ML20147J258

Part 21 Rept Re 970119 Defect Associated W/Packing Nuts on One Inch Valves Used on UF6 Cylinders.Feed & Withdrawal Operations for Cylinders Equipped W/Cda 636 Packing Nuts

ML20147J258
Person / Time
Site:	Paducah Gaseous Diffusion Plant
Issue date:	04/11/1997
From:	Rafakes G UNITED STATES ENRICHMENT CORP. (USEC)
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-97 GDP-97-0063, GDP-97-63, NUDOCS 9704160113
Download: ML20147J258 (12)

Text

o United Sta'es Enrichment Corporation L~S 2 Democracy Genter 6903 Rockledge Drive Bethesda, MD 20817 Tel: (301)564-3200 United States Enrichtnent Corporation George P. Rifakes Dir; (301) 564-3301 Executive VICE PRESIDENT, Operations Fax: (301) 571-8279 April 11,1997 SERIAL: GDP 97-0063 U.S. Nuclear Regulatory Commission Attention: Document Control Desk Washington, D.C. 20555-0001 Paducah Gaseous Diffusion Plant (PGDP)

Docket No. 70-7001 Written Notification of 10 CFR 21 Report The purpose of this letter is to provide Written Notification to satisfy the requirements of 10 CFR 21.21(d)(3)(ii) of a reportable defect that was discovered at the Paducah Gaseous Diffusion Plant (PGDP).

This Written Notification is a follow up to the Initial Notification sent to the NRC by letter GDP 97-0036, dated March 14,1997.

The defect is associated with the packing nuts on 1 inch valves used on UF cylinders. The firm 6

supplying the items is Hunt Valve Co, Inc.,1913 E. State Street, Salem, Ohio,44460. The defect was initially discovered on January 19,1997.

The nature of the defect was cracking of the valve packing nut. Metallurgical analysis of the cracked nuts has shown intergrannular cracking to be the degradation mechanism.

Packing nuts with intergrannular cracks were found in cylinder valves which had been used in various stages of the enrichment process. In addition, intergrannular cracking was found in the packing nuts of cylinder valves removed from new cylinders to allow internal inspection of the cylinders. The removed cylinder valves l

were in storage and had not been exposed to the plant process chemicals or handling practices which affect the packing nut. This indicates that the problem is probably a material or manufacturing problem with the nuts. Three valve packing nut materials are currently used: monel, ASTM B150 613 alloy, and CDA 636 alloy. An inspection ofvalves from other suppliers that are manufactured from all three materials indicate that the cracking problem is observed only in the 636 alloy nuts on valves supplied by Hunt Valve Co.,

Inc.

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U.S. Nuclear Regulatory Commission Attn: Document Control Desk March 11,1997 GDP 97-0063 Page 2 Failure of the stem packing nut during plant operations to fill or empty a UF cylinder could allow the 6

j stem packing rings to be forcefully ejected from the valve, resulting in a UF release, a hazard to plant 6

personnel, and a challenge to plant safety systems. Failure of a cylinder valve packing nut and ejetion ofthe valve packing with an open valve on a full cylinder would constitute a failure of a UF confinement 6

system, and, therefore, could create a substantial safety hazard. Cracking of the stem packing nut on closed cylinder valves does not pose a hazard since the packing gland is isolated from the UF cylinder 6

contents.

The 1 inch cylinder valves are used in the 30B Portsmouth Gaseous Diffusion Plant (PORTS) cylinders and the 48X,48Y,48G, and 48H PGDP cylinders. The 1 inch cylinder valves are procured by PGDP for use on all of the cylinders identified above at both PGDP and PORTS. The valves are provided by PGDP to the cylinder vendors for installation on new cylinders supplied to PGDP and PORTS. The 1 inch cylinder valves are supplied by PGDP to PORTS for any replacements required on the 30B cylinders. The total number of applications is bounded by the number of valves supplied with CDA 636 packing nuts by Hunt Valve Co. The total number of valves provided was 4500. The number of valves with CDA 636 packing nuts currently in sersice is less than 4500 due to valves removed for cylinder inspections, repairs, replacements, etc. The exact number in service is currently unknown. The 1 inch cylinder valves are not used on any of the other cylinder designs.

The corrective action that has been taken at PGDP is to prohibit feed and withdrawal operations for cylinders equipped with 1 inch Hunt Valve Co. valves equipped with CDA 636 packing nuts. CDA 636 packing nuts are replaced with monel or ASTM B150 613 packing nuts prior to use of a valve in feed or withdrawal operations. Long Term Orders have been established in accordance with the governing procedure to ensure compliance with the prohibition. The Long Term Orders require checking of the cylinder valve prior to use to identify any Hunt valves equipped with CDA 636 packing nuts and prahibit their use. The valve body is clearly marked with the name of the manufacturer and the nut is marked with the material designator. Therefore, Hunt valves equipped with CDA 636 packing nuts can be readily identified and excluded from use.

PORTS has been notified of the Hunt Valve Co packing nut defect. A PORTS Daily Operating Instruction was issued for the X-342, X-343, and X-344 facilities to implement stop work notices which require inspection of all cylinder valves prior to heating, filling, and transferring of cylinders. Any cylinder found to have a 1 inch Hunt cylinder valve with a CDA 636 packing nut installed will not be heated, filled, or transferred. Caution tags are installed on all prohibited valves, and operatione may not continue until I

the valve packing nuts have been replaced with approved replacements (i.e., newCDA 636 material). A procedure containing guidelines for inspection and rejection of cylinders was revised to include the requirement to immediately replace any packing nuts on Hunt cylinder valves stamped with "636", or hang a caution tag on the subject valve and reject the cylinder. Hunt cyhnder valves with the CDA 636 packing nuts were removed from stock. The valves will not be put back into stock until the packing nuts are replaced with another material.

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U.S. Nuclear Regulatory Commission 1

Attn: Document Control Desk

. March 11,1997 l

GDP 97-0063 Page 3 PGDP efforts to determine the root cause of the failure mechanism are continuing. These efforts are

) focused on the nut fabncation methods and the raw material production. The suspect population of 1 inch cylinder valves may be narrowed to a subset of the current 4500 valves as a result of the continuing investigation. In the event that some number of the 4500 valves can be excluded from the potentially j

defective population, the corrective actions may be revised at that time to allow the use of Hunt Valve Co.

1 inch cylinder valves with CDA 636 packing nuts from the population excluded from being potentially j

defective. The prohibition on the use ofvalves with nuts from the suspect population for withdrawal or feed will be maintained. This corrective action is adequate to preclude a UF release due to the identified 6

l defect.

l The associated PGDP 10 CFR 21 evaluation checklist and a copy of pertinent PGDP problem reports j

are enclosed. New commitments made in this letter are to continue the ongoing corrective actions i

descr.oed above to prohibit the use of cylinders with 1 inch Hunt Valve Co. valves with CDA 636 packing nuts at both PGDP and PORTS. Any questions related to this subject should be directed to Mark l

Lombard at (301) 564-3248.

Sincerely, l

[/Q e'

George. Rifakes Executive Vice President, Operations i

Enclosures:

as stated J

i cc: NRC Region III Office NRC Resident Inspector - PGDP i

NRC Resident Inspector - PORTS Mr. Randall M. DeVault (DOE) i l

L!-

A ENCLOSURES PGDP PART 21 CHECKLIST AND RELATED PROBLEM REPORTS i

03/19 '97 09:11 IDSRA FAX:5024416798 PAGE 5

g Uh2.hu-Uh1039, Kev. l' Page 17 'of 15 ww ase 10 CFR PART 21 EVAfl/ATION CHECKLIST Page 1 off 3 u g,,g, i

I ll toll: wing questions provide the criteria for evalution of 30 CFR Part 21 reportability; 4

A.1 No.,tf Yes _,,,,,

Has the NRC al cady been informed of this condition pursuant to.10 CFR 21 (for example, by a

]

', suppjier)?

i A.2 No _ Yes If yes, has USEC or LMUS been nained as a recipient of the defective item?

l A.3 No_/ Yes _

Has this condition already been reported to NRC in accordance with procedure UE2 MC.RE1030? '

If the answer to Questions A.! and A.2 are 'Yes', or the answer to Question A,3 is "Yes", the condition need not be reported under 10 CFR 21. Attach objective evidence of notification of the NRC and complete Part #.

If the answers to Questions A.1, A.2, and A,3 are 'No', continue with the evaluation.

B.1 No _ Yes g Is the identified condition a deviation or failure to comply associated with a basic component (including design, analysis, inspecuon, testing, fabrication, ivplacemoot pans, or consultag i

services)7 i

If the answer to Question B.! is 'No', the conditionis not reportable under 10 CFR 21; attach basis for conclusions and proceed to Section l E. If the answer to Question B.1 is *Yes", continue the evaluation.

i No_ Yes r If the answer to Question B.1 is *Yes', has the basic component been delivered to USEC/LMUS and accepted for use in the plant or an activity (includes USEC-dedicated commercial grade items)?

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i If the answer to Quesuon B.2 is *No", the condition is not reportable under 10 CFR 21; attach basis for conclusions and proceed to Section E.

If the answer to Question 3.2 is "Yes", condition is potenually reportabic, Continue with tbc evaluation.

C.

Further, does t6e activity or-basic camponent contain any of tbc following types of conditions? (Deviation means a departure from the technical requirements included in a procuronient-document.)

I

(

No_ Yes f 1)

The installation, use, or operation of a basic compon" eat containing a deviation?

No_7 Yes,_.

2)

A condition or circumstance involving a basic component that could contribute to exceeding l

a safety limit as defined in the GDPs Technical Safety Requirements (TSRs)?

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No_# Yes _

3)

A failure to comply with any applicable regulation, order, or certificate issued by the NRC7 If all of the answers in this secuon are 'No', the conditma ns not reportabic; attach basis for conclusion and proceed to Section E. If any

! answers are 'Yes', continue with the evaluation.

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03/19 '97 09:11 10: TEA FAX:5024416798 PAGE-6 UE7 EG-GE1039, Rev.1

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t Could the deviation or failure to comply create a substantial safety hazard resulting in any of the following (assume the.

no redundant or back-up systems):

No_< Yes.__

1)

Exposure in excess of 10 CFR 20.1201 limits Exposure of an individua!' a'a unrestricted area to more than 0 5 rem in one calendar yi.ar l

No_._. Yes _

2) m (10 CPR 20.1301(c))

l No T Yes _.

3)

Release of radioactive material to an unrestricted area m excess of the limits in 10 CF/. 20, Appendix B, Table 2 l

l No Yes E 4)

A deficiency which seriously compromised the ability of a UF, corfmement system to perform its desipated function I

i No_' Yes _

5)

Other (explam)

If all answers in this section are "No', the condition is not reportable;. complete Part E. If any answer is "Yes*, condition is reportable.

Continue with evaluation.

E.

Evaluation results and recommendation. Recommend condition be reported?

I

)

l No_

Yes _-

If answer is 'Yes", sign this part and continue to follow procedure UE2 EG-GE1039. Sign the evaluation checklist and forward to the Manager, NRA. If answer is *No', evaluation is complete. Sign the evaluation checklist and forward to Commitment Management for closure of

, Problem Report.

Attach written summary of evaluation and basis for conclusions.

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_ _. _.,03,4 9 '97. 09:12 iD:NRA FAX:5024d16798 PAGE 7

I 10 CFR PART 21 EVALUATION CllECKLIST Page 3 of 3

SUMMARY

OF EVALUATION AND BASIS FOR CONCLUSIONS l

I The 1 inch cylinder valve used on UF. cylinders is equipped with a packing nut which retains the packing gland follower and packing rings. USEC-651, Rev 7, Uranium Hexafloride, A Manual of Good Handling Practices, section 5.4 6, discusses part defects in I inch cylinder valves and the potential adverse effects. One past defect was packing nuts which have split during service. It is identified that this condition could allow the stem packing rings to bc forcefully ejected from the valve, resuking in a UF., release.

Feilure of a cylindgr valve packing nut and ejection of the valve packing with an open valve on a full cylinder,would constitute 4

a failure of a UF, conGnement system. Therefore, the cylinder valve packing nut is a basic component for which failure could create a substantial safety hazard.

Tbc cylinder valves were procured by the Paducah Gaseous Diffusion Plant as commercial grade items and were dedicated for l'

use on the UP. cylinders. The dedication process has been completed for any valves installed on UF. cylinders thereby l

establishing the appliisability of 10-CFR 2Llo the>e components.

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l On 1/19/97, a UF. release was detected during pigtail purging operations on a full cylinder. %e release was visible as a small" i

wisp of smoke after the pigtail was pressurized above atmospheric. The cylinder valve was closed and the release was terminated. Inspection of the valve revealed a visible crack in the valve packing nut. An investigation was initiated to l

determine the cause of the valve nut failure. A similar failure occurred on 2/7/97 and was included in the investigation.

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De 2 failed nuts were examined metallurgically and were found to exhibit intergrannular cracking. Both of these nuts are l

from Hunt valves and are CDA 636 material.

Valve packing nut inspections were performed as part of the investigation in order to determine the extent of the problem.

Eddy current inspection techniques were used in addition to visual inspections to help identify potentially degraded valve packing nuts. As a resuk of the inspections additional cracked valve packing nuts were identified. The following is a summary of the additional nut inspection:

136 Hunt CDA 636 nuts from valves from Paducah Gaseous Diffusion Plant cylinders have been inspected by eddy current.13 of these have exhibited cracks. One of these was on a cylinder stored in the E yard and the cracks were detected visually. Another, detected by eddy current, was on a "new" valve in storage following removal to allow inspection of a new UF. cylinder. Metallurgical analysis was performed on the "new" nut and confirmed the presence I

of intergrannular cracks.

25 llunt DISO 613 nuts were eddy current tested and no cddy current indications were detected. Onc of these was I

e subjected to metallurgical analysis and no cracking was detected.

28 Superior valve nuts of CDA 636 were eddy current tested and no indications were detected.

20 Hunt 636 nuts were examined from customer cylinders. 3 showed indications including I with a visible crack. 2 l

of these were metallurgically examined and the indications confirmed. Three nuts that showed no indications were j

examined rnetallurgically and only one showed very slight indications that would not be picked up b) eddy current..l Three valve packing nut materials are currently used, rnonel, ASTM DI5O 613 alloy, and CDA 636 sitoy. The cracking problem has been observed only in the 636 alloy nuts on valves supplied by Hunt Valve Co.,Inc. The intergrannular cracking has been detected in Hunt CDA 636 cylinder valve packing nuts which have been used in various stages of the enrichment l

process and in the packing nuts of"new" cylinder valves removed from new cylinders to allow tcccipt inspections. The

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removed valves were placed in storage anthvere not exposed to p,lant process chemicals or handling practices ofrecting the packing nut. This indicates that the problem is a material or manufacturing problem with the nuts. No defects or failures have been identined in nuts of CDA 636 material on other vendors valves or in nuts of alternate materials on Hunt vahes.

f A total of 4500 valves were supplied by Hunt Valve Co. with CDA 636 packing nuts. Investigation and analysis is continuing i

to determine if the entire population is susceptible to the intergrunnular cracking problem or if the effected population is n subset of the 4500. Until further analysis determines otherwise,it will be assurned that the entire 4500 is affected.

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• 034 9 '97 09:12 ID:tRA FAX:5024416798-PAGE 8

j 316 Business Priorititetten System rege Problem Report Response shr.t g

155Ut TITtt.. smort RELEAlto FROM CTtlNDER VALYE 04 PP.254f M Response Ove: //

AlsL55HENT...: PROSLEM REPORT 5 JANUART

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• Operations' ORIGINAIING CaQUP.....: 79)

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DiscovtRf DATE........: 01/19/1997 2200 BUILDING... 3 C 3t0~,

Mall $109,...:.C.331

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DFSCRIPfloot UPGitAotD To (VENT REPORT PA0 tR 1997 001 A small wisp of smoke was released from the cylinder volve en cylinder PP 2549. PCLC Yt 75 over the as withdrevet position pigtail was actuated, Tre operators were in the process of evacuating / purging the pietatt on a full prodvet cylinder. The wisp was observed af ter the pigtait was pressured above etenosphere. A noticestile crack circuwents the packing nut. The operators exited the eres and donned additional ppt. The pigtall was purped using eubetmospherie doubting purges and the cylinder volve confirmed closed. Cylleder was disconnected with no further incident end defective valve ter end caution tog was placed on the cylinder. MT and weerifun eagles were putted with negative results. The ARP was f0ll owed and the PS$ notified.

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, i NONE RfCommH0E0 ACTfows,,

Replace cytinder valve on PP 2549."Ardlyte f aMure of vdve cap.

l P55 JU$7tFICAil0N/COMMfMT$

Urine senvles were obtelned. Ur6 detection saf ety system was actuated end operated es designed. 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> event report l

PAD.1997 002 isswed. Criteria met Appendix ! l(s) W6vsual and Appendix F. J (2) 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />. smell wisp reltesed from cracked pecking nut w'ien pigtait pressured up, HP smeers were negative. This PR should be eve lueted for 10CfR21 l

,reportebility.

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pg8CRIPTiest A emell wiep of emoke see released f rom the cylinder volve en cylinder PK.593 during purging operatione. 'Jhie setivated roLD 78 7) in the is withdrewel poettien ventA3stion duet. The wiep wee observed ef ter the pisteil wee proveured above atmosphere. A noticeeDie crack cirguenente the pack 8ng nut.

Ac*r20na TAKEN 1

Operations immedtetely emited the area. Alarm wee reopended to per procedure. MF semples and wipes wdre no9etive.

The pigtett wee purged using evbetmospherie doubling purg,0. tylinder wee disconnected with no further incident, e

RR7MIEFPEP ACTIQM$

Replace cylinder velve pack &cg nut on PK.591.

Investigate failure of pecking nut.

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i 24 muur Event poport per Us2.sec.psto30, Appendia s criteras 1. I. vnueuel (e), and Appendte r criterle J.3.

Appropriate response wee mode. MF and HP surveys were negative. Precautionary urine semples were obtained from the two workere who wese present, kEM&EEE 03/06/97: Per PRsc, eseign to Operettore for disposition. Thie PR will be closed to PR CO.97 0600 which le a SCAQ.

03/05/97: por reporteble evente doe to DOS on/ef ter 03/05h? Idete NRC eseumed regulatory oversight) have been downgreded to ptchlem reporte. PR.CO.9106eg hee been pieced back in PART etatus and will be teken back to the Screening Comittee for SCAQ determination, eetion plan dde date, etc. Svent Report PAD.BR.1997 004p (UC1710810) Ide liten concelled.

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'01d 9l'97 09:13 ID:NRA FAX:5024416798 PAGE

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'UC9711002 Butiness Prieritis:tten $ystem Pagt.1 Probtsui Riport R sponse Sheet "31" PR0 SLIM R(P0til q, -

p if'JUE TI TL E...: PACE!NG NUT QN CYLINn(R PP 2520 IN E YAA0 CMCr[0

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The packing nyt on cylincer PP 2520 in the f yard Wes f ound crocked erovnd the circumference tat poprontmately the top thread) through epprenimately 807. of the section. This is a "Nunt"volve elloy "6 36" nut.

(Lot #390775 8).

This pack ing nut f vre was f ound while inspecting Paducah Ple it cylinders with en eddy current prot >e for indications of J

cretted nuts, ut was' clearly vis %le.wlth crack opening of approAlmately 1/S".

The cytinder appeared to'be empty.

t ACff0NT TArfN NONE i

Pt CO*utNOLO ACT f ON$

I NONE i

P N5tIF ICAfl0NrCOMM(Nf 3 found during a rendem sampling of Nunt valves wfth the "6 36" packing nut. No sign of any teakage. 10 ton cylinder.

Per NMCIA records, il en enipty eylinder with notation requiring a valve change. This should be eve lUsted for 10 CfA 21 end 71.95 applicability.

RfMAPKt 02/20/97: Part A is assigned to Operations and Mene9ement rescense provicec et PRSC. No further action required-Part e is essigned to Engineering to evoluste for 10 CFR applieseltityi i

I MANACiuf v7 RTSPON5(

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i Name of person prov{dlng responsei 4h e

Printed 02/20/1997 at 13:23:

14We Revised 02/20/1997 at 09:5f 34 '

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4 FUEL CYCLE FACILITY EVENT NUMBER:

31954

! FACILITY: PADUCAH GASEOUS DIFFUSION PLANT

• NOTIFICATION DATE: 03/14/97 RXTYPE: URANIUM ENRICHMENT FACILITY NOTIFICATION TIME: 13:30 [ET) i COMMENTS: 2 DEMOCRACY CENTER EVENT DATE:

03/14/97 6903 ROCKLEDGE DRIVE EVENT TIME:

00:00(CST)

BETHESDA, MD 20817 (301)S64-3200 LAST UPDATE DATE:

04/11/97 CITY: PADUCAH REGION: 3 COUNTY: McCRACKEN STATE: KY NOTIFICATIONS

' LICENSE # GDP-1 AGREEMENT: Y DOCKET: 0707001 WAYNE KROPP RDO JOSEPHINE PICCONE EO

'NRC NOTIFIED BY: MARK LOMBARD KEVIN RAMSEY (FAX)

NMSS iHQ OPS OFFICER:

STEVE SANDIN

' EMERGENCY CLASS: NOT APPLICABLE

!10 CPR SECTION:

CDEG 21.21(c) (3) (i)

DEFECTS / NONCOMPLIANCE EVENT TEXT I

10 CFR PART 21 NOTIFICATION REGARDING STRESS CORROSION CRACKING OF CYLINDER

' VALVE PACKING NUTS IT HAS BEEN DETERMINED THAT STRESS CORROSION CRACKING OF THE 1-INCH CYLINDER VALVE PACKING NUTS USED IN VARIOUS STAGES OF THE ENRICHMENT PROCESS HAS, IN ONE CASE, RESULTED IN A REPORTABLE RELEASE OF UF6.

THIS PROBLEM HAS ONLY BEEN OBSERVED IN THE 636-ALLOY NUTS ON VALVES SUPPLIED BY HUNT VM,VE CO., INC.

• *

• UPDATE 1740EDT 4/11/97 FROM MARK LOMBARD TO S. SANDIN * *

• 4 THE LICENSEE SUBMITTDD AN UPDATE VIA FAX.

NOTIFIED R3DO(MADERA) AND FORWARDED TO NMSS(RAMSEY).

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4 FROM suscc set.sc4 32to 1997.04 11 1s:33 g73s p,egfgg UNITED STATES ENRICHMENT CORPORATION li Two Democracy Center a 4th Floor e 6903 Rockledge Drive e Bethesda, MD 20817 i

Fax! Memorandum a

DATE:

April 11.1997 TIME:

5:39 om I

NRC Operations Centd FAX:

TO:

}

PHONE:

1 FROM:

Mark Lombard FAX:

301 564-3210 PHONE:

S01 564 @ 48 1

NUMBER OF PAGES (includingicover shee1): 46 //

1

SUBJECT:

Part 21 written report' attached. for concurrence. Please call me if you have any questions. The hard copy will follow by mail.

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