Part 21 Report - 1999-222

ACCESSION #: 9905140213

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RG AND E

ROCHESTER GAS AND ELECTRIC CORPORATION
89 EAST AVENUE, ROCHESTER, N. Y. 14649-0001
AREA CODE 716 546-2700

ROBERT C. MECREDY
Vice President
Nuclear Operations

May 7, 1999

U.S. Nuclear Regulatory Commission
Document Control Desk

Attn:	Guy S. Vissing Project Directorate I-1 Washington, D.C. 20555
Subject:	10 CFR Part 21 30 Day Report R.E. Ginna Nuclear Power Plant

Docket No. 50-244

Dear Mr. Vissing:

The attached 10 CFR 21 report is hereby submitted in accordance with 10 CFR Part 21, Reporting of Defects and Noncompliance, Section 21 (d) (3) (ii), which requires "Written notification to the NRC ... on the identification of a defect or a failure to comply".

Very truly yours, Robert C. Mecredy

xc:

Mr. Guy S. Vissing (Mail Stop 8C2) Project Directorate I-1 Division of Reactor Projects - I/II Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, D.C. 20555 Regional Administrator, Region I U.S. Nuclear Regulatory Commission 475 Allendale Road King of Prussia, PA 19406

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U.S. NRC Ginna Senior Resident Inspector

10CFR21 30 DAY WRITTEN REPORT

I. NAME AND ADDRESS OF THE INDIVIDUAL INFORMING THE COMMISSION:

NAME:	Robert C. Mecredy Vice President Nuclear Operations Group
ADDRESS:	Rochester Gas & Electric Corporation 89 East Avenue Rochester, New York 14649

II. IDENTIFICATION OF THE FACILITY, THE ACTIVITY, OR THE BASIC COMPONENT SUPPLIED FOR SUCH FACILITY WHICH FAILS TO COMPLY OR CONTAINS A DEFECT:

The basic component is the ALCO turbocharger (Model 730), installed on the "B" Emergency Diesel Generator (ALCO Model 16-251F) at Ginna Station. A replacement turbocharger was installed on the "B" Emergency Diesel Generator (EDG) on March 25, 1999.

III. IDENTIFICATION OF THE FIRM CONSTRUCTING THE FACILITY OR SUPPLYING THE BASIC COMPONENT WHICH FAILS TO COMPLY OR CONTAINS A DEFECT:

The turbocharger was supplied to RG&E by Coltec Industries.

Coltec Industries
Fairbanks Morse/ALCO Engine Division
701 White Avenue
Beloit, WI 53511

Coltec procured the turbocharger from Elliot Turbocharger Group as a commercial item and performed a Commercial Grade Dedication prior to providing it to Rochester Gas and Electric as an Appendix B component.

IV. NATURE OF THE DEFECT OR FAILURE TO COMPLY AND THE SAFETY HAZARD WHICH IS CREATED OR COULD BE CREATED BY SUCH DEFECT OR FAILURE TO COMPLY:

The nature of the defect consisted of a manufacturing deficiency in the replacement turbocharger for the "B" EDG. The machining of a drain port in the exhaust turbine side of the intermediate casing was omitted, preventing engine lubricating oil from being able to drain back to the engine sump from the turbocharger shaft and bearings. Therefore, the replacement turbocharger exhaust turbine side drain port did not function as the design intended. This defect created the condition where engine lube oil was being directed into cylinders through the exhaust manifold piping. With oil in the cylinders, the engine could have been seriously damaged when started. This would have resulted in a loss of redundancy in the on-site sources of 480V AC power. However, the EDG was not operable at the time the defect was discovered. The deficiency was first indicated when the pre-lube system was in operation.

The "B" EDG was being prepared for post-maintenance testing on March 29, 1999, while the plant was defueled. No actual safety hazard existed, because the post-maintenance testing had not been performed.

V. THE DATE ON WHICH THE INFORMATION OF SUCH DEFECT OR FAILURE TO COMPLY WAS OBTAINED:

The information was obtained on March 30, 1999, following disasssembly of the turbocharger.

VI. IN THE CASE OF A BASIC COMPONENT WHICH CONTAINS A DEFECT OR FAILS TO COMPLY, THE NUMBER AND LOCATION OF ALL SUCH COMPONENTS IN USE AT, SUPPLIED FOR, OR BEING SUPPLIED FOR GINNA STATION:

There are 2 (two), permanently installed EDGs at Ginna Station. Only the "B" EDG was provided with a replacement turbocharger, which was found to contain the manufacturing deficiency stated in IV. above. The turbocharger on the "A" EDG was not replaced, and does not contain the stated deficiency.

VII. THE CORRECTIVE ACTION WHICH HAS BEEN, IS BEING, OR WILL BE TAKEN; THE NAME OF THE INDIVIDUAL OR ORGANIZATION RESPONSIBLE FOR THE ACTION; AND THE LENGTH OF TIME THAT HAS BEEN OR WILL BE TAKEN TO COMPLETE THE ACTION:

The corrective action taken was to remove the new replacement turbocharger from the "B" EDG and disassemble and inspect it. During disassembly, it was discovered that the intended drain port had not been machined into the intermediate casing. Under the supervision of the manufacturer's representative, the intermediate casing was reworked to original requirements, opening the drain path. The turbocharger was reassembled and reinstalled on the "B" EDG. Post-maintenance and operability testing was successfully performed and the "B" EDG declared operable on April 2, 1999.

Personnel from Rochester Gas and Electric Nuclear Engineering Services and from Ginna Station Maintenance Department were responsible for the corrective action, with the assistance of the manufacturer's representative. Corrective actions were completed on April 2, 1999.

VIII. ANY ADVICE RELATED TO THE DEFECT OR FAILURE TO COMPLY ABOUT THE FACILITY, ACTIVITY, OR BASIC COMPONENT THAT HAS BEEN, IS BEING, OR WILL BE GIVEN TO PURCHASERS OR LICENSEES:

A missing oil drain port cannot be observed without disassembly of the turbocharger. In nuclear service applications, the use of a Coltec Industries Model 730 turbocharger on the ALCO 251 engine is unique to Ginna Station. Organizations procuring or installing turbochargers supplied by Coltec Industries under an Appendix B program should consider the potential for this deficiency. This issue will be discussed at a future meeting of the ALCO Owners' Group.

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