United States Nuclear Regulatory Commission - Protecting People and the Environment


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 ***



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