ML18047A335

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Inservice Testing of Selected Safety-Related Pumps, Revision 5
ML18047A335
Person / Time
Site: Palisades Entergy icon.png
Issue date: 09/04/1981
From:
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML18047A334 List:
References
EM-09-04, EM-9-4, NUDOCS 8205250209
Download: ML18047A335 (11)
v • d • e


Text

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BULK POWER OPERATIONS

  • PROC HO PAGE EM-09=04 11 OF 11 PALISADES NUCLEAR PLANT REVISION 5

. ENGINEERING MANUAL consumers Power - . DATE 9-4-8:1 I ( .

TITLE.: INSERVICE TESTING OF SELECTED SAFETY-RELATED PUMPS TABLE 2.

ALLOWABLE RANGES OF TEST OUANTITIES 3

Alen Range Required Action Range* -

"Test 4 -*

Quantity Acceptable Range Low Values High Values Low Values High Values I I J I I Pi AP .93 to 1.02 APr .90 to .93APr 1.02 to 1.03APr < .90APr > 1.03.:iPr Q .94 to 1.02 Qr .90 to .94 Qr 1.02 to 1.03 Qr <.soar > 1.03 Qr v When 0 <.Vr <: 0.5 mil 0 to 1 mil None 1 to 1.5 mil None > 1.5 mil v When 0.5 mil <Vr <. 2.0 mil Oto 2Vr mil None 2Vr mil to None >3Vr mil 3Vrmil ...

v When 2.0 mil <Vr <. 5.0 mil 0 to (2 + Vrl mil None

  • 12 + Vr I mil to None > t4 + Vrl :nil .

.;, . .. .. **-* .14 + Vr) mil . .. .. ..  :

v When Vr > 5.0 mil 0 to 1.4Vr mil None 1.4Vr mil to *.'None > 1.SVr mil Tb .. 2 2 ,

1.8 Vr mil *"¥*

, 2

.*, (Table IWP-3100-2)

1. As specified in pump records.
2. As specified in pump records.
3. Vr, Pr, etc. are reference values (specified on pump graphs).
4. Definitions:

Pi - Pump inlet pressure

~p - Pump differential pressure Q - Pump flow rate V - Vibration amplitude Tb - Bearing temperature J 8205250209 820520 PDR ADOCK 05000255

--* P . PDR

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' COM1ROllEU CDP~

  • BULK POWER OPERATIONS PROC NO EM-09-04 PAGE 10 OF 11 PALISADES NUCLEAR PLANT ENGINEERING MANUAL REVISION 5 consumers Power DATE 9-4-Sl'* ".

TITLE: INSERVICE TESTING OF SELECTED SAFETY-RELATED PUMPS TABLE 1 PUMP TESTING REQUIREMENTS

  • ASME TEST PUMP CLASS PROCEDURE P7A, B, C, Service Water Pumps 3 M0-16 PSA, B, Auxilliary Feedwater Pumps 3 M0-24 P52A, B, C, Component Cooling Pumps 3 M0-18 P54, A, B, C, Containment Spray Pumps 2 M0-19 P55A, B, C, Charging Pumps 2 M0-20 P56A, B, Boric Acid Pumps 2 M0-21 P66A, B, c, HP Safety Injection Pumps 2 M0-22 P67A, B, LP Safety Injection Pumps 2 M0-23
  • Based on ASME B&PV Section XI, 1977 edition, with Addenda through 879. Includes those pumps important to Reactor safety which transfer automatically and restart on an emergency power supply under accident conditons.

-~, .

CuNTRDllED COPY.

  • PALISADES NUCLEAR PLANT
  • PROC NO EM-09-04

@) TITLE; ENGINEERING MANUAL

~NSERVICE TESTING OF SELECTED PAGE 9 RE-VISION OF 11 5

consumers Power SAFETY-RELATED PUMPS DATE 9-4-81 5.0 PROCEDURE (Contd) 5.5.1 NOTE: When the calculated limiting values for the Required Action Range are entered in the pump record, the Project Engineer shall also ensure that these values are also entered in the appropriate locations in each pump test procedure to provide a ready reference for the Shift Supervisor.

5.5.2 After transferring the required data to the graphs, the completed Working Copies of the procedures shall be routed as indicated on each procedure~and filed in the completed Tech Spec surveillance procedure file.

5.5.3 At the end of each 20-month program interval, the Project Engineer shall assemble the graphs and any other pertinent information, and file them under the same index number with the same retention period as the completed Tech Spec surveillance procedures.

5.5.4 When the required action limits for pump parameters change, the Project Engineer must ensure that the specified test procedure limits are also changed to appropriate new values. Since the first level Shift Supervisor review provides immediate verification of pump operability, these limits must be kept current.81-034 Approved

.flA/flUU~ SEP 2 4 1981 PRC 9-4-81 ~~---~~~~~~~-:-~--~-'---

Plant General Manager GOPY:

  • PALISADES NUCLEAR PLANT
  • PROC NO EM-09-04

@) Tl TLE i ENGINEERING MANUAL

£}TSERVICE TESTING OF SELECTED PAGE 7 REVISION OF 11 5

consumers Power SAFETY-RELATED PUMPS DATE 9-4-81 5.0 PROCEDURE (Contd) 5.3.l Following graphing and data evaluation, the Project Engineer notes any ab-normal conditions under Remarks and signs the completed test.

5.3.2 The allowable ranges for the pump operating par~meters are d~fined in Table 2.

If these ranges cannot be met, expanded range limits shall be specified in the basis document for the affected test and these limits shall be used in lieu of those given in Table 2. These limits shall also be specified in the pump test procedure, If any measured parameter falls outside the Acceptable range, the evaluator shall initiate corrective action per 5.4 below.

5.3.3 Where available, the data sheets require that motor currents and voltages be recorded as an additional aid for pump performance evaluation. Although this information is not required by Code, the Project Engineer should consider using this information and/or obtaining similar data from other pumps using a clamp-on ammeter when necessary to evaluate a change in pump operating parameters.

5.3.4 If trends can be detected in pump parameters, the Project Engineer should attempt to predict when the parameter will enter the Alert or Required Action Ranges. This prediction should then be used to schedule necessary maintenance during a convenient outage when practical.

5.4 Non-Conformances 5.4.l Any variation of a measured parameter outside the specified Acceptable Range shall be documented on a Deviation Report (QA-16) and forwarded to the Technical Superintendent for evaluation.

COHTROllED COPY

  • PALISADES NUCLEAR PLANT

@) TITLEi ENGINEERING MANUAL INS~RVICE TESTING OF SELECTED PROC NO EM-09-04 PAGE 8 OF 11 REVISION 5 consumers Power SAFETY-RELATED PUMPS DATE 9-4-81 s.o PROCEDURE (Contd) 5.4.2 If a measured parameter falls outside the specified Required Action Limits, the pump shall be considered inoperable and identified to prevent its use, except in an emergency, until the condition has been dispositioned. It should be noted that this may require the submittal of an Event Report rather than a Deviation Report, and NRC notification. The corrective action is not consi-dered complete until a successful inservice test is completed following re-pairs and the new operating parameters evaluated.

It should also be noted that the disposition may also include accepting the pump performance as-is as long as an analysis shows the pump is operating acceptably and is capable of performing its design function.

5.5 Records 5.5.1 The results of the monthly inservice tests for each pump shall be recorded on graphs in a format adequate to identify trends in pump performance.

Parameters to be recorded in the pump record include, as available:

a. Pump differential pressure as calculated by the evaluator (measured discharge pressure minus calculated or measured suction pressure), or as directly measured (if available).
b. Pump Flow (if available).
c. Pump Vibration.
d. Entries referencing significant maintenance actions or other pertinent comments.

Each graph shall be set up to contain the required parameters for the 20-month test program interval.

A

  • PALISADES NUCLEAR PLANT PROC NO EM-09-04

@) TITLE i ENGINEERING MANUAL lNSERVICE TESTING OF SELECTED PAGE 5 REVISION OF 11 5

consumers Power SAFETY-RELATED PUMPS DATE 9-4-81 5.0 PROCEDURE (Contd) 5.1. 2 If a pump is operated more frequently than once per month, it need not be started or stopped specifically for the test. In order to take credit for normal pump operation, however, all required test data must be recorded per Reference 3.1.

5.1. 3 Bearing temperatures are only required to be measured once per year. These should be done in January or during the first Inservice pump test of the year.

5. 1. 4 If a pump is replaced or a repair is made which may have affected the pomp performance parameters as determined by the Project Engineer based on the Code requirements and pump design requirements, the inservice test must be performed within a maximum of 96 hours0.00111 days <br />0.0267 hours <br />1.587302e-4 weeks <br />3.6528e-5 months <br /> after returning the pump to service to verify existing reference values or to establish new values. Return to service in this context implies operating during normal plant operation. It should be noted that Tech Specs may require this test to be performed and data evaluated prior to this 96 hour0.00111 days <br />0.0267 hours <br />1.587302e-4 weeks <br />3.6528e-5 months <br /> limit. (IWP-3111) 5.1. 5 If pump parameters determined during an inservice test fall within the Alert Range, the test frequency shall be doubled; ie, the Project Engineer and TSSPA shall cause the test to be performed semi-monthly until the cause of the deviation is corrected and the existing reference values verified or a new set established.

5.2 Reference Conditions 5.2.1 The reference values for pump operating parameters are determined from the initial inservice test performed when the pump is known to be operating acceptably. It is permissible to have more th~n one set of reference values*

to allow the test to be run under different plant conditions or equipment  :!

PALISADES NUCLEAR PLANT

@) TITLE; ENGINEERING MANUAL INS~RVICE TESTING OF SELECTED PROC NO EM-09-04 PAGE 6 REVISION OF 11 5

consumers Power SAFETY-RELATED PUMPS DATE 9 ....!ksi 5.0 PROCEDURE (Contd) 5.2.1 operating modes. These additional sets of reference values shall be determined in accordance with Code paragraph IWP-3112 and documented in the basis document for the applicable tests.

5.2.2 As specified in step 5.1.4 above, a new set of reference values must be established or the previous values confirmed for repairs or replacements which may affect pump operating parameters. The test must be run to establish the values within 96 hours0.00111 days <br />0.0267 hours <br />1.587302e-4 weeks <br />3.6528e-5 months <br /> after the pump is returned to service. In general,

  • this is accomplished by making the Tech Spec surveillance test a retest re-quirement on the EOR used to take the pump out of service. It should be noted that when a pump is declared inoperable because of a failure of an inservice test, it cannot be considered to be operable until a successful inservice test has been completed.

Data Evaluation (IWP-3220) 5.3.. 1 The initial evaluation of test data and ~etermination of pump operability is conducted by the operator who performed the test and is reviewed by the Shift Supervisor.

A followup evaluation is performed by the Project Engineer or his designate to monitor trends in pump hydraulic performance (pump d/p and flow for given suction pressure and speed) and mechanical performance (vibration, bearing temperature). In addition, when the test results are used as new reference values such as after maintenance or for a new system configuration, the Project Engineer's evaluation must verify that the new values represent acceptable pump performance. In the latter case, a revision to the test basis document may be required.

  • PALISADES NUCLEAR PLANT ENGINEERING MANUAL PROC NO EM-09-04 PAGE 3 OF 11 INSERVICE TESTING OF SELECTED REVISION 5 consumers Power TITLE i

. SAFETY-RELATED PUMPS DATE 9-4-81 2.0 SCOPE (Contd) 2.2.4 In general, instrumentation is not available to measure both flow and discharge pressure for the pumps under test. It is, therefore, not possible to set a given reference flow while pressure is being measured. For all pumps except service water, however, the system test conditions are repeatable so that sys_tem resistance can be considered constant. Either d/p or flow, therefore, provides sufficient information to monitor pump hydraulic performance.

For the service water system, flow resistance of the system will vary because of temperature control valves in the lines to many of the components cooled by service water. No flow indication is available, however. For these pumps, an empirical curve of discharge pressure vs lake *temperature is used for the pump acceptance criteria *

.2.. 3 This procedure and the associated surveillance procedures are effective for the 20-month program interval from Nov. 1, 1981 through June. 1, 1983, in accordance with Reference 3.2. Eight months prior to end of this interval, the assigned Project Engineer shall reyiew all applicable procedures and update them as necessary to comply with the next required Code edition.

3.0 REFERENCES

3.1 ASME Boiler and Pressure Vessel Code,Section XI, Subsection IWP, 1977 edition with Addenda through Summer 1979.

3..2 10CFR50. 55a

3..3 Technical Specification 4.3.c.

3.4 Techni.cal Specification 4. 6. 3.

PALISADES NUCLEAR PLANT ENGINEERING MANUAL

  • PROC NO EM-09-04 PAGE 4 OF 11 TITLEi INSERVICE TESTING OF SELECTED REVISION 5 consumers Power SAFETY-RELATED PUMPS DATE
  • 9-4-81 4.0 DEFINITIONS 4.1 Alert Range - That range (Table 2) for a given pump parameter outside the normal operating range in which an increased testing frequency is specified.

4.2 Required Action Range - That region (Table 2) outside the upper and lower limits of the Alert Range in which the pump is considered inope.rable until further action is taken.

4.3 Pump Record - Information showing the history of a pump, including the original manufacturer's test data, surveillance test results and significant maintenance actions. At Palisades, the pump record includes the Vendor print files (original pump data), the completed TS surveillance test file (test results),

the Maintenance Order files (pump maintenance docume~tation and post-maintenanc test results) and the applicable surveillance test procedure basis document (source of test limits and basis).

2;.....4 Project Engineer - That individual assigned by the Technical Superintendent to oversee performance of the pump testing program, evaluate test data and coordinate required repairs identified by these tests *

.4.4 Technical Specification Surveillance Program Administrator (TSSPA) - That individual responsible for the administration of the Tech Spec surveillance program.

5.,;D PROCEDURE 3.1 Frequency and Scheduling of Tests (IWP - 3400) 3 1 J_ Each pump test must be run monthly except when the plant is shutdown. If a monthly test is not performed during a shutdown, it must be performed within one week of return to normal plant operation.

Normal plant operation is defined by the Code to include those periods during

.start-up, hot standby, operation or cooldown.

.,.* 'r

  • PALISADES NUCLEAR PLANT PROC NO EM-09=04 ENGINEERING MANUAL PAGE 1 OF 11

- REVISION 5 TITLE; INSERVICE TESTING OF SELECTED consumers Power . SAFETY-RELATED PUMPS DATE 9-4-81 1.0 PURPOSE To establish procedures for Inservice Testing and evaluation of selected pumps~

2.0 SCOPE 2.1 This procedure provides general requirements for the performance and adminis-tration of the Inservice Testing Program for selected pumps. Table 1 provides a complete listing of those pumps included in this program and specifies the procedure to be used to perform each test.

2.2 This procedure complies with all requirements of Reference 3.1 with the-exception of the following items for which relief requests have been sub-mitted to the NRC:

2.2.1 No provisions have been made on any of the pumps listed in Table 1 to directly measure pump suction pressures. These will be calculated from the height difference between each pump and the level in the expansion tank on the sue- '

tion side of the pump. These tank levels will be measured once with the pump:

running, since tank level with the particular pump turned off is immaterial.

2.2.2 An indication of bearing temperature and trends will normally be obtained using a calibrated contact pyrometer on the outside of the bearing housin.g.

When no measurement can be made, the specific exception to this Code require-ment will be noted in each individual test procedure. For consistency, when :

a good location has been identified for the required measurements, it should

  • be marked with a black dot or otherwise identified in each procedure.

2.2.3 Since Plant design will not permit direct measurement of differential pressures, they will be derived using the measured pump discharge pressure and the calculated pump suction pressure. This derived differential pressure will be used as .the basis for comparing pump performance from test to test.

PALISADES NUCLEAR PLANT

--<~~-:1 ,_ _ ..:.,..

(@ TITLEi ENGINEERING MANUAL INSERVICE TESTING O~ SELECTED PROC NO EM-09-04 PAGE 2 OF 11 REVISION 5 consumers Power SAFETY-RELATED PUMPS DATE 9-4-81.

2.0 SCOPE (Contd) 2.2.3 Pump suction pressures will be derived using the following general formula:

2

  • p2 = pl + .0067V2 + .433 (hxt Ehf)

Where:

P1 = Tank pressure, psig.

. p2 = Pump suction pressure, psig v2 = Fluid velocity at pump suction in ft/sec hxt = Height of expansion tank level a*bove pump suction Ehf Flow losses in suction piping between pump suction and point where expansion tank surge line connects to pump suction piping.

hf values will be determined for each section of piping of each size, and these values summed to give total suction flow losses Ehf ~or each pump. hf values are determined by using the formula:

2 L v

  • hf = f Jd 2g" Where:

f = Friction factor, approximately .02 L/d = Length to diameter ratio for pipe or the equivalent value for valves and fittings as determined from standard reference books such as the Mechanical Engineers Handbooks or Piping Handbooks.

V = Fluid velocity in that section of piping under study.

  • Source and derivation of these formulas can be found in Mechanical Engineers Handbook.

Specific details of calculations for each pump in the program can be found in the Basis Document for the applicable test procedure. (See Table 1)

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