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Confirms 870902 Telcon Re 870811 Confirmatory Action Ltr Concerning 870807 Manual Scram Initiated Due to Feedwater Sys Oscillation Problems Which Resulted in Damages to Sys Supports
	ML17199S912
Person / Time
Site:	Dresden
Issue date:	09/04/1987
From:	Davis A; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:	Reed C; COMMONWEALTH EDISON CO.
References
	CAL-RIII-87-14, NUDOCS 8709150282
	Download: ML17199S912 (27)
	v • d • e

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NUCLEAR REGULATORY COMMISSION Docket No. 50-249 Conrnonwealth Edison Company ATTN:

Mr. Cordell Reed Senior Vice President Post Office Box 767 Chicago, IL 60690 Gentlemen:

REGION Ill 7 ltOOSEVELT ROAD CLEN ELLYN, ILLINOIS 60137 SEP

' 1987

SUBJECT:

CONFIRMATORY ACTION LETTER NO. CAL-RIII-87-014 This letter confirms the telephone conversation between E. Greenman of this office and N. Kalivianakis and J. Eenigenburg of your staff on September 2, 1987, related to your actions taken in response to our Confirmatory Action Letter (CAL) dated August 11, 1987, regarding Dresden Unit 3~

On August 7, 1987, a manual scram was initiated due to feedwater system oscillation problems which resulted in damage to system supports, a feedwater flow transmitter root valve shearing off, and a drain line on the reactor water cleanup system return line shearing off. The CAL was issued to document our understanding that you would perform the following actions:

1.

Determine the cause of the pipe breaks which occurred, or plan and submit a course of action to deter~ine the cause through monitoring of systems during return to power operations.

2.

Determine and implement corrective actions to repair the damage frorr.

these breaks.

3.

Conduct a thorough review anc analysis of the recurring feedwater system abnonnalities.

4.

Based on the results of this review, implement corrective actions to avoid future feedwater systerr. transients similar to those which led to the events on July 11 and August 7, 1987.

The CAL also specified that the plant would not be restarted without the concurrence of me or my designee.

With regard to item 1, you have prepared an "operability test plan" which you will implement to collect data on system operating conditions.

For iterr. 2, with one exception, you have completed repairs to the broken lines and damaged supports, and perfonned nondestructive testing on the small bore feedwater piping and high stress areas around the feed regulator valves. The one

\\I Conrnonwealth Edison Company 2

-SEP

' t9S1 exception, installation of additional supports on a feed pu~p minimum flow line, will be completed before being put in service. The *reviews and analysis of item 3 have not conclusively identified the root cause for the abnormali-ties and the data gathering you propose in the operability test plan is to allow for further analysis.

With regard to item 4, further corrective actions will depend, in part, on the analysis of the data taken during startup testing.

Based on a review of your corrective actions and on the results of our Augmented Inspection Team inspection, I believe you have made adequate progress on your corrrriitments and plans for final resolution of this matter.

Therefore, the CAL is terminated and I concur with your request to start up the plant and proceed with your "operational test plan 11 We plan to implement augmented inspections during your restart and operational testing.

We also plan to monitor your reviews and corrective actions based er, the test.results.

cc:. D. Butterfield, Nuclear Licensing Manager J. Eenigenburg, Plant Manager DCS/RSB (RIDS)

Licensing Fee Management Branch Resident Inspector, RIII Richard Hubbard J. W. Mccaffrey, Chief, Public

Utilities Division E. L. Jordan, Director, Office for Analysis and Evaluation of Operational Data D. M. Crutchfield, Director, Division of Reactor Projects III/IV/V, NRR J. Liebennan, Director, Office of Enforcement Sincerely, A. Bert Davis Regional Administrator

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M-3470-87 1-13-87 SYSTEM MATERIALS ANALYSIS DEPARTMENT REPORT ON A FAILED REACTOR WATER CLEAN UP LINE DRAIN ARD A FEED KATER INSTRUMENT LINE AT DRESDEN STATION. UNIT 3 on 1/7/87. a clean-up line drain (3-12t6-l*) and a feed water inatruaent line for 3-6ttc fAiled after

transient at Dresden Station Unit 3.

A aetallurqical investivation was perforaed to deteraine tbe cause of failure.

The aating fracture surfaces from both lines were received for analysis.

Fiqures la and lb are photographs of the aating fracture surfaces from the clean-up drain line.

The fracture occurred in the drain line at the toe of the fillet weld joining it to an e* pipe.

Tbe fillet veld leg length averaged approxiaately 3/8" on the side of the B" pipe and 3/16" on the drain line side.

The diain line was fabricated of an austenitic stainless steel pipe and had a* nominal ID of 7/8" with a 3/16" thick wall.

Visual and low power optical examination of the drain line fracture surfaces revealed beach marks and river patterns typically associated with fatigue induced crack propagation.

A large portion of the fracture surface (approx. 40\\) was flat and exhibited evidence of fatigue crack propogation.

The fatigue cracks appear to bave initiated at the toe of the fillet weld on the tube side, and were probably through wall at the tiae of the transients.

several other fatigue crack initiation sites were also observed: these areas are marked in Figures la and lb.

The remainder of the fracture surface appeared to be ductile.

R-ltlU-ISI Page 2 Tbe failed instruaent line fracture surfaces are sbovn in Figures 2a and 2b.

The fracture surface was located on the instru*ent line side at the toe of the weld joinino it to the ie*

feed water line.

The average fillet leq lenqth aeasured 3/16*.

The instruaent line was fabricated of a carbon steel and bad a noainal I.D. of approxiaately s1e* with an average wall thickness of 1132*.

Figure 3 also shows that the f atique crack was very close to propagating through wall.

Conclusion Based on this analysis. the final failure. mode of both the clean-up line drain and the feed water instrument line was ductile overload.

In addition. both were found to have pre-existing flaws as a result of fatique induced cracking.

Approved by:~ )r;f#v copies to:

E. ::onigenburg -

J. S. Abel ~ SNED Reported by~;J'"-

Plant Mqr.

J. D. Brunner - Asst.

R. H. Mirochna -

SNED supt. Tech. serv.

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l Figure la M-3470-87 Page 3 Fracture surface and fillet weld from the clean up drain line.

Arrows mark probable fatigue crack initiation sites.

A dashed line highlights a large fatigue crack fracture surface.

The large fatigue fracture appears to extend completely across the wall thickness.

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Figure lb M-3470-87 Pa9e 4 The mating fracture surface to that shown in Figure la.

This surface exhibits the same fracturE characteristics.

Figure 2a M-3470-87 Page 5 Feed wat.er ~~~:,.*:111u.rline fracture surface and adjoining fillet weld.

The dashed line highlights a fatigue fracture surface.

Diametrically opposed to the fatigue fracture surface is a flat surface which has been mechanically damaged and the microscopic fracture features have been destroyed.

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Figure 2b M-3470-87 Page 6 The mating ~racture face to Figure 2a.

A dashed line highlights the faLigue fracture surface.

i Figure 3 M-3470"-87 Page 7 A magnified view of the highlighted area from Figure 2a.

The fatigue crack which initiated at the toe of the fillet weld appears to be close to being through wall.

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TABLE 1 Table 1 Feedwater System Instrumentation Control Room Indication Indication Reactor Water Level (2)

Reactor Pressure (2)

Steam Flow (4)

Total Steam Flow (1)

Feedwater Flow (3)

Feedwater Regulating Valve Position Significant Alarm Alarm Feedwater Pump Maximum Capacity Feedwater Control Signal Failure Loss of Air to Feedwater Regulating Valves Main Steam Line Leakage Significant Interlocks Interlocks Recirculation Pump Minimum Feedwater Flow Rod Worth Minimizer Auto Bypass 0 - 60 in.

0 - 1200 psig 0 - 3 X 106 lbm/hr O - 12 X 106 lbm/hr 0 - 6 X 106 lbm/hr 0 - 100%

Setpoint 5.6 X 106 lbm/hr Loss of Controller Output Below 75 psig 10% mismatch between turbine and main steam flow Setpoint 2 X 106 lbm/hr Steam flow > 20% and Feed flow > 10%

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Rod Worth Minimizer Low Power Alarm Point Significant Trips

.Trip Feedwater Pump Maximum Capacity Yarway Indications Controls Control Reactor Level Selector Switch Vessel Level Control Mode Switch Runout Reset Pushbutton Lockout Reset Pushbutton FRV Auto/Manual Transfer Station Master Controller Auto/Manual Transfer Station Manual/Auto Controller Auto/Manual Transfer Station 2

Table 1 Steam Flow < 34%

Setpoint 5.6 X 106 lbm/hr Both yarway indications

> 20 in.

Function Allows operator to select level 11A 11 or level 118 11 Allows operator to select either single-element or three-element control Allows for the manual reset of runout logic circuit Allows for the reset of FRV lockout condition Allows for individual manual control of an FRV Allows for simultaneous manual control of the FRV Allows manual control of the Bypass Valve

. i Table 2 TABLE 2 Tentative List of Network 90 Parameters To Be Monitored Dresden 3 F.W.

From BLK Baile~ DWG CE. Co.

System Point Name BTl<No No. Add.

08101350C DWG.

11 A Rx. Lvl.

1000 500 AA-1 12E34.19 Sht.13 Transmitter "B" Rx. Lvl.

1040 501 AA-1 12E34.19 Sht.13 Transmitter "A" Compensated 33 502 AA-1 12E34.19 Sht.13 Rx. Lvl.

"B" Compensated 38 503 AA-1 12E34.19 Sht.13 Rx. Lvl.

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182 504 AA-3 12E34.19 Sht.15 "A" Stm. Flow 65 505 AA-2 12E34.19 Sht.14 "B" Stm. Flow 67 506 AA-2 12E34.19 Sht.14 "C" Stm. Flow 69 507 AA-2 12E34.19 Sht.14 II D" Stm. Flow 71 508 AA-2 12E34.19 Sht.14 Total Stm. Flow 113 509 AA-2 12E34.19 Sht.14 "A" F.W. Flow 125 516 AA-2 12E34.19 Sht.14 "B" F.W. Flow 127 517 AA-2 12E34.19 Sht.14 "C" F.W. Flow 129 518 AA-2 12E34.19 Sht.14 Total F.W. Flow 163 519 AA-3 12E34.19 Sht.15 Master Level 222 520 AA-4 12E34.19 Sht.16 Set Point Runout Flow 211 521 AA-4 12E34.19 Sht.16 Control Demand 11A 11 FCV Flow 263 522 AA-5 12E34.19 Sht.17 Demand

Table 2 "Sensed" 118 11 1013 523 AA-7 12E34.19 Sht.19 FCV Demand "B" FCV Flow 264 524 AA-5 12E34.19 Sht.17 Demand "Sensed" 118 11 1023 525 AA-7 1ZE34.19 Sht.19 FCV Demand Rx. Low Flow 272 526 AA-6 12E34.19 Sht.18 Rx. Lvl.

1016 530 AA-1

'12E34.19 Sht.13 Select SW.

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54 531 AA-1 12E34.19 Sht.13 Select Logic Mode Select SW.

1006 532 AA-3 12E34'.19 Sht.15 Scram Signal 1007 533 AA-4 12E34.l9 Sht.16 Bad Input Det.

313 534 AA-8 12E34.19 Sht.20 I/0 Card Failure 319 535 AA-9 12E34.19 Sht.21 D.C.S. Failure 321 536 AA-9 12E34.19 Sht.21 MFC Bk.Up 320 537 AA-9 12E34.19 Sht.21 Failure Master Station 218 538 AA-4 12E34.19 Sht.16 A/M Select Runout Flow 1046 539 AA-4 12E34.19 Sht.16 Control Select "A" Reg. Vlv.

326 545 AA-7 12E34.19 Sht.19 Interlock "B" Reg.* Vlv.

328 546 AA-7 12E34.19 Sht.19 Interlock "A" DCS A/M 234 547 AA-5 12E34.19 Sht.17 Select 118 11 DCS A/M 249 548 AA-5 12E34.19 Sht.17 Select Rx. Low Flow 274 549 AA-6 12E34.19 Sht.18 A/M Select Recir. MG Set 299 550 AA-7 12E34.19 Sht.19 Interlock 2

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