ML083030141
| ML083030141 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley, Millstone, Davis Besse, Surry, Clinton, Quad Cities  |
| Issue date: | 10/21/2008 |
| From: | Woolard S Engine Systems |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| 10CFR21-0095, Rev 0 | |
| Download: ML083030141 (7) | |
Text
ENGINE SYSTEMS, INC.
175 Freight Road Rocky Mount, NC 27804 Telephone: 252/977-2720 Fax: 252/446-1134 October 21, 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. 10CFR21-0095, Rev. 0 Ingersoll-Rand Series 89 Air Start Motors, P/N 8367694-ESI
Dear Sir:
The enclosed report addresses a reportable notification for Ingersoll-Rand series 89 air start motors, P/N 8367694-ESI.
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
ENGINE SYSTEMS, INC.
175 Freight Road, Rocky Mount, NC 27804 Telephone: 252/977-2720 Fax: 252/446-1134
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Report No.
Rev. 0:
1 OCFR21-0095 10/20/08 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT:
SYSTEM:
CONCLUSION:
Ingersoll-Rand series 89 air start motors P/N 8367694-ESI Emergency Diesel Generator - air starting system Reportable in accordance with 10CFR21.
Prepared By:
Reviewed By:
Engineering Manager Quality Assurance Manager Date:
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Date:
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Quality Performance With Pride
Report No.
10CFR21-0095 Record of Revisions Page:
1 of 1 REV DATE PAGE DESCRIPTION 0
10/20/08 Initial issue.
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Report No.
10CFR21-0095 Revision:
0 Date:
10/20/08 Page:
1 of 4 COMPONENT:
Diesel engine air start motor, part number 8367694-ESI (Ingersoll-Rand series 89)
DISCUSSION:
Engine Systems Inc. (ESI) began a 10CFR21 deviation evaluation on 9/10/08 after inspection of two (2) engine air starting motors (part number 8367694-ESI), returned from Nuclenor, revealed that the starters were incorrectly assembled.
This evaluation was completed on 10/20/08.
Nuclenor reported that the two (2) new air starters did not port air properly at the pinion engagement port. The motors were never installed on the engine and were being bench tested when the operability issue was observed.
Both motors were returned to ESI for warranty evaluation.
ESI inspection determined that Ingersoll-Rand used the wrong pinion engagement piston during assembly of the air motors. A new style piston with an elastomer seal ring (used in I-R's series 88 air starters) was incorrectly installed in the drive housing instead of the required piston with a metallic seal ring (required for the series 89 motor).
Series 88 Drive Pinion Series 89 Drive Pinion INCORRECT CORRECT
Report No.
Revision:
Date:
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1 OCFR21-0095 0
10/20/08 2 of 4 Pinion air inlet t
Pinion airoue Piston]
AIR START MOTOR CROSS-SECTION Installation of the elastomer seal and piston within the series 89 starter could impact starting reliability of the diesel engine for the following reasons:
(1) the elastomer seal is located further away from the drive gear on the piston; this requires increased travel of the piston to port air from the pinion outlet port. During abutment of the starter drive gear with the engine ring gear, air will not port from the starter to activate the main air start valve and thus engine cranking will not occur.
(2) the elastomer seal can be cut by the pinion outlet port hole in the starter drive housing after a number of starter engagements. This could cause binding of the piston within the drive housing and or excessive air leakage past the seal. Both conditions could increase the time required for the pinion to engage with the engine flywheel and thus compromise the fast start capability of the engine.
ESI and Ingersoll-Rand (the starter manufacturer) have identified 20 air motors that were incorrectly assembled. These are identified as serial numbers SP071011063 thru SP080516043 having a date range of Oct. 11, 2007 thru May 16, 2008. I-R determined the root cause to be linked to one assembly technician that was pulling material from memory instead of using the part number specific pick list. Starter serial numbers include the year, month and day of manufacture.
Serial number breakdown is as follows:
S/N SP080516039:
SP 08 location*
year 05 month 16 day 039 sequencial number
- SP: Southern Pines, NC plant
Report No.
10CFR21-0095 Revision:
0 Date:
10/20/08 Page:
3 of 4 During evaluation of this issue, ESI contacted all customers that were shipped the incorrectly assembled starters.
All starters have been inspected by ESI and confirmed that they were incorrectly assembled with pistons containing elastomer seals instead of the required metallic seals. None of the starters had been installed on the diesel engines and therefore they remained in customer inventory.
The last lot of starters supplied prior to the starters from Oct. 11, 2007 (071011) was assembled on June 18, 2007 (070618). ESI had two starters from the 070618 lot in inventory; these have been inspected and confirmed to be assembled correctly. Two other starters from a lot assembled on Jan. 22, 2007 were also inspected and confirmed to be assembled correctly. Based on this sampling of starters, it appears the assembly problem began with the Oct. 11, 2007 starters.
AFFECTED USERS:
A listing of nuclear safety related air start is shown below.
motors shipped with incorrectly assembled pinion pistons ESI S.O.
ESI C-of-C Date Customer Customer P.O.
Starter P/N Starter SIN ESI P.O.
SP080516039 3004530 5/29/2008 Davis-Besse 55108276 8367694-ESI SP080516040 81229 SP080516041 S P080516042 SP080211016 83786 3004427 6/05/2008 Millstone 45586442 8367694-ESI SP080211023 SP080516043 81229 SP080513004 SP080513005 85566 3004342 5/22/2008 Surry 45578190 8367694-ESI SP080513007 SP080516038 81229 SP080211021 83786 3004322 5/22/2008 Nuclenor N2008/027 8367694-ESI SP080511021 8376
_______SP080513006 85566 SP080211017 3004033 2/19/2008 Beaver Valley 45253894 8367694-ESI SP080211018 83786 SP080211019 SP080211020 3003748 11/20/07 Quad Cities 703; rel. 11581 8367694-ESI 82126 SP071011064 3003561 3/06/08 Clinton 703: rel. 11553 8367694-ESI SP080211022 83786 CORRECTIVE ACTION:
- 1.
ESI has contacted all affected customers that were shipped the incorrectly assembled starters. All starters have been returned to ESI.
- 2.
ESI has added verification of correct pinion piston and seal assembly to the critical characteristic inspection activity for future starter shipments.
- 3.
If desired, users can inspect other starters in their inventory to verify correct assembly of the pinion piston and seal. An inspection procedure is provided on the following page.
Report No.
Revision:
Date:
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1 0CFR21-0095 0
10/20/08 4 of 4 INSPECTION PROCEDURE (OPTIONAL):
The pinion piston can be viewed through the pinion air outlet port to determine proper configuration. Refer to photos below.
Grooves in piston Pinion gear Piinotet port INCORRECT Smooth piston I
Pinion gear CORRECT