ML18136A030

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Responds to IE Bulletin 79-15, Deep Draft Pump Deficiencies. Major Repair Efforts Limited to Four Outside Recirculation Spray Pumps Experiencing Excessive Bearing Wear
ML18136A030
Person / Time
Site: Surry, North Anna  Dominion icon.png
Issue date: 09/14/1979
From: Stallings C
VIRGINIA POWER (VIRGINIA ELECTRIC & POWER CO.)
To: James O'Reilly
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
References
582-071179, 582-71179, NUDOCS 7910040661
Download: ML18136A030 (22)
v • d • e


Text

{{#Wiki_filter:.. L VIRGINIA ELECTRIC AND POWER COMPANY RXCHHOND,VXBGXNJ:A 23261 September 14, 1979 Mr.* James P. O'Reilly, Director Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission Region II 101 Marietta Street, Suite 3100 Atlanta, Georgia 30303 Serial No. PO/FHT:baw Docket Nos: License Nos.

SUBJECT:

IE BULLETIN 79-15 SURRY POWER STATION UNITS 1 AND 2 NORTH ANNA POWER STATION UNITS 1 AND 2

Dear Mr. O'Reilly:

582/071179 5~280 5~281 5~338 5~339 DPR-32 DPR-37 NPF-4 CPPR-78 .*~... -;c: ---,-.~ 2: ::J -.,J --{ 0

-: f!J c3 In response to the subject Bulletin, "Deep Draft Pump Deficienciesu, Vi.Itinia ',::,

Electric and Power Company herewith provides responses for Surry and Nfni>th ..' ~,:: Anna Power Stations in attachments 1 and 2. Additional information is.._ -;.~ contained in previous correspondence on this topic and a reference list is provided as attachment 3 for your information. Attachments cc: Mr. Victor Stello, Director Office of Inspection and Enforcement (' +-r-** HOf-L ~--* Very truly yours, C. M. Stallings Vice President-Power Supply and Production Operations !t'9J0040 &1

e.. e Surry Power Station Units 1 and 2 Response to IE Bulletin No. 79-15 Deep Draft Pump Deficiencies The following response to IE Bulletin 79-15 covers data and information pertinent to deep draft pum-ps as utiH.ze<.t in* Safety Related applications at Surry Power Station. NRC REQUEST : "l. The mmber of deep draft pumps utilized in safety related applications in -_ each facility*."

RESPONSE

Six (6) deep draft pumps are used ill-safety related appiica~ions in Surry~1 and six (6) deep draft pumps.are used in safety related applications in Sur;ry Unit 2. Three{)} deep draft pumps are used in safety related applications common to.both Surry Units 1 and 2. NRC REQUEST: "2. Manufacturer, model, capacity and plant-application."

RESPONSE

Surry Unit 1 APPLICATION Inside Containment Recirculation Spray Outside Containment Recirculation Spray Low Head Safety Injection Surry Unit 2 APPL I CATI OU Inside Containment Recirculation Spray Outside Containment Recirculation Spray Low Head Safety Injection TAG NillIBER 1-RS-P-lA 1-RS-P-lB l-RS-P-2A 1..:.RS-P-2B 1-SI-P-lA 1-SI-P-lB TAG NUMBER 2-RS-P-lA 2-RS-P-lB 2-RS-P-2A 2-RS-P-2B 2-SI-P-lA 2-SI-P-lB MANUFACTURER MODEL Bingham Pump Co. 10Xl8B-VCR Bingham Pump Co. 10Xl8B-VCR Bingham Pump Co. 10Xl8B-J-VCR Bingham Pump Co. 10Xl8B-J-VCR Byron Jackson 18CKXH Byron Jackson 18CKXH *. MANUFACTURER MODEL Bingham Pump Co. lOX18B..:vcR Bingham Pump Co. 10Xl8B-VCR Bingham Pump Co. 10X18B-J-VCR Bingham Pump Co(t 10Xl8B-J-VCR '-Byron Jackson 18CKXH Byron Jackson 18CKXH CAPACITY 3500 GPM 3500 GPM 3500 GPM 3500 GPM 3000 GPM 3000 GPM CAPACITY 3500_ GPM 3500.GPM 3500 GPM 3500 GPM 3500 GPH 3500 GPM

e 2 - Surry Units* 1 & 2 All three Emergency Service Water pumps are identical, manufactured by: BinghaI!l Pump Co. Model: 24 x 36 VTLM Capacity: 15,000 gpm at 45 ft. head

  • Plant application: Emergency Service Water Pumps Tag Numbers:

1-SW-P-lA, lB, and lC NRC REQUEST: "3. Overall dimensions of pumps."

RESPONSE

See attachments: Inside Contaimneiit Recirculation Spray Pumps: Figure 1. Outside Containment Recirculation Spray Pumps: Figure 2. Low Ilead Safety Injection Pumps: Figure 3. Emergency Service Wacer Pumps: ~igure~ 4 and 5. NRC REQUEST: "4. Summary of startup, testing, and routine maintenance history."

RESPONSE

Startup tests on Unit 1 Low Head Safety Injection pumps were performed on ?farch 6, 1972. 1-SI-P-lA was tested satisfactorily in the recirculation mode at 176 psig and 181 gpm. 1-SI-P-lB was 'tested satisfactorily in the same mode at 177 ps_ig and 181 gpr:i. Unit.2 Low Head Safety Injection pumps were startup te*sted .on November 27, 1972.

  • Both pumps tested satisfactorily in* the recirculation mode with 2-SI-P-lA developing 172 psig and 225 gpm.

Unit 2 flow rates are higher due to a different valve lineup. All four pumps are tested monthly in accor.dance with PT 18.1. lhe results of these tests have all been satisfactory. Routine mainten-ance on these pumps has consisted of periodic inspection with no repairs necessary

  • with the exception of 2-SI-P-lB which required replacement of the mechanical seal due to leakage.

3 - The Unit 1 Recirculation Spray pumps were satisfactorily tested May 8, 1972. All pumps were run with. a shut-off head. Data below: 1-RS-P-lA 1-RS-P--lB l-RS-P-2A l-RS-P-2B 152 psig at 351 Ft. H20 155 psig at 358 Ft. H20 174 psig at 402 Ft. H20 175 psig at 403 Ft. H20 Additionally, pumps 1-RS-P-lA and 1-RS-P-lB were dry tested on March 13, 1973 to determine acceptance criteria for periodic testing. -.1-RS-P-lA showed 99 amps and l..a5/-P-1B showed 100 amps. Pumps 1-RS-P-lA and lB are dry tested monthly while pumps l-RS-P-2A and 2B are tested monthly with a shut-off head. Routine maintenance for these pumps also consists of.periodic inspections. The Unit 2 Recirculation Spray pumps were tested satisfactorily on October 13, 1972. All pumps were run with a shut-off head. See data below: 2-RS-P-lA 2-RS-P-lB 2-Rs-P-2A 2-Rs-P-2B 145 psig at 340 Ft. H20 150 psig at 352 Ft. H2o 155 psig at 408 Ft. H20 155 psig at 408 Ft. H2o Again, the inside pumps were dry tested, 2-RS-P-lA ran at liO amps and lB ran at 100 amps. Testing and routine maintenance is the same as Unit 1. All three Emergency Service Water pumps were satisfactorily startup tested on September 28, 1971 under full flow conditions. Periodic Testing consists of monthly tests in accordance to PT 25.3. Routine maintenance bas consisted of the annual preventative maintenance and periodic repacking of the packing glands. NRC REQUEST: "5. Operational problems and major repair efforts."

RESPONSE

To date, there have been no operational problems or major repair efforts associated with the Low Head Safety. Injection pumps on either unit. There have been no major operational problems associated with the recir-culation spray pumps on both units. Major repair efforts have been limited to the four outside recirculation spray pumps. In May of 1978 all four pumps were disassembled and the shafts were sent off-site to be chromed. This was a result of _excessive bearing wear identified at North Anna~ The shafts were chromed as a preventive measure to reduce bearing wear~ To date, only 1-RS-P-lA

  • has shown excessive clearances, Reference LER-78-012. 'Foreign ~tter was trapped between the impeller wear ring and casing wear ring and light scoring was found on the wear rings.

To date, there have been no operational problems or major repair efforts on the emergency service water pumps, with the exception of 1-SW-P-lA which required. a new shaft and all bearings replaced. This repair effort was due to a non-level base plate which was corrected. _ __J

e NRC REQUEST: "6. The longest interval that each pump has been available for operation without corrective maintenance. Identify the numbe_r of cycles of operation during this interval, the duration of each cycle and the operating mode. Identify the longest continuous operation at or near rated flow conditions for each pump and the status of the pump operability at the end of the run.

RESPONSE

Following manufacture, all twelve pumps were run at rated flow for between 45 and 60 min. All pumps were satisfactory at the end of the run. See Table

  • for operational history.

PUMP INTERVAL NO. OF CYCLES DURATION OPERATING MODE 1-SI-P-lA 74 mo. 74 15 30 min. Recirc mini flow* 1-SI-P-lB 89 mo. 89 15 30 min.

  • Recirc mini flow 2-SI-P-lA 81 mo.

81 15 - 30 min. Recirc mini flow 2-SI-P-lB 67 mo. 67 . 15 30 min. Recirc mini flow 1-RS-P-lA 70 mo. 70 30 sec. Dry-test 1-RS-P-lB 73 mo. 73 30 sec. Dry-test l-RS-P-2A 69 mo. 69 30 sec. Shut-off head 1-RS-P-2B 70 mo. 70 30 sec. Shut-off head 2-RS-P-lA 69 mo. 69 30 sec. Dry-test 2-RS-P-lB 69 mo. 69 30 sec. Dry-test 2-RS-P-2A 58 mo. 58 30 sec. Shut-off head 2-RS-P-2B 58 mo. 58 30 sec

  • Shut-off head

. Following manufacture, all three Emergency Service Water pumps were run at rated flow for between 70 and 100 min. All pumps were satisfactory at-the end of the run. Operational *history below: ~ INTERVAL NO. OF CYCLES DURATION OPERATING MODE 1-SW-P-lA 69 mo. 69 15 min. Rated Capacity 1-SW-P-lB 95 mo. 95 15 min. Rated Capacity 1-SW-P-lC 95 mo. 95 15 min. Rate~- Capacity

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.L.,., I, 4 :" "/;. _;, '* * ~ ..,. ;,, ? -== e.* NORTH ANNA POWER STATION UNITS 1 AND 2 RESPONSE TO IE BULLETIN NO. 79-15 DEEP DRAFT PUMP DEFICIENCIES

1.

The number of deep draft pumps similar to those shown in Figures 1 and 2 utilized in safety related applications in each facility. There are 10 deep draft pumps per unit.

2.

Manufacturer, model, capacity and plant application.

a.

Two low head safety injection pumps manufacturer - Ingersoll - Rand model - 25 APK-2

  • . capacity - 3000 gpm
b.

Two inside recirculation spray pumps manufacturer - Bingham - Willamette size and type - 10 x 18B - VCR capacity - 3700 gpm

c.

Two outside recirculation spray pumps manufacturer - Bingham - Willamette size and type - 10 x !SB-VCR capacity - 3700 gpm

d.

Two service water pumps manufacturer - Johnston Pump Company size and type - 2A QMC/QHC capacity - 11,500 gpm

e.

One screenwash pump (service water) manufacturer - Johnston Pump Company size and type - 10 CC capacity - 500 gpm

f.

One screenwash pump (circulating water) manufacturer - Johnston Pump Company size and type - 12cc capacity - 910 gpm

3.

Overall dimensions of pumps See attached diagrams

4.

Summary of startup, testing and routine maintenance history * . a. Unit 1 Low Head Safety Injection pumps 1-SI-P-lA and 1-SI-P-lB The pumps were preoperationally tested by Vepco in April 1977 to verify pump operating characteristics consistent with design speci-fications. All test results were acceptable except that-.recirculation flow for each pump was below the minimum acceptable value,; Further analysis, however, proved the low flow rates acceptable for mini-flow operation. These pumps are presently required by Technical Speci....: fications to be tested every 31 days by operatin~ at recirculation

e e flow for 5 to 10 minutes to insure they meet the head flow curve. The pump motors periodically have their oil analyzed and changed if necessary.

b.

Unit 1 Inside Recirculation Spray Pumps 1-RS-P-lA and 1-RS-P-18 The pumps were preoperationally tested by Vepco in May 1977 with acceptable results. In April 1979, a special test was perfonned on the pump motors to verify that a tolerance problem with the lower bearings did not exist. The test involved erection of a temporary dike around the containment sump and operating the pumps on recirculation to and from the sump at full flow. Bear*ing temperatures were*.monitored by use of thennocouples inserted in the lower bearing grease relief plug and upper grease fitting. Test data revealed that the lower bearing temperatures peaked after. *:;t. some five hours of operation. Each pump was operated an additional six to seven hours with no further increase in bearing temperature, indicating that the bearings installed were sufficiently "loose 11 to preGlude seizure of the shaft due to heatup. Presently, the inside recirculation spray pumps are tested every 31 days to check pump start and shaft rotation by running the pumps in the dry condition for no longer than a 30 second time period. *

c. Unit l Outside Recirculation Spray Pumps 1-RS-P-2A and l-RS-P-28 The pumps were preoperationally tested by Vepco in July 1977 with satisfactory results. The pumps are presently required to be tested every 31 days during which pump start and shaft rotation is verified by filling the pump cans and operating the pumps in the wet condition for no longer than a 30 second interval. The pumps are also tested every 18 months by running on recirculation flow for 5 to 10 minutes. This test insures that they meet their respec-tive head flow curve.

Periodically the oil in the outside recirculation spray pump motors is sampled and analyzed. The oil is changed if analysis reveals *. excessive concentrations of water or sediment.

d. Unit 1 Service Water Pumps 1-SW-P-lA, 1-SW-P-lB.

These pumps were tested starting in November 1977 with satisfactory results. The pumps are required to be tested every 31 days. They are run for at least 5 minutes with normal flow for the test.

e. Unit 1 Service Water Screenwash Pump 1-SW-P-2 This pump was tested starting in November 1977 with satisfactory results. Presently, it is required to test this pump every 31 days.

The pump is tested by running it on recirculation flow for.5 to 10 minutes.

e* 3 - e

f.

Unit 1 Circulating Water Screenwash Pumps l-CW-P-2B This pump was first tested in November 1977 with satisfactory results and is periodically tested at 31 day intervals. The pump is tested by running-it on recirculation flow for 5 to 10 minutes.

g.

Unit 2 Low Head Safety Injection Pumps 2-SI-P-lA and 2-SI-P-lB. The pumps were preoperationally tested by Vepco in February 1979. All test results were acceptable. Presently, Unit 2 is still in the initial testing phase. The LHSI pumps will undergo the same periodic testing and maintenance as the Unit 1 pumps.

h.

Unit 2 Inside and Outside Recirculation Spray Pumps 2-RS-P-lA, 2-RS-P-lB, 2-RS-P-2A and 2-RS-P-2B. The pumps were preoperationally tested by Vepco from January 1979 until March 1979 with satisfactory results. All four pumps will be tested and maintained at the same periodicity as their Unit 1 counterparts.

i. Unit 2 Service Water Pumps 1-SW-P-lA, 1-SW-P-lB The pumps were tested starting in May 1979 by Vepco with satisfactory results.

Both pumps will undergo the same periodic testing and maintenance as the Unit 1 pumps.

j. Unit 2 Screenwash Pumps 2-SW-P-2, 2-CW-P-2A.

The pumps were first tested in February 1979 with satisfactory results. Both pumps will undergo the same periodic testing and maintenance as the Unit 1 pumps.

5.

Operational problems and major repair efforts.

a.

Unit 1 and 2 Low Head Safety Injection Pumps 1-SI-P-lA, 1-SI-P-lB, 2-SI-P-lA and 2-SI-P-lB. The pumps developed bearing problems and model testing indicated that bearing wear was attributed to flow pr_oblems in or near the pumps suction piping. The following modifications were made on the Unit 1 and Unit 2 LHSI pumps:

1.

Flow straightening devices were installed in the bottom of the LHSI pump cans to eliminate vortexing.

2.

A third bearing in the pump element was added to increase shaft rigidity in the region.

3.

The bearing material was changed from nic~l filled carbon to solid carbon.

4.

Bearing pockets were made larger to increase bearing*. stability.

5.

The line shaft coupling was chrome plated to reduce tolerances.

6.

Pump sections were divided in half which doubled the number of bearings and the shaft was chrome plated at the bearings. e

b. Unit 1 Inside Recirculation Spray Pumps 1_-RS-P-lA and 1-RS-P-1B Prior to acceptance*testing, the pumps experienced some startup problems which were corrected. Both pumps required re-machining of the spacer coupling between pump and motor. Hanger re-work was also required on the recirculation discharge lines of both pumps.

The lB pump bound up in June 1977 and foreign material was found in the first stage. Four bearings were replaced and the pump was reassembled and successfully operated. ~.

  • In April 1979, a lower bearing in a Unit 2 inside recircul.ation spray pump motor failed due to inadequate clearance in the doubJe row ball bearing used as a guide and thrust bearing on the lower end of the motor. To prevent this problem from recurring, the motors will be fitted with a single row angular contact split inner ring bearing which has ratings exceeding the original. The end shield opening will be increased in size to give a greater radial clearance around the shaft. Also, to minimize this increase, the labyrinth sealing slinger on the lower end of the end shield will be made larger in diameter, one labyrinth surface will be added, plus the labyrinth clearances will be made closer and the distance the lab seal sits on the seal will be made longer. These modifications, which have already been made on the Unit 2 inside

. recirculation spray pump motors,- will be made on Unit 1 during the upcoming refueling outage.

c. Unit 1 Outside Recirculation Spray Pumps 1-RS-P-2A and l-RS-P-2B Prior to May 1977, several startup problems were experienced with the pumps and corrected. The 2A pump had motor to pump misalign-ment, which was corrected by realignment and retorquing the bolts.

The 2A pump was also damaged during a run when a piece of wood, which was apparently left in the suction line, passed through the* pump. The shafts and several bearings were replaced. The 2B motor bearings* were replaced because-of binding experienced when- ; rotating the shaft. All of these startu'p problems were corrected prior to May and pump operation has been successful since that time.

6. The longest interval that each pump has been available for operation with-*

out corrective maintenance. Identify the number of cycles of operation during this interval, the duration of each cycle and the operating mode(s) (recirculation, rated flow, etc.). Identify the longest continuous opera-tion at or near rated flow conditions for each pump and.the status of the pump operability at the end of the run.

a. The Unit 1 low head safety injection pumps have been available for operation since initial operation of the u*nit in Apr:-il 1978. During this 16 month period, 1-SI-P-lA has been operated a total of. 20 times and 1-SI-P-lB has been operated 20 times to satisfy periodic surveil-1 a nee requirements.

Each pump run lasted 5 to.1 O minutes on rec i r-culation flow. After the longest runs, which lasted 10 minutes, the pumps were in good running order.

-- e

b.

The longest interval that the Unit 1 inside recirculation spray .pumps have been available for operation without corrective mainte-nance has been 16 months. During this period, 1-RS-P-lA and l-RS-P-18 were operated dry 12 times for no longer than 30 seconds. The longest continuous operation for each pump was_during the perfonnance of a special test where the pumps ran for._ 12 hours. At the completion of this test both pumps were in good running condition.

c. The Unit 1 outside recirculation spray pumps have been available for operation without corrective maintenance since the unit went critical in April 1978. During this 16 month period, both pumps have been operated wet 12 times for no longer than 30 seconds.
  • 1-RS-P-2A and l-RS-P-2B were also satisfactorily operated on recirculation flow for 10 minutes to satisfy the 18 month surveil-lance requirement. After this test, both pumps remained in good running order.
d. The Unit'l_Service Water Pumps have been available for operation without corrective maintenance since initial operation of the unit in April 1978. During this 16 month period.1-SW-P-lA has been operated for testing 20 times and 1-SW-P-lB has been operated for testing 18 times.

One of these pumps is always running and are nonnally alternated on a weekly basis.

e. The Unit l service water screenwash pump has been available for operation since initial operation in April 1~78~

During this 16 month period, 1-SW-P-2 has been operated for testing purposes 17 times. The pump is also cycled for durations* up to l hour when it is ~eeded. f* *. The Unit l circulating water screenwash pump has been available for operation since initial operation in April 1978. During this 16 month period, l-CW-P-28 has been operated for testing purposes 18 times. The pump is also ~ycled for durations up to 30 minutes.

g. The Unit 2 low head safety injection pumps, inside recirculation spray pumps and outside recirculation spray pumps have all had the necessary modifications made to them.and are presently under-going further testing to verify their capabilities.
h.

The Unit 2 service water pumps and screenwater pumps have been cycled in the same manner as their Unit 1 counterparts but have only been available for operation since April 1979 * ~-

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DEEP DRAFT PUMP MODIFICATIONS AND TESTING REFERENCES* A. Surry B. I. Our letter Serial No. 269A/030578, dated May 26, 1978, provided Surry Unit 1 pump inspection results.

2.

Our letter Serial No. 269B/030578, dated July 26, 1978, provided Surry

3.
4.
5.

Unit 2 pump inspection results. Our letter details of Our letter additional Our letter additional Serial No. 296C/030578, dated September 29, 1978, provided proposed modifications to the pumps. Serial 603A/101978, dated December 15, 1978, provided pump testing and inspection information. Serial 603B/101978, dated January 31,' 1979, reported information relative to testing and modal analysis. North Anna

1.

Our letter Serial 152, dated March 23, 1978, reported the results of pump testing.

2.

Our letter Serial 185, dated April 10, 1978, provided a modal analysis of the recirculation spray pumps.

3.

Our letter Serial 309, dated June 2, 1978, provided the results of the 450 hour test of the Outside Recirculation Spray pump.

4.

Our letter Serial 386, dated July 14, 1978, provided the results of the 23.day test of the Low Head Safety Injection Pump.

  • Note: Additional information is contained in the considerable amount of correspondence exchanged between Vepco and NRC on this subject.

The above list is only intended to provide an introduction into the discussions which occurred during the recognition and resolution of these problems. J}}

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