ML13316A138
| ML13316A138 | |
| Person / Time | |
|---|---|
| Site: | Perry, Catawba, Harris, Grand Gulf, Columbia, River Bend, Vogtle, San Onofre, Comanche Peak, Rancho Seco, Bellefonte, Shoreham, Hartsville  |
| Issue date: | 11/25/1992 |
| From: | Labrun H COOPER INDUSTRIES, INC. |
| To: | NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
| References | |
| REF-PT21-92 QCG-9190, NUDOCS 9212010038 | |
| Download: ML13316A138 (9) | |
Text
Cooper -industries Cooper-Bessemer Reciprocating Products Division 150 Lincoln Avenue Grove City, PA 16127-1898 412 458-8000 November 25, 1992 COOPER Cooper Energy Services Our Ref: QCG-9190 Document Control Desk U.S. Nuclear Regulatory Commission Washington, D.C. 20555
Dear Sir:
In accordance with the requirements of the Nuclear Regulatory Commission Title 10, Chapter 1, Code of Federal Regulations, Part 21, Cooper-Bessemer Reciprocating Products Division, a division of Cooper Industries, hereby notifies the Commission of a potential defect in a component of a DSRV and DSR Enterprise Standby Diesel Generator System. There exists a potential problem with cylinder heads cast prior to August 1, 1984.
These cylinder heads are installed, or may be in stores as replacement parts at the following sites:
UTILITY SITE SERIAL NO.
MODEL LILCO Shoreham 74010-12 DSR-48 ENTERGY Grand Gulf 74033-36 DSRV-16-4 GULF STATES River Bend 74039-40 DSR-48 CP&L Shearon Harris 74046-49 DSRV-16-4 DUKE Catawba 75017-20 DSRV-16-4 SO CAL EDISON SONGS I 75041-42 DSRV-20-4 CLEVELAND ELEC Perry 75051-54 DSRV-16-4 TVA BelIefonte 75080-83 DSRV-16-4 WPPS WPPS I 75084-85 DSRV-16-4 TU ELECTRIC Comanche Peak 76001-04 DSRV-16-4 GEORGIA POWER Vogtle 76021-24 DSRV-16-4 TVA Hartsville 77024-35 DSRV-16-4 SMUD Rancho Seco 81015-16 DSR-48 9212010038 921125 PDR ADOCK 05000206 S
PDR Cooper-Bessemers *-Enterprise'..Penn'
QCG-9190 November 25, 1992 Page 2 These cylinder heads are the design responsibility of Cooper-Bessemer Reciprocating Products Division. The cylinder heads are identified by part numbers 03-360-03-OF, 1 A-6446, 1 A-6447, 1 A-6879, 1 A-6240, 1 A-6239, 1 A-7062, 1 A-5559, 1A-5558, 1A-6266, or 1A-6265.
On October 15, 1992, the Division I emergency diesel generator at Gulf States Utilities Company (GSU) was removed from service to investigate traces of engine cooling water that had been found in samples of the lube oil. The source of the water was identified as a minute leak from the #4 cylinder head into the valve train area on the head which migrated to the engine base. Much of the water collected in a low point drain located between the base and sump. This occurrence is well documented in GSU's Informational Report of November 16, 1992, to the Commission.
Subsequent to the actions at GSU, the cylinder head was returned to Cooper Bessemer Reciprocating, Grove City, Pennsylvania manufacturing plant for root cause analysis. On November 17 and 18, 1992 hydro testing and exploratory machining was performed on the cylinder head. This was performed with a representative from GSU and FEV of America (Engineering Consultant to GSU) present. Hydro test at this time showed no leakage but some wetness at the bottom of one 3/4"-10 capscrew hole.
The location of this hole is on the shroud (top) side of the head near the exhaust end (see attached sketch). The head cylinder stud sleeve next to the leaking tapped hole was removed by machining methods for further examination. The casting next to the leaking tapped hole was wire brushed and revealed a very thin wall section between the tapped hole and interior casting surface. Comparison of this area to the casting drawing is different in that the casting drawing shows a cast boss which is not present on the GSU leaking head.
Further investigation revealed a change to the casting in July 1984 to add this boss as a result of Engineering and Manufacturing efforts to improve producibility of the cylinder head. Hydro test records from the period preceding this drawing change also document leak problems associated with 3/4"-10 holes in these cylinder heads, which were repaired and subsequently passed water test. Current cylinder head rough stock has been reviewed and the boss at this area is readily apparent.
The root cause for the failure of this cylinder head is due to inadequate casting wall thickness at this tapped hole.
To the best of our knowledge, this condition is seen as an isolated occurrence.
Although the same condition was found at Cleveland Electric Illuminating Company in December 1990, no other similar conditions have been reported by members of the TDI Diesel Owners Group.
QCG-9190 November 25, 1992 Page 3 Corrective actions have-not been determined. Our Design Engineering Department is investigating several alternatives which would not require the removal of the cylinder head. We will complete our evaluation within 30 days. In the interim, oil analysis should be performed monthly to monitor the oil for jacket water contamination.
If you have any questions regarding this issue, please contact John R. Schneider, Quality Assurance Manager or Ron G. Billig, Supervisor Enterprise Engineering at 412-458-8000.
SinceT ly,
/
/
Y H. A. LaBrun4 Vice Presid t and General Manager Attachment HAL/kIl cc:
J. R. Schneider - CES/GC B. R. Sedelmyer - CES/GC A. D. Gillette - CES/GC D. T. Blizzard - CES/GC J. M. Horne - CES/GC R. G. Billig-CES/GC K. E. Tasik - CES/GC J. A. Manno - CES/Alameda B. C. Guntrum - CES/Alameda R. L. Nimmo - CES/Alameda Lee Duck - CES/Alameda Mr. Walter Haass - NRC One White Flint North Mailstop 9D4 Washington, DC 20555 Entergy Operations P. O. Box 429 Echelon One 1340 Echelon Parkway Jackson, MS 39286-1995 Attn:
T. H. Cloninger Vice Pres. Nucl. Eng.
QCG-9190 0
November 25, 1992 Page 4 cc:
Carolina Power and Light Co.
Harris Nuclear Project P. 0. Box 165 New Hill, NC 27562 Attn:
Dept. Mgr.
Carolina Power and Light Co.
Harris Nuclear Project P. 0. Box 165 New Hill, NC 27562 Attn:
Mr. C. S. Hinnant Plant Gen. Mgr.
Carolina Power and Light Co.
P. 0. Box 1551 Raleigh, NC 27602 Attn:
R. A. Watson Sr. Vice President Carolina Power and Light Co.
Shearon Harris Nuclear Project P. 0. Box 1551 Raleigh, NC 27602 Attn:
S. D. Floyd Mgr. Nuclear Licensing Carolina Power and Light Co.
Shearon Harris Nuclear Project P. 0. Box 165 New Hill, NC 27562 Attn:
Mr. O.C. Olexik Mgr. of Regulatory Committee Carolina Power and Light Co.
Shearon Harris Nuclear Plant P. 0. Box 165 New Hill, NC 27562 Attn:
Jerry R. Cribb Mgr, Quality Control Cleveland Electric Illuminating Perry Nuclear Power Plant P. 0. Box 97 Perry, OH 44081 Attn:
M. Lister
QCG-9190 November 25, 1992 Page 5 cc:
Cleveland Electric Illuminating Perry Nuclear Power Plant P. 0. Box 97 Perry, OH 44081 Attn:
Russell J. Tadych Manager, Quality Control Cleveland Electric Illuminating Perry Nuclear Power Plant P. 0. 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:
Mike Anthony Duke Power Co.
Nuclear Generation Dept.
P. 0. Box 1007 Charlotte, NC 28201-1007 Attn:
Mgr., Nuclear Safety Duke Power Co.
Nuclear Generation Dept.
P. 0. Box 1007 Charlotte, NC 28201-1007 Attn:
W. T. Robertson Vice President, Procurement Entergy P. 0. Box 429 Port Gibson, MS 39150 Attn:
Fred Titus Dir., Nuclear Plant Eng.
Entergy P. 0. Box 756 Port Gibson, MS 39150 Attn:
Vice Pres., Nuclear Operations
QCG-9190 0
November 25, 1992 Page 6 cc:
Entergy P. O. Box 756 Port Gibson, MS 39150 Attn:
D. L. Pace Design Engineering Georgia Power Co.
Plant Vogtle P. 0. Box 1295 Birmingham, AL 35201 Attn:
Mr. T. Green Mgr., Engineering and Licensing Georgia Power Co.
Plant Vogtle P. 0. Box 1600 Waynesboro, GA 38030 Attn:
Mr. W. B. Shipman Gen. Mgr.
Manager, Quality Control Gulf States Utilities P. 0. Box 220, MA-3 St. Francisville, LA 70775 Attn:
Director Nuclear Licensing Long Island Lighting Co.
Shoreham Nuclear Power Station North Country Rd.
Wading River, NY 11792 Attn:
Mgr. Nuclear Operat.
Support Dept.
Southern California Edison Co.
San Onofre Nuclear Generating Station P. 0. Box 128 San Clemente, CA 92672 Attn:
Manager, Nuclear Oversight Div.
Sacramento Municipal Utility District Rancho Seco Nuclear Power Plant 14440 Twin Cities Road Herald, CA 95638 Attn:
Vice Pres. & Gen. Manager
QCG-9190 0
November 25, 1992 Page 7 cc:
Tennessee Valley Authority 1101 Market Street, LP 4F Chattanooga, TN. 37402 Attn:
Tim Chan Tennessee Valley Authority 1101 Market Street, LP 5B Chattanooga, TN 37402 Attn:
Mr. M. J. Fecht Mgr. Nuclear Experience Review Tennessee Valley Authority Bellefonte Nuclear Authority P. 0. Box 2000 Hollywood, AL 35752 Attn:
C. W. Fulwider Texas Utilities Electric 400 North Olive Street, L.B. 81 Dallas, TX 75201 Attn:
W. J. Cahill Group Vice President Washington Public Power Supply P. 0. Box 460 Richland, WA 99352 Attn:
Mr. L. C. Oakes Manager, WNP-1 Engineer Mr. Oh, Young Sik Plant Mgr., KORI 3 & 4 Korea Electric Power Corp.
216 Kori, Jangan-Eup Yangsan-Gun Kyungnam, Korea 626-950 Sang Kee Park General Manager Korea Electric Power Corporation Gangnam-Ku Yeong Dong P.O. Box 40 Seoul, 135-791 Korea
QCG-9190 0
November 25, 1992 Page 8 cc:
Hong, Jin Moon Plant Mgr., Yonggwang Nuclear Unit 1 & 2 Korea Electric Power Co.
517, Kyema-Ri Hong Nong-Eup Yonggwang-Gun Jeon Nam Korea 513-880 G. C. Lee, Superintendent Taiwan Power Company Kuosheng Nuclear Power Station 60 Pa-Tou Yeh-Liu Village Wan Li Hsiang, Taipei Hsien (20703), Taiwan, R.O.C.
Y. H. Chen Director, Nuclear Quality Dept.
Taiwan Power Company 17F, 242, Sec. 3, Roosevelt Road Taipei, Taiwan R.O.C.
S. H. Soong Station Superintendent Third Nuclear Power Station Taiwan Power Company P. 0. Box 39 Heng-Chun, Ping-Tung Hsein Taiwan, 924 R.O.C.
cc:
File K5fa22
Attachment to QCG-990 LEAK OCCURRED AT BOTTOM OF THIS THREADED (3/4"-10) HOLE R-4 CYLINDER HEAD SHROUD SIDE VIEW