United States Nuclear Regulatory Commission - Protecting People and the Environment

ACCESSION #: 9605280150

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

                                        Ajax [Registered Trademark]
                                        Coberra [Registered Trademark]
COOPER                                  Cooper Bessemer [Registered
ENERGY SERVICES                           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
QCG-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 77483                     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
Susquehanna Steam Electric Station        7566
P. O. Box 467                           Phoeniz, AZ 85072-2034
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
Pennsylvania Power and Light              7636
2 North Ninth Street                    Phoeniz, AZ 85072-2034
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-1 0272                      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

117                                Pennsylvania Power and Light- SSES
117959

QCG-1 0272                      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

*** END OF DOCUMENT ***

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