ML20101B528

Part 21 & Const Deficiency Rept Re GE-identified Defective Type AKR-30 Circuit Breakers.Initially Reported on 831123. Complete Reinsp,Rework & Testing Program for AKR-30 Breakers Completed

ML20101B528
Person / Time
Site:	Hope Creek
Issue date:	11/26/1984
From:	Martin T Public Service Enterprise Group
To:	Murley T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
References
REF-PT21-85-071-000 PT21-85-071-000, PT21-85-71, NUDOCS 8412200357
Download: ML20101B528 (13)

Text

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l Public Service Electric and Gas Company Thomas J. Martin 80 Park Plaza, Newark, NJ 07101 201-430-8316 Mailing Address: P.O. Box 570, Newark, NJ 07101 Vica President Engineering and Construction November 26, 1984 Dr. Thomas E. Murley, Administrator U. S. Nuclear Regulatory' Commission Office of Inspection and Enforcement Region I 631 Park Avenue 5

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King of Prussia, Pennsylvania 19406

Dear Dr. Murley:

SIGNIFICANT CONSTRUCTION DEFICIENCY GE TYPE AKR-30 CIRCUIT BREAKERS HOPE CREEK GENERATING STATION On November 23, 1983, a report was submitted to your office concerning defective parts identified by a General Electric Service Advice letter applicable to type AKR-30 circuit breakers. Subsequently, on December 23, 1983, a verbal report was made to your office concerning improper operation of several AKR-30 circuit breakers during start-up testing.

Status reports were provided on Canuary 18, 1984, February 24, 1984, May 14, 1984 and September 14, 1984.

The defects found in the AKR-30 circuit breakers could cause the breakers to fail to close upon command. These breakers supply class lE loads that are needed for the safe shut down of the unit. Therefore, this deficiency is reportable in accordance with 10CFR50.55e.

In our February letter we committed to a complete reinspection, rework and testing program for all of the affected AKR-30 breakers. This activity was performed by GE at their  ;

Connecticut facility and included 244 AC and 91 DC AKR-30 '

circuit breakers. A copy of the inspection and testing checklist is attached for your information. In addition, the same program was applied to AKR-50 circuit breakers which are not used in safety related applications.

l E 8412200357 841126"'

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Dr. T. E. Murley 2 11/26/84 In our September letter we advised you of the potential

. relevance of problems with GE circuit breakers at Diablo Canyon to the Hope Creek circuit breakers. Analysis of this issue by General Electric concluded the problem was not applicable to the AKR-30 design.

In order to verify operability of the reworked breakers and to correct any deficiencies caused by return shipment to Hope Creek, PSE&G will functionally test each breaker prior to installation. These tests will be witnessed by PSE&G Quality Assurance personnel.

Complete records of the work performed by General Electric, analysis by Bechtel and the testing performed by PSE&G are available for review by your inspectors.

Should you need any additional information, please let me know.

Very truly yours,

'1 Attachment C Office of Inspection and Enforcement Division of Reactor Construction Inspection Washington, D. C. 20555 NRC Resident Inspector - Hope Creek P. O. Box 241 Hancocks Bridge, NJ 08038

Records Center Institute of Nuclear Power Operations 1100 Circle 75 Parkway, Suite 1500 Atlanta, GA 30339

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• HOPE CREEK NUCLEAR POWER PLANT AKR-30/50 CIRCUIT BREAKERS AUDIT CHECK LIST F129492 BREAKER TYPE INSPECTOR BREAKER BREAKER 4

SERIAL NO. CODE DATE GENERAL ELECTRIC COMPANY OUALITY ASSURANCE APPROVAL BECHTEL POWER CORPORATION

• ENGINEER NOTES:

1.

Record all deviations found and corrective action taken in Table 4.

2. Reinspection and sign off of all rework is required.

i PREPARED BY P. M . _E,i,q u e i r a REVISION- 3 DATE ISSUED February 10. 1984 DATE April 03. 1984

APR 11 '84 0 2 6 2 3 9 5 l

- F1294sg!

• GAGE FINAL euRCK POINT NO. REFERENCE ACCEPT REJ ACCEPT Nameplates in place. --- 425D407

2. a. Verify that the serial --- ---

number, ID, and ratings are correct on the name-plate.

b. Verify the remaining summary information is correct on the name-clates.

Labels in place. 425D407

}

4. Verify that the arc chutes --- ---

are correct per summary and were correctly assembled.

5. a. For DC breakers verify 568B627G27 g[ that the 568B627G17 --- 568B622P5 rejection brackets are 568B622P9 installed.

b. For AC breakers verify 568B627G10 that the 568B627G10 568B627P1 rejection brackets are 568B627P8 installed.

6. For ELECTRIC and MANUAL --- Ser. Adv.

jg breakers, verify that the 175-9.6 latest ratchet assembly desion is installed.

7. a. Verify that the closing spring prop assembly has the black identifying

/k b.

mark.

Verify that the closing --- Serv. Adv.

spring prop drive spring 175-9.11 is properly assembled.

The spring leg must extend over the edge of the front frame and not rest in a hole.

c. Verify the switchette has a code date of 82-22 or hicher.

8. For ELECTRIC breakers, I-1297 ---

verify that the distance 2ki between the mechanism l frame and the motor frame in the area of the upper spacers is 1 5/16 +- 1/16.

9 Secondary disconnect wipe. --- ---

d. Check for free action. __

10. Verify that the control --- ---

l wiring is free of abrasion or damage. Replace all danaced wires.

11. Force to trip breaker is NK1-10B140 llM44.2 jg 24 in. or max. (check with toroue meters).

, ., , ua 11 84 02 6 2 3 95 .

F 1 7 Q ,1 Q' .:

. GAGE FINAL' CHECK POINT NO. REFERENCE ACCEPT REJ ACCEPT ,

12. Verify that the positive K2-4938 11M44.2 I interlock operates freely A and trips the breaker

• within a 0.38" movement. --

13. Rail pin adjustment is K2-435B 11M44.2

.795 +- .015".

Mounting bracket flush --- ---  !

14.

within i .015" to lower I side of front frame.

15. Distance between rack pins K2-394B 11M44.2 d on same side is 10.625 in.

16. Trip button depression to K2-381B 11M44.2 triD breaker is 5/16 max.

17. For MANUAL breakers, the NK1-10B110 11M44.2 force to close the breaker

/bi is 15 lbs. maximum.

18. Verify.that racking mech. --- 11M44.2 i has 1-2 1/2 turns afte:

breaker trips,and that racking door is function- 1 ino properly. )

19. Manual handle centerline --- 11M44.2 l within 5 decrees. '

20. Insulations and barriers --- ---

complete and in place.

2 (. Primary disconnect finger K2-391B13 ---

2 force is 95 +- 10 pounds. _,

22. a. With breaker closed. --- 11M44.2 buffer clearance to be

.005" minimum (without 2nd charge,

b. Verify that the buffer --- ---

washers are free of cuts or cracks and are not deformed by over compression.

c. Verify that the buffer ---

hardware is tightened enough to just put pressure on the buffe; washers and not to deform them.

23. With the breaker opened K110B-103 Ser. Adv.

and closing spring dis- 175-9.7 charged. verify that the y flat head screw on the closing spring assembly holds a 60 in.-lbs. torque counterclockwise.

24. Verify that the racking I-1300A Ser. Adv.

mechanism has been ad- T-1300B 175-9.18 b iusted. .

I-1300C

25. a. Verify correct shunt ...

11K44.4 trip rating and coil Ib ratino.

APR 11 '84 0 2 6 2 3 9 5 i

F128492 GAGE FINAL CHECK POINT NO. REFERENCE ACCEPT REJ ACCEPT

b. Armature must seat pro- ---

perly and must not bind.

c. Verify that the trip  :

paddle is securely assembled to the trip shaft. Use a visual 11K44.4 check. Also, verify there is no paddle move-ment on the trip shaft by physically trying to note the trip paddle.

d. Verify that the paddle I-1291 lines up with the shunt trip armature and that there is a .030" min.

clearance between shunt trip and paddle with breaker closed.

e. Verify .030 in. minimum I-1292 overtravel after the coint of trippino.

26. a. Verify correct closing coil solenoid number or rating.

Record

b. Verify the closing sol- ---

enoid armature engages and disengages with its magnet without binding by manually operating it.

c. Verify that the breaker 11K44.4 may be closed by manual-ly operating the closing solenoid armature.

d. Verify that the armature I-1293 of the closing solenoid has a minimum of 1/32" overtravel by placing a 1/32" shim between the magnet and armature and closing the breaker A using the closing sole-N noid.

27. a. For DC breakers verify

~

286A8637G1 that the EC device trip V6447766P2 paddles consist of a 286A8637G1 paddle and a V-6447766P2 clamp.

b. For AC breakers verify ---

192A9567P1 that the flux shifter K6203939P5 trip paddle consists of jg a K6203939P5 paddle and a 192A9567P1 clanD. ,,

APR 11 8402 6 2 3 95 GAGE F129492

__gN_gCE_EQLNT NO. FINAL REFERENCE _ , ACCEPT REJ ACCEPT

• c. Verify that the trip ---

device paddles,are se-curely assembled to the trip shaft. Use a 1 visual check. Also, )

verify there is no paddle movement on the trip shaft by physically A trying to move the trip 5 paddle.

I

28. Clearance between flux I-1299 LIK44.4 shifter trip paddle and trip rod is .078 .140 with breaker in charged posi-tion. '

29. Gap between coupling and I-1296 11K44.4

~

~ " ~ ~

roll pin is 0.040" minimum b with hr_eaker r closed.

30. Gap.between trip button I-1298 11M44.2 r

b .od and paddle is .100 14 0 wi t h br es k e r_,Sha r_g.e_d .

31. Verify that the ___

192A6990P153 192A6990P153 opening Ab sprinos are installed.

'3 2 . a. Verif y anti-pump relay per summary.

11K44.1

b. Verify integrity of anti- ---

10L1.1 pump (W) relay solder connections.

c. Verify that the anti-pump --- ---

relay bracket mounting screws extend .062" b minimum.,_ __

33. For ELECTRIC breakers.

___11K44.4 verify the control (X) relay j hi is por the summary.

~~

34. a. For ELECTHIC breakers.

verify that the cut-off switch paddle is pro-perly oriented to acti-vate the switches.

i

t. Use the breaker wirino --- ---

diagram for steps 34d and 34e. Record the wiring diagram number:

c. Verify that the cut-ott --- ---

switch electrical con- j nections are tight.

Verify the ring ter-minals are securely in-4 stalled to the wires by pulling on the wires and moving them back and forth. There must not be any motion be-jg tween the wire and the crimped barrel.

. . . m 11'840262395 ,

F128492 GAGE. FINAL CHECK POINT NO. REFERENCE ACCEPT REJ ACCEPT

d. With the breaker OPEN and DISCHARGED, use a continuity checker to verify that there is continuity across the "G" contacts, also check that there is no con-tinuity across the "F" contacts.

e. Turn the camshaft 10 --- llK44.4 teeth with the mainte-nance handle (count the teeth as they pass the holding pawl). At this point, use a continuity checker to verify that there is no continuity across the "G" contacts, also check'that there is continuity across the "F" contacts.

f. Once the checks of 34e ---

are accepted, add Glyp-tol type 1201 to the j{g external mounting nuts of the cut-off switches. -

35. a. Verify that holding pawl nut is torqued to 250 in.-lbs. minimum.

b. Add LOCTITE 290 retain- ---

139C4616 ing compound to the threads of the holding pawl pivot pin.

c. Verify that the holding

/kg pawl spring has been properly installed.

36. Gap between top contact I-1266 11M44.2 and its' pivot (.050"-

.080") in AKR-30 without jg Check 2nd charge (contact wipe).

adiustment.

I

37. Verify that the moveable ---

11M44.2 and stationary arcing contacts centerlines are within 1/16" when the breaker is closed.

38. "A" contacts of auxiliary 11K44.4 switch make when arcing contacts close within I-1306 j{g .250 .500" at their closest point.

I L

l APR 11 '840 2 6 2 3 9 5  ;

GAGE F12R492~

CNECK POINT NO. REFERENCE FiiiAC

• ACCEPT 39 . Verify that the electri- --- --- REJ._ JCCKET )

cal connections and crimp terminations associated with the phase C/T's, shunt trip, switchette.

closing solenoid. x-relay, and auxiliary switch are secure. Check the crimp terminations by pulling and moving the wires looking for any motion between the wire and the crimped

___ _ barrel.

40. Accessible lock washers. --- ---

cotter pins. retaining rings assembled properly (visual).

41. Verify hardware listed in --- ---

Table 1 is properly tor-cued and assembled.

42. For MANUAL bre'akers operate ---

11K44.1

' ~~

shunt trip two times at minimum voltage. two times at maximum, and five times at nominal.

43. For ELECTRIC breakers per- ---

11L44.1 ~

form necessary electrical

operations. Breaker must not nuisance trip and breaker impulse.

must close on 1st

44. For electric breakers per-l form 3 anti-pump opera-11L44.1 ~ ~ ~ ~ -

tions.

, 45. Verify that while manually --- ---

performing a 2nd charge operation, the breaker doesn't trip.

46. Dielectric test performed. ---

12L44.3

47. a. Programmer checked for catalog number,

b. For SST equipped breakers. ---

check the phase C/T's for tap setting. Record in Table 2.

c. For DC breakers check ---

coil ratings and settings.

Record in Table 3.

d. For AC breakers, perform 15K44.1 calibration check.

Record calibration data in Table 2.

e. For DC breakers, perform 15K44.2 calibration check.

2k1 record calibration date in Table 3.

) , _ , - , _ _ . _ , - _ - . _ . _ _ - _ , , _ _ _ - _ _ . _ . , _ + , . - , _ -

_ _c- . . , , , . - - _ -.- -- _ _ -

APR 11 '840 2 6 2 3 9 5 GAGE F12RdS2 FINAL-CHECK POINT NO. REFERENCE ACCEPT REJ ACCEPT

48. Verify the following areas --- ---

j are lubricated: -

1

a. Dravout mechanism screw.

b. Flux shifter reset b linkane. , _ _ , __ _,

49. Remove any lubrication --- ---

from the primary discon-nects and attach a tube of Mobil 28 to the breaker frame.

50. Verify that the mechanism --- ---

return spring is properly installed. __ ,, _

51. Verify that all contact 11M44.2 end projections engage the I-1305 g contact stop fingers by a minimum of .062". _ _ _ _ , , _ _ _ _ , ,

l

. m 11 840 2 6 2 3 9 5

, F128492 TABLE 1 - TORQUE REQUIREMENTS ITEM HARDWARE TORQUE No. DESCRIPTION SIZE TYPE (IN.-LBS.)

1 Primary Disconnect Hex 5/16 - 18 100 15 2 Lower Connector / Pivot Block - 3/8 - 16 Cap 250 1 10 AC Breaker 3 Backframe Channel 5/16 - 18 Her F.H. 100 15 Hex

, Dr.

4 Secondary Disconnect Assembly 1/4 - 20 Hex 45 15 5 Racking Mechanism Mounting Hex 1/4 - 20 60 t 5 6 Buffer Block 3/8 - 16 Cap 250 t 10 7 Buffer Mounting 1/4 - 20 Hex 60 1 5 8 Closing Spring Intl. Adi. Screw 10 - 32 R.H. 23 - 32 9 Lower Connector / Primary 1/4 - 20 Hex 110 - 130 Disconnect - AC Breaker 10 EC Trip Device - Holding Clamp 1/4 - 20 R.H. 15 1 5 Screws 11 EC Trip Device - Lower 3/8 - 16 Cap Connector / Pivot Block 250 1 10 l

1 i

APR 11 '84 0 2 6 2 3 9 5 TABLE 2 - SST CALIBRATION DATA d fggg

. SST CATALOG NUMBER- S/N C/T TAP SETTING Left Pole Center Pole Richt Pole 1 COT at 1.1X minimum 300 sec. no trip delay 200% at ,. 6 X min. band trip 34-56 sec.

300% at .6X int. band max. band trip 37-64 trip 84-143 sec. sec.

ground tault __

pick up + 10% min. band int. band max. band trip 065 - 140ms trip 165 - 260ms 320 - 420ms ground fault pick up - 10% min, band int. band max. band no trip no trip no trip TABLE 3 - EC TRIP DEVICE CALIBRATION DATA d l

EC TYPE: EC1 EC2A COIL: AMPS LONG TIME SHORT TIME INSTANTANEOUS 1A Pickup 2A Range X Yes Range X 1B  % _ 2B Set 9 X No Set @ X IC 2C LEFT POLE RIGHT POLE Test Current Actual Trip Time . . . , _ _ _

Limits

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F129492 DEVIATION CORRECTIVE ACTION DONE BY

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