ML17006A010

Engine Systems, Inc. - Part 21 Issues Identified with the Enterprise Diesel Engine Subcover

ML17006A010
Person / Time
Site:	Perry, Vogtle
Issue date:	12/29/2016
From:	Horner T Engine Systems
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML17006A010 (7)

Text

1212912016 U.S. Nuclear Regulatory Commission Operations Center Event Report Pagel Part 21 (PAR) Event# 52466 Rep Org: ENGINE SYSTEMS, INC Notification Date I Time: 12/29/2016 16:54 (EST) Supplier: ENGINE SYSTEMS, INC Event Date I Time: 12/21/2016 (EST) Last Modification: 12/29/2016 . Region: 1 Docket#: City: ROCKY MOUNT Agreement State: Yes County: License#: State: NC NRC Notified by: TOM HORNER Notifications: STEVE ROSE R2DO HQ Ops Officer: JEFF HERRERA MARK JEFFERS R3DO Emergency Class: NON EMERGENCY PART 21/50.55 REACTORS EMAIL 10 CFR Section: 21.21 ( d)(3)(i) DEFECTS AND NONCOMPLIANCE PART 21 -ISSUES IDENTIFIED WITH THE. ENTERPRISE DIESEL ENGINE SUBCOVER The following information is an excerpt from a facsimile report submitted:* "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 affected facilities are: . First Energy -Perry Georgia Power -Vogtle

• Also listed was the following affected facility: Korea -Yonggwang Component: Subcover Assembly, P/N 1A-7846 ********************************************************************************************************************************

, 111 04:42:29 a.m. 12-28-2016 ENGINE SYSTEMS, INC. 175 Freight Road Rocky Mount, NC 27804 Date: Company: Fax Number: Verification No.:

Reference:

From: Page:

Dear Sir:

TELEFAX December 29, 2016 NRC Operations Center 301/816-5151 301/816-5100 Report No. 10CFR21-0114, Rev. 0 Tom Horner 1of6 Telephone: 252/Bn-2720 Fax: 252/446*1134 Following this cover is a copy of our report 10CFR21-0114, Rev. 0, for a 10CFR21 reportable notification on a subcover assembly, P/N 1A-7846. A copy of this report will be mailed to the NRC Document Control Desk and to our affected nuclear customers. Should you have questions, please let us know. Sincerely, ENGINE SYSTEMS, INC. Tom Horner Quality Assurance Manager Quality Performance With Pride , /6 1111 ENGINE SYSTEMS, INC. 175 Freight Road, Rocky Mount, NC 27804 04:42:42 a.m. 12-28-2016 Telephone: 252/977-2720 Fax: 252/446-1134 Report No. 10CFR21-0114 Rev. 0: 12/28/16 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: Subcover Assembly, P/N 1A-7846 SYSTEM: Emergency Diesel Generator CONCLUSION: Reportable in Accordance With 10CFR21 Prepared ....... /M.c...:..;;...' ------- Engineering Manager Reviewed By: __ Quality Assurance Manager Quality Performance With Pride Date: 1z /zsl1to Date: 2 /6 1111 04:42:53 a.m. 12-28-2016 3 /6 Report Na. 1 OCFR21-0114 Record of Revisions Page: 1of1 REV DATE PAGE DESCRIPTION 0 12/28/16 Initial Issue.

1111 04:43:00a.m. 12-28-2016 416 Report No. Revision: 10CFR21-0114 0 Date: 12/28/16 Page: 1of3 COMPONENT: Subcover assembly, P/N 1A-7846. 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 Sub cover 1111 Item #2: Photo 1: Visual Depiction of Inadequately Drilled Bolt Hole Correct Machining (note radius) Figure 2: Ideal Pedestal Machining 04:43:25 a.m. 12-28-2016 5 /6 Report No. Revision: 10CFR21-0114 0 Date: 12128/16 Page: 2 of 3 Photo 2: Attempted Bolt Install Photo 3: Actual Machining 1111 DISCUSSION: 04:45:37 a.m. 12-28-2016 6 /6 Report No. Revision: Date: Page: 10CFR21-0114 0 12/28/16 3 of 3 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 DSRV-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 EDG 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 Hsted below are subject to the pedestal machining discrepancy and may subject to the Inadequately drilled bolt hole. ESI Sales Order Order Date Customer Customer PO Quantity ESI Certification ShlDDed Date 8001930 12119/2011 First Energy -Perry 45307431 4 1/30/2013 (qty 1) CAFW#3168) 7/27/2013 Calv 3) 3006881 (qty 14) 214/2010 Korea-Yonggwang Y090528171 15 7/27/2013 (qty 14) 8001963 (atv 1) 10/1812013 (atv 1) 3009694 2123/2012 Korea -Yonggwang NYG1-02M0007-550 2 7127/2013 3009847 4/5/2012 First Energy -Perry 45389292 8 7/27/2013 (qty 5) 9/27/2013 (atv 3) 3009695 2/23/2012 Korea -Yonggwang Y050089101 2 10/18/2013 3015101 12129/2015 Georgia Power -Vogtle

• SNG10122963 2 4/21/2016 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 ls desired, perform the following: a) Inspect for the bolt hole (item #1). If rework ls 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 o.ooo* 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.