ML19252A292

Responds to NRC 780105 Questionnaire Re Standby Diesel Generator Unit Reliability

ML19252A292
Person / Time
Site:	Three Mile Island
Issue date:	01/20/1978
From:	METROPOLITAN EDISON CO.
To:
Shared Package
ML19209B793	List: ML19209B792 ML19209B795 ML19209B796 ML19252A292
References
PROB-780120, NUDOCS 7910100483
Download: ML19252A292 (126)

Text

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< s-Ouestionnaire for NUCLEAR REG'JLATCRY C0!'llISSIC 1 C RELIABILITY STUDY j

. of b

e 4 Standby Ciesel Generator Units .

Date Questionnaire Completed: 1-5-78 ___ [

Plant Name: Three Mile Island Unit No. 1 Diesel Manufacturer: Fairbanks-Morse tiodel: non Ti1 o 1/q Number of Units: 2

^

Size Kw/ Unit: 3000 KW Rated Speed: onn nou Average Coerating Hours Per Unit to Date: 426 DIESEL GE?ERATCR STATUS A. Enoine:

1. Problems are caused chiefly by (give estimated number)

a. Defective parts 2

b. Installation errors: o

c. Failure of system to responc properly in function or sequence: 0 ...

d. Faulty adjustment: 0 i

e. Operator Error-Exact Number not known but triis.smost frequent fai'aure.

2. Would nore stringent inspection and testing requirements during acceptance or preoperational tests significantly ,

improve the diesel-generator power plant performance? 7 Yes  !!o X B. Starting Systens (indicate which): ,

1. Air-to-cylirder cranking. Yes 1412 222 -f Air cranking notor No "ir. 'l/ A Model tio. nua ,-

Electric cranking motor No M f r.' N/A  !!0cel ?!c. tu A L-'

Dedet G E[ . -"

Controlt 1. '

Date --

ofDoceeit:

REGULATORY 00CXET FILE

I .

2. If air cranking, then: i n i '. * . ., , , ,

- -/ .- . Give size of starting air tank: Length 103" Diameter laa i

Normal standby air tank pr3ssure 250 psi. [

u Is pressure reducer used? Yes No X - _ .

Reducer pipe size? N/A inches.

Starting air control admissten valve pipe size in air piping system, 1 1/2 inches. ,

Minimum air tank pressure for engine cranking 75 psi.

Number of five-second cranking ceriods between above pressures with no tank recharging UN .

Number of air tanks per engine 2 .

Can starting air tanks serve more than one engine?

Yes No y Is air pipe to engine fren top of air tank? Yes x No Does starting air tank ha"e water condensate drain?

Yes X No (Off bottom of start air receiver)

Does starting air pipe have water condensate trap and drain near engine? Yes No y Is starting air piping horizontal? Yes No Both X Does it slant toward drain? Yes No X

'l If water condensate draint are provided, then is draining:

+

a. Automatic through flott valve? Yes No X

b. Manual by hand valve? Yes x No

c. If manual, then is draining water condensate done: .

-! 1 35 1412 224

?

e e

t 3-G .,

daily? l weekly? x

~

, conthly? '

before each start if manual?

no procedure? l Is dirt and rust filter provided in starting air pipe? -a Yes X Ho - -

If provided, where installed? Upstream of air _ start olenoid valves.

How is it cleaned? "Y" Strainers - Manual

• How of ten and wher.? Annually - Year end Give pipe size of filter: _24 inches.

How is it known whether filter is plugged or has high oressure drop? No OPI installed.- Not kanwn Is starting air pipe to engine positioned:

a. Below floor? X -

D. On the floor?

c. Overhead? X What is air pressure droo fron air tank to engine during cranking N/A psi Give approximate icngtn (nearest ten feet) of -tartine air oice for individual engine or all engines from air tank  ;

to:

~

t

a. Hearest engine 25 feet

b. Furthest enoine 25 feet ,

L._

1412 W 4

e

e Diameter of starting air pipe from:

Air tank to starting valve jn._ inches ,

]

-7;7}. - a. _ --"

-~

b. At air starting valve 14 incnes

_I.

' ~ ~ ~ ~

c. At engine 1k inches What is the primary source of power for the starting air ,.

(_ _ ,.

system? el oc 34 77 7.g;;;7 Is there a duplicate and redundant motor and air compressor set? Yes No x What is the time required to recharge one air tank?

UN minutes Does starting air supply system have independent secondary power supply for compressor? Yes y No If yes, then by:

a. Gasoline engine? A

b. !1otor driven? Nn

c. Other? (Specifyl ONAN Ofasel canine This Section 3. If electric (Battery powered) cranking, then:

is N/A.

a. Battery charging: Continuous trickle charger Intermittent charging If so, how is charging requirement determined?

" Time cycle Test Other

b. Battery used: Ccomon Plant Individual Unit Other Starting cable size  ; Length: Battery to engine (longest) e 6

1

- \

M C. Fuel Oil System: Bulk Tank to Day Tank

1. Does the bulk tank to day tank fuel supply system (viz: -

pump, motor, etc.) have redundant indeoendent pcwer -

supplies? Yes X No .

. sh Does this system have a hand-operated energency fuel _._

pump? Yes No y If yes, is this hand-operated pump and ciping in immediate operating condition? Yes N/A No _3fA ,

2. Is there a water and sediment drain frem the very botton cf the:

a. Bulk tank? Yes No y

b. Day tank? Yes X No

3. Is the requiar functional fuel oil cutlet slightly above (two to three inches) the botten of the:

. a. Bulk tank? Yes X No

b. Day or integral tank? Yes X No

4. Is bottom of day tank and/or intecral tank above all parts and piping of the enaine fuel injection systems?

Yes - No y If yes, .

Give approximate amount inches N/A feet N/A

5. Does the engine fuel system have a fuel bleed return line to the fuel day tank and/or integral tank? -

Yes x No During extended operation, such as more than two to three hours, does the fuel in the day tank become: (yes or no)

a. Warm? No 'l

b. Hot? yn (above 130*F) ( '

e- -

O 1412 226 e

m-What is fuel oil return line size (ncminal)? ] L 3

a. Pipe size 3/4 inches ~

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b. Tubing size in _ inches - .

. . -.'._.. _... ;.'"n"

. . . _ . , i .[

Do engine fuel oil filters have air bleed or vent vaLvas plugs i 6.

~

readily accessible? Yes y No l ..

7. How is fuel transferred frem day tank to er.gine fuel system?

a. By gravity un

b. Engine driven pump y

c. Electric motor driven pu(. pat rated y speed) .

d. Is a manual pump also previceo fdk'l8fe@$g speed) system filling and/or air venting af ter servicing or replacement of parts in the fuel injection system? Yes No X If yes, is the manual pump in immediate operating condition?

Yes N/A Ho y

8. Type of fuel (e.g. , #1, #2, #3, JP-4, etc.) 32 .

9. Approximate bulk tank capacity, 30,000 gallons.

10. Typical frequency of refilling (weekly, conthly, etc.) evarv s -ne moninall y.

11. Typical refill (gallons), e n n n ,,. _,4 ., _.,.

D. Lube Oil System

1. Lube oil

a. Type Ester GLX-30

b. Vi scosi ty SAE 30 ~

c. Specification number UN _

d. Oil change determined by:

Time interval: Yes No y Give interval N/A nonthly, yearly By oil analysis: Yes x No 4

1412 227

s p-w Lube oil filters are:

2. ' '

a. Full flow sn i

b. Bypass Nn C. Combination yne _

3. Interval and/or basis for changing filter cartridce: 22 a ~.

a. Monthly No

b. Yearly yne

c. By running time No hcurs y

d. By oil analysis. Yes No No y

e. By pressure drop. Yes -

f. Does provisions exist for changing cartridges during

- engine operation? Yes No x

4. Oil Pressure Monitoring Normal operating pressure 31 psi a.

b. Alarm 16 psi

c. Shutdcwn 16 psi

5. Oil temperature control:

• F.

a. By standby heater in engine sump N/A

b. Heating neans for maintaining stancby tenperature:

Direct in oil un Oil-to-water heat exchanger Yes Other (Specify) No E. Coolino System - Enoine Water Temperature control by:

' 1. ~

No

a. By thermostat in water? Yes y I If yes, then:

j Bypass thermostat? Yes y No Throttle thermostat? Yes No X i }

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b. By radiator shutte : None

c.-

' : i ' :

l-Automatic No - - - - *

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ilT . ' Manual Other (2give type) nn ,, ,

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2. Corrcsion control (water additive)? Yes y No _ _

If yes, give chemical additive or name of compound.

Permanent Antifree~ze - Brand Name Proportion or concentration control:

a. By additive measurement? Yes No X

b. By water coolant analysis? Yes X No

3. Engine cooling water cooled by:

a. Radiator? X

b. Heat exchanger f rcm sea, river or other water? X

c. Other? (give type) X

4. Engine cooling water tamperature-monitoring

a. Standby temperatura 120 *F

b. Nomal operating tamperature 12018Q,*F

c. Alarm temperature 195 -F

d. Shutdown temperature None *F

e. Water circulation during stancby:

Themo-syphon J_

Pump vas

5. Water Pressure Monitoring: Yes X No

a. Alarm Yes

b. Shutdown No

c. Both No I '

e-s A*

1412 229 6

t I

6. Water temoerature Sensor Position: q

a. In piping from engine Yes_ ,

b. In engine piping yn F -.

c. In engine direct yn ,

7. Water surge or supply tank in system. Yes x No .b

1. _ ,

If yes, then bottom connected to:

a. Water pump suction? Yes X No

b. Top of system? Yes X No

c. Both of above? Yes X No

d. Is bottom of surge tank aoove top of engine system? Yes X No _

e. Does engine have constant air bleed from top of engine water piping to surge or supply tank?

Yes X No

f. Give size of oleed or vent line, UN inches.

g. fianual air bleed only? Yes X No F. Governor - Soeed Control

~

fianufacture r Woodward Electric (speed sensing) No Hydraulic Yes Type or coce (sucn as EG8-35, LSG-10, etc.) VG8 Automatic load sharing? Yes X No

1. Is compensation or stability control and/or speed of response manually adjustable? Yes X No If yes, adjusted by:

a. Eye and ear? No -

b. Test and specification? _Ygg_, ,

c. Other? (Speci fy) No .

2. Engine - generator normal shutdown or stopping means and method. _

Electrically Trip out Fuel Racks and Manually ( ,,

-. a i412 230 n

5

Is the engine stopped:

a. tianually? Yes X No

. . ~ - ' ~ ~

- Y

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Directly at engine? Yes X No Through 1ocal control panei? Yes x No J s ._

b. Autcmatically through the controls in the control room? Yes X- No

c. By setting governor to " fuel-off" position?

Yes No X

d. By over-ride of governor settings and control position directly to fuel injection pumps?

Yes Un No Un

e. Other means. Describe briefly. No

3. When engine is stopped, is fuel control in:

a. Full fuel or maximum fuel position? No

b. Full off or no fuel position? ys

c. Intermediate? No

d. Rendem? No (If not consistent and typical in above, then give the usual. )

4. When starting frcm the standby condition after shutdown for at least 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, give number of seconds frca start-to-crank to full fuel or maximum fuel position of governor and fuel control, <l seconds.

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1412 231

G. Governor - Overspeed (shutdown) j

[A

1. Speed sensing? -I

.g

a. Electrical yes -

b. _J

c. Flyball A)

Other (Specify No .

2. Fuel shutoff force generated by:

a. Spring? Yes

b. Air? No -

c. Hydraulic? No

d. Electrical? No

e. Other? (Specify) No .___

~

3. Overspeed sensing setting? (in terms of full speed)

a. 115t Nn

b. 110% NA

c. Other (Specify) A niacal e 11a.45%: B Diesel @ 115.55%

4. Is oversceed tripping set point tested periodically?

Yes No x If yes, then how of ten? N/A (yearly, monthly, etc. )

. Type H. 1. Generator fifr. Fairbanks Morse  ?.o . TGZDJ Single bearing or two bearings? 2 Does generator have damper wincings? Yes No y

2. Does generator have any obvious fault or difficulty?

Yes No X Is problem recetitive? Yes No x I--]

If yes, then describe briefly. N/A __

( J 1412 232 a

I. Exciter and Voltace Reculator

1. Exciter Manufacturer: Basler Type: Rotating jiode] SBHV -

]

No Static VeS

[2(!/h .

If rotating drive? Direct N/A --- YP '"

'-- Belt or Chair. N/A .

DC with f' eld control N/A .[

Brushless with rectifier N/A

.f.,

2. Voltage Regulator: Manufactu er Basler Model SBHV Type: flechanical No Static Yes

3. Are paralleled units of automatic load sharing centrol of fully automatic type? Yes No X If yes, has any cbvicus influence or interrelationship been noted between the stability and response time of the engine governor and the stability and voltage control of the generators? Yes No 1,

4. Have engine governor and voltage reculator/exci cr adjustments been mJae on the site or under any con-ditions since any of the units have been placed in

ervice? Yes X Ho If yes, by means of what tests and what standards?

Give name or very brief description. Station Maintenance Procedure d1420-E_G,-l

5. If any difficulties have occurred, give approximate nu=ber of problems,

a. Conponents 0 .

b. Wiring 0 ~i

c. Other (damage in service or dropping of r.iscellaneous '

hardware into switchboard, etc.) 0 .

1

-f 1412 233 6

J. Parallelino: Engine-Generator Units - This Section N/A L-i a

1. Do all units consistently have the proper voltage output?

Yes No -

2. Do all units automatically share both the "real" or in-phase load and also the reactive load reasonably well? Yes No

_a

~ ~

3. At the same Kw load, are both the field and the armature line currents of the several units consistently close to the same value? Yes No If no, approximate percent difference.

4. Synchronizing

a. In automatic synchronizing do circuit breakers close immediately after reaching full synchronous speed?

Yes No

b. If "no" above then, does speed of some units drif t slowly while failing to synchroni:e and close circuit breakers?

How many seconds? _

Occasionally ,

Always Never K. Switch Gear and Electrical Con (other than exciter /

voltage regulator)

1. If any difficulties have occurred, then give approximate '

number of problems.

ed

a. Components 1

b. Wirin9 0

. c. Other (aamage in service or dropping of niscellanecus hardware into switchocard, etc.) n

d. Design concept faults. That is, does the switch ,-

Cear and its controls perform the proper functions l_.

and in proper sequence and timing. O 1412 234 e

e

2. a. Do the on-site diesel generator units and related support e'quipment have any storage battery power systems for any service whatsoever? Yes X

)

fio .j 2

C _ .. _. 2 b , .; Identify each storage battery power systen associated = ,_ . - - ,y, . -

g-_ {. j

- - - ,' with_ the on-site diesel' generator dni t .and i ts - ' ~ ~ '

' ~

' ci

' function. Start Emerg. Air Comoressor Oiesel - -

n '.]

Ld

c. Does each systen identified above adequately fulfill the service requirements for wnich it is intended?

Yes X No If no, briefly describe.

d. Is there a DG battery maintenance program? Yes X No L. Safety Shut downs Give safety shut down settings compared to equilibrium operating conditions.

~

1. Engine and generator speed. Give rpa or hert::

a. Synchronous and usua'. 900 rpm or Hz

b. Overspeed shutdown setting 1033 for "A" rpa or HL 1040 for "B"

2. Engine cooling water (see E.4)

a. Equilibrium 175 'F

b. Alarn 195 *F

c. Shut down None 'F

3. Lube oil pressure (see D.4)

"""} -

a. Equilibriun 31 psi ' }1

b. Alarn 16 psi

c. Shut down 16 psi 9

, . . _a 1412 235

?

6

5

4. Lube oil temperature

a. Equilibrium 180 *F "F

b. Alarm 90

c. Shutdown None 'F .

5. Indicate all other protective interlocks (give name __

and;)

a. Usual or proper conditien Crankcase ui Drace e/n

b. Shutdown condition Cranking 'imer - Max 7 Sees Manual & Auto Star + (1 +imar o=ch) Low Startino Luba Oil Drace

6. a. What source of oower is provided to operate alarms and shutdown controls? (See G.2) 125 VDC

b. Do the generator units automatically shutdown in case of the electrical power loss to its control system? Yes No _X_

N. Emeroency or Alert Conditions

1. Are all safety shutdown and safety interlocks bypassed during emergency conditions? Yes No x

2. If "no" above, then which are not bypassed. Name items.

Low Lube Oil Press. Crankcase prest u4. eng n.. .c-re s I

3. For each interlock not byoassed is coincident locic used? Yes No X_ '

1 If yes, is it testable? Yes N/A No M/A

,J j

_a N. Maintenance j4j}-

1. Does plant have re ularly scheduled maintenance pro-cedures? Yes If so, return cooy of these crocedures witn cuestionnaire.

See 1:01-2.2 Attached t

e

.le. P00RORMA

)

2. When need for minor adjustments obviously exists, then: i

.]

-- __ . -l ; a .. ls remedial. . action taken irmediately or at earliest -

. 1

, practical opportunity? Yes. X No .' T . ..

- a

b. Is remedial action taken only at periodic prescheduled t i or programmed times and conditions? Yes No y

[

c. For best performance record which of above appears better:

immediate or early ac.icn? Yes as scheduled only? yg

d. Must permission for minor maintenace be obtained from some higher out-of-plant authority? Yes No X

e. Is maintenance referred to above allowed and encou aged?

Yes X No

f. In periodic surveillance tests, simulated alert standby tests, etc., is the criteria " pass /not pass" the test used? Yes X Ho __

g. Is there a conscious .:ontinuing policy to detect and remedy marginal condi tior.. or imminent trouble: for examples: lube oil p essure shutdown only two to five psi below operating pressure or, perhaps overspeed governor setting only one or two percent above starting speed surge or etc.? Yes X No

h. Are efforts to remedy marginal or questionable conditions as mentioned above en:ouraged by plant management? n-

.l Yes y No .

i. Are remedial steps on items similar to the above taken or allowed when the unit has started and operated satisfactorily witnin specified limits or conditions? ,-

Yes X No ., f, ,

0. Startino Cencitions

1. Give starting or necessary cranking time as ex::erienced.

a.

b.

Starting time ::er soeci fic ation Usual starting time _4-5 seconcs 7 seconds j4}2 23f

c. Maximum starting tice Ooservec <7 seconds e

a e

k

E'

2. Give usual time intervals as folicws: ]

Time from start-to-crank to first firing of any 1

. a.

cylinder. UN seconcs

b. Time from start-to-crank to approximate full firing of all cylinders. 4-5 seconds .

_J a.

3. Give maximun' speed surge when starting; use both tachometer and frequency meter if possible.

a. Usual conditions UN rpm UN HZ

b. Maximum observed UN "p-UN Hz

4. During a surveillance test, give time frea start-to-crank to when steady synchronous speed is attained and maintained.

a. Usual <10 seconds

b. Maximun 10 seconds

. c. As spec-:fiec 7-10 seconds.

5. Give briefly the most troublesome problems in starting.

a. Most trcublesome Lube Oii Press Switchac .

b. Next to most troublesome None .

P. Air Cleaner or Air Filter - Combustion Air

1. Combustion air source: tat:en from engine roca or inside the building, or from outdaars?

a. Indoors yes '

)

b. Outdoors No

?

5  :

,a L...

1412 238

?

?

2. Give type and nake of air cleaners' or air filter.: '

j 2 .:a.c.0il bath. No. . itake N/A -, -~

'.. f _]

_ _ - - - - . . . w _ _. .. c .:. b. 011 we tted sc reer. Yes  !!ake Not vnnwn 2

JJ

c. Paper No- itage N/A _. q

!!ake n/A 3

d. Other No

._ j

e. Precleaner: Yes flo y

3. Excessive air flow restriction and servicing need determined by?

a. Instrunent such as:

manometer X If other give type N/A

b. Personal juogement Dy appearance, etc. Air Filtar Inspection

c. By sack'ng exhaust No

d. Tine schedule Annual

e. Other (Specify) No

4. Are climatic extremes r.ormally experienced such as:

a. Air heavily loaded with water mist, high humidity

• and low temperature? Yes No X

b. Blowing sand anc cust? Yes flo X

c. Blowing snos (biizzards)? Yes No X

d. Other-Name

5. Are climatic extremes potentially possible such as:

a. Air heavily leaded with water mist, high humidity and low temperature? Yes flo y y

b. Blowing sand anc cust? Yes No

c. Blowing snow (bli::ards)? Yes X No i d. Other-Name .73 Temcerature Conditions  ;

- Q.

1. Ambient outside hot;est 100 'F. f

2. Ambient outside coldest -s *F.  ;

110 *F . -I

3. Engine-generator roca hottest .

4 Engine-generator reca coldest 50 *F. 1412 239 o

5. Inside switch gear hottest 3d g

6. Inside. voltage. regulater er a:. blent near voltare reculater 100 o--

hottest

~

7. Anbient at exciter hottest inn CF .

Operator Qualifications (as presently exists, and suggested 9 R.

minimums if cifferent) j e '

1. Minimum education required (check) e Existing Suogested

a. High School ves not diffarent

b. Trade School

c. Technical School

d. No minimum

2. Minimum Years of operating experience (diesel electric

~

generator) -

Existing Suogested

a. 0-3 2 vears nn* dif'arent

b. 3-6

c. 6-10

d. 10-15

3. Operator training Existira Succested

a. Military

b. Industrial

c. On-the-job

d. Conbination of a, b, Combination not diffarent and c (indicate which) as required

4. Licensing required Existing Sugeested i

a. State

b. Federal voc nn. a4 ,,m. ant

c. Utility or self f ,

d. None

_a

>>m8 y

e

I q

S. Are any foreien cases such as propane, freon, halon, car 3on dioxide,.etc. storea in the: Diesel Encine roca? ... ..-

['

. r- - -

[j.

. = O-. . . - - . .! Yes 2No: X or_ adjacent buildings? Yes - - No--F- -

r --

. v-If yes, (other than hand portable fire extinguishers), taen identify gases and give approximate tank size. .

((

3 Gases N/A Volume (f t ) y/a N/A N/A N/A N/A N/A N/A .

N/A N/A T. Does control system autcnatically bypass, in emergency starting, any engine temporarily out of service for -

maintenance? Yes No X If yes, then how many failures to bypass have occured?

N/A U. Does the control system automatically override the test mode under emergency conditions? Yes No X ,

V. Have repetitive mechanical failures occurred in any component Jart or subsystem of the engine, generator, or switch gear, etc.?

Yes No x If yes, then which part or subsystem? N/A _

How many failures? N/A Give nature of failure. N/A F

'1 i

W. Would periodic (yearly or otner) evaluation and/cr testing by "outside experts" contribute significantly to the diesel- ,

generator reliability? Yes No X  ;

l J Give brief reasons for the answer. TMI has anough coali#iad -

Decole and thorouch enough orncaanroe +e =sarn=+oly ~,4 +24, the diesel cenera*crt.

1412 241 6

e

1 X. 1. Give the accumulated time-load operating record for each diesel-generator unit from installation to the presen* 3

. (Running Hours): i PreoperaConal test Date y

Engine  : Sury. Test 1nc &  : Emergency  : Total  : 1

Serial 110. :

Maintenance Ars. : and Other No load : Loaded : Service Hrs. :

Hours  :

7_

Diesel B : 380870076 ::  :  :  : 414  :

TDSM 12 UN UN UN Diesel A :38D870073 ::  :  :

Tncu 19 UN UN  : UN 438  :

2. Surveillance test load (percent of continuous rating) lone

3. Give tha projected or planned time-load operation for each diesel-generator unit during the next 12 months.

Surveillance 4  : Emergency : Total  :  :

Main:enance Hrs. : and other : Hours  :  :

cervice Hrs. :  :

25 UN  :

125  :

4. Provide the following summary of the periodic surveillance testing experience: .

a. Starting date of surveillance testing (OL datel 9/2/74

b. Periodic test interval Monthlv  !

c. Total number of surveillance tests performed M=212 ,

d. Total number of test failures 1 failure to start 1 failure to accept load 0 -f i failure to carry loaa 0 failures due to ocerator error * ,J failure due to ecuinnent not being operative during energency 6 -

conditiens 0

e. Supply a copy of the surveillance test procecures with this concleted cuestionnaire. See 1303-4.16 and 1303-11.10 attached.

1412.7242

M Additional Comments

,_ , 3 .,. -- -- No c e --- - - -

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- :.2 B

Y. General Succestions Briefly give constructive criticism or suggestions as to improvement in reliability of the diesel generators. These remarks may cover tests, naintenance, oractices, orders, policy, adjustments, etc.

The present monthly testing program is too extensive in that the machinery is " Tested to death". If these tests were eliminated, fewer corrective maintenance requirements would be generated.

The . Annual Inspection is deemed necessary and desireable.

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