ML20030A506
| ML20030A506 | |
| Person / Time | |
|---|---|
| Site: | Big Rock Point File:Consumers Energy icon.png |
| Issue date: | 06/22/1966 |
| From: | Haueter R CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| References | |
| NUDOCS 8101090792 | |
| Download: ML20030A506 (20) | |
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{ii Docket No. 50-155 Tw Report of Operation of Big Rock Point Nuclear Plant License No. DPR-6 November 1, 1965 Through April 30, 1966 This report, submitted in accordance with Paragraph 3.D.(3) of Operating License No. DPR-6 (effective May 1,1964), covers the fourth six-month period of operation of the Big Rock Point Nuclear Plant (Plant) under this license.
I.
SUMMARY
OF OPERATIONS A.
Power Operation The Plant resumed operation on November 5,1965 after a 7-day outage during which 22 control rod drives were modified. This modification consisted of a new flange strainer and an improved collet sleeve, both designed to reduce the sensitivity of the drives to foreign particles. The remaining lo drives had been modified during August 1965 The Plant operated continuously from November 5, 1965 until January 18, 1966 when a shutdown was required to repair a leaking tube in the high-pressure, feed-water heater. The leak was confined to one tube and repair was effected by fitting and welding steel plugs in the tube sheet at both ends of the U-tube.
On January 23, full power operation was resumed.
On February 2, load was reduced to 20 Mwe to take up the packing on the 3/4-inch valve in the vent line from the reactor to the steam drum. The_ recycle valve controls on the No.1 and No. 2 reactor feed pumps were also repaired. During January, the release rate of radio-active gas to the environs had started increasing from approximately 18,~000 pc/sec (this level had remained essentially constant since November 1, 1965) until it reached 50,000 }:e/see on February 10.
This increasing re-lease rate indicated an increased deterioration of the fuel cladding.
Therefore, power was reduced from TO Mwe to 60 Mwe (net) on February 10 g
to reduce fuel deterioration Prior to the shutdown in April. This geLeo @
~
2 reduction was not required by license limitations since the release rate was still well below the limit of 1.0 curie (s) per second. This 10 Mwe load reduction lowered the release rate to 36,000 pc/see where it stabil-ized.
On March 22, the unit was removed from service to repair the 3/4" valve in the vent line from the reactor vessel to the steam drum. This valve packing had been leaking badly. Since this valve is normally open to vent noncondensibles from the vessel dome, the salve 4
was removed from the line and a section of pipe installed. The Plant was returned to operation on March 2h following tha above repairs.
01 April 1, the Plant was again shut down to repair leaks in the high-pressure, feed-water heater tubes. A total of four tubes was found leaking and repairs were made by fitting and welding plugs in both ends of the deftetive tubes. The Plant was returned to service on April 3 following these repairs.
The Plant was removed from service on April 9 for a re-fueling outage and remained shut down for the balance of the report period.
D ',ing this report period, erratic operation of the control rod drives was experienced on two occasions. On January 21, 1966, the drive ir Position D-6 was observed to drift from the full in position when tue drive supply pump was stopped. The drive returned to the full in position and latched properly when the supply pump was restarted.
Subsequent removal and inspection of the drive on January 22, 1966 re-vealed t o defects or explanation for the malfunction and it was concluded that a hydraulic path must exist to cause this type of performance.
During the two-day period, April 12-13, following the upril 9 shutdown, the drives in Positions B-2, E-4, C-2, D-6 and F-h drifted from the core under the following conditions:
1.
Drives B-4 and C-2 drifted from the core while they were being removed from service for maintenance by closure of their iso-lation valves. When the isolation valves were opened, the drives reinserted and latched.
2.
Drive B-2 drifted from the core when a bypass valve was i
opened which directed supply pump flow directly to the reactor and dropped
.s 3
i drive insert pressure to 18 psig.. When a second drive pump was started and the bypass valve closed, the drive reinserted. The bypass valve was b
again partially opened and no movement occurred.
3 When the drive supply pump was stopped, Drive D-6 drifted i
to the full out position and Drive F h withdrew one notch.
Both drives a
reinserted when the pump was started.
A study of the hydraulic circuitry, following the January
- r 1
incident, brought to light the possibility that pressurization of the scram dump ' tank could possibly be the mechanism. Accordingly, during the April
. refueling shutdown, instrumentation.was installed on the scram dump tank.
Subsequent testing definitely established that a buildup of pressure in the scram' dump tank was occurring following a scram. This prescurization is caused by leakage of water through the drive seals from the insert header to the withdraw header when the control rod drive pumps are operating.
' Adequate pressure (observed 'to 160 psig) builds up in the dump tank to open the collet piston locking device on the drives. When insert pressure 1
is then lost as by stoppage of the rod drive pump or closure of the insert isolation valve, a drive may withdraw from the core until the pressure in the scram dump tank decays to a level where the collet piston will close.
This situation has been' remedied by the installation of a j-vent line between the scram dump tank and the reactor vessel which will prevent a pressure differential from being developed when in the scram po-sition. -This line is equipped with isolation. valves which operate in con-l junction with the scram valves.
Check valves are also provided to prevent reactor water flow into the scram dump tank.
t These modifications were performed after the end of this report period (May 3-5,1966) and a detailed report of the drive malfune-I tions and dump tank modifications is now in preparation. This report will
.be submitted upon completion.
B.
Refueling Outage Prior to shutdown, flux tilting procedures were carried out-in an attempt to identify possible failed fuel in the core. On the basis of these tests,-it was determined that one of the developmental bundles (PE-3) was a probable leaker. Immediately following removal of
'the head after shutdown, fuel sipping operations were initiated in an s
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attempt to identify failed fuel. These results indicated two probable failures and eight suspects. Resolution of the test was poor at best and results deteriorated rapidly after approximately two days of sipping due to the decay of short-lived isotopes. One of the least suspect bundles (A-56) from the sipping tests was removed from the core to the fuel pocl and visibly inspected. This revealed a gross failure of one rod, with approximately 8 inches of fuel missing below the mid-die spacer. Since this was a bundle with a relatively low sip signal and burnup, it was decided to visually examine all bundles with burnups greater than 7000 Mwd /T. This involved an inspection of 30 bundles.
A total of four bundles was found to have gross defects by this visual examir.at ion. These were A-56, A-kl, A-51 and PE-3 PE-3 had five failed rods, two on the periphery and three central rods which were discovered when the handle was being changed.
An estimated total of 12 inches of fuel was missing from the central rods. A-41 had two rods grossly failed with approximately 3 inches of fuel missing from each rod.
A-51 had onc failed rod in the second row in the vicinity of a corner; however, it was not possible te determine if any fuel was missing.
It is estimated that approximately 90 percen+. of the missing fuel was recovered in the failed fuel container, when the bundles were removed from the reactor.
Inspection of the bundles was also made for evidence of crud buildup. All bundles inspected were free of crud deposits with only a thin film deposit visible where crud had previously been noticed. Par-ticular attention was given to the surfaces around the spacers in the bundles and no deposits were in evidence.
A total of 24 bundles was removed from the core as de-pleted fuel and replaced during the outage. All of these bundles had burnups in excess of 7500 Mwd /T. Of the reload bundles,16 were Zircaloy-2 clad with four rods in each bundle containing cobalt targets.
Several significant maintenance items were performed during this shutdown and are covered in Section IV - Maintenance.
i
5 C.
Statistics The reactor was brought critical five times Erl was critical for 3556 5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br /> during this reporting period. Total heat produced by the reactor was 766,859 Mwh(t). The turbine generator was on the line for 3526.7 hours8.101852e-5 days <br />0.00194 hours <br />1.157407e-5 weeks <br />2.6635e-6 months <br /> with a gross electrical generatirn of 246,173 Mvh.
Net plant electrical generation for this period was 232,690 Mwh.
D.
R&D Program No special R&D Program tests were performed during this reporting period.
Two of the Phase I development bundles were removed from the reactor during the April refueling outage.
These were bundles PO-2 and PE-3 with burnups of 7686 and 7508 Mwd /T, respectively.
Twenty-three R&D fuel bundles were in the reactor following the April refueling. These included three Phare I bundles and 20 Phase II bundles, all of which had been previously irradiated.
One bundle from each type of the 20 Phase II bundles was visually inspected. A dimensional profile check wac also made on rods from selected bundles. All appeared in good condition with no abnormali-ties noted.
Bundle PO-2 of the Phase I bundles was inspected and appeared to be in good condition. The remaining three PO bundles were returned to the core on the basis of this inspection.
TI.
ROUTINE RELEASES. DISCHARGES AND SHIPMENTS OF RADIOACTIVE MATERIALS A.
The gaseous radioactivity released fro.n the stack during power operation averaged 30,000 pc/see of activation and fission gases.
Based upon 3195 effective full power hours of operation during this reporting 5
period, this recults in a total release of approximately 3.45 x 10 curies of activation and fission gases to the environs. Gaseous release during periods of shutdown was negli;ible.
B.
During this reporting period, the liquid radioactivity releases to Lake Michigan, by way of the circulating water discharge canal, num-bered 66 batches, with a total activity of 2.03 curies. One batch was released cn a partially identified basis wherein at least 90 percent of 58 all the activity was determined to be a combination of Co and En All other batches were released under unidentified limits.
6 I
C.
There were eight off-site shipments of radioactive material during this reporting period.
Shipment T ansfer Transfer Ty pe of No.
Date From To Radioactive Material 1
11/h/65 DPR-6 ACNC 200 Cu Ft of Radioactive 20-685-2 Spent Recin - 72 e 2
11/11/65 DPR-6 ACNC 130 Cu Ft of Radioactive 20-685-2 Spent Resins - 50 e and 3 Drum Low-Level Dry Waste 3
1/26/66 DPR-6
- Isotopes, Two Bottles (200 ml Capa-Inc.
city Each) - 0.01 me Contain-29-55-6 ing Radioactive Liquid 4
2/16/66 DPR-6
- Isotopes, Two Bottles (200 ml Capa-Inc.
city Each) - 0.16 me Contain-29-55-6 ing Radioactive Liquid 5
3/2h/66 DPR-6 Dresden Water and Steam Sampling 12-5650-1 Equipment <0.1 mr/hr at Contact 6
3/23/66 DPR-6
- Isotopes, Two Bottles (300 ml Capa-Inc.
city Each) - 0.1 me Contain-29-55-6 ing Radioactive Liquid 7
3/25/66 DPR-6 GE-Val Wooden Box No. ICC 15A 200 0017-60 1 5 me containing Millipore (Calif)
Filter Paper Samples 8
4/25/66 DPR-6 GE-Val Wooden Box No. ICC 15A 200 0017-60
< 1 mr/hr @ l Meter Contain-(Calif) ing Crud Samples III. RADIOACTIVITY LEVELS IN PRINCIPAL FLUID SYSTEMS (FOR 6 MONTHS)
A.
Primary Coolant Minimum Average Maximum Reactor Water Filtrate ("
-2 1
pc/cc 1.0 x 10 5.8 1 9 x 10
- Reactor Water Crud ("
pc/cc/ Turbidity 5 5 x 10 '
l.2 4.1 Iodine Activity
-5 pc/cc 8.5 x 10 2.0 93
- Based on APHA turbidity units and 500 ml of filtered samples.
" A counter efficiency based on a gamma energy of 0.662 Mev and one gamma photon per disintegration decay scheme is assumed to convert count rate to microcuries. All cocnt rates were taken at 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> after sampling.
i (b) Based on efficiency of Iodine-131, 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> after sampling.
7 B.
Reactor Cooling Water System Minimum Average Maximum Reactor Cooling Water ("}
-2
~1 J2c/cc 3 3 x 10 3 6 x 10 1.1 x 10 C.
Spent Fuel Pool Spent Fuel Pool ("
-3
-2
-2 pc/cc 7.1 x 10 1.2 x 10 3,g x 1g Iodine Activity
-9
-6 1
J2c/cc 6.5 x 10 1.0 x 10 2.2 x 10 '
The principal radionuclides in the reactor cooling water system were K and Cr These resulted from the activation of the potassium-chromate inhibitor. Radioactivity in the spent fuel pool is principally activated corrosion productions going into solution from the fuel and core components.
Some fission product contribution was made during April due to the storage of failed fuel bundles in the pool.
IV.
PRINCIPAL MAINTENANCE PERF0pmD The primary maintenance items not mentioned in Section I were performed during the refueling outage in April 1966.
Some of the more significant items are listed below.
A.
Both reactor feed pump motors were cleaned and inspected. An oil leak which had developed in No. 1 motor was found to be caused by a loose resistance temperature device in the inboard bearing. No major defects were discovered. In addition, both reactor feed pumps were disassembled, cleaned and inspected. The pumps were found in good condition with no de-fects noted.
B.
All weld penetrations to the containment vessel were visually in-spected for defects. This included removal of insulation where necessary to examine the welded joint. All were in good condition with no defects noted.
(" A counter efficiency based on a gamma ener y of 0.662 Mev and e
one gamma photon per disintegration decay scheme 1e assumed to convert count rate to microcuries. All count rates were taken at 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> after sampling.
I (b) Based on efficiency of Iodine-131, 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> after sampling.
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C.
Electrical coaxial penetration Plate H-58 was changed with a new plate installed. This change was due to shorted contacts in the i
amphenol connectors and'not related to suspectsd or known leakage.
l D.
Settling chambers were installed on both sides of the core dif-ferential pressure-transmitter. Erratic readings have been experienced a
in the past which were caused by the accumulation of foreign particles in the transmitter. These new chambers are designed to trap any such material before it reaches the transmitter.
I j
E.
The thermal shield and seal ring todifications effected during 1965 (see third semiannual report dated December 24,1965) were inspected visually. All components were found in good condition with no defects noted.
V.
CHANGES, TESTS'AND EXPERIMENTS PEPJORMED PURSUANT TO 10 CFR 50. m N This section describes the changes made to the facility within the six-month period without prior Commission approval pursuant to Section 50 59(a) of Title 10, Code of Federal Regulations, to the extent that such changes constitute changes in the facility as described in the Final Fazards Summary Report (FHSR).
It also includes tests and experiments carried out at the Plant without prior Commission approval i
pursuant to Section 50 59(a).
Each change, test or experiment described was authorized only after a finding by Consumers Power Compat.y that it did not involve a change in the Technical Specifications incorporated in Operatiag License DPR-6 (effective May 1,1964) or an unreviewed safety question.
A.
Facility Changes 1.
A self-contained condensate pumping unit was added to the off-gas drain line to accommodate the moisture accumulation in the off-gas holdup line. The dircharge of this unit is piped to the radwaste system clean receiver tanks.
2.
Test Jacks were installed on all neutron monitoring
. picoammeter scram trip circuits to aid in adjustment of the trip circuits and to monitor the outputs prior to monthly tests of the reactor protection system.
3 Flanges were added.to the pump discharge check valves in the core spray system. This permits removal of the valve fer assembly 4
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I of the check disc. Problems had been encountered with binding of the check disc and it was discovered that assembly of the valves with the check disc in the closed position could cause this binding. This modi-j fication allows assembly of the valve with the check disc open and also -
allows irapection after assembly to ensure movement of the check disc.
Similar problems had been encountered at other Company locations with this split-body type check valve.
h.
A vent line was installed on the discharge of the reactor feed pumps to allow venting of the pumps during start-ups.
5 The 3/4" manual valve in the vent line from the re-actor to the steam drum was removed and a section of pipe welded in place.
This valve was always open for the venting of noncondensibles from the
. reactor and had required maintenance in a high radiation area. Since the valve was not needed, it was removed.
B.
Tests and/or Experiments l
1.
Flux Tilting Test -
3 A limited version of the flux tilting test conducted in October 1965 was performed prior to the April shutdown for refueling.
The primary objective of the test was to determine the integrity of the
- r two thin (10 mil) stainless steel clad development bundles in the core.
Reactor power was reduced to approximately 75 percent with an even control rod pattern. After equilibrium was reached, data on off-gas activity, neutron flux level, steam flow and electrical output vere. recorded. An individual centrol rod was then fully inserted and data again recorded after equilibrium was reached. The rod was then returned to its or$ ginal' position and base conditions reestablished. This. cycle wasrepeatedforeEchcontrolrodinhheareasofinterest.
Data analysis resuits were inconclusive with the relative off-gas activity changes approximately the same as in the October 1965,est.
On the basis of the test. it was decided to remove and visually l
inspedtthePhaseIR&Dbundleinthe}areaofthecoregivingthestronr.est responheand'leavetheotherbundlesiortestingbyothermeans.
7 2.
Fuel Sipping Test -
-Water samples from within the channels containing
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selected fuel bundles were obtained for radiochemical analysis as an indicatar to determine if cladding failures had occurred in the bundles.
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The-procedure consisted of sealing the top.of a channel for approximately 30 mire 'es to allow fission products to accumulate. A
. one-liter sample was then drawn from the channel and taken to the chemical 1aboratory for-iodine extraction and. counting.
i Resolution of the results of this method deteriorated
~_ ith time after shutdown.
Several bundles were labeled as leakers or sus-w pects based on the results of this test. However, one of the least suspect 4
-bundles was found by visual examination to have a gross failure of the clad-ding..It was determined that this technique could give indications of clad failures, but did not conclusively identify -leakers.
j 3
Powdex Demineralizer Test -
A small pilot Powdex demineralizer was connected to the 7
5 suction of the reactor feed pumps. This unit will be used to evaluate the performance of the Powdex resins at water temperatures up to 250 F.
The Powdex process utilizes powdered resin coated onto a filter and has the ability to act as both a demineralizer and filter.
4.
Environmental Monitoring Program -
j Attached as Appendix A are figures summarizing the re-sults derived from the environs monitoring program.
The data cover the
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period October 1962 through January 1966. A study of this data shows that the operat' ion of the Big Rock Point Nuclear Plant has had no adverse effects l
.on the. environment.
5 Centainment Integrated Leak Rate Test -
An integrated leak rate test at 10 psig was started on the last day of the report period (April 30). Preliminary results indicate i
the integrity of the containment vessel is within specified limits, i
A report of the results of this test will be forwarded when complete..T.etails of the leak rate test of 1964 will also be included l
ac requested in your letter of July 1h, 1965 VI.
PERIODIC TESTING PERFORhED AS REQUIRED BY THE TECHNICAL SPECIFICATIONS.
i The following table shows the required frequency of testing, plus the testing dates of the systems or functions which must be tested
- periodically as required by the Technical Specifications:
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11 System or Function Frequency of Dates i
Undergoing' Test Routine Tests Tested Control Rod Drives Continuous withdrawal and insertion Each major refueling and 11/h/65 of each drive over its stroke.with at least once every six h/22/66 normal hydraulic system pressure.
months during periods of Minimum withdrawal time shall be 23 power operation.
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seconds.
Withdrawal of each drive, stopping Each major refueling and 11/h/65 at each locking position to check at least once every six h/s2/66 latching and unlatching operatione months during periods of and the functioning of the position power operation.
indication system.
Scram of each drive from the fully Each major refueling and 11/h/65 withdrawn position. Maximum scram at least once every six h/22/66 time from system trip to 90 percent month, during periods of of insertion shall not exceed 2 5 power operation.
seconds.
3 Insertion of each drive over its Each maje* refueling but 11/h/65 entire stroke with reduced hydraulic not lee-frequently than h/s2/66 system pressure to determine that once a year.
drive friction is normal.
Control Rod Interlocks Rod withdrawal blocked when any Each major refueling but 1/sl/66
. tvo accumulators are at a pressure not less frequently than 4/s3/66 below 700 psig.
once every 12 months.
Rod withdrawal blocked when two Each major refueling but
-1/22/66 of three power range channels read not less frequently thar.
h/s3/66 below 5 percent on O percent - 125-once every 12 months.
percent scales (or below 0 percent on their 0 percent - 40 percent scales) when reactor power is above the minimum operating range of these channels.
. Rod withdrawal blocked when scram Each major refueling but 1/21/66 dump tank is bypassed, not less frequently than h/23/66 once every 12 months.
Rod withdrawal blocked when mode Each major refueling but 1/21/66 selector' switch is in shutdown not less frequently than h/23/66 position.
once every 12 months.
Other Liquid poison system component Two months or less.
- 11/ /65 check.
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12 System or Function Frequency of Dates Undergoing Test Routine Tests Tested Other (Contd)
Post-incident spray system automatic At each major refuel;ng h/23/66 control operation.
shutdown but not less frequently than once a year.
Core spray system trip circuit.
Not less frequently than
'/66 once every 12 months.
Emergency condenser trip circuits.
K it less frequently than h/23/66 once every 12 months.
Containment Containment sphere access air locks Once every six months or 2/6/66 and vent valves, leakage rate.
less.
Isolation valve operability and At least once every 3/23/66 leak tests.
12 months.
Isolation valve controls and in-Approximately quarterly.
1 /22/66 strumentation tests.
h/23/66 Penetration inspection.
At least once every h/16/66 12 months.
Integrated leak test.
Once every two years.
h/30/66 The following instrument checks and calibrations were per-formed at least once a month: Reactor safety system checks on circuits not requirir; plant shutdown to crack; air ejector off-gas monitor cali-bration; tcack-gas monitor calibration; emergency condenser vent monitor calibretion; process monitor calibration; and the area monitoring system calibration.
By Robert L. Haueter (Signed)
Robert L. Haueter Assistant Electric Production Superintendent - Nuclear Consumers Power Company Jackson, Michigan Date: June 22, 1966 Sworn and subscribed to before me this 22nd day of June 1966.
(
(SEAL)
Grace Warner (Signed)
Notary Public, Jackson County, Michigan My commission expires February 16, 1968
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