ML20080C485

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Preliminary Rev 0 to Pressurized Performance, Test Results Rept for 830603-17
ML20080C485
Person / Time
Site: Palo Verde, 05000000
Issue date: 08/20/1983
From: Stearns W
AFFILIATION NOT ASSIGNED
To:
Shared Package
ML20080C249 List:
References
FOIA-83-609 91HF-1RC02, 91HF-1RC02-R00, 91HF-1RC2, 91HF-1RC2-R, NUDOCS 8402080111
Download: ML20080C485 (6)
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TEST RESULTS REPORT e

PROCEDURE NO.

91HF41RCO2 PROCEDURE TITLE Pressuri.ned Performance REVISION AT THE COMMENCDfENT OF TESTING 0

DATE S-17-83 REVISION AT COMPLETION OF TESTING 0

DATE 7-4-83 LATEST TES1 L'HANGE NOTICE NO.

018 DA' E 8-9-83 DATES OF TEST PERFORMANCE 6-3-83 to 6-17-83 PAGE 1 0F 6

Review and Approval of Test Results PREPARED BY:

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8-70-8J CROUP SUPERVISOR REVIEW-2%

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DATE:

PLANT REVIEW BOARD MEETING NUMBF.R:

DATE:

QUALITY ASSURANCE REVIEW:

DATE:

(Required for Test Results Reports not reviewed by TWG) l l

STARTUP MANAGER APPROVAL:

DATE:

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TEST PURPOSE AND SCOPE t

The purpose of this procedure was to demonstrate pressurizer pressure and level control systLas function during normal hot standby conditions. All 8

automatic and manual functicas and interlocks were tested which include the following equipment:

1) normal spray
2) auxiliary spray
3) proportional heaters
4) backup heaters
5) letdown control valves
6) charging pumps This procedurs was specifically written to satisfy FSAR section 14.2.12.2.5

' amendment 6 and associated licensing commitments (Ref. serial #'s 041393, 041394, 041395, 041396, 041398) LlR # 83-208 was written for clarification on serial #041397.

Remote level control from RRS (Reactor Regulation System) was not tested for the following reasons:

1) Preoperational Test previously simulated RRS input
2) Tave did not vary during hot functional B.

COMPLDfENTARY TESTS:

1) Presurizer Spray Valve & Control Adjustment 73HF-lRC10
2) Remote Shutdown Panel Operation 91HF-12ZO3
3) Presurizer Pressure and Level Control System Preoperational Test 92PE-lRC01 (73HF-lRC10, 92PE-lRC01 and 91HF-lRC02 satisfy licensing commitment #007657)

C.

TEST DESCRIPTION The method used virtually throughout this procedure to obtain test results was to exercise both the pressurizer pressure and level control systems

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throughout their normal operating parameter ranges and monitor systems responses while in the hot standby mode.

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TEST EVENTS Commenced testing on 6/3/83, the following TER's were written:

001 - 6/2/83 - 2nd isolation valve (V059) to RDT - Pressurizer Spray from

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loop 1A interferes with insulation preventing it from being fully closed.

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Page 3 of 6 J002 - 6/3/83 - With 3 RCP's running and th[ pressurizer spray bypass valves fully open spray line temperature would drift below 150*F delta T (SFR-RC-

.i 100 written)

(Re( TER 022) i, i

003 - 6/3/83 - Spray valve J-RCE-PV-100 E failed to indicate full closed after manual control stroking. The actuation arm was found loose, TER 003 was ratested satisfactory on 6/13/83.

004 - 6/3/83 - Spray valve controller output did not increase above 0% with PZR pressure at 2290 psia. TCN 009 was written, placing the master 1

controller (RCN-PIC-100) in AUTO. Retested TER 004 with satisfactory results 6-4-83.

005 - 6/3/83 - Maximum proportional heater controller current obtained was 6.26 ma, Resolution to TER 004 resolved the TER 005 problea. IIR 005 was retested 6-4-83 with satisfactory results.

006 - 6/3/83 "PZR TRBL" annunciater did not annunciate "PZR HI-LO PRESS" did. TER 006 was resolved 6/3/83 TCN 011 implemented.

i 007 - 6/3/83 "PZR TRBL" annunciator did not annunciate "PZR HI-LO PRESS" did. TER 007 resolved 6/4/83 TCN 011 implemented.

008 - 6/3/83 - Pressurizer. Pressure did not match the pressurizer pressure setpoint in steady state. SFR 1RC 099 written (Refer to TER 010)

RCS heat loss was great enough that one backup heater bank was required i

to balance heat input to heat loss and stay within the proportional l

heater control band to maintain 2250 psia.

009 - 6/3/83 - Pressurizer spray valve did not open when the spray valve controller was placed to AUTO above 2300 psi. Resolution to TER 004 resolved the TER 009 problem 6/4/83.

010 - 6/4/83 - Pressurizer pressure did not match the pressurizer pressure setpoint in steady state, SFR 1RC099 written, (See TER 008).

011 - 6/4/83 - Charging pump #2 failed to trip on "Hi Level Error" (SFR-1CH-321 written).

012 - 6/4/83 - Backup heater bank (RCN-HS-100-8) could be energized after receiving PZR Level Lo-Lo (25%) (Refer to TER 015 below) Replaced relay 63xLC110LL retested 6/24/83 with satisfactory results.

013 - 6/5/83

" Pressurizer Level Ch x Hi" did not clear within the acceptance criteria. Recalibrated Foxboro module and ratested with satisfactory results 6/23/83.

014 - 6/5/83

" Pressurizer Level Ch. x Lo" did not actuate within the acceptance criteria. Recalibrated Foxboro module and retested with kM h

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satisfactory results 6/23/83.

l 015 - 6/5/83 - Backup heater bank (RCN-HS-100-8) could be energized after receiving PZR Level Lo-Lo (25%) same resolution as TER 012.

016 - 6/5/83 "PER Level Ch. x LO", annunciator did not clear within the acceptance criteria. Recalibrated Foxboro module and retested with satisfactory results 6/23/83.

017 - 6/5/83 "PZR LVL HI-LO" annunciator did not clear within the acceptance criteria. Recalibrated Foxboro module and retested with satisfactory results 6/23/83.

TER's 018, 019, 020, 021, 023, 024, 026, 027 are all related to the same problem of meeting the automatic minimum and maximum letdown flow requirements of IJ-CHE-110P and 1J-CHE-110Q, TER's 018, 019, 020, 021 initially identified the problem.

1J-CHE-110P was balanced to match the flow characteristics of IJ-CHE-110Q. Retest generated TER's 023 and 024. Subsequent to retest it was determined that both letdown valves were plugged so both valves were rebuilt and the next retest generated TER's 026 & 027.

A further contribution to this problem arises from the tolerances for acceptance: minimum auto letdown flow 29-30 gym (.5% accuracy) maximum auto letdown flow 135-138 gpm (1.5% accuracy) both of which are unrealistic expectations. SFR 1CH-346 was written.

018 - 6/5/83 - Maximum AUTO leta)wn flow using CHE-LV-110P did not meet acceptance criteria.

019 - 6/5/83 - Minimum letdown flow using CHE-LV-110P did not meet acceptance criteria (Refer TER 023) 020 - 6/5/83 - Maximum letdown flow using CHE-LV-110Q did not meet acceptance l

criteria.

i 021 - 6/5/83 - Minimum letdown flow using CHE-LV-110Q did not meet acceptance criteria (Refer TER 024) 022 - 6/6/83 - With 4 RCP's operating there was not enough delta P across the reactor vessel to provide adequare spray line flow to meet delta T requirements with the bypass valves wide open. Defer to post core setting during 73HF-1RC10 Pressurizer Opray Valve and Control Adjustment.

023 6/14/83 - Minimum letdown flow using CHE-LV-110P did not meet acceptance

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criteria during retest.

(Refer TER 026) i 024 - 6/14/83 - Minimum letdown flow using CHE-LV-110Q did not meet acceptance '

criteria during retest.

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. 025-6/22/83-1EBackupheatercurrentiniicationwasnotavailablefor taking readings. Current transmitter had not been installed yet TER 025 i written to insure retest.

e 026 - 7/4/83 - Minimum and madmum letdown flow did not meet acceptance criteria using CHE-LV-110P.

~027-- 7/4/83 - Maximum letdown flow did not meet acceptance criteria using CHE-LV-110Q. ;

Completed section 8.0 testing 6/17/83 Thioughout the hot functional testing program problems with letdown occurred.

Specifically, pressure relief valve CHN-PSV-345 (upstream of letdown heat exchanger) would open frequently to the EDT on the slightest system upsets

'for example:

1) ~ swapping backpressure control valves PV-201P & 201Q
2) adjusting LIC-110 setpoint (PZR level controller)
3) swapping latdown control valves LV110P & LV110Q.

(Reference SFR-1CR-325)

As time went'on'it became exceedingly more difficult to reseat PSV-345.

C.E. determined that the opening of the relief valve was caused by the back pressure control valve responding to slow to aystem pressure changes.

So the PID' controller was adjusted to increase response time. Further, a snubber was ins.talled to dampen out an actual 200-320 psi oscillation that PIT-201 was seeing resulting in rapid oscillation of the back pressure control valve. The reason for the letdown pressure oscillation is not clear.

(po'ssible in-line flashing) s Another problem which occurred during the course of hot functional was the failing of E/P converters on pressurizer spray valve PV 100E & PV-100F causing rapid loss-of pressurizer pressure and inability from the control room to stop pressurizer spray (SFR 1RC-148 was written) The failure is assumed to be caused by high spray valve room temperature.

On 6/3/83, while making preparations to begin testing, the control room operators pointed out that RCB-HS-100-5 backup heater override mode did not function properly. Since no specific step had failed no TER was written.,However, the PSE was notified and the problem was corrected.

Problems were also encountered with the charging pump mode selector switch (CHN-HS-4). SFR 1CH-321 was written to identify and~ describe the type of behavil3r seen. The resolution to the SFR stated handswitch was operating s as designed.c The PSE is aware of the problems encountered and is going' to retest this circuit when the plant conditions permit to verify if a new mode of pump' transfer is required.

E.

TEST RESULTS 1

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1) TER 001 - remains open and is addressed by SFR-1RC-097. Insulation was preventing valve from fully closing.
2) TER 008 and TERO10 are resolved, however, it should be noted that RCS heat loss was sufficient to require one backup heater bank to be energized to stay in the proportional heater control range.
3) TER 022 remains open and must be defered until postcore testing. During

-precore there was insufficient differential pressure across the core to maintain spray line temperature with only the bypass valves.

~ 4) TER 025 rema!ns open as a construction completion item.

1E backup heater control room current indication was not available to record measurements.

5) TER 026 and 027 are open and addressed by SFR #1CH-346 and #1CH-357. Auto minimum and maximum letdown flow acceptance criteria was not met.

F.

CONCLUSION The pressurizer pressure and level control systems have been demonstrated to operate as designed. With the exception of TER's listed in Section E.

The following licensing commitments have been met (041393, 041394, 041395, 041396, 041397).

G.

RECOMMENDATIONS Additional tests required include:

1) Prerequisite and preoperational testing of the IE backup heater bank control room current indication.
2) Charging pump mode selector switch (2,3,1; 1,2,3; 3.1,2) requires further testing to verify. pump transfer techniques and determine if l

added operator training is required.

3) Setting.of the pressurizer spray bypass valves will be accomplished l

postcore during procedure "3HF-1RC10.

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4) Minimum & Maximum letdown auto flow should be retested per new acceptance criteria'given in ICH-357.

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