ML15280A352
| ML15280A352 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 10/05/2015 |
| From: | Bolt T AZZ Incorporated |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| Download: ML15280A352 (5) | |
Text
I0/0.T/2015 U.S. Nuclear Regulatory Commission Onerations Center Event Renort Part 2l (PAR)
Event #
51454 Rep Org: AZZINUCLEAR LOGISTICS INC Notification Date/ITime: 10/05/2015 17:47 (EDT)
Supplier: AZZ/NUCLEAR LOGISTICS, INC.
Event Date I Time: 10/05/2015 (CDT)
Last Modification: 10/05/2015 Region:
4 Docket #:
City:
FORT WORTH Agreement State:
Yes County:
License #:
State: TX NRC Notified by: TRACY BOLT Notifications:
NICK TAYLOR R4DO HQ Ops Officer: JEFF HERRERA PART 21/50.55 REACTORS EMAIL Emergency Class: NON EMERGENCY 10 CFR Section:
21.21 (d)(3)(i)
DEFECTS AND NONCOMPLIANCE ELECTRONIC POSITION CONTROLLER FAI LED INTERNAL COMPONENT "NLI manufactured the reverse engineered units to replace the existing obsolete electronic position controller NLI Model: NLI-10OA-LM-P.
'The failed component within the controller was sized based on the original published ratings of the original components installed. The unit had an internal component that was subjected to a current value that was higher than the rating for the component. The actual applied current value was not originally provided to NLI when the units were being designed. NLI and the affected plant has been in communication regarding the component condition since the first reported failure.
"Electronic Position Controller units, NLI Model NLI-10A-LM-P that have been manufactured and supplied are identified beo.
Affected Plant is Callaway.
10/0512015 16:46 100105 54 AX)
P.0011004 NU C:LEAR To:
Fax (301) 816 - 5151 Document Control Desk U.S. Nuclear Regulatory Commission Washington, DC 20555 From:
Tracy Bolt Director of Quality Assurance AZZINLI Nuclear Logistics, Inc.
7410 Pebble Drive Fort Worth, Texas 76118 817-284-00.77 Pursuant to 10CFR 21.21 (d)} (3) (ii), AZZINLI is providing in the following letter the written notification of the identification of a deviation.
Total Pages including this page: 4 AZZ Nuclear I NLI 7410 Pebble Drive F Iort Worth, TIX 761 18 J Phont 800.A48.4 124 I Fax: 817.590.0484 J azznuclear.com/nhi
10/0512015 16:46 1005215184 WX P.0021004 GAZZ Date: October 5, 2015 NUCLEAR Document Control Desk U.S. Nuclear Regulatory Commission Washington, DC 20555 Part 21 Report No: P21-10052015
Subject:
Electronic Position Controller Model: NLI-1OA-LM-P Pursuant to 10CFR 21.21 (d) (3) (ii), AZZINLI is providing written notification of the identification of a deviation.
On the basis of our evaluation, it is determined that AZZINLI does not have sufficient information to determine if the subject condition if left uncorrected could have created a Substantial Safety Hazard or could have created a Technical Specification Safety Limit violation as it relates to the subject plant application.
The following information is required per 10CFR 21.21 (d) (4).
(i)
Name and address of the individual or Individuals informing the Commission.
Tracy Bolt, Director of Quality Assurance Nuclear Logistics, Inc.
7410 Pebble Drive Ft. Worth, TX 76118 (ii) Identification of the facility, activity, or the basic component supplied for such facility or such activity within the United States which fails to comply or contains a defect.
The specific part which contains a deviation:
Electronic Position Controller NLI Model: NLI-1OA-LM-P (Revision 0)
(iii) identification of the firm constructing or supplying the basic component which fails to comply or contains a defect.
NLI manufactured the reverse engineered units to replace the existing obsolete equipment_
AZZ Nuclear ] NLJ 7410 Pebble Drive [ Fort Worch, TX 76118 I Phone: 800.448,4124 I Rax: 817.590.0484 1 azznuclear~com/nli
10/0512015 16:46 100105 64 AX)
P.0031004 (iv)
Nature of defect or failure to comply and the safety NUCLEAR hazard which is created or could be created by such defect or failure to comply.
The failed component within the controller was sized based on the original published ratings of the original components installed. The unit had an internal component that was subjected to a current value that was higher than the rating for the component. The actual applied current value was not originally provided to NLI when the units were being designed. NLI and the affected plant has been in communication regarding the component condition since the first reported failure.
(v)
The date on which the information of such defect or failure to comply was obtained.
On September 29, 2015, enough information was gathered from the evaluations being performed to determine the reportability of the deviation that is the root cause for the event.
(iri)
In the case of a basic component which contains a defect or fails to comply, the number and location of these components in use at, supplied for being supplied for, or may he supplied for, manufactured or being manufactured for one or more facilities or activities subject to the regulations in this part.
Electronic Position Controller units, NLI Model NLI-1OA-LM-P that have been manufactured and supplied are identified below.
Plant Name Purchase Serial Number
_________order Callaway 568677 SR NLI-1OA-LM-P-1003-0, N LI-1OA-LM-P-1004-0, NLI-1OA-LM-P-1005-O, NLI-10A-LM-P-1I006-0, NLI-1OA-LM-P-1007-0, NLI-1OA-LM-P-1008-0, NLI-1OA-LM-P-1009-0 and NLI-1OA-LM-P-1010-0 original version units)
AZZ Nuclear I NLJ 7410 Pebble Drive Fort Worth, TX 76118 I Phone: 800.448.4124 I Fax: 817.590.0484 I azznuclear.com/nli
10105/2015 16:46 100105F64 AX)
P.0041004 (vii) The corrective action which has been, Is being, or will be taken; the name of the individual or organization responsible for the action; and the length of time that has been or wili be taken to. complete the action.
Three of units that initially failed in the plant have already been returned to NJLI for failure analysis and design modifications. These units were modified by installing a larger bridge rectifier and wire wound resistor onto the revision 0 circuit board. The modified versions, quantity of three, S/N: NLI-1OA-LM-P-1003-0, NLI-1OA-LM-P-1004-0 and NLI-1OA-LM-P-1006-O have been returned to Calloway under purchase orders 689233 SR and 694253 SR and have been accepted and installed into the plant and are working with no reported issues.
The model number NLI-1OA-LM-P, has been redesigned with a larger bridge rectifier of a higher rating and wire wound resistor that will withstand the applied current in the intended application.
The parent circuit boardl has also been revised to revision 1 to accept the larger bridge rectifier without impacting other components on the board.
The remaining unmodified revision 0 units that were originally supplied have not yet been returned to NL-I for incorporation of the design modification.
NLI recommends that at the plant's earliest convenience, the remaining units be returned to NLI to be retrofitted with the latest design configuration (revision 1 circuit board).
(viII) Any advice related to the defect or failure to comply about the facility, activity, or basic component that has been, is being, or will he given to purchasers or licensees.
The unmodified units should not be installed into the intended application. The units should be returned to NLI to have the units retrofitted with the latest configuration.
Tracy Bo t Director of Quality Assurance AZ? Nuclear NI!
7410 Pebble Drive I Fort Wortlh, TX 76118 I Phone: 800.448.4124 I Fax: 817.590.0484 J azznuclear, coi/nli
I0/0.T/2015 U.S. Nuclear Regulatory Commission Onerations Center Event Renort Part 2l (PAR)
Event #
51454 Rep Org: AZZINUCLEAR LOGISTICS INC Notification Date/ITime: 10/05/2015 17:47 (EDT)
Supplier: AZZ/NUCLEAR LOGISTICS, INC.
Event Date I Time: 10/05/2015 (CDT)
Last Modification: 10/05/2015 Region:
4 Docket #:
City:
FORT WORTH Agreement State:
Yes County:
License #:
State: TX NRC Notified by: TRACY BOLT Notifications:
NICK TAYLOR R4DO HQ Ops Officer: JEFF HERRERA PART 21/50.55 REACTORS EMAIL Emergency Class: NON EMERGENCY 10 CFR Section:
21.21 (d)(3)(i)
DEFECTS AND NONCOMPLIANCE ELECTRONIC POSITION CONTROLLER FAI LED INTERNAL COMPONENT "NLI manufactured the reverse engineered units to replace the existing obsolete electronic position controller NLI Model: NLI-10OA-LM-P.
'The failed component within the controller was sized based on the original published ratings of the original components installed. The unit had an internal component that was subjected to a current value that was higher than the rating for the component. The actual applied current value was not originally provided to NLI when the units were being designed. NLI and the affected plant has been in communication regarding the component condition since the first reported failure.
"Electronic Position Controller units, NLI Model NLI-10A-LM-P that have been manufactured and supplied are identified beo.
Affected Plant is Callaway.
10/0512015 16:46 100105 54 AX)
P.0011004 NU C:LEAR To:
Fax (301) 816 - 5151 Document Control Desk U.S. Nuclear Regulatory Commission Washington, DC 20555 From:
Tracy Bolt Director of Quality Assurance AZZINLI Nuclear Logistics, Inc.
7410 Pebble Drive Fort Worth, Texas 76118 817-284-00.77 Pursuant to 10CFR 21.21 (d)} (3) (ii), AZZINLI is providing in the following letter the written notification of the identification of a deviation.
Total Pages including this page: 4 AZZ Nuclear I NLI 7410 Pebble Drive F Iort Worth, TIX 761 18 J Phont 800.A48.4 124 I Fax: 817.590.0484 J azznuclear.com/nhi
10/0512015 16:46 1005215184 WX P.0021004 GAZZ Date: October 5, 2015 NUCLEAR Document Control Desk U.S. Nuclear Regulatory Commission Washington, DC 20555 Part 21 Report No: P21-10052015
Subject:
Electronic Position Controller Model: NLI-1OA-LM-P Pursuant to 10CFR 21.21 (d) (3) (ii), AZZINLI is providing written notification of the identification of a deviation.
On the basis of our evaluation, it is determined that AZZINLI does not have sufficient information to determine if the subject condition if left uncorrected could have created a Substantial Safety Hazard or could have created a Technical Specification Safety Limit violation as it relates to the subject plant application.
The following information is required per 10CFR 21.21 (d) (4).
(i)
Name and address of the individual or Individuals informing the Commission.
Tracy Bolt, Director of Quality Assurance Nuclear Logistics, Inc.
7410 Pebble Drive Ft. Worth, TX 76118 (ii) Identification of the facility, activity, or the basic component supplied for such facility or such activity within the United States which fails to comply or contains a defect.
The specific part which contains a deviation:
Electronic Position Controller NLI Model: NLI-1OA-LM-P (Revision 0)
(iii) identification of the firm constructing or supplying the basic component which fails to comply or contains a defect.
NLI manufactured the reverse engineered units to replace the existing obsolete equipment_
AZZ Nuclear ] NLJ 7410 Pebble Drive [ Fort Worch, TX 76118 I Phone: 800.448,4124 I Rax: 817.590.0484 1 azznuclear~com/nli
10/0512015 16:46 100105 64 AX)
P.0031004 (iv)
Nature of defect or failure to comply and the safety NUCLEAR hazard which is created or could be created by such defect or failure to comply.
The failed component within the controller was sized based on the original published ratings of the original components installed. The unit had an internal component that was subjected to a current value that was higher than the rating for the component. The actual applied current value was not originally provided to NLI when the units were being designed. NLI and the affected plant has been in communication regarding the component condition since the first reported failure.
(v)
The date on which the information of such defect or failure to comply was obtained.
On September 29, 2015, enough information was gathered from the evaluations being performed to determine the reportability of the deviation that is the root cause for the event.
(iri)
In the case of a basic component which contains a defect or fails to comply, the number and location of these components in use at, supplied for being supplied for, or may he supplied for, manufactured or being manufactured for one or more facilities or activities subject to the regulations in this part.
Electronic Position Controller units, NLI Model NLI-1OA-LM-P that have been manufactured and supplied are identified below.
Plant Name Purchase Serial Number
_________order Callaway 568677 SR NLI-1OA-LM-P-1003-0, N LI-1OA-LM-P-1004-0, NLI-1OA-LM-P-1005-O, NLI-10A-LM-P-1I006-0, NLI-1OA-LM-P-1007-0, NLI-1OA-LM-P-1008-0, NLI-1OA-LM-P-1009-0 and NLI-1OA-LM-P-1010-0 original version units)
AZZ Nuclear I NLJ 7410 Pebble Drive Fort Worth, TX 76118 I Phone: 800.448.4124 I Fax: 817.590.0484 I azznuclear.com/nli
10105/2015 16:46 100105F64 AX)
P.0041004 (vii) The corrective action which has been, Is being, or will be taken; the name of the individual or organization responsible for the action; and the length of time that has been or wili be taken to. complete the action.
Three of units that initially failed in the plant have already been returned to NJLI for failure analysis and design modifications. These units were modified by installing a larger bridge rectifier and wire wound resistor onto the revision 0 circuit board. The modified versions, quantity of three, S/N: NLI-1OA-LM-P-1003-0, NLI-1OA-LM-P-1004-0 and NLI-1OA-LM-P-1006-O have been returned to Calloway under purchase orders 689233 SR and 694253 SR and have been accepted and installed into the plant and are working with no reported issues.
The model number NLI-1OA-LM-P, has been redesigned with a larger bridge rectifier of a higher rating and wire wound resistor that will withstand the applied current in the intended application.
The parent circuit boardl has also been revised to revision 1 to accept the larger bridge rectifier without impacting other components on the board.
The remaining unmodified revision 0 units that were originally supplied have not yet been returned to NL-I for incorporation of the design modification.
NLI recommends that at the plant's earliest convenience, the remaining units be returned to NLI to be retrofitted with the latest design configuration (revision 1 circuit board).
(viII) Any advice related to the defect or failure to comply about the facility, activity, or basic component that has been, is being, or will he given to purchasers or licensees.
The unmodified units should not be installed into the intended application. The units should be returned to NLI to have the units retrofitted with the latest configuration.
Tracy Bo t Director of Quality Assurance AZ? Nuclear NI!
7410 Pebble Drive I Fort Wortlh, TX 76118 I Phone: 800.448.4124 I Fax: 817.590.0484 J azznuclear, coi/nli