ML11103A017

Submittal of Revision 1 to Notification of Potential Part 21 Reporting of Defects and Non-Compliance - Engine Systems, Inc. Report No. 10CFR21-0100

ML11103A017
Person / Time
Site:	Grand Gulf
Issue date:	04/05/2011
From:	Woolard S Engine Systems
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
10CFR21-0100, Rev 1
Download: ML11103A017 (7)

Text

I EE ES NGINE SYSTEMS, INC.

175 Freight Road Telephone: 252/977-2720 Rocky Mount, NC 27804 Fax: 252/446-1134 April 5, 2011 U.S. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555-0001

Subject:

10CFR21 Reporting of Defects and Non-Compliance -

Engine Systems, Inc. Report No. 10CFR21-0100, Rev. 1 EMD Water Pump, P/N 8324589

Dear Sir:

The enclosed report addresses a revision to reportable notification for an EMD water pump, P/N 8324589. The report has been revised to address the safety hazard which is created or could be created by this defect.

A copy of the report has been mailed to all users with safety related EMD Diesel engines.

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.

e40-Susan Woolard 4e'4741 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

I-A ENGINE SYSTEMS, INC.

175 Freight Road, Rocky Mount, NC 27804 Telephone: 2521977-2720 Fax: 252/446-1134 Report No. 10CFR21-0100 Rev. 0: 04/26/10 Rev. 1: 03/30/11 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: EMD water pumps SYSTEM: EMD Emergency Diesel Generator - jacket water system CONCLUSION: Reportable in accordance with 10CFR21.

Prepared By: Date: 3/.3 0/11

, Engineering Manager Reviewed By: Date: 3 "_ /__ -

Quality Assurance Manager Quality Performance With Pride

Report No. 10CFR21 -0100 Record of Revisions Page: 1 of 1 REV DATE IPAGE I DESCRIPTION 0 04/26/10 Initial issue.

1 03/30/11 1 Under Summary, 2 nd paragraph, added the last 2 sentences to address the safety hazard which is created or could be created by this defect.

Report No. 10CFR21-0100 Revision: 1 Date: 03/30/11 Page: 1 of 4 COMPONENT:

EMD water pump P/N 8324589

SUMMARY

Engine Systems Inc. (ESI) began a 10CFR21 evaluation on 03/23/10 following a corrective action request from Entergy - Grand Gulf. The request was written as the result of Grand Gulf having an EMD jacket water pump (P/N 8324589, S/N 96M1464V) with an incorrect impeller.

Specifically, the impeller installed in the pump was for rotation opposite of the pump housing. ESI supplied the jacket water pump to Grand Gulf in January 1997. ESI does not know if the pump has been in storage since that time or if any rework activities have been performed on the pump.

The evaluation was concluded on 04/26/10 and was determined to be a reportable defect as defined by 10CFR21. Installation of the incorrect impeller would result in considerable loss of engine cooling water flow. This would cause elevated engine cooling water temperature that could impact engine performance and/or load carrying capability with the possibility of eventual engine failure, thereby preventing the emergency diesel generator from performing its safety related function.

DISCUSSION:

EMD diesel engines utilized for emergency diesel generator sets use two engine jacket water centrifugal pumps (one for each bank) to circulate fluid throughout the engine for cooling. Each pump is mounted on the front of the engine and rotates in the opposite direction of the engine crankshaft. For single engine generator set applications (i.e. left hand rotation engine, viewed from the rear of the engine), the pumps used on each bank contain identical components; the only difference is the position of the impeller housing in relation to the pump shaft housing. When viewed from the front of the engine, these water pumps rotate counterclockwise (see Figure 1 below).

For tandem generator set applications, one engine is left hand rotation and the other is right hand rotation. For each engine, the pumps used on each bank contain identical components and the only difference is the position of the impeller housing in relation to the pump shaft housing.

However, for a right hand rotation engine the water pumps rotate clockwise when viewed from the front of the engine (see Figure 2 below).

)" .i* b*.-'- ;t, Z -

Right Bank Left Bank Right Bank Left Bank Figure 1 Figure 2 Water Pumps for LH Rotation Engine Water Pumps for RH Rotation Engine

Report No. 10CFR21 -0100 Revision: 1 Date: 03/30/11 Page: 2 of 4 It was reported by Grand Gulf that "while troubleshooting low Div III DJ jacket water pressure it was discovered that the wrong impeller was supplied in the P81C007A pump. The supplied impeller was intended to rotate in the opposite direction as the pump rotation. This appears to be the cause of low jacket water pressure in the A engine."

Subsequently, the water pump was returned to ESI for further inspection. It was apparent from a visual inspection that the incorrect impeller was installed for this pump. P/N 8324589 corresponds to a right hand rotation, left bank water pump for use on a 12-cylinder EMD 645E4 or E4B engine.

As shown in Photos 1 and 2 below, the housing corresponds to a right hand rotation pump, but the impeller is for left hand rotation. Figure 3 shows the correct impeller for a right hand rotation pump.

coew 0112TATI IMPELLER R.H. ROTATION Photo 1: Water Pump Returned by Customer ROTATIO:

(note impeller fin orientation)

..-..-- a Figure 3: Correct Housing and Fin Orientation for RH Rotation Photo 2: Close-up of Water Pump (note impeller fin orientation)

Report No. 10CFR21 -0100 Revision: 1 Date: 03/30/11 Page: 3 of 4 EVALUATION OF PREVIOUS SHIPMENTS:

A review has been performed to evaluate the impact on past supply of EMD water pumps.

Historically, ESI has supplied a quantity of over 280 water pumps under 17 different EMD part numbers dating back to 1988. The pump returned by the customer was supplied in January 1997.

After reviewing the history of dedication activities performed on the water pumps it was found that dedication reports for EMD water pumps have always contained an inspection requirement to verify the correct operational rotation; however reports written prior to 2000 did not include a clear visual depiction of what the correct operational rotation is. It appears that this was an isolated incident where the inspector made an error when performing the inspection. Since April 2000, all EMD water pumps shipped were inspected to a dedication report that included a clear visual depiction of proper impeller geometry. This one incident is the only known instance of an EMD water pump with the incorrect impeller.

As noted above, ESI supplied this water pump in 1997. Since that time ESI is unaware if any rework or refurbishment activities have been performed on the pump but it was noted that paint had chipped off the heads of the capscrews, indicating that the screws had been removed at some time. There exists a possibility that the pump impeller may have been previously removed.

AFFECTED USERS:

Based on the above review of previous EMD water pump shipments, it appears that this was an isolated incident. However, there exists the potential that an incorrect impeller was installed in an EMD water pump supplied by ESI prior to April 2000. Therefore, this notification is applicable to all users with safety related EMD diesel engines.

CORRECTIVE ACTION:

ESI recommends that as a precaution, all customers with an EMD water pump in stock which was supplied by ESI prior to April 2000 should perform a visual inspection to ensure the correct impeller is installed. A pump which has been installed on the diesel engine is considered acceptable based on successful operation of the diesel engine. The impeller inspection is easily performed, without disassembly, by looking into the inlet port of the pump to confirm the orientation of the impeller matches the pump housing. A listing of the various part numbers supplied prior to April 2000 is included in Table 1. Figures 4 and 5 contain visual guidance to ensure the impeller corresponds to the installed pump housing.

Report No. 10CFR21 -0100 Revision: 1 Date: 03/30/11 Page: 4 of 4 Part Number Rotation Bank Type of Engine 40004235 LH RIGHT 16 & 20-645E4 & E4B 40004234 LH LEFT 16 & 20-645E4 & E4B 8347607 LH LEFT 16 & 20-645E4 & E4B 8364236 RH RIGHT 16 & 20-645E4 & E4B 8364237 RH LEFT 16 & 20-645E4 & E4B 8269664 LH RIGHT 12-645E4 & E4B 9336390 LH LEFT 12-645E4 & E4B 8269638 LH LEFT 12-645E4 & E4B 8324588 RH RIGHT 12-645E4 & E4B 8324589 RH LEFT 12-645E4 & E4B Table 1: Listing of Water Pump P/Ns Supplied Prior to April 2000 cew. IN

-ROTATIO IMP LER R.H. OTATION PUMP HSNG. R .H.. ROTATION Figure 4: Correct Housing and Fin Figure 5: Correct Housing and Fin Orientation for LH Rotation Orientation for RH Rotation