Protecting People and the EnvironmentUNITED STATES NUCLEAR REGULATORY COMMISSION
ACCESSION #: 9605240250
150 Lincoln Avenue
Grove City, PA 16127-1898
Tel 412 458 8000
Fax 412 458 3574
COOPER Ajax [Registered Trademark]
ENERGY SERVICES Coberra [Registered Trademark]
Cooper Bessemer [Registered Trademark]
Enterprise [Trademark]
En-Tronic [Registered Trademark]
Penn [Trademark]
Superior [Registered Trademark]
May 21, 1996
Our Ref: QCG-10272
Document Control Desk
U. S. Nuclear Regulatory Commission
Washington. D.C. 20555
Dear Sir:
In accordance with the requirements of the Nuclear Regulatory Commission
Title 10, Chapter 1, Code of Federal Regulations, Part 21, Cooper-
Bessemer Reciprocating Products, a division of Cooper Cameron
Corporation, hereby notifies the Commission of a potential manufacturing
defect of the KSV emergency diesel generator (EDG) system.
The potential defect concerns the fuel injection pump delivery valve
Holder (DVH), C-B part number 2-50F-049-143, contained in fuel injection
pumps 2-50F-049-004, 2-50F-049-005 and 2-50F-030-004 supplied by Haynes
Corporation. The defect noted has been the development of cracks
compromising the integrity of the DVH. The cracks could leak fuel
causing degraded performance and/or fire hazard.
The defect has been limited to DVH's of Lot No. LCH. 184. The cracks
have, become apparent after 160 to 250 hours of operating time. Five
failures have been reported: Niagara Mohawk (NMP2) 8/95, Arizona Public
Service (PVNGS) 2/96. Commonwealth Edison (Zion-2 DVH's) 3/96, and
Pennsylvania Power and Light (SSES) 4/96. The apparent cause of the
cracking concerns characteristics of the material near the center of the
bar from which they were made in combination with the drilled hole
surface finish. Evidence to date indicates that not all DVH's of Lot No.
LCH 184 are prone to cracking. However, there is no non-destructive
method to determine those prone to cracking.
Either of two recommended corrective actions are possible. Note that a
technical evaluation indicates that the engine would operate normally for
an extended period of time with one or more cracked DVH's, as the leakage
is insignificant in relation to the normal flow.
Page 2
May 21, 1996
OCG-10272
Recommended Corrective Action:
1] Replace all DVH's of Lot No. LCH 184. This may be accomplished as
the unit is available for normal maintenance.
2] Monitor and replace only those which develop leaks.
See attached Exhibit 1 for affected part numbers/serial numbers,
utilities and sites.
In addition, preliminary information has indicated that DVH lot 304 may
also be prone to cracking for the same reasons. Although none have
cracked to date, continued monitoring and observation is recommended.
If you have questions concerning this report, please contact Andrew P.
Steffan, Supervisor, Quality Engineering at 412-458-3455 or John M.
Horne, Manager, Nuclear and Analytical Engineering at 412-458-3543.
Sincerely,
COOPER CAMERON CORPORATION
J. D. Mowery
Vice President and General Manager
Attachment
/kll
cc: D. T. Blizzard - CES/GC
J. M Horne - CES/GC
A. D. Gillette - CES/GC
M. A. Schleigh - CES/GC
P. J. Shimek- CES/GC
L. T. Stewart - CES/GC
A. P. Steffan - CES/GC
File: K5fa37
Page 3
May 21, 1996
QCG-10272
Copies to:
Mr. Walter Haass Mr. Terry O'Brien
U. S. Nuclear Regulatory Commonwealth Edison Co.
Commission 1400 Opus Place
One White Flint North Downers Grove, IL 60515
Washington, DC 20555
Mr. Lenny Schiavone
Niagara Mohawk Power Corp.
Mr. Gary Hunt 301 Plainfield Road
Houston Lighting and Power North Syracuse, NY 13212
South Texas Project
Wadsworth, TX 774-93 Ms. Kathleen Russo
Niagara Mohawk Power Corp.
Mr. James Kenny Nine Mile Road - Unit 2
Licensing Group Supervisor P. O. Box 63
Pennsylvania Power and Light Lycoming, NY 13093
Two North Ninth Street Annex 6 1
Allentown, PA 18101 Mr. Neil Thibodaux
Arizona Public Service
Mr. Matthew Heidorn Palo Verde Nuclear Generating Station
Pennsylvania Power and Light P. O. Box 52034 Mail Station 7566
Susquehanna Steam Electric Station Phoeniz, AZ 85072-2034
P. O. Box 467
Berwick, PA 18603 Mr. Thomas Bradish
Manager, Nuclear Regulatory Affairs
Mr. Terence Bannon Arizona Public Service
Licensing Group ALPHA 6 1 P. O. Box 52034 Mail Station 7636
Pennsylvania Power and Light Phoeniz, AZ 85072-2034
2 North Ninth Street
Allentown, PA 18101 Mr. Terry Vandevoort
Commonwealth Edison
Mr. David Baran Zion Generating Station
Commonwealth Edison Co. 101 Shiloh Blvd.
Byron Nuclear Power Station Zion, IL 60099
4450 North German Church Rd.
Byron, IL 61010 Mr. Arthur G. Killinger
MPR Associates, Inc.
Mr. Michael Kneble 320 King Street
EnTergy Associates Alexandria, VA 22314-3238
Louisiana Power and Light
Waterford 3 SES
Highway 18
Taft, LA 70006
Mr. Dave Gustafson
Commonwealth Edison Co.
Braidwood Nuclear Power Station
Tech Staff Electrical Group
Route 1, Box 84
Braceville, IL 60407
Mr. Doug Mullen
Nebraska Public Power District
Cooper Nuclear Station
P. O. Box 98
Brownville, Nebraska 68321
QCG-10272 EXHIBIT Page 1 of 4
May 21, 1996
Part No. 2-50F-049-143
C-B S/N Qty Utility/Site
1C45 4 Pennsylvania Power and Light-SSES
YY36 64 Niagara Mohawk-NMP2
*1E54 24 Commonwealth Edison - Braidwood
**1C45 50 Pennsylvania Power and Light- SSES
**1C45 100 Arizona Public Service-PVNGS
*Lot S/N 1E54 contains 15 of 24 Lot LCH 184.
**Lot S/N 1C45 contains 49 of 150 Lot LCH 184.
Part No. 2-50F-030-004
Pump S/N Utility/Site
114831 Pennsylvania Power and Light- SSES
117951
122475 Niagara Mohawk - NMP2
120058
120060
122473
117926 Pennsylvania Power and Light- SSES
117959
QCG-10272 EXHIBIT Page 2 of 4
May 21, 1996
Part No. 2-50F-049-004
Pump Serial No. Utility/Site
891232 Commonwealth Edison - Byron
891213 Niagara Mohawk-NMP2
891229
891230
9003038
9003045
9003047
9003049
8902050
87010010 Commonwealth Edison - Byron
891204
118909
891220
891224
891222
891211
891205
118574
891240
891247
118923
9006002
120082
87010004
891219
891242
891250
891241
891218
119030
118902 Arizona Public Service -PVNGS
118954
119089
119107
119802
118927
119074
119091
119796
122529
QCG-10272 EXHIBIT Page 3 of 4
May 21, 1996
Part No. 2-50F-049-004
Pump Serial No. Utility/site
122495 Commonwealth Edison - Zion
114863
87110002
87110010
87110008
87110018
114291
115853
87110003
87110006
8902043
87110016
87110005
114311
87110017
114309
87110001
122491
87110004
87110012
119025 Commonwealth Edison - Byron
120072 Commonwealth Edison - Byron
120131
120084
122492
9003019 Commonwealth Edison Braidwood
8902024
9003013
8902014
8902010
8902021
9003012
QCG-10272 EXHIBIT Page 4 of 4
May 21, 1996
Part No. 2-50F-049-004
Pump Serial No. Utility/Site
117947 Arizona Public Service - PVNGS
9012014
9012016
9012018
9012019
9012060
9109014
9103022
9109013
9109022
9109003
9109021
9102005
9109028
9012043
9003003
9003037
9012004
9012007
9012020
9012037
9103017
9103021
9103018
9109029
9109027
9109017
9109020
9109019
9012039
9012009
9012011
9012012
9012013
9012023
9012041
9103019
9103023
9103020
9103025
9109022
9109031
9103016
9109024
GENERAL INFORMATION or OTHER EVENT NUMBER: 30520
LICENSEE: COOPER ENERGY SERVICES NOTIFICATION DATE: 05/22/96
CITY: GROVE CITY REGION: 1 NOTIFICATION TIME: 09:24 [ET]
COUNTY: STATE: PA EVENT DATE: 05/22/96
LICENSE#: AGREEMENT: N EVENT TIME: 00:00[EDT]
DOCKET: LAST UPDATE DATE: 05/22/96
NOTIFICATIONS
NRC NOTIFIED BY: JOHN D. MOWREY VERN HODGE, NRR/PCEB NRR
HQ OPS OFFICER: LEIGH TROCINE
EMERGENCY CLASS: NOT APPLICABLE
10 CFR SECTION:
CDEF 21.21 (b) (2) DEFECTS/NONCOMPLIANCE
EVENT TEXT
POTENTIAL (10 CFR PART 21) MANUFACTURING DEFECT OF THE KSV
EMERGENCY
DIESEL GENERATOR (EDG) SYSTEM REPORTED BY COOPER ENERGY SERVICES.
THE DEFECT CONCERNS THE FUEL INJECTION PUMP DELIVERY VALVE HOLDER
(DVH)
C-B PART NUMBER 2-50F-049-143, CONTAINED IN FUEL INJECTION PUMPS 2-50F-
049-004, 2-50F-049-005, AND 2-50F-030-004 SUPPLIED BY HAYNES CORPORATION.
THE DEFECT NOTED HAS BEEN THE DEVELOPMENT OF CRACKS COMPROMISING
THE
INTEGRITY OF THE DVH. THE CRACKS COULD LEAK FUEL CAUSING DEGRADED
PERFORMANCE AND/OR FIRE HAZARD. THE DEFECT HAS BEEN LIMITED TO DVHs
WITH
LOT NUMBER LCH-184, AND THE CRACKS BECOME APPARENT AFTER 160 TO 250
HOURS
OF OPERATING TIME. THE APPARENT CAUSE OF THE CRACKING CONCERNS
CHARACTERISTICS OF THE MATERIAL NEAR THE CENTER OF THE BAR FROM
WHICH
THEY WERE MADE IN COMBINATION WITH THE DRILL HOLE SURFACE FINISH.
EVIDENCE TO DATE INDICATES THAT NOT ALL DVHs OF LOT NUMBER LCH-184
ARE
PRONE TO CRACKING. HOWEVER, THERE IS NO NON-DESTRUCTIVE METHOD TO
DETERMINE THOSE PRONE TO CRACKING. A TECHNICAL EVALUATION
INDICATES THAT
THE ENGINE WOULD OPERATE NORMALLY FOR AN EXTENDED PERIOD OF TIME
WITH ONE
OR MORE CRACKED DVHs AS THE LEAKAGE IS INSIGNIFICANT IN RELATION TO
THE
NORMAL FLOW. THE FOLLOWING FAILURES HAVE BEEN REPORTED TO COOPER
ENERGY
SERVICES: NINE MILE POINT 2 (AUGUST 1995), PALO VERDE (FEBRUARY 1996),
ZION 2 (MARCH 1996), AND SUSQUEHANNA (APRIL 1996). THE ATTACHMENT TO
THIS 10 CFR PART 21 NOTIFICATION LISTED AFFECTED PART NUMBERS/SERIAL
NUMBERS FOR THE FOLLOWING SITES: BRAIDWOOD, BYRON, NINE MILE POINT 2,
PALO VERDE, SUSQUEHANNA, AND ZION.
IN ADDITION, PRELIMINARY INFORMATION HAS INDICATED THAT DVH LOT
NUMBER
304 MAY ALSO BE PRONE TO CRACKING. ALTHOUGH NONE HAVE CRACKED TO
DATE,
COOPER ENERGY SERVICES IS RECOMMENDING CONTINUED MONITORING AND
OBSERVATION.
COOPER
ENERGY SERVICES
Quality Assurance Dept.
150 Lincoln Avenue
Grove City, PA 16127
PH: (412) 458-8000 FAX: (412) 458-3563
PH: (412) 458-8000
FACSIMILE TRANSMITTAL
TO: FAX #:
COMPANY:
FROM: TOTAL NUMBER OF PAGES SENT:
DATE: TIME:
REMARKS:
If you do not receive all of the pages, please contact us
as soon as possible at (412) 458-3575
*** END OF DOCUMENT ***
