ML20062H141

Final Significant Deficiency 63 Re Colt Industries Emergency Diesel Generator Malfunctioning Thermostatic Valve.Generators Will Be Corrected Per Vendor Instructions. Also Reported Per Part 21

ML20062H141
Person / Time
Site:	Limerick
Issue date:	08/03/1982
From:	Kemper J PECO ENERGY CO., (FORMERLY PHILADELPHIA ELECTRIC
To:	Haynes R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
References
REF-PT21-82 10CFR-050.55E, 10CFR-50.55E, NUDOCS 8208130319
Download: ML20062H141 (4)

Text

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s .e PHILADELPHIA ELECTRIC COMPANY 23O1 M ARKET STREET P.O. BOX 8699 1881 -1981 PHILADELPHI A. PA.19101 JOHN S. KEMPER VICE PRESIDENT AUG 3 1982 Mr. Ronald C. Haynes, Director Office of Inspection and Enforcement Region I United States Nuclear Regulatory Commission 631 Park Avenue King of Prussia, PA 19406

Subject:

Significant Deficiency Report No. 63 Colt Industries Emergency Diesel Generator Possible Thermostatic Valve Malfunction Limerick Generating Station, Units 1 6 2 Attachments: a) Letter Robertshaw-Controls Company to Colt Industries, May 13, 1982 b) Letter Colt Industries to USNRC Region III, May 25, 1982 c) Letter Colt Industries to USNRC Region III, June 28, 1982 File: QUAL 2-10-2 (SDR#63)

Dear Mr. Haynes:

The attachments have brought to our attention a deficiency in the subject Colt Industries emergency diesel generator thermostatic valves which has been previously reported to the USNRC under the provisions of 10CFR, Part 21. The subject diesel generators have been supplied by Colt Industries for use at Limerick Generating Station.

We consider the deficiency described in the attachments a significant deficiency per 10CFR50.55(e) and are hereby notifying you as required.

We believe that the Colt Industries report submitted under the provisions of 10CFR, Part 21 provides the information required for 10CFR50.55(e) reporting. Therefore, we anticipate that this letter will be our only report to you on this subject.

8208130319 820803 d PDR ADOCK 05000352 -

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l We will of' course assure that the Limerick diesel generators are corrected in accordance with instructions received from the -

vendor.

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-Sincerely, S..AF'_ad - jr -- -

' Attachments Copy to: Director of Inspection and Enforcement United States Nuclear Regulatory Commission Washington, DC 20555 E. B. McCabe, USNRC 4

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ROBERTSHAW CONTROLS COMPANY hisOhlA M Alir - i 4'W W M4FI W

,.- FULTON SYLPHON DIVISION 2318 KINGSTON PKE. S W. *****

P O. BOX 400 + KNOxvlLLE. TENNESSEE 37901 AREA COoE 615

• TELEPHONE 546-0550

• TWX 810 - 583 - 0143 May 13, 1982 Colt Industries Fairbanks Morse 701 Lawton Avenue Beloit, Wisconsin 53511 Attention: Mr. Peter R. Vander Vennett

Purchasing Agent Centlemen

This letter is to inform you of an incident involving a Robertshaw thermostatic valve supplied for use at a nuclear power plant. This information should be evaluated by the criteria set forth in Title 10 of the Code of Federal Regulations Part 21 (10CFR21) .

Robertshaw Models 1284 and 1285 in the 5" and 6" sizes incorporate a lower overrun assembly which absorbs movement generated by tbe thermal assemblies under certain conditions. The overrun assembly consists of a spring restrained between two end pieces whose length and " breakdown" is set by an axial bolt and nut. Under normal conditions, this assembly acts as a rigid member. Should the nut not be firmly affixed in place and " backoff" the longer length of the overrun assembly results in valve stroke which is not generated by the thermal assembly. This additional -stroke makes the thermal assembly control at a lower temperature, thus, over cooling the system.

In the Fall of 1977, it was reported to us that the nut had com-pletely " backed off" in one valve intended for nuclear service.

This allowed the valve to go into the full cooling position. At that time the design of the overrun assembly called for the nut to be staked in place. The design was revised to require solder-ing the nut to the bolt. No further reports were received of any difficulty.

In mid-April of this year, the Chief Froject Engineer responsible for the design of these thermostatic valves visited the Virgil C. Summer Nuclear Station to aid in the investigation of over cooling of the engines used in the Stand-By Diesel Generators.

Plant personnel reported to him that when the valves were opened for inspection at an earlier date, one valve had the nut missing from the lower overrun assembly. This group of valves had been supplied prior to the described design revision. It-vas deter-mined that improper overrun assemblies were not responsible for the engine over cooling at this site.

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Colt Industries Beloit, Wisconsin Attn: Mr. Peter R. Vander Vennett Page May 13, 19t2 .

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Valves known to have the " staked" overrun construction have been supplied to your comp.any for use at the following sites:

Millstone Virgit C. Summer 7eaver Valley Our investigation following the report from the Virgil Summer site disclosed that the design change made in 1977 was a "USE" change, i.e., completed overrun assemblies and completed ther-mostatic valve assemblies were "used" before the design change was implemented. 'Ihese overrun assemblies are also used in conunercial valves, and it is impossible to determine how many, if any, assemblies with the staked construction were supplied to nuclear power plant after the design change was made.

In our investigation we also discovered that at least one lot of overrun assemblies for the 5" size valves had been placed in our stock without solder locking the nut in place. Again, since this is also used in corwnercial valves, we cannot determine if any of this group was actually supplied to you for use at a nuclear power plant site.

Sites which may be affected are: '%

Limerick '.

Snupps Seabrook Marble 11111'

• llope Creek In our judgement, this type of fallute does not constitute a sub-stantial safety har.ard; however, we cannot adequately evaluate the effect of over cooling in your application for these valves.

Therefore, as required by 10CFR21, we raquest that you evaluate this information considering your application.

Yours very truly, ROBERTSilAW CONTROLS COMlWIY Fulton Sylphon Division T. T. Ilowell Quality Manager TTil:g cc: Mr. I. O. Johnson Mr. J. A. Ilowell

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Colt !ndustries y,*,"yfy*,'

.RECOVED 701 Lawton Avenue Beloit. Wisconsin 53511 g[$ j j 1g?;,

608/364-4411 l May 25, 1982 R A MULFORQ , ,

Heret my Nav Office cf Inspection & Enforcement '

U. S. Nuclear Regulatory Commission '

608 364-8010 799 Roosevelt Road Glen Ellyn, Ill. 60137 (EffectiveJune7j Attention: Mr. James G. Keppler, Director, Region III

Subject:

Colt Industries-Fairbanks Morse Engine Division Emergency Diesel Generators Possible Thermostatic Valve Malfunction Fail Safe To " Full Cooling Position" Part 21 Report

Enclosure:

Robertshaw Controls Company May 13, 1982 letter to Colt Industries Gentlemen:

We have been advised by Robertshaw Controls that certain thermostatic valves have a potential failure mode as described in the enclosure.

Although Robertshaw judged that the fail safe mode didn't constitute a substantial safety hazard, Colt's engineers feel that extreme overcooling with attendant risk of engine damage could occur with low raw water supply temperatures and that this ~=.,

possibility does constitute a substantial safety hazard.

D.G. sets at nuclear plants that have the potential defect are:

1) Northeast Utilities, Millstone III. -

2) South Carolina Electric & Gas, Virgil C. Summer

3) Duquesne Light Co., Beaver Valley Unit 2

4) Philadelphia Electric Co., Limerick 1 and 2

5) SNUPPS a) Wolf Creek Unit 1 b) Callaway Unit 1

6) Fublic Service of New Hampshire, Seabrook Units 1 and 2

7) Public Service of Indiana, Marble Hill Unit 1

8) Public Service Electric & Gas Co., Hope Creek Unit 1 D.G. Set #1

9) Jersey Central Power & Light, Three Mile Island Unit 2.

10) Alabama Power Co., Farley Units 1 & 2 (PC-2)

Only the Farley and Sunmer Station engines are operable; the remainder are shut-down, in storage, or awaiting start-up at the various sites.

Colt is presently working with Robertshaw to obtain from them a procedure for the disassembly, inspection, possible repair and reassembly of the affected valves as well as their advice as to who should make the inspections / repairs.

When this information is available, inspections will be made by Colt, Robertshaw or requested of the utilities, first on the Farlay and Summer units and on all other units before they're started up. We will keep you advised of the progress of the inspections / repairs.

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L Nuclear Regulatory Commission

. May 25, 1982 - Page 2 A copy of this report is being forwarded to the utilities involved and to Robert-shaw Control Company.

Very truly yours, 8

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. M. Moriarty MANAGER UTILITY A S JMM:jc cc: Stone & Webster Engineering Corp. Bechtel Power Corp.

P. O. Box 2325 P. O. Box 3965 Boston, Mass. 02107 San Francisco, CA 94119 Attention: Lead Electrical Engineer Attention: Hope Creek Project Engr.

J.0. No. 12179 (Millstone III)

South Carolina Electric & Gas Co. Metropolitan Edison Co.

P. O. Box 764 P. O. Box 542 Columbia, South Carolina 29218 Reading, PA 19640 Attention: Mr. Dan Nauman Attention: Project Engr. TMI-Unit 2 Manager, Q. A. & Security Stone & Webster Engineering Corp. Alabama Power Company P. O. Box 2325 P. O. Drawer 470 Boston, Mass. 02107 Ashford, AL 36312 Attention: Project Engineer for Attention: Mr. George Hairston Duquesne J.0. 12241 Philadelphia Electric Co. U. S. Nuclear Regulatory Commission 2301 Market Street c/o Document Management Branch Philadelphia, PA 19101 Washington, D.C. 20555 Attention: Mr. Dick Mulford Limerick Project Manager Bechtel Power Corp. Robertshaw Controls Company P. O. Box 607 P. O. Box 400 Gaithersburg, MD 20760 Knoxville, TN 37901 Attention: SNUPPS Project Engineers Attention: T. T. Howell, Quality Mgr.

United Engineers & Constructors, Inc.

P. O. Box 8223 Philadelphia, PA 19101 Attention: Mr. D. H. Rhoads Project Engrg. Manager (Seabrook)

Sargent & Lundy Engineers 55 E. Monroe Street Chicago, IL 60603 Attention: P. L. Wattelet Marble Hill Project Manager 4

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' Colt industries Falsanks Mome Engine Division 701 Lawton Avenue RECf!VE0 seroit wisconsin sas11 608/364-4411 JUL - 119??

June 28, 1982 k A MULrge Office of Inspection & Enforcement U. S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Ill. 60137 Attention: Mr. James G. Keppler, Director, Region III

Subject:

Colt Industries-Fairbanks Morse Engine Division Emergency Diesel Generators Possible Thermostatic Valve Malfunction Fail Safe To " Full Cooling Position" -

Part 21 Report Supplemental Report No. 1

Reference:

May 25,1982 Part 21 Report - Robertshaw Valves - same subject Gentlemen:

The referenced report contained information from Robertshaw indicating solder was used to " stake" nuts on certain override assemblies and that a potential failure mode exists if the soldering operation had been omitted.

Since the referenced report was made, Robertshaw has been advised by Colt that solder can be attacked by certain jacket water corrosion inhibitors. Robertshaw, I

therefore, has determined that overrun assemblies utilizing swagged locking should be installed, as replacements, in all of the plants indicated as being suspect.

Procedures for the replacement of the assemblies and documentation sign-of f sheets are being prepared and will be forwarded to the NRC and the utilities involved when available. Information relative to availability of replacement assemblies is also being developed. The replacement parts will be supplied by Robertshaw upon receipt of no-charge purchase orders from the utilities. The parts shipments will be accom-panied by documentation sign-off sheets along with instructions that the sign-off sheet be filled out by the utility after the replacement and returned to Robertshaw.

Robertshaw will then forward copies to Colt so that actions at each site can be properly closed out by further supplemental reports.

We will keep you advised of our progress in this matter.

A copy of this report is being forwarded to the utilities involved and to the Robertshaw Controls Company.

Very truly yours,

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. Moriarty

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. Ll. .S. Nuclear Regulatory Commission June 28, 1982 - Page 2 cc: Stone & Webster Engineering Corp. Bechtel Power Corp.

P. O. Box 2325 P. O. Box 3965 Boston, Mass. 02107 San Francisco, CA 94119 Attention: Lead Electrical Engineer Attention: Hope Creek Project Engr.

J.0, No. 12179 (Millstone III)

South Carolina Electric & Gas Co. Metropolitan Edison Co.

P. O. Box 764 P. O. Box 542 Columbia, South Carolina 29218 Reading, PA 19640 Attention: Mr. Dan Nauman Attention: Project Engr. TMI-Unit 2 Manager, Q. A. & Security Stone & Webster Engineering Corp. Alabama Power Company P. O. Box 2325 P. O. Drawer 470 Boston, Mass. 02107 Ashford, AL 36312 '

Attention: Project Engineer for Attention: Mr. George Hairston Duquesne J.0. 12241 Philadelphia Electric Co. U. S. Nuclear Regulatory Commission 2301 Market Street c/o Document Management Branch Philadelphia, PA 19101 Washington, D.C. 20555 Attention: Mr. Dick Mulford Limerick Project Manager Bechtel Power Corp. Robertshaw Controls Company

[ P. O. Box 607 P. O. Box 400 Gaithersburg, MD 20760 Knoxville, TN 37901 Attention: SNUPPS Project Engineers Attention: T. T. Howell, Quality Mgr.

l'g United Engineers & Constructors, Inc.

P. O. Box 8223 Philadelphia, PA 19101 Attention: Mr. D. H. Rhoads Project Engrg. Manager (Seabrook)

Sargent & Lundy Engineers 55 E. Monroe Street Chicago, IL 60603 Attention: P. L. Wattelet Marble Hill Project Manager

.