ML20093F242

Forwards Applicant to NRC Describing Diesel Engine 1B Insp.Ltr Also Provides NRC W/Applicant Plans for Return to Svc Testing of Diesel Engine.Related Correspondence

ML20093F242
Person / Time
Site:	Catawba
Issue date:	07/16/1984
From:	Carr A DUKE POWER CO.
To:	Foster R, Joseph Kelly, Purdom P Atomic Safety and Licensing Board Panel
References
OL, NUDOCS 8407180304
Download: ML20093F242 (9)

Text

_ _ _ _ _ _ _ _

3.,~l RELATED CORRESP0aur_NCE.

7 DUKE POWER GOMPANY l

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P. O. Box 33180

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July 16,1144 g jg g

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KONALD L.OlSSON James L. Kelley,. Chairman

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Atomic Safety and' Licensing Board U. S. Nuclear Regulatory' Commission Washington, D. C. 20555 l

1 Dr. Paul W. Purdom 235 Co'lumbia Driva Decatur, Georgia 30030 Dr. Richard F. Foster Post Office Box 4263

.i Sunriver, Oregon 97702 Re: Duke Power Company, et al.

Catawba Nuclear Station, Units 1 and 2 Docket Nos. 50-413pnd 50-414 OG.

Gentlemen:

I am transmitting to the Board a copy of Applicants' July 6, 1984 letter to the NRC Staff which describes the Catawba 18 diesel engine inspections.

In keeping with a commitment made in Applicants' June 29 report to the NRC Staff (transmitted to you by my letter of July 11) the July 6 letter also provides the NRC Staff with Applicants' plans for return to service testing of the Catawba IA diesel.

The parties have already been served with a copy of the July 6 letter.

Sincerely yours, Albert V.

rr, Jr.

c: All Parties (w/o attach.)

8407180304 840716 PDR ADOCK 05000 G

1 DuxE POWER GoNaPANY P.O. BOX 33180 RAL B. TUCKER CHARLOTIT, N.C. 28242 memen (704) o73-453:

July 6,1984 Mr. Harold R. Denton, Director Office of Nuclear Reactor Regulation U. S. Nuclear Regulatory Commission Washington, D. C. 20555 Attention: Ms. E. G. Adensam, Chief Licens' tng Brarich No. 4 Re: Catawba Nuclear Station Docket Nos. 50-413 and 50-414

Dear Mr. Denton:

of the Catawba 1B diesel engine and the return to servic lA engine following reassembly after inspection. The Duke Power Company pla for these two items appear below:

A.

Catawba 18 Diesel Engine Inspections Our letter of April 5,1984 forwarded a report entitled " Catawba Nuclear Station Extended Operation Tests and Inspections of Diesel Generators."

Section 6 of this report noted that the extent of inspections to be carried out of the Catawba 18 diesel would be based upon the results of the Catawba lA diesel inspections and other TDI emergency diesels.

The Catawba ~1A diesel inspections are now complete.

i The Catawba lA diesel inspection results as well as the Owners Group inspection requirements for the second i

for.the Catawba 1B diesel has been developed from this re 18 inspection plan matrix is shown in a revised Table 5-1 to the above The Catawba mentioned report and is included as an enclosure to this letter.

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'to the revised Table 5-1, sample size of components to be inspected onReferring the Catawba 18 diesel will be the same as the Catawba lA diesel except as noted by parentheses.

Where parentheses are included inspection.for the Catawba 1B diesel appears in the paren, theses. ' sample size of B.

Catawba Diesel 1A Return to Service Testina

-In accordance with a commitment made in " Catawba Nuclear Station Engine 1A Component Revalidation Inspection. Final Report " of June 29, 1984, the following is the Duke Power Company plan for return to service

'I testing of the Catawba lA diesel.

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Mr. Harold R. Denton, Director July 6, 1984 Page 2 1.

Run-In Operation:

This will be in acco$ dance with TDI Instruction Manual, Chapter 6, Part C (page 6-C-18). The runs are mainly for seating new rings in the cylinder liner and consist of running the engine at various speeds and loads, inspections of the engine following various run.s, hot crankshaft. web deflection checks, and cold compression checks.

In additio', during these runs, control systems, vital engine parameters, n

and auxiliary services will be monitored to assure proper operation.

2.

Modified Load Tests:

Ten modified load tests will be run at a load of at least 3500 kW.

Pertinent parameters that will be adhered to are as follow:

A test will be of one hour minimum duration followed by. ct a.

least one and a half hours with the engine secured prior to the next modified load test, b.

All test starts will be performed. with a pre-lube of the engine.

During a test, the load will be increased to a minimum of 3500 KV c.

in a period less than five minutes.

d.

Vital engine parameters will be monitored on a fifteen minute basis during the one hour run at power to assure proper operation.

3.

24-Hour Run:

A twenty-four hour run test will be conducted.

of twenty-two hours at 7000 KW and two hours at 7700 kW.This test will consist Pertinent parameters that will be adhered to are as follow:

The engine test starts will be performed after the engine has a.

been pre-lubed.

b.

During the test, all load changes will be accomplis,hed in five minutes or less.

Vital engine parameters will be monitored on a one-hour basis to c.

assure proper operation.

4.

Fast Start Test:

Two fast start tests will be conducted.

will be adhered to are as follow:

Pertinent parameters that S

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Mr. Harold R. Denton, Director 1 July 5,1984 Page 3

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'i Js Diesd1 engine will come upato speed and voltage within eleven y'

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a.

segonds.

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b.

Diesel engine wiil be loaded with ' accelerated blackout loads in the period of eleven seconds to thirty seconds. Peak load will be about 4100 KW. This is the highest load obtainable with the loed sequencer under ESF or blackout conditions.

After lhe engfne has achieved 410b KW, each test will last for c.

gg a period of one hour followed by a shutdown of at least one and a half hours. The one hour duration at load is set so that

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auxiliary cooling devices will not have to be cut in for some of the respective loads which would place an undue burden on x

thk plant for the performance of these tests.

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d.

0ne of these tests will be conducted under pre-lube conditions.

The other of these tests will be performed with the engine in ready standby sutus without pre-lube.

e. ' Vital engine parameters will be monitored on a 15-minute basis, Further, visacorder tracings of diesel generator voltage and 1

frequency will be made during starting and loading transients.

'. Trip Device Verification:

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There are ten trips which cause the engine to shut down under normal operation and tnree trips which cause shutdown under emergency operation.

W To verify propdr opert. tion of these trip devices, shutdown from the tests outlined *In B-2 through 8-4 above will be accomplished by sequentially

-introducing thesh trips for each of the thirteen tests.

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6.

Load Rejection:

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To assure that on a load refec;the diesel generator does not go over five hundred RPM tion of ~1000 KW, visacorder tracings of frequency will be made during the trio frca 7000 KW outlined -in B-3 above.

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'M Criteria used to judge the tests outlinsd above as to what is a successful test, as opposed to a failed test, will be according to the foll.; wing plan:

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The operation runs %u: tlined in'1-1 above are for break-in and grooming.

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As such, there are not any pass /{ ail criteria applied to them. In addition t

to break-in, this rpn will be to as ure that the diesel generator is ready for tests B-2. through '8-6.

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Tests? outlined in II-2 throtgh B-6Wil'1'he conducted in accordance with the o

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pars / fail criteria of NRC Regulatory, Guide 1.108.

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a Mr. Harold R. Denton, Director July 6,1984 Page 4 of the Catawba Unit i diesels.We trust the above information is keeping yo service.

Please call me if I can be of any further Very truly yours, 44 k r Hal B. Tucker NAR/php Mr. James P. O'Reilly, Regional Administrator cc:

U. S. Nuclear Regulatory Commission Region II 101 Marietta Street, NW, Suite 2900 Atlanta, Georgia 30323 NRC Resident Inspector Catawba Nuclear Station Robert Guild, Esq.

Attorney-at-Law P.O. Box 12097 Charleston, South Carolina 29412 Palmetto Alliance 21351 Devine Street Columbia, South Carolina 29205 Mr. Jesse L. Riley Carolina Environmental Study Group 854 Henley Place Charlotte, North Carolina 28207 bec:

.D/G ~ Task Force J. M.'McGarry A.'V. Carr C. Newton J. M. Hart C. L. Ray C. L. Hartzell M. S. Tully N. A. Rutherford R. C. Futrell

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L. T. Parker R. O. Sharpe SREC NC MPA-1 NCEMC Group File: CN-801.01

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Latam i*uit J Diesch Inspection Plan &trix s

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Saz:ple Size, Pehent of Frgine Parts Inspected j

s Part Nmn

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'e p,g,y Surf. Vol.

Part 2., Claus Lizen. Visual 10E IDE Inbe Oil Pressure lhgulatin Valve v --**- -'-t-kterial Rutiness Eag Ev ktes 00 420 t,,-

Jacket Wter SWp? e, Ftres, Casket f

00-700A 3

r 100 L

X 9

Jacket %tdr Staafpipa@lts

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00-7003 B

~ Jacket Eter Stanipipe Supp)tm ' -

00-700C B

100 X

9 Jacket Eterstan! pipe Svirrheb/ '.

00-700E B

Jacket Eter Stan3 pipe Boltin;&u ial.100-700F s,

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B X

9 Nin Beariq Cap Base Assenbly 02-305A A

100' ~

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min Bearing Studs ami Ets 50(0) 50(0) 02-305C A _10(0) 30(0) min Bearirg caps

, Inbe Oil Internal Beaders

' 02-305D A

e 50(0 5C(0) 100 "} '

%.f-307A A

lube Oil 'Ibbing an! Fittings-IntdLiO2 '97P A

lobe Oil Line Supports-Inte:nal- ',. i 02-@f,'D B

100 Crarkshaft'

-i 100 Crakshaft Bearitz Shell

'02-310A A 100 NI %.

38(0) 02-3103 [ A 50(0) $0(0) 3,4 Crmkshaft huat Bearing Ring 3

02-3100 ~ A 100-Crankcase assenbly 02-311A A

4 Cam Iceing Caps tal Dowels 7C0

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02-3113 B

Crms. case Wuntirs Faz6ere 02-311D B

X 9

C'lialer Block 7

'S-f Cylinder liner

02--31 %

A 40(25) 20(25)

X(0) 9 N

02-315C A 100 100 2-Cylinfer Block Jacket Eter knifold 20(0), 20(0)

,02-315D E

Cylinder Head Studs 100' u ? n2-315E B

-s Cpl. Block Jr@t Wtr. &nifold Nts ' 02-315F B

25 3(0)

CylindedBloc.k Scals and Cackets-loo A.

02-315G B

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Jacket kater Inlet knifold Asse::bly ~'02-316A 100 X(0) 9 B

Jacket Eter Inlet. Uanifold Coupliat 02-316B B

Jacket Wter Discharge maifold

' 02-317A E

100 %

Jacket Eter Disch. &nifnld Coupling 02-317B B

10 0 '

Jocket Eter Disch. Enifald Supporth 02-317C 100 B

F1pheel 100

%f 02-33'M A

Flywheel Bolting

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Front Cear Case Bolting C2-33W A

100 X(0) 9 s

02-335B

'C' Connecting Rods ani Bushings 100 02-340A A 100(0) 100 100 Connecting Rod Bearing Shells v

25l0) 25(0)-

Piston 02-340B A 100 100 100 100 Piston Rings 02-341A A 100(0)100 100(0) 02-341B A

25(0) 100(0)

Piston Pin Asser:bly 5,10 I'i(0)

< Intake Tappets 02:341C A

25(0)100 11 7'

15(0) 25(0)

N 1 Tappets 02-34 %

A 25 A

02-345B A

h1 Pmp hse AsnAly 13 02-345C B

Cashaft Assembly, canshaft l'earig 02-350A A Nv 100 X(0) 9 r.-

02-3503 F s

Onrhaft Supports, 'Boltiyg'ani Cear 100

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0215f5 ' A ' k-i

' Crcakshalt Cear

'100(0)/'i -

7 10@)

10X0) i 02-3554 '

"A.

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Idfer Cear Asserbly

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100 Air Start Valve

. s (135Ld' A ' { -

100

<02-3 W "

A 100 [ 10t Q -

100(0)

Cylinier Head

i. 0@cA-C 100 100 '

100 100 Intake and hh:nst Valves

. - 101-360B / s B 25(0)100 X

Cylinder Bead Bolticg aaf Gidets Ob360J, $ B 25(0) 2,9

_ V21ve Spriegs 9

02-3630 - B 100 X(0) l Subcowr Assecbly I

Feel Injection Pu:n

< 02-3% _,B

i 100 100,

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1 10'-3bh B

hi Injectio2 Tips 100

'10C(0) 100(0)

X 9

- S2-365U

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Catz.ta Unit 1 Diesels Inspection Plan Matrix Sacple Size, Percent of Engine Parts Inspected Page 2 Part Nase Surf. Vol.

Part No. Class Dimen. Visual )DE10E h1 Injection Ming Material Hardness hg Dr Notes 02-365C B

h 1 Injection % bizs Supports 100 100 02-365D B

100 8

h1 Puup Linkage and control Shaft 02-371A A

h1 Puup, Linkge, Bearings and Shaft 100(0) 100(0)

Intake Manifolds 02-371B A

100 Exhaust Manifold 02-375 B

100 02-380A B

Exhaust Ihnifald Bolting 100 100 i

100(0) 100(0) 02-380B B

9 9'

8 Cylixxier Block Cover, Caskets an! Bolts 02-3853 C

Crankcase Cover Gaskets and Bolting 02-386B C

100 X(0) 9 Intake & Intermediate Rocker Arm Asably. 02-390A B

Exhasst Rocker Arm Assenbly 100 100(0) 100(0) 100(0) 02-390B B

Intake and N = nt Pushreds; 100 100(0) 100(0) 100(0)

Connector hhrod

, 02-390C B

100 100 02-39(D B

' Rocker Arm Bushirgs 100 100 02-390E B

Rocker Arm Folting 100 02-390G B

Overspeed Trip Covernor 100 100 02-410A A

100(0) 100(0)

Overspeed Trip & Accessory Drive 02-410B A

X(0) 9 Overspeed Trip Couplings 100(0)100(0) 100(0) 100(0) 02-4100 A

Overspeed Trip Vent Valves 100 02-410D A

Speed Rgulatizg Governor Drive 02-411A A

X(0) 9 Govemor Drive Couplings 100(0)100(0) 100(0) 100(0) 02-411B A

Governor Linkage 100 100 02-413 A

h1 Pucp Linkage-Auto Slutdom Cylinder 02-413B 100 Speed Raulating Governor B

100 02-41 %

A Govemor Booster Servonotor 02-415B B

X(0) 9 Covernor Heat Excharger Assenbly 02-415C A

X 9

lobe Oil Puup 02-420 A

X(0) 9

" Jacket Water Puap 02-42 %

A 100(0)

X(0) 9 Intercooler Piping-Coupling, Bolt, Cskt.

100(0) 100(0) 02-4363 A

-W:bo Cooling Water Pipe ani Fittings 02-437A B

100 l

hrbo Cooling Water Pipe Supports 100 02-437B A

Start Air Manifold Pipe, Abits & Fttng. 02-441A 100 A

Start Air Manifold Vivs, Stmers, Fitrs. 02-441B 100 A

Start Air Manifold Pipe Supports 02-441C A

Iti)

X(0) 9 Starting Air Distributor Assenbly 02-442A A 100(0)100(0)

Start Air Distributor 7bg., Ftg., Cskts. 02-442B 100 100(0)

A Fuel Oil Booster Punp 6

02-445 A

bl Oil Piping and wbing 02450B A

100 X(0) 9 h1 Dil Piping Supports 02-450D A

M 1 Oil Filters 100 h1 Oil Strainers 02-45%

B 1

02-455B B

X(0) 9 h1011 Filter Mounting Harduare 02-455C A

X(0) 9 Externa 11nbe oil Lines 100 02-46%

A Extemal lube Oil Line Supports 100 02-465B A

External Inbe Oil Valves 100 02-465C A

Arbocharger Inbe Oil Piping 02-467A B

Wrbocharger Inbe Oil Piping Supports 100 X

9 02-467B B

Arbochstger Bracket 100 02-47 %

B Wrbocharger Air Butterfly Valve 100 02-475B A

hrbocharger Bracket Bolting 100(0) 100(0) 100(0)

Control hel Cabinet 02-475D B

8(0)

Control Air Accuuulator 02-500A A

8(0) 12 Control Air System Valves 02-500F A

X 9

02-5000 A

X 9

X 9

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Table 5-1.

Cat.* M 1 Dierals Inspection Plan htrh S.mple Siza, Percsnt of Engina Parts Inspscted Page 3 Part 11ase Surf. Vol.

Part Ib. Class Dinen. Visual NDE NDE heerial Esrdness Etg 27 Notes Catrol Air System Pressure switches 02-5031 B

cmtrol Systen Belays 02-500T A

I 9

Cetrol System Solanoid Valves 02-500t A

I 9

cmtrol Air Systes Pipirg, Tbbirg, Ptngs 02-500M B

I

~9 100 Cmtrol Panel Wiring o02-540A B

02-500N A

Inbe Oil Smp Tank I

9 100 Iube 011 Sep Tank Bolting 02-540B B

100 Inbe Oil Sep Tank muotirg Harthere 02-540C B

100 Fourziation Bolts and Anclors02-550 B

Insen - *fon h r = ples 02 4 300 3

I(0) 9 Ergine & A-41t=7 2dula Wiring Confuit 02488&

I 9

A 100 Ergine and L=illig 2dule Wiring

. 02488B A

Engine and k=itia7 2dnIn Wiring Boxes 02-688C A

I 9

Ergine Alarm Sensors 02490 A

I 9

off Engina Safety Alarm Sensors-evitebes 02-691A I

9 B

Ergine Stutdoza Ibbica and Fittings 02495&

B I

9 100 Ibgine Stutdout Yalves, Ecgs. & Orifice 024 958 A

Ergine Shutdann liip Switches 02495C A

I 9

lbel 011 Duplex Strainer 02-825D A

I 9

lbrbochar;;er Ihrust Bearirg Inbe Systra 02<I2 I

9 C

100 hatatic Valve C 135-40 B Intake Air Filter -

@ l06 B

I 9

Intake Air Silm er CN-107 B

I 9

Befora and After Inbe Oil Pmp

@ l09 A

I 9

lb11 Flor Zube Oil Filter CH-110 A

I 9

Inbe Oil Heat Webmar

@ lli B

I 9

Cenerator Shaft armi Bearings G-119A A

I 9

Jacket Water Heat heb==r

@ l20 B

I 9

011 Prelube Filter CN-122 A

I 9

Iube Oil Keeptarm Strainer CN-131 A

I 9

Intercooler F-068 A

I 9

100 100 1hrbocharger HP-022/3 A 100 100 Inbe Oil 1%11 Pressure Strainer SE-025 A

I 9

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l Notes to Table 5-1 1.

Intake and exhaust valve springs have proper olor code.

2.

Ultrasonic wall thickness measurement of fire deck area an

. area.

3.

A torsiograph will be developed of the crankshaft.

4.

the diesel both hot and cold. Crankshaft web deflec'tio'n 5.

Measure torque on belleville spring loaded bolts.

6.

Hardness of the spools will be measured only if excessive wear is measured on one or more of the spools.

7.

of the camshaft bearings will be performed.If inspection of cam 8.

Eddy current test to determine if there are cracks.

9.

Engineering validation (Eng Ev) of diesel 'lA part including visual inspection to determine that part is per bill of materials and review of unscheduled maintenance reports associated with part.

i engineering validation consists of reviewing unscheduled maintenanceFor dies reports.

10.

Piston skirts will be replaced on the 1B diesel.

Surface NDE and hardness weneperformed in receipt inspection.

11.

New piston rings will be installed on the new skirts.

12. All bolting will be replaced.

13.

Catawba 18 frequency of inspections same as CatawFa lA except as parentheses.

Where parentheses are included, frequency of inspection for Catawba 18 appears in the parentheses, t

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