United States Nuclear Regulatory Commission - Protecting People and the Environment

ACCESSION #: 9610310065

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     AV                      AUTOMATIC VALVE
               41144 Vincent  Court     Novi MI USA     48375-1924
               Telephone 810-474-6700   Facsimile     810-474-6732

                   World Class Air Valves and Controls

OCTOBER 28, 1996

SUBJECT: 10CFR21 NOTIFICATION OF POTENTIAL DEFECT

On 09-02-96 Jim Wethington, of Commonwealth Edison-Quad Cities NPS,
notified Automatic Valve that a Main Steam Isolation Valve (MSIV) EPN
1-0203-1D had failed to close in the 3-5 seconds required by their
technical specifications.  The solenoid valves associated with the MSIV
had recently been replaced by Quad Cities personnel.  Following
replacement, the MSIV stroked property under cold conditions (reactor
shutdown and solenoid valves de-energized prior to testing).  The concern
was identified while re-timing the MSIV during plant start-up.  After the
solenoids had remained energized for several hours the MSIV would not
close within the required 3-5 seconds.

On 09-03-96 Todd Hutchins of Automatic Valve inspected the solenoid at
the Quad Cities facility and determined that the 6910-0x0 solenoid
plunger was 1.322-1.327" in length.  The correct specified length is
1.287-1.295".  The probable cause of the incorrect length appeared to be
a missed machining operation at time of manufacture.

A solenoid plunger of this length restricts the exhaust port in the
plunger stem.  This potentially can prevent any equipment operated by the
solenoid from operating within its intended time requirement.

On 09-04-96 Todd Hutchins and Jim Wethington discussed the non-
conformance and initial corrective action with Keith Walton and Laura
Collins of the Nuclear Regulatory Commission located at the Quad Cities
facility.

Automatic Valve verified that all of the 6910-0x0 solenoid plungers
currently in their stock were the correct length and added a specific
inspection requirement for all future plungers.

To prevent any additional valves from being rebuilt with potentially long
plungers Automatic Valve requested all customers who had received kits
containing the 6910-0x0 solenoid plunger in the last two years to verify
the plunger length.  It had been Automatic Valve's experience that kits
supplied previous to the two year cutoff were already installed in
operating valves and could not immediately be measured.

The defective solenoid from Quad Cities was returned on 09-27-96 to
Automatic Valve for additional testing and root cause determination.
Frank Lentin of Commonwealth

Page 2
October 28, 1996
Subject: 10CFR21 Notification of Potential Defect

Edison notified Automatic Valve that a 10CFR21 review had been initiated
and that a decision on potential reportability was required by 11-04-96.

On 10-17-96 preliminary test data indicated that field detection of the
non-conforming plunger was possible with a dimensional inspection
(requiring the solenoid to be disassembled) or time testing the product
after the solenoid had reached it's stabilized temperature (but not
during its initial cold state).

Since the missed machining operation on the plunger was an omission in
the machining process, the problem is not lot specific.  Potentially all
solenoid valves manufactured since 02-03-70 (utilizing the 10 watt #6910-
0x0 solenoid) with the model numbers prefixed A, B, C, K, or U are
affected.  If you are unsure as to whether this affects you, please
submit questionable part numbers to Automatic Valve for verification.

There have been no reported non-conforming plungers shipped in the
previous 26 years.

All known customers (list attached) were verbally notified of the
potential problem, verbally notified of the recommended corrective
action, given an assurance that a formal 10CFR21 decision would-be made
by 11-04-96 and that they would receive a copy.

The formal corrective action report (attached) was completed on 10-28-96
and outlines the problem, root cause, corrective action, implementation,
and preventative action.

This letter intends to fulfill Automatic Valve's obligation under
10CFR21 and is being sent with all attachments to all known customers who
have purchased products containing the potentially long plunger and who
have imposed 10CFR21 in their purchase order.

Should you have any additional questions, please feel free to contact me.

Very truly yours,
AUTOMATIC VALVE CORPORATION

Todd Hutchins
President

TJH/cb
10cfr2[Trademark]1.doc

AUTOMATIC VALVE            CORRECTIVE ACTION                     10/28/96
                                  9622A

1.   Team: Jim Wethington, Quad Cities NPS, tel:309.654.2241x2190
          Todd Hutchins, Automatic Valve, tel:810.474.6700

2.   Problem: On 09-02-96 MSIV #1-0203-1D would not fast close within the
     3-5 second technical specification when the solenoids had been
     energized for a minimum of two hours at a minimum of 90'F ambient.

3.   Containment: Air pack ser# D53325 was removed from MSIV #1-0203-1D
     for inspection by Automatic Valve personnel at Quad Cities.  Air
     pack ser# D53332 was rebuilt for installation on MSIV #1-0203-1D on
     09-04-96.

4.   Cause: One plunger from solenoid 6910-0x0 missed the machining
     operation after the viton insert was pressed in.

5.   Corrective action:
          5.1 For products in the field:
               Verify the plunger length to be 1.287-1.295" or
               verify when de-energized that the application speed meets
               technical specifications after the solenoid has been
               energized for a minimum of two hours at a minimum of 90'F
               ambient.
          5.2  For products at Automatic Valve:
                    Verify flow/response time and/or verify plunger
                              length.

6.   Verification:
          6.1  Verified that the non-conforming plunger was fully
               assembled but had missed the machining operation (based on
               x-rays and photos).
          6.2  Verified that the non-conforming plunger when energized
               for minimum of two hours at a minimum of 90'F ambient
               would cause significant delay in de-energize flow time
               (test report PV-UTL-46 attached).
          6.3  Verified that the non-conforming plunger could be
               identified by a flow/response time test.

7.   Implementation:
          7.1  Plants should verify that the plunger length is 1.287-
               1.295" or verify when de-energized that the application
               speed meets technical specifications after the solenoid
               has been energized for a minimum of two hours at a minimum
               of 90'F ambient.
          7.2  Automatic Valve added plunger length as a critical 'to be
               inspected' dimension on the inspection print (print #6910-
               0X0 attached).  Current stock at Automatic Valve was re-
               inspected and found all to be within tolerance.  Service
               kits sold to customers in 1995 and 1996 still in stock
               were re-inspected and found all to be within tolerance
               (contacts attached).

                                    1

AUTOMATIC VALVE            CORRECTIVE ACTION                    10/28/96
                                  9622A

          7.3  Automatic Valve verified flow/response time and/or plunger
               length on all shipments since 09-04-96.
          7.4  On 10-28-96 Automatic Valve notified in writing all known
               customers who had purchased products containing the
               potentially long plunger and who had imposed 10CFR21 in
               their purchase order.

8.   Prevention:
          8.1  Plants should add plunger dimensions to field rebuild
               instructions (example attached).
          8.2  Automatic Valve added critical solenoid dimensions to
               engineering 'critical characteristics' procedure.
          8.3  Automatic Valve added flow/response time requirements to
               final test procedure.

9.  Verification: Monitor testing and field feedback data.

                                    2

AUTOMATIC VALVE          LOCN: I:\DSS\DOCUMENT\PVUTL46   DATE: 10-26-1996
TEST NUMBER: PV-UTL-46

PURPOSE:

To determine the effects of ambient temperatures on the energize and de-
     energize times of solenoid 6910-0X0, with:
     o    Non-conforming 6910-001 solenoid plunger - length of 1.322 -
          1.327 - as returned from Commonwealth Edison.
     o    Conforming 6910-001 solenoid plunger - length of 1.287 - 1.295

TEST PROCEDURE:

1.   Run all tests at 80 psig using filtered non-lubricated air.

2.   Attach solenoid manifold with non-conforming plunger to test plate
     AX-402.

3.   With the manifold at ambient temperature, record the following
     temperatures - also refer to figure 1.
     3.1.  Ta-Ambient temperature
     3.2.  T1 - Temperature of solenoid adapter nut.
     3.3.  T2- Temperature of solenoid coil housing.
     3.4.  T3 - Temperature of solenoid manifold block.

     (Note: Physically mark the locations where temperature readings are
     taken and take all subsequent temperature readings at the same
     locations.)

4.   Determine flow and exhaust response times taking 3 to 5 readings
     waiting a minimum of 10 minutes between readings to allow system to
     stabalize.
     4.1  During each reading record temperatures at locations designated
          in paragraph 3.

5.   With the manifold at ambient temperature, energize the solenoid for
     a minimum of 2 hours.
     5.1.  Record temperatures T1 through T3 per paragraph 3.
     5.2   Determine flow and exhaust response times and record
           temperatures per paragraphs 4 through 4.1.

6.   Disconnect air inlet line, remove the pressure transducer and place
     the manifold, test plate, and load chamber in an oven and heat to 90
     degrees F for a minimum of 1/2 hour with the solenoid energized.
     6.1. Measures temperatures T1 through T3 per paragraph 3 prior to
          running response tests.
     6.2  Determine flow and exhaust times and record temperatures per
          paragraphs 4 through 4.1.
          6.2.1     During the wait between readings, reinsert the
                    manifold in the oven to re-establish temperatures.

7.   Repeat paragraph 6 through 6.2 at oven temperatures of 90 degrees F,
     100 degrees F, 125 degrees F, and 150 degrees F.

8.   Repeat paragraphs 2 through 7 with conforming solenoid plunger.

TEST EQUIPMENT:

     Number         Description                        Calibration  Date
     APG-2          0 to 60 160 PSIG pressure gage     10-02-1996
     NIC-3091       Osciloscope                        06-10-1996
     7199           Thermocouple thermometer           10-04-1996
     TTT-1100-550   Thermometer                        11-07-1995
     SPT-667388     Pressure transducer                06-24-1996

AUTOMATIC VALVE     LOCN: I:\DSS\DOCUMENT\PVUTL46      DATE: 10-26-1996

Table  "TEST RESULTS (AVERAGES" omitted.

ANALYSIS/CONCLUSIONS:

1.   Ambient temperature fluctuations have little effect on either the
     energized or de-energized times with the conforming plunger
     installed.

2.   Ambient temperature fluctuations have only a slight effect on the
     energized times with the non-conforming plunger installed.

3.   Ambient temperature fluctuations have a significant effect on de-
     energized times with the non-conforming plunger As the data shows,
     at an ambient temperature of 90 degrees F the unit became, for
     practical purposes, non functional.  The 'quickest' exhaust time
     with the surface of the body at 93.4 degrees F was 54 seconds
     compared to 0.145 for the manifold with the conforming plunger.

4.   At a minimum ambient temperature of 90 degrees F and with the
     solenoid coil energized for a minimum of 2 hours, the delay in the
     de-energized time would be easily detectable.  As the ambient
     temperature increases, the delay becomes more and more noticable.

Conducted by : Brian Bielat   Title: Engineer     Date: 10-25-1996

Analized by:                  Title: VP Eng/Mfg   Date: 10-26-1996

Approved by:                  Title: VP Eng/Mfg   Date:

Figure "AUTOMATIC VALVE SOLENOID #6910-0X0 10/28/96" omitted.

AUTOMATIC VALVE          SHIPPEDKITSWITH6910-0X0       10/25/96

Table omitted.

                                 Page 1

                                                       QCEMS 0250-16
                                                       UNIT 1 (2)
                                                       REVISION 7

Figure 4 "Ref: GE SIL 505, MSIV SOLENOID MANIFOLD" omitted.

GENERAL INFORMATION or OTHER            EVENT NUMBER: 31229

LICENSEE : AUTOMATIC VALVE              NOTIFICATION DATE: 10/28/96
     CITY: NOVI          REGION: 3      NOTIFICATION TIME: 12:13 [ET]
   COUNTY:                STATE: MI     EVENT DATE:        10/28/96
LICENSE #:            AGREEMENT: N      EVENT TIME:        00:00[EST]
  DOCKET:                               LAST UPDATE DATE:  10/28/96

                                                  NOTIFICATIONS

NRC NOTIFIED BY: HUTCHINS
HQ OPS OFFICER: CHAUNCEY GOULD          VERN HODGE

EMERGENCY CLASS: NOT APPLICABLE
10 CFR SECTION:
WINF                INFORMATION ONLY
CCCC 21.21          UNSPECIFIED PARAGRAPH

                               EVENT TEXT

AUTOMATIC VALVE WAS NOTIFIED BY COMMONWEALTH EDISON-QUAD CITIES
THAT A
MAIN STEAM ISOLATION VALVED FAILED TO CLOSE WITHIN THE 3-5 SECONDS
REQUIRED BY THEIR TS.  FURTHER INSPECTION BY AUTOMATIC VALVE
PERSONNEL
DETERMINED THAT THE "6910-0X0" SOLENOID PLUNGER WAS TOO LONG.  THE
PROBABLE CAUSE FOR THE INCORRECT LENGTH APPEARED TO BE A MISSED
MACHINING
OPERATION AT TIME OF MANUFACTURE.

AUTOMATIC VALVE VERIFIED THAT ALL SOLENOID PLUNGERS OF THIS TYPE IN
THEIR
STOCK WERE THE CORRECT LENGTH AND ADDED A SPECIFIC INSPECTION
REQUIREMENT
FOR ALL FUTURE PLUNGERS.  AUTOMATIC VALVE REQUESTED THAT ALL
CUSTOMERS
WHO RECEIVED KITS WITHIN THE LAST 2 YEARS CONTAINING THIS TYPE
PLUNGER TO
VERIFY THE PLUNGER LENGTH.

AUTOMATIC VALVE           10CFR21NOTIFICATION                    10/25/96

Table omitted.

                                 Page 1

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