Protecting People and the EnvironmentUNITED STATES NUCLEAR REGULATORY COMMISSION
ACCESSION #: 9712190096
150 Lincoln Avenue
Grove City, PA 16127-1898
Tel 412 458 8000
Fax 412 458 3574
Ajax[Registered copy]
COOPER Coberra[Registered copy]
ENERGY SERVICES Cooper-Bessemer[Registered copy]
Enterprise [TradeMark]
En-Tronic [Registered copy]
Penn [TradeMark]
December 12, 1997 Superior [Registered copy]
Our Ref: QCG-10446 (K-5fa42)
Document Control Desk
U.S. Nuclear Regulatory Commission
Washington, D.C. 20555
Subject: 10 CFR 21 Notification, Enterprise DSR-4 and DSRV-4 Emergency
Diesel Generator Adjusting Screw Failure
Dear Sir:
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 manufacturing defect of the Enterprise
[Copyright] DSR-4 and DSRV-4 Emergency Diesel Generators (EDG's).
Discussion:
On September 26, 1997, Entergy Operations River Bend Station reported the
failure of an adjusting screw, Cooper Energy Services part number IA-
7840. The adjusting screw is a ball and swivel assembly utilized to
allow for angular movement between the rocker arm and intake and exhaust
valve stems of the power cylinder head. The adjusting screw is assembled
by swaging a "swivel pad" on to a "ball".
Subsequent investigation determined that the swaging process and tooling
was of a design that allowed for "overswaging" of the pad, reducing the
amount of free angular movement in the assembly. This condition
potentially caused the material of the upper edge of the swivel pad to be
over stressed. and/or limit the ability of the assembly to accommodate
the required angular movement with undue stress.
The failure of the assembly was the cracking of the swivel pad material
at the upper edge. This failure has the potential to cause an
operability concern due to the assembly separating and excess clearance
(valve lash) being established which could lead to catastrophic failure
of the valve stem or remaining ball portion of the assembly. Multiple
failures of the assembly without catastrophic failure could also reduce
engine output due to decreased valve lift. In addition, loose pieces of
the assembly could cause secondary damage in the engine.
Page 2
December 11, 1997
QCG-10446
Cooper Energy Services has supplied the 1A-7840 adjusting Screw to the
following utilities and sites:
AFFECTED UTILITIES SITE REMARKS
Entergy Operations River Bend Replaced
Duke Power Catawba
Korea Electric KORI 3 & 4
CORRECTIVE ACTION
The subject assemblies at River Bend Station have been replaced with
acceptable assemblies.
The swaging tooling has been corrected to limit the amount of "swage".
Acceptance criteria assuring the necessary freedom of the assembly has
been defined and will be verified during manufacture,
USER RECOMMENDATIONS
Utilities currently in possession of 1A-7840 assemblies are instructed to
verify that a minimum of 18 degrees of angular movement from centerline
is available in all directions, with no indication of roughness when
moving.
If you have any questions concerning this report, please contact Andrew
P. Steffan, Supervisor, Quality Engineering at 412-458-3455 or Ronald G.
Billig, Supervisor Aftermarket Engineering at 412-458-3584.
Sincerely,
COOPER CAMERON CORPORATION
R. M. Cote
Vice President and General Manager
:kll
cc: J. M. Home - CES/GC R. A. Johnston - CES/Alameda
B. C. Guntrum - CES/Alameda R. Nimmo - CES/Alameda
R. G. Billig - CES/GC L. A. Duck - CES/Alameda
A. P. Steffan - CES/GC
S. R. Johnston - CES/Alameda
S. A. Chubbuck - CES/Alameda
File: K5fa42
Page 3
December 11, 1997
QCG-10446
Copies to:
Duke Power Co.
Mr. Stephen Alexander Nuclear Generation Dept.
U.S. Nuclear Regulatory Commission P. O. Box 1006
QA Vendor Insp. & Maintenance Branch Charlotte, NC 28201-1006
One White Flint North Attn: Mgr., Nuclear Safety
Mailstop 9A1 ECO59
Washington, DC 20555
Duke Energy Corp.
Carolina Power and Light Co. OEA Manager.
Harris Nuclear Project Nuclear Assessment Division
P. O. Box 165 Mail Code EC 05P
New Hill, NC 27562 Box 1006
Attn: William Robinson Charlotte, NC 28201-1006
Vice President
Entergy
Carolina Power and Light Co. P. O. Box 429
P. O. Box 1551 Echelon One
Raleigh, NC 27602 1340 Echelon Parkway
Attn: Manager Nuclear Licensing Jackson, MS 39286-1995
Attn: F. W. Titus (Fred)
Vice President, Engineering
Carolina Power and Light Co.
Department Manager Entergy
Harris Nuclear Plant P. O. Box 756
P. O. Box 165, State Road 1134 Port Gibson, MS 39150
New Hill, NC 27562 Attn: C. R. Hutchinson (Randy)
Vice Pres., Operations-GGNS
Carolina Power and Light Co.
Robinson Nuclear Plant Entergy
SC Hwy. 151 and 23, Box 790 P. O. Box 756
Hartsville, SC 29550 Port Gibson, MS 39150
Attn: Department Manager Attn: D. L. Pace, Director
Design Engineering-GGNS
Cleveland Electric Illuminating
Perry Nuclear Power Plant Entergy
P. O. Box 97 P. O. Box 756
Perry, OH 44081 Part Gibson, MS 39150
Attn: Russell J. Tadych Attn: M. J. Meisner
Manager, Quality Control Director, NS&RA
Cleveland Electric Illuminating
Perry Nuclear Power Plant Manager, Quality Services
P. O. Box 97 Entergy Operations
Perry, OH 44081 Box 756
Attn: Harold M. Coon Port Gibson, MS 39150
Southern Nuclear Operating
Company
Cooper-Enterprise Clearinghouse Vogtle Project
Duke Engineering & Service P. O. Box 1295
230 South Tryon St. Birmingham, AL 35201
P. O. Box 1004 Attn: Mgr., Nuclear Engineering
Charlotte, NC 28201-1004 and Licensing
Attn: G. A. Harrison
Page 4
December 11, 1997
QCG-10446
Georgia Power Co.
Plant Vogtle Mr. S. H. Soong
P. O. Box 1600 Station Superintendent
Waynesboro, GA 30830 Third Nuclear Power Station
Attn: Mr. W. B. Shipman Taiwan Power Company
General Manager P.O. Box 39
Heng-Chun, Ping-Tung Hsein
Taiwan, 924 R.O.C.
Gulf States Utilities
P. O. Box 220 Mr. Koh, Kyoo-Kun
St. Francisville, LA 70775 Plant Manger, Kori 3 & 4
Attn: L. A. England Korea Electric Power Corp.
Director Nuclear Licensing 216 Ko-Ri Jangan-Up
Yangsan-Gun
Kyung-Nam, Korea 626-950
Long Island Power Authority
Corporate Quality Assurance
140 Hoffman Lane Mr. Hong, Jo Boo
Centril Islip, NY 11722 Manager, Nuclear Power
Attn: Mr. Joseph Gilliard Generation Dept.
Korea Electric Power Corp.
Operating Experience Manager 167, Samsong-Dong, Kangnam KU
Tennessee Valley Authority Seoul, 135-791 Korea
1101 Market Street, LP 4A-C
Chattanooga, TN 37402
Mr. Lee, Hee-Sung
TU Electric Company Plant Manager, Yonggwang
P. O. Box 1002 Nuclear Unit 1 * 2
Glen Rose, TX 76043 Korea Electric Power Corp.
Attn: Group Vice President - Nuclear 517, Kyema-Ri Hong Nong-Eup
Yonggwang-Gun Jeon Nam
Korea 513-880
Washington Public Power Supply
P. O. Box 460
Richland, WA 99352
Attn: Mr. L. C. Oakes
Manager, WNP-1 Engineer
T. R. Ho, Superintendent
Taiwan Power Company
Kuosheng Nuclear Power Station
60 Pa-Tou Yeh-Liu Village
Wan Li Hsiang, Taipei Hsien
(20703), Taiwan, R.O.C.
Mr. S. J. Tsuei
Director, Nuclear Safety Dept.
Taiwan Power Company
242 Roosevelt Road, Sec. 3
Taipei, Republic of China
GENERAL INFORMATION or OTHER EVENT NUMBER: 33398
LICENSEE: COOPER ENERGY SERVICES NOTIFICATION DATE: 12/12/97
CITY: GROVE CITY REGION: 1 NOTIFICATION TIME: 15:30 [ET]
COUNTY: STATE: PA EVENT DATE: 12/12/97
LICENSE#: AGREEMENT: N EVENT TIME: 15:30[EST]
DOCKET: LAST UPDATE DATE: 12/12/97
NOTIFICATIONS
PAUL FREDRICKSON RDO
NRC NOTIFIED BY: ANDREW STEFFAN JOHN PELLET (REG 4) RDO
HQ OPS OFFICER: JOHN MacKINNON VERN HODGE (RVID) NRR
EMERGENCY CLASS: NOT APPLICABLE
10 CFR SECTION:
CDEG 21.21(c)(3)(i) DEFECTS/NONCOMPLIANCE
EVENT TEXT
10 CFR 21 NOTIFICATION, ENTERPRISE DSR-4 AND DSRV-4 EMERGENCY DIESEL
GENERATOR ADJUSTING SCREW FAILURE.
ON SEPTEMBER 26, 1997, ENTERGY OPERATIONS RIVER BEND STATION
REPORTED THE
FAILURE OF AN ADJUSTING SCREW, COOPER ENERGY SERVICES PART NUMBER
1A-
7840. THE ADJUSTING SCREW IS A BALL AND SWIVEL ASSEMBLY UTILIZED TO
ALLOW FOR ANGULAR MOVEMENT BETWEEN THE ROCKER ARM AND INTAKE
AND EXHAUST
VALVE STEM OF THE POWER CYLINDER HEAD. THE ADJUSTING SCREW IS
ASSEMBLED
BY SWAGING A "SWIVEL PAD" ON TO A "BALL".
SUBSEQUENT INVESTIGATION DETERMINED THAT THE SWAGING PROCESS AND
TOOLING
WAS OF A DESIGN THAT ALLOWED FOR "OVERSWAGING" OF THE PAD,
REDUCING THE
AMOUNT OF FREE ANGULAR MOVEMENT IN THE ASSEMBLY. THIS CONDITION
POTENTIALLY CAUSED THE MATERIAL OF THE UPPER EDGE OF THE SWIVEL PAD
TO BE
OVER STRESSED, AND/OR LIMIT THE ABILITY OF THE ASSEMBLY TO
ACCOMMODATE
THE REQUIRED ANGULAR MOVEMENT WITH UNDUE STRESS.
THE FAILURE OF THE ASSEMBLY WAS THE CRACKING OF THE SWIVEL PAD
MATERIAL
AT THE UPPER EDGE. THIS FAILURE HAS THE POTENTIAL TO CAUSE AN
OPERABILITY CONCERN DUE TO THE ASSEMBLY SEPARATING AND EXCESS
CLEARANCE
(VALVE LASH) BEING ESTABLISHED WHICH COULD LEAD TO CATASTROPHIC
FAILURE
OF THE VALVE STEM OR REMAINING BALL PORTION OF THE ASSEMBLY.
MULTIPLE
FAILURES OF THE ASSEMBLY WITHOUT CATASTROPHIC FAILURE COULD ALSO
REDUCE
ENGINE OUTPUT DUE TO DECREASED VALVE LIFT. IN ADDITION, LOOSE PIECES
OF
THE ASSEMBLY COULD CAUSE SECONDARY DAMAGE IN THE ENGINE.
COOPER ENERGY SERVICES HAS SUPPLIED THE 1A-7840 ADJUSTING SCREW TO
THE
FOLLOWING SITES: RIVER BEND, CATAWBA, AND KORI 3 & 4 (KOREA ELECTRIC).
(Continued on next page)
LICENSEE: COOPER ENERGY SERVIC PAGE # 2 OF EVENT NUMBER: 33398
CORRECTIVE ACTION:
THE SUBJECT ASSEMBLIES AT RIVER BEND STATION HAVE BEEN REPLACED WIT
ACCEPTABLE ASSEMBLIES.
THE SWAGING TOOLING HAS BEEN CORRECTED TO LIMIT THE AMOUNT OF
"SWAGE".
ACCEPTANCE CRITERIA ASSURING THE NECESSARY FREEDOM OF THE
ASSEMBLY HAS
BEEN DEFINED AND WILL BE VERIFIED DURING MANUFACTURE.
USER RECOMMENDATIONS:
UTILITIES CURRENTLY IN POSSESSION OF 1A-7840 ASSEMBLIES ARE INSTRUCTED
TO
VERIFY THAT A MINIMUM OF 18 DEGREES OF ANGULAR MOVEMENT FROM
CENTERLINE
IS AVAILABLE IN ALL DIRECTIONS, WITH NO INDICATION OF ROUGHNESS WHEN
MOVING.
*** END OF DOCUMENT ***
