ML20197E594
| ML20197E594 | |
| Person / Time | |
|---|---|
| Issue date: | 04/25/1986 |
| From: | Merschoff E, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20197E518 | List: |
| References | |
| REF-QA-99901054 99901054-86-01, 99901054-86-1, NUDOCS 8605150286 | |
| Download: ML20197E594 (11) | |
Text
s ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
PARSIPPANY, NEW JERSEY REPORT INSPECTION INSPECTION NO.- 99901054/86-01 DATE: 3/17-18. 24 A 26/86 JN-SITE H0llRS: 20 CORRESPONDENCE ADDRESS: ASCO Electrical Products Company, Inc.
ATTN: Mr. Thomas H. Jensen President 7 Eastmans Road Parsippany, New Jersey 07054 ORGANIZATIONAL CONTACT: R. Schuff TFtCPWONE NUMACDi 701 M 0000 NUCLEAR INDUSTRY ACTIVITY: Replacement parts for equipment installed in nuclear power plants.
ASSIGNED INSPECTOR: ,
0/23/94 K. R. Naidu, Reactive Inspection Section (RIS) Date OTHER INSPECTOR (S):
/.PPROVED BY: . . 5 4 E. V. Merschoff, Ch ( RIS, Vendor Program Branch Date INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR 50 Appendix B and 10 CFR Part 21.
B. SCOPE: Review engineering specifications and quality assurance records relative to the electrical panels supplied to Limerick and Peach Bottom nuclear power plants; observe installed panels at Limerick and Peach Bottom nuclear power plants; review records of surveillance testing and corrective action relative to the failure of Reactor Protection System
/ DDd newne e ninnl u trin ci rctif t h en m ir a re ma ni n f a c t u rp ri by Lloctinnhnuto PLANT SITE APPLICABILITY: Limerick Unit 1(50-352); Peach Bottom Units 2 & 3 (50-277; 50-278).
8605150286 860513 pop GA999 EMV***** PDR 99901054
b ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
PARSIPPANY, NEW JERSEY REPORT INSPECTION NO.- 99901054/86-01 RESULTS: ) AGE 2 of 10 _
A. Violation:
Contrary to 10 CFR 21.21, ASCo Electrical Products ( AEP) had not developed and implemented a precedure to evaluate deviations or inform the licensee or purchaser of the deviation in order that the licensee or purchaser may evaluate the deviation. The Material Requisition (specification) required AEP to comply with 10 CFR Part 21.
B. Nonconformancej:
No nonconformances were identified.
C. Unresolved I' ems:
No unresolved items were identified.
D. Inspection Findings and Other Comments:
- 1. Review of Technical Requirements for RPS Transfer Panels AEP, previously known as B-K Manufacturing Company, manufactured the Da 1ctor Protection System (RPS) power supply transfer panels for toe Limerick and Peach Bottom nuclear power stations. The RPS transfer panels contain monitoring relays which sense overvoltage, undervoltage, and underfrequency conditions in the RPS power supply and disconnect the power supply to the RPS components. Peach Bottom and Limerick nuclear power stations reported several failures of the shunt trip coils, installed in the Westinghouse type molded case circuit breakers installed in the RPS panels. Activation of any one of the protective relays energizes the shunt trip coil and trips the circuit breaker to disconnect the abnormal RPS power supply.
The technical requirements for the RPS breaker panels for Limerick Units 1 and 2 nuclear power plants are contained in Material Requisition (MR) 8031-E 16 dated October 13, 1975 titled 'C distribution equipment. Bechtel Power Corporation (Bechtel),
the architect engineer for Limerick issued the MR and included the technical requirements for 125 volt DC power distribution panels and 125/250 volt fuse boxes. The MR and subsequent 18 revisions were stamped "Q" to identify the equipment classification as
" seismic" and QA designation as " Class 1." In Revision 4 dated April 21, 1977, Bechtel imposed 10 CFR Part 21 requirements on AEP.
Item 31 in Revision 18 of the MR dated January 7,1985, specified six RPS transfer panels intended for installation at Peach Bottom
i ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
PARSIPPANY, NEW JERSEY REPORT INSPECTION
_ NO.- 99901054/86-01 RESULTS: ) AGE 3 of 10 nuclear power plants Units 2 and 3. The installation of these panels are addressed in the Amendments No. 99 and 101 to the Facility Operating Licenses No. DPR-44 and DPR-56 for the Peach Bottom Units 2 and 3. These panels upgrade the existing design to monitor the electric power to RPS in BWRs.
The technical data for the undervoltage, overvoltage and under-frequency relays utilized to monitor the RPS power supply are specified on the schematic drawings. AEP submitted two Supplier Deviation Disposition Requests (SDDRs) 10 and 13, to Bechtel both dated October 21, 1982, requesting approval to use ITE undervoltage relay catalogue #211R6175 instead of the specified 21186175 and Buchanan type terminal blocks instead of the specified Marathon terminal blocks. Bechtel approved both SDDRs in their letter 137973 dated October 11, 1982.
- 2. Review of AEP Purchase Orders The inspector selectively reviewed the purchase orders issued by AEP for the procurement of relays and circuit breakers to determine whether AEP conveyed the technical and quality require-ments including the 10 CFR Part 21 reporting requirements to the subtier suppliers. The following purchase orders were reviewed:
- a. AEP (previously known as Biksun Manufacturing Cor.pany) issued purchase order 11128 dated June 15, 1983, to Westinghouse Electric Company, Hillside, New Jersey to supply four LBB 22250MW circuit breakers with 125 volt DC shunt trips, 2 Pole, 400 ampere, with magnetic overload (trip range 1125-2250). These breakers were for installation in Reactor Protection System (RPS) panels intended for the Limerick nuclear power plant.
- b. AEP issued purchase order 12796 dated March 18, 1983 to Westinghouse Electric Company, to supply 12 LBB 22250 MW circuit breakers with the same characteristics described above for installation in RPS panels intended for the Peach Bottom nuclear power plants.
Both the above purchase orders (P0s) requirbd that Westinghouse issue a Certificate of Compliance (CoC) certifying that the circuit breakers are qualified to IEEE 344 (seismic qualf fication).
1
t ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
PARSIPPANY, NEW JERSEY REPORT INSPECTION N0.- 99901054/86-01 RESULTS: PAGE 4 of 10 .
- c. AEP issued P0 13279 dated April 21, 1983 (Peach Bottom) to Brown Boveri for the purchase of undervoltage relays type ITE-27-D and overvoltage relays type ITE 59-D and required a CoC certifying that the relays are qualified to IEEE 344.
- d. AEP issued P0 11123 dated June 11, 1983 to General Electric (GE) company for the supply of underfrequency relays type 125FF 31 CIA and required a CoC certifying that the relays are qualified to IEEE 344.
- e. The inspector determined that AEP did not state in their purchase orders that the vendors are required to comply with 10 CFR Part 21 requirements. Review of AEP's QC manual, issued March,1974 and revised September,1983 indicates that the AEP does not have a procedure to implement the requirements of 10 CFR Part 21. The inspector informed AEP personnel that failure to develop a procedure to implement 10 CFR Part 21 requirements as required in Revision 4 of the MR was a violation of the NRC requirements as noted in Section A of this report.
- 3. Review of QA Records The inspector reviewed the quality assurance records relative to the components purchased by AEP, the final inspections performed at AEP and the seismic qualification report.
- a. CoCs were available from the following manufacturers:
(1) ITE type 27-D undervoltage relay manufactured by ;
Brown Boveri (2) ITE type 59-D overvoltage relay manufactured by Brown Boveri (3) GE type SFF31C underfrequency relay manufactured I by General Electric (4) AGASTAT type EGPDGLM time delay relay manufactured by AGASTAT (5) Circuit breaker type LBB 222250MW manufactured by Westinghouse with 125 DC shunt trip coil 2605Ds15G24 l
b ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
PARSIPPANY, NEW JERSEY REPORT INSPECTION NO.- 99901054/86-01 RESULTS: PAGE 5 of 10
- b. The documentation met the requirements of item 31j of the MR which states "The documentation requirements are stated in the attached form 8031-0 for class 1E equipment. Included are reouirements for documentation in accordance with IEEE 344-1975. Environmental / seismic documentation for components supplied by General Electric (GE) shall be provided by GE.
A non-proprietary version is acceptable."
Brown Boveri issue.1 a Certificate of Conformance specifying the serial numbers of the relays and that they were designed and tested for conformance to ANSI C 37.90 and C 37.90a. The CoC further stated that the relays were manufactured where a quality assurance program which complied with the requirements of 10 CFR 50 Appendix B, MIL-I-45208 and ANSI 45.2-1977 was in effect.
- c. Bechtel reviewed the tests performed by Wyle Laboratories to qualify the RPS panels and determined that the RPS panels would successfully withstand site specific acceleration.
During the installation of the panels at the Limerick site, it was determined that the mounting of the panels had to be modified. AEP sent the details of the revised mounting to Wyle Laboratories to ascertain whether the tests already performed would be valid for the revised configuration. Wyle Laboratories analyzed the revised configuration and informed AEP that it would meet the IEEE-344 qualification.
- d. AEP documented the typical inspections performed on an RPS panel in a Testing and Final Inspection Report. The following attributes were verified during the inspection:
(1) General: Physical arrangement, paint and overall i dimensions. !
(2) Mechanical Check: Operation of moving parts in .
circuit breakers and switches, alignment of removable I components ind fit of doors.
(3) Electrical Check: Correct size and spacing of busbars, correct size and type of cable, proper voltage rating of components, circuit continuity check and proper settings on all adjustable equipment. The attribute
" Actual operational check where applicable" was marked l "not applicable."
k ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
PARSIPPANY, NEW JERSEY REPORT INSPECTION NO.- 99901054/86-01 RESULTS: > AGE 6 of 10 (4) Insulation Check: Performed with a Hi-Pot instrument.
(5) Label Check: The ratings cn the labels of components, circuit identification and instruction name plates.
- 4. Review of the RPS Panels Installed at Limerick Unit 1 The inspector observed the installed the RPS panels supplied by AEP at the Limerick nuclear power plant, reviewed the records of surveil-lance tests performed to meet the relevant Technical Specifications, reviewed the failure of a Westinghouse breaker installed in the RPS panels and discussed with the licensee personnel the corrective actions taken. The results of the inspection are as follows:
- a. Observation of the RPS Panels Installation The RPS panels in Limerick Unit I have been mounted as per
. the relevant installation drawings. The as-installed configuration is representative of the analysis performed by Wyle Laboratories to confirm that the RPS panels will withstand a saismic event.
- b. Review of Test Records The RPS Panels were functionally tested prior to operation.
The settings of the overvoltage, undervoltage, and under-frequency relays were set to trip at the values prescribed in the relevant Technical Specifications (Tech Specs). The Tech Specs require a channel functional test be performed at least once every six months and that the operability of overvoltage, undervoltage and underfrequency protective relays be demon-strated every 18 months.
- c. Review of Circuit Breaker Failures in RPS Panels On November 9,1986, a half scram occurred when a short circuit occurred in the IB Reactor Protection System. This initiated the auto-transfer feature of the static transfer switch from the preferred DC power source to the alternate AC power source. The monitoring relays in the RPS panels sensed that the RPS voltage was 127 volts and tripped the circuit breakers. Subsequent multiple attempts to reclose the circuit breaker resulted in burning out the shunt trip coils. The AC voltage was decreased J
t ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
PARSIPPANY, NEW JERSEY REPORT INSPECTION NO.- 99901054/86-01 RESULTS: ) AGE 7 of 10 to 120 Vac, the feeder breakers were replaced and power was restored to the RPS from the alternate AC source. The short circuit condition in the static inverters wcs rectified and the power was transferred to the preferred DC source.
No further problems were identified at this station. However, similar failures of circuit breakers were reported at Peach Bottom and are discussed in Paragraph SC.
- 5. Review of the RPS Panels Installed at Peach Bottom Units 2 and 3 The inspector observed the installated RPS panels supplied by AEP at the Peach Bottom Unit 2 nuclear power plant, reviewed the records of surveillance tests performed to meet the relevant Technical Specifications (TS), reviewed the failures of Westinghouse breakers installed in the RPS panels and discussed with licensee personnel the corrective actions taken. The results of the inspection are as follows:
- a. Observation of the RPS Panel Installation The RPS panels in Peach Bottom Unit 2 have been mounted as per relevant installation drawings. The as-installed configuration is representative of the analyses performed by Wyle Laboratories to confirm that the RPS panels will successfully withstand a seismic event.
- b. Review of h st Records The RPS panels were functionally tested prior to installation in Units 2 and 3. The settings of the undervoltage, overvoltage and underfrequency relays are reflected in the Tech Specs and agree with the values specified in the Licensing Amendments No. 99 and 101, to the Facility Operating Licenses Nos. DPR-44 and DPR-56 for Peach Bottom nuclear power station Units 2 and 3.
The test values indicate that undervoltage, overvoltage and underfrequency relays have been adjusted to trip the circuit breaker at values indicated in the Tech Specs.
- c. Review of Circuit Breaker Failures in RPS Panels The Westinghouse molded case circuit breakers (breaker) type LBB 22250 MW installed in the RPS panels experienced failures i on two occasions during bench tests prior to installation in 1
(
b ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
PARSIPPANY, NEW JERSEY REPORT INSPECTION NO.- 99901054/86-01 RESULTS: 3 AGE 8 of 10 the plants. In both cases, replacement breakers were obtained from the Limerick station.
Subsequent to the installation of all RPS panels in Units 2 and 3, Modification Acceptance Tests were performed and the breakers installed in them performed satisfactorily. On January 16, 1986, the shunt trip coil of a breaker installed in one of the panels in Unit 3 smoked and failed. On January 24, 1986 the shunt trip coil in the circuit breaker in series with this circuit breaker was determined to be inoperative (open).
Both breakers were replaced. On February 5, 1986, a breaker installed in one of the RPS panels in Unit 2 failed to operate due to an open shunt coil. This breaker was replaced.
The inspector observed the internal mechanism of a disassembled failed RPS breaker, discussed the problems with field engineering personnel and determined the following:
The 2-pole molded case circuit breaker is equipped with an A contact that is operated by toggle operating links controlled by the breaker operating handle. The A contact is an' auxiliary switch which is open when the breaker is in the open or tripped position and is closed when the breaker is closed (on position).
This A contact is in series with the 125 volts-de shunt trip coil. When the breaker is closed, the auxiliary A contact is closed and the shunt trip coil is ready to receive a signal to trip the breaker if any one of the RPS power monitoring relays senses an abnomal voltage condition. The shunt trip cd 1 is not rated for continuous duty and will not withstand full voltage for more than a few seconds before failing.
The shunt trip coil can be made to fail, after the breaker has tripped by any one of the following actions:
(1) If the operating handle is pushed to the on position without resetting the breaker, with a trip signal present.
This will not close the breaker, but will close the A contact, thus energizing the shunt trip coil.
(2) Resetting the breaker and, before clearing the trip signal, attempting to close the breaker. Where the l operating handle is pushed to the on position, the main !
1 1
I
4 ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
PARSIPPANY, NEW JERSEY REPORT INSPECTION NO.- 99901054/36-01 RESULTS: PAGE 9 of 10 contacts will trip free, but, due to an interference between the metal operating handle and the toggle opera-ting links, the latter jams in the on position unless the operating handle is pushed toward the off or reset position.
Corrective Action Taken The Plant Operation Review Committee (PORC) reviewed the breaker failures and documented the following plan in a document dated February 5, 1986, as a temporary solution until the cause and the corrective action is determined.
(1) Install a sign at the breaker panels which informs the operator not to attempt to reclose the breaker if the trip light is on.
(2) Inform the shift that the breakers should not be closed if the associated M/G set or alternate feed trouble alarm is annunciated.
(3) Inform the shift to immddiately open the control room feed switch and the associated M/G set or alternate feed alarm annunciated and to preclude its use until the trip condition has been cleared.
(4) Prior to startup, check the operability of the trip lights.
(5) Prior to startup, check the continuity of each of the shunt trip coils and institute a weekly check of these devices.
(6) Institute a monthly functional test to verify operation of the shunt trip coil / breaker pending manufacturer's recommendations on coil operations. This requirement was revised on February 20, 1986, because it would cause undue risk to the plant. When the breakers are tested, the RPS MG set or Alternate Feed must be removed from service in order to test the breaker. l To accomplish this, the operator must manually ;
transfer the power supply to the RPS logic by '
operating a switch in the control room. This actuation produces a half scram on the affected RPS channel, a Group II and Group III half isolation,
's ORGANIZATION: ASCO ELECTRICAL PRODUCTS COMPANY, INC.
. PARSIPPANY, NEW JERSEY REPORT INSPECTION NO.- 99901054/86-01 RESULTS: PAGE 10 of 10 and closes half of the isolation valves. It will also isolate ventilation and disrupt the AC power to half of the MSIV solenoids. The PORV recommended to continue the weekly monitoring of the coil continuity and not perform the monthly functional test.
E. Persons Contacted:
ASCo Electrical Products T. H. Jensen, President R. F. Schuff, Director of Engineering J. F. Fuentes, Quality Control Supervision All of the above individuals attended the exit interview on March 18, 1986.
Limerick Nuclear Power Station C. Endriss, Licensing Engineer G. Edwards, Electrical Engineer J. Corcoran, QA Manager C. Harmon, QA Engineer J. J. Milito, Electrical Engineer Peach Bottom Nuclear Power Station J. L. Clupp, I&C Engineer A. Fulvio, Technical Engineer C. Rojers, Field Engineer C. Patton, Field Engineer 1
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