Engineering Evaluation and Recommendation (Continued):

VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Dvners Group in this DR/QR report, the inspections performed and their results, the modifications performed, and the action taken to address the above additional concern, these components are acceptable for their intended use at Rancho Seco.

l 1

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Sheet 1 of 3 RANCNO EECO DIESEL GENERATOR RECUALIFICATION ENGINEERING

SUMMARY

REPCRT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

CYLINDER HEAD STUDS Part Number: 03-315E

REFERENCES:

CIDR MC172-017 NDE Report Number:

NONE Associated Reports:

IM-QC-17-35-85, 15-15-85, 18-25-85, 18-15-84, 16-5-84 Engineering Evaluation and Recommendations

\\

I.

ATTRIBUTES"TO BE VERIFIED a.

Perform visual inspection of head studs, any 4 cylinders.

Record all visible ID numbers (all station engines).

b.

Perfor.m materini comparator on 4 studs (.tvo each end) per engine (one station engine).

Verifyinstallationkorquewithexistingdocumentation(allstationengines).

c.

d.

Upon reinstallation of cylinder head studs into block, verify that stud block-side threads are lubricated with a 50-50 mixture of povered graphite and engine lubricating oil.

Verify upon reassembly that studs are properly torqued.

Care should be taken e.

not to further tighten the head studs during installation of the heads and torquing of the head stud nuts to 3600 ft-lbs.

CAUTION: Do not use impact-type tools to tighten studs.

f.

Use the necessary lock washers (shims) to obtain a stud free length of 15 +/-

1/16".

The free length is measured from the block top to the end of the cylinder head stud.

II.

ACCEPTANCE CRITERIA a.

Absence of signs of distress.

b.

Material is comparable to AISI 4140/4142.

c.

Torque Values: 20 to 120 ft-lbs.

d.

Visual evidence f lubrication.

b!2I/87

• Evaluated By:

~-

Date:

Date:

/

Reviewed By:

(/

Req ~ualificaticn Project Engineer

a 1

ii i

Sheet 2 of 1 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-315E Engineering Evaluation and Recommendation (Continued):

II.

ACCEPTANCE CRITERIA (Cont.)-

e.

Torque Values: 80 to 120 ft-lbs.

l f.

Stud Free Length:

15 +/- 1/16' l

III.

INSPECTION FINDINGS s.

Visual inspection results of new studs were satisfactory.

Studs were marked

'03-315-01-0A-H' for cylinder 1, 5,'7 and 8.

i b.

A spectrographic test was performed in lieu of a material comparator test.

Results confirmed AISI 4140/4142 material.

L c.

Initial installation torque values were acceptable.

M I

d.

Studs are properly lubricated.

e.

Torquing was satisfactorily performed.

Impact-type tools were not used.

Precautions were taken to prevent over tightening head studs during torquing of head stud nuts.

f.

Stud free lengtho are satisfactory.

I V.

CURRECTIVE ACTIONS None required.

V.

MODIFICATIONS In response to to a product improvement recommendation from TDI, Rancho Seco has replaced all head stude with the latest design (Part No.. 03-315-01-0A-H) and the

)

above inspection findings apply to the replacement studs (except for item c).

VI.

ADDITIONAL CONCERNS 1

The District was also made aware of another concern with this component from NUREG-1216.

NUREG-1216, Section 2.1.3.-14 requires that plant specific programs

)

address cylinder head stud installation procedures identified in Owners Group letter of 09/24/84 This requirement will be included in maintenance procedures at j

Rancho Seco.

I l

Sheet 3 of 3_

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING 3UMMARY REPORT CONTINUATION Diesel Engine Serial Number 81016, Part No. 03-315E Engineering Evaluation and Recommendation (Continued):

VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in this DR/QR report, the inspections performed and their results, the modifications performed, and the action taken to address the above additional concern, these components are acceptable for their intended use at Rancho Seco.

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Sheet L of 3 RANCHO SECO DIESCL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A i

Part

Description:

CONNECTING RODS & BUSHINGS l

Part Number: 03-340A

REFERENCES:

CIDR MC172-025, MC172-114 NDE Report Number:

UST-PT-16-84, 17-84, 18-84, 31-84, 32-E4, 36-84, 37-84, 40-84, 122-85, 125-85, 126-85 Ansociated Reports: FaAA Report 84-3-13 (June 1984); OG Inspection Plan 25 Rev. 13 OG-SMUD 2-4-87; HCR-S-4214, 4328; IM-QC-15-18-85, 15-16-85, 19-16-85, 15-10-85, 19-14-85, 17-23-85, 15-1-8, 15-9-84, 18-15-84, 18-8-84, 17-8-84 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.' Determine that the proper material is used in three (3) randomly selected connecting rods.

(f:":e engine only) 1 b.

Perform cuperficia1\\ hardness test on three (3) randomly selected connecting i

rods.

(One engine only)

I c.

Perform material comparator and superficial hardness tests on a sample of three spares, it applicable.

d.

Verify bolt torque en reassembly.

e.

Liquid penetrant inspection of vrist pin bushings (I.D. surface only).

f.

Perform visual inspection of upper connecting rod bushing eye oil passage without removal of bushings.

Map machined surface conditions (RMS).

II.

ACCEPTANCE CRITERIA a.

Material to meet the requirements of FaAA Report # FaAA-84-3-13.

b.

Hardness to be 149 to 207 Brinell.

c.

Material to meet the requirements of FaAA Report # FaAA-84-3-13.

Hardness to be 149 to 207 Brinnell.

d.

Bolt torque to be 875 ft.-lbs.

/26/87 Evaleated By:

c#

Date:

Reviewed By: _

e Date:

E 07 f(/

Requ'alifi' cation Proyect Ennineer

Sheet 1 of.3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION l

Diesel Engine Serial Number 81015 Part No. 03-340A 1

Engineering Evaluation and Recommendation (Continued):

II.

ACCEPTANCE CRITERIA Cont.

e.

No indications shall be allowed in the lower segment of the wrist pin bushings in an area +/- 15 from BDC.

f.

No surface flaws shall be visible.

III.

INSPECTION FINDINGS a.

Based on correspondence from the TDI Owners Group (Segrest-Bobbitt February 4, 1987) and certified material test reports, the connecting rod material meets the requirements of FaAA Report #FaAA-84-3-13.

b.

Hardness was determined to be 170 to 197 Brinnell.

c.

Since no spare connecting rods were purchased by the District, material J

g comparator and hardness testing of spa,re. rods were not possible, I

d.

Bolt torques were verified to be 875 ft.-lbs. +/- the tolerance as specified-en Page 6-A-2, Vol. I, of the TDI Instruction Manual e.

Wrist pin bushings were all LP exLmined and found free of any indications.

f.

Visual examinations were performed on each connecting rod bushing eye oil hole.

Results were all satisfactory. Mapping of surfaces was not documented since there was no evidence of scratches, c't other surface flaws.

I NGTE:

Additional inspections performed include magnetic particle testing of the connecting rod bolts on connecting rods #5, #6, and #7.

These inspections revealed no detectable cracks at the root of the threads.

/: additionally, the connecting rod bolts, nuts, and washers on connecting rods #5, #6, and

1. 7 yere visually inspected.

These inspections revealed no cracks.

IV.

CORRECTIVE ACTIONS l

None required.

l V.

MODIFICATION!15 l

Ncne required.

j

Sheet 1 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING'

SUMMARY

REPCRT.

CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-340A Engineering Evaluation and Recommendation.(Continued):

VI.

ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component from NUREG-1216.

The DR/QR inspections described above have resolved these concerns.

VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group in.this DR/QR report,.the inspections performed and their results, the connecting rods are acceptable for their intended use at Rancho Seco.

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Sheet 1 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATICN ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016-Engine Train B Part

Description:

CONNECTING RODS & BUSHINGS Part Number: 03-340A

REFERENCES:

CIDR MC172-025 NDE Reoort Number:

UST-PT-77-84, 57-84, 78-84, 59-84, 60-84, 58-84, 79-84, 80-84 Associated Reports: FaAA Report 84-3-13 (June 1984); OG Inspection Plan 25 Rev. 11 OG-SMUD 2-4-87; IM-QC-17-42-85, 18-15-84, 18-35-85, 18-37-85, 18-38-85 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.

Determine the acceptability of the material of three (3) randomly selected connecting rods.

10ne engine only)

P b.

Perform superficial hardness test on three (3) randomly selected connecting rods.

(One engine only) c.

Perform material comparator and superficial hardness tests on a sample.of three I

spares, if applicable.

d.

Verify bolt torque on reassembly.

Liquid penetrant inspection of v'rist pin bushings.(I.D. curface only).

e.

f.

Perform visual inspection of upper connecting rod bushing eye oil passage without removal of bushings.

Map machined surface conditions (RMS).

II.

ACCEPTANCE CRITERIA a.

Material to meet the requirements of FaAA Report # FaAA-84-3-13.

b.

Hardness to be 149 to 207 Brinell.

c.

Material to be AISI 4140/4142 in accordance with Owners Group Inspection Plan No. 25.

Hardness to be 149-207 Brinell.

d.

Eolt torque to be 875 ft.-lbs.

Evaluated Bys

. 14-rtso W

A Date:

E 87 Reviewed By:

A.

Date:

($'

Requalification Project Engineer

Sheet 2,of 3

. RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-340A Engineering Evaluation and Recommendation (Continued):

e.

No indications shall be allowed in the lower segment of the wrist pin bushings in an area +/- 15 from BDC.

f.

No surface flaws shall be visible.

III.

INSPECTION FINDINGS a.

Engine

'A' tested.

b.

Hardness was determined to be 170 to 197 Brinnell.

c.

Since no spare connecting rods were purchased by the District, material comparator and hardgess testing of spare rods were not possible.

d.

Bolt torques were verified to be 875 ft.-lbs. +/- the tolerance as specified on 4

Page 6-A-2, Vol. I, of the TDI Instruction Manual e.

Wrist pin bushings were all LP exasined and found free of any indications.

i.

Visual examinations were performed on each connecting rod bushing eye oil hole.

Results were all satisfactory.

Mapping of surfaces was not documented since there was no evidence of scratches, or other surface flaws.

NOTE:

Additional inspections performed include magnetic particle testing of the connecting rod bolts on connecting rods #5, #6, and #7.

These inspections revealed no detectable cracks at the root of the threads.

Additionally, the connecting rod bolts, nuts, and washers on connecting rods #5, #6, and

1. 7 were visually inspected.

These inspections revealed no cracks.

IV CORRECTIVE ACTIONS S

None required.

V.

MODIFICATIONS Mone required.

VI.

ADDITION A), CONCERNS The District was also made aware of sisilar concerns with this component from NUREG-1216.

The DR/QR inspections described above have resolved these concerns.

)

Sheet 3 of 1 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEF: RING

SUMMARY

REPORT CONTINUATION k

Diesel Engine Serial Number 8101@,

Part No. 03-340A

\\

i Engineering Evaluation and Recommendation (Continued):

VII.

RESULTS AND CONCLUSIONS Eased upon the evaluation made by the TDI Owners Group in this DR/QR report, and

{

the inspections performed and their results, the connecting rods are acceptable for i

their intended use at Rancho Seco.

1 I

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Sheet 1 of 3 i

-RANCHO SECO DIESEL' GENERATOR REQUALIFICATION i

ENGINEERING

SUMMARY

REPORT l

-i Diesel Engine Serial Number 81015 Engine Train A.

Part

Description:

CONNECTING ROD BEARING SHELLS Part Numberf 03-340B

REFERENCES:

CIDR MC172-026, MC172-114 NDE Report Number UST-PT-038-84, 39-84, 41-84, 42-84, 43-84, 44-84, 45-84, 46-84, 47-84, 48-84; 850301-1 (FaAA)

Associated Reports: NCR-S-4295, 4304, 4360; IH-QC-15-10-85, 15-18-85, 17-15-84, 17-16-84, 17-17-84 I

Engineering Evalustion and Recommendation:

I.

ATTRIBU'IES TO BE VERIFIED a.

Perform a visual inspection of the connecting rod bearing shells.

b.

Perform a liquid penetrant test on the connecting rod bearing shells.

I c.

Perform a dimensional check of the connecting rod bearing shells.

d.

Perform a radiographic inspection on the upper and lower connecting rod oearing shells e.

Perform an eddy current test on the connecting rod bearing shells as required to identify surface discontinuities.

II.

ACCEPTANCE CRITERIA a.

Refer to QCI No. 112 Nondestructive Testing Visual Examinat: ion.

I b.

Refer to QCI No. 101 Nondestructive Testing Liquid Penetrant.

i I

c.

Refer to Appendix III, Page 8-4 of the TDI Instruction Manual.

l.

1 j

d.

Refer to Radiographic Procedures NDE 9.2 by FaAA as amended by TER 99-011 of the TDI Owners Group.

e.

Refer to FaAA NDE Procedure 11.7.

b 7

Evaluated By:

Oodo Dates u

Reviewed By:

A Date:

Requalification Project Engineer A

Sheet 2 cf 3 RANCHO SECO DIESEL GCHERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-3408 Engineering Evaluation and Recommendation (Continued):

III.

INSPECTION FINDINGS a.

Visual examination found one spare bearing sheil (SN-034) with minor scratches on the babbitt surface The cause of these scratches was improper handling.

b.

Liquid penetrant examinations found twelve (12) bearing shells with indications.

These twelve (12) shells were automatically required to undergo eddy current testing.

See item III.e. below.

c.

The thicknesses of all ber. ring shells were all in accordance with TDI's instruction manual.

d.

Radiographic examinations determined that two bearing shells on engine 81015 had voids and/or inclusions greater than the allowables for use in either the upper or lower position on the connecting rods.

Three more bearing shells were identified as being usable in only the lower position.

e.

Eddy current testing was performed on the twelve (12) bearing shells that had linear indications and/or other markings as found by the liquid penetrant examination.

The eddy current results determined that all twelve (12) indications and/or markings were superficial blemishes and are not detrimental to their safe use in the engine.

I V.

CORRECTIVE ACTIONS The bearing with the visible scratch was polished lightly until the sharp edges a.

which protruded above the normal surface were removed.

b.

For the corrective actions for the twelve (12) bearings which showed indications during liquid penetrant examination, see the response under the eddy current Inspection Findings III e.

c.

No corrective action required.

d.

The two bearing shells with unacceptable voids and/or inclusions have been re]ected.

The three bearings identified as usuable as lower bearings have been reinstalled in the engine in lower positions.

e.

No corrective action required.

___.__m-

o Sheet 1 of 1 RANCHG SECO DIESEL' GENERATOR REQUALIFICATION-ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-3408 Engineering Evaluation and Recommendation (Continued):

i l

V.

MODIFICATIONS-I None required.

VI.

ADDITIONAL CONCERNS The District was also made aware of an additional concern with this component in NUREG-1216 regarding periodic oil contamination analysis.

This concern has been addressed in Appendix II,. Maintenance and Surveillance Program, page II-C-21 under component number 02-540A.

VII.

RESULTS AND CONCLUSIONS Basedupontheevaluat1SnmadebytheTDIOwnersGroupinthisDR/QRreport, the inspections performed, the corrective actions taken, and the actions taken to l

address the above additional concerns, the con:ecting rod bearing shells are acceptable for their intended use at Rancho Seco.

1 I

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Sheet 1 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATIOh ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

CONNECTING RCD BEARING SHELLS Part Number: 03-340B

REFERENCES:

CIDR MC172-026, MC172-114 NDE Report Number: UST-PT-049-84, 50-84, 51-84, 52-84, 53-84, 51-84, 55-84, 56-84; 850301-1 (FaAA)

Associated Reports:

NCR-S-4295, 4304, 4353, 4361; IM-QC-17-18-84, 17-39-85, 17-42-85 1

Engineering Evaluation and Recommendation:

l I.

ATTRIBUTES TO BE VERIFIED l

l a.

Perform a visual inspection of the connecting rod bearing shells.

b.

Perform a liquid penetrant test on the connecting rod bearing shells, t

c.

Perform a dimensional check of the connecting rod bearing shells.

l d.

Perform a radiographic inspection on the upper and lower connecting rod bearing j

shells e.

Perform an eddy current test on the connecting rod bearing shells as required to identify surface discontinuities.

I II.

ACCEPTANCE CRITERIA a.

Refer to QCI No. 112 Nondestructive Testing Visual Examination.

b.

Refer to QCI No. 101 Nondestructive Testing Liquid Penetrant.

c.

Refer to Appendix III, Page 8-4 of the TDI Instruction Manual.

d.

Refer to Radiographic Procedures NDE 9.2 by FaAA as amended by TER 99-011 of the TDI Owners Group.

e.

Refer to FaAA NDE Procedure 11.7.

d!Z_S 87 Date:

Evaluated By:

hw

--<'h-

.Y

'j3 Reviewed By:

A

~ ~'

Date:

<6/

Requalification Project Engineer v

l

__-.______________o

2 Sheet 2.of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-340B Engineering Evaluation and Recommendation (Continued):

III.

INSPECTION FINDINGS o.

All bearings were acceptable.

b.

Liquid penetrant examinations found six (6) bearing shells with indications.

These six (6) shells were automatically required to undergo eddy current testing.

See item III.e. below.

c.

The thicknesses of one bearing shell were out of tolerance with TDI's instruction manual.

d.

Radiographic examinations determined that two bearing shells on engine 81016 had voids and/or ine,1usions greater than the allowables for use in the upper position on the connecting rods.

One bearing shell was found to be unacceptable fer use in either the upper or lower position.

e.

Eddy current testing was performed on the six (6) bearing shells that had linear indications and/or other markings as found by the liquid penetrant examination.

The eddy current results determined that all six (6) indications and/or markings were superficial blemishes and are not detrimental to their safe use in the engine.

V.

CORRECTIVE ACTIONS a.

No cotrective action was required as the result of the visual examinations.

b.

For the corrective actions for the six (6) bearings which showed indications during 11guld penetrant examination, see the response under the eddy current Incpection Findings III e.

c.

One bearing shell was polished lig'atly to bring it back into tolerance with the TDI specifications.

d.

The single bearing shell with unacceptable voids and/or inclusions has been re]teted.

The two bearings identified as usuable as lower bearings have been reinstalled in the engine in lower positions, e.

No corrective action required.

Sheet 3 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEF: RING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 8101@,

Part No. 03-340B Engineering Evaluation and Recommendation (Continued):

V.

MODIFICATIONS None required.

VI.

ADDITIONAL CONCERNS i

The District was also made aware of an additional concern with this component in NUREG-1216 regarding periodic oil contamination analysis. This concern has been addressed in Appendix II, Maintenance and Surveillance Program, page_II-C-21 under component number 02-543A.

VII.

RESULTS AND CONCLUSIONS Based upon the evaluatiEn made by the TDI Owners Group in this DR/QR report, the inspections performed, the corrective actions taken, and the actions taken to

{

address the above additional concern, the connecting red bearing shells are ecceptable for their intended use at Rancho Seco.

O u__-_____

}

)

Sheet }. of p_

~

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPCRT Diesel Engine Serial Number 81015, Engine Train A_

Part

Description:

PISTONS Part Number: 03-341A

REFERENCES:

CIDR MC172-027, CIDR MC172-114 NDE Report Number: UST-PT-083-84, 81-84, 88-84, 89-84, 82-84, 98-84, 95-84, 96-84, 99-84, 103-84, 97-84, 110-85, 111-85 Associated Reports: NCRs S-4214, 4296, 4314, 4320, 4330i IMs QC-17-2-84, 17-7-84, j

18-8-84, 19-8-84, 15-7-84, 19-11-84, 15-11-84, 17-1-85, 17-23-85, 19-12-85, 19 l 85, 17-27-85, 19-17-85 j

l Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.

Liquid penetrant inspection of the piston skirts in the stu'd boss area.

Liquidpenetrntinkpectionofthepistonskirtsontheribareanearthe b.

piston pin and on the rib at the intersection of the piston pin boss.

i 1:

c.

Visual inspection of the piston skirt and crown outside diameters and of the combustion bowls of the crowns.

II.

ACCEPTANCE CRITERIA s

l l

s.

No linear indications per SMUD procedure #QCI-101.

1 l

b.

No linear indications per SMUD procedure #QCI-101.

l l

c.

No signs of scuffing on piston skirt and crown outside diameters.

No signs of pitting in the combustion bowls of the crowns.

III.

INSPECTION FINDINGS a.

The stud boss areas of all pistons are acceptable.

b.

The rib / pin boss areas of all pistons are acceptable, c.

The piston outside diameters and combustion bowls of all pistons are acceptable.

Evaluated By:

Date: 6 -/ 7 'E 2

/

Reviewed By:

• I

~4' Date

~

g Requalification Project Engineer

e i

t[

l-Sheet 2 of 3 i

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

-REPORT CONTINUATION I

Diesel Engine Serial Number 81015 Part No. 03-341A Engineering Evaluation and Recommendation (Continued):

d.

The following additional findings were reported by Q.C..during disassembly / reassembly of Rancho Seco's TDI diesel generators:

1.

A cold gap between the crown and skirt, point "X' as shown an drawing i

TDI-03-341-7319, was found to be out of tolerance for piston assembly #8.

2.

The pisten pin could not be removed from "AN' piston skirt #2 during disassembly worki it nad selred in place.

3.

During installation of the groove pins into the crown-to-skirt studs, the i

pins were determined to be too soft to be driven into place.

The pins would deform and become Jammed when only part way into the stud holes.

4.

Piston skirt #7 had excess flashing in both piston pin recess areas.

5.

Piston crown #3 was found with a diameter 0.002 inches larger than specifications.

I V.

CORRECTIVE ACTIONS a.

None required.

b.

None required.

l c.

None required.

1 d.

1.

The pisten and crown were returned to the TDI factory for repair /revork.

2.

The piston skirt was replaced as part of the change over from "AN' skirts to ".AE' skirts.

For a. discussion of wrist pin corrective actxon refer to the Engineering Summary Report for component no. 03-341C.

3.

The TDI furnished groove pins were too soft and were replaced with new hardened groove pins from TDI.

4.

The excess flashing material was removed prior to piston use.

5.

After evaluation by TDI engineering, the slightly oversize crown was accepted as is.

After about lee hours of engin4 run time during preoperational testing, this pist.on essembly way removed and visually inspected. There was no evidence of unusual or excessive wear on the rings, liner, and crown.

Sheet 3 of 2 RANCHO SECO DIESEL GENERATOR REOUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81012.

Part No. 03-341A Engineering Evaluation and Recommendation (Continued):

V.

MODIFICATIONS The TDI Owners Group recommended that 'AN' style piston skirts be replaced with the

'AE' style.

The District has implemented this change for all pistons.

VI.

ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from an INPO Operations and Maintenance Information Exchange notice (#326 dated December 14, 1981), and from NRC NUREG-1216 (sections 2.1.3.18 and 2.1.3.20).

The INPO notice indicated that an abnormal engine noise was caused by failure of some spherical washere v,hich were used to bolt the piston crowns to the skirts.

This situation will not ' occur at Rancho Seco because the pistons have an improved design and use Belleville washers instead of spherical washers.

W NRC NUREG-1216 indicates that 'AN' style pistons should not be used in nuclear 1

service and that 'AE' style pistons should undergo Own'ers Group quality revalidation inspections.

The DR/QR inspections described above have resolved these concerns.

VII.

RESULTS AND CONCLUSI0HS Based upon the evaluations made by the TDI Owners Group in this DR/QR report, the

~

inspections made, the corrective actions taken, and the modifications implemented, the pistons are acceptable for their intended use at Rancho Seco, l

i I

I

Sheet 1 of 1 RANCHO SECO DIESEL. fiENERATOR REQUALIFICATION, ENGINEERING.

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train E Part

Description:

PISTONS Part Number: 03-341A

REFERENCES:

CIDR MC172-027, CIDR MC172-114 NDE Report Number: UST-PT-123-85, 124-85 Associated Reports: NCRs S-4343, 4351; In-QC-16-24-85, 17-36-85, 17-34-85, 17 85, 17-32-85, 17-31-SS, 17-29-85, 15-09-85, 16-11-85, 15-11-85, 17-06-85, 17-01-84 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.

Liquid penetrant inspection of the piston skirts in the stud boss area.

b.

Liquid penetrant inspection of the piston skirts on the rib area near the piston pin and on the rib at the intersection of the piston pin boss.

c.

Visual inspection of the piston skirt and crown outside diameters and of the combustion bowls of the crowns.

II.

ACCEPTANCE CRITERIA a.

No linear indications per SMUD procedure tQCI-101.

b.

No linear indications per SMUD procedure #QCI-101.

c.

No signs of scuffing on piston skirt and crown outside diameters.

No signs of pitting in the combustion bowls of the crowns.

III.

INSPECTION FINDINGS The stud boss areas of all pistons are acceptable.

a.

b.

The rib / pin boas areas of all pistons are acceptable.

The piston outside diameters and combustion bowls ci all pistons are c.

acceptable.

Evaluated By:

h3 e'

Date 6'/947 Reviewed By:

Date:

b Requalification Project Engineer

4 1

l i

Sheet 2,of 3, 1

\\

RANCHO SECO DIESEL GENERATOR REQUALTFICATION ENGINEERING

SUMMARY

REPORT J

CONTINUATION l

l 1

Diesel Engine Serial Number 81016 Part No. 03-3414 i

Engineering Evaluation and Recommendation (Continued):

d.

The following additional findings were reported by Q.C. during disassembly / reassembly of Rancho Seco's TDI diesel generators:

1.

A spot face in the stud boss area of one new "AE' piston skirt was found-

.to have 0.455 inches in excess metal.

2.

A spot face in a stud boss of another new "AE' piston skirt was found to have 0.003 inches in excess metal.

IV.

CORRECTIVE ACTIONS a.

None required.

\\

b.

None required.

c.

None required.

d.

1.

The piston skirt was returned to TDI for remachining of the spot face.

2.

The pisten skirt was reworked by the Di, strict to remove excess metal from the spot face.

V.

MODIFICATIONS The TDI Owners Group recommended that "AN' style piston skirts be replaced with the "AE' style.

The District has implemented this change for all pistons.

VI.

ADDITIONAL CONCERNS The District was also made aware of other concerns with this component from an INPO Operations and Maintenance Information Exchange notice (#326 dated December 14, 19S1), and from NRC NUREG-1216 (sections 2.1.3.18 and 2.1.3.20).

The INPO notice indicated that an abnormal engine noise was esused by failure of some spherical washers wich were used to bolt the pisten crowns to the skirts.

This situation will not occur at Rancho Seco because the pistons have an improved design and use Belleville washers instead of spherical washers.

NRC NUREG-1216 indicates that "AN' style pistons should not be used in nuclear service and that 'AE' style pistons should undergo Owners Group quality revalidation inspections.

The DR/QR inspections described above have reselved these concerns.

Sheet 1 of 3 RANCHO SECO DIESEt GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION l

Diesel Engine Serial Number 81016 Part No. 03-341A Engineering Evaluation and Recommendation (Continued):

l l

VII.

RESULTS AND CONCLUSIONS Eased upon the evaluations made by the TD'I Owners Group in.this DR/QR-report, the inspections made, the corrective actions taken, and the modifications implemented,.

the pistons are acceptable for their intended use at Rancho Seco.

\\

^*

l~

5

.e

Sheet [ of 1 l

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEE, RING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A.

Part'

Description:

AIR START VALVES Part Number: 03-359

REFERENCES:

CIDR MC172-038, MC172-213 NDE Report Number: NONE-Associated Reportsf NCRs 5-6165, S-4260; FPR 13, FPR 15; IM-QC-15-04-85, 18-22-85, 18-23-85, 18-16-84, 18-10-84 Engineering Evaluation and Recommendation:

i I.

ATTRIBUTES TO BE VERIFIED a.

Verify adequate _ seating of the valve and. valve ring.

b.

Verify initial and hot torque of hold-down capscrews.

c.

Perform a dimensional check on two hold-down capscrews.

d.

Verify that locking pin is in valve arm lock nut.

1 e.

Visually inspect valve for wear and corrosion.

f.

Verify gasket seal to cylinder head is proper material.

9 Perform a. material comparator test on the hold-down capscrews (2 cylinders).

i II.

ACCEPTANCE CRITERIA j

a.

Confirm existence of a continuous metallic-appearing ring on the valve ring contact surface.

ll b.

Torque to 150 ft.-lbs.

Retorque to 150 ft.-lbs. every eight hours until there is no change in torque value.

Retorque to 150 ft.-lbs. every twelve _to twenty-four hours of engine operation until there is no change in the torque value.

j i

.c.

Capscrews should be 2-3/4' long.

1 d.

Locking pins shall be in place for each valve.

e.

Visual inspection criteria: No evidence of wear and corrosion.

Date:

87 Evaluated By:

M.e

%A-oeo-1 op ash >7 Date:

Reviewed By:

[/

Requalification Project Engineer

i Sheet 2 of 1 I

RANCHO SECO DISSEL GENERATOR REQUALIFICATION i

ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No.03-359 Engineering Evaluation and Recommendation-(Continred):

f.

Gasket seal shall be copper (not steel).

g.

Material to be SAE Grade 5 (Min) as specified in the TDI Owners Group Supplementary Design Review Report dated April, 1984.

III.

INSPECTION FINDINGS

~

a.

The valve ring contact surfaces were acceptable, b.

All copper gaskets were replaced and a torque of 150 ft.-lbs. was verified during reassembly.

Retorquing to 150 ft.-lbs. will be performed during further engine testin'g.

c.

All capscrews were ve ified to be 2-3/4' long.

d.

Locking pins were found to be acceptable.

e.

.The sliding surfaces of the air start valves were acceptable.

f.

All air start valve gaskets were verified to be copper material.

g.

The material was found comparable to ASTM A-325 which is equivalent to SAE Grade 5 material.

NOTE: In addition, the District performed visual inspections that verified that no carbon deposits existed on the valve internals.

I V.

CORRECTIVE ACTIONS None required.

V.

MODIFICATIONS None required.

)

i 3

J i

1

?

Sheet 2 of 3, I

RANCHO SECO DIESEL' GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT i

CONTINUATION 1

Diesel Engine Serial Number 81015, Part No.03-359 Engineering. Evaluation and Recommendation (Continued):

VI.

ADDITIONAL CONCERNS The District was also made aware of similar. concerns with this component from NRC NUREG-1216.

The DR/QR inspections described above have resolved these concerns.

VII.

RESULTS AND CONCLUSIONS

~

Based upon the evaluation made by the TDI Owners Group in this DR/QR report and the inspections performed, the air start valves and their associated hardware are acceptable for their intended use at Rancho Seco.

\\

4 l

i

r Sheet 1 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

AIR START VALVES Part Number: 03-359

REFERENCES:

CIDR MC172-038, MC172-213 NDE Report Number: NONE Associated Reoorts:

IM-QC-15-04-85, 18-24-85, 18-23-85 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES'TO BE VERIFIED a.

Verify adequate seating of the valve and valve ring.

b.

Verify initial and hot torque of hold-down capscrews.

I c.

Perform a dimensional check on two hold-down capscrews.

d.

Verify that locking in is in valve arm lock nut.

I e.

Visually inspect valve for wear and corrosion.

f.

Verify gasket seal to cylinder head is proper material.

g.

Perform a material comparator test on the hold-down capscrews (2 cylinders).

II.

ACCEPTANCE CRITERIA a.

Confirm existence of a continuous metallic-appearing ring on the valve ring contact surface.

~

b.

Torque to 150 ft.-lbs.

Retorque to 150 ft.-lbs. every eight hours until there is no change in the torque value.

Retorque to 150 ft.-lbs. every twelve to twenty-four hours of engine operation until there is no change in the torque value.

c.

Capscrews should be 2-3/4' lor.g.

d.

Locking pins shall be in place for each valve.

e.

Visual inspection criteria: No evidence of wear and corrosion.

6~/87 h

Date:

Evaluated By:

em 1.

b L'?[!l Date:'i25, r\\

Reviewed By:

M

'/

[/

Requalification Project Engineer

q j

Sheet 1 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION l

Diesel Engine Serial Number 8101@,

Part No.03-359 l

Engineering Evaluation and Recommendation (Continued):

f.

Gasket seal shall be copper (not steel).

g.

Material to be SAE Grade 5 (Min) as specified in the TDI Owners Group Supplementary Design Review Report dated April, 1984.

III.

INSPECTION FINDINGS a.

The valve ring contact surfaces were acceptable.

)

b.

All copper gaskets were replaced and a torque of 150 ft.-lbs. was verified during reassembly.

Retorquing to 150 ft.-lbs. will be performed during further engine testing.

Allcapscrewswereherifiedtobe2-3/4"long.

c.

d.

Locking pins were found to be acceptable.

I e.

The sliding surfaces of the air start valves were acceptable.

f.

All air start valve gaskets were verified to be copper material.

g.

The material was found to be comparable to ASTM A-325 which is equivalent to SAE Grade 5 material.

i l

l NOTE: In addition, the District performed visual inspections that verified that no l

carbon deposits existed on the valve internals.

l IV.

CORRECTIVE ACTIDHS None required.

V.

MODIFICATIONS None required.

l l

Sheet 3 of 1 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 8101@,

Part No.03-359 Engineering Evaluation and Recommendation (Continued):

VI.

ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component from NRC NUREG-1216.

The DR/QR inspections described above have resolved these concerne.

VII.

RESULTS AND CONCLUSIONS Based.upon the_ evaluation made by the TDI Owners Group in this DR/QR report and the inspections performed, the air start valves and their associated hardware are acceptable for their intended use at Rancho Seco.

Sheet 1 of 3, RANCHO SECO DIESEL GENERAT'OR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A

)

Part

Description:

CYLINDER HEADS Part Number: 03-360A

REFERENCES:

CIDR MC172-039; CIDR MC172-114 HDE Report Number:

UST-PT-033-84, 34-84, 110-84, 112-84 Associated Reports: NCR S-4250; IM QC-16-1-84, QC-17-14-84, QC-18-22-85, QC-18-23-85, QC-19-6-84 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.

Liquid penetrant testing of the valve seating surfaces.

b.

Magnetic particle testing.of the fire deck ares (excluding the valve seating area).

c.

Determine the fire deck thickness by ultrasonic testing.

NOTE:

NDE inspections are to be performed on a 25% sample plan (i.e. - two cylinders).

II.

ACCEPTANCE CRITERIA a.

Liquid penetrant testing shall sht no cracks in the seating surface.

Pin holes that do not exceed 1/32' diameter, numbering 3 or less in one surface, and not closer to each other than 1/8",

are eeceptable.

s b.

Magnetic particle testing shall show no relevant indications as defined below:

o Hot tears, crackt:, or linear indications that exceed ASTM E-125, Class I-1.

o Shrink that exceeds ASTM E-125, Class II-1.

o Inclusions that exceed ASTE E-125, Class III-1.

o Porosity that exceeda ASTM E-125, Class V-1.

o Linear inclusions that exceed 1/4 inch.

c.

Fire deck minimum thickness is 0.400 inches.

5-/9-32 Evaluated By:

O Date:

/

]7 Reviewed By:

'I Date:

J9 Requalification Project Engineer

Sheet 2.of 3, RANCHO SECO, DIESEL GENERATOA REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-360A 4

1 l

Engineering Evaluation and Recommenda' ton (Continued):

III.

INSPECTION FINDINGS The valve seat stamped with a K on cylinder head #5 was found with two rounded a.

indications less than t/8 inches apart from each other.

1 NOTE: Additional liquid penetrant inspections were performed on the valve seating surfaces of cylinder head #3 and no indications were found.

b.

The firing deck surfaces are acceptable.

l NOTE: Additional magnetic particle inspections were performed on all other cylinder head surfaces and no indications were found.

c.

All firing deck thic nesses are acceptable.

"I IV.

CORRECTIVE ACTIONS a.

Valve seat K on cylinder head #5 was relapped, then liquid penetrant tested; the indications were removed.

b.

None required.

c.

None requiref.

V.

MODIFICATIONS None required.

j VI.

ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component frcm NRC IE Notice 83-51, which indicated that a cylinder head at the Shoreham Nuclear Power Station had cracked.

However, the DR/QR inspections described above have resolved this concern.

1

4 I

l Sheet 3 of 3

]

RANCHO SECO DIESEL GEdERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT l

CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-360A

)

l Engineering Evaluation and Recommendation (Continued):

]

I i

NRC NUREG-1216 has ident111ed the following additional considerations regarding this component:

o The air-roll tests in the maintenance matrix should not be performed when the other diesel engine or other AC sources are already inoperable, since doing so would place the engine in a condition where it cannot receive a I

start signal.

l o

Cylinder heads with any throughwall weld repair of the fire deck should not be placed in nuclear standby service if the repair was performed from one side only.

l The District has reviewed these concerns of NUREG-1216 and has addressed them as Iollows:

}

o Although the maintenance and surveillance procedures for this equipment i

have not yet been issued, they will indicate that air-rolls shall not be I

performed when the other diesel or other AC sources are already inoperable (i.e. - Action Statement 3.7.2).

j l

l o

Discussions with TDI have revealed that no cylinder head for nuclear service has been throughwall repaired in the firedeck area by TDI.

Subsequent to engine delivery, the District has not repaired any cylinder i

heads.

However, TDI also indicated that prior to October 1984 some heads had been repaired in the injector port area using a technique which leaves I

l a visible internal Joint between the in]ector seal ' plug' and the cylinoer head.

Any Jacket water leakage at this Joint is actually external to the cylinder and will rise to the top of the head. Report PNL-5600 identified this condition (section 4.10.3.3), noting that the heed should be replaced if exterior leakage in the injector area is detected during the monthly engine test, which is consistent with the Owners Group Appendix II Maintenance Matrix, Revision 2.

The District performed a boroscopic inspection of all cylinder head injector passages and detected a Joint in cylinder heads #4, 5, and 8.

Although the operating procedures for this equipment have not yet been issued, they will indicate that the cylinder heads will be checked for external leakage in the in]ector port area.

VI.

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

Sheet 1 of 4 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT

~

~

Diesel Engine Serial Number 81016 Engine Train B Part

Description:

CYLINDER HEADS Part Nurber: 03-360A

REFERENCES:

CIDR MC172-039 NDE Report Number: UST-PT-075-84, 76-84, 99-84, 101-84 Associated Reports: NCR S-4250, S-43563 IMs DC-18-23-85, QC-18-24-85, QC-19-22-85 Engineering Evaluation and Recommendation:

I I.

ATTRIBUTES TO BE VERIFjfJl a.

Liquid penetrant testing of the valve seating surfaces.

b.

Magnetic particle testing on the fire deck area (excluding the valve seating area).

4 c.

Determine the fire deck thickness by ultrasonic testing.

NOTE:

NDE inspections are to be performed on a 25% sample plan. (i.e. - two cylinders).

II.

ACCEPTANCE CRITERIA a.

Liquid penetrant testing shall show no cracks in the seating surface.

Pin holes that do not exceed 1/32" diameter, numbering 3 or less in one surface, and not closer to each other than 1/8', are acceptable.

b.

Magnetic particle testing shall show no relevant indications as defined below:

o Hot tears, cracks, or linear indications that exceed ASTM E-125, Class I-1.

o Shrank that exceeds ASTM E-125, Class II-1.

o Inclusions that exceed ASTM E-125, Class III-1.

o Porosity that exceeds ASTM E-125, Class V-1.

o Linear inclusions that exceed 1/4 inch.

b ~/i'E 7 Evaluated By:

Date:

Reviewed By:

<fv < {'

W (C S/07

______Da t e :

pf/ ' Requalification Project Engineer

1

)

1 9

Sheet 7.of i RANCHO SECO DIESEL GENERATOR RECUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION l

Diesel Engine Serial Number 81016 Part No. 03-360A l

Engineering Evaluation and Recommendation (Continued):

)

i i

II.

ACCEPTANCE CRITERIA (Cont.)

]

i c.

Fire deck thickness minimum thickness is 0.400 inches.

)

l III.

INSPECTION FINDINGS a.

The valve seating surfaces are acceptable; no indications were found.

b.

A short (3/16 inch) linear indication was fcund near the valve seat star. ped with an X on cylinder head #8.

NOTE:

Upon finding this indication, additional magnetic particle inspections were performed on all other cylinder head surfaces, but no other indications were iound.

c.

All firing deck thicknesses are acceptable.

d.

The following additional finding was reported by Q.C. while inspecting the cylinder heads: cylinder head #5 had a small nick or scratch on an inside edge of a water passage.

IV.

CORRECTIVE ACTIONS a.

None required.

b.

The indication on cylinder head #8 was polished and examined at TDI's factory and found to be a blemish only; no further corrective action was required.

c.

None required.

d.

The scratch on the water passage of cylinder head #5 head was filed smooth to remove the sharp edges.

V.

MODIFICATIONS l

None required.

Sheet 3,of 4 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT 1

CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-360A Engineering Evaluation and Recommendation (Continued):

VI.

ADDITIONAL CONCERNS The District wac also made aware of similar concerns with this component from NRC IE notice 83-51, which indicated that a cylinder head et the Shereham Nuclear Power Station had cracked.

However, the DR/QR inspections described above have resolved this concern.

NRC NUREG-1216 has identified the following additional considerations regarding this component:

o The air-roll tests in the maintenance matrix should not be performed when the other diesel engine or other AC sources are already inoperable, since doing so would place the engine in a condition where it cannot receive a start signal.

s

\\

o Cylinder heeds with any throughwall veld repair of the fire deck should not g

be placed in nuclear standby service if the repair was performed frou one side only.

The District has reviewed these concerns of NUREG-1216 and has addressed them as follows:

o Although the maintenance and surveillance procedures for this equipment

)

have not yet been issued, they will indicate that air-rolls shall not be j

performed when the other diesel or other AC sources are already inoperable (ie. - Action statement 3.7.2).

o Discussions with TDI have revealed that no cylinder head for nuclear service has been throughwall repaired in the firedeck area by TDI.

Subsequent to engine delivery, the District has not repaired any cylinder heads.

However, TDI also indicated that prior to October 1984 some heads had been repaired in the injector port area using a technique which leaves a visible internal joint between the injector seat " plug" and the cylinder head.

Any Jacket water leakage at this Joint is actually external to the. cylinder and will rise to the top of the head.

Report PNL-5E00 identified this condition (section 4.10.3.3), noting that the head should be replaced if exterior J

1eakage in the injector area is detected during the monthly engine test, which is consistent with the Owners Group Appendix II Maintenance Matrix, i

D L Sheet i of i RANCHO SECO DIESEL GENERATOR RECUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 8101@,

Part No. 03-360A' Engineering Evaluation and Recommendation (Continued):

VI.

ADDITIONAL CONCERNS (Cont.)

J

)

Revision 2.

The District performed a boroscopic inspection of all cylinder head injector passages and no Joints were found.

Although.the operating.

j procedures for this equipment have not yet been issued, they will indicate

_l that the cylinders heads will be checked for external leakage in the i'

injector port area.

VII.

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

1 i

l 4

s e

1 l

l i

j

'l Sheet L of L

~

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

FUEL INJECTION TUBE ASSEMBLY Part Number: 03-365C

REFERENCES:

CIDR MC172-044 NDE Reoort Number: NONE Associated Reports:

IM QC-19-3-85 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED Eddy current inspection of fuel injection tube assembly.

II.

ACCEPTANCE CRITERIA As stated in FaAA NDE Procedure 11.10 ' Eddy Current Inspection Procedure - High-Pressure Fuel Lines - Carbon Steel".

III.

INSPECTION FINDINGS l

The inside diameters of all the high pressure fuel injection lines were inspected

[

by eddy current testing.

All the lines were found to be free of flaws.

IV.

CORRECTIVE ACTIONS None required.

V.

MODIFICATIONS 1

None required.

1 l

VI.

ADDITIONAL CONCERNS 1-l The District was*also made aware of similar concerns with this component from NRC NUREG-1216, which also identified an optional modification to install shrouded, double wall fuel oil, injection lines.

Although the DR/QR inspections described J

above had resolved these concerns, the District subsequently installed the shrouded lines as a product improvement.

i VII.

RESULTS AND CONCLUSIONS l

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

b - # 9 ~D

. Evaluated By:

Date:

f !25/07 Reviewed By:

~

Date:

,/?"

Requalification Pro 3ect Engineer

Sheet 1 of 1 RANCND SECO DIESEL GENERATOR REQUALIF] CATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

FUEL INJECTION TUBE ASSEMBLY Part Number: 03-365C

REFERENCES:

CIDR MC172-044 NDE Report Number:

NONE essociated Reports:

IM CC-19-3-85 I

Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED Eddy current inspection of fuel injection tube assr:mbly.

II.

ACCEPTANCE CRITERIA As stated in FaAA NDE Procedure 11.10 " Eddy Current Inspection Procedure - High Pressure Fuel Lines - Carbon Steel".

III.

INSPECTION FINDINGS The inside diameters of all the h'igh pressure fuel injection, lines were inspected by eddy current testing.

All the lines were found to be free of flaws.

3 IV.

CORRECTIVE ACTION:

i None required.

V.

MODIFICATIONS I

l None required.

VI.

ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component from NRC NUREG-1216, which also identified an optional modification to install shrouded, double wall fuel oil injection lines.

Although the DR/QR inspections described above had resolved these concerns, the District subsequently installed the shrouded lines as a product improvement.

VII.

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

the actions taken to address the above additional concerns, the fuel injection tube assembly is acceptable for its intended use at Rancho Seco.

0

~

Evaluated By:

Date:

28/57 Reviewed By:

Date:

,/'

Requalification Project Engineer l

l 1

l Sheet )_of 2_

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT

)

')

Diesel Engine Ser:.a1 Number 81015..

j Engine Train A_

l Part

Description:

INTAKE, EXHAUST & CONNECTOR PUSHRODS Part Number: 03-390C&D 1

REFERENCES:

CIDR MC172-053 NDE Reoort Number: NONE-Associated Reports:

IM-QC-15-13-84 Engin,*ering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.

Verify that pushrods are friction welded.

1 b.

Perform either an LP or visual examination of friction welds.

(

II.

ACCEPTANCE CRITERI!

a.

Friction veld design.

b.

LP fa visual acceptance criteria: No cracks or indications allowed along the bond line between the rod end and the tube as specified by SMUD LP Procedure No. QCI-101 or SMUD Visual Inspection Procedure No. QCI-112.

4 III.

INSPECTION FINDINGS

'I a.

The District replaced all intake, exhaust, and connector pushrods from the ball-er.d design to the never friction veld design as recommended by the Owners Group.

j b.

The friction welds on all pushrods were liquid penetrant enmined at the TDI factory and witnessed by SMUD QA. level III personnel.

Pushrods installed in Rancho Seco's TDI diesels have all satisfactorily pas. sed LP examination.

d!AI 87 Date:

Evaluated By:

W u

~

7' Reviewed By:

Date:

( Requalification Project Engineer

Sheet 2,of 2.

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-390C&D Engineering Evaluation and Recommendation (Continued):

IV.

CORRECTIVE ACTIONS None required.

l V.

MODIFICATIONS l

1 The TDI Owners Group has recommended that ball-end pushrods be replaced with new modified design pushrods having friction velded ends and the District has implemented this change.

VI.

ADDITIONAL CONCERNS The District was also m'ade aware of similar concerns with this component from NRC NUREG-1216.

The DR/QR inspections described above have resolved these concerns.

VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Ov'ners Group in this DR/QR report, l

the inspections performed, the modifications made and the actions taken to address the additional concerns, these components are acceptable'for their' intended use at Rancho Seco.

l l

l I

Sheet 1 of 2 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diesel Engine Serial Number 81016 Engine Train B Part

Description:

INTAKE, EXHAUST & CONNECTOR PUSHRODS Part Number: 03-390C&D

REFERENCES:

CIDR MC172-053 NDE Recort Number: NONE Associated Reports:

IM-QC-15-13-84 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIF!ED a.

Verify that pushrods are friction welded, b.

Perform either an LP or visual examination of friction velds.

\\

II.

ACCEPTANCE CRITERIA 1

a.

Friction veld design.

b.

LP & visual acceptance criteria: No cracks or indications allowed along the bond line between the rod end and the tube as specified by SMUD LP Procedure No. QCI-101 or SMUD Visual Inspection Procedure No. QCI-112.

III.

INSPECTION FINDINGS a.

The District replaced all intake, exhaust, and connector pushrods from the ball-end design to the newer friction weld design as recommended by the Owners Group.

b.

The friction velds on all pushrode were liquid penetrant examined at the TDi factory and witnessed by SMUD QA level III personnel.

Pushrods installed in Rancho Seco's TDI diesels have all satisfactorily passed LP examination.

Evaluated By:

ryt49 Date:

87 5! 7 Reviewed By:

"A-Date:

/,'/

Requalification Project Engineer

l Sheet 2 of 2 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPO9T CONTINUATION Diesel Engine Serial Number 81016 Part No. 02-290C&D Engineering Evaluation and Recommendation (Continued):

IV.

CORRECTIVE ACTIONS None required.

l V.

MODIFICATIONS The TDI Owners Group has recommended that ball-end pushrods be replaced with new modified design pushrods _having friction welded ends and the District has implemented this change.

VI.

ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component from NRC NUREG-1216.

The DR/QR inspections described above have resolved these concerns.

VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Ovners Group in this DR/QR report, the insp.?ctions performed, the modifications made and the actions taken to address the additional concerns, these components are acceptable for their intended use at Rancho Seco.

1 1

i

I i

i i

Sheet }_ of 'l RANCHO SECO DIESEL GENERATOR RFQUALIFICATION.

I ENGINEERING S'JMMARY REPORT Diesel Engine Serial Number 81015 Engine Train A._

Part

Description:

ROCKER ARMS AND PUSHRODS - MISC. BOLTS & DRIVE STUDS Part Number: 390G

REFERENCES:

CIDR MC172-054, MC172-114

)

NDE Report Number: NONE Associated Reports: NONE Engineering Evaluation and Recommendation

]

I.

ATTRIBUTES TO BE VERIFIED a.

Perfora a magnetic particle test on the thread root area of all capscrews.

b.

Perform a visual inspection on the drive stude.

Verify that the prop,er torque loads are applied to the rocker arm capocrews by c.

reviewing existing documentation.

{

J d.

Determine the material of the capocrews (sample of four), one engine.

e.

Determine the hardness of the capscrews.(sample of four), one engine.

II..

ACCEPTANCE CRITERIA a.

No linear indications found on the thrend root area of the rocker arm capscrews.

b.

Drive stude are properly installed (tight and intact), and are not damaged.

]

j c.

Torque to 365 ft.-ibs.

d.

The material of the capscrews shall be comparable to AISI 4140.

e.

Hardness of the capscrews to be 254 to 285 Brinell.

j

/6!87

~

Dates Evaluated By:

W -

C/

'Date: ' zO !7 Reviewed By:

.mv

[. '

Requalification Project-Engineer r

u.-

i J

a

t I.

Sheet l'of 2

{

~

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING'

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81015' Part No. 03-390G Engineering Evaluation and Recommendation (Continued):

III.

INSPECTION FINDINGS a.

No linear indications were found.

b.

All drive stude are properly installed and do not show any signs of damage.

c.

All rocker arm capscrews torqued to 365 ft.-lbs.

d.

Material is comparable to AISI 4140.

e.

The hardness of the capscrews was verified to be 262 to 275 Brinell.

NOTE:

Additional inspections performed include verification that the rocker arm capscrews were of the modified design.

IV.

CORRECTIVE ACTIONS

.j None required.

V.

MODIFICATIONS None required.

VI. ADDITIONAL CONCERNS The District was also made aware of similar concerns with this component from IE Notice 83-51 and NRC NUREG-1216.

The DR/QR inspections above have resolved these concerns.

VII.

RESULTS AND CONCLUSIONS Based upon the evaluation made by the TDI Owners Group-in this DR/QR report and the inspections performed these components are acceptable for their intended use at Rancho Seco.

Sheet 1 of 2 RANCHO SECO DIESEL GENERATOR REQUtLIFICATION ENGINEERING

SUMMARY

REPCRT Diesel Engine Serial Number 81016 Engine Train B l

Part

Description:

ROCKER ARMS AND PUSHRODS - MISC. BOLTS & DRIVE STUDS Part Number: 03-390G

REFERENCES:

CIDRs MC172-054, NDE Report Number: NONE Associated Reoorts:

IM-QC-17-38-85 l-Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED a.

Perform a magnetic particle test on the thread root area of all capscrews for linear indications.

b.

Perform a visual inspection on the drive stude for signs of irregularity.

c.

Verify that the proper torque loads are applied to the rocker arm capscrews by reviewing existing documentation.

d.

Determine the material of the capscrews (sample of four), one engine.

e.

Determine the hardness of the capscrews (sample of four), one engine.

II.

ACCEPTANCE CRITERIA a.

No linear indications found on the thread root area of ti,e rocker arm capscrews.

1 b.

Drive stude are prcperly installed and are not damaged.

c.

Torque to 365 ft. Ibs.

d.

The material of the capscrews shall be comparable to AISI 4140.

e.

Hardness of the capscrews to be 254 to 285 Brinell.

[!28 87

~

Evaluated By:

Date:

v 5

Date:

7 Reviewed By:

(7 Requalification Project Engineer

n:

f' Sheet 2,of 2_

f

~

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION l

Diesel Engine Serial Number 81016 Part No. 03-390G Engineering Evaluation and Recommendation (Continued):

III.

INSPECTION FINDINGS a.

Two rocker arm capscrews had linear indications in the root areas.

b.

All drive studs are properly installed and do not show any signs of damage.

c.

All rocker erm capscrews torqued to 365 ft.-lbs.

d.

(Engine "A" tested.)

i e.

(Engine "A" tested.)

NOTE:

Additional inspections performed include liquid penetrant inspections on four rocker arm shaft bolts (all were acceptable) and verification that the rocker arm capscrews were of the modified design.

l l

IV.

CORRECTIVE ACTIONS l

s a.

Both of these rocker arm capscrews were replaced with suitable new parts.

b.

None required.

c.

None required.

d.

None required.

e.

None required.

V.

MODIFICATIONS None required.

VI. ADDITIONAL CONCERNS The. District was also made aware of similar concerns with this component from IE Notice 83-51 and NRC NUREG-1216.

The DR/QR inspections above have resolved these concerns.

VII.

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

inspections performed these components are acceptable for their intended use at Rancho Seco.

Sheet L of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION l

ENGINEERING S'JMMARY REPORT Dicael Engine Serial Number 81015 Engine Train A Part

Description:

JACKET WATER PUMP (ENGINE DRIVEN)

Part Number: 03-425A

)

REFERENCES:

CIDR HC172-063, SOURCE INSPECTION 6/20/85 NDE Report Number: NONE Associated Reports: FaAA REPORT APRIL 1984; NCR S-6131, S-5264, S-4991; FPR #279,

1. 21 l

l Engineering Evaluation and Recommendation:

l j

l I.

ATTRIBUTES TO BE VERIFIED I

l a.

Determine hardness of pump shaft.

j b.

Determine the material of the pump shaft.

l c.

Perform a visual inspection of the pump.

l 5

l d.

Perform a visual inspection of the pump driven gears.

e.

Perform a liquid penetrant test on the gear teeth and transition area (gear to shaft).

f.

Perform a visual inspection on the wear ring.

II.

ACCEPTANCE CRITERIA a.

Hardness - 135 to 180 Brinell.

b.

Shaft Material - 303 SS c.

Absence of excessive galling, wear or scoring.

d.

Absence of pitting or galling.

e.

No evidence of linear indications in accordance with SMUD procedure No. QCI 101.

I 1

t d

f.

Absence of galling or excessive wear.

Date:

7-87 Evaluated By:

m V

5!05 Reviewed By:

W<'

Date:

ef l

f Requalification Project Engineer L

1 l

Sheet 1 of 1 I

RANCHO SEC3 DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT l

l CONTINUATION l

Diesel Engine Serial Number 81015 Part No. 03-425A Engineering Evaluation and Recommendation (Continued):

III.

INSPECTION FINDINGS a.

Hardness was determined to be 165 to 168 Brinell.

(Ecth engines tested.)

l b.

Shaft material was determined to be comparable to 303 SS.

(Both engines j

tested.)

c.

No evidence of galling, wear or scoring on the pump shaft, d.

No evidence of pitting or galling on pump driven gear.

e.

No linear indications on gear ~ teeth or transition area.

f.

Only minor wear was observed on the wear ring.

Note:

Additional insp'ections performed include:

1) Measure the minimum gap between the wear ring and the impeller.

The 1

gab was determined to be 0.007 inches.

2) Verify the torque of the impeller nut.

The torque was verified to be 40 ft.-lbs.

IV.

CORRECTIVE ACTIONS None required.

V.

MODIFICATIONS The TDI Owners Group recommended that the impellers be changed from cast iron to ductile iron (ASTM-536, Grade 65-45-12).

The District has implemented this change.

j VI.

ADDITI[yAL CONCERNS j

The District was made aware of other concerns with this component from NUREG-1216.

The DR/QR inspections described above have resolved these concerns. The District was also made aware of another concern with this component from IE Notice 83-51, where the jacket water pump shaft at Shoreham had failed due to fatigue initiating from the keyway.

The District has modified the pumps to eliminate this keyway.

l

i

)

[

Cineet 2 of 3 RANCHO SECO DIESEL GENERATOR REQUAl.IFICATION ENGINEERING

SUMMARY

REPORT l

CONTINUATION Diesel Engine Serial Number 81015 Part No. 03-425A Engineering Evaluation and Recommendation (Continued):

j 1

I l

VI.

RESULTS AND CONCLUSIONS 1

Based on the evaluation made by the TDI Owners Group iri this DR/QR report, the modifications made, the inspections performed, and the actions taken to address the i

above additional concerns, this componer.t is acceptable for its intended use at j

Rancho Seco.

j i

i l

l

\\

l s

i l

1 l

4 Sheet L of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT Diese1' Engine Serial Number 81016 Engine Train B Part

Description:

JACKET WATER PUMP (ENGINE DRIVEN)

Part Number: 03-425A

REFERENCES:

CIDR HC172-063, SOURCE INSPECTION 6/20/85 NDE Reoort Number: NONE Associated Reports: FaAA REPORT APRIL 1984; NCR S-4991 Engineering Evaluation and Recommendation:

I.

ATTRIBUTES TO BE VERIFIED- (One Engine Only) a.

Determine hardness of pump shaft.

b.

Determine the meterial of the pump shaft.

c.

Perform a visual in pection of the pump shaft.

d.

Perform a visual inspection of the pump driven gears.

e.

Perform a liquid penetrant test on the gear teeth and transition area (gear to shaft).

f.

Perform a visual inspection on the wear ring.

II.

ACCEPTANCE CRITERIA' i

a.

Hardness - 1.35 to 180 Brinell.

b.

Shaf t Mater:.a1 - 303 SS.

c.

Absence of excessive galling, wear or scoring.

d.

Absence of pitting or galling.

e.

No evidence of linear indications in accordance with SMUD procedure No. QCI 101.

b

• 87 l Date:

Evaluated By:

e

(((/'

5/ 7

~

Reviewed By:

/

Date:

20 '

Requal'ification Project Engineer 9

1

e t

[

Sheet 2 of 1 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-425A Engineering Evaluation and Recommendation (Continued):

II.

ACCEPTANCE CRITERIA CONT.

f.

Absence of galling or excessive wear.

III.

INSPECTION FINDINGS a.

Hardness was determined to be 165 to 168 Brinell.

(Both engines tested.)

l b.

Shaft material was determined to be comparable to 303 SS.

(Both engines tested.)

c.

(Engine

'A' examined.)

d.

(Engine

'A' examined )

l' e.

(Engine

'A' examined.)

f.

(Engine

'A' examined.)

Note:

Additional inspections performed include:

l 1)

Myasure the minimum gap between the wear ring and the impeller.

The minimum gap was determined to be 0.005 inches.

2)

Verify torque of the impeller nut.

The torque was verified to be 48 ft.-lbs.

I V.

CORRECTIVE ACTIONS None required.

V.

MODIFICATIONS The TDI Owners Group recommended that the impe11ers be changed from cast iron to ductile iron (ASTM-535, Grade 65-45-12).

The District has implemented this char.ge.

1 Sheet 3 of 3 RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPORT CONTINUATION Diesel Engine Serial Number 81016 Part No. 03-425A

)

Engineering Evaluation and Recommendation (Continued):

I VI.

ADDITIONAL CONCERNS The District was made aware of similar concerns with this component from NUREG-1216.

The DR/QR inspections described above have resolved these concerns.

The I

District was also made aware of another concern with this component from IE Notice 83-51, where the Jacket water pump shaft at Shoreham had fsiled due to fatigue initiating from the keyway.

The District has modified the pumps to eliminate this keyway.

V':I.

RESULTS AND CONCLUSIONS Eased on the evaluation wade by the TDI Owners Group in this DR/QR report, the i

modifications made, the inspections performed and the actions taken to address the l

above additional concerns, this component is acceptable for its intended use at Rancho Seco.

1 1

1 i

l l

l l

1 l

e

[

Sheet L of L

)

RANCHO SECO DIESEL GENERATOR REQUALIFICATION ENGINEERING

SUMMARY

REPCRT Diesel Engine Serial Number 81015 Engine Train A Part

Description:

ENGINE & AUX. HDDULE WIRING MAT'L - WIRING & TERMINATIONS Part Number: 03-688B

REFERENCES:

NO CIDR l

NDE Report Number: NONE Associated Reports: PIR 83-07 I.

ATTRIBUTES TO BE VERIFIED

, i Quality revalidation is not required.

I II.

ACCEPTANCE CRITERIA j

l l

None required.

III.

INSPECTION FINDINGS Not applicable.

\\

.j IV, CORRECTIVE ACTIONS

. None required.

I V.

MODIFICATIONS N=ne required.

VI.

ADDITIONAL CONCERNS The District was also made aware of another concern with these components.

Bechtel Problem Investigation Request (PIR) 83-07 identified problems with cables that failed IEEE 383 insulation flame test.

These cables are not used at Rancho Seco.

i VII.

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

Evaluated By:

Sh

~

Date:

Z 87 Reviewed By:

Date:

jd7 Requalification Project Engineer i

mm e]

4,

I

[

Sheet 1 of 1 RANCHO SECO DIESEL GENERATOR REQUALIFICATION I

ENGINEERING

SUMMARY

REPORT j

Diesel Engine Serial Number 8101@.

I Engine Train B_

j

)

1 Part

Description:

ENGINE & AUX. MODULE WIR'.'NG MAT'L - WIRING & TERMINATIONS l

Part Number: 03-688B REFF:RENCES:.NO CIDR NDE Report Number: NOEE l

Associated Reports: PIR 83-07 l

I.

ATTRIBUTES TO BE VER1FIED

]

l l

Guality revalidation is not required.

j II.

ACCEPTANCE CRITERIA 1

None required.

III.

INSPECTION FINDINGS Not applicable.

I V.

CORRECTIVE ACTIONS I

None required.

V.

MODIFICATIONS None required.

VI.

ADDITIONAL CONCERNS The District was also made aware of another concern with these components.

Bechtel Problem Investigation Request (PIR) 83-07 identified problems with cables that failed IEEE 383 insulation flame test.

These cables are not used at Rancho Seco.

VII.

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

d/M~/87 Evaluated By:

de Date:

L S-

.eM4/

Ynb7 Reviewed By:

e

/

Date:

[

Requalification Project Engineer