Isolated Phase Bus Duct Hot Spot CAP060701 / CE006754 10/29/08 Problem Statement: B phase of the isolated phase

bus has a hot spot which was identified via thermography techniques (see attached Figure #1). The hot spot exists at the connection between the isolated phase bus and the generator bushing box. Attempts to resolve the hot spot in RFO19 and RFO20 were unsuccessful.

Isolated Phase Bus Duct Hot Spot History: During thermography in January 2004, a hot spot was found on the isolated phase bus duct (see attached Figure #1). Originally it was determined that gasket material cracking between the isolated phase bus and generator bushing box caused abnormal eddy current to flow. This theory was supported by visual indication of gasket material cracking and an evaluation of the isolated phase bus design as shown on the plant drawings. Per the drawings, the generator bushing box and isolated phase bus were electrically isolated from each other. WO A67774 was worked during RFO19. When the generator bushing boxes were opened, it was discovered the plant drawings were in error and the generator bushing boxes were actually electrically connected to the isolated phase bus. Paint surrounding the connection bolts had been cleaned away, apparently during original construction, and an oxidation retardant had been applied (see attached Figure #2). This arrangement is similar to that shown in isolated phase bus vender manual GEI-72694C (figures 8A and 8C). Per the vender manual, the generator bushing boxes and the isolated phase bus are part of one circuit and are insulated from the main generator casing. Drawing E005-018 was revised to reflect this arrangement via DDC4803. The generator bushing box interior components were inspected and there were no indications of overheating on the isolated phase bus conductor. The generator bushing box connection bolts were removed and inspected. Several bolts from the B bushing box were noticeably darkened as compared to bolts taken from bushing boxes that did not have high temperatures identified (see attached Figure #3). The bushing box to isolated phase bus connections were disassembled, cleaned, replaced and torqued per manufacturers directions. Post RFO19 temperatures were taken prior to power ascension to 1840 MWth by system engineering using a portable infrared thermometer. This method of temperature detection indicated a slight decrease in the hot spot temperature to about 220 F. However, thermography taken after power uprate indicated temperatures were at about 240 F (Note: the portable infrared thermometer is not as accurate as thermography). Thus, post RFO19 thermography data indicated that the hot spot was still an issue. As isolated phase bus currents increase, hot spot temperatures may also increase. While power uprate has increased the current flow in the isolated phase bus closer

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Isolated Phase Bus Duct Hot Spot CAP060701 / CE006754 10/29/08 to the 18,000 ampere rating, there has been no significant increase in the hot spot temperature at full power since 2004 (Note: full power has increased from 1790 MWth to 1880 MWth during this time period). Based upon the internal inspection of the main generator bushing box and the interior components and the current thermography results, the hot spot is clearly due to the connection between the bushing box and the isolated phase bus. Based upon this theory it was determined that the high resistance connection needed to be disassembled and re-cleaned in RFO20. The conduction path which connects the isolated phase bus duct to the bushing box consists of the following connection points: isolated phase bus duct, non conducting gasket, 2 washers, bolt and generator bushing box. During RFO19 the bolt, washers and connecting surface of the generator bushing box were cleaned. It is unclear whether the inner threads in the isolated phase bus duct mini-flux plate were cleaned. In RFO20 all three generator bushings were replaced, which required that the bushing boxes be removed. As part of that work the connection points including the inner threads were cleaned. Once again upon startup, thermography was taken and the hot spot remained. Design Inputs The isolated phase bus connects the output of the generator to the main and aux transformers. The power uprate projects associated with DAEC have increased plant capacity and therefore the current flow through the bus in steps over the last several cycles. The increased losses associated with the higher current flow through the bus may be a significant contributor to the local hot spot associated with the center generator bushing box and isolated phase bus connection. The original bus was designed based upon the magnitude and distribution of losses in order to keep temperature rises of the bus components within limits specified in ANSI/IEEE C37.23. Additionally, proper sizing of forced cooling equipment was based upon these losses. Power loss in the isolated phase bus occurs in both the conductor and in the enclosure or ducting itself. Power loss in the enclosure (Pe) occurs when currents flowing in the main conductors induce voltages in the enclosures. The voltages cause currents to flow in patterns dependant upon how the enclosures are interconnected. From ANSI/IEEE C37.23, current flows in the enclosures produce heat losses which may be expressed in the form: Pe = KI2R, where I is the line current in the main conductor K is a loss factor for the particular enclosure and
arrangement

R is the ac resistance of the particular enclosure corrected

to the operating temperature of the enclosure

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Isolated Phase Bus Duct Hot Spot CAP060701 / CE006754 10/29/08 The losses are calculated at the assumed operating temperature of the enclosure or at the maximum temperatures specified by ANSI/IEEE C37.23. These maximum temperatures are 80 C (176 F) in accessible areas or 110 C (230 F) in inaccessible areas. The interpretation is that the effects of local hot spots due to current crowding and deviations due to normal ventilation and external heat sources and heat sinks are limited to 110 C (230 F). And that areas where the temperature of the enclosure temperature is due to induced current flows and are unaffected by the previous issues, the temperature limit is 80 C (176 F). At the present time there are two areas on the isolated phase bus that are at or approaching ANSI/IEEE C37.23 limits. They are the connection to the center (B) generator bushing box and the isolated phase bus diaphragms located near the bushing box. Conclusion Due to power uprate the isolated phase bus is being operated at >95% of its 18,000 ampere rating. The bus is designed such that at the design rating the bus temperatures will be less than or equal to the temperatures specified by ANSI/IEEE C37.23 (80 C (176 F) in accessible areas or 110 C (230 F) in inaccessible areas). Apparently the center bushing box connection to the isolated phase bus, whose temperature is at or slightly above this temperature limit at >95% rated current flow, is one of the system configuration details that limit the bus to 18,000 amperes. It is reasonable to assume that all three phases of the isolated phase bus ducts are conducting similar current flows. Apparently, due to the location of the center bushing box, the magnetic flux from the outer two bushing boxes is distorting the center box flux. This distortion is forcing more current flow in the bolts on the top and bottom of the bushing box. The concentration of current in these areas is likely the cause of higher temperatures.

Evaluation: The isolated phase bus is being upgraded from an 18,000 ampere rating to a 20,000 ampere rating via ECP1858 as part of power uprate. The known hot spots (i.e., diaphragms, mini-flux plate to generator bushing box connection) need to be addressed under the ECP. Under ECP1858, replacement of the diaphragms (if warranted) and/or installation of jumpers will resolve the diaphragm hot spots. Additional inspections may occur during RFO21, if warranted, to identify potential future actions.

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Isolated Phase Bus Duct Hot Spot CAP060701 / CE006754 10/29/08 Efforts to restore a low resistance electrical connection between the isolated phase bus and generator bushing boxes (i.e., the original design and installation) during RFO19 and RFO20 have not reduced the hot spot temperatures at full power. Additional thermography of the isolated phase bus in the Turbine Building was performed on 10/22/08; including the top side of the hot spot joint, along the length of each isolated phase bus and up along the generator bushing connection. This additional data confirmed that both the bottom and top portions of the B phase isolated phase bus to generator bushing box connection were hot spots. Potential solutions being considered were based on the following general design principles: Maintain the original design that this is an electrically connected joint. Options to maintain the original design and lower the resistance (to reduce heating) could include the installation of jumpers. This would be similar to the successful resolution of diaphragm (expansion bellows) hot spots by other plants. Modify the design such that this will be an electrically isolated joint, similar to the interface between the isolated phase bus and the main transformer. Options to create an electrically isolated joint could include hardware and configuration as shown in the vendor manual (GEI-72694, figure 8C, enlarged view D). Maintaining the original design intent and installing jumpers to lower resistance would be similar to other plants resolution of diaphragm hot spots. However, the isolated phase bus duct to generator bushing box hot spot appears to be different because the current flow is not uniform around the joint (i.e., majority of current is passed through the top and bottom portions). Additionally, the current source is not clearly defined by design. Inquiries to several vendors were made to solicit input on the use of jumpers for resolution of this hot spot. Independent feedback from two vendors, including the OEM, indicated that this hot spot is due to the old GE isolated phase bus duct design (i.e., the electrically connected joint) and the installation of jumpers will not solve the hot spot issue. Both vendors recommended that the isolated phase bus duct be electrically isolated from the generator bushing boxes, and also ensure that each generator bushing box is independently grounded to station ground (i.e., preclude potential for circulating currents). Modifying this joint to be electrically isolated is the recommended course of action based on independent feedback from two vendors and no significant change in hot spot temperatures following maintenance to reduce electrical resistance of the joint.

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Isolated Phase Bus Duct Hot Spot CAP060701 / CE006754 10/29/08 Industry Operating Experience: The following industry operating experience is included in CE002883: OE16933 Degraded Isophase Bus Duct Expansion Joint 07/28/2003, Perry 1 Routine thermography survey of the isophase bus ducts revealed degradation of the expansion joints. Cracks were found in the outer layer of the expansion joint. The supports adjacent to the expansion joint had uneven settlement. DESCRIPTION During a routine thermography survey of the isophase bus ducts, a thermal anomaly was observed on the C phase isophase bus duct expansion joint just outside the Turbine Building. Closer inspection of phase C revealed cracks in the outer layer of the expansion joint. The electromagnetic field, created by current flow from the generator, induces current in the bus duct. The circulating bus duct currents do not cancel out and can produce localized heating at discontinuities. The hot spot detected with thermography was found on the expansion joint, near the crack. Cracks were also found in the A phase expansion joint. Indications of potential pending cracks were found in the A phase expansion joint. CAUSES The apparent cause of the expansion joint degradation is uneven settlement of the isophase bus duct supports. The isophase ducts are supported on the Turbine Building structure on one side of the expansion joint and on the compacted fill yard area on the other side. The support foundation in the yard area has uneven settlement, resulting in noticeable vertical displacement. This induced additional stresses in the expansion joints. CORRECTIVE ACTIONS During an unplanned forced outage in August 2003, solid aluminum shunts were installed across the expansion joint to provide electrical continuity for all 3 isophase bus ducts. A rubber boot was placed over the shunts to maintain duct integrity and cooling capability in case all layers of the expansion joint cracked. Additionally, slots were provided in the duct supports to allow for thermal expansion of the duct to offset the additional structural rigidity of the shunts. Shims were placed between the isophase ducts and the support members to mitigate the impact of the uneven settlement. Longer-term actions are to replace the expansion joints and to fix the uneven settlement of the isophase bus duct support foundations. This event is NOT SIGNIFICANT because there was no component failure. DAEC ACTIONS Based upon the operating experience the system engineer performed a visual inspection of all three expansion joints in this area. No cracks were noted during this inspection. The alignment of the bus duct itself was also visually inspected, for any signs of misalignment due to settling, again no abnormalities were noted.

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Isolated Phase Bus Duct Hot Spot CAP060701 / CE006754 10/29/08 The current temperatures in the area of the generator-bushing box to isophase hot spot are not of immediate concern. The current temperatures of 240 F are just over the EPRI recommended upper limit of 230 F. At this temperature the components in question are unlikely to be damaged. Isophase Bus Issues OE Digest July 2004 INPO has identified a continued adverse trend related to isophase bus events. Since February 2004, several operating experiences and 50.72 reports have been issued on these events. These events indicate that an adverse trend over the past few years continues. Since January 1999, there have been 10 additional operating experience, licensee event, and 50.72 reports addressing isophase bus events. Though causes of these events vary, common outcomes include plant scrams, power reductions, or plant shutdowns, sometimes resulting in extensive generation loss. The purpose of this report is to highlight the recent problems with the isophase bus system that have caused recent plant transients and to promote renewed awareness in maintaining a good preventive maintenance and inspection program. OE18613 While operating at 100 percent power, a generator load rejection and reactor scram occurred because of a fault associated with the 22-kV isophase bus duct. The fault caused damage to an oil line flange above the main transformer, igniting oil leaking from the conservator. The fault caused mechanical damage in an area around the isophase bus duct and a low voltage bushing atop the main transformer. Equipment damage appeared to be confined to isolated phase bus duct components and the low voltage bushings. As a result of this event, the plant was shut down for 15 days for repairs to be completed. OE18225 In March 2004, during a refueling outage preventive maintenance inspection and cleaning, pieces of the isophase bus duct de-ionizer grid were found in the C phase throat bushing area above the potential transformer compartment. The de-ionizer grid is designed to fail into 2-inch pieces, to avoid larger pieces of FME in the isophase bus duct. The de-ionizer grid problem appears to be fatigue failure caused by normal flow rates through the duct in combination with equipment nearing end of life. OE18112 A unit was manually tripped in February 2004 based on indications of a ground fault between the main generator and main transformer. Troubleshooting identified a short on the A phase output terminal of the generator. The outer copper layer of the flexible link connector to the isophase bus broke such that contact was made with the isophase duct, which resulted in a ground fault. The ground fault resulted in generator neutral voltage (GNV). Consequently, the unit was shut down for 10 days.

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Isolated Phase Bus Duct Hot Spot CAP060701 / CE006754 10/29/08 OE18095 With the unit at full power, a unit trip occurred because of a phase-to-ground fault that occurred in the B phase of the isophase bus duct. Visual inspection identified two faulty components that had the potential to cause the shutdown. The first was a test lead for the partial discharge analyzer (PDA), which is a wire that connects the generator to the isophase bus. Approximately seven 12-inch "arc strike" marks were noted on a damper vent (grounded) that is located near the PDA lead. Additionally, portions of the lead were found melted in this same area. The second possible cause is a damaged flexible link. The flexible links are located periodically along the bus to permit thermal expansion and contraction of the isophase bus. As a result of this event, the unit was shut down for three days.

Recommended Resolution: The isolated phase bus is being upgraded from an 18,000 ampere rating to a 20,000 ampere rating via ECP1858 as part of power uprate. Additional current flowing through the bus duct could aggravate the existing hot spot problem. Further research was conducted on the existing isolated phase duct configuration to determine the effective resolution to the hot spot issue. The following is based on available data from previous site evaluations and independent input from two isolated phase bus duct vendors, including the OEM. 1. Modify the joint configuration between the isolated phase bus duct and the generator bushing boxes to be electrically isolated. 2. Independently connect each generator bushing box to station ground. 3. Perform construction assurance testing to verify each generator bushing box is electrically isolated (from the other generator bushing boxes, from the isolated phase bus and from the main generator) and to verify each generator bushing box is independently connected to station ground. 4. Collect thermography data at appropriate power levels and compare to the ANSI/IEEE C37.23 criteria and previous thermography data (e.g., 10/22/08 data) to assess effectiveness of ECP1858. 5. The isolated phase bus duct vendor supporting ECP1858 (Delta-Unibus) should be invited to the site, both during online operation and during RFO21, to perform an independent study/evaluation of the existing isolated phase bus duct hot spot problem and to recommend additional actions for complete resolution of this issue,. The scope of ECP1858, which includes resolution of known hot spots, is adequate for upgrading the isolated phase bus to a 20,000 ampere rating.

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Isolated Phase Bus Duct Hot Spot CAP060701 / CE006754 10/29/08

Figure #1 DAEC Main generator bushing box to Isophase bus duct hot spot.

All connection bolts were removed, connections cleaned and NO OXID coated, bolts and washers replaced and torqued per manufacturers directions

Hot area connection between bushing box and isophase below inner phase connection

Figure #2 Interior view of the center main generator bushing box.

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Isolated Phase Bus Duct Hot Spot CAP060701 / CE006754 10/29/08

Connection bolt removed from A phase bushing box, Normal isophase temperature

Connection bolt removed from B phase in area of high temperature

Figure #3 Bolts removed from main generator bushing box.

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