ML20138B744
| ML20138B744 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde, Vogtle, 05000000 |
| Issue date: | 12/05/1985 |
| From: | Britt M AMERICAN AIR FILTER CO. |
| To: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| References | |
| REF-PT21-85, REF-PT21-85-491-000 PT21-85-491, PT21-85-491-000, NUDOCS 8512120374 | |
| Download: ML20138B744 (10) | |
Text
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S Saslss1lG3o ypy'< 0 MmeriCall /4ir E-ilter Jo-SE/ 45 7 A
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' A.3 AN ALLIS CHALMERS COMPANY i? -. b_. d* -
21$ CENTRAL AVENUE, LOUISVILLE. KENTUCKY 40208
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REPLY 10:
CLEAN AIR DIVISION P.O. BOX 35260 LOUISylLLE, KY 40232 TELEX: 20-4351 December 5, 1985 OPEawR: <s023 637 00ii (O CALL WRITER DIRECT TELEPHONE: (502) 637-0 United States Nuclear Regulatory Commission 101 Marietta Avenue Suite 2900 Atlanta 3 GA 30323 Attention: Regional Administrator
Subject:
10 CFR 21 Reportable Item 1.
This is a formal notification made in accordance with 10 CFR 21, Paragraph 21.21.
2.
PROBLEM: Nuclear Power Plant facilities listed in Attachment A of this document have air handling units supplied by AAF.
There }3 a possibility that these units may have cracked. cast iron fan wheel hibs.
3 BACKGROUND:
At Arizona Public Service's Palo Verde Nuclear Power Plant, two cast iron fan hubs have been identified as having developed cracks.
These fans are manufactured by Chicago Blower Company.
Attachment B is a metallurgical report on the hub failures.
Also contained in Attachment B are copies of photographs taken of the failed hubs.
4.
RECOMMENDATION:
Place an immediate hold on air handling units identified in Attachment A and do not allow operatic % rutil the fan wheel hubs are inspected for cracks.
Standard me.thods for liquid penetrant inspection per ASTM-E-165 should be used to identify cracks.
If cracks are identified, one of the individuals listed in Paragraph 5 should be contacted immediately for replacement hubs,.
If cracks are not identified, the hubs should be inspected at three-month intervals for one year to insure that cracks have not developed.
8512120374 851205 DR ADOCK 05000424 PDR IE 19 Better Air is Our Business i
L 8
U.S. Nuc. Rsg. Commission Dactmber 5, 1985 i
Page 2 5
CONTACT: For further information, contact AAF at:
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(502) 637-0684 Mr. Alex O' Nan Chief Engineer, NES or (502) 637-0782 Mr. Monroe A. Britt Manager, Quality Assurance American Air Filter Company P.O. Box 35250 Louisville, KY 40232 Sincerely, 5*
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- l M. A. Britt Manager, Quality Assurance MAB/cmh Att.
Distribution: See attached list j
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I DISTRIBUTION United States Nuclear Regulatory Commission Bechtel Power Corporation Washington, DC 20555 P.O. Box 60860, Terminal Annex Los Angeles, CA 90060 Attn: Paul Cortland Attn:
H. G. Cronoos Bechtel Power Corporation Waldinger Corporation P.O. Box 60860, Terminal Annex c/o Bechtel Power Corporation Los Angeles, CA 90060 P.O. Box 49 Palo Verde, AZ 85343 Attn:
R. Lopez Attn: Paul Kneblick Waldinger Corporation Tennessee Valley Authority 2601 Bell Avenue 400 West Summit Hill Drive P.O. Box 1612 Knoxville, TN 37902 Des Moines, IA 50306 Attn: Glen Silver Attn:
C. R. Boswell Institute of Nuclear Power Operations 1100 circle 75 Parkway 1
Suite 1500 Atlanta, CA 30339 Attn:
J. P. Flynn 4
Internal AAF R. J. Urlocker M. Hargan A. O' Nan i
G. Schroeder
ATTACHMENT A CHICAGO BLOWER AIR FOIL WHEELS TVA 91-1348 Yellow Creek Item Fan Size Tag Nos.
1-4 36 1&2VA-MAHU-283-B 1&2VA-MAHU-282-A 5-12 22 1&2VA-MAHU-027-B 1&2VA-MAHU-028-A 1&2VA-MAHU-116-B 1&2VA-MAHU-101-A 1A & B 15 1-XX-MAHU-XXXLH&RH 17-20 9
1&2VA-MAHU-651-A 1&2VA-MAHU-703-B 95-96 15 1&2VA-MAHU-011 121-124 36 1&2VC-MAHU-156-A 1&2VC-MAHU-157-B 125-128 36 1&2VC-MAHU-003-A 1&2VC-MAHU-004-B 133-136 31 1&2VC-MAHU-001-A 1&2VC-MAHU-002-B 137-140 18 1&2VC-MAHU-219-A 177-180 1&2VC-MAHU-220-B
'1&2VC-MAHU-275 1&2VC-MAHU-276 165-168 52 1&2VC-MAHU-221 153-156 1&2VC-MAHU-222 1&2VC-MAHU-123 1&2VC-MAHU-066 161-164 52 1&2VC-MAHU-211 1&2VC-MAHU-224 169-176 25 1&2VF-MAHU-039 1&2VF-MAHU-044 1&2VC-MAHU-233 1&2VC-MAHU-249 13-16 15 1&2VA-MAHU-023-B 1&2VA-MAHU-022-A 157-160 52 1&2VC-MAHU-120 1&2VC-MAHU-064 s-
ATTACHMENT A (Continued) 4 Arizona Public Service 91-1343 Palo Verde Fan Size Tag Nos.
31 1,2&3-MHJN-A03 i
Korea Electric 91-1397 Korea 7 & 8 Fan Size.
Tag Nos.
22 A-7&8M-GL-F041 B-7&8M-GL-F042 31 B-7&8M-GK-F025 A-7&8M-GK-F022 7&8M-GK-039 7&8M-GK-040 i
Georgia Power 91-1335 Vogtle Fan Size Tag Nos.
41 1&2-1532-A7-001/002-000 1
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ATTACHMENT B M ATERI ALS D EVE LO PM E NT. INC.
Materials and Process Evaluation Failure investigation Testing and Consultation Technical Report #1069 for American Air Filter Co.
215 Central Ave.
Louisville, KY 40208 Cast Iron Fan Hubs Arizona Public Service Palo Verde, Sta.
Two cast iron fan hubs were submitted to the writer for examination and test.
One,which had seen an unspecified period of service had fractured cad had been removed, blades removed and returned.
This part is shani in Figs. 1-4.
The field failed hub was arbitrarily designated "A" and bore an AAF Nuclear Environmental Systems tag that stated " Hub Ass'y from 1-M-HJB-ZO4."
Spokes on hub are cracked.
The returned hub which had not been in service but which showed two of the three hub spokes cracked was marked "B" and showed the following marking'on the AAF tag
" Hub Ass'y from 3-M-HJB-ZO4." The "B" sample is seen in Figs. 5,6.
The fans were driven by 7 HP motors at 3600 RPM.
The "A"
sample in addition to the 9" hub flange section detached from the hub had three small flange sections which
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were fractured thru the bolt holes.
There are six uniformly spaced bolt holes in the hub flange, nominally
" holes.
These sections were numbered so they could be re-assembled in their original location.
The "A" hub had two of the three spokes cracked and cracks thru the diameter of the six flange bolt holes.
A 3/8" wide section was cut thru the flange of "A" and "B" and hardness and microstructure was examined and tested on each.
The results are as shown:
Rockwell B Hardness Converted BHN A. 89-91 18' 190 B. 83-85 159-165 Microstructure A.
The unit cell size was larger than B, there was considerable decarburization under the painted (unmachined) surface.
On that same surface there was also evidence of a " Smooth-on" or casting surface repair compound having been applied.
The microstructure P.O. BOX 174 PROSPECT, KENTUCKY 40059.
TELEPHCNE: AREA CODE 502 966 8755 LABORATORY 4100 BISHOP LANE LOUISVIL'.E, KENTUCKY 402G I
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TR #1069 Page 2 showed, free. ferrite, large graphite nodules and flakes but with a predominantly pearlitic matrix.
One sizable pocket of porosity was evident.
B.
The B sample showed no surface conditioning under the paint, showed a finer cell size and no appreciable porosity or decarb.
While there was a pearlitic matrix, there was more free ferrite evident and numerous large graphite nodules than noted in A.
This is consistent with the lower hardness values found.
The fracture surfaces on "A" were examined under a stereo-scopic low power microscope (50-100X).
Flange bolt hole section 2, section 1 showed evidence of rust and peening of fracture faces indicative of pre-existing cracks.
Section 3 showed 4
less. The spoke hub fracture also showed peening indicating i
wear before final fracture.
When placed on a glass plate the vertical mis-match of the two spoke fractures is quite evident.
1 "B" had no fracture faces to examine but measuring the two sides of the flange cut made for a test section also showed sig-nificant mis-match.
From the laboratory examination and measurements made the 1
following conclusions are set forth:
1.
The iron is a 20,000 psi gray iron with a duplex (ferrite-pearlite) microstructure and of marginal quality.
2.
Surface repair had been practiced which is generally not acceptable for castings with a strength requirement.
3 i
3.
The very heavy hub section, short spokes, and thin spoke and flange sections give a poor casting and service stress distribution.
4.
The evidence of mismatch indicates that the castings had not been stress-relieved.
2 5.
The fracture face indication is strong evidence that cracks pre-existed service and fracture to-final failure propagated quite rapidly.
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June 11, 1985 Harold J.
Smith, P.E.
. Metallurgical Engineer
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