ML20065G697

Containment Isolation Valve Replacement Program Rept

ML20065G697
Person / Time
Site:	FitzPatrick
Issue date:	10/09/1990
From:	Greene J, Swinburne P POWER AUTHORITY OF THE STATE OF NEW YORK (NEW YORK
To:
Shared Package
ML20065G693	List: JAFP-90-0742, Forwards Reactor Containment Bldg Integrated Leakage Rate Test, & Containment Isolation Valve Replacement Program Rept ML20065G694 ML20065G697
References
NUDOCS 9010230018
Download: ML20065G697 (8)

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l l are so-o742 ATTACHMENT - (2 )

r NEW YORK POWER AUTHORITY.

' !- JAMES A. FITZPATRICK NUCLEAR POWER PLANT I

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CONTAINMENT ISOLATION VALVE REPLACEMENT

'I PROGRAM REPORT I

OcTossa 1990 lI q I

tl. PREPARED BY: J. GREENE /0!/!94 JAF LICENSING ENGINEER DATE NGv % . $Q ACCEPTED BY: P. SWINBURNE /*[9!f#

JAF PERFORMANCE ENGINEER DATE g

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g, CONTAINMENT ISOLATION VAINE REPIACEMENT PROGRAM Introduction I The Authority described a containment isolation valve (CIV) leakage improvement corrective action plan (CAP) to the NRC in JPN 88-012 dated 4/8/88. This CAP resulted in the f replacement of 32 CIVs during the 1988,1989, and 1990 outages. (One of the original 33 valves in the program was rescheduled to 1991 due to difficulties in procuring a suitable replacement (Ref: NYPA letter to the NRC (JPN-89-077), dated 11/17/89). In JPN-88-012,

; the Authority also committed to implement a number of other corrective actions and to provide the NRC a follow up report discussing the effectiveness of the corrective actions.

This appendix to the ILRT test report provides that follow-up report.

Objectives of Corrective Action Plan

.I A. Determine through historical review which valves have contributed an excessive amount of leakage during performance of LLRT tests.

This review was conducted in 1988. The results of this review identified the 33 valves selected for replacement. He Authority recognizes that not every valve that fails its  !

L1RT test is necessarily a candidate for replacement. Particularly severe service conditions, unique valve designs and other factors can make valve replacement less valuable as a corrective action. The MSIVs are typical of this type of valve. During the late 1970's, these valves have exhibited leakage characteristics that could be seen as indications for replacement. Instead, improved maintenance through purchase of an MSIV seat maintenance tool coupled with additional training have reduced the MSIV LLRT failure rate to an acceptable level.

I B. Determine through historical review which valves have shown a history of minimal or no leakage.

This review was also conducted during 1988. The selection of replacement valve designs and vendors conside. red the results of this review. The replacement valves were

_I also specified to take adyruitage of more advanced designs and material considerations which did not exist at the time of initial plant construction. Some of these advanced features incorporated with the replacement valves are:  ;

e Low cobalt alloys in seating surfaces to reduce cobalt transport to the reactor and

.g the resulting neutron activation. His enhances the plant's overall ALARA program by reducing the quantity of Co-60 in the reactor coolant system.

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't l e I.ive load packings to reduce valve stem leakage and prolong p@ing lifetimes, ,

u This also reduces the amount of corrective maintenance required to tighten or ;l replace packings. ']

ng f .- Hard/ soft seat construction on Feedwater check valves to maintain leak tight performance under both the 1000 psig service condition and 45 psig IIRT test h; condition.

g. . Parallel double disk gate valve design to reduce thrust loads, reduce seat wear, LF improve maintainability, and improve leak tight performance over the original ,

g "flexwedge" gate valve design.

C. Develop LLRT trending to track penetration / valve performance.

. g W Dis trending program was developed using a personal computer and commercially i available spreadsheet software and was fully implemented in September,1988. The -

graphing routines of the spreadsheet program provides a visual trending capability. In 7 i  ;

addition to valve and penetration ID number, the data include valve manufacturer and --

model number to allow for review of which types of valves have had good and bad f'

leakage characteristic. The historical reviews discussed above were facilitated by use of ,

this trending program.

! Corrective Action - LLRT Program A. Improved Valve Maintenance Practices

1. Purchase main steam isolation valve seat maintenance tool This tool was purchased from the MSIV manufacturer. Use of this tool has greatly improved the quality of MSIV seat repairs. The results are seen as an improvement in the long term leakage characteristics of the MSIVs.

2. For penetrations where multiple containment' isolation valves are tested in '

combination, perform LLRT retest after maintenance is performed on a single valve.

Maintenance practices have changed such that whenever practical, only one j containment isolation valve located in a combined valve test configuration receives maintenance prior to 11RT retest. This more time consuming technique has now become standard practice at FitzPatrick. Although there may be times  ;

when other constraints (outage critical path, or ALARA concerns) necessitate a return to the past practice of repairing both valves prior to retesting, this has

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allowed a more accurate determination of the leakage characteristics of many containment penetrations.

~I 3. Improve the quality of valve repairs.

Plant mechanics have received special training from valve vendors in conducting leak repairs. An INPO certified apprenticeship program for mechanics has been. -)

implemented at FitzPatrick which includes job training and qualification. _ Greater  !

control of valve repair is also obtained by having all valve repairs performed or 1 directly supervised by Authority personnel. The selection of replacement valve designs has considered maintainability as a design specification. m replacement-valves should be easier to repair and have better results.

B. Identification of Valve Type / Manufacturer

,- 1. Using historical data, identify the type / manufacturer of valves which have contributed an excessive amount ofleakage during the performance of LLRTs. ,

l 2. Using historical data, identify the type / manufacturer of valves which have -

shown a history of minimal or no leakage during the performance of LLRTs.

The valve type and manufacturer data was included in the valve leakage trending .

program discussed above. The Authority is confident that it hes identified those. o manufacturers whose valves tend to deliver superior or substandard performance.

I! This information was considered in the selection of replacement valves.

• f W. C. Correction of Problem Penetrations:

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y Recommend / implement effective repair or replacement methods on containment isolation valves identified as historically poor performers (excessive leakage).

The 33 valves selected for replacement are the direct result of this corrective action.

ll The Authority believes that it has implemented an effective testing and maintenance u

L. program for containment isolation valves. The result can be seen as a demonstrated L

overall improvement in the "As-found* leakage characteristic of the primary containment system. The data contained in this ILRT test report show an improvement to the extent that many of the valves installed during the 1988 and 1989 outages did not

'I require maintenance during the 1990 refueling outage. This trend is expected to continue with fewer valves requiring repeated maintenance in future refueling outages.

It should be noted that valves in these service conditions have historically been poor I

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I performers consistently failing the "as-found" LLRT and requiring repeated

' maintenance - .

L There were three replacement valves (12MOV-15,13MOV-15, and 23MOV-15) y I whose performance did not meet Authority expectations , For reasons still under investigation by the valve manufacturer, the valve disks and seats distorted slightly during the operating cycle. The Authority believes that this behavior was due to thermal cycling from operating conditions to test conditions and that the warping was L. l .

a stress relieving mechanism. As such, the Authority expects that this behavior is limited to the " break-in period" of the valve and should_not result in long term leakage degradation. This will be confirmed when the valves are next tested during L the 1991 refueling outage.

D. Augmented LLRT Program Following completion of the currently scheduled valve replacements, consideration will be given to an augmented LLRT program if expected LLRT leakage reductions do not occur.

With the exception of the three valves discussed above, the results of the valve.

replacement program has met all objectives of our corrective action plan. "As-found" leakage has been reduced significantly, and fewer valves require corrective L maintenance for leakage reduction. Valve maintenance, when required, is also easier to accomplish and generates higher quality results. The Authority is satisfied with I-l these results.

It should be noted that the Authority's Inservice Testing (IST) program for. valves l

l exceeds the requirements of Appendix J. The IST program' specifies individual valve -

. leakage criteria and accelerated testing for valves which exceed their leakage criteria.

This in itself can be considered an augmentation to the requirements of Appendix J.

I In actual practice, we repair valves before they exceed their acceptance criteria based upon historical trending of their leakage performance. The Authority does not plan to

. modify the existing LLRT test program.

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't I JAF LLRT IMPROVEMENT VALVE LLRT DATA i r

k VALVE 10 1987 LLRT 1988 LLRT 1990 LLRT REPLACEMENT POST CNANGE I RE SULTS RESULTS- RESULTS- DATE LLRT RESULTS AS FOUND/AS LEFT AS FOUN0/AS LEFT AS FOUND/AS LEFT AS LEFT

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02 2A0V 39 1.8731/1.8731 1.3896/.3563 .261.117/.509 88 RF0 0.3563 02 2A0v 40 .2443/.2443 5.4553/.3843 194.947/.5228 - 88 RF0 0.3843 10MOV 26A (6) 3.3594/3.3954 14.2011/12.1142- 2.4382/2.4382 88 RF0 5?,1104 10MOV 26s' (7) 712.6/26.0608 1084.17/1.75 .3793/.3793 88 RF0 1.7500-10Mov 31A (6) .SEE NOTE 6 SEE NOTE 6 SEE NOTE 6 88 RF0 SEE NOTE 6 10MOV 31B (7) SEE NOTE 7 SEE NOTE 7 SEE NOTE 7 88 RFC SEE NOTE 7 11SLC 16 44.435/9.7932 10.165/10.165 .3314/.2450 90 RF0 0.2450 12MOV 15 93.5542/1.6593 104.854/39.3457 GROSS /28.8094 88 RF0 39.3457

................ ................. ................. ................. ............ ............. I 12MOV 18 (3) 107.818/23.5158 193.929/6.6933 391.93/29.8274 90 RF0- 29.8274

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! 12MOV-80 (3,14) SEE NOTE 3 SEE NOTE 3 SEE NOTE 3 90 RFO SEE NOTE 3 L 13MOV 15 17.4587/17.4587 4.2858/3.1726 401.601/7.7443 88 RF0 3.1726- ,

' .13MOV 16 (11) .1018/.1018 SEE NOTE 11 SEE WOTE 11 90 RF0 SEE NOTE 11 P  !

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13RCIC 4 212.253/40.3128 8459.58/17.1024. 44.8938/44.8938 88 RF0 17.1024 lE 13RCIC 5 96.6082/43.265 677.479/54.1067 '0 0167/49.0167 88 RF0 54.1067 l

l 13RCIC 7 .6296/.6296 4.2960/8.2814 NA 88 RF0 8.2814 13.081;'

13RCIC-8 13.9975/13.9975 .1425/13.0813 NA 88 RF0

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.t 20A0V 95 570.08/21.9888 3.7204/3.7204 40.4655/15.27 NOT CHANGED NA 1 j

20MOV 94 308.454/21.887 4.0618/4.0618 44.1812/21.887 90 RF0 21.8870 1 I -23HP! 11 (12) SEE NOTE 12 SEE NOTE 12 23HPI-12 7889.5/8.5766 1 3736.06/96.4555 SEE NOTE 12

.2189/.2189' 88 RF0

-SEE NOTE 12 96.4555

,23HP! 65 8194.4/78.1315 94.8776/94.8776 2.9828/2.9828 88 RF0 94.8776 23MOV 15 (8,14) 369.025/5.0579 1338.67/35.0956 Gross /9.5794 88 RF0 35.0956 l

g 23MOV 16 (8,14) SEE NOTE.8 42: WOTE 8 SEE WOTE 8 88 RF0 SEE NOTE 8 l 27 CAD 67. (9) 11.6561/8.5817 8.9228/8.9228 1.6639/1.6639 89 MO 0.5278 t

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!s I s- JAF LLRT IMPROVEMENT VALVE LLRT DATA l VALVE ID 1987 LLRT 1988 LLRT 1990 LLRT REPLACEMENT POST *CNANGE i RESULTS RESUI.TS RESULTS DATE LLRT RESULTS

!~ AS FOUND/AS LEFT A5 FOUND/AS LEFT AS FOUND/AS LEFT AS LEFT 27 CAD 68 (4) 843.413/16.288 432.65/5.003 GROSS /.1018 89 Mo - 0.2662 27 CAD 69 (5) 57.9242/.3471 4.2807/4.2807 .8765/.8765 89 No 0.5400-

!: 27 CAD.70 (10) 87.3444/25.0937 39.2998/39.2998 .2820/.2820 .89 No 0.1018 y ................ ................. ................. ................. ............ .............

l ' 2780V 124E1 .1517/.1517 .3715/.1089 .1304/.1304 NOT CNANGED NA 2780V 124E2 .3 772/.3772 .2469/.2219 .1018/.1018 NOT CHANGED MA

! l . 27sov 125A .8984/.47D6 7,8895/7.8895 SEE NOTE 13 88 RF0 7 SEE NOTE 13 2780V 1258 .6973/.4942 1.5728/1.5728 SEE NOTE 13 88 RF0 7 SEE NOTE 13 2780V 135A 11,737.9/.1018 .1018/.1018 SEE NOTE 13 88 RF0 ? SEE NOTE 13 2780V 135B 10,739.9/.6999 .1018/.1018 SEE NOTE 13 88 RF0 7 SEE NOTE 13 I: 2940V 74 .1018/.1018 .1018/.1018 926.889/.1018 90 RF0 0.1018 1.

34NRV 111A (1) 46.5226/46.5226 20.6654/156.772 .1018/.1018 90 RF0 0.1018 34NRV 1118 (2) Gros $ ' 279.95/3.11 279.95/3.11 90 RF0 3.1100 NOTES : (1)' VALVE 34NRV 111A is TESTED IN CONJUNCTION WITH 13MOV 21 AND 12RWC 62 (12M0V 69 AFTER 1987)

(2) VALVE 34NRV 111B TESTED IN C0!; JUNCTION WITH 23MOV 19 (3) VALVES 12MOV 18 AND 12MOV 80 ARE TESTED TorETHER (4) 27 CAD 68 TESTED IN CONJUNCTION WITH 27A0V 131A (5) 27 CAD 69 TESTED IN CONJUNCTION WITH 27A0V 1318 (6) ' VALVES 10MOV 26A AND 1DMOV 31A TESTED TOGETHER i

(7) VALVES 10MOV 268 AND 10Mov 318 TESTED TOGETHER-(8) VALVE 23MOV 15 TESTED IN CONJUNCTION WITH 23MOV 16 AND 23MOV 60 (9) 27 CAD 67 TESTED TOGETHER WITH 27A0V 132A (10) 27 CAD 70 TESTED TOGETHER WITH 27A0V 1328 (11) 13MOV 15 ANO 13MOV 16 TESTED TOGETHER Page 2

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JAF LLRT IMPROVEMENT- .I VALVE LLRT DATA-  ;

1 VALVE 10 1987 LLRT 1988 LLRT-I 1990 LLRT REPLACEMENT POST CHANGE. -l' 4 RESULTS RESULTS RESULTS DATE LLRT RESULTS AS FOUND/AS LEFT AS FOUND/AS LEFT AS FOUND/AS LEFT AS LEFT-(12) 23HPl 11 !$ NOT A Civ. 23NPl*12 AND 23HPl*65 ARE TESTED THROUGH THis VALVE .

(13) THESE VALVES WERE MOVED AND RELA 8ELED DURING THE 88 RF0. 'l l

(14) THESE VALVES WERE NOT COVERED UNDER JPN 88 012- 'J t

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