Home NRC Library Document Collections Events, Reports Associated with Part 21 Reports 1997

Part 21 Report - 1997-871

ACCESSION #: 9712190096 150 Lincoln Avenue Grove City, PA 16127-1898 Tel 412 458 8000 Fax 412 458 3574 Ajax[Registered copy] COOPER Coberra[Registered copy] ENERGY SERVICES Cooper-Bessemer[Registered copy] Enterprise [TradeMark] En-Tronic [Registered copy] Penn [TradeMark] December 12, 1997 Superior [Registered copy] Our Ref: QCG-10446 (K-5fa42) Document Control Desk U.S. Nuclear Regulatory Commission Washington, D.C. 20555 Subject: 10 CFR 21 Notification, Enterprise DSR-4 and DSRV-4 Emergency Diesel Generator Adjusting Screw Failure 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: On September 26, 1997, Entergy Operations River Bend Station reported the failure of an adjusting screw, Cooper Energy Services part number IA- 7840. The adjusting screw is a ball and swivel assembly utilized to allow for angular movement between the rocker arm and intake and exhaust valve stems of the power cylinder head. The adjusting screw is assembled by swaging a "swivel pad" on to a "ball". Subsequent investigation determined that the swaging process and tooling was of a design that allowed for "overswaging" of the pad, reducing the amount of free angular movement in the assembly. This condition potentially caused the material of the upper edge of the swivel pad to be over stressed. and/or limit the ability of the assembly to accommodate the required angular movement with undue stress. The failure of the assembly was the cracking of the swivel pad material at the upper edge. This failure has the potential to cause an operability concern due to the assembly separating and excess clearance (valve lash) being established which could lead to catastrophic failure of the valve stem or remaining ball portion of the assembly. Multiple failures of the assembly without catastrophic failure could also reduce engine output due to decreased valve lift. In addition, loose pieces of the assembly could cause secondary damage in the engine. Page 2 December 11, 1997 QCG-10446 Cooper Energy Services has supplied the 1A-7840 adjusting Screw to the following utilities and sites: AFFECTED UTILITIES SITE REMARKS Entergy Operations River Bend Replaced Duke Power Catawba Korea Electric KORI 3 & 4 CORRECTIVE ACTION The subject assemblies at River Bend Station have been replaced with acceptable assemblies. The swaging tooling has been corrected to limit the amount of "swage". Acceptance criteria assuring the necessary freedom of the assembly has been defined and will be verified during manufacture, USER RECOMMENDATIONS Utilities currently in possession of 1A-7840 assemblies are instructed to verify that a minimum of 18 degrees of angular movement from centerline is available in all directions, with no indication of roughness when moving. 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 R. M. Cote Vice President and General Manager :kll cc: J. M. Home - CES/GC R. A. Johnston - CES/Alameda B. C. Guntrum - CES/Alameda R. Nimmo - CES/Alameda R. G. Billig - CES/GC L. A. Duck - CES/Alameda A. P. Steffan - CES/GC S. R. Johnston - CES/Alameda S. A. Chubbuck - CES/Alameda File: K5fa42 Page 3 December 11, 1997 QCG-10446 Copies to: Duke Power Co. Mr. Stephen Alexander Nuclear Generation Dept. U.S. Nuclear Regulatory Commission P. O. Box 1006 QA Vendor Insp. & Maintenance Branch Charlotte, NC 28201-1006 One White Flint North Attn: Mgr., Nuclear Safety Mailstop 9A1 ECO59 Washington, DC 20555 Duke Energy Corp. Carolina Power and Light Co. OEA Manager. Harris Nuclear Project Nuclear Assessment Division P. O. Box 165 Mail Code EC 05P New Hill, NC 27562 Box 1006 Attn: William Robinson Charlotte, NC 28201-1006 Vice President Entergy Carolina Power and Light Co. P. O. Box 429 P. O. Box 1551 Echelon One Raleigh, NC 27602 1340 Echelon Parkway Attn: Manager Nuclear Licensing Jackson, MS 39286-1995 Attn: F. W. Titus (Fred) Vice President, Engineering Carolina Power and Light Co. Department Manager Entergy Harris Nuclear Plant P. O. Box 756 P. O. Box 165, State Road 1134 Port Gibson, MS 39150 New Hill, NC 27562 Attn: C. R. Hutchinson (Randy) Vice Pres., Operations-GGNS Carolina Power and Light Co. Robinson Nuclear Plant Entergy SC Hwy. 151 and 23, Box 790 P. O. Box 756 Hartsville, SC 29550 Port Gibson, MS 39150 Attn: Department Manager 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 Part Gibson, MS 39150 Attn: Russell J. Tadych Attn: M. J. Meisner Manager, Quality Control Director, NS&RA Cleveland Electric Illuminating Perry Nuclear Power Plant Manager, Quality Services P. O. Box 97 Entergy Operations Perry, OH 44081 Box 756 Attn: Harold M. Coon Port Gibson, MS 39150 Southern Nuclear Operating Company Cooper-Enterprise Clearinghouse Vogtle Project Duke Engineering & Service P. O. Box 1295 230 South Tryon St. Birmingham, AL 35201 P. O. Box 1004 Attn: Mgr., Nuclear Engineering Charlotte, NC 28201-1004 and Licensing Attn: G. A. Harrison Page 4 December 11, 1997 QCG-10446 Georgia Power Co. Plant Vogtle Mr. S. H. Soong P. O. Box 1600 Station Superintendent Waynesboro, GA 30830 Third Nuclear Power Station Attn: Mr. W. B. Shipman Taiwan Power Company General Manager P.O. Box 39 Heng-Chun, Ping-Tung Hsein Taiwan, 924 R.O.C. Gulf States Utilities P. O. Box 220 Mr. Koh, Kyoo-Kun St. Francisville, LA 70775 Plant Manger, Kori 3 & 4 Attn: L. A. England Korea Electric Power Corp. Director Nuclear Licensing 216 Ko-Ri Jangan-Up Yangsan-Gun Kyung-Nam, Korea 626-950 Long Island Power Authority Corporate Quality Assurance 140 Hoffman Lane Mr. Hong, Jo Boo Centril Islip, NY 11722 Manager, Nuclear Power Attn: Mr. Joseph Gilliard Generation Dept. Korea Electric Power Corp. Operating Experience Manager 167, Samsong-Dong, Kangnam KU Tennessee Valley Authority Seoul, 135-791 Korea 1101 Market Street, LP 4A-C Chattanooga, TN 37402 Mr. Lee, Hee-Sung TU Electric Company Plant Manager, Yonggwang P. O. Box 1002 Nuclear Unit 1 * 2 Glen Rose, TX 76043 Korea Electric Power Corp. Attn: Group Vice President - Nuclear 517, Kyema-Ri Hong Nong-Eup Yonggwang-Gun Jeon Nam Korea 513-880 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 Yeh-Liu Village Wan Li Hsiang, Taipei Hsien (20703), Taiwan, R.O.C. Mr. S. J. Tsuei Director, Nuclear Safety Dept. Taiwan Power Company 242 Roosevelt Road, Sec. 3 Taipei, Republic of China GENERAL INFORMATION or OTHER EVENT NUMBER: 33398 LICENSEE: COOPER ENERGY SERVICES NOTIFICATION DATE: 12/12/97 CITY: GROVE CITY REGION: 1 NOTIFICATION TIME: 15:30 [ET] COUNTY: STATE: PA EVENT DATE: 12/12/97 LICENSE#: AGREEMENT: N EVENT TIME: 15:30[EST] DOCKET: LAST UPDATE DATE: 12/12/97 NOTIFICATIONS PAUL FREDRICKSON RDO NRC NOTIFIED BY: ANDREW STEFFAN JOHN PELLET (REG 4) RDO HQ OPS OFFICER: JOHN MacKINNON VERN HODGE (RVID) NRR EMERGENCY CLASS: NOT APPLICABLE 10 CFR SECTION: CDEG 21.21(c)(3)(i) DEFECTS/NONCOMPLIANCE EVENT TEXT 10 CFR 21 NOTIFICATION, ENTERPRISE DSR-4 AND DSRV-4 EMERGENCY DIESEL GENERATOR ADJUSTING SCREW FAILURE. ON SEPTEMBER 26, 1997, ENTERGY OPERATIONS RIVER BEND STATION REPORTED THE FAILURE OF AN ADJUSTING SCREW, COOPER ENERGY SERVICES PART NUMBER 1A- 7840. THE ADJUSTING SCREW IS A BALL AND SWIVEL ASSEMBLY UTILIZED TO ALLOW FOR ANGULAR MOVEMENT BETWEEN THE ROCKER ARM AND INTAKE AND EXHAUST VALVE STEM OF THE POWER CYLINDER HEAD. THE ADJUSTING SCREW IS ASSEMBLED BY SWAGING A "SWIVEL PAD" ON TO A "BALL". SUBSEQUENT INVESTIGATION DETERMINED THAT THE SWAGING PROCESS AND TOOLING WAS OF A DESIGN THAT ALLOWED FOR "OVERSWAGING" OF THE PAD, REDUCING THE AMOUNT OF FREE ANGULAR MOVEMENT IN THE ASSEMBLY. THIS CONDITION POTENTIALLY CAUSED THE MATERIAL OF THE UPPER EDGE OF THE SWIVEL PAD TO BE OVER STRESSED, AND/OR LIMIT THE ABILITY OF THE ASSEMBLY TO ACCOMMODATE THE REQUIRED ANGULAR MOVEMENT WITH UNDUE STRESS. THE FAILURE OF THE ASSEMBLY WAS THE CRACKING OF THE SWIVEL PAD MATERIAL AT THE UPPER EDGE. THIS FAILURE HAS THE POTENTIAL TO CAUSE AN OPERABILITY CONCERN DUE TO THE ASSEMBLY SEPARATING AND EXCESS CLEARANCE (VALVE LASH) BEING ESTABLISHED WHICH COULD LEAD TO CATASTROPHIC FAILURE OF THE VALVE STEM OR REMAINING BALL PORTION OF THE ASSEMBLY. MULTIPLE FAILURES OF THE ASSEMBLY WITHOUT CATASTROPHIC FAILURE COULD ALSO REDUCE ENGINE OUTPUT DUE TO DECREASED VALVE LIFT. IN ADDITION, LOOSE PIECES OF THE ASSEMBLY COULD CAUSE SECONDARY DAMAGE IN THE ENGINE. COOPER ENERGY SERVICES HAS SUPPLIED THE 1A-7840 ADJUSTING SCREW TO THE FOLLOWING SITES: RIVER BEND, CATAWBA, AND KORI 3 & 4 (KOREA ELECTRIC). (Continued on next page) LICENSEE: COOPER ENERGY SERVIC PAGE # 2 OF EVENT NUMBER: 33398 CORRECTIVE ACTION: THE SUBJECT ASSEMBLIES AT RIVER BEND STATION HAVE BEEN REPLACED WIT ACCEPTABLE ASSEMBLIES. THE SWAGING TOOLING HAS BEEN CORRECTED TO LIMIT THE AMOUNT OF "SWAGE". ACCEPTANCE CRITERIA ASSURING THE NECESSARY FREEDOM OF THE ASSEMBLY HAS BEEN DEFINED AND WILL BE VERIFIED DURING MANUFACTURE. USER RECOMMENDATIONS: UTILITIES CURRENTLY IN POSSESSION OF 1A-7840 ASSEMBLIES ARE INSTRUCTED TO VERIFY THAT A MINIMUM OF 18 DEGREES OF ANGULAR MOVEMENT FROM CENTERLINE IS AVAILABLE IN ALL DIRECTIONS, WITH NO INDICATION OF ROUGHNESS WHEN MOVING. *** END OF DOCUMENT ***

Page Last Reviewed/Updated Wednesday, March 24, 2021