United States Nuclear Regulatory Commission - Protecting People and the Environment

ACCESSION #: 9605240250

                                   150 Lincoln Avenue
                                   Grove City, PA 16127-1898
                                   Tel 412 458 8000
                                   Fax 412 458 3574

COOPER                             Ajax [Registered Trademark]
ENERGY SERVICES                    Coberra [Registered Trademark]
                                   Cooper Bessemer [Registered Trademark]
                                   Enterprise [Trademark]
                                   En-Tronic [Registered Trademark]
                                   Penn [Trademark]
                                   Superior [Registered Trademark]

May 21, 1996

Our Ref: QCG-10272

Document Control Desk
U. S. Nuclear Regulatory Commission
Washington.  D.C. 20555

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, a division of Cooper Cameron
Corporation, hereby notifies the Commission of a potential manufacturing
defect of the KSV emergency diesel generator (EDG) system.

The potential defect concerns the fuel injection pump delivery valve
Holder (DVH), C-B part number 2-50F-049-143, contained in fuel injection
pumps 2-50F-049-004, 2-50F-049-005 and 2-50F-030-004 supplied by Haynes
Corporation.  The defect noted has been the development of cracks
compromising the integrity of the DVH.  The cracks could leak fuel
causing degraded performance and/or fire hazard.

The defect has been limited to DVH's of Lot No. LCH. 184.  The cracks
have, become apparent after 160 to 250 hours of operating time.  Five
failures have been reported: Niagara Mohawk (NMP2) 8/95, Arizona Public
Service (PVNGS) 2/96.  Commonwealth Edison (Zion-2 DVH's) 3/96, and
Pennsylvania Power and Light (SSES) 4/96.  The apparent cause of the
cracking concerns characteristics of the material near the center of the
bar from which they were made in combination with the drilled hole
surface finish.  Evidence to date indicates that not all DVH's of Lot No.
LCH 184 are prone to cracking.  However, there is no non-destructive
method to determine those prone to cracking.

Either of two recommended corrective actions are possible.  Note that a
technical evaluation indicates that the engine would operate normally for
an extended period of time with one or more cracked DVH's, as the leakage
is insignificant in relation to the normal flow.

Page 2
May 21, 1996
OCG-10272

Recommended Corrective Action:

1]   Replace all DVH's of Lot No. LCH 184. This may be accomplished as
     the unit is available for normal maintenance.

2]   Monitor and replace only those which develop leaks.

See attached Exhibit 1 for affected part numbers/serial numbers,
utilities and sites.

In addition, preliminary information has indicated that DVH lot 304 may
also be prone to cracking for the same reasons.  Although none have
cracked to date, continued monitoring and observation is recommended.

If you have questions concerning this report, please contact Andrew P.
Steffan, Supervisor, Quality Engineering at 412-458-3455 or John M.
Horne, Manager, Nuclear and Analytical Engineering at 412-458-3543.

Sincerely,

COOPER CAMERON CORPORATION

J. D. Mowery
Vice President and General Manager

Attachment

/kll

cc:  D.  T. Blizzard - CES/GC
     J.  M  Horne - CES/GC
     A.  D.  Gillette - CES/GC
     M.  A.  Schleigh - CES/GC
     P.  J.  Shimek- CES/GC
     L.  T.  Stewart - CES/GC
     A.  P.  Steffan - CES/GC
     File:   K5fa37

Page 3
May 21, 1996
QCG-10272

Copies to:

Mr.  Walter Haass                  Mr.  Terry O'Brien
U. S.  Nuclear Regulatory          Commonwealth Edison Co.
  Commission                       1400 Opus Place
One White Flint North              Downers Grove, IL 60515
Washington, DC 20555
                                   Mr. Lenny Schiavone
                                   Niagara Mohawk Power Corp.
Mr.  Gary Hunt                     301 Plainfield Road
Houston Lighting and Power         North Syracuse, NY 13212
South Texas Project
Wadsworth, TX 774-93               Ms.  Kathleen Russo
                                   Niagara Mohawk Power Corp.
Mr.  James Kenny                   Nine Mile Road - Unit 2
Licensing Group Supervisor         P. O. Box 63
Pennsylvania Power and Light       Lycoming, NY 13093
Two North Ninth Street Annex 6 1
Allentown, PA 18101                Mr.  Neil Thibodaux
                                   Arizona Public Service
Mr.  Matthew Heidorn               Palo Verde Nuclear Generating Station
Pennsylvania Power and Light       P. O. Box 52034 Mail Station 7566
Susquehanna Steam Electric Station Phoeniz, AZ 85072-2034
P.  O. Box 467
Berwick, PA 18603                  Mr.  Thomas Bradish
                                   Manager, Nuclear Regulatory Affairs
Mr. Terence Bannon                 Arizona Public Service
Licensing Group ALPHA 6 1          P. O. Box 52034 Mail Station 7636
Pennsylvania Power and Light       Phoeniz, AZ 85072-2034
2 North Ninth Street
Allentown,  PA 18101               Mr. Terry Vandevoort
                                   Commonwealth Edison
Mr.  David Baran                   Zion Generating Station
Commonwealth Edison Co.            101 Shiloh Blvd.
Byron Nuclear Power Station        Zion, IL 60099
4450 North German Church Rd.
Byron, IL 61010                    Mr. Arthur G. Killinger
                                   MPR Associates, Inc.
Mr.  Michael Kneble                320 King Street
EnTergy Associates                 Alexandria, VA 22314-3238
Louisiana Power and Light
Waterford 3 SES
Highway 18
Taft, LA 70006

Mr. Dave Gustafson
Commonwealth Edison Co.
Braidwood Nuclear Power Station
Tech Staff Electrical Group
Route 1, Box 84
Braceville, IL 60407

Mr. Doug Mullen
Nebraska Public Power District
Cooper Nuclear Station
P. O. Box 98
Brownville, Nebraska 68321

QCG-10272                     EXHIBIT                         Page 1 of 4
May 21, 1996

                         Part No. 2-50F-049-143

     C-B S/N        Qty       Utility/Site

1C45                 4        Pennsylvania Power and Light-SSES
YY36                64        Niagara Mohawk-NMP2
*1E54               24        Commonwealth Edison - Braidwood
**1C45              50        Pennsylvania Power and Light- SSES
**1C45              100       Arizona Public Service-PVNGS
*Lot S/N 1E54 contains 15 of 24 Lot LCH 184.
**Lot S/N 1C45 contains 49 of 150 Lot LCH 184.

                         Part No. 2-50F-030-004

     Pump S/N                 Utility/Site

114831                        Pennsylvania Power and Light- SSES
117951
122475                        Niagara Mohawk - NMP2
120058
120060
122473
117926                        Pennsylvania Power and Light- SSES
117959

QCG-10272                       EXHIBIT                       Page 2 of 4
May 21, 1996

                         Part No.  2-50F-049-004

     Pump Serial No.          Utility/Site

891232                        Commonwealth Edison - Byron
891213                        Niagara Mohawk-NMP2
891229
891230
9003038
9003045
9003047
9003049
8902050

87010010                      Commonwealth Edison - Byron
891204
118909
891220
891224
891222
891211
891205
118574
891240
891247
118923
9006002
120082
87010004
891219
891242
891250
891241
891218
119030

118902                        Arizona Public Service -PVNGS
118954
119089
119107
119802
118927
119074
119091
119796
122529

QCG-10272                       EXHIBIT                       Page 3 of 4
May 21, 1996

                         Part No.  2-50F-049-004

  Pump Serial No.             Utility/site

122495                        Commonwealth Edison - Zion
114863
87110002
87110010
87110008
87110018
114291
115853
87110003
87110006
8902043
87110016
87110005
114311
87110017
114309
87110001
122491
87110004
87110012

119025                        Commonwealth Edison - Byron

120072                        Commonwealth Edison - Byron
120131
120084
122492
9003019                       Commonwealth Edison Braidwood
8902024
9003013
8902014
8902010
8902021
9003012

QCG-10272                       EXHIBIT                       Page 4 of 4
May 21, 1996

Part No.  2-50F-049-004

  Pump Serial No.             Utility/Site
117947                        Arizona Public Service - PVNGS
9012014
9012016
9012018
9012019
9012060
9109014
9103022
9109013
9109022
9109003
9109021
9102005
9109028
9012043
9003003
9003037
9012004
9012007
9012020
9012037
9103017
9103021
9103018
9109029
9109027
9109017
9109020

9109019
9012039
9012009
9012011
9012012
9012013
9012023
9012041
9103019
9103023
9103020
9103025
9109022
9109031
9103016
9109024

GENERAL INFORMATION or OTHER            EVENT NUMBER: 30520

LICENSEE: COOPER ENERGY SERVICES        NOTIFICATION DATE: 05/22/96
    CITY: GROVE CITY     REGION: 1      NOTIFICATION TIME: 09:24 [ET]
  COUNTY:                STATE: PA      EVENT DATE:        05/22/96
LICENSE#:                AGREEMENT: N   EVENT TIME:        00:00[EDT]
  DOCKET:                               LAST UPDATE DATE:  05/22/96

                                             NOTIFICATIONS

NRC NOTIFIED BY: JOHN D. MOWREY         VERN HODGE, NRR/PCEB NRR
HQ OPS OFFICER: LEIGH TROCINE

EMERGENCY CLASS: NOT APPLICABLE
10 CFR SECTION:
CDEF 21.21 (b) (2)  DEFECTS/NONCOMPLIANCE

                               EVENT TEXT

POTENTIAL (10 CFR PART 21) MANUFACTURING DEFECT OF THE KSV
EMERGENCY
DIESEL GENERATOR (EDG) SYSTEM REPORTED BY COOPER ENERGY SERVICES.

THE DEFECT CONCERNS THE FUEL INJECTION PUMP DELIVERY VALVE HOLDER
(DVH)
C-B PART NUMBER 2-50F-049-143, CONTAINED IN FUEL INJECTION PUMPS 2-50F-
049-004, 2-50F-049-005, AND 2-50F-030-004 SUPPLIED BY HAYNES CORPORATION.
THE DEFECT NOTED HAS BEEN THE DEVELOPMENT OF CRACKS COMPROMISING
THE
INTEGRITY OF THE DVH.  THE CRACKS COULD LEAK FUEL CAUSING DEGRADED
PERFORMANCE AND/OR FIRE HAZARD.  THE DEFECT HAS BEEN LIMITED TO DVHs
WITH
LOT NUMBER LCH-184, AND THE CRACKS BECOME APPARENT AFTER 160 TO 250
HOURS
OF OPERATING TIME.  THE APPARENT CAUSE OF THE CRACKING CONCERNS
CHARACTERISTICS OF THE MATERIAL NEAR THE CENTER OF THE BAR FROM
WHICH
THEY WERE MADE IN COMBINATION WITH THE DRILL HOLE SURFACE FINISH.
EVIDENCE TO DATE INDICATES THAT NOT ALL DVHs OF LOT NUMBER LCH-184
ARE
PRONE TO CRACKING.  HOWEVER, THERE IS NO NON-DESTRUCTIVE METHOD TO
DETERMINE THOSE PRONE TO CRACKING.  A TECHNICAL EVALUATION
INDICATES THAT
THE ENGINE WOULD OPERATE NORMALLY FOR AN EXTENDED PERIOD OF TIME
WITH ONE
OR MORE CRACKED DVHs AS THE LEAKAGE IS INSIGNIFICANT IN RELATION TO
THE
NORMAL FLOW.  THE FOLLOWING FAILURES HAVE BEEN REPORTED TO COOPER
ENERGY
SERVICES: NINE MILE POINT 2 (AUGUST 1995), PALO VERDE (FEBRUARY 1996),
ZION 2 (MARCH 1996), AND SUSQUEHANNA (APRIL 1996).  THE ATTACHMENT TO
THIS 10 CFR PART 21 NOTIFICATION LISTED AFFECTED PART NUMBERS/SERIAL
NUMBERS FOR THE FOLLOWING SITES: BRAIDWOOD, BYRON, NINE MILE POINT 2,
PALO VERDE, SUSQUEHANNA, AND ZION.

IN ADDITION, PRELIMINARY INFORMATION HAS INDICATED THAT DVH LOT
NUMBER
304 MAY ALSO BE PRONE TO CRACKING.  ALTHOUGH NONE HAVE CRACKED TO
DATE,
COOPER ENERGY SERVICES IS RECOMMENDING CONTINUED MONITORING AND
OBSERVATION.

                                 COOPER
                             ENERGY SERVICES
                         Quality Assurance Dept.
                           150 Lincoln Avenue
                          Grove City, PA 16127

PH: (412) 458-8000                                    FAX: (412) 458-3563

PH: (412) 458-8000

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as soon as possible at (412) 458-3575

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