ML20012C063

LER 90-005-01:on 900209,defect Found in Casing of Limitorque Model HBC-1 Gear Operators,Causing Valve Motion to Cease Prematurely in Open Direction.Caused by Excess Matl on Housings.Also Reported Per Part 21.W/900308 Ltr

ML20012C063
Person / Time
Site:	Beaver Valley
Issue date:	03/08/1990
From:	Noonan T DUQUESNE LIGHT CO.
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-90 LER-90-005, LER-90-5, ND3MNO:2031, NUDOCS 9003200029
Download: ML20012C063 (9)

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E Telephone { '.12) 093-6000 Nuclear Group PO. Box 4 l, Shippmpport. PA 15077 6 f.t March 8, 1990  ;

ND3MNO:2031-i Beaver Valley Power Station, Unit No. 1.

Docket No. 50-334,.. License No. DPR-66 LER 90-005-01 United States Nuclear Regulatory Commission Document Control Desk

Washington, DC- 20555 Gentlemen

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In accordance with Appendix A Beaver Valley Technical Specifications, the following revised Licensee Event Report is submitted:

LER 90-005-01, 10 CFR 21.21.b.1, " Casting Defect in Limit Stop_ Housing".

This revision is being-isued to correct the plant reference stated on the cover letter and Forms 366 and 366A.

Very truly yours, M

T. P. Iconan General Manager Nuclear. Operations s1 Attachment i'

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March 8, 1990

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cc: Mr. William-T. Russell Regional Administrator United States Nuclear Regulatory Commission Region 1 475 Allendale Road King of Prussia, PA 19406 C. .A. Roteck, Ohio Edison Mr. Peter Tam, BVPS Licensing Project Manager United States Nuclear Regulatory Commission Washington, DC 20555 J. Beall, Nuclear Regulatory Commission, BVPS Senior Resident Inspector Dave Amerine Centerior Energy j 6200 Oak Tree Blvd.

Independence, Ohio 44101 I

INPO Records Center Suite 1500 1100 Circle 75 Parkway Atlanta, GA 30339 G. E. Muckle, Factory Mutual Engineering, Pittsburgh Mr. J. N. Steinmetz, Operating Plant Projects Manager j Mid Atlantic Area  !

Westinghouse Electric Corporation Energy Systems Service Division Box 355 Pittsburgh, PA 15230 1 i

American Nuclear Insurers .

c/o Dottie.Sherman, ANI Library f The Exchange Suite 245  ;

270 Farmington Avenue Farmington, CT 06032 Mr. Richard Janati  !

Department of Environmental Resources P. O. Box 2063 j 16th Floor, Fulton Building '

Harrisburg, 9A 17120 ,

Director, Safety Evaluation & Control Virginia Electric & Power Co.

P.O. Box 26666 One James River Plaza l Richmond, VA 23261

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f ACILITY N AME H) DOcst ET NUMBE R (2) PAG 6 04 Beaver Valley Power Station, Unit 1 ol510loIoI 1 1 1l0Fl017 I TITLE 14e Casting Defect in Litnit Stop Housing EVENT DATE 156 LER NUMBEh 161 REPORT DATE (71 OTHER F ACILITIES INVOLVED (81 MONT H DAY VEAR YEAR SE[j ' , ' ' ((g7 MONTH DAY vtAR FaciLITV Nauts DOC 8LE T NvMBEHist BVPS - Unit 2 o l510 l o ; o g 4l1 l 2

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NAME TE LEPHONE NUMBER AME A COOL Thomas P. Noonan, General Manager Nuclear Operations 4l1 l 2 6l4 1 3l1l2l5l81 COMPLETE ONa LINE FOR E ACH COMPONENT F AILURE DESCRISED IN THl$ REPORT l136 M ' "

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This report is being submitted under a 10CFR21. Six Limitorgue Corporation gear operators, model HBC-1, were found to contain a defect in the casting of the limit stop housing. These six operators are used at Beaver Valley for automatic opening discharge valves in the safety related river water (service water) system. The subject valve operators were manufactured in 1971. The affected valves normally use open and close limit switches to cease valve motion. The casting defect, located on the limit stop housing, causes the valve motion to cease

! prematurely in the open direction. This occurs because excessive l~ torque, required to overcome the defect, actuates the installed torque switch and stops further valve travel. The defect was corrected, during the seventh Refueling Outage, by machining the excess material. There were no safety implications as a result of this event. A river water pump remains continuously in service with its discharge valve open. The defect alone will not cause a loss of river water cooling. Two trains of Auxiliary river water were available at all times. Operation of other valves, of the same or similar model, were reviewed and no safety concerns were identified.

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DESCRIPTION During the Seventh Refueling Outage, BARTS (Butterfly Analysis and Review Test System ) was used to troubleshoot a persistent problem with a safety related river water pump discharge valve. During pump starts and testing, the discharge valve would trip during its stroke from the closed to-open position on excessive torque.

Repair efforts had centered around the torque switch Increasing the setting and replacing the switch failed to resolve the valve tripping. BARTS testing identified the motor as supplying equal torgue in both open and close directions. When coupled to the gear train, however, the opening torque was greater than the closing torque. Upon inspection of the gear train, it was noted that the limit stop housing contained an area of larger surface where the bearing contacts the housing. This larger-area also contained rub marks where the inner race of the bearing-had contacted the housing where, normally, the outer race is the only portion of the bearing which makes contact with the housing ( See figure 1 ).

This larger surface area was caused by excessive material in what should be a recess in the limit stop housing. The excess material had been machined flat by the manufacturer and now made contact See figure 2 ). When the with valvethe wasinner stroked raceinofthe theopen bearing direct (ion, the worm shaft would force the inner race of the bearing against the limit stop housing and increase the torque required to stroke the valve open.

Inspections of the remaining five river water pump discharge valves identified the existence of the defect in all five limit stop housings, in varying degrees. A maintenance history review noted that premature tripping of the valves was common to four of the six valves, two valves experiencing no problems.

It was later noted that the identical part number (Limitorque Corporation 60-014-007) for the limit stop housings is also used in gear operator models HBC-2 and HBC-3. A maintenance history review did not identify any stroking difficulty with any of the HBC-2 and HBC-3 valves.

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0l1 0l 3 oF 017 iCXT tX nawe wece in Newmt. one ennmnet MC Fonn 3laWs) (1D bAFETYIMPLICATIONS j There'were no safety implications identified at Beaver Valley. One train of-river water is always in service. Two redundant auxiliary o -river water' pumps are available, in addftion to the three pumps of .j the normal system. The defect alone could not have caused a total j loss of river water.

Of all valves with the HBC-1,2, or 3 gear operators, a review <

determined.that the. valves are either normally open, or stroke  !

closed to their safety related positions, or are tested during surveillances under normal flow conditions.

Beaver Valley Unit II construction was initiated after the period when the valves were manufectured. A review determined no valves at Unit II are affected. .i A generic safety issue arises based on the application of the gear I operators, models HBC-1,2, and 3, at other plants. The valves may  !

not stroke fully open to permit design flows to be delivered to l their respective components.

COMPANY SUPPLYING BASIC COMPONENT Limitorque Corporation LOCATION OF BASIC COMPONENTS CONTAINING DEFECT Six safety related river water pump discharge valves were found to contain the defect. The Beaver Valley mark numbers are MOV-1RW-102A1, A2, B1, B2, C1, and C2. j CORRECTIVE ACTION i

- 1. The six river water pump discharge valves limit stop housings were machined to remove the excess material. This was completed during the seventh refueling outage.

2. A review of the operating and maintenance history of the remainincJ HBC-1,2, and 3 model valves was conducted by the Engineering and Electrical Maintenance Departments. No indication of a defect was found based on proper valve operation and testing when the valves'were stroked to the open position with a differential pressure across the disk.

3. Engineering review has determined that Beaver Valley Unit II does not have the affected gear operators installed.

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1. Based on conversations with the vendor, Plants utilizing models HBC-1,2,3 gear operators, or having replacement parts, which were manufactured prior to 1975 may be susceptible to the described failure.

2. Increasing the torque switch setting in response to premature tripping may mask the defect if the increased setting allows the gear operator to overcome the defect. Persistent torque switch tripping, even at the higher settings, will be indicative of a potential defect. This will only occur during the opening stroke of the valve.

3. Inspection programs, when applied, will be able to identify the defect.by rub marks on the limit stop housing where the inner race of the worm shaft bearing contacts the limit stop housing.

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PARTS LIST 1 PC. NO. DESCRIPTION PC. NO. DESCRIPTION PC. NO. DESCRIPTION 1 HOUSING 8 POINTER 15 WORM SHAFT "O" RING 2 HOUSING COVER . 9 POINTER CAP 16 STOP SCREW COVER 3 END CAP' 10 END & THUR CAP GASKET 17 STOP SCREW & LOCKSC AEW -

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