ML20128E888

Revised Program Plan for Tdi Standby Diesel Generators

ML20128E888
Person / Time
Site:	River Bend
Issue date:	05/17/1985
From:	GULF STATES UTILITIES CO.
To:
Shared Package
ML20128E882	List: ML20128E888 RBG-21-026, Forwards Revised Program Plan for Tdi Standby Diesel generators.Post-test Insps Will Be Completed During May 1985
References
PROC-850517, NUDOCS 8505290501
Download: ML20128E888 (29)

Text

D Culf States Utilities Company Program Plan fx the Transamerica Delaval, Inc.

Standby Diesel Generators at River Bend Station Revision 1 tiay 17, 1985 4

8505290501 850517 PDR ADOCK0500g8 G

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7 TABLE OF CONTENTS SECTION PAGE TABLE OF CONTENTS 1 LIST OF TABLES 2 LIST OF FIGURES 3

1.0 INTRODUCTION

4 2.0 PROGRAM ACTIVITIES 8 2.1 Industry Experience Review 9 2.2 Design Review 10 2.3 Preservice Inspection 10 2.4 Rework 14 .

2.5 Testing 15 2.6 Post Test Inspection 20 2.7 Surveillance and Monitoring 23 3.0 SUllMARY OF RESULTS AND CONCLUSIONS 23

4.0 REFERENCES

23 Submittal Date APPENDIX 1 - FSAR Revisions 7/19/84 APPENDIX 2 - Diesel 1A Inspection Reports 10/16/84 APPENDIX 3 - Diesel 1A Inspection Reports 12/21/84 APPENDIX 4 - Diesel IB Inspection Reports 12/21/84 APPENDIX 5 - Diesel 1A Post Test Inspection Reports 12/21/84

' APPENDIX 6 - Diesel IB Post Test Inspection Reports 12/21/84 PAGE I

! LIST OF TABLES l

PAGE NO.

TAB LE 1 - Design Revi.ews (Deleted 12/21/84 - See Phase II Report) NONE TABLE 2 - Preliminary Testing of Auxiliary Components and Systems (Deleted 5/17/85 - See Reference 5 RAI Response 4) NONE TABLE 3A - Preservice Inspections (Engine IA) 12 TABLE 3B - Preservico Inspections (Engine 1B) 13 TABLE 4 - Rowork Activities (Deleted 5/17/85 - See Section 2.4) NONE TABLE 5A - Operational Testing (Engine 1A) 16 TABLE SB - Operational Testing (Engine 18) 18 TABLE 6A - Post Test Inspections (Engine IA) 21 TABLE 6B - Post Test Inspections (Engine IB) 22 2

PAGE

LIST OF FIGURES PACE A N0.

FIGURE 1 - River Bend Station TDI Standby Emergency 6 Diesel Qualification Activities FIGURE 2 - TDI Standby Emergency Diesel Generator Program Schedule (Deleted 5/17/85 - Program Complete) NONE PAGE 3

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1.0 INTRODUCTION

I This topical report has three purposes:

(1) To present the Gulf States Utilities Company (GSU) Program' Plan

. to qualify the Transomerica Delaval, Inc. (TDI) canufactured standby diesel .sonerators for River Bend Station.

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

monitoring.

I

~(3) Tc submit for NRC Staff review, the. current results of design l review and preservice inspection activities at River Bend-

-Station.

I- GSU initiated the TDI Diesel Generator Qualification Program at River Bend Station in November 1983 in response to TDI diesel generator-component failures'elsewhere and identified potential deficiencies.in TDI's quality assurance programe l' The objectives of the River Bend Station Diesel Generator l Qualification Program are:

(1) To evaluate the TDI diesel generators, and; (2) To determine what is necessary to assure reliable standby power at~ River Bend Station. The Diesel Generator Qualification

- Program includes activities to solve the known problems of the

[ TDI diesel generators, and; h

~(3) ' To obtain NRC approval of .the stdndby power supplies for River L

Bend Station.

U ;The.GSU approach to qualification of the TDI diesel generators is:

(1) To correct the known problems before .the diesel generators 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 generator reliability by_a program of.

p inservice surveillance, inspection, monitoring, and preventive

. maintenance.

4 i

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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 generator 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. Afte.r rebuilding, the engines are tested to confirm operational reliability. After testing, the engines are inspected to

. identify latent defects not disclosed during rebuilding or testing.

This inspection involves minor disassembly, sufficient to detect latent problems, but not so extensive as to require retesting.

_ Figure 1 shows the logical relationship of program tasks. The initial phase involves evaluation of industry experience, design review recommendations, and preservice inspection results. The second phase involves engine rework, rebuilding, confirmatory testing and post test inspection. This phase is expected to result in successful qualification of the TDI diesels generators at RBS.

The last phase is a program of continuing surveillance, inspection, monitoring, and preventive maintenance. The continuing surveillance and monitoring program is finalized after the post test inspection is completed.

i This report describes the plans for design reviews, inspections, testing, and long term preventive 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.

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I; 2.0--' PROGRAM-ACTIVITIES

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F:9 The following: subsections provide information relating to current.

activities with respect to GSU's approach to the qualification of the TDI diesel generators. GSU is a member and an active participant.in

..the TDI Diesel Gerarator Owners' Group. GSU has assembled and

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l- ;ntilized.ths experience of other TDI diesel generator owners in the River Bend Station program. All the recommendations of the Phase I g design review recei.ved to.date and all the recommendations oc the

- manufacturer are ir corporated into this program. The recommendations

.from the Phase II design review are also incorporated into this L program. The. Design Review and Quality Revalidation (DR/QR) Report,

_ Revision 1 (See Reference.1) . incorporated the recommendations ~from the

( Phase II Design, Review. In:the letter listed as Reference 2 of-this L report, a tabulation of the recommended modifications frcm the DR/QR

~

Report,. Revision 1, was made. .This letter identified all L . recommendations' including those which would not be incorporated at RBS'

. .and provided technical justification supporting each exclusion.

L The .following sections document GSU's compliance to the Staff position

. fo r . interim licensing as. outlined in Section 4 of the NRC Staff

[

E '. Safety Evaluation Report' (SER) on the TDI Diesel Generator Owners' Group Program Plan dated August 13, 1984:

l Phase I - Resolution of Known Problems. _ .

l ,.

The River Bend Station TDI Diesel Generator Qualification Program' meets the recommendations of the TDI Diesel Generator Owners' Group with respect to resolution of known problems.

Phase II - Design Re' view and Quality Revalidation The River Bend Station Phase II Design Review Program was issued on

. December 7, 1984. See the DR/QR Report, Revision 1 (Reference 1).

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~ Engine Testing and' Inspection

-The following paragraphs address the interim test and. inspection considerations stated in Section '4.6 of the SER.

I 1)' The qualified' load:for the River Bend Station diesel generators is provided in Table 8.3-2 of the Final Safety.' Analysis Report.

Applicable-experience from testing of the DSR-48 engine at the Shoreham Nuclear Power Station and at other facilities is factored into the River Bend Station Program.

2)- -Item '2 of Section 4.6- of the SER is not applicable since the

.plston skirts in the River Bend Station engines-are the AE

_ design.

[c 3) GSU has prepared appropriate operating procedures to ensure.that the River Bend Station diesel. generators are not loaded above qualified load.

f. PAGE 8 L'

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4) GSU has revised the River Bend Station Technical Specifications to limit testing of the TDI diesel generators to the qualified load.

5) With regard to the requirements of Item 5 of Section 4.6

" Interim Basis for Licensing," both diesel generators 9ere disassembled for inspection and rebuilding prior to preoperational testing. The inspections defined in Section 2.3 of this report include all components considered part of the TDI Diesel Geno.rator Owners' Group Phase I program, plus inspection of engine gears and wrist pin bushings. Other components are included in the inspection based on operating experience at other plants, and the recommendations of the TDI Diesel Generator Owners' Group.

A summary of the inspections performed and the results are included in Section 2.3 of this report. Where the type of inspection or acceptance criteria deviate from that of the TDI Diesel Generator Owners' Group, the deviation is specifically identified and justification provided.

6) Following engine reassembly, hot and cold crankshaft deflection measurements were taken co verify that the crankshaft alignment is within manufacturer's recommendations. The hot deflection measurements began within 15 to 20 minutes of engine shutdown, -

when practicable, consistent with personnel safety. A torsiograph test was performed for Diesel Generator 1A. Engine tests consistent with Item 6 and defined in Section 2.5 of this report were performed.

7) A program for maintenance and surveillance has been developed by the TDI Diesel Generator Owners Group. This program is included in the Phase II Design Review Report which has been submitted for NRC Staff review in the DR/QR Report, Revision 1 (Reference

1) and in the letter identified as Reference 6 in this report.

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 River Bend Station:

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

- Visits by River Bend Station personnel to observe diesel generator inspections at other nuclear stations.

Participation in TDI Diesel Owners Group meetings and activities.

PAGE 9 J

Informal exchange of information with other TDI diesel generator owners.

The accumulated experience is evaluated for applicability to the River Bend Station diesel generators. Those items considered applicabic are further investigated. This either is done as part of the TDI Diesel Cencrator Owners Group Design Review and Quality Revalidation ef t: ort, 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 reficcted in the plans for design review, preservice inspection, rework, testing, post test inspection, and surveillance and monitoring which are describcd in later sections of this report.

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 has performed design reviews of TDI supplied components whose failure might affect the safety functions of the diesel generators.

The TDI Diesel Generator Owners Group has prepared a comprehensive, RBS specific DR/QR Report, Revision 1 (Reference 1) for TDI supplied .

components. This report constitutes final documentation of the completion of the DR/QR Program on the River Bend Station TDI Diesel Generators with exceptions to modifications recommended by the DR/QR Report, Revision 1 noted in the letter identified as Reference 2 of this report.

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 complies with the design requirements. This is 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.

(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, performance and vibration testing of PAGE 10 L

I pumps and compressors, performance testing of air dryers, and

. individual checkout of all electrical components and instrument loops. Results of this testing was submitted in the response to RAI No. 4 of the letter identified as. Reference 4 of this report.

(3) Preservice disassembly inspection. 'lhe purpose of this inspection is to verify that the m.inufactured quality of the engines is in' accordance with the requirements established by the TDI Diesel Generator Owners Group design reviews. This inspection involves rer.ioval of cylinder heads, pistons, connecting rods, and cylinder liners for detailed part-by part In'spection . In addition, the turbochargers are disassembled for

-inspection. Inspection of the crankshaft, gear case, and camshaft is performed in situ.

A summary of the engine component groups and inspection results are listed in Table 3A (Engine 1A) and 3B (Engine IB). Where parts are replaced, the replacements are subjected to the same inspections.

PAGE 11

TABLE 3A PRESERVICE INSPECTION SITfARY

, STANDBY. DIESEL - 1A Part-Name Part Number Class Results Turbocharger- MP-020 B See Appendix 2 Base & Bearing Caps-Base Assembly 03-305A A See Appendix 2 03-305D See Appendix 2

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Base and Bearing. Caps A Crankshaft 03-310A A See Appendix 3 Crankshaft Bearing-Bearing Shells 03-310B- A See Appendix 2 Engine Cylinder Block 03-315A A See Appendix 3 Cylinder Block Liner 03-315C A See Appendix 2 Cylinder Block Liner & Manifold 03-315D B See Appendix 3 Cylinder Block Stud 03-315E B See Appendix 3 Cylinder Block Nuts 03-215F B See Appendix 2 FrontLGear Case Gaskets / Bolting 03-335B C See Appendix 3 Connecting Rod .

03-340A A See Appendix 3 Connecting Rod Bearing Shells 03-340B A See Appendix 3 Pistons 03-341A A See Appendix 2 Piston Rings 03-341B A See Appendix 2

-Piston Pin Assembly 03-341C A See Appendix 3 Tappets & Guides-Intake & Exhaust 03-345A A See Appendix 3 Tappets &' Guides-Fuel Tappet Assy 03-345B A See Appendix 3 Camshaft Assembly 03-350A A See Appendix 3 .

. Camshaft-Supports, Bolting & Gear 03-350C A See Appendix 3 Idler Gear Assy Crank to Pump Gear 03-355A A See Appendix 2 Idler Gear Assembly 03-355B A See Appendix 3

' Air Start Valva 03-359 A See Appendix 3 Cylinder Head and Valves 03-360A B See Appendix 3 Cylinder Hd Vivs-Intake &'Exhst 03-360B B See Appendix 3 Cylinder'Hd Vivs-Bolting & Gaskt 03-360C B See Appendix 2

' Cylinder-Hd Vivs-Sprngs & Retaints 03-360D B See Appendix 2 Cylinder Head Subcover Assembly 03-362A B See Appendix 2 Fuel Injection Tube Assembly 03-365C B See Appendix 2 Fuel Pmp'Lkge-Fuel Pmp Cntrl Shaft 03-371A A See Appendix 2 Fuel Pump Linkage 03-371B A See Appendix 2 Intake Manifold _

03-375 B See Appendix 2 Exhaust Manifold Gaskets & Bolting 03-380B B See Appendix 3 Cylinder Block Covers 03-385B C See Appendix 3 Intke & Intrmdte Rkr. Arm Shft Assy 03-390A B See Appendix 3 Exhaust Rocker Arm Assemblies _03-390B B See Appendix 3 Pushrods-Intake and Exhaust 03-390C B See Appendix 2 Pushrod-Connector 03-390D B See Appendix 2 Rocker Arm Bolts & Drivestuds 03-390G B See Appendix 3 Govnr Drive Coupling, Pins, & Keys 03-402B A~ See Appendix 3 Overspeed Governor _

03-410A A See Appendix 2 Governor & Accessory Dirve'Assy 03-410B A See Appendix 3 Overspeed Trip - Couplings 03-410C A See Appendix 3 Governor Linkage 03-413 A See Appendix 2 Governor Head Exchanger 03-415C A See Appendix 2 Jacket Water Pump 03-425A . A See Appendix 2 Fuel Oil Filters-& Strainers 03-455A B See Appendix 2 -

Trbochrgr Brkt-Air Btrfly Vive Assy 03-475B A See Appendix 2

. Lube Oil-Sump Tank 03-540B B See Appendix 3 PAGE 12

TABLE 3B PRESERt* ICE INSPECTION SIDS!ARY STANDBY DIESEL - 1B

.Part Name' Part Number Class Results Turbocharger MP-020 B See Appendix 4 Crankshaft 03-310A A See Appendix 4 Engine Cylinder Block 03-315A A- See Appendix 4 Cylinder Block Liner 03-315C A See Appendix 4

' Cylinder Block Liner & Manifold 03-315D B See Appendix 4 Cylinder Block Stud 03-315E B See Appendix 4 Cylinder Block Nuts 03-315F B See Appendix 4 Front Gear Case Gaskets / Bolting 03-335B C See Appendix 4 Connecting Rod .

03-340A A See Appendix 4 Connecting Rod Bearing Shells 03-340B A See Appendix 4 Pistons 03-241A A See Appendix 4 Piston Rings 03-341B A See Appendix 4 Piston Pin Assembly 03-341C A See Appendix 4 Tappets & Guides-Intake & Exhaust 03-345A A See Appendix 4 Tappets & Guides-Fuel Tappet Assy 03-345B A See Appendix 4 Camshaft Assembly 03-350A A See Appendix 4 Camshaft-Supports, Bolting & Gear 03-350C A See Appendix 4

Idler Gear Assy Crank to Pump Gear 03-355A A See Appendix 4 Idler Gear Assembly 03-355B A- See Appendix 4

. Air Start Valve 03-359 A See Appendix 4 -

-Cylinder Head and Valves 03-360A B See Appendix 4 Cylinder Hd Vivs-Intake & Exhst 03-360B- B See Appendix 4

-Cylinder Hd Vivs-Bolting & Gaskt 03-360C B See Appendix 4 Cylinder Hd Vivs-Sprngs & Retaints 03-360D B See Appendix 4 Cylinder Head Subcover Assembly 03-362A B See Appendix 4

. Fuel Injection Tube Assembly _ 03-365C B -See Appendix 4 Fuel Pump Linkage 03-371B A See. Appendix 4

. Intake Manifold 03-375 B See Appendix 4 Exhaust Manifold Gaskets & Bolting 03-380B B See Appendix 4 Intke &_Intrmdte Rkr Arm Shft Assy 03-390A B See Appendix 4 Exhaust Rocker Arm Assemblies- 03-390B B See Appendix 4

-Pushrods-Intake ar.d Exhaust 03-390C B See Appendix 4 Pushrod-Connector 03-390D B See Appendix 4 Rocker Arm Bolts & Drivestuds 03-390G B See Appendix 4 Govnr Drive Coupling, Pins, & Keys 03-402B A See Appendix 4 Overspeed Governor 03-410A A_ See Appendix 4 Governor & Accessory Dirve Assy 03-410B A See Appendix 4 Overspeed Trip - Couplings 03-410C A See Appendix 4 Governor Linkage 03-413 A See1 Appendix 4 Governor Head Exchanger -

03-415C A See Appendix 4 Fuel Oil Filters.& Strainers- 03-455A B See Appendix 4 Trbochrgr Brkt Bolting & Gaskets 03-475D B See Appendix 4 Lube Oil Sump Tank 03-475D B See Appendix 4 o

PAGE 13

2.4 Rework & Replacement A number of product improvements and upgrades are now available for TDI engines which improve reliability. GSU has elected to install a number of these improvements. The following paragraphs describe the 4 benefits of the significant upgrades.

1) Cylinder block and liners. The cylinder liners, cylinder head, studs and block liner landing surfaces were 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 liner landing surface. These

-measurements increase the margin against cylinder block cracking. Stud threads were c1 caned using dies.

2) Pistons. The original pistons were replaced by the improved model "AE" piston, the current TDI production standard, and then inspected to the criteria of the TDI Diesel Generator Owners Group. As part of the AE piston installation, other TDI product improvements have been installed. These include improved piston rings to reduce the likelihood of liner scuffing during break-in, rework of piston crowns to reduce liner wear and oil -

consumption, and an improved piston pin retaining ring to improve maintainability.

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

4) Jacket water pump. The jacket water pump will be reworked to include a nodular iron impeller without a keyway as recomrended by the TDI Diesel Generator Owners Group.

5) Turbocharger. The turbocharger lubrication system was modified to improve lubrication during starting and reduce thrust bearing wear. The turbocharger mounting bracket was stiffened to reduce vibration. Turbocharger lube oil pressure was monitored to verify turbocharger thrust bearing wear status.

PAGE 14

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6) Fuel injection equipment. Fuel injection tubing, shown by -

t inspection to have ID surface defects deeper than the 0.004 inch

[ acceptance criteria, have been 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 abic to supply fuel injection tubing which has been given an autofrettage treatment to improve its fatigue resistance. This tubing has boca ordered.

The original fuel injector tips with a 140 degree spray angle were replaced with an improved model with a 135 degree spray angle to eliminate fuel spray on cylinder walls and reduce liner wear. The 135 degree tips are the current TDI production standard.

The fuel injection pump return line has been replaced with heavier wall tubing as recommended by TDI.

7) Idler gear. An improved idler gear locknut has installed as a TDI recommended product improvement.

8) Cylinder heads. New manufactured cylinder heads are installed on Diesel Generator 1A. These cylinder heads are referred to as Group III heads in the TDI Diesel Generator Owners Group Design ~

Review Report (see Section 2.2). These heads were 100%

inspected as described in the detailed inspection reports.

2.5 Confirmatory Testing The purpose of this activity is to verify engine reliability following engine inspection and rebuilding. Table SA and 5B describes the confirmatory testing performed on Engines 1A and IB, respectively.

The preoperational tests described in FSAR Section 14.2.12.1.36 (revised in Enclosure 3 of the letter identified as Reference 5 of this report.)

The proposed testing program complies with the requireme.nts of .

Regulatory Guide 1.108 as clarified in the letter identified as Reference 11 to this report.

)- PAGE 15

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, TABLE 5A NOTE: .. Testing Completo l

-OPERATIONAL TESTINC' l

l STANDBY' DIESEL - 1A l I

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-l TEST OfMECTIVE ACCEPTANCE CRITERIA ~ RESULTS OR GCHEDULEO COMPLETION -

1 ) Manufacturer recommended .

test in accordance with TDI Se rvico I n fo rma t ion 1 Memoranda #99 l - \

a) Ini tia l 'sta rt, slow idle, Operating parameters Sa t i sfac to ry No load,-(15 minutes) in the norma l rango l Satisfactory crankcase l l inspection ' l

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l l .b) 150 4 rpm, no load, Adjust governor .

Sa t i s fa c to ry .

(30 minutes) Overspeed trip satisfactory Vorify generator differential 1 shutdown- 'l

, Ope ra t i ng pa rame te rs . i n no rma l -l l ra ngo l

.l~ Sati sfactory crankcaso inspect. ion l 1 l l c) Generator phasing Satisfactory Generator electrical Sa t i s fac to ry l l checks l l Set olectrical portion of governor

.l l d) I hour at 25% Ope ra t i ng pa rame te rs i n no rma l Sa t i sfac to ry rated load ra nge -

I o) .I hou r a t 50% Operating pa rameters in normal satisfactory I ra ted load rango l ll 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 in no rma l Sa t i s fac to ry l rated load rango l

l g) Return to 25% Opera ting pa rameters ip norma l ~ Sa t i s fa c to ry ra ted load ra ngo

• l Ve ri fy pa rame te rs cons i s ten t with Stop (d) i h) le hours at 100% load Ope ra t i ng pa ra me te rs i n no rma l Sa t i s facto ry

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TABLE Su NOTE: Testing Completo I-OPERATIONAL TESTING STANDBY DIESEL - 1B (Continued) l TEST OBJECTIVE ACCFPTAt4CF CRITERIA RESULTS OR SCHfDULED COMPL ETION ,

1 Cencrator winding temperaturo 1 I

I 2) Engine timing and Smooth operation Sa t i sfac to ry i I adjustments. Cylinder firing pressures in I i

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. ( powe r du ra t ion may va ry) Operating pa rameters in norma l I ra ngo Crankcase web deflection I

1.

1 l

l l l l 3) Engine performance test. Operating pa rameters in normal L l Demon s t ra te that each ra ng e . All sta rt l I dicsol operates within attempts successful.

design pa rameters at 100%

ra ted load, and demonst rate I starting reliability.

I i a) 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> at 100% Sa t i s fac to ry l ra ted load 1

l b) Ten modified starts (Note 1) Sa t i s fac to ry i I to the load required by a l I loss of of fsite power i I (approxirnately 75% of ra ted l l load) and run for a minimum I l of one hour. I I I l c) Two fast starts (Note 2) Sa t i s facto ry l l to 100% of rated load, and I run for a minimum of four bours, j i

i i l NOTES I I I l 1. A modified sta rt is defined as a start including a prelube period as recommended by the manufacturer and a 3 to 5 l l minuto loading to the specified load level. Modified starts may be conducted with the engino at operating temperature. I I

2. Fast starts are simulated " black starts" on simulation of an CSF signal with the engine on ready standby. status. I I I I I I l i i l l I i l PAGE 19 l l 1

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- 2.6 Post Test Inspection Following the_ tests-described in Section 2.5, GSU, performs an engine

. inspection'on'many of the component' groups. A summary of the' engine component groups aad post. test inspection results are listed.in Table

.6AL(Engine 1A) and 6B_(Engine-1B). The purpose of this inspection-is

'Lto look for. potential Latent problems not discovered in earlier inspections 'and-tests and verify readiness for further operation. The

. preoperational? test phase,. consisting of the tests defined in FSAR Section 14.2.12.1.36,. began upon satisfactory' completion of the inspection and any required rework or retesting.

The pos't testLinspection program is designed to. provide a thorough

~ engine 1 inspection without major engine disassembly. Major disassambly

'is not considered necessary because of- the thoroughness of- the preservice inspection and design review program. Critical components

-cantbe adequately inspected by. removing access covers and by oil analysis. The oil analysis indicates abnormal wear of bushings and b' earings and tho' elemental. analysis identifies the component in-distress. The oil analysis.also serves as a baseline for continued surveillance in the' operating phase. Visual inspections to verify.

nominal wear, absence of ' discoloration .from overheating, water

leakage, and absence of wear products (metal' particles) identifies distress conditions in combination with oil analysis. ,

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PAGE 20 E_

TABLE 6A POST TEST INSPECTION SIDDfARY 7, STANDBY DIESEL - 1A

~Part Name Part Number Class Results

. Tappets ~&. Guides-Intake & Exhaust 03-345A A See Appendix 5 Tappets & Guides-Fuel Tappet Assy 03-345B A. See Appendix 5 Camshaft Assembly 03-350A See Appendix 5

~

A Camshaft-Supports, Bolting & Gear 03-350C A See Appendix 5 Idler Gear Assy Crank to Pump Gear 03-355A A See Appendix 5 Cylinder Hd Vivs-Bolting & Caskt 03-360C- B See Appendix 5 Overspeed Trip - Coupling 03-410C A See Appendix 5 Governor Linkage 03-413 A See Appendix 5 Lube Oil Sump Tank 03-540B B See Appendix 5 i.

l i

l PAGE 21 I; .

U-

TABLE 6B POST TEST INSPECTION

SUMMARY

', STANDBY DIESEL - IB Part Name Part Number Class Results Tappets & Guides-Intake & Exhaust 03-345A A See Appendix 6 Tappets & Guides-Fuel Tappet Assy 03-345B A See Appendix 6 Camshaft Assembly 03-350A A See Appendix 6 Camshaft-Supports, Bolting & Gear 03-350C A See Appendix 6 Idler Gear Assy Crank to Pump Gear 03-355A A See Appendix 6 Idler Gear Assembly 03-355B A See Appendix 6 Air Start Valve 03-359 A See Appendix 6 Cylinder Hd Vivs-Bolting & Gaskt 03-360C B See Appendix 6 Govnr Drive Coupling, Pins, & Keys 03-402B A See Appendix 6 Governor Linkage 03 /.13 A See Appendix 6

' Lube 011 Sump Tank _ 03-540B B See Appendix 6 k

. s PAGE 22 1

2.7 Surveillance and Monitoring

- GSU will implement a program of preventive maintenance, surveillance and monitoring to ensure long term engine reliability. This program is contained in Appendix II of the TDI Diesel Generator Design Review cnd Quality Revalidation (DR/QR) Report Revision 1 (Reference 1).

3.0 CONCLUSION

S GSU believes that the problems 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 generator owners. Solutions to those problems are provided for River Bend Station through the measures described in this report. This program includes all the recommended actions of the TDI Diesel Generator Owners Group and Transamerica Delaval Inc. GSU believes these measures will provide reliable standby power for River Bend Station.

4.0 REFERENCES

1. DR/QR Revision 1 Report - Letter from J. C. Doddens (GSU) to H.

R. Denton (NRC) dated March 7, 1985 (GSU Letter No. RBG-20351).

2. Tabulation of DR/QR Modifications - Letter from J. E. Booker .

(GSU) to H. R. Denton dated May 3, 1985 (GSU letter No. RBG-20891).

3. Partial Response to 12/29/83 NRC RAI - Letter from J. E. Booker to H. R. Denton dated April 11, 1955 (GSU Letter No. RBG-20685).

4. Completed response to 12/29/83 NRC RAI - Letter from J. E.

Booker to II. R.> Denton dated April 22, 1985 (GSU Letter No. RBG-20791).

5. Partial reponse to 1/29/85 NRC RAI - Letter from J. E. Booker to H. R. Denton dated April 11, 1985 (GSU Letter No. RBG-20684).

6. Completed response to 1/29/85 NRC RAI - Letter from J. E. Booker-to H. R. Denton dated April 22, 1985 (GSU Letter No. RBG-20790).

7. Completed response to 2/11/85 NRC RAI - Letter from J. E. Booker to H. R. Denton dated April 9, 1985 (GSU Letter No. RBG-20681).

8. Information regarding the crankshaft - Letter from J. E. Booker to H. R. Denton dated April 9, 1985 (GSU Letter No. RBG-20646).

9. Diesel Generator 1A Inspection Reports - Letter from J. E.

Booker to H. R. Denton dated October 16, 1984 (GSU Letter No.

RBG-19210).

PAGE 23

L

10. Diesel Generator Program Plan, Revision 0 - Letter from J. E.

Booker to H. R. Denton dated December 21, 1984 (GSU Letter No.

RBG-19762).

11. Completed Response to 4/1/85 and 4/30/85 NRC RAIs - Letter from J. E Booker to H. R. Denton dated 5/15/35 (GSU Letter No. RBG-20994).

PAGE 24

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APPENDIX 1 Deleted 5/17/85 - See FSAR Section 14.7. 12.1.36 as tuodified by Reference 5 h

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Submitted as part of Reference 10 4

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APPENDIX 4 Submitted as part of Referetice 10 4

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