ML15162A023
| 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 OperationsCenter Event Report Pace I Part 21 (PAR) Event # 51129 Rep 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: 06/05/2015 Region: 1 Docket #:
City: ROCKY MOUNT Agreement State: Yes County: License #:
State: NC NRC Notified by: TOM HOMER Notifications: STEVE ROSE R2DO HQ Ops Officer: NESTOR MAKRIS PART 21/50.55 REACTORS EMAIL Emergency Class: NON EMERGENCY 10 CFR Section:
21.21 (d)(3)(i) DEFECTS AND NONCOMPLIANCE PART 21 - INCORRECT PART NUMBER RELAY SHIPPED TO BRUNSWICK NUCLEAR PLANT The following is an excerpt of communication received via fax:
"Summary:
Engine Systems Inc. (ESI) began a 10CFR21 evaluation on 04/13/15 upon discovery that governor control panels shipped to Brunswick Nuclear Plant contained an incorrect part number relay. The evaluation was concluded on 06/05/15 and it was determined that this issue is a reportable defect as defined by 10CFR Part 21. Under certain adverse conditions, a panel with the incorrect part number relay may lose power thereby resulting in inoperability of the electronic control portion of the control system. This could prevent the emergency diesel generator set from performing 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 panel assembly 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 EMC testing, it was determined that the EMI suppression diode within in the GCASP relay must be removed in order for the EUT to comply with the requirements of [International Electrotechnical Commission] IEC 61000-4-5. When the diode was installed and the negative polarity portion of surge testing forward biased the diode, this resulted in a short circuit connection between the supply and return conductors of the control panel's power. This caused the fuses designed to protect the panel from overcurrent conditions to fail open; resulting in a loss of power to the control panel.
"In place of the EMI suppression diode, a [Metal Oxide Varistor] MOV (P/N V1 50LA1 OAP) was added across terminals 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 OperationsCenter Event Report Page 2 responds appropriately to either polarity of surge waveform. The MOV is external to the relay and is considered 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 number change. The relay part number that should have been installed is PIN 219XBX283NE. The part number of the relay actually installed was P/N 219XBX282NE. The difference between the two relays is 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 incorrect GCASP relay installed 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 VDC bus 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 remain operable 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 the issue 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 Control Panel' sent on 04/15/15. The correct relays were then supplied to the customer as dedicated, safety-related replacements on ESI IWO 8002474 (Brunswick PO 00786240) for installation in the panels. There are four panels affected, each containing one of these relays. ESI supplied four replacement relays which were [Certificate of Conformance] C-of-C'd and shipped on 04/17/15. These are plug-in style relays and to replace the relay only requires pulling out the old relay and plugging in the new relay. No special tools or instructions are necessary."
1.'
175 Freight Road Engine Systems, Inc.
12//.'
Rocky Mount, NC 27804 Telephone:
ESI 252-977-2720 Fax: 252-446.-3830 Telefax DATE: June 5. 2015 COMPANY: NRC Operations Center FAX: 301-816-5151 FROM: Tom Homer RE: Report Number 10CFR21-0112 Ifyou do not receive all pages listed, please call the sender at: 252-407-8512 Number of pages including cover sheet: 5 Dear Sir.
Following this cover is a copy of our report IOCFR21-0112, Rev. 0, for a 10CFR21 reportable notification on an incorrect relay installed in a governor control panel. ESI P/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 our affected customer.
Should you have any questions please let us know, Sincerely, ENGINE SYSTEMS, INC.
Tom Homer Quality Assurance Manager
(E4rENGINE SYSTEMS, INC.
FE-I 175 Freight Road, Rocky Mount NC 27804 Telephone: 2521977-2720 I
Fax: 252J446.1134 Report No. 10CFR21-0112 Rev. 0: 06/05115 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: Incorrect Relay Installed in Governor Control Panel P/N 8002096-PANEL SYSTEM: Emergency Diesel Generator CONCLUSION: Reportable in Accordance With 10CFR21 Prepared By: Date: ___16_____
Engineering Manager ReviewedB, Date: C-5"--
Quality Manager Quality Performance With Pride
Report No. 10CFR21-0112 Record of Revisions Page: 1 of 1 REV DATE PAGE DESCRIPTION 0 06/05/15 Initial issue.
Report No. 10CFR21-0112 Revision: 0 Date: 06/05/15 Page: 1 of 2 Component:
Incorrect relay within governor control panel P/N 8002096-PANEL Summa rv:
Engine Systems Inc. (ESI) began a 1CFR21 evaluation on 04/13/15 upon discovery that governor control panels shipped to Brunswick Nuclear Plant contained an incorrect part number relay. The evaluation was concluded on 06/05/15 and it was determined that this issue is a reportable defect as defined by 10CFR Part 21. Under certain adverse conditions, a panel with the incorrect part number relay may lose power thereby resulting in inoperability of the electronic control portion of the control system. This could prevent the emergency diesel generator set from performing 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 panel assembly 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 EMC testing, it was determined that the EMI suppression diode within in the GCASP relay must be removed in order for the EUT to comply with the requirements of IEC 61000-4-5. When the diode was installed and the negative polarity portion of surge testing forward biased the diode, this resulted in a short circuit connection between the supply and return conductors of the control panel's power. This caused the fuses designed to protect the panel from overcurrent 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 and responds appropriately to either polarity of surge waveform. The MOV is external to the relay and is considered 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 number change. The relay part number that should have been installed is P/N 219XBX283NE. The part number of the relay actually installed was P/N 219XBX282NE. The difference between the two relays is 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 incorrect GCASP relay installed 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 VDC bus 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 remain operable on the mechanical governor though the electronic control portion would be inoperable.
Report No. 10CFR21-0112 Revision: 0 Date: 06/05/15 Page: 2 of 2 Root 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 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:
ES] sales Part Number Customer Customer ESI Serial Number C-of.C Date Oty 8002096-1.1-1 8002096 8002096-PANEL Duke Energy Brunswick Plant-Progress Nuclear 00655050 8002096-1.1-2 8002096-1.1-3 10/14/14 4 8002096-1.1-4 Corrective 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 as dedicated, safety-related replacements on ESI IWO 8002474 (Brunswick PO 00786240) for installation in the panels. There are four panels affected, each containing one of these relays. ESI supplied four replacement relays which were C-of-C'd and shipped on 04/17/15, These are plug-in style relays and to replace the relay only requires pulling out the old relay and plugging in the new relay. No special tools or instructions are necessary.