ML18016A901

Part 21 Rept Re Defect in Component of DSRV-16-4,Enterprise DG Sys.Caused by Potential Problem with Connecting Rod Assemblies Built Since 1986,that Have Been Converted to Use Prestressed Fasteners.Affected Rods Should Be Inspected

ML18016A901
Person / Time
Site:	Perry, Catawba, Harris, Grand Gulf, Vogtle, Comanche Peak
Issue date:	04/12/1999
From:	Billig R COOPER ENERGY SERVICES
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
REF-PT21-99 QCG-10530, NUDOCS 9904160099
Download: ML18016A901 (9)

Text

ACCESSION NBR FACXL:,50-400

'50-413 50-414 50-416 50-424 50-425 50-440 50-445 50-446 AUTH'NAME BILLIG,R.G.

RECIP. NAME CATEGORY 1 ~

REGULATORY INFORMATION DISTRIBUTION SYSTEM~(RIDS).

9904160099 DOC.DATE: 99/04/12 NOTARIZED: NO DOCKET Shearon Harris Nuclear Power Plant, Unit 1, Carolina 05000400 Catawba Nuclear Station, Unit 1, Duke Power Co.

05000413 Catawba Nuclear Station, Unit 2, Duke Power Co.

'05000414 Grand Gulf Nuclear Station, Unit 1, Mississippi Power 05000416 Alvin W. Vogtle Nuclear Plant, Unit 1, Georgia Power 05000424 Alvin W. Vogtle Nuclear Plant, Unit 2, Georgia Power 05000425 Perry Nuclear Power Plant, Unit 1, Cleveland Electric 05000440 Comanche Peak Steam Electric Station, Unit 1, Texas U

0500044K Comanche Peak Steam'lectric Station, Unit 2, Texas U

05000446 AUTHOR AFFILIATION A

Cooper Energy Services RECIPIENT-AFFILIATION T

Records Management Branch (Document Control Desk)

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SUBJECT:

Part 21 rept re defect in component of DSRV-16-4,Enterprise DG Sys.Caused by anomaly in CES design documentation 5:

compounded, by typographical error in assembly instruction literature. Suspect assemblies should be inspected next R O.

DISTRIBUTION CODE: IE19T COPIES RECEIVED:LTR ENCL SIZE:

TITLE: Part 21.Rept (50 DKT)

NOTES:Application for permit renewal filed.

Application for permit renewal filed.

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1 VNSOOCUMEM'OTE TO ALL "RIDS" RECIPIENTS:

HAS BEEN SCAN EEN SCANNERS PLEASE HELP US TO REDUCE WASTETH TO HAVE YOUR NAME OR ORGANIZATION REMOVED FROM DISTRIBUTION LISTS OR REDUCE THE NUMBER OF COPIES RECEIVED BY YOU OR YOUR ORGANIZATION, CONTACT THE DOCUMENT CONTROL DESK (DCD)

ON EXTENSION 415-2083 FULL TEXT CONVERSION REQUIRED TOTAL NUMBER OF COPIES REQUIRED:

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150 unmln Avenve Grove City, PA 16127-1898 Tel 'l2%5s-oooo Fax '724 458-3574 April 12,'1999 Fax: 301%16%151 AJax Cob errae Cooper Bessemer Enterprise' En-laconic Penn>>

Superior Our Ref: QCG-10530 Document Control Desk U.S, Nuclear Regulatory Commission Nashington, D.C. 20555 Cooper Energy Services 10CFR21 Report No. 45 SubJect:

10CFR21 Notification, Enterprhe DSRV-4 Emergency Diesel Generator Con11ecting Rod Prestressed Fasteners 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 defect in a component of a DSRV-16-4 Enterprise Diesel Generator System.

There exists a potential problem with connecting ro'd assemblies built since September, 1986, that use or have been converted to use prestressed fasteners to attach the rod box to the master rod.

Our records indicate that the following utilities purchased new P/N 1A-7802 rod assemblies that come assembled with prestressed fasteners that are suspected to be of ihcorrect length.

~UTI ITIES

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~N Southern Nuclear Operating Co.

Voglls 78O21-4 1 (Order COOE78448)

CJeyefand Electric Perry 75051-2 2 (Order COOE76581)

It should be noted. that these plants have been notified and have taken appropriate action, In addlgon, any ulllltles with DERv4 engines who have purchased replacement 1A.8280 or 1A-8281

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connecting rod assemblies (with bolts) since September, 1986 and have subsequently converted these to prestressed fasteners (or are planning to convert to prestressed fasteners) could also be affected. The utilities that may be affected are as follows.

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~LIT ITIES Entergy CP8L Duke Cleveland Electric Texas VtlTlties Southern Nuclear BOITE Grand Gulf Shearon Harris Catawba Perry Comanche Peak Plant Vogtle

~*LN Mlt 74033-6 74046.9 75017-20 75051-4 76001-'4 76021'ny utilities meeting the described criteria are recommended to contact Cooper Energy Services for clarification.

9904ih0099 990412 PDR ADQCK 05000400 S

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Page 2 April 12, 19)9 QCG-10530 Enterprise developed a method of preloading connectfng rod bolts using hydraulic prestressers (facks$

instead of the more'traditional applied torque method. The hydraulic prestresser method eliminated any possibility of galling or seizing of fastener parts due to hfgh contact force sfkflng motfon. This methodology was offered for DSRV-4 engines as a product improvement for equipment in service and as an option for new rod assemblies starting in the rnid 1980's. The prestressed hardware fncludes four studs which bottom in thread tappings fn the rod box. The studs were offered ln two sizes to fita variety of rod assemblies that could differ In rod box hole depth.

A recent rod replacement/prestressed fastener installation at Cleveland Electric's Perry Plant revealed that incorrect parts were provfded. Studs of the longer design were furnished with a rod box that required theshortstuds.

A subsequent reviewfoundananomalyintheCESdeslgndocumentation.

While it was debatable as to whether the assembly coufd be completed based on sound mechanicaf practice, the potential for error was demonstrated.

This problem was compounded by a typographical error in assembly instruction literature that was intended to alert customers to the difference between rods and fastener lengths. When properly assembled the stud end willextend 3-9/1 6 inch past the face of the master rod. That dimension wiffbe off by 3/8 inch ifthe wrong stud is installed. The assembly. instructfons provided the correct 3-9/1 6" dfmensfon but indicated that an incorrect stud would differby 7/8 fnch.

The effect of fnstalling the wrong stud is that the thread engagement ln the rod box tapping fs reduced to potentially unacceptable dimensions.

CO E

V TIO Any engines with suspect assemblies Installed should be inspected at their next refueling outage. In addition, any affected rod assemblies In utilities'nventory should likewise be inspected. Suspect connecting rod assemblies can be verified by measuring the length of the stud extending from the face of the master rod to the fastener end wfth a scafe or tape. The correct length should be 3-9/1 6". Ifthe wrong prestressed fasteners are installed, the measurement willdeviate from this by+/- 3/8". For any rod assemblies where this measurement differs from the recommended 3-9/16", CES Englneerfng should be contacted forfurther evaluatfon and potential stud rework or replacement.

Ifyou have any questions regarding this Issue, please contact T. L. Miller, Quality Engineering at 724-458-3448 or Ronald Billig,Manager, Aftermarket Technical Servfces at 724-458-3584.

Sincerefy, Coopers Energy Services Ronald G. Biliig Manager, Aftermarket Technical Services I

Page 3 April 12, 1999 QCG-1 0530 Document Control Dqsk U.S. Nuclear Regulatory Commission Washington, D.C. 20555 Mr. Stephen Alexander U.S. Nuclear Regulatory Commfssfon QA Vendor lnsp. & Mainten. Branch One White Flint North Maiistop 9A1 Washington, DC 20555 Enter gy P.O. Box 429 Echelon One l340 Echelon Parkway Jackson, MS 39286-1995 Attn:

Fred W. Titus Vice President, Engineering Entergy Operations P.O. Box 756 Port Gibson, MS 39150 Attn:

Wm. K. Hughey Director, NS&RA Carolina Power and Light Co.

Harris Nuclear Project P.O. Box 165 New Hill, NC 27562-1065 Attn:

Jim Scarola Vice'President Carolina Power and Light Co.

P.O. Box 1551, CPB9 Raleigh, NC 27602 Attn:

Donna Alexander, Manager Performance Eval. & Reg. Affairs Cleveland Electric Illuminating Perry Nuclear Power Plant P.O. Box 97 Perry, OH 44081 Attn:

Mr. R, G. Colllngs Manager, Quality Assurance Cleveland Electric Illuminatfng Perry Nuclear Power Plant

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P.O. Box 97 Perry, OH 44081 Attn:

Harold M. Coon Cooper-Enterprise Clearinghouse Duke Engineering &Service 230 Sofjth Tryon St.

P.O. Box 1004

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Charlotte, NC 28201-1004 Attn:

G. A. Harrison Duke Power Company OEA Manager Nuclear Assessment Div.

P.O. Box 1006 Charlotte, NC 28201-1006 Southern Nuclear Opearting Company Plant Vogtle P.O. Box 1600 Wayriesboro, GA 30830 Attn:

Mr. J. T. Gasser General Manager TU Electric Company P.O. Box 1002 Glen Rose, TX 76043 Attn:

Sr. Vice President & Principal Nuclear Offfcer B. C. Guntrum - Afameda L. A. Duck - Alameda M. Donlin Alameda D. D. Sfuart - Alameda Sue Johnston - Alameda, R. Johnston - Alameda J. M. Horne-GC R. G. Bflllg-GC W. R. Slusher-GC T. L Miller-GC R. Boyles - GC

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t/4/12/1999.S.

Nuel gulatory Commission Operations Center E eport Q4

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General Information or Other (PAR)

P~ae I Event ¹ 35580 Rep Org: COOPER ENERGY SERVICES Supplier: COOPER ENERGY SERVICES Region:

1 City:

GROVE CITY County:

'State:

PA Notificatlon Date / Time: 04/12/1999 15:55 (EDT)

Event Date /T)me: 04/12/1999 (EDT)

Last Modification: 04/12/1999 Docket¹:

Agreement State:

No License¹:

NRC Notified by: BILLIG(FAX)

HQ Ops Officer. CHAUNCEYGOULD Emergency Class: NON EMERGENCY 10 CFR Section:

21.21 UNSPECIFIED PARAGRAPH Notifications:

DAN HOLODY WALTERRODGERS JOHN JACOBSON LINDASMITH YERN HODGE R1 R2 R3 R4 NRR THIS PART 21 IS CONCERNED WITHA POTENTIAL DEFECT IN A COMPONENT OF A DSRV-16K ENTERPRISE DIESEL GENERATOR SYSTEM. THE POTENTIAL PROBLEM IS WITHA CONNECTING ROD ASSEMBLIES BUILTSINCE SEPT 1986 THATUSE OR HAVE BEEN CONVERTED TO USE PRESTRESSED FASTENERS TO ATlACH THE ROD BOX TO THE MASTER ROD, THESE NEW ROD ASSEMBLIES(P/N 1A-7802) COME ASSEMBLED WITH PRESTRESSED FASTENERS THATARE SUSPECTED TO BE OF INCORRECT LENGTH. THE PLANTS INVOLVEDARE VOGTLE(ENGINES/N 760214) AND PERRY(ENGINE S/N 75051-2).

IN ADDITIONUTILITIESWITH DSRV< ENGINES WHO HAVEPURCHASED REPLACEMENT P/N 1A-6280 OR 1A-6281 CONNECTING ROD ASSEMBLIES (WITH BOLTS) SINCE SEPT., 1986 AND HAVESUBSEQUENTLY CONVERTED THESE TO PRESTRESSED FASTENERS(OR PLANNINGTO CONVERT) COULD ALSO BE AFFECTED. THE FOLLOWING SITES MAYBE AFFECTED GRAND GULF(ENGINE S/N 740334),

HARRIS(ENGINE S/N 74046-9), CATAWBA(ENGINES/N 75017-20), PERRY(ENGINE S/N 75051<),

COMANCHE PEAK(76001-4), ANDVOGTLE(ENGINES/N 760214).

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