ML16154A643

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Insp Repts 50-269/94-21,50-270/94-21 & 50-287/94-21 on 940615-0716.Violations Noted.Major Areas Inspected:Review Circumstances Surrounding Inadvertent Lockout of Keowee Overhead Emergency Power Path on 940614
ML16154A643
Person / Time
Site: Oconee  Duke Energy icon.png
Issue date: 07/22/1994
From: Harmon P, Skinner P
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML16154A644 List:
References
50-269-94-21, 50-270-94-21, 50-287-94-21, NUDOCS 9408090248
Download: ML16154A643 (11)


See also: IR 05000269/1994021

Text

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UNITED STATES

o

NUCLEAR REGULATORY COMMISSION

REGION II

101 MARIETTA STREET, N.W., SUITE 2900

ATLANTA, GEORGIA 30323-0199

Report Nos.:

50-269/94-21, 50-270/94-21 and 50-287/94-21

Licensee:

Duke Power Company

422 South Church Street

Charlotte, NC 28242-0001

Docket Nos.: 50-269, 50-270, and 50-287

License Nos.: DPR-38, DPR-47, and DPR-55

Facility Name: Oconee Units 1, 2, and 3

Inspection Conducted: June 15-July 16, 1994

Inspectors:

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P. E. Harmon, Senior Resident Inspector

Date Signed

W. K. Poertner, Resident Inspector

L. A. Keller, Resident Inspector

P. G. Humphrey, Resident Inspector

Approved by:

Act n1=Da

  • P.

H. Skinner, Actinf ChiefDt

in'

Reactor Projects Branch 3

SUMMARY

Scope:

This special inspection was conducted to review the circumstances

surrounding the inadvertent lockout of the Keowee overhead

emergency power path on June 14, 1994.

Results:

One apparent violation was identified involving a single failure

vulnerability for the Keowee Units that existed from initial

construction until the completion of-a modification on June 23,

1994. Specifically, loss of all or part of the non-seismically

qualified, non safety-related air system for Air Circuit Breakers

(ACBs) 1 through 4, could have resulted in an automatic lockout of

the emergency overhead power path. This combined with a single

failure that would deenergize the underground emergency power path

would have resulted in a complete loss of on-site emergency power.

In addition to the single failure vulnerability, several

additional concerns were identified during the inspection effort:

Operability determinations were not conducted in a manner

commensurate with the safety significance of the emergency

power supplies. The initial failure occurred on June 14,

1994, but the applicable Technical Specification Limiting

Condition for Operation was not entered until June 22.

9408090248 940722

PDR

ADOCK 05000269

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2

During that period, active work on the air system was

suspended for three days over a weekend. In addition,

the resident inspectors expressed concern to the operations

staff about the apparent single failure vulnerability

of the air system design as early as June 15, but a

formal/documented operability evaluation was not initiated

until June 22.

Numerous single failure vulnerabilities in the emergency

power system have been identified in the past. These

prompted programmatic efforts to identify and correct all

potential single failure vulnerabilities. As evidenced by

this event, these programmatic efforts have not been

completely successful.

The design basis and features of the ACB protective

circuitry for Keowee were not well documented or completely

understood by the plant staff.

Testing of the air system for ACBs 1 through 4 was not

adequate to identify the failure of safety-related check

valves to prevent excessive blowdown of the air reservoirs

associated with ACBs 3 and 4.

Components and systems supplied and designated as "skid

mounted" are considered exempt from the licensee's

controlled drawing program, even when those systems and

components are safety-related. In particular, the breaker

air system did not have a drawing associated with it.

Valve identification tags are not provided for skid-mounted

equipment, even when valves and systems are safety-related.

Maintenance on the air system was not adequate to identify

corrosion buildup in the internals of one of the pressure

regulating valves. The malfunction of this valve, due to

corrosion buildup, contributed to the June 14 lockout event.

REPORT DETAILS

1.

Persons Contacted

Licensee Employees

  • B. Peele, Station Manager

S. Benesole, Regulatory Compliance Manager

  • D. Coyle, Systems Engineering Manager

J. Davis, Engineering Manager

  • B. Dolan, Safety Assurance Manager
  • W. Foster, Superintendent, Mechanical Maintenance
  • J. Hampton, Vice President, Oconee Site
  • D. Hubbard, Component Engineering Manager

C. Little, Superintendent, Instrument and Electrical (I&E)

  • G. Rothenberger, Operations Superintendent
  • R. Sweigart, Work Control Superintendent
  • L. Wilkie, Safety Review Manager

Other licensee employees contacted included technicians, operators,

mechanics, security force members, and staff engineers.

  • Attended exit interview.

2.

Background

The Oconee design basis requires that the Keowee Emergency Power System

be capable of supplying power via two independent and separate paths to

all three units of the Oconee Nuclear Station. These paths are referred

to as the overhead path and the underground path. The design basis also

requires that the Keowee Emergency Power System meet the system

functional design basis for design basis events while sustaining a worst

case single failure; and that it not lose its capability to perform

intended safety functions during and following a maximum hypothetical

earthquake.

Keowee Unit 1 can be aligned to the overhead path via Air Circuit

Breaker (ACB)-1, or the--underground path via ACB-3. Keowee Unit.2 can.

be aligned to the overhead path via ACB-2, or the underground path via

ACB-4. ACBs 1-4 are identical 13.8 kV Westinghouse type CA 1500

compressed air circuit breakers. The type CA circuit breaker is

essentially electro pneumatic in operation. These breakers utilize

compressed air at a pressure of 150 pounds per square inch (psi) as a

means for mechanically opening and closing breaker contacts, as well as

for arc suppression during breaker opening operation. Operation of a

breaker utilizes approximately 25 psi of air for an opening cycle and 2

psi during a closing cycle. Keowee has routinely operated with one or

both units generating to the grid. An Engineered Safeguards signal will

automatically divorce the Keowee Units from the grid by opening ACB 1

and 2.

The compressed air system supplying the ACBs consists of two air

compressors, each with an attached header supply tank, feeding a common

2

air header for all four ACBs.

Each air compressor maintains its header

supply tank between 260 and 300 psi.

A pressure regulator associated

with each air compressor maintains header pressure at 150 psi.

Each

ACB has its own reservoir, check valve, and two pressure switches

located on the breaker skid. The reservoir, check valve, and pressure

switches are classified QA Condition 1 and are seismically qualified.

All portions of the air system upstream of the check valves (i.e., the

compressors, their pressure regulators, and the air header) are not

safety-related or seismically qualified. Each check valve is located in

the air piping between the incoming air line and the breaker reservoir

so that a loss of air supply to the breaker will cause the check valve

to close; thereby, preventing air from flowing out of the breaker

reservoir. According to the valve vendor, the acceptable leakage past

the check valve is 5 psi per hour. The two pressure switches have

sensing lines located between the reservoir and check valve. Each

pressure switch has two sets of electrical contacts and employs a

bellows and spring arrangement to "make" or "break" these contacts at

predetermined pressures. If the air reservoir pressure for any of the

four ACBs dropped below 118 psi while that breaker was in service (i.e.,

the breaker and its disconnects closed), then one set of contacts off

the first pressure switch (PS1) would open causing a lockout of the

overhead path (i.e., ACBs 1 and 2 would trip open, and could not be re

closed until the lockout condition cleared). If the air pressure

reduced to 112 psi on any ACB, then both sets of contacts on the second

pressure switch would open and deenergize control power for that

individual breaker; thereby, making it impossible to close or trip the

breaker electrically. The Keowee operator rounds sheet ensures that ACB

air pressure is between 140 -160 psi.

Therefore, ACB air pressure could

be as low as 140 psi without corrective action being taken.

3.

June 14, 1994 Lockout Event and Related Issues

On June 14, at approximately 1:20 p.m., an automatic protective lockout

of the Keowee overhead path occurred. At the time, Keowee Unit 2 was

operating and generating power to the grid via ACB-2, and Keowee Unit 1

was in standby aligned to the underground path via ACB-3.

Technical

Specification (TS) Limiting Condition for Operation (LCO).3.7.1 was

entered due to the overhead path being unavailable. The underground

path was subsequently tested and determined operable within one hour, as

required by TS 3.7.2. The test was performed per OP/0/A/1106/19, Keowee

Hydro At Oconee, utilizing enclosure 3.6, Operability Verification. The

test was performed satisfactorily. The lockout condition was cleared

and the LCO exited at 5:23 p.m.

Subsequent investigation by the licensee revealed that the cause of the

lockout was low air pressure on ACB-3. This occurred when ACB-1 was

being returned to service after completion of a preventive maintenance

activity. Specifically, its air accumulator was being filled from the

common air header for ACBs 1 and 3. The licensee determined that a

combination of leakage past the check valve associated with ACB-3 and a

faulty pressure regulator resulted in a drop of accumulator air pressure

for ACB-3. The problem associated with the regulating valve was due to

'3

corrosion buildup on the valve's internals which resulted in the valve's

discharge pressure being lower than the required 150 psi (licensee

estimated discharge pressure was approximately 120 psi).

Both pressure

regulators were subsequently refurbished following the event.

The

inspectors noted that prior to this event the regulating valves had not

undergone any preventive maintenance.

The inspectors reviewed the incident and performed an inspection of the

Keowee facility the following day. The licensee had replaced the check

valve associated with ACB-3 as a result of the lockout event and

subsequent testing which revealed excess leakage past the seat. The

inspectors observed that there were no obvious visual indications of

degradation on this check valve. The inspectors requested the results

of the previous leak testing of the ACB check valves. The licensee

informed the inspectors that these check valves were not in their ASME

Section XI Program and were not specifically tested for leakage.

However, they were periodically inspected to verify that the check valve

disc moved freely and that there was no visual evidence of wear or

corrosion. Additionally, the entire skid was periodically tested for

leak tightness by closing the individual isolation valve for the

specific ACB and measuring the subsequent pressure drop over time. The

inspectors noted that this test would only be effective in verifying the

overall skid integrity and would not measure the leakage past the check

valve. Consequently, the check valves had never been adequately tested.

The inspectors also noted that there was not a controlled drawing for

the ACBs'compressed air supply system and that the subject check valves

and the skid isolation valves did not have identification tags. The

licensee pointed out that the issue of testing these check valves was

addressed during the Electrical Distribution System Functional

Inspection (EDSFI), conducted January 25 - March 5, 1993 (NRC Inspection

Report 50-269,270,287/93-02). The report noted procedural weaknesses;

but based on discussions with licensee personnel, concluded that the

licensee's practices were adequate to identify a malfunctioning check

valve.

On June 15, the inspectors questioned the design basis for a low

pressure condition on one of the underground.feeder breakers resulting

in a lockout of the overhead path. This appeared to violate the

required independence of the overhead and underground paths. The

inspectors noted that while the 112 psi pressure switch protective

setpoint was part of the vendor's breaker design, the 118 psi pressure

switch setpoint had been added by the licensee (evidently during

construction of the hydro units).

The licensee could not provide the

inspectors the rationale behind the 118 psi lockout. The inspectors, at

that time, expressed concern regarding the testing of the subject check

valves, given their importance to safety. The inspectors communicated

to the licensee that if one or more of these check valves did not meet

its functional requirement, then Keowee was apparently susceptible to a

single failure rendering both emergency power paths inoperable. The

specific scenario communicated to the licensee was a lockout of the

overhead path (resulting from a seismically induced failure of the non-

4

safety, non-seismic air header with leaking ACB check valves) combined

with a single failure that takes out the underground feeder path.

The licensee agreed to look into these issues, but felt that even though

they could not readily explain the purpose of the lockout in question,

the current Keowee design would meet all design basis requirements.

After a review of all applicable design basis documentation and internal

discussions with personnel experienced with the Keowee design, the

licensee was still unable to determine the intent behind having a low

air pressure condition on an underground feeder breaker result in a

lockout of the overhead path. On June 16, the licensee informed the

inspectors that they intended to test the ACBs' check valves on June 20

to verify that the check valves would meet the 5 psi per hour criteria.

The inspectors were also informed that the licensee was considering a

long-term modification to the ACB protective circuitry to delete the

lockout of the overhead path on low ACB air pressure.

On June 20, the licensee began testing the check valves. The check

valves for ACBs-1 and 3 met the acceptance criteria (the check valve for

ACB-3 had been replaced on June 15), but the check valve for ACB-4 was

found to have unacceptable leakage. The parts necessary to repair the

check valve for ACB-4 were initially unavailable; therefore, the

licensee delayed testing the check valve for ACB-2 until repairs were

completed on the ACB-4 check valve. At this point, the inspectors again

expressed concern about the operability of Keowee and questioned why the

licensee was not under the TS LCO until the testing was completed and

all discrepancies resolved. The licensee responded that they did not

have to assume the remaining ACB-2 check valve would not pass the leak

test. Furthermore, it was indicated that they did not have to assume

the non-safety, non-seismic air header would fail during a seismic

event. On June 22, the check valve for ACB-2 successfully passed its

leak test.

On June 22, the licensee entered TS LCO 3.7.2.a.1 for an inoperable

overhead emergency power path. The licensee stated that they entered

the LCO as a conservative measure because the operability was

"indeterminate".

On June 23, the licensee made a 10CFR50.72b.ii.b one

hour call which stated:

"The electrical power system for Oconee is presently vulnerable to

single failure due to reliance on a non-safety system. It was

discovered that an interlock exists which under certain conditions

could lockout the Keowee main transformer. If the air pressure

which operates the Air Circuit Breakers becomes low, a relay will

lockout the overhead power path.

Portions of the air supply to

the ACBs are non-safety. This has resulted in the technical

inoperability of the overhead power path for an indeterminate

time".

The basis for declaring the system inoperable was essentially the same

as the scenario postulated by the inspectors, but with the additional

observation that even if the check valves in question did not leak

5

excessively, the system was not single failure proof. This was due to

the fact that if a Keowee Unit was generating to the grid, and an

Engineered Safeguards signal occurred, the overhead ACB path breakers

would cycle and use up 27 psi of the associated reservoir's supply.

This loss of 27 psi of air, combined with acceptable system leakage (< 5

psi per hour) would result in an eventual lockout of the overhead path.

Subsequent to the notification made to the NRC, the inspectors

determined that the allowable operating range of the ACB air system

(140 - 160 psi) could potentially cause a lockout of the overhead power

path regardless of the status of the air system. Assuming that the air

pressure in a breaker's accumulator was at the low end of the allowable

pressure band (i.e., 140 psi), opening an ACB to remove a Keowee unit

from the utility's grid would rapidly deplete 25 psi pressure in the

reservoir. It is not known whether the 1 inch supply line (assuming it

was available) could have replenished the reservoir's pressure prior to

reaching the 118 psi setpoint.

On June 23, the licensee completed a temporary modification

(TM-1151) which blocked the initiation of the overhead lockout. The LCO

was subsequently exited at 6:36 p.m. The single failure vulnerability

discussed above is identified as Apparent Violation

50-269,270,287/94-21-01:

Single Failure Vulnerability for the On-Site

Emergency Power System Associated with the Keowee Air Circuit Breaker

Protective Circuitry.

The inspectors concluded that the temporary modification was adequate to

remove the single failure vulnerability in question. However, the

protective circuitry associated with the 112 psi setpoint (fails the

breaker "as-is") was still in place. Therefore, the check valves on the

ACB skids still perform an important function. The licensee indicated

that future annual preventive maintenance activities associated with the

ACBs would include adequate testing of these check valves.

4.

Recent History of Design Issues/Studies at Keowee

Keowee was originally constructed as a hydro unit without full quality

assurance programs which are applied to nuclear power plants. Therefore

there were few programmatic controls in place to control and capture the

design basis. From 1989 until January 1993, there were approximately 12

Licensee Event Reports (LERs) submitted regarding Keowee design

deficiencies. Most of these design deficiencies were original

design/construction problems identified during programmatic reviews by

the licensee. As a result of questions raised by these events, and as

part of the corrective actions to ensure that design vulnerabilities had

been identified, the licensee performed a design study of the Keowee

Hydro facility. This study, Keowee Single Failure Analysis, Calculation

OSC 5096, was completed January 1993. The study applied the single

failure criteria as stated in Section 8.3.1.2 of the Final Safety

Analysis Report.

6

The EDSFI found that the licensee had not adequately analyzed potential

single failures within the hydro unit governor control systems. The

EDSFI also identified several other potential single failure

vulnerabilities which had not been sufficiently analyzed (Inspection

Report 269,270,287/93-02).

LER 269/92-14 and NRC Inspection Report 269,270,287/92-24 identified a

relay (Westinghouse MG-6) which had not been properly maintained or

tested. One of these relays had failed and would not have performed its

function. As a result, the Keowee overhead path had been inoperable for

an indeterminate time. Part of the licensee's corrective action for

this issue was to complete the Design Basis Documentation program and to

strengthen the testing program to identify post maintenance, post

modification, or incipient failures in the various safety systems.

5.

Exit Interview

The inspection scope and findings were summarized on July 18, 1994, with

those persons indicated in paragraph 1 above. The inspectors described

the areas inspected and discussed in detail the inspection findings

addressed in the summary and listed below. The licensee did not

identify as proprietary any of the material provided to or reviewed by

the inspectors during this inspection.

Item Number

Description/Reference Paragraph

50-269,270,287/94-21-01

Apparent Violation: Single Failure

Vulnerability for the On-Site Emergency

Power System Associated with the Air

Circuit Breaker Protective Circuitry

(paragraph 3).

ENCLOSURE 2

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Nuclear Reulatory Commission.

Final Environmental Statement.

comments may be submitted to the

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Docketing and Service Branch.

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request and did not consult other

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Finding of No Significant ipact

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to prepare an envaronmental impact

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Washington. DC 20013-7082 telephone

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The NRCs current policy on

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National Technical Information Servac

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120 L Street. NW. Washington. DC

on a standing order basis. Details on

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room at Greenfield Community College.

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the.

ato

do as but the Cmm

is able to

ee ad publ iaterest in

rCumens and ..... *s.oo

in

assure comsideratio only for coIN,.

(4)econere

....

n

w

. Iten

i

on or bf re this dai

do ainment Conference.

d1*

ENCLOSURE 2

Fedwina Raio

J VoL 57. No. 133 / Friday, July 10. 1M

/ Nodome

MS76

O

L

Criteria for Sels1

Oe

three catepins of Linr

will be

subject to persomi wceenng that

WamfEN

Coi

e

conuinoal operating reactom.

sigm banne

sers. *&inu ot alarger

Enforcement conferences will not be

hospuials andi other licess. Wh

thanl ir be pamed. and tha

open to tAe MAWli if the aniorcemmn

WWl cousai of the remaining types ai

disruptive persons may be remved.

acio usin Comaiptas

-

Lesit.Ec

-mlofngwWl con

(1) Would be taken qarn

an

I. Ainonamd

Ope ftafmstt

condtict the efroiut

onflerence

iividual. or if the action. Ihougo not

Corn euce

ros

an accerdaoca with regional

take agins anindvidal. urn oa As oon atit i deermnedtha an practime The eaforsmat

coerence

wtake aan

inndividual. cotted 04

a ta

eerie

ht

will continue to be a meoag betwe

wneter A

I*+/-M C~nmited

enforcement confettence will be Open to

the NRC and the licensee While the

wro"OIXpublic observanoz6 the NRC will orally

enforcement conference Is Open for

(2) Involves Aphcfiant paanl

n~

the licnse

that the enfoaicemnt

public observonm. it is not open for

failures where the NRC Wa requested

cofrec tvil be open to publicpuicerael.

that the individual4s) involved be

observation as part of the agency's tria

pi

p

-r

mjnpemm

present at the conference;

prgr

and mad the licensee a copy of

ronPerson aendn ope e tha 41

t

(3)1Is based on the findings of an NRC

thi Fedeal Rs0~to noudce that outlines

apparence voan

mmdoed

a(Iten

Offce f Ivesgeons(01 reortor the program. Licensees wifl be asked to

enfor-sent coafsa

are subject to

(4) Involves safeguardsif formatin

estimate the number d participants it

frhrrve

n

a

esbett

Privacy Act inforatinon. ot otherute

rve

uxorannwhckcol b aerd

will brimg to the menfwwment conference

chnepc

to any reuing

infrmtio wichcold e onsised so that the NRC can schendule an

enfoss mal

acton and (2) dhe

proprietary.

appropriately sized confeenc room.

steensoveworepssnsf

Enforcement conferences involving

The NRC will also, motdy epism

staen

ts o m adeb r emploes at

mfedical mzsadminiatratons or

State liaison officers that en

openin n ma

confRCempees rt

ovarexowes will be open assuming

enforcmn

cofsune~

be been

oack tenforcemnt conerns

the

the conferenc. can be conducted

schedtiled and that it is open to public

lakeprs

a

no otwiW

torbles

without disclosing the sirpoeed

observation.

rern fad' to proidon buelefo.

ind~vdual's name. In addition.

The NRC

Intends to announce open

In

~

adiont rin comnsan

enforcinot c R Imroe will nost be

enforcuent , 6

r

to the pubeS

i

the guysidalc prora thi n o

di ers

open to the public ff thu cF, Im

will

normally at least 10 workzag days in

atte i

n op n nfamenticonperns

be cndutedby elehon oradvance of the enforceumt conference

w be0 provided an apporemwt to

conference will be conducted at a

thog

the olowg u

stimt ritenco

noymosl

relatkiey smal Licensee's facilty.

(1)PNodm

-posetds

k

sumito

Werigion @3...l Thne

muza

Finally. with the approal afth

dwDcma

001

otereogofc.raea

mt

Executive Director for Operations.

(2) Tod1.e

tophne

a *agw

n

will subsequently be fiortwded to the

enforcement conferences wil not be

(3) Toil-free electonac buliom boerd

Director of the Ocs of infrm

for

open to the public in Specal Cam sesnlL

review end considerain

where good mai has bmei shamn altar

Ps;&q establishmeant of the toll-fre

Doted at 8Ae,

i.

t

an h dad muy

balanci ta h s~of public

meA s

MYSm.

the public my cell

IU.

observation against the potential ipact

(poll 492-4M1 to obtain a reVCftn of

For the itueifs asy Cmau

a.

on the agencys anIurmnt action In a

upcof

GPM emamoeme

SB

I. 006li

particular case.

coal ereuces. The NRC will ise another seawuryfahe C

The NRC will strive to conduct open

Federa Regis~

eter ntnah b toil-fre VF Dor 93la

pgd 740f US eaa

enforcement conferences dum@ the

message wete

an eeabmd.

MLL

-OO 109

two~yea mel p~m

an owdam

TO 410011st do NRC to

mub

____________

with the follwing three vaws

approPhate wrefnsilm

to 4 Frt

(1) Apom

as2 pent of ean

public obsurvedof

d

I

a

conuctd by the £4RC wil be open io

atteing!, puuar~lr~

pubic obsurvanm

coe1

q eshomM notify 6s, toividud

m ug

~

m

faR

(2) At loast m open

Id

idendibd in Ow

nef *

msom

du

W

F

conference will be coanmamd i sk &

an

f the opemfu

I

oo

n ~

m .

the regonal offices and

I

m e as i

then Ine b~ir

92n

(3) Open entatm

mi commee

days Poer so the

I

will be conducted wftha imulsy o

oen.M

I

~s

types of licensesm

U4m

To avad pol- mi Wa

e Is

6

A um

seecinA p110ms. ed In am lo met

the three goals sIe &bow @=Wy

Immooodemmwith

msa

luM ~

9110100h

inin n ame dmue aqerns o

to

noa~be MM #do

NBC -- e--1m 44. U.S Cdim,

Nae=

l

iemee wbe

sen in do

@3meon.

M u

o " pbic

momsaemad a

public defthe &W gren&

allowed aess lo the NBC wgid

raised klni

-,i-e,

toad

Howeve. in cee where de

is am

offama to sand "Maen

u

m

forma R1 35-7 Is dAppbmdm fo

ongoing adibetey pmsWAt

Iofmne in aio4

dwith

Redof e(Rdi

Dednm

oOM or G IM tv"os -i Standard Opmung" roaemes for

(CSj.COPMito

avWU

coFea do es

edinis

m ad 10

Provldhq fewmity8-o 9qHM

Fe, NR

IInhel BMWd

so ma

aed baiwe

the subjec meflraof

6"be~

11diaa&

&is~~

V Is~

Mulibe

pse

ia dofawom

adliliao my ale be opened For

Nevey er2.

1

3m

) 2MI

'MThese comdmg~mwn. uM@ekebe