Information Notice 1994-41, Problems with General Electric Type CR124 Overload Relay Ambient Compensation

Problems with General Electric Type CR124 Overload Relay Ambient Compensation

ML031070040
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, Three Mile Island, 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, Fort Saint Vrain, Shoreham, Satsop, Trojan, Atlantic Nuclear Power Plant
Issue date:	06/07/1994
From:	Grimes B Office of Nuclear Reactor Regulation
To:
References
IN-94-041, NUDOCS 9406010125
Download: ML031070040 (10)

UNITED STATES

NUCLEAR REGULATORY COMMISSION

OFFICE OF NUCLEAR REACTOR REGULATION

WASHINGTON, D.C. 20555 June 7, 1994 NRC INFORMATION NOTICE 94-41: PROBLEMS WITH GENERAL ELECTRIC TYPE CR124 OVERLOAD RELAY AMBIENT COMPENSATION

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

notice to alert addressees to the potential for out-of-tolerance ambient

compensation in certain configurations of General Electric (GE) Type CR124 overload relays. It is expected that recipients will review the information

for applicability to their facilities and consider actions, as appropriate, to

avoid similai'--problems. However, suggestions contained in this information

notice are not NRC requirements; therefore, no specific action or written

response is required.

Description of Circumstances

After some field test failures, in which several Type CR124 overload relays

exhibited out-of-tolerance trip times, the relays were returned to the

manufacturer, GE Electrical Distribution and Control (ED&C). GE ED&C

discovered that on relay models CR124K028, K128, L028, and L128, manufactured

before October 1990, many of the ambient temperature-compensating bimetal

elements (sometimes called ambient compensating springs) had been installed

upside down because of a problem with the marking of the elements. In this

condition, the incorrectly installed element can adversely affect the trip

timing of the relay. These overload relays are typically used in conjunction

with starters or motor controllers, many of which may serve safety-related

loads. In April 1991, GE Nuclear Energy (GE NE) issued a "Germane to Safety"

letter to all boiling water reactor customers and certain other customers

concerning the relays. However, the NRC has learned that other licensees may

also be affected.

Discussion

The ambient temperature compensating bimetal element or spring is intended to

adjust the trip forces inside the relay so that the trip time as a function of

overload current is consistent with the design characteristic curves over a

wide range of ambient temperatures. According to GE, the improperly installed

ambient compensating bimetals will permit the overload relays to work

correctly within a temperature range of 15-200C [59-68*F]. However, at lower

temperatures, i.e., 0-15'C [32-59°F], the ambient compensation would cause

9406010125 PC tE No '("C-e qCT -ot L q

slot 'M shaA

IN 94-41 June 7, 1994 trip times above published specifications (time-current curves). At higher

temperatures, i.e., 20-40'C [68-1040F], which is more typical of nuclear plant

installations, the ambient compensations would cause trip times below

published specifications. GE ED&C did not have data on the magnitude of

deviations from the published time-current curves.

GE NE indicated that the above identified models made before October 1990 may

be affected by this problem. To identify when the relays were built, they are

marked with date codes consisting of two letters. The first letter, "N"

through "Z" (skipping IQ"), indicates month of manufacture. The second letter

indicates the year with "D" meaning 1989, NER meaning 1990, etc. Hence relays

of the affected models built before October 1990, i.e., in September 1990 and

earlier (date codes "WE" and earlier), are affected. ED&C has issued no

service advice letters (SALs), nor has GE NE issued any service information

letters (SILs), on this issue. Since late 1991, ED&C has used 5-character, alphanumeric, in lieu of 2-letter date codes for the relays and similar

components.

Because the affected relays are reported to work properly within the

temperature range of 15-20*C [59-68*F], ED&C recommended evaluating individual

applications in terms of actual service conditions and performance

requirements to determine the potential impact on operability of the overload

relays with defective ambient compensation. In addition, because some of the

potentially affected relays may not be defective, GE ED&C provided a test

procedure that may be used as an alternative to wholesale replacement to

identify those relays that actually have the improperly installed ambient

compensation bimetal. The procedure is to test the relays at a nominal

overload current (e.g., 300 percent) at room temperature (e.g., 25°C [770F])

and then repeating the test after thermal soaking at 40*C [104°F] and

verifying that the cool and warm trip times at the same overload level are

within 10 percent of each other. If these relays fail this test and the

condition cannot be tolerated because of requirements of the application, ED&C

stated that these relays would need to be replaced because they cannot be

repaired. ED&C also recommended the test procedure described above for

general use on ambient compensated thermal overload relays, installed or in

storage, which ED&C recommended testing at least every five years.

IN 94-41 June 7, 1994 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 Nuclear

Reactor Regulation (NRR) project manager.

Bran K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contact: Stephen D. Alexander, NRR

(301) 504-2995 Attachment:

List of Recently Issued NRC Information Notices

A tachment 1 IN 94-41 June 7, 1994 LIST OF RECENTLY ISSUED

NRC INFORMATION NOTICES

Information Date of

Notice No. Subject Issuance Issued to

94-40 Failure of a Rod Control 05/26/94 All holders of OLs or CPs

Cluster Assembly to Fully for pressurized-water

Insert Following a Reactor reactors (PWRs).

Trip at Braidwood Unit 2

94-39 Identified Problems in 05/31/94 All U.S. Nuclear Regulatory

Gamma Stereotactic Commission Teletherapy

Radiosurgery Medical Licensees.

94-38 Results of a Special NRC 05/27/94 All holders of OLs or CPs

Inspection at Dresden for NPRs and all fuel cycle

Nuclear Power Station and materials licensees

Unit 1 Following a Rupture authorized to possess spent

of Service Water Inside fuel.

Containment

94-37 Misadministration Caused 05/27/94 All U.S. Nuclear Regulatory

by a Bent Interstitial Commission Medical Licensees

Needle during Brachy- authorized to use brachy- therapy Procedure therapy sources in high-,

medium-, and pulsed-dose- rate remote afterloaders.

94-36 Undetected Accumulation 05/24/94 All holders of OLs or CPs

of Gas in Reactor for nuclear power reactors.

Coolant System

91-81, Switchyard Problems that 05/19/94 All holders of OLs or CPs

Supp. 1 Contribute to Loss of for nuclear power reactors.

Offsite Power

94-35 NIOSH Respirator User 05/16/94 All holders of OLs or CPs

Notices, "Inadvertent for nuclear power reactors, Separation of the Mask- and all licensed fuel

Mounted Regulator (MMR) facilities.

from the Facepiece on the

Mine Safety Appliances (MSA)

Company MMR Self-Contained

Breathing Apparatus (SCBA)

and Status Update"

OL = Operating License

CP = Construction Permit

IN 94-41 June 7, 1994 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. oWginalsigned DI

Brian IL 1rneS

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contact: Stephen D. Alexander, NRR

(301) 504-2995 Attachment:

List of Recently Issued NRC Information Notices

• See previous concurrence.

OFFICE VIB/DRIL SC/VIB/DRIL TECH ED BC/VIB/DRIL D/DRIL

NAME SAlexander* GCwalina* RSanders* LNorrholm* CERossi*

DATE 101/07/94 01/13/94 02/02/94 01/24/94 Ad 01/31/94 I'7 OFFICE EELB/DE OGCB/DORS IABC/OGCB/DORS D/M< N

D 9 0 . AE 0 -20

NAME CBerlinger* PWen* AKug ler *{/

DATE 02/22/94 03/08/94 03/16/94 06/1 /94 DOCUMENT NAME: 94-41.IN

IN 94-XX

March xx, 1994 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.

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contact: Stephen D. Alexander, NRR

(301) 504-2995 Attachment:

List of Recently Issued NRC Information Notices

• See previous concurrence.

OFFICE I VIB/DRIL SC/VIB/DRIL TECH ED BC/VIB/DRIL D/DRIL

NAME SAlexander* GCwalina* RSanders* LNorrholm* CERossi*

DATE 01/07/94 01/13/94 02/02/94 01/24/94 01/31/94 OFFICE EELB/DE OGCB/DORS ABC/OGCB/DORS D/DORS/NRR

NAME CBerlinger* PWen* AKugler B_ __KGrimes

DATE 02/22/94 03/ /94 03/08/94 03/1K/9403/ /94 DOCUMENT NAME: CR124AC.PCW ,tJt 1e)

V'

.- IN 94-XX

March xx, 1994 No specific action or written response is required by this information notice.

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

contact listed below or the appropriate Office of Nuclear Reactor Regulation

(NRR) project manager.

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contact: Stephen D. Alexander, NRR

(301) 504-2995 Attachment:

List of Recently Issued NRC Information Notices

• See previous concurrence.

OFFICE VIB/DRIL SC/VIB/DRIL TECH ED BC/VIB/DRIL D/DRIL

NAME SAlexander* GCwalina* RSanders* LNorrholm* CERossi*

DATE 01/07/94 j01/13/94 J02/02/94 101/24/94 101/31/94 OFFICE EELB/DE OGCB/DORS ABC/OGCB/DORS D/DORS/NRR

NAME CBerlinger* T PWen

IC__ AKugler BKGrimes

DATE 02/22/94 03___94 __03/ /94 03/ /94 103/ /94 OCUMENT NAME: CR124AC.PCW

1-.%

IN 94-XX

February XX, 1994 GE NE stated that annf the affected models made before October 1990 should

be considered suspect a should be replaced. To identify when the relays

were built, they are markel with date codes consisting of two letters. The

first letter, "NO through " " (skipping "Qu), indicates month of manufacture.

The second letter indicates t year with "E"meaning 1990, OF" meaning 1991, etc. Hence relays of the affec d models stated above built before October

1990, i.e., in September 1990 an earlier (date codes "WE" and earlier), are

affected. ED&C reportedly correct the problem on these models in September

1990 so that date codes for October 90 and later, i.e., "XE" (October 1990),

"YE" (November 1990), "ZE" (December 90), INF" (January 1991), etc., should

not be affected. ED&C has issued no se ice advice letters (SALs), nor has GE

NE issued any service information letters (SILs) on this issue.

GE NE also reported that ED&C recommend , in addition to replacing suspect

relays, testing thermal overload relays that re installed and in storage at

least every 5 years. ED&C's procedure is to st the relays at a nominal

overload current (e.g., 300 percent) at room teperature (e.g., 25OC/77'F) and

also after thermal soaking at 40*C/104OF and ver ying that the cool and warm

trip times at the same overload level are within 1 percent of each other. If

not, ED&C recommended replacing the relays because ey cannot be repaired.

No specific action or written response is require by this information

notice. If you have any questions regarding this matt r, please contact one

of the technical contacts listed below or the appropria Office of Nuclear

Reactor Regulation (NRR) project manager.

Brian K. Grimes, Directo

Division of Operating Rea tor Support

Office of Nuclear Reactor Regulation

Technical contacts: Stephen D. Alexander, NRR (301) 504-2995 Attachments: 1. List of Recently Issued NRC Information Notices

• See previous concurrence.

OFFICE VIB/DRIL SC/VIB/DRIL TECHED BC/VIB/DRIL D/DRIL

NAME SAlexander* GCwalina* RSanders* LNorrholm* CERossi*

DATE 01/07/94 01/13/94 02/02/94 01/24/94 01/31/94 COPY YES YES NO NO NO

OFFICE EELB______i__e__OGCB/DORS BC/OGCB/DORS D/DORS/NRR

NAME CBerlfnger -Rliies4 BKGrimes

DATE 02/22/94 02/ /94 02/ /94 02/ /94 02/ /94 COPY YES NO YES NO YES NO YES NO YES NO

OFFICIAL RECORD COPY DOCUMENT NAME: CR124AC.IN

IN 94-XX

January XX, 1994 GE NE stated t t any of the affected models made before October 1990 should

be considered susp t and should be replaced. To identify when the relays

were built, they are arked with date codes consisting of two letters. The

first letter, "N" thro h HZ" (skipping "Q"), indicates month of manufacture.

The second letter indic es the year with "E"meaning 1990, "F"meaning 1991, etc. Hence relays of the ffected models stated above built before October

1990, i.e., in September 1 %0 and earlier (date codes "WE" and earlier), are

affected. ED&C reportedly c rrected the problem on these models in September

1990 so that date codes for Octqber 1990 and later, i.e., "XE" (October 1990),

"YE" (November 1990), "ZE" (Decei er 1990), "NF" (January 1991), etc., should

not be affected. ED&C has issued b Service Advice Letters (SALs), nor has GE

NE issued any Service Information Le ters (SILs) on this issue.

GE NE reported also that ED&C recomended, in addition to replacing suspect

relays, testing thermal overload relays at are installed and in storage at

least every 5 years. ED&C's procedure is o test the relays at a nominal

overload current (e.g., 300 percent) at roo temperature (e.g., 25OC/770F) and

also after thermal soaking at 40*C/104*F and erifying that the cool and warm

trip times at the same overload level are with 10 percent of each other. If

not, ED&C recommended replacement because these elays cannot be repaired.

No specific action or written response is requ ed by this information

notice. If you have any questions regarding this aitter, please contact one

of the technical contacts listed below or the approptate Office of Nuclear

Reactor Regulation (NRR) project manager.

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contacts: Stephen D. Alexander, NRR (301) 504-2995 Attachments: 1. List of Recently Issued NRC Information Notices

• See previous concurrence. -  :- l

OFFICE VIB/DRIL SC/VIB/DRIL TECHED BC/VIB/DRIL DDRI

NAME SAlexander* GCwalina* yiua.,k14 LNorrholm* CERossi*

DATE 01/07/94 01/13/94 02/ V&/94 01/24/94 01/31/94 COPY YES YES NO NO NO

OFFICE EELB/DE OGCB/DORS BC/OGCB/DORS D/DORS/NRR

NAME CBerlinger RKiesel BKGrimes

DATE 01/ /94 01/ /94 01/ /94 01/ /94 01/ /94 COPY YES NO YES NO YES NO YES NO YES NO

a_&_hf Al9 UNI4lA AP TE

OFFICIAL RECORD COPY UULUMtNI N Li X1~t;

IN 94-XX

January XX, 1994 GE NE stated that any of the a fected models made before October 1990 should

be considered suspect and should e replaced. To identify when the relays

were built, they are marked with ate codes consisting of two letters. The

first letter, IN' through "Z" (ski ping "Q"), indicates month of manufacture.

The second letter indicates the yea with "E" meaning 1990, "F" meaning 1991, etc. Hence relays of the affected m dels stated above built before October

1990, i.e., in September 1990 and ear ier (date codes "WE" and earlier), are

affected. ED&C reportedly corrected t problem on these models in September

1990 so that date codes for October 199 and later, i.e., "XE" (October 1990),

"YE" (November 1990), "ZE" (December 199 I, INFO (January 1991), etc., should

not be affected. ED&C has issued no Servi e Advice Letters (SALs), nor has GE

NE issued any Service Information Letters ( ILs) on this issue.

GE NE reported also that ED&C recommended in addition to replacing suspect

relays, testing thermal overload relays that re installed and in storage at

least every 5 years. ED&C's procedure is to t st the relays at a nominal

overload current (e.g., 300 percent) at room te perature (e.g., 25OC/770F) and

also after thermal soaking at 40OC/104OF and ve *fying that the cool and warm

trip times at the same overload level are within 10 percent of each other. If

not, ED&C recommended replacement because these r lays cannot be repaired.

No specific action or written response is requ red by this information

notice. If you have any questions regarding this atter, please contact one

of the technical contacts listed below or the appr iate Office of Nuclear

Reactor Regulation (NRR) project manager.

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contacts: Stephen D. Alexander, NRR (301) 504-2995 Attachments: 1. List of Recently Issued NRC Information Notices

OFFICE VIB/DRIL SC/ VW RIL TECHED BC/ I /DRIL D/DRIL

NAME SAlexand GC_Wi

DATE 01/c1/94 0l13 94 01/ /94 01 94 COPY Y YE NO NO YES YNOYESNO

OFFICE EELB/DE OGCB/DORS BC/OGCB/DORS D/DORS/NRR

NAME CBerlinger RKiesel BKGrimes

DATE 01/ /94 01/ /94 01/ /94 01/ /94 01/ /94 COPY YES NO YES NO YES NO YES NO YES NO

ncr~rTIAI nrrnnnr, rrl.hraI- AK ,.I ,^AM T&I

Urr LUlRL ICUKU bUM UUUUMtNI NMMt: LK1z4qA%.1N