ML15280A352

Callaway Plant, Part 21 Report Electronic Position Controller Failed Internal

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 RenortPart 2l (PAR) Event # 51454Rep 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: YesCounty: License #:State: TXNRC Notified by: TRACY BOLT Notifications:

NICK TAYLOR R4DOHQ Ops Officer:

JEFF HERRERA PART 21/50.55 REACTORS EMAILEmergency 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 NLIModel: NLI-10OA-LM-P.

'The failed component within the controller was sized based on the original published ratings of the originalcomponents installed.

The unit had an internal component that was subjected to a current value that was higherthan the rating for the component.

The actual applied current value was not originally provided to NLI when theunits 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 areidentified beo.Affected Plant is Callaway.

10/0512015 16:46100105 54 AX) P.0011004 NU C:LEARTo:Fax (301) 816 -5151Document Control DeskU.S. Nuclear Regulatory Commission Washington, DC 20555From:Tracy BoltDirector of Quality Assurance AZZINLI Nuclear Logistics, Inc.7410 Pebble DriveFort Worth, Texas 76118817-284-00.77 Pursuant to 1OCFR 21.21 (d)} (3) (ii), AZZINLI is providing in the following letter thewritten notification of the identification of a deviation.

Total Pages including this page: 4AZZ Nuclear I NLI7410 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 16:461005215184 WX P.0021004 GAZZDate: October 5, 2015 NUCLEARDocument Control DeskU.S. Nuclear Regulatory Commission Washington, DC 20555Part 21 Report No: P21-10052015

Subject:

Electronic Position Controller Model: NLI-1OA-LM-P Pursuant to 1OCFR 21.21 (d) (3) (ii), AZZINLI is providing written notification of theidentification 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 aSubstantial Safety Hazard or could have created a Technical Specification Safety Limitviolation as it relates to the subject plant application.

The following information is required per 1OCFR 21.21 (d) (4).(i) Name and address of the individual or Individuals informing theCommission.

Tracy Bolt, Director of Quality Assurance Nuclear Logistics, Inc.7410 Pebble DriveFt. Worth, TX 76118(ii) Identification of the facility,

activity, or the basic component supplied for suchfacility or such activity within the United States which fails to comply orcontains 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 obsoleteequipment_

AZZ Nuclear ] NLJ7410 Pebble Drive [ Fort Worch, TX 76118 I Phone: 800.448,4124 I Rax: 817.590.0484 1 azznuclear~com/nli 10/0512015 16:46100105 64 AX) P.0031004 (iv) Nature of defect or failure to comply and the safety NUCLEARhazard which is created or could be created by such defect or failure tocomply.The failed component within the controller was sized based on the originalpublished ratings of the original components installed.

The unit had an internalcomponent that was subjected to a current value that was higher than the ratingfor the component.

The actual applied current value was not originally providedto NLI when the units were being designed.

NLI and the affected plant has beenin communication regarding the component condition since the first reportedfailure.(v) The date on which the information of such defect or failure to comply wasobtained.

On September 29, 2015, enough information was gathered from the evaluations being performed to determine the reportability of the deviation that is the rootcause 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 beingsupplied 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 beenmanufactured 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 NLJ7410 Pebble Drive Fort Worth, TX 76118 I Phone: 800.448.4124 I Fax: 817.590.0484 I azznuclear.com/nli 10105/2015 16:46100105F64 AX) P.0041004 (vii) The corrective action which has been, Is being, or will be taken; the name ofthe individual or organization responsible for the action; and the length oftime 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 NJLIfor failure analysis and design modifications.

These units were modified byinstalling a larger bridge rectifier and wire wound resistor onto the revision 0circuit 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 toCalloway under purchase orders 689233 SR and 694253 SR and have beenaccepted 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 bridgerectifier of a higher rating and wire wound resistor that will withstand the appliedcurrent in the intended application.

The parent circuit boardl has also beenrevised to revision 1 to accept the larger bridge rectifier without impacting othercomponents on the board.The remaining unmodified revision 0 units that were originally supplied have notyet been returned to NL-I for incorporation of the design modification.

NLIrecommends that at the plant's earliest convenience, the remaining units bereturned to NLI to be retrofitted with the latest design configuration (revision 1circuit 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 topurchasers or licensees.

The unmodified units should not be installed into the intended application.

Theunits should be returned to NLI to have the units retrofitted with the latestconfiguration.

Tracy Bo tDirector 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 RenortPart 2l (PAR) Event # 51454Rep 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: YesCounty: License #:State: TXNRC Notified by: TRACY BOLT Notifications:

NICK TAYLOR R4DOHQ Ops Officer:

JEFF HERRERA PART 21/50.55 REACTORS EMAILEmergency 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 NLIModel: NLI-10OA-LM-P.

'The failed component within the controller was sized based on the original published ratings of the originalcomponents installed.

The unit had an internal component that was subjected to a current value that was higherthan the rating for the component.

The actual applied current value was not originally provided to NLI when theunits 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 areidentified beo.Affected Plant is Callaway.

10/0512015 16:46100105 54 AX) P.0011004 NU C:LEARTo:Fax (301) 816 -5151Document Control DeskU.S. Nuclear Regulatory Commission Washington, DC 20555From:Tracy BoltDirector of Quality Assurance AZZINLI Nuclear Logistics, Inc.7410 Pebble DriveFort Worth, Texas 76118817-284-00.77 Pursuant to 1OCFR 21.21 (d)} (3) (ii), AZZINLI is providing in the following letter thewritten notification of the identification of a deviation.

Total Pages including this page: 4AZZ Nuclear I NLI7410 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 16:461005215184 WX P.0021004 GAZZDate: October 5, 2015 NUCLEARDocument Control DeskU.S. Nuclear Regulatory Commission Washington, DC 20555Part 21 Report No: P21-10052015

Subject:

Electronic Position Controller Model: NLI-1OA-LM-P Pursuant to 1OCFR 21.21 (d) (3) (ii), AZZINLI is providing written notification of theidentification 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 aSubstantial Safety Hazard or could have created a Technical Specification Safety Limitviolation as it relates to the subject plant application.

The following information is required per 1OCFR 21.21 (d) (4).(i) Name and address of the individual or Individuals informing theCommission.

Tracy Bolt, Director of Quality Assurance Nuclear Logistics, Inc.7410 Pebble DriveFt. Worth, TX 76118(ii) Identification of the facility,

activity, or the basic component supplied for suchfacility or such activity within the United States which fails to comply orcontains 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 obsoleteequipment_

AZZ Nuclear ] NLJ7410 Pebble Drive [ Fort Worch, TX 76118 I Phone: 800.448,4124 I Rax: 817.590.0484 1 azznuclear~com/nli 10/0512015 16:46100105 64 AX) P.0031004 (iv) Nature of defect or failure to comply and the safety NUCLEARhazard which is created or could be created by such defect or failure tocomply.The failed component within the controller was sized based on the originalpublished ratings of the original components installed.

The unit had an internalcomponent that was subjected to a current value that was higher than the ratingfor the component.

The actual applied current value was not originally providedto NLI when the units were being designed.

NLI and the affected plant has beenin communication regarding the component condition since the first reportedfailure.(v) The date on which the information of such defect or failure to comply wasobtained.

On September 29, 2015, enough information was gathered from the evaluations being performed to determine the reportability of the deviation that is the rootcause 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 beingsupplied 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 beenmanufactured 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 NLJ7410 Pebble Drive Fort Worth, TX 76118 I Phone: 800.448.4124 I Fax: 817.590.0484 I azznuclear.com/nli 10105/2015 16:46100105F64 AX) P.0041004 (vii) The corrective action which has been, Is being, or will be taken; the name ofthe individual or organization responsible for the action; and the length oftime 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 NJLIfor failure analysis and design modifications.

These units were modified byinstalling a larger bridge rectifier and wire wound resistor onto the revision 0circuit 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 toCalloway under purchase orders 689233 SR and 694253 SR and have beenaccepted 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 bridgerectifier of a higher rating and wire wound resistor that will withstand the appliedcurrent in the intended application.

The parent circuit boardl has also beenrevised to revision 1 to accept the larger bridge rectifier without impacting othercomponents on the board.The remaining unmodified revision 0 units that were originally supplied have notyet been returned to NL-I for incorporation of the design modification.

NLIrecommends that at the plant's earliest convenience, the remaining units bereturned to NLI to be retrofitted with the latest design configuration (revision 1circuit 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 topurchasers or licensees.

The unmodified units should not be installed into the intended application.

Theunits should be returned to NLI to have the units retrofitted with the latestconfiguration.

Tracy Bo tDirector 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