ML13246A087
| ML13246A087 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley, Dresden, Browns Ferry, Oconee, Perry, Catawba, Saint Lucie, Watts Bar, Sequoyah, Turkey Point, San Onofre, Bellefonte  |
| Issue date: | 08/23/2013 |
| From: | Thigpen J Baldor Electric Co |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| Download: ML13246A087 (7) | |
Text
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Baldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA A MEMBER OF THE ABB GROUP Tel 678.947.7350 August 23, 2013 To:
Document Control Desk United States Nuclear Regulatory Commission Washington, DC 20555
Dear Sir or Madam:
In accordance with Title 10, Code of Federal Regulations, Part 21, Baldor Electric is making written notification as required by 10CFR21.21 for event #49302.
A.
Name and address of the individual informing the NRC.
James Thigpen Quality Assurance Manager Baldor Electric/Gainesville Motor Plant 4349 Avery Drive Flowery Branch, Georgia 30506 B.
Identification of Basic Component being Supplied.
AC Motor C.
Name of firm supplying basic component.
Baldor Electric/Gainesville Motor Plant 4349 Avery Drive Flowery Branch, Georgia 30506 D. Nature of the defect, deviation, or failure to comply.
Subject:
Nuclear Nonconformance Event Number 49302 This is a reportable 10CFR21 notification because we believe it is possible that some 1 E motors in frame sizes 360, 400, and 440 may have been shipped by Baldor Electric, which contain an entry point for blast media to enter the motor during post shipment paint treatment preparations.
During a recent inspection of a returned motor some foreign materials were discovered inside the motor which appeared to consist of two types of blast media.
One type of blast media found is used during the manufacturing process to clean the rotor end ring area before applying an end ring coating. This media is non-conductive and is typically cleaned away as part of the treatment process. The presence of blast media is a key inspection point at rotor final inspection. In mid 2008 this type of blast media was eliminated from Baldor processes and substituted with C02 blast media.
The other blast media found inside the motor is not used during the motor manufacturing process at Baldor. It was a metallic bead media and used during a paint preparation process after leaving Baldor. The entry point of this material was found to be through a small window in the frame casting that normally is closed with
IBaldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA A MEWBER OF THE ABB GROUP Tel 678.947.7350 weld after the stator is assembled into the frame. In this instance, one of the stator weld notches was aligned with one (of the two) small windows in the frame casting.
This allowed the blast media to enter and travel along the OD of the stator core weld notch and into the motor.
Engineering and Quality reviewed all nuclear orders to verify the frame sizes that may have used the weld slot construction. The frames were determined to be 360, 400, and 440 during the time frame when the welds may not have been verified.
The date range was established as 2002 thru 2013.
Nuclear Motor Assembly Checklist RGGFCD-00004, used as part of the dedication of Class 1 E motors, was reviewed and found not to have a verification check for the stator/ frame welds. The puddle welds were not required to be verified as part of the documented dedication characteristics by Quality personnel. Therefore we believe it is possible that other 1 E motors in frame sizes 360, 400, and 440 may have been shipped with this same entry point for blast media.
Frame Window with no visible weld.
Acceptable since the stator weld notch is not visible.
Frame Window with visible stator weld notch (painted green for recognition)
Engineering reviewed and confirmed for 360,400, and 440 frame sizes, the stator/frame assembly mechanical construction without the welds present was adequate to meet torsional or axial loads for motor performance and seismic loads.
A review of reported quality issues found no winding failures have ever been reported for FME (blast media) in any of the 360, 400, or 440 frame sizes.
Baldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA A MEMBER OF THE ABB GROUP Tel 678.947.7350 This is a reportable 10CFR21 notification because there is a possibility that other Nuclear Class 1 E motors have shipped with both the following:
a.The frame weld window on identified 360, 400, or 440 frame motors shows no weld.
b.The stator core weld notch is visible in at least one (of the two) frame weld windows.
The combination of both these items would allow an entry point for external conductive blast media (FME) to enter the motor.
STEPS TAKEN TO PREVENT FUTURE OCCURRENCES Containment:
All in process and on the dock motors were inspected to verify the welds were in place. No motors were found without the proper weld during this inspection.
Engineering and Quality reviewed all nuclear orders to verify the frame sizes that may have used the weld slot construction. The frames were determined to be 360, 400, and 440 during the time frame when the welds may not have been verified.
The date range was established as 2002 thru 2013.
Nuclear Motor Assembly Checklist RGGFCD-00004 used as part of the dedication of Class 1 E motors was reviewed and found not to have a verification check for the stator/ frame welds.
Engineering reviewed and confirmed for 360,400, and 440 frame sizes, the stator/frame assembly mechanical construction without the welds present was adequate to meet torsional or axial loads for motor performance and seismic loads.
A review of reported quality issues found no winding failures have ever been reported for FME (blast media) in any of the 360, 400, or 440 frame sizes.
CONCLUSION The problem is the possibility that motors shipped with a path thru a stator weld notch into the motor. The possibility of this happening is confined to the specific sales orders identified.
D.
The Discovery Date.
June 24, 2013.
E.
The Quantity and Location of Motors Affected.
Quantity On Hand: 0 Shipped:
63 PART/COMPONENT NUMBER:
A MEMBER OF THE ABB GROUP Baldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA Tel 678.947.7350 Customer Name Customer PO #
Motor Serial #
End User / Location A
AREVA NP, INC.
1007010502 7405444-001 T1 Mark For: P/N 1706512-007 JOB NAME: 2362 ISA B
DAVID BROWN 168038 7280451-001 T1 Mark For: RI05136AN/BN - SHIN UNION PUMPS CO.
7280451-001 T2 KORI RI05137AN/BN-SHIN 7280451-002 T1 WOLSONG 7280451-002 T2 C
DUKE ENERGY DP3894, ITEM 6503869 T1 Mark For: STK COD 560661-1 CORP 0010 CATAWBA AUX BLDG FILTERED FAN
- NE23183, 7189552-001 T1 Ship to Catawba Site, Mark For:
ITEM 0010 Stock Code 595706-1
- NE23183, 7189552A-001 Ship to Catawba Site, Mark For:
ITEM 0020 T1 Stock Code 560661-1 78439, ITEM 7259472-001 T1 Ship to Catawba Site, Mark For:
0001 Stock Code 560661-1 AUX BLDG FILT EXH FAN MOTOR P83059 7314258-001 T1 Ship to Catawba Site, Mark For:
Stock Code 560661-1 50624 L/I 001 7242046-001 T1 Ship to Catawba Site, Mark For:
STOCK CODE 594014-1 81537 L/I 001 7306866-001 T1 Ship to Catawba Site, Mark For:
STOCK CODE 594014 00114161 L/I B464441-010 T1 Oconee Nuclear Station SSF RC 0001 MAKEUP PUMP MOTOR 00131213 B604345-010 T1 Ship to Catawba Site D
ENERTECH 615544 6933365-001 T1 Mark For: ENTERGY CAT ID 00922470033 PO 10105466 L/I 0001 114835 7296045-001 T1 Ship to GOULDS PUMPS, 240 Fall Street SENECA FALLS, NY.
Mark For: 840071 P/N D4224S 114835-2 7398284-001 T1 Ship to GOULDS PUMPS, 240 ITEM#30 Fall Street SENECA FALLS, NY.
Mark For: PO#1 14835 IT#30 P/N D5501S 840071 E
FIRST ENERGY 45349776, L/I B655271-010 T1 Ship to: Perry Main Warehouse, 00002 B655271-010 T2 Perry Nuclear Power Plant, 10 B655271-010 T3 CENTER ROAD, PERRY OH 44081 45374079, L/I B809528-010 T1 Ship to: Perry Main Warehouse, 00001 B809528-010 T2 Perry Nuclear Power Plant, 10 CENTER ROAD, PERRY OH 44081 45390853, L/I B869861-010 T1 Ship to: Perry Main Warehouse, 00001 Perry Nuclear Power Plant, 10 CENTER ROAD, PERRY OH 44081 F
FIRST ENERGY 45192009 7163989-001 T1I Ship to Perry Nuclear Power
A MEMBER OF THE ABB GROUP Baldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA Tel 678.947.7350 SERVICE CO.
Plant. Mark For: MAT#96953395 PO#45192009 45303885, L/
B502150-010 T1 Ship to 10 CENTER ROAD 00001 PERRY, OH 44081 Mark for: MAT
- 96953395 PO # 45303885 G
FLOWSERVE HEL-013995 3769966A-001 Ship to FLOWSERVE PUMP PUMP DIVISION-T1 DIVISION SPAIN 3769966A-001 Flowserve Spain Avd Fuentemar, T2 26-28 3769966A-001 COSLADA, MADRID. Mark For:
T3 PO#HEL-013995 3769966A-001 10.05.77.11079 T4 H
GEORGIA POWER 7051394, ITEM 1KXV60398 T1 CO 001 7051394, ITEM 2KXV60398 T1 L
002 I
HOWDEN BUFFALO INC 17156 1 KXV60503 T1 Exelon Generation Company LLC, Dresden Warehouse, 6500 North Dresden Rd, Morris,,IL 60450-9765 17578 1KXV60514 T1 United Controls International, 5139 S. Royal Atlanta Drive, Tucker, GA 30084 25947 6869298-001 T1 Southern California Edison /
6869298-001 T2 P.O. Box 128 / San Clemente, CA 92674-0128 26942 6982377-001 T1 KHNP / 167 Samsung-Dong, Gangnam-Gu / Seoul 135-791 /
Republic of Korea 27592 7164652-001 T1 First Energy / Beaver Valley Power Station / P.O.Box 4 /
Shippingport, PA 15077 29445 7221083-001 T1 KHNP / 167 Samsung-Dong, Gangnam-Gu / Seoul 135-791 /
Republic of Korea 29619 7251392-001 T1 First Energy / Beaver Valley Power Station / P.O.Box 4 /
Shippingport, PA 15077 40294 B523030-010 T1 Southern California Edison I P.O.Box 128 / San Clemente, CA 92674-0128 40796 B534396-01 0 T1 First Energy / Beaver Valley Power Station / P.O.Box 4 /
Shippingport, PA 15077 40869 B536076-010 T1 Trentec, A Business Unit of B536076-010 T2 Curtiss-Wright Flow Control B536076-01 0 T3 Corporation, 4600 East Tech Drive, Cincinnati, OH 45245 40869 B536220-020 T1 Trentec, A Business Unit of Curtiss-Wright Flow Control Corporation, 4600 East Tech
A MEMBER OF THE ABB GROUP Baldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA Tel 678.947.7350 I Drive, Cincinnati, OH 45245 41391 B549766-010 Ti Southern California Edison /
B549766-010 T2 P.O. Box 128 / San Clemente, CA 92674-0128 43094 B612674-010 Ti First Energy / Beaver Valley Power Station / P.O.Box 4/
Shippingport, PA 15077 42700 B619134-010 TI TVA Nuclear/ Nuclear Assurance and Liscensing / 1101 Market St /
Chattanooga, TN 37402-2801 42978 B605377-010 Ti TVA Nuclear / Nuclear Assurance B605377-01 0 T2 and Liscensing / 1101 Market St /
Chattanooga, TN 37402-2801 Po011990 B944153-010 Ti Ergytech, Inc. / 2400 Augusta, B944153-010 T2 Suite 310 / Houston, TX 77057 PO 010456 B792616-010 Ti Ergytech, Inc. / 2400 Augusta, Suite 310 / Houston, TX 77057 J
LIMITORQUE 125024 6504992 Ti Mark For: PO#125024 LI 001 6504992 T2 R-608-F04-0800 K
SPENCER 97716, L/ 1 B658247-010 TI Mark for: PROJECT# 209355 TURBINE CO B721200-020 Ti B721200-020 T2 B721200-020 T3 L
TAIWAN POWER 8911120165 8KXV60501 T1 COMPANY 008971120105, B446279-010 Ti ITEM 006 M WESTINGHOUSE 4500199978 L/I 7192126-001 TI Mark for: PO#4500199978 ELECTRIC 1
SO#05A01820 COMPANY CUST PO#1772211 MAT#7650458 4500336630 L/l B588514-010 Ti Ship to FLORIDA P&L, 6501 S.
1 OCSAN DRIVE, JENSEN BEACH, FL 34957 F.
The Corrective Action which has been completed.
Baldor initiated corrective action per Baldor CAR-00409 on July 10, 2013 which was completed and received final approval by James Thigpen QA manager Baldor. Final verification of actions will be verified for effectiveness by 11/19/2013.
- a. Manufacturing, Quality and Design Engineering personnel were made aware of the issue through an employee communication posting. RGGWI-00002 Frame Assembly and Weld Procedure was revised to detail the 360,400, and 440 frames with weld slots must always be welded and verified as welded as part of the operator final inspection.
- b. Nuclear Motor Assembly Checklist RGGFCD-00004 was revised to include a quality verification that all 360, 400, or 440 stator/frame assemblies are verified to be welded if the design requires this process. Note: Many of 360 frame motors do not have the frame weld slots as part of the design.
Baldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA A MEMBER OF THE AB13 GROUP Tel 678.947.7350 G.
Other Information.
We suggest the motors identified as possibly having this non-conformance, be inspected for the following.
and
If both these issues are present then we recommend the following:
- 1. Remove the motor from service
- 2. Remove the brackets from the motor
- 3. Inspect for FME (blast media) and if found vacuum it off the windings and inside the frame and brackets.
- 4. Verify the winding integrity through use of meggar, hypot, resistance and surge test.
- 5. Re-assemble motor.
- 7. Perform routine test to verify the motor meets requirements.
Sincerely, Mr. James Thigpen Quality Assurance Manager, Gainesville Motor Plant Baldor Electric Co.