ML20106E195
| ML20106E195 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 11/02/1992 |
| From: | Labrun H COOPER INDUSTRIES, INC. |
| To: | NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
| References | |
| REF-PT21-92 NUDOCS 9211060219 | |
| Download: ML20106E195 (15) | |
Text
l Cooper indstrin j
Cooper R=sem:r R:ciprociting Pr: ducts Divi:un 150 Uncoln Avenue orove City. PA 1612L1898 412 458 8000 f'
r.
W November 2,1992 Our Ref: OCG-9081 Document Control Desk U.S. Nuclear Regulatory Commission Washington, D.C. 20555
Subject:
Fuel Nozzle Tip 10 CFR Part 21 Final Report
Dear Sir:
The following is a report of activities and corrective action associated with the subject 10CFR21 which have taken place since our initial repod of April 5,1991. We believe that these have provided sufficient hformation to warrant closure of this issue.
On April 6,1991, the HRC was notified in writing of a failure involving a standby diesel generator at Houston Light and Powei Company's South Texas Project Electric Generating Station. Subsequent investigation revealed that a cracked fuel nozzle tip purchased from Bendix, (a supplier of Cooper Bessemer), Lot 150006, caused the failure. Affected utilities were notified and a parts recall was initiated.
Subsequent interim reports to the NRC dated July 23,1991, September 20,1991, and L
October 31,1991 detall the distribution of fuel nozzle tips to the affected utilities and actions taken during this time period.
Since then, additional testing of fuel nozzle tips performed by the Materials Technology Division (MTD) of Houston Light and Power in conjunction with Cooper Bessemer, the Cooper-Bessemer Owners Group and MPR Associates has been completed, reviewed and recommendations to prevent further failures made. Samp'es of production lots from utility inventories were submitted to MTD for examination which included visual examination, wet fluorescent magnetic examination (WFMT), intemal ligament thickneos, effective nitrided case depth, visual nitridad cc.se depth, thickness of the Fe,N compound l
layer, and core hardness. Each spray tip sample was visually examined for clogging.
l_
Secondly, the sample was transversely cut immediately below the ligament tip for l
subsequent sectioning by EDM. EDM conical sectioning through the three passage holes allowed WFMT on the fuel hole surfaces. Additional purposes of the EDM sectioning were to ensure precision measurements of the ligament thicknesses between the fuel passage l
holes and the center bore to make precise metallographic sections through the ligaments.
l A metallographic section was produced for each lot examined. This section is a radial axial plane that passes through the thinnest part of the ligament between the fuel passage hole.and the center bore. The nitrided case depth was determined for each sample by determining the distance from the surface to a depth at which the Knoop hardness equivalent to Rockwell "C" scale 55 was reached.
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9211060219 921102 PDR - /> DOCK 05000498 b'
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. Pcge 2 OCG 9081 Noverrber 2,1992 e
The effective depth of the case was determined for each metallographic sample at the surface of the fuel passage hole and at the surface of the center bore. In addition to measuring the effective case depth of the nitrided caso, the metallographic section was also used to determine the visual case depth, the presence and tb!ckness of the white Fe,N compound layer, and core hardness.
The results of the metallurgical and dimensional examinations can be found on Table 1-(MTD Report MT 3309 dated July 16,1991) and Table 1 IMTD Report MT 3822 datsi May 4,1992). A brief summary of the results is as follows:
1.
The inner ligament thickness measurements ranged from a low value of.039 inch on lot 150004 to a high value of.063 inch on lot LC001090. The spray tip from Lot 160004 which had failed the Haynes Go-NoGo gage test contained the smallest ligament dimension, had a deep nitride case, and contained cracks on the surface of two of the three fuel passage holes at the ligament between tile fuel passage hole and the center hole.
2.
The effective nitride case depth in all spray tips examined was lower than the visual nitride case depth.
l 3.
Other than the tin submitted from Lot 150004, none of the remaining lots contained any cracking as determined by visual and WFMT examination.
4.
All samples were visually examined for the presence of clogging of the spray holes.
The tips of the samples were clean and free of clogging in the as-received condition.
The root cause of this failure of the fuel nozzle tip has been determine ( to be insufficient ligament thickness (less than 0.048 inch) along with improper nitriding resulting in a too deep case depth (over 45% ratio of case depth to core size).
Revised technical specifications require an effective caso depth of.008.011" and a ratio of visual case depth to core size of 45% maximum measured 1/32" from the ligament tip.,
This will be verified by destructive examination at the heat treat vendor and again by the Haynes Corporation. Ugament thickness and location of fuel delivery holes will be verified by use of Haynes gauge #44-703039.
Process controls as outlined in our letter to the NRC (our reference OCG-8434 dated 9/20/91) have been revised and are current practice with above stated specifications.
Agreement between Cooper Bessemer and the Cooper-Bessemer Owners Group at the May 1992 meeting and subsequent discussions have resulted in the classification of all fuel nozzle lots as either acceptable or reject.
Acceotable Lots are those w!th no known failures or found to meet technical requirements.
These lots are identified at. 'ae early unnumbered or unrecorded lots (most before 1979),
001110, LC001059, LC001090, LC001091, 20C40,150001,150002,150003,150005, 150010,150013, LCH1, LCH19, and all later LCH series which are now confirmed with Qualitv Assurance efforta at Haynes Corporation and Cooper Bessemer.
n....
-.y 4"
Pzgo 3 :
- OCG 9081 November 2,1992 Lot 150003 will have dimensional inspections imposed as fuel nozzle assemblies are reconditioned as one sample did not pass inspection with the new Haynes hole angle -
gauge, but in the direction of greater ligament thickness.
?
Reject Lots are those with known failures or falling to meet technical criteria of ligament
- thickness and nitride case depth as a result of destructive examination at MTD. The previously recalled lots in 1988 and 1991 as a result of 10CFR Part 21 notification to the NRC are 1124 (includes 1135),150006, and 150008. In addition, Cooper Bessemer is adding to this recall list lots 150004,150009, and 0870001. These fuel nozzle tips should be replaced at the next scheduled plant refueling outage and tips in warehouse stores -
should not be installed in a diesel engine.
The attached listing shows the serial numbers, tot numbers, quantity and location of all-reject lot fus,1 nozzle tips, a
in conclusion, Cooper Bessemer, in agreement with the_ Cooper Bessemer Owners Group, and MPR Associates believe that the corrective actions taken by Hayaes Corporation (current manufacturer of nozzle tips), Cooper Bessemer and the utilities are sufficient to -
preclude this failure from recurring and that this incident should be closed. If you have-any questions, please contact J. R.' Schneider, Quality Assurance Manager, or J. M.
Home, Manager of Nuclear Engineering at 412-458 8000.
Since et,
O
/ _ gx i
. A. LdBrun Vice President and General Manager HAllkil cc:
D. T. Blizzard - CES/GC I
J. M. Home - CES/GC
- J. S. Baron CES/GC i
W. O. Ferguson - CES/MV -
L A. D. Gillette - CES/GC B. R. Sedelmyer CES/GC cc:
Mr. Walter Haass - NRC One White Flint North :
Mallstop 9D4 Washington, DC 20555
[
Mr. Arthur G. Killinger MPR Associates,'Inc.
1050 Connecticut Avenue, N.W.
L.
Washington, DC 20036 L-l l
d j
-e
. Pcgo 4 OCG 9081 Novenber 2,1992 1
cc:
Mr. Ted Fryat Houston Lighting and Power
- South Texas Project Wadsworh, TX 77483 Mr. Matthew Heldom
)
Pennsylvania Power and Ught I
Two North Ninth Street Allentown, PA 18101 Mr. Elmer Hemandez Commonwealth Edison Co, Byron Nuclear Power Station 445 North German Church Rd.
Byron,IL 61010 Mr. Michael Kneble EnTergy Associates Louisiana Power and U ;ht Waterford 3 SES Highway 18 -
Taf' LA 70006 Mr. Dwain Lambert Commonwealth Edison Co.
Braidwood Nuclear Power Station
- Route 1, Box 81 Braceville, IL 60407 Mr. Doug Mullen Nebraska Public Power District Cooper Nuclear Station P. O Box 98 Brownville, Nebraska 68321 Mr. Terry O'Brien Commonwealth Edison Co.-
1400 Opus Place Downers Grove, IL. 60515 Mr. Lenny Schiavone - SM 3 l
Niagara Mohawk Power Corp.
l 301 Plainfield Road North Syracuse, NY 13212
Pcge 5 OCG 9081 Novernber 2,1992 1
cc:
Mr. Neil Thibodaux Arizona Public Service Palo Verde Nuclear Generating Station P. O. Box 52034 Phoeniz, AZ 85072 2034 i
Mr. Terry Vandevoort Commonwealth Edison Zion Generating Station 101 Shiloh Blvd.
Zion, IL 60099 l
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TABLE f.
"M OF M.AP EMAffleATIEEEE OF CIENL REL 1EJECTM SPBAY TIPS
^
SAIW'EE BEERIPTItBf WOIEEStautitW TESTimC 918EMEIMAL & SETM tm! CAL EEARTIS ImmER NOM 14AL EFFELi!VE VISUAL 1
WH11E LICAMENT LIGAMENT CASE CASE VISUAL LAYER CORf SERVICE Mote EODY CURRENT THICKNESS AWEA DEPIB 0*PTN CASE DEPTN NAR0eESS MT f LOT #
_HOURL f
TESilNG
- VJyi, (IWCMES)
(S0. fW.)
((NCM{$)
{[WCW($)
O(PT4 (INCMES)
(MRC) 3259-1 150010 357 1
WD ACC 0.048 0.224 0.0?2 0.016 52 WOME 41 2
REJ 0.052 0.221 3
REJ 0.049 0.212 e
3309-1 150006 382 1
REJ
'aEJ 0.011 0.157 0.015 0.016 100 0.0007 40.5 2
.REJ 0.013 0.159 3
REJ 0.012 0.153 3309-2 150010
-357 1
ACC ACC
~
0.056 0.245 0.018 0.020 54 0.001
'42.5 2
ACC 0.051 0.243 3
ACC 0.049 0 241 3309-3 LL1091 217 1
ACC ACC C.052 0.233 0.013 0.012 32 WOME 48 2
ACC 0.045 0.233 3
.ACC 0.040.
0.228 3309-4 150006 324 1
HJ REJ 0.012 0.174 No no up mo vi 2
REJ 0.013 0.1 75 3
ACC 0.013 0.175 1
3309-5 150006 432 1
REJ ACC 0.012 0.174 0.011 0.017 100 0.0005 45.5 2
REJ 0.017 0.1 73 3
REJ 0.018 0.174 3309-6 150010 WD 1
ACC
.ACC 0.055 0.261 30 wo ND ND ND
-2 ACC 0.054 0.252~
3 ACC 0.054 0.252 3309-7 150010 357 1
ACC ACC 0.055 0.244 0.011 0.016 50 0.0005
- 42.0 2
ACC 0.055 0.250 3
ACC 0.051' O.246 3309-8 LCH19 wtW 1
ACC ACC 0.05' O 226 0.008 -
0.006 30 0.001
!41.5 2
ACC 0.05 0.228 ~
3 ACC 0.053 0.228 3309-9 LCM 19 WEV 1
ACC ACC 0.052 0.231 MD mo No NO
' NO 2
ACC 0.053 0.230 3
ACC 0.051 0.236 3309-10 150009 100 1
ACC REJ 0.047 0.215 0.012
- 0.019 63 0.0005 41.0 2
REJ 0.047
'O.215 3
REJ 0.046 0.215 q
E09-11 150006 324 1
ACC REJ 0.019 0.173.
0.013 0.018 '
100 0.0005 42.0 2
REJ 0.021 0.182
)
3 REJ 0.021 0.181 3309-12 LCM 1 NEW 1
ACC ACC 0.056
'O.238 0.010 0.01G 23 NOME -
41.5 2
ACC 0.056 0.238 I
ACC 0.056 ~
0.234 t
NO =
NCT DETERMINED.
MT-3309
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TAlllE 1.
SUMMARY
OF III &P liXAMINATIONS OF DIESEI. FUlil. INJECI'OR SPRAY 11PS Samgk Destviguion Dimmuores & W Emluation Samgde Im #
thility Ikk #
WFMT Imn EHective vaual Owe Whise kjentificatirwa Results ligamme Case Case Vaual liardnrss layer Ihanda 1%kn.m th puh lie,sh Case (IIRQ
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Drgeh fendus) 3822-1 10001059 Pl3L
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ACC 0 0$6 0 007 0.013 40.4 42.7 None 2
AT 0 053 3
AT 0 048 1822 2 10001090 APS 1
ACC 0 042 0 008 0 012 47.1 45 2 None 2
ACC 0.044 3
ACC 0.%3 3822-3 00!!10 PP&L 1
AT 0 041 0.007 0.011
$0.2 43 3 None 2
ACC 0 041 3
'AT 0 050 3S22 4 150004 PP&L 1
ACC 0 045 0 008 0 015 64 6 45.2 0 0002 (Tag 2
ACC 0 047 4E1616) 3 ACC 0 051 3R22 5 150004 IT&L 1
RD 0 040 0 010 0.018 77.6 45.5
' O.0002 (Tag 2
RU 0 041 4E1607 3
ACC 0 039 3822-6 150013 Al"5 1
AT 0 055 0 008 0 014 453 45.8 0.00%.
2 ACC 0057 3
ACC 0.059 3822-7 200440 P'&L 1
- CC 0 042 0 007 0 610 38.6 45,7 None 2
AT 0 043 3
.AOC n044 J S22-4 087001 APS
'1 AT 0 043 0 012 0.016 725 44.7
'None 2
ACC 0 041 3
.ACC' 0 042
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