ML20207E931
| ML20207E931 | |
| Person / Time | |
|---|---|
| Site: | Dresden, Nine Mile Point, FitzPatrick  |
| Issue date: | 02/26/1999 |
| From: | Brosemer J External (Affiliation Not Assigned) |
| To: | NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS) |
| References | |
| REF-PT21-99 NUDOCS 9903110112 | |
| Download: ML20207E931 (11) | |
Text
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Sent By:. INTEGRATED RESOUCES; 4028735809; Feb 26 9919 :26AM; Page 2 m
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NTEGRATED RESQURCES, IMC, Director, Of5cc of Nuclear Material Safety and Safeguards Fchruary 26,1999 U. S. Nuclear Regulatory Commission Washington, DC 20555
Dear Sirs:
On January 22,1999 Integrated Resources, Inc. made a 10CFR Part 21 Notification Number 35304 to the U. S. Nuclear Regulatory Commission reporting the fact that there is a potential that i
Sprague Model TE1302 capacitors with a date code of 9322H were installed in some Safety Related instruments that were refurbished and repaired by Integrated P csources, Inc., and that the capacitors appeared to be failing prematurely. This letter and the attached report serves as the final analysis and report on this incident.
The failure has been determined to be a manufacturing defect and Integrated Resources, Inc.,
recommends that all of the affected capacitors be replaced.
If you should have any other questions conceming this notification or if we may be of any other service to you please contact me at 402-873-5859.
Sincerely,
})f&:
2 John F. Brosemer President Integrated Resources,Inc.
/J IRI9901-01
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! ~Sent By:.INTEORATED RESOUCES; 4028735809; Fob 26 9911:27AM; Page 3 INTEGRATFD RFCOURCFA INCORPORATFD TECHNICAL REPORT COVER SHEET IRI PROJECT NUMBER: IRI-9901 CLIENT PROJECT /P. O. NUMBER: VARIOUS CLIENT: VARIOUS PROJECT TITLE: 10 CFR 21 NOTIFICATION 35.304 DOCUMENT TITLE: TECHNICAI RFPORT ON SPRAGUE MODEI TE1302 ALUMINUM ELECTROLYTIC CAPACITORS WITH A DATE CODE OF 9377H.
DOCUMENT TOTAL PAGES (INCLUDING COVER SHEET): 1 ORIGINATOR: /2 7 Ae-as DATE:
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Sent By:. INTEGRATED RESOUCES; 4028735809; Feb 26 9911:27AM; Page 4 lIRI JOB NO. IRI-9901 REPORT NO. TRI-9901-01 PAGE 1 OFA_ i INTRODUCTION This technical report is to provide final analysis and the root cause of the failures experienced due to aluminum electrolytic capacitors, Sprague Model TE1302 as reported to the Nucicar Regulatory Commission by Integrated Resources, Inc. as a 10 CFR Part 21 failure report number 35.304.
TECHNICAL REPORT ANDFD(DINGS Dresden Nuclear Station advised IRI that they had experienced several failures of GEMAC Square Root Converters, Model Number 50-565100AAAC1, refurbished by TRI in 1993 and i
1994. DreMen Nuclear Station returned 9 of the square root converters to IRI reqacsting that failure analysis be performed on them. Of the 9 units two had been refurbished and calibrated when bench checked by IRI (Serial Numbers 16481447 and 334712442), two additional units (serial numbers 334712437 and 524731551) had never been refurbished. These four units were refurbished, calibrated and returned to Dresden Nuclear Station.
The remaining square root converters (serial numbers 384724651,394724607, 374724643, 334712437 and 3747246.41) were subjected to full component by component failure analysis.
This analysis revealed that on all five of the units capacitor Cl had failed and was prevennns the square root converters from rnecting the calibration specifications satisfactorily.
All five of the capacitors removed from the modules were Sprague Electric Co. model TE1302 alumimtm electrolytic capacitors with a value of 3 pFD,50 VDC, and a date code of manufa:turc of 9322H These capacitors were manufactured for Sprague by Barker Microfarads, Inc., (BMI) ofHillsville, Virginia.
The loss of capacitance resulted in the Square Root Converters not being able to be calibrated to Original Equipment Manufacturers (OEM) SpeciScations. The square root converters did not fail but were not able to be calibrated and were, therefore, providing inaccurate outputs.
Preliminary testing of the capacitors was performed by IRI, showing that four of the five were open and the fifth had extrernely high equivalent series resistance. IRI contacted Mr. Richard Edmonson, Quality Assurance Manager (Acting) of Barker Microfarads, Inc., and sent the failed capacitors to BMI for failure analysis. Having found that ceir.ggsnt failure had caused the square root converters to fail to calibrate,IRI issued a preliminary report to Dresden Nuclear Station of the results of the failure analysis and commenced searching instrument records to j
deternune if any of the TE1302 capacitors with the 9322H date code had been used on any safety lREVISIONNO.._D ORIGINATOR INITIALS:
,A DATE:
2/25/99 l a
Sent By:. INTEGRATED RESOUCES; 4028735809; Feb 26 99 11:27AM; Page 5/12 w
l_IRI' JOB NO. mr 9901_
REPORT NO. IRI-9901-01 PAGE J_OF1l related units. This records search identified 96 separate refhrbished units that contain the capacitors with a date code of 9322H, five of which were safety related, at two separate nuclear j
facilities, as follows:
1.
Niagara Mohawk Power Corporation, Nine Mile point Unit #1 GEMAC Square Root Converter, model number 50-565100AAACl, serial number 114624441.
( %fAC Function Generator, model number 50-566103ABAA2, serial number WP3283 i
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2.
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. ark Power Authority, J. A. Fitzpatrick Nuclear Station GEMAC Basic Contmiler, model number 50 540017HAMM2PSY, serial number j
203325049.
GEMAC Basic Controller, model number 50 540017HAMM2PSY, serial number 4
- WP1950, GEMAC Basic Controller, model number 50-540017HAMM2PSY, serial number i
WP1949.
Having found that Nuclear Safety Related units had the capacitors installed IRI iuued a verbal i
notification of the 10 CFR 21 report on January 22,1999 at 1420 CST and was inued a d incident number of 35,304. IRI also ve6 ally notified Mr. M. Reno (NYPA) and Mr. B: inn Barrett (NIMO) of the 10 CFR 21 report and the models and serial numbers of the uni's that the capacitors were installed in., is the complete list (Nuclear Safety Related and Non-Nuclear Safety Related)of all 4
I units identified during the IRI records search that contain the 9322H date coded capacitors. IRI will transmit this list to each of the affected utilities, with this report, for all of the affected i
modules.
Failure analysis of the capacitors at BMI found that "...all of the parts were very diied out, and there was basically no electrolyte left. The seal bead dimmsion on all five parts measured 0.225". This is slightly larger than the cumnt specification of 0.205 *0.008. Four ofthe five 4
2 espacitors anode wirc was broken internally, but it could not be determined what caused this
]
thilure. However, the fifth capacitor was not severed, but was still dried ont. This is why we feel lREVISIONNO._D_. ORIGINATOR INITIALS:
/3 DATE:
2/25/99 l y
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Sent By:. INTEGRATED RESOUCES; 4028735809; Feb 26 99 11:28AM; Page 6/12 S
[IRI' JOB NO. IRI-9901 REPORT NO. IRI-9901-01 PAGE __4_ OF 4_ l the root problem of the failurcs was the drying out of the capacitors." (See Attachment 1 for the fullletter from BMI).
CONCLUSION AND RFCOMMENDATIONS IRI has concluded that the Sprague model TE1302 capacitors with a date code of 9322H were manufactured with an cnd seal bead that was larger than specifications currently allow, the end seal allowed the capacitor's electrolyte to dry out (offgas) in an accelerated manner, causing the capacitors to fail in an accelerated manner. The failure mechanism of the capac. tors are in the normal manner of all aluminum electrolytic capacitors, drying of the electrolyte which results in increasing equivalent series resistance (ESR) leading to increased heating of the electrolyte, leading to increased electrolyte drying, leading to increasing ESR, until the electrolyte is totally dried out and the capacitor fails.
IRI recommends that these capacitors be replaced as soon as practical. Since these capacitors have served over 60% of the expected shelf /useful life of the aluminum electrolytic capacitors IRI recommends that the modules that they are installed in be totally refurbished and all aluminum electrolytic capacitors in the modules replaced, during replacement of the affected capacitors.
lREVISIONNO.D_ ORIGINATOR INITIALS:
f3 DATE:
2/25/99 l 1
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l sent By INTCORATED RESOUCES; 4028735809; Feb 26 9911:28AM; Page 7/12 ATTACHMENT 1
,Y BARKER
{ MICROEARAUS,INC, TEL SMU$.9ni no un h
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g P.Q. ROX 491, MILL STREET, HillMII.LE. VIRGINIA 24343 FAXSWns-9144 culiiihn l
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pp January 28,1999
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- F Mr. John Brosemer F
Integrated Resources pF 113 South 9* Street UF P.O. Box 310 F
Nebraska City, NB 68410
Dear John:
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pp in regards to the five capacitors that were retumed for analysis, BMI has conduded' i
pp that the parts were no lonDer within the acceptable parameters. The parts were all datedwith the 9322 date code pF
- F Failure analysis showed that all of the parts were very dried out, and there was pF bascally no electrolyte left. The seal bead dimension on all five parts measured F
0.225". This is slightly larger than the current specirmation of 0.205
- 0.008". Four pp of the five capedtors anode wire was broken intomaly, but it could not be determined pp what caused this failure. However, the fifth capadtor (SM 334712437) was not j
pg severed, but still was dried out. This is why we feel the root problem of tha failures was the drying out of the c.ipadL5.
- F As we discussed on the telephone, BMI had not roosived a field failure complaint for F
this reason to date. In addition, due to ti)e nature of your application BMI suggests pp that you replace the capacitors in all the field parts BMI will supply you with new pp capacitors that are sealed to the currently specified dimens~ ens, which should pg prevent this pr@n from occumng again.
If you have any further questions or need more information, feel free to contad me
- F anytime. We will try to assist you in every possible way. Thank you for your patience pF in this matter.
- F pg Sincerely, fp.WY issac K Murrell Engineering Manager
- F pF N
cc: Rkhard Edmondson pF Tony Beamer l
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Attachunent 2 UNITS CONTAINING TE1302 CAPACITORS WITH 9322H DATE CODE Page.L Of.5_.
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IIDOULETYPE SERIAt.NUREBER CUSTORIER P.O.
CUSTORIER l
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TVA-9404 AMPLIFIER TVA9404-1 94N2P-107710 BROWNS FERRY h
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TVA-9404 AAFl.lFER TVA9404-2 94N2P-107710 BROWNS FERRY j
TVA 9404 BASIC CONTROU.ER 064317160 94N2P-107710 BROWNS FERRY r
TVA4404 BASIC CONTROLLER 064317162 94N2P-107710 BROWNS FERRY TVA-9404 BASIC CONTROLLER 193113020 94N2P-107710 BROWNS FERRY t
CECO-9302-1 FUNCTION GENERATOR 394629054 807752 DRESDEN
,f bi CEC 04302-1 FUNCTION GENERATOR 404629052 807752 DRESDEN y
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f CECO-9305 AMPUFER CECO-9305-5 810095 DRESDEN CECO-9305 AMPUFIER CECO-9305-7 810095 DRESDEN f;
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CECO-9305 AMPUFIER CECO-9305-8 810095 DRESDEN t
CECO-9406 SQUARE ROOT CONVERTER 344712446 807752 DRESDEN
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i CECO-9406 SQUARE ROOT CONVERTER 374724633 807752 DRESDEN
.y i cr i CECO-9406 SQUARE ROOT CONVERTER 374724639 807752 DRESDEN 4i
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CECO-9406 SQUARE ROOT CONVERHER 384724649 807752 DRESDEN E
CECO-9406 SQUARE ROOT CONVERTER 414724668 807752 DRESDEN l
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[l CECO-9501 AAFLIFIER CECO 9501-1 813399
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CECO-9501 AlWUFIER CECO 9501-2 513399 DRESDEN i
CECO-9501 SQUARE ROOTCONVERTER 16881444 813399 DRESDEN i
CECO-9501 SQUARE ROOTCONVERTER 344712447 813399 DRESDEN 2l 2-G, t
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i UNITS CONTAINING TE1302 CAPACITORS WITH 9322H DATE CODE Page.2. Of i_
8 IRIJOB NO.
MODULE TYPE SERIAI. NUMBER CUSTOMER P.O.
CUSTOMER CECO-9501 SQUARE ROOT CONVERTER 374724643 813399 DRESDEN n
E CECO 9501 SOUARE ROOT CONVERTER 384724651 813399 DRESDEN g
CECO-9501 SQUARE ROOT CONVERTER 394724607-813399 DRESDEN E
CECO-9503 SQUARE ROOT CONVERTER 384724646 355503-DR1 DRESDEN CECO-9503 SQUARE ROOT CONVERTER 484713308 355503-DR1 DRESDEN CECO-9503 SQUARE ROOT CONVERTER 484713315 355503-DR1 DRESDEN CECO-9505 SQUARE ROOT CONVERTER 014721620 355503-DR4 DRESDEN 8
CECO-9505 SOUARE ROOT CONVERTER 194917342 355503-DR4 DRESDEN in CECO-9505 SQUARE ROOT CONVERTER 374724640 355503-DR4 DRESDEN g
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CECO-9505 SQUARE ROOT CONVERTER 374724641 355503-DR4 DRESDEN CECO-9510 SQUARE ROOT CONVERTER 484713302 355503-DR7 DRESDEN CECO-9511 SQUARE ROOT CONVERTER 014721621 355503-DR8 DRESDEN y
CECO-9511 SQUARE ROOT CONVERTER 194917343 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVERTER 254700305 355503-DR8 DRESDEN E
CECO-9511 SQUARE ROOT CONVERTER 264730815 355503-DR8 DRESDEN Ceco-95ii SQUARE ROOT CONVERTER
'334712437 355503-DR8 DRESDEN
'g CECO-9511 SQUARE ROOT CONVERTER 334712438 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVERT 1ER 334712439 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVtMiEM 374724630 355503-DR8 DRESDEN CECO-9511 SOUARE ROOT CONVERTER 374724636 355503-DR8 DRESDEN e
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~5 Attachrsent 2 UNr?S CONTAINING TE1302 CAPACITORS WITH 9322H DATE CODE Page.l. Of.5 5
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200DULE TYPE SERIAL NUMBER CUSTOMER P.O.
CUSTOMER CECO-9511 SQUARE ROOT CONVERTER 384724644 355503-DR8 DRESDEN
=
CECO-9511 SOUARE ROOT CONVERTER 384724645 355503-OR8 DRESDEN g
CECO-9511 SQUARE ROOT CONVERTER 384724647 355503-DR8 DRESDEN E
CECO 95!1 SQUARE ROOT CONVERTER 384724648 355503-DR8 DRESOEN CECO-9511 SQUARE ROOT CONVERTER 394724603 I 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVERTER 394724606 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVERTER 394724608 355503-DR8 DRESDEN g
CECO 4511 SQUARE ROOT CONVERTER 404724654 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVERTER 514028561 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVERTER 514028565 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVERTER 514028569 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVERTER 524731544 355503-DR8 DRESDEN CECO-9511 SQUARE ROOT CONVERTER 524731547 355503-DR8 DRESDEN CECO-9512 SQUARE ROOT CONVERTER 16481452 355503-DR10 DRESDEN CECO-9512 SQUARE ROOT CONVERTER 254700303 355503-DR10 DRESDEN CECO-9512 SQUARE ROOT CONVERTER 3447-12448 355503-DR10 DRESDEN d
CECO-9512 SQUARE ROOT CONVERTER 484713305 355503-DR10 DRESDEN CECO-9513 FUNCTION GENERATOR 02465026 355503-DR11 DRESDEN CECO-9513 FUNCT10N GENERATOR 394629055 355503-DR11 DRESDEN NIMO-9305 BASIC CONTROLLER 364320001 01177 NIMO s
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ase-hw-s 2 UNI 13 CONTAINING TE1382 CAPACITORS WITH 9322H DATE CODE Page 4.Of.1..
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i umJoe NO.
MODULE TVPE SENAL NURIBER CUSTORIER P.O.
CUSTORIER D
mi O f MR4( M 421 SQUARE ROOTCONVERTER 274700208 04151 NWO i
E NRMM413 SQUARE ROOTCONVERTER 114824441 03981 NM4CP g
L 2j NMO.9419 FUNCTION GEIERATOR WP3283 04405 NNO' 3i r
NYPA9802 FUNCTION GENERATOR WP2228 C 96 J1327 NYPA NYPM401 BASIC CONTROLLER WP1949 S M 57200 NYPA*
i NYPA-9403 BASIC CONTROLLER 203325049 S M 57984 NYPA*
i NYPA 9407 BASIC CONTROLLER WP1950 S M 88491 NYPA*
8!
BECO-9602 BASIC CONTROLLER WP2831 RRR002182 P8.GRN 5i ti i CECO 0403 FUNCTION GENERATOR 254814400 811501 QUAD CITIES 3l
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CECO-9404 FUNCTION GENERATOR 24487374 811502 QUAD CITIES '
t 3
CECO 9409 BASIC CONTROLLER 353927003 811688 QUAD CITIES t
CEOO MOS FUNCTION GENERATOR 254614399 fil1888 QUAD CITIES m
CECO # MOB FUP4CTION GENERATOR WP3152 811888 QUAD CITIES g;
e 4
CECO.9502 SQUARE ROOT CONVERTER 00081278 813907 QUAD CITIES EI 6i CECO 9502 SQUARE ROOTCONVERTER 00081278 813907 QUAD CITES
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CECO 9502 SQUARE ROOT CONVERTER 00081280 813907 QUAD CITIES U;
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CECO 9502 SQUARE ROOT CONVERTER Ou081281 813907 QUAD CITIES
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i CEC 04502 SQUARE ROOT CONVERTER 00081282 813907 QUAD CITIES L
CECO-9502 SQUARE ROOT CONVERTER 00081290 813907 QUAD CITES t
o f CECO-9502 SQUARE ROOT CONVERTER 00081292 813907 QUAD CITIES a!
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Attachement 2 UNITS CONTADGNG TEl302 CAPACITORS WITH 9322H DATE CODE PageiOf1.
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RIODULE TYPE SEIWAL N.
CUST0 TIER P.O.
CUSTOREIR D
O CECO-9602 SQUARE ROOTCONVERTER 00061293 813907 QUAD CfTIES
=E, i-CECO-9502 SQUARE ROOT CONVERTER 00061294 813907 QUAD CITIES 8l o
CEOO 9502 SQUAl4E ROOT CONVERTER 00061295 813907 QUAD CITIES E
CECO-9502 SQUARE ROOT CONVERTER 00061296 813907 QUAD CfTIES CEC 04602 SQUARE ROOT CONVERTER 00061301 813907 QUAD CITIES o
CECO 4502 SQUARE ROOT CONVERTER 00061302 813907 QUAD CITIES i
l CECO 9502 SQUARE ROOT CONVERTER 00061303 813907 QUAD CITIES g(
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CECO-9502 SQUARE ROOT CONVERTER 00061304 813907 QUAD CfTIES 5i St !
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CECO-9502 SQUARE ROOT CONVERTER 00061313 813907 QUAD CITIES 8[
e,
CECO-9602 SQUARE ROOT CONVERTCR 154614054 813907 QUAD CITIES r
D CECO-0502 SQUARE ROOT CONVERTER 13497240 813907 QUAD CfTIES CECO-9502 SQUARE ROOT CONVERTER 14028572 813907 QUAD CITES i
i CEC 04502 SQUARE ROOT CONVERTER 164618353 813907 QUAD CITIES h,
CECO-9602 SQUARE ROOT CONVERTER 21467303 813907 QUAD CITIES CECO 4502 SQUARE ROOT CONVERTER 234630351 813907 QUAD CmES 8l CECO-9502 SQUARE ROOTCONVERTER 264624518 413907 QUAD CITES G!
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E CECO-9502 SQUARE ROOT CONVERTER 284610302 813907 QUAD CITES
- Denotes Nuclear Safety Reisted Un8s.
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