Information Notice 1992-48, Failure of Exide Batteries
| ML031210752 | |
| Person / Time | |
|---|---|
| Issue date: | 07/02/1992 |
| From: | Rossi C Office of Nuclear Reactor Regulation |
| To: | |
| References | |
| IN-92-048, NUDOCS 9206260043 | |
| Download: ML031210752 (7) | |
1-11 UNITED STATES
NUCLEAR REGULATORY COMMISSION
OFFICE OF NUCLEAR REACTOR REGULATION
WASHINGTON, D.C. 20555 July 2, 1992 NRC INFORMATION NOTICE 92-48: FAILURE OF EXIDE BATTERIES
Addressees
All holders of operating licenses or construction permits for nuclear power
reactors.
Purpose
The U.S. Nuclear Regulatory Commission (NRC) is issuing this information by
notice to inform addressees of failure of a Type GC battery manufactured GN
Exide used in safety-related applications and the potential failure of Type
batteries used in safety-related applications. It is expected that recipients
will review the information for applicability to their facilities and consider is
actions, as appropriate. However, no specific action or written response
required.
Description of Circumstances
face
On October 7, 1991, Omaha Public Power District reported cracking on the at the
of Exide's Class lE Type GC-23 battery jars installed in February 1980,
Fort Calhoun nuclear station (Fort Calhoun), causing leakage of electrolyte
and subsequent inoperability of the battery.
The root cause was attributed to inadequately designed battery terminal post
seals. The terminal post radial gland seal cracked due to corrosion buildup
which led to cracking on the jar cover and face and subsequent leakage of
electrolyte.
Discussion
Exide discovered the cracking problem in 1982 when the Southern New England a
Telephone Company informed Exide that the terminal post seals had cracked on
Type GW battery purchased from Exide. Exide's battery Types GC, GN (nuclear
grade) and GW had identically designed terminal post radial gland seals. and
Exide evaluated the problem and determined that the seal between the coverin
terminal posts was inadequately designed. Corrosion builds up over time
the seal area at the positive post because electrolyte enters, becomes
trapped, and reacts with the post material. The corrosion buildup stresses
the seal area and the plastic nut around the seal, and, ultimately, the cell
cover cracks. Consequently, in 1983, after notifying all holders of Type GN
cells, Exide corrected the design of the seals at the battery terminal.
However, due to a time lag in the supply chain, batteries received prior to
1985 may still have been of the old design. The old design is characterized
a e1h-sided nut around each battery terminal post.
9206260043 z J
IN 92-48 July 2, 1992 On March 24, 1983, the licensee for the Palo Verde nuclear plant notified the
NRC staff of a deficiency in Exide GN batteries involving cracking of the
plastic seals/covers at the terminal posts and electrolyte leakage. The
notification was based on Exide's service bulletin which addressed this issue
for Type GN batteries and suggested three levels of optional field
modifications (Levels I, II, and III) to repair batteries installed in nuclear
plants. Fort Calhoun had a Level III repair performed because of numerous
cracks on the battery covers. The Level III repair technique creates an all- enveloping secondary cover over the cracked cover. However, this repair tends
to mask any further cracking until catastrophic battery failure occurs, as was
the case at Fort Calhoun when one-third of the electrolyte leaked out and the
battery had to be replaced.
The NRC wants to inform the nuclear industry that Exide Type GC and GN
batteries received prior to 1985 with an eight-sided nut around each battery
terminal post may be susceptible to corrosion buildup and subsequent cracking
at the positive terminal posts; this condition could ultimately render the
battery incapable of performing its intended safety function. This phenomenon
could occur regardless of whether or not the batteries had the optional field
modifications installed.
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 techntcal contacts-listed-below or tteapproprtate--Offtc-of
Nuclear Reactor Regulation (NRR) project manager.
6ar~les E~. o~ssi '/Dirco
Division of Operational Events Assessment
Office of Nuclear Reactor Regulation
Technical contacts: Randolph N. Moist: NRR
(301) 504-2945 Frederick H. Burrows: NRR
(301) 504-2901 Attachment: List of Recently Issued NRC Information Notices
Attachment
IN 92-48 July 2, 1992 LIST OF RECENTLY ISSUED
NRC INFORMATION NOTICES
Information Date of
Subject Issuance Issued to
Notice No.
Intent
ional Bypassing 06/29/92 All holders of OLs or CPs
92-47 for nuclear power reactors.
of Automatic Actuation
of Plant Protective
Features
Thermo-Lag Fire Barrier 06/23/92 All holders of OLs or CPs
92-46 for nuclear power reactors.
Material Special Review
Team Final Report Findings, Current Fire Endurance
Tests, and Ampacity Cal- culation Errors
Incorrect Relay Used in 06/22/92 All holders of OLs or CPs
92-45 for nuclear power reactors.
Output Breaker Control
Circuitry
Problems with Westing- 06/18/92 All holders of OLs or CPs
92-44 for nuclear power reactors.
house DS-206 and DSL-206 Type Circuit Breakers
Defective Molded Phen- 06/09/92 All holders of OLs or CPs
92-43 for nuclear power reactors.
olic Armature Carriers
Found on Elmwood Con- tactors
Fraudulent Bolts in 06/01/92 All holders of OLs or CPs
92-42 for nuclear power reactors.
Seismically Designed
Walls
Consideration of the 05/29/92 All holders of OLs or CPs
92-41 for nuclear power reactors.
Stem Rejection Load in
Calculation of Required
Valve Thrust
Inadequate Testing of 05/27/92 All holders of OLs or CPs
92-40 for nuclear power reactors.
Emergency Bus Under- voltage Logic Circuitry
OL = Operating License
CP = Construction Permit
IN 92-48 July 2, 1992 On March 24, 1983, the licensee for the Palo Verde nuclear plant notified the
NRC staff of a deficiency in Exide GN batteries involving cracking of the
plastic seals/covers at the terminal posts and electrolyte leakage. The
notification was based on Exide's service bulletin which addressed this issue
for Type GN batteries and suggested three levels of optional field
modifications (Levels I, II, and III) to repair batteries Installed in nuclear
plants. Fort Calhoun had a Level III repair performed because of numerous
cracks on the battery covers. The Level III repair technique creates an all- enveloping secondary cover over the cracked cover. However, this repair tends
to mask any further cracking until catastrophic battery failure occurs, as was
the case at Fort Calhoun when one-third of the electrolyte leaked out and the
battery had to be replaced.
The NRC wants to inform the nuclear industry that Exide Type GC and GN
batteries received prior to 1985 with an eight-sided nut around each battery
terminal post may be susceptible to corrosion buildup and subsequent cracking
at the positive terminal posts; this condition could ultimately render the
battery incapable of performing its intended safety function. This phenomenon
could occur regardless of whether or not the batteries had the optional field
modifications installed.
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 Office of
Nuclear Reactor Regulation (NRR) project manager.
Charles E. Rossi, Director
Division of Operational Events Assessment
Office of Nuclear Reactor Regulation
Technical contacts: Randolph N. Moist: NRR
(301) 504-2945 Frederick H. Burrows: NRR
(301) 504-2901 Attachment: List of Recently Issued NRC Information Notices
- See previous concurrence.
RIS-2:VIB DST:SELB AC:RIS-2 TECHEDIT
- RMoist *FBurrows *JJacobson *JMain
5/14/92 5/14/92 5/14/92 5/14/92 BC:VIB:DRIS DIR:DRIS OGCB:DOEA D
- LJNorrholm *BKGrimes *CBerlinger
5/18/92 5/20/92 5/27/92 2 DOCUMENT NAME: 92-48.IN
IN 92-XXX
MAY XX, 1992 PAGE 2 of 2 On March 24, 1983, the licensee for the Palo Verde nuclear plant
notified the NRC staff of a deficiency in Exide GN batteries
involving cracking of the plastic seals/covers at the terminal
posts and electrolyte leakage. The notification was based on
Exide's service bulletin which addressed this issue for Type GN
batteries and suggested three levels of optional field
modifications (Levels I, II, and III) to repair batteries
installed in nuclear plants. Fort Calhoun had a Level III repair
performed because of numerous cracks on the battery covers. The
Level III repair technique creates an all-enveloping secondary
cover over the cracked cover. However, this repair tends to mask
any further cracking until catastrophic battery failure occurs, as was the case at Fort Calhoun when one-third of the electrolyte
leaked out and the battery had to be replaced.
The NRC wants to inform the nuclear industry that Exide Type GC
and GN batteries manufactured prior to the 1983-1985 time period
with an eight-sided nut around each battery terminal post may be
susceptible to corrosion buildup and subsequent cracking at the
positive terminal posts; this condition could ultimately render
the battery incapable of performing its intended safety function.
This phenomenon could occur regardless of whether or not the
batteries had the optional field modifications installed.
This information notice requires no specific action or written
response. If you have any questions about the information in
this notice, please contact the technical contacts listed below
or the appropriate Office of Nuclear Reactor Regulation (NRR)
project manager.
Charles E. Rossi, Director
Division of Operational Events Assessment
Office of Nuclear Reactor Regulation
Technical contacts: Randolph N. Moist: NRR
(301) 504-2945 Frederick H. Burrows: NRR
(301) 504-2901 Attachment: List of Recently Issued NRC Information Notices
RIS-2:VIB DST:SELB AC:RIS-2 TECHEDIT
RMoist * FBurrows
- JJacobson * JMNa 94
5/14/92 5/14/92 5/14/92 5/14/92 BC:VIB:DRIS DIR:DRIS OGCB:DOEA DIR:DOEA
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5/18/92 *- 5/20/92 * 5/27/92 5/ /92
- previously concurred
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IN 92-XXX
MAY XX, 1992 PAGE 2 of 2 On March 24, 1983, the licensee for the Palo Verde nuclear plant
notified the NRC staff of a deficiency in Exide GN batteries
involving cracking of the plastic seals/covers at the terminal
posts and electrolyte leakage. The notification was based on
Exide's service bulletin which addressed this issue for Type GN
batteries and suggested three levels of optional field
modifications (Levels I, II, and III) to repair batteries
installed in nuclear plants. Fort Calhoun had a Level III repair
performed because of numerous cracks on the battery covers. The
Level III repair technique creates an all-enveloping secondary
cover over the cracked cover. However, this repair tends to mask
any further cracking until catastrophic battery failure occurs, as was the case at Fort Calhoun when one-third of the electrolyte
leaked out and the battery had to be replaced.
The NRC wants to inform the nuclear industry that Exide Type GC
and GN batteries manufactured prior to the 1983-1985 time period
with an eight-sided nut around each battery terminal post may be
susceptible to corrosion buildup and subsequent cracking at the
positive terminal posts; this condition could ultimately render
the battery incapable of performing its intended safety function.
This phenomenon could occur regardless of whether or not the
batteries had the optional field modifications installed.
This information notice requires no specific action or written
response. If you have any questions about the information in
this notice, please contact the technical contact listed below or
the appropriate Office of Nuclear Reactor Regulation (NRR)
project manager.
Charles E. Rossi, Director
Division of Operational Events Assessment
Office of Nuclear Reactor Regulation
Technical contact: Randolph N. Moist: NRR
(301) 504-2945 Frederick H. Burrows: NRR
(301) 504-2901 Attachment: List of Recently Issued NRC Information Notices
RIS-2:VIB DST:SELB AC:RIS-2 TECHEDIT EXIDE
RMoist * FBurrows
- JJacobson * IBaeringer +
5/14 92 5/14 5/14/92 5/14/92 5/15/92 B: URIS D4i { SC"i OG9M
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5/92 '/,o/92 5/' /92 5/ /92
- previously concurred + concurred by telephone on 5/15/92 F ME 7i~raL cc" wTe'Ar x #. V.
IN 92-XXX
MAY XX, 1992 PAGE 2 of 2 On March 24, 1983, the licensee for Palo Verde notified the NRC
staff of a deficiency in Exide GN batteries involving cracking
around terminal posts and electrolyte leakage. The notification
was based on Exide's service bulletin which addressed this issue
for Type GN batteries and suggested three levels of optional
field modifications (Level I, II, III) to repair batteries
installed in nuclear plants. Fort Calhoun had a Level III repair
performed because the battery covers exhibited numerous cracks.
The Level III repair technique creates an all enveloping
secondary cover over the old one. However, this repair may not
be adequate as it tends to mask any further cracking until it is
too late and catastrophic battery failure occurs as was the case
of Fort Calhoun when one third of the electrolyte was lost and
the battery had to be replaced.
The NRC wants to inform the nuclear industry that Exide Type GC
and GN batteries manufactured prior to the 1983-1984 time period
with an 8-sided nut around each battery terminal post may be
susceptible to corrosion build up and subsequent cracking around
the positive terminal posts which could ultimately render the
battery incapable of performing its intended safety function.
This phenomena could occur regardless of whether or not the
batteries had the optional field modifications installed.
This information notice requires no specific action or written
response. If you have any questions about the information in
this notice, please contact the technical contact listed below or
the appropriate Office of Nuclear Reactor Regulation (NRR)
project manager.
Charles E. Rossi, Director
Division of Operational Events Assessment
Office of Nuclear Reactor Regulation
Technical contact: Randolph N. Moist: NRR
(301) 504-2945 Frederick H. Burrows: NRR
(301) 504-2901 Attachment: List of Recently Issued NRC Information Notices
RIS-2:VIB DST:SEJB
AC:RNP-2 TECHEDIT EXIDE
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5/ /92 5/ /92 5/ /92 5/ /92