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| {{#Wiki_filter:e i | | {{#Wiki_filter:}} |
| CPPA-39224 *
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| \
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| TEXAS UTILITIES GENERATING CO31PANY P. O. BOX 1002 GLEN ROSE. TEXAS 76'A3 June 7, 1984 Thomas A. Ippolito Comanche Peak Project Director Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, D.C. 20555
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| ==SUBJECT:==
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| COMANCHE PEAK STEAM ELECTRIC STATION (CPSES)
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| Docket Nos. 50-445 and 446 CPSES Unit 1 Train A Diesel Generator Inspection Results References : 1) CPSES Diesel Generator Requalification Program Plan, April 30, 1984
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| : 2) T.D.I. Diesel Generator Owners' Group Program Plan, March 2, 1984
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| ==Dear Mr. Ippolito:==
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| Texas Utilities, as established in Reference 1, is an active participant in the T.D.I. Diesel Generator Owners' Group and is firmly committed to the implementatfor at CPSES of the Owners' Groups' program (Reference 2) for requalification of T.D.I. diesel generators. The purpose of this document is to provide NRC with the results of the inspections performed on the CPSES Unit 1 train A diesel generator in accordance with the referenced programs.
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| The specific inspection findings and actions taken as a result of these in-spections are described in the enclosure to this letter. A description of the procedural aspects of this effort is provided below.
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| The CPSES Unit 1 diesel generators were disassembled in February and March of 1984 for the original purpose of replacing the furnished Type AH pistons with new Type AE pistons. Due to the extent of the Owners' Group's antici-pated inspections, however, it was decided to fully disassemble the two engines to permit detailed examination. These inspections are now complete on the train A engine and are nearing completion on the train B engine. The train A engine has been reassembled, and is currently undergoing reperformance of the original, NRC-required diesel generator preoperational test program along with additional testing as recommended by the Owners' Group.
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| The train A engine inspections were performed in accordance with component inspection plans developed by the Owners' Group specifically for CPSES. These inspection plans covered the 16 generic problem components associated with T.D.I. diesel generators, except for on-engine wiring and fuel injection lines, as well as many other engine omponents which the Owners' Group technical staff l designated for inspection. ine on-engine wiring for the CPSES diesel generators
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| ~
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| was replaced earlier with fully qualified cable and the fuel injection lines are being replaced with shielded tubing. Therefore, no inspections were required for these components.
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| 8406110132 840607 PDR ADOCK 05000445 ij G PDR _
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| f Mr. Tho' mis A. Ippolito i Ju'ne 7, 1984
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| ~
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| Page 2 - CPPA-39224 The types and extent of inspections varied from component to component, but included visual and dimensional checks as well as liquid penetrant, magnetic particle, ultrasonic, eddy-current and radiographic testing. Acceptance criteria were specified by the Owners' Group for most of the inspections, however, some inspection plans called for simply recording all marks or indications found on a component without their being evaluated against a specified acceptance cri-teria. In such cases, the results were forwarded to the Owners' Group for evalu-ation, It should also be noted that, in some case where unsatisfactory conditions were found based on visual or liquid penetrant test acceptance criteria, follow-up inspections were performed using one of the more sophisticated techniques, as specified in the inspection ~ plans, to provide further information for evaluation of the suspect areas. Pany of these follow-up inspections resulted in the con-clusion that the defects found by visual or liquid penetrant testing were, in fact, acceptable.
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| The inspection-plans were carried out by TUGC0 Maintenenace personnel in accordance with approved CPSES maintenance and quality assurance procedures.
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| Maintenance Action Requests -(MAR's) were generated based on the inspection plans in order to provide a decailed, comprehensive and step-by-step schedule of the activities required. All inspections were documented on TUCCO Inspection Report forms with all acceptance criteria clearly specified. Conditions that mre found to be unsatisfactory per the.0wners' Group acceptance criteria or otherwise in the judgement of TUGC0 maintenance personnel were documented on TUGC0 Nanconformance Repor.t (NCR) forms.
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| Disposition of NCR's was handled in three ways: use-as-is, repair / rework, or replace the unsatisfactory component. All replacement components were sub-jected to the same level of inspections as the components being replaced. Dis-position was initiated by TUGC0 maintenance and approved by the TUGC0 Operations Engineering and Quality Assurance organizations. Verbal concurrence with all NCR dispositions was also obtained from the Owners' Group technical staff. Two of the NCR dispositions, however, are interim only and are being carried out under the direction of the Owners' Group. These two NCR's concern cracks found in the cylinder block and a defect found in the engine base assembly. Condi-tional releases were obtained for these components, based on Owners' Group recommendations, in order to permit diesel generator reassembly and preopera-tional. testing, while the design reports on these components are being finalized by'the Owners' Group. Final recommendations for disposition of these two NCR's will be obtained from the Owners' Group prior to fuel loading of Unit 1.
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| Although final' conclusions are not possible until both the train A and train B diesel generators have successfully completed reperformance of the preopera-tional test program and until the Owners' Group issues its final report on the design review and quality revalidation of the CPSES engines, Texas Utilities believes that the train A inspection findings and the accomplished disposition of unsatisfactory conditions serve as a good indicator that the Owners'' Group and CPSES diesel generator programs will result in a fully qualified and reliable onsite electric power system at CPSES.
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| .. , #AThomas A. Ippolito .
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| r*- 'Juhe 7., ,1984-I Page 3 '- LCPPA-39224 y ,
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| Sincerely,
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| . Ge rg
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| ~
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| Vice. Preside / Project G neral Manager
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| - JBG/SMS/1p-
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| -enclosure H. C. Schmidt
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| ~ cc:
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| C. Berlinger (NRC)-- ,
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| D.'. Wade x- N. Reynolds
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| CPPA-39224 Enclosure - June 7,1984 4
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| :o^ -
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| CPSES UNIT 1 TRAIN A DIESEL GENERATOR INSPECTION RESUL1S
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| . Attached are the following documents for each component inspected:
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| : 1) Component Revalidation Checklists, and
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| -2) . Inspection Plans -
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| The.results of each component inspection are summarized in the "Results and Conclusions" box of each Component Revalidation Checklist (CRC). It should be noted, however, that a number of modifications were made in the
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| , development of the Inspection Plans that were-not incorporated -in the CRC's. ,
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| i Therefore, all results stated on the CRC's apply to the tests and acceptance criteria specified in corresponding Inspection Plans.
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| ^* ~ " "-
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| )j TEXAS UTILITIES j; TASK DESCRIPTION NC. QR MP022/ 3 COMPONENT REVALIDATICN CHICKLIST
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| . Q.
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| C' Turbocharger
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| 'COMPCNENT DOCUMENT NO QR-1 PART NUMSER MP022/3 SCHEDULID FOR CCMPLETION. P
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| .SNPS PART NUMBER MP-017
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| . TASK DESCRIPTION:
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| After 100 hcurs run or pre-op testing program, visually inspect nozzle rings and bearings for adverse wear and/or cracking. Assemble andreview existing documentation.
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| ATTRIBUTE TO BE VERIFIED: O Gracxs, pa:s, nac.ts on :an cAaces, scoring, pitting, dimensions on turbocharger bearings.
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| : 2) Quality status of ccmponent document package.
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| ACCEPTANCE CRITERIA: 1) No cracks or excessive pitting (indicative of wear) on Turbocharger nozzle rings. 2) Lack of scoring, pitting on bearings. Bearing dimensions per manufactursrs tolerances.,
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| RITERENCES: TDI & Turbocharger =anual, applicable specifications.
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| 1 h* . '* 'Yi CCCUMENTATION REQUIRED: 1) Quality evaluation report of Turbocharger, '
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| fan & bearings. 2) Document Summary Sheet.
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| GROUP CHAIRPERSON N v
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| $ L.
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| u PROGRAM MANAGER d __ 3 __ t -9 b fy.
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| CCMPCNIUT REVID;:
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| l I .-- e P.CSULTS AND CONC!USIONS: CPSES Unit 1, Train A (Serial No. 76001) l Nicks found on fan blades of both turbochargers. Also, superf!cial scratches. Left' bank impeller had one superficial scratch. Nozzle ring blades showed numerous nicks, i
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| some blades bent on trailing. edges, fiajority of both bank turbine blades had nicks.
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| Right tiank had light pitting on 3 blades. Turbocharger bearings showed varying ,
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| l degrees of scoring, pitting, scratches and raised babbits. Shafts, thrust collars
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| .and left bank turbine end oil seal were out of tolerance.
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| '_ ,/ Both rotor assemblies were replaced with spares, other unsatisfactory areas were i *V we furbished.
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| *~~
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| [
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| l GROUP'CHAIRD RSCN PROGPW1ItASAGER
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| Sheet 2 of. -
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| }
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| 'I N .1l GENEldTOR QUAI.1TY REVAl.IllATION PROGRAM #
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| \ (X4tHANCllE l'EAK '
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| Job Humber No.
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| , STyNE&WKilSTERENGINEERINGCORPORATION 11600.63 NP - 22/3 +
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| NO. :tev Chg Q.UAL!ITY ASSUR ANCE-INSPECTION PLAN q f o.a. zase 22 i a TITLE '
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| j s
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| { Reference !
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| I)escription/ Instructions i i INSPECTION:
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| .I 1
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| Visually inspect fan blades, norzle rings, and bearings paying particular attention to: cracks, pits. nicks on the fan blades, scoring and pitting.
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| 2.*
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| . Dimensionally check the shaf t, oil seals and thrust collar.
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| ACCEPTANCE CRITERIA:
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| . No cracks or excessive pitting (Indicative of wear) on fan blades Report any evidence of scoring, pitting on bearings
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| * Dimensional check of bearings was deleted by Tugco because .
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| no equipment was availiable to measure three point sleeve bearing.
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| c
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| Quality Control Insp./ Engr. Date v l-L i
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| 4 d'/M
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| COMPONENT CONDITION REPORT 7P ITDi NO. COMPONENT NO./ DESCRIPTION 9 6 . No.
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| tetr NO.
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| -IR ITri NO. TYPE OF INSPECTION *
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| * Docu=ent bf words or sketches the inspection performed.
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| * Show location of measure =ents/ conditions applicable.
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| NR%aE.EQb SE44t\4G - - -
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| %T. I SLT. 2.4955- 2.434o
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| _3 1f _
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| on. ca.t.t. T.hf MD Cil *\. BEE MO T*# D'M 9 7 l- M S i Sco . 5.13 M SAT 335c0- 33540 SAT,3M to-1
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| ..__1
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| . L 3%2a l ~
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| PERFOLED SY DATE i
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| 7 QC VERIFIED DATE
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| = ' ' " ' ~ ' ~ ^~ ~ ~ ~' ~
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| - 29 %~ :~ *- .~ f=" -'''
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| ' [j '
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| * TEX /sS UTILITIES
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| '3n a- TASK DESCRIPTION NO. CR- 10 0 2-305A
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| ' \
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| 1 COMPONENT REVALIDATION CHECKLIST O'' Sase & Bearing Caps-COMPONENT Base Assembly DCCUMENT NO CR-1 n
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| PART NUMSER 02-305A SCHEDULED FOR COMPLETION-SNPS PART NUMBER 03-305A
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| - --TASR - 0 ESCRIPTIO N :
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| Perform LP Inspection of main bearing, Saddle areacn
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| # 5 bearing on one engine. (Area as indicated on attached sketch). Perform visual inspection of cap mating surfaces for evidence of fretting.
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| ATTRIBUTE TO SE VERIFIED: Sase to ce :ree or cracxang or :reccang, ecc.
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| - . ACCEPTANCE CRITERIA: No rejectable linear indication,/no evidence of excessive wear i.e. fretting, erosion or corrosion.
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| | |
| ==REFERENCES:==
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| TD2 Instruction Manual & Parts List.
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| h CCCUMENTATION REQUIRED: Acceptable inspection report for the above criteria.
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| GROUP CRAIRPERSON" T*d ko zu h 9
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| PRCGRAM MANAGER
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| ;p
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| %. 6k .
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| .a m COMPCNCUT REVIEW:
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| 4 i
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| -RESULTS AND CCNCLUSloNS: GP5ts Unit 1, Irain A (derla t No. hUU1)
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| Linear indications found on Nos.1, 3, and 9 bearing saddles. Owners' Group has evaluated indications on 1 and 9 as acceptable; No. 3 still under evaTuation.
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| Conditional release for DG reassembly and testing obtained based on 0.G. recom-
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| . mendati'on. Final disposition recommendation on No. 3 to be obtained from 0.G.
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| and implemented prior to fuel load. ,
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| ,/. .
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| (- M - , . - _ _ . . . . - . . . . . _ . . . , . _ _ _ . . . ,
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| y .s l
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| L GRCUP CHAIRPERSCU PRCGRAM t1ANAGER - - - - - -
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| 'EL CENERATOR QUALITY REVALIDATION PROGRAM O Shrzticf c0 COMANCllE PEAK Job Number No.
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| f 11600.63 02-305A STQNE & WEBSTER ENGINEERING CORPORATION -
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| NO. lev Chg ''
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| QUALITY ASSURANCE-INSPEOTidN PLAN
| |
| : o. c. INSe. - 36 0 0 TITLE Base and Bearing Caps - Base Assembly igem Attri .
| |
| { Reference Description / Instructions '
| |
| INSPECTION ,
| |
| 1 TDI Instruction . L.P. - Perform an L.P. Inspection of base assembly. No linear Manual and Parts indications acceptable. (See attached sketcit.) .
| |
| 2 TDI Instruction . Visual - Perform visual inspection. Look for, signs of fretting,
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| ~
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| Manual and Parts erosion or corrosion List o
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| t I L 4
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| TEXAS U"'ILITIES TASK DESCRIPTION NC. QR- 10m tocn
| |
| 'l
| |
| ! ' . CCMPONENT REVALIDATICN CHECKLIST Base & Bearing _ Caps-COMPCMENT Main Bearine Caes. DOCUMENT-NO -CR-1 l'
| |
| . - PART NUMBER. 02-305D SCHEDULED FOR CCMPLETION_
| |
| SNPS PART NUMBER 03-305D __
| |
| .-- - - ~ ~~ TASK OESCRIPTION: ,
| |
| Perform visual inspection of cap mating surface for evidence of
| |
| } fretting.
| |
| l 1-
| |
| ~ ~ ~ ~
| |
| ~ ~ ATTRIBUTE TO BE VERIFIED:
| |
| Bearing cap mating surface to be free of fretting, etc.
| |
| ACCEPTANCE CRITERIA:
| |
| No evidence of excessive wear, i.e. fretting,
| |
| ~
| |
| erosion or corrosion.
| |
| | |
| ==REFERENCES:==
| |
| | |
| ! TDI Instruction Manual & Parts List.
| |
| : C.*t y CCCUMENTATION. REQUIRED:
| |
| Acceptable inspection report forAthe above kI ,[, C. k .pm_
| |
| criteria.
| |
| PROGRAM MANAGER GROUP CHAIRPERSON
| |
| , h M h.b. g
| |
| ~ ~
| |
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| |
| COMPONE11T REVIEW:
| |
| i
| |
| ~
| |
| \
| |
| ' 'RCSULIS AND CONCLUSIONS: CPSES Unit 1 Train A (Serial No. 76001)
| |
| All caps are s'atisfactory.
| |
| l l .
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| |
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| . -. .G.RO. .U.P _C.HAIRPERSON PROGRAM !!ANAGER F
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| e j '! shentl'of sLlCENERATORQUALITYREVALIDATIONPROGRAM l l COMMANCHE PEAK Job Number N STONE & WEBSTER ENGINEERING CORPORATION 11600.63 02-305o r NO. Rev Chg QUALIT_Y' ASSURANCE-INSPECTidN PLAN o. a. inse. - s6 0 0 l TITLE t
| |
| Base & Bearing Caps - Main Bearing Caps Item Attri H /
| |
| No . Mpgp InE
| |
| . Reference Description / Instructions 1
| |
| 1 TDI Inst. t1anual Perform visual inspection of cap siating surface for evidence of fretting.
| |
| & Parts List I
| |
| (
| |
| i !
| |
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| . dil TEXAS UTILITIES
| |
| [ "} TASK DESCRIPT!CN NO. QR 02-307A COMPONENT REVALIDATION CHECKLIST
| |
| ; - f1 Lube oil Fittings
| |
| , CCMPCNENT Internal-Headers CCCUMENT NO QR-1 PART NUMSER 02-307A SCHEDULED FOR CotiPLETION'. .-
| |
| SNPS PARh hiUMBER 03-307A
| |
| - TASK -DESCRIPTION :
| |
| : 1) Assemble and review exi.iting documentation. .
| |
| .- j 2) Verify as-built conditions to the existing drawings.
| |
| i ATTRIBUTE To BE VERIFIED:
| |
| . 1) Satisfactory component package.
| |
| : 2) As-Built conditions of installed tubing and associated suppcrts.
| |
| ~ '
| |
| ACCEPTANCE CRITERIA: 1) Satisfactory component package
| |
| ,. 2) Acceptable inspection report based on attached criteria.
| |
| | |
| ==REFERENCES:==
| |
| TDI drawing or supplied as-built O
| |
| ~
| |
| r~~- ocCUMENTATICu REcUIRED: 1) occ== ne eion Su a=v Saese .
| |
| : 2) Inspection Report
| |
| : 3) Component drawing }
| |
| GROUP CHAIRPERSON M M A b PROGRAM MANAGER r. - (. -.
| |
| () 4 --
| |
| ,iv . . . . . ~ .
| |
| .- - CCMPONEUT REVIEW: '
| |
| /
| |
| i
| |
| -.: r - RESULTS AND CCNCLUSIONS: CPSES Unit 1, Train A (Serial No. 76001)
| |
| All piping is satisfactory.
| |
| l 6.--
| |
| LO =
| |
| GROUP Cl!AI' P 5.500.
| |
| PROGRAM !!ANAGER ._
| |
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| Ik j GENERATOR yllAI.lTY HEVAI.ll)ATION l' lum ltAH l SheetI of ?
| |
| * l I CottANCNE l'EAK
| |
| . i l Iol' Nurnber No.
| |
| STpNE e, NEHSTElt ENt:INEEHitN; COHt'0HATION 11600.'63 02-307A i "" '"
| |
| Q'UALITY ASSUR ANCE-INSPECTidN PLAN D. G.;.INSP - 38 1 0
| |
| Lube Oil fittings - Internal lleader Piping ~
| |
| I t clu At t ri ll) /
| |
| No' ,18 n . Heference 11 esc ript ion / Inst ruct ions e
| |
| A QC Inspector shall perform a field inspection' of the internal header pfping. lie shall use a copy of the attached sketches to ensure that items I thru 9 have been accurately incorporated onto the sketch. A tolerance on all dimensions of i 3" shall be considered accurate and ,
| |
| acceptable. The following items are to be checked:
| |
| 1 All piping dimensions, including end-to-end dimensfons.of valves or other in-Ifr.e equipment (such as flow elements), must be recorded and laid out on the drawing such that their orientation with the global axes can be determined. This includes any A0V/H0V orientation with relation to pipe or global axes.
| |
| 2 .
| |
| All support location dimensions (in reference to the pipe), shall be identified and also gang hanger locations must be Indicated on the individual isometric.
| |
| 3 .
| |
| It must be indicated when pipe has been socket welded; for all other cases, butt welds will be assumed. All butt welds at locations other than fittings shall be noted.
| |
| 4 .
| |
| All fittings, such as ANSI tees, elbows, reducers, reducing elbows, "Y" fittings, laterals, etc., shall be explicitly identified on the Isometric. In the case of an elbow; a 5 diameter bend, or short radius elbow should be identified; otherwise, a standard long radius elbow will be assumed.
| |
| 5 .
| |
| All branch connections must be located for all piping and explicitly identified.
| |
| (EX.: Tee, reinforced or unreinforced branch, sockolet, elbolet, latrelet, weldolet, bosses, etc.) '
| |
| 6 .
| |
| Bend radil, orientation or arcs, and.elther angles, chord lengths or arc lengths between supports for all annular piping configurations.
| |
| 7 .
| |
| Piping termination points shall be identified indicating equipment ID when appilcable (f.e., Jacket Water Pump, Lube 011 Strainers, etc.)
| |
| 8 .
| |
| All attachment points to the piping shall be noted (f.e., if small bore piping or equip-ment is supported off large bore flanges or pipe, this should be noted).
| |
| , a quality Control Insp./ Engr. 1)at e i !
| |
| | |
| -- j l
| |
| h 1(
| |
| /^
| |
| CENERATOR QtlAl.lTY REVAl.ll>ATION~ l'HOGRAM f\ Slitet2 of 2
| |
| ! COMANCilK PEAK Jota Neunlie r No.
| |
| f STj)NE & $85TER E:N INEERING CORl'URATION 11600.63 02-307A OjuAldlTY ASSURANCE-INSPECTidN PLAN "'' "''
| |
| 70i,,s,.3, l i
| |
| TITI E tohe Oii rittings - Internai neader riping .
| |
| t i
| |
| i t een Attrj .s No' ,
| |
| i
| |
| . Reference 1)escription/ Instructions 9 .
| |
| When appilcable, the isometrics shall indicate continuation references to adjoining isometrics. '
| |
| * 10 .
| |
| The inspector shall " redline" all out of tolerance discrepancies between the as-t ullt and the as-fasta11ed piping on the reproduced copy of the isometric. The "redifned" copies of the isometric shall then be transmitted to SWEC site representative.
| |
| IP The reverification deleted by Tugco.
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| .. . TEXAS UTILITIES
| |
| ,'] 3 TASK DESCRIPTION NO. QR 02-307B COMPONCIT REVALIDATION CHECKLIST L""* oi 'i'**''''
| |
| ??
| |
| - 'C''- CCMPCNINT ~ Internal-Headers CCCUMENT'NO QR-1 q . _ _
| |
| PART NUMBER 02-307B SCHEDULED FOR COMPLETION. I' SNPS PART NUMBER 03-307B I.
| |
| . TASI' DESCRIPTION:
| |
| : 1) Assemble and review existing documentaticri.
| |
| : 2) Verify as-built conditions to the existing drawings.
| |
| nTTRIBUTE TO SE VERIFIED:
| |
| . 1) Satisfactory component package.
| |
| : 2) As-Built conditions of installed tubing and associated supports.
| |
| . ACCEPTANCE CRITERIA: 1) Satisfactory component package
| |
| ; 2) . Acceptable inspection report based on attached criteria.
| |
| l REFERINCES: TDI drawing cr supplied as-built -
| |
| (3, DCCUMCITATION REQUIRED: 1) Documentation Summary Sheet
| |
| .- 2) Inspection Report ,
| |
| Component drawing GRCUP CHAIRPERSON MM[)d t) 3
| |
| \n PROGRAM MANAGE"RN 1p C.[
| |
| ;- -- ---CCMPCNEUT- REVIEW : *
| |
| /.
| |
| . J- .
| |
| t r
| |
| l r -- -- - RESULTS- ANO CONCLUSIOGS : CPSESUnit1,TrainA(SerialNo.76b01) l All tubing and fittings are satisfactory, t
| |
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| t . GRCUP CHAIRPERSCU PRCCRAM MANAGER
| |
| . n . - . - . . .
| |
| .k ~.*- 3 *
| |
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| |
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| ' 'l{ d, CENEHATOR yllAI.ITY REVAl.ll$ATION l'HOCHAH ( Slint I of f i h [ CottAt!CilE PEAK i Job Humber No. }'
| |
| STbHE & W'EllSTER EtE tNEERING CORPORATION *
| |
| [ Q[UALITY ASSURANCE-INSPECTidN PLAN 1
| |
| TITLE o$.i,lsp.3, Y 7
| |
| ; tube on ntungs internai - Headers Tubing & rittings- '
| |
| ^
| |
| * 6,
| |
| 'l Reference flescription/Instructlons i
| |
| VALIDATION OF TUBING & SCHEMATIC SKETCHES:
| |
| A Q.C. Inspector shall perfor1s a field inspection of tubing and fittings. He should use
| |
| * a copy of the attached sketches to ensu e ftens 1 thru 5 have been accurately incorporated onto the sketch; checking for,the following:
| |
| 1
| |
| . Tubing runs (without regard to actual dimensions).
| |
| 2 . Tubing sizes (0.D.)
| |
| 3 .
| |
| The relationship to each other of all intarmediate fittings: elbows, unions.
| |
| TPPS. coupilngs, etc..*(without regard to actual dimensions).
| |
| 4 .
| |
| The relationship to each other of all supports and attachments and to adjacent e installed fittings (without regard to actual dimensions).
| |
| 5 .
| |
| Tubing terminations point identiffcation - indicating equipment I.D. when appitcable (f.e.. F.O. Strainers. F.O. Booster Pump). '
| |
| 6 l The inspector shall "redifne" any discrepancies .between the as-built and (f.e as-installed tubing on the reproduced copy of the isometric 1.n accordance with Attributes 1 through 5. -
| |
| The "redilned" copies of the isometric shall be: transmitted tg the SWEC site representative.
| |
| 7*
| |
| 4 The reverification deleted by Tugco.
| |
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| ; i Quality Cont rol Insp./ Engr. Date
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| : l. j.'14 * ~ * '
| |
| 7 TEXAS UTILITIES l 1Ei .A TASK DESCRIPTION NO. OR 0 2-3 0 70 ,
| |
| COMPONENT REVALIDATION CHECKLIST
| |
| .^
| |
| - i
| |
| ,4? h
| |
| ~"
| |
| COMPONENT Lube Oil Fittings
| |
| -Internal-Headers "VR-1
| |
| .; . _. ._ DOCUMENT NO.
| |
| PART NUMBER 02-307D (.
| |
| j , SCHEDULED FOR. COMPLETION. -
| |
| SNPS PART NUMBER 03-307D . _ _
| |
| ' --' TAST-DESCRIPTION :
| |
| ., 1) Assemble and review existing dccumentation.
| |
| : 2) Verify as-built conditions to the existing drawings.
| |
| -- --- ATTRISUTE TO SE VERIFIED :
| |
| . 1) Satisfactory ecmponent package.
| |
| : 2) As-Suilt conditions of installed tubing and associated supports.
| |
| ACCEPTANCE CRITERIA: 1) Satisfactory componens Esackage
| |
| : 2) Acceptable inspection report based on attached criteria.
| |
| | |
| ==REFERENCES:==
| |
| TDI drawing or supplied as-built
| |
| : p. -
| |
| . M f@ DOCUMENTATION REQUIRED: 1) Documentation Summary Sheet
| |
| : 2) Inspection Report !-
| |
| i 3 '
| |
| GROUP CHAIRPERSON @d b) 'dCommonent drawing PROGRAM MANAGER N e,w d. </ -
| |
| u q , _ . w,_ _ _ _ _ _ _ _ . ..
| |
| i e c----- - CCMPONEUT - REVIEW :
| |
| . .l 9
| |
| RESULTS--AND CONCLUSIONS: CPSES Unit 1, Train A (Serial No. 76001)
| |
| All tubing supports are satisfactory.
| |
| .,/
| |
| ];,
| |
| y...--....~...
| |
| ,j . _ _ . - - . _ . _ . _ . . . . _ ._
| |
| GROUP CHAIRPbRSON PROGRAM l'.ANAGER - -
| |
| 4
| |
| '.. . -. ~ ~ . :- .. .,.. ,- -.
| |
| 'e . , n.1 ., . e .,3~-
| |
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| |
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| (
| |
| ll . GENEHATOR I)UAI.lTY REVAl.IDATION Pit 0GHAH I. COMANCilE PEAK l
| |
| l , Job Huanber No.
| |
| ST(INE e WEllSTER ENGINEERING CORPORATION 11600.63 02-3070 t.
| |
| QUAL llTY ASSURANCE-INSPECTidN PLAN .o;:,,sp..,o I I
| |
| TITLE tube Oii riitings, internai supports. (lieader pi,ing & iubing i
| |
| 7f I t ein ll t
| |
| At L r:1 /
| |
| ; No l
| |
| , P[
| |
| . ,lgInld. Reference I)escription/ Instructions l'
| |
| i t i VALIDATION OF ENGINEFRING SKETCilES OF INSTALLED PIPING & TUBE "MIPPORTS" A Q.C. Inspector shall perform a fleid inspection of " Supports" on header piping and tubing.
| |
| He shall use a copy of the attached sketch to ensure that items I thru 9 have been accurately incorporated onto the sketch, lhe following items are to be checked: j 1 . Support identification and orientation.
| |
| 2 . liardware items (U-bolts, clamps, clips, rubber inserts, etc.)
| |
| 3 . Configuration, size, dimension of structural supporting elements 4 . Location, size and types of bolts and screws t
| |
| 5 . Configuration, size and type of welds 6 . Critical clearances 7 . Notes sprcifying any special conditions such as inaccessibility, lack of clearance, etc.
| |
| * 8 . Location and size of oversized and/or slotted holes in baseplates
| |
| , 9 . Support attachment points shall be identified Dimensions which are within the following toler4nces shall be considered accurate and acceptable: (for above items 1 - 9).
| |
| l A Structural supporting members shall be i 1/2" for each measurement.
| |
| B i 1/4" between bolt or base plate edge. b C Clearance gaps between the tube and supporting elements shall not be greater than 1/16" in the direction of restraint D Weld thicknesses as noted on sketch shall be a minimum requirement.
| |
| !E Dimensions such as plate thickness sha11 be a minimum requirement.
| |
| 10 '
| |
| . The inspector shall " redline" all out of tolerance discrepancies between the as-built and the as-installed supports on the reproduced copy of the f sometric. The" redlined" copies of the e
| |
| isometric shall then te transmitted to the SWEC site representative.
| |
| If
| |
| '
| |
| * The reverification was deleted by Tugco.
| |
| r .
| |
| j i ',
| |
| j Quallt,y Control Insp./liigr. 1)a t e
| |
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| | |
| TEXAS UTILITIES TASK DESCRIPTION NO. OR-10-02-310A COMPONENT REVALIDATION CHECKLIST Crankshaft & Bearings COMPONENT Crankshaft & Turning Gear DOCUMENT NO OR-1 PART NUMBER 02-310A SCIIEDULED FOR COMPLETION SNPS PART NUMBER 03-310A
| |
| ~ ~
| |
| TASK DESCRIPTION:
| |
| (1) Assemble and review existing documentation (2) Perform visual inspection of crankpin journal surface for signs of distress. Document with photographs.
| |
| (3) Perform eddy current inspections of crankpin journal fillets numbers 3 (governor end) 4, 5, 6, 7, 8 (both sides) . To be performed on one station engine only.
| |
| ATTRIBUTE TO BE VERIFIED:
| |
| (1) Quality status of vendor component package (2) Visual inspection of crankpin journal surface for signs of distress.
| |
| (3) Eddy current inspection of crankpin journals
| |
| -d ACCEPTANCE CRITERIA:
| |
| \j/ (1) Satisfactory component document package (2) & (3) Review of inspection results by design group
| |
| | |
| ==REFERENCES:==
| |
| | |
| Applicable site / vendor documents DOCUMENTATION REQUIRED:
| |
| (1) Document Summary Sheet (2) & (3) Inspecrion Report GROUP CHAIRPERSON c i ,d htN k PROGRAM MANAGER M C @t w i_.
| |
| O COMPONENT REVIEU:
| |
| RESULTS AND CONCLUSIONS: CPSES Unit 1, Train A (Serial No. 76001)
| |
| . minor scratch visible on Journal No. 3 was machined Crankshaft is satisfactory.
| |
| out.
| |
| GROUP CHAIRPERSON PROGRAM tiANAGER
| |
| | |
| d s w,r CENERATOR QltatlTY REVALIDATION PROGRAM '
| |
| ' Sheet 1 of1 COMANCliF. PEAK b Nundier No.
| |
| STONI,& WEBSTER ENGINEERING CORPORATION 11600.63 02-310A NO. Tev I:he^
| |
| QUALITY > ASSUR ANCE-INSPECTidN PLAN o. o. insp _ 6o o o TITLE Crankshaft
| |
| " All fI
| |
| * j '
| |
| g Reference Description / Instructions 1
| |
| Perform a visual inspection of all crankpin journals (crankshaft journals at rods) for signs of scoring, wear or damage. Record results of visual inspection.
| |
| 2 .
| |
| Perform eddy current of crankpin journal #3 governor e'nd and journals 4, 5, 6, both sides (each engine). Record results of eddy current inspection.
| |
| p quality Control Insp. / Engr.
| |
| Date
| |
| ~. N/A
| |
| _sh
| |
| _ _ _ _ _ _ . - _ _ _ _ _ _ _ _ m_
| |
| | |
| .-- . . . . _ . . . a: ~ . . . - . . . . - ...
| |
| .y; ..Shc _ - . -- + n---' ..
| |
| < rn ,. :.:. : <- = =:..c...~-.. .... n M.w m. -
| |
| t 4 ,
| |
| i T TEXAS UTILITIES ij ._
| |
| TASK DESCRIPTION NO. QR- 10 0 2-310 B O. ccM>cn=== azv^tIo^ tic = carextzS C. Waft Bearings-
| |
| {'. CCMPONENT Bearing Shells ,
| |
| DCCUMENT NO ~QR-1 F
| |
| PART NUMBER _
| |
| 02 ~3 i o B SCHEDULED FOR CCMPLET!ON.
| |
| SNPS PART NUMBER 03-310B TASK ~ DESCRIPTION:
| |
| : 1) After 100 Hrs, run or pre-optesting, visually examine sample bearings for excessive wear, or cracking.
| |
| Minimum sample to include $5 main bearing shells.
| |
| -~ ~ - ATTR13UTE--TO SE VERIFIED :
| |
| : 1) Thickness, presence of scoring, galling, or cracks.
| |
| ACCEPTANCE CRITERIA:
| |
| : 1) Thickness per TDI Manual, lack of-scoring & galling.
| |
| | |
| ==REFERENCES:==
| |
| | |
| Vol I, of TDI Manual, design group acceptance criteria.
| |
| i h DCCUMENTATICN REQUIRED:
| |
| Quality evaluation report GROUP CHAIRPERSON M N o.t L PROGRAM MANAGER *t h- _ . - - -
| |
| y ( . . _ .
| |
| - - - - COMPONCUT- REVIEW :
| |
| ... ..; ..-__..- .-- RESULTS- -AND- CONCLUS ICGS :
| |
| CPSES Unit 1, Train A (Serial No. 76001)
| |
| Scoring of Babbitt visible on Nos. 3, 7, and 8 top shells and on No.1 bo'ttom shell.
| |
| Inclusions visible on No. I top and bottom shells. LP showed linear indications in most she,lls, which were evaluated as surface scratches ~ caused by Babbit s'mearing.
| |
| No.10 top and bottom shells were replaced with acceptable spares, all others are ,
| |
| acceptable for use.
| |
| l
| |
| ~ C, .
| |
| - . .......-.=..--. ..:= - -
| |
| GROUP CHAIRPERSON
| |
| * PROGRAM ttANAGER .
| |
| m -.
| |
| ' '~+,, \. ~+- x :- ~ c - , * ,- ; -=: ,
| |
| *-- ~~ y ,1 -:- : .. v - -' . ~~. -.--~~~=:, ' .. r t ~ m , ;*,: - a
| |
| , .- .i . , , -
| |
| | |
| f% i-
| |
| .. p ,
| |
| t j
| |
| ' (tJ "L CENERATOR QUALITY REVALIDATION PROGRAM s
| |
| : r Shsst Iof.'
| |
| #b j l
| |
| 'g' COMANCilE PEAK js (*%
| |
| N Job Number
| |
| ~f No.
| |
| I !
| |
| STONEaWfBSTRR,ENGINEERINGCORPORATION -
| |
| 11600.63 02-310B
| |
| (( QUA4lTV ASSURAN.'
| |
| i G E-INSPECTidN- LAN 7.'a.iNSe.-41 ""
| |
| o 7 i
| |
| .L .
| |
| i
| |
| {
| |
| -TITLE ;
| |
| . Crankshaf t Bearings - Bearing Shells 1'
| |
| I *"
| |
| g A''f1
| |
| *hd Reference l Description / Instructions INSPECTION: t-
| |
| ; , [
| |
| .e-1 TDI Manual . Verify bearir.g ' thickness.
| |
| 2 .
| |
| Visually inspect bearing for presence of scoring, galling or cracks. ;
| |
| Acceptance Criteria -
| |
| I
| |
| . Lack of scoring and galling.
| |
| 3* . Perform LP Inspection of the main bearing shells.
| |
| fI t
| |
| I h
| |
| ! ; *LPf of main bearing shell was { performed per TUGC0 direction. Quality controi Insp./kngr. Date j ; j i N/A
| |
| | |
| 4
| |
| , , ~. , . . . , . . - , . . . ~ - - - - .---. - - .- - -
| |
| LIQUD FCGlTRANT ACWMCZ CL.TZ2:A O- .V ,
| |
| t~
| |
| \ Aessutance Crite 2.s .-
| |
| ; s 4'.2.1 Acceptance cri:eria are generally included in the code or !
| |
| specification which establishes :he required examisation.
| |
| Such specifier. critaria shall be used to datarnise the specific type, size and location of observed disconti=ui:ies.
| |
| ' ' When acceptance criteria is not specified is the documentation .
| |
| establishing the requirement for the examisatico.the 'following
| |
| ~~ ~
| |
| .. . ......:~-
| |
| =ajor dimensions greater than 1/16 inch shall be consideredrelevan
| |
| ~
| |
| relevant. ''
| |
| f a) Wreueht. Forted or Velded Items: -
| |
| : t. Any crack or linear indication
| |
| : 2. Rounded indications vi:h di=ensiens greacar :has 1/8 inch for chickness less than 3/8 inch and greater than 3/16 inch for thick =ess of 5/S isch and greater. ~
| |
| : 3. Four or = ore indications in lise separated by 1/16 isch or less edge :n edge.
| |
| J 4. Ten or = ore indications is any 6 square inches of area
| |
| 'f.- '
| |
| whose =ajor dimension is oc more than 6 inches wi:h the dimensions taken in the most unfavorabia location relative to the indications being evaluated. ~
| |
| : 3) Solt.t and 3oltine Material Crea:er : hen ! inch Normai Size
| |
| !. Any lissar monaxial indications.
| |
| t
| |
| : 2. Linear axial indications greatar than f isch.
| |
| f l
| |
| CL -
| |
| 9
| |
| -m- -y -- - - , y ,e ,, a . , . . , , . . - - _~_ - _ - - - - - - - - - - - - - - - . - - - - - - -
| |
| | |
| .-gx g a m--
| |
| ~- ~
| |
| ]M._. .:
| |
| : 1. . ,, _ .. ; _
| |
| u.m- #-" ~ ~ ~- - - ~~ - ~- - -' f-~ - - - - -
| |
| #~
| |
| TEXAS UTIT IT!ES
| |
| . ..,! TASK DESCRIPTION NO. OR 0 2-311 A COMPCNENT RIVALIDATION CHECKLIST
| |
| -1 ..COMPCNENT Crankcase-Crankcase Assy DOCUMENT NO QR-1
| |
| , v-d PART NUMBER 02-311A SCHEDULID FOR COMPLETION,. __
| |
| < SNPS PART NUMBER 99-311A _
| |
| - ~~ ^ '' TASK DESCRIPTION:
| |
| , 1) Varify material based on fcundary records.
| |
| . , } 2) Visually inspect machines surfaces in nut procket-area.
| |
| .4
| |
| - ATTR23UTE TO BE VERIFIED : 1) Crankcase material composition & strength j -
| |
| : 2) No sharp discontinuities between machine surfaces and casting.
| |
| .^
| |
| ' ACCEPTA::CE CRITERIA: 1) Submit records to design group.
| |
| ; 2) Smooth radii between machine /as-cast surfaces. -
| |
| | |
| ==REFERENCES:==
| |
| | |
| Foundary records.
| |
| m
| |
| * O. . Q1 CCCUME'TATION REQUIRID:
| |
| - c.
| |
| I Visual inspection report-Cran a material
| |
| " records.
| |
| GROUP CEAIRPEROCN b
| |
| .... ..~ . -
| |
| g dq h. PROGRAMMANAGERh'.
| |
| _ _,y
| |
| /( -
| |
| k&m ._.
| |
| -~ - -- -CCMPCt4E ;T-REVIEW :
| |
| /
| |
| R$"-
| |
| - - REE!;LTS -A::D CCtiCLUSlor:S : CPSES Unit 1 Train A (Serial No. 76001f Material is satisfactory. No machined surfaces on these components.
| |
| /
| |
| 3 L h .) .
| |
| GROUP 9EAIRPERSCI PROGRAM tiANAGER t , 7.. -
| |
| ~.
| |
| i'
| |
| * ' # "4*I *
| |
| * * . ' '[* O' '' i ' *
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| | |
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| |
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| 'j
| |
| ', '.l. * ;;he< i lof I~~ i
| |
| * ' ::EMERATOI: sillAI.lTY l(KVAl.lDATitlN l'itiM: RAM '~i-
| |
| , :OMAN8:llE PEAK .lol> Niember I ?
| |
| No. [
| |
| I OHtpoHA irlON ST Hl: A WEllSTEl: EM lNEEltiM: 11600.63 02-311A : +
| |
| f Q{AL'ITY ASSUR ANlCE-INSPECTION PLAN "['. a. inse. - 34 'S" Y >
| |
| TITLE Crankcase Assembly t
| |
| ~
| |
| li ca No; At t ri
| |
| , }ll
| |
| * C ite f! .&it e"
| |
| , 1
| |
| ; , Desc r i pt ion / Ins t renc t ions
| |
| .. I l , i INSPECTION:
| |
| 1*' . Visually inspect machined surfaces in the nut pocket area of the i casting archs for sharp changes in surface configuration. I ACCEPTANCE CRITERIA
| |
| . Smooth radi'i at any machined surface inner corners. '
| |
| 9 4
| |
| %sr a
| |
| 4
| |
| . +
| |
| k 6
| |
| s l 1 ( .
| |
| l
| |
| *
| |
| * Re,' v. I i
| |
| Clarification 8}.nal I t y Cont rol insp /Ensjr
| |
| . . Itat o
| |
| , N/A l l , .__.________ _ _.. .
| |
| | |
| S p a; . -
| |
| COMPONENT CONDITION REPORT
| |
| .P. NO. ITEM NO. COMPONENT NO./ DESCRIPTION
| |
| -~"
| |
| IR. NO.
| |
| ~-
| |
| IR ITEM NO. TYPE OF INSPECTION
| |
| * Document b words or sketches the inspection performed.
| |
| * Show location of measurements / conditions applicable.
| |
| l
| |
| \ ,
| |
| . I -
| |
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| |
| ' /// ~
| |
| . // VV_ ~ af ' 'l s , 81 l
| |
| b ,
| |
| .,E. I uur nea r
| |
| & R E 6-PERFORMED BY DATE Q.
| |
| QC VERIFIED DATE .~
| |
| y .
| |
| | |
| 9i n.cw 2.. . . _ _ _ . . _
| |
| cn u g ,a .,,2,.,._u,,
| |
| . _ . .u ,, . ;. . .._ _ ..__,._.m.,
| |
| .EXA5 UTILITIES TASK DESCRIPTION NO. QR- 10-0 2 - 315 A l COMPONENT REVALIDATION CHECKLIST o CCMPCNENT Cvlinder Block DOCUMENT NO QR-1 l q _PART NUMBER 02-315A SCHEDULED FOR COMPLETION. I' SNPS PART NUMBER 03-315A TASK DESCRIPTION:
| |
| SEE PAGE 2
| |
| -- ----ATTRIBUTE TO~~BE VERIFIED : SEE PAGE 2 ACCEPTANCE CRITERIA: SEE PAGE 2
| |
| | |
| ==REFERENCES:==
| |
| SEE PAGE 2 .
| |
| v'.]-
| |
| DOCUMENTATION REQUIRED: SEE PAGE 2 GROUP CHAIRPERSON M] a$ 2 PROGRAM MANAGER hCo-.,, ( 1 -
| |
| v g _ y
| |
| -COMPONENT- RIVIEW :
| |
| /
| |
| -~~--
| |
| RESULTS - AND CONCLUSIONS : CPSES Unit 1, Train A (Serial No. /6001)
| |
| LP inspections showed indications at cylinders 4R, SR, and 6L. Eddy-Current showed GL is satisfactory;- 4R and SR are still under evaluation by the Owners'. Group.
| |
| Conditional release for DG reassembly and testing obtained based on 0.G. recom-mendation. Final disposition recommendation to be obtained from Owners' Group and implemented prior to fuel load. ,
| |
| l
| |
| ._.._x_-0~ s. l _ _ .. _ , . .
| |
| GROUP CHAIRPERSON PROGRAM MANAGER l~
| |
| ' p g ;;; , . *
| |
| , ; ~.; * - m ;?- - .
| |
| * * ' ' ''o '
| |
| * t*<''*~'' Tt*~ M. , , V. *
| |
| * 2 1
| |
| | |
| a.a.a ,
| |
| ' n , < . - .c~ - ~,'
| |
| .Am
| |
| == m .- ;g;=
| |
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| |
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| |
| -~
| |
| - --- n c h 2 - -ww.
| |
| *h*a.*.-
| |
| a .
| |
| ' ' j fj . -
| |
| y.; -
| |
| , ! Page 2 of 3
| |
| ! .j O ,,
| |
| TASK DESCRIPTION:
| |
| j.: 1. Assemble and review existing documentation. .
| |
| b
| |
| : 2. Develop inspection plan for area of concern around cyl. liner, including liner landing demensional check.
| |
| . 3. Perform LP Insp. of Cyl. Bik. Liner landing along top landing
| |
| ~ surface, fillet radius, and vertical face adjacent to landing surface. Inspect four lin:: 12 fin;: (with liners rem ). If' 9 linear indication found, increase inspection plan to 004 I~
| |
| : 4. LP inspection of engine block top, cylinder head mating surface, f.;
| |
| * Inspection to include areaInspection adjacent to stud ho g and between'~ --
| |
| adjacent cylinder heads. plan t 2....ud; cylinders r; 'L, .~ L , E ar 4?, n ;M 'ar Increase to 00% if linear
| |
| ~ ~ ~
| |
| : , -indications found.
| |
| . 5. Perform Eddy-Current exam. of cylinder head stud holes, if required. i.e. linear indications found ;; ;tud hele.
| |
| 5 we mAE45 ATTRIBUTE TO BE VERIFIED: . . _ _ .
| |
| B 4 1. Cuality Status of component document package. -
| |
| ~
| |
| '. i .
| |
| : 2. Establish dimensional data similiar to data requested on attached sketch, 3&4 LP inspection of cylinder block & liner landing.
| |
| f) C.
| |
| : v. *
| |
| : 5. Eddy-current inspection of cylinder head stud holes, if linear
| |
| ... ;a indications found near bolt stud holes.
| |
| ACCEPTANCE CRITERIA: __
| |
| a 1. Satisfactory component package. '
| |
| .; 2. Submit dimensional data for Design Group review.
| |
| 344 Review of documentation and test results by design group.
| |
| j 5. Recording criteria in accordance with FaAA Procedure NDE 11.8.
| |
| | |
| ==REFERENCES:==
| |
| TDI Drawing I
| |
| . DCCUMENTATION REQUIRED: ,
| |
| .:.._._ - l.. ... Document Summary Sheet "
| |
| i
| |
| : 2. Inspection Report 4 3&4 Test report & review
| |
| : 5. Test report & review (if applicable) e 4
| |
| /
| |
| 4, I
| |
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| emy' mpea^&A s e*+4.- 5 P *-* *-M" .*h* M I E .$1- & .
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| |
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| |
| 'EL CENERATOR QUALITY REVALIDATION PROGRAM '
| |
| ~
| |
| COMANCilE PEAK p Job Number No. ,
| |
| g STONE &W{BSTERENGINEERINGCORPORAION 11600.63 02-315A (
| |
| " {f
| |
| ) QUALjTV ASSURANCE-INSPECTidNi$LAN "
| |
| ofo.1,Sg._21 1 $" I
| |
| ! TITLE i cyiinder niont
| |
| * I =
| |
| N Attr L
| |
| .g{ Reference l Description / Instructions I!
| |
| r, INSPECTION: o
| |
| : 1. . Perform as built dimensions for all cylinder block linear landings as I shown on attached sketch. (Locations, J. K. M, N S & U).
| |
| 2a .
| |
| Perform specified LP inspections of cylinder blocks liner landing along top landing surface, fillet radius and vertical face adjacent to ,
| |
| landing surface.
| |
| 2b* . Perfdrm specified MT inspection of blocks, cylinder head mating surface, area between stud hole and liner, and between adjacent cylinder head ~
| |
| stud holes. 100% inspection. :
| |
| : 3. . Perform an eddy-current inspection of cylinder head stud holes as s required, i.e., linear indications found at stud holes, extending into therads. ,
| |
| l
| |
| : i i ; t 1
| |
| i , ,
| |
| I
| |
| , 4
| |
| !'X Mk was performbd per 10GC0 directidn, in lieu of fT (See I.P. 21. Rev. 0) Quality Control Insp./sn pAm .
| |
| j l -
| |
| N/A t i l l
| |
| | |
| . _ . . . . . _ _ _e. .. . - -
| |
| t ACCEPTANCE CRITZEIA 4
| |
| Accestance Criteria
| |
| \
| |
| Nef.I Accepeance criteria are generally included in the code or specification which establishes the required examination. ,
| |
| 3 j
| |
| Such specified criteria shall be used to determine the '
| |
| i- specific type, siae and location of observed discontinuities.
| |
| l .
| |
| . When acceptance criteria is not specified in the doc'.nnentation establishing the requirement for the ==f nation,the following relevant major indications dimensiona greater are unacceptable. than I/I6 inch Only shall indications be considered with. l relevant.
| |
| i a) Wrought, Forted or Welded Items; -
| |
| , I. Any crack or linear indication
| |
| ! 2. Rounded indications with di=ensions greater than 1/8 inch for thickness less than $/8 inch and greater than 3/16 inch for thickness of 5/8 inch and greater.
| |
| : 3. Four or = ore indications in line separated by 1/16 inch or less edge to edge.
| |
| : 4. Ten or more indications in any 6 square inches of area whose major dimension is no more than 6 inches with the
| |
| - Q''' dimensions taken in the most unfavorable location relative to the indications being evaluated..
| |
| : 3) Botti and Botting Material Creater then I fneh Normal-Stre _ -.
| |
| : f. Any linear nonaxial indications.
| |
| : 2. Linear axial indications greater than !" inch.
| |
| ; ./
| |
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| ~6@~PUUENk CONDITION REPORT I.P. NO. LIDt NO. CCMPONENT NO./ DESCRIPTION s- . . NO. -
| |
| IR ITEi NO. TYPE OF INSPECTION i___.
| |
| ~~ ~ '
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| 7 6ccus at bf words or sketches the inspection performed.
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| * Shott location of measurements /conditiens applicable.
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| TEXAS UTILITIES Oh TASK DESCRIPTION NO.QR-10-02-315C
| |
| :O CCMPONENT. REVALIDATION N N ST l . ' '.s . l
| |
| ).
| |
| COMPONENT Cvlinder Liner DOCUMENT NO. QR-1 P PART NUMBER 02-315C SCHEEULED FOR CCMPLETION
| |
| ! ', SNPS PART NUMBER 03-315C _ - - - . . - _ .
| |
| --+ ---TASK-DESCRIPTION:
| |
| : i. 1) Assemble and review existing documention
| |
| : 2) Verify dimensions including bore, length, height, O.D. and shoulder height. Perform visual inspection of outside pilot
| |
| . Dia. at top where it contacts cylinder block. Look for~
| |
| ~ ~
| |
| indications of contact spalling. Visually inspect piston liner over zone or pisten travel. Look for indications of
| |
| ', ~
| |
| scuffing, scoring. 100% sample plan. Document all inspections with photographs.
| |
| : 3) Develop inspection plan to' verify material properties.
| |
| l- "- .p-- --ATTRIBUTE TO SE VERIFIED :- SEE PAGE 2
| |
| ., JLCCEPTANCE CRITERIA: SEE PAGE 2
| |
| | |
| ==REFERENCES:==
| |
| SEE PAGE 2 i
| |
| h DOCUMENTATION REQUIRED: SEE PAGE 2 GROUP CHAIRPERSON.@l d h PROGRAM MANAGER r , .$% -
| |
| 4 w . . . . . _ _ _ . . .
| |
| --g- ----- - -- .- COMPO NENT REVIEW : .
| |
| . /
| |
| , 'RESULTS AND CCNCLUSIONS: CPSES Unit 1, Train A (Serial No. /6001)
| |
| Liner No. 8R was replaced because of a visible casting flaw on the outside diameter, c
| |
| (' , All other cylinders are satisfactory and were machined to conform with the latest TDI cylinden head-product improvement recommendation.
| |
| . 9
| |
| ; GROUP Cl!AIRPERSON PROGRAM MANAGER
| |
| ,. .. .J - - - . . . - . .
| |
| \
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| ( -
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| a _ _ . ~ , . - , _ _ . . - . _ _ _ . _ . . . _ _ . . _ _ _ ___ _ . -
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| | |
| _.. .....w,=-
| |
| . --. yy: .
| |
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| a, j;... .. .
| |
| ,jq- -
| |
| o Page 2 of 2
| |
| . *'O .QR-10.-0 2-315C
| |
| . .] g , - - '
| |
| i '' ATTRIBUTES TO BE VERIFIED: .
| |
| , .]! ,
| |
| : 1. Qual.i.ty status of component document package and vendor quality'!
| |
| rating.
| |
| : 2. Verify dimensions including bore, length, height, o.D. and shoulder height. Perform visual inspection of outside pilot Dia. at top where it contacts cylinder block. Look for
| |
| ' , indications of contact spalling. Visually inspect pisten liner ove Look for indicatiens of
| |
| ; scuffing,gIscoring. zoge or piston Document travel..
| |
| all inspections with photographs.
| |
| l 3. Verify material chemistry and properties.
| |
| ACCEPTANCE CRITERIA: *
| |
| : 1. Sat.1.sfactory ecmponent package.
| |
| . 2a. Liner bore should be within tolerances specified in TDI Instruction Manual.
| |
| [ 2b. Design Group shall determine acceptable tolerances of other
| |
| ! measured dimensions and visual inspections. -
| |
| : 3. Design Group shall determine acceptance criterium for material chemistry and properties.
| |
| [ ; 4. Review of inspection results by Design Group.
| |
| TD structic'n Manual - Sections 5-0 & 6-D, Appendix III. -
| |
| .' ~. g *. ,
| |
| ' DCCUMENTATION REQUIRED: -
| |
| {''
| |
| : 1. Document Summary Sheet.
| |
| 2a. Report for acceptable liner bore dimensions.
| |
| ;. 2b. Provide visual inspection report and measured dimensions, as shown on inspection report, to design group for review and -
| |
| acceptability.
| |
| 5
| |
| : 3. Perform physical and mechanical properties tests such as j
| |
| 'f chemistry, yield, ultimate tensile stress, elongation, hardness, and metallographic determination of praphite type or percent i nodularity at inner surface. Material is reported to be nodualar
| |
| ! iren. Design Group to review for acceptability.
| |
| ; , 4. One section of 12" x 12" will be cut from an undamaged center i ,
| |
| portion of a scrap cylinder liner. This 12" x 12" section shall-i be used to perform tests required by Item 3 above.
| |
| 1
| |
| , 5. NOTE: Upon completion of Items 2 through 4 above, the data shall l be_ submitted to the Design Group for their review and comment.
| |
| , h '. M i*
| |
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| |
| | |
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| g e ENEllATE] dltlAI.lTY REVAl.lDATinti'I'ROGHAM She:L cff
| |
| , i >
| |
| ~ Job Humiber No.
| |
| (fastlAtiCIIE l'EAK -
| |
| STpilE & WEllSTEl{ EfM;ltlEERING CORPORATIOli 11600.63 02-315C Q:U ALITY, ASSUR ANCE-INSPECTION PLAN NO.
| |
| (ev i:h g -
| |
| : n. C. inse. - 24 3 0 TITLE ObNnEn uNea - -
| |
| A II'
| |
| * g b Reference Description /lpstructions I Hi r. 's lustr. INSPECrlON:
| |
| Manual Verify dlaiensions including bore ( (Itameter) length, height ID and shoulder height. 100% inspection.
| |
| 2 Mfr's Instr. lHSPECTION:
| |
| Hanual Perform visual insection of outside pilot diameter where it contacts the cylinder block. Look for indacations of contact, spalling, polishing or erosion. 100% inspection 3 Mf r's Inst r. lHSPECTION:
| |
| 9 Manual Visual inspect liner over zone of piston travel. Look for indications of scuf fing/ scoring. 100% inspectlon.
| |
| 4 IriSPECTION:
| |
| Document visual inspections with photographs, t
| |
| Se INSPECTION:
| |
| * Verify one section of 12" x 12" cylinder liner was cut and sent to Failure Analysis Associates.
| |
| i -
| |
| t 6* l 1NSPECTION:
| |
| Verify liners have been modified in accordance with the attached letter.
| |
| 01.P. 24. Sev. Ojrequired comparator test. Comparator test was deleted when a s ,) sality Control Insp./ Engr
| |
| * Dat e' Ot. pare P. 24. liner
| |
| , Rev.becanie2.This isavailable forf destructive a nwi.fi ficat <m testing.
| |
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| . . . .. Attentions.I.elanie Lange ... - - ..
| |
| .e .', % . -
| |
| * I A. .M. '" ''
| |
| co. '.a S4jects . t h ==eh- Faak' Station Diesel Cenerator hit 8/N 7600L * .
| |
| . %,s- 9 . - - . .. .. . 7 0 CF.003,4 . . .. . . . . , . . . . . . . . . . . . ,
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| b,yy,cer,s.e saference Yone talaeopy dated April 9,.1964
| |
| ' T. ; * * .**d'bh r:5.1.E.U*''5.NT."la '.hM **S.4 ,g wi '; . ; 6.a N l',. a"M:AM.:*s T $;i. : /. :..n--
| |
| .c ' s
| |
| : .c....r. . .. .
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| |
| ; As previonely discussed with Mr. Cearse Mattiussi and in our phone I
| |
| Q "7 h .% -
| |
| ,' conversation TDI has since modified the cylinder head stude and nose recastly .the cylinder liners to help reduce strese in t!e stud bore.
| |
| , ;;, w,, , and liner Isading ereas respectively. Our earlier telecen included
| |
| ,g,w .
| |
| e ' ~ ' "
| |
| your des.i.re to isc.orpor.at.e. a.ny rela.t.e.d
| |
| -.i.mpro.vem.e.n.t..e.
| |
| - concerning thie.
| |
| 7A,.
| |
| g.. . .
| |
| , ; g .
| |
| : 1. -..a.,, ,=r,
| |
| .s
| |
| ' a{. In response to your concera of the beishe of the liner ledge vs.
| |
| ., hlock land, we have no provna data to indicate that liner prendness
| |
| ..w of up to. 008 inch v12.L cause crache in ths liner land area of the
| |
| . @n.p block, however, ouc carrant. etandard for production enginee is 0 to amw .003 tach s .
| |
| Y Ins additioer, we have deter =b=d 1ry strain gauge testing and field
| |
| ** I 'l experience that a reduction in ther upper liner ledge diameter of w .005 inch.will also help reduce stress. This improvement has resulted L;.y.p
| |
| @ la a reduction in, the leds* diameter from 19.499/19.501 to 19.494/19.696
| |
| -i inebes. Ia coopeactica vith this diameter reduction the first step
| |
| , just belmaa that ladge has, alse. been reduced f rom 18.995/18.99y inchee !
| |
| , .G ,z .- to 18.990/18.991 inches .
| |
| .. . s i
| |
| * t
| |
| * . ._. . . . .Pi. e. mmer de. n..o. e. .m. i.s.in.e. .oc. t.hese.m._od_ificationa.. t.o b.e.. e.r r.e. a.irem. ane... . ,... . <
| |
| as T3E has marry ine . .
| |
| * , clous of engines.wTtE thousaade o operating .. .
| |
| homes withour these improvements. houwwer, since the diesel engine
| |
| =
| |
| ...* _ __r,r. s 1er currently conveniently disassembled, we suggest yea consider e __
| |
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| the Utility to do so.
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| ye. . . l
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| ..e.w . *. : t If this-to contact office us. can be of further assistance. Please do not. hesitate
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| * U 7ery t M l '" * ,
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| * hw I . .'., las D$ck Engineer, Cuetomer Servica .
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| COMPONENT CONDITION REPORT '
| |
| I.P. NO. ITEM NO. COMPONENT NO./ DESCRIPTION
| |
| ~
| |
| ' ' id. No. IR ITEM NO. TYPE OF INSPECTION
| |
| * Document b9 words or sketches the inspection performed.
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| * Show location of measurements / conditions applicable, rv,o us s #
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| AND L
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| * NG Z T V D L W AL (L) To TH E ENGINS CGNrERL2NE
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| : 2. Trr Zen uess ment un e tn R NT To B &V T A rt EN PovR Pt nc o t , 9e
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| * ntner
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| , PERFORMED BY DATE O 4 ees.m-.
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| * QC VERIFIED DATE
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| * ~
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| ,,i.
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| TEXAS UTILITIES
| |
| , y ,- TASK DESCRIPTION NO. QR- 10 0 2-315E COMPONENT REVALIDATION CHECKLIST 0.
| |
| 9,
| |
| ...CCMPCNENT Cylin~ der Block.5tuds .DCCUMENT NO QR-1 1
| |
| PART NUMBER 02-315E SCHEDULED FOR COMPLETIOS I'
| |
| , SNPS PARy NUMBER 03-315E
| |
| --~ ~ TASK-- OESCRIPTION : .
| |
| Perform visual inspection of head studs for signs of
| |
| . distress, 4 cylinder. Record all visible ID numbers. Perform material
| |
| , ,' comparitor test on 4 studs per engine. Perform superficial hardness test on one stud per engine. Verify installation tor,que with existing documentation. .
| |
| ATTRISUTE TO SE VERIFIED: visuaA Anspec:acn as neac sc.ucs a ma dar;.4.
| |
| j ,
| |
| . comparitor test and superficial hardness
| |
| ; cast.
| |
| i ACCEPTANCE CRITERIA: Review of documentation & inspection results l
| |
| j ,
| |
| | |
| ==REFERENCES:==
| |
| TDI Drawing
| |
| .s
| |
| .O. ky DCCUMENTATION REQUIRED: Inspection Report p
| |
| . , a GROUP CHAIRPERSON N aa b L. PRCGRAM MANAGER
| |
| ' '- -^ -
| |
| U 4 -
| |
| n?- ~
| |
| ; -- --CCMPONEUT- REVIEW r . .
| |
| MOCi Mf2c#.tME4I
| |
| , /
| |
| * c 1
| |
| RESULTS AND CCNCLUSIONS: GP5E5 Unit 1, train a erici no. 76001)
| |
| All studs are satisfact6ry, but have been replaced with improved (necke.d) studs from TDI.
| |
| l
| |
| , . /.. . . . . .
| |
| N le .
| |
| ;. a _ _ - . . . . . . . .
| |
| GROUP CHAIRPERSCH PROGRAM l'w*iNAGER l
| |
| , ., . . . . . . , . .. .. ... ..~. . . , s . . . , , . , .,,. ;,. . . : - .
| |
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| . ! IERATOR QUAI.ITY REVAl.IDATION FROGRAM ICot:ANCHE FEAK -
| |
| Sheet 1:fI[\l *
| |
| ? ' Job Nisaber No.
| |
| , g STONE & WERSTER ENGINEERING CORPORATION 11600.63 l' 02-315E QUAlllT ASSURANCE-INSPECTidN PLAN o. a. inSe. - 17 [
| |
| TITLE cyiinder siock studs
| |
| 'E" ^*L''
| |
| h[. Refprence Description / Instructions ~
| |
| [ ; L k; k-INSPECTION: :. -
| |
| q !
| |
| p .
| |
| 2 A comparator test is to be performed utilizing a knownistd. or !!
| |
| verifying the availability of a spare or discard whichimay be _
| |
| comparator date (on fourtested and per old studs sentengine).
| |
| out for destructive testing tat a later) ;
| |
| 3 .
| |
| Perform a superficial hardness test on one old stud per engine. '
| |
| 4
| |
| , i. :i
| |
| * Item 1 was deleted by Tugco because the, 11 !
| |
| purchased from TDI. new modified studs were 6 J'
| |
| l l 3
| |
| il 1 '..
| |
| ' t2 .
| |
| I ;: ci
| |
| , I . .
| |
| I i ,.
| |
| i Quality, Control Inspy[ Engr. l Dlte
| |
| _ _ . . - _ _~ _ - _
| |
| | |
| :2 - -r , .-* -
| |
| r . v ._ __ '. . - d~ Eg -
| |
| + ~ - - <- '=
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| 4.-
| |
| , 't -
| |
| . TEXAS UTILITIES
| |
| , I] TASK DESCRIPTION NO. QR-10-02-315F
| |
| . .{ . ..
| |
| [4 CCMPONENT REVALIDATION CHECKLIST
| |
| " .5.;15O
| |
| *CCMPCNENT Cyl six- tin r a wa=er Manifold-Nuts DOCUMENT NO QR*-1
| |
| 'i -
| |
| PART NUMBER 02-315F SCHEDULED FOR CCMPLETICN. b _
| |
| [ SNPS PART NUMBER 03-315F . .
| |
| ~ ~ ' " "' ' TASK DESCRIPTION: 1)
| |
| Assemble & rev:.ew e;t:. sting documentat .on
| |
| +
| |
| : 2) Visual exam of all nuts for identifying marks
| |
| : 3) verify proper ins.ca11ation & torquing of nuts
| |
| : 4) Visual inspection, sample basis, for forging laps i SEE PAGE 2
| |
| ~ "~ ~ 'ATTRI3UTE TO SE VERIFIED:
| |
| $ SEE PAGE 2 -
| |
| ACCEPTANCE CRITERIA:
| |
| SEE PAGE 2
| |
| | |
| ==REFERENCES:==
| |
| a
| |
| === >^a= 2
| |
| ' *O. ; pj DOCUMENTATION REQUIRED:
| |
| GROUP CHAIRPERSON bk PROGRAM MANAGER h ,r. (. l... .
| |
| ; w w
| |
| a
| |
| .-....p_ _ _
| |
| , ___.CCMPONENT. REVIEW: .
| |
| t i
| |
| ': /
| |
| \
| |
| * O r. . .. .
| |
| RESULTS AND CONCLUSIONS: CPSES Unit 1. Train A (Serial No. /6001)
| |
| All nuts are satisfactory, some do not have identifying marks. -
| |
| t
| |
| * 4
| |
| . , /
| |
| .l.,
| |
| (~n p ,,~~
| |
| \
| |
| . GRCUP CRAIRPERSON PROGRAM MANAGER t
| |
| .mi 9 e ,h*
| |
| * 91 "*
| |
| 'I-#..,* # . 4 , D " ;g !* / . 7. ' '#S. * '
| |
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| g i
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| I
| |
| ~ ATTRIBU*E TO BE VERIFIED:
| |
| !,3 O 1) -Quality. status of vender component package quality:.Tating.
| |
| lj
| |
| ~
| |
| . 2) Identifying marking. ;,
| |
| l
| |
| _ 3) verify proper installation and torquing of nuts. .
| |
| ; - , 4) Visual inspection to insure nuts are free from forging laps.
| |
| ACCEPTANCE CRI"ZRIA: .
| |
| i
| |
| * i 1) Satisfactory component package
| |
| : 2) Record all nut markings.
| |
| : 3) Torque values of nuts in compliance with TDI manual.
| |
| : 4) Nuts to be free from forging laps.
| |
| REFERENCES 1
| |
| . TDI Instruction Manual CCCUMENTATION REQUIRED: . . . . . . _ . . ,
| |
| : 1) Document summary sheet J
| |
| : 2) Inspection report on of nuts for review by design group.
| |
| : 3) Report for verification of nuts being properly installed and
| |
| , torqued.
| |
| l --
| |
| 8 .
| |
| . = ,
| |
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| |
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| 7
| |
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| |
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| |
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| |
| * I CENEHATOR tjuAI.ITY REVAl.lHATION 1*ROGRAN 2 Sheet lof I
| |
| * CONANCllE l'EAK I Job Nimmber l No.
| |
| l 11600.63 STj)NE & IJERSTER ENGINEERING CORI*0 RATION 02-315F j Q;UAldlTY ASSURANCE-INSPECTION PLAN NO.
| |
| .. ~
| |
| tev I:hR o.a. iNsP. - 32 -
| |
| : 1. O
| |
| ! TITLE :critader Block Liner & Manff Id Nuts
| |
| 'At t ri 1(em .
| |
| Refe rence Description / Instructions 1
| |
| TDI Instruction INSTALLATION & TORQUING * ,
| |
| Manual l ~,
| |
| Verify proper installation and torquing of nuts.
| |
| Torque values of nuts to be in compliance with TDI Hanual.
| |
| 2.
| |
| Perform L.P. Inspection on all nuts for forging laps.
| |
| 3.
| |
| Perform a visual examination of all nuts for identification markings.
| |
| Record all markings.
| |
| ACCEPTAllCE CP.ITERIA Forging lap indications which continue less than 1/32" onto the machined end surfaces are acceptable, s ,,
| |
| w This was added as a clarification to the acceptance criteria e of Rev. O.
| |
| ' t f f '
| |
| i ,
| |
| ! s
| |
| , I .
| |
| t I f f}uality Cont rol Insp./ Engr. Ilate i n ,a i
| |
| | |
| .ACCEPTANCZ CRITZ12A Accestance Criteria .
| |
| w 4'*2.1, Acceptance critaria are generally included in the code or specification which establishes the required examination. t
| |
| . Such specified criteria shall be used to determine the specifi= type, siae and location of observed discontinuities.
| |
| When acceptance criteria is not specified in the documentation establishing the requirement for the examination,the following major dimensions greater than 1/16 inch shall be consideredrelevantindica
| |
| ~
| |
| relevant.
| |
| a) Vrousht. Totted or Welded Teems;
| |
| ~
| |
| : 1. Any crack or linear indication
| |
| : 2. Rounded indications with di=ensions greater than 1/8 inch for thickness less than 3/8 inc.5) and greater than 3/16 inch for thickness of 5/5 inch and greatar.
| |
| : 3. Tour or = ore indications in line separated by 1/16 inch or less edge to edge.
| |
| ! < 4. Ten or nore indications in any 6 square inches of ares N
| |
| whose major dimension is no more than 6 inches with the
| |
| ' dimensions taken in the most unfavorable location relative to the indications being evaluated
| |
| : 3) Botti and Bottine Material Creater the i I inch Nor r.a1 Slee -. -
| |
| : f. Any linear nonaxial indications. ,
| |
| : 2. I.inear axial indications greater than l' inch.
| |
| I i
| |
| I e
| |
| ~
| |
| g a h
| |
| Oa .
| |
| e
| |
| | |
| f g a hw w' ''''
| |
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| |
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| |
| ~
| |
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| |
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| |
| { . .,: TEXAS UTILITIIS tr' TASK DESCRIPTICN NC. QR 0 2-330B l'
| |
| 1 .
| |
| I CCMPONENT REVALIDATICN CHECKLIST
| |
| , 4,
| |
| : C ,
| |
| .CCMPCNENT Fivwheel Bolting COCUMENT NC QR-1 1
| |
| PART NUMBER 02-3303 SCHEDULED FOR CCMPLETICN '''
| |
| SNPS PART NUMBER 03-3305
| |
| . TASK DESCRIPTICN:
| |
| AssemcJ.e existing documentation on IAywneeA coAcang and verify that the torque loads applied meet the latest specified,requirem'ents.
| |
| t 4
| |
| 1 -
| |
| ' - - -J - . --
| |
| s f
| |
| --ATTR13UTE TC BE VERIFIED: DEL Fh4 4 e
| |
| ( ,
| |
| ~~ '
| |
| , ACCEPTANCE CRITERIA: SEE*PAGE 2 i
| |
| ( .
| |
| | |
| ==REFERENCES:==
| |
| TDI INSTRUCTION MANUAL i
| |
| ~
| |
| (.[, DCCUMENTATION REQUIRED: SEE PAGE 2 1
| |
| dL.#bk GROUP CHAIRPERSON hb PROGRAM MANAGER A ,2 h W d.. ,
| |
| , i ~--- -- -- -
| |
| !! (I . ._. .. v g . _ . . _ . .
| |
| .CCMPONE14T - REVIEW :.
| |
| /
| |
| l RCSULTS At:D cot 4CLUS10(10 :
| |
| CPSES Unit 1. Train A (Serial No. 76001)
| |
| All bolts are satisfactory.
| |
| : i t
| |
| . e.
| |
| /
| |
| 1.
| |
| , .p._._... l" . . . _ ....
| |
| ^ ~ ' ~
| |
| u .. .
| |
| l ;j GRCUP CHA HPERSCtl PROGRAM l'.ANAGER -
| |
| ,. .. , . . . . . .. me- .
| |
| ;e . ~ . . . . r g,- . ~ rg- .. t 9, -. ,3., ; s r.,;---- . -* v, * , ~. =. *..~ . .--~~ -+ .
| |
| : s. ,'
| |
| .. . . -s . 1 ,
| |
| ..e- n - - -
| |
| | |
| . ;: . = ,a c . ~~- - ..: - a. . ?--~~ : -. w - - -- - l
| |
| : a. _ _
| |
| ,yy- .
| |
| t.
| |
| 'l -..
| |
| t Page 2.of 2 J
| |
| ( , c-QR-1D-02-330B ATTRIBUTE TO BE VERIFIED: g
| |
| .] , _
| |
| - - 1) Q6ality sO tus of vendor component package and vendor quality rating.
| |
| : 2) Verify tor,que loads applied meet latest requirements.
| |
| ACCEPTANCE CRITERIA: _ . _ .
| |
| : 1) Satisfactory component package.
| |
| : 2) Verification that the flywheel bolts are tightened to the value ~ ~ ~ '~ ~ -
| |
| -] given in accordance to TDI's specifications.
| |
| . .. DOCUMENTATION REQUIRED: _ _. . _ _
| |
| : 1) Document Summary Sheet
| |
| ,~,
| |
| : 2) Report for verification of proper torques used in tightening
| |
| ^
| |
| flywheel bolts J
| |
| e i.
| |
| I DcD
| |
| ~
| |
| 1
| |
| . r f
| |
| t 4 .e a
| |
| l l l (,3
| |
| .. : . 'r-w--. . L-. _
| |
| v:. ..
| |
| } ,. . . .. _
| |
| l
| |
| .5
| |
| ; .-?.-,- .
| |
| .;v . ,-.-=y- : a w.-- - :.. u; ,
| |
| .v.-,. <p , e .3 . ; , ., ,.,
| |
| . _ _. J
| |
| * . s . 1 _ . s. ' , . ~ e .a .~. * , I
| |
| ' l
| |
| .+. .-. -
| |
| | |
| , g
| |
| .. ~ . - .
| |
| l l_
| |
| /' p b) j i l l.
| |
| A She:t Icf, j 's
| |
| *L'CENERATOR
| |
| ; QUALITY REVALIDATION PROGRMi
| |
| 'I l C NCllE PEAK . Job Number No.
| |
| l ] 1600.63 02-330B f STgNE & WEBSTER: ENGINEERING CORPORATION -
| |
| lev Chg~
| |
| l QUALITK ASSURANCE-INSPECTION PLAN . o. 1 NO. rus, _ 43 o o TITLE Flywheel Bolting Ihg*m Atte .
| |
| } Reference Description / Instructions INSPECTION: +
| |
| 1 TDI Instruction . Verify torque loads meet lates't requirement.
| |
| Manual 4
| |
| ! f e
| |
| i j i
| |
| ! i t i > i ,
| |
| I !
| |
| i I I !
| |
| f' { l 'i ..
| |
| 1 i
| |
| Quality Control Insp./ Engr. Date J
| |
| N/A
| |
| | |
| ....,,t _~--... :- ;-e , :- . -
| |
| =+4~%7 ~= " '='- E - w' ' ' "' '^ ~* ^
| |
| .(.1'W -h 1.
| |
| -a ,,
| |
| c TE GS UTILITIES j ,q. TASK DESCRIPTION NO. OR 02-335B fk K)
| |
| COMPONEIT REVALIDATION CHECKLIST 1^ O' ?ront Gear Caso i'
| |
| -, u ...COMPCNENT Gaskets and..SoltinV .CCCUMENT NO -QR-1 PART NUMDER 02-335B SCHEDULED FOR CCl!PLETION. l ''
| |
| ENPS PART NUMSIR 03-335B - . . . _ .
| |
| ,-- - - - - ---TASK OESCRIPTIOti: 1) Assemcle & rev:.ew exastang documentation -
| |
| : 2) Verify. bolting installations (visual) where
| |
| } accessible.
| |
| .?
| |
| w
| |
| ...e.
| |
| . . _ _ . 37;g;3g73 70. SF. '.'ChiFIED : 1) Qualaty status at vendor component package & vender quality rating.
| |
| : 2) Veri ~fy front gear case bolt are installed properly.
| |
| ACCEPTA::CE CRI' ERIA: 1) Satisfactory component package
| |
| ' 2) Visual inspection of front gear bolts per applicable assembly drawing.
| |
| TDI Instruction manual and gear case parts list c
| |
| | |
| ==REFERENCES:==
| |
| | |
| s . ~
| |
| ' (". /*- CCCUMEUTATION REQUIRED: 1) Document summary sheet
| |
| : 2) Satisfactory report of prope:. bolt installations.
| |
| ',5 GROUP CHAIRPERSON *$h$ M h h f g PROGRAM MANAGER kw d. k. b _
| |
| _....yr..._.............
| |
| -- -- COMPCl;U;;T REVIEW:
| |
| i b
| |
| - - RESULTS AND COIiCLUSIOGS : CPSES Unit 1, Train A (Serial No. /6001)
| |
| , All bolts and gaskets are satisfactory.
| |
| l
| |
| :.,3- ~ .,. . L . - . . . . . . . .
| |
| lD i- *
| |
| : , GROUP CHA!HPERSON PRCCRAM ttA::AGER r
| |
| i.; :
| |
| ,1 5[-
| |
| n l :: , , . . . .. y : ~ . . > . - ;.. -. - .,-. c . - .n---
| |
| n.: : . ~ : ev v , : a. s .:.- -- .~ : v ,.--.- - - - ~ ~ ~ - - - -
| |
| l ;, ,.. ,: ,
| |
| . , . . ..;. 5 - ''
| |
| | |
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| CENERATOR QUALITY REVALIDhTION PROGRAM i e l COHHANCllE PEAK M Neer No.
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| ! 8 i
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| * STONE & WIBSTER ENGINEERING CORPORATION 11600.63 02-3358 '
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| ; QUALITY ASSURANCE-INSPECTION PLAN NO.
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| Da inse - 8 Tev Chg 0 0 l TITLE I rront sear case - Gaskets and Bolting Attri i
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| [f . Jh Reference I Description / Instructions 1 TDI Parts List . Perform visual inspection of front i
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| & Instruction assembly drawing (where accessible) gear case bolts per applicable Manual 03-335 .
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| 1 L
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| t Quality Control Insp.-/ Engr. Date b, .
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| l' :.i. . ~. __JL ..~.~ .%'~~~ _ _ . . .U~ T- -
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| . . :. : ..a~ --- ~- ~ ~ ~ - - - - - -
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| _ a.. . .w . --
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| 1 '* .
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| J
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| * d' TEXAS UTILITIES
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| } TASK DESCRIPTION NO. QR- 10-0 2 -3 4 0 A Jg CCMPONENT REVALIDATION CHECKLIST j"
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| f*
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| COMPONENT JConnecting' Reds & Bushing CCCUMENT'NO 703y1 g ._
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| .1 PART NUMBER 02-340A SCHEDULED FOR COMPLETION.--. ___. F l
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| SNPS PART NUMBER 03-340A . . .
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| -T - TASK-DESCRIPTION: '
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| , SEE PAGE 2 s
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| -- --- - ATTRISUTE TO BE VERIFIED: 644 Ph4 4
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| .a ACCEPTANCE CRITERIA: SEE PAGE 2 RETERENCES: SEE PAGE 2 ,
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| f- n. -
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| y DOCUMENTATION REQUIRED: SEE PAGE 2 -
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| GROUP CHAIRPERSON @d Ma.: b PROGRAM MANAGER , C. k., $u . -
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| U i -__.__(.p_.__..... . . . _ _ _ _ __.
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| ---- - -, -- -- COMPONEITI REVIEW :
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| / .
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| ~
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| ~~'-~] ~ RESULTS AND CCI;CEUS10!;S : CPSES Unit 1, Train A (Serial No. 76001)
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| Signs of galling found on connecting rod bolts, studs and washer contact surface:;.
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| Linear indicati.ons found on connecting rod box external surfaces. Galling has been honed out, rod box external surfaces were evaluated as acceptable as is. Linear indications are due to babbit smearing in the rod thrust face area and are non- .
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| relevant. Washers have been replaced with improved (hardened) washers from TDI.
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| /
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| g ._. __ _._ __..
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| . -o. .
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| i s.
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| GROUP CHA!RPERSON -PROGRAM ttANAGER . .._ .--
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| t .g ., e r.7- .- -r- - - e : --- , .-./t- ** ,
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| * 7.., . ? r. .P * '
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| /._
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| Page 2 of 2
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| ,. c QR-10-02-340A
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| .. . TASK DESCRIPTION: _ . - . f Nj I:
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| . . 1) _ Assemble and review existing documentation.
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| ~
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| : 2) Perform material comparitor test on connecting rod and bushing cylinders. Perform superficial hardness test on connecting rods
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| . . . .. and bushing. Perform material comparitor and superficial hardness tests on spares if available. Sample basis.
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| : 3) Eddy current inspection for female threads in red box, one
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| ..' engine,100% inspection.
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| .- 4) MT inspection of conn rod bolts one engine, 100% inspection.
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| . . '.i . ... . ) . . . Visual inspection of conn red bolt washers and contact surfaces ~
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| for galling, 100% inspection.
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| : 6) Verify bolt torque on reassembly 100%. Latest TDI recommended
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| . value.
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| . .e E
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| : 7) LP Conn rod box external surfaces in area between conn rod bore and link rod bore (sample basis) . ? 50
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| * 7*
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| 1 8) LP link rod bushing (sample basis)., iou % -
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| l ACCEPTANCE CRITERIA: - - - - - -
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| l.
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| ,,' 1) Quality status of vendor' component package.
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| : 2) To.be determined by design group.
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| dQ
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| : 3) Recording criteria per FaAA Eddy current procedure.
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| -N
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| : 4) No relevant linear indications.
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| : 5) No galling on washers M coatt::f SdP%.CEG
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| .g 6) Verify an installation.
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| .c 7) 8) See attached sheet.
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| . REFERENCES 1 '.2 ~
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| f 1) TDI Manual .
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| e 2) Approved Inspection Procedures 5 - -
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| DOCUMENTATION REQUIRED:
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| I 1) Summary Sheet
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| : f. '
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| : 2) Inspection report.
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| : 3) Photograph any non conforming conditions for review by design group.
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| - a WA J])?[ d LIQUID PENETRANT ACCEPTMICE CRITERIA Q
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| 7, , , O . ' 2 *==eee==== c=ic +-
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| I l; U2.1 A~cceptance critaria are generally included in the code or !
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| J: - -
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| specification which establishes the required examination. #
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| -' Such specified criteria shall be used to determine the specific type, size and location of observed discontinuities.
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| . When acceptance critaria is not specified-in the doctanentation establishing the requirement for the examination,the following relevant indications are unacceptable. Only indications with major dimensions greater than 1/16 inch shall be considered
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| '; relevant.
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| ~
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| a) Wrouthe, Forted or Welded Items;
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| - - IT Any crack or linear indication i 2. Rounded indications with di=ensions greater than 1/8 inch
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| , for thickness less than 5/8 inch and greater than 3/16 inch for thickness of 5/8 inch and greater.
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| [ 3. Four or more indications in line separated by 1/16 inch a
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| or less edge to edge.
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| . e a
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| : 4. Ten or more indications in any 6 square inches of area -
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| Q whose major dimension is no more than 6 inches with the dimensions taken in the most unfavorable location relative
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| ,; to the indications being evaluated.
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| ,i
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| : 5) Selts and Soltint Material Gre_ater than I inch Normal Size . _ .
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| ]', l. Any linear nonaxial indications.
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| ! ,e 2. Linear axial indications . greater than I inch.
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| flilESl*' *:1 TIH: ejilAl.1TV HEVAl.1 DATION Pl:elGRAM *
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| j k 4:HMANs:llE Pl'AK r ',i7
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| .1o1 Number No. 7 /
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| * STE,8NE t. Wl'h' ITER l:t#;l NEER1 fH: i:Ol:PORATIUN *
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| * I QU ALjlTY ASSUR AN,CE-INSPECTidN PLAN
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| , -~
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| TITL CONN. ECTI NG.. .ROI)S ANil BilSill PK;S t
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| n.C. iNSr. _ 44
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| '{'7 :
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| 18 e m Asari, il No: I,'hsnl l.1/- Hu l u s'ent'e .
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| 1)escript lon/Isint ruct ions s.
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| I INSPECTION:
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| 1 NOTE: See Attachment I for assembly drawing. l.
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| tK)TE: A comparator test is to be performed utilizing a known std.
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| or verifying the availability of a spare or discard which may ,
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| be comparator tested and sent out for dest ructive testing at a later date. (Inspect 4)
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| Perform material comparator test on the following ,
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| . a. Haster Rod '
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| : b. I. ink Rod
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| : c. Rod Box
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| : d. Connecting Rod Bushings !:
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| : e. Rod flox Bushing
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| : f. Link Rod Pin
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| . g. Spares, if available
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| }
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| 2 Perform a superficial hardness test on the following: 1.
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| : a. 1-laster Rod . !
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| : h. Link Rod ' !
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| : c. Rod flox
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| : d. Connecting Rod Bushings
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| ~
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| : e. Rod Box Bushing .'
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| I
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| : f. Link Rod Pin
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| : g. Spares, if available
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| .r -
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| 3 '
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| l Perform Eddy Current Inspection of female threads in Rod Box, one engine - 100%.
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| i
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| -~ -*~ .
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| 4 4
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| ' Perform HT Inspection of the following:
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| ; ! a. Link rod to link rod pin bolts I '
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| I b. Con, rod bolts I
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| : c. Con rod studs
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| * See-Rev. 2 Acceptance Criteria One engine - 100%
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| I -_ _
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| ,),ia l I t y Cont ro l i nsp. /Enl:r. Date i !.
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| M _ _ _ _ _ _ _
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| . , .j .}}
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