ML20246K220

Part 21 Rept Re EMD Air Start Motors/Ingersoll Rand 150 Bmp Model D.Initially Reported on 890404.Problem Not Considered 10CFR21 Finding by Div Based on Encl Investigation Rept & Corrective Actions Taken by Power Sys Div.Matter Closed

ML20246K220
Person / Time
Site:	Browns Ferry
Issue date:	05/02/1989
From:	Kulchak R MORRISON-KNUDSEN CO., INC.
To:	Murley T Office of Nuclear Reactor Regulation
References
REF-PT21-89, REF-PT21-89-072-000 PT21-89-072-000, PT21-89-72, NUDOCS 8905180005
Download: ML20246K220 (18)

Text

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, L .'. , 4-MORRISON KNUDSEN CORPORATION

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.2 May 1989 Mr. Thomas Murley, Director Office of Nuclear Reactor Regulation 11555 Rockwell Pike Rockwell, Maryland 20852 q

Subject:

. Potential 10CFR21 Finding EMD Air Start Motors /Ingersoll Rand 150 BMP Model D

Reference:

Initial Letter Dated 4 April 1989 S/N 10CFR21-89-1

Dear Sir,

Reference is: made to our-letter S/N 10CFR21-89-1 dated 4 April 1989 ad-

. vising you of a potential 10CFR21 finding 'regarding Air Start Motors (see original letter attached). Enclosed'is our report that resulted from our-investigation into the potential 10CFR21 finding as well . as a . list of'

- 0wners that were notified of the potential problem and the recommended corrective action.

Based' on 'our report and the corrective actions taken by Power Systems Division do not consider:this problem to be a 10CFR21 finding and consider

~

the matter closed.

Very truly yours, k

R. D. Kulchak Director-Quality Assurance

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E9'O5280005 8905O2 ADOCK 05000259 (Y gDR PDR gif- p$u RDK:ed19 l- Enclosures cc: F. M. Adams H. W. Falter  !

J. G. Fearon V. Mitchell gg[1 M. Sharpe \  ;

File I L

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i MORRISON KNUDSEN CORPORATION HO $A.83707 4' April 1989 S/N 10CFR21-89-1 Ref. 10CFR21-0045 -

l -l Mr. Thomas Murley Director - Office of Nuclear Reactor Regulation 11555 Rockwell Pike Rockwell, Maryland 20852

Subject:

. Potential 10CFR21 Finding EMD Air Start Motor - Ingersoll Rand 150 BMP Model D for Emergency Power Generator ,

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Dear Sir,

I have been advised by 'our Power Systems Division of a potential 10CFR21 Finding regarding EMD Air Start Motors - Ingersoll Rand 150 BMP Model D furnished to the. Tennessee Valley Authority as spare parts for the Emergency Power Generators. These items were returned from stores and had not been installed on -the Emergency Power Generators.

We are investigating the problem and will provide additional.information as it becomes available.

Very truly yours,i

k. $b M R. D. Kulchak Director - Quality Assurance RDK89:ed6 cc: F. M. Adams H. W. Falter /

J. G. Fearon Mitchell V.

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i M. ' Sharpe /1 File g -

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Director of 9.A. Philadelphia Electric Company GPU Nuclear 2301 Market St.

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Maine )ankee Atesic Power Co. Cessor, wealth Edison Coapany Edison Drive P.O. Box 767 _

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April 28,'1989 1

10CFR21 Reporting of Defects and Non-Compliance i

COMPONENT - air start motors used to start the EMD-645E4 Diesel Generator

[ units aoplied as standby oower

\ Sucolles for Nuclear Power Generatina Stations.

gent e 88 sass,,

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,,4e s s a s it ti"'g# Manager l

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PAGE 1 1.0

SUMMARY

1.0 FIG. 1, FIG 2 2.0 SUBJECT

. 2 .1 OCCURRENCE 2.2 MK/PSD RECEIPT INSPECTION 3.0 DISCUSSION 3.1 MANUFACTURER - INGERS;LL-RAND 4.0 INVESTIGATION

[ 5.0 CCNCLUSION 6.0 RECOMMENDED CORRECTIVE ACTION 7.0 NOTIFICATION l

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a__--___ - _ _. -_ i

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PAGE 2 1.0 Summary 1.1 Nine out of sixteen air start motors that were rebuilt by MK/PSD for the TVA Browns Ferry l Nuclear Plant were-returned because the starter pinion could not be rotated by hand.

1.2 Inspection at MK/PSD revealed that only four of.the nine starter motors had pinions that could not be. I rotated.

1.3 MK/PSD disassembled the motors for which the pinion could not be rotated and discovered that the cause was starter vanes which were too long.  ;

1.4 Investigation revealed that the vanes are of a plastic material that can absorb moisture from humidity and as it absorbed moisture, the vanes expanded in all dimensions including length. The growth was enough so that the vanes pushed hard against the air motor rear and forward end plates effectively preventing rotation of the air motor rotor. Moisture inside the air motor was the primary cause of the defect.

1.5 Ref. Fig. 1 - Cross section of the air motor assembly Fig. 2 - Exploded view of the air motor-O

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SUBJECT:

Rebuilt air start ~ motors for the LMD 645E4 Generator. The air start motors are EMD

~( P/N 8377435 and 8367694, Ingersoll-Rand

'( ') 150BMP Air Starter Model D, Models D89RH-46 and D89LH-50.

2.1 OCCURENCE

Power Systems Division, Morrison Knudsen Co. Inc. rebuilt nine air start motors for the TVA Browns Ferry Nuclear Plant. TV4 returned the nine starters out of a total of 16 starters to MK/PSD.because the starter motor pinions did not rotate when an attempt was made to rotate them by hand. ,i l

2.2 MK/PSD RECEIPT INSPECTION:

MK/PSD received the returned motors and checked them with the following results:

PSD Factory Test Date (a) Two starters - pinion rotated freely by hand. Ser. No. 78263 9/26/88 Ser. No. 13786 9/26/88 (b) Three starters - needed a little air pressure to break free and then the pinions turned freely by hand.

/~~N Ser. No. 80453 8/31/88

(,,) Ser. No. 78283 8/31/88 Ser. No. 13794 8/31/88 (c) Four air start motors - pinion would not turn even with application of air.

Ser. No. 50338 9/26/88 Ser. No. 13791 8/31/88 Ser. No. 13816 9/26/88 Ser. No. 78289 8/31/88

3.0 DISCUSSION

The air motors had been rebuilt per MK/PSD procedure RCP-102 and were tested for functional operation by means of compressed air before shipment to customer. All start motors tested operated correctly.

3.1 MANUFACTURER Innersoll-Rand states that the motor pinions should rotate freely by hand. Sometimes the vane l is positioned in the rotor such that the pinion cannot be moved by hand because of the high gear ratio in the drive from the rotor to the pinion. Compressed air will break this loose and then the pinion

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s should rotate freely. This is an acceptable procedure.

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(~% - 4 ks PAGE 6 I

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' INVESTIGATION - MK/PSD ACTION '

4.i One of the air start motors was disassembled in stages to determine what caused the motor pinion to j am.

It was discovered that when the air inlet housing cover bc1ts were loosened, the pinion .

rotated freely and when the bolts were I tightened, the pinion j ammed .

The end surfaces of each vane was blued. The motor was reassembled and all bolts tightened.

The pinion would not turn. The motor was disassembled and it was found that the blueing on the end faces of the vanes made a clear distinct imprint on the rear and front end plate surfaces facing the rotor.

The cylinder, into which the rotor and vanes are placed, was measured and was in tolerance.

The length of the five vanes were measured and were found to be between 4.991 and 5.nn2 inches 7w long. The correct length should be 4.973 (+/-)

( j .001 long.

Considerable moisture was also noted.

4.2 This increase in length was discussed with Mr. S. Carrington of Ingersoll-Rand. The vanes are made of a plastic material that expands when exposed to moisture (humidity). All vanes are sample tested from production lots and subj ected to a high humidity test (85%RH) for a period of time. The limiting acceptable dimension shall not exceed 5.000" in length.

4.3 Two expanded vanes were selected and placed into an oven heated 254 degrees Fah from 4-7-89 to 4-14-89. The vanes then were removed and allowed to cool down enough to hardle, but while still hot were again measured. The vanes were 5.000" long. After the vanes cooled down, they were again measured.

After Oven Before Oven Cooled Down Cooled Down i

Vane #2F 4.958" 4.989" I Vane #5F 4.972" 4.995" The oven dried vanes showed a significant reduction in length.

J PAGE 7 i

'l i

7- 4. 4 - MK/PSD then disassembled one air motor -<

( ). (SN 78263) in which the pinion rotated freely l V and checked the length of the vanas.

The vanes measured:

Vane Length

]

1 4.9935 l 2 4.990 3 4.990 4 4.989  !

5 4.994 The internals of the motor showed signs of moisture.

4.5 MK/PSD then disassembled one motor in which the pinion did not turn until compressed air was applied. The pinion then turned freely by hand.

Vane Length 1 4.987 2 4.991 2 3 4.990 l

( 4 4.891

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5 4.991 l Both motors had clearance bs.- tween the end t plates and the vanes. The end plates are separated by the cylinder whien is 5.000 +000

-001 long. .!

4.6 Measurement of new vanes taken from thro manufacturers starter rebuild kit:

Set #1 Set #2 4.9775 4.983 4.976 4.985 4.9765 4.984 4.976 4.982 4.9785 4.981 In the area of the rotor and the vanes.

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%> PAGE 8 S.0 COUCLUSION: All nine motors were MK/PSD shop tested with compressed air and functioned correctly.

Moisture entered the rotor and vane area either )

during the factory test or in storage. The motors were shipped from MK/PSD in August 1988 '

and September 1988. The vanes do not immediately-expand due to high humidity immediately in one step, but expand gradually  !

over a long period. It was over this storage period that the vanes of four of the nine ,

motors expanded enough to jam the starter pinion.

Therefore, the cause of this defect is moisture inside the air motor assembly that caused the ,

vanes to expand. l This is the first recorded incidence of this f occurrence. These motors are on all EMD Model 64SE4 diesels. Some installations have air r^g dryers for the starting air system and others

( ,) do not. There has, however, been no reported instances that MK/PSD is aware of where any failure to start was a result of expanded vanes. The starting reliability of EMD systems has been high. Apparently once the motors are installed and tested on a monthly schedule, there doesn't appear to be any problem.

Therefore, one could conclude the defect is limited to air motore stored over a period of time. If a jammed air motor were installed on the engine, it would not function on the check test. Since the defect would be found before putting the engine into service, it would not i have been called upon to do a safety related function.  ;

6.0 RECOMMENDED CORRECTIVE ACTION t

i- Advise owners of EMD 64SE4 Diesels in Nuclear Service of this occurrence.

. Review MK/PSD rebuild procedure to assure that the length of vares used are within acceptable limits and that no moisture is

() 3-introduced Anto the air motor during test.

Review MK/PSD procedure to address packaging for long term storage.

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'N_/ PAGE 9 4- Review packaging of vanes in rebuilt kit.

7.0 NOTIFICATION Advise all people we supplied motors for as follows:

(a) For air motors that are installed and working, no action is necessary because the vanes have not expanded.

(b) For motors in stock or storage, rotate the pinion by hand. If it rotates, it is acceptable.

(c) If the pinion does not rotate, apply approximately 50 psi air to the air start motor. If it does not rotate, return the air motor to MK/PSD for corractive action.

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