Morning Report for August 17, 2005

Headquarters Daily Report

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Part 21 2005-0030 - Potential Issue with Struthers-Dunn Relays

Licensee/Facility: CATAWBA STRUTHERS-DUNN Dockets: License No:

Notification: MR Number: H-2005-0021 Date: 08/02/2005

Source Document: Call / Fax from Licensee

Reviewer: TABATABAI, OMID

Discussion:

Part 21 2005-0030 - Potential Issue with Struthers-Dunn Relays

In August 2005, the manufacturer of Struthers-Dunn relays informed Duke Energy Corporation of a manufacturing defect regarding the subject relays. These relays were made in China between January 2003 and June 2004. The defect was that the annealing step in the manufacturing process of the relays was skipped, which causes the relay coil to draw almost twice its rated current and fail after an extended period of time in the energized state.

Duke Energy Corporation purchased potentially affected relays of this type as commercial-grade and subsequently dedicated them for use in safety-related applications.

The following is a summary of information obtained from Struthers-Dunn concerning the affected relays:

(1) Relays manufactured between January 2003 and June 2004 (date codes 0301B through 0424B on the cover)
(2) Any 219 series relay with 120 AC and 240 AC coils
(3) "Made in China" marked on the cover
(4) Also "Made in USA" marked on the cover with a 'B' in the date code could be affected

The NRC will continue to evaluate this issue.

Accession Numbers:

Accession No	Accession Date
ML052170170	08/02/2005

Contacts:

Name	Office Abbrev	Phone No	E-Mail
TABATABAI, OMID	NRR	(301) 415-6616	OTY@nrc.gov

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Part 21 2005-0031 - Potential Failure of Certain Eaton Electrical Freedom Series Heater Pack Models

Licensee/Facility: AREVA Dockets: License No:

Notification: MR Number: H-2005-0022 Date: 08/08/2005

Source Document: Letter

Discussion:

Part 21 2005-0031 - Potential Failure of Certain Eaton Electrical Freedom Series Heater Pack Models

Framatome ANP informed NRC on August 8, 2005 that certain Freedom Series Heater Pack models have failed during installation or removal of the heater pack. This condition potentially exists for Eaton Cutler-Hammer Freedom Series Heater Packs H2009B-3 through H2014B-3, which utilize spot welds with a nickel slug to join the brass screw terminal to the heater coil. Framatome ANP recommends the replacement of all H2009B-3 through H2014B-3 Eaton Electrical Freedom Series Heater Packs manufactured between September 1, 2004 and May 31, 2005.

The potential for failure is due to a possible deficiency in the weld which joins the screw terminal to the heater coil. Specifically, if the weld on an Eaton Electrical Freedom Series Heater Pack failed after installation into a Freedom Overload Relay, the failed heater could create an open circuit resulting in the current for that pole to be removed from the load. If the weld on an Eaton Electrical Freedom Series Heater Pack failed after installation into a Freedom Overload Relay, the failed heater could create an open circuit resulting in the current for that pole to be removed from the load. If the load was not running at the time of failure, there would be no indication of failure until attempted start of the load. The load would not start in this condition and would draw excessive current which should trip the overload. No failures have been reported while in operation.

The preliminary results of the investigation have determined that the root cause of the failure of the bond between the brass terminal and the nickel slug associated with the subject Eaton Electrical Freedom Series Heater Pack styles was due to the following major deficiencies:

1) Incorrect current settings on the welding machine
2) Fluctuations in power supply voltage
3) Inconsistent application of inspection criteria

Supplier corrective actions implemented include; increased current settings, voltage regulation, documented daily inspections of the welding machine current settings, documented destructive sample testing and increased documented production sample inspections. Corrective actions to prevent recurrence are being developed by Framatome ANP which will be included in dedication activities that address weld integrity acceptance. These corrective actions will be communicated prior to the close of the subject Condition Report and implemented immediately following development. The evaluation completion schedule is by September 30, 2005.

Customers that purchased Eaton Electrical Freedom Series Heater Packs Style H2009B-3 through and including H2014B-3;

Nuclear Customer Plant Component Quantity Note

American Electric Power DC Cook H2009B-3 4 A
Georgia Power Vogtle H2009B-3 37 A
Georgia Power Vogtle H2013B-3 1 A
First Energy Service Co. Beaver Valley H2009B-3 17 A
First Energy Service Co. Beaver Valley H2010B-3 11 A
First Energy Service Co. Beaver Valley H2009B-3 10 A,B
First Energy Service Co. Beaver Valley H2010B-3 2 A,B
First Energy Service Co. Beaver Valley H2013B-3 2 A,B

Notes:
A. The suffix "-3" indicates a package of three (3) heaters of type H20XXB, where "XX"
represents the size of the heater.

B. Suspect heaters were installed in replacement MCC buckets.

Accession Numbers:

Accession No	Accession Date
ML052220267	08/08/2005

Contacts:

Name	Office Abbrev	Phone No	E-Mail
TABATABAI, OMID	NRR	(301) 415-6616	OTY@nrc.gov