ML041320381

10CFR21 Reporting of Defects and Non-Compliance - Engine Systems, Inc. Report No. 10CFR21-0088, Rev. 0

ML041320381
Person / Time
Site:	Millstone, Mcguire, Cooper, Byron, River Bend, McGuire
Issue date:	04/30/2004
From:	Woolard S Engine Systems
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
10CFR21-0088, Rev 0
Download: ML041320381 (5)

Text

I XS ENGINE SYSTEMS, INC, A

1220 S. Washington St., Rocky Mount, NC 27801 P.O. Box 1928, Rocky Mount, NC 27802-1928 Telephone: 252/977-2720 Fax: 2521446-1134 April 30, 2004 U.S. Nuclear Regulator Commission Document Control Desk Mail Stop OP1 -17 Washington, DC 20555

Subject:

10CFR21 Reporting of Defects and Non-Compliance -

Engine Systems, Inc. Report No. 10CFR21-0088, Rev. 0 Woodward DRU Controls

Dear Sir:

The enclosed report addresses a reportable notification about Woodward DRU controls (manufactured between November 2000 and January 2002) - P/N 9903-365, 9903-439 and 9903-470.

A copy of the report has also been sent to the NRC.

Please sign below, acknowledging receipt of this report, and return a copy to the attention of Document Control at the address above (or, fax to number 252/446-1134) within 10 working days after receipt.

Yours very truly, ENGINE SYSTEMS, INC.

Susan Woolard Document Control Please let us know if ANY of your mailing information changes - name of recipient, name of company/facility, address, etc. Mark the changes on this acknowledgment form and send to us by mail or FAX to the number above.

RECEIVED:

(93)

DATE:

Quality Performance With Pride

'

o'

i

ENGINE SYSTEMS INC.

_1220 S. Washington St., Rocky Mount, NC 27801 P.O. Box 1928, Rocky Mount, NC 27802-1928 Telephone: 2521977-2720 Fax: 252/446-1134 Report No.

Rev. 0:

1 OCFR21 -0088 04/30/04 IOCFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT:

SYSTEM:

CONCLUSION:

Woodward DRU Controls (manufactured between Nov. 2000 & Jan. 2002)

P/N 9903-365, 9903-439 and 9903-470 Governor Controls Reportable in accordance with 1 0CFR21.

Prepared By:

/

Engineering Manager Date:

</30/of Reviewed By:

Quality Assurafce Manager Date: 4Rus-fo, 2 Quality Performance With Pride

Report No.

10CFR21-0088 Record of Revisions PAGE:

1 of 1 REV DATE PAGE DESCRIPTION

Report No.

10CFR21-0088 Revision:

0 Date:

04/30104 Page:

1 of 2 COMPONENT:

Woodward DRU Controls (manufactured between Nov. 2000 & Jan. 2002)

P/N 9903-365, 9903-439 and 9903-470 DISCUSSION:

Engine Systems Inc. (ESI) has concluded an investigation of a condition reported with a Woodward DRU control by Fairbanks Morse Engine (event number 40699).

Event 40699 states the following: "On April 21, 2004, Fairbanks Morse Engine evaluation determined a potential safety hazard exists for Woodward DRU's. The FM P/N is 12998236 and the Woodward P/N is 9903439. The defect exhibits erratic ramp up of speed and hence the inability to reach rated RPM and inability to apply load to the engine. The cause has been traced to a random contamination problem of an integrated circuit (IC) in DRU's manufactured by Woodward between November 2000 and January 2002. The rate of occurrence is less than 10 in the US and approx 20 worldwide. There are approx 38,000 Woodward units worldwide that use this IC. Only one US nuclear utility has experienced this failure and the failure occurred during testing prior to declaration of operability. In all cases, the failure occurs within a very few hours of operation. Therefore, if a DRU has been installed and has been operating for many hours/years, it is not at risk for this failure."

The following DRU's were supplied by ESI that were manufactured between November 2000 and January 2002. None of these have experienced the condition report above.

SUSPECT DRU's SUPPLIED BY ESI 24 hr DRU S/N Part Number Customer ESI S.O.

Ship date Power up performed 12382054 9903470 Korea-Yonggwang

• 102141 Dec 2002 yes 12382055 9903-470 Entergy-River Bend

• 114277 Nov 2003 no

• 11427 Nov2003 yes 12382056 9903-470 Entergy-River Bend 80843 May 2001 no 12806*114277 Nov 2003 yes 12382057 9903-470 Entergy-River Bend 80843 May 2001 no

• 1 14277 Nov 2003 yes 13149513 9903-470 Dominion-Millstone 94806 Dec 2001 no 13149514 9903-470 Dominion-Millstone 94806 Dec 2001 no 13149515 9903-470 NPPD-Cooper Nuclear

• 106919 Mar 2003 yes 13175373 9903-365 Exelon-Byron 93244 May 2002 no 13186111 9903-439 Duke-McGuire 92470 Feb 2002 no Items with an asterisk (*) had the aluminum electrolytic capacitor replaced as per ESI report 1 OCFR21-0082. Because of the replacement, the control was treated as a repair and return item and therefore a 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> bum-in was performed. As standard practice, ESI requires all repair and return Woodward controls to have a 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> burn-in test performed after repair/refurbishment.

The bum-in is not imposed for new controls.

Report No.

10CFR21-0088 Revision:

0 Date:

04/30/04 Page:

2 of 2 CONCLUSION:

The suspect DRU's that have not been placed in service could experience the random IC failure identified by Event Number 40699. Some of this DRU's have been exposed to a 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> burn-in.

ESI cannot determine if 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> is sufficient operating time to detect the failure; therefore, all customers with the suspect DRU's will be notified.

CORRECTIVE ACTION:

1.

Customers must determine if a suspect DRU is in-service.

2.

Suspect DRU's that have been operating successfully in service are not affected by this notification.

3.

Suspect controls that have not been placed in service should be returned to ESI to have the IC replaced. Contact ESI's Customer Service department with the part number and serial number of the DRU.