ML20078Q780
| ML20078Q780 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 06/01/1994 |
| From: | Pacy M HOUSTON LIGHTING & POWER CO. |
| To: | |
| Shared Package | |
| ML18065B259 | List: |
| References | |
| NUDOCS 9502220065 | |
| Download: ML20078Q780 (17) | |
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, HOUSTON LIGHTING AND POWER SOUTH TEXAS PROJECT ELECTRIC GENERATING STATION '
PLANT PROCEDURES MANUAL 1
DEPARTMENT PROCEDURE NON SAFETY-RELATED (NON-O)
WOV Tracking and Trendine Pronram F9 PEP 07-ZE@07 '
Rev. 2 (General)
Page 1 of 17 ,
O APPROVED: /O/S b!2Y/N-NbM ENGINE ERINd PRoGRAd 4ANAGER DATI' APPROVED DATE b vE U
l.0 Purpose and Scope 1.1 This procedure defines the engineering review requirements and documentation to satisfy provisions of Generic Letter 89-10, paragraph H.
1.2 This procedure applies to those MOVs defined by OPGP03-ZE-0037, Addendum I, Generic Iztter 89-10 Motor Operated Valve Program.
1.3 This procedure describes the method by which MOVs requiring frequent and repeated use of maintenance resources are identified so that actions can be taken to remedy all detectable generic problems. In addition, operational impacts can be mitigated by the identification of generic problems.
2.0 Definitions 2.1 BASELINE TEST - The initial verification test of a set of MOV pararneters to provide adequate assurance that the MOV will perform its intended function.
2.2 FAILURE - The inability of a motor operated valve or individual component to perform one or more ofits required functions.
2.3 Service Request (SR) - Form used to document and evaluate the need for a maintenance work activity and to request general manpower support services.
2.4 Station Problem Report (SPR) - Form used to identify deficiencies or significant deficiencies.
9502220065 950216 PDR ADOCK 05000498
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t MOV Tracking and Trending Program OPEP07-ZE-0007 '
Rev.2 Page 2 of 17 r
2.5 TRACKING - The condition of being aware of a fact or progression. {
2.6 TREND - The general movement over a period of time of some statistical change that indicates a prevailing tendency or inclination.
2.7 GROUP - A collection of MOVs with one or more common characteristics. The common characteristics used to define the group may vary depending upon the situation. .
2.8 TRACKING AND TRENDING DATABASE (TTDB)- The combination of the MOV Database, Diagnostic Database and the MOV Maintenance HistoryDatabase as used by EPD/MOV Group to determine trends of MOV failures and other characteristics.
3.0 Responsibilities 3.1 The Engineering Programs Department (EPD) Manager is responsible for the ;
following: '
3.1.1 The development, rnaintenance, and implementation of this procedure. j 3.1.2 Assign MOV Tracking and Trending Coordinator.
3.1.3 Assign MOV Engineer to perform Trend Investigations, maintenance !
trend ana!ysis and test trend analysis.
3.2 The MOV Tracking and Trending Coordinator is responsible for the following:
3.2.1 Maintain the MOV, Diagnostic, MOV Maintenance History and other related databases that apply to MOV tracking and trending activities.
3.2.2 Down loading data fmm the plant Equipment History Database on a regular basis and formatting it for use with the other databases. :
3.2.3 Obtaining data from applicable activities for input to the MOV and Test !
databases. ,
3.2.4 Produce reports as described in this procedure.
MOV Trackinn and Trendinn Pronram OPEP07-ZE-0007 !
Rev.2 !
Page 3 of 17 i i
3.3 The MOV Engineer is responsible for the following activities:
e 3.3.1 Initiate and perform Trend Investigations. ;
3.3.2 Assignment of maintenance work codes shown in Addendum 1 to the .
records in the MOV maintenance historydatabase.
3.3.3 Analysis of maintenance activity and test data for trends.
3.3.4 Publish reports and recommendations based upon maintenance activity i and test data analysis.
4.0 Procedure I i
4.1 EPD SHALL establish a process for acquiring, compiling, storing, manipulating and analyzing selected MOV related information, and producing Trend t Investigation Reports as described in this procedure.
4.2 Data Collection ,
4.2.1 Information from the following datahases is used to derive the trends described in this procedure-t 4.2.1.1 MOV Database !
4.2.1.2 Diagnostic Database 4.2.1.3 MOV Maintenance History Database 4.2.2 Collectively the information contained in and extracted from these databases is known as the Tracking and Trending Database (TTDB).
4.2.3 All of the databases must be sufficiently protected (security measures such as passwords and read only files) to assure that the quality of source inputs and the resulting trend outputs is maintained. Data input by EPD/MOV SHOULD be validated prior to use for tracking and ;
trending.
4.2.4 The MOV Data Base pmvides the design infornation associated with ;
each GL 89-10 Class 1E MOV. This information consists of design ;
data on the valve and its actuator, its use in the system, its location !
within the plant and valve limit switch setpoints.
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MOV Trackina and Trwia= Pmaram OPEP07-ZE4007 Rev.2 _
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4.2.5 The Diagnostic Data Base consists of test data collected in OPMP05-ZE-0309, Test Sheets -3, -4, -7 and Addendum 44. This test data is collected from both static and dynamic testing of the MOVs. {
4.2.6 - The Equipment History System (OPGP03-ZA-0503) consists of 1 historical records of corrective (SRs) and preventative maintenance ;
(PMs) work associated with each MOV. .This data is maintained by !
Systems Engineering Department (SED). Data is downloaded fmm this ,
system and modified to add maintenance work codes in the MOV maintenance historyDatabase. i i
4.2.7 The MOV Maintenance History Database consists ofinformation down-loaded from the Equipment History System modified to add maintenance work codes (Addendum 1). This allows tracking and trending of specific types and categories of failures and maintenance work as def'med by the MOV engineer.
4.3 Test Data Tracking and Trending j 4.3.1 Test data tracking and trending consists of tabulating the test data from j tests performed in accordance with OPMP05-ZE-0309 (Test Sheets -3, .
-4,-7 and Addendum 44), entering the data into the MOV Diagnostic ,
Database and trending the data shown in Addendum 2.
l 4.3.2 The MOV Tracking and Trending Coordinator SHALL:
4.3.2.1 Produce reports of trends for the data shown in Addendum 2 at least 7 months prior to the Unit refueling outage. ;
4.3.2.2 Produce other test data trending reports as requested by the MOV Engineer.
4.3.3 The MOV Engineer SHALL t 4.3.3.1 Review the Test History Reports to determine if test data indicates an adverse MOV performance trend.
4.3.3.2 Initiate and perform a Trend Investigation when test data indicates an adverse trend in MOV performance.
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i MOV Trackins and Trendina Program OPEP07-ZE-0007 Rev.2 Page 5 of 17 4.3.3.3 Initiate corrective action in accordance with OPGP03-ZX-0002 Corrective Action Program or OPGP03-ZA.0090, Work Process Program.
4.3.3.4 Prepare a MOV Test Data Trend Summary (at least 6 :
months prior to the Unit refueling outage) that discusses MOV performance as indicated by the test data over the - ,
last period, conclusions drawn from the trends, corrective action taken for the period covered and EPD actions I required during the next period. The report shall be forwarded to the Manager, EPD and a copy to Records ;
Management filed under File No. G03.08 (GL 89-10 Program). !
4.3.3.5 All EPD actions identified in the MOV Test Data Trend l Summary SHALL be placed in the Engineering s Management Tracking System (EMTS).
4.4 Maintenance Activity Tracking and Trending 4.4.1 Maintenance activity tracking and trending consists of periodic i downloading of equipment history data from the Equipment History !
Sysem that is described in OPGP003-ZA-0503. The data is formatted ,
for use with the MOV Database and MOV Diagnostic Database, '
additional maintenarice work codes (Addendum 1) are added to each ;
record in order to trend work history with other MOV data as desired. ,
4.4.2 The MOV Tracking and Trending Coordinator SHALL i 4.4.2.1 Periodically (a minimum of once every 3 months) download i from the SED /RE ~ Equipment History Database the ;
information shown in Addendum 3 for all MOVs in the GL 8910 Program into the MOV Maintenance History Database. All SRs and PMs SHOULD be included in the i downloaded data. '
4.4.2.2 Produce a MOV Maintenance Trend Report at least 7 l months prior to the Unit refueling outage.. The report trends mair.tenance work activity by the groups shown in Addendum 1.
MOV Tracking and Trendine Program OPEP07-ZE-0007 Rev.2 Page 6 of 17 4.4.2.3 Produce other reports and trends as requested by the MOV Engineer.
4.4.3 The MOV Engineer SHALL 4.4.3.1 Review the MOV Maintenance Trend Report and determine !
if adverse trends exist.
4.4.3.2 Initiate and perform a Trend Investigation when an adverse maintenance work trend is identified.
4.4.3.3 Initiate corrective action in accordance with OPGP03 ZX-0002, Corrective Action Program or OPGP03-ZA-0090, Work Process Program.
4.4.3.4 Prepare a MOV Maintenance Trend Summary (at least 6 months prior to the Unit refueling outage) that discusses '
trends analyzed, conclusions drawn from the trends, corrective action taken for the period covered and EPD actions required. The report shall be forwarded to the Manager, EPD and a copy to Records Management filed under File No. G03.08 (GL 89-10 Program).
4.4.3.5 All EPD actions identified in the MOV Maintenance Work Summary SHALL be placed in the EMTS. j 4.5 Trend Investigation 4.5.1 The Trend Investigation is a detailed analysis of the MOV failure 'or ;
adverse trend with consideration of related or similar failures, i maintenance work history, test data and industry wide information.
P 4.5.2 A Trend Investigation SHALL be initiated when:
4.5.2.1 A hardware SPR is generated for a MOV 4.5.2.2 A test data trend indicates deteriorating MOV performance ;
4.5.2.3 An adverse maintenance work trend is identified 4.5.2.4 Management request i l
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4 MOV Tracking and Trending Pronram OPEP07-ZE-0007 Rev.2 ,
Page 7 of 17 4.5.3 The MOV Tracking and Trending Coordinator SHALL:
4.5.3.1 Provide assistance to the MOV engineer to extract failure, maintenance and test data from the TTDB for the failed MOV and the defined group (s) for use in the Trend Investigation as requested by the MOV engineer.
4.5.3.2 Update the MOV Database to show that a Trend Investigation has been completed for the failed valve.
4.5.4 The MOV engineer SHALL: #
4.5.4.1 Complete the Trend Investigation Data Request (Addendum
- 4) and obtain MOV Maintenance Work and Test Data History for the failed MOV from the MOV Tracking and Trending Coordinator.
4.5.4.2 Obtain and review all previous Trend Investigations for the failed MOV.
4.5.4.3 Obtain and review all previous SPRs for the failed MOV.
4.5.4.4 Request industry related information based upon the MOV from the NPRDS Coordinator. Evaluate the data when received.
4.5.4.5 Evaluate maintenance work and test data histories for the failed MOV.
4.5.4.6 For Trend Investigations initiated by an adverse trend or when an individual failum indicates that a generic problem may exist, define a group or groups of MOVs with similar characteristics and perform steps 4.5.4.1 through 4.5.4.5.
4.5.4.7 Initiate corrective action in accordance with OPGPO3-ZX-l 0002, Corrective Action Program or OPGP03-ZA-0090, l Work Process Program.
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. MOV Trackinn and Trendma Pronram OPEP07-ZFA007 Rev.2 Page 8 of 17 4.5.4.8 Prepare a Trend Investigation Report using the outline in Addendum 5. The report SHALL be forwarded to the Manager, EPD and a copy to Recortis Management fded under File NO. 003.08 (GL 89-10 Program).
4.5.4.9 All EPD actions identified in the Trend Investigation Report SHALL be placed in the EMTS.
4.5.4.10 Notify the MOV Tracking and Trending Coordinator and obtain signoff on the cover sheet that the MOV Database has been updated.
5.0 References i
5.1 NRC Generic letter 89-10, " Safety-Related Motor Operated Valve Testing and Surveillance", dated June 28,1989.
5.2 OPGP005-ZE-0309, MOV Diagnostic Testing 5.3 OPGP03-ZE-0037, Motor Operated Valve Program 5.4 OPGP03-ZA-0503, Equipment History Program 5.4 OPGP03-XX 0002, Corrective Action Program 5.5 OPGP03-ZA-0090, Work Process Program 5.6 OPGP03-ZE-0026, NPRDS Failare Reporting Procedure l
l 5.7 OPGP03-ZA-0038, Nuclear Plant Reliability Data System Program l
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MOV Tracking and Trending Program OPEP07-ZE-0007 Rev.2 Page 9 of 17 6.0 Support Documents 6.1 Addendum 1 - MAINTENANCE WORK CATEGORIES 6.2 Addendum 2 - TRENDED MOV TEST DATA 6.3 Addendum 3 - MAINTENANCE HISTORY DATA 6.4 Addendum 4 - MOV TREND INVESTIGATION DATA REQUEST 6.5 Addendum 5 - MOV TREND INVESTIGATION REPORT l
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i MOV Tracking and Trending Program OPEP07-ZE-0007
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Rev.2 '
Page 10 of 17 ADDENDUM 1 MAINTENANCE WORK CAT 2GORIFE (Page I of 1)
ACTUATOR Item Work Scope Refurbishment Complete Refurbishment of the actuator (may be combined with others)
Motor All maintenance work on the motor Torque Switch All maintenance work on the torque switches including replacement, adjustments and limiter plate adjustments Limit Switch All maintenance work on the limit switches including replacement and adjustment Internal Wiring All activities that repair or replace internal wiring including re-lugging, terminal strips and new or repaired wiring l
Lubrication All maintenance work involving lubrication including filling, replacing, I cleaning to remove from unwanted areas, unacceptable grease samples and I external leakage (not including PMs that did not add grease)
Stem Nut All work involving the stem nut including rework, cleaning, replacement l Spring Pack All work involving the spring pack including cleaning, modification, i replacement i Internal Gears All work on worm gear, pinion gear, wormshaft gear, pins and keys HBC All maintenance involving the HBC gearbox except lubrication As Found Test All SRs that performed an As Found diagnostic test As Left Test All SRs that performed an As 1.cft diagnostic test Other All other work on the actuator. All SRs where work was performed ,
including minor adjustments, loose items, gasket replacement.
VALVE Packing All valve stem packing work including leaks, adjustments and replacement Stem All maintenance work involving the valve stem including bent, galled, scratched , repaired and replaced stems Internal All maintenance work involving the valve internals including seats, disks, guides and other intemal parts Other All maintenance work on the valve itself except the items listed above ELECTRICAL DISTRIBUTION Electrical All extemal electrical work related to the Tag /IPNS number of the valve or actuator including wiring and breakers
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, MOV Trackins and Trendine Prezrsm OPEP07-ZE-0007 l Rev.2 ;
Page 11 of 17 ADDENDUM 2 I TRENDED MOV TEST DATA r (Page 1 of 3) ,
i ALL TEST DATA IS FROM STATIC TESTS i
l ALL VALVES (RISING STEM AND QUARTER TURN) i ITEM SELECTION CRITERIA i
Running Current, Opening Last test value > Nameplate Cununt l (Corrected for measured voltage)* !
Running Current, Closing Last test value > Nameplate Current i (Corrected for measured voltage)* i Peak Inrush Current, Opening Greater that 10% increare over last 4 tests i Peak Inrush Current, Closing Greater that 10% increase over last 4 tests !
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Contactor Drop Out Time, Open Any consecutive increase over last 4 tests Contactor Drop Out Time, Closed Any consecutive increase over last 4 tests ,
LIMIT CONTROLLED VALVES ONLY .
Streke Time, Open Any consecutive increase over last 4 tests Stroke Time, Closed Any consecutive increase over lasi 4 tests '
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- Measured Current x hicasured Voltane :
Nameplate Voltage !
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MOV Tracking and Trending Program OPEP07-ZE-0007 Rev.2 Page 12 of 17 ADDENDUM 2 TRENDED MOV TEST DATA (Page 2 of 3)
RISING STEM VALVES ITEM SELECTION CRITERIA Stem Factor, QSS Any value above design allowable Stem Factor, DMT Running Load Thrust, Opening Any As Left to As Found increase > 20% or any value above design allowable Running Load Thrust, Closing l
Running Load Torque, Opening ,
Running lead Torque, Closing LIMIT TORQUE CONTROLLED CONTROLLED Thrust : At CST AL* - AF* > 10% AL - AF > 20%
Total "
Unseating "
Torque: At CST "
(Springpack) Total " "
Unseating "
Torque: At CST "
(QSS) Total "
Unseating "
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. 1 MOV Tracking and Trendine Program OPEP07-ZE-0007 Rev.2 ,
Page 13 of 17 ADDENDUM 2 l TRENDED MOV TEST DATA l (Page 3 of 3) ;
l OVERTHRUST /OVERTORQUE - YES NOTE: EVALUATION REFERENCES ARE TO OPMP05-ZE-0309 REV 8.
BUTTERFLY VALVES:
HBC Ovenorque Full Stroke Open (Evaluation A)
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HBC Ovenorque BARTS* Open (Evaluation B)
HBC Ovenorque Full Stroke Closed (Evaluation E)
HBC Ovenorque BARTS Closed (Evaluation F) ,
SMB Overtouque Open or Closed (Evaluation I)
- Butterfly Analysis, Review and Test System-RISING STEM VALVES I SMB Ovenbrust Open (Evaluation A) [
SMB or Valve Overthrust Closed (Evaluation E) i' SMB Ovenorque Open or Closed (Evaluation F) 4v i
. MOV Tracking and Trendine Program OPEP07-ZE-0007 Rev.2 Page 14 of 17 ADDENDUM 3 MAINTENANCE HISTORY DATA (Page 1 of 1)
The following data is transfened from the Equipment History System:
Tag /TPNS Number Work Activity Number (WAN)
Work Activity Description SR or PM Number Date Work Activity Closed As Found description Failure Description Action Taken Description As Ixft Condition Referenced Documents Severity level
- Failure Symptom
- Failure Detection
- Cause Category
- System Effect*
Plant Effect* i Corrective Action
- Part Numbers , Descriptions and Quantities
- Refer to OPGP03-ZA-0503, Equipment History Program for description and codes b
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s MOV Tracking and Trending Program OPEP07-ZE-0007 Rev.2 Page 15 of 17 ADDENDUM 4 MOV TREND INVESTIGATION DATA REOUEST !
(Page 1 of 1)
MOV TREND IMTSTIGATION DATA REQUEST l
FATU.D ITD4 DESCRIPTION TAGr!PNS MODEL Fall 1D ITEM DATA Test History : From To Facids to pnnt
- Sort Dy:
Mainienance History: Froen To Fields to pring t
sort By: ,
GROUP DESCRJPTION (Records to Select)
Valve Charactenstics. '
Actuator Characteristics:
Test Hatory Test Dau Maensenance History GROUP DATA REQUIRED (Dau to be pnnted in the report)
Valve Characteristics:
Actuator Characaeristics-Test History i Test Data Mainienance Histcry Sort Reccwds By i
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MOV Tracking and Trendine Program OPEP07-ZE-0007 Rev.2 Page 16 of 17 ADDENDUM 5 MOV TREND INVESTIGATION REPORT ,
(Page 1 of 2)
HOUSTON l.lGHTING AND POWER SOUTH TEXAS PROJECT ELECTRIC GENERATING STATION MOV TREND INVESTIGATION REPORT TAG /TPNS NUMBER:
DESCRIPTION:
VALVE DATA: Type: Size: Manufacturer:
Serial Number: Orientaten:
I ACTUATOR DATA: Type / Size: Serial Number:
Torque Rating:
FAILURE IDENTIFIED BY: (SPR SR, Trend)
FAILURE / TREND DESCRIPTION:
REPORT
SUMMARY
f T
Prepared By' Date:
Approved By: Date:
MOV Databav Updated By: Date:
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. . i MOV Tracking and Trending Program OPEP07-ZE-0007 t Rev.2 :
Page 17 of 17 ADDENDUMS MOV TREND INVESTIGATION REPORT -
(Page 2 of 2)
TABLE OF CONTENTS Section Page
- 1. ProblemfTrend Description
- 2. Test History Summary
- 3. Maintenance History Summary 3.1 Corrective Maintenance 3.2 Preventive Maintenance
- 4. Failure History Summary 4.1 Previous Failures 4.2 SPRs
- 5. NPRDS Summary
- 6. Analysis
- 7. Conclusions
- 8. Corrective Action
- 9. Recommendations