ML20207M923

Amended Part 21 Rept Re Cooper-Bessemer Ksv EDG Power Piston Failure.Total of 198 or More Pistons Have Been Measured at Seven Different Sites.All Potentially Defective Pistons Have Been Removed from Svc Based on Encl Results

ML20207M923
Person / Time
Site:	Nine Mile Point, Palo Verde, Grand Gulf, Cooper, Byron, Waterford, South Texas, Zion
Issue date:	03/12/1999
From:	Horne J COOPER ENERGY SERVICES
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-99 QCG-10528, NUDOCS 9903190275
Download: ML20207M923 (7)

Text

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150 Lincoln Avenue

. e Grove City, PA 16127 1898 Tel 412 458 8000 Fax 412 458 3574 Ajame COOPER *'=*

ENERGY SERVICES ln e"J'"""*

- En-Tronic@

Penn*

Superior @

March 12,1999 Fax: 301-816-5151 Our Ref: QCG-10528 i Document Control Desk U.S. Nuclear Regulatory Commission Washington, D.C. 20555

Subject:

Amendment to 10 CFR Part 21 Notification, Cooper-Bessemer KSV Emergency Diesel Generator Power Piston Failure.

Dear Sir- l Following the failure of a KSV power piston due to a hydraulic lock at Commonwealth

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Edison, Zion Station in January,1997, we issued a part 21 notification letter dated May l 29,1997, our reference OCG-10389 The piston which failed had a minimum crown thickness of 0.040 inches, but had operated successfully for several years, and failed only because of the unusual hydraulic lock event. That letter recommended that KSV '

pistons be inspected for crown thickness by ultrasonic or other methods when the  !

pistons were exposed in the course of normal maintenance activities. A conservative v minimum thickness limit of 0.100 inches was established.

In the two years since the Zion failure, L total of 198 or more pistons have been measured at seven different sites. Of these, one was found initially in our plant with a thickness of .070 inches and was destroyed. All other pistons checked have been above the 0.100 inch limit, and the actual measured thickness was recorded for 157 of these. All but seven of those documented have had a minimum thickness of 0.150 inch or greater. The attached graph shows the distribution of minimum thickness for the pistons which have been documented. These results, in combination with the successful operating history of the KSV engine provide reasonable assurance that all l potentially defective pistons have been rcmoved from service.

9903190275 990312 <

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- March 12,1999 QCG210528 <

Based on this information, Cooper Bessemer believes it is not necessary to continue to  !

measure the thickness of piston crowns during other maintenance activities. If you j have any questions, please call John M. Horne at 724-458-3543 Sincerely,

~

I COOPER CAMERON CORPORATION l

(,. -

4 J. M. Horne ,

Engineering Attachment JMH:kil File: K5fa40 - Piston Failure  ;

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! KSV PISTON CROWN - MINIMUM MEASURED THICKNESS l

30 -

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! 25- '

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, m l @ 20- -

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{ $ 15- -

! E i e g 10- - -

i 5- '

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! 0' I .100- .125- .150- .175- .200- .225-' .250- .275- .300- .325- .350- .375- >.400 l .125 .150 .175 .200 .225 .250 .275 .300 .325 .350 .375 .400

MEASURED THICKNESS -INCHES i .

, _ - , - - , , , , . . .- , . - , . - . _ _ . - , . _ . - - . , ~ - - , , - - - . - , , - - - - , ,

d Page 3 March 12,1999

! OCG-10528  :

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Document Control Desk Section Leader U.S. Nuclear Regulatory Procurement Engineering Commission l'*" , Arizona Public Service Washington, D.C. 20555

• P. O. Box 52034, Mall Station 7990 Phoenix, AZ 85072,2034

, Mr. Stephen Alexander U.S. Nuclear Regulatory Ms. Angela K. Krainik Commission ~ Manager, Nuclear Regulatory QA Vendor insp. & Mainten. Branch Affairs One White Flint North Mallstop 9A1 Arizona Public Service Washington, DC 20555 P. O. Box 52034 Mail Station 7636 Phoeniz, AZ 85072-2034 OER Program Administrator

Nebraska Public Power District Mr. Arvin Ho

pg Cooper Nuclear Station Commonwealth Edison Company P. O. Box 98 1400 Opus Place, Suite 400 Brownville, NE 68321 Downers Grove,IL 60515 IRC Supervisor Mr. William Wah i Nebraska Pubile Power District Commonwealth Edison Co. l Cooper Nuclear Station c#ed Byron Nuclear Power Station ,

P. O. Box 98 4450 North German Church Road  !

Brownville, NE 68321 Byron,IL 61010 Vendor Manual Specialist Mr. Terry Vandevoort  ;

Nebraska Public Power District Commonwealth Edison Co.  !

Cooper Nuclear Station t' " Zion Generating Station l P. O. Box 98 101 Shiloh Blvd. '

Brownville, NE 68321 Zion, IL 60099 1 D G System Engineer Entergy Operations Nebraska Public Power District Waterford 3 SES, Highway 18 Cooper Nuclear Station wrTC^M Taft, LA 70006 P. O. Box 98 Attn: Mr. Early Ewing Brownville, NE 68321 Director, NS & RA Mr. Greg Stefl STP Nuclear Operation Company pGW d Niagara Mohawk Power Corp. 3*'^h South Texas Project Electric g Nine Mile Road - Unit 2 M P. O. Box 289 l P.O. Box 63 Wadsworth, TX 77483 l Lycoming, NY 13093 Attn: Director Quality & Licensing j Ms. Kathleen Russo Mr. James Kenny Niagara Mohawk Power Corp. Licensing Group Supervisor Nine Mile Road - Unit 2 Pennsylvania Power and Light P. O. Box 63 Two North Ninth Street Annex NA6-1 Lycoming, NY 13093 Allentown, PA 18101

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!- March 12,1999 1 QCG-10528 Mr. Robert Bingman 4

Pennsylvania Power and Light ~N 'N g g , g />o/ 47 (34wewr3Susquehanna Steam Electric Station s u. s G COM^" g P. O. Box 467 Berwick, PA 18603 gc i o 4 3 Mr. John Kocher -

Pennsylvania Power and Light Co. 6 Y40 M Susquehanna Steam Electric Station )

P. O. Box 467 (NUCSA-3)

Berwick, PA 18603 g9

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i Entergy 0 " # #g

{ p#> P. O. Box 429 V &#

l j G Echelon One fwp 1340 Echelon Parkway Jackson, MS 39286-1995 W A ~C-6A F0g Attn: Fred W.Titus g g c. y 7VM Vice President, Engineering CA*Pg ggg ,

Entergy Operations P. O. Box 756 .

Port Gibson, MS 39150 )

Attn: Wm. K. Hughey Director, NS&RA INTERNAL COPIES:

B. C. Guntrum - Alameda S. Johnston - Alameda M. Donlin - Alameda R. Johnston - Alameda R. Boyles - Grove City

' R. Billig - Grove City J. M. Horne'- Grove City l

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,0MIM1999 U.S. Nuclear Reg:latory Commission Oper1tions Center Event Report Psgei GeneralInformation or Other (PAR) Event # 35466 Rep Org: COOPER ENERGY SERVICES Notification Date / Time: 03/12/1999 16:27 (EST)

Supplier: COOPER ENERGY SERVICES Event Date / Time:03/12/199912:00 (EST)

, Last Modification: 03/12/1999 Region: 1 Docket #:

i City: GROVE CITY Agreement State: No 1

' County: License #:

State: PA .

1 NRC Notified by: JOHN M. HORNE Notifications: TOM MOSLAK R1 l 4

HQ Ops Officer: DICK JOLLIFFE RONALD GARDNER R3 l 4

Emergency Class: NON EMERGENCY GARY SANBORN R4 l 10 CFR Section: VERN HODGE NRR l 21.21(c)(3)(i) DEFECTS / NONCOMPLIANCE i

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, - Amendment to 10 CFR Part 21 - Cooper-Bessemer KSV Emergency Diesel Generator Power Piston Failure -

(R;fer to event #32416 for additional information.)

{ .

) Following the failure of a KSV power piston due to a hydraulic lock at Commonwealth Edison Zion Station in j Jtnuary,1997, Cooper Cameron Corporation issued a Part 21 notification letter dated May 29,1997, reference.

QCG-10389. The piston which failed had a minimum crown thickness of 0.040 inches, but had operated j successfully for several years, and failed only because of the unusual hydraulic lock event. That letter ,

recommended that KSV pistons be inspected for crown thickness by ultrasonic or other methods when the pistons  ;

j were exposed in the course of normal maintenance activities. A conservative minimum thickness limit of 0.100  ;

l inches was established. l i

7 l In the 2 years since the Zion failure, a total of 198 or more pistons have been measured at seven different sites.

j Of these, one was found initially in our plant with a thickness of 0.070 inches and was destroyed. All other pistons i checked have been above the 0.100-inch limit, and the actual measured thickness was recorded for 157 of these.

4 All but seven of those documented have had a minimum thickness of 0.150 inch or greater. The distribution of minimum thickness for the pistons has been documented to be from 0.100 to >0.400 inches. These results, in '

combination with the successful operating history of the KSV engine, provide reasonable assurance that all pot:ntially defective pistons have been removed from service.

B: sed on this information, Cooper-Bessemer believes it is not necessary to continue to measure the thickness of piston crowns during other maintenance activities.

This 10 CFR Part 21 Amendment applies to the following plants:

Region 1 - Nine Mile Point and Susquehanna Region 3 - Byron and Zion Region 4 - Cooper, Palo Verde, Waterford, South Texas and Grand Gulf.

(Cill the NRC Operations Center for a contact telephone number.)

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n0EEN sanvicus QUAUTY ASSURANCE DEPT.

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j?-p, 150 UNCOLN AVENUE GROVE CITY, PA 16127 PHONE: 458-3575 FAX: (724)458-3461 (7jt4)/99  !

DATE: 3 //>

TO: O 72 ddM - /h& I COMPANY: FAX: :IS/- 8/6 -f/C /

FROM:/

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TELEPHONE: FAX:

NUMBER OF PAGES INCLUDING COVER: ,b PLEASE CALL (724) 458-3575, IF YOU DID NOTRECEIVE ALL OF THE PAGES l

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i PLEASE NOTE eOUR NEW FAX NUMBER IS 724-458-3461.