ML13284A084

Deficiency Report from Baldor Electric Co., on Nuclear Nonconformance Event No. 49302

ML13284A084
Person / Time
Site:	Beaver Valley, Dresden, Browns Ferry, Oconee, Perry, Fermi, Catawba, Grand Gulf
Issue date:	10/03/2013
From:	Thigpen J Baldor Electric Co
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
49302
Download: ML13284A084 (11)

Text

~~ ~D OI  ! 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 October 3, 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 final 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 1E 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

I= A TBaldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA A MEMBER 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 1E 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. J.

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.

.A .L D O  : Baldor Electric Cco 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 1E 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:

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 Customer Customer PO # Motor Serial # End User / Status Name Location A AREVA NP, 1007010502 7405444-001 T1 Mark For: P/N Contacted INC. 1706512-007 'anthony.zusin JOB NAME: as@areva.co

_2362 ISA ml B DAVID 168038 7280451-001 T1 South Korea, Contacted istout*,,clydeu BROWN 7280451-001 T2 Shin-Kori Unit UNION PUMPS 7280451-002 T1 1,Tag # 1-451- nion.com and CO. 7280451-002 T2 M-PP03 Leslie, Bryan Pump Serial # bryan.leslieD RI05136AN-1 spx.com Motor Serial #

7280451-001 - End User T1 notified by Leslie, Bryan Shin-Kori Unit bryan.leslie@

2, Tag # 2- spx.com 451 -M-PP03 Pump Serial #

RI05136BN-1 Motor Serial #

7280451-002-T1 Shin-Wolsong Unit 1 Tag # 1-451-M-PP03 Pump Serial #

RI05137AN-1 Motor Serial #

7280451-001 -

T2 Shin- Wolsong Unit 2 Tag # 2-451-M-PP03 Pump Serial #

RI05137BN-1 Motor Serial #

7280451-002-T2 C DUKE DP3894, ITEM 6503869 T1 Mark For: STK Contacted ENERGY 0010 COD 560661-1 Mike.Bouknig CORP CATAWBA ht@duke-AUX BLDG energy.com FILTERED FAN NE23183, ITEM 7189552-001 T1 Ship to Contacted

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 0010 7189552-001 T2 Catawba Site, Mike.Bouknig Mark For: ht@duke-Stock Code energy.com 595706-1 NE23183, ITEM 7189552A-001 Ship to Contacted 0020 T1 Catawba Site, Mike.Bouknig Mark For: ht@duke-Stock Code energy.com 560661-1 78439, ITEM 7259472-001 T1 Ship to Contacted 0001 Catawba Site, Mike.Bouknig Mark For: ht@duke-Stock Code energy.com 560661-1 AUX BLDG FILT EXH FAN MOTOR P83059 7314258-001 T1 Ship to Contacted Catawba Site, Mike.Bouknig Mark For: ht@duke-Stock Code energy.com 560661-1 50624 L/I 002 7242046-001 T1 Ship to Contacted Catawba Site, Mike.Bouknig Mark For: ht@duke-STOCK CODE energy.com 858815-1 81537 LU 002 7306866-001 T1 Ship to Contacted Catawba Site, Mike.Bouknig Mark For: ht@duke-STOCK CODE energy.com 858815-1 00114161 L/I B464441-010 T1 Oconee Contacted 0001 Nuclear Mike.Boukniq Station SSF htcduke-RC MAKEUP enerqy.com PUMP and MOTOR 'donnie.jarrett Catalog ID @duke-864584 energy.com' 00131213 B604345-010 T1 Ship to Contacted Catawba Site Mike.Bouknig Catalog ID ht@duke-858815-1 energy.com D ENERTECH 615544 6933365-001 T1 sold to Entergy Contacted

@ Grand Gulf RDeKleine(c Plant their PO# urtisswricqht.c to Enertech om was 10105466 End User notified by RDeKleine(c

~ALDQR 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 urtisswri-qht.c om 114835 7296045-001 T1 sold to Detroit Contacted Edison @ RDeKleine@c Fermi Plant urtisswright.c their PO# to om Enertech was NR-418336 End User notified by RDeKleine@c urtisswright.c om 114835-2 7398284-001 T1 was sold to Contacted ITEM#30 Detroit Edison RDeKleine@c

@ Fermi Plant urtisswright.c their PO# to om Enertech was End User NR-418336 notified by RDeKleine@c urtisswright.c om E FIRST 45349776, UI B655271-010 T1 Ship to: Perry ENERGY 00002 B655271-010 T2 Main B655271-010 T3 Warehouse, Perry Nuclear Power Plant, 10 CENTER ROAD, PERRY OH 44081 45374079, LI B809528-010 T1 Ship to: Perry 00001 B809528-010 T2 Main Warehouse, Perry Nuclear Power Plant, 10 CENTER ROAD, PERRY OH 44081 45390853, Ul B869861 -010 T1 Ship to: Perry 00001 Main Warehouse, Perry Nuclear Power Plant, 10 CENTER ROAD, PERRY OH 44081 F FIRST 45192009 7163989-001 T1 Ship to Perry ENERGY Nuclear Power SERVICE CO. Plant. Mark

23,,ALDOI 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 For:

MAT#9695339 5

PO#45192009 45303885, UI B502150-010 T1 Ship to 10 00001 CENTER ROAD PERRY, OH 44081 Mark for: MAT #

96953395 PO

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G FLOWSERVE HEL-013995 3769966A-001 Ship to Contacted PUMP T1 FLOWSERVE grevenga@flo DIVISION- 3769966A-001 PUMP wserve.com SPAIN T2 DIVISION 3769966A-001 Flowserve T3 Spain Avd 3769966A-001 Fuentemar, T4 26-28 COSLADA, MADRID Motors are related to the Vandell6s II job.

H GEORGIA 7051394, ITEM 1 KXV60398 T1 Verified OK POWER CO 001 MSKINNER@

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7051394, ITEM 2KXV60398 T1 Verified OK 002 MSKINNER@

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I HOWDEN 17156 1KXV60503 T1 Exelon Contacted BUFFALO INC Generation Jim.Elco(aho Company LLC, wden.com, Dresden and end user Warehouse, 'kurt.kalenak 6500 North @exeloncorp.

Dresden Rd, com' and Morris, ,IL 'scott.senffner 60450-9765 @exeloncorp.

comr 17578 1KXV60514 T1 Electronuclear Contacted P0450003923 Jim.Elcoaho rev 1 (UCI SO: wden.com 948), shipped and Korina to Rio de Looft Janero, Brazil <KLooft@unit 20030-021. edcontrols.co Project Angra m>

3AM TDOUR Baldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA A MEMBER OF THE AB1B GROUP Tel 678.947.7350 Unit 1 25947 6869298-001 T1 Southern Contacted 6869298-001 T2 California Jim.Elco@ho Edison / wden.com P.O.Box 128 I San Clemente, CA 92674-0128 26942 6982377-001 T1 KHNP / 167 Contacted Samsung- Jim.Elco@ho Dong, wden.com Gangnam-Gu /

Seoul 135-791

/ Republic of Korea 27592 7164652-001 T1 First Energy / Contacted Beaver Valley Jim.Elco@ho Power Station I wden.com P.O.Box 4 /

Shippingport, PA 15077 29445 7221083-001 T1 KHNP / 167 Contacted Samsung- Jim.Elco@ho Dong, wden.com Gangnam-Gu /

Seoul 135-791

/ Republic of Korea 29619 7251392-001 T1 First Energy / Contacted Beaver Valley Jim.Elco@ho Power Station / wden.com P.O.Box 4 /

Shippingport, PA 15077 40294 B523030-010 T1 Southern Contacted California Jim.Elco@ho Edison / wden.com P.O.Box 128 I San Clemente, CA 92674-0128 40796 B534396-010 T1 First Energy / Contacted Beaver Valley Jim.Elco@ho Power Station / wden.com P.O.Box 4 /

Shippingport, PA 15077 40869 B536076-010 T1 Trentec, A Contacted B536076-010 T2 Business Unit Jim. Elco(),ho B536076-010 T3 of Curtiss- wden.com Wright Flow and Control RDeKleine~c

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 Corporation, urtisswright.c 4600 East om Tech Drive, Cincinnati, OH 45245 40869 B536220-020 Ti Trentec, A Contacted Business Unit Jim.ElcoCho of Curtiss- wden.com Wright Flow and Control RDeKleine@c Corporation, urtisswright.c 4600 East om Tech Drive, Cincinnati, OH 45245 41391 B549766-010 Ti Southern Contacted B549766-010 T2 California Jim.Elco@ho Edison / wden.com P.O.Box 128 /

San Clemente, CA 92674-0128 43094 B612674-010 Ti First Energy / Contacted Beaver Valley Jim.Elco@ho Power Station / wden.com P.O.Box 4 /

Shippingport, PA 15077 42700 B619134-010 TI TVA Nuclear/ Contacted Nuclear Jim.Elco@ho Assurance and wden.com Liscensing /

1101 Market St

/ Chattanooga, TN 37402-2801 42978 B605377-01 0 Ti TVA Nuclear / Contacted B605377-010 T2 Nuclear Jim.Elco@ho Assurance and wden.com Liscensing /

1101 Market St

/ Chattanooga, TN 37402-2801 Po011990 B944153-010 T1 Ergytech, Inc. / Contacted B944153-010 T2 2400 Augusta, Jim.Elco@ho Suite 310 / wden.com Houston, TX 77057 PO 010456 B792616-010 TI Ergytech, Inc. / Contacted 2400 Augusta, Jim.Elco@ho Suite 310 / wden.com

wALDOZ= 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 Houston, TX 77057 J LIMITORQUE 125024 6504992 T1 Limitorque PN Contacted 6504992 T2 R-608-F04- <jmcconkey@fl 0800. Located owserve.com>

@TVA Browns Ferry, installed on (2)

SMB-5T actuators on Flowserve order 33365

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209355, DOE Cont # DE-AC27-01RV14136 L TAIWAN 8911120165 8KXV60501 T1 POWER 008971120105, B446279-010 T1 COMPANY ITEM 006 M WESTINGHOU 4500199978 L/I 7192126-001 T1 Mark for: Contacted SE ELECTRIC 1 PO#45001999 ellismr@westi COMPANY 78 nghouse.com SO#05A01820 CUST PO#1772211 MAT#7650458 4500336630 L/I B588514-010 T1 Ship to Contacted 1 FLORIDA P&L, ellismr@westi 6501 S. nghouse.com 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

b I 1*,

Baldor Electric Co P. 0. Box 250, 4349 Avery Drive Flowery Branch, GA 30542 USA A MEM BER OF THE ABB GROUP Tel 678.947.7350 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.

G. Other Information.

We suggest the motors identified as possibly having this non-conformance, be inspected for the following.

a. The frame weld windows on identified 360,400 or 440 frame motors show no weld.

and

b. The stator core weld notch is visible in at least one (of the two) frame weld windows.

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.

6. Grind off any paint from the weld slot area and puddle weld to fill the bottom of the window.

7. Perform routine test to verify the motor meets requirements.

Sincerely, Mr. James Thigpen Quality Assurance Manager, Gainesville Motor Plant Baldor Electric Co.