ML20079G079

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Interim Deficiency Rept Re Broken/Cracked Puffer Piston Rods in Model 5 Hk Breakers Mfg by Brown-Boveri.Initially Reported on 831213.Safety Evaluation Performed. Nonconformance Rept Issued.Next Rept by 840330
ML20079G079
Person / Time
Site: Midland
Issue date: 01/12/1984
From: Jackie Cook
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To: James Keppler, Keppler J 14P
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
26661, 83-13-#1, NUDOCS 8401190402
Download: ML20079G079 (14)
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Consumers power James W Cook Vice Presil,nt - Projects, Engineering and Construction General offices: 1945 West Parnell Road, Jock.on, MI 49201 e (517) 788 0453 January 12, 1984 83-13 #1 Mr J G Keppler, Regional Administrator US Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND ENERGY CENTER PROJECT DOCKET NOS 50-329 AND 50-330 BROWN-B0 VERI BROKEN / CRACKED PUFFER PISTON ROJS FILE:

0.4.9.85 SERIAL:

26661 On December 13, 1983, Consumers Powar Company notified your staff of a potential 10CFR50.55(e) condition involving broken / cracked Puffer Piston Rods in Model 5 Hk breakers manufactured by Brown-Boveri.

This letter is an interim 10CFR50.55(e) report. The attachments to this letter describe the concern and summarize the investigation and corrective action taking place.

Another report, either interim or final, will be sent on or before March 30, 1984.

JWC/AHB/lr Attachments:

(1) MCAR-1, Report No 77, dated December 14, 1983.

(2) MCAR-77, Interim Report 1, dated January 3, 1984.

CC: Do'cument Control Desk, NRC

~

Washington, DC RJCook, NRC Resident Inspector Midland Nuclear Plant DHood, USNRC Office of NRR INPO Records Center 8401190402 840112 PDR ADOCK 05000329 S

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Q AN 16 S34 OC0184-0025A-MP01 TJ [-)3

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Serial 26661 83-13 #1 OM/0L SERVICE LIST Mr Frank J.Kelley Atomic Safety & Licensing Attorney. General of the-Appeal Board State of Michigan U S Nuclear Regulatory Commission Ms Carole Steinberg, Esq Washington, DC 20555 Assistant Attorney General

~

Environmental Protection Division Mr C R Stephens (3) 720 Law Building.

Chief, Docketing & Services

. Lansing, MI 48913 U S Nuclear Regulatory Commission Office of the Secretary -

Per Myron M Cherry, Esq

- Suite 3700 Ms Mary Sinclair Three First National Plaza 5711 Summerset Street Chicago, IL 60602 Midland, MI 48640 LMr Wcndell H Murshall Mr William D Paton, Esq RFD 10-Counsel for the NRC Staff Midland, MI 48640 U S Nuclear Regulatory Commission Washington, DC 20555

~ Mr Cliarles Bechhoefer,- Esq Atomic Safety & Licensing Atomic Safety & Licensing Board Panel Board Panel U S Nuclear Regulatory Commission U S Nuclear Regulatory Commission Washington,'DC 20555 Washington, DC 20555

- DrLFrederick P Cowan Ms Barbara Stamiris

.6152 N Verde Trail'

.5795 North River Road Apt B-125 Rt 3 Boca Raton, FL 33433 '

Freeland, MI 48623 Mr Fred C Williams

_Mr Jerry Harbour

.Isham, Lincoln & Beale Atomic Safety.& Licensing 1120-Connecticut Ave, NW, Suite 325 Board Panel Washington, DC 20036 U S Nuclear Regulatory Commission e

Washington, DC 20555 Mr James E Brunner Esq Mr M I Miller, Esq Consumers. Power Company Isham, Lincoln & Beale 212 West Michigan Avenue Three First National Plaza-

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EJackson, MI 49201-52nd Floor Chicago, IL 60602 Mr_D F.Judd.

10: John Demeester, Esq Babcock.& Wilcox Dow Chemical Building PO Box'1260-Michigan Division Lynchburg, VA 24505 Midland, MI_48640 l

.Mr Steve Gadler, Esq~

Ms Lynne Bernabei

-2120 Carter Avenue Government Accountability Project St Paul, MN 55108 1901 Q Street, NW Washington, DC 20009 OC0184-0025A-MP01

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' "OUALITY ASSURANCE PROGRAM i

MANAGEMENT CORRECTIVE ACTION REPORT 77 MCAR-1 REPORT NO.

.x 12/14/83 J

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7220 0 NO. _

DATE l' DESCHIPTION (Including references):

Model 5 hk breakers manuf actured by 3rown BoverI from 1960 through 1980 may have broken / cracked puffer pistons. If these puf fer pistons are not broken / cracked, there is potential for such cracking.

(continued)

  • RECOMMENDED ACTION (Optional) 1.

Conplete a safety evaluation to cetermine the lupact on safety of operations at the Midland plant.

2.

Identif y all suspect breakers and ensure they are controlled in accordance with project procedures for nonconforming items.

(continued)

REFERRED TO 2 ENGINEERING O CONSTRUCTION O OA MANAG MENT O

NWb /MdM O PROCUREMENT ISSUED Y o* NOTE: This was reported to the NRC by client on P ProjectOA Engin /

bate 12/13/83 as a notentially reportable 10CTR 50.55(e) condition.

Il REPORTABLE DEFICIENCY NOTIFIED CLI O NO

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Project Mag

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111CAUSE l

l CORRECTIVE ACTION TAKEN AUTHORIZED BY Date STANDARD DISTRIBUTON ADDITONAL DISTRIBUTON AS APPROPRIATE DMSON OA MANAGER LNGINEERNG MANAGER FORMAL REPORTTO CLIENT MANAGER OF OA BPC PROJECT ENGNEER (if Sectionll Applies)

Date GPD OA MANAGER OE SUPERVISOR LAPD OA MANAGER SFPD OA MANAGER CONSTRUCTON MANAGER PROJECT MANAGER PROJ SUPT /PROJ CONSTR MANAGER CLIENT CHIEF CONSTR OC ENGINEER CORRECTIVE ACTION IMPLEMENTED DMSON PROCURENT MGR PROJ PROCUREMENT MGR PROCUREMENT SUPPUER QUAUTY MGR AND DfV SUPPUER QUAUTY MGR VERIFIED BY Projec'OA Engmeer Date

  • Describe in space provided and attach reference document.

AAPD-0161

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MCAR 77 Page 2 137137 Description (continuedh Because the puf fer pistons cre needed to extinguish an arc at low current values (approximately l

1,000 amperes and below), the damaged puf fer pistons could result In f ailure to open circuit breakers on demand. The inability to extinguish en arc may result in permanent damage to the sw itc!.gaar. The inability to open circuit breakers on demand and possible damage resulting from not extinguishing an arc could result in Inability of safety-related loads to perform their Intended function.

Recommended Action (continued):

3.

Coordinaie with Brown Bovert to determine the cause of puf for piston cracking and corrective actions necessary to prevent recurrence.

4.

Investigate and determine if there, are similarities in design and/or materials in other types of breakers which may make them subject to puf for piston cracking.

5.

Issue a report, Interim or final, by December 29, 1983.

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13870g Bechtel Power Corporation 777 East Eisenhower Parkway Ann Arbor, Michigan Matt Ad@ess: P.O. Box 1000, Ann Arbor. Michigan 48106 January 3, 1984 BLC-18756 Consumets Power Company 1945 Parnall Road Jackson, Michigan 49201 Attention: Mr. J.W. Cook Vice President Projects, Engineering and Construction

Subject:

Midland '.iant Units 1 and 2 Consumers Power Company Bechtel Job 7220 MCAR 77 - Interim Report 1 Interim Report 1 for MCAR 77, concerning broken / cracked puffer pistons in Class lE type 5 HK breakers (manufactured by Brown Boveri between 1960 and 1980), is attached for your information and use.

The next report, interim or final, will be issued by March 14, 1984 Very truly yours, M

l John utgers y Proj Manage.r JAR /GEC/ mrv l

Attachment:

MCAR 77 - Interim Report 1 CC:

W.R.' Bird )

F.W. Buckman J.W Cook G.R. Eagle W. Friedrich L. Gibson J.P. Knight D.T. Pe."ry D.L. Quamme B.W. Marguglio i

R.A. Wells l

(all w/a)

Written Response Requested: No i

'b3 85 5 4 Bechtel Associates Professional Corporation i3810I

SUBJECT:

MCAR 77 (issued 12/14/83)

Broken / Cracked Puffer Piston Rods in Model 5 Hk Breakers Manufactured by Brown Boveri Between 1960 and 1980 INTERIM REPORT 1 DATE:

January 3, 1984 PROJECT:

Consumers Power Company Midland Plant Units 1 and 2 Bechtel Job 7220 Introduction This report provides the status and course of action required pursuant to MCAR 17.

Description of Deficiency Brown Boveri Type 5 Hk circuit breakers manufactured between 1960 and 1980 may have broken / cracked puffer piston rods.

Summary of Investination and Historical Background This deficiency was identified by The Detroit Edison Company at the Fermi nuclear plant and documented in a Brown Boveri letter to Bechtel dated Octobor 31, 1983 (com 133441) (Attachment 1).

The Midland 4,160 V, Class 1E switchgear uses Brown Boveri Model 5 Hk circuit breakers. All breakers (except breakers in cubicles 1A06-12 and 2A06-12) supplied for the Midland plant were manufactured between 1960 l

and 1980.

l Analysis of Safety Implication i

The puffer piston rodt (one for each pole of a breaker) ensure extinction l

of an arc at low current values (below 1,000 amperes). If the puffer piston rods of a circuit breaker are broken, opening of the breaker may not interrupt the resulting arc. The presence of an are could lead to a path to ground resulting in a ground fault for the entire assembly, causing permanent damage to the switchgear. The safety-related ac loads, powered from these switchgears, may therefore be unable to perform their intended function.

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138554 Bechtel Associates Professional Corporation En 77

$00 0$

Interim Report 1 Page 2 i

The above analysis is based on Brown Boveri's interim report and verbal clarifications. Further analysis will be made upon receipt of the final report from Brown Boveri and will be included in our next report.

Probable Cause L

Brown Boveri stated in a telephone conversation that the root cause is a lack of quality control at the subsupplier's facility manufacturing the puffer piston rods. There was a lack of definition of the length of time for holding the temperature of the puffwr piston rod material before pouring. Written confirmation and further explanation are being roguested from the vendor regarding the probable cause and corrective actions taken to prevent recurrence and will be included in our next report.

Corrective Action The corrective actions to resolve this NCAR are as follows.

1.

A safety evaluation was performed to determine the impact on safety of operations at the Midland plant, and was documented in Bechtel internal correspondence (Com 137410, dated December 16, 1983).

2.

Nonconformance Report (NCR) D-00005 was issued December 20, 1983, to identify and control this nonconforming condition. The Class IE breakers will be examined for broken / cracked puffer piston rods (see ).

This activity is forecast to be complete by February 29, 1984. Any broken / cracked puffer piston rods found during the fleid inspection will be replaced.

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j 3.

Requirements will be added to inspect the breakers at normal j

maintenance intervals for broken / cracked puffer piston rods. QAR RD0023 was issued for inclusion of the puffer piston rod inspection into the appropriate maintenance procedure.

4.

An investigation of the Midland design indicates that there are no other safety-related breakers with similar design and/or material.

Therefore, only Class 1E, 4,160 V breakers manufactured by Brown Boveri (see Attachment 2) could be subject to the concern of broken puffer piston rods.

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p.p 138554 Bechtel Associates Professional Corporation 3870l MCAR 77 Interin Report 1 Page 3 5.

The next report for this MCAR is forecast to be' issued March 14, 1984.

Submitted by:

AM gg E.B. Poser l' Project Engineering Manager pproved hw-

.H. Smith /

/

Engineering Manager Concurrence by:

Mb fst-M. A. Dietr[ ject Quality h

Midland Pro Assurance Engineer I

JGK/M/sune*(E)

Attachments:

1.

Brown Boveri Electric, Inc., letter to Bechtel, 10/31/83 (Com 133441) 2.

List of Class IE, 4,160 V Breakers Supplied by Brown Boveel and Manufactured Between 1960 and 1980 l

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I33441 October 31, 1983 i

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P.O. Box 1000 i

Ann Arbor, MI 48106 ATTENTION:

Mr. Rutgers l

Project Manager EUBJECT:

P.O. 7220-E-205-AC Bechtel/ Consumers (Midland)

Metal Clad Switchgear

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S.O. 33-50382 --

REFERENCE:

Detroit Edison Company Enrico Fermi Generating Station CFR50.55 (E) Report Dated March 17, 1983 Brown Boveri Electric 5HK250/350, 1200/2000 amp Circuit Breakers - Cracked and Broken Puffer Piston Rods GENTLEMEN:

Enclosed you will find a copy of a letter from Brown Boveri Electric, Inc.

with attachments sent to the US Nuclear Regulatory Commission dated October 5, 1983.

Regards, BROWN BOVERI ELECTRIC, INC.

I. Jack Fahlen Executive Sales Engineer IJF/kaf Enclosures (fyJi' ERTY.~Nughes ' ~3echeQ'7 5

(313) 866 0333 20200 orchard Lake Reed. Suite 110 Fermington Hills, MI 40018 e

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. : _S_C _B. ro.w.. n..-. '--) vari Electric,.inc.'0-Manufacturer of 8-T-E Electrical Power Equ'ptnern,.

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Office of Inspection & Enforcement U. S. Nuclear Regulatory Commission Washington, D. C.

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Dear Mr. DeYoung:

On March 17, 1983 Detroit Edison Company (Fermi II) filed a 10CFR50.55(e) report with the NRC concerning some cracked and broken puffer piston rods in the Brown Boveri Electric SHK 250/350,1200/2000A circuit breakers.

l Attached is an interim report on the BBE evaluation status to date on this '

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Based on the test results and other information available at this time the BBE recommendation is to inspect for cracked or broken puffer piston push rods at rmal mainten&nce intervals and to replace the puffer piston assem 1, this c.dition is found.

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DDD/ja Attachment cc:

A. E. Boetticher W. E. Laubach v.E. W.;Rhoads-l L. B. Schmidt f

J. R. Silverio I

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-PUFFER PISTON RODS l

The purpose 'of this interia report is to summarize the status of the evalu-ation to date and to provide a history regarding cracked / broken puffer piston rods (Part No. 193642-B) in the Brown Boveri Electric SEK 250/350,1200/2000A circuit breakers.

In January,1983, a report of some cracked / broken puffer piston rods at the

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Mohave Generating Station of Southern California Edison in lauglin, Nevada was received. These circuit breakers are SEK 350-1200A supplied on S.O.

l 33-44107 and have been in operation since about 1970. The cracks / breakage of the puffer piston rods occurs at the operating pin hole. The conditiota were i

noted while performing an overhaul on the circuit breakers, with some twenty i

(20) circuit breakers in Unit No.1 and twenty (20) in Unit No. 2, thus a total of 120 puffer pistons are in operation at this station. A total of eight (8)

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puffer piston rods were found to be broken. The number of puffer piston rods that were cracked is not known, however the user ordered a total of twenty (20)

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replacement parts.

The average ambient temperature at this station is about 80*F.

Temperature excursions normally vary between 35'F and 125'F, but extreres to a low of

+30*F and a high of 135'F have occurred.

The hunidity is normally between 10% and 15%. No more than one broken puffer piston rod per breaker was found during any inspection.

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A March 17, 1983 report received from Detroit Edison (Fermi) indicates that one (1) broken puffer piston rod and nine (9) cracked rods in 5HK 350-1200A circuit breakers were found.

These circuit breakers were manufactured in 1973 on S.0. 33-47196 and the reported conditions were noted in a total of five (5) circuit breakers. No operation count was reported on these breakers.

A BBE Service Engineering Report dated August, 1983 identifies that some i

5HK 250-1200A and 2000A at the Salt River. Project / Navajo Generating Station manufactured between 1972 and 1980 were --hed for puffer piston rod cracks.

There are approxi'mately eighty41x (86) circuit breakers at this location, i

some of which have over 10,000 operations. This inspection showed that there were no cracks or breakage in any of the puffer piston rods. The environ-

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mental conditions at this station are similar to those noted at the Mohave Generating Station.

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The 5R circuit' breakers have been in production since 1960 with essentially I

the same design configuration and materials used today.

The puffer piston I'

tube was originally made with Zytel 101 unfilled materish This material was used until 1980 when the vendor and material was changed ts Wylafil El-30-EM.

Puffer piston rods of both the Zytel and Nylafil material have been subjected to thermal aging tests with no significant degradation trend being noted after initial " drying out" of the nylon material.. When humidified after long exposure 'at high temperature the material returns to essentially the same strength characteristics as when new. Thermally aged puffer piston rods in the dry condition were subjected to endurance testing of over 5000 operations.

Subsequent inspection of these items disclosed no cracking or damage to the j

puffer piston rods.

Three (3) puffer piston rods with cracks were obtained from Detroit Edison Termi 2 station. These were subjected to mechanical endurance testing in a test breaker to investigate the tendency for existing cracks to progress into failures. Af ter 1200 operations, the inspection indicated that the cracks g

did not propagate nor did any parts break One of the puffer piston rods for

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this rett was modified wherein the holes for the operating pin were redrilled in a smaller diameter to, determine if this interference fit of the pin could result in a test failure.

The inspection of this part upon the completion of the endurance test (1200 operations) indicated that cracks had not devel-oped.

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A puffer piston in the SEK circuit breaker performs two functions. For low current interruptions the puffer is needed to assist the magnetic forces to sove the arc into the interrupting chamber. A puffer piston also provides a pneumatic cushion which reduces the shock forces imposed on the mechanism and current carrying parts on opening.

For lower values of current, arc inter-ruption could be adversely affected by failure of one puffer piston with failure to extinguish the arc. Mechanically, loss of a puffer could reduce the number of operations before maintenance would be necessary.

BBE has never experienced a circuit breaker failure due to a broken puffer i-piston rod.

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~At this time, theBBE evaluation of data indicate that aging is not a likely cause for the puffer piston rod cracks. Also, BBE resting and the sampling 9

inspections conducted to date also indicate that the cracking is not a generic defect e.

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Efforts are under way to obtain additional aged samples from the field and consultations with other materials. experts are planned. At the time of this interim report there is no clear explanation for the presence of puffer piston rod cracks at Terni 2.

Tnformation gathered to date also indicates that no more than one. broken puffer piston rod per breaker has been found at any inspection.

BBE is continuing its evaluation of this situation at.d will keep you advised of any significant findings.

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The BBE recommendation at this time is to inspect for this condition at normal maintenance intervals and to replace cracked or broken assemblies. The assembly part number is 193989-T2.

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