ML13238A253

Notification of Potential Part 21 Report - Foxboro Power Supply Potential Failures Due to Defective the Wraps and Holders

ML13238A253
Person / Time
Site:	Millstone, Peach Bottom, Nine Mile Point, Palo Verde, Indian Point, Fermi, Kewaunee, Point Beach, Pilgrim, Arkansas Nuclear, Three Mile Island, Crystal River, San Onofre, Fort Calhoun, FitzPatrick
Issue date:	08/21/2013
From:	Brosemer J Integrated Resources
To:	Office of Nuclear Reactor Regulation
References
48863
Download: ML13238A253 (28)

Text

0812112013 U.S. Nuclear Regulatory Commission Operations Center Event Report Pa2e I Part 21 (PAR) Event# 48863 Rep Org: INTEGRATED RESOURCES, INC. Notification Date / Time: 03/28/2013 15:53 (EDT)

Supplier: INVENSYS (FOXBORO METER CO.) Event Date / Time: 03/27/2013 15:30 (CDT)

Last Modification: 08/21/2013 Region: 4 Docket #:

City: NEBRASKA CITY Agreement State: Yes County: License #:

State: NE NRC Notified by: JOHN F. BROSEMER Notifications: GREG PICK R4DO HQ Ops Officer: HOWIE CROUCH PAUL KROHN R1DO Emergency Class: NON EMERGENCY PART 21 GROUP EMAIL 10 CFR Section: DEBORAH SEYMOUR R2DO 21.21 (d)(3)(i) DEFECTS AND NONCOMPLIANCE JULIO LARA R3DO PART 21 REPORT - FOXBORO POWER SUPPLY POTENTIAL FAILURES DUE TO DEFECTIVE TIE WRAPS AND HOLDERS Mr. John F. Brosemer, President of Integrated Resources, Inc., reported discovery of repeated defects in Foxboro Meter Company's N-2ARPS-A6, Style D power supplies. When manufactured, the power supplies utilized Thomas and Betts TC105A aluminum wire tie holders in random numbers and placements. As the power supplies age, the tie wrap holder adhesive degrades and the tie wraps embrittle resulting in the separation of the tie wraps and loss of holder adhesion to the power supply enclosure. This causes the wraps and holders to fall to the bottom of the enclosure which could result in shorts when the aluminum comes in contact with electronic components. In one particular power supply, all tie wrap holders in use failed and separated from the enclosure.

The power supplies are used in Foxboro SPEC-200 cabinetry that are used throughout the industry. At the time of this notification, Integrated Resources has one power supply from Three Mile Island and two power supplies from Ft. Calhoun undergoing refurbishment. Integrated Resources will be following up this telephonic notification with a written report once their internal investigation is done.

• Recommended corrective actions are for affected facilities to open and inspect all power supplies and remove the aluminum tie wrap holders and replace the tie wraps and holders with Teflon types.

• *

• UPDATE FROM BROSEMER TO SNYDER AT 1530 EDT ON 4/1/13 ***

"Suspecting this to be a common mode failure IRI [Integrated Resources, Inc.] opened and inspected two Foxboro N-2ARPS-A6 power supplies which were sent to IRI for refurbishment by Fort Calhoun Nuclear Station.

Examination revealed that both of the power supplies have the same failures of the tie wrap aluminum mounting plates adhesive with the majority of the plates being held on the wire bundles by age embrittled nylon wire ties.

08/21/2013 U.S. Nuclear Regulatory Commission OperationsCenter Event Report Page2 Part 21 (PAR) Event # 48863 "Confirmation of the common mode failure by inspection of the Fort Calhoun Nuclear Stations was on or about 1530 CDT on March 27, 2013.

"IRI is not the OEM or Original supplier for this power supply and cannot provide the number nor locations of these components. However, by searching the RAPID database IRI has found the power supplies at the following:

"Arizona Public Service - Palo Verde Nuclear Generating Station; Constellation Energy - Nine Mile Point Nuclear Power Plant; Detroit Edison - Fermi 2 Nuclear Power Plant; Dominion Nuclear - Millstone Nuclear Power Plant; Dominion Nuclear - Kewaunee Nuclear Power Plant; Eletronnuclear - Angra Nuclear Power Plant; Entergy Nuclear - Arkansas Nuclear One; Entergy Nuclear - Indian Point Energy Center; Entergy Nuclear - Pilgrim Nuclear Power Plant; Entergy Nuclear - J. A. Fitzpatrick Nuclear Power Plant; Exelon Corporation - Three Mile Island Nuclear Plant; Exelon Corporation - Peach Bottom Atomic Power Station; NextEra Energy - Point Beach Nuclear Power Plant; Progress Energy Florida - Crystal River Nuclear Power Plant; Southern California Edison - San Onofre Nuclear Generating Station.

"IRI suspects several other utilities and units are affected by this report.

Corrective action taken: "IRI's preliminary suggestion is inspection and removal of failed tie wrap mounting plates which are being held on to wire bundles by aging nylon tie wraps. IRI also suggests replacement of age embrittled nylon tie wraps with Tefzel tie wraps."

Contact Information:

John F. Brosemer; President Integrated Resources, Inc.

113 South 9th Street Nebraska City, NE 68410 Notified R1DO (Dwyer), R2DO (Seymour), R3DO (Daley), R4DO (Kellar) and-Part 21 Reactors (Email).

• *

• UPDATE FROM JOHN BROSEMER (VIA EMAIL) ON 8/21/13 AT 1628 EDT * - *

"IRI's final recommendations are to remove all Thomas and Betts Co. model TC1 05A wire tie holders and to replace any embrittled wire ties with TEFZEL wire ties in all of the affected Foxboro Co. power supplies.

"IRI also discovered during the course of the investigation that Thomas and Betts Co. supplied these wire tie holders through normal distribution to all of the manufacturers. IRI recommends that the industry, during normal inspections, inspect for the these types of wire tie holders in all other installed equipment and to remove the failed wire tie holders."

Notified R1DO (Schmidt), R2DO (Haag), R3DO (Kozak), R4DO (Werner) and Part 21 Reactors (via email).

NTEGR._ATED RESOURCES, INC.

July 5, 2013 Document Control Desk U. S. Nuclear Regulatory Commission Washington, D.C., 20555-0001

Subject:

10 CFR Part 21 Report Notification, Foxboro, Co. N-2ARPS-A6 Power Supplies Common Mode Failure of Thomas and Betts Model TC 105A Ty-Rap Mounting Plates Adhesive Final Report.

Dear Sir or Madam:

Integrated Resources, Inc., (IRI) submits this letter and the attached report to provide the final report and recommendations on IRI 10 CFR 21 notification event 48863.

IRI's final recommendations are to remove all Thomas and Betts, Co., model TC105A wire tie holders and to replace any embrittled wire ties with TEFZEL wire ties in all of the affected Foxboro, Co., Power Supplies.

IRI also discovered during the course of the investigation that Thomas and Betts, Co., supplied these wire tie holders through normal distribution to all of the manufacturers. IRI recommends that the industry, during normal inspections, inspect for these types of wire tie holders in all other installed equipment and to remove the failed wire tie holders.

Sincerely, John F. Brosemer President Integrated Resources, Inc.

(402) 873-5859 P.O. BOX 310

• NEBRASKA CITY, NE 68410 * (402) 873-5859

INTEGRATED RESOURCES, INC.

DOCUMENT TITLE AND REVISION STATUS SHEET

Title:

Document Number:

FINAL REPORT ON IRI FOXBORO METER CO.,

POWER SUPPLY MODEL N-2ARPS-A6 SERIAL TMI-1201-100 NUMBER 4935949 TIE WRAP HOLDERS.

Document Type: Project No:

Technical Evaluation TMI-1201 Client: Purchase Order No:

Three Mile Island Nuclear 80 046008 Page 1 of 5 Station SAFETY RELATED - THIS DOCUMENT CONTAINS A SAFETY RELATED ITEM - YES X NO REVISIONS NO DESCRIPTION DATE 0 Initial Release 7/5/13 ORIGINATOR/DATE CHECKED BY/DATE APPROVED/DATE John F. Brosemer 7/5/13 Marvin F. Shimmel 7/5/13 John F. Brosemer 7/5/13

TECHNICAL EVALUATION GENERAL INFORMATION DESCRIPTION OF TECHNICAL EVALUATION:

This report provides the final results of IRI's investigation pertaining to IRI's 10 CFR Part 21 report number 48863.

GENERAL TECHNICAL EVALUATION GENERAL INFORMATION TECHNICAL EVALUATION:

During the refurbishment of a safety related Foxboro Model N-2ARPS-A6 STYLE D power supply Serial Number 4935949 from Three Mile Island Nuclear Plant Integrated Resources, Inc. (IRI) found a one inch by 1/2/ inch Ty-Rap aluminum mounting plate lying loose in the bottom of the power supply. (Attachment 1)

Further examination of the power supply found that the adhesive had failed on 14 of the 15 remaining aluminum mounting plates leaving the plates attached to the wire harnesses by age embrittled nylon wire ties. The only mounting plate that had not failed was not used (no tie wrap was installed).

Suspecting this to be a common mode failure IRI opened and inspected two Foxboro N-2ARPS-A6 STYLE D power supplies Serial Numbers 4484237 and 4484239 which were sent to IRI for refurbishment by Fort Calhoun Nuclear Station. Examination revealed that both of the power supplies have the same failures of the Ty-Rap aluminum mounting plates adhesive with the majority of the plates being held on the wire bundles by age embrittled nylon wire ties.

Confirmation of the common mode failure by inspection of the Fort Calhoun Nuclear Station power supplies and engineering analysis that the failure could pose a threat of the failure causing the power supplies not being capable of fulfilling their safety function was completed on or about 1530 CDT on 27 March 2013.

Based on this inspection and analysis Integrated Resources, Inc., (IRI) initiated a 10 CFR 21 verbal report dated 28 March 2013, at 1553 EDT, to Mr. H. Crouch (U.S.

NRC) of a potential common mode failure of the Ty-Rap mounting plates adhesive used in Foxboro, Co. Power Supplies Model N-2ARPS-A6.

STM,-1201-100 I REVISION 0 PAGE2 OF5

GENERAL INFORMATION TECHNICAL EVALUATION: (CONTINUED):

With the initial suggested resolution to remove the wire tie holders and replace affected wire ties with TEFZEL tie wraps.

IRI provided a full written report via email on 1 April 2013.

On 2 April 2013 contacted Ms. Sandy Brenneman at Invensys, Inc., (Previously Foxboro, Co.) and provided IRI's written 10 CFR part 21 report via email.

On 17 April 2013, IRI contacted the tie wrap holder manufacturer Thomas and Betts, Co., Product Manager, Mr. Steve Mcllwain. Mr. Mcllwain informed IRI that the TC105A product was withdrawn from the market after customer complaints of failing adhesive with the last production run occurring on 17 February 1998. The TC105A was replaced by the TC105 and a two part epoxy adhesive, which is the currently offered product. (Attachment 2).

Mr. Mcllwain also provided product drawings of the TC105A, TC105 and the old adhesive specification (Attachment 3).

On June 7, 2013 Invensys, Inc., published a Customer Advisory 2013027abi, titled Invensys Response to US NRC 10CFR21 Event Number 48863 as Reported by Integrated Resources, Inc., and Instruction SI 0-00616 titled SPEC200 Hardware Nuclear (N-2ARPS Series) and commercial (2ARPS Series) Power Supply Cable Tie Replacement for Heat Sink Mounted Cable Harness. (Attachment 4)

These documents conclude that "The cable tie holders serve no safety related function and those that are loose or detached should be removed."

During a review of the Invensys, Inc., Documents IRI noted that the documents speak only of those wire tie holders used in the main compartment of the power supplies and those attached to the Heatsink. On June 10, 2013, IRI em ailed Invensys, Inc., to inquire if the tie wrap holders contained in the "false bottom" area were covered by the same recommendation.

On June 25, 2013, IRI received an email from Mr. Norm Provost of Invensys, Inc.,

which states "All cable ties and holders within the affected products have been considered in the evaluation. Note that only those wire tie holders that are (or were) attached to the vertical interior walls of the power supply are the ones of concern.

This is reflected in the customer notice and Special Instruction." (Attachment 5)

TM1-1201-100 1REVISION 0 1PAGE 3 OF 5

SPECIFIC INFORMATION (CONTINUED):

IRI disagrees with the final statement, in that any loose metallic objects within the affected power supplies could affect the safety function of the power supply during or subsequent to a seismic event.

Since Invensys, Inc., has concluded that the wire tie holders "serve no safety related function" and the adhesive will continue to fail, IRI suggests removal or ALL wire tie holders and replacement of the aging wire ties with TEFZEL tie wraps.

CONCLUSION/SUGGESTED DISPOSITION IRI concludes that removal of all wire tie holders and any aging wire ties, replacing the wire ties with TEFZEL wire ties.

This concludes IRI's information and recommendation on the Foxboro, Co., power supply problem. However, as a result of research for this report it was found that Thomas and Betts, Co., sold the TC105A through distributors and would not have any records concerning end user information. The fact that this product was used extensively during the years that the current generation of nuclear plants were being built would indicated to IRI that it is very likely that these wire tie holders may have been used by different vendors and other equipment. IRI recommends that other equipment be visually examined as part of the normal maintenance program and that if loose wire tie holders are found to be present they be removed and the wire ties replaced with TEFZEL wire ties.

REFERENCES AND ATTACHMENTS

REFERENCES:

1. The Foxboro, Co., MI 2AR-102, MAINTENANCE INSTRUCTION MULTINEST POWER SUPPLY +15 AND -15 VDC, MODEL 2ARPS STYLE D, dated June 1980.

2. The Foxboro, Co., TI 2AR-102, TECHNICAL INFORMATION SPEC 200 MULTINEST POWER SUPPLY 2ARPS SERIES (STYLE D), dated May 1977.

TMI-1201-100 IREVISION 0 1PAGE 4 OF 5

-A ATTACHMENTS:

1. ATTACHMENT 1 - PHOTOGRAPH OF FAILED TIE WRAP HOLDER TC105A (1 PAGE).

2. ATTACHMENT 2 - RECORD OF CONVERSATION DATED 17 APRIL 2013 (1 Page).

3. ATTACHMENT 3 - THOMAS AND BETTS, CO., ENGINEERING INFORMATION (3 PAGES).

4. ATTACHMENT 4- INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION (13 PAGES).

5. ATTACHMENT 5 - INVENSYS, INC., EMAIL DATED 25 JUNE 2013 (2 PAGES).

I TMI-1201-100 I REVISION 0 1 PAGE 5 OF 5

ATTACHMENT 1 - PHOTOGRAPH OF FAILED TIE WRAP HOLDER TC105A Page 1 of 1 1A Figure 1 - TC105A with failed adhesive

ATTACHMENT 2 - RECORD OF CONVERSATION DATED 17 APRIL 2013 Page I of 1 Date: 4/17/2013 Page 1 Of 1 RECORD OF CONVERSATION NAME: Steve Mcllwain TITLE: Product Manager COMPANY: Thomas & Betts TIME: 1430 CDT

SUBJECT:

Thomas & Betts TC105A Tie Wrap Holders SUBJECT OF CONVERSATION Discussed the ongoing investigation of the failed Tie Wrap Holders. Mr. Mcllwain indicated that the Tie Wrap Holders were removed from the market after several reports from customers that the adhesive had prematurely failed typically 10 to 15 years after application. The last production run of the TC-1 05A Tie Wrap Holders was on February 17, 1989. After that date the standard TC105 product was supplied with a two part epoxy adhesive. This product is still offered by Thomas and Betts today.

The tie wrap holders were provided to various distributors over the life of the manufacture of the wire ties and that Thomas and Betts would have no way of tracking which manufacturers had used the Tie Wrap Holders.

Mr. Mcllwain offered to email me the product specifications for the TC105A, TC105 and adhesive that was used.

SIGNATURE:

The information contained in this document and any attached or referenced documents is proprietaryand containsprivileged and confidentialinformation belonging to IntegratedResources, Inc. This information is intended for use by Integrated Resources, Inc., and its Client. Disclosure, dissemination,copying, or distributionof this document, or any portion thereof is strictlyprohibited without the priorexpress written permission of IntegratedResources, Inc.

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MATERIAL:

ALUMINUM 3003H14 PER SPEC. 0 Q-A-250/2B THIS DRAWING AND THE INFORMATION CONTAINED THEREIN IS THE PROPERTY OF THOMAS & BETTS FINISH: CORPORATION. NO USE OR REPRODUCTION OF CLEAN & FINISH PER THIS DRAWING AND/OR SUCH INFORMATION IS MIL-C-5541D PERMITTED UNLESS SPECIFIC CONSENT TO DO SO IS GRANTED. ALL RIGHTS RESERVED.

CLASS III CLEAR COPYRIGHT, THOMAS & BETTS CORPORATION.

APPROVING ENGR PRODUCT MANAGER DESCRIPTION TY-RAP MOUNTING PLATE FOR USE WITH STRAPS .190 WIDE kAX Thomas & Betts Corporation Memphis, Tennessee IF DUAL DIMENSIONED, SIZE REV. REV. AS40321TE SALES DWG. NO.

THIRD ANGLE DIMENSIONS ARE SHOWN IN PROJECTION E "-N-'A 5

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10/3/00 SHEET OP COMPUTER GENERAHTED

• P-CAD E MIE-HYBRID 4-Ocl-2000 15:45.53

3 ADHESIVE BACKED TY-RAP-GMOUNTING PLATE I&-E-coB. T N BETT FOR USE WITH TY-RAPOSTRAPS .190 WIDE MAX.

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I I TYPICAL TEST RESULTS.,

MOUNTING SURFACE BAKED ENAMEL FINISH

-- e APPLIED TO BAKED ENAMEL SURFACE

- MOUNTING PLATE PULL OFF FORCE a

!STATIC LOAD 0

z CURE TIME STATIC LOAD., LBS. PULL OFF FORCE, LBS.

15 MINUTES 2 1I' I HOUR 4 20 24 HOURS 15 9 48 HOURS 20 RECOMMENDED STATIC LOAD AFTER A MINIMUM CURE OF 15 MIM MES 2 LBS. MAX.

THE THOMAS & BETTS CO. REV. APPROVED 13Y DATE I SIZE I W0. NO.

DIVq.'OThOMAS& BiETSCORPORATioN -

ELIZ.ASETH NEW JERSEY"AS403213 A...... ..... A I AS 03 IN CANADAI THOMAS0, BCT10LTD., ISBOIVILLIC.P.O.I I

I 100151 DISSlONO Do. 39614 as Sao

THE HEATVA%& P&A 2B,~~ O BETTS, ACND ~EERING INTffEM1?Tj~r3 DISTRBIWrORf 3 ELIZABETH NEW JERSEY SERVES AND SAVES IN CANADA.THOMAS & BETTS. LTD.. MONTREAL TECHNICAL DATA SHEET PRODUCT: ADHESIVE RACKED TT-RAP MUMJMFM PLATES Adhesive Backing is a general purpose, quick-setting, high bond strenpth film. The Solvent Activation Is desipned to suit DSRIMWTIOM application needs.

Over one year in normal, Industrial storage conditions. Laboratory retained samples (filed at 70F) have rencted normally to solvent after as long as three years. All adhesive films should be stored SME61~3 in a coolp dry place away from daylight.

Surfaces to be adhered must be clean, dryp, and free from gease, oilp or other contaminants. T&B Solvent W-110 may be used to clean surfaces. Do not use dauber as a wiper.

Apply Solvent TC-10 to entire surface of adhesive backing with dauber suppliedp taking care not to puddle. The proper bonding character of the film appears when strong cobwebs or legs develop after solvent activation. Time cycle is from 5-20 seconds, depending upon atmospheric conditions and the amount of solvent applied. The bond should be closed at once under firm, even pressure.

Excessive solvent will delay the reset of bond. Insufficient solvent fails to produce proper tack. Allow as much time as possible for curing. The bond continues to develop for as long as 30 days.

BONDS: Adhesive backed mounting plates muy be mounted to many types of surfaces, including moot plastics and mctaLs. It is not recommended for the following: zinc# nickel, tin and some synthetic finishes such as melamine type, polyethylene, vinyl and other special type plastics such as teflon and mylar (DuPont).

PWtA SPe.I Bonds are resistant to water, oil, moisture, veak acids alkalis; semi-flexible. Material complies with MIL P-6906, NIL D-8634 1 MI1-N-25076 2 excellent electrical characteristics (@ 500 V-D-C. : 25 x 10 megohms).

Temperature performance range: -30°F+l0°F, with short duration exposures up to 2000F. (Some performance at higher temperatures depending on durationp mounting load and bond area.) Not recomuended for use vhere temperature will continue at or above 1400°F.

STATEN=T or Because or the conditions under which these devices may be applied and the surfaces to which they may be bonded are beyond our controlp we cannot accept responsibility for the results obtained. No warranty, expressed or implied, is made by us with respect to perforTmace.

THIS DRAWING IS INTENDED ONLY FOR DESCRIPiTVE PURPOSES AND RIGHT IS RESERVED TO DEVIATE FROM ANY OF THE DETAILS SHOWN HEREON.

NOT TO BE COPIED IN WHOLE OR iN PART EXCEPT BY OUR WRITTEN PERMISSION.

-. 3-q-(. 4- Sg- 4ATI REVISION NUMIBE icCm AS 40078-A DRAWN IR.IaACH. 3119/64APPROED 1:, - I I I I I 1A 0 7 -

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ATTACHMENT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Page 1 of 13 FOXBORO Customer Advisory # 2013027abi Invensys Response to US NRC 10CFR21 Event Number 48863 as Reported by Integrated Resources, Inc.

June 7, 2013 FOXBORO NUCLEAR SPEC200 POWER SUPPLY POTENTIAL FAILURES DUE TO DEFECTIVE CABLE TIES AND CABLE TIE HOLDERS Invensys has completed an investigation of the reported condition and has made the following determination:

It has been determined that two models of FOXBORO SPEC 200 Power Supplies could have age-related failure of wire harness cable ties and cable tie holders. The cable tie holders which are aluminum, if fully detached, could fall onto live electrical connections within the power supply and could result in electrical failure of the supply.

The affected model codes are as follows:

• Model N-2ARPS, all styles and option codes, manufactured in 1995 or earlier

• Model N-2ARPS05, all styles and option codes, manufactured in 1995 or earlier Extent of condition:

The cable tie holders in the above mentioned models are secured to the interior wall of the power supplies with an integral adhesive. Inspecting a sample of three older power supplies in the age group revealed 100%

adhesive failure. In all cases the cable ties themselves were intact and so no holders had fallen into the power supply, although several cable ties did however indicate some discoloring from age. Two such power supplies were subsequently tested on a shake table up to 20 Hz at 13 g's of acceleration in order to simulate a seismic event. Under this test condition one cable tie became detached resulting in its' holder falling into the supply.

There are approximately ten such holders in each supply.

Analysis indicates that the consequence of the holder bridging live parts can cause the output of the supply to fail, i.e. the output voltage of the supply can fall to zero volts. Typically two supplies in a SPEC 200 rack in a primary and backup configuration would need to fail in this manner in order for the SPEC 200 card nests to lose power.

The nuclear SPEC 200 product line has been reviewed for other instances where this cable tie holder is used and could pose a similar risk. It was determined that there are none.

Invensys repair history has no record of the metal cable tie holder identified as a root cause for failure in any N-2ARPS or N-2ARPS05 power supplies independent of age, style or option codes.

Power Supply Identification:

The model codes involved are as follows:

(1) Model N-2ARPS, all styles and option codes, manufactured in 1995 or earlier (2) Model N-2ARPS05, all styles and option codes, manufactured in 1995 or earlier To determine if the instrument is affected by this issue, examine the origin number on the data plate (e.g. 2A9501).

Invensys Operations Management, 33 Commercial Street, Foxborough, MA 02035 USA

ATTACHMENT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Page 2 of 13 The origin code of affected units is between 2A9501 (January 1995) and prior. The manufacturing date format is PPYYWW where:

• PP = Plant of manufacture code (in this example, 2A, 2B)

• YY = Year of production

" WW = Week of production If the date code is beyond the manufacturing year of 1995, then no action is necessary.

Actions or Resolutions It is recommended that the affected model codes within the manufacturing date range be cycled out of service for inspection as soon as practical. The cable tie holders serve no safety related purpose and those that are loose or detached should be removed. The cable ties themselves are recommended for seismic integrity and should be replaced. Instructions for performing these actions are detailed in Special Instruction SI 0-00616.

For information If you have any questions regarding this notification, please contact your local Invensys/Foxboro Representative or an Invensys Operations Management support center at:

GCS Center America's GCS Asia Pacific GCS EMEA GCS Location Foxboro MA USA Singapore Baarn NL Phone +1-866-746-6477 +65-66829-8899 +31-3554-84125 Internationally +1-508-549-2424 Fax +1508-549-4999 +65-6829-8898 +31-3554-84230 Email support(iips.invensvs.co csc.ap@ips.invensys.co emeatac@ips.invensys.co Inm m m

Regards, Jo Petty Dirctor Global Client Support Distribution to Invensys/Foxboro Customers and Internal Personnel Only DO NOT REPRODUCE All trademarks are registered to their respective owners.

All brand names are property of their respective owners.

© Invensys Systems, Inc., 2013 All Rights Reserved.

Advisory # 2013027abi ATTACHMENT: SI 0-00616 Invensys Operations Management, 33 Commercial Street, Foxborough, MA 02035 USA

ATTACHMENT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Page 3 of 13 Instruction SI 0-00616 May 2013 SPEC200 Hardware Nuclear (N-2ARPS Series) and Commercial (2ARPS Series)

Power Supply Cable Tie Replacement for Heatsink Mounted Cable Harness AG101CX Kit Quantity Part No. Description 12 N0139FR Cable Ties 1 P0928HV Label, Revision Marking 1 SI0-00616 Special Instructions Overview

- NOTE This is not a product recall. This repair is specific to cable ties and cable tie hold-downs only.

Industry Notification There is a potential that in the Foxboro Model N-2ARPS Series (including N-2ARPS05 Series) and the Model 2ARPS Series (including 2ARPS05 Series) power supplies, the wire harness cable ties and cable tie holders could fail in units that were manufactured in 1995 or earlier. As soon as practical, these SPEC200 power supplies should be temporarily removed from service and inspected. Customer site maintenance should determine whether there is an issue that needs rework.

The cable tie holders serve no safety-related purpose; however, those that are loose or detached should be removed. The cable ties themselves are necessary and should be replaced as needed. Instructions for performing these actions are detailed in this SI.

Customer List A letter will be sent to all affected customers and an advisory will be published on our Invensys Global Customer Support website.

i n vx.bn sr. s Foxboro .

j XO1JAOMGNT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Page 4 of 13 Page 2 Affected Modules The affected model codes are:

• Nuclear

• Model N-2ARPS Series SPEC200 Power Supplies containing all styles and option codes manufactured in 1995 or earlier.

• Model N-2ARPS05 Series SPEC200 Power Supplies containing all styles and option codes manufactured in 1995 or earlier.

• Commercial

• Model 2ARPS Series SPEC200 Power Supplies containing all styles and option codes manufactured in 1995 or earlier.

• Model 2ARPS05 Series SPEC200 Power Supplies containing all styles and option codes manufactured in 1995 or earlier.

Affected Date Codes Recommendation is for inspection of power supplies with year date codes 1995 and earlier. The prob-ability of occurrence of adhesive failure would appear to be high for this age group of equipment.

(See Figure 3 and Figure 4.)

Issue Resolved Potential common mode aging failure of metal cable tie holders used in Foxboro Model Power Sup-plies. For the age group involved, the qualified life of 14 years as stated in PSS 9-7A1A has been exceeded.

Work to be Performed The cable tie holders are out of the warranty period, and as such are no longer warranted. These tie holders are not a safety-related or required item. The recommendation is to contact your authorized repair center for inspection and repair. In the event that you wish Invensys to make these repairs, con-tact Invensys and Invensys will provide a quote and a time period of its availability to perform these repairs. For further information, you can consult your Invensys field service representative.

Recommended Timing of Required Action It is recommended that all potentially affected power supplies be cycled out of service for inspection and corrective action as soon as practical. Instructions for inspection and.corrective action will be detailed or else referenced in a letter sent to customers.

ATTACHMENT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION W -*(Q.616 Page 3 Basic Concern Aging Adhesive on Cable Tie Holder and Aging Cable Ties IThe adhesive that was integral to the aluminum cable tie holder was utilized in production from initial sales release until the year 1995. It has determined that this age group is at risk of adhesive failure based on the field reports and our own observations. (See the example of adhesive embrittlement in the photo to the left.)

Background

Cable harnesses mounted on the Power Supply Rear Heatsink Assembly are secured to the interior wall of the power supply using the aluminum cable tie holders with an integral adhesive (reference Foxboro p/n A3300AK). Typically, ten cable tie hold-ers are utilized in a single Power Supply. The associated cable ties are a common variety made from nylon (reference Foxboro p/n NO139FR).

In some cases, these cable tie and holder systems are located above live un-insulated electrical parts within the power supply. Field reports indicate that during one particular inspection all cable tie hold-ers were found to be detached from the interior walls of a power supply and in one instance, an embrittled cable tie had fractured causing the (metal) cable tie holder itself to fall into the bottom of the supply. It is surmised that if the cable tie holder had bridged live electrical parts that this condi-tion, while in service, could result in potential failure of the power supply. A population of similarly aged power supplies in service and having this condition could then possibly result in a common mode failure situation.

Basic Analysis and Related Information Cable Tie Holder The adhesive that was integral to the aluminum cable tie holder was utilized in production from the initial sales release until the year 1995. It has been determined that this age group is at risk of adhesive failure based on the field reports and our own observations.

Cable Tie Cable Tie Threaded Thru It has been determined that embrittlement and even-tual fracture of nylon tie wraps is a credible failure mode that can be caused by the combination of aging and service conditions. The probability of occurrence is considered to be low to moderate for the affected Cables age group.

Cable Tie%older (Metal)

Consequence of ElectricalShorts within the Power Supply It has been determined that an electrical short caused by a falling cable tie holder could result in loss of function of the power supply. The consequence would, however, in effect be no more severe than a random electrical failure. When considering single failures caused by a cable tie holder-related electri-cal short, the only significant impact would be a reduced MTBF compared to normal operation.

,MAR9 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION ISIBNT Page 6 of 13 Page 4 History of the Reported FailureCondition Invensys repair history has no records of the cable tie holder identified as a root cause for failure in any SPEC200 product.

Overall Analysis, Conclusions and Additional Considerations PotentialIssue Information obtained to date supports the possibility that a number of cable tie holders and cable ties are in various stages of deterioration within power supplies performing a safety-related function. Dur-ing normal operation, it is possible that multiple cable tie holders in the power supplies could simul-taneously fail and possibly bridge live parts which could cause electrical short circuits. Multiple power supply failures may occur.

ATTACHMENT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION 1A0Qr1o 6 Page 5 Hardware Upgrade Process The cable tie holders serve no safety-related purpose and those that are loose or detached should be removed. Only the new cable ties supplied in this kit will be used for the cable bundle tie-down.

Figure I illustrates a Heatsink Assembly TA hardware assembly overview with nine cable bundle tie-

• down locations and Figure 2 is a photo of the rear heatsink assembly with the tenth cable bundle tie-down location in the chassis.

For each of the ten locations, inspect the cable bundle condition one cable tie holder/cable tie at a time and perform the following for each:

• Remove the individual cable tie holder and discard. If the cable tie holder is still in place, gently pry to remove.

- NOTE If a cable tie holder is very solid and will not come loose, it is recommended that you leave the holder in place and install a new cable tie.

• Remove the associated cable tie and replace it with a new cable tie from this kit.

The label included in the kit is placed on the front of the power supply to indicate that the cable ties have been replaced.

SMAMOSNT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Page 8 of 13 Page 6 Figure 1. N-2ARPS-05 Heatsink Assembly TA (with Cable Bundle Tie-down Locations 1 - 9)

ATTACHMENT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Page 7 Figure 2. Rear Heatsink (with Cable Bundle Tie-down Locations)

Recommended Rework Procedures

- NOTE Prior to inspection of the power supply, make sure that all power to the unit has been removed and the unit is then removed from the rack. Take proper maintenance precautions when servicing this equipment.

Perform the following tasks:

1. Verify the product type and model on the front of the Power Supply as shown in Figure 3.

Verify the product date codes as shown in Figure 3 and/or Figure 4.

To determine if the instrument is affected by this issue, examine the origin number on the data plate (e.g. 2A9501).

a. The origin code of affected units is between 2A9501 (January 1995) and prior. The manufacturing date format is PPYYWW where:

• PP = Plant of manufacture code (in this example, 2A, 2B)

• YY = Year of production

• WW = Week of production

b. If the date code is beyond the manufacturing year of 1995, then no action is necessary.

V04MIGNT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Page 10 of 13 Page 8 U

Figure 3. Product Type and Model and Top Level Date Code Figure 4. Chassis Date Code

2. Remove the screws and screws/washers in the power supply top cover as shown in Figure 5 and lift the cover.

ATTACHMENT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Pajge4OQ619 Page 9 Figure 5. Power Supply Top Cover

3. The following examples indicate a close-up of an aging cable tie holder in the rear heat-sink location and the chassis location.

i-igure b. Hear meatsinK Location Figure 7. Chassis Location

4. See Figure 1 for the location of the nine cable tie holders in the rear heatsink and Figure 2 for the location of the tenth cable tie holder in the chassis.

5. Individually, snip out the loose cable tie holder/cable tie and discard. Gently pry the cable tie holder to remove or if it cannot be removed, leave the holder in place.

6. Individually, install a new cable tie provided in this kit.

7. Repeat this process for each of the identified cable bundle tie-down locations.

8. Replace the power supply top cover securing it with the appropriate screws and screws with washers.

9. Place the label (p/n P0928HV) on the front of the power supply in the lower left corner of the power supply (Figure 3).

10. Complete the attached AG 101CX Retrofit Configuration Control Record (one sheet per kit) and return to Invensys Systems, Inc. by FAX or mail as stated on the form.

SFGAMGNT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Page 12 of 13 Page 10 Invensys Operations Management Invensys, Foxboro, and the Invensys logo are 10900 Equity Drive trademarks of Invensys plc, its subsidiaries, and Houston, TX 77041 United States of affiliates.

America All other brands and product names may be the http://iom.invensys.com trademarks of their respective owners.

Copyright 2013 Invensys Systems, Inc. All rights Global Customer Support reserved. Unauthorized duplication or distribution is Inside U.S.: 1-866-746-6477 strictly prohibited.

Outside U.S.: 1-508-549-2424 or contact your local Invensys representative.

i n Ve. n s-.ýj s- Website: http://support.ips.invensys.com MB 185 0513

ATTACHMENT 4 - INVENSYS, INC., CUSTOMER ADVISORY AND SPECIAL INSTRUCTION Page0 Q616 Page 11 Retrofit Configuration Control Record AG1O1CX Kit This form is used to update the Invensys Foxboro Configuration Control Records. It must be filled out and faxed to 1-508-549-4999 or mailed to: Invensys Systems, Inc., Mail Code: B52-AB, 33 Commercial Street, Foxboro, MA 02035. Please complete only one sheet per kit. List all Invensys Foxboro Sales Order Numbers involved.

CUSTOMER NAME: CUST ID:

LOCATION:

PRODUCT TYPE:

FOXBORO SALES ORDER NO:

KIT PART NUMBER:

EXCLUDING SPARES - HOW MANY TOTAL UNITS ARE AT THE CUSTOMER'S SITE?

HOW MANY OF THESE UNITS ARE AFFECTED BY THIS CHANGE?

HAS KIT BEEN INSTALLED? YES __ NO __ IF YES, QTY. INSTALLED THIS TRIP:

FOXBORO SERIAL/IDENTIFICATION/ORIGIN DATE CODE:

ON-SITE SPARES:

HAS THE CUSTOMER ANY SITE-SPARES THAT REQUIRE THIS CHANGE? YES NO IF YES, HOW MANY TOTAL SITE-SPARES:

HAS KIT BEEN INSTALLED? YES - NO - IF YES, QTY. INSTALLED THIS TRIP:

COMMENTS: **HOME OFFICE USE ONLY

• • REQD INF YRWK

• • SITE KIT INSTALLER CLOCK NUMBER DATE

Page 1 of2 ATTACHMENT 5 - INVENSYS, INC., EMAIL DATED 25 JUNE 2013 Page 1 of 2 John Brosemer From: Provost, Norm [Norm.Provost@invensys.com]

Sent: Tuesday, June 25, 2013 8:16 AM To: John Brosemer Cc: Francis, Karen

Subject:

RE: Foxboro Part 21 report Attachments: Customer Advisory #2013027abi.pdf; SI_0-00616a.pdf; "AVG certification".txt Mr. Brosemer, Here is the status and Invensys final conclusion.

Attached are copies of the customer notification and the inspection/rework procedure for the subject issue, for reference. These have been sent by certified mail to all users. Users are Invited to contact Invensys for support as required. No further action by Invensys related to this issue beyond user support is anticipated at this time.

All cable ties and holders within the affected products have been considered in the evaluation. Note that only those tie holders that are (or were) attached to the vertical interior walls of the power supply are the ones of concern. This is reflected in the customer notice and Special Instruction.

Regards, Norm Provost, Chairman (Invensys) Nuclear Product Safety Committee Invensys Systems Inc.

33 Commercial Street Foxboro, MA 02035 USA From: Francis, Karen Sent: Tuesday, June 25, 2013 7:08 AM To: Provost, Norm Cc: Dale Overbeck; Marvin Shimmel; John Brosemer

Subject:

RE: Foxboro Part 21 report Good Morning Norm, Can you please address John's email?

Thank You Karen From: John Brosemer [1]

Sent: Tuesday, June 25, 2013 2:39 AM To: Francis, Karen Cc: Dale Overbeck; Marvin Shimmel

Subject:

Foxboro Part 21 report Ms Francis, 7/3/2013

Page 2 of 2 ATTACHMENT 5 - INVENSYS, INC., EMAIL DATED 25 JUNE 2013 Page 2 of 2 Isthere any "status" concerning the T&B TC105A's installed inthe false bottom of the power supplies? IRI is approaching our estimated final report date to the NRC. Will itbe necessary for me to initiate an "interim" report?

Or does Foxboro anticipate being able to put this issue to rest inthe next week or two?

I am currently out of the office and can be reached via email or via cell phone at (402) 209-0510.

John F. Brosemer President Integrated Resources, Inc.

(402) 873-5859

• Confidentiality Notice: This e-mail, including any associated or attached files, is intended solely for the individual or entity to which it is addressed. This e-mail is confidential and may well also be legally privileged. Ifyou have received it In error, you are on notice of its status.

Please notify the sender immediately by reply e-mail and then delete this message from your system. Please do not copy it or use it for any purposes, or disclose its contents to any other person. This email comes from a division of the Invensys Group, owned by Invensys plc, which is a company registered in England and Wales with its registered office at 3rd Floor. 40 Grosvenor Place, London, SWIX 7AW (Registered number 166023). For a list of European legal entities within the Invensys Group, please select the Legal Entities link at invensys.com, You may contact Invensys plc on +44 (0)20 3155 1200 or e-mail reception@invensys.com. This e-mail and any attachments thereto may be subject to the terms of any agreements between Invensys (and/or its subsidiaries and affiliates) and the recipient (and/or its subsidiaries and affiliates).

7/3/2013