ML081130777
| ML081130777 | |
| Person / Time | |
|---|---|
| Site: | McGuire, Mcguire  |
| Issue date: | 04/15/2008 |
| From: | Woolard S Engine Systems |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| Download: ML081130777 (6) | |
Text
ENGINE SYSTEMS, INC.
175 Freight Road*
Rocky Mount, NC ý27804
- Telephdne: 252/977-2720 Fax: 252/446-1134 April 15, 2008 U.S. Nuclear Regulatory Commission Document Control Desk Mail Stop 03H8 Washington, DC 20555
Subject:
10CFR21 Reporting of Defects and Non-Compliance -
Engine Systems, Inc: Report No. 10CFR21-0094, Rev. 0 Plunger and Barrel Assembly, Fuel Injection Pump.
Haynes P/N 9041367
Dear*Sir:
The enclosed, report addresses a reportable notification for plunger and barrel.
assemblies used in the diesel engine fuel injection pump.
A copy of the report has also been sent to our only affected user, Duke Energy -
McGuire Nuclear Plant.
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
.ENGINE SYSTEMS, INC.'
175 Freight Road, Rocky Mount, NC 27804 Telephone: 252/977-2720 Fax: 252/446-1134 Report No.
Rev. 0:
1 OCFR21-0094 04/15/08 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT:
SYSTEM:
CONCLUSION:
Plunger and barrel assembly, fuel injector pump Haynes P/N 9041367 Emergency Diesel Generator - fuel system Reportable in accordance with 1 OCFR2 1.
Prepared By:
Reviewed By:
Engineeri anager Date:
Date:
- Quality Assurance Manager Quality Performance With Pride
Report No.
10CFR21-0094 Record of Revisions Page:
1 of 1 REV]
DATE I PAGE DESCRIPTION 0
04/15/08 Initial issue.
Report No.
10CFR21-0094 Revision:
0 Date:
04/15/08 Page:
1 of 3 COMPONENT:
Plunger and barrel assembly, fuel injector pump: Haynes part number 9041367 DISCUSSION:
Engine Systems Inc. (ESI) began a 10CFR21 evaluation on 3/14/08 after receiving a recall notification from Haynes Corporation.
The notification advised ESI that part number 9041367 plunger and barrel assemblies supplied in December 2007 did not meet functional requirements and should be returned. The evaluation was concluded on 4/14/08 and determined this issue to be a reportable defect as defined by 1 OCFR21.
The pump barrels (Haynes P/N 9041375) were manufactured with only 2 drilled ports instead of 3 drilled ports as required by the final configuration print for this part number barrel. The notification also states that use of the supplied barrels in a fuel injector pump would result in the pump not passing functional calibration requirements.
iNLer-PORTC SPILL This PCORT a
Figure 1: Typical pump barrel (see references on page 3)
Haynes supplied 62 of the. recalled plunger and barrel assemblies to purchase orders as identified in Table 1 below.
ESI on two (2) separate ESI Barrel Barrel Received P.O. No.
Haynes P/N material lot heat lot quantity.
ESI receipt date 79959 9041367 LCH 1057 HLO 455 37 Dec. 27, 2007 78521 9041367 LCH 1057 HLO 455 25 Jan. 02, 2008 Table 1: Recalled plunger& barrel assy's received from Haynes
Report No.
10CFR21-0094 Revision:
0 Date:
04/15/08 Page:
2 of 3 FUNCTION:
(see references on page 3)
The plunger and. barrel assembly is a sub-component of the Haynes (Bendix) type FDX fuel injector pump utilized on diesel engines by various manufacturers (Enterprise, CES, Worthington, Nordberg).
Fuel injection is accomplished by the barrel's inlet and spill ports working in conjunction with a helix (passage) in the plunger. Basic theory of operation is as follows: With the plunger at its lowest position, fuel enters the barrel from the pump inlet chamber through the inlet ports (INTAKE). The fuel in the chamber also enters the plunger helix which extends to the top of the plunger. As the plunger rises, it eventually covers the barrel inlet ports and the area within the barrel bore above the plunger becomes a pressure chamber. Pressure continues to rise as the plunger continues upward. High pressure fuel is forced through the pump delivery valve to the fuel injector (INJECTION). Fuel injection continues until the plunger rises high enough for the helix to reach the spill port. When this occurs, the high pressure fuel in the barrel chamber is released (spills) into the inlet chamber via the plunger helix; fuel pressure drops and injection stops (END OF INJECTION).
FUEL INJECTOR FUEL INJECTOR PUMP FUEL INJECTOR FUEL INJECTOR PUMP Figure 2: Typical plunger & barrel application (see references on page 3)
Report No.
1 0CFR21-0094 Revision:
0 Date:
04/15/08 Page:
3 of 3 AFFECTED USERS:
Shipments of part number 9041367 plunger and barrel assemblies affected by this notification are shown in Table 2 below.
Haynes P/N Ship ESI ship date S.O. No.
P.O. No.
P.O. No.
Hys.
3003324 Duke - McGuire 00089732.
79959 9041367 36 Feb. 26, 2008 3002554 Duke - McGuire 00085589 78521 9041367 24 Jan. 15, 2008 Table 2: Recalled. plunger & barrel assy's shipped to customers' CORRECTIVE ACTION:
The customer has returned all 36 assemblies from order 3003324 to ESI. 23 assemblies have also been returned to ESI from order 3002554 (the remaining assembly was utilized by the customer for material testing).
CONCLUSION:
The fuel pump plunger and barrel assembly recall is limited to assemblies with barrels having both material lot LCH 1057 and heat lot HLO 455. ESI shipped 60 assemblies from this lot to Duke -
McGuire Nuclear Plant on ESI sales orders 3002554 & 3003324 (the remaining 2 assemblies were ESI material test specimens). The machining error was discovered prior to installation of any of the assemblies in fuel injector pumps. Had any been installed, the corresponding fuel injection pumps would not have operated properly. This would have resulted in inoperability of the installed EDG during site post-maintenance testing.
REFERENCES:
The functional'description, Figure 1 and, Figure 2 were obtained from: Installation, Maintenance and Overhaul Instructions for Diesel Fuel Injection FDX Series Flange Type Pumps, Form L-549, The Bendix Corporation, printed March 1967,