United States Nuclear Regulatory Commission - Protecting People and the Environment

ACCESSION #: 9506220313

Cooper Industries
Cooper-Bessemer
Reciprocating Products Division
150 Lincoln Avenue
Grove City, PA 16127-1898
412 458-8000

June 15, 1995                      COOPER

                                        Cooper Energy Services

Our Ref: QCG-10167

Document Control Desk
U.S. Nuclear Regulatory Commission                Enterprise
Washington, D.C.  20555                           Report #167

Dear Sir:

In accordance with the requirements of the Nuclear Regulatory Commission
Title 10, Chapter 1, Code of Federal Regulations, Part 21, Cooper-
Bessemer Reciprocating Products Division, a division of Cooper
Industries, hereby notifies the Commission of a potential defect in a
component of a DSRV and DSR Enterprise Standby Diesel Generator System.

There exists a potential problem with a Bellofram Air Cylinder, Cooper
part number AJ-009-000 which is used to control a butterfly valve in the
diesel engine intake air system.  These air cylinders are installed on
all nuclear Enterprise EDG's currently in service.

     UTILITY             SITE                SERIAL NO.     MODEL

LILCO                    Shoreham            74010-12       DSR-48
ENTERGY                  Grand Gulf          74033-34       DSRV-16-4
GULF STATES              River Bend          74039-40       DSR-48
CP&L                     Shearon Harris      74046-48       DSRV-16-4
DUKE                     Catawba             75017-20,      DSRV-16-4
                                             74049
CLEVELAND ELEC           Perry               75051-54       DSRV-16-4
TVA                      Bellefonte          75080-83       DSRV-16-4
TVA                      Hartsville          77024          DSRV-16-4
TU ELECTRIC              Comanche Peak       76001-04       DSRV-16-4
GEORGIA POWER            Vogtle              76021-24       DSRV-16-4

INTERNATIONAL SITES

KOREA ELECTRIC           KORI 3 & 4          79029-32       DSRV-16-4
KOREA ELECTRIC           Yonggwang 1 & 2     81021-24       DSRV-16-4
TAIWAN                   Kuosheng            75005-08       DSR-48
TAIWAN                   Maanshan            78006-09       DSRV-16-4

Page 2
QCG-10167
June 15, 1995

On May 16, 1995, a newly installed air cylinder failed at Grand Gulf
Nuclear Station on engine S/N 74033, during their refueling outage RF07,
after fewer than 12 actuations the left bank air cylinder piston/rod
assembly separated which allowed the butterfly valve to go closed.  With
the left bank butterfly valve closed, the engine tried to maintain load
with the right bank cylinders, which caused the right bank turbocharger
to be overloaded and the EDG was shut down.

Inspection of the failed cylinder revealed that the piston/piston rod
assembly had failed in the area where they were joined by projection
welding.  The root cause of this failure was a poor quality weld between
the piston/piston rod.

Cooper-Bessemer has discussed this failure with the manufacturer of the
air cylinder, Bellofram Corporation, and has reviewed their processes
utilized in manufacturing and testing of the affected cylinder.
Bellofram Corporation reports no known failures in other commercial
applications of this type of air cylinder.  Cooper-Bessemer also has no
previously reported failures of this cylinder.  Based on this information
from Bellofram, Cooper-Bessemer has judged this failure to be an isolated
incident, with no further corrective action required at affected
utilities or at Cooper-Bessemer.

Our investigation into this matter was concluded on June 12, 1995.  If
you have any questions concerning this report, please contact Ronald G.
Billig, Supervisor, Enterprise Engineering or John R. Schneider, Quality
Assurance Manager at 412-458-8000.

Sincerely,

COOPER CAMERON CORPORATION

John D. Mowery
Vice President and
General Manager

JDM/kll

cc:  J. R. Schneider - CES/GC
     B. R. Sedelmyer - CES/GC
     A. D. Gillette - CES/GC
     D. T. Blizzard - CES/GC
     J. M. Horne - CES/GC
     R. G. Billig- CES/GC
     B. C. Guntrum - CES/Alameda
     R. L. Nimmo - CES/Alameda
     Lee Duck - CES/Alameda

Page 3                   June 15, 1995                 QCG-10167

Copied to:

     S. S. OwYoung - CES/Alameda
     J. R. Andrews - CES/Alameda
     R. A. Johnston - CES/Alameda
     File: K5fa35 - Bellofram Air Cyl.

     Mr. Walter Haass - NRC
     One White Flint North
     Mailstop 9D4
     Washington, DC 20555

     Entergy Operations
     P. O. Box 429
     Echelon One
     1340 Echelon Parkway
     Jackson, MS 39286-1995
     Attn:     T. H. Cloninger
               Vice Pres. Nucl. Eng.

     Carolina Power and Light Co.
     Harris Nuclear Project

     P. O. Box 165
     New Hill, NC 27562
     Attn:     William Robinson
               Plant Gen. Mgr.

     Carolina Power and Light Co.
     P. O. Box 1551
     Raleigh, NC 27602
     Attn:     W. S. Orser
               Exec. Vice President

     Carolina Power and Light Co.
     Shearon Harris Nuclear Project
     P. O. Box 165
     New Hill, NC 27562
     Attn:     Mickey Hamby

     Carolina Power and Light Co.
     Brunswick Nuclear Plant
     NC Hwy. 87, 2-1/2 Mi. North
     Southport, NC 28461
     Attn:     Roy A. Anderson
               Vice President

Page 4              June 15, 1995                 QCG-10167

Copied to:

     Carolina Power and Light Co.
     Robinson Nuclear Project
     SC Hwy. 151 and 23, Box 790
     Hartsville, SC 29550
     Attn:     C. S. Hinnant
               Vice President

     Cleveland Electric Illuminating
     Perry Nuclear Power Plant
     P. O. Box 97
     Perry, OH 44081
     Attn:     M. Lister

     Cleveland Electric Illuminating
     Perry Nuclear Power Plant
     P. O. Box 97
     Perry, OH 44081
     Attn:     Russell J. Tadych
               Manager, Quality Control

     Cleveland Electric Illuminating
     Perry Nuclear Power Plant
     P. O. Box 97
     Perry, OH 44081
     Attn:     Harold M. Coon

     Cooper-Enterprise Clearinghouse
     Duke Engineering & Service
     230 South Tryon St.
     P.O. Box 1004
     Charlotte, NC 28201-1004
     Attn:     G. A. Harrison

     Duke Power Co.
     Nuclear Generation Dept.
     P. O. Box 1007
     Charlotte, NC 28201-1007
     Attn:  Mgr., Nuclear Safety

     Duke Power Co.
     Nuclear Generation Dept.
     P. O. Box 1007
     Charlotte, NC 28201-1007
     Attn:  W. T. Robertson
            V. P. Procurement

Page 5                   June 15, 1995                 QCG-10167

Copied to:

     Entergy
     P. O. Box 429
     Echelon One
     1340 Echelon Parkway
     Jackson, MS 39286-1995
     Attn:  F. W. Titus
            Vice President, Engineering

     Entergy
     P. O. Box 756
     Port Gibson, MS 39150
     Attn:  C. R. Hutchinson
            Vice Pres., Operations-GGNS

     Entergy
     P. O. Box 756
     Port Gibson, MS 39150
     Attn:  D. L. Pace, Director
            Design Engineering-GGNS

     Entergy
     P. O. Box 756
     Port Gibson, MS 39150
     Attn:  M. J. Meisner
            Director, NS & RA

     Manager, Quality Services
     Entergy Operations
     Box 756
     Port Gibson, MS 39150

     Southern Nuclear Operating Company
     Vogtle Project
     P. O. Box 1295
     Birmingham, AL 35201
     Attn:  Mgr., Engineering
            and Licensing

     Georgia Power Co.
     Plant Vogtle
     P. O. Box 1600
     Waynesboro, GA 30830
     Attn:  Mr. W. B. Shipman
            General Manager

Page 6                   June 15, 1995                 QCG-10167

Copied to:

     Gulf States Utilities
     P. O. Box 220
     St. Francisville, LA 70775
     Attn:     L. A. England
               Director Nuclear Licensing

     Long Island Power Authority
     Shoreham Nuclear Power Station
     North Country Rd.
     Wading River, NY 11792
     Attn:  Mgr. Licensing & Regulatory
            Compliance Department

     Tennessee Valley Authority
     1101 Market Street, LP 4F
     Chattanooga, TN 37402
     Attn:  Mr. M. J. Fecht
            Manager, Nuclear Experience Review

     TU Electric - Production Division
     Group Vice President - Nuclear
     Skyway Tower
     400 North Olive Street, L.B. 81
     Dallas, TX 75201
     Attn:  C. L. Terry

     Mr. Koh, Kyoo-Kun
     Plant Mgr., Kori 3 & 4
     Korea Electric Power Corp.
     216 Ko-Ri Jangan-Up Yangsan-Gun
     Kyung-Nam, Korea 626-950

     Mr. Hong, Jo Boo
     Manager, Nuclear Power Generation Dept.
     Korea Electric Power Corporation
     167, Samsong-Dong, Kangnam KU
     Seoul, 137-791 Korea

     Mr. Lee, Hee-Sung
     Plant Mgr., Yonggwang Nuclear Unit 1 & 2
     Korea Electric Power Co.
     517, Kyema-Ri Hong Nong-Eup
     Yonggwang-Gun Jeon Nam
     Korea 513-880

Page 7                   June 15, 1995                 QCG-10167

Copied to:

     Mr. T. R. Ho, Superintendent
     Taiwan Power Company
     Kuosheng Nuclear Power Station
     60 Pa-Tou Yeh-Liu Village
     Wan Li Hsiang, Taipei Hsien
     (20703), Taiwan, R.O.C.

     Mr. A. H. Jeng
     Director, Nuclear Safety Dept.
     Taiwan Power Company
     242 Roosevelt Road, Section 3
     Taipei 100, Republic of China

     Mr. S. H. Soong
     Station Superintendent
     Third Nuclear Power Station
     Taiwan Power Company
     P. O. Box 39
     Heng-Chun, Ping-Tung Hsein
     Taiwan, 924 R.O.C.

*** END OF DOCUMENT ***

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