ML20079M636

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Leakage Reduction Program Test Results
ML20079M636
Person / Time
Site: San Onofre Southern California Edison icon.png
Issue date: 01/25/1984
From:
SOUTHERN CALIFORNIA EDISON CO.
To:
Shared Package
ML20079M621 List:
References
RTR-NUREG-0737, RTR-NUREG-737, TASK-3.D.1.1, TASK-TM NUDOCS 8401270381
Download: ML20079M636 (15)
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LEAKAGE REDUCIION PROGRAM TEST RESULTS FOR THE SOUTHERN CALIFORNIA EDISON COMPANY SAN ONOFRE NUCLEAR GENERATING STATION UNIT 3 9

8401270381 840125

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I.

INTRODUCTION NUREG 0737, Item III.D.l.1 (Reference A), established requirements for developing a program to reduce. leakage from Engineered Safety Features (ESF) systems outside containment which could potentially contain radioactive fluids during a serious transient or accident. The program requirements addressed measures for both immediate and continuing leakage reduction. 'Immediate measures within the program scope are:

(1) to implement all practical measures to reduce leakage in systems that could carry radioactive fluids outside containment, and (2) to measure actual leakage rates with systems in operation. Reference A further required that these leakage rates be reported to the NRC staff.

Southern California Edison, in the FSAR response to NUREG 0660 Item III.D.l.1 (Reference B), has reported the establishment of a leakage reduction program meeting the requirements of Reference A.

As reported in Reference B, all practical measures to immediately reduce system leakage have been implemented. Station procedures have been developed, approved and executed to measure actual system leakage rates. This report augments the information previously provided in Reference B and reports the ESF system leakage measurement results.

II.

OBJECTIVE The objective of the leakage reduction program outlined in Reference B is to maintain ESF system leakage to as low as practical. The program objective is met in part, by conducting measurements on the individual components in the ESF systems outside containment. These leakage measurement test results then provide a basis for planning maintenance on leaking components. The first cycle of leakage measurement tests have been completed on the systems designated for leakage testing in Reference B utilizing station procedures (References C through F).

Components that exhibited significant leakage were repaired and retested. The total measured ESF system leakage from all components in the systems tested subsequent to repair and retest is 25 cc/ hour.

III. TEST RESULTS i

This section provides a discussion of the criteria used to select l

systems requiring leakage testing and describes the leakage measurement l

test results.

l l

The NRC test program requirements identified in Reference A specified l

leak-testing the following generic plant systems:

o Residual Heat Removal (RHR) o Containment Spray Recirculation l

o High Pressure Injection Recirculation l

l o

Containment and Frimary Coolant Sampling 1, -.- -.- - -

o-Reactor. Core Isolation Cooling

- o Makeup and Letdown o

Waste Gas System In response to this listing, a review was conducted of the corresponding San Onofre systems. Also included in the review were all plant systems having post accident: functions. The following San Onofre systems outside containment as described in Reference (B) could potentially contain highly radioactive fluids following a serious accident. These systems are:

o High Pressure Safety Injection System - Recirculating Portion Only i

o Low Pressure Safety Injection System - Shutdown Cooling Portion Only o

Reactor Coolant Sampling System - Post Accident Sampling Piping Only o

Containment Spray System - Recirculation Portion Only o

Radioactive Waste Gas System - Post Accident Sampling Return Piping Only o

Liquid Radwaste System - Post Accident Sampling Return Piping Only Systems were excluded from the review if ;uch. systems were not required to pump post-accident radioactive fluids. A listing of these excluded

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systems, together with a summary justification for exclusion, is l

provided in Table I.

The requiremen'ts establishea for the two phase program outlined in Reference B include efforts to immediately reduce' system leakage and establishment of a continuing leakage reduction program.

Part I of the two phase program involved the following immediate measures:

Capping vent and drain lines to contain seat ' leakage.

o o

Visual inspection of the packing of all valves (except packless diaphragm valves) for evidence of leakage, o

Visual inspection of packless diaphragm valves.

c Visual inspection of the seals and packing on all pumps for evidence of leakage.

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Inspection (snooping) of valves, fittings and compressor seals in gaseous systems for leakage.

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- 4 Maintenance was performed on individual components as reported in l

Reference'B.

The remaining aspect of Part I involved pressurization of the systems and measurement of component leakage rates. The individual components leak tested included valve stem packing, pump seals and non-welded connections.

Leakage measurements were taken using simulated conditions as close to r.ormal operation as possible in accordance with station procedures (Reference C through F).

Table II illustrates the portions of the systems identified above which were leak tested. For the purposes of this evaluation, leakage is defined as all valve stems, valve packing, pipe fitting, valve seat and equipment leakage that allows fluids or gases to leak beyond the system bour.daries both to the i

environment or to other plant systems. Those comacnents and/or valves comprising the system boundary are shown in Table III.

Part II-of the two phase program involves a continuing leak reduction program to ensure that lcakage rates remain as low as practical.

Walkdowns will be performed to identify observable leakage.

Leaking components will be reported to the Maintenance Division for subsequent inspection and repair as necessary. As defined in Reference B, system leak rate testing measurements will be conducted at intervals not to exceed each refueling outage.

Observable leakage discovered during j'

these intervals would be identified in the walkdowns of the ESF systems j

and would subsequently be corrected.

The initial measured leakage from ESF systems outside containment identified' for testing in Table II is 9107 cc/ hour. Two drain valves 1

(1204MR030 and 1204MR161) accounted for 7080 cc/ hour of the initial measured leakage. Metal debris were found in the piping and valves which prevented proper seating. The pipes were cleaned and the valves were cleaned, repaired and retested. No leakage was observed on the first retest. The final component measured leakage from ESF systems outside containment was 25 cc/ hour. This total leakage rate is less than the FSAR expected value of 1,243 cc/ hour and less than the value of 2486 cc/ hour used in the safety analysis.

Direct methods to measure system leakage as well as inferred methods such as pressure decay were utilized. The guidelines used to assess acceptable leakage were:.(1) <10 cc/hr per inch of valve stem diameter, (2) <50 cc/hr per pump seal, (3) O cc/hr (i.e., no visually detectable leakage) for mechanical joints and non-welded connections, and (4) 0 cc/hr (i.e., no visually detectable leakage) for packless valves. Table IV identifies fifteen components tested which exhibited significant leakage. Leakage less than 1 cc/ hour was not included and components with acceptable leakage were grouped together as other components in Table IV.

Repairs were conducted as necessary and leak testing of the components was completed on a basis not to interfere with plant operations. Two of the components have not been retested because of system unavailability.

Reworking and retesting of these two components will not be conducted at this time as the subsequent reduction in the total leakage would not be significant.

f.

TABLE I SYSTEMS EXCLUDED FROM THE LEAKAGE MEASUREMENT PROGRAM System Basis for Exclusion Liquid Radwaste System _

This is not utilized when high coolant activity stists. Samples except post _ accident are taken by the Post Accident Sampling System (which is leak sampling return piping, tested) and returned to the containment. Also, the LRS has been excluded by the NRC in a regional meeting.

Radioactive Waste Gas System _

This. system is not required for use under post accident conditions.

except past accident Post accident degassing of the reactor coolant system is accomplished 4

1 sampling return piping.

by the reactor coolant gas vent system.

1, Reactor Coolant Letdown System This systcm is not required to function under post accident conditions. The plant can be brought to a cold shutdown condition without the letdown system.

The letdown system is isolated on Safety Injection and Containment Isolation actuation signals.

i Reactor Coolant Pump Seal This sys.em is not required to function outside containment under post Bleedoff System accident conditions. The system is isolated outside containment on a Containment Isolation actuation signal and remains isolated.

If seal bleedoff is required post accident, a header relief valve will lift providing a flow path to the quench tank.

Charging System The charging system does not contain radioactive fluid under post 4

i accident conditions since the lotdown system is isolated. The charging system switches suction from the Refueling Water Tank upon receipt of a Safety Injection Signal.

TABLE II SYSTEMS LEAK TESTED WHICH MAY CONTAIN POST-ACCIDENT RECIRCULATIDN FLUIDS

. Low Pressure Safety Injection System o

Pump P-015 suction and discharge piping.

o Pump P-016 suction and discharge piping, o

Pumps P-015 and P-016 common discharge piping to containment.

o Pumps.P-015 and P-016 common suction piping.

o Heat exchanger E-003 inlet and outlet piping.

o Heat exchanger E-004 inlet and outlet piping.

o Heat exchangers E-003 and E-004 common return piping.

Hiah Pressure Safety _ Injection System o

.HPSI pump number l - Train A.

o HPSI pump number 2 - Train B.

o HPSI pump number 3.

o Piping common to Trains A and B (between the closed HPSI header isolation valves and containment).

Containment Soray System o

Pump P-012 suction piping.

.o Pump P-012 discharge piping.

o Pump P-013 suction piping.

o Pump P-013 discharge piping.

Post Accident Samolina System o

Reactor Coolant System sample piping to PASS.

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HPSI pump miniflow piping to PASS.

o PASS sample station high pressure piping.

o PASS sample station low pressure piping:

o Return piping from PASS sample station.'

o PASS gaseous sample piping.

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TABLE III List of components outside containment which may contain post-accident recirculation fluids.

LPSI System P-015 Suction & Discharae P-016 Suction & Discharge 531201MUO15 S31201MU018 S31201MUO15 Bypass S31201MU018 Bypass S31204MUO22 S31204PUO23 S31204MUO22 Bypass S31204MUO23 Bypass 3PP-9433 3PI-9435 Flange by S31204MR266 Flange by S31204MR111 531204MR266 S31204MR111 3PI-9434 3PP-9435 Flange-Pump Suction Flange-Pump Suction Pump Seals Pump Seals Flange-Pump Discharge Flange-Pump Discharge 3FO-9311 3FO-9312 S31204MR295 S31204MR112 S31204HV8162 3HV-8163 S31204MUO37 S31201MR031 S31204MUO24 S31201MR120 S31204MR091 S31204MUO63 S31204MR371 S31204MUO25 P-015 & P-016 Common 01scharae to Containment P-015 & P-016 Common Suction S31204MUO81 S3120lMR196 S31204MUO81 Bypass S31201MUO37 S31204MR099 Flange by S31201MUO37 3HV-0396 3HV-9336 3PI-0307 (S31204MR076)

S31201MR080 S3i204MR102 S31201MR079 S31204HV8160 S3120lMR024 S31204HV8161 3HV-9379 S31204MUO82 S3120lMUO36 S31204MR368 Flange by S3120lMUO36 S31204MU194 3PSV-9387 3FE-0306 S31201MU017 S31204MR095 S31201MR087 3PSV-9318 S3120lMR091 S31201MR081 S31201MUO31 S31201MR124 S3120lMUO33 S3120lMR078 S31201MR020 S31204MR272 S31201MR995 -. _.

I LPSI System (cont.)

P-015 & P-016 Common Discharae to Containment E-003 Inlet & Outlet S31204MR271 3HV-8153 3HV-9359 3HV-8153 Bypass 3HV-9353 3F0-9426 S31204MR259 S31206MU014 S31204MR258 3FE-0348 3FO-9428 3PT-0303-2 S31204MR257 S31206MU019 S31204MR255 S31206MUO21 3HV-9328 S31206MU020 S31204MR362 3TE-0303-2 3F0-9410 S31206MR041 3HV-9325 S31206MR056 S31204MR361 S31206MU005 3FO-9400 3HV-8151 3HV-9322 S31206MU002 i

S31204MR360 l

3HV-9331 l

S31204MR363 I

l E-004 Inlet & Outlet E-003 & E-004 Common Return S31206MU002 S31204MU162 3HV-8152 S31206MU018 3HV-8152 Bypass S31212MU205 3FO-9427 S31206MR001 (3AP-9317) 531206MUG12 S3120!MR039 3FE-0338 3PT-0303-1 S31206MUO22 S31206MUO23 S31206MUO24 3TE-0303-1 S31206MR040 S31206MU003 S31206MR021 3HV-8150 S31206MU001 1. -. _ _,. - _ _ _ _ _ _ _ _. _

HPSI System HP3I Pumo #1 - Train A S31204MU006 3F09314A S31204MUO65 S31204MR372 S31204MU184 S31204MR174 S31204MU190 S31204MUO34 3F09423 S31204MU365 S31204MUO12 3HV93?7 3PSV8155 S31204MR103 3PSV9320 S31204MU007 S31204MR001 (PI 0314)

S31204MR021 S31204MR212 (PP 9437)

S31204MR353 (PP 9438B) 3F09401 6" flange by PP 9437 S31204MR167 3HV9324 S31204MR088 S31204MR171 S31204MR187 S31204MR213 (PP 9438) 3F09402 3HV9333 P017 suction flange 3HV9330 P017 seals 531204MU154 P017 discharge flange S31204MU155 4" flange by PP 9438A 2FE9421 S31204MR352 (PP 9438A)

S31204MR199 (FE 9421)

S31204MR279 S31204MR200 (FE 9421) 3F09314 S31204MR173 S31204MUO34 S31204MUO64 3HV9420 HPSI Pumo #2 - Train B S31204MU189 S31204MR356 3PSV8154 S31204MR094 S31204MR026 S31204MU364 3PSV9319 3FE9435 S31204MUC09 S31204MUO17 S31204MR201 (FE 9435)

S31204MU008 S31204MR292 S31204MR202 (FE 9435)

S31204MR127 (PP 9431)

S31204MR004 (PI 0309)

S31204MUO44 6" flange by 3PP9431 S31204MR172 3HV9434 S31204MR089 3F09425 S31204MUO45 S31204MR128 (PI 9432) 3HV9329 S31204MR030 P019 suction flange S31204MR354 (PP 94380) 3HV9332 P019 seals S31204MR176 P019 discharge flange 3F09403 4" flange on pump discharge 3HV9326 3F09315 S31208MU005 3F09315A 3PV9321 S31204Mui85 3F09424 S31204MUO35 S31204MR023 S31204MR105 3HV9323 S31204MUO15 l

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HPSI System (cont.)

HPSI Pumo (3 Common To Train A&B*

S31204MUO10 S31204MR170 S31204MR367 3FE0331 S31204MR028 S31204MR009 (FE 0331)

S31204MR096 S31204MR010 (FE 0331)

S31204MUO11 S31204MR175 S31204MU191 3FE0321 S31204MR214 (PP 9439)

S31204MR007 (FE 0321) 3PSV8156 S31204MR008 (FE 0321)

S31204MR388 S31204MR027 8" flange by PI 9440 S31204MR022 S31204MR215 (PI 9440) 3FE0311 P018 suction flange S31204MR005 (FE 0311)

P018 seals S31204MR006 (FE 0311)

P018 discharge flange 3FE0341 S31204MR032 S31204MR011 (FE 0341) 4" flange on P018 discharge S31204MR012 (FE 0341) 3F09313 S31204MUO36 S31204MU104 3F09313A S31204MU186 S31204MU016 S31204MR106 S31204MR100 S31204MU013 S31204MR104 S31204MUO14

  • Items to be inspected located between closed HPSI header isolation valves and containment.

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Containment Soray System P-012 Suction Lines P-012 Discharge Lines

  • 3HV-9300 P012 Seals S31204MU115 Flange at P012 Outlet Flanges on S31204MU001 S31205MR010 S31204MU109 3F09384 S31204MR075 (3AP9401)

S31206MUO10 S31204MR161 3HV9?37 Flanges on S31204MU003 S31206MUO12 S31204MR538 531206MU003 S31204MUO62 S31206MR008 S31204MR205 (3PP9411) 3F09413 Flange by S31204MUO88 S31206MU008 2" Flange by 3MV9399 Flange by S31206MU008 3HV9399 3HV9367 S31204MR389 S31206MUO25 S31204MR083 Flange by S31206MUO25 S3PI9420 S31204MU188 Flange by S31204MU188 S31206MU193 3PSV8158 Flange at P012 Inlet

  • All items between valves S31206MUO12 and S31206MU003 were included in the LPSI System test.

P-013 Suction Lines P-013 Discharoe Lines

  • 3flV-9301 P013 Seals S31204MU114 Flange at P013 Outlet Flanges on $31204MU002 3F09385 S31204MU110 S31206MUO11 S31204MR074 (3AP9400) 3HV9348 S31204MR109 S31206MR011 Flanges on S31204MU004 S31206MR053 S31204MR029 S31206MR017 SS1204MU005 S31206MUO14 Flange by S31204MUO87 S31206MU005 S3120;MR084 (3PP9412) 3F09414 2" Flange by 3HV9398 S31206MU009 S31204MR349 Flange by S31206MU009 3HV9398 S31206MR052 S31204MR206 3HV9368 3PI9419 S31206MU017 S31204MU187 Flange by S31206MU017 Flange by S31204MU187 S31204MU192 3PSV8157 Flange at P013 Inlet
  • All items between values S31206MUO14 and S31206MU005 were included in the LPSI System test.._

Post-Accident Samplina System RCS Sample Lines to PASS HPSI Pumo Mini-Flow Lines to FASS 3HV-0513 S31204MUO61 S31212MU269 S31212MU261 3HV-0518B S31204MU151 3HV-0518A S31212MU262 S31212MUO84 S31212MR106 3HV-0584 S31212MR173 3AX-0494 S31212MR168 3TSH-0504 S31212MR239 3HV-0587A S31212MR183 3HV-05878 S31212MR187 S31212MU299 S31212MR188 S31212MR162 S31212MR223 3HV-0509 S31212MR156 S31212MU268 S31212MR222 3HV-0519B S31212hR155 3HV-0519A S21212MR218 S31212MUO70 3HV-0588A 3HV-0582 3HV-05888 3AX-0492 S31212MU301 3TSH-0582 3PSV-0589 3HV-0586A S31212MR233 3HV-0586B S31212MU300 S31212MU304 RETURN LINES FROM PASS SAMPLE STATION PASS GASEOUS SAMPLE LINES

531902MR027 l

S319G2MR033 S31902M:1032 S31902MR077 S31902MR080 S31902MU144 S31902MR236

  • Fittings on PASS Gaseous Sample Lines were also leak tested. _

TA8LE IV

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i ESF COMPONENT LEAKAGE RATES (cc/hr) 1 Initial Test First Retest (l)

System Component Leakaae Date Leakaae Date LPSI P-016 360 1/20/83 0

5/22/83 Other components (2) 15 1/20/83 375 cc/hr - 360 cc/hr retest reduction =

15 cc/hr HPSI 3PSV-8155 12 2/20/83 0

3/7/83 1204MR103 480 1/25/83 0

2/20/83 1204MR105 300 1/25/83 0

2/20/83 1204MR030 3840(3) 1/25/83 0

6/23/83 1204MU016 105 1/25/83 0

6/23/83 1204MUO14 90 1/25/83 0

3/4/83 P-017 seal

>50 1/25/83 0

8/3/83 P-017 casing drain 0

8/25/83 P-018 casing drain 600 1/25/83 0

3/4/83 P-019 casing drain 0

2/20/83 1204MU013 9(4) 1/25/83

>5486 cc/hr - 5477 cc/hr retest reduction =

9 cc/hr CS 1204MU001 flanges 3

1/20/83 0

5/18/83 1204MR161 3240(3) 1/20/83 0

3/4/83 1204MU002 flanges

_ 3 1/20/83

<1(4) 3/2/83 3246 cc/hr - 3245 cc/hr retest reduction -

1 cc/hr PASS No component exhibited measurable leakage during initial test conducted during February 1983.

TABLE IV (cont.)

Footnotes (1) These components demonstrated unacceptable leakage during the first system test and were repaired / reworked as plant conditions allowed.

(2) Measured leakage for these valves was 110 cc/hr each per inch of valve stem diameter.

(3) Metal debris found in drain valve and piping which prevented valve from seating.

(4) Although these components leaked in excess of their established guidelines, they will not be reworked at this time as the subsequent reduction in the total leakage would not be significant.

Summary of leakaae Rates Initial Retest System Leakage Leakaae LPSI 375 cc/ hour 15 cc/ hour HPSI

>5486 9

CS 3246 1

PASS 0

_.0_

TOTAL >9107 cc/hr 25 cc/ hour e

IV.

REFERENCES A.

NUREG 0737, Item III.D.1.'

" Integrity of Systems Outside Containment Likely to Contain Radioactive Materials for Pressurized Water Reactors" 8.

Response to NRC Action Plan, NUREG 0660, San Onofre Nuclear Generating Station, Units 2 and 3; Item 111.D.1.1:

" Primary Coolant Sources Outside the Containment Structure" C.

San Onofre Nuclear Generating Station, Unit 3, Special Procedure 503-SP-201-01, Revision 0:

Low Pressure Safety Injection System Leak Rate Measurement D.

San Onotre Nuclear Generating Station Unit 3 Special Procedure 503-SP-201-02, Revision 0: High Pressure Safety Injection System Leak Rate Measurement E.

San Onofre Nuclear Generating Station, Unit 3, Special Procedure S03-SP-202-01, Revision 0: Containment Spray System Leak Rate Measurement F.

San Onofre Nuclear Generating Station, Unit 3, Special Procedure S03-SP-243-01, Revision 0:

Post Accident Sampling System Leak Rate Measurement GPvN:0222F 9

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