ML19354D441

LER 89-019-00:on 891004,inadequate Instrumentation Used on Core Spray Pumps for ASME Section XI Testing.Caused by Inadequate Design Change Package.Event Reviewed W/Station Inservice Testing engineer.W/891103 Ltr

ML19354D441
Person / Time
Site:	Hope Creek
Issue date:	11/03/1989
From:	Cowles R, Hagan J Public Service Enterprise Group
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
LER-89-019-02, LER-89-19-2, NUDOCS 8911090077
Download: ML19354D441 (6)

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.Public Service Eiectric and Gas Cornpany. P.O. Box 236 Hancocks Bridge, New Jersey 08038 '

Hope Creek Operations l i

November 3, 1989 U..S.' Nuclear Regulatory Commission' Document Control Desk.

Washington,.DC. 20555  :

Dear Sir:

HOPE' CREEK GENERATING STATION '

' DOCKET NO. 50-354 UNIT NO. l' LICENSEE EVENT REPORT 89-019-00

• This Licensee Event Report is being submitted pursuant .to the requirements of 10CFR50.73 (a) (2) li) .

Sincerely,

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.J. gan l General Manager -

Hope Creek Operations

'RBC/' . ,

l- Attachment SORC Mtg.89-125  ;

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1 TITLE (4): '!10NICAL SPS3FICATIGI VIMATIN - USE T DEADEQUATk DU11GENTATION W CORE SPRAY PLYS M ASME SECTIGI XI 1ESTDC DUE 10 INAIEQUAE IESIGN CHAINE PACKAGE l

EVENT DATE ($) IB NWBDt (6) REPORT DATE (7) 0111ER FACILITIES INVOLVED (8)

Inmi ** NWBER **' IDmi DAY YEAR YEAR REV DAY YEAR DCILITY NAME(S) DOCKLT IOSDt(S) 1 0 0 t 8 9 8 9 -

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NAME 'Im5'IDE IGBUt R.B. Cowles, lead Th:dne - Technical 6 0 9 3 3 9 5 2 6 4 CCIP!EIT ONE LDE M EACH CGIPOEDff TAIwRE TUTED IN 11 TIS REPORT (13) i CAUSE SYSTDI CGIPONDif MANUDC- REPORTABLE \\\\\\\ CAUSE SY::TRI 00MP W Dff MANUDC- REPQtTABLE ,

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ABS 11 TACT (16)

ASME Code IWP-4120 states, "The full scale range of each instrument <used for process measurement during the test) shall be three times the i reference value or less.". The Core Spray System flow indicators l utilized for pump performance monitoring in these tests have a scale of 0 to 10,000 GPM. The baseline rated flow of each Core Spray Pump is 3200 GPM, hence, the maximum range allowed on associated flow instrumentation (for test purposes) is 9600 GPM. Because Technical Specification 4.0.5 l mandates adherence to ASME Boiler and Pressure Vessel Code Section XI, l this condition constitutes a Tech Spec violation. All Core Spray Pumps l were declared inoperable on 10/4/89, and the required quarterly inservice tests were completed with portable test equipment meeting the Section XI requirements. The primary cause of this occurrence was an inadequate design change package (DCP) which was utilized to determine baseline data for ASME Section XI required single pump testing of Core Spray Pumps. The implications of ASME Section XI instrumentation requirements were not l recognized during the preparation and review of this DCP. This error was

! carried through to the IST procedures for Core Spray single pump testing l which were developed as a result of this DCP. The primary corrective i action for this event centers on the creation of an IST Instrument l Verification Project. The scope of this project includes verification that all IST required instrumentation meets the requirements of ASME B&PV Section XI. This incident has been reviewed with the station IST Engineer to ensure he is aware of the circumstances surrounding this occurrence and can apply this knowledge to future IST reviews of DCPs and procedures.

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IKFE CRIIK GINIRATING STATION 05000354 99 -

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ELANT AND' SYSTEM IDENTIFICATION General Electric - Boiling Water Reactor (BWR/4)

Core Spray System (EIIS Designation: BG)

IDENTIFICATION OF OCCURRENCE Technical Specification Violation -

Use of Inadequate Instrumentation on Core Spray Pumps for ASME Section XI Testing Due to Inadequate Design Change Package Event Date: 10/04/89 l Event Time: 1000 This LER was initiated by Incident Report No.89-123 CONDITIONS PRIOR TO OCCURRENCE Plant in OPERATIONAL CONDITION 5 (Refueling) i DESCRIPTION OF OCCURRENCE '

During a control room walkdown of an Operations Department procedure, a Nuclear Shift Supervisor (NSS, SRO licensed)  !

noted that the instruments used to indicate flow for the Core i Spray system were scaled from 0 to 10,000 GPM. The NSS (a ,

member of the PSE&G Inservice Testing Instrumentation Project  !

team) recognized that the instruments did not appear to meet  ;

the range requirements of ASME Section XI, IWP-4120 l requirements for Inservice Testing (IST) of Class 1,2, and 3 pumps (ranged less than 3 times rated flow). (The Core Spray j pumps are each rated at 3200 GPM, thus the maximum allowable flow instrumentation range is 9600 GPM per ASME Section XI.)

After consulting with the station IST Engineer, the NSS i initiated an incident report to document his findings. On  !

10/4/89, the IST Engineer, upon review of the findings, i determined that the flow instruments were in fact outside of l the range specified in ASME Section XI, IWP-4120 for the IST requirements of the Core Spray pumps (single pump test) by ,

approximately 200 GPM (adjusted for instrument accuracy). A deficiency report was initiated to document the finding, and all Core Spray Pumps were declared inoperable until the corrective actions as specified in the deficiency report could be implemented.

The required IST procedures for single Core Spray pump tests were re-performed utilizing portable flow instrumentation meeting the range requirements of ASME Section XI. It should be noted'that the Core Spray pumps were not required to be operable when declared inoperable.

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YEAR \\ NLISER \\RW I lors cRant coaRATING STATIM 05000354

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0 0 0 3 0F 0 5 l-f APPARENT CAUSE OF OCCURRENCE l The primary cause of this occurrence was an inadequate design change package (DCP) which was utilized to determine baseline data for ASME Section XI required single pump testing of the Core Spray Pumps. This DCP was performed in January, '1989.

The implications of ASME Section XI instrumentation requirements were not recognized during the preparation and review of this DCP. This error was carried through to the IST procedures for single Core Spray Pump testing which were developed as a result of this DCP.

ANALYSIS OF OCCURRENCE Hope Creek Technical Specification 4.0.5 states:

Surveillance Requirements for inservice inspection and testing of ASME Code Class 1,2,& 3 components shall be applicable as follows:

a. Inservice inspection of ASME Code Class 1,2, and 3 components and inservice testing of ASME Code Class 1,2, and 3 pumps and valves shall be performed in accordance with Section XI of the ASME Boiler and Pressure Vessel Code and applicable Addenda as required by 10CFR50, Section 50.55a(g), except where specific written relief has been granted by the Commission pursuant to 10CFR50, Section

50. 55a (g) (6) (i) .

Each Core Spray pump (2 core spray loops, 2 pumps per loop) is rated at 50% loop capacity. As such, since initial system operation (1986), the flow of each Core Spray loop was obtained I using two pumps ir. operation to verify system flow t capabilities. The flow instrumentation utilized to monitor /

l verify total loop flow was designed and engineered for proper ASME Section XI range and tolerance criteria for two pump operation. Technical Specification requirements for Core Spray I system flow capabilities are based on two pump operation.

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ANALYSIS OF OCCURRENCE In late 1988, it was determined by a PSE&G IST working group that testing the Core Spray pumps individually, as well as in parallal, would bettar represent and satisfy the intent of ASME Section XI requirements. As a result, a DCP was developed to test the loop flow characteristics with one pump running versus two pump operation. Data and testing methods obtained from this DCP were transferred to the next revision of the Core Spray pump permanent IST procedures. The error involving the instrumentation range was essentially a hidden deficiency that was not recognized until the NSS, familiar with the requirements of ASME Section XI, IWP-4120, recognized the discrepancy.

PREVIOUS OCCURRENCES No incidents relating to ASME Section XI IST testing have occurred at Hope Creek.

SAFETY SIGNIFICANCE The conditions noted in this report did not present a significant safety concern with regard to operability of the Core Spray system. Technical Specifications related to Core .

Spray testing for ECCS system operability are predicated on the basis of 100% loop flow capacity (2 pump operation).

Additionally, testing following discovery of this condition ,

verified that all Core Spray pumps met the IST requirements of l

ASME Section XI.

p CORRECTIVE ACTIONS

1. The primary corrective action for this event centers on the continuation of an IST Instrument Verification Project, which has been ongoing since 1988. The scope of this project includes verification that all IST required I instrumentation meets the requirements of ASME Section XI, l IWP-4120.

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0 0 0 5 7 0 5 CORRECTIVE ACTIONS, CONTINUED

2. This incident has been reviewed with the station IST engineer to ensure he is aware of the circumstances surrounding this occurrence and can apply this knowledge to future reviews of IST related procedures.

Sincerely,

.J. gan General Manager -

Hope Creek Operations RBC/ j SORC Mtg.89-125 I