ML25073A045
| ML25073A045 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley, Millstone, Hatch, Dresden, Davis Besse, Oconee, Mcguire, Nine Mile Point, Palisades, Catawba, Harris, Point Beach, Watts Bar, Grand Gulf, Sequoyah, Byron, Pilgrim, Arkansas Nuclear, Braidwood, Prairie Island, Columbia, Seabrook, Surry, North Anna, Turkey Point, River Bend, Ginna, Diablo Canyon, Vogtle, Waterford, Farley, Robinson, Cook, Quad Cities, FitzPatrick, McGuire, Crane  |
| Issue date: | 03/13/2025 |
| From: | Salsbury E Ametek, Solidstate Controls |
| To: | Office of Nuclear Reactor Regulation, Document Control Desk |
| References | |
| EN 57402 | |
| Download: ML25073A045 (1) | |
Text
02-190147 Rev. A Page 1 of 11 SOLIDSTATE CONTROLS 875
Dearborn Drive,
Columbus, OH 43085 U.S.A.
Telephone: 614-846-7500 E-mail: ethan.salsbury@ametek.com March 13, 2025 U.S. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555-0001 Attention:
Document Control Desk
Subject:
Notification of Potential Defect - 10CFR Part 21 Product:
AMETEK Charger Control Board, X302, 80-9214031-90 AMETEK Solidstate Controls Inc. is submitting the following revised Report of a Potential Defect in accordance with the requirements of 10CFR Part 21. The potential defect was discovered September 23, 2024, and investigations have been ongoing. Duke Energy Carolinas, LLC.
submitted an interim report on October 28, 2024, reference EN 57402. This revision includes items that were initially omitted unintendedly. There is no change to the affected users, purchase orders, findings, or resolution. Only the Component Description section was revised to include additional variations of the charger control board variations.
Please contact me if you require any further information.
Sincerely, Ethan Salsbury Director of Quality Ametek Solidstate Controls
.\\METEK
02-190147 Rev. A Page 2 of 11 COMPONENT DESCRIPTION:
AMETEK Solidstate Controls part number 80-9214031-90 is a charger control printed circuit board with a locator ID of X302. During evaluation, AMETEK identified two failed capacitors in two separate cases. The details of the failed capacitors are provided below.
Capacitor C35 o AMETEK part number:
03-010003-00 o Manufacturer:
Sprague o Manufacturer Part Number: TE1202 o
Description:
CAP,ELC,5UF,25V Capacitor C36 o AMETEK part number:
03-011006-00 o Manufacturer:
Sprague o Manufacturer Part Number: 199D4769090E6V1 o
Description:
CAP,ELC,47UF,20V,TAN,20%
The capacitors are installed in charger control board, part number 80-9214031-90, which can be modified to create a variation of the charger control board, listed below.
Charger Board Variation Description 80-9214041-90 PCB ASSY CHGR 6SCR 24VDC 80-9214039-90 PCB ASSY CHGR 6SCR 48VDC 80-9214056-90 PCB ASSY, BAT CHG, 3/6 SCR, 130VDC 80-9214055-90 PCB ASSY, BATCHG, 12 SCR 80-9214036-90 PCB ASSY,BAT CHG,12 SCR 80-9214035-90 PCB ASSY,BAT CHG,12 SCR 80-9214051-90 PCB ASSY,BAT CHG,12 SCR,130VDC,MASTER 80-9214057-90 PCB ASSY,BAT CHG,12 SCR,130VDC,MASTER 80-9214052-90 PCB ASSY,BAT CHG,12 SCR,130VDC,SLAVE 80-9214058-90 PCB ASSY,BAT CHG,12 SCR,130VDC,SLAVE 80-9214038-90 PCB ASSY,BAT CHG,6 SCR,130VDC 80-9214032-90 PCB ASSY,BAT CHG,6 SCR,260VDC 80-9214037-90 PCB ASSY,BAT CHG,6 SCR,260VDC 80-9214029-90 PCB ASSY,BAT CHG,12 SCR 80-9214030-90 PCB ASSY,BAT CHG,12 SCR The list provided in the appendix section includes AMETEK job numbers from the previous 10 years which included the charger control board, either as a spare part replacement or installed in new equipment.
PROBLEM YOU COULD SEE:
Three failures were reported by Duke Energy between August 21, 2024 and September 17, 2024. One failure showed signs of intermittent operation. This charger control board returned from Duke McGuire, PCB serial number R301857005 from equipment serial number C69374, is documented in AMETEK FAR 24-005. This C35 capacitor had failed after approximately 5 years of operation.
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02-190147 Rev. A Page 3 of 11 The second charger control board was replaced after approximately 8 years in operation when the DC output voltage was fluctuating on charger C43185 at Duke Catawba. FAR 24-006 captures this condition with PCB serial number R9182003. The failure is attributed to a premature failure of the C36 capacitor.
The third board, serial number R301857002, did not demonstrate failures experienced by the customer during the evaluation and the board performed as expected. This board was also returned from Duke Catawba. Since AMETEK was unable to recreate the issue, the failure mode could not be determined.
In the repeatable instances, the capacitors were observed to fail prematurely, resulting in an inability to maintain voltage output (C36 capacitor failure) of the charger and loss of output/inability to turn on (C35 capacitor failure).
EFFECT ON SYSTEM PERFORMANCE:
With these failures, the charger can see fluctuations in voltage and loss of charging ability during normal operation. C35 failures will create noticeable fluctuations on the panel voltage meter and could prevent startup. A C36 failure will prevent the charger from reaching full voltage and will not meet the charging requirements of the battery. A low voltage alarm will indicate a failure at specified voltage output ranges of the charger. This is specific to the charger settings.
CAUSE:
Capacitor C35 experienced an end-of-life failure. The capacitor case opened, allowing electrolyte to escape, degrading the capacitors performance. Upon arrival at AMETEK Solidstate Controls, the C35 capacitor showed no signs of capacitance. The capacitor was sent to the manufacturer (Vishay) for further evaluation (reference CAR S-51-5-1). The manufacturer was not able to identify any similar failures with this part within the quality records from prior years.
The charger control board is on a 10-year replacement schedule. Based on aging analysis reports and the limited instances of failures identified with this component in this nature, there is not concern of a reduced lifespan in the application.
Capacitor C36 failed due to a hole in the manganese dioxide layer, resulting in high leakage according to the failure analysis conducted by the manufacturer (Vishay, reference CAR IL24007). This appears to be a manufacturing defect. This failure also appears to be an isolated incident as AMETEK does not see widespread failures of this component.
ACTION REQUIRED:
AMETEK does not see either failure as a widespread or systemic issue. Both cases could be assignable to common cause variation in the manufacturing process and outliers in the lifespan.
Potential mitigating actions to avoid similar issues include:
Inspect C35 capacitors for brown discoloration, indicating leakage of electrolyte Replace boards at regularly scheduled intervals Monitor output voltage of the charger, specifically evaluating fluctuations and/or low voltage (e.g. below battery voltage)
Ensure printed circuit boards with electrolytic capacitors do not exceed the two-year shelf life.
AMETEK SOLIDSTATE CONTROLS CORRECTIVE ACTION:
Considering the rarity of these failures and the apparent cause being isolated incidents, AMETEK does not see an immediate design or component change as a warranted action.
.\\METEK
02-190147 Rev. A Page 4 of 11 AMETEK will be conducting further design evaluations on PCB 80-9214031-90 and considering design and/or component changes that will further enhance the reliability of the charger control board. This is expected to extend through June 2025 with a new charger board available after September of 2025.
.\\METEK
02-190147 Rev. A Page 5 of 11 APPENDIX - AMETEK Jobs with Charger Control Boards The list below includes all job numbers since 2014 that include the charger control board in the equipment or as a spare part. Jobs beyond this timeframe would be outside of the 10-year replacement schedule. 960-prefix job numbers also correspond to the prefix of the equipment serial number. 46-prefix numbers correspond to spare part orders.
Owner Site Job Number PO Number ALABAMA POWER COMPANY FARLEY NUCLEAR PLANT 46003377 SNA31574-0313 46003453 SNA31574-0326 46004902 SNA31574-0433 46005204 SNA31574-0459 AMETEK CTS GMBH STERNENHOFSTRASSE 15 46002768 PO-CH312467 BEIJING CHUANDE SUN MECHANICAL UNAVAILABLE 46003639 CHD20210407-SCI-2 46003918 CHDSCI202211020 46004017 CHDSCI20220117 46004078 CHD20190523-SCI 46004493 CHD20230403-SCI CHINA NUCLEAR UNAVAILABLE 46002744 PO-CH312467 46002767 PO-CH312467 46002769 PO-CH312467 CONSTELLATION ENERGY BRAIDWOOD 46002234 00623517 REV 001 46002506 00664653 REV 001 46003738 822696 46004065 1342214 46004589 1396585 BYRON 46003548 807620 46004434 01386643 REV. 001 46004543 01394958 REV. 001 46004912 01433566 REV. 004 96000075-1 542478 96000075-13 542478 96000075-16 542478 DRESDEN STATION 46004977 01453174 REV. 003 46000995 00519913 REV 001 46001096 525376 46001328 544449 46004018 01343933 REV 002 46004988 01451816 REV 003 EXELON NUCLEAR -
THREE MILE ISLAND 46002192 00624114 REV 001 FITZPATRICK 96000151-1 00703581 / CONTRACT #
00703580
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02-190147 Rev. A Page 6 of 11 Owner Site Job Number PO Number 96000151-3 00703581 / CONTRACT #
00703580 GINNA NUCLEAR PLANT 46001297 00542360 REV 001 46003252 00725166 REV. 001 46003886 1336197 NINE MILE POINT 46000944 7735939 46001193 532715 46001251 00538275 REV 001 46001598 00564024 REV. 002 46003712 816974 46003838 1331325 46004470 01386397 REV. 001 46004603 01398303 REV 001 46004898 01436061 REV 001 QUAD CITIES 96000169-1 806177 96000169-3 806177 UNAVAILABLE 46001330 00544170 REV 002 46001462 00550335 REV 002 DOMINION MILLSTONE POWER STATION 46001640 4500271012 46001675 4500277156 46002099 4500372847 46002225 4500406038 46005340 4500951237 REV 001 96000166-1 70375163 96000166-11 70375163 96000166-3 70375163 96000166-4 70375163 NORTH ANNA 46002963 70352307 46003250 4500598907 46004311 4500810353 REV 1 96000149-1 70351611 SURRY POWER STATION 46001368 4500213884 46001476 4500232076 46001525 4500243562 46001551 4500251471 46003850 4500711808 46004035 4500744839 46005194 4500937728 REV 1 DUKE ENERGY CATAWBA NUCLEAR 46001937 3034660 46002034 03041345 REV 001 46002337 03059504 REV. 001 46002340 3059268
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02-190147 Rev. A Page 7 of 11 Owner Site Job Number PO Number 46002384 03067022 REV. 004 46002742 3079463 46004028 3138955 46005212 3187309 46005294 3190444 H.B. ROBINSON PLANT 46002021 03040504 REV 001 HARRIS NUCLEAR PLANT 46003151 03106503 REV. 001 46004114 03142492 REV. 001 MCGUIRE NUCLEAR STATION 46000945 179364 46001556 3006705 46002258 3054819 46002386 3064507 46004733 3169093 46005288 03172055 REV. 002 46005301 3190750 OCONEE NUCLEAR STATION 46001011 181126 46001167 00190159 REV. 002 46001439 3000213 46002808 3076169 46003051 03103593 REV. 001 46004031 03139080 REV. 001 46005232 03188200 REV 002 ROBINSON NUCLEAR PLANT 46003176 03107594 REV. 001 UNAVAILABLE 46002895 3097443 ELECTRONUCLEAR UNAVAILABLE 46000999 4500169804 46001480 4500182470 46003921 4500045399 ELETROBRAS TERMONUCLEAR ELETRONUCLEAR 46002856 4500014326 UNAVAILABLE 46004637 4500067052 ENERGY HARBOR BEAVER VALLEY 46001250 45463437 REV. 001 46001255 45462004 46001302 45467183 46001350 45470158 REV. 1 46001718 45487072 46001988 45506321 46002209 45518276 46002312 45526656 46002683 45548538 46003913 45665891 46004052 45669397
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02-190147 Rev. A Page 8 of 11 Owner Site Job Number PO Number 46004058 45669675 46004082 45670958 46004094 45671611 46004158 55141197 46004583 45686562 REV 1 46005226 45696203 46005411 45698341 REV 1 DAVIS BESSEE NUCLEAR POWER 46001806 45497222 46002720 45547187 46004385 45681660 46004698 45688690 52002691 45562767 ENERGY NORTHWEST COLUMBIA GENERATING STATION 46005374 00365532 REV 001 46003338 356788 46004751 00363066 REV 2 46005225 00363947 REV 001 96000178-1 PO 00359222 / CONTRACT 359223 96000178-3 PO 00359222 / CONTRACT 359223 ENTERGY ARKANSAS NUCLEAR ONE 46001028 10406654 REV 001 46002003 10502024 46002069 10508415 46002639 10570331 REV 001 46003085 10599747 46003127 10602234 46003535 10632253 BEAVER VALLEY 46002580 45542082 GRAND GULF NUCLEAR 46002319 10534064 REV. 002 PALISADES NUCLEAR PLANT 46003246 10608305 PILGRIM NUCLEAR POWER STATION 46001527 10456449 RIVER BEND 46002901 10589321 46003396 10620711 46003430 10623935 46003713 10642084 WATERFORD 3 NUCLEAR 46003538 10629046 96000100-1 10475893 96000130-1 10511769 UNAVAILABLE 46002846 10587780
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02-190147 Rev. A Page 9 of 11 Owner Site Job Number PO Number GEORGIA POWER CO HATCH NUCLEAR PLANT 46003416 SNG10240812 VOGTLE 1 AND 2 ELEC GENERATING PLANT 46003080 SNG10220964 46004847 SNG31574-0428 46003436 SNG31574-0323 UNAVAILABLE 46004882 SNG31574-0435 REV 1 46004961 SNG31574-0441 REV 5 46005274 SNG10346696 52003312 SNG10297872 52003726 SNG10340499 INDIANA MICHIGAN POWER CO DC COOK 46003048 1598354 46003162 1598781 46003679 1602726 UNAVAILABLE 46003113 1598628 KHNP UNAVAILABLE 46003031 563764 46001072 RMA C88013 46001657 K150432631 46001869 K160440591 MJT INC KHNP 46005055 K240097051 NEXTERA ENERGY SEABROOK STATION 46003197 2408952 46003301 2413582 46003846 CONTRACT 02430613 / PO 02431350 46004243 2445454 46005148 02470765 REV 001 96000189-1 2453687 96000189-17 2453687 TURKEY POINT 46001421 2337821 46001638 2346823 46003653 2419331 46004395 02451619 REV 1 96000187-3 2449022 NEXTERA ENERGY POINT BEACH 46003269 02411945 REV. 002 46003499 2420260 96000185-1 2447219 96000185-3 2447219 NPP KRSKO VRBINA 12 46002993 3190403/913 UNAVAILABLE 46003285 3200463/913 46004784 3231326/913 46001204 3141685/913,REV.0 46004820 3231838/913 96000067-1 3140571/913
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02-190147 Rev. A Page 10 of 11 Owner Site Job Number PO Number 96000067-3 3140571/913 96000067-6 3140571/913 PACIFIC GAS &
ELECTRIC DIABLO 46004016 3501284379 46004070 3501289141 46004242 3501306085 46004809 3501348070 REV 2 46005243 3501378513 UNAVAILABLE 46001101 3501009294 46001202 3501024017 REV 1 46001408 3501046038 46003341 3501233228 46003503 3501247083 46004389 3501318864 STP NUCLEAR UNAVAILABLE 46000979 171506 46001085 175371 REV 001 46001116 176685 REV 001 46001152 178499 46003572 252909 46003951 261075 46004116 265082 46004507 275684 46005439 293409 TVA KENTUCKY HYDRO PLANT 46004602 7449561 REV 1 SEQUOYAH NUCLEAR PLANT 46004677 7504684 46004978 7603646 REV 1 46005002 7611854 REV 1 46002019 2758244 REV 1 46002962 5716603 46003211 6132093 REV 1 46003513 6644298 REV. 1 46003553 6700783 REV. 1 46003805 6710757 96000164-10 6245126 96000164-11 6245126 96000164-13 6245126 TVA SPRING CITY 46001936 2465931 REV. NUM. 1 WATTS BAR NUCLEAR PLANT UNIT 1 46002678 4850297 46002706 4920007 REV 1 46002951 5679332 46002367 3538599 REV 1 46002956 5601172
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02-190147 Rev. A Page 11 of 11 Owner Site Job Number PO Number 46003575 6719867 REV. 3 46005454 7713908 VISTRA ENERGY COMANCHE PEAK 46003599 1072497 46003945 1138637 46003955 1146461 46004111 1183108 46004394 1756857 46005056 2471748 46001291 B 0207303 123 46001756 343184 46002454 522832 46002482 526151 46003745 1114824 REV 1 46004090 1178113 46004161 1194861 46004452 1971507 46004572 2242661 XCEL ENERGY PRAIRIE ISLAND NUCLEAR 46003243 4000015358 REV. 1 46004112 4000024637 46004427 4000028917
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