United States Nuclear Regulatory Commission - Protecting People and the Environment

ACCESSION #: 9909290055

ENGINE SYSTEMS, INC.

1220 S. Washington St.,
Rocky Mount, NC 27801
P.O. Box 1928,
Rocky Mount, NC 27802-1928
Telephone: 919/977-2720
Fax: 919/446-1134

September 23, 1999

U.S. Nuclear Regulator Commission
Document Control Desk
Mail Stop 0-11A1
Washington, DC 20555

Subject: 10CFR21 Reporting of Defects and Non-Compliance Engine Systems, Inc. Report No. 10CFR21-0079 Woodward EGM controllers

Dear Sir:

The enclosed report addresses a reportable defect and the corrective action to be taken by users of the EGM controllers.

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:(92)
DATE:

Quality Performance With Pride


ENGINE SYSTEMS, INC.

1220 S. Washington St.,
Rocky Mount, NC 27801
P.O. Box 1928,
Rocky Mount, NC 27802-1928
Telephone: 252/977-2720
Fax: 252/446-1134

Report No. 10CFR21-0079
Rev. 0: September 21, 1999

10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE

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.
PREPARED BY: DATE:
Donald D. Galeazzi
Engineering Manager
REVIEWED BY: DATE:
Michael/Nuding
Quality Assurance Manager

Quality Performance With Pride


REPORT NO. 10CFR21-0079
REVISION 0: 9/21/99
PAGE: 1 OF 2
SUMMARY: Engine Systems Inc. (ESI) has received notification from Woodward that EGM controllers manufactured between December 1997 and May 1999 may have questionable soldering workmanship. Soldering workmanship was affected because of inadequate personnel training. This issue was discovered by PECO, Limerick Station during a visual inspection of internal components of an EGM controller. Deficiencies identified included wire strands, excessive solder flux (splash) and cold solder connections.

To date, users have not reported any operabitiy issues with the suspect EGM's. ESI has thermally, radiation and seismically tested two (2) (#9903-085 & #9903-109) of the suspect EGM's without any failures. Each part was also subjected to an additional seismic test by ESI; again, no failures were observed. In addition, each EGM was subjected to a 50 hour burn-in test at Woodward as part of their normal manufacturing tests.

COMPONENT: Woodward EGM controllers (P/N 9903-081, 9903-085, 9903-109 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 and these are identified in Exhibit 1. The listing contains all suspect EGM's; and identifies controllers supplied by ESI as well as controllers supplied directly by Woodward. Only customers with suspect EGM's supplied by ESI are listed below.
Carolina Power & Light, H.B. Robinson
Commonwealth Edison
Georgia Power, Hatch
Illinois Power, Clinton
Nebraska Public Power, Cooper
Northern States Power, Prairie Island
PECO Energy, Limerick
DEFECT: The controller circuit boards may have soldering workmanship deficiencies because of inadequate personnel training at the time of assembly.
CORRECTIVE ACTION: 1. Engine Systems issued a Corrective Action Report. Woodward had already performed corrective action to require proper personnel training/certification in the assembly area.
2. Users should return suspect controllers for repair. For controllers supplied by ESI, please contact ESI's Customer Service Department. Please 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.

REPORT NO. 10CFR21-0079
REVISION 0: 9/21/99
PAGE: 2 OF 2

EXHIBIT 1: SUSPECT WOODWARD EGM CONTROLLERS


REPORT NO. 10CFR21-0079
REVISION 0: 9/21/99
EXHIBIT 1
PAGE: 1 OF 2

SUSPECT WOODWARD EGM CONTROLLERS SUPPLIED BY ENGINE SYSTEMS, INC.

Customer Part Number Serial Number
Carolina Power & Light, Robinson 9903-109 11985991
9903-109 11985992
Commonwealth Edison 9903-085 12049616
9903-085 12049617
9903-085 12049618
9903-085 12049619
9903-085 12049620
9903-085 12049621
9903-085 12049622
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
9903-085 12048591
Nebraska Public Power, Cooper 9903-085 12047526
9903-085 12047527
9903-109 11983334
9903-109 12048594
9903-109 12048596
Northern States Power, Prairie Island 9903-109 12044586
Peco, Limerick 9903-085 12046552
9903-085 12046553
9903-085 12046554
9903-085 12046555
9903-085 12046556
9903-085 12046557
9903-109 12048592
9903-109 12048593
9903-109 12048595
9903-109 12048597
9903-109 12049425
9903-109 12049426


REPORT NO. 10CFR21-0079
REVISION 0: 9/21/99
EXHIBIT 1
PAGE: 2 OF 2

SUSPECT WOODWARD EGM CONTROLLERS SUPPLIED DIRECTLY BY WOODWARD

Customer Part Number Serial Number
Arizona Public Service 9903-085 12004728
9903-085 12019248
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
9903-085 11946948
9903-085 12034000
9903-085 12034001
9903-085 12034002
9903-085 12034003
9903-085 12034004
9903-085 12034005
9903-085 12054126
9903-085 12054127
9903-085 12054128
9903-109 11993328
9903-109 11993329
9903-109 12036290
9903-109 12036291
9903-109 12036292
9903-109 12036293
9903-109 12036294
9903-109 12036295
9903-109 12036296
Northern States Power, Prairie Island 9903-085 12017640
Pennsylvania Power & Light 9903-085 12083808
9903-085 12083809
9903-085 12083810
9903-109 12056912
9903-109 12056913
Woodward - Japan 9903-081 11937746
9903-085 11925080
9903-085 11948690
9903-085 11984451
9903-085 11984452
9903-085 11984453
9903-085 11992393
9903-150 11955454


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