IR 05000302/1989002
| ML20246L875 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 02/27/1989 |
| From: | Blake J, Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20246L872 | List: |
| References | |
| 50-302-89-02, 50-302-89-2, NUDOCS 8903240303 | |
| Download: ML20246L875 (17) | |
Text
{{#Wiki_filter:_ _ _ 8 Pf cq., UNITED STATES - ,I NUCLEAR REGULATORY COMMISSION Ag ': c ., [N, E REGION ll n g, 'j, 101 MARIETTA STRFET, N.W.
- ATL ANTA, GEORGI A 30323 -
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, Qu ..*** , , ' Report No.: 50-302/89-02 , Licensee: Florida Power Corporation 3201 34th Street, South f St. Petersburg,.-FL 33733 Docket No.: 50-302 License No.: DPR-72 , Facility Name:- Crystal River 3 , , , l Inspection Cor et January 30-31, 1989 -
Inspect r:- /b
7' - ' M ir c6nomos Date Signed-Acco anyi-e on eb J. Rajan, NRR - -- - d
Approved by.
< J.
'.'B1ake, Chief Date Signed a riar and Processes Section En ineering Branch Division of Reactor' Safety SUMMARY ! Scope: This-special unannounced inspection' was-performed to provide.NRR onsite' assistance in their effort to review the licensee's reactor coolant pump (RCPT, vibration monitoring system data ' acquisition, interpretation and written instructions for protective measures to be taken in the event that rotating assembly failure is indicated.
l Results: The inspectors flound /the licensee's vibration monitoring program to l be satisfactory but 'made seYeral observations and suggestions for l enhancement of the vibration monitoring procedure.
Personnel in charge were knowledgeable and sincere in their efforts to obtain a good understanding of the root cause of the problem in RCP "1A".
. Site management war, very rauch ' involved in the-resolution of this problem and very responsine to questions / suggestions.
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e a' REPORT DETAILS 1.
Persons Contacted Licensee Employees
- F. R. Bailey, Superintendent Projects
- G. A. Becker, Manager, Site Nuclear Engineering Services
- G. L. Boldt, Vice President, Nu' clear Production W-J. Brewer, Nuclear Engineer, Systems
. '
- M. D. Clary, Principal Nuclear Mechanical Engineer Services P. F. McKee, Director, Nuclear Plant Operations
- V. R. Roppel, Manager, Nuclear Maintenance W. Rossfeld, Manager, Nuclear Compliance
, R. C. Wide 11, Director, Nuclear Operations Site Support M. S. Williams, Nuclear Regulatory Specialist K. R. Wilson, Manager, Nuclear Licensing Other licensee. employees contacted during this inspection included craf tsmen, engineers, and administrative personnel. ' Other Organization - Brookhaven National Laboratory Dr. J. Currari, Mechanical Engineer,- Consultant NRC Resident Inspectors
- P. Holmes-Ray, Senior Resident Inspector
, J. Tedrow, Resident Inspector l l
- Attended exit interview.
2.
Corrective Maintenance (62703) - Vibration Monitoring System and Data Acquisition for Reactor Coolant Pumps (RCP) l Background The licensee presented information regarding the pump shaft separation that occurred on January 1,1986, on the "A" pump at Crystal River.3.
In
the Babcock and Wilcox report of this failure, it was noted that there were both axial and circumferential cracks in the shaf t.
Their fracture mechanics analysis of the shallow axial cracks showed that they were ( probably caused by cyclic thermal. stress and were not propagating further.
The circumferential crack was located in a groove directly below the threaded region.
Stress concentration at the split ring groove was the l major contributing factor for crack initiation. They concluded that this l, -_ i
. .
1 l l l crack growth had also been arrested.
After a long pause, crack growth resumed due to the additional loads from the broken impeller-to-shaft bolts plus normal bending loads, resulting in the shaft failure.
j l Four new replacement rotating assemblies were installed in the CR-3 reactor coolant pumps.
Each had been modified to improve the impeller-to-shaft joint integrity. This involved a change of material for the cap screws and pins as well as an increase in the screw preload.
l An improved monitoring system was also installed at each pump. The system consists of three Bently Nevada non-contact probes per pump.
Two probes . are mounted at 90 degrees. The third probe is mounted so that it monitors l a notch in the pump shaft coupiing.
This provides a phase reference signal. The monitoring system has been operational since August 1988 and i ' is intended to signal structural changes in the shaft so that operational decisions can be made.
In November 1988, the licensee's review of vibrational data indicated a change in the vibrational characteristics of RCP-1A.
Appendix A shows some of the Bently Nevada records that were made of this event.
These include the X and Y vibration magnitude, the IX component phase lag j and magnitude as well as the 2X component phase lag and magnitude.
Considerable departure from the norm is seen in each of these records for i . RCP-1A. The vibrational data that were made at the same time for pumps j l 1B, 1C and 10 are also shnwn for comparison in Appendix A.
Action was ] I taken in response to the vibrational signal and the pump was shut down at that time.
Examination and testing revealed cracks in the gusset welds in the lower bearing support.
Following repair, the RCP-1A system was started up again on January 11, l 1989.
The initial startup of the pump showed a vibrational signature ! similar to other RCPs.
Af ter several hours of operation, the vibration i levels changed. These changes are shown by the recordings of the IX and 2X vibration levels and phase angles in Figures 1 and 2.
Both magnitudes and phase angles showed changes that were in excess of the November 1988 levels that resulted in the shutdown.
Ample warning was given by the motion detector of an impending problem during a period of seven days, but no action was taken until the pump failed.
The failure of the pump was discussed in a report attached to a letter dated January 27, 1989, from W. S. Wilgus, Vice President Nuclear Operations, FPC.
The report discussed the event that occurred on January 18, 1989.
The control room received a low RCS loop "A" flow alarm, and a loose parts monitor alarm from an accelerometer mounted near the motor end of the pump.
These signals meant that the pump was not functioning and caused the operators to take action and shut down the RCP1A.
The following paragraph is an excerpt from this report:
1' ._-- - - . _ --_a
, _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ , - % e ,
. "The transient parameters suggest a planar separation _ has _ occurred somewhere between the RCP-1A pump coupling and the impeller with the most probably location below the effective center'of the hydrostatic ' bearing.
There are three scenar.ios which could account for the observed parameters, (1) a shaf t fracture between 48 and 62 inches from the top _of the shaft, (2) the 1mpeller cap screws and fasteners failed allowing the impeller to separate from the shaft, or'(3) the impeller -cap screws and driver pins failed allowing the impeller to , rotate on the center fasteners.
All.of the information reviewed j indicates the transient was bounded by the 1986 pump shaft break ~ which did not result in - any degradation of the Reactor Coolant
' System (RCS) pressure boundary."
j In addition, the inspectors reviewed FPC document No. 89-08, dated January 27, 1989, which is entitled Short-Term Instruction.
It contains recommendations concerning RCP vibration monitoring which are intended to - be used until such time.that the plant is shut down for repair of RCP-1A. This is stated to occur no later than March 23, 1989.
The overall impression was that the instrumentation appears to be capable of providing ample warning.
However, the instructions for using the-i vibration data were not specific enough and the inspectors expressed-a.
concern that they might be misinterpreted.
The inspectors stated that the instruction should be clear about procedures to be followed in the event that the instrumentation signals a potential problem.
In this regard, the inspectors expressed the following concerns and questions about some of the contents of the Vibration Monitoring procedure.
Possible misinterpretation on the intent of Alert Levels: a.
On Notes 1, 2 and 3, in Section II; levels a're described "above the nominal levels" or "above the present trends."
The inspectors understand that "the present trends" mean the same :as the nominal level.
The inspectors further understood that the nominal level refer to the stable readings achieved after startup.
Should . i " nominal levels" be substituted for "present trends?" b.
The Alert Levels are set higher than the nominal levels. Should the Alert Levels be set for both higher and ' lower bounds since changes in both directions could indicate a departure from the norm that-might require attention? c.
The. phase data for the Alert Levels for RCP-1C and RCP-10 show very different nominal values, as indicated by the numbers in the Alert Levels table. These range from 45 degrees to 340 degrees in the IX nrobe.
It is conceivable that there tuuld be a nominal reading of, say, 340 degrees. If 30 degrees is added, it brings the Alert Level to 370. But readings beyon_d 360 go-back to zero and so 370 might be designated as 10 This is not what is intended and so how could the procedure be set up to avoid this ambiguity? . _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _
v l
i '. .
i I
d.
Under Section III, the instruction is given to monitor the Bently Nevada system at least twice per shif t.
Should nominal monitoring hours be specified to avoid any misinterpretation of "twice per shift?" e.
Under Section IV, the instruction is given that En;ineering should be notified along with SS00 if any Alert Levels are exceeded. Three telephone numbers are given on the RCP Vibration Monitoring Log.
Should the word "immediately" or "as soon as possible" be inserted into these instructions? i f.
What action plans are expected to be followed in the event'that
Engineering is notified because of alert exceedances? What different l choices or scenarios are anticipated, directed or planned? What are ! the conditions that would require shutdown and who is responsible for this decision? l l Th licensee agreed to respond to all of the NRC concerns and questions I within the week of February 5,1989.
On February 2,1989, the licensee l provided the inspectors a copy of the revised instruction for vibration monitoring.
The inspectors reviewed the revised instruction _and are satisfied that all questions and concerns expressed have been addressed.
Within the areas inspected, no violations or deviations were identified.
3.
Exit Interview l The inspection scope and results were summarized on January 31, 1989, viith those persons indicated in paragraph 1 above.
The inspectors dascribed the areas inspected and discussed in detail the inspection results.
Although reviewed during this inspection, proprietary information is not contained in this report. Dissenting comments were not received from the licensee.
l Appendix A: Bently Nevada Records l l _ * . , ,,,,, ,
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