ML20087P758
| ML20087P758 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 03/29/1984 |
| From: | Jackie Cook CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| REF-PT21-84 28057, 84-02-#1, 84-2-#1, NUDOCS 8404090346 | |
| Download: ML20087P758 (14) | |
Text
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Consumers Power James W Cook O
h Vice President - Projects, Engineering and Construction General offices: 1945 West Parnell Road, Jackson, MI 49201 * (517) 78& O453 March 29,1984 84-02 #1 Mr J G Keppler, Regional Administrator US Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND ENERGY CENTER PROJECT DOCKET NOS 50-329 AND 50-330 EXCESSIVE WEAR - LINEAR CONVERTER SHAFT GUIDES FILE:
0.4.9.89 SERIAL: 28057 On February 28, 1984, Consumers Pover Company notified your staff of a potential 10CFR50.55(e) condition involving excessive wear in the shaft guides of Pacific Air Products linear converters.
This letter is an interim 10CFR50.55(e) report. Attachments 1 and 2 provide the descriptions of the deficiencies and the Project's planned investigative actions, probable cause, and corrective actions as of March 13, 1984.
Subsequent to this Project work, Attachment 3 was received by the Project.
from Pacific Air Products Company.
Information in this attachment conflicts with some of the initial information we had received in terms of root cause of the excessive wear on the linear converter shafts. This information must be reconciled as part of our future activities.
Another report, either interim or final, will be sent on or before July _9, 1984.
JWC/AHB/1r Attachments 1: MCAR-81, Initial Issue, dated March 2, 1984 2:
MCAR-81,~ Interim Report 1, dated March 13, 1984 3: Pacific Air Products Letter dated March 7, 1984, Log No 7043-31 i
8404090346 840329 PDR ADOCK 05000329 APR 2 884 S
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2 Serial 28057 84-02 #1 CC:. Document Control Desk, NRC.
Washington, DC RJCook,'NRC.-Resident Inspector-Midland Nuclear Plant.
DSHood, NRC' Office of.NRR
.Bethesda, MD INPO Records Center.
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OC0384-0027A-MP01~
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3 Serial 28057 84-02 #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.
Washington,LDC 20555 Assistant: Attorney General Environmental Protection Division Mr C R Stephens (3) 720 Law Building Chief, Docketing & Services
. Lansing, MI 48913 U S Nuclear Regulatory Commission Office of the Secretary Washington, DC 20555 Mr Myron M Cherry, Esq 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 1-0 Counsel for the NRC Staff
, Midland, MI 48640 U S Nuclear Regulatory Commission Washington, DC 20555
'Mr Charles Bechhoefer, Esq aAtomic Safety & Licensing Atomic Safety & Licensing Board Panel Board Panel
~ U S-Nuclear Regulatory Commission U S Nuclear Regulatory Commission East-West Towers,-Room E-413 Washington, DC 20555
- Bethesda, MD 20014 Ms Barbara Stamaris Dr Frederick P Cowan-
'5795 North River Road 6152;N:. Verde Trail-Rt 3 AptLB-125 Freeland, MI 48623 Boca Raton.nFL~33433, Dr Jerry Harbour-Mr Fred C Williams Atomic Safety & Licensing Isham, Lincoln &:Beale Board Panel 1120 Connecticut Ave,'NW, Suite 840 U-S Nuclear Regulatory Commission
- Washington, DC.20036 East-West Towers, Room E-454
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Bethesda, MD 20014
'Mr~ James E Brunner, Esq
- Consumers P,wer Company Mr M I Miller, Esq_
212 West Michigan Avenue Isham, Lincoln & Beale
- Jackson, MI 492011 Three First National Plaza 52nd Floor-Chicago, IL 60602 q0C0384-0027A-MP01
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Serial 28057 84-02 #1 Mr DIF Judd-
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PO Box 1260-Mr John Demeester, Esq
-Lynchburg, VA 24505 Dow Chemical Building Michigan Division-
- Mr-Steve'Gadler,~Esq Midland MI 48640 2120 Carter Avenue St Paul, MN.55108 Ma Lynne Bernabei Government Accountability Project Mr P Robert Brown-1901 Q Street, NW Clark, Klein &-Beaumont-Washington.DC 20009
- 1600 First Federal Bldg Woodward-Ave-Detroit, MI 48226 3/14/84 m
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.I44232 co s.,, nonc, OUALITY ASSURANCE PROGRAM 8h-02 #1
.i MANAGEMENT CORRECTIVE ACTION REPORT MCAR-1 REPORT NO. 81 1
J O. 7220 0 NO.
DATE 3/2/84 l' DESCRIPTION (Including references):
Pacific Air Products Company (PAPCo) notified the NRC and Consumers Power Company (CPCo) of a potential 10CFR21 concern regarding excessive wear of shaft guides in the linear converters of damper operators used on certain HVAC units (ref: com 142465 - PAPCo to CPCo dated 2/1/84). To date, it has been determined that subject converters supplied to Midland have been used on the following eight safety related dampers:
(continued)
- RECOMMENDED ACTION (Optional) 1.
Prepare complete listing of all safety related dampers utilizing subject converters and determine safety impact of those not previously identified.
2.
Obtain final results of PAPCo's investigation of the concern relative to closure of their 10CFR21 report.
(continued)
REFERRED TO 3lXENGINEERING O CONSTRUCTION O OA MANAGEMENT O
3bb4 O PROCUREMENT ISSUED BY CPCo as 6"r-Project OA ErQineer Date
- This concern was reported to the NRC by/28/84.
a notentially reportable condition on 2 ll REPORTABLE DEFICIENCY NOTIFIEDCL NT O NO
- @ YES b 8 8f Protect Mgr I
' Ifete 111 CAUSE CORRECTIVE ACTION TAKEN l
1 i
AUTHORIZED BY Date STANDARD DISTRSUTON ADDITONAL DISTREUTON AS APPROPRIATE DMSON OA MANAGER ENGINEERNG MANAGER FORMAL REPORTTO CLIENT De e MANAGER OF OA BPC PRWECT ENGINEER (If Sectionll Applies)
GPD OA MANAGEF:
OE SUPERVISOR LAPD QA MANAGER SFPD OA MANAGER CONSTRUOTON MANAGER PRW SUPT /PROJ CONSTR MANAGER PROJECT MANAGER CHIEF CONSTR OC ENGINEER CUENT CORRECTIVE ACTION IMPLEMENTED DMSON PROCURENT MGR PROJ PROCUREMENT MGR PROCUREMENT SUPPUER QUAUTY MGR AND DIV SUPPUER QUAUTY MGR VERIFIED BY Project OA Engineer Date
- Descrtie in space provided and attach reference document.
AAPD-0161
MCAR 81 Page 2 l44232 1.
DESCRIPTION (continued):
2 Auxiliary building normal exhaust isolation dampers (OMO-54003, OMO-54004) 2 ESF filtration system control dampers (OMO-54005, OMO-54006) 4 Diesel generator building exhaust modulating dampers (ITV-6803 Al/B1, 2TV-6803 A1/Bil, Of the above safety related appl'ications, Bechtel engineering has concluded that a malfunction or failure of the auxiliary building exhaust
~
isolation dampers and the E57 tiltration system dampers would pose no safety concern during plant operations at Midland. The safety impact of a malfunction or failure of the diesel generator exhaust modulating dampera cannot be determined at this time due to insufficient information. As such, the condition is considered indeterminate until a
'more definitive conclusion can be made.
RECOMMENDED ACTION (continued):
3.
If it is determined from PAPCo's investigative results that the related hardware is found to be nonconforming, initiate proper controls in accordance with project procedures for nonconforming items.
4.
Evaluate corrective action (s) provided by PAPCo and provide process corrective action, as appropriate.
5.
Determine root cause of condition and provide corrective action to preclude recurrence.
6.
Based on determination of root cause from 4 abcve, investigate, as appropriate, for similar or related conditions which may exist on the Midland project.
7.
Issue report, interim or final, by March 19, 1984.
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Attach:nent 2 Serial 28057 l45070 Bechtel Associates Professional Corporation au-02 n 145178
SUBJECT:
MCAR 81 Excessive Wear of Pacific Air Products Company Linear Converter Shaft Guides INTERIM REPORT 1 DATE:
March 13, 1984 PROJECT:
Consumers Power Company Midland Plant Units 1 and 2 Bechtel Job 7220
REFERENCE:
Letter, Pacific Air Products to CPCo, 2/1/84 Introduction a.
This report addresses linear converter shaft guides supplied on HVAC dampers manufactured by Pacific Air Products that have potential excessive shaft guide wear problems. The converters transform linear actuator motion to rotary motion to operate the dampers.
Backaround
(
i-Pacific Air Products received two linear converters that exhibited excessive wear to the brass shaft guides from the nonnuclear Edgewood s'
generating plant as reported in the referenced letter. Pacific Air Products notified the NRC and Consumers Power Company of the potential 10 CFR 21 reportability. Subsequently, Pacific Air Products received two l
additional converters exhibiting excessive shaft guide wear from the j.
Byron Nuclear Station.
Investimative Action g
Pacific Air Products is investigating the causes for the shaft guide wear in its laboratory. As part of its investigation, converters with and without shaft guide lubrication have been cycled to obtain additional data. As a result, the vendor has been able to duplicate the shaft guide wear with a side load on the shaft and no lubrication. Preliminary Indications are that the cause of the wear is a combination of shaft l
misalignment and lack of lubrication. Bechtel's review of the operating and maintenance instructions supplied by the vendor indicated that maintenance, lubrication, and inspection of converters are not specifically addressed.
l l
0535m l
.l.45570 Bechtel Associates Professional Corporation l45l78 ac^m 81 Interim Report 1 page 2 Analysis of Safety Implication The linear converters are used on the eight safety-related dampers listed below:
Quantity Tan No.
Nomenclature 2
0M0-54003 Aux 111ary' building normal exhaust OM0-54004 isolation damper 2
050-54005 Engineered safety features (ESF) filtration system
+
OM0-54006 control damper 4
1TV-6803Al Diesel generator building ITV-6803B1 exhaust modulating damper 2TV-6803Al 2TV-680381 s
The possibility exists that excessive wear of the converter shaft guides could lead to failure of a damper to function._ The auxiliary building exhaust isolation dampers and the ESF filtration system dampers are used after a loss-of-coolant accident (LOCA) to provide filtration of the ESF pump room air. These dampers are not expected to function often during plant operation, and wear would not be a factor during plant life.
Damper failure is acceptable because the current Final Safety Analysis Report radiation analysis does not take credit for the RSF filtration of normal leakage in ESF systems post-LOCA. Even assuming a passive l
failure, such as pump seal leakage, it can be shown using realistic assumptions that the doses released will be below 10 CFR 100 guidelines, without taking credit for the ESF filters.
The diesel generator building exhaust modulating dampers are used for temperature control in each of the four diesel generator rooms. Shaft guide wear is a common mode failure. Failure of the demper to operate could lead to excessive temperatures in the diesel generator room. There is insufficient information currently available to justify a conclusion l
of damper failure. Therefore, the safety impact of this concern is indeterminate.
I probable Cause Based on vendor-supplied information, the following are probable causes of excessive wear:
a.
A combination of shaft misalignment and operation without lubrication b.
Vendor's operation and maintenance instructions not specifically addressing lubrication and inspection of converters 0535u
L'-
l'45070 l
Bechtel Associates Professional Corporation "c^n 82 145178 Interim Report 1 Page 3 Corrective Action 1.
The vendor drawings have been reviewed to ensure that all safety-related dampers that use this converter lave been identified.
Those dampers are the eight listed in the Analysis of Safety Implication section of this report.
k 2.
Pacific Air Products is presently investigating this concern and is expected to submit a report by May 1, 1984.
3.
If evaluation of Pacific Air Product's report indicates that the i
converters do not conform to requirements, nonconformance reports will be initiated and processed in accordance with project procedures.
4.
Pacific Air Product's recommended corrective action will be evaluated and incorporated'into project documentation as appropriate. If needed, dampers at the Midland jobsite will be inspected, reworked, or repaired in accordance with vendor instructions.
5.
A root cause will be determined before issuance of a final report and action (s) will be taken to preclude recurrence.
Reportability This concern was reported to the NRC by Consumers Power Company as a potential reportable condition on February 28, 1984.
4 i
Submittedby:gst 4
4
&7s_
E.B. Poser i
Project Engineering Manager s
Approved by-d.T. Pravel Mechanical Chief Engineer r.
Approved by:
nA E.H. SmLL th " ~
Engineering Manager Concurrence by:
p'M.A.Dietrich Project Quality Assurance Engineer TGB/IE./smac8(N)
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Attachnent'3 Scrial 20057 RAW W 02 i1
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fl.AR 1519841519845
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. 3133 West Horvord Street. Santo Ana, California 92704. P.O. Box 5277. Telephone 714/557-1710. Telex No. 67-8319
. March 7, 1984-Log No. 7043-31
-Consumers. Power Company
' Midland Nuclear Power Station Midland, Mich'igan 48640 LAt' ten tio n :
Quality. Assurance Director Regarding:
Midland Nuclear _ Power Station Linear Converter. Investigation Update Gentl emen :
- UnLFebruary-1, 1984,.we issued a concern regarding' abnormal wear on the lir. ear converters manufactured _by Pacific Air
~
~ ! Products 100.-
11 would~.like to; bring you up-to-date on the-progress of.'our:in.vestigation.
L 1.
Our testing program-is well underway.and is running according to. plan'and schedule.
we We have been able to duplicate the pattern
' ~
of wear that has been-reported to us from the field.
.2.
Our investigation of field conditions is
~
providing'us with some insight into the causes of-excessive wear and I would like
~,
.to relay lsome'of thi.sfinformation to you.
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A 4
(2) o A.
Actual field conditions confirm that the ex-cessive wear on the linear converters is caused by " hunting" of the control circuitry.
For example, in one case a volume sensing device was installed downstream of the dampers.
When the dampers opened, the air was aimed directly on the velocity sensing device.
At that moment, the de-vice sensed the increased velocity and caused the damper to change position thereby deflecting the airstream away from the sensing device.
The sensing device once again called for the damper to open, etc., etc..
This field condition,
" velocity stratification", caused the damper to
" hunt".
(We estimate that this condition could cause short cycle response at about 21,000 strokes per day or 651,000 strokes per month or 3,906,000 strokes in a six month period.)
B.
Not only can velocity sensing devices cause hunting _
but temperature sensing devices, where the differ-ential is closely set, may also cause the same con-dition.
I am enclosing a photograph of the input shaft of a linear converter that was returned to us from the field.
The wear pattern is indicative of the hunt-ing problem.
I would suggest that your project be inspected to determine whether any of the tell-tale signs are present.
Hunting caused by the control circuit not only affects the linear converter but it also affects the damper and the actuator.
If this condition exists, it should be remedied as soon as possible.
A determination of the number of cycles run by the equipment should also be made to assist.in evaluating the replacement or servicing that may be required.
We are starting the final phase _of our testing program and will have some definitive data available soon.
E 4
1
. j -
(3)
If you have any questions concerning the information contained herein, please call me at (714) 557-1710.
Very truly'yours,
- PACIFIC AIR PRODUCTS CO.
tyt&.s h%
ames'P. Dodson Director of Quality Assurance
Enclosure:
(1)
JPD:dg cc:
Bechtel. Ann Arbor (Q.A.)
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