ML14101A342

Notification of Part 21 - Potential Defect in General Electric SB1 Switches and Hea Relays

ML14101A342
Person / Time
Site:	Oconee, Saint Lucie, Seabrook, Turkey Point
Issue date:	04/10/2014
From:	Looft K United Controls International
To:	Office of Nuclear Reactor Regulation
References
50013
Download: ML14101A342 (13)

Text

-0411012014 Pa*p I

.4/ /.014.U.S.

.. Nuclear Re....torv Comn ission Onerations Center Event Renort Pa-- I Part 21 (PAR) Event# 50013 Rep Org: UNITED CONTROLS INTERNATIONAL Notification Date I Time: 04/09/2014 13:37 (EDT)

Supplier: UNITED CONTROLS INTERNATIONAL Event Date I Time: 03/25/2014 (EDT)

Last Modification: 04/09/2014 Region: 1 Docket #:

City: NORCROSS Agreement State: Yes County: License #:

State: GA NRC Notified by: KORINA LOOFT Notifications: RAY POWELL R1DO HQ Ops Officer: STEVE SANDIN MALCOLM WIDMANN R2DO Emergency Class: NON EMERGENCY JAMES DRAKE R4DO 10 CFR Section: NRR PART 21 GROUP EMAIL 21.21 (a)(2) INTERIM EVAL OF DEVIATION 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

6i '

04/10/2014 U.S. NuclearRegulatory Commission OperationsCenter Event Report Page 2 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 165BIFB2C85SWM2Y; Utility Nextera Seabrook; Order 2259825-3; Quantity 1 Part Number 16SB1LB2C01LSM2P; Utility CFE; Order 700327408; Quantity 3 Utility CFE is the Comisi6n Federal de Electricidad (Mexico) and Utility Antung is located in Taiwan.

"Ifyou 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.,

APR/09/2014/WED 01:37 PM United Controls FAX No. P.001/011 uC' FAX TRANSMITTAL DATE: April 9, 2014 TO: NRC OPERATIONS FROM: Korina Looft/UCI CENTER FAX: 301-816-5151 FAX: 770-496-1422 TEL: 301t816-5100 .TEL: . 770-496-1406 cc: Interim letter PAGES: 11 pages. with cover page COMMENTS:

I WILL FOLLOW UP AS DIRECTED TO MAKE SURE THE FAX TRANSMITTAL WAS RECEIVED.

THANK YOU, KORINA LooFT

APR/08/2014/WED 01:37 PM United Controls FAX No. P. 002/011 UNITED CONTROLS INTERNATIONAL 10CFR21 INTERIM LETTER April 8, 2014 U.S. Nuclear Regulatory Commission Document Control Desk Washington D.C. 20555-0001

Subject:

10CFR21 Interim Letter, UCI Not Capable to Determine if Defect Exists General Electric SB1I Switches and HEA Relays 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 SB 1 series switches and HEA series relays use the same contact arrangement design as the SBM series switches. The contact assemblies of the SB1I 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 SBl switches and GE BEA relays to perform in their intended safety related application.

UCI will notify the affected Utilities to our findings.

Required information as per 10CFR Part 21.21(d)(4) follows:

(i) Name andAddress of the individualor individualsinforming the Commission Robert Hale (orDesignee)

President and Chief Executive Officer United Controls International 205 Scientific Drive Noreross, GA 30092 www.unitedcontrols.com

..APR/09/2014/WED 01:38 PM United Controls FAX No, P.003/011 UNITED CONTROLS INTERNATIONAL (ii) Identification of the facility, the activity, or the basiccomponent suppliedfor such facility orsuch activity within the United States which fails to comply or contains a defect.

General Electric SB 1 series switches and HEA series relays, manufactured during 2009 and later. Note: UCI is unable to determine if the manufacturing change in 2009 is a potential defect and whether it could pose a substantial safety hazard at any U.S. licensee using such relays and switches.

(iWl) Identificationof the firm constructingthe facility orsupplying the basic component which fails to comply or contains a defect.

United Controls International 205 Scientific Drive Norcross, GA 30092 (iv) Nature of the defect orfailure to comply and the safety hazard which is created or could be createdby such defect orfailure to comply.

The manufacturing process of the contact assemblies on General Electric SB1 series switches and HEA series relays was changed in 2009. As part of the new process, the entire contact assembly (contact holder and contact tip) is tin plated.

UCI is unable to evaluate if this manufacturing change could create a substantial safety hazard. UCI does not know the storage conditions, in service environmental conditions or in service cycling rates of the switches and relays or how 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 relays and determine if the change in contact material could possibly create a safety hazard and effect the ability of the switches and relays to perform in their safety related application.

(v) The date on which the information ofsuch defect orfailure to comply was obtained, March 25, 2014 www.unitedcontrols.com

APR/68/2014/WED C1:38 PM United Controls FAX No. P. 004/011 UNITED CONTROLS INTERNATIONAL (vi) In the case of a basic component which contains a defect orfails to comply, the number and locationof these components in use at, suppliedfor, being supplied for, or may be suppliedfor, manufacturedor being manufacturedfor one or more facilitiesor activities subject to the regulationsin this Part.

Part Number Utility Purchase Order Quantity 12HEA61B235X2 CFE 700372018 3 12HEA61C236X2 FPL Turkey Point 02260642-34 2 12HEA61C237 OPPD 180520 4 12HEA61C238X2 OPPD 180520 3 12HEA61C237 OPPD 185929 2 12HEA61C237X2 OPPD 188314 2 12HEA63C239X2 FPL St. Lucie 02260642-41 8 HEA61C234X2 Antung PP100204 2 HEA61C244X2 OPPD 179664 5 HEA61C241X2 OPPD 179664 2 HEA63C239X2 FPL St. Lucie 02260642-103 3 12HEA61C238X2 OPPD 194686 4 16SBIBB339STS2P Duke Oconee 156606 11 Nextera 16SB1FB2C85SWM2Y Seabrook 2259825-3 1 1SB1ILB2C01LSM2P CFE 700327408 3 (vii) The corrective action which has been, is being, or will be taken; the name of the individualor organizationresponsiblefor the action; and the length of time that has been or will be taken to complete the action.

At this time UCI is notifying all Utilities to which it has supplied safety related BEA relays and SB1 switches to since the manufacturing process change in 2009.

(viii) Any Advice relatedto the defect orfailureto comply about the facility, activity, or basic component that has been, is being, or will be given to purchasersor licensees.

U.S. Licensees with installed or in storage SB 1 switches and HEA relays should evaluate if tin plated contacts are acceptable for use in their specific installed system and location.

www.unitedcontrols.com

APR/09/2014/WED 01:38 PM United Controls FAX No. P.005/011 L.

UNITED CONTROLS INTERNATIONAL (ix) In the case of an early sitepermit, the entities to whom an early site permit was transferred.

Not Applicable.

If you have any questions or wish to discuss this matter or this report, please contact:

Jim Garrison Engineering Manager, Seismic and Equipment Qualification jgarrisonOuntiedcontrols.com 770-496-1406 x 103 Sincerely,

\U, 9 Robert B. Hale President United Controls International www.unitedcontrols.com

APR/03/2014/WED 01:39 PM United Controls FAX No, P. 006/011 United Controls International 205 Scientific Drive Norcross, Georgia 30092 (770) 496 1406 tel (770) 496 1422 fax UNITED CONTROLS INTERNATIONAL ENGINEERING EVALUATION REPORT EER-14-94013-03 Revision 0 SB1 Selector Switches and HEA Relays Prepared Date: q/&jzol, Engineering Reviewed By: Date: Itg Entreering .

Approved By: Date:

Quality Assurance www.unitedcontrols.com

,APR/09/2014/WED 01:39 PM United Controls FAX No. P. 007/0 11 EER-14-94013-03, Rev. 0 Revision Flistory:

Date Revision I Description 04108/14 0 Initial Issue 1.0: Customers and Applicable Purchase Orders:

Omaha Public Power, Purchase Orders: 180520, 185929, 188314, 179664, 194686 Florida Power and Light, Purchase Orders: 02260642-34, 02260642-41, 02260642-103 Nextera, Purchase Order: 2259825-3 GFE Purchase Orders: 700372018, 700327408 Antung Purchase Order: PP100204 Duke Energy Purchase Order: 156606 2.0: Manufacturer:

General Electric 3.0: Part Numbers:

12HEA61B235X2, 12HEA61C236X2, 12HEA61 C237, 12HEA61C238X2, 12HEAd1 C237X2, 12HEA63C239X2, HEA61C234X2, HEA61C244X2, HEAdI C241X2, HEA63C239X2, 16SB1lBB339STS2P, 16SB1FB2C85SWM2Y, 16SB 1LS2C01LSM2P 4.0:

References:

1. General Electric Material Process E-Mail Dated 3/25/2014 5.0:

Description:

This Engineering Evaluation is being written as a 10CFR 50, Part 21 Interim letter to document findings regarding the change of a manufacturing process of the contact assemblies of GE SB1 switches and HEA relays.

6.0: Technical Evaluation I Analysis I Disposition:

A prior issue was discovered due to the failure of several GE SBM switches during on-site contact resistance testing. The SBM switches failed at a customer site due to high contact resistance across closed contacts. It was determined during that investigation that the manufacturing process of the contact assemblies of the GE SBM switches had changed in 2009 to include the tin plating of the entire contact assembly (contact holder and contact tip). Further investigation determined that the same contact assembly is used on GE SB1 switches and HEA relays. Both of the items are affected by the same manufacturing process change as the GE SBM switches.

Page 2 of 6 United Controls InternationalC 205 Scientific Dr. Norcross, GA 30092 CONFIDENTIAL AND PROPRIETARY DOCUMENT: Do not disclose to third party without express written consent from United Controls.

APR/08/2014/WED 01:39 PM United Controls FAX No, P. 008/011 EER-14-94013-03, Rev. 0 7.0

Conclusions:

Based on the above findings, there was a significant manufacturing process change to the General Electric SB1 series switches and HEA series relays in 2009- The high resistance across switch contacts in the GE SB1 switches and HEA relays could lead to a failure of the switch and relay 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 SR1 switches and HEA relays or already installed SR1 switches and HEA relays that were provided to the customers on the purchase orders listed in section 1.0. UCI does not know the storage conditions, in service environmental conditions or in service cycling rates of the switches and relays 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 ifthe change in contact material could possibly create a safety hazard and effect the ability of the switches to perform in their safety related application.

8.0 Attachments

I. General Electric Material Process E-Mail, Dated 312512014 Page 3 of 6 United Controls International l 205 Scientific Dr. Norcross, GA 30092 CONPDMENTIAL AND PROPRIETARY DOCUMENT: Do not disclose to third party without expres written eonSent from United Controls.

APR/09/2014/WED 01:40 PM United Controls FAX No. P.009/011 EER-14-94013-03, Rev. 0 Attachment 1 General Electric Material Process Email Dated 3125/2014 Page 4 of 6 United Controls International[ 205 Scientific Dr. Norcross, GA 30092 CONFIDENTIAL AND PROPRIETARY DOCUN{8NT; Do not disclose to third prty without oxpress written consent from United Controls.

APR/09/2014/WED 01:40 PM United Controls FAX No. P. 010/011 EER-14-94013-03, Rev. 0 Jim Garrison Front: Statton, Jim (GE Energy Management) <James.Statton@ge.com>

Sent! Tuesday, March 25, 2014 3:40 PM To: Jim Garrison; Colson, Kados Cc- Korina Looft

Subject:

RE; SBM Switch Question.

Helo Jim, The coined contact process applies to all; SBM, SBI and HE-A products.

Regards, Tim From: Jim Garrison rmailto:_Garrlson@unltedcontrots.com]

Sent, Tuesday, March 25, 2014 2:15 PM To: Statton, Jim (GE Energy Management); Colson, Karlos Cc: Kouina Looft

Subject:

RE: SBM Switch Question Jim, Thank you for the arnswer.

Did this new manufacturing process also extend to the $51switches and HEA relays?

Jim Garrison Engineering Manager United Controls International (770)-496-1406 ext. 103 Fromn Statton, Jim (GE Energy Management) imallto:james.Stattonfae.com]

Sent: Wednesday, March 05, 2014 11:31 AM To: Jim Garrison; Colson, Karlos Cc: Jeannette Martin

Subject:

RE: SBM Switch Question Hello Jim, Please see comments from our designer The SBIvM contacts are pure silver tips coined to a brass contact holder, Since the beginning of 2009, the process changed to have the whole assembly (contact bolder and contact tip) tin plated.

However, this process does not affvcts dih resistivity and reliability of the contacts. Both tho old process and the new process are doomed equivalent.

There is no particular contact resistance value and/or tolerance that can be used for a pass/fail ceizeria found ort the products department publishad data. None ofthe switches product publications indicate any numerical value or tolerance for contact resistance.

Using a rcsistance meter to ascertain contact resistance for 9B type switches is not recommended or advisable au a methodl to ascertain contact contnirty. Any attempt to use much a meter will produce variable readings. Should resistance verification be desired the method that is recommended is to use a test circuit that includes a DC source connected to a Page 5 of 6 United Controls International5 205 Scientific Dr. Norcross, GA 30092 CONFIDENTIAL AND PROPRISTARY DOCW;NT: Do not diselose to third party without express written consent from United Controls.

APR/09/2014/WED 01:40 PM United Controls FAX No, PF011/011 EER-14-94013-03, Rev. 0 known resistance load through the switch's closed contacts and to measure the voltage drop across the closed contacts, There is no defite value or prediction of how much tiis voltage drop will be but is is expected it will be a negligible value.

Regards, Jim From: Jim Garrison rnailtv:JGarrisonOunitedcoritoiscom]

Sent. Monday, Marth 03, 2014 12:10 PM To: Statton, Jim (GE Energy Management); Colson, Karios Cc-Jeannette Martin

Subject:

RE: SEM Switch Question Jim, From talking with our customer, they believe that contacts in the SBM were of a different design. The stationary contacts being pure silver with a steel back coined to a nickel plated brass base and the moving contact being pre silver with a steel back coined to a brass base, They confirmed this through testing an old switch that they had in storage. Do you know when the material specification and process for the contacts may have changed? Please let me know, thanks.

Jim Garrison Engineering Manager United Controls International (770)-496-1406 ext. 10.

From: Stattan, Jlm (GE Energy Management) (mallto:James.Stattonage.coml Sent: Wednesday, January 15, 2014 8:04 AM To: Colson, Kados Cc Jim Garrison

Subject:

RE, 5BM Switch Question Helio Karlos, Please see comments from our designer; As far as I know, we have never experienced corrosion on the SBM contacts. This condition has not been reported by our customers.

The SBM contacts are not welded, instead they are coined to the base. It is what we call coining process where the silver tip contact is placed in a confined die and subjected to sufficiently high pressure to induce plastic flow on dhe surface of the material.

The moving contact base is made of cartridge brass (70-30) and the stationary contact base is made of tinned COtZn-Sn alloy. In both cases the conract tip are made of silver .109 DLA_

Can we get a picture of these contacts?

Regards, Jim From: Colson, Karlos [rnallto:Kado§;C&lson*Gexmarorn]

Sent: Monday, January 13, 2014 3:12 PM To: Statton, Jim (GE Energy Management)

Cc; Jim Garrison (]Ggrrison~unitedcontrols.com)

Subject:

FN: SIBM Switch QuestIon Importance: High 2

Page 6 of 6 United Controls International[ 205 Scientific Dr.Norcross, GA 30092 CONPIDENTIAL AND PROPRIETARY DOCUMENT: Do not disclose to third party without express written consent from United Controls.