ML20058K384
| ML20058K384 | |
| Person / Time | |
|---|---|
| Site: | Perry, Catawba, Harris, Grand Gulf, River Bend, Vogtle, San Onofre, Comanche Peak, Rancho Seco, Bellefonte, Washington Public Power Supply System, Shoreham, Hartsville  |
| Issue date: | 12/09/1993 |
| From: | Labrun H COOPER INDUSTRIES, INC. |
| To: | NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
| References | |
| REF-PT21-93 QCG-9689, NUDOCS 9312150186 | |
| Download: ML20058K384 (10) | |
Text
1
. Cooper In'ustries ciprocat ng P duct) Division
=
150 Lincoln Avenue Grove City A 16127-1898 W
COOPER December 9,1993 Cooper Energy Services i'
Our Ref: OCG-9689 Document Control Desk P
U.S. Nuclear Regulatory Commission Rep d #165 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 the subcover which is assembled atop the power head.
These subcovers were supplied as the individual or assembly part number 02-362 AC,02-362-04-AD,1 A-5529, or 1 A-5975 to the following utilities:
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 SONGSI 75041-42 DSRV-20-4 CLEVELAND ELEC Perry 75051-54 DSRV-16-4 TVA Bellefonte 75080-83 DSRV-16-4 WPPS WPPSI 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 1onn-9312150186 931209 e
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December 9,1993 Page 2 Numerous engines have exhibited cracks in the portion of the subcover upon which the intake and exhaust rocker shafts mount. To date, all the subcover cracks have been discovered in the side closest to the exhaust transverse push rod during routine maintenance inspections. If left unchecked, failure of the bolted joint could cause a fatigue failure of the threaded fastener.
Information recently compiled dealing with the incidence of subcover cracking has revealed a more widespread occurrence than originally believed. Catastrophic failures have been documented for both Nuclear and Commercial applications.
A probable scenario describing the sequence of events leading up to an engine failure due to subcover cracks are as follows. Due to a marginal section thickness in the subcover pedestal between the vertical machined inner surface and the rocker shaft hold-down bolt hole counterbore, a crack would initiate as a result of the reaction loads from the rocker shaft assemblies. When the crack opened up enough, the bolt preload would be lost and the fastener would then be subjected to a much larger portion of the cyclic loads caused by the operation of the rocker arms. Fatigue failure of the fastener would follow to a point where the valves would no longer open. It would not be recommended that the engine be allowed to run under these conditions for any appreciable period of time, such as would be necessary should a diesel generator be required to come on line and run unattended for seven days, in accordance with its nuclear mission.
It is recommended that starting with each facility's next refueling outage, a Liquid Penetrant or Magnetic Partical Inspection be performed on a 100% basis, every five (5) years. Recently inspected subcovers may have the five year inspection frequency applied to the time of last inspection. Any subcovers exhibiting cracks of any size should be replaced. Due to a new subcover design, described in the following paragraph,_the 'old style" subcover is no longer available. However, replacement components may be drawn from each facility's existing stock, provided the above referenced inspection procedure is satisfied.
On April 14,1993 a Product improvement Bulletin (PIB) was issued introducing a new R4 subcover design. The new design consists of increasing the material thickness in the previous crack location by a factor of three, and stiffening the pedestals by adding j
a significant amount of material to the outboard ends. Refer to the attached PIB for new part numbers.
l Our investigation on this matter was concluded on December 8,1993. If you have any questions regarding this issue, please contact John R. Schneider, Quality
~
OCG-9689 December 9,1993 Page 3 j
Assurance Manager or Ron G. Billig, Supervisor Enterprise Engineering at 412-458-~
8000.
Sincerely,
!yf
/lAC&hl
//
H. A. aBru Vice Presid tand General Mhnager i
Attachment HAL/ rec 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 -
B. C. Guntrum - CES/ Alameda R. L. Nimmo - CES/ Alameda Lee Duck - CES/ Alameda S. S. OwYoung - CES/ Alameda J. R. Andrews - CES/ Alameda R. A. Johnston - 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.
Carolina Power and Light Co.
Harris Nuclear Project P. O. Box 165 New Hill, NC 27562 Attn:
Dept. Mgr.
QCG-9689 December 9,1993 Page 4 cc:
Carolina Power and Light Co.
Harris Nuclear Project P. O. Box 165 New Hill, NC 27562 Attn:
William Robinson Plant Gen. Mgr.
Carolina Power and Light Co.
P. O. Box 1551 Raleigh, NC 27602 Attn:
R. A. Watson Sr. Vice President Carolina Power and Light Co.
Shearon Harris Nuclear Project P. O. Box 1551 Raleigh, NC 27602 Attn:
Robert Prunty Mgr. RNP/HNP Licensing Carolina Power and Light Co.
Shearon Harris Nuclear Project P. O. Box 165 New Hill, NC 27562 Attn:
Mickey Hamby Acting Mgr. of Regulatory Committee Carolina Power and Light Co.
Shearon Harris Nuclear Plant P. O. Box 165 New Hill, NC 27562 Attn:
Jerry R. Cribb Mgr. Quality Control Carolina Power and Light Co.
Manager, Nuclear Licensing P. O. Box 1551 Raleigh, NC 27602 Attn:
David McCarthy Carolina Power and Light Co.
Brunswick Nuclear Project NC Hwy. 87,2-1/2 Mi. North Box 10429 Southport, NC 28461 Attn:
Roy A. Anderson Vice President
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OCG-9689 December 9,1993 Page 5 cc:
Carolina Power and Light Co.
Robinson Nuclear Project SC Hwy.151 and 23, Box 790 Hartsville, SC 29550 i
Attn:
Charles R. Dietz 1
Vice President Cleveland Electric illuminating Perry Nuclear Power Plant P. O. Box 97 Perry, OH 44081 Attn:
M. Lister Cleveland Electric illuminating Perry Nuclear Power Plant P. O. Box 97 Perry, OH 44081 Attn:
Russell J. Tadych Manager, Quality Control Cleveland Electric illuminating Perry Nuclear Power Plant P. O. 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:
R. C. Day Duke Power Co.
Nuclear Generation Dept.
P. O. Box 1007 Charlotte, NC 28201-1007 Attn: Mgr., Nuclear Safety Duke Power Co.
Nuclear Generation Dept.
P. O. Box 1007 Charlotte, NC 28201-1007 i
Attn: W. T. Robertson Vice President, Procurement
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QCG-9689 December 9,1993 Page 6 i
cc:
Entergy P. O. Box 429 Echelon One 1340 Echelon Parkway l
Jackson, MS 39286-1995 Attn:
F. W. Titus Vice President, Engineering Entergy 1
P. O, Box 756 Port Gibson, MS 39150 Attn: C. R. Hutchinson Vice Pres., Operations-GGNS j
Entergy P. O. Box 756 r
Port Gibson, MS 39150 Attn: D. L. Pace, Director Design Engineering-GGNS Entergy
[
P. O. Box 756 Port Gibson, MS 39150 Attn: M. J. Meisner Director, NS&RA a
Manager, Quality Services Entergy Operations l
Box 756 Port.Gibson, MS 39150 Southern Nuclear Operating Company Vogtie Project P. O. Box 1295 Birmingham, AL 35201 Attn.
E.',gr., Engineering and Licensing Georgia Power Co.
Plant Vogtle P. O. Box 1600 Waynesboro, GA 30830 Attn: Mr. W. B. Shipman General Manager
QCG-968e December 9,1993 Page 7 cc:
Gulf States Utilities P. O. Box 220 St. Francisville, LA 70775 Attn:
L A. England Director Nuclear Licensing Long Island Power Authority i
Shoreham Nuclear Power Station North Country Rd.
j Wading River, NY 11792 Attn: Mgr. Licensing & Regulatory
)
Compliance Department Southem Califomia Edison San Onofre Nucl:.r Generating Station P. O. Box 128 San Clemente, CA 92672-0128 Attn: Manager, Nuclear Oversite Div.
Southem California Edison San Onofre Nuclear Generating Station P. O. Box 128 San Clemente, CA 92672 Attn: ISEG Supervisor i
Sacramento Municipal Utility District Rancho Seco Nuclear Power Plant i
14440 Twin Cities Road Herald, CA 95638 Attn: Vice Pres, & Gen. Manager TennesseeVa!!ey Authority 1101 Market Street, LP 4F i
Chattanooga, TN 37402 j
Attn: Mr. M. J. Fecht Manager, Nuclear Experience Review TU Electric - Production Division
-l Group Vice President - Nuclear Skyway Tower 400 North Olive Street, LB. 81 Dallas, TX 75201 Attn: W. J. Cahill, Jr.
Washington Public Power Supply P. O. Box 460 Richland, WA 99352 Attn: Mr. L. C. Oakes Manager, WNP-1 Engineer
OCG-9689 I
December 9,1993 Page8 cc:
Mr. Oh, Yong Shick f
Plant Mgr., Kori 3 & 4 Korea Electric Power Corp.
216 Ko Ri Jangan-Up Yangsan-Gun Kyung-Nam, Korea 626-950
(
Mr. Jong Sok Kim j
Manager, Nuclear Power Generation Dept.
Korea Electric Power Corporation 167, Samsong-Dong, Kangnam KU Seoul,137-791 Korea 4
Mr. 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 Mr. T. R. Ho, Superintendent i
Taiwan Power Company Kuosheng Nuclear Power Station 60 Pa-Tou Yeh Liu Village Wan Li Hsiang, Taipei Hsien i
(20703), Taiwan, R.O.C.
A.H.Jeng I
Director, Nuclear Safety Dept.
Taiwan Power Company
_242 Roosevelt Road, Section 3 Taipei 100, Republic of China S.H.Soong Station Superintendent Third Nuclear Power Station t
Taiwan Power Company P. O. Box 39 Heng-Chun, Ping-Tung Hsein Taiwan, 924 R.O.C.
File K5fa28
CCCPER PRODUCTIMPROVEMENT BULLETIN April 14,1993 ENTERPRISE R4 AND RV-4 SUBCOVER REDESIGN Description This memo addresses the cracking of rocker arm shaft suppon pads on R4 and RV-4 engine subcov-ers. A solution now exists in the form of redesigned subcovers. For old and new part numbers, refer to the chan below. Also, see illustration on the following page.
Recommendations Numerous engines have exhibited cracks in the portion of the subcover upon which the intake and exhaust rocker arm shafts mount. To date, all the subcover cracks have been discovered in the side 4
closest to the exhaust transverse pu>h rod during routine maintenance inspections. If this were to go unchecked, failure of the bolted joint could cause a fatigue failure of the threaded fastener.
The redesign consists of moving the rocker shaft mounting holes outboard, which results in more material between the bolt hole and the inner milled face of the subcover. Redesigned intake and ex-haust rocker ann shafts are also required. In addition, material was added adjacent to the maunting pads to add stiffness in response to forces caused by the exhaust transverse push rod. Finally, the subcover to bonnet gasket was recontoured to allow clearance for the lengthened rocker shafts. The gasket part number was not changed and will work for new and old applications.
The old subcover has been permanently obsoleted and is no longer available. Old style rocker shafts, however, will still remain available.
Method Each replacement subcover requires one gasket and two rocker shafts. The following chan lists old and new pan numbers for both R4 and RV-4 engines:
OLD NUMBER DESCRIPTION & QUANTITY NEW NUMBER 1 A-5529 Subcover Assembly:
1 A-7846 03-362-01-OB Dowel-2 per assy.
L3-362-01-OB 03-362-04-AC Subcover-1 per assy.
03-362-04-AH 1A-5975 Subcover Assembly:
1 A-7847 03-362-01-08 Dowel-2 per assy.
03-362-01-OB 03-362-04-AD Subcover - 1 per assy.
03-362-04-AJ 03-390-06-AA Rocker Shaft - 2 per assy.
03-390-06-AB i
03-362-04-AB Gasket -1 per assy.
03-362-04-AB i
Pace 1 i
-~..
'COTPER PRODUCT IMPROVEMENT BULLETIN i
April 14,1993 Extra Matenal Three Times More Material Section Added in Crack Location Than Exhaust Previous Design Rocker Shaft Exhaust Rocker
/ Arm O
O
\\
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QL
%.J' Exhaur Transverse Push Rod
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NEW DESIGN Exhaust Side Shown SEE INSETS N['%\\g 0:
/ N intake
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Rocker Shaft
\\
Cracks
\\ Foundin intake Rocker This Loca.
Arm PREVIOUS DESIGN Exhaust Transverse Exhaust Side Shown Rocker Arm ENTERPRISE R4 & RV-4 SUBCOVER REDESIGN Page 2