ML20137G626

Svcs Part 21 Rept Re Emergency Generators Installed at Zion Station Which Developed Significant Drop in Crankcase Lube Oil Level.Caused by Crack in Liner Wall,Allowing Jacket Water to Enter Chamber

ML20137G626
Person / Time
Site:	Nine Mile Point, Palo Verde, Cooper, Byron, Braidwood, Susquehanna, South Texas, Zion  File:ZionSolutions icon.png
Issue date:	03/25/1997
From:	Cote R AFFILIATION NOT ASSIGNED
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-97 QCG-10373, NUDOCS 9704010450
Download: ML20137G626 (4)

Text

150 lincoln Avenue

, Grove City I'A 16127-1898 e

Tel 412 458 0000 Fax 412 458 3574 Ajax@

COOPER [;","l,,,,,n ,,

ENERGY SERVICES enmpm ~

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March 25,1997 [*","[,,

Our Ref: OCG 10373 Document Control Desk U.S. Nuclear Regulatory Commission  !

Washington, D.C. 20555

Subject:

Commonwealth Edison Company, Zion Station, EDG i Piston and Liner 10 CFR 21 Interim Report  !

)

Dear Sir:

The purpose of this letter is to provide initial notification and interim report of a 10  !

CFR 21 evaluation associated with the Cooper-Bessemer KSV Emergency Diesel l I

Generators installed at Commonwealth Edison (CECO) Zion Station.

On January 27,1997 CECO identified a significant drop in crankcase lube oil level.  !

Subsequent investigation revealed that a crack had developed in the cylinder liner wall j allowing jacket water to enter the combustion chamber. Jacket water in the l combustion chamber is incompressible and caused a hydraulic lock which resulted in l a fracture in an area of the piston crown, relieving the hydraulic lock. Upon review of l the failed piston it was noted that the piston crown thickness in the area of failure was below drawing specifications.

While the EDG continued to operate, :he potentiallong term effect of the above could be dilution of the crankcase oil with jacket water, accompanied by a reduction in lubrication, ultimately resulting in seizure of critical assemblies.

l This event resulted in two distinct investigations, namely, the liner failure causing the event and the piston crown thickness. Each is discussed below. \0 1

KSV Power Cylinder Liner Cooper-Bessemer part number G18-9-12A#3 (safetyerelated) and G18-9-12A#2 (commercial, non-safety related).

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9704010450 970325 PDR S ADOCK 05o00295 pgg 010 % 1 gl,ilgapgl1,1151,11,14

. Pago 2 ,

March 25,1997 OCG-10373 i This is the only known failure of subject liner. Evaluation activities include sectioning of the liner, metallurgical analysis and finite element analysis. CECO has taken the primary role in this investigation, assisted by Cooper-Bessoner. Initial analysis has determined acceptable stress levels. Additional analysis is being conducted based on review of the initial analysis by Cooper-Bessemer / CECO.

This liner design is only in use on "early" KSV engines in use at Commonwealth Edison Company's Zion Station and Nebraska Public Power District's Cooper Nuclear Station. "Later" vintage KSV engines utilize liners of different design and are not  ;

affected by this evaluation. ]

An improved design has been developed by Cooper-Bessemer which, in essence, retrofits the " earlier" engines to the "later" design. (New part number KSV-9-3F#1). _

Use of this liner as a replacement will be recommended and is not dependent on the I outcome of this evaluation. It is expected that this evaluation will be completed before )

May 28,1997. )

i I

KSV Power Piston Cooper-Bessemer part number KSV-5-A, KSV-5-A#1, KSV-5-3A#1 (commercial, non- i safety) and KSV-5 A#2, KSV-5-2A, KSV 5-2A#1 (safety-related).

Failure of this piston was a direct result of the liner failure. No other such failure has been documented. It has been determined that the subject piston crown thickness at the point of failure was below drawing requirements. Investigation has determined that the pattern for the piston casting was incorrect. Preliminary stress analysis indicates that stresses are relatively low in this area even for crown thickness considerably below the drawing requirements. Any piston operated for 600 hours0.00694 days <br />0.167 hours <br />9.920635e-4 weeks <br />2.283e-4 months <br /> or ,

greater has experienced 10 x 108 stress cycles and thus is unlikely to fail under normal loading.

Finite element analysis is being conducted by Cooper-Bessemer to determine acceptable minimum thicknesses for the piston crown section. l l

This evaluation could affect the following KSV users <

Arizona Public Service- Palo Verde l Commonwealth Edison - Braidwood j Commonwealth Edison - Byron l Commonwealth Edison - Zion Entergy Operations - Waterford 111 Houston Lighting and Power - STP Nebraska Public Power District - Cooper Nuclear Station Niagara Mohawk - NMP2 Pennsylvania Power and Light - SSES 4

. Paga 3 March 25,1997

• QCG-10373 ]

It is expected that this evaluation will be completed before May 28,1997.

Please contact Andrew Steffan at 412-458-3455 or John Horne at 412-458-3543, if i you have any questions.

Sincerely, .j COOPER CAMERON CORPORATION

/&41L -

R. M. Cote Vice President and General Manager

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cc: D. T. Blizzard - CES/GC J. M. Horne - CES/GC T. W. Kearns - CES/GC W. H.- A. Lambert A. P. Steffan - CES/GC File: K5fa40

_ , . Pago 4 i i

March 25,1997

. OCG-10373,  ;

Copies to:

Mr. Walter Haars Mr. Doug Mullen i U.S. Nuclear Regulatory Commission Nebraska Public Power District ,

One White Flint North Cooper Nuclear Station Washington, DC 20555 P. O. Box 98 ,

Brownville, Nebraska 68321 '

Houston Lighting and Power Co.

South Texas Project Electric P. O. Box 289 Mr. Terry O'Brien Wadsworth, TX 77483 Commonwealth Edison Co.

Attn: General Manager 1400 Opus Place Nuclear Assurance & Licensing Downers Grove, IL 60515 Mr. James Kenny Mr. David Zink Licensing Group Supervisor Niagara Mohawk Power Corp. I Pennsylvania Power and Light Nine Mile Road - Unit 2 Two North Ninth Street Annex 61 P. O. Box 63 Allentown, PA 18101 Lycoming, NY 13093 i

Mr. Matthew Heidorn Ms. Kathleen Russo Pennsylvania Power and Light Niagara Mohawk Power Corp.

Susquehanna Steam Electric Station Nine Mile Road Unit 2 P. O. Box 467 P. O. Box 63 Berwick, PA 18603 Lycoming, NY 13093 Mr. Terence Bannon Arizona Public Service Licensing Group ALPHA 61 P. O. Box 52034 Mail Station 6325 I Pennsylvania Power and Light Phoeniz, AZ 85072-2034 2 North Ninth Street Attn: Department Leader Allentown, PA 18101 Nuclear Materials Management Mr. David Baran Ms. Angela Krainik Commonwealth Edison Co. Manager, Nuclear Regulatory Affairs Byron Nuclear Power Station Arizona Public Service  ;

4450 North German Church Rd. P. O. Box 52034 Mail Station 7636 Byron, IL 61010 Phoeniz, AZ 85072-2034 Mr. Michael Kneble Mr. Terry Vandevoort EnTergy Associr.tes Commonwealth Edison Louisiana Power and Light Zion Generating Station Waterford 3 SES 101 Shiloh Blvd. j Highway 18 Zion, IL 60099 i Taft, LA 70006 Mr. Dave Gustafson Mr. Arthur G. Killinger Commonwealth Edison Co. MPR Associates,Inc.

Braidwood Nuclear Power Statioa 320 King Street Tech Staff Electrica! Group Alexandria, VA 22314-3238 Route 1, Box 84 Braceville, IL 60407