ML20056D707
| ML20056D707 | |
| Person / Time | |
|---|---|
| Site: | Perry, Oyster Creek, Sequoyah, Turkey Point, San Onofre, Quad Cities, FitzPatrick  |
| Issue date: | 07/15/1993 |
| From: | Galeazzi D, Nuding M MKW POWER SYSTEMS, INC. |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| REF-PT21-93 NUDOCS 9308170345 | |
| Download: ML20056D707 (10) | |
Text
- JUL 16 '93 E!7:531%I POER SYSTEf'S R
P.E MKWPMFM@F5Y@hhe.
i E i..........
REPORT NO. 10CFR21-0066 JULY 15, 1993 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT:
75 PSIG Relief Check Valve, 1" NPT EMD #9521844 Kepner Products Co. #416C-1-75 SYSTEM:
Lube Oil System of Diesol Generators with EMD Engines CONCLUSION:
Defect is Reportable in Accordance with 10CFR21 PREPARED BY:
DATE:
Donald D. Caleazzi Engineering Manager APPROVED BY: E,/__/ /I4; DATE:
74f/rf Michael Nuckthg General Manager, Quality Assurance 28000E Post O!! Lee Box 1928. Accky Mount. North Carphns 278021928 e Phone:(919) 977-2720 (ff l TWX: (510) 929-072$ FAX. (019) 446-3830 l
f 9308170345 930715 ADOCK0500g PDR u
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JUL 16/93 07:53 iMI poler SYSTDiS R
[ EN M,Inc. -
f L,-
301 South Church Street I
Station Square, Suite 100 k,,_.......
H Rocky Mcunt,NC 27804 Phone: (919) 977-2720 -
TWX:
(510) 929-0725 i
FAX:
(919)446-1134 i
TELEFAX DATE July 15, 1993 COMPANY:
Office of Nuclear Reactor Reculation I
FAX NUMBER:
301-504-2260 I
ATTENTION:
Walter Haas 10CFR21-0066, Reportable Defect-75 psig. relief check REFERENCE valve, 1" NPT, EMD #9521844: Kenner #416C-1-75, FROM:
Michael Nudina IF YOU DO NOT RECEME ALL PAGES LISTED, PLEASE CA!1 EXTENSION 253,
PAGES(INCLUDING COVER SHEET):
10
Dear Sir:
Following this cover'is the above report.
being mailed to you under separate cover.. A copy is also Sincerely,.
MKW POWER SYSTEMS, INC.
. WW f
Michael Nuding_
General Manager-Quality Assurance
'/jb
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'JUL 16 '93 07:5411Kl4 POWER SYSTD15 R
P.3 REPORT NO.:
10CFR21-0066 PAGE:
1 OP 6 snMMAny:
HKW Power Systems received written notification from Southern California Edison, San Onofre Nuclear Generating Station on 7/7/93 about rusty 75 psig relief check valves (see Exhibit 1).
Six (6) of the eight (8) valves supplied by MKW Power Systems failed to relief until pressure was between 110 and 290 peig.
These valves were inspected by SCE and were found to be rusty inside.
The 75 psig relief check valve was added to the EMD diesel engine lube oil system as part of the EMD M.I. 9644 " Lube 011 Modification upgrade and serves as a bypass relief path a
for the turbocharger soakback oil filter.
This report addresses the rusty valve issue relative to generic concerns.
Users of the 75 psig relief check valve with suspect rust problems have been determined and will be notified accordingly.
cnupnNvnT:
75 PSIG rolief check valve, 1" NPT EMD #9521844 or Kepner Products Co. #416C-1-75
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- JUL 16 '93 07:54 t1Kl4 POLER SYSTEMS R
P.4 REPORT NO.
PAGE:
2 OF 6
)?
i crismovenc APPPcsi The users affected by this notification are listed below:
MKW Ship cumenenr cuot.
p.o.
nn, s.o. Nn, Part Nn, Qtg Dggg Comm. Ed. - Quad Cities 807497 9011 416C-1-75 3
11/06/89 RELXX21E 504590 9521844 2
11/04/91 GPU Nuclear-Oyster Creek 0324310 503607-9521844 2
04/04/91 FP&L - Turkey Point C91672 90152 503447 9521844 2
05/06/91 NYPA - Fitzpatrick 89-5004 51891 9521844 3
08/09/89 Perry Nuclear S116328 51186 9521844 1
03/09/09 S122380 501527 9521844 1
03/26/90 S125384 502686 9521844 2
12/30/90 S131248 506463 9521844 2
08/25/92 SCE - Enn Onefes 6A252001 60rAis eloc-1-75 7
02/24/93 1
04/02/93 TVA - Sequoyah 90NLH-85146B 502152 9521844 3
07/11/90 nerPrt:
i The internals of the valve rusted, requiring excessive pressure to actuate the valve.
The rust has been attributed to water used by 19M Power System during hydrostatic testing of the valves.
'JLL 16 '93 07:55 M34 POTR SYSTDs R
REPORT NO.:
10CFR21-0066 PAGE:
3 OF 6 ANALYRTE:
The valves identified by SCE with rust inside were tested by -
MKW Power Systems before shipment.
Review of MKW Power Systems nuclear dedication reports for the valves indicated that they were hydrostatically tested.
The valve body and poppet (ball) are carbon steel; therefore, it appears that the rust was caused by the test fluid.
MKW Power Systems has performed a review of its nuclear dedication reports for valves.
Only two (2) reports have been identified which specified hydrostatic testing for carbon steel valves; EMD #9521844 and Kepner Products Co.
- 416-C-1-75.
Both valves are identical.
Hydrostatic testing of the valves began in February 1989.
Valves shipped from MKW prior to this date are not affected.
As a result of this review, MKW Power Systems will now perform pneumatic testing with nitrogen gas instead of hydrostatic testing on these valves.
This will correct the rust problom.
The 75 psig relief check valve is used as a bypass relief path for the turbocharger soakback filter (see Exhibit 2).
During initial startup of the standby lube oil system with cool oil, the 3 GPM pump outlet pressure will bypass through the valve until the immersion heater has operated for a sufficient amount of time to heat the oil.
As the oil warms, its viscosity decreases and the pump outlet pressure falls below the relief setpoint, causing all of the oil to flow through the turbocharger soakback filter.
The valve also provides a relief path in case of a piping cbstruction (clogged filter, etc).
The valve is spring load, holding the poppet against its seat; therefore, rust accumulation will only cause the valve to fail closed.
If a rusty valve was installed without first being bench tested at the site, its failure would be detected during initial startup of the standby lube oil systam.
Excessive turbocharger oil pressure would be observed which could cause oil leakage from the soakback filter cover (maximum operating pressure for the filter is 90 psig).
The valve has a relief setpoint of 75 psig 110%.
Pressures in excess of 83 peig at the 3 gpm pump outlet indicato a failed relief check valve.
If such a valve was installed and no failure was detected during initial startup of the standby lube oil system, the system will operate correctly (once the lube oil heats up to standby temperatures).
Based on normal monitoring and
+
preventive maintenance practices of the nuclear safety related diesel generator systems, users that have suspect valves installed in the EDG lube oil system can address this notification at their next refueling outage.
JUL 16 '93 OD55 iMJ POWER SYS'.' EMS R
P.6 REPORT NO.
. " ~
PAGE:
4 OF 6 I-CORRPPTTVE AETTON:
Users affected by this notification should examine their stock for suspect valves.
Users with suspect valves installed, without having evidence of valve operability, should test the valves (75 psig 10%) and replace as necessary during their next refueling outage.
Contact MKW Parte Department for valve return and replacement.
1 1
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. JUL 16 '93 07:55 F534 FGER SYSTDE R
P.7 f2
~
REPORT NO.:
10CTR21-0066 PAGE:
5 0F 6 EXHTMTP 1 SCE Fax dated 7/7/93 (1 page)
I
JLL 16 '93 07:56 f1KW POWEP SYSTDTS R
P.8 4;Igo7<03 10:04 D714 368 6S35 SONGS DJD 2002<002 (109] Frcm: ROGER STorlR at ROOF 3 7/7/93 G:47A*4 (1901 bytes: 27 in)
To: DOUGLAS TXJDSON at SOUTH, BILL STROM, ROGER STOKER Sub:} ect : 10CFR21 Censideraticn Of Rusty Rolief Check Valves Message Centents ------------------.-----------
A total of sixteen check valves were originally received from 10:W, eight 30 psi valves and eight 75 psi valves.
Procurement confinned that the valves were pop tested at the vancor and thus SCE did not plan en testing them prier to installation in the four DG trains at Units 2 & 3.
Two each of the 30 and 75 psi valvos were installed in the Unit 2 Train "B" DG during the current refueling shutdown and during functional testing on June 24,1993, it was cbaarved that the 75 pai valves were stuck closed.
-he six remaining 75 psi check valves were then pop-tested to
- "etermine their functional condition.
Four cf these valves failed to relieve until pressure was between 110 psig and 290 peig.
Onese four valves were then taken apart and found to be extremely rusty inside.
The remaining two valves were satisfactorily pop-tested and subsequently installed in the Unit 2 Train "B" DG.
A1A 30 psi valves were found to be in new condition a.nd testad saticfactorily.
'"he six rusty 75 psi valves were then sent back to the vendor for replacement or rework.
Nanconfor=anca Report (NCE) 93060146 was wrif, ten to document the 75 pei check valve defects and initiate a 10CTR21 reportability evaluation.
The valves are used to relieve prelube oil pressure and a valve failure could result in pump inoperability.
Failure of the prelube oil purp is a significant eafety issue and could create a substantial safety hazard at
$CNGS Units 2 or 3.
The 10CFR21 rcporting proceso is a norma.1 supplier function and MKW is curruntly considering how best to dischnrge that rt:eponsibility.
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JUL 16. '93 07:56 IM4 poi 1ER SYSTEMS -
R P.9 '
REPORT NO.:
~-
PAGE:
6 OF 6 PYMTETT 2 Lube Oil System Scheme, tic (1 page) a_.
- JUL 3 6. '93 07:56 f1't,I POWER SYSTE!13 R
P.10 -
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I i
r Siphon Break (Connect To Side Outlet Of Tee On Oil Filter Vent Line At 1/2"
- Indicates Sight Glass Engme As Shown) f{ Steel Tube (Vertical Height Critical)
Cemshaft C' Weight \\(
j 3
V 7 ent Housing
\\
7 r1/8" Orifice f
6 Engine
.f 4"lPS Steel Tubs ~~]5/8" O.D Q
1/2"O.D.
b
/
o Steel Tubb X
3/8" O.D. Tubing To Turbo Oi!
t Pressure Gauge And 060" Alarm Switch (TOS)
- O/ Orifice Luce Gauge E pst Oil Main Bearing X
v Switch Pickup - 10 psi
~~
e' Falter Pressure Pump' Switch Drop ut - 6 psi Outlet Elbow
'N r
I Turbo Soak 5/8"O.D. / Prime Plug
\\1/2"IPS Swing :
--Beck Oil
[
Fetter Steel Tube Lune Check Vetve Oil Stramer i To,, Turbo hrQS cev.,, _, _ j Box g
0.0. Steel
% EMD # D2 M Plug \\
Strainer 30 psi 76 psi Strainer o
um
- 46C-1-75 4- -
.: m ngine 6 gem Pump ' 3. jp h ek k
1 " IPS
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'co co s
1 " !PS 3 gpm Pump o
,, p
'\\
3/8" Tubing To Circulating Oil
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1 1/2[IPS Pump Alarm Pressure Switen (COPSI Pump "in" Plug Pickup At 20 psi-Dropout At 16 psi System Schematic Diagram b
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