Information Notice 2010-25, Inadequate Electrical Connections: Difference between revisions
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| issue date = 11/17/2010 | | issue date = 11/17/2010 | ||
| title = Inadequate Electrical Connections | | title = Inadequate Electrical Connections | ||
| author name = | | author name = Mcginty T | ||
| author affiliation = NRC/NRR/DPR | | author affiliation = NRC/NRR/DPR | ||
| addressee name = | | addressee name = | ||
Line 13: | Line 13: | ||
| document type = NRC Information Notice | | document type = NRC Information Notice | ||
| page count = 6 | | page count = 6 | ||
}} | }} | ||
{{#Wiki_filter: | {{#Wiki_filter:UNITED STATES | ||
NUCLEAR REGULATORY COMMISSION | |||
OFFICE OF NUCLEAR REACTOR REGULATION | |||
WASHINGTON, DC 20555-0001 November 17, 2010 | |||
NRC INFORMATION NOTICE 2010-25: INADEQUATE ELECTRICAL CONNECTIONS | |||
==ADDRESSEES== | ==ADDRESSEES== | ||
All holders of an operating license or construction permit for a nuclear power reactor issued under Title 10 of the Code of Federal Regulations (10 CFR) Part 50, | All holders of an operating license or construction permit for a nuclear power reactor issued | ||
under Title 10 of the Code of Federal Regulations (10 CFR) Part 50, Domestic Licensing of | |||
Production and Utilization Facilities, except those who have permanently ceased operations | |||
and have certified that fuel has been permanently removed from the reactor vessel. | |||
==PURPOSE== | ==PURPOSE== | ||
The U.S. Nuclear Regulatory Commission (NRC) is issuing this information notice (IN) to inform addressees about operating experience involving loose electrical | The U.S. Nuclear Regulatory Commission (NRC) is issuing this information notice (IN) to inform | ||
* lack of work order documentation indicating that connections had been loosened or removed | |||
* failure to follow vendor- or industry-recommended torque requirements | addressees about operating experience involving loose electrical connections. The NRC | ||
* inadequate quality control verification of connection torque and resistance measurement | |||
* incomplete or inappropriate maintenance practices | expects recipients to review the information for applicability to their facilities and consider | ||
* improper washer installation | |||
* lack of resistance verification to verify adequate torque | actions, as appropriate, to avoid similar problems. The suggestions that appear in this IN are | ||
* inadequate tightening of connection after the removal of test leads | |||
* failure to crimp and inspect the tightness of a lug connection* marginal electrical connection during installation | not NRC requirements; therefore, no specific action or written response is required. | ||
* loose fuse holder retaining clips | |||
* thermal cycling of electrical connections over time | ==DESCRIPTION OF CIRCUMSTANCES== | ||
* electrical connectors that are not fully seated | The Office of Nuclear Reactor Regulation reviewed operating experience related to inadequate | ||
* worn or high-resistance electrical connector pins and sockets The events described below are examples of recent electrical connection | |||
electrical connections and found that the following issues often caused connection problems: | |||
* lack of work order documentation indicating that connections had been loosened or | |||
removed | |||
* failure to follow vendor- or industry-recommended torque requirements | |||
* inadequate quality control verification of connection torque and resistance measurement | |||
* incomplete or inappropriate maintenance practices | |||
* improper washer installation | |||
* lack of resistance verification to verify adequate torque | |||
* inadequate tightening of connection after the removal of test leads | |||
* failure to crimp and inspect the tightness of a lug connection | |||
* marginal electrical connection during installation | |||
* loose fuse holder retaining clips | |||
* thermal cycling of electrical connections over time | |||
* electrical connectors that are not fully seated | |||
* worn or high-resistance electrical connector pins and sockets | |||
The events described below are examples of recent electrical connection problems. | |||
===Columbia Generating Station=== | |||
On August 5, 2009, an electrical fault occurred on a 6.9-kilovolt (kV) nonsegregated bus at | |||
Columbia Generating Station while the plant was operating at 100-percent power. The fault | |||
caused a main generator differential lockout, which resulted in a main turbine trip and the | |||
subsequent actuation of the automatic reactor protection system. The nonsegregated bus | |||
experienced a catastrophic failure, and the associated fire generated enough smoke in the | |||
turbine building to require the declaration of a notification of an unusual event. Although the | |||
extent of damage to the bus made it impossible for plant personnel to substantiate a direct | |||
cause, the licensee postulated that the most probable cause was the failure of a link assembly | |||
that allowed a short circuit between phase conductors. The failure of the link was attributed to | |||
thermal cycling that caused the bolted connections on the central flexible link to loosen. The | |||
Dresden Nuclear Power Station, Unit 3 On October 29, 2008, with Unit 3 at approximately 85 percent power, licensee personnel at Dresden Nuclear Power Station identified that the open indication light for the normally open primary containment isolation valve was | licensee omitted steps in its preventive maintenance procedure for torque verification and high- potential testing without evaluating the scope and implications of these omissions. The licensee | ||
could have prevented the bus failure by performing these steps. (See Licensee Evaluation | |||
Report (LER) 397/2009-004-00, 6.9 kV Non-Segregated Electrical Bus Failure, issued 2009, Agencywide Documents Access and Management System (ADAMS) Accession No. | |||
ML092870468.) | |||
===Waterford Steam Electric Station, Unit 3=== | |||
In May 2008, workers at Waterford Steam Electric Station (Waterford), Unit 3, replaced a cell in | |||
a safety related battery bank. The licensee failed to ensure that the scope of work was | |||
adequate. Specifically, the electricians did not (1) torque all of the affected intercell connections | |||
as recommended by the vendor, (2) obtain the required quality control inspector verification for | |||
every connection torque, (3) ensure that all the resistance measurements for the electrical | |||
connections were performed, and (4) ensure that the quality control verification for resistance | |||
checks met technical specification (TS) limits. These errors resulted in an undetected loose | |||
electrical connection that rendered the Train B battery inoperable. On September 3, 2008, Waterford operations declared the station battery 3B-S inoperable because of low voltage and | |||
entered TS 3.8.2.1. Licensee personnel discovered loose bolts on an intercell connector | |||
between two battery cells and immediately corrected the condition by tightening and verifying | |||
intercell resistance. The licensee declared the battery operable on the same day. (See LER | |||
382/2008-004-01, Loose Intercell Connecting Bolts on 125 vdc Station Battery (Revised), | |||
issued 2010, ADAMS Accession No. ML101800330.) San Onofre Nuclear Generating Station, Unit 2 On March 25, 2008, plant personnel at San Onofre Nuclear Generating Station, Unit 2, were | |||
performing TS Surveillance Requirement 3.8.4.1 of a Class 1E battery while the unit was | |||
operating at 100-percent power and discovered that its voltage was below the required value. | |||
Subsequently, the licensee observed signs of a loose connection on the breaker that provides | |||
charging current for the battery in its normal configuration. The licensee declared the battery | |||
inoperable, as required by TS Surveillance Requirement 3.8.4, Action A. The licensee torqued | |||
the loose connection bolts and completed the required TS surveillance requirements with | |||
satisfactory results. The licensee concluded in its root cause evaluation that it had most likely | |||
not fully torqued the connection bolts on March 17, 2004, when it last replaced the breaker. The | |||
bolts were not torqued because of an incomplete work plan and the lack of an effective second | |||
check of the critical steps. (See LER 361/2008-006-00, Loose Connection Bolting Results in | |||
Inoperable Battery and TS Violation, issued 2008, ADAMS Accession No. ML082660036.) | |||
===Dresden Nuclear Power Station, Unit 3=== | |||
On October 29, 2008, with Unit 3 at approximately 85 percent power, licensee personnel at | |||
Dresden Nuclear Power Station identified that the open indication light for the normally open | |||
primary containment isolation valve was flickering. Troubleshooting on November 1, 2008, led | |||
to the discovery of an intermittent high-resistance electrical connection for control power to the | |||
valve. The intermittent electrical connection caused the indicator light to flicker, and the | |||
intermittent connection would have prevented valve closure from the control room. The licensee | |||
declared valve 3-3702 inoperable and took actions in accordance with the requirements of | |||
TS 3.6.1.3. The licensee restored the valve to operable status on the same day. The most | |||
probable cause of the high resistance connection was a marginal electrical connection during | |||
original installation and equipment vibration over time causing the intermittent connection. | |||
Additionally, the cause of not entering TS 3.6.1.3 on October 29, 2008, was a lack of proper | |||
procedural guidance that led operations personnel to assume the problem was simply a faulty | |||
light socket. (See LER 249/2008-002-00, Unit 3 Primary Containment Isolation Valve Declared | |||
Inoperable, issued 2008, ADAMS Accession No. ML090060879.) | |||
==BACKGROUND== | ==BACKGROUND== | ||
* Torque verification | ===Related Generic Communications=== | ||
* Visual inspections | * IN 2008-18, Loss of a Safety-Related Motor Control Center Caused by a Bus Fault, dated December 1, 2008 | ||
* Periodic thermography measurements | * IN 89-64, Electrical Bus Bar Failures, dated September 7, 1989 | ||
* Resistance measurements | * IN 88-11, Potential Loss of Motor Control Center and/or Switchboard Function Due to | ||
* Adherence to vendor recommendations | |||
* Use of proper lubricants for switch contact surfaces | Faulty Tie Bolts, dated April 7, 1988 Related Operating Experience Smart Samples | ||
* Identification of single point connection vulnerabilities IN | |||
* FY 2009-01, Inspection of Electrical Connections for Motor Control Center, Circuit | |||
Breakers, and Interfaces, issued 2009 | |||
==DISCUSSION== | |||
Inadequate electrical connections can lead to unanticipated plant transients and the failure or | |||
unavailability of safety related equipment. They can also affect equipment important to safety or | |||
can potentially challenge safety related equipment. A recent review of operating experience has | |||
determined that the following items are important to ensuring the integrity of electrical | |||
connections: | |||
* Torque verification | |||
* Visual inspections | |||
* Periodic thermography measurements | |||
* Resistance measurements | |||
* Adherence to vendor recommendations | |||
* Use of proper lubricants for switch contact surfaces | |||
* Identification of single point connection vulnerabilities | |||
==CONTACT== | |||
This IN requires no specific action or written response. Please direct any questions about this | |||
matter to the technical contacts listed below. | |||
/RA/ | |||
Timothy McGinty, Director | |||
Division of Policy and Rulemaking | |||
Office of Nuclear Reactor Regulation | |||
Technical Contacts: Joseph Giantelli, DIRS/IOEB Matthew McConnell, DE/EEEB | |||
301-415-0504 301-415-1597 E-mail: Joseph.Giantelli@nrc.gov E-mail: Matthew McConnell@nrc.gov | |||
Jesse Robles, DIRS/IOEB | |||
301-415-2940 | |||
E-mail: Jesse.Robles@nrc.gov | |||
Note: NRC generic communications may be found on the NRC public Web site, http://www.nrc.gov, under Electronic Reading Room/Document Collections. | |||
==CONTACT== | |||
This IN requires no specific action or written response. Please direct any questions about this | |||
matter to the technical contacts listed below. | |||
/RA/ | |||
Timothy McGinty, Director | |||
Division of Policy and Rulemaking | |||
Office of Nuclear Reactor Regulation | |||
Technical Contacts: Joseph Giantelli, DIRS/IOEB Matthew McConnell, DE/EEEB | |||
301-415-0504 301-415-1597 E-mail: Joseph.Giantelli@nrc.gov E-mail: Matthew.McConnell@nrc.gov | |||
Jesse Robles, DIRS/IOEB | |||
301-415-2940 | |||
E-mail: Jesse.Robles@nrc.gov | |||
Note: NRC generic communications may be found on the NRC public Web site, http://www.nrc.gov, under Electronic Reading Room/Document Collections. | |||
ADAMS Accession Number: ML102530012 TAC ME4481 OFFICE NRR/DIRS/IOEB BC/NRR/DIRS/IOEB D/NRR/DIRS Tech Editor NRR/DLR/RASB BC/DE/EEEB | |||
NAME JGiantelli JThorp FBrown KAzariah-Kribbs CDoutt RMathew | |||
DATE 10/26/10 10/28/10 11 /12 /10 09/16/10 e-mail 11/03/10 10/27/10 | |||
OFFICE D/DE/EEEB DPR/PGCB DPR/PGCB DPR/PGCB BC/DPR/PGCB D/NRR/DPR | |||
NAME PHiland (GWilson for) ARussell CHawes TAlexion SRosenberg TMcGinty | |||
DATE 11/04/10 11/15 /10 11/15/10 11/16 /10 11/17/10 11/17/10 | |||
OFFICIAL RECORD COPY}} | |||
{{Information notice-Nav}} | {{Information notice-Nav}} |
Latest revision as of 14:28, 13 November 2019
ML102530012 | |
Person / Time | |
---|---|
Issue date: | 11/17/2010 |
From: | Mcginty T Division of Policy and Rulemaking |
To: | |
Russell Andrea, 415-8553 | |
References | |
IN-10-025 | |
Download: ML102530012 (6) | |
UNITED STATES
NUCLEAR REGULATORY COMMISSION
OFFICE OF NUCLEAR REACTOR REGULATION
WASHINGTON, DC 20555-0001 November 17, 2010
NRC INFORMATION NOTICE 2010-25: INADEQUATE ELECTRICAL CONNECTIONS
ADDRESSEES
All holders of an operating license or construction permit for a nuclear power reactor issued
under Title 10 of the Code of Federal Regulations (10 CFR) Part 50, Domestic Licensing of
Production and Utilization Facilities, except those who have permanently ceased operations
and have certified that fuel has been permanently removed from the reactor vessel.
PURPOSE
The U.S. Nuclear Regulatory Commission (NRC) is issuing this information notice (IN) to inform
addressees about operating experience involving loose electrical connections. The NRC
expects recipients to review the information for applicability to their facilities and consider
actions, as appropriate, to avoid similar problems. The suggestions that appear in this IN are
not NRC requirements; therefore, no specific action or written response is required.
DESCRIPTION OF CIRCUMSTANCES
The Office of Nuclear Reactor Regulation reviewed operating experience related to inadequate
electrical connections and found that the following issues often caused connection problems:
- lack of work order documentation indicating that connections had been loosened or
removed
- failure to follow vendor- or industry-recommended torque requirements
- inadequate quality control verification of connection torque and resistance measurement
- incomplete or inappropriate maintenance practices
- improper washer installation
- lack of resistance verification to verify adequate torque
- inadequate tightening of connection after the removal of test leads
- failure to crimp and inspect the tightness of a lug connection
- marginal electrical connection during installation
- loose fuse holder retaining clips
- thermal cycling of electrical connections over time
- electrical connectors that are not fully seated
- worn or high-resistance electrical connector pins and sockets
The events described below are examples of recent electrical connection problems.
Columbia Generating Station
On August 5, 2009, an electrical fault occurred on a 6.9-kilovolt (kV) nonsegregated bus at
Columbia Generating Station while the plant was operating at 100-percent power. The fault
caused a main generator differential lockout, which resulted in a main turbine trip and the
subsequent actuation of the automatic reactor protection system. The nonsegregated bus
experienced a catastrophic failure, and the associated fire generated enough smoke in the
turbine building to require the declaration of a notification of an unusual event. Although the
extent of damage to the bus made it impossible for plant personnel to substantiate a direct
cause, the licensee postulated that the most probable cause was the failure of a link assembly
that allowed a short circuit between phase conductors. The failure of the link was attributed to
thermal cycling that caused the bolted connections on the central flexible link to loosen. The
licensee omitted steps in its preventive maintenance procedure for torque verification and high- potential testing without evaluating the scope and implications of these omissions. The licensee
could have prevented the bus failure by performing these steps. (See Licensee Evaluation
Report (LER) 397/2009-004-00, 6.9 kV Non-Segregated Electrical Bus Failure, issued 2009, Agencywide Documents Access and Management System (ADAMS) Accession No.
Waterford Steam Electric Station, Unit 3
In May 2008, workers at Waterford Steam Electric Station (Waterford), Unit 3, replaced a cell in
a safety related battery bank. The licensee failed to ensure that the scope of work was
adequate. Specifically, the electricians did not (1) torque all of the affected intercell connections
as recommended by the vendor, (2) obtain the required quality control inspector verification for
every connection torque, (3) ensure that all the resistance measurements for the electrical
connections were performed, and (4) ensure that the quality control verification for resistance
checks met technical specification (TS) limits. These errors resulted in an undetected loose
electrical connection that rendered the Train B battery inoperable. On September 3, 2008, Waterford operations declared the station battery 3B-S inoperable because of low voltage and
entered TS 3.8.2.1. Licensee personnel discovered loose bolts on an intercell connector
between two battery cells and immediately corrected the condition by tightening and verifying
intercell resistance. The licensee declared the battery operable on the same day. (See LER 382/2008-004-01, Loose Intercell Connecting Bolts on 125 vdc Station Battery (Revised),
issued 2010, ADAMS Accession No. ML101800330.) San Onofre Nuclear Generating Station, Unit 2 On March 25, 2008, plant personnel at San Onofre Nuclear Generating Station, Unit 2, were
performing TS Surveillance Requirement 3.8.4.1 of a Class 1E battery while the unit was
operating at 100-percent power and discovered that its voltage was below the required value.
Subsequently, the licensee observed signs of a loose connection on the breaker that provides
charging current for the battery in its normal configuration. The licensee declared the battery
inoperable, as required by TS Surveillance Requirement 3.8.4, Action A. The licensee torqued
the loose connection bolts and completed the required TS surveillance requirements with
satisfactory results. The licensee concluded in its root cause evaluation that it had most likely
not fully torqued the connection bolts on March 17, 2004, when it last replaced the breaker. The
bolts were not torqued because of an incomplete work plan and the lack of an effective second
check of the critical steps. (See LER 361/2008-006-00, Loose Connection Bolting Results in
Inoperable Battery and TS Violation, issued 2008, ADAMS Accession No. ML082660036.)
Dresden Nuclear Power Station, Unit 3
On October 29, 2008, with Unit 3 at approximately 85 percent power, licensee personnel at
Dresden Nuclear Power Station identified that the open indication light for the normally open
primary containment isolation valve was flickering. Troubleshooting on November 1, 2008, led
to the discovery of an intermittent high-resistance electrical connection for control power to the
valve. The intermittent electrical connection caused the indicator light to flicker, and the
intermittent connection would have prevented valve closure from the control room. The licensee
declared valve 3-3702 inoperable and took actions in accordance with the requirements of
TS 3.6.1.3. The licensee restored the valve to operable status on the same day. The most
probable cause of the high resistance connection was a marginal electrical connection during
original installation and equipment vibration over time causing the intermittent connection.
Additionally, the cause of not entering TS 3.6.1.3 on October 29, 2008, was a lack of proper
procedural guidance that led operations personnel to assume the problem was simply a faulty
light socket. (See LER 249/2008-002-00, Unit 3 Primary Containment Isolation Valve Declared
Inoperable, issued 2008, ADAMS Accession No. ML090060879.)
BACKGROUND
Related Generic Communications
- IN 2008-18, Loss of a Safety-Related Motor Control Center Caused by a Bus Fault, dated December 1, 2008
- IN 89-64, Electrical Bus Bar Failures, dated September 7, 1989
- IN 88-11, Potential Loss of Motor Control Center and/or Switchboard Function Due to
Faulty Tie Bolts, dated April 7, 1988 Related Operating Experience Smart Samples
- FY 2009-01, Inspection of Electrical Connections for Motor Control Center, Circuit
Breakers, and Interfaces, issued 2009
DISCUSSION
Inadequate electrical connections can lead to unanticipated plant transients and the failure or
unavailability of safety related equipment. They can also affect equipment important to safety or
can potentially challenge safety related equipment. A recent review of operating experience has
determined that the following items are important to ensuring the integrity of electrical
connections:
- Torque verification
- Visual inspections
- Periodic thermography measurements
- Resistance measurements
- Adherence to vendor recommendations
- Use of proper lubricants for switch contact surfaces
- Identification of single point connection vulnerabilities
CONTACT
This IN requires no specific action or written response. Please direct any questions about this
matter to the technical contacts listed below.
/RA/
Timothy McGinty, Director
Division of Policy and Rulemaking
Office of Nuclear Reactor Regulation
Technical Contacts: Joseph Giantelli, DIRS/IOEB Matthew McConnell, DE/EEEB
301-415-0504 301-415-1597 E-mail: Joseph.Giantelli@nrc.gov E-mail: Matthew McConnell@nrc.gov
Jesse Robles, DIRS/IOEB
301-415-2940
E-mail: Jesse.Robles@nrc.gov
Note: NRC generic communications may be found on the NRC public Web site, http://www.nrc.gov, under Electronic Reading Room/Document Collections.
CONTACT
This IN requires no specific action or written response. Please direct any questions about this
matter to the technical contacts listed below.
/RA/
Timothy McGinty, Director
Division of Policy and Rulemaking
Office of Nuclear Reactor Regulation
Technical Contacts: Joseph Giantelli, DIRS/IOEB Matthew McConnell, DE/EEEB
301-415-0504 301-415-1597 E-mail: Joseph.Giantelli@nrc.gov E-mail: Matthew.McConnell@nrc.gov
Jesse Robles, DIRS/IOEB
301-415-2940
E-mail: Jesse.Robles@nrc.gov
Note: NRC generic communications may be found on the NRC public Web site, http://www.nrc.gov, under Electronic Reading Room/Document Collections.
ADAMS Accession Number: ML102530012 TAC ME4481 OFFICE NRR/DIRS/IOEB BC/NRR/DIRS/IOEB D/NRR/DIRS Tech Editor NRR/DLR/RASB BC/DE/EEEB
NAME JGiantelli JThorp FBrown KAzariah-Kribbs CDoutt RMathew
DATE 10/26/10 10/28/10 11 /12 /10 09/16/10 e-mail 11/03/10 10/27/10
OFFICE D/DE/EEEB DPR/PGCB DPR/PGCB DPR/PGCB BC/DPR/PGCB D/NRR/DPR
NAME PHiland (GWilson for) ARussell CHawes TAlexion SRosenberg TMcGinty
DATE 11/04/10 11/15 /10 11/15/10 11/16 /10 11/17/10 11/17/10
OFFICIAL RECORD COPY