ML18037A447
| ML18037A447 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 04/16/1993 |
| From: | DUKE ENGINEERING & SERVICES |
| To: | |
| Shared Package | |
| ML18037A445 | List: |
| References | |
| EMD9314, NUDOCS 9309080153 | |
| Download: ML18037A447 (63) | |
Text
~i EMD6"k.RC3I.0 NO.EMD9314 DATE 04I1 6I93 DVKE ENGINEERING ck SERV1CES, INC.EMD-PS OWNERS GROVP INI6 ORNA TION 8 VI.LETIN INFORMATION ONLY RESPONSE REQUESTED (if checked see below).-,)vP
SUBJECT:
EMD-PS Owners Group"Recommended Maintenance Program-Final Version dated February, 1993.EI Enclosed is the final version of the"Recommended Maintenance Program" for the EMD-PS Owners Group.Refer to EMD9309 for a copy of MKW-PS letter of endorsement of this program.l9 Enclosure (20 pages).Submit Response to: R.C.(Dick)Day Duke Engineering
&Services, Inc.230 South Tryon Street P.O.Box 1004 Charlotte, NC 28201-1004
~Telecopy No.(704)382-8770 IF YOU IIAVE ANY QUESTIONS, PLEASE CONTACT R.C.DAY AT (704)382-2763.
9309080153 930902 PDR ADOCK 05000259'PDR EMD9314.wP C~I 4~1l t
~~EMD OWNERS GROUP RECO1QKENDED MAINTENANCE PROGRAM FEBRUARY 1993 The following represents the tasks reviewed and considered applicable for Nuclear Standby Service for EMD Diesel Generators.
This information was compiled from the EMD Maintenance Instructions MI-1723, MI-1728 and MI-1742.This maintenance program is based on experience generated by the EMD Owner's Group nuclear utility members and is.intended to address maj or engine components and support systems.Instrumentation and electrical components have been purposely excluded from these instructions.
This maintenance program is based on the following conditions:
Fuel oil used in the engines will meet the specifications of EMD Maintenance Instruction 1750.2..Lubricating oil used in the engines will meet the specifications of EMD Maintenance Instructions 1760 and 1764, and will be changed at the intervals specified in this RECOMMENDED MAINTENANCE PROGRAM.'Engine coolant used in the engines will meet the specifications of EMD Maintenance Instruction 1748.Lubricating oil filters will be'hanged at the intervals specified in this RECOMMENDED MAINTENANCE PROGRAM.6.Operating load limitations will be adhered to.Torquing procedures contained=
in this RECOMMENDED MAINTENANCE PROGRAM will be followed for new engines and for newly installed replacement parts.'I 1 of 20
~~
4 TABLE OR CONTENTS Section Description Page(s)2.3.-4 5.6.Non-Operating Engine Log (Daily/Weekly)
Engine Pre-Start Checks Monthly Engine Operating Checks Quarterly Engine Checks Refuel Cycle Engine Checks Alternate Refuel Cycle Engine Checks 1 6 Year Engine Checks 12 Year Engine Checks 4-5 6-7 9-14 15-16 17-18 19-20 2 of 20
~~~~
NON-OPERATING ENGINE LOG (DAILY/WEEKLY)
Com onent Task Comments Cooling Cooling Fuel Fuel Lube Lube Start Start Gov engine Check for leaks Check coolant level Check for leaks Check Fuel supply Check for leaks Check oil level Check for leaks Drain Condensate Check oil level Keep warm system Ops shift'Daily or Weekly)~B Check for proper operation.
'3 of 20 t~~
ENGINE PRESTART CHECKS Com onent Task Comments Gov Fuel Cooling Engine Check oil level Check fuel supply Check coolant level Manual Bar over See Manufacturer Spec.initiate engine prime Expansion tank Unless run within last 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> period.Engine Prelube thru main pump Only if MI 9644 not installed.
(2)Engine Check no oil 8 cams Top deck inspection (1).Lube ube Lube Start Start Start Check oil level in pan Check strainer oil level Check lube oil'irc.pump(s)operation Drain condensate Check Air Pressure Visual inspection leaks/degradation Not required (2).Insure proper standby oil system operation.
(3)Unless installed air start dryers (4).Prior to start.(3)Should be prestart check.Most engine runs are performed on a monthly frequency.
4 of 20
~~l l AR-16" 1993 16: 11 FROIR TVA t lUCLEAR I'A I HT.ro 917297952'.86
~~ENGINE PRESTART CHECKS (continued)
MSTrPXCaTXOm:
(1)This check is to verify that the turbo filter check valves are not leaking by opening the top deck,and verifying that thex'e is no oil pumping down on th5 cams.(2)Pre-lube not required if LO mod installed.
Xf prelube mod is installed, check prelube mod pax'ametex's (LO level gauges, pump pressures, etc.).This assures strainer is full., Otherwise,>30psi at circ.pump dischaxge.
Still no need to open strainer.(3)Most engine runs are done on a monthly basis.For those cases where the engine xuns are more frequent,'his type of check is considered good.practice.The pumping components are necessary for reliable engine performance.
The objective being to assure that engine tux'bocharger has oil during starting for proper lubrication.
(4)This a good practice regax'dless.
However', the use of air dryexs will eliminate most all condensate concerns which would require this task.gof 20
~~f MONTHLY ENGINE OPERATING CHECKS Com 6nent Task Comments Intake Intake Intake Intake Lube Lube Check air box drains Inspect handhole covers for leaks Inspect cylinder test valves for leaks Visual inspection for leaks/degradation Check for leaks Idle-check LO level For excess fluids bef ore start, for blockage while engine running.~While engine running While engine running While engine running While engine running Not required if pres tart check is performed.
24hr runs will however require periodic checks.Lube Lube Cooling Check Oil Pressure Filter press DP (=25psi Visual inspection for leaks/degradation At Load Filter clogging check.While engine running.Fuel Exhaust Visual inspection for leaks/degradation Check for leaks While engine running.While engine running.Ops Starter tarter Run min 1 HR)=7S~Check air line lubr.oil level or verify proper operation Check air compressor V 6 of 20 Yes if at all possible.Not a firm requirement
.but considered
<<'a good practice.',Reduces exhaust system fouling and cylinder glazing.Prior to each start.(1)
~~MONTHLY ENGINE OPERATING CHECKS continued JUSTIFICATION:
(1)The vendor recommends that the oil level be checked monthly.It is unlikely that the oil lubricator will consume the entire contents within the normal periodic testing frequencies done between refueling cycles.Normal lube oil consumption is approximately 1 tablespoon with each start.At this rate, the lubricator reservoir contains sufficient oil to properly operate for a full fuel cycle unless in accelerated testing.Therefore, it is recommended that proper operation be checked with each start (ie.oil residue or some other appropriate means).(2)PM for Station batteries should not be governed by engine maintenance.
Most plants have air start motors and battery power is required for engine controls or field flashing..
This is normally part of the plant station battery systems and checked accordingly.
If using electric start motors, then this parameter is not to be omitted.7 of 20 QUARTERLY ENGINE CHECKS Com onent Task Comments Cooling Check engine coolant Quarterly analysis Reference MI-1748 Fuel Lube Drain condensate from day tank Take LO sample for analysis Monthly (1)Lube Oil Analysis serves as the basis for many tasks R frequencies (3)Intake Engine Check air filter oil level (oil bath type)Check LO drain e turbo Where applicable Check quarterly (2)JUSTIFICATION:
1)The vend or does not recommend this task.However, based on the type of service, it is considered good practice to assure that there is not a buildup of condensate in the day'ank.This also be considered as an engine prestart check.(2)The vendor recommends a quarterly check.It is considered very unlikely that the soak back system would not be draining properly.With the prestart check of the circulating pump operation, it is very unlikely that the engine oil would not be draining from the turbocharger gear train.Trending of the pumping system pressures will give indications that there may be a blockage in the turbocharger.
(3)Lube oil analysis should be a part of every utility maintenance program in the EMD Owners Group.The basis for many of the frequencies of tasks requires a lube oil analysis program be in place.The minimum recommendation is for quarterly analysis, however, the preferred frequency would be monthly (or following every loaded engine run).The analysis program selected should evaluate the oil qualities, (wear metals, etc)and take into consideration the oil additive package.8 of 20
~~A REFUEL CYCLE (1 8-2 4 MONTHS)Com onent Task Comments Starter Starter Test operation of sep.bank of starter motors (grease/lube) starters Refuel interval inspection.
(1)Omit for air start motors w/air line lubricators, otherwise perform 8 refuel intervals (2).Starter Exhaust Remove/Clean/Inspect starter motors Manifold bolt toigue check Applies to electric starter motors only.Refuel interval inspection.
(1)Exhaust Exhaust 0-Fuel inspect turbo screen Visually inspect f'ex connectors Fuel line leak check, Clean FO pump suction strainers Refuel interval inspection.
(1)Refuel interval inspection.
(1).Refuel interval inspection.
(3)Refuel interval inspection.
Fuel Fuel Fuel intake Intake Cooling Clean FO transfer pump strainers/filters Replace fuel xfer filt.Replace fuel filters Check Aftercooler DP Xnsp oil bath filter Cooling system'eak check Refuel interval inspection.
Or on high filter DP.Or on high filter DP.For oil bath filters only.Clean/change as required (4)Refuel interval inspection.
(3)Cooling Rebuild/Repl AMOT vlv Leave at 3 years.Perform 8 refuel intervals for 24 month refuel cycl'es only.Check cooling fan/motor Check belts, tension, blade clearances/pitch, lubricate bearings R,motor Quarterly (9).9 of 20
REFUEL CYCLE (18-24 MONTHS)continued Com onent Task Comments Cooling Check shutter linkage and blades Check and adjust as req.(9)Lube Lube Lube Replace lube oil Clean strainer box Change main filters Use LO analysis a'nd change based on analysis (S).Refuel interval inspection To include cutout and full inspection of f il ter media (6).Lube Lube Change aux turbo filter Check DC pump operation Replace DC circulating pump brushes See Main f il ter changeout (6).Refuel interval inspection (7).Refuel intervals only for continuous duty service.For standby service, inspection PM recommended.
Lube Check Turbo-filter check valves Refuel interval inspection Lube Replace Turbo filter element Refuel interval inspection Lube Clean Main oil filter housing Perform with f il ter change Lube Engine Engine Engine Engine Engine ngine Clean/Inspect circ pump and motor Check lash adjusters Check auto start sequ.Inspect upper deck area Adjust injector timing.and rack settings Perform overspeed tr'ip Inspect pistons 8 rings'heck alignment, seal, grease/lube.
Refuel interval inspection (8)~Refuel interval inspection (8);Refuel interval inspection (8).Refuel interval inspection (8).Refuel interval inspection (8).Refuel interval inspection (8).10 of 10
REFUEL CYCLE (18-24.MONTHS)continued Com onent Task Comments Engine Engine Engine Engine Inspect cylinder liners Check torq on crab bolts, Perform lead wire readings Perform visual ckcs insp Refuel interval inspection (8).Refuel interval inspection.
Refuel interval inspection.
Includes connecting rod&crankshaft inspection as well as P pipe alignment check (11)Gov Gov-Gen Elec Elec Lube gov.linkage.Replace oil Chk brush'condition Inspect/replace brushes Clean/Inspect collector rings Perform alarm test Megger LO circ pump mtr Refuel interva'l inspection (8).Check 8 refuel intervals change as per governor manufacturer guidelines Refuel interval inspection (8).Refuel interval inspection (8).Refuel interval inspection (8)Refuel interval test (8).Not required unless incorporated in predictive maintenance.
Elec.Elec.Calibrate all TDR relays Check voltage regulator operation" See (10)See (10)Elec.Clean/inspect voltage regulator See (10)Elec.Check operation of relays/controls/br'eakers See (10)11 of 20 0
REFUEL CYCLE (18-24 MONTHS)continued JUSTIFICATION:
The vendor recommended frequency would require an engine outage to perform the task.This is undesirable'n nuclear standby service, there is approximately 50 hours5.787037e-4 days <br />0.0139 hours <br />8.267196e-5 weeks <br />1.9025e-5 months <br /> (or less)run time placed on the engine.With so few operating hours,-it is very unlikely that any significant wear has been accumulated.
The components inspected have no degradation as a result of the installation (ie.heat, oil, water, corrosion, etc.attack causing degradation).
(2)All air start installations have in line lubricators, There is no need to provide additional lubrication.
For greased motors, it is feasible to extend the maintenance interval to refuel cycles based on the fact that the grease will not'e consumed, evaporate, or loose its lubricating properties within this time period.(3)O.(5)Each monthly engine'perating check will inspect engine systems for leaks.The task can be.considered redundant.
However, at refuel, the engine is operated for maintenance activities which include a open top deck inspection.
Fuel or coolant leaks in this area can be located visually.Similar leaks can be detected with oil analysis.The oil does not evaporate (appreciably) and is not consumed with the low engine run time.The condition of the filter can be inspected and if necessary, cleaned at regular scheduled outag'es.This inspection frequency applies to all filter types.Most all signs of engine distress are detected early via lube oil analysis.MI-1760 provides detailed basis for lube oil analysis and likewise.recommends such a program.Lube oil analysis is strongly recommended.
It should be.noted that lube oil analysis is the basis for much of the owners group recommendations.
Without implementation of oil analysis, much of the justification presented herewith cannot be substantiated and therefore extension of vendor recommended maintenance practices cannot be supported by the owners group.Maximum calendar time between lube oil changes should not exceed 6.years.Lube oil analysis programs should include means for analyzing current condition of oil additive materials.
(6)Vendor recommendations for annual filter replacement are based upon experiences where engine lube oil has caused deterioration fo the filter media.MI-1760 qualifies this.recommendation based on the*type of lubricating oil~used and pro'nged high temperature service.Nuclear standby service experiences does not appear to cause severe deterioration of the filter media.Additionally, there is not sufficient engine run time.to'ause filter fouling.12 of 20 I
REFUEL CYCLE (18-24 MONTHS)continued JUSTIFICATION:
(6)(cont)Lube oil keep warm system temperature is not considered high.It has not been determined if'any.one type of oil will cause accelerated f il ter media degradation.
While maintaining lube oil quality in accordance with MI-1760, it is further recommended that the filters be replaced at each refuel cycle and that every filter be cut open and the media inspected for signs of degradation.
(7)For continuous duty service,=the DC brushes will wear considerably faster than that for standby applications.
1f the engine uses DC circulating pumps in continuous operation, it is recommended that they be first inspected new, then at.the recommended annual interval measuring the accumulated wear and finally at the refueling interval to quantify the wear.At this point it can be determined if refueling service intervals are sufficient.
Most nuclear standby service applications use DC circulating pumps as a backup to AC pumps which are normally in continuous operation.
For this application, there is very few actual hours of operation.
over the life of the motor such that this PM may be deleted entirely.These engine checks are basic maintenance items done on.either a"calendar" periodic basis or every 8000 hours0.0926 days <br />2.222 hours <br />0.0132 weeks <br />0.00304 months <br /> of operation.
It is acknowledged that nuclear standby emergency diesel engines will not accrue major maintenance overhaul.operational hours.However, the annual recommendation likewise, does not account for the considerable idle time associated with nuclear standby service.Between refuel cycle, actual engine operating hours will be less that 1%of the 8000 hours0.0926 days <br />2.222 hours <br />0.0132 weeks <br />0.00304 months <br /> recommended for the same inspections.
Actual experience has shown that inspections performed at refuel intervals yields negligible variance from vendor specified operating limits.(10)The engines are in stand by service and the cooling fans do not see more that 20 hours2.314815e-4 days <br />0.00556 hours <br />3.306878e-5 weeks <br />7.61e-6 months <br /> of operation monthly during normal operation.
These components vary in manufacturer and model.The exact operation can likewise vary based upon the vendor of the Diesel-Generator package.Maintenance is to" be performed in accordance with the specific manufacturers recommendations consistent with site specific requirements which may inclued generic applications.
13 of 20
REPUEL CYCLE (18-24 MONTHS)continued JUSTIFICATION:
(11)Engine crankcase, ,crankshaft and connecting rod inspections are primarily visual inspections which attempt to locate obvious signs of engine distress.The use.of oil analysis will indicate any abnormal signs of engine wear long before they become visible in the crankcase.
With the engine full of oil, there is a greater potential for oil contamination with the opening of the lower covers for such an inspection.
A visual inspection is virtually useless without some breakdown of various components such that bearing surfaces can be properly inspected and~service limits measured.If the oil is to be changed, then it is advisable to inspect the engine crankcase, crankshaft and connecting r'ods.Likewise, if oil analysis indicates that significant problems are'ocated in these areas, proper attention should be given to determination of cause and problem resolution regardless of this recommendation.
14 of 20
ALTERNATE REFUEL CYCLE (3 6-48 MONTHS)Engine Cooling Cooling Cooling Task Check wtr jumper torque Repl Coolant Fill Cap inspect filler neck for damage Rebuild/Repl AMOT vlv Comments Note Power Pointer 2P-78 (1).2nd refuel inspection.
(1).2nd refuel inspection.
(1)3 year replacement.
Perform every other refuel interval for 18 month refuel cycles only.Starter Dissas.Clean/insp/repl.
Sol.vlv.6 Starters, Every 4 years with air dryers.Otherwise.
every 50 starts (2).Lube Lube LO circ system check valves (30]j 8 755)Repl 6QPM circ pump/mtr 2nd refuel inspection to clean and inspect valves.Replace as required per per f ormance monitoring otherwise every 4 years (3).Lube Turbo Replace 6 gpm Circ Pump coupling spider Replace 3 gpm circ pump Replace as required if DC backup Otherwise every 4 years (3).Replace as required if DC back up otherwise every 4 yrs.(3)Engine Check torque on duct to aftercooler 2nd refuel inspection.
(1)Engine Check torque on head frame to crankcase'nd refuel inspection.
(1)Engine Check torque on turbo to duct bolts 2nd refuel inspection.
(1)Engine Check vibration damper for freedom of movement 2nd refuel inspection.
(1)Engine Engine Replace crankcase pressure detector Check Engine protector for proper operation See engine protector recommendation below.(4)Replace every 2nd refuel and delete this requirement.
(4)15 of 20 r
ALTERNATE REPUEL CYCLE (3 6-4 8 MONTHS)JUSTIFICATION:
The owners group recommendation affects only those utilities which have 2 year refuel cycles (18 month refuel cycles meet the vendor recommendations).
Based on actual operating hours, the engine does not accumulate sufficient wear to require;a)replacement of fuel oil pump coupling spider, b)replacement of coolant fill cap and filler neck inspection, c)vibration damper check-especially when vibration analysis/trending is also performed.
Bolt'orque checks on various engine components are primarily utilized to assure leak tightness.
Complete engine.inspections are recommended to be performed by the owners group of the associated systems at each refuel cycle whereby leaks are to be detected and,corrected.
With the exception of the water inlet jumpers, all other potential leak paths can and are recommended by the owners group to be inspected prior to or during monthly engine runs.Oil analysis will identify.any internal water leaks which are not readily visible.(2)The vendor recommends annual maintenance on the air start motors.This component may see more activity in nuclear standby service than in other forms of stationary power application.
However, it is recognized that the quality of air is considered the governing factor affecting degradation.
With clean, dry, lubricated air, the wear associated in starting the engine is significantly reduced.Water and other corrosion induced contaminants are not present with a'ir dryer installations and therefore, extending the qualified life of the air start motor is justified.
The 6GPM soak back (circulating) pump operates continuously.
However,m most nuclear applications utilize a DC backup.The performance of the main soak back pump can be trended and replaced upon failure or near failure with no impact on engine operability status.Check not recommended.
The engine protector (Low water, Crankcase pressure)must be removed to check.Calibration testing involves actual trip of the component.
Each trip can, and in most cases, induces some degradation.
It is considered more detrimental to the reliability of the component to test it rather that mere replacement.
There are no consumable or time dated components within the detector assembly.The elastomer materials used (O-rings, diaphragms, gaskets, screws)are not in corrosive, harmful, or high wear environments.
The engine maintenance manual recommends periodic testing but not replacement.
Experience has shown that calibration testing is harmful to the component.
Replacement as recommended meets the intent of the vendor recommendations.
16 of 20 6 YEAR ENGINE CHECKS Com onent Task Comments Fuel Fuel Fuel Lube Lube Replace eng drvn fuel pump coupling spider Replace DC Fuel pump coupling spider Qualify injectors Inspect and.clean lube oil separator Clean/inspect eductor.tubes 6 yrs or 3rd refuel.(2)6 yrs or 3rd refuel.6 yrs or 3rd refuel.6 yrs or 3rd refuel.(1)6 yrs or 3rd refuel.(1)Governor inspect booster motor seals and brushes 6 yrs or 3rd refuel.enerator Generator Reverse collector ring polarity latches'nsp.
&grease, bearing 6 yrs or 3rd refuel.Also suggest grease sample analysis at this time Engine Engine Engine Replace power assembly head gasket Replace power assembly head to liner water'eals (grommets)
Replace wtr jumper seals 6 yrs or 3rd refuel.6 yrs or 3rd refuel.6 yrs or 3rd refuel.17 of 20 6 YEAR ENGINE CHECKS (cont)JUSTIFICATION:
(1)The fouling associated withe this component is primarily related to engine run time.In nuclear standby service, the engine run time is minimal ((500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br />)'.Both engine operation at light load (idle and (75: power)and lube oil/fuel oil add some fouling since low load operation induces higher lube oil consumption and poor lube oil/fuel oil quality yields higher carbon fouling.However, fouling of any type can only be induced while the engine is operating regardless of load.Xn nuclear standby service, the fuel oil and lube oil quality strictly adheres to manufacturers specifications (Ref.MI-1750 and MI-1760).Assuming 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br /> of actual engine operation, the extension of this maintenance interval is justified.
(2)Based on actual operating hours,, the engine does not accumulate sufficient wear to require the replacement of the fuel oil pump coupling spider.The engine, will accumulate approximately 600 run hour during this period.This component does not degrade over time such that replacement at the extended interval meets the vendor recommendation.
18of 20 12 YEAR, ENGINE CHECKS Com onent Task Comments Cooling Cooling Cooling Fuel Lube Lube Engine Replace rubber seals on cooling system Clean/inspect heat'ex.Repl/rebuild wtr pumps'eplace eng drvn fuel pump Clean/insp LO cooler Replace lube oil filter bypass valve Replace top deck seals and latches Leave at 12 years Leave at 12 years Perform every 12 years.(1)Replace every 12 years.(1)Leave at 12 years Perform every 12 years.(1)Replace every 12 years (2)engine Replace power assembly lower liner seals Perform every 12 years (already EMD approved).
Engine Engine Check exh valve timing Replace crankshaft damper Perform every 12 years (3).Applies to viscous type damper only.Gear type damper does not require replacement.
JUSTIFICATION:
(2)There is no major consequence.with the failure of either.of these components.
Leakage will be the main concern which will either become a housekeeping concern or prompt a corrective maintenance job to replace these components.
These compone'nts have no degradation as a result of the installation (ie.heat, oil, water, corrosion, etc.attack causing degradation).
0 19 of 20 (1)In nuclear standby service, there is approximately 1000 hours0.0116 days <br />0.278 hours <br />0.00165 weeks <br />3.805e-4 months <br /> (or less)run time placed on the engine.With so few operating hours, it is very unlikely that any significant wear has been accumulated.
These components have.no degradation as a result of the installation, (ie.heat, oil, water, corrosion,'etc.'attack causing degradation).
The primary failure mode associated with the pumping components will be mechanical seal failure which will be detected during either prestart or operating engine checks.
12 YEAR ENGINE CHECKS (cont)JVSTIPICATIOH:
(3)This inspection is primarily used to check engine gear train wear.Engines used for nuclear standby service do not accumulate sufficient operating hours to require this inspection over the life of the plant.Unless there has been engine operation with severe oil contamination or other forms of catastrophic engine failure, it is very unlikely that there has been sufficient gear train wear to require this check at the six (6)year interval.20.of 20 ENCLOSURE 3 MKW-PS OWNERS GROUP PROPOSED MAINTENANCE PROGRAM LETTERS DATED MAY 25, 1993 4 0 DDEEZ<NrlNziERdvrz SERFICES/PC ZiMS-PS 0/AYERS GROUP lPFORiNXSNBD~TIiY NO.EMlUQK3 DATE INFORMATION ONLY H RESPONSE RE(UESTED~(if checked see below)
SUBJECT:
MKW-PS/Owners Group Proposed Maintenance Pro ram.Letter dated 5-25-93 from Larry Deans, VP MKT Sales.Letter dated 5-25-93 from David Strickland, Prod.Sup.Engr.nclosed are two letters from MKW-PS related to the Proposed Maint.Program.Please use as appropriate to support your.Diesel's.-.No response to DEdmlS required.Contact two correspondents if any questions.Enclosures (4 pages)Submit Response to: R.C.(Dick)Day Duke Engineering
&Services, Inc.230 South Tryon Street P.O.Box 1004 Charlotte.
NC 28201-1004 Telecopy No.(704)382-8770 IF YOU HAVE ANY QUESTIONS.
PLEASE CONTACT R.C.DAY AT (704)382-2763.
MKW.o SVÃi%K4)no, ONE Ei(G(1)hr.i.:Q.'0 S."..~!C~cS, P)C.BFC" P7F0 h)AY 2 7 1993 F()8 ALT<-2.2.~2 AIAlsO~I C Mav 25, 1993 Ccp)",o'";t t;r)/err'o EMD-PS Owners Group Duke Engineering and Services, 230 Tryon Street P.0;Box 1004 Charlotte, NC 28201.Inc.vP,re~q I/;.~.4a.('VI,~~()p~
Attention:
Subject:
Reference:
Dear Mr.Day:
R.C.Day Proposed Maintenance Program (1)Meeting'on January 19, 1993 with the Owners Group, h(KN Power Systems and Electro-Motive Division of General h(otors (2)EMD Owners Group Recommended Maintenance Program Do'cument Dated I'ebruary, 1993 (3)EMD Maintenance Instruction (MI)1723, 1728 and 1742 I The Owners Group recommended Maintenance Program, as defined in Reference (2), ha's been reviewed bv MKW Power Systems as the Authorized Distributor for EMD servicing.the nuclear industry." Ne support and encourage all of our customers in efforts made to increase the overall operati'ng efficiency of the equipment.
Increased operating efficiencv provides overall cost reductions..
while maintaining or increasing reliability.
This program has been developed to coincide with the scheduled outages, which has altered scheduled maintenance periods defined in EMD's maintenance Instructions (MIs)shown in Reference (3).These'Maintenance Instructions are not written specifically for, the nuclear industry and are only intended to serve as a guide to establish a maintenance schedule.Noting that these maintenance Instructions are provided as a guide only and are not necessarily addt essing the nuclear power industry, the history which the industry has experienced becomes very important information when defining its scheduled maintenanc'e.
Based on this historical information, and the experience MKN Power Systems has gained through working for 20 years in every domestic nuclear power plant operating EMD engines, we approve of PAGE 1 of 4 Post Oltice Box 1928~Rocky Mount, North Caro!ina 27802-1928
~Phone: (919)977-2720 TWX: (510)929-0725~fAX: (919)446-3830 1
arnaO~t EMD-PS Owners Group May 25, 1993 Page 2 this program (Reference 3)with the following three modifications:
Reference 3 states that the following tasks are to be performed during the 18-24 month.refueling'cycle.Refuel Cycle (18-24 months)Com onent Task Comments Fuel Lube l.ub e Change 1'uel f i 1 ter Change aux,turbo filter Change main filters, or on high filter DP or on high filter DP or on high filter DP It is necessary to have the ability to monitor the differential pressure (DP)on the above filters if the usage cycle is to be increased to 18-24 months.Nithout the ability to monitor DP, the condition of these filters is not clearly def.ined.Nith the implementation of this program, we stress the impor"tance of monitoring and trending.Any new information should be considered for action.This action will continually improve operation.
efficiency and the reliability of the industries emergency diesel generators.
If you have any questions or comments.please do not hesitate to call.Sincerely, MKN PO'WER~g,g,/Larry I.Vice Pr si Marketin SYSTEMS, INC.cans ent nd Sales lid/bhp st5-19 PAGE 2 of 4
~MKW May 25, 1993 DNE NG!i(ffni')GA'(OS, pg, Advanced thclr-f P:o8r~s RECDilED MAY 2 7 1995 Fi!e Hl7 s-z2./2.QICTIKI 40'OpY 70 4:tit:r>(tt!
r'0 EMD-PS Owners Group Duke Engineering and Services, Inc.230 South Tryon Street.P.O.Box 1004 Charlotte, NC 28201 XC'r~r',-(f iP f({>~I Attention:
R.C.Day t".(..J.F;!.~
(~j-RW
Reference:
Proposed Maintenance Program Gentlemen:
MKW Power Systems, Inc.has completed our review of the Owners Group Proposed Maintenance Program.As we have indicated in our previous letter we find the Proposed Maintenance Program acceptable with the stipulation that monitoring of differential pressures across the main lube oil filter, auxiliary turbo filter and fuel filters should be included before extending the change out interval of the filter elements.The pricing for each of the modifications listed b'elow includes all necessary materials, drawings and installation i'nstructions for installation of the differential pressure gauges in a safety related application.
Installation of each modification is available through MKW Power System, Inc.under our standard rates for field service at nuclear facilities.
The estimated installation time required is listed with each modification.
MAIN LUBE OIL FILTER DIFFERENTIAL PRESSURE Installation
$3, 311.00 1 Day AUXILIARY TURBO DIFFERENTIAL PRESSURE 4,457.00~Installation 1 Day PAGE 3, of 4 Post Ofiico Box 1928~Rocky Mount.North Carolina 27802-1928
~Phono: (919)977-2720 TWX: (510)929-0725~FAX: (919)446-3830 EMD-PS Owners Group May 25, 1993 Page 2 FUEL OIL FILTER DIFFERENTIAL PRESSURE Installation 3,311.00 1'Day Additionally, all 16 cylinder engines without the water manifold support bracket as described in Power Pointer 2P-78 will require this modification.*
PARTS KIT 9326240 WATER MANIFOLD SUPPORT KIT Two required per engine Installation 62.30 1 day Please do not hesitate to contact us at 1-800-759-2720 if you have questions or require clarification for any of the above modifications.
Sincerely, MKW o r s, Inc.David A.Strickland Product Support Engineer PAGE 4 of 4
ENCLOSURE 4 ADDITIONAL INFORMATION CONCERNING EDG TECHNICAL SPECIFICATION CHANGE
ENCLOSURE 4 ADDITIONAL INFORMATION CONCERNING EDG TECHNICAL SPECIFICATION CHANGE BFN has eight Emergency Diesel Generators (EDGs).Since accurate records concerning start and valid test data have been kept (beginning in 1987), BFN has had a total of 586 valid tests (as defined in USNRC Reg Guide 1.108), and only three valid failures (two load run failures and one start failure).This corresponds to an estimated reliability of approximately 99.5 percent.BFN currently has a performance monitoring program in use for the EDGs.This program consists of recording diesel operating parameters at 15 minute intervals for the first hour of operation, and then 30 minute intervals thereafter.
This data is then compiled and analyzed to determine if any adverse trend is developing.
This trend may be done by manual comparison, or by computerized database manipulation.
The data has been recorded and maintained since 1987.The data points monitored and trended are: priming fuel oil pressure, normal fuel oil, engine lube oil pressure, lube oil filter pressure, engine cooling water outlet temperature, lube oil cooler cooling water outlet temperature, and lube oil cooler lube oil outlet temperature.
The engine oil level, governor oil level, and expansion tank level are also monitored.
Due to the vintage EDGs in use at BFN, no additional trending points are available to monitor.BFN also has a program in place to monitor the condition of the lubricating oil used in the EDGs.This program takes a sample of the lubricating oil and analyzes it for contaminants, viscosity, total base number, etc., as required by Electomotive Division (EMD)Maintenance Instruction (MI)1760.This sample is taken every other month.Upon final implementation of the EMD Owners Group maintenance program, this interval will be increased to a monthly check.The Morrison Knudsen Wartsila-Power System (MKW-PS)concurrence letter dated May 25, 1993, stipulated that in order to extend the changeout interval of the lube oil filters and the fuel oil transfer filters, differential pressure indication must be available and monitored.
BFN currently has no dP indicators for these filters, so the current yearly changeout will continue.The engine driven and motor driven fuel oil filters each have filter input pressure gauges which are recorded and trended on a monthly basis.The original EMD Maintenance Instructions (MI 1728 and 1742)set the replacement interval for these filters at two years.The replacement interval will be two years for these filters based on the MI's and the trending.
The endorsement of the EMD Owners Group maintenance program by MKW-PS in the letter to the EMD Owners Group dated May 25, 1993, contained three exceptions to the standard as written in the February 1993 revision.These three exceptions required differential pressure monitoring of the main, auxiliary turbocharger, and fuel filters in order to increase the replacement interval to once every two years.BFN does not have this type monitoring installed, so the changeout interval for these filters will remain at once every year.The technical specifications currently require annual maintenance based on vendor recommendations.
The vendor (EMD)recommendations give specific tasks to perform once per year and make no mention of allowable deviances.
BFN currently allows a 25 percent deviation in surveillance intervals.
This revision will perform vendor maintenance at two year intervals based on the EMD Owners Group maintenance program.A 25 percent surveillance extension will be allowed in accordance with BFN current technical specifications.
As with the current one year requirement, the proposed two year interval does not represent an absolute maximum interval.The per engine reliability breakdown is as follows: Diesel Generator D 3A 3B 3C 3D Total for site Number of valid tests 76 78 69 77 65 73 74 586 Number of valid failures Reliabil ity 100 100 100 100 98.6 100 98.6 98.6 99'
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The EMD Owners Group recommends that fuel oil, lube oil, and coolant be maintained in accordance with the applicable EMD Maintenance Instruction (MI).BFN maintains and analyzes its diesel fuel oil in accordance with ASTM D975-89.MI 1750 (Diesel Fuel Recommendations) is consistent with BFN's program.BFN's lube oil analysis program is consistent with the requirements of EMD MI 1760, Lubricating Oil for EMD Engines.The engine coolant used in the BFN diesels is water with an EMD approved corrosion inhibitor.
The inhibitor is checked monthly to ensure the proper concentration is in use.This is in accordance with EMD MI 1748, Engine Coolant.
ENCLOSURE 5 BFNiS PROPOSED EDG 18-24 MONTHS INSPECTIONS AND CHECKS 1
ENCLOSURE 5 BFNiS PROPOSED EDG 18-24 MONTHS INSPECTION AND CHECKS The following is a item by item discussion of the Electromotive Division (EMD)Owners Group Maintenance Program, revision dated February 1993 (ref.EMD9314, EMD9309, and EMD9323).This discussion will cover only the 18-24 month checks.The 18-24 month checks are'comprised of the 12 month checks currently used at BFN as required by the existing annual maintenance technical specification.
All checks are currently performed at BFN on an annual maintenance basis unless noted.1)Test operation of separate bank of starter motors.This item is currently performed every six months by performing a fast start using starter bank 1 in December and starter bank 2 in July of each year.This will not change.2)Grease/lube starters.BFN uses starters with air line lubricators.
If the existing starters have grease/lube fittings, then perform as t recommended by EMD Owners Group maintenance program.3)Remove/clean/inspect star'ter motors.This item applies only to electric starters.BFN uses air starters.4)Exhaust manifold bolt torque check.This check is currently performed every 18 months.Perform as recommended by EMD Owners Group maintenance program.5)Inspect.turbocharger screen.Perform as recommended by EMD Owners Group maintenance program.6)Visually inspect exhaust flex connectors.
Perform as recommended by EMD Owners Group maintenance program.7)Fuel line leak check.Fuel leaks checks are performed every month during the monthly surveillance.
Perform additional leak checks under the top deck as recommended by EMD Owners Group maintenance program. Clean fuel oil pump suction strainers.
Perform as recommended by EMD Owners Group maintenance program.Clean fuel oil transfer pump strainers.
Perform as recommended by EMD Owners Group maintenance program.Replace fuel transfer filters.This task will continue to be performed on a yearly basis.As Morrison Knudsen Wartsila-Power System (MKW-PS)stated in their letter dated May 25, 1993, these filters may be changed every 24 months if pressure drop (dP)across these filters is monitored.
BFN does not have dP indication across these filters, so the changeout frequency will remain once every 12 months.Replace fuel filters.Perform as recommended by EMD Owners Group maintenance program.These filters are currently replaced every 12 months to correspond with the existing annual maintenance requirement.
The original EMD Maintenance Instructions on which the EMD Owners Group document and BFN's diesel maintenance is based requires changeout of these filters every two years.Fuel oil filter inlet pressure is monitored and trended and replacements may be required based on increasing filter pressure.Check aftercooler differential pressure.BFN does not check aftercooler dP because our diesels do not have the instrumentation installed to perform this check.Inspect oil bath air filter.Perform as recommended by EMD Owners Group maintenance program.Cooling system leak check.Cooling system leak checks are performed every month during the monthly surveillance.
Perform additional leak checks under the top deck and in the air box as recommended by EMD Owners Group maintenance program.Lube oil analysis will also identify any coolant leaks.
fp 4~I Rebuild/replace AMOT valve.This item is currently performed once every three years.Zf BFN implements a two year diesel outage schedule, the AMOT valve will be replaced/rebuilt once every two years.16)17)Check cooling fan/motor.
This item is not applicable to BFN.Check shutter linkage and blades.This item is not applicable to BFN.18)19)Replace lube oil.BFN currently replaces the engine lube oil once every three years.The interval will be changed to once every four years, or when lube oil analysis recommends changeout.
BFN currently performs lube oil analysis and may base the frequency of changeout only on this analysis in the future.This is in accordance with the proposed maintenance program.Clean strainer box.Perform as recommended by EMD Owners Group maintenance program.20)Change main lube oil filters.This task will continue to be performed on a yearly basis.As MKW-PS stated in their letter dated May 25, 1993, these filters may be changed every 24 months if pressure drop (dP)across these filters is monitored.
BFN does not have dP indication across these filters, so the changeout frequency will remain once every 12 months.21)Change auxiliary turbocharger lube oil filter.22)This task will continue to be performed on a yearly basis.As MKW-PS stated in their letter dated May 25, 1993, these filters may be changed every 24 months if pressure drop (dP)across these filters is monitored.
BFN does not have dP indication across these filters, so the changeout frequency will remain once every 12 months.Check DC pump operation (lube oil).Not applicable to BFN.
V A 0, 23)Replace DC circulating pump brushes (lube oil).Not applicable to BFN.24)Check turbocharger filter check valve.Perform as recommended by EMD Owners Group maintenance program.25)Replace turbocharger filter element.Perform as recommended by EMD Owners Group maintenance program.26)Clean main oil filter housing.This task will be performed with the main oil filter change.27)Clean/inspect lube oil circulating pump and motor.Perform as recommended by EMD Owners Group maintenance program.Perform as recommended by EMD Owners Group maintenance program.29)Check autostart sequence.This task is performed every six months during the redundant start test.The six month test schedule will not be changed.30)Inspect upper deck area.Perform as recommended by EMD Owners Group maintenance program.31)Adjust injector timing and rack settings.Perform as recommended by EMD Owners Group maintenance program.32)Perform overspeed trip test.Perform as recommended by EMD Owners Group maintenance program.
ri u 33)Inspect pistons and rings.Perform as recommended by EMD Owners Group maintenance program.34)Inspect cylinder liners.Perform as recommended by EMD Owners Group maintenance program.35)Check torque on crab bolts.Perform as recommended by EMD Owners Group maintenance program.36)Perform lead wire readings Perform as recommended by EMD Owners Group maintenance program.37)Perform visual crankcase inspection Perform as recommended by EMD Owners Group maintenance program.38)Lubricate governor linkages.Perform as recommended by EMD Owners Group maintenance program.39)Replace governor oil.Perform as'recommended by EMD Owners Group maintenance program.40)Check generator brush condition.
Perform as recommended by EMD Owners Group maintenance program.The brushes are also checked each month during the two hour load run.41)Inspect/replace generator brushes.Perform as recommended by EMD Owners Group maintenance program.42)Clean/inspect collector rings.Perform as recommended by EMD Owners Group maintenance program.
43)Perform alarm tests.Perform as recommended by EMD Owners Group maintenance program.44)Megger lube oil circulating pump motor.This item will be done every two years.BFN determines the need for motor replacement based on these periodic megger readings.45)Calibrate all time delay relays.The timers will be checked every two yea'rs.The critical timers which involve the proper operation of the starting circuits will continue to be checked every six months during performance of the redundant start tests.46)Check voltage regulator operation.
~47)The regulator setpoints will be checked every two years.Operation of the regulator is checked during every run of the diesel (typically once a month).Clean/inspect voltage regulator.
This item will be performed every two years.Any regulator performance problems will be noted during the monthly runs.48)Check operation of relays/controls/breakers.
This check will be done once every two years.Any operational problems will be detected during the monthly runs or the six month redundant start tests.
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