United States Nuclear Regulatory Commission - Protecting People and the Environment

ACCESSION #: 9908270106

CD TECHNOLOGIES
Power Solutions

Director of Quality Assurance
401 Washington St.
Conshohocken, PA 19428
Phone: (610) 825-2150
Fax: (610) 832-0252

25 August 1999
US Nuclear Regulatory Commission
Washington, DC 20555-0001
Attn: Document Control Desk

VIA FACSIMILE: 301-816-5151

Dear Sirs;

This letter is to inform you of a nonconformance within LCR-25 safety related lead acid battery cells manufactured by C&D for Nebraska.public Power District's Cooper Nuclear facility. The cells were purchased by NPPD under PO 95-60 for 356 LCR-25 cells. NPPD has reported to as that they have seen growth in the positive plates within the some cells and at least one cell was removed when a short developed. Since NPPD made the report, cells have been returned to C&D and analysis of the cells has been completed in conjunction with NPPD personnel. Analysis of the positive grid material shows nonconforming levels of calcium within the positive grid alloy.

All effected cells within our knowledge were manufactured within 5 work order numbers, and all cells for these work orders have been accounted for. To the best of our knowledge, no other utility has been effected by this nonconformance besides NPPD.

The high calcium grid alloy will cause higher than expected growth within the positive grids overtime. Eventually this will lead to loss of contact between the grid and the positive active material of the plate and lead to reduced capacity, reduced voltage and shedding of material. The first sign of the defect is visible growth within the positive plate. After the growth is detected there will be gradual degradation capacity and voltage, eventually leading to shedding of material, All indications are that the cells which have been evaluated will continue to supply the required load for the plant until they can be replaced during the next schedule outage.

A final evaluation will be delivered to the NRC and to effected utilities within 30 days.

Sincerely,

Terry Kinden
Director Quality Assurance

cc: Tom Shudek-NPPD QA
File: QA7887

08/26/1999

U.S. Nuclear Regulatory Commission Operations Center Event Report

Page 1

General Information or Other (PAR) Event# 36073
Rep Org: CD TECHNOLOGIES Notification Date / Time: 08/25/1999 18:00 (EDT)
Supplier: CD TECHNOLOGIES Event Date / Time: 08/25/1999 (EDT)
Last Modification: 08/25/1999
Region: 1 Docket #:
City: CONSHOHOCKEN Agreement State: No
County: License #:
State: PA Notifications: KATHLEEN MODES R1
NRC Notified by: TERRY KINDEN PHIL HARRELL R4
HQ Ops Officer: FANGIE JONES RICHARD WESSMAN NRR
Emergency Class: NON EMERGENCY VERN HODGE (FAX) NRR
10 CFR Section: 21.21 UNSPECIFIED PARAGRAPH

10CFR PART 21 REPORT DUE TO SAFETY RELATED LEAD ACID BATTERY CELL NONCONFORMANCE

A nonconformance within LCR-25 safety related lead acid battery cells manufactured by C&D for Nebraska Public Power District's (NPPD's) Cooper Nuclear facility has been discovered. The cells were purchased by NPPD and they reported to C&D that they have seen growth in the positive plates within some cells and at least one cell was removed when a short developed. Analysis of the cells has been completed by C&D, in conjunction with NPPD personnel, showing nonconforming levels of calcium within the positive grid alloy.

To the best of C&D's knowledge, no other utility has been effected by this nonconformance besides NPPD.

A final evaluation will be delivered to the NRC and to effected utilities within 30 days.


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