ML20095G943

Response to ASLB 840615 Request for Addl Info Re Tdi Diesel Generators.Aslb Should Conclude That Tdi QA Program Adequate at All Times.Related Correspondence

ML20095G943
Person / Time
Site:	Comanche Peak
Issue date:	08/25/1984
From:	Reynolds N BISHOP, COOK, PURCELL & REYNOLDS, TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
ML20095G949	List: ML20095G943
References
OL, NUDOCS 8408280265
Download: ML20095G943 (29)

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' UNITED STATES OF AMERICA DOCKETED NUCLEAR REGULATORY COMMISSION USNR; BEFORE THE ATOMIC SAFETY AND LICENSING BOARD,,,D ?? lm n=

!L In the Matter of

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Docket Nos. 50-445 TEXAS UTILITIES ELECTRIC

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50-446 O(,,

. COMPANY, et al.

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)

(Application for

( Comanche Peak Steam Electric

)

Operating Licenses)

Station, Units 1 and 2)

)

APPLICANTS' RESPONSE TO JUNE 15, 1984 BOARD REQUEST FOR ADDITIONAL INFORMATION CONCERNING TDI DIESEL GENERATORS 1.

Introduction The Board has previously requested that Applicants provide information concerning the adequacy of the quality assurance program at Comanche Peak d n relation to the Transamer'ca Delaval, Inc. ("TDI") diesel generators.1 Applicants responded on May 11, 1984 by filing the information requested.2 Subsequent to this response the Board issued a "clarifi-cation" of its information request.

Specifically, the Board stated:

What we are looking for is something in the nature of a table, whici. set [s] forth each specific deficiency in the generators, discusses whether they are design or construction deficiencies, arialyzes what the problem was, and sets forth how it was resolved.

And then, a f ter 1

Memorandum (Adequacy of. Record:

Delaval Diesel Generators),

January 31, 1984.

2

" Applicants' Response to January 31, 1984 Board Memorandum Requesting Information Concerning Delaval Diesel Generators,' May 11, 1984.

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l that's done so that the information available to the' applicants is set forth in a clear fashion,

-we'd like some kind of an analysis as to whether or not, [given] the information [available] to the applicants, some general problem should have risen in their minds, concerning_the [ adequacy]

of the Delaval diesels.

The question is at what point in the history of the Delaval diesels do you reach a point that there are enough indi-vidual questions that you say, we better go to the Delaval plant and find out in more detail whether they are doing things adequately.

Now, we don't know the answer to that question.

But, given the history of the Delaval diesels, we want that addressed, in terms of the adequacy record on QA, QC.3 To address this clarification and request for additional information, Applicants provide this further response.

Appli-cants note that the Board has recognized the limitations of the issues to be addressed in this response.

As the Board has stated, with respect to the question of the adequacy of the Comanche Peak diesel generators to assure public health and safety:

Applicants need not address that particular question right now.

It will be addressed only if we find that the design and construction QA oversight

. were inadequate.

If we don't find that they are inadequate, we will trust that particular question to the staff.

We would agree with applicants that it would require us to declare a sua sponte issue for us to go into that matter.*

For the record, Applicants continue to maintain that because this matter was not raised by the Intervenor, the Board should not have initiated, sua sponte, its own inquiry into it.

See 3

Conference call of the Board and Parties, June 15, 1984, Tr.

14,054-55.

4 Id. at 14,056.

" Applicants' Response to January 31, 1984 Board Memorandum Requesting Information Concerning Delaval Diesel Generators," at 9.

Nonetheless, in an effort to expedite the timely conclusion of_this proceeding, Applicants provide additional information to address the two questions from the Board's January 31 Order concerning (1) the adequacy.of Applicants' QA program to detect

~

design or construction problems in TDI diesel generators, and (2) the ' frequency and seriousness of problems with the Comanche Peak diesel generators.

In providing this further response, Applicants interpret the Board's request for information concerning " construction problems" to mean those related to the manufactore of the diesel generators.

'2.

QA Activities Conducted By TUGCO A chronology of audit and inspection activities performed by or on behalf of TUGCO has been assembled and is appended as.

This chronology demonstrates the operation of the TUGCO QA program in the periods prior to award of the contract to TDI, during the manufacture of the diesel generators and auxili-ary systems, assemblies and components, and once the diesel engine, generator, auxiliary systems, assemblies, and components were received on-site at Comanche Peak.

Prior to contract issuance and the placing of the orders for the diesel generators with TDI, a pre-award survey was conducted on behalf of TUGCO by the Architect / Engineer ( A/E), Gibbs and Hill.

This pre-award survey was conducted October 1-3, 1975 and covered compliance with 10 C.F.R. Part 50, Appendix B, and ANSI

Standards N45.2.9, N45.2.11, and N45.2.13 (subsets of N45.2).

Several programmatic deficiencies were found, and TDI made commitments to correct the deficiencies.

Subsequently, on January 26, 1976, in a response to Gibbs and Hill, TDI addressed all deficiencies.

This pre-award activity was followed by an audit conducted by TUGCO on May 11-12, 1976.

This audit addressed compliance of the TDI QA program with 10 C.F.R. Part 50, Appendix B, and ANSI Standard N45.2.

This audit verified the implementation of corrective action on deficiencies identified during the pre-award survey and no new deficiencies were identified.

The purchase order was issued April 8, 1976.

During the period from the purchase order issuance until the Unit 1, Train A5 diesel engine and generator were delivered to the Comanche Peak site on November 11, 1977, TUGCO engaged in six documented inspections.

Prior to shipment of the engine, generator, and associated equipment for the Unit 1, Train A machine, TUGCO conducted a release inspection October 24-27, 1977.

Subsequent to this activity, a release inspection for the major components of Unit 1, Train B was conducted November 29, 1977.

The Unit 1, Train B diesel engine and generator were received on-site December 19, 1977.

The major components (engine and generator) were installed on their foundations (" landed")

September 13, 1978 (Unit 1, Train B) and September 16, 1978 (Unit 5

Each unit has two diesel generators, denoted Train A and Train B.

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1, Train A).

Ad4'tional Unit 1, Train A and B equipment was-Linspected and released for shipment throughout the period from December, 1977 to July, 1979.

.This process was repeated for the diesel generators for Unit 2.

Performance. tests for the Unit 2, Train A engine were witnessed July 22, 1979.

The Unit 2, Train B_ performance tests were witnessed August 22-25, 1979 and found acceptable.

The Unit 2, Train A engine was released for shipment August 31, 1979 and received on-site September -21,-1979.

This engine was subsequently landed on its foundation September 27, 1979.

The Unit 2, Train B engine release inspection was held Septembe r 17-21, 1979.

The engine for Unit 2, Train B was received on-site on October 9, 1979 and-landed October 10, 1979.

Again, as for Unit 1,

the diesel generator components and -assemblies for the Unit 2 systems were fabricated, tested, inspected, and shipped separately.

Following the inspection, release, shipment, receipt, and installation of the diesel generator major components, other com-ponents continued to be fabricated and shipped.

These components were-subjectea to inspection and testing during the period up until August, 1982, when preparations for preoperational testing were.being made.

The Unit 1 engines were first run in September, 1982.

The Unit 2 engines have not yet been completely assembled and run.

i The chain of events detailed above indicates the time lag that occurred between the time the engines were manufactured and delivered on-site and the time at which testing was initiated.

Numerous OA activities were undertaken by TUGCO during this period.

Because the diesel. generator systems were not yet fully assembled, TUGCO relied upon the TDI QA program and TUGCO witnessing of shop tests of components and assemblies to assure compliance with 10 C.F.R. Part 50, Appendix B.

After the Unit 1 machinen were assembled on-site and preparations for preoperational testing began, deficiencies were noted, which were documented by Nonconformance Reports ("NCRs").

De ficiencies detected during preparation for and conduct of preoperational testing were documented in Test Deficiency Reports ("TDRs").

The deficiencies detected are discussed in the next section.

3.

Analysis of Deficiencies The NCRs, TDRs, vendor 10 C.F. R.

Part 21 reports, and 10 C.F.R. Part 50.55(e) reports have been examined for the Unit 1, Trains A and B diesel generator systems.

The Unit 1 diesel generators were chosen because they have been completely assembled on-site at Comanche Peak and have been run for extended periods.

The Unit 2 machines are not fully assembled and have not yet been run on-site.

Therefore, only the Unit 1 diesel generators provide an accurate picture of the extent and nature of deficiencies encountered in the TDI diesel generators at Comanche Peak.

i The deficiencies are tabulated in Attachment 2.

The table indicates.in which Train the deficiency occurred, provides a brief description of it, categorizes it (design, manufacture,

-installation,' documentation, qualified commercially-procured component,6. shipping, storage, or a combination in cases of uncertainty), provides its significance (high, moderate or low),

provides the date and document in which reported, indicates the detecting organization and time in the procurement and testing process, and the resolution of the deficiency.

There are a. total of 42 deficiencies documented by NCRs.

Of these 42, the deficiencies in 12 were initially reported to TUGCO by TDI using 10 C.F.R. Part 21 reports.

As a result of receiving the 10 C.F.R. Part 21 reports, TUGCO documented the potential deficiencies using NCRs.

Also, of the 42 NCRs, only 17 occurred prior to 1982 (th2 period during which the vast majority of diesel generator assemblies and components were fabricated and shipped to the Comanche Peak site).

At that juncture virtually all of the design, fabrication and installation activities had taken place.

Five NCRs documented in 1984 are included in the list, although these have occurred after the Shoreham crankshaft failure and the formation of the TDI owners' Group.

There were 27 deficiencies documented by TDRs.

All but two of the TDRs occurred in preparation for, or conduct of, the preoperational testing of the Train A and B diesel generators.

6 Some components are commercially procured and qualified as, for instance, many electrical components and systems.

These are normally qualified by actual testing.

. Two occurred during subsequent testing.

The number of TDRs is not very large when it is considered that a very complex piece of equipment was being prepared for service.

The deficiencies can be broadly classified as follows:

(a) turbocharger and governor lube oil systems -- 3: (b) pumps and governor -- 3; (c) brackets, supports and piping -- 12; (d) miscellaneous mechanical items -- 12; (e) electrical wiring, marking and motors -- 20; ( f) instrumentation -- 7; (g) instrument and electrical equipment calibration -- 9; (h) pushrods -- 1; and (i) documentation -- 2.

Although there were several instrument calibration and electrical deficiencies reported, their number and type are not unusual for the complexity of the systems involved, recognizing that the components were not brought together until their assembly at the site.7 None of the above deficiencies was of sufficient significance or repetitive nature to cause concern for the adequacy of the TDI CA program with the exception of the welding on and material selection of the auxiliary skid and its supports.

The Board has already been made aware of this matter.8 As explained in the previous section, the major elonents of 7

See Affidavit of Edward J.

Kreh, Jr.,

(Attachment 4) at p.4, a quality assurance expert retained by Applicants to assist in the preparation of this response.

8 The Board cited this particular issue in its January 31, 1984, Order.

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procurement and delivery of the diesel generators for both Units 1 and 2 were completed prior to the initial detection of this particular deficiency. includes a tabulation of the deficiencies detected as a result of TUGCO activities following the crankshaft failure at Shoreham in August, 1983.

These deficiencies are not included in the count above because they occurred after industry had been alerted to potential problems at TDI.

With respect to the findings of the recent disassembly and inspection of the Unit 1 Train A and B' diesel generators, there were several deficien-cies in components which have engendered reservations as to the implementation of the TDI QA program.

However, the nature of the detected deficiencies was such that they would not have been observable by TUGCO without disassembling the engine and in many cases ' would not have been revealed until after a significant number. of hours of operation.

Such disassembly would not normally occur other than during a planned maintenance outage.

Itowever, as with the earlier auxililary skid deficiency, these results became known to TUGCO well after the major elements of

.the design, fabrication and assembly of these machines had been completed.

Based on the examination of deficiencies outlined above, it is apparent that neither the number nor nature of deficiencies (other than the lone case of the deficiencies in the auxiliary skid) was indicative of potential problems in the TDI QA program.

Furthermore, the time sequence between procurement and testing

. ~

. ~. _ _

.was such as to foreclose such a concern being raised any earlier than-July, 1980, well after. delivery of the major components.

As for the deficiencies detected during the test and inspection

' program these were detected as a result of industry reaction to the Shoreham crankshaft faliure in August, 1983, and were not

'known to TUGCO at a time in which' remedial QA action could be taken.

It.should be noted that TUGCO is participating in the TDI Owners' Group effort, which is rigorously addressing and j

resolving deficiencies in the TDI diesel generators.

Further-more, TUGCO has included its QA oversight of TDI.

This has included increased NDE requirements and the witnessing of all required NDE and shop testing of replacement parts and inspection-of individual components.

[

4.

Summary d'

'In an effort to be fully responsive to the Board's 4

information request, Applicants retained the services of Edward J..Kreh, Jr.,

an expert on vendor QA programs.

Mr. Kreh's affidavit is appended as Attachment 4.

Mr. Kreh examined nonconformance reports, test deficiency reports, TDI 10 CFR Part 21 reports, disassembly _and inspection reports, and other documents.

He discussed the deficiencies contained therein with cognizant TUGCO employees.

Mr. Kreh also examined audit and inspection reports and discussed them with QA personnel.

Based upon this objective assessment, the following has been demonstrated:

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1, 3.

1.

TUGCO,'through its A/E Gibbs and Hill, conducted pre-award evaluations of TDIr deficiencies were found; TDI committed to implement a QA program in compliance with 10 C.F.R.

Part-50, Appendix B and proceeded to undertake corrective action.

TUGCO's actions comported with industry practice and were in compliance with 10 C.F.R. Part 50, Appendix B (Kreh Affidavit, pp. 2-3).

2.

TDI was placed on the Approved Vendors List (" AVL"), awarded the contract for the diesel generators, and the order for the diesels was placed with TDI.

TUGCO was justified in placing TDI on the AVL and procuring the diesel generators from TDI based upon their source evaluation of TDI capability in accordance with ANSI Standard N45.2.12 and the vendor's commitments to implement an adequate QA program.

Again, such action by TUGCO comported with 10 C.F.R Part 50, Appendix B.

(Id.)

3.

TUGCO audited the implementation of TDI's OA program over the period from contract award to the shipment of the diesel generator assemblies and components; four audits and approximately 35 inspections were conducted at vendor sites.

Among these activities were the witnessing by TUGCo of shop testing by vendors of components and assemblies.

(Id.,

p. 3.)

4.

TUGCo relied upon their audit and inspection verification of the adequacy of the TDI QA program for the design and manufacture of the diesel generators; TUGCO witnessed shop

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-tests of components and assemblies followed by testing of the fully assembled diesel generators at the plant site.

Such a means of verifying the design and manufacture of the

-machines comports with 10 C.F.R. Part 50, Appendix B and applicable industry standards to which TUGCO has committed.

(Id., pp. 3-4.)

5.

The record of audits and inspections indicates that TUGCO L

took corrective action when the need arose.

This included refusal to release equipment for shipment and communications between TUGCO's management and TDI's management to address L

discrepancies.

(Id., p. 5.)

6.

' During the period front the time the diesel generators were ordered until the major components were received on-site, there were no indications that the TDI QA program was not l

acceptable. (Id.)

This comported with industry experience l

with TDI (Id., pp. 4-5), wherein no najor deficiencies were found and no concerns about the TDI QA Program raised until the occurrence of the cracked crankshaft at Shoreham.

7.

The vast majority of deficiencies were detected only after l

the engines had been received on-site, stored, assembled, l

and preparations were made for preoperational testing.

(Id., p. 6.)

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. s 8.,

With the. exception of the auxiliary skid and support deficiencies, _ the deficiencies detected during the period prior to preoperational testing and during preoperational testing did not indicate a breakdown in-TDI QA.

(Id., p.

5.)

9.

The types and quantity of deficiencies (other than-the auxiliary ekid) were minor and lacked-the significance and repetitive nature to suggest that there was a QA breakdown at TDI.

(Id., pp. 5-6.)

10.

The deficiencies discovered during the disassembly and inspection of the Unit 1 diesels suggest that the TDI QA program may have been inadequate (Id. p.6).

This was widely recognized by industry in the formation of the TDI Owners' Group.

5.

Conclusion From the foregoing, the Board should conclude that at all pertinent times during the design, fabrication and delivery of the major elements of the diesel generators, there was no indication that the TDI QA program was inadequate.

With the exception of the auxiliary skids, the frequency and seriousness of the deficiencies were not sufficient to have warranted a determination that TDI's QA program was inadequate.9 The types of deficiencies detected during the preparation for and conduct 9

It should be noted that TUGCO spent considerable time and resources in resolving the deficiencies in the auniliary skids.

(Kreh Affidavit, p. 5.)

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n of preoperational testing were minor and of the kind to be expected.

These deficiencies were not sufficiently numerous to cause concern that the TDI QA program was inadequate.

With respect to the auxiliary skid deficiencies and the deficiencies detected during the disassembly and inspection of the Unit 1 diesels, the major components of the diesel generators had been manufactured and delivered well in advance of TUGCO becoming aware of these deficiencies.

Respec fu y submitted, W

Nichol Sf Reynolds Michae D.IUhite BISHOP LI' l lRMAN, COOK, PURC LL <

REYNOLDS 1200 Seven'eenth Street, N.W.

Washington, D.C.

20036 August 25, 1984

CHROt! OLOGY OF TUGCO QA ACTIVITY RELATED TO TDI DIESEL GENERATORS AT COMANCHE PEAK Date Organization Activity 10/1-3/75 Gibbs and Hill (on Pre-award survey of TDI; behalf of TUGCO) 10 CFR 50, App.

B, ANSI N45.2.9, N45.2.11, N45.2.13 1/26/76 TDI All deficiencies detected in pre-award survey addressed 4/8/76 TUGCO QA Purchase order for diesel generators placed with TDI l

5/11-12/76 TUGCO QA Audit of TDI addressing 10 CFR 50, App.

B, ANSI N45.2; pre-award commitments by TDI met; no new deficiencies found 1/77-10/77 TUGCO QA Inspections of engine and generator components and witnessing of shop tests 10/24-27/77 TUGCO QA Release inspection of Unit 1; Train A at TDI 11/11/77 TUGCO Receiving Unit 1, Train A delivered to Comanche Peak site 11/29/77 TUGCO QA Release inspection of Unit 1, Train B at TDI 12/19/77 TUGCO Receiving Unit 1, Train D delivered to Comanche Peak site

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Page No. 2 Date-Organization Activity 12/77-9/78 TUGCO QA Inspections of auxiliary and additional miscellaneous equipment 9/13/78 TUGCO Engineering Unit 1, Train B placed on foundation (" landed")

9/16/78 TUGCO Engineering Unit 1, Train A landed 10/10/78 TUGCO QA Audit of TDI designated TDT-1; no deficiencies found 9/78-7/79 TUGCO Receiving Receipt inspection of auxiliary equipment, air-start skids, crankcase fans, water jacket heaters, pedestal bearing, fuel oil day tanks, airstart receiver tanks, tubing, connectors, heat exchangers, gauges, brushes, brush holdors, thermostats, exhaust system expansion joint, current transformers 12/78-7/79 TUGCO QA Inspections of control boards, fuel oil transfer pumps, jacket water piping brackets, heat exchangers, grounding resistors, con-trol panels, fuel oil tanks 7/21-22/79 TUGCO QA Witness performance test of Unit 2, Train A 8/22-25/79 TUGCO QA Witness performance test of Unit 2, Train B 8/31/79 TUGCO QA Release of Unit 2, Train A for shipment 9/17-21/79 TUGCO QA Release inspection of Unit 2,

Train B 1

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I Page No. 3 r

I Date Organization Activity 9/21/79 TUGCO Receiving Unit 2, Train A received on-site at Comanche Peak 9/27/79 TUGCO Engineering Unit 2, Train A landed 10/9/79 TUGCO Receiving Unit 2, Train B received on-site at Comanche Peak 10/10/79 TUGCO Engineering Unit 2, Train B landed 9/79-7/80 TUGCO Receiving Receipt inspection of control panels, miscella-neous components, generator rotor, air dryers, pipes, supports, gaskets, couplings, nuts, flywheels, jacket water pump, and gauges 10/79-7/80 TUGCO QA Release inspections of fly-wheel, auxiliary skids, miscellaneous components, generator stator, valves, plugs, water jacket cooler, lube oil cooler, jacket water standpipe, electric motors, pumps, strainers, control panels, and grounding resistors 3/10-12/80 TUGCO QA Audit of TDI - TDT-2 7/17/80 TUGCO Engineering Improper fabrication of auxiliary skids, Unit 1, Trains A & B detected 7/80-9/82 TUGCO Receiving Receipt inspection of gaskets, valves, auxiliary water pump, jacket water pump, gaskets, nuts, sup-ports, capscrews, tubos, pipes, flanges, heater strip, relief valve, air inlet pipe, flywheel guard, tape, enamel insulated wire, and expansion joints m

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Page No. 4 Date Organization Activity 7/80-9/82 TUGCO QA Release inspections of valves, jacket water pumps, expansion joints 4/30/82 TUGCO QA Reinspection of auxiliary skids and support brackets to evaluate acceptability of repair welds 9/16/82 TUGCO Startup First run of Unit 1, Train B 9/29/82 TUGCO Startup First run of Unit 1, Train A 11/23/82 TUGCO Startup First preoperational test run of Unit 1, Train A 11/29/82 TUGCO Startup First preoperational test run of Unit 1, Train B 3/15-16/83 TUGCO QA Audit of TDI - TDT-3 3/29/03 TUGCO Startup Last preoperational test run, last run prior to disassembly, Unit 1, Train A 3/31/83 TUGCO Startup Last preoperational test run, Unit 1, Train B 5/31/83 TUGCO Startup Last run of engine prior to disassembly, Unit 1, Train D l

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Pego E4. 4 DE SCA PT104 CMEODRf

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TRMN (1 ASSI FICAllO4 B (Si Os lFICMCE I DATE MD DOCUB4}4T DETECTING OE4412ATIO4 sESauTIO4 o

A Turteer2er odeptor Manuf acture (L) 9/30/82 NCR TU - Startup detected during Reessembled alth new seal rings t

lacorrectly Installed M-82-01604S preparation for preap. testing (misc. noch.)

A&B Floalble drive aupflag hub Menuf acture (M) 1/27/84 NCR TDI - I ssued 10 C.F.R. 28 Report Coupling reworked per TDI loose on shaf t (alse. modt.l W 84-001085 R.I 1/9/84 lastructions

\\

A48 Piston pin retsining rings Documentation (L.)

4/2S/84 NCR TU - QA detected during receipt Documentation corrected leproperly listed on docu-M-84-Ol257 R.1 Inspection mentotton (bcumentation)

A48 fuel oli supply tubing not Manuf acture (M) 2/28/84 NCR TDI - I ssued 10 C.F.R. 21 Inspected and additional clamps adequately cleeped (brackets 3 M-84-00683 R.I Report 9/21/83 added as necessary; shrouded tublng scheduled to replace original tubing A&8 Somter end transfer pumps Manufacture / Installation (L) 7/22/81 NCR TU - Engineering detected daring Pump motors transferred to and motors Interchanged M-80-00006 R.3 lastallation correspond alth correct nu m ers (electrical - entorst A48 Control panel alros numbered Manuf acture (L)

S/21/88, 6/1/88 NCR TU - QA detected durlag lastellation Lugs changed and alros Incorrectly (electricall E-88-00168, E-88-00183 properly Identifled A

Control panel has 3 lugs on Manuf acture (L)

S/29/88 NCR TU - QA detected during Instellation Terminal roscrked onn terminal (electricall E-81-00l?6 A48 vendor alrIng numers do not Manuf acture (L) 8/14/81 f4CR TU - QA detected during Installation laspected, evaluated and found match drawing (electricall E-81-004 7 5 acceptable e

Cable minimum bend radius Manuf acture (L) 12/10/81 NCR TU - QA detected during lastellation Ihplaced cable and reworked vlotated telectricall E-81-01699 R.1 raceway 8

Outboard bearing thermo-Manuf acture (L) 3/l7/82 NCR TU - Startup detected during Replaced eith correct thornuacouple couple of erong type E-82-002S35 preparation for preop. testing (Instrumentation)

A48 Control penal string not in Manuf acture (L) f 4/8/82 NCR TU - QA detected during prog.

Reelred both train A48 control pensis eccordance eith draulng og E-82-003385 checkout Train A (electricall NOTEI $1gr.tf tcence: Low (L), Moderate (M), High (H)

I e

Page to. 5 DE SC~ Pil od CAT EDRI TRMN (CL AS$4 FI CATIO4 )

(SI GelFICmCE)

DATE MD DOCueetT DETFil4G OEANt2ATIO4 ESOLUT104 AE Questlanable selsele Design (M) 4/21/82 NCR TDI - Issued 10 C.F.R. 28 Amport Af fected llee selselcelly quellflod quellflcation of volve in 1-82-004265 R.2 3/19/82 by 70 air stort line and slaing of Ilne ortflee f asch. - welvel Am Thereoccuple alring condult Design (L) 4/22/82 NCR TU - Startup detected during Proper supports added laproperly supported E-82-00415 R.I preparation for preop. testing a

(electricall A

Def active field current Manu f acture/i nstallation (L B S/4/82 NCR TU - Startup detected during Replaced defective elements noter and eucitetton relay E-82-005335 R.8 preparation for proep. testing (electricall AB leadequate merk1ng of Manufacture (L) 7/22/82 NCR TU - QA detected during wires reldentitled terminal blodas and devices E-82-Ol0275 preparation for precp. testing telectricall i

AM Pneumatic devices ulth Design (L) 9/14/83 NCR TU - Startup detected during Stiffer spring lastalled laproper spring character =

l-82-014575 R.I preparation for proep. testing latics (Instruamatetton) l Am Nonquellfled commercial ofre Design (M) 11/16/82 NCR 1D1 - t sseed service meno Replxed ulth quellflod alre used in engine tachometer E-82-02033S 11/4/82, followed by 9/27/83 relay oogpietic pidtup and 10 C.F.R. 21 report l

Governcr circults l

E Ins trumentation)

A Engine tachoneter would not Comunercial (L) 6/30/82, IDR 220 TU - Startup detected during thplaced tachcenter callbrate (callbration) preparation for preop. testing l

i e

, NOTE: Significance: Low (L t. Iederate (M), High (H) t i

1

rapeeu.e-DE L PIIO6 CJ.TEOGR$

T fW 9

((U S$8 FICAT104 )

151041FICMCE) treTE MD C0Ctsoef DETICTING O K 4ellATIO4 IE 91uTI O4 Asa Fuel oil suction pressure, P-clal (L) 2/13/82. TDR 224 Tu - Startup detected during Replaced gauges and ther-ples stralner Inlet pressure, preparation for preop. testing.

booster pump dlscharge pressure, lobe oil duples outlet pressure gauges would not calibrate and Jacetet mater outlet thereo-couple defective lcallbretton)

A Open prloery mlnding on e - clal G.)

7/28/82, TDR 229 Tu - Startup detected during Transformer replaced potential transformer No. 2 preparation for prog. testing telectricall A

undervoltage relay 27 2 rwclat (L) 7/30/82, TDR 242 Tu - Startup detected during Relay replaced would not callbrate preparation for preop. testing (callbretton) 8 Fleid current DC emmeter r-clel (La 8/2/82, TDR 243 TU - Startup detected during Replaced emmeter would not callbrate preparation for preop. testing teollbration) 8 Generefor stator temp.

r - clal (LI 8/10/82, TDR 25l Tu - Startup detected during Replaced Indicator ladicator would not preparetton for proop. testing cellbrate feellbrationt 8

$hcrted diode la power ComuurClel (La 8/12/82, TDR 254 TU - Startup detected during Replaced diodo supply voltage regulator preparation for preop. testing (electricall 8

Hlgh temp. bearing trip Installatlon (L) 8/13/82, TDR 2SS Tu - Startup detected during Replaced trip device device deneged preparation for proap. testing Elastrumentation)

A Two esples filter pressure e-clal (L) 8/23/82, TDR 264 TU - Startup detected during Replaced gouges gauges sould not callbrate preparation for preop. testing (cellbrationt j

NOTE: Significance Low (LI, Itadorate (M), Hlgh (H) b,

Page Co. #

DE SCOPT104 COIEGDRY Tim 1:3 (G.CSSI F ICATIO4 )

(Sl eelFlce4CO DSTE AND COCleENT DETECfl4G OWA41ZQtios E n UTies

)

1 8

Generator pedestal bearing Manuf acture/ installation (L) 9/2/92, TDR 276 TU - Startup detected durleg Replacent dust seal dust seal demoges preparation for preop. testing ielse. mech.I A

Over and under frequency e-rclel (LB 9/13/82, TDR 291 TU - Startup detected during Replaced relay alare relay would not preparation ter preop. testing celltrate tcalibretton) 1 A

undervoltage DC relay would r===ecl al (L )

9/13/82, TDR 292 Tu - Startup detected during Replaced relay not callteate teallbration) preparation for preop. testing j

A Undervoltage relay would Commercial (L) 9/27/82, TDR 319 TU - Startup detected during lhplaced relay not callbrate (c allbretton) preparet ton for y,. testing A

Pneumatic logic device has Commercial (L) 9/27/82, TDR 321 TU - Startup detected during lhplaced relay cracked 0-ring preparetton for precp. testing finstrumente+1on) 8 Lube oil pump does not Manufacture (LI 9/30/82, IDR *23 TU - Startup detected durlap Neo pump Installcd correctly supply suf ficient pressure engine start tests tolsc. mech.)

8 Voltogo regalator relay Commercial (L) 10/28/82, TDR 370 TU - Startup detected during Ihplaced reley i

has open cell telectricall engine start tests A48 Mem.-Min. escitet ton Commercial (L) 10/29/82, TDR 386 TU - Startup detected during Replaced defective components lletters would not operate engine start tes9s telectricall i

A Pressure Indicator gauge P-rcial (L) 11/16/82, TDR 424 TU - Startup detected during Replaced pressure gauge failed to operate engine start tests finstrumentation)

A Erratic operation of frequen-r-clal (L) 11/29/82, TDR 457 TU - Startup detected during Motor repaired cy meter Clastrumentation)

)

preap. testing NOTE: Significance: Lou (LI Moderate (M), Hlgh (H) l 1

4 4

i

Page Ko. O i

DESC6 PTius CATLGORF TR44 N (Q. ASSl FI CAfl 04 )

(SIQelFICMCf 3 DATE MD DOCumEMT DETECTING Of0MlFAflO4 8E91_UTIOe B

Power fuses bleu due to 11pt r-cl a t (L 3 11/29/82, TDR 453 Tu - Startup detected durIng Bulb and fuses replaced; circuit bulb f allure telectricall preop. testing endifled A

Engine tripped due to y ound Design (L) 1/14/83, TDR S47 TU - Startup detected durIng Circuit modifled relay circuit defect 3/2S/83, TDR 827 preop. testing telectricall B

Annuncletor horn M not P-cl el (L )

2/16/83, TDR 631 TU - Startup detected during lhplaced horn operate telectricall preop. testing B

Techometer relay power Caseercial (L) 3/B/83, TDR 728 Tu - Startup detected during Pomer supply replaced supply falled (electricall prog. testing A

Annuncletor hora does not r = clel (L3 3/9/83, TDR 733 Tu - Startup detected during Ihplaced horn operate telectricall preep. testing 8

Falled motor space tweter rwclel (L 3 II/18/83, TDR 233l TU - Startup detected during Amplaced space heater on fuel oll booster pump engine start tests (electricall 8

Riget bed # 8 elr intake leanuf acture (L) 11/15/83, TDR 2328 TU - Startup detected during Bolt holes slotted to porelt elbos did not fit to be engine start tests correct aligneont leak-flekt (ptaing elboost 8

Jacket meter hemp wera pump lesnu f acture/ Storage /

6/14/82, TDR 208 Tu - Startup detected during Ihplaced pump overheeting Shlpping (L) preparetton for preop. testing (electrical - motor)

NOTEl Significance: Low (LI, 8txterate (M), High (H) 4 4

Att % 3 0'SES LMIT I DIESEL GestimTOR IGFICID9CIES IGTECTED DU4NG DISAESDELY 460 INSPECTIO4 PRDGRAM Page No. I i

k TRn64 DE SC4 Pil00 CATEGOpf DATE 44D DOCueENT DETECTING OfE44L2ATI04 IES01 UT4 04 A

Damaged turbocharger blades OperattenAtenu f acture 6 D 4 4, Qfkl0-eP022/3 Tu - Malatenance detected durlag Rotor esseelles and beerIngs k

and bearings; shafts art of disasseely and Inspection replaced; shafts refurbished.

tolerance 8

. Turbocharger rotor bladas OperettonAtenufacture 6n944, Ofklo-eN22/3 Tu - Malatenance detected during One turbocharger replaced; rotor nicked, one blado elssing, disasseely and Inspection essemblies and bearings replaced, i

I bearings and shaf t scored both banks A

Lineer ladlcations on emin OperationAtenu f acture 6n44, OfklO-02-305A Tu - Melntenance detected during Evaluated as acceptable other then bearing saddles disassembly and Inspection saddle no. 33 conditionally released for testine 8

one-f ach lineer Indication, OperationAtenufacture 6/2944, QR-lM2-3054 Tu - Maintenance detected during Indication la noestructural area bearing cap 8 disasseely and Inspection and acceptable Am Lineer Indications In cred-Operes tonAtenu f acture 6n44, 6/2944; Tu - Melntenance detected during Bearing shells on atfacted bearings shaft bearing shells QiblO-02-3108 disasseely and Inspection replaced i

As Lineer Indications found in Manufacture 6 D 44, 6/29 44; Tu - Melntenance detected during Final disposition pending based on cylinder blo A QR-10-02-31SA disasseely and Inspection TDI ommers' group recommendation e

t 1

l 4

Pego Ko. 2 TRMes DESCf5 PTIO4 CAffGORY

- DATE add DOCUIENT DETECTING C N IFATIOd IESauTIDs i

Am-Casting flew in cyllador senaufacture 6nA4, 6/2944; TU - sestatenance detected during ftsplaced ef fected liners

er et g,

liners QW1042-315C disasseely and laspection 8

2 connecting rod bushlags Operet tonAtenuf acture 6/2944, QR-lH2-340A TU - Melatenance detecte1 during Amplaced Isushings and pins.

scored; gauling on link pin disasseely and inspection 4

)

'AM LInser ladications la con =

Manufacture 6n/84, 6n9/84 Tu - Malatenance detected during Replaced af fected shell halves nocting rod bearing shells QR-1042-340B disasseely and Inspection a

AS Cylinder heads susceptible Des ignAnonuf acture 6n/84; 6/2944 TU - Malatenance detected during Replaced cylinder heads to creding and Incorrect OR-10-02-360A disessembly and Inspection j

fire dock thickness AB Scuffing and scoring of Manufacture 6M/94; 6/2944 TU - Melntenance detected during Replaced selected velves welvos OR-8042-360B disassembly and laspection AS Lineer ladications In Manufocature 6MA4; 6/29/B4 TU - Melatenance detected during Replaced selected covers i

cyllader head covers QR-lO-02-362A disasseely and laspection J.

i AB Breen corner on latake Manu f acture/Operet ton /

6 M/84; 6/29/84 TU - Melntenance detected eering finplaced elbows i

montfold elbow fienge l astellation QR-1042-375 dlsesseely and laspection j

4 1

8 i

l 4

9" i

Page No. 3-ll TMIM DE SCf3 Pil oe CATEGORY DATE add 00CUntNT DETECilisG OEJN17 ADO 4 IE S(LUTIO4 AS Exhaust mentfold bolts, Manufacture 64 44; 6/2944 TU - Maintenance detected during Selected bolts replaced Incorrect length on some Q & lo-02-3ts08 disassemely and laspection bolts A

Lloser Indicottons in Intake Manuf acture 6nA4, OR-lH2-390A TU - Maintenance detected earing fhplaced or ref urb 1thed ef fected rocker eres dlsessembly and Inspection rodter eras ANB Ibcher are and pushrod Manufacture /Operetton 6n44; 6/29A4 TU - Melatenance detected during Leaming lif ters replaced lif ters did not pass leak-QR= lo-02-390F disassantly and lespectica doen test A

Overspeed trip capling Manufacture 6444, QR-804)2-410C TU - Malatenance detected during Spider replaced spider mIcked dlsessembly and Inspection A

Excessive wear on jedtet Operation 6A44, QR-10-02-4254 TU - Maintenance detected enring Pump replaced seter paap shaft; loose disassembly and laspection t apeller 8

Deformed Jacket eater pump Manufacture /Melatenance 6/DA4, OR-10-02-4424 TU - Maintenance detected during Replaced tapeller and backplate disassembly and Inspection blackplate l

A Excessive user la starting Operation 6AA4, OR-BM2-442A TU - Maintenance detected durleg Replaced essemelles elr distributor assemelles disassently and lospection Am Turbom erger bracket bolts Manufacture 6nA4; 6/2944 TU - Maintense.co detected during Replaced bolts l

ulthout merking QR-BM2-4 MD disassembly and Inspection I

i I