ML020440018

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Resubmittal of Final Report No. 41, Report of a Potential Safety Hazard from Dresser-Rand
ML020440018
Person / Time
Site: Palo Verde, Catawba, Saint Lucie, Callaway  NextEra Energy icon.png
Issue date: 01/15/2002
From: Lauzze J
Dresser-Rand
To:
Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML020440018 (9)
v • d • e


Text

DRESSER-RAND 37 Coats Street Wellsville, NY 14895-0592 PH: 716/593-1234 FAX: 716/593-5815 January 15, 2002 Documentation Control Desk US Nuclear Regulatory Commission Washington, DC 20555

Subject:

10CFR21 Reporting Please find attached another copy of Final Report No. 41 original sent out on November 21, 2001. This is being sent again at the request of Mr. Vern Hodge who has advised Mr. Ed Grandusky that the one we mailed out was not received.

J. Micheal Lauzze Indise Nuclear Sales Analyst

'7

DRESSER-RAND - Wellsville Operations FINAL REPORT IOCFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Report No.

41 Page 1 of 8 PREPARED BY:

George Hermann

//-2/-i/

Date:

11/21/01 File No:

Various TITLE:

Nuclear Product Engineer Serial No:

See Attached Terry Turbine Type:

GS & ZS Frames PART NAME:

Gimpel Trip Throttle Valve Screw Spindle Ref:

Aux. Feed I RCIC DR Part No:

105245A18 REVIEWED BY:

/-r* z, DR Dwg No:

105245A

/

Rev. Level: J

1. DESCRIPTION O ECT OR NON-COMPLIANCE Material substitution of grade 12xx (tested as 1212 & 1215) steel in place of grade 1018 carbon steel specified by design.

Additional background information provided on Pages 2 & 3.

2. POTENTIAL SAFETY HAZARD OR NON-COMPLIANCE Substitution of material could contribute to screw spindle failure resulting in isolation of steam from emergency feedwater pump turbine rendering it unable to perform its safety-related function.
3. NUMBER AND LOCATION OF ALL COMPONENTS See Attached Listing - Pages 4-7.
4. CORRECTION ACTION BY: _7N/A T COMPLETED BY N/A Dresser-Rand believes that effective controls are currently in place to prevent recurrence of this Type of substitution. The current level of quality and material control on these components far exceeds those in place at the time of this subvendor material substitution, and is verified and maintained through both the Gimpel and Dresser-Rand quality systems. The discovery of this defect does serve as an important example and reminder that continued vigilance and-attention to rigorous quality control standards must be maintained throughout the entire chain of component supply.
5. ADVICE TO EFFECTED CLIENT RELATED TO THIS REPORT
1) Units using Gimpel T&T Valves identified as affected in the attached serial number listing, which may have the original screw spindle installed should replace the screw spindle at their next maintenance opportunity. The original screw spindles should be discarded. A listing of affected valve serial numbers is attached as pages4-7.
2) It is additionally recommended that any Gimpel screw spindles in-stock or in-service which may have been supplied in the 1974-75 timeframe be treated as suspect and be tested to confirm that the material is correct. (Grade 1018 Carbon Steel).

EF-066, Rev. C - 05/16/01 REF: NNSOP 1.2.001

DRESSER-RAND - Wellsvillie Operations FINAL REPORT 10CFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Report No.

41 Page 2 of 8

Background:

Following the failure of an installed screw spindle in the trip valve of the Catawba unit #2, May 25, 2000 the material of the failed screw was subsequently analyzed and found to be Grade 1212 steel in place of the design specified grade 1018 carbon steel material.

Steels in the Grade 12xx family are known as re-sulfurized, steels. The structure of these steels is such that there are banded inclusions within the material resulting in directional reduction of impact properties. In this application this material is less desirable than the design 1018 carbon steel material which does not have banded inclusions.

Following testing, the failed screw spindle was returned to Gimpel for analysis. Gimpel gave verbal confirmation that the screw material was incorrect (Grade 1213 and 1215 steel) at the Terry Turbine Users Group meeting on July 18, 2001. Gimpel had traced the supplied material to a single lot of approximately 50 original screw spindles manufactured in 1974. The material was manufactured and certified correct by Royal Screw & Machine Co. who was Gimpel's supplier at that time.

Following the incident at Catawba, additional information was received indicating that a screw spindle installed in Palo Verde Unit 1 was found cracked in 1992, and was determined to be grade 1213 steel.

A third failure was also reported to have occurred at the Callaway site in the late 1980's. The root cause of this failure was determined to be a specific problem with the Limitorque valve actuator. In this incident, the torque switch failed to stop the motor operator when the valve reached and subsequently passed full open position. The material of this failed spindle screw is unknown.

Dresser-Rand tested the material of a functional, undamaged screw spindle removed from an in house test valve (serial number 74-12243) and determined the material was grade 1212.

Gimpel has subsequently performed testing of a spindle screw specifically manufactured from 1215 material for increased validation of its functionality. The test valve was cycled 300 times (equivalent to at least 10-15 years of service). No indication of failure was found.

It is unknown whether the material-substitution was a c6rtributing factor in the failures of the spindle screws at these sites. The trip valves in question have been in operation for many years, and although the material used is less desirable in this application than the design specified material, the limited number of failures indicates that the immediate risk of continued operation is minimal. The testing performed by Gimpel also supports this assertion.

Applicability:

Gimpel has provided information linking the supply of incorrect material to a single lot of material purchased and supplied in approximately 50 valves in the 1974 timeframe. The subvendor material certifications provided with this lot of material, in fact certified that the material was the correct grade (1018). Gimpel provided written confirmation of this defect and the following listing of affected valves to Dresser-Rand on 10/11/01.

According to Gimpel, the Trip & Throttle valve serial numbers affected are: 74-12201-01 to 74-12244 02 inclusive, 78-13215-01, and 78-13091-01. This list has been expanded and revised due to the factors below. It is recognized that the full listing identifies slightly in excess of the actual 50 valves affected; however the valves identified are the most likely to have the nonconforming material.

EF-066, Rev. C - 05/16/01 REF: NNSOP 1.2.001

DRESSER-RAND - Wellsvillie Operations FINAL REPORT 10CFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Report No.

41 Page 3 of 8 It is important to note that physical verification of the valve serial number on the valve or testing of the screw material is the ONLY positive means of identifying an affected valve. The site information listed in the attached table is not 100% accurate as order processing at Terry Turbine resulted in various re assignments of the supplied valves. As an example, the test valve currently located at Dresser-Rand Wellsville was originally assigned to St. Lucie unit 2.

In addition, when major valve re-work was performed by Gimpel, such as adding a motor operator to an existing valve, the valves were re-numbered, although most components remained unchanged.

Whenever possible the attached listing of Gimpel Valves lists these serial number changes.

It is also possible that nonconforming spindle screws or trip valves originally supplied to a site which was never commissioned could have been installed or maintained as spares in another site.

Effect Of Failure:

Failure of this component results in the T&T valve disc dropping onto its seat, thereby isolating steam from the emergency feedwater pump drive turbine. This renders the turbine inoperable although limit switch indication (when present) may indicate that the valve is open.

Additional Information:

Also attached (Page 8) is Gimpel documentation including the procedure for replacing the spindle screw, as well as recommendations for valve inspection and maintenance activities.

EF-066, Rev. C- 05/16/01 REF: NNSOP 1.2.001

DRESSER-RAND - Wellsvillle Operations FINAL REPORT 10CFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Report No.

41 Page 4 of 8 APPLICABILITY:

Because both original valves and spare valves / spindle screws could be affected, the attached listing of affected sites includes ALL nuclear sites supplied with Gimpel valves on their Terry Turbines.

Note that the valve serial numbers are NOT correctly matched to the turbine serial number in all cases.

ALL listed sites MUST verify the actual valve serial number on their unit and address this issue accordingly. Valves in bold and marked with an asterisk ( * ) are affected.

INSTALLATION LIST NUCLEAR POWER PLANTS GIMPEL Job / Valve #

Valve Turbine Size Serial No.

Owner Valve Location 67-10154-01 67-10154-03 67-10154-04 67-10154-05 67-10155-01 67-10155-02 67-10155-03 67-10155-04 67-10190-01 68-10284-01 68-10284-02 68-10284-03 68-10371-01 68-10372-01 68-10386-01 68-10386-02 68-10416-01 68-10416-02 68-10416-03 68-10416-04 69-10539-01 70-10908-01 70-10908-02 70-10910-01 71-10961-01 71-10963-01 71-10963-02 71-11013-01 72-11371-01 72-11372-01 72-11372-02 73-11690-01 73-11690-02 73-11697-01 73-11697-02 73-11715-01 73-11715-02 73-11759-01 3-900 3-900 3-900 3-900 2-900 2-900 2-900 2-900 2-900 2-900 2-900 2-900 2-900 2-900 3-900 3-900 4-900 4-900 4-900

--4-900 3-900 3-900 3-900 3-900 4-900 3-900 3-900 4-900 4-900 4-900 4-900 3-900 3-900 4-900 4-900 3-900 900 3-900 35691A

35692A, 35686A 35687A 35688A 35685A 35938A 35689A 35690A 35693A 35939A 35940A 36181A 36182A 36178A 36179A 36318A 36319A 36320A

-36321A 36555A 37008A 37008B 37035A 37168A 37059A 37059B 37273A 37665A 37686A 37686B 37948B 37948A 38117A 38117B 38032A 3803-2B.......

38032A PECO / GE Peach Bottom 2 PECO'/ GE Peach Bottom TVA Browns Ferry 2 TVA Browns Ferry 3 Commonwealth Edison Quad Cities TVA Browns Ferry 1 NOW 80-13710-01 Vermont Yankee Commonwealth Edison Quad Cities Northern States Power Monticello NOW 81-13978-01 Pilgrim 1 Nebraska Public Pwr.

Cooper NOW 82-14098-01

_. Fitzpatrick Wisconsin Power Point Beach Wisconsin Power Point Beach Virginia-Electric Surry 1 Virginia Electric Surry 2 Virginia Electric Surry 2 Virginia Electric Surry 2 Virginia Electric Surry 2

-Virginia Electric Surry 2 Duquesne Light Co.

Beaver Valley 1 Northern States Prairie Island 1 Northern States Prairie Island 2 Wisconsin Public Svc.

Kewaunee Sacremento Util. Dist.

Rancho Seco Virginia Electric North Anna I Virginia Electric North Anna 2 Northeast Utilities Millstone 2 Arkansas Nuclear ANO Toledo Edison Davis Besse Toledo Edison Davis Besse NOW 83-14276-01 Duke - McGuire 2 NOW 81-13951-01 Duke - McGuire 1 Electricite De France Fessenheim EDF Fessenheirn Cancelled N. Anna 3 used as 73-11759 Cancelled.....

N.-Anna 4-used as 73-11759 Virginia Electric North Anna 3 EF-066, Rev. C - 05/16/01 REF: NNSOP 1.2.001

DRESSER-RAND - Wellsvillie Operations FINAL REPORT IOCFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Report No.

41 Page 5 of 8 73-11759-02 3-900

  • 74-12201-01 4-900
  • 74-12202-01 4-900
  • 74-12203-01 4-900
  • 74-12204-01 4-900
  • 74-12205-01 4-900
  • 74-12206-01 4-900
  • 74-12207-01 4-900
  • 74-12208-01 4-900
  • 74-12209-01 4-900
  • 74-12210-01 4-900
  • 74-12211-01 4-900
  • 74-12212-01 4-900
  • 74-12213-01 4-900
  • 74-12214-01 4-900
  • 74-12215-01 4-900
  • 74-12216-01 4-900
  • 74-12217-01 4-900
  • 74-12218-01 4-900
  • 74-12219-01 4-900
  • 74-12220-01 4-900
  • 74-12222-01 4-900
  • 74-12223-01 4-900
  • 74-12223-02 4-900
  • 74-12224-01 4-900
  • 74-12224-02 4-900
  • 74-12224-03 4-900
  • 74-12224-04 4-900
  • 74-12225-01 3-900
  • 74-12226-01 4-900
  • 74-12226-02 4-900
  • 74-12227-01 4-900
  • 74-12228-01 4-900
  • 74-12228-02 4-900
  • 74-12229-01 4-900
  • 74-12230-01 4-900
  • 74-12230-02 4-900
  • 74-12231-01 4-900
  • 74-12232-01 4-900
  • 74-12233-01 4-900
  • 74-12234-01 4-900
  • 74-12234-02 4-900
  • 74-12235-01 4-900
  • 74-12235-02 4-900
  • 74-12236-01 4-900
  • 74-12236-02 4-900
  • 74-12237-01 4-900
  • 74-12237-02 4-900
  • 74-12238-01 4-900
  • 74-12239-01 4-900
  • 74-12240-01 4-900
  • 74-12241-01 4-900 38032B 38170A 38171A 38172A 38173A 38174A 38175A 38176A 38177A 38178A 38179A 38180A 38181A 38182A 38183A 38184A 38185A 38186A 38187A 40040A 38280A 41062A 38467A 38467B 38483A 38483B 38483C 38483D 38492A 38498A 38498B 38587A 38880A 38848B 38765A 38677A 38677B 39622A 38848A 39622B 39623A 39623B 40101A 40101B 40225A 40225B 40096A 40096B 40176A 40177A Cancelled Virginia Electric Spain Niagara Mohawk Taiwan Power Co.

North Anna 4 Cofrentes Nine Mile Point 2 Kuo Sheng ENL Alto Lazio Swiss, Power Liebstadt Miss. Power & Light Grand Gulf I Cleveland Electric Perry Houston L & P Co.

Aliens Creek Taiwan Power Co.

Kuo Sheng Spain CNV Miss Power & Light Grand Gulf Cleveland Electric Perry Gulf States Riverbend Puget Sound P & L Shagit I TVA Hartsville TVA Hartsville Spain CNV Illinois Power Clinton TVA Hartsville Entergy Corporation Waterford 3 NOW 80-13521-01 Seabrook Spain Almaraz I Spain Almaraz 2 NOW 78-13106-01 CPL - Shearon Harris NOW 78-13106-02 CPL - Shearon Harris NOW 78-13106-03 CPL - Shearon Harris NOW 78-13106-04 CPL - Shearon Harris Duquesne Light Co.

Beaver Valley 2 EDF Bugey EDF Bugey Northeast Utilities Millstone 3 EDF Bugey EDF Bugey So. Carolina E & G Summer I TVA Watts Bar I TVA Watts Bar 2 Texas Utilities Comanche Peak 1 Fumas Cent. Elec. SA Angra Texas Utilities Comanche Peak 2 Spain Asco 1 Spain Asco 2 Southern Cal Edison San Onofre Southern Cal Edison San Onofre Consumer Power Co. Midland Consumer Power Co. Midland NOW 81-14021-01 Duke - Catawba NOW 81-14021-02 Duke - Catawba NOW 83-14239-01 Union - Callaway NOW 83-14260-1 Wolf Creek Used As 80-13689-01 Seabrook 2 Union Electric Co.

Callaway #2 EF-066, Rev. C - 05116/01 REF: NNSOP 1.2.001

DRESSER-RAND - Wellsvillle Operations FINAL REPORT 10CFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Report No.

  • 74-12242-01
  • 74-12243-01
  • 74-12244-01
  • 74-12244.02 77-12872-01 77-12872-02 77-12872-03 77-12873-01 77-12873-02 77-12873-03 77-12874-01 77-12874-02 77-13015-01
  • 78-13091-01
  • 78-13106-01
  • 78-13106-02
  • 78-13106-03
  • 78-13106-04 78-13126-01 78-13127-01 78-13127-02
  • 78-13136-01
  • 78-13215-01 79-13274-01 79-13279-01 79-13280-01 79-13281-01 79-13281-02 79-13281-03 79-13281-04 79-13338-01
  • 80-13521-01 80-13547-01 80-13639-01 80-13639-02
  • 80-13689-01 80-13710-01 80-13748-01 80-13748-02 80-13748-03 80-13749-01 80-13749-02 80-13768-01 80-13768-02 80-13768-03
  • 81-13804-01
  • 81-13805-01 81-13808-01 81-13808-02 81-13808-03 81-13843-01 81-13843-02 41 Page 6 of 8 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 2-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 4-900 3-900 3-900 3-900 4-900 4-900 EF-066, Rev. C - 05/16/01 REF: NNSOP 1.2.001 Cancelled 40230A 40349A 40349B 40042A 40041A 40043A 40568A 40568B 40568C 40593A 40814A 40716A 40366A 38483A 38483B 38483C 38483D 40905A 40893A 40893B 40749A 40749B 41170A 41171A 41172A 40809A 40809C 40809D 40809B 41056A 41062A 41411 A 41482A 41482B 41063A 35938A 41696A 41695A 41862A 41173A 41173B 41057A 40809A 40809B 40749B 40749A 41812A 41812B 41812C 41930A 40930B Northern States PowerTyrone #1 FPL - St. Lucie 2 (At Dresser-Rand)

Wash. Public Power WPPS I Wash. Public Power WPPS 4 TVA Phipps Bend TVA Hartsville TVA Phipps Bend Arizona Public Service Palo Verde I Arizona Public Service Palo Verde 2 Arizona Public Service Palo Verde 3 Belgium Doel 3 Belgium Hay, Liege ENL Alto Lazio 2 Yugoslavia Krsko Was 74-12224-01 Shearon Harris Was 74-12224-02 Shearon Harris Was 74-12224-03 Shearon Harris Was 74-12224-04 Shearon Harris Tokyo Electric Power Fuku 2-1 Taiwan Power Co.

Maanshan 1 Taiwan Power Co.

Maanshan 2 Now 80-13805-01 South Texas Now 80-13804-01 South Texas Belgium Doel 4 Korea Electric Co.

KORI 2 National Power Corp.

AGAC 1 (Philippines)

NOW 80-13768-02 WPPSS 3 Wash Public Power WPPSS 5 Wash Public Power WPPSS 5 NOW 80-13768-03 WPPSS 3 CPL

-Shearon Harris 1 Was 74-12222-01 Seabrook I Tokyo Electric Power Fuku 1-2 Korea Electric Co.

KORI 5 Korea Electric Co.

KORI 6 Was 74-12240-01 Seabrook 2 Was 67-10155-03 Vermont Yankee Tepco Kashiwazaki Kariwa Tepco Fuku 2-3 Tepco Fuku 2-4 Georgia Power Vogtle I Georgia Power Vogtle 2 CPL Shearon Harris 2 Wash Public Power WPPSS 3 Wash Public Power WPPSS 5 Was 78-13215-01 South Texas 1 Was 78-13136-01 South Texas 2 Florida Power & Light Turkey Point 3 & 4 Florida Power & Light Turkey Point 3 & 4 Florida Power & Light Turkey Point 3 & 4 Korea Electric co.

KORI 7 Korea-Electric-co.

....... KORI 8

DRESSER-RAND - Wellsvillie Operations FINAL REPORT 10CFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Report No.

41 Page 7 of 8 81-13908-01 81-13908-02 81-13910-01 81-13951-01 81-13978-01 81-13978-02

  • 81-14021-01
  • 81-14021-02 82-14086-01 82-14086-02 82-14086-03 82-14098-01 82-14143-01 82-14143-02 82-14207-01 82-14218-01 82-14237-01
  • 83-14239-01
  • 83-14260-01 83-14276-01 83-14289-01 83-14289-02 83-14301-01 83-14376-01 84-14450-01 85-14531-01 87-14817-01 87-14818-01 88-14979-01 88-14980-01 90-15205-01 90-15291-01 90-15292-01 90-15309-01 90-15310-01 90-15339-01 91-15481-01 92-15585-01 93-15684-01 93-15685-01 93-15687-01 93-15687-02 94-15804-01 94-15811-01 94-15811-02 3-900 42054A 3-900 42055A 4-900 42006A 3-900 37948A 2-900 35693A 2-900 35940A 4-900 40096A 4-900 40096B 3-900 42265A 3-900 42272A 3-900 42266A 2-900 35940A 3-900 42319A 3-900 42320A 4-900 42264A 3-900 42374A 3-900 42423A 4-900 40176A 4-900 40177A 3-900 37948B 3-900 42461A 3-900 Unknown 4-900 41925A 4-900 Unknown 4-900 Unknown 4-900 Unknown 4-900 Unknown 4-900 Unknown 3-900 Unknown 3-900 Unknown 3-900 Unknown 3-900 Unknown 3-900 Unknown 3-900 Unknown 3-900 Unknown 3-900 Unknown 3-900 Unknown 2-900 Unknown 4-900 Unknown 3-900 Unknown 4-900 Unknown 4-900 Unknown 4-600 Unknown 4-600 Unknown 4-600 Unknown EDF Paulel EDF Paulel Belgium Tihange 3 Was 73-11690-01 Duke - McGuire I Was 67-10284 Boston Ed. - Pilgrim NOW 82-14098-01 Fitzpatrick Was 74-12237-01 Duke - Catawba 1 Was 74-12237-02

_-Duke - Catawba 2 EDF St. Alban EDF Paulel EDF St. Alban Was 81-13978-02 Fitzpatrick EDF Cattenom EDF St. Alban Arkansas Power ANO EDF Cattenom EDF Flamanville Was 74-12238-01 Union - Callaway Was 74-12239-01 Wolf Creek Was 73-11690-02 Duke - McGuire 2 EDF Paulel EDF Spain Vandellos 2 EDF France EDF France EDF France EDF France EDF France EDF France EDF France EDF France EDF France EDF France EDF France EDF France EDF France Yankee Electric Rowe, Massachusetts Unknown EDF France EDF France PSE&G - Hancocks, Bridge, NJ PSE&G - Hancocks Bridge, NJ EDF France EDF France EDF France EF-066, Rev. C- 05/16/01 REF: NNSOP 1.2.001

DRESSER-RAND - Wellsvillle Operations FINAL REPORT 10CFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Report No.

41 Page 8 of 8 Schedule Inspection & screw spindle Replacement For Gimpel 4" CL 900 TMTTV Inspect every Five(5) years (or 200 operational. cles-which ever comes sooner) and replace at least everm Ten(1 0) years (or 200 operational c*cles-which ever comes sooner).

Reference:

Part List P4975 Instruction Manuals GC-103,124 GC - 277 Visual Inspection:

All disassembled parts to be checked for abnormal wear, galling, permanent deformation and corrosion.

The damaged parts must be replaced.

Dimensional Inspection:

Check clearance between moving parts. Stem (pc # 28) and bushing (21 and 22) clearance in excess of 0.006" may require replacement of stem, or bushing.

Check axial clearance of screw spindle (pc-# 32).- It should be-approximately-0.-005". -Clearance in excess of 0.005" may require replacement of screw spindle and/or thrust washer (pc # 10).

Inspect disc pin (pc # 27) for deformation. TIR should be within 0.002". Replace if deformed, or if TIR exceeded 0.002".

NDT Inspection:

All seating surfaces and screw spindle head are to be PT inspected for unacceptable indication and check Seat contacts. Rework or replace parts as necessary.

Limitorque Setting The switches are to be set according to Gimpel Procedure GC 124. The valve is position seated in open position (not torque seated).

Screw Spindle Replacement In addition to the inspection and replacement requirements for five(5) to ten(10) year cycles, the original screw spindle (pc # 32) installed in the following valve serial numbers should be replaced with a new screw spindle made of AISI 1018 material. The split ring (pc #9) should also be replaced. The valves suspected to have wrong AISI 1213/1215 material are: (S/N 74-12201-1 to 74-12244-02), 78-13136-01, 78-13215-01 and 78-13091-01.

Note: Any time valve is opened for inspection, all gaskets (pc # 17) and packing (pc # 25) must be replaced.

EF-066, Rev. C - 05/16101 REF: NNSOP 1.2.001

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