ML092590250

Notification of Potential Part 21 Re Reporting of Defects and Non-Compliance - Engine Systems, Inc. Report No. 10CFR21-0097, Rev. 0. Woodward 2301A & DRU with Unapproved Supplier IC, P/N: 9903-303, 9903-337, 9903-444 and 9903-470

ML092590250
Person / Time
Site:	Mcguire, Palo Verde, McGuire
Issue date:	09/09/2009
From:	Woolard S Engine Systems
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
10CFR21-0097, Rev 0
Download: ML092590250 (5)

Text

ENGINE SYSTEMS, INC.

175 Freight Road Telephone: 252/977-2720 Rocky Mount, NC 27804 Fax: 252/446-1134 September 9, 2009 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. 10CFR21-0097, Rev. 0 Woodward .2301 A and DRU with unapproved supplier IC P/N: 9903-303, 9903-337, 9903-444 and 9903-470

Dear Sir:

The enclosed report addresses a reportable notification for a Woodward 2301A and DRU with unapproved supplier IC, P/N: 9903-303, 9903-337, 9903-444 and 9903-470.

A copy of the report has also been sent to the NRC.

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, g4~4-2 ENGINE SYSTEMS, INC.

41X 0

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:

L iJ Quality Performance With Pride

ENGINE SYSTEMS, INC.

175 Freight Road, Rocky Mount, NC 27804 Telephone: 252/977-2720 Fax: 252/446-1134 Report No. 10CFR21-0097 Rev. 0: 09/09/09 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: Woodward 2301A and DRU with unapproved supplier IC P/N: 9903-303, 9903-337, 9903-444 & 9903-470 SYSTEM: Emergency Diesel Generator - governor system CONCLUSION: Reportable in accordance with 10CFR21.

Prepared By:. Date: ________

K Engineering Manager Reviewed By: Date: 1?'vy Quality Assurance Manager Quality Performance With Pride

Report No. 10CFR21-0097 Record of Revisions Page: 1 of 1 REV DATE [ PAGE DESCRIPTION 0 09/09/09 Initial issue.

Report No. 10CFR21-0097 Revision: 0 Date: 09/09/09 Page: 1 of 2 COMPONENT:

Woodward 2301A and DRU with unapproved supplier IC P/N: 9903-303, 9903-337, 9903-444 & 9903-470 DISCUSSION:

Engine Systems Inc. (ESI) began a 10CFR21 evaluation on 8/14/09 to evaluate the use of an integrated circuit (IC) used in some 2301A and DRU controls. The suspect IC was obtained by Woodward from an unapproved supplier. The evaluation was concluded on 09/08/09 and was determined to be a reportable defect as defined by 10CFR21.

On 8/14/09, Woodward confirmed that they had shipped ESI a total of thirty-four (34) 2301A and DRU controls with nuclear part numbers that contained an IC (Woodward P/N 1688-767) from a suspect lot. The lot was dated 12/12/08 and was received by Woodward from an unapproved supplier. Eight (8) of the 34 controls were subsequently shipped by ESI to nuclear customers (2 domestic plants and 3 foreign plants) before the issue was identified. To date, no operability issues have been reported or observed with 2301A and DRU controls containing the suspect IC.

In the DRU, the IC is used in the raise-lower circuit and in the ramp time circuit (the ramp time circuit controls the ramp rate of the DRU). The DRU is primarily used as the speed reference input signal to the 2301A and provides remote speed adjustment for the 2301A (similar to the function of a motor operated potentiometer - MOP). In some applications, the DRU has also been used as a replacement for the voltage regulator MOP; in this case, the DRU provides the voltage adjustment signal to the voltage regulator. Failure of this IC could impact speed (frequency) control (and in some cases voltage control) of the EDG.

In the 2301A, the IC is used in the start fuel limit circuit and in the speed signal input (magnetic pickup) circuit. The 2301A is the electronic governor used on many EDG's. It provides speed and/or load control of the diesel engine by communicating with the governor/actuator mounted on the diesel engine. Failure of this IC could impact speed (frequency) control of the EDG.

-I.

Report No. 10CFR21-0097 Revision: 0 Date: 09/09/09 Page: 2 of 2 AFFECTED USERS:

Thirty-four (34) controls were shipped to ESI containing IC's from the suspect lot. Twenty-six (26) of the suspect controls were in ESI inventory and have been returned to Woodward to have the suspect IC replaced. ESI shipped eight (8) controls with suspect IC's to nuclear customers as safety related items as identified in the tables below.

LISTING OF WOODWARD CONTROLS SHIPPED WITH SUSPECT IC's (DOMESTIC PLANTS)

Part Woodward ESI Sales ESI Customer Number Type S/N Order Ship Date Customer Purchase Order 9903-337 2301A 16466280 3005430 5/19/2009 McGuire 00114776 9903-470 DRU 16517000 3005474 5/14/2009 Palo-Verde 500529186 9903-470 DRU 16519303 3005474 5/14/2009 Palo-Verde 500529186 9903-444 2301A 16614277 3005474 8/12/2009 Palo-Verde 500529186 LISTING OF WOODWARD CONTROLS SHIPPED WITH SUSPECT IC's (FOREIGN PLANTS)

Part Woodward ESI Sales ESI Customer Number Type S/N Order Ship Date Customer Purchase Order 9903-470 DRU 16470403 3005479 7/30/2009 Korea-KHNP K080553241 2009/015 9903-470 DRU 16487942 3005458 6/30/2009 Almaraz 2R09/015 ER09AT06805MA 9903-337 2301A 16467615 3005458 6/30/2009 Almaraz 2009/015 ER09AT06805MA 9903-303 2301A 16529294 3005621 6/08/2009 KRSKO NEK-10271/309 CORRECTIVE ACTION:

The controls listed in the tables above should be returned to Engine Systems Inc. to have the suspect IC replaced as soon as possible. Contact ESI's Customer Service department with the part number and serial number of the control to be returned.