ML15162A023

Part 21 - Incorrect Part Number Relay Shipped to Brunswick Nuclear Plant

ML15162A023
Person / Time
Site:	Brunswick
Issue date:	06/09/2015
From:	Homer T Engine Systems
To:	Document Control Desk, NRC/RGN-II
References
Download: ML15162A023 (7)

Text

06/09/2015 U.S. Nuclear Regulatory Commission Operations Center Event Report Pace IPart 21 (PAR) Event # 51129Rep Org: ENGINE SYSTEMS, INC Notification Date /Time: 06/05/2015 18:12 (EDT)Supplier: Event Date I Time: 06/05/2015 18:12 (EDT)Last Modification: 06/05/2015Region: 1 Docket #:City: ROCKY MOUNT Agreement State: YesCounty: License #:State: NCNRC Notified by: TOM HOMER Notifications: STEVE ROSE R2DOHQ Ops Officer: NESTOR MAKRIS PART 21/50.55 REACTORS EMAILEmergency Class: NON EMERGENCY10 CFR Section:21.21 (d)(3)(i) DEFECTS AND NONCOMPLIANCEPART 21 -INCORRECT PART NUMBER RELAY SHIPPED TO BRUNSWICK NUCLEAR PLANTThe following is an excerpt of communication received via fax:"Summary:Engine Systems Inc. (ESI) began a 1OCFR21 evaluation on 04/13/15 upon discovery that governor control panelsshipped to Brunswick Nuclear Plant contained an incorrect part number relay. The evaluation was concluded on06/05/15 and it was determined that this issue is a reportable defect as defined by 1 OCFR Part 21. Under certainadverse conditions, a panel with the incorrect part number relay may lose power thereby resulting in inoperabilityof the electronic control portion of the control system. This could prevent the emergency diesel generator set fromperforming its safety-related function during an emergency event."Discussion:The relay in question is the Governor Control At Setpoint (GCASP) relay installed in the governor control panelassembly P/N 8002096-PANEL. The panel provides speed control functions for the emergency diesel generator(EDG). In the original panel design the part number specified was 219XBX282NE. During the course of EMCtesting, it was determined that the EMI suppression diode within in the GCASP relay must be removed in order forthe EUT to comply with the requirements of [International Electrotechnical Commission] IEC 61000-4-5. When thediode was installed and the negative polarity portion of surge testing forward biased the diode, this resulted in ashort circuit connection between the supply and return conductors of the control panel's power. This caused thefuses designed to protect the panel from overcurrent conditions to fail open; resulting in a loss of power to thecontrol panel."In place of the EMI suppression diode, a [Metal Oxide Varistor] MOV (P/N V1 50LA1 OAP) was added acrossterminals 6 & 7 of the GCASP relay socket. The MOV provides similar EMI suppression to the removed diode and 06/09/2015 U.S. Nuclear Regulatory Commission Operations Center Event Report Page 2responds appropriately to either polarity of surge waveform. The MOV is external to the relay and is considered aseparate component. The MOV is not affected by this notification."Removal of the internal EMI suppression diode for the GCASP relay resulted in a part number change. The relaypart number that should have been installed is PIN 219XBX283NE. The part number of the relay actually installedwas P/N 219XBX282NE. The difference between the two relays is that P/N 219XBX282NE contains an internalsuppression diode whereas 219XBX283NE does not."Impact on Operability:During normal operating conditions, the EDG will perform its safety related function with the incorrect GCASP relayinstalled in the governor control panel. Both relays provide the same switching function."However, if a negative polarity surge similar to the requirements of IEC 61000-4-5 were to occur on the 125 VDCbus with the incorrect relay installed, the control panel may lose power. The 27GP relay would de-energize,alerting plant personnel of an under-voltage condition within the governor control panel. The EDG would remainoperable on the mechanical governor though the electronic control portion would be inoperable."Root cause evaluation:An error by a technician in conjunction with a lapse in oversight allowed this problem to occur. Contributing to theissue was that only one digit differentiates the two part number relays and both have the same overall appearance(size, shape, case style, etc)."Evaluation of previous shipments:This issue only affects one part number (qty 4) supplied on one customer purchase order."Corrective Action:The customer was advised of the situation via letter 'Notice of GCASP Relay Discrepancy -Governor ControlPanel' sent on 04/15/15. The correct relays were then supplied to the customer as dedicated, safety-relatedreplacements on ESI IWO 8002474 (Brunswick PO 00786240) for installation in the panels. There are four panelsaffected, each containing one of these relays. ESI supplied four replacement relays which were [Certificate ofConformance] C-of-C'd and shipped on 04/17/15. These are plug-in style relays and to replace the relay onlyrequires pulling out the old relay and plugging in the new relay. No special tools or instructions are necessary."

1.'Engine Systems, Inc.175 Freight Road 12//.'Rocky Mount, NC 27804 ESITelephone: 252-977-2720Fax: 252-446.-3830TelefaxDATE: June 5. 2015COMPANY: NRC Operations CenterFAX: 301-816-5151FROM: Tom HomerRE: Report Number 10CFR21-0112If you do not receive all pages listed, please call the sender at: 252-407-8512Number of pages including cover sheet: 5

Dear Sir.Following this cover is a copy of our report IOCFR21-0112,

Rev. 0, for a 1OCFR21reportable notification on an incorrect relay installed in a governor control panel. ESIP/N 8002096-PANEL, supplied to Duke Energy Progress -Brunswick Nuclear Plant.A copy of this report will be mailed to the NRC Document Control Desk and to ouraffected customer.Should you have any questions please let us know,Sincerely,ENGINE SYSTEMS, INC.Tom HomerQuality Assurance Manager (E4rFE-IENGINE SYSTEMS, INC.175 Freight Road, Rocky Mount NC 27804ITelephone: 2521977-2720Fax: 252J446.1134Report No. 10CFR21-0112Rev. 0: 06/051151OCFR21 REPORTING OF DEFECTSAND NON-COMPLIANCECOMPONENT:SYSTEM:CONCLUSION:Incorrect Relay Installed in Governor Control PanelP/N 8002096-PANELEmergency Diesel GeneratorReportable in Accordance With 10CFR21Prepared By:Engineering ManagerDate: ___16_____ReviewedB,Quality ManagerDate: C-5"--Quality Performance With Pride Report No. 10CFR21-0112Record of RevisionsPage: 1 of 1REV DATE PAGE DESCRIPTION0 06/05/15 Initial issue.

Report No. 10CFR21-0112Revision: 0Date: 06/05/15Page: 1 of 2Component:Incorrect relay within governor control panel P/N 8002096-PANELSumma rv:Engine Systems Inc. (ESI) began a 1CFR21 evaluation on 04/13/15 upon discovery that governorcontrol panels shipped to Brunswick Nuclear Plant contained an incorrect part number relay. Theevaluation was concluded on 06/05/15 and it was determined that this issue is a reportable defect asdefined by 10CFR Part 21. Under certain adverse conditions, a panel with the incorrect part numberrelay may lose power thereby resulting in inoperability of the electronic control portion of the controlsystem. This could prevent the emergency diesel generator set from performing its safety-relatedfunction during an emergency event.Discussion:The relay in question is the Governor Control At Setpoint (GCASP) relay installed in the governorcontrol panel assembly P/N 8002096-PANEL. The panel provides speed control functions for theemergency diesel generator (EDG). In the original panel design the part number specified was219XBX282NE. During the course of EMC testing, it was determined that the EMI suppression diodewithin in the GCASP relay must be removed in order for the EUT to comply with the requirements ofIEC 61000-4-5. When the diode was installed and the negative polarity portion of surge testingforward biased the diode, this resulted in a short circuit connection between the supply and returnconductors of the control panel's power. This caused the fuses designed to protect the panel fromovercurrent conditions to fail open; resulting in a loss of power to the control panel.In place of the EMI suppression diode, an MOV (P/N V150LA10AP) was added across terminals 6 &7 of the GCASP relay socket. The MOV provides similar EMI suppression to the removed diode andresponds appropriately to either polarity of surge waveform. The MOV is external to the relay and isconsidered a separate component. The MOV is not affected by this notification.Removal of the internal EMI suppression diode for the GCASP relay resulted in a part numberchange. The relay part number that should have been installed is P/N 219XBX283NE. The partnumber of the relay actually installed was P/N 219XBX282NE. The difference between the two relaysis that P/N 219XBX282NE contains an internal suppression diode whereas 219XBX283NE does not.Impact on Operability:During normal operating conditions, the EDG will perform its safety related function with the incorrectGCASP relay installed in the governor control panel. Both relays provide the same switchingfunction.However, if a negative polarity surge similar to the requirements of IEC 61000-4-5 were to occur onthe 125 VDC bus with the incorrect relay installed, the control panel may lose power. The 27GP relaywould de-energize, alerting plant personnel of an under-voltage condition within the governor controlpanel. The EDG would remain operable on the mechanical governor though the electronic controlportion would be inoperable.

Report No. 10CFR21-0112Revision: 0Date: 06/05/15Page: 2 of 2Root cause evaluation;An error by a technician in conjunction with a lapse in oversight allowed this problem to occur.Contributing to the issue was that only one digit differentiates the two part number relays and bothhave the same overall appearance (size, shape, case style, etc).Evaluation of previous shipments:This issue only affects one part number (qty 4) supplied on one customer purchase order:ES] sales Part Number Customer Customer ESI Serial Number C-of.C Date Oty8002096-1.1-18002096 8002096-PANEL Duke Energy Progress -00655050 8002096-1.1-2 10/14/14 4Brunswick Nuclear Plant 8002096-1.1-38002096-1.1-4Corrective Action:The customer was advised of the situation via letter "Notice of GCASP Relay Discrepancy -Governor Control Panel" sent on 04/15/15. The correct relays were then supplied to the customer asdedicated, safety-related replacements on ESI IWO 8002474 (Brunswick PO 00786240) forinstallation in the panels. There are four panels affected, each containing one of these relays. ESIsupplied four replacement relays which were C-of-C'd and shipped on 04/17/15, These are plug-instyle relays and to replace the relay only requires pulling out the old relay and plugging in the newrelay. No special tools or instructions are necessary.