ML19327A834

Summary of In-Plant Test of Fine Motion Crd.

ML19327A834
Person / Time
Site:	05000605
Issue date:	09/29/1989
From:	GENERAL ELECTRIC CO.
To:
Shared Package
ML19327A831	List: ML19327A830 ML19327A834
References
NUDOCS 8910180231
Download: ML19327A834 (16)

Text

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SUMMARY

OF THE l IN-PLANT TEST CF FINE MOTION CONTROL ROD DRIVE i

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SEPTEMBER 29, 1989 i I

f PREPARED BY i GENERAL ELECTRIC COMPANY i

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IARLE 0F CONTENTS l

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1. INTRODUCTION AND PURPOSE 1:

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' 2. PERIOD OF THE TEST PROCRAM i 3,

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-3. DESCRIPTION AND SUEMARY OF RESULTS' 1 .

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SUMMARY

OF FUNCTICNAL TESTS 2 ,

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E. TESTS AT GE ENGINEERING TEST FACILITY (ETF) 2 }

i li C. TESTING AT LA SALLE 2 PIANT 8

~D. OPERATIONAL ANOMALIES AT IA FAILE 9 l t

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- 4,. COMPARISON OF THE TEFT FMCRD WITH THE FINAL DESIGN FMCRD 11 .i t

i 1 5. CONCLUSIONS 12 I l ,12 ,  ;

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i^ lw s ,, INTRODUCTION AND PURPOSE i

The program for the In Plant Demonstration of the Fine Motion Control  ;

Rod Drive'(FMCRD) was conducted to demonstrate the reliability of the i FMCRD at.J to confirm its capability and operability characteristics in er operating reactor ensironment. This report provides a summary of the '

results of this program. j

2. PERIOD OF THE TEST PROGRAM This program started on July 15, 1981 and will end on 1 September 30, 1989..

3. DXsCRIPTION AND

SUMMARY

OF RESULTS A new FMCRD was manufactured under this program in Japan and delivered to GE. Nuclear Energy / San Jose facility. This new FMCRD underwent five year life testing at GE's Engineering Test Facility (ETF) followed by a demonstration test in an operating planc in the United States. The new ,

FMCRD was designed, manufactured and stamped in accordance with Section i III of the American Society of Mechtaical Engineers (ASME) Boiler and Pressure Vessel Code. Also provided were: (1) the necessary new CRD related eluctrical and hydraulic controls; (2) position indicator '

readout and electrenics; (3) special tools; and (4) instructions fcr operation, handling, installation and maintenance. Before shipment to the U.S. .

the FMCRD and associated equipment underwent qualification testing in Japan.

The new FMCRD was installed in the high pressure vessel of ETF, then subjected to a life test equivalent to approximately five years of reactor service. The primary purpose of this test was to condact an  ;

engineering evalustion and familiarit. tion test of the M4CRD prior to its installation at the la Salle 2 plant. The objectives of the San Jose test portion of the in plant FMCRD test were to:

(1) Familiarize personnel with normal 1MCRD handling and operating characteristics.

(2) Gain In Laderstan61ng of the FMCRD under typical site operating conditions.

(3) Explore FMCRD behavior when subjected to " abnormal" conditinas.

(4) Cain confidence that the FMCRD would function reliably, as intended, subsequent to installation at the La Salle site.

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The FMCRD was installed in ETF. The high pressure vessel utilir.ed for l this test simulated a complete Boiling Water Rt.astor production j driveline, consisting of:  :

(1) Control rod  ;

(2) Guide tube  ;

(3) Fuel support . ,

(4). CRD housing (5) Puel bundles (dummy) l Test vessel internals alignment conformed with the allowable range specified for normal BVR drivelines.

t The FMCAD was tested to determine teceptability of performance characteristics under normal operating conditions and environment, with the exception of radiation. In addition, the FMCRD was subjected to tests under conditions acdeled.for abnormal states, in order to Sain increased understanding of its operating -

charecteristics.

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SUMMARY

OF PUNCTIONAL TESTS j i

Testing of the FMCRD prior to shipment to the La Salle site, including i testing in Japan, 5 year life test at ETF and additional engineering -

tests at San Jose resulted in the following estimated accumulated cyclic life:-

Operating Design Life Syr Cycles Motor Cycles Meters of Mode 40-Yr Basis Cveles Tested On/Off Travel ,

Scram 600 75 600 1,270 4,267 Step Select 180,000 22,500 62,000 62,090 10,394 Continuous __.1.002 125 300 600 2.195 ,

181,600 40,281 62,900 63,800 16,856 B. TESTS AT GE ENGINEERING TEST FACILITY (ETF) -

ABBREVIATED LIFE AND ABNORMAL CONDITIONS TESTING ,

Tcst Pretor.A1122 Testing initially conducted at ETF consisted of Abbreviated Life

• Testing and Abnormal Conditions Testing. The combined total number of cycles accumulated during both of these tests was equivalent to

• ten or mort years of the 40 year FMCRD design basis life in a control cell core application.

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I a l Testing covered a 0 1250 psi vessel pres.sure range with I approximately 10% of the required " step select" cycles accumulated at 0 psig vessel condition, and the remaining 90% accumulated at 1090 and 1250 psig vessel conditions.

Since all ETF testing was *ithin FMCRD design limits, specific 1 Abbreviated Life and Abnormat Conditions test, sequences were l intermixed to conserve test time. and limit the number of vessel  !

heatup and cooldown cycles require;d. Abbreviated Life Testing was l based on accumula*8.ng a predetermined quantity of cyclic operation j under normal ope. rional conditions.  ;

Abnormal Conditions _'esting consists of those conditions that the FMCRD and its associated controls night logically be expected to l n encounter at some time during plant operation. Abnormal Conditions )

Testing was conducted to determine equipment response to these  ;

stimuli and consisted mainly of INCRD system logic checks and FMCRD performance response as a function of design specification limits.

Inasmuch as ETF Abbreviated Life Testing and Abnormal Conditions Testing comprised five years of the 40 year cyclic life of the FMCRD in a control core cell application, test cycle distribution was targeted for: .,

Activity Cycles f

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a. Scram Test 38

b. Operational Scrams 69 '

c. Step Cycles 40,000 (6,700 m travel)

d. Drive Cycles 125 Zero Vessel Pressure Testine Accumulated cycles during this phase of test were:

Operatine Mode Cveles Sc?am 23 S'.ap Select 3,012 (673 m travel) continuous Insert / Withdraw 15 A total of 23 full stroke scrams were accumulated to establish an FMCRD reference scram base.

A total of 3,912 individual step-select insert / withdrawal commands, approximat;ng the equivalent of 10% cf the required FMCRD five-year cyclic life basis, were accumulated while exereiri g FMCRD full >

stroke. In all instances, step select commands were accepted and executed correctly. Upon completion of the final cycle, FERD 3

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• non valid commands.

Fifteen full stroke continuous insert / withdrawal FMCRD cycles were completed without incident. .

Scram Profile Test ,

During this test phase, the req' tired data were generated to construct a scram profile curve. At discrete vessel pressures of 200 400, 600, 800 and 1000 psig, two. full stroke 1600/1350 psig scrans and one short stroke (position 450 mm) 1600/1350 psig accumulator scrams were completed. Note that 1600 psig_is the ,

water charge pressure and 1350 psig is the nitrogen gas precharge '

c pressure._ Figure I shows FMCRD scram response during vesse'.

heatup. '1

.All scrams, bjth full and short stroke, were completed '

satisfactorily.

1090 vsir Vc . 1 Pressure Testine ,

Total accumulated cycles during this phase of test are shown below:

Ocerarine Mode Cveles Scram 41 Step Select 39,944 (6,000 m travel)

Continuous Insert / Withdraw 98 Scram performance was satisfactory. i t

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.k A total of 34,944 individual step < select insert / withdrawal commands, approximating the equivalent of 87% of the required FMCRD five year cyclic basis, were accumulated while exercising M4CRD '

full-stroke. In all instances, permissible commands w..e accepted and nonpermissive commands rejected.

Ninety eight full-stroke continuoua insert / withdrawal cycles ware completed during this test phase.

1250 osin Vessel Pressure Testing 7 Total FMCRD operating cycles accumulated during this portion of test are shown below:

Ooeratine Mode Cycler Scram 4 Step Select 924 (154 m travel) '

Continuous Inse et/ Withdraw 10 Four full stroke scrams, conducted such that final vessel pressure was limited to 1250 psig maximum, were satisfactorily completed. .

A total of 924 step select cycles, comprisirg the equivalent of r approximately 3% of the required FMCRD rive year cyclic life, were completed at this time. In all instcnces, permissibic commands were accepted, while nonpermissible commands were rejected. ,

Ten full stroke FMCRD insett/ withdrawal cycler were completed at 1250 psig vessel pressure.

1090 osin Vessel Pressure Testing l Abnormal conditions testing subjected the FMCRD and its associated '

controls to logically expected (within design limits) stimuli to determine equipment response primarily s 2 tem logic and FMCRD performance characteristics.

(1) Low Enercy Scram (1090 osic)

This test simulated a loss of scram accumulator nitrogen gas charge such that the accumulator low pressure alarm is tripped. Under this conditions, the FMCRD must fully insert upon scram command.

Both full- and pcrtial stroke scrams were satisfactorily completed after the fully charged scram accumulator nitrogen side pressure was allowed to decay to the alarm trip point prior to scram initiation.

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iE (2) Scram with Simulated Loss of System Pressure (1090 esimi This condition simulated complete loss of the CRD hydraulic system for a maximum period of ten minutes. The applicable test results show that at the completion of the ten minute ,

holding period, indicated scram accumulator charge remained unchanged, thus verifying a leakuight HCU system. A normal ,

full stroke scram resulted.

(3) Parte Water Pressure Low (1090 esia) l A partially r6stricted purge water flow orifice was simulated

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'by reducing purge flow to 0.1 gpm. Reference CRD housing i temperature stabilized at 96 dag F, at which time FMCRD performance was verified. j MHCR0 operation in_the step select and continuous insert / '

withdrawal operating modea was satisfactory. Scram performance also was untffected by the reduction in purge  !

flow. ,

(4) &ggs of Purre Water -

Testing in this instance explored FMCRD response to loss of purge water under two separate suppositions: (1) with system ,

isolated, to prevent reve:sc flow through drivs, and (2) with system permitted to back flow through the drive via a leaking HCU cooling water check valve. .

i At each of the above stabilized conditions, full-stroke scrams  :

were conducted, as well as step select and continuous insert / withdrawal cycles.

Mechanical performance of the FHCRD *can satisfactory.

Zero usin Vessel Pressure Testine (1) An assumed increase in HCU surrounding temperature to 150 d$g F rould result in a higher final accumulator water charge, essuming a leaktight chstging lino-check valve. The scram accumulator was stabi;ised at the ,igher value and full-stroke scram conducted, as well as step select and continuous insert-withdrawal cycles, to determine FHCRD response under this high energy scram condition.

FMCRD scram performan".e was satisfactory.

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i (2) Purre Water' Pressure Hirh (0 nsiel This was intended to be the final drift test of the RICRD l prior to removal from the est vessel, post test. Drive-line  !

drift as a function of pressure under the hollow piston was observed. j l

Kesults at this time compared favorably with the pro-test  ;

drift pressure range, j 1

(3) Drive / Scram 9vstem Loric Checks (0 osic) i FMCRD System response was observad by initiating partial j stroke accumulator scram while the FMCRD was operating in each  ;

of the following modes; continuous insert, emergency insert. l step-select insert, continuous withdraw, and step-select J withdraw. )

Tn al.1 instances, system logic responded correctly. ,

(4). Contiroous/ Sten Insert Nithdrawal with Emerrenev Insert and Scram (0 osir)-

FMCRD response was observed under the following, conditions:

(a) Continuous / emergency insert. '

(b) Continuous emergency insert /ecram.

(c) Step-select /omergency insert, ,

(d) Continuous withdraw / emergency insert. 3 (e) Continuous withdraw / emergency insert / scram. l (f) Step.s clect withdraw /emergmey insert.

(g) _ Step select withdraw / emergency insert / scrams.

In all instances, the system responded correctly.

(5) 3ipulated Lors of System Power'(0 osir)

With the FMCRD System in the normal operating mode, external electrical supply power to the Local and Control Panels was.

manually switched off (scram valves remained energized). No  !

switch or circuit breaker settings were disturbed prior to power reapplication.

Upon reapplication of system electrical power, Local Panel shutdown occurred.

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(6) Fvstem Entrained Air FMCRD Scram Response (0 esie) 1 To verify system insensitivity to entrained air in the i hydraulic system, the FMCRD was removed from the test vessel, inverted, drained of water, then reinstalled in the test  ;

vessel. Purge flow was established, full stroke insert and j P withdrawal conducted, and full stroke scram response verified.

During the ETF testing there was one occasion when the MKCRD j stopped while being commanded to move in the insert direction end subsequently repeated this performance in the withdraw direction. ,

Extensive further testing resulted in no repeat of this anomaly and  ;

subsequent investigation showed no possible cause. Hence it was considered a test aberration.

Post ' fast Disassembiv and Inseeetion f Following test completion, the FMCRD was removed from the test facility, disassembled, and inspected. Results of this inspection showed no significant changes as compared to the initial, pre-test inspection.

i In general, FMCRD condition post test was felt to be consistent with the environmental exposure accumulated during testing.

The FMCRD was then shipped to La Salle for the in plant test phasc. i C. TESTING AT THE LA SALLE 2 PLANT j Pre Operational Testing EBCRD Continuous Insagt/ Withdraw Performance Confirmation Testing was conducted to verify proper system operation during continuous insert and withdraw. A full-stroke emergency insert -

cycle was satisfactorily also completed satisfactorily, FMCRD Ster Select Insert / Withdraw Performance Confirmation Step select cycling was comprised of four full stroke insert / withdraw cycles. In all instances, step select commands were accepted and executed correctly. Upon completion of the finn 1 i

cycle, the FMCRD system logic responded correctly to valid and non valid commands.

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DiCRn Scram Performance Confirmation Preoperational Test, completed April 14, 1987, checked 04CRD single rod scram performance (with manually initiated scram following) with a series of five full-stroke accumulator scrams.

Doerational Tesig

,. FMCRD Continuous Insert / Withdraw Performance Confirmation Five full stroke FMCRD continuous insert / withdraw cycles were completed, with resulting performance judged acceptable.

A full stroke emergency insert cycle was satisfactorily completed and the emergency insert circuit logic verified when, during Step-Select 100 withdraw operation, Emergency Insert was initiated.

The FMCRD responded as required.

EgGBD Sten L' elect insert / Withdraw Performance Confirmation As during preoperational testing, step select cycling was comprised of four fu11 strok6 insert / withdraw cycles Upon completion of the final withdraw cycle, FMCRD System accept / reject command logic was verified. In all instances, step. select com% ands were accepted and E executed correctly. .Upon completion of the final cycle, the FMCRD l system logic responded correctly, accepting valid and rejesting l non. valid cr2mands.

l l FMCRD Scram Performance Confirmation l:

Five full stroke sincie rod accumulator scrams were successfully completed.

D. PMCRD La Salle-2 Operational Activity l ' The FMCRD remained operational at LS-2 during the time period June 30, 19Li through October 14, 1988. After shutdown, for refueling the testing described below was conducted.

FMCRD Pre Removal Functional Test FMCRD Continuous Insert / Withdraw atic Sten Performance Confirmation Two full stroke FMCRD continuous insert / withdraw cycles were completed satisfactorily. One full insert and withdraw cycle was performed in the step select mode. These data were consistent with April 1987 FMCRD preoperational test data.

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Two full stroke emergency insert cycles were also conducted at this )

time. System operation was satisfactory.  :

Pre Removal Functional Test Results i'

The FMCRD self interrupt anomaly (as discussed in E below), that initally occurred during the operation phase, also occurred during -

final testing. However, as in the prior instances, repeated FMCRD '

operation allowed the anomaly to self+ clear. Once self clearing was accomplished, the self interrupt anomaly did not recur. This is consistent with prior self interrupt anomaly occurrences.

During periods when the FMCRD stopped, motor current increased while voltage and frequency 1emained constant. There was no interruption of motor current and voltage. This is an indication of stalling of the motor while electrical power was continuously -

applied. l Relay signal status and other Local and Control Panel indicators showed no abnormal or spurious changes when the anomalies occurred.  ;

E. QZERATIONAL ANOMALIES AT 1A SALLE Et(CRD Sticking There was an event on March 9, 1988, in which the FMCRD failed to move after control rod hydraulic insertion, electrically as it was designed to do. It was discovered that the operators had disabled the Operational Panel using the keyswitch. Vnen the key was switched back on to allow the electrical movement-of the FMCRD, the drive failed to start moving as expected. The FMCRD was finally l induced to start moving by on and off movements of the keyswitch and was inserted for a distance by jogging it inward in this manner. After a several such operations the apparent restraint was ,

reduced or eliminated, and the FMCRD moved smoothly inward in the Scram Following mode.  ;

Repeated operations after this event did not result in further failure to move. As a result of this event, the plant operators were requested to perform periodic testing. During May, the FMCRD j performed satisfactorily during two tests. The next test was performed on July 21, 1988, and, during this test, the FMCRD again stuck during the initial movement and then moved freely.

The FMCRD was moved many times after these events, and the failure to start moving never recurred.

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PMCRD Intermittent Stovoint On a number of occasions at the La Salle-2 plant, the FMCRD unexpectedly stopped while being electrically driven continuously in the insert or withdraw direction. During these operations the l operator was manually moving in either the Withdraw or Insert direction when the movement suddenly stopped. There were many '

FMCRD continuous movement operations at La Salle in which the FMCRD )

moved without stopping; therefore, these anomalous stopping  ;

occurrences were intermittent in nature. Documented occurrences of intermittent stopping of the FMCRD is as follows:

DAlg Location Descrintion 10/6/86 ETF San Jose Once on insert, once on withdraw  :

8/18/88 La Salle-2 Several times on insert 8/22/88 La Salle 2 Nine times on withdraw 8/31/88 La Salle 2 Several times on insert 10/1/88 la Sc11e 2 Once on insert wf.th the rod in the scrammed and latched positions i

Causes and Remedies for Failure to Insert after Scram and l Intermittent Stocoine l t

i Investigation of these two problems show that their causes are related to high starti.ig and running friction torque in the FMCRD shaft seal design (packing). A second related condition was a low margin on motor starting (pull in) and running (pull-out) torque

-vs. the resistance torque of the FMCRD (primarily packing torque).

In the ongoing design effort, the shaft seal (packing) design will be modified to prevent high starting and running torque variability during operation. Secondly, the motor used at La Salle was designed for 4.2 kg m, while the current design requirement is 6.5 kg a, When the design is finalized and fully tested, these two remedies will prevent the failure to start and intermittent stopping.

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4. COMPARISDN OF THE TEST FMCRD WITH THE FINAL DESIGN FMCRD i -l TABLE 4 In Plant Test FMCRD Final Desien FMCRD Continuous Full-in No Yes  !

Indication railed Buffer Detection No -Yes Redundant Separation No Yes Indication Coupling Type . Spud and Socket Bayonet Position Indication Each 10% to 60% 10%, 40%, 60% & 100% ,

l During Scram ,

t Scram Ports 2 Insert & Withdraw One j both converted to scram ports Motor Torque Spec, 4.2 kg e 6.5:kg m -

Rod Ejectios Check Valmie Testable Check Valve .

Prevention' and Testable Electro-magnetic Brake llCU Quantity volume for 1 EHCRD Volume for 2 """,RDs 2 2 HCU-Pressure 120 kg/cm 150 kg/cm Drive Ejection External Support. Internal Support .

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The differences between the in-plant FMCRD and final design FMCRD are evolut onary and do not negate the value of the test.

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} 5. CONCLUSIONS l

l. The In Plant Test indicated that the basic design of the FMCRD is l acceptable. The FMCRD scram performance met requirements. The FMCRD l and system met the specified position accuracy and response I characteristics. The TMCRD functioned perfectly during scram festing and all safety functions were successfully demonstrated. l 1

There were some anomalous events which were diagnosed as high shaft seal i friction and-low motor torque margin. The final design FMCRD incorporates a highe': torque motor, adequate to overcome'the high seal ,

friction. In addition, the final design will incorporate improved -

L packing with lower torque requirements.

! The failure to detect the anomalous behavior in the preinstallation  ;

testing both by the makers and subsequently by the testing in ETF is attributable to the following factors:

(1) Emphasis _ of testing was placed on safety functions and the anomaly affected non safety function (2) The anomaly was intermittent in nature appearing only occasionally (3) The anomaly is environmentally induced. Previous environmental ,

testing had been limited to safety functions only.  ;

Further it should be noted that the purpose of the in plant test was specifically to-search for anomalous behavior that might not appear '

in development tests.

i Subsequent investigation of the anomalous behavior has shown that it was  !

caused by the the high temperature of-the underdrywell environment and that it could be reproduced in component testing. Since the component tes.8.ng can reproduce the problem, there is no need to perform .,

e further in plant tests with the final packing design.

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