United States Nuclear Regulatory Commission - Protecting People and the Environment

Morning Report for November 6, 2003

Headquarters Daily Report

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N/A

Part 21 - 2003-0013-00, 13-01, 14-00, 14-01, 15-00, 15-01 - Potential Defect in ABB Inc. Class 1E Type TD-5 Relay, Type KLF/KLF-1 Relay, and Type COV-8/COV-9 Relay

Licensee/Facility:


ABB INC.
Coral Springs, Florida
Dockets:

License No:
Notification:

MR Number: H-2003-0033
Date: 07/01/2003


Source Document: Fax

Reviewer: Samuel Lee

Discussion:


Part 21's 2003-0013-00, 2003-0013-01, 2003-0014-00, 2003-0014-01, 2003-0015-00, 2003-0015-01

ABB Inc. Substation Automation & Protection reported potential defect associated with three of their Class 1E relay types. They include: Type TD-5 Relay, Type KLF/KLF-1 Relay, and Type COV-8/COV-9 Relay. This report pertains to Part 21, Numbers 2003-0013-00, 2003-0013-01, 2003-0014-00, 2003-0014-01, 2003-0015-00, and 2003-0015-01 concerning these three relay types.

ABB Inc. Substation Automation & Protection has been in the process of conducting their "Qualification Verification Program" where seismic qualifications were performed to assure continued performance of their products. Three of their Class 1E relay types have been identified as having potential defects. These relay types include: TD-5 Relay, Type KLF/KLF-1 Relay, and Type COV-8/COV-9 Relay.

The initial test results for the type TD-5 relay was that the telephone (T) relay normally-open contacts passed at the table shaker testing limit of 5.6g and the normally-closed contacts passed at 2.3g. Further evaluation was performed as ABB's original zero period acceleration (ZPA) rating for the type TD-5 relay was 8.0g. It was not until December 2002 that ABB had concluded that type TD-5 relay contained a potential defect with regards to the T relay normally-closed contacts. The type TD-5 relay has since been re-designed and is now qualified at the table shaker testing limit of 5.6g for all contacts. ABB is notifying their customers that if they determine the new ZPA contact ratings are not acceptable for their application, they are to contact ABB for available options.

During the seismic testing of three KLF relays, a structural deviation was realized. The deviation was initially communicated in July 2002 and was considered to be a potential defect in October 2002. A design change was proposed based on the initial communication and was implemented after a seismic testing proved that the T relay provided the structural integrity needed. The change involves the addition of a latch to the relay frame. Further testing of the KLF relays resulted in a ZPA rating of 3.1g whereas ABB's original seismic testing resulted in a ZPA rating of 4.6g. A modification (latch) kit has been developed and is being provided to their customers who have purchased the KLF or the KLF-1 type relay, as indicated by their records. ABB is also providing their customers with a copy of the test curves and are requesting a response as to whether the 3.1g rating is acceptable for their application. A replacement type 40 Circuit Shield with a ZPA rating of 6.0g will be offered to those who consider the 3.1g rating to be unacceptable.

During the seismic testing of three COV-8 relays, a structural deviation was realized. It was reported to ABB on October 1, 2002 that on one of the three COV-8 relays tested, the T relay mounting bracket came loose from the switchjaw pedestal to which it was mounted. A design change has been implemented and subsequent retesting has confirmed that the potential problem has been corrected. The change involves replacing the T relay mounting bracket with an improved part, the addition of a spacer, and the replacement of the mounting hardware. A modification kit has been developed and is being offered to ABB's customers who have purchased the COV-8 or the COV-9 type relay, as indicated by their records. It should also be noted that the seismic table test limit was 5.6g, so ABB is changing their ZPA rating from 5.7g to 5.6g accordingly.

Accession Numbers:

Accession No Accession Date
ML031830141 07/01/2003
ML031470289 05/16/2003
ML031470313 05/16/2003
ML031470326 05/16/2003

Contacts:

Name Office Abbrev Phone No E-Mail
LEE, SAMUEL S NRR (301) 415-1061 SSL@nrc.gov

N/A

Part 21 - 2003-0022-00 - Seabrook Spent Fuel Pool Test Coupons

Licensee/Facility:

FLORIDA POWER & LIGHT
SEABROOK 1
SEABROOK, New Hampshire
Dockets: 05000443

License No:
Notification:

MR Number: H-2003-0034
Date: 09/15/2003


Source Document: Letter

Reviewer: BENNER, ERIC J

Discussion:


Part 21 - 2003-0022-00

Florida Power & Light (the licensee) has identified an abnormality of a Boral test coupon which was removed from the spent fuel pool (SFP) at Seabrook for inspection. Boral test coupons have been located in the SFP as monitoring specimens to assess the performance of similar Boral neutron poison material incorporated into the SFP racks. Boral is a boron carbide and aluminum composite material. The SFP racks were supplied by Westinghouse Electric Corporation using Boral material manufactured by AAR Inc. of Livonia, MI.

The anomaly was identified by visual inspection of the test coupon which revealed blistering of the aluminum cladding that normally encapsulates the internal boron carbide and aluminum composite material. The boron areal density in the Boral has been measured via neutron attenuation testing. This testing and subsequent analysis determined that areal density was within specification, that no loss of control material existed, and that the Boral is presently performing its design function.

However, the rate of blister formation and the long-term effects of these blisters on SFP criticality analyses are not known. Because of this uncertainty, the licensee will implement a Boral monitoring program and add a blistering allowance in the SFP criticality curves. As the root cause of the blistering is not yet known, other facilities using Boral may also be affected.

Accession Numbers:

Accession No Accession Date
ML032650709 09/15/2003
ML032880525 10/06/2003

Contacts:

Name Office Abbrev Phone No E-Mail
BENNER, ERIC J NRR (301) 415-1171 EJB1@nrc.gov


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REGION IV

Part 21 - 2003-0019-00 - Thermo Westronics Model 2100C Series Recorders

Licensee/Facility:

THERMO ELECTRON CORPORATION
THERMO ELECTRON CORPORATION
HOUSTON, Texas
Dockets:

License No:
Notification:

MR Number: H-2003-0035
Date: 07/22/2003


Source Document: Letter

Reviewer: FOSTER, JACK W

Discussion:


Part 21 - 2003-0019-00

Thermo Electron submitted a Part 21 report in which they determined that a random reset anomaly could possibly occur on the Series 2100C recorder. This anomaly surfaced during the manufacture of three (3) commercial grade Series 2100 recorders. When the reset occurs, the recorder must be re-initialized to resume normal function. The root cause of the anomaly has been traced to a timing issue between the CPU Printed Circuit Board Assembly (PCBA) and the Memory Module.

The manufacturer of the EPROM, used as a decoder on the Memory Module, has changed several times during the life of this product. The EPROM as produced by the original manufacturer is no longer available. Newer versions of this EPROM typically function at faster speeds. The faster chip speed can cause a delay in the transition from "send" to "receive"' on the CPU Module and thereby result in the reset. This reset event is random and does not occur on every recorder. After an engineering evaluation, Thermo Electron incorporated a modification to the CPU PCBA to ensure compatibility with the faster EPROM on the Memory Module. This modification eliminates the timing delay and subsequent possibility of the reset. Future shipments of this CPU Module shall incorporate this modification.

To ensure compatibility on previously installed recorders, the Memory Module shall only be offered as part of a kit that includes the newer version CPU PCBA. The scope of the notification includes ten (10) Series 2100C safety related recorders, all of which the vendor has stated, were thoroughly tested and did not exhibit this reset at the time of shipment. However, since it was not possible to determine the exact manufacture date of the EPROM used on these recorders, notification was issued by Thermo Electron to the following customers.

Serial Number Ship Date Customer Shipped To Purchase Order

2100C1824 12/04/02 Com Fed De Electricidad Laguna Verde, Mex. 01-2-23014-CNP
2100C1827 01/08/03 Dominion Nuclear Millstone Site 45138755 Rev. 4
2100C1828 02/19/03 Dominion Nuclear Millstone Site 45138755 Rev. 4
2100C1829 08/16/02 Duke Power Co. Catawba Site NE 5462 001
2100C1830 08/16/02 Duke Power Co. Catawba Site NE 5462 001
2100C1831 01/25/03 Duke Power Co. Catawba Site NE 5462 001
2100C1832 01/25/03 Duke Power Co. Catawba Site NE 5462 001
2100C1833 01/28/03 Duke Power Co. McGuire Site NE 5703 001
2100C1834 01/28/03 Duke Power Co. McGuire Site NE 5703 001
2100C1835 01/28/03 Duke Power Co. McGuire Site NE 5703 001

Thermo Electron has received conformation of notification regarding this issue with the customers listed above (with the exception of the Laguna Verde, Mexico site). In addition, they have made arrangements to implement the design modification, either by rework at the Thermo Electron - Houston facility, or by providing replacement kits to the customer site.

Accession Numbers:

Accession No Accession Date
ML032170035 07/22/2003

Contacts:

Name Office Abbrev Phone No E-Mail
FOSTER, JACK W NRR (301) 415-3647 JWF@nrc.gov
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