ML20245K675

Rev 2 to Review 18 Month PM Items for Diesel Generator & Evaluate Extension to 30 Months

ML20245K675
Person / Time
Site:	Davis Besse
Issue date:	08/02/1989
From:	Falter H MORRISON-KNUDSEN CO., INC.
To:
Shared Package
ML20245K475	List: ML20245K472 ML20245K675
References
6993-2, 6993-2-R02, 6993-2-R2, NUDOCS 8908210113
Download: ML20245K675 (19)

Text

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POWEn SYSTEMS DMSION s -, . _ _

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' / ROCKY MOUNT. NOF TH Ct *tOUNA *?att 1926 I PHONE: (919) 977-2721, I TW: (510) 9494725

- FAX (919)446-3830 -

IW UI 7, 1989 j TEVISICN 1 REPORT NO. 6993 '? AUGUST 2, 1989 WEVISION O REVISION 2 FEBRUARY 16, 1989 7, '

f REVIEW 18 MONTH PM ITEMS FOR DIESEL j- GENERATOR AND EVALUATE EXTENSION TO 30 110N THS TOLEDO ED150N DAV13-DESSE. NUCLEAR STATION PURCHASE ORDER # 01 o744-SO FUNCTION /JUD ORDER: 2415-1 MORRISON-KNUDSEN COMPANY. INC.

POWER SYSTEMS DIVISION 7%

- 4 IWO 6993 - SUPPLEMENT 2 LJ ,,,,w m ,, , ,,

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PREPARED DY: _ _ _ _ _ M.4q_W_._ __ _ ._ .~. _ _ _ _ _. _ _ _ _ _. ,' L U A M p. ._ _ _ _ _ .

Harry Falter, P.E. 7033 4s en m o n' Date APPROVED BY _ _ , . , , , _ _ . _ , , , . _ _

._,._f,[.,____.,,______,__,,,___. ),7 Engineeri g - Department He'ad Date

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APFROVED BY: _[Mg/M '._, ._x.gyg.__,_,,, ___,, _ _[/7 _,,

Quality Assur ice - Departmerit Hes.d

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8908210113 890st1 PDR ADOCK 05000346 P PDC -

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REVISION SHEET REVISION NO. DATE PAGE DESCRIPTION AAEROVED BY 1 3/7/89 2 Under Purpose", *

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added paragraphs 2, 3, and 4:

" Toledo Edison wishes... approval each time."

13 Comment added under

" Clean all air

/~} passages." "The

z. y engine room...TO 30 MONTHS."

15 Last paragraph under

" Comment": Deleted first two sentences "If diesel generator...

on a monthly basis.

2 8/2/89 3 (a) First paragraph, last sentence revised hW to clarify example.

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REPORT.NO.: 6993-2.

---,- .. REVISION: 2

-' DATE: 7-89.

PAGE: 1 of 17

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"'onclus ion :

a ;1sve reviewed 11 e M- m7nt,n preventative mainten-9.n'.:e r_ regram *o --v e ' ; a t a *he c<ptic n rf :in *::t r r.s i ;n from S ma r.th:. .; ^n ~.,nthe.

The +y.t enr i c n ..s barea upon the conce;t ,f rendine data r.: v+rify that *here la nc degradati n with time.

Tne sttached report identifies the parts cf the

,. s Preventative maintenance that are 3Prroved for the

/ ') 20 month e::rension as well as those that have not

'v/ been extended. "'he ex tension io besed upon cur field service experience and engineering judgement.

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"0  ?> REPORT NO.'s 6993-2 REVISION: k '

< DATE: 8/02/89 CYJ -

PAGE 2 OF 17

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%f) , 1 l Scopes: -Surveillance' Test. Procedure DB-SC-03072, Emergency Diesel Generator 1, Refueling Surveillance Test Revision O Dated-April 23, 1988 Purposes! Review the surveillance' test procedure DB-SC-03072 for the purpose of. extending the 18 month-Diese11 Generator maintenance Schedule to

.30 months on.

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Toledo Edison wishes to extend the surveillance interval-for 18 month requirements to 30 months to accommodate'the possibility.of an unusually long' outage. The plant is currently permitted by its. license to' extend an 18 month surveillance-requirement-to 22.S months.

I f. a refueling outage lasts longer than originally scheduled, it is possible that a surveillance requirement, such as diesel engine maintenance, ~

could come due again prior to reaching the next scheduled shutdown for refueling. If this occurs, it'would force either an expensive shutdown solely

]f' for1the performance of preventive maintenance, or N_jf 'the attempt to obtain a one-time extension ~for the

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maintenance from the NRC.

Toledo'Ecison. prefers to' resolve the possible schtduling problem by.a. technical justification that a maximum maintenance interval of thirty months.

.rather than the current allowed 22.5 months, is acceptable, with~any.necessary enhancements in 1 monitoring / trending of diesel performance. The

. intent is not to perform the maintenance only at this maximum 30' month interval each time. Plant operat'ing cycles are expected to remain as they are now, and the maintenance will normally be performed within the current requirements of 22.5 months. The extension to 30 months is only intended to allow greater.' flexibility to accommodate the infrequent Tsituations that could make a delay in maintenance desirable, without the need for NRC involvement'and approval each time.

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] REPORT NO. 6993-2 REVISION: 2 L. DATE: 8/02/89 PAGE: 3 OF 17 7_

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Reference:

Toledo Edison Task-Authorization #177-553-875'/-00, Job Order 2415-1.

Toledo Edison DB-SC-03072-OO attachment 3

> Diesel Generator maintenance Schedule - 18 l' month.

Forward: A program that trends diesel generator per-formance shall be instituted to assure relia-bility and provide early data for any correc-tive action that may be warranted.

The. trending program will utilize data from the monthly diesel generator load test and other tests by comparing the most recent test results with an old test record (approximately 6 to 12 months ago) and with recent prior tests. No special tests should be required. Readings should be taken at the same test KW load for consistent results.

The parameters are:

('s (a) Diesel cylinder exhaust temperatures.

d)

Diesel exhaust temperatures can vary directly with the variation of combustion air ambient temperatures. For example, if there is a 20*F increase in embient temperature between R7_

different days that exhaust readings are taken, that 20'F increase will also appear in the later exhaust temperature reading..

Consistency of the exhaust temperatures indicates that there are no significant changes in the combustion chamber process. The injectors are in good condition and properly adjusted. Exhaust valves ano piston rings are seating properly.

(b) Consistency in the crankcase pressure readings ir.dicates that the crankcase evacuation system is in good order, that there is no excessive piston ring blow-by, and no hot spots are forming in the crankcase.

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.,7 ';- REPORT NO. 6993-2 REVISION: 2 5 DATE: 8/02/89 l

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(c) 'The engine systems pressure and tempera-tures (for lube oil, engine water and fuel) chould also be compared.

u The constancy of the water leveloof the expansion tank would indicate that the water i system'is tight.

Consistent readings over a period of time indicate that tha systems are performing normally.

(d) The load test run readings for KW, voltage and frequency would verify settings and the units ability to deliver power as well as stable voltage and frequency.

(e) Generator RTD readings that are consistent indicates that the generator is in proper condition.

(f) The action of the air start motors in

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their ability to crank the diesel generator should also appear consistent to the operator.

Comparisons should be made at approximately the same air receiver pressures.

(g) Trending a monthly lube oil analysis may provide data to assist in evaluating the diesel. Figure 1 is an interpretation of lube oil sample analysis taken from the EMD MI 1762.

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REPORT NO.: 6993-2 REVISION: 2 DATE: 8/02/89 PAGE: 5 DF 17 f}

O Figure 1 M.I.1762 INTERPRETATION OF LUEE C!L SAMPLE ANALYSIS NORMAL ECROERL!NE HIGH RFCOMMENOED ACTICN LUBE BASIS Correct I a Shut Down Engine. Drain Lube Oit.

FOR No Acuen Teke Extra CIL Oil Samples Concition I IChange Filters.

ANALYS!S ANALYSIS Recuired Viscosary & Flasn Pomt . Screerline - find anc fix fuel team.

Check for dilution if fresh High -check mam bearings per mainte.

Fuel point less than 400* F or 0 to 2% 2 to 5% Above E% nonce manual, Lean . oil viscosity drops 15% or more at 100* F.

Resamole witn cry centamer. Find anc fin l None Any lean. Checx man bearmss per mamte 1 Free Water nance manual.  !

Water Lean Chromate innibitor l 0 to 20 com l 20 to 40 ppm l Above 40 ppm pg g tant pressure.

Baron innibitor l 0 to 10 ppm l 10 to 20 ppm l Above 20 ppm 0 to 5 ppm 5 to 10 ppm Above to ppm improved air filter mamtenance ret;uired.

Silicon k[tranon

• Mirt TEN- Change Oil Lf short oil hfe eersists. chectl (0 46460.5 lube on cuality, fuel sulfur content. oil.

TEN (0 664) cooier efficiency. engme temperature TEN f0 2E9t:1 (0 229511.0 Excesswe una. ves. Rise 30% contrDiri power output tgevernor ano rack Viscesity Rise Meet pr$ 5.0 semngst engine conoition tworn rings.

Omicanon pr.t Man. Pem. irmat. 2% cracxec pistons. poor c=mbustioni, ont Pentane insolubles filtration. or oil pump suction lesa.

Cheat fuel citantmess. Noufv fuel succhera Contami.

nated fuel Alummum Above 5 ppm an "'5* *h'C"

"'a"9'"* 5* '" lector cainbranonitio erosion. Ch (cracumg Magnesium excessively worn. l O cata'vst) .

t I Check af oil is comacung galvanaec or rine-

\ Above to com becomes pamted surfaces. Cheen if matte up cel m 0 to 10 ppm more cancerous wim m. stecx tt witnm specifications. Noutv tubes Zinc oil sucober. Checa for silver bearmg creasmg vaiues.

failures.

Check if oil contams zine or is corroswe to Oil sover. Checa for b.caen piston ecolmg Contarm. tuces. mertic:ent ois center. or imcrocert temperature centrot. Feet sices of piston 4 0 to 1 pom 1 to 2 ppm Above 2 ppm pmt for signs of cistress. Measure pistent Saver to neaa meerance w.m ieso reso ngs. Oill crammg is not mancatory Checa strainersi ano cottom of oil can ter cebris. Consiceri turco ocarmg cenoition. l l- Abnormai Chromium (Not acon. l l 10 to 20 ppm Cheet for raoic wear of rmgs & Imers-cacie if enromate ccotant 0 to 10 ppm i Above 20 ppm Wear Or I inewonor is useat i I Corrosion Measure pistnn so r'eac ciearance wim ieac t (R acia l Cooper 0 to 75 ppm (. 75 to 150 comeAbove 150 pom resomgs to locate worn piston inrusti meresses wasners I

l I wirnm normal - tron i O to 75 ccm 75 to 125 come Above 125 ccm ICneca for raoio wear c rmes & Imers..

,Mc.st timesv seno riasn is cissoivmg .

range bearmgs. Premature teac rerr. oval. before s snouac be bearmgs are croken in. can teso to erar mg i consicereo - cistress. inscect ano replacr upper con roc t borcerime bearmqs m service tess snan 6 montns af t conostiam Above 75 ppm Leaa O to 50 com 50 to 75 com lean flasn nas eeen removeo from sne{

uruoaced area of the fitnback bearmg{

surface on turbocharger engmes. If ccn roc bearmgs recuir* rectacement. wrist I pm Dearmgs should also be cnected and regiaced if lead riash has been removed.

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! Check for cebris under crankst'att gear

( in Coocer Two out of inrec eiemenes maicatrve of gear tram buinmq cistress.

Chect ioter gear bearmg clearances.

Comoma. Iron Checa main ano can roc bearmgs per main.

n trrtaruns or nayirange.

tron Leao tenance manuaa. Oil crammg .s not e

mancatory l

• tn areas wnere suel sulfur content escreos 0 5*'. ame TEN levet sno sid ret be aliowed to drop teca 1.0 (0 6646 or 3 010 28961

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' V.. I'JC REPORT NO.: 6993-2

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i, < i REVISION: 2 DATE:' 8/02/89 gl1 PAGE: 6 OF 17 x5 G$._,]'.

Assumptions:

'The diesel generator is an emergency stand-by power supply. It is normally tested once a month which it is load to 3/4 to full load for-approximately one hour before being shut down. This test run may be trf.a one or two hour length.

.Therefore for the span of thirty months the ciesel generator will.make 60 starts and operate for approximately 60 hours6.944444e-4 days <br />0.0167 hours <br />9.920635e-5 weeks <br />2.283e-5 months <br />. In addition the diesel engine mayJbe called upon ts run for a seven day period or another 168 hours0.00194 days <br />0.0467 hours <br />2.777778e-4 weeks <br />6.3924e-5 months <br />. This totals an estimated 228 hours0.00264 days <br />0.0633 hours <br />3.769841e-4 weeks <br />8.6754e-5 months <br /> and 60 starts over the 30 month period.. Therefore wear as a result of operation is minimal.

Evaluation of 18 Month PM ltems.,For Diesel Generatpr For Extension to 30 Months Attachment 3: Diesel Generator Main tenan celg;ttefyle_

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18. Months

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? Engine Any bolts / nuts / screws fggnd to be loohg may tae tightened per desioney toraue values o_r_

per t he M a i n t en a n c e F o r e, mta n d inej;;1 ion .

Comment:

During.the periodic diesel generator test run, visually observe exterr.al fasteners for indications of looseness. Loose fasteners should be scheduled to be tightened when found.

Remove and clean crankcase evacuation system oil se_parator screen and element.

Inspecl/ clean ej e c tor tube.

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REPORT NO.

.. 1- 6993-2 4

REVISION: 2 DATEt 8/02/89 PAGE: 7 OF 17 7-i J-

'V Comment:

The diesel generator operating hours during the 30 month extension period is expected to be less than 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br />. This maintenance can be extended from 18 to 30 months. However, the crankcase pressure should be monitored when the unit periodically tested to trend the increase in pressure. If the crankcase pressure should go from negative to positive pressure as time goe%'by, the above maintenance should be scheduled.

LUBE OIL Chance all lobe oil filters. Clean strainers and housings._

Comments:

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The lube oil filters shall be changed on an annual basis bECad%e the glue used in the filter element degrades with time.

. ,,s . The lube oil strainers elements should be

'[ } cleaned at the same time.

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Check piston cooling oil tube alignment.

Comment:

There is no history of piston cooling tubes going out of alignment anless they have been struck by-some object. This inspection may be extended to 30 months.

Analyze lube oil, if required, change lube oil.

(Lube oil must be changed at least

__every 3 years.)

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Comment:

Lube oil shall be analyzed on a monthly schedule tioting the changes in water, oxidation, fuel, inhibitor, lead, silver tin, coppercor Terrous material for trending 4 purposes. (MI 1760)

J.+,.h y!Lgt and clean exhaust manifold and manifold

- s cl,!?'101 Conment:

The estimated hours of operation for the 30 month period is less than 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br />. Most of the operation during this period will be at approximately 3/4 load or greater. The engine will be operating at its optimum load for a clehn exhaust and negligible lute oil carryover. Therefore there will be very little carbon build up on the manifold screen.So that

("] . the flow of exhaust gas will not be restricted i f by carbon build up on the screen. This maintenance can be extended from 18 months to 30 months.

Inspect crankshaft and connect rodAt

[n_s_pect oisj;ons and piston ringit in_spect cylinjer liners.

Insoect cylinder head mechanism and valve gear for proper oilino durina post _ maintenance idle run, with enoine at operatino temperature.

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- . REPORT NO.: 6993-2 REVISION: 2 DATE: 8/02/89 PAGE: 9 OF 17 I i Comments:

The above maintenance is scheduled every 2000 hours0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br /> of operation for an industrial engine.

The ir.spection of the crankshaft and connecting rod is done visually after removing thetrankcase cover doors. Look for signs of j h heat distress and babbitt at the edges of the j bearings.

1 The piston and piston ring can be visually inspected after removing the air box cover, through the liner ports for scuffing of the piston and worn or br oken rings. Improcer seating of the rings can cause the crar.kcase pressure to increase because of blow-by. If i there is no increasing trend of crankcase pressure, the piston rings are seated properly.

- The liner can also be inspected through the liner ports, inspection is for scuffing. Any evidence of water may indicate a crack in the

1. liner or cylinder head. This would be detected when the unit is " blown down" prior to each test start when the cylinder blowdown valve is open and engine is cranked over.

The cylinder head mechanism can be viewed for

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proper oil flow by raising the cover enough to view the meenknism while the engine is at iole speed during the engine shut down period.

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Based aper- previous experience at Davis Bessa and the limited expectuo hours of operation e , during the 30 month period, this maintenance o can be extended from 19 montns.

".f Check 1g91 anjector timino.

'i Chpgh._fgel iniezq, tor ra c k ,lgf3qf h with eng_ine G.91Au i

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REPORT NO. 6993-2

. '.- REVISION: 2 DATE: 8/02/89 p PAGE: 10 OF 17 ff sq

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w-Comments:

The injector timing and rack length should not change for the limited hours of operation during the 30 month period. Trending the cylinder exhaust gas temperature over'a period of_ time will provide verification that no changes have occurred.

This maintenance can be extended from 18 months to 30 months.

Inspect and clean turbocharger oil filter check valve.

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6993-2 4

, ,1 '.. REVISION: 2 DATE: 8/02/89' PAGE: 11 OF 17 ps

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V Comment '

Only filtered' lube oil passes through the turbocharger oil filter check valve. The valve should remain clean. This maintenance can be extended from 18 months to 30 months.

Replace flexible coyplinos on all oumos ontv i f_

e_x_c es s i ve l y . wo rn . _ Cfle_gk cou o_1_in as f or wear 2 Check all pump seal _s and bearinas. lubricate pumps as reauired.

Comments:

During monthly operation of diesel generator.

Jacket Water Pump:

Visually check the engine jacket water pump seals and the inlet pipe coupling for signs of water leakage. No lubrication is requir ed.

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\ss Lube Oil Scavenging Pumps and Fuel Oil Pump:

There is an oil seal at one scavenging pump shaft that drives the fuel oil pumps.

Visually check thiF area for signs of lube oil leakage. No lubrication is required.

Fuel Oil Pump (Engit.e Driven):

When the diesel is not in oper ation , check the condition of the flexi ble coupling drive on a trimonthly schedule. Note any signs of excessive er progressive wear, Vist ally inspect for fuel leakage around the shaft is t the housing.

Visually chack the flexible pipe connection fcr oil lea?.5,. No l u ori c a ti o.1 is r? quired.

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Pis'on Cooling and Pressurrs Pump:

Visually c her;k the joint ot Lt.e gasketed and place for lube oil leakage.

There are no flexible piping connections. No lubrication is required.

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REPORT NO.'s 6993-2 grg REVISIONS-p ,( p ,-- <

2 DATE: O/02/E9

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ltip_tg f_D_1ven f Fue1 011 Pump

-Motor Driven Circulating Lube Oil Pumo (6_GPM)

, Motor-Driven Turbo-Soak Back Pumo (3 GPM)

.3 Comments:

q Visually. check- the. purr

ps for- oil leakage.

-If motors have means to. add oil to the ~

. bearings, add oil every three months.

Every six-months: stop motors to check the-7, . flexible coupling for wear. Replace only if V ~ Worn.

Clean sludse out of enoine sumo. insoeet and

.. .plean air box drains crankcase.

~ Comments:

The monthly analysis of the lube oil for s oxidation'should be trended. If xidation shows no significant increase,- tht' sludge is

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' not being 1ormed.

?% ) _. I During operation, the air box drain lines should be cracked open. The amount of blow-

- down' collected should be noted. .I f the trend

s. hows a significant increase with. time, an inspection is warranted.

The' crankcase inspection may be extended for 30 months.,if the lube oil sample trending does not show significant increases in tin or lead, If so, a visual inspection of the main and connecting rnd bearings should be done, looking 4 i for tell tale babbitt at the ends of the bearing shells.

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REPORT NO. 6993-2

,.;. ,, , REVISION: 2 i

DATE: 8/02/89 PAGE: 13 OF'17

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]I Generator -

Clean'and visually inspect cenerator.

Comment:

Extend to 30 months.

Check brush tension.

Comments-Note if sparking at slip rings when

-diesel generator is tested. If oper-ation is-free of sparking, extend 30 months.

Clean all air passaces.

The engine room _is clean and Comment: no excessive contamination of the air passages through the

. generator should occur-EXTEND

[~~'i. TO 30 MONTHS.

Y.Y Reverse polarity of brushes (swap leads on brush holders [._

Comment:

Extend 30 months.

Check cenerator air cap.,

o Comment:

Extend 30 months.

EleXstance check SCRs and ret _Q,r_?L._

Comments Extend 30 mor-ths.

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s-4 REPORT NO. 6993-2 3,pi, = REVISION: 2 P DATE: 8/02/89 k PAGE: 14 OF 17 p

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[ v' Check oil rino for freedom of movementu

. Comment:

When engine is tested monthly check by feel for excessive bearing tempera-ture.

Control -

Calibrate _Alnce Pyrometer (cold end adiustment).

Comment:

Extend 30 months.

Clean' carbon deposits off of exhaus1 hermocou_p_les.

Comment:

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/  ; If trending thermocouple reading shows

_/ no significant changes with time, extend 30 months.

Clean. air filters an vents of elec1rical_

gontrol cabinets.

Comment:

Replace filters on an annual basis.

J_n_spp_c_t_ vo l t a c e r e_qu i a t o r s , r e_l a_y s t and contactors.

Comment:

If systems ind:cate normal operation, extend 30 months.

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REPORT NO.s 6993-2

- q ?, REVISION: 2 ,

E DATE: 8/02/89 PAGE: 15 OF 17

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Comment:

Extend 30 months.

Visually check electrical connections in control cabine_ts for tightness. Clean cabinets. Spot check condition of electrical contacts.

Check conduit fittinos and straps for ti,ghtnesst Loop check / calibrate annunciator and enoine shutdown devices.

P_EL_20145(46). PSL 20147(48). PSL 201492501 TSH 20153(54). PSH 20179(80). TSH 201511521 PSL 1098(96L PSL 515.8(601, PSL_5159(All TSL 21055(56Ja PSH 20143(441 Check DC fuel oil pump motor brushes and commutators.

(~N Locp check / calibrate enoine speed switches and

( ,) . indicators: ST 6221. SI 6222A. SI 6222 (ST 6231. SI 6232A. SI 6232).

Comment:

Trending during periodic monthly tests should show consistent results. This would verify that relaying etc. are working correctly. If results are consistent, extend to 30 months.

Attachment _3: Diesel Generator Maintenance Schedule (cont.)

18 M tnth t cont ,_1 Fuel Oil -

Chance all fuel oil filters.

, -s Comment t

Extend 30 months.

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' j.i ' **- REPORT NO.2 ~ 6993-2

.J,'* . REVISION: 2 DATE: 8/02/89 PAGE: 16 OF 17

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..q.) Clean fuel oil strainer.

Comment:

. Extend.30 months.

Engine Air -

Drain air intake oil bath cleaner. clean sumo e.nJ;L_r_p_f_i_1 1 with clean pil 2 Comment:

Extend 30 months unless air box pressure trends upwsrd.

Jacket Water -

Inspect and pressure test ex_pansion tank c a p_,_

replace if required.

Comment:

Extend 30 months.

(~% Insoe_ct e_xpansion tank filler neck for damage 2 A

Comment:

Extend 30 months.

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' REPORT NO.t 6993-2 REVISIONS. 2  !

DATE: 8/02/89 PAGE: 17 OF'17 .

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Check toroue of flexikJe ofDe couplino UQ_Lt_s2 Comment:

On an annual basis.

Governor -

L_u_tse f ca t e linkace and moving oarts.

T,,,o r_qp_e_ gov e rn o r friction clutch locknut while_

ho l d i_n_g_sp_eed settina knob to 4 to S lb-in. 11 locknut wa_s_ loo _se, contact Maintenance Engineer.

Comment:

Lubricate at 18 months.' Extend torque to 30 months.

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l L___.___. _- . __