ML20217A169

Part 21 Rept Re Engine Sys,Inc Controllers,Manufactured Between Dec 1997 & May 1999,that May Have Questionable Soldering Workmanship.Caused by Inadequate Personnel Training.Sent Rept to All Nuclear Customers

ML20217A169
Person / Time
Site:	Hatch, Dresden, Cooper, Byron, Braidwood, Prairie Island, Limerick, Robinson, Clinton, Quad Cities, Zion, LaSalle
Issue date:	09/22/1999
From:	Nuding M External (Affiliation Not Assigned)
To:	Hodge V NRC (Affiliation Not Assigned)
References
REF-PT21-99 NUDOCS 9910080097
Download: ML20217A169 (6)

Text

E' SENT BY: 0-22-99 .

1G :iFi . ENGINE SYSTEMS. INC- 3014152444;# 1/ G -

h.; 1220s.w, ENGINE SYSTEMS, ar.sa st.INC. ujuount.wc 27ac1 Tei.pnene

2szrs77.zrzo P.O. Bow 1928, Rocky Mount, No 27002-1928 Fax: 252/446-1134 ]

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Date: September 22,1999  !

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Company: Onice of Nuclear Reactor Megulation Fax Number: 301/415-1887

, 1 Attention: Vern Hodge 1

Reference:

Report #10CFR21-0079 From: Michael Nuding Page: 1 of 6

Dear Sir:

Following this cover is a copy or our report 10CFR21-0079 for a 10CFR21 reportable defect with Woodward type EGM controllers commonly used on turbine applications.

A copy of this report is also being mailed to you and to all of our affected nuclear customers. Please note that suspect EGM controllers were also supplied directly by Woodward to other nuclear customers. Because ESI did not supply these controllers, were are unable to send notifications to the Woodward customers.

Should you have questions, please let us know.

Sincerely,  !

ENGINE SYSTEMS, INC.

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I Michael Nuding, I fe/tI Quality Manager gg&

9910000097 990922 O PDR ADOCK 05000010 S PDR h\

Quality Perforn!$1nce With Pride

F- . SINT 13Y : 9-22-D9 ; 16:20 .

ENGINE SYSTEMS. INC- 3014152444:# 2/ O 1

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L ENGINE SYSTEMS, INC.

1220 S. WasNngton St., Rocky Mourt. NC 2780i Telephone: 2524r/7-2720 P.O. Bow 1028, Rocky Mount, NC 27802-1928 Fac 252/4461134 Report No.10CFR21-0079 i Rev. 0: September 21,1999 I l

I 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE ,

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i COMPONENT: Woodward EGM Controls (P/N 9903-081,9903-085,9903-109 & 9903-150)

SYSTEM: Turbine control systems CONCLUSION: Defect is reportable in accordance with 10CFR21.

d 070034 PREPARED BY: " - ' ' DATE: I #///

DonajarD. Galetazzi Engineering Manager #

, REVIEWED BY: /E14 J#aA," ,

DATE: il u ff /9ff MichaeFNuding Quality Assurance Manager l

Quality PerforI' nance With Pride

SENT BY; D-22-DD 16:2G ENGINE SYSTEMS, INC*

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3014152444:# 3/ G REPORT NO.10CFR21-0079 REVISION 0: 9/21/99 PAGE: 1OF2

SUMMARY

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Engine Systems Inc. (ESl) has received notification from Woodward that EGM controllers

manufactured between December 1997 and May 1999 may have questionable soldering l

workmanship. Soldering workmanship was affected because ofinadequate personnel training. This issue was discovered by PECO, Limerick Station during a visual inspection of intomal components of an EGM controller. Deficiencies identified included wire st.1nds, excessive solder flux (splash) and

- cold solderconnections.

To date, users have not reported any operabitiy issues with the suspect EGM's. ESI has thermally, l radiation and seismically tested two (2) (#9908-085 & #9903-109) of the suspect EGM's without any .i failures. Each part was also subjeded to an additional seismic test by ESl; again, no failures were observed. In addition, each EGM was subjecte'.! to a 50 hour5.787037e-4 days <br />0.0139 hours <br />8.267196e-5 weeks <br />1.9025e-5 months <br /> bum-In test at Woodward as part of their normal manufacturing tests.

I COfrONENT:

]

Woodward EGM controllers (P/N 9003-081,9903-085,9903-100 and 9903-150) manufactured between December 1997 and May 1999.

CUSTOMERS AFFECTED' Woodward has provided a list of all suspect EGM's by serial number. Only new EGM's are suspect i and these are identified in Exhibit 1. The listing contains all suspect EGM's; and identifies controllers i

supplied by ESI as well as controllers supplied directly by Woodward. Only customers with suspect EGM's supplied by ESI are lis'wl below.

. Carolina Power & Light, H.Be Robinson Commonwealth Edison Georgia Power, Hatch lllinois Power, Clinton Nebraska Public Power, Cooper Northem States Power, Prairie Island PECO Energy, Limerick DEFECT:

The controller circuit boards may have soldering workmanship deficienci'os because of inadequate personnel tralning at the time of assembly.-

Q_qLRRECTIVE ACTION:

1. Engine Systems issued a Corrective Action Report. Woodward had already performed corrective action to require proper personnel training /cnstification in the assembly area.

2. Users should retum suspect controllers for repair. For controllers supplied by ESI, please contact ESI's Customer Service Department. Piease contact Woodward (Steve Thompson @ 970/498-3196) for repair of controllers supplied directly by Woodward.

Because operability problems have not been identified, controllers can be returned at customer's convenience, t I

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'7 '~ SENT BY: 0-22-99 : 16:27 ' ENGINE SYSTEMS, INC- 3014152444:0 4/.6 E

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REPORT NO.10CFR21-0079 REVISION 0: W21/99 PAGE: 2 OF 2 l

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EXHIBIT 1 SUSPECT WOOOWARD EGM CONTROLLERS

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SENT BY: 3-22-99 . 16:7; . DGINE SYSTDIS, INC- 3014152444:# 5/ G i REPOR* MO.10CFR210079

, REVISION 0; 9/21/99

' ' EXHIBIT 1 PAGE: 1OF2 SUSPECT WOODWARD EGM CONTROLLERS SUPPLIED BY ENGINE SYSTEMS,INC.

Customer Part Number Serial Number Carolina Power & Li9ht, Robinsul 9903-109 11985991 9903-109 11985992 Commonwealth Edison 9903-085 12049016 9903-085 12C49617 9903-085 12049618 9903-085 12049619 9903-085 12049620 9903-085 12049621 9903-085 12040622 9903-085 12049623 9903-085 12049624 Georgia Power, Hatch 9903-085 11983380 9903-085 11983381 9903-085 11983382 9903-085 11953484 9903-085 11953485 9903-109 11983332 9903-109 11983333 9903-109 11983335 9903-109 11955402 9903-109 11955403 Illinois Power, Clinton 9903-085 12048589 9903-085 12048590 y 9903-085 12048591 . .

Nebraska Public Power, Cooper 9903-085 12047526 9903-085 12047527

. _ _ . _ 9903-109 _.___. 11983334 _ ,_..... ._. __

, 9903-109 12048594 9903 109 12048596 Northem States Power, Prairie l'. land 9903-109 12044588 1

Peco, Limerick 9903-085 12046552 9903-085 12046553 9903-085 12046554 9903-085 12046555

( 9903-085 12046556 j 9903-085 12046557 r 9903-109 12048592 9903-109 12048593 9903-109 12048595 9903-109 12048597 9903-109 12049425 9903-109 12049426 l

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,a SENT BY: 9-22-D3 . IG:2 4 .

ENGINE SYSTEMS. I R'C-+ 3014152444:# 6/ G y- l

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REPORT NO.10CFR21-0079

' REVISION 0: 9/21/99 i

@. EXHIBIT 1

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h' PAGE: 2 OF2 q ,-

'n f SUSPECT WOODWARD EGM CONTROLLERS -

f SUPPLIED DIRECTLY BY WOODWARD

• Customer Part Number Serial Number l Arizona Public Service 9903-085 12004728 9903-085 12019248 i

Commonwealth Edison 9903-085 12071911 Dresser Rand .9903-085 12086357 9903-109 12049427 Energy Northwest (Wash Pub Ser) 9903-085 12017603 9903-085 12017604

@' GE Nuclear- San Jose 9903-085 11946520 t

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' 9903-085 11946948

-[f(bq h # 9 get g Y U(Ik 9 9903-085 12034000 90 V h# gy /yke( .

9903-085 9903-085 9903-085 12034001 12034002 12034003 l

8 {}\ hvn, g(,h,Q>dg$g#g 6* k 9903-085 9903-085 12034004 12034005 j

0g,,(Hg P4 g d. 6Q y D6 9903-085 9903-085 12054128 12054127 id VE0 p q d g

@(*[\\ 9903-085 12054128 9903-109 O "? -109 11993328 11993329 -

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i 9903-109 12036290 5

7 9903-109 12036291 j 9903-109 12036292 9903 109 12036293.

y 9903-109 12036294

y. 9903 109 12036295

f. . . . 9903-109 12036296 1 Northern States Power, Pralrie island 9903-085 12017640 Pennsylvania Power & L10ht 9903-085 12083808 9903-085 12083809 9903-085 12083810 i 9903-109 12056912 9903-109 12056913 Woodward - Japan 9903-081 11937748 9903-085 11925080 9903-085 11948890 9903-085 11984451 9003-085 11984452 9903-085 11984453 9903-085 11992393 9903-150 11955454