ML053250374
| ML053250374 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 11/17/2005 |
| From: | Reidmeyer M Prime Measurement Products |
| To: | Clark J, Omid Tabatabai Office of Nuclear Reactor Regulation, NRC Region 4 |
| References | |
| 42151 | |
| Download: ML053250374 (9) | |
Text
-'- 1111712005 U.S. Nuclear Regulatory Commission OperationsCenter Event Report Paee I Power Reactor Event# 42151 Site: CALLAWAY Notification Date/Time: 11/17/2005 16:25 (EST)
Unit: I Region: 4 State: MO EventDate(Time: 11/17/2005 08:30 (CST)
Reactor Type: [1] W-4-LP Last Modification: 11/17/2005 Containment Type: DRY AMB NRC Notified by: M. A. REIDMEYER Notifications: JEFFREY CLARK R4 HQ Ops Officer: STEVE SANDIN OMID TABATABAI NRR Emergency Class: NON EMERGENCY 10 CFR Section:
21.21 UNSPECIFIED PARAGRAPH Unit IScram Code I)RXCritlInitPower I Initial RX Mode ICurr Power ICurrent RX Mode 1 N No 0 Hot Standby 0 Startup INITIAL PART 21 NOTIFICATION - PRIME MEASUREMENT PRODUCTS, MODELS 763 & 763A PRESSURE TRANSMITTERS AND MODEL 764 DIFFERENTIAL PRESSURE TRANSMITTERS The following information was received via facsimile:
"On 11/2/05 SGT LLC, primary contractor for Steam Generator replacements at Callaway Plant, received notification from PRIME Measurement Products, (formerly ITT Barton) of a manufacturing defect in Model 763, 763A, and 764 pressure transmitters involving use of Zener diodes that were not in compliance with purchase specifications. Subsequently, on 11/3/05 SGT LLC notified AmerenUE Callaway Plant of the potential manufacturing defects involving the aforementioned transmitters. These transmitters provide input to steam generator level indication and control functions.
"The notification provided by PRIME stated the purchasing specifications required JANTX components, but in some cases commercial variations of the required parts were used to manufacture some transmitters. This condition was potentially reportable under 10 CFR 21, depending on the specific application at facilities using these instruments manufactured by PRIME Measurement Products. The following is a summary of the information obtained from PRIME Measurement Products:
- 1. This notification involves 76 specific transmitters manufactured between 2/10/04 and 9119105.
- 2. Each transmitter contains two Zener diodes which may not comply with purchase specifications.
- 3. The JANTX Zener diodes are different in appearance with respect to the commercial variations. Some JANTX Zener diodes used in the recent past have bodies that are solid orange or light blue in color or clear glass. The commercial Zener diodes in question have a clear glass body. The commercial Zener diode is larger (0.095" diameter X 0.275" long) than the smaller JANTX Zener diode (0.072" diameter X .155" long).
a; 1111712005 U.S. Nuclear Regulatory Commission Operations CenterEvent Report Pag Power Reactor Event# 42151
- 4. The existence of the commercial Zener diode can be confirmed by removal of the transmitter electronics cover and observing the Zener diodes at locations CR2 and CR3, as shown on manufacturer supplied circuit board drawings.
- 5. The Zener diodes are not field replaceable, as it is necessary to electronically reestablish the calibration zero which will likely necessitate replacement of a calibration resistor. This calibration resistor is located in a temperature sensitive portion of the electronic circuit and requires thermal performance validation.
- 6. PRIME believes that transmitters with commercial Zener diodes that are currently installed in a plant can be relied upon to continue to operate and perform their safety-related function in the event of an accident. This belief is based on the facts that the commercial Zener diodes installed in any transmitter have been shown to be functional at the accident maximum sustained temperature and because the radiation effects on commercial Zener diodes are known to be within the margin of the original Barton qualification.
"SGT LLC purchased 22 of the suspect transmitters for use in the Callaway Plant Steam Generator replacement project. Additionally, 6 suspect transmitters had been supplied directly to Callaway Plant. Physical inspections by SGT LLC and Callaway Plant staff determined 21 of the transmitters had the commercial Zener diodes installed.
These transmitters were returned to PRIME where the commercial Zener diodes were replaced with qualified Zener diodes and proper transmitter operation was verified. The affected transmitters have since been returned to Callaway as fully qualified for safety related use in nuclear applications.
"On 11 /16105, Callaway Plant personnel completed evaluations and determined the use of commercial Zener diodes constituted a defect per 10 CPR 21, requiring initial notification to the NRC within two days. Per the information provided by PRIME, all other affected customers have been notified.
'The concern was identified while Callaway Plant was shutdown for a refueling outage when the transmitters were installed, and prior to being returned to service. Therefore, no other reporting criteria apply.
"The NRC Resident Inspectors have been notified of this issue."
11/17/2005 15:40 FAX 6764202 QA I001/007 IA mewnx FACSIMILE TRANSMISSION DATE: 0,)o t /7 Z7-TO : P/Zr 64!iHt0S COMPANY: AS/ 2 C-FAX No.: _________________
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11/17/2005 THU 16:41 [TX/RI NO 7155] [j0D1
.11/17/2005 15:40 FAX 6764202 QA a 002/007 November 2, 2005 NRC's Document Control Desk U.S. Nuclear regulatory Commission Washington, DC 20555-001
Subject:
Nuclear Industry Advisory PRIME Measurement Products, formerly Barton Instrument Systems & ITT Barton, is a supplier of basic components to the commercial nuclear power industry. This letter transmits a notification of concern that is being mailed to all the facilities that have potentially nonconforming transmitters as listed in the attachment. A copy the notification made to our customers is being provided for you information and action as deemed applicable.
PRIME has identified that some Model 763, 763A and 764 transmitters were manufactured using Zener diodes that were not compliant with the design specifications. While the purchasing specifications called for JANTX components, commercial variations of the required parts were used to manufacture some transmitters.
The attached notification identifies the specifics of our concerns and recommends factory rework of aul problem transmitters. Recent thermal and radiation testing on commercial Zener diodes show that these parts perform within acceptable limits considering the margin available in the original qualification thereby supporting continued operation of currently installed transmitters until suitable replacements can be obtained.
Questions regarding this issue should be addressed to Mark Larson, Nuclear & Government Product Engineering Manager, at (626) 961-2547, extension 228.
Sincerely, Bradley W. Spahr President and CEO
Attachment:
6 pages 11/17/2005 THU 16:41 [TX/RX NO 71551 IaOO2
11/17/2005 15:40 FAX 6764202 QA 003/007 PRIME Measurement Products, LLC NUCLEAR INDUSTRY ADVISORY November 2, 2005 Barton Model 763, Model 763A and Model 764 Zener Diodes PRIME Measurement Products, formerly Barton Instrument Systems & ITT Barton, is a supplier of basic components to the commercial nuclear power industry. The specific components being reported are Barton Model 763 & 763A Gage Pressure Transmitters and Barton Model 764 Differential Pressure Transmitters. PRIME sells these transmitters as fully functional LOCA qualified devices.
PRIME has identified that some Model 763, 763A and 764 transmitters were manufactured using a commercial variation of a Zener diode that should have been a JANTX device. This situation occurred as a result of a purchasing problem and was not discovered during receipt inspection / part dedication process.
PRIME has identified that the first commercial Zener diodes of concern arrived into our stock system on February 10, 2004. No transmitters with the commercial Zener diodes have been shipped from the factory since September 19, 2005. All Models 763, 763A and 764 transmitters shipped between these dates need to be considered a potential problem. The 76 specific transmitters of concern are identified in the attached listing.
There were still 69 JANTX Zener diodes in stock at the time the commercial diodes were added to stock.
Therefore, some of the transmitters of concern identified in this notification may not have the commercial Zener diodes installed. Each transmitter has two Zener diodes so it is very likely that at least 34 of the reported 76 transmitters are not actually problems. In addition, there is a possibility that some other circuit boards with JANTX Zener diodes had already been assembled but not tested prior to the time the commercial Zener diodes went to stock. This situation would further reduce the population of transmitters with commercial Zener diodes.
The JANTX Zener diodes are different in appearance with respect to the commercial variations. Some JANTX Zener diodes used in the recent past have bodies that are solid orange or light blue in color or clear glass. The commercial Zener Diodes that have been used have a body that is clear glass. The attached photo compares the larger commercial Zener diode (0.095" diameter X 0.275" long) with the smaller JANTX Zener diode (0.072" diameter X .155" long) that has a glass body. The existence of the commercial Zener diode can be verified by visual inspection. Remove the transmitter electronics cover and visually observe the Zener diodes at locations CR2 and CR3 as shown on the attached drawing of the circuit board.
All Zener diodes have passed factory performance testing at 3401F (the maximum sustained PWR LOCA temperature) prior to transmitter shipment. Therefore there is a high degree of confidence that the transmitters shipped with commercial Zener diodes will perform at the accident temperatures as intended.
The original Barton qualifications for the transmitters allowed a 200 Mrad radiation induced shift of
+/-10% while the actual radiation induced shift experienced did not exceed 2.2%. Radiation testing at 200 Mrads total equivalent gamma exposures performed on the commercial Zener diodes demonstrates that they will contribute only an additional 0.34% in transmitter radiation induced accuracy degradation.
Furthermore, the radiation testing performed on the commercial Zener diodes demonstrates that the thermal performance of these parts is not degraded by the radiation exposure maintaining the validity of the transmitter factory temperature compensation process.
PRIME believes that transmitters with commercial Zener diodes that are currently installed in a plant can be relied upon to continue to operate and perform their safety-related function in the event of an accident, This belief is based on the facts that the commercial Zener diodes installed in any transmitter 11/17/2005 THU 16:41 [TX/RX NO 7155] [a003
11/17/2005 15:40 FAX 6764202 4A 1a004/007 have been shown to be functional at the accident maximum sustained temperature and because the radiation effects on commercial Zener diodes are known to be within the margin of the original Barton qualification.
Although the commercial Zener diodes perform within acceptable limits, they do not perform as well as the JANTX parts. Furthermore, while PRIME believes that our manufacturing processes screen parts for performance similar to the MD SPEC applicable to the JANTX parts, we have not performed thermal aging and other tests to validate the qualified life of the commercial Zener diodes. PRIME is therefore offering to rebuild the transmitters containing the commercial Zener diodes, at no customer expense, using two new JANTX Zener diodes. It is recommended that all transmitters with commercial Zener diodes be returned to the factory for Zener diode replacement as soon as practicable. Tn this replacement, the transmitters will be recalibrated and temperature compensated to the original transmitter factory performance requirements and as tested nuclear qualified configuration.
The Zener diodes are not field replaceable, as it is necessary to electronically reestablish the calibration zero which will likely necessitate replacement of a calibration resistor. This calibration resistor is located in a very temperature sensitive portion of the electronic circuit requiring thermal performance validation.
In the event a transmitter verified to contain commercial Zener diodes can not be returned to the factory for repair because it is contaminated or can not be removed from service because of plant operability concerns please contact the factory for replacement scheduling. PRDME recognizes that these situations may represent a significant concern with regard to continued power generation for your customers and will give the repair and replacement activities associated with this issue the highest manufacturing priority. It is estimated that a diode replacement repair activity can be completed in about two weeks while manufacturing of a new transmitter can take upwards of three months depending on the range, configuration and amount of transmitters that need to be manufactured or repaired at the time.
Questions regarding this issue should be addressed to Mark Larson, Nuclear & Government Product Engineering Manager, at (626) 961-2547, extension 228. To schedule transmitter repairs and replacements please contact Mabel Loo, Contracts Administration Manager, at (626) 937-0335.
11/17/2005 THU 16:41 [TX/RI NO 7155] [004
.11/17/2005 15:41 FAX 6764202 0 005/007 Larser Commercial Zener Diode & Smaller Similar Glass Bodv JANTX Zener Diode ZENER DIODE Model 763, 763A and 764 Circuit Board Dramwing Sbowing Zener Diode Locations 11/17/2005 THU 16:41 [TX/Rx NO 7155] [os05
11/17/2005 15:41 FAX 6784202 QA l000/007 Customer Model SIN Customer PO Prime Order Alabama Power (Farley) 764 5564 QP040574 28894 Barton, United Kingdom 763 2471 ZP00647 28788 (British Energy) 763 2472 ZP00647 28788 763 2473 ZP00647 28788 763 2474 ZP00647 28788 763 2475 ZP00647 28788 764 4298 29678 25595 British Energy 764 5604 SZB-40148872 32159 NAVICP 764 5547 N00104-04-C7028 28181 764 5548 N00104-04-C7028 28181 764 5582 N00104-04-PBQ8B 29857 764 5583 N00104-04-PBQ88 29857 764 5584 N00104-04-PBQ88 29857 764 5585 N00104-04-PBQ88 29857 764 5599 N00104-04-C7028 28181 Entergy (Waterford 3) 763A 418 10045946 25832 First Energy (Beaver Valley) 763A 424 45139403 30414 Fluid Controls (TPC) 764 5555 T41061 PR 27891 764 5556 T41061 PR 27891 764 5557 T41061 PR 27891 764 5558 T41061 PR 27891 764 5562 T41061PR 27891 764 5563 T41061 PR 27891 KHNP 764 5606 K040374471 30921 764 5607 K040374471 30921 SGT Ltd. (Callaway) 764 5564 9221-3881 29475 764 5565 9221-3881 29475 764 5566 9221-3881 29475 764 5567 9221-3881 29475 764 5568 9221-3881 29475 764 5569 9221-3881 29475 764 5570 9221-3881 29475 764 5571 9221-3881 29475 764 5572 9221-3881 29475 764 5573 9221-3881 29475 764 5574 9221-3881 29475 764 5575 9221-3881 29475 764 5576 9221-3881 29475 764 5577 9221-3881 29475 764 5578 9221-3881 29475 764 5579 9221-3881 29475 764 5580 9221-3881 29475 764 5581 9221-3881 29475 764 5600 34430-1005-PO 30985 764 5601 34430-1005-PO 30985 764 5602 34430-1005-PO 30985 764 5603 34430-1005-PO 30985 11/17/2005 THIU 16:41 ITX/RX NO 7155] ID006
11/17/2005 15:41 FAX 8764202 QA Z 007/007 Customer Model SIN Customer PO Prime Order Union Electric (Callway) 764 5608 198001 SR 31597 764 5609 198001 SR 31597 764 5610 198001 SR 31597 764 5611 198001 SR 31597 764 5612 198001 SR 31597 764 5613 198001 SR 31597 Electrobras TermonuclearS.A. 764 5586 4500060123 30915 Westinghouse 764 5587 4500148633 30125 764 5588 4500148633 30125 764 5589 4500149482 30308 764 5590 4500149482 30308 764 5591 4500149482 30308 764 5592 4500149482 30308 764 5593 4500149482 30308 764 5594 4500149482 30308 764 5595 4500149482 30308 764 5596 4500149482 30308' 764 5597 4500149482 30308 764 5598 4500149482 30308 764 5605 4500154485 31037 763A 419 4500117146 24997 763A 420 4500117146 24997 763A 421 4500117146 24997 763A 422 4500117146 24997 763A 423 4500145093 29541 763A 425 4500117165 25035 763A 426 4500117165 25035 763A 427 4500117165 25035 763A 428 4500117165 25035 11/17/2005 THIU 16:41 [TX/RI NO 7155] 1j007