ML20064L148
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'1 UNITED STATES 3
NUCLEAR REGULATORY COMMISSION AE0D/E2yy E
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WASHINGTON, D. C. 20555
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This.is an internal, pre-4,o g.
FEB. L41982 decisional document not necessarily representing a position of AE0D or NRC.
MEMORANDUM FOR:
Carlyle Michelson, Director Office for Analysis and Evaluation of Operational Data FROM:
Eugene V. Imbro, Lead Reactor Systems Engineer Reactor Operations Analysis Branch
SUBJECT:
REPETITIVE FAILURES OF EMERGENCY FEEDWATER FLOW VALVES AT ARKANSAS UNIT 2 BECAUSE OF VALVE OPERATOR HYDRAULIC PROBLEMS On December 12, 1981, during a routine review of. Combustion Engineering LERs, it was decided to acquire more information on LER 81-32 of Unit 2 of the Arkansas Nuclear One Power Plant. This LER described two separate failures of redundant Emergency Feedwater (EFW) supply valves, 2CV-1038 and 2CV-1075, associated with the electric motor driven EFW pump. Specifically, on August 15 EFW supply valve 2CV-1038 failed to operate because of a blown power supply fuse and on September 1, valve '
75 would not operate due to a lack of hydraulic pressure to the valv 6or caused by a leaking mechanical seal.
Our attention was drawn to this cR by the reference to eight previously reported similar events on the LER form.-
When each of the referenced LERs was examined, it was apparent that the fuse failure was an isolated event, and that valve operator hydraulic problems were a repetitive mode of failure in the EFW system.
(There are only two hydraulically operated valves in the EFW system, 2CV-1025 and 2CV-1075 - see attached flow diagram.)
It was found that some of the referenced LERs were not for problems similar to the original LER; however, the LERs that did pertain to valve operator hydraulic problems refer'enced some additional LERs that were not referenced in the original LER. This sequence of acquiring LERs.on Emergency Feedwater flow control valve failures due to failures of the hydraulic operator was persued until all relevant LERs were acquired. A draft table of the reported failures and the relevant LERs are attached.
In sumary, in the past three years, there have been eight instances of a problem with the hydraulic valve operator system that prevented the closure of one-of-the-two Emergency Feedwater flow valves in the two loop system, In particular, valve 2CV-1025 failed to function on seven occasions as shown in the table below.
In each case, the valve failed to close on demand from the control room. Failure-to-close would be the " safe" position for the valve in order to maintain auxiliary feedwater flow to the steam generators but one degree of redundancy would bglost if the valve was required to close on a main steam isolation signal (MSIS).-
In each case, the redundant valve in the same loop and the valves in the alternate flow loop were tested operable. /
hb F tnote attached.
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Carlyle Michelson 2
Failure of Valve 2CV-1025 to Actuate Date Reason for Failure 4
10/6/78 Hydraulic pump motor failed making the valve i
6/9/79 Valve operator required to be filled and vented l
with oil.
i 11/22/79 Valve operator hydraulic pressure was low.
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Hydraulic system vented and pressure returned to normal.
11/24/79 Dirt in the valve operator hydraulic system.
11/25/79 Low valve operator hydraulic fluid - no leaks j
could be found.
12/1/79 Low fluid level in hydraulic accumulator due to leakage - accumulator replaced.
1/20/80 Lack of hydraulic pressure caused by air in the system.
The frequency and repetitive nature of the information in this table would lead to the suspicion that either the maintenance / surveillance has not been optimized or a thorough understanding of the operation of the valve operator's hydraulic i
system is lacking. This. thought is strengthened by the f act that valve 2CV-1025 failed to actuate four times in a 2-week period. While the failure of this valve to operate in tiie Emergency Feedwater system presents no apparent consequence greater than a loss of redundancy, the root cause of the repetitive failures was unknomi.
On February 1,1982, we telephoned the licensee to discuss our observations on the hydraulic operators in the Emergency Feedwater system at Arkansas-2. The licensee, too, had been familiar with the repetitive nature of the failures and had implemented a corrective program shortly after reporting LER-80-3 in January 1980 (the last reported failure of valve 2CV-1025). The licensee's modifications included replacing the manifold of the Borg-Warner operators with a manifold that had significantly less fittings to reduce total air leakage into i
the hydraulic system. The check valves were replaced with softer seated valves, an internal filtration system was added, and the individual hydraulic accumulators were modified to retain pressure longer.
In addition, a periodic preventive maintenance program was initiated to detect potentially degraded operation appreciably before the event becomes reportable.
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Carlyle Michelson -
Apparently, the licensee has recognized the problan and has provided the proper corrective action.
Since initiation of the hydraulic operator modifications and the preventive maintenance program, valve 2CV-1025 has not failed to function; valve 2CV-1075 failed once, but the problem was not directly related to the previous events.
In the last 20 months, 2CV-1075 has required two additions of hydraulic fluid and valve 2CV-1025 has had five additions.
Previously, the systems were re-filled at more frequent intervals, i.e., when leakage was detected. This was generally before the valve became inoperable, and hence, before reportable.
The EFW control valves are safety grade valves and are readily accessible during all conditions. They can be operated manually, if desired, by pumping the handle of a hand pump located on the side of the valve operator.
Although Arkansas-2 has apparently reduced the number of problems with the hydraulic valve actuation system to a reasonable level and adopted a successful monitoring program, we recommend that hydraulic valve operators be added to the AE0D " watch list." As a " watch list" item, similar problems at other operating plants can be trended and the dissemination of possible fixes, such as those in effect at Arkansas-2, can be transmitted to the licensees.
/Y46 Eugene V. Imbro, Lead Reactor Systems Engineer Reactor Operations Analysis Branch Attachments:
As Stated cc w/attachnents:
E. Brown, AEDD R. Martin, NRR W. Johnson, IE w,
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MAC FORas3a4 U. S. 88UCLE AR RESULATORY COndaelsseOse LICENSEE EVENT REPORT EXHIBIT A CoNinot eLOCic: l l l l l l l@
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MSPo.eT o.it 80 EVENT DESCRIPTION AND PROSAILE CON 5tOUENCES h i On 8/15/81, during unit startup, Emergency Feedwater (EFW) flow valve, i
.2 i 2CV-1038, failed rendering one flowpath to "A" Steam Generator inoperables o
On 9/1/81, during Mode 1 operation, EFW flow falve, 2CV-107'5, would not i
1 i operate from the Control Room, again rendering one flowpath to "A" Steam i o,
.. i Generator inoperable. Alternate flowpath remained operable in both cases, o > I The 8/15/81 occurrence is similar to t ER's 50-368/78-026.79-037. The i
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OUD I 9/1/81 occurrence is similar to LER's79-043, 79-036,79-037, 79-090, i
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CAU$( DESCRIPTION AND CORRECflVE ACTIONS h Nalve 2CV1038 failed due to a power supply fuse blown caused by a relay a
i failure. The relay was replaced and the valve was returned to operable i gi g gl t status.
Valve 2CV1075 failed dbe to a lack of hydraulic ore =sure caused i gi by a low fluid level caused by a leakin9 mechanical seal.
The seal was i g i replaced and the valve was returned to ooerable status.
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fiiTil i During Mode 3 nnera tion. with the electrir driven Fmornenry Fooc8 water i
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fn* n7, p ps et_,,n I g iSteam Generator feeo. EFW flow control valve. 2CV-1025-1. failed to close 1 ion demand from the Control Room.
The valve failed in the EFW, or safe I
e s l oosition. The block valve was used to control level and all redundant i
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IEFW valves were proven operable. Similar to LER 50-368/79-092.79-090.
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CAust OtsCAePTION AND Commtcrivt ACTIONS linvestigation ravealed that tha valve failed tn onorata due to the lack I
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The hydran14r cyctam wat vented A filled with I i
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The recuirements of Action Statement T.S.3.7.1.2 were met.
One i
's tvalve ooerator was returned to vendor for analysis.
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..e eones ans LICENSEE EVENT REPORT EXHISIT A cowtaot stocic: l l l l l 1 l@ ~ '
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,o.ve as aveNT oESCaseflow ANo esosASLE coNStoutwets h g I Durina hode 2 ODeration. with the electric driven rmaroency Feedwater i
g i pump, 2P78, in service as an auxiliary feedwater pumo for normal startup i g i Steam Generator feed. EFW flow control valve. 2CV-1025-1. failed to closet j
g i on demand from the Control Room.
The valve failed in the EFW. or safe.
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I position.
All redundant EFV valves were succett'ully stroked from the i
E I Cohtrol 3oom.
This occurrence is similar to LER 50-368/79-090.79-089.
I i 79,088 and 79-043.
Other 1.ER's involvina valve 2CV-1025-1 are 50-368/
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' '79-068,14n054, M;pS1 c.1],-035,78-028 and 73-009.Segrtabj4 per T.S.6.9.'1.9.b.
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I investication revealed that the valve failed to coerate due to the lack of i.
m I hydraulic oressure caused bv a low fluid level in the hydraulic accumula-1 I tor because of leakace.
The accumulator was replaced and the system was i g i filled and vented.
The valve was declared ooerable within 19 hours2.199074e-4 days <br />0.00528 hours <br />3.141534e-5 weeks <br />7.2295e-6 months <br />, i
g I meetino the reouirements of Action Statement T.S. 3.7.1.2.
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U.L NUCLEAm mgGULA7o47 Comenstssaow as.C poene 3 4 nm LICENSEE EVENT REPORT EXHIBIT A costTROL BLOCit l 1 l \\
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gPLg As4 Palett om tvPt ALL fitouinto sospomanateos.3 e
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G I Durino Mode 3 operation. with the e dectric driven re'aroency Faadwater 1
g i pumo, 2P7B, in service as an auxiliary feedwater oumo for normal startup i E I Stenm Generatne feed. F N finw ennten1 valve. 7cV-1n?4-1_ failed tn eineal i on demand from the Control Room.
The valve failed in the EFW, or safe, t
o E I oosition?
All redundant FN valvec wer* eneces c n11y <trnked fenm tbo 1
e E I Control Room.
Thit occurrence it timilar to IFR 50-36R/70-080 70-088.
I rrrn i 79-043.
Other occurrences involvino 2CV-1025-1 are 50-368/79-068,79-05d,i
- 79-051. l#r,035. UCot-p28,aJ. coo,ttd 78-009.
Reportable per,J,...S. 6.),;,1.9.b.
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8 I investication revealed thht tha valve coprator's hydraulic svstem was lowl E I ci fluid.
No leaks could be found.
The system was filled and the valve i I wat declavad naprahle within enor (al hnnre. maa'iro the racuiramante nf I E I Action Statomont T.S. " 7.1. 7.
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,1.lCENSEE EVENT REPORT EXHIBIT A j
l tettast ensur on tyre ALL atouinto supoansAT own j
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7b est.o.T oats se EVENT DESCairfloM ANo rRQ3 A$t( con $(oVENCa$ Q ITTT11 Durino Mode 3 operation, with the electric driven Emeroency Feedwater i
3 pump, 2P7B, in service as an auxiliary feedwater oumi for normal startup 1 o
I Steam Generator feed. EFW flow control valvo. 2CV-1025-1. failed tn eineet o
i on demand from the Control Room.
The valve failed in the EFW. or safe.
I o s g i position.
All redundant EFW valves we're cuccaccfo11v stenked from tFa i
r3TG I Control Room.
This occurrence h similar to LER 50-368/79-088 and 79-043L
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70 n;1 1 to L*J l Other ocetArrenc9s involvino 2CV-1025-1__ are 60 VRno n;R_74-nsa
' '79-035, AE,-J28 acM8-Oph, Reportable per T.S. 6.U 9.b,,,,,
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CAUSE oESCAi'TiCN AND CORRECflVE ACTIONS 1 m I invat+in=+ inn ravaplad +rach in tha valva nnavator'e hydraulic evctam andt m I tha hvdraulic snobber out of ediustmant. restrictino oil flow in nne i
[]-[D l direction. The hydraulic svstem was cleaned. the hydraulic snubber was i
07]D 1 ad.iusted. the val've stroked satisfactcrily and declared coerable within ~ i 07.-] 1 13 hours1.50463e-4 days <br />0.00361 hours <br />2.149471e-5 weeks <br />4.9465e-6 months <br />, meetino the recuire nents of Action Statement T.S. 3.7.1.2.
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. LICENSEE EVENT REPORT EXHIBIT A i
CONTROL SLOCat: l l !
l l l.th (Pttast PalNT OR TYPE ALL REQuimtD eNFORMATlOsst l AIR l Al Nl 0 l2 lg,[.0 l0 l -l0 l0 l 0l Og 0 l-l 0 l0 lp. l1 l 1l1 l 1l g
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..o.,Da,3 EVENT OtsCRlPTION AND Pmos ABLE CONSIOVENCES O'a rom i Durina Mode 3 coeration, with the electric driven Emeroency Feedwater i
E t Dumo, 2P73, in service as an auxiliary feedwLter cumo for norinal startuo I r:-
uu. ; i Steam Generator feed, EFW fiow control valve. 2CV-1025-1. failed to closel E I on demand from the control Room.
The valva " failed in the FFW. or safe.
I o a lDosition.
All redondant FMI valvet were enreacefully etenked fenm tho I
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fiiTTl I Control Room.
This occurrence is similar to I ER 50-368/79-043. Other I
r5 Tin Loccurrence involvino valve 2CV-1025-1 are 50-368/79-068.79-054 79-051.i
- 79-035, J.- 8 aqQ8-0QL, Reportable per T.S. 6.9,<1,9.bs,m a
Cool ECot SW. Cool Co.a.o=Ew, Cout 59 3st ssuccot E, 8
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u CAUSE OthCAiPTION AND CO. REC fivt ACTIO.g3 m I Investication regaled that the valve operator's hydraulic oressure was i
m ilow.
The hydraulic system was vented, the reservoir was returned to m i ncrmal level, and the hydraulic oressure was adjusted. The valve was i
L'_w I successfullv stro'ke tested and declared operable within 29 hours3.356481e-4 days <br />0.00806 hours <br />4.794974e-5 weeks <br />1.10345e-5 months <br />. meetin91 A 1 the ranni re-ed nf Ac tinn 9 t;.'erant T 9
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h4, U. S 8.UCLE AC CE&Ut A)CQY Co.d**B58.oss ur m LICENSEE EVENT REPORT EXHIBIT A COmnot stoC= [_1 1
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.,Po.e t isa,g EVENT OL3Cate Ost ANO P40s.AOLE CC'est0utaeCES h g IDurinn.'Sde 3 operation. Emergency Feedwater flow control valves g i from the electric driven EFW pump. 2P7A. to the "A" Steam i
g IGenerator, 2CV-1025-1 and 2CV-1033-1 failed to close from a i
gontrol room demand signal.
The open position is required for EFAS; therefpre, o
ithe EFW flowpath would be uneffected in an emergency situation. He remainder O.
lof the EFW valves were successfully tested from the control room. Occurrence o a E, tsimilar to 50-368/79-035,78-028, 6 78-009. Reportable per T.S.6.1.9.1(b).I
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- TION AND COamECflVC ACTIONS h linvestic:stion revealed that 2CV-1038-1 would not operate due to i o i
g ga loose wire on the h'andswitch.
Valve 2CV-1025-1 required to be i
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- rented with oil.
n e valves were operable within I
m Ithe 2 hou ts as reouired by Action Statement T.S.3.7.1.2.
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