ML20096F592

Followup to 920417 Part 21 Rept 10CFR21-0062 Re Failed Shaft in DG W/Emd 645 Series Engines Using Turbochargers Remanufactured from May 1991 to Jan 1992.Turbochargers Should Be Removed & Returned to EMD for Insp/Repair

ML20096F592
Person / Time
Site:	Monticello, Davis Besse
Issue date:	05/11/1992
From:	Galeazzi D, Matthew Mitchell M/K SYSTEMS, INC.
To:
Shared Package
ML20096F580	List: ML20096F576 ML20096F592
References
REF-PT21-92 10CFR21-0062, 10CFR21-62, NUDOCS 9205210236
Download: ML20096F592 (4)

Text

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REPORT NO.: 10CFR21-0062 DATE: May 11, 1992 6

10CFR21 REPORTING OF DEFECTS AND NON-CONFORMANCE COMPONENT: EMD TURBOCHARGER PLANETARY BEARING SHAFT SYSTEM: D:ESEL GENERATORS WITH EMD 645 SERIES ENGINES USING TURBOCHARGERS THAT WERE REMANUFACTURED FROM MAY, 1991 TO JANUARY, 1992 CONCLUSION: DEFECT IS REPOHTABLE IN ACCORDANCE WITH 10CFR21

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PREPARED BY: '//^b~- D \TE 5/IlhL Donald D. Gal,sazzi, Engineering Manager

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APPROVED BY: '

DATE I!'i b M. Vann Mitchell, Qudlity Manager Post Office Box 1928. Rocky Mourt, North Carchna 27802-1928. Phone: (919) 977-2720 9205210236 920511 m (510) 92&o725. N (919) 46-3830 DR ADDCK 05000263 PDR _

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REPORT NO.: 10CFR21-0062 DATE: MAY-11, 1992 PAGE: 1 OF 4 SMi!1ARY This is-a-follow-up report to MNW Power Systems' notification to Mr.:-Thomas Murley of the NRC dated 4/17/92 (see Exhibit 1).

MKW Power Systems received protiminary notification on-4/15/92

< from Electro-Motive Division of GM (EMD) about a-possible manu-facturing-defect with the engine turbocharger-planetary bearing shaft. ' Final notification was received on 5/11/92 and is contained in Exhibit 2. Or9 failure of a remanufactured turbocharger was attributed to improper grinding of the planetary

, bearing shaft by tho manufacturer. Users of turbochargers with suspect planeta y bearing shafts have been determined and will be notified accordingly.

- C011P_QREtLI EMD turbochargers that were remanufactured from May 1991 to January 1992.

C_QSIQdERS AFFECTED

-The users affected by this notification are listed below:

~ CQSIQMER IMRB_Q_SM1 f1KW_QERER_ttQ .

Ebasco - Laguna Verde CFE-Division 3 73K1-1207 502971

1. E. PIMS 76K1-1127 6089 Korea Electric Power --KORI 11 79L1-1239 -503465 Toledo Edison - Davis-Besse 91C3-5012 503772 Northern States-Power - tiont i c e l l o 91L3-5067 505244 I

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REPORT NO.: 10CFR21-0062 DATE: MAY 11, 1992 PAGE: 2 OF 4

- DEEECIL

' Manufacturer produced thrs pienetary bearing shaftF USing a centerless grinding proc-ess (which is not to EMD specifications).

'1D 's process specification reauires that the shafts be ground on centers. A failed sna#t, which was produced improperly, was lobed and out-of-round.

CORRECI_LY.E_ACll.ON Turbochargers.with serial numbers listed under " Customers Affected" should perform one u" the following.

1. Remove the turbocharger, disassemble the carrier bearing-support and bearing assembly, idler gear assembly, and remove the gear drive assembly. With the planetary gear assembly r enov e d , inspect the planetary bearing abafts, if the shafts are the centerless ground type, the planet carrier assembly should be replaced. If the shafts have the

-centering holes, then the turbocharger can be reassembled and replaced on the engine.

2. Remove the turbocharger and ship t- 'O for inspection / repair.

3. Remove turbocharger a.d replace with a. qualified Utex assembly. EMD will make turbochargers meeting the critical emergency start criteria available to be cha"3ed out at the customer's convenience.

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-l REPORT NO.

10CFR21-0062 '

_,_ DATE: MAY 11, 1992 ,

PAGE: 3 OF 4-I t

EXHIBIT 1 *

(2 pages) .,

3 NOTIFICATION TO NRC DATED 4/17/92 j

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Antil l~, 1992 Mr. Thomas Murl /

Director - Offic' af Nuclear Reactor Regulation 11555 Rockvilla /ike Rockville, Maryland 20852

Subject:

Potential Reportable Defect for EMD turbocharger

Dear Sir:

On 4/15/92, Mhw Power Sys tems received notification f rom Electro-Motive Division o' General Motors Corporation (EMD) of a pcssible manufacturing defect with their turbochargers which are used on their 645 series dies 31 engine. This notification is very preliminary and we do not know the details of the potential defect at this time.. The turbochargers in questions are shown on the attached list.

We are in the proccas of reviewing our files to determine the current location of these turbochargers. Most of the but we suspect on turbochargers that the list were shipped to commercial users, some were shipped to nuclear users.

Upon receipt of more thorougn information from EMD we will L issue a formal report.

Sincerel'*, _

MKW POWER SYST'EMSc INC.

8). N ,_ [ M M. Vann Mitchell Quality Manager dg attachment l

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Post Office Box 1928 Aocky Mount. North Carohna 27802-1928 e Phone (919) 977-?720

'* TWX: (510) 929-0725 . F A X: 19191446-3830

3ORTED BY MKW 000,1 EMD GRDER # ORDER DATE

' ART # SERIAL #

UTEX OR MKW PO #

R&R HA91015001 1/15/91 9525864 73K1 - 1207 HA9110B002 4/18/91 R 65959 9529908 79Ki-1006 BD31093005 R 66497 4/3/91 8377566 LG91122007 91 83-5044 U 5/02/91 9526864 66565 HA91137001 91 C3-6039 U 5/17/91 X911279 66694 BD91150009 91F3-5006 U S6785 5/30/91 8368598 BD91150009 90M3 5032 U 68944 3/30/91 836 1 36 LG91161017 9183-5048 U 66944 5/31/91 8370751 E091183003 9183-5047 'U 68948 7/02/91 8377586 LG91214012 91 E3-5070 0 8/02/91 9529908 67206 LG91214013 91G3-5016 U 8/02/91 9521991 67264 LG91247023 91 G3-5017 U 9/04/91 9523864 67204 CA91232001 91J3-5052 U 67281 B/20/91 9526864 BD91232013 91 G3-6011 U 8/20/91 9536274 67368 LG91246016 91 03 - 5002 U 9/03/91 9521991 87390 HA91274001 91H3-5022 U 67410 10/01/91 9526867

.G91261017 73K1 -1006 R 9/16/91 6377666 67547 HA91281001 91F3-5033 U 8755t 9/18/91 6370751 HA91276001 9103 -6023 0 67801 10/03/91 9526864 91 K3-5040 HA91323002 11/19/91 U 87845 8377536 BSJ3-5001 HA91323001 R 67883 11/19/91 8370751 89J3-6044 LG91536030 R 67883 12/02/91 9526967 76K1 -1057 LG91336030 R 67899 12/02/91 952E867 LG91301026 76K1-1127 R 67899 10/28/91 63775S8 91H3-5008 U 67902 trAD Power Products SeMee 15-Apr-92

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.l REPORT NO.:- 10CFR21-0062. l

",,. - OATE: MAY 1 1 ', 1992' PAGE: 4 OF 4 l

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EXHIBIT 2 (2 pages)

EMD-NOTIFICATION A4..

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,SENT BY. 3-11-92 8:20Asi YKR Po".ER5YsTDis-919 4w 1134  :- 1/ 2

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rc Mr. Don Galeazzi '; il MKW F0WER SYSTEMS, INC. ... - k Station Squaro, suite 100 B g ;:C# _~~ " . .

301 South Church Strost

.~.ocky Mount, NC 27004-1928 1

SUBJECT! M tiDTARY BEARING 8 Halls. TURDOCEARQER

Dear Mr. Galeazzi:

Turbocharger planetary bearing shaf ts supp'.iod by a vendor aro suspected of causing a failure on one remanufactured turbocharger.

! The cause of failure van deterr.ined to be a planetary bearing ehaCt lobed and over the roundness spee. Further invnctigation revealed that the vendor produced the planetary bearing shafts using a centeriess grinding process (which is not to E'lD print spec).

L EMD's procass specification requires that the chafts be ground on l centers.

l The following turbes in nuclear standby may have a planetary hearing shaft produced by the centerless grinding process:

i Seria_1 Number Custor y

1) 73K1-1207 EBASCO

> 2) 75K1-1057 Wisconsin Electric 76K1-1127 GE - P.I.M.S.

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() 79L1-1239 Korea Electric Power S) 91c3-5012 Toledo Edison

6) 91L3-5067 Northern States FoWor Thi's does not indicate that centerless ground shaftn are i

defectivo, but those turbos uhould bo inspected.

d4W NT MWW fog- due>uwC) Continued on Page 2 MWt#J WwL 0-a <- / CEP WE rs%

3-11-92 W,r0MER5iSTENS-91044dJ 11d4~  :: #2

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m Hr. Den Galeazzi MKW Power Systems, Inc.

May 8 1947 Pag 2 Doponding on the customar and his operating conditions, one of the following scenarios could be used to insure the turbo reliability:

1. Remove the turbo, citassemble the carrier bearing support and bearing assembly, idler gear ass s bly, and remove the gear drive assembly. With the planetary gear assembly removed, inspact the planetary bearing sharts. If the shaf ts are the centerless ground type, the planet carrier arsembly should be replaced. If the shafts have the centering holes, than the turbo can be roascombled and replaced on the engine.

2. Remove the turbo ard ship to EMD for inspection /rcpair.

3. Remove turbo and replace with a qualified Utex assembly.

EMD will nake turbochargers seeting the critical emergency start critaria available to be changed out at the customor 's cor.venience.

Again, it chou?4 be stressed that only one turbo failure out of approximately 1400 turbos rebuilt has been attributed to the centerless ground planet;ry bearing shaft.

\;e will continuo to work closely with you to resolve this issue. If you have additional questions, please advise, s'  !

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M. A. Lagomarcino i

Manager Powcr Products Servico CJ F/ MAI,:Vad

! cc: C. J. Farber l