ML20024C410
| ML20024C410 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 05/21/1979 |
| From: | Spangler W BABCOCK & WILCOX CO. |
| To: | Olds G BABCOCK & WILCOX CO. |
| References | |
| TASK-03, TASK-3, TASK-GB GPU-2344, NUDOCS 8307120599 | |
| Download: ML20024C410 (11) | |
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TH'E SABC0CK & WILCOX COM*"NY POWER GENERATION GROUP To lG.M. Olds-Manager lI Field Engineering & Services
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From W. H. Spangler - Manager di M
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Plant Startup Services (Ext. 22-I ses **:..s i
1 Cust.
File No.
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or Ref.
g Subj. Hi, story of PORY Malfunctions Date f:
May 21. 1979
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E Er Attached please fin.d suranaries of nine (9) documented cases of various types t
of malfunctions involving the FORV, its control system, or its power supply E
system.* These nine incidents are in addition to the March 28 TMI-2 incident.
- f. o These wer located in a search of our SFR files. I believe we have uncovered b'
all the sienificant events that _were recc.r.d.ed_,, I have no way of knowing of
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any other events tnat might have occurred.
L Incident No. 8 involved a " failed open" situation upon loss of power to the control system. This prompted me to check the status of other plants relative to that aspect, i.e., upon loss of power will the FORY go open or closed? The response we got is somewhat confusing, but apparently none of ouIp~1 ants will e
now have the valve open on loss of power. There is a question on some of.them as to what would happen if the pcwer failed while the valve is open, i.e.,
would the valve stay open or go closed? This needs seme fo11cw-up. John Castanes is investigating for me.
I should have seme75efsYefore Thurscay i
morning.
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INCIDENT #1
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PLANT: NSS-4, Oconee Unit 2 f
thl DATE OF OCCURRENCE: 8/15/73 c
VA!.VE MANL'FACTURER: Dresser
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m SPR No.: 109 t
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PLANT STATUS AT TIME OF OCCURRENCE: Pre-operational testing in progress.
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TYPE OF MALFUNCTION: Yalve failed to close after intentional lift because
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of install,atic_n,vi ring,e,r_r_or.
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SUMMARY
, OF INCIDENT: During the h'igh pressure section of the quench tank i
operational test, the PORY was opened via the key P
switch at 2155 psig RCS pressure. The PORY did not E
close because of an installation wiring error to the f
solenoid actuator.
RESC3JTIO:I: Wiring errer was corrected by rewiring in accordance with t
applicable drawings.
B&W FOLI.0n*-UP ACTION: Duke Power Company also corrected the wiring error on
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Oconee Unit 3 (Unit I had already been satisfactorily tested). This problem was not considered generic to i"
other B&W plants since it was an installation wiring error (drawings were correct).
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INCIDEIT R2 C
PLANT: NSS-4, Oconee Unit 2 L
OATE OF OCCURRENCE: 11/6/73 I
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VALVE MANUFACTURER: Dresser I
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SPR NO.: 148 7
PLANT STATUS AT TIME OF OCCURRENCE: R3 hee. tup in progress.
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i TYPE OF MALFUNCTION: The PORV would nut fully close because of leaking E
pilot valve.
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SUMMARY
OF INCIDENT: The PORY pilot valve was cycled at RCS conditions of 2155 psig and 545 F.
RCS pressure decreased to 2125 psig and the quench tank pressure increased to % 8 - 10
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psig indicating that the PORY w.s not closing. Elec.
i' trical indications were that the FORY was closed. In-vestigttien revealed some stee. coming from the exhaust port sn the pilot valve which indicated the pilot valve I..
was not seating properly.
R*. SOLUTION: The pilot valve seat was lapped and succeeded in stopping steam flow frem the exhaust port. The pilot valve and PORV were cycled i.-
every 50 F during heatup and operation was satisfactory.
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B&W FOLLOW-UP ACTION: Unconfimed infomatien: Lette-s were sent to Project ____
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Managers of other B&W plants re:uesting that their
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resolution.
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PLANT: NSS-9, Oconee Unit 3 t
DATE OF OCCURRENCE: % 6/4/74 F. :
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VALVE MANUFACTURER: Dresser m
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SPR NO.: 58
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6 PLANT STATljs AT TIME OF OCCURRENCE: Pre-operational testing in progress.
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TYPE OF MALFUNCTION: PORY failed to open during the low pressure section of b
the quench tank operational test. Subsequent investi-
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gation revealed that the vent port plug cap. which it should have been removed during installation, nad not d
been removed. After the cap was removed, the valve E,.'
opened noma 11y; however, it would not close. The r
scienoid shaft had become cocked and, famed against t'
J the pilot valve lever arm.
RESOLUTION: After realigning the shaft and lutricating the roller. the valve operated properly.
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'B&W FOLLOW-UP ACTION: No further action taken since this was 'an error made during PCRV. inst.allation.
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INCIDENT #4 i
PLANT: NSS-9, Oconee Unit 3
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DATE OF OCCURRENCE: 6/13/75
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VALVE MANUFACTURER: Dress '-
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SPR NO.: 107 L
PLANT STATUS AT TIME OF OCCURRENCE: Operation at % 125 power.
L TYPE OF MALFUNCTION: The PORY failed to close after an RCS pressure transient F
because of corrosion of PORY actuating parts.
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SUMMARY
.OF INCIDENT: Power was being reduced to % 12% in preparation for cold shutdown for RCP seal replacement. During transition P
from turbine to turbine bypass operation.. the RCS -
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experienced a pressure transient to 2267 psig. The PORY actuated at 2257 psig, but failed to close. Inspection of the PORY after shutdown indicated that the pilot valve lever had remained in the ported position preventing the PORY from reseating. Restraint of the lever was caused by corrosion of the lever pin, lever hinge, and solenoid i
bracket. (See NSS-9 SPR-108 for further information on 1
I RESCLUTION: The FORY was repaired and reinstalled. Repair was effected by increasing the clearance for t!.e lever pin in both the solenoid
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bracket and the lever hinge bearing points. The pilot valve y
disc and seat were refurbished to achieve tig5t seating.
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.P4W FOLLOW-UP ACTION: A site instruction was issued to other B&W plants advising the utilities to conduct periodic inspections for presence of corrosion products and to perfonn manual / visual checks for freedcm of motion during plant shutdowns. (Also,see NSS-7SPR-304.)
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L INCIDENT #5 l'
PLAfff: MSS-7, Cr/stal River Unit 3
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' CATE OF CCCURRENCE: % 11/75 VALVE MANUFACTURER: Dresser F.
l SPR NO.: 304 PLANT STATUS AT TIME OF OCCURRENCE: Pre-operational testing in progress.
E.E l TYPE OF MALFUNCTION: PORY actuating solenoid was found to be stuck.
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SUMMARY
OF INCIDENT: While electrical checks were being perfomed. the PORV actuating solenoid was found to be stuck in the down (ported) position. Inspection showed binding between L I the spring bracket and spring guide.
RESOLUTION: The PORY actuating pa-ts were readjusted, cleaned, and lubricated to obtain free r. otic.. Further electrical checks showed no indi-cation of the problem returning.
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B&W FOLLOW-UP ACTION: This problem and NSC-g SPR-107 resulted in field changes
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being issued to B&W plants with Dresser PORVs which modified the pilot valve lever pin (lever and bracket) and added new bushing type bearings.
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INCIDENT #6 j
g-PLANT: NSS-14 Davis-Besse !
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DATE OF OCCURRENCE: 9/24/77
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. VALVE MANUFACTURER: Crosby.
SPR NO.: 369 J.
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PLANT STATUS AT TIME OF OCCURRENCE: Reactor at 95 power, turbine off line.
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TYPE OF MALFUNCTION: Valve opened nomally due to reactor overpressure.
t Cycled open and shut rapidly nine (9) times due to electrical problem in control circuit (missing relay).
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Rapid cycling damaged pilot valve causing it to stick f
open.
SUMMARY
OF INCIDENT: Lost feedwater due to malfunction in steam, feedwater rupture control system (SFRCS). System pressure went above 2255 and relief valve opened. At same time, pressurizer level increased and operator manually tripped reactor. PCRV cycled rapidly nine (9) times
'y and then stuck open. Valve was open approximately 20 minutes before operator realized it and shut block valve.
SFAS was initiated at 1600 psig. Coolant system pressure dropped as icw as 875 psig. Tave was as high as 577 F.
It is susoected that a steam bubble was fomed in the RC system.
The PORV apparently stuck epen due to pilot valve stem being bent and galled dgg the, rapid,cyc1,1,ng.
RESOLUTION:
Pilot valve was replaced from parts stock and the control circuit
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was corrected by installing a missing relay in the system.
B&W FOLLOW-UP ACTION: None - not considered generic.$c,4 y/a d wdbd61
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1 PLANT: NSS-14, Davis-Besse I r
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DATE OF CCCURRENCE: 10/13/77 YALVE MANUFACTURER: Crosby b
5' SPR NO.: 386 P
PLANT STATUS AT TIME OF OCCURRENCE: Hot standby f-TYPE OF MALFUNCTION: Pilot valve stuck open during PORY testing.
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SUMMARY
,OF INCIDENT: PORY was being tested following pilot valve replacement
[0 as a result of incident described in SPR 369. The valve had been cycled six (6) times successfully. On the l.!
seventh time it stuck open. The pilot valve did not l'
i close.
RESOLUTION:. A Crosby representative came to the site and after inspection he reco.canded increasing the clearances between pilot valve stem and
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nozzle, eliminating some binding. In addition, the pilot valve was adjusted so that maximum travel is 0.125" rather than the previous 0.375*.
Following the above c:odification, the valve was cycled ten (10) times at 1100 psig, and one (1) time at 2150 psig without -
i problems.
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B&W FOLLOW-UP ACTION: None - not considered generic since this is our only
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INCIDENT #8 P
PLANT: NSS-6, TMI Unit 2 1
DATE OF OCCURRENCE: 3/29/78 E. J '
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VALVE MANUFACTURER: Dresser E. J q...
SPR N0.: 183 E?
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PLANT STATUS AT TIME OF OCCURRD:CE: Zero power physics testing in progress.
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.e TYPE OF MALFUNCTION: PORY went open upon loss of power to the solenoid it a actuator.
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SUW.ARY,, OF INCIDENT: While performing RS isolation and cooling surveillance y,,
testing, the vital bus which feeds the RCP-1A monitoring E.-
L' circuit was de-energized (fuse blew). Since RCP-2A was already down for clutch repairs, the loss of power to P
c the RCP-1A monitoring circuit registered no pumps
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operating in the "A" loop and the reactor tripped. The
'3 vital bus also supplies power to the bus for NNI. Because of the loss of the NNI bus, the PORV received an open l
comand which initiated a rapid system depressurization.
The PORV closed when power was restored.(ic'~ s,$ -..)
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REIOLUTION: Burns & Roe (Arch. Eng.) made change to have the PORY remain h
closed upon loss of pcwer.
7 S&W FOLLOW-UP ACTION: No further action required. At other B&W plants, the
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PORY remains closed upon loss of power.,
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PLNG: NSS-6. THI-2 DATE OF OCCURRENCE: Apprcximately 9/78 VALVE MAtCJFACTURER: Dresser SPR NO.: 195 PLANT STATd5 AT TIME OF OCCURRENCE: Not known
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j TYPE OF MALFUtiCTION: Valve failed to open at prescribed set point due to electrical malfunction.
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SUMMARY
.0F INCIDENT:
With system pressure at 2275 (set point 2255) valve failed to open. Tried opening by turning switch to
'q manual position. Valve still did not open.
RESOLUTION: Visual inspection of the solenoid showed a wire physically keeping a switch open. The wire was re-routed and valve functioned properly.
I,1 B&W FOLLOW-UP ACTION: None - not considered generic.
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