ML20093N528

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Forwards Program Plan for Evaluating & Testing Tdi Standby Diesel Generators.Program Includes All Recommended Actions of Tdi Owners Group & Tdi.Changes to Number of Start Tests & Overload Tests Requested
ML20093N528
Person / Time
Site: River Bend Entergy icon.png
Issue date: 07/19/1984
From: Booker J
GULF STATES UTILITIES CO.
To: Harold Denton
Office of Nuclear Reactor Regulation
References
RBG-18-244, NUDOCS 8408020025
Download: ML20093N528 (43)
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Text

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F GULF STATES POST OFFICE OOX 2951 UTILITIES COMPANY

. BEAUMONT. TEXAS 77704 kl AREA CODE 713 838-6631 July 19, 1984 RBG- 18,244 File No. G9.5, Mr. H. R. Denton, Director Office of Nuclear Reactor Regulation U. S. Nuclear Regulatory Commission Washington, D. C. 20555

Dear Mr. Denton:

River Bend Station - Unit 1 Docket No. 50-458 Enclosed for your review is Gulf States Utilities Company (GSU) program plan for evaluating and testing the standby diesel generators manufactured by Transamerica Delaval Inc. (TDI).

In November, 1983, GSU initiated the Diesel Qualification Program at River Bend Station and has been involved in the TDI Owners Group (TDIOG) since December, 1983. The program presented herein includes all recommended actions of the TDIOG and the manufacture.

This program plan addresses the plans for testing scheduled to commence'at the end of this month, the post-testing inspection, and long term surveillance and monitoring. In addition, GSU is requesting changes to the number of start tests and to the overload test being performed on these engines.

Si cerely I' ', b J. E. Bc $ker Manager-Engineering Nuclear Fuels & Licensing River Bend Nuclear Group JEB/ /kt

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TABLE OF CONTENTS j

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.SECTION. PAGE-c

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1.' O INTRODUCTION 4

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2.0 . PROGRAM ACTIVITIES

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.), ,, 2.1 Industry Experience Review 9

2 '. 2
Design Review 10

,-P 2.3' -Preservice Inspection 17 w- . :r  :- 2. 4 Rework 23 2.5 1

' Testing 25 2.6 - Post Test Inspection 28-

'2. 7 Surveillance and Monitoring- .34 i

s L 3.0 ?

SUMMARY

OF.RESULTS AND CONCLUSIONS 35 l

4.0 NRC QUESTIONS AND IISPONSES (LATER) 36 APPENDIX 1 -~ FSAR Revisions

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I LIST OF TABLES PAGE NO.

TABLE 1 - Design Reviews 11 TABLE 2 - Preliminary Testing of Auxiliary Components and Systems (LATER)

TABLE 3 - Preservice Inspections 13 TABLE 4 - Rewcrk Activities (LATER)

TABLE 5 - Operational Testing 26 TABLE 6 - Post Test Inspections 29

'1, PAGE 2

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LIST OF FIGURES PAGE NO.

FIGURE 1 - River Bend Diesel Qualification Activities 6

i. FIGURE 2 - Program Schedule 7 F

PAGE 3

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1.0 INTRODUCTION

This topical report has three purposes:

(1) To present GSU's Program Plan to qualify the Transamerica Delaval, Inc. (TDI) manufactured standby diesel generators for River Bend Station.

(2) To provide the Staff an opportunity to review, in advance, the plans for testing, post test inspection, and long term surveillance and monitoring.

(3) To submit for NRC Staff review, the current results of design review and preservice inspection activities at River Bend Station.

'GSU initiated the Diesel Qualification Program at River Bend Station in Novemb.z, 1983 in response to TDI diesel component failures elsewhere and identified potential deficiencies in TDI's quality assurance program.

The objectives of the River Bend Diesel Qualifications Program are:

(1) To evaluate the TDI diesels and; (2) to determine what is necessary to assure reliable standby power at River Bend Station. The Diesel Qualification Program includes activities to solve the known problems of the TDI diesels and; (3) to obtain NEC approval of the standbv power supplies for River Bend Station.

The GSU approach to qualification of the TDI diesels is:

(1) To correct the known problems before the diesels are operated at River Bend Station. This involves preservice engine disassembly for inspection, upgrading, and rebuilding.

(2) To confirm engine reliability by testing and post test inspection, without engine disassembly.

(3) To assure continued diesel reliability by a prcgram of inservice surveillance, inspection, monitoring, and preventative maintenance.

PAGE 4

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The feasibility of this approach has been established through the design reviews provided by the TDI Diesel Generator Owners Group, the testing and inspections performed by the TDI diesel owners, and the product improvement recommendations provided by TDI. GSU and its contractors have devoted an intensive effort to accumulate this experience and to implement corrective action to improve diesel generator reliability prior to operation of the engines at River Bend Station. After rebuilding, the engines will be tested to confirm operational reliability. After testing, the engines will be inspected to identify latent defects not disclosed during rebuilding or testing. 3 -

This inspection will involve minor disassembly, sufficient to detect latent problems, but not so extensive as to require retesting. y 5

Figure I shows the logical relationship of program tasks, and Figure 2 y shows the program schedule. The initial phase involves evaluation of _

industry experience, design review recommendations, and preservice j inspection results. The second phase involves engine rework, rebuilding, confirmatory testing and post test inspection. This phase g is expected to result in successful qualification of the TDI diesels.  ;

3 The last phase is a ' program of continuing surveillance, inspection, j monitoring, and preventative maintenance. The continuing surveillance j and monitoring program will be finalized after the post test -

inspection is completed. j m

This report describes the plans for design reviews, inspections, j testing, and long term preventative maintenance, surveillance and  ;

monitoring. The format of the report permits the results of ongoing =

activities to be added by revisions or supplements as the work  ;

proceeds. When complete, the report will describe, or incorporate by _

reference, the results of the design reviews, preservice inspections, -

rework activities, testing, and post test inspections. Data presented i is current as of July 5, 1984. 1 s

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r-2.0- PROGRAM ACTIVITIES The following subsections detail the work to be performed and current results.

PAGE 8

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2.1 Industry' Experience Review The purpose of this activity is to define the known problems of the

'TDI engines and to determine if these problems might be applicable to g -River Bend Station.

Review of industry experience data accumulated by the TDI Diesel Generator Owners Group.

Visits by River Bend Project Personnel to observe diesel inspections at other nuclear stations.

-1 Participation in TDI Diesel Owners Group meetings and activities.

' ' Informal exchange of information with other TDI diesel owners.

The accumulated experience is evaluated for applicability to the River Bend Station diesels. Those items considered applicable are further investigated. This either is done as part of the TDI Diesel Generator Owners Group Review Quality Revalidation effort, or they are added to the work list of inspections, tests, or investigations conducted'by GSU and its contractors at River Bend Station. Results of industry experience reviews conducted to date are reflected in the plans for design-review, preservice inspection, rework, testing, post test inspection, and surveillance and monitoring which are described in later sections of this report.

l PAGE 9 l

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2.2 Design Review The-purpose of this activity is to verify the design adequacy of the diesel generator components and systems. The TDI Diesel Generator Owners Group will perform design reviews of TDI supplied components whose failure might affect the safety functions of the diesel generators.

Tabic.1 lists the TDI supplied components to the parts group level as listed in the TDI parts manual. For-each component, the table lists the design review report reference, and summarizes the conclusions of the_ design review. Those reports listed are thereby incorporated by reference in this report.~ Product. improvements or upgrades are also identified in the table.

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J l . TABLE 1 l DESIGN REVIEWS NOTE: DATA' CURRENT.TO 07/05/84'-

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l COMPONENT .

' DESIGIL REVI EW REPORT I NUMBER DESCRIPTION (IMPROVEMENTS) . REFERENCE ' CONCLUSIONS' l-1 03-305' Base and Bea ring Caps Ref. :14 - . Adequate, subject'to.' inspection 1 03-307 Lube Oil Fittings-Internal . Phase 2

'1 03-310 Crankshaf t and Main Bea rings: Ref.,15 Adequate for Shoreham. River Bend Report to be submitted 11/84- - 03-315 Cylinder Block Liners and . .

Her. 5,7,8 Adequate, subject to' inspection.

Water Manifold (see Section 2.4) 1 03-317 . Water Discharge Manifold Phase 2 03-330 Flywheel Phase 2 -

03-331 Flywheel Gua rd Not Requi red 03-335 Gea r Case Not Required

.03-340 Connecting Rods .Ref. 3,12 Adequate,' subject to inspection.03-341 Piston (AE Pistons Ref. 1, 2 Adequate i installed, see i Section 2.4) 1 l 03-345 Tappets and Guides Phase-2 l

I 03-350 Camshaf t-Cam Bea ring Phase 2 l and Cam Cea r I

l 03-355 Idler and 1 - Miscel laneous Gea rs ( see Sect ion 2.4) l 1 03-359 Ai r Sta rt Va lve Ref. 13 Adequate i

1 03-360 Cylinder Head and Valves Ref. 4 Adequate. Fire deck thickness and casting qua l i ty to be verified, and replaced where necessa ry. G roup II heads requi re period ic leak testing 03-361 Cylinder Indicating Locks Not Required 03-362 Cylinder Head Covers Phase 2 03-365 fuel injection Equipment Ref. 11 Adequate if inspection criteria are met 03-371 Fuel Pump Linkage Phase 2 l

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l. DESIGN REVIEWS ' It0T E: ' DATA CURRENT TO 07/05/84 l (Centinued)

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!, - COMPONENT .

DESIGN REV1EW REPORT

l. 'guMBJ DESCRIPTION (IMPROVEMENTS) .

REFERENCE CONCLUSIONS I

I'03-375 intake ManiroId Phase 2 l

l '.03-320 Exhaust Manifold Phase 2 l

I- 03-385 Covers-Cylinder Block Phase 2 1

1 03-387 Crankcase Ventilator ' Phase 2 1

03-390 Rocker Arms and Pushrods Ref. 10,16 Rocker a rms adequate, subject to

( f riction we.ded pushrods, see section 2.4) inspection ll Pushrods upgraded to f riction welded I design which is adequate 1

l 03-402 Governor Drive Phase 2 I

l 03-410 Overspeed Trip Phase 2 l

l .03-413 Governor Linkage Phase 2 1-1 03-415 Gove rno r Phase 2 l

l 00-420 Pressure Regulating Phase 2 I Valve-Lube Oil 03-420 LuDe Oil Pump- Phase 2 I; Engine Driven l

03-425 Water Pump Jacket Water Ref. 6 Replace impeller change material and eliminate keyway.

I 435 Jacket Water Fittings Phase 2 l'

.Il 03-437 Tu rbocha rge r- Pha se 2 i Water Fittings03-441 Starting Air Lines Phase 2 1 03-442 Starting Air Distributor Phase 2 l I I 03-445 Fuel Booster Pump Phase 2 I

I 03-460 Strainer, Duplex Phase 2 i Lube Oil l

l 03-465 Lube Oil Fittings Phaso 2 I

l 03-467 Turbocharger Lube Phase 2 l' Oil Fittings l

l NB-002 I nte rcoo le r Phase 2 il 1 PAGE 12

_4 l TABLE 1 l l DESIGN REVIEWS LOTE: DATA CURRENT TO 07/05/8:4- 1, I (Continued)

I l COMPONENT DESIGN REVIEW REPORT I NUMBER DESCRIPTION (IMPROVEMENTS) REFERENCE CONCLUSIONS I

i 03-475 Turbocha rger and Phase 2 l Ir.tercooler Brackets I MP-020 Tu rbocha rge r Ref. 9 Modify prelube system. Preiodic l inspection of bea rings I

i 00-491 Air inlet Adapter Not Pequired l

l 00-495 Exhaust Outlet Adapter Not Required l

l 03-503 Thermometer Not Required l

l 03-500 Cont ro l Panet Phase 2 l

03-515 Thermostatic Va lve Phase 2 1

1 03-520 Instruction Plates Not Requi red l

l 03-525 Barring Device- Phase 2 1 Pneumatie l

1 03-530 Engine Platform Not Required l

l 03-531 P l a t fo rm. Ladde r Not Required l

l 03-540 Lube oil Sump Tank Phase 2 l

1 03-550 Foundation Bolts Phase 2 l

I 03-630 Pyrometer Condui t Phase 2 1

1 03-650 Electrical Equipment Phase 2 I

l 03-688 Electrical Wiring Phase 1 1

I 03-689 Off Engine Wiring Phase 2 I

I 03-690 Safety Ala rm On Engine Phase 2 l

l 03-691 Of f Engine Ala rm Sensors Phase 2 l 8

1 03-695 Safety Shutdown Phase 2 I

I 03-700 Standpipe Phase 2 l

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l TABLE 1 l l DESIGN F EVIEWS N0lE: DATA CURRENT TO 07/05/84' l (Continued) ,

1 I l COMPONENT DESIGN REVIEW REPORT l NUMBLR DESCRIPTION (IMPROVEMENTS) REFERENCE CONCLUSIONS I

I 03-715 Sub Base Phase 2 1

1 03-717 Aux!Ila ry Skid Phase 2 I

i 03-800 Heater, Jacket, Phase 2 I Wa te r Hea te r, I Lube Oil Sump Tank I

l 03-805 Intake and Exhaust Phase 2 1 Equipment i

I 03-810 Jacket Water Equipment Phase 2 I

I 03-820 Lube Oil Equipment Phase 2 l

l 03-825 Fuel oil Equipment Phase 2 I

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' Design Review Report heferences:

1. Investigation of Type AF and AE Piston Skirts. TDI Owners Group letter 0GTP-41; C.L. Ray Jr to H.R. Denton, 5/24/84
2. The Influence of Thermal Distortion on the Fatigue Performance of AF and AE Piston Skirts; TDI Owners Group letter OGTP-72; C.L. Ray Jr to H.R. Denton, 6/14/84.
3. Design Review of Connecting Rods TDI Inline DSR-48 Emergency Diesel

' Generators; TDI Owners Group letter OGTP-79; 6/18/84.

4. Evaluation of Cylinder Heads of TDI Series R-4 Diesel Engines; TDI Owners Group letter OGTP-25; C.L. Ray Jr. to H.R. Denton, 5/14/84.
5. Design Review of TDI R-4 Series Emergency Diesel Generators Cylinder Blocks and Liners; TDI Owners Group letter 0GTP-90; C.L. Ray Jr. to H.R. Denton, 6/25/64.
6. Emergency Diesel Generator Engine Driven Jacket Water Pump Design Review; TDI Owners Group letter TDI-15; W.J. Museler to H.R. Denton 4/16/84.
7. Emergency Diesel Generator Cylinder Head Stud Analysis; TD1 Dwners Group letter TDI-8; W.J. Muscler to H.R. Denton, March 30, 1984.
8. Supplement to the Emergency Diesel Generator Cylinder Head Stud Stress Analysis; April 1984.
9. Design Review of Elliot Model 90G Turbocharger used on TDI DSR-48 and DSRV-16 Emergency Diesel Generator Sets; TDI Owners Group letter OGTP-26; C.L. Ray to H.R. Denton 5/14/84.
10. Design Review of Rocker Arm Capscrews; TDI Owners Group letter TDI-19; W.J. Muselor to H.R. Denton, 4/25/84.
11. Design Review of Fuel Oil Injection Tubing; TDI Owners Group letter OGTP-8; C.L. Ray to H.R. Denton, 4/27/84.
12. Design Review of Connecting Rod Bearing Shells; W.J. Museler to H.R.

Denton, 3/12/84.

13. Design Review of Air Start Valve Compressor Dimension and Stress Analysis; TD1 Owners Group letter TDIO-5; W.J. Museler to H.R. Denton, 3/15/84.
14. Design Review of Engine Base & Bearing Caps; TD1 Owners Group letter OGTP-10; C.L. Ray to H.R. Denton, 4/27/84.
15. Design Review of Crankshaft; TDI Dwners Group letter TDI-17; W.J.

Musoler to H.R. Denton, 4/20/84.

PAGE 15

16. Design Review of Pushrods; TDI Owners Group letter TDI-16; W.J.

Museler to H.R. Denton, 4/19/84.

PAGE 16

2.3 Preservice Inspection The purpose of the preservice inspection effort is to verify that the installation is complete and correct and that the manufactured quality of the engines comply with the design requirements. This will be done in three steps:

(1) As built installation verification. This includes inspections by TDI and major subvendors to TDI, including Electric Products (electric generator), RTE Delta (switchgear), Elliot (turbocharger), and Woodward (governor). In addition, GSU inspects other components selected from industry experience information. The purpose of these inspections is to verify that the engine installation is complete and correct. A list of inspections performed and the results are listed in Tabis 3.

(2) Preliminary testing of auxiliary components and systems. The purpose of these tests is to verify that auxiliary systems, interlocks, controls, and alarms operate in accordance with specifications. This includes system flushing, hydrostatic testing, relief valve testing for setpoint and seal leakage, initial startup, operation, and performance testing and vibration testing of pumps and compressors, performance testing of air dryers, and individual checkout of all electrical components and instrument loops.

(3) Preservice disassembly inspection. The purpose of this inspection is to verify that the manufactured quality of the engines is in accordance with the requirements established by the TDI Diesel Generator Owners Group design reviews. This inspection involves removal of cylinder heads, pistons, connecting rods, and cylinder liners for detailed part-by-part inspection. In addition, the turbochargers will be disassembled for inspection. Inspection of the crankshaft, gear case, and camshaft will be performed in situ.

Table 3 lists the engine component groups, the inspection methods employed, and inspection results. Where parts are replaced, the replacements are subjected to the same inspections.

PAGE 17

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.I- PRESERVICE. INSPECTIONS' DATA CURRElIT TO: 07/05/8:s ~

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I l COMPONENT .

I IIUMBER DESCRIPTION INSPECTION METHOD RESULTS l DIESEL A DIESEL'B i

-l 03-305 Base and Bearing Caps .LP of mating surraces. . l l or base and bearing cap I

i- 03-307 Lube Oil Fittings- Visual', for proper

-1 i nte rna l connection and security i

!03-310 Crankshaf t and Visual and LP of crank pin journal, 1 Main Bearings and crank pin journal tillets. -l l EC or. crank pin Journa l tillets 1 on cylinders 5, 7, and 8.

l LP or #5 ma in - bea ri ng she I I -

l On engine 8.

-1 l 03-315 Cylinder Block Liners Dimensional inspection of liner, I and Water Manifold and l iner landing. . LP of block I liner landing. MT or block top.

1- Visual of l i ne r. Visual of I water mani fold. . Visual, I material and hardness test or I cylinder head studs. Visual I of stud nuts.

l 03-317 Water Discharge Manifold Visual for leakage at couplings I 03-330 Flywheel Bolt torque verification 1

03-331 Flywheel Gua rd Visual for security 1 03-335 Cea r Ca se Bolt torque verification l

l 03-340 Connccting Rods EC & visual of connecting rod oil l passage. Material hardness test or I con rod. LP wrist pin bushing, i Visual, LP and RT of con rod I bearing shells.

I i 03-341 Piston LP and visual of piston skirts i Visual of crown i Visual of piston rings I LP of piston pins l 03-345 Tappets and Guides Visual I valve lash and clea rances ll l

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_ DESCRIPTION- INSPECTION METHOD. RESULTS l NUMBER DIESEL A ' DIESEL-B

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i 03-350 Camsha f t-Caa Bea ri ng ' Visual .and hardness test of l 1

'can lobes 1 1- and Can Gea e .

Verify proper assembly : l .I 1

l Valve timing .' l --  !

I l ' Visual of crank to pump l l 03-355 -idler and l Miscellaneous Gears gear, bolts and gaskets 1 j

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l 03-359 Air Start Valve Visual of valve seating l Bolt torque verification i Veri fy p rope r gasket '

l- Cylinder head: LP of valve seats 1 03-360 Cylinder Head I and Valves UT, MT of fire deck-l LP and visual or valves l Bluing of valve seating i Vi st a l of valve springs i Visual and PT of subcovers l

I 03-365 Fuel injection 'EC fuel injection-tube ID Equipment Check spray tips for clogging l l -l l Verify tubing support assembly l

l l l 03-371 Fuel Pump Linkage liardness test -of shGf t >

l Verify assembly, f ree travel, l proper lubrication l

l 03-375 Intake Panifold Visual for cracks at -

I flange facing i

1 03-380 Exhaust Manifold Bolt torque verification l

l 03-385 Covers-Cyl inder Block Bolt torque verification 03-387 Crankcase Ventilator Visual for leaktightness ll

.and security I j l 03-390 Rocker Arms and Visual l Push Rods . Material test on one rocker arm l Torque verification i LP push rods one cylinder l

MT rocker arm capscrews i Material, ha rdness of rocker a rm I capscrews Verify clearances l

PAGE 19 l

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I . . DATA CURRENT'.TO: .07/05/84 ,

PRESERVICE INSPECT 10NS'

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I I COMPONENT . I-RESULTS I' DESCRIPTION INSPECTION METHOD .

' NUMBER . DIESEL A ' DIESEL B! l l I I .

Visua l < for . leaktightness ~ -l' l 03-465 Lube Oil Fittings '

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I ~ 03-a#67 Tur bocha rger Lube I- . Oil-Fittings . assembly 1

N8-002 Inte rcoole r Visual for leaktightness . ll

-l and security l

l Bolt torque verification I Visual of butterfly valve for wear-l 03-475 Turbocharger and intercooler Brackets Bolt torque verification ,

1 I- lLP stationary nozzle ring l MP-020 Tu rbocha rge r Visual of thrust bearing, i thrust bearing clea rance ,

l l I

Bolt torque verification 00-491 Air inlet Adapter Visua l for . security l -Visual for security l 00-495 Exhaust Outlet Adapter l

l 03-503 The rmomete r None. Verified by test  ;

I l 03-500 Cont rol Pa ne t Verify cleanliness l

l 03-515 Thermostatic Valve Rebuild per IE Notice l 82 l l 03-520 instruction Plates None requi red l

l 03-525 Barring Device-Pneumatic None requi red I

l 03-530 Engine Visual for security l

1 03-531 Pla tform, Ladder Visual for security 4

03-540 Lube oil Sump Tank Visual for leakage 03-550 Foundation Bolts Bolt torque verification y i 03-630 Pyrometer Conduit . Visual for security I

ll ll PACE 21 ll

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~ ,< DATA' CURRENT 10: 07/05/84 i[L l-

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PFESERVICE INSPECTIONS " f l'

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(Continuec) -

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NUMBER COMPONENT .-

DEMRIPTION t[' lNSPECTION METHOD o ,

-~

RESULTS ;

l l

I -

DIESEL A DIESEL B l f i 03-650 [letd.rica l Equipment --

Visual of brush assemblies ll t Visual or slip rings for roundness ll  ; ', and fit brushes to rings ,

i t , Visual for cleanliness .* '

l -

/ Dimensional for a l ignment, ^

I mechanical center, y i r gap ~ s' l  : Visual for lubricat ion f ' F

?

l Bolt torque verirlsation i Megger test -

I I 03-688 Electrical Wiring Visual for security -

l 7~

l 03-689 Orr Engine Wiring Constructi6n QC '

< r l' I T l 03-690 Sa fe ty Al a rm On Eng ine None. Verified by test , g i

I 03-691 Orr Engine Ala rm Sensors None. Verified by test i

I 03-695 Safety Shutdown None. Verified by test -

I .

1 00-700 StanJpipe Visual for security l -

cleanliness e l.

-l .

1 03-715

~

Sub Base Visual for integrity l of grout I

l 03-717 Auxi l ia ry Skid Check strainers for SAT l cleanl iness, ca l ib rate I relier valves 1 -

1 03-800 Heater, Jacket Visual for leakage and I Wa te r Hea t e r, security of corrections i Luoe Oii_ Sump Tank I

i 03-805 Intake and Visual for leakage and i Exhaust Equipment secu ri ty I

l 03-810 Jacket Water Visual for leakage i Equipment and security i

I 03-820 Lube Oil Visual for leakage l I Equipment and security I

l 03-825 fuel Oil Equipment Visual for leakage 1 I and security l l l i

I PAGE 22 I

a f a

2.4 Rework A number of product improvepents and upgrades are now availabic for TDI engines which improve reliability. GSU has elected to install a number of these improvements as detailed la Table 1. The following paragraphs describe the benefits of the significant upgrades, w

Cylinder block and liners. The cylinder liners, cylinder head,

, studs and block liner landing surfaces will be modified to -

comply with TDI's current manufacturing specification. The modification reduces cylinder block stress by reducing mechanical interference between the cylinder head, block and liner, and by increasing the vertical distance between the stud threads in the block and the liher landing surface. These menstrements will increase the margin against cylinder block cracking.

Pistons. The original pistons will be replaced by the improved model "AE" piston, the current TDI production standard, inspected to the criteria of the TDI Diesel Generctor Owners Group. Availabic information indicates that the original heat treated and stress relieved AN pistons are acceptable for service. However, the AE pistons were considered desirable because of lower piston skirt stresses and favorable operating experience. As part of the AE piston installation, other TDI product improvements will be installed. These include improved piston rings to reduce the likelyhood of liner scuffing during break-in, rework of piston crowns to reduce liner wear and oil

- 'Lonsumption, and an improved piston pin retaining ring'to improve maintainability.

Valve pushrods. The improved friction welded pushrods were installed as recommended by the TDI Owners Group Design Review.

Jacket water pump. The jacket water pump will be reworked to include a modular iron impellar without a keyway as recommended by the TDI Diesel Generator Owners Group.

Turbocharger. The turbocharger lubrication system will be modified to improve lubrication during starting and reduce thrust bearing wear. The turbocharger mounting bracket will be stiffened to reduce vibration and a turbocharger speed measuring device will be installed on one engine to obtain test data useful in verifying the adequacy of the prelubrication system.

PAGE 23

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- "*I.Fuel" njection eq ipment. Fuel injection tubing, shown by

' inspection to have ID surface defects deeper than the 0.004 inch accept'ance criteria,will be shrouded on a temporary basis to

  • permit-engine testing. The shrouding will contain fuel spray in the event of tubing rupture. By the end of 1984 TDI will be able to supply fuel injection tubing which has been given an autofre.ttage treatment to improve its fatigue resistance. This
  1. J tabing'has been ordered.

' h, The original fuel.Jnjector tips with a 140 degrna spray angle, N .will'Fe-replaced with an improved model with a 135 degree spray 4;f -a'ng1,e r to eliminate fuel spray on cylinder walls and reduce liner

.* . weaq. The 135 degree tips are che current TDI production

' standard. /

. The fuel. injection pump r~eturn line will be replaced with u9 heav'ier wall tubing as recommended by TDI.

) ' }~( 'a

^

). 4 Q( 3 Id'lat. gear. An improved idlor gear locknut will be installed as c

r a TDI recommended prcduct improvement.

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2.5I Con'firmatory Testing The ' purpose of this activity is to verify engine reliability following engine inspection and rebuilding. Table 5 describes the tests to be performed. The preoperational tests described in Section 14.2.12.1.36 (Revised) will be performed in conjunction with the tests described in this section. The revised FSAR Section 14.2.12.1.36 is reproduced as Appendix 1 of this report.

The proposed testing program does not comply with the requirements of Pegulatory Guide 1.108. The number of start tests is less than specified in Regulatory Guide 1.108, Section C.2.a(9), and the overload test described in Regulator Guide 1.108, Section C.2.a(3), is not planned. With respect to the start tests,.given the documented high starting reliability of the TDI engines, the proposed program of

.y ten modified starts and.two fast starts is considered an adequate J: demonstration of starting reliability. -Additional fast starts would impose additional wear on the engines, thereby subjecting the engines to service for more severe than the expected plant service conditions.

11us overload test is not considered necessary, because the River Bend Station diesels will not be operated above the continuous rating of

.3,500KW. Therefore, testing at the overload rating is not considered necessary, and could reduce long term engine reliability by subjecting engine components to unnecessary stress cycles more severe than expected to occur in accident conditions.

In tho' event of component failures during testing, GSU uill investigate the root cause, and take corrective action to remedy the problem and prevent reoccurrence. Retesting would be performed if the corrective action is considered to affect the test objectives i.e.:

.1) the ability to deliver rated output, 2) the ability to start reliably,'or 5) the torsional vibrator characteristic of the crankshaft.

L c

PAGE 25

7, :n 7 .,+--=

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i l TABLE 5 NOTE: Testing not Complete -

I OPERATIONAL TESTING- Data Current as of. 07/05/84 .I l

i TEST OBJECTIVE ACCEPTANCE CRITERIA RESULTS OR SCHEDULED COMPLETION l l

.1 ) ~ Manufacturer recommended . l test in accordance with l

.TDI Service Information I

. Memoranda #99 l

. . -. . I a) Initial s ta rt,' slow idle, Oper& ting pa rameters 1 No 1oad, (15 minutes) in the norma I . range Satisfactory crankcase

. Inspection b) 450 rpm, no load, Adjust governor (30 minutes) Overspeed trip satisfactory -

Verify generator differential shutdown Operating pa rameters in norma l ra nge Satisfactory crankcase inspection i i

c) Generator phasing Satisfactory Generator electrical I checks Set electrical port!on of governor

d) I hour at 25% Ope ra t i ng pa rame te rs i n ro rma l ra ted load range e) I hour at 50% Operating pa rameters in norma l ra ted load range f) 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> at 75% Operating pa rameters i n no rma l ra ted load range . I g) Return to 25% Operating parameters i n no rma l ra ted load range 11 Verify pa rameters consistent I with Step (d) l l

h) 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> at 100% toad Operating pa rameters in norma l  !

(3500KW), followed by ra nge internal engine C ra nkca se inspection inpsection, tu rbocha rge r Crankshaf t web deflection v i b ra t i on, bea ring cooling Piston ski rt wea r and lubrication test Cy l i nde r l ine r wea r Gea r set wea r ll Valves and rocker arms wea r and I c l ea rance s l Cold compression pressure I Gene ra to r wi nd i ng tempe ra tu re PAGE 26

~

TABLE 5 NOTE: Testing not Complete .

1 OPERATIONAL TESTING' Data Current as of 07/05/84 l (Continued) ,

ACCEPTANCE CRITERIA. .RESULTS OR SCHEDULED COMPLETION

' TEST OBJECTIVE

. I

1) Engine timing and . Smooth operation adj ustment s. . Cylinder firing pressures in 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> at 100% . . balance. . l-load. ' (power dura tion may va ry) Ope ra t i ng .pa ramete rs in no rma l .i ra nge l Crankcase web deflection l t
2) Crankshaf t torsional Cranksha f t stresses vibration test with allowable values
3) Engine performance test. Operating parameters in normal l Demonstrate that each ra nge . All sta rt diesel operates within attempts successful, design parameters at 100%

ra ted load,' and demonstrate sta rting rel iabi l ity.

a) 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> at 100% .

ra ted load b) Ten modified starts (Note 1) to the load required by a loss of offsite power (approximately 75% of rated load) and run for a minimum of one huur, c) Two fast starts (Note 2) to 100% of ra ted load, and run for a minimum of four hours.

NOTES

1. A modified s ta rt is defined as a start including a Tsrelube period as recommended by the manufacturer and a 3 to 5 minute loading to the specified load level. Modif ed starts may be conducted with the engine at operating temperature.
2. Fa s t starts are simulated " black starts" on simulation of an ESF signal with the engine on ready standby status.

1 1

1 PACE 27 ll

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2.6 Post Test Inspection Following the. tests described in Section 2.5, GSU will perform an engine inspection consisting' of the items in Table 6. The purpose of this inspection is to look for potential latent problems not discovered in earlier-inspections and tests and verify readiness for x -further operation. The preoperational test phase, consisting of the 1 tests defined in FSAR Section 14.2.12.1.36, (see Appendix 1), will begin'upon satisfactory completion of the inspection and any required

rework or retesting.
, ;The post; test inspection program is_ designed to provide a thorough

-engine inspection without_ major engine' disassembly. Major disassambly

. is not considered necessary because of the . thoroughness of the preservice inspection a'dn design review program. Critical components 1' can be adequately inspected by removing access covers and by oil analysis. The oil . analysis will indicate abnormal wear of bushings

.and bearings and the elementa1Lanalysis will identify the component in distress. The oil analysis will also serve as a baseline for continued surveillance _in the operating phase. Visual inspections to verify nominal wear, absence of discoloration, from overheating, water p ~

leakage, and absence of wear products (metal particles) will identify

. distress conditions'in combustion with oil analysis.

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PAGE 28

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l TABLE 6-l ' POST TEST INSPECTIONS-I COMPONENT . ..

NUMBER DESCRIPTION ' INSPECTION METHOD - RESULTS'03-305' Base and Bea ring . . Visual fo r no rma l wea r Caps and absence or discoloration Oil analysis

' Torque veri fication 03-307 Lube OiI Fittings- . Visual, for security Internal l

03-310 Crankshart and Hot web deflection-Ma in Bea rings Thrust bea ring clea rance 03-315 Cylinder Block Visual fo r no rma l wea r of - l i ne rs Liners and Water Visual for cleanliness, water leakage Manifold 03-317 Water Discha rge ~ Visual for security and Manifold leaktightness03-330 Flywheel Bol t torque

~

03-331 Flywheel Gua rd Vi sua I, For securi ty 03-335 Gea r Ca se Visual, for norma l wea r pattern, security B 03-380 4 Connecting Rods Visual, for norma l wea r and absence or discoloration Oil analysis 03-3f1 4 Piston Visual fo r no rma l wea r f rom crankcase Bo rescope inspection of piston crown and combustion chamber Oil analysis 03-3 % Tappets Visual fo r no rma l wea r and Guides Valve leak and clea rances03-350 Cam Shart- Visual or cam lobes for Cam Bea ring no rma l wea r and Cam Gea r Valve timing i PACE 29 i

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TABLE 6 ~ 'I ct . POST: TEST INSPECTIONS-

.I ~

,(Continued)

.-[11 i

COMPONENT' NUMBER :pESCRIPTION -INSPECTION METHOD RESULTS-  !

, 355; idler and - Visua l . for norma l wea r i Miscellaneous Gea rs: :and security. ,

I l- 03-359 Al r. Start Va lve Ca psc rew ' tu rque .. -

l.

l - Bo re scope inspection from.

! ' combustion chamber

,I Leak tightness (air start supply filter)03-360 Cyl i nde r Head . , Borescope inspection of and Valves combustion chamber and va lves

'Leaktightness of gaskets-Ba r eng i ne wi th cyl i nde r cocks open for leakago 03-365'- ~

fuel injection Visual on tips for normal Equipment fi ring, ' roundness03-371 Fuel Pump Linkage Visual for security and free movement

'03-375 .'ntake i Manifo'Id ' Retorque bolts Visual for leak .

tightness, and security 03-380 Exhaust Manifold Retorque bolts Visual for leak tightness and. security 03-385 Covers-Cylinder Retorque bolts Block.03-387 C ra nkca se Visua l - for leak tighte.ess Ventilator and security 03-390 Rocker Arms ' Visual for norma l wea r and Push Rods and lubrication Valve lash and clea rances03-102 4 Covernor Orive Visual for security 03-410 Overspeed Trip Visual for security 03-413 Covernor Linkage Visual for security, free 1 movement PAGE 30

~ * ' ,

= a. .. , :- .- -

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I - TABLE 6 l'

.+. POST TEST INSPECTIONS -

1. (Continued) ,

COMPONENT- .

NUMBER . DESCRIPTION INSPECTION METHOD. RESULTS.

03-415- . Cove rno r None. Veri ried during ope ra t ion I .00-420 ' Pressure Regulating None. Verified during i Valve-Lube Oil ope ra t ion

.03-420 Lube Oil Pump- . Visual for wea r and

. Engine Driven clea rances03-425 Ka ter Pump . Scheduled disassembly for. I Jacket Water replacement of impeller- '03-435 Jacket Water Visual for security and fittings 'leaktightness03-437 Tu rbocha rge r- Visual for security and Water Fittings - leaktightness03-441 Starting Air Lines Visual for security and l ea k t. i g h tne s s.

Visual or air supply filter for f ree flow, cleanliness on engine side.03-442 Sta rting Ai r Visual for security and Distributor leaktightness03-445 Fuel Booster Visual for security and Pump leaktightness l

1 03-460 St ra i ne r, Duplex VisuaI , for cleanliness Lube Oil Evaluate particles ir found 03-465 Lube Oil Visual for leaktightness ll fittings and security 03-467 ' T u rbocha rge r Visual for leaktightness Lube Oi1 Fittings end securi ty NB-002 Intercooler Visual for leakage and secu ri ty Retorque bolts03-475 Turbocharger and fletorque bolts intercooler Brackets Visual for integrity or velds, and security PAGE 31 1

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.T O nsr u u d d d u u k u r un u u d H ue c c e e e c c a c potci c c e

. T' T yrv e e if i i d e e s s e e i s lfner e e i S E rh s s f f e sl esa s s f O M ate r ssm e ir ir i i

-- P' n u r r r r i u

r r isr r etrb r r o of en N ofq o o en en en o of lyof e o fhso O ior f f Voi q f f osufl f Vo I t o Vo Voii e

r a u q

uj a i T alt l l t t l l nl l l rdl t l i C ta . a a .t a .a .a a a aa r a abaas a a .t a E sut u u er er er e e u u u ot u u ue u u er P sl s s ne ne ne n n op op op o o s s l s s sddsd s s ne op S Dio i e i nnie i

.M LVB iV Vi No No No N N V iV iiOV R V iVaaVP iV V No L.

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- T a e e- t t I m

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P h l tr m l s c gt ia t t i i I

c n se o o o u na e o OT a e rt r n yg R

C b o i ut ap m

r' t r m r tr im ru ing a bmf t ep n o d m c'

t c

E tn eE S r r ha e- n e s re u r e e f f TE u i xd h o h n an n l uu o y l - l f an ND T ~

A EA T C T I BP E P LS F P E E O SO E

N O'

P M

0- 0 0 0 8 9 0 OR 1 5 3 0 5 0 5 0 1 0 CE 2 9 9 0 0 1 2 2 3 3 4 5 3 5 8 8 9 6 6 6 "B

M 0

4 4 5

5 5

5 5 5 5 5 5 6 6 3

3 U P 0 0 3 3 3 3 3 3 3 3 3 3 3 3

-N M- 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 L

II 1

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- l' ' POST: TEST-INSPECTIONS l-

.(Continued)- l R l

.. COMPONENT - .

I NUMBER DESCRIPTION '

INSPECTION METHOD RESULTSJ Jl, t

03-691: Orr Engine .

None. . Verified (aring Alarm Sensors ope ra t ion :

'I 03-695 Safety Shutdown None. Veriried during -

,, ope ra t ion 00-700 Standpipe - Visua l. For leakage,' securi ty.03-715' Sub Base Visual ror integri ty. or. grout .03-717 Auxiliary Skid.~ ' Retorque bolting 03-800: Heater, Jacket, . Visual for leakage Wa te r He s te r, and security or Lube Oil Sump Tank co rrect ions03-805 Intake and . Visual for leakage and .

Exhaust Equipment secu ri ty 03-810 Jacket Water . . ' Visual for leakage and Equipment. security 03-820 Lube Oil Equipment Visual for leakage and security'03-825 fuel Oil Equipment Vis6al for leakago .and secu ri ty 4

4 1

1 l

PAGE 33

. . _ . . . _ _ _m . _. _

a

.  :;v g-2,7 Surveillance and Monitoring

- GSUwill implement a program of preventative maintenance, surveillance and monitoring to ensure long term engine reliability. This program will be added to the report in'a revision following the completion of engine testing and post test inspection.

JCL.

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- ~ 3;0. CONCLUSIONS U 'GSU believes that th'e nroblems of the TDI diesel generators are now understood as a result of the work of the TDI Diesel Generator Owners

. Group and the TDI Diesel Owners. Solutions to those problems are

,provided for River Bend Station through the measures described in this

. report. This program includes all the recommended' action of the TDI Diesel Generator Owners Group and Transamerica Delevalve Inc. GSU

, believes these measures will provide' reliable standby power for River

. Bend Station.

L 4

PAGE 35 wi._._

4.0 NRC QUESTIONS AND RESPONSES (LATER)

PAGE 36

APPENDIX 1 e

1-1 4

(

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I 1:

1'

p -

r RBS FSAR

d. Demonstrate in conjunctidn: with the RHR preoperational test that the RHR system can be g+'

operated -in the suppression pool cooling mode and the shutdown cooling mode from the remote shutdown panel.

e. Demonstrate in conjunction with the nuclear boiler preoperational test that the three designated safety relief valves can be operated from the remote shutdown panel. ,
4. Acceptance Criteria
a. Remote shutdown system valves, controls, ~

instruments, and pumps operate in all required modes as specified by the GE Preoperational

~

Test Specification.

~s ~

s b. Operation of the RHR, RCIC, standby service water, and safety relief. valve systems functions as specified by the GE Preoperational Test Specification.

14.2.12.1.'56 . Standby Diesel Generator Preoperational Test

1. ' Test objectives  : ..
a. To demonstrate the reliability of the standby diesel generator power sources

.b. To provide assurance that the system is capable of providing standby electrical power during normal and simulated accident conditions

c. ~ Tc demonstrate the system's ability to pick up .

standby loads during simulated accident. ,

conditions

~
d. -To demon' strate the operability of the diesel M

. generator auxiliary systems, i.e., diesel fuel . r.

oil transfer and diesel generator starting air

, supply. system ^

2. Prerequisites .

'as[' -

-a. Required preliminary tests completed

, b. All instrument calibration and loop checks. .

.x completed _

V -

Amendment 13 14.2-82 June 1984 t

\

'n '

.m v,' , - a p

"4 6,. W4. l $ e

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. - .]:.p..8 . ?A.Q %..- .N.;.

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. y?.ty7,cn O^ --.a.---,--.-. - , . - .--.-..- ,. _ _..

p RBS FSAR 7.';2c c. The following systen and/or . components

'# available:

(1) Fire protection system in diesel generator room (2) SWP -

(3) Pneumatic sources -

(4) Electrical power to motors, fans, etc -

(5) Diesel generator building ventilation system as required to support testing l1s

d. Sufficient diesel fuel on site to perform tests
3. Test Procedure '.'

~

a. Test all diesel starting and trip sequences to assure proper operation.
b. Test all auxiliary systems to demonstrate that they operate in accordance with test specifications. 2 .~_
c. Verify that all interlocks, controls, and alarms operate in accordance with test specifications.
d. Demonstrate proper manual and automatic operation of the diesel generators and that they can start automatically upon simulated loss of ac voltage and attain the required frequency and voltage within the specified .

-limits.

e. Demonstrate proper response and operation for test basis accident (DBA) loading secuence to test basis load requirements, and verify that

. voltage and frequency are maintained within specified limits.  ;

f. Demonstrate proper operation of the diesel .

generator during load shedding, load sequencing, and load rejection. Include a test of loss of the largest single load while maintaining voltage and frequency within test 3, limits, and a test of the complete loss oi ..,#..,

.M -

Amendment 13 14.2-83  : June 1984 -

~

1:73 -

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p RBS FSAR load in which overspeed' limits are not ..-

exceeded.

g. Demonstrate full-load carrying capability of the diesel generators for a period of not less than 24 hr, cf hich 22 hr cr not lece then at 3500 kw.

th equifalent DB.^. full lead value for the rcepcctive standby bus, and 2 hr arc at the DEFIA o Lauda&d 2-hu lval &otiuw '110 percent of na= plat: r ting). Verify that voltage and frequency are maintained within test limits -

and that the diesel cooling systems function

. within test limits.

'h. Demonstrate functional capability at operating temperature conditions by reperforming tests d .

and e above immediately (within 5 nin), after completion of the 24-hr load test g above. .

i. Demonstrate the ability to:

(1) Synchronize the diesel generators with offsite power while connected to the standby load (2) Transfer the load fred the diesel generators to the offsite power (3) Isolate the diesel generators and restore them to standby status.

j. Demonstrate that the rate of fuel consumption while operating at the DBA load is such that the requirements for 7-day storage inventory are met for each diesel generator.
k. The reliability of each diesel generator unit is demonstrated as per Regulatory Guide 1.108, paragraph C.2.a(9)3-c INSERT
1. Demonstrate that the capaoility of the diesel generators to supply standby power within the required time is not impaired during periodic surveillance testing.
m. Demonstration of reliability and independence

~

of the redundant diesel generator units is provided through their simultaneous starting c,3 during the testing discussed in Section 14.2.12.1.44.

Amendment 5 14.2-84 August 1982 /g

3. .

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f l

Insert for FSAR Section 14.2.12.1.36(k) except that the number of start tests is less thau specified in Section C.2.a(9) and the overload test described in Section C.2.a(3) of Regulatory Guide ' t.108 will not be performed. The overload test is not

. considered necessary because the diesels will not be operated above the continuous rating of 3500kw.

L s

h.

8 0

I RBS ESAR (jsh n. Demonstrate that the standby diesel generator can be started from minimum design starting air pressure and that the starting air system 5 provides the number of starts by design with the recharging compressors isolated.

4. Acceptance Criteria
a. System configuration and operation are comparable to that shown in the manufacturer's ~

technical instruction manual.

b. Automatic sequencing of generator-driven equipment occurs as specified by FSAR Chapter 8, Table 8.3-2.
c. All auxiliary systems function as specified by 5 FSAR Chapter 9, Sections 9.5.4, 9.5.5, 9.5.6, 9.5.7, and 9.5.8, and the manufacturer's technical instruction manual.
d. Rated load and frequency can be attained,
e. Load rejection does not result in exceeding speeds or voltages which cause diesel generator tripping or mechanidal damage.
f. The standby diesels start with minimum air pressure and start with the recharging air compressors isolated, as specified by FSAR Chapter 9, Sections 9.5.6.1 and 9.5.6.2.1.

14.2.12.1.37 Vessel Internals Vibration Preoperational Test

1. Test Objective Vibration tests are conducted to verify the structural integrity of core support structure and reactor internals in accordance with Regulatory -

Guide 1.20. The jet pumps are part of this program. -

2. Prerequisites
a. Reactor recirculation system operational #
b. Capability to maintain reactor pressure and temperature requirements has been established.

'( p Amendment 5 14.2-85 August 1982 L _ - _ _ _ _ _ _ _ __, _ _ _ _ _ _ _ _ _ _ _ _ _ . . _ __ i

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