ML22098A117
| ML22098A117 | |
| Person / Time | |
|---|---|
| Site: | Watts Bar  |
| Issue date: | 03/29/2022 |
| From: | Woolard S Engine Systems |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| Download: ML22098A117 (7) | |
Text
ENGINE SYSTEMS, INC.
175 Freight Road Telephone: 252/977-2720 Rocky Mount, NC 27804 Fax: 252/446-1134 March 29, 2022 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. 10CFR21-0134, Rev. 0 EMO Cylinder Head with Fireface Thickness Below Specification Cylinder Head P/N 40121485
Dear Sir/ Madam:
The enclosed report addresses a reportable notification on an EMO cylinder head with fireface thickness below specification, Cylinder Head P/N 40121485.
A copy of the report has also been mailed to our affected nuclear customers.
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 252/446-3830) within 10 working days after receipt.
Yours very truly, ENGINE SYSTEMS, INC.
Susan Woolard Document Control Coordinator 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:
71 ---------
DATE:
Quality Performance With Pride
ENGINE SYSTEMS, INC.
175 Freight Road, Rocky Mount, NC 27804 Telephone: 252/977-2720 Fax: 252/446-1134 Report No. 10CFR21-0134 Rev. 0: 03/29/22 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: EMO Cylinder Head with Fi reface Thickness Below Specification Part Number 40121485 Date Code 18K SYSTEM: Emergency Diesel Generator CONCLUSION: Reportable in Accordance With 10CFR21 Prepared By: ~~ Date: 3/zq/ii-(J Engineering Manager Reviewed By: a. f2JJt Quality Manager Date: 3J:;.1LJ.J.
Quality Performance With Pride
Report No. 10CFR21-0134 Record of Revisions Page: 1 of 1 REV DATE PAGE DESCRIPTION 0 03/29/22 Original Issue.
Report No. 10CFR21-0134 Revision : 0 Date: 03/29/22 Page: 1 of 4 Pursuant to 10 CFR 21.21(d)(4), ESI is presenting the required information as follows:
(i) Name and address of the individual or individuals informing the Commission.
Dan Roberts John Kriesel Quality Manager Engineering Manager Engine Systems Inc. Engine Systems Inc.
175 Freight Rd. 175 Freight Rd.
Rocky Mount, NC 27804 Rocky Mount, NC 27804 (ii) Identification of the basic component supplied within the United States which fails to comply or contains a defect.
EMO Cylinder Head, PIN 40121485, DIC 18K (iii) Identification of the firm supplying the basic component which fails to comply or contains a defect.
Engine Systems Inc. (ES/)
(iv) Nature of the defect or failure to comply and the safety hazard which is created or could be created by such defect of failure to comply.
A fatigue crack was discovered in the fireface of an EMO cylinder head installed on an emergency diesel generator set. The crack initiated on the coolant side and propagated through the fireface wall to the combustion side resulting in a water leak. Fatigue failure was likely caused by a reduced fireface thickness which reduced overall rigidity of the fireface, allowing increased deformation and ultimately failure due to high tensile stress at the blend between the fireface and valve seat.
The cylinder head is integral to operation of an emergency diesel generator set. Each head assembly, one per engine cylinder, forms the top wall of the combustion chamber which allows the buildup of pressure for fuel ignition. Within its assembly, the head contains jacket water passages adjacent to the fireface to remove heat and regulate fireface metal temperatures. A reduced fireface thickness could result in a through wall crack that would introduce jacket water into the combustion chamber. A minimal amount of leakage would have no immediate impact on engine operation; however, over time if the crack propagated or went undetected engine damage may occur. In standby conditions, fluid in the combustion chamber is typically detected when barring the engine over prior to a normal engine start.
This common practice safeguards against damage due to such an event and leakage is observed as fluid discharging from the cylinder indicator valve . During an emergency start, where engine barring does not occur, a significant amount of fluid in the combustion chamber could cause hydraulic lock.
During engine operation, fluid leakage into the combustion chamber could lead to cylinder liner scuffing and progressive engine damage . Ultimately, a crack in the fireface could lead to failure of the diesel engine which would prevent the emergency diesel generator set from performing during a safety-event.
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Fireface / Figure 1: Cylinder Head Figure 2: location of Crack (side view) (transition of fireface to valve seat)
Report No. 10CFR21-0134 Revision : 0 Date: 03/29/22 Page : 2 of 4 (v) The date on which the information of such defect or failure to comply was obtained .
January 27, 2022 (vi) In the case of a basic component which contains a defect or fails to comply, the number and location of these components in use at, supplied for, being supplied for, or may be supplied for, manufactured , or being manufactured for one or more facilities or activities subject to the regulations in this part.
Cylinder heads from DIC 18K were supplied within the power pack assemblies listed below. Note the serial number of the power pack assembly is the serial number of the cylinder head.
Customer ES/ Sales Part Number ES/ C-of-C Customer Serial Number PO Order Ordered Date 18K0405 8/6/2020 18K0454 8/6/ 2020 18K0477 8/6/2020 40124897 18K2011 8/6/2020 NUCLEAR POWER (Fork Power Pack) 18K2084 8/6/2020 3200432/1269 3020124 PLANT KRSKO+
18K2112 8/6/2020 18K2116 8/6/2020 18K2122 8/6/2020 40124898 18K0427 8/6/2020 (Blade Power Pack) 40124897 18K0481 1/ 15/2021 (Fork Power Pack) 18K0520 1/ 15/2021 18K0120 1/ 15/2021 18K0408 1/ 15/2021 6311467 3020536 18K0448 1/15/2021 40124898 18K0483 1/15/2021 (Blade Power Pack) 18K1961 1/ 15/ 2021 TENNESSEE VALLEY 18K2118 1/ 15/2021 AUTHORITY-WATTS BAR 18K212111i 1/ 1512021 18K0010 12/14/2021 40124897 18K051812i 12/14/2021 (Fork Power Pack) 18K052212i 12/14/2021 6311864 3020939 18K004612i 12/14/2021 40124898 18K0440l2i 12/14/2021 (Blade Power Pack) 18K208512i 12/14/2021 18K21 13 12/14/2021 Table 1: List of Customers for Cylinder Head PIN 40121485 and DIC 18K Notes: (1) This is the head that developed the crack.
(2) These heads were returned to ES/ and inspected during the Part 21 evaluation process. It was confirmed they do not exhibit the same condition as the failed head.
Report No. 10CFR21-0134 Revision : 0 Date: 03/29/22 Page: 3 of 4 (vii) The corrective action which has been, is being, or will be taken; the name of the individual or organization responsible for the action ; and the length of time that has been or will be taken to complete the action.
For affected customers:
ES/ recommends an ultrasonic thickness inspection on the fireface to confirm thickness is within specified range . This requires removal of the cylinder head from the power pack assembly to access the fireface . If desired, ES/ will assist with an on-site inspection and/or provide equipment to support the inspection. Alternatively, power pack assemblies may be returned to ES/ for this activity.
Upon successful completion of the inspection, reassemble power pack assemblies using, at a minimum, a new head-to-liner gasket PIN 40099569 (qty 1) and new head-to-liner locknuts PIN 8060089 (qty 8) .
For ES/:
To prevent reoccurrence, ES/ has revised the dedication package to increase the number of ultrasonic thickness inspection points. An additional enhancement is the inclusion of an inspection map for guidance and clarity of the locations to be measured. The revision was implemented on March 15, 2022.
(viii) Any advice related to the potential defect or failure to comply about the facility, activity, or basic component that has been, is being, or will be given to purchasers or licensees .
To ease identification of affected cylinder heads, Photo 1 below shows location of serial number stamping on the head.
Photo 1: Location of Serial Number Identification (ex. SIN 20L0707)
Report No . 10CFR21-0134 Revision : 0 Date: 03/29/22 Page: 4 of 4 To perform an ultrasonic inspection of the cylinder head fireface , the map below shows locations of interest. For best results, a 2.5 Mhz probe should be used with the ultrasonic thickness gauge.
Fireface thickness at these eight (8) locations should be no less than 0.230".
0 0 0 Figure 3 Sonic Thickness Measurement Locations