Information Notice 1994-71, Degradation of Scram Solenoid Pilot Valve Pressure & Exhaust Diaphragms
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UNITED STATES
NUCLEAR REGULATORY COMMISSION
OFFICE OF NUCLEAR REACTOR REGULATION
WASHINGTON, D.C.
20555
October 4, 1994
DEGRADATION OF SCRAM SOLENOID PILOT VALVE
PRESSURE AND EXHAUST DIAPHRAGMS
Addressees
All holders of operating licenses or construction permits for boiling water
reactors (BWRs).
PurDose
The U.S. Nuclear Regulatory Commission (NRC) is issuing this information
notice to alert addressees to the potential failure of scram solenoid pilot
valve diaphragms to function properly to the end of their recommended service
life. It is expected that recipients will review the information for
applicability to their facilities and consider actions, as appropriate, to
avoid similar problems. However, suggestions contained in this information
notice are not NRC requirements; therefore, no specific action or written
response is required.
Description of Circumstances
On March 26, 1994, a control rod failed to scram at Washington Nuclear Plant
(WNP-2) during the routine 120-day test of 10 percent of the control rods.
Testing was expanded to include all control rods and 5 more rods were
identified as having slower than normal notch-45 scram times but were within
technical specification limits.
On April 17, 1994, the licensee for Pilgrim Station discovered during routine
scram time testing that a control rod exceeded the 7-second full insertion
time limit.
Several other rods, while within technical specification limits, had notably slower scram times than their previous baseline test data. Three
rods were slow enough to cause their 2 by 2 arrays to exceed the technical
specification limit. The licensee performed additional testing and, on
April 22, 1994, shut down the plant to replace the pilot valve diaphragms for
approximately 20 control rods which had exhibited slow but acceptable scram
times. The licensee found that the pilot valve diaphragms for five of these
control rods were severely hardened.
Discussion
Automatic Switch Company (ASCO) model HVA-90-405 (referred to as the "dual"
type valve) is commonly used as the scram solenoid pilot valve in BWR-2, BWR-3, BWR-4 and BWR-5 type plants. It is a 3-way valve and directs supply
air to pressurize the scram valves or exhausts air to depressurize the scram
valves and cause a reactor scram (Figure 1).
The pilot valve haone solenoid
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IN 94-71 October 4, 1994 and, when the solenoid changes state, the exhaust and pressure diaphragms in
each pilot valve flex to allow air to pass through internal pathways or block
air from passing. In this way, the air operated scram valves are opened to
cause a reactor scram and closed to reset the scram.
Two dual type valves are connected in series and installed at the top of each
control rod hydraulic control unit. The upper pilot valve is designated as
V-118 and the lower pilot valve is V-117. The location of the V-118 pilot
valve, Just above V-117, results in slightly higher temperatures for the V-118 valve because it receives some of the heat generated by the V-117 solenoid
coil, as well as its own self-generated heat.
The V-118 exhaust diaphragm is
under the most stress when the system is in the normally energized state (no
scram condition) because there is system pressure on the upstream side and
atmospheric pressure on the downstream side. The heat and stress combine to
cause the V-118 exhaust diaphragm to generally age faster than the other three
The problems at both WNP-2 and Pilgrim were caused by the degradation of the
Buna-N rubber diaphragms in the scram solenoid pilot valves. The failure of
the control rod to insert at WNP-2 was due to a 900 circumferential crack in
the V-118 exhaust diaphragm and a hardened V-118 pressure diaphragm that
allowed an air leakage path that prevented the exhaust diaphragm from lifting
off its seat when the pilot valve coil was deenergized. The slow control rod
at Pilgrim was caused by a 60° circumferential crack in the exhaust diaphragm
that prevented full flow of air out of the exhaust port.
The deterioration of the diaphragms at WNP-2 and Pilgrim was much more severe
than what has normally been observed at the end of service life for these
diaphragms. This may indicate that the life expectancy of the diaphragms is
less than the 7-year combined shelf and service life and the 3 to 4-year
service life recommended by GENE. Although some diaphragms exhibited overall
hardening, the diaphragms at both plants were found to be most severely
hardened in areas that are normally in contact with system air (as opposed to
areas that are in contact with metal valve surfaces). Any torsional or
twisting force applied to the removed degraded diaphragms caused them to
crack. According to the NSSS supplier, General Electric Nuclear Energy
(GENE), a normal diaphragm at the end of service life tends to have only a
slight loss of flexibility and is somewhat hardened all over, with no
particular area harder than another.
The diaphragms installed at WNP-2 during the 1990 refueling outage were found
to have assembly dates of 1983, 1987 and 1989.
Material records from Pilgrim
show that all of its scram solenoid pilot valves were rebuilt in June 1991 with kits assembled in either 1987 or 1990.
For both plants, the diaphragms
that exhibited severe degradation were from the 1989-1990 replacement kits.
Analysis by several independent materials laboratories has indicated that the
1989-1990 diaphragms contained somewhat lower levels of nitrile along with
indications of different concentrations of plasticizer and variations in the
curing agents compared to diaphragms with an earlier assembly date. However, prior to 1993, there is no direct correlation between the actual cure date of
the Buna-N components and the assembly date.
IN 94-71 October 4, 1994 In addition to the above, residues were found on some of the degraded
diaphragms where none would be expected, indicating that a chemical reaction
with some contaminant could have contributed to the deterioration of the
diaphragms. The origin of the contaminant is unknown at this time.
The
licensees involved stated that no chemical agent is used to clean the valve
bodies or the Buna-N rubber components during the refurbishment process. The
manufacturer (ASCO) indicated that no chemical cleaning agents are used
during the assembly process and postulated that a contaminant may be
introduced by the licensee air supply system.
In response to recent GENE communications, several licensees have submitted
diaphragm samples to GENE for material analysis.
Degradation has been
observed in a small number of diaphragms from Dresden Station, Quad Cities
Station, and Cooper Nuclear Station.
However, other diaphragms from these
sites, as well as samples from Limerick Nuclear Generating Station and Duane
Arnold Energy Center, have not shown signs of degradation.
Related Communications from GENE and the NRC
GENE Rapid Information Communication Services Information Letter (RICSIL)
No. 069, Rev. 1, issued May 11,
1994, informed licensees that diaphragm kits
or valve assemblies assembled after early 1989 may have a shorter service life
than the 3 to 4 year service life recommended in earlier GENE communications.
GENE Services Information Letter (SIL) No. 575, issued October 27, 1993, discussed potential causes of slow control rod start of motion times. The SIL
indicated that the combined shelf and service life of Buna-N components is
7 years and that the installed service life should be limited to approximately
4 years as recommended in earlier GENE communications.
NRC Generic Letter 91-15, "Operating Experience Feedback Report, Solenoid- Operated Valve Problems at U.S. Reactors," issued September 23, 1991, informed
addressees of an Office for Analysis and Evaluation of Operational Data (AEOD)
case study report, NUREG-1275, Volume 6, "Operating Experience Feedback
Report - Solenoid-Operated Valve Problems," and alerted the industry to the
potential for common-mode failure of solenoid-operated valves. Although
degradation of Buna-N diaphragms was not specifically addressed, degradation
of elastomeric components from aging and thermal factors was discussed.
NRC Information Notice 86-57, "Operating Problems Valves at Nuclear Power
Plants," issued July 11,
1986, discussed several causes of solenoid-operated
valve failures, including Buna-N diaphragm degradation.
NRC Information Notice 86-109, "Diaphragm Failure in Scram Outlet Valve
Causing Rod Insertion," discusses failure of a Buna-N diaphragm in a scram
outlet valve because of age related degradation.
The notice also discussed
lack of an adequate program to monitor shelf life and service life of these
diaphragms and similar components susceptible to age-related degradation.
NRC Bulletin 78-14, "Deterioration of Buna-N Components in ASCO Solenoids,"
issued December 19, 1978, described an event at one licensee facility where a
control rod was slow to scram because small pieces of the Buna-N disc in the
IN 94-71 October 4, 1994 scram solenoid pilot valve had wedged between the core assembly and the valve
body, preventing movement of the core assembly.
The NRC bulletin referenced
GENE SIL No. 128, Revision 1, issued January 30, 1976, and its supplement, SIL
No. 128, Revision 1, Supplement 1, Revision 2, issued March 2, 1984, addressed
deterioration of Buna-N components in scram solenoid pilot valves and
recommended that these components be replaced at periodic intervals and that
the diaphragms be replaced after 3 to 4 years of service. In addition, the
SIL recommended that the work for any one outage be scheduled so that pilot
valves are rebuilt in a distributed checkerboard pattern.
This information notice requires no specific action or written response. If
you have any questions about the information in this notice, please contact
one of the technical contacts listed below or the appropriate Office of
Nuclear Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Project Support
Office of Nuclear Reactor Regulation
Technical contacts: Kamalakar Naidu, NRR
Joseph Petrosino, NRR
(301) 504-2980
(301) 504-2979 Harold Ornstein, AEOD
David Skeen, NRR
(301) 415-7574
(301) 504-1174 Attachments:
1. Figure 1 - ASCO Model HVA-90-405 Scram Solenoid Pilot Valve
2. List of Recently Issued NRC Information Notices
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)Wachment 2 IN 94-71
October 4, 1994 LIST OF RECENTLY ISSUED
NRC INFORMATION NOTICES
Information
Date of
Notice No.
Subject
Issuance
Issued to
94-70
94-69
94-68
94-67
94-66
Issues Associated with Use
of Strontium-89 and Other
Beta Emitting Radiopharma- ceuticals
Potential Inadequacies
in the Prediction of Torque
Requirements for and Torque
Output of Motor-Operated
Butterfly Valves
Safety-Related Equip- ment Failures Caused by
Faulted Indicating Lamps
Problem with Henry
Pratt Motor-Operated
Butterfly Valves
Overspeed of Turbine-
Driven Pumps Caused by
Governor Valve Stem
Binding
Potential Errors in
Manual Brachytherapy
Dose Calculations
Generated Using a
Computerized Treatment
Planning System
Reactivity Insertion
Transient and Accident
Limits for High Burnup
Fuel
Boric Acid Corrosion of
Charging Pump Casing
Caused by Cladding Cracks
09/29/94
09/28/94
09/27/94
09/26/94
09/19/94
09/12/94
08/31/94
08/30/94
All U.S. Nuclear Regulatory
Commission Medical
Licensees.
All holders of OLs or CPs
for nuclear power reactors.
All holders of OLs or CPs
for nuclear power reactors.
All holders of OLs or CPs
for nuclear power reactors.
All holders of OLs or CPs
for nuclear power reactors.
All U.S. Nuclear Regulatory
Commission medical
licensees.
All holders of OLs or CPs
for nuclear power reactors
and all fuel fabrication
licensees.
All holders of OLs or CPs
for pressurized water
reactors.
94-65
94-64
94-63 OL = Operating License
CP = Construction Permit
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October 4, 1994 scram solenoid pilot valve had wedged between the core assembly and the valve
body, preventing movement of the core assembly. The NRC bulletin referenced
GENE SIL No. 128, Revision 1, issued January 30, 1976, and its supplement, SIL
No. 128, Revision 1, Supplement 1, Revision 2, issued March 2, 1984, addressed
deterioration of Buna-N components in scram solenoid pilot valves and
recommended that these components be replaced at periodic intervals and that
the diaphragms be replaced after 3 to 4 years of service.
In addition, the
SIL recommended that the work for any one outage be scheduled so that pilot
valves are rebuilt in a distributed checkerboard pattern.
This information notice requires no specific action or written response. If
you have any questions about the information in this notice, please contact
one of the technical contacts listed below or the appropriate Office of
Nuclear Reactor Regulation (NRR) project manager.
Original signed by
Brian K. Grimes
Brian K. Grimes, Director
Division of Project Support
Office of Nuclear Reactor Regulation
Technical contacts:
Kamalakar Naidu, NRR
(301)
504-2980
Joseph Petrosino, NRR
(301) 504-2979
Harold Ornstein, AEOD
(301) 415-7574 Attachments:
1. Figure 1 - ASCO Model HVA-90-405 Scram Solenoid
2. List of Recently Issued NRC Information Notices
David
(301)
Skeen, NRR
504-1174 Pilot Valve
- See nreviniir rnncurrence
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DATE
05/16/94
05/17/94
05/10/94
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DATE
05/17/94
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DATE
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[OFFICIAL RECORD COPY]
DOCUMENT NAME:
94-71.IN
IN 94-XX
October X, 1994 This information notice requires no specific action or written response.
If
you have any questions about the information in this notice, please contact
one of the technical contacts listed below or the appropriate Office of
Nuclear Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contacts:
Kamalakar Naidu,
(301) 504-2980
Joseph Petrosino, NRR
(301) 504-2979
Harold Ornstein, AEOD
(301) 415-7574 Attachments:
1. Figure 1 - ASCO Model HVA-90-405 Scram Solenoid
2. List of Recently Issued NRC Information Notices
David Skeen, NRR
(301) 504-1174 Pilot Valve
- See previous concurrence
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05/16/94
05/17/94
05/10/94
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NAME
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05/17/94
05/20/94
06/06/94
07/28/94 OFC
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DATE
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DATE
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[OFFICIAL RECORD COPY]
DOCUMENT NAME: G:\\SSPVBUNA.JLB
IN 94-XX
August xx, 1994 This information notice requires no specific action or written response. If
you have any questions about the information in this notice, please contact
one of the technical contacts listed below or the appropriate Office of
Nuclear Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contacts:
Kamalakar Naidu, NRR
(301) 504-2980
Joseph Petrosino, NRR
(301) 504-2979
Harold Ornstein, AEOD
(301) 415-7574 Attachments:
1. Figure 1 - ASCO Model HVA-90-405 Scram Solenoid
2. List of Recently Issued NRC Information Notices
David Skeen, NRR
(301) 504-1174 Pilot Valve
- See previous concurrence
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IN 94-XX
July xx, 1994 This information notice requires no specific action or written response.
If
you have any questions about the information in this notice, please contact
one of the technical contacts listed below or the appropriate Office of
Nuclear Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contacts:
Kamalakar Naidu, NRR
(301) 504-2980
Joseph Petrosino, NRR
(301) 504-2979
Harold Ornstein, AEOD
(301) 415-7574 Attachments:
1. Figure 1 - ASCO Model HVA-90-405 Scram Solenoid
2. List of Recently Issued NRC Information Notices
David Skeen, NRR
(301) 504-1174 Pilot Valve
- See previous concurrence
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DATE
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05/17/94
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[OFFICIAL RECORD COPY]
DOCUMENT NAME: G:\\SSPVBUNA.JLB
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IN 94-XX
July xx, 1994 This information notice requires no specific action or written response.
If
you have any questions about the information in this notice, please contact
one of the technical contacts listed below or the appropriate Office of
Nuclear Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contacts:
Kamalakar Naidu, NRR
(301) 504-2980
Harold Ornstein, AEOD
(301) 415-7574
Joseph Petrosino, NRR
(301) 504-2979 David Skeen, Pv'
(301) 504-1174 Figure 1 - HAV-90-405 Scram Solenoid Pilot Valve
List of Recently Issued NRC Information Notices
Attachments:
- See previous concurrence
OFC
OEAB:DORS
SC/OEAB:DORS
PUB:ADM
SPLB:DSSA
NAME
DSkeen*
RDennig*
Tech Ed*
CGratton*
DqATE
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05/17/94
05/10/94
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DATE I
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/94
/
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/
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[OFFICIAL RECORD COPY]
DOCUMENT NAME: G:\\DLS\\SSPVBUNA.IN
IN 94-XX
June xx, 1994 Related Generic Communications
Generic Letter 91-15 was issued on September 23, 1991, to alert the industry
to the potential for common-mode failure of solenoid-operated valves.
Although the Buna-N diaphragm age and temperature degradation of SSPVs was not
specifically addressed, aging and thermal degradation were discussed in
NUREG-1275, Volume 6, 'Operating Experience Feedback Report -
Solenoid
Operated Valve Problems."
This information notice requires no specific action or written response.
If
you have any questions about the information in this notice, please contact
the technical contact listed below or the appropriate Office of Nuclear
Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contact:
David Skeen, NRR
(301) 504-1174 Attachment:
List of Recently Issued NRC Information Notices
- See previous concurrence
OFC
OEAB:DORS
SC/OEAB:DORS
PUB:ADM
SPLB:DSSA
NAME
DSkeen*
RDennig*
Tech Ed*
CGratton*
DATE
05/16/94
05/17/94
05/10/94
05/17/94 I
OFC
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DATE
05/17/94
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06/06/94
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NAME
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AKugler
BGrimes
DATE
/
/94
/
/94
/94
[OFFICIAL RECORD COPY]
DOCUMENT NAME: G:\\DLS\\SSPVBUNA.IN
IN 94-XX
May xx, 1994 "Operating Experience Feedback Report - Solenoid Operated Valve Problems."
This information notice requires no specific action or written response. If
you have any questions about the information in this notice, please contact
the technical contacts listed below or the appropriate Office of Nuclear
Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contacts:
Kamalakar Naidu, NRR
(301) 504-2980
David Skeen, NRR
(301) 504-1174 Attachment:
List of Recently Issued NRC Information Notices
- See previous concurrence
OFC
OEAB:DORS
SC/OEAB:DORS
PUB:ADM
SPLB:DSSA
NAME
DSkeen
RDennig*
Tech Ed*
CGratton*
DATE
05/16/94
05/17/94
05/10/94
05/17/94 OFC
lC/SPLB:DSSA
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DATE
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/94
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D/DORS
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NAME
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BGrimes
DATE
/ /94
/ /94
/ /94
[OFFICIAL RECORD COPY]
DOCUMENT NAME:
G:\\DLS\\SSPVBUNA.IN
IN 94-XX
May xx, 1994 NUREG-1275, Volume 6, "Operating Experience Feedback Report - Solenoid
Operated Valve Problems.'
This information notice requires no specific action or written response. If
you have any questions about the information in this notice, please contact
the technical contacts listed below or the appropriate Office of Nuclear
Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contacts:
Kamalakar Naidu, NRR
(301) 504-2980
David Skeen, NRR
(301) 504-1174 Attachment:
List of Recently Issued NRC Information Notices
- See previous concurrence
OFC
OEAB:DORS
SC/OEAB:DORS
PUB:ADM
SPLB:DSSA
NAME
DSkeen
RDennig*
Tech Ed*
CGratton*
DATE
05/16/94
05/17/94
05/10/94
05/17/94 iOFC
C/SPLB:DSSA
C/EMCB:DE
T/RVIB:DRIL
AD/DSSA
NAME
CMcCracken*
JStrosnider*
LNorrholm
MVirgilio
DATE
05/17/94
05/20/94
/
/94
/
/94 OFC
C/OEAB: DORS
AC/OGCB:DORS
D/DORS
NAME
AChaffee
AKugler
BGrimes
DATE
/
/94
/
/94
/
/94
[OFFICIAL RECORD COPY]
DOCUMENT NAME:
G:\\DLS\\SSPVBUNA.IN
IN 94-XX
May xx, 1994 This information notice requires no specific action or written response. If
you have any questions about the information in this notice, please contact
the technical contact listed below or the appropriate Office of Nuclear
Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contact:
David Skeen, NRR
(301) 504-1174 Attachment:
List of Recently Issued NRC Information Notices
- See previous concurrence
OFC
OEAB:DORS
SC/OEAB:DORS
PUB:ADM
SPLB:DSSA
NAME
DSkeen
RDennig*
Tech Ed*
CGratton*
DATE
/
/94
05/17/94
05/10/94
05/17/94 l OFC
C/SPLB:DSSA
lC/EMCB:DE
/RVIB:DRIL
AD/DSSA
NAME
CMcCracken*
JStrosnide1..
LNorrholm
MVirgilio
DATE
05/17/94 S'/ zo/94
/
/94
/94 l OFC
C/OEAB:DORS
AC/OGCB:DORS
D/DORS
l
_
_
NAME
AChaffee
AKugler
BGrimes
DATE
/
/94 I
/94
/
/94
[OFFICIAL RECORD COPY]
DOCUMENT NAME: G:\\DLS\\SSPVBUNA.IN
IN 94-XX
May xx, 1994 This information notice requires no specific action or written response. If
you have any questions about the information in this notice, please contact
the technical contact listed below or the appropriate Office of Nuclear
Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contact:
David Skeen, NRR
(301) 504-1174 Attachment:
List of Recently Issued NRC Information Notices
- See previous concurrence
OFC
OEAB:DORS
SC
RS
PUB:ADM
C/OEAB:DORS
NAME
DSkeen0
R nni
Tech Ed*
AChaffee
DATE
5 / /6/94 L- /94
05/10/94 I /
94 OFC
SPLB:DSSAQ
C/OGCB:DORS
D/DORS
NAME
CGratton
CMcCracken
AKugler
BGrimes
DATE
5/ 1)/94
- /2/94
/ /94
/ /94
[OFFICIAL RECORD COPY]
DOCUMENT NAME: G:\\DLS\\SSPVBUNA.IN
IN 94-XX
May XX, 1994
Page X of X
This information notice requires no specific action or written response.
If
you have any questions about the information in this notice, please contact
the technical contact listed below or the appropriate Office of Nuclear
Reactor Regulation (NRR) project manager.
Brian K. Grimes, Director
Division of Operating Reactor Support
Office of Nuclear Reactor Regulation
Technical contact:
David Skeen, NRR
(301) 504-1174 Attachment:
List of Recently Issued NRC Information Notices
OFC
OEAB:DORS
_ SC/OEAB:DORS
PUB:ADM
C/OEAB:DORS
NAME
DSkeen
RDennig
Tech Ed AA1C] AChaffee
DATE
/
/94
/
/94
(//O/94
/
/94 OFC
TECH BRANCH
CHF TECH BR
AC/OGCB:DORS
DDORSl
NAME
CGratton
AKugler
BGrimes
DATE
/
/94
/
/94
/
/94
/
/94
[OFFICIAL RECORD COPY]
DOCUMENT NAME: G:\\DLS\\SSPVBUNA.IN
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