ML20366A048

From kanterella
Jump to navigation Jump to search
10CFR21 Reporting of Defects and Non-Compliance - Engine Systems, Inc. Report No. 10 CFR21-0114, Rev. 1
ML20366A048
Person / Time
Site: Perry, Vogtle, Comanche Peak  Southern Nuclear icon.png
Issue date: 12/07/2020
From: Woolard S
Engine Systems
To:
Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML20366A048 (6)


Text

.. .

-@*ENGINE svsTEMs, tNc.:* ::

175 Fretght Road ,  : :* Telephone: 252/9TT-2720

. Rocky Mount, NC 27804 . . . * * . Fax: 252/446-1134 December 7, 2020 U.S. Nuclear Regulato.ry Commission:*.:*

Document Control Desk **

Washingt9n, DC 20555-0001 .

Subject:

. 10CFR2°1 *Reporting* of Defects and Non-Compliance -

  • Engine Systems, Inc. Repo~ N~. 10CFR21-01.14, Rev. 1 Subcover Assembly, PIN A-7846, and Machined Subcover, P/N 03-362"--0:4-AH

Dear Sir/ Madam:

The enclosed* :report, 10CFR21-0114, Rev, 1, *addresses a reportable notification on an *Enterprise emergency diesel generator subcover assembly P/N *1A-7846, and

. machined subcover P/N 03-362-04-AH:

A CC?PY *Of the report _ha_s -been mailed to our affected _nuclear customer.

Please sign below, acknowledging receipt of this report, arid retµm a copy to the ...

attention of pocument Contrql ~t the address: abqve (or, fax to number 252/446-11_34) withir:i 10 -working days after receipt. . * * .* -

Yours very truly, ENGIN~ S)'STEMS, fN~ .

.ei-~*d)~~*

Susan Woolard Doc_ument 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:

Q*u*ality Performance With Pride

ENGINE SYSTEMS, INC . .

175 Fretght Road, Rocky Mount, NC 27804 Telephone* 252/9TT-2720 Fax: 252/446-1134 Report No. 10CFR21-0114 Rev. 0: 12/28/16 Rev. 1: 12/04/20 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: Subcover assembly PIN 1A-7846 an~ machined subcover P/N 03-362-04-AH SYSTl=M: Emergency Diesel Generator CONCLUSION: Reportable in Accordance With 10CFR21 Prepared By: ___ __k""-+-..___0M'_* _________ Date:

0 Engineering Manager

. Reviewed By: _ _.....;a~....,;;.;_...:_w-__:...,..._.;;.,;;;._..._ _ _ _ _ __ Date:

  • Quality Assurance Manager Quality Performance With Pride

Report No. 10CFR21-0114 Record of Revisions Page: 1 of 1 REV DATE PAGE DESCRIPTION 1 12/04/20 Cover In Component section, added machined subcover 03-362-04-AH 1 In Component section, added machined subcover 03-362-04-AH.

3 In Affected Users and Shipments table, added column for part number and added last row.

It was discovered that ES/ supplied qty 2 machined subcovers, PIN 03-362-04-AH, to Comanche Peak that were not captured in the revision 0 notification. PIN 1A-7846 is the typically supplied subcover assembly whereas PIN 03-362-04-AH is the bare machined subcover.

I

Report No . 10CFR21-0114 Revision : 1 Date: 12/04/20 Page : 1 of 3 COMPONENT:

Subcover assembly, P/N 1A-7846, including machined subcover, P/N 03-362-04-AH.

SUMMARY

Engine Systems Inc. (ESI) began a 10CFR21 evaluation on November 18, 2016 upon notification of an issue with a subcover assembly at Perry Nuclear Plant. Attempts to install the subcover on their Enterprise diesel engine revealed two issues that prevented successful installation . First, one of the bolt holes was not fully machined through the entire depth of the subcover. Though the bolt could be inserted into the top of its corresponding hole, it would not pass completely through . The second issue was an interference between the rocker arm shaft and its mating pedestal. It was found that incomplete machining of the pedestal prevented the shaft from sitting flat on the pedestal.

The evaluation was concluded on 12/21 /16 and it was determined that this issue is a reportable defect as defined by 10CFR21 . The figures and photos below and on the following page provide visual detail of the deficiencies.

Item #2 : Location of incomplete machining of pedestal Item #1 : Location of inadequately drilled bolt hole Figure 1: Outline Drawing of Subcover

Report No . 10CFR21 -011 4 Revision: 1 Date: 12/04/20 Page: 2 of 3 Photo 1: Visual Depiction of Inadequately Photo 2: Attempted Bolt Install Drilled Bolt Hole Item #2:

Sc.TA.i L ry' Correct Machining (note radius)

Photo 3: Actual Machining Figure 2: Ideal Pedestal Machining

I Report No. 10CFR21-0114 Revision : 1 Date: 12/04/20 Page : 3 of 3 DISCUSSION:

The subcover is a device that is fastened to the top of the cylinder head and provides support for the rocker arms and rocker shafts and encloses the valve stem area. There is one subcover per cylinder head and thus for a model OSRV-16-4 Enterprise engine there are 16 subcovers. Failure of a subcover would impact the ability of either of the corresponding rocker arms to provide the mechanical force to actuate the intake and exhaust valves. Without valve actuation, that particular power assembly would be unable to generate power which would reduce the output of the emergency diesel generator (EOG).

Failure of the EOG to produce its nameplate rated power could prevent the safe shutdown of the nuclear power plant during an emergency situation .

The issue regarding the inadequately drilled bolt hole would be detected during installation since it would prevent the bolt from passing through the hole. Therefore, it is determined this issue would have no impact on operability since the cover could not be installed with an incompletely drilled bolt hole.

With regard to the incompletely machined pedestal , there is the potential that a customer could install the rocker arm shaft without detecting this issue. In this situation, the shaft will partially fit on the pedestal and the bolt will thead into subcover; however, the shaft will not seat fully on the pedestal.

This prevents full contact with the pedestal and inhibits adequate preload throughout the bolted joint.

If a customer were to install the rocker arm shaft (with mating rocker arms, pushrods, etc) onto the engine without realizing this issue, operability and durability of the engine would be compromised .

This could present a substantial safety hazard .

AFFECTED USERS AND SHIPMENTS:

All of the subcovers listed below are subject to the pedestal machining discrepancy and may subject to the inadequately drilled bolt hole.

ESI Sales Order Order Date Part ESI Certification Customer Customer PO Qty Number Date 8001930 45307431 1/30/2013 (qty 1) 12/1 9/2011 First Energy - Perry 1A-7846 4 (AFW#3168 ) 7/27/2013 (qty 3) 3006881 (qty 14) 7/27/2013 (qty 14) 2/4/2010 Korea - Yonggwang Y090528171 1A-7846 15 8001963 /atv 1) 10/ 18/2013 /atv 1) 3009694 2/23/2012 Korea - Yonggwang NYG1-02M0007-550 1A-7846 2 7/27/2013 3009847 4/5/2012 First Energy - Perry 45389292 7/27/2013 (qty 5) 1A-7846 8 9/27/2013 /atv 3) 3009695 2/23/2012 Korea - Yonggwang Y050089101 1A-7846 2 10/1 8/2013 3015101 12/29/2015 Georgia Power - Vogtle SNG10122963 1A-7846 2 4/21/2016 3012736 4/21 /2014 EFH - Comanche Peak B 0209108 171 03-362-04-AH 2 8/6/2014 CORRECTIVE ACTIONS:

Customers may elect to perform corrective machining to restore the subcover to its design dimensions.

Otherwise , return the affected subcovers to ESI for inspection and rework. If customer rework is desired , perform the following:

a) Inspect for the bolt hole (item #1 ). If rework is necessary, drill through to a diameter of 13/16".

b) For the incomplete machining of the rocker arm pedestal (item #2), first remove the installed dowel which has 0.000" to 0.001 " clearance . Then machine a 2" radius relief at the affected area. All other dimensions such as pedestal height shall remain unchanged.

The root cause analysis determined the cause to be machining errors that were not detected during ESl 's dedication activities. As subcovers are returned , they will be re-machined at the vendor's facility, inspected by ESI, and returned to customers within 60 days of receipt. ESI will also incorporate revisions to the dedication report prior to the supply of any new or reworked subcovers to further clarify the inspection of these features during the dedication process, thereby preventing reoccurrence.