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Information Notice No. 89-45, Supplement 1: Metalclad, Low-Voltage Power Circuit Breakers Refurbished with Substandard Parts
UNITED STATES NUCLEAR REGULATORY COMMISSION OFFICE OF NUCLEAR REACTOR REGULATION WASHINGTON, D.C. 20555 July 6, 1989 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 Circumstances: 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 to be refurbished with nonstandard and substandard parts. In conducting followup inspections at utilities that have procured circuit breakers of this type and other related electrical equipment from Satin Ameri- can Corporation, the NRC has learned 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: Recent information, received in the course of the NRC's review and inspections of refurbished electrical equipment, indicates that GE EC-type, series overcurrent trip devices (particularly EC-1 and EC-2A) commonly used in GE 8907060183 . IN 89-45, Supplement 1 July 6, 1989 Page 2 of 3 AK-type, low-voltage power circuit 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 trans-formers 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 function properly under the conditions of high accident radiation dose rates. Of particular concern is the fact that, in addition to irregular nameplates and refurbishments not 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, disassembly and detailed examination of trip units supplied to Nine Mile Point, Unit 1, by Satin American revealed that some trip units were modified, apparently to alter their trip characteristics, by (1) substituting series coils with nonstandard numbers of turns, (2) changing instantaneous trip springs and/or varying the number of active spring turns and/or adjusting tension to compensate, and (3) altering longtime trip characteristics by such practices as using nonstandard longtime trip calibration springs, apparently enlarging the bleed orifices in the dashpot pistons and/or substituting pistons (the markings of some of which were found to be incorrect for the nameplate longtime trip characteristic and current rating) or using other than 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 degraded 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. . 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 characteristic 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 differences or deficiencies have been found that are similar to those described in IN 89-45 and this supplement. Of special interest is information on recent procurements. 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 serviced 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 response 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. Charles E. Rossi, Director Division of Operational Events Assessment Office of Nuclear Reactor Regulation Technical Contacts: S. D. Alexander, NRR (301) 492-0995 U. Potapovs, NRR (301) 492-0984 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 . Attachment 1 IN 89-45, Supplement 1 July 6, 1989 Page 1 of 1 OBSERVED DIFFERENCES IN ORIGINAL AND REFURBISHED TRIP DEVICE CONSTRUCTION This attachment 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. COMPONENT ORIGINAL GE REFURBISHED *1. Magnetic structure Fastened with Fastened with split pole-piece laminations rivets pins (also called roll-pins) *2. EC-2A dashpot fasteners Riveted to frame Bolted to frame with nuts and machine screws 3. Longtime calibration Half near adjusting Slightly larger spring (EC-2A) thumbwheel is painted; diameter and not color corresponds to painted rating range. 4. EC-2A instantaneous Usually 8 active turns > 9 active turns, trip adjusting spring and 1 inactive turn, painted including screw unpainted (1) adjusting nut or < 8 active turns *5. Paint on magnetic Flat black, even and Glossy, drips, may be structure and/or frame smooth applied over rust 6. Dashpot lever arm shaft Secured with two wraps May still use old style rubber oil seal boots of copper wire, ends pinch/spring type twisted since 1984 "hose" clamps 7. Longtime trip dashpots Cast aluminum alloy Body may have been body - unfinished sandblasted *8. Square, flat cardboard Usually bears handwrit- Often shows no marking series coil insulators ten instantaneous trip or is a used insulator, setting marking and the inverted so original tester's rubberstamp marks are hidden *9. EC-1 trip setting or Factory set for long- Replacement plates calibration plates time and short-time stamped to work on characteristics, refurbished unit, bright aluminum, coarse matte finish, finer stamped characters stamped characters *10. Series coil: condition, Uniform amber "varnish" Discolored/darkened; number of turns, lug insulation, number of may appear recoated, type, and position turns correct for cur- overheated; may have rent rating wrong lug pattern or number of turns ________________ Note 1: Consult technical documentation and/or the manufacturer for specific functional and construction specifications if in doubt. . Attachment 2 IN 89-45, Supplement 1 July 6, 1989 Page 1 of 1 OBSERVED DIFFERENCES IN AUTHENTIC AND IRREGULAR TRIP DEVICE NAMEPLATES 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. These attributes can usually be observed without removing an installed trip unit from its circuit breaker (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 White anodized/matte- nameplates finished aluminum 2. Finish on EC-2A White anodized finish Similar finish, nameplates often lacquered but not lacquered 3. "INSPECTED" block Unique, single-line Blank or stamp figure stamps (made at GE closed figure/shape(1) 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 stamped 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 with irregular ta factory, 1984 on) in upper left corner(1) nameplates 5. Date code (should not Stamped, 2-ltr code on Present on most EC-2As, appear on plates with top line between catalog missing on many EC-1s shop order number)(1) "NO." and type desig- examined, year and nation, year ltr month letters same different weight from weight month letter 6. "NO." block (catalog 0549D0497G-1 printed on May be stamped onto part or drawing number) EC-2As of this design irregular nameplates 7. "NO." block "NO." corresponds to Numbers may not type and unique "NP" correspond correctly (nameplate) number for or be valid at all each design(1) 8. "NO." block "8"s in "NO." block on Plain figure "8"s EC-1s appear as: "8 " e.g., 238D685G-1 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 12.EC-2A type designation "EC-2A" printed "A" suffix stamped ________________ Note 1: Consult manufacturer for identification of valid date codes, catalog numbers (and corresponding nameplate numbers), inspection stamps, and shop order numbers. . 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 Capability by a or CPs for nuclear High-Energy Line Break power reactors. 89-54 Potential Overpressurization 6/23/89 All holders of OLs of the Component Cooling or CPs for nuclear Water System power reactors. 89-53 Rupture of Extraction 6/13/89 All holders of OLs Steam Line 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 holders of OLs Operational Problems or CPs for nuclear power reactors. 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. 89-48 Design Deficiency in the 5/22/89 All holders of OLs Turbine-Driven Auxiliary or CPs for nuclear Feedwater Pump Cooling power reactors. Water System _____________________________________________________________________________ OL = Operating License CP = Construction Permit ..
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