Part 21 Report - 1999-400

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

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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

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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

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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

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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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