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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 56293 | 7 September 2022 17:00:00 | 10 CFR 21.21(a)(2), Interim Report for Comply or Defect in Component | Part 21 - Power Supply Failures | The following information is a brief summary of the report provided by the licensee via fax: Modicon Primary/Secondary Power Supply units that were supplied by United Controls International (UCI) to Dominion's Surry Power Station failed after installation. Hard failures that shutdown the associated programmable logic controller were observed. All units appeared to function properly at initial installation. When the subject items were returned to UCI for evaluation, substantial shipping damage was noted and can be attributed to poor shipping practices. Due to the complexity of the items, unavailability of design documentation, and noted shipping damage, further evaluation of item failures requires manufacturer evaluation and therefore additional time to complete the root cause evaluation. UCI continues to follow up with the manufacturer and plans to provide further evaluation by March 4, 2023. Plant affected: Surry Power Station For questions concerning this potential 10 CFR 21 issue, please contact: Anu Kulkarni Quality Assurance Director United Controls International (470) 610-0851 | ||
| ENS 56388 | 7 September 2022 05:00:00 | 10 CFR 21.21(a)(2), Interim Report for Comply or Defect in Component | Part 21 - Deviation to Qualified Design | The following information was provided by United Controls International via email: Schneider Electric part number: ASP840-000 Modicon Primary/Secondary Power Supply units failed to operate several days after installation at Dominion's Surry Power Station with hard failures that shutdown the associated programable logic controller. The units were returned to UCI and initial observations indicated heavy shipping damage that was not present when initially supplied. Further evaluation of the damaged components requires manufacturer evaluation due to item complexity and proprietary design documentation. Investigation into the root cause(s) of the failures is ongoing. Evaluation of whether these failures represent deviations or failures to comply that would be associated with substantial safety hazards will be complete by July 2, 2023. For questions concerning this potential 10 CFR 21 issue, please contact: Anu Kulkarni Quality Assurance Manager United Controls International (470) 610-0851 | ||
| ENS 56209 | 7 September 2022 04:00:00 | 10 CFR 21.21(a)(2), Interim Report for Comply or Defect in Component | Part 21 - Primary/Secondary Power Supply Failures | The following is a summary of information provided by United Controls International (UCI) via email: On September 7, 2022, Dominion's Surry Power Station notified UCI that 3 Schneider Electric P/N: ASP840-000 Modicon Primary/Secondary Power Supply units failed to operate several days after installation at Dominion's Surry Power Station with hard failures that shutdown the associated (programmable logic controller). The units were returned to UCI and initial observations indicated heavy shipping damage that was not present when initially supplied. Further evaluation of the damaged components requires manufacturer evaluation due to item complexity and proprietary design documentation. Investigation into the root cause(s) of the failures is ongoing. Evaluation of whether these failures represent deviations or failures to comply that would be associated with substantial safety hazards will be complete by January 3, 2023. Contact Information: Anu Kulkarni, Quality Assurance Manager United Controls International (700- 496-1406)
The letter date on the original transmittal letter from UCI to the USNRC was incorrectly listed as November 4, 2021. UCI is hereby submitting a corrected letter dated November 4, 2022. Notified R2DO (Miller) and Part 21 and 50.55 Reactors email group. | ||
| 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 51243 | 3 June 2015 04:00:00 | 10 CFR 21.21(a)(2), Interim Report for Comply or Defect in Component | Potential Part 21 - Allen Bradley Failure to Document Design Change | The following information is excerpted from an email received from United Controls International: (In) August 2014, United Controls supplied four (4) time delay relays to Omaha Public Power-Fort Calhoun Station. The subject relay was qualified in accordance with IEEE 323-74/83, IEEE 344-1975/1987 and IEEE C37.98-1987, for use in mild environment safety related applications. Per NRC Part 21 notifications, UCI was informed that the Allen Bradley relays base model 700RTC contain a Complex Programmable Logic Device (CPLD) which was unpublished. This design change could not be noticed since the external appearance of the relay and the relay part number remained the same. Hence, UCI has qualified the subject relay as solid state relay whereas the presence of the CPLD device elects the item as a digital device which can be affected by EMI/RFI noises. At this time, UCI has no sufficient information to determine whether this design change would create a Substantial Safety Hazard as it relates to the plant applications for the subject relay. Per the Nutherm Part 21 ML 1516IA230, Allen Bradley has indicated that a rolling change occurred from mid-2009 with no specific manufacturing date to distinguish between the old and the new configuration. Hence, all units manufactured during 2009 and later are suspect. If you have any questions or wish to discuss this matter or this report, please contact: Jim Garrison Engineering Manager jgarrison@unitedcontrols.com 770-496-1406 x 103 Affected facility: Omaha Public Power-Fort Calhoun Station Part Number: 700-RTC-11200U1 Quantity: 4 | ||
| ENS 50935 | 30 January 2015 04:00:00 | 10 CFR 21.21(a)(2), Interim Report for Comply or Defect in Component | Part-21 Notification - Sense and Transfer Module Resistive Short | The following excerpted report was received via e-mail: Sense & Transfer Module (part number 41-09-339904) was provided to PSEG under purchase order 4500726553. The customer identified an abnormal curve trace (resistive short) on the integrated circuit installed at location IC825 pin 6 on this printed circuit board. The customer performed an evaluation which included dissection of the subject IC (integrated circuit) however, this dissection provided inconclusive results as to the cause of the IC anomaly. At this time, UCI requires additional time to evaluate the results provided by PSEG and to work with the manufacturer in identifying the root cause. UCI currently considers this issue to be an isolated event as no previous instances of this failure have been observed by UCI to date. PSEG has returned the item to UCI for evaluation and rework (received by UCI on 3/25/2015). If you have any questions or wish to discuss this matter or this report, please contact: Wesley Hickle Procurement Engineer whickle@unitedcontrols.com 770-496-1406 x 165 Potentially affected plants are Salem and Hope Creek.
The following excerpted report was received via e-mail: Follow up to previously reported by United Controls International (UCI) as requiring additional evaluation time and to correct purchase order information previously reported to the NRC with a report in general conformity of the requirements of 10 CFR Part 21.21. Notified R1DO (McKinley) and Part 21 group via email. | ||
| ENS 50331 | 4 June 2014 04:00:00 | 10 CFR 21.21(a)(2), Interim Report for Comply or Defect in Component | Part 21 Interim Report - Temperature Switch Set Points Out of Calibration | On June 19, 2014, United Controls International (UCI) issued a Return Material Request to Florida Power and Light, Turkey Point. It was discovered that a tool used in the verification of the temperature switch set points was out of calibration during the impact analysis of the out of tolerance condition these switches were identified as needing to be returned for adjustment and re-testing. At this time, UCI is unable to complete our evaluation into the possible effects the out-of-calibration tool had on the temperature switches. Florida Power and Light has not returned the items to UCI for evaluation and rework. June 4, 2014, is the date on which the information of such defect or failure to comply was obtained. If you have any questions or wish to discuss this matter or this report, please contact: Jim Garrison Engineering Manager, Seismic and Equipment Qualification jgarrison@unitedcontrols.com 770-496-1406 X 103 | ||
| ENS 50013 | 25 March 2014 04:00:00 | 10 CFR 21.21(a)(2), Interim Report for Comply or Defect in Component | Part 21 - Potential Defect in General Electric Sb1 Switches and Hea Relays | The following is an excerpt from a fax received from United Controls International (UCI): The purpose of this letter is to provide the NRC with a report in general conformity of the requirements of 10CFR Part 21.21. On March 19, 2013, United Controls Issued an Interim letter regarding a discovered manufacturing change in the contact assembly of General Electric SBM series switches. Since 2009, the manufacturing process of the contact assembly of the SBM switch contacts has changed to have the whole assembly (contact holder and contact tip) tin plated. This was discovered while investigating an SBM switch that failed at a customer site due to high contact resistance across closed contacts. The finding that there was a manufacturing process change in the SBM switches lead to further discussions and evaluations regarding equipment of similar design. General Electric SB1 series switches and HEA series relays use the same contact arrangement design as the SBM series switches. The contact assemblies of the SB1 switches and HEA relays are subject to the same tin plating process of the contact assembly as previously reported on the SBM series switches. At this time, UCI is unable to evaluate if this manufacturing change may have an adverse effect on the capability of the General Electric SB1 switches and GE HEA relays to perform in their intended safety related application. UCI will notify the affected Utilities to our findings. The affected Part Number, Utility, Order Number and Quantity is listed below: Part Number 12HEA61B23SX2; Utility CFE; Order 700372018; Quantity 3 Part Number 12HEA61C236X2; Utility FPL Turkey Point; Order 02260642-34; Quantity 2 Part Number 12HEA61C237; Utility OPPD; Order 180520; Quantity 4 Part Number 12HEA61C238X2; Utility OPPD; Order 180520; Quantity 3 Part Number 12HEA61C237; Utility OPPD; Order 185929; Quantity 2 Part Number 12HEA61C237X2; Utility OPPD; Order 188314; Quantity 2 Part Number 12HEA63C239X2; Utility FPL St. Lucie; Order 02260642-41; Quantity 8 Part Number HEA61C234X2; Utility Antung; Order PP100204; Quantity 2 Part Number HEA61C244X2; Utility OPPD; Order 179664; Quantity 5 Part Number HEA61C241X2; Utility OPPD; Order 179664; Quantity 2 Part Number HEA63C239X2; Utility FPL St. Lucie; Order 02260642-103; Quantity 3 Part Number 12HEA61C238X2; Utility OPPD; Order 194686; Quantity 4 Part Number 16SB1BB339STS2P; Utility Duke Oconee; Order 156606; Quantity 11 Part Number 165BlFB2C85SWM2Y; Utility Nextera Seabrook; Order 2259825-3; Quantity 1 Part Number 16SB1LB2C01LSM2P; Utility CFE; Order 700327408; Quantity 3 Utility CFE is the Comisi�n Federal de Electricidad (Mexico) and Utility Antung is located in Taiwan. If you have any questions or wish to discuss this matter or this report, please contact: Jim Garrison Engineering Manager, Seismic and Equipment Qualification JGarrison@unitedcontrols.com 770-496-1406 X 103 The 10CFR Part 21.21 received on March 19, 2014 is EN #49940., | ||
| ENS 49940 | 21 March 2014 04:00:00 | 10 CFR 21.21(a)(2), Interim Report for Comply or Defect in Component | Part 21 - Sbm Selector Switches Contact Assembly Unplanned Manufacturing Change | The following is an excerpt from a fax received from Unified Controls International (UCI): ...there was a significant manufacturing process change to the General Electric SBM series switches in 2009. The high resistance across switch contacts in the GE SBM switches could lead to a failure of the switch to change state when required. Concerns have been raised regarding tin plated movable contacts used for make or break service and in use without protective lubrication. UCI is not capable to complete an evaluation of the affect that this change may have on in storage SBM switches or already installed SBM switches that were provided to the customers on the purchase orders listed in section (below). UCI does not know the storage conditions, in service environmental conditions or in service cycling rates of the switches or how the each of these items may affect the change in contact resistance. Each affected customer needs to evaluate their in storage and in service switches and determine if the change in contact material could possibly create a safety hazard and effect the ability of the switches to perform in their safety related application. The applicable purchase orders are: Duke Energy, Purchase Orders: 131116,133980, 147875,129193,130989 (Non-Safety Related), 133920, 148974 (Non-Safety Related), 152090 (Non Safety Related), 133972, 169525 Antung Trading Company, Purchase Order: PP120210 CFE, Purchase Order: 700327408 Fluor, Purchase Order: A3PB-6-0016-00Q1 | ||
| 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. |