Part 21 Report - 1999-231

ACCESSION #: 9904160099

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	150 Lincoln Avenue Grove City, PA 16127-1898 Tel 724-458-8000 Fax 724 458-3574
	Ajax [Registered Trademark] Coberra [Registered Trademark]
COOPER ENERGY SERVICES	Cooper-Bessemer [Registered Trademark] Enterprise [Trademark] En-Tronic [Registered Trademark] Penn [Trademark] Superior [Registered Trademark]
April 12, 1999
Fax: 301-816-5151
Our Ref: QCG-10530
Document Control Desk U.S. Nuclear Regulatory Commission Washington, D.C. 20555	Cooper Energy Services
	10CFR21 Report No. 45
Subject:	10CFR21 Notification, Enterprise DSRV-4 Emergency Diesel Generator Connecting Rod Prestressed Fasteners

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 defect in a component of a DSRV-16-4 Enterprise Diesel Generator System. There exists a potential problem with connecting rod assemblies built since September, 1986, that use or have been converted to use prestressed fasteners to attach the rod box to the master rod.

Our records indicate that the following utilities purchased new P/N 1A-7802 rod assemblies that come assembled with prestressed fasteners that are suspected to be of incorrect length.

UTILITIES	SITE	ENGINE S/N	QTY. PURCHASED
Southern Nuclear Operating Co.	Vogtle	76021-4	1 (Order COOE78448)
Cleveland Electric	Perry	75061-2	2 (Order COOE76581)

It should be noted that these plants have been notified and have taken appropriate action.

In addition, any utilities with DSRV-4 engines who have purchased replacement 1A-6280 or 1A-6281 connecting rod assemblies (with bolts) since September, 1986 and have subsequently converted these to prestressed fasteners (or are planning to convert to prestressed fasteners) could also be affected. The utilities that may be affected are as follows.

UTILITIES	SITE	SERIAL NUMBER
Entergy	Grand Gulf	74033-6
CP&I	Shearon Harris	74046-9
Duke	Catawba	75017-20
Cleveland Electric	Perry 7	5051-4
Texas Utilities	Comanche Peak	76001-4
Southern Nuclear Plant	Vogtle	76021-4

Any utilities meeting the described criteria are recommended to contact Cooper Energy Services for clarification.

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Page 2

April 12, 1999

QCG-10530

DISCUSSION:

Enterprise developed a method of preloading connecting rod bolts using hydraulic prestressers; (jacks) instead of the more traditional applied torque method. The hydraulic prestresser method eliminated any possibility of galling or seizing of fastener parts due to high contact force sliding motion. This methodology was offered for DSRV-4 engines as a product improvement for equipment in service and as an option for new rod assemblies starting in the mid 1980's. The prestressed hardware includes four studs which bottom in thread tappings in the rod box. The studs were offered in two sizes to fit a variety of rod assemblies that could differ in rod box hole depth.

A recent rod replacement/prestressed fastener installation at Cleveland Electric's Perry Plant revealed that incorrect parts were provided. Studs of the longer design were furnished with a rod box that required the short studs. A subsequent review found an anomaly in the CES design documentation. While it was debatable as to whether the assembly could be completed based on sound mechanical practice, the potential for error was demonstrated.

This problem was compounded by a typographical error in assembly instruction literature that was intended to alert customers to the difference between rods and fastener lengths. When properly assembled the stud end will extend 3-9/16 inch past the face of the master rod. That dimension will be off by 3/8 inch if the wrong stud is installed. The assembly instructions provided the correct 3-9/16" dimension but indicated that an incorrect stud would differ by 7/8 inch.

The effect of installing the wrong stud is that the thread engagement in the rod box tapping is reduced to potentially unacceptable dimensions.

CORRECTIVE ACTION:

Any engines with suspect assemblies installed should be inspected at their next refueling outage. In addition, any affected rod assemblies in utilities' inventory should likewise be inspected. Suspect connecting rod assemblies can be verified by measuring the length of the stud extending from the face of the master rod to the fastener end with a scale or tape. The correct length should be 3-9/16". If the wrong prestressed fasteners are installed, the measurement will deviate from this by +/- 3/8". For any rod assemblies where this measurement differs from the recommended 3-9/16", CES Engineering should be contacted for further evaluation and potential stud rework or replacement.

If you have any questions regarding this issue, please contact T. L. Miller, Quality Engineering at 724-458-3448 or Ronald Billig, Manager, Aftermarket Technical Services at 724-468-3584.

Sincerely, Cooper Energy Services

Ronald G. Billig
Manager, Aftermarket Technical Services

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Page 3

April 12, 1999

QCG-10530

Document Control Desk
U.S. Nuclear Regulatory Commission
Washington, D.C. 20555

Mr. Stephen Alexander
U.S. Nuclear Regulatory Commission
QA Vendor Insp. & Mainten. Branch
One White Flint North
Mailstop 9A1
Washington, DC 20555

Entergy
P.O. Box 429
Echelon One
1340 Echelon Parkway
Jackson, MS 39286-1995

Attn:

Fred W. Titus Vice President, Engineering

Entergy Operations
P.O. Box 756
Port Gibson, MS 39150

Attn:

Wm. K. Hughey Director, NS&RA

Carolina Power and Light Co.
Harris Nuclear Project
P.O. Box 165
New Hill, NC 27562-1065

Attn:

Jim Scarola Vice-President

Carolina Power and Light Co.
P.O. Box 1551, CPB9
Raleigh, NC 27602

Attn:

Donna Alexander, Manager Performance Eval. & Reg. Affairs

Cleveland Electric Illuminating
Perry Nuclear Power Plant
P.O. Box 97
Perry, OH 44081

Attn:

Mr. R. G. Collings Manager, Quality Assurance

Cleveland Electric Illuminating
Perry Nuclear Power Plant
P.O. Box 97
Perry, OH 44081

Attn: Harold M. Coon

Cooper-Enterprise Clearinghouse
Duke Engineering & Service
230 South Tryon St.
P.O. Box 1004
Charlotte, NC 28201-1004

Attn: G. A. Harrison

Duke Power Company
OEA Manager
Nuclear Assessment Div.
P.O. Box 1006
Charlotte, NC 28201-1006

Southern Nuclear Operating Company
Plant Vogtle
P.O. Box 1600
Waynesboro, GA 30830

Attn: Mr. J. T. Gasser, General Manager

TU Electric Company
P.O. Box 1002
Glen Rose, TX 76043

Attn: Sr. Vice President & Principal Nuclear Officer

INTERNAL COPIES:

S. C. Guntrum - Alameda
L. A. Duck - Alameda
M. Donlin - Alameda
D. D. Stuart - Alameda
Sue Johnston - Alameda
R. Johnston - Alameda
J. M. Home - GC
R. G. Billig - GC
W. R. Slusher - GC
T. L. Miller - GC
R. Boyles - GC

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04/12/1999

Page 1

U.S. Nuclear Regulatory Commission Operations Center Event Report

General Information or Other (PAR) Event# 35580

Rep Org: COOPER ENERGY SERVICES	Notification Date / Time: 04/12/1999 15:55 (EDT)
Supplier: COOPER ENERGY SERVICES	Event Date / Time: 04/12/1999 (EDT)
	Last Modification: 04/12/1999
Region: 1	Docket#:
City: GROVE CITY	Agreement State: No
County:	License#:
State: PA
NRC Notified by: BILLIG (FAX)	Notifications: DAN HOLODY R1
HQ Ops Officer: CHAUNCEY GOULD	WALTER RODGERS R2
Emergency Class: NON EMERGENCY	JOHN JACOBSON R3
10 CFR Section:
LINDA SMITH R4
21.21 UNSPECIFIED PARAGRAPH	VERN HODGE NRR

THIS PART 21 IS CONCERNED WITH A POTENTIAL DEFECT IN A COMPONENT OF A DSRV-16-4 ENTERPRISE DIESEL GENERATOR SYSTEM. THE POTENTIAL PROBLEM IS WITH A CONNECTING ROD ASSEMBLIES BUILT SINCE SEPT 1986 THAT USE OR HAVE BEEN CONVERTED TO USE PRESTRESSED FASTENERS TO ATTACH THE ROD BOX TO THE MASTER ROD. THESE NEW ROD ASSEMBLIES(P/N 1A-7802) COME ASSEMBLED WITH PRESTRESSED FASTENERS THAT ARE SUSPECTED TO BE OF INCORRECT LENGTH. THE PLANTS INVOLVED ARE VOGTLE(ENGINE S/N 76021-4) AND PERRY(ENGINE S/N 75051-2).

IN ADDITION UTILITIES WITH DSRV-4 ENGINES WHO HAVE PURCHASED REPLACEMENT P/N 1A-6280 OR IA-6281 CONNECTING ROD ASSEMBLIES (WITH BOLTS) SINCE SEPT., 1986 AND HAVE SUBSEQUENTLY CONVERTED THESE TO PRESTRESSED FASTENERS(OR PLANNING TO CONVERT) COULD ALSO BE AFFECTED, THE FOLLOWING SITES MAY BE AFFECTED GRAND GULF(ENGINE S/N 74033-6), HARRIS (ENGINE S/N 74046-9), CATAWBA(ENGINE S/N 75017-20), PERRY(ENGINE S/N 75051-4), COMANCHE PEAK(76001-4), AND VOGTLE(ENGINE S/N 76021-4).

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