ML20203J252

Deficiency Rept Re Failed Mdr Relays at Entergy Operations Inc,Waterford 3 Nuclear Generation Station.Caused by Contaminated Grease.Housekeeping Procedures Formalized & Added Enclosed Booth Isolating Mdr Final Assembly

ML20203J252
Person / Time
Site:	Waterford
Issue date:	12/01/1997
From:	Market D SIEMENS POWER CORP. (FORMERLY SIEMENS NUCLEAR POWER
To:	Buckholz J ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY
References
REF-PT21-97 NUDOCS 9712190171
Download: ML20203J252 (8)

Text

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AHB Combustion Engineering Nuclear Operations p0 llox 500 2000 Day liill Road Windsor. CT 06095 0500 Attn' Jack R. Buckholz RIO l ailed MDR Relays n' Eritergy Operations, Inc.

Jacx, AllB has forwarded three reports from Southwest Msearch Institute to Siemens li cetromechanical Components pertaining to three failed MDR-7032 "mediuin" relays at

!!ntergy Operations, Inc.'s Waterford 3 Nuclear Generating Ststion. Included in these reports ale an analysis and a conclusion. Siemens Electromechanical Components agrees with the analysis contained in these reports, however, Siemens Electromechanical Components has reached a different conclusion based on its own analysis and testing.

Siemens Electromecharucal Components performed a number of temperature tests to determine if the Nye Nyogel 718B grease degrades for the possible temperature operations of these types of devices. Temperature testing of bearings shows both bearings are approximately the same temperature. A temperature test was conducted on the MDR.7068 the highest wattage of the suspected relays. With a 10% over voltage of

,13 0 VDC, the bearing near the mounting base checked $8'C. and the bearing at the contact end checked 59'C Nye Nyopi 718B grease, is rated by the manufactue.fr for 200*C. The bearings operate 200'C below the manufacturer max rating. A weight loss test of the Nyogel grease is an on going test. After 696 houis at 150'C, there was only 1.312% weight loss.

Siemens filectromechanical Components' theory is the grease was contaminated by silicon

• dioxide fibers. To test this theory, relays were built using contaminated grease (test samples) and uncontaminated grease (controi samples)in the bearings. Relays were cycled for 162,000 operations then left energized continuously for 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> at 65'C. The relays with uncontaminated grease still had fluid gresse while the units with contaminated grease was a thick paste. The conclusions of these test shows that Nyogel grense does not degrade and cause the ielay to bind. The results clearly show that the contaminated grease is the root cause of the failure 9712190171 971201 Page1 (f

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Siemens Electromechanical Components did not analyze the failed relays at Waterford 3 because these units were not submitted to us. The amount ofcontamination that was within the relays is not known. Prior documented history Return Material Evaluation number 34017 (attachment one) had 4 MDR 1701 relays recalled from ABB due to contamination within the relays, with date code of 9412. These 4 relays were the total order built for ABB. The contamination contained silicon dioxide fibers from contact ring When silicon insulator plates, flaker, from the switch rings, and flakes of the coil epore.

dioxide 6ber is mixed in grease it becomes very abrasive, similar to leppi g compound.

This caused abnormal wear particles from the shaR and bearings. The grease then absorbs the wear particles and becomes too stiff for the relay to operate.

Only the medium relays listed in attachment 2 are suspected to beve this problem. There has been no reported failures on the small relays. The date codes of the suspected medium MDR rclays are from 9317 to 9532. The reason 9317 is the suspected date codes is the statt up date of the line aRer moving from Princeton, IN to Marion, KY. Date code 9532 is the initiation of a continuous improvement team. The team formalized housekeeping procedures and added an enclosed booth'that isolated MDR final assembly from general production area preventing contamination. The relay listed in attachment 2 with the date codes 9317 to 9532 can be returned to the factory for inspection.

Itespectfully sub6nitted,

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Dick Market Staff Technical Specih Product Engineering Attachments: RME #34017 and #34406, and Part list of Potential Affected Devices.

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f'O T T ER-BRUMi l EL D-1D:5029651212 DEC 02'97 10:22 f40.004 P.04 SIEMENS PROBLEM SOLVING AND RESOLUTION

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Title:

Date Opened: 9/18/96 Assigned To:

l34017 I Contacts frozen First Rev.

MDR Line l

1) Tearn Leader; interim U

Problem Reported By:

RME #:

[(Mark Brvant ! Final Customer 34017 & 34406 Date: 9/18/96 Rt., sonsibthty M. Bryant (2.) Describe Problem:

ABB Combustion Entoneennt, Nuclear Ooorations Customer:

PO Box 500 M/S 94',G 1930 Windsor. CT 060950M O Attn: Jack Buckholt Product-MDR 170-1 Date (s):

9412 (rod) (S/N 514)

Mfg. Plant :

Marion.

Customer

References:

CE Order # 407112-01. CE Referenco# 01195873-Or140 RA# 9643077, Ack# 13745. PO# 407112 Siemens

References:

RME 32270 (S/N 513). RME 34406 (S/N 511 & 512)

Reason t or Customer Return:

Contacts frozen.

Problem IdentificationNerification:

Venfied by Princeton Failure Analysis Lab. rotor remains t>ound in energl2Hd position without coil power.

Dato: 9/23/96 Rosponsibility: M. Bryant (2.) Evaluation:

Black substanco rollod up around the tip of the rotor shaf t on the bottom bell Substanco is causing f otor to bind _which provents propor contact operation.

Dato: 9/18/96 Responsibility: M. Bryant h3$) Containment & Interim Corrective Action (s):i Contacted Sales to (RA 9643079 / RME 344061) l the onginal release in 1994. S/N 511 & 512

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- he isolated nature of these f ailures,it is not believed there is a major risk of having similar occur with MDR units presently in service or on the shelf i stu'.

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Pate #2 fl(MbI !.4017-14.) Define & Verify Hoot Cause(Codes):

Data *2/18/96 R:sponsioliity: M.Bryant

/ Viatariots & Procosses i.ao has oetermineo the cause for couno rotor was contamination o The contaminants reacted with the coating gf obso with glasc particles arid other ceoris (S/N Sidi

_l groaso to form a olack suostance wnich would not allow ine These components are inherent to carts handling in the assembly

. platos and flavos of coil ecory j area :M&P Lab found similar contamination in S/N 511 & 512 although these units were sttil operapio. S/N 513 returneo n October '95, snould also be considered to fall under this response Oof. RA 9541066 / AME 32276)

Exactty how such a quant.ty of contaminants could secumtinte in these 4 relays is not known. Due to line improvements. layout changos and personnel turnover since 1994 it is difficult to identify a specific root causo for this isolated problem.

M&P lab idontification of the contaminants shows no Indication this problem is related to the coil varnish outgassing problem which caused similar binding problems in the past (units built prior to date code 9024L Coils woro gaged on the MDR line and found to be well within tolerance and in no way oversire.

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DEC 02'97 10:23 No.004 P.06 f01TCf-BRUMFIELD 1D:5029651212 page n -

{ MMFW4017 j(S.) Ehtablish Corrective Action Plan Date: 1/8/97 R:soonsionity: M Bryant

' While the tource of the contamination to the motor assembly couid not be oefinitely determinea. the

' f oilowing smorovements have occurreo since the discrepant units were manuinctured in 1994:

Encioce6 bootti built to isolate MDR final assembly stations from general proeuction area to roduce

comamination and noise levels.Aoded add?.ional process step to f abrication of insulato blanking operation in order to removo loose particles and fibers.

Initiation of Continuous improvement teams and successful OS9000 effort have resulted in

' formaliicd housokoeping proceduros which mandate daily clean up by the operators. These have contr'outoo groativ to improving general production area cleontiness.

- Continuous improvement teams have also worked to significantly reduce the inventory level of The reduced parts and sub assemblics stocked on tho oroduction line and in the Stockroom inventory levels tosult in more of a JIT system which limits the opportunity for contamination to tho sub assombhes A review of the prosent MDR proouction for further potenttal sources of contamination showed the following problem areas:

- The assembly operators maintained a small cup of grease at each assembly station and used a toothpick to apply a dab of grease from the cup to the bearing surf aces. The grease cups were uncovered and would collect contaminatton on the surf ace of the grease supply.

Thesu cups woro replaced with plastic syringes which seal off the grease supply from any contaminants felf 9640,10/1/96)

. No instructions existed to prevent the operators from beginning assembly of a unit and then later setting it asido to work on a different unit. The possibthty existed for a partially assembled unit to ccHoct contaminants on a greased boaring surface.

Operators havo been instructed to ensure any partially assembled units are properly covered when it becomos necessary to put them asido or they are to complete the unit to the point of sealing the Groase is to be romoved from any 4aestionable units and fresh grease applied.

motor assembly Instructions reflecting those requiroments are in process to be added to MDR Engineering Specifications (eff 9640)

Existing assembiv instructions require each motor assembly be blown out with do ionized air in order to remove any contamination prior to capping the motor assambly with the top end bell. It is felt that the procent MDR assombly methoos process controls and housokoooing measures are adequato to proclude further occurrence of this problem (6.) Imploment & Verify Corrective Action (s):

Date: 1/8/97 Responsibility M. Bryant 5 piece MDR sample taken from present MDR production and examined for contamination. No contaminated motor assemblies woro found.

0 MDR units successfully complotod mechanical life testing to 500.000 operations @ 5 ops./ min. on 12/22/95 This is submitted as an indication of the reliability of recont production.

Dato impiemonted Date Verified.

Venfied By.

10/1/96 1/8/97 M.Bryant

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17.) Actions to Prevent Recurrence:1 Date: 1/8/97 __

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SIEMENS Part List of Potential Affected Devices With Date Codes of 9317 to 9532 MDR 141 1 MOR4054 MDR 7033-SCE-0 MDR 141 1 SCE-2 MDR4059 MDR 7034 MDR 1412 -

MDR4060 MDR ?O34 SCE-0 MOR 1421 MDR4064 MDR TG33-SCE 1 MDR 1671 MDC 4069 MDR-7036 MDR 1701 MDR4074 MDR 7045 MOR 170-1 SCE 2 MDR4100 MDR 7048 MDR 170 2 MDR4101 MDR-7052 MOR 1721 MDR-66-4 MDR 7056 MDR 1731 MDR 7020 MDR 7059 MOR 6007 MDR 7025 MOR 7067 MOR 6019 MDR 7029 MDR 7068 MDR4041 MDR 7032 MDR-7069 MOR 60$0 MDR 7032 SCE-0 MDR 7033 Siemens Electromechanical Components,Inc.

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Pottor & Brumfield Products Division 726 Chapoi Hal Road Marxm. KY 47064 502 906 3193