Part 21 Report - 1996-611

ACCESSION #: 9607150052 150 Lincoln Avenue Grove City, PA 16127-1898 Tel 412 458 8000 Fax 412 458 3574 Ajax [Registered Trademark] COOPER Coberra [Registered Trademark] ENERGY SERVICES Cooper Bessemer [Registered Trademark] Enterprise [Trademark] July 9, 1996 En-Tronic [Registered Trademark] Penn [Trademark] Superior [Registered Trademark] Our Ref: QCG-10291 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 Energy Services (CES), a division of Cooper Cameron Corporation, hereby notifies the Commission of a potential manufacturing defect of the Enterprise [Copyright] DSR-4 and DSRV-4 Emergency Diesel Generators (EDG's). Discussion: The potential defect concerns the starting air admission valves (block and vent valves) Enterprise part number KR-001-000. The valve operates on receipt of a start signal to admit stored air receiver pressure to the engine headers, beginning the process that rolls the engine for starting. The valves are parT of redundant starting circuits such that two are employed for a Model DSR-4 (in-line) engine and four on a Model DSRV-4 (Vee) engine. The valves were originally manufactured by Calcon Corporation. Amot Controls Corporation has since purchased the Calcon product line and maintains the design and production. The potential defect was reported to CES by Entergy Operations, Inc., River Bend Station (EOI-RBS) as three valves had failed during engine operation or while on bench test. The first valve failed on engine, failing to open fully (with the redundant valve isolated), This resulted in an insufficient supply of air to roll the engine. The second valve failed to cycle during EOI-RSS bench test. The third valve successfully passed the bench test but stuck open during its first use on engine. Page 2 July 9, 1996 QCG-10291 The above valves, and three other valves thought to be suspect were returned on January 31, 1996 to CES for evaluation. The investigation indicated no common root cause of malfunction. Probable contributing factors were spring discrepancies and valve body casting anomalies. While not found by itself to cause the reported failures, all springs were noticeably bent or lacked squared and ground ends. A recent poll of utilities indicated that no other significant failures have occurred since the issuance and implementation of CES Service Information Memo (S.I.M.) No. 379 (Redesigned spool assembly, Viton seals). S.I.M. 379 was issued 12/1/89. CONCLUSION: The investigative activities yielded no clear cause for the failures at EOI-RBS. As failure of these valves could render the EDG inoperable, and in light of the deficiencies found it is prudent to report the failures, conditions, and recommended actions under 10 CFR Part 21. RECOMMENDATIONS: 1] Verify in-service valves - each monthly surveillance run should be preceded by an air roll initiated by a single starting air admission valve. Alternate which valve is used each month to routinely verify all valves on a regular basis. 2] Return any spare valves for inspection/evaluation by CES. LIST OF AFFECTED UTILITIES SITE ENGINE SERIAL NO. Carolina Power and Light Shearon Harris 74046-48 Cleveland Electric Illuminating Perry 75051-54 Duke Power Catawba 75017-20, 74049 Entergy Operations Grand Gulf 74033-34 Entergy Operations River Bend 74039-40 Georgia Power Vogtle 76021-24 Korea Electric KORI 3 & 4 79029-32 Korea Electric Yonggwang 1 & 2 81021-24 Taiwan Power Co. Kuosheng 1 & 2 75005-08 Taiwan Power Co, Maanshan 1 & 2 78006-09 Texas Utilities Comanche Peak 76001-04 Tennessee Valley Authority Bellefonte 75080-83 Washington Public Power WNP-1 75084-85 Page 3 July 9, 1996 QCG-10291 If you have any questions concerning this report, please contact Andrew P. Steffan, Supervisor, Quality Engineering at 412-458-3455 or Ronald G. Billig, Supervisor Aftermarket Engineering at 412-458-3584. Sincerely, COOPER CAMERON CORPORATION John D. Mowery Vice President and General Manager :kll c: D. T. Blizzard - CES/GC J. M. Horne - CES/GC B. C. Guntrum - CES/Alameda R. L. Nimmo - CES/Alamada R. A. Johnston - CES/Alameda R. G. Billig - CES/GC A. P. Steffan - CES/GC File. K5fa39 Page 4 July 9, 1996 QCG-10291 Copies to: Cooper-Enterprise Clearinghouse Mr. Walter Haass Duke Engineering & Service U. S. Nuclear Regulatory Commission 230 South Tryon St. One White Flint North P. O. Box 1004 Washington, DC 20555 Charlotte, NC 28201-1004 Attn. G. A. Harrison Carolina Power and Light Co. Harris Nuclear Project Duke Power Co. P. O. Box 165 Nuclear Generation Dept. New Hill, NC 27662 P. O. Box 1006 Attn; William Robinson Charlotte, NC 28201-1006 Vice President Attn: Mgr., Nuclear Safety Carolina Power and Light Co. Duke Power Co. P. O. Box 1551 Nuclear Generation Dept. Raleigh, NC 27602 P. O. Box 1006 Attn: W. S. Orser Charlotte, NC 28291-1006 Executive Vice President Attn: W. T. Robertson Attn: Vice President, Carolina Power and Light Co. Procurement Harris Nuclear Plant P. O. Box 165 Entergy New Hill, NC 27562 P. O, Box 429 Attn: Mickey Hamby Echelon One 1340 Echelon Parkway Carolina Power and Light Co. Jackson, MS 39286-1995 Brunswick Nuclear Plant Attn: F. W. Titus (Fred) NC Hwy. 87, 2-1/2 Mi. North Vice President, Engineering Box 10429 Southport, NC 28461 Entergy Attn: Roy A. Anderson P. O. Box 756 Vice President Port Gibson, MS 39150 Attn: C. R. Hutchinson (Randy) Carolina Power and Light Co. Vice Pres., Operations-GGNS Robinson Nuclear Plant SC Hwy. 151 and 23, Box 790 Entergy Hartsville, SC 29550 P. O. Box 756 Attn: C. S. Hinnant Port Gibson, MS 32150 Vice President Attn: D. L. Pace, Director Design Engineering-GGNS Cleveland Electric Illuminating Perry Nuclear Power Plant Entergy P. O. Box 97 P. O. Box 756 Perry, OH 44081 Port Gibson, MS 39150 Attn: Russell J. Tadyeh Attn: M. J. Meisner Manager, Quality Control Director, NS&RA Cleveland Electric Illuminating Manager, Quality Services Perry Nuclear Power Plant Entergy Operations P. O. Box 97 Box 756 Perry, OH 44081 Port Gibson, MS 39150 Attn: Harold M. Coon Page 5 July 9, 1996 QCG- 10291 Southern Nuclear Operating Mr. S. J. Tsuei Company Director, Nuclear Safety Dept. Vogtle Project Taiwan Power Company P. O. Box 1295 242 Roosevelt Road, Sec. 3 Attn: Mgr., Nuclear Engineering Taipei, Republic of China and Licensing Mr. S. H. Soong Georgia Power Co. Station Superintendent Plant Vogtle Third Nuclear Power Station P. O. Box 1600 Taiwan Power Company Waynesboro, GA 30830 P.O. Box 39 Attn: Mr. W. S. Shipman Heng-Chun, Ping-Tung Hsein General Manager Taiwan. 924 R.O.C. Gulf States Utilities Mr. Koh, Kyoo-Kun P. O. Box 220 Plant Manger, Kori 3 & 4 St. Francisville, LA 70775 Korea Electric Power Corp. Attn: L. A. England 216 Ko-Ri Jangan-Up Director Nuclear Licensing Yangsan-Gun Kyung-Nam, Korea 026-950 Long Island Power Authority Shoreham Nuclear Power Station Mr. Hong, Jo Boo Box 628 Manager, Nuclear Power North Country Rd. Generation Dept. Wading River, NY 11792 Korea Electric Power Corp. Attn: Mgr. Licensing & Regulatory 167, Samsong-Dong, Kangnam KU Compliance Department Seoul, 135-791 Korea Operating Experience Manager Mr. Lee, Hee-Sung Tennessee Valley Authority Plant Manager, Yonggwang Nuclear Unit 1101 Market Street 1 & 2 BR 4J Korea Electric Power Corp. Chattanooga, TN 37402 517, Kyema-Ri Hong Nong-Eup Yonggwang-Gun Jeon Nam Korea 513-880 TU Electric - Production Division Group Vice President - Nuclear Skyway Tower 400 North Olive Street, L.B. 81 Dallas, TX 75201 Attn: C. L. Terry Washington Public Power Supply P. O. Box 460 Richland, WA 99352 Attn: Mr. L. C. Oakes Manager, WNP-1 Engineer T. R. Ho, Superintendent Taiwan Power Company Kuosheng Nuclear Power Station 60 Pa-Tou Yoh-Liu Village Wan L. Hsiang, Taipei Hsien (20703), Taiwan, R.O.C. *** END OF DOCUMENT ***

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