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| Start date | Reporting criterion | Title | Event description | System | LER | |
|---|---|---|---|---|---|---|
| ENS 56469 | 12 April 2023 04:00:00 | 10 CFR 21.21(d)(3)(i), Failure to Comply or Defect | Part 21 - Schneider Electric Power Supply Hard Failures | The following information was provided by the licensee via email: On September 7, 2022, Dominion's Surry Power Station notified United Controls International (UCI) that three Schneider Electric PIN: ASP840-000 Modicon Primary/Secondary Power Supply units that were supplied by UCI in 2014 had failed after installation. Hard failures that shutdown the associated programmable logic controller were observed. The first unit was installed since June 6, 2017, and then failed in August of 2022. The second and third units failed approximately three days after installation. All units appeared to function properly at initial installation. The subject items were returned to UCI on October 19, 2022, for evaluation. Items were received at UCI with substantial shipping damage noted. One item was received with a loose transformer inside the unit. All items were received with bent or cracked cases. These issues are attributed to poor shipping practices as items were not supplied in such conditions and these issues would have been noted at receipt by the utility. Due to the complexity of the items and unavailability of design documentation for these obsolete items, further evaluation of item failures required manufacturer (Schneider Electric) evaluation. UCI returned all three items to the manufacturer for evaluation of failed components. The manufacturer was able to repair one item by replacing several capacitors, transistors, integrated circuits, and resistors; however, a specific cause of the failure could not be identified. The remaining two items were determined to be unrepairable, and cause of failure could not be identified. UCI is not capable of providing any further evaluation as to the root cause of the subject module failures. The item manufacturer Schneider Electric was also unable to provide a determination as to the cause of failure. Since the root cause of failure cannot be determined or inspected for, UCI will no longer be supplying these modules which are now obsolete. North Anna and Surry Power Station are the plants affected. | ||
| ENS 55551 | 18 June 2021 04:00:00 | 10 CFR 21.21(d)(3)(i), Failure to Comply or Defect | Part 21 Report - Failure of a Basler Electric Transformer in a York Temperature Control Module | The following is a synopsis of information received via facsimile: On June 18, 2021, STP Nuclear Operating Company returned a York TCM-1A temperature control module with the reported issue that the module would not respond in auto or manual vane control and that internal relays 1R and 2R would not pick up. The subject temperature control module was previously returned by STP Nuclear Operating Company to United Controls International (UCI) for refurbishment and modification, after which it was returned by UCI to STP Nuclear Operating Company on March 13, 2017. Troubleshooting performed by UCI identified that the secondary of the Basler Electric BE13410001 transformer that is used to isolate and step down the input voltage from 115V AC to 22V AC had an open circuit. When the subject transformer was bypassed, the module operated as designed. UCI is unable to determine the cause of the transformer failure. Post refurbishment/modification testing performed by UCI included verifying functionality of the unit before and after performance of a 48 hr. burn-in period. The only facility that is listed as being affected is STP Nuclear Operating Company. If you have any questions or wish to discuss this matter or this report, please contact: Wesley Hickle, Engineering Manager, whickle@unitedcontrols.com, 470-610-0870. | ||
| ENS 54758 | 1 May 2020 04:00:00 | 10 CFR 21.21(d)(3)(i), Failure to Comply or Defect | Part 21 - Abb/Thomas & Betts/Cyberex Printed Circuit Board Shorts to Ground When Installed in Host Battery Charger | The following is a summary of information received from United Controls International: On May 1, 2020, Peach Bottom Atomic Power Station notified United Controls International (UCI) that a printed circuit board (PCB) in a station battery charger was shorting to ground. UCI has determined that an energized trace was too close to the mounting screw/washer causing the short. The trace was too close because the mounting holes were modified at the time of installation prior to commercial grade dedication. The modification was not documented. However, this modification was made to subsequent Time Delay Oscillator PCBs. UCI has determined that in this application the energized trace is not used and can be removed from the board without affecting the function. The subject boards should be returned to UCI for this additional modification. UCI will remove the trace and inspect to ensure sufficient clearance exists. The component is used in ABB/Thomas & Betts/Cyberex P/N: 93-41-119385. The subject board was supplied to Peach Bottom Generating Station in May, 2009. CONTACT: Wesley Hickle Engineering Manager whickle@unitedcontrols.com 770-496-1406 x 165 | ||
| ENS 54476 | 27 December 2019 05:00:00 | 10 CFR 21.21(d)(3)(i), Failure to Comply or Defect | Part 21 - Incorrect Tip Material Used on Gauges | On December 27, 2019, United Controls International received a Product Advisory Letter from Ashcroft Inc. dated December 2, 2019 informing of a potential error in the tip material used on Ashcroft 2 « inch and 3 « inch model 1009, 63 mm model 2008, 63 mm and 100 mm model 1008 industrial gauges along with Weksler 3 « inch regal gauges. Due to a supplier issue, 304SS tip material may have been supplied on the subject gauges instead of the specified 316SS material. In certain applications the 304SS tip material may be subject to accelerated oxidation or degradation, resulting in potential release of process media. However, no detrimental effects are expected in non-corrosive applications. Hatch and Farley have been identified as the affected plants and have been notified of this issue. Please contact Wesley Hickle, Engineering Manager, at (770) 496-1406 ext. 165 or whickle@unitedcontrols.com for any questions. | ||
| ENS 52579 | 24 February 2017 05:00:00 | 10 CFR 21.21(d)(3)(i), Failure to Comply or Defect | Uci Terminal Boxes P/N 005650-01 Discoloration and Corrosion | The following information is excerpted from an email submitted by the reporting organization: In July of 2016, UCI (United Controls International) identified extensive discoloration and corrosion on P/N: 005650-01, terminal box enclosures, that were fabricated under UCI's Quality Assurance Program in April of 2015. The identified discoloration and corrosion was not present at the completion of fabrication and became evident when pulled from stock in July of 2016. It was determined that the fabrication process was changed during fabrication of the April of 2015 items to utilize a different vendor for fabrication activities. Evaluation of the fabrication process performed on the subject items identified that this new vendor utilized a polishing process that was not performed on previously fabricated items. Particles/crystals from the discolored areas of the affect items were analyzed by Fourier Transform Infra-Red (FTIR) method and it was identified that ammonium phosphate crystals had formed on the items. It is the determination of UCI that the affected items were cleaned/polished with unknown chemicals during the polishing process of fabrication that resulted in the formation of these crystals and degradation of the enclosure material overtime. The items manufactured utilizing this new process were supplied to Clyde Union Limited under purchase orders 4500109863/4 (Qty. 1) and 4500113688/4 (Qty. 1). Clyde Union Limited was notified of the subject issue on January 13, 2017 and UCI is awaiting concurrence from Clyde Union Limited that the affected items are to be returned for replacement items manufactured per the original manufacturing process. If you have any questions or wish to discuss this matter or this report, please contact: Wesley Hackle Engineering Manager whickle@unitedcontrols.com 770-496-1406 x 165 | ||
| ENS 51574 | 12 October 2015 05:00:00 | 10 CFR 21.21(d)(3)(i), Failure to Comply or Defect | Part 21 Report - Improper Silver Plating During Refubishment of Ak-25 Type Circuit Breakers | The following information is a synopsis of information received via E-mail: During refurbishment of General Electric AK-25 type circuit breakers (P/N's: AK-2A-25-1, AK-3A-25-1, and AK-7A-25-1) by United Controls International (UCI), non-current carrying/non-copper based components of the upper stud assembly were silver plated. Bubbling of the silver plating was later noted which is an indication that the plating material was not adhering to the base metal. Flaking of the silver plating material may occur and may introduce conductive foreign material into the host circuit breaker. Introduction of this conductive material could create the possibility of a short circuit of the current sensor terminal board for circuit breakers configured with RMS-9 trip units and subsequent failure of the circuit breaker. Fort Calhoun Nuclear Station is the only known recipient of affected breakers. Fort Calhoun received 18 breakers that contained improperly silver plated components. 14 of these 18 circuit breakers have been returned to UCI. Four of the 18 circuit breakers have been installed at Fort Calhoun and UCI is currently awaiting the return of these four circuit breakers. | ||
| ENS 49932 | 18 March 2014 04:00:00 | 10 CFR 21.21(d)(3)(i), Failure to Comply or Defect | Part 21 - Thomas and Betts Printed Circuit Boards | The following was received via fax: This report documents the supply of faulty Logic Power supply assembly printed circuit boards for a Cyberex 20KVA Model AC Power Supply. These power supplies have the incorrect strap installed on the transformers of Cyberex P/N (Part Number) 30-80-56620 which potentially can lead to the transformer being loose and can cause failure of the power supply. Per the manufacturer, the band should have been made of stainless steel but the bands on the installed transformers were made of carbon steel and a corrosion resistant coating. The details of the potential failure of the power supply and the root cause are being evaluated and will be documented in the final report. UCI (United Controls International) reviewed all the orders that were supplied to the customers and determined that two UCI orders are affected and the customer was notified on the day the issue was identified. Part Number 90-41-974313 (UCI serial numbers 03996-01 -0001, -0002, -0003) and P/N 41-01-596701 (UCI serial numbers 03967-03 -0001, -0002, -0003) supplied to Public Service Electric and Gas (PSEG) are affected.
The following was received via fax: This engineering evaluation is being written to document the supply faulty Power supplies for the 20KVA Cyberex Model AC Power supply with the Cyberex part numbers 41-01-596701 and 90-41-974313. SUMMARY: UCI issued a certificate of conformance to PSEG for S/N: 003967-03-0001 thru 0003 on December 22nd 2012, to be used in safety related applications where seismic is the only design basis event. During the pre-installation testing in February 2014, PSEG identified loose transformers and a loud noise frequency whine and the power supply boards were returned to UCI. Below table lists the details of the power supplies that were returned to UCI. On February 2nd 2014, UCI has initiated part 21 evaluation to determine the root cause for the failure and evaluate if a defect existed. During the evaluation, it was determined that the transformer strap band installed on Cyberex P/N 30-801-56620 transformer at the location T501 should have been made of stainless steel but the strap band on these power supplies was made up of zinc plated carbon steel. Due to this material difference, the transformer warped and it was evident it became loose. The installation of the incorrect strap bands on the transformer apply to only one batch of manufactured PCB assemblies. The manufacturer addressed this issue since this was discovered and this was verified by UCI. UCI determined that the order along with the boards that failed pre-installation testing, were the only boards affected by this issue. The customer PSEG was notified on March 13th 2014 and the initial notification letter to NRC was sent on March 19th 2014. The above mentioned power supplies were recalled from PSEG and two power supply boards of S/N: 003996-01-0002 and 003996-01-0003 are currently at UCI for evaluation and rework. However the S/N: 003996-01-0001 board has not yet been returned to UCI by PSEG. UCI performed an XRF analysis on one of the affected power supplies per part number lot and on UCI control samples to confirm and compare the material of the transformer strap bands. EFFECT OF THE DEFECT: The installation of the incorrect transformer strap band resulted in the loosening of the transformer from the band. When installed in the system, the transformer might become loose and cause a loud whining noise. The installation of the incorrect material band on the transformer might lead to loosening of the transformer and causes whining noise when installed but no functional test failure will be observed. However, the loose transformer affects the safety function of the item during or after seismic event due to loss of structural integrity. CORRECTIVE ACTIONS PERFORMED: A UCI corrective action # CAR 14-14 was opened to document the issue found and the corrective and preventive actions taken. As a result, UCI will create two new Commercial Grade dedication procedures for P/N: 41-01-596701 and 90-41-974313 to include the material verification of the transformer bands installed on these power supplies. These new procedures will be used for the existing and future orders of these part numbers. All the affected power supply boards except S/N: 003996-01-0001 are currently at UCI undergoing rework to replace the transformer of the incorrect material strap band with a transformer of the correct (stainless steel) strap band. After rework, dedication will be performed per new dedication procedures as specified above. Notified R1DO (Burritt) and Part 21 Group via email. |