ML060540188

10 CFR 21 Reporting of Defects and Non-Compliance - Engine Systems, Inc. Report No. 10CFR21-0092, Rev. 0; Woodward 505 Controls (Manufactured Between December 2003 and June 2004, P/N: 9903-543

ML060540188
Person / Time
Site:	Vogtle
Issue date:	02/10/2006
From:	Woolard S Engine Systems
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
+sunsi/sispmjr=200603, 9903-543 10CFR21-0092, Rev 0
Download: ML060540188 (5)

Text

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E ENGINE SYSTEMS 175 Freight Road ITnC.

Telephone: 252/977-2720 Rocky Mount, NC 27804 Fax: 252/446-1134 February 10, 2006 U.S. Nuclear Regulator Commission Document Control Desk Mail Stop OP1-17 Washington, DC 20555

Subject:

10CFR21 Reporting of Defects and Non-Compliance -

Engine Systems, Inc. Report No. 10CFR21-0092, Rev. 0 Woodward 505 Controls (manufactured between December 2003 and June 2004), P/N: 9903-543

Dear Sir:

The enclosed report addresses a reportable notification about a small population of Woodward 505 digital controls.

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

A I I

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%Ii ENGINE SYSTEMS. INC.

175 Freight Road, Rocky Mount, NC 27804 Telephone: 252/977-2720

. o_ Fax: 252/446-1134 Report No. 10CFR21-0092 Rev. 0: 02/10/06 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: Woodward 505 Controls manufactured between Dec. 2003 & June 2004 P/N: 9903-543 SYSTEM: Turbine Governor Control CONCLUSION: Reportable in accordance with 10CFR21.

Prepared By: - Date: ____ A____

7 Engineering Manager Reviewed By: Date: -)Z&/&12(C Quality Assurance Manager Quality Performance With Pride

Report No. 10CFR21-0092 Record of Revisions Page: 1 of 1 REV DATE PAGE DESCRIPTION 0 02/10/06 Initial issue..

Report No. 10CFR21-0092 Revision: 0 Date: 02/10/06 Page: 1of 2 (ALY COMPONENT:

Woodward 505 Controls manufactured between Dec. 2003 & June 2004 P/N: 9903-543 DISCUSSION:

Engine Systems Inc. (ESI) has concluded an investigation of a condition reported by Woodward for their 505 controller. The 505 is a digital controller used to control speed of steam turbines. Only a small number of 505 controls are utilized in nuclear service; these are identified by the "9903-" part number prefix.

Woodward service bulletin 01365 (attached\ reports that a low voltage issue with the internal power supply has been detected in a small population of 505 controls that have been returned for service.

This issue has been attributed to a problem with the mechanical connection between the controller's internal fuse and the fuse clips that are installed in-line with the unit's CPU. The low voltage condition results in a continuous reboot of the control; this causes the control's output signal to go to zero volts. For most commercial applications, the 505 controls are configured such that zero volts results in turbine shutdown; thus, the potential failure mode would result in a safe shutdown of the control and the turbine (as reported in the Woodward bulletin).

For nuclear applications however, the 505 controls are configured for maximum speed at zero volts output. This is necessary to keep the governor valve open during standby so that steam can be admitted to the turbine by the trip and throttle valve to begin startup. Once turbine speed is detected by the 505, it will take control and close the governor valve as necessary to maintain the required speed setting. In this case, the potential failure mode would result in shutdown of the control which would cause the turbine speed to abruptly increase until the overspeed device trips and shuts down the turbine.

AFFECTED CUSTOMERS:

The following three (3) nuclear 505 controls are affected by this notification. Of these, only two (2) were shipped for nuclear service.

Part No. Serial No. Customer Customer PO ESI SO 9903-543 13804744 N/A, ESI test specimen N/A 8000006 9903-543 13804745 Southern Nuclear - Vogtle 7059691 8000006 9903-543 13804975 Southern Nuclear - Vogtle 7059691 8000006 CORRECTIVE ACTION:

Suspect 505's should be returned to ESI as soon as possible to have the power supply module reworked. Contact ESI's Customer Service department with the part number and serial number of the control.

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t Iw Report No. 10CFR21 -0092 Revision: 0 Date: 02/10/06 Page: 2 of 2

,N$I WOODWARD SERVICE BULLETIN 505 & 505E Control Internal Power Supply Issue February 2006 01365 Issue An internal power supply issue has been detected in a small population of 505 and 505E controls. This internal power supply issue can cause the controllers CPU to reboot and stay in its reboot mode, resulting in a safe shutdown of both the control and turbine.

Description Woodwvard has identified a small population of 505 and 505E controls (less than 2.5%) that have been returned for service due to a continuous reboot condition caused by a low internal 5-volt power supply. It has been determined that the main contributing factor of this issue is the mechanical connection between the controllers internal 5-volt fuse and the fuse clips in-line with the unit's CPU.

The potential failure modes of an affected unit results in a safe shutdown of both the controller and turbine, with the controller's front panel typically displaying 'Testing RAM..." while continuously rebooting. This reboot condition may also occur during any phase of the control's initialization routine as well, so the actual text displayed may vary.

Affected Units The following 505 and 505E control item numbers manufactured between December 1, 2003 and June 29, 2004, are susceptible to this internal power supply issue.

Item Serial Number Item Serial Number Number Range Number Range 9903-543 13804744 to 9907-166 13646050 to 13804975 13903823 9907-118 Only 13647807 9907-167 13603298to

___.. 13906519 9907-162 13647819 to 9907-805 13679854 to 13900521 13809952 9907-163 13652264 to 9907-813 13660897 to 13906533 13898920 9907-164 13632578to 9907-814 13660901to 13918086 14122459 9907-165 13631766to 9907-815 13646106to

_ 13915341 13903072 Corrective Action Woodwvard has implemented process improvements, and an engineering change to the controller's power supply module to prevent the issue from occurring.

If it is determined that a unit needs to be returned to Woodward, please Customer Action select one of the following options:

• Contact your Woodward customer service representative for a return authorization number (RAN) and return the unit(s) to Woodward.

• If a return is not feasible, contact your Woodward customer service representative to discuss the availability of replacementlexchange unit(s).

I Please refer to this service bulletin number when scheduling your return.

I Service bulletin actions will be performed at no charge within the product warranty period.