Text

Forwards Addl Info Re PRA Performed to Support Proposed ATWS Recirculation Pump Trip (RPT) Design,Per 870715 Meeting.Info Re Testability of Alternate Rod Injection/Rpt Will Be Provided Under Separate Cover
	ML20236A762
Person / Time
Site:	Brunswick
Issue date:	07/22/1987
From:	Zimmerman S; CAROLINA POWER & LIGHT CO.
To:	; NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM)
References
	NLS-87-151, NUDOCS 8707280208
	Download: ML20236A762 (50)
	v • d • e

CP&L

.1 e..m e.

..... w. m.m.

Carolina Power & Light Company I

mangrew c%umemfn.3 July 22, 1987 SERIAL: NLS-87-151 10CFR50.62 I

United States Nuclear Regulatory Commission ATTENTION: Document Control Desk washington, DC 20555 BRUNSWICK STEAM ELECTRIC PLANT, UNIT NOS.1 AND 2 DOCKET NOS. 50-325 & 50-324/ LICENSE NOS. DPR-71 & DPR-62 ATWS-RPT -- ADDITIONAL INFORMATION Gentlemen:

On July 15, 1987, a meeting was held between Carolina Power & Light Company (CP&L) and the NRC staff concerning the Anticipated Transient Without Scram (ATWS) Recirculation Pump Trip (RPT) feature used at the Brunswick Steam Electric Plant (BSEP) Units 1 and 2.

In that meeting CP&L committed to provide additional information regarding the Probabilistic Risk Assessment (FRA) performed to support the proposed BSEP RPT design. This information j

is attached. Information concerning testability of the Alternate nod Injection /RPT system will be provided under separate cover, j

i Please refer questions regarding this matter to Mr. Stephen D. Floyd at (919) 836-6901.

Yours very truly, ft S. R. Zim nerman Manager Nuclear Licensing Section BAT /ccj (5241 BAT)

Attachment ec:

Dr. J. Nelson Grace (NRC-RII)

Mr. W. H. Ruland (NRC-BNP)

Mr. E. Sylvester 8707280208 870722 PDR ADOCK 0500032$

'\\

P PDR i

____.__...._..-__-.)

I

SUMMARY

New fault tree quantifications are provided for the Monticello j

and BSEP design for RPT failure to trip. Data for the new quantifications is taken from NUREG/CR 4126 (draft) and actual industry experience. Key portions of the referenced data is included in Appendix A.

Data for the 4kv breakers is taken from the NUREG.

Justification for using this data is provided on Attachment 3.

Data for the field breaker failure to trip was taken from actual industry experience at Brunswick and Pilgrim stations.

The derivation of the failure rate used is provided on.

The NUREG data was not deemed to be

]

appropriate for the field breakers. Justification is given on.

Additional data on low voltage metal clad breaker reliability is given on Attachment 4. This data was not included in the analysis and is provided for information only.

The detailed fault tree quantifications are included in the appendix. A summary of the results are:

Monticello design

8. 2 E-3 BSEP design

2. 2 E-4 Our conclusion is that our proposed RPT design will be considerably more reliable than the referenced standard.

ATTACHMENT 1 Failure data for low voltage load breakers in NUREG CR 4126 does not appear to apply to the recirc MG set field breakers ( AK F-2-2 5). This conclusion is based on the following analysis.

Detailed failure data applied to GE low voltage load breakers is given in Table 2,

" Summary of Circuit B reaker input D ata. for LER Rate Estimations," (Page 35, attached). Fallut e to open (coded "A")

data is supplied for the following plants.

Plant -

No. of Failures Dresden 2 (DR2) 1 Oyster. Creek (OC1) 1 Quad-Cities 2 (QC2) 2 Susquehanna 1 (SQ1) 1 The LERs relating to the above failures are listed in Appendix D, Pages i

D17-D24 (attached). The key to relating the LER to the specific failure is the plant and the "A" code under " Mode f, Cause."

The specific failures are as follows.

l Plant Date Comments j

DR2 03-13-76 HPCI steam valve failure (Page D20). This is a 480v molded case breaker.

QC2 02-11-79 RHR suction valve failure (Page D24). This is a 480v molded case breaker.

QC2 05-18-81 RHR MOV failure (Page D24). This is a 480v molded case breaker.

SQ1 05-30-83 KCIC discharge valve (Page D24). This is a 480v molded case breaker.

The fifth failure could not be determined from the data.

Two recire MG set field breaker " failure to open" were not counted.

These LERs are as follows.

Plant Date Comments M01 03-17-79 Page D22 PIL 04-03-83 Page D23 l

Table. 2, Page 36 (attached) shows that these failures are not counted.

Note that neither the Monticello nor the Pilgrim plants have an "A" type failure listed under the " low voltage load breaker" column.

ATTACHMENT 2 DATA:

FAILURE OF RECIRC MG SET FIELD BREAKER TO OPEN ASSUMPTIONS

1) TEN YEAR PERIOD 1976 - 1986 (ARBITRARY TIME PERIOD)

2) TWO BREAKERS PER PLANT (ACTUAL NUMBER) 3)

25 CYCLES PER YEAR (CONSIDERED CONSERVATIVE BY A FACTOR OF 2)

4) TRIP MECHANISM FAILURES ARE 13% OF THE TOTAL (PER NUREG/CR 4126, FIC. 21, PAGE 53, ATTACHED)

BSEP DATA 10 YEARS X 2 PLANTS X 2 BKR X 25 DEMANDS = 1000 DEMANDS PLANT BKR THREE FAILURES TO OPEN DATE WORK ORDER NUMBER 06-23-81 WRSA 2-E-81-2483 04-19-82 WRSA 1-E 1643 07-27-84 WRSA 1-E 3 644 PILGRIM DATA 10 YEARS X 1 PLANT X 2 BKR X 25 DEMANDS = 500 DEMANDS PLANT BKR FOUR FAILURES REF USNRC IEN 87-12, " POTENTIAL PROBLEMS WITH METAL CL AD CIRCUlT BREAKERS, CENERAL ELECTRIC TYPE AKF-2-25" ( ATTACHED)

1) 02-09-85

2) 03-15-85

3) 06-29-86 REF NUREG/CR 4126 ( APPENDIX D, PAGE D23)

INPO SER 28-83 ( ATTACHED)

4) 04-03-83 CONCLUSION FAILURE RATE 7/1500 4.67 E-3/d

=

X COLL =

4. 67 E-3 X.13

6. 07 E-4

=

X OTHER = (4.67 E-3) - (6. 07 E-4)

4. 06 E-3

=

~

1 1

ATTACHMENT 3 l

DATA:

FAILURE OF THE 4KV BREAKER TO OPEN ASSUMPTIONS:

1)

NUREG/CR 4126 DATA FOR MEDIUM VOLTAGE LOAD BREAKERS IS USED.

2)

NUREG /CR 4126 COIL / TRIP MECH ANISM l

FAILURES ARE 13% OF THE TOTAL.

i CALCU LATION :

l X

4KV BREAKER TOTAL

= 1.10 E-4 X

COIL

= 1. 43 E-5 OTHER

= 9. 57 E-5 l

l COMMENT:

THE FAILURE DATA IN THE NUREG APPEARS TO BE APPLICABLE FOR THE

" MEDIUM VOLTAGE LOAD BREAKERS." THE FAILURE RATES ARE BASED ON TWO FAILURES AT OYSTER CREEK (OCl) - (TABLE 2, PAGE 36, ATTACHED). THE LERs DESCRIBING THESE FAILURES ARE DESCRIBED IN APPENDIX D, PAGE D22 (ATTACHED).

l l

ATTACHMENT 4 l

DATA: ADDITIONAL SUPPORTING DOCUMENTATION ON LOW VOLTAGE METAL CLAD BREAKER RELIABILITY

.)

o TWO FAILURES AT'MONTICELLO 1) 03-17-79 REFERENCE NUREG/CR

4126, APPENDIX D, PAGE D22 ( ATTACHED) 2)

02-06-84 REFERENCE INPO SER 48-84 (ATTACHED)

I l

o ONE FAILURE AT DRESDEN 3 i

l 1) 09-02-83 REFERENCE NRC IEN 87-12 ( ATTACHED) o MG SET FIELD BREAKERS (AK F-2-25) ARE OF SIMILAR DESIGN TO PWR REACTOR TRIP BREAKERS (SEE ATTACHED VENDOR BULLETIN). NU REG-1000, VOL I,

" GENERIC IMPLICATIONS OF ATWS EVENTS AT THE SALEM NUCLEAR POWER PLANT", GIVES AN OVERALL FAILURE RATE OF 3.00 E-3/d FOR PWR RTB (PAGE 3-23, ATT ACH ED).

l

)

APPENDIX A SUPPORTING DOCUMENTATION j

l 1)

MONTICELLO FAILURE TO TRIP FAULT TREE

)

2)

MONTICELLO FAILURE TO TRIP QUANTIFICATION 3)

BSEP FAILURE TO TRIP FAULT TREE 4)

BSEP FAILURE TO TRIP QUANTIFICATION 5)

NRC IEN 87-12 6)

GE SIL 448 7)

INPO SER 48-84 I

8)

INPO SER 28-83 l

9)

VENDOR BULLETIN -- LOW VOLTAGE BREAKERS 10)

NUREG/CR 4126 (SELECTED PORTIONS) 11)

NUREG-1000

l RPT PAGE 1 OF 5

EllHER LEEtdER r as 'B-i FAILS 10 1 RIP l

RPI-61 I i

FAULT TRII: NONTICi1LO TAIIJIRE f 0 7 RIP A

Till MME: RPT h]

MfE:

7-17-87 1

IBREALER 'A' BREALER B FAILS 10 TRIP FAILS TO TRIP l

1 RPT-62 I RPT-63 i PASE 2 PAGE 4 i

i i

i l

i

RPT PAGE 2 OF 5

TRANSFER 10 PAGE 1 BREAKER 'A' FAILS TO TRIP RPT-62 I I

BREAKER A BOTH A TRIP i

FAILS CLCSED COILS Fall TO TRIP BREAKER l

RRS-BKR -BKRA RPT-64 s

i i

i TRIP C0ll Al TRIP CDIL A2 FAILS TO TRIP FAILS TO TRIP l

BREAKER BREAKER l

RPT-65 I RPI-66 i PAGE 3

)

1 i

TRIP C0!L Al NO TRIP S16NAL FAILS TO TRIP C0ll Al RRS-TCL4A-TCA1 RPT-67 I o

9 I

I NO LOW LEVEL N0 HIGH S16NAL PRESSURE S16NAL RPT-68 I RPT-69 i A LOW LEVEL C LOW LEVEL A HIGH C H16H SIGNAL FAILS S16NAL FA!LS PRESSURE PRESSURE I

SIGNAL FAILS SISNAL FAILS RRS-ACT

-LLA RRS-ACT -LLC RRS-ACT

-HFA RRS-ACI

-HPC

.\\

l l

l

RPT PAGE

'3 OF 5

TRANSFER 10 FASE 2 TRIP C0ll A2 FAILS TO TRIP BREAKER RPT-66 I I

TRIP C0ll A2 NO TRIP SIGNAL FAILS.

TO CDIL A2-RRS-TCL4A-TCA2 RPT-6103 0

Q i

i NO LOW LEVEL NO H16H S!6NAL PRESSURE S16hAL RPT-611i RPT-612I I

I B LOW LEVEL D LOW LEVEL-B HIGH D H:SH l

S!BML FAILS SIGNALFAILS FRESSURE PREESURE SISNALFAILS SIS %L FAILS 4

l RRS-ACT -LLB RRS-ACT -LLD RRS-ACT4A-HPB RRS-ACT

-HPD 1

1 1

I 8

]

l i

l

-8

'RPT PAGE

.4 DF 5

'1RANSCEP 10 FASE 1 lFAILSTOTRIP 6REAKER S l

RPT-63 I l

r l

BREAKER B BOTH B TRIP FAILS CLOSED COILS Fall TO TRIP BREAKER l

RRS-BKR-tC-BKRB RPT-613i 0

g TRIP C0lt B1 TRIP C0ll 92 FAILS TO TRIP FAILS TO TRIP BREAKER BRE4KER RPT-614i RPT-615I PA6E 5 l

TRIP C0ll B1 NO TRIP S!6NAL FAILS TO TRIP C0ll l

B1 RRS-ICL4A-TCB1 RPI-616I 0

Q l

i i

NO LOW LEVEL N3 H16H i

SISNAL PRESSURE 4

SI6NAL' 1

RPI-617i RPT-618i i

A LOW LEVEL' C LOW LEVEL-A H16H C H16H l

SIGNAL FAILS SIGNALFAILS PRESSURE PRESSURE j

S16NALFAILS S16NALFAILS l

A*

A h*Aw

C' 1

i l

RPT PAGE 5 OF 5

1P,ANS?ERTDFME 4 IRIP C0ll B2 FAILS TO TRIP BREALER RPT-615I I

TRIP C0ll B2 NO TRIP S!6NAL FAILS TO TRIP C0!L B2 RRS-TCl4A-TCB2 RPT-619I i

0 Q

I I

'k0 LOW LEVEL N0 HIGH S!6NAL PRESSUPI RI6NAL 1

l RPT-620i RPI-62'!

B LOW LEVEL D LOW LEVEL B HIGH

'D HI6" j

S!6NAL FAILS S:6NAL FAILS PRESSURE PRESSUht SIGNAL FAILS SIGNAL FAILS RRS-ACT-PA-LLB RRS-ACT4A-LLD RRS-ACi4 A-HPB RRS-ACT4A-HPD 0

0 0

0 l

l

)

_____-_-_-_-w

,., _,,_,m _

m _ v o y o z

~

RAIJK - MINIMAL CU'l SET ULilERAiING ROU1INE i

RVI 7/1b/B1 IJUMI:ER UF E VL NI S t 14 FAllLT TREE: NONilCELLO FellJiRE 10 TRIP 1

FILE NAME: RPT

'l BATE:

7-17-87 l

'.IST OF EVENTS - BY INDEX INDEX EVENT UNAVAILABILITY

.1 RRS-ACT-FA-HPB 2.OE-05 2

RRS-ACT-FA-HPD 2.OE-Ob 3

RRS-ACT-FA-LLB 2.OE-05 l

4 RRS-ACl-FA-LLD 2.OE-05 5

RRS-ACT-FA-HPA 2.OE-05 6

RRS-ACl-FA-HPC

- 2.OE-05 4

7 RRS-ACT-FA-LLA 2.OE-05 8

RRS-ACT-FA-L.LC 2.OE-05 9

RRS-TCL-FA-TCB2 6.dE-04 10 RRS-TCL-FA-TCB1 6.1E-04 1

11 RRS-TCL-FA-TCA2 6.1E-04 i

12 RRS-TCL-FA-1CA1 6.iE-04 13 RRS-BKR-CC-BKRB 4.1E-03 14 RRS-BKR-CC-BKRA 4.1E-03 MINIMAL CUT SETS AND INDICES FOR ORDER 1 CLIT INDEX EVEN1 1

13 RRS-BKR-CC-BKRB 2

14 RRS-BKR-CC-BKRA RANKED SINGLE FAULTS i

l

)

UNAVAIL INDEX EVENT 4.1E-03 13 RRS-DKR-CC-DKRD 4.1E-03 14 RRS-BKR-CC-BKRA i

IDT AL. UNAVAILABILI T Y DLIE TO ABOVE 2 SI NGLE FAULTS = 8. ;?E-03 I

* * * * * * * * * * * * * * * * * * * * + * * * * * * * * * * * * * * * * * * * * * *. * * * * * * * * *,,, * *,, *,,,,,.,,,,,

TOTAL NUMBER OF SINGLE FAULTS =

2 i

TOTAL UNAVAILABILITY DUE 10 SINGLE FAULTS = 8.2E-03 i

+ + + * * +. * + + * + * * + + + + + + + + + * * * + * * * + + * * * * * * + + * * + * * * + * + + + + * * + + * * * + + + + + + + + + + + + *

MIN] MAL CUT SETS AND INDICES FOR ORDER 2 CUl INDEX EVEN1 INDEX EVENT I

1 RHS-ACT-I 4-Hl'8 5

RRS-ACI-FA-HPA il 1

RRS-AG I-F A-HPD 6

RRS-AUI-1(-HFU S

1 RRS-ACT-FA-HPJi

?

RRS-AU I-E n-t t A

-s 1

Plchd l n Hi 'h H

R P, A1;i -I A -t 1.1

H-1 HRS-Aul-FA-HPh 12 RRS-l Cl.-F n-I Uni

.9 -

2 RRS-ACI-FA-HPD S

RRS-AC T-- F A-HP A 10 2

RRS-ACI-FA-HPD 6

RRS-ALi-FA-HPU 11 2

RRS-ACT-FA-HPD 7

RRS-ACl-FA-Lt.A 12 2

RRS-AC1-FA-HPD 8

RRS-AU T - F A --I LO 13 2

RRS-AC 1 -F A-HPD 10 RRS - 1 CL-F A-I CB1 14 2

RRS-ACl-FA-HPD 12 RRS-1CL-FA-TCA1 15 3

RRS-ACT-FA-LLB 5

RRS-ACT-FA-HPA 16 3

RRS-ACl-FA-LLD 6

RRS-ACT-FA-HPC 17 3

RRS-ACT-FA-LLB 7

RRS-ACT-FA-LLA 18 3

RRS-ACT-FA-LLB B

RRS-ACT-FA-LLC 19 3

RRS-ACT-FA-LLB 10 RRS-TCL-FA-TCB1 20 3

RRS-Art FA-LLB 12 RRS-TCL-FA-TCA1 21 4

RRS-ACI-FA-LLD 5

RRS-ACT-FA-HPA 22 4

RRS-ACT-FA-LLD 6

RRS-ACT-FA-HPC 23 4 - RRS-AC7 r.'4-LLD 7

RRS-ACT-FA-LLA 24 4

RRS-ACT-FA-LLD 8

RRS-ACT-FA-LLC 25 4

RRS-ACT-FA-LLD 10 RRS-TCL-FA-TCB1 26 4

RRS-ACl-FA-LLD 12 RRS-TCL-FA-TCA1 27 5

RRS-ACT-FA-HPA 9

RRS-TCL-FA-TCB2 28 5

RRS-ACT-FA-HPA s 11 RRS-TCL-FA-TCA2 29 6

RR3-ACT-FA-HFC 9

RRS-TCL-FA-TCB2 30 6

RRS-ACT-FA-HPC 11 RRS-TCL-FA-TCA2 31 7

RRS-ACT-FA-LLA 9

RRS-TCL-FA-TCB2 32 7

RRS-ACT-FA-LLA 11 RRS-TCL-FA-TCA2 33 8

RRS-ACT-FA-LLC 9

RRS-TCL-FA-TCB2 34 8

RRS-ACT-FA-LLC 11 RRS-TCL-FA-TCA2 35 9

RRS-TCL-FA-TCB2 10 RRS-TCL-FA-TCB1 36 il RRS-TCL-FA-TCA2 12 RRS-TCL-FA-TCA1 l

RANKED DOUBLE FAULTS l

UNAVAIL.

INDEX EVENT INDEX EVENT 3.7E-07 9 RRS-TCL-FA-TCB2 10 RRS-TFl-FA-TCB1 3.7E-07 11 RRS-TCL-FA-TCA2 12 RRS-li. IA-TCA1 1.2E-08 1 RRS-ACT-FA-HPB 10 RRS-1CL-FA-TCB1 1.2E-OB 1 RRS-ACT-FA-HPD 12 RRS-TCL-FA-TCA1 1.2E-08 2 RRS-ACT-FA-HPD 10 RRS-TCL-FA-TCB1 1.2E-08 2 RRS-ACl-FA-HPD 12 RRS-lCL-FA-TCA1 1.2E-08 3 RRS-ACT-FA-LLB 10 RRS-TCL-FA-TCB1 1.2E-08 3 RRS-ACT-FA-LLB 12 RRS-TCL-FA-TCA1 1.2E-08 4 RRS-ACT-FA-LLD 10 RRS-TCL-FA-TCB1 1.2E-OB 4 RRS-ACT-FA-LLD 12 RRS-TCL-FA-TCA1 1.2E-08 5 RRS-ACT-FA-HPA 9 RRS-TCL-FA-TCB2 1.2E-08 5 RRS-ACT-FA-HPA 11 RRS-TCL-FA-1CA2 1.2E-08 6 RRS-ACT-FA-HPC 9 RRS-TCL-FA-TCB2 1.2E-OB 6 RRS-ACT-FA-HPC 11 RRS-TCL-FA-TCA2 1.2E-OB 7 RRS-ACT-FA-LLA 9 RRS-TCL-FA-TCB2 1.2E-08 7 RRS-ACT-FA-LL.A 11 RRS-TCL-FA-TCA2 1.2E-08 8 RRS-ACT-FA-LLC 9 RRS-TCL-FA-TCB2 1.2E-OP B RRS-ACT-FA-LLC 11 RRS-1CL-FA-1CA2 4.OE-10 1 RRS-AC'-FA-HPB 5 RRS-ACT--F A-HPA 4.OE-10 1 RRS-ACT-FA-HPB 6 RRS-ACT-FA--HPC 4.OE-10 1.RRS-ACT-FA-HPB 7 RRS-ACT-FA-LLA 4.OE-10 1 RRS-ACT-FA-HPB B RRS-ACl-FA-LLC 4.OE-10 2 RRS-ACT-FA-HPD-5 RRS-ACT-FA-HPA 4.OE-10 2 RRS-ACT rg a,D 6 RRS-ACT-FA-HPC 4.OF-10 2 RRS-ACT-A-HPD 7 RRb-AC 1 -F A-l.L A 4.OE-10 2 RRS-AC) -F A-H: 'D H RHS-ACl-l'A-1iU 4.OL-10

. RIG-AUl, &LIH 5 F:RP ACl-F A-lil'h

4. s ti -19

? RRU-ALI-iiril D 6 l H, - At.,1

n 101

4.ift:- 10

9. HHS-AUi-lA-LLU

/ HHt -nU l

--l A-L t.O

4. OE-10 3 RHS-ACl-FIEL.L.D U RRb-nCl-FA-lLU 4.OE-10' 4 HRS-AC1-fA-LLD b RH3-ACl-FA-Hi"'A 4.OL-10 4 HRS-AC~l - F 0- Ll D 6 RHB - At :~l --F A-H1 'U 4.OE-10 4 RRS-ACT-FA-LLD 7 RRS-ACT-FA-LLA 4.OE-10 4 RRS-AC~l-FA-LLD 8 RRS-ACT-FA-LLC TOTAL UNAVAILABILITY DUE TO ABOVE 34 DOUBLE FAULTS = 9.5E-07

- - - - ++**************+********+++***+*+******

TOTAL NUMBER OF DOUBLE FAULTS =

34 TOTAL UNAVAILABILITY DUE TO DOUBLE FAULTS = Y.5E-07 MINIMAL CUT SETS AND INDICES FOR ORDER 3 CUT INDEX EVENT INDEX EVENT INDEX EVENT l

RANKED TRIPLE FAULTS UNAVAIL INDEX EVENT INDEX EVENT INDEX EVENT l

- - - - +********** m ** m ********** m ** m **********

TOTAL NUMBER OF TRIPLE FAULTS =

0

' LOT AL UNAVAILABILITY DUE TO TRIPLE FAULTS =

.OE400

m*************** m ******************-**** m ************ m

m *** m **

- - - - +****

TOTAL SYSTEM UNAVAILABILITY'.=8.2E-03

- - - +***+*********** m *****+*********

9 IY i

RPI2 P Ali E 1 OF S

EITHER BREALER

'A' OR 'B' FAILS TO TRIP i

RPT2-61i FAULT TREE: If5EP FAllERE TO TRIP FILE NAME: RFf2 MIE:

7-17-87 i

BREAKER A BREAKER B j

FAILS TO TRIP FAILS 10 TRIP j

RPT2-62i RPT2-63i PAGE 2 PAGE 4

RPI2 PAGE 2 OF 5

l l

IPANSFER 10 PASE I I

1 BREAKER A FAILS TO TRIP 1

RPT2-623' F

BREAKER A TRIP CO!L A FAILS CLOSED FAILS TO TRIP BREAKER A RRS-BKR-tC-BKRA RPT2-641 0

0 l

TRIP COIL Al NO TRIP SIGNAL FAILS TO TRIP COIL l

RRS-TCC-FA-TCA1 RPT2-651 0

0 i

NO LOW LEVEL N0 HIGH j

SIGNAL FRESSURE SIGNAL RPT2-66i RPT2-67i PAGE 3 I

l NO A CHANNEL NO B CHANNEL LOW LEVEL LOW LEVEL SIGNAL SIGNAL

\\

RPT2-68I RPT2-69i i

1 A LOW LEVEL C LOW LEVEL B LOW LEVEL D LOW LEVEL l

SIEr FAILS SIGNAL FAILS SIGNALFAILS SIGNAL FAILS i

RRS-ACT A-LLA RRS-ACT -LLC RRS-ACT -LLB RRS-ACT -LLD 1

1 t

RPT2 PAGE 3 OF 5

IPANSFER TO FAGE 2

N0 HIGH PRESSURE SIGNAL RPT2-67I e

i i

NO A CHANNEL NO B CHANNEL HIGH PRESSURE HIGH PRESSURE SIGNAL SibNAL RPT2-6101 RPT2-6111 l

1 l

A HIGH C HIGH B HIGH D HI6t!

PRESSURE PRESSURE PRESSURE PRESSURE S16NAL FAILS SIGNAL FAILS SIGNAL FAILS SIGNAL FA!LS RRS-ACT

-HPA RRS-ACT

-HPC RRS-ACI

-HPB RRS-ACT

-HPD l

l l

I l

l

\\

I

RPT2 F' A G E 4 UF 5

TMNSFER TO PAGE 1

BREAKER B FAILS TO TRIP l

RPT2-63I' I

BREAKER B TRIP COIL B j

FAILS CLOSED FAILS TO TRIP l

BREAKER B J

i H

RRS-BKR-tC-BKRB RPT2-6121 l

0 0

I TRIP CDIL B1 NO TRIP SIGNAL j

FAILS TO TRIP C0ll l

RRS-?tC -TCB1 RPT2-6!

NO LOW LEVEL N3 Hl6H

$16NAL PRESSURE l

SIGNAL RPT2-6143 RPT2-6151 PAGE 5 i

i NO B CHANNEL NO A CHANNEL LOW LEVEL LOW LEVEL SIGNAL SIGNAL

\\

RPT2-6161 RPT2-6171 i

i B LOW LEVEL D LOW LEVEL A LOW LEVEL C LOW LEVEL SIGNAL FAILS S!6NAL FAILS SIGNAL FAILS SIGNAL FAILS RRS-ACT LLB RRS-ACI

-LLD RRS-ACT -LLA RRS-ACT-A-LLC

HP 12' PAGE 5 UF 5

IP aSFER 10 fAGE 4

N0 HIGH PRESSURE SIGNAL RPf2-6151 I

I NO B CHANNEL NO A CHANNEL HIGH PRESSURE H15H PRESSURE S!6NAL SIGNAL RPT2-SIBl RPT2-6191 I

f I

B HI6H D HIGH A HIGH C HIGH FRESSURE PRESSURE PRESSURE PRESSURE SIGNAL FA!LS S!GNAL FAILS SIGNAL FAILS SIGNAL FAILS RRS-ACT

-HPB RRS-ACT

-HPD RRS-ACT

-HPA RRS-ACI

-HPC

,o *>x+*vv*,t,..,,,y.

3>>..**ww+

>,e**e-**owuxu

,. >, y t. o *, *

h 0NI.

11{ N 1l h k CUl SEI 13h NERA l [Ill3 h(Jd l [NE.

'HP12 7/16/87 NUMBER OF EVENTS =

12 M.T TE M FAIM M TM LIST OF EVENTS BY INDEX Fil.E ItME: RFf2 DATE:

7-17-87

-]

INDEX EVENT UNAVAILABILITY 1

RRS-- AC T-F A-HPA 2.OE-05 2

RRS-ACT-FA-HPC 2.OE-05 3

.RRS-ACT-FA-HPB 2.OE-05 4

RRS-ACT-FA-HPD 2.OE-05 5

RRS-ACT-FA-LLA 2.OE 6 RRS-ACT-FA-LLC 2.OE-05 7

RRS-ACT-FA-LLB 2.OE-05 8

RRS-ACT-FA-LLD 2.OE-05 9

RRS-TCC-FA-TCB1 1.4E-05 10 RRS-TCC-FA-TCA1 1.4E-05 i

11 RRS-BRR-CC-BKRB 9.6E-05 12 RRS-BKR-CC-BKRA 9.6E-05 i

MINIMAL CUT SETS AND INDICES FOR ORDER 1

)

i CUT INDEX EVENT I

1 9

RRS-TCC-FA-TCB1 l

2 10 RRS-TCC-FA-TCA1 3

11 RRS-BKR-CC-BKRB 4

12 RRS-BKR-CC-BKRA i

i RANKED SINGLE FAULTS l

UNAVAIL INDEX EVENT 9.6E-05 11 RRS-BKR-CC-BKRB l

9.6E-05 12 RRS-BKR-CC-BKRA s

1.4E-05 9 RRS-TCC-FA-TCB1 1.4E-05 10 RRS-TCC-FA-TCA1 i

l TOTAL UNAVAILABILITY DUE TO ABOVE 4 SINGLE FAULTS = 2.2E-04 l-

%%%%% %%%* % *% * %4* %%%%%* %%%%%%%%%%%%%%%%%% *5%%%%% *t%%* t %%%%%%%%%%%%%%%%%%%

TOTAL NUMBER OF SINGLE FAULTS =

4 TOTAL UNAVAILABILITY DUE TO SINGLE FAULTS = 2.2E-04

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til N 1 Moi, CU l SEIS iiND ( ND ( CES l-OR URDER '.'

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UU1 INDEX kVENI INDEX ENE.N I l

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RRS-ACT-FA-LLB 12 6

RRS-ACT-FA-LLC 8

RRS-ACT-FA-LLD RANKED DOUBLE FAULTS t

UN4 VAIL INDEX EVENT INDEX EVENT 4.OE-10 1 RRS-ACT-FA-HPA 3 RRS-ACT-FA-HPB 4.OE-10 1 RRS-ACT-FA-HPA 4 RRS-ACT-FA-HPD 4.OE-10 2 RRS-ACT-FA-HPC 3 RRS-ACT-FA-HPB 4.OE-10 2 RRS-ACT-FA-HPC 4 RRS-ACT-FA-HPD 4.OE-10 5 RRS-ACT-FA-LLA 7 RRS-ACT-FA-LLB 4.OE-10 5 RRS-ACT-FA-LLA B RRS-ACT-FA-LLD 4.OE-10 6 RRS-ACT-FA-LLC 7 RRS-ACT-FA-LLB 4.OE-10 6 RRS-ACT-FA-LLC 8 RRS-ACT-FA-LLD TOTAL UNAVAILABILITY DUE TO ABOVE 8 DOUBLE FAULTS = 3.2E-09 c o n o o * * * * * * * *

u * * *. n * *

u

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n * * * * *

n *

p n

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n * * *

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l TOTAL NUMBER OF DOUBLE FAULTS =

8 l

TOIAL UNAVAILABILITY DUE TO DOUBLE FAULTS = 3.2E-09 1

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MINIMAL CUT SETS AND INDICES FOR ORDER 3 CUT INDEX EVENT INDEX EVENT INDEX EVENT RANKED TRIPLE FAULTS UNAVAIL INDEX EVENT INDEX EVENT INDEX EVENT 1

l oooo* n*******

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u* n u n u n* u* n** n u n TOTAL NUMBER'OF TRIPLE FAULTS==

0 TOTAL UNAVAILABILITY DUE TO TRIPLE FAULTS =

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RECEIVED FEB 2 31987 h.y1 SSINS No.:

6835 Nf IN 87-12 UNITED STATES gS-t: b d

NUCLEAR REGULATORY COMISSION OFFICE OF INSPECTION AND ENFORCEMENT WASHINGTON, D.C.

20555 February 13, 1987 IE INFORMATION NOTICE 87-12:

POTENTIAL PROBLEMS WITH METAL CLAD CIRCUIT BREAKERS, GENERAL ELECTRIC TYPE AKF-2-25 j

Addressees _:

All nuclear power reactor facilities holding an operating license or a construction permit.

Purpose:

This notice is to alert recipients of potential probless with the General Electric Company (GE) AKF-2-25 type circuit breakers failing to fully open on demand.

It is expected that recipients will review the information for applicability to their facilities and consider actions, if appropriate, to preclude similar problems.

However, suggestions contained in this infomation notice do not constitute NRC requirements; therefore, no specific action or written response is required.

Description of Circumstances:

i 1.

Pilgria Nuclear Power Station On June 29, 1986, the "A" recirculation pump (RP) motor / generator (MG) set field breaker (AKF-2-25) failed to trip while the MG was being removed free service.

Licensee investigation revealed that the breaker was mechanically bound and could not be actuated by rotating the trip shaft.

Because the breaker had not fully opened, the breaker auxiliary switch "a" contact, which is in series with the shunt trip coil (STC), did not open the circuit to the STC, which then burned out.

Improper lubrication and misadjustment appeared to be the cause of binding.

On March 15, 1985, the turbine generator field breaker (AKF-2-25) failed-to open when it received a trip signal from its manual control switch.

Examination determined that there was insufficient lubrication on the link and cas of the centenole of the breaker and that the eccentric can bushing was improperly installed.

On February 9,1985, the "A" RP MG-set field breaker (AKF-2-25) failed to open on demand after the "A" RP motor tripped.

The control /ATWS STC was observed to be burned and open circuited.

Additionally, the auxiliafy switch that was connected to the breaker trip shaft was found to have loose mounting bolts and to be damaged.

The licensee determined that mechanical b(nding and/or auxiliary switch problems caused the failure of the breaker to trip on demand.

8702110132

IN 87-12 February 13, 1987 Page 2 of 4 On April 3,1983, the "B" RP MG-set field breaker (AKF-2-25) failed to open; consequently, the STC burned out when the "B" RP was secured by the control room operators.

The licensee maintenance. personnel found mechanical binding of the breaker unit, which required partial disassembly to free the breaker.

The licensee determined that the shunt trip device rotated the trip shaft, thereby starting the trip action; however, the can arrangement failed to complete its intended action and the trip action was interrupted.

2.

Dresden Unit 3 On September 2, 1983, personnel could not open the "B" RP MG-set field breaker (AKF-2-25) and found the STC burned out.

The STC was replaced and the breaker was cleaned and lubricated.

On March 1, 1982, while performing the ATWS surveillance, which requires tripping and reclosing the field breaker, the plant personnel found the field breaker inoperable.

Plant personnel investigated and found the operator are disconnected from the auxiliary contacts.

The are was reconnected and the surveillance was performed.

Discussion:

On February 21, 1980, the NRC issued an order requiring the installation of an ATWS RP trip function.

Some licensees installed a second STC on the two RP MG-set field breakers and the necessary instrumentation / logic to cause a breaker trip when certain parameters are sensed.

Pilgria and Dresden have this arrangement.

Other licensees installed the ATWS trip coils in the 4.16 kV/6.9 kV circuit breakers that supply power to the two MG-sets.

The AKF-2-25 circuit breaker is a field switch without overcurrent protection.

It ir, a three polt breaker with the center pole modified specifically to serve as a de switch.

In the ATWS RP trip function application, the AKF-2-25 field breaker is equipped with two STCs, one of which is dedicated to respond to an ATWS demand.

Each STC is energized through a normally open "A" contact that is controlled by the breaker's moving contacts.

The "A" contact is an auxiliary switch that opens when the breaker is fully open and closes when the breaker is closed (0N position).

The "A" contact is in series with the STC.

Thus, when the breaker is closed, the "A" contact is closed and the STC is ready to trip on receipt of a signal from the control room or the ATWS logic.

The STC is not rated for continuous duty and will overheat and fall if subjected to full voltage for more than a few seconds.

If a breaker does not fully open-when demanded by an STC, the "A" contact will not open and the STC will overheat and fail.

Therefore, if a subsequent ATWS trip signal is initiated, the safety function will not be performed.

An STC failure can only be detected by testing; remote indication is not provided.

IN 87-12 February 13, 1987 Page 3 of 4 The most recent breaker failure at Pilgrim has been attributed to improper maintenance performed by GE service technicians, who at the time were unaware of special maintenance practices developed by the GE Atlanta Service Shop.

The GE Atlanta facility disassembled the failed breaker and discovered that it was out of adjustment and that improper lubricants had apparently been used.

GE has issued Service Information Letter Number 448 to address special maintenance practices developed for the entire AK type breaker series which includes AK, AKU, AKF, and AKR type circuit breakers.

The ATWS trip function is required by 10 CFR 50.62(c)(5) and specific quality assurance guidance has been provided for non-safety-related ATWS equipment (NRC Generic Letter 85-06 dated April 16,1985).

The GE AKF type circuit breakers have been shown to be susceptible to failure as a result of binding within the breaker can mechanise, unless proper maintenance procedures are developed and followed by individuals trained specifically to service the AKF breaker.

GE has suggested that the following maintenance information be incorporated into licensee programs for GE AKF-type circuit breakers:

(1) Maintenance / inspection intervals of every 12 months or at each refueling outage.

A complete breaker overhaul every 5 years is recommended to complement the annual cyclical maintenance.

(1) Only specified lubricants shou.1d be used on these circuit breakers.

Molykote BR2 Plus grease or equivalent for the slot in the circuit breaker center-pole cas-link and GE Specification 050H038 (Mobil 28) for all other applications.

The grease of GE Specifications 050H15 and 050H47 is no longer recommended for this breaker.

NOTE:

D50le38 lubricant should not be mixed with D50H15 and 050H47 Tu5ricants.

Before changing to 050H038 lubricant, maintenance personnel should clean the circuit breaker thoroughly to remove all D50H15 and 050H47 lubricant from the circuit breaker.

(3) Because of the complexity and difficulty in properly making crucial adjustments unique to GE AKF type circuit breakers, only qualified, properly trained personnal should perform these maintenance activities.

(4) For type AKF circuit breakers which have not yet been converted to 050H038 lubricant, cycle the breakers a few times between maintenance and inspec-tion events whenever plant conditions allow.

6

IN 87-12 February 13, 1987 Page 4 of 4 No specific action or written response is required by this notice.

If you have j

any questions regarding this matter, please contact the Regional Administrator i

of the appropriate regional office or this office.

d rd or Divisi of Emergency Preparedness i

and ngineering Response Office of Inspection and Enforcement Technical Contacts:

K. R. Naidu, IE I

(301) 492-4179 I

J. Jacobson IE (301) 492-8845

Attachment:

List of Recently Issued Information Notices I

i

)

{

1 IN 87-12 February 13, 1987 I

LIST OF RECENTLY ISSUED IE INFORMATION NOTICES Information Date of Notice No.

Subject Issue Issued to l

I 87-11 Enciosure of Vital Equipment 2/13/87 All power reactor Within Designated Vital facilities holding Areas an OL or CP j

87-10 Potential for Water Hammer 2/11/87 All BWR facilities During Restart of Residual holding an OL or CP J

Heat Removal Pumps 87-09 Emergency Ofesel Generator 2/5/87 All power reactor Room Cooling Design facilities holding Deficiency an OL or CP J

87-08 Degraded Motor Leads in 2/4/87 All power reactor Limitorque CD Motor facilities holding Operators an OL or CP 87-07 Quality Control of Onsite 2/3/87 All power reactor Dewatering / Solidification facilities holding Operations by Outside an OL or CP Contractors 87-06 Loss of Suction to Low-1/30/87 All power reactor Pressure Service Water facilities holding System Pumps Resulting From an OL or CP Loss of Siphon 87-05 Miswiring in a Westinghouse 2/2/87 All Westinghouse Rod Control System power reactor facilities holding an OL or CP i

87-04 Diesel Generator Fails 1/16/87 All power reactor Test Because of Degraded facilities holding l

Fuel an OL or CP 87-03 Segregation of Hazardous 1/15/87 All NRC licensees 87-02 Inadequate Seismic Quali-1/15/87 All power reactor fication of Diaphrage facilities holding Valves by Mathematical an OL or CP Modeling and Analysis t

OL = Operating License CP = Construction Permit

EdDPa!l INFORMATION LETTER 3

SAN JOSE. CALIFORNIA December 23, 1986 SIL No. 448 File Tab S Category 2 MAINTENANCE AND LUBRICANTS FOR GE TYPE AK CIRCUIT BREAKERS

Background

Analyses of recent performance problems with a General Electric Type AKF-25 circuit breaker at a BWR/3 have resulted in GE's revising its recommendations for maintenance procedures and lubricants for GE's entire product line of Type AK circuit breakers, including Type AKF.

The Type AX Series includes AK, AKU, AKF and AKR circuit breakers. The purpose of this Services Information Letter is to communicate those recommendations.

Discussion Several failures of Type AKF circuit breakers to trip on command have occurred during the past few years.

Also, some Type AK circuit breakers used as reac-tor trip breakers in Pressurized Water Reactors have failed to trip (these failures of Type AK breakers, which have been corrected, were addressed by NUREG 1000.)

GE attributes failure to trip on command to circuit breaker mis-adjustment or lubrication problems (or both) in most of the circuit breaker failures GE has examined.

In these, the failures usually reaulted from a combination of mis-adjustment and use of improper lubricant.

t,

-r The most significant improvement in Type AK circuit breaker operation results from using GE Specification D50HD38 lubricant (Mobilgrease No. 28) in the breakers (except on the cam-link slot of the AKF breaker).

D50HD38 gradually replaced GE Specifications D50H15 and D50H47 lubricants.

In July 1985, GE 9

Specification D50HD38 became the only recommended lubricant for Type AK cir-cuit breakers except as noted above for the cam-link slot of the AKF breaker.

GE believes the changes in lubricants, maintenance and maintenance intervals recom:dended in this SIL will eliminate virtually all trip failures in Type AK breakers except trip failures cause by failure of circuit breaker components.

I i

E GENERAL $ ELECTRIC

_. _, -,.,, n,,,,., n,,,-. - n,,,., -,s - -, -

1 o

SIL 448 Category 2 References 1.

GEI-50299E, Maintenance Instructions for Types AK-2/2A-15, AK-2/3/2A/3A-25 and AKU-2/3/2A/3A-25 Circuit Breakers 2.

GEI-93863A, Supplement to GEI-50299, Instructions for AK Power Circuit Breakers, Electrically and Manually Operated Types AKF-2-25 and AKF-2A-25 3.

General Electric Service Advice Letter 175-CPDD-9.3,' issued April 2, 1979 4.

' General Electric Service Advice Letter 175-CPDD-9.3S, issued April 19, 1979 l

5.

General Electric Service Advice Letter 175-CPDD-9.20, - issued March 21, I

1984 l

If you want additional information on this subject, please contact your local l

General Electric Service Representative.

e Technical Source:

G. W. Sanders J. M. Austin A

Issued by:

LV.Cf)A f

/

B. H. Eldridge, Mayager '

Services Information and Analysis l

l Product

Reference:

S22: Breakers, Switches

-3 1

________J

hubjhbt$

kNhD SIbNIF5 CANT EVENT RkPORT (SER):

48-84

)

BUBJECT.:.

RECIRCULATION PUMP MOTOR-GENERATOR (MG) SET I

DRIVE MOTOR BREAKER AND GENERATOR FIELD c

BREAKER FAILURES V

1 fNIT(TYPE):

MONTICELLO (BWR) l XX: NO/LER NO:

50-263/84007, 84008 I

EVENT DATE:

02/06/84, 02/07/84 eSSS/AE:

GENERAL ELECTRIC /BECHTEL i

1 tEFERENCE:

SER 28-83, " RECIRCULATION PUMP FIELD BREAKER FAILURE" BUMMARY:

)URING SHUTDOWN OF A REACTOR RECIRCULATION PUMP MG SET, THE MG BET DRIVE MOTOR BREAKER FAILED TO OPEN.

THE GENERATOR FIELD BREAKER ON THE SAME MG SET ALSO FAILEP TO OPEN.

BOTH BREAKER PAILURES WERE CAUSED BY MECHANICAL BINDING DUE TO LACK OF l

LUBRICATION.

l l

DESCRIPTION:

FHE PLANT WAS IN COLD SHUTDOWN FOR MAINTENANCE AND REFUELING.

)URING SHUTDOWN OF A REACTOR RECIRCULATION PUMP MO SET, THE DRIVE 10 TOR AC CIRCUIT BREAKER FAILED TO OPEN REMOTELY AND HAD TO BE FRIPPED MANUALLY.

l iN INVESTIGATION REVEALED THAT THE LUBRICANT IN THE TRIP ROLLER tND CAM F3LLOWER ROLLER HAD DRIED RESULTING IN BINDING OF THE ROLLERS WiICH, IN TURN, PREVENTED THE TRIP COIL ARMATURE FROM ORCING THE BREAKER LINKAGE TO COLL 4*SE AND OPEN THE BREAKER.

PHE ROLLE R.S WERE CLEANED AND REPACROD WITH THE VENDOR APPROVED

>UBRICAN1, REASSEMBLED, AND CYCLED i:E FORE BEING RETURNED TO BERVICE.

THIS SAME BREAKER ALSO FAILED TO OPEN APPROXIMATELY FHREE MONTHS BEFORE THIS EVENT.

AT 7 HAT TIME, THE TRIP COIL WAS OUND TO BE IN A DEGRADED CONDITION, BUT THE ACTUAL CAUSE OF THE 7AILURE WAS UNKNOWN.

THE BREAKER IS A GENERAL ELECTRIC (GE) 1AGNE-BLAST CIRCUIT BREAKER, TYPE AMH-4.76-2DO-OD.

THE PLANT HAD 70LLOWED GE RECOMMENDATIONS (GEI-88771C, INSTRUCTIONS AND RECOMMENDED PARTS FOR MAINTENANCE) FOR PREVENTIVE MAINTENANCE.

SHORTLY AFTER REPAIR OF THE DRIVE MOTOR BREAKER, AN ATTEMPT TO BTART THE RECIRCULATION PUMP MG SET WAS UNSUCCESSFUL.

THE FIELD BREAKER WAS FOUND IN THE INTERMEDIATE POSITION WITH A FAILED

! OVERHEATED) SHUNT TRIP COIL.

BUBSEQUENT INVESTIGATION REVEALED THE FOLLOWING:

APPARENTLY, ON RECEIPT OF THE TRIP SIGNAL DESCRIBED IN PARAGRAPH ONE, THE SHUNT TRIP COIL WAS ENERGIZED.

THE ENERGIZED TRIP COIL BEGAN THE 3REAKER TRIPPING SEDUENCE AS WOULD BE EXPECTED.

HOWEVER, AS THE

)REAKER MECHANISM MOVED FROM THE CLOSED POSITION TOWARD THE OPEN

0SITION, THE MECHANISM BECAME INTERNALLY BOUND.

THE MAIN ONTACTS WHICH SHOULD HAVE OPENED, REMAINED CLOEED (WITH A SIGNIFICANTLY REDUCED CONTACT FORCE).

THE SHUNT TRIP COIL REMAINED ENERGIZED.

THE TRIP COIL THEN FAILED DUE TO 3VERHEATING.

THE AUXILIARY CONTACTS OF THE BREAKER PROVIDED INCORRECT REMOTE INDICATION THAT THE BREAKER WAS OPEN, THUS 1ASKING THE PROBLEM.

THE CAUSE OF THE FAILURE WAS EXCESSIVE RICTION DUE TO DIRT COUPLED WITH THE LACK OF LUBRICATION EnutTHMG VN TRRMnfMR rdrF TMFF Ed&UTFR Pnl # L 7MVaAK WFr & m n

a

. +.

.o l

f* Urllispie (INFO) 6-Jun-83 II:43AM-PDT sect! INPO SIGNIFICANT EVENT REPORT (SER)I 28-n3 SUBJECT!

RECIRCULA110N PU6P FIELD BREAKER FAILURE UNIT (TYPE):

PILGRIM (BWR)

DOC N0/LER N0f 50-293/293-83013 i

EVENT DATEi 4/3/83 NSSS/AE!

GENERAL ELECTRIC /DECHTEL

SUMMARY

WITH THE PLANT SHUTDOWN, THE

B' RECIRCULATION PUMP WAS TRIPPED FROM THE CONTROL ROOM FOR PL'ANNED MAINTENANCE. SUBSEQUENTLY, IT WAS FOUND THAT THE FIELD BREAKER HAD FAILED TO TRIP DUE TO MECHANICAL BINDING RESULTINd IN A BURNED OUT TRIP COIL..

DESCRIPTION:

MOTOR GENERATOR

'D' WHICH DRIVES

'B' REACTOR RECIRCULATION PUMP MOTOR, WAS STOPPED IN ORDER TO PERFORM MAINTENANCE ON THE SLIP RING BRUSHES. NORMALLY. THE FIELD BREAKER OPENS TO DEENERGIZE THE FIELD AS THE MOTOR GENERATOR COASTS DOWN STCPPING THE PUMP N010R.

HOWEVER, DUE TO MECHANICAL BINDING, THE FIELD BREAKER ONLY PARTIALLY MOVED. THC TRIP COIL, WHICH ENERGIZES TO TRIP 1HE BREAKER AND SHOULD HAVE DEENERGIZED WHEN THE BREAKER MOVED A HECHANICAL TAB, REMAINED ENER0! ZED AND BURNED UP..

THE TRIP COIL IS DESIGNED TO DE ENERGIZED ONLY MONEN1AR1LY TO TRIP THE BREAKER. THE PUMP COASTED TO A STOP WITH THE MO SET.

A TECHNICI AN S'bW THAT THE BREANER HAD NOT OPENED AND ATTEMPTED 10 LUCALLY TRIP THE BREAKER OPEN TO NO AVAIL.

(THIS IS A MCCHANICAL PUSHBUTTON DCVICE NOT RELATED 10 THE ELECTRICAL TRIP COIL.)

INITIAL INSPECTION REVEALED THE BREAKER TO BE SLIGHTLY DIRTY AND DRY OF LUBRICANT. THE DREAKER WAS THEN DISASSEMBLED, THE BURNED COIL REPLACED. AND REASSEMBLED. THE BREAKER WAS LUBRICATED WITH

'LPS' OIL (A NON-GREASY LUDRICANT). TESTED TWENTY TIMES SUCCESSFULLY AND RETURNED TO SERVICE.

COMMENTS!

)

1 i

1) SINCE THE FAILED BREAKER IS Uf!LIZED IN THE ANTICIPATED IRANSIF.HT WITHOUT SCRAM (ATWS) TRIP LOGIC OF THE RECIRCULA1 ION PUMP, THERE ARE POTENTIAL GENERIC IMPLICATIONS ASSOCIATED WITH THIS FAILURE.-

2) THE FAILED BREAKER WAS A GENERAL ELECTRIC MODEL AK-F-2-25.

IT SHOULD BE NOTED THAT THE IRIP CGIL FAILURE WAS FIRST THOUGHT TO BE THE CAUSE AND NOT THE RESULT OF THE FAILUME.

3) BOSTON EDISON IS STUDYING THE BREAKER MAINTENANCE PROGRAM AT

'l PILGRIM WITH THE ASSIGTANCE OF GCNERAL ELECTRIC, WITH j

EMPHASIS ON SELECTIhD THE PROPER LUDRICANT TO PERMIT ONCE PER CYCLE (APPROXIMATELY 10 MONTHS) LUBRICATION, AND OBJECTIVE TESTING THAT WILL INDICA 1E ACCEPTANCE OR REJECTION.

4) NPRDS SHOWS THAT THERE ARE 603 RECORDS OF AN-2 BREAKERS WITH 32 FAILURES FOR VARIOUS REASONS REPORTED.

INPO IS CONTINUING TO INVESTIGATE BREAKER FAILURES.

INFORMATION CONTACT: KEN BROWN, INPO (404) 953-5428

hF s g

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'4 Quantity Type Amps Volts I.C. vocot 95 AE 1-25 50-600A 600V 25

/Q7 520 AL2 50 200-1600A 600V 50

,y g* }:

l 40 AL2-75 2000-3000A 600V 75 15 AL2-100 4000-6000A 600V 100 l.*-

16 M OS-A 2000-6000A 750VDC Quantity Type Amps Volts I.C. roow

+

60 AK 1-15 50-225 600V 15

) !

M 25 AK-2-15 50-225 600V 15

\\f

'E 230 AK-1 -25 100-600A 600V 25 320 AK5.5A-25 mrm 100-600A 600V 25 515 AK2.2A 25 mrwi 100-600A 600V 25 115 AKU2.5-25 mew.

100-600A 600V 200 40 AKF 1B.

FIELD BKR 250V 25 e-

- aps 55 AKF-2-25 mewi FIELD BKR 250V 25 90 AKR4,5-30 me m 100-800 600V 30 i

25 AKR U4.5-30 mew, 100-800 600V 200 52 AKR4.5 30H mew.

100-800 600V 42 F i' 175 AK-1 50 200-1600 600V 50 h

80 AK2.2A 50 200-1600 600V 50 l

%A' 35 AK5.5A-50 200-1600 600V 50 79il 37 AKU2.5 50 200-1600 600V 200 l

t

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70 AKR4.5-50 me w.

200-1600 600V 50 i

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200-1600 600V 50

{ }f 15 AKR4.5-50H mtw 200-1600 600V 65 i

(y %

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.f 20 AK 5.5A-75 2000-3000 600V 75 15 AKU2.5-75 2000-3000 600V 200 4

AKF-2D FIEt.D BKR 500V 75 3

AKR4,5 75 mewi 2000-3000 600V 75 j

12 AK-1 -100 4000 600V 100 1

12 AK2.2A-100 4000 600V 100 l

10 AK5.5 A 100 4000 600V 100 3

AKR4.5-100 mrw.

4000 600V 100 i

l 5

AKF-2E mtw, FIELD BKR 500V 100 Ottantity Type Amps Volts B.C. tooo:__

'g 60 DK-25 50-600A 600V 25 W

M.

N.. -

280 DA 50 200-1600A 600V 50 j

35 DA 75 2000-3000A 600V 75

'b 16 DA 100 4000-6000A 600V 100 l

pv 23 DR-150 4000-8000A 850VDC

.. gy

, {8 Quantity Type Amps Volts I.C. roooi i p,

__ J 40 DB-15 50 225A 600V 15 l

g '

___:7 210 D8-25 100-600A 600V 25 30 DBL-25 100-600A 600V 200 40 DS-206 mrwi 100 800A 600V 30

{

17 DSL 206 mewi 100-800A 600V 200 i

150 D B-50 i poo 200-1600A 600V 50 l

53 DB-50 a pos, 2001600A 600V 50 l

40 DBL-50 2001600A 600V 200 W

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'i 42 DS 416 mtw, 200 1600 600V 50

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19 DSL-416 mtwa 200-1600A 600V 200 i'

tj) ei CJ 25 DB 75 n com 2000-3000 600V 75 3

28 08 75 o pos, 2000-3000 600V 75 3

s T

2 DS-532 mim 2000 3000 600v 50

]G 6

DS-632 iwr wi 2000-3200 600V 75 9>

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DB-100 4000 600V 100 1

2 DS440 mewi 4000 600V 100

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thso nc.r. v reni:3I ubra7 NUREG-1000 "^4 Vol.1 Cor/,,.c'; ' UftCompan9 i Ra!cish, NC 27602 0FD _ F# Generic Implications of ATWS Events at the Salem Nuclear Power Plant Generic Implications U.S. Nuclear Regulatory Commission Office of Nuclear Reactor Regulation ,.... ~,, r %....../ f

4 3.2 Operating Experience y[1 The operating history of the circuit breakers used in the reactor trip system (RTS) at Salem and otb operating nuclear power plants is reviewed in this section. -The failure oi breakers in operating plants designed by Westinghouse. -1 Babcock &'Wilcox, and Combustion Engineering was reviewed.to determine their reliability and to determine if a forecast of the common mode failures experi-enced at Salem could have been made based upon an analysis of operating experi-ence. Since the RTS breaker is one component in a complex, multiple-component 4 electromechanical system, other reported failures in the RTS were also reviewed to determine if overall operational experience supports the need for a more 3 diversified reactor trip system design. The failures of the breakers at Salem have been attributed to problems in the l undervoltage trip attachments. The undervoltage trip attachment has also been j identified as the source of breaker failures at other' operating plants both l before and after the Salem events. The results of an investigation by the NRC ] contractor, the Franklin Research Center (FRC), to determine the failure mode i for these undervoltage trip attachments is discussed in Section 3.2.7. l l l 3.2.1 Circuit Breaker failures in Reactor Trip Systems i All operating Westinghouse plants, except McGuire Units _1 and 2, farley Units.1 i and 2, and V. C. Summer Unit 1, employ DB-50 circuit breakers in the R15. The L exceptions employ Westinghouse DS-416 circuit breakers. The Babcock & Wilcox and Combustion Engineering plants (except Palisades and Ft. Calhoun)^ use the i j General Electric type AK-2 circuit breakers. General Electric plants do not employ. breakers in the reactor trip system; neither do Palisades and Ft. Calhoun. Prior to the Salem ATWS events in February 1983, the' reported RTS breaker failures involved either the Westinghouse DB-50 or the General Electric type-AK-2 breakers. The 53 RTS breaker failures now known to have occurred.through 1982 are tabulated in Table 3.2 The table shows that the failures occurred at 20 different plants and identifies the causes of the failures. i The Westinghouse DB-50 breaker was designed in the 1940s and used in nonnuclear applications before it became part of nuclear plant RTS designs in the 1960s. i Yankee Rowe began commercial operation with the DB-50 in 1961. Failures of the i DB-50 were first reported at H. B. Robinson and Haddam Neck in 1971. These l events were of particular concern because Haddam Neck experienced simultaneous l failures of the undervoltage trip attachment in two reactor trip system breakers I when an RPS trip signal was initiated during a surveillance test. Since the 1 -- I shunt attachments on both breakers were determined to be operable, this event-did not constitute a complete failure of the trip system. As a result, the } Atomic Energy Commission (AEC) issued the first of 34 Bulletins and other notices (listed in Table 3.3) concerning various types of circuit breakers and relay failures in reactor safety systems. Four of these documents relate to failures in the reattor trip system. I i

As discussed in Section 3.1.2.3, these plants do not use the undervoltage trip attachment in the RTS and are not subject to the same failure as other plants s

e which use the AK-2. n } 3-21 iW

V \\ In IE Bulletin 71-2 the causes of a series of DB-50 failures were attributed to dirt, broken parts, and mechanical binding of the undervoltage trip attachment. With few exceptions since 1971, the 26 reported failures of the Westinghouse DB-50 breakers involved the undervoltage trip attachment. The causes are hard to interpret from the data available, but most appear cf.nerally to be failures of the mechanical portion of the undervoltage trip attachment caused by dirt, wear, lack of lubrication, and component failures. A few were failures of the electrical coils. One failure was attributed to the undervoltage trip attach- ~ i e first of 27 reported failures (through 1982) of the General Electric type AK-2 circuit breaker in reactor trip systems occurred in Babcock & Wilcox plants in 1972. Since then, failures have occurred in AK-2 breakers in both B&W and CE reactor trip systems. Like the Westinghouse breaker, the AK-2 breakers was designed about 25 years earlier for nonnuclear applications. From 1975 to 1979 there were 12 reported failures of the AK-2 design in safety- '1 related systems including the RTS. As a result of these failures, the NRC issued Bulletin 79-09 reporting that the causes were either binding within the linkage mechanism of the undervoltage trip attachment and trip shaft, or out of-adjustment conditions in the linkage mechanism. The Bulletin attributed the failures to inadequate preventive maintenance programs. There have been Other failures of the AK-2 reported since the 1979 bulletin. Of the 21 RTS l breaker failures reported from 1972 through 1982 at Babcock & Wilcox plants, 18 identified the undervoltage trip attachment as the cause of breaker f ailure. ~% - - Combustion Engineering plants also use the General Electric type AK-2 breakers [l in the RTS (except at Fort Calhoun and Palisades). A total of six failures of this breaker occurred at three Combustion Engineering plants, i.e., Calvert Cliffs Units 1 and 2 and St. Lucie Unit 1 (see Table 3.3) prior to the Salem u I ATWS events. 1his small number of reported failures compared to the number of f ailures at Cabcock & Wilcox plants is probably due to the diverse breaker-i I tripping mechanisms employed in the type AK-2 breakers at CE plants. Both a } shunt trip and an undervoltage trip attachment operate simultaneously to open the breaker and a failure of either device would not be recognized during a i

scram, in addition, both trip attachments have often been tested together.

Thus a failure of the undervoltage trip attachment would not necessarily be detected if the shunt trip attachment operated properly. In 1980 an event involving unusual RTS breaker f ailures occurred at St. Lucie Unit 1, a Combustion Engineering designed plant. An analysis of this event by l the NRC Office for Analysis and Evaluation of Operational Data resulted in the issuance of IE Circular 81-12 pointing out that the periodic tests used at CE plants should verify the trip function of the undervoltage trip attachmen p independent of the shunt trip attachment. fs/ h 4 ( < ~ n.- v .- p -- ~ / ~. /As a result of an AK-2 breaker f ailure of Rancho Seco in 1982, generic problems j / with the AK-2 " opening springs" and " positioning of the trip paddle" were j identified by NRC Region V in an October 4,1982 letter f rom J. L. Crews, NRC jl Region V. After the Salem events, IE Bulletin 83-01 was issued. It required testing of DB-50 type breakers used in the RTS of Westinghouse plants. No / failures were reported. Shurtly thereaf ter during testing of the AK-2 breakers / in the RTS at San Onofre Units 2 and 3, four failures of UV attachments were / observed; three reactor trip breakers on Unit 2 and one on Unit 3 failed to / / ~N ._ s/-A ~% ^ / ..a- . ~ =

b

' ]

open on activation of only the undervoltage trip attachment. IE Bulletin 83-04 L was then issued requiring undervoltage trip function testing for all PWR licen-sees with other than DB-50 breakers in the RTS. Failures of AK-2 breakers j occurred during subsequent testing at Calvert Cliffs Units 1 and 2 and at Maine w

Yankee, aj In addition to the recent failures at Combustion Engineering plants, McGuire i

Units 1 and 2 and Farley Unit 1 5 ave reported failures of the Westinghouse A DS-416 breakers used in their RTSs. Table 3.4 shows the RTS breaker failures j 9 reported at operating plants since the Salem events and malfunctions reported i as the result of IE Bulletin 83-04, which required reporting of malfunctions j not previously reported. For these latter uses, Table 3.4 also identifies the lh basis for the licensee jud'gement that the observed malfunctions were not .i reportable as an LER. l 1 \\ The following listing shows a'pproximate failure rates for each vendor design l based on an estimated number of demands, which was confirmed to the Task Force by the Regulatory Response Groups. The number of demands were estimates of routine surveillance test frequency and were not based on plant-specific { analysis. Estimated Breaker Failures i Vendor Failures Breaker Demands Probability / Demand Westinghouse 26 6,000 0.004 Combustion Engineering 6^ 5,000 0.001* l Babcock & Wilcox 21 5,000 0.004 l All Plants ^1his value is questionable since the undervoltage and shunt trip attachments may not have been tested independently in the CE design. ] The comparison shows that the performance of the RTS breakers appears comparable with the rate computed in the " Reactor Safety Study" (WASH 1400) considering the uncertainties in the analyses. (WASH 1400 used a best-estimate value of 0.001 4 and a range of 0.0003 to 0.003.) This type of analysis, by itself, would not generate concern for RTS breaker reliability based on operating experience. i Salem Unit I had not reported any breaker failures prior to the ATWS events h( in February 1983. However, Salem Unit 2 had experienced breaker failures on February 6,1979, August 20, 1982, and January 6,1933. The failure of the bypass breaker on February 6, 1979 occurred during preoperational testing and was, therefore, not required to be reported in an LER. The LER reporting the I failure on August 20, 1982 did not identify the cause of. the UV trip attachment I-failure. An LER dated January 27, 1983, reported the breaker failure on January 6,1983, and identified dirt or corrosion as the cause for the UV trip attachment failure. The Unit 2 breaker that failed in January was subsequently repaired and installed in Unit 1 and failed again during the events on &t February 22 and 25,1983. H V k I ( 3-23 Ld

\\' t l 1 ^ Routine statistical analysis of single failures and failure rate data would probably not have suggested a high potential for common cause failure resulting in multiple, simultaneous breaker failures. However, with hindsight it appears that proper identification of root causes with common mode failure potential coupled with a detailed engineering understanding and careful review of LERs might have given an advance warning of the Salem failures. Complete narrative descriptions reporting the failures and indepth engineering review would be necessary to identify the potential common cause failures. Future reporting requirements associated with the proposed LER Rule should result in improved reporting of significant events such that engineering analyses can address the generic implication of failures. Component failures must be better reported under an improved NPROS (see Section 3.2.4). The trend of RTS breaker failures versus time is shown in Figure 3.7. Caution must be used in interpreting this trend because of the small number of breaker failures and the associated large uncertainties. The histogram shows an upward trend in 1978. About this time, the increasing number of failures was identi-fied by the NRC, and an IE Bulletin (IEB 79-09) was issued requesting licensee action. The decreasing trend of failures after 1979 probably can be attributed to licensee actions in response to the Bulletin. The number of RTS breaker f ailures in recent years would not have prompted a concern regarding the reli-ability of the breakers because the failures were occurring randomly at a few plants which were experiencing apparently unique difficulties, e.g., repeated failures of same breaker. The multiple failures at St. Lucie in 1980 where one breaker failed and two others acted sluggishly may have been indicative of com-mon cause failures. There was investigation into the failures at St. Lucie By AEOD, which led to the issuance of IE Circular 81-12. Nowhere prior to Salem, however, did any of the operating experience reviews uncover the lack of suf-ficient design margin in the undervoltage trip attachments for either the DB-50 or the AK-2 breakers (See Section 3.2.6.2). l 3.2.2 Other Failures in the Reactor Trip System l Review of operating experience with the RTS has identified numerous relay, logic, and other electrical failures. In fact, approximately 2,500 failures have been reported in Licensee Event Reports pertaining to the RTS since about 1972. Relay failures comprise a large portion of the 2500 failures. Common cause failures of relays have occurred in the RTSs at Kahl (Federal Republic of Germany) and Monticello (U.S.) and in the RTS logic at Angra (Brazil). Similarly, the 14 scram pilot valve failures at Grand Gulf represent a potential common cause failure in the BWR RTS. This evidence of common cause failures confirms the need for diveristy in the RTS (See Section 3.3). The Task Force contacted foreign nuclear agencies to obtain their experience for failures in the RTS, including breaker failures. A failure was identified at a foreign plant in February 1983. The sequence-of events recorder indicated that one breaker failed to open on an automatic reactor trip. The breakers are of the Westinghouse 08-25 design which use only an undervoltage trip attachment to effect automatic scram. It was indicated that the undervoltage trip attach-ment had not previously been tested independently of the shunt trip attachment. The test procedures have since been changed accordingly. 3-24 ~}}

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