United States Nuclear Regulatory Commission - Protecting People and the Environment


ACCESSION #: 9804220222



Form EF-066                   DRESSER-RAND

Rev C                       WELLSVILLE N.Y.                 Report No. 40

NNSOP 1.2.001                                               page 1 of 3



                       FINAL REPORT 10CFR PART 21

                   REPORT OF A POTENTIAL SAFETY HAZARD



     PREPARED BY                                  File No:   Various

                                                  Serial No: Various

     APPROVED BY:                                 Type: GS &  ZS

                                                  Ref: N/A

                                                  D-R Part No: pg 3

     PART NAME: Governor Valve Stem               DR Dwg No: pg 3

                                                  Rev Level: pg 3



1.   Description of Defect or Non-Compliance



     Inconel 718 material was used in place of 410 stainless steel for

     the new spray coated valve stems.  The Material selection process

     did not fully evaluate the impact of a higher coefficient of thermal

     expansion in the steam seal arrangement using carbon washers for

     steam seals.



2.   Potential Safety Hazard or Non-Compliance:



     If the cold clearance is not adequate to accommodate the stem growl

     control problems will result that may prevent the turbine/pump

     assembly from performing it's intended function.



3.   Number and Location of all components:



     A total of 28 sites have purchased these stems, 23 domestic and 5

     foreign.



               List on page 2.



4.   Corrective Action by Nuclear Product Engr.  completed by 6/1/98



     ECR# 10673 issued to create a new carbon spacer part number 800714-

     002.  This carbon spacer has an inside diameter that is 0005" larger

     than the original spacer p/n 800714-001.  This will return the

     running clearance at operating temperature to the values of the

     original nitrided 410 SS stems.



               Continued on page 3



5.   Advice to Effected Customer Related to This Report



     a.   For stock parts not assembled in valve body assembly.



          Insure the clearance between the carbon washers and the stem is

          at least .0015" when assembled in the valve.



     b.   For parts in an operational AFW or RCIC turbine.



          Perform a surveillance test that insures the control

          characteristics of the turbine are adequate after the turbine

          reaches its maximum operating temperature.



Form EF-066                   DRESSER-RAND

Rev C                       WELLSVILLE N.Y.            Report No. 40

NNSOP 1.2.001                                          page 2 of 3



Number and Location of all components;



COUNT               TURBINE S/N              LOCATION

1                   T35685A                  BROWNS FERRY 1

2                   T35686A                  BROWNS FERRY 2

3                   T35687A                  BROWNS FERRY 3

2                   T35690A                  MONTICELLO

3                   T35693A                  PILGRIM 1

4                   T35939A                  COOPER

5                   T36546A                  MAINE YANKEE

6                   T36555A                  BEAVER VALLEY 1

                    T38492A                  BEAVER VALLEY 2

7                   T36565A                  DIABLO CANYON 1

                    T36566A                  DIABLO CANYON 2

8                   T36681A                  EDWIN I.HATCH

9                   T36683A                  BRUNSWICK 2

10                  T37008 A & B             PRAIRIE ISLAND 1 & 2

11                  T37009A                  CRYSTAL RIVER

12                  T37273A                  MILLSTONE 2

13                  T37476A                  HANFORD 2

14                  T37549A                  ST. LUCIE 1

                    T40230A                  ST. LUCIE 2

15                  T37858 A & B             FARLEY 1 & 2

16                  T37948A                  McGUIRE 1

17                  T38171A                  NINE MILE POINT 2

18                  T38677 A & B             WATTS BAR 1 & 2

19                  T38765A                  SUMNER 1

20                  T39622A                  COMANCHE PEAK

21                  T41062A                  SEABROOK 1

                    T41063A                  SEABROOK 2

22                  T41173 A & B             ALVIN W.VOGTLE 1 & 2

23                  T41812 A,B & C           TURKEY POINT 3&4

24                  T38174A                  LEIBSTADT

25                  T40366A                  KRSKO,

26                  T41925A                  VANDELLOS 2

27                  T37476C                  TOKAI 2

28                  T38848A                  ANGRA



Form EF-066                   DRESSER-RAND

Rev C                       WELLSVILLE N.Y.            Report No. 40

NNSOP 1.2.001                                          page 3 of 3



Corrective Action by Nuclear Product Engr. completed by 6/1/98



The failure to adequately evaluate the potential effects of the thermal

expansion characteristic of the new material was a design oversight that

occurred even though procedures for controlling the design process are

currently in place.  These procedures include:



EA-001    Engineering Design Control

          Section 5      part B item number 2 places the control of

                         Nuclear units and repair orders under Product

                         Engineering.

          Section 5      part C item 4 identifies EA-025 as the Process

                         Control Procedure for New Concepts and

                         Development Programs.

          Section 8      gives guidance for Design Verification and New

                         Drawing Approval.

          Section 9      gives guidance for Design Validation.



EA-025    Design Control for New Concepts And Development Programs.



          Section 4      Project Planning and Authorization establishes

                         objective, scope and time/cost estimates.

          Section 5      Execution and Control defines a project leader,

                         review requirements and reporting format.

          Section 8      Verification & Completion gives guidance for

                         Design review and verification.

          Section 9      Final Report defines minimum requirements for

                         the documentation in the report, required

                         signatures and storage location.



NNSOP 1.2.004 Drawing Approval referenced in EA-001



          Section 4.0    states design engineering must satisfy all the

                         requirements of ED-1-018.

          Section 4.1.2  requires checker to verify all interface

                         requirements and have drawing reviewed by other

                         groups if necessary.

          Section 4.1.3  requires a Supervisor to review drawing against

                         ALL DESIGN REQUIREMENTS.

          Section 4.1.4  requires the Nuclear Product Engineer to review

                         drawing against ALL DESIGN REQUIREMENTS and

                         proper material and processing.



Per our procedure NNSOP 1.1.001, a Corrective Action Request

(form QC-5), CAR NO.: 0953 has been initiated to address this design

oversight issue.  In response to this Corrective Action Request existing

procedures will be thoroughly reviewed with special focus on paragraphs

with potential relevance to this design oversight experience.  Then

procedures will be revised and/or supplemented, e.g.  by check lists

and/or personnel training, as judged necessary to maximize the

probability that all potentially relevant factors will be considered and

adequately evaluated in future executions of our design process.  similar

design projects performed since the formation of Dresser-Rand will also

be reviewed for compliance to these design requirements.  As noted above

this Corrective Action will be defined and fully implemented by June 1,

1998.



D-R Part Numbers and Drawings for Governor Valve Stems:



               800743-001 800743 rev n/a

               800744-001 800744 rev n/a

               800745-001 800745 rev n/a

               800746-001 800746 rev n/a

               800768-001 800768 rev n/a

               800768-002 800768 rev n/a

               800777-001 800768 rev n/a



QC-5                DRESSER-RAND(WELLSVILLE, NEW YORK PLANT)     CAR NO.:

2/19/90

                       CORRECTIVE ACTION REQUEST



Pg. 1 of 2



TO:                                FROM:



REQUEST DATE:                           REPLY DUE DATE:



CC:       Quality Assurance Manager

          Plant Superintendent

          Other Copies to



SUBJECT:

          AUDITS:   INTERNAL CHECKLIST #:         DATED:

                    EXTERNAL REPORT #: DRW        DATED:



          PRODUCT:  D-R ORDER                NMR#           QTY.

                    CSTG.#                   GOV'T. ORDER#

                    DWG.#

                    PC#                      DCAS DISPOSITION:



The nonconformance frequency of this piece

number is recorded in Computer Run No. J-1221.



        GUIDELINES FOR COMPLETING CORRECTIVE ACTION REQUEST FORM



     A)   Sections 1, 2, 6 and 7 to be completed by originator (or his

          delegate).



     B)   Sections 3, 4 and 5 to be completed by the addressee and

          returned to the Individual who Identified the finding by the

          reply due date.



1.   Program/Product Specification Requirements:

     (Quote or paraphrase document by Section, Paragraph)



2.   Finding/Nonconformance:

     (Describe deficiency in detail; i.e.  What? Numbers? Where? Impact

     on quality of activity or equipment?



     Identified by:                                    Date:



Pg.  2 of 2



3.   Cause of condition: (What contributed to the nonconformance.)



     Evaluation by:                               Date:



4.   Corrective Action:



     Proposed completion date           Condition corrected by   Date



5.   Action taken to prevent recurrence:



     Signature:                    Date:          Completion Date:



6.   Reply Review: proposed corrective action is:



          [ ]  Satisfactory   [ ]  Unsatisfactory      [ ] incomplete



                    Remarks:



     Evaluation by:                               Date



7.   Corrective Action Verified: [ ] Yes [ ] No Comment: (Describe

     details of follow-up where possible.)



                                        Verification by

     Audit Finding Closed [ ]           Date



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Page Last Reviewed/Updated Thursday, March 29, 2012