United States Nuclear Regulatory Commission - Protecting People and the Environment


ACCESSION #: 9710160120



                                   ABB



                                        October 13, 1997

                                        LD-97-028



Document Control Desk

U.S.  Nuclear Regulatory Commission

Washington, DC 20555



Subject:  Report Pursuant to 10 CFR 21 Regarding Certain Models of Potter

          & Brumfield Relays



Gentlemen:



The purpose of this letter is to notify the Nuclear Regulatory Commission

of a defect pursuant to 10 CFR 21, "Reporting of Defects and

Noncompliance." The identified "defect" is contamination of lubricant

which has led to the hardening of the lubricant in certain Potter &

Brumfield Products Division NOR relay models 170-1 and 7032 such that the

relays could fail to function, These relays are used in the Plant

Protection System (i.e., Engineered Safety Features Actuation System and

Reactor Protection System).



Waterford Steam Electric Station (WSES) has informed ABB-CE of four

failed Potter & Brumfield Type MDR rotary relays.  Although not all of

the failed relays were supplied by ABB-CE, they were manufactured by

Potter & Brumfield at the same facility utilizing similar components,

lubrication material, and techniques.  The failed relays initially

reported were limited to AC versions of the MDR Relay.  A recently

reported failure of a Model 7032 (DC Version) relay by WSES may indicate

that the problem applies to both AC and DC voltage relays.  Potter &

Brumfield has verbally indicated that they believe model MDR relays

potentially affected are date-coded 94XX, and that earlier (93XX) and

later (95XX) date-coded relays are not affected.



WSES had a failure analysis of each relay performed by Southwest Research

Institute after removal of the relay from service, In all cases,

Southwest Research Institute identified the problem to be hardened

bearing lubricant.



Potter & Brumfield's initial evaluation of the reported problem is that

the lubricant hardening effect is likely due to contaminants introduced

into the lubricant and potentially excessive application of lubricant

which occurred during assembly of the suspect relays.



              ABB Combustion Engineering Nuclear Operations



Combustion Engineering,  PO. Box 500             Telephone (203) 638-1911

Inc.                     1000 Prospect Hill Road  Fax (203) 285-9512

                         Windsor, Connecticut

                         06095-0500





                                                                LD-97-028

                                                                   Page 2



ABB-CE's investigation to date has revealed that Potter & Brumfield

supplied approximately 96 relays of the models identified above to ABB-CE

that are date-coded 94XX.  These have been supplied to various nuclear

power plants as delineated in the attachment as part of the information

specifically required by 10 CFR 21.



                                        Very truly yours,

                                        COMBUSTION-ENGINEERING, Inc.



                                        Ian C. Richard, Director

                                        Operations Licensing



cc: M.  F Barnoski (ABB-CE)





                                                            Attachment to

                                                                LD-97-028



ABB Combustion Engineering Nuclear Operations

10 CFR 21 Report of a Defect or Failure to Comply



The following information is provided pursuant to 10 CFR 21.21 (c)(4):



(i)       Name and address of the individual informing the Commission:



               Ian C.  Rickard, Director

               Operations Licensing

               Combustion Engineering

               2000 Day Hill Road

               Windsor, CT 06095-0500



(ii)      Identification of the facility, the activity, or the basic

          component supplied for such facility or such activity within

          the United States which fails to comply or contains a defect:



          The basic components are Potter & Brumfield MDR relay models

          170-1 and 7032.  Information from Potter & Brumfield indicates

          that the concern potentially affects not only the 170-1 and

          7032, but also the 7033 and 7034 relays date-coded 94XX



(iii)     Identification of the firm constructing the facility or

          supplying the basic component which fails to comply or contains

          a defect:



          The relays were supplied to ABB-CE by Potter & Brumfield and

          were subsequently provided to the nuclear plants identified in

          item (vi) below by:



               Combustion Engineering, Inc.

               2000 Day Hill Road

               Windsor, CT 06095-0500



(iv)      Nature of defect or failure to comply and the safety hazard

          which is created or could he created by such defect or failure

          to comply:



          The defect is lubricant contamination and excessive application

          of lubricant leading to hardening of the lubricant in Potter &

          Brumfield MDR relay models (date-coded 94XX) 170-land 7032 and

          potentially 7033 and 7034 such that the relays could fall to

          function.  These relays are used in the Plant Protection System

          (i.e., Engineered Safety features Actuation System and Reactor

          Protection System), and their failure could prevent proper

          functioning of the Plant Protection System.





                                        2                   Attachment to

                                                                LD-97-028



(v)       The date on which the information of such defect or failure to

          comply was obtained.



          ABB-CE received information regarding failures of the subject

          relays on August 6, 1997.



(vi)      In the case of a basic component which contains a defect or

          fails to comply, the number and location of all such components

          in use at, supplied for, or being supplied for one or more

          facilities or activities subject to the regulations of this -

          part:



          ABB-CE has supplied MDR relays as replacement or original

          equipment as follows:



               Utility             Plant               Model Nos.



          Arizona Public      PVNGS 1, 2, 3       7032,7033,7034

          Service Co.

          Entergy             ANO 2               7032,7033,7034.170-1

          Entergy             Waterford 3         7032,7033,7034,170-1

          Edison              SONGS 2, 3          7032,7033,7034,170.1

          International,

          Inc.



          These relays are normally energized, and are deenergized to

          actuate.



(vii)     The corrective action which has been, is being, or will be

          taken; the name of the individual responsible for the action;

          and the length of time that has been or will be taken to

          complete the action:



          ABB-CE is currently evaluating potential corrective actions.



(viii)    Any advice related to the defect or failure to comply about the

          facility, activity, or basic component that has been, is being,

          or will be given to purchasers or licensee:



          In parallel with providing this 10 CFR 21 report to the NRC,

          ABB-CE will distribute copies of the report to utilities having

          an ABB-CE designed Nuclear Steam Supply System.  Those

          utilities will also be provided with ABB-CE's recommended

          corrective actions, when developed.







GENERAL INFORMATION or OTHER            EVENT NUMBER: 33077



LICENSEE: ABB COMBUSTION ENGINEERING    NOTIFICATION DATE: 10/13/97

    CITY: WINDSOR        REGION: 1      NOTIFICATION TIME: 13:42 [ET]

  COUNTY:                 STATE: CT     EVENT DATE: 08/06/97

LICENSE#:             AGREEMENT: N      EVENT TIME: 00:00[EDT]

  DOCKET:                               LAST UPDATE DATE: 10/13/97



                                             NOTIFICATIONS



                                        JOHN PELLET    RDO



NRC NOTIFIED BY: HESS                   VERN HODGE     NRR

HQ OPS OFFICER: CHAUNCEY GOULD



EMERGENCY CLASS: NOT APPLICABLE

10 CFR SECTION:



CCCC 21.21     UNSPECIFIED PARAGRAPH



                               EVENT TEXT



ABB COMBUSTION REPORTED A PART 21 ON CERTAIN MODELS OF POTTER &

BRUMFIELD

RELAYS.  THEY HAVE IDENTIFIED THE "DEFECT" AS CONTAMINATION OF

LUBRICANT

WHICH HAS LEAD TO THE HARDENING OF THE LUBRICANT IN CERTAIN POTTER

&

BRUMFIELD PRODUCTS DIVISION MDR RELAYS(MODELS "170-1" AND "7032"). 

THIS

"DEFECT" COULD RESULT IN RELAY FAILURE.  THESE RELAYS ARE USED IN THE

PLANT PROTECTION SYSTEM.  THERE IS ALSO THE POTENTIAL FOR RELAY

MODELS

11703311 AND 11703411 TO FAIL TO FUNCTION CORRECTLY.  THESE RELAYS HAVE

BEEN SUPPLIED TO PALO VERDE 1, 2 AND 3, ARKANSAS NUCLEAR ONE UNIT 2,

WATERFORD 3, AND SAN ONOFRE 2 AND 3.  ABB-CE IS CURRENTLY EVALUATING

POTENTIAL CORRECTIVE ACTIONS WHICH WILL BE PROVIDED TO THE UTILITIES

WITH

ABB-CE DESIGNED NUCLEAR STEAM SUPPLY SYSTEMS.





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