United States Nuclear Regulatory Commission - Protecting People and the Environment

ACCESSION #: 9510030061

RGandE
ROCHESTER GAS AND ELECTRIC CORPORATION o 89 EAST AVENUE, ROCHESTER,
N.Y.14649-0001  AREA CODE 776 546-2700

ROBERT C.  MECREDY
Vice President
Nuclear Operations

                                             September 25, 1995

U.S.  Nuclear Regulatory Commission
Document Control Desk
Attn: Allen R.  Johnson
      Project Directorate I-1
Washington, DC 20555

Subject:  10 CFR Part 21 30 Day Report
          R.E.  Ginna Nuclear Power Plant
          Docket No.  50-244

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

                                        Very truly yours,

                                        Robert C.  Mecredy

xc:  U.S.  Nuclear Regulatory Commission
     Mr.  Allen R.  Johnson (Mail Stop 14B2)
     Project Directorate I-1
     Washington, D.C.  20555

     Regional Administrator
     U.S.  Nuclear Regulatory Commission
     Region I
     475 Allendale Road
     King of Prussia, PA 19406

     U.S.  NRC Ginna Senior Resident Inspector

                                                                   PAGE 2

                      10CFR21 30 DAY WRITTEN REPORT

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

               NAME:     Robert C.  Mecredy
                         Vice President Nuclear Operations

               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 facility is the R.  E.  Ginna Nuclear Power Plant.  The
          basic component is the engine-driven, internal gear, positive
          displacement pump used as the fuel oil booster pump on the "A"
          and "B" Emergency Diesel Generators (EDG)

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

          The pumps of concern were manufactured by:

               Tuthill Corporation
               Tuthill Pump Division
               12500 South Pulaski Road
               Chicago, Illinois 60658

          The pumps were purchased commercial-grade, were dedicated by
          Rochester Gas & Electric Corporation (RG&E), and met all
          technical requirements included in the procurement documents.

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 pumps were supplied as exact replacements (by model number)
          for the original components and were tested to meet pump
          performance requirements, established within the EDG vendor
          technical manual (VTM), that incorporated requirements of the
          pump manufacturer (Tuthill Corporation).

                                                                   PAGE 3

          During a scheduled maintenance outage of the "B" EDG (in
          August, 1995), fuel oil booster pump post-maintenance testing
          revealed fuel oil system pressure readings of 32 PSIG, in the
          "required action" low range.  (This "required action" range is
          an administrative band below the normal operating range of 35
          to 45 PSIG, established by RG&E based on VTM guidance,
          historical performance data, and the application of ASME Code
          OMa-1988.) After other trouble-shooting activities were
          performed, the fuel oil booster pump was replaced with a new
          spare pump.  With the new spare pump installed, post-
          installation testing revealed that fuel oil system pressure was
          still in the "required action" low range.  This pump was then
          replaced with a second new pump and an unacceptable pressure
          was again observed.

          The pump manufacturer VTM states that pump capacity is affected
          by rotor end play and can be adjusted by removing/adding shims
          from/to the pump end plates.  A third pump (a rebuilt pump that
          had been previously used and had produced satisfactory fuel oil
          system pressure when installed) was removed from stock.  The
          shimming on this pump was adjusted to reduce axial rotor end
          play, and then the pump was installed on the "B" EDG.  Testing
          demonstrated that fuel oil system pressure for the "B" EDG was
          restored to an acceptable pressure of 44 PSIG.

          The potential existed that fuel oil booster pumps could be
          procured that meet the pump manufacturer performance
          requirements, but fail to satisfy fuel oil system pressure
          requirements.  (Note that during the procurement of the spare
          pumps, they were satisfactorily tested to pump manufacturer
          performance requirements.) If the deficient fuel oil booster
          pump had been installed and post-installation testing had not
          been performed to detect this defect, a substantial safety
          hazard could have existed.  The basis for this conclusion is
          the fuel oil booster pump would not achieve the fuel oil system
          pressure administratively established by RG&E; therefore, the
          EDG could not be guaranteed to carry its full design loading
          under all postulated conditions.

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

          The information was obtained during maintenance trouble-
          shooting activities performed on August 3 to August 5, 1995.

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 two deficient Tuthill model 2CF-CC pumps, located as
          spare pumps in stock.

                                                                   PAGE 4

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:

          On August 5, 1995, Ginna Maintenance personnel installed a
          rebuilt fuel oil booster pump on the "B" EDG that restored
          acceptable fuel oil system pressure to the "B" EDG.

          At no time was the "B" EDG declared operable with a deficient
          fuel oil booster pump installed.

          No corrective action was necessary for the "A" EDG, which was
          not affected by this condition.

          RG&E Procurement Engineering is working with the pump
          manufacturer and the EDG original equipment manufacturer (OEM)
          to clarify the required pump performance requirements.  Upon
          conclusion of this effort, Procurement Engineering will revise
          the dedication plan for these pumps.  These actions are
          expected to be completed by March 1, 1996.

          The two deficient spare fuel oil booster pumps have been placed
          on "hold", pending completion of these actions.

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:

          The potential exists that fuel oil booster pumps could be
          procured to meet the pump manufacturer booster pump performance
          requirements, but fail to satisfy fuel oil system pressure
          requirements (established either by the EDG manufacturer or the
          end-user).

          Subsequent to the installation of a new fuel oil booster pump,
          if fuel oil system pressure (as recommended by the diesel OEM)
          is not achieved, adjustment of pump end play clearance may
          increase pump pressure.

*** END OF DOCUMENT ***

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