ML17019A351

Submittal of 10CFR21 Reporting of Defects and Non-Compliance Rev. 0, Emo Fuel Injector

ML17019A351
Person / Time
Site:	Arkansas Nuclear
Issue date:	01/10/2017
From:	Woolard S Engine Systems
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML17019A351 (5)

Text

ENGINE SYSTEMS, INC.

175 Freight Road Telephone: 252/977-2720 Rocky Mount, NC 27804 Fax: 252/446-1134 January-10, 2017 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. 10CFR21-0115, Rev. 0 EMO Fuel Injector P/N 40084 720

Dear Sir:

The enclosed report addresses a reportable notification on an EMO fuel injector, P/N 40084720, for Entergy Operations, Inc. -Arkansas Nuclear One.

A copy of the report has been mailed to our affected nuclear customer.

• 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. 10CFR21-0115 Rev. 0: 01/06/17 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: EMD Fuel Injector P/N 40084720 SYSTEM: Emergency Diesel Generator CONCLUSION: Reportable in Accordance With 10CFR21 Prepared By:--~=+-____;_-=~-'---------- Date: --'-'-JI 7.._____

..;:_;{p/'-'--J

() Engineering Manager Reviewed By: -~~~=:.=.==---...i:;Jk-==-,#-'JA~#'-------

Quality Assurance Manager Date: ____.f'--.....liJ~-.....1.L'--7'----

Quality Performance With Pride

Report No. 1 OCFR21-0115 Record of Revisions Page: 1 of 1 REV DATE PAGE DESCRIPTION 0 01/06/17 Initial issue.

Report No. 10CFR21-0115 Revision: 0 Date: 01/06/17 Page: 1 of 2 Component:

EMO Fuel Injector, P/N 40084720.

Summary:

Engine Systems Inc. (ESI) began a 10CFR21 evaluation on November 12, 2016 following the seizure of a fuel injector at Entergy Operations Inc. - Arkansas Nuclear One (ANO). ANO had completed installation of new fuel injectors on both of their EMO emergency diesel generator sets. During post-maintenance surveillance testing

• the fuel injector installed in the #7 cylinder of unit K4A seized (injector S/N 16C2 3186). During an attempt to shut down the unit, operators were unable to reduce the engine's load because of the seized injector/fuel rack.

The seized fuel injector was then returned to ESI for failure analysis where it was received on November 161h.

The failure investigation determined that foreign material within the injector was the cause of the seizure. The

• report (8002768-FA) was completed on December 8, 2016 and submitted to the customer for review.

Impact on Operability:

A seized fuel injector would affect the load carrying capability of the diesel engine. Due to the fuel rack configuration utilized by ANO, an injector seizure also prohibits control of diesel engine. Many utilities use spring loaded injector linkages which allow the engine to continue to operate in the event of a frozen injector rack. In those cases, the remaining injectors are controlled by the engine's governor and credit may be taken that sufficient output is available from the remaining cylinders to carry the safety-related load. In the case of ANO, their emergency diesel generator set contains a solid injector linkage design. Seizure of one fuel injector locks the common fuel layshaft and prevents it from rotating thereby preventing the engine's governor from controlling fuel delivered to the engine. Operation in this condition would prevent the emergency diesel generator from adequately controlling and/or carrying its design safety related loads.

Root cause evaluation:

The root cause of the failure was determined to be foreign material which likely entered the fuel injector during manufacture/assembly. Once the injector was installed on the engine, it was during engine surveillance (run) testing that this foreign* material migrated into the plunger and bushing assembly. This decreased the running clearance between the components which ultimately lead to seizure.

Evaluation of previous shipments:

The date code imbedded within the serial number (16C) indicates the injector was manufactured in March 2016.

The only customer to whom ESI has supplied injectors with date code "16C" is ANO. A total qty 34 injectors were supplied in May 2016 of which qty 32 have a 16C date code (the other two were 15G). To date, only the one injector with serial number 16C2 3186 has failed. Given the amount of run time accumulated on the installed injectors during surveillance testing, any other injectors which may have contained foreign material would be expected to result in a similar seizure. Furthermore, aside from the qty 32 injectors supplied to ANO, ESI has qty 51 injectors in stock with the same 16C date code. All of the injectors were inspected by removing the supply and return filter elements and visually examining the filters and the cavity directly beneath the filters. For all 51 injectors, no evidence of foreign material was found. Therefore, based on the review performed by ESI this issue is determined to be an isolated incident. It is the position of ESI that:

• At most, this issue applies to injectors of date code 16C. The next closest date code injectors supplied by ESI are 15G (July 2015) and 16H (August 2016). Given these are five or more months apart from date code 16C (March 2016), they are considered sufficiently independent from this issue.

• For injectors with date code 16C that have been installed on an engine and have accumulated an appreciable amount of run time (meaning the engine was brought up to rated load and fluid temperatures/pressures have stabilized), then the injector is not susceptible to seizure from this type of foreign material.

• For all remaining injectors from date code 16C that have not been successfully installed on an engine, they are considered suspect and should be returned to ESL

Report No. 10CFR21-0115 Revision: 0 Date: 01/06/17 Page: 2 of 2 Affected Customers:

Entergy Operations Inc.- Arkansas Nuclear One is the only customer to whom ESI has supplied suspect fuel injectors. A listing of the serial numbers is provided in the table below:

ESI Sales Customer Part ESI C-of-C Customer* Qty Serial Numbers Order P.O. Number Date 16C2 3148 16C2 3192 16C2 3154 16C2 3193 16C23157 16C2 3194 16C2 3158 16C2 3196 16C2 3160 16C2 3197 16C2 3162 16C2 3200 16C2 3168 16C2 3202 Arkansas 16C2 3172 16C2 3203 3015200 10470233 40084720 32 05/16/16 Nuclear One 16C2 3183 16C2 3204 16C2 3184 16C2 3205 16C2 3186 16C2 3207 16C2 3187 16C2 3209 16C2 3188 16C2 3210 16C2 3189 16C2 3211 16C2 3190 16C2 3214 16C2 3191 16C2 3233 Corrective Action:

• Fuel injectors installed on engine:

No action is required. Successful completion of on-engine testing indicates the injector is not susceptible to failure due to foreign material.

e Fuel injectors in inventory (not-installed) on engine:

All fuel injectors in inventory with a 16C date code are considered suspect and should be returned to ESI for evaluation and additional testing.

• To prevent recurrence of this issue, ESI will implement an extended run time test as part of fuel injector functional testing requirements. This extended run time test will supplement the standard calibration testing performed on each injector and will provide additional assurance of internal cleanliness.

o Completion of the extended run time test stand is expected within 90 days. In all cases, it will be complete prior to any future EMD fuel injector shipments.