ML20081H480
| ML20081H480 | |
| Person / Time | |
|---|---|
| Site: | Oconee, Mcguire, Catawba, Seabrook, River Bend, McGuire, 05000000, Marble Hill |
| Issue date: | 11/03/1983 |
| From: | Duvall D BBC BROWN BOVERI, INC. (FORMERLY BROWN BOVERI CORP. |
| To: | Deyoung R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| References | |
| REF-PT21-83-049-000 IEIN-83-63, PT21-83-049-000, PT21-83-49, NUDOCS 8311070472 | |
| Download: ML20081H480 (15) | |
Text
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9 BBC Brown Boveri eiectric, inc.
BROWN BoVERI Manufacturer of I-T-E Electrical Power Equipment November 3, 1983 Mr. R. C. DeYoung, Director Office of Inspection & Enforcement U. S. Nuclear Regulatory Commission Washington, D. C.
20555
Dear Mr. DeYoung:
This letter is a follow-up to a telephone report made to Mr. W. Laudan of your office on October 12, 1983.
It is also a follow-up to a Brown Boveri Electric 10CFR Part 21 report to the NRC dated April 27, 1983 which resulted in the issuance of IE Information Notice No. 83-63; Potential Failures of Westinghouse Electric Corporation Type SA-1 relays, wherein a potential problem of defective SCR's was identified.
Enclosed is an October 25, 1983 letter from Westinghouse Electric Corporation which identified additional potential problems with the SA-1 relay caused by a tantalum capacitor leaking electrolyte and the possibility that some of the relays do not meet the SWC requirement of ANSI C37.90-1978.
Although the capacitor and SCR problems could result in a malfunction of the SA-1 relay, BBE does not consider the SWC condition to be a reportable problem.
With the advent of solid state devices for protection in power systems, a surge test was developed to " screen" solid state relays for adequacy of the electronic junction devices to withstand electrical surges. The requirements of that "new" standard (ANSI C37.90-1978) imposed a capacitor-stored charge which reaches a peak voltage of 2400V. Due to a field malfunction of an SA-1, Westinghouse conducted exlaustive tests on the SA-1 relay indicating the only test-related shortcoming to be a tolerance on the DC input of only 1800V, thus falling short of the surge withstand criteria.
The malfunction experienced by Westinghouse during the electronic component " screening" surge test was not an electronic component malfunction and no permanent damage resulted.
Control systems data under all conditions of primary fault interruption and DC component operations indicates that actual transient voltage peaks in switch-gear control systems are well below the 1500V limitation imposed by industry standards. Thus the demonstrated capability of the Westinghouse device is adequate to withstand expected transients on 125VDC control systems.
It is our position, based on the above described situation, that the malfunction requiring a modification is not a problem which degrades the safety of a switch-gear system utilizing the SA-1 relay.
It is a failure to meet a test criteria imposed by ANSI C37.90 but is not a probable cause of a system malfunction under 8311070472 831103 PDR ADOCK 05000269 5
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Spring House, PA 19477 e (215) 628 7400 t
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BROWN BoVERI Mr. R. C. DeYoung Novecher 3, 1983 Page 2 any conditions which we can reasonably postulate.
Therefore, the SA-1 relay problem concerning the SWC requirement is not a reportable defect under 10CFR Part 21.
The enclosed letter lists certain SA-1 relays identified by Westinghouse as Class lE relays delivered to Brown Boveri Electric.
These SA-1 relays have been used as follows:
S/N CUSTOMER 4772 Duke Power /McGuire 5768A (In stock at Chalfont, Pa.)
6912 Stone & Webster / River Bend Project 7808 Stone & Webster / River Bend Project 8416 Stone & Webster / River Bend Project 8417 Stone & Webster / River Bend Project 8418 Stone & Webster / River Bend Project Other SA-1 relays have been used in Class lE applications by Brown Boveri Electric which include:
Public Service Indiana Marble Hill Public Service New Hampshire Seabrook Duke Power Oconee Duke Power Catawba There are possibly other SA-1 relays which have been used in Class lE applica-tions. BBE will continue to research the records to identify other users and identify them at a later date.
Please advise us if we can be of any further assistance in this matter.
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D. D. DUVALL
[f Vice President DDD/jm Enclosure cc:
A. V. Boetticher, J. A. Cosgrove, D. Dalasta, W. E. Laubach, D. R. Purkey, E. W. Rhoad s, J. R. Silverio, W. Laudan - NRC
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ElectricCorporation ay coraispins,rkrknaa0es (305) 752 4700 October 25, 1983 Mr. E. W. Rhoads Brown Boveri Electric, Inc.
Switchgear Systems Division Spring House, PA 19477 Re: SA-1 Class lE Relays Required Modifications
Dear Mr. Rhoads:
This letter is intended to provide my approval of field modification of SA-1 Class lE relays in lieu of returning them to Coral Springs
.for replacement of tantalum capacitors.
Since you and I discussed this by phone on October 12, I thought the most expeditious action was to write to you directly rather than going through Mr. Taboga, as with previous correspondence.
Background:
As you are aware, we have discovered three potential problems with the SA-1 relay.
The intent of this round of modifica-tions must be to correct all the problems and bring the relays into agreemene with the latest design.
The problems that require correc-tion are listed below.
Not all relays in the field will need correc-tion for all problems, since some corrective actions have already been taken and later production relays encorporated corrections 1 l
and/or 2 in their design.
1.
Not meeting the full SWC requirement of ANSI C37.90-1978.
2Property "ANSI code" (as page type) with input value "ANSI C37.90-1978.</br></br>2" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process..
Uninitiated trip output potential in relays containing ST Semicon trip output SCR's.
3.
Tantalum capacitors leaking electrolyte.
Listed below are the SA-1 Class lE relays that we have supplied to you which require one or more of the action (s) outlined as follows.
Please note that this list includes, serial numbers 8416, 17 and 18, shipped to you in June 1983.
These three relays will
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only require-the replacement of the tantalum capacitors, Item 3 below.
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Mr. E. W. Rhoads October 25, 2983 Page 2 Serial No.
(W) G.O. No. & Item Customer Order No.
4772 PH68333-N1-H1 J96608-53566 5768A PH69899-N1-D J52531-53170 6912 PH61036-N1-C J57018-51128 7808 PH61316-N1-I J66315-51126 8416 PH61459-N1-C T70418-41059 8417 PH61459-N1-C T70418-41059 8418 PH61459-N1-C T70418-41059 Required Field Action:
The basic action required is to check each SA-1 relay for it's potential for exhibiting one or more of the problems listed above.
Identification of the potential for the problem and it's correction is outlined below:
1.
SWC Enhancement:
See Fig. 1, attached, to determine if relay must be modified to enhance it's surge withstand capability.
The following is background to this problem:
Idaho Power Company informed us of a SA-l' relay that.
was providing incorrect trip signals in a shunt reactor protection application in a substation.
Idaho believed the incorrect trips were caused by electrical noise.
Engineering investigated the situation by testing in accordance with Section 9, SWC Tests, of ANSI C37.90-1978.
The" relay was found to incorrectly trip on the common mode test for crest values of the oscillatory SWC test wave above 1.8kV, (the ANSI specification calls for a range of 1.5-3.0 kV) applied to terminals 1-2 and 1-10.
Engineering has developed a surge protection module that will bring the SWC capability of a 48/125 Vdc Class 1E SA-1 relay up to a level in excess of the requirements of ANSI C37.90-1978.
If inspection to Fig. 1 indicates that this module is not present style number 1584C21G01 surge protection module should be ordered.
Installation of this module may/be accomplished by following the " Supple-mentary Instru,dtions - Installation of SWC Module" included with this letter.
2.
SCR Replacement:
See Fig. 2, attached, to identify and locate the SCR that may be a source of uninitiated trip outputs.
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Mr. E. W. Rhoads October 25, 2983 Page 3 2.1 Tag the wires when disassembling to insure correct reconnection to the replacement SCR.
2.2 Do not stress the anode and cathode leads of the SCR when reconnecting the wires.
2.3 Do not overheat the SCR leads when resoldering.
Heat sinks applied to the SCR terminals during
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resoldering will help to-assure that overheating does not occur.
2.4 Correct replacement will be verified by the test and calibration procedure called for in the next action: tantalum capacitor replacement.
3.
Tantalum Capacitor Replacement:
Since it is the intent of this modification to bring relays in-line with the latest design, the whole printed circuit module will'be replaced rather than replacing only the tantalum capacitors.
See Fig. 1 attached to locate the printed circuit module to be replaced.
Replacement of the module should be accomplished by following the steps below.
Replacement of the module will probably affect relay calibration.
Test and calibration, step 3.5 below must be accomplished in it's entirety.
3.1 Remove the two mounting screws at the top sides of the module.
Remove the module from the socket.
3.2 Perform steps 2 and 3 under the heading " Test" in the attached " Supplementary Instructions - Test and Calibration".
3.3 Replace with a new module 408C673G0lSUB35 date coded CSA/0883 or later (see Fig's. 1 and 4 attached).
3.4 Replace the two mounting screws.
3.5 Test and calibrate the relay in-line with the attached
" Supplementary Instructions - Test and Calibration".
I
Mr.
E. W. Rhoads October 25, 1983 Page 4 4.
Documentation:
When there is assurance that all of the above modifications are present and the relay is calibrated (see 3.5 above) document as follows:
-4.1 Replace the nameplate with a new nameplate that indicates the style to be 1329D62A01D (the suffix indicates that all the modifications have been made).
4.2 Bring your own documentation up to date.
Send a copy of the amendment to your documentation to Warren J. Schmidt,
.QA Manager, Westinghouse Relay-Instrument ~ Division, 4300 Coral Ridge Drive, Coral Springs," Florida 33065.
4.3 Add " ADDENDUM TO WESTINGHOUSE I.L.41-348.11", effective June 1983, to the file.
It should be especially noted that this. addendum, under Page 4 - Par. 8 Maintenance, states: "The tantalum capacitors C1, C2, C3, C4, and "13 may have'a common mode failure characteristic and sivuld be checked visually for symptoms of electrolyte leakage every. year and replaced if necessary.
Change these capacitors every ten years".
Replacement Parts:
The following parts should be ordered through your local field sales office.
They will be supplied on a no charge basis.
The numbers called for are on a per relay basis.
Thefollowingparts.sgouldbeorderedonlyifrequired:
9 Silicon Controlled Rectifier (1) 184A614H05 (1) 1584C21G01 Surge Protection Module (1) 188A349H01 Mounting Bracket (L.H.)
(1) 188A349H02 Mounting Bracket (R.H.)
(2) 877A498H03 Screw (2) 183A917H02 Lockwasher The following parts are required in all instances:
(1) 3520A39H01 Nameplate (1) 408C673G01 Printed' Circuit Modula (3) 187A290H18 51 Ohm Fixed Composition Resistor (Type BTS - 1/2 Watt 5%)
(3) 187A290H21 68 Ohm Fixed Comoosition Resistor
.(Type BTS - 1/2 Watt t 5%)
a.
Mr. E. W. Rhoads October 25, 1983 Page 5 As noted in earlier correspondence, these modifications may also be accomplished by returning the relays to (W).
Please make arrange-ments for this option through your local field sales office.
Please let me know if I can be of furth.er assistance in this matter.
Yours very truly,
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W-l x Warren J.
Schmidt, Manager Quality Assurance WJS:vmy atc(s) cc:
G. F. Jackson, BBE, Chalfont D. A. Toboga, Philadelphia J. N. Santilli, RID R. Lakin, T. Brandenburg, W. Glassburn, M. Barreto,.~"
R. Weber, Attachments:
(W) IL 41-348.11, Effective: July 1979; " Type SA-1 Generator Differential Relay for Class lE Applications".
Addendum to (W) IL 41-348.11, Effective: June 1983 Fig. 1; Annotated Fig. 1. from IL 41-348.11 Fig. 2; Annotated Fig. 2. from IL 41-348.11 Fig. 3; Annotated Fig. 12. from IL 41-348.11 Fig. 4; Annotated Fig. 4. from Addendum to IL 41-348.11 Fig. 5; Installation of SWC Module
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GUPPLEMENTARY INSTRUCTIONS - INSTALLATION OF SWC MODULE:
Background:
Addition of a style number 1584C21G01 Surge Suppression Module to a 48/125 Vdc Class lE SA-1 relay insures that it's surge withstand level will be-in excess of ANSI C37.90- 1978.
The following steps are followed in installation:
Installation:
1.
Remove the printed circuit module at the front of the relay (see Fig. 1).
2.
Remove the printed circuit module connector from it's mounting bracket, (see Fig. 1).
Be careful not to break any of the electrical connections.
3.
Remove the mounting brackets and replace with style numbers 188A349H01 (L.H.) and H02 (R.H.).
4.
Mount the Surge Suppression Module (SPK) style number 1584C21G01 to the bracket oriented as shown in Fig. 5.
Fasten as illustrated.
5.
Connect the' leads from the Surge Suppression Module to the appropriate points in the relay as indicated in Fig. 5.
Note that the lead from point 4 on the printed circuit board must be soldered to the anode end'of the tripping SCR.
The following precautions must be observed:
5.1 Do not stress the anode or cathode leads of the SCR when connecting the lead from point 4 on the printed circuit board to the anode.
5.2.
Do'not overheat the SCR lead when resoldering.
A heat sink applied to the SCR terminal during resoldering will help to assure that overheating does not occur.
6.
Replace the printed circuit module connector.
7.
Replace the' printed circuit module.
8..
Perform tests 1-4 described in the " Supplementary Instructions -
Test and Calibration".
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SUPPLEMENTARY INSTRUCTIONS - TEST AND CALIBRATION:
Background:
Replacement of the printed circuit module (see Fig. 1), will probably change the calibration of the relay.
It is recommended however, that the relay be tested first, before attempting to calibrate to dete_mine if all modifications have been completed correctly.
The recommended test circuitry is shown in Fig. 3, Note (2) regarding the need for sinusoidal test currents is especially important.
The printed circuit module is delviered with three resistors R17, 18 and 19 (33 ohms, S/N 187A290H13, Fixed Composition Resistor - Type BTS, 1/2 watt 5%) soldered to standoffs.
These resistors control the calibration of the percentage slope characteristic at a normal operating current of 30 amperes. These resistors can be changed over a range from 0 - 100 ohms, to bring the percentage slope characteristic into calibration.
Test:
The relay should be tested for correct operation and calibration by following the steps below:
1.
The relay is applicable to 48 or 125 Vdc trip circuits.
The relay is shipped from the factory set for 125 bdc operation.
If the relay is'to be used in a 48 Vdc application, use the mid-tap on the resistor mounted at the top of the relay. The red dot on the resistor is.the common tap.
The connection to this tap should not be moved.
2.
Using the test circuit of Fig. 3, apply Step 2 de voltage to the relay.
Check to see that the de voltage on the printed circuit module connector terminals (8 and 12) is between 22.8 and 25.2 Vdc (see Fig. 4).
3.
.With ISR and IO at zero amperes, turn the dc voltage ON and OFF at least five times.
The WL switch should not pick up (the trip SCR should not false trip).
4.
Perform the test for minimum trip current and differential characteristic given on page 4 of IL 41-348.11 (effective July 1979) under the heading " Routine Test".
Note that the addendum to IL 41-348.11 (effective June 1983) modifies the opening. paragraph and 2.b.
If the relay passes the above test, no calibration is necessary and the relay may be placed in service.
Calibration:
The following information is intended to augment the information in the Calibration Section (page 4) of IL 41-348.11 and it's Addendum.
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5.
Connect the relay as shown in Fig.
4.
Note that the dc trip circuit should not be energized during'any of the calibration steps below.
6.
Minimum Trip Current:
With ISR at zero amperes, raise Io until the trip-indicator light (see Fig. 1).comes ON.
If Io is not in the range between 136-144 milliamps, adjust the slide on the adjustable resistor "UT" (slide tap toward front of relay to increase Io at trip point) to bring Io in range (see Fig. 2 for position of renistor "UT").
Percentage slope characteristic (low current).
7.
Set ISR to 5 amperes; raise Io until the trip indicator light comes on.
If Io is not in the range between 145-260 milliamps, adjust the slide on the adjustable resistor "LT" to bring Io in range (moving the rear of the relay increases Io at trip).
8.
Repeat ~ steps 6 and 7 for phases 2 and 3.
9.
Percentage slope characteristic (high current) - Return to phase 1 and increase ISR to 60 amperes.
Note:
This current may only be applied to the relay for 1 - 2 seconds at a time...
allow several minutes between applications for transformer to cool.
With relay completely de-energized the restraint trans-former carresponding to the pahse being calibrated (see Fig. 2) should not be allowed to get too hot to touch.
Raise Io to the point where the trip indicator light comes ON with both ISR and Io applied.
If Io is not in the range between 28. -- 3 0 ampere s, resistor R17 (phase 1) must be removed and replaced.. Increasing R17 decreases the I current at which trip takes place.
The parts called for in these instructions provide the following R17 resistance values:
0 ohms Jumper Customer Suppli.ed 33 ohms style No. 187A190H13 Supplied witi Module 51 ohms Style No. 187A290H18 Supplied Loose 68 ohms Style No. 187A190H21 Supplied Louse If closer calibration is desired, use an appropriate fixed composition resistor - Type BTS 1/2 watt
- 5% in the range between 0 and 100 ohms.
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If R17 must be changed, it is suggested that alternate values
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be tried using clip leads to insert in the circuit.
When the desired calibration is attained the resistor may be soldered in permanently.
- 10. Repeat step 9 for phaces 2 (R28) and 3 (R19).
- 11. Recheck and " touch-up" the minimum trip current (step 6) and the low current and slop characteristic (step 7) as needed.
The relay is now completely calibrated and may be placed in service.
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