United States Nuclear Regulatory Commission - Protecting People and the Environment

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"


*** END OF DOCUMENT ***


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