ML20101B144
| ML20101B144 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 12/06/1984 |
| From: | Van Brunt E ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR |
| To: | Kirsch D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| References | |
| REF-PT21-84 ANPP-31358-TDS, DER-84-77, NUDOCS 8412200127 | |
| Download: ML20101B144 (13) | |
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Arizona Nuclear Power Project P O. box $2034 e PHOENIX, Aal2ONA 85072-2034 December 6,1984 ANPP-31358-TDS/TRB U. S. Nuclear Regulatory Commission Region V 1450 Maria Lane - Suite 210 Walnut Creek, California 94596-5368 Attention: Mr. D. F. Kirsch, Acting Director Division of Reactor Safety and Projects
Subject:
Final Report, Revision 1 - 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 B) ANPP-31043, dated November 2,1984 (Final Report)
Dear Sir l
Attached is Revision 1 to our final written report of the Reportable Deficiency under 10CFR50.55(e), referenced above. This Revision provides clarification to the Condition Description as requested by your office in the November 30, 1984 Exit Meeting held at Palo Verde.
Very truly yours, s
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APS Vice President Nuclear Production ANPP Project Director EEVB/TRB/nj Attachment
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- 1 Mr. D. F. Kirsch DER 84-77 Page Two
.cet Richard DeYoung, Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D. C.
20555 T. G. Woods, Jr..
D. B. Karner 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. 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. Matt T. J. Bloom D. N. Stover J. D. Houchen J. E. Kirby D. Canady Records Center Institute of Nuclear Power Operations 1100 circle 75 Parkway, Suite 1500 Atlanta, CA 30339
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- 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 af ter January 10, 1984, may have a leakage path in-the seal of the threads between the sensor mo/.ule and the electronics housing. Moistur'e 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 applications throughout the PVNGS, so a faulty transmitter could cause malfunction of safety-related systems.
The initial quantity of Rosemount pressure transmitters which are-affected are identified by NCRs JX-1185, JF-1186, JC-1201, and listed below. It is anticipated that any additional discoveries for which Rosencint will identify in writing shall reference this DER for the necessary corrective action.
SERIAL NUMBER TAG NUMBER 286398 1J-SLA-LT-704 286399 IJ-SIB-LT-705 362483 2J-SIA-LT-704 362484 2J-SIB-LT-705 286400 3J-SIA-LT-704 286401 3J-SIB-LT-705 286318 N/A 408675 N/A 409152 N/A 409153 N/A 409154 N/A 409084 N/A The root cause of the leakage path is a manufacturing error which is addressed by the manufacturer in Attachment B.
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 lef t 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 evaluated as reportable under 10CFR50.55(e).
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DER 84-77 Page Two This condition is evaluated as reportable under 10CFR Part 21. The supplier, Rosemount, Inc., has previously made notification as required byfthis regulation.
III.
Corrective Action 1.
All 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 verify 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.
3.
Recognizing the need to address the generic implications of improper Q-Class instrumentation installations, the ANPP has initiated a comprehensive review of Q-Class instrumentation deficiencies. This review will evaluate Q-Class instrumentation installations to provide assurance that Q-Class instruments are installed per the requirements of applicable design documents.
The scope of the evaluation and the results will be included in the final report for DER 84-27.
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.
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ROSE MOUNT INC.'
12001 wes: 78tn street Ecer. Pra.ne. Minnesota $5344 U.S.A.
Tef(6121941 5560 4
TWr 910 576 3103 TE'EX 29 0183
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Rosemount Septmber 10, 1984 F
Arizona Public Service Co.
P. O.
Box 21666, M. S. 3 003
- 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.
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416071 Genti ca en:
Rosemount has determined that a notification to you, our cus t om er, is r eq ui r ed un d er th e r egul a ti ons call ed out ' in
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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 the threads between the sensor module and the electronics housing.
Th er e i s a po s si bil i ty th a t thi s l ea k pa th co ul d allea moisture f rom the ambient surrounding environment to enter the electronics housing during abnormal operating condi ti ons.
This moistur e may cause the transmitter to stop f un ctioning (i. e.
the output signal will sa turate high, anproximately 27 mA, saturate lea, approxima tely 3 mA, or mm e unstabl e. )
This 1 cak in no way af f ects the pr ensur e integrity of the transmitter pr essur e boundary.
As part of the Rosemount periodic quality audit a sample of transmitters in tested for el ectronic housing pr essur e int eg r i ty.
The test is perf ormed using a 5 PSI (ai r)
I sour ce to pr essuriz e th e internal el octr oni cc housing.pr essur e Q:
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" Snoop" is then used to detect leaks on all sealing
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During the most recent audit, a l eak was observ ed on' two out of tw elve pr essur e transmitters tested.
These units w ere randomly sel ect ed f rom product hardware by Q. A.
for the
.' Product Audit.
Based on these f ailures, an addi tional 87 production units,wer e l eak test ed per ' th e Product Audit
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Procedure.
Eight of the 87 units f ail ed the test.
Th e val idi ty of th e Pr odu ct Audi t l ea k t es t is being verified by subj ecting sev eral of these units to a LOCA simulation.
This LOCA simulation is also being used to help determine the ca use of th e l ea k pa th and wha t ambi ent 1 w els thes9 pr essur e transmitters will withstand.temperatur e/pr essur e The Model 1153 Series B Pressure Transmitter has been placed on hold f or both production and shipment.
to determine a specific cause for Testing is underway specific cause has bcen identified th e l ea k pa th.
On ce th e (we anticipate in about two w eeks ), a corrective action will tic establish ed.
An updats letter will be sent to you when further data is availa'ble regarding the units that you have and any corrective action that may be necessary.
receipt of that update l etter, pl ease conta ctShould you have any questions prio us.
Very truly yours,
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ATTACHMENT A Purchase Order No.10407.-F-163459-HO R'osemount Order No. 415691 744 iiunders Serial Numbers N/A 408675 1
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Aracituent 8 W
NOSEMOUNT INC.
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'12001 West 78th Street Eden Preme. Mermesota 55344 U.S.A.
Tel. (612) 941 5560 TWX 910.s76 3103 TELEX 29-0183
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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 scal problem previously reported.
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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, 1984.
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 serial numbers listed on the enclosure were manufactured in ibis t:imeframe. We are un6' le u
to determine 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 rescaling.
We encourage the return of these transmitters to our Eden Prairie, MN. facility.
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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 612-328-3540.
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..
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R.C. LaSell Manager Enclosure A
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Rosemount INTRACOMPANY MEMS
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CIRCULATE TO:
Jerry Anderson A8 John Berra A26 Andy Habiger C6 DATE:
October 11, 1984 TO:
Dick LaSell - Manager, Nuclear Products (A10) s 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, pressurizing the inside of the transmitter to 5 psi and' checking t.he module / housing interface point for leaking with a special soap solution.
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Of the 146 units, nine were found to be questionable and worthy of further investigation.
Seven of the questionable Jnits 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 process may have o, curred. 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 focreased 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 te ' pass the LOCA Simulation Test.
This indicated the process was "in controI* as determined by the only true indicator 'we have -- the LOCA Simulation Test (a destructive test).
' Subsequently, the 5 psi process control seal integrity checks produced no l
questionable units until. June, 1984. The June, 1984 check initiated the j
sequence of actions which resulted in the 9/10/84 notification to affected customers.
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MODULE NECK SEAL - MODEL 1153B Page 2 10/11/84
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1-EVENTS LEADING TO NOTIFICATION,
During Product Audit Testing conducted in June,"1984, twohubstionable 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 Connittee. Additional investigation,of the process and the units which failed in the LOCA Simulation Test resulted in a Nuclear Review Comittee meeting on 9/5/84. The Comittee recomended 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 6
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.
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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.
Tb-Mid notice was conditionally released on 10/9/84.- All units manufactureu _(ter this date will include this process change in order to assure only qualification level units are shipped.
REMEDIAL 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.
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Bechtcl Construction, Inc.
s Pafo Verde Nuclear Generating Station P.O. Box 49
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i October 29, 1984 B/RI-K-14129-J FLN 24209 kosemount, Inc.
12001 West 78th Street Eden Prairie, Minn. 55344 Attention: Mr. Bob VandenBoom
Subject:
Palo Verde Nuclear Generating Station Bechtel Job No. 10407 10CTR 21 Notificaticin Rosemount Model 1153 Series B Neck Seal kevork File:
JM-311 Reference; a)
Rosecount Letter dated Sept. 10, 1984 b)
Rosemount Letter dated Oct. 9, 1984 c) Rosemount Letter dated Oct. 26, 1984 RMA No. VA207621
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Centlemen:
This letter serves to inform you of Bechtel Construction, Inc.'s schedule requirements for the refurbishment of the reference twelve (12) 1353 Series B transmitters.
SERIAL NUMBER TAG NUMBER DATE REQUIRED 286398 IJ-SIA-LT-704 11-30-84 or bcfore 286399 IJ-SIB-LT-705 11-30-84 or before 362483 2J-SIA-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 286318 N/A 5-1-85 408675 N/A 5-1-85 409152 H/A 5-1-85 409153 N/A 5-1-85 409154 N/A 5-1-85
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409084 N/A 5-l-85
- CRITICAL ITDiS n
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Bechtel. Construction, Inc.
B/RI-K-14129-J Nr. Bob VandenBoom October 29, 1984 Page 2 The first six (6) items vill be returned to your facility on a rotation 9
schedule, (i.e., Unit 3 vill be returned first and installed in Unit Unit I will be returned and installed in Unit 2 1.
Unit 2 vill be returned and installed in Unit 3).
The latter six (6) vill 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 conc 6rns, your contact at PVNGS will be Ron Rhodes (602) 271-5087.
Very truly yours, BECHTEL CONSTPUCTI
,N, INC.
W. [Y tubble field Field Construction Hanager
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