ML14113A370

Part 21 - Thomas and Betts Printed Circuit Boards

ML14113A370
Person / Time
Site:	Salem, Hope Creek, Diablo Canyon
Issue date:	04/18/2014
From:	Looft K United Controls International
To:	Office of Nuclear Reactor Regulation
References
49932 EER-14-6216-01, Rev 0
Download: ML14113A370 (16)

Text

0411812014 U.S. Nuclear Reeulatorv Co mission Overations Center Event Rmort Pam, I Part 21 (PAR) Event # 49932 Rep Org: UNITED CONTROLS INTERNATIONAL Notification Date / Time: 03/19/2014 15:36 (EDT)Supplier:

UNITED CONTROLS INTERNATIONAL Event Date / Time: 03/18/2014 (EDT)Last Modification:

04/17/2014 Region: 1 Docket #: City: NORCROSS Agreement State: Yes County: License #: State: GA NRC Notified by: KORINA LOOFT Notifications:

BLAKE WELLING R1DO HQ Ops Officer: DANIEL MILLS PART 21 GROUP EMAIL Emergency Class: NON EMERGENCY 10 CFR Section: 21.21 (d)(3)(i)

DEFECTS AND NONCOMPLIANCE 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.* *

• UPDATE ON 4/17/2014 AT 1442 EDT FROM KORINA LOOFT TO DONG PARK * * *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.

0411712014 U.S. Nuclear Regulatory Commission Operations Center Event Report Pagre 2"

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 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 R1 DO (Burritt) and Part 21 Group via email.

APR/17/2014/THU 03:06 PM FAX No, P. 001 ucI FAX TRANSMITTAL DATE: April 17, 2014 TO: NRC OPERATIONS FROM: Korina Looft/UCI CENTER FAX: 301-816-5151 FAX: 770-496-1422 TEL: 301-816-5100 TEL: 770-496-1406 CC: Part 21 Final Report for PAGES: 14 pages with cover page Event No. /Accession No.ML14085A013

_ * ..COMMENTS: 1 WILL FOLLOW UP AS DIRECTED TO MAKE SURE THE FAX TRANSMITTAL WAS RECEIVEDR THANK YOU, KORINA LOOFT APR/17/2014/THU 03:06 PM FAX No.P. 002 UNITED CONTROLS INTERNATIONAL 1OCFR21 FINAL REPORT April, 17t 2014 U.S. Nuclear Regulatory Commission Document Control Desk Washington D.C. 20555-0001

Subject:

10CFR21 Reporting of Defects and Non-Compliance Thomas & Betts Printed Circuit Boards P/N 41-01-596701 and P/N 90-41-974313 This final 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 30-80-56620.

Due to this material difference, the transformer warped and it was evident it became loose. The details of the potential failure of the power supply and the root cause are documented in the attached final report (United Controls International, Engineering Evaluation Report, EER-14-6216-01, Rev.0).Sincerely, Robert B. Hale President United Controls International 205 Scientific Drive Norcross, GA 30092 (770) 496-1406 Phone (770) 496-1422 Fax www.unitedcontrols.com APR/17/2014/THU 03:06 PM FAX No, P. 003 UNITED CONTROLS INTERNATIONAL ENGINEERING EVALUATION REPORT EER-14-6216-01 Revision 0 Part 21 Evaluation Final Report of Printed Circuit Boards Prenared By: dh d. AdA ~ iASJU..--r- -.. .d Reviewed By Approved By Engineering A r 6hgineerimng"Quality Assuranc Date: _ _ _ _Date: Date:c4 ri 4 www. unitedcontrols.com APR/17/2014/THU 03:06 PM FAX No, P. 004 EER-14-6216-01, Rev: 0 Revision Histor y: Date Revision Description I 04/17/14 0 Initial Issue 1.0:

References:

A. Email from the manufacturer stating that the issue is confined to one batch of boards, Dated March 071h 2014.B. UCI XRF Material test report # 6216X-01, Rev.0 C. UCI XRP Material test report # 6259X-01, Rev.0 D. UCI XRF Material test report # 6216X-02, Rev.0 E. Email from the manufacturer stating the effect of the defect, Dated March 2 0 m 2014.F. Email from PSEG stating that no immediate concern is necessary, Dated April 16t" 2014.2.0:

Description:

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.

3.0: Technical Evaluation

/ Analysis / Disposition:

SUMMARY

UCI issued a certificate of conformance to PSEG for S/N: 003967-03-0001 thru 0003 on December 2 2 nd 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.Table 1 Part Number UCI Sales UCI Serial Qty. Customer Name Customer Customer Current Status order-line Number PO # PO line Number 41-01-596701 003967-03 003967-03-0001 3 Public Service 4500576271 00030 Returned by 003967-03-0002 Electric & Gas PSEG on 003967-03-0003 (PSEG) 02/14/14 and at UCI for evaluation On February 2da 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 30-80-56620 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 (See Table 3 for material test results on one of these boards). Due to this material difference, the transformer warped and it was evident it became loose.Page 2 of 12 United Controls International 0 205 Scientific Drive 0 Norcross, GA 30092 APR/17/2614/THU 03:07 PM FAX No, P. 005 EER-14-6216-01, Rev: 0 Per the manufacturer's attached email (Attachment 1), 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 below mentioned 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 1 9 rn 2014.Table 2 Part Number UCI Sales UCI Serial Qty. Customer Name Customer Customer Current Status order-line Number PO# PO line Number 90-41-974313 003996-01 003996-01-0001 3 Public Service 4500579283 00010 Recalled from 003996-01-0002 Electric & Gas PSEG 003996-01-0003 (PSEG) (Notified on 03/13/14)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. The table below lists the material test results.Table 3 Part Number UCI Sales Material Material test Attachment

1. Order/Serial Report #Number 41-01-596701 003967-03-0001 Nickel-Tin plated 6216X-02, Rev.0 Attachment 4 Carbon Steel 90-41-974313 003996-01-0003 Nickel-Tin plated 6259X-01, Rev.0 Attachment 3 Carbon Steel 41-01-596701 2200-1-2 Stainless Steel 6216X-01, Rev.0 Attachment 2 (Control Sample) 304 90-41-974313 1808-01-CS Stainless Steel 6216X-01, Rev.0 Attachment 2 (Control Sample) 304 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. Per the manufacturer's email (Attachment 5), 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 fhnctional 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.

Page 3 of 12 United Controls International 0 205 Scientific Drive 11 Norcross, GA 30092 APR/17/2014/THU 03:07 PM FAX No, P. 006 EER-14-6216-01, Rev: 0 AFFECTED USERS: Tables I and 2 list all the affected power supplies and all the serial number of the boards that are at UCI for evaluation and rework except S/N: 003996-01-0001 which is installed in the plant at PSE&G. PSF.&G was notified about the issue; PSE&G performed an evaluation internally and determined that no immediate impact was necessary (See Attachment 6).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 fox 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.4.0: Attachments:

1. Email from the manufacturer stating that the issue is confined to one batch of boards, Dated March 07'h 2014.2. UCI XRF Material test report # 6216X-01, Rev.0 3. UCI XRF Material test report # 6259X-01, Rev.0 4. UCI XRF Material test report # 6216X-02, Rev.0 5. Email from the manufacturer stating the effect of the defect, Dated March 20' 2014.6. Email from PSEG stating that no immediate concern is necessary, Dated April 1 6 th 2014.Page 4 of 12 United Controls International fl 205 Scientific Drive 5 Norcross, GA 30092 APR/17/2014/THU 03:07 PM FAX No, P. 007 EER-14-6216-01, Rev: 0 Froln: To: Subject-Dam, Attachment I Re." P/N: 41-01-596701 Transformer Mourning Issues Frdav, March 07, 2014 3:07:43 PM Good afternoon, Sameera.RBB response: I do not know a specific batch that had bad bands, I can tell you the serial numbers to the assembly's that have the transformer with the new upgraded to stainless steel band. I hope this is helpful.Entry Date AlternateKeyl UC0 SN (S) WITNESS JOB S/17/2011 41-01-596701 Y 37 38127 12/22/2011 41-01-596701 Y 038-040 41962 1/26/2012 90-41-974313 Y 014-015 40901 3/29/2013 41-01-596701 IY 41 44489 Have a great rest of the day, and an even better weekend!Regards, Harry Orrock, Jr.Quality Specialist Thomas & Bett Power Solutions A Member o the AM8 Grop 804-236-4061 (Office)804-236-404'7 (Fax)o-mailh harryorrockkbtnkcom Thomas & Betts Power Solutions provides power quality solution that protect critical points in th, electrical infraetricture under the folliwIng brands: Current Technology, Cybeirn, Joslyn Electronic., and Unitted Power.On Wed, Feb 19, 2014 at 10:26 AM, Sameera Jeereddy<Seered jdy)unitedcontrolsnom>

wrote: Harry, If this is confined to only one batch, is there a way to figure out if the transformers from this batch were used on any other boards? We are trying to recall the boards with these transformers from the plants and wanted to see if we can short list any of them-Page 5 of 12 United Controls International 0 205 Scientific Drive 5 Norcross, GA 30092 APR/17/2014/THU 03:08 PM FAX No, P. 008 EER-14-6216-01, Rev: 0 Thanks!Sameera ieereddy Lead Engineer-Electrical Dedication United Controls international (770) 496-1406 ext. 150 From: Harry Orrock [1]

Senrt: Tuesday, February 18, 2014 5:16 PM To: Wesley Hickle Cc: Craig Perkey; Sameera .leereddy

Subject:

Re: P/N: 41-01-596701 Transformer Mounting Issues Good evening, Wesley.Engineering response concerning your corrective action question on p/n 41-01-596701: Nothing has changed on that part and no Corrective Actions have been issued. It was an isolated incident and was confined to that one batch. We have not seen any other instances-Have a great evening!Regards, Harry Orrock, Jr.Qutlity Specialist Thomas & Betts Power Solutions A Memben of the ABS Group Page 6 of 12 United Controls International 0 205 Scientific Drive 0 Norcross, GA 30092 C (U (0 (N (i~w w L216X-01, Rev 0 I of I.1 CN 02 mU E I (1) I.(esurd e~mwbn la aewg ma~e~al ame xeneisW 4iisclafJia stemi Type 304 AIJNS No- 83D4001_______

I TesteffYl cmnp asftii sep~fled in A STtI AA lf4h-3 _ _________

sraltut D ab'PftMPUt IfM I1* baPWWubd ri~n vicutw~abJ1expqwwoWVCI.TWS rVWl Mmsm-UwWgsaidf moot~ Obnei1 ftls tmom i s~~eldl n~tbbcwdmW kIna onsAmoramm*1e ofl~s o=mdtw 4ff Lkv AFORM 10.15A REV 25 1/3/ii 2014 C2 C4 T LU 6259X-Dl, Rev 0 1 of I XRF CHEMICAL TEST REPORT Reportt 626QX411 R~ev: 0 Date: April 9, 2014 Description I Item; LOG IC POWER SUPP1Y/ 9341-974313 Material Designafforr Not Specified XRF An~alyzer:

Model: XL3t 9O0S Sete &: QG589CA Test Duration (->Ssec) M~imun 5 Sw aacube a:05________corn Copstin :welght %Positive MabartaI Alloy Refence Cwisitry Sn NI CSP' r](3 Fe Sn HE Ca Fe wn T1 S P dItfao Weore B~efore, Momar Wore i~eans. After After After After After Aftier After After Strip SWtp StrIp Stti Strip Snip Strip strip Strip Strip Strip Strip Strip iAo Met0ls Handook yo.0. 1- -t edO- May.- Max. Max.7M~rcmernband f~talsled 2.16 20-5 0.98 0.20 78.13 OM.03 1 I-0 9.7 12 .0 -)11 DXS___________________________

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_ __ _ _L:_ _ I oaj .I_ _M 0 toov a4 C 0 IQa 0 U"0*bd Z.(l)Ikhe swiples were kw~d to be Mclce(Ni)-

rTh ($q) Plasted carboe ste based on duIfmwftel ev~aaln of Tefore Sblp'P2) Mteasured Oamads ontmi bse mateitelara ows~starrtvf CarbonSe $ioeamiposrfon spedfled In Bhe ASM M~sa~nboo Vot, O t adn- *miafow Only OffmDi element ssuch asVobit (Co) and TImsilum am present In the plaft -1nfonnadteonly Tesmai 81': RL-Aawed e~r lb!Wi rneW In ifbeieo d WM"*fthaiPUW at UCI.Thj3 naWtwmrbieiltiqnwoajr~he r ýfc~ Atwrshlnhsed.E aod it oXcabexddU4O I,au ewlrm fLiaeeei(Ifa

, OA FORM 10.15A REV 15 1/31./2014 0 0 4 0 I-LL ILu 6215X-02, ev 0 lof 1 XRF CHEMICAL TEST REPORT R~eport U: 621OX-C2 Rev- 0 Date: API! 15, 2014 Descrlption i Item: POWERSUP PLY-LOGICASSEMBLY I 41-01-59-700-Mataeil Desination:

Not Spedfied[Z NON,-DEMRucrETnS XRF Analyzer.

Mode]: XL31 900S S/N: 55898 Tested per QCP 10.15 est Duratton (6sec) Mlnmun 5 Sec, Match number (52): 0.12 Test Results...... .. Co________

Weiht 5$roUMo]n: -----Poalftve Ileteuel Alloy RdwbnceChtaistry Sn NI Coa'R TIMa Fe Sn NI Co Fe Mn Ti S P Before Before Before Before Boiom A'ter After After After After Altar After Alter Stp Stp Strip Strip MSip Stri p Srp Strip Strip Strip Otrip Ship Mi MeW Handbook, Mx.00 0.050 0.00 V9.1, 10th editioc, Carbon steel .... .--Max, -Max.Max.S"nple D)006216-01-00004 Transformer band installed 2.23 20.23 0.73 0.20 76.45 0.03 0.16 0.00 98.62 0.22 0.00 0.031 0.000 SA0 " on -1).W967-03A0001

,~i.'U 0.0 Its ca 2 (1) The samples mieettn to beNictey-Thn (Sn) Plated ceton steetased on differentra eiakouaffn WOPMfSttSnid" teing (2) Meamnd xeed=wton hase mmaleiare m lrstntvdthCEacum Sbeloompiion pedieod itn kte ASIM MeW fladbaob Vol 10M edfton -hInoMarion OWry (3) Othterwe-isudch as CcAf tCo) end Tltennkm weprasatkra the.pa -Inbtrlzc a only_______________

slgnatre Dat VTMawd BY.Rsfeedatdr.

ThU s nqzy natbc reaat umwdbnl 1 a apSpmfllflfW,.T atl Is wMeloflbetxikel i 9sus. m wnAcdkh atdke M WL efaunnm.S aMabp Mmqtslel aaw w QA FORM 10.15A REV 15 1/31/2014 APR/17/2014/THU 03:09 PM FAX No, P. 012 EER-14-6216-01, Rev: 0 Attachment 5 Fronu To: Cc: Subjectl Date:)Imot'ihy Ieat'ty Re: PIN: 41-01-596701 Transfomer Mountdng Issue Thursday, March 20, 2014 3;411 15 PM Good afternoon, Sameera.RBB response: These boards emit a loud high frequency whine during normal operation.

Some of the noise is directly from the large transformer.

The noise can be quite irritating especially during a bench test or when the system cabinet is open.A transformer that is loose will emit mare noise. This Is the only effect that I know of, but since the noise can be quite irritating, the quieter the unit is the better.The power supply will still deliver the correct voltages.Have a great rest of the dayl Regards, Harry Orrock, Jr.Quality Specialist Thomas & Betts Power Solutions A Member of the ABB Group 804-236-4061 (office)804-236-404'7 (jax)e-mail: hary.orrnckN@tnbc.om Tbonmas & ISette Power soutions providls power quality solutions that protect crtical points isl the elecgtrial infrastnmeturv unier the fIIIowtng brands: Current Technology, cyberex, Joslyn Electronics, mnd United Power.On Wed, Mar 19, 2014 at 3:24 PM, Sameera Jeereddy<S3eereddyv1unitedcontrols.com>

wrote: Harry, Page 10 of 12 United Controls International 0 205 Scientific Drive [0 Norcross, GA 30092 APR/17/2014/THU 03:09 PM FAX No, P. 013 EER-14-6216-01, Rev: 0 There is a recent failure that we encountered where there was loud high frequency whine encountered during the pre-installation testing and the transformer was loose. So, I am trying to figure out how the function of the board is affected with the transformer becoming loose and if it is installed in the system.Thanks!Sameera Jeereddy Lead Engineer-Electrical Dedication United Controls International (770) 496-1406 ext. 150 from: Harry Orrock [mailto~harry.orrockCWtb.carm Sent- Wednesday, March 19, 2014 2:36 PM To: Sameera Jeereddy

Subject:

Re: P/N: 41-01-596701 Transformer Mounting Issues Good afternoon, Sameera.RBB response: I think that if someone encounters a transformer on an older board that is loose to the extent of causing excess vibration, the transformer should be replaced.

If the transformer is not loose then the unit will operate reliably.I have not typically seen the band break except on very old units where the transformer was visibly overheated or in shipping where the unit likely experienced severe shock.Have a great rest of the day!Regards, Page I I of 12 United Controls International 0 205 Scientific Drive 01 Norcross, GA 30092 APR/17/2014/THU 03:09 PM FAX No, P. 014 EER-14-6216-01, Rev: 0 Attachment 6 Front: To:

Subject:

Date: Pataick Iackson.c-aEgdchf Fwd: Part 21 Initial Notification Report Wednesday, April 16, 2M!4 3:46(48 PM Sent from my iPhone Begin forwarded message: From: "Thompson, Joseph" <Joseph.Thompsonhpseg.com>

Date: April 16, 2014 at 3:32:32 PM EDT To: Patrick Jackson <PJackson(Lunitedcontrols.com>

Subject:

Re: Part 21 Initial Notification Report Patrick, Although the final evaluation isn't due until tomorrow, an interim disposition has been entered that states that the carbon steel strap is not an immediate concern-Sent from my Rlacklerry 10 smartphone on the Verizon Wireless 46 LTE network-From: Patuick Jackson Sent! Wednesday, April 16, 2014 2:19 PM To: Thompson, Joseph Cc: Sameera Jeereddy Sublect: FW: Part 21 Initial Notification Report Joe, Per our earlier conversation, Is there any way that you can send that report to us so that we can attach it to the NRC letter.Thanks, Patrick From- Patrick Jackson Sent: Wednesday, April 16, 2014 1:06 PM To: Sameera Jeereddy

Subject:

RE, Part 21 Initial Notification Report That seems to be the case. They must have figured the carbon would hold for another few months.Either way they evaluated and elected to move on with the one that they have.Page 12 of 12 United Controls International El 205 Scientific Drive C1 Norcross, GA 30092