ML15211A496
| ML15211A496 | |
| Person / Time | |
|---|---|
| Site: | Columbia, Limerick, Quad Cities  |
| Issue date: | 07/24/2015 |
| From: | Roy M Flowserve Corp |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| 51260 | |
| Download: ML15211A496 (9) | |
Text
0712412015 PaaD I 0724205.I NulearI Rem& ulnr Commission, (nnppations~Cejnter Event'R-onrt Pnaa I Part 21 (PAR) Event# 51260 Rep Org: FLOWSERVE CORPORATION Notification Date / Time: 07/24/2015 04:55 (EDT)
Supplier: FLOWSERVE CORPORATION Event Date/ Time: 07/24/2015 (EDT)
Last Modification: 07/24/2015 Region: 1 Docket #:
City: RALEIGH Agreement State: Yes County: License #:
State: NC NRC Notified by: MICHAEL ROY Notifications: SILAS KENNEDY R1 DO HQ Ops Officer: JEFF ROTTON AARON MCCRAW R3DO Emergency Class: NON EMERGENCY HEATHER GEPFORD R4DO 10 CFR Section: PART 21/50.55 REACTORS EMAIL 21.21(d)(3)(i) DEFECTS AND NONCOMPLIANCE PART 21 - ACTUATOR SHAFT DID NOT MEET DIMENSIONAL REQUIREMENTS The following information was excerpted from a facsimile provided by Flowserve:
"In accordance with the provisions of 10CFR Part 21, [Flowserve] has identified a potential issue and is submitting our evaluation of the event.
"DESCRIPTION: Energy Northwest - Columbia Station reported a replacement actuator shaft for 6-900 Anchor/Darling swing check was different than the one removed and could not be installed. After consultation with Flowserve, it was determined the actuator shaft did not meet the dimensional requirements of the manufacturing drawing. The shaft includes an off-set lug that engages the hinge and allows testing or exercising the valve disc.
The shaft diameter opposite the lug was too large but must be equal to or less than the basic diameter adjacent to the lug in order to allow free disc swing.
"SCOPE: Replacement actuator shafts supplied by Flowserve using manufacturing drawings that do not definitively specify the radius/diameter at the lug. Applies to Anchor/Darling swing check valves with levers or actuators.
"PROPOSED ACTION: Flowserve will revise actuator shaft drawing to clearly define the radius/diameter at the lug. Flowserve will notify the customers of the attached evaluation of the defect and will request that the actuator shafts be returned to Flowserve for evaluation and/or replacement at no charge.
SUBJECT:
Actuator Shaft supplied for 6-900 Exercisable Swing Check Valve, Drawing No. 3489-3 manufactured by Anchor/Darling Valve Co. and installed at Energy Northwest (ENW) - Columbia Station.
07/24/2015 U.S. Nuclear Regulatory Commission OperationsCenterEvent Report Page2 "ROOT CAUSE: The actuator shaft was machined by a Flowserve subvendor which incorrectly interpreted the machining drawing and produced the shaft with a large, out of tolerance radius around the lug. The drawing was not clear to the subvendor. Flowserve inspection did not discover the discrepancy during subsequent dimensional inspection.
"POTENTIAL EFFECT: An excessively large diameter at the lug will not allow installation of a replacement actuator shaft. A shaft with a diameter opposite the lug that is greater than design but still small enough to allow installation could retard or prevent free disc swing and adversely affect check valve function.
"EVALUATION: Swing check valves normally operate automatically reacting to fluid flow and do not include external operating mechanisms. Some valves include external mechanisms to confirm valve operation using an external lever or actuator to cycle the disc. Normally these check valves are allowed to swing freely and the external mechanism is not engaged. The external mechanism is only engaged for testing or exercising. The engagement is accomplished by a lug on the actuator shaft that rides in a cut out in the hub of the hinge. The hinge rotates on the actuator shaft during normal, free operation therefore the clearance between the hinge hub bore and shaft is a critical design feature and can affect operation. Proper operation of valve assemblies are verified during production testing therefore are not within the scope of this evaluation.
"CONCLUSION: Although the ENW actuator shaft could not be installed due to the excess material, inadequate removal to allow installation could affect the function. In addition shafts manufactured to similar manufacturing drawings supplied as replacement parts could be capable of installation but not allow complete free disc / hinge swing."
Affected plants include Exelon - Limerick, Exelon - Quad Cities, and Energy Northwest - Columbia.
!I I'd" 13310 naieigri iviarKetiny imort u4;:)4;:)v pan. Ut -Z4-ZU ID Flow Control Division Anchor/DarlingValves FLOWSE RVE Valtek BW/IP Valves Edward Valves Control Products Worcester Valves July 24, 2015 US Nuclear Regulatory Commission Document Control Desk 11545 Rockville Pike Rockville, MD 20852-2746
Subject:
Energy Northwest Columbia - Actuator Replacement Shaft Drawing 3489-3 Exelon Limerick - Actuator Replacement Shaft Drawing W9223896 Exelon Quad Cities - Actuator Replacement Shaft Drawing W8422061, 62.
This is to notify the US Nuclear Regulatory Commission that, in accordance with the provisions of 10CFR Part 21, we have identified a potential issue and are submitting our evaluation of the event.
DESCRIPTION: Energy Northwest - Columbia Station reported a replacement actuator shaft for 6-900 Anchor/Darling swing check was different than the one removed and could not be installed. After consultation with Flowserve it was determined the actuator shaft did not meet the dimensional requirements of the manufacturing drawing. The shaft includes an off-set lug that engages the hinge and allows testing or exercising the valve disc. The shaft diameter opposite the lug was to large but must be equal to or less than the basic diameter adjacent to the lug in order to allow free disc swing.
SCOPE: Replacement actuator shafts supplied by Flowserve using manufacturing drawings that do not definitively specify the radius/diameter at the lug. Applies to Anchor/Darling swing check valves with levers or actuators. See table 1 of attached evaluation for list of applicable replacement parts.
PROPOSED ACTION: Flowserve will revise actuator shaft drawing to clearly define the radius/diameter at the lug. Flowserve will notify the customers in table I of the attached evaluation of the defect and will request that,the actuator shafts be returned to Flowserve for evaluation and/or replacement at no charge.
Please do not hesitate to contact me if you have any questions or require additional information.
Respectfully su itted, Michael V. Roy Quality Assurance Manager Flowserve Corporation 1900 S Saunders St.
Raleigh, NC 27603 Flowserve US Inc Raleigh Operations, Toll Free: 1-800-225-6989 Flow Control Division PO Box 1961 Phone: 1-919-832-0525 1900 South Saunders Street Facsimile: 1-919-831-3369 Raleiah. NC 27603 www.flowserve.com
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P.; Ui-z4---U I 1 FLOWSE RVE ENGINEERING EVALUATION IOCFR21 File No. 89 Page I of 4 A 7/23/15
SUBJECT:
Actuator Shaft supplied for 6-900 Exercisable Swing Check Valve, Drawing No.
3489-3 manufactured by Anchor/Darling Valve Co. and installed at Energy Northwest (ENW) -
Coluhifbia Station.
PROBLEM: ENW - Columbia reported the replacement actuator shaft was different than the one removed and could not be installed. After consultation with Flowserve it was determined the actuator shaft did not meet the dimensional requirements of the manufacturing drawing.
The shaft includes an off-set lug that engages the hinge and allows testing or exercising the valve disc. The shaft diameter opposite the lug must be equal to or less than the basic diameter adjacent to the lug in order to allow free disc swing. See figures 1 photos and 2 drawing.
SCOPE: Replacement actuator shafts manufactured by a Flowserve subvendor using manufacturing drawings that do not definitively specify the radius/diameter at the lug. Only applies to Anchor/Darling swing check valves with levers or actuators. See table 1 for list of applicable replacement parts.
ROOT CAUSE: The actuator shaft was machined by a Flowserve subvendor which incorrectly interpreted the machining drawing and produced the shaft with a large, out of tolerance radius around the lug. The drawing was not clear to the subvendor. Flowserve inspection did not discover the discrepancy during subsequent dimensional inspection.
POTENTIAL EFFECT:
An excessively large diameter at the lug will not allow installation of a replacement actuator shaft. A shaft with a diameter opposite the lug that is greater than design but still small enough to allow installation could retard or prevent free disc swing and adversely affect check valve function.
EVALUATION: Swing check valves normally operate automatically reacting to fluid flow and do not include external operating mechanisms. Some valves include external mechanisms to confirm valve operation using an external lever or actuator to cycle the disc. Normally these check valves are allowed to swing freely and the external mechanism is not engaged. The external mechanism is only engaged for testing or exercising. The engagement is accomplished by a lug on the actuator shaft that rides in a cut out inthe hub of the hinge. The hinge rotates on the actuator shaft during normal, free operation therefore the clearance between the hinge hub bore and shaft is a critical design feature and can affect operation.
Proper operation of valve assemblies are verified during production testing therefore are not within the scope of this evaluation.
CONCLUSION: Although the ENW actuator shaft could not be installed due to the excess material, inadequate removal to allow installation could affect the function. Inaddition shafts manufactured to similar manufacturing drawings supplied as replacement parts could be capable of installation but not allow complete free disc I hinge swing.
Flowserve U S Inc Raleigh Operations Toll Free: 1-800-225-6989 Flow Control Division PO Box 1961 Phone: 1-919-832-0525 1900 South Saunders Street Facsimile: 1-919-831-3369 Raleigh, NC 27603 ww.flowserve.com
Maleign MarKeting Nort U4.:)U.I P.111, UIZ4-ZUIJ j II FLOWSERVE ENGINEERING EVALUATION 10CFR21 File No. 89 Page 2 of 4 A 7/23/15 Figure 1 ENW Photos of Removed and Replacement Actuator Shafts nnri Winnin %Ajith ric-r Flowserve US Inc Raleigh Operations Toll Free: 1-800-225-6989 Flow Control DiMvlon PO Box 1961 Phone: 1-919-832-0525 1900 South Saunders Street Facsimile: 1-919-831-3369 Raleiqh, NC 27603 ,ww*flowserve corn
Kiaieign iviarKeling irort U4. 30;U3 PJ.rTI. U/ -U I D '4/1 FLOWSE RVE ENGINEERING EVALUATION IOCFR21 File No. 89 Page 3 of 4 A 7/23/15 Figure 2 Drawing Showing Installed Actuator Shaft and Evaluated Area Flowserve US Inc Raleigh Operations Toll Free: 1-800-225-6989 Flow Control Divon PO Box 1961 Phone: 1-919-832-0525 1900 South Saunders Street Facsimile: 1-919-831-3369 Raleiqh, NC 27603 www flowservecom
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FLOWSERVE ENGINEERING EVALUATION 10CFR21 File No. 89 Page 4 of 4 A 7/23/15 TABLE 1 REPLACEMENT ACTUATOR SHAFTS A/DV Swing Check Actuator Shafts Supplied as Replacements Evaluation 10CFR21-89 Manufactured by Subvendor CAR 1392 MDC 7/10/2015 I
Shaft Part No. QTY Drawing SO Customer Drawing Description Ship Date 10411193269991100 1 B62041 110965 Exelon - Limerick W9223896 3-150 SC Test Lever 4/22/2015 "041016552283801 I B63931 22838 Exelon - Quad Cities W8422061,62 4-900 SC Test Lever 2/27/2003
'041290536019701 I C32576 60197 ENW-Columbia 3489-3 6-900 SC Exercisable 12/30/2010 Air Cylinder Prepared By: ark D. Cowell, PE Engineering Specialist Flowserve Inc., Raleigh Operations Flowserve US Inc Raleigh Operations Toll Free: 1-800-225-6989 Flow Control Division PO Box 1961 Phone: 1-919-832-0525 1900 South Saunders Street Facsimile: 1-919-831-3369 Raleiqh, NC 27603 wwwftowsprve-corn
!I IM5 IZ$Jfo Kaieign iviameiing r4on U4a:e!%flI Pam.eU Ig-Zon U~lf U,1 400"UnWAIA-1 FLOWSERVE DATE INITIATED: 6/4/15 PROPOSAL DUE: 6/16/15 CORRECTIVE MANAGER/SUPERVISOR OR VENDOR: Rebecca Blankenship ACTION PART,' RT# OR OTHER IDENTIFIER: PO00331494, Part number 04129053 6019701 REQUEST IOCFR21 EVALUATION REQUIRED? Y Z N 04i"eC INTERNAL Z EXTERNAL I-HOW IDENTIFIED: Energy NW VCAR 331494-01 CAR# 1392 INITIATED BY: Kerri Madden CODE MATERIAL? YDE NZ IFCODE, ANI REVIEW:
PROBLEM STATEMENT -( to be completed by QA or responsible department):
Contrary to PO requirement that the parts were to be interchangeable in fit form and function.., as to those they are replacing, the actuator shafts would not function as delivered to the customer.
BELOW DESCRIBE THE CONDITION OR CIRCUMSTANCE VIOLATING THE ABOVE LISTED REQUIREMENT ACKNOWLEDGEMENT OF RECEIPT OF THIS REQUEST. SIG-A RE/DAr . .. . ,
(BUYER ACKNOWLEDGES EXTERNAL REQUESTS) I (.41#*L611l44 -r115 ROOT CAUSE AND PROPOSED ACTION (to be completed by responsible manager or designee)'
Root Cause: The Actuator Shaft was sent outside for machining, After a discussion with our vendor it was determined that the drawing was unclear in regards to the required diameter in the area where the operating lug is located.
Proposed Action: Revise the current drawing to clearly identify the diameter requirements in the area where the operating lug is located.
ACTIONS WILL BE COMPLETED BY (DATE): RE DAT CORRECTIVE ACTION TAKEN TO PRECLUDE RECURRENCE: (attaclh evidence of actions taken)'
Drawing has been revised to clearly show the requirements by using a cut out labeled Section A-A. See attached revision completed on 6/23/15. Part 21 Evaluation was performed and notification was performed with all parties. See attached.
SYBMflTED BY (printed name) "SiGiATRE AND DATE (11k -121A~5 CONFIRMATION OF CORRECTIVE ACTION TAKEN (To be completed by Flowserve QA after review of evidence)
EVIDENCE SUFFICIENT TO CLOSE? Y [-] N - FURTHER FOLLOW UP REQUIRED? Y L--1 N IF]
CORRECTIVE ACTION REVIEWED DATE SIGNATURE BY (QA Manager or Designee.)
FORM Q-985 REV. 2 Form No. Q-985 Rev. 2
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.SECTION A-A STANDARD FINISH V- 250, RIIMS BREAK ALL EDGES ........ .1)64 MIN.
FILLETS 1184 MIN.. ANGLES&.+/-21 CHKABY: gr*_=WU t APP-D BY: II