ML20088A277

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Rev 2 to Procedure Toprp, Turbine Overspeed Protection Reliability Program
ML20088A277
Person / Time
Site: Wolf Creek, Callaway, 05000000
Issue date: 03/16/1984
From: Robinson W
STANDARDIZED NUCLEAR UNIT POWER PLANT SYSTEM
To:
Shared Package
ML19268E760 List:
References
TOPRP, NUDOCS 8404110309
Download: ML20088A277 (15)
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1 CALLAWAY'S i 4

TURBINE OVERSPEED PROTECTION RELIABILITY PRCGRAM l 1

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TOPRP March 16, 1984 Revision 2 CALLAWAY PLANT  :

TURBINE OVERSPEED PROTECTION RELIABILITY PROGRAM RESP. DEPT. T I Tk PREPARED BY W k b'k.5 m s

APPROVED BY Lm [ c ,& dv[ DATE .3 - /7- F f DATE ISSUED This procedure contains the following: -

Pages 1 through 12 Attachments 'through Appendices through Checklist through l

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Section Page Number 1.0 , Introduction and Summary 1 1

2.0 , tPurpose and Scope 3 i

3.0 Definitions c 3 k k - J' s

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-8.0 Revisions to the Turbine'overspeed Protection Reliability Program 12 9.0 ' References 12 3' N 1

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Proccd. No. TOPRP I Rev. 2 i

TURBINE OVERSPEED PROTECTION RELIABILITY PROGRAM

1.0 INTRODUCTION

AND

SUMMARY

1.1 The Union Electric Company " Turbine Overspeed Protection Reliability Program" (TOPRP) con-sists of a comprehensive program for turbine inspection and the maintenance, calibration and testing of the turbine overspeed protec-tion system. This program is designed to l provide assurance that flaws or component

. failures in the overspeed sensing and trip-ping subsystems, in the Main Stop Valves, Control Valves, Combined Intercept Valves, and Extraction Nonreturn Valves that might lead to an overspeed condition above the

- design overspeed rating will be detected and thus provide assurance of turbine integrity.

l 1.2 This program is based on recommendations by l General Electric Company regarding valve maintenance, testing, inspection and calibra-tion, operating experience at Nuclear Plants with similar units, operating experience at other Union Electric Company plants, and reg-i ulatory guidance. The objective of this pro-gram is to assure turbine integrity and to maintain maximum reliability of the turbine overspeed protection system.

9 1.3 The testing program as presented in section j 5.2.1 includes testing of the turbine over-11 speed protection system and the Main Stop, Control, Combined Intercept , & Extraction Nonreturn valves. Testing is performed dur-ing turbine startup, unless previously tested within the required test interval, including startup after each refueling outage.

1.4 The. maintenance and inspection program as presented in section 5.2.3 includes periodic inspection a'nd maintenance of the turbine as-sembly, the Main Stop, Control, Combined In-tercept, and Extraction Nonreturn Valves.

Procsd. No. TOPRP

/ Rev. 2 t ,

e 1.51 -The. calibration program as presented in sec-tion 5'2.2 consists of calibration of the turbine overspeed protection system at least once per 18 months or following major main-g tenance on the turbine overspeed protection system.

1.6 Union Electric Company's commitment to the Nuclear Plant Reliability Data System (NPRDS) as presented in.section 6.0 will include the Main Stop, Control, Combined Intercept and

. Extraction Nonceturn Valves so that defi-ciences may be reported and reviewed and necessary. revisions may be made to the Union

. Electric Company " Turbine Overspeed Protec-tion Reliability Program" based on reliabil-ity data.

1.7 This. integrated inspection, testing, calibra-tionLand maintenance program is the subject of on-going review and evaluation by Union Electric Company and is subject to revision based on-operating data from this and other similar units or changes to the manufacturers recommendations. This, program shall be im-plemented by-the use of approved procedures, maintenance work requests and outage work

,- schedules <as appropriate. Deviatio'ns from this program or deficiencies identified dur-ing/ inspection,. test.ing, calibration and maintenance /will be evaulated by Union Elec-tric Company and appropriate action taken.

The "Turbinc Overspeed Protection' Reliability G

l . Program";and.any subsequent changes thereto p shall be# reviewed in accordance with Callaway

' " Plant' Administrative' Procedures, the Callaway l

L Plant Technical Specifications-and imple-L , mented:in accordance with the provisions of l 10CFR50.59. <}.

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Procsd. No. TOPRP Rev. 2 2.0 PURPOSE AND SCOPE. .

2.1 The purpose of the Turbine Overspeed Protec-tion Reliability Program is to insure Turbine Rotor Integrity, operability of the Turbine Overspeed Protection System and overall reli-ability of the Main Turbine through a compre-hensive periodic maintenance, calibration, testing and inspection program.

2.2 The Turbine Overspeed Protection Reliability Program shall include the inservice inspec-tion programs for the Main Turbine and tur-bine valves including periodic valve cycling and. valve.diassembly in accordance with the manufacturers recomm.endations and general guidelines. Modifications may be made based on Union Electric Company's turbine operating experience for similar. units, industry ex-perience, or engineering evaluations.

3.0 DEFINITIONS .-

3.1 NUCLEAR PLANT ' RELIABILITY DATA SYSTEM (NPRDS)

Nuclear Plant Reliability Data System (NPRDS)

.is a computerized data base, managed by INPO, used to track and trend nuclear power plant

-equipment reliability.

. 4.0 RESPONSIBILITIES 4.1 NUCLEAR SAFETY REVIEW BOARD (NSRB)

I The Nuclear Safety Review Board shall be responsible for review of safety evaluations

.for changes to this program in accordance H .with Callaway Plant Technical Specifications section 6.5.2.8.

4.2 MANAGER, CALLAWAY PLANT The Manager, Callaway Plant shall be respo'n-sible for the review, approval,-and-implemen- ~

tation of the Turbine Overspeed Protection

~ Reliability Program and changes thereto.

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Procad. No. TOPRP Rev. 2 4.3 ON-SITE REVIEW COMMITTEE (ORC)

The On-Site Review Committee shall be respon-sible for review of the Turbine Overspeed Protection Reliability Program and changes thereto in accordance with Callaway Plant Technical Specifications Section 6.5.1.6 and this program.

4.4 ASSISTANT MANAGER, OPERATIONS AND MAINTENANCE The Assistant Manager, Operations and Mainte- r nace shall be responsible for:

4.4.1 Development of implementing procedures to meet the requirements of the Turbine Over-speed Protection Reliability Program.

<4.4.2 Ensuring testing _ requirements of the Turbine Overspeed Protection Reliability Program are met or that the deviations are reviewed and approved in accordance with this program, Callaway Plant Administrative procedures and the Callaway Plant Technical Specifications.

4.4.3 Ensuring test results are reviewed against the acceptance criteria as specified in the implementing procedures and the initiation of remedial or corrective action in accordance with APA-ZZ-005.00, " Nonconforming Operations Reporting and Corrective Actions", for unac- "

ceptable results.

5.0 PROCEDURE 5.1 PROGRAMMATIC-5.1.1 The Turbine Overspeed Protection Reliability Program shall be reviewed by the on-Site

. Review Committee and approved by the Manager, Callaway Plant prior to implementation.

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Procsd. No. TOPRP Rev. 2 5.1.2 Changes to the. Turbine overspeed Protection Reliability Program shall be reviewed by the Responsible Department Head and submitted for review by the On-Site Review Committee and approved by the Manager, callaway Plant. Im-plementation of changes to the Turbine Over-speed Protection Reliability Program will be accomplished in accordance with Callaway Plant Technical Specifications.

5.1.3 Implementing procedures for the Turbine Over-speed Protection Reliability Program shall be written, reviewed, and approved in accordance with Callaway Plant Technical Specifications, Section 6.5.3, " Technical Review and

, Control," and Callaway Plant Administrative Procedure, APA-ZZ-00101, " Preparation, Review, Approval and Control of Plant Procedures."

5.1.4 Variation from the frequency requirements of the Turbine Overspeed Protection Reliabilty l Program.

5.1.4.1 Variance from the turbine valve testing pro-gram as described in Section 4.2.1 shall be approved as follows:

5.1.4.1.1 No test frequency shall exceed 1.25 times the required test interval without prior approval of the-Manager, Callaway Plant or the Emergency. Duty Officer.

h 5.1.4.1.2 No more than two consecutive tests shall be deferred without the prior review of the On-Site Review Committee and approval by the Manager, Callaway Plant.

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A_. _, a . . _ _ _ r- a :L s,. _. ~ .s Procad. No. TOPRP Rev. 2 5.1.4.2 Variation from the test frequencies for those Turbine Overspeed Protection Reliability Pro-gram tests / inspections / calibrations as described in Sections 5.2.2, 5.2.3, and 5.2.4 shall be approved as follows:

5.1.4.2.1 No test frequen:y shall exceed 1.25 times the required test interval without an engineering evaluation performed in accordance with Cal-laway Plant Administrative Procedures, APA-ZZ-00140, " Conduct of Engineering &

Safety Evaluations," reviewed by the on-Site Review Committee and approved by the Manager, Callaway Plant.

5.2 TECHNICAL 5.2.1 The inservice testing program for those com-ponents important to the turbine overspeed protection system shall include the following:

5.2.1.1 Turbine Generator Startup Testing - each of the following tests shall be completed weekly and prior to each startup unless performed within the last 7 days as recommended by Gen-eral Electric Company:

5.2.1.1.1 Mechanical overspeed Trip Test - during this test the Electrical Trip and Monitoring Sys-

. tem energizes the oil Trip Solenoid valve which admits lubrication oil to the overspeed Trip Device causing it to trip. A coordi- .

nated actua?. ion of the Mechanical Lockout Solenoid Valve prevents the Emergency Trip System from actually tripping the turbine.

This-test should be completed just after the Backup Overspeed Trip test as shown in sec-tion 5.2.1.1.4.

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Procad. No. TOPRP Rev. 2 5.2.1.1.2 Mechanical Trip Piston Test - during this test the Electrical Trip and Monitoring Sys-tem energizes the Mechanical Trip Solenoid valve shunting oil from the piston causing it to trip. A coordinated actuation of the Mechanical Lockout Solenoid valve prevents the Emergency Trip System from actually trip-ping the turbine.

5.2.1.1.3 Electrical Trip Test - during this test the Electrical Trip and Monitoring system de-energizes both 24 VDC solenoids causing the Electrical Trip Valve System to trip. A coordinated actuation of the Electrical Lock-out Solenoid Valve prevents the Emergency Trip System from actually tripping the turbine.

5.2.1.1.4 Backup Overspeed Trip Test - during this test

, the logic circuits for the two-out-of-three logic are tested. Since each may be tested independently, no. actual turbine trip occur,s.

5.2.1.1.5 Thrust Bearing Wear Detector Test - excessive wear of one thrust plate activates two pres-sure switches set at different-levels of pressure, which correspond to different shaft displacements, the first representi'ng an alarm level, and the second a trip. The pressure switch contacts are connected in series developing a two-out-of-two logic.

During this test, a third series . contact per-mits the trip line to be open preventing an actual turbine trip.

5.2.1.1.6 Power Load Imbalance Test - during this test a load loss is simulated exercising the load imbalance circuitry.- This test can only be

. performed when turbine load is greater than

, 40%.

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Procsd. No. TOPRP Rev. 2 I

l 5.2.1.2 Actual Turbine Trip Tests - each of the fol-lowing tests-shall be performed at least once per 18 months or when major maintenance is t performed on the turbine.

5.2.1.2.1 Actual Turbine Trip - during this test the turbine speed is allowed to increase to the trip setpoint of 109.5% causing mechanical and electrical trip actuation.

5.2.1.2.2 Actual Back-up Overspeed Trip (BOST) Test -

during this test the turbine speed is allowed to increase.to the backup trip value of 105%

and then tripped by BOST action.

5.2.1.3 Turbine Valve Testing - the inservice testing of turbine valves shall be as follows:

1' 5.2.1.3.1 Main Stop Valves and Combined Intercept Valves will be tested daily.

5.2.1.3.2 Control Valves and Extraction Nonreturn Valves will be tested weekly.

l 5.2.1.3.3 At least once per week, closure of each valve during test will be verified by direct obser-vation of the valve motion.

[ 5.2.1.3.4 All Main Stop Valves, Control Valves, Extrac-tion Nonreturn Valves, and Combined Intercept Valves will be tested under load. Pushbut-tons on the_EHC test panel permit full strok-ing of the Main Stop Valves, Control valves and Combined Intercept-Valves. Extraction.

Nonreturn Valves-are tested locally by equalizing air pressure across the air cylinder. Movement of the valve arm is ob-served upon action of the spring closure  :

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Procsd. No. TOPRP Rev. 2 5.2.2 The calibration program for the turbine over-speed protection program shall include the following at least once per 18 months or fol-lowing major maintenance on the turbine gen-erator or the overspeed protection syr5 m.

5.2.2.1 Mechanical Overspeed Trip Calibration - the mechanical overspeed trip test is designed to verify calibration of the turbine mechanical l overspeed trip system. The turbine speed is increased to the trip setpoint of 109.5% and speed at which the trip occurs is recorded.

If the as-found trip value is out of tol-erance, the trip setpoint is adjusted and the test is repeated.

5.2.2.2 Backup Overspeed Trip Calibration - the BOST

- is designed to verify calibration of the l electrical Auxiliary Speed Sensor unit. In the NORMAL mode tilis tr'ip is set at 110% of rated speed and i.s a backup to the mechanical

- overspeed trip. In the STANDBY mode this trip is reduced to 105% and provides the first line of protection. The actual speed at which the trip occurs is compared to the trip setpoint. If the as-found trip value is out of tolerance, the trip setpoint is ad-justed and the test is repeated.

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Procsd. No. TOPRP Rev. 2 l

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'l 5.2.3 Maintenance and Inspection Program.

5.2.3.1 The' inservice inspection examination of valves important to overspeed protection shall include the following:

5.2.3.1.1 All Main Stop, Main Control, Combined Inter-cept and Extraction Nonreturn valves will be inspected once during the first three years.

Inspection of all valves of one type will be conducted if any unusual condition is discovered. Subsequent inspections will be scheduled so that each valve is inspected at 3- to 5-year intervals. The' inspections will be conducted for:

a. Wear of linkages and stem packings
b. Erosion of valve seats and stems
c. Deposits on stems and other valve parts which could. interfere with valve opera-tion
d. Distortions, misalignments 5.2.3.2 Tightness tests of the main stop and control valves are performed at least once per 18

'l months by checking the coastdown characte-ristics of the turbine from no load with each set of four valves closed alternately. Plat-forms provided for valve maintenance permit observation of the valve motion.

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r Procad. No. TOPRP Rev. 2 5.2.3.3 The inservice inspection program for the tur-bine assembly includes the disassembly of the i turbine and complete inspection of'all nor-mally inaccessible parts, such as couplings, coupling bolts, turbine shafts low-pressure turbine buckets, low-pressure wheels, and high-pressure rotors. During plant shutdown coinciding with the inservice inspection schedule for ASME Section III components, as required by the ASME Boiler and Pressure Ves-sel Code,Section XI, turbine inspection is done in sections during the refueling outages so that-in 10 years total inspection has been completed at least once.

i 5.2.3.3.1-This inspection consists of visual and sur-face examinations as indicated below:

a. Visual examination of all accessible surfaces of rotors and wheels
b. Visual and surface examination of all low-pressure buckets
c. 100-percent visual examination of couplings and coupling bolts 5.2.3.3.2 Inservice inspection of the bores and keyways of the low-pressure turbine discs will be in accordance with the manufacturer's recommendations.

6.0 . REPORTING 6.1 The Main Stop Control, Combined Intercept, and Extraction Nonreturn valves shall'be in-cluded in the Nuclear Plant Reliability Data System (:NPRDS). Deficiencies shall be reported and included in the data bank, and reviewed so that appropriate changes may be made in the Callaway Plant program based on reliability information.

7.0 RECORDS 7.1 Records for the Turbine Overspeed Protection Reliability-Program shall be maintained in accordance with the. implementing procedures.

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Procsd. No. TOPRP Rev. 2 8.0 REVISIONS TO THE TURBINE OVERSPEED PROTECTION RELIABILITY PROGRAM Modifications, deviations, and other changes to the Turbine Overspeed Protection Reliabil-ity Program as a result of on-going review by Union Electric Company shall be initiated and processed in accordance with Callaway Plant

~ Administrative Procedures, Callaway Plant Technical Specifications and implemented in accordance with the provisions 10CFR50.59.

9.0 REFERENCES

9.1 Callaway Plant Technical Specifications 9.2 APA-ZZ-00101, " Preparation, Review, Approval, and Control of Plant Procedures" 9.3 APA-ZZ-00140, " Conduct'of Engineering and Safety Evaluations" 9.4 Final Safety Analp51s Report 9.5 GEK-65907 VOL. I 9.6 GEK-64907 VOL. II u -

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