ML100512907

Part 21 Notification - Installation of Incorrect Transformer on a Control Board for a Battery Charger

ML100512907
Person / Time
Site:	Peach Bottom
Issue date:	02/12/2010
From:	Hale R United Controls International
To:	Office of Nuclear Reactor Regulation
References
45696
Download: ML100512907 (7)

Text

"_- 0 024212/010 U.S. Nuclear Regulatory Commission Operations Center Event Report Paze I General Information or Other (PAR)Event# 45696 Rep Org: UNITED CONTROLS INTERNATIONAL Notification Date / Time: 02/12/2010 12:28 (EST)Supplier:

THOMAS AND BETTS Event Date / Time: 02/12/2010 (EST)Last Modification:

02/12/2010 Region: 1 Docket #: City: TUCKER Agreement State: Yes County: License #: State: GA NRC Notified by: ROBERT B. HALE Notifications:

RAY POWELL RIDO HQ Ops Officer: VINCE KLCO S. PANNIER (E-MAIL) NRR Emergency Class: NON EMERGENCY J. THORP (E-MAIL) NRR 10 CFR Section: 0. TABATABI (E-MAIL) NRO 21.21 UNSPECIFIED PARAGRAPH INTALLATION OF INCORRECT TRANSFORMER ON A CONTROL BOARD FOR A BATTERY CHARGER On January 6, 2010, Thomas & Betts (TNB) informed United Controls International (UCI) that TNB's sub-contractor (RBB Systems) had installed the incorrect transformer on a sub-component (control board) of a Cyberex battery charger.During a review of the Bill of Material (BOM) and assembly documentation for the control board by TNB, it was discovered that the incorrect transformer was being installed on the board. The control board affected is designed for systems with a 120 VAC primary input voltage. The incorrect transformer installed is designed for systems with a'208 VAC primary input voltage.Subsequent testing and risk assessment performed by TNB's sub-contractor, RBB Systems, found that under nominal input voltage, the control card operated marginally.

Under low input voltage, the card could fail to operate properly, which could cause a failure of its parent component, the battery charger.Per TNB, the only sale on record of the Cyberex battery charger is of eight units sold to Philadelphia Electric Company (now part of Exelon-Peach Bottom Nuclear Power Station) in 1993, which are designed for 120 VAC primary input voltage to the control board.1 EAci~s~I~

Received at: 02/12/2010 11:35 FEB/12/2010/FRI 11:46 AM UNITED CONTROLS FAX No, 7704961422 P. 001 PLEASE TRANSMIT THE FOLLOWING DOCUMENT BY FACSIMILE TO (301) 816-5151 (PROVIDE REPORT)BY US MAIL TO U.S. NUCLEAR REGULATORY COMMISSION DOCUMENT CONTROL DESK WASHINGTON D.C. 20555-0001 PVb/I /'ZUlU/FR l'i:4b AM UNITED CONTROLS FAX No, 7704961422 P.002 United Controls International 5139 S. Royal Atlanta Drive.tucker, Georgia 30084 (770) 496 1406 tel (770) 496 1422 fox February 12, 2010 U.S. Nuclear Regulatory Commission Document Control Desk Washington D.C. 20555-0001 S ubj ect: 1OCFR21 Reporting of Defects and Non-Compliance Thomas & Betts Printed Circuit Board P/N 93-41-119381 The enclosed report addresses a reportable notification for a Thomas & Betts Printed.Circuit Board P/N 93-41-119381.

A copy of the report has been mailed to our affected nuclear customers.

Please sign below, acknowledging receipt of this report, and return a Copy to at the address above or via fax to (770) 496 1422 within 10 working days after receipt.Sincerely, RoberCB. Hale President Enclosure Report 20100212_Notification_93-41-119381, 4 pages Received by Date v www.unitedcontrols.com FEB/12/2010/fRI 11:47 AM UNITED CONTROLS United Controls International 5139 S. Royal Atlanta Drive Tu4ker, G14or2a 30084 (770) 496 1406 tel.( 770) 496 1422 fax : FAX No, 7704961422 P. 003 1OCFR2! REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT:

SYSTEM: CONCLUSION:

REPORT ID: Thomas & Bett§ Printed Circuit BSoard P/N 9341-119381 125 VDC Battery Charger -Control Board Defect reportable in accordance with 10CFR21 20100212_Notification 93-41-119381 File: 20100212_Notificationi_93-41-119381.doo Reviewed By: i-ai uks Engineering Reviewed By:___ _ _Enginee~ing Approved By: M ssur Quality Assurance Date:

Date: 041 Date:zit o www. unitedcontrols.com FEB/12/2010/FRI 11:47 AM UNITED CONTROLS FAX No.7704961422 P. 004 20100212 Notification 93-41-119381 .Page 2 of 4 COMPONENT:

Thomas & Betts Printed Circuit Boa-d Thomas & Betts P/N: 93-41-119381 PURPOSE: This report documents the installation of an incorrect transformer on a control board for Cyberex Battery Charger model 130-200R3-S.

SUMMARY

On January 6tl', 2010, Thomas & Betts (TNIB) informed United Controls International CLCI) that TNB's suab-contractor (EBB Systems) had installed the incorrect transformer on a sub-component (control..

board) of a Cyberex model 130-200R3-S battery qharger.During a review of the Bill of Material (BOM) and assembly documentation for the control board by TNB, it was discovered That the incorrect transformer was being installed on the board. The control board (p/n: 93-41-119381) affected is designed for systems with a 120VAC primary input voltage. The incorrect transformer installed (p/n: DCP-34-125) is designed for systems with a 208 VAC primary input voltage. The correct transformer for 120 VAC input system is P/N: DCP-56-80.

Subsequent testing and risk assessment performed by TNB's sub-contractor, RBB Systems, found that under nominal input voltage, the control card operated marginally.

Under low input voltage, the card could fail to operate properly, which could cause a failure of its parent component, the battery charger.AFFECTED USERS: Exelon -Peach Bottom Nuclear Power Station Per TNB; the only sale on record of the Cyberex model 130-200R3-S battery charger is of eight.units sold to Philadelphia Electric Company (now part of Exelon) in 1993, which are designed for 120 VAC primary input voltage to the control board.Six circuit boards have been manufactured and sold by TNB. All six of these boards were supplied to UCI. See table I below for information on these six circuit boards.1' United Controls International FEB/12/2010/FRI 11:47 AM UNITED CONTROLS FAX No.770496i422 P. 005 Page 3 of 4 20100212 Notification 93-41-119381 Table 1 Part number TNB S/N UCI S/N Comments 93-41-119381 1009-006 3539-01-0001 Quarantined at. UCI, transformers have been replaced and board has been retested.Quarantined at UCI, transformers have been replaced and board has been retested.Quarantined at Peach Bottom Nuclear Power 93-41-119381 0809-004 3568-03-0001 Station. Waiting for board to be returned to UCI to have transformers replaced and retested..

Quarantined at Peach Bottom Nudlear Power Station. Waiting for board to be retumed to 93-41-119381 0809-005 3568-03-0002 UCI to have transformers replaced and retested.Quarantined at Peach Bottom Nuclear Power 93-41-119381 0503-001 1055-4-1 Station. Verified to have correct transformers installed.

93-41-119381 unknown 1055-4-2 Installed in plant at Peach Bottom Nuclear Power Station.The systems engineer at Peach Bottom was consulted with regarding this issue. It was confirmed that one of the boards in question (UCI s/n: 1055-4-2) was installed in a safety related batter charger. He.further stated that this charger is one of two redundant chargers and that their license only required one charger to be in service for operation.

Examination of the schematic diagrams of this circuit board, concluded that this transformer supplies the+/- 12VDC power supply for this control board, which controls the battery charger rectifiers.

And, if the supply voltage became low enough, that it could cause the control board to stop operating correctly and subsequently cause the battery charger to become inoperable.

.Since the other board that was supplied on the same purchase order (UCI S/N 1.055-4-1) was verified to have the correct transformer, there is a very high probability that the installed control board has the correct transformer installed, however this cannot be verified until a visual inspection is made.United Controls International FEB/12/2010/FRI 11:48 AM UNITED CONTROLS FAX No, 7704961422 P.006 20100212 Notification_93-41-119381

.. Page4 of 4 CORRECTIVE ACTIONS Preventive Actions .Taken The manufacturer (Thomas & Betts) has made procedural changes to improve. their Bill of Materials.

."(BOM) and revision control to preventreoccurrence of this error;Corrective Actions Taken Of the six potentially affected circuit boards:'1. Two circuit boards have been quarantined at UCI and have had the incorrect.

transformers replaced and retested-2. Three circuit boards have been quarantined at Peach Bottom Nuclear Station. Two of which have been verified to have the incorrect transformer and are waiting to be returned.

for transformer replacement and re est. The third circuit board has been verified to have the correct transformers installed.

Corrective Actions to be Taken I. Only one of the six manufactured circuit board is installed in the Peach Bottom Nuclear Power Station. This board needs to be inspected to verify which transformer is installed on the board. If the incorrect transformer is installed then it needs to be removed from service and returned to UCI for transformer repladement and retest.2. The two currently quarantined circuit boards at Peach.Bottom that have the incorrect transformers are to be returned to UCI for transformer replacement and retest,-end of document-U.-.United Controls International