Protecting People and the EnvironmentUNITED STATES NUCLEAR REGULATORY COMMISSION
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.
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