ML13073A107

Notification of Potential Part 21 Report - Defective Raw Material Used to Manufacture Valve Stems

ML13073A107
Person / Time
Site:	Wolf Creek, Point Beach, Cooper, Prairie Island, Callaway, Clinton, San Onofre
Issue date:	03/12/2013
From:	Martin D G Dresser-Rand
To:	Office of Nuclear Reactor Regulation
References
48745
Download: ML13073A107 (5)

Text

0311212013 U.S. Nuclear Regulatory Commission Operations Center Event Report Page I Part 21 (PAR)Event# 48745 Rep Org: DRESSER-RAND Notification Date / Time: 02/12/2013 16:52 (EDT)Supplier:

DRESSER-RAND Event Date / Time: 02/01/2013 (EST)Last Modification:

03/11/2013 Region: 1 Docket #: City: WELLSVILLE Agreement State: Yes County: License #: State: NY NRC Notified by: D. G. MARTIN Notifications:

ANTHONY DIMITRIADIS R1DO HQ Ops Officer: DONALD NORWOOD BOB HAGAR R4DO Emergency Class: NON EMERGENCY PART 21 RX GROUP E-MAIL 10 CFR Section: 21.21 (d)(3)(i)

DEFECTS AND NONCOMPLIANCE PART 21 REPORT -DEFECTIVE RAW MATERIAL USED TO MANUFACTURE VALVE STEMS Dresser-Rand is reporting that one of its vendors supplied annealed material instead of the specified heat-treated material.

Dresser-Rand used the defective raw material to manufacture valve stems for Terry Type Emergency Feedwater pump drive turbines.

Dresser-Rand has verified that the annealed material is not acceptable for the finished product.The two customers (Wolf Creek Nuclear Plant and Callaway Nuclear Plant) that received the affected parts have been notified of this issue and have confirmed that the components in question are not in service at their facilities.

The remaining material and affected parts have been quarantined at the Dresser-Rand plant in Wellsville, NY.All questions should be addressed to: Joe Menichino Manager, Navy/Nuclear Product Engineering 37 Coat Street Wellsville, New York, 14895 Phone: (585) 596-3406 jamenichino@dresser-rand.com

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• UPDATE FROM JOE MENICHINO TO CHARLES TEAL ON 3/11/13 AT 1614 EDT * * *The following was excerpted from a facsimile received from Dresser-Rand: "DESCRIPTION OF DEFECT OR NON-COMPLIANCE 03/12/2013 U.S. Nuclear Regulatory Commission Operations Center Event Report Pakre 2 Part 21 (PAR) Event# 48745"Specific designs of steam turbine control valve stems are made from heat treated ASM 5663M Inconel Bar raw material.

Certifications associated with heat numbers of certain inventory of this material indicate that the material vendor incorrectly supplied material in an annealed condition (AMS 5662M)."POTENTIAL SAFETY HAZARD OR NON-COMPLIANCE"Valve stems are used to control steam turbine speed and power. The valve stems must be free to move within the guiding assembly during operation.

Stems are made using materials that have the correct material properties to reduce the risk of failure. The use of inconel raw stock in an annealed condition is unacceptable for steam turbine valve stems due to the risk of unacceptable wear and strength characteristics which could lead to sticking or tensile failure in the mating guide bushings within the valve assembly."ADVICE TO EFFECTED CLIENT RELATED TO THIS REPORT"For those affected sites identified, locate and return the material to Dresser-Rand immediately." Affected facilities include Point Beach, Clinton, Wolf Creek, Cooper, Callaway, San Onofre, and Prairie Island.Notified R1 DO (Dentel), R3DO (Dickson), R4DO (Powers), and the Part 21 Group via email.

DRESSER-RAND Wellsville Operations 37 Coats Street P.O. Box 592 Wellsville, NY 14895 PH: 716/593-1234 March 11, 2013 To: Nuclear Regulatory Commission Reference

-1 OCFR Part 21 Reporting of Defects -Final Report Please accept transmittal of the attached IOCFR Part 21 Final Report Number 45.Please call if additional information or discussion is required.ino, MGR1Navy Nuclear Product Engineering Dresser-Rand Government Business Unit 585-596-3406 office 585-307-4125 cell£4 'd 8£2,L8k~TsTs9T8To2Te:oi IINfl *5fl8 YiOE9:LO~l d~t,:20 2102-TT-ýIW t' rV9 lC OZ0/ l, /CO :112 pGA!GGoej FINAL REPORT 10CFR PART 21 REPORT OF A POTENTIAL SAFETY HAZARD Report No. 45 Page 1 of 2 PREPARED BY: J.A. Menichino File No: None Y_.. e1/rfs Serial No: Various TITLE: Mgr, Navy/Nuclear Produc-Engineering Type: None Ref: None PART NAME: Inconel Valve Stem DR Part No: See List, Pg. 2 DR Dwg No: See List, Pg. 2 Rev. Level: See List, Pg. 2 1. DESCRIPTION OF DEFECT OR NON-COMPLIANCE Specific designs of steam turbine control valve stems are made from heat treated AMS 5663M Inconel Bar raw material.

Certifications associated with heat numbers of certain inventory of this material indicate that the material vendor incorrectly supplied material in an annealed condition (AMS 5662M).2. POTENTIAL SAFETY HAZARD OR NON-COMPLIANCE Valve stems are used to control steam turbine speed and power. The valve stems must be free to move within the guiding assembly during operation.

Stems are made using materials that have the correct material properties to reduce the risk of failure. The use of inconel raw stock in an annealed condition is unacceptable for steam turbine valve stems due to the risk of unacceptable wear and strength characteristics which could lead to sticking or tensile failure in the mating guide bushings within the valve assembly.3. NUMBER AND LOCATION OF ALL COMPONENTS Sheet 2 defines all affected Dresser-Rand part numbers. It also identifies all end users and quantities of the.affected parts that were shipped during the period that the raw material In question was in the Dresser-Rand system.4. CORRECTIVE ACTION BY: DR Staff COMPLETED BY I See dates below 1- Identify and isolate all affected raw material.

Competed 2-15-13 by DR QA.2- Revise Part Inspection records to include a hardness verification check on the finished parts. Completed 2-8-13 by DR QA 3- Revise Part Dedication records to include a hardness verification check on the finished parts. Completion due date 3-15-13. Action by DR N/N Engineering 4- Revise DR Matedal Specification to include a hardness verification of the raw material during receipt inspection.

Completion duedate 3-15-13. Action by DR Metallurgy and N/N Engineering.

5- Notify all affected customers (ref sheet 2) and recall affected parts. Completed 2-25-13 by DR Aftermarket 6- Issue internal DR Corrective Actions for Certification Review Process (CA2013002375) and Raw Material Control Process (CA2013002377).

Initiated 2-22-13 and 2-26-13 by DR QA 7- Issued DR Supplier Quality Corrective Action (20130208-2 and 20130208-1) to the raw material supplier.Initiated 2-8-13 by DR SCM 5. ADVICE TO EFFECTED CLIENT RELATED TO THIS REPORT For those affected sites identified on sheet 2 of this report, locate and return the material to Dresser-Rand immediately.

NNSOP12001Fl (Final Report 10 CFR Part 21 Report of a Potential Safety Hazard), REV. 00, 25JUN08 Reference NNSOP-1-2-001 22 8~2.L8ikdTST9Teio2T9

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~TT9F~~8S lNf 'sfl *n09:Wo'dd d~t?:20 ET02-TT-ýJW C k .+ I Dresser-Rand ginzi Rcrnnrt Part~ 21 No 45 rserRn I_-* rt** 'A ~ .- -.-Potential Affected Part Numbers: 800777-001 800743-001 800768-701 801061-701 800768-702 800741-701 800858-001 800744-001 800740-701 800745-001 800746-001 800748-001 800739-001 800742-001 Contracts and Part Numbers of Affected Parts that must be Recovered: (Based on the 2/20/12 non-conformance start date)1- Customer and DR Order No. : Point Beach C34587 PN: 801061-701 Qty 1 (A292081)PN: 801061-701 Qty 1 (A292082)Status- Not shipped, on hold at DR Wellsville 2- Customer and DR Order No. : Clinton 513114 PN: 800858-001 Qty 2 (A296109)PN: 800858-001 Qty I (N17338)Status: Shipped, Customer notified and recovery in process 3- Customer and DR Order No. : Wolf Creek C34590 PN: 800858-001 Qty 1 (N 16958)PN: 800858-001 Qty I (N16445)Status- Shipped, Customer notified and recovery in process 4- Customer and DR Order No. : Cooper 478937 PN:801061-701 Qty I (N16541)PN:801061-701 Qty 1 (N16540)Status- Not shipped, on hold at DR Wellsville 5- Customer and DR Order No.: ATC/Callaway CSS515969 PN: 801743-001 Qty 1 (N16594)Status- Shipped, Customer notified and recovery complete 6- Customer and DR Order No. : ATC/ San Onofre CSS 522675 PN: 800858-001 Qty 1 (N16782)Customer notified and requested to return matl. under CSS 542255 7- Customer and DR Order No. : ATC/Praire Island CSS 531682 PN: 800740-701 Qty 1 (N17197)Customer notified and requested to return mat!. under CSS 542268 3-11-13 2/2'd 8U_68f7dT9T99TeTO2Te:oi 6T22T96STs8s

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