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NRC: Part 21 Report: 2003-004-01
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SCIENTECH M. R. Booska, Director, Quality Operations
2310 Potomac Camp Road, Oakland MD, 21550
Phone 301-334-23S2
Fax 301-334-2353 (Call above Number to ensure
Science and Technology for a Safer World proper fax connection)
Fax No.: 21-03-01-02
Total Pages 9 (1ncluding this page)
COMMENTS: Follow-up Report, Reference Event #39516
This is the follow-up fax report to the USNRC of a potential defect under the provisions of 10 CFR Part 21. The preliminary report was filed on JanUary 16, 2003. Potentially affected clients are being provided a copy ofthis report as indicated below. The following Fax addressees are requested to foward this information to the appropriate internal organizations where shown in the attached list.
Analysis and Measurement Services, QA Manager, Dan Beverly, Fax # 865-691-9344
Carolina Power and Light (Progrcss Energy) Buyer, Fax # 919-546-6750
Constellation - Nine Mile Point, Procurement QA Supervisor Fax # 315-349-7957
Dominion - Millstone, Manager - Nuclear Safety Engineering, Fax # 860-437-5802 Procur~rnent
Entergy - James A. Fitzpatrick, Attn. Dan Doherty - Purchasing. Fax # 315-349-6059
Entergy- Indian Point 2 & 3, Purchasing, Fax # 914-736-8138
Entergy - Pilgrim, Purchasing Fax # 508-830-8880
First Energy - Beaver Valley Power Station, Purchasing, Fax # 724-682-7850
Public Service Elcetric and Gas, Procurernent Assessment Manager, Fax # 856-339-7707
Rochester Gas and Electric, Quality Assurance Manager, Purchasing Fax # 585-771-3907
NMC Kewaunee Site Procurement Engineering Organization, Buyer Fax ~ 920-388-8772
440 West Broadway, Idaho Folk, Idaho 83402-3638 Main Phone 208-524-9200, Fax 208-524-9282
Subject: Determination of Defect under 1OCFR Part 21
Reference: Event # 39516
The NRC Operations Center was sent a preliminary notification by facsimile on January 16, 2003, indicating that SCIENTECH, Inc.'s subsidiary, NUS Instruments, Inc. (NUSI) had determined that a Basic Component, supplied in one safety related CMM9OO module to Constellation-Nine Mile Point (P.O. #00-31440) contained a defect that was reportable under 1OCFR21 (Two other modules supplied to Entergy-Fitzpatrick listed in prellirinary notification were later discovered to be non-safety related). Additionally, NUSI determined that other clients had been supplied assemblies containing components that may contain similar defects. NUSI has notified all affected clients as stated in the preliminary report.
The NUSI evaluation determined that there was not a significant safety hazard to the functionality of the modules, however; the utilities were given the affected module ID numbers to determine the safety hazard specific to their application. Client feedback has indicated that there is not a
significant safety hazard due to this defect, however it is utility specific.
Enclosed please find SCIENTECH Inc.'s subsidiary NUS Instruments, Inc. ~USI) fonnal report as a follow up to the preliminary notice.
If you have questions or comments, please feel flee to contact us at the munbers listed below.
(407) 333-8895 (ploch@scientech.com)
Martin R. Booska
(301) 334-2352 (mbooska@scientech.com)
10 CFR PART 21 REPORTING FORM
FOR REPORTING OF DEFECTS AND NONCOMPLIANCE
NOTIFICATION 1121-03-01 EVENT # 39516
NAME AND ADDRESS OF REPORTING INDIVIDUAL(S) OR ORGANIZATIONS.
Paul Loch, President SCIENTECH, Inc.
Longwood, FL 32779-2757 E-mail: ploch@scientech.com
FACILITY, COMPONENT AND/OR PRODUCT THAT IS NONCOMPLIANT.
The facility is Constellation - Nine Mile Point (Formerly Niagara Mohawk).
The component is a CMM9OO module, P/N: NUS-AOO4PA-l, Revision 0, containing Texas Instruments operational amplifier, P/N: OPA2111.
SUPPLYING FIRM IDENTIFICATION (NAME, ADDRESS).
NATURE OF THE DEFECT, ASSOCIATED SAFETY HAZARD, AND THE DATE THIS
Three modules containing Texas Instruments (TI) OPA2111 operational amplifiers were returned to NUSI after suffering premature failures in the field. The components were supplied in two non-safety related CMM9OO modules to Entergy-Fitzpatnck (P.O. #4500510231) and one safety related CMM9OO module to Constellation-Nine Mile Point (P.O. #00-31440). The components were sent to TI for failure analysis and TI concluded that a manufacturing process defect existed in the amplifier that could result in a premature failure. After NUSI Engineering performed an analysis of the TI information and determined that the condition was potentially reportable for the safety related module, a 10 CFR Part 21 file was logged and numbered 21-03-01 on January 9.
Based on information received from Texas Instruments regarding the operational amplifier manufacturing process problems, the date codes of the potentially defective amplifiers are between January of 2000 and October of 2002. Based on detailed evaluations, NUSI and Texas Instruments have determined that the components are unlikely to fail if they have been in operation beyond two weeks. After two weeks the failure rate is no greater than that of a random failure. Since the one Safety related module supplied to Constellation-Nine Mile Point had been in operation for over seven weeks, it is considered to be in a random failure category and therefore, does not create a substantial safety hazard. No other failures of safety related class lE modules containing the potentially defective amplifier have been reported to NUSI.
Three other components (part numbers OPAl11 0PA404, and 3656) have been identified by Texas Instruments as utilizing the same manufacturing process as the OPA2I 11 component.
However, NUSI clients have not reported any failures of modules containing those amplifier part numbers.
NUSI's detailed evaluation determined that because the failure ofthe safety related CMM9OO module supplied to Corstellation-Nine Mile Point was a random failure (module had been in operation for over seven weeks) there was not a significant safety hazard to the flinctionality of the modules. However the utilities that had been supplied IE modules containing the potentially defective amplifiers were given the affected module ID numbers to enable them to determine the safety hazard specific to their application. Client feedback as of this date has indicated that there is not a significant safety hazard due to this defect.
THE NUMBER AND LOCATION OF ALL SUCH COMPONENTS IN USE AT, SUPPLIED FOR, OR BEING SUPPLIED TO ONE OR MORE FACILITIES SUBJECT
TO 10CFR21.
NUSI determined that there were approxunately 300 modules at 9 utilities that have the one of the three above listed amphfiers installed. A list of affected IE modules was faxed to the applicable points of contact at each of the utilities.
CORRECTIVE ACTION, WIIICH HAS BEEN, IS BEING, OR SHOULD BE TAKEN, INCLUDING RESPONSIBLE PARTIES AND AN ESTIMATE OF T~IE INVOLVED.
The suspect components located within NUSI that contain the January of 2000 through October of 2002 date codes have been tagged with a conditional release. If the components are installed, the assembly will have a mandatory two-week burn-in to induce any failures that may be premature. For induced failures, the component will be replaced with one previously tested by the supplier, or with a component from a known good lot.
TI has performed an over voltage stress test (OVST on 350 of the OPA2111 components with the January 2000 through October 2002 date codes and will continue to provide OVST components from this lot as they become available. This testing is equivalent to a two-week burn-in and will be installed by NUSI as available until inventory can be replaced with known good date codes.
Clients have been advised that applicable IE modules that have not been installed longer than two weeks may be returned to NUSI for an additional two-week burn-in or the utillty may elect to perform the bench burn-in on site.
Technical Bulletin, Volume 04, was issued January 21, 2003 to all IE affected clients to the attenhon of the technical point of contact to provide awareness of the component issue and details of client actions to be taken.
A statement will be added to all ftiture purchase orders to TI and TI suppliers, indicating that components, OPA21 11, 0PA404, OPAl 11, and 3656 tliat were manufactured between January of 2000 and October of 2002 are not to be scnt to NUSI. This will be validated at the receipt inspection process.
See attached Technical Bulletin supplied to utih.ties.
POTENTIALLY AFFECTED CLIENTS FOR 1OCFR PART 21 RFPORTABILITY
#21-03-01
Contact: QA Manager, Dan Beverly
Fax #865-691-9344
Carolina Power and Light (Progress Energy)
Manager - Nuclear Licensing Departiuent Manager
Box 1551 Brunswick Nuclear Projuct
Raleigh, North Carolina 27602 NC Highway 87, Box 10429
Dcpartment Manager Deparanent Manager
harris Nuclear Proj eel Robinson Nuclear Project
State Road 1134, Box 165 SC HWY. 151 & 23, Box 790
New Hill, North Carolina 27562 Hartsville, South Carolina 29550
Fax #919-546-6750 (Buyer Fax#)
Crystal River 3 Nuclear Project
15760 WPower Line St
Crysta1 River. Florida 34228
Constellation - Nine Mile Point (Formerly Niagara Mohawk)
Procurement Quality Assurance Supervisor
PO flox 63
Fax # (315-349-7957 Procurement)
Dominion - Millstone
P0 Box 128
Attn: Manager -Nuclear Safety Engineering, (860-437-5802 Procurement Fax #)
Entergy - James A. Fitzpatrick
Attn. Dan Doherty-Purchasing. (Fax # 315-349-6059 Purchasing)
Entergy - Indian Point 2 & 3
Buclaanan,NY 10511
IP3 Fax #914-736-8138 (Purchasing)
POTENTIALLY AFFECTED CLIENTS FOR lOCER PART 21 REPORTABIUTY
Entergy - Pilgrim
Fax 508-830-8880 (Purchasing)
Fax # 724-682-7850 (Purchasing)
Please Foward to Manager of Nuclear Services and Manager of Licensing
Procurement Assessment Manager', Fax #856-339-7707
Mail Code W04
Fax # 585-771-3907 (Purchasing)
NMC (Formerly Wisconsin Public Service Corporation)
Sites Procureinent Engineering Organization
NMC Kewaunee
North 490, Hwy 42
Fax #920-388-8772 (Buyer)
See PDF file to view the Attachment to Final Report 21-03-01 Event # 39516