ML20134D857
| ML20134D857 | |
| Person / Time | |
|---|---|
| Site: | Quad Cities  |
| Issue date: | 10/28/1996 |
| From: | Hutchins T AUTOMATIC VALVE CORP. |
| To: | NRC |
| References | |
| REF-PT21-96 NUDOCS 9610310065 | |
| Download: ML20134D857 (11) | |
Text
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10/'28/96 13:13 FAX 810 474 6732 AUTOMATIC VALVE @ 002 AlJTOMATIC VALVE 41144 Vincenti Court Novi MI USA 48375-1924 Telephone 810-474-6700 Facsimile 810-474-6732 F an World Class Air Valves and Controls l
I l OCTOBER 28,1996 l
l
SUBJECT:
10CFR21 NOTIFICATION OF POTENTIAL DEFECT On 09-02-96 Jim Wethington, of Commonwealth Edison-Quad Cities NPS, notified l Automatic Valve that a Main Steam Isolation Valve (MSIV) EPN 1-0203-1D had failed to
! close in the 3-5 seconds required by their technical specifications. The solenoid valves
! associated with the MSIV had recently been replaced by Quad Cities personnel.
Following replacement, the MSIV stroked properly under cold conditions (reactor shutdown and solenoid valves de-energized prior to testing). The concern was identified white re-timing the MSIV during plant start-up. After the solenoids had remained energized for several hours the MSIV would not close within the required 3-5 seconds.
On 09-03-96 Todd Hutchins of Automatic Valve inspected the solenoid at the Quad Cities facility and determined that the 6910-0x0 solenoid plunger was 1.322-1.327" in length. The correct specified length is 1.287-1.295". The probable cause of the incorrect l length appeared to be a missed machining operation at time of manufacture.
l A solenoid plunger of this length restricts the exhaust port in the plunger stem. This l potentially can prevent any equipment operated by the solenoid from operating within its intended time requirement.
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On 09-04-96 Todd Hutchins and Jim Wethington discussed the non-conformance and initial corrective action with Keith Walton and Laura Collins of the Nuclear Regulatory ,
Commission located at the Quad Cities facility.
Automatic Valve verified that all of the 6910-0x0 solenoid plungers currently in their stock were the correct length and added a specific inspection requirement for all future plungers.
To prevent any additional valves from being rebuilt with potentially long plungers Automatic Valve requested all customers who had received kits containing the 6910-Ox0 solenoid plunger in the last two years to verify the plunger length. It had been r Automatic Valve's experience that kits supplied previous to the two year cutoff were already installed in operating valves and could not immediately be measured.
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The defective solenoid from Quad Cities was returned on 09-27-96 to Automatic Valve for additional testing and root cause determination. Frank Lentin of Commonwealth g {
9610310065 961028 i PDR ADOCK 03000254 l
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10/28/96 13:13 FAX 810 474 6732 AUTOMATIC VALVE
- . . @ 003 l 3/u l Page 2 l October 28,1996 l
Subject:
10CFR21 Notification of Potential Defect i
Edison notified Automatic Valve that a 10CFR21 review had been initiated and that a i decision on potential reportability was required by 11-04-96.
! On 10-17-96 preliminary test data indicated that field detection of the non-conforming plunger was possible with.a dimensional inspection (requiring the solenoid
! to be disassembled) or time testing the product after the solenoid had reached it's stabilized temp 3rature (but not during its initial cold state).
Since the missed machining operation on the plunger was an omission in the machining process, the problem is not lot specific. Potentially all solenoid valves manufactured since 02-03-70 (utilizing the 10 watt #6910-Ox0 solenoid) with the model numbers prefixed A, B, C ,K, or U are affected. if you are unsure as to whether this affects you, please submit questionable part numbers to Automatic Valve for verification.
There have been no reported non-conforming plungers shipped in the previous 26 years.
l l All known customers (list attached) were verbally notified of the potential problem, verbally notified of the recommended corrective action, given an assurance that a formal 10CFR21 decision would be made by 11-04-96 and that they would receive a copy.
The formal corrective action report (attached) was completed on 10-28-96 and outlines the problem, root cause, corrective action, implementation, and preventative action.
l This letter intends to fulfill Automatic Valve's obligation under 10CFR21 and is being sent with all attachments to all known customers who have purchased products containing the potentially long plunger and who have imposed 10CFR21 in their purchase order.
Should you have any additional questions, please feel free to contact me.
Very truly yours, AUTOMATIC VALVE CORPORATION T// M 7 Todd Hutchins
- President l TJH/cb 10cfr2 1. doc L
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10/28(96 13:14 FAX 810 474 6732 AUTOMATIC VALVE @ 004 AUTOMATIC VALVE CORRECTIVE ACTION 10/28/96 9622A '//so j l
- 1. Team: Jim Wethington, Quad Cities NPS, tel:309.654.2241x2190 I
Todd Hutchins, Automatic Valve, tel:810.474.6700 l
- 2. Problem: On 09-02-96 MSIV #1-0203-1D would not fast close within the 3 second technical specification when the solenoids had been energized for a minimum of two hours at a minimum of 90'F ambient. J
- 3. Containment: Air pack ser# D53325 was removed from MSIV #1-0203-1D for I inspection by Automatic Valve personnel at Quad Cities. Air pack ser# ;
D53332 was rebuilt for installation on MSIV #1-0203-1D on 09-04-96.
- 4. Cause: One plunger from solenoid 6910-0x0 missed the machining operation after the viton insert was pressed in. l
- 5. Corrective action:
5.1 For products in the field:
Verify the plunger length to be 1.287-1.295" or verify when de-energized that the application speed meets i technical specifications after the solenoid has been energized ;
for a minimum of two hours at a minimum of 90'F ambient. !
5.2 For products at Automatic Valve:
)
Verify flow / response time and/or verify plunger
! length. i H ;
- 6. Verification:
6.1 Verified that the non-conforming plunger was fully assembled but had missed the machining operation (based on x-rays and photos).
6.2 Verified that the non-conforming plunger when energized for minimum of two hours at a minimum of 90'F ambient would cause significant delay in de-energize flow time (test report PV-UTL-46 attached).
6.3 Verified that the non-conforming plunger could be identified by a flow / response time test.
- 7. Implementation:
7.1 Plants should verify that the plunger length is 1.287-1.295" or verify when de-energized that the application speed meets technical specifications after the solenoid has been energized for a minimum of two hours at a minimum of 90'F ambient.
7.2 Automatic Valve added plunger length as a critical 'to be inspected' l dimension on the inspection print (print #6910-0X0 attached). Current stock at Automatic Valve was re-inspected and found all to be within !
tolerance. Service kits sold to customers in 1995 and 1996 still in l stock were re-inspected and found all to be within tolerance (contacts j attached). :
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10rzs/su 1s:15 FAX 810 474 6732 Alr10MATIC VALVE (d OO5 AUTOMATIC VALVE CORRECTIVE ACTION 9622A 10/28/96 (/,o 7.3 Automatic Valve verified flow / response time and/or plunger length on all shipments since 09-04-96.
7.4 On 10-28-96 Automatic Valve notified in writing all known customers who had purchaced products containing the potentially long plunger and who had imposed 10CFR21 in their purchase order.
- 8. Prevention:
1 8.1 Plants should add plunger dimensions to field rebuild instructions -
(example attached).
8.2 Automatic Valve added critical solenoid dimensions to engineering
, ' critical characteristics'. procedure.
l 8.3 Automatic Valve added flow / response time requirements to final test procedure.
- 9. Verification: Monitor testing and field feedback data.
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10/28f96 13:15 FAX 810 474 6732 AITIUMATIC VALVE @ 006
. AUTOMATIC VALVE LOCN: 1:\ DSS \DOCUMENRPVUTL46 TEST NUMBER; PV-UTL-46 DATE: 10-26-1996 GM PURPOSE:
To d;termine the effects of ambient temperatures on the energize and de-energize tinies of solenord 6910-0X0, with: l e Non-conforming 6910-001 solenoid plunger- length of 1.322 - 1.327 - as retumed from Commonwealth Edison. l e Conforming 6910-001 solenoid plunger - length of 1.287 - 1.295 l
l TEST PROCEDURE:
- 1. Run all tests at 80 psig using filtered non-lubricated air.
- 2. Attach solenoid manifold with non-conforming plunger to test plate AX-402.
- 3. With the manifold at ambient temperature, record the following temperatures - also refer to figure 1.
3.1. Ta - Ambient temperature 3.2. T1 - Temperature of solenoid adapter nut.
3.3. T2-Temperature of solenoid coil housing.
3.4. T3 -Temperature of solenoid manifold block.
(Note: Physically mark the locations where temperature readings are taken and take all subsequent temperature
! r:adings at the same locations.)
1
- 4. Dttermine flow and exhaust response times taking 3 to 5 readings waiting a minimum of 10 minutes between rsedings to allow system to stabalize.
4.1 During each reading record temperatures at locations designated in paragraph 3.
- 5. With the manifold at ambient temperature, energize the solenoid for a minimum of 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />.
5.1. Record temperatures T1 through T3 per paragraph 3.
5.2 Determine flow and exhaust response times and record temperatures per paragraphs 4 through 4.1.
- 6. Disconnect air inlet line, remove the pressure transducer and place the manifold, test plate, and load chamber in an
) oven and heat to 90*F for a minimum ofi/2 hour with the solenoid energized.
6.1. Measures tempe atures T1 through T3 per paragraph 3 prior to running response tests.
6.2 Determine flow and exhaust times and record temperatures per paragraphs 4 through 4.1.
6.2.1 During the wait between readings, reinsert the manifold in the oven to re-establish temperatures.
- 7. Repeat paragraph 6 through 6.2 at oven temperatures of 90 F,100*F,125'F, and 150 F.
- 8. Repeat paragraphs 2 through 7 with conforming solenoid plunger.
l i TEST EQUIPMENT:
l Nraber . Description 1 Calibration Date -
APG-2 0 to 60160 PSIG pressure gage 10-02-1996 NIC-3091 Osciloscope 06-10-1996 7199 Thermocouple thermometer 10-04-1996 4i1-1100-550 Thermemeter 11-07-1995 SPT-667388 Pressute transducer 06-24-1996 3
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! 10/28/96 13:16 FAA 810 474 6732 ALTf0MATIC VALVE IdOO7 _
' .AUTOhAATIC VALVE LOCN: 1:tDSStDOCUMENTTPVUTL46 DATE: 10-26-1996 7[,
TEST RESULTS (AVERAGES Conforming Plunger i Non-conforming plunger '
Length 1.287-1.296 Length 1.322-1.327 Solznoid Temperatures Solenoid Solenoid Temperature Solenoid Solenoid En:rgize Degrees F energized de-energized Degrees F energized de-energized Time to 72 psig to 8 psig to 72 psig to 8 psig (seconds) (seconds)
Oven Body (seconds) (seconds)
Oven Body 0 (COLD) None - 71 71.4 0.182 0.142 None - 72 72.5 0.200 0.234 ambient ambient 2 hrs None - 71 91.2 0.181 0.145 None - 72 93.5 0.214 67.3 ambient ambient 2 hrs *NR *NR *NR *NR 90 108 0.210 146.1 t 2 hrs *NR *NR *NR *NR 100 112 "NR 157.2 !
! 2 hrs 125 121 0.174 0.241 125 115 *N R 180.4
! 2 hrs 154 152 0.167 0.244 150 127 0.215 249.0 l *NR - NO READING l
ANALYSIS / CONCLUSIONS:
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- 1. Ambient temperature fluctuations have little effect on either the energized or de-engerized times with the conforming plunger installed.
2.
mbient temperature fluctuations have only a slight effect on the energized times with the non-conforming plunger
- 3. Ambient temperature fiuctuations have a significant effect on de-energized times with the non-conforming plunger As the data shows, at an ambient temperature of 90 degrees F the unit became, for practical purposes, r.on functional. The " quickest" exhaust time with the surface of the body at 93.4 degrees F was 54 seconds compared to 0.145 for the manifold with the conforming plunger.
- 4. At a minimum ambient temperature of 90 degrees F and with the solenoid coil energized for a minimum of 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />, the delay in the de-engerized time would be easily detectable. As the ambient temperature increases, the delay becomes more and more noticable.
Conducted by : Brian Biefat -
Title:
Engineer Date: 10-25-1996 Analized by: w
Title:
VP Enc / Mfg '
Date: 10-26-1996
, Approved by: ac
Title:
VP Eng/Mfa Date: #18M[
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. 1 10/28/96 13:16 FAX 810 474 6732 AUTOMATIC VALVE id OO8 l i
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10/28/96 13:17 FAX 810 474 6732 AUTOMATIC VALVE @ 009
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,' AUTOMATIC, VALVE SHIPPEDKITSWITH6s10-0X0 10/25/96 5
CUSTOMER PO# SHIPPED QTY PART# COMMENTS I l ,
IOWA ELEC T02883 5/2/95 2 K-C5450-5-110 N/A SINCE FUNCTION IS Fall ENERGlZED l PECO BW603502 12/4/95 2 K-C6930-010 INSPECTED 10-04-96 BY NEPCO 4 COMED 356396 2/12/96 10 K-C6930-010 INSPECTED 09-30-96 BY COMED '
- PECO LS604405 2/12/96 1 K-C6930-010 INSPECTED 09-25-96 BY NEPCO l l PECO BW606621 4/18/96 19 K-C6930-010 INSPECTED 10-04-96 BY NEPCO l PECO LS607873 7/26/96 9 K-C6930-010 INSPECTED 09 25-96 BY NEPCO l IOWA ELEC T13195 9/27/96 6 K-C5450-5-110 INSPECTED 09-17-96 BY AV I DETROIT ED NR315280 10/21/96 3 K-C6930-010 INSPECTED 10-18-96 BY AV i
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. 10/28/96 13: 17 FAX 81,0,474 6732 AUTOMATIC VALVE . @ 010 l ,
". QUAD CITIES STATION : 9- 5 14:59 COMNONWEALTH EDISON- 810 474 6732; 2/ 2
\
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OCEMS 0250-16 /
UNIT 1(2) fo/IO REVISION 7 l RECOMMENDED FIELD REBUILD INSTRUCTIONS l l
MSIV SOLENOID MANIFOLD N UT 1._
j g Coll. AND HOUSING ASSEMELY i I
l PLUNCER (,;UIDE - . - t
- 7 I, r - - , I l i
L 1 (N3 FALL LARGER 00 END -*-
OF SFRtNG iNTO 3DT l OF PLUNCER GUICE suALLEP 00 ENO or SPRiNo - -
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CouPENSATING PLUNCER ~ ~F [
AND SPRING A33EMSLY l 1
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t.zgo V.cos "3
- VERIFY CORRECT LENGTH l
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3ENERAL INFORMATION or OTHER EVENT NUMBER: 31229
- ICENSEE
- AUTOMATIC VALVE NOTIFICATION DATE: '10/28/96 CITY: NOVI REGION: 3 NOTIFICATION TIME: 12:13 [ET]
COUNTY: STATE: MI EVENT DATE: 10/28/96
- ICENSE#
- AGREEMENT: N EVENT TIME: 00 : 00 [EST)
DOCKET: LAST UPDATE DATE: 10/28/96 NOTIFICATIONS fRC NOTIFIED BY: HUTCHINS IQ OPS OFFICER: CHAUNCEY GOULD VERN HODGE LMERGENCY CLASS: NOT APPLICABLE
's0 CFR SECTION:
SINF INFORMATION ONLY 2CCC 21.21 UNSPECIFIED PARAGRAPH EVENT TEXT AUTOMATIC VALVE WAS NOTIFIED BY COMMONWEALTH EDISON-QUAD CITIES THAT A MAIN STEAM ISOLATION VALVED FAILED TO CLOSE WITHIN THE 3-5 SECONDS REQUIRED BY THEIR TS. FURTHER INSPECTION BY AUTOMATIC VALVE PERSONNEL DETERMINED THAT THE "6910-0XO" SOLENOID PLUNGER WAS TOO LONG. THE PROBABLE CAUSE FOR THE INCORRECT LENGTH APPEARED TO BE A MISSED MACHINING OPERATION AT TIME OF MANUFACTURE.
AUTOMATIC VALVE VERIFIED THAT ALL SOLENOID PLUNGERS OF THIS TYPE IN THEIR STOCK WERE THE CORRECT LENGTH AND ADDED A SPECIFIC INSPECTION REQUIREMENT FOR ALLL FUTURE PLUNGERS. AUTOMATIC VALVE REQUESTED THAT ALL CUSTOMERS WHO RECEIVED KITS WITHIN THE LAST 2 YEARS CONTAINING THIS TYPE PLUNGER TO VERIFY THE PLUNGER LENGTH.
.- ~~
10/28/96 13:12 FAX 610 474 6732 Alfi'OMATIC VALVE @ 001 I/1 AUTOMATIC VALVE 10CFR21 NOTIFICATION 10/25/96 4
(PLANT OR CO. CONTACTED CONTACT TEL ;
FAX FAXED COMMENTS KiBIOOD / 10/23/96 BRIAN SULLIVAN 508.744.5690X131 741.3626 10/28/96 RESELL
- PILGRIM < 10/22/96 BILL CARROLL 508.830.8386 8920 10/28/96 YES-Q DRESDEN ' 10/18/96 BILL POPPE 815.942.2920X3878 0579 10/28/96 YES-Q QUAD X 10/18/96 JIM WETHINGTON 309.654.2241X2190 2265 10/28/96 YES-Q j CECO / MSG 10-22-96 FRANK LENTIN 630.663.7450 2099 10/28/96 10CFR21 DEFENSE y 10/25/96 RICHARD BUSH 313.741.2195 2022 NOT REO NO 21 4
FERMI / 10/18/96 ALEX KLEMPTNER 313.586.1805 4911 10/28/96 NO-O DRESSER x 10/22/96 LAURIE LUCKHARDT 905.335.3529 5315 NOT REO NO 21 BEAVER VALLEW 10/24/96 ROY BROSI 412.393.5210 643.4671 10/28/96 NO SOL HATCH x 10/24/96 KEITH CUMBIE 912.367.7781X2214 2666 10/28/96 NO-Q
- GENERAL ELEC ' 10/23/96 CLYDE NIEH 408.925.1849 2790 10/28/96 RESELL OYSTER CREEK / 10/24/96 JAY ANVARI 609.971.4801 4651 10/28/96 NO SOL
- HILLER - 10/23/96 DAVE BORClK 412.325.1200 1589 10/28/96 DIFF SOL f CLINTON / 10/24/96 STEVE LAKEBRINK 217.935.8881X3768 6014 10/28/96 DIFF SOL
. DUANE ARNOLDs MSG 10-24-96 TODD ANDERSON 319.851.7730 7364 10/28/96 DIFF APP FITZPATRICK x 10/22/96 GERRY OTTMAN 315.349.6548 342.6374 10/28/96 DIFF SOL MONTICELLO s 10/22/96 DAVE PENNINGTON 612.295.1354 1017 10/28/96 YES-Q
, NRC a MSG 10-24-96 HAL ORNSTEIN 301.415.7574 5151 10/28/96 10CFR21
---> NRC 10/24/96 BOB STRANSKY 301.816.5100 5151 10/28/96 10CFR21 LIMERICK 10/18/96 GINNY ANGUS 610.718.1200X3521 3599 10/28/96 NO-O
< PEACH 10/18/96 ED GUARINO 717.456.7014X3484 4845 10/28/96 YES-Q SUSQUEHANNA 10/18/96 JERRY MAERTZ 717.542.3019 3177 10/28/96 YES-Q J (HOPE 10/22/96 JOE ONDISH 609.339.3105 5250 10/28/96 NO-O GINNA 10/24/96 DAVE LOVGREN 716.771.3872 3903 10/28/96 NO sat ES TARGET ROCK 10/24/96 RICH MARTIN 516.293.3800X663 3714 10/28!96 NO SALES BROWNS 10/18/96 DAVID CURTHS 205.729.7955 7952 10/28/96 NO-Q VERMONT YANK 10/22/96 BOB CURRENT 802.258.5457 5544 10/28/96 YES-Q
- WYLE 10/24/96 CLAUDE THIBAULT 205.837.4411X255 721.0144 10/28/96 RESELL i
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