ML20094S497

Part 21 Rept Re Separation of Rod Eye Connected to Piston Rod from Threaded Portion of Piston Rod at Approx 750,000 Lb Stress Load.Caused by Insufficient Matl Thickness to Withstand Faulted Load.Matl Certification Encl

ML20094S497
Person / Time
Site:	Prairie Island
Issue date:	08/16/1984
From:	Mills C CHICAGO FLUID POWER CO.
To:	NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
References
REF-PT21-84-423-000 PT21-84-423, PT21-84-423-000, NUDOCS 8408210298
Download: ML20094S497 (4)

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• 1 Phone: 312 -- 830-7400 ER OCORPORATION 411 North Avenue . Streamwood, lllinois 60103 August 16, 1984

$(p - 2 b'd 3 h b Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D. C. 20555

Subject:

Notification of Test Failure Gen tlemen :

Tb the extent that a component was manufactured to a purchase order stipulating part 10CFR21, we as seller and manufacturer of the component are not clear if it is our responsibility in reporting such failure, but feel obligated, due to the stipulation of part 10 CFR21 to do so, that we may be advised if it was necessary at this stage to have reported such failure.

Purchaser: ITT Grinnell of Providence R. I. , P.O. P-12211 Seller & Manufacturer of component: Chicago Fluid Power Corporation Streamwood, Illinois Component : Snubber cylinders believed to be used for pipe support.

(4 units)

Nuclear Station to be delivered to: Northern State-s Power, Prairie Island 1 or 2 Nature of Defect: Rod eye connected to piston rod separated from threaded portion of piston rod at approximately 750,000 lbs stress load. Load requirement is 1,000,000 lbs.

Reason for Failure: Material and material thickness not sufficient to withstand faulted load.

Background:

Purchaser hired seller to design and manufacture cylinder snubber to replace existing snubbers in current service. The cylir, der snubbers were to withstand 10,000 PSI hydraulic pressure representing 1,000,000 lbs loading. c/linder snubbers were designed with 5-1/2" thick rod eye and eye me.ating. Purchaser then informs seller that the ma~.imum thickness of eye mount and rod eye can .only be 2-7/8" thick to match existing mounting space with maximum center to center dimensions established. There were no dimension restrictions on the cylinder itself, but rather only on the eye mount and rod eye. The purchaser was to specify the rod bearing and seal materials and configuration, all other design was to be done by seller. After noti.

fication of the requirement of 2-7/8" maximum thickness of the rod h

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i OCORPORATION ER USNRC August 16, 1984 eye and eye mounting, there was considerable verbal communication between purchaser and sellers engineering departments as to whether the eyes would handle the load, it was determined that if appropriate material and testing of the material were supplied that the faulted load could be obtained mathematically, however, the final determin-ation would be made during testing.

The cylinder snubbers were hydrotested to 10,000 PSI, witnessed, certified, and shipped to purchaser. In order to meet their speci-fications the purchaser was to sandblast and paint the cylinder snubbers. In doing so, sand particles lodged in some of the fastener holes also did some damage to the rod bearings. Purchaser then sent back the snubbers to have the sand flushed out and sent new rod bearings to replace the possibly damaged ones. This was accomplished and the snubber cylinders were re-assembled, hydro tested again and returned to purchaser to complete actual load testing.

Notification: On 8-14-84, purchaser notifies seller by phone that during load testing a rod eye had separated and could a representative from seller be in purchasers Warren Ohio plant the following morning for eve.luation. On 8-15-84, the writer of this report arrived at purchasers facilities to evaluate failure. An additional load test was performed on a third unit after two previous units had separated during this test the third unit separated. It was concluded that seller would return separated pieces to home facilities for further evaluation and that both purchaser and seller would calculate a stress analysis to see if any material with the limited dimensions could withstand the 1,000,000 faulted load, or if by re-designing the rod eye engagement to the threaded portion and adding additional metal would afford the additional strength required. This is the current status ot the project.

Conclusion:

There are no cylinder snubbers of this manufacturer in service at any nuclear facility. Further, we would like to obtain an invitation to the Northern States Power Prairie Island f acility to examine the material specifications and design of the existing cylir. der snubters to see if they could experierce this possible failure, considering the high grade materials and testing done on the materials by Chicago Fluid Power Corporation (copies enclosed ), or if the existing units have been exposed to actual fault load testing on equipment similar to that owned by ITT Grinnell. As it has become apparent that mathematical calculations do not always agree with actual testing. It is not clear at this time how long the redesign and evalu-ation and manufacturing will take, an estimate would be 8 to 10 weeks.

Respectf FM[ ______

C. . Mills, President CRM/eb Enclosures cc: Q/A Dept

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CHICAGO FLUID POWER CORP MATERIAL CERTIFICATION 411 NORTH AVE STREAMWOOD, IL 60103 DATE$ HIPPED ITEM OF CUSTOMER JOB NUMBER CUSTOMER ORDER NUMBER 1 1 SERIAL #204-1,204-2,204-3,204-4 10/14/83 C-3814-N WA DATE PREP ARED E'P NUMSER PART NUMBER D-1 TURK'S 10/17/03 DESCRIPTION OF MATERIAL AND SPECIFICATIONS ._ - - - - - - - - - - - - _ _ _ -----------

88 FORGINGS PERTB/P D-1 STEEL TO MEET ASTMjA-668 CLASS L (AISI,.414.0.)A.G.)

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NORMALIZE.

GUENCH 8, TEM.'ER TO 125,000LTENSILE 105,000 YIEtD 16% ELOG 7.50%7 RED #

9IN AREA (255/321 BHN)

• HEAT TREATMENT TOjBESDONEfBY CUSTOMER /S SOURCE -

LINDBERGH HEATpTREATING CD., MELROSE PARK

• PHYSICAU4 TEST / REQUIRED-

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CHARPY V-NOTCH TEST REGUIREDit<38, DEGREES F..(+-2 DEGREES) TO MEET 15 FT/LBS AVERAGE WITH NOT,0NE4 SPECIMEN LESS THAN 12 FT/LBS

• DESTRUCTIVE TESTINO TO.BE'DONE?BY CUSTOMER'S SOURCE -

CHICAGO SPECTRO SERVICE LABS,. CHICAGO

• ROUGH MACHINE WITH~ ALLOWANCE TO FINISH TO SIZES SHOWNj0N(B/P - 250.RMS

' ' " ' ULTRASONIC TEST:REGUIRED~PER'.SS-N-437 PARAGRAPHSmi, 2, 3, &.19 ..r ,m. ,

HAGWETIC PARTICLE' TEST REQUIRED /PER3SS-M-437. PARAGRAPHS-1,2,3r-& ^

LIC.VID PENETRANT INSPECTION t REQUIRED' PER SS-N-437. PARAGRAPHS .1,2,3, &7

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i NON-DESTRUCTIVE-TESTINO-TOEBE"DONE BY CUSTOMER,'_S SOURCE - ,

MAONAFLUX GUALITY SERVICES, ELK GROVE VILLAGE *

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NO. OF PIECES .

SU SI NI CR MO CU AL OTHER GRAIN CARBON MN PHOS 7

.430 .830 .015 .021 .290 .150 .960 . 180 110

• JOMINY HARDENABILITY

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SCOT FOR THISIS TO CERTIFY THAT THE REPORTED LADLE AN ALYSIS(AND/OR TESTS) SHOWN ON THIS REPORT ARE CORRECT AS CONTAINED IN THE RECORDS OF THE COMPANY.

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cuMTON.wt BOX 8 SPRING GROVE,IL 60081 CHICAGO FLUID POWER CORP MATERIAL CERTIFICATION 411 NORTH AVE STREAMWOOD, IL 60103 OF CUSTOMER JOS NUM8ER DATE SHIPPED CUSTOMER ORDER NUMBER ITE M C-3814-N 1 1 SERIAL #204-1,204-2,204-3,204-4 10/14/03 B/P NUM8ER VIA DATE PREPARED P ART NUMBER D-1 TURK'S 10/17/83 PHYSICAL PROPERTIES

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TENSILE YIELD PSI ELONGATION REDUCTION PCS PSI (.2% OFFSET) 4 % '

OF AREA % COMMENTS 1 144,600 115,900 -

j 76.7 tL MPACT2RE LTS TEMP 1st .

3rd A ' COMMENTS (CHARPY) 38 20. FT/LBS ((19

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/W' BRINELL PCS s;. I u ,.'e, 'l30'00 KG LOAD 1 />M g IJ ':

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MAGNETIC PAR TICLE,.'4 TESTED bdACCEP. TABLE =,;PER SS-N-437-PARAGRAPHS 1?' 2,3,$ & 4111,, ' .

LIQUID PENETRANT ' INSPECTED. &kACCEPTABLEiPER SS-N-437 PARAGRAP_NS ifk/3,'..di7GG & -

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• fE l THIS IS TO CERTIFY TH AT THE REPORTED LADLE AN ALYSIS(AND/OR TESTS) SHOWN ON THIS REPORT ARE CORRECT AS CONTAINED IN BY: , o THE AECORDS OF THE COMPANY.

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