Text

Reports Progress & Results to Date of Investigation Re Main Steam Flow Restrictor Assembly
	ML20056B800
Person / Time
Site:	Monticello
Issue date:	07/02/1971
From:	Duncanson R; NORTHERN STATES POWER CO.
To:	Morris P; US ATOMIC ENERGY COMMISSION (AEC)
References
	NUDOCS 9102110350
	Download: ML20056B800 (8)
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NORTHERN 5TATES POWER COMPANY 6

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Dr Peter A Morris, Director

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United States Atomic Energy Commission Gg n %..za g/

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MONTICELLO NUCLEAR GENERATING PIANT Dacket No 50-263 License No DPR-22 Main Steam Flow Restrictor Anomaly In our letter of May 12, 1971, concerning inoperable t ain steam line high flow sensors, we reported a significant discrepancy between the measured differential pressure and the vendors calculated flow restrictor calibration curve. ' Ibis letter reports the progress and results to date of the investigation of this phenomenon and our plans for further investigation.

The flow restrictors perform two safety functions. First, they are designed to limit the steam flow from the reactor vessel to 200% of rated flow in the event of a main steam line break outside of primary containment. Secondly, they pro-vide a differential precsure signal which is used to initiate main steam isola-tion.

The Technical Specifications require the isolation setpoint to be f_140%

of rated flow.

i The data available at the time the discrepancy was first discovered indicated that the measured pressure differential was about 40% of the value predicated by the vendor's calibration curve. The setpoints of the high flow sensors were immediately reduced from 122 psid to assure that the Technical Specification limit would not be exceeded.

An immediate review of the restrictor design data and the physical installation was conducted. Independent calculations performed by NSP, the designer (General Electric Co.), and the vendor (the Permutit Company) verified that the calculated calibration curve was correct. The location of pressure taps, condensing chambers, i

and sensing instruments, as well as the slope and routing of sensing lines was verified as correct. Vendor representatives were called to the site by General Electric Co. to examine the installation and review the data. NSP has not received a report of their findings or conclusions.

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91021i0350 710702

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CF ADDCK 05000263 CF 3Or4

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THERN CTATED POWER 9OMPANY I

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Dr Peter A Marri.,

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July 2, 1971 The possibility that the restrictors were installed backwards has been eliminated.

The restrictors were factory installed near one end of an approximately 12 foot long section of pipe. The actual location of the primary teps shows that these sections of pipe are correctly installed.

Correct installation is also confirmed by the fact that the high pressure tap is upstream of the low pressure tap.

If the restrictors were backwards the relative positions of the high and low pressure taps would also be backwards, since the restrictor throat would bu the lowest pressure point regardless of the direction of flow.

Prior to resuming operation following an extended cold shutdown for turbine re-pairs, Gich ended on June 18, 1971, insulation was removed from the C steam line and the restrictor was radiographed.

The radiograph verified that the restrictor throat diameter was correct and that the restrictor was correctly installed.

In discussion with representatives of General Electric Co. we were informed tha t:

1)

Tnic phenomena has been observed at several General Electric Co.

EWR plants outside of the United States, some of which have been in operation for a considerable time.

2)

The phenomena appears to be associated with restrictors manufactured by a particular vendor.

3)

Differential pressure vs. flow data at other plants where the phencmens has been observed has been repeatable and has not changed as a function of time.

h)

There is a likelihood that there may be a leakage path within the flow restrictor which would reduce the differential pressure. How-ever, we were assured that the structural integrity of the restrictors has been reviewed and is not adversely affected.

5)

The ability of the restrictors to limit flow to 200% of rated has not been affected.

6)

Modifications are being made on restrictors for other plants which have not yet gone into operation and tests of these modifications are g

being planned.

7)

Plans are being made to perform scale model tests on piping layouts using steam. These tests may help determine whether the problem is due to the nozzle design or location.

b N

THERN STATES POWER COMPANY Dr Peter A Morris July 2, 1971 Two theories exist concerning the cause of the low differential pressure measure-ments. First, it is Possible that there is leakage between the welding ring and the pipe wall, or between the welding ring and the upstream 'or downstream sections, such that the pressure is increased in the low pressure sensing line. he second theory is that the upstream pressure is being incorrectly measured because of a possible ncn-uniform static pressure distribution caused by elbows in the line upstream of the restrictor.

The Operations Coccittee has reviewed the situation on several occasions and has approved continued plant testing based upon the verification of correct installa-tion and throat diameter, the repeatability of the pressure vs. flow data, and the assurance from the designer that: 1) The present high flow isolation setpoints were within the technical specifications, 2) the restrictor will limit flow to 200% of rated, and 3) the structural integrity of the restrictors is adequate.

The Operations Committee will continue to review any new information as it becomes known. A quorum of the Safety Audit Committee was informed of the situation, including both consultants from outside the NSP and GE organizations, and they concurred with the Operations Committee.

The subject is again scheduled for review at the next SAC meeting.

Pressure differential vs. flow data vas obtained as power was increased during the startup test program.

Shortly after reaching 100% steam flow for the first time a main steam line high flow trip occurred, resulting in main steam isolation and a reactor scram.

he trip was due to hydraulic " noise" in the differential pressure signals. Snubbers have now been installed in the censing lines to damp the noise.

Also, the setpoints of the high flow sensors have been adjusted to h3 psid. Extra-polation of the measured data indicates that this is below 140% of rated flow.

The vendors calculated calibration curve and the measured data are shown on the attached log-log plots. Tne data has been plotted vs. total feedwater flow, which is essentiall/ equal to total steam flow under steady state conditions. Feedwater flow was accurately measured using certified calibration flow nozzles.

The measured data is from two sources; the average of the indications from the high flow switches, and the output of the transmitters for the control room flow indicators. The data scatter, which is particularly noticeable at flow of 50% of rated or less, is pri-marily due to the inherent nonlinearity and deadband in these instruments.

1 j

A special test was conducted to obtain data for restrictors B and D at flows up to about 113% of rated. The test was conducted by closing isolation valves in the A & C lines and adjusting reactor power to obtain the desired flows.

Tne data continued to follow the extrapolated curve and lends additional confidence that the extrapolation to 140% of rated flow is valid.

Readings from the high flow switches are being recorded and evaluated daily to detect any changes in the pressure vs. flow relationship. A memo has been issued to inform the operating crew of the situation and request that they remain particu-larly alert to changes in indicated steam flow and other parameters which could indicate a steam leak, such as reactor water level, main steam tunnel area temp-erature, feedwater flow, and power level.

g NORTHERN OTATED POWER COMPANY Dr Peter A Morris

-h-July 2,1971 The steam flov instrucentatica used for the control room indicators and reco has been recalibrated based en the measured data and assuming that the steam flov in each line is equal to one-fourth of the total feedvater flow under steady s tate condi ti ons.

Over the range of 30-100% power the agreement between indicated steam and feedwater flows is good.

1he plant design includes instrumentation which compares turbine first stage which is directly proportioned to turbine steam flow, with total reactor

pressure, steam flow.

An alarm is initiated when reactor steam flow exceeds turbine flow by more than LOO,000 lb/hr.

(This is less than 2k% of rated flow through one steam j

line).

This instrutentation has been tested and is fully operational.

Although further testing has been approved, we feel it is important to continue to pursue a more complete understanding of this ancmaly. We are presently attempting to obtain the following information from or through the General Electric Compa ny.

1)

Information regarding the assumptions and methods of calculation used to determine the flov limiting capability of the restrictors.

2)

Additional information concerning the likelihood of leakage and the mechanist of such leakage and the effect on the structural integrity of the restri c tors.

3)

An analysis of all available data from Monticello and other plants, including a comparisen of the design of restrictors which have exhibited the problem with those that have functioned properly.

Also, we suggested that postulated theories as to the cause of the low readings be evaluated against the data and that their reason-ableness be established by calculations or measurements.

4)

Additional information concerning tests and todifications that have been performed or which are planned.

5)

Additional information concerning the history of the phenomena.

Yours very t -aly, O1 R 0 D2ncanson, Jr., P.E.

Gen Sapt of Power Plants-Mechanical Chairman-Monticello Safety Audit Committee ROD /FMC/t1 1

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ASTM-A-105 GR.11 6

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