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1 in84034.txt at Page 1 of 9 SSINS No.: 6835 UNITED STATES NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT WASHINGTON, D.C IE INFORMATION NOTICE NO : RESPIRATOR USER WARNING: DEFECTIVE SELF- CONTAINED BREATHING APPARATUS AIR CYLINDERS Addressees: All nuclear power reactor facilities holding an operating license (OL) or construction permit (CP), research and test reactor facilities, fuel cycle licensees, and Priority 1 material licensees. Purpose: This information notice is intended to alert licensees of a serious defect in self-contained breathing apparatus (SCBA) hoop-wrapped aluminum air cylinders rated at 4,500 psi, manufactured under the Department of Transportation (DOT) Exemption DOT-E During refilling operations at a fire department, one cylinder ruptured and injured one person. The National Institute of Occupational Safety and Health (NIOSH) has issued a Respiratory Users Notice, in concert with a DOT Federal Register Notice limiting filling/operating pressure of the affected cylinders to 4,000 psi until further notice. NRC regulations require that only NIOSH-certified respiratory equipment shall be used as emergency devices. Licensees are expected to review the information for applicability to their facilities respiratory protection program and take actions, as required, to maintain NIOSH and DOT certifications for affected equipment and to minimize the probability of catastrophic cylinder failure. Further NRC action may occur after the DOT/NIOSH evaluations are completed and reviewed by the staff. No written response to this notice is required. Description of Circumstances The NRC recently has learned of a serious defect in certain SCBA air

2 in84034.txt at Page 2 of 9 cylinders that caused a rupture of a high-pressure (4,500 psi) air cylinder (rated for 30-minute service) manufactured by Luxfer Limited in 1978 for Scott Aviation. On February 4, 1984, a Scott 4.5 cylinder ruptured at the neck area during a routine refilling at a New York City fire station. The air charging hose that was still attached to the ejected cylinder material, struck the attending fireman. Although not seriously injured, the fireman was severely bruised in the shoulder area, transported to a nearby hospital, and treated and released the same day. The fireman was fortunate that a flying metal fragment did not hit him. This cylinder was not subject to an earlier product recall discussed below. Page 2 of 3 On October 11, 1983, the NRC reported in IE Information Notice 83-68, "Respirator User Warning: Defective Self-Contained Breathing Apparatus Air Cylinders," that several identical Luxfer cylinders manufactured since mid 1982 for Scott and other vendors, had developed cracks around the neck area. Two of these cylinders had ruptured. A product recall directed at a specific manufacturing batch of these hoop-wrapped cylinders had been initiated at that time. Discussion: In response to the recent New York City event and other evidence of cylinder cracking, the DOT Office of Hazardous Material Regulation has amended the exemption to limit the filling pressure for all high pressure (4,500 psi) composite hoop-wrapped cylinders manufactured under Exemption DOT-E The Federal Register Notice (49 FR 39, p see Attachment 1), issued by DOT February 27, 1984, states that Persons owning, using, or otherwise having control over cylinders marked DOT-E , must limit the filling pressure to 4,000 psi, and reduce to 4,000 psi the pressure in cylinders already charged. (emphasis added) NIOSH issued a Respirator User Notice on February 29, 1984 (see Attachment 2), which establishes interim actions to be taken by all users in order to maintain a revised NIOSH certification for the units effective until further DOT action, at which time the certification may be reaffirmed, revised, or revoked. Under this temporarily revised certification (unit rated as a "not less than 25-minute" device), each user should

3 in84034.txt at Page 3 of 9 1. Refill and operate all Luxfer 4,500 psi, 30-minute, hoop-wrapped aluminum cylinders at the reduced pressure of 4,000 psi. 2. Follow the instructions provided by Luxfer for immediate removal from service and physical examination of affected cylinders manufactured before May General recommendations (p. 3 of Attachment 2), issued by NIOSH, offer users sound advice for further reducing the probability of cylinder catastrophic failure and, thereby, increasing worker safety. The interim actions, established by DOT and NIOSH, must be carefully observed to continue the NIOSH certification of the unit as a "not less than 25-minute" device. However, licensees also are reminded that Section III.H of 10 CFR 50, Appendix R (Fire Protection Program for Nuclear Power Facilities Operating Prior to January 1, 1979), requires a rated operating air supply of at least 30-minutes for all SCBA provided for use by fire brigade, damage control parties, and control room personnel. If any affected cylinders are fulfilling 10 CFR 50, Appendix R, requirements, then appropriate compensatory air supplies must be provided. Licensees may choose to request temporary exemption from the 30-minute-rated supply requirement in 10 CFR 50 by contacting their appropriate NRC licensing office. Page 3 of 3 To provide further information, copies of Scott Aviation and Survivair warning letters to their customers are attached (Attachments 3 and 4). If you have any questions concerning this problem, please call the number listed on the appropriate customer warning letter or contact the Regional Administrator of the appropriate NRC Regional Office or this office. Edward L. Jordan, Director Division of Emergency Preparedness and Engineering Response Office of Inspection and Enforcement Technical Contacts: J. E. Wigginton, IE (301)

4 in84034.txt at Page 4 of 9 L. Hendricks, RES (301) Attachments: 1. DOT Federal Register Notice 2. NIOSH Respirator Users Notice 3. Scott Aviation Letter 4. Survivair Letter 5. List of Recently Issued IE Information Notices DEPARTMENT OF HEALTH & HUMAN SERVICES Centers for Disease Control National Institute for Occupational Safety and Health--ALOSH 944 Chestnut Ridge Road Morgantown, WV February 29, 1984 RESPIRATOR USERS NOTICE Attachment 2 Reduced Service Pressure and Physical Examination of 4500 psi Hoop-wrapped Aluminum Cylinders Manufactured by Luxfer USA Ltd., rd Street, Riverside, CA The National Institute for Occupational Safety and Health (NIOSH) has been informed of two recent actions which affect the continued safe use of Luxfer 4500 psi hoop-wrapped aluminum cylinders and the certified status of self contained breathing apparatus incorporating them in their assemblies. (1) The Department of Transportation (DOT) has announced in the Federal Register that in order to accomplish a reduction in the sustained stress in 4500 psi hoop-wrapped aluminum cylinders manufactured by Luxfer under Exemption DOT-E 7235, the maximum cylinder charging pressure must be reduced from 4500 to 4000 psi, effective February 28, This restriction does not apply to 4500 psi fully-wrapped aluminum cylinders. (2) Luxfer USA Ltd. has determined that some 4500 psi/dot-e 7235 hoopwrapped aluminum cylinders manufactured prior to May, 1981, may rupture

5 in84034.txt at Page 5 of 9 or develop longitudinal cracks in the threaded section of the cylinder neck. All such cylinders with manufacturing dates before May, 1981, should be immediately examined in accordance with Luxfer's instructions which may be obtained from the self-contained breathing apparatus manufacturer. Cylinders manufactured after May, 1981, should be examined during the normal hydrostatic test. The following self-contained breathing apparatus certified by the Mine Safety and Health Administration (MSHA) and NIOSH, incorporate 4500 psi/dot- E 7235 hoop-wrapped aluminum cylinders manufactured by Luxfer: Manufacturer Approval No. Model No. AGA TC-13F Clifton Precision TC-13F , -2, -3, -4 (Bendix) MSA TC-13F , National Draeger TC-13F , -201, -202, -203, -204, -205, -206 Siebe Gorman TC-13F Scott TC-13F , -01, -30,-31 TC-13F , -01, -10, ,-21,-30, -31, -40, -41, -50, -51 USD TC-13F , -22; , -22 TC-13F , -01, -02, -03,--20,-21, -22, , -23 Attachment 2 Page 2 of 3 Reduction of Service Pressure Users of self-contained breathing apparatus incorporating any Luxfer 4500 psi/dot-e 7235 hoop-wrapped aluminum cylinders (including those manufactured before and after May, 1981) should immediately reduce the pressure in such cylinders from 4500 to 4000 psi. Pressure reduction may be safely accomplished by attaching the cylinder to a self-contained breathing apparatus and following the breathing apparatus manufacturer's instructions for depressurization until the cylinder pressure has reached 4000 psi. DO NOT OPEN THE VALVE OF ANY PRESSURIZED CYLINDER THAT IS NOT ATTACHED TO A SELF-CONTAINED BREATHING APPARATUS OR OTHER DEVICE THAT WILL SAFELY CONTAIN THE RELEASED PRESSURE. When depleted Luxfer 4500 psi/dot-e 7235 hoop-wrapped aluminum cylinders are recharged after use, the maximum pressure of 4000 psi must not be exceeded.

6 in84034.txt at Page 6 of 9 Status of MSHA/NIOSH Certifications The reduction in maximum service pressure from 4500 to 4000 psi affects the MSHA/NIOSH certification of the self-contained breathing apparatus to the extent that they will no longer meet the service time requirements of Title 30 Code of Federal Regulations Part 11 for a 30-minute duration apparatus. Therefore it is necessary for NIOSH to temporarily revise the certifications for these apparatus to continue their certified status. After consideration of the several factors involved in the maximum pressure reductions, NIOSH has decided to temporarily reduce the certification rated service time for each of the apparatus listed above, from 30 minutes to not less than 25 minutes. The revised certifications will be effective until further action is taken by DOT, at which time they will be further revised, canceled, or made official by publication in the Federal Register. This temporary change does not otherwise affect the certifications of these apparatus. Respirator users should immediately take the reduced service time into consideration in their continued use of the apparatus. NIOSH will also temporarily modify the certification to the extent of continuing to require the remaining service time indicator to continue to function within the range of 20 to 25 percent of the original 30-minute service time rating. Therefore, users will observe no change in the amount of service time remaining after initial activation of the remaining service time indicator, and will have the usual service time available for escape from an atmosphere immediately dangerous to life or health. Physical Examination of Cylinders Users of self-contained breathing apparatus incorporating any Luxfer 4500 psi/dot-e 7235 hoop-wrapped aluminum cylinders should immediately observe the manufacturing date of each such cylinder. This date is either stamped on the cylinder neck or is printed on a label which appears on the side of the cylinder under the outer filament wrapping. Hoopwrapped cylinders may be identified by lack of filament winding on the bottom and neck areas. Luxfer recommends that each of their 4500 psi/dot-e 7235 hoop-wrapped aluminum cylinders manufactured before May, 1981, be removed from service, be completely depressurized, devalved, and examined according to Luxfer's instructions which may be obtained from the self-contained breathing apparatus manufacturer. Contact the respirator manufacturer or distributor if you have not received the necessary instructions. Cylinders manufactured after May, 1981, should be examined during the normal hydrostatic test. Attachment 3

7 in84034.txt at Page 7 of 9 February 24, 1984 Dear Customer, Page 1 of 1 Luxfer USA Limited is the manufacturer of the 30-minute duration hoopwrapped high pressure cylinder, Scott P/N , which is used in Air-Pak 4.5 self-contained breathing apparatus. A copy of their letter to us dated February 23, 1984 regarding this cylinder is attached. In view of the situation outlined in the Luxfer letter, it is imperative that you immediately follow the instructions contained in that letter including: - To reduce the service pressure on all 30-minute 4500 psi hoopwrapped cylinders to 4000 psi immediately and to take whatever steps are necessary to assure future fillings will not exceed 4000 psi. - To visually inspect all 30-minute 4500 psi hoop-wrapped cylinders as soon as possible after receipt of Luxfer's recommended inspection procedure. NOTE: These recommended actions are limited to the one cylinder, the 30- minute hoop-wrapped 4500 psi cylinder, Scott P/N , used in Scott's 4.5 Air Paks. If you have any questions, please contact Mr. Dennis Browner at (716) Ext Be assured of our continuing interest in safety and in your full satisfaction with Scott Aviation and our products. We will keep you informed on this matter. Cordially, Lincoln C. Bailey Vice President Sales & Marketing Health/Safety Products Attachment 4 IN Page 1 of 2

8 in84034.txt at Page 8 of 9 Dear Survivair Distributor: February 29, 1984 URGENT SAFETY NOTICE We have been notified by Luxfer and NIOSH of two (2) recent accidents involving Scott 4500 psi hoop wrapped aluminum cylinders manufactured by Luxfer. Whereas no Survivair cylinders have been involved in any accident, Luxfer has determined that some 4500 psi DOT E7235 hoop wrapped aluminum cylinders may rupture or develop longitudinal cracks in the threaded section of the cylinder neck. And even though the threaded section of the Survivair cylinders are significantly different from the Scott cylinders that have been involved in these accidents, you are urged at the direction of the Department of Transportation, NIOSH, Luxfer and Survivair to immediately reduce the service pressure of all Survivair hoop wrapped cylinders in your possession bearing DOT E7235 on the cylinder neck from 4500 psi to 4000 psi. You are also urged to contact all your customers of these cylinders and likewise advise them to immediately reduce the service pressure to 4000 psi. We have been informed by NIOSH that this reduction in service pressure will not void NIOSH certification. However, users should take the reduced service time into consideration in their continued use of the apparatus. OSHA has also informed NIOSH that it will permit use of apparatus with a not less than 25 minute service time rating until further resolution of the problem. Please advise your customers that this reduction in service pressure to 4000 psi will reduce the service time of the Mark I and Mark 2 high pressure units from 30 minutes to approximately 26 minutes. This notice does not affect or request any action on any other Survivair cylinders other than those bearing DOT E7235. These cylinders are only used in Survivair's Mark I (since 1978) and Mark 2 High Pressure, 30 minute units. (since 1983). Attachment 4 Page 2 of 2 A more detailed letter of explanation to follow. Your immediate action and follow up in bringing this matter to the attention of your customers or

9 in84034.txt at Page 9 of 9 known users of these cylinders is greatly appreciated. Failure to do so may potentially result in serious bodily injury, death, and/or property damage. Should you need any further information on this matter please call the Survivair Marketing Department at 714/ Sincerely, Michael M. Chapman Vice President, Marketing