ML19209A584

Responds to IE Bulletin 79-15.Thirteen Deep Draft Pumps Found in safety-related Applications.Outlines Location,Model Number,Capacity & Manufacturer

ML19209A584
Person / Time
Site:	Peach Bottom
Issue date:	09/06/1979
From:	Gallagher J PECO ENERGY CO., (FORMERLY PHILADELPHIA ELECTRIC
To:	Thornburg H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
References
NUDOCS 7910050023
Download: ML19209A584 (14)

Text

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PHILADELPHIA ELECTRIC COMPANY 2301 M ARKET STREET P.O. BOX 8699 PHILADELPHI A. PA.19101 JOSEPH W. GALLAGHER atactnic Pacouc7 om capanTasant Q1N M M 3 September 6, 1979 Re: Docket Nos.: 50-277 50-278 IE Bulletin 79-15 Mr. Harold D. Thornburg, Director Division of Reactor Construction Inspection Office of Inspection & Enforcement United States Nuclear Regulatory Commission 631 Park Avenue Y.ing of Prussia, PA 19406

Dear Mr. Thornburg:

This letter is in response to IE Bulletin 79-15, wh*ch you forwarded to us on July 11, 1979, concerning manufacturing deficiencies which have been identified in deep draft pumps utilized in safety related applications in several facilities.

The " Action to be Taken by Licensees" and our responses are treated sequentially.

Action To Be Taken 3v Licensee

1) Provide information relative to the number of deep draft pumps similar to those shown in Figures 1 and 2 utilized in safety related applications in each facility.

2) Provide information relative to manufacturer, model, capacity and plant application of applicable pumps.

Response

There are 13 deep draft pumps in safety related applications at PBAPS. Four pumps serve Unit 2, four serve Unit 3, and the remaining five are common to both Units. All of the above described pumps are similar to Figure 1.

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. s Mr. Thornburg Page 2 The High Pressure Service Water Pumps (HPSW) function to provide cooling water (river water) to the Residual Heat Removal (RHR)

Heat Exchangers for all modes of the RHR requiring cooling water.

The Emergency Service Water Pumps (ESU) normally provide cooling water (river water) to the Emergency Diesels and upon loss of normal Service Water to various ECCS pumps, motor and room coolers and to the Reactor Building Closed Cooling Water Heat Exchangers. The Emergency Cooling Water (ECW) Pump serves as a back-up pump to the two ESW pumps.

The Diesel and Motor Driven Fire Pumps are the water source for all water type fire protection systems.

Capacity Equipt Flow-gpm No. Plant Application Model No. Head-Feet Manufacturer UNIT 2 2AP42 High Pressure D-24821 4500 Layne &

Service Water 700 Bowler 2BP42 High Pressure D-24821 4500 Layne &

Service Water 700 Bowler 2CP42 High Pressure D-24821 4500 Layne &

Service Water 700 Bowler 2DP42 High Pressure D-24821 4500 Layne &

Service Water 700 Bowler UNIT 3 3AP42 High Pressure D-27517 4500 Layne &

Service Water 700 Bowler 3BP42 High Pressure D-27517 4500 Layne &

Service Water 700 Bowler 3CP42 High Pressure D-27517 4500 Layne &

Service Water 700 Bowler 3DP42 High Pressure D-27517 4500 Layne &

Service Water 700 Bowler COMMON 0AP57 Emergency D-26074 8000 Layne &

Service Water 96 Bowler OBP57 Emergency D-26074 8000 Layne &

Service Water 96 Bowler 00P186 Emergency D-28460 8000 Layne &

Cooling Water 96 Bowler 00P63 Diesel Driven 6927F 2500 Fairbanks-Fire Pump 289 Morse 00P64 Motor Driven 6927F 2500 Fairbanks-Fire Pump 289 Morse i108 298

Mr. Thornburg Page 3 Action To Be Taken Bv Licensee

3) Provide overall dimensions of applicable pumps.

Response

The requested information is provided as follows:

Pump Length (1) Diameter (2)

High Pressure Service Water 372.75" 18.75" Emergency Service tiater 359" 30.75" Emergency Cooling Water 520.25" 30.75" Motor and Diesel Driven Fire Pumps 316" 15.45" (1) Length is overall length of pump, exclusive of driver.

(2) Diameter is pump column diameter (maximum bowl diameter).

Action To Be Taken Bv Licensee

4) Provide summary of startup, testing and roucine maintenance history.

Resnonse Startup testing for all pumps consisted of flow, discharge pressure, pump shutoff head pressures, motor current (except Diesel Fire Pump), vibration and temperature data collection.

Routine testing of subject pumps is performed in accordance with the Peach Bottom Atomic Power Station Technical Specifications and In Service Inspection pump testing requirements which address ASME B&PV Code Section XI, and, in general, consists of the above mentioned parameters. Routine maintenance history is included below in conjunction with response to question 5.

Action B Be Taken h Licensee

5) Provide information relative to operational problems and major repair efforts.

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!!r . Thornburg Page 4

Response

Included in this section, in addition to information from 5) above, is the partial response to 4), relative to routine maintenance history. Operational problems, as such, are exhibited by the need for corrective action and therefore are an integral part of the below provided information:

High Pressure Service Unter Pumps UNIT 2 2AP42 Work Performed 5/29/73 Repacked pump 10/22/73 Shaft sleeve bound on shaft Replaced with 3AP42 pump 1/20/76 Reset impeller clearances 6/19/76 Reset impeller clearances 3/22/77 Replaced Column Flange Bolts for seismic upgrade 6/20/77 Repacked pump and installed new shaft sleeve.

8/30/77 Replaced coupling bolts and nuts found not to be within specifications 5/30/79 Repacked pump 2BP42 Work Performed 10/5/73 Reset impeller clearances 2/13/74 2BP42 Removed for vendor inspection, replaced with 3BP42 5/20/75 Repacked pump 5/26/75 Repacked pump 3/15/76 Rebuilt pump (low capacity) 6/19/76 Rebuilt pump (Broken Shaft Coupling) 1108 300

Mr. Thornburg Page 5 10/6/76 Rebuilt pump (Broken Shaft Coupling)

Evaluation made and coupling hardness reduced.

8/17/77 Replaced Column Flange 3olts for Seismic Upgrade 9/11/77 Replaced coupling bolts and nuts found not to be within specifications 7/12/78 Reset impeller clearances 9/25/78 Rebuilt pump (low capacity) dCP42 Work Performed 10/5/73 Reset impeller clearances 10/8/73 Adjust packing 6/19/76 Reset impeller clearances 4/14/77 Replaced Column Flange Bolts for seismic upgrade 7/21/77 Repacked pump and replaced lantern ring 8/31/77 Replaced coupling bolts and nuts found not to be within specifications 9/28/78 Rebuilt pump (low capacity) 2DP42 Work Performed 10/5/73 Reset impeller clearances 1/19/75 Adjusted packing 5/22/75 Repacked pump 3/1/77 Repacked pump 7/28/77 Removed obstruction from first stage impeller and reset impeller clearances i108 $01

Mr. Thornburg Page 6 9/11/77 Replaced column flange bolts for seismic upgrade and replaced coupling nuts and bolts found not to be within specifications 7/7/78 Reset pump clearances 5/22/79 Adjusted packing UNIT 3 3AP42 Work Performed 8/20/74 Reset impeller clearances 3/14/76 Adjusted packing 2/22/77 Adjusted packing 3/18/77 Replaced column flange bolts for seismic upgrade 4/10/77 Adjusted packing 9/13/77 Replaced coupling bolts and nuts found not to be within specifications 2/2/79 Pump removed for rebuild (low capacity) 3BP42 Work Performed 8/20/74 Impeller clearance checked 8/23/74 Repacked pump 9/13/77 Replaced coupling bolts and nuts found not to be within specifications 9/26/77 Replaced column flange bolts for s'*smic upgrade 12/8/77 Added packing to pump 7/18/78 Reset impeller clearances 8/30/78 Reset impeller clearances 9/21/78 Repacked pump i108 302

Mr. Thornburg Page 7 3CP42 Work Performed 8/20/74 Checked impeller clearance 1/6/76 Pump repacked 4/4/77 Replaced column flange bolts for seismic upgrade 9/27/77 Replaced coupling bolts and nuts found not to be within specifications 7/13/78 Reset impeller clearance 3DP42 Work Perforned 8/20/74 Reset impeller clearances 11/20/76 Repacked pump 5/3/77 Replaced column flange bolts for seismic upgrade 9/7/77 Pump rebuilt (motor had been improperly reconnected and subsequently run in reverse rotation) 12/7/77 Repacked pump 9/22/78 Adjusted packing COMMON OAP57 - Work Performed Emergency Service Water 'A' 3/22/77 Replace motor hold down bolts for seismic upgrade OBP57 - Work Performed Emergency Service Water 'B' 4/20/77 Replace motor holddown bolts for aeismic upgrade i108 303

Mr. Thornburg Page 8 00P186 -

Work Performed Emergency Cooling Water NONE NONE PERFORMED 00P63 - Work Performed Diesel Driven Fire Pump 4/12/73 Pump removed for inspection during construction. Long run times at minimal flow caused silt buildup in pump and subsequent starting p roblems 00P64 - Work Performed Motor Driven Fire Pumo 9/20/78 Repacked pump Action To Be Taken By Licensee

6) Provide information relative to the longest interval that each pump has been available for operation without 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 operation at or near rated flow conditions for each pump and the status of the pump operability at the end of the run.

Response

The requested information is provided as follows:

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Mr. Thornburg Page 9 AVAILABILITY FOR OPERATION WITHOUT MAJOR

• CORRECTIVE MAINTENANCE High Pressure Service Water UNIT 2 Pump Period Duration A 10/22/73 - 1/20/76 2 years, 98 days B 2/13/74 - 3/15/76 2 years, 32 days C 10/5/73 - 6/19/76 2 years, 284 days D 10/5/73 - 7/28/77 3 years, 323 days UNIT 3 Pump Period Duration A 8/20/74 -

2/2/79 4 years, 192 days B 8/20/74 - 8/30/78 4 years, 355 days C 8/20/74 -

7/13/78 3 years, 328 days D 8/20/74 - 7/17/78 3 years, 332 days

• Major Corrective Maintenance is specified to indicate that some maintenance which would not affect pump performance or operability, i.e., packing leakage, was performed during these periods.

Fmergency Service Unter A & 3 No major corrective maintenance has been required on these pumps.

Emergency Coolinq Water No major corrective maintenance has been required on this pump.

Diesel and Motor Driven Fire Punps With the exception of the silt problem on the Diesel Fire Pumps during plant construction as described in response 5), no major corrective maintenance has been required on these pumps.

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Mr. Thornburg Page 10 CYCLES AND CYCLE DURATION SUhMARY FOR LONGEST INTERVAL UITHOUT MAJJR CORRECTIVE MAINTENANCE UNIT 2 HIGH PRESSURE SERVICE WATER PUMPS Cycle A Pump B Pump C Pump D Pump Duration (Cycles) (Cycles) (Cycles) (Cycles) 5 min. 5 4 6 13

-30 min. 9 5 12 43 30-60 min. 4 15 7 66 1-10 hr. 30 42 46 65 10-50 hr. 5 10 21 16 50-100 hr. 2 4 100-120 hr. 1 120-140 hr. I 140-160 hr. I 160-180 hr.

180-200 hr.

200-220 hr.

22C-240 hr. 1 UNIT 3 HIGH PRESSURE SERVICE WATER PUMPS Cycle A Pump B Pump C Pump D Pump Duration (Cycles) (Cveles) (Cycles) (Cveles) 5 min. 33 31 24 25 5-30 min. 60 35 19 23 30-60 min. 27 2 5 5 1-10 hr. 68 24 20 31 10-50 hr. 15 11 10 8 50-100 hr. 3 3 4 6 100-120 hr. 4 2 120-140 hr. I 1 3 140-160 hr. I 160-180 hr. 2 2 180-200 hr. 1 200-220 hr. 1 220-240 hr.

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Mr. Thornburg Page 11 A AND B EMERGENCY SERVICE WATER PUMPS AND EMERGENCY COOLING WATER PUMP Cycle A Pump B Pump ECW Pump Duration (Cycles) (Cycles) (Cycles) ,

1 min. 810 810 1660 15 min. 25 25 5 30 min. 230 230 -

I hour 580 580 -

Various (1) 120 120 -

(1) Cycle durations vary in this category from approximately 15 minutes to 16 hours1.851852e-4 days <br />0.00444 hours <br />2.645503e-5 weeks <br />6.088e-6 months <br />. Included in this category are estimated ESW pump starts during emergency diesel runs for various infrequent surveillances, trouble shooting, governor testing, and startup feed outages.

DIESEL AND MOTOR DRIVEN FIRE PUMPS

• Cycle Diesel Driven Motor Driven Duration Fire Pumo Fire Pump 15 min. 21 18 30 min. -

72 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> 6 6 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> - 12

• Cycle and Cycle durations are estinated.

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Mr. Thornburg Page 12 LONGEST CONTINUOUS OPERATION AND PUMP STATUS AFTER RUN High Pressure Service Water Hours Subsequent Pump Status UNIT 2 2A Pump 47 Satisfactory flow, discharge head and physical condition.

2B Fump 231 Satisfactory flow, discharge head and physical condition.

2C Pump 101 This run occurred during an outage.

Subsequent to this run, the pump was run an additional 330 hours0.00382 days <br />0.0917 hours <br />5.456349e-4 weeks <br />1.25565e-4 months <br />, at which time the discharge pressure of the pump was low and was increased by resetting impeller clearances.

2D Pump 155 This run was terminated due to a sudden decrease in discharge pressure.

Pump was removed, foreign obstruction (rope) found in first stage impeller, pump reinstalled and performance satisfactory. (Subsequent inspection performed by diver in all bays for foreign material)

UNIT 3 3A Pump 197 Satisfactory flow, discharge head and physical conditicu.

3B Pump 168 Satisfactory flow, discharge head and physical condition.

3C Pump 100 Satisfactory flow, discharge head and physical condition.

3D Pump 132 Satisfactory flow, discharge head and physical condition.

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Mr. Thornburg Page 13 Emergency Ser" ice Water and Emergency Cooling Water Pumps The ESU pumps are run primarily to provide cooling water to the emergency diesels. As a result, there have been no significantly long continuous operations of these pumps. The longest run for these pumps is estimated to have been approximately 16 hours1.851852e-4 days <br />0.00444 hours <br />2.645503e-5 weeks <br />6.088e-6 months <br />. No corrective maintenance has been required on these pumps.

Similarly, there have been no significantly long continuous operations of the ECW pump, which had also required no corrective maintenance.

Diesel and Motor Driven Fire Pumps There have been no significantly long continuous operations of these pumps, and with the exception of the silt problem on the '

Diesel Fire Pump during plant construction, as described in response 5), no major corrective maintenance has been required on these pumps.

In addition to the information provided above, the following information is availaale at the plant site and ^ur central maintenance shops, where pump rebuild work 14 p 'ormed, for inspection:

1) Drawings, sectional assemblies a r. d p a r t s list.

2) Detailed history of pump maintenrnce (alignment, parts replacement, etc.) including beating wear data, replacement frequency and a comparison with ,;h e manufacturers rated life for wearing surfaces.

3) Quality assurance and reliability testing requirements.

4) Design specifications.

5) Results of tests performed during operation or prior to licensing.

6) Details of the procedures used to align the pump column.

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Mr. Thornburg Page 14 Maintenance and Operating History Evaluation High Pressure Service Water _ Pumps The major problems associated with the HPSW pumps have been identified and resolved. In summary, column flange bolts were seismically upgraded, coupling bolts and nuts were installed to specification, shaft coupling material hardness was decreased.

Additionally, an ongoing program of mud / silt accummulation measurement and removal exists to eliminate suspected shaft coupling damage from the same, and to eliminate some degree of pump wear leading to low capacity. The HPSW pumps do not presently meet design specifications relative to discharge pressure at rated flow, however, the technical specification discharge pressure at rated flow is significantly below design; present pump discharge pressures, at rated flow, are approximately 45 psig above the technical specification values.

Based on the above, the operability status of the HPSU pumps is deemed to be adequate and no further actions are anticipated.

Emergency Service Water, Emertency Cooling Water, and Fire Pumps The maintenance and operating history of these pumps indicate reliable performance and conformance to design requirements.

Based on this history, no action is anticipated with respect to these pumps.

Should you have any questions or require additional information, please do not hesitar.e to contact us.

Sincerely, cc: Boyce H. Grier U. S. Nuclear Regulatory Commission Region 1 631 Park Avenue King of Prussia, PA 19406 i108 310