ML20246P473

Forwards NRC Info Notice 89-045,Suppl 1, Metalclad,Low Voltage Power Circuit Breakers Refurbished W/Substandard Parts. No Action or Response Required

ML20246P473
Person / Time
Site:	07200001, 07001308
Issue date:	07/19/1989
From:	Roberts J NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS)
To:	Ingels T GENERAL ELECTRIC CO.
References
IEIN-89-045, IEIN-89-45, NUDOCS 8907200217
Download: ML20246P473 (1)

Text

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General Electric Company G. E. Morris Operation ATTN: 'T. E. Ingels Managa ,iberis Operation 7555 East Collins Road Morris, IL 60450-9740 Gentlemen:

The enclosed NRC Information Notice No. 89-45, Supplement 1: "Metalclad, Low-Voltage Power Circuit Breakers Refurbished With Substandard Parts" is provided for your information. No specific action or written response is required.

Sincerely, Original Signed by John P. Roberts -

John P. Roberts, Section taader Irradiated Fuel Section Fuel Cycle Safety. Branch

Enclosure:

As stated

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Distribution: N 03Y Docket 72-1 PDR NRC File Center ER/F '

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UNITED STATES NUCLEAR REGULATORY COMMISSION OFFICE OF NUCLEAR REACTOR REGULATION WASHINGTON, D.C. 20555 July 6, 1989 NRC INFORMATION NOTICE NO. 89-45, SUPPLEMENT 1: METALCLAD, LOW-VOLTAGE POWER CIRCUIT BREAKERS REFURBISHED WITH SUBSTANDARD PARTS Addressees:

All holders of operating licenses or construction permits for nuclear power reactors.

Purpose:

.This information notice supplement is being provided to present additional information regarding the supply of surplus or refurbished circuit breakers and related electrical equipment to nuclear power plants as discussed in NRC Information Notice No. 89-45. It is expected that recipients will review this information for applicability to their facilities and consider actions, as appropriate, to avoid similar problems. However, suggestions contained in this information notice do not constitute NRC requirements; therefore, no specific action or written response is required.

Description of Circumsta.. es:

NRC Information. Notice No. 89-45 discussed a General Electric (GE) type AKF-2-25 metalclad, low-voltage power circuit breaker (field discharge configu-ration) from the Quad Cities nuclear power plant found te ce refurbished with nonstandard and substandard parts.

In conducting followup inspections at utilities that have procured circuit i breakers of this type and other related electrical equipment from Satin Ameri-can Corporation, the NRC has l_ earned of the existence of other equipment from Satin American, refurbished with nonstandard and possibly substandard parts and fabrication methods, some of which may contain latent defects resulting from the introduction of nonstandard materials and components. These defects may not be readily detectable by means of normal inspection and testing, and the -

nature of the defects is such that they could render the equipment inoperable without warning.

Discussion:

l Recent information, received in the course of the NRC's review and inspections j of refurbished electrical equipment, indicates that GE EC-type, series i overcurrent trip devices (particularly EC-1 and EC-2A) commonly used in GE

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1 IN 89-45, Supplement 1 I July 6,1989 i Page 2 of 3 AK-type, low-voltage power circu.it breakers, and supplied by a vendor other than the original manufacturer, may have been represented as new or original

. equipment. Documentation such as " certificates of certification" stated that the trip devices were " duplicates" of " identical" equipment originally sup-plied, when in fact, they were refurbished. Many were fitted with irregular nameplates and nonstandard and substandard parts. The trip devices were supplied primarily during the period 1983 through 1987. These electro-mechanical devices are presently used in Class 1E DC electrical systems because the newer solid-state devices use current transformers as sensors which do not operate on DC. They are also used in safety-related AC_ electrical systems that may be exposed to the harsh radiation environments of design-basis accidents.

Solid state trip devices have limited capability to withstand the effects of accident radiation doses greater than 10,000 rads or to ~ unction properly under the conditions of high accident radiation dose rates.

Of particular concern is the fact that, ir addition to irregular nameplates and refurbishment nat in accordance with the manufacturer's specifications, some of the units could be considered potentially defective as a result of the use of nonstandard parts and questionable refurbishing methods. Specifically, I disassembly and detailed examination of trip units supplied to Nine Mile Point, Unit 1, by Satin American revealed that some trip units were modified, appar-ently to alter their trip characteristics, by (1) substituting series coils with nonstandard numbers of turns, (2) changing instantaneous trip springs and/or varying the numbe: of active spring turns and/or adjusting tension to ,

compensate, and (3) altering longtime trip characteristics by such practices as k' using nonstandard longtime trip calibration springs, apparently enlarging the 1 bleed orifices in the dashpot pistons and/or substituting piston; (the markings of some of which were found to be incorrect for the nameplate longtime trip I characteristic and current rating) or using other inan the original dashpots to obtain different time delays. Additionally, in some trip units examined, the samples of oil taken from the dashpots exhibited some variance from their expected color and odor, indicating that the mechanical modifications may have been. complemented by the use of nonstandard dashpot oils (of yet undetermined composition, viscosity, and compatibility) to aid in obtaining the desired longtime trip characteristics.

Aside from the issue of representation of refurbished equipment as original, such modifications constitute the introduction of potential latent defects into equipment, already of indeterminate quality, that would not be readily detected by normal field testing and inspection and which could result in oegraded trip unit performance, inability to be adjusted properly, or failure to operate entirely.

Attachment 1 identifies differences that have been observed between several characteristics of construction of refurbished series overcurrent trip devices as supplied by Satin American and original ones from GE. Some of these at-tributes, identified by an asterisk (*), can often be observed without removing an installed trip unit from its circuit breaker (although the breaker may have to be racked out) and the rest may be observed by removing only the trip unit cover. These attributes may be used to identify refurbished units, although they, in themselves, may not all represent defects.

1 IN 89-45, Supplement 1 July 6, 1989 Page 3 of 3 Attachment 2 tabulates differences between various attributes of irregular nameplates found on some refurbished series overcurrent trip devices supplied by Satin American and authentic ones from GE. These differences may also be used to identify refurbished units.

Addressees are cautioned that although the differences described in Attachments 1 and 2 may be used to identify refurbished units from one vendor, each charac-teristic should be considered, since not all refurbished units will exhibit all of the differences that have been identified. Therefore, the lack of some of the differences described, or variations on them, should not be considered sufficient evidence to conclude that a given trip unit has not been refurbished.

The NRC is particularly interested in obtaining information on circuit breakers and related electrical equipment supplied by Satin American or others in which -

l differences or deficiencies in IN 89-45 and this supplement. have been found that are similar to those described Of special interest is information on recent '

procurement. Documentation, in as much detail as practicable, of any such differences or deficiencies discovered, especially in cases in which a piece of equipment may have been improperly cerviced or refurbished, is important.

Licensees may communicate information of this type by telephone to one of the-technical contacts listed below.

No specific action or written respom e is required by this information notice supplement. If you have any questions about this matter, please contact one of the technical contacts listed below or the Regional Administrator of the appropriate regional office.

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Charles E. Rossi, Director Division of Operational Events Assessment Office of Nuclear Reactor Regulation Technical Contacts: S. D. Alexander, NRR (301) 492-0995 j i

U. Potapovs, NRR (301) 492-0984 l 1

Attachments:

1. Observed Differences in Original and Refurbished Trip Device Construction 2.

Observed Differences in Authentic and Irregular Trip Device Nameplates

3. List of Recently Issued NRC Information Notices I

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Attachment 1 l IN 89-45, Supplement 1 July 6, 1989 Page 1 of 1=

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$ OBSERVED DIFFERENCES IN ORIGINAL VICE CONSTRUCTION AND1

! This attachment identifies differences tnat have bee as supplied by Satin American and tributes, identified by an asterisk (*) .

original rrent trip devices- on Some of these at-to be racked out) and the rest may cover. be may e breaker observe have These attributes may be used to identify refurbishedremovin units.

COMPONENT

• 1. ORIGINAL GE Magnetic structure _ REFURBISHED pole piece laminations Fastened with

• 2. rivets Fastened with split pins' EC-2A ' dashpot fasteners (also called roll pins)

Riveted to frame

3. Longtime calibration Bolted to frame with nuts and machine screws spring (EC-2A) Half near adjusting thumbwheel is painted; Slightly larger diameter color corresp and not painted

4. rating range.onds to EC-2A instantaneous trip adjusting spring Usually 8 active turns and 1 inactive turn, > 9 active turns, painted

• 5. unpainted 1 includin Paint on magnetic nut or <g screw adjusting Flat black, even and 8 active turns structure and/or frame smooth Glossy, drips may be 6.

Dashpot lever arm shaft applied over r,ust rubber oil seal boots Secured with two wraps of copper wire, ends May still use old style

7. twisted since 1984 pinch / spring type " hose" Longtime trip dashpots clamps Caet aluminum alloy body Body may have been

• 8.

Square, flat cardboard unfinished sandblasted series coil insulators Usually bears handwrit-ten instantaneous trip Often shows no marking setting marking and the or is a used insulator,

• 9. tester's rubberstamp inverted so original EC-1 trip setting or marks are hidden calibration plates Factory set for long-time and short-time Replacement plates characteristics, stamped to work on bright aluminum, coarse refurbished unit, stamped characters matte finish, finer

• 10. Series coil: condition, stamped characters numtwr of turns, lug Uniform amber " varnish" type, and position insulation number of Discolored / darkened; may turns corre,ct for cur- appear recoated overhea-rent rating 1 ted; may have wr,ong lug pattern or number of turns Noteli Consuit' functional and technical construction documentation specificationserifand/or for btthe manu specific in do u .

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IN 89-45, Supplement 1 July 6, 1989 Page 1 of 1.

OBSERVED DIFFERENCES IN AUTHENTIC AND IRREGULAR TRIP DEV This attachment tabulates differences between various attributes of irregular nameplates found on some refurbished series overcurrent trip devices supplied by Satin American and authentic ones from GE.

observed without removing an installed trip unit from its circuit breakerThese attr (although the breaker may have to be racked out). These differences may be used in conjunction with Attachment 1 to identify refurbished units.

ATTRIBUTE AUTHENTIC GE IRREGULAR NAMEPLATE

1. Finish on EC-1 Bright brushed aluminum nameplates White anodized / matte-finished aluminum

2. Finish on EC-2A nameplates White anodized finish Similar finish, often lacquered but not lacquered

3. "INSPECTE0" block Unique, single-line stamps (made at GE Blank or stamp figure closed figure / shape l made by reorienting Plainville, CT factory (not used on new units and/or superimposing prior to about 1984) made after 1984 at GE one standard :, tamped Atlanta, GA factory) character on another

4. Shop or work order (

Letters "ATL " followed Not seen on refur-number (only on trip by unique five-digit bished trip units [

units made in GE Atlan- number usually stamped {

ta factory, 1984 on) with irregular in upper left corner 1 nameplates

5. Date code (should not Stamped, 2-ltr code on top Present on most appear.on plates with line between catalog "NO." EC-2As, missing on shop order number)1 and type designation, year many EC-1s examined, ltr different weight from year and month let-month letter. ters same weight

6. "NO." block (catalog 054900497G-1 printed on May be stamped onto part or drawing number) EC-2As of this design irregular nameplates

7. "NO." block "NO." corresponds to type Numbers may not ind unique "NP" (nameplate) correspond correctly namber for each design 1 or be valid at all

8. "NO." block "8"s in "NO." block on Plain figure "8"s EC-1s appear as: " 8' "

e.g., 2380685G-1 i

9. Frequency symbol "CY" Printed on EC-1s Stamped

10. Stamped characters Darkened with paint Darkened with grease

11. EC-1 trip setting Coarse stamped numbers Finer numbers, gradu-calibration plates ations closer spaced

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12. EC-2A type designation "EC-2A" printed "A" suffix stamped i 1

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Consult manufacturer for identification of valid date codes, catalog j numbers (and corresponding nameplate numbers), inspection stamps, and '

shop order numbers.

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Attachment 3 IN 89-45, Supplement 1 July 6, 1989-Page 1 of 1 LIST OF RECENTLY ISSUED NRC INFORMATION~ NOTICES Information Date of Notice No. Subject Issuance- Issued to 89-55 Degradation of Containment 6/30/89 All holders of OLs Isolation Capchility by a or cps for nuclear High-Energy Lina Bresk power reactors.

89-54 Potential Overpressurization 6/23/89 All holders of OLs of the Component Coo',ing or cps for nuclear Water System power reactors.

89-53 Rupture of Extraction 6/13/89 All holders of OLs Steam Li ,e on High or cps for nuclear Pressure Turbine power reactors.

88-46, Licensee Report of 6/8/89 All holders of OLs Supp. 3 Defective Refurbished or cps for nuclear Circuit Breakers power reactors.

89-52 Potential Fire Damper 6/8/89 All halders of OLs Operational Problems or cps for nuclear power reactore.

89-51 Potential Loss of Required 5/31/89 All holders of OLs Shutdown Margin During or cps for nuclear Refueling Operations power reactors.

88-88, Degradation of Westinghouse 5/31/89 All holders of OLs Supp. 1 ARD Relays or cps for nuclear power reactors.

89-50 Inadequate Emergency 5/30/89 All holders of OLs Diesel Generator Fuel or cps for nuclear Supply power reactors.

89-49 Failure to Close Service 5/22/89 All holders of OLs Water Cross-Connect or cps for nuclear Isolation Valves power reactors.

C0-48 Design Deficiency in the 5/22/89 All holders of OLs Turbine-Oriven Auxiliary or cps for nuclear Feedwater Pump Cooling power reactors.

Water System OL = Operating License CP = Construction Permit L___._________________.__--_-.--_