United States Nuclear Regulatory Commission - Protecting People and the Environment

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  
Page Last Reviewed/Updated Thursday, March 29, 2012