ML20108F530
| ML20108F530 | |
| Person / Time | |
|---|---|
| Site: | Dresden, Saint Lucie, Point Beach, Columbia, FitzPatrick  |
| Issue date: | 03/20/2020 |
| From: | Woolard S Engine Systems |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| Download: ML20108F530 (7) | |
Text
ENGINE SYSTEMS, INC.
175 Freight Road Telephone: 252/977-2720 Rocky Mount, NC 27804 Fax: 252/446-1134 March 20, 2020 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. 10CFR21-0129, Rev. 0 Test Stand Deficiency- EMD Fuel Injectors P/N H40084720
Dear Sir/ Madam:
The enclosed report addresses a reportable notification on a test stand deficiency for EMD fuel injectors, P/N H40084720.
A copy of the report has been mailed to our affected nuclear customers.
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. 10CFR21-0129 Rev. 0: 03/19/20 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE
SUBJECT:
Test Stand Deficiency - EMO Fuel Injectors P/N H40084720 SYSTEM: Emergency Diesel Generator CONCLUSION: Reportable in Accordance With 10CFR21 Prepared By:_..,...,~=-+--'-=b_' ____________
\]"Engineering Manager Reviewed By: _ _ a__ ---------
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Quality Assurance Manager Date: 3 /; 1 J~ o;;. o Quality Performance With Pride
Report No. 10CFR21-0129 Record of Revisions Page: 1 of 1 REV DATE PAGE DESCRIPTION 0 03/19/20 Initial issue.
Report No. 10CFR21-0129 Revision: 0 Date: 03/19/20 Page: 1 of 4 Pursuant to 10 CFR 21.21(d)(4), ESI is presenting the required information as follows:
(i) Name and address of the individual or individuals informing the Commission.
John Kriesel Dan Roberts Engineering Manager Quality Manager Engine Systems Inc. Engine Systems Inc.
175 Freight Rd. 175 Freight Rd.
Rocky Mount, NC 27804 Rocky Mount, NC 27804 (ii) Identification of the basic component supplied within the United States which fails to comply or contains a defect.
EMO fuel injector, P/N H40084720.
(iii) Identification of the firm supplying the basic component which fails to comply or contains a defect.
Engine Systems Inc. (ESI)
(iv) Nature of the defect or failure to comply and the safety hazard which is created or could be created by such defect of failure to comply.
The endurance test stand utilized for new EMO fuel injectors was found to contain a deficiency that may damage injectors during the testing process. There is a potential for the actuating stem of the endurance test stand to strike the injector follower off center, creating side loading that results in inadvertent rubbing between the follower and body. The condition is exacerbated by a lack of continuous lubrication from the test stand. Over the 2-hour test duration, the running surface of the follower scores and metal particles are introduced into the top end of the injector. The migration of these particles through the injector could initiate a seizure.
An improperly functioning fuel injector could affect the load carrying capability of the diesel engine. An EMO 645 engine will typically tolerate one inoperable cylinder and maintain rated load; however multiple inoperable cylinders (as in the case of multiple injector failures) will further decrease engine output and likely prevent the engine from carrying its required load. This adversely affects the ability of the emergency diesel generator set to perform its safety-related function.
(v) The date on which the information of such defect or failure to comply was obtained.
February 14, 2019 (vi) In the case of a basic component which contains a defect or fails to comply, the number and location of these components in use at, supplied for, being supplied for, or may be supplied for, manufactured, or being manufactured for one or more facilities or activities subjectto the regulations in this part.
)
All new P/N H40084720 injectors supplied by ES! have been through the 2-hour endurance test and are considered suspect. There are qty 240 new P/N H40084720 injectors shipped on safety-related orders as shown in Table 1 on the following pages.
Report No. 10CFR21-0129
'-I Revision: 0 Date: 03/19/20 Page: 2 of4 Customer Qty C ofC ESI Order Customer Serial Numbers PO Number Shipped Date B1820004 B1820022 B1820051 B1820061 B1820009 B1820023 B1820052 B1820062 B1820010 B1820024 B1820053 B1820067 B1820012 B1820026 B1820054 B1820071 B1820013 B1820035 B1820055 B1820076 Energy Northwest - 351170 40 8/29/2018 3017814 Columbia B1820015 B1820036 B1820056 B1820079 B1820016 B1820041 B1820057 B1820082 B1820019 B1820046 B1820058 B1820097 B1820020 B1820048 B1820059 B1820102 B1820021 B1820050 B1820060 B1820113 B1820001 B1820042 B1820089 B1820116 B1820006 B1820044 B1820104 B1820117 B1820025 B1820047 B1820107 B1820119 Florida Power & Light - 2382577 28 6/12/2018 B1820034 B1820070 B1820109 B1820130 3018480 .
St Lucie B1820038 B1820072 B1820111 B1820138 B1820039 B1820075 B1820112 B1820139 B1820040 B1820078 B1820115 B1820140 B1820008 B1820081 B1820110 B1820136 B1820045 B1820087 B1820114 B1820143 3018761 Exelon - Dresden 703-13002 18 9/27/2018 B1820049 B1820094 81820122 81820145 B1820077 81820096 B1820126 B1820080 B1820101 81820135 B1820029 B1820095 B1820125 B1820137 81820033 B1820103 B1820127 B1820141 81820037 B1820108 B1820128 B1820142 Florida Power & Light - 2389033 26 1/2/2019 B1820069 B1820118 B1820131 B1820144 3018897 St Lucie B1820073 B1820121 B1820132 B1820146 B1820074 B1820123 B1820133 B1820088 B1820124 B1820134 B1820002 B1820065 B1820086 81820098 B1820003 B1820066 B1820090 B1820099 3018966 Exelon - Fitzpatrick 675479 20 1/21/2019 B1820011 B1820083 81820091 B1820100 B1820030 B1820084 81820092 B1820105 B1820064 B1820085 81820093 B1820106 A1909011 A1909044 A1909100 A1909113 A1909012 A1909052 A1909107 A1909125 14 12/18/2019 NextEra Energy Point A1909016 A1909072 A1909110 3019020 2392198 Beach LLC A1909017 A1909075 A1909112 A1909042 A1909071 A1909101 5 12/20/2019 A1909061 A1909084 Table 1: ESI Supply History for New PIN H40084720 Injectors (continued on next page)
Report No. 10CFR21-0129 Revision: 0 Date: 03/19/20 Page: 3 of4 Customer Qty C ofC ESI Order Customer , Serial Numbers PO Number Shipped Date Florida Power & Light - 1/11/2019 B1820017 B1820027 B1820031 B1820068 3019124 2390768 4 St Lucie B1820005 B1820028 B1820043 B1820120 8 4/25/2019 B1820007 B1820032 B1820063 B1820129 Florida Power & Light -
3019195 2391269 Turkey Point A1909014 A1909076 A1909088 A1909142 7 12/19/2019 A1909040 A1909083 A1909136 A1909009 A1909037 A1909086 A1909137 Energy Northwest - A1909092 3019958 355071 10 12/20/2019 A1909022 A1909059 Columbia A1909035 A1909079 A1909108 A1909004 A1909039 A1909121 A1909140 A1909008 A1909043 A1909128 A1909147 00000703- 18 11/27/2019 A1909034 A1909115 A1909132 A1909149 3019967 Exelon - Quad Cities 13229 A1909036 A1909117 A1909135 A1909038 A1909120 A1909139 A1909002 A1909077 A1909127 A1909143 A1909007 A1909078 A1909129 A1909144 A1909027 A1909085 A1909130 A1909148 Florida Power & Light - 11/26/2019 3020114 2402697 22 St Lucie A1909029 A1909105 A1909131 A1909150 A1909031 A1909118 A1909134 A1909074 A1909119 A1909138 A1909010 A1909032 A1909091 A1909124 A1909015 A1909033 A1909102 A1909126 Energy Operations - A1909073 A1909103 A1909133 3020226 10595310 20 12/18/2019 A1909026 Grand Gulf Nuclear A1909028 A1909081 A1909104 A1909141 A1909030 A1909087 A1909116 A1909146 Total Supplied 240 Table 1: ESI Supply History for New P/N H40084720 Injectors (vii) The corrective action which has been, is being, or will be taken; the name of the individual or organization responsible for the action; and the length of time that has been or will be taken to complete the action.
For end users:
- Fuel injectors installed on engine:
No action is required. Successful completion of on-engine testing indicates the injector is not susceptible to failure.
- Fuel injectors in inventory (not-installed) on engine:
Fuel injectors in inventory are considered suspect and should be returned to ESI for evaluation.
Report No. 10CFR21-0129 Revision: 0 Date: 03/19/20 Page: 4 of4 For ESI:
The following corrective actions pertaining to the endurance test stand have been implemented:
a) Coordinated with the injector manufacturer to modify and correct the endurance test stand.
Engineering controls are now in place to eliminate possibility of off center strikes, regardless of the individual operator.
b) Added steps in the test procedure to verify the injector and actuator are aligned on the test stand prior to testing.
c) Added steps in the test procedure to saturate the top of the injector (follower/body interface) with oil prior to testing and every 30 minutes during testing.
d) Following the 2-hour endurance test, added inspection of the follower to verify no scoring present and inspection of the top of the injector to verify the oil remains clean.
These items will be verified prior to any future shipments.
(viii) Any advice related to the potential defect or failure to comply about the facility, activity, or basic component that has been, is being, or will be given to purchasers or licensees.
N/A.