ML11186A891

Notification of Potential Part 21 Seal Failure and Leakage Associated with Model B5497-301 Valves

ML11186A891
Person / Time
Site:	Harris, McGuire, Mcguire
Issue date:	07/01/2011
From:	Kenneth Armstrong Automatic Valve
To:	Office of Nuclear Reactor Regulation
References
470150
Download: ML11186A891 (10)

Text

0710112011 U.S. Nuclear Regulatory Commission OperationsCenter Event Report PagelI Part 21 (PAR) Event# 47015 Rep Org: AUTOMATIC VALVE CORPORATION Notification Date I Time: 07101/2011 15:56 (EDT)

Supplier: AUTOMATIC VALVE CORPORATION Event Date / Time: 06/28/2011 07:00 (EDT)

Last Modification: 07/01/2011 Region: 3 Docket #:

City: NOVI Agreement State: No County: License #:

State: MI NRC Notified by: KEVIN ARMSTRONG Notifications: CHRISTINE LIPA R3DO HQ Ops Officer: JOE O'HARA MARK FRANKE R2DO Emergency Class: NON EMERGENCY PART 21 GRP EMAIL 10 CFR Section:

21.21 UNSPECIFIED PARAGRAPH SEAL FAILURE AND LEAKAGE ASSOCIATED WITH MODEL B5497-301 VALVES The following was received via fax:

Automatic Valve Corporation made this report based upon its investigation and engineering evaluation of valve serial number 57056 which was leaking following an outage test stroke at McGuire Station. Automatic Valve Corporation determined that the cause of the leakage was seal failure as a result of the seal being displaced from its retaining groove. The displaced seal became trapped between the poppet face and valve seat inside the valve body. Automatic Valve Corporation reported that seal replacement combined with inspection; and testing would prevent additional failures.

Shearon Harris and McGuire utilize these types of valves. Automatic Valve Corporation has no reported failures of these valves at Shearon Harris.

I14

'LI/,!

I/ LU1I / ,kL UJ . j L I M W --Iui FlhlJ YfI Y1 k-U VJ / V-,

I'tA 14UL. I/L, U ItI tUIJj_ 1. U UI NRC Operations Center 301-816-5151 (FAX) 10 CFR PART 21 Notification:

Automatic Valve Corporation 41144 Vincenti Court, Novi MI 48375

Contact:

Kevin Armstrong, President, 248-474-6700 ext. 170 Basic Component Model Numbers:

B5497-301 Nature of the Defect, Extrusion of internal seals creates seal displacement and leakage.

Number and Location of Components:

Valve Model Quantity Customer D5497-301 20 RA Hiller Corrective Action to Be Taken:

Please see attached report.

Advice to Purchasers:

Please see attached report. Automatic Valve will rebuild units as necessary.

Date the Evaluation of the Defect was Complete: 06/28/2011

jUL UI/ iUJI I1/fA UD.JI .i i-IUMt'Ii.i. V.MLYF, UVU.J fA ii'j, 1 IjlUi]L r.U*U AUTOMATIC VALVE NUMBER: D7174-003 Page 1 of 8 TITLE: CORRECTIVEI ACTION LOCN: l:\WORD\DOCUMENT\D7174003.DOC DATE: 10-21-1999 SUBJ: CORRECTIVE ACTION TYPE: FORM DEPT RESP: DQA REV: F-0N8020 REQUIREMENTS:

NUMBER: 643 Type of Problem: Part B5497-301 Procedure Date: 06-09-2011 Who found Problem: Supplier Distributor X Customer Company: Duke - McGuire Station Contact Name: Ryan Printy Address: 12700 Hager's Forry Road Huntersville, NC 28078-9340 1 Team Working on Problem: Leader: Kevin Armstrong Members:

Brian Bielat, Tom Troy, Todd Hutchins

2. DescrIbe Problem (Initial Concern and Symptoms):.

Valve, serial number 57056, was noted to be leaking after an outage test stroke.

Contain Symptom (Action):

All elastomeric components require replacement. Valve to be returned to customer in as originally shipped condition.

Approved by: -- Te: Date: 7 ,,

4. Root Cauaels of Problem: 10 CFR Part 21 Report Required: Yes A 10 CFR 21Is report required based on the statement made by plant staff on June 28'":

'when the 4-Way for 2CF-20AB failed we drained the tank in a relatively short period of time and weeactually startedlto drain the main nitrogen header the leak was so large. Ifthis happens again during a feedwater isolation we would violate one of our requirements tb maintain a minimum of 60 psig in the tank for a 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> period."

The root cause of the valve leakage is seal failure, The seal on item 3. A5497-314, is displaced from its retaining groove, (See attached print Sheets land 3; photograph 1) This created a condition where the displaced seal was trapped between the poppet face and the valve seat inside the valve body.

This creates a gap through which nitrogen passes directly between the inlet port and exhaust port. The exact size of this leak is dependent on several factors including volume and pressure of nitrogen available to force the piston (item 6, attached print sheet 1) ) into its fully stroked position. This piston, inturn, drives the unseated seal back into the poppet grove, and creates an (Imperfect) seal on the rolled edge or the face of the poppet. At normal operating pressure, above 265 psi, testing shows the displaced seal is forced back (imperfectly) into its retaining groove, The valve leaks but still functions, At lower pressures, the displaced seal will create a larger leak path.

The seal failed due to compression set. It extruded and rolled over the wall of the poppet face (Photograph 2).Note that the extrusion only occurs on the end of poppet which is exposed to ambient pressure ( 344 psig) around the entire area of an unconstrained seal. The seal on the poppet face which mated to the valve body seat during in-service operation does not extrude. (Photograph 3).

As the extrusion continues the seal begins to cut. The cut either creates a leak path, which is formed where the high pressure nitrogen can pass under the seal causing it to lift or the cut causes the seal to loose squeeze and high pressure differentials during shift create the lift. Automatic Valve has not been able to duplicate the displacement of an extruded seal.

Other issues of note not directly related to the failure; FME was noted at disassembly of the vale (photograph 4), Ifthe FME is taken into the valve through vent ports it would be expected to degrade lubrication. Degraded lubrication can be expected to both increase minimum operating pressures and slow movement of Internal components. This will tend to increase the impact of the displaced seal.

Plant staff Indicate a low pressure requirement of 50 pslg. The valve prints do not specify this pressure. No testing was done by Automatic Valve below 90 pslg. Please see print sheet 2 of 3, Notes 5 and 10.

The only other installation of these valves is at Shearon Harris. Automatic Valve has had no reports of failures from that plant.

Three replacement units were purchased by Shearon Harris in October of 2008. after an original installation in 1999.

Approved by

Title:

.ste:

jUL' hi /U I / fP. i U.J . 'j fI rY MUIUIVIMI.B., VMLV&I .UarI* F 11,A IqV. I Z 't O't i 'tU I D L r, U UUD AUTOMATIC VALVE NUMBER: D7174-003 Page 2 of 8 TITLE: CORRECTIVE ACTION LOCN: I:\WORD\DOCUM EN-RD7174003. DOC DATE: 10-21-10999 SUB J: CORRECTIVE ACTION TYPE: FORM DEPT RESP: DQA REV: F-CN8020

5. Corrective Action, Time required for compression set and extrusion to occur is unknown. The valve has, however, functioned without failure since 1999, Replacement of seals combined with additional inspection; testing and replacement protocols would prevent an In-service unit from developing the same failure mode..

Additional work is required to modify the seal such that compression set will not impact performance.

Approved byi*

• 4

Title:

_ 4. 4 Date: * /.

6. Implementation:

Approved by:

Title:

Date:

7. Corrective Action to System to Prevent Recurrence:

Approved by:

Title:

Date:

8, Verification (Describe):

Approved by:

Title:

PRS Date:

dJL/J Ij/ iU1I I/ PIAI U_ .*I LII MUIUIYII 1,ý V MLI F, aUflr f AA DilJ. I Lt 011'tU I - f, UUIt AUTOMATIC VALVE NUMBER: D7174-003 Page 3 of 8 TITLE: CORRECTIVE ACTION LOCN; I:\WORD\DOCUMENT\D7174003.DOC DATE: 10-21-1999 SUBJ: CORRECTIVE ACTION TYPE: FORM DEPT RESP: DQA REV: F-CN8020 B5497-301 Revision D, Print Sheet 1 2211 t.,... I nra I I I E

3 =AOXO 4 222-P IL2 r

• LEA 1 3 ' ) kwo Iew2U2.'

I Lt1 04M 2?.

t 2222'3 II 4£I O lO,221lkZ4 7 =400P Ia 1 02 142222

" p 2m I I"*2 cam z 4724 is.9A I 5ip-24 2 Isa111im lt R1 I WHIM2 A 2

£ \ I 2244.2.14I am X A mI= 1424-4 Zi

-' ~ ~ 7211fa401 1,S.

OWXI N Olt225t1 I

,jtZ.[

li "A rl'771'0 0202

_ , 02 7 9,_1"*

I-- [*2 CV OILA VA

• "222272 40J1U K i2 I 4 ~ I DI J -"G .

212l1222-ll211 z I Orl fl1 l A222,0I.1 I .U 3.44 %122

- + ¶2 m2 "3~l02, 1-0A pp m

U I 22224a Z &

.0) W U

-W 7,9 22 14144 ILFc 2

1 m wm c 1 ~

A22I2ll1P in2-a crum hmu1d im9&UM w tP90 It2 1 2UI- I.122 2122 1 2222122ir:

M 222 I uw I K T~ "/'

• ATIC VALVE CVS9.0 ATL W&10Ah-i* 1NIM ... . .. .1 ,+V t 12 P,4.

$I. 171 2o097-301

, ~i w,2p2C41 I 2242-311 K2PL2I1:

,uLi/J UI L." I I " I n'1 1.) j , j U I IV 5 nv lI Ui-ini ij I ni-~v i., v.AumI-ll I nil LIU.i~ u ~ u ~~

1z.1ru1T11r1j1j-, ~u~ I, . UJ-AUTOMATIC VALVE NUMBER: D7174-003 Page 4 of 8 TITLE: CORRECTIVE ACTION LOON: I:\WORD\DOCUMENT0D7174003.DOC DATE: 10-21-1999 SUBJ: CORRECTIVE ACTION TYPE: FORM DEPT RESP: DQA REV: F-CN8020 B5491-307 Revision D, Print Sheet 2 c Im e m-m ri I'm D jQR4M !KM1EP HIM9-MI P 17763 10~.LIZKIKM1ff EILSUE =. XW&.3.1o81W LUUlIL 10V11%WHWLQ* I[ mm08 IHJOt w0

~IU 50P311,AI a& 1.

min SIW rag.I1 of rm 8W 5PamW 4'4"=11 5L1*51f luw=hWPZ8W= 805051 "W.

OM IAAI d" I" MAHI knw* Mm803185. x11505 W mWS.

3 OPKFMUM MI'M" of-VN~l5m 6'3 50a1a 3 I0A. 3;& 1=l~ 4.ayo mm1ft fu ,and811 "

5815 0 to fu PmlIOwD IF A MI*1Z0 LM a85. ýU .Y q=0. ZF0 NZ .88*

8iT al0mm m F181101 10goame128M8 VLIU~:

Z3IR1YE WF IMfEMIA d EZr IZZI!

FI I OahuS I=T rI I rn i~ .IITflM.flr VAr80

~.8. ~ ~ [5~-C S(3lPTIM: VALVE W/ PIY &1L 105497-3cI

U L/. ýl I / ý, 111 1 ! 1' 1%,

1 Ul J - 'i 0 1 It MU I Ulylh L I ý/ V hL V L UIJAr rhA INV. I Zi(Di liU 13ý r, uuo AUTOMATIC VALVE NUMBER: D7174-003 Page 5 of 8 TITLE: CORRECTIVE ACTION LOCN: I:\WORD\DOCUMENT\D7174003.DOC DATE: 10-21-1999 SUBJ: CORRECTIVE ACTION TYPE: FORM DEPT RESP: DQA REV: F-CN8020 85491-307 Revision D, Print Sheet 3

'JUI.. I

'JI' uLl)IrI/ 11'.L U JJ-U IA "nul"L.Y JItvi in7v "h11£ yTUY, I I Lil, i11V. I LT 'J'T I T U ý -1L i 1 11 11 i 1..UUI AUTOMATIC VALVE NUMBER: D7174-003 Page a of 8 TITLE: CORRECTIVE ACTION LOCN: I:\WORD\DOCUMEN0RD7174003.DOC DATE: 10-21-1999 SUBJ: CORRECTIVE ACTION TYPE: FORM DEPT RESP: DQA REV: F-CNS020 Photograph 1: Displaced, as found, Seal S , .. .... ; . .. . . ,. . .. .

Photograph 2: Seal Extrusion

1/ L'UI.

Q, I II I U7 , .UU im I'-1Lt ll - ll i,-Ifi* 'j i" l I f"luv.

iLUV, TI UI 1. UUU AUTOMATIC VALVE NUMBER: D7174-003 Page 7 of 8 TITLE: CORRECTIVE ACTION LOCN: I:\WORD\DOCUMENT-D7174003.DOC DATE: 10-21-1999 SUBJ: CORRECTIVE ACTION TYPE; FORM DEPT RESP: DQA REV: F-CN8020 Photograph 3: Seal Face -Without Extrusion - Compressed Against Face In Service

d J-iJ ll ItJ/ I A' I ItIII f-ltl nu lilf-I I, Y fi.YlY . J.Lli r '"afJ , i, I .UU.J AUTOMATIC VALVE NUMBER: D7174,003 Page 8 of 8 TITLE: CORRECTIVE ACTION LOCN; I;\WORD\DOCUMENT\D7174003. DOC DATE; 10-21-1999 SUBJ: CORRECTIVE ACTION TYPE; FORM DEPT RESP: DQA REV: F-CN8020 Photograph 4: FýME As Found Normally Closed Side, Inlet Face