ML16342B865

Summary of 920220 Meeting W/Util in Rockville,Md to Discuss Open Issues from Three NRC Staff Inspections of Commerical Grade Procurement & Dedication of Sixth Emergency Diesel Generator Currently Being Installed at Facility

ML16342B865
Person / Time
Site:	Diablo Canyon
Issue date:	03/11/1992
From:	Rood H Office of Nuclear Reactor Regulation
To:	Office of Nuclear Reactor Regulation
References
TAC-M82775, NUDOCS 9203260331
Download: ML16342B865 (92)

Text

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UNITED STATES NUCLEAR REGULATORY COMMISSION WASHINGTON, D.C. 20555 March ll, 1992 Docket No. 50-323 LICENSEE:

FACILITY:

SUBJECT:

Pacific Gas and Electric Company (PG&E)

Diablo Canyon Nuclear Power Plant

SUMMARY

OF FEBRUARY 20, 1992 MEETING HELD IN ROCKVILLE, MARYLAND TO DISCUSS THE COMMERCIAL-GRADE PROCUREMENT AND DEDICATION OF THE 6TH DIESEL GENERATOR AT DIABLO CANYON (TAC NO. 82775)

On February 20, 1992, the NRC staff met with representatives of the Pacific Gas and Electric Company (PGKE) in Rockville, Maryland to discuss the open issues from three NRC staff inspections of the commercial-grade procurement and dedication of the 6th emergency diesel generator (EDG) currently being installed at Diablo Canyon Unit 2.

The inspection reports discussed are:

1.

Inspection Report No. 50-323/91-202, "Inspection of the Procurement and Commercial-Grade Dedication of the Sixth (2-3) Emergency Diesel Generator Set for Diablo Canyon Nuclear Plant, Unit 2," transmitted to PG&E by letter dated November 15, 1991 2.

Inspection Report No. 999007722/91-01, "Inspection of a Safety-Related Power Generator Supplied to Diablo Canyon Nuclear Power Plant Unit 2,"

transmitted to NEI Peebles

- Electric Products, Inc. by letter dated January 15, 1992 3.

Inspection Report No. 99901065/91-01, "Inspection of a Safety-Related Power Generator Supplied to Diablo Canyon Nuclear Power Plant Unit 2,"

transmitted to NEI Peebles Limited by letter dated February 13, 1992 Attendees at the February 20, 1992 meeting are listed in Enclosure l.

Viewgraphs presented by PG&E at the meeting are given in Enclosure 2.

During the meeting, PG&E presented a revised and/or clarified approach to the dedication of the diesel engine.

The new approach was presented to address the staff's concerns regarding (1) the performance history of the engine, and (2) the long-term degradation and cy'clic fatigue of certain critical parts.

PG&E addressed Item (1) by redefining the applicability of the commercial grade

survey, source verification, and special test and inspections, and Item (2) by incorporating site preoperational testing of the EDG into the dedication program.

At the meeting, the staff suggested that PG&E consider additional endurance testing in combination with a breakdown and inspection of specific parts of the engine and generator.

The staff suggested that Mi 1 Standard 23457-B could be used as a basis for developing guidance for the EDG endurance test.

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Pacific Gas and Electric Company March ll, 1992 At the conclusion of the meeting PG&E agreed to develop, in consultation with the diesel engine manufacturer, a program of supplemental endurance testing of the EDG.

The target schedule for future PG&E activities includes (1) a working meeting with the staff in about two weeks, (2) submittal of a test program plan and (3) submittal of a response to the staff's February 13, 1992 inspection report in about a month.

The staff indicated that a supplemental inspection at PG&E's offices would be held in late April, 1992.

Encl osures:

1. Attendees 2.

PG&E Viewgraphs cc w/enclosures:

See next page EJordan ACRS (10)

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Pacific Gas and Electric Company At the conclusion of the meeting PG&E agreed to develop, in consultation with the diesel engine manufacturer, a program of supplemental endurance testing of the EDG.

The target schedule for future PG&E activities includes (1) a working meeting with the staff in about two weeks, (2) submittal of a test program plan and (3) submittal of a response to the staff's February 13, 1992 inspection report in about a month.

The staff indicated that a supplemental inspection at PG&E's offices would be held in late April, 1992.

Enclosures:

1. Attendees 2.

PG&E Viewgraphs cc w/enclosures:

See next page Harry Rood, Senior Project lianager Project Directorate Y Division of Reactor Projects III/IV/VOffice of Nuclear Reactor Regulation

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Pacific Gas and Electric Company Diablo Canyon CC Regional Administrator, Region V

U.S. Nuclear Regulatory Commission 1450 Maria Lane, Suite 210 Walnut Creek, California 94596 Hr. Peter H. Kaufman Deputy Attorney General State of California 110 West A Street, Suite 700 San Diego, California 92101 NRC Resident Inspector Diablo Canyon Nuclear Power Plant c/o U.S. Nuclear Regulatory Commission P. 0.

Box 369 Avila Beach, California 93424 Richard F. Locke, Esq.

Pacific Gas 5 Electric Company Post Office Box 7442 San Francisco, California 94120 Mr. John Hickman Senior Health Physicist Environmental Radioactive Hgmt. Unit Environmental Management Branch State Department of Health Services 714 P Street, Room 616 Sacramento, California 95814 Michael H. Strumwasser, Esq.

Special Assistant Attorney General State of.California Department of Justice 3580 Wilshire Boulevard, Room 800 Los Angeles, California 90010 Managing Editor The Count Tele ram Tribune 1321 Jo nson Avenue P. 0. Box 112 San Luis Obispo, California 93406 Chairman San Luis Obispo County Board of Supervisors Room 370 County Government Center San Luis Obispo, California 93408 Hs. Sandra A. Silver Mothers for Peace 660 Granite Creek Road Santa Cruz, California 95065 Dr. R. B. Ferguson, Energy Chair Sierra Club California 6715 Rocky Canyon Cres'ton, California 93432 Ms. Nancy Culver 192 Luneta Street San Luis Obispo, California 93401 Ms. Jacquelyn C. Wheeler 3303 Barranca Court San Luis Obispo, California 93401 Hr. Gregory H. Rueger Senior

'Yice President and General Manager Nuclear Power Generation Business Unit Pacific Gas and Electric Company 77 Beale Street, Room 1451 San Francisco, CA 94106

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ENCLOSURE 1

Attendees February 20, 1992 Meeting to discuss commercial dedication of 6th diesel NAME Richarrr.'.

Anderson Usama Farradj Warren Fujimoto Brian Grimes Walter P.

Haass Gary Holahan Edwin R. Kahler Denn'is Kirsch M. R.

Khan James E. Knight Brian F. Love Steven M. Matthews Leif J.

Norrholm Thomas W. Packy Uldis Potapovs J.

Rajan Christopher M. Regan Harry Rood J. A. Sexton James Tomkins Ed Walters Jay C. Young ORGANIZATION RKE7R g,N 1.Eg.lC t.

PG&E/Mechanical Engineering PG&E/VP, Nuclear Tech. Services NRC/Director, DRIS NRC/DRIS/RVIB NRC/Deputy Director, DST PG&E/Replacement Parts Supervisor NRC/Region V/Chief, RSB PG&E/Supervisor, Dynamic Analysis NRC/DST/SELB PG&E/PQA Auditor NRC/DRIS/RVI8 NRC/DRIS/Chief, RVIB PG&E/PQA Auditor NRC/DRIS/RVIB NRC/DET/EMEB NRC/DRPW/PD5 NRC/DRPW/PD5 PG&E/Manager, QA PG&E/Director, Nucl.

Reg. Affairs PG&E/Replacement Parts Eval. Grp.

PG&E/PQA Auditor

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ENCLOSURE 2

Viewgraphs presented by PGIIE February. 20, 1992 Meeting to discuss commercial dedication of 6th diesel

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NRC/PGS.E MEETING DIABLO CANYON POWER PLANT SIXTH DIESEL ENGINE FEBRUARY 20, 1992

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MEETING AGENDA ENGINE INTRODUCTION MEETING OBJECTIVES OVERVIEW OF ENGINE DEDICATION ISSUES FROM NRC INSPECTION REPORT.

(60-323/91 -202)

CONCLUSIONS/FUTURE ACTIONS

MEETING OBJECTIVES TO DISCUSS AND RESOLVE ISSUES IDENTIFIED IN THE NRC INSPECTION REPORT ON THE DCPP SIXTH DIESEL ENGINE IDENTIFY FUTURE ACTIONS NEEDED TO SUPPORT MARCH 1993 SIXTH DIESEL INSTALLATION

ENGINE PROCUREMENT. CHRONOLOGY 5/89 DECISION TO PROCURE ALCO ENGINE PROVEN DESIGN RELIABILITY OF FIVE DCPP ENGINES HUMAN FACTORS, EASE OF OPERATION, MAINTENANCE 3/89 7/89 1 /90 GL 89-02 ISSUED NRC/PG&E MEETING RE:

DECISION TO PROCURE. ALCE) E'NGINE PURCHASE ORDER ISSUED TO ALCO (GE-L) 9/90 NRC/PG8E MEETING INSTALLATION SCHEDULE DEDICATION ACTIVITIES 1/91 NRC/PG8E MEETING 2/91 3/91 DETAILED DISCUSSION OF DEDICATION ACTIVIT IES ENGINE TESTED (MONTREAL) AND SHIPPED TO GEC ALSTHOM (TORONTO)

PG8E LETTER TO NRC SUMMARIZING DEDICATION ACTIVITIES I

ENGINE PROCUREMENT CHRONOLOGY (cont'd) 4/91 GL 91-05 ISSUED 5/91 NRC INSPECTION AT PG8E 7/91 ENGINE GENERATOR UNIT TESTING COMMENCES 7/91 NRC/PG8E MEETING DISCUSSION OF FOLLOV/UP QUEST IONS 8/91 UNIT SHIPPED FROM GEC ALSTHOM 9/91 UNIT RECEIVED AT DCPP 11/91 NRC INSPECTION REPORT 1/92 PGE.E

RESPONSE

TO INSPECTION 2/92 TODAY'S MEETING 7/92-PRE-OPERATIONAL TESTING 3/93 3/93 DIESEL GENERATOR OPERABLE

STATUS UPDATE FOR ENGINE DEDICATION AND INSTALLATION DESIGN CHANGE REVIEW DETAILED REVIEW HAS BEEN COMPLETED TO IDENTIFY CHANGES IN DESIGN

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VERY FEW CHANGES REQUIRING FURTHER EVALUATION COMPLETION OF EVALUATIO.N MAY

- RESULT IN ADDITIONAL COMPENSATORY ACTIONS INDUSTRY-MflDE SURVEY

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DATA RECEIVED TO DATE CONSISTENT WITH EPRI DATA

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ENGINE PROCUREMENT VERSUS STANDARD PGKE COMMERCIAL GRADE DEDICATION PROGRAM PG&.E'S STANDARD COMMERCIAL GRADE PROGRAM USES PRIMARILY METHOD 1

ENGINE IS A UNIQUE DEDICATION

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COMPLEXITY (MANY PARTS)

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PROVEN TECHNOLOGY

~ ABILITY TO PERFORM EXTENSIVE FUNCTIONAL TESTING FOR DESIGN AND OVERLOAD CONDITIONS

II IIIII Method 2 Commercial Grade Survey of Supplier

~ Design

~ Material

~ Manufacturing Process Review of Design Changes Method 4 Acceptable Supplier/Item Performance Record I

Similarity W W W W W W W m W W W W W W W W W m W W W W W W W W W W W W W W W W W W I Evaluation Power Train Parts

'14 Items)

Programmatic Audit Mechanical Parts (Includes all Non-Power Train Parts)

Establish 14 Categories Method 1 CE-L Functional Testing Special Tests and Inspections Sixth Diese. Dedicatio!~ A"';oach W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W % % W H W W W W W W W W W W W W W P 'W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W WI I I

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s I WI IIIIIIIII I

II II Identify Sample Part for Each Category IIIIII

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IIIII' Purchase Order Required Annual Auditof Subsu liers Identify Critical Characteristics for Parts/Categories Method 3 Manufacturing. Process Source Inspection Identify Subsup plier Audit Issues Survey CE-L Program Regarding Control of Critical Characteristics

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VerifySubsupplier Cerb6cations Documentation Issues Implement Follow-Up Actions Based'on Survey Findings lWWWW WWWWWWWW Site Pre-Operational W W W W W W W & W W & W W && W W & W W W W Ik & W W W W & W &&& W W & W W && W W W Testing

MANUFACTURER FUNCTIONAL TESTING AT GE-LOCOMOTIVE {MONTREAL)

ENGINE BREAK-IN TEST

~ NO-LOAD TEST --

2, 5,

10-MINUTE RUNS AND RUN TILL JACKET WATER

'EMP REACHES NORMAL OPERATING TEMP.

AFTER EACH TEST, VISUALLY INSPECT PISTON SKIRT LINERS, CONNECTING RODS, AND CHECK BEARING TEMP.

INSPECT LUBE OIL FILTERS AND STRAINERS

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LOAD TEST 26%

1 HR.

0% -

1 HR.

75%

2 HRS.

00%

2 HRS.

REPEAT NO-LOAD INSPECTIONS AFTER EACH RUN

MANUFACTURER FUNCTIONAL TESTING (conf'd)

AT GEC ALSTHOM (TORONTO) "- ENGINE GENERATOR FUNCTIONAL TEST

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CONTROL SYSTEM TESTING REPERFORM BREAK"IN TEST -.

STARTING ACCELERATION TEST (VERIFY START AND RATED VOLTAGE/FREQUENCY WITHIN REQUIRED TIME)

DEAD LOAD PICK-UP TEST (VERIFY RATED VOLTAGE/FREQUENCY FOR STEP LOAD LARGER THAN L'ARGEST PLANT LOAD)

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PERFORMANCE RUN (1300 KW, 1950 KW, 2600 KW 2860 KW ( I0% OVERLOAD) 15-MINUTE RUNS)

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STARTING CAPACITY (100 CONSECUTIVE STARTS WITH RATED VOLTAGE/FREQUENCY WITHIN REQUIRED TIME)

LOAD REJECTION TEST (REJECT RATED LOAD, 2600 KW, WITHOUT CAUSING OVERSPEED TRIP)

RATED LOAD TEST (2 HRS.

AT 10%

OVERLOAD FOLLOWED BY 22 HRS.

AT RATED LOAD)

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PRE-OPERATIONAL TESTING AT DCPP PRIOR TO OUTAGE REPERFORM BREAK-IN TEST REGULATORY GUIDE 1.9 (DRAFT REV. S)

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23 CONSECUTIVE VALID STARTS PER REGULATORY 6UlDE '1.9 DEFINITION IEEE 387 SITE TESTING

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ELECTRICAL TEST (TEST OF GENERATOR, EXCITATION SYSTEM, VOLTAGE REGULATION SYSTEM, ENGINE GOVERNOR SYSTEM, AND CONTROL AND SURVEILLANCE SYSTEM)

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SUBSYSTEM TESTING (LUBE OIL, FUEL OIL, JACKET WATER, AIR START, TURBO AIR, COMBUSTION, AND EXHAUST AIR SYSTEMS)

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LOAD ACCEPTANCE TEST (VERIFY RATED VOLTAGE/FREQUENCY UTILIZING LOAD BANK SIMULATED SEQUENCING OF LOADS)

PRE-OPERATIONAL TESTING AT DCPP PRIOR TO OUTAGE (cont'd)

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RATED LOAD TEST (CONTINUOUS RATING TO NORMAL OPERATING TEMP PLUS ONE HOUR AT RATED LOAD FOLLOWED BY OVERLOAD FOR TWO HOURS)

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LOAD REJECTION TEST LOAD CAPACITY TEST (CONTINUOUS RATING TO NORMAL OPERATING TEMP PLUS TWO HOURS AT OVERLOAD FOLLOWED BY 22 HOURS AT RATED LOAD}

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MARGIN. TEST (VERIFY RATED VOLTAGE/

FREQUENCY FOR APPLICATION OF LOAD 10% LARGER THAN LARGEST EXPECTED PLANT LOAD}

MONITORING AND INSPECTION DURING PRE-OPERATIONAL TESTING (PRIOR TO TIE-IN)

MONITOR CRITICAL PARAMETERS (I.E.,

OIL PRESSURE, JACKET WATER TEMPERATURE, HEAD TEMPERATURE)

EVALUATE ENGINE PERFORMANCE USING ENGINE ANALYZER PERFORM PRE-AND POST-TEST OIL ANALYSIS INSPECT. CYLINDER HEADS AND LINERS AFTER TESTING

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SUMMARY

OF NRC INSPECTION REPORT CONCERNS COMMERCIAL GRADE SURVEY ADEQUACY FATIGUE/CYCLICAL FAILURE BASES INDUSTRY PERFORMANCE HISTORY SOURCE INSPECTION PLAN ADEQUACY

'PECIAL TESTS AND INSPECTION ADEQUACY

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ADDITIONALDEDICATION.ACTIVITIES TO ADDRESS AREAS OF CONCERN IDENTIFIED IN NRC INSPECTION REPORT GLARIFIGATION COMPLETION OF COMMERCIAL DETAILED OF ALCO GRADE SURVEY DESIGN EXPANDED NUCLEAR COMPENSATORY REVIEW TESTING SURVEY ACTIONS COMMERCIAL GRADE SURVEY FATIGUE/

CYCLIGAL FAILURE BASES INDUSTRY PERFORMANCE HISTORY SOURCE INSPECTION PLAN SPECIAL TESTS AND IN SP ECT I ON S

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ADDITIONALDEDICATION ACTIVITIES TO ADDRESS AREAS OF CONCERN IDENTIFIED IN NRC INSPECTION REPORT ADEQUACY OF COMMERCIAL GRADE QA PROGRAM CONTROL OF DESIGN, MATERIAL, AND MANUFACTURING PROCESS (DEFICIENCIES 01 AND 02, UNRESOLVED ITEMS 03 AND 04)

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DETAILED DESIGN REVIEW WITH RESPECT TO ORIGINAL FIVE DlESELS TO SUBSTANTIATE GE-l.CONTROLS AND SUPPORT PG8E SEISMIC ANALYSIS

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DEDICATION TESTING EXPANDED TO INCORPORATE PRE-OPERATIONAL LOAD BANK TESTING AT DCPP TO SUBSTANTIATE PRODUCT QUALITY FOR GE-L AND SUBSUPPLIER PARTS

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CHARACTERIZATION BY PG8E OF COMPENSATORY ACTIONS AS METHODS AND 3 WAS NOT APPROPRIATE, INSPECTIONS OF A SAMPLE OF COMPONENTS WAS UTILIZED TO SUBSTANTIATE ADEQUACY OF GE-L CONTROLS FOR WHICH DOCUMENTATION WAS LIMITED 5

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ADDITIONALDEDICATION ACTIVITIES TO ADDRESS AREAS OF CONCERN IDENTIFIED IN NRC INSPECTION REPORT (cont'd)

EVALUATION WITH RESPECT TO POTENTIAL FOR FATIGUE AND CYCLICAL FAILURES {UNRESOLVED ITEMS 01, 0?,

AND 08}

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DEDICATION TESTING EXPANDED TO INCORPORATE PRE'OPERATIONAL LOAD BANK TESTING AT DCPP TO SUBSTANTIATE PRODUCT QUALITY FOR GE-L AND SUBSUPPLIER PARTS INDUSTRY PERFORMANCE HISTORY BASES

{UNRESOLVED ITEM 02}

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COMPLETION OF ALCO NUCLEAR INDUSTRY SURVEY

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DETAILED DESIGN REVIEW WITH RESPECT TO ORIGINAL FIVE DIESELS TO SUBSTANTIATE GE-L CONTROLS AND SUPPORT PG8E SEISMIC ANALYSIS

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DEDICATION TESTING EXPANDED TO INCORPORATE PRE-OPERATIONAL LOAD BANK TESTING AT DCPP TO SUBSTANTIATE PRODUCT QUALITY FOR GE-L AND SUBSUPPLIER PARTS 5

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ADDITIONALDEDICATION ACTIVITIES TO ADDRESS AREAS OF CONCERN IDENTIFIED IN NRC INSPECTION REPORT (cont'd)

SOURCE INSPECTION PLAN ADEQUACY

{UNRESOLVED ITEMS 05 AND 06}

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CHARACTERIZATION BY PGS.E OF COMPENSATORY ACTIONS AS METHODS 1

AND 3

WAS NOT APPROPRIATE, INSPECTIONS OF A SAMPLE OF. COMPONENTS WAS UTILIZED TO SUBSTANTIATE ADEQUACY OF GE-L CONTROLS FOR WHICH DOCUMENTATION WAS LIMITED SPECIAL TESTS AND INSPECTIONS ADEQUACY (UNRESOLVED ITEMS 07 AND 08)

DEDICATION TESTING EXPANDED TO INCORPORATE PRE-OPERATIONAL LOAD BANK TESTING AT DCPP, TO SUBSTANTIATE PRODUCT QUALITY FOR GE-L AND SUBSUPPLIER PARTS

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CHARACTERIZATION BY PG8E OF COMPENSATORY ACTIONS AS METHODS

1. AND 3

WAS NOT APPROPRIATE, INSPECTIONS OF A SAMPLE OF COMPONENTS WAS UTILIZED TO SUBSTANTIATE ADEQUACY OF GE-L CONTROLS FOR WHICH DOCUMENTATION WAS LIMITED

DISCUSSION OF INSPECTION REPORT DEFICIENCIES RSUAF

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ITEM 50-323/91-202-,01 AND 02 QUALITYREQUIREMENTS PURCHASE ORDER 0'f-A.

CRITICAL COMPONENT'SED IN THE DESIGN SPECIFICATION VS. 'CRITICAL PART'SED IN SPECIFICATION NO. CG-P" DIESEL CLARIFIED IN REVISION 3 OF CG-P "DIESEL B.

ENGINEERING CHANGE NOTICE PROCEDURES WERE NOT REVIEWED DURING THE AUDIT PROCEDURE WAS REVIEWED BY PGSE PRIOR TO ISSUING P.O.

AND WAS FOUND TO COMPLY WITH DESIGN CONTROL SECTIONS OF CG-P -DIESEL C.

MATERIAL TRACEABILITY FOR POWER TRAIN PARTS TRACEABILITY P ROVIDED BY SUBSUPPLIER MATERIAL CERTIF ICATIONS VERIFIED CERTIFICATIONS BY MATERIAL TESTING D.

SUBSUPPLIER QUALIFICATION DID NOT SUBSTANTIATE QUALITY OF POWER TRAIN PARTS TAKEN FROM STOCK TO COMPENSATE, MATERIAL TESTING DIMENSIONAL VERIFICATIONS WERE IMPLEMENTED

ITEM 50-323/91-202-.01 AND 02 QUALITYREQUIREMENTS PURCHASE ORDER (cont'd) 01-E.

AUDIT DID NOT SUBSTANTIATE GE"L'S QA PROGRAM ADEQUATE TO ENSURE PROCESS CONTROL IN CG-P "DIESEL PGKE ERRONEOUSLY IDENTIFIED AS PARAGRAPH 4.18.2 OF CG-P-DIESEL, SHOULD HAVE BEEN 4.17.2 02-A.

TECHNICAL AND QUALITY REQUIREMENTS FOR THE MECHANICAL COMPONENTS CG-P-DIESEL IMPOSES THE SAME REQUlREMENTS ON ALL DIESEL ENGINE COMPONENTS, WITH THE EXCEPTION OF SUBSUPPLIER ANNUAL AUDIT I

B.

BASIS FOR CONSIDERING MECHANICAL COMPONENTS AS NON-CRITICAL MECHANICAL COMPONENTS CONSIDERED CR ITICAL CLARIFICATION OF WORDING OF PURCHASE ORDER VS. CG-P"DIESEL, REVISION 1.

SEE REVISION 3 OF CG-P-DIESEL

DISCUSSION OF INSPECTION REPORT UNRESOLVED ITEMS RdUAF

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ITEM 50-323/91-202-01 BASIS FOR SELECTION OF POWER TRAIN PARTS 01-A.

CAN3-Z299.3 QA PROGRAM LIMITED TO THE HIGHEST LEVEL AVAILABLE FROM SUPPLIER'S QA PROGRAM B.

CAN3-Z299.3 QA PROGRAM DOES NOT PROVIDE CONTROLS FOR DESIGN PLANNING, DESIGN PROCESSES, DESIGN VERIFICATIONS, OR DESIGN REVIEWS CG-P-DIESEL IMPOSES DESIGN REQUIREMENTS IN ADDITION TO Z299.3 C.

DESIGN SPECIFICATION CRITERION FOR DETERMINING IF A COMPONENT IS CRITICAL CRITICAL COMPONENTS" IN THE PURCHASE SPECIFICATION ARE NOT THE ONLY SAFETY-RELATED ITEMS ALL ENGINE PARTS ARE REQUIRED TO MEET CAN3-Z299.3 AND CG-P-DIESEL D.

LISTING OF POWER TRAIN PARTS ALSO INCLUDED VALVE INSERTS, CONNECTING ROD BOLTS, AND CONNECTING ROD NUTS WHICH WERE NOT LISTED IN THE DESIGN SPECIFICATION VALVE INSERTS PART OF VALVES CONNECTING ROD NUTS AND BOLTS PART OF CONNECTING ROD

ITEM 50-323/91-202-02 ADEQUACY OF PERFORMANCE HISTORY 02-A.

DOCUMENTATION OF BASES USED TO SELECT FAILURES WHICH WERE DIRECTLY APPLICABLE PREVENTIVE MAINTENANCE, EQUIPMENT CLEANING, REPLACEMENT OF CONSUMABLES, OR TIGHTENING OF FASTENERS CONSIDERED TO HAVE NO BEARING ON PERFORMANCE HISTORY FAILURES OF EDG COMPONENTS SUCH AS INSTRUMENTS, RELAYS, AND SWITCHES WERE EXCLUDED FROM REVIEW EXCLUDED FROM FURTHER REVIEW WERE REPLACEMENTS ATTRIBUTABLE TO NORMAL PERIODIC MAINTENANCE PROGRAM ACTIVITIES REVIEW OF THESE FAILURES DID NOT TRACE PROBLEMS TO WEAKNESS IN DESIGN AND MANUFACTURING CONTROLS ADDITIONAL INSPECTION OF THE ASSOCIATED GOMPONENTS WAS INCLUDED IN THE METHOD AND 3 INSPECTIONS B.

EVALUATION OF NPRDS FAILURE DATA FOR THE PALISADES EVENT CONSUMERS POWER COMPANY'S PALISADES PLANT WAS ERRONEOUSLY IDENTIFIED BY PG8E IN THE REPLACEMENT PART EVALUATION (RPE)

AS CONSOLIDATED EDISON'S INDIAN POINT, UNIT 2

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ITEM 50-323/91-202-02 ADEQUACY OF PERFORMANCE HISTORY (cont'd) 02-C.

EPRI NP-4264 AND EPRI/NSAC-108 PERFORMANCE HISTORY DATA ELIMINATION OF BEGINNING-OF-LIFE FAILURES DOES NOT DETRACT FROM USEFULNESS OF DATA DATA FROM THESE STUDIES USED BY PGLE IN CONJUNCTION WITH OTHER INDUSTRY SURVEYS OF DIESEL RELIABILITY (NUCLEAR, NON-NUCLEAR, DCPP)

SURVEY RESULTS FAILED TO INCLUDE DATA FROM GINNA AND INDIAN POINT AND DATA FOR THE TIME FRAMES NOT INCLUDED IN EPRI REPORTS SCOPE OF PGBE SURVEY REGARDING RELIABILITY OF ALCO EDGs IS BEING EXPANDED TO INCLUDE THE DATA IDENTIFIED ABOVE E.

EQUIPMENT BULLETINS CONSIDERED APPLICABLE TO THE PROCUREMENT APPLICABLE BULLETINS WERE DETERMINED BASED ON THE ENGINE MODEL F.

ATI AUDIT IMPLICATIONS SELECTIVE TO GE-L CONTROL OF DESIGN, MATERIAL AND MANUFACTURING P ROC ESSES ATI PROBLEMS IDENTIFIED BY GE-L ADDITIONAL VERIFICATION ACTIVITIES IMPLEMENTED FOR ATI SUBSUPPLIER ACTIVITIES

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ITEMS 60-323/91-202.-03 8, 04 REPRESENTATIVE PARTS FOR AND VYEAKNESSES OF COMMERCIAL GRADE SURVEY 03-A.

COMMERCIAL QUALITY CONTROLS FOR MECHANICAL COMPONENTS CONTROLS FOR ALL MECHANICAL ITEMS (EXCLUDING ANNUAL SUBSUPPLIER AUDITS)

ARE THE SAME AS FOR POWER TRAIN PARTS B-5.

DOES MECHANICAL COMPONENT SELECTED ADEQUATELY REPRESENT OTHER MECHANICAL COMPONENTS WITHIN THIS PRODUCT TYPE B-2.

ARE THE CRITICAL CHARACTERISTICS OF THE 14 REPRESENTATIVE MECHANICAL COMPONENTS TECHNICALLY IDENTICAL TO THE FIVE EXISTING DEs BASIS FOR SAMPLE INCLUDES SUBSUPPLIER, PRODUCT TYPE, CONSTRUCTION PROCESS, INDUSTRY EXPERIENCE AND PERFORMANCE

'ECORD REPRESENTATIVE SAMPLE WAS USED TO VERIFY DURING THE COMMERC)AL GRADE SURVEY THAT QA PROGRAM WAS PROPERLY IMPLEMENTED AREAS IN WHICH DOCUMENTATION WEAKNESSES WERE IDENTIFIED HAVE BEEN RESOLVED BY ADDITIONAL TESTING AND INSPECTION

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ITEMS 50-323/91-202-03

& 04 REPRESENTATIVE PARTS FOR AND WEAKNESSES OF COMMERClAL GRADE SURVEY (cont'd) 04-A" 1.

ADEQUACY OF QUALITY PROGRAM ELEMENTS SURVEYED TO ENSURE PROPER QA CONTROLS FOR THE 54 SELECTED MECHANICAL COMPONENTS A-2.

ADEQUACY OF THE QUALITY PROGRAM TO CONTROL THE REMAINING MECHANICAL COMPONENTS THAT WERE NOT EVALUATED IN THE SURVEY PURPOSE OF SURVEY WAS TO DETERMINE THE ADEQUACY OF GE-L's COMMERCIAL QUAL ITY P ROG RAM PROGRAMMATIC CONTROLS OVER DESIGN, MATERIALS, AND MANUFACTURING PROCESSES HAD BEEN ADEQUATELY IMPLEMENTED BY GE-L WHERE SURVEY IDENTIFIED WEAKNESSES, PGSE PERFORMED ADDITIONAL INSPECTIONS,

TESTS, AND SOURCE VE R IF ICATION

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ITEMS 50-323/91-202-05 8, 06 ADEQUACY OF SOURCE INSPECTION PLAN AND CRITICAL CHARACTERISTICS FOR METHOD 3 06-A.

INSPECTION PLAN DID NOT INCLUDE GE-L QUALITY CONTROL ELEMENTS TO BE VERIFIED, SURVEILLANCE METHODS OR VERIFICATION ACTIVITIES TO BE PERFORMED, AND AN EVALUATION TO DETERMINE THE ADEQUACY OF THE SUPPLIER'S CONTROL QUALITY CONTROL ELEMENTS REQUIRED BY QA SPECIFICATION ARE ADDRESSED VIA METHOD 2 SOURCE INSPECTION PLAN PROVIDES ACCEPTANCE CRITERIA FOR THE PG&E SOURCE INSP ECTORS SURVEILLANCE METHODS ARE IN ACCORDANCE WITH.STANDARD PG&E PROCEDURES AND UTILIZED QUALIFIED, EXPERIENCED PERSONNEL EVALUATION OF ADEQUACY OF S U P PL IE R'S CONTROLS ARE PERFORMED BY ENGINEERING PERSONNEL 06-A.

LIMITED SAMPLING OF GE-L'S VERIFICATION ACTIVITIES WERE WITNESSED DURING SOURCE VERIFICATIONS FOR ENGINE BLOCK SOURCE INSPECTION PLAN INCLUDES WITNESS POINTS FOR:

MACHINING INSPECTION; HYDROSTATIC TESTING; AND MAGNAFLUX INSP ECTION INDEPENDENT MATERIAL AND MATERIAL STRENGTH TESTING WAS PERFORMED SRUhF

ITEMS 50-323/91-202-05 8t, 06 ADEQUACY OF SOURCE INSPECTION PLAN AND CRITICAL CHARACTERISTICS FOR METHOD 3 (cont'd) 06-B-1.

ADEQUACY OF NDE SAMPLING OF WELDMENTS 8-2.

WAS EXAMINATIONFOR SURFACE DISCONTINUITIES AN ADEQUATE BASIS FOR ACCEPTING WELDMENTS WITNESSED PORTIONS OF NDE AND REVIEWED NDE DOCUMENTATION FOR ALL.

WELDING PROVIDES BASIS FOR ADEQUACY C.

USE OF LESS SENSITIVE REJECTION CRITERIA FOR THE AIR AND EXHAUST VALVES THE TWO CALIBRATION METHODS IN ACCORDANCE WITH THE GE" L SPECIFICATION D.

ADEQUACY OF TECHNICAL BASES FOR THE CRITICAL CHARACTERISTICS CHOSEN AND VERIFIED DURING THE SOURCE VERIFICATION ACTIVITIES VERIFICATION ACTIVITIES CONDUCTED IN CONJUNCTION WITH THE ASSOCIATED ENGINEERING EVALUATIONS PROVIDE REASONABLE ASSURANCE THAT THESE SUBSUPPLIER COMPONENTS WERE ADEQUATE REVIEW IN PROGRESS TO IDENTIFY THOSE COMPONENTS WHICH ARE NOT TECHNICALLY IDENTICAL TO THE EXISTING FIVE DIESELS

)

I

ITEMS 50-323/91-202-07

8. 08 DOCUMENTATION OF AND ADEQUACY OF SPECIAL TESTS AND INSPECTIONS 07-A.

INSPECTION PLAN DID NOT ADDRESS SPECIAL TEST AND INSPECTION ACTIVITIES SP ECIAL TESTING ACTIVITIES ARE SPECIFIED IN R PE B.

NEED FOR DOCUMENTED PLAN TO CONTROL AND PRESCRIBE THE GEC ALSTHOM SPECIAL TEST AND INSPECTIONS PLAN FOR THE GEC ALSTHOM TESTING WAS GENERATED BY GE-L AND WAS REVIEWED AND APPROVED BY PG8t.E

. 08 "A.,

TECHNICAL BASES FOR THE SPECIAL TESTS AND INSPECTION ACTIVITIES VERIFICATION ACTIVITIES CONDUCTED TO PROVIDE REASONABLE ASSURANCE THAT THESE SUBSUPPLIER COMPONENTS WERE ADEQUATE REVIEW IS IN PROGRESS TO IDENTIFY THOSE COMPONENTS WHICH ARE NOT TECHNICALLY IDENTICAL TO THE EXISTING FIVE DIESELS

4 1

J I

i'

SUMMARY

OF DEDICATION APPROACH ENGINE'S ABILITY TO PERFORM ITS INTENDED SAFETY FUNCTION IS EQUIVALENT TO 'THAT OBTAINED UNDER A

0'0 CFR 50, APPENDIX B PROGRAM COMBINATION OF ALL FOUR NCIG-07 METHODS PER GL 89-02 UNIQUE APPROACH USED FOR A UNIQUE ITEM MANY PARTS, YET PROVEN TECHNOLOGY EXTENSIVE PRE-OPERATIONAL TESTING ENVELOPES DESIGN REQUIREMENTS

'0 0

CONCLUSIONS/

FUTURE ACTIONS seUAF

4

\\

I

INSPECTIONS FOR POWER TRAIN PARTS VALIDATIONOF SUBSUPPLIER CERTIFICATION (cont'd)

COMPONENT TOTAL NUMBER TESTED FOR CONFIGURATION TESTED FOR MATERIAL CON PECTIN G ROD NUTS CONNECT I N G ROD BOLTS MAIN BEARINGS SHELL MAIN BEARINGS THRUST CAMSHAFT SECTIONS 72 72 18

'I0 72 72 18 10 8

MATE RIAL 18 MATERIAL STRENGTH 8 MATERIAL 18 MATERIAL STRENGTH 6

MATERIAL 10 MATERIAL STRENGTH

f

~ Z II J

INSPECTIONS FOR POWER TRAIN PARTS VALIDATIONOF SUBSUPPLIER CERTIFICATION COMPONENT TOTAL NUMBER TESTED FOR CONF IG URATION TESTED FOR MATERIAL BLOCK CRANKSHAFT CYLINDER LINERS CYLINDER HEADS 18 18 18 18 18 6

MATE RIAL 10 MATERIAL STRENGTH SOX OF WELDS ALL CRITICAL PLATES AIR EXHAUST VALVES VALVE INSERTS P ISTON BODIES P ISTON CAPS CONNECT ING RODS 72 72

'f8 72 72 18 72 8'

MATERIAL 18 MATE RIAL STRENGTH 18 9

MATERIAL 18 MATERIAL STRENGTH 10UAF

0 v

SIXTH DIESEL DESIGN REVIEMf VS.

ORIGINAL FIVE DIESELS EXAMPLES OF DESIGN CHANGES IDENTIFIED LUBE OIL FILTER CHANGE IN MODEL NUMBER, NEW FILTER HAS 2 GAGES INSTEAD OF CYLINDER PRESSURE INDICATOR VALVE

~

CHANGE IN MANUFACTURER AND MODEL

'UMBER AIR START MOTOR LUBRICATOR CHANGE IN MODEL NUMBER DUE TO OBSOLETE PART AIR START MOTOR NEW MODEL DUE TO OBSOLETE PART AIR ELBOW GASKET, CYLINER HEAD TO BLOCK MATERIAL CHANGE TO REMOVE ASBESTOS

N, t

II

~l I

GE-L FINDINGS AND COMPENSATORY ACTIONS FOR GEC ALSTHOM PGEE ACCOMPANIED GE-L ON THEIR 10/90 AND 3/91 ASSESSMENTS OF THE UNIT ASSEMBLER GEC ALSTHOM (GEC)

~ 1 GE-L IDENTIFIED 13 CORRECTIVE ACTION REPORTS (CARs) REQUIRING EVALUATION AND COMPENSATORY ACTION FOR PGKE'S UNIT TWO INSPECTION PLANS'DESCRIBED BELOW). WERE DEVELOPED AND CONCURED TO BY GEC, GE-L AND

'G8 E.FOR RESOLUTION OF CARs

~

REINSPECTION PLAN OF SYSTEMS ASSEMBLED BY GEC INSPECTIONS CONDUCTED TO ENSURE ALL CRITICAL COMPONENTS MET SPECIFICATION BASED ON REVIEW OF SPECIFICATIONS AND DRAWINGS (I.E., CONFIGURATION, MATERIAL, FITUP, TORQUE, ALIGNMENT)

~

INSPECTION OF SUBSUPPLIER PARTS INSPECTIONS CONDUCTED TO RESOLVE ISSUES RELATED TO QUALIFICATION OF SUBSUPPLIERS BASED ON THE STATUS OF THE SUPPLIER QUALIFICATION, ADDITIONAL INSPECTIONS PERFORMED (I.E., MATERIAL, MATERIAL STRENGTH, CONFIGURATION) ON AFFECTED PARTS I%I

}

SUMMARY

OF GE-L CAR'S FOR GEC CAR P1 -- INSTRUCTIONS FOR IN-PROCESS AND FINAL INSPECTIONS, DRAWING REVISION REQUESTS, AND DISCREPANT MATERIAL REPORTS

~

COMPENSATORY ACTION ""

REINSPECTION PLAN" CAR P2 "- CALIBRATION PROCEDURES FOR MEASURING I TEST EQUIPMENT

~

COMPENSATORY ACTION -- GE-L REVIEW OF PROCEDURES AND THEIR IMPLEMENTATION CAR P3 -- GEC'S VENDOR QUALITY LIST (VQL}

NOT MAINTAINED

~

COMPENSATORY ACTION - -

REINSPECTION PLAN" AND INSPECTION OF SUBSUPPLIER PARTS" CAR i4 -- DESIGN DRAWINGS NOT UP TO DATE

~

COMPENSATORY ACTION - - "REINSPECTION PLAN" AND 'INSPECTION OF SUBSUPPLIER PARTS" CAR 4'5"- INSPECTION.5 TEST PLAN INCOMPLETE

~

COMPENSATORY ACTION "" "REINSPECTION PLAN"

.+

Z'a

SUMMARY

OF GE-L CAR'S FOR GEC (cont'd)

CAR k6 -- INSPECTION PROCESS NOT PROPERLY IMPLEMEN TED

~

COMPENSATORY ACTION "-

REINSPECTION PLAN" CAR P7 -- ASSEMBLY INSTRUCTIONS WERE NOT P ROVIDED COMPENSATORY ACTION -"

REINSPECTION PLAN" CAR P8 -- INCOMPLETE CERTIFICATION OF SP ECIAL P ROCESSES

~

COMPENSATORY ACTION - -

REINSPECTION PLAN" CAR P9 - - QUALITY RECORDS WERE LOST, MISPLACED, OR NOT GENERATED

~

COMPENSATORY ACTION - -

"REINSPECTION Pl AN" AND 'INSPECTION OF SUBSUPPLIER PARTS"

eC

6th EOG Inspection Report (IR) Issue Matrix NRC Issue Unresolved Item (UI) 91-202-01 Deficiency (D) 91-202-01 D 91-202-02 UI 91-202-02 UI 91-202-03 UI 91-202-04 UI 91-202-05 UI 91-202-06 UI 91-202-07 UI 91-202-08 IR Page 5

Page 7

Page 9

Page 19 Page 20 Page 27 Page 28 Page 39 Page 41 Page 49 PGLE Res onse Page 3

Page 5

Page 9

Page 11 Page 15 Page 17 Page 18 Page 19 Page 22 Page 24 Slide Item IR a

e 27/

1A (p.5),

/ lc (p.7),

/

1D (p.7) 24/

1A (p.5),

/

1B (p.6),

/

1C (p.7),

/

1D (p 7).

25/

1E (p.7) 28/ 2A (pp.8, 10),

/ 2B (p.ll) 29/ 2A (pp.8, 10),.

/ 2B (p.ll),

/ 2C (pp.12, 13),

/ 20 (pp.13, 14),

/ 2E (p. 14),

/ 2F (p.18) 30/

3A (p.19),

/ 3B-1 (p.20),

/ 38-2 (p.20) 31/ 4A-1 (p.27),

/ 4A-2 (p.27)

'32/

5A (p.28) 32/

6A (p.31),

33/ 6B-1 (p.32),

/ 6B-2 (p.32),

/ 6C (p.35),

/ 60 (p.39) 34/

7A (p.40),

/ 78 (p.41)'4/

BA (p.49)

~ o "s

)~

~.

sa NRC Issue IR Generator

~G&E 51id 91-202-A 91-202-8 91-202-C Nonconformance (NC) 91-01-01 NC 91-01-02 Cvr letter Page 2

Cvr letter Page 2

Cvr letter Page 2

Page 2

NCR Pp.

1,8 Enc.

Page 3

NCR Pp.

1, 9 Enc.

Page 5

Page 5

Page 5

Page 7

Page 8

None Hone None 10 HC 91-01-03 Page 4

NCR Page 10 Pp.

1, 3, 25 Enc.

NC 91-01-04 UI 91-01-05 Other Specific References F(1)

F(2)

F(3)

F(4)

F(5)

Page 5

NCR Pp. 2, 27 Enc.

Pp. 2, 7 Enc.

Page 9

Pp.

10, 13 Page 11 Page 11 Page 13 Page 11 Page 12 Page 13 Page 13 Page 15

. Page 15 Page 15 12 None 14 15, 16 17, 18 19 20

r'i

.0 4"

)r~~~

I