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REPORT OF ASSIST INSPECTION 1
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' Licensee:
Jersey Central Power & Light Company j.
Oyster Creek 1 Docket No. 50-219
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d Dates of Inspection:
May 20-21, 1970
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Inspected By:
D. E', Pomeroy, Nucleap 4ngineer, TSB
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Reviewed By:
H. R. Denton, Chief, TSB Date j
s Proprietary Information:'
None l SCOPE A special, announced inspection was conducted to review records associ-ated with the rebuilding and requalification.of.all the control rod.
drives (CRD's). Messrs. D. L. Capton and R. J. McDermott, CO:I, were present during the. inspection.
SUMMARY
Noncompliance Items The lack of d 1ve. exercising on April 15, questioned in the 1 st inspec.
tionreport,1.7is an item of noncompliance (II.G.).
Other Significant Items I
1.
The reactor had been shutdown since April 19, 1970. The program -
to rebuild all the CRD's was completed on May 15.
i 2
A review of the disassembly records indicated that'all drives had
,s, experienced at least one broken seal and that over half the drives
- lh had yielded index tubes (II.A.).
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- 3. A review of' the withdrawal stall' flow tests for installed drives i
indicates that flows were well within desired range of 1-2 spm,
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except for that two drives that were over 4 gpm (II.B.3.).
JERSEY CENTRAL POWER & LIGHT CO.
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CO Report No. 219/70-5 Addendum 4 h 80 g 4 950227 Page 1 of 21 pages.
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- 4. A review of the insert stall flow tests for installed drives' indi-
-cated that most drives (131) were greater than the expected 1 gpm.
. The average was 1.5 gpm(II.B.3.).
Y 5.
The new venting procedure 'was successful on all but about 20 drives.
_ These drives were redone successfully, except for one drive which had to. be replaced (II.C.1.).
3 7
6.
One drive was replaced due to high friction. ' The inspector identified four additional drives that did not appear to meet the licensee's acceptance criteria (II.C.2.).,
7.
The cold scram test records indicated a range of 1.5 6 0.2 seconds' for 907. insertion (II.D.).
DETAIIS I.
Persons Contacted
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The following persons were contacted during the inspection:
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Jersey Central T. McCluskey, Station Superintendent J. Carroll, Operations Supervisor D. Ross, Technical Supervisor ~
j W. Riggle, Maintenance Supervisor i
II..Results of Record Review A.
Disassembly Reports The disassembly reports _/ for 139 control rod drives were re-2 viewed. The following summari were removed from' the reactor.ggs the findings for the 136 drives that The three spare drives are not included.
% Broken or Damaged Stop Piston Seals -
Top pair 74 Bottom pair 87 Bushings -
Top 15 Bottom 7
Drive Piston Seals Internal -
Buffer 24
\\ Up 19 Down CO REPORT NO. 219/70 15 Addendum 4 Paca 2 of. - 21 nacer
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, l,3 Drive Piston (con't)
Seals External -
10.
Bushings Internal -
4
- 3 1
Bushings External -
4 T
Garter Springs -
15 J.
Collet Piston
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Seal Rings, Internal -
16 Seal Rings Stuck, External -
24 j
Yeilded Index Tubes (> 20 mils) 57
!Bellville Springs 40 i
\\Plugged Cooling Water Orifices 49
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in October 1969 we identified,.
l The 22 drives that were rebuilt and the records' for the recent disassembly of these drives were reviewed.
The only 'pignificant difference in the reported damage was that only 1%
of-the ga ter springs were broken compared to 15% on unrebuilt drives.
1 1
I B.
Seal Leakage Measurements 1.
Prior to Disassembly In order to determine the sources of seal leakage, the first' eight drives removed from the reactor were leak checked prior to disassembly. The insert flows ranged from 0.3 to 2 gpm. The withdrawal flows ranged from 0.7 to. 9 spm. The 9 spm seal leakage was distributed - 3.5 gym stop piston, 3 gpm drive piston internal and 2.5 gpm collet piston. The' general results of these tests indicated,much higher than i
normal leakage, with the.stop piston seals being notably
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worse than the others.
2 Following Drive Reassembly
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Each drive was seal leak checked following rebuilding. The results are summarized below:
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l CO REPORT NO. 219/70-5 Addendum 4 I
l Page 3 of 21 pages.
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1 Range!of Seals Allowed nom Measurements. nom LInsert (P-under)
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.02 Stop piston 0.05 t-Collet 0.3 0 - 0.1
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- Drive ' piston internal 0.2 0 - 0.16 Total 0.55 0 - 0.2-l 4
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Withdrawal (P-over)
Stop piston 0.3 0 - 0.25 i
Collet 0.7 0.05 - 0.6-Drive piston internal 0.2 -
0 - 0.17 ~
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Totali 1.2 -
0.1 - 0.85-
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The pressure correction used by the. licensee to calculate.
allowable leakage found incorrect in the previous inspection, has been corrected (See Attachment 3).
3.
Following Installation to the Reactor Each drive was vented, stroked, timed and flow-checked following installation..Information was-recorded-on the attached form (Attachment 4).
The expected stalled withdrawal flow is ~ 2 spm.4/' The.
I average for 136 drives was 1.2 gpm. Five drivesLwere noted i
to be,slightly over '2 gpm. One-drive was 4.1 gpm and another.
I was of fscale (. > 5 gpm). The licensee was not able to pro-vide any explanation for the high leakage flow to these.two l
drives.
' The expected stalled insert flow is ~ 1. gpm.4_/ The average.
for 136 drives was 1.5 spm with 10l drives over 2 gpm. - No explanation was available; however, Mr. Carroll said that G-E had been advised of this and had : indicated that they did not believe that the measured leakage was excessive. -
C.
Oscilloscope Traces 1.
Venting The high point in the piping between the hydraulic control.
units and the CRD's were vented and each drive was stroked (00-48) 15 times. Each drive was.then given a notch-out.
signal from position 00 to. 02 while a storage-oscilloscope recorded the pressure ' differential across the drive piston.
-l CO REPORT NO. 219/70-5
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Addendum 4 Page 4.of 21 pages.
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A scale.of 50 psi per em and 0.5~sec.per cm w,ts used.-
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Analysis of the photographed pressure-time trace. is made.
to determine that the drive is ' air free.' The presence,of i.f air is indicated by traces thatshow a pressure rise or fall'
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- is not vertical.. About 20 drives. indicated
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some air was still present. These drives were stroked seven.
additional times and retested. All but one' was determined
,. s to,be air free,. this drive _(#162) was replaced and its' re.
ir placement satisfactorily-vented.
2.
Friction.
5 2
A continuous insertion friction test (48-00) was. performed -
on each' drive following the venting. A scale of 50 psi per.
cm and 5 see per em was used. The acceptance criterion was that the maximan pressure. change over the full stroke.be -
less than 15 psi.2/ If this limit was exceeded, a " notch--
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out and settle" friction test'was performed. The. acceptance criterion for this test was a minimum of 30 psi settling ~
pressure.
Two drives required the notch-out test.. One drive -(#520) did not pass it and was replaced. The second - indicated l'
slightly high friction ( ~ 25 psi settling pressure)in the notch 45-48 position but was not replaced. This drive.
t j-(#576) in location 18-11, has been placed on the scram time
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recorder for further monitoring.
4 An examination bf the inspector of continuous insertion photographs revealed that.in many instances the scale of 50 psi /cm made a comparison with the allowable variation of-
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15 psi-very difficult.. In four instances the review indi-34' cated marginal conformance. These drives swere identified and the results reviewed with Mr. Carroll. He stated that continuous insertion tests would be repeated for these drives with a 20 psi /cm scale setting./ These drives are in locations 1
18-35, 18-43, 34-47, and 42-31.
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D.
Scram Times 1;
Cold, unpressurized scrams were performed'on May 15,1970. - The :
following scram times (seconds) were obtained:
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CO REPORT NO. 219/70-5 Addendum 4 j
Page 5 of 21 pages.
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% Insertion 90 10_
50 Average 0.34
'1.006
~ 1.718'
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Fastest-0.29
.90
- 1.55 i
Slowestf 0.41,,
1.14 1.92 1.35-1.6[
k (Pre-op 0.31-0.40-0.82-1.01 A comparison of the range of values obtained prior to initial criticality indicated that the reduced accumulator pressure is' ' '
slowing the drives in the unpressurized mode.
E.
Buf fer Action The licensee reviewed the scram timing charts for' proper buffering.
action and found all drives to be acceptable. The review consists of ob.
serving the spacing and length of _ the reed switch " tick marks"? on the.
chart for the last 10% of travel. According to the' licensee, proper. buffer f action is indicated by increasing spaces between ticks as the drive approaches the end of travel. No quantitative criteria have been' developed-by G-E or JC for-analyzing the buffer action.
F.
Reassembly Report y
The QA program for reassembly:of the CRD's had not been fully developed at the time of the last inspection. During that inspection, the lack of a reassembly check sheet was reviewed with Mr. Riggle, who stated that a form would be prepared. As a result of this discussion,, sheets 1-3.was prepared for the use of the QA inspector.
The completed sheets for each drive had become contaminated and were in the process _ of being copied and, therefore, unavailable for review during this inspection.
G.
CRD Surveillance with two Inoperable Drives -
Following~ the April 14 scram with two CRD's out of service,' daily rod exercising was required.1/ Records of CRD exercising were reviewed 4
during the last' inspection for April 16-18.:. Records for April 15 were not located. During this inspection, Mr. Carroll was questioned 'concerning.
the required drive exercising on the 15th. He stated that the exercising was not done.
CO REPORT NO. 219/70-5 Addendum 4 Page 6 of 21 pages.
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, III.
Continued Surveillance 0I In discussions of the surveillance requirements in the DRL letter the licensee indicated the following:
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A.
Prior to High Power Operation
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With the' reactor at normal pressure and temperature each drive will be scram timed and the buffer action will be observed. Mr. Carroll
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i stated that the stall flow tests will also be repeated hot.
B.
During Power Operation Scram times and buf fer action for 26 drives will be monitored for each scram and the Division of Compliance will be inforned of any scram time for 907. insertion that is outside the range of 1.9 to 3.6 seconds. The licensee interprets this reporting requirement as applying oniv to scrams with the reactor. pressurized, although the referenced letter does not state this limitation.
The withdrawal stall flows for all drives will be measured monthly.
If the total of 137 drives exceeds 500 gpm, the PORC and GORB will evalu-ate the situation. If the total flow exceeds 400 gpm, the Division of Compliance will be notified.
(The total flow measured cold was 158 spm.)
)
In addition, if any individual stall flow exceeds 5 gpm, the Division of Compliance will be. notified. Since 5 gpm is presently the upper range of the instrument, Mr. McCluskey stated an intention to use 10 gpm for any drive that exceeds,5 spm when computing the total stall flow.
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CO REPORT No. 219/70-5 Addendum 4
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FOOTNOTES h:
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1/ Hemo, Denton to Carlson, Report of Assist Inspection, May 14, 1970.
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- 2) Attachments 1 and 2 to this report and Attachment 2 to the May 14 memo.
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- 3) Note: The reactor location of CRD's by drive flange number is pro-l vided in Attachments 6 and 7 for the period prior to the April 19 shutdown and as of May 21, 1970.
4/ G-E CRD Manual, GEI 92807.
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,5) Le t te r, I. F infrock to P. A. Morris, May 18, 1970.
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l 6_/ Oyster Creek inspection report No. 219/69-4
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,7) Technical Specifications 4.2D 8/ \\ Letter, Morris to Sims, May 20, 1970.
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CO REPORT NO. 219/70-5
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Addendum 4
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Page 8 of 21 pages.
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3, DRIVE INSPECTION'
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Foreign material removed from inside and on spud.
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. I 4) ' Distance between uncoupling rod and end of s* pud measuied and re:orded.
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All se: ews safety wired on upper screen.
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Strainer not damaged.
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PRESSURE SEAL TEST REPCRT FORM
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j P-UNDER Allowed MLMin.
Actual ML Min.
160 psig.
200 psig.
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.l Coupling, Spud 169 189 Collet Port-1016 1135
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Over Pressure Water Port 677 757 a
Total 1862 2081'
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P OVER
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Allowed ML/ Min. '
Actual ML/ Min.
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160 psig.
200 psig.
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Coupling Spud 1016 1135 Collet Port 2371 26h9 Under Pressure Water Port 677 757
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CO. REPORT NO. 219/70-5
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Addendum 4 ATTAC10ENT 3 Page 11 of 21 pages.
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REASSE BLY REPORT F CONTROL ROD DRIVE _.
FLANGL-DRAVING\\237E179 SERIAL NO.
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DATE:
PLANT IDENTIFICATICN Using the DRIVE MECHANISM REASSEMBLY INS 7RUCTION in OEI-29808 as a guid y
C0KMENT on any observations that could contribute gv 4
checkthe[o11owingitems.
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to drive failure that are not listed on this form.
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New Graphitar Seals Installed?_
DRIVE PISTON
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Checked location of radial and bridge seals with respect to one
'another I'
Are locking band tabs set deep enough to prevent loosening lduring operation?
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s erify orientation of the spring washers.
STOP PISTON Does the hole in the piston tube stud align with the hole in the stop piston?
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Are the split bushings properly installed?
Verify that' markings on the stop piston seals are matched and i
facing in the same direction.
Verify that the gap in the seal ring does not 411gn with the gap in the expander spring.
Verify that the locking band tabs are set deep enough INDEX TUBE in the slots.
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. Continued on sheet 2,
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CO REPORT NO. 219/70-5 I
Addendum 4 4
Page 13 _ of 21 pages, f
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fHEET 2 of 3 - Att:chment 5:
f PISTON 7tmE & CYLINDER, TIGE, AND FLANGE - '
1 Minimum metal-to-metal ' contact between the index tube and tho' l
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i-inner cylindpr.
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Verify that the markings on the external seals of the' drive
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1 piston are matched and facing in the same direction *
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~ Verify that the gap in the seal ring does not' align'with the l
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-l gap in the expander spring.
Were the 0-rings lubricated with castor oil?
Inspect the 0-rings on the piston head for damage after i.
installing piston tube into the cylinder, tube, and flange Were the cap screws torqued to 15-17 ft.-lb.?
_ COLLET-LOCKING MECHANISM Was the index tube supported after the. split guide ring was-removed?
Verify that the internal seal rings are not stuck.
The diameter of the outer cylinder at the guide cap plugs must not exceed h.217 inches.
DRIVE FLANGE COMPONENTS Verify that the face of the 0-ring spacer with the countersunk screw holes is up and the screws do not project beyond the upper face of the space.
INTERNAL FILTEli, SPUD,/QUNCOUPLING RCD ASSEMBLY -
7 The distance fm the top of the uncoupling rod assembly to the top of the coupling spud must be 1-1/8 (1 1/6h) inch.-
>L The distance from the 0-ring spacer on the drive flange to the top cf the uncoupling rod assembly;must be 173-9/32 (1 1/32) inches.
Addendum Page 14 of 21
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pg g' 3 Sheet 3 of 3 - Attechme,nt
.REASSE>TaLY REPORT FOiCONTROL ROD DRIVE 5
l LOCKWIRE_
The lockwire is 0.032 inch diameter annealed Type-302
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stainless steel wire.
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I C0!MENTS:
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i INSFECTED BY:
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CO REPORT No. 219/70-5 Addendum 4 Page 15 of 21 pages.
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