ML20217D570
| ML20217D570 | |
| Person / Time | |
|---|---|
| Site: | Perry, Hope Creek, Limerick  |
| Issue date: | 03/20/1998 |
| From: | Loughlin R DRESSER-RAND CO. |
| To: | NRC |
| References | |
| REF-PT21-98 33958, NUDOCS 9803300072 | |
| Download: ML20217D570 (13) | |
Text
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GENERAL INFORMAtION or OTHER EVENT NUMBER: 33958 LICENSEE; DRESSER-RAND NOTIFICATION DATE: 03/25/98 CITY: WELLSVILLE REGION: 1 NOTIFICATION TIME: 08:04 [ET)
COUNTY: STATE: NY EVENT DATE: 03/20/98 LICENSE #: AGREEMENT: Y EVENT TIME: 00:00(EST)
DOCKET: LAST UPDATE DATE: 03/25/98 NOTIFICATIONS ROBERT SUMMERS / REG 1 RDO 1
NRC NOTIFIED BY: ROBERT M. LOUGHLIN VERN HODGE NRR HQ OPS OFFICER: LEIGH TROCINE PAUL FREDRICKSON R2DO MIKE JORDAN R3DO EMERGENCY CLASS: NOT APPLICABLE BILL JONES R4DO 10 CFR SECTION:
CCCC 21.21 UNSPECIFIED PARAGRAPH EVENT TEXT 10-CFR-PART-21 NOTIFICATION GOVERNOR VALVE STEMS MADE OF INCONEL-718 MATERIAL WILL EXPAND MORE THAN THE ORIGINAL 410 STAINLESS STEEL STEMS FOR THE SAME TEMPERATURE RISE. VALVE ASSEMBLIES THAT STROKE FREELY WHEN ASSEMBLED BIND OR DRAG AT OPERATING l TEMPERATURES. THIS CONDITION RESULTS IN LOSS OF GOVERNOR CONTROL AND HAS I BEEN REPORTED TO HAVE OCCURRED AT THE FOLLOWING THREE NUCLEAR POWER PLANTS:
LIMERICK (S/N 36691), HOPE CREEK (S/N 37123), AND PERRY (S/N 38176).
l l ALL REPORTED CONTROL PROBLEMS HAVE BEEN TRACED TO VALVE STEMS MANUFACTURED l BY BW/IP. THE BW/IP MANUFACTURING DRAWING ALLOWS FOR A DIAMETER OF 0.4980/0.5000", AND THE DRESSER-RAND DRAWINGS ALLOW 0.4985/0.4990". ANY :
INCONEL STEM WITH A DIAMETER GREATER THAT 0.4988" IS SUSCEPTIBLE TO l INTERFERENCE WITH THE CARBON WASHERS AT TEMPERATURES ABOVE 500oF AND COULD RESULT IN TURBINE CONTROL PROBLEMS. THE PERFORMANCE OF THE DRESSER-RAND i
INCONEL STEMS WITH THE CARBON SPACERS IS MARGINAL AT ELEVATED TEMPERATURES I
WITH THE MAXIMUM SAFE OPERATING TEMPERATURE BEING WELL BELOW 600*F.
l 9803300072 980320 PDR ADOCK 05000352 S pm
, *7165963369 D-R STANDARD PROD F-903 T-159 P-001 MAR 20 '98 17:15
- 3315 1
~'
DRESSER-RAND Energy Systems Division Wellsville,NY NRC CORRESPONDENCE Date: March 20,1998 To: NRC Operations Center Fax No. 301-816-5151 From: Robert M. Loughlin Dresser-Rand Engineering Phone 716-596-3343 Fax 716-596-3369
Subject:
" Verbal" Notification by facsimile of a Potential Safety Hazard 10CFR Part 21 Initial Report No. 040 A copy of approved 10CFR Part 21 Initial Report No. 040 is provided as pages 2 through 12 of this facsimile transmittal (complete transmittalis 12 pages).
Dresser-Rand Energy Systems Division will submit a written Final Report no later than April 19,1998.
Questions relating to this 10CFR Part 21 Report may be directed to any of the following Dresser-Rand engineering personnel.
Edward Grandusky 716-596-3631.
Richard Kling 716-596-3288 Robert Loughlin 716-596-3343 Robert M. Loughlin Manager - Nuclear and Navy Product Engineering
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- 7165963369
. D-R STANDARD PROD F-903 T-159 P-002 MAR 20 '98 17:15 64 Ftrm EF-065 Rev D -
REPORT NO. 40 NNSOP f.2.001 page 1 of 4 INITIAL REPORT 10CFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Date: 2/16/98
- 1. ISSUED TO: File No: DIA R. Loughlin Mgr. Navy / Nuclear Eng. l Serial No: D/A R. Klina Nuclear Product Engineer Type: GS & ZS M. sghmiedel QA Manager Ref: Dia W iebe VP Config. Engr. & Factory Ops. '
Part Not Various W ;ffman VP Project Management l Dwg No various W 3rbach Director Services Steam Turbine Prod. key Levels n/a
- 2. PREPARED BY: Edward Grandusky_
TITLE: Nuclear Product Engineer FART NAME: Governor Valve Stem 1
- 3. DESCRIPTION OF DEFECT:
Governor valve stems made of Inconel 718 material will expand more than the original 410 stainless steel stems for the same temperature rise. Valve assemblies that stroke freely when assembled bind or drag at operating l temperatures. This condition results in loss of governor control and has been reported to have occurred at 3 Nuclear power plants, Limerick (s/n 36691), Hope Creek. (s/n 37123) and Perry (s/n 38176) .
- 4. ENGINEERING EVALUATION & RECOMMENDATION:
All reported control problems have been traced to valve stems manufactured l by BW/IP. The BW/IP manufacturing drawing (attached) allows for a diameter I of .4980/.5000, the D-R drawings allow .4985/.4990 . Any Inconel stem with a diameter greater than .4988" is susceptible to interference with the carbon washers at temperatures above 500*F and could result in turbine control problems. The performance of the D-R Inconal stems with the carbon spacers is marginal at elevated temperatures, with the maximum safe operating temperature being well below 600*F.
Continued on page 2.
Evaluati
Title:
/Rcommenpetiog we Prepared3 By/ N/ d
- g-ate:
d f,)
Approved by [Mgr.
EIN Navy / Nucle @ product Engineering; ~ ~ /
~
Date: S/2O 6 v
r 1
- 5. DISPOSITION, CHECK ONE Yes, this constitutes a safety hazard and requires that a Final report be prepared (Form EF-066)
No, this does not constitute a safety hazard and does not require any further r.pporting.
Disposition by D-R Presidents w b _ Date:2ck9/'
/ /
RETURN TO MGR. NAVY / NUCLEAR PRODUCT ENGINEERING
.
- 7165 % 3369
. D-R STANDARD PROD F-903 T-159 P-003 MAR 20 '98 17:16 Form EF-065 Rev D -
REPORT NO. 40 NNSOP i.2.001 page 2 of 4 nackarounds' Riference our Field Service Report for the Perry Nuclear Power Plant, Job #
RS-7458 with an attached Customer's Analysis Report, signed by Howard Conrad on 10/23/97. The Perry Analysis Report establishes the root cause of the control problem as different rates of thermal expansion between the inconel stem and the carbon washers.
The reverse engineered valve stem diameter measured .4999". This is .0009"'over I the D-R design limit and is the obvious cause for the stem sticking in this case. However, the calculations in the Perry report do establish the .
S consequences of different rates of expansion and have resulted in industry inquiries. as to how DR justified the larger growth rate of inconel in the ciready restrictive clearances of the carbon packing.
The issue of the carbon spacer- dimensions was resolved as the carbon spacers
-were returned to D-R knd the I.D. confirmed to be between .5000" and .5005" as required by the drawing, analysis:
A review of the process used for the selection of inconel 718 material for the new spray coated stem revealed no documented evaluation for the difference in thermal expansion between the Inconel 718 material and 410 stainless steel. The following calculations at MMC (Maximum Material condition) of the parts show an interference can occur with the inconel stem that can not occur with the original stem. Maximum operating temperature is 560*F.
Cric4n=1 stainless steel _nitrid&d stem:
Coefficient of Thermal Rxpansion for P-03 carbon is 2.5 pin /in *F.
Coefficient of Thermal Expansion for 410 stainless is S.5 pin /in *F.
(500*F delta T) .
Ring .5000 + (2.5 pin /in*F x.5000 in x 500*F) = .5006" Stem .4990 + (S.5 pin /in*F x.4990 in x 500*F) = .5004"-
Clearance = .0002" Inconel coated stem:
Coefficient of Thermal Rxpansion for P-03 carbon is 2.5 pin /in *F Coefficient of Thermal Expansion for 718 inconel is 7.2 pin /in *F.
(500*F delta T) .
Ring .5000 + (2. Spin /in*F x.5000 in x 500*F) = .5006" Stem .4990 + (7.2 pin /in*F x.4990 in x 500*F) = .5008" Interference = .0002*
These calculations show the new material closes the original hot running clearance by .0004", and a .0002" clearance is now a .0002" interference. The coefficients for thermal expansion used above are from the Analysis Report done at the Perry NPU The values for these coefficients that are available from different references vary widely for Inconel (7.2 to 8.6 pin /in* F) and leave the analytical approach open to debate as to which is the correct value. A simple test ( see pg.4) was carried out to verify if the calculated interference could occur with the D-R stem. The results of the test confirn.ed that the clearance does diminish and eventually bind the carbon washers to the stem. This binding occurred at an approximate temperature of 600*F when the cold clearance was just
-under .0010". A atom with an initial cold clearance of .0013" stroked freely at 500*F but a substantial increase in force was required when the temperature was raised to 600*F.
- 7165 % 3369
. D-R STANDARD PROD F-903 T-159 P-004 MAR 20 '98 17:16 l
FJrm EF-065 REPORT NO. 40 R3v D .
page 3 of 4 NNSOP 1'.2'.001 Conclu'sions:
An Inconel stem with an ambient diametric 4.learance of less than .0010" will cxperience an interforence with the cerbon spacers that is sufficient to prevent the proper operation of the governor valve. Stems with an ambient diametric clearances between .0010" and .0015" will experience some degree of drag but may perform properly.
All reported problems have been with Inconel 718 stems manufactured by BW/IP These stems had an ambient clearance with the carbon spacers of .0010" or less.
The different thermal expansion characteristic of the Inconel 718 material was not addressed in the material selection process for the new D-R valve stem. The testing done for this report indicates the current arrangement is marginally cceeptable at best, The maximum force applied to move the test stem with 12 carbon spacers was on the order of 50 lbs. EL-20827 established the net servo force available to move the stem as 131 lbs for the cam type linkage. This will barely be sufficient to move a test stem with the 22 carbon spacers, the number the valve bonnets use. Even though no control problems have been reported with the D-R spray coated stems currently in service, the clearances should be increased to produce full temperature running clearances the same as those previously experienced with the 410 nitrided stems.
Rgcceaandations:
The history of these helear valve stems has demonstrated a conflict between the design philosophy of close fits for steam seals and their impact on the stems during standby. The valve stem corrosion / binding problem has always been associated with the close tit of the carbon washers to the stem. While a tighter clearance nay be desirable for steam seal purposes, it increases the probability of the valve stem binding due to corrosion or deposition. Since the latter is a more critical concern to the nuclear industry the following actions should be taken:
- 1. Increase the I.D. of the carbon spacer from .5000/.5005 to at least
.5005/.5010. This will testore the original running clearance at operating temperature between the inconel stem and packing. Use of these carbons with 410 material stems will result in a diametrical clearance that is still within the recommended operating range and produce only slightly higher steam leakage. Further analysis may support even greater clearances.
- 2. Provide instructions with all carbon spacer orders that advise the user to verify a minimum cold diametrical clearance of .0015" before assembling the parts. The maximum clearance will vary from site to site' depending on acceptable steam leakage.
- 3. Inform all af.fected parties of the potential for control problems after the turbine reaches an operating temperature above 500*F. Recommend that the minimum cold clearance be verified before assembling these parts. If the parts are already in service, then the turbine must be operated long enough to reach the maximum operating temperature and the control capability of the governor valve verified. 1 I
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- 7165 % 3369
. D-R STANDARD PROD F-903 T-159 P-005 MAR 20 '98 17:17 d
Fcrm EF-065 R2v D -
REPORT NO. 40 l NNSOP 1'.2.001 page 4 of 4 Test Proceduret An L-gland assembly as shown on drawing A-11097 was assembled using nuclear p/n 800738-001 for the washers and 800714-001 for the carbon spacers. A Spray Coated Inconel valve stem p/n 800746-001, was inserted into this assembly. and positioned so the largest diameter (.4991" in the uncoated area) was inside the packing and heated to a temperature greater than 600*F, then Stroking of the stem was attempted.
The configuration of the oven would not allow for the bushing assembly to be positioned on the spray coated area of the stem. Therefore, the parts were ;
heated separately in the same oven. When the parts stabilized at the desired l temperature the oven was opened and the parts were assembled and stroked.
i Test Resulta DATA l
CARBON I.D.
- 1. .5001 Valve stem P/N 800746-001
- 2. .5001 1 Ht# N60
- 3. .5001 0.D. .4988 @ 67*F
- 4. .5001 j
- 5. .5002 Smallest Carbon I.D. .5001"
- 6. .5002
- 7. .5002 Smallest Cold Clearance .0013"
- 8. .5002 ,
- 9. .5002 Sliding Force, Cold 2 3b e 80*F (Stem Vertical) l
- 10. .5003 1 Sliding Force. Hot LOCKED UP e 600*F
- 11. .5003
- 12. .5003 2 @ 500*F !
Sliding Force, Hot FREE BUSHING 2 Sliding Force, Hot 50 to 75 LB @ 600*F I.D.
Both .5035" 1 The stem was heated while inserted in the packing assembly. The carbons were located on the uncoated area of the stem with a cold diameter of .4991". The stem could be rotated in the guide bushings but no sliding could be accomplished until the stem cooled to under 500*F.
2 The stem and packing were heated separately and then the .4988" coated diameter was inserted into the bushing assembly.
At 500*F the coated area stroked freely in the packing, no reading on scale.
At 600*F the goated area could be inserted into the packing. Once inserted it could be moved only with considerable force. Accurate measurements were not possible.
Attaek-entti Dresser-Rand Field Service Repore #RS-7458 BW/IP Governor valve Stem Drw #200022 Dresser-Rand Governor Valve Stem Drw #B00746 Dresser-Rand Bonnet Bushing Assy Drw #A-11097 Pure Carbon Physical Properties sheet for Purabon P-03
7165 % 3369 D-R STANDARD PROD F-903 T-159 P-006 MAR 20 '98 17:17
, t-lE L U O cr%W N C nn-. vna DRESSER-RAND Services Divition CUSTOMER: Peny Nuclear Power Plant PAGE 2 of 3 Wellsville, NY 14895 LOCATION: 10 Center Road DATE 10/27/97 l Peny, Ohio 44081 TYPE OF UNIT: GS-2N JOB #: RS-7458 SIZE OF UNrt: S/N: T-38176A DRIVEN EoulP: Pump S/O:
Title Page information is for brief overview only. Repost wort; done daily on Deteds of Daily We A Pages.
DETAILS of DAILY WORK 10/22 Met with Mr. Rick Hays and discussed govemor valve sticking problem. Customer had fpund a broken governor valve stem carbon ring at the outer most gland. Carbon ring was replaced and turbine was on line. Turbine will run for one hour, after the hcur run it will be shut down and restarted.
Turbine speed set point was set for 2000 rpm for shut down. When rpm reached 2900 rpm, speed did not drop any lower. Trace readings indicated the govemor valve was opened about 25%, and not moving. Unable to go to turbine location at this tirne.
When able to go to the turbine location (approximately 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br />. after shut down) I found the govemor valve free to move. The linkage was disconnected and the servo checked for binding or sticking through out its range of travel. Also, the govemor valve was checked for sticking or binding. No sticking or binding was felt. Checked govemor valve travel, set @ 13/16" with approximately 1/8" servo safety travel.
Started inspection / disassembly of the turbine govemor valve. There was clearance around the outer packing stem guide ( bolted on packing case) to the valve stem. No '
broken carbon packing rings were found. The inner packing guide had to be tapped out from its fit in the bonnet bore. The valve stem looked in good condition with no signs of scoring or galling evident. Turbine plug valve is in good condition.
Plan is to remove valve stem (non-OEM inconel stem) and replace it with the OEM stem. Run the turbine for one hour, shut down and then do turbine quick start.
Customer will inspect and document valve stem dimensions. A copy of this inspection report was sent in separate from this field report, along with a copy of a telephon conference memorandum the customer had with Bill Sweeney.
sos 710 Rev. 5 daded: 04Kl1/96 SICNED: Peter Gagnon _
I , 7165 % 3369 D-R STANDARD PROD MhLU bt;MVibt MLF-903 Un8T-159 P-007 (1AR 20 '9817:13
' DRESSER-RAND Services Division CUSTOMER: Peny Nuclear Power Plant PAGE 3 of 3 Wellsville, NY 14895 LOCATION: 10 Center Road DATE 10/27/97 Perry, Ohio 44081 L ,
l TYPE CF Unit GS-2N JOB #: RS-7468 SIZE OF UNin S/N: T-38178A DRIVEN EQUIP: Pump S/O:
, Tlee Page infamellon is for brief overvow espy. Repost wo* done daily on Detans of Deily Wem Pages.
10/23 Govemor valve re-built and we are waiting to start unit. Customer had found the non-i OEM valve stem to be over size (0.4997"- 0.4999") to our spec, of 0.49990" max.
AI,s, o, carbon rings part # 800714-001 were found to be under size 0.4996", spec. is 0.500" +.0005" .0000".
Under size carbon rings were reamed to correct size and installed.
Turbine started and ran for one hour end ten minutes, shut down. Governor valve moves freely throughout full range of travel. Turbine was quick started twice without any govemor control problems. Plant declared turbine operational and put back in service.
When the turbine was tripped out using the solenoid, the trip linkage from the bearing cover unistched. Discussed this with Mr. Hays and advised the trip linkage be inspected for wear and correct adjustment.
Mr. Hays was satisfied with the turbine operation and I was released from site.
4 SD# 710 Rev. 5 dated: 04/01/96 SIGNED: _ Peter Gagnon _ _ _ _
, 7165963369 D-R STANDARD PROD F-903 T-159 P-008 MAR 20 '98 17:18 lifirmition / D:ta segsrdlig RCIC vah e I E51 F05t l, Csvtrnor Valve From drawing 25-098. Rev 0, the new inconel 718 valve stem diameter is 0.498 - 0.500 inches Actual measurements taken in Dedication 1.ab on 10/23/97 by Mike Brown using an Opticom Qualifier 14B:
Valve stem CD - plug end before taper beg. ins OA997' OD - middle of shaf 0.4999" OD - top of shaft before 4.5" threaded section 0.4997* -
Abraded area near top of shaft at approximately the valve spring sent has ridges / burrs approximately 0.0007" - 0 0008" high.
Dere were no areas found out of round and no bending of the stem was evident. This was determined using the Opticom.using depth gauge and sliding V block setup, and using a calibrated flat table, it should be noted that the threaded area at the top of the shaft
(~1.5" is a sti 5htly smaller diameter than the rest of the shaft.
Analysis of the shaft using a backscatter analysis confirmed the shaft material as Inconel 718 i
ID 0.4996"
, Thk 0.1250" ]
Carbon spacer was from the warehouse, part number S/C 9006743 which is the nere low sulfur j carbon spacer, vendor part number 800714-001 on 10/23/97. Dese spacers are beught non-safety I and are not receipt inspected to verify tolerances.
Manufacturer tolerances per telecon on 10/23/97 Howard Conrad to Bill Sweeney (Dresser Rand):
Valve stem: OD 0.4985"-0.4990" Carbon spacer: OD 0.990" 0.001" ID 0.500" +0.0005"-0.000F*
THK 0.125" 20.001" Note: The tolerances pn the old carbon spacars was the same as for the new ones.
Dimensions from BWIP drawing, CEI number 4549-25-098, Rev 0 gives the valve stem diameter as 0.49s"-0.50&*.
The coemcient of expansion for inconel 718 (new valve seem material) is 7.2 y in/In *F (ref Machine:y's .
Handbook,25th ed) and for Stainless Steel ASTM A276 Gr S41000 (old / original seem mate:ial) is 5.5. Therefore, for 0.5" of material this equates to approximately a 30% increase in thermal expansion in the new (lacone!) material over the old material. Therefore, given a 5007 temperature change and 0.5", the increase in sias is approstmately:
Inconel718: 0.0018" '
A276 Or 41000: 0.0014" The end result using the dimensions above for the laconel seem and the new earbon specors is stem OD cold: 0.4999" hot: 0.5017" i l
spacerID asmeasured 0.4996" as it should be: 0.5000" - 0.5005 Using the old seem at the lower limit of diameter of 0.4985" 8 / ~
stem OD cold: 0.4985'Jie hot: 0A999" ,
spacerID as measured 0.4996" asit should be: 0.5000" - 0.5005 cc: Rick Hayes 7 Daryl Grover i /
Hirarn Reppert , ',s JeffVargo Paul Roney Dave Reyes
{O f3 N Steve Mackowski ke Ishif9) *
. ', 7165 % 3369 D-R STANDARD PROD F-903 T-159 P-009 t1AR 20 '9817:19 3 $ 0 l I!! dIwI
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ApparchtDensity,gm/ca' IJ2 FleznralStrength, pal 8,000 Hardness,Selaroscope 75 Compressive Susagth,pd 20.000 Tensue Sirsagth,pd 5,500 Modulus of Elasddty,pel 1.8 x 108 Spec 15c *teststance,ots/ lack cube .0006 Ash, % Kdght 0.2 Corradon Resistance Group (See Catalog) A Ferosity, % Volmne 8 Fors Vola:ne,em3/gm 0.H Permeability.microDardes 1200 Grainshe(Inches) .002 Tempersttre Limic 0xidizing Atmosphere.T 1000 Neutral Atmosphers.T 6000 Specific Reat BTUllb790 to1000*F) .21 Coe!Octent of Thermm1 Conductivity, NTUC r. R8 "Fift.(at 70*F) 40 Coetadent of ThermalExpaaston, p-Inita'F(70 to 1000*T) 2.5 Maren 8,1SM 441 Hau Avenus. St. Marys. FA 15857 U S A Pnone: (814) 781-1573. Fax: 814 781-9262 or 814-78192E4 O
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