United States Nuclear Regulatory Commission - Protecting People and the Environment

General Information or Other Event Number: 38919
REP ORG: ABB, INC. NOTIFICATION DATE: 05/14/2002
LICENSEE: ABB, INC. NOTIFICATION TIME: 08:05 [EDT]
CITY: FLORENCE REGION: 2 EVENT DATE: 05/14/2002
COUNTY: STATE: SC EVENT TIME: [EST]
LICENSE#: AGREEMENT: Y LAST UPDATE DATE: 05/14/2002|
DOCKET: PERSON ORGANIZATION
DANIEL HOLODY R1
ROBERT HAAG R2
RONALD GARDNER R3
   
   
NRC NOTIFIED BY: PATRICK O'NEAL (fax) DAVE LOVELESS R4
HQ OPS OFFICER: LEIGH TROCINE VERN HODGE NRR
EMERGENCY CLASS: NON EMERGENCY
10 CFR SECTION:
CCCC 21.21 UNSPECIFIED PARAGRAPH

EVENT TEXT

NOTIFICATION OF A POTENTIAL DEFECT REGARDING K-LINE MECHANISM FAILURES TO CHARGE AND CLOSE

The following text is a portion of a facsimile received from ABB, Inc.:

"In August of 2001, Southern California Edison, San Onofre Nuclear Generating Station, reported and submitted an operating mechanism for evaluation to the ABB, Inc., Florence, SC Breaker Manufacturing Facility due to suspected shipping damage causing 'failure to charge' symptoms. The mechanism was a special configuration of the base 709774 Model '05' mechanism manufactured in 1011997. This mechanism was in a Nuclear Safety-Related application. The mechanism was received by the factory in September of 2001, and the reported failure mode was not duplicated in Florence. However, under the auspices of a 'refurbishment,' ABB, Inc., personnel performed an evaluation of critical characteristics for parts that could be contributory to the failure mode described herein."

"On 7 February 2002, Ameren - Union Electric's Sioux Generating Plant reported a failure to charge and close of a Model '05' K-Line K-600S circuit breaker (Serial Number 935461B--010496) manufactured 04/96. This breaker was purchased for a Non-1E application. The cause of the breaker failure was determined to be a culmination of energy utilization deficits.

Specifically, the condition of lubricant (Anderol 757), the surface and finish of parts critical to the charging operation, and the interaction of critical latching surfaces serve to impede the ability of the mechanism to fully charge through the end of the charge cycle."

"In March 2002, Dominion Virginia Power's Surry Nuclear Station reported the failure to charge and close of a 1993 K-800M (Serial Number 865613B033--010793). In this case the breaker was refurbished in the hopes of alleviating the symptoms, only to find they returned a short time after return to service. ABB, Inc., had already initiated Part 21 reporting proceedings as this latest failure was announced, and the Florence Breaker Manufacturing Facility is awaiting a customer report to verify the failure mode."

"In all cases, the end user is observing a failure to charge and/or close in electrically operated mechanisms. These failures are due to one of the following two scenarios:"

"1. A failure to charge and close, either mechanically or electrically, until the needed energy is supplied to rotate the charging cam over the center-point into a fully charged position -- either by mechanical vibration or operator rotation of the charging cam." |

"2. A failure to close where the above scenario does not exist but the fully charged mechanism does not close due to the fact that the primary close latch does not fully clear in response the secondary close latch actuation."

"With the introduction of the Model '07' mechanism in December 1998, while maintaining backward compatibility with pre-existing models, ABB has facilitated improvements to be incorporated into every mechanism that is built at the Florence Breaker Manufacturing Facility. ABB recognizes that this failure mode may exist in any K-Line circuit breaker manufactured or having undergone mechanism repair, refurbishment, or replacement between January 1, 1988 and December 31, 1998 and, therefore, recommends that utilities address this issue at the next available maintenance interval. This includes any 'spare' K-Line mechanisms manufactured during the afore determined time frame that may be in stock."

"Three equally viable options are available to rectify this situation. They are, listed in order of ABB preference, most desirable first:"

"1. Replacement of suspect K-Line operating mechanism (ABB part number 709774T##) with a Model '07' mechanism (ABB part number 7l6785T##). This option will require the purchase of an Engineering Qualification Report Addendum so that 1E dedication traceability is maintained."

"2. Upgrade of suspect K-Line operating mechanism to a Model '07' mechanism utilizing one of ABB upgrade kits, numbers 716659T03 through T10. This option will require the purchase of an Engineering Qualification Report Addendum so that 1E dedication traceability is maintained."

"3. Improvement of suspect K-Line operating mechanism within the original model class utilizing ABB repair kit number 716659T01 or T02."

"Work required by the options listed above should only be performed by personnel trained and/or authorized by ABB, Inc. ABB is available to perform the work in the Florence, South Carolina, factory or perform in-factory training if non-ABB personnel are to be used or contracted."

"Note: If work associated with options 2 or 3 above is performed by personnel outside of the Florence, SC factory, one minor configuration change must be noted. During mechanism re-assembly, technicians must relocate the washer (ABB part number 650351A57) from its original location on the control device side on the Primary Close Latch Pivot Pin (ABS part number 702883D00) to the charging motor side."

"ABB [plans to] notify all Nuclear Utility Companies."

Call the NRC operations officer for ABB, Inc., contact information.

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