ML20012C135
| ML20012C135 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 03/08/1990 |
| From: | Stolba F COOPER INDUSTRIES, INC. |
| To: | Murley T Office of Nuclear Reactor Regulation |
| Shared Package | |
| ML20012C136 | List: |
| References | |
| REF-PT21-90, REF-PT21-90-040-000 PT21-90-040-000, PT21-90-40, QCG-6843, NUDOCS 9003200166 | |
| Download: ML20012C135 (4) | |
Text
d COOPER BESSEMER RECIPROCATING
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March 8, 1990 Dur Ref: OCG-6843 Dr. Thomas E. Murley, Director Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Cormiission Washington, D.C.
20555
Subject:
KSV-Standby Diesel / Generators Houston Light and Power South Texas Project Unit DG22, Connecting Rod failure
Dear Mr. Murley:
On December 8, 1989 we notified you that a connecting rod had failed at the South Texas Project in one of our engines.
An interim report covering root cause investigations was sent to you on January 30, 1990.
We are enclosing herewith the following documents which comprises our final report to you in compliance with the requirements of 10CFR Part 21:
Cooper-Bessemer - Applied Mechanics Report AM-1852-C-1A. Final
- Report,
" Finite Element Analysis of the KSV-4-2A Master Connecting Rod".
Immediately following the incident, Houston Lighting and Power (H. L. & P. ) undertook a mechanical and chemical analysis of the f ailed rod, it was determined that these properties were within specification, details of which are available from H.L. & P.
In
- addition, H.L.
P.
hired Aptech Engineering Services of California to conduct a finite element analysis (F.E. A.) of the portion of the rod which failed.
Simultaneously, Cooper-Bessemer (C-B) carried out an F.E.A.
The results of the two F.E. A. 's were substantially similar and led to the conclusion that they were in agreement with one another, pf h
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Dr. Thomas E. Murley March 8, 1990 Page 2 C-B commissioned Battelle Columbus laboratories to also carry out an independent failure analysis.
This comprised a
fractographic examination of a portion of the failed rod provided by H.L.
P.
and some basic fracture mechanics and fatigue calculations to attempt to rationalize the cracking behaviour.
Battelle also reviewed the F.E. A. work performed by C-B.
The following " conclusion" is extracted from Page 6 of the C-B report:
Conclusion Any of the KSV-4-2A connecting rods which have the central 3/8 inch lubricating oil hole drilled past the transverse oil hole, but not through the surface of the articulated pin bore, will have a minimum cyclic f ailure f actor of 2.83 near the tip of the
- hole, under normal operating conditions.
The CFF will be greater than 2.42 under the worst credible operating condition (overspeed trip setting).
Rods which have the hole drilled through and radiused will have a higher CFF.
Thus all of these rods presently installed in KSV engines are safe for continued operation."
The No.
4 master connecting rod failed November 28, 1989 damaging the crankshaf t, no. 4 lef t and right piston and liners, the centerframe and miscellaneous other damage.
The engine was repaired and restarted for tests on December 28, 1989 and declared operable January 10, 1990.
In this regard, please see a copy of C-B letter ref. OCG-6740.
Steps have been taken to preclude over-drilling of the oil holes in the future.
No KSV master connecting rods have been manu-factured since the incident at the South Texas Project.
We therefore regard this matter closed.
COOPER BESSEMER RECIPROCATING E"O
Dr. Thomas E. Murley March 8, 1990 Page 3 With this submission, we regard the 10CFR Part 21 reporting requirements as closed, there being no generic impact and corrective action has been taken to preclude a similar failure.
Sincerely, bhau bMd*
F. Bruce Stolba FBS/bja Attachments cc: D. T. Blizzard R. J. Brager Jai R. N. Rajan - NRC W. O. Ferguson - MV W. Haass - NRC J. M. Horne T. W. Kearns KSV User's Group W. H. A. Lambert R. A. Miklos D. Musick - H.L.& P.
M. A. Schleigh B. R. Sedelmyer E. B. Tomlinson - NRC A. E. Bice/0.A. Staff Files: K5falB 4-1 S0-0420/P5c
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Our Ref: OCG 6740 l
Mr. T. J. Jordan Plant Engineering Manager Houston Lighting and Power Co.
P. O. Box 1700 Houston TX 77001
Subject:
Standby Diesel / Generator DG22 Serial No. 7193
Dear Mr. Jordan:
We note the following nith respect to returning the above diesel / generator to full operability fo'icaing *.he loss of number four throw rod:
1.
All inspections per our letter reference 00G 6605 revision 1.
datee December 16, 1989 were carried out and complied with the detail contained therein.
2.
All connecting rod tearings were replaced.
3.
Following break in the engine was run 160 hours0.00185 days <br />0.0444 hours <br />2.645503e-4 weeks <br />6.088e-5 months <br /> at 1001 load of which the first 130 hours0.0015 days <br />0.0361 hours <br />2.149471e-4 weeks <br />4.9465e-5 months <br /> were essentially continuous running with the last 30 hours3.472222e-4 days <br />0.00833 hours <br />4.960317e-5 weeks <br />1.1415e-5 months <br /> being site specific tests.
4.
Using the INSPEC 3000 instrument the engine was analyzed and found to be in satisfactory condition.
5.
The engine was declared operable on January 10, 1990.
Please be advisee that in consideration of the above, Diesel / Generator DG.
SN 7193 has been restored to a like new condition.
Very truly,yours.
W. H. A. Tambert Manager, Quality Assurance and Nuclear,0perations ec: D. Musick - HLSP R. A. Miklos J. M. Horne K. R. Young - ESG Hou M. A. Schleigh File:<K-Sfa18
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