Information Notice 1994-03, Deficiencies Identified During Service Water System Operational Performance Inspections

Deficiencies Identified During Service Water System Operational Performance Inspections

ML031070061
Person / Time
Site:	Beaver Valley, Millstone, Hatch, Monticello, Calvert Cliffs, Dresden, Davis Besse, Peach Bottom, Browns Ferry, Salem, Oconee, Mcguire, Nine Mile Point, Palisades, Palo Verde, Perry, Indian Point, Fermi, Kewaunee, Catawba, Harris, Wolf Creek, Saint Lucie, Point Beach, Oyster Creek, Watts Bar, Hope Creek, Grand Gulf, Cooper, Sequoyah, Byron, Pilgrim, Arkansas Nuclear, Three Mile Island, Braidwood, Susquehanna, Summer, Prairie Island, Columbia, Seabrook, Brunswick, Surry, Limerick, North Anna, Turkey Point, River Bend, Vermont Yankee, Crystal River, Haddam Neck, Ginna, Diablo Canyon, Callaway, Vogtle, Waterford, Duane Arnold, Farley, Robinson, Clinton, South Texas, San Onofre, Cook, Comanche Peak, Yankee Rowe, Maine Yankee, Quad Cities, Humboldt Bay, La Crosse, Big Rock Point, Rancho Seco, Zion, Midland, Bellefonte, Fort Calhoun, FitzPatrick, McGuire, LaSalle, Fort Saint Vrain, Shoreham, Satsop, Trojan, Atlantic Nuclear Power Plant
Issue date:	01/11/1994
From:	Grimes B Office of Nuclear Reactor Regulation
To:
References
IN-94-003, NUDOCS 9401050494
Download: ML031070061 (13)

UNITED STATES

NUCLEAR REGULATORY COMMISSION

OFFICE OF NUCLEAR REACTOR REGULATION

WASHINGTON, D.C. 20555 January 11, 1994 NRC INFORMATION NOTICE 94-03: DEFICIENCIES IDENTIFIED DURING SERVICE WATER

SYSTEM OPERATIONAL PERFORMANCE INSPECTIONS

Addressees

All holders of operating licenses or construction permits for nuclear power

reactors.

Purpose

The U.S. Nuclear Regulatory Commission (NRC) is issuing this information

notice to alert the addressees to deficiencies identified by the NRC during

service water system operational performance inspections that were recently

performed. It is expected that recipients will review the information for

applicability to their facilities and consider actions, as appropriate, to

avoid similar problems. However, suggestions contained in this information

notice are not NRC requirements; therefore, no specific action or written

response is required.

Description of Circumstances

Design and operational concerns associated with service water systems have

been identified in licensee event reports and during NRC inspection

activities. To address these concerns, the NRC issued Generic Letter 89-13, Service Water System Problems Affecting Safety-Related Equipment,' on

July 18, 1989. This generic letter requested that licensees and applicants

perform actions to ensure that their service water systems are in compliance

with 10 CFR Part 50 (Appendix A, General Design Criteria 44, 45, and 46 and

Appendix B,Section XI). The NRC conducted four workshops on Generic

Letter 89-13 and issued information developed from the transcripts of these

workshops as Supplement 1 to the generic letter on April 4, 1990.

Because problems continued to be experienced with service water systems, the

NRC developed the service water system operational performance inspection to

assess licensee actions i-n response to Generic Letter 89-13 and to evaluate

such aspects of the service water system as design, operations, maintenance, surveillance/testing, and quality assurance/corrective actions. These

inspections are performed in accordance with Temporary Instruction 2515/118, Revision 1, 'Service Water System Operational Performance Inspection

(SWSOPI)," contained in the NRC Inspection Manual. As indicated in the

temporary instruction, these inspections will generally be conducted at plants

licensed before 1979, as well as at newer plants that are perceived to have

service water system problems or more general maintenance, engineering, and

technical support problems.

9401050494 PDR It e M Ie Li -o

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S~t/ellsE X

VVIN 94-03 January 11, 1994 Discussion

During the initial seven service water system operational performance

inspections, deficiencies and weaknesses were found in the evaluation of heat

transfer requirements and in the development of testing programs and

procedures. In addition, the results of these inspections indicated that, in

general, licensees have not taken all actions requested by Generic

Letter 89-13 in a completely effective manner.

Some examples of the deficiencies and weaknesses that were identified during

the initial inspections are summarized in this section.

(1) Evaluation of Heat Transfer Requirements

The findings in this area pertain to inadequacies in analyses of the

heat loads to be removed by the service water systems, evaluations of

the performance of the heat exchangers and room coolers, and

verification of hydraulic analyses. For example, the following

deficiencies were identified:

• The calculated heat load in a compartment containing safety-related

pumps exceeded the rated room cooler capacity. Also, initial

calculations failed to include heat loads from auxiliary motors

located in the compartment. During the inspection, the licensee

performed a new calculation and determined that equilibrium room

temperature would be higher than the existing analyzed temperature

in the compartment. Additional evaluations were performed to verify

that the electrical equipment in these areas could operate at the

higher room temperature. (Quad Cities)

• A calculation to demonstrate the heat removal capacity of a safety- related room cooler failed to consider that the actual flow through

the room cooler was less than design flow. (Monticello)

(2) Testing Programs and Procedures

The findings in this area are related to failure to include safety- related service water system valves in the inservice testing (IST)

program, failure to perform required tests in accordance with the IST

program, failure to test the service water system components to verify

their functional capabilities, and failure to use appropriate test

acceptance criteria. For example, the following deficiencies were

identified:

• Various safety-related valves were omitted from the IST programs at

several plants. In one case, many manual valves in the service

water system that perform specific functions in shutting down the

reactor were not included in the IST program. In another case,

IN 94-03 January 11, 1994 manual valves and check valves that perform safety functions in

aligning the emergency backwash lines to the essential service water

strainers were not included in the IST program. Also, power- operated flow-control valves that are normally closed, but perform

a safety function in opening to admit service water flow, were not

included in the IST program. (Monticello, South Texas, Quad Cities)

• Periodic testing of valves as required by the IST program was not

performed. The service water system valves in the control room

heating, ventilation, and air conditioning system were not tested

quarterly, as required by the plant's IST program. (Quad Cities)

• Deficiencies were noted in IST programs for the service water system

pumps. The service water pump curves were used in testing the pumps

instead of specific reference values as required by Section XI of

the ASME Boiler and Pressure Vessel Code (ASME Code) without

obtaining NRC staff approval for relief from the provisions of the

Code. Flow instruments that were not in compliance with the

instrument accuracy requirements specified by Section XI of the ASME

Code were used in the testing of essential cooling water pumps

without obtaining relief from the Code requirements.

(Monticello, South Texas)

• The preoperational test results of the service water system had not

been reconciled with the current system configuration and operation.

For example: (a)the system was tested with the nonsafety-related

portions isolated, although the existing operation of the system did

not isolate these portions on a safety injection signal alone, (b)

the system was not tested with two pumps operating to verify system

performance under post-accident recirculation conditions, and (c)

the system flow balance was established on the basis of three-pump

operation instead of the limiting case of one-pump operation

supplying all the loads. (Ginna)

(3) Weaknesses in the Implementation of Generic Letter 89-13 In addition to the specific deficiencies discussed above, weaknesses

were noted in the implementation of Generic Letter 89-13 actions.

Significant weaknesses in the implementation of Actions II and III of

Generic Letter 89-13 are discussed below.

Action II of Generic Letter 89-13 requested that licensees establish a

test program to periodically verify the heat transfer capability of all

safety-related heat exchangers cooled by service water. The total test

program was to consist of an initial test program and a periodic retest

program. The following examples illustrate some of the implementation

weaknesses found at one or more plants for this action item:

• Several safety-related room coolers were not tested in accordance

with commitments in the licensee response to the generic letter.

JIN 94-03 January 11, 1994 * No baseline testing was done to verify that minimum flow to each

component was achieved.

• Where the periodic maintenance method was chosen in lieu of heat

transfer performance testing of heat exchangers and room coolers, no

sound technical basis for inspection and preventive maintenance

frequencies was established.

• The design temperature difference across a heat exchanger was used

as an acceptance criterion without correcting for the actual test

conditions where the test heat load was substantially less than the

design value.

Action III of Generic Letter 89-13 requested that licensees establish a

routine inspection and maintenance program for open-cycle service water

system piping and components to ensure that corrosion, erosion, protective coating failure, silting, and biofouling would not degrade

the performance of the safety-related systems supplied by service water.

The following examples illustrate some of the implementation weaknesses

found at one or more plants for this action item:

• Adequate training or guidance was not provided for personnel to

evaluate potentially degraded conditions of service water system

components.

• Maintenance and inspection programs did not provide assurance that

critical instrument lines and small-bore piping would not become

clogged or degraded.

• Actions were not taken within a reasonable time period to inspect

and clean room coolers in the second unit when similar coolers in

the first unit were found to be significantly degraded.

• Nonsafety-related service water system piping in the discharge path

from safety-related components was not included in an inspection and

maintenance program.

The findings of these inspections illustrate the importance of systematic

engineering analyses, testing, inspection, and maintenance of service water

systems.

IN 94-03 January 11, 1994 This information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact

the technical contacts listed below or the appropriate NRR projectp^nager.

'Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contacts: S. K. Malur, NRR

(301) 504-2963 S. R. Jones, NRR

(301) 504-2833 Attachments:

1. List of SWSOPI Reports

2. List of Recently Issued NRC Information Notices

Ailachment 1 IN 94-03 January 11, 1994 List of SWSOPI Inspections

The following seven SWSOPI reports were reviewed to identify the types of

deficiencies and weaknesses that are discussed in this Information notice:

1. 50-237/93008(DRS); 50-249/93008(DRS) (Dresden Nuclear Power Station)

2. 50-244/91-201 (Ginna Nuclear Power Station)

3. 50-335/91-201; 50-389/91-201 (St. Lucie Plant)

4. 50-263/92010 (Monticello Nuclear Generating Plant)

5. 50-254/92-201; 50-265/92-201 (Quad Cities Nuclear Power Station)

6. 50-498/92-201; 50-499/92-201 (South Texas Project)

7. 50-397/93-201 (Washington Nuclear Plant, Unit 2)

Ats.,hment 2 IN 94-03 January 11, 1994 LIST OF RECENTLY ISSUED

NRC INFORMATION NOTICES

Information Date of

Notice No. Subject Issuance Issued to

94-02 Inoperabllity of General 01/07/94 All holders of OLs or CPs

Electric Magne-Blast for nuclear power reactors.

Breaker Because of Mis- alignment of Close-Latch

Spring

94-01 Turbine Blade Failures 01/07/94 All holders of OLs or CPs

Caused by Torsional for nuclear power reactors.

Excitation from Electrical

System Disturbance

93-101 Jet Pump Hold-Down Beam 12/17/93 All holders of OLs or CPs

Failure for boiling-water reactors.93-100 Reporting Requirements 12/22/93 All U.S. Nuclear Regulatory

for Bankruptcy Commission licensees.

91-29, Potential Deficiencies 12/22/93 All holders of OLs or CPs

Supp. 2 Found During Electrical for nuclear power reactors.

Distribution System

Functional Inspections

93-99 Undervoltage Relay and 12/21/93 All holders of OLs and CPs

Thermal Overload Setpoint for nuclear power reactors.

Problems

93-98 Motor Brakes on Valve 12/20/93 All holders of OLs and CPs

Actuator Motors for nuclear power reactors.

93-97 Failures of Yokes 12/17/93 All holders of OLs or CPs

Installed on Walworth for nuclear power reactors.

Gate and Globe Valves

93-96 Improper Reset Causes 12/14/93 All holders of OLs or CPs

Emergency Diesel for nuclear power reactors.

Generator Failures

93-95 Storm-Related Loss of 12/13/93 All holders of OLs or CPs

Offsite Power Events for nuclear power reactors

due to Salt Buildup located close to a large

on Switchyard Insulators body of salt water.

0L = Operating License

CP = Construction Permit

IN 94-03 January 11, 1994 This information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact

the technical contacts listed below or the appropriate NRR project manager.

Original signed by

Brian K. Grimes

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contacts: S. K. Malur, NRR

(301) 504-2963 S. R. Jones, NRR

(301) 504-2833 Attachments:

1. List of SWSOPI Reports

2. List of Recently Issued NRC Information Notices

• See previous concurrences

RSIB:DRIL* RSIB:DRIL* RSIB:DRIL* DRIL:NRR* DE:NRR*

SKMalur DPNorkin EVImbro CERossi JTWiggins

08/24/93 09/08/93 09/08/93 09/18/93 DSSA:NRR* OGCB: DORS* Tech Ed* OGCB:DORS*

AThadani TJKim RSanders GHMarcus

11/06/93 11/23/93 11/09/93 11/24/93 01/7 /94 OFFICIAL RECORD COPY

DOCUMENT NAME: 94-03.IN

IN 93-XX

December XX, 1993 This information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact

the technical contacts listed below or the appropriate NRR project manager.

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contacts: S. K. Malur, NRR

(301) 504-2963 S. R. Jones, NRR

(301) 504-2833 Attachments:

1. List of SWSOPI Reports

2. List of Recently Issued NRC Information Notices

• See previous concurrences

RSIB:DRIL* RSIB:DRIL* RSIB:DRIL* DRIL:NRR* DE:NRR*

SKMalur DPNorkin EVImbro CERossi JTWiggins

08/24/93 09/08/93 09/08/93 09/18/93 10/08/93 DSSA:NRR* OGCB:DORS* Tech Ed* OGCB: DORS* DORS:NRR

AThadani TJKim RSanders GHMarcus BKGrimes

11/06/93 11/23/93 11/09/93 11/24/93 12/ /93

OFFICIAL RECORD COPY

DOCUMENT NAME: SWSOPI.TJK

IN 93-XX

December XX, 1993 This Information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact

the technical contacts listed below or the appropriate NRR project manager.

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

Technical contacts: S. K. Malur, NRR

(301) 504-2963 S. R. Jones, NRR

(301) 504-2833 Attachments:

1. List of SWSOPI Reports

2. List of Recently Issued NRC Information Notices

• See previous concurrences

RSIB:DRIL* RSIB:DRIL* RSIB:DRIL* DRIL:NRR* DE:NRR*

SKMalur DPNorkin EVImbro CERossi JTWiggins

08/24/93 09/08/93 09/08/93 09/18/93 10/08/93 DSSA:NRR* OGCB:DORS* Tech Ed* OGCB:DORS* DORS:NRR

AThadani TJKim RSanders GHMarcus BKGrimes

11/06/93 11/23/93 11/09/93 11/24/93 12/ /93

OFFICIAL RECORD COPY

DOCUMENT NAME: SWSOPI.TJK

K)

IN 93-XX

November XX, 1993 This information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact

the technical contact listed below or the appropriate NRR project manager.

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

S. K. Malur, NRR

(301) 504-2963 S. R. Jones, NRR

(301) 504-2833 Attachments: 1. List of SWSOPI Reports

2. List of Recently Issued NRC Information Notices

• See previous concurrences

RSIB:DRIL* RSIB:DRIL* RSIB:DRIL* DRIL:NRR* DE:NRR*

SKMalur DPNorkin EVImbro CERossi JTWiggins

08/24/93 09/08/93 09/08/93 09/18/93 10/08/93 DSSA:NRR* OGCB: ff Tech Ed* OGCB:DORS DORS:NRR

AThadani TJKi3/ RSanders GHMarcusGM BKGrimes

11/06/93 11/09/93 11/2y/93 I1/ /93

OFFICIAL RECORD COPY

DOCUMENT NAME: SWSOPI.TJK

IN 93-XX

October XX, 1993 This information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact

the technical contact listed below or the appropriate NRR project manager.

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

S.K. Malur, NRR

(301) 504-2963 Attachments: 1. List of SWSOPI Inspection Reports

2. List of Recently Issued NRC Information Notices

• See previous concurrences

RSIB:DRIL* RSIB:DRIL* RSIB:DRIL* DRIL:NRR* DE:NRR*

SKMalur DPNorkin EVImbro CERossi JTWiggins

08/24/93 09/08/93 09/08/93 09/18/93 10/08/93

64, DSJA:a OGCB: DORS Tech Ed *- OGCB:DORS DORS:NRR

Alhadan TJKim GHMarcus BKGrimes

Iy/ j /93 10/ /93 13/o7/93 10/ /93 10/ /93 OFFICIAL RECORD COPY

DOCUMENT NAME: G:\SWSOPI.IN

IN 93-XX

October XX, 1993 This information notice requires no specific action or written response. If

you have any questions about the information in this notice, please contact

the technical contact listed below or the appropriate NRR project manager.

Brian K. Grimes, Director

Division of Operating Reactor Support

Office of Nuclear Reactor Regulation

S.K. Malur, NRR

(301) 504-2963 I. LWsI of SwsoPL zsaet Ot.KoReporfs

Attachment:z .List of Recently Issued NRC Information Notices

• See previous concurrences

RSIB:DRIL* RSIB:DRIL* RSIB:DRIL* DRIL:NRR* 1~E:NRR -,

SKMalur DPNorkin EVImbro CERossi \0'V TWiggin!

08/24/93 09/08/93 09/08/93 09/18/93 10/8 /93

9l> AThadani

DSSA:NRR OGCB D Tech Ed OGCB:DORS

GHMarcus

DORS:NRR

BKGrimes

10/ /93 10 /9 10/ /93 10/ /93 1O/ /93 OFFICIAL RECORD COPY

DOCUMENT NAME: G:\SWSOPI.IN