ML20246J040
| ML20246J040 | |
| Person / Time | |
|---|---|
| Issue date: | 08/10/1989 |
| From: | Cwalina G, Haass W Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20246J011 | List: |
| References | |
| REF-QA-99900702 NUDOCS 8909050023 | |
| Download: ML20246J040 (15) | |
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- ORGANIZATION: MORRISON-KNUDSEN COMPANY, INC.
- ROCKY MOUNT, NORTH CAROLINA 1
REPORT INSPECTION INSPECTION l
N0.: 99900702/89-01 DATE: June 6-8, 1989 ON-SITE HOURS: 63 CORRESP0!iDENCE ADDRESS: Morrison-Knudsen Company, Inc.
Power Systems Division l
Mr. M. Vann Mitchell, Quality Assurance Manager 101 Gelo Road Rocky Mount, North Carolina 27802 ORGAf;IZATIONAL CONTACT: Mr. M. Vann Mitchell, Quclity Assurance Manager TELEPHONE NUMBER: 919-977-2720 NUCLEAR INDUSTRY ACTIVITY:. Morrison-Knudsen/PSD is the only world-wide distributor of sufety-related spare and replacement parts for GM/EMD diesel engines used in nuclear plants. The nuclear-related activity of the vendor comprises approximately 50% of its current business volume.
ASSIGNED INSPECTOR: - /* [
W. P. Haass, Sped aTProjects Section (SP5) Date OTHERINSPECTOR(S): E. B. Tomlinsoa nPD4 H. Wescott, SPS'
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APPROVED CY: ~ ~ ~ ~
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'G.Cwalina, Chief,SF3p'endoiInspectioneranen LTtT
- _. r INSPECTION BASES AND SC0FE:
A. BASES: 10 CFR Part 50/ Appendix B and 10 CFR Part 21 B. SCOPE: Review procedures and records of implenientation for the classi-tication and dedication of spare and replacement parts for safety related service in emergency dietel generators, and review the analysis and corrective action taken on recent diesel engine parts supply and events at licensed facilities.
PLANT SITE APPLICABILITY: All nuclear plants with emergency diesel generators manufactured by GM/EMD.
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W ORGANIZATION: MC1RISDN-KNUDSEE COMPANY, INCORPORATED
. ROCKY MOUNT, NORTH CAROLINA'
' REPORT INSPECTION NO.: ,99900702/89-01 RESDLTS: PAGE 2 of 15 A. VIOLATIONS:
None.
B. NONCONFORMANCES:
None.
C. UNRESOLVED ITEMS,:
As noted in Section D.3. below, MK/PSD has not been able to'obtain the necessary information from some of its suppliers of items ultimately used ir safety-related applications to permit the preparation of dedication reports. This deficiency should be resolved as soon as practicable. (89-01-01)
D. OTHER FINDINGS AND COMMENTS:
- 1. Backgrcund:
In earl 1988, Morrison-Knudsen Company, Power Systems Divisior.
(NK/PS was authorizec by General Motors, Electro-Motive Division (GM/EMD to be the sole distributor of.GM/EMD diesel engines and their spare and replacement parts, both safety-re' sated and nonsafety-relcted, for the domestic and foreign nuclear industry.
Since GM/EMD provides only commercial grade engines and parts, tiK/PSD has assumed the responsibility for identifying those spare and replacement partr that are classified as safety-related, end for properly dedicating the parts for safety-reltted service.
MK/PSD also provides maintenance and overhaul services as requested.
- 2. Classification System:
Over the past year or so, MK/PSD has performed failure modes and effects analyses (FMEAs) for all parts provided by or through GM/EMD for diesel generator sets manufactured by GM/EMD. -The purpose of the FMEAs was to determine whether the failure of the diesel engine parts would prevent the diesel engine from performing its intended safety function. All parts that fall into this category are considered to be safety-related and to require the proper qualification for this type of service. It was ' determined that MK/PSD took a conservative approach to the classification of parts as evidenced by the fact that only about 20 parts out of a total population of 987 were assigned a nonsafety-related classification. Safety-related parts cover a wide spectrum from such major parts as crankshafts, pistons, and connect- 4 ing rods to lesser parts such as pumps, fuel injertors, gaskets and )
bolts. The inspectors reviewed several FMEAs and concluded that the i a
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4 ORGAH12ATION: MORRISON-KNUDSEN COMPANY INCORPORATED ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION d NO.: 99900702/89-01 RESULTS: PAGE 3 of 15 analyses were properly conservative.
- 3. Dedia tion Program:
MK/PSD has established a dedication program to ensure that commercial grade parts, procured from GM/EMD as the manufacturer, are properly qualified for safety-related applications. Implementation of the program involves the identification of the critical characteristics of the part and the performance of the necessary inspections, test-ing, and/or analyses to determine whether the part is qualified. The critical characteristics include such items as dimensional correct-
- ness, seismic qualification, environmental qualification, radiation exposure capability, service life, and overall quality of manufac-ture.
To establish a basis for the qualification of the parts, MK/PSD obtained site-specific criteria for each nuclear plant for which GM/
EMD emergency diesel generator sets are installed. The site-specific criteria include seismic response data, potentini radiation exposure, and the normal operatbg environment. The most stringent condition i 4 for each of these criteria was selected as the basis for c,ualsfiu-(
tioso hence, the qualification of the part becnmes generic. In addition, Mr/PSD alsn evaluctes insanice life and shelf or storege life of the parts.
The qualification of diesel engine parts is established by MK/EMD as follows: ,
o Seismic capability: The capability of a part to withstand the effects of the worst case seismic event is demonstrated by actual shake testing, or by analysis. In general, actual shake testing is utilized for smaller parts such as relays and switches, and analysis is applied to larger parts such as pistons, bearings, and pumps. The inspectors reviewed documentation addressing both methods of seismic qualification and found thern acceptable.
o Environn. ental: In all cases, diesel generators are located in a mild environment. Therefore, qualification testing to LOCA condi-tions is not required. The capability of parts to operate in the worst case mild environment is established by laboratory test.
This testing is applicable primarily to electrical parts; mechani-cal parts have been shown to be capable of withstanding their operating environment over the years through extensive operational experience. The inspectors found the methods for establishing environmental qualification to be acceptable.
l o Radiation: MK/PSD uses its own manual "fluelear Environmental
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. ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION HO.: 99900702/89-01 RESULTS: PAGE 4 of 15 Ovalification Program for MK/PSD" to determine the effect of radi-ation on the most sensitive material / subassembly in a part. As stated above, the radiation exposure level used is the worst case condition at all the nuclear plants involved. The MK/PSD manual was developed by Corporate Consulting and Development Co., Ltd.
The inspectors reviewed this methodology and found it acceptable.
o Service Life: MK/PSD establishes a service life for parts as an aid in determining maintenance requirements. For electrical parts, MK/PSD bases service life on the cyclic capability as stated by vendors. This is a change from past practice wherein service life was based on the Arrhenious formula. The inspectors concur that the cyclic methodology is more representative of actual service conditions, and therefore preferable to the formula methodology which is consistent with the requirements of IEEE-3?3-1985. The service life of mechanical parts, in gentral, is stated by the vendor in terms of engine operating hcurs. No er.trepola-tion of diesel generatcr operating hours into operational cycles is required, The inspeptorc found tha NK/PSD methodology for determining service lh e to be acceptable. l o Shelf Life: MK/PSD establishes the shelf life of parts based on the manufacturer's recommendation, cr by analysis. In the latter r case, shelf life is based on the shortest life expectancy of any material / subassembly in the part. In ger;eral, shelf life is applicable to electrical items, gaskets, seals, etc; most mechani-cal parts have an indefinite shelf life. MK/PSD also provides the storage requirements to ensure optimum shelf life. The inspectors found this portion of the MK/PSD cedication program to be accep-table.
In augnenting GM/EMD's and other vendor's quality assurance programs j to ensure the quality of diesel engine parts, MK/PSD establishes the '
critical characteristics required to be checked for safety-related service. To accomplish the checking, MK/PSD has obtained detailed J drawings and specifications for all of the diesel engine parts from GM/EMD. The critical characteristics vary as a function of the part's significance to safety and the complexity of manufacture.
The following provide some examples of the critical characteristics checked.
o Gas kets: dimensions, visible damage, and surface condition as it impacts sealing capability, o Fuel filters: dirensions, and physical canage. l
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ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION NO.: 99900702/89-01 RESULTS: PAGE 5 of 15 l
o Pumps: binding of internals, dimensions that can be checked with-out disassembly, and hydrotesting. Pumps are not tested 3 for functional perforniance since their operational t capability would be verified at the time of installation. j o -Piston Pins: Dimensions and physical damage. Verification of material and surface finish is not performed by MK/
PSD; reliance is placed on the GM/EMD quality assurance program to attest to these aspects.
For some of the parts, none of the critical characteristics are veri-
. fied by MK/PSD upon receipt. Rather, due to the complexity of their manufacture and assembly, MK/PSD conducts inspections and audits at the manuf acturer's facility. Some examples of this type of dedica-tion include:
o Turbocharger: MK/PSD reviews the GM/EMD n.anufdcturing and assem-bly precedures, inspects parts es they are produc-ed, and witnesses shop assembly and final testing <
for each unit. No additional inspections (other than for shipping damage) or tests are performed by MK/PSD at receipt.
o Connecting Rods: Forgings are furnished by Kropp Forge and finish machined by GM/EMD. MK/PSD audits the GM/EMD inspections of the connecting rods during manu-facture to assure that the critical characteris-tics related to material and surface finish are adequately verified. No additional checks are made by MK/PSD upon receipt.
O Crankshafts: Finished products are provided to GM/END by an inde-pendent vendor. MK/PSD witnesses all NDE activities including those for the forging, if applicable, and all final dimensional checks and surface finish checks. These activities are performed at the vendor's facility. If requested by a licensee, M4/
PSD will conduct independent NDEs of the forging or finished Troduct. However, no additional inspec-tions are performed by MK/PSD after receipt.
A dedication report has been prepared for essentially all safety-related parts; although approximately 800 reports have been prepared to date, some remain to be prepared since the program is still under development. The inspectors reviewed several dedication reports; they included a brief section on the FMEA results, a listing of
ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION NO.: 99900702/89-01 RESULTS: PAGE 6 of 15 the critical characteristics to be verified by MK/PSD, the seismic qualification data, and data relating to service life, radiation limits, operating conditions, and shelf life. The dedication reports are maintained on file at the MK/PSD offices and are available for review by customers. A copy of the dedication report is not'provided with the purchase of a safety-related part. Examples of dedication reports reviewed by the inspectors are:
- Flexible Connection Mounting Gasket, P/N 9570751, 4/26/89,Rev 1
- Bolt,1/2-20x2, Hex. Head, Expansion Joint & Adapter Mounting, P/N 8287827, 3/16/89
- Fuel Oil Manifold Mounting Gasket, P/N 9570770, 5/16/09, Rev 1
- Governor Oil Line Mounting Gasket, P/N 9570732, 5/9/89, Rev 1
- Dowel, Camshaft Drive End Counterweight, P/N 8045884, 1/24/89
- Handhole Cover to Crankcase Gasket, P/N 8060601,2/3/89 Preparation cf a dedication report requires detailed cesign and manu-facturing information on the part from GM/EMD. Through a cor.tractual i arrangement, the required information is made available to MK/PSD.
Approximately 98% of the parts supply activity by MK/PSD involves GM/
EMD parts. Of the remaining 2% that come from other vendors, it was estimated that about 5% (or 0.1% of the total) will not provide the necessary information for the preparation of a dedication report.
This issue has been identified as in unresolved item (see page 2, 89-01-01).
The inspectors concluded that the MK/PSD dedication program appears to be an effective step forward in assuring the acceptability of spare and replacement parts for use in emergency diesel generators at nuclear power plants. It should be noted, however, that the program is only about one year old ano is still developing. An area of improvement indicated by the inspectors was that the correctness of those critical characteristics for which reliance is placed on GM/EMD without verification by MK/PSD (e.g., surface finish and material
- correctness) should be more accurately attested to by MK/PSD by in-creasing their audits and source inspections at the GM/EMD manufac-turing facilities (See Section 6 of this report). Further, the listing of critical characteristics should be made complete by in-l cluding the characteristics for which reliance is placed on GM/EMD rather than iust those verified by MK/PSD. Also, it is recommended 3
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ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED ROCKY MOUNT, NORTH CAR 01.INA REPORT INSPECTION NO.: 99900702/89-01 RESULTS: PAGE 7 of 15 that the dedication reports include any pertinent operating experi-ences reported in Part 21 and licensee eve.nt reports in the section entitled "Part Operating Experience".
- 4. Interfaces With Licensees:
As a supplier of safety-related parts, MK/PSD has assumed respon-sibility for the implementation of 10 CFR Part 21. In the event a manufacturing or design defect in a part is identified with potential generic implications, MK/PSD will inform all licensees known to possess the affected part regarding the problem (See
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Sectirn 8 of this report). This action is taken for all safety-related parts whether or not MK/PSD dedicates the part.
NK/PSD distributes data to licensees on product improvements and re-commended maintenance practices developed by GM/EMD. These are .I identified as Power Pointers and Maintenance Instructions. MK/PSD alsc develops and distributes its own maintenance instructions to licensees based on its own experience. Recent examples of MK/PSD-issued maintenance instructions (MI) include MI-058901 which informs the nuclear industry that certain relays are nearing the end of their qualified life, and MI-058902 which clarifies the applicability and use of repair kits for air start motors. This information is distri-buted for the purpose of assisting licensees in the maintenance of their emergency diesel engines for optimum reliability. The MK/PSD procedure that governs this activity is:
Issue and Control of EMD and MK/PSD Maintenance Instructions /
Power Pointers", EP-814, Rev 0, 5/26/89 As noted in Section 8 below, MK/PSD maintains a complete listing of all licensees and the type of diesel engine owned and parts supplied.
This information permits MK/PSD to verify that parts ordered by a licensee are the correct ones.
In addition to supplying parts, MK/PSD is the authorized GM/EMD ser-vice agent for the nuclear industry. MK/PSD provides service person-nel to assist licensees with maintenance activities on diesel genera-tor units. MK/PSD personnel are also available for investigation and evaluation of diesel generator operating events.
- 5. Morrison-Knudsen Quality Assurance Program:
The inspectors reviewec the vendor's " Quality Assurance Manual",
second edition, approved on October 19, 1988. The manual addresses each of the eighteen criteria of 10 CFR Part 50, Appendix B, and, in Y-
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ORGANIZATION: MORRIS 0N-KNUDSEN COMPANY, INCORPORATED
- l. ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION HO.: 99900702/89-01 RESULTS: PAGE 8 of 15 the brief time available for the inspectors to review the manual, l eppeared to be consistent with regulatory requirements. The QA {
manual also contained the ASME Certificates of Authorization H-2370 l l
for Class 3 piping and NPT-2371 for Class 3 piping subassemblies and l component supports. These certificates were authorized on November 8, 1988 and expire en January 7,1992. The manual additionally I requires "For Nuclear Safety-Related Non-Code Items and Services" (
that welding procedures and welder and welding operators must reet all requirements of ASME Section IX. Procedures QAM-19 and QAM-20 and s i address the inspection of the Authorized Nuclearactivities, data Inspection reports,(ANIS)ymbol Supervisor stamping and the At,thorized Nuclear Inspector (ANI). The manual is supplemented by a series of procedures.
- 6. Audits of GM/EMD by Morrison-Knudsen: ;
1 The inspectcrs reviewed the two most recent audit reports of surveil- !
' lances performed by Morrison-Knudsen of the diesel engine manufactur-ing cperations at GM/EMD. The vendor's QA program requires an audit of its suppliers on a triannual frequency. Also reviewed were the qualification records of one of the Level III MK/PSD auditors invol-ved in the audits.
- The vendor's audit of GM/EMD on December 8-10, 1987 focused on the QA controls in the manufacturing process for connecting rods from the procurement of forgings (Kropp Forge) to the shipment of the finished product. A process document (traveler) is utilized to identify each step in the manufacturing procedure and each quality check to be porformed. The full pcpulation of rods is magnafluxed several times during the manufacturing process to assure a good quality forging and finished product. Other qual-ity checks include extensive receipt inspection, hardness and tensile testing, material analysis (SAE 4140H), and dimensional measurements. During receipt inspection, GM/EMD destructively tested five forgings out of the total population of 300.
No deficiencies were noted in the audit report.
- The vendor's audit of GM/EMD on March 7-10, 1989 focused on sever-el aspects of the QA program. It is planned to address other aspects of the QA program in subsequent audits. The findings were primarily in the areas of " Identification and Control of Materials, Parts and Components" and " Control of Special Process-es" and included:
- a. Lack of records availability for training and requalification of NDE examiners.
- ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION NO.: 99900702/89-01 RESULTS: PAGE 9 of 15
- b. Lack of follow-through on color-coding of subdivided parts from parent material.
- c. Observed lack of protection for records from theft and degradation (was not a requirement by GM/EMD).
- d. Observed need of traceability of measuring gauges to the inspected piece (also was not a requirement by GM/EMD).
GM/EMD's response to these findings was as follows:
- a. Employees will be retrained and decertified prior to July 1989.
- b. Training records will be improved.
- c. Personnel will be re-instructed to color-code subdivided material.
- d. Periodic audits of the quality measures will be performed.
- e. The need for cuality improvements based on the observations made will be evaluated.
Based on the above audit reports and responses from GM/EMD and on discussions with the vendor, the inspectors concluded that GM/EhD is definitely more responsive now to problems and corrective actions that it was in the past. It was further concluded that there is a clear need for the vendor to continue its auditing of GM/EMD since, as noted above, heavy reliance is placed on the inspections perform-ed by GM/EMD in certain areas to qualify the commercial grade items ,
for safety related service. The frequency of auditing is currently approximately annually; this frequency of auditing should not be reduced and perhaps should be increased depending on experience derived from the field. This area will be further reviewed during subsequent inspections.
The inspectors also reviewed the following GM/EMD documents relatert to quality assurance:
- " Targets for Excellence for GM Manufacturing Divisions and Out-side Suppliers of Production Material and Service Products",
dated June 1987. This document provides guidelines for quali-l fying suppliers for GM and requires continuous improvement of l the product.
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' ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED
, ROCKY MOUNT, NORTH CAROLINA 1
REPORT _ INSPECTION NO.: 99900702/89-01 RESULTS: PAGE 10 of 15
" Electro-Motive Product Assurance Manual", dated 8/10/88.
This docunent described the overall QA controls for EMD-manufacturing.
- 7. Delivery of Parts to the Customer:
As stated previously, MK/PSD has been designated hy GM/EMD as the sole distributor of spare and replacement parts for GM/EMD diesel engines and generators in the nuclear industry. Licensees must con-tact MK/PSD for all replacement parts end services. Licensees nay order replacement parts as safety-related, in which case the part is dedicated hy MK/PSD, or as corrercial grade. For the former case, MK/PSD provides a Certificate of Conformance (C0C) that attests to the performance of a dedication activity consistent with the committ-ments incluoed in the dedication report for the part. For the latter case, if the part is not safety-related, a C0C is provided that so states. However, for this case, if the part is seiety-related, a COC is provided that so states, with the added requirement that the part must be properly dedicated hy the purchaser to assure it is qualified for its intended application. In all cases, a COC is provided that clearly indicates the safety classification of the part and whether the dedication activity has been or remains to be perforaed. In no event is b dedication report sent to the licensee.
All safety-related diesel engine parts supplied to licensees by MK/PSD are subject to the provisions of 10 CFR Part 21 whether the par' are procured as safety-related or not. This requirement is alss indicated on the'C00.
- 8. Records:
!!K/PSD maintains a complete computerized listing of all customers and the type of diesel engine owned and parts supplied. This informa-tion permits the vendor to rapidly identify each owner that may be affected by an engine part with a generic problem. In addition, a file is maintained for each sales order that contains at a minimum the customer's purchase order, the purchase order to GM/EMD, results of inspections, results of the dedication process, and a copy of the certificate of conformance.
- 9. Audits of tiorrison-Knudsen hy Licensees:
The inspectors reviewed several reports of audits of MK/PSD prepared by licensees to determine the licensees' views of the classification l
and dedication programs established by the vendor. The results of these audits were generally as follows:
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ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED ROCKY tiOUNY, NORTH CAROLINA REPORT. INSPECTION NO.: .99900702/89-01 RESULTS: ,
PAGE 11 of 15
- Florida Power and Light Company, Audit 08.03.PSDNC.89.1 dated February 21-23,1989, identified five detailed findings and the lack of material verification as a deficiency in the dedication program.
- Sacranento Municipal Utilities District, Audit 89-V-003 dated February 1-3,1989, identified no negative findings.
- Commonwealth Edison Company, Audit QA-CI-890050 dated May 1989, was a review of the QA Manual only.
- Wisconsin Electric Power Company, Audit A-V-89-10 dated March 14-16, 1989, identified a need for dimensional tolerance information in the dedication reports.
- Northern States Power Company, Audit VHF 73501 dated December 16, 1988, retained Gilbert / Commonwealth Engineers and consultants to perfura the audit and one negative finding was identified.
- Cleveland Electric Illuminating Company, audit dated July 7, 1988, did a survey in the form of a questionnaire. The report described the vendor's system for dedicating parts and concluded that the vendor should be placed on the approved vendors list.
MK/PSD was generally responsive to the licensee findings.
- 10. Nonconformance Reports by Morrison-Knudsen:
An integral part of the MK/PSD dedication program is the inspection of parts to provide assurance that critical characteristics are met and that no shipping damage has been incurred. If HK/PSD determines that a defect exists in the part, a non-conformance report (NCR) is generated. The NCR describes the defect, and the part is returned to the vendor for a determination of the root cause of the defect and the corrective actions to be taken. Some examples of recent NCRs generated by MK/PSD are as follows:
o Cylinder head crab bolts: These bolts are used to secure the power packs to the engine crankcase. Several bolts in a shipment from GM/EMD were found to be of inadequate length during the dedication process. (It should be noted that dimensional checks by GM/EMD on bulk items may be on a sampling basis only which is consistent with a comercial grade product.) The cause was determined to be improper adjustment of the automatic machinery.
The cut-of-dimension bolts were in process of return to the manufacturer.
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ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED
. ROCKY MOUNT, NORTH CAROLINA REPORT INSPECTION NO.: 99900702/89-01 RESULTS: PAGE 12 of 15 o fuel oil filters: These filters are used to remove dirt and debris from fuel oil prior to the fuel oil entering the fuel sys-tem. The filters are of the screw on variety and MK/PSD found during the dedication process that the mating thread on the filter was incorrectly machined. The defective filters were to be returned to GM/EMD along with the NCR for disposition.
o Jacket water heat exchanger: This heat exchanger is used to remove engine heat by transferring it to the engine cooling water system. The heat exchanger is installed in the jacket water system using bolted, flanged connections. The heat exchanger was ordered by Niagara Mohawk Power Corporation and was rejected by the purchaser because the 0.010" TIR flatness requirement for the face of the two flanges was not met. In addition, this dimension-al requirement was not included as a critical characteristic in MK/PSD's dedication report. MK/PSD has coramitted to replace the heat exchanger with one that meets the interfacing dimensional requirer.ents and in the future not to ship any parts until the dedication report is complete and accepted by the customer. The cause of the flange trisalignnent prchlem was attributable to a manufacturing error.
MK/PSD indicated that approximately 50 NCRs have been generated to date in 1989. The rate of NCR generation has been increasing over the last several years. MK/PSD also indicated that GM/EMD has been quite responsive to the NCRs even though their nuclear related manufacturing activity is relatively small.
- 11. Recent Part 21 Events:
1 The following Part 21 reports of events involving deficiencies in parts supplied by GM/EMD through MK/PSD were reviewed. The results are as described below:
- a. EMD Air Start Motors /Ingersoll Rand 150 BMP Model D:
Out of sixteen air start motors that were rebuilt by MK/PSD for )
Browns Ferry, nine were returned because the starter pinion could not be rotated by hand. Further inspection by the vendor indicat-ed that only four could not be rotated. Disassembly of the motors revealed that the starter vanes on the rotor were too long. Con- i siderable moisture was noted in the notor internals. In discus- !
sions with Ingersoll-Rand personnel, it was learned that the vanes I
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' ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED L. ROCKY MOUNT, NORTH CAROLINA i
REPORT INSPECTION l NO.: 99900702/89-01 RESULTS: PAGE 13 of 15 are made of a plastic material that expands when exposed to moisture. This was confirmed by measuring the vanes, oven-heating them to dry the material, cooling, and remeasuring. The oven-dried vanes showed a significant reduction in length.
It was concluded that moisture had entered the rotor and vene area either during the factory test or in storage. The motors were shipped frora MK/PSD in 8-9/8B and over a period of several months in storage the vanes expanded 'ausing the rotors to jam. This was the first recorded incidence of this type. These motors have been used on all EMD Model 645E4 dieseis with some installations having air dryers for the starting air system and others not. It appears that once these notors are installed on the engine and tested on a monthly schedule, their reliability is high.
The corrective actions determined by the vendor are as follows:
- A letter dated 5/2/89 was sent to all owners advising them to check motors held in storage to determine their freedom to rotate. If the rotors are tighi, apply 5 psi air pressure; if the rotors are still tight, return the motors to MK/PSD for refurbishment. Installed motors need not be checked.
- Review the MK/PSD rebuild and test procedures to assure that the length of the vanes used are within acceptable limits and that no moisture is introduced into the air motor during test.
(MK/PSD has added a' dryer to the compressed air system in their test fa:ility.)
- Review the MK/PSD procedure to assure that proper packaging is provided for long term storage. Also, review the packaging of vanes included in rebuild kits.
- b. Failure of High-Yoltage Cable Insulation:
TVA reported that the insulation on the high-voltage cable to the potential transformer in two diesel generator exciter cubicles at the Watts Bar plant had deteriorated at the transformer termina-tions causing the cable to short to ground on one of the units. i In a Part 21 repcrt, TVA indicated that the causes of the problem were inadequate cable insulation thickness for the 6900-volt application, improper type of cable insulation n.aterial, and lack of stress relief at the termination (none of the cables was penciled). ]
MK/PSD indicated that the failed cables were requested from TVA, l
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.ORGAt;IZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED ROCKY NOUNT, NORTH CAROLINA REPORT INSPECTION NO.: 99900702/89-01 RESULTS: PAGE 14 of 15 but were informed that they had been discarded. Therefore, no analysis by the vendor was possible. Assembly of the cubicle is performed by MK/PSD including the installation of the cable runs.
The failure at Watts Bar was determined to be a unique occurrence since the vendor's procedure for cable preparation calls for penciling of the cable ends. To provide greater assurance, the vendor revised the procedure to utilize a special kit and tooling to accomplish the penciling. The TVA claim of inadequate cable insulation thickness and material was determined to be not valid by the vendor. The cable was a jumper-type cable designed for 8000 volt service. Since that time, the cable type has been
- changed to a control-type cable, but only because of product availability.
- c. Lack of Drilling of. Venturi Holes in Lubricator:
In a Part 21 report from MK/PSD dated January 27, 1986, the vendor made notification that the venturi hole had not been drilled in the lubricator on two assemblies for the diesel air starting motor at the Davis Besse plant. The blocked venturi holes would prevent lubricating oil from reaching the starting air passing to the air start motors. The lack of imbrication could cause rapid wear of the motor vanes and a starter motor malfunction, thereby prevent-ing an engine start.
The lubricator assemblies are manufactured and assembled by Norgren and installed on the diesel engine by MK/PSD. Analysis of this event resulted in the conclusion that the lack of drilled holes was a unique occurrence; no other occurrences of this nature have been reported previously.
The vendor notified all diesel engine owners that utilize this lubricator to verify that lubricating oil was being dripped into the starting air; this was to be done by observing a change in oil level in the sight glass as the air starting motor was operated.
For future deliveries of lubricators, the MK/PSD dedication pro-gram includes a test to assure lube oil drip-through.
The inspectors enncluded that the vendor had performed the necessary analysis of the above described Part 21 problems, determined and implemented proper corrective actions, and notified all af f ected owners. These Part 21 reports are considered to be resolved.
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- ORGANIZATION: MORRISON-KNUDSEN COMPANY, INCORPORATED ROCKY MOUNT, NORTH CAROLINA REPORT IHSPECTION NO.: 99900702/89-01 RESULTS: PAGE 15 of 15
- 12. Tour of Shop Facilities:
The inspectors toured the MK/PSD shop arez.s including diesel engine assembly and testing facilities, control cabinet assembly area, receiving inspection area, and parts storage area. It was noted that proper care was exercised to tag and separate safety related parts from others. However, in the area of assenbly of electrical control cabinets, improved separation of safety-related and nonsafety-related parts storage and assembly activities should be considered.
The tour also included observation of the MK/PSD training area for customer personnel ano a training class in session.
E. PERSONS CONTACTED:
The following MK/PSD personnel were contacted during this inspection:
- + Randall W. Fulp Dedication Engineer
- + Donald D. Galeazzi Engineering Manager
- + Francis P. Amend Equipment Qualification Supervisor
- + M. Vann Mitchell Division Quality Manager
- + Harry Falter Principal Engineer
- Milton Sharpe General Manager Thomas Bulluck Service Manoger
+ Michael Ring Manager, Support Services
+ Anne Whitaker Executive Secretary
+ T. J. Dunn Contracts I;anager
- indicates attendance at the entrance meeting
+ indicates attendance at the exit meeting i
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