Information Notice 1987-62, Mechanical Failure of Indicating-Type Fuses

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Mechanical Failure of Indicating-Type Fuses
ML031130464
Person / Time
Site: Beaver Valley, Millstone, Hatch, Monticello, Calvert Cliffs, Dresden, Davis Besse, Peach Bottom, Browns Ferry, Salem, Oconee, Mcguire, Nine Mile Point, Palisades, Palo Verde, Perry, Indian Point, Fermi, Kewaunee, Catawba, Harris, Wolf Creek, Saint Lucie, Point Beach, Oyster Creek, Watts Bar, Hope Creek, Grand Gulf, Cooper, Sequoyah, Byron, Pilgrim, Arkansas Nuclear, Braidwood, Susquehanna, Summer, Prairie Island, Columbia, Seabrook, Brunswick, Surry, Limerick, North Anna, Turkey Point, River Bend, Vermont Yankee, Crystal River, Haddam Neck, Ginna, Diablo Canyon, Callaway, Vogtle, Waterford, Duane Arnold, Farley, Robinson, Clinton, South Texas, San Onofre, Cook, Comanche Peak, Yankee Rowe, Maine Yankee, Quad Cities, Humboldt Bay, La Crosse, Big Rock Point, Rancho Seco, Zion, Midland, Bellefonte, Fort Calhoun, FitzPatrick, McGuire, LaSalle, 05000000, Zimmer, Fort Saint Vrain, Shoreham, Satsop, Trojan, Atlantic Nuclear Power Plant, Crane
Issue date: 12/08/1987
From: Rossi C
Office of Nuclear Reactor Regulation
To:
References
IN-87-062, NUDOCS 8712020019
Download: ML031130464 (7)


-

IN 87-62

UNITED STATES

NUCLEAR REGULATORY COMMISSION

OFFICE OF NUCLEAR REACTOR REGULATION

WASHINGTON, D.C.

20555

December 8, 1987

NRC INFORMATION NOTICE NO. 87-62:

MECHANICAL FAILURE OF INDICATING-TYPE

FUSES

Addressees

All holders of operating licenses or construction permits for nuclear power

reactors.

Purpose

This information notice is being provided to alert addressees to potential

problems resulting from the mechanical failure of indicating-type fuses.

It is expected that recipients will review the information for applicability

to their facilities and consider actions, as appropriate, to avoid similar

problems.

However, suggestions contained in this information notice do not

constitute NRC requirements; therefore, no specific action or written response

is required.

Description of Circumstances

The Nuclear Regulatory Commission has been notified of four separate events in

the past two years related to the mechanical failure of indicating-type fuses.

The events occurred at McGuire Nuclear Station, Unit 1; Catawba, Unit 2; and

Sequoyah Nuclear Plant and are described herein.

On March 25, 1986, Duke Power Company's McGuire Nuclear Station, Unit 1, ex- perienced a reactor trip on a steam generator low-low level signal when the

mechanical failure of a Bussman FNA-type fuse caused a main feedwater contain- ment isolation valve to close.

McGuire personnel determined that the failure

was the result of the fuse element having pulled loose from the solder joint

inside the fuse.

The solder joint was found unbroken; the element wire had

pulled out of the solder joint. The licensee found that 8% of the spare fuses

in stock also had failed mechanically.

Previously, in December 1981 and

December 1985, the licensee had reported to the NRC the mechanical failures of

FNA-type fuses [Licensee Event Reports (LERs) 369-81-179 and 369-85-036].

On July 3, 1986, the NRC issued a Confirmation of Action Letter (CAL) to Duke

Power Company as a followup to an event at Catawba, Unit 2. In that event one

of the auxiliary feedwater trains failed to start during testing because of a

mechanically failed FNA-type fuse.

On July 7, 1986, Duke Power notified the

NRC of the preliminary results of a review of all safety-related circuits where

FNA-type fuses were used.

The review included the inspection of approximately

IN 87-62 December 8, 1987 2500 fuses.

The inspection found 14 failed FNA-type fuses, 9 of which were

determined to have failed mechanically.

The inspection of the spare fuses

in the warehouse stock found an additional 11 mechanically failed fuses.

On October 29, 1986, the Tennessee Valley Authority (TVA) submitted a notifica- tion on Bussman MIS-5-type fuses to the NRC pursuant to the requirements of 10 CFR Part 21.

The Bussman MIS-5 actuating fuse consists of two very thin wires

in a sand-like filler.

One of the wires, which is approximately 96% silver, acts as a fuse link; the other, a nichrome alloy, acts as a retaining wire for

a spring-loaded actuator/indicator rod that is located at one end of the fuse

assembly.

In the notification TVA indicated that fuses at the Sequoyah Nuclear

Plant had exhibited partial actuation, not detectable in all cases by visual

examination, that was the result of the elongation of very thin wires.

The

elongation of these wires could significantly change the characteristics of the

fuse and its current-carrying characteristics.

This is particularly true if

the silver wire breaks but remains in contact with the elongated and unbroken

nichrome wire.

TVA contacted Bussman and established the resistance and

current values that could be used to conclusively test the operability of the

remaining fuses.

On July 20, 1987, TVA submitted an LER on Littlefuse Incorporated FLAS-5 type

fuses to the NRC (LER 327-87-030).

The LER noted that there had been two

separate Engineered Safety Feature actuations of the Sequoyah Nuclear Plant's

onsite emergency diesel generators as a result of blown FLAS-5-type fuses in

the emergency diesel generator start logic circuitry.

The FLAS-5 fuse consists

of-a fuse wire in-parallel withf a 56ohm resistor ,a-sping lQaded-indicator

_

pin, and sand-like filler.

The indicator pin is mechanically attached to the

spring.

At the end of the spring, the resistor and the fuse wire are soldered

together.

The solder material used is a eutectic alloy that has a low melting

point.

During normal operating conditions, the fuse wire carries the operating

current.

During a fault condition the solder material rapidly melts.

During

overcurrent conditions, the resistor heats up with increasing current and serves

as the heat source that melts the solder material. When the solder joint melts

it interrupts the circuit and releases the indicator pin.

The indicator pin- itself causes annunciation only and does not trigger any safety features.

Because 69 out of 3200 installed FLAS-5-type fuses have failed to date, TVA

perceives that a mechanical weakness, such as a defect in the solder joint, is

the main cause of the blown fuses in at least two FLAS-5-type fuse lots.

The

vendor believes that the problem-has been corrected by modification of the

solder material and processes.

Discussion:

The fuses involved in the events described above are of the pin indicating

type.

These fuses have an internal spring-loaded indicating pin that protrudes

from the end of the fuse when the fuse links separate. These fuse links are

designed to melt when the current exceeds the design load; however, in the cases

described above, the fuses apparently failed as a result of either a cold solder

joint, creep, or fatigue induced by the internal spring tension.

Bussman and

Littlefuse supply other indicating-type fuses, and other fuse suppliers also

make indicating-type fuses.

The fuses that have failed mechanically are of

the same type that have successfully undergone seismic testing.

IN 87-62 December 8, 1987 The NRC staff reviewed 575 fuse-related LERs for the period 1981-1986. They

showed no additional cases of specific mechanical failure; however, 183 reports

indicated that the licensee had determined the failure to be from unknown

causes, and many of the reports identified a blown fuse as the cause of the

associated circuit failure.

Fuse replacement was the usual corrective action

taken.

Because of the large number of fuses involved, the total number of fuse

failures may not be abnormal.

However, the experience of Duke Power Company

and TVA shows that the safety significance evaluation is dependent on an ac- curate root-cause determination.

In the event of an indicating fuse failure, additional investigation, including internal examination of the fuse, may be

warranted if an electrical fault cannot be found.

No specific action or written response is required by this information notice.

If you have any questions about this matter, please contact the technical

contact listed below or the Regional Administrator of the appropriate regional

office.

harl~esE. Rossi, Director

Division of Operational Events Assessment

Office of Nuclear Reactor Regulation

Technical Contacts. James C. Stewart, NRR

(301) 492-4644

Joseph J. Petrosino, NRR

(301) 492-4316 Attachment:

List of Recently Issued NRC Information Notices

Attachment_

/

IN 87-62

December 8, 1987

LIST OF RECENTLY ISSUED

NRC INFORMATION NOTICES 1987

I n f -at. i n

. _

Notice No.

87-61

87-60

86-108, Supp. 2

87-59

87-58

87-57

87-56

87-55 Subject

Failure of Westinghouse

W-2-Type Circuit Breaker

Cell Switches.

Depressurization of Reactor

Coolant Systems in

Pressurized-Water Reactors

Degradation of Reactor

Coolant System Pressure

Boundary Resulting from

Boric Acid Corrosion

Potential RHR Pump Loss

Continuous Communications

Following Emergency

Notifications

Loss of Emergency Boration

Capability Due to Nitrogen

Gas Intrusion

Improper Hydraulic Control

Unit Installation at BWR

Plants.

Portable Modsture/Denalty

Gauges:

Recent Incidents

of Portable Gauges Being

Stolen or Lost

unto OT

Issuance

12/?/87

12/4/87 Issued to

All holders of OLs

or CPs for nuclear

power reactors.

All holders of OLs

or CPs for PVRs.

11/19/87

All holders of OLs

or CPS for nuclear

power reactors.

11/17/87

All holders of OLs

or CPs for nuclear

power reactors.

11/16/87

All nuclear power

reactor facilities

holding an OL and

the following fuel

facIlities that have

Emergency Notification

Systems:

Nuclear

Fuel Services, Erwin, TN; General Atomics, San Diego, CA; UNC,

Montville, CT; and

B & W LRC and B & W

Navy. Lynchburg, VA.

11/6/87

All holders of OLs

or CPs for nuclear

power reactors.

11/4/87

All holders of OLs

or CPs for boiling

water reactors (BWRs).

10/29/87 All NRC licanes.

authorized to

possess portable

gauges.

OL = Operating License

CP = Construction Permit

UNITED STATES

NUCLEAR REGULATORY COMMISSION

WASHINGTON, D.C. 20555

OFFICIAL BUSINESS

PENALTY FOR PRIVATE USE, $300

FIRST CLASS MAIL

POSTAGE & FEES PAID

USNRC

PERMIT No. 0-67

IN 87-62 December 8, 1987 The NRC staff reviewed 575 fuse-related LERs for the period 1981-1986. They

showed no additional cases of specific mechanical failure; however, 183 reports

indicated that the licensee had determined the failure to be from unknown

causes, and many of the reports identified a blown fuse as the cause of the

associated circuit failure.

Fuse replacement was the usual corrective action

taken.

Because of the large number of fuses involved, the total number of fuse

failures may not be abnormal.

However, the experience of Duke Power Company

and TVA shows that the safety significance evaluation is dependent on an ac- curate root-cause determination.

In the event of an indicating fuse failure, additional investigation, including internal examination of the fuse, may be

warranted if an electrical fault cannot be found.

No specific action or written response is required by this information notice.

If you have any questions about this matter, please contact the technical

contact listed below or the Regional Administrator of the appropriate regional

office.

Charles E. Rossi, Director

Division of Operational Events Assessment

Office of Nuclear Reactor Regulation

Technical Contacts:

James C. Stewart, NRR

(301) 492-4644

Joseph J. Petrosino, NRR

(301) 492-4316 Attachment:

List of Recently Issued NRC Information Notices

The draft of this information notice was transmitted to DOEA

from J. Partlow dated 10/8/87.

by DRIS in a memorandum

  • SEE PREVIOUS CONCURRENCES
  • OGCB:DOEA:NRR *SICB:DEST:NRR

JGuillen

JCStewart

11/17/87

11/17/87

  • RVIB: DRIS: NRR

JJPetrosino

11/23/87

  • PPMB:ARM

TechEd

11/04/87

  • C/OGCB:DOEA:NRR DUQEA:NRg

CHBerlinger

1

11/24/87

12/ 21B7

IN 87-XX

November xx, 1987 and TVA shows that the safety significance evaluation Is dependent on an

accurate root-cause determination. In the event of an indicating fuse failure, additional investigation, including internal examination of the fuse, may be

warranted if an electrical fault cannot be found.

No specific action or written response is required by this information notice.

If you have any questions about this matter, please contact the technical

contact listed below or the Regional Administrator of the appropriate regional

office.

Charles E. Rossi, Director

Division of Operational Events Assessment

Office of Nuclear Reactor Regulation

Technical Contacts:

James C. Stewart, NRR

(301) 492-4644

Joseph J. Petrosino, NRR

(301) 492-4316 Attachment:

List of Recently Issued NRC Information Notices

IOiUS CONCURRENCES

OGCl R EA:NRR

ICB:DEST:NRRI DRIS:NRR

JGui 1 n

_OOCStewart

RPetrosino

11/% WE7

-1

'/J'W87

113/87

  • PPMB:ARM

TechEd

11/04/87 Cal5 C/OGCB:DOEA:NRR

CHBerlinger

11/q/87 D/DOEA:NRR

CERossi

11/ /87

IN 87-XX

October xx, 1987

Page 2 of

No specific action or written response is required by this information notice.

If you have any questions about this matter, please contact the technical

contact listed below or the Regional Administrator of the appropriate regional

office.

Charles E. Rossi, Director

Division of Operational Events Assessment

Office of Nuclear Reactor Regulation

Technical Contacts:

James C. Stewart, NRR

(301) 492-4644

Joseph J. Petrosino, NRR

(301) 492-4316 Attachment:

List of Recently Issued NRC Information Notices

OGCB:DOEA:NRR

JGuillen

10/ /87 SICB:DEST:NRR

JCStewart

10/ /87 RVIB:DRIS:NRR

JJPetrosino

10/ /87 PPMB:ARM C/OGCB:DOEA:NRR

TechEdd- CHBerlinger

1/ 1q/87 10/ /87 D/DOEA:NRR

CERossi

10/ /87