ML20079E279

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Interim Deficiency Rept 83-11 1 Re Potentially Defective Capstan Springs in Pacific Scientific Mechanical Shock Arrestors.Initially Reported on 831207.Investigation Continuing.Next Rept Will Be Submitted by 840316
ML20079E279
Person / Time
Site: Midland
Issue date: 01/06/1984
From: Jackie Cook
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To: James Keppler
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
26651, 83-11-#1, MCAR-1, NUDOCS 8401170212
Download: ML20079E279 (18)


Text

. _ _ _ _ _ _ _ _ _ _ - _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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Consumels i

power Jarus W Cook Vste President - Projects, Engineen'ng and romtruction n

General Cifices: 1945 West ParneH Road, Jackson, MI 49201 * (517) 78& O453 U

P[? 114'1 January 6, 1984 Mr J G Keppler, Regional Administrator

!,PRIJ;glPAL STAFF US. Nuclear Regulatory Commission

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-j Region III d/PI ' ~ [3 799 Roosevelt Road h7M EASP Glen Ellyn, IL 60137 TC

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i MIDLAND ENERGY CENTER PROJECT l

_ DOCKET NOS 50-329 AND 50-330 E l u i

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POTENTIAL DEFECTS IN MECHANICAL SHOCK ARRESTORS FILE:

0.4.9.83 SERIAL: 26651 December 7,1983 Consumers Power Company notified your staff of a pote.ntial 10CFR50.55(e) condition involving defective capstan springs in Pacific Scientific mechanical shock arrestors.

/

This letter is an interim 10CFR50.55(e) report. The attechttents co ' this letter describe the concern and summarize the investigation and corrective, action taking place.

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j-r Another' report, either interim or final, will be sent on or before March 16, 1984.

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Attachments:

(1) MCAR-1, Report No '/5, dated December 8,-1983 I

r (2) MCAR-75, Interim Report 1, dated Pecember 20, 1983.<'

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-CC: Document Control Desk, NRC

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Washington, DC r

p RJCook, NRC Resident Inspector

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Midland Nuclear Plant DHood USNRC Office of NRR l

INP0 Records Center r

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8401170212 840106 I

OC0184-0006A-MP01 gDRADOCK 05000329

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Serial 26651 83-11 #1 OM/0L SERVICE LIST Mr Frank J Kelley Atomic Safety & Licensing Attorney General of the Appeal Board State of Michigan U S Nuclear Regulatory Commission Ms Carole Steinberg, Esq Washington, DC 20555 Assistant Attorney General Environmental Protection Division Mr C R Stephens (3) 720 Law Building Chief Docketing & Services

1 Lansing, MI 48913 U S Nuclear Regulatory Commission Office of the Secretary Washington, DC 20555 Mr Myron M Cherry, Esq

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Suite 3700 Ms Mary sinclair Three First National Plaza 5711 Summerset Street Chicago, IL 60602 Midland, MI 48640 Mr Wendell H Marshall Mr William D Paton, Esq RFD 10 Counsel for the NRC Staff Midland, MI 48640 U S Nuclear Regulatory Commission l

Washington, DC 20555 l

Mr Charles Bechhoefer, Esq Atomic Safety & Licensing Atomic Safety & Licensing Board Panel Board Panel U S Nuclear Regulatory Commission U S Nuclear Regulatory Commission Washington, DC 20551 Washington, DC 20555 Dr Frederick P Cowan Ms Barbara Stamiris 6152 N Verde Trail 5795 North River Road Apt B-125 Rt 3 Boca Raton, FL 33433 Freeland, MI 48623 Mr Fred C Williams Mr Jerry Harbour Isham, Lincoln & Beale Atomic Safety & Licensing 1120 Connecticut Ave, NW, Suite 325 Board Panel Washington, DC 20036 U S Nuclear Regulatory Commission Washington, DC 20555 Mr James E Brunner, Esq Mr M I Miller, Esq Consumers Power Company Isham, Lincoln & Beale 212 West Michigan Avenue Three First National Plaza Jackson, MI 49201 52nd Floor Chicago, IL 60602 Mr D F Judd Mr John Demeester, Esq Babcock & Wilcox Dow Chemical Building PO Box 1260 Michigan Division Lynchburg, VA 24505 Midland, MI 48640 L

Mr Steve Gad]cr, Esq Ms Lynne Bernabei 2120 Carter Avenue Government Acccuntability Project St Paul, MN 55108 1901 Q Street, NW Washington, DC 20009 OC0184-0006A-MP01 L

pb (nj Serial 26651 m_,,

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136688 OUALITY ASSURANCE PROGRAM Xp MANAGEMENT CORRECTIVE ACTION REPORT MCAR-1 REPORT NO.

75 g.

JOBNO.

7220 O NO.

DATE 12/8/83 l* DESCRIPTION (including references):

Pacific Scientific Company's mechanical shock arrestor Models PSA-l and PSA-3 f t rnished to the Midland Project by ITT Grinnell Corporation may have cracked caosten springs. The suspect capstan springs were furnished to Pacific Scientific by one of two spring manufacturers. iTT Grinnell has identified 283 shock arrostcrs furnished to Midland which contain suspect springs.

Cracks In the capstan springs could result in spring failure under design conditions which could lead to failure of safety related piping.

  • RECOMMENDED ACTION (Optional) 13 Deter'alne if any PSA-1 or PSA-3 shock arrestors were furnished to the Midland project from sources other than ITT Grinnell.

2)

Ensure that all suspect shock arrestors are located, Identified and controlled in accordance with the project procedure for nonconforming items.

3)

Provide for examination of all c.apstan springs In the identifled PSA-1 and PSA-3 shock arrestors, and replacement of those with cracks.

4)

Engineering to review and concur with Pacific Scientific's identifled root cause of the deficiency and actions to prevent recurrence.

5)

Issue Interim or final report by December 22, 1983.

REFERRED TO QD ENGINEERING 00 CONSTRUCTION O QA MANAGEMENT O

O PROCUREMENT ISSUED BY

[lM'*1 /2~0~ 3 Project QA Engneef Date NOTE: This deficiency was reported to the NRC by the client on 12/7/83 /

NOTIFIEDCLIENp

/XM/#f 11 REPORTABLE DEFICIENCY O NO XX YES Jil'or

/

f TWIrect Manager /

Date ~

lli CAUSE CORhECTI'vE ACTION TAKEN AUTHORIZED BY Date STANDARD DISTRIBUTON ADDITONAL DLSTRIBUTON AS APPROPRIATE DIVISION OA MANAGER ENGINEERf G MANAGER FORMAL REPORT TO CUENT MANAGER OF GA BPC PROJECT ENGINEER (if Section11 Applies)

Date GPD - OA MANAGER OE SUPERVISOR LAPD OA MANAGER SFPD QA MANAGER CONSTRUCTON MANAGER PROJECT MANAGER PROJ SUPT /PROJ CONSTR MANAGER CUENT CHIEF CONSTR OC ENGINEER CORRECTIVE ACTION IMPLEMENTED DIVISON PROCURENT MGR PROJ PROCUREMENT MGR PROCUREMENT SUPPLIER QUALITY MGa AND DIV SUPPUER QUALITY MGR VERIFIED BY Project GA Engneer Date

  • Describe in space provided and attach reference document.

AAPD-0161

137869 v

Serial 26651 Bechtel Associates Professional Corporation 83-n n

SUBJECT:

MCAR 75

,137880 Potential Defects in Mechanical Shock Arrestor Models PSA-1 and PSA-3 INTERIM REPORT 1 DATE:

December 20, 1983

(

PROJECT:

Consumers Power Company Midland Plant Units 1 and 2 Bechtel Job 7220 Introduction This report addresyes potentially defective capstan springs in Pacific Scientific Company shock arrestors supplied to the Midland project. This has been idencified as a 10 CFR 21 condition by Pacific Scientific.

Description of Deficiency The attachment has identified certain Pacific Scientific Company mechanical shock arrestor Models PSA-1 and PSA-3 furnished to the Midland project by ITT Grinnell Corporation that may have cracked capstan springs. The suspect capstan springs were supplied to Pacific Scientific by one of two spring manufacturers.

ITT Grinnell has identified 283 shock arrestors furnished to Midland that contain suspect springs.

Summary of Jnvestimation and Historical Background Pacific Scientific Company has investigated the subject deficiency and concluded that springs with possible cracks are 1tnited to those supplied by one spring maaufacturer. ITT Grinnell has identified those snubbers furnished to the Midland project that contain the suspect springs.

Investigation will address those snubbers identified by ITT Grinnell, and other snubbers, if any, that were supplied by sources other than ITT Grinnell which may contain suspect springs.

Analysis of Safety Implication Cracks in the capstan springs could result in spring failure during dynamic loading, thereby potentially affecting the ability of the component to perform its intended safety function.

Probable Cause As discussed in the attached Pacific Scientific letter, Mettek's report indicates that sprin5 cracking cecurred because of stresses induced during spring forming, which caused hydrogen cracking during subsequent silver plating.

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____s

Bechtel Associates Professional Corporation I37869 I37880 MCiR 75 Interim Report 1 December 20, 1983 Page 2 l

l l

Corrective Action Bechtel field engineering has been requested to initiate an NCR to identify and track thl6 deficiency.

All affected snubbers will be inspected.

Repairs / replacement will be made as necessary. This task will be carried out by qualified personnel with the approval of ?acific Scientific company.

Project engineering will ensure that ITT Grinnell will provide a root cause and corrective action before the final MCAR report is issued.

Reportability Based on the safety implications, this deficiency was reported to the NRC as retentially reportable in accordance with Title 10 of the code of Federal Regulations, Part 50'.55(e) on December 7, 1983.

Submitted by:

,E.B. Poser Project Engineering Manager

_ Approved by:

{

E.'H. Se.

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Engine ring Manager Concurrence by:

dr M.A. Dietridh Project Quality Assurance Engineer l

RFT/MS/jsh*(PD) l

Attachment:

ITT Grinnell letter, 10/5/83 (Com 131017) 0503u

I31.8.8.0 c.

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I3'7869 ITTGrinnellCorporation headeafscar m West &dagesaset am@nce,mooteislandmi (MI)D1-M October 5 '83 8echtel Associates Professional Corp.

P.O. Box 100 Ann Arbor, MI 48106 Attn: Mr. E. M. Hughes - Project Engineer Re: MIDLAND PLANT - UNITS 1 & 2 P.O. No. 7220-M-106-AC

Subject:

Pacific Scientific Mechanical Shock Arrestors Model PSA-1 and PSA-3 Capstan Spring Potential Quality Problem Gentlemen:

Attached plcae find a copy of Pacific Scientific's letter to us dated 9-21-83 (Attachment I) which identifies a potential quality problem with Size 1 and 3 Mechanical Shock Arrestor Capstan Springs. The scope of the problem is identi-fied on Page 4 of 5 of the attached report, and the arrestors supplied to ITT Grinnell are suonarized on Page 5 of 5.

A review of our records indicates that the mechanical shock arrestors - as listed on Attachment II - have been supplied on the subject contract by ITT Grinnell. We are confident that Attachment II represents a complete listing of the arrestors supplied to your project, since of the (2,888) arrestors supplied to ITT Grinnell, all but (70) units (19 Size il and 51 Size #3) have been identified to a specific customer shipment. Any additional arrestors supplied to your project will be identified to your attention as soon as possible.

As a valued customer of ours, we are bringing this information to your atten-tion for appropriate action. We reconnend that you contact the following -

directly - to resolve this problem:

Mr. Paul A. Hadnagy - Director Technical Operations or W. Peter M. Zatezalo - Director of Marketing D

l37880 Page #2 131017 137869 Oct. s, '83 Pacific Scientific Co.

1346 S. State College Blvd.

Anaheim, CA 92803 Tel. No. (714) 774-5217 It is our position that all charges for this effort are to Pacific Scientific's account.

Please let us know if you require any additional infomation.

Very truly yours,

'I Q.L RPORA ION k

(CI.,

,d' N. A. DeCRIST0FAR Project Manager NAD/m (Att.)

cc's w/Att.

R. Kon - Prov.

F. Shepard - Bechtel/ Ann Arbor D. Sewell - War.en B. Kelly - Prov.

P. Zatezalo - P.S. Co.

P. Hadnagy - P.S. Co.

7-f Kin. Tech Divist::n 137880 O Pa CIFIC SCIENTIFIC i31017 137869 21 September 198' C t. '.

b.csb4ETEA N

D.Sewat4 B.VrLL T ITT Grinnell 621 Dana Street N.E~.

Warren, Ohio 44481 Attention:

Mr. T. Lauka subject:

Pacific Scientific Mechanical Shock Arrestors Model PSA-1 and PSA-3

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Reference:

Service Report No. SR83-01 Gentlemen:

e The attached report discusses potential problems with certain serial number PSA-1 and PSA-3 snubbers.

Onr records indicate that the units shown on Attachment A are in the affected group and were delivered to you.

At your convenience, please return these snubbers to us for inspection and repair as necessary.

If the snubbers are still i

in warranty (one year warranty if shipped prior to 1 April 1983 l

and five year warranty if shipped on or after 1 April 1983),

this will be done at no charge to you--excluding freight.

Should the units be beyond the warranty period, there will be a $100.00 l

per unit charge, also excluding freight.

1 l

All affected snubbers will be returned to you within 30 days aftep we receive them.

l fhe foregoing will apply to snubbers returned to us through 31 December 1884.

We apologize for any inconvenience this may cause you.

Very ruly yours, P. A. Hadnagy Director Technical Operations l

PAH:sf

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Enclosure TracAmear 1346 S. State Ccilegs Boulevard, Anaheim, Califomia 92803, (714) 774 5217, TELEX 65 5421 76, t eF 6

KinTech Divislan s

I37880 Pacif:lc SCIEEnTil:lC I31017 131869 Sa s3-01 SEOCK ARRESTOR CAPSTAN SPRING SERVICE REPORT During testing of, Pacific Scientific Company's PSA-1 Shock Arrestors, part number 1801102-05, at Union Electric Callaway Station by Daniel International personnel, 4 of 7 anubbers tested revealed a broken capstan spring tang.

Pacific Scientific Company requested failed springs for indepen-dont nietallurgic,al examination.

Failed components were returned to Pacific Scientific Company who forwarded broken springs to "Mattek", 1805 E. Carnegie, Santa Ana, CA 92705, (714) 549-1083, for metallurgical and fracture analysis.

One spring exhibiting a visual crack in one tang (removed from enubber S/N 21524 which we.s returned by Union Electric) was in-stalled by Pacific Scientific Co. into a snubber and subjected to a full load (1500 lbs.) acceleration test.

This test was repeated 5 times (10 full load cycles) with no failures.

The cracked spring was then aubjected to a dynamic load cycling test.

This test cycles the snubber at 3 Hertz intervals from 3-33 Hertz tor 10 seconds at each interval at 100%, 75% and la rated loads, a total of 5940 cycles.

The cracked spring satisfactorily passed this test.

Springs from the identical lot as those that failed were traced to snubbers located at Kansas Gas & Electric Co. Wolf Creek Station.

These were returned to Pacific Scientific for testing and evaluation.

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Eleven (11) each 1801102-05 PSA-1 Shock Arrestors returned to Pacific Scientific Co. by Kansas Gas & Electric Co. Wolf Creek Station were visually and functionally tested by Pacific Scien-tific Co. personnel in the presence of KG&E and Union Electric Co. personnel.

All elevian PSA-1 Shock Arrestors (S/Ns 21511 thru 21521) were disassembled to a level permitting verification that the capstan spring was properly" installed and whole.

The Shock Arrestors were reassembled and subjected to a successful acceleration test at full rated load (1500 lbs.).

Following successfui acceleration test, all eleven Shock Arres-tors were disassembled to facilitate visual and non-destructive examination of the capstan springs:

S/N 21511 - No apparent visual defects.

Magnetic particle non-destructive examination revealed indications in both spring tangs with one tang exhibiting three separate indications.

Indications were suspected to be micro cracks.

j f 1846 s. State college Bouleverd. Anaheim, Califomia 92803. (714) U4 5217. TELEX 65 5421

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137869

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SEOCK ARRESTOR CAPSTAN RVICE REPORT -,(Cont'd.)

131017

's/N.21512 - No apparent visual defects.

Magnetic particle examina-7 tion exhibited an indication of one micro crack on ene tang.

8/N 21513 - No apparent visual defects. ~No magnetic particle swamination indications.

i S/N 21514 - No apparent visual defects.

No magnetic particle i

examination indications.

S/N 21515 - No apparent visual defects.

Both tangs exhibited a magnetic particle micro crack indication.

I S/N 21516 - No apparent visual defects.

No magnetic particle examination indications.

S/N 21517 - No apparent visual defects.

No magnetic particle awamination indications.

s S/N 21518 - No, apparent visual defects.

Both tangs exhibited

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a magnetic particle micro crack indication.

S/N 21519 - No apparent visual defects.

Both tangs exhibited a magnetic particle micro crack indication.

S/N 21520 - No apparent visual defects.

One tang exhibited a magnetic p:.rticle micro crack indication.

S/N 21521 - No Epparent visual defects.

One tang exhibited a magnetic particle micro crack indication.

Five (5) capstan springs exhibiting non-destructive magnetic particle examination indications were assembled into a test snubber and subjected to a dynamic load of 1500 lbs. at fre-quencies of 3 to 33 Hertz intervals for 10 seconds each at 1004, 754 and 50% of rated load.

The springs tested represented the " worst case" as determined by the non-destructive magnetic particle inspection.

They were i

S/Ns 21511, 21515, 21518, 21519 and 21520.

Springs, S/Ns 21515 and 21518, survived the entire test (5940 cycles).

Spring, S/N 21511, survived 533 full load cycles beforo both tangs failed.

S/N 21518 survived 1800 full load cycles before one tang failed, and S/N 21520 survived 1850 full load cycles before one tang failed.

Metallurgical report by Mettek Material Engineering Technology I

Laboratories indicates spring cracking occurred because of stresses induced during spring forming which caused hydrogen cracking during subsequent silver plating.

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f37869 SBOCK ARRESTOR CAPSTAN SPRING SERVICE REPORT - (C nt'd.)

allurgical report also explains that, although the spring fracture face exhibited brittl'eness at the crack onset, the core of the spring was ductile and spring fracture was simple dimple (ductile) rupture.

This accounts for the ability of the springs to withstand the full load functional and dynamic load testing conducted and suggests that the useful life of springs which contain cracks remains to be substantial.

The capstan springs are manufactured for Pacific Scientific Co.

by a spring manufacturer.

These springs are supplied formed, stress relieved cad 1004 magnetic particle inspected to Pacific Scientific Co., who then subcontracts the springs for silver l

plating.

Pacific Scientific Co. Part numbers for the capstan springs are as follows:

PSA-1 (1801613)

PSA-3 (1801614)

Pacific Scientific is effecting corrective action with the spring manufacturer, the nature of which is not yet fully established.

I Recommendations At your earliest convenience, return the affected snubbers to Facific Scientific for inspection.

Inspection will include removal of spring to facilitate examina-tion for tang cracks by use of magnetic particle or liquid penetrant non-destructive examination.

Urgency of inspection is to be assessed by individual owners based on snubber system application and analysis of results of tests conducted on failed snubbers and reported herein.

Affected Serial Numbers PSA-1 Pacific Scientific Part No. 1801102-05 S/Ns 15672 thru 16921 o u ssa s to u, z.

18211 thru 21160 21411 thru 22060 22311 thru 22710 117p ZL%t.D a

PSA-3 Pacific Scientific Part No. 1801106-05 S/Ns 21311 thru 21610 zosst w co 20867 2c9ss-24311 thru 25310 w 810 25361 thru 25950 W

27194 thru 28543 to3ot toz$f 306 Tw s eo 1.orso

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m ori.r.n211 13 7 8 8 0 anscum A l37869 131017 1) adodel Number PSA-1 Part Number 1801102-05 and -07 Serial Numbers IG SL G this ikk&L 16667 thru 16733 16754 thru 16920 18346 thru 19445 18709 thru 18724 18725 thru 18735

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18736 thru 18765 18766 thru 18908 19482 thru 19551 19552 thru 19576 19982 thru 20081 20418 thru 20547 20691 thru 20736 i

20961 thru 21060 21061 thru 21084 22443 thru 22542 22711 thru 22860 2)

Model Number PSA-3 Part Number 1801106-05 and -07 Serial Numbers 28144 thru 28232

?.0637 275:3 thru 17693 23700 I

2 E 5 thru 27937

<20851 thru 20869 27696 thru 27738 20870 thru 20955 27739 thru 27905 25826 thru 25916 25444 thru 25498 25532 P.hru 25642 25646 chru 25759 25036 25393 thru 25443 24711 thru 24910 21565 thru 21610 506 thru 510 (-07) 486 thru 487 (-07) 24311 thru 24410 21461 thru'21495 20302 thru 20395 20551 thru 20636 20398 thru 20400 e

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!!9439 MD-A21 MIDLND 1-616-4-541 M998 MD-A21 MIDLND 1-616-2-582 11000 MD-A21 MIDLND 1-616-2-582 88863 MD-A55 MIDLND 2-617-5-131

&8842 MD-A55 MIDLND 1-616-2-534 B8726 MD-A90 MIDLND 1-652-1-522 68789 MD-A98 MIDLND 1-652-1-523 E0046 MD-A46 MIDLND 1-E88-2-3-H4 L8785 MD-A98 MIDLND 2-652-1-519 liS824 MD-A98 MIDLND 2-652-1-528 L8730 MD-A98 MIDLND 2-652-1-521

C721 MD-A56 MIDLND 1-638-14-581 L8729 MD-A56 MIDLND 1-638-14-581 l.8711 MD-A56 MIDLND 1-638-14-583

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