ML20237H155
| ML20237H155 | |
| Person / Time | |
|---|---|
| Site: | Sequoyah  |
| Issue date: | 04/18/1987 |
| From: | Bolgeo R, Cuzzort F TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML20237H133 | List:
|
| References | |
| SI-105, NUDOCS 8708170086 | |
| Download: ML20237H155 (65) | |
Text
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Al rrAcHateur 8
.v TENNESSEE VALLEY AUTHORITY-SEQUOYAH NUCLEAR PLANT SURVEILLANCE INSTRUCTION '
SI-105 ,
VITAL BATTERY BANK AND NORMAL CHARGER PERFORMANCE TESTS Unit 0 Revision 20 PREPARED BY:__ Richard T. Bolceo / Frank D. Cuzzort RESPONSIBLE SECTION: E1IctricalMaintenance REVISED BY: Richard T. Bolgeo / Frank O. Cuzzort SUBMITTED BY: 3h /742w_
Resp 6nsible Sdction Supervisor PORC REVIEW DATE: App i R 10A7 APPROVED BY:
.x , Plant Manager DATE APPROVED: 8OP I 4 Iifi7 REVIEHED BY: Jerry W. Carpenter I Craftsman Reason for revision (include all In'struction Change Form Nos.):
. Revised to comply with SI Review Program, & add additional information I
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concerning 5th Vital Battery. Resolves CATS 86503 CATS 86505, i
CATS 86713, NC0870013001, PRO 1-86-229, PRO 1-86-230, PRO 1-86-340 DR 86-224, DR 87-0023.
The SI-1 review checklist, Appendix F, consti-tutes a biennial review. This revisten documents OES endorsement for I l !
-1, DPM N73M13 (TS 05.08.01.14.01) in'accordance with SQA188, Attachment 1.
The last page of this instruction is number: 59 f
8708170006 PDR ADOCK 87 g h P PDR
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'4 Standard Practice SQA188 Revision 1 f ,'. , gf.'-,
SEQUOYAH NUCLEAR PLANT .
Procedure Interface / Concurrence Coversheet -
ATTACL! MENT 1 I..
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Interim procedure systeth coordination / documentation record for #f -
l Procedure Identity Number Rev Level 2/
RESPONSIBLE SECTION:
Submitted By: _h 4 Responsible S p upervisor
/ //-7-8'7 Date CONCURRENCE /A o L:
/mmD ea!% s4Jn f~/ Engineering /" ,,
Bate' d, . Nb ?st /- r-3 7 i
Construction Date j NA Pe s-s-e7 Safety and Licensing Date e
%. U 1 ty Assurance h(6 M "Dats L
NA~ W $f/2/U i
{; Engineering' Assurance ~
' Date Nk 0/E d- 8'47 t
g Division of Nuclesr Services
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Oate
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N/$ ~?DC c-r-cf/
Nucidar Personnel Staff .
Date. >1
/VA pac 44r?
Planning and financial Staff _
Date I
AM Other (identify) ur s-r-e7 i QR. Lntto Date t la/o jaditeDirector ~
/ba td
{7 Reason () for Concurrence:
/
To lieudocument of higher tier headquarters endorsement of existing site instruction in document number /2#//f A/Zr,ry//g p I Tf os', dRp/, /@/)
To document transfer of responsibility.
To document concurrence of procedure interface.
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SEQUOYAH NUCLEAR PLANT 9
PLANT INSTRUCTION REVISION LOG L
SURVEILLANCE INSTRUCTION SI-105 REVISION Date Pages
'_ LEVEL Approved REASON FOR REVISION (INCLUDE COMMIT-Affected MENTS AND ALL ICF FORM NUMBERS) 15 12/26/84 ALL ,
_15 05/15/85 4:14.29 2,4,5.30, 17 06/07/85 31
,9,13,14,
- 1. 18 08/08/85 16,29,30 Revised in accordance with ICf No. 85- 759 PORC approved 07/30/85.
1,18,23-
_19 12/04/85 26,29,30 Revised to make a gene _ral update.
Revised to comply with SI Review Program, &
add additional information concerning 5th Vital Battery. Resolves CATS 86503, I CATS 86505, CATS 86713, NC0870013001, PRO 1-86-229, PRO 1-86-230, PRO 1-86-340, DR 86-224, DR 87-0023. The SI-l review checklist, Appendix F, consti.tutes a.
[ 20- .
04/18/87 All 01.14.01) in accordance with SQA188, Attachment 1.
, Revised to clarify and add editorial changes identified by the surveillance instruction validation and verification review group.
Also battery capacity requirement was cor-rected on the data sheet and the charger performance test section rewritten for better clarity. This revision documents AN 19 ~19% ES endorsement for DPM.N73M13 .
21 All (TS 05.08.01.14.01) in accordance with SOA188 Attachment 1.
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1.0 SCOPE This is an inspection and test of the 125V vital battery system. It-involves the following:
1.1 At'least once each 18 months
.);;g Perform a visual inspection of the batteries and battery racks.
-[ 1.1.2 Perform a _two hour battery service test involving the I
use of the battery discharge unit to demonstrate that the battery capacity is adequate to supply and maintain all of the actual emergency loads.
1.1sJ' Perform a battery charger performance test to demonstrate that the charger is capable of supplying at
( lerst 150 amperes at 125,,
volts for at least four hours.
1.2 At least once each 60 months 1.2.1 Perform a battery performance test involving the use of the battery discharge unit to time the discharge of the
- a. battery at a fixed current value until the battery terminal voltage reaches the minimum design voltage.
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The minimum design voltage is 105 volts for the 60 cell
- l vital battery banks I through IV and 108.5 for the 60 L
cell vital battery bank V. The results are used to verify that the battery capacity is at least 94 percent-for vital battery bank I through IV and 92*/. for vital l- battery V of the manufacturer's rating. This test is
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performed in lieu of the two (2) hour service test.
l An annual performance discharge test of battery capacity will be
- given to any vital battery bank that shows signs of degradation or has reached 85 percent of it's service life. Degradation is indicated when the battery bank capacity drops more than 10 percent of rated capacity from the average on previous performance tests, or is below 94 percent for vital batteries I through IV and 92 percent for vital battery V of the L manufacturer's rating. I, II, III, and IV vital batteries will L
reach 85 percent of their service life on June 27, 1991. Vital battery V will reach 85 percent of its service life on December 5, 2001.
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L 1.0 SCOPE (continued)
These tests and inspections are designed to meet the
, requirements of the following surveillance requirements (SRs) applicable in the modes noted:
Fulfills SRs Applicable Modes 4.8.2.3.2.c.4 partially (SI-303 will 1,2,3,4 y, complete the requirements by testing j the spareschargers.)
4.8.2.3.2.d 1, 2, 3, 4
. . . 4.8.2.3.2.e 1, 2, 3, 4 4.8.2.3.2.f 1,2,3,4 4.8.2.4.2 partially (SI-100, SI-100.1, SI-100.3 and SI-303 will complete the
( requirements of this SR's reference to l 4.8.2.3.2) ,
5, 6 This procedure can be performed in modes 1 through 6, provided-the battery under test is spared out of service by the 5th vital battery. If Vital Battery V is unavailable for service, then
, -Vital Batteries I through IV can only be tested when both units are in modes 5 and/or 6.
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2.0 REFERENCES
2.1 "IEEE Recommended Practice for Maintenance, Testing, and Replacement of Large Lead Storage Batteries For Generating Stations and Substations," IEEE Standard 450-1975/1980.
2.2 B_attery Capacity Test System Instruction Manual, Alber Engineering, Contract 84PJ5-940398.
2.3 TVA Drawing Numb'ers:
45N703-1 ~
- 2.4 SI-100, Vital Battery Operability 2.5 SI-303, Spare 480 Vital Battery Charger Performance Test.
2.6 S01-250, Low Voltage ac/dc Electrical Systems. (Breaker Line-ups) l l
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2.0 -%%
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REFERENCES (continued) '
I 2.7 TVA SQNP Test Scoping Document: Test Number PMT-31
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l-2.8 Sequoyah Nuclear Plant Technical Specification, unit I and 2:
LCO 3.8.2.3 and 3.8.2.4 .
L.
' SR 4.8.2.3.2.c.4.
SR 4.8 2.3.2.d
' SR 4.8.2.3.2.e '
SR'4.8.2.3.2.f SR 4.8.2.4.2 ,
2.9 125 Vdc vital battery and charger capacity evaluation, R0; 860814A0103, RIMS 843 860808 905 1
l' 2.10 EMSL-A36, maintenance initiated common-mode failures
, 2.11 Vendor drawing BCT-1207-D331 contract 84-940398 i
2.12 i Instruction Manual - Three Phase Magnetic Amplifier controlled Battery Charger / Eliminator - contract 72-83738 3.0 PREREQUISITES
.c - f 3.1
" Planning and scheduling or the cognizant engineer is to list in-the data package the last performance date for SI-100 and SI-100.3 for'the selected battery system of this SI.
3.2- Coordination shall be made with Operations section. Operations section approval shall be obtained prior to the work by the Unit 1 and Unit 2 Senior Reactor Operator (SR0/SE) signatures on the
_ Data Package Cover Sheet. ,
3.3 Notify the Unit I and Unit 2 Opere. tors (UO's) prior to the
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performance of this procedure.
3.4 Verify that the spare charger is available and SI-303~ is not being performed on the spare charger at the same time as this
_ SI. .
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. 1' Page 4 Revision 21 3.0, ' PREREQUISITES (continued)
'3.5 SE shall identify and have transferred any necessary loads from.
'the battery system to be tested. Battery bank and charger to be {
~ l' tested shall be isolated from its respective board. The battery ,
board shall remain energized from.the fifth vital battery (when performing this SI on the fifth vital battery all boards will be fed from their normal battery charger). Conditions and restraints of Technical Specifications LCOs 3.8.2.3 or 3.8.2.4 shall be applicable. Any transferring shall be done in accordance with S0I-250.
g NOTE: The words "should not" are used in step 3.6, 3.7 and
): 3.10 to alert the planners and foreman of the interplay-I between the listed procedures, but would not invalidate test results if schedule dates of Surveillance Instructions (sis) force performance or if unscheduled performances were not identified. This avoids the appearance of prepping the battery for service testing.
3.S SI-100 shall have been performed within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> prior to the 60 I. month performance test (resistance readings not required for this performance). A copy of the SI-100 data sheets will be included in the SI-105 data package. SI-100 should not have
" ~ , been performed within the.7 week period prior to the 18 month service test.
3.7 f Verify that the battery has had an equalizing charge completed more than three (3) days and less than seven (7) days prior to the start of the 60 month performance test. An equalize charge
_should not be performed prior to the 18 month service test.
3.8 Obtain fire door and security breaching permits for battery room door to be blocked open.
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Page 5 Revision 21 3.0 Prerequisites (continued) -
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3.9 Comply with EMSL-A36, Maintenance Initiated Common-Mode Failures.-
Areas identified are: .
a)
Do not use the same individual craftsman on more than one Battery Group (see below) or use two qualified craftsmen.
b)
Do not use the same M&TE on more than one battery group or check calibration of M&TE before using on a second group and again before using on a third battery group.
c)
Do not perform this instruction on more than one vital battery bank at a time.
Vital Battery Groups Group 1 Group 2 Vital Battery Bank Iand III - use Train A M&TE Group 3 Vital Battery Bank II and IV - use Train 8 M&TE Vital Battery Bank V - use special M&TE 3.10 SI-100.3 should not have been performed within the 5 month period prior to the 18 month service test (Ref step 3.1).
< NOTE:
Due to frequency of this SI the available craftsmen may unit.be experienced on the operation of the Alber te.st not Foreman with step 3.11. is to consult with craftsmen and comply 3.11 Use craftsmen experienced on this equipment or obtain Cog. Engr.
assistance for the performance of the discharge test of this SI.
3.12 A vital battery room exhaust fan is operating. A portable fan placed fans areininoperable.
the doorway is acceptable if both room and exhaust i'
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3.13 All precautions of section 4.0 have been read, understood, and addressed for the performance of this SI.
All craftsmen shall comply. ,
4.0 PRECAUTIONS 4.1 Care shall be taken to ensure that this test is performed on the specified vital battery system (I, II, III, IV, or V).
4.2 Approved goggles and face shields, acid resistant aprons and gloves shall be worn while working on batteries in any activity }
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5.0 SPECIAL TEST EQUIPMENT (continued) 5.6 M&TE 500 V megger (accuracy of any standard megger is -
acceptable).
5.7 M&TE torque wrench (accuracy e 6 in-lbs); Measurement 150 in-lbs.
5.8 M&TE digital low resistance ohm meter with factory leads (accuracy z 1 percent of measurement (see data pkg) + 1 digit 20*F-130*F); Range: 0 to 200 micro-ohms as a minimum.
5.9 Cables for cell strapout. (Performance test only)
(Vendor supplied equipment.)
6.0 INSTRUCTIONS V
NOTE: This is common equipment that effects unit 1 and unit 2 operability. '
6.1 Pre-Discharge Visual Inspection This section performs a visual inspection to ensure the battery
( can safely be discharged. This is for the protection of
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personnel and equipment and is not to prepare the battery for a discharge test. If it is determined that the battery cannot be safely discharged without damage to the battery, a licensee event report (LER) has occurred and a potential reportable occurrence (PRO) shall be initiated.
i 6.1.1 Visually inspect the cells for grid fractures, L
discoloration of plates, plate buckling, plate growth, cell cracks or leaks, or any abnormal deterioration relative to the rest of the cells of the battery bank.
~ Record o'n the data sheet if any of the above conditions are found. If any cell plate or cell shows a visual Indication of physical damage or abnormal deterioration immediately notify the SE (PAX number 6211) and then your supervi.sor.
6.1.2 Visually inspect battery racks for loose bolts, distorted members or any abnormal deterioration. Record on the data sheet if any of the above conditions are found. If any battery rack shows a visual indication of
' physical damage or abnormal deterioration that could effect the physical integrity of the rack, immediately notify the SE (PAX number 6211) ana then your supervisor.
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6.0 INSTRUCTIONS (continued) O
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6.1.3 Visually verify the battery to battery and terminal connections are clean, tight and coated with anti-corrosion material; if not, immediately notify the SE (PAX number 6211) and then your supervisor. '
6.2 Battery Service (18 months) and Performance Discharge (60 months) Test 6.2.1 Notify Assistant Shift Engineer (ASE) of the test to be performed and have the board transferred to the fiftn vital battery in accordance with 501-250 (if test is on the fifth vital battery verify the battery boards are fed from their normal battery), ASEs to sign on data sheet.
NOTE:
Steps to connect cables can,be performed in any order.
However, the power must be ,on the electronic control unit (ECU) prior to turning on the load units and must remain on whenever the load units are on. If not turned on in this order, contactors may pick up before the test is ready to begin and the battery will discharge.
.e 6.2.2 Battery test unit setup Prerequisite - Obtain fire door and security breaching permits for battery room door.
NOTE: Power Up When power is first applied to the EC/DLU the computer sequences through a series of internal self checks and also blinks each of the front panel lights, beeps the
- audio alarm, and prints a solid rectangular pattern in each printer column. The current and voltage displays will initially show all zeros and the Man / Auto light will turn on to show that the system is in the Auto Mode. The time display and keyboard display will show the letters "BCT-30". The keyboard display shows the message only momentarily. '
If any of the above falls to happen it implies that a problem exists.
When power is applied to the load unit the cooling fans turns on and one or more contactors may momentarily energize. Make sure all fans are on before proceeding with a load test.
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Page 10 Revision 21 6.0 INSTRUCTIONS (continued) _ _ _ . -
6.2.3 (continued) -
Equipment needed:
(1) M&TE Digital low range voltmeter capable of the following ranges with an accuracy of 0.025 percent of reading plus one digit.
Range 0-100mV (min) with resolution of .01mV.
Range 0-200V with resolution of .01V.
(2) DC voltage source with a 0-11V range and a 0-110mV range.
(3) DC voltage source with a 0-150V range.
All calibration adjustments are located on the '
analog board. The zero a8justment is the same for all meters and must be calibrated first. The current gain affects the other two meters and must be adjusted following the zero adjust. Overall volts and cell volt gains are independent and may be adjusted separately.
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6.2.3.1 Zero adjustments
' Verify thac switch number 2 on the I/O board is in the ON position. Enter 122 then press the TEST button. The channel number will appear in the ,
l display. tl'at is normally used for current readings and the para.neter to be measured will appear in the overali voltage display. Ignore the decimal point.
Connect a low impedance millivolt source between pins 4 and'5 on the connector labeled " load control" (J3) and adjust it for zero volts. Adjust P1 for a zero reading in the display labeled overall volts.
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6.2.3.3 (continued)
Adjust the voltage source for 4.00V and 8.00V, and verify that the overall voltage display meter tracks linearly to within at least .5 percent of the settings. If necessary, readjust P3.
Reconnect the cell sense leads 1 and 2 to the
. battery bus.
6.2.3.4 Overall voltage adjustment Connect the overall voltage sense leads to the 150V adjustable source.
Ente- 120, then press the TEST key. The channel number selected will appear in the current display and the voltage to be read will -
appear in the overall Itage display. This !
time the decimal point ooes fall in the correct place.
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Adjust the voltage source to 150.0V. If necessary, adjust P4 for a reading in the overall voltage display of 150.0V e .75V.
Adjust the voltage source for 105.0V and 130.0V l and verify that the overall voltage display tracks linearly within 2 .5 percent of the settings. If necessary, readjust P4
' Reconnect the overall voltage sense leads to the battery bank termin,als.
6.2.3.5 Exiting test mode Enter 999, then press TEST key. The unit will I now go through a power up routine, blinking the front panel lights, etc. and in the process will also erase any progr,am that may have been entered.
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.f 6.0 INSTRUCTIONS (continued) 6.2.4 (continued)' ~
To avoid automatic test termination, the program entered -
should be consistent with both the battery to be tested
[. and the load capabilities of, the BCT-30. To best 3 ' illustrate how the BCT system is programmed a typical test programming sequence is shown below. Note that, key actuations are underlined.
a.
Assume, for this illustration, that the test consists of a 3-step service test of a 125V battery. Test parameters are:
200 cmps for the first minute; f 120 amps for the next 29 minutes; l' 75 amos for the next 2 flours; low overall voltage alarm setting is 105V; low cell alarm setting is 1.75V f- number of cells. scanned is 60; print internal is 10 minutes.
l~ To enter the first step of the sample program, press the l,1 ,
keys in the following order:
, [ (1) Step - Program step identify. The "1" entry is
)~ optional since the program will auto increment whenever the STEP key is depressed. Op tional j entries are indicated by parentheses.
200 - First step current value selection. t Amps - Enters first step current value. 1 1 1- First step time value in minutes.
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Time - ~ Enters first step time value. .;
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. Enter - Enters the entire fi,rst step.
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I- 6.0 INSTRUCTIONS (continued) 6.2.4 (continued) -
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( Note that the value is entered first, followed by the i parameter identity. Before the ENTER key is depressed,
{ any of the parameters may be changed by first entering I the new value and subsequently depressing the key which identifies the parameter. .
f In similar fashion, enter the second and. third steps of the program.
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_ Step 120 load amps 29 time enter (3) - Step 75 load amps 120 time enter 10),, - Steo The above keystrokes pro, gram the current and time parameters. Remember, a program step will not be recorded unless it is terminated by the ENTER i keystroke. In order to indicate to the computer that f- programming is finished, the last step must be 0 l
step.
- As the NUMERIC keys are activated, the number pressed will appear in the keyboard display. This number is f entered into memory and the display is reset to zero 1, when a TEST PARAMETER key is pressed.
To complete the programming of the test program proceed
, as follows:
105 Overall - When a battery Cutoff Volts voltage is equal to or less than this value, the alarm will sound and the ,
test will stop.
- 60 No. of Cells - Instructs data logger Scanned -
relative to the number of cells to be monitored. l L
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6.0 INSTRUCTIONS (continued) -
6.2.4 (continued) l 1.75 Cell Alarm - Sets the cell voltage (of any cell) at which the alarm will sound and the data logger will print out the identity and voltage of the discrepant cell.
10 Print - By preceeding " Print" with 10, the data logger will be programmed for an automatic printout every 10 minutes.
A print time of zero will be interpreted by the computer to mean no automatic printing other than manually initiated printouts.
The remainica keyboard swit'ches operate as follows:
-/+ .
This key changes the signs of the numbers displayed. If the display indicates negative, pressing the key will
, change the display to positive. The only time the minus signs have significance is when they are followed by the INC/DEC key. At all other times, the minus sign is ignored.
Clear Entry Pressing this key will clear the program entry. It is used for correcting entry errors.
INC/DEC' This key is active only in the inanual test mode. It is used to step change the load current up or down by a fixed value.- For example, pressing "5" followed by INC/DEC would increase the current control by 5 amperes. For a decrease of 5 amperes, press 5, INC/DEC. The INC/DEC key may be used to increment or decrement the control current by any value.
i The manual test mode is primarily used to check the currant limiting characteristics of battery chargers.
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When the test mode is used, the relay channel selected will appear in tha Amp display and the voltage that is
- i. r applied to that particular channel input will be shown l in the overall voltage display. For the test mode it is necessary to ignore the decimal point in the overall voltage display. For instance if relay channel number 1 1 I is selected and there is a voltage of 2.10V applied between sense leads 2 and 1, then this voltage will appear in the overall voltage display as 21.0.
The following channel numbers are used for overall battery voltage, load unit voltage and current:
f Channel No. for
" R0-Cell System Overall Battery Voltage 120 Load Unit Voltage I Current 121 122 g
The relay diagnostic mode is normally only used for d[ , trouble shooting and calibrating the BCT-30. Once the test mode has been entered, the relay diagnostic nessage will appear in the time and keyboard display. To exit <
the test mode, it is necessary to enter the number 999 and then test. The unit will now go through a power up routing, blinking the front panel lights, etc., and in '.
the process will also erase any program that may have been entered.
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6.0 B STRUCTIONS (continued) -
6.2.4 (continued) ~
{. When switch number 2 on the I/O board is in the 0FF -
position, the TEST key acts as a selector switch between
( the ac and de test mode. When the unit initially powers t up, it selects a dc mode. To select the ac mode, press any NUMERIC key other thaa " " and then the TEST key. .
.g- To return to the de mode, press "0" and the TEST key.
- g. The difference between ac and de mode is that the relay scanner- slows down to allow an RMS/DC converter time to convert the ac input. Note that when the program is
{ listed, it will tell you whether the unit is selected to the ac or de mode.
Cell Select
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This key can be used to display.the voltage of any cell by entering the cell identification number, followed by f the CELL SELECT key.
in progress.
It is functional when the test is When cell select zero is entered, this causes the individual cells to be displayed one.at a time at a one per second rate.
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Erase program 1
This key is used to erase the entire program previously entered. Depressing this key once will cause the following to appear in the display: " Erase Prg.?". '
Depressing the key a'second time will result in the program being erased. If erasure is not desired, depressing the CLEAR ENTRY key will terminate the erase
_ mode. This key will be ignored if no program has been entered or l' a load program is being executed by the l
system.
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6.0 INSTRUCTIONS (continued) -
6.2.4 (continued) ~
LIST PROGRAM
[ This key is active all the time and is used to command a l printout of the program that has been entered. Print format is as follo.<s:
f STEP 1
AMPS HR/ MIN N
g Total run time
[ Hours Min BCT-30 Status I DC Mode Cell Select
=
=
Cell Scan No. =
l Print Interva; -
J. -
Cut-Off Volts =
Cell Alarm Volts =
Paper Feed This key will feed paper 1 line.
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General Programming Notes -
[. .The test program can'be edited by pressing the step 1
number to be edited and then changing the amps and time as desired. The new information is accepted only when -
-the enter key is pressed. -
The program should be listed before starting a load l
test, or any time that the program has been changed to l
{ verify that the information has been entered correctly.
l The following function switches are not active once a i ['- test has been started: Step, Amps, Time, Enter, l [ INC/DEC, Ident, Test, Erase program, Auto / Man. All other switches may be used during a test.
f When programming the low cell alarm level, make sure to program all 3 digits even when the last digit is a zero.
6.2.4.1 Press STEP key -
6.2.4.2 Enter the current value for the test in accordance with the following table:
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BATTERY DISCHARGE RATES Battery Name Service Test Performance Test Discharge Rate -Discharge Rate Vital I 585 amps 714' amps
' Vital II 585 amps 714 amps
_. Vital III -
585 amps 714 amps Vital IV 585 amps 714 amps
- Vital V 585 amps 736 amps 6.2.4.3 Press AMPS key 6.2.4.4 For service test (18 month) enter "120". For performance test (60 month) enter "240". '
6.2.4.5 Press TIME key. I '
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6.0 . INSTRUCTIONS (continued) 6.2.4.6 Press ENTER key.
6.2.4.7 Enter "0".
6.2.4.8 Press STEP key 6.2.4.9 Enter "105" for vital batteries I throuch IV OR enter "108" for vital battery V.
L 6.2.4.10 Press CUTOFF VOLTS key 6.2.4.11 Enter "60" 6.2.4.12 Press NO. CELLS SCANNED key f 6.2.4.13 Enter "1.40" , , ,
L, 6.2.4.14 Press CELL ALARM key i
6.2.4.15 Enter "10" 6.2.4.16 Press PRINT key
~
- ~
6.2.4.17 Press IDENT key 6.2.4.18 Enter the month number 6.2.4.19 Press IDENT key 6.2.4.20 Enter day number 6.2.4.21 Press IDENT key 6.2.4.22 Enter year number. ,
6.2.4.23 Press IDENT key 6.2.4.24 Enter the number of the battery being tested (1, 2, 3, 4, or 5) then press IDENT key.
_ (example: Vital Battery I would be 1)
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' Revision 21 6.0 INSTP!!CTIONS (continued)
'_~
- 6.2.4.25 Press LIST PROGRAM key. The printer will list the program. Correct any errors.
6.2.4.26 Press PRINT key. The printer will print out '
all 60 cell voltages after approximately 25 seconds scan.
6.2.4.27 Verify that all 60 cell voltages printed are s within the expected range (2.10-2.40 volts).
6.2.5 Battery load cable connections f 6.2.5.1 Verify hold order (HO) on battery test breaker 001 (for vital battery V, Breaker 103, distribution panel A).
NOTE:
Both load banks are identical master / slave load units. Step 5.1 indicates which load unit is to be used as the master load unit.
6.2.5.2 Connect current cable from J14 on master unit to J10 on slave unit.
6.2.5.3 Connect current cable from J16 on master unit to J13 on slave unit.
6.2.5.4 Connect master to slave control cable fnm J17 to J17 on each unit.
" 6.2.5.5 Connect jumper cables from J11 to J12 on both units.
6.2.5.6 Connect ECU control cable from JB to master unit J2.
(; 6.2.5.7 Connect ac power cables from J1 on load units to ,120V ac receptacles.
6.2.5.8 Verify power is on on the ECU. Then turn power
~ on the load units by toggle switch on side of loac' units and verify that load unit fans are operating.
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Revision 21 -
6.0 INSTRUCTIONS (continued)
{ 6.2.5.9 Connect current cable from J10 of master load unit to positive lugs of discharge test J8. <
[
l 6.2.5.10 Connect current cable from J13 of master load unit to negative lugs of discharge test JB.
6.2.5.11 Verify the master / slave load unit designated as f the master unit in step ".1 has been connected up as the master unit. 1
[
t 6.2.5.12 Megger with a 500V megger from each cable to I ground and to load unit case. Verify the resistance to be at least 1 megohm.
NOTE: The r,esistance across the load Bank leads is usually greater than 5,000 ohms except when testing Vital Battery I or Vital Battery V. The low resistance is caused by an indicator lamp on Distribution Panel A associated with the Vital Battery V discharge I. .
cable tie into Vital Battery Board I.
6.2.5.13 Check resistance between leads and verify {
resistance is greater than zero (i.e., not a dead short). If nat, contact Cognizant Engineering for assistance.
6.2.5.14 Notify Operations to release H0 on test breaker 001 (for vital battery V release H0 on test breaker 103 on distribution panel A) and close
~
in breaker 001, (103) and to open the battery charger breaker to isolate the battery and the l
discharge test load from the charger. I
- \
6.2.5.15 Measure and record the temperature of cells i number 6, 12, 18, 24, 30, 36, 42, 48, 54, and {
- 60. Calculate the average temperature and record on the data sheet.
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Page 25 Revision 21 f 6.0- ' INSTRUCTIONS (continued)
.6.2.6 Battery discharge test ~
- f. 6.2.6.1 To start discharge, press start /stop push ,
button. The following action will take place:
- 1. Start light will light m 2. The elapsed time display., which has been-displaying BCT-30 up to now, starts to run showing hours, minutes, a'nd seconds.
f 3. The keyboard display shows the step number that the test is on, as well as the amps that have been programmed and the time part
[' of the display starts acting as a down I counter shoying time to go.
- 4. The appropriate load contactors energize and 1
the ammeter starts to display actual load current flowing.
- 5. The cell voltage scanner starts to scan, sequentially displaying all of the cells
', - e that have been programmed to be scanned.
( 6. The computer will readjust the resistance value if the actual current flowing is not equal to plus 1 percent +1 amp minus 0 of l
the programmed current. l l
NOTE: Step 6.2.6.2 is only applicable for the test i on vital battery Number V. It is not applicable to any other vital battery during the performance or service tests. Cut off voltage is approximately 1.81V X 60 cells or
~ 108.5V but the load unit can only be set to
.whole integers. Cut off voltage for the '
other vital batteries is a whole integer.
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Revision 21 ~ ~ -
6.0 INSTRUCTIONS (continued) -
NOTE:
{ Monitor conditions for both step 6.2.6.2 and 6.2.6.3 and skip step 6.2.6.2 to -
continue with step 6.2.6.3, if necessary.
[
6.2.6.2
{ Monitor the battery terminal voltage of vital battery Number V. If the battery terminal voltage drops to 108.5 volts during the conduct f of the test, prass the " Print" key to obtain a battery status printout, which will also document the length of the discharge. Record l { the discharge time from test start until the i voltage of 108.5 was reached in the data sheet. Test will automatically terminate at 108 volts.
NOTE:
The test may be terminated by any one of the following:
i
- 1. The program timer times out
- 2. Manually pressing the stop pushbutton
- 3. If the overcurrent or low voltage
- ~
- alarm is tripped Remember that the test program is still stored in memory and will start over from time 00 if the start push-button is pressed again following the termination of the test.
If it is desirable to halt a test momentarily, and then resume again from
~
that particular point in the test, this may be done using the Pause / Resume switch. -
i The battery test unit will now discharge the battery keeping the current at the programmed value and printing out the cell voltages once every ten minutes until the 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> have elapsed (for service test) or until the terminal
~ drops to 105 volts or for vital battery V 108 volts (for the performance test).
If the test is stopped because of a cell voltage less than 1.0 volts, that cell must be strapped out and test resumed in accordance with the following steps.
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6.0' INSTRUCTIONS (continued) .
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6.2.6.2 (continued)
NOTE: Strapping out a cell when it is going '
l.,to cell reversal is only permitted f during a performance test and is not allowed in a service test.
NOTE: Steps 6.2.6.3 through 6.2.6.10.10 must be performed as quickly as possible.
NOTE: Steps 6.2.6.3 to 6.2.6.11 are applicable only to the performance (60 month) test. Mark them "N/A" for the service test or if not used during performance test.
6.2.6.3 For the performance test (60 months) only if cell voltage (s) less than 1.0 volt occurs, I record the time (EST) and perform steps 6.2.6.4 through 6.2.6.10.10.
i 6.2.6.4 Press the PRINT key on the EC/DLU and wait for
-e ' {
the printout to complete. !
I 6.2.6.5 l Press the STOP key on the EC/DLU to stop the discharge test.
6.2.6.6 Unbolt and remove the intercell connectors from both sides of the affected cell.
6.2.6.7 Install the jumper cables between the cells on
~ ~
both sides of the affected cell. Tighten bolts finger tight.
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~f Page 28 Revision 21 6.0 INSTRUCTIONS (continued) p 6.2.6.8 Torque all bolts connecting the jumper cables ~
.l to 150 in-lbs.
~ ,
y veudos jumyer ~ c 3 l- I I
I lJ n' O O- l1 o .
)
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_ (
> and cell --
R O O O ,
l-) ! J !-
t-l a s-VeMdotjuyck Vendot- jamfer cons /S$S Of Ad?ee calrlef) tem m aled og a. metal plaz'e at eacA end Figure 1: Jumper connection for a bad cell (typical) 6.2.6.9 Measure the inter-cell connection resistance of J- -
the inter-cell connection by measuring from:
- a. Terminal Post A to Terminal Post C
- b. Terminal Post B to Terminal Post D If resistance is greater than 150 micro-ohms for any reading, redo the connections until the resistance is less than or equal to 150 micro-ohms.. Record the final readings.
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Page 2'9 Revision 21 f 6.0 INSTRUCTIONS (continued)
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6.2.6.10 Reprogram the test . I
{
6.2.6.10.1 Press STFP key. -
[ 6.2.6.10.2 Enter time in minutes remaining in l l test (determined from printout of l
step 6.2.6.4).
j f '
6.2.6.10.3 Press TIME key. I 6.2.6.10.4 Press ENTER key.
- 6. 2 . is' .10. 5 Enter new clitoff volts, g'
_ New Cut Off Voltage
[ Cells Remainin_q 59 58 Vital Batt. I-IV 103 102 Vital Batt. V 107 105 _
6.2.6.10.6 Press OVERALL CUT 0FF key.
6.2.6.10.7 Enter "0".
6.2.6.10.8 Press STEP key.
~ 6.2.6.10.9 Record the time (EST) and calculate the time lapse from step 6.2.6.3 on the data sheet.
6.2.6.10.10 Resume test by going to and continuing with step 6.2.6.1.
6.2.6.ll' Record the cell numbers of the cells jumpered out on the data sheet._
6.2.7 Record the total test time on the data sheet of the discharge test (s) from the last printout of a test or if applicable step 6.2.6.2.
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f-6.0 INSTRUCTIONS (continued) 6.2.8 For the-battery performance discharge test (60 month),
E
- f. calculate the battery capacity using-the following equation:
Percent capacity-(77"F) T.- x 100 (f~ - _
(Ts) x (K) 1 where; .
T4 =
actual' duration (in minutes) of the test to the designated final battery terminal voltage.
Ts - rated time to final test voltage-120 minutes (o K =
capacity correction. factor relating to
[ temperature (optained from Appendix.1 with the average temperature value from step 6.2.5.15) i NOTE: Record N/A for the battery service test (18 i month).
I' Verify that the capacity is greater than 89 percent for Vital batteries I through IV and 87 percent;for. vital battery V. Notify the SE (PAX 6211) and then your supervisor any time the capacity is less than the
, specified capacity.
6.2.9 For the vital battery services tests (18 month test only), verify the battery bank carried at least 573 4
amperes for two (2) hours. If the service test is not met, immediately notify the SE (PAX 6211) and then your !
supervisor.
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Page 31 Revision 21 )'
f~ 6.0 INSTRUCTIONS (continued) -
6.2.10 All automatic cell voltage printouts obtained from the ~
l Alber' discharge unit during the performance of the test shall be labeled and included into the data package of -
i this SI.
6.3 Vital Battery Charger Performance Test (18 months).
NOTE: This test is to fol. low the completion of the battery service test and/or the battery performance discharge f test (for batteries I - IV). '
i l 6.3.1 Have Operations reconnect the battery bank with their respective battery charger (charger shall be set on equalize for the battery recharging). Record the time I, at which the charger was reconnected to the battery on the data sheet. ,,
NOTE: Leave test breaker 001 closed.
6.3.2 Monitor the charger's output current and the charger's voltage using an M&TE voltmeter by alternately reading across the charger ammeter shunt (1 mV - 4 Amps) and the f - -
charger voltmeter.
NOTE: Initial battery charging current may pull I_ charger voltage below 125 volts due to the l current limiting feature. Charger voltage will l i
recover when battery charging current drops 0FF.
]
NOTE: Perform steps 6.3.4 and 6.3.5 concurrent with step 6.3.3.
6.3.3 Establis'h and maintain at least 150 amps (try 155 amps) with a voltage of greater than 125 volts using the discharge unit and steps 6.3.3.1 and 6.3.3.2 to adjust the load to the charger for 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br />.
NOTE: Removing power by way of keyboard or power plug will drop all load from the discharge unit. To restore power to the discharge unit, the EC/DLU -
must be energized before energizing the load unit or a random load will be applied with no control accepted from the EC/DLU.
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1, SON f SI-105 Page 32
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l Revision 21 ..,
4-L6.0 -INSTRUCTIONS (continued) -
6.3.3 (continued) ~
l.. 6.3.3.1 Increase load by entering number of amperes '
desired (over existing ampere load showing in l 1- the " load current amps" display) from the I. keyboard into the programming display and pressing the INC/DEC key with the EC/DLU in -
manual.
6.3.3.2 Decrease load by entering number of amperes desired (under existing ampere load showing in {
l' the " load current amps" display) from the keyboard into the programming display, pressing
-the 2 key, and pressing the INC/DEC key with the EC/DLU in manual.
6.3.4 Record the start time on the data sheet of the charger performance test when the current exceeds 150 amperes I- with a voltage of 125' volts or greater. If a value of 150 amps at 125 volts cannot be obtained, stop the test and initiate a HR to repair the charger. Immediately notify the SE/5RO (PAX 6211) and then your supervisor of the problem.
NOTE: If the required current or voltage was.not
- I-':.- maintained during the four hours due to personnel problems or error, restart the charger performance test by re-performing steps 6.3.4 and 6.3.5.
6.3.5 Record the charger voltage and current (using the M&TE meter) o.n the data sheet immediately following step 6.3 4 and every 30 minutes for the next four (4) hours.
6.3.6 Verify the required current and voltage (Ref, step
' 6.3.3) step 6.were 3.5. -maintained for four hours as demonstrated in 6.3.7 At the end of the 4 hour4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> test, discontinue load applied i
thru discharge unit.
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-1 SI-105 Page 33 Revision 21' -C ,
l 6.0 INSTRUCTIONS (continued) ~
6.4 Return To Service 6.4.1 -Obtain H0 on discharge test breaker 001 (for vital l- battery V, breaker 103, distribution panel A).
.. 6.4.2 Disconnect all test leads from test JB in turbine l, building.
l- -
6.4.3 Disconnect test leads from battery and control cable JB- .
<{. 6.4.4 Monitor the pilot-cell voltages and the cell specific L f. gravity. Perform SI-100 as soon'as the battery has charged enough to meet the allowable values in Table f 4.8-2 of SI-100 and-include a copy of the SI-100 data
' [ sheets as part of this data package. Mark these copies "AFTER TEST". BatterybankcanbedeclaredOPERABLEas soon as SI-100 is complete and the allowable values are met. Notify the SE, the battery is OPERABLE and can be returned to service. Record time on the data sheet.
f 6.4.5 Record time and date on the data sheet when the battery
' ) charging current drops less than 2 amps (.33mV measured at the shunt on on the battery board). Record millivolt reading on the data sheet.
NOTE: If steps 6.2.6.3 through 6.2.6.11 were not performed, mark steps 6.4.6 through 6.4.8 "N/A" on data sheet.
6.4.6 Notify the SRO that a cell (s) has/have been jumpered out.
6.4.7 Issue a temporary alterations change form (TACF) to document the jumper on the cell and r_ecord the TACF l number on data sheet.
6.4.8 Issue a work request (WR) to replace the jumpered out cell and record the WR number on data sheet.
_. 6.4.9 For the 18-month service test, verify the selected battery has not reached 85 percent of its service life by verifying the year of the present performance date is
- earlier than the year 1991 for vital batteries I through IV or 2001 for vital battery V. If the battery has reached 85 percent of its service life, perform step 6.4.12.
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Page 34 .. ,i Revision 21 - - >
- l 6.0 INSTRUCTIONS (continued) 6.4 Return To Service 6.4.10 for the 60 month test only, calculate the average !
battery capacity from the previcus performance tests.
6.4.11 For the 60-month performance test, verify the selected battery is not showing signs of degradation by:
{
- a. verifying battery capacity (calculated in step 6.2.8) is equal to or greater than 94 percent for vital battery I through IV, or 92 percent for vital battery V.
- b. verifying battery cepacity has not dropped below 1" 10 percent rate capacity from its average on previous performance tests, l- c. verifying the year of the present performance date is earlier than the year 1991 for vital batteries I through IV or 2001 for vital battery V.
If the battery is degredated, perform step 6.4.12.
tJL0E: Unless steps 6.4.9 or 6.4.11 calls for \
L performing of step 6.4.12, it is to be NA'ed. {
l 6.3.12 Request the Maintenance and Surveillance Scheduling
\
Section (M&S) to increase the frequency of the i j
peformance test for the selected battery from every 60 months to every 12 months. M&S is to sign on the data sheet that the new frequency is implemented. If the tested' battery is already on increase frequency for the performance test the cognizant engineer can sign.
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Revision 21 - - -
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, SI DATA PACKAGE COVER SHEET Page 1 of 2 l
VITAL BATTERY BANK AND NORMAL CHARGER PERFORMANCE TESTS f Vital Battery System Battery Service Test (18 month) O Battery Performance T'est (60 month) O 1
(Terminal Voltage 105 or 108.5 volts)
' f- Date/ Time Started /
Date/ Time Completed /
Performed By 1
1 1
1 1
, I.. .
i Approval for SI Performance:
Unit 1 SR0/SE Signature Date Unit 2 SRO/SE Signature Date
, Reason for test:
Required by schedule Maintenance complete on (WR# )
~ Another system ( ) inoperable Plant condition (explain)
Other (explain) 4 j
_ - _ - - - _ _ _ _ - - _ - - - _ - _ - - _ _ - - _ - - - _ _ _ _ - - _ _ _ _ _ _ _ _ _ _ _ _ - - _ - - - _ - _ _ - _ - - _ - _ - _ _ - - - _ _ - - _ - -t List of data sheets attached.
Instructions No. Data Sheet No. No. of Pages l
l 1
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Revision 21 ~ '
SI DATA PACKAGE COVER SHEET
- Page 2 of 2
[ t VITAL 8ATTERY BANK AND [10RMAL CHARGER PERFORMANCE TESTS l Did all SI data meet acceptance criteria?
"As Found" Yes No, "As Left" Yes No Verified by:
l' ,
Signature and Title i
r- If criteria were not satisfied, notify the SE who completes the following.
l Has a Potential Reportable Occurrence (PRO) initiated? Yes No Was a Limiting Condition for Operation (LCO) required?
Yes (explain in remarks) No (explain in remarks)
Verified by: .
Date SE Time Review of Test FOREMAN Date I
.f- Review and Approval of Test Elect. Maint. Supv. or Enge. Date QE&C Review of Test QE&C Staff Date Remarks s !
I l
1 n.
J W
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Revision 21 '"
DATA SHEET _
Page 1 of 26 3.0 PREREQUISITES -
3.1 Last performance dates:
SI-100 SI-100.3
(
3, P&Sch or Cog Engr
/
Date 3.2 Operations section approval has been obtained indicated by the Unit 1 and Unit 2 SR0s/SE signature on the cover sheet.-
/
Signature Date 3.3 Notify the Unit 1 and Unit 2 Operators (UO's) prior to the performance
{ of this procedure.
[ /
Signature Date 3.4 Verify that the spare charger is available and SI-303 is not being 4-f performed on the spare charger at the same time as this SI.
/
Signature Date 3.5 SE shall identify and have transferred any necessary loads from the battery system to be tested. Battery bank and charger to be tested shall be isolated from its respective board.
/
Signature Date 3.6 SI-100 shall have been performed within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> prior to the 60 month t performance test and a copy of the data sheets be included in this data package. SI-100 shou'Id not have been performed within the 7 week period prior to the 18 month service test.
I Signature Date 3.7 Verify that the battery has had an equalizing charge completed more than three (3) days and less than seven (7) days prior to the start of the 60 month performance test. An equalizing charge should not be performed prior to the 18 month service test.
/
Signature Date 0703R/dlh
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DATA SHEET r Page 2 of 26 l 3.8 \
Fire door and security breaching permits to block battery door open have been obtained. ]>
/
Signature Date
~
3.9 Comply with EMSL-A36, Maintenance Initiated Common-Mode Failures.
/
Foreman Date 5
{
3.10 SI-100.3 should not have been performed within the 5 month period prior j to the 18 months service test. (Ref step 3.1) ;
l o
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i
.. Signature Date i NOTE Foreman is to consult craftsmen for determination of step 3.11 3.11 Use craftsmen experienced with this equipment or obtain Cog. Engr.
Assistance for the performance of the discharge test of this SI.
se'
/
Foreman Date 3.12 A Vital Battery room exhaust fan is operating. A portable fan placed in the doorway is acceptable if both room exhaust fans are inoperable.
_ /
Craftsman Date l i 3.13 All precautions heve been read, understood, and addressed for the '
L.
performance of this 51. All craftsmen shall comply.
(1) / (3) /
Signature 0 ate Signature Date (2) / (4) /
Signature Date Signature Date 5.0 SPECIAL TEST EQUIPMENT
- !. 5. 1 M&TE Portable Alber' BCT-30 discharge unit with connecting cables.
~~
EC/DLU Unit; TVA ID No.
' Cal. due date
' Master Load Unit; TVA ID No.. Cal . due date I Siave Load Unit; TVA ID No. Cal. due date i
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DATA SHEET -
Page 3 of 26 '
l 5.0 SPECIAL TEST EQUIPMENT (continued) '
i NOTE: Field personnel to calibrate the Alber' discharge unit in the body of the procedure.
) [ 5.2 M&TE Digital low range voltmeter; (Accuracy of both ranges 0.025 percent j of reading plus'one digit.) Minimum millivolt range 0-100mV with resolution to .0lmV. Minimum Volt range 0-200V with resolution to .01V.
TVA ID No. Calibration Due Date 5.3 Power Supply, minimum Range 0-150V de, adjustable to tenths of a volt.
TVA ID No. Note: Output voltage verified by M&TE.
5.4 Power Supply, Range 0 - llV dc, adjustable to hundredth of a volt and l' . Range 0-110 mV dc, adjustable to hundredth of a Millivolt.
TVA ID No. Note: Output voltage verified by M&TE.
I- 5.5 M&TE Thermometer (accuracy of e 2*F)
Range: 60*F to 100*F as a minimum TVA ID No. Calibration Due Date NOTE: Thermometer shall not have been used in batteries other than lead calcium.
5.6 M&TE 500V megger (accuracy of any standard megger is acceptable)
L.
TVA ID No. Calibration Due Date 5.7 M&TE torque wrench (accuracy z 6 in-lbs); measurement-150 in-lbs.
TVA Tag No.
- 17. of measurement plus 1 digit, 20*F to 130*F; Range:
0 to 200 micro-ohms as a minimum
. TVA Tag Nc.
Calibration Due Date 0703R/dlh 4
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SQN SI-105 Page 40 . . _ ,
Revision 21 --
DATA SHEET Page 4 of 26 5.0 SPECIAL TEST EQUIPMENT (continued)
( 5.9 Cables for cell strapout. (Not M&TE) /
(Vendor supplied equipment) Data Recorded by NOTE: If during the conduct of this SI any piece of M&TE fails, record which piece of equipment failed in the Remarks Section and record the TVA tag number and calibration due date of the new piece of M&TE. Also record the step in which the M&TE failed and the new one used.
Remarks:
[ 6.0 INSTRUCTIONS 6.1.1 Visual Inspection of Cells and Cell Plates Cell No. and Abnormal Conditions Found (if any)
Remarks The cells and cell plates show no visual indication of nhysical
.! damage or abnormal deterioration.
./
Signature Date
~
IF ANY PHYSICAL DAMAGE OR ABNORMAL DETERIORATION IS FOUND, IMMEDIATELY NOTIFY THE SE (PAX 6211) AND THEN YOUR SUPERVISOR. i b
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SQN SI-iO5 Page 41 .__.t Revision 21 -~
DATA SHEET _
6.0 INSTRUCTIONS (continued) 6.1.2 Visual Inspection of Battery Rack ,
Abnormal Conditions Found (if any)
Remarks I
Thebatteryracksshownovisualindicati$nofphysicaldamageor abnormal deterioration, i I
,, Signature Date IF ANY PHYSICAL DAMAGE OR ABNORMAL DETERIORATION IS FOUND, IMMEDIATELY NOTIFY THE SE (PAX 6211) AND THEN YOUR SUPERVISOR.
6.1.3 Visual inspection of battery electrical connections i- #
Cell No and Abnormal conditions found (if any)
Remarks The battery to battery and terminal connections are clean, tights and coated with anti-corrosion material.
./
Signature Date
~
IF ANY BATTERY TO BA'TTERY OR TERMINAL CONNECTION IS NOT CLEAN, TIGHT OR C0ATED WITH ANTI-CORROSION MATERIAt IMMEDIATELY NOTIFY
... THE SE (PAX 6211) AND THEN YOUR SUPERVISOR.
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Revision 21
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DATA SHEET Page 6 of 26 i'
6.0 INSTRUCTIONS (continued) 6.2.1 Vital battery and its normal charger are spared out in accordance with 50I-250. Technical Specification LCOs 3.8.2.3 and 3.8.2.4 have been reviewed for Unit 1 and Unit 2 and no LCO has been entered.
/ /
Unit 1 ASE/SRO Signature Time Date
/
r Unit 2 ASE/SRO Si,i nature Time _ / Date 6.2.2 Battery Test Unit Setup...
(. Fire door and security door breaching permits for battery room door have been obtained and door may be breached.
J
/ /
Initials Time Date
~ ~
NOTE:
g For steps 6.2.2.1 through 6.2.2.6 reference Alber drawing BCT-1207-D331. Rev. B.
6.2.2.1 Connect ECU control cable from EC/DLU J3 to JB connector.
/
Initials Date 1
6.2.2.2 Connect ac power cables from EC/DLU J4 to receptacle ,
/
~ Initials Date 6.2.2.3 Turn on power to EC/DLU by pressing power on switch.
6 l
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Revision 21 --<
DATA SHEET _
Page 7 of 26 6.0 INSTRUCTIONS (continued) '
6.2.2.4 Connect the overall volts cable from the EC/DLU J9 to the positive bus of cell 1 and to the negative bus of cell 60.
Initials Date 6.2.2.5 Connect the sense cables from the.EC/DLU J5 and J6 connectors to the interconnection bus or strap between r each cell starting with number 1 on the cell 1 negative to cell 2 positive bus. (Notice that sense lead 60 will go on the cell 60 negat.tve bus along with the overall sense lead.)
c
/
Initials Date 6.2.2.6 Verify that the overall voltage meter displays the
, {. -
correct voltage anj polarity of the battery.
/
![
Initials Date 6.2.3 Battery test unit calibration 6.2.3.1 a. Switch #2 on I/O board is in the ON position.
/
r.
Initials Date
- b. Enter "122" /
Initials Date
- c. Press TEST /
. nitials Date
- d. Connect millivolt source between pins 4 and 5 of Connector J3 on the EC/DLU (must disconnect cable temporarily)
/
1 Initials Date I
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Revision 21 - - -
DATA SHEET Page 8 of 26 6.0 ,IETRUCTIONS (continued) 7 6.2.3.1 (continued)
- e. Adjust millivolt source to 0.00 millivolts. (M&TE meter reading.)
MV /
_ M&TE Meter Initials Date f.
Adjust P1 on analog board to obtain a zero reading in the overall voltage display.
/ /
Display Initials Date 6.2.3.2 a. Adjust the millivolt s'ource to 100.00 millivolts.
(M&TE meter reading.)
-~
MV /
M&TE Meter Initials Date
- . . b. Adjust P2 on analog board to obtain 750 2 .5 percent (Ignore decimal point).
/ /
) Display Tnitials Date
- c. Adjust millivolt source to 60.00 millivolts. (M&TE meter reading) Verify that the display reads 450 2
.5 percent.
MV / /
M&TE Meter Display Initials Date :
- d. Adjust millivolt source to 30.00 millivolts. (M&TE meter reading) Verify that the display reads 225 : {
.5 percent. {
MV / / )
M&TE Meter Display )
Initials Date ,
If (c) or (d) readings are not within .5 percent perform ;
steps 6.2.3.1 and 6.2.3.2 again until they follow within .5 percent of listed value.
- e. Reconnect the control cable to 33 connector.
- / l Initials Date f
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Revision 21 -
DATA SHEET Page E of 26 I
6.0 INSTRUCTIONS (continued)
[ 6.2.3.3 a. Remove cell sense leads 1 and 2 from battery and l e connect to the 0-11 volt dc voltage source.
r-Initials Date
- b. Enter "1" in the EC/DLU l
- c. Press TEST key. The number 1 should appear in the current display and the reading of the voltage source will appear in the overall voltage display (ignore the l 1. decimal point) ,,
e d. Adjust the voltage source to 10.00V (M&TE meter reading).
V /
M&TE Meter Initials Date
. - e. Adjust P3 to give a reading at 1000 m 1 on the c
overall voltage display:
- - V /
Display Initials Date f.
Adjus t the voltage source to 8.00V (M&TE meter reading).
V /
M&TE Meter Initials Date e
4.
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0ATA SHEET p- Page 10 of 26 6.0 INSTRUCTIONS (continued) 6.2.3.3 (continued) 9 Verify a reading of 800 4 in the overall voltage l' display:
{ V /
Display Initials Date E
l
- h. Adjust the voltage source to 4.00V (M&TE meter reading).
V /
M&TE Meter Initials Date F
- 1. Verify a reading of 400 e 2, the overall voltage display.
V /
Display Initials Date P
l '
If g and i are not within tolerance perform steps (d)
.ccc j.
, thru (1) again. If still not within tolerance, immediately notify supervision.
- k. Reconnect the cell sense leads 1 and 2 to the battery l bus.
i, I Initials Date l 6.2.3.4 a. Connect the overall voltage sense leads to the 150V 9- adjustable source.
/
Initials Date m
- b. Enter "120" in the EC/DLU
/
. Initials Date
- c. Press TEST key. Number 120 will appear in the current display and the voltage to be read will appear in the 1
overall voltage display.
~
Initials Date 0703R/dlh
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Revision 21 2._ .!'
DATA SHEET Page 11 of 26 6.0 INSTRUCTIONS (continued) -
6.2.3.4 (continued)
- d. Adjust the voltage source to 150 volts.
E V /
M&TE Me ter Initials Date
- e. Adjust P-4 to obtain 150.0 volts e .75V r
V /
Display Initials Date
- f. Adjust the voltage souFce to 130.0 voits.
f V / '
M&TE Meter Initials Date
- g. Verify a reading of 130 volts .650 in che display. j
. .e j
i Display Initials Date
- h. Adjust the voltage source to 105.0 volts.
f- V /
M&TE Meter Initials Date j 1. Verify a reading of 105 z .5 volts on display.
L
__ V / ~~
Display Initials Date
~
- j. If reading of steps (g) and (i) are not within (
tolerance, perform steps (d) thru (i) again. )
- k. Reconrect the overall voltage sense leads to the l i
battery.
/
. Initials Date
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Revision 21 ' - -
DATA SHEET Page 12 of 26 l
6.0 INSTRUCTIONS (continued) i
[ 6.2.3.5 a. Enter "999" /
Initials Date
- b. Push TEST key. The unit will now go through a power-up q routine.
/
L Initials Date l 6.2.4 TEST PARAMETERS PROGRAMMING 6.2.4.1 Press STEP key /
,, Initials Date r 6.2.4.2 Enter the current value for the test in accordance with the following table.
,. BATTERY DISCHARGE RATES
,. Vital Battery Service Test Performance Test Bank Discharge Current Discharge Rate 1 585 amps 714 amps.
i II 585 amps 714 amps III 585 amps 714 amps IV 585 amps 714 amps V 585 amps
<, 736 amps
/ /
Discharge Rate Initials Date
~ .
6.2.4.3 Press AMPS key. /
Initials Date {
- l 6.2.4.4 Enter "120" for Service Test (18 months). l Enter "240" for perfornmace test (60 months).
/ /
Value Entered Initials Date
. 6.2.4.5 Press TIME key. /
Initials Date 6.2.4.6 Press ENTER key. / !
1 Initials Date i l \
\
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f SON SI-105 Page 49 .__.
Revision 21 >
DATA SHEET Page 13 of 26 6.0 INSTRUCTIONS (continued) -
6.2.4.7 Enter "0". /
Initials Date r
6.2.4.8 Press STEP Key.
/
Initials Date 6.2.4.9 Enter "105" for vitai batteries I L through IV OR enter "108" for vital battery V.
l
/ /
Value Entered Initials Date 1
6.2.4.10 Press CUT 0FF VOLTS key. - /
Initials Date 6.2.4.11 Enter "60. /
Initials Date 6.2.4.12 Press No. CELLS SCANNED key. /
o- Initials Date 6.2.4.13 Enter "1.40" /
Initials Date
{ 6.2.4.14 Press CELL ALARM key. /
Initials Date 6.2.4.15 Enter "10". /
L-Initials Date 6.2.4.16 Press PRINT key. /
m Initials Date j 6.2.4.17 Press IDENT key. /
Initials Date 6.2.4.18 Enter the month number. /
Month ~ Initials Date 6.2.4.19 Piess IDENT key. /
Initials Date 0703R/dlh
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Revision 21 --
DATA SHEEi Page 14 of 26 6.0 INSTRUCTIONS (continued) -
f 6.2.4.20 Enter the day number.
Day Initials
/
Date f 6.2.4.21 Press IDENT key. /
} Initials Date 6.2.4.22 Enter year number. /
l .
Year Initials Date
- 6.2.4.23 Press IDENT key. /
Initials Date 6.2.4.24 Enterthenumberofthebat5erybeing g tested then press IDENT key. / /
l VB No. Initials Date 6.2.4.25 Press LIST PROGRAM key. The printer
(. will list the program. Verify to be correct. /
, Initials Date 6.2.4.26 Press PRINT key. The printer will printout all 60 cell voltages after approximately 25 second scan. /
Initials Date I 6.2.4.27 Verify all cell voltages are within L the expected range (2.10-2.40 volts) /
i Initials Date 1- 6.2.5 Battery load cable connections j 6.2 5.1 Verify H0 on battery test breaker 001 (for vital battery V, breaker 103, distribution panel A).
/
, Initials Date
. NOTE: Both load banks are identical master / slave load units. Step 5.1 Indicates which load unit is to be used as the master load unit.
0703R/dlh
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Revision 21 '"
DATA SHEET i- Page 15 of 26 6.0 INSTRUCTIONS (continued) -
6.2.f.2 Connect current cable from J14 on master unit to J10 on slave unit.
/
T Initials Date L
6.2.5.3 Connect current cable from J15 on master unit e to J13 on slave unit.
L /
_, Initials Date 6.2.5.4 Connect master to slave control cab'e frcm J17 to J17 on each unit.
~
/
Initials Date 6.2.5.5 Connect jumper cables from J11 to J12 on both
, load units.
/
.e Initials Date 6.2. 5. 6 Connect ECU control cable from JB to master unit J2.
/ I h Initials Date I 6.2.5.7 Connect ac power cables from J1 on load units
{ to 120V ac receptacles.
Initials Date l o.2.5.8 Verify power is on the ECU, then turn power on to load units by toggle switch on side of load units and verify that load unit fans are
~
operating.
/
, Initials Date i
. 6.2.5.9 Connect current cable from J10 of master load I unit to positive lugs of discharge test JB.
_ / I Initials Date l 1
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- Revision 21 -
1 DATA SHEET l
Page 16 of 26 6.0 INSTRUCTIONS (continued) f 6.2.5.10 Connect current cable from J13 of master load unit to negative lugs at discharge test JB.
/
[ Initials Date 6.2.5.11 Verify the master slave load unit designated as the master unit in step 5.1 has been connected up as the master load unit.
/
[ ... Initials Date 6.2.5.12 Megger with a 500V megger from each cable to 1 ground and to master load unit case. Verify resistance to be at least 1 megohm.
r /
Initials Date
.a 6.2.5.13 Check resistance between leads and verify to be greater than zero. (i.e. not a dead short). If not then contact the Cognizant Engineer for assistance.
/
[ Initials Date 6.2.5.14 a. Notify Operations to release H0 L- ,
Initials Date
. b. Test breaker 001 closed by Operations I
i Initials Date (Breaker 103 for Vital Battery V, distribution panel A),
- c. Battery charger breaker opened by Operations
/
Initials Date l
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Revision 21 -~~
DATA ~ SHEET Page 17 of 26 ~
l- 6.0 INSTRUCTIONS (continued) ,
6.2.5.15 Battery cell temperatures.
a CELL NUMBER TEMPERATURE *F CELL NUMBER TEMPERATURE *F 6
36 12 '
42 18 48 '
24 54 30 60 I Total of battery temperatures - *F.
Average battery temperature.- Total battery temperature /10.
i.
T,vc= ( ) *F/10 T,vc = *F '
l '
/
Initials Date 6.2.6 Battery discharge test.
6.2.6.1 Test start: Press START key
/ /
i Initials Time Date 6.2.6.2 For 5th vital battery bank service / performance test, l monitor battery terminal voltage. If/when voltage drops to L 108.5 volts, press the " Print" key to obtain a battery '
status printout. Record the total discharge time from test start until voltage of 108.5 was reached: __ minutes
/ /
Signature Time Date I
NOTE:
Step 6.2.6.3 through 6.2.6.10.10 are only performed if the test must be interrupted.
. NOTE:
Strapping out a cell when it is going into cell reversal is only allowable during a performance test (60 month) and is not allowable in a service test. )
1 l
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Revision 21 - -
DATA SHEET 6.0 INSTRUCTIONS (continued)
NOTE: Steps 6.2.6.3 through 6.2.6.10.10 must be performed as quickly as possible.
NOTE: Steps 6.2.6.3 through 6.2.6.11 are applicable only to the performance (60 month) test. Mark them "N/A" for the service test or if not used during performance test.
f 6.2.6.3 For the performance test (60 months) only - if cell voltage (s) less than 1.0 volt occurs, record the time (EST) of the event and perform steps 6.2.6.4 through 6.2.6.10.10. ;
... /
Time (EST) Initials Date NOTE: Steps 6.2.6.3 through 6.2.6.10.10 are dorse only if cell voltage is < 1 volt. Otherwise, N/A. I 6.2.6.4
{ -
Press the PRINT key on the EC/DLU and wait for the printout to complete.
/
I Initials Date 6.2.6.5 Press the STOP key on the EC/DLU to stop the discharge test.
i
" /
Initials Date 6.2.6.6 Unbolt and remove the intercell conr.ectors from both sides of the affected cell.
/
Initials Dati 6.2.6.7 Install the jumper cables between the cells on both sides s the affected cell. Tighten bolts finger tight.
/
Initials Date m 6.2.6.8 Torque all bolts connecting the jumper cable to 150 in..lbs.
/
_ Initials Date 0703R/dlh
_ _ _ _ . _ _ _ _ . _ _ _ _ _ _ _ _ . _ - - _ - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - ~ - - ~ ^ - - ^ - - - - - - - ~ ~ -
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Revision 21 ~
DATA SHEET ~
Page 19 of 26 6.0 INSTRUCTIONS (continued) -
f 6.2.6.9 Measure the resistance of the inter-cell connection by measuring from (see page 28 for diagram) a) Terminal Post A to Terminal Post C f b) Terminal Post 8 to Terminal Post 0
[ If resistance is greater than 150 micro-ohms for any reading, rework che connections until the resistance is less than or equal to 150 micro-ohms. Record final readings.
A to C micro-ohms B to D micro-ohms
/
[ - Initials Date 6.2.6.10 Reprogram the test.
6.2.6.10.1 Press the STEP key. /
Initials Date
., 6.2.6.10.2 Enter time in minutes remaining in test (determined from printout of step 6.2.6.4).
/
Initials Date 6.2.6.10.3 Press TIME key, /
Initials Date 6.2.6.10.4 Press ENTER key. /
Initials Date l 6.2.6.10.5 Enter new cutoff volts.
New Cell' Cutoff Voltage l Cells Remaining 59 58 l
Vital Batt. I-IV 103 102 l Vital Batt. V 107 105 l
/ / l New Cutoff Voltage Initials Date l 1
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DATA SHEET Page 20 of 26 j 6.0 INSTRUCTIONS (continued) i 6.2.6.10.6 Press OVERALL CUTOFF key, /
Initials Date 6.2.6.10.7 Enter "0". /
Initials Date 6.2.6.10.8 Press STEP key. /
f Initials Date 6.2.6.10.9 Record time (EST) and the calculate the time lapse from
[ step 6.2.6.3.
EST /
Time Time Lapse Initials Date 6.2.6.10.10 Resume test by going to and continuing with step 6.2.6.1.
/
Initials Date 6.2.6.11 Record the cell numbers of the cells jumpered out.
Cell No.(s) _ /
Initials Date
'- 6.2.7 Record the total test time of the discharge test (s) from the last print out of a test or (if applicable) step 6.2.6.2.
minutes /
Initials Date 6.2.8 Battery performance test (60 month test only).
Percent capacity (77'F) - T3 1007.
(Ts) (K)
= ( MIN) 100%
( MIN)( )
= ( MIN) 100%
( MIN)
~
= ( ) 1007.
7.
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Revision 21 -
DATA SHEET Page 21 of 26 6.0 INSTRUCTIONS (continued) .
6.2.8 (continued)
Verify the battery capacity is greater than 89 percent for vital.
batteries I through ;V or 87 percent for vital battery V.
Verified by: /
Signature Date IF REQUIRED CAPACITY IS NOT MET, IMMEDIATELY NOTIFY THE SE-(PAX 6211)
AND THEN YOUR SUPERVISOR.
6.2.9 Battery service test (18 month. test only). Verify the battery bank carried at least 573 amperes for two hours.
Verified by: /
Signature Date IF THE SERVICE TEST IS NOT MET, IMMEDIATELY NOTIFY THE SE (PAX 6211)
,. AND,THEN YOUR SUPERVISOR.
6.2.10 Label the roll of automatic voltage printout (s). These printouts are to become part of this Data Package.
/
Initials Date 6.3 Charger Performance Test 6.3.1 Have Operations. reconnect the battery bank with its respective u battery charger and place batteries on equalize charge. (Leave test breakers 001 closed)
/
Initials Date 6.3.2 Monitor charger current and voltage with a M&TE voltmeter.
/
Initials Date too 0703R/dlh
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SQN S.1-105 Page 58 .. ._. 3 Revision 21 ;
DATA SHEET Page 22 of.26 _
'6.0 INSTRUCTIONS (continued)
NOTE:
Perform steps 6.3.4 and 6.3.5 concurrent with step 6.3.3.
6.3.3 Establish and maintain at least 150 amps (try 155 amps) with a voltage of greater than 125. volts using the discharge unit and
.[ steps 6.3.3.1 and 6.3.3.2 to adjust the load.to the charger for 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br />. .;'
/
Initials Date NOTE: Removing power by way of keyboard or power plug will
-f- drop all load from the discharge unit. To restore power
[ to the discharge unit, the EC/DLU must be energized before energizing the load unit or a random load will be applied with no control accepted from the EC/DLU l 6.3.3.1. Increase load by entering number of amperes desired 1 (over existing ampere load showing in the " load current j l amps" display) from the keyboard into the programming J. -
display and pressing the INC/DEC key. ,
-g' 6.3.3.2 Decrease load by entering number of amperes desired
[~ (under existing ampere load showing in the " load current amps" display)'from the keyboard into the programming display, pressing the 2 key, and pressing the INC/DEC
' key.
NOTE: If the required current and voltage were not maintained j during the four hours due to personnel problems or L- error, restart the charger performance test by re-performing steps 6.3.4 and 6.3.5. .
- 6.3.4 Record the start time of the charger performance test when the current exceeds 150 amperes with a voltage of 125 volts or greater. If a value of 150 amps at 125 volts cannot be
}L obtained, stop the test and initiate a WR to repair the !
charger. Immediately notify the SE/SRO (PAX 6211) and then your supervisor of the problem. I
_ E.S.T. /
Initials Date
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l
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DATA SHEET -
Page 23 of 26 6.0 INSTRUCTIONS (continued) ~
6.3.5 Record the charger Voltage and Current using an M&TE voltmeter immediately after step 6.3.4 and every 30 minutes for the next 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br />. ~
t 0 Min 30 Min 1 Hr 90 Min 2 Hr 150 Min 3 Hr 210 Min 240 Min Voltaae Cjirrent f Initials
/
Initials Date 6.3.6 The required current and voltage were maintained for four g hours.
[ ~
Initials
/
Date 6.3.7 Discontinued load applied through discharge unit.
/
Initials Date 6.4 Return to Service 6.4.1 Obtain H0 on discharge test breaker 001 (for vital battery V, breaker 103, distribution panel A).
/
Initials Date 6.4.2 Disconnect all te'st leads from test JB in turbine building.
_ /
Signature Date 6.4.3 Disconnect test leads from battery and control cable JB. Second Person to verify /
Signature Date
/
Second Person Date 0703R/dlh
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Revision 21 -
DATA SHEET 6.0 INSTRutTIO!!S (continued) 6.4.4 SI-100 completed, a copy of the data sheet marked "AFTER TEST" included in the data package, and SE notified battery bank operable.
f (SE)
Initials
/
Date
/
Time I (Electrician) / /
Initials Date Time 6.4.5 Time Battery charging current dropped less than 2 amp (.33mV)
Time EST , , .
Date Millivolt reading mV
/
Initials Date
- NOE : If steps 6.2.6.3 through 6.2.6.11 were not performed, mark steps 6.4.6 through 6.4.8 "N/A".
f 6.4.6 Notify the SRO that a cell (s) has/have been jumpered out.
/
- Initial Date 6.4.7 Issue a TACF to document the jumper on the cell (s) and record the TACF number.
l.
TACF No.
/.
Signature Date
- Cognizant Engineer 6.4.8 Issue a WR to replace the jumpered out cell (s) and record the WR number.
WR No.
/
Signature Date Cognizant Engineer
,_ 0703R/dih
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Revision 21 -"
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0ATA SHEET -
'2. 0 INSTRUCTIONS (continued) 6.4.9 for the 18-month service test, verify the sele:ted battery has not reached 85 percent of its service life by ?erifying the year of the pitsent performance date is earlier than the year
[ 1991 for vital batteries I through IV or 2001 for vital battery
[ V. If the battery has reached 85 percent of its service. life, perform step 6.4.12.
85% of service life met or exceeded yes no
/
Initials Date 6.4.10 For the 60-month test ONLY, record battery capacity from previous performance test.
Date of Test Capacity of Battery Tested
~
..e l
L Total from capacity of battery tested (TCBT) =
Average capacity of battery from previous tests
- TCBT/# of tests
= ( %)/
Average battery capacity from previous tests (60 month test
_ only):
% Number of tests
/
Signature Date 0703R/dlh
o SQN SI-105 .__.
Page 62 -"
Revision 21 -
DATA SHEET 6.0 INSTRUCTIONS (continued) 6.4.11 For the 60-month performance test, verify the selected battery is not showing signs of degradation by:
[ a.
] verifying battery capacity (calculated in step 6.2.8) is equal to or greater than 94 percent for vital batteries I through IV, or 92 percent for vital battery IV, b.
verifying battery capacity has not dropped below 10 percent rate capacity from its average on previous performance tests, ,
c.
verifying the year of the present performance date I is earlier than the year 1991 for vital batteries I through IV or 2001 for vital V.
If the battery is degradated, perform step 6.4.12.
,e L
- Battery shows signs of degradation yes no.
[
L /
Initials Date NOTE:
Unless steps 6.4.9 or 6.4.11 call for performance of step 6.4.12, i,t is to be NAed.
6.4.12 Request the Maintenance and Surveillance Scheduling
- Section (M&S) to increase the frequency of the performance months to every test 12for the selected battery from every 60 months.
frequency is implemented. IfM&S is to sign that the new the tested battery is already on, increase frequency for the performance test the cognizant Engineer can sign.
/
M&S/ Cog Eng. Date 0703R/idw j - .
SQN f.
SI-105 Page 63 Revision 21 _n?
Appendix 1 -
Page 1 of 1 CAPACITY CORRECTION FACTORS FOR TEMPERATURE ,
P (Taken from lEEE Standard 450-1975)
Temperature - *F Factor (K) f 62 63 0.936 0.941 64 0.945 65 0.950 l 66 0.954 67 0.959 g 68 0.963
[ 69 0.968 70 O.972 71 0.976 72 0.980 1 73 0.984 1 74 0.988 75 0.992
, 76 0.996 77 1.000 78 1.003 79 1.006 i 80 1.008 81 1.011 82 1.014 83 1.017 i 84 1.019 l 85 1.022 86 1.025 87 1.027 88 1.030 89 1.032 !
90 . 1.035 9e 1.037 l 92 1.039 l l \
1
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t
_ 0703R/dih il ll
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l
.Z-A7TAfHMEUT* (
l I 10USS Water fleactOf W8:;t
Electri c Corporation DMslons Bcx 355
- *
- F " " '"8'323 " 333 NS-PAT-PLPA-87-059 April 7, 1987 Mr. William Mirs Te.vessee Valley Authority WID 119C-K 400 West Su= nit Drive -
t Kncocville, TN 37902 -
l Dear Billt Attached on the Se you should find the Westirghcuse position and Aicession coolig. quoyah centri %al chargig pumps rochanical seal and the Westirghause Pu=p & Valve Eng.ineerirq Depart =ent.'Ihe positio
.)
l g
- 1 Docurented By:
Approved by:
i W M L. @lth, Engineer d_ _
l /
Plant Risk Analysis pchacP/f.Hitchler, Manager Z Plan /* hisk Analysis J
(
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- i prs-R~ PLRA-87-059
,r Page 1 Westinghouse Position on sequoyah j
Charoina Puno cooline Requirements 1
The purpose of this paper is to present the Westinghouse position on i the c,antrifugal charging pumps' mechanical seal cooling.
BACKGROUND The High Pressure Injection and Recirculation System Notebook (reference 1) was developed as part of the Sequoyah Nuclear Plant !
Unit one Individual Plant Evaluation for the Tennessee Valley !
Authority.
The analysis evaluated the availability of the high Pressure system which utilizes the safety injectior pumps and c ntrifugal charging pumps to deliver watsr to the reactor coolant
-cyctem cold leg loops following a postulated LOCA. The safety injection pumps require three types of cooling: (1) the essential
~ raw cooling water (ERCW) system provides water to the oil coolers, (2) the ERCW cools the pump room cooler, and (3) the component y
cooling system (CCS) provides water to the mechanical seal coolers.
Ths charging pumps also require three types of cooling: (1) the ERCW cools the oil coolers, (2) the ERCW also provides the cooling source to the charging pump room coolers, and (3) the CCS provides cooling to the pumps' mechanical seal coolers.
ASSUMPTION
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During the course of the analysis, it was learned that the cooling to the charging pumps' mechanical seal housings was to be removed prior to the next plant startup.. This information came in the form of engineering change notice (ECN) L-5706. The ECN justifies the R ramoval of the ERCW cooling water to the mechanical seal housings (pots the seals are themselves cooled by the CCS) and the replacement of the housings with a new material (SA 182). This change was initiated following the discovery of extensive corrosion problems within the charging pump seal housing during routine maintenance on t'*1 pumps.
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S-RAT-PLRA-87-059 Page 2 I
~ which leads to the point of this' report. The assumption was made fthat cooling to the centrifugal charging pumps; mechanical seals .
clso do not require cooling once the ECN was implemented. This
.cssumption was made since pump upgrades of this type h' ave occurred at other power plants and the newer pumps' external seal cooling (
'have been eliminated. It was later verified by a plant walkdown of -
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'the sequoyah chemical and volume control system in February 1987 j l
(reference 2) that the seal housings had already been changed Occording to ECN L-5706; however, TVA personnel noted that the seals ;
themselves may still require cooling via the CCS.
At this point, the analysts discussed the issue of whether scal
. cooling was required with Westinghouse pump and valve engineers and TVA personnel.
Based on these discussions, the Westinghouse decision has been made. -
The Westinghouse position is the centrifugal charging pumps require ERCW cooling to the pumps' oil and room coolers, but the charging pumps will still function properly without the CCS mechanical seal ec - cooling.
BASIS FOR DECISION l
s The determination was made that the charging pumps do not need mechanical seal cooling based on recent Westinghouse analysis of the capabilities of th's mechanical seals. According to Westinghouse Pump and Valve Engineering, the mechanical seals have bee.n tested end shown not to require seal cooling as documented in Bulletin No.
3472. The tests were not performed on pumps but on seal mock ups of Pumps.
The tests performed on the seals were at the maximum design t:mperature of,300*F, which corresponds to the loss of mechanical seal cooling water. The seals showed no leakage prior to 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> and projected the seal life at this condition to be 1,920 hours0.0106 days <br />0.256 hours <br />0.00152 weeks <br />3.5006e-4 months <br />. In the event of complete seal failure, a secondary safety bushing limits flow from the pump. Leakage past the bushing at maximum
- J(, tssperature is 1.25 gpm maximum. At normal temperature, leakage would be 0.16 gpm. Seal pressure was varied with tests conducted at t _ _ _ . . _ _ _ _ _ _ _ . _ _ _ _ _ _ . _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ . _ _ _
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NS-RkT-PLRA-87-059 Page 3 60 p31g, 200 psig, and 400 psig. 'This greatly exceeds suction proccure which the seals normally experience. After the accident c:ndition, which would increase fluid temperature, the systen will - -
caoldokm and maximum temperature conditions will decrease to approximately 160'F. It should be noted that the heat added to the pumpa by the mechanical seals is negligible even without seal cooling.
ToroiterhtheWestinghouAepositiononthematteroftheSequoyah centrifugal charging pumps, ERCW cooling is required for the pumps' oil cnd room coolers, but the charging pumps will still function preparly without CCS mechanical seal cooling.
REFERENCES
- 1. High Pressure Injection and Recirculation System Notebook, Tennessee Valley Authority Sequoyah Nuclear Unit one, Individual
- Plant Evaluation, March 1987.
- 2. Sequoyah Unit II System Evahation Report (SYSTER), Chemical and Volume Contrcl System - 62, February 1987.
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