ML20154R975

Rev 0 to Part 21 Rept 10CFR21-0037-1 Re diesel-generator Standby Power Supply for Nuclear Power Stations EMD Model 999 Sys.Power Sys Div Will Notify All Stations Which Were Supplied W/Emd 999 Units

ML20154R975
Person / Time
Site:	Browns Ferry
Issue date:	09/28/1988
From:	Kulchak R MORRISON-KNUDSEN CO., INC.
To:	Murley T Office of Nuclear Reactor Regulation
References
REF-PT21-88, REF-PT21-88-116-000 10CFR21-0037-1, 10CFR21-37-1, PT21-88-116, PT21-88-116-000, NUDOCS 8810040405
Download: ML20154R975 (27)

Text

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CONTRACTORS ENGINEERS DEVELOPERS hMORRISON-KNUDSEN COMPANY, INC.

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SepteTber 28, 1988 Serial #10CR21-88-9 i

Mr. Thonus Abriey Director-Office of Nclear Reactor Regulation Nuclear Regulatory CaTmission 11555 Rockwell Pike Ruckwell, Maryland 20852

Subject:

Report of Defects and NoncaipiIance - 10CR21 Diesel Cencrator Standby Pom r Supply for Nuclear Pcwer Stations i

Dear Sir:

Pursuant to previously supplied information regarding the Type 999 Unit BTurgency Pcwer Generator (Serial #10CFR-88-1 ), enclosed is the stbject report prepared by our Pcwer Systems Division in Rocky Abtnt, North Carol ina.

The Pcwer SystaTis Division will notify all stations which were supplied with e.D 999 units. Mdl tlonal Infonmtion wliI be provided as it beccmas available.

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Very truly yours,

.ShN R. D. Kulchak

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Director QualI ty Assurance fEK/gs Encl.

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REPORT NO.:

10CFR21-0037-1

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9/27/88 REV.:

0 MORR V

-.vm.ISON-KNUDSEN COMPANY, INC.

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TELt.x 307307 Pscytyuo REPORTING OF DEFECTS AND NONCOMPLIANCE 10CFR-21 MORRISON-KNUDSEN COMPANY INC.

SERIAL NO. 10CFR21-88-1 COMPONENT:

Diesel-Generator Standby Power Supply for Nuclear Power Stations l

EMD Model 999 Systems Only LOCATION:

TVA - Browns Ferry Nuclear P* ant Os EVENT:

During a 24-hour test run, the generator field circuit breaker tripped open causing loss of generator voltage, resulting in a failure of the diesel-generator to perform its safety faccion.

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Harry W. Falter, P.E.

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/,. % f Principal Engineer Yp.,

'%,, /[*d*/g$/N.C. License No. 7033 fi 1

REPORT NO.:

100FR21-0037-1

'T[J DATE:

9/27/88 REV.:

0 INDEX SECTION 1

REPORT:

Introduction Event Recommendation Action Taken Conclusion 2

REFERENCE:

Specifications for General Motors 999 System Geners. ting Plant Specification No. 7500 Rev. B 3

PRIOR NOTICE TO NRC:

HK Serial No. 10CFR21-88-1 4

REFERENCE:

EMD/GM Letter May 25, 1988 EMD/GM Letter April 28, 1988

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MK/PSD Letter S/N 6981C-0-0010 5

DRAWINGS:

Fig. 1 - Generator Panel-Location of Generator Field Cir-cuit Breaker Fig. 2 - Partial Schematic Exciter Field Power Supply Browns Ferry Test Results for Operating Temperatures Inside Generator Control Panel:

Fig. 3 - Rear Fig. 4 - Front Fig. 5 - Plan & Exhaust l

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PAGE 1.1 of 1.3 l

l REPORT NO.:

10CFR21-0037-1 O

DATE:

9/27/88 REV.:

0 t

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REFERENCE:

H-K Notice to NRC on February 5, 1988 Morrison-Knudsen Serial No. 10CFK21-88-1 Power Systems Division Serial No. HE-0-0045 HK/PSD File No. 10CFR21-0037 l

SUBJECT:

Potential 10CFR21 Finding Conclusion i

EMD 20-645E4 Type 999 L

Unit Emergency Power Generator

(

Generator Control Panel INTRODUCTION:

The Electro-Hotive Division furnished diesel-i generators as emersoney standby power supplies for nuclear power plant.

The diesel-generator with its auxiliaries and controls is identified as Model 999 system generating plant.

The specifications for the model 999 system are shown in Section 2.

This type of diesel-generator system was furnished f

during the late 1960 and early 1970 period.

O 1

EVENT:

Power Systems Division of Horrison Knudsen received a phone call from Mr. Ed Freeman of the TVA-Browns Ferry Nuclear Plant on 1/25/88 in which he reported that the generator field breaker l

tripped open during a 24 hr. load test while the diesel-generator was carrying 2950 KW G 0.8 P.F.

l The field current at the field circuit breaker was j

measured to be 96 amps.

The field current to the i

generator was measured to be 112 amps.

The EMD j

characteristic curves show that the generator field requires 100 amp at a load of 2600 KW and 80% P.F.

j L

The readings taken at Browns Ferry appear to be correct.

The formula that relates the AC power i

input:

Field Amps x 1.731.

40 Amp 112 Amps x.C66 = 96.kd u 97 Amps This agrees reasonably with the field readings at 2,950 KW and 0.8 P.F. of 96 Amps at the breaker and 112 Amps at the generator field.

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PAGE 1.2 of 1.3 REPORT NO.:

10CFR21-0037-1

()

DATE:

9/27/88 REV.:

0 The field circuit breaker is a General Electric size 100 amp, type TED 138100 which has a 5 to 10%

margin.

It is located in the generator control panel as shown in Fi!- 1 and in the circuit shown schematically in Fin. 2 (located in Section 5).

EMD normally used a Square D 100A circuit breaker which had a 15% tolerance.

At the time, since no instances were reported to date, it was thought that this higher tolerance would have prevented the circuit breaker trip.

Since only the Browns Ferry diesel-generators had the GE circuit breakers, it was thought the problem may be limited to the Browns Ferry plant.

RECOMMENDATION:

1.

On a February 9, 1988, Morrison-Knudsen advised Mr. Ed Freeman by phone of the following tentative recommendations:

O (a)

Replace the 100 amp circuit breaker with a 125 amp circuit breaker.

Original breaker was a G.E. TED 138100.

(b)

Replace the #4 AWG field wire with a minimum size #2 AWG but no larger than a size "00".

2.

An alternative possible solution is as follows:

(a)

Remove the trip devices from the circuit breaker and convert it to a contactor.

This would provide for control of the circuit breaker by means of the shunt trip coil in case of a differential relay trip signal.

This would eliminate the tripping of the circuit breaker at any cost or risk to equip-mont.

If there is a failure in the field, you have lost the safety function anyway and the high voltage fuses may blow.

(b)

Determine the life of the #4 AWG field wire considering that the total operating hours for 40 years may not exceed 8,000.

During that time, most of the load would be lose than 100%

of rated and that the 200 hr. rating may only be used for a total of 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br />.

If the O'

study shows the #4 AWG wire insulation can survive the service life, then it need not be

replaced, i

l PAGE 1.3 of 1.3 1

REPORT NO.:

10CFR21-0037-1

~'

(d' DATE:

9/27/88 REV.:

0 3.

HK/pSD advised TVA of the recommendation by the engine manufacturer in our letter dated 7/1/88 (Serial No. 8981C-0-0010) located in Section 4.

ACTION TAKEN:

During a phone conversation between Mr. Ed Freeman of Browns Ferry and Harry Falter of HK/PSD on 9/21/88, the correctivc action completed by Browns ferry was to replace the circuit breaker with a contsetor with no overicad coil but with a trip coil that would be actuated by the 88 relay.

Also, the field wire was replaced by a larger size wire.

This then eliminated the problem of field current tripping the field circuit breaker.

CONCLUSION:

i Recently, Browns Ferry conducted a test to record O.

temperatures inside the generator cabinet.

The temperatures recorded are shown on Figura M.

4 and 5 (located in Section 5).

The results indicate that the air temperatures around the field circuit could er.ceed 50o0 at loads of 2850 KW and 0.8 P.F. which may cause the field breaker to trip at a lower amperage during an extended run period.

Since all Model 999 generator control panels are basically the same design and construction, the potential for the field circuit breaker to trip due to combined air temperatures and field current exists at all nuclear plants which have the Model 999 System.

Therefore, the recommendations given to Browns Ferry could be applicable to other nuclear power plants with the EMD 999 diesel-generator system.

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PAGE 2.1 of 2.5 4

4 Ou Specifications for GENERAL MOTORS MODEL 999 SYSTEM GENERATING PLANT GM l

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Specification No. 7500 Rev B January,1970 l

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1 Electro-Motive Division i

Q, General Motors Corporation La Grange, Illinois 60525 U.S.A.

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i SECTION I GENERAL DESCRIPTION This specification describes the EMD Model 999 System - a diesel-electric generating concept designed for nuclear power plant emergency standby protection by the Electro-Motive Division of General Motors Corporation.

The Model 999 System has been specifically developed to protect a nuclear reactor in case of major accident and to provide a completely independent source of start-up power for the nuclear station.

The Model 999 System can start automatically, be at synchronous speed and full voltage and be ready to accept load, all withinten seconds after the start signal. The Model 999 System can be at full load within 30 seconds after receipt of a start signal. When motor starting requirements exceed the capability of a single Model 999 System, the System can be modified to permit multiple unit installations on a common bus. In this case, the Systems will be in synchronism and readyto accept load within the time limits specified above.

This specification deals in detail with how the Model 999 System, engineered as an integrated arrangement, using proven components, and with but one source of responsi-bility, meets the design requirements.

Each System includes a complete unit embodying the engine, generator, and basic accessories mounted on a rigid common subbase. This unit is completely assembled, piped, wired and tested at the factory. In addition, the System includes an electrical cabinet and other accessories which are provided separately for mounting where convenient in the nuclear station.

The Model 999 System is available at two ratings:

2850 KW - Model 999-20 System - 2750 KW With EMD Radiator Cooling 2400 KW - Model 999-16 System - 2300 MW With EMD Radiator Cooling s

The difference between the two models is the size of the Diesel engine. The Model 999-20 System is equipped with a 20-cylinder engine while the Model 999-16 System is supplied with a 16-cylinder engine. Unless otherwise indicated in this specification, each item discussed is common to either model.

R ATING CONDITIONS All ratings contained herein apply under the following conditions:

90' F. Air Intake Temperature O

28.25" lig. Barometer (Minimum) 19,350 BTU /LB. Fuel (IllIV) 6" II 0 Air Intake Depression (Maximum) 2 5" !! 0 Exhaust Back Pressure (Maximum) 2

PAGE 2.4 of 2.5 SECTION I

.O GENERAL DESCRIPTION TEMPERATURE AND ALTITUDE EFFECTS The Model 999 System will maintain rated output at altitudes up to 6000 feet above sea level. For ratings at altitudes above 6000 feet, application should be made to Electro-Motive Division.

The Model 999 System ratings are based on combustion air inlet temperature of 90' F.

3 For ratings at temperatures above 90*

F.. application should be made to Electro-l Motive.

,I STARTING METHODS

..l The Model 999 System will accept two types of starting signals:

l

1) Emergency / Automatic. This signal which is normally furnished from customer-supplied relays (such as no-voltage or under-frequency). provides the Model 999 with the intelligence to operate as an isolated source of power. This signal will I

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enable the engine-genc ~ator set to start and arrive at full speed and be ready l

1 to accept load within ten seconds. If multiple Model 999 Systems are to operate i

In parallel with each other. modifications permit synchronizing and real and 4

reactive load sharing.

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Exercise. In order to permit the Model 999 System to be loaded in parallel f

with the nuclear plant bus during routine maintenance exercises, an alternate starting signal is required. The 999 System is then under operator control.

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t MOTOR STARTING CAPABILITY l

The Model 999 System has been specifically designed to protect the reactor in case of severe accident. and to provide start-up power for nuclear plants. These design parameters require the starting of large inductionmotors driving centrifugal pumps.

i Maximum reliability with minimum voltage drop has been achieved with a static Ij excitation system. Iow impedance generator and special field forcing equipment.

i 1

Use of this combination allows comnutation of minimum voltage using the sub-

'i transient reactance value rather than the more common transient reactance.

More important than the maximum voltage drop is rapid voltage recovery for ac-r

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celeration of the motor and load. This is accomplished through the use of special "Power Current Transformers" which supplement the power available to the exciter from the Control Power Transformer.

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PAGE 2.5 of 2.5

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SECTION I GENERAL DESCRIPTION Q

The graph below shows the voltage that can be expected when loads of various starting inrushes are applied to the Mode 1999 System. The curve labeled 0.1 second indicates the voltage at 6 cycles,.which is very close to the minimum voltage that will occur. The curve labeled 1.0 second shows the voltage that will be available for accelerating the load.

When multiple Model 999 Systems are installed on a common bus, sharing of real and reactive load during motor starting is required. This is accomplished through use of the Load Sharing Governor modification (See Section 8).

When the Model 999 System is so equipped, the curves can be used by dividing the motor starting KVA inrush by the number of Model 999 Systems installed on the bus.

l MODEL 999 SYSTEM DEAD LOAD PICKUP CAPABILITY J

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CONTRACTORS PAGE 3.1 of 3.7 ENGINEERS oEVELOPERS j WW4Q l

hMORRISON KNUDSEN COMPANY,INC.

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ma memswnm une February 5, 1988 Serial #10 CIT <21-88-1 Mr. James Taylor USMC 1717 H Street Washington, D.C.

20555

Subject:

Potential 10CFR21 Finding - Testing of EhD20-645E4 Type 999 Oilt Energency Power Generator

Dear Sir:

We have been ackised by our Power Systuns D1 vision in Rocky Vasit, North Carolina of a potential problan with the above subject Type 999 011t vd11ch is in nuclear service (correspondence attached).

Please accept ny apologies for the delay in transmitting this potential finding. We will forwarc acMitional Infonmtion as it beccmes available.

Very truly yours,

.W' L

A R. D. Kulchak Director Quality Assuranco Fu lgs Attach.

i cc:

H. Falter V. Mitchell File 3

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Serici No. ME-0-0045 MORRISON-KNUDSEN COMPANY, INC.

PAGE 3.2 of 3.7 INTER OFFICE ConnESPONDENCE f

January 26, 1988 eate Pcn Kulchak (Quality-Boise) vann Mitchell, Ken Lewis and Harry W. Falter "o"

Don Galea:21 (Ibcky Mount) toca tion -

Bocky Mount, llc Locatio" Browns Ferry - Possible 10CFR21 suonct.

Call 1/25/88 - Mr. Ed Freeman - 205-729-3363 l

1.

Browns Ferry were corriucting a test on the DD20-645E4 -

Type 999 unit. They were carrying a 2950 KW @ 80 PF when the field breaker tripped.

2.

Frectnn reported that they had neasured 96 hip at the circuit breaker arti 112 hip in the field.

3.

Attached is a copy of the schatatic which shows a 100A circuit breaker. Fretstun identified the circuit breaker as a G.E. Typa ED136100. The schmatic is frm an DD drawing and the 100A is DD's notation.

4.

'Ihe DD Characteristic Curves show that the generator field requires 100 hips at 2600 KW and 801 PF.

O 5.

It w>uld aE: pear that 100 hip is too low a rating and should be 125 hnp, but this would require a larger frann size circuit breaker for whien there would not to enough roon in the cabinet.

6.

I have asked DD to check into this rnatter.

I do not know d

why the Arps at the breaker should be less than the htps at

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the field. As I see it, all the field hips care fran the EPr atti PCT transfomers.

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()

ELECTRO MOTIVE Dectro Motive Omston General Motors Corporation LaGrange. Ilunois 60525 (312) 387-6 coo P>ff.1CI y T

Fw May 25, 198?

C

3. M

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Mr. Harry Falter Power Systems Division /M-X rf

.L t/,

P. O. Box 1928 A.L N

Rocky Mount, NC 27801 1.L-. MAY 3 { @@3 MORRISON 9001EN 00., INO.

SUBJECT:

Model 999 Excitation System PDFER S'WS D)V.

Circuit Breaker and Wiring T.V. A. Brown's Ferry

Dear Harry:

This is in response to the T.V.A.'s inquiry into the sizing of the exciter cable and excitation power circuit breaker for the subject units.

Electro-(^')

Motive has investigated the excitation power circuit breaker and wiring loads

\\'

and offer the following recomendations.

1.

The circuit breaker should be changed to a 125 ampere 600 volt breaker. The General Electric E150 line is calibrated to carry full load at 500 C and would be a good replacement. Add i tional interlocks or shunt trips required for the installation will specify the part number for the breaker.

2.

If the synbol III cables are tightly bound together, they should be separated to provide some air space between them.

EMD recomends that the cables be inspected for cable insulation condition approximately every 6 years or closest convent nuclear plant refueling outage. (.Ihere should be no thermal ageing for the duty cycle of these unitQ er y )C WN Wu ft WO "S

fagsu~

E. W. Ralls, Manager Power Products Service EWR:vad cc:

M. J. Fleckenstein J. J. Ha Wen K. E. Jones G. B. Moman P. B. Russell K. R. Thompson

CLICTRO MOTlvt l

OMstm4l Cineral httats *erygtion.

PAGE 4.2 of 4.3 LaGrange',1111no'is (6525 O

April 28, 1988

'V FAX: 919-446-3830 Power Systems Division /M X Rocky Mount, NC ATIN: Harry falter

$UBJELT:

Brown's Ferry Nuclear 999 Model Generating Units Operating Ambient Temperatures 4

In response to TVA's request for maximum ambient temperatures under which skid-mounted components and controls cabinets e,an function, we offer the following:

I The limiting factors used 'in establishing maximum ambient room l

air temperatures is the ratings of components within the j

electrical cabinets. EMD estimates the maxirrum allowable I

amtbent for the electrtcal c aoinet to be 600 C (1400

~

F).

1 I trust that the above provides the information needed.

1 Very truly yours,

8. w. Rak 44 1

E. W. Ralls, Manager Fower Products Service

~

EWR,:vad cc:

M. J. Fleckenstein G. B. Moman X. E. Jones P. B. Russell X. R. Thompson l

I 4

I

'~

PAGE 4.3 of 4.3 y

4,,

, M,M.O.RR.I.S. ON KNUDSEN COMPANY, INC.

i, o

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cost osse.s soa isa

= =,',3~#f=,;;is;'"

,m.,,, mm July 1, 1988 S/N 6981C-O-0010 Tennessee Valley Authority Browns Terry Nuclear Plant Decatur, Alabama 35601 Attention:

P.J. Speidel

Reference:

Tennessee Valley Authority Browns Ferry Nuclear Plant Model 999 Excitation Syste:n Circuit Breaker and Wiring Centlement r

In response to your inquiry into the sizing of the exciter cable and excitation power circuit breaker for subject units, MK/PSD contacted Electro Motive who in turn investigated the excitation power circuit breaker and wiring loads. The have offered the f ollowing reecceendations.

O g

1.

The circuit breaker should be changed to a 125 ampere 600 volt breaker. The General Electric E150 line is calibrated to carry full load at 50 C and would be a good replacement. Additional interlocks or shunt trips required for installation will specify the part nu=ber for the breaker.

2.

If the symbol III cables are tightly bound together, they should be separated to provide some air space between them. EMD reccumends that the cables be inspected for cable insulation condition approxicately every six (6) years or closest convent nuclear plant refueling outage. The duty cycle is such that there is no i

i significant thermal aging for the life of these units.

Very truly yours, MORRISON KNUDSEN COMPAh7 POWER SYSTDiS DIVISION C

q Kathy L. Cary Contracts Admin trator KLC/jm bc: ;R. Falter x

K. Lewis I

PAGE 5.1 of 5.6 GENERATOR FIELD CIRCUIT BREAKER h

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