Protecting People and the EnvironmentUNITED STATES NUCLEAR REGULATORY COMMISSION
UNITED STATES
NUCLEAR REGULATORY COMMISSION
OFFICE OF NUCLEAR REACTOR REGULATION
WASHINGTON, D.C. 20555
September 5, 1990
Information Notice No. 90-57: SUBSTANDARD, REFURBISHED POTTER &
BRUMFIELD RELAYS MISREPRESENTED AS NEW
Addressees:
All holders of operating licenses or construction permits for nuclear power
reactors.
Purpose:
This information notice is intended to alert addressees to the discovery of
rotary, non-latching type relays, originally manufactured by Potter &
Brumfield (P&B) of Princeton, Indiana, that have been apparently modified
and/or refurbished and that have been found to be materially and
functionally substandard, such that they may not operate as required. The
affected relays include, but may not be limited to, P&B types MDR-138-8,
MDR-173-1, MDR-134-1, and MDR-142-1. It is expected that recipients will
review this information for applicability to their facilities. However,
suggestions contained in this information notice do not constitute NRC
requirements; therefore, no specific action or written response is required.
Description of Circumstances:
Carolina Power and Light Company's (CP&L's) Shearon Harris Nuclear Power
Plant recently received a shipment of 22 P&B MDR-type relays. Although
these were purchased from Spectronics, Inc., of Mobile, Alabama, an
authorized distributor of P&B relays, the shipment was received directly
from their supplier, Stokley Enterprises of Norfolk, Virginia. CP&L
purchased the relays as commercial-grade items to be dedicated for use in
the emergency diesel generator safety bus sequencer system at Shearon
Harris. CP&L expected Spectronics to supply new relays from P&B, although
the purchase order did not so state. CP&L was alerted to potential quality
problems when the relays were received much sooner than the normal 10 to 12
weeks from P&B. Discrepancies were identified by CP&L during receiving
inspection, during subsequent examination at Shearon Harris by NRC staff and
a P&B technical representative, and later during inspection and testing at
the P&B factory, observed by NRC staff. The relays were improperly
adjusted, lacked lubrication, and all failed one or more of the P&B tests.
They contained assortments of nonstandard and/or substandard parts and
obsolete parts used by P&B or its predecessor, Magnetic Devices, Inc. The
parts were assembled in incorrect, non-original configurations. These
conditions, indicative of refurbishment, are listed in Attachment 1 to this
information notice.
Discussion:
Through a continuing series of inspections at licensee and vendor
facilities, the NRC staff has learned that Spectronics, Inc., has supplied
apparently
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IN 90-57
September 5, 1990
Page 2 of 2
modified and/or refurbished P&B MDR-type relays that are materially and
functionally substandard directly and/or indirectly to (1) at least three
nuclear plants, including Shearon Harris, Watts Bar, and Sequoyah; (2)
various vendors to nuclear plants; (3) at least one dedicator of
commercial-grade components for nuclear plants, Nutherm International (Mount
Vernon, Illinois); and (4) possibly one or more electrical equipment
fabricators for installation in relay and switchgear panels for nuclear
plants. These apparently modified and/or refurbished P&B-type relays were
obtained directly or indirectly from either Stokley Enterprises or The
Martin Company of Chesapeake, Virginia. Stokley Enterprises and The Martin
Company may have supplied such P&B-type relays, and various other types of
modified and/or refurbished electrical components from other manufacturers,
to distributors of electrical equipment who deal directly or indirectly with
nuclear utilities.
This information notice requires no specific action or written response. If
you have any questions about the information in this notice, please contact
one of the technical contacts listed below or the appropriate NRC regional
office.
Charles E. Rossi, Director
Division of Operational Events Assessment
Office of Nuclear Reactor Regulation
Technical Contacts: K. R. Naidu, NRR (301) 492-0980
S. D. Alexander, NRR (301) 492-0995
Attachments:
1. Conditions Indicative of Substandard/Refurbished Relays
2. List of Recently Issued Information Notices
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Attachment 1
IN 90-57
September 5, 1990
Page 1 of 1
CONDITIONS INDICATIVE OF SUBSTANDARD/REFURBISHED RELAYS
The following conditions, observed with P&B MDR-type relays supplied by
Stokley Enterprises and/or The Martin Company through Spectronics, Inc.,
and/or Nutherm International, may be observed on similar relays supplied
through various other distributors and dealers and are indicative of
substandard refurbishment:
1. Non-standard reddish-brown paint used to stake the nuts securing the
motor and rotor assemblies (paint may be wet and adhering to the
carton)
2. Sloppy coil lead solder joints at terminal strips with possible wicking
3. Painted relay base grommets (normally clear plastic) for coil leads
4. Terminal strips fastened with eyelets (discontinued in 1967) instead of
rivets currently used by P&B
5. Grey painted rivets fastening the terminal strip to the relay housing
where original P&B relays have unpainted rivets
6. Field termination screws (supplied with the relays) shipped in brown
paper bags instead of heat-sealed, plastic bags
7. Cartons differing from original P&B cartons in color and labelling and
relays packed with bubble wrap instead of wrapped in a plastic bag and
packed in styrofoam as done by P&B
8. Apparently silk-screened nameplates, clearly different from original
9. Repainted inner bell-surface and relay base marks indicating prior use
10. Date codes and inspection and testing stamps missing or inconsistent
with relay type (as determined by comparison with P&B production
records), indicating interchanged relay caps
11. Cap nuts (discontinued in 1977) on rotor and motor assembly bolts,
instead of currently used hex nuts, that are not torqued to P&B
specifications
12. Incorrect shaft-relay cover clearance, incorrect rotor shaft end play,
and lack of bearing lubricant
13. Coil lead insulation color inconsistent with that of current P&B
relays
14. Orange paint (not used by P&B after 1972) on tops of rotor shafts
15. Slots on tops of rotor shafts not painted black as currently required
16. Nonuniform numbers stamped on the contact decks, indicating decks made
up from various relays
17. High potential test failure on coils and between contacts and contact
sections
18. Functional test failure - actuation above P&B-specified "maximum
operate" [pick-up] voltage and/or drop-out below minimum drop-out
voltage
19. Widely varying coil winding resistance among relays, indicating
manufacture during various periods of time
20. Incorrect coil - one 125-VDC relay found with 200-VDC coil. Coil had
twice the specified winding resistance and relay actuated at high,
out-of-specification operate voltage.
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