ML101100225
| ML101100225 | |
| Person / Time | |
|---|---|
| Site: | Salem, Hope Creek  |
| Issue date: | 04/14/2010 |
| From: | Hale R United Controls International |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| Download: ML101100225 (7) | |
Text
0411412010 U.S. NuclearRegulatory Commission OperationsCenter Event Report Page I General Information or Other (PAR) Event# 45839 Rep Org: UNITED CONTROLS INTERNATIONAL Notification Date / Time: 04/14/2010 16:49 (EDT)
Supplier: THOMAS & BETTS Event Date / Time: 03/09/2010 (EDT)
Last Modification: 04/14/2010 Region: 1 Docket #:
City: TUCKER Agreement State: Yes County: License #:
State: GA NRC Notified by: ROBERT HALE Notifications: MEL GRAY R1DO HQ Ops Officer: DONG HWA PARK PART 21 GROUP EMAIL Emergency Class: NON EMERGENCY 10 CFR Section:
21.21 UNSPECIFIED PARAGRAPH FAULTY MODULATION INDEX CONTROL CIRCUIT BOARD USED IN A POWER SUPPLY The following is a summary of information received via fax:
"UCI [United Controls International] personnel witnessed system level functional testing of three [Modulation Index Control] MIC circuit boards in a spare unit on March 9-10, 2010 at the PSEG Nuclear LLC training center as part of the dedication process. Initially, the boards were accepted based on the test results but later irregularities were noticed on the output side of another card (reference oscillator) in the system. The Original Equipment Manufacture (Thomas & Betts) began troubleshooting the issue and determined that two resistors (R336 and R347) had one leg each terminated in the wrong location. Subsequent repair and testing confirmed this to be the issue and that once corrected, the irregularities were gone.
"The affected licensees are PSEG Nuclear LLC - Salem and Hope Creek Nuclear Generating Stations."
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nlhUted Controls International 5139 S. Royal Atlanta Drive Tucker, Georgia 30084 (770) 495 1406 tel (770) 496 1422 fax April 14, 2010 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 Board P/N 41-01-251512 The enclosed report addresses a reportable notification for a Thomas & Betts Printed Circuit Board P/N 41-01-251512-A copy of the report has been mailed to our affected nuclear customers.
Sincerely, Robert B, Hale President Enclosures
- 1. Report 20100414_Notification 41-01-251512, 3 pages
- 2. Inspection Instruotion for R336 and R347 Location on Thomas & Betts P/N 41-01-251512, 1 page www.unitedcontrols.com
United Controls International 5139 S. Royal Atlanta Drive Tucker, Georgia 30084 (770) 4,96 1406 tel (770) 495 1422 faX IOCFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: Tihomas & Betts Printed Circuit Board P/N 41-01 :-251512 SYSTEM: Cyberex 20 kVA Model AC Power Supply CONCLUSION: Defect reportable in accordance with 10CFR21 REPORT ID: 20100414 Notification 41-01-251512 File: 20100414_Notification 41-01-251512.doe Reviewed By: Date:. I- ,
Engineering Reviewed By: ,rd2vrt' EngineeriAh
"- I J Date:
Approved By: Date: t 9t/
Quality Assurance
- wwwmunitedcontrois,com
20100414 Notification. 41-01-251512 Page 2 of 3 COMPONENT Thomas & Betts Printed Circuit Board Thomas & Betts PIN: 41-01-251512 PURPOSE This report documents the supply of faulty Modulation Index Control (MIC) circuit boards for a Cyberex 20 WA Model AC Power Supply.
SUMMARY
UCI personnel witnessed system level functional testing of three MIC circuit boards in a spare unit on March 9-10, 2010 at the PSEG Nuclear LLC training center as part of the dedication process. Initially, the boards were accepted based on the test results but later irregularities were noticed on the output side of another card (reference oscillator) in the system. The OEM (Thomas & Betts) began troubleshooting the issue and determined that two resistors (R336 and R347) had one leg each terminated in the wrong location. Subsequent repair and testing conftrmed tlhis to be the issue and that once corrected the irregularities were gone.
Utilizing technical support from Thomas & Bets, UCI personnel began an evaluation to determrine the potential effects of the incorrectly installed resistors. On March 12, 2010, Thomas & Betts provided the following statement in an email from Steve Wendell, Director - Service Support Technologies for Thomas & Betts Global Solutions:
The Inverter THD specification is < 5% and RMA voltage regulation is +/- 21.
The test results are within these parametersthough the THD appears to be temperature sensitive and requires adjustment with any change in ambient temp. However, placement
$resistors f R33 6 and !2347 in the "short"holes, as found on the 3 boardsreturnedfrom the site, alters the operation qf 1C3 05 and IC306.
Consequently the circuits cannotfunction as designed. We believe the temperature sensitivity is a result of the incorrect resistorsand are awaitingresults offurther testing from the site to confirm our suspicions.
It is owu recommendation that all applicableMIC cards be inspected as soon as practical and correctedas necessary. It is our belief only five MIC boards are affected by this manufacturingissue and all those boards have been identified and corrected.
As stated by Thomas & Bets above, the incorrect installation of the two resistors is believed to be limited to five boards originally supplied under PSEG Nuclear LLC purchase order 4500482392. Two.
boards from previous orders (S/N 2172-I-CS from PO 4500361396 and S/N UCI-3047-9-2 from PG 4500471119) were verified to be correct. However, they do recommend that the existing population be inspected as soon as practical.
United Controls International
20100414 Notification 41-01-251512 Page 3 of 3 AFFECTED USERS PSEG Nuclear LLC - Salem and Hope Creek Nuclear Generating Stations According to UCI records, a total of 15 Modulation Index Control circuit boards (P/N 41-01-251512) were supplied by Thomas & Betts to UCI to fulfill PSEG Nuclear LLC orders, The current status of these 15 circuit boards is shown in table 1 below.
Table 1 No. UCI Serial Number PSEG Purchase Order Current Status Current Location 1 2172-1-CS 4500361396 Correct as-built UCI 2 UCI-2172-1-1 4500361396 Unknown PSEG 3 UCI-2496-3-1 4500406519 Unknown PSEG 4 UC1-2711ld-1 4500430804 UnloCown PSEG 5 UCI-2711-1-2 4500430804 Unknown PSEG 6 UCI-2711-1-3 4500430804 UnkInown PSEG 7 UCI-2711-1-4 4500430804 Unknown PSEG 8 UCI-3047-9-1 4500471119 Unknown PSEG 9 UCI-3047-9-2 4500471119 Corrct as-built PSEG 10 UCI-3135-1-1 4500482392 Corrected PSEG 11 UCI-3135-1-2 4500482392 Corrected UCI 12 uCI-3135-l-3 4500482392 Corrected UCI 13 UCI-3135-1-4 4500482392 Corrected UCI 14 UCI-3135-1-S 4500482392 Conrected UCI 15 003466-01-0001 4500521319 Unknown PSEC CORRECTIVE ACTIONS Correction Performed The five boards from UCI job 3135 supplied under PSEO order 4500482392 have been corrected and one (SIN UCI-3135-1-1) has been tested on-site at PSEG and confirmed to be functional. The remaining four are in controlled storage at UCI and can be tested at PSEG as-needed for installation.
Correction to be Performed Pending any inspection (see Attachment I for instructions) performed by PSEG on field population, an5y defective units found will be reworked to original specifications and dedicated accordingly.
Corrective Action UCI has revised the applicable dedication procedure (CGDS-308) to include a component level inspecbion with specific instructions for the configuration of the two subject resistors. Additionally, a system level functional test at PSEG has been added.
ATTACHMENTS
- 1. Inspection Instruction for R336 and R347 Location on Thomas & Betts P/N 41-01-251512 United Controls International
Attachment 1
,Page I of 2 INSPECTION INSTRUCTION FOR R336 AND R347 LOCATION ON THOMAS AND BETTS P/N: 41-01-251512
- 1. See figure 1 below for a picture of the Cyberex logic power supply board, p/n: 41-01-251512.
- 2. Inspect the board for the correct location of the resistor leads as shown in figure 2.
- 3. If resistor lead is installed as shown in figure 3 then notify UCI and an RMA will be issued for the repair.
Figure 1, Modulation Index Control Card P/N: 41-01-251512
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Attachment I Page 2 of 2 INSPECTION INSTRUCTION FOR R336 AND R347 LOCATION ON THOMAS AND BETTS P/N: 41-01-251512 Figure 2,- Correct location of resistor leads Figure 3, Incorrect location of the resistor leads