ML082390106

Notification of Potential Part 21 on Failure of F and G Switches

ML082390106
Person / Time
Site:	Beaver Valley, Millstone, Hatch, Monticello, Calvert Cliffs, Dresden, Davis Besse, Peach Bottom, Browns Ferry, 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, Ginna, Diablo Canyon, Callaway, Vogtle, Waterford, Duane Arnold, Farley, Robinson, Clinton, South Texas, San Onofre, Cook, Comanche Peak, Quad Cities, Zion, Fort Calhoun, FitzPatrick, McGuire, LaSalle, Fort Saint Vrain
Issue date:	08/25/2008
From:	Porter D GE-Hitachi Nuclear Energy Americas
To:	Document Control Desk, Office of New Reactors
References
MFN 08-645
Download: ML082390106 (10)

Text

Dale E. Porter Safety Evaluation Program Manager 3901 Castle Hayne Rd.,

Wilmington, NC 28401 USA T 910 602-4491 F 910 341-2555 Dale.Porter@ge.com August 25, 2008 MFN 08-645 Attn: Document Control Desk U.S. Nuclear Regulatory Commission Washington, DC 20555-0001

Subject:

Failure of F and G Switches

Reference:

GE Hitachi Nuclear Energy, Transfer of Information SC 08-07 Failure of F and G Switches Dated August 25, 2008 Summary During utility testing of an AK-2A-50 circuit breaker it was identified that a failure in a Safety Related GE Hitachi Nuclear Energy (GEH) model F (part number Q192A7153P7) cutoff switch had occurred. An investigation indicates that the failure was caused by an apparent weak spring in the switch that creates the motive force to change position. Both the F and G cutoff switches both utilize the same spring to provide motive forces to change position.

GEH provided the F and G cutoff switches (part numbers Q192A7153P7 and Q192A7153P8 respectively) under unspecified application purchase orders and as such did not have the information required to determine if a Substantial Safety Hazard may exist or have been created, or this potential defect could have lead to the violation of a Technical Specification Safety Limit, therefore, GEH provided a Transfer of Information to the utilities that purchased these devices as unspecified application in accordance with 10CFR21.21(b) so that each identified utility could review their individual plant conditions to determine if the noted condition represents a reportable condition.

However, since additional licensees may have obtained these devices through other means, GEH cannot assure that all end-users have been identified and/or notified.

GEH is therefore providing this information to the NRC for appropriate action.

MFN 08-645 Page 2

Background

On February 13, 2008 a General Electric AK-2A-50 circuit breaker failed to close electrically during preventive maintenance activities at a utility. The F switch (Q192A7153P7) was replaced during a circuit breaker overhaul performed by maintenance personnel at that utility. The circuit breaker was last overhauled in 2004. The F switch is a normally open switch that closes when activated, which is part of a control permissive circuit to allow the circuit breaker to close electrically.

The circuit breaker was opened and removed from the plant in support of preventive maintenance activities. A test box was connected to cycle the circuit breaker electrically. The close button was operated and the 52X relay picked up, but the circuit breaker did not close. The F switch was shown to be open by a resistance test. It was then verified that the F switch was fully activated. The F switch was then actuated an additional 3/16-inch and was still found to be open by a resistance test. The F switch was then cycled on the bench and still found to be open.

A replacement F switch, which was obtained from site stock, also failed after 35 cycles. The F switch was replaced again with an F switch from site stock from a more recently purchased batch than the previous switches that had failed. The circuit breaker was then cycled to ensure it was working satisfactorily, and the test was performed satisfactorily. The breaker was returned to service. There have been two other documented events involving defective F switches at this utility.

The defective F switches were returned to GEH for evaluation.

This same switch is sold as a renewal part by GEH as part number Q0192A7153P007 and is used in the overhaul and refurbishment of the AK-50/75/100 and AKR-30/50 families of safety related low voltage power circuit breakers.

GE-Industrial Systems Product Department issued Service Advisory Letter (SAL) 316.0 on January 16, 2003. This SAL described a defect found with the G switch, which is a Normally Closed (NC) pushbutton switch, part number 192A7153P8. The SAL describes an issue where AKR & WavePro Low Voltage Power Circuit Breakers, produced during fiscal week 43 of 2002 (Date code P243&) and fiscal week 44 of 2002 (Date code P244&) may have been manufactured with non-conforming Motor cutoff G switches that may fail to open and fail to de-energize the electric charging motor. GE-Industrial Systems uses this switch in various electrically operated low voltage power circuit breaker control circuit designs. The switch provides a control permissive to the circuit breaker closing spring charging motor and opens when the closing spring is fully charged. The switch opening interrupts power to the charging motor and the motor stops. The defect, as described in SAL 316.0, causes sufficient variability of the switch operating point that in application the switch may not reliably open when acted upon by the parent circuit breaker linkage. If this occurs the charging motor will continue running until damage occurs caused by overheating.

MFN 08-645 Page 3 A similar switch (Type G) is sold as a renewal part by GEH as part number Q0192A7153P008 and is used in the overhaul and refurbishment of the AK-50/75/100 and AKR-30/50 families of safety related low voltage power circuit breakers. A switch failure of the type, described in SAL 316.0, has not been reported in safety related applications.

Refer to figures 1 - 3 for F & G switch typical installation and electrical application.

Figure 1: Motor cutoff switch unit Figure 2: F & G switch mounting location

MFN 08-645 Page 4 Figure 3: Typical elementary diagram for electrically operated drawout breaker with F and G switches. Contact positions are shown with breaker open and closing springs discharged.

Discussion Per the GEH evaluation it was concluded, by examination of an X-ray of the internal components of the F switch (Q192A7153P7), that the contact carrier assembly between the lower and upper contact clips had not adequately changed position indicating a weakness in the internal spring. Item 14 (spring) was identified as the weak spring for the F switch (Q192A7153P7), causing a failure to change state.

Also, per SAL 316.0 it was noted, for the G switch (Q192A7153P8), the supplier built the switch with an incorrect, weaker spring supporting the switchs over-travel button. Both the F switch (Q192A7153P7) and G switch (Q192A7153P8) were manufactured with the same internal components with the only difference being the orientation of the contact carrier assembly during component assembly (refer to figures 4 & 5).

MFN 08-645 Page 5 Figure 4: F & G switch internal component view Figure 5: F & G Internal component description

MFN 08-645 Page 6 Per GE C & I, Plainville, Cutler-Hammer was the manufacturer for both the F (Q192A7153P7) and G (Q192A7153P8) switches, which later sold the product line in approximately 2003 to another vendor. Cutler-Hammer was the manufacturer of both the F and G switches that have experienced the documented failures.

Therefore, this notification applies to all F (Q192A7153P7) and G (Q192A7153P8) switches shipped during or before 2003 that are marked by C-H on the bottom of the base. There have been no reported failures or defects for either the F or G switches since Cutler-Hammer sold the product line to the new manufacturer. GE C & I continues to use both the F & G switches in present breaker designs with no documented failures since the change in suppliers.

Recommendation Those plants that utilize GEH Type F or G cutoff switches (part numbers Q192A7153P7 and Q192A7153P8 respectively) utilized in AK-50/75/100 and AKR-30/50 families of Safety Related low voltage power circuit breakers, or Eaton Cutler-Hammer switches (part number 8980K250 or 8980K251) utilized in any Safety Related application, should identify those applications, review the impact of the potential defect described above on the Safety Related system and schedule replacement of any devices marked with C-H on the base of the switch with switches that do not bear the C-H marking, at the earliest convenience.

If you have any questions, on this information, please call me at (910) 602-4491.

Sincerely, Dale E. Porter Safety Evaluation Program Manager cc: M. C. Honcharik (NRR/ADRO/PDR/PSP) Mail Stop OWFN 12 E1 C. V. Hodge (NRR/ADRO/DIRS/IO) Mail Stop OWFN 12 G13 P. L. Campbell (GEH)

M. E. Harding (GEH)

J. F. Harrison (GEH)

J. F. Klapproth (GEH)

A. Lingenfelter (GNF)

PRC File

MFN 08-645 Attachment 1 Potentially Affected Plants Utility Plant X AmerGen Energy Co. Clinton X AmerGen Energy Co. Oyster Creek X Constellation Nuclear Nine Mile Point 1 X Constellation Nuclear. Nine Mile Point 2 X Detroit Edison Co. Fermi 2 X Dominion Generation Millstone 1 X Energy Northwest Columbia X Entergy Nuclear Northeast FitzPatrick X Entergy Nuclear Northeast Pilgrim X Entergy Operations, Inc. Grand Gulf X Entergy Operations, Inc. River Bend X Entergy Nuclear Northeast Vermont Yankee X Exelon Generation Co. CRIT Facility X Exelon Generation Co. Dresden 2 X Exelon Generation Co. Dresden 3 X Exelon Generation Co. LaSalle 1 X Exelon Generation Co. LaSalle 2 X Exelon Generation Co. Limerick 1 X Exelon Generation Co. Limerick 2 X Exelon Generation Co. Peach Bottom 2 X Exelon Generation Co. Peach Bottom 3 X Exelon Generation Co. Quad Cities 1 X Exelon Generation Co. Quad Cities 2 X FirstEnergy Nuclear Operating Co. Perry 1 X FPL Energy Duane Arnold X Nebraska Public Power District Cooper X Nuclear Management Co. Monticello X Pooled Equipment Inventory Co. PIM X PPL Susquehanna LLC Susquehanna 1 X PPL Susquehanna LLC Susquehanna 2 X Progress Energy Brunswick 1 X Progress Energy Brunswick 2 X PSEG Nuclear Hope Creek X Southern Nuclear Operating Co. Hatch 1 X Southern Nuclear Operating Co. Hatch 2 X Tennessee Valley Authority Browns Ferry 1 X Tennessee Valley Authority Browns Ferry 2 X Tennessee Valley Authority Browns Ferry 3 1

MFN 08-645 Utility Plant X BKW-FMB, Ltd Muehleberg X Chubu Electric Power Co. Hamaoka 1-4 X Chugoku Electric Power Co. Shimane 1-2 X Comision Federal de Electricidad Laguna Verde 1-2 X Forsmarks Kraftgrupp AB Forsmark 1-3 X Iberdrola SA Cofrentes X Hokuriku Electric Power Co. Shika 1 X Japan Atomic Power Co. Tokai 2 X Japan Atomic Power Co. Tsuruga 1 X Kernkraftwerk Gundremmingen Gundremmingen B, C GmbH X Kernkraftwerk Leibstadt AG Leibstadt X Nuclenor SA Santa Maria De Garona X OKG Aktiebolag Oskarshamn 1-3 X Taiwan Power Company Chinshan 1-2 X Taiwan Power Company Kuosheng 1-2 X Taiwan Power Company Lungmen 1-2*

X Tokyo Electric Fukushima Daiichi 1 X Tokyo Electric Fukushima Daiichi 2 X Tokyo Electric Fukushima Daiichi 6 X Tokyo Electric Fukushima Diani 1-4 X Tokyo Electric Kashiwazaki 1-5 X Tokyo Electric Kashiwazaki 6-7 X Vattenfall AB Ringhals 1

• Under construction Note: Fukushima Daiichi # is 1F# - Daiichi means 1. Fukushima Diani # is 2F# - Diani means 2.

1F1 and 1F2 are Mark I containment 1F6 and 2F1-4 are Mark II containments 2

MFN 08-645 Utility Plant X Ameren/UE Corp. Callaway X AmerGen Energy Three Mile Island 1 X Arizona Nuclear Power Project Palo Verde 1 X Arizona Nuclear Power Project Palo Verde 2 X Arizona Nuclear Power Project Palo Verde 3 X Carolina Power & Light Robinson X Carolina Power & Light Shearon Harris X Constellation Nuclear Calvert Cliffs 1 X Constellation Nuclear. Calvert Cliffs 2 X Dominion Generation Millstone 2 X Dominion Generation Millstone 3 X Dominion Generation North Anna 1 X Dominion Generation North Anna 2 X Dominion Generation Surry 1 X Dominion Generation Surry 2 X Duke Energy Nuclear LLC Catawba 1 X Duke Energy Nuclear LLC Catawba 2 X Duke Energy Nuclear LLC. Oconee 1 X Duke Energy Nuclear LLC. Oconee 2 X Duke Energy Nuclear LLC. Oconee 3 X Duke Power Co. McGuire 1 X Duke Power Co. McGuire 2 X Entergy Nuclear Arkansas Nuclear One 1 X Entergy Nuclear Arkansas Nuclear One 2 X Entergy Nuclear Indian Point 2 X Entergy Nuclear Indian Point 3 X Entergy Operations, Inc. Waterford 3 X Exelon Generation Co. Braidwood 1 X Exelon Generation Co. Braidwood 2 X Exelon Generation Co. Byron 1 X Exelon Generation Co. Byron 2 X Exelon Generation Co. Zion 1 X Exelon Generation Co. Zion 2 X First Energy Nuclear Operations Beaver Valley 1 Co.

X First Energy Nuclear Operations Beaver Valley 2 Co.

X FirstEnergy Nuclear Operating Co. Davis-Besse X Florida Power & Light Co. St. Lucie 1 X Florida Power & Light Co. St. Lucie 2 X Florida Power & Light Turkey Point 3 X Florida Power & Light Turkey Point 4 X Florida Power Corp. Crystal River 3 X Indiana Michigan Power Cook 1 X Indiana Michigan Power Cook 2 3

MFN 08-645 Utility Plant X Maine Yankee Atomic Power Co. Maine Yankee X North Atlantic Energy Service Corp. Seabrook X Nuclear Management Co. Kewaunee X Nuclear Management Co. Palisades X Nuclear Management Co. Point Beach 1 X Nuclear Management Co. Point Beach 2 X Nuclear Management Co. Prairie Island 1 X Nuclear Management Co. Prairie Island 2 X Omaha Public Power District Fort Calhoun X Pacific Gas & Electric Co. Diablo Canyon 1 X Pacific Gas & Electric Co. Diablo Canyon 2 X PSEG Nuclear LLC Salem 1 X PSEG Nuclear LLC Salem 2 X Rochester Gas & Electric Corp. Ginna X South Carolina Electric & Gas Co. Summer X South Texas Project Nuclear South Texas Project 1 Operating Co.

X South Texas Project Nuclear South Texas Project 2 Operating Co.

X Southern California Edison Co. San Onofre 2 X Southern California Edison Co. San Onofre 3 X Southern Nuclear Operating Co. Farley 1 X Southern Nuclear Operating Co. Farley 2 X Southern Nuclear Operating Co. Vogtle 1 X Southern Nuclear Operating Co. Vogtle 2 X Tennessee Valley Authority Sequoyah 1 X Tennessee Valley Authority Sequoyah 2 X Tennessee Valley Authority Watts Bar 1 X TXU Electric Generation Co. Comanche Peak 1 X TXU Electric Generation Co. Comanche Peak 2 X Wolf Creek Nuclear Operating Wolf Creek Corp.

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