ML17265A638

Part 21 Rept Re Replacement Turbocharger Exhaust Turbine Side Drain Port Not Functioning as Design Intended.Caused by Manufacturing Deficiency.Turbocharger Was Reaasembled & Reinstalled on B EDG

ML17265A638
Person / Time
Site:	Ginna
Issue date:	05/07/1999
From:	MECREDY R C ROCHESTER GAS & ELECTRIC CORP.
To:	VISSING G S NRC (Affiliation Not Assigned), NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-99 NUDOCS 9905140213
Download: ML17265A638 (6)

Text

CATEGORY1REGULA'INFORMATION DISTRIBUTIO~

SYSTEM(RIDS)JACCESSION NBR:9905140213 DOC.DATE:

99/05/07NOTARIZED:

NODOCKET¹FACIL:50-244 RobertEmmetGinnaNuclearPlant,Unit1,Rochester G05000244AUTH.NAMEAUTHORAFFILIATION MECREDY,R.C.

Rochester GasSElectricCorp.RECIP.NAME RECIPIENT AFFILIATION VISSING,G.S.

SUBJECT:

Part21reptrereplacement turbocharger exhaustturbinesidedrainportnotfunctioning asdesignintended.

Causedbymanufacturing deficiency.

Turbocharger wasreaasembled'Sc reinstalled on"B"EDG.DISTRIBUTION CODE:IE19TCOPIESRECEIVED:LTR ENCLSIZE:TITLE:Part21Rept(50DKT)NOTES:License Expdateinaccordance with10CFR2,2.109(9/19/72)

.05000244ATERECIPIENT IDCODE/NAME LPD1-1INTE:FILEENTER01DRWARD,M.RGN1.RGN3COPIESLTTRENCL1111111111RECIPIENT IDCODE/NAME VISSING,G.

NRR/DRIP/REXB RES/DET/EIB RGN2RGN4COPIESLTTRENCL1111111111EXTERNAL:

INPORECORDCTRNRCPDR1111NOACSILVER,ENUDOCSFULLTXT1111D'ENOTETOALL"RIDS"RECIPIENTS:

PLEASEHELPUSTOREDUCEWASTE.'TO HAVEYOURNAMEORORGANIZATION REMOVEDFROMDISTRIBUTION LISTSORREDUCETHENUMBEROFCOPIESRECEIVEDBYYOUORYOURORGANIZATIONS CONTACTTHEDOCUMENTCONTROLDESK(DCD)ONEXTENSION 415-2083FULLTEXTCONVERSION REQUIREDTOTALNUMBEROFCOPIESREQUIRED:

LTTR14ENCL14

~O4NDROCHESTER GASANDELECTRICCORPORATION

~89EASTAVENUE, ROCHESTER, N.Yld6rI90001AREACODE71654'6-2700 ROBERTC.MECREDYVicePresident NvctearOperations May7,1999U.S.NuclearRegulatory Commission DocumentControlDeskAttn:GuyS.VissingProjectDirectorate I-1Washington, D.CD20555

Subject:

10CFRPart2130DayReportR.E.GinnaNuclearPowerPlantDocketNo.50-244

DearMr.Vissing:

Theattached10CFR21reportisherebysubmitted inaccordance with10CFRPart21,Reporting ofDefectsandNoncompliance, Section21(d)(3)(ii),whichrequires"Writtennotification totheNRC...ontheidentification ofadefectorafailuretocomply".Verytrulyyours,RobertC.Mecedyxc:Mr.GuyS.Vissing(MailStopSC2)ProjectDirectorate I-1DivisionofReactorProjects-I/IIOfficeofNuclearReactorRegulation U.S.NuclearRegulatory Commission Washington, D.C.20555RegionalAdministrator, RegionIU.S.NuclearRegulatory Commission 475Allendale RoadKingofPrussia,PA19406U.S.NRCGinnaSeniorResidentInspector 99oSX40Z13 99O5O7PDRADOCK05000244SPDRs llh 10CFR2130DAYWRITTENREPORTNAMEANDADDRESSOFTHEINDIVIDUAL INFORMING THECOMMISSION:

NAME:ADDRESS:RobertC.MecredyVicePresident NuclearOperations GroupRochester Gas8ElectricCorporation 89EastAvenueRochester, NewYork14649II~IDENTIFICATIONOFTHEFACILITYITHEACTIVITYORTHEBASICCOMPONENT SUPPLIEDFORSUCHFACILITYWHICHFAILSTOCOMPLYORCONTAINSADEFECT:Thebasiccomponent istheALCOturbocharger (Model730),installed onthe"B"Emergency DieselGenerator (ALCOModel16-251F)atGinnaStation.Areplacement turbocharger wasinstalled onthe"B"Emergency DieselGenerator (EDG)onMarch25,1999.III.IDENTIFICATION OFTHEFIRMCONSTRUCTING THEFACILITYORSUPPLYING THEBASICCOMPONENT WHICHFAILSTOCOMPLYORCONTAINSADEFECT:Theturbocharger wassuppliedtoRGSEbyColtecIndustries.

ColtecIndustries Fairbanks Morse/ALCO EngineDivision701WhiteAvenueBeloit,WX53511Coltecprocuredtheturbocharger fromElliotTurbocharger Groupasacommercial itemandperformed aCommercial GradeDedication priortoproviding ittoRochester GasandElectricasanAppendixBcomponent.

IV.NATUREOFTHEDEFECTORFAILURETOCOMPLYANDTHESAFETYHAZARDWHICHISCREATEDORCOULDBECREATEDBYSUCHDEFECTORFAILURETOCOMPLY:Thenatureofthedefectconsisted ofamanufacturing deficiency inthereplacement turbocharger forthe"B"EDG.Themachining ofadrainportintheexhaustturbinesideoftheintermediate casingwasomitted,preventing enginelubricating oilfrombeingabletodrainbacktotheenginesumpfromtheturbocharger shaftandbearings.

Therefore, thereplacement turbocharger exhaustturbinesidedrainportdidnotfunctionasthedesignintended.

Thisdefectcreatedthecondition whereenginelubeoilwasbeingdirectedintocylinders throughtheexhaustmanifoldpiping.Withoilinthecylinders, theenginecouldhavebeenseriously damagedwhenstarted.Thiswouldhaveresultedinalossofredundancy intheon-sitesourcesof480VACpower.However,theEDGwasnotoperableatthetimethedefectwasdiscovered.

Thedeficiency wasfirstindicated whenthepre-lubesystemwasinoperation.

The"B"EDGwasbeingpreparedforpost-maintenance testingonMarch29,1999,whiletheplantwasdefueled.

Noactualsafetyhazardexisted,becausethepost-maintenance testinghadnotbeenperformed.

V.THEDATEONWHICHTHEINFORMATION OFSUCHDEFECTORFAILURETOCOMPLYWASOBTAINED:

Theinformation wasobtainedonMarch30,1999,following disasssembly oftheturbocharger.

VI.INTHECASEOFABASICCOMPONENT WHICHCONTAINSADEFECTORFAILSTOCOMPLY,THENUMBERANDLOCATIONOFALLSUCHCOMPONENTS INUSEATgSUPPLIEDFORgORBEINGSUPPLIEDFORGINNASTATION:Thereare2(two),permanently installed EDGsatGinnaStation.Onlythe"B"EDGwasprovidedwithareplacement turbocharger, whichwasfoundtocontainthemanufacturing deficiency statedinIV.above.Theturbocharger onthe"A"EDGwasnotreplaced, anddoesnotcontainthestateddeficiency.

VII~THECORRECTIVE ACTIONWHICHHASBEEN~XSBEXNGgORWILLBETAKEN;THENAMEOFTHEINDXVIDUAL ORORGANIZATION RESPONSIBLE FORTHEACTION;ANDTHELENGTHOFTIMETHATHASBEENORWILLBETAKENTOCOMPLETETHEACTION:Thecorrective actiontakenwastoremovethenewreplacement turbocharger fromthe"B"EDGanddisassemble andinspectit.Duringdisassembly, itwasdiscovered thattheintendeddrainporthadnotbeenmachinedintotheintermediate casing.Underthesupervision ofthemanufacturer's representative, theintermediate casingwasreworkedtooriginalrequirements, openingthedrainpath.Theturbocharger wasreassembled andreinstalled onthe"B"EDG.Post-maintenance andoperability testingwassuccessfully performed andthe"B"EDGdeclaredoperableonApril2,1999.Personnel fromRochester GasandElectricNuclearEngineering ServicesandfromGinnaStationMaintenance Department wereresponsible forthecorrective action,withtheassistance ofthemanufacturer's representative.

Corrective actionswerecompleted onApril2,1999.VIII.ANYADVICERELATEDTOTHEDEFECTORFAILURETOCOMPLYABOUTTHEFACILITY'CTIVITY'R BASICCOMPONENT THATHASBEEN'SBEING,ORWILLBEGIVENTOPURCHASERS ORLICENSEES:

Amissingoildrainportcannotbeobservedwithoutdisassembly oftheturbocharger.

Innuclearserviceapplications, theuseofaColtecIndustries Model730turbocharger ontheALCO251engineisuniquetoGinnaStation.Organizations procuring orinstalling turbochargers suppliedbyColtecIndustries underanAppendixBprogramshouldconsiderthepotential forthisdeficiency.

Thisissuewillbediscussed atafuturemeetingoftheALCOOwners'roup.