Part 21 Report - 1996-552

 
 
ACCESSION #:  9611150001

RG AND E

ROCHESTER GAS AND ELECTRIC CORPORATION o 89 EAST AVENUE, ROCHESTER,
N. Y.
14649-0001 AREA CODE 716546-2700

ROBERT C.  MECREDY
Vice President
Nuclear Operations

                                             November 6, 1996

U.S.  Nuclear Regulatory Commission
Document Control Desk
Attn: Guy S.  Vissing
      Project Directorate I-1
Washington, D.C.  20555

Subject:  10 CFR Part 21 30 Day Report
          R.E.  Ginna Nuclear Power Plant
          Docket No.  50-244

Dear Mr. Vissing:

In accordance with 10 CFR Part 21, Reporting of Defects and
Noncompliance, Section 21 (d) (3) (ii), which requires "Written
notification to the NRC ...  on the identification of a defect or failure
to comply", the attached 10 CFR 21 report is hereby submitted.

                              Very truly yours,

                              Robert C.  Mecredy

xc:  Mr.  Guy S.  Vissing (Mail Stop 14C7)
     Project Directorate I-1
     Washington, D.C.  20555

     Regional Administrator
     U.S.  Nuclear Regulatory Commission
     Region I
     475 Allendale Road
     King of Prussia, PA 19406

     Ginna Senior Resident Inspector

                                                                   Page 2
                      10CFR21 30 DAY WRITTEN REPORT

I.        NAME AND ADDRESS OF THE INDIVIDUAL INFORMING THE COMMISSION:

               NAME:     Robert C.  Mecredy
                         Vice President Nuclear Operations

               ADDRESS:  Rochester Gas & Electric Corporation
                         89 East Avenue
                         Rochester, New York 14649

II.       IDENTIFICATION OF THE FACILITY, THE ACTIVITY, OR THE BASIC
          COMPONENT SUPPLIED FOR SUCH FACILITY WHICH FAILS TO COMPLY OR
          CONTAINS A DEFECT:

          The facility is the R.E.  Ginna Nuclear Power Plant.  The basic
          component is a 350 HP, 1800 RPM, 460 VAC, 3 phase, 5006P Frame,
          1.15 SF, vertical hollow shaft motor for use as a Service Water
          (SW) pump motor.  This component was installed at the R.E.
          Ginna Nuclear Power Plant to upgrade the motor for the "A" SW
          pump from a 300 HP to a 350 HP motor.  (The "A" SW pump was
          never declared operable with this defective motor installed.)

III.      IDENTIFICATION OF THE FIRM CONSTRUCTING THE FACILITY OR
          SUPPLYING THE BASIC COMPONENT WHICH FAILS TO COMPLY OR
CONTAINS
          A DEFECT:

          The motor was a commercial-grade motor manufactured by:

               U.S.  Electrical Motors
               Division of Emerson Electric Co.
               8100 W.  Florissant Ave.
               PO Box 3946
               St.  Louis, MO 63136

          The motor was procured from:

               Auburn Armature, Inc.
               48 Canoga St.
               Auburn, NY 13021

          Note: This motor was purchased commercial-grade, was
          commercially-dedicated by Rochester Gas & Electric, and
          satisfied all testing requirements included in the procurement
          documents.

                                                                   Page 3

IV.       NATURE OF THE DEFECT OR FAILURE TO COMPLY AND THE SAFETY
HAZARD
          WHICH IS CREATED OR COULD BE CREATED BY SUCH DEFECT OR FAILURE
          TO COMPLY:

          A 350 HP motor was installed on the "A" SW pump in July, 1996.
          Post-modification functional testing revealed unacceptable
          megger readings.  The motor was removed from the "A" SW pump,
          disassembled and inspected.  The inspection revealed
          degradation of motor insulation integrity due to damaged motor
          leads, which could result in the failure of the motor in
          service.  The overall quality of the motor was below that
          normally expected for a commercial grade motor.

          The safety hazard which could be created by such a defect is
          the complete loss of Service Water.  In the scenario of the "C"
          SW pump out of service and a concurrent loss of power to Bus 17
          (which supplies power to the "B" and "D" SW pumps), a loss of
          all SW would occur if the "A" SW pump failed to operate due to
          the identified defect.

V.        THE DATE ON WHICH THE INFORMATION OF SUCH DEFECT OR FAILURE TO
          COMPLY WAS OBTAINED:

          The information was obtained on August 5, 1996.

VI.       IN THE CASE OF A BASIC COMPONENT WHICH CONTAINS A DEFECT OR
          FAILS TO COMPLY, THE NUMBER AND LOCATION OF ALL SUCH
COMPONENTS
          IN USE AT, SUPPLIED FOR, OR BEING SUPPLIED FOR GINNA STATION:

          There are four (4) SW pumps located in the Screenhouse Building
          at Ginna Station.

          A 350 HP motor had previously been procured separately.  This
          motor was installed to upgrade the existing 300 HP motor on the
          "D" SW pump in August, 1995.  This 350 motor is of similar
          design to the 3 motors discussed below, and was also
          manufactured by U.S.  Electrical Motors.  This motor was tested
          satisfactorily and placed in service in August, 1995, and
          operated trouble-free.  As discussed below, this motor did not
          contain a defect.

          Three (3) 350 HP motors, manufactured by U.S.  Electrical
          Motors, were purchased at a later date (as a group) for upgrade
          of the existing 300 HP motors on the "A", "B", and "C" SW
          pumps.  As discussed below, two of these three motors were
          discovered to be defective.

                                                                   Page 4

VII.      THE CORRECTIVE ACTION WHICH HAS BEEN, IS BEING, OR WILL BE
          TAKEN; THE NAME OF THE INDIVIDUAL OR ORGANIZATION RESPONSIBLE
          FOR THE ACTION; AND THE LENGTH OF TIME THAT HAS BEEN OR WILL BE
          TAKEN TO COMPLETE THE ACTION:

          The following corrective actions have been completed:

          1.   Ginna Station Maintenance personnel removed the defective
               350 HP motor from the "A" SW pump, and shipped this motor
               and one uninstalled 350 HP motor to an Appendix B motor
               facility.  These two motors both exhibited degradation of
               motor insulation integrity.  The motors were tested,
               inspected, and confirmed to be defective.  They were
               refurbished by the motor facility, and returned to Ginna
               Station.

          2.   The "A" SW pump remained inoperable until one of the above
               refurbished motors was reinstalled and satisfactorily
               tested in August, 1996.

          3.   The similar 350 HP motor, installed on the "D" SW pump in
               August, 1995, had shown no signs of motor degradation.
               However, this motor was removed from the "D" SW pump in
               October, 1996, and was replaced by the other refurbished
               spare motor.

          4.   Thus, corrective action was completed for these two
               defective motors in August, 1996, and these two
               refurbished motors were subsequently installed on the "A"
               and "D" SW pumps, and have fulfilled operability test
               requirements.

          5.   Electrical testing on the other two 350 HP motors did not
               indicate any degradation of the motor insulation
               integrity.  Nevertheless, as a conservative measure, they
               were shipped to an Appendix B motor facility in October,
               1996, for diagnostics and troubleshooting.

          6.   These remaining two 350 HP motors have been disassembled,
               inspected, and tested at an Appendix B motor facility.
               Electrical testing, performed at the motor facility,
               achieved satisfactory performance results, confirming that
               the motor (previously installed on the "D" SW pump) was
               operable while in service.  However, some minor deficient
               conditions were noted on both motors.  These motors were
               also refurbished.  These refurbishments are considered to
               be conservative corrective measures which involved motor
               rereading, insulation redip and bearing rework.

          The following corrective actions are scheduled for completion
          by March, 1997:

          1.   Safety-related motor Commercial Grade Item Engineering
               Evaluations (CGIEE's) will be revised to enhance steps for
               the examination of windings and overall workmanship to
               ensure motors are constructed with acceptable quality.

          2.   CGIEE preparation guidelines will be enhanced to
               incorporate the lessons learned from these defective
               motors.

                                                                   Page 5

VIII.     ANY ADVICE RELATED TO THE DEFECT OR FAILURE TO COMPLY ABOUT
          THE FACILITY, ACTIVITY, OR BASIC COMPONENT THAT HAS BEEN, IS
          BEING, OR WILL BE GIVEN TO PURCHASERS OR LICENSEES:

          1.   Source surveillance during motor assembly may have
               detected this defect.

          2.   A detailed physical inspection (or disassembly) upon
               receipt may have detected this defect.

          3.   Completion of commercial dedication could be dependent
               upon satisfactory completion of post-modification
               functional testing.

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