ML20072F680
| ML20072F680 | |
| Person / Time | |
|---|---|
| Site: | Bellefonte  |
| Issue date: | 06/20/1983 |
| From: | Mills L TENNESSEE VALLEY AUTHORITY |
| To: | James O'Reilly NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| References | |
| 10CFR-050.55E, 10CFR-50.55E, NUDOCS 8306280092 | |
| Download: ML20072F680 (25) | |
Text
{{#Wiki_filter:x t ~. *,.; #*I., ~' TENNESSEE VALLEY AUTHORITY CHATTANOOGA. TENNESSEE 374ot 400 Chestnut Street Tower II NC F@
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June 20, 1983 EE ?. 'B y !J, o r* PN BLRD-50-438/82-79 (D co U.S. Nuclear Regulatory Commission ' Region II c.n 5"* Attn: Mr. James P. O'Reilly, Regional Administrator 101 Marietta Street, NW, Suite 2900 p Atlanta, Georgia 30303
Dear Mr. O'Reilly:
.2 BELLEFONTE NUCLEAR PLANT UNITS 1' AND 2 - DISRUPTION AND COLLAPSE OF SODIUM HYDROXIDE STORAGE TANK - BLRD-50-438/82 SECOND INTERIM REPORT The subject deficiency was initially reported to NRC-0IE-Inspector P. E. Fredrickson on November.24, 1982 in accordance with 10 CFR 50.55(e) as NCR_2082. This was followed by our interim report dated December 27, 1982. Enclosed is our second interim report.- We expect to submit our next report by December 16, 1983 If you have any questions, please.get in touch with R. H. Shell at FTS 858-2683. + Very truly yours, TENNESSEE VALLEY AUTHORITY L. M. Mills, nager l. Nuclear Licensing I Enclosure oc:.Mr. Richard C. DeYoung, Director (Enclosure) Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission l. Washington, D.C. 20555 Records Center (Enclosure) In'stitute of Nuclear Power Operations 1100 Circle 75 Parkway, Suite 1500 Atlanta, Georgia 30339 l omcatcow; m EA B306200092 030620 DR ADOCK 0500C g DR An Equal Opportunity Employer
.. s i., ENCLOSURE BELLEFONTE NUCLEAR PLANT UNITS 1 AND 2 DISRUPTION AND COLLAPSE OF SODIUM HYDROXIDE STORAGE TANK BLRD-50-438/82-79 10 CFR 50.55(e) NCR 2082 SECOND INTERIM REPORT Description of Deficiency - During a filling operation of the sodium hydroxide storage tank, TVA site personnel discovered the following damage: The base plate for the supports was lifted from the foundation. 1. 2. The concrete foundation was broken. The sway struts at three locations around the tank were sheared in 3 half. At the time of these discoveries the tank was full of water and overflowing, resulting in the filling of the adjacent expansion loop with The tank was drained and additional investigation revealed the tank water. had collapsed on three sides and the associated piping was sprung. Interim Progress . A site investigation team was organized to determine the events leading to the collapse, the possible causes of the failure and the appropriate The results of this investigation are provided in the corrective action.The tank is to be repaired by representatives of Richmond attached report. Engineering Company (RECo) as authorized by NSSS Change of No. 397 j sent to TVA's Division of Engineering Design (EN DES)' for evaluation. All damaged foundation Damaged embedments will be replaced as required. concrete (and any concrete removed to allow repair of the steel embedments) is to be removed and replaced according to TVA's Division of Construction j Specification G-34. The lateral restraint system will be redesigned using the existing embedments. No vendor drawing revision is required. TVA drawings will be revised as required to depict any necessary modifications. EN DES has additionally prepared Engineering Change Notice (ECN) 3072 which l will provide fail-safe vacuum breakers for the sodium hydroxide tank. l l
W-4 o ATTACIBfENT 4 1 5'
5 T SODIUM HYDROXIDE TANK 15CIDENT REPORT T The NaOH tsnk is a vertical 42 foot X 8.5 foot stainless steel tank with a volume of 16,456 gal. It was manufactured by Ametec, Inc. - Schutte & Koerting Div., Whitlock Plant, West Hartford, Conn. in 1975 under ASME r Code, Section III, Class 2. The tank is made of SA-240 type 304, 0.25 inch stainless steel with a tensile strength of 75,000 PSI. The Unit One Sodium Hydroxide Tank (here af ter referred to as the NaOH Tank) was collapsed which resulted in the following damage: 1. The foundation was broken on the east side. Ref. Attachment 1-Sheet 1 i 2 2. The NaOH tank support base ring was raised 1 inch from the foundation i on the east side. Ref. Attachment 1 - Sheet 1 3. The 1 inch vent line El. 690'-7" was bent at the location of hanger INS-MPCH-0303. Ref. Attachment 1 - Sheet 1 & 2 j 4. The 2 inch tank nozzle for the pressure and vacuum relief system El. 689'-1" was bent. Ref. Attachment 1 - Sheet 1 & 2 5. The recirculation pump discharge line tank nozzle was bent. Ref. - Sheet 1 & 2 6. Two seismic pipe supports were damaged. 7. The four seismic restraints for the NaOH tank were broken. All associated damage is shown in the attached photographs'and has been reported on NCR 2082. nO* \\cdV ded m 10 C.FR. 50. 55 LO rep o rt. 9hoto g ra.9)h5 l I \\
} HISTORY OF TANK The tank was sold to TVA by Babcock & Wilcox Co., on contract No. 71C62-3 54114-2, Task No. 39 at a cost of $40,000. It was received at the Bellefonte site on June 19, 1975, where it was stored until installation at its present location on May 8, 1980. During an inspection while in storage, it was discovered that the bolts in the manway covers had rusted. When they were replaced in the 18" manway cover it was found that the bolt holes in the tank had not been drilled perpendicular to the flange. Ref. NCR# 1176, BLN 80 0421 122. The bolt holes were corrected per B&W 1etter SL-300-SPR #177-1. While the tank was being installed in April of 1981, it was found that a 1 inch nozzle for the level transmitter had been left off of the tank. Ref. NCR No. 1398, BLN '81 0312 109. The nozzle was installed per B&W FCP-148, NEB '81 0812 368 on September 1, 1981. A hydrostatic test for the nozzle installation was performed on September 20, 1981. This was the first time that water had been placed in the tank on the job site. It was hydro tested to a pressure of 32 PSIG as read on a guage installed on top of the tank. On October 2, 1981 the 18 inch Manway Cover was removed from the tank to allow an inspection of the inside of the tank to verify that it was clean. On December 10, 1981 the tank was filled to approximately 8' to be used as makeup water for flushes NSFB and NSFC performed on December 10 and 12. On February 18, 1982 temporary bolts were removed from the stabilizer struts at the top of the tank and new ones installed. The temporary bolts were installed because bolts of the correct' strength were not available on the job site and had to be ordered. At the time of installation of these bolts a plastic protective cover was in place and there was no apparent damage to the tank. On June 26, 1982 the tank was filled to approximately 30' with demineralized water used as make-up during flushes NSFC* and NSFB* conducted on June 26-28 and August 11 respectively. No tank deformation was noted at this time and the plastic protective cover remained on the tank. . l o'
Y. 1 DESCRIPTION OF INCIDENT Tuesday, November 9, 1982 at 10:30 a.m. the filling of the NaOH tank, located on elevation 647, capacity 16,456 gallon, started. The tank was being filled in support of flush NVFA by Mark Henderson of the Start-up 4 Testing and Coordination Unit using a procedure written by him for the purpose of filling the tank. Ref. Attachment 2. It was being filled from .the demineralized water head tank, capacity 15,000 gallon, which is located at' elevation 763 of the Turbine Building.' After lunch (11:30 am CST) a check was made on the tank by Mark Henderson and he found that the tank had stopped filling. The tygon tubing placed on the side of the tank to indicate the level in the tank ~ revealed that the tank was approximately 2/3 of the way full (approx. 11,000 gallon). Mark placed a call to the Control Room to inform them that water had stopped running into the tank. The Unit Operator said.that the head tank was empty. According to the log book at the demineralized water plant (location 649 Turbine Building) the head tank was reported empty at 12:28 p.m. and good water was flowing to the L demineralized water head tank at 1:15 p.m. with a flow rate of 135 GPM. .This water was also going to the NaOH tank because the two tanks were tied together through associated piping. Approximately ten minutes after he i reported to the unit operator that the tank was not filling, Mark Henderson returned to the NaOH tank room to check the tank. When he arrived at the tank room, Mark observed that water was running onto the floor from the overflow and vacuum breaker line and the tank was making loud noises. Mark closed the valve used for filling and climbed to the top of the tank to check and see what the noise.was, but found nothing. Later.on that afternoon it was discovered by Joe Stillwell (Electrical i Maintenance RB 1) that water was running on the floor behind the tank in the NaOH tank room and the level was approaching a space heater which had been installed that morning to keep the tank from freezing. He did not enter the room at this time because he was afraid of electrical shock from-the heater. After he made his observations he went to Jessie Patterson's (Assistant General Forman RB 1) field office which is located beside the tank room. When the report was made to the fitters they went to the tank room.and the tank was making loud noises and water was running on the floor. As they stood by the tank aLloud noise was heard and the tank i jumped pulling the tank support base plate from the foundation high enough to place a fist under it.- A short time later the tank popped again. It was discovered later after Ray Mahaffa (Fitter Foreman RB 1) climbed to the top of the tank that the stabilizer struts at the top of the tank had been broken from'the walls. He also observed that the water that was flowing into the room was coming out of the' floor sleeve at the back of the tank. This sleeve is the sleeve for the pressure and vacuum relief system pipe which dumps into the sump under the tank room. By.this time it was feared by Max Howe (Assistant Construction Superintendent) that the tank might fall over. So the order was given by Max to drain'the tank. Jessie Patterson was assured by David Bedford (D-4, STCU) that the tank would vent while draining because the pressure and vacuum relief system has no valve. After the draining operation was begun all personnel were ordered from the room and the door locked. After the ~ tank had drained for a while some question was raised as to if the tank was venting properly. A hold order was removed from valve INS-IFSV-073 (the vent valve for the tank) and the valve was opened. ~.
',o The following morning (November 10, 1982) the tank room was opened and authorized personnel were permitted to examine the tank. From the top of the tank, it was quite evident that the tank had collapsed. The extent of the damage was not apparent at this time because the tank was still covered with the plastic protective cover. Upon removal of the protective cover it was found that the tank had collapsed on three sides resulting in the damage described. Ref. attachment 3. While examining the room it was found that the sump under the room contained about 6 feet of water and the concrete form and shoring that was used when the tank room fleor was poured. The shoring covered the sump side of the pressure and vacuum relief pipe penetration, effectively closing it off and forcing the water to travel across the floor to the sump access opening. A threaded rod extended through the shoring through the penetration, and into the open end of the pressure and vacuum relief pipe and this threaded rod held a piece of duct tape (originally installed to keep the pipe closed and clean) effectively reducing the vent outlet to half or less of its cross-sectional area. It was also noted during the initial examination of the tank that the temperature of the tank skin in the area directly illuminated by the space heater was very hot. This was verified by Richard Gipson (System Engineer for the Reactor Building Spray System) on November 19, 1982 when the temperature of the outside skin of the tank measured at different locations showed that the overall temperature was 80 Degrees Fahrenheit with a hot spot temperature of 149 Degree Fahrenheit.
.O .~., POSSIBLE CAUSES WHICH WERE CONSIDERED 1. Tank collapsed during a previous flush and damage was not discovered because the tank was covered with a plastic cover. 2. Over pressurization of the tank due to the overflow being restricted. 3. Possible collapse of the tank when water was drained from demineralized header while the tank was being filled. 4. Possible collapse of the tank by a syphon created by the pressure and vacuum relief system piping. 5. -~ Possible collapse of the tank when cold fill water was initiated into the heated tank. 6. Possible failure of foundation, breaking lateral support struts, then tank collapse as a result of draining.,
(o ' CONCLUSION The overflow condition of the tank at the conclusion of the filling operation resulted in a solid column of water in the tank and the pressure and vacuum relief system pipe. The column in the presure and vacuum relief system was approximately 44 feet high. When the fill valve was closed, the water in the pressure and vacuum relief system continued to flow out the open end on the bottom with no vent capability in the tank, resulting in a negative pressure on the tank which exceeded the structural capability of the-tank walls (see calculations - Attachment 5). As the tank began to collapse it forced more_ water out through the pressure and vacuum relief pipe and the system was effectively in a self-destructing condition. This phenomenon resulted in the extensive damage to the NaOH tank / system. CAUSE The specific cause of the NaOH tank damage is difficult to ascess as a simple determinant since there were so many contributing factors which had a synergetic effect. Some of these contributing factors were: 1. Restricted flow in the pressure and vacuum relief pipe. 2. Filling procedure omitted the filling precaution found in B&W Technical Document No. 67-1002781-00. Ref. Attachment 4. 3. Tank left in an unmonitored condition during filling operation allowing the overfill condition. 4. Basic design of system allowing such a phenomenon to develop. 5. Failure to remove sump shoring. A review of the actions leading up to and resulting in the NaOH tank damage reveals that the phenomenon would not have developed had the filling procedure specified the required level and the filling operation been closely monitored to assure that the tank was only filled to the desired level. The accident could also have been prevented if the precautions in the B&W Technical Document had been followed. ACTION REQUIRED TO PREVENT RECURRENCE Filling and emptying procedure for tanks and systems shall be revised to include positive measures for monitoring levels and a sign off for review and check of design limits and precautions. EN DES to investigate feasibility of providing fail-safe vacuum breakers for the NaOH tank and other tanks which could be inadvertently over filled. I V D' don Smit'tri As ista Const. Engineer A bt A U T. Walker, Quality Manager mM ~A T Brothers, HEU Supervisor,
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-- ATTACHMENTS: 1-Drawings showing location of damage NaOH tank fill procedure. - 2. ~ 3. , Sketch'of~-tank damage ~ -4. Technical document.for th'e NaOH tank 5. Calculations 6. Sketch ofIfill line' configuration ' ketch of pressure and vacuum relief system piping S ^ 7. I e L.... 9 4-f 5-
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Fhe fa, k and y revide till ro u le. A Hey + k e va lye lineup is comi,le+c a open valve INS-V G A b-lli +o. fill I h e +ntr. Ob serve [he level indi ca-for fof;)] }an k {o +be reg ujyed le vel, Hien c.lo se INS-v&AD -1)L e t
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0,en Closed -(/) Valve !!o. Open Closed (/ ) 1 INS-VH AB-073 / l lhIS-VGAD -026 ^V l l INS VGAb-Ill V lNs-VDAB-o 72 Y-INS-V3&ttl/B v v' lNs-VbA B -05Y V V Iris v7AB-Io2-A y / I ins - YGAB-b 77 Y h !NS VKMbstb v V lNs-V bhB- 06/ V / b IHS-Y3AD-101 Y / lNS-Vbf B 045 y / INS-YMB-lo5-A Y / INS-VG Ab -Il3 V / INS-Y3Ab-D93-h _V y' INS-VGAb -o 76 y / JIM-v3A b-107 y v' /Ws VD})8-87/ V* / lits-VpAB-off-B y ] JNS-VGA D -2Y f V / JN;-Vbh8-loS-A V f INS-VDA B- 071 y' / IHs-vbAR-78 v / ins-VTAB-o71-A y / Its-VGAb -075 V" V' ins-VJAB-615-A v / If/S-VbAB b83-A y / INS-VbAB-Id'l-A v / INS -VbAB-b85-A y / ins-YDAB-JDI-B y / INS-VSA B-692-B v V INS-VS A B-D2'l-A y / INS-Y5AB -Iba -8 V / JNS-VS A B-lo 7-A V / ins-VG Ab-a19 v / INS-VGhD-bSo y-V INS-VGA b-694 V / INS-vGAb-)lO V t/ .-All positions verified as checked. Sign.1t u re Date t T 'n -~-r-n -, - - - ~ s w< - ~ > > - - - + - - - ~ - - - +~ - - - + .* ~ - ~ -,
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A. Pressure (at tank bot:ca) 25 psig $..J','p A.. ; 200F ~.., 3. Temperature M;j';h ' ' ' .s.. o:,.w. 16,456 gal. J.';I .' Volt:se
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~- . n :9. u.*.'.... 424.45 gal /f: n- ' %Q.: L. D. Volu::= per foot ei straight. shell a.4 r;<.: . ). ['j;;,e,3 p.,E q - 4.,. E. Volume below lower level :ap. t 211 ga.1. e5(.k.(". [. a". e a..... f., E..r. :,. Nomal Oueratine Canditiens ~. ' a
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,~~~ shall be iner:cd with nitrezen to a f, g... ~. 3,. l." positive pressure above atmospheric to yyc ..1.,..... .. ;' Q' C,.'. y'..*C prevent air inleslage thus prelenging sodium hydroxida storage life. The :W u: .,"...././:.J.C"".f.,,J,.d, ?.H..,* ; " M *
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