ML20081K520

Followup Part 21 Rept Re Leaking Tantalum Capacitors in Class IE,SA-1 Relays (Ref IE Info Notice 83-63).Customers Given Option of Returning Relays or Performing Field Mod

ML20081K520
Person / Time
Site:	McGuire, Mcguire
Issue date:	11/01/1983
From:	Schmidt W WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP.
To:	Lauden W NRC
References
REF-PT21-83-042-000, REF-SSINS-6835, REF-SSINS-SSINS-6 IEIN-83-63, PT21-83-042-000, PT21-83-42, NUDOCS 8311100099
Download: ML20081K520 (15)

Text

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Westinghouse Power Systems n iay-instrum niousea Electric Corporation CoralSpnngs,Fhida 33065 (305) 75m00 November 1, 1983 Mr. Wolfgang Lauden U.S. Nuclear Regulatory Commission Washington, DC 10555

Subject:

NRC IE Information Notice 83-63

Dear Mr. Lauden:

As I indicated in our recent phone conversation, I have inforn.ed all of the customers listed in your IN 83-63, dated September 26, 1983, of a new problem we have discovered in our Class lE, SA-1 relays. The problem involves leaking tantalum capacitors and has 1

.been reported through the Westinghouse Field Sales organization.

In addition to the serial numbered relays listed in IN 83-63, we have shipped the following relays which do not contain the hermeti-cally sealed tantalum capacitor that is now specified by Engineering:

SA-1 Relay Customer Serial No. (W) G.O. No. Customer-

& Item Order Number Brown-Boveri Electric 8416 PH61459-N1-C T70418-41059 Chalfont, PA 8417 PH61459-N1-C T70418-41059 8418 PH61459-N1-C T70418-41059 Duke Power Co. 8338 CH13915-N1-1 H31257-85 McGuire Nuclear Stn. 8339 CH13915-N1-1 H31257-85 I had requested that all relays be returned to Coral Springs for modification. My reason for requesting return was to enable QA at Coral Springs to check calibration and up-date our records. Dis-cussion with Mr. Rhoads at BBE indicated that many plants would find it very difficult to take relays out of service for the time it would take to ship them back to Coral Springs for modification. Mr. Rhoads further indicated that it was common practice for customers to recali-brate relays as part of their routine maintenance procedures. I had to agree that this was true. Our instruction leaflet provides instruc-tions on how to recalibrate. Westinghouse calibration records only 1 assure the state of the relay whan it left Coral Springs and.do not reflect the calibration and/or f.etting of the relay as applied by the customer.

8311100099 831101 PDR ADOCK 05000369 -~ j S PDR.. /

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Mr. Wolfgang Lauden U.S. NRC November 1, 1983 Page 2 This being the case, I agreed with Mr. Rhoads that we would follow our commercial practice and give the customer the option of modifying relays in the field. I have sent Mr. Rhoads the attached letter summarizing the problems we have had with Class lE SA-1 relays and providing the information that will allow customers to modify relays in the field if they so desire.

As a follow-up to paragraph one, I am sending a copy of this letter to all our customers giving them the option of field modification.

Mr. Doug Naaf, Safety Review Engineer, Pacific Gas & Electric Diablo Canyon Nuclear Plant, has also contacted me about SA-1 relay problems and I am sending him a copy of the attached letter to Mr. Rhoads.

This should bring you up to date relative to our Class lE SA-1 relay problems. If you require any more information please let me know.

Yours very tru y, AAbM Warren J. Schmidt, Manager Quality Assurance WJS:vmy atc.

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% g CoralSptngs, Florida 33066 (306) 752-6700 October 25, 1983 Mr. E. W. Rhoads Brown Boveri Electric, Inc.

Switchgear Systems Division Spring flouse, PA 19477 Re: SA-1 Class 1E Relays Required Modifications

Dear Mr. Rhoads:

This letter is intended to provide my approval of field modification of SA-1 Class lE relays in lieu of returning them to Coral Springs for replacement of tantalum capacitors. Since you and I discussed this by phone on October 12, I thought the most expeditious action was to write to you directly rather than going through Mr. Taboga, as with previous correspondence.

Background:

As you are aware, we have discovered three potential problems with the SA-1 relay. The intent of this round of modifica-tions must be to correct all the problems and bring the relays into agreement with the latest design. The problems that require correc-tion are listed below. Not all relays in the field will need correc-tion for all problems, since some corrective actions have already been taken and later production relays encorporated corrections 1 and/or 2 in their design.

1. Not meeting the full SWC requirement of ANSI C37.90-1978.

2. Uninitiated trip output potential in relays containing ST Semicon trip output SCR's.

3. Tantalum capacitors leaking electrolyte.

Listed below are the SA-1 Class IE relays that we have supplied to you which require one or more of the action (s) outlined as follows. Please note that this list includes serial numbers 8416, 17 and 18, shipped to you in June 1983. These three relays will only require the replacement of the tantalum capacitors, Item 3 below.

Mr. E. W. Rhoads October 25, 2983 Page 2 Serial No. (W) G.O. No. & Item Customer Order No.

4772 PH6b333-N1-H1 J96608-53566 5768A PH69899-N1-D J52531-53170 6912 PH61036-N1-C J57018-51128 7808 PH61316-N1-I J66315-51126 8416 PH61459-N1-C T70418-41059 8417 PH61459-N1-C T70418-41059 8418 PH61459-N1-C T70410-41059 Required Field Action:

The basic action required is to check each SA-1 relay for it's l

potential for exhibiting one or more of the problems listed above.

Identification of the potential for the problem and it's correction is outlined below:

1. SWC Enhancement: See Fig. 1, attached, to determine if relay must be modified to enhance it's surge withstand capability. The following is background to this problem:

Idaho Power Company informed us of a SA-1 relay that was providing incorrect trip signals in a shunt reactor protection application in a substation. Idaho believed the incorrect trips were caused by electrical noise.

Engineering investigated the situation by testing in accordance with Section 9, SWC Tests, of ANSI C37.90-1978.

The relay was found to incorrectly trip on the common mode test for crest values of the oscillatory SWC test wave above 1.8kV, (the ANSI specification calls for a range of 1.5-3.0 kV) applied to terminals 1-2 and 1-10.

Engineering has developed a surge protection module that will bring the SWC capability of a 48/125 Vdc Class 1E SA-1 relay up to a level in excess of the requirements of ANSI C37.90-1978. If inspection to Fig. 1 indicates that t

this module is not present style number 1584C21G01 surge protection module should be ordered. Installation of this module may be accomplished by following the " Supple-mentary Instructions - Installation of SWC Module" included with this letter.

2. SCR Replacement: See Fig. 2, attached, to identify and locate the SCR that may be a source of uninitiated trip outputs.

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Mr. E. W. Rhoads October 25, 2983 Page 3 2.1 Tag the wires when disassembling to insure correct reconnection to the replacement SCR.

2.2 Do not stress the anode and cathode leads of the SCR when reconnecting the wires.

2.3 Do not overheat the SCR leads when resoldering.

Heat sinks applied to the SCR terminals during resoldering will help to assure that overheating does not occur.

1 2.4 Correct replacement will be verified by the test and calibration procedure called for in the next action: tantalum capacitor replacement.

3. Tantalum Capacitor Replacement:

Since it is the intent of this modification to bring relays in-line with the latest design, the whole printed circuit module will be replaced rather than replacing only the tantalum capacitors. See Fig. I attached to locate the printed circuit module to be replaced.

Replacement of the module should be acc led by following the steps below. Replacement of the moc ill probably affect relay calibrat' ion. Test and calibs_.lon, step 3.5 below must be accomplished in it's entirety.

3.1 Remove the two mounting screws at the top sides of the module. Remove the module from the socket.

3.2 Perform steps 2 and 3 under the heading " Test" in the attached " Supplementary Instructions - Test and Calibration".

3.3 Replace with a new module 408C673G01SUB35 date coded CSA/0883 or later (see Fig's. I and 4 attached).

3.4 Replace the two mounting screws.

3.5 Test and calibrate the relay in-line with the attached

" Supplementary Instructions - Test and Calibration".

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Mr. E. W. Rhoads '

October 25, 1983 Page 4

4. Documentation:

When there is assurance that all of the above modifications are present and the relay is calibrated (see 3.5 above) document as follows:

4.1 Replace the nameplate with a new nameplate that indicates the style to be 1329D62A01D (the suffix indicates that all the modifications have been made).

4.2 Bring your own documentation up to date. Send a copy of the amendment to your documentation to Warren J. Schmidt, QA Manager, Westinghouse Relay-Instrument Division, 4300 Coral Ridge Drive, Coral Springs, Florida 33065.

4.3 Add " ADDENDUM TO WESTINGHOUSE I.L.41-348.11", effective June 1983, to the file. It should be especially noted that this addendum, under Page 4 - Par. 8 Maintenance, i

states: "The tantalum capacitors C1, C2, C3, C4, and C13 may have a common mode failure characteristic and should be checked visually for symptoms of electrolyte leakage every year and replaced if necessary. Change these capacitors every ten years".

Replacement Parts:

The following parts should be ordered through your local field sales office. They will be supplied on a no charge basis. The numbers called for are on a per relay basis.

The following parts should be ordered only if required:

(1) 184A614H05 Silicon Controlled Rectifier (1) 1584C21G01 Surge Protection Module (1) 188A349H01 Mounting Bracket (L.H.)

(1) 188A349H02 Mounting Bracket (R.H.)

(2) 877A498H03 Screw (2) 183A917H02 Lockwasher The following parts are required in all instances:

(1) 3520A39H01 Nameplate 4

(1) 408C673G01 Printed Circuit Module (3) 187A290H18 51 Ohm Fixed Composition Resistor (Type BTS - 1/2 Watt 5%)

(3) 187A290H21' 68 Ohm Fixed Composition Resistor (Type BTS - 1/2 Watt t 5%)

Mr. E. W. Rhoads October 25, 1983 Page 5 t

As noted in earlier correspondence, these modifications may also be accomplished by returning the relays to (W). Please make arrange-ments for this option through your local field sales office.

Please let me know if I can be of further assistance in this matter.

Yours very truly, fm 4 Warren J. Schmidt, Manager Quality Assurance WJS:vmy 1

ate (s) cc: G. F. Jackson, BBE, Chalfont D. A. Toboga, Philadelphia

J. N. Santilli, RID R. Lakin, "

T. Brandenburg, "

W. Glassburn, "

M. Barreto, "

R. Weber, "

Attachments:

(W) IL 41-348.11, Effective: July 1979; " Type SA-1 Generator Differential Relay for Class lE Applications".

i Addendum to (W) IL 41-348.11, Effective: June 1983 Pig. 1; Annotated Pig. 1. from IL 41-348.11 Fig. 2; Annotated Fig. 2. from IL 41-348.11 Pig. 3; Annotated Fig. 12. from IL 41-348.11 Pig. 4; Annotated Pig. 4. from Addendum to IL 41-348.11 l

Pig. 5; Installation of SWC Module r v e r-- , - - - , e-

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SUPPLEMENTARY INSTRUCTIONS - INSTALLATION OF SWC MODULE:

Background:

Addition of a style number 1584C21G01 Surge Suppression Module to a 48/125 Vdc Class lE SA-1 relay insures that it's surge withstand level will be in excess of ANSI C37.90- 1978. The following steps are followed in installation:

Installation:

1. Remove the printed circuit module at the front of the relay (see Pig. 1).

2. Remove the printed circuit module connector from it's mounting bracket, (see Pig. 1). Be careful not to break any of the electrical connections.

3. Remove the mounting brackets and replace with style numbers 188A349Il01 ( L . ll . ) and 1102 ( R . fl . ) .

4. Mount the Surge Suppression Module (SPK) style number 1584C21G01 to the bracket oriented as shown in Fig. 5. Fasten as illustrated.

5. Connect the leads from the Surge Suppression Module to the i appropriate points in the relay as indicated in Fig. 5. Note that the lead from point 4 on the printed circuit board must be soldered to the anode end of the tripping SCR. The following precautions must be observed:

5.1 Do not stress the anode or cathode leads of the SCR when connecting the lead from point 4 on the printed circuit board to the anode.

5.2 Do not overheat the SCR lead when resoldering. A heat sink applied to the SCR terminal during resoldering will help to assure that overheating does not occur.

6. Replace the printed circuit module connector.

7. Replace the printed circuit module.

8. Perform tests 1-4 described in the " Supplementary Instructions -

Test and Calibration".

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SUPPLEMENTARY INSTRUCTIONS - TEST AND CALIBRATION:

Background:

Replacement of the printed circuit module (see Fig. 1), will probably change the calibration of the relay. It is recommended however, that i the relay be tested first, before attempting to calibrate to determine if all modifications have been completed correctly.

The recommended test circuitry is shown in Fig. 3, Note (2) regarding the need for sinusoidal test currents is especially important.

The printed circuit module is delviered with three resistors R17, 18 and 19 (33 ohms, S/N 187A290H13, Fixed Composition Resistor - Type HTS, 1/2 watt 5%) soldered to standoffs. These resistors control the calibration of the percentage slope characteristic at a normal operating current of 30 amperes. These resistors can be changed over a range from 0 - 100 ohms, to bring the percentage slope characteristic into calibration.

Test:

The relay should be tested for correct operation and calibration by following the steps below: -

1. The relay is applicable to 48 or 125 Vdc trip circuits. The relay is shipped from the factory set for 125 Vdc operation.

If the relay is to be used in a 48 Vdc application, use the mid-tap on the resistor mounted at the top of the relay. The

red dot on the resistor is the common tap. The connection to this tap should not be moved.

2. Using the test circuit of Fig. 3, apply Step 2 de voltage to the relay. ISR and 10 should be zero. Check to see that the de voltage on the printed circuit module connector terminals (8 and 12) is between 22.8 and 25.2 Vdc (see Fig. 4). O

3. With ISR and Io at zero amperes, turn the de voltage ON and OFF at least five times. The WL switch should not pick up (the trip SCR should not false trip).

4. Perform the test for minimum trip current and differential characteristic given on page 4 of IL 41-348.11 (effective q July 1979) under the heading " Routine Test". Note that the addendum to IL 41-348.11 (effective June 1983) modifies the opening paragraph and 2.b.

If the relay passes the above test, no calibration is necessary and the relay may be placed in service.

Calibration:

The following information is intended to augment the information in the Calibration Section (page 4) of IL 41-348.11 and it's Addendum.

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5. Connect the relay as shown in Fig. 4. Note that the de trip '

circuit should not be energized during any of the calibration j steps below.

6. Minimum Trip Current: With IsR at zero amperes, raise Io until the trip indicator light (see Fig. 1) comes ON. If Io is not in the range between 136-144 milliamps, adjust the slide on the adjustable resistor "UT" (slide tap toward ,

front of relay to increase 10 at trip point) to bring 10 in i

range (see Fig. 2 for position of resistor "UT"). Percentage j

slope characteristic (low current).

7. Set IsR to 5 amperes; raise Io until the trip indicator light comes on. If Io is not in the range between 145-260 milliamps,

,i adjust the slide on the adjustable resistor "LT" to bring Io

) in range (moving the rear of the relay increases Io at trip).

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8 Repeat steps 6 and 7 for phases 2 and 3.

) 9. Percentage slope characteristic (high current) - Return to phase 1 and increase ISn to 60 amperes. Note: This current may only be applied to the relay for 1 - 2 seconds at a time...

, allow several minutes between applications for transformer to cool. With relay completely de-energized the restraint trans-former corresponding to the pahse being calibrated (see Fig. 2) should not be allowed to get too hot to touch.

' Raise Io to the point where the trip indicator light comes ON with both ISR and Io applied. If Io is not in the range between i 28 - 30 amperes, resistor R17 (phase 1) must be removed and replaced. Increasing R17 decreases the I current at which trip takes place. The parts called for in these instructions provide the following R17 resistance values:

0 ohms Jumper Customer Supplied l

! 33 ohms Style No. 187A190H13 Supplied with Module 51 ohms Style No. 187A2,90H18 Supplied Loose i 68 ohms Style No. 187A190H21 Supplied Loose.

If closer calibration is desired, use an appropriate fixed 1

composition resistor - Type BTS 1/2 watt

• 5% in the range between 0 and 100 ohms.

I If R17 must be changed, it is suggested that alternate values be tried using clip leads to insert in the circuit. When the desired calibration is attained the resistor may be soldered in permanently.

10. Repeat step 9 for phases 2 (R28) and 3 (R19).

11. Recheck and " touch-up" the minimum trip current (step 6) and the low current.and slop characteristic (step 7) as needed.

l The relay is now completely calibrated and may be placed in service.

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