ML13127A012
| ML13127A012 | |
| Person / Time | |
|---|---|
| Site: | Pilgrim, Limerick, FitzPatrick |
| Issue date: | 05/03/2013 |
| From: | Debonis J Curtiss Wright Flow Control Co |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| 48996 | |
| Download: ML13127A012 (8) | |
Text
05/03/2013 U.S. NuclearRegulatory Commission OperationsCenterEvent Report Paee I Part 21 (PAR) Event# 48996 Rep Org: CURTISS WRIGHT FLOW CONTROL CO. Notification Date / Time: 05/03/2013 09:25 (EDT)
Supplier: CURTISS WRIGHT FLOW CONTROL CO. Event Date / Time: 05/03/2013 (EDT)
Last Modification: 05/03/2013 Region: 1 Docket #:
City: EAST FARMINGTON Agreement State: Yes County: License #:
State: NY NRC Notified by: JOHN DEBONIS Notifications: GORDON HUNEGS R1DO HQ Ops Officer: CHARLES TEAL PART 21 GROUP EMAIL Emergency Class: NON EMERGENCY ERIC DUNCAN R3DO 10 CFR Section:
21.21 (a)(2) INTERIM EVAL OF DEVIATION INTERIM PART 21 REPORT OF POTENTIAL DEFECT IN A RELIEF VALVE BELLOWS The following was excerpted from a fax:
(ii) Identification of the basic component supplied for such facility or such activity within the United States which may fail to comply or contains a potential defect.
Target Rock P/N: 303480-1, Bellows, Manufactured by Target Rock.
(iii) Identification of the firm supplying the basic component which fails to comply or contains a defect.
Target Rock, Business Unit of Curtiss-Wright Flow Control Corporation 1966E Broadhollow Road East Farmingdale, NY 11735 (iv) Nature of the defect or failure to comply and the safety hazard which is created or could be created by such defect or failure to comply.
During as-found steam testing on March 5, 2013 of a Pilgrim Main Steam Safety Relief Valve (MS-SRV) (TR Model 09J-001, valve assembly SIN 5, pilot assembly S/N 23, bellows PIN 303480-1 SIN 607) a loud pop was heard and as-found testing was secured. Subsequently, the pilot assembly was removed from the valve assembly and subjected to a leak test and would not hold pressure. The pilot assembly was disassembled and a visual inspection of the PIN 303480-1 bellows convolutions revealed a through wall failure in one of the convolutions. It is noted the steam testing was performed at an offsite test facility and the valve did not fail installed in the plant.
0510312013 U.S. Nuclear Regulatory Commission OperationsCenter Event Report Pajee 2 Part 21 (PAR) Event # 48996 The bellows acts as a pressure sensor responsible for initiating the opening of the MS-SRV at set pressure. Failure of the bellows does not directly impact the integrity of the Reactor Coolant System (RCS) pressure boundary, which is maintained by the bonnet assembly that surrounds it, but does impair the ability of the MS-SRV to provide over-pressure protection of the RCS. This technology has an extensive history of reliability in nuclear power systems and has been used in Commercial Nuclear Power Plants (NPPs) since the 1970s. This is the first reported incident regarding a thru wall bellows failure.
Target Rock initiated a comprehensive root cause evaluation pursuing several areas of investigation. In parallel, Entergy is conducting an independent investigation and we are cooperating with them. A complete review of our paperwork confirms all manufacturing procedures and processes were performed in accordance with all specified requirements. This includes:
- Raw material analysis
- Dimensional inspections
- Cleaning
- Heat Treatment
- Manufacturing processes
- Testing
- Review of design stresses Preliminary metallurgical analysis of the failed bellows indicates cracks forming in an inter-granular manner as would be expected from Inter Granular Stress Corrosion Cracks (IGSCC) originating at pit like location on the interior pressurized surface. The source of this cracking is the focus of on going investigations. Target Rock has also visually inspected two other bellows of the same part number, one manufactured from the same material lot and another manufactured from an earlier material lot. Both of these bellows were installed in valves steam tested at Target Rock. One of these valves bellows was also full flow tested at Wyle Labs. Neither of these additional bellows contained pit-like locations and may indicate this potential failure mechanism is an isolated incident.
However, to date, neither Target Rock nor Pilgrim can draw final conclusions with the information collected and analyzed.
The mode of failure has not been determined; however, in order to address the potential for a common mode failure, Target Rock is continuing metallurgical testing of the failed bellows and the two other bellows with the same part number. Based on these results, it is likely we will need to evaluate bellows that have been installed in other NPP as they become available.
(v) The date on which the information of such defect or failure to comply was obtained.
The as-found steam test and identification of the potential defect occurred on March 5, 2013.
(vi) In the case of a basic component which contains a defect or fails to comply, the number and location of these components in use at, supplied for, being supplied for, or may be supplied for, manufactured, or being manufactured for one or more facilities or activities subject to the regulations in this part.
The following plants are running with bellows P/N 303480-1 installed: Limerick 1 & 2, Pilgrim, and J.A. Fitzpatrick.
(vii) The corrective action which has been, is being, or will be taken; the name of the individual or organization responsible for the action; and the length of time that has been or will be taken to complete the action.
The root cause of the potential defect is not yet known as of the date of this report. Therefore, no specific corrective actions have been initiated. Target Rock Corrective Action Request CAR 13-013 will document the corrective actions when they are determined. This determination will be based on further mechanical and material evaluations. TR anticipates completing these evaluations within 45 days; however, in the event the evaluations are not completed, TR will forward another interim report within 45 days.
05/03/2013 U.S. NuclearRegulatory Commission OperationsCenterEvent Report Page 3 Part 21 (PAR) Event# 48996 (viii) Any advice related to the defect or failure to comply about the facility, activity, or basic component that has been, is being, or will be given to purchasers or licensees.
Target Rock will recommend that the end user perform a detailed visual inspection of the interior convolutions of installed bellows PIN 303480-1 at the next opportunity to determine if any areas of pitting or cracking exist on the interior walls of the bellows. This is a difficult inspection to perform due to the following: internal geometry of the convolutions, a trained inspector is required and specific inspection technology is needed to yield reliable results.
Target Rack 1966E Broadhollow Road East Farmingdale, NY 11735 Ce¶RTI5 I Phone: 631.293.3800
- Fax: 631.293.4949 www.targetrockcwfc. corn
- .)Flow
- ControlCompany Tbrget Rock NID#13243 May 3, 2013 Attn: Document Control Desk U.S. Nuclear Regulatory Commission Washington, D.C. 20555-001
Subject:
10 CFR Part 21 Interim Report Notification of a Potential Defect. Bellows Failure
Dear Sir or Madam:
This letter provides interim notification of a potential defect in a relief valve bellows manufactured and supplied by Target Rock (TR). The evaluation for a potential defect is underway but could not be completed within (60) sixty days of discovery. The information required for this notification is provided below:
(i) Name and address of the individualor individuals informing the Commission.
William Brunet Director of Quality Assurance James White General Manager Target Rock, Business Unit of Curtiss-Wright Flow Control Corporation 1966E Broadhollow Road East Farmingdale, NY 11735 (ii) Identification of the basic component suppliedfor such facility or such activity within the United States which may fail to comply or contains a potential defect.
Target Rock P/N: 303480-1, Bellows, Manufactured by Target Rock.
Page I of 5
Target Rock 1966E Broadhollow Road East Farmlngdale, NY 11735 II Phone: 631.293.3800 - Fax: 631.293.4949 www. targetrockcwfacorn C Rrll7.
) lw ControlCompany Target Rock (iii)Identification of thefirm supplying the basic component which fails to comply or contains a defect.
Target Rock, Business Unit of Curtiss-Wright Flow Control Corporation 1966E Broadhollow Road East Farmingdale, NY 11735 (iv) Nature of the defect orfailure to comply and the safety hazard which is created or could be created by such defect orfailure to comply.
During as-found steam testing on March 5, 2013 of a Pilgrim Main Steam Safety Relief Valve (MS-SRV) (TR Model 09J-001, valve assembly S/N 5, pilot assembly S/N 23, bellows P/N 303480-1 S/N 607) a loud pop was heard and as-found testing was secured. Subsequently, the pilot assembly was removed from the valve assembly and subjected to a GN 2 leak test and would not hold pressure. The pilot assembly was disassembled and a visual inspection of the P/N 303480-1 bellows convolutions revealed a through wall failure in one of the convolutions. It is noted the steam testing was performed at an offsite test facility and the valve did not fail installed in the plant.
The bellows acts as a pressure sensor responsible for initiating the opening of the MS-SRV at set pressure. Failure of the bellows does not directly impact the integrity of the Reactor Coolant System (RCS) pressure boundary, which is maintained by the bonnet assembly that surrounds it, but does impair the ability of the MS-SRV to provide over-pressure protection of the RCS. This technology has an extensive history of reliability in nuclear power systems and has been used in Commercial Nuclear Power Plants (NPPs) since the 1970s. This is the first reported incident regarding a thru wall bellows failure.
Target Rock initiated a comprehensive root cause evaluation pursuing several areas of investigation. In parallel, Entergy is conducting an independent investigation and we are cooperating with them. A complete review of our paperwork confirms all manufacturing procedures and processes were performed in accordance with all specified requirements. This includes:
" Raw material analysis
" Dimensional inspections
" Cleaning
" Heat Treatment
" Manufacturing processes
" Testing
" Review of design stresses Page 2 of 5
Target Rock 1966E Broadhollow Road East Farmingdale, NY 11735 Phone: 631.293.3800
- Fax: 631.293.4949 www targetrockcwfc.corn "FlowControlCompany Target Rock Preliminary metallurgical analysis of the failed bellows indicates cracks forming in an inter-granular manner as would be expected from Inter Granular Stress Corrosion Cracks (IGSCC) originating at pit-like location on the interior pressurized surface. The source of this cracking is the focus of our on-going investigations. Target Rock has also visually inspected two other bellows of the same part number, one manufactured from the same material lot and another manufactured from an earlier material lot. Both of these bellows were installed in valves steam tested at Target Rock. One of these valves/bellows was also full flow tested at Wyle Labs. Neither of these additional bellows contained pit-like locations and may indicate this potential failure mechanism is an isolated incident. However, to date, neither Target Rock nor Pilgrim can draw final conclusions with the information collected and analyzed.
The mode of failure has not been determined; however, in order to address the potential for a common mode failure, Target Rock is continuing metallurgical testing of the failed bellows and the two other bellows with the same part number. Based on these results, it is likely we will need to evaluate bellows that have been installed in other NPP as they become available.
(v) The date on which the information of such defect orfailureto comply was obtained.
The as-found steam test and identification of the potential defect occurred on March 5, 2013.
Page 13 of 5
Target Rock 1966E Broadhollow Road East Farmingdale, NY 11735 CURT99r. I Phone: 631.293.3800 - Fax: 631.293.4949 www.targetrockcwfc.corn
,Flow Control Company Target Rock (vi) In the case of a basic component which contains a defect or fails to comply, the number and location of these components in use at, supplied for, being supplied for, or may be supplied for, manufactured, or being manufacturedfor one or more facilities or activities subject to the regulationsin this part.
The following plants are running with bellows P/N 303480-1 installed:
Plant Total Operating Nameplate Remarks Valves Pressure Set Pressures Installed (psig) (psig)
Limerick 28 1040 1170, 1180, 3-Stage MS-SRVs Units I & 2 1190 with bellows installed 1999 Pilgrim 4 1035 1155 3-Stage MS-SRVs with bellows installed 2011 J, A. 3 1050 1145 3-Stage MS-SRVs FitzPatrick with bellows I installed 2011 (vii) The corrective action which has been, is being, or will be taken; the name of the individual or organizationresponsiblefor the action; and the length of time that has been or will be taken to complete the action.
The root cause of the potential defect is not yet known as of the date of this report. Therefore, no specific corrective actions have been initiated. Target Rock Corrective Action Request CAR 13-013 will document the corrective actions when they are determined. This determination will be based on further mechanical and material evaluations. TR anticipates completing these evaluations within 45 days; however, in the event the evaluations are not completed, TR will forward another interim report within 45 days.
Page I4 of 5
Target Rock 196SE Broadhollow Road East Farmingdale, NY 11735 I Phone: 631.293.3800 - Fax: 631.293.4949 www.targetrockcwfc.corn Flow ControlCompany Target Rock (viii) Any advice related to the defect orfailure to comply about the facility, activity, or basic component that has been, is being, or will be given to purchasersor licensees.
Target Rock will recommend that the end user perform a detailed visual inspection of the interior convolutions of installed bellows P/N 303480-1 at the next opportunity to determine if any areas of pitting or cracking exist on the interior wails of the bellows. This is a difficult inspection to perform due to the following: internal geometry of the convolutions, a trained inspector is required and specific inspection technology is needed to yield reliable results, (ix) In the case of an early site permit, the entities to whom an early sitepermit was transferred.
Not applicable.
Should you have any questions regarding this matter, please contact Steven Pauly, Vice President Energy Products at (631) 293-3800, ext. 4640.
Very Truly Yours, General Manager Target Rock, Business Unit of Curtiss-Wright Flow Control Corporation cc: Michael Cinque William Brunet Steve Pauly Alex DiMeo John DeBonis Ed Bradshaw Page 15 of 5