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| | number = ML071080406 | | | number = ML071080406 |
| | issue date = 04/05/2007 | | | issue date = 04/05/2007 |
| | title = Brunswick, Emergency Diesel Generator No. 1 Trip and Failure of Engine Crankshaft Bearing | | | title = Emergency Diesel Generator No. 1 Trip and Failure of Engine Crankshaft Bearing |
| | author name = | | | author name = |
| | author affiliation = Progress Energy Carolinas, Inc | | | author affiliation = Progress Energy Carolinas, Inc |
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| {{#Wiki_filter:Brunswick Nuclear Plant Emergency Diesel Generator No. 1 Trip and Failure of Engine Crankshaft Bearing IntroductionScotty HinnantSenior VP & CNOJim ScarolaSite Vice PresidentSteve HowardManager OperationsRandy IveyManager Support ServicesSusan RogersManager MaintenanceTim TraskManager EngineeringBob RishelSupervisor -PSA Agenda Opening Remarks Event Review Diesel Generator Reliability Mitigating Systems Key Lessons Learned Closing Comments Opening Remarks BNP agrees with the finding and preliminary significance determination. | | {{#Wiki_filter:Brunswick Nuclear Plant Emergency Diesel Generator No. 1 Trip and Failure of Engine Crankshaft Bearing |
| EDG 1 -Sequence of EventsPlanned Maintenance October 23 -30 Oct 23 rd -EDG 1 Removed From Service For Planned Maintenance Activities. Corrective MaintenancePreventive Maintenance72 Month Inspection ActivitiesMargin ImprovementPower Potential Transformer Replaced EDG 1 -Sequence of EventsPlanned Maintenance October 23 -30 Oct 29 th EDG 1 AvailablePost-maintenance testing run, lubricating oil strainer high differential pressure alarms were
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| received Oct 28 th& 29 thPost maintenance activitiesEDG 1 started and was run 5 timesCumulative run time ~15 1/2hours Oct 30 th EDG 1 declared operable At Power Electrical System Lineup U2 SAT Flex Link on Phase A Fails Operators Insert Manual Trip on U2 Loss of Offsite Power Unloaded DG 1 Trip Backfeed Established Emergency Power Loads EDG 4 E4 Division II EDG 3 E3 Division I EDG 1 E1 Division I EDG 2 E2 Division II CSW Pump 1A RHR SW Pump 1B RHR SW Pump 2B CSW Pump 2B RHR Pump 1B Fire Pump CS Pump 2B RHR Pump 2B NSW Pump 2B E4 Loads RHR SW Pump 1A RHR SW Pump 2A CSW Pump 2A RHR Pump 1A CS Pump 2A RHR Pump 2A NSW Pump 2A E3 Loads CSW Pump 2C RHR SW Pump 2C RHR SW Pump 1C CSW Pump 1A RHR Pump 2C CS Pump 1A RHR Pump 1C NSW Pump 1A E1 Loads RHR SW Pump 2D RHR SW Pump 1D CSW Pump 1C RHR Pump 2D Fire Pump CS Pump 1B RHR Pump 1D NSW Pump 1B E2 Loads Unit 2 Unit 1 EDG 1 Trip On Low Lube Oil Pressure EDG 1 Trip On Low Lube Oil Pressure High Differential Pressure Caused By:Aluminum shavings from failed bearingFibrous material from towel left in system during maintenance
| | Introduction z Scotty Hinnant Senior VP & CNO z Jim Scarola Site Vice President z Steve Howard Manager Operations z Randy Ivey Manager Support Services z Susan Rogers Manager Maintenance z Tim Trask Manager Engineering z Bob Rishel Supervisor - PSA |
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| activities EDG 1 Trip On Low Lube Oil Pressure Root Cause of Trip: Inadequate FME controls resulting in a cleaning cloth left in lube oil system Contributing Causes:
| | Agenda z Opening Remarks z Event Review z Diesel Generator Reliability z Mitigating Systems z Key Lessons Learned z Closing Comments |
| -Method of refilling LO duplex strainer basket while DG running
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| -Rationalized cleaning duplex strainer multiple times following maintenance as normal
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| -Shavings from failed bearing contributed to high dp EDG 1 Trip On Low Lube Oil Pressure Inadequate Worker Practice Action to Prevent Recurrence: Establish High FME Job Classification for the DG Crankcases Immediate Actions:Improved High FME ControlAccountability for Cleanliness Closeout Failure Of Main Journal Bearing #9 Bearing Failure Occurred Prior to Diesel Trip Bearing Damage/Cracking Probably Occurred Prior to Final Run Damage Similar to 1992 Failure of Same Bearing Bearing # 9 in
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| Service 14 years Prior Bearing in Service 16 years Failure Of Main Journal Bearing #9 Cause: Increased Crankshaft Bearing ClearancesResulted In Lower Initial Bearing CrushGreater Operational Stresses on Bearings Failure Of Main Journal Bearing #9 Action to Prevent RecurrenceReplace DG1 Main Journal Bearings With Oversized Bearings Failure Of Main Journal Bearing #9 Other Corrective ActionsDetermine Methodology for Performing Lift ChecksInstall New BearingsEstablish Accurate Bearing Clearance MeasurementPerform plastigauge or similar measuring techniqueReplace Main Journal Bearings on DG #2, #3 and #4 Evaluate Bearing WearEstablish Preventative Maintenance ActivitiesReplace Connecting Rod Bearings on All DG'sDetermine Acceptable Babbitt Thickness Diesel Generator Reliability Review Completed in January 2007 Performed Pareto Analyses using key inputs:MSPIMaintenance RulePlanned and Unplanned UnavailabilityCorrective Action ProgramWork OrdersSelf Assessments, Benchmarks, Audits, NRC InspectionsVendor Input / Industry OE Diesel Generator Reliability Review Key Reliability Improvements Items Allen Bradley Control RelaysAll Normally Energized Critical Relays replacedEDG #3 and #4 Normally De-energized Critical Relays replaced in Refueling OutageEDG #1 and #2 Normally De-energized Critical Relays to be replaced before June 2007 Starting Air Reconfiguration and Improvements6 of 8 Pressure Reducing Valves replaced. EDG #2 to complete before June 2007.6 of 8 Shuttle Valve replaced. EDG #1 to complete before June 2007.Design work commencing to change from air-to-run to air-to-stop Aging of Capacitors in Control System30 of 56 Capacitors replacedSpecial Manufacturing Run in progressNo current evidence of degradation. Power Potential Transforme r replaced on all EDGsEDG #3 and #4 logic upgrade (27 PK Relays) complete. EDG #1 and #2 in Unit 1 2008 Outage. EDG #1 Bearings Diesel Generator Reliability Preventive Maintenance EvaluationIn Progress, To Complete in May 2007 ObjectivesValidation of component criticalitiesUpgrade of existing functional equipment groupsIdentification of single-point vulnerabilitiesStrengthening of PM basis Identification & prioritization of health issuesSystem monitoring improvements Diesel Generator Reliability Interim Actions Increased Monitoring During EDG runs:Thermography of electrical cabinets / componentsMonitoring of critical engine parametersMonitoring of operation and health of support systems Diesel Generator Reliability Technology TransferEngine Solution Inc. to acquire NAK Technology (current vendor for Nordberg
| | Opening Remarks z BNP agrees with the finding and preliminary significance determination. |
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| EDGs)Joint Progress Energy / Duke agreementEnsures continued and improved vendor
| | EDG 1 - Sequence of Events Planned Maintenance October 23 - 30 z Oct 23rd - EDG 1 Removed From Service For Planned Maintenance Activities. |
| | Corrective Maintenance Preventive Maintenance 72 Month Inspection Activities Margin Improvement Power Potential Transformer Replaced |
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| support for EDGs Other Mitigating Systems Mitigating System ReliabilityReviewing mitigating systems for similar vulnerabilitiesService WaterHigh Pressure Coolant InjectionResidual Heat RemovalReactor Core Isolation CoolingDetailed review of NCRs generated over the
| | EDG 1 - Sequence of Events Planned Maintenance October 23 - 30 z Oct 29th EDG 1 Available Post-maintenance testing run, lubricating oil strainer high differential pressure alarms were received z Oct 28th & 29th Post maintenance activities EDG 1 started and was run 5 times Cumulative run time ~15 1/2 hours z Oct 30th EDG 1 declared operable |
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| past 5 years Lessons Learned Technical Rigor FME Culture and Practices Improved Contingency Plans Corrective Action Program Improvements Closing Comments Mr. Scotty Hinnant Senior Vice President and Chief Nuclear Officer Questions & Comments}} | | At Power Electrical System Lineup U2 SAT Flex Link on Phase A Fails Operators Insert Manual Trip on U2 Loss of Offsite Power Unloaded DG 1 Trip Backfeed Established Emergency Power Loads Unit 2 Unit 1 E4 E3 E1 E2 Division II Division I Division I Division II EDG 4 EDG 3 EDG 1 EDG 2 E4 Loads E3 Loads E1 Loads E2 Loads NSW Pump 2B NSW Pump 2A NSW Pump 1A NSW Pump 1B RHR Pump 2B RHR Pump 2A RHR Pump 1C RHR Pump 1D CS Pump 2B CS Pump 2A CS Pump 1A CS Pump 1B Fire Pump Fire Pump RHR Pump 1B RHR Pump 1A RHR Pump 2C RHR Pump 2D CSW Pump 2B CSW Pump 2A CSW Pump 1A CSW Pump 1C RHR SW Pump RHR SW Pump RHR SW Pump RHR SW Pump 2B 2A 1C 1D RHR SW Pump RHR SW Pump RHR SW Pump RHR SW Pump 1B 1A 2C 2D CSW Pump 1A CSW Pump 2C |
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| | EDG 1 Trip On Low Lube Oil Pressure EDG 1 Trip On Low Lube Oil Pressure z High Differential Pressure Caused By: |
| | Aluminum shavings from failed bearing Fibrous material from towel left in system during maintenance activities |
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| | EDG 1 Trip On Low Lube Oil Pressure z Root Cause of Trip: Inadequate FME controls resulting in a cleaning cloth left in lube oil system z Contributing Causes: |
| | - Method of refilling LO duplex strainer basket while DG running |
| | - Rationalized cleaning duplex strainer multiple times following maintenance as normal |
| | - Shavings from failed bearing contributed to high dp |
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| | EDG 1 Trip On Low Lube Oil Pressure z Inadequate Worker Practice z Action to Prevent Recurrence: Establish High FME Job Classification for the DG Crankcases z Immediate Actions: |
| | Improved High FME Control Accountability for Cleanliness Closeout |
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| | Failure Of Main Journal Bearing #9 z Bearing Failure Occurred Prior to Diesel Trip z Bearing Damage/Cracking Probably Occurred Prior to Final Run z Damage Similar to 1992 Failure of Same Bearing z Bearing # 9 in Service 14 years z Prior Bearing in Service 16 years |
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| | Failure Of Main Journal Bearing #9 z Cause: Increased Crankshaft Bearing Clearances Resulted In Lower Initial Bearing Crush Greater Operational Stresses on Bearings |
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| | Failure Of Main Journal Bearing #9 z Action to Prevent Recurrence Replace DG1 Main Journal Bearings With Oversized Bearings |
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| | Failure Of Main Journal Bearing #9 z Other Corrective Actions Determine Methodology for Performing Lift Checks Install New Bearings Establish Accurate Bearing Clearance Measurement Perform plastigauge or similar measuring technique Replace Main Journal Bearings on DG #2, #3 and #4 Evaluate Bearing Wear Establish Preventative Maintenance Activities Replace Connecting Rod Bearings on All DGs Determine Acceptable Babbitt Thickness |
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| | Diesel Generator Reliability Review z Completed in January 2007 z Performed Pareto Analyses using key inputs: |
| | MSPI Maintenance Rule Planned and Unplanned Unavailability Corrective Action Program Work Orders Self Assessments, Benchmarks, Audits, NRC Inspections Vendor Input / Industry OE |
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| | Diesel Generator Reliability Review Key Reliability Improvements Items z Allen Bradley Control Relays All Normally Energized Critical Relays replaced EDG #3 and #4 Normally De-energized Critical Relays replaced in Refueling Outage EDG #1 and #2 Normally De-energized Critical Relays to be replaced before June 2007 z Starting Air Reconfiguration and Improvements 6 of 8 Pressure Reducing Valves replaced. EDG #2 to complete before June 2007. |
| | 6 of 8 Shuttle Valve replaced. EDG #1 to complete before June 2007. |
| | Design work commencing to change from air-to-run to air-to-stop z Aging of Capacitors in Control System 30 of 56 Capacitors replaced Special Manufacturing Run in progress No current evidence of degradation. |
| | z Power Potential Transformer replaced on all EDGs z EDG #3 and #4 logic upgrade (27 PK Relays) complete. |
| | z EDG #1 and #2 in Unit 1 2008 Outage. |
| | z EDG #1 Bearings |
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| | Diesel Generator Reliability Preventive Maintenance Evaluation z In Progress, To Complete in May 2007 z Objectives Validation of component criticalities Upgrade of existing functional equipment groups Identification of single-point vulnerabilities Strengthening of PM basis Identification & prioritization of health issues System monitoring improvements |
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| | Diesel Generator Reliability Interim Actions z Increased Monitoring During EDG runs: |
| | Thermography of electrical cabinets / components Monitoring of critical engine parameters Monitoring of operation and health of support systems |
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| | Diesel Generator Reliability z Technology Transfer Engine Solution Inc. to acquire NAK Technology (current vendor for Nordberg EDGs) |
| | Joint Progress Energy / Duke agreement Ensures continued and improved vendor support for EDGs |
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| | Other Mitigating Systems z Mitigating System Reliability Reviewing mitigating systems for similar vulnerabilities Service Water High Pressure Coolant Injection Residual Heat Removal Reactor Core Isolation Cooling Detailed review of NCRs generated over the past 5 years |
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| | Lessons Learned z Technical Rigor z FME Culture and Practices z Improved Contingency Plans z Corrective Action Program Improvements |
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| | Closing Comments Mr. Scotty Hinnant Senior Vice President and Chief Nuclear Officer |
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| | Questions & Comments}} |
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Category:Meeting Agenda
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[Table view] Category:Meeting Briefing Package/Handouts
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Robinson NPP Tours During the Shearon Harris Scol Environmental Site Audit of Alternative Sites ML0403505052004-01-0707 January 2004 Meeting Handouts with Progress Energy to Discuss Fire Protection Initiatives ML0333601902003-11-25025 November 2003 Meeting Summary - Brunswick Steam Electric Plant ML0327206212003-09-24024 September 2003 Examiner - Vendor Matrix with Phone Number ML0327206112003-09-22022 September 2003 Exam Process 2022-09-14
[Table view] Category:Slides and Viewgraphs
MONTHYEARML22251A2352022-09-14014 September 2022 Presentation Slides for September 14, 2022, Observation Public Meeting ML22109A2122022-04-20020 April 2022 Duke Energy Pre-Submittal Public April 20, 2022, Meeting Presentation ML22091A1332022-04-0101 April 2022 Bru Har Combined 2021 Assessment Meeting Slides ML21322A3262021-11-29029 November 2021 Duke Energy November 29, 2021 Pre-Submittal Public Meeting Slides for EOF Relocation Licensing Amendment Request ML21090A1162021-03-31031 March 2021 Combined 2020 Aam Presentation ML21041A4532021-02-17017 February 2021 Brunswick/Nrc Pre-submittal Meeting: LAR to Adopt TSTF-505, Rev. 2 (Risk-Informed Completion Times) Presentation ML21033A7022021-02-0303 February 2021 Pre-submitting for Planned LAR for Standby Liquid Control Tank Volume Increase ML21011A0822021-01-12012 January 2021 Pre-Submittal Meeting January 12, 2021, Revision to VRR-01, Full Stroke Testing of Safety/Relief Valves - Presentation Material ML20100G6342020-04-0909 April 2020 Revised- Bru 2019 Annual Assessment Meeting Slides ML20099C9992020-04-0808 April 2020 Har 2019 Mtg Slides ML20099D1282020-04-0808 April 2020 Bru 2019 Mtg Slides ML19318F2912019-11-18018 November 2019 Duke Energy Presentation for the Pre-submittal Meeting on November 18, 2019, Regarding the RPV Stud Examination Relief Request ML19214A0562019-08-0707 August 2019 Presentation: Duke Energy Presubmittal Meeting - August 7, 2019 ML19123A3532019-05-0202 May 2019 Public Meeting Summary - Brunswick Steam Electric Plant, Docket Nos. 05000325 and 05000324 ML18255A0142018-09-12012 September 2018 BWROG Presentation Slides for Public Meeting Sept 12 2018 ML17331A6272017-11-29029 November 2017 Duke Energy Pre-Submittal Meeting Presentation, Brunswick, Harris, and Robinson License Amendment Requests Regarding 10 CFR 50.69 ML17297B7892017-10-26026 October 2017 Meeting Slide for Partially Closed Pre-submittal Public Meeting with Duke Energy for License Amendment Request to Adopt Areva'S XM-11 Fuel Methodology for Brunswick Steam Electric Plant ML17229B2942017-08-22022 August 2017 Meeting Slide Regarding Partially Closed Pre-submittal Public Meeting with Duke Energy for a License Amendment Request for Brunswick Steam Electric Plant ML16231A1322016-08-18018 August 2016 Materials for 8/18/16 Pre-Application Meeting Brunswick Mellla+ LAR ML16210A5152016-07-28028 July 2016 Bnp Commercial Grade Dedication Issue (Printable) ML16134A1742016-05-12012 May 2016 Summary of Public Meeting - 2015 Annual Assessment Regarding Brunswick, Units 1 and 2 ML14140A1882014-05-19019 May 2014 Summary of Public Meeting - 2013 Annual Assessment Regrading Brunswick Steam Electric Plant ML14135A5112014-04-17017 April 2014 Enclosure 4 to BSEP 14-0048 - Areva Mellla+ Methods Applicability Presentation (Non-Proprietary Version) ML14135A5092014-04-17017 April 2014 Enclosure 1 to BSEP 14-0048, Duke Energy Presentation - Brunswick Mellla+ Methods Applicability, Pre-Application Meeting ML13312A9882013-11-0808 November 2013 Summary of Public Meeting with Duke Energy Carolinas, LLC, to Provide Opportunities to Discuss the Planned Fukushima-Related Modifications ML13308A0072013-11-0101 November 2013 Open Phase Resolution Update Meeting Duke Energy Entitled Open Phase Detection and Protection. ML13277A0382013-09-24024 September 2013 GEH Presentation on Methods Applicability to Areva Atrium 10XM Fuel ML13277A0372013-08-20020 August 2013 Duke Energy Presentation - Brunswick Mellla+ Methods Applicability, Pre-Application Meeting, August 20, 2013 ML13130A2552013-05-10010 May 2013 4/24/2013 - Meeting Summary - Category 3 Public Meeting - Annual Assessment of Brunswick Steam Electric Plant ML12181A0362012-06-29029 June 2012 Meeting Summary - Category 1 Public Meeting - Annual Assessment of Brunswick Steam Electric Plant, Docket Nos. 50-325, 50-324 ML12158A3442012-06-0606 June 2012 Meeting Slides for Pre-Application Meeting with Carolina Power and Light Company Regarding Emergency Diesel Generator Completion Time Extension for Brunswick Steam Electric Plant, Units 1 and 2 ML11102A0052011-04-12012 April 2011 Progress Energy - Slides for NFPA 805 Pre-LAR Application Meeting April 12, 2011 ML1020304622010-07-20020 July 2010 Groundwater Protection Status ML1016705232010-06-0808 June 2010 NRC Fire Protection Screening Criteria, Brunswick Nuclear Plant ML1015404182010-05-27027 May 2010 Meeting Summary - Public Meeting - Brunswick Steam Electric Plant Annual Assessment - Reactor Oversight Program 2009 Presentation Slides ML1001507632010-01-15015 January 2010 Meeting Presentation Brunswick Nuclear Plant Human Performance ML1001507042010-01-14014 January 2010 Human Performance Slides ML0930206712009-10-22022 October 2009 Emergency Diesel Generators - Progress Energy ML1019400952009-10-0808 October 2009 Marsh, River, and Creek Tritium Results Updated 10/08/09 ML1019400932009-10-0808 October 2009 Groundwater Well Samples Results, Updated 10/08/09 ML0923210802009-08-20020 August 2009 MELLLA Plus Implementation ML0921609632009-08-0404 August 2009 Meeting Summary - Public Meeting Category 1 - Preliminary White Finding - Brunswick Steam Electric Plant ML0830800052008-10-31031 October 2008 Meeting Slides, Progress Energy Public Meeting, NRC Region II Visit ML1019404532008-05-21021 May 2008 Email from Grzeck, Lee to Heather Gepford, Austin, Joe, George Kuzo, England, Louise, Kemp, Daniel and Dale.Dusenbury@Ncmail.Net; Subject: Storm Drain Collection Basin and Storm Drain Stabilization.Pdf; Sampling Locations Data Updated 5-19- ML0813006582008-05-0101 May 2008 EOC 2007 NRC Slides ML0813006662008-05-0101 May 2008 EOC 2007 Progress Energy Slides ML1019405012008-04-0101 April 2008 Annual Report Slides BSEP 07-0108, Areva Presentation Slides for Brunswick Fuel Transition License Amendment Request2007-07-31031 July 2007 Areva Presentation Slides for Brunswick Fuel Transition License Amendment Request ML0711503272007-04-23023 April 2007 Brunswick, EOC Slides, Cy 2006 ML0710803842007-04-18018 April 2007 Presentation Slides from Public Management Meeting to Discuss Brunswick Site and Emergency Diesel Generator Improvements 2022-09-14
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Brunswick Nuclear Plant Emergency Diesel Generator No. 1 Trip and Failure of Engine Crankshaft Bearing
Introduction z Scotty Hinnant Senior VP & CNO z Jim Scarola Site Vice President z Steve Howard Manager Operations z Randy Ivey Manager Support Services z Susan Rogers Manager Maintenance z Tim Trask Manager Engineering z Bob Rishel Supervisor - PSA
Agenda z Opening Remarks z Event Review z Diesel Generator Reliability z Mitigating Systems z Key Lessons Learned z Closing Comments
Opening Remarks z BNP agrees with the finding and preliminary significance determination.
EDG 1 - Sequence of Events Planned Maintenance October 23 - 30 z Oct 23rd - EDG 1 Removed From Service For Planned Maintenance Activities.
Corrective Maintenance Preventive Maintenance 72 Month Inspection Activities Margin Improvement Power Potential Transformer Replaced
EDG 1 - Sequence of Events Planned Maintenance October 23 - 30 z Oct 29th EDG 1 Available Post-maintenance testing run, lubricating oil strainer high differential pressure alarms were received z Oct 28th & 29th Post maintenance activities EDG 1 started and was run 5 times Cumulative run time ~15 1/2 hours z Oct 30th EDG 1 declared operable
At Power Electrical System Lineup U2 SAT Flex Link on Phase A Fails Operators Insert Manual Trip on U2 Loss of Offsite Power Unloaded DG 1 Trip Backfeed Established Emergency Power Loads Unit 2 Unit 1 E4 E3 E1 E2 Division II Division I Division I Division II EDG 4 EDG 3 EDG 1 EDG 2 E4 Loads E3 Loads E1 Loads E2 Loads NSW Pump 2B NSW Pump 2A NSW Pump 1A NSW Pump 1B RHR Pump 2B RHR Pump 2A RHR Pump 1C RHR Pump 1D CS Pump 2B CS Pump 2A CS Pump 1A CS Pump 1B Fire Pump Fire Pump RHR Pump 1B RHR Pump 1A RHR Pump 2C RHR Pump 2D CSW Pump 2B CSW Pump 2A CSW Pump 1A CSW Pump 1C RHR SW Pump RHR SW Pump RHR SW Pump RHR SW Pump 2B 2A 1C 1D RHR SW Pump RHR SW Pump RHR SW Pump RHR SW Pump 1B 1A 2C 2D CSW Pump 1A CSW Pump 2C
EDG 1 Trip On Low Lube Oil Pressure EDG 1 Trip On Low Lube Oil Pressure z High Differential Pressure Caused By:
Aluminum shavings from failed bearing Fibrous material from towel left in system during maintenance activities
EDG 1 Trip On Low Lube Oil Pressure z Root Cause of Trip: Inadequate FME controls resulting in a cleaning cloth left in lube oil system z Contributing Causes:
- Method of refilling LO duplex strainer basket while DG running
- Rationalized cleaning duplex strainer multiple times following maintenance as normal
- Shavings from failed bearing contributed to high dp
EDG 1 Trip On Low Lube Oil Pressure z Inadequate Worker Practice z Action to Prevent Recurrence: Establish High FME Job Classification for the DG Crankcases z Immediate Actions:
Improved High FME Control Accountability for Cleanliness Closeout
Failure Of Main Journal Bearing #9 z Bearing Failure Occurred Prior to Diesel Trip z Bearing Damage/Cracking Probably Occurred Prior to Final Run z Damage Similar to 1992 Failure of Same Bearing z Bearing # 9 in Service 14 years z Prior Bearing in Service 16 years
Failure Of Main Journal Bearing #9 z Cause: Increased Crankshaft Bearing Clearances Resulted In Lower Initial Bearing Crush Greater Operational Stresses on Bearings
Failure Of Main Journal Bearing #9 z Action to Prevent Recurrence Replace DG1 Main Journal Bearings With Oversized Bearings
Failure Of Main Journal Bearing #9 z Other Corrective Actions Determine Methodology for Performing Lift Checks Install New Bearings Establish Accurate Bearing Clearance Measurement Perform plastigauge or similar measuring technique Replace Main Journal Bearings on DG #2, #3 and #4 Evaluate Bearing Wear Establish Preventative Maintenance Activities Replace Connecting Rod Bearings on All DGs Determine Acceptable Babbitt Thickness
Diesel Generator Reliability Review z Completed in January 2007 z Performed Pareto Analyses using key inputs:
MSPI Maintenance Rule Planned and Unplanned Unavailability Corrective Action Program Work Orders Self Assessments, Benchmarks, Audits, NRC Inspections Vendor Input / Industry OE
Diesel Generator Reliability Review Key Reliability Improvements Items z Allen Bradley Control Relays All Normally Energized Critical Relays replaced EDG #3 and #4 Normally De-energized Critical Relays replaced in Refueling Outage EDG #1 and #2 Normally De-energized Critical Relays to be replaced before June 2007 z Starting Air Reconfiguration and Improvements 6 of 8 Pressure Reducing Valves replaced. EDG #2 to complete before June 2007.
6 of 8 Shuttle Valve replaced. EDG #1 to complete before June 2007.
Design work commencing to change from air-to-run to air-to-stop z Aging of Capacitors in Control System 30 of 56 Capacitors replaced Special Manufacturing Run in progress No current evidence of degradation.
z Power Potential Transformer replaced on all EDGs z EDG #3 and #4 logic upgrade (27 PK Relays) complete.
z EDG #1 and #2 in Unit 1 2008 Outage.
z EDG #1 Bearings
Diesel Generator Reliability Preventive Maintenance Evaluation z In Progress, To Complete in May 2007 z Objectives Validation of component criticalities Upgrade of existing functional equipment groups Identification of single-point vulnerabilities Strengthening of PM basis Identification & prioritization of health issues System monitoring improvements
Diesel Generator Reliability Interim Actions z Increased Monitoring During EDG runs:
Thermography of electrical cabinets / components Monitoring of critical engine parameters Monitoring of operation and health of support systems
Diesel Generator Reliability z Technology Transfer Engine Solution Inc. to acquire NAK Technology (current vendor for Nordberg EDGs)
Joint Progress Energy / Duke agreement Ensures continued and improved vendor support for EDGs
Other Mitigating Systems z Mitigating System Reliability Reviewing mitigating systems for similar vulnerabilities Service Water High Pressure Coolant Injection Residual Heat Removal Reactor Core Isolation Cooling Detailed review of NCRs generated over the past 5 years
Lessons Learned z Technical Rigor z FME Culture and Practices z Improved Contingency Plans z Corrective Action Program Improvements
Closing Comments Mr. Scotty Hinnant Senior Vice President and Chief Nuclear Officer
Questions & Comments