Morning Report for June 4, 2003
Headquarters Daily Report
JUNE 04, 2003
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REPORT NEGATIVE
ATTACHED INPUT RECEIVED
HEADQUARTERS x
REGION I x
REGION II x
REGION III x
REGION IV x
PRIORITY ATTENTION REQUIRED MORNING REPORT - HEADQUARTERS JUNE 4, 2003
Licensee/Facility: Notification:
Part 21 Database MR Number: H-03-0022
Electrak Date: 06/04/03
Subject: Part 21 - Initial Notification - Error in fire protection
software
Discussion:
VENDOR: Electrak PT21 No.: 2003-009-00
DATE OF DOCUMENT: 03/07/03 ACCESSION NUMBER: ml030940364
SOURCE DOCUMENT: LETTER REVIEWER: RORP, V. Hodge
Electrak, a vendor of software for cable management and fire protection
data, reports being notified by the Susquehanna licensee that the
TRAK2000 fire hazard module incorrectly reports the total BTU value
assigned to a given fire zone after user input of an suitable additive
BTU margin. The software incorrectly adds the BTU margin to zero instead
of the stored cumulative value, resulting in a lower and therefore less
conservative value. Electrak is tracking this software error as Software
Change Request SCR-0375. The Fermi, Nine Mile Point Unit 1, and Vermont
Yankee nuclear power plants may be affected.
Contact: V. Hodge, NRR
301-415-1861
E-mail: cvh@nrc.gov
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HEADQUARTERS MORNING REPORT PAGE 2 JUNE 4, 2003
Licensee/Facility: Notification:
Part 21 Database MR Number: H-03-0023
Abb Inc. Date: 06/04/03
Subject: Part 21 - Initial Notification - Failed circuit breakers
manufactured by ABB
Discussion:
VENDOR: Westinghouse Electric Co. PT21 No.: 2003-010-00
DATE OF DOCUMENT: 03/14/03 ACCESSION NUMBER: ml030790432
SOURCE DOCUMENT: FAX REVIEWER: RORP, S. Lee
Pursuant to the requirements of 10 CFR 21 to report a potential existence
of a substantial safety hazard associated with defective equipment,
Westinghouse reported, on March 14, 2003, of an issue concerning failure
of ABB medium voltage 4 KV circuit breakers to close and latch.
Westinghouse supplied these breakers for safety-related applications at
the Calvert Cliffs Nuclear Power Plant.
Medium voltage (4 KV) 5VHKR/250 Model 80, 1200A circuit breakers were
manufactured by ABB Inc and were commercially dedicated for Class IE
applications. These breakers, with Model 5 operating mechanisms, were
shipped to the Calvert Cliffs Nuclear Power Plant to be applied by
Westinghouse for the plant's Class IE systems. Recently, Westinghouse had
retrofitted the breakers with Model 7 operating mechanisms manufactured
by ABB Inc. Westinghouse validated that the original breaker
qualifications (for Class lE applications) are still applicable with the
Model 7 operating mechanism installed. Two of these breakers failed to
close and latch during testing at Calvert Cliffs. The first breaker
failed to close and latch during acceptance testing on January 18, 2003.
The second breaker failed to close and latch during its installation
acceptance test in the breaker cubicle on January 27, 2003.
Westinghouse reported that the direct cause of the failures is the result
of out of tolerance primary and secondary trip latches in the ABB Model 7
operating system. The root cause investigation is on-going to determine
if manufacturing, inspection and test procedures could have contributed
to these failures. The extent of the out of tolerance parts has not been
determined. Westinghouse is expected to submit a report within 60-days of
the initial report date to provide an explanation of the cause of the
failures and its potential generic applicability.
The out of tolerance parts could result in a common mode failure for
redundant breakers in safety systems. Based upon testing of the failed
breakers, the failure to close and latch condition is intermittent. In
the case of Calvert Cliffs, if both breakers failed to close when
containment spray is required, the plant could be in a condition outside
the accident analysis.
Calvert Cliffs and ABB Inc. are aware of the out of tolerance primary and
secondary trip latches. Calvert Cliffs took corrective actions to remove
the breakers that are required to close or re-close to provide a safety
HEADQUARTERS MORNING REPORT PAGE 3 JUNE 4, 2003
MR Number: H-03-0022 (cont.)
function. ABB Inc. is currently investigating to determine if low voltage
circuit breakers with the Model 7 operating mechanism are affected by the
out of tolerance parts.
Contact: S. Lee, NRR
(301) 415-1061
E-mail: ssl@nrc.gov
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HEADQUARTERS MORNING REPORT PAGE 3 JUNE 4, 2003
Licensee/Facility: Notification:
Part 21 Database MR Number: H-03-0024
Woodward Date: 06/04/03
Subject: Part 21 - Initial Notification - Stability and amplifier gain
potentiometers swap on EGM control
Discussion:
VENDOR: Engine Systems, Inc. PT21 No.: 2003-011-00
DATE OF DOCUMENT: 04/21/03 ACCESSION NUMBER: ml031200116
SOURCE DOCUMENT: FAX REVIEWER: RORP, T. Markley
Engine Systems Inc. (ESI) has concluded an investigation of a condition
reported with a Woodward EGM control. An EGM control, part number
9903A601 serial number 10019993 was sent to ESI for repair and
refurbishment because of an instability problem. After
repair/refurbishment, the site reported that the Stability and Amplifier
Gain potentiometers were swapped. This condition could have been detected
by verifying the control's actuator output signal for a voltage range of
at least +/-8 VDC. Woodward's functional test procedure for this part
number EGM did not contain a requirement to verify the range of the
actuator output signal and therefore the swapped potentiometers were not
detected. The Woodward test procedures for all EGM (and the similarly
designed EGA) controls supplied by ESI for nuclear service were reviewed
for adequacy to detect the swapped potentiometer condition. The test
procedures for the part number controls listed by ESI (P/N 9903-014,
9903-16, 9903-188, 9903-460) were determined to be inadequate. These EGM
controls have been previously supplied or refurbished by ESl.
Contact: T. Markley, NRR
301-415-3165
E-mail: awm@nrc.gov
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