ML051960227

Event #41819 on 05/05/2005 Re Part 21 Notification of Failed Surface Coatings on Fans

ML051960227
Person / Time
Site:	Oconee
Issue date:	07/13/2005
From:	Stewart P Howden Buffalo
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
Event #41819
Download: ML051960227 (7)

Text

- t 0711312005 U.S. NuclearRegulatory Commission OperationsCenter Event Report Pace I General Information or Other (PAR) Event# 41819 Rep Org: HOWDEN BUFFALO Notification Date I Time: 07/01/2005 18:32 (EDT)

Supplier: HOWDEN BUFFALO Event Date I Time: 05/05/2005 16:15 (EDT)

Last Modification: 07/02/2005 Region: 3 Docket #:

City: NEW PHILADELPHIA Agreement State: Yes County: License #:

State: OH NRC Notified by: PAUL STEWART Notifications: JAMNES CAMERON R3 HQ Ops Officer: MARK ABRAMOVITZ JOHN WHITE R1 Emergency Class: NON EMERGENCY BRIAN BONSER R2 10 CFR Section: JEFFREY CLARK R4 21.21 UNSPECIFIED PARAGRAPH OMID TABATABAI email NRR PART 21 NOTIFICATION OF FAILED SURFACE COATINGS ON FANS Howden Buffalo provided the following information via facsimile:

"In accordance with subject regulation and Howden Buffalo internal procedures, Howden Buffalo is submitting a report of a defect or failure to comply for basic components supplied to a nuclear facility.

"Duke Energy, Oconee Plant, reported insufficient adhesion of Carboline topcoat to Carboline primer, resulting in separation of the topcoat on two fans and one other fan inlet bell. The items were manufactured, painted, and supplied to Duke Oconee during the period February 2002 thru March 2002, as basic components in a nuclear safety related application. The three affected items were part of ten complete fans delivered to Duke Oconee both before and after the affected units.

"Howden Buffalo conducted an initial investigation that included both Duke Power Materials Engineering & Lab Services and Carboline. Our investigation concluded that coating materials were not defective however, application of Carboline primer was not in accordance with Carboline recommendations for sufficient curing of the primer, resulting in accumulation of VOC's from the uncured primer and ultimate separation of the topcoats.

"Howden Buffalo has reviewed internal plant procedures for application of Carboline primer and topcoat, including surface preparation, and found that the procedures failed to incorporate Carboline updated requirements for sufficient curing of the primer. All internal procedures are now revised to incorporate Carboline requirements in their entirety. Howden Buffalo procedures for supplying Carboline coating as a basic component were applicable during the period of October 2001 thru March 2005. Howden Buffalo is contacting each of these customers to a) advise of a potential defect in the Carboline coating, b) recommend inspection criteria, and c) provide contact information.

"Summary evaluation: Review of documentation for this sales order, including all paint surveillance records, does not support a conclusion that this defect is limited only to the fans delivered for this order. Root cause of paint

07/13/2005 U.S. NuclearRegulatory Commnssion OperationsCenter Event Report Page 2 General Information or Other (PAR) Event# 41819 failure would appear to be insufficient training in procedures for surface preparation and preparation and application of primer and paint. Environmental limitations for temperature and relative humidity may not have been correctly considered for drying time requirements. Notification to NRC and to all customers of safety-related coating is required."

Howden Buffalo item number: 540059-080 Reactor building cooling unit fans serial numbers 004, 005, and 006 Nature of defect: Insufficient adhesion of Carboline topcoat to Carboline primer - topcoat flaking from two fans and one fan inlet bell.

Affected safety related orders: Duke (Oconee) shipped 11/2/01 Exelon (Dresden) shipped 3/28/03 Edison Material Supply (SONGS) shipped 7/28/04 Amergen Energy (Oyster Creek) shipped 10/31/02

Ju1-01-2005 19:32 From-HOWDEN BUFFALO INC +330 339 8210 T-162 P.002/005 F-839 HowdenBuffalo Now Phladlphla DivIsion 338 5ouSth Smdw P.Q Box 5000 Now PhiladelphIa OH 44663-2151 330-339-11 II Faxc31019-810 Date: June 27, 2005 From: Mr. Paul Stewart. General Manager Howden Buffalo Inc.

Nzw Philadelphia Division 338 South Broadway NewPhiladelpia, Ohio 44663 To: Documeni Control Desk U.S. Nuclear Regulatory Commission Washington. DC 20555 Subj: IOCFR:21 Reporting ofPotential Defects and Noncompliancc, Sec 21.21 Notification of tilurc to comply or edstence of a defect and its evaluation Attachments: 1. Howden Buffalo Report ofPotential Defect Shipped, QSF 4.13-4

2. HowdcnBuEfaloiLstotAffected Customeis"

3. Howden Buffalo Customer Complaint Report (CCR) 5574. QSF 8.2-1 In accordance with subject regulation and Howden Buffalo internal procedures. Howden Buffalo is submitting a report of a defect or failure to comply for basic components supplled to a nuclear facility (Attachmneat 1).

Duke Energy. Oconee Plant. reportcd insufficicnt adhesion of Carboline topcoat to Carbolinc primer, resulting in separation of the topcoat on two fans and onc other f=n inlet bell. The items were manufactured, paintd, and supplied To Duke Oconee during the period Februaiy 2002 thru March 2002, as basic components in a nuclear safety related application. 7be threcaffected items were part of ten complete fans delivered to Duke Oconee both before and after the affccted units.

Howden Buffao conducted an Initial investigation that included both Dukc Power Materials Enginring & Lab Services and Carboline. Our invrstigation concluded that coating mateTials weir not defective however, applicalion of Carboline primer was not in accordance with Carbollne recommendations for suflcint curing of the primer, resulting in accumulation of VOC's from the uncured primer and ultimate separation of the topcoats.

Howden Buffalo has reviewed inrnmal plant procedures for application of Carboline primer and topcoat, including surface preparation, and found that the procedures failed to incorporate Carboline updated requirements for sufficient curing or the primer. All Internal procedures are now revised to incorporate Carboline requirements In their entirety. Howden Buffalo procedures for supplying Carboline coating as a basic component were applicable during the period of October 2001 thn March 2005.

07/01/2005 FRI 18:20 7[TX/RI NO 5671] IEj 002

Jul-01-2005 18:32 From-HOWDEN BUFFALO INC t330 833 8210 T-162 P.003/006 F-839 List of Affctd Customers (Attactment 2) Includes all customers that were supplied with a safety ielated coating of Carboline paint during the affected period. Howden Bulo is contacting each of these customers to:

a. advise of a potential defect in the Carboline coating,

b. rccornmend Inspection criteria, and

c. provide contact information Questions regarding thee status oF this notiEication or corrective actions should be addressed directly to:

Mr. Rod Furniss, Nuclcar Sales Manager Howden Buffalo, New Philadelphia Division Now Philadelphia, Ohio 330339-Jill exr276 Yours truly, Paul Stewart cc: N Angelini, HBI T Gunvalson, HBI C Prat, BI

.D Lewton, NPO R Furniss, NPO 07/01/2005 FRI 18:20 [MM/RX ND 5671] 1003

Jul-01-2005 19:32 Friz-HOWDEN BUFFALO INC +330 Sao 8210 T-162 P.004/006 F-839 Howden Buffalo, Inc. Howden Buffalo, Inc.

339 South Broadway 2029 DeKalb St.

New Philadelphia, OH 44663 Camden, SC 29020 REPORT OF POTENTIAL DEFECT SHIPPED NUCLEAR SAFETY RELATED PRODUCT EMPLOYEE MAKING REPORT: DATE REPORTED: TIME REPORTED:

Curt Pratt, from customer report CCR 5574 05105105 4:15 PM NOT MANDATORY SUPERVISOR: (Name and signature)

Todd Gunvalson, Quality Managers EQUIPMENT/COMPONENT INFORMATION:

ITEM NUMBER: ITEM DESCRIPTION:

540059-080 Reactor Building Cooling Unit (RBCU) fans (3)

SERIAL NUMBER: SALES ORDER:

-004, -005, and -006 New Philadelphia Division 540059 NATURE OF DEFECT:

Insufficient adhesion of Carbollne topcoat to Carbollne primer - topcoat flaking of from two (2)fans and one (1)other fan Inlet bell.

FORWARD TO DEPARTMENT MANAGER NOTIFY VP COMMERCIAL OPERATIONS AND QUALITY MANAGER ASSIGNED INVESTIGATION COMMIlTEE:

C Pratt- Execute and manage per HBI procedure QSP 413-3, ' OCFR21 Reporting Requirements' D Lewton, Quality Manager, HBI New Philadelphia R Fumiss, Nuclear Product Manager, HSI New Philadelphia B Woost, Manufacturing Manager, HBI New Philadelphia P Stewart, General Manager New Philadelphia, (Notification to NRC lAW QSP 4.13-3)

ASSIGNED BY: (Name and signature) 7 /I ( DATE:

Angellnil, VP Sales & Marketing A k a ap l 05/10/05

SUMMARY

EVALUATION:

Review of documentation for this sales order, including all paint surveillance records, does not support a conclusion that this defect Is lmited only to the fans delivered forthis order. Root cause of paint failure would appear to be Insufficient training in procedures for surface preparation and preparation and application of primer and paint Environmental limitations for temperature and relative humidity may not have been correctly considered for drying time requirements. Notification to NRC and to all customer of safety-related coating Is required.

ATTACH ALL ORIGINAL BACKGROUND RECORDS NOTIFCATION REQUIRED - Refer to I0CFR Part 21 for Report Outline NRC: YES ICUSTOMERS: YES NOTIFICATIONS MADE BY: (Name and signature) DATE OF NOTIFICATION:

P Stewart, General Manager NPO 06127105

'n z2 NRC OPERATIONS CENTER DOCUMENT CONTROL DESK FAX: 301-816-5151 U. S. NUCLEAR REGULATORY COMMISSION PHONE: 301-816-5100 WASHINGTON, DC 20555 ACTIONS APPROVED BY: (Name and signature DATE:

N Angelini, VP Sales & MarketIng 7I 47/0 or CONFIDENTIAL - NOT FOR DISCLOSURE QSF4.13-4 Rev 01/01 07/01/2005 FRI 18:20 7TX/RI NO 5671] Io004

Jui-01-2005 18:32 From-HOWDEN BUFFALO INC +330 331 E210 T-162 P.005/006 F-839 i,

HowdenBuffalo New Phlhdelphia Division 338 South Broadway New Philadelphia, OH 44663-2151 U.SA 330-339-1111 Fax: 330.339-8210 Web; www.howdenbuffalo.com SAFETY REALTED ORDERS CARBOZINC 11 SG PRIMER CARBOGUARD 890N Customer PURCHASE HBI Shipped Date Order SALES

.DUKE NS-373 QDER 540059 11/2/01 EXELON, 50648 REV 1 540078 3/28/03 DRESDEN _

Edison Material 6X6D301 5 540090 7/28/04 Supply (SONGS) REV I Amergen Energy, 80 005264 560460 10/31/02 OYSTER CREEK _

07/01/2005 FRI 18:20 [TX/RI NO 5671] [005

Jul-01-2005 18:32 From-HOWDEN BUFFALO INC t330 330 t210 T-1 62 P.000s/006 F-838 Customer Complaint Report Howden Buffalo Customer: Duke Energy (Sold to)

End User: Dake Energy Ocouct Job Site Address: 7800 RochesterHWY, Seneca SC, 29672 Job Site

Contact:

Kent Alter Phone: 864-885-3255 Produt: Nucler containment fans Order No: 540059 Description of Complaint: Nameplate Data Paint adhesion, top coat flaking off on two (2) fans and (1) other fan inlet bell Wasranty Status: 0 Standard Parts E Extended Parts - End Date:

0 In Place Standard M In Place Extended - End Date: Special:

Phone: 330-339-1111 Date: 515/05 Report originator. Rod Furniss x276 e-mail: rfurniss@,howden WARRANTY ADI)M STRATOR USE CCR Assigned To: Foote M Warranty E Project Report No.

Report Sent to Originaor iness UnitNo. 1 5574 Persons filling out the CCR form, enter data as follows: AL_ NTRIES MUST BE COMPLEED NOTE!! Do not use the following symbol on the report - ")i. e., "1inch" mark.

CUSTOMER - Howden Buffalo's Customer -List "Sold to" customer END USER - Final Customer JOB SITE ADDRESS - Final Customer's address JOB SITE CONTACT - Name and Title PHONE - Phone number of 3ob Site Contact PRODUCT - Equipment description (Size, Arrangement, Type)

ORDER NO. - Original Sales Order on which equipment was delivered DESCRIPTION OF COMPLAINT - Brief but detailed sunmary of the problem NAMEPLATE DATA - Information from nameplate(s) of affected equipment WARRANTY STATUS - Check appropriate box. If Extended indicate end date. If Special, brief description.

DATE - Date of the Complaint REPORT ORIGINATOR - Person writing the Customer Complaint PHONE - Phone number of person writing the complaint E-MAIL - e-mail address of person writing the complaint Deliver completed form to Warranty Administrator, by e-mail only, to address at top of form.

QSF 8.2-1 Rev: 09103 07/01/2005 FRI 18:20 [TX/RI NO 5671] 16006