ML032870422
| ML032870422 | |
| Person / Time | |
|---|---|
| Site: | Point Beach  (DPR-024, DPR-027) |
| Issue date: | 10/09/2003 |
| From: | Starr F Framatome ANP |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| LTR 03-310 | |
| Download: ML032870422 (9) | |
Text
I1010912003 U.S. NuclearRegulatory Commission Operations Center Event Report Pare I General Information or Other (PAR)
Event #
40234 Rep Org: FRAMATOME ANP Notification Date Time: 10/09/2003 11:22 (EDT)
Supplier: EATON CUTLER HAMMER Event Date I Time: 10/09/2003 (EDT)
Last Modification: 10/09/2003 Region: 1 Docket #:
City: CRANBERRY TOWNSHIP Agreement State:
No County:
License #:
State: PA NRC Notified by: FRAN STARR Notifications: RONALD BELLAMY RI HQ Ops Officer: MIKE RIPLEY KERRY LANDIS R2 Emergency Class: NON EMERGENCY KENNETH O'BRIEN R3 10 CFR Section:
WILLIAM JOHNSON R4 21.21 UNSPECIFIED PARAGRAPH JACK FOSTER NRR PART 21 REPORT A potential safety condition was reported which may exist with the Eaton Cutler-Hammer Type W Vintage Unit plug in stabs. On July 3, 2003, Framatome ANP, Inc - Electrical Products received from Eaton Cutler-Hammer an Eaton Cutler-Hammer Type W Vintage Unit Product Advisory, dated June 27, 2003. The advisory warns that the condition exists when a unit of a particular Manufacturing Date Code range is withdrawn from a Motor Control Center structure. Under this condition, the clip holding the stab finger in place may dislodge. As a result, the stab finger remains plugged onto the vertical bus until the breaker cable connection forces the stab finger off the bus.
The potential of a unit being extracted from live bus may cause arcing or single phasing or risk of personal injury, death or property damage.
On July 3, 2003, Framatome ANP, Inc. - Electrical Products determined that the defective Eaton Cutler-Hammer Type W Vintage Unit Plug in Stabs were supplied as a Safety Related component installed in Safety Related Type W MCC Buckets to only one Nuclear Customer. On July 3, 2003, Framatome ANP, Inc. - Electrical Products notified the Point Beach Nuclear Plant (Nuclear Management Company). Corrective actions implemented by Framatome ANP, Inc. - Electrical Products included the replacement of thirteen (13) Type W Stab Assemblies, with new Type W Stab Assemblies manufactured by Eaton Cutler-Hammer with "updated clips" (clips with wings) at the Point Beach Nuclear Plant Site on July 11, 2003.
Affected Plant:
Point Beach 19l 1
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A FRAMATOME ANP An AREVA and Siemens Company FRAMATOME ANP, Inc.
FAX COVER SHEET DATE:
10/9103 Total Pages Including Cover 8 TO:
NRC Operations Center COMPANY:
TELEPHONE:
FROM:
COMPANY:
TELEPHONE:
COMMENTS:
United States Nuclear Regulatory Commission 301-816-5100 FAX:
301-816-5151 Fran Starr TITLE:
OA Manager Framatome ANP, Inc. - Electrical Products 724-779-9800 ext.
FAX:
724-779-9844 1321 See Below
Subject:
I 0CFR Part 21 NRC Initial Notification Attached please find Framatome ANP, Inc. - Electrical Products, Letter No. LTR-03-310 which Identifies a Potential Safety Condition for the Eaton Cutler-Hammer Type W Vintage Unit Plug In Stabs Should you have any questions, please contact me at (724) 779-800 ext. 1321.
Thank You, Framatome ANP, Inc.
Fran Starr Quality Manager - Electrical Products FRAMATOME ANP, Inc. - Eleetricul Products 200 West Kensinger Drive, Suite 600 Cranberry Township, PA 16066 Telephone: 724-779-9800 ext. 1321 Emall:Fran.StarrO framatome-inp.com 10/OS/2003 TU 11:00
[Tl/RI NO 88831 0001
rrmEaXOmS AP cranberry PA 724 771 1344 2/3 A
FRAMATOME ANP An AREVA and Siemens Company FRAMATOME ANP, Inc.
October S, 2003 LTR 03-310 Document Control Desk United States Nuclear Regulatory Commission Washington, DC 20555 Attention:
Director, Office of Inspection and Enforcement
Subject:
Potental Safety ConditIon for Eaton Cutler-Harnner Type W Vintage Unit Plug In Stabs The following Information Is provided pursuant to the requirements of 100CFR Part 21 to report a potential safety concern. A potential safety condition may exdst with the Eaton Cutler-Hamrnmer Type W Vintage Unit plug In stabs.
This condition exists when a unit of a particular Manufacturing Date Code range Is withdrawn from a Motor Control Centerstructure. Under this condition, the clip holding the stab finger In place may dislodge. As a result, the stab finger remains plugged onto the vertical bus until the breaker cable connection forces the stab finger off the bus. The potential of a unit being extracted from live bus may cause srcing or single phasing or risk of personal Injury, death or property damage.
Description of Events:
On July 3, 2003, Frarnatome ANP, Inc - Electrical Products received from Eaton Cutler-Hammer the atached Eaton Cutler-Hammer Type W Vintage Unit Product Advisory, dated June 27,2003. The Product Advisory warned that the Type W Vintage Unit plug In stabs manufactured between October 1, 2000 and March 26,2003 should NOT be removed from the Motor Control Center Structure with the streture bus energized. The attachment to the Product Advisory, dated June 25,2003 Indicates that the results of the Eaton Cutler-Hammer Investigation / evaluation determined that the clips were out of specification tolerance from the Intended design; specifically, the top *wIngs of the spring clip. The attachment also outlined the corrective action~s) Implemented by Eaton Cutler-Harrner for replacement stabs.
On July 3, 2003, Framatome ANP, Inc. - Electrical Products determined that the defective Eaton Cutler-Hammer Type W Vintage Unit Plug In Stabs were supplIed as a Safety Related component Installed In Safety Related Type W MCC Buckets to only one Nuclear Customer. On July 3,2003, Framatome ANP, Inc, - Electrical Products notified the Point Beach Nuclear Plant (Nuclear Management Company). Corrective actions Irnplemented by Farnmatome ANP, Inc. - Electrical Products Included the replacement of tfIrteen (13) Type W Stab Assemblies, with new Type W Stab Assemblies manufactured by Eaton Culler-Hamnmer with 'updated cips' (clips with wings) at the Point Beach Nuclear Plant Site on July 11, 2003.
On August 14,2003, Framatorns ANP, Inc. Electrical Products was notified by the Point Beach Nuclear Plant that whfle performing their pre-nstallation bucket check J inspection on the Safety Related Type W MCC Buckets supplied by Framatome ANP, Inc. - Electrical Products during June 2003, (outside of the Date Code range of the Product Advisory) some of the stab assemblies, which were manufactured by Eaton Cutter-Hammer with the new / updated clips, were found to have one or two (of three) stabs loose. Further Inspection by the Point Beach Nuclear Plant revealed that each clip for Oh loose stab was not positioned within the phenolic slab assembly correctly. The quality status of all new updated Type W Stab Assemblies manufactured by Eaton Cutler-Hammer and suppried by Frarnatome ANP, Inc. - Electrical Products to the Point Beach Nuclear Plant site were rendered as Indeterminate /
suspect.
On August 20,2003, the manufacturer, Eaton Cutler-Hammer confirmed that the updated clp (clip with wings) utilized as a resuft of the corrective action(s) to prevent recurrence associated with the Eaton Cutler-Hammer Product Advisory were utilized to produce the TypeW (replacement) Stab Assemblies and were nonconforming. The nonconforming cip could cause the stab to separate from the housing.
FRAMATOME ANP, Inc.
130 Commonwealth Drive, Warrendale, PA 15086 Tel: 724-779-5827 Fax: 724-779-5030 Emall:Fran.StarrG f ramatome-anp.com 10/09/2003 TM) 11!nn 10/0/203 T~ 11)0r'vr/DIr wn 0oco'a Mn,'
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FRAMATOME ANP An AkEVA and Siemens Company FRAMATOME ANP, Inc.
Document Control Desk LTR-03-310 Director, Office of Inspection and Enforcement Page 2 of 2 Further Investigation by Eaton Cutler-Hammer determined that the root cause of the failure, as Identified by the Point Beach Nuclear Plant, was due to:
Clip not In accordance with the drawing due to the worn stamping die Inadequate Insertion of the dip Into the stab housing insufficlent assembly nstructions for the stab assembly Insuffident quality check In place to test the overall assembly, and Drawing missing / requiring additional tolerance dimensions / material specification Immediate corrective action(s) Implemented by Eaton Cutter-Hammer Inciuded Rework of the stamping die Insertion tool designed I implemented to the manufacturing floor for clp Insertion Operation Methods Sheets established In the stab assembly manufacturing area Personnel training Tolerance dimensions established On September 12, 2003, at the Point Beach Nuclear Plant, Immediate corrective actions implemented by Eaton Cutler-Hammer, In conjunction wMi enhanced Inspection acthvtles by Framatome ANP, Inc. - Electrical Products Involved the replacement of suspect stab assemblies for all Safety Related Type W MCC Buckets (supplied by Framatome ANP, Inc. - Electrical Products) not Installed In Motor Control Centers. Al remaining Safety Related Type W MCC Buckets, supplied by Framatome ANP, Inc. - Electrical Products, that are currently Installed In Motor Control Centers at the Point Beach Nuclear Plant will be removed for replacement of suspect stab assemblies when Point Beach Nuclear Plant can do-energize the Motor Control Center for safe bucket removal.
The supply of the Type W Stab Assembly, as Safety Related, by Framatome ANP, Inc. - Electrical Products s Isolated to only one Nuclear Customer (Ie. Nuclear Management Company), however, based on the events described, the Eaton Cutlerliarnmer Type W Stab Assembly manufactured / produced and supplied prior to the Eaton Cutler-Hanmer recent corrective actions may create a potential safety condition (I.e. personnel safety Issue) to any facility receivin Type W MCC Buckets from any source oter than Framrnatone ANP, Inc. - Electrical Products.
As an obigation to the Nuclear Industry, Framatome ANP, Inc. - Electrical Products feels that this potential safety concern should be reported under 10CFA Part 21.
For additional Information please contact Pat Patterson, Projact Manager - Frarnatome ANP, Inc. - Electrical Products at (724) 779-9800 ext 1317/ E-mal: laurence.patterson Cframatome-anp.com.
Sincerely, ramatome ANP, Inc.
- Electrical Products Fran Starr Manager, Quality Assurance Attachment Eaton Cutler-Hammer Type W Vintage Unit Product Advisory, dated June 27,2003 cc:
Gary (GUson -FANP EmDyA. Mayhew - FANP Lauren Patterson - FANP Tam W. Wrrer-FANP Dan Llvwmore - FANP Ell Boes - Eaton Cutlsr-Hanrner Dan Mikow - FANP Gary Klann - Eaton Ciller-Hammer WElaR= Orga - FANP Deborah Renaud - Eaton Cutler-Harrr Jm Mallay - FANP Fax Cox-Eaton Cler-Harrmer FL md FRAMATOME ANP, Inc.
130 Commonwealth Drive, Warrendaie, PA 1506 Tel: 724-779-65827 Fax: 724-770-6980 Emall:Ftan.Starr C tramatome-anp.com 10/09/2003 THU 11:00 T1/R1 NO 88831 Onnf
a CiffiafOllerf-ammer BOO oe BEat Rd.
kTo N FeUed C25390 lo(91O) 67.6 bt (910) MM June 27.2003 To: Valued Cutler-Hammer In. Customer Re: Type W Vintage Unit Product Advisory Product Advisory Type W Vintage Unit Product Advisory Descriptlon A potential safety condition may exist with Cutter-Hammer Type W Vintage Unit plug In stabs. The condition exists when a unit of a particular Manufacturng Date Code range Is withdrawn from a Motor Control Center structure. Under this condition, the cip holding the stab finger In place may dislodge. As a result the stab fin er remains plugged onto the vertical bus until the breaker cable connectionforoes the stab finger off-the bus. The operator must exert extra force to remove the unit. The Issue only affects Type W SlAbs manufactued during the date ranges stated below, and does not affect any other Cutler-Hammer manufactured plug In stab.
Lf-Wan~ng&
Typb Wvintage Unt plug hi stabs manufctuirid between 06toiiot:1, 2000 and March 26,2003 shoulI V
'be removed frormi the J otoF Control Cente structure with the Structure bus energized. The potential of a unit being extrcted from liWe bus may cause arcing or single phasing In risk of property damage, personal Injury or death.
Corrective Actions If you have received Type W Vintage plug In stab units between October 1, 2000 and March 26, 2003 please do one of the following:
If you are able to power down your bus system, remove the affected unit from the vertical bus.
Contact Fayettevile's warranty administrator, Debbie Renaud at 910-677-5206 for a replacement stab assembly.
If you are unable to power down your bus system at this time, walt until your next scheduled maintenance power down to extract the units.
Cutler-Hammer continuously strives to produce the highest quality products. We apologize for any inconvenience this may have caused you.
Sincerely.
Bill Boes Product Une Mgr.
Power and Control Systems 10/09/2003 THU 11:00 1 [
/RI NO 8883] 1l004
Cutler-Hammer 2900 Doc Sennett Road Fayelteville, NC 28306 (910) 483-2222 Fax: 19101 6774297 IN June 25, 2003 Jim Lepin - E&I Superintendent Georgia-Pacific Wauna Mill PO Box 2185 Clatskarle, OR 97016 Cc: C-H Portland Service Center Jim Avery Cc. C-H Portland Sales - Scott Anderson Cc: C-H Portland Sales - bave Durocher Cc: C-H Fayetteville - BiD Boes
Subject:
Georgia Pacific Wauna - Type W Stab Failures In. response to the Type W stab dips dislodging from the stab housing, Cutler-Hammer Fayettville would like to offer and update on both our activity and progress since the return of this product and of orrective actions established regarding the issue.
Fve stab assemblies were received from the G-P Wauna mill with at least one stab finger~otit of each tab molding. Some stab ragersand holdi Acjs for these stab assemblies wre also tumeL Upon Inspecting the stab clips It Is evident that the clips are out of specification toleranceftm the qSnded design; specifically, the top Wngs' of the spring dip. has been cut or sheered offrntely e digital picture attached ta this letter)...
- Evaluation:
The non-conforring clips are shortened by at least.040 inches allowing the clip to be dislodged.from the stab housing. This Is comparable to the G-P reported ncident. Cutler-Harmer conducted a pull test on a retumed stab finger that had remained In the stab housing and found the remaliningstabs separated from the stab assembly at over 350-Ft lbs., well within the subassembly design criteria.
The remaining dips were not cut off as much as the loose dips. We condude that upon first removal of the bucket this Issue wil occur If the clip Is cut off greater than.040 Inches.
Rework:
During Oct 2001 the spring clip was Identified as non-conforing material. The vender was notified of the non-conformity. Corrected parts were received and approved in Feb 2002. The corrective action for the supplier stated "rework was being done to the existing parts In the warehouse". We may have reworked parts here as well. As best as can we deternined, the reworked parts were used until March 2003 (our current stock has been checked to print and conforms to updated specifications).
Form records of shipments by general order number, All G-P shipments occurred during the time frame of reworked parts. We are determining If other customers received modified parts. Within this specified time window, G-P Wauna was Fayetteville's largest customer for Type W units.
Containment and Permanent corrective action Is detailed In the 8D report attached to this email. The replacement stabs provided to G-P have been sampled before shipment Minimum pull force of 290-Ft lbs. was recorded.
Cutler-Hammer has Implemented additional process checks in assembly to detect out of specification holding dips via a put force test We are also initiating a product advisory for this Issue per the Eaton Corporate Advisory Procedure.
GP Type W cverdac (Faye Cox) 10/09/2003 THU 11:00
[TX/RI NO 88831 005
Thank you for communicating this issue to us and allowing Eaton Cutler-Hammer to replace the stabs in your facility. We are wilfing to work with your operations as necessary to assure a safe and orderly change out of Type W stab assemblies with the updated holding cips. If you have any additional questions please contact us at 910-677-5381.
Sincerely, Faye Cox Quality Engineer Eaton I Cufler-Hammer Fayetteville, NC Dan Yount Quality Manager Eaton I Cutler-Hammer Fayetteville, NC Ie 2
10/09/2003 THU 11:00
[T2/RI NO 8883]
006
rramtome AMP Cranberry PA 724 779 944 7/8 Corrective Action Request Source: Field Failure Date: 5/20103 To: Cutler Hammer I Due Date: 5/23/03 Revised Due Date:
Desaiption of Nonconformance: The spring cip (112B146H01) of the ndividual stabs failed t hold the stab finger Into the stab housino.
Prioriy.
a 13Crcal
_~3MO io Cause of Nonconfbrmance:
The spring dip (1128146H01) of the ndivdual stabs failed to hold the stab finger Into the stab housing. The dip was not to print.
Improper rework had been performed to the dip. Engineering Instruction for rework was NOT given to the production floor.
Incoming Inspection process was not utirized.
Corretive Action Response:
- 1. 1Te stabs are being replaced on site with corfct spring dips nstalled.
2.. The vender was ntifed and correct parts were' received. Oct 2001; however, they continued to send In old stock until March 03.
- 3. Receiving Inspection process Is now mandatory on all part changes.
- 4. The dip drawing was missing dimensions on the print. Those dimensions are being added.
- 5. Processes now In place to properly nstruct disposition of nonconforming material.
"On hold' form Is now used for suspect material In producton arid/or shipping. The form Is typically used when a material sort Is possible (i.e. date coded material) and Engineering Issues sort or rework Instruction.
"Material deviation" form Is used when material can be used substituted of corect part or reworked. Engineering Issues test or rework nstruction.
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The picture depicts a correct clip from aurrent stock and a dip returned from he field._
The sides
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10/09/2003 TU 11:00
[O/RI NO 8883]
008