ML20099C767
| ML20099C767 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 11/02/1984 |
| From: | Van Brunt E ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR |
| To: | Bishop T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| References | |
| REF-PT21-84 ANPP-31043-TDS, DER-84-77, NUDOCS 8411200057 | |
| Download: ML20099C767 (13) | |
Text
p..
.)
gestu W,0 1
Arizona Public Service Company
.g pg -5 !3 9 "_,'
i November 2,cl@84 W 9 ANPP-31043-TDS/LBS U. S. Nuclear Regulatory Commission Region V Creekside Oaks Office Park 1450 Maria Lane - Suite 210 Walnut Creek, California 94596-5368 Attention: Mr. T. W. Bishop, Director Division of Reactor Safety and Projects
Subject:
Final Report - DER 84-77 A 50.55(e) Reportable Condition Relating To Rosemount Transmitter - Potential Leakage Path In The Seal Of The Threads Between The Sensor Module And The Electronic Housing.
File: 84-019-026; D.4.33.2
Reference:
A) Telephone Conversation between D. Hollenbach and T. Bradish
~~
on October 3,1984
Dear Sir:
Attached is our final written report of the Reportable Deficiency under 10CFR50.55(e), referenced above.
Very truly yours,
(
CLLL Y%L E. E. Van Brunt, Jr.
APS Vice President Nuclear Production ANPP Project Director EEVB/LBS/nj Attachment cc: See Page Two 8411200057 841102 PDR ADOCK 05000528 5
pop 8
I ZE.z7
,~
Mr. T. W. Bishop
' DER 84-77 Page' Two 4
cc: '
Richard ~DeYoung, Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D. C.
20555 T. G.' Woods, Jr.
D. B. RKarner W.-E. Ide D. B. Fasnacht A. C. Rogers L. A. Souza D. E. Fowler T. D. Shriver C. N. Russo B. S. Kaplan J. Vorees J. R. Bynum J. M. Allen A. C. Gehr W. J. Stubblefield W. G. Bingham R. L. Patterson R. W. Welcher H. D. Foster D. R. Hawkinson R. P. Zimmerman L. Clyde M. Woods T. J. Bloom D. N. Stover J. D. Hauchen i
J. E. Kirby i
D. Canady Records Center Institute of Nuclear Power Operations 1100 Circle 75 Parkway, Suite 1500 Atlanta, GA 30339 i
l
{
t i
I I
I
h FINAL REPORT - DER 84-77 DEFICIENCY' EVALUATION 50.55(e)
' ARIZONA PUBLIC SERVICE COMPANY (APS)
PVNGS UNITS 1, 2, 3
^
I.
Description of Deficiency Rosemount, Inc. has notified PVNGS under 10CFR Part 21 that Model 1153, Series B pressure transmitters manufactured after January 10, 1984, may have a leakage path in the seal of the-threads between the sensor module and the electronics housing. Moisture from the surrounding environment could enter the electronics housing (Note:
Transmitter pressure boundary integrity is not affected).
Evaluation Rosemount pressure transmitters are used in many safety-related appl 3 cations throughout the PVNGS, so a faulty transmitter could cause malfunction of safety-related systems.
Rosemount pressure transmitters, which are affected, are idfentified in NCRs JX-1185 and JF-1186 and listed below:
P.O. No.
Serial'No.
Held By
. Disposition 10407-F-163459
'408675 Bechtel Warehouse (Q5-2)
Quarantined 10407-F-164171 409152 APS Warehouse
- Quarantined 10407-F-164171 409153 APS Warehouse Quarantined 10407-F-164171 409154 APS Warehouse Quarantined 10407-F-164171 409084 APS Warehouse Quarantined All five transmitters involved have been quarantined to the APS and Bechtel warehouses. The root cause of the leakage path is a manufacturing error which is being addressed by the manufacturer.
This condition is not one that could be expected to be detected during receiving inspection.
II.
Analysis of Safety Implications Based on the above, this condition if left uncorrected, is evaluated as a significant safety hazard since one or all of the identified transmitters could possibly have been installed in a safety-related system. This condition is therefore evalnated as reportable under 10CFR50.55(e).
This condition is evaluated as reportable under 10CFR Part 21. The supplier, Rosemount, Inc., has previously made notification as required by this regulation.
i i
fi-.
?r Final Report DER 84-77 Page Two III. Corrective Action 1.
Jul defective transmitters identified by serial number -shall be returned to Rosemount for either refurbishment or replacement and brought into compliance with JM-311' specification for Q Class transmitters. Documentation will be requested to be provided to ve,rify that refurbishment or' replacement of transmitters was completed.
- 2.. Rosemount has formally addressed the manufacturing problem in writing, outlining the corrective' steps they will take to preclude recurrence of a similar problem in the future, and is included as Attachment B.
All subsequent findings shall refer to this DER for the necessary corrective action.
IV.
References / Attachments 1.
Attachment A - Rosemount to APS Letter of Notification required under 10CFR Part 21 Regulations dated 9/10/84.
2.
Attachment B - Rosemount to Bechtel letter dated 10/15/84 which includes a Rosemount Intracompany Memo of 10/11/84.
3.
Attachment C - Bechtel to Rosemount letter informing Rosemount of our requirements to refurbish twelve 1153 Series B transmitters.
t I
l
--,,, - ~..
" fi c'
yst.MebT k ROSEMOUNT INC.
12001 West 78tn Street Eoen Praine. Mennesota $5344 U.S.A.
Tei (612 9415560 TWX 910-576 3103 TELEX 29-0183 Rosemount Sept enber 10, 1984 Arizona Public Service Co.
P. O.
Box 21666, M.S. 3003
- Phoenix, AZ 85036 Attention: Darryl Palmer Subj ect :
Notification Under 10CFR Part 21 Regulations
~
Ref er ence: Pur chase Order 10407-F-164171-HO/Rosemount H. O.
416071 Gentlenen:
Rosemount has determined that a notification to you, our cus t om er, is required under the regulations called out in 10CFR Part 21.
This notification applies only to any Model 1153 Series B Pressure Transmitter manuf actured af ter January 10, 1984 and does not aff ect any other model.
Th e situation is as f ollows:
Rosemount has identified a potential leakage path in the seal of th e th r ea ds betw een th e sensor modul e and th e el ectr oni cs housing.
There is a possibility that this leak path could allow moisture f rom the ambient surrounding environment to enter the el ectronics housing during abnormal operating conditions.
This moistur e may cause the transmitter to stop f unctioning (i. e.
th e output signal will sa turate high, approximately 27 mA, saturate low, approximately 3 mA, or becam e un sta bl e. )
This 1 eak in no way af f ects the pr essur e integrity of the transmitter pr essur e boundary, i
As part of the Rosemount periodic quality audit a sample of transmitters is tested f or electronic housing pr essure int egrity.
The test is perf ormed using a 5 PSI (air) pr essur e 1 -o 2 -
sour ce to pr essuriz e th e internal electronies housing.
> 0
" Snoop" is then used to detect leaks on all sealing interf aces.
i, M O
n i
LL-
r e 3 r.'
(
(
During the most.recent audit, a leak was observed on two out of twelve pr essur e transmitters tested.
These units wer e randomly sel ected f rom product hardware by 0. A.
for the Product Audit.
Based on these f ailur es, an additional 87
, production units were leak tested per the Product Audit Procedure.
Eight of the '87 units f ail ed the test.
Th e validi ty of th e ' Product Audi t l eak test is being verified by subj ecting several of these units to a LOCA simulation.
This LOCA simulation is also being used to help determine the cause of the leak path and what ambient temperatur e/pr essure 1 ev els these pr essur e transmitters will withstand.
Th e Model 1153 Series B Pressure Transmitter has been placed on hold f or both production and shipment.
Testing is underway to determine a specific cause for the leak path.
Once the specific cause has been identified (we anticipate in about two weeks),
a corrective action will be established.
An updats letter will be sent to you when further data is available regarding the units that you have and any corrective action that may be necessary.
receipt of that update letter, please contactShould you have any questions prior to us.
Very truly yours, 8 en)
/
~
Richard C. LaSell !
Manager
/jka b
.m 3
O
'M j
m.z i
\\
O N*
?
O n %
1 (d) %
,\\
\\
\\
l
6 6
4
~
ATTACHMENT A i
^
Purchase Order No.10407-F-163459-H0 j
Rosemount Order No. 415691 Ida Mund =rs Serial Numbers N/A 408675 4
i j
i 4
e l.
I e
l i
4
..--,-w.-+-
w4m-
--,--e-.y e-m---,...m,w----..me--...,.w..ww,..---,,-..,--4v--
-,m.,,
,r,y,-wm,-,w-m,,
we.-.--,,,y,.v.,,--=m--
)17AufMfd 8
{., r3,)'
y*
nosamouwt nec.
'Wi 12001 West 70th Street Eden Praene. Mermoeons $5344 U.S.A.
Tel. (612) 941 5600 TWX 910-576-3103 TELEX 29-0183 Rosemourc October 15, 1984 Mr. Wayne Sutton Arizona Public Service Co.
P.O. Box 21666 M.S. 3003 Phoenix, AZ 85036
Subject:
Our September 10, 1984 Notification Under 10CFR 21
Reference:
Purchase Order 10407-F-163459-H0/RMT Order 415691 Gentlemen:
This letter updates our findings and defines corrective action on the potential neck seal problem previously reported.
The past few weeks have been dedicated to investigating the problem, including the review of all associated production processes, piece part modifications and any other variation which could be possible contributors. A summary of our findings and corrective action is detailed in the attached memo of October 11, 1934.
Some of the 1153 Series B transmitters manufactured from January 1984 to August 1984 may be affected by questionable integrity of the neck seal and will require resealing.
The transmitters se_rfal numbers listed on the enclosure were manufactured in this t:imeframe.
We are una'ule i
to deterniine which of these units will leak, and therefore recommend rework of all units produced during this period.
Current production units have been successfully tested to LOCA conditions.
We are prepared to receive, rework, and return to you, certified, all transmitters identified in the enclosure.
The complete rework and retest facilities of the factory are available to accomplish and certify the resealing.
4 We encourage the return of these transmitters to our Eden Prairie, MN. facility.
l i
~
.rh
- 3. -
CJ C-The rework efforts are being coordinated by Robert VandenBoom of our Nuclear Marketing Department at our Eden Prairie facility.
Bob can be reached at A/C 612-828-3540.
It is our intention to perform this repair in the shortest time possible to minimize your inconvenience while considering each cutomers particular need. We are confident of your cooperation and understanding during this period.
Very truly,
- f. $. c hA R.C. LaSell Manager Enclosure e
i e
i i
e
u*
..a 2
~-3
- Rosemouilt INTRACEMPANY MEM9 CIRCULATE TO:
Jerry Anderson A8 John Berra A26 Andy Habiger C6 DATE:
October 11, 1984 TO:
Dick LaSell - Manager, Nuclear Products (A10)
FROM:
Bill Koch - Director. Quality Assurance (A3)
SUBJECT:
MODULE NECK SEAL - MODEL 1153B BACKGROUND Process Control Audits on Nuclear Pressure Transmitters were started as an internal control procedure in March,1981. Between 3/81 and 6/84, 146 units were checked for seal integrity by presst:rizing the inside of the transmitter to 5 psi and checking the module /hcusing interface point for leaking with a special soap solution.
Of the 146 units, nine were found to be questionable and worthy of further investigation. Seven of the questionable units were detected in April and May of 1982. These units were found to have lower than specified torque on the lock nut and lacked the usually visible excess sealant at the housing / module neck joint. Qualification testing (which included a LOCA Simulation Test) was being conducted on units built at about the same time as the questionable units and there was no other information to indicate a change in proce.r, may have occurred. An in-depth study brought forth no assignable cause.
All units passed the LOCA Simulation Test and the process was determined to be "in control." To. add assurance, operators were reinstructed regarding proper torquing techniqu'es and to use an increased amount of sealant.
Subsequent process control checks were found to be acceptable throughout 1982.
In June of 1983, two more questionable units were detected.
Casting flash on the housing lock nut interface was determined to be causing low torque values. Qualification testing on units produced shortly after the audit test units (same process) were found to pass the LOCA Simulation Test.
This indicated the process was "in control" as determined by tne only true indicator we have -- the LOCA Simulation Test (a destructive test).
Subsequently, the 5 psi process control seal integrity checks produced no questionable units entil June, 1984. The June,1984 check initiated the sequence of actions hich resulted in the 9/10/84 notification to affected l
customers.
l l
l l
l
'! (.. ;
b{[
[ -)) g.:
'/ 4"JW w: -
- ~
MODULE NECK SEAL - MODEL 11538 Page 2 l
10/11/84 j
t EVENTS LEADING TO NOTIFICATION _
- n..._..
During Product Audit Testing conducted in June,1984, two questionable neck
~
seals were detected.- The in-depth followup investigation was unable to identify an assignable cause.
No qualification program that included a LOCA Simulation Test was ongoing or planned at that time; therefore, a special LOCA Simulation Test (completed 8/29/84) was planned and performed to determine if a true leakage problem existed.
During this LOCA Simulation Test, 5 of 8 units failed to complete the 72-hour test. All five units were found to have moisture in the electronics housing. A hold notice had been previously issued on 8/22/84. Following the completion of the LOCA Simulation Test, the matter was referred to the Nuclear Review Committee. Additional investigation of the process and the units which failed in the LOCA Simulation Test resulted in a Nuclear Review Committee meeting on 9/5/84. The Committee recommended a customer notification be issued. A notification letter was issued on 9/10/84 to all affected customers. To determine the block of units which could be affected, the manufacturing date of 1/13/84 was used. All units prior to this date are considered to be conforming, based on the previous acceptable product audit and LOCA Simulation Test results. Although this approach may include a large number of conforming units, it appears to be a reasonable criteria under the circumstances.
CORRECTIVE ACTION Detailed information regarding all materials and parts was accumulated.
The most significant information obtained indicated that 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> of curing at elevated temperatures provides a more predictable seal.
Six test samples were produced with this process change. These samples were successfully tested in a LOCA Simulation Test ending on 10/3/84. The hold notice was conditionally released on 10/9/84. All units manufactured after this date will include this pro 9ess change in order to assure only qualification level units are shipped.
RENEDIAL ACTION All units within the block of potentially questionable units in customer control should be disassembled, cleaned, and reassembled per our new process (including elevated temperature cure for 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> at 200*F)..This can be accomplished in the factory at Eden Prairie, Minnesota.
9 9
e 4
0
ArrscHMNr C
l B';cht:1 Construction, Inc.
Pato Verde Nuclear Generating Station P.O. Box 49 Pa!O Verde, Arizona 65343 October 29,.1984 B/RI-K-14129-J FLN 24209 Rosemount, Inc.
I2001 West 78th Street Eden Prai-ic, Minn. 55344 Attention: Mr. Bob VandenBoom Subject; Palo Verde Nuclear Generating Station Bechtel Job No. 10407 10CFR 21 Notification Rosemount Hodel 1153 Series B Neck Seal Hework File JM-311 Reference; a)
Rosemount Letter dated Sept. 10, 1984 b)
Rosemount Letter dated Oct. 9, 1984 e) Rosetnount Letter dated Oct. 26, 1984 RMA No. VA207621 Centlemen:
This letter serves to inform you of Bechtel Construction, Inc.'s schedule requirements for the refurbishment of the reference twelve (12) 1153 Series B transmitters.
SERIAL NWGER.
TAG NtTMBER DATE REQUIRED 286398 IJ-SIA-LT-704 11-30-84 or before 286399 IJ-SIB-LT-705 11-30-84 or before 362483 2J-SI A-LT-704 1-11-85 362484 2J-SID-LT-705 1-11-85 286400 3J-SIA-LT-704 3 1-85 286401 3J-SIB-LT-705 3-1-85 2863I8 N/A 5 25 408675 N/A 5-1-85 409152 N/A 5-1-85 4091$3 N/A 5-1-85 409154 N/A S-1-85 409084 N/A 5-1-85
Bechtel Construction, Inc.
B/RI-K-14129-J t
Nr. Bob VandenBoos October 29, 1984 Page 2 The first six (6) items will be returned to your facility c,n a rotating schedule, (i.e., Unit 3 vill be returned first and installed in Unit 1.
Unit' I will be returned and installed in tInit 2.
Unit 2 will be returned and installed in Unit 3).
The latter six (6) will be returned with the first shipment for refurbishment at your convenience.
Your cooperation in supporting these construction ' schedules will be greatly appreciated.
If you have any questions or concerns, your contact at PVNGS will be Ron Rhodes (602) 271-5087.
Very truly yours, BECHTEL CONSTRUCT N,INC.
u W.j.Stubbiofield Field Constrtletion Manager b
WJS:RR:kad l
4 11 10 t **r L * & >
EEE SEE'M NME_
6_!_0_i___ __ W W Ti _____
_ ___