ML20080C434
| ML20080C434 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde, 05000000 |
| Issue date: | 09/17/1983 |
| From: | Heneage J AFFILIATION NOT ASSIGNED |
| To: | |
| Shared Package | |
| ML20080C249 | List: |
| References | |
| FOIA-83-609 1797B-0978B, 1797B-978B, 91HF-1SF03-DRFT, 91HF-1SF03-R00-DR-07, 91HF-1SF3-DRFT, 91HF-1SF3-R-DR-7, NUDOCS 8402080088 | |
| Download: ML20080C434 (20) | |
Text
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~. P ,/ _ - q d/f 5 Test Results Repott 91HF-lSF03, Draft 7 Rev. O TCN 23 Page 1 of 20 TEST RESUL13 REPORT PROCEDURE NO. 91HF-lSF03 PROCEDURE TITLE PRE-(X)RE TURBINE BYPASS CONTROL SYSTEM TEST REVISION AT THE COM!!ENCEMENT OF TESTING 0 DATE 6/1/83 REVISION AT COMPLETION OF TESTING 0 DATE 6/1/83 LATEST TEST CHANGE NOTICE NO. 23 DATE 7/4/83 DATES OF TEST PERFORMANCE 6/1/83 through 7/5/83 PAGE 1 0F 20 Review and Approval of Test Results PREPARED BY: J.HENEAGE +- >~A np DATE 9//'4J TECHNICAL REVIEW: W.STEARNS / c.\
- ,7 ,j DATE P////f3 l GROUP SUPERVISOR REVIEW
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TEST WORKING GROUP MEETING' NUMBER: DATE l
PLANT REVIEW BOARD MEETING NUMBER: DATE QUALITY ASSURANCE REIVEW: DATE -
STARTUP MANAGER APPROVAL: DATE
! 1797B/0978B '
l 8402080088 831116 PDR FDIA 5a : GARDE 83-609 pyg 1
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.g-Test Rasults R: port 91HF-1SF03, Draft 7 Rev. O TCN 23 Page 2 of 20 A. TEST PURPOSE AND SCOPE The Pre-core Turbine Bypass Control System (SBCS) Test, 91HF-lSF03, was performed to demonstrate that the system would operate at design conditions (secondary steam at nominal conditions of 1170 psig and 565'F). The test simulates all of the major control actions of the SBCS. The test was conducted to verify that each of the eight SBCS valves would quick open, quick close, modulate open and modulate close within the design time limits, and while hot with normal steam flow. The test also intended to demonstrate the quick open (turbine trip) and steam pressure control modes function as designed.
Additionally, in conjunction with 91HF-lSG01 (MSIV HFT), the main steam lines were flushed using a "sacrifical" valve disk stack in
-SG-PV-1006 as p&rt of the initial energization of the secondary steam system. Steam flow in excess of one minutes duration was not possible due to cooldown limits applicable to the primary plant, however, these brief teats were adequate to test the system.
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o Test Results Report 91HF-lSF03, Draft 7
- Rev. O TCN 23 Page 3 of 20 B. COMPLEENTm TESE Pre-Operational Tests 91PE-lSF04, Steam Bypass Control System Test.
Hot Functional Tests 91H?-ISG01, Main Steam Isolation and Bypass Valves.
91HF-LED 01, Main Steam Traps and Drains.
Post Core Hot Functional Tests Post Core Hot Functional Test of the Turbine Bypass Control System (recommended post core test) or 91HF-lSF03, Rev.1, Precore Turbine Bypass Control System Test (if conducted).
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Test Results Report 91HF-lSF03, Draft 7 Rev. O TCN 23 Page 4 of 20 C. TEST DESCRIPTION The initial portion of the test supported the valve lineup of the main steam and steam bypass piping for warmup of the steam lines.
Following the warmup of the steam lines; the 4 main steam lines, two from each steam generator, were each individually flushed a minimum of 3 times (through MS1V's 170, 180, 171 and 181). This flush consisted of fully opening SBCS valve SG-PV-1006 (the farthest valve from the steam generators) and allowing full steam flow until the RCS temperature was reduced to 15* - 25"F from a starting point of 565'F (approximately 45 seconds per flush). Each of the 8 SBCS valves were isolated and stroked while at operating temperatire, both manually and using the valve's control system to confirm that the valves were free to travel.
The eight valves were then individually tested for correct response
'i n the quick open, quick close and modulate open/close modes with steam flow. Following individual valve operability and performance testing, the SBCS was tested as an integrated system. This portion of the test simulated a turbine trip (simultaneous quick open of all 8 valves; however, this section was not actually performed, see TER
- 31) and the automatic pressure control mode (modulation) of the valves.
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Test Results Report s 91HF-lSF03, Draft 7
. Rev. O TCN 23 l Page 5 of 20 D. TEST EVENTS j- The Official Test Package was assembled on June 2, 1983. Actual testing in Section 8 commenced on June 4,1983. 'The test was suspended on' July _5,1983 with open TER's so that plant cooldown r could ' commence in conjunction with 91HF-12ZO3, Remote Shutdown. The
.i initial lineup and warmup of the steam line was accomplished with the exception of SG-PV-1004, SG-PV-1005 and SG-PV-1008 which did not initially warmup to the required temperature (TER No. 1) as the permanent insulation for these valves had not been completely installed. Temporary insulation was attached to the valve bodies and these valves then reached the required temperature. The mechanical operability check of the valves was completed with the exception of SG-PV-1001, 1002, 1006, 1007 and 1008, (TER's 2, 3, 4, 5 and 6). The SBCS system performed satisfactorily during steam flushing through SG-PV-1006. (Section 8.2) Some delays were experienced with the MSIV's while they were made operational. Following steam flushing, inspection of SG-PV-1006 revealed a large amount of debris, including a 12" cresent wrench, in the valve body. (See Work Order No. 16248 for details)
Individual valve testing was conducted between June 13 and July 4, 1983. Nineteen TER's were generated during this time (TER's 7-20,
- 29, 30). The simulated turbine trip, quick open function was not tested because pending modifications to the steam line drains had not been installed (TER 31, DCP SM SG .69).
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Test Results Report 91RF-lSF03, Draft 7 Rev. O TCN 23 Page 6 of 20 During the steam pressure control mode portion of the t.est four TER's were generated (TER's No. 25, 26, 27 and 28). SFR-lSG-131 was issued to document that pressure transmitters SG-PT-1024 and SG-PT-1027 were initially calibrated incorrectly (originally 800 - 1300 psia, reset to 900 - 1300 psia).
During the performance of the entire test the steam trap system piping exhibited both leaking connections and the traps themselves malfunctioned on several occasions. This caused some delay although it was generally possible to work around this problem since the valves were tested individually. (See 91HF-LED 01, Traps and Drains, for details)
The fo'llowing TERs and scope intent TCNs were issued either during the performance of the test or during the preparation of this report:
TER 001: (Step 8.15.4.4/5/7) Valves SG-PV-1004, SG-PV-1005 and SG-PV-lC08 did not achieve body temperatures within 50*F of the steam saturation pressure as required by the manufacturer. Temporary insulation was installed on valves SG-PV-1004 and SG-PV-1005 thereby allowing them to achieved the required temperature. SG-PV-1008 was deleted from the test program by scope intent TCN 016 due to safety considerations.
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Test Results Report 91HF-1SF03, Draft 7 Rev. O TCN 23 Page 7 of 20 TER 002: (Step 8.1.7.1.12) Valve SG-PV-1006 would not stroke from the control room. Pressure switch CDN-PSH-59 was found isolated, and the air booster relay on the valve's pneumatic operator was found to be dirty on the insidc.
The valve was restored to service.
4 TER 003: (Step 8.1.7.2) Valve SG-PV-1001 would not stroke freely using the manual handwheel. After stroking the valve automatically several times the valve moved freely. The valve was restored to service.
TER 004: (Step 8.1.7.3.12-2) Valve SG-PV-1002 would not stroke smoothly using the controller in manual. This TER is open.
TER 005: (Step 8.1.7.7.12) Valve SG-PV-1007 would not stroke smoothly using the valve's controller in manual. This TER is open, i
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l TER 006: (Step 8.1.7.8.12-1,2) Valve SG-PV-1008 would not stroke smoothly using the valve's controller in manual. This valve was deleted from the test program by TCN 016. This TER is open.
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Test Results Report 91HF-ISF03, Draft 7 Rev. O TCN 23 Page 8 of 20 TER 007: (Step 8.2.6.7) A test switch to simulate a loss of feed pump signal could not be installed per the instructions in the procedure, a cabling pin was pulled out.
Reinstalled pin and wrote TCN No. 10 to select an citernate location for the test switch.
TER 008: (Step 8.5.3.40) Valve SG-PV-1003 would not open more than 10% (only pilot valve opened). Valve was rebuilt by the vendor and the valve then opened satisfactorily.
TER 009: (Step 8.3.3.18) Valve SG-PV-1001 would not quick open.
Loose wires were found in vacuum switches CDN-PSH-59, 57
& 61 and tightened. Valve retested satisfactorily.
TER 010: (Step 8.9.3.37) Valve SG-PV-1007 did not operate smoothly and did not track the position demand signal.
Recalibrated positioner and valve tested satisfactorily.
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TER 011: (Step 8.6.3.37/38) Valve SG-PV-1004 would not modulate open and close within the design time limits. The vendor representative adjusted the control system and the valve stroked within the design time limits, i
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Test Results Report 91HF-lSF03, Draft 7 Rev. O TCN 23 Page 9 of 20 TER 012: (Step 8.7.3.37/38) Valve SG-PV-1005 would not modulate open within the design time limit. Valve was rebuilt by the vendor and retested. Retest failed and generated TER 020.
TER 013: (Step 8.8.2) Valve SG-PV-1006 was not warmed to within 50*F of the steam saturation temperature. Temporary insulation was installed and the valve body then reached the required temperature, i
TER 014: (Step 8.8.3.37/38) Valve SG'PV-1006 failed to modulate open/close within the design time limits. The valve was rebuilt under supervision of the vendor and retested satisfactory.
TER 015: (Step 8.8.3.22/23) Valve SG-PV-1006 failed to quick open/close within the design time limits. The vendor representative adjusted the control system and the valve was retested. The retest failed and generated IER 021.
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.c Test Results Repsrt 91HF-1SF03, Draft 7 Rev. O TCN 23 Page 10 of 20 TER 016: (Step 8.10) Valve SG-PV-1008 could not be tested with steam through it since the steam discharge presented-a safety hazard to personnel and equipment. Scope intent TCN No. 16 deleted this valve from the test. SFR-lSG-136 written. This TER is open.
TER 017: (Step 8.6.3.23) Valve SG-PV-1004 did not operate properly from the test cabinet. Loose wire found and tightened in cabinet. Retest was satisfactory.
TER 018: (Step 8.5.3.20) Valve SG-PV-1003 did not operate properly from the test cabinet. Relays found not reset.
Corrected and retested, retest failed and generated TER 019.
TER 019: (Step 8.5.3.22) Valve SG-PV-1003 failed to quick open in the allowed design time limit. Valve was rebuilt under vendor representative supervision and retested. Retest failed and generated TCR's 029 and 030.
TER 020: (Step 8.7.3.37/38) (Retest of TER 012) Valve SG-PV-1005 retested and met required modulation stroke times.
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Test Results Report i
91HF-lSF03, Draft 7 Rev. O TCN 23 Page 11 of 20
. TER 021: (Step 8.8.3.23/24) (Retest of TER 015) Valve SG-PV-1006 failed to quick open and close within alloOed design time limits. Vendor representative adjusted control system and loose wire (TER 017) was tightened. Retest was.
satisfactory.
TER 022: (Step 8.8.3.22) Valve SG-PV-1005 failed to lift off seat for stroke timing. Generated SFR ISG-159 (generic) and ISG-163. This TER is open.
TER 023: (Step 8.4.3.22) Valve SG-PV-1002 did not quick open within the allowed design time limit. SFR 1SG-159 written. This TER is open.
TER 024: (Step 8.9.3.34/35) Valve SG-PV-1007 did not modulate open/close within the allowed design time limit. Vendor representative adjusted control system. Retest satisfactory.
TER 025: (Step 8.12.17) SBCS system would not control pressure in Auto. Found flexible instrument lead to pressure transmitter SG-PT-1027 was ruptured. Replaced hose and continued with test.
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Test Results Report 91HF-lSF03, Draft 7 Rev. O TCN 23 Page 12 of 20 TER 026: (Step 8.12.21/22) Valve SG-PV-1002 could not be used during automatic pressure control mode testing due to being too unreliable. This TER is open.
TER 027: (Step 8.12.23/24) Valve SG-PV-1003 could not be tested during automatic pressure control mode testing because the vendor representative was working on it at the time.
Valve SG-PV-1004 did not open past the pilot seat in Automatic pressure control mode. This TER is open.
TER 028: (Step 8.12.25) Valve SG-PV-1006 was not tested in the automatic pressure control modulation mode. Valve would have operated in parallel with SG-PV-1005 and this potentially could have interferred with a Boration/Dillution test then on going. f: tis TER is open.
TER 029: (Step 8.5.3.20) (Retest TER 019) Valve SG-PV-1003 did not operate properly in relation to control system commands.
This TER is open.
TER 030: (Step 8.5.3.22) (Retest TER 019) Valve ?;G-PV-1003 did not quick open within the allowed design time limit. This TER is open, t t
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l Test Results Report 91HF-lSF03, Draft 7 Rev. O TCN 23 Page 13 of 20 TER 031: (Step 8.11) A test of all SBCS valves, response to a simulated turbine trip (quick open), was deferred to Post-core HFT because steam line trap and drain modifications had not been inplemented. This TER is open.
TER 032: (Step 8.1.2.1.6-3) During inial valve lineup of the SBCS valves, outlet trap isolation valve SG-V246 was not closed. The trap inlet valve, SG-V245 was closed, however; omission of this step was evaluated and there was no adverse impact on the test performance or test results.
TER 033: (Step 8.12.8) Valve SG-PV-1003 was not tested in the automatic pressure control mode.(sec. TER 27). This TER is open.
TER 034: (Step 8.2.1.14) A step to open MSIV bypass valve SG-PV-169 was not completed (signed) during performance of the test. Omission of this step was evaluated and there was no adverse impact on the test performance or the test results.
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Test Results Report 91HF-lSF03, Draft 7
. Rev. O TCN 23 Page 14 of 20 TCN 016: SFR-lSG-136 was written to document the possibility of damage to the control building from the discharge of SG-PV-1008. Since resolution of this problem would not occur prior to the completion of HFT this TCN was issued to delete all testing requirements for SG-PV-1008. This TCN received interim approval on June 16, 1983 and final approval on July 5, 1983. See TER 16.
The SBCS valves consistantly exhibited both erratic motion and occasional failure to open throughout the test. These problems were indentified early in the SBCS testing and are documented by over 57 references in the Test Log for 90HF-1ZZ01, HFT ControUltg Document.
Similar problems have been experienced and documented at other facilities using CCI SBCS valves. Testing was suspended and a vendor representative requested on June 16. Through the remainder of HFT the valves were selectively disassembled, rebuilt and tested under the vendors supervision. Several vendor representatives were on site l to provide 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> coverage during the rebuild process. At one l
! point, one of the valves's " piston ring" was modified in an attempt to eliminate the jerky, sticking operation (SG-PV-1003). The results j from this modification and subsequent retest were inconclusive. At the suspension of the test the vendor indicated that the valve's performance and design would be evaluated and subsequent recommendations would be issued.
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Test Results Report 91HF-lSF03, Draft 7
- Rev. O TCN 23 Page 15 of 20 E. TEST RESULTS The steam flush, section 8.2, of the procedure was completed satisfactorily in that all four main steam lines were flushed a minimum of three times. The test did not satisfy the quick open time i criteria (Section 2.1.1.1) for SG-PV-1002, SG-PV-1003 and
.; SG-PV-1008. The test did not satisfy the modulation time criteria for SG-PV-1004 and SG-PV-1008 (Section 2.1.1.3). The test did not satisfy the modulation, pressure control mode test (Section 2.1.2) fcr the group controllers. The simulated turbine trip quick open test (Section 2.1.3) was not performed and was therefore not i
satisfied.
t Appendix A summerizes the performance of the 8 SBCS valves during this test and the status (open TERS) at the completion of testing.
!- SFR ISG-139 was written to document that the 8 SBCS valves do not stroke smoothly when operated under design conditions. SFR-lSG-136 was written to document problems associated with the discharge of SG-PV-lC08. SFR-lSF-076 was issued to document interim setpoints placed in the SBCS Control System logic. SFR-ISG-163 was issued to l document that both the ADV and SBCS valves appear to stick at or near 1200 psia.
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Test Results Report 91HF-lSF03, Draft 7 Rev. O TCN 23 Page 16 of 20 F. CONCLUSIONS It is the conclusion of the Test Results Reviewer, John F. haneage, that 91HF-1SF03, Pre-Core Turbine Bypass Control System Test, was
. performed to the extent possible during HFT. At the completion of HFT testing, 13 TERS were open. The test was suspended based on the Engineering opinion that some form of design modification would be required. Since such a modification would require extensive review, additional time could not be reasonably allocated from the HFT schedule to continue hot testing. The test did not satisfy the Acceptance Criteria for the system, although, individual couppnents did satisfy some of the criteria. The system has not demonstrated that it is capable of fulfilling its design function at this time.
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t Test Results Report 91HF-lSF03, Draft 7 Rev. O TCN 23 Page 17 of 20 G. RECO:DENDATIONS Additional Testing: It is recommended that the SBCS be retested either prior to core load if conditions permit or in post core hot functional. The retest should include quick open/close, modulate open/close, simulated turbine trip (all valves quick open) and group modulation (automatic pressure control) for all of the 8 SBCS valves. The retesting should be performed only after the vendor, Control Component Inc., completes additional rework and testing on the valves.
The following open TER's should be placed on the Master Tracking System to insure resolution during retesting:
TER 004 TER 26 TER 33 TER 005 TER 27 TER 006 TER 28 TER 016 TER 29 ,
TER 022 TER 30 TER 023 TER 31 t r
Test Results Report 91HF-lSF03, Draft 7 Rev. O TCN 23 Page 18 of 20 TER's 32 and 34 should be closed as there was no adverse impcet on the test performance or results.
Test Techniques: Incorporate TCN's No. 1, 2, 4, 5, 6, 7, 8, 10, 11, 12, 13, 14, 15, 17, 19, 20, 21, 22 and 23 into the test procedure. The steam flushing should be increased from a minimum of three to four times per line to satisfy concerns expressed by Control Components, Inc. (the SBCS valve manufactuer) that erratic performance of the valves may have been caused by dirt in the system. No further changas are recommended concerning testing techniques.
Further Use of Test: The applicable TCNs should be extracted and incorporated for use in Sections 8.3 through 8.10. These sections in turn may be used as the basis for on-line testing of the SBCS on a periodic basis. Sections 8.1 and 8.3 through 8.12, with the applicable TCN's incorporated should be used as the basis for additional system testing as recommended above in
" Additional Testing".
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Test Resulte Report
- 91HF-ISF03, Draft 7 Rev. O TCN 23 Page 19 of 20 Test Acceptance: It is recommended that test section 8.1 and 8.2, steam line and valve body warmup and steam line-flushing be accepted as performed. It is recommended that the acceptance of the quick open/close, modulate open/close, turbine trip and group modulation (pressure control) tests (Sections 8.3 through 8.12) be rejected as these tests have 13 open TERs.
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Joh,37,F. Heneage APB Hot Functional Test Engineer, Level III a
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Test Results Report j 91HF-ISF03, Draft 7 Rev. 0 TCN 23 Page 20 of 20 I APPENDIX A
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91HF-ISF03 SBCS Valve Performance Summary Valve Identification ritaria or Test 1001 1002 1003 1004 1005 1006 1007 1008 alva Body within YES YES YES No TER 1 No TER 1 YES YES No TER 1
- 0*F of saturation passed passed TER 13 deleted emparature retest retest passed by retest 'TCM 16 ,
'alva scves smoothly TER 3 YES YES YES YES YES YES YES
, han manually stroked
..y hind wheel
'alve moves smoothly YES TER 4 YES YES YES TER 2 TER S TER 6 l han cpzrated by (open TER) passed l cntroller -
retest
!'alva quick opens TER 9 TER 23 TER 18,TER 19 PASS PASS TER 15,TER 21 PASS TER 16 n 1 second retest OK TER 29,TER 30 l'sive quick closes PASS PASS PASS TER 17 PASS TER 15,TER 21 PASS TER 16 t n 5 seconds retest passed retest i passed
, 'alva modulates open PASS PASS PASS TER 11 TER 12,TER 20 TER 14 PASS TER 16 i .5 - 20 seconds TER 22 passed passed retest j; retest PASS PASS PASS TER 11 PASS TER 14 TER 24 TER 16 l 'alva modulates close passed passed i.5 - 20 seconds retest OK 1_ retest retest
'alva cpens and closes YES TER 35 TER 8 YES YES YES TER 10 TER 16 rith controller and passed retest OK
- term retest .
iBCS all valves quick TER 31 TER 31 TER 31 TER 31 TER 31 TER 31 TER 31 TER 31
,ipan, turbine trip liBCS codulation TER 25 TER 26 TER 33 TER 27 TER 28 TER 28 PASS .TER 16 l;hsck-autooperation passed TER 27 retest
?.*ERs by valve TER 26 TER 31 TER 27 TER 31 TER 31 TER 31 TER 6 ,