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Emergency Diesel Generators NUREG/CR-68 19, Vol. 1 INEEL/EXT-99-006 13 Common-Cause Failure Event Insights Emergency Diesel Generators Idaho National Engineering and Environmental Laboratory U.S. Nuclear Regulatory Commission Office of Nuclear Regulatory Research ,,,g, Washington, DC 20555-0001 AVAILABIUTY OF REFERENCE MATERIALS IN NRC PUBLICATIONS NRC Reference Material Non-NRC Reference Material As of November 1999, you may electronically access Documents available from public and special technical NUREG-series publications and other NRC records at libraries include all open literature items, such as NRC's Public Electronic Reading Room at books, journal articles, and transacUons, Federal htto://www.nrc.aov/readina-rm.html. Publicly released Register notces, Federal and State legislaton, and records include, to name a few, NUREG-series congressional reports. Such documents as theses, publications; Federal Register notices; applicant, dissertations, foreign reports and translatons, and licensee, and vendor documents and correspondence; non-NRC conference proceedings may be purchased NRC correspondence and intemal memoranda; from their sponsoring organizaton. bulletins and informaton notices; inspection and investigative reports; licensee event reports; and Copies of industry codes and standards used In a Commission papers and their attachments. substantive manner in the NRC regulatory process are maintained at- NRC publicatons in the NUREG series, NRC The NRC Technical Ubrary regulations, and Title 10, Energy, in the Code of Two White Flint North Federal Regulations may also be purchased from one 11545 Rockville Pike of these two sources. Rockville, MD 20852-2738 1. The Superintendent of Documents U.S. Govemment Printing Office These standards are available in the library for Mail Stop SSOP reference use by the public. Codes and standards are Washington. DC 20402-0001 usually copyrighted and may be purchased from the Intemet bookstore.gpo.gov originating organization or. If they are American Telephone: 202-512-1800 National Standards, from- Fax: 202-512-2250 American National Standards Institute 2. The Natonal Technical Informaton Service 11 West 42 nd Street Springfield, VA 22161-0002 New York, NY 10036-8002 www.ntis.gov www.ansi.org 1-800-553-6847 or, locally, 703-605-000 212-842-4900 A single copy of each NRC draft report for comment is available free, to the extent of supply, upon written Legally binding regulatory requirements are stated only in laws; NRC regulations; licenses, icluding request as follows: technical specifications; or orders, not in Address: Office of the Chief Information Officer, Reproduction and Distribution NUREG-series publications. The views expressed In contractor-prepared publications in this series are Services Section of the NRC. U.S. Nuclear Regulatory Commission not necessarily those Washington, DC 20555-0001 The NUREG series comprises (1) technical and E-mail: [email protected] administrative reports and books prepared by the Facsimile: 301-415-2289 staff (NUREG-XXX) or agency contractors Some publications in the NUREG series that are (NUREG/CR-XXXX), (2) proceedings of conferences (NUREG/CP-XXXX), (3) reports posted at NRC's Web site address htto://www.nrc.aovlreadina-rm/doc-collections/nureas resulting from intematonal agreements (NUREG/IA-XXXX), (4) brochures are updated periodically and may differ from the last (NUREGIBR-XXXX), and (5) compilations of legal printed version. Although references to material found orders of the Commission and Atomic on a Web site bear the date the material was accessed, decisions and and Safety Licensing Boards and of Directors' the material available on the date cited may decisions under Section 2.206 of NRC's regulations subsequently be removed from the site. (NUREG-0750). DISCLAIMER: This report was prepared as an account of work sponsored by an agency of the U.S. Govemment. Neither the U.S. Govemment nor any agency thereof, nor any employee, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for any third party's use, or the results of such use, of any information, apparatus, product, or process disclosed in this publicaton, or represents that its use by such third party would not infringe privately owned rights. NUREG/CR-6819, Vol. 1 INEEL/EXT-99-00613 Common-Cause Failure Event Insights Emergency Diesel Generators Manuscript Completed: March 2003 Date Published: May 2003 Prepared by T. E. Wierman, INEEL D. M. Rasmuson, NRC N. B. Stockton, INEEL Idaho National Engineering and Environmental Laboratory Idaho Falls, ID 83415 T.R Wolf, NRC Project Manager Prepared for Division of Risk Analysis and Applications Office of Nuclear Regulatory Research U.S. Nuclear Regulatory Commission Washington, DC 20555-0001 NRC Job Code Y6194 ABSTRACT This report documents a study performed on the set of common-cause failures (CCF) of emergency diesel generators (EDG) from 1980 to 2000. The data studied here were derived from the NRC CCF database, which is based on US commercial nuclear power plant event data. Ihis report is the result of an in- depth review of the EDO CCF data and presents several insights about the EDO CCF data. The objective of this document is to look beyond the CCF parameter estimates that can be obtained from the CCF data, to gain further understanding of why CCF events occur and what measures may be taken to prevent, or at least mitigate the effect of, EDG CCF events. This report presents quantitative presentation of the EDG CCF data and discussion of some engineering aspects of the EDG events. iii CONTENTS Abstract ............ iii Executive Summary .............. xiii Foreword ............. xvii Acknowledgements .. ............ xix Acronyms ................. xxi Glossary ... .. .xxiii 1. Introduction...1 1.1 Background .1 1.2 Common-Cause Failure Event Concepts .2 1.3 Report Structure .5 2. Component Description . .7 2.1 Introduction .7 2.2 Risk Significance .7 2.3 Component Description and Boundary .7 2.4 Sub-System Description .. 2.4.1 Battery 8 2.4.2 Combustion Air .8 2.4.3 Cooling .................... 8 2.4.4 Engine .9 2.4.5 Exhaust .9 2.4.6 Fuel Oil .9 2.4.7 Generator .9 2.4.8 Instrumentation and Control . 9 2.4.9 Lubrication Oil .9 2.4.10 Output Circuit Breaker .10 2.4.11 Starting Air ...... 10 2.5 Failure Modes .10 3. High Level Overview Of Emergency Diesel Generator Insights ........................................... 13 3.1 Introduction .13 3.2 CCF Trends Overview .14 v 3.3 CCF Sub-System Overview ...................... 17 3.4 CCFProximate Cause ...................... 17 3.5 CCF Coupling Factors ...................... 20 3.6 CCF Discovery Method Overview ...................... 22 3.7 Other EDG CCF Observations ...................... 23 4. Engineering Insights By Emergency Diesel Generator Sub-System ............................................. 27 4.1 ntroduction .................. 27 4.2 Instrumentation and Control .................. 29 4.3 Engine .................. 33 4.4 Fuel Oil .................. 36 4.5 Generator .................. 39 4.6 Cooling .................. 41 4.7 Starting Air .................. 44 4.8 Output Circuit Breaker .................. 47 4.9 Lube Oil .................. 49 4.10 Exhaust ........................................ 49 4.11 Battery ....................................... 50 5. Insights from EDG foreign Experience ........................................ 51 5.1 International Common-cause Data Exchange Project ............... ........................ 51 5.2 Scope of the EDG Event Collection ........................................ 51 5.3 Summary of European Events ........................................ 51 5.4 Comparison of USA and European Experience ....................................... 52 6. How To Obtain More Detailed Information ....................................... 59 7. References ......................................... 61 vi Appendix A D Summaryata .................... A-1 Appendix B Data Summary by Sub-System ................... B-i vii FIGURES Figure ES-1. Trend for all EDG CCF events. The decreasing trend is statistically significant with a p-value = 0.0001 ................................................................. xiv Figure ES-2. Proximate cause distribution for all EDG CCF events ................................................. xv Figure ES-3. Distribution of EDG events by the affected sub-system .. .......................................... xv Figure 2-1. Emergency diesel generator component boundaries ......................................................... 8 Figure 3-1. Trend for all EDG CCF events. The decreasing trend is statistically significant with a p-value = 0.0001 ................................................................. 14 Figure 3-2. Trend for Complete EDG CCF events. The decreasing trend is statistically significant with a p-value = 0.0001. The trend from 1985-2000 is not statistically significant (p-value 0.4874) ................................................................. 15 Figure 3-3. Trend for all EDG CCF events for the fail-to-start failure mode. The decreasing trend is statistically significant with a p-value = 0.0001 .......................................................... 15 Figure 3-4. Trend for all EDG CCF events for the fail-to-run failure mode. The decreasing trend is statistically significant with a p-value = 0.0001 .......................................................... 16 Figure 3-5. Sub-system distribution for all EDG CCF events ........................................................... 17 Figure 3-6. Proximate
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