Part 21 Report - 1998-120
ACCESSION #: 9802020122
ESI
ENGINE SYSTEMS, INC.
1220 S. Washington St., Rocky Mount, NC 27801 Telephone: 919/977-2720
P.O. Box 1928, Rocky Mount, NC 27802-1928 Fax: 919/446-1134
January 26, 1998
USNRC
Attn: Vern, Hodge
Mail Stop 0-11A1
Washington, DC 20555
Subject: 10CFR21 Reporting of Defects and Non-Compliance -
Engine Systems, Inc. Report No. 10CFR21-0077
Graham-White Air Start Solenoid Valves #712-015 & #712-065
Dear Sir:
The enclosed report addresses a reportable defect and the corrective
action to be taken by users of the subject air start solenoid valves.
Should you have any questions, please feel free to call.
Please sign below, acknowledging receipt of this report, and return a
copy to the attention of Engineering Document Control at the address
below (or, fax to number 919/446-1134) within 10 working days after
receipt.
Yours very truly,
ENGINE SYSTEMS, INC.
Jo-Ann Mason
Engineering 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:
DATE:
Quality Performance With Pride
ESI
ENGINE SYSTEMS, INC.
1220 S. Washington St., Rocky Mount, NC 27801 Telephone: 919/977-2720
P.O. Box 1928, Rocky Mount, NC 27802-1928 Fax: 919/446-1134
Report No. 10CFR21-0077
January, 22, 1998
10CFR21 REPORTING OF DEFECTS
AND NON-COMPLIANCE
COMPONENT: Graham-White Air Start Solenoid Valves #712-065 &# 712-015
SYSTEM: Standby diesel generators with EMD diesel engines and air
start systems.
CONCLUSION: Defect is reportable in accordance with 10CFR21.
PREPARED BY: DATE:
Donald D. Galeazzi
Engineering Manager
REVIEWED BY: DATE:
Michael Nuding
Quality Assurance Manager
Quality Performance With Pride
REPORT NO. 10CFR21-0077
PAGE: 1 OF 6
SUMMARY:
MKW Power Systems, Inc. (former name of Engine Systems, Inc) issued
Report No. 10CFR21-0055 on June 13, 1990 which provided a 10CFR21
reportable defect with the air start solenoid valve commonly used on EMD
diesel generators (EMD #9513134 / Graham-White #712-051). The valves
exhibited air leakage when maximum allowable inlet air (200 psig) was
applied. This would not prevent the engine from starting; however, the
leakage may cause the air compressor(s) to constantly cycle. After
consulting with the valve manufacturer (Graham-White), MKW determined
that a 275 psig valve was also available. The 275 psig valve was
identical to the 200 psig valve except that it had a different spring.
MKW made the recommendation to replace the valve's spring with a
different spring which was rated for 275 psig. MKW also discontinued
sale of the 200 psig valve for nuclear service and recommended the 275
psig valve as a replacement. The 275 psig valve is Graham-White #712-065
(without mounting bracket) or #712-015 (with mounting bracket).
Engine Systems, Inc (ESI) has recently learned that the 275 psig valve
does not meet the minimum DC voltage requirement of most nuclear
applications when inlet pressures below 200 psig are applied to the
valve. The solenoid valve relies on system air pressure to assist the
coil in overcoming the force of the spring and thus operating the valve
plunger. The reduced system pressure combined with the reduced coil
voltage results in the inability of the valve to operate satisfactorily.
This problem is not applicable to the original 200 psig valve because it
has a weaker spring and therefore less air pressure is needed to overcome
the lower spring force.
COMPONENT:
Graham-White #712-065: Valve without mounting bracket, 125 VDC nominal
coil.
Graham-White #712-015: #712-065 valve with mounting bracket.
Graham-White #1508-003 (#1508-3): Spring, 275 psig.
CUSTOMERS AFFECTED:
All nuclear users of EMD diesel engines with air start systems will be
notified. ESI sales of the affected components to nuclear customers is
provided in Exhibit 1.
DEFECT:
The valve does not meet the minimum DC voltage requirement of most
nuclear applications (usually 90 VDC or 105 VDC is specified) when inlet
pressures below 200 psig are applied to the valve. The solenoid valve
relies on system air pressure to assist the coil in overcoming the force
of the spring and thus operating the valve plunger (see valve literature
contained in
REPORT NO. 10CFR21-0077
PAGE: 2 OF 6
Exhibit 2). For the EMD engine, 200 psig is the maximum allowable inlet
pressure for the on-skid air start manifold piping and air starting
motors. Minimum allowable starting pressure is 125 psig to 150 psig,
depending upon the specific design of the diesel generator. To meet this
criteria for all applications, the air solenoid valve must operate
satisfactorily at 125 psig with 90 VDC applied to the coil. ESI tested
three valves with the 275 psig springs. The following results were
achieved:
Valve Pressure Pickup Voltage (VDC)
#1 200 psig 104
#2 200 psig 96
#3 200 psig 90
#1 175 psig 107
#2 175 psig 96
#3 175 psig 96
#1 150 psig 112
#2 150 psig 100
#3 150 psig 99
#1 125 psig 116
#2 125 psig 105
#3 125 psig 105
CORRECTIVE ACTION:
A. If the site minimum voltage is below 105 VDC, replace the valve's
spring or replace the entire valve assembly. ESI consulted with
Graham-White's spring supplier and obtained valve springs designed
for 230 psig maximum inlet pressure. Eight (8) solenoid valves with
the 230 psig springs installed were tested by ESI. All valves
operated satisfactorily at 100 psig with 90 VDC applied to the
coils. In addition, the valves did not experience leakage with
inlet pressures up to 230 psig.
1. Replace the valve spring:
Use the procedure contained in Exhibit 3. Replace the 275 psig
spring with a 230 psig spring. Spring information is provided
below.
Spring Color Part Number Comments
275 psig Red #1 508-003 Recommended by 10CFR21-0055.
230 psig Blue #1 508-002(6.54#) Recommended by this
notification.
200 psig Silver #1508-001 Originally provided by EMD.
REPORT NO. 10CFR21-0077
PAGE: 3 OF 6
Parts required for spring replacement are as follows:
Item Part Number Qty
Spring 1508-002(6.54#) 1
Seal 1807-000 1
Seal 1469-000 1
Seal 2741-000 1
Nameplate MKN50745-1 1
2. Replace the entire valve
Solenoid valve with mounting bracket: P/N MKN50745
Solenoid valve without mounting bracket: P/N MKN50746
Both valves have 125 VDC coils and 230 psig springs.
B. If the site minimum voltage is 105 VDC or above, test any installed
or stocked solenoid valves. ESI testing of the 275 psig valve
resulted in somewhat inconsistent results, especially for test valve
#1. When testing the solenoid valve, use site specific minimum
voltage and minimum allowable air inlet pressure expected at the
solenoid valve. Apply the inlet pressure to Port 2 of the valve,
energize the coil and verify the solenoid valve changes state by
monitoring for air exiting the valve at Port 3. If the valve fails
to change state at the minimum voltage and inlet pressure
requirements, or if testing is not elected to be performed, replace
the valve spring or replace the entire valve in accordance
Corrective Action item A.
C. This notification is written specifically to address the minimum
voltage issue of the 275 psig valve. If the original EMD supplied
solenoid valve (200 psig) is still in use, the air leakage concern
of MKW report 10CFR21-0055 can be corrected by replacing the valve
spring or by replacing the entire valve as previously discussed in
Corrective Action item A.
REPORT NO. 10CFR21-0077
PAGE: 4 OF 6
EXHIBIT 1
ESI SALES INFORMATION FOR
Graham-White #712-065: Valve without mounting bracket,
125 VDC nominal coil.
Graham-White #712-015: #712-065 valve with mounting bracket.
Graham-White #1508-003 (#1508-3): Spring, 275 psig.
(1 PAGE)
Table "ESI SALES INFORMATION 10CFR21-0077".
REPORT NO. 10CFR21-0077
PAGE: 5 OF 6
EXHIBIT 2
GRAHAM-WHITE DRAWING 712-015
(1 PAGE)
Figure 712-015 "SALEM SOLENOID VALVE, SINGLE UNIT - NORMALLY CLOSED"
REPORT NO. 10CFR21-0077
PAGE: 6 OF 6
EXHIBIT 3
VALVE SPRING REPLACEMENT PROCEDURE
(1 PAGE)
| VALVE SPRING REPLACEMENT PROCEDURE | 10CFR21-0077 |
| 1. | Place the valve assembly on a horizontal surface with the coil side up. |
| 2. | Remove the valve's exhaust nut and remove the coil assembly (item 3). Note orientation of coil body relative to the valve body for reassembly. |
| 3. | Use a wrench to unscrew the coil pole and remove the spring (item 4). |
| 4. | Remove seal (item 7) from the valve body and replace with #2741-000. |
| 5. | Remove seal (item 6) from the coil pole and replace with #1469-000. |
| 6. | Install blue spring #1508-002(6.54#) into the valve body cavity and around the plunger assembly (item 5). |
| 7. | Install the coil pole into the valve body. Push down on the coil pole to compress the spring and turn to engage the threads. Tighten the coil pole hand (snug) tight. |
| 8. | Install the coil assembly (item 3) over the coil pole. Maintain the same orientation of the coil assembly relative to the valve body as noted in step 2 above. |
| 9. | Remove seal (item 2) from the exhaust nut and replace with #1807-000. |
| 10. | Install exhaust nut onto the threaded end of the coil pole. Tighten the exhaust nut hand (snug) tight. |
| 11. | Remove protective film from the valve nameplate (if present). Clean nameplate surface. Remove backing from new nameplate #MKN50745-1 and install over existing nameplate. |
| 12. | Apply 230 psig to Port 2 and verify no air leakage from Ports 1 & 3. Apply 100 psig to Port 2 and then apply 90 VDC to the coil. Verify the valve changes state by monitoring for air exiting the valve at Port 3. |
Figure "SINGLE UNIT BRACKET"
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