ML19332G060

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Summary of Operating Reactors Events Meeting 89-43 on 891206.On 891128,high Cycle Fatigue Failure of Master Connecting Rod Assembly Occurred at South Texas,Unit 2.RHR Leakage Noted on 891201 at Braidwood,Unit 1
ML19332G060
Person / Time
Site: Braidwood, South Texas, 05000000
Issue date: 12/07/1989
From: Haughney C
Office of Nuclear Reactor Regulation
To: Rossi C
Office of Nuclear Reactor Regulation
References
OREM-89-043, OREM-89-43, NUDOCS 8912200105
Download: ML19332G060 (18)


Text

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December 7,.1989 MEMORANDUM FOR:

Charles E. Rossi, Director Division of Operational Events Assessment FROM:

Charles J. Haughney, Chief Events Assessment Branch Division of Operational Events Assessment

SUBJECT:

THE OPERATING REACTORS EVENTS MEETING December 6, 1989. MEETING 89-43 On Decernber 6,1989, we ccnducted an Operating Reactors Events meeting (89 43) to brief senior managers from NRR, AE00, ACRS, RES, Comission staff, and regional offices on selected events that occurred since our last meeting on November 29, 1989. lists the attendees. presents the significant elements of the discussed events. contains a summary of reactor scrams for the week ending 12/03/89. Two significant events were identified for input into the NRC performance indicator program.

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Charles J. Haughno/

Charles J. Haughney, Chief Events Assessment Branch Division of Operational Events Assessment

Enclosures:

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December 7,1989 1

MEMORANDUM FOR:

Charles E. Rossi, Director Division of 0?erational Events Assessment FROM:

Charles J. Haughney, Chief Events Assessment Branch i

Division of Operational Events Assessment

SUBJECT:

THE OPERATING REACTORS EVENTS MEETING'

. December 6, 1989 - MEETING 89-43

~

On' December 6, 1989, we conducted an Operating Reactors Events meeting (89-43) to brief senior managers from NRR, AE00, ACRS, RES, Coraission staff, o

and regional-offices on selected events that occurred since our last meeting 1

on November 29, 1989.- Enclosure 1 lists the attendees.

l,

' presents the significant elements of the discussed events. contains a summary of reactor scrams-for the' week ending 3

12/03/89.. Two significant events were identified for input into the NRC-'

performance indicator program.

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1 Charles J. Ha ney, Ch Events Assessment BT1rEch Division of Operational Events Assessment =

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Enclosures:

b As. stated cc w/ Encl.:

See Next Page L

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t ENCLOSURE 1 r

LIST OF ATTENDEES OPERATING REACTORS EVENTS BRIEFING (89-43)

December 6,1989 NAME ORGANIZATION NAME ORGANIZATION T. Murley NRR/DONRR J. Partlow NRR/ADP V. Benaroya AEOD/DSP B. Grimes NRR/DRIS J. Zwolinski NRR/ADR-III W. Lanning NRR/DRIS P. Cortland NRR/TVA J. Wechselberger NRR/DLPQ W.'Troskoski OE R. Perfetti OE-G. Dick NRR/PD P. O'Connor NRR/PD-4 E. Brach NRR/RVIB T. Ross NRR/PD3-2 T. Gody, Jr.

NRR/LPEB

0. Chopra NRR/SELB W. Jensen NRR/DOEA H. Alderman ACRS A. Vietti-Cook OCM/KC K. Connaughton OCM/JC M. Peranich NRR/ILPB P. Bobe AEOD/DSP W. Haass-NRR/RVIB J. Richardson NRR/DET F. Miraglia-NRR/ADT C. Haughney NRR/DOEA P. Baranowsky NRR/D0EA G. Holahan NRR/DRSP 1

W. itinners RES/DSIR E. Rossi NRR/D0EA M. Reardon NRR/D0EA

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ENCLOSURE 2 i-1; l-l L

OPERATING REACTORS EVENTS BRIEFING 89-43 l

EVENTS ASSESSMENT BRANCH LOCATION:

16B-11, WHITE FLINT L-WEDNESDAY, DECEMBER 6, 1989, 11:00 A.M.

l SOUTH' TEXAS UNIT 2-FAILURE OF DIESEL GENERATOR i

(UPDATE)

BRAIDWOOD UNIT 1 RCS LEAKAGE THROUGH RHR.

SUCTION RELIEF VALVE (AIT TO SITE)

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89-43 e

SOUTH TEXAS UNIT 2 FAILURE OF DIESEL GENERATOR (UPDATE)

WOVEMBER 28, 1989 PROBLEM FAILURE OF DIESEL GENERATOR.

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CAUSE-l

.HIGH CYCLE FATIGUE FAILURE OF THE MASTER CONNECTING R0D ASSEMBLY (BETWEEN THE ARTICULATED R0D PIN AND THE CRANKSilAFT R0D JOURNAL) l BECAUSE OF IMPROPER MACHINING 0F AN OIL PASSAGE H0LE.

SAFETY SIGNIFICANCE FAILURE OF A DIESEL GENERATOR RESULTS IN THE-LOSS OF CAPABILITY TO PROVIDE ONSITE EMERGENCY POWER TO ONE TRAIN OF ESF EQUIPMENT.

THERE'ARE THREE DIESEL GENERATORS PER. UNIT AT SOUTH TEXAS.

TWO OUT OF THE THREE DIESEL GENERATORS (AND THE ASSOCIATED ESF EQUIPMENT) ARE NEEDED TO MITIGATE THE CONSEQUENCES OF DESIGN BASIS' ACCIDENTS.

DISCUSSION o-ALL SIX DIESEL GENERATORS (DG) AT THE SOUTH TEXAS SITE ARE MODEL KSV-20 MANUFACTURED BY COOPER-BESSEMER, o THE NO. 22 DG HAD COMPLETED APPROXIMATELY-10 HRS OF A 24 HR FULL LOAD TEST (REQUIRED PER TECHNICAL SPECIFICATIONS)-WHEN

-PERSONNEL IN Tile AREA HEARD LOUD BANGING / KNOCKING NOISES AND SAW SMOKE COMING FROM THE DG ENGINE.

THE DG STOPPED ON ITS

-l 0WN.

L o DG PARTS DEBRIS WAS FOUND ON THE FLOOR (PIECES OF BOTH N0. 4 L

PISTONS AND THE ARTICULATED ROD, AND OIL).

SOME SMALL PIECES WERE FOUND IN NEARBY CABLE TRAYS AND ON THE CATWALK AB0VE THE DG ENGINE.

BOTH BLOWOUT COVERS LOCATED IN THE INSPECTION L

PLATES AT EACH NO. 4 CYLINDER WERE FOUND SEPARATED FROM THE L

CONTACT:

R. KENDALL SIGEVENT:

NO

REFERENCES:

10 CFR 50.72 # 17212, MORNING REPORTS 11/29 AND

-11/30/89, AND PRELIMINARY NOTIFICATION PNO-IV-89-66 L

1 L i SOUTH TEXAS UNIT 2 89-43 DISCUSSION (CONTINUED)

PLATES, AND ONE OF THE INSPECTION PLATES WAS FOUND DETACHED FROM THE DG, o NO EVIDENCE OF CRANKCASE EXPL0SION: MECHANICAL DAMAGE ONLY, o TEST READINGS TAKEN HOURLY PRIOR TO THE FAILURE INDICATED NORMAL DG OPERATION, NO ALARMS WERE RECEIVED IN THE CONTROL i

ROOM PRIOR TO THE FAILURE, o EXAMINATION OF THE FAILED PARTS SHOWED THAT AN OIL SUPPLY H0LE

-IN THE MASTER CONNECTING ROD BETWEEN THE MAIN R0D BEARING OIL GROOVE AND THE LATERAL OIL PASSAGE TO THE ARTICULATED R0D PIN

'WAS FOUND TO BE OVERBORED, o THE R0D DID NOT PASS VENDOR QA INSPECTION (APPR0X 10 YEARS AG0).

THE H0LE WAS SUBSEQUENTLY TAPPED AND PLUGGED, AND CONSIDERED ACCEPTABLE, o LABORATORY ANALYSIS CONFIRMED THAT THE ROOT CAUSE FOR FAILURE-0F THE MASTER CONNECTING R0D BETWEEN THE LATERAL OIL PASSAGE AND TW ARTICULATED R0D PIN WAS HIGH CYCLE FATIGUE.

IT APPEARS THAT infS FAILURE LED TO LOSS OF LUBRICATION TO THE ARTICULATED R0D PIN AND SUBSEQUENT OVERHEATING AND GROSS FAILURE OF THE

ROD, THE LICENSEE'S INVESTIGATION (METALLURGICAL ANALYSIS) IS CONTINUING, o ALL OTHER DG PARTS APPEAR TO HAVE RECEIVED ADEQUATE LUBRICATION, o INTERNAL DAMAGE TO THE DG WAS LESS THAN EXPECTED, o THE FAILED DG HAD APPR0XIMATELY 640 HRS OF OPERATION.-

A 24 HR FULL LOAD TEST WAS SUCCESSFULLY COMPLETED IN DECEMBER 1988.

.ALL'DGs AT SOUTH TEXAS SUCCESSFULLY COMPLETED 100 HR FULL LOAD TESTS PRIOR TO COMMERCIAL OPERATION, GENERIC IMPLICATIONS STILL UNDER INVESTIGATION, VENDOR RECORDS INDICATE THE FIX (I.E.,

TAP H0LE AND INSERT PLUG) TO BE UNIQUE TO THE FAILED PART.

HOWEVER, OTHER RODS HAVE BEEN IDENTIFIED WITH OVERBORED HOLES THAT ARE NOT DOCUMENTED IN THE VENDOR RECORDS.

THE VENDOR IS ANALYZING THE EFFECT OF OVERBORED H0LES ON PART PERFORMANCE, COOPER-BESSEMER DGs ARE INSTALLED AT 16 REACTOR UNITS (36 ENGINES, 330 RODS).

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SOUTH TEXAS UNIT 2 89-43 E0LLOWUP o THE LICENSEE AND THE DIESEL GENERATOR VENDOR ARE CONTINUING TO INVESTIGATE, NRC HEAD 00ARTERS AND REGIONAL PERSONNEL HAVE BEEN SENT TO THE SITE TO MONITOR THE INVESTIGATION, o COOPER-BESSEMER IS PREPARING A PART 21 NOTIFICATION, o RVIB IS PLANNING AN INSPECTION AT THE COOPER-BESSEMER FACILITY IN-GROVE CITY, PA, NUCLEAR PLANTS USING COOPER-BESSEMER DIESEL GENERATORS BRAIDWOOD UNITS 1 8 2 BYRON UNITS 1 8 2 COOPER NINE MILE POINT UNIT 2 PALO VERDE UNITS 1, 2, 8 3 SOUTH TEXAS UNITS 1 8 2 SUSQUEHANNA UNITS 1 8 2 WATERFORD UNIT 3 ZION UNITS 1 & 2

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71 BRAIDWOOD UNIT 1 RCS LEAKAGE THROUGH-RHR SUCTION RELIEF VALVE (AIT TO SITE)

DECEMBER 1, 1989' ggy

'68,000 GALLONS'0F RCS WATER DISCHARGED.THROUGH THE SUCTION RELIEF VALVE ON THE:"B" TRAIN OF THE RHR SYSTEM TO THE RECYCLE HOLDUP

TANKS, 1

THE: RELIEF VALVE ON THE SUCTION OF THE "B" TRAIN OF THE RHR SYSTEM PREMATURELY OPENED AND FAILED TO RESEAT.

n LAfETY SIGNIFICANCE EVENT UNDERSCORES NEED FOR-E0Ps IN MODES OTHER THAN 1, 2,.0R 3.

DISCUSSION

.o ON DECEMBER 1, 1989, AN ALERT WAS DECLARED AT BRAIDWOOD 1 DUE TO 68,000: GALLONS OF-WATER HAVING DISCHARGED THROUGH THE RHR SUCTION RELIEF VALVE TO THE RECYCLE HOLDUP TANK,

.o PLANT CONDITIONS WERE AS FOLLOWS:

-- UNIT INLREFUELING OUTAGE SINCE SEPTEMBER 2, 1989, q'-

LICENSEE HAD COMPLETED: TESTING OF SI ACCUMULATOR CHECK VALVES IN PREPARATION FOR HEATUP, PLANT WAS SOLID WITH RCS TEMPERATURE AND PRESSURE AT 175 DEGREES AND 350 PSI, RESPECTIVELY, PRESSURIZER HEATERS ON.

"A" TRAIN OF RHR IN OPERATION WITH "B" TRAIN.AVAILABLE, "A" CHARGING PUMP BEING THROTTLED, LETDOWN INCREASED TO MAXIMUM IN PREPARATION FoR DRAWING A BUBBLE, o

SEQUENCE OF EVENTS:

1:42 AM CST, WHILE DRAWING A PRESSURIZER BUBBLE, RCS PRESSURE INCREASFD TO 416 PSI WHEN A RAPID LOSS OF PRESSURI2ER LEVEL OCCURRED WITH APPR0XIMATELY L

14,000 GALS OF WATER BEING RELIEVED TO THE RECYCLE HOLDUP TANK, RCS PRESSURE DROPPED FROM i

416 PSI TO 272 PSI, AIT:

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CONTACT:

N. FIELDS SIGEVENT:

YES

REFERENCES:

10 CFR 50,72 # 17235 (AND UPDATES), MORNING REPORTS OF 12/01 AND 12/04/89, AND PRELIMINARY NOTIFICATIONS PN0-III-89-78 AND PNO-III-89-78A

BRAIDWOODLUNIT 1 89-43 DISCUSSION (CONTINUED) 1:55 AM CST, "B" TRAIN OF RHR PLACED IN SERVICE AND "A" TRAIN WAS ISOLATED, LETDOWN WAS ISOLATED, CHARGING PUMP SUCTION SWITCHED FROM VCT TO RWST, 1:59 AM CST, SHUTDOWN ONE RCP BECAUSE OF SHAFT SEAL CONCERNS, 2:35 AM CST, WITH THE "A" CHARGING PUMP ALREADY RUNNING, THE "B" PUMP WAS STARTED.

PRZ SURGE LINE TEMP DROPPED AND RCS PRESSURE-INCREASED SLIGHTLY, 2:45 AM CST, STOPPED "B" CHARGING PUMP, FAILED TO REGAIN PRESSURIZER LEVEL.

2:53 AM CST, RESTARTED "B" CHARGING PUMP, 3:49 AM CST, RHR TRAIN "A" WAS RESTARTED AND TRAIN "B" WAS

ISOLATED, j

3:53 AM CST, PRESSURIZER LEVEL WAS REC 0VERED IN A CONTROLLED

MANNER, APPR0XIMATELY 54,000 GALS OF WATER WERE PUMPED FROM THE RWST DURING THE EVENT.

5:0G AM CST, THE-UNIT WAS STABILIZED AT 360 PSI AND 175 F, o

THE TRAIN "B" RHR SUCTION RELIEF VALVE WAS FOUND TO HAVE FAILED OPEN, CAUSE OF FAILURE UNDER INVESTIGATION, o

ABOUT 30 TO 50 GALLONS OF WATER WERE RELEASED T0 THE AUX BUILDING VIA A LEAK ON THE RELIEF VALVE OF THE RAD WASTE EVAPORATOR LINE CONNECTED TO THE RHR RELIEF VALVE DISCHARGE HEADER.

NO PERSONNEL WERE CONTAMINATED, o

THROUGHOUT THE EVENT, VESSEL LEVEL WAS MAINTAINED AT 100 PERCENT WITH THE CHARGING PUMPS.

THERE WERE N0 INDICATIONS OF VOIDING IN THE VESSEL.

FOLLOWUP o

AN AIT WAS DISPATCHED TO THE SITE, o

A FIVE PERSON INP0 INSPECTION TEAM WAS DISPATCHED TO THE SITE.

INP0 IS PREPARING AN SOER ON CROSBY VALVES FAILURES, o

REGIONAL AND HEAD 0VARTERS PERSONNEL ARE FOLLOWING LICENSEES'

ACTION, o

A CROSBY VALVE AND GAGE COMPANY REPRESENTATIVE IS AT THE SITE,

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ENCL.05URE 3 N

12/06/89' r

PERFORMANCE INDICATORS SISN1FICANT EVENTS

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PLCiNAME-(VENT EVENT DESCRIPfl0N 01R SlfC FICANCE DATE e

BRAIDN000_l' 12/01/89 60,000 SALLONS OF RCS NATER' LEAKED THROUGH THE SUCT10N 1 PDTENTIAL FOR OR ACTUAL DESRADATION REllEF VALVE ON THE 'I' TRAIN OF THE RNR SYSTEN.

OF CONTAINRENT OR SAFETY-RELATED EDU!PNENT.

PALISADES 11/21/89 A PRES $URilER PORV ilARET ROCK BRAND) OPEED NHEN TE 1 POTENilAL FOR OR ACTUAL DESRADAi!0N BLOCK VALVE NAS OPENED. THE BLOCK VALVE COULD NOT DE OF PRlHARY COOLANT PRESSURE CLOSED 10ISOLATETHEOPENPORV. Ali 70 SiiE. ALSD BOUNDARY.

NORNINSREPORTS!!/24/89AND11/27/09.

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REACTOR SCC

SUMMARY

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NEEK ENDIN6 12/03/09 l

1. PLANT SPECIFIC DATA e

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.UN!i PONER SISNAL CAUSE COMPLI-yid YTD YTD CAT 10NS AB0VE DELON TOTAL

,151 '151 11/29/89 THREE MILE 1 100 A EQUIPMENT NO 1

0' 1

ISLAND 12/01/89 RIVER DEND.

1 ' 97 A E00lPMENT NO 2

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12/01/B9 NINE MILE PolNT 2

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'IIL.' COMPARISON:OF-WEEKLY-STATISTICS WITH INDUSTRY AVERAGES SCRAMS FOR WEEK ENDING 12/03/09 x

. SCRAM CAUSE.

POWER NUMBER 1989 1988 1987 1986 1985 OF WEEKLY WEEKLY WEEKLY WEEKLY WEEKLY SCRAMS (5)

AVERAGE AVERAGE AVERAGE AVERAGE-AVERAGE YTD (3)(4)

(8)(9)=

(

t** ' POWER >15%

EQUIP. RELATED,

>15%

3 2.9 3.1 3.9, 4,3 5,4 PERS. RELATED(6)'>15%

0 1.0 1.0 1.3 i.e.

2.0

'OTHER(7).

>15%

O-0.1 0.5 1.2

'O.4 0.6

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3 4.0 4.6 6.4 6.5 8.0

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' * *. POWER.<15%

EQUIP. RELATED

<15%

0 0.4 0.5 1.2 1.4 1.3 PERS'. RELATED

<15%

0 0.3 0.3 0.6 0.8 0.9-

-OTHER

<15%

0 0.0 0.1 0.3 0.2 0.2

    • Subtotal **

O O.7 0.9 2.1 2.4 2.4 it**ETotal ***

3 4.7 5.5 0.5 8.9 10.4 MANUAL VS AUTO SCRAMS T

-TYPE NUMBER 1989 1988 1987 1986 1985 OF WEEKLY WEEKLY WEEKLY WEEKLY WEEKLY SCRAMS AVERAGE AVERAGE-AVERAGE-AVERAGE AVERAGE YTD

' MANUAL SCRAMS O

O.9 1.0 1.4

- 1. 0 1.0 AUTOMATIC SCRAMS.

3 3.8 4.5 7.0 7. 9.

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,a NOTES 1.

PLANT SPECIFIC DATA BASED ON INITIAL REVIEW 0F 50.72 REFORTS FOR THE WEEK OF INTEREST. PERIOD IS MIDNIGHT SUNDAY THROUGH HIDNIGHT SUNDAY.

SCRAMS ARE DEFINED AS REACTOR PROTECTIVE ACTUATIONS WHICH RESULT IN R00 fl0 TION, AhD EXCLUDE PLANNED TESTS OR SCRAMS AS PART OF PLANNED SHUTDOWN IN ACCORDANCE WITH A PLANT PROCEDURE. THERE ARE 111 REACTORS HOLDING AN OPERATING LICENSE.

E.

COMPLICATIONS: RECOVERY COMPLICATED BY EQUIPMENT FAILURES OR PERSONNEL ERRORS UNRELATED TO CAUSE OF SCRAM.

3.

PERSONNEL RELATED PROBLEMS INCLUDE HUMAN ERROR, PROCEDURAL DEFICIEliCIES, AND MANUAL STEAM GENERATOR LEVEL CONTROL PROBLEMS.

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"0THER" INCLUDES AUTOMATIC SCRAMS ATTRIBUTED TO ENVIRONMENTAL CAUSES (LIGHTNING) - SYSTEM DESICil, OR UNKNOWN CAUSE.

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