ML20203H989

Part 21 Rept Re Potential Manufacturing Defect of Enterprise DSR-4 & DSRV-4 Edgs.Cooper Energy Svcs Supplied 1A-7840 Adjusting Screw to Affected Utils & Sites.River Bend Station Replaced W/Acceptable Assemblies

ML20203H989
Person / Time
Site:	Catawba, River Bend
Issue date:	12/12/1997
From:	Cote R COOPER ENERGY SERVICES
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-97 NUDOCS 9712190096
Download: ML20203H989 (6)

Text

150 Lhcoln Avenue

, b Grove Crty. PA 16127 1898 Tel 412 458 8000 J

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December 12,1997 Our Ref: OCG 10446 (K 5fa42)

Document Control Desk U.S. Nuclear Regulatory Commission Washington, D.C. 20555

Subject:

10 CFR 21 Nottication, Enterprise DSR 4 and DSRV-4 Emergency Diesel Generator Adjusting Screw Fallure

Dear Sir:

In accordance with the requirements of the Nuclear Regulatory Commission Title 10, Chapter 1, Code of Federal Regulations, Part 21, Cooper Energy Services (CES), a division of Cooper Cameron Corporation, hereby notifies the Commission of a potential manufacturing defect of the Enterprisec DSR 4 and DSRV 4 Emergency Diesel Generators (EDG's).

Discussion:

• On September 26,1997, Entergy Operations River Bend Station reported the failure of an adjusting screw, Cooper Energy Services part number 1 A 7840. The adjusting screw is a ball and swivel assembly utilized to allow for angular movement between the rocker arm and intake and exhaust valve sterns of the power cylinder head. The adjusting screw is assembled by swaging a " swivel

\ pad" on to a " ball".

Subsequent investigation determ.ned that the swaging process and tooling was of a design that allowed for *overswaging' of the pad, reducing the amount of free angular movement in the assembly. This cond! tion potentially caused the material of the upper edge of the swivel pad to be over stressed, and/or limit the ability of the assembly to accommodate the required angular movement with undue stress.

The failure of the assembly was the cracking of the swivel pad material at the upper edge. This failure has the potential to cause an operability concern due to the assembly separating and excess clearance (valve lash) being established which could lead to catastrophic failure of the valve stem or remaining ball portion of the assembly. Multiple failures of the assembly without catastrophic failure could also reduce engine output due to decreased valve lift. In addition, loose  ;

pieces of the assembly could cause secondary damage in the engine.

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' Page 2 December 11,1997 OCG 10446 Cooper Energy Services has supplied the 1 A 7840 adjusting screw to the following utilities and sites:

AFFECTED UTILITIES Sjilg REMARKS Entergy Operations River Bend Replaced Duke Power Catawba Korea Electric KORI 3 & 4 1 CORRECTIVE ACTION I

The subject assemblies at River Bend Station have been replaced with acceptable assemblies.

The swaging tooling has been corrected to limit the amount of " swage". Acceptance criteria assuring the necessary freedom of the assembly has been defined and will be verlflod during manufacture.

USER RECOMMENDATIONS Utilities currently in possession of 1 A 7840 assemblies are instructed to verify that a minimum of 18 degrees of angular movement from centerline is available in all directions, with no indication of roughness when moving.

ll you have any questions concoming this report, please contact Andrew P. Steffan, Supervisor, Quality Engineering at 412 458 3455 or Ronald G. Billig, Supervisor Aftermarket Engineering at 412-458 3584.

Sincerely, COOPER CAMERON CORPORATION Ab R. M. Cote Vice President and General Manager

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cc:. J. M. Home CES/GC R. A.Johnston-CES/ Alameda B. C. Guntrum - CES/ Alameda R. Nimmo- CES/ Alameda R, G. Billig - CES/GC L A. Duck-CES/ Alameda A, P. Steffan CES/GC S. R. Johnston-CES/ Alameda S. A. Chubbuck- CES/ Alameda File: K5fa42

' Page 3 December 11,1997

OCG 10446 i

.- e Copies to: Duka Power Co.

Nuclear Generation Dept.

Mr. Stephen Alexander P. O. Box 1006 '

U.S. Nuclear Regulatory Commission Charlotte, NC 28201 1006-QA Vendor insp. & Maintenance Branch Attn: Mgr., Noclear Safety  ;

One White Filnt North EC059 Mallatop 9At Washington, DC 20555 Duke Energy Corp. I OEA Manager.

Carolina Power and Light Co. Nuclear Assessment Division Harris Nuclear Project Mall Code EC OSP P. O. Box 165 Box 1006

- New Hill, NC 27562 Charlotte, NC 28201 1006

- Attn: William Robinson

• Vice President Entergy P. O. Box 429 Carolina Power and Light Co. - Echelon One

. P. O. Box 1551 1340 Echelon Parkway Raleigh, NC 27602 Jackson, MS 39286 1995 Attn: Manager Nuclear Licensin9 Attn; F. W, Titus (Fred) -

Vice President, Engineering Carolina Power and Light Co.

Department Manager Entergy Harris Nuclear Plant -

P. O. Box 756 P. O. Box 165, State Road 1134 Port Gibson,' MS 39150 New Hill, NC 27562 Attn: C. R. Hutchinson (Randy)

Vice Pres., Operations-GGNS Carolina Power and Light Co, Robinson Nuclear Plant Entergy SC Hwy.151 and 23 Box 790 P. O. Box 756 Hartsville, SC 29550 Port Gibson, MS 39150

. Attn: Department Manager Attn: D. L. Pace, Director Design Engineering-GGNS Cleveland Electric illuminating Perry Nuclear Power Plant Entergy P. O. Box 97 P. O. Box 756 Perry, OH 44081 Port Gibson, MS 39150 Attn: ' RussellJ. Tadych Attn: M. J. Meisner Manager, Quality Control Director, NS&RA Cleveland Electric illuminating Manager, Quality Services i Perry Nuclear Power Plant Entergy Operations P. O. Box 97 Box 756

- Perry, OH 44081 Port Gibson, MS 39150 Attn: - Harold M. Coon -

i Southern Nuclear Operating Company

. Cooper

• Enterprise Clearinghouse Vogtle Pro [ect t

. Duke Engineering & Service ~ ' P. O, Box 1295 -

230 South Tryon St.' Birmingham, AL 35201 i P.O. Box 1004 -

Attn: Mgr., Nuclear Engineering -

Charlotte. NC 28201 1004 and Licensing i

Attn: G. A. Harrison ,

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i P ge 4 December 11,1997 OCG 10446 -

Georgia Power Co.  :- Mr. S. H. Soong Plant Vogtle - Station Superintendent h,0yn Third Nuclear Power Station-j-

ro, A 30830 Taiwan Power Compny Attn: = Mr. W. B. Shipman P.O. Box 39 General Manager Heng-Chun, Ping Tung Hsein Talwan,924 R.O.C.

Gulf states Utilities P. O. Box 220 Mr. Koh, Kyoo-Kun St. Francisville, LA 70775 Plant Manger, Kori 3 & 4 3

Ko '

director ucearLicensing 2j6 o Ja n p g am rea 0 or at ou t urar e 140 Hoffrnan Lane

- CentrilIslip, NY 11722 Mr. Hong, Jo Boo

Attn

Mr. Joseph Gilliard Manager, Nuclear Power Generation Dept.

Korea Electric Power Corp.

Operating Experience Manager Tennessee Valley Autho$ eou 1 91 Kore 1101 Market Street, LP 4A C Chattanooga,TN 37402 Mr, Lee, Hee-Sung Plant Manager, Yonggwang Nuclear Unit 1

• 2 TU Electric Company Korea Electric Power Corp.

P. O. Box 1002 - 517, Kyerna.Ri Hong Nong-Eup Glen Rose,TX 76043 Yonggwang Gun Jeon Nam Attn: Group Vice President Nuclear Korea 513-880 Washington Pubile Power Supply P. O. Box 460 Richland, WA 99352 Attn: Mr. L. C. Oakes Manager, WNP 1 Engineer T. R. Ho, Superintendent Taiwan Power Company

- Kuosher.g Nuclear Power Station 60 Pa Tou Yeh-Llu Village Wan Li Halang. Taipel Hsien (20703), Taiwan. R.O.C.

Mr. S. J. Tsuel Director, Nuclear Safety Dept.

Taiwan Power Company 242 Roosevelt Road. Sec. 3 Taipel, Repubtle of China -

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GENERAL INFORMATION or OTHER EVENT NUMBER: 33398 L LICENSEE: COOPER ENERGY SERVICES NOTIFICATION DATE: 12/12/97 CITY: GROVE CITY REGION: 1 NOTIFICATION TIME: 15:30 [ET]

COUNTY: STATE: PA EVENT DATE: 12/12/97 LICENSE #: AGREEMENT: N EVENT TIME: 15 : 3 0 (EST)

DOCKET: LAST UPDATE DATE: 12/12/97 NOTIFICATIONS PAUL FREDRICKSON RDO NRC NOTIFIED BY: ANDREW STEFFAN JOHN PELLET (REG 4) RDO HQ OPS OFFICER: JOHN MacKINNON VERN HODGE (RVIB) NRR EMERGENCY CLASS: NOT APPLICABLE 10 CFR SECTION:

CDEG 21.21(c) (3) (i) DEFECTS / NONCOMPLIANCE EVENT TEXT 10 CFR 21 NOTIFICATION, ENTERPRISE DSR-4 AND.DSRV-4 EMERGENCY DIESEL GENERATOR ADJUSTING SCREW FAILURE.

ON SEPTEMBER 26, 1997, ENTEkGY OPERATIONS RIVER BEND STATION REPORTED THE FAILURE OF AN ADJUSTING SCREW, COOPER ENERGY SERVICES PART NUMBER 1A-7840.

THE ADJUSTING SCREW IS A BALL AND SWIVEL ASSEMBLY UTILIZED TO ALLOW FOR ANGULAR MOVEMENT BETWEEN THE ROCKER ARM AND INTAKE AND EXHAUST VALVE STEM OF THE POWER CYLINDER HEAD. THE ADJUSTING SCREW IS ASSEMBLED BY SWAGING A "CWIVEL PAD" ON TO A " BALL".

SUBSEQUENT INVESTIGATION DETERMINED THAT THE SWAGING PROCESS AND TOOLING WAS OF A DESIGN 'IHAT ALLOWED FOR "OVERSWAGING" OF THE PAD, REDUCING THE AMOUNT OF FREE ANGULAR MOVEMENT IN THE ASSEMBLY. THIS CONDITION POTENTIALLY CAUSED THE MATERIAL OF THE UPPER EDGE OF THE SWIVEL PAD TC BE OVER STRESSED, AND/OR LIMIT THE ABILITY OF THE ASSEMBLY TO ACCOMMODATE THE-

-REQUIRED ANGULhR MOVEMENT WITH UNDUE STRESS.

THE FAILURE OF THE ASSEMBLY WAS THE CRACKING OF THE SWIVEL PAD MATERIAL AT THE UPPER EDGE. THIS FAILURE HAS THE POTENTIAL TO CAUSE AN OPERABILITY CONCERN DUE TO THE'ASSEMPLY SEPARATING AND EXCESS CLEARANCE (VALVE LASH)

BEING ESTABLISHED WHICH COULD LEAD TO CATASTROPHIC FAILURE OF THE VALVE STEM OR REMAINING BALL PORTION OF THE ASSEMBLY. MULTIPLE FAILURES OF THE ASSEMBLY WITHOUT CATASTROPHIC FAILURE COULD ALSO REDUCE ENGINE OUTPUT DUE TO DECREASED VALVE LIFT. IN ADDITION, LOOSE PIECES OF THE ASSEMBLY COULD CAUSE-SECONDARY DAMAGE IN THE ENGINE.

COOPER ENERGY SERVICES HAS SUPPLIED THE 1A-7840 ADJUSTING SCREW TO THE FOLLOWING SITES: RIVER BEND, CATAWBA, AND KORI 3 & 4 (KOREA ELECTRIC).

(Continued on next page)

LICENSEE; COOPER ENERGY ~SERVIC-

. PAGE.#--2:OF EVENT' NUMBER:-33398 CORRECTIVE ACTION:

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THE' SUBJECT = ASSEMBLIES AT RIVER BEND-STATION HAVE BEEN REPLACED WIT ACCEPTABLE-ASSEMBLIES.

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THE! SWAGING TOOLINGLHAS BEEN CORRECTED-TO LIMIT THE AMOUNT OF " SWAGE"..

.i ACCEPTANCE CRITERIA-ASSURING THE NECESSARY FREEDOM OF.THE ASSEMBLY'HAS BEEN

-DEFINED-AND-WILL.BE VERIFIED DURING MANUFACTURE.

USER RECOMMENDATIONS:--

UTILITIES CURRENTLY..IN POSST;SSION OF~1A-7840: ASSEMBLIES ARE INSTRUCTED TO '

VERIFY THAT A MINIMUM OF-18 DEGREES OF ANGULAR MOVEMENT FROM CENTERLINE IS-AVAILABLE-IN:ALL-DIRECTIONS,:'WITH NO INDICATION OF ROUGHNESS WHEN MOVING.'

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