ML102990307
| ML102990307 | |
| Person / Time | |
|---|---|
| Site: | Cooper  |
| Issue date: | 10/18/2010 |
| From: | Gacad L ASCO Valve |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| Download: ML102990307 (5) | |
Text
EMERSONM Industrial Automation ASCO Valve, Inc.
50 Hanover Road Florham Park, NJ 07932 USA T (973) 966 2000 F (973) 966 2628 www.asconumatics.com October 18, 2010 NRC Documents Control Desk U.S. Nuclear Regulatory Commission Washington, D.C. 20555-001
Subject:
External leakage in NP8320 solenoid valve Reference A - ASCO letter to AREVA dated 9/13/2010 Reference B - ASCO Returned Material Authorization (RMA) number 44797 Gentlemen:
The enclosed information relates to a single NP8320 ASCO valve identified by Cooper Nuclear Station to exhibit external leakage. The customers who have received similar valves potentially susceptible to external leakage are being notified.
ASCO does not have adequate knowledge of the actual installations and operating conditions of these valves to determine whether this condition could create a "substantial safety hazard" as defined in 10CFR21.3. This information is intended to provide investigation results and corrective action.
Background - On 9/8/2010, a single NP8320 solenoid valve (NP832094E 120/60,110/50, serial number A408921-004) was returned to ASCO with a reported problem of external leakage at the bonnet area below the coil housing. This valve was 1 of 5 produced on an order for AREVA in April 2010. The valve was returned from Cooper Nuclear Station through AREVA, who was the distributor. See Ref. B.
The returned valve was retested at ASCO. No external leakage was observed when the valve was tested in the de-energized state. However, when the valve was tested in the energized state (power, was applied to the valve coil), the reported leakage was confirmed. The root cause of the leakage was determined to be'a misaligned 0-ring between the Solenoid Base Sub Assembly (SBSA) and the valve body.
ASCO's NP8320 series valves are offered in 2 different body materials, brass or stainless steel; with 2 different types of seals and disc, Ethylene Propylene or Viton; and for 3 different forms of flow, Normally-Closed, Normally-Open and Universal. The NP832094E returned is a stainless steel valve with Ethylene Propylene seals and Discs for Normally-Closed form of flow.
For Normally-Closed valves, air pressure is to be applied at port 2. This port is blocked when the valve is de-energized and the cylinder port 1 is exhausted through the exhaust port 3. When the valve is energized pressure is allowed to flow to the cylinder port at 1, and the exhaust port at 3 is blocked. See Figure 1 on next page.
For Normally-Open valves, pressure is applied at port 3. This port is connected to port 1 when de-energized and port 2 is blocked. When the valve is energized, port 3 is blocked and the pressure at the cylinder port 1 is exhausted through port 2.
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Viton is registered Trademark of DuPont Co.
Universal valves can be connected as either Normally-Closed or Normally-Open.
NORMALLY CLOSED NORMALLY OPEN UNIVERSAL DE-ENERGIZED ENERGIZED DE-ENERGIZED ENERGIZED DE-ENERGIZED ENERGIZED SOL SOL SOL SSO PRESS 2 3
PRESS 1
EXH 2
X EX4H C
EX Y
PRESS 7 4CYL PRESS~
CYL Figure 1 ASCO Investigation Results - As part of ASCO's investigation, ASCO requested that AREVA return all NP8320 valves in their stock for retest. 91 more valves were returned and retested at ASCO. None exhibited external leakage in either the energized or de-energized state.
As a further part of our investigation we discovered that the written test procedure did not provide explicit instructions to energize the valve during the external leakage portion of the test. For Normally-Closed and Universal valves the solenoid must be energized to pressurize the internal cavity (The internal cavity of the valve is defined by the SBSA, valve body and lower end cap). For Normally-Open valves, the internal cavity is pressurized when de-energized, so they are not affected).
The manufacture of the NP8320 valve series was transferred to Aiken, SC from Florham Park, NJ on October 1, 2009. Interviews with Engineering and test personnel at Aiken indicated that the valves were not energized to pressurize the cavity when conducting the external leakage test. Interviews with Engineering and test personnel at Florham Park indicated that the valves were energized to pressurize the cavity when conducting the external leakage test, even though the test procedure did not specifically require this. ASCO has therefore concluded that NP8320 valves manufactured and shipped from Aiken, SC after the transfer date could be potentially affected, but not the valves produced at Florham Park.
Impact on Performance - ASCO believes that any external leakage caused by a misaligned O-ring would likely be immediately apparent and detectable upon initial installation and operation. This condition does not affect basic operation of the valve and is unlikely to degrade over time.
Interim Action - The test procedure for the NP8320 valves has been revised to ensure that any external leakage is detected.
Containment Action - A preliminary report was provided to AREVA (Reference A) on 9/13/2010. There were a total of 174 of this series valves shipped from Aiken, SC since October 1, 2009. 145 of the 174 valves were shipped to AREVA (includes the 92 retested above). 25 valves were shipped to our subsidiary, ASCO ASIA. 4 valves were shipped to Ralph A. Hiller Co. of Export, PA.
Corrective Action - The customers that were shipped affected NP8320 valves are being notified of the potential non-conformance. ASCO will recommend the affected valves be returned to be retested in accordance with the updated test procedure.
If you have any questions, you can contact Bob Arnone at 803-641-9395.
Very Truly Yours, Lars Ga d
Vice-President Quality AASCO Valve, Inc.
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EMERSON.
Industrial Automation ASCO Valve, Inc.
1561 Columbia Highway Aiken, SC 29801 USA T (803) 641-9200 F (803) 641-9290 www.asconumatics.com September 13, 2010 AREVA NP Inc.
3315-A Old Forest Road Lynchburg, VA 24501 Attn:
Chris Marsh Re:
ASCO RMA 44797 AREVA RDR 10-206, AREVA PO # 1010038058
Dear Chris,
One NP832094E 120/60, serial number A408921-004, was received with reported problem of leaking externally at the bonnet area.
An external inspection of the valve had revealed it to be new and unused. The ports and visible passageways were free of any particulate matter and no pipe sealant was noted on any of the ports. No excessive solenoid noise was heard when a test voltage of 102/60 was applied without pressure. The valve was cycled ten times. The valve did function satisfactorily when cycled and no internal leakage was recorded in either state. The valve was then checked for external leakage at the bonnet area. None was detected when the valve was de-energized, however; there was leakage when energized. The valve was disassembled for inspection and the cause was attributed the o-ring was not completely on the ledge of the valve body (figure 1).
Figure 1 There were five valves manufactured on this order and the test logs had indicated all were checked for external leakage and 10 and 175 PSI. There has not been any return history of any solenoid valves with these symptoms and is therefore considered an anomaly.
The AREVA purchase order had indicated to repair if possible. It would be suggested to place a no charge replacement order. If there are any further questions, please contact me at 803-641-9395.
Sincerely, Bob Arnone Technical Service Engineer ASW numaTlIC..
ASCOValveNet - ValveReturn Page I of 2 ATMG numaTINsF PRODUCT INFO AF3PLICATIONS SERVICES SITE LINKS SITE MAP HELP LOGOUT RMA # 44797 Return Type: Service Created By Marsh, Chris 7/29/2010 2:27 PM - Modified By Arnone, Robert 10/18/2010 7:36 AM Customer Information Account #
170151 RMA #
44797 ASCO Invoice Location Territory Contact Name Customer's Reason for Return AREVA NP INCAREVA NP INC 3315-A OLD FOREST ROAD,LYNCHBURG,VA,24501 USA 001 Customer Type AUTH. VALVE DIST.
Chris Marsh Phone #
434-832-2930 Email chris.ma rsh@areva.com Evaluation Other Valve Return from customer for failed bench test Products To ASCO Valve Inc. -
Dispo-Aiken Instru(
Status Closed, material not Other returned Do you intend to take a deduction for this return Debit Memo Number Debit Purchase Order To Credit Use sition ctions To be determined Order #
Amount Amount Catalog #
NP 8320 094 E Voltage / Hz 120/60,110/50 Pressure psi Length of time in Service Cycling Rate How are valves mounted?
Number of valves in use?
Has this problem occurred in more than one location?
Is this a new application?
Serial Media Min Pn times Product(s) to be returned A408921-004 ressure psi per Second Quantity Ambient Temperature Max Pressure Fluid Temperature 0 F psi oF Problems Experienced
- Primary Problem
- Secondary Problem
- Other Problem Reported Problems Confirmed Problems Found Primary Problem Found Other Problem Found Comments See Additional Remarks See Additional Remarks Valve failed customer bench test ASCO Findings / Response Yes Warranty Secondary Problem Found see attached report File Attached By Customer No User Name Additional Remarks Description Correction to entry of 9/8/2010:
Date Entered http://www.ascovalvenet.com/ASCOvalvenetlApplications/ValveReturn/ValveRetumlnte...
10/18/2010
ASCOValveNet - ValveReturn Page 2 of 2 ArnoneR ArnoneR ArnoneR LCARROLL ArnoneR cmarsh No external leakage detected when de-energized.
Report is attached. If a replacement is required, suggest placing a no charge replacement order.
External leakage confirmed at the bonnet area when energized. No external leakage detected when energized. Valve will be carefully disassmbled tomorrow to determine root cause.
Attached purchase order for evaluation.
Attached RDR 10-206 has been attached. Is the purchase order included in the carton?
Valve was returned from NPPD/Cooper for failing their bench test. Valve was leaking at bonnet area undersolenoid coil housing. Reference RDR 10-206 attached.
AREVA to issue no cost purchase order for evaluation/replacment.
ASCO Internal Remarks Description Date Enterc 10/15/2010 11:42:23 AM 9/13/2010 12:40:26 PM 9/8/2010 3:25:18 PM 8/3/2010 2:37:19 PM 7/30/2010 8:04:18 AM 7/29/2010 2:27:01 PM ed Product Evaluation 03 AM No User Name ArnoneR NCMR 5676 issued Confirmed external leakage when energized, none detected de-ArnoneR energized.
Attached pictures of disassembly 9/15/2010 9:25:1 9/10/2010 11:25:27 AM Yes File Attached By ASCO Internal Email Circulation Email Recipient's Name Type (Assigned to/
CC)
Assigned to Arnone, Robert CC Casadevall, Steve;Greame, Jim;Loprete, Jeffrey;Ingles, Nicholas Follow up By 07/31/2010 http://www.ascovalvenet.com/ASCOvalvenet/Applications/ValveRetumNValveReturnlnte...
10/18/2010